MDDP_BA_66606-4-en_US-1603

Operating instructions Roller mill Dolomit (Mark II) MDDP four-roller mill MDDQ eight-roller mill Original operating instructions MDDP-MDDQ-66606-4-1603-en- US

Table of contents 1 Important information 7 1.1 Scope ............................................................................................................ 7 1.2 Applicable documents ................................................................................... 7 1.3 Contact .......................................................................................................... 7 1.3.1 Address .......................................................................................... 8 1.4 Personnel qualification .................................................................................. 8 1.4.1 Mechanics ...................................................................................... 8 1.4.2 Electricians .................................................................................... 8 1.4.3 Bühler service personnel .............................................................. 8 1.4.4 Owner's service personnel ............................................................ 8 1.5 Presentation conventions .............................................................................. 8 1.5.1 Explanation of warning messages ................................................ 8 2 Safety 10 2.1 Intended use ................................................................................................. 10 2.2 Technical condition ....................................................................................... 10 2.3 ATEX labeling ............................................................................................... 10 2.4 Personnel qualification .................................................................................. 10 2.5 Personal protective equipment ..................................................................... 11 2.6 Securing device against unexpected startup ............................................... 11 2.7 Protective devices ......................................................................................... 11 2.8 Safety signs ................................................................................................... 11 2.9 Safe work environment ................................................................................. 11 2.9.1 Slipping and tripping hazards ....................................................... 11 2.9.2 Aspiration ....................................................................................... 12 3 Technical data 13 3.1 Environmental conditions .............................................................................. 13 3.2 Performance characteristics .......................................................................... 13 3.2.1 Drive powers ................................................................................. 13 3.2.2 Speeds of corrugated and smooth rollers (depending on passage) ........................................................................................ 13 3.3 Operating supplies ........................................................................................ 13 3.3.1 Gearmotor for feed rollers ............................................................ 13 3.3.2 Roller bearing grease .................................................................... 15 3.3.3 Gear drive (option) ........................................................................ 16 3.4 Driving wheels to main drive ........................................................................ 17 3.4.1 Narrow V-belt SPB measured values .......................................... 17 3.5 Roller drive .................................................................................................... 17 3.5.1 Measured values for timing belts ................................................. 17 3.6 Gear drive (option) ........................................................................................ 18 3.7 Consumption data ......................................................................................... 18 3.8 Acoustic emission ......................................................................................... 19 3.8.1 MDDP measured values (standard values) ................................. 19 3.8.2 Measuring conditions .................................................................... 19 3.8.3 MDDQ measure values (standard values) ................................... 19 Bühler AG MDDP-MDDQ-66606-4-1603-en-US 2 Table of contents

3.8.4 Measuring conditions .................................................................... 19 3.9 Weights .......................................................................................................... 20 3.9.1 Four-roller mill MDDP-250/800 ..................................................... 20 3.9.2 Four-roller mill MDDP-250/1000 ................................................... 20 3.9.3 Four-roller mill MDDP-250/1250 ................................................... 20 3.9.4 Four-roller mill MDDP-300/1000 ................................................... 20 3.9.5 Four-roller mill MDDP-300/1250 ................................................... 20 3.9.6 Eight-roller mill MDDQ-250/1000 .................................................. 20 3.9.7 Eight-roller mill MDDQ-250/1250 .................................................. 21 3.9.8 Single parts ................................................................................... 21 3.10 Dimensions .................................................................................................... 22 3.10.1 Four-roller mill MDDP D 250 ........................................................ 22 3.10.2 Eight-roller mill MDDQ D 250 ....................................................... 23 3.10.3 Four-roller mill MDDP D 300 ........................................................ 24 3.11 Electrical specifications ................................................................................. 24 3.11.1 Control systems ............................................................................. 24 3.11.2 Frequency converter of the feed roller drive motor ..................... 25 3.11.3 Drive motors of the grinding rollers .............................................. 25 3.12 Pneumatic system ......................................................................................... 25 3.13 Coolant filling of the grinding rollers ............................................................ 25 4 Description 26 4.1 Identification .................................................................................................. 26 4.1.1 Nameplate ..................................................................................... 26 4.2 Overview ........................................................................................................ 29 4.2.2 Zones and passages ..................................................................... 30 4.2.3 Main components .......................................................................... 30 4.2.4 Product inlets ................................................................................. 30 4.2.5 Product outlets (option) ................................................................. 33 4.2.6 Scrapers ........................................................................................ 33 4.2.7 Direct aspiration (option) ............................................................... 35 4.2.8 Options .......................................................................................... 35 4.3 Operating principle ........................................................................................ 36 4.3.1 Feeder unit .................................................................................... 36 4.3.2 Gas pressure springs .................................................................... 36 4.3.3 Roller assembly ............................................................................. 36 4.3.4 Aspiration ....................................................................................... 36 4.3.5 Control ........................................................................................... 36 4.3.6 Lubrication lines ............................................................................ 36 4.4 Operating modes ........................................................................................... 37 4.5 Machine stop ................................................................................................. 37 4.6 Protective devices ......................................................................................... 38 4.6.1 Cladding ......................................................................................... 38 4.6.2 Hand guard .................................................................................... 38 4.6.3 Hand guard .................................................................................... 39 4.6.4 Safety switch ................................................................................. 39 4.6.5 Protective device for machine ...................................................... 40 4.7 Safety signs ................................................................................................... 41 4.8 Operating and display elements ................................................................... 41 5 Transportation 42 5.1 Safety ............................................................................................................ 42 5.1.1 Suspended load ............................................................................ 42 5.2 Packaging symbols ....................................................................................... 42 Bühler AG 3 MDDP-MDDQ-66606-4-1603-en-US Table of contents

5.3 Checking delivery .......................................................................................... 42 5.4 Intermediate storage ..................................................................................... 42 5.5 Lifting instructions ......................................................................................... 43 5.5.1 With forklift ..................................................................................... 43 5.5.2 With crane ..................................................................................... 43 6 Assembly 45 6.1 Preparing installation location ....................................................................... 45 6.2 Installation ..................................................................................................... 45 6.2.1 MDDP ............................................................................................ 45 6.2.2 MDDQ ............................................................................................ 45 6.2.3 Transporting the roller mill ............................................................ 45 6.2.4 Setting up roller mill ...................................................................... 47 6.2.5 Removing protective foil ................................................................ 48 6.2.6 Converting the hinge part at the side panel ................................ 49 6.3 Installing product connections ...................................................................... 49 6.3.1 Fitting inlet container to MDDQ .................................................... 49 6.3.2 Product inlet .................................................................................. 50 6.3.3 Setting grinding gap aspiration ..................................................... 51 6.3.4 Through-spouts (option) ................................................................ 51 6.3.5 Product outlet (option) ................................................................... 52 6.3.6 Direct aspiration (option) ............................................................... 53 6.4 Connecting supply units ................................................................................ 54 6.4.1 Electrical installation ...................................................................... 54 6.4.2 Connecting compressed air .......................................................... 57 6.4.3 Air circuit Schematics .................................................................... 58 6.4.4 Connecting internal aspiration ...................................................... 59 7 Commissioning 60 7.1 Checking the commissioning ........................................................................ 60 7.1.1 Removing the anti-corrosion protection from the rollers ............. 60 7.1.2 Re-lubricating grinding roller bearings .......................................... 60 7.1.3 Checking the feed gap .................................................................. 60 7.1.4 Checking the grinding gap ............................................................ 61 7.1.5 Checking roller drive ..................................................................... 61 7.1.6 Checking scraper .......................................................................... 61 7.1.7 Checking pneumatic system ......................................................... 61 7.1.8 Checking the commissioning ........................................................ 61 7.1.9 Fire and explosion protection ....................................................... 62 7.1.10 Electric safety functions ................................................................ 62 7.2 Setting ........................................................................................................... 63 7.2.1 Feed roller gap and speed ........................................................... 63 7.2.2 Manually adjusting the grinding gap ............................................ 64 7.2.3 Setting position indicator ............................................................... 64 7.3 Blockage sensor MDDQ ............................................................................... 66 7.3.1 Empty alignment ............................................................................ 66 7.3.2 Full alignment ................................................................................ 66 7.4 Aspiration pipe to product inlet .................................................................... 67 7.4.1 Individual internal aspiration ......................................................... 67 7.4.2 Internal aspiration half open ......................................................... 67 7.4.3 Closing internal aspiration ............................................................. 68 7.5 Setting direct aspiration ................................................................................ 69 7.5.1 Setting opening ............................................................................. 70 7.5.2 Setting aspiration pipe .................................................................. 70 Bühler AG MDDP-MDDQ-66606-4-1603-en-US 4 Table of contents

8 Operation 71 8.1 Preparing for production ............................................................................... 71 8.1.1 Check ............................................................................................. 71 8.2 Starting and stopping .................................................................................... 71 8.2.1 Starting .......................................................................................... 71 8.2.2 Starting after machine stop ........................................................... 71 8.2.3 Stopping ......................................................................................... 71 8.3 Checks during operation ............................................................................... 72 8.3.1 Checking and adjustment ............................................................. 72 8.3.2 Checking knife scraper ................................................................. 72 8.4 Work during operation .................................................................................. 73 8.4.1 Settings .......................................................................................... 73 8.4.2 Extracting product samples ........................................................... 74 8.4.3 Extracting product sample with sampler (option) ......................... 75 8.4.4 Setting knife scraper ..................................................................... 77 9 Fault elimination 79 9.1 Faults ............................................................................................................. 79 10 Maintenance 83 10.1 Cleaning ........................................................................................................ 83 10.1.1 Interrupting compressed-air supply ............................................... 83 10.1.2 Cleaning schedule ......................................................................... 84 10.1.3 Preparing ....................................................................................... 84 10.1.4 Cleaning feeding chamber ............................................................ 86 10.1.5 Cleaning the product inlet ............................................................. 87 10.1.6 Cleaning aspiration pipe to product inlet ..................................... 89 10.1.7 Cleaning grinding gap aspiration .................................................. 90 10.2 Heat treatment .............................................................................................. 90 10.3 Lubrication ..................................................................................................... 91 10.3.1 Lubrication schedule ..................................................................... 91 10.3.2 Lubricating the grinding roller bearings ........................................ 91 10.4 Maintenance .................................................................................................. 93 10.4.1 Maintenance schedule .................................................................. 93 10.4.2 Tensioning roller assembly timing belt ......................................... 94 10.4.3 Tensioning the V-belt of the drive ................................................ 97 10.4.4 Tensioning the feed roller drive timing belt ................................. 98 10.4.5 Checking feed roller timing belt tension ....................................... 99 10.4.6 Setting hand guard ........................................................................ 100 10.4.7 Gear drive (option) ........................................................................ 101 11 Repair 103 11.1 Preparing repairs ........................................................................................... 103 11.2 Replacing the brush scraper ........................................................................ 103 11.3 Replacing knife scraper ................................................................................ 104 11.4 Adjusting the grinding gap ............................................................................ 105 11.5 Replacing the grinding rollers ....................................................................... 105 11.5.1 Preparing the roller mill ................................................................. 105 11.5.2 Preparing cover ............................................................................. 106 11.5.3 Removing grinding rollers at the front .......................................... 108 11.5.4 Removing grinding rollers at the rear .......................................... 111 11.5.5 Installing the rear grinding rollers ................................................. 113 11.5.6 Installing grinding rollers in front .................................................. 116 11.6 Replacing bearings ....................................................................................... 119 Bühler AG 5 MDDP-MDDQ-66606-4-1603-en-US Table of contents

11.7 11.6.1 Removing the bearings ................................................................. 120 11.6.2 Fitting the bearing ......................................................................... 122 11.8 Replacing the belt pulley with a hand tool .................................................. 128 11.7.1 Removing belt pulleys ................................................................... 128 11.9 11.7.2 Fitting belt pulley ........................................................................... 129 11.10 Replacing the belt pulley with a hydraulic tool ............................................ 131 11.8.1 Removing belt pulleys ................................................................... 131 11.11 11.8.2 Fitting belt pulley ........................................................................... 134 12 Checking installation ..................................................................................... 136 12.1 11.9.1 Checking installation of roller assembly ....................................... 136 12.2 Replacing gear wheels ................................................................................. 137 11.10.1 Removing gear wheel ................................................................... 137 13 11.10.2 Fitting gear wheel .......................................................................... 138 13.1 Replacing gas pressure spring ..................................................................... 139 13.2 Decommissioning 141 Disassembly .................................................................................................. 141 Disposal ......................................................................................................... 141 12.2.1 Disposing of operating supplies .................................................... 141 12.2.2 Disposing of the machine ............................................................. 141 Spare parts 142 Spare Parts ................................................................................................... 142 Ordering instructions ..................................................................................... 142 Bühler AG MDDP-MDDQ-66606-4-1603-en-US 6 Table of contents

1 Important information 1.1 Scope Designation Type Four-roller mill D 250 MDDP-250/800 MDDP-250/1000 Four-roller mill D 300 MDDP-250/1250 Eight-roller mill D 250 MDDP-300/1000 MDDP-300/1250 MDDQ-250/1000 MDDQ-250/1250 1.2 Applicable documents The following documents are part of these instructions: Designation Identification number Roller mill control unit MEAG-MDDx-66690-x-1 Description of the serial interface RS-485 MDDx-66411-x-21 Conversion to timing belt drive MDDP-MDDQ-66606-x-2 Universal roller removal device MDDX-66798 Manual roller removal device roller assembly MDDX-H-66486-x-1 Roll-out device roller assembly MDDX-R-66486-x-2 Spare parts catalog MDDP D 250 MDDP-7987 Spare parts catalog MDDP D 300 MDDP-8286 Spare parts catalog MDDQ D 250 MDDQ-7988 Temperature strip MYUA-67203 1.3 Contact ► If you have any questions, please contact the nearest branch of the Bühler Group. See www.buhlergroup.com. ► Keep the instructions handy. ► Keep the machine number handy. Bühler AG 7 MDDP-MDDQ-66606-4-1603-en-US Chapter 1 Important information

1.3.1 Address Bühler AG 1.4 Customer Service Grain Milling CH-9240 Uzwil, Schweiz 1.4.1 T +41 71 955 30 40 1.4.2 F +41 71 955 33 05 1.4.3 [email protected] 1.4.4 Personnel qualification 1.5 Mechanics 1.5.1 Personnel who work on mechanical devices must be technically qualified or have completed the manufacturer's training. Electricians Personnel who work on electrical devices must be technically trained or have completed training provided by the manufacturer. Bühler service personnel Manufacturer's personnel who execute the assembly and commissioning, as well as complex service and maintenance tasks. Owner's service personnel Individuals who operate the machine must be technically trained or have attend- ed and passed the manufacturer's training. Presentation conventions Explanation of warning messages DANGER Nature and source of the danger. The danger will result in death or severe injuries. ► Measures to protect against the danger. WARNING Nature and source of the danger. The danger may result in death or severe injury. ► Measures to protect against the danger. CAUTION Nature and source of the danger. The danger may result in injuries. ► Measures to protect against the danger. Bühler AG MDDP-MDDQ-66606-4-1603-en-US 8 Chapter 1 Important information

CAUTION Nature and source of the danger. The danger may result in property damage. ► Measures to protect against property damage. Bühler AG 9 MDDP-MDDQ-66606-4-1603-en-US Chapter 1 Important information

2 Safety 2.1 Intended use The four-roller mill MDDP and the eight-roller mill MDDQ are intended exclusive- ly for grinding grain with 10 ... 17% moisture. Grinding other products requires special clarification from Bühler AG and must be documented. ► Use the machine only as intended. ► Operate the machine only according to these operating instructions. ► Maximum product temperature of 50 °C is not exceeded at the product inlet. 2.2 Technical condition If the machine is operated in poor technical condition, its safety, function and availability are compromised. ► Operate the machine only when it is in perfect technical condition. ► Comply with the maintenance schedule. ► Only use original spare parts listed in the spare parts catalog. ► If the operating behavior of the machine changes, check the machine for faults. ► Eliminate any faults immediately. ► The machine must not be modified or converted without approval from the manufacturer. 2.3 ATEX labeling The ATEX designation indicates the conditions under which the machine may be used in a potentially explosive zone or connected to a potentially explosive zone. ► Note the nameplate. 2.4 Personnel qualification Unqualified personnel cannot recognize risks and are thus exposed to greater danger. ► Allow only technically qualified personnel to perform the activities described in these operating instructions. ► Ensure that personnel comply with the local laws and regulations in order to work safely, keeping the dangers in mind. ► Define and communicate work responsibilities. Provide keys and passwords to designated staff only. Bühler AG MDDP-MDDQ-66606-4-1603-en-US 10 Chapter 2 Safety

2.5 Personal protective equipment 2.6 ■ Wear the following personal protective equipment: 2.7 □ Close-fitting protective clothing 2.8 □ Wear close-fitting hand protection 2.9 □ Hair net □ Non-slip safety footwear 2.9.1 ■ Keep the following protective equipment at hand: □ Protective headgear □ Ear protection □ Eye protection ■ Take the following safety measures: □ Keep personal protective equipment fully functional. Ensure the right fit. □ Take off jewelry and rings. ► The machine's safety concept requires operators to use personal protective equipment. Securing device against unexpected startup If the machine starts up unexpectedly, individuals working on the machine could be severely injured. ► Set the safety switch to <0> and lock it. ► Pull out the key and keep it with you. Protective devices People are at risk when protective devices are not functioning effectively. ► Before operating the machine, ensure that all protective devices are function- ing effectively. Safety signs If safety signs are not noticeable, people are at risk. ► Replace safety signs which are not noticeable. ► Do not remove or cover safety signs. Safe work environment Slipping and tripping hazards Slippery surfaces and tripping hazards may result in serious accidents. ► Keep aisles, handles, steps, ladders, platforms and guard rails free of grease, oil and other contamination. ► Do not use the machine as a climbing aid or storage area. Use only the steps and platforms provided. ► Wear non-slip safety footwear. Bühler AG 11 MDDP-MDDQ-66606-4-1603-en-US Chapter 2 Safety

2.9.2 Aspiration Gases and dusts are harmful to health and can result in dangerous situations during operation of the machine. ► Leave aspiration equipment activated during operation of the machine and do not remove. Bühler AG MDDP-MDDQ-66606-4-1603-en-US 12 Chapter 2 Safety

3 Technical data 3.1 Environmental conditions Value Unit 5 … +50 °C 3.2 Designation –10 … +60 °C Temperature during operation 3.2.1 Temperature during standstill 3.2.2 Performance characteristics Value Unit ≤ 45 kW 3.3 Drive powers ≤ 22 kW 3.3.1 Designation Break passages Reduction passages Speeds of corrugated and smooth rollers (depending on passage) Designation Value Unit Roller diameter 250 380 … 970 rpm Roller diameter 300 380 … 760 rpm Operating supplies Gearmotor for feed rollers Gear oil The viscosity (ISO VG class) stated on the gearbox's nameplate determines the choice of oil. Designation Value Unit Gearbox oil type on nameplate CLP PG 220 Base Synthetic Supplier: Aral Value Unit Synthetic Designation Degol GS 220 Base Product recommendation Bühler AG 13 MDDP-MDDQ-66606-4-1603-en-US Chapter 3 Technical data

Supplier: BP Value Unit Designation Synthetic Base Enersyn Product recommendation SG-XP220 Supplier: Castrol Value Unit Designation Synthetic Base Alphasyn Product recommendation PG 220 Supplier: Esso Designation Value Unit Base Synthetic Product recommendation Glycolube 220 Supplier: Fuchs Value Unit Designation Synthetic Base Renolin PG 220 Product recommendation Value Unit Supplier: Klüber Synthetic Designation Klübersynth Base GH-6-220 Product recommendation Value Unit Supplier: Mobil Synthetic Designation Glygoyle HE 220 Base Product recommendation Value Unit Synthetic Supplier: Shell Shell Tivela Designation Base S 220 Product recommendation Bühler AG MDDP-MDDQ-66606-4-1603-en-US 14 Chapter 3 Technical data

3.3.2 Roller bearing grease Grease Rolling bearings require fat of a mineral or synthetic oil base suitable for high pressures. Base oil viscosity Designation Value Unit < 70 °C Bearing housing temperature at least ISO VG 100 > 70 °C Bearing housing temperature at least ISO VG 220 In the factory, mineral oil-based grease (Kunlun) is filled. When applying addi- tional grease, that grease must be compatible with Kunlun. Mineral oil-based grease Value Unit Supplier: Pero China Lubricating Grease Mineral oil base Designation Kunlun (initial fill- Base ing at factory) Product recommendation Supplier: Klüber Value Unit Mineral oil base Designation Base Klüberplex Product recommendation BE31-222 Supplier: Exxon Mobil Value Unit Mineral oil base Designation Base Mobil Grease Product recommendation XHP 222 Supplier: Shell Value Unit Mineral oil base Designation Base Shell Gadus S3 Product recommendation V220C Bühler AG 15 MDDP-MDDQ-66606-4-1603-en-US Chapter 3 Technical data

3.3.3 Greases with NSF H1 food-use approval Value Unit Supplier: Fuchs Cassida Grease 16 Designation Product recommendation EPS2 Supplier: Klüber Value Unit Designation Klübersynth Product recommendation UH1 14-222 Supplier: Exxon Mobil Value Unit Designation Mobil SHC Poly- Product recommendation rex 222 Gear drive (option) Gear oil Value Unit Designation – Food-use approved Base Mineral Product recommendation Shell Omala Oil Gear oil with NSF H1 food-use approval 460 Designation Shell Omala Oil Base Product recommendation 680 Mobil 634 Gear oil with NSF H2 food-use approval Designation Value Unit Base Synthetic Product recommendation Mobil SHC 634 Klübersinth GH 6-460 Value Unit Mineral Klüberoil GEM 1-460 Klüberoil GEM 1-680 Bühler AG MDDP-MDDQ-66606-4-1603-en-US Chapter 3 Technical data

3.4 Driving wheels to main drive 3.4.1 Type Diameter [mm] Grooves Narrow V-belt type MDDP 355 4, 6, 8 SPB 3.5 MDDQ 355 4, 6 SPB 3.5.1 Narrow V-belt SPB measured values The test load depends on the diameter of the small V-belt pulley. Designation Value Unit V-belt pulley (D1) 160 … 224 mm 35 … 50 N V-belt pulley (D1) 236 … 315 mm 50 … 65 N Roller drive Important The roller drive permits maximum wear for both grinding rollers of 14 mm in di- ameter each. The roller drive works with timing belts. Depending on the passage, the following speed reduction ratios can be installed. Roller diameter Speed reduction ratios [mm] 1:1.23 1:1.51 1:2.0 1:2.5 1:2.9 – – – 250 1:1.04 1:1.27 1:1.59 1:2.07 1:2.5 1:3.03 1:3.51 1:3.75 300 Measured values for timing belts Fig. 3.1 Measured values for timing belts Bühler AG 17 MDDP-MDDQ-66606-4-1603-en-US Chapter 3 Technical data

Break passage D 250 Value Unit Designation 55 Hz Disk diameter, at the rear: 265 and 331 mm Speed reduction ratio 1:1.51 to 1:2.9 Break passage D 300 Value Unit 45 Hz Designation Disk diameter, at the rear: 331, 400 and 428 mm Speed reduction ratio 1:1.59 to 1:3.75 Reduction passage D 250 Value Unit Designation 65 Hz Disk diameter, at the rear: 216 mm Speed reduction ratio 1:1.23 Reduction passage D 300 Value Unit Designation 55 Hz Disk diameter, at the rear: 265 mm Speed reduction ratio 1:1.04 to 1:1.27 3.6 Gear drive (option) Important The gear drive permits maximum wear for both grinding rollers of 10 mm in di- ameter each. The gear drive works with a wheel and piston. Depending on the passage, the following speed reduction ratios can be installed. Roller diameter [mm] Speed reduction ratios 250 1:1.05 1:1.25 1:1.5 1:1.8 1:2 1:2.6 3.7 Consumption data Designation Value Unit Compressed air requirement Vn approx. 0.5 Nm3/h Bühler AG MDDP-MDDQ-66606-4-1603-en-US 18 Chapter 3 Technical data

3.8 Acoustic emission 3.8.1 MDDP measured values (standard values) 3.8.2 The measured values do not take ambient effects into account. 3.8.3 Designation Value Unit 3.8.4 Sound power level of the machine Lw 92 dB (A) 75 dB (A) Equivalent measuring surface-related emission level Leq 18 dB 77 dB (A) Measuring surface measurement Ls Equivalent workplace emission level Leq Measuring conditions Value Unit C1 Designation 15 kW Passage 1.6 t/h/m Drive power Product throughput 250 mm Product type: hard wheat Grinding roller diameter MDDQ measure values (standard values) The measured values do not take ambient effects into account. Designation Value Unit Sound power level of the machine Lw 89 dB (A) 71 dB (A) Equivalent measuring surface-related emission level Leq 19 dB 73 dB (A) Measuring surface measurement Ls Equivalent workplace emission level Leq Measuring conditions Value Unit B1/B2 Designation Passage 30 kW Drive power 3.2 t/h/m Product throughput Product type: hard wheat 250 mm Grinding roller diameter Bühler AG 19 MDDP-MDDQ-66606-4-1603-en-US Chapter 3 Technical data

3.9 Weights Value Unit 2650 kg 3.9.1 Four-roller mill MDDP-250/800 2990 kg 3.9.2 Designation 3.9.3 Net 8 m3 3.9.4 Gross 3.9.5 Volume Value Unit 3.9.6 2930 kg Four-roller mill MDDP-250/1000 3290 kg Designation Net 8 m3 Gross Volume Value Unit 3430 kg Four-roller mill MDDP-250/1250 3800 kg Designation Net 8.5 m3 Gross Volume Value Unit 3430 kg Four-roller mill MDDP-300/1000 3780 kg Designation Net 8.5 m3 Gross Volume Value Unit 3960 kg Four-roller mill MDDP-300/1250 4260 kg Designation Net 9.5 m3 Gross Volume Value Unit 5070 kg Eight-roller mill MDDQ-250/1000 5440 kg Designation Net 8.5 m3 Gross Volume Bühler AG MDDP-MDDQ-66606-4-1603-en-US 20 Chapter 3 Technical data

3.9.7 Eight-roller mill MDDQ-250/1250 Value Unit 3.9.8 6060 kg Designation 6480 kg Net D L Gross 9.5 m3 Volume 250 – 250 – Weight Single parts 300 – 11.5 kg Designation 17.0 kg Side panel door 13.5 kg MDDP MDDQ 5.5 kg MDDP 6.5 kg 8.0 kg Grinding chamber door 250 800 6.0 kg MDDP 250 1000 7.5 kg MDDP/Q 250 1250 MDDP/Q 300 1000 4.0 kg MDDP 300 1250 5.0 kg MDDP 6.5 kg Maintenance door, bottom 250 800 24.0 kg MDDP 250/300 1000 26.0 kg MDDP/Q 250/300 1250 29.0 kg MDDP/Q 27.0 kg 30.0 kg Cover, bottom 250 800 MDDP 250 1000 35.0 kg MDDP/Q 250 1250 39.0 kg MDDP/Q 300 1000 MDDP 300 1250 25.0 … 40.0 kg MDDP 17.0 … 37.0 kg Cover, middle 250 1000 5.0 … 36.0 kg MDDQ 250 1250 27.0 kg MDDQ Driving wheel MDDP/Q 250/300 – – Drive toothed lock washer MDDP/Q 250/300 – — Drive V-ribbed belt pulley MDDP/Q 250/300 Idler pulley MDDP/Q 250/300 Bühler AG 21 MDDP-MDDQ-66606-4-1603-en-US Chapter 3 Technical data

Designation D L Weight Holder for idler pulley MDDP/Q 250/300 — 18.5 … 22.5 kg Gear wheel for drive 250 — 5.0 … 31.0 kg Knife scraper including holder 250 800 Knife scraper including holder 250/300 1000 6.5 kg Knife scraper including holder 250/300 1250 7.5 kg 10.0 kg Dimensions 3.10 Four-roller mill MDDP D 250 3.10.1 Fig. 3.2 Four-roller mill MDDP D 250 Bühler AG MDDP-MDDQ-66606-4-1603-en-US 22 Chapter 3 Technical data

B (grinding roller length) C1 C3 C4 C5 C6 C7 C8 800 1208 506 1068 812 1610 1102 1614 1000 1408 506 1268 1012 1810 1302 1814 1250 1658 755 1518 1262 2060 1552 2064 3.10.2 Eight-roller mill MDDQ D 250 Fig. 3.3 Eight-roller mill MDDQ D 250 B (grinding roller length) C1 C1 C2 C3 C4 C5 C6 C7 C8 (4 SPB) (6 SPB) 1000 1250 1608 1658 1408 506 1268 1012 1940 1302 1944 1858 1908 1658 755 1518 1262 2190 1552 2194 Bühler AG 23 MDDP-MDDQ-66606-4-1603-en-US Chapter 3 Technical data

3.10.3 Four-roller mill MDDP D 300 Fig. 3.4 Four-roller mill MDDP D 300 C1 C3 C4 C5 C6 C7 C8 1408 506 1268 1012 1810 1302 1814 3.11 B (grinding roller length) 1658 755 1518 1262 2060 1552 2064 1000 3.11.1 1250 Electrical specifications Value Unit 24 V DC Control systems 20 W Without additional outputs Designation Voltage Power Bühler AG MDDP-MDDQ-66606-4-1603-en-US 24 Chapter 3 Technical data

3.11.2 Frequency converter of the feed roller drive motor Value Unit 3.11.3 380 … 500 V AC Designation approx. 2.6 A 3.12 Voltage 3.13 Nominal current Drive motors of the grinding rollers Value Unit Current requirement depending on passage and load 380 … 500 V AC Designation Voltage Pneumatic system Value Unit ≤ 5 µm Designation Compressed air must be free from oil and fil- 6 bar tered Operating pressure Coolant filling of the grinding rollers The grinding rollers D 300 are half filled with coolant (1) at the factory. The cool- ant is frost-resistant down to –15 °C. ■ Coolant Shell FM Coolant H1 (UXB -22000-033) = 33 %, water 66 % Fig. 3.5 Coolant filling of the grinding rollers Value Unit 6l Designation 8l Rollers L = 1000 Rollers L = 1250 Bühler AG 25 MDDP-MDDQ-66606-4-1603-en-US Chapter 3 Technical data

4 Description 4.1 Identification 4.1.1 Nameplate Fig. 4.1 Nameplate (4) Year of manufacture (5) Machine number (1) Manufacturer (6) ATEX marking (2) Place of manufacture (3) Machine type Position of nameplate Nameplate on the side of the main passage (side 1). Fig. 4.2 Nameplate position (1) Nameplate Bühler AG MDDP-MDDQ-66606-4-1603-en-US 26 Chapter 4 Description

Machine number position The machine number is located on the machine mount on the side of the main passage. See page 30, chapter “Zones and passages”. Fig. 4.3 Machine number position (1) Machine number Type code Machine code Diameter of grinding roller MDDP-250/1000-Ex Length of grinding roller MDDP Approval for potentially explosive atmosphere 250 1000 Ex ATEX marking for use in Zone 22 The ATEX marking indicates the conditions under which the machine may be used in a hazardous area or connected to one. II 2/3D T=125 °C Explanation of symbols: → ATEX symbol II → Equipment group 2/ → Internal category 2 /3 → External category 3 D → Dust atmosphere T → Maximum expected surface temperature in °C in normal operation at full load and at an ambient temperature TA Bühler AG 27 MDDP-MDDQ-66606-4-1603-en-US Chapter 4 Description

ATEX marking without approval for use in hazardous areas II 2/-D Explanation of symbols: → ATEX symbol II → Equipment group 2/ → Internal category 2 /- → Not approved for use in Zone D → Dust atmosphere Bühler AG MDDP-MDDQ-66606-4-1603-en-US 28 Chapter 4 Description

4.2 Overview Fig. 4.4 General arrangement drawing (1) Product inlet (8) Feed rollers (2) Product detection (9) High speed grinding roller (3) Feed segment (10) Slow speed grinding roller (4) Distribution screw (11) Adjustable knife scraper (5) Feed roller (12) Handwheel for grinding gap adjust- (6) Brush scraper ment (7) Hopper (direct aspiration) (13) Aspiration pipe (air suction) (14) Control box Bühler AG 29 MDDP-MDDQ-66606-4-1603-en-US Chapter 4 Description

4.2.2 Zones and passages 4.2.3 4.2.4 A Product inlet D Product outlet B Feeder unit E Reduction passage (smooth roll- C Reduction zone ers) F Break passage corrugated roller The main compressed air connection and control box (14) are assembled on the main passage (side 1). Main components ■ Product inlet ■ Machine stand ■ Feed module ■ Roller assembly ■ Cladding ■ Product outlet ■ Machine control system ■ Standstill monitoring of the feed rollers. Product inlets Product inlet E1 Fig. 4.5 Product inlet E1 (1) Product inlet 1 × ⌀ 150 (2) Aspiration cone, bottom Product inlet E2 Fig. 4.6 Product inlet E2 (1) Product inlet 2 × ⌀ 150 (2) Partition wall (3) Aspiration cone, bottom Bühler AG MDDP-MDDQ-66606-4-1603-en-US 30 Chapter 4 Description

Product inlet E3 Fig. 4.7 Product inlet E3 (1) Product inlet 2 × ⌀ 150 (2) Aspiration cone, bottom Product inlet E9 Fig. 4.8 Product inlet E9 (1) Aspiration connection (2) Product inlet 1 × ⌀ 150 (3) Protective cap Product inlet E11 Fig. 4.9 Product inlet E11 (1) Aspiration connection (2) Product inlet 2 × ⌀ 150 (3) Protective cap Bühler AG 31 MDDP-MDDQ-66606-4-1603-en-US Chapter 4 Description

Product inlet E12 Fig. 4.10 Product inlet E12 (4) Protective cap (1) Aspiration connection (5) Aspiration cone, bottom (2) Product inlet 2 × ⌀ 150 (3) Partition wall Product inlet E13 Fig. 4.11 Product inlet E13 (1) Product inlet 2 × ⌀ 150 (2) Partition wall (3) Aspiration cone, bottom Bühler AG MDDP-MDDQ-66606-4-1603-en-US 32 Chapter 4 Description

4.2.5 Product outlets (option) 4.2.6 Fig. 4.12 Product outlets (option) Scrapers Knife scraper Fig. 4.13 Knife scraper (5) Catch angle (6) Cam disk (1) Knife (7) Fastening sheet (2) Clamping bar (3) Weight rod ⌀ 28 (4) Knife holder Bühler AG 33 MDDP-MDDQ-66606-4-1603-en-US Chapter 4 Description

Knife scraper for corrugated rollers Fig. 4.14 Knife scraper for corrugated rollers (1) Knife (5) Catch angle (2) Clamping bar (6) Cam disk (3) Weight rod ⌀ 20 (7) Fastening sheet (4) Knife holder Brush scraper Fig. 4.15 Brush scraper (3) Holder (4) Fastening sheet (1) Scraper brush (2) Bolt Bühler AG MDDP-MDDQ-66606-4-1603-en-US 34 Chapter 4 Description

Without scraper 4.2.7 Fig. 4.16 Without scraper (1) Fastening sheet (2) Bolt Direct aspiration (option) Fig. 4.17 Direct aspiration (4) Guard panel (5) Direct aspiration (1) Pressure pipe, top (2) Coupling (3) Pipe support with sight glass 4.2.8 Options ■ Through-spouts See page 51, chapter “Through-spouts (option)”. ■ Direct aspiration See page 35, chapter “Direct aspiration (option)”. ■ Outlet hoppers. See page 33, chapter “Product outlets (option)”. ■ Grinding roller drive with toothed gear unit (only D 250) ■ Roller temperature monitoring. See page 40, chapter “Temperature strip (option)”. ■ Sampler. See page 75, chapter “Extracting product sample with sampler (option)”. Bühler AG 35 MDDP-MDDQ-66606-4-1603-en-US Chapter 4 Description

4.3 Operating principle 4.3.1 Feeder unit 4.3.2 4.3.3 The product quantity flowing in is determined by a load cell in the inlet. The feed rollers are driven according to the data saved in the machine control system and 4.3.4 the load cell signal. The feed gap set during the commissioning of the product 4.3.5 guarantees a safe discharge. If there is too little product in the inlet, the grinding 4.3.6 rollers are automatically put in the disengaged position. Gas pressure springs To support moving and fixing in the end positions, gas pressure springs are mounted to the cladding and feed modules. The gas pressure springs are under high internal pressure and therefore may not be opened with force or exposed to temperatures over 100 °C. Roller assembly The cereals are macerated, chopped up and ground through the relative move- ment of the grinding rollers. The force-fit roller assembly is equipped with foreign body safeguarding. Pneu- matic cylinders are installed for engaging and disengaging. Fine adjustment of the grinding gap is conducted via 2 handwheels. The grinding rollers are connected to a tensioning device. The tensioning device consists of a tension rod, which elastically connects the two bearing housings via a pre-tensioned disk spring. This arrangement ensures that the grinding roll- ers incur no major damage from passing foreign objects. Aspiration The product inlet is connected to the bottom via a pipe. This pipe is connected with the outlet pipe before lifting. See page 59, chapter “Connecting internal aspiration”. For smooth passages, a channel system is installed under the grinding rollers. The dust-laden air is suctioned upstream from the grinding gap. Control The engage or disengage command of the roller assembly for the entire plant ensues from the superordinate control. The control of the machine is program- med to the product being processed. Upon faults in the machine, corresponding alarms are transmitted to the superordinate control. Lubrication lines The grinding roller bearings are lubricated via grease nipples with grease. The lines from the grease nipples to the bearing housings and the bearings are filled with grease at the factory. Bühler AG MDDP-MDDQ-66606-4-1603-en-US 36 Chapter 4 Description

4.4 Operating modes ■ The machine is controlled electronically. For product dosing, the speed of the feed rollers for the incoming product quantity is adjusted via a mechani- cal detection system with electronic evaluation. ■ The engagement and disengagement of the grinding rollers is operated with a pneumatic cylinder. When a sufficient quantity of product is present in the inlet, the grinding rollers are engaged and the feed rollers begin to rotate and throw product into the grinding gap. When there is too little product in the inlet, the grinding rollers disengage and the feed rollers stop. See page 7, chapter “Applicable documents”. ■ The grinding gap is adjusted with a handwheel. ■ The roller temperature must be even throughout the entire length. To carry out a check or inspection, the front roller cover must be lifted by authorized personnel. Measure with a non-contact measuring instrument. ■ The speed of the feed rollers, the product level and the capacity of the drive motor can be read on the display. See page 7, chapter “Applicable documents”. ■ The serial interface enables information on a computer to be viewed and an intervention to be carried out directly on the computer. See page 7, chapter “Applicable documents”. 4.5 Machine stop The machine stop stops the machine in dangerous situations. See page 41, chapter “Operating and display elements”. The machine stop is integrated into the plant control system. When the machine stop releases, the machine stops after 60 s run-down time. When the machine stop releases, the solenoid valve (1) pneumatically switches off with a switch-off delay of 10 s. Fig. 4.18 Machine stop Bühler AG 37 MDDP-MDDQ-66606-4-1603-en-US Chapter 4 Description

4.6 Protective devices 4.6.1 Cladding Fig. 4.19 Cladding (5) Maintenance door (6) End casing (1) Front sheet (7) Cam latch (2) Impact plate 4.6.2 (3) Glazed door (4) Grinding chamber door Hand guard Fig. 4.20 Hand guard (1) Hand guard Bühler AG MDDP-MDDQ-66606-4-1603-en-US 38 Chapter 4 Description

4.6.3 Hand guard 4.6.4 Fig. 4.21 Hand guard (1) Hand guard (only MDDQ) Safety switch Fig. 4.22 Safety switch (1) Safety switch for feed roller drive motor Bühler AG 39 MDDP-MDDQ-66606-4-1603-en-US Chapter 4 Description

4.6.5 Protective device for machine Standstill monitoring of the feed rollers Fig. 4.23 Standstill monitoring of the feed rollers (1) Standstill monitoring of the feed rollers Temperature strip (option) The sensors integrated in the temperature strip measure the temperature pro- gression over the entire roller width. See operating manual MYUA-67203. Fig. 4.24 Temperature strip (1) Temperature strip Bühler AG MDDP-MDDQ-66606-4-1603-en-US 40 Chapter 4 Description

4.7 Safety signs Fig. 4.25 Safety signs 4.8 Operating and display elements Fig. 4.26 Operating and display elements (1) Machine stop (2) Operating interface (3) Grinding gap position indicator Bühler AG 41 MDDP-MDDQ-66606-4-1603-en-US Chapter 4 Description

5 Transportation 5.1 Safety 5.1.1 Suspended load 5.2 Falling loads can cause serious injuries. ► Use only undamaged hoisting devices with a sufficient rating. ► Fasten loads in accordance with regulations. ► Do not step or stand under suspended loads. ► Ensure that there is no one in the danger zone. Packaging symbols (1) (2) (3) (4) (5) (6) (7) Fig. 5.1 Packaging symbols (5) Do not roll (6) Do not stack (1) Top (7) Attach here (2) Protect against moisture (3) Fragile (4) Forklift permitted on this side ► Observe the packaging symbols. 5.3 Checking delivery ► Check the completeness of the delivery according to the shipping note. ► Report any missing parts or transportation damage. See page 7, chapter “Contact”. 5.4 Intermediate storage ► Observe the packaging symbols. ► Leave the machine and machine parts in the original packaging until assem- bly work begins. ► Do not store the machine outdoors. ► Protect the machine from the effects of weather. ► Avoid temperature fluctuations. Bühler AG MDDP-MDDQ-66606-4-1603-en-US 42 Chapter 5 Transportation

5.5 Lifting instructions 5.5.1 With forklift Lift transport crate with long clevises. (1) 5.5.2 Fig. 5.2 Lifting instruction with forklift (1) Long clevis With crane Use eyebolts for suspension from a crane. The following is included in the tool kit: D 250 ■ 2 lifting eyebolts M48 ■ 2 washers made of plastic (prevent paint damage) D 300 ■ 2 lifting eyebolts M36 ■ 2 washers made of plastic (prevent paint damage) Bühler AG 43 MDDP-MDDQ-66606-4-1603-en-US Chapter 5 Transportation

Fig. 5.3 Lifting instruction with crane Attach the hoisting sling Fig. 5.4 Eyebolt 1. Remove disk (1). 2. Place washer made of plastic (2). 3. Tighten eyebolt (3). 4. Attach hoisting sling. 5. Lift and position machine. 6. Remove hoisting slings. 7. Remove eyebolt and washer. 8. Close threaded hole with disk. Bühler AG MDDP-MDDQ-66606-4-1603-en-US 44 Chapter 5 Transportation

6 Assembly 6.1 Preparing installation location 6.2 ► Space requirements, floor openings, support surfaces and floor loadings in accordance with separate planning documents. 6.2.1 6.2.2 ► Cordon off the installation area so that no unauthorized persons have access 6.2.3 to it. ► Secure the working area (e.g. prevent tripping hazards etc.). ► Keep enough space free for installation and adjustment work. Installation MDDP The roller mill MDDP is delivered to the site mechanically and electrically pre-as- sembled. ► Position the machine in the intended position. MDDQ The roller mill MDDQ is delivered to the site mechanically and electrically pre-assembled. The inlet container is delivered loose. ► Position the machine in the intended position. Transporting the roller mill Fig. 6.1 Mounting frame Bühler AG 45 MDDP-MDDQ-66606-4-1603-en-US Chapter 6 Assembly

Only transport the roller mill on the transport frame mounted at the factory. ■ On rolls ■ Mobile mounting frame Important ► Do not remove the transport frame until in the final position. ► Before transporting and setting up, remove the base cover (2) and side pan- el (1) from both sides to prevent damage. Bühler AG MDDP-MDDQ-66606-4-1603-en-US 46 Chapter 6 Assembly

6.2.4 Setting up roller mill Fig. 6.2 Roller mill base (1) Side frame (6) Anti-rotation device (2) Insulation element 30 mm (7) Protective cap (3) Insulation element 20 mm (8) Bolt (4) Mill base (9) Wall plug (5) Anti-rotation device Set up roller mill on mill base. Important ► Property damage due to vibrations in areas subject to earth quakes. ► Secure with four additional anti-rotation devices (6). ► MDDP: Insert insulation element outside per foot with a thickness of 30 mm and inside with thickness of 20 mm. ► MDDQ: Insert insulation element outside and inside with a thickness of 30 mm. 1. Screw side frame (1) on both sides to the mill base (4). 2. Align the mill base horizontally. ► Bolt to the building structure (8, 9). 3. Insert protective cap (7). 4. Insert insulation element (2, 3). 5. Place machine centrally on the insulation element. Bühler AG 47 MDDP-MDDQ-66606-4-1603-en-US Chapter 6 Assembly

6.2.5 6. For precise leveling, insert the leveling sheet between the mill base and the insulation element. 7. Fasten 4 anti-rotation devices (5) to the machine mount. Removing protective foil Fig. 6.3 Removing protective foil (1) Protective foil (2) Front sheet ► Remove the protective foil (1) from the front sheet (2). Bühler AG MDDP-MDDQ-66606-4-1603-en-US 48 Chapter 6 Assembly

6.2.6 Converting the hinge part at the side panel Where space is limited, convert the fastening element of the side panel at the bottom. Important ► In the standard design, the holder (3) is installed. 1. Remove side panel (1). (1) (1) 6.3 (4) (3) (2) 6.3.1 2. Remove holder (3). 3. Remove hinge part (2). 4. Mount hinge part (4). 5. Fit side panel (1). Installing product connections Fitting inlet container to MDDQ Required materials: ■ Sealant “EGO MS 801” (included in tool kit). 1. Fit inlet container (1) and tighten bolts (2). Bühler AG 49 MDDP-MDDQ-66606-4-1603-en-US Chapter 6 Assembly

2. Remove the bolts (4) and the cover (3). 3. Check fit of the felt seal (5). 4. Fit cover and tighten bolts. 5. Apply sealant along the transition edges (6). 6.3.2 Product inlet 1. Screw product inlet to the inlet container. ► The product inlet is designed for feed pipes with bead. ► Aspiration connecting piece, product inlet and partition wall are delivered loose. 2. Connect the feed pipes according to the system design. 3. During the first break passage, close the internal aspiration. See page 68, chapter “Closing internal aspiration”. ► Close an aspiration for the inlet on the plant. Bühler AG MDDP-MDDQ-66606-4-1603-en-US 50 Chapter 6 Assembly