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SAFETY
WHENEVER MAINTENANCE, CLEANING OR ANY OTHER WORK IS PERFORMED
ON THE PULVERIZER, AN OSHA APPROVED WORK PLATFORM SHOULD BE INSTALLED
AROUND THE EQUIPMENT TO SERVICE ALL AREAS THAT CAN NOT BE SERVICED
FROM THE GROUND. IN THE ABSENCE OF A PERMANENT PLATFORM AN OSHA
APPROVED WORK PLATFORM PROPERLY ATTACHED TO A FORK TRUCK SHOULD BE
USED. FAILURE TO USE PROPER WORK PLATFORMS WILL RESULT IN FALLING
HAZARDS WHICH MAY RESULT IN SERIOUS BODILY INJURY OR EVEN DEATH.

As with any piece of industrial equipment, serious bodily injury can occur if general common
sense safety practices are not followed. Some of the safety practices, which should be followed,
include:
1 - HEARING PROTECTION SHOULD BE WORN AT ALL TIMES WHILE OPERATING THIS
EQUIPMENT.

2 - Whenever performing any adjustment or maintenance on the pulverizer, the machine must
be TURNED OFF AND LOCKED OUT.

3 - THE PULVERIZER MUST BE SHUT DOWN AND LOCKED OUT WHENEVER

MAINTENANCE IS PERFORMED. These items include, but are not limited to:
-Adjustment or removal of sifter socks
-Removal of feeder throat magnet
-Adjustment of drive belts or chains
-Greasing of bearings
-Do not make any adjustments to the sifter or attempt to remove screens.

4 - DO NOT OPERATE PULVERIZER WITH CONTROL PANEL DOOR OPEN.

5 - DO NOT WEAR LOOSE FITTING CLOTHING WHILE OPERATING EQUIPMENT.

6 - WEAR SAFETY GLASSES WHILE OPERATING THE PULVERIZER.

7 - DO NOT REMOVE OR OPERATE THE PULVERIZER WITH OUT THE DRIVE

GUARDS.

8 - DO NOT REMOVE, BY-PASS, OR OPERATE THE PULVERIZER WITH OUT THE

ELECTRICAL SAFETY INTERLOCK SWITCHES.

9 - DO NOT PUT HANDS INTO ANY OPENING ON THE PULVERIZER including:

-The mill feeder throats
-The air inlet holes

10 - DO NOT OPEN MILL DOOR WHILE MILL IS RUNNING.

11 - DO NOT OPEN MILL DOORS UNTIL THE FLYWHEEL HAS COME TO A

COMPLETE STOP.

12 - DO NOT TOUCH SIFTER WHILE RUNNING.

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ASSEMBLY OF YOUR REDUCTION ENGINEERING PULVERIZER

Uncrate the machine and remove all wrapping. All necessary fasteners are located at the surfaces
where components mate together.

1- Locate the base frame on a level surface. If the floor is not level, then shimming may be required to
ensure that the frame and sifter are level. Secure the base frame to the floor using 1/2"Dia. masonry
fasteners. All legs should have a minimum of two anchors. The length of the anchors will be dependent
on floor thickness.

2- In photo 1-A, locate the cyclone top and lift onto the cyclone/airlock assembly. Attach one 10”, 90° “long
sweep” elbow to the cyclone material inlet. Next, attach two 8”, 90° “short sweep” elbows, one to the
cyclone/blower inlet, the other to the blower. Attach the straight section with one 8” adjustable nipple and
two 8” dia. 30” lg. straight sections between the blower and cyclone elbows. Next, lift the cyclone assembly
off the shipping pallet and remove the shipping feet from the bottom; lift the cyclone/blower assembly into
position and bolt in place on top of the sifter.

CAUTION: THE CYCLONE UNIT IS UNBALANCED AND UNSTABLE. FOR SAFETY, THE UNIT
SHOULD BE CLAMPED TO THE FORKS IF A TOW MOTOR IS USED DURING ASSEMBLY.

Locate and attach the hopper mounting and supports, as well as the railing and supports for the platform,
as shown in photo 2-A. Secure the air lock guard to the air lock using the supplied fasteners. Connect the
sock to the air-lock guard and to the top of the sifter using the supplied clamps.

3-The sifter assembly fastens to the top of the base frame, in the center. Safely raise the sifter assembly
into position and secure with the supplied fasteners. (The motor of the sifter will be at the right side of the
base frame.) Make sure that the outlets of the sifter line up with the sleeves in the top plate of the base.
Connect the socks from the bulkhead tubes in the base frame to the sifter and clamp.

PHOTO 1-A PHOTO 2-A

4-For the Mill to Cyclone piping: PHOTO 3-A

Clamp the 8” 30° elbows to the mills. Clamp the Y branch to the mill elbows. Next assemble the 10”
adjustable nipple and three 10” straight lengths. Lift the assembled straight length and attach
2

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between the cyclone inlet and the mills.

For the Hopper to Feeder Inlet piping (single and double hopper): PHOTO 4-A
Clamp the 5” 45° elbows on either end of a 5” straight 11” long. Clamp the 5” adjustable nipple to a
5” straight; clamp the 5”-3” reducer to the end of the run and clamp to the fixed bracket on the
frame.

PHOTO 3-A PHOTO 4-A

5-Electrical controls and wiring have all been pre-wired at the factory. Once the machine is assembled the
yellow cords from the Airlock, Blower and Sifter will need to be plugged into their appropriate locations
on the back of the motor contactor panel. ALSO the proxy cables for the cyclone and the feed hopper will
need to be run with the cable going to the airlock. These cables are hanging on the back of the main
contactor panel and will plug into the proxy. The only field wiring required will be the main power that will
be brought to the motor contactor panel. A suitable earth ground must be connected to the control panel or
all warranties will be null and void. Once power has been established to the panel the motors rotations
must be checked. Follow the start up report check- list included in the back of this manual for complete
start up instructions.

CAUTION: REVIEW THE ELECTRICAL SCHEMATIC TO ENSURE THAT ALL CONNECTIONS ARE
CORRECT BEFORE ENERGIZING THE PANEL. IMPROPER INSTALLATION COULD CAUSE
COMPONENT FAILURE OR SERIOUS INJURY!

(READ THROUGH THIS SECTION ENTIRELY

BEFORE STARTING YOUR PULVERIZER!! )

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COMPONENT DESCRIPTIONS

MILL HOUSING- The size reduction of the material takes place in the mill housing. The mill consists of a
disk, which is bolted to the flywheel. This flywheel is in turn attached to the end of a shaft driven via a
series of belts by an electric motor. Opposite this spinning disk, is a stationary disk, which is bolted to the
housing door. The disks consist of an open center, and a series of coarse, file like teeth on the outer
surface. The teeth on these disks fan out from the imaginary center of the disk. The outer edge of the
disks is slightly higher than the inner edge of the disk teeth. The distance between the spinning and
stationary disk is called the gap. This gap is measured at the smallest distance between them at the
outside edge of the disks. This gap is generally smaller than the material introduced to the mill. Material is
feed to the grinding mill through the center opening. Centripetal force takes the material as it is introduced
and moves it between the opposing disks. As the material moves between the disks, the material is
reduced in size.

VIBRATORY FEEDERS- A permanently mounted electromagnet mounted below the feeder tray. As
voltage is applied the tray vibrates. As voltage increases, the vibration increases. As the tray vibrates the
material moves along the feeder tray.

FEED COLLARS-The feed-collar is the adjustable ring over the cylinder at the bottom of the feed hopper
tubes.

BLOWER-The blower consists of fan impeller bolted to a motor. The blower moves the material through
the piping into the cyclone.

CYCLONE-The cyclone separates the material from the airflow generated by the blower.

AIRLOCK-The airlock regulates the material flow into the sifter as well as keeps unnecessary air from
entering the sifter.

SIFTER-The sifter separates the over sized material from the acceptable material. The over sized material
is then sent back for further processing.

ELECTRICAL COMPONENT DESCRIPTIONS

VACUUM DISPLAY-The amount of system vacuum as registered in the ductwork and behind the rotating
disk in each mill housing. The low set point, (the numerical alarm value entered in the vacuum display)
should be set approximately 1"-2" H2O lower than actual operating condition. This can be found
and modified on the HMI Settings Page.

% OF FULL MOTOR LOAD - Monitors the amount of work done by the mill motors. (At 100%, the motor is
working at full rated horsepower.)

VOLTAGE (SP) -The amount of voltage being applied to the vibratory feeder. (Maximum voltage is 120
Volts) This can be found on the HMI Mill Settings Screen (Set Point or SP).

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DISCONNECT HANDLE- Turns off all voltage, (both high and low) to the control cabinet. CAUTION- THIS
WILL NOT TURN OFF VOLTAGE INTO THE TOP OF THE DISCONNECT. THE POWER FEEDING
THE TOP MUST BE TURNED OFF, AND LOCKED OUT, PRIOR TO WORKING ON THIS
DISCONNECT.

E-STOP BUTTON-Turns off low voltage to the control cabinet. CAUTION- THIS WILL NOT TURN OFF
HIGH VOLTAGE. WHEN WORKING IN THE CONTROL CABINET, THE POWER FEEDING THE TOP
OF THE MAIN DISCONNECT MUST BE TURNED OFF AND LOCKED OUT.

RESET TEST BUTTON - Resets system faults.

HOUR METER- Located on the HMI Operations Screen.

MOTOR PUSH BUTTONS -Turns on or off the different motors of the pulverizer; located on the Operations
Screen of the HMI.

FEEDER AUTO/OFF/MANUAL- While in auto, the pulverizer will monitor motor loads and mill housing
temperatures and adjust the feeder accordingly. In manual, the feeder is independent of motor loads and
temperatures. CAUTION-DO NOT OPERATE PULVERIZER INDEPENDENTLY WHILE IN THE
MANUAL MODE.

FEEDER SPEED- This is the maximum percent value that the feeder can run. This is the Set Point
Value(SP) and should be normally set at 100%. (Example: If set point value is 50%, feeder will produce at
maximum 60 volts of the 120 volts available.) This can be accessed on the Mill Settings Screen.

COMPONENT INDICATORS – Component graphic will change from a red, non-operational state or fault
condition, to a green when operational or running state.

ELECTRIC SERVICE REQUIREMENTS:

MODEL ULTRA - 300 AMP SERVICE

Note: No compressed air is required to operate this machine

Note: Tools and touch up paint for your machine have been placed in
the large control cabinet on the end of the machine. You will want to
remove these items before wiring the machine.
1 – Can Touch Up Paint
1 – Allen Wrench For Mill Port Plugs
1 – Set Feeler Gauges For Gaping Mill Plate

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PULVERIZING: GENERAL THEORY OF OPERATION

ELECTRIC MOTORS- An electric motor is designed to run at a specific speed or revolutions per minute
(RPM). The motor develops a certain amount of work to run at this RPM. The unit of measure for this work
is referred to as horsepower. (H.P.). When external forces are applied to the motor, which would slow the
speed of the motor down, (by driving a set of belts, by putting a brake on the motor etc.), the motor
maintains the same RPM by working harder (using more H.P.) As long as the motor user knows the H.P.
rating of the motor being used, he needs to remain at, or below, the full H.P. rating of the motor. If the user
can control the external forces on the motor, he can perform the same amount, or more, of physical work,
without putting unnecessary work, or load, on the motor. This should be thought of as the efficient use of
the motor H.P.

% OF FULL MOTOR LOAD METER- In REDUCTION ENGINEERING pulverizers, a meter showing the
user the amount of work that the motor is doing, is the % of full motor load meter. At 100% the motor
would be developing the full rated H.P. of the motor. At 50%, the motor would be developing
approximately 1/2 of the full rated H.P.

ELECTRIC MOTOR DRIVING A GRINDING DISK- In order to pulverize material in a grinding mill at a
satisfactory rate, maximum H.P. must be developed efficiently. Because this motor is being used for size
reduction, the external forces applied against the motor in this process must be identified, and its effects
on the development of H.P. discussed. The size of the material, and the amount of material being ground,
and the gap between the grinding disks effects the development of H.P.

THE SIZE OF THE MATERIAL AND ITS EFFECTS ON H.P.- EXAMPLE: The mill motor is developing a
specific amount of H.P. and the material being ground is 1/4" in diameter. If the size of the material
changes to 1/8" in diameter, and all other operating conditions remain the same, the amount of H.P.
developed will be reduced. (The smaller pellet size required the motor to work less to accomplish the
same sized particle through the mill.) The opposite would be true if the size of the pellet became larger.

THE AMOUNT OF MATERIAL BEING GROUND AND ITS EFFECTS ON H.P.- The amount of material
fed into the mill is directly related to the mill motor amperage, and the heat generated in the mill. The more
material that is fed into the mill, the higher the amperage and heat that is generated.

THE MILL GAP AND ITS EFFECTS ON H.P.- If the gap was set at 1/8"(.125) and the material to be
pulverized is 1/4"(.250) in diameter, the motor will develop a certain amount of H.P. If the gap became
smaller, for example to 1/16"(.063), and all other operating conditions remained the same, the H.P.
developed would be greater. The opposite would occur if the gap became larger.

It can therefore be said that the following rules can be applied in regards to the development of
motor H.P. and, the size of material, amount of material being ground, and the mill gaps used:

AS THE MATERIAL SIZE INCREASES --------------THE GENERATED H.P. INCREASES

AS THE MATERIAL SIZE DECREASES -------------THE GENERATED H.P. DECREASES

AS THE MILL GAP IS CLOSED ------------------------THE GENERATED H.P. INCREASES

AS THE MILL GAP IS OPENED ------------------------THE GENERATED H.P. DECREASES

AS THE RATE OF MATERIAL INCREASES---------THE GENERATED H.P. INCREASES

AS THE RATE OF MATERIAL DECREASES--------THE GENERATED H.P. DECREASES

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In a single-mill pulverizing system that disposes of all oversize material, any changes in material
size or rate, mill gap and how it effects production, would be very easy to see. However, most pulverizing
systems reprocess the oversize material back in the mill. Often times, a dual mill system is used. The
initial size reduction is done in the primary mill and the over sized material is reduced further in the
secondary mill. Because the material going into the secondary mill is directly related to the adjustments
made on the primary mill, sometimes the effect on the secondary mill is not as clear. Even though the
previous rules will always hold true, sometimes the effect can be unexpected. When this occurs, an
evaluation must be done as to why the results were different. The following are two examples of an
expected result that is different from an actual result:

EXAMPLE:

Situation: In an attempt to lower the motor load on the secondary mill, the mill gap was closed on the
primary mill.

Expected Result: By closing the primary mill, the size of the material going to the secondary mill should
become smaller, resulting in lower motor load on the secondary mill.

Actual Result: The motor load went up, possibly due to an increase in finer particles (also called ‘fines’),
generated by the primary mill, even though the size of the material going to the secondary mill became
smaller. In this situation, the overall amount of material going to the secondary mill is now greater than it
was initially. The smaller particle size was offset by the increased amount in overall material resulting in a
higher motor load.

FRICTION, HEAT AND THE DEVELOPMENT OF HORSEPOWER

Heat is a by-product in any pulverizing system. Too much heat can mean meltdown, too little heat
and the finished powder will have poor flow. Although the material being pulverized is heat sensitive, this
heat can be used to improve material quality.
As H.P. increases, the generation of heat will also increase. The key to successful grinding is
dependant on the development of heat in the mill and this heat’s relationship between efficient H.P. and
the material’s meltdown point – also referred to as the ‘hot grind zone’. Once this zone is determined, the
pulverizer’s control system can be set just below the meltdown temperature. This will allow the pulverizer
to grind the material at maximum efficiency. The heat will ‘polish’ the material (removal of ‘hooks and tails’)
and will yield a finished powder with good flow.

MILL GAPS
Setting the mill gap will depend on two factors. The first is the specific characteristics of the
material being pulverized(i.e. hard, soft, easy to melt, etc.), and the second being the environment where
the pulverizing takes place(i.e. machine location).
Some of the specific characteristics of the material that will effect mill gaps will be material type
including density, melt index, components of the material etc., the material size and shape, size of the
finished material, melting temperature in the grinding mill, and the initial temperature of the material as it
goes into the mill.
Some of the pulverizing environment effects on mill gaps will be: the ambient temperature of the
grinding environment, running chilled water into the water jacket in the mill door; the condition of the
grinding disks; and the proximity to other operations.
Because every processor has a different set of variables, it is impossible to give specific answer to
the question of the mill gap settings. Even though variables may be different from processor to processor
the following generalities can be said. The gap on the secondary mill should be at least 0.010" closer than
the primary mill. The gap on the secondary mill should not be closer than 0.005". A close mill gap on the
primary mill will yield higher grinding temperatures and lower throughputs. If the amount of recycle going
into the secondary mill is excessive, a close gap on the secondary mill will yield a greater throughput.

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Not only will mill gaps effect throughputs, but will also effect finished material quality
characteristics. Therefore, the optimum gaps will need to be obtained through experimentation with the
individual processor's variables. It is also important that as adjustments are made to the pulverizer, these
changes should be documented to expedite changeovers.

NOTE: BE SURE A SUITABLE EARTH GROUND HAS BEEN

CONNECTED TO THE MACHINE PRIOR TO OPERATION. FAILURE TO
CONNECT A SUITABLE EARTH GROUND WILL VOID ALL
WARRANTIES ON ELECTRICAL COMPONENTS.
FOR FURTHER ASSISTANCE PLEASE CONTACT OUR CUSTOMER SERVICE
DEPARTMENT AT 1- 800- 844-2927 8:00AM to 5:00PM EST

YOU MAY ALSO REACH US THROUGH OUR WEB PAGE AT

www.reductionengineering.com

Also available on our web site is a troubleshooting guide to help you with
processing problems and other technical questions. Please visit our web site to
contact us for further assistance and answers to technical questions.

(READ THROUGH THIS SECTION ENTIRELY

BEFORE STARTING YOUR PULVERIZER!! )

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PRIOR TO STARTING YOUR REDUCTION ENGINEERING PULVERIZER:
- Check to ensure the flywheel nut is tight and tab locked into nut.

- Check to ensure all bolts on the disks are tight.

- Close the mill-housing door and secure. Make sure to torque the mill housing door bolts between 54-
94 N-m.

- Check the gap setting between the disks. (Refer to "Gap Setting" section of this manual.) Make sure the
disks are not touching each other.

- Check to ensure the sifter frames are securely in position and the socks are clamped to the inlets and
outlets.

- Check to ensure that all pipes are securely clamped.

- Check to ensure that all drives are secure and all guards and safeties are in place. CAUTION: IF
GUARDS OR SAFETIES ARE NOT IN PLACE DO NOT OPERATE.

- Set the HMI to the correct temperature of the material being pulverized. If this temperature is not known
set it low and gradually increase it.

- CHECK ALL MOTOR ROTATIONS TO INSURE THEY ARE IN A CLOCKWISE DIRECTION.

SETTING OF MILL GAP

The gaps between the disks are critical in producing a quality product while maintaining sufficient
throughput.
REDUCTION ENGINEERING pulverizers have a unique "Push / Pull" method for mill gap
adjustments. Mill doors need not be opened, or disks removed, to adjust the gaps between the stationary
and rotating disks. This system is designed for operator ease in mind, while limiting downtime to a
minimum.
The stationary disk is bolted to a plate, which can be moved in, or away, from the rotating disk.
The "Push / Pull" system incorporates a series of three push screws and three pull studs for each mill
housing. The stationary disk is "pushed in" to close, (decrease) the gap, and "pulled out" to open,
(increase) the gap. The process for the adjustment process is explained below.
Ensure the pulverizer is shutdown and that the mills have come to a complete stop. LOCK OUT
POWER. Remove the three inspection port plugs from the housing. Using the supplied 12" long feeler
gauges, feel the distance between the rotating and stationary disks.
To OPEN the gap: Loosen the three push screws. Loosen the upper nut on the three pull studs.
Turn the three lower nuts on the pull studs clockwise; pulling the stationary disk upward, until the gap is
opened to the desired distance. Care should be taken to tighten the three nuts evenly. Once the desired
gap is obtained, while holding the bottom nut, tighten the upper jam nut. Snug up the three push screws.
DO NOT OVER TIGHTEN. Re-check the gap. Re-install the three plugs. Spin the rotating disk at least
one full revolution, by hand, to make sure the disks do not touch.
To CLOSE the gap: Loosen the three upper nuts on the pull studs. Turn the three lower nuts
counter-clockwise. As these nuts are being turned, snug the push screws against the disk. These
adjustments should be done evenly. Continue until the desired gap is obtained. Re-check the gap. Re-
install the three plugs. Spin the rotating disk at least one revolution, by hand, to make sure the disks do
not touch.

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SETTING OF THE PULVERIZER INSTRUMENTS
The setting of the values in your MAAG REDUCTION pulverizer is critical in assuring trouble-free
operation of your machine. Setting of the values is limited to the proper setting of the HM display.

Setting of the Vacuum Values: This can be found on the Settings Screen of the HMI. The Vacuum
values monitors three process values, the vacuum in inches of water column in Mill #1, Mill #2 and the
System vacuum. These values are being communicated to the HMI display through the Embedded
Controller from the vacuum transducer boards located in the control panel.. The Vacuum monitoring
system is factory preprogrammed and will not require any further adjustments other than alarm set point
values. If the operational vacuum falls below the alarm set point, the feeder and sifter will shut off and the
vacuum or meltdown fault will occur alerting the operator of a vacuum loss in the system or a meltdown in
one of the mills or system. In order to give the operator and pulverizer as much protection as possible, this
low set point should be set approximately 1”-2” of H2O less than the actual process value.. UNDER NO
CIRCUMSTANCES SHOULD THE LOW SET POINT EVER BE LOWERED IF A VACUUM FAULT
SHOULD ARISE. LOWERING THE SET POINT WHEN A VACUUM ALARM CONDITION ARISES MAY
RESULT IS SEVERE DAMAGE TO THE EQUIPMENT OR CAUSE SERIOUS INJURY. Setting the low
set point ALARM more than 1”-2” H2O lower than the PROCESS VALUE will not provide the level of
protection to operate the machine safely and WILL VOID ALL MANUFACTURERS WARRANTIES ON
MILL COMPONENTS.

10

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VACUUM TRANSDUCER BOARD CALIBRATION

Tools required: Multi-meter

Small Screwdriver
Manometer

1. Connect the wiring to the board per the electrical print. (See section 10 of
Manual sheet #5)
2. Connect a digital multi-meter set to DC volts to terminal #4 for (System
Vacuum) or terminal #3 for (Mill #1 Vacuum) or terminal #6 for (Mill #2
Vacuum). Place the red lead of the meter probe on one of the above
terminal numbers and the black lead on terminal #3.
3. With the machine at rest (no motors running) or at normal atmospheric
pressure and vacuum lines removed from the board fittings, adjust the VS,
V1 or V2 port bias pots until the meter reads .1VDC or 100mV (Mill volts).
Adjust all three pots for Mod. 400 and only VS and V1 for a Mod. 100.
4. Connect the tubing from a digital monometer and apply a negative
pressure of -10 inches water column.
5. With -10 inches water column being maintained on the vacuum port VS, V1
or V2. Adjust gain pot for the respective port until the meter reads 5.1VDC
for normal range or (.5 VDC / Inch of water) or 4.1VDC for extended
measuring range (.4 VDC / Inch of water).
6. Repeat steps 3 – 5 one more time for better accuracy.
7. Disconnect the tubing from the vacuum port and adjust the respective
Vacuum bias port until the meter reads 1.0 VDC.
8. Repeat steps 2 – 7 for each of the vacuum ports on the board. VS, V1 and
V2.
Normal Operating Range Values: 1V = Zero Pressure
6V = -10” Water Column Pressure (Negative)
10V = -18” Water Column Pressure (Negative)

Extended Operating Range Values: 1V = Zero Pressure

5V = -10” Water Column Pressure
(Negative)
10V = -22.5” Water Column Pressure
(Negative)

11

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Pressure sensors used in the SIVAC1 vacuum transducer board have a fast
response time. Therefore in typical use Embedded Controller based operating
systems for display purposes, a software filter with a time constant of 1 – 5
seconds must be used to get stable readings.

Pressure sensors can be destroyed by over pressure. Blowing compressed air

near or into the tubing connected to the vacuum port may damage the sensor.

This pressure sensor is a strain gauge device, and the bias may drift with time.
After the installation, or in operation, it may be necessary to re-adjust the BIAS pot
for 1.0 Volt output if the zero pressure reading is not correct.

DO NOT ADJUST GAIN POTS – The gain does not drift.

Do not over-tighten the green screw terminals when attaching wires.

WARNING
Note:
To clear obstructed tubing line, disconnect the tubing line from
the board and the respective use or sensing point. Then blow air
through the tubing line to clear the obstruction. Always blow air
from the disconnected line on the board towards the use or
sensing point. Never blow air towards the control panel.

12

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FEEDER BOARD
Tools Required: Multi meter for measuring AC voltage, small
screwdriver, safety glasses, alligator clips for test meter leads (optional)
Note: AC volt meter on panel door may be used for this calibration if
multi meter is not available.

1. Turn on the entire machine and ensure that all conditions are satisfied so
the feeder can run. (Hopper is full; Cyclone not full; Sifter running etc.)

2. Turn the feeder pot on the out side of the panel door to 20%.

3. Put the feeder in the Manual Mode.

4. Using a 120 VAC meter place the red lead of the meter on terminal L (Wire
#1212) and the black lead of the meter on terminal N (Wire #108C).
Voltage should read 24-30 VAC.

5. If not correct, turn the bias pot located on the right side of the SCR to
adjust the indicted voltage mentioned above in step 4.

6. Turn the feeder pot to 100%.

7. The voltage should read 110-120 VAC.

8. If not correct, turn the gain pot to adjust the indicted to the value mentioned
above in step 7.

9. Repeat Steps 5-7 again to further fine-tune the feeder SCR.

NOTE: When tuning the SCR in step 8 you find that you cannot set the voltage
any higher than 110VAC, CHECK THE INCOMING LINE VOLTAGE TO THE
PANEL. Should the voltage be on the lower side of the transformer primary
voltage range the secondary or output voltage will also be low. 120VAC may not
be achievable unless the incoming voltage is at least 460 to 480 volts AC. When
incoming line voltage is 440 volts AC or lower a lesser value such as 110VAC
may be the highest voltage limit setting attainable with the gain pot on the SCR.

13

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Mill Door Safety Interlock Switches

How The Switch Operates:

NOTE: WHEN THE PULVERIZER IS FIRST ENERGIZED THERE WILL BE A 2

MIN. 15 SEC. TIME DELAY BEFORE THE MILLS MAY BE ACCESSED. IF THE
PULVERIZER LOSES POWER OR THE EMERGENCY SHUTDOWN IS USED,
THE SAFETY INTERLOCK SWITCH KEY MUST BE USED TO OPEN THE
MILL WHEN THE PANEL IS NOT ENERGIZED!

1) When the key is inserted or the door is in the closed position, contacts11 +
12 close and contacts 33 + 34 open.
2)
3) When the key is out, or the door is in the open position contacts 33+ 34 are
closed.
4) When the key is in (door closed) contact 11+ 12 are closed and the coil in
the switch is de-energized then contact 21 + 22 are also closed.
5) The safety limit input (line 239 and 240 on the electrical schematics) tells
the Embedded Controller if the door is closed or open. When the key is out
(door open) the input is on contact 33 + 34 are closed on the interlock
switches.
6) When the door is closed (key in) the contact 33 + 34 is broken. And 12 and
21 close, allowing the mill start button to work. The input to the Embedded
Controller is then turned off. This will allow the mill motors to operate.
7) When the mill motor stop button is pushed the motor contactor drops out
and a delay timer in the Embedded Controller begins to time out. Once the
timer times out the output The delay timer is programmed for 2 min. 15 sec.
8) In the event of an emergency, the safety interlock may be defeated, by
using the by-pass key shipped with your pulverizer. This is the small black
plastic key that is wire tied to the main power disconnect shaft in the
pulverizer control panel. (One key is supplied for each interlock switch)

NOTE: THESE KEYS SHOULD NOT BE LEFT ACCESSIBLE TO OPERATORS

OR OTHER PERSONNEL. ONLY AUTHORIZED OR MAINTENANCE
PERSONNEL SHOULD HAVE ACCESS TO THE SAFETY INTERLOCK SWITCH
BYPASS KEY. PREVENTION OF ANY TAMPERING WITH THE SWITCHES TO
DEFEAT THEIR PURPOSE OF KEEPING THE MILL DOOR INACCESSIBLE
UNTIL THE MILL(S) ARE AT REST IS THE SOLE RESPONSIBILITY OF THE
CUSTOMER.

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VIBRATORY FEEDER,
HEAT CONTROLLERS,
MOTOR LOAD METERS
AND SYSTEM FUNCTIONS

Your REDUCTION ENGINEERING pulverizer is equipped with two vibratory feeders,

which feeds material into the mills. The feeders can be controlled either automatically or manually.
If the pulverizer is run in an automatic mode, the temperatures generated in the mill
housings as well as the percentages of full motor loads are monitored by the Embedded
Controller. The pulverizer and the Embedded Controller will increase or decrease voltage to the
feeder to keep the pulverizer running at 100% of full motor load, or to the set points of the
temperature controllers. While the pulverizer is below full motor load or set temperatures, the
voltage will continue to increase until an upper limit is reached; F.M.L. of mill 1 or 2; Temperature
set point of mill 1 or 2; or until the voltage limitations of the feeder has been reached. (120 volts.)
If the voltage limitations of the feeders have been reached before an upper limit has been reached,
the collar at the bottom of the hoppers must be raised in order to achieve the upper limits. Once an
upper limit is reached, the Embedded Controller will then regulate the voltage to the vibratory
feeder to keep the pulverizer running within the established limits.
In order to keep your pulverizer running as evenly as possible, as well as develop
maximum throughput, it is recommended that the following procedure be followed on a start-up
whenever sharp disks or different materials are pulverized. Set the temperature on the mills low
so that the pulverizer controls on this limitation and observe the motor loads on both mills as well
as the temperature. If the load and temperature are within acceptable limits, gradually increase
the temperature on the mills to establish the upper limitations. For example: With the set
temperature for the mills at 150 degrees, the motors should be developing 70% of Full Motor Load.
If the mills are developing 70% or less of Full Motor Load and are generating 150 degrees or less
of temperature, then it can be safely concluded that as the temperature is turned up on the mills,
the pulverizer will run consistently. However, should the mill temperature be greater than 150
degrees, or greater than 70% of Full Motor Load, it can be concluded that when the temperature is
increased on the mills the upper limitations will be reached. This would result in either low or
inconsistent throughputs or meltdown. It would therefore be necessary to adjust mill gaps in order
to ensure consistent and maximum throughputs.
The Embedded Controller WILL NOT regulate the voltage to the feeder but instead will
only shut the feeder off in the event an upper limitation is reached. Once the operating condition is
below the upper limitation, the feeder will then restart.

REFINER BLADE SELECTION

The refiner plates in your pulverizer have been supplied to produce maximum output while
maintaining a quality pulverized material. The preferred supplier for new or reconditioning of your
refiner plates is:
REDUCTION ENGINEERING INC.
235 PROGRESS BLVD.
KENT, OHIO 44240

800-844-2927
TEL: (330) 677-2225 FAX: (330) 677-4048

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REDUCTION ENGINEERING MODEL ULTRA START UP PROCEEDURE
(AUTOMATIC MODE)
1 – Turn the “MAIN DISCONNECT” handle to the “ON” position.

2 – Pull the red “POWER” knob to the “ON” position.

3 –The HMI will power on and the Home Screen will show on the display.

4 – Start motors using the Start/Stop Screen buttons from top to bottom. Note: If the machine is equipped
with reduced voltage starting components and/or a variable frequency drive for the blower refer follow the
below steps.
A - Press the “MILL #”1 (Primary) start button. Allow mill to reach max speed before starting Mill 2.
B - Press the “MILL #2” (Secondary) start button. Allow mill to reach max speed before starting Blower.
C - Press the “BLOWER” start button. Wait until the actual vacuum values have stabilized.
D - Press the “AIRLOCK” start button.
E - Press the “SIFTER” start button.

5 – “FEEDER SPEED” can be changed by adjusting the feeder Set Point Value on the Mill Settings
Screen on the HMI..

6 – Turn the “FEEDER” switches to the “START” position.

The pulverizer is now running in automatic mode. The Embedded Controller equipped with the
pulverizer will adjust the feeder voltage to obtain the prescribed parameters. Refer to pulverizer
optimization for details.

REDUCTION ENGINEERING MODEL ULTRA SHUT DOWN PROCEDURE

(MANUAL OR AUTOMATIC MODE)

Note: The pulverizer motors are stopped in the reverse order of starting.
1 – Turn the “FEEDER” switches to the “OFF” position. Push the last 4 inches back into the tray.
Note: Wait for a minimum of 15 minutes for the sifter to clear residual material.
2 – Press the “SIFTER” stop button.
Note: Wait until the sifter comes to a complete stop.
3 – Press the “AIRLOCK” stop button.
4 – Press the “BLOWER” stop button.
5 – Press the “MILL #2” (Secondary) stop button.
6 – Press the “MILL #1” (Primary) stop button.
7 – Push the red “POWER” knob to the “OFF” position on the operator’s panel.
8 – Switch the “MAIN DISCONNECT” handle to the “OFF” position.

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REDUCTION ENGINEERING MODEL ULTRA START UP PROCEEDURE
(AUTOMATIC MODE) with exiting material conveying equipment
1 – Turn the “MAIN DISCONNECT” handle to the “ON” position.

2 – Pull the red “POWER” knob to the “ON” position.

3 –The HMI will power on and the Home Screen will show on the display.

4 – Start motors using the Start/Stop Screen buttons from top to bottom. Note: If the machine is equipped
with reduced voltage starting components and/or a variable frequency drive for the blower refer follow the
below steps.

A - Press the “TAKEAWAY BLOWER” start button.

B - Press the “TAKEAWAY AIRLOCK” start button
C - Press the “MILL #”1 (Primary) start button.
D - Press the “MILL #2” (Secondary) start button.
E - Press the “BLOWER” start button. Wait until the actual vacuum values have stabilized.
F - Press the “AIRLOCK” start button.
G - Press the “SIFTER” start button.

5 – “FEEDER SPEED” can be changed by adjusting the feeder Set Point Value on the Mill Settings
Screen on the HMI..

6 – Turn the “FEEDER” switches to the “START” position.

The pulverizer is now running in automatic mode. The Embedded Controller equipped with the
pulverizer will adjust the feeder voltage to obtain the prescribed parameters. Refer to pulverizer
optimization for details.

REDUCTION ENGINEERING MODEL ULTRA SHUT DOWN PROCEDURE

(MANUAL OR AUTOMATIC MODE) with exiting conveying equipment

Note: The pulverizer motors are stopped in the reverse order of starting.
1 – Turn the “FEEDER” switches to the “OFF” position. Push the last 4 inches back into the tray.
Note: Wait for a minimum of 15 minutes for the sifter to clear residual material.
2 – Press the “SIFTER” stop button.
Note: Wait until the sifter comes to a complete stop.
3 – Press the “AIRLOCK” stop button.
4 – Press the “BLOWER” stop button.
5 – Press the “MILL #2” (Secondary) stop button.
6 – Press the “MILL #1” (Primary) stop button.
7 – Press the “”TAKEAWAY AIRLOCK” stop button.
8 – Press the “TAKEAWAY BLOWER” stop button.
7 – Push the red “POWER” knob to the “OFF” position on the operator’s panel.
8 – Switch the “MAIN DISCONNECT” handle to the “OFF” position.

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DOCUMENTATION
In order to enhance the productivity of your pulverizer, a system of gathering and
maintaining information of the equipment and the process is strongly recommended. A
recommended list of some of the things that should be documented is listed below.

EQUIPMENT DOCUMENTATION
- Maintenance including:
- Preventive maintenance
- Break down maintenance
- Operator maintenance including:
- Cleaning of sifter socks and screens
- Changing of the grinding disks

PROCESS DOCUMENTATION
- Process variables including:
- Gaps
- Percentage of full motor loads
- Mill temperatures
- Voltage
- Feed collar height
- Throughputs
- Flow
- Sieve analysis
- Bulk density
- Operator observations of abnormal pulverizer operations

This list, along with the frequencies and the method of the documentation, should be
tailored to the needs of the individual processor. The important issue is that the processor has the
appropriate information gathered in order to make fact-based decisions with the collected data.

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*NOTICE*
FOR INDIVIDUAL COMPONENT
INFORMATION CONCERNING ANY
OF THE ELECTRICAL CONTROLS,
PLEASE REFER TO THE
ELECTRICAL SECTION IN THIS
MANUAL. ANY PRINTED PRODUCT
LITERATURE NOT FOUND IN THIS
MANUAL WILL BE SHIPPED INSIDE
THE CONTROL PANEL ENCLOSURE
ON YOUR NEW PULVERIZER. ALSO
REFER TO THE USB DRIVE
ENCLOSED IN THIS MANUAL
CONTAINING OTHER
SUPPLEMENTARY INFORMATION.

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MAINTENANCE OF YOUR REDUCTION ENGINEERING PULVERIZER
As with any piece of mechanical equipment, a preventive maintenance program will
keep your pulverizer in optimum operating conditions for many years. Below is a list of items,
which should be included in your preventive maintenance program along with the recommended
frequencies. (Your frequencies may vary depending on your operating situation.)

CAUTION: BEFORE SERVICE OF ANY KIND IS PERFORMED ON THE PULVERIZER, ALL

POWER MUST BE SHUT OFF AND LOCKED OUT TO PREVENT INJURY.
CAUTION: MAINTENANCE SHOULD ONLY BE PERFORMED BY A QUALIFED
TRAINED TECHNICIAN OR PERSONNEL ONLY.
WHENEVER MAINTENANCE, CLEANING OR ANY OTHER WORK IS PERFORMED ON THE
PULVERIZER, AN OSHA APPROVED WORK PLATFORM SHOULD BE INSTALLED AROUND THE
EQUIPMENT TO SERVICE ALL AREAS THAT CAN NOT BE SERVICED FROM THE GROUND. IN THE
ABSENCE OF A PERMANENT PLATFORM AN OSHA APPROVED WORK PLATFORM PROPERLY
ATTACHED TO A FORK TRUCK SHOULD BE USED. FAILURE TO USE PROPER WORK
PLATFORMS WILL RESULT IN FALLING HAZARDS WHICH MAY RESULT IN SERIOUS BODILY
INJURY OR EVEN DEATH.

ITEM FREQUENCY

1 - Remove and clean all sifter socks. Every 3-4 days

2 - Check for proper location of thermocouple. Every time mill door is opened.

3 - Adjustment of the following belts:

Mill drives Once per month
Sifter drive Once per month

4 - Adjustment of airlock drive chain (if needed) Once per month

5 - Cleaning and inspection of sifter screens Once per month

6 - Greasing of motor bearings Frequency based on motor

Manufacturer’s Recommendation.

THE SHAFT BEARINGS ARE SEALED AND DO NOT REQUIRE GREASE.

7 - Greasing of sifter pillow block bearings Once every 6 months

8 - Remove and clean mill magnet Every shift

9 - Remove vacuum tube from the Vacuum Once per week

Transducer Board and clean tubes with
compressed air. CAUTION: DO NOT BLOW COMPRESSED
AIR INTO THE BOARD!

10 - Check tightness of all fasteners. Once per month.

Along with the above items, the pulverizer operators should be conscious of the normal
operating conditions, and be aware of abnormal situations. These abnormal situations should
be brought to someone's attention immediately and corrected.
The condition of the grinding disks will also greatly impact the performance of the
pulverizer. Dull grinding disks will generate unnecessary heat, low grinding rates and poor
finished material quality. The service life of a sharp set of disks will vary depending on the type
of material pulverized. The determination to install re-sharpened disks should be based on
overall pulverizer performance.
Please consult the appropriate sections of this manual for specific maintenance
instructions related to other components used in the manufacture of this machine. Or call MAAG
REDUCTION for information concerning maintenance questions.
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CHANGING MEMORY CARD

1) Look at machine run time hours in the secondary screen options through
the vacuum monitoring display. Write down the machine run time hours;
they will need to be re-entered at the end of this procedure.
2) Turn off the main power to the control panel.
3) Remove the Memory Card from the Embedded Controller
4) Turn Power back on
5) Any issues Call Maag Reduction 1-800-844-2927

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CLEANING OF YOUR PULVERIZER

WHENEVER MAINTENANCE, CLEANING OR ANY OTHER WORK IS PERFORMED ON THE

PULVERIZER, AN OSHA APPROVED WORK PLATFORM SHOULD BE INSTALLED AROUND
THE EQUIPMENT TO SERVICE ALL AREAS THAT CAN NOT BE SERVICED FROM THE
GROUND. IN THE ABSENCE OF A PERMANENT PLATFORM AN OSHA APPROVED WORK
PLATFORM PROPERLY ATTACHED TO A FORK TRUCK SHOULD BE USED. FAILURE TO
USE PROPER WORK PLATFORMS WILL RESULT IN FALLING HAZARDS WHICH MAY
RESULT IN SERIOUS BODILY INJURY OR EVEN DEATH.

Your REDUCTION ENGINEERING pulverizer has been designed to make system clean
outs easy and quick. Your pulverizer has been built using "quick disconnect" pipes so that the
entire system can be quickly disassembled and thoroughly cleaned whenever changeovers are
required. A complete clean out procedure is listed below.

1 – Shut down pulverizer.

2 – LOCK OUT POWER SUPPLY per company practices.

3 – Remove all piping from the mill(s) to the cyclone including air diverter.
NOTE: It is not necessary to remove the piping between the cyclone and the blower.

4 – Disconnect piping between cyclone and blower then open cyclone.

5 – Some machines are equipped with a Kwik Klean airlock. Remove fasteners that hold the rotary
wheel in the housing and slide rotary wheel from the housing.

5 – Remove sifters socks: top and bottom

6 – Open the sifter by turning the jack screws counter-clockwise.

NOTE: Lower each side in 2”/50mm increments.

7 – Remove the sieves at numbered end by lifting up and pulling out.

NOTE: An additional person may be necessary to assist with sifter disassembly.

8 – Swing feeder away from inlet tube and empty Material hopper of all material.

9 – Remove mill magnets from inlet tube(s)

10 – Remove fasteners that hold the mill door(s) and open.

NOTE: Turn the mill door safety switch to the “OFF” position: counter-clockwise.

11 – Remove mill gapping plugs from side of mill housing.

At this time the machine is completely open and it is ready to start the cleaning
process. It is best to put the cleaned parts in an area that will not be affected by the rest of
the cleaning process.

12 – Remove the screens from the sieves. Note that the screens only can be installed in the
sieves one way this is important upon reassembly.

13 – Clean screens and sieves.

A – Vacuum material off screens and sieves.
B – Blow screens and sieves off with compressed air.
C – Sweep off the screens with a soft brass brush.
D – Blow screens off again with compressed air.
NOTE: Small hair like balls attach to the screens and are difficult to remove. Running the
tips of your fingers across these balls usually gets this material off.

14 – Vacuum material from inside the sifter framing and any other areas the have a large amount
of material present.
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15 – Using compressed air blow the machine off from top to bottom, including Kwik Klean rotary
wheel, cyclone, airlock, sifter framing, material hopper, feeder tray and mill housings(s). Pay
special attention to areas that material can hide: between the mill door and water jacket, mill
gapping holes, airlock, plate bolts, etc.
NOTE: Standard airlocks hold material in and on the rotary wheel. For best results the airlock
should be turned on and cleaned by blowing compressed air from in the cyclone and from the
bottom side where the airlock guard is attached.
16 – Clean piping using compressed air and/or by wiping with a cloth.
NOTE: Some materials leave a thin film in the piping. A more aggressive method may be
necessary to rid the piping of this material.

17 – Turn sifter socks inside out and clean off with compressed air. Brush off by hand and blow off
with compressed air again. Turn the socks right side out and blow off once more.

18 – Blow off mill gapping plugs, air diverter, mill magnet and all other components removed.

The pulverizer is now ready to be reassembled. Again, make sure the screens are
positioned properly in the sieves. The sieves are to be placed in the sifter frame as numbers shown
prior to disassembly. Reverse steps for all parts removed.

REDUCTION ENGINEERING - Pulverizer After-Filter Cleaning Procedure

1 – Remove clamps from the collection barrels.

2 – Empty barrels of all material.

3 – Remove clamps and bags from plenum head.

4 – Vacuum material from inside of plenum head.

5 – Clean inside of barrels with cloth and empty again.

6 – Clean plenum head with cloth and use compressed air to remove dust.

7 – Turn filter bags inside out.

8 – Sweep/clean an area on the floor in which the bags can be laid down.
NOTE: Depending on floor surface it may be better to lay the bags on a piece of cardboard.

9 – Lay the bags flat on floor and sweep material off along the side holding the bag with your foot. A
stiff bristle broom works well.

10 – Turn the bag over and repeat sweeping.

11 – Remove bags from floor and sweep the material that has came off the bags away from the work
area.
12 – Repeats steps 9 and 10.

13 – Turn bags right side out.

14 – Sweep both sides of the bag as previously stated for the inside of the bags.

15 – Vacuum and clean the area in which the After Filter is located.

16 – Install bags on plenum head.

NOTE: This task is much easier with an additional person.
17– Put the barrels in place and reconnect the bottom side of the bag to the barrel.

MAKE SURE ALL CONNECTIONS ON PIPES AND COMPONENTS ARE

SECURE BEFORE ENERGIZING THE PANEL FOR START UP.
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PARTS REQUEST FORM
Date: ______________ Purchase Order No: __________________

Company Name: __________________Company Phone No:______________

Contact Person: ___________________Company Fax No:________________

Machine Model No.__________ Machine Serial No. _________________

Please fill out the table below with the part number and a description of the item you are
wishing to order. We will return fax to you pricing and availability along with shipping costs.
Please also select how you would like us to ship your parts order to you.
Phone: 800-844-2927 330-677-1343 Fax: 330-677-4048
www.reductionengineering.com

QTY. PART NO. DESCRIPTION COST

Total Parts
Total Shipping
Total Order
Shipping Request, please check appropriate box:

UPS Ground UPS Next Day UPS Second Day Fed Ex

Common Carrier Ours Common Carrier Yours :___________________________

Other Specify: __________________________________________________________

Shipment to go: Prepaid Collect

Sales Person: ________________________ Date: __________________

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RECOMMENDED SPARE PARTS
The list of recommended spare parts for your REDUCTION ENGINEERING pulverizer will vary
based on numerous operator considerations. The local availability of necessary spare parts, the
dollar value of a spare parts inventory; the number of pulverizers in the customers facility; the
cost of equipment downtime and the frequency of pulverizer color or material changes. These are
some of the items, which must be considered in determining appropriate levels.

Below is a list of spare parts all processors' should have on hand.

Extra Grinding Disks

O-Ring Kits (For Water Jackets)

Thermocouple

Mill Spindle

Mill Bearings

Mill Seals

Drive belts

Flywheel Key

Retaining nut/ washer for the flywheel

Retaining nut/ washer for the bearings

Fly Wheel Nut Wrench

2-Bearing Nut Wrenches

Ducting Clamps & Fittings

Feeler Gauge Sets

Extra Sifter Socks *

Extra Screen Inserts *

* Recommended for those processors who make numerous color or material changes

Please contact us at REDUCTION ENGINEERING for your spare parts inventory.

TOLL FREE 800- 844- 2927

PHONE (330) 677-1343
FAX (330) 677- 4048

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