Machine manual

en-AS.CPT.001.A

SEPOL® LM high-efficiency separator

Client
RAIN CEMENTS LTD., KURNOOL (A.P.)

Work Order Number

6M.0118

Equipment Number
5F1.AS01
Machine manual Contents
SEPOL® LM high-efficiency separator

Contents

1 Safety ........................................................................................................ 1-1

2 Technical data........................................................................................... 2-1
3 Components and mode of functioning ...................................................... 3-1
3.1 Components.............................................................................................. 3-1
3.2 Wear protection....................................................................................... 3-22
3.3 Mode of functioning................................................................................. 3-24
4 Transport and assembly ........................................................................... 4-1
4.1 Transport and storage instructions ........................................................... 4-1
4.2 Assembly instructions ............................................................................... 4-1
4.3 Assembly of the separator housing........................................................... 4-3
4.4 Assembly of the rotating parts .................................................................. 4-5
4.5 Assembly of the drive unit for the design with coaxial gear unit (4A) ..... 4-15
4.6 Assembly of the drive unit for the design with combined spur and bevel
gear unit (4B) .......................................................................................... 4-15
4.7 Assembly of the pin coupling .................................................................. 4-15
4.8 Assembly of the pin-type coupling .......................................................... 4-16
4.9 Assembly of the lubrication piping .......................................................... 4-17
4.10 Assembly of the upper shaft seal............................................................ 4-17
4.11 Assembly of various components ........................................................... 4-17
5 Lubrication................................................................................................. 5-1
5.1 Lubrication................................................................................................. 5-1
6 Commissioning.......................................................................................... 6-1
6.1 Checks prior to the test run....................................................................... 6-1
6.2 Initial setting of the guide vanes................................................................ 6-2
6.3 Test run ..................................................................................................... 6-3
6.4 Monitoring equipment ............................................................................... 6-4
6.5 Regulation of the fineness of the finished material ................................... 6-5
6.6 Adjusting the sealing air quantity (only for SEPOL® LMRS, LMZS) ......... 6-5
6.7 Adjusting the material feed system (only for SEPOL® LMRS, LMZS) ...... 6-5
7 Maintenance.............................................................................................. 7-1
7.1 Safety instructions..................................................................................... 7-1
7.2 Inspection.................................................................................................. 7-3
7.3 Maintenance.............................................................................................. 7-4
7.4 Repair........................................................................................................ 7-5
7.4.1 General notes............................................................................................ 7-5
7.4.2 Dismounting the separator rotor (3.1)....................................................... 7-6
7.4.3 Replacing the rotor blades (3.2)................................................................ 7-7
7.4.4 Replacing the guide vanes (1.7) ............................................................... 7-7
7.4.5 Replacing the sealing at the housing side (1.11)...................................... 7-8
7.4.6 Replacing the grit cone (2.2)..................................................................... 7-9

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Contents Machine manual
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SEPOL LM high-efficiency separator

8 Trouble shooting ....................................................................................... 8-1

9 Spare parts................................................................................................ 9-1
9.1 Suggestions for enquiries and orders of spare parts ................................ 9-1
9.2 Spare parts................................................................................................ 9-1
10 Appendix ................................................................................................. 10-1
10.1 Technical drawings ................................................................................. 10-1
10.2 Subsuppliers' documentation .................................................................. 10-1
10.3 Measurement records ............................................................................. 10-1

Note
All details/features of this manual may not be identical with
the equipment supplied under the contract. Please refer
relevant drawings for actual details/supply.

en-AS.CPT.001.A
Machine manual Safety
SEPOL® LM high-efficiency separator 1-1

1 Safety
IMPORTANT
Be sure to comply with the general safety instructions in the supplement
Important notes on the documentation.

● The machine is exclusively intended for separating non-combustible and dry

feed materials into coarse material and fine material. Be sure to comply with
the specification of the intended use in the section Technical data.
● Any use other than the intended use, such as separating combustible or
excessively moist material, is forbidden. POLYSIUS AG is not responsible for
damage resulting from any use other than the intended use. All other use is at
the owner's own risk.
● The intended use also includes observance of the instructions in the machine
manual and compliance with the maintenance instructions.
Transport and assembly
● All transport instructions in this machine manual refer exclusively to transport
of the machine at the plant site.
● Only use suitable hoisting gear and load-carrying equipment which is in
serviceable order and has a sufficient load-bearing capacity. Select the
correct attachment points in compliance with the relevant regulations and
rules of engineering.
● Never work under a suspended load.
● Cordon off the working area and any accesses.
● When using scaffolds, comply with the relevant regulations.
● Electrical equipment has to be selected according to the conditions on site.
When working with electrical equipment and operating electrical systems,
ensure that any potential hazards are avoided if the machine is used as
intended.
Operation
● Any safety checks before or during operation depend on the relevant national
regulations. The plant management is responsible for the performance and
recording of such checks.
● If changes in the machine or its operating behaviour occur that are relevant to
safety, shut the machine down immediately.
● Excessively moist feed material causes incrustations in the rotor system,
which may result in dangerous unbalances.
● The machine may afterrun after shutdown. For this reason the machine may
only be entered for assembly or maintenance purposes after it has come to a
complete stop.

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Safety Machine manual
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1-2 SEPOL LM high-efficiency separator

Maintenance
● Make absolutely sure that all machines and motors whose operation might
endanger persons or equipment are switched off and safeguarded against
restarting for the entire duration of the maintenance work.
● Make absolutely sure that all rotating parts of the machine have come to a
complete standstill before you remove any protection devices or open any
covers.
● Before performing any work on the machine, make absolutely sure that there
is no danger of suffering burns when touching the machine, and before
opening any inspection and service covers make absolutely sure that there is
no longer any hot material inside the machines.
● Make sure that the interior of the machines has cooled down so far that the
personnel will not suffer any burns on entering.
● Pay attention to worn-out components when entering the separator. The dust-
laden separating air can cause material erosion leading to extremely sharp
edges. Wear proper protective clothing.
● Treads and grab handles have to be cleaned from material deposits before
entering the separator.
● Keep the machine free of oily and flammable substances and materials. Never
use gasoline or other easily inflammable substances to clean the machine.
● Disconnect the power supply of all electrical components before beginning
any maintenance work and safeguard them against restarting.
● Before carrying out work on the central lubrication system with pneumatically
operated barrel pump, you must disconnect the barrel pump from the
compressed air supply system.
● Make absolutely sure that the piping of the central lubrication system is
relieved of pressure. After finishing all maintenance work, check all joints and
connections for leaks.
● Only use 24 volt lamps to illuminate the interior of the machine.
● Strictly observe the welding instructions when performing any welding work.
● When electric arc welding or cutting is being performed, you must ensure that
personnel cannot come into contact with electrically conductive components.
Use insulating underlays for this purpose.
● Never situate the source of the welding current in a confined space where
walls have conductive properties.
● If you carry out electric welding on any part of the machine, never conduct the
welding current through plain or antifriction bearings, other moving connecting
elements or measuring devices. Always directly connect the welding current
return lead to the part being welded.
● Remount all protection devices when the maintenance work has been finished.
Make absolutely sure that no persons are inside the plant section before you
properly close the inspection and service covers.

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Machine manual Technical data
SEPOL® LM high-efficiency separator 2-1

2 Technical data
IMPORTANT
Information concerning the electrical equipment is contained in the separate
electrical documentation or in the subsuppliers' documentation.

Specification of the intended use

Feed material Combi-Ball mill circulating material

Bulk density of the feed material For OPC - 1.08 t/m3

Maximum grain size of the feed 5 mm

material

Maximum moisture content of the feed 1%

material

Maximum temperature of the feed 110 deg C

material

Maximum separating air flow rate - Design capacity of fan 290000 m3/h

High-efficiency separator
Size/type SEPOL LMZS 310

Year of manufacture: 2019

Maximum circumferential speed of 30 m/s

separator rotor

Direction of rotation of the separator clockwise rotating (top view)

rotor

Diameter of the separator rotor 3100 mm

Distributing plate yes / no

Total weight of the rotor 7900 kg

Flap valve
Size/type 500 mm Single pendulum double stage

See machine manual No.- FV.CPT.003

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Technical data Machine manual
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2-2 SEPOL LM high-efficiency separator

IMPORTANT
The following technical data may vary depending on the specific design of the
machine.

Wear protection and materials of the separator

Guide vane (1.7), thickness-- Compound liners (IS 2062+Vautid 100), 15+5 mm

Housing side sealing (1.11), thickness-- Creusabro 4800 / Equivalent, 10,20 mm

Material feed system (1.14) Creusabro 4800 / Equivalent,

10 mm
Thickness

Grit cylinder (2.1), thickness Creusabro 4800 / Equivalent, 8 mm

Grit cone (2.2), thickness Compound liners (IS 2062+Vautid 100), 8 + 4 mm

Grit pipe (2.6), thickness Surface welding 5 mm

Rotor blade (3.2), thickness Creusabro 4800 / Equivalent, 8 mm

Protective pipe (3.9/3.10) for tension rod and Surface welding 5 mm

lubrication piping, thickness

Rotor side sealing (3.16) Creusabro 4800 /

Equivalent
Thickness 10, 15 mm

Distributing plate (3.17) :Compound liners (IS

2062+Vautid 100),
Thickness 10+10 mm

Wear protection (5.1) for housing cone, thickness Wearflex 1000 / Equi, 20 mm

Wear protection (5.2) for basic housing, Compound liners (IS 2062+Vautid 100),
cylindrical area, thickness 10+5 mm

Wear protection (5.3) for basic housing,

Wearflex 1000 / Equi, 20 mm
conical area, thickness

Wear protection (5.4) for fines area, thickness Wearflex 1000 / Equi, 20 mm

Grit pre-collection (7) no

Thickness

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Machine manual Technical data
SEPOL® LM high-efficiency separator 2-3

Fig. 1: Wear protection and materials of the separator (the design with distributing plate)

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Technical data Machine manual
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2-4 SEPOL LM high-efficiency separator

Monitoring equipment
Temperature sensor at the upper no
bearing (optional)

Temperature sensor at the lower yes - type PT 100

bearing

Vibration sensor at the drive bracket no

(optional)

Proximity sensor of the flap valve no

Separator accessories (optional)

Grit pre-collection no

Central lubrication system, see no

machine manual no.

Motor of the separator

Manufacturer Bharat Bijlee

Type of construction IMB3

Type designation Low voltage squirrel cage motor

Required motor rating 270 kW

Type of speed control Variable speed frequency controlled AC

Speed range of the motor 267-1500 rpm

Gear unit of the separator

Manufacturer Siemens

Type designation B2 SV 09

Maximum drive speed 1500 rpm

Maximum output speed 185 rpm

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Machine manual Technical data
SEPOL® LM high-efficiency separator 2-5

Gear unit cooling of the separator

Gear unit cooling yes - external oil-water cooling system

Cooling medium Water/air

Water quantity 20 lpm

Feed temperature of coolant 30 deg C

Coupling, motor - gear unit

Manufacturer Siemens (Flender)

Type designation RWN 320

Coupling, gear unit - rotor

Manufacturer Siemens (Flender)

Type designation RWN 560

IMPORTANT
Be sure to comply with the technical information and information relevant for the
installation in the subsuppliers' documentation for motor, gear unit, vibration
sensor, proximity switch and temperature sensor.

en-AS.CPT.001.A
Machine manual Components and mode of functioning
SEPOL® LM high-efficiency separator 3-1

3 Components and mode of functioning

3.1 Components
IMPORTANT
Some details of the drawings in this manual may not be identical with the
drawings supplied under the contract.

The separator consists of the housing, the rotor, the drive unit for the rotor and
various materials for protecting the separator.
The drive unit is equipped with a coaxial gear unit or a combined spur and bevel
gear unit, depending on the separator size.
Optionally, the separator can be supplied with the following accessories:
● a lubrication system for supplying the lower rotor bearing arrangement with
lubricant
● a device for grit pre-collection
● a vibration monitor of the rotating separator parts.

IMPORTANT
If a component has different design variants these will be designated with A, B,
C etc. in the following.

Depending on the range of applications, the following machine designs can be

distinguished for the SEPOL® LM high-efficiency separator:

Designation of the Application Additional material feeding

design via distributing plate

LMR Raw material grinding No

LMRS Raw material grinding Yes

LMZ Cement grinding No

LMZS Cement grinding Yes

®
Tab. 1: SEPOL LM machine designs

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Components and mode of functioning Machine manual
®
3-2 SEPOL LM high-efficiency separator

Main assemblies of the separator

Fig. 2: Main assemblies (the design with distributing plate)

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Machine manual Components and mode of functioning
SEPOL® LM high-efficiency separator 3-3

No. Name Description

1 Housing sections without distributing plate (1A) or with distributing plate (1B)

2 Internal fittings for grit return

3 Rotating parts without distributing plate (3A) or with distributing plate (3B)

4 Drive Coaxial gear unit (4A) or combined spur and bevel gear unit
(4B)

5 Wear protection See section Technical data

6 Flap valve (optional)

7 Grit pre-collection (optional)

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Components and mode of functioning Machine manual
®
3-4 SEPOL LM high-efficiency separator

Housing sections (1A)

Fig. 3: Housing sections (1A), design without distributing plate

en-AS.CPT.001.A
Machine manual Components and mode of functioning
SEPOL® LM high-efficiency separator 3-5

No. Name Description

1.1 Basic housing

1.2 Inspection cover

1.3 Separator supporting

bracket

1.4 Separator cover

1.5 Fines discharge

1.6 Housing cone

1.7 Guide vane

1.7.1 Eyebolt for lifting the guide vanes during repair work

1.7.2 Hexagon nut

1.7.3 Hexagon section

1.8 Cover for guide vanes

1.9 Bearing bracket

1.10 Seal shaft

1.11 Seal housing side

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Components and mode of functioning Machine manual
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3-6 SEPOL LM high-efficiency separator

Housing sections (1B)

Fig. 4: Housing sections (1B), design with distributing plate

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Machine manual Components and mode of functioning
SEPOL® LM high-efficiency separator 3-7

No. Name Description

1.1 Basic housing

1.2 Inspection cover

1.3 Separator supporting

bracket

1.4 Separator cover

1.5 Fines discharge

1.6 Housing cone

1.7 Guide vane

1.7.1 Eyebolt for lifting the guide vanes during repair work

1.7.2 Hexagon nut

1.7.3 Hexagon section

1.8 Cover for guide vanes

1.9 Bearing bracket

1.10 Seal shaft

1.11 Seal housing side

1.11.4 Sealing air supply system,

1.14 Material feed system

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Components and mode of functioning Machine manual
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3-8 SEPOL LM high-efficiency separator

Internal fittings (2)

Fig. 5: Internal fittings (2) (design with distributing plate)

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Machine manual Components and mode of functioning
SEPOL® LM high-efficiency separator 3-9

No. Name Description

2.1 Grit cylinder

2.2 Grit cone

2.3 Inspection cover at the grit not illustrated

cylinder

2.4 Accessible grate

2.5 Grit guide plate

2.6 Grit pipe

2.7 Lower guide vane holder

en-AS.CPT.001.A
Components and mode of functioning Machine manual
®
3-10 SEPOL LM high-efficiency separator

Rotating parts (3A)

Fig. 6: Rotating parts (3A), design without distributing plate

en-AS.CPT.001.A
Machine manual Components and mode of functioning
SEPOL® LM high-efficiency separator 3-11

No. Name Description

3.1 Separator rotor

3.2 Rotor blade

3.3 Supporting ring for rotor blade

3.4 Drive trunnion

3.5 Bearing trunnion

3.6 Upper bearing assembly

3.7 Lower bearing assembly

3.8 Tension rod

3.9 protective pipe for tension rod

3.10 Protective pipe for lubrication piping

3.11 Hexagon nut

3.12 Cup springs

3.13 Mounting protective pipe

3.14 Eyebolt for lifting the rotor during repair work

3.15 Lubrication pipes

en-AS.CPT.001.A
Components and mode of functioning Machine manual
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3-12 SEPOL LM high-efficiency separator

Rotating parts (3B)

Fig. 7: Rotating parts (3B), design with distributing plate

en-AS.CPT.001.A
Machine manual Components and mode of functioning
SEPOL® LM high-efficiency separator 3-13

No. Name Description

3.1 Separator rotor

3.2 Rotor blade

3.3 Supporting ring for rotor blade

3.4 Drive trunnion

3.5 Bearing trunnion

3.6 Upper bearing assembly

3.7 Lower bearing assembly

3.8 Tension rod

3.9 protective pipe for tension rod

3.10 Protective pipe for lubrication piping

3.11 Hexagon nut

3.12 Cup springs

3.13 Mounting protective pipe

3.14 Eyebolt for lifting the rotor during repair work

3.15 Lubrication pipes

3.16 Seal rotor side

3.17 Distributing plate

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Components and mode of functioning Machine manual
®
3-14 SEPOL LM high-efficiency separator

Upper bearing assembly (3.6)

Fig. 8: Upper bearing assembly (3.6)

en-AS.CPT.001.A
Machine manual Components and mode of functioning
SEPOL® LM high-efficiency separator 3-15

No. Name Description

3.6.1 Bearing housing

3.6.2 Oil sight glass

3.6.3 Drain plug

3.6.4 Damming pipe

3.6.5 Upper ring frame

3.6.6 Upper lamellar ring

3.6.7 Upper sealing ring

3.6.8 Bearing support

3.6.9 Holding ring

3.6.10 Bearing cover

3.6.11 Oil filling spout

3.6.12 Venting system

3.6.13 Lower ring frame

3.6.14 Lower lamellar ring

3.6.15 Lower sealing ring

3.6.16 Split ring

3.6.17 Antifriction bearing

3.6.18 Temperature sensor (optional)

PT100

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Components and mode of functioning Machine manual
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3-16 SEPOL LM high-efficiency separator

Lower bearing assembly (3.7)

Fig. 9: Lower bearing assembly (3.7)

en-AS.CPT.001.A
Machine manual Components and mode of functioning
SEPOL® LM high-efficiency separator 3-17

No. Name

3.7.1 Labyrinth sealing ring

3.7.2 Seal

3.7.3 Thrust ring

3.7.4 Clamping element

3.7.5 Bearing housing

3.7.6 Bearing cover

3.7.7 Clamping sleeve

3.7.8 Antifriction bearing

3.7.9 Temperature sensor PT100

3.7.11 Locknut

3.7.12 Grease outlet bore

en-AS.CPT.001.A
Components and mode of functioning Machine manual
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3-18 SEPOL LM high-efficiency separator

Drive unit with coaxial gear unit (4A)

Fig. 10: Drive unit (4A), design with coaxial gear unit

en-AS.CPT.001.A
Machine manual Components and mode of functioning
SEPOL® LM high-efficiency separator 3-19

No. Name Description

4A.1 Motor

4A.2 Coaxial gear unit

4A.3 Coupling distance piece

4A.4 Coupling rotor end

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Components and mode of functioning Machine manual
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3-20 SEPOL LM high-efficiency separator

Drive unit with combined spur and bevel gear unit (4B)

Fig. 11: Drive unit (4B), design with combined spur and bevel gear unit

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Machine manual Components and mode of functioning
SEPOL® LM high-efficiency separator 3-21

No. Name Description

4B.1 Motor

4B.2 Coupling motor end

4B.3 Combined spur and bevel

gear unit

4B.4 Coupling distance piece

4B.5 Coupling rotor end

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Components and mode of functioning Machine manual
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3-22 SEPOL LM high-efficiency separator

3.2 Wear protection

The lining of the housing sections may consist of the following materials:
● ceramic castable applied on the base plates
● compound liner plates with surface welding and fastening bolts
● ceramic tiles which are cemented on
Additionally, the following materials can be used as construction materials
(without further lining):
● wear resistant special steel
● compound liner plates with surface welding
● base plate with increased thickness

IMPORTANT
When applying the materials for the wear protection, pay attention to the
documents and instructions of the manufacturer.

IMPORTANT
You will find further instructions on wear protection and materials in the section
Technical data.

en-AS.CPT.001.A
Machine manual Components and mode of functioning
SEPOL® LM high-efficiency separator 3-23

Wear protection (5)

Fig. 13: Wear protection (5) (design with distributing plate)

No. Name Description

5.1 Wear protection Housing cone

5.2 Wear protection Basic housing

5.3 Wear protection Fines discharge

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Components and mode of functioning Machine manual
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3-24 SEPOL LM high-efficiency separator

3.3 Mode of functioning

The SEPOL® LM is a dynamic separator for granular material.
The separator separates the mill feed material into a fine fraction (also named
fines or finished product) and a coarse fraction (also named coarse material or
grits). The figure Flow of material (see figure 14, page 3-26) illustrates the
principle of functioning.
Fines are separated in high-efficiency cyclones or a separate dust collection filter.
The coarse material is fed back into the grinding process.
The SEPOL® LM is mainly used in the cement industry for manufacturing raw
meal and cement. A typical application is the use in combination with a static
separator stage or with an air-swept mill. It is also possible to use it with a flash
dryer. In the minerals industry, the SEPOL® LM can be used for separating
ground minerals.
The material to be separated enters the separator from below with the air stream
and is directed upwards between the housing cone (1.6) and the grit cone (2.2),
where it is introduced into the upper housing section. Adjustable guide vanes (1.7)
and the rotation of the separator rotor (3.1) cause the material flow to rotate.
The material to be separated is divided into coarse and fine components under
the influence of the gravitational and airflow forces.
The fine material follows the flow forces and enters the separator rotor interior.
From here it is discharged from the separator by the air stream through the fines
discharge device. In a downstream high-efficiency cyclone or in a filter, the fine
material is separated from the air stream.
The coarse material which is not discharged by the air stream falls into the grit
cone. From here it is fed back in the grinding process.
®
In case of the SEPOL LMZS or LMRS (design with distributing plate), material to
be separated can additionally be fed from above via the material feed system
(1.14). The material to be separated falls from the material feed system onto the
distributing plate (3.17), is flung outward as a result of the rotary motion and thus
evenly distributed in the separating chamber. There it is separated into coarse
material and fine material.
To prevent the coarse material from getting into the fines area, the separator rotor
(3.1) is sealed towards the basic housing by means of a sealing (1.11). In case of
®
the SEPOL LMZS or LMRS the sealing is additionally supplied with sealing air
from the outside. The sealing air flows through feed piping into the sealing (1.11)
and prevents a bypass air stream by means of sealing the coarse material zone
in the fine material zone. During this time, the sealing (1.11) is wear-free and
provides splash protection for classifying the separator fine material.
The grain size of the finished material can be varied during operation by changing
the rotational speed of the separator rotor (3.1) and by changing the setting of the
guide vanes (1.7) during machine stoppage. The finished material can also be
influenced by the air flow rate. Provided that the separator is used in combination
with a mill or a static separator stage, the air flow rate can only be changed in
coordination with the upstream machines.

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Machine manual Components and mode of functioning
SEPOL® LM high-efficiency separator 3-25

Optionally, a grit pre-collection unit (7) may be installed at the separator inlet. The
grit pre-collector (7) removes coarse material which is discharged between grit
cone (2.2) and housing cone (1.6). The coarse material slides down the housing
cone (1.6) wall until it falls into the annular gap of the grit pre-collector (7). From
there, it is guided in a duct around the gas pipe and fed back into the grinding
process. Without the grit pre-collector (7), this coarse material would slide back
into the separator inlet from where it was taken up again by the air stream and fall
out again.
The separator can additionally be equipped with a central lubrication system that
automatically supplies the antifriction bearing and the labyrinth seal of the lower
bearing assembly of the rotor with lubricating grease. The lubrication points are
supplied in a lubrication cycle. The cycle time and the lubricant quantities depend
on the frame size of the machinery and can be adapted to the operating
conditions.
The separator can be equipped with a vibration monitoring device for the rotating
parts. Should major vibrations occur, e.g. caused by deposits of material at the
separator rotor, the separator drive unit will be switched off in order to protect the
machine.

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Components and mode of functioning Machine manual
®
3-26 SEPOL LM high-efficiency separator

Fig. 14: Flow of material

Fine material and gas or air stream

Feed material, distributing plate (only in the case of the

LMRS, LMZS)

Feed material and gas or air stream

Coarse material (grit)

en-AS.CPT.001.A
Machine manual Transport and assembly
SEPOL® LM high-efficiency separator 4-1

4 Transport and assembly

4.1 Transport and storage instructions
The machine is transported in individual parts or in subassemblies. Make
absolutely sure that suitable lifting equipment is employed for lifting all the parts
from the transport vehicles and transferring them to the storage area.
When they arrive at the site, all parts must be inspected for transport damage and
placed on wooden beams with the provision of suitable protection against
moisture, soiling and damage. Never place the parts directly on the ground.
Make absolutely sure that motors, couplings, gear units and measurement and
control equipment are stored in well-ventilated rooms and protected against
moisture.
The wear protection material must be stored in accordance with the supplier's
instructions.
The carrying ropes for the gear units may only be attached to the same at the
designated points.
Take special care with the transportation of gear units already equipped with oil
pumps and piping. Prior to any transportation, remove the piping and close all
pipe sockets and openings with weather-resisting and impact-proof sealing
covers to prevent the ingress of tramp material. Make sure that all sealing covers
can be easily removed.

4.2 Assembly instructions

Required personnel
A pre-requisite for correct performance of the work is careful selection of field
assembly personnel who are specially trained for the tasks involved.
Required tools
It is a prerequisite for the correct performance of the work that all tools and
appliances are carefully selected.
Whether or not you need auxiliary equipment, such as scaffolds or hoists,
depends on the operating conditions in your plant.

DANGER
Injury hazard due to failure of the structure or to components falling down
Platforms and supporting structures may collapse. Insufficiently secured
components may fall down during the assembly and cause severe injuries
or even death.
I. Never use platforms and their supporting structures as auxiliary
mounting supports or storage areas for heavy components.
II. Secure components until stability is ensured.
III. Always disconnect cables before mounting.

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Transport and assembly Machine manual
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4-2 SEPOL LM high-efficiency separator

ATTENTION
Danger of damage due to welding current.
Movable connecting elements or measuring devices could be damaged.
I. Always directly connect the welding current return lead to the part
being welded.
II. Never conduct the welding current through plain or antifriction
bearings, other moving connecting elements or measuring devices.

IMPORTANT
Make sure that the separator is installed on vibration-free floors.
As regards the arrangement of the separator in the building, please refer to the
general arrangement drawing and to the assembly drawing. See Technical
Drawings in the section Appendix.
If several separators are to be erected at one plant, this should happen in
accordance with the relevant markings in the general arrangement drawing.
Subassemblies that are marked at their joints must be assembled according to
their marking.

IMPORTANT
Depending on the separator size, the housing sections are delivered in one
piece or in several pieces. Thus the assembly sequence may slightly differ from
the description below. In this cause, the housing sections have to be joined by
welding or, in case of flanged joints, by using bolts.

IMPORTANT
All joints of the housing and of the air piping have to be sealed with the seals
provided.

IMPORTANT
The following description provides an overview of the assembly work to be
carried out which is described in more detail later on. The sequence of work
operations can be adapted to the local conditions:

● Weld the basic housing (1.1) to the grit cylinder (2.1).

● Align the preassembled unit at the place of installation and bolt or weld it to
the platform.
● Align the grit cone (2.2) and mount it to the grit cylinder (2.1).
● Bolt the housing cone (1.6) to the basic housing.
● Bolt the separator cover (1.4) to the basic housing (1.1).

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SEPOL® LM high-efficiency separator 4-3

● Mount the guide vanes (1.7).

● Install the separator rotor (3.1) into the basic housing (1.1).
● Mount the fines discharge device (1.5).
● Set down the bearing bracket (1.9) and mount the upper bearing assembly
(3.6).
● Mount the tension rods (3.8) and align the rotor.
● Mount the sealing (1.11).
● Mount the drive (4).
● Mount the flap valve (6) (if applicable).

IMPORTANT
Individual assembly steps may vary depending on the division of supply and the
type of the machine.
Any transport stiffeners and transport devices which may have been installed
must be removed in the respective work steps.

4.3 Assembly of the separator housing

IMPORTANT
The bottom flange of the grit cylinder is only welded to the same during the
assembly of the grit cone (2.2). Bolted joints have to be provided with
appropriate sealing compounds.

Step 1: Mount basic housing (1.1) and grit cylinder (2.1).

1.1 Align and weld the segments of the grit cylinder (2.1).
1.2 Place the quarter segments of the basic housing (1.1) around the grit
cylinder (2.1).
1.3 Align the grit cylinder (2.1) and the basic housing (1.1) to each other and
join them with assembly weld seams.
1.4 Line the preassembled units with the wear protection (5.2).
1.5 Place the assembly group on the substructure according to the
arrangement drawing.
The vertical separator housing axis must be aligned vertically to be later in flush
with the rotor axis. If necessary, packing plates must be inserted underneath the
separator supporting brackets (1.3).

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4-4 SEPOL LM high-efficiency separator

Step 2: Mount grit cone (2.2).

2.1 Align the segments of the grit cone (2.2) to each other and join them with
assembly weld seams (if necessary).
2.2 Insert and align the grit guide plate (2.5) and the access grate (2.4) and
weld them.
2.3 Align the grit cone (2.2) according to the general arrangement drawing
(taking into account the grit outlet position) and bolt onto the loose flange of
the grit cylinder (2.1).
2.4 Execute the assembly weld seam of the loose flange.
Step 3: Mount housing cone (1.6).
3.1 Bolt together the segments of the housing cone (1.6).
3.2 Line the preassembled units with the wear protection.
3.3 Bolt together the housing cone (1.6) and the basic housing (1.1) such that
the openings of the grit discharge are in true alignment.
3.4 Mount the grit pipe (2.6) between the grit cone (2.2) and the housing cone
(1.6).
Step 4: Mount separator cover (1.4).
4.1 Align and weld the segments of the separator cover (1.4).
4.2 Place the separator cover (1.4) onto the basic housing (1.1) and bolt them
together.
Step 5: Mount the guide vanes (1.7).
Use an eyebolt (1.7.1) to lift in the guide vanes (1.7).

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Machine manual Transport and assembly
SEPOL® LM high-efficiency separator 4-5

4.4 Assembly of the rotating parts

Prerequisites
The separator rotors of separator sizes 130-170 are supplied in one piece.
The separator rotors of separator sizes 185-610 are supplied in three pieces.
When delivered, the flange connections of the drive trunnion (3.4) and of the
bearing trunnion (3.5) are provided with a transport bracket. Before installing the
rotor, the drive trunnion (3.4), the bearing trunnion (3.5) and the lower bearing
(3.7) must be mounted.

Fig. 15: Transport bracket of the rotor

IMPORTANT
The connecting surfaces of the flanges must be cleaned and be free of
protective coating before assembly. Observe the markings (punch marks on the
flanges) during assembly and tighten the bolts of the flange connections with the
specified torque. See item Technical Drawings in the section Appendix.

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4-6 SEPOL LM high-efficiency separator

IMPORTANT
Before installing the separator rotor, the auxiliary assembly devices (8) must be
mounted.

Step 1: Install the separator rotor (3.1) in the separator housing.

1.1 Screw the eyebolt (3.14) into the drive trunnion (3.4) of the separator rotor
(3.1).
1.2 Attach the load-carrying equipment onto the provided eyebolt (3.14).
1.3 Lift the separator rotor (3.1) into the housing using suitable hoisting gear
and place it inside the separator onto the four auxiliary assembly devices
(8) for the separator rotor.

IMPORTANT
The separator rotor needs to be underlaid such that the groove of the drive
trunnion protrudes slightly more than the split ring (3.6.16) of the upper bearing
which is to be installed later. The rotor weight must be distributed over the four
assembly aids as uniformly as possible.

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Machine manual Transport and assembly
SEPOL® LM high-efficiency separator 4-7

Fig. 16: Auxiliary assembly device (8)

Step 2: Assembly of the fines discharge device (1.5) and the sealing at the housing
side (1.11) (for distributing plate design)
2.1 Depending on the separator size, the fines discharge (1.5) is supplied in
one piece and has to be preassembled accordingly.
2.2 Line the fines discharge device (1.5) with the wear protection.
2.3 Push the respective adapter ring (1.11.2) and the respective static sealing
part (1.11.3) into the sealing.

Fig. 17: Sealing at the housing side (1.11)

2.4 Safeguard the static sealing part (1.11.3) against falling out using tack
welds at the deflector plate (1.11.1).

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4-8 SEPOL LM high-efficiency separator

Fig. 18: Sealing at the housing side (1.11)

2.5 Align the fines discharge (1.5) in accordance with the arrangement drawing
and bolt it to the separator cover (1.4).
Step 3: Assembly of the fines discharge device (1.5) and the sealing at the housing
side (1.11) (for design without distributing plate)
3.1 Depending on the separator size, the fines discharge (1.5) is supplied in
one piece and has to be preassembled accordingly.
3.2 Install wear protection in the fines discharge device (1.5).
3.3 Install the segments of the sealing at the housing side (1.11) into the
housing and bolt them to the separator cover (1.4) in the topmost position.

Fig. 19: Sealing at the housing side (1.11)

3.4 Align the fines discharge (1.5) in accordance with the arrangement drawing
and bolt it to the separator cover (1.4).

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Machine manual Transport and assembly
SEPOL® LM high-efficiency separator 4-9

Step 4: Assembly of the upper bearing

4.1 Bolt the bearing bracket (1.9) to the upper baring (3.6).
4.2 Place the preassembled module together with the eyebolts (3.6.19)
provided for this purpose onto the fines discharge and bolt the same to the
bracket plate (1.12).
4.3 Carefully push the bearing over the separator shaft to prevent the lamellar
labyrinth seal from being damaged.

Fig. 20: Assembly of the upper bearing (3.6)

4.4 Put the split ring (3.6.16) around the groove of the separator shaft, then
mount the holding ring (3.6.9).

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4-10 SEPOL LM high-efficiency separator

4.5 Slightly lift the separator rotor (3.1), remove the auxiliary assembly devices
(8) and lower the separator rotor (3.1).

IMPORTANT
The groove needs to be easily accessible for mounting the two-part ring. If the
groove does not protrude sufficiently from the bearing, the separator rotor (3.1)
has to be slightly lifted and appropriately underlaid.

Now, the split ring supports the weight of the separator rotor (3.1).
Step 5: Inspection of the lower bearing
5.1 After the upper bearing (3.6) has been installed, check whether the lower
bearing (3.7) has been displaced.
5.2 Remove the bearing cover (3.7.6).
5.3 If the clamping sleeve (3.7.3) is not flush with the bearing trunnion end,
loosen the locknut (3.7.11) and correct the seat of the bearing.

Fig. 21: Fixing of the lower bearing (3.7) and alignment of the separator rotor (3.1)

5.4 Check the seat of the labyrinth sealing ring (3.7.1) and, if necessary,
correct using the thrust ring (3.7.3).

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Machine manual Transport and assembly
SEPOL® LM high-efficiency separator 4-11

Requirement
The distance between the punch mark and the upper edge of the thrust ring
(3.7.3) must be 10 mm.

For separator sizes 130 - 200 75 Nm

For separator sizes 215 - 610 86 Nm

Tab. 2: Tightening torque for the bolts of the thrust ring (3.7.3)

Step 6: Assembly of the tension rods (3.8)

IMPORTANT
Prior to executing of the following steps, ensure that the separator rotor (3.1)
can be turned easily by hand and does run up against anything. Repeatedly
check this when performing the aligning work.

6.1 Insert the four tension rods (3.8) through the housing cone (1.6) and attach
them to the bearing housing (3.7.5).
6.2 Tension the sets of cup springs at the tension rods (3.8) to the length "c".

Fig. 22: Assembly dimension „c“ for set of springs

For separator sizes 110 - 200 54.4 mm

For separator sizes 215 - 410 68.0 mm

For separator sizes 440 - 610 78.6 mm

Tab. 3: Assembly dimension "c" for set of springs
6.3 Lock the hexagon nuts (3.11) of the tension rod (3.8) with counter nuts.

IMPORTANT
The lower bearing is designed as floating bearing. In order to avoid constraints,
the tension rod must not have contact to any parts.

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4-12 SEPOL LM high-efficiency separator

6.4 After the tension rods (3.8) have been tightened, check once again for
exact alignment of the rotor axis. If required, correct the position of the
rotor axis by adjusting the dimension "c".
This achieves smooth running of the separator and prevents premature wear of
the antifriction bearings.
6.5 Record the actual values from the measurement. Form sheets for the
measurement records are enclosed in section Appendix.
Step 7: Align the bracket plate

IMPORTANT
The fine adjustment of the inclination of the contact surface for the upper rotor
bearing is carried out using the setscrews (1.13) of the bracket plate (1.12).

7.1 Place the magnet holder of the dial gauge on the drive trunnion of the
separator.
7.2 Set the dial gauge to the reference diameter (d) in accordance with the
table (limit values for adjusting the bracket plate) such that the feeler of the
dial gauge touches the measuring area.

Fig. 23: Dial gauge for aligning the bracket plate

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Machine manual Transport and assembly
SEPOL® LM high-efficiency separator 4-13

7.3 Determine the position with the smallest indication of the dial gauge by
slowly turning the separator rotor by hand and set the dial gauge to zero at
this position.
7.4 After a further rotation of the separator rotor, determine the maximum
indication value of the dial gauge.
7.5 Adjust the position of the bracket plate using the four setscrews (1.13) until
the maximum indication value is smaller than the limit value given in the
table of the measurement record (LVadm).
This ensures that the axes of the upper bearing assembly and of the separator
rotor are flush.
7.6 Measure the maximum radial runout at the drive trunnion (3.4) by placing
the dial gauge onto the bearing housing (3.6.1) and slowly turning the
separator rotor (3.1) by hand.

Fig. 24: Measurement of the maximum radial runout

7.7 Record the actual values of the measurements in writing. Form sheets for
the measurement records are enclosed in section Appendix.
Step 8: Setting the sealing at the housing side (1.11)
(for distributing plate design)

IMPORTANT
When the separator rotor (3.1) is turned, the sealing may have no contact to the
separator rotor or rub against the same.

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4-14 SEPOL LM high-efficiency separator

Fig. 25: Setting the clearance for the sealing at the housing side (1.11) (design with distributing plate)

8.1 Loosen the tack welds at the static sealing part (1.11.3) and provide a seal
gap of 3 mm using spacer plates.
8.2 Remove a segment of the sealing of the rotor side (3.16) for the assembly
weld seams at the flange with deflector plate and perform the peripheral
welds.
Step 9: Setting the sealing at the housing side (1.11)
(for design without distributing plate)

Fig. 26: Setting the clearance for the sealing at the housing side (1.11) (design without distributing plate)

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Machine manual Transport and assembly
SEPOL® LM high-efficiency separator 4-15

9.1 Loosen the segments of the sealing at the housing side (1.11) and provide
a seal gap of 3 mm using spacer plates.
9.2 After aligning, bolt the segments of the sealing at the housing side (1.11)
together.

4.5 Assembly of the drive unit for the design with coaxial gear unit (4A)
Step 1: Mount the coupling halves (4A.4) onto the drive trunnion (3.4) of the
separator rotor (3.1) and the output shaft of the gear unit.
Step 2: Mount the coupling distance piece (4A.3).
Step 3: Mount the gear unit (4A.2) with the motor (4A.1) onto the coupling distance
piece (4A.3) and set the coupling gap.

IMPORTANT
Also observe the manufacturer's installation instructions. For the used coupling
type, see section Technical data.

4.6 Assembly of the drive unit for the design with combined spur and
bevel gear unit (4B)
Step 1: Mount the coupling halves (4B.5) onto the drive trunnion (3.4) of the
separator rotor (3.1) and the output shaft of the gear unit.
Step 2: Mount the coupling distance piece (4B.4).
Step 3: Mount the gear unit (4B.3) onto the coupling distance piece (4B.4) and set
the coupling gap.

IMPORTANT
Also observe the manufacturer's installation instructions. For the used coupling
type, see section Technical data.

Step 4: Mount the motor (4B.1) including motor frame and the coupling halves
(4B.2), align the motor and compensate the axis misalignment by inserting
packing plates and set the coupling gap.

IMPORTANT
Also observe the manufacturer's installation instructions. For the used coupling
type, see section Technical data.

4.7 Assembly of the pin coupling

The following description relates to a coupling of the type Flender N-EUPEX A.
Also observe the manufacturer's documentation.
Measured quantity to determine the axial and angular offset
The measured quantity to determine the axial and angular offset is the gap S1 at
the circumference of both coupling halves, measured over 360°. The two extreme
values S1min and S1max result from the measurement.

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4-16 SEPOL LM high-efficiency separator

● The axial offset ΔKa of the coupling parts must be within the admissible limit
values for S1adm.
● It makes sense to measure the angular offset ΔKw as difference of the gap
( ΔS1 = S1max - S11min). The admissible values for the difference of the gap
ΔKwadm can be found in the table.
● The radial offset has to be measured over 360°. The max value must be
smaller than ΔKradm.
Step 1: Setting the coupling
1.1 Setting the axial offset
1.2 Setting the offset angle
1.3 Setting the radial play
Step 2: Record the actual values from the measurement in writing.
Form sheets for the measurement records are enclosed in section Appendix.

4.8 Assembly of the pin-type coupling

The following description relates to a coupling of the type Flender-RUPEX RWN.
Also observe the manufacturer's documentation.
Measured quantity to determine the axial and angular offset
The measured quantity to determine the axial and angular offset is the gap S1 at
the circumference of both coupling halves, measured over 360°. The two extreme
values S1min and S1max result from the measurement.
● The axial offset ΔKa of the coupling parts must be within the admissible limit
values for S1adm.
● It makes sense to measure the angular offset ΔKw as difference of the gap
( ΔS1 = S1max - S11min). The admissible values for the difference of the gap
ΔKwadm can be found in the table.
● The radial offset has to be measured over 360°. The max value must be
smaller than ΔKradm.
Step 1: Setting the coupling
1.1 Setting the axial offset
1.2 Setting the offset angle
1.3 Setting the radial play
Step 2: Record the actual values from the measurement in writing.
Form sheets for the measurement records are enclosed in section Appendix.

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Machine manual Transport and assembly
SEPOL® LM high-efficiency separator 4-17

4.9 Assembly of the lubrication piping

Step 1: Prior to assembly, clean the lubrication piping (3.15) to prevent the
contamination of the bearing assemblies.
Step 2: Mount the lubrication piping.
Step 3: Fill the lubrication point with lubricant of the stipulated quality and quantity.
See the section Lubrication.

4.10 Assembly of the upper shaft seal

Step 1: Mount the sealing of the shaft (1.10).
Step 2: Check whether the sealing (1.10) is centrical to the rotor shaft and that the
felt ring has uniform contact.

4.11 Assembly of various components

Step 1: Mount the cover (1.8) for the guide vanes.
Step 2: Mount the material feed system (1.14) (if applicable).
Step 3: Mount the grit pre-collector (7) (if applicable) to the housing cone (1.6).
Step 4: Mount the flap valves (6) and the inspection doors.
Step 5: Mount the signs and warning notices as well as all required protection
devices in their intended places.

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Machine manual Lubrication
SEPOL® LM high-efficiency separator 5-1

5 Lubrication
5.1 Lubrication
IMPORTANT
The POLYSIUS table of lubricants with the lubricant reference numbers is
contained in the supplement Important notes on the documentation. The
supplement is contained in this folder or at the beginning of the overall
documentation. Each lubricant has a unique reference number to which the
lubrication instructions in this section relate. The table gives a complete list of all
suppliers and products approved by POLYSIUS AG. It is the responsibility of the
lubricant supplier to select appropriate lubricants corresponding to the lubricant
reference numbers. POLYSIUS AG accepts no liability for the correctness of
these data. If you wish to use a lubricant that is not included in the Table of
lubricants, you have to first obtain the express permission of POLYSIUS AG.
The supplement Important notes on the documentation also includes general
information on lubrication.

WARNING
Danger of injury to health due to lubricants
Contact with lubricants can cause allergic reaction and skin irritation.
I. When handling lubricants, always wear safety gloves.
II. Do not swallow, do not inhale vapours.
III. After unintentional eye contact thoroughly rinse the eyes with large
amounts of water and if necessary, consult a doctor.
IV. After skin contact, wash the skin thoroughly using large amounts of
water and soap.
V. Comply with the safety data sheets of the lubricants manufacturer.

ATTENTION
Danger to the environment due to false handling of the lubricants
Improper handling of substances which are dangerous for the
environment and particularly their incorrect storage and disposal leads to
considerable environmental damage.
I. Ensure that the environment is not polluted when you store, use and
dispose of lubricants.
II. You have to comply with the applicable national regulations for the
protection of the environment when handling lubricants.
III. If lubricants which are dangerous for the environment accidentally
escape into the environment, immediately take appropriate measures
or inform the responsible public authorities.

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Lubrication Machine manual
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5-2 SEPOL LM high-efficiency separator

Fig. 27: Lubrication points

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Machine manual Lubrication
SEPOL® LM high-efficiency separator 5-3

Lubrication points Quantity (l, kg) per Lubrication intervals (weeks)

lubrication point

No. Qty. Designation Lubricant Initial filling Topping up Topping up First Further
ref. no. change changes

1 1 Labyrinth seal via 81

forced lubrication
nipple from outside

2 1 Lower antifriction 81
bearing via forced
lubrication nipple
from outside

3 1 Upper bearing 37
assembly

4 1 Electric motor See the instructions of the manufacturer

5 1 Gear units See the instructions of the manufacturer

6 2 Flap valve (if

See separate machine manual
installed)

The different makes of lubricant corresponding to the lubricant reference numbers are shown in the Table of
lubricants in the supplement Important notes on the documentation. The supplement is contained in this folder or at the
beginning of the overall documentation.

Tab. 4: Lubrication chart

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Machine manual Commissioning
SEPOL® LM high-efficiency separator 6-1

6 Commissioning
6.1 Checks prior to the test run
After completing the assembly work and prior to the first test run, check all parts
of the plant in accordance with the list below. Make absolutely sure that all
material remnants, tools and assembly appliances have been carefully removed.
1. Have all transporting devices and stiffeners been removed?
2. Have all foundation bolts been correctly tightened?
3. Have all bolted connections of the motor frame been correctly tightened?
4. Is the rotor axis of the separator exactly vertically aligned?
5. Have the four tension rods (3.8) been adequately pretensioned and have
you made sure that they have no contact with the separator housing?
6. Can the separator rotor (3.1) be easily turned by hand?
7. Does the sealing of the rotor side (3.16) run contact-free and with a narrow
gap?
8. Have the gear unit and the coupling been mounted in accordance with the
manufacturer's instructions?
9. Does the separator rotor turn in the specified direction of rotation? (See
section Technical data)
10. Is the separator connected to the cyclone or to the dust collection filter?
11. Have all flange connections been bolted on tightly and have the provided
seals been fitted correctly?
12. Have the lubrication piping and all lubrication points (3.15) been filled with
lubricant according to instructions?
13. Have all monitoring devices been correctly connected and the correct
switching values been set, and have the devices been checked for correct
functioning?
14. Have the machine interlocks been checked for proper functioning?
15. Is the cooling water supply pipe to the oil cooler connected, and is sufficient
cooling water of the required water quality available? (see section Technical
data)
16. Has the oil cooler been checked for proper functioning?
17. Have all signs and protection devices been mounted?
18. Have all doors and flaps been securely closed, and have the provided seals
been fitted?

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6-2 SEPOL LM high-efficiency separator

6.2 Initial setting of the guide vanes

The guide vanes (1.7) are set to 25° during the first installation. For this purpose,
a scale with angle values is provided at the guide vane holder.

Fig. 28: First installation of the guide vanes

Optimisation of the setting is carried out during commissioning depending on the

separator efficiency, the separator selectivity and the sharpness of separation.
(See section Regulation of the fineness of the finished material)
Slightly loosen the hexagon nut (1.7.2) to adjust the guide vanes. The guide vane
must be locked with a counter nut at the hexagonal profile (1.7.3) using a tool to
prevent the guide vane from rotating during loosening and tightening.

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SEPOL® LM high-efficiency separator 6-3

Fig. 29: Setting the guide vanes

6.3 Test run

IMPORTANT
It is a prerequisite of our warranty that the first test run is carried out in the
presence of specialists from POLYSIUS AG and in accordance with their
instructions.

● After having completed all checks and setting work, a test run must be
performed.
● If possible, this test run should have a duration of at least four hours without
any interruptions.
● Make absolutely sure that the grease lubrication of the antifriction bearings
and labyrinth seals is functioning properly and that sufficient lubricant is being
supplied.
● During the test run, the electrical interlocking systems of all machine-relevant
plant components must be checked for their correct functioning.
● Start the drive (4) of the separator with the lowest speed and then bring it up
to the operating speed.
● The separator rotor (3.1) must run quietly and free of vibrations. If higher
vibrations occur, it may be necessary to dynamically balance the separator
rotor (3.1).
● After the test run, all bolted connections for which a tightening torque is
specified must be checked and retightened if necessary.

IMPORTANT
Please see the relevant instructions in the documentation for the parts from
subsuppliers for further checks to be performed during the test run (See section
Appendix).

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6-4 SEPOL LM high-efficiency separator

6.4 Monitoring equipment

To detect disturbances of the process sequence as early as possible, electric
safety devices are installed. The safety devices of the separator have to be
integrated into the electrical interlocking system of the overall grinding plant.

Vibration monitor of the rotating separator parts

If a vibration monitor is installed, the motor (4A.1 or 4B.1) must be switched off
via the interlocking system if higher vibration occurs.

Flap valve monitoring unit

If a flap valve is installed, inductive limit switches monitor the weaving of the flap
vane plates.
The timer of the monitoring unit has to be set to approximately 3 minutes.
If during this time no movement of the flap valve arm is detected, an optical or
acoustic warning signal is triggered. The specified times are reference values and
can be adjusted to the operating conditions of the plant.

Temperature monitoring of the bearings

A PT100 temperature sensor measures the bearing temperature. Thus,
alterations of the process sequence and of the operating behaviour of the
machine can be detected. The switching points of the temperature monitoring
system must be coordinated with the temperature ranges of the lubricants.

Recommended values for setting the monitoring equipment

Measuring point During commissioning During operation

Emergency Emergency
Alarm Alarm
off off

Temperature sensor at the upper bearing 100°C 100°C 95°C 100°C

Temperature sensor at the lower bearing 140°C 140°C 130°C 140°C

Timer of the flap valves monitoring system - - 3 min. -

Temperature monitoring system of the

In accordance with the manufacturer's instructions
gear unit

Vibration monitoring system at the bearing

4.0 mm/s 8.0 mm/s 4.0 mm/s 8.0 mm/s
bracket

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Machine manual Commissioning
SEPOL® LM high-efficiency separator 6-5

6.5 Regulation of the fineness of the finished material

The grain size of the finished material can be varied during operation by changing
the rotational speed of the separator rotor and by changing the setting of the
guide vanes (1.7) during machine stoppage.
Producing finer finished material
● You obtain finer finished material by increasing the rotor speed.
● To alter the slope of the grain size distribution curve, you may additionally
have to reduce the aperture angle of the guide vanes.
Producing coarser finished material
● You obtain coarser finished material by reducing the rotor speed.
● If the control range is not sufficient, you may additionally have to increase the
aperture angle of the guide vanes.

6.6 Adjusting the sealing air quantity (only for SEPOL® LMRS, LMZS)
The required fresh air for the sealing (1.11) is sucked in as a result of the
pressure gradient in the inside of the separators. You can vary the sealing air
quantity by adjusting the dampers.
Completely close the dampers for commissioning. In case of oversize particles in
the product, open the dampers step by step to reduce the oversize particles.
In this way, the sealing air quantity can be adjusted such that as little as possible
inleaked air is brought in.
If you detect an increased wear of the sealing (1.11), increase the sealing air
quantity.

6.7 Adjusting the material feed system (only for SEPOL® LMRS, LMZS)
The height of the material feed system (1.14) can be varied using intermediate
flanges.
The height of the outlet opening should be set as closely as possible above the
distributing plate (2.17) of the rotor. This ensures a more homogenous material
distribution over the separating chamber.
In case of blockages of the material feed system it may be necessary to increase
the distance to the distributing plate.
Distributing plate and material feed system must not make any contact or rub
against each other.

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Machine manual Maintenance
SEPOL® LM high-efficiency separator 7-1

7 Maintenance
7.1 Safety instructions
WARNING
Injury hazard due to rotating parts.
Rotating parts in the inside of the separators can crush, shear, cut or cut-
off limbs and pull them into the machine.
I. During operation, do not touch the moving parts.
II. Do not open any flaps or maintenance covers during operation.
III. Observe overtravel time: Prior to opening any flaps for the purpose of
maintenance and/or control, ensure that all components have come to
a complete standstill.
IV. Prior to performing any work on moving components of the separator,
shut down the concerned function unit and safeguard it against
restarting. Wait until all components have come to a complete
standstill.
V. In the danger area, wear tight-fitted protective clothing with low tear
strength.

WARNING
Danger due to parts falling down.
Deposits of material and machine components the fastenings of which are
worn out may fall down and cause severe injuries.
I. Always wear safety helmet, safety boots and protective clothing when
entering the danger area.
II. Clean the machine using a compressed air blower.

WARNING
Danger due to stumbling and falling down from great height.
Danger of stumbling and falling down when performing work on the
machine cover and inside the machine.
I. Install and use auxiliary platforms inside the machine.
II. Make sure you have a save standing.
III. Wear a seat belt.

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Maintenance Machine manual
®
7-2 SEPOL LM high-efficiency separator

WARNING
Injury hazard due to hot surfaces.
Components heat up during operation. Skin contact with hot surfaces
causes severe burns.
I. Always wear heat resistant protective clothing and safety gloves when
working in the vicinity of hot surfaces.
II. Ensure that all surfaces have cooled down to ambient temperature
before commencing any work on the plant.

WARNING
Injury hazard due to harmful dusts.
In the long term, inhaled dusts can cause pulmonary conditions or other
health impairment.
Direct eye contact with dusts can irritate or inflame the eyes.
I. Wear basic respiratory equipment and protective goggles when
performing any work within the danger area.
II. Clean the machine using a compressed air blower.

WARNING
Injury hazard due to escaping material to be conveyed.
Opening any inspection covers during operation or leaks of the unit can
cause escaping of the material to be conveyed. This can cause severe
injuries.
I. Do not open inspection covers during operation.
II. In case of leaks, immediately switch off the unit and arrange for repair.
III. Wear personal protective equipment.

CAUTION
Injury hazard on sharp edges and corners.
Wear inside the machine causes sharp edges which can lead to abrasive
burn and cuts.
I. When working in the vicinity of sharp edges and corners, proceed with
utmost care.
II. Wear protective clothing in the danger area.

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Machine manual Maintenance
SEPOL® LM high-efficiency separator 7-3

CAUTION
Injury hazard due to impacts.
Impact hazard in vicinity of the flap valves and inside the machine.
Wear protective clothing in the danger area.

7.2 Inspection
No. Work to be performed Frequency Comments

1 Check for abnormal noises. daily

2 Check the flap valves for proper functioning daily See separate
machine
manual

3 General inspection of the separator for cracks and every 4 weeks

leaks

4 Check the drive see

subsupplier's
information

5 Check the central lubrication system for proper See separate

functioning (if installed) machine
manual

6 Check that the antifriction bearings and the labyrinth every 2 weeks
seals are receiving sufficient lubricant

7 Check the lubrication pipes for leaks every 2 weeks

8 Check the bolted connections for proper fit and, if every 6 during first
necessary, tighten with the specified tightening torque. months commissioning
after 100
operating
hours

9 Check for wear of every 4 weeks

● at the grit cylinder (2.1)
● at the grit cone (2.2)

10 Check for wear at the guide vanes (1.7) every 4 weeks until there is
no more
overlapping
with the
neighbouring
guide vanes

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Maintenance Machine manual
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7-4 SEPOL LM high-efficiency separator

No. Work to be performed Frequency Comments

11 Check for wear at the sealing (1.11) every 4 weeks maximum gap
width 5 mm

12 Check for wear every 4 weeks ● until first

● at the protective pipes (3.9) for the tension rods holes
appear
● at the protective pipe (3.10) for the lubrication piping
● turning the
protective
pipe
increases
the time to
replaceme
nt

13 Check for wear at the rotor blades (3.2) every 4 weeks replace at
40% of the
remaining
width

14 Check for wear at the wear protection lining every 4 weeks until the base
metal
becomes
partly visible
or until parts of
the lining have
become loose
or are missing

15 Check for wear every 4 weeks until the base

● at the distributing plate (3.17) (if installed) metal
becomes
● at the material feed system (1.4) (if installed) partly visible

7.3 Maintenance
No. Work to be performed Frequency Comments

1 Repair or renewal of the wear lining as required

2 Replace as required
● the rotor blades (3.2)
● the guide vanes (1.7)
● the material feed system (1.14) (if installed)
● the distributing plate (3.17) (if installed)

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Machine manual Maintenance
SEPOL® LM high-efficiency separator 7-5

No. Work to be performed Frequency Comments

3 Replace the sealing (1.11) at the housing side as required when

readjusting is
no longer
possible

4 Replace the sealing (1.10) of the shaft as required

5 Maintenance work on the coupling see replace the

subsupplier's coupling sets
information if the torsional
play is
excessive

6 Maintenance work on the drive (4A) see

subsupplier's
information

7 Maintenance work on the central lubrication system (if see

installed) subsupplier's
information

8 Clean the grease outlet bore at the lower bearing as required

7.4 Repair

7.4.1 General notes

If damage is found during the checks described in the sections Inspection and
Servicing, you must repair the defective parts or replace them with new parts.

Required tools
You need an oil pressure pump in order to easily remove the antifriction bearings.
No special tools are required. However, you may need torque wrenches of a
bigger size than normal.
Whether or not you need auxiliary equipment, such as scaffolds or hoists,
depends on the operating conditions in your plant.

General
Switch off the power supply to all electrical components before beginning any
repair work.
Ensure absolute cleanliness at all times during the repair work in order to prevent
dirt from entering the bearings, the drives or other sensitive parts of the machine
or plant.
Do not remove or open any covers or protection devices before all rotating parts
have come to a complete standstill.

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Maintenance Machine manual
®
7-6 SEPOL LM high-efficiency separator

In order to replace wear parts in the separator, you do not have to disassemble
the separator. All wear parts can be brought in through the inspection flaps.
When carrying out repair work on the gear unit, the motors, couplings and the
circulating air fan, closely follow the manufacturer's instructions.

IMPORTANT
After you have completed the repair work, you must check the machine/plant
again in accordance with section Checks prior to the test run.

7.4.2 Dismounting the separator rotor (3.1)

Step 1: Dismount the drive (motor, gear unit, cupling and coupling distance piece).
Step 2: Remove the sealing (1.11).
Step 3: Remove the lubrication piping (3.15) and safeguard the bearing against
contamination by closing the bores using blind plugs.
Step 4: Reduce the pretensioning of the tension rods.
4.1 Loosen the connection of the tension rods to the lower bearing assembly
(3.7).
4.2 Pull the tension rods out of the separator until the bearing is free.
Step 5: Mount the four auxiliary assembly devices for the separator rotor (3.1).
Step 6: Remove the connecting bolts of the upper bearing assembly (3.6) and the
bracket plate (1.12).
Step 7: Attach the eyebolt at the drive trunnion of the separator rotor (3.1) and
attach load-carrying equipment at the eyebolt.
Step 8: Lift the separator rotor until the ring (3.6.16) is relieved of load.
Step 9: Insert a packing plate underneath the separator rotor (3.1) at the auxiliary
assembly devices for the separator rotor and set it back down.
The split ring must now be relieved of load. Otherwise, insert another packing
plate underneath the separator rotor (3.1).
Step 10: Loosen the load-carrying equipment and eyebolt.
Step 11: Remove the holding ring (3.6.9) for the split ring (3.6.16), then remove the
split ring (3.6.16).
Step 12: Remove the upper bearing assembly (3.6) and the bearing bracket (1.9).
Pay attention not to damage the sealing rings of the bearing assembly.
Step 13: Remove the fines discharge device (1.5).
Step 14: Pull the separator rotor (3.1) on the eyebolt (1.7.1) upwards out of the
separator.

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Machine manual Maintenance
SEPOL® LM high-efficiency separator 7-7

7.4.3 Replacing the rotor blades (3.2)

WARNING
Danger of death due to falling down from great height.
Fall hazard when performing work in great height.
I. Use a ladder or a lifting platform.
II. Make sure you have a safe standing when using ladders.
III. If necessary, wear safety harnesses.

WARNING
Stumbling hazard.
Risk of stumbling or falling when inspecting the machine and performing
work inside the machine.
I. Install and use auxiliary platforms inside the machine.
II. Wear a safety harness and safety belts.

IMPORTANT
First, remove the cover plate when rotor blades must be replaced in the upper
area of the rotating parts.

IMPORTANT
Never remove more than ten rotor blades at once before installing new ones to
prevent the separator rotor (3.1) from being damaged.

Step 1: Loosen bolts and remove the rotor blades (3.2).

Step 2: Install new rotor blades and tighten bolts with the specified tightening
torque.

7.4.4 Replacing the guide vanes (1.7)

IMPORTANT
If the gap of the guide vanes (1.7) in the lower guide vane holder (2.7) have
excessive play, replace this holder.

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Maintenance Machine manual
®
7-8 SEPOL LM high-efficiency separator

Step 1: Remove the cover (1.8) of the guide vanes (1.7).

Step 2: Screw the eyebolt (1.7.1) into the guide vanes (1.7) to lift them.
Step 3. Remove the lower guide vane holder (2.7).
Step 4. Loosen the neighbouring guide vanes and slightly push them to the side.
Step 5: Loosen the upper guide vane holder and lift the guide vane (1.7) out of the
separator.

IMPORTANT
Guide vanes that cannot be lifted directly upwards out of the separator must be
pulled away in circumferential direction under the fines outlet (1.5). Prior to this,
it is essential that you remove the lower guide vane holder (2.7).

Fig. 30: Replacement of the guide vanes

Step 6. Install the new guide vanes (1.7) in reverse order.

7.4.5 Replacing the sealing at the housing side (1.11)

IMPORTANT
When the adjustment distance of the sealing at the housing side (1.11) is
completely used, the sealing has to be replaced in good time.
The segments fit through the inspection ports in the fines discharge device and
thus can be replaced without dismounting further housing parts.

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Machine manual Maintenance
SEPOL® LM high-efficiency separator 7-9

Step 1. Replace the multipart sealing at the housing side (1.11) with the inspection
cover in the fines discharge device (1.5).
Step 2: After the complete replacement set the gap to 3 mm.

7.4.6 Replacing the grit cone (2.2)

Since the grit cone is directly exposed to the material-laden air stream, it is
subjected to increased wear. If a complete replacement should be necessary,
proceed as follows:
Step 1: Remove the piping upstream of the separator.
Step 2: Remove the flap valves (6) and the grit pipe (2.6).
Step 3: Homogeneously loosen the flange connection between the grit cyclinder
(2.1) and the grit cone (2.2).

IMPORTANT
This leads to lowering of the grit cone until it is supported by the radial ribs (9) of
the housing cone (1.6).

Step 4: Loosen the flange connection between the basic housing (1.1) and housing
cone (1.6) and remove the housing cone (1.6) with the grit cone (2.2).

Fig. 31: Replacement of the grit cone

Step 5: Perform assembly in reverse order.

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Machine manual Trouble shooting
SEPOL® LM high-efficiency separator 8-1

8 Trouble shooting
WARNING
Injury hazard due to rotating parts.
Rotating parts in the inside of the separators can crush, shear, cut or cut-
off limbs and pull them into the machine.
I. During operation, do not touch the moving parts.
II. Do not open any flaps or maintenance covers during operation.
III. Observe overtravel time: Prior to opening any flaps for the purpose of
maintenance and/or control, ensure that all components have come to
a complete standstill.
IV. Prior to performing any work on moving components of the separator,
shut down the concerned function unit and safeguard it against
restarting. Wait until all components have come to a complete
standstill.
V. In the danger area, wear tight-fitted protective clothing with low tear
strength.

WARNING
Danger due to parts falling down.
Deposits of material and machine components the fastenings of which are
worn out may fall down and cause severe injuries.
I. Always wear safety helmet, safety boots and protective clothing when
entering the danger area.
II. Clean the machine using a compressed air blower.

WARNING
Danger due to stumbling and falling down from great height.
Danger of stumbling and falling down when performing work on the
machine cover and inside the machine.
I. Install and use auxiliary platforms inside the machine.
II. Make sure you have a save standing.
III. Wear a seat belt.

en-AS.CPT.001.A
Trouble shooting Machine manual
®
8-2 SEPOL LM high-efficiency separator

WARNING
Injury hazard due to hot surfaces.
Components heat up during operation. Skin contact with hot surfaces
causes severe burns.
I. Always wear heat resistant protective clothing and safety gloves when
working in the vicinity of hot surfaces.
II. Ensure that all surfaces have cooled down to ambient temperature
before commencing any work on the plant.

WARNING
Injury hazard due to harmful dusts.
In the long term, inhaled dusts can cause pulmonary conditions or other
health impairment.
Direct eye contact with dusts can irritate or inflame the eyes.
I. Wear basic respiratory equipment and protective goggles when
performing any work within the danger area.
II. Clean the machine using a compressed air blower.

WARNING
Injury hazard due to escaping material to be conveyed.
Opening any inspection covers during operation or leaks of the unit can
cause escaping of the material to be conveyed. This can cause severe
injuries.
I. Do not open inspection covers during operation.
II. In case of leaks, immediately switch off the unit and arrange for repair.
III. Wear personal protective equipment.

CAUTION
Injury hazard on sharp edges and corners.
Wear inside the machine causes sharp edges which can lead to abrasive
burn and cuts.
I. When working in the vicinity of sharp edges and corners, proceed with
utmost care.
II. Wear protective clothing in the danger area.

en-AS.CPT.001.A
Machine manual Trouble shooting
SEPOL® LM high-efficiency separator 8-3

CAUTION
Injury hazard due to impacts.
Impact hazard in vicinity of the flap valves and inside the machine.
Wear protective clothing in the danger area.

IMPORTANT
If any faults occur which are not described below, please consult the suppliers'
documentation for more information about faults, their causes and their
elimination.

Fault Cause Elimination

Unbalance of the separator Tension rods (3.8) not in Check the pretensioning of
(3.1) proper working order the tension rods; the tension
rods must have no contact to
any other parts.

The rotor blades (3.2) are Insert new rotor blades and
unevenly worn re-balance separator rotor

Uneven material incrustations Clean the separator rotor

at separator rotor (3.1)

Guide vanes (1.7) vibrate Lower guide vane holder (2.7) Replace worn-out guide vane
is worn out holder

Noises The lubricant supply to the ● Check the oil level in the
● upper bearing assembly bearing assemblies is upper bearing assembly
(3.6) insufficient and refill if necessary

● lower bearing assembly ● Check the lubrication pipes

(3.7) ● Check the central
lubrication system

The antifriction bearings are Replace faulty bearings

faulty

The material outlet is blocked Tramp material on the flap Remove tramp material
valve

Flap valves are stiff or faulty See separate machine

manual

en-AS.CPT.001.A
Trouble shooting Machine manual
®
8-4 SEPOL LM high-efficiency separator

Fault Cause Elimination

The material to be separated The rotor speed is not correct Readjust the rotor speed
is too coarse or too fine.
Guide vanes (1.7) are wrongly Readjust the guide vanes
set

Dust escapes from the Seals are defective. Replace defective seals
separator.

Finished product contains Excessive air gaps of the Readjust or replace the
oversize particles sealing at the housing side sealing at the housing side
(1.11) (1.11)

Gear unit becomes too hot In the case of water cooling: ● Increase cooling water
● Insufficient cooling water flow rate
flow rate ● Check the cooling water
● Cooling water supply supply system
system is defective

In case of air cooling: Check the cooling air fan,

● Inadequate cooling air clean or replace the air filter,
volume suck in cooling air from the
outside
● Excessive cooling air
temperature

The gear lubrication system is ● Check the oil quantity in

not functioning correctly the gear unit
● Check the oil quality

en-AS.CPT.001.A
Machine manual Spare parts
SEPOL® LM high-efficiency separator 9-1

9 Spare parts
9.1 Suggestions for enquiries and orders of spare parts
Dear Customer,
POLYSIUS AG want to make spare part enquiries and spare part order
placement as easy and efficient as possible. For this purpose we have prepared
a table containing all data required by our spare parts department to ensure
optimum processing in the most speedy and trouble-free manner.
Please copy the title page as well as the page with the respective table, and mark
those parts which you require with a cross in the column "Order" or in the column
"Enquiry".
If the table refers to more than one machine, please also inform us of the
POLYSIUS Order Code (POC) of the machine for which you require the spare
parts.

9.2 Spare parts

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Spare parts Machine manual
®
9-2 SEPOL LM high-efficiency separator

Housing sections (1A)

Fig. 32: Housing side (1A), design without distributing plate

en-AS.CPT.001.A
Machine manual Spare parts
SEPOL® LM high-efficiency separator 9-3

No. Name Qty. Unit Order Enquiry

1.7 Guide vane

1.10 Seal

1.11 Seal

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Spare parts Machine manual
®
9-4 SEPOL LM high-efficiency separator

Housing sections (1B)

Fig. 33: Housing side (1B), design with distributing plate

en-AS.CPT.001.A
Machine manual Spare parts
SEPOL® LM high-efficiency separator 9-5

No. Name Qty. Unit Order Enquiry

1.7 Guide vane

1.10 Seal

1.11 Seal

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Spare parts Machine manual
®
9-6 SEPOL LM high-efficiency separator

Internal fittings (2)

Fig. 34: Internal fittings (2) (design with distributing plate)

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Machine manual Spare parts
SEPOL® LM high-efficiency separator 9-7

No. Name Qty. Unit Order Enquiry

2.6 Grit pipe

2.7 Lower guide vane holder

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Spare parts Machine manual
®
9-8 SEPOL LM high-efficiency separator

Rotating parts (3A)

Fig. 35: Rotating parts (3A), design without distributing plate

en-AS.CPT.001.A
Machine manual Spare parts
SEPOL® LM high-efficiency separator 9-9

No. Name Qty. Unit Order Enquiry

3.1 Separator rotor

3.2 Rotor blade

3.3 Supporting ring

3.8 Tension rod

3.9 protective pipe

3.10 Protective pipe

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Spare parts Machine manual
®
9-10 SEPOL LM high-efficiency separator

Rotating parts (3B)

Fig. 36: Rotating parts (3B), design with distributing plate

en-AS.CPT.001.A
Machine manual Spare parts
SEPOL® LM high-efficiency separator 9-11

No. Name Qty. Unit Order Enquiry

3.1 Separator rotor

3.2 Rotor blade

3.3 Supporting ring

3.8 Tension rod

3.9 protective pipe

3.10 Protective pipe

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Spare parts Machine manual
®
9-12 SEPOL LM high-efficiency separator

Upper bearing assembly (3.6)

Fig. 37: Upper bearing assembly (3.6)

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Machine manual Spare parts
SEPOL® LM high-efficiency separator 9-13

No. Name Qty. Unit Order Enquiry

3.6.6 Upper lamellar ring

3.6.7 Upper sealing ring

3.6.14 Lower lamellar ring

3.6.15 Lower sealing ring

3.6.17 Antifriction bearing

3.6.18 Temperature sensor PT100

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Spare parts Machine manual
®
9-14 SEPOL LM high-efficiency separator

Lower bearing assembly (3.7)

Fig. 38: Lower bearing assembly (3.7)

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Machine manual Spare parts
SEPOL® LM high-efficiency separator 9-15

No. Name Qty. Unit Order Enquiry

3.7.2 Seal

3.7.4 Clamping element

3.7.7 Clamping sleeve

3.7.8 Antifriction bearing

3.7.9 Temperature sensor PT100

en-AS.CPT.001.A
Spare parts Machine manual
®
9-16 SEPOL LM high-efficiency separator

Drive unit with coaxial gear unit (4A)

Fig. 39: Drive (4A), coaxial gear unit design

en-AS.CPT.001.A
Machine manual Spare parts
SEPOL® LM high-efficiency separator 9-17

No. Name Qty. Unit Order Enquiry

4A.2 Coaxial gear unit

4A.4 Coupling

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Spare parts Machine manual
®
9-18 SEPOL LM high-efficiency separator

Drive unit with combined spur and bevel gear unit (4B)

Fig. 40: Drive (4B), combined spur and bevel gear unit design

en-AS.CPT.001.A
Machine manual Spare parts
SEPOL® LM high-efficiency separator 9-19

No. Name Qty. Unit Order Enquiry

4B.2 Coupling

4B.3 Combined spur and bevel gear unit

4B.5 Coupling

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Spare parts Machine manual
®
9-20 SEPOL LM high-efficiency separator

Wear protection (5)

Fig. 41: Wear protection (5) (design with distributing plate)

en-AS.CPT.001.A
Machine manual Spare parts
SEPOL® LM high-efficiency separator 9-21

No. Name Qty. Unit Order Enquiry

5.1 Wear protection for housing cone

5.2 Wear protection for basic housing

5.3 Wear protection for fines discharge device

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Machine manual Appendix
SEPOL® LM high-efficiency separator 10-1

10 Appendix
10.1 Technical drawings

Note - For Digital Copy

The drawings are part of manual as attachment and can be viewed/opened by

a double click either on the paperclip icon appearing beside the drawing
number or on the drawing file appearing within attachment button of navigation
pane.

Designation Drawing number

Assembly separator CMT-AS-03530-SH-1-2

Separator rotor CMT-AS-03525-0_0

Rotating parts CMT-AS-03524-1-0

Danger spots and sign location CMT-AS-07774-2/4

10.2 Subsuppliers' documentation

Drive Ref. VOL. - 3(Siemens)

Wear protection lining Not available - tkII scope

Temperature sensor Ref. VOL. - 5

Lubrication system Ref. VOL. - 3(Siemens)

Vibration monitoring system Ref. VOL. - 5

10.3 Measurement records

Measurement record LM high-efficiency separator Attached

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