SOMMER Maltman 220 Manuel utilisateur

Version: 11.10.2017 Page 1

Operation manual

Maltman 220, Maltman 220 S, Maltman 400, Maltman 400 S,

Maltman 500, Maltman 500 S

Handbuchart manual

Maschine Malt-

man

MaschinenTyp ma-

chine

GENERAL DESCRIPTION

Page 2

This operation manual is a document or instrument in the sense of the Law on Unfair Competition.

The copyright remains with

Egon Sommer Maschinenbau GmbH & Co. KG

Pagenstecherstraße 146

D-49090 Osnabrück

Telefon: +49 (0)541 125085

Telefax: +49 (0)541 129557

E-Mail: service@sommer-maschinenbau.de

Internet: www.sommer-maschinenbau.de

This operation manual is intended for the user/owner of the machine and its staff. It contains texts, pictures and

drawings that, without the express permission of Egon Sommer Maschinenbau GmbH & Co. KG, may not be



reproduced,



disseminated or



disclosed in any other.

Permission is granted for internal use to the user/owner of the machine.

The manufacturer reserves the right to make technical changes and improvements at any time without prior notice.

GENERAL DESCRIPTION

Page 3

Table of contents



General description....................................................................................................................... 4



Information about this Operation manual ............................................................................... 4



Layout of the Operation manual............................................................................................. 4



Use of the Operation manual................................................................................................. 4



Obligations of the machine owner.......................................................................................... 4



Personnel requirements ........................................................................................................ 5



Intended use ......................................................................................................................... 5



Unintended use ..................................................................................................................... 5



Safety instructions ........................................................................................................................ 6



Safety symbols used in this Operation manual....................................................................... 6



Warning labels on the Machine.............................................................................................. 6



Safety guidelines................................................................................................................... 7



Technical data ............................................................................................................................. 10



Setup and function...................................................................................................................... 11



Safety devices ............................................................................................................................. 12



Shutdown in case of power outage ...................................................................................... 12



Protective grid ..................................................................................................................... 12



Protective cover .................................................................................................................. 12



Transport/Setting up/Assembly of the Machine ........................................................................ 13



Installation and assembly .................................................................................................... 13

6.1.1 Attaching the Machine .......................................................................................... 13



Initial start-up .............................................................................................................................. 14



Connecting the power supply............................................................................................... 14

7.1.1 Check for the correct direction of rotation.............................................................. 14



Operation..................................................................................................................................... 14



Basic checks before and after operations ............................................................................ 14



Operating elements ............................................................................................................. 14



Operating procedure/Crushing cereals ................................................................................ 15

8.3.1 Adjust the feed regulator....................................................................................... 15

8.3.2 Adjusting the crushing gap.................................................................................... 16

8.3.3 Reduce the crushing gap ...................................................................................... 16

8.3.4 Ejecting foreign bodies ......................................................................................... 16



Maintenance and care................................................................................................................. 17



Maintenance schedule......................................................................................................... 17



Special Maintenance Work .................................................................................................. 18

9.2.1 Retightening the V-belt ......................................................................................... 18

9.2.2 Replace the V-belt ................................................................................................ 18



Malfunction.................................................................................................................................. 19



List of malfunctions.............................................................................................................. 19



EC Declaration of Conformity..................................................................................................... 20

GENERAL DESCRIPTION

Page 4



General description

This chapter contains notes on this manual, along with general safety instructions for handling the machine of the

Maltman-series.

The Maltman is referred to as the machine in the following.



Information about this manual

This manual is an integral part of the user documentation for the machine. Observe all instructions, data, and direc-

tives contained in the manual. The manual will help you to operate the manual safely, and with a high level of avail-

ability.

We reserve the right to make changes designed to improve the machine described in the manual at any time with-

out notice.



Layout of the manual

Safety-relevant instructions are identified by the appropriate symbols.

Steps that must be performed in the specified order are enumerated and the results of the steps are shown in ital-

ics.

Example:

1. Step 1 to be performed

Result of step 1

2. Step 2 to be performed

2.1 Sub-step of step 2 to be performed



Use of the manual

The manual is to be supplemented by existing national directives concerning accident prevention and environmen-

tal protection.

Ensure that the manual is always available at the usage site of the machine and in a legible condition.

In addition to the manual and the binding regulations for accident prevention applicable in the country and site of

implementation, the recognised industry-specific rules for safety and professional work must be complied with.



Obligations of the machine owner

The machine user/owner is obliged to only permit persons to work on the machine , who



Observe the basic directives concerning health and safety at work and accident prevention,



Are regularly instructed in difficulties, hazards, and other particular rules of conduct.

The owner/operator undertakes to:



observe and communicate to staff the current mandatory regulations on accident prevention, environmental

protection and handling of dangerous goods in addition to the instructions in this manual, as required by

law.



provide personal protection equipment.



Establish the authority of the machine operator to enable the machine operator to reject third party instruc-

tions that contradict safety considerations.



assure safety-aware work of personnel at regular intervals.



observe legal requirements and rules at the site of the machine.

GENERAL DESCRIPTION

Page 5



Personnel requirements

The machine may only be operated by persons of a minimum age of 16 years.

Before commencing work, all persons tasked with working on the machine undertake to:



observe the basic directives concerning health and safety at work and accident prevention,



Read the safety and warning instructions in this manual and to confirm with their signature that they have

understood them,



Use personal/workplace-specific protective clothing and auxiliary materials that serve occupational safety

while working, where these are required from a safety/technical point of view.



comply with specifications of competence.



Intended use

The machine is used exclusively to process various grain types (such as oats, barley, wheat, maize, spelt, etc.) so

that their form is beneficial for animal feed.

The machine must be operated exclusively within the performance limits stated in chapter 3 "Technical data".

Uses other and beyond this shall be deemed improper and unintended. Egon Sommer Maschinenbau GmbH & Co.

KG will not be held liable for any damage caused by unintended use.

Intended use also includes:



Observing all information and directives in the manual and all accompanying documents.



Observing the mandatory service and maintenance intervals, or the service and maintenance intervals

specified in the manual and applicable documentation.



Unintended use

Unintended use particularly includes:



Using the machine for purposes other than crushing cereals.



Crushing of materials with a high moisture content/that are very sticky will cause them stick to the rollers of

the crusher (exception:) Use of scrapers).



Operating the machine with bridged safety devices.



Operating the machine with incomplete protection.



Operation of the machine by more than one person.



Operating, maintaining and repairing the machine by non-authorised and non-instructed persons.



Operating the machine in an area with a risk of explosion.

SAFETY INSTRUCTIONS

Page 6



!"#$% &' ($ )* +$&,'(

-./

Safety symbols used in this Fehler! Verweisquelle konnte nicht gefunden werden.

DANGER

"DANGER" identifies an immediate danger which can cause severe or even fatal injury.

WARNING

"WARNING" identifies a potentially dangerous situation which can cause severe or even fatal injury.

CAUTION

"CAUTION" identifies a potentially dangerous situation which could to minor injury.

NOTE

"NOTICE" identifies a potentially dangerous situation that can harm property and the environmental.

This signal word is also used for application instructions and other useful information.

-.-

Warning labels on the machine

Fig. 2-1: Warning labels on the machine

Pos. Label Description

Warning of hazardous electrical voltage.

SAFETY INSTRUCTIONS

Page 7

Risk of drawing in, crushing.



Safety guidelines

DANGER

Risk to persons and the machine!

Only qualified and authorised persons are permitted to operate the machine.

Maintain all safety and hazard instructions at and on the machine in a complete and legible condi-

tion!

Always exercise care and attention in the entire work area of the machine.

Exercise great care when carrying out setup and troubleshooting work requiring the disabling of

safety equipment and/or covers.

Dismantled safety equipment must be refitted after completing the work.

Avoid any unsafe methods of working.

Keep the operating manual available at the machine site at all times.

The machine's operator must have read and understood the Operating Instructions.

Stop the machine immediately and report the fault to the responsible department/person when

safety-relevant modifications are made to the machine line or the operating behaviour of the ma-

chine changes!

Stop the machine immediately and report the fault to the appropriate office/person if safety-relevant

modifications have been made or the operating behaviour of the machine changes!

The applicable worker's compensation association (BG) rules for Occupational Safety and Health.

Do not remove or modify safety devices and warning signs from the machine.

Do not convert machine components without our approval.

Access to the workplace on the machine is not permitted for unauthorised persons.

Always exercise care and attention in the entire work area of the machine.

RISKS

Risk of electric shock!



Leave the danger area immediately if electricity leaks to defective components and wiring.



Only have electrical systems installed on machine components by an expert and accord-

ing to the wiring diagram.



To protect the machine the power supply must be protected with a residual current circuit

breaker provided by the customer.

RISKS

Danger of injury due to unexpected actuation!



Switch off the machine before setup work, maintenance, repairs and troubleshooting, and

protect against unexpected restarting.



Disconnect the mains plug of the machine.

DANGER

SAFETY INSTRUCTIONS

Page 8

Risk of explosion!

The machine is not explosion-protected as a factory standard. Accumulations of dust can cause an ex-

plosive atmosphere.

Do not use the machine in areas with a potentially explosive atmosphere.

Ensure sufficient ventilation of the room, as crushing causes dust accumulations.

Ensure good ventilation of the machine to avoid an explosive atmosphere building up.

Regularly clean the machine (especially the drive motor) to avoid a layer of dust accumulating.

DANGER

Risk of fire due to V-belt slipping!

Slipping belts can overheat and cause fires

Make sure the V-belts are tensioned correctly.

Comply with maintenance intervals. First check of V-belt tension after 10-20 hours of operation,

then extend the interval gradually to 3-6 months.

WARNING

Risk of injury due to trapping or pulling in!

Do not wear loose-fitting clothing.

Do not wear ties, necklaces, shawls, scarves or similar.

Tie back long hair (e.g., use a hair net).

WARNING

Risk of crushing, drawing in!

In particular, on the pinch rollers and drive parts (belts and gears, etc.).

Do not reach into rotating/moving machine elements or devices.

Do not reach into the outlet while the machine is running.

WARNING

Parts being ejected!

There may be foreign bodies in the milled material (e.g. ball bearings). During crushing, they may be

propelled upward and out of the hopper with unexpected force by the pinch rollers, thus causing serious

injury.

Do not bend over the feed hopper on the machine during operation.

Remove any foreign bodies that accumulate from the machine (e.g. foreign body ejector).

WARNING

Risk of injury though noise!

Use the mandatory hearing protection.

SAFETY INSTRUCTIONS

Page 9

WARNING

Risk of injury due to dust!

Ensure good supply and exhaust ventilation of the workplace.

Wear the prescribed dust mask/air filter mask if required.

WARNING

Risks of damage to the machine!

Attach the machine at operation height.

Do not firmly attach hopper enlargements (e.g., avoid welding on).

In case of feeding from a silo: Allow the silo outlet to protrude by 1-2 cm into the hopper of the grain

crusher. It must be possible to pull the grain crusher out from below the silo.

When using feed wagons/catchment containers, maintain a short distance to the machine outlet;

otherwise the milled material might drop out next to the catchment container.

CAUTION

Risk of injury during filling

Filling of materials for rolling goods from sacks into the grain crusher may cause back injuries due to

incorrect lifting techniques due to lifting heavy loads.

Pay attention to correct lifting techniques when lifting heavy loads.

NOTE

Pollution!

Dispose of replaced parts, consumables and auxiliary materials in a safe and environmentally

friendly manner.

NOTE

Possible damage due to rain and moisture!

Do not set up the machine outdoors without rain and moisture protection. There is a risk of very se-

rious damage to the electrical components and bearings.

NOTE

Extended periods of operation in the wrong direction of rotation!

Extended periods of machine operation in the wrong direction of rotation, especially under load (milling

materials on the rollers) can cause damage to the machine.

NOTE

Use only original spare parts.

Only use materials and original spare parts recommended by the manufacturer.

TECHNICAL DATA

Page 10

Technical data

Machine Malt mill Malt mill Malt mill

Type Maltman 220 & 220 S Maltman 400 & 400 S Maltman 550 & 550 S

Grain throughput [kg/h]

(depending on the degree of

crushing and type and humidity

of the

material to be crushed)

approx. 300 – 400

approx. 600 – 800

approx. 900 – 1000

Motor output [kW] 2,2 4,0 5,5

Electrical connection 400 V, 3-phase 400 V, 3-phase 400 V, 3-phase

Weight [kg] 112 144 170

Dimensions [cm] (W x H x D) 60 x 58,5 x 41

65 x 58,5 x 53

70 x 58,5 x 56

Degree of protection IP 54 IP 54 IP 54

Emission sound pressure level

at idle speed [dB(A)] 70.2 71,9 72,3

Permissible materials for pro-

cessing

Grain (such as malt oats,

barley, etc.)

See before See before

Crushing gap [mm] 0 – 2.6 0 – 3,4 0 – 3,4

23445678597 :;<=>?

How loud is the machine when crushing

material? Is information on typical milling material available?

In case of a sound pressure level above 80 dB(A), the sound power

level LW must also be stated.

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