Double Disc Refiner

Installation and Commissioning

To guarantee equipment running smoothly without malfunction, so correct installation and precise adjustment on foundation is important, following is our suggestion:

1. Prepare foundation

Movable foundation is convenient for adjusting equipment precisely and eliminating influence caused by vibrating, so movable foundation is advisable.

2. Prepare movable foundation

Make a fixed foundation on the floor, the height is about 60-100mm, lay an isolating layer after the foundation becomes solid, then make a movable concrete foundation on the isolated layer, please notice:

Set aside suitable space for two seamless steel pipes (Φ159*10, vent pipe) at the width direction of the movable concrete foundation so that the foundation can be supported up by steel pipes after it becomes solid.

Reserve space for second pouring, the height is 300-320mm.

Distribute rebars for second concrete pouring and the rebar should be integrated with those of movable foundation, but the height is less than 320mm, for the height of the anchor bolt is 350mm.

Concrete embedded metal parts (prepared by users) onto movable concrete foundation (namely, on the bottom face of second pouring), the distribution is same with anchor bolts.

3. Arrange bumper block

After the concrete movable foundation becomes solid, let two round steel pass through the prefabricated Φ159×10 seamless steel pipes, use jack to support movable foundation, make it separate from fixed foundation. Clean the isolating layer, put the bumper blocks between the movable concrete foundation and fixed foundation. The height of the fixed foundation is 60-100mm, the block should not be soaked by water (see diagrammatic drawing for arrangement of block), lay down the movable concrete foundation onto the bumper block

4. Install equipment

Lift the equipment and fix the special T-bolts (Yunda provides), T-nuts (Yunda provides) and the same amount of concave steel washers (customer provides) and cooper washers (customer provides) to the equipment. The steel washer and cooper washer is placed between equipment and T-bolt

Put the equipment incl. T-bolts and T-nuts onto the embedded metal part on the movable foundation.

Rectify the equipment by the bolts which are at the bottom of the T-bolt

5. Install motor and reducer

If assemble reducer, install the gear coupling to output shaft of the reducer. Between motor and reducer, transmit power through gear coupling; if no reducer, install the gear coupling to the shaft of the motor. The installation procedure is the same as the equipment installation. Please note that the distance between motor or outer tooth shaft sleeve end surface of the gear coupling at keep a distance of 60-65mm or more between the end of outer gear sleeve of gear coupling on the reducer or motor and the end of outer gear shaft sleeve of the gear coupling on the principal shaft of refiner.

6. Correct the concentricity and parallelism of equipment

According to below drawings, correct the refiner main shaft with motor or with reducer shaft. This is very important to extend service life of bearing and coupling, avoid shaking and lower the noise. The parallelism between two shafts must be less than 0.25mm (≤0.25mm), the concentricity between two shafts less than Φ0.16mm (≤Φ0.16mm). Please note that the dial indicator must vertically contact the component.

7. Second concrete pouring

After the parallelism and concentricity between main shaft and reducer or between main shaft and motor shaft meet the requirements, weld strictly the bottom of the T-type bolts and embedded metal part. Pack T-type nuts tightly with adhesive tape to avoid concrete getting in and then conduct second concrete pouring and surface calendaring.

8. Final adjustment

After second pouring concrete becomes solid, proceed to second adjustment and precise adjustment, check the parallelism and coaxiality between two outer tooth sleeves by dial indicator, increasing or reducing concave steel washers help to complete the adjustment.

9. Install annular gear of the gear coupling

Install fasten annular gear and add machine oil.

10. Install pipeline

Install inlet and outlet pipe and valves; for movable foundation, flexible interconnecting pieces are required and the pipeline must be supported with column, don’t let its load onto the equipment. Install a cleaning water pipe at the behind of the inlet pipe valve for cleaning when shut down machine.

11. Install sealing cooling water

The sealing water must be clear water. If equipped with reducer, the reducer must be equipped with sealing cooling water. Water pressure must be higher than inlet pressure about 0.05- 0.1MPa

12. Install electrical cabinet and connect wires for motor

13. Install on-site instrument accordingly

Operation Instruction

1. Check all following points before start

Check the cleanness inside the refiner to ensure the inlet and outlet is unblocked and the valve and sealing work well.
Check the lubrication and make sure no oil leak
Check the motor and electrical control system
Check the pressure meter of inlet pipe and outlet pipe
Fasten the bolt of refiner disc, and make sure the main shaft turn flexibly and there are space between two discs.
Check the valves of accept pipe and the outlet pipe.

2. Start steps

Open the fresh water valve and sealing water valve to fill fresh water to refiner.
Start the refiner
Start the pulp pump.
Switch on feed valve and off the washing water valve
Feed by improving pressure (user could adjust the space between abrasive discs, pressure of inlet and outlet, flow and electrical current)
Open the accept pipe valve and close the circle valve after check pulp up to standard.

3. Stop steps

Open outlet pipe valve and close the accept pipe valve
Withdraw the movable pedestal until there is around 3mm space between two abrasive discs
Open fresh water valve and close inlet pipe valve
Stop feeding pump
Stop the machine
Close washing water valve and sealing water valve and clean the refiner.

Maintenance

Keep the equipment clean
Add lubricating grease to bearings each three months, change and clean the oil each six months.
Add lubricating grease to sliding surface between movable pedestal and machine cover each week, change and clean the oil each three months.
Add lubricating grease to trapezoid screw each three months, change and clean the oil each year.
Add lubricating grease to bearing pedestal every day to keep good lubrication of sliding sleeve, change and clean the oil each three months.
Check the axial movement of rotating disc regularly; if overload and feeder works not well, check the outer side of the Nylon column pin of coupling and timely change if there is any pit.

Change abrasive disc

When grinding teeth ≤1.5mm, change abrasive disc, the changing sequence is as follows:

Shut down and power it down.
Retreat the movable pedestal into machine cover.
Loose the fastener and open the machine cover
Take down the rotating disc
Dismount the abrasive disc
When install new abrasive discs, fix well and adopt abrasive disc with left lines at movable pedestal side while other side right lines.

Change mechanical sealing:

If sealing part is worn seriously and leaks water or pulp, change mechanical sealing, the sequence is as follows:

Shut down and power it down.
Open the machine cover, take down the rotating disc.
Loose the fastening screw and take down the rotating ring
Loose the sealing plate at the back of machine cover, take down stationary ring
Re-install the stationary ring, the accuracy requirement: circle run-out of stationary ring surface relative to axis surface of main shaft should be less than 0.025mm
Install the rotating ring, fasten the screw, check the running condition, when all is well, install the rotating disc and close the machine cover.

Spare Parts

Left abrasive disc 2 pcs
Right abrasive disc 2 pcs
Sealing ring 1pc

Fitting