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FrymaKoruma 102192 Operating Manual Download Page 1

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14.02.2008   12:07:51

Deckblatt_Romaco.indd   1

14.02.2008   12:07:51

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Deckblatt_Mappe_Romaco.jdf Bogen:1 A

   

PANTONE Process Blue C

PANTONE 7409 C

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Summary of Contents for 102192

Page 1: ...PANTONE Process Blue C PANTONE 7409 C 08 02 14 _12 09 38 Y 80 40 K 80 40 C 80 40 M 80 40 Y 80 40 K 80 40 C 80 40 M 80 40 Y 80 40 K 80 40 C 80 40 M 80 40 Y 80 40 K 80 40 C 80 40 M 80 40 Y 80 40 K 80 40...

Page 2: ...and to instruct the operator on its use Annex Declaration of CE Conformity Figure 0 1 MZ 190 TABLE OF CONTENTS GENERAL 1 1 Overview Operating Manual and Documentation 2 2 Purpose of the FrymaKoruma Op...

Page 3: ...ions 4 Operating Modes and Controls 5 Commissioning 6 Operating 7 Maintenance 8 Repairs 9 Recycling 10 Transport Part 2 Components 1 Parts Lists 2 Drawings 3 Vacuum System 4 Sealing Liquid Unit Mechan...

Page 4: ...and in the correct way we recommend that you contact the FrymaKoruma customer service Target group These operating manuals are intended for all persons who may operate maintain or service the machine...

Page 5: ...For modifications of programs or of process control or the process itself the approval of FrymaKoruma is required Furthermore conformity is guaranteed only with the use of original spare parts 4 Cust...

Page 6: ......

Page 7: ...nvoice Address VAT no Delivery Address Your reference Phone no Machine Typ of machine Serial No Year of construction Specification of spare parts Part no Quant Drawing Pos No Description FrymaKoruma A...

Page 8: ...rocess Functions of individual Units and Parts Operating Modes and Controls Controls for Operating and Primary Set up Operating Modes Commissioning Instruction for Assembly and Primary Set up Wiring D...

Page 9: ...on TABLE OF CONTENTS 1 MACHINE DESCRIPTION 1 1 1 INTRODUCTION 2 1 1 1 Order specific application 3 1 1 2 Non order specific application 3 1 1 3 Safety measures 5 1 1 4 Conformity with respect to safet...

Page 10: ...it the application in hand spacers can be used to make a fixed adjustment As an option a stepless adjustment system that uses a thread is available to permit manual or automatic adjustment of the grin...

Page 11: ...An application that is not contractually agreed upon or whose scope exceeds the application s named here is considered a non order specific application Danger It is not permitted to process or use mat...

Page 12: ...d pressure limit values being exceeded where the intermediate and end products of chemical reactions cause damage to the construction materials elastomers plastics or metals where the specified proces...

Page 13: ...urity The product components processed in the machine must not contain any tramp material Any tramp material must be removed or restrained by suitable means e g filter visual control etc before it ent...

Page 14: ...d be available at the site of operation Hot water and cooling water steam Water quality To ensure optimum performance we recommend the following The electric conductivity should not exceed max 500 S c...

Page 15: ...bient temperature between 18 C and 27 C at a relative humidity of less than 70 With respect to the height above sea level the cooling system of the control cabinets is laid out for an average ambient...

Page 16: ...Hz Schutzart Protection class degr de protection IP 55 WERKSTOFFE MATERIAL MAT RIAUX Produktber hrende Teile Product contacting parts Partie en contact avec produit 1 4435 AISI 316L Mahlelemente Grind...

Page 17: ...and to indicate generally valid safety measures TABLE OF CONTENTS 2 SAFETY REGULATIONS 1 2 1 LAYOUT 2 2 2 FUNDAMENTALS 3 2 3 GENERALINFORMATION 3 2 4 ORGANISATIONAL MEASURES PERSONNEL ISSUES 4 2 4 1 U...

Page 18: ...iate threats Which can lead to grievous bodily harm or death Possible dangerous situation which could lead to serious injury or death Possible dangerous situation which could lead to slight bodily inj...

Page 19: ...ication This is featured in Section 1 1 of this operating manual Keep the machine in perfect condition maintenance as per instructions do not make any impermissible modifications Operate the machine i...

Page 20: ...operating manual cannot make allowances for hazardous substances employed by the user In many cases these are not even known to FrymaKoruma e g trade secrets In accordance with the industrial safety d...

Page 21: ...ity Responsible for implementation of the 89 655 EEC directive governing the use of plant and equipment and also for instructing all machine users in issues of safety in the prevention of risks and in...

Page 22: ...Avoid the danger zone when adjusting the grinding set Before opening the homogeniser switch off the master switch and engage the safety lock Never start the machine if ductings are removed Danger of...

Page 23: ...Avoid the danger zone when adjusting the grinding set Before opening the homogeniser switch off the master switch and engage the safety lock Never start the machine if ductings are removed Danger of...

Page 24: ...about the design and principle of operation of the machine TABLE OF CONTENTS 3 STRUCTURE AND FUNCTION 1 3 1 INTRODUCTION 2 3 1 1 Principle of operation 2 3 2 DESIGN 3 3 2 1 Modules 3 3 2 2 Electrical...

Page 25: ...ystem and grinding set All components are easy to exchange and clean The stator of the standard version is formed by between 1 and 3 internally toothed steel rings The rotor which has a preliminary gr...

Page 26: ...ted disc mill The MZM toothed ring machine is available for emulsifying tasks The machines are in modular design so that dependent on the machine size the dispersing and grinding units are interchange...

Page 27: ...e machine is in explosion protected design the control cabinet must be installed outside of the Ex zone In this case the wiring between the control cabinet and the control panel must be carried out on...

Page 28: ...The machine was built with a minimum of dead zones to GMP standards and is furthermore equipped for CIP procedures All parts which come into contact with the product are easily accessible for inspect...

Page 29: ...isite for commissioning Section 5 and operating Section 6 the machine TABLE OF CONTENTS 4 CONTROLSAND INDICATORS 1 4 1 INTRODUCTION 2 4 2 WARNING SIGNALS AND SAFETY ELEMENTS 2 4 2 1 Alarms 2 4 2 2 Saf...

Page 30: ...ilities of influencing the process there are only a few controls at the machine itself 4 2 Warning signals and safety elements 4 2 1 Alarms The standard machine version has no alarms Note Visual signa...

Page 31: ...in the operating manual the machine must be switched off and secured against unauthorised restarting before any procedures can be carried out To this end Switch off the master switch Slide the switch...

Page 32: ...trols and Indicators CREATED MZ xx PAGE 4 OF 9 14 01 09 DOC MZ04E CHAPTER 4 The electrotechnical documentation in Section 5 contains details of the contents of the electric control cabinet Ammeter ON...

Page 33: ...for dry running 4 3 3 Controls for adjusting the grinding gap One revolution of the hand wheel corresponds to an actual grinding gap regulation of 87 my A dividing line on the scale corresponds to a...

Page 34: ...t should be higher than 60 C Water oil and glycerine are commonly used as sealing liquid Standard scope of delivery The filter sieve with shut off valve a pressure gauge and a manual regulating valve...

Page 35: ...on when there is a sufficient sealing pressure If the sealing pressure drops below a certain level the gear is immediately switched off to prevent the seal running dry The pressure detector is to be c...

Page 36: ...monitored by a level controller The sealing liquid circulates automatically Compressed air regulated by means of a pressure reduction valve 3 is fed into the vessel containing the sealing liquid Seali...

Page 37: ...ck draft can be prevented which may lead to a overheating It also ensures that there is no hollow space with explosive gas If there are intermediate bearings they have to be greased via the lubricatin...

Page 38: ...tions 2 5 1 2 Personnel requirements 2 5 1 3 Technical documentation 2 5 2 INSTALLATION 3 5 2 1 Prerequisites 3 5 2 2 Transport 3 5 2 3 Site of installation 3 5 2 4 Handling unpacking and cleaning 3 5...

Page 39: ...Any electrical equipment provided by the customer must meet the requirements stipulated in EN 60204 1 IEC 204 1 Any electrical equipment provided by the customer must meet the requirements stipulated...

Page 40: ...tected against the weather whereby the required ambient conditions as per Section 1 2 4 must be observed 5 2 3 Site of installation Transport mass and weight Refer to the system dimension sheet and to...

Page 41: ...e individual components for transport These must be replaced prior to commissioning On site provisions The customer is charged with providing carrying out the following site of installation suitable f...

Page 42: ...m Product connections Compressed air If applicable leakage connections e g for the sliding ring seal Ductings for the waste water or the dirty CIP water Media ducting and power connections The media c...

Page 43: ...the electrotechnical documentation for details The control cabinet must be connected up to mains power by a qualified electrician With ex protected designs the control panel must be installed outside...

Page 44: ...le if delivery scope includes the operating panel as a special option Warning If a password is entered by an unauthorised person user third party this can lead to machine damage Personal injury is als...

Page 45: ...Sealing integrity of installed shut off components OK YES NO Sealing integrity of complete pipe work successfully checked Sealing integrity of sliding ring seal checked in operation visual control of...

Page 46: ...uctings during this process Recommended cleaning agent Hot water It may be necessary to repeat the cleaning process several times to achieve the desired cleaning effect Activate the operating media Co...

Page 47: ...ble options and cost effective machine operation TABLE OF CONTENTS 6 OPERATION 1 6 1 INTRODUCTION 2 6 1 1 Safety regulations 2 6 1 2 Personnel requirements 2 6 2 PRODUCTION SEQUENCEAND ORGANISATION 2...

Page 48: ...es This training is aimed at showing experienced staff all the working steps to ensure correct process management and safe operation of the machine 6 2 Production sequence and organisation Every compa...

Page 49: ...plastic scraper to remove any product residues Wet cleaning Add detergent or additives Dependent on the product heat the liquid If expected to improve the cleaning effect allow the machine to run Dra...

Page 50: ...l operating sequence to manufacture the product includes the following steps Fill the components into the machine Start up the processing units pump machine Mix homogenise emulsify or grind the produc...

Page 51: ...Always use this method in the case of repairs weekend shut downs and holidays etc 6 4 2 Prolonged shut downs Shut down the machine by switching off the master switch In addition Close the shut off val...

Page 52: ...level Temperature of operating media Working pressure of operating media Homogeniser power consumption speed Check the sliding ring seals pipes ductings valves and auxiliary units e g sealing liquid v...

Page 53: ...If people the environment or the product are endangered as a result the product liability of the manufacturer becomes null and void FAULTS POSSIBLE CAUSE S MEASURES FIND IN REPLACE Code 1 REPAIR Code...

Page 54: ...codes are identical with those in Column 5 Warning Procedures carried out by unauthorised persons can lead to the loss of warranty rights If people the environment or the product are endangered as a...

Page 55: ...ance materials Appendix B Lubricating schedule TABLE OF CONTENTS 7 MAINTENANCE 1 7 1 INTRODUCTION 2 7 1 1 Safety regulations 2 7 1 2 Personnel requirements 2 7 2 MAINTENANCE SCHEDULE 2 7 3 OPERATING M...

Page 56: ...ration 7 2 Maintenance schedule Configuration and contents of the maintenance schedule The machine must be maintained regularly Column 1 The maintenance procedure and components Column 2 The work whic...

Page 57: ...x x Working area x x Water supply filter x x Inspections Safety equip ment 7 4 1 Function x x Product feed units 7 4 4 2 Check screws x x Working area 7 4 4 3 Check proc essing elements for wear x x...

Page 58: ...or and have a low viscosity A viscosity of 0 8 to max 40 cSt mm2 s brings good results The pressure downstream of the pump should be between 1 and 3 bar The boiling point should be as high as possible...

Page 59: ...age to the insulation Warning Damaged electric cables connectors and units must be repaired by a qualified electrician 7 4 2 Cleaning procedures 7 4 2 1 Cleaning the machine Warning Never use liquids...

Page 60: ...e leakage rate of sliding ring seals only if fitted Every sliding ring seal SRS secretes a minimum amount of sealing liquid at the interface of the sliding ring surfaces The leakage rate of a SRS is d...

Page 61: ...wings and parts lists in the documentation 7 4 4 2 Checking the assembly screws Vibrations can cause the assembly screws to loosen during transport and operation All assembly screws and bolts must be...

Page 62: ...ersonnel or by those who have been given instruction by FrymaKoruma Refer to the drawing delivered along with the machine The hopper all feed ductings and the working area itself must be emptied and c...

Page 63: ...FrymaKoruma Operating Manual Maintenance CREATED MZ xx PAGE 9 OF 18 16 01 09 DOC MZ07E CHAPTER 7...

Page 64: ...FrymaKoruma Operating Manual Maintenance CREATED MZ xx PAGE 10 OF 18 16 01 09 DOC MZ07E CHAPTER 7 Rotor Once the clamping screw has been released the rotor can be pulled carefully off the shaft...

Page 65: ...FrymaKoruma Operating Manual Maintenance CREATED MZ xx PAGE 11 OF 18 16 01 09 DOC MZ07E CHAPTER 7 Sliding ring seal...

Page 66: ...ng Manual Maintenance CREATED MZ xx PAGE 12 OF 18 16 01 09 DOC MZ07E CHAPTER 7 Checks For wear and damage to the processing tools That rotor shaft runs true without runout or bearing play Replace part...

Page 67: ...nes Refer to the lubrication schedule for details of permitted lubricants Assembly in reverse sequence to dismantling All seating surfaces must be cleaned Don t forget to insert the O rings Notice Che...

Page 68: ...elements finally lightly touch which makes itself noticeable by a slight grinding noise Now slacken off the adjusting by a 1 4 turn This is the contact setting Now the scale is turned to zero and set...

Page 69: ...01 09 DOC MZ07E CHAPTER 7 0 0 0 1 0 2 0 3 0 4 0 5 0 6 0 7 0 8 0 9 1 0 1 1 1 2 1 3 1 4 1 5 0 000 1 147 2 295 3 442 4 590 5 737 6 884 8 032 9 179 10 327 11 474 12 621 13 769 14 916 16 064 17 211 X S 7...

Page 70: ...a list of the error messages Additional descriptions of alarms are contained in the supplier documentation e g for the frequency converter or other electronic equipment This documentation is also appe...

Page 71: ...ure in accordance with section 2 1 3 1 Entry in the drawing Example for M12 A4 70 screw MA Nm MA 50 Nm 2 4 Treatment condition of surface Surfaces A B C D have to be executed blank and primed without...

Page 72: ...eratures b Anti fatigue bolts flange bolts with ribs c Materials with reduced admissible surface pressure e g plastics d Property class for screw and nut different from the one indicated Tightening to...

Page 73: ...al paired with plastic FK plastic paired with plastic FK X Seals FK X FK O O FK Mechanical seal sealing liquid FK O Radial shaft sealing rings NBR FPM MVQ never EPDM FK Radial shaft sealing rings EPDM...

Page 74: ...burags NBU 8 EP Sta burags NBU 12 091111 Friction bearing FK X O X X Solid metal FK O Sintered metal FK X X Plastic X FK Hydraulic X FK Pumps devices X FK Cylinder FK X X Valves X FK Chains FK X O O...

Page 75: ...OF CONTENTS 8 REPAIRS 1 8 1 INTRODUCTION 2 8 1 1 Safety regulations 2 8 1 2 Personnel requirements 2 8 1 3 Servicing concept 2 8 2 GENERALINFORMATION 3 8 2 1 Special tools measuring and testing equip...

Page 76: ...he working area 2 Clean if necessary Use a safety lock to secure the master switch against unintentional restarting 8 1 2 Personnel requirements This section is directed at those persons who are respo...

Page 77: ...als delivered with the system are listed in Part 2 of this operating manual in the section Legends parts lists 8 3 Troubleshooting 8 3 1 Categorisation according to function sequence A table with a de...

Page 78: ...ing play Exchange parts as necessary Exchanging the sliding ring seals Sliding ring seals can be exchanged by experienced or specially trained staff Install new sliding ring seals in accordance with t...

Page 79: ...tions provided by the suppliers for details 8 4 4 Tasks reserved for FrymaKoruma s service division Only FrymaKoruma specialists are permitted to exchange or renew the following parts Components belon...

Page 80: ...cycling CREATED xxx PAGE 1 OF 1 05 01 09 DOC D09EN CHAPTER 9 9 Recycling Empty file If you have any questions relating the recycling of the machine or units belonging to please ask the customer servic...

Page 81: ...CREATED MZ xx PAGE 1 OF 2 19 01 09 DOC MZ10E CHAPTER 10 10 Transport Objective To provide information on proper and professional machine transport TABLE OF CONTENTS 10 TRANSPORT 1 10 1 LIFTING THE MAC...

Page 82: ...must have a minimum load bearing capacity as per the data sheet 2 After loading the machine proceed as described in Section 5 2 2 10 2 Transporting the machine Dependent on the means of transport the...

Page 83: ...d Unit Mechanical Seal Operating Instructions CIP Cleaning Conveying Pump Operating Instructions Instrumentation Fittings Pneumatic Compressed Air Heating Cooling Units Vessel and Piping Blending Vess...

Page 84: ...00 1 RM 310129 Drive ENG 036118 01 1 RM 310145 Housing ENG 036118 01 1 RM 310131 Housing Top ENG 036118 01 1 RM 310152 Mechanical seal 93 00 63 04 1 RM 310138 Grinding unit ENG 036118 01 1 RM 310163 P...

Page 85: ...nvoice Address VAT no Delivery Address Your reference Phone no Machine Typ of machine Serial No Year of construction Specification of spare parts Part no Quant Drawing Pos No Description FrymaKoruma A...

Page 86: ...Page Legend Machine No 651343 310129 BASE FRAME RM No Ident No Description Drawing No Qty Description Drawing Pos Ident No SP BASE FRAME 145183 1 STK 1 BASE FRAME HORIZONTAL 011642 4 STK 2 LEVELLING...

Page 87: ...No Ident No Description Drawing No Qty Description Drawing Pos Ident No SP MOTOR ACCESSORIES ENG 036118 00 210935 1 STK 1 M MOTOR 45KW 400 690V 50HZ 010024 4 STK 4 SCREW 000411 1 STK 5 MOTOR CENTRIFUG...

Page 88: ...O RINGE F GEHAEUSE ENG 036118 00 405212 1 STK A 39 OUTLET SEAL 050279 1 STK A 40 O RING 270 R 050245 1 STK A 121 O RING 142 R 050123 1 STK A 122 O RING 153 R 050230 1 STK A 1 213 O RING 113 R SAFETY...

Page 89: ...NG 000301 1 STK 14 FLANGE 000300 1 STK 15 FIXING LEVER 010456 1 STK 16 HANDLE 000296 1 STK B 17 SLIDING RING 010099 6 STK 18 SCREW 010477 1 STK 19 HANDWHEEL 010273 2 STK 20 SPRING COTTER 000302 1 STK...

Page 90: ...G ELEMENT STATOR 051054 1 STK B 65 PRESSURE SPRING 000209 4 STK 67 SCREW WITH PIN 010591 4 STK A 68 SEALING RING SEALING LIQUID CONNECTION 105 90 37 01 1 021042 1 STK 1 DIRT TRAP 020629 1 STK 2 NIPPLE...

Page 91: ...Ident No Description Drawing No Qty Description Drawing Pos Ident No SP GRINDING UNIT ENG 036118 00 040719 1 STK B 1 402 STATOR 041272 1 STK B 1 405 ROTOR CROSS CUT HOLDING SCREW ENG 036118 00 003213...

Page 92: ...ne No 691775 310160 INLET RM No Ident No Description Drawing No Qty Description Drawing Pos Ident No SP INLET ENG 036118 00 022533 2 STK 0 FLANGE 011527 4 STK 0 SCREW 010365 4 STK 0 NUT SEALING RING E...

Page 93: ...No Description Drawing No Qty Description Drawing Pos Ident No SP OUTLET ENG 036118 00 022541 2 STK 0 FLANGE 011527 4 STK 0 SCREW 010365 4 STK 0 NUT 010110 4 STK 632 SCREW 000047 1 STK 1 601 DISCHARG...

Page 94: ...nts Part 2 MZ 190 Com 102192 2 2 DRAWINGS PID ENG 039393 01 1 Layout ENG 039392 00 1 Working area ENG 036118 00 1 Security switch 93 89 12 02 1 Mechanical seal 93 00 63 04 1 Sealing liquid connection...

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Page 101: ...Table of contents Part 2 MZ 190 Com 102192 3 3 VACUUM SYSTEM...

Page 102: ...Table of contents Part 2 MZ 190 Com 102192 4 4 SEALING LIQUID UNIT MECHANICAL SEAL...

Page 103: ...Table of contents Part 2 MZ 190 Com 102192 5 5 CIP CLEANING CONVEYING PUMP ACCESSORIES...

Page 104: ...f contents Part 2 MZ 190 Com 102192 6 6 INSTRUMENTATION P T F L FITTINGS VALVES SAFETY DEVICES PNEUMATIC FITTINGS Security switch Euchner NZ VZ Excess pressure valve Samson Type 44 6 Flow monitor Meis...

Page 105: ...Table of contents Part 2 MZ 190 Com 102192 7 7 HEATING COOLING UNITS VESSEL AND PIPING BLENDING VESSEL AND MIXER...

Page 106: ...Table of contents Part 2 MZ 190 Com 102192 8 8 DRIVES AND GEARS Motor EMWB Regreasing EMWB...

Page 107: ...Table of contents Part 2 MZ 190 Com 102192 9 9 PARTS IN THE SWITCHGEAR...

Page 108: ...Table of contents Part 2 MZ 190 Com 102192 10 10 CERTIFICATES...

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