Instructions for MB Ball Mill（2）

4.2.1磨機試運轉   The test-run of mill
上述準備工作完成后，即可進行試運轉。
The test-run can begin after the completion of above mentioned preparations.
(1)空轉：No-load operation
 磨機不加研磨體，連續運轉12小時，要求軸承溫度在60℃以下。停磨后檢查所有堅固螺栓有無松動現象，設備有無不符合設備安裝要求的缺陷，如發現應及時調整和處理。（特別是中空軸與筒體連接螺栓）
The grinding compartment are not loaded with grinding media and the mill is confinuously operated for 12 hours. The temperature of main bearing should not be higher than 60℃. Every fastening bolts should be checked to see if they are loose. After machine halt, the adjustment and treatment should be done in time if some installation defects are found. (Especially check joint central bolt between trunnion shaft and shell)
(2)半負載運轉:Partial-load operation:
   在粗磨倉,細磨倉中各加入研磨體裝載的1/3,喂入相應數量的物料,連續運載48小時,觀察并檢查所有軸承的溫度應符合要求,各零,部件應符合安裝要求的規定。若出現不正常現象應及時（特殊檢查中空軸與筒體連接螺栓，擰緊力矩為每平方毫米0.9～1.1N.m,且所有螺栓力矩要保持一致.）
The coarse and fine grinding compartments are load with grinding media of 1/3 loading capacity, and the mill is fed with material of corresponding quantity. After 48 hours and every elements should be checked, and should fit the technical requirements. If any abnormal conditions appear should be treated in time. (especially) check joint bolt between trunnion shaft and shell. Tighten moment  is 0.9～1.1n.m/mm2).
再將研磨體加至總量的2/3，喂入相應數量的物料，運轉96小時，檢查我異常現象后，再將研磨體加至5/6，喂入相應的物料，運轉96小時。
Afresh add grinding media to 2/3 of total quantity, feed in appropriate quantity of material, run 96 hours, if never abnormal condition appeared by checking, therefore, afresh add grinding media to 5/6 , feed in corresponding quantity of material, run 96 hours again.
(3) 全負荷運轉：Full-load operation：
 在空載和半負荷運轉正常的基礎上，裝入全部裝載量的研磨體，補充相應物料，連續運轉72小時以后，如情況正常，可投入正常轉。
On the basis of normal operation of no-load and partial-load operation, load with total loading capacity of grinding media, complement corresponding quantity of material, after 72 hours normal and continous operation, the full-load operation of mill can begin.
磨機在負載試運轉時應達到下列要求：
When the mill is test-run of load operation, it should make achievement as following:
(a)工作平穩，無急劇周期性的振動。
Operation is smooth and stable. There is no rapid periodic vibration.
（b）主電機的電流無異常波動。
There is never abnormal wave motion on electric current of main motor.
（c）磨機的端襯板、筒體襯板、隔倉板和磨門等的螺栓部位應無漏漿或漏灰現象，如有則應立即停磨消除。
 Around the bolts of the liners of mill end covers, of the liners of the shell. Of the compartment separators and the mill doors. Etc. should be never mortar or ash leakage, or should stop the mill and eliminate them soon.
（d）檢查各部位的螺栓是否松動、折斷或脫落，如發現上述問題應及時處理，特別注意擰緊中空軸與筒體連接螺栓，擰緊力矩為0.9～1.1N.m/mm2且所有螺栓擰緊力矩應保持一致.
Check over all bolts, treat them on time if the bolts became flexile, were broken or were dropped. Especially check joint bolt between trunnion shaft and shell. Tighten moment is 0.9～1.1N.m/mm2
(e)主軸承的軸瓦溫度應不高于65℃;主軸承的回油溫度應不高于50℃
 The temperature of main bearing bushes should be never higher than 65℃, the temperature of main bearing return oil should be never higher than 50℃.
(f)減速器內潤滑油的溫升可為20～25℃.
The temperature rise of lubricant oil in decelerator may be 20～25℃.
(g)新安裝的減速器經過運轉250小時后,減速器內的潤滑油應更換或用濾油機將油過濾后再用.
After 250 hours operation for new installing decelerator, the ludricant oil in decelerator should be changed, or to be filtered by filtrator before to be operated again.
(4)全負荷運轉一星期,打開磨門在各倉中每一米長的地方取樣,檢查物料粉粉磨細度以確定研磨體的裝卸量及級配.再次擰緊中空軸與筒體連接螺栓,擰緊力矩為0.9～101N.m/mm2.
After one week full-load operation. Open the mill doors, sample the material in the places of every meter along the mill axis to check the fineness of the material powder for determining the loading capacity and grading of the grinding media .(check joint bolts between trunnion shaft and shell. Tig  hten moment is  0.9～101N.m/mm2)
4.1.3磨機起動 The start of mill
經嚴格檢查并完全符合要求后,即可發出磨機起動信號,待磨機及運輸設備附近的人員離開設備以后可以起動磨機.
After careful check over and fit requirements, may emit driving signal, await personnel who around the mill and transport equipments have departed from the equipments, may start the ball mill.
磨機起動順序:
The mill can be started as following sequence;
(1)接通主軸承冷卻水系統,并向主軸承上澆注相當的潤滑油.(用稀油站的則先開動稀油 ,大型磨機應同時開動電機和減速機的供油系統和冷卻系統)
Turn on the cooling device of the main bearings , and pour adequate lubricant oil into the main bearings.(if using thin oil station, we firstly open it . For large-sized mill, suppling oil station cooling system are open at the same time)
(2)開動選粉機及收塵設備.
Start the classifier and dust collectors.
 (3)開動輸送設備(提升機,卸料設備).
Start the conveying equipments (lifter and discharging equipment).
(4)開動主電動機.
Start the main motor.
(5)開動喂料設備.
Start the feed equipment.
4.1.磨機的動轉4Operation of the mill
當磨機運轉后,有關人員應及時進行下列各項工作:
When mill is in operation, the following items should be checked on time;

1. 所有外露堅固件有無松動現象.

If all exposed fastening bolts have come loose.

1. 主軸承、滾動軸承、減速器和電動的潤滑是否正常, 各個軸承是否有過熱現象.

If the lubrication lf main bearings, rolling bearings decelerator and motor is normal, and if superheat of every bearing happens.

1. 磨機運轉是否正常平穩,有無不正常的劇烈振動.

If the lubrication of main bearings, rolling bearings decelerator and motor is normal, and if superheat of every bearing happens.

1. 各密封處是否嚴密,有無漏料、漏灰、漏油、漏水等現象.

If the phenomena of material, ash, oil and water leakage happen in the place of sealing places.

1. 主軸承冷卻水系統是否正常.

If the cooling system of main bearings is in normal operation.

1. 減速器是否正常(減速器的使用注意事項見其說明書),大小齒輪的嚙合是否正常.

If the decelerator is normal (matters needing attention of decelerator see the instructions), and if the engagement of the girth gear and pinion is normal.

1. 電動機的電流數值及波動情況.

The value and fluctuation of motor electrical current.

1. 各測溫點的溫度是否正常.

If the temperature in each measurement point is normal.

1. 磨機產量及磨內物料流動情況.

The throughput and the material flow of the mill.
4.1. 磨機的停車:    5Machine halt of mill
磨機欲停車時,應先做好停車的準備工作.首先以預定的信號通知各附屬的人員應做好停車準備工作,停車順序如下:
Before machine halt, the preparations should be made, predetermined signals should be notified the operators of auxiliary equipment for them to make preparations for machine halt. The machine halt sequence in as following;

1. 先停喂料設備. Firstly, stop feed device.

2. 停止主電動機. Stop main motor.

3. 停止輸送設備. Stop conveying devices.

4. 停止選粉同及收塵設備.Stop classifier and dust collectors.

5. 停止潤滑及冷卻系統.Stop lubrication and cooling systems.

4.1.6 磨機的緊急停機: Emergency cut-off of mill:
在運行中發生下列情況之一,應緊急停磨:
When one of following conditions happens, the mill should be emergency cut-off:

1. 主軸承的振動幅度超過0.15mm時.

The  vibration amplitude of main bearing exceed 0.15mm.

1. 主軸承溫度高于60℃.

The temperature of main bearing higher than 60℃.

1. 襯板、人孔門、回轉部分及其他聯接螺栓松動或脫落時.

The bolts of liners, manhole door , rotating part and other parts have come loose or off.

1. 隔倉板、出料篦板或出料篩堵塞影響生產時.

The blocking up of compartment separators, discharging grate plates or screen seriors affects the normal mill production.

1. 磨機機件或襯板脫落或破裂時.

Components or liners of the mill have fallen off or broken.

1. 潤滑系統發生斷油故障時.

Oil cut-off trouble arises in the lubricating system.

1. 減速器或電動機發行異常現象(如嚙合不正常,溫升過高)時

Abnormal  phenomena arises in decelerator or motor (such as abnormal engagement, exceeding normal temperature).

1. 冷卻水溫升過或突然中斷.

The temperature of the cooling water is too high or the cooling water is suddenly cut-off.

1. 主軸承冷卻水有滲漏水進入潤滑油中時.

The cooling water of the main bearings leaks into the lubrication oil.

1. 磨機的其他機件,如傳動部件的聯接螺栓松動或部件損壞影響安全生產時.

Other loosed or damaged mill components and parts such as bolts of transmission components affect the production.

1. 大齒輪的對口螺栓松動時.

Alignment bolts of girth gear are loosed.
4.2 維護和保養Maintenance
4.2.1維護和保養Maintenance
磨機的維護和保養是極其重要的,而且是經常性的工作,應與磨機的操作和檢修密切配合起來進行.磨機的維護保養工作直接影響到磨機的運轉率和使用壽命,因此應有專職人員值班檢查,以便能及時排除故障,保證正常生產.
The maintenance of the mill is an important day-today work, and should be in harmony with operation and overhaul, it directly affects the utilization rate and service life of the mill, so full time personnel should be on duty to check and fix a breakdown to keep normal production.

1. 主軸承、滾動軸承、減速器、電動機同甘共苦注入的潤滑油、潤滑脂必須清潔,裝油處必須密封良好,使油保持干凈.注油量應符合各油位指示器要求,潤滑油要按規定定期添加和更換.

The lrbrcation oil grease of the main bearings, rolling bearings, decelerator and bearings of motor should be clean .The lubrication site should be sealed let oil and grease chean . The oil charge should be in accordance with oil level indicators. The oil should be added and replaced at regular intervals.

1. 對新裝或更換的摩擦潤滑件,注油運轉30天后,應將油全部倒出另換新油.換油時必須保證潤滑清潔無雜質,并符合應采用的牌號(潤滑劑表列地本說明書后部).同時應刷洗油池.

For newly installed of replaced frictional lubricating elements, after 30 days operation, the lubrication oil should be poured with fresh oil which is clean and non impurity, moreover, their trademarks should fit requirements (the lubricant table is tabulated on the rear of this instructions).

1. 已變質的或不干凈的油禁止使用.冬季加油或換油時,應預先將油加熱至20℃左右.

The deteriorated or soiled oil is forbidden to be used, when oil is added or replaced in winter season, the oil should be pre-heated to about 20℃.

1. 經常檢查各軸承溫度不得超過60℃,檢查潤滑點的油位高度和潤滑油系統供油壓力和供油量,主軸承溫度控制在15～60℃.若低于15℃應將主軸承冷卻水減少或暫時關閉.

The temperature of every bearing must not exceed 60℃. The oil level height of lubuication site, oil charging pressure and oil quamtity charge of the lubricating system should be checked regularly. The temperature of main bearing should be  controued between 15℃ and 60℃. If the temperature is lower than 15℃, the cooling water should be reduced or turned off temporarily.

1. 新裝襯板的螺栓,在開始數日運轉中常發生松動,因此須隔一定時間檢查并擰緊,并注意檢查襯板螺栓有無斷裂.

The bolts of newly installing linere happen loose frequently in first few days, so should be reduced or turned off temporarily.

1. 要注意檢查并記錄電動機電流值的變化.若電流下降(這說明磨內研磨體和襯板磨損過多),應及時調整,更換研磨和襯板.

Variations of the motor current should be checked and recorded. If the current has dropped (this reflects the wear of grinding media and liners), the grinding media and liners should be adjusted and replaced without delay.

1. 除日常維護外,要定期檢查主軸承,中空軸,筒體,減速器,大小齒輪,襯板的磨損情況并做好記錄,發現問題及時處理,做好檢修計劃.

Besides ordinary maintenance, wear condition of main bearings, trunnion shafts, mill shell. Decelerator, girth gear and pinion and liners should be checked and recprded at regular intervals. Treatment and overhaul should be given when troubles happen to the mill.
4.2.2 注意事項:  Points for attention:
(1)在冬季,若停磨時間較長,應將裝在主軸承進水口處的三通旋塞(即三通閥)轉到放水位置.利用虹吸作用,將球面瓦水道內積水排除,以免凍裂球面瓦或軸承座.
In winter season, if the mill is stop working for a long period of time. The three-way cock (namely “T cock”)which installed in the water inlet of the main bearing should be turn to “drain out” position to drain off the accumulated water in globe bearings by siphon principle to avoid frost crack of globe bearings and bearing seats.
(2)停磨后每隔5～10分鐘,將磨機轉動半圈(180o),反復進行直到磨身充分冷卻為止,以防磨
機變形.
Every 5～10 minutes after machine halt. The mill should be turned semicircumference (180℃), and should be kept on doing until the mill shell cool down to prevent the mill shell deforming.
(3)若在運轉中突然停電,應將磨機和附屬設備的電動的電源拉開(即斷開),以免來電時發生事故.
If power cut unexpectedly in operation, the power switches of motor and auxiliary equipments should be turned off (namely cut off) to prevent the accidents when power is suddenly on.
(4)長期停磨時應把研磨體倒出,以免筒體變形.
If the mill stop working for a long period of time. The grinding media should be discharged to prevent the mill shell deforming.
(5)在冬季,生產時要注意磨尾氣保溫工作,若溫度低于露點,會出現冷卻水,損壞收塵器.
In winter season. Hat preserving of cxhausting gases on the mill tail should be treated in operation. If the temperature is lower than dew-point. Condensating water will appear and damage the dust collector.
(6)在冬季(我國北方),停磨8小時以上,在開動磨機前應將主軸承潤滑油放出,加熱至20℃,再倒入主軸承內.
In winter season (in the northern part of our country). After machine halt for more than 8 hours, the lubrication oil should be poured out and heated up to 20℃, then poured into main bearing before mill starting.
4.3檢修Overhaul
磨在運轉過程中,某些零件或部件會產生磨損.若不定期檢修,會影響設備正常運轉,甚至會發生事故.為保證及時恢復每個零件部件的原來作用,使用單位必須根據設備磨損情況,制定出切合實際的檢修計劃(和使用周期).檢修中包括對機件作全面檢查、調整、清洗和修復及更換.
Partial parts and partial components will be worn down in mill operation. Irregularly scheduled overhaul oil influence the normal production of every components and parts, according to wear of equipments, the consumers should lay down practical overhaul scheme which includes check up ,adjustment , wash, replacement as well as repair of some mill components and parts.
4.3.1 傳動裝置的檢修:  Overhaul of transmission device
(1)電動機的檢修應按電動機說明進行.
The overhaul of the motor should be accordanced  with instructions of motor.
(2)減速器的檢修應按減速器說明進行.
The overhaul of decdlerator should be accordanced with instructions of decelerator.
(3)大小齒輪磨損至原齒厚的75%或斷裂掉齒時應及時更換與修復.
When the tooth thickness of girth gear and pinion is worn down to 75%of its original tooth thickness or the tooth is broken or fallen off, the replacement and repair should be conducted.
(4)傳動軸出現深10mm裂紋應檢修或更換.
The repair or replacement should be conducted when 10mm deep crack appears in the transmission shaft.
(5)滾動軸承密封不良有漏油現象,滾動軸承由于磨損使徑向間隙大于0.3mm,應更換.
The rolling bearings should be replaced or restored if it has oil leak or its diametral clearance is larger than 0.3mm because of wear.
(6)齒輪罩中刮油器磨損或不起刮同作用,應修復與更換.
Oil scrapers and wipers in the gear corers should be replaced or restored if they are damaged or cannot work properly
(7)齒輪罩的密封裝置如不能良好密封時,應及時調整或更換.
The sealing devices of gear covers should be adjusted or replaced promptly if it has oil leak.
4.3.2主軸承的檢修:Overhaul of main bearings
(1)球面瓦的巴氏合金被壓潰或磨損5mm時,須重新澆注巴氏合金.
The babbit metal should be pouring again when it is broken down or is worn down 5mm thickness.
(2)主軸承表面磨損出現拉絲深度超過1mm須修復,中空軸出現裂紋應修復與更換.
The repair should be conducted when the depth of scratch appeared on the main bearing surface exceeds 1mm , and the repair or replacement should be conducted when crack appears in the trunnion shaft.
(3)刮油器處的油圈刮油,帶油的情況不好,應及時修復或更換.
When oil ring of oil wiper cannot work properly, it should be repaired or replaced.
(4)主軸承的密封應良好.如發現漏油應檢查密封墊是否磨損,如磨損應及時調整或更換.如刮油板,刮油刷安裝角度不對,應及時調整.刮油板,刮油的安裝位置和角度.與磨機回轉方向有關.
Main bearing should be sealed well. When oil leakage happens , please check if the gaskets are woun down and the installtion angles of oil wipers and oil scrapers are correct. The worn down gaskets should be adjusted or reolaced. The right installation positions ad angles of oil wipers and oil scrapers are related to rotation direction of the mill.
(5)球面瓦或主軸承座漏水,以致水與油混合,應及時修復或更換.
When globe bearing or main bearing seat water leakage happens so lubrication oil is mixed in water therefore. Should repair or replace them on time.
4.3.3回轉部分的檢修Overhaul of rotating part
(1)進出料螺旋筒和葉片磨穿或磨損至原來厚度的70%須修復或更換.
When charging and discharge screw tubes are worn into holes or their thickness are worn down to 70﹪ of their original thickness. They should be repaired or replaced.
(2)篦板,單層隔倉板磨損超過原來厚度的50%應更換.
The grate plates and single layer compartment separator plates should be replaced when their thickness are worn down over 50﹪ of their original thickness.
(3)磨頭襯板和(或)筒體襯板破裂,不完整等(掉邊,掉角,裂紋)或磨損超過原來厚度70%,應更換.
The liners of mill header, and of shell body, should be replaced they are broken or incomplete, etc. (lost edge, lost angle. Cracked) or their thickness are worn down over 70﹪ of their original thickness. Or cracks or partial deformation appears.
(4)筒體厚度磨損了原來厚度20%或有裂紋,局部變形,應修復或更換.
The repair or replacement should be conducted when the thickness of the mill shell is worn down 20﹪ of their original thickness, or cracks or partial deformation appears.
(5)入孔蓋及其密封墊損壞時,應時更換.
Manhole covers and their gaskets should be replaced when they are damaged.
(6)研磨體磨損應定期清倉,分選,及時補充.嚴禁從進料螺旋筒加研磨體入磨,以防止損壞進料螺旋筒等.
Because of wear, grinding media should be cleared away. Classified and complemented at regular intervals. It is prohibited severely to add grinding media from charging screw tube. In order to avoid its damage.
(7)襯板的螺栓磨損,松動,須更換螺栓.
The bolts of liners should be replaced when bolts are worn down or loosed.
4.3.4 進料部分的檢修:Overhaul of charging part
(1)進料漏斗磨損,磨空,須焊補或更換.
Welding patches or replace should be conducted when charging funnel is worn down or worn into holes.
(2)進料漏斗與進料螺旋筒間的密封被磨損造成漏料或漏灰時應修復或更換.
When the sealing material between the charging funnel and charging screw tube is worn down  to cause material and ashes leak, it should be repaired or replaced.
4.3.5 出料部分的檢修:Overhaul of discharging part
(1)出料罩密封失效造成漏灰時應及時修復或更換.
When the seal of discharging cover is failure to cause ashes leak, it should be repaired or replaced.
(2)出料篩孔磨損過大,篩孔間磨穿或堵塞應及時焊補,修復,清理,更換.
The discharging screen should be welded up. Repaired. Cleared up and replaced when screen. Is blinding. Worn down or worn through between its holes.

1. 出料罩磨至1mm或磨穿時應焊補或更換.

Welding patches or replacement should be conducted when the thickness of the discharging cover is worn down to l mm thick or worn into holes.
5.附表ADDITIONAL LIST
潤滑劑項目表Lubricant items