Book13 - Roller Screen RR1439 - P0EBD72 (TR 1-59)

OPERATING
INSTRUCTIONS
SONG HAU 1
THERMAL POWER PLANT
BOOK 13
Roller screen RR1439
P0EBD72
Manual 1
Use of machine in accordance with
intended purpose
FAM
Magdeburger Förderanlagen
und Baumaschinen GmbH
Sudenburger Wuhne 47
39112 Magdeburg
Phone: +49 391 6380 10700

Hotline-Fax: +49 391 6380 10799
SH1-FAM-P0-100-GE-M02-HDD-0001 Book13_M1 1/6

CONTENTS
1 USE OF MACHINE IN ACCORDANCE WITH INTENDED PURPOSE ................................................... 3
1.1 Preface ...................................................................................................................................................... 3
1.2 Basic notes ............................................................................................................................................... 3
1.3 Responsibility of the operator ................................................................................................................ 4
1.4 Responsibility of the personnel ............................................................................................................. 5
1.5 Warranty and liability .............................................................................................................................. 5
1.6 Copyright .................................................................................................................................................. 5
1.7 Constructional changes .......................................................................................................................... 6

1 USE OF MACHINE IN ACCORDANCE WITH INTENDED PURPOSE
1.1 Preface
These operating instructions are intended for machine operators who have been trained by the operator and
have confirmed this with their signature.
It is also intended for experts (like machine setters, electricians and metalworkers) who are charged with
installation, commissioning, setting up, retrofitting, maintenance, repair and dismantling of the machine/system.
Before commissioning, read through the operating instructions of the machine/plant completely to be able to
use every function correctly and securely.
The operating instruction contains important information on how to operate the machine/installation securely,
properly and economically. Taking notice of these instructions helps to avoid risks, minimize repair costs and
downtimes and increase reliability and durability of the machine /installation.
Due to existing national regulations for accident prevention and environment protection, the operating
instructions have to be complemented by instructions.
The operating instructions must always be available on site of the machine/installation.
1.2 Basic notes

The machine/plant has been manufactured to the latest state of the art and under consideration of the FEM
Codes and Standard (Fédération Européenne de la Manutention), ISO und DIN standards and the
acknowledged rules of safety engineering. Nevertheless, use of this equipment might involve risks to life of
operators or third parties or damage to the machine/plant or other property.
Therefore, the operator of this machine/plant shall prepare job-specific instructions on the basis of the intra-
company occupational safety and accident prevention codes and declare them obligatory so that accident-free
operation, repair and maintenance of this machine/plant can be ensured.
This machine/plant should be used only in technically perfect condition and in full accordance with the intended
purpose, with safety awareness and under strict adherence to the operation and maintenance instructions.
Troubles that might impair operational safety must be eliminated immediately.
The machine/plant shall be used only for the application parameters described in Section „Technical Data“. Use
of equipment for other purposes and/or different application parameters is considered as not in accordance with
the intended purpose. The manufacturer rejects claims resulting from this, and the risk shall be fully on the
user’s side.
The user is obliged to study the complete documentation so that he understands it.
IMPORTANT

1.3 Responsibility of the operator
The operator is obliged to ensure that the personnel are instructed on all potential dangers and selected
safety measures. These instructions must be repeated at appropriate intervals.
The operator is obliged to only allow persons to work with the machine/installation, who are familiar
with the nationally applicable laws and regulations and with the applicable plant-internal occupational
health & safety and accident prevention regulations.
We recommend you check that your personnel are working in a safety-conscious

manner at regular intervals!
IMPORTANT
The operator is obliged to familiarise the personnel on how to operate the machine/installation.
The operator is obliged to only operate the machine/installation when in a faultless condition from a
safety-related perspective.
The operator is obliged to only have work on the electrical and electronic machines / systems carried
out by electricians under observance of the valid safety regulations for working with electrical systems.
The operator is obliged to have the specified setting, maintenance and inspection work executed by
the due date by skilled personnel.
The operator is obliged to follow the respective, valid legal environmental protection regulations in
addition to the information provided in these operating instructions.
The operator is obliged to only allow persons to work on the system, who
have the legal age
are not under the influence of drugs or alcohol
are familiar with the basic occupational safety, health and environmental protection regulations and
have been trained on how to work with the system.
have read and understood these operating instructions and have confirmed this through their
signature.
The operator is obliged to check that his/her personnel are working in a safety-conscious manner and
to counteract deviations from safety measures with suitable measures.
The operator is obliged to provide the operating and maintenance personnel with personal protective
equipment. The design of the personal protective equipment is the responsibility of the system operator.
The operator is obliged to make sure that all security and warning notes on the machine/installation are
not removed and are in legible condition.

1.4 Responsibility of the personnel
All persons, who are assigned to work with the machine/installation, are obliged:
to observe the respective, nationally applicable Labour Protection Act and the regulations of the
Industrial Health and Safety Ordinance;
to carefully read through the operating instructions before operating the machine to ensure that these
are always near at hand;
to observe the respective manufacturer operating instructions when working with and/or on machine
components! This applies in particular for personnel, who only work occasionally with the machine, e.g.
in the case of machine maintenance;
to report changes in the machine performance immediately to the responsible location or person;
in the case of malfunctions, which endanger the safety of persons or parts, to immediately shut down
the machine and to inform the responsible location / person.
1.5 Warranty and liability

Any warranty and liability claims are excluded for damage to man and equipment if such damage is due to one
of the following causes:
Use of machine/plant not in accordance with the intended purpose;
Improper assembly, start-up, operation and maintenance;
Operation of machine/plant with defective protective appliances or guards and safety devices not fitted
correctly or not functioning properly;
Non-observance of operation and maintenance instructions;
Modifications or conversions made without the express approval by FAM;
Insufficient supervision of system and machine components which are subjected to wear, as well as
improperly executed repair work.
Catastrophic situation by foreign objects or cases of force majeure.
1.6 Copyright
The copyright in this documents remains with Magdeburger Förderanlagen und Baumaschinen GmbH.
Reproduction, disclosure to third parties, announcement or similar modes of publication and use for any other
purposes are prohibited without the express written approval of the copyright owner.
All rights are reserved for the case of patent granting or registration of utility models.
Infringements may result not only in order to refrain but also in claims for damages.

1.7 Constructional changes
Unauthorized constructional changes on the machine/plant are not admissible for reasons of safety – the same
applies as well to welding work on load bearing structures.
All planned modifications require prior written approval by FAM.
Make sure that only original spare parts, wearing parts and accessories are used
since they are specifically designed for use in the machine/plant. When parts from
other sources are used, the stress-bearing capacity and safety aspects cannot be
NOTE guaranteed.
Parts and special components not supplied by FAM must be considered as items not released for use by FAM.

OPERATING
INSTRUCTIONS
SONG HAU 1
THERMAL POWER PLANT
BOOK 13
P0EBD72
Manual 2
Basic safety requirements
FAM
39112 Magdeburg
Phone: +49 391 6380 10700

Hotline-Fax: +49 391 6380 10799

CONTENTS
1 BASIC SAFETY REQUIREMENTS .......................................................................................................... 3
1.1 Explanation of symbols and notes ........................................................................................................ 3
1.2 Safety and protective appliances ........................................................................................................... 9

1.2.1 Basic rules......................................................................................................................................9
1.2.2 EMERGENCY STOP pushbuttons ..............................................................................................10
1.3 Notes describing specific kinds of potential hazard ......................................................................... 11

1.3.1 Potential hazards caused by electric power ................................................................................11
1.3.2 Potential hazards caused by hydraulic components....................................................................11
1.3.3 Gas, dust, vapours and smoke ....................................................................................................12
1.4 Specific areas where hazards might exist .......................................................................................... 12
1.5 Cleaning the machine/plant and waste disposal in general .............................................................. 13
1.6 Noise level of machines ........................................................................................................................ 14
1.7 Environmental protection ..................................................................................................................... 14

1 BASIC SAFETY REQUIREMENTS
1.1 Explanation of symbols and notes
The following symbols are used in the operation manual for dangers and advices:
This symbol means: Warning of very dangerous areas- imminent risks to the life and
health of persons.
This danger sign marks a very dangerous situation with the consequence that non-
observance of the required rules of behaviour might cause most severe bodily injuries (e.g.
DANGER heavy skin burns) or property damage. Even fatal injuries are possible.
This symbol means: Warning of a dangerous area - potential risk to the life and health
of persons.
This warning sign marks a very dangerous situation. Non-observance of the required rules
of behaviour might cause severe bodily injuries, even the loss of limb or severe property
WARNING damage.
This symbol means: Caution, Warning of a dangerous area and a potentially hazardous
situation involving risks to the health of persons.
of behaviour might cause light bodily injuries and/or property damage.
CAUTION
This symbol stands for hints and other particularly important information.
IMPORTANT
This symbol stands for specific instructions for the operator that can be followed or are of
specific importance as background information.
NOTE

This symbol means: „Warning of suspended load“.
Work should not be carried out under suspended load, as far as possible.
The diligent crane operator will do its best to avoid load movements across the heads of
persons. Should it be unavoidable to move loads over the heads of people, the crane
operator must release a warning signal so that people may leave this zone.
DANGER
Work under suspended load (e.g. work under load lifted by floor conveyors) is prohibited.
DANGER TO LIFE!
This symbol means „Warning of hazardous electrical voltage“.

Only those persons should carry out work on electrical equipment and in control rooms who
are suitably qualified (e.g. skilled electricians or other qualified persons) and authorized to
do so.
This danger symbol stands for extremely dangerous situations. Non-observance of the
DANGER behaviour rules might cause most severe bodily injuries (e.g. heavy skin burns) or property
damage. Even fatal injuries are possible.
This symbol means: „Warning of automatic start-up“.

Start-up of machines in production plants is announced by flashing light and/or audible
signal. From this moment all work on the production plant must be stopped.
After signal release all persons must leave the dangerous area.
Be sure to keep a sufficient distance to components that might move since there is the risk
of bruising injury or getting caught by moving machine parts.
DANGER
of behaviour might cause severe bodily injuries, even the loss of limb or severe property
damage.
This symbol means: „Warning of explosive substances“.

Warning of risks caused by explosive substances kept in rooms or getting into contact with
equipment items like machines, tools etc.
Areas marked by this symbol are subject to the risk of explosions.
Persons doing work in the marked rooms and/or on the marked equipment parts should
work carefully and strictly observe the applicable rules of behaviour.
DANGER
heavy skin burns) or property damage. Even fatal injuries are possible..

This symbol means: “Never use floor conveyors for transport of persons“.
heavy skin burns) or property damage. Even fatal injuries are possible.
DANGER
This symbol means: ”Danger, „Ban on open flame, open light and smoking“.
This safety sign is used in areas where inflammable or explosive solid, liquid or gaseous
substances are stored so that the risk of fire is present.
No ignition sources are admissible in the areas marked by this sign.
(For exceptions and necessary type approvals for components for use in the individual
zones see the Directives on Explosion Protection.)
Work where ignition sparks are developed must not be carried out in these areas, such as
welding, grinding, abrasive or flame cutting).
The following ignition sources must not be used in areas marked with the safety sign:
Open flames and hot gases (e.g. candles, matches, welding pearls, welding sparks,
glowing charcoal or tobacco)
Heated or hot surfaces (e.g. radiators, hotplates, bulbs, engine bowls, exhaust gas
DANGER systems)
Friction heat (e.g. bearings running hot)
Mechanically generated sparks (e.g. rock, concrete or metal sparks generated by
grinding, abrasive cutting or by hammer blows)
If such kind of work is necessary in areas marked by this sign, specific safety measures
must be taken before.
heavy skin burns) or property damage. Even fatal injuries are possible.

This symbol means: „Warning, danger of squashing-off limbs“.
Work in areas marked by this sign involves the risk of squashing-off limbs.
Persons working in these areas or with products marked by this sign should do their work
with utmost care.
WARNING of behaviour might cause severe bodily injuries, even the loss of limbs or severe property
damage.
This symbol means: „Warning, danger of falling“.

The risk of failing down exists in all height levels above 1.0 metres without protective railings
or similar, or in places where the risk of sinking exists.
Work in areas marked by this sign requires utmost care.
If necessary, workers should use safety belts and/or suitable safety clothing.
WARNING
of behaviour might cause severe bodily injuries, even the loss of limbs.
This symbol means: „Warning, Hot liquids and vapours“

The presence of hot liquids and vapours emerging from open vessels or under high pressure
cannot be safety detected under all circumstances.
Protective gloves should be used when getting into contact with hot liquids or vapours.
WARNING of behaviour might cause severe bodily injuries, even the loss of limbs or severe property
damage.
This symbol means: „Caution, danger of stumbling“.

Normally all paths can be used without any risks and without the need to permanently look
down. However, steps might be provided for equalization of height differences between
workplaces.
Cables and hoses laid on the ground may cause further temporary danger of stumbling.
Therefore, people walking there should occasionally look down in order to detect uneven
CAUTION areas so that stumbling cannot occur.
This warning sign marks a dangerous situation. Non-observance of the required rules of
behaviour might cause light bodily injuries.

This symbol means: „Prior to work, isolate machine from power supply“.
Only skilled electricians should carry out work on electrical plants and equipment items.
Prior to work, the electrical plant and the equipment items must be isolated from power
supply.
Non-observance of this rule may cause damage to health.
This symbol means: „Use catching safety belt“ (personal safety equipment for protection
against falling).
If an area (e.g. erection site) involves a higher danger of falling, catching safety belts and
the personal safety equipment must be used for protection against falling.
Non-observance of this instruction may cause damage to health and even fatal injuries.
This symbol means: „Use protective clothing“.

If a specific type of protective clothing is required on a workplace, the shown sign must be
provided there and a written note must be added to the operation instructions.
Special protective clothing could be among others:
Weather protection, heat protection or frost protection clothing
Clothing for protection against chemicals, welder’s protective clothing
Isolating protective clothing for electricians
Non-observance of these rules may cause damage to health.
This symbol means: „Use ear protectors“.

If a high noise level is present in certain areas, ear protectors must be used.
In areas with a sound pressure level of 85 dB(A) or more, this sign should be provided to
remind the workers of their duty to use ear protectors.
Areas marked by this sign and/or operation of machines and equipment generating such a
sound pressure level make it compulsory to use the correct type of ear protectors. Otherwise
the workers could loose the hearing power of their ears (reversible hearing impairment after
an extended rest period) or suffer from impairment of hearing (irreversible hearing damage).

This symbol means: „Escape route“.
These signs are fitted along the escape route.
In case of emergency (e.g. fire or explosion) all persons should follow the arrow marking on
the escape route signs. Normally the escape routes are not confined. Escape routes must
be kept permanently free. In most cases they show the shortest way out of the dangerous
area up to the next structural unit (e.g. neighbouring building, way out to the open air).
The directional arrow must show the way to the next structural unit or to the open air.
This symbol means: „Danger of environmental pollution“.

Non-observance of this instruction may cause effects detrimental to the environment.
This symbol means: „Marking of containers provided for disposal of used oils and
lubricants“.
Non-observance of this instruction may cause effects detrimental to health and to the
environment.
This symbol means: „Marking of containers provided for disposal of oily cleaning
cloths“.
Non-observance of this instruction may cause effects detrimental to health and to the
environment.

1.2 Safety and protective appliances
1.2.1 Basic rules
Operation of the machine/plant without effective protection equipment might cause
severe injuries of operating staff.
Therefore, make sure that the machine/plant is never operated without protective wire
mesh guards, railings, protective covers or other safety appliances.
Never bypass or remove effective safety appliances since machine operators would be
exposed to the risk of accidents.
DANGER
Moving mechanical components might cause severe injuries.
Lethal electric shocks might occur.
Make sure that operators use the required personal safety equipment.
Before putting the machine/plant into operation, check if all guards are fully operable and fitted correctly.
Check all safety and monitoring appliances of the machine/plant for safe function. Never start the
machine/plant with missing or defective safety appliances.
Never remove or bypass safety appliances.
The machine is working with rotating machine components that can provoke squeezing injuries.
If the removal of safety appliances is required for repair or maintenance work and this removal has
been authorized before, the equipment must be shut down and isolated from power supply so that the
machine/plant cannot be erroneously restarted. Once the repair and maintenance work has been
completed, all safety appliances must be re-installed in their original positions again.
All EMERGENCY STOP pushbuttons must be freely accessible. They must not be covered so that they
are not visible, and their settings must not be changed.
Automatically actuated switches must not be blocked so that safe release is possible.
Make sure that all fire alarming and fire-fighting equipment is in a technically sound condition. Keep all
operating staff informed about the locations and correct use of such fire alarming and fighting
equipment.
Observe all safety and warning panels of the machine/plant and keep them in a good legible condition.
Keep all limit switches and other safety appliances in a clean state, fully operable and free from dirt so
that their function cannot be impaired.

Make sure to adhere to the setting, maintenance and inspection activities and intervals plus data on
replacement of parts and components contained in the operation manual. All those activities should be
accomplished only by qualified personnel (skilled work force).
Qualified personnel (skilled work force) are persons who have been authorized by the re-sponsible
for maintaining the safety of the components/ plant, to perform such activities and to detect and avoid
possible dangers as a result of their training, experience, instruction or familiarity with the relevant
Standards, regulations, accident prevention measures and operating conditions.
1.2.2 EMERGENCY STOP pushbuttons
In case of danger, operate the EMERGENCY STOP pushbutton or the pull-cable

switch. The machine/plant stops immediately.
ATTENTION: Observe the overtravel time of the machine!
IMPORTANT
Do not use the EMERGENCY STOP pushbuttons for service stops of equipment since this mode of equipment
stop should be restricted to cases of emergency. Moreover, the use of EMERGENCY STOP pushbuttons for
service stop of equipment may cause damage to the machine.
Sudden movements of equipment components may cause severe injuries.

Before unlocking the EMERGENCY STOP pushbutton and resuming operation of the
equipment, make sure that the risk of accidents and damage can be excluded.
DANGER

1.3 Notes describing specific kinds of potential hazard
1.3.1 Potential hazards caused by electric power
Switch off the machine/plant immediately in case of troubles in the electric power supply!
POTENTIAL HAZARDS CAUSED BY ELECTRIC POWER!

Only well-qualified electricians shall accomplish all work on power supply systems.
Make sure that machine and equipment subject to compulsory inspections, repair and
maintenance work are – if required - iso-lated from power before such work is carried
out. To be sure, check the isolated equipment items if they are still under voltage. Earth
and short-circuit them and isolate other equipment in the vicinity of power supply.
DANGER If work is necessary on live components, a second person must be available for safety
reasons who may open the circuit breaker or isolate the equipment in case of need. This
second person must be well familiar with resuscitation measures.
Check the electrical equipment at regular intervals. Defects found must be eliminated
immediately.
Keep the control cabinet closed. Access to the control cabinet is limited to authorised
persons.
1.3.2 Potential hazards caused by hydraulic components
ALL WORK SHALL BE CARRIED OUT BY WELL QUALIFIED STAFF

The system must be relieved from pressure before repair and mainte-nance work,
including opening of system parts and pressure pipes, can be carried out.
Check the hydraulic components at regular intervals (leak tightness of the system,
WARNING
hydraulic oil filters).
CAUTION, HOT LIQUIDS AND VAPOURS

Be careful when handling hot utilities and auxiliary materials. Risk of skin burning!
WARNING

1.3.3 Gas, dust, vapours and smoke
CAUTION, RISK OF EXPLOSION AND FIRE!

Welding, flame cutting, soldering and grinding work must not be carried out without the
express permission by the manager or the competent foreman. All applicable safety
measures must be strictly followed. This includes the cleaning of machines/plants and
the elimination of dust and inflammable materials. Ensure sufficient ventilation.
DANGER
Cover broken-out spots with non-inflammable materials.
1.4 Specific areas where hazards might exist
CAUTION, SUSPENDED LOADS!

Persons must not stay under suspended loads. All load handling operations shall be
supervised by a number of persons. Crane operator and supervisors must have direct
contact with each other.
DANGER
CAUTION, RISK OF DOWNFALL!

Working, maintenance and repair platforms without safety railing involve the risk of
downfall!
WARNING
CAUTION, RISK OF STUMBLING!

When walking on working, maintenance and repair platforms, note the risk of stumbling
caused by ledges in objects provided on the floor.
DANGER
CAUTION, RISK OF SQUEEZING!

In mobile machine/plant parts, all persons must be kept out of the safety zones.
DANGER

CAUTION, RISK OF DOWNFALL!
Certain repair and maintenance work may make it neces-sary to climb over the
safety barriers of shutdown ma-chine/plant.
DANGER Only well instructed workers who are well familiar with the potential hazards
should be nominated for this work.
The use of safety belts, safety harnesses shall be used for protection against
downfall.
All zones where safety facilities are changed or even removed must be blocked. Access
to these zones must be blocked with safety chains.
DANGER
1.5 Cleaning the machine/plant and waste disposal in general
CAUTION RISK OF FIRE! / CAUTION RISK OF EXPLOSION!

Note that there is a risk of fire and explosion when using solvents and sol-vent-
containing cleaning agents.
DANGER
When using solvents and solvent-containing cleaning agents, note that there is a ban
on
naked fire of any kind and smoking!

DANGER
USE CLOTHS AND MATERIALS CORRECTLY AND DISPOSE THEM PROPERLY, WITH
THE EMPHASIS ON:
Work on lubrication systems and appliances.
Cleaning by use of solvents.

1.6 Noise level of machines
Depending on the local conditions on site, a higher sound pressure level may develop
and cause hardness of hearing- In such causes the workers are obliged to wear ear
protectors or to take other protective measures.
1.7 Environmental protection
All lubricants, cooling or cleaning agents hazardous to environment must be disposed

of in compliance with the latest statutory requirements.
During all work with or on the equipment the rules on the avoidance of wastes and the
correct disposal or recycling of wastes shall be observed.
Substances like
Hydraulic fluids
Oils and greases
Coolants
Solvent-containing cleaning agents
required for installation, repair and maintenance work must not get into the soil or enter
the sewage system.
These fluids must be collected in suitable vessels before they are disposed of properly.

OPERATING
INSTRUCTIONS
SONG HAU 1
THERMAL POWER PLANT
BOOK 13
P0EBD72
Manual 3
Technical data
FAM
39112 Magdeburg
Phone: +49 391 6380 10700

Hotline-Fax: +49 391 6380 10799

CONTENTS
1 TECHNICAL DATA ................................................................................................................................... 3

1 TECHNICAL DATA

OPERATING
INSTRUCTIONS
SONG HAU 1
THERMAL POWER PLANT
BOOK 13
P0EBD72
Manual 4
Design and function
FAM
39112 Magdeburg
Phone: +49 391 6380 10700

Hotline-Fax: +49 391 6380 10799

CONTENTS
1 DESCRIPTION OF SYSTEM FUNCTION ................................................................................................. 3
1.1 General function and locking conditions .............................................................................................. 3

1.1.1 Basics.............................................................................................................................................3
1.1.2 On-site operation............................................................................................................................4
1.1.3 Alarm list ........................................................................................................................................4
1.1.4 Activation release...........................................................................................................................4
1.1.5 Activation process ..........................................................................................................................5
1.1.6 Deactivation release ......................................................................................................................5
1.1.7 Deactivation ...................................................................................................................................5
1.1.8 Fault analysis .................................................................................................................................6
1.1.8.1 Basics ..................................................................................................................................6
1.1.8.2 Emergency stop...................................................................................................................6
1.1.8.3 Standstill of the removing system........................................................................................6
1.1.8.4 Speed monitoring.................................................................................................................6
1.1.8.5 Switching on-site operating points .......................................................................................7
1.1.8.6 Failure of the lubrication system ..........................................................................................7
1.1.8.7 Electrical faults, tripping of protection elements ..................................................................7
1.1.8.8 Voltage failure at the infeed .................................................................................................7
1.1.8.9 Maintenance and servicing ..................................................................................................7
1.2 Function description lubrication system for the roller screen ........................................................... 8
1.2.1 General ..........................................................................................................................................8
1.2.2 Activation release...........................................................................................................................8
1.2.3 Activation........................................................................................................................................8
1.2.4 Deactivation release ......................................................................................................................8
1.2.5 Deactivation ...................................................................................................................................9
1.2.6 Fault analysis .................................................................................................................................9
1.2.6.1 Basics ..................................................................................................................................9
1.2.6.2 Grease container - Fill level below min................................................................................9
1.2.6.3 Switching on-site operating points .......................................................................................9
1.2.6.4 Electrical faults, tripping of protection elements ..................................................................9
1.2.6.5 Voltage failure at the infeed .................................................................................................9

1 DESCRIPTION OF SYSTEM FUNCTION
1.1 General function and locking conditions
1.1.1 Basics
The roller screen consists of several rollers placed in sequence and consisting of polygonal discs. The roller
set is made of several rollers placed in parallel with each other on which the load is divided according to the
separating size.
Fine grain (smaller than the separating size) leaves the rollers downwards. Coarse grain (larger than the
separating size) is transported on to the end of the roller screen on the rollers (overflow).
On-site operation via a local operator panel (LOP) must be provided:
The following signals must be provided:
· EMERGENCY STOP
· SELECTION SWITCH for on-site operation
· Switch normal, reversing
· START all rollers
· STOP all rollers
Rotating direction reversal only possible after 5s (adjust at commissioning).
IMPORTANT

1.1.2 On-site operation
Working in on-site operation, remote operation must be locked and the speed monitoring must be bridged.
Transport of material in on-site operation must be prevented.
Emergency stop is always active. Motor currents must be protected against overcurrent via the motor protection
switch.
1.1.3 Alarm list

Field device Alarm Measured value Comments
Rotating speed of Underspeed for more than 1 90% nominal speed
rollers second in at least one roller;
reverse all rollers for 1 second.
Then let the rollers turn again
normally. If the rated speed is not
reached after 2 seconds, stop the
rollers.
(Alarm 3)
Temperature motor Temperature HH Value according to Provide PTC
coil manufacturer's evaluation unit
(Alarm 3)
documentation
(3x1 PTC)
Motor current Triple power intake for more than 1 Value according to Provide for current
second manufacturer's recording and read
documentation in control
Stop rollers.
(Alarm 3)
An Alarm 1 generates a warning in the control centre and requires inspection in the system.
An Alarm 2 generates deactivation of the supplying system. If the system is switched on while there is an alarm
2, the roller screen cannot be started up.
If an Alarm 3 is generated during operation, the roller screen must be switched off at once.
1.1.4 Activation release

The following prerequisites are needed to activate the roller screen:
The removing system must be in operation in the locked (remote) operation.
In the unlocked (on-site-operation) condition, operation takes place solely in the responsibility of the
operator.

1.1.5 Activation process
The roller screen is activated in the same manner in the locked (remote) and unlocked (on-site) operation.
The rollers are switched on in sequence at an interval of 0.5 seconds, starting with the last roller in the conveying
direction. An acoustic and visual warning signal must be tripped before the shear roller crusher starts up (5x
buzzer + flash lamp each). Persons who are in the danger area must have enough time to leave the danger
area.
The roller screen is deemed on:
· once it has been started
The roller screen is deemed ready:
· when both rollers have reached their nominal speeds
1.1.6 Deactivation release

The following prerequisites are needed to deactivate the roller screen:
· The supplying system must be out of operation in the locked operation.
· In the unlocked condition, operation takes place solely in the responsibly of the operator.
1.1.7 Deactivation
In locked (remote) operation, a lag time of approx. 60 seconds must be complied with to empty the roller screen
first.
In unlocked (on-site) operation, this time is not needed. Then both rollers are switched off at the same time.
Then both rollers are switched off at the same time.
The roller screen is deemed off:
· when all rollers have been switched off
The roller screen is deemed out of operation:
· When both rollers have reached rotating speed 0

1.1.8 Fault analysis
1.1.8.1 Basics
Switching procedures that are initiated due to faults can be performed independently of the activation or
deactivation releases.
The cause of the fault must be signalled accordingly.
After the deactivation, independent reactivation of the system is not permitted. If the roller screen switches off,
a signal must be formed that can be used to switch off the supplying system. At normal operation, the power
intake of the motors is monitored. When the triple nominal current is reached within 1 second, the roller screen
is switched off.
1.1.8.2 Emergency stop

Two emergency stop buttons must be provided. When an emergency stop is tripped, all rollers are switched off
at once. Reactivation is only permitted after inspection on site and confirmation.
1.1.8.3 Standstill of the removing system

In locked (remote) operation, all rollers are switched off at once when the removing system is standing still.
In unlocked (on-site) operation, standstill of the removing system has no influence.
Reactivation is possible at once in compliance with the activation release.
1.1.8.4 Speed monitoring

Every roller of the roller screen is monitored separately for undercutting of the nominal speed. When the roller
starts up, the speed evaluation is bridged for one second.
If the min. speed of a roller is below the nominal speed, this may be due to catching. To release this, all rollers
are briefly reversed. During the process, the rotating speed evaluation of the rollers is bridged. The process
goes as follows:
Immediate deactivation of all rollers
Waiting time 1 second
Activation of all rollers in the opposite direction
Deactivation of the reversed rollers
Activation of all rollers in the normal rotating direction
Activation of the rotating speed monitoring after one second
If the rotating speed of the same rollers is undercut again within 10 minutes after reversing, all rollers must be
switched off at once. Reactivation is only permitted after removal of the causes and confirmation.

1.1.8.5 Switching on-site operating points
When the roller screen is not switched off and switching at the on-site operating point takes place from on-site
to remote or vice versa, all rollers must be switched off at once. Reactivation is only permitted after confirmation.
1.1.8.6 Failure of the lubrication system

In the locked condition, all rollers will be switched off after 24 operating hours of the roller screen. Reactivation
is only permitted after removal of the causes and confirmation. In the unlocked condition, operation takes place
solely in the responsibly of the operator. There is no deactivation in this case.
1.1.8.7 Electrical faults, tripping of protection elements

Faults from failure of electrical operating equipment or tripping of protection elements (motor protection switch,
safety monitoring, etc.) will lead to immediate deactivation of all rollers. Reactivation is only permitted after
removal of the causes and confirmation.
1.1.8.8 Voltage failure at the infeed

When the voltage returns after a voltage failure at the infeed, the roller screen will not start up again on its own.
Reactivation is only permitted after confirmation.
1.1.8.9 Maintenance and servicing

During maintenance or servicing, the system generally must be powered down and the emergency stop must
be pushed.

1.2 Function description lubrication system for the roller screen
1.2.1 General
The lubrication system is made up of a pump, a main and two subdistributors that supply the lubrication points
with grease. The distributors are designed as progressive distributors. The main distributor has a sensor for
lubrication cycle monitoring.
Lubrication takes place in intervals. For precise setting of the intervals, the control must use a variable time link
(break times) and a variable counting element (cycle number).
On-site control must be provided.
1.2.2 Activation release

The following prerequisites are needed to automatically activate the lubrication system:
· The roller screen must be in operation in the locked (remote) operation.
· In the unlocked (on-site-operation) condition, operation takes place solely in the responsibility of the
operator.
1.2.3 Activation
The lubrication system is activated in locked (remote) operation.
The lubrication pump is running in the following intervals:
Activation of the lubrication pump after the break times set in the time link (usually 3 minutes).
The break time between the lubrication cycles may be between 60 minutes and 0 minutes in locked
(remote) operation (usually approx. 40 minutes).
Deactivation of the lubrication pump after the cycle number set in the counting element (flank change
0-1).
In unlocked (on-site) operation, the lubrication system at the on-site control is switched on by activation of the
lubrication pump; the lubrication pump runs in permanent operation.
1.2.4 Deactivation release

The following prerequisites are needed to automatically deactivate the lubrication system:
The roller screen must be out of operation in the locked (remote) operation.
In the unlocked (on-site-operation) condition, operation takes place solely in the responsibility of the
operator.

1.2.5 Deactivation
In locked (remote) operation, the lubrication system is switched off by deactivation of the roller screen.
The lubrication system is deemed off when:
The roller screen is switched off in the locked (remote) operation.
The lubrication pump is off in the unlocked (on-site) operation.
1.2.6 Fault analysis

1.2.6.1 Basics
The cause of the fault must be signalled accordingly.
After the deactivation, independent reactivation of the system is not permitted. If the lubrication system is
switched off, a signal must be formed that can be used to switch off the roller screen with a delay.
1.2.6.2 Grease container - Fill level below min

If the fill level in the supply container undercuts the lower limit, the lubrication pump will be switched off at once.
1.2.6.3 Switching on-site operating points

When the lubrication system is not switched off and switching at the on-site operating point takes place from
on-site to remote or vice versa, the lubrication pump must be switched off.
Reactivation is only permitted after a starting command.
1.2.6.4 Electrical faults, tripping of protection elements

Fault from failure of electrical operating equipment or tripping of protection elements (motor protection switch,
safety monitoring, etc.) will lead to immediate deactivation of the lubrication pump.
Reactivation is only permitted after removal of the causes and confirmation.
1.2.6.5 Voltage failure at the infeed

When the voltage returns after a voltage failure at the infeed, the lubrication pump will not start up again on its
own. Reactivation is only permitted after confirmation.

OPERATING
INSTRUCTIONS
SONG HAU 1
THERMAL POWER PLANT
BOOK 13
P0EBD72
Manual 5
General view drawing
FAM
39112 Magdeburg
Phone: +49 391 6380 10700

Hotline-Fax: +49 391 6380 10799

CONTENTS
1 GENERAL VIEW DRAWING .................................................................................................................... 3
1.1 Drawing directory .................................................................................................................................... 3

1 GENERAL VIEW DRAWING
1.1 Drawing directory
Description Drawing-No. Revision Page
ROLLER GRIZZLY.RR.14.39.P-E 0000019063 0 1

OPERATING
INSTRUCTIONS
SONG HAU 1
THERMAL POWER PLANT
BOOK 13
P0EBD72
Manual 6
Maintenance
FAM
39112 Magdeburg
Phone: +49 391 6380 10700

Hotline-Fax: +49 391 6380 10799

CONTENTS
1 MAINTENANCE ........................................................................................................................................ 3
1.1 Basic safety notes ............................................................................................................................... 3
1.2 Ropes and rope fixtures ..................................................................................................................... 6
1.3 Torques for tightening of bolts .......................................................................................................... 6
1.4 Basic safety notes for repair .............................................................................................................. 8

1.4.1 Replacing polygon discs .................................................................................................................11
1.4.2 Replacing wear plates of the scrapers ............................................................................................11
1.4.3 Replacing of the geared motor........................................................................................................11
Annex 1: Lubrication
Annex 2: Control and Maintenance
Annex 3: Spare and wear parts

1 MAINTENANCE
1.1 Basic safety notes
Please note the information in the manual 1 “Use of machine according to intended
purpose” and manual 2 “Basic safety requirements”.
The supplied documentation of attachment parts (e.g. gearbox, motors etc.)
supplements the following statements and should be understood as obligatory.
IMPORTANT
Make sure to adhere to the setting, maintenance and inspection activities and intervals plus data on
replacement of parts and components contained in the operation manual. All those activities should be
accomplished only by qualified personnel (skilled work force).
Qualified personnel (skilled work force) are persons who have been authorized by the responsible for
maintaining the safety of the components/ plant, to perform such activities and to detect and avoid possible
dangers as a result of their training, experience, instruction or familiarity with the relevant Standards,
regulations, accident prevention measures and operating conditions.
Data on lubrication points, lubricants, filling volume and frequency of lubrication

may be found in the lubrication chart in Appendix 1.
NOTE Data on maintenance actions and frequencies may be found in the maintenance
plan in Appendix 2.
During all work with or on the equipment the rules on the avoidance of wastes and
the correct disposal or recycling of wastes shall be observed.
Substances like
Hydraulic fluids
Oils and greases
Coolants
Solvent-containing cleaning agents
required for installation, repair and maintenance work must not get into the soil or
enter the sewage system.
These fluids must be collected in suitable vessels before they are disposed of
properly.

WARNING! OVERPRESSURE
Prior to repair or maintenance, the equipment items and pressure lines to be opened
must be relieved from pressure.
WARNING Work should be carried out only by skilled workers.
CAUTION, HOT LIQUIDS AND VAPOURS

Be careful when handling hot substances. Risk of skin burns and scalds.
WARNING
POTENTIAL HAZARDS CAUSED BY ELECTRIC POWER

POTENTIAL RISK OF AUTOMATIC OR UNINTENDED START OF MACHINE
Only qualified electricians should carry out work on the power supply system.
DANGER Make sure that machine and plant equipment subject to compulsory inspections,
repair and maintenance work are isolated from power before such work is carried
out. To be sure, check the isolated equipment items if they are still under voltage.
Earth and short-circuit them and isolate other equipment in the vicinity from power
supply.
DANGER
Prior to all repair and erection work, the equipment and its components should be
isolated from power supply so that drives cannot be started by mistake while repair
work is carried out.
All cable connections of components to be replaced must be disconnected. After
reassembly, cable connections must be made again!
DANGER FOR THE DRIFT STABILITY

Suitable measures must be taken to ensure at any time that all repair and
maintenance work can be safely accomplished without impairing the stability of the
overall machine. If brakes are removed, additional fixtures (e.g. clamping devices)
DANGER must be used that have the same effect.
WARNING, DANGER OF SQUEEZING INJURIES

Utmost care is required when suspending or threading-in auxiliary tools for lifting of
loads (chains, lifting belts, ropes). Note the risk of squeezing-off limbs.
WARNING

CAUTION, SUSPENDED LOADS!
Nominate only well-experienced persons for suspension of loads and for giving
instructions to the crane operator. The person giving instructions to the crane
operator must be positioned so that it is in sight contact with the crane operator or
may communicate with him through a radiotelephone set.
When replacement of single parts or larger components is required, the parts must
be safely fitted to the hoisting gear and handled so that all risks are excluded. Only
suitable hoisting gears and load carrying attachments in technically sound condition
and with sufficient hoisting capacity shall be used.
DANGER
For handling of plant components only the provided suspension points and marked
eyebolts shall be used.
Persons must not stay or work under suspended loads.
It is prohibited to transport persons together with the load or on the load suspension
devices.
ATTENTION IN CASE OF WORK IN ELEVATED POSITIONS!

Never use equipment parts for climbing.
When work in overhead positions is required, use only tested and approved
DANGER equipment for protection against falling down.
In case of repair or maintenance work in elevated positions the workforce may fall
down and suffer heavy injuries or even death.
Therefore, use only approved climbing aids and working platforms.
DANGER DUE TO BLOCKED ESCAPE ROUTES

DANGER Keep escape routes free from all obstacles: never put down or store components in
escape routes and observe the applicable safety rules.
Damage to the paint must be eliminated according to the paint specification after
having finished maintenance works.
IMPORTANT

1.2 Ropes and rope fixtures
· Ropes must be kept under supervision while they are in operation and while they are not used. This is
applicable not only to the ropes but also to the rope fixtures, rope connections and rope guides.
· In case of wire rope fixtures, the specified number of rope clips must not be reduced.
Nominal size (rope) Required torque for Tensile force required Required number of
tightening in the rope clip thread wire rope clips
[Nm] [N]
5 2,20 2300 5
6,5 3,85 3200 5
8 6,60 4700 6
10 9,90 7100 6
13 36,30 15400 6
16 53,90 21000 6
19 74,47 28900 6
22 117,70 40800 7
26 161,70 47600 7
30 233,20 62300 8
34 325,60 79200 8
40 399,30 89800 8
1.3 Torques for tightening of bolts

Bolt size Bolt property class 10.9 Bolt property class 8.8
Tightening moment to be applied Tightening moment to be applied
MA [Nm] MA [Nm]
M8 20
M10 40
M12 100 70
M16 250 170
M20 450 300
M22 650 450
M24 800 600
M27 1250 900
M30 1650 1200
M36 2800 2100
MA = Required torque for tightening with torque wrench

All torques for tightening are applicable to bolts with metric thread according DIN 13, nut with MoS 2
treated

Bolt size Stainless steel / Tightening moment to be applied
3)
A2-70; A4-70 MoS2 4) µges~0,10
Nm
M8 15
M 10 30
M 12 51
M 16 125
M 20 245
M 24 421
M 27 620
M 30 844
3) Metric thread acc. to DIN 13

4) nut with MoS2 or equivalent lubricant treated

1.4 Basic safety notes for repair
DANGER FOR THE STABILITY!

All repair work must be realized only at wind speeds up to maximum 5 m/s. During
the repairs, the wind speed must not exceed 10 m/s!
DANGER
DANGER DUE TO UNINTENDED RE-START!

Prior to repair, the conveying routes affected and upstream conveyors of
machines must be made empty. Suitable actions are required to ensure that such
equipment cannot be started by mistake.
DANGER Starting of the electrical or hydraulic drives of the assembly groups that are being
worked on, must be excluded.

In case repair work technology makes it necessary to erect piles between ground
level and machine, the load carrying capacity of soil must be calculated before the
piles are erected (the permitted ground pressure need to be complied).
The piles must be erected on a ground level sufficiently able to take the maximum
load.
The size of the piles must be selected according to the permitted ground pressure
DANGER and the imposed load.
The piles must be secured against overturning.
In this process need to be ensured that the piles are positioned vertically and
centrically under the support points.

In case of using mobile lifting devices, the load carrying capacity of soil must be
calculated before (the permitted ground pressure need to be complied).
DANGER
DANGER DUE TO OBJECTS FALLING DOWN!

For all repair works it is forbidden to stay under the repair area! This area has to
be closed off across a large area.
DANGER Falling objects may cause severe bodily injury or loss of life.

WARNING! RISK OF INJURIES CAUSED BY SPRING TENSION/CHAIN TENSION!
When installing or removing components under mechanical stresses, persons
might suffer injuries and equipment parts may become damaged or even
destroyed.
DANGER Before performing work on such components suitable action should be taken to
exclude such potential risks.
RISK OF SQUEEZING-OFF LIMBS

The conveying belt is always under tension, even while a belt conveyor is switched
off. In the case of works where the conveyor belt exerts a direct or indirect effect,
pretension must be neutralized by relieving the conveyor belt before starting the
work. This might result in a short movement of the conveyor belt and the take-up
DANGER device.
RISK OF SQUEEZING-OFF LIMBS

For all belt-drive repair works suitable measures (e.g. belt clamps) have to be used
to secure the conveyor belt against self-actuated movement.
DANGER
DANGER DUE TO MISSING OR NOT CORECTLY INSTALLED SAFETY

APPLIANCES
After repair all safety devices must be checked for mounting and function and a
start-up test without transported material must be realized!
DANGER

Repair works at
· Spherical bearings of the bridge segments
· Ball-bearing slewing ring
· Hoisting -and levelling cylinder
· Main carrying construction
DANGER As well as the disassebly of machine parts of the travel drive notably affect the
stability of the entire plant. That is why these works may only be carried out after
having consulted the company FAM and only by qualified maintenance personnel.
Non-observance of this instruction may lead to damages at the plant, severe or
even fatal injuries.

In case of repair where fitting bolts or fitting bolt connections are to be removed,
the parts concerned shall be properly marked so that they can be re-installed in the
correct positions!
If the fitting bolt connections have been removed, in the course of reassembly they
should be replaced by new bolts with a thicker fitting shaft. Conjointly the holes
IMPORTANT should be bored to a larger size.
If components (such as drive units or belt drums) are not immediately reinstalled
after disassembly, the previously disassembled railings, grating grids or protective
grilles must be reassembled after disassembly until the component is rebuilt.
Failure to observe this instruction can result in serious injury or death.
GEFAHR
For the transport of the plant components, only the intended anchor points or stop
lugs are to be used (see information in the supplier documentation).
GEFAHR
After repair, all safety devices must be checked for mounting and function!
GEFAHR

1.4.1 Replacing of the roller
Separate the coupling halves of the drives
Disassemble cover and material guide with lifting device and lay down
Disassemble the sealing
Loosen the upper part of the bearing blocks on both sides
Attach roller (approx. 275 kg/piece) to lifting device, lift and further transport to the repair workshop
Dismount the bearings
Mount the bearings to the new roller
Assembly is carried out in reverse order
Adjust the gap between wear plates and lower edge of the polygon discs
1.4.2 Replacing wear plates of the scrapers
Cover the chute under the roller grizzly by means of timber blocks, so that the wear
plates can be reached safely.
Danger
Replace the wear plates from the inside
Adjust the gap between wear plates and lower edge of the polygon discs
1.4.3 Replacing of the geared motor
See Documentation of the drive unit roller screen in manual 7.

NOTE
Isolate the roller screen from power supply and secure it against unauthorized, erroneous and unintended
start-up.
Dismount the supply lines.
Separate the roll from the geared motor by loosening the screw fittings and coupling.
Sling the geared motor to the crane and secure it against tilting.
Remove the fastening bolt connections of the geared motor.
Lift the geared motor.
Slew the crane and lower the geared motor on a suitable truck and secure it against moving.
Further transport to the repair shop and there dismounting the components, if necessary.
Re-assembly of the disassembled components is performed in the reverse order of disassembly.

OPERATING
INSTRUCTIONS
SONG HAU 1
THERMAL POWER PLANT
BOOK 13
P0EBD72
Manual 6
Maintenance
Annex 1
Lubrication
SH1-FAM-P0-100-GE-M02-HDD-0001 Book13_M6.1 1/2

Project: Song Hau 1 Lubrication Plan
Legend Lubrication period: HH..........operation

Betriebsstunden
hours
TT.....
.....days
Tagen
WW.... ....weeks
Wochen
Order No.: 124442 MM.....month
..... Monaten
J J.. .....
... year
Jahren
Plant unit: Roller grizzly RR1439
Supplier: FAM Code: P0EBD72
No. Lubrication point Manufacturer Lubricant Type of Lubricant Amount of Lubrication Cycle Date of Company/ Signature
Points
name Lubricant Control First lubricant Relubrication Renewal of filling or Name
Manufacturer
No. of lubric.
Lubricant supply renewal Quantity Lubricant control
1 Drive 14 R87 Oil CLP220 2,3 every 3000 H ** at the latest
Spur gear Fill in Mineral oil Litre at least every 6 months every 3 years
2 Drive 28 R87 Grease Renolit CX-TOM15 * ** at the latest
Bearing Spur gear Fill in Fuchs every 3 years
* -FFor ffast-running
t i b bearings
i (Motor-
(M t and d gear unitit iinputt end):
d) Fill the
th cavities
iti b between
t th
the rolling
lli elements
l t one-third
thi d ffullll with
ith grease.
- For slow-running bearings (in the gear unit and gear unit output end): Fill the cavities between the rolling elements two-thirds full with grease.
** - Depending on the operating conditions as oil temperature (see Assembly and Operating Instructions Gear Unit chapter 6.3)
3 Central lubrication 1 Grease GADUS.S.2.V.100.2 10 Liter Electrical fill level control
unit Fill in Shell Tank 8 Liter Refill when signal occurs
4 Bearing 28 Grease GADUS.S.2.V.100.2 8 signals for 1 complete lubrication cycle; Adjust the interval between lubrication cycles between 60
Central lubrication
Rollers unit
Shell minutes and 0 minutes during commissioning (normally 40 minutes)
Note the special information on lubrication in the add-on parts documentation!
Control
Comment: Date: .............................................. Name: ........................ Signature: .................................
Status: 28.02.2017
File: 124442_M6_AN1_E.xls Sheet: 1 of 1
OPERATING
INSTRUCTIONS
SONG HAU 1
THERMAL POWER PLANT
BOOK 13
P0EBD72
Manual 6
Maintenance
Annex 2
Control and Maintenance

Maintenance Plan
Legend of maintenance intervals: a - Daily; b - Weekly; c - Monthly; d - Every 3 months; e - Every six months; f - Yearly; S - Special intervals
Pos. device/assembly group

measurements/comments a b c d e f S
No. description of scope of services
1. General maintenance
<> General visual inspection of all plant components Daily X
<> Visual inspection for bulk material accumulation and dirt Weekly (remove bulk material accumulation and dirt if necessary) X
<> Cleaning the surfaces of equipment items and electric components Monthly X
1.1. General controls
<> Overall check up Check for sound condition daily before start of work shift X
<> Check for corrosion every 6 months; X
Defects in the paint coating must be repaired under consideration of coating specification
<> Check for: Every 6 months; X
-- Deformation
-- Loose joints of bolted, screwed and other connections
-- Visual damage to welded connections
<> Check all fasteners like bolts, nuts, pins etc. for firm seating X
<> Check for cleanliness clean if necessary X
<> Thorough cleaning Use scraper, brush and compressed air for cleaning in repair shift X
<> Check the internal space for material baking Baking found in the internal space must be removed manually X
<> Check the wear plates for firm seating weekly X
• visual check
2. Drive
2.1 Gear motor R87 DRN112M4/TF
<> Inspect the motor: every 10000 hours of operation; see "Operating
Operating instructions SEW: Chapter 7"
7 X
- Check rolling bearing and change if necessary
- Replace the oil seal
- Clean the cooling air passages
<> Touch up or renew the surfaces/anticorrosion coating depending on external factors
Bearing of the bevel-helical gear unit
<> Occasionally check the condition of the grease filling
<> Renewal of the ball-bearing grease approx. 2 years, together with due oil change of the gear unit, see operating instructions SEW X
when re-greasing, clean the bearings with suitable solvents, only 2/3 of the free room of the
bearing filled with grease
Date: 27.02.2017 Page 1 of 3

Maintenance Plan

Gear unit R87 see "Operating instructions SEW"
<> Check the oil and the oil level every 3000 operating hours, at least every 6 months; see chapter 6 X
<> Check running noise for possible bearing damage every 3000 operating hours, at least every 6 months X
<> Visually check the seals for leakage every 3000 operating hours, at least every 6 months X
<> For gear units with a torque arm: Check the rubber buffer and change it, if necessary every 3000 operating hours, at least every 6 months X
<> Change synthetic oil Depending on the operating conditions (see chapter 6), at least every 3 years X
see also chapter 6
<> Replace roller bearing grease Depending on the operating conditions (see chapter 6), at least every 3 years X
<> Replace oil seal (do not install it in the same track) Depending on the operating conditions (see chapter 6), at least every 3 years X
see also chapter 6
<> Touch up or renew the surface/anticorrosion coating depending on external factors, see chapter 6 X
Bearing of the motor
<> Change of ball bearing together with the due grease change of the gear unit bearing, see operating instructions SEW X
3. Progressive grease central lubrication system

Given that the plant is only operated with clean lubricant, the corresponding plant components do not need special maintenance. All metallic and movable parts within the lubrication area are
located in the middle of the lubricant to be conveyed and therefore lubricate themselves. Furthermore we refer to the corresponding technical information on operating and maintenance
regulations. They are an inherent part of the operating instructions and have to be kept in mind.
3.1 Grease p
pump p
<> Check for cleanliness, leak tightness and function if necessary, clean; always keep the container tightly closed, X
check for unusual noises X
3.2 Grease pump - Level switch
<> Check level switch for function Sensor surface has to be clean, do not soil with lubricant when filling ! X
Function control with open lid by means of a suitable test area X
3.3 Pressure relief valve NU-A
<> Check for possibly leaked out lubricant Leaked out lubricant is a sign for overpressure in the system or a faulty valve X
Troubleshooting necessary. Possible reasons might be: Loss of pressure too high in the lines,
distributor or lubrication point blocked. X
3.4 Lubricant distributor
<> Check for cleanliness, leak tightness and function if necessary, clean; check for function of the motion indicator X
Check for lubricant leakage at the consumption point X
3.5 Tube and hose connections, Hydraulic-screw joints and fasteners
<> Check for leak tightness and firm seat replace damaged or porous hose lines X
Date: 27.02.2017 Page 2 of 3

Maintenance Plan

4. Rollers
<> Check polygon discs for wear Visual check; replace worn out elements X
<> Check bearings for warming and smooth running X
<> Check bearings for lubrication see Lubrication plan
5. Housing
<> Check wear plates for wear monthly visual check, replace worn out wear plates X
6. Local electrical appliances
<> Check for dirt X
<> Check electrical connections for safe fixings and damage X
<> Check for correct function X
7. Scrapers (4 pcs.)
<> Check wear plates for correct setting and excessive wear One visual inspection per month. If necessary, correct the scraper gap (5 mm) and X
replace wear plates
<> check the seals for wear Visual inspection, if necessary replace X
Note the special information about maintenance in the technical documentation of the add-on parts and prefer them to those mentioned above.
Date: 27.02.2017 Page 3 of 3

OPERATING
INSTRUCTIONS
SONG HAU 1
THERMAL POWER PLANT
BOOK 13
P0EBD72
Manual 6
Maintenance
Annex 3
Spare and wear parts

Dear Ladies and Gentlemen,
The standard package of services rendered by FAM Förderanlagen Magdeburg for your project
includes an electronic spare parts catalog.
The electronic catalog provides a detailed overview of all mechanical spare, wear and add-on parts as
well as their installation locations in the equipment supplied by FAM:
Spare parts drawing
Project overview
Spare parts list
The catalog is available online. To use the online version, please follow the link:
https://etk.fam.de/template/index.php
or use the access from our FAM website:

The LOGIN page of the electronic spare parts catalog appears:
Select the option ”Forgot your password?“ and send the automatically generated e-mail with your
request to the pre-set address:
[email protected]
You can contact us directly via the above mentioned address.
In this case, the members of our service team will get in touch with you as soon as possible.
We are looking forward to a successful cooperation.
Best regards,
Your Service-Team
FAM Förderanlagen Magdeburg
D-39112 Magdeburg
Postfach 35 40
D-39010 Magdeburg
Tel.: +49-(0)3 91 / 63 80-10700

Fax.: +49-(0)3 91 / 63 80-10799
[email protected]
http://www.fam.de
Projekt: Verschleiss- und Ersatzteilliste
Project:
Song Hau 1 Spare and Wear Parts List
Projekt-Nr.: ROLLENROST P0EBD72

Project-No.:
124442 ROLLER SCREEN P0EBD72
FAM Art.-Nr. eingebaute Anzahl
Zeichng.-Nr. / Detail Pos.-Nr. Menge Einheit Gewicht ET VT AnT
insgesamt
Bezeichnung Description
Total No. of
FAM Ident No. Drawing-No / Detail Pos.-Nr. Qty Unit Weight SP WP AnT
installed Parts
[kg]
0 VN.124442A.40A.380044 ROLLENROST P0EBD72 ROLLER SCREEN P0EBD72 1 ST 1 ST

1 9302448 ROLLENROST.RR.14.39.P-E ROLLER.SCREEN.RR.14.39.P-E_E EVT 09302448 1 1 ST 1 ST 11380,00
2 9302450 ROLLENSATZ SET.OF.ROLLERS EVT 09302450 1 1 ST 1 ST 3820,00
3 9300076 ROLLE ROLL EVT 09300076 1 7 ST 7 ST 275,00 X
4 9300078 WELLE SHAFT EVT 09300078 1 7 ST 7 ST 245,00 X
5 9300085 POLYGONSCHEIBE POLYGON.DISK 4 98 ST 196 ST 0,90 X
4 10005405 BUCHSE BUSH 2 14 ST 28 ST 4,30 X
4 10005400 LAGERDECKEL BEARING.COVER 3 14 ST 28 ST 2,20 X
4 10005404 LABYRINTHRING LABYRINTH.RING 6 21 ST 42 ST 1,10 X
4 10002825 SCHALTFAHNE SWITCH.FLAG 7 7 ST 14 ST 0,20 X
4 20013236 PASSFEDER PARALLEL.KEY 8 28 ST 56 ST 0,12 X
4 52358 PASSFEDER PARALLEL.KEY 9 7 ST 14 ST 0,10 X
4 9306241 NUTMUTTER SLOTTED.NUT 10 7 ST 14 ST 0,56 X
4 20001267 SICHERUNGSBLECH LOCK.PLATE 11 7 ST 14 ST 0,06 X
4 3290 WAELZLAGER ROLLER.BEARING 16 14 ST 28 ST 3,50 X
3 9300077 ROLLE ROLL EVT 09300077 2 7 ST 7 ST 275,00 X
4 9300079 WELLE SHAFT EVT 09300079 1 7 ST 7 ST 245,00 X
5 9300085 POLYGONSCHEIBE POLYGON.DISK 4 98 ST 196 ST WT 0,90 X
4 10005405 BUCHSE BUSH 2 14 ST 28 ST WT 4,30 X
4 10005400 LAGERDECKEL BEARING.COVER 3 14 ST 28 ST WT 2,20 X
4 10005404 LABYRINTHRING LABYRINTH.RING 6 21 ST 42 ST WT 1,10 X
4 10002825 SCHALTFAHNE SWITCH.FLAG 7 7 ST 14 ST WT 0,20 X
4 20013236 PASSFEDER PARALLEL.KEY 8 28 ST 56 ST WT 0,12 X
4 52358 PASSFEDER PARALLEL.KEY 9 7 ST 14 ST WT 0,10 X
4 9306241 NUTMUTTER SLOTTED.NUT 10 7 ST 14 ST WT 0,56 X
4 20001267 SICHERUNGSBLECH LOCK.PLATE 11 7 ST 14 ST WT 0,06 X
4 3290 WAELZLAGER ROLLER.BEARING 16 14 ST 28 ST WT 3,50 X
2 9302449 GEHAEUSE HOUSING EVT 09302449 2 1 ST 1 ST 3130,00
3 9302479 AUSLAUFTEIL OUTLET.PART 2 1 ST 1 ST 370,00 X
3 9131558 QUERSTEG CROSS.BEAM 5 3 ST 5 ST 31,00 X
3 9114532 OBERTEIL UPPER.PART 6 2 ST 2 ST 58,00 X
3 9114534 OBERTEIL UPPER.PART EVT 09114534 9 2 ST 2 ST 60,00 X
4 9110244 KLAPPE FLAP EVT 09110244 6 2 ST 2 ST 9,00 X
5 20021364 ZELLKAUTSCHUK INDIAN.RUBBER.STRIP 9 2,8 M 11,52 M 0,13 X
4 9110245 SCHUTZGITTER GUARD EVT 09110245 7 2 ST 2 ST 2,70 X
5 20021364 ZELLKAUTSCHUK INDIAN.RUBBER.STRIP 3 2,8 M 11,52 M WT 0,13 X
3 9306242 RAHMEN FRAME EVT 09306242 11 1 ST 1 ST 405,00
4 9131558 QUERSTEG CROSS.BEAM 1 2 ST 5 ST WT 31,00 X
3 9103323 DISTANZBLECH SPACER.PLATE 12 8 ST 8 ST 1,60 X
Ersatzteilliste_124442_P0EBD72.xlsm 1/3
insgesamt
Total No. of
installed Parts

3 9110262 DECKEL END.COVER EVT 09110262 20 4 ST 4 ST 9,70 X
4 20021364 ZELLKAUTSCHUK INDIAN.RUBBER.STRIP 3 5,92 M 11,52 M WT 0,13 X
2 9302436 ANTRIEB DRIVE EVT 09302436 3 1 ST 1 ST 1720,00
3 7000133 ANTRIEBSEINHEIT DRIVE.UNIT EVT 07000133 1 14 ST 14 ST 117,00
4 27000037 G-MOTOR GEAR.MOTOR 1 14 ST 14 ST 102,00 X
4 27000038 KUPPLUNG COUPLING 2 14 ST 14 ST 15,00 X
3 9302489 DISTANZRING SPACER.RING 2 14 ST 14 ST 0,17 X
2 9304319 ZUBEHOER.U.MONTAGEMAT ACCESSORIES.A.ASSEMBLY.MATERIAL EVT 09304319 4 1 ST 1 ST 1270,00
3 9267225 ABDICHTUNG SEAL EVT 09267225 1 1 ST 1 ST 355,00
4 9103347 DICHTUNGSRING PACKING.RING EVT 09103347 7 28 ST 28 ST 4,00
5 10078839 FILZRINGSEGMENT SEGMENT OF FELT STRIP 3 112 ST 112 ST 0,02 X
4 12713 ZELLKAUTSCHUK INDIAN.RUBBER.STRIP 14 5,5 M 5,5 M 0,64 X
3 9302432 MATERIALFUEHRUNG MATERIAL.GUIDANCE EVT 09302432 3 1 ST 1 ST 465,00
4 9131663 SEITENFUEHRUNG SIDE.GUIDE EVT 09131663 1 1 ST 1 ST 42,00 X
4 9302433 SCHLEISZPLATTE WEAR.PLATE 7 1 ST 1 ST 15,00 X
4 9302435 SCHLEISZPLATTE WEAR PLATE
WEAR.PLATE 9 1 ST 1 ST 18 50
18,50 X
4 9304314 KONSOLE BRACKET 10 3 ST 3 ST 11,50 X
4 20080660 SCHRAUBE BOLT 11 12 ST 12 ST 0,06 X
4 20055527 SCHEIBE WASHER 12 12 ST 12 ST 0,03 X
4 20096918 MUTTER NUT 13 12 ST 168 ST 0,02 X
4 20007719 MUTTER NUT 15 18 ST 18 ST 0,02 X
3 9302437 ABDECKUNG COVER EVT 09302437 4 1 ST 1 ST 83,00
4 9302438 SCHUTZHAUBE PROTECTION.HOOD 1 1 ST 1 ST 12,00 X
4 9103354 STUETZE SUPPORT 9 4 ST 4 ST 3,90 X
4 9103359 STUETZE SUPPORT 10 1 ST 1 ST 3,40 X
2 9304318 LAGERUNG BEARING EVT 09304318 5 1 ST 1 ST 890,00
3 9304317 LAGERBOCK BEARING.BLOCK 1 28 ST 28 ST 31,00 X
2 9302427 REINIGER CLEANER EVT 09302427 6 1 ST 1 ST 495,00
3 9302428 REINIGER CLEANER EVT 09302428 1 13 ST 13 ST 26,00 X
4 9302429 TRAGROHR SUSPENSION.TUBE 1 13 ST 13 ST 22,00 X
4 20111881 STOPFEN PLUG 3 26 ST 26 ST 0,01 X
4 20096918 MUTTER NUT 5 156 ST 168 ST WT 0,02 X
insgesamt
Total No. of
installed Parts
3 9304315 HALTER SUPPORT 2 26 ST 26 ST 4,20 X

2 9306244 SCHMIERANLAGE LUBRICATION.SYSTEM EVT 09306244 7 1 ST 1 ST 53,00
3 27000045 PUMPE PUMP 6 1 ST 1 ST 15,00 X
3 20059387 PROGRESSIVER.SCHMIERSTOFFVERTEILER PROGRESSIVE.GREASE.DISTRIBUTOR 7 1 ST 1 ST 1,03 X
3 20059389 PROGRESSIVER.SCHMIERSTOFFVERTEILER PROGRESSIVE.GREASE.DISTRIBUTOR 8 2 ST 2 ST 1,60 X
3 10197142 VERROHRUNGSMATERIAL PIPPING.MATERIAL 9 1 ST 1 ST 30,00 X
Legende: Key:
ET - Ersatzteile SP - Spare Parts
VT - Verschleiszteile WP - Wear Parts
AnT - Anbauteile AnT - Attachements
Ersatz- und Verschleiszteile aus den Anbauteilen sind Spare and wear parts of the attachment can be
der Dokumentation zu entnehmen. Dichtringe sind auch found in the documentation. Seals are also generally
hier grundsätzlich Verschleiszteile. wear parts.
KG - Kilogramm KG - kilogram
ST - Stück ST - piece
M - Meter M - metre
Kategorie A - strategische Teile Category A - Strategic Parts

Kategorie B - für 2 Jahre Betriebszeit Category B - Part for 2 Years operation
Kategorie C - für Inbetriebnahme Category C - Commissioning Part
WT - Wiederholteil WT - Repeating Part

Book13 - Roller Screen RR1439 - P0EBD72 (TR 1-59)

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OPERATING

Phone: +49 391 6380 10700

SH1-FAM-P0-100-GE-M02-HDD-0001 Book13_M1 1/6

1.1 Preface ...................................................................................................................................................... 3

1.2 Basic notes ............................................................................................................................................... 3

1.3 Responsibility of the operator ................................................................................................................ 4

1.4 Responsibility of the personnel ............................................................................................................. 5

1.5 Warranty and liability .............................................................................................................................. 5

1.6 Copyright .................................................................................................................................................. 5

1.7 Constructional changes .......................................................................................................................... 6

SH1-FAM-P0-100-GE-M02-HDD-0001 Book13_M1 2/6

1.2 Basic notes

SH1-FAM-P0-100-GE-M02-HDD-0001 Book13_M1 3/6

We recommend you check that your personnel are working in a safety-conscious

SH1-FAM-P0-100-GE-M02-HDD-0001 Book13_M1 4/6

1.5 Warranty and liability

SH1-FAM-P0-100-GE-M02-HDD-0001 Book13_M1 5/6

SH1-FAM-P0-100-GE-M02-HDD-0001 Book13_M1 6/6

Phone: +49 391 6380 10700

SH1-FAM-P0-100-GE-M02-HDD-0001 Book13_M2 1/14

1.1 Explanation of symbols and notes ........................................................................................................ 3

1.2 Safety and protective appliances ........................................................................................................... 9

1.3 Notes describing specific kinds of potential hazard ......................................................................... 11

1.4 Specific areas where hazards might exist .......................................................................................... 12

1.5 Cleaning the machine/plant and waste disposal in general .............................................................. 13

1.6 Noise level of machines ........................................................................................................................ 14

1.7 Environmental protection ..................................................................................................................... 14

SH1-FAM-P0-100-GE-M02-HDD-0001 Book13_M2 2/14

SH1-FAM-P0-100-GE-M02-HDD-0001 Book13_M2 3/14

This symbol means „Warning of hazardous electrical voltage“.

This symbol means: „Warning of automatic start-up“.

This symbol means: „Warning of explosive substances“.

SH1-FAM-P0-100-GE-M02-HDD-0001 Book13_M2 4/14

SH1-FAM-P0-100-GE-M02-HDD-0001 Book13_M2 5/14

This symbol means: „Warning, danger of falling“.

This symbol means: „Warning, Hot liquids and vapours“

This symbol means: „Caution, danger of stumbling“.

SH1-FAM-P0-100-GE-M02-HDD-0001 Book13_M2 6/14

This symbol means: „Use protective clothing“.

This symbol means: „Use ear protectors“.

SH1-FAM-P0-100-GE-M02-HDD-0001 Book13_M2 7/14

This symbol means: „Danger of environmental pollution“.

SH1-FAM-P0-100-GE-M02-HDD-0001 Book13_M2 8/14

SH1-FAM-P0-100-GE-M02-HDD-0001 Book13_M2 9/14

1.2.2 EMERGENCY STOP pushbuttons

In case of danger, operate the EMERGENCY STOP pushbutton or the pull-cable

Sudden movements of equipment components may cause severe injuries.

SH1-FAM-P0-100-GE-M02-HDD-0001 Book13_M2 10/14

POTENTIAL HAZARDS CAUSED BY ELECTRIC POWER!

1.3.2 Potential hazards caused by hydraulic components

ALL WORK SHALL BE CARRIED OUT BY WELL QUALIFIED STAFF

CAUTION, HOT LIQUIDS AND VAPOURS

SH1-FAM-P0-100-GE-M02-HDD-0001 Book13_M2 11/14

CAUTION, RISK OF EXPLOSION AND FIRE!

1.4 Specific areas where hazards might exist

CAUTION, SUSPENDED LOADS!

CAUTION, RISK OF DOWNFALL!

CAUTION, RISK OF STUMBLING!

CAUTION, RISK OF SQUEEZING!