Muyang SYPL(C) Continuous Type Liquid Coating System
Foreword 1. Thanks for purchasing Muyang SYPL Continuous Type Liquid Coating System. 2. This Operation Manual is an important technical document for the safe and correct operation of Muyang SYPL Continuous Type Liquid Coating System. 3. Prior to operation, please read over this operation manual carefully, well know the attention item for safety, different performances, requirements to installation and operation etc. of this liquid coating system so that you able to adroitly operate and use this machine, and create more benefits. 4. This machine must be operated in accordance with this Manual. Improper operation or breach of the operation regulations will cause severe loss. 5. Following are Safety-Alert Symbol and signal words in this Manual. ①
②
③
6. Prior to use, please read through this Manual and well understand the signal words, especially the DANGER points. 7. Operation and maintenance personal should read carefully this Operation Manual prior to use and then carry out the operation and maintenance of the equipment. 8. Keep the Manual in a place near the machine, so as to look up it at any moment. 9. Please operate and maintenance this machine with thoroughly understanding this Operation Manual. 10. Please contact our Company to purchase a new Operation Manual for this machine if there is any omission or damaged of this Manual. 11. If the machine is transferred to the third party, please over this Manual together with the machine. 12. Attention, Following are some explanations about the application and the warranty of this machine. ①
Application: Installed after pellet mill or extruder for coating liquid on the surface of feed pellets.
②
Content of warranty: the body of coating system.
③
Warranty period: within 1 year after purchase of the equipment, except wearing parts.
[Note]: (1) Jiangsu Muyang Group reserves the copyright of this document and related contents. The receiver of this Manual shall admit the copyright and shall not provide the document wholly or partially to the third party without our authorization in writing beforehand, and shall not use it for other purpose. (2) It will not be notified if the relative technologies and the parameters are changed. (3) The foreign language edition of this Operation Manual is translated based on the Chinese edition of this Operation Manual of Jiangsu Muyang Group, therefore, in case of divergence, the Chinese edition of this Operation Manual shall govern.
CONTENTS
1 Safety attention points ............................................................................................................................ 1 1.1 Environment conditions ....................................................................................................................... 1 1.2 Description of warning marks .............................................................................................................. 1 1.3 Description of safety marks ................................................................................................................. 2 1.5 Safety attention points in transport, storage and installation ............................................................... 4 1.7 Personal protection ............................................................................................................................. 7 1.8 Explosion Protection: Countermeasures against dust explosion and fire hazard ................................ 8 1.9 Other attention points (environmental protection measurements) ..................................................... 10 2. General................................................................................................................................................. 11 2.1 Application and adaptability ................................................................................................................ 11 2.2 Features ............................................................................................................................................. 11 2.3 General outline and main structure feature ........................................................................................ 11 2.3.1 Overall structure ....................................................................................................................... 11 2.3.2 Working principle ...................................................................................................................... 11 2.3.3 Main components and structure features ................................................................................ 12 2.4 Production process (feeding and discharging) (Fig.2-8) .................................................................... 19 2.4.1 Feeding ................................................................................................................................... 19 2.4.2 Discharging ............................................................................................................................. 19 3 Specification of Coating System ........................................................................................................... 20 3.1 Basic Specifications ........................................................................................................................... 20 3.1.1 Working condition .................................................................................................................... 20 3.2 Main technical parameters ................................................................................................................ 22 3.2.1 Technical parameters of liquid coating system ........................................................................ 22 3.2.2 Model composition and its meaning ........................................................................................ 22 4 Transport, installation and adjustment .................................................................................................. 24 4.1 Transport ........................................................................................................................................... 24 4.2 Mechanical installation ...................................................................................................................... 25 4.3 Electric installation ............................................................................................................................. 30
5 Running ................................................................................................................................................ 39 5.1 Attention points for operations ........................................................................................................... 39 5.2 Functional inspection prior to test-run................................................................................................ 39 5.3 Commissioning .................................................................................................................................. 39 5.4 Use and operation ............................................................................................................................. 40 5.5 Operation of control system............................................................................................................... 41 5.5.1 Control system composition .................................................................................................... 41 5.5.2 Attention points ........................................................................................................................ 41 5.5.3 Operation procedures.............................................................................................................. 41 5.5.4 Parameters description ........................................................................................................... 46 5.5.5 Other description ..................................................................................................................... 46 6 Inspection, repair and maintenance...................................................................................................... 47 6.1 Attention points for inspection, repair and maintenance .................................................................... 47 6.2 Daily inspection and regular inspection ............................................................................................. 48 6.2.1 List of daily inspection items (prior to each running or during each running) ........................... 48 6.2.2 List of regular inspection items ................................................................................................ 49 6.2.3 Machine stoppage ................................................................................................................... 50 6.2.4 Mechanical maintenance ......................................................................................................... 50 6.2.5 Pneumatic maintenance .......................................................................................................... 50 6.3 Malfunction and troubleshooting ........................................................................................................ 52 6.4 Tools for repair and maintenance ...................................................................................................... 55 6.5 Long-term stoppage .......................................................................................................................... 56 6.6 Spare parts ........................................................................................................................................ 56 6.6.1 Spare parts .............................................................................................................................. 56 6.6.3 Ordering list of spare parts ...................................................................................................... 66 7 Appendix............................................................................................................................................... 67 7.1 Attached documents .......................................................................................................................... 67 7.2 Contract information .......................................................................................................................... 67 7.3 Muyang SYPL(C) Continuous Type Liquid Coating System (list of operation manuals) .................... 68
1 Safety attention points 1.1 Environment conditions In order to operate this equipment safely, please install it according to following operating conditions. (1) Please install this equipment indoors according to following conditions: ． Ambient temperature range (-10~+40°C) ． Relative humidity range: 30%~85% ． Altitude: less than 1000m ． Guarantee indoor cleaning and ventilation ． Guarantee that the equipment is far away from the corrosive gas, inflammable and explosive gas as well as steam (2) Power source: as for Voltage and Frequency, please refer to the nameplate; pressure ≧0.6Mpa. (3) For easy use, operation and maintenance, please check this equipment and reserve enough space for it. (Please refer to scaled drawing for installation in chapter 4) (4) Please place the equipment horizontally. (5) The vibration to be borne under effects of many complicated environments may not exceed 12 mm·s-1.
1.2 Description of warning marks (1) In order to well understand this operation Manual, the safety warning marks are divided into following kinds. (2) These warning marks have been worked out according to the operating regulations and safety attention points for this equipment. In order to avoid dangerous accidents, this Operation Manual also includes concrete preventive measures. Please operate this equipment according to the instructions based on sufficient understanding of warning marks. This mark expresses that in order to avoid death and serious injury accidents, please be sure to operate this equipment according to relevant stipulations of safety attention points. This mark expresses that in order to avoid potential dangerous accidents and serious injury accidents, please operate this equipment according to relevant stipulations of safety attention points. This mark expresses that in order to avoid slight wound and potential moderate injury accidents, please operate this equipment according to relevant stipulations of safety attention points. 1
1.3 Description of safety marks (1) Relevant safety marks are pasted on different corresponding positions of this equipment, which are property dangerous to personal safety. See Fig.1-1. (2) All the safety marks are indicated in Table 1-1. Please carefully understand and install, adjust, operate, maintain and inspect this equipment according to the contents in Table 1-1. (3) Please place these safety marks near the equipment. (4) When these safety marks have fallen off or been damaged, please replace them with new marks. (5) If you want to order new marks, please contact our company.
Fig. 1-1 Safety marks at the dangerous position of the equipment
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Table 1-1 Description of safety marks Safety mark: Do not open the junction box until the power supply is switched off.
Safety mark: Do not open the operating gate when the machine is running and until it has not been completely stopped. Instruction mark: Attention! Protect head and hands from injury when opening the access doors.
Beware of scalding! Do not touch the machine with bare hands when it is working.
It is prohibited to heating the heater rod without liquid. Attention must be paid to check the liquid level of tank. Prohibition mark: Do not remove the guard shield when the machine is running.
Instruction
mark:
Maintain
according
to
Operation Manual.
Instruction mark:
Regulate the correct rotating
direction. Do not rotate the machine reversely to protect machine from damage. Instruction mark:
Regulate the correct rotating
direction. Do not rotate the machine reversely to protect machine from damage.
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1.4 General safety attention points (1) The here said equipment operators refer to all personnel who participate in operation, inspection and maintenance etc. (2)The equipment operator must carry out the operation on the basis of sufficient understanding the Operation manual. (3) For safety attention points, the owner has the duty and obligation to deliver the contents of the Operation Manual for the equipment to all working personnel. (4) At the same time when obeying all the safety attention points, the users also must obey the safety regulation and stipulations to prevent accidents. (5) All related employees should receive safety education. The enterprise management should be in charge of it and respect the national, local and the other enterprise’s safety regulations of the users. (6) This equipment is used for coating liquid on the surface of granular materials. All the responsibilities for any accidents or damage to the equipment shall not be borne by manufacture and commission agent if the equipment is not operated according to the stipulations. (7) Please install, use and operate the equipment correctly. Whoever takes off guard or makes it dysfunctional should be responsible for the safety result. (8) Any reformation of the equipment may not affect the functions and safety performances of the equipment. (9) Be sure to run the Coating System under strict obeying all regulations for prevention of accidents. (10) If any accidents are caused due to not obeying the stipulations in the Operation in the Operation Manual and the control system for Muyang equipment is not used as per the conditions mentioned above, the Muyang Group will refuse to take any responsibility. If the Muyang Group is required to take responsibility, the Group will reserve the right to investigate and affix the responsibility of the operator.
1.5 Safety attention points in transport, storage and installation (1) The equipment must be placed and handled by professionals. (2) Please use designated tools (steel cable, crane, hoisting machine etc.) for hoisting, and carry out the hoisting according to designated sequence and method. (3) Staff only when carrying out hoisting. (4) In order to prevent serious injury accidents, no one is allowed to be under the equipment when carrying out hoisting. 4
(5) The permissible load of hoisting tools should be more than total weight of the equipment. (6) When the equipment is stored temporarily, please place the equipment horizontally and keep a normal temperature and clean indoors. (7) For transportation and handing, it is not allowed to damage the equipment by binding. It should be reported to the manager immediately in case of any machine damage and missing of parts in transporting. (8) In installation, enough space should be reserved for future maintenance and replacement of the equipment. (9) Prior to installation, all machine parts must be kept in their original package. The machine parts and packing boxes should be properly covered and stored in places sheltered from rain, sunning and damp. (10) The cover plate, protecting hood or guard grating are usually installed and delivered together with the machine. They can only be disassembled with tools. And the machines with such kind of devices can never put into work until the above-mentioned devices have been properly installed.
1.6 Safety attention points in operation, inspection and maintenance (1) The operation, inspection, repair and maintenance of the equipment shall be carried out only by the trained technical personnel according to different specifications provided together with the equipment. Electric installation shall be carried out only by professional persons according to relevant electric safety standards. (2) Whenever maintenance or repairing is to be done the power must be cut off so as to prevent the motor from accidental staring. (3) For operation, installation, repair and maintenance after stop, please be sure to cut off and lock the main supply switch, and place the signboard at the workshop gateway, in front of the electric control cabinet and near the Coating System respectively, so as to prevent the motor from accidental staring. (4) In operation, a special attention shall be paid to the positions with attached safety marks. (5) Do not operate when the safety protection device and operating gate are open. It is prohibited to open the operating gate until the machine has been fully stopped. (6) If any troubles occur in the operating gate and safety protection device, please repair or replace them at once. (7) The safety protection devices can never be dismounted, covered or overlapped at will. It can never be opened until the machine has completely stopped. And the machine can only be started when these safety protection devices are in good order. (8) The security mechanism of the operating gate is equipped with the travel switch for 5
opening, it must be correctly wired as per requirement to ensure the power-off when the access door is opened, and additionally in such case the machine cannot be started. Owing to the fact that this safety mechanism is related to life safety, it can never be removed or discarded! Whenever there is anything wrong with this mechanism, it should be repaired or renewed promptly. (9) When the machine is under stoppage, attention must be taken to prevent the Coating System from being started by any accidental starting mode. (10) Except the maintenance of the equipment, it is not allowed to take off the guard shields of the two cylinders. (11) When the safety guard shields or operating gates have to be opened or the safety devices have to be disassembled in order to inspect, adjust, repair and maintain the equipment or replace the parts, please well negotiate about the required safety attention measures and work out the safety countermeasures prior to the operations and then carry out the inspection work. (12) When the machine is running, it is strictly forbidden to put fingers near the running components, such work as inspection, maintenance and cleaning etc cannot be done until the coating drum has been completely stopped. (13) In case maintenance and inspection work should be done with a welder or other tools that can generate sparks, strict safety precautions must be taken against dust explosion and combustion (see "Explosion protection"). (14) If the parts are damaged, please repair or replace them immediately. (15) Guarantee the safety of the electric system. Before the electric circuit is cut off, it is strictly prohibited to open the terminal box for avoiding electric shock. (16) The electric control system of the Coating System must follow the following points. Otherwise, the technical safety responsibility of the supplier will be canceled. ① The electric control system of the Coating System must be supplied by Jiangsu Muyang Group. ② The equipment must be checked up by an expert
from Muyang Group before
commissioning. ③ The electric control is a component part of the safety regulations for accident precaution. ④ Prior to commissioning the control system must be tested by an expert from Jiangsu Muyang Group in light of the testing list and a permit will be signed by him. ⑤ If the control system for Muyang machinery equipment is not used as per the conditions mentioned above, the Muyang Group will refuse to take any responsibility. If the Muyang Group is required to take responsibility, the Group will reserve the right to investigate and affix the responsibility of the operator. 6
1.7 Personal protection (1) All the mechanical equipments manufactured by Jiangsu Muyang Group are equipped with safety devices, which are consistent with modern technical level and universally effective safety rules prior to ex works, so that the customers can use the machines in accordance with the regulations. (2) If the operators employed cannot read or write, the owner has the duty to explain to them clearly where dangers exist and warn them that special attention should be paid. (3) In order to guarantee the safety and health of labors during production process, it is necessary to use labor protection articles (such as gloves, breathing masks and labor shoes) during operation. (4) Please execute the special regulations on accidents prevention in the operation manual provided by us. (5) The enterprises are obligated to execute following regulations to guarantee operators' safety. ① The shield cap must be mounted at any moment and keep closing. It is very dangerous when they are opened or disassembled. It may cause casualty accident. This is also applicable for the preventive device of the manipulator. ② The safety limit switches should always be kept in good order. Overlap or discard of the safety limit switches is not allowed. ③ The driving motor must be switched off completely to make the machine stop when carrying out inspection, commissioning, repair and maintenance. This can be done through a full-phase separating and lockable switch which is installed near the machine or on the operation desk, or the control panel on the site. It is not enough only to screw off the fuse wire! ④ If the machine needs other energy like pneumatic, hydraulic, steam and hot water energy, it is necessary to cut off their energy supply or turn off the switch, and eliminate the pressure in the internal pipeline system of the machine. ⑤ As for handling heated or cooled parts and components of the machine, especial care should still be taken for the danger of burning, to prevent any scald. ⑥ If you have pressed the emergency stop switch to stop the machine and you want to reset the switch, so it is not permissible to only re-press this button to restart the machine. ⑦ If some machines are equipped with a local shutdown system, especial care should be taken. Read the instruction manuals attached with the machine carefully. In such machines with a local shutdown system, temperature will rise because pressure or vacuum will occur after they have been used for a period. ⑧ The cleaning, lubricating and oiling of the machine or its parts and components may be 7
carried out only when the machine is stopped. If you have to climb on or enter the machine to do such work, the mandatory provisions shall be made without exception: the power supply of motors must be cut off completely and the switch must be locked, fix the coating drum before entering the Coating System. Attention must be paid to safety measures for climbing. ⑨ Be careful, sampling from inside the machine can never be carried out unless there is not any danger. Usually, the samples can be taken from the pipe under the machine instead of inside machine. ⑩ Clear off the deposited dust, dirties and materials frequently. Keeping the machine clean can enhance production safety and the cleaning level of workshop, and is also beneficial to prevent dust explosion. ⑾ If oil (grease) leakage occurs, clean it immediately and seal well the place where leakage occurs. For oil or grease leaked on the floor will easily bring about hazards to the operators. ⑿ In production operation, the machine must be equipped with safety devices, which may be neither removed and abandoned nor reduced in functions. Otherwise, we are not responsible for any accidents resulted here from, and reserve the right to ascertain where the responsibility lies.
1.8 Explosion Protection: Countermeasures against dust explosion and fire hazard (1) Common cleaning work ① Keeping the working site with combustible dust clean is an important condition for safe production. ② Try not to pile bagged or bulk materials between machines. ③ In order to reduce dust emission to surrounding areas, all conveying devices, air pipe, filtering bag should be kept in good condition. Especially, the unsealing of pipes or top covers should be avoided. ④ In order to reduce dust explosion hazard, dust everywhere must be cleaned out frequently and effectively. ⑤ Keep all motors free of deposited dust. (2) Regular inspection and maintenance ① Check the safety devices such as speed monitor or the like regularly, at least once a week. ② Check and clean the connection of direct-coupling speed reducing motor and machine body, at least once a day. ③ In order to avoid heat generation, it is necessary to regularly check the functions of all bearings, at least once a week, and to regularly fill up lubricating oil.
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(3) Electric apparatus Regularly check the electric apparatus and articles, and special attention should be paid to the following points: ①It is forbidden to use any flashlights and other lamps without shielding or explosion-proof glass. ②It is forbidden to use any lengthened cable or electric furnace. ③It is necessary to immediately repair or replace the electric apparatus and equipment if any failure occurs. ④The cables without conduits are not allowed to be installed on the floor. ⑤ Cut off the power supply of the machine after work. ⑥An electrician should be assigned to check the insulation of all the lines of electric network according to relevant regulations on heavy current, at least once a year. (4) Smoking and welding ① Smoking is forbidden, which is applicable to all workers and staff of the enterprise as well as guests, customers, foreigners and drivers visiting the factory. ②If the tools such as welding machine or soldering lamp (flame soldering lamp) etc. are required for repair or installation, do as best as possible to arrange the work in a special workshop or on a special site. ③If it is necessary to carry out welding or the like directly in production area or storehouse once in a while, written applications must be submitted to a related supervisor in advance for written approval. The above mentioned operations can be carried out only when special safety measures have been taken, such as laying pieces of water soaked canvas or canvas special for covering on the surrounding area and preparing fire extinguishers. After completion of the operation, the welding site and the surrounding area are to be monitored at least for 10h. ④The gas cutting sparks are very dangerous, for people can't see where they will fly on earth. They can cross through the narrow clearance of walls and drop downstairs or to the next rooms, or even fly off 10 m away in distance. If the sparks drop in dusts, fire accidents may occur at any time. ⑤Welding is prohibited on a running conveyor. If the welding work is necessary, shut down the machine first, and then make a thorough cleaning and isolate both sides of the welding site tightly with materials like mineral wool to avoid connecting with other conveying devices, silos or tanks. If the work is to be done on the chutes or conveying pipes, it is necessary to disassemble them or divert their lower ends and seal them to avoid welding sparks entering the conveying pipes or silos.
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(5) Effect of static electricity ① In order to ensure the safety of electric circuits and avoid explosion resulted from spark discharge. ② The paint coat at the electric connections must be removed.
1.9 Other attention points (environmental protection measurements) If you decide not to use the machine any longer after it is used for a certain number of years (about 8-10 years), the measures for environmental protection and reutilization should be taken. (1) Drain the liquids inside the machine (like motor oil, gearbox oil, brake oil and coolant etc.) into special containers and send them to the preparation workshop. (2) The plastic parts shall be picked out for reutilization. (3) The metal parts shall be sorted out so as to be ground or scraped.
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2. General 2.1 Application and adaptability SYPL Continuous Liquid Coating System, which locates behind pelleting and extrusion, is suitable for coating feed pellets with liquefied oil/fat, enzyme, vitamins, anti-oxidants and amino acids etc. The post liquid coating system can protect the heat sensitive nutrition and drugs from damaged by high temperature.
It has been used and popularized in feed mills more and more.
2.2 Features
It is full-automatically controlled by computer, and characterized by few working parameters and convenient operation;
Strong short-time overload capacity, which can adapt to a wide fluctuation of pellet mill production capacity;
The dynamic continuous metering accuracy can be guaranteed by means of static weighing method under differential weighing batch metering principle. The proportion of pelleting capacity versus liquid spray coating amount is very accurate and of high spraying uniformity.
2.3 General outline and main structure feature 2.3.1 Overall structure
This liquid coating system is composed of mechanical components and electronic control components (see Fig 2-1). The mechanical components include: feeding device, SSCJ differential gravimeter, TWLD belt feeder, drum for pellet feed and liquid adding system (see Table 2-1). The electronic control components include: surge hopper level indicator, adjusting system of the gravimeter, frequency converter, and mimic panel for automatic control system. 2.3.2 Working principle
The height of pellet feed in the surge hopper is measured by a level indicator, and feeding or not and how many pellets to be fed are determined by the material level. The inclinable drum is such a piece of equipment through which the feed pellets are coated and scrawl towards the outlet of the drum. Pellets are fed into the drum through a differential gravimeter. The liquid is sprayed according to the percentage (set value) of actual flow rate (discharging rate) of pellet feed, and the liquid spraying speed is adjusted automatically by the actuator. All nozzles are opened, and the liquid can be fully atomized by the compressed-air.
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1. Feeding device 2. Differential gravimeter 3.Conveying section ( belt feeder) 5. Liquid control pipeline
4.Drum
6.Liquid storing and delivering system 7. Automatic control system
Note: The feeding device can be designed on site by user self.
Fig. 2-1 Structure diagram of Continuous Type Liquid Coating System.
2.3.3 Main components and structure features
(1) SCCJ differential gravimeter and TWLD belt feeder When feed pellets are weighed and discharged through the SCCJ differential gravimeter, it can automatically calculate the discharging rate of feeder and determine the output of the frequency converter by comparing to the set value. With a TWLD belt feeder, feed pellets can be conveyed into the drum smoothly and the feeding rate can be adjusted in real-time according the actual capacity. It is characterized by that the static weighing method is adopted to ensure the dynamic accuracy of continuous weighing, guaranteeing the metering accuracy of feed rate and liquid spraying amount.
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Table 2-1 Mechanical components Continuous Type Liquid Coating System
SYPL15C
SYPL25C
SYPL35C
SCCJ difference
Part code
SCCJ25
SCCJ25
SCCJ35
measurement scale
Muyang code
SCCJ001C
SCCJ001C
SCCJ002C
Part code
TWLD35B
TWLD35B
TWLD45
Muyang code
TWLD005C
TWLD005C
TWLD004C
Power(KW)
1.1
1.1
1.5
Part code
SYPL15C.01
SYPL25C.01
SYPL35C.01
TWLD belt feeder
Muyang code Drum assembly
SYPL01291303 SYPL01391307 SYPL01491316
Diameter (m)
0.8
1
1.35
Length(m)
2.4
3.2
3.5
Power (KW)
2.2
3
5.5
Part code
SYPL15C.02
SYPL25C.02
SYPL35C.02
Muyang code Volume(m3) Liquid storing and delivering
Liquid delivering
system
pump(KW) Liquid coating pump(KW) Electric heating (optional)(KW)
SYPL01291302 SYPL01391303 SYPL01491302 1
1
1
2.2
2.2
2.2
0.55
1.5
1.5
2+2+2
2+2+2
2+2+2
(2) Drum assembly The drum makes the material move continuously, and the vaporous liquid sprayed out of the high pressure nozzle and fully contacts the pellet surface that ensures the uniformity of coating and the smoothness of pellet surface, as well as the water durability and digestibility of pellet product. This equipment can be used for coating finished pellet before or after cooling. It is applicable for coating liquid such as oil/fat, molasses, active enzyme, flavoring material, organic acid etc onto the pellet surface.
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Fig.2-2 Schematic diagram of drum assembly Coating pipeline (Fig.2-3) is installed in the drum, and compressed air is supplied through hose, so as to prevent damage form rigid vibration. The unique nozzle adjusting manner ensures the nozzles be in the right position and in right angle. a reasonably set coating zone can make the best use of the compressed air atomizing nozzles and ensure uniform coating.
Fig.2-3 Schematic diagram of coating pipeline
The structure of coating pipeline is related to the specification of coating system. The coating pipeline of SYPL15 C Continuous Type Liquid Coating System is shown as Fig.2-4a. The coating pipeline of SYPL25 C Continuous Type Liquid Coating System is shown as Fig.2-4b. The coating pipeline of SYPL35 C Continuous Type Liquid Coating System is shown as Fig.2-4c.
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Air进气口 inlet
Solenoid valve 喷气电磁阀
Liquid inlet 进油口
Fig.2-4a Structure diagram of coating pipeline of SYPL15C Continuous Type Liquid Coating System. The pipeline consists of two air atomizer nozzles. It is supplied with compressed air from the inlet of one side and liquid from the other side. When starting coating process, first supply air and delay for 3-5s, and then open the valve for supply liquid, and the nozzle start spraying liquid. When stop coating, close the liquid valve first, and then close the pneumatic valve for 3-5s.
Air inlet 进气口
Solenoid valve 喷气电磁阀
Liquid inlet
进油口
Fig.2-4b Structure diagram of coating pipeline of SYPL25C Continuous Type Liquid Coating System. The pipeline consists of two air atomizer nozzles. It is supplied with compressed air from the inlet of one side and liquid from the other side. When starting coating process, first supply air and delay for 3-5s, and then open the valve for supply liquid, and the nozzle start spraying liquid. When stop coating, close the liquid valve first, and then close the pneumatic valve for 3-5s.
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进气口 Air inlet
Solenoid valve 喷气电磁阀
Solenoid valve 喷气电磁阀
Solenoid valve 喷气电磁阀
Solenoid valve 喷气电磁阀
Solenoid valve 喷气电磁阀
Liquid 进油口inlet
Fig.2-4c Structure diagram of coating pipeline of SYPL35C Continuous Type Liquid Coating System. The pipeline consists of five SUE45 air atomizer nozzles. It is supplied with compressed air from the inlet of one side and liquid from the other side. When starting coating process, first supply air and delay for 3-5s, and then open the valve for supply liquid, and the nozzle start spraying liquid. When stop coating, close the liquid valve first, and then close the pneumatic valve for 3-5s. Table 2-2 Nozzles for SYPL No.
Model
Nozzle type
Qty
1
SYPL15C
1/4JN-SS+SUE45-SS
2
2
SYPL25C
1/4JN-SS+SUE45-SS
3
3
SYPL35C
1/4JN-SS+SUE45-SS
5
Table 2-3 Pressure flowmeter of nozzle Nozzle type
Liquid pressure (MPa)
Liquid flow rate
Air pressure(MPa)
Air consumption
SUE45
0.15
280
0.56
600
Note: Unit of liquid flow rate: L/h, Unit of air consumption: L/min.
(3) Liquid control pipeline (Fig.2-5) The liquid control pipeline is mainly composed of a flowmeter, a pneumatic ball valve, a coating valve, ball valves and a pressure gauge. See Fig.2-5 for the structure of liquid control pipeline. When calibrate the liquid adding amount (or the metering accuracy of flowmeter), put a volumetric tank at the outlet of flowmeter, open the ball valve for metering flow rate, and close the coating ball valve. After a certain time, calculate the liquid increase amount in the tank and the error of metering controller, and then have the
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systematic error correct. The flowmeter and frequency-variable pump forms a closed loop system, who serves the function as stabilizing the liquid flow rate at the required value. When the metering accuracy of the whole system is adjusted in normal range, open the coating ball valve and close the metering ball valve on the draining pipeline. At this time, the liquid control pipeline can be put into normal production.
Pneumatic ball valve Blowing Hose
Pressure
Ball valve Flow meter
Filter
Fig.2-5a Structure diagram of liquid control pipeline for SYPL15C and SYPL25C
Fig.2-5b Structure diagram of liquid control pipeline for SYPL35C
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(4) Liquid storing and delivering system The liquid storing and delivering system is composed of an oil heating tank, a filter, a gear pump, a motor, an overflow valve, a solenoid valve, pipelines, pipe fittings and so on.
Fig.2-6 Structure diagram of liquid storing and delivering system There are two heating methods for oil/fat in oil heating tank, one is steam heating controlled by a steam solenoid valve, another is electrical bar heating (3 optional electrical bars) to heat oil/fat. The liquid temperature is automatically controlled by a temperature control instrument through a temperature sensor; the liquid volume inside the oil tank is displayed and controlled by a glass tube liquid level indicator and a liquid level control instrument. A blow-off valve is mounted at conic bottom of the tank for discharging residual liquid and dirt. A gear pump with a sex-pole motor is used as power for this system; The overflow valve in the system is used for load-off and safety protection. Two-stage filtration is used for the system to effectively reduce the effect of dirt and foreign matters on the gear pump, and to solve the blockage trouble for flowmeter and nozzles. The filter shall be cleaned regularly, as shown in Fig 2-7, you only need to open the top cover and hold the handle, and then take out the filter screen to pour out the foreign matters.
1.Handle of filter screen
2.Filtering tank
Fig.2-7 Schematic diagram of filter
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2.4 Production process (feeding and discharging) (Fig.2-8) 2.4.1 Feeding
(1) Feeding feed pellets into the drum. The pellet to be coated is conveyed into the surge hopper (001). Make sure the surge hopper of enough storing volume and equipped with upper level indicator and lower level indicator. For the sake of convenient maintenance of surge hopper, the surge hopper needs to be detachable. When feeding, pellets from surge hopper passing through differential gravimeter (002) and belt feeder (003) and fed into the drum. (2) Liquid coating. Liquid to be coated from the liquid storing and delivering system (004) passing through the liquid control pipeline (005) and finally spraying into the drum (006) continuously. 2.4.2 Discharging
After coating, feed pellets are sent to the subsequence process continuously by the conveying device (007). 001
003
007
005 004
006 Fig. 2-8 Diagram of production process
19
3 Specification of Coating System 3.1 Basic Specifications 3.1.1 Working condition
(1) Material characteristics Particle size of materials: Length of edge shall be less than 30mm Bulk density: 0.15~0.8 t/m3 Liquid addition: 0.5~6% (2) Environmental conditions The ambient temperature for the continuous liquid
coating system is -5°C～40°C, when
it is below 10°C or when use animal oil/ fat which is liable to freeze, users mounted fluid pipelines shall carry out heating and warmth keeping measures by themselves. ② Relative humidity range: 30%~85% ③ Altitude: less than 1000m ④ Temperature range for normal transportation is:-25～55℃ ⑤ Air supply for normal use is above 0.6Mpa ⑥ Electric supply for normal use: AC380V Note: if the actual condition fails to accord with the environment condition ①, the temperature shall be adjusted properly. If it fails to accord with conditions ② and ③, a speed reducing motor shall be customized. If it fails to accord with condition ⑥, please refer to the motor nameplate. (3) Configuration conditions ① The liquid coating system should match the equipments before and after it in process flow. ② Configuration shall be carried out within the power supply for normal use (permissible voltage deviation ±5% and frequency deviation ±1%).
③The user must configure an over-voltage protection device for the power supply.
20
(4) Noise testing during normal production
Table 3-1 Noise testing condition and method
Noise—pressure level
LP≤
-
dB（A）
Idling noise—power level
LW≤
-
dB（A）
Noise on test-surface—pressure level
LP=
85
Test-surface specification
LS=
-
Equivalent noise—power level
Lweq=
21
dB（A）
dB（A）
-
dB（A）
3.2 Main technical parameters 3.2.1 Technical parameters of liquid coating system
(1) Liquid addition ratio is usually set at 0.5%-6%, and can be adjusted at will as required; (2) Liquid metering accuracy＜1％, pellet metering accuracy＜1％; (3) Other technical parameters and performance indexes (see Table 3-1). Table 3-1 Main technical parameters and performance indexes Model
SYPL15C
SYPL25C
SYPL35C
Capacity, t/h
1～8
2～15
10～25
Drum motor, kW
2.2
3
5.5
Feeding motor kW
1.1
1.1
1.5
Coating motor, kW
0.55+2.2
1.5+2.2
1.5+2.2
Note: Bulk density of feed pellet is 0.75t/m3.
3.2.2 Model composition and its meaning
(1) Model composition of Continuous Type Liquid Coating System: S
YP
L
□
□
× □ Qty of coating pipe: indicated by figure, not indicate if n=11 Upgrade code: indicated by A, B, C...; Specification code: 15, 25, or 35 Model Code: Continuous type Machine code: Liquid coating system Industry code: Feed processing machinery
(2) Model composition of TWLD belt feeder: T
WL
D
□
□ Upgrade code: indicated by A, B, C... Product specification: effective width of conveying belt (cm) Model Code: Belt type Machine code: Feeding equipment Industry code: Common machinery
22
(3) Model composition of SCCJ difference measurement scale: S
C
CJ
□
□ Upgrade code: indicated by A, B, C... Product specification: handling capacity per hour (m3) Model Code: difference measurement scale Machine code: Feeding equipment Industry code: Common machinery
23
4 Transport, installation and adjustment 4.1 Transport Warning! Transport can only be carried out by the trained personnel who are skillful in this work.
(1) Hoisting The SYPL(C) Continuous Type Liquid Coating System is hoisted in separated assemblies. It is necessary to check whether the hoisting device is able to bear the weight of equipment or not. The angle between two hoisting ropes should not exceed 65°. Hoist the machine by the hoisting eyes (totally four ones) on the machine body (see Fig.4-1 Hoisting diagram of different assemblies of SYPL(C) Continuous Type Liquid Coating System). Adjust the hoisting ropes to make the bottom of the machine level after lifting up. When moving the machine horizontally, make sure the moving speed not exceed 0.5m/s. The hoisting rope should be able to bear the weight of the machine to be hoisted (refer to Table 3-2 Main technical parameters).
Fig.4-1 Hoisting diagram of different assemblies of SYPL(C) Continuous Type Liquid Coating System
(2) Transport ① When leave the factory, whether to use a packing case is determined according to actual conditions. ② If a packing case is not used in transport, rain-proof measures shall be taken and it shall be prevented against collision and overturn of the equipments. ③ If a packing case is used, the complete machine and accessories shall be fixed securely in the case and a certain distance shall be reserved from the plate of the packing case, so as to avoid collision and damage in transport. If the height is in excess of the standard, the whole packing shall be separated into 24
parts. ④ During transport, any overturn, intense pressure or collision are not allowed on the machine body. ⑤Instruments such as: electric heater (optional), pressure gauge, and platinum resistance thermometer sensor should be packed individual carefully and installed onto the machine only after delivered to site, so as to protect them from damage during transportation.
Protect the liquid coating system for collision
during hoisting and transportation.
(3) Storage ① When the machine equipment is to be stored in the open air, the facilities for prevention of rain, sunshine and water accumulation should be available. When the machine equipment is to be stored indoors, the measures for ventilation and damp proof shall be taken. ② The equipment should be stored in ventilated, dry and cool place for long-time storage, and damp proof measures should be taken, the exposed surface without painting should be painted with rust-proof oil.
4.2 Mechanical installation (1) Unpacking and inspection ① When the machine arrives at the destination, unpack it and check careful if there is any phenomenon like collision or friction occurs during the transportation. ② Count the documents and accessories attached compared with the packing list. (2) Necessary drawing for installation ① Scaled drawing for the installation of SYPL(C) liquid coating system, see Fig.4-2 a, b: ② Installation requirements a The mixer is delivered generally as a complete set. Firstly check if there is any damage during transportation when unpacking; b Installation field should be firm and roomy. When installation, leave an enough space for maintenance and replacement of fittings; c)（Please refer to the scaled drawing of the liquid coating system installation provided when ordering） d) The proper maintenance platform and staircase should be provided if necessary, the staircase shall be equipped with guardrails. （See Fig.4-2 Schematic diagram for machine installation） e) This liquid coating system should be fixed on a flat concrete base floor or a steel frame with enough strength by fixing onto the floor with foundation bolts. Or else, it will result in severe vibration or accident. f) Please refer to Table 4-1 for the tightening torque of the foundation bolts. Any accident caused by unsetting machine is out of Muyang's responsibility.
25
Table 4-1 Tightening torque of foundation bolt Bolt spec.
Tightening torque(N.m)
Remarks
M12
65
Machine base
g) Properly feeding device should be installed on the feeding inlet of the liquid coating system. The feeding device can be designed and fabricated on job site, however, feeding device of a volume at least 2m3 should be guaranteed for SYPL15C, and a volume at least 3m3 should be guaranteed for SYPL25C, a volume at least 5m3 should be guaranteed for SYPL35C; h) Adjust the rotating direction of the drum to make it in accordance with that pointed by the arrow on the machine housing; i) Adjust the inclination angle α of the pellet drum into 5° ( normally adjustable in the range of 0～7°), then adjust the position of the gear motor to properly tension the belt; j) After installing the differential gravimeter, remove the fixing bolts to make the weighing cell in working condition. (Note: do not climb onto the differential gravimeter) k) Check the opening and closing condition of the feeding gate of differential gravimeter and adjust the pressure of cylinder and the position of limit switch to keep the feeding gate closed tightly and opened easily. l) The differential gravimeter is coupled with the belt conveyor (or screw conveyor), and a flexible connection is adopted between the upper storage hopper and the lower feeding hopper of drum. It is required to keep all connectors sealed and free of dust. m) All elements of the liquid coating system have already been assembled before delivery; the user should keep it intact without any change.
26
775
1750 min800
2400 min800
A
255
305 335
出料
min800
B
765
4Xφ18
708
10Xφ10
947
进料
1918
min800 3200
1954
8Xφ10
技术要求 1.设备所配料仓需要两个料位计和一个振动气锤；
Outlet
2.所配料仓容积不得小于2m3。
8Xφ14
1000 920
DN20 D进口 DN15 接D进口
min1000 q 374 344 q 294
344
Feeding inlet
180 1633
686 846
520 490 440 200
1257 1300
746 906
A
2775
1750 4044
3025
248 298 328
出料
min1000
A
765
4X?18
708
进料
920
8X?10
min800
2000 913
160
q 374 344
q
920 1000
294
R11/2
4X?18
344
4310
min800 2400 1876 min800
D出口 DN15 接D出口
1500 1457
技术要求
8X?
1.设备所配料仓需要两个料位 2.所配料仓容积不得小于3m3
669
接D进口
min800
D进口
983 830
进料
q 374 344 q 294
930 1010
8X?10
4315
3147
2867
2440 min800
MIN1500KG
出料口
min1000
1837
技术要求
4550
16X?14
10X?10
B
A
765
328 1.图中双点划线画出的上料仓按用户场地自行设计； 2.C出口和D进口的其它连接管道根据安装现场的设备布置由工艺定尺寸； 3.由工艺定的尺寸应遵循接点尽量紧凑的原则； 4.管件连接处使用密封生料带； 5.管件连接好后应使用1.6MPa压力试压,不得有渗漏现象； 6.该系统在使用时应在储油罐外包以石棉或硅酸铝等保温材料； 7.管道外根据不同客户要求，可以选择使用VS×20-2自调控伴热带并包以 保温材料。
520 490 200
1205 1365
1290 1450 1757 1800
4X?18
248 708
1790 min800
1900
4X?18
344
min800
4.3 Electric installation (1) Electric connection ① For the schematic diagram of electric control see Fig.4-6 ②The wiring chutes of wires from site to electric cabinet in central control room must be protected. ③The electric cabinet should be kept clean and free of dust.
2 1
4
3
1. SYPL Series Continuous Liquid Coating System 2.Electric Cabinet 3.Cables for junction box 4. Cables for motor
Fig.4-6 Electric wiring diagram of SYPL Series Continuous Liquid Coating System
(2) Schematic diagram of electric control ① For the schematic diagram of the SYPL Series Continuous Liquid Coating System see Fig. 4-8 to 4-14. ② The coating system should be equipped with a relevant starting device, a safety guard and electric instruments. ③ All the motors and electric control panel must be well earthed. ④ The relevant instruction manuals should be taken as the criterion for installing and using the electric elements, which are required to run safely and reliably. ⑤ User should provide the cables to connect the motor and junction box to the electric cabinet.
30
AC 3P / N / PE 380V & 50Hz
L1 L2 L3
QFa L31
QF2 L12 L22 L32
L21
QF1 L11
A1 B1 C1 N PE
Danfoss L1; L2; L3 V.F.D U; V; W
VVVF1 VLT-2800
KM2
KM1
U2 V2 W2
ABB
V1
W1
U1' V1' W1'
L11 121 131
U1
VVVF1 ABB-ACS355
U1; V1; W1 V.F.D U2; V2; W2
M1
M
3～
M
M1'
3～
U1 V1 W1
①
M2
②
M
3～
③
Fig. 4-8 Schematic diagram of electric control of SYPL Series Continuous Liquid Coating System (a) Note: ①Feeder motor (frequency conversion); ②Fan; ③Mixing motor; The connection of Danfoss frequency converter is adopted in above drawing. For the connection of ABB-ACS355 frequency inverter refer to method as shown in the bottom left of the dashed box.
31
L1 L2 L3 PE
L14 L24 L34
L15 L25 L35
QF5
QF4
L33
L23
L13
QF3
Danfoss L1; L2; L3 V.F.D U; V; W
VVVF3 VLT-2800 ABB
V3
W3
U3' V3' W3'
W4
U4 V4
U5 V5 W5
L13 L23 L33
U3
KM5
KM4
KM3
VVVF3 ABB-ACS355
U1; V1; W1 V.F.D U2; V2; W2
EH1+EH2+EH3
M3
M
3～
M
M
M3'
3～
U3 V3 W3
②
①
M4
3～ N
③
④
Fig. 4-9 Schematic diagram of electric control of SYPL Series Continuous Liquid Coating System (b) Note: ①Oil jetting motor ②Fan ③Oil-conveying motor ④Electric heating rod. The connection of Danfoss frequency converter is adopted in above drawing. For the connection of ABB-ACS355 frequency inverter refer to method as shown in the bottom left of the dashed box.
32
L1
PLC
OUT
QF5
L1-2
N
①
127
128
129
130
131
YV11
KM1
KM2
KM3
KM4
KM5
②
③
④
⑤
⑥
KA2
⑦
⑧
KA3
⑨
YV7
YV1
YV2
FU15
YV3
FU16
126
FU14
125
FU13
124
YV13
FU12
123
YV12
FU11
122
QF5
FU10
121
QF4
FU09
120
QF3
FU08
119
QF2
FU07
118
QF1
FU06
117
115
FU05
114
FU04
113
FU03
112
E-STOP
F02
111
FU01
116
L1-1
YV4
YV5
KA4
⑩
11
12
13
14
15
16
17
18
Fig. 4-10 Schematic diagram of electric control of SYPL Series Continuous Liquid Coating System (c) Note: ①Emergency stop ② Feeder motor ③Drum motor ④Oil pump ⑤Oil-conveying motor ⑥Electric heating rod ⑦Steam solenoid valve ⑧Startup of weighing instrument⑨Stop of weighing instrument ⑩Malfunction alarm Pneumatic ball valve of coating pipe valve 1 #
⑪Oil jetting solenoid valve ⑫ Cleaning solenoid valve ⑬Pneumatic gate solenoid valve ⑭Solenoid
⑮Solenoid valve 2 # ⑯Solenoid valve 3 # ⑰Solenoid valve 4 #, Solenoid valve 5 #; Air jetting solenoid valve 2～5 # only suitable for SYPL35C.
33
KA12
KA13
KA14
KA16
SQ3
SQ4
I2.3
SL1
14
I2.2
SQ2
13
12
I2.1
SQ1
11
I2.0
KM4
I1.5
KM3
⑨ ⑩
I1.4
KM2
⑧
⑦
I1.2
I1.1
DC 24V
I1.0
～ －
KM1
⑥
106
I0.0
AC 220V
⑤
U7
SF1
U3 200W
④
I0.6
QF6
③
I0.5
②
①
I0.4
24V+
I0.3
DC24V
L1
①
PLC
N
IN
DC0V
Fig. 4-11 Schematic diagram of electric control of SYPL Series Continuous Liquid Coating System (d) Note:①Flow rate monitoring; ② Motor for conveying oil; ③ Motor for spraying oil; ④Drum motor; ⑤Belt motor; ⑥ Surge bin high level;⑦Surge bin low level; ⑧ Level switch of liquid; ⑨Output of instrument pause; ⑩ Output of instrument stability; ⑪ Output of instrument running; ⑫ Alarm of instrument weighing; ⑬ Open gate in place; ⑭ Close gate in place;
34
24V+
KM4 241
18
12
V.F.D
U2 1
246
2
27
53
251
18
55
250
12
V.F.D
U4
VLT-2800
245
1
2
27
VLT-2800 53
253
55
252 KA2
KA3
KA16
214
KA14
212
KA13
211
KA12
210
PLC OUT
I0.7
PLC OUT
222
242
221
KM2
①
②
③
④
0V
⑤
⑥
Fig. 4-12 Schematic diagram of electric control of SYPL Series Continuous Liquid Coating System (e) Note: PLC frequency input and alarm; ① Output of instrument pause; ② Output of instrument stability; ③ Output of instrument running; ④ Output of instrument alarm; ⑤ Input of instrument running; ⑥Input of instrument stop; 35
210
212
214
222
OUT1
OUT4
OUT2
OUT5
OUT3
OUT6
0V
⑤ ⑥ ⑦
OUT7
OUT8
N
OUT9
L
G
20mA+ 217
N
20mA216
GND
RX/B
RX/A
E
SIG290
SIG+
SN-
291
EX292
SN+
EX+
GM8806A1
293
L1-2
OUT10
IN4
U5 E-STOP
④
IN1
24G
IN2
+24
IN3
24V+
③
221
②
L1
211
①
N
Fig. 4-13 Schematic diagram of electric control of SYPL Series Continuous Liquid Coating System (f) Note: ①Emergency stop; ②Input of instrument stop ③Input of instrument running; ④Output of instrument stability; ⑤Output of instrument pause; ⑥Output of instrument running; ⑦Alarm of instrument weighing
36
U6
B41783 G
G
G
G
290
S-
S-
S-
S-
291
S+
S+
S+
S+
292
E-
E-
E-
E-
293
E+
E+
E+
E+
1#
SP1
2#
SP2 ①
3#
SP3 ②
③
Fig. 4-14 Schematic diagram of electric control of SYPL Series Continuous Liquid Coating System (g) Note：① Weighing cell 1; ② Weighing cell 2; ③ Weighing cell 3;
37
Attention!
1. All cables shall be with a specification of 0.75mm2. 2. The user must configure an over-voltage protection device for the power supply. 3. In order to ensure safety, it is necessary to install a safety switch nearby the coating system (an emergency stop switch or a lock-up maintenance switch). 4. The above schematic diagrams are only for the independent operation of the SYPL Coating System, the interlocking of the coating with its upstream and downstream processing equipment should be taken into account in process design. 5. The relevant instruction manuals should be taken as the criterion for installing and using the electric elements, which are required to run safely and reliably. 6. Check the wiring at least once a year to ensure the insulation of the electric wiring in good condition.
38
5 Running 5.1 Attention points for operations Note: When operation is implemented on the machine, besides the safety points specified in Chapter 1, the regulation items of the owner's enterprise shall also be obeyed. (1) Pay attention to the place where the dangerous marks are attached. (2) The safety protection devices can never be dismounted, covered or overlapped at will.
5.2 Functional inspection prior to test-run (1) Before leaving the manufacture plant, a perfect test-run has already been conducted to the machine. (2) The initial test run in the user’s factory cannot be done until following checks have been conducted. ① There should be no abnormal contact of the liquid coating system or between the other accessories. ② All connecting points must be checked carefully to ensure there is not any looseness. ③ Check the pellet drum for flexible rotation, and make sure there is
not any abnormal sounds
resulted from blockage, collision or abrasion etc. ④ Check the pellet drum for the rotating directions matching with that indicated, for this it may need to start the motor for a short time; meanwhile, check the motor for any change in its rotating direction. Check the rotating direction of the pumps with the same method. The rotating direction is marked on the pump. ⑤ Emergency stop switch Check whether the emergency stop switch is in good working condition or not. ⑥ Check whether the heating process and the temperature of the liquid is well controlled. ⑦ Check whether the solenoid valves move freely or not. ⑧ Check whether the signal of flow rate is input correctly or not. ⑨ Check whether the control signal of liquid addition is sent out correctly or not. Make sure there is no miss sending or missing sending.
5.3 Commissioning ① Before each commissioning or after each unexpected interruption, the residual materials in the pellet drum must be emptied, and the drum must be cleaned. ② Only when the access door is closed and other related equipment is running, the coating system can be started, and do not feed materials into the pellet drum until the rotor is running normally. 39
③ Inch the liquid coating system to check for any abnormal situation. If any, correct it. ④ The temperature rise of bearing should not higher than 35℃ when ideal running for 0.5h, and the lubricating and sealing function still perform well. ⑤ Check the running condition of the motor, which should be consistent with that required in its instruction. ⑥ Screws, fasteners and lubricating points should be checked for normal performance if
ideal
running for 1 hour.
5.4 Use and operation ① The operator should well know the structure, performance and operating methods of the machine, and have received the training organized by Jiangsu Muyang Group. ② Feed pellet should be fed evenly in production and may not be sometimes more and sometimes less, so as to ensure the motor running under a rated load. ③ After working, the pellet drum must make an idle run for 1-2 min. prior to shutting down, so as to discharge all materials out of the machine. ④ If violent vibration occurs when the drum is running, it should be stopped immediately to find out the cause and may only be restarted for work until the fault is eliminated. ⑤ The temperature raise (refers to the risen temperature above ambient temperature) of the bearings should not be higher than 35℃, and the maximum temperature should not be higher than 70℃ (ambient temperature should not be higher than 40℃). ⑥ Carry out necessary cleaning and inspection when each shift of work is finished. ⑦ Materials cannot be fed until the drum is running normally. Muyang refuses to responsible for all
accidents that result from starting machine with load Additives should be added in when
half of the major materials has entered into the machine, and oil /fat should not be sprayed until all materials have entered the machine. Keep spraying for a certain period of time after spraying, and then discharge. ⑧ When the machine is stopped and not to be used, oil/fat must be emptied out of the liquid pipe, so as to avoid pipe blockage due to oil solidification. ⑨ Metal or other large impurities should not be included in the material, or else the drum may be damaged. ⑩ The speed reducer, cylinder and other accessories should be used in accordance with the relevant stipulations in their operating instruction manuals. ⑾ After a period of using, check the screws, nuts, and lubricating points for normal performance, and tight the other fasteners as well. ⑿ Avoid overload running, so as to protect the rotating parts from broken. Feeding amount 40
should strictly accord with that required in Table 2-2. Accident resulted for overload is not Muyang's responsibility. ⒀ Before each restart, any residues in the drum must be emptied. Material cannot be fed until the drum is running normally.
5.5 Operation of control system 5.5.1 Control system composition This control system consists of the following units, and any unit’s irregular working will result in improper working of the production system. (1) Programmable logic controller (2) Human Machine Interface (HMI) (3) Weighing instrument (4) Feeding frequency controller 5.5.2 Attention points (1) The input and output signals of all equipment are transmitted to the PLC. To check the working condition of each piece of equipment by checking address list. (2) After booting, HMI automatically show up on the screen, the power light and running light on the panel are turned on. HMI has been set to automatically screen saving state if without operation in 100s. It is only allowed to press the F6 or F7 key to activate the liquid crystal screen so as to avoid the false operation of equipment. (3) When the feeder motor failure to run, check whether there are indicators (such as alarm light on, error code prompt, etc.) of frequency converter failure, and check for correct settings. (4) Attention points for operating the touch screen: The operation buttons on touch screen can only be touched by fingers instead of pencil, pen, etc. Meanwhile, since the touch screen is vulnerable and sensitive, it should not be touched too hard, or else it will lead to a shorter serve life. 5.5.3 Operation procedures (1) Switch on the power supply in cabinet, the system begin self-checking, and the operation menu appears on the screen after a few seconds, as shown in Figure 5-1:
41
Fig. 5-1 Operation manu (2) Enter into parameter setting screen (as shown in Fig.5-2a, b, c), check whether the set parameters are correct or not. If revise needed, please press button “ input permission”, then move the cursor by touching “UP” or” DOWN” key to the data column which need to be modified, input data by number key, and press “enter” key to confirm. In this case, if the data input is a reasonable range, the number keys will be hidden automatically, or else the data cannot be accepted by the system. There are screen switching keys prompting on the upper left and the lower right of the screen.
42
Fig.5-2a Window of parameter setting 1
Fig.5-2b Window of parameter setting 2 (SYPL15C)
43
Fig.5-2c Window of parameter setting 2 (SYPL25C)
(3) After data input and confirmation completed, press button “Manual/ Automatic” to enter into automatic production screen. When the bottom is switched to “Automatic”, the coating system will be started to production automatically, and when it is switched to “Manual”, the machines can be started up one by one manually. (4) For working status screen, see Fig.5-3a, b. The details are shown as follows: ① The button “Manual/ Automatic” can only direct real time working status rather than start or stop the equipment. To stop equipment must enter into “parameter setting” screen and press the button “Manual/ Automatic”. ② Press button “clean data” to realize zero cleaning of oil accumulative weight; ③Press button “pause” to set the working status into pause state, and if press again it will continue with automatic work. ④ When working status is in manual state, each piece of equipment can be started or stopped alone.
44
Fig.5-3a Window of working status (SYPL15C)
Fig.5-3b Window of working status (SYPL25C)
45
5.5.4 Parameters description (1) Oil adding proportion: set oil adding amount (2) Flow rate upper limit: set the maximum feed rate (3) Flow rate lower limit: set the minimum feed rate (4) Weight upper limit: set the maximum weight of feed in the hopper. (5) Weight lower limit: set the zero range of the weight of a empty hopper. When startup, automatic production is allowed if the load higher than the value. And during production, if the weight of feed in the hopper is less than this value, the feeding gate will be opened to let feed flow into the feeding hopper. (6) K1, K2: The flow rate of every nozzle has been calibrated. (7) Delay time for drum to shutoff (s): after the “Automatic Production“ stopped for the delay time, the drum be stopped. (8) Material level adjusting time(s): time for adjusting the flow rate of nozzles when the material level is full or empty with feed. (9) Kp, Ti: control parameter. It is not allowed to change the settings at will after adjustment. ( adjustment can be done under the manufacturer’s guidance ), the recommended value is: Kp: 0.1～0.5, Ti: 16～32. 5.5.5 Other description (1) The system will be shut down immediately if the load is less than lower limit for more than 20s. (2) For the last batch of feed, if its weight doesn’t reach the upper limit, the value of upper limit can be adjusted below the current weight level. The material shall be continuously regulated till emptying material, and then the equipment can automatic shut down. (3) When the system is in manual state, motors can be opened to clean out residuals according to the following order. Drum motor
Variable-frequency feeding motor
Feeder gate
(4) When starting the equipment, if the tare weight of hopper greater than lower limit, the computer will alarm to remind the operator of residues inside the weighing hopper. Handling method: ①discharge the residues and then press the “clear alarm” button to continue the working procedures; ②Set the lower limit greater than the displaying weight on instrument and then press the “clear alarm” button to continue the working procedures. (5) In production, the yield can be adjusted. Press the “plus yield” key, the nozzle will be turn up a level and the corresponding feed rate will be increased. Press the “minus yield”, the nozzle will be turn down a level. New order for capacity adjustment will not be accepted within 10s after press the button for above mentioned adjustment. And when feed flow is will accordingly reduced or feed is fed into the scale hopper, the order for capacity adjustment cannot be accepted as well.
46
6 Inspection, repair and maintenance 6.1 Attention points for inspection, repair and maintenance Besides those mentioned in Chapter 1, following attention points should be obeyed when carrying out inspection, repair and maintenance. (1) Whenever inspection, commissioning, repair and maintenance are to be done the power must be cut off first. (2) Directly open operating gates and air inlet only can be done when the power is off and the machine is completely stopped. (3) Only trained technical personnel is allowed to do works with danger-potential such as parts replacement and repair. (4) The replacement or maintenance of electric elements should only be done by trained personnel. (5) The machine can only be started when all protection devices, including cover plate, protecting hood, guard grating, etc. are installed and in good order functionally. (6) When the safety guard shields or access doors have to be opened or the safety devices have to be disassembled in order to inspect, adjust, repair and maintain the equipment or replace the parts, please well negotiate about the required safety attention measures and work out the safety countermeasures prior to the operations and then carry out the inspection work. (7) Be sure that the above said safety devices and guards are installed to their positions after inspection, adjustment, repair and maintenance. (8) When operation, installation, repair and maintenance, please be sure the execution mark boards [ In Process of Maintenance and Inspection] are placed on the workshop gateway, in front of the electric control cabinet in the control room and near the mixer respectively, so as to let other people know about it and prevent the motor from accidental staring. (9) Attention! Improper operation and maintenance may cause accident.
Note: The machine must be operated in the light of operating regulations, and necessary checking and cleaning should be conducted for each working shift. The internal of mixer could be cleaned by flushing with material such as corn. It can also be cleaned by blowing with air if an air-sac blowing device is adopted.
47
6.2 Daily inspection and regular inspection In daily and regular inspection, stop the machine rapidly and take on proper measures in case of any abnormality in machine operation. Re-use the machine after confirming that the machine is recovered to normal operation. 6.2.1 List of daily inspection items (prior to each running or during each running) No.
Position
Items
Cycle
Method
1
Air hose
Air leakage
Everyday
Listening
Check for any abnormal noise
Everyday
Listening
Check for any vibration
Everyday
Inspection
Check for any abnormal noise
Everyday
Listening
Checking
Everyday
Thermometer
Checking
Everyday
Inspection
Checking
Everyday
Thermometer
Checking
Check for any abnormal noise
Everyday
Listening
Checking
Electric current
Everyday
Ammeter
Cleaning
Check for normal execution
Everyday
Inspection
Check for liquid leakage
Everyday
Inspection
Everyday
Inspection
2
3
Machine
Bearing
Check for temperature lower than 80℃
4
Pressure guage
Check for pressure rising Check for temperature lower
5
6
7
Motor
Reducing motor Solenoid valve
8
Pipeline
9
Nozzle
than 80℃
Check Whether the liquid is atomized
48
Solution Repair and correct it Checking Repair and correct it
Repair and correct it Repair and correct it Cleaning
6.2.2 List of regular inspection items No.
Position
Items
Cycle
1
Machine appearance
Cleaning
2
Liquid tank
Cleaning
Every month
3
Filter
Filtering out impurities in
Every two
the liquid
weeks
4
Inside the drum
Every two weeks
Every two
Residues
weeks
Method
Solution
Observing
Cleaning
Cleaning
Draining
Observing
Cleaning
Cleaning
Cleaning
Cleaning
5
Filling grease
Chain and sprocket
Check whether the
wheel
tension state is in good condition 6
Sealing elements
Cleaning
Belt and belt pulley
tension state is in good condition
8
Shaft coupling
9
Nozzle
weeks Every two
connection
weeks
blockage
Cleaning
Every two
Check for reliable
Check the nozzle for
Adjusting
weeks Every month
Check whether the 7
Every two
Every week
Adjusting
Cleaning
Note1) The above-mentioned cycle applies 12h a day and 25 days a month. Customers can adjust it by themselves according to actual conditions
Note2) Three frequently-used greases for lubricating bearing : ①LITEAEP6-077（ASEOL） ②BEACOMPZ（ESSO） ③ARALUBHLP (ARAL) Gear motor: ISO VG220
49
Note 3) List of current for drums of different power Model
Rated power
Rated current
Working current
SYPL15C
2.2KW
5.2 A
<4.8A
SYPL25C
3KW
6.8 A
<6.3A
SYPL35C
5.5KW
11 A
<10A
Note: 1.The above mentioned working current is the current of the drum when normally running. 2. If current of motor is larger than the normal working current, it is needed to check the bearings of roller and make sure the mixer is not overloaded. 3. Exclude the momentary current of machine when startup, and feeding material.
6.2.3 Machine stoppage
(1) Before carrying out any maintenance or repairing work, the machine and other related equipment must be shut down. (2) When the machine is under stoppage, attention must be taken to prevent the coating system from being started by any accidental starting mode. 6.2.4 Mechanical maintenance
(1) Lubricating grease should be replaced regularly for each bearing; the lubricating grease applied should be the sodium base grease (GB492-65) Zn-3. (2) When the speed reducer has been operated for 500 h after the first lubricating, the grease shall be replaced, and afterwards change the grease once after a half-year continuous operation (8 h working system). If the operating time is long, the intervals of grease changing can be shortened properly, refer to the operation manual of speed reducer; (3) All components of liquid adding pipeline shall be maintained according to the operation manual; (4) The system shall be cleaned to avoid any blockage or corrosion if long time halt 6.2.5 Pneumatic maintenance
(1) Clean the dust accumulated in the driving mechanism regularly.
(2) Clean the filter core, water cap and oil cup regularly.
(3) The metal parts should be cleaned with mineral oil, and the rubber parts with soap liquid. Both the oil and water cups should be rinsed in the petroleum solution, but not in acetone, ethyl acetic ester or toluene solution etc. 50
(4) Check the oil level of the atomizer regularly, and supply it with oil in time once it drops to close the low-level. It is suggested to adopt 1# turbine oil ISOVG32 (no additive) but not engine oil or spindle oil. (5) Check the water level of filter regularly, drain out water in time if water level rises to approach the filter core, and then close the draining valve immediately when little water is left in the filter. (6) All the parts should be handled gently to avoid any collision when disassembling.
51
6.3 Malfunction and troubleshooting Note: If the machine is suddenly stopped during operation, the motor should be restarted only after the materials have been discharged. Start up the Mixer with load is not allowed. (1) Malfunction of main shaft, bearing and seal strip, refer to Table 6-3. Table 6-3 Malfunction and troubleshooting of main shaft, bearing and seal strip Trouble
Causes The nut of
Solution
seal strip is
Material leakage at
loose
shaft end
The seal at shaft end has
Tightening the nuts
Replace with a new seal.
been aged.
(2) Abnormal noise during mixing , refer to Table 6-4
Table 6-4 Malfunction and troubleshooting for abnormal noise during mixing Trouble
Causes
Solution (e.g.)
The fixing screws of motor fan are unfastened Friction
between
fan
blades and its hood. There is dirt on the fan hood Abnormal
noise
Tightening screws.
Adjust the fan hood
Clean up the dirt
from
motor fan during Coating
The
blades
of
fan
is
damaged Machine
oil
for
motor
bearing is not enough
Replace the blade Fill with proper amount machine oil or
of
butter
Replace the bearing or the Motor bearing is damage
motor (This is the most unlikely situation)
Abnormal
noise
from
reducing motor ( not from
Bad lubricating
Replace the grease
the fan)
52
(3 ) Vibration during coating, refer to Table 6-5 Table 6-5 Malfunction and troubleshooting for vibration during coating Trouble
Causes
Solution (e.g.)
The foundation is not level
Flat the foundation
Insufficient
Ensure the foundation with enough
rigidity
of
foundation Vibration
during
running
rigidity
The foundation bolts are unfastened Bad lubricating of roller bearing Roller bearing is damage
Tightening bolts
Replace the grease Replace the bearing
（4）Failures of spraying out liquid or liquid addition with large error, refer to Table 6-6. Table 6-6 Malfunction and troubleshooting for failures of spraying out liquid or liquid addition with large error Trouble
Causes
Misconnection of pipelines, Reverse rotation of motor, Pipeline is obstructed, Failures of spraying out liquid or liquid addition of
Solution correct it according to the schematic diagram; rewiring; turn
on
related
plug
valve; remove it and clear off
Nozzle tip is obstructed,
large error, refer to Table
the obstruction with a thin pin and clean it;
6-6. Solenoid valve fails to actuate, Oil tank is lack of liquid, Electric control or quantitative control instrument is out of control,
53
dismount it and check or replace it by a new one; add liquid again; Check or replace it by a new one.
(5) Failures of pneumatic control, refer to Table 6-7
Table 6-7 Malfunction and troubleshooting for failures of pneumatic control Trouble Air
pressure
increased
can by
Causes
Solution
The spring is broken
Replace the spring
be the
pressure-relief valve There is dirt between attracting faces of iron; Abnormal
noise
from
Remove the dirt
the The electric voltage is
magnet
lower than the rated
Adjust the voltage
voltage Bad wiring of the main
Check the electric circuit and
valve
have it correct.
The
solenoid
valve
exhausts air slowly or The
main
switch
doesn't
Cleaning the solenoid valve
does not exhaust air
reverse or reverse inflexibly
Check and clean the solenoid Bad lubricating and low air pressure
valve.
Increase
the
air
pressure that supplied to the oil mist lubricator, check for air leakage.
Deficient air supply Atomization
efficiency
nozzle is not good.
Regulate the pressure relief valve
of The pressure relief valve and the throttle needle valve are locked tightly.
54
Adjust the needle valve to improve atomization efficiency.
6.4 Tools for repair and maintenance No.
Tool name
1
Torque wrench
2 3 4 5
A group of inner hexagon spanner
Spec.
Tightening bolts, torque for tightening refer to the table of related parameters.. Width (mm): 4~22
Double-ended
Opening width (mm):
wrench
8×10, 12×14,17×19
Monkey wrench
Function
Tightening bolts Tightening bolts and nuts
Max. opening width
Tightening bolt M24 on motor base
(mm): 46
A group of socket
Tightening bolts and nuts
wrench
6
Clearance gauge
Measuring the windage of big bearing
7
Chain block (2T)
Hoisting or lifting heavy parts
8
Steel rope
Hoisting or lifting heavy parts
9
Scissors
Cutting
10
Screwdriver
Tightening bolts
11
Ammeter
Measuring the current of motor
12
Thermometer
Measuring the temperature of motor and bearing
13
Knife
Cutting
14
Vernier caliper
Length measuring
15
Flexible ruler
Length measuring
16
Long straight ruler
Length measuring
17
Oil gun
Filling oil
18
Iron hammer
Knocking
19
Rubber hammer
Knocking
20 21
Portable electric
Drilling hole
driller (0~13mm) Electrical heating
Heating bearing
device for bearing
22
Retainer pliers
Retaining rind disassembling
23
Glass cement gun
Filing glass cement
24
Multimeter
25
Hearing needle
Checking
26
Scraper
Cleaning
27
Metal bush
Cleaning
28
Air gun
Cleaning
29
Barrel
Current and voltage
Measuring
20L/piece
Cleaning (bearing, etc.)
55
6.5 Long-term stoppage If the machine is to be halted for a long time, it must be thoroughly cleaned both inside and outside and the dustiness must be removed to avoid rusting of the machine and aging of rubber parts.
6.6 Spare parts Important note: Our works is responsible for repairing or replacing parts (exclusive wearing parts) which are faulted due to manufacturing quality within one year from the date of leaving the factory under normal use and safekeeping by the customer, excluding the operations not in accordance with the operating instructions and human factor. Our works continues to undertake maintenance and repair after one year from the date of leaving the factory, to ensure normal use of the customer, but the expenses shall be borne by the customer. 6.6.1 Spare parts
Some parts and components in this equipment are worn off gradually when in use. If these parts are still used after worn to a certain degree, the property of equipment will be affected and dangerous accidents will occur probably. Therefore, these parts and components shall be replaced timely after used for a certain period. The spare parts in this Operation Manual is also called wearing parts. Whether the spare parts can be ordered timely and accurately will influence your production. So in order to purchase right spare parts, when place an order, please mention the corresponding serial number, code, description of the spare part
and the quantity needed in the order list (see Section 7.3 Ordering list
of spare parts). And provide us the order list via mailing or e-mail; if possible, please attach a sketch of the spare parts you require. 6.6.2 Spare part list 4
2
3
5
6
6 7
8
Fig.6-1 Schematic diagram of Spare parts of SCCJ differential gravimeter 56
Table 6-8 List of Spare parts of SCCJ differential gravimeter Delivery No
Model
.
Part code
Part name
Muyang
Qt
code
y
Supplier
Classifica
cycle
tion
Replacemen t frequency
(month) 1
SYPL15C,
QGSN2
25C, 35C
63×100B.CA
SYPL15C,
2
25C, 35C SYPL15C,
3
25C, 35C
4
PU10.0-8.0×200
25C, 35C
BU
25C, 35C SYPL15C,
6
25C, 35C SYPL15C,
7
25C, 35C SYPL15C,25 C
0011 DAE0905
pedestal
0601
Quick
G0401010
connector
0014
Hose Φ10
AC3010-03D
Air unit Silencing
ASN2-01
G0106010
Bearing with
PC10-02
SYPL15C,
SYPL15C,
5
UCF206
Cylinder
throttle valve G1/8
VF3130-4D-02
HSX200
G0502010 0010 G0301010 0004 G0208010 0002
Solenoid
G0202010
valve
0007
Weighting
Q1502000
cell
2
Weighting
Q1503000
cell
1
1
Wuxi Hengli
2
5
1
1
2
1
3
Wuxi Hengli Wuxi Hengli Wuxi Hengli Wuxi Hengli Wuxi Hengli Ningbo Keli
2
1
B
2
1
B
2
2
B
2
2
B
2
1
B
2
1
B
2
1
B
2
1
B
2
1
B
8 SYPL35C
HSX-A300KG
3
Ningbo Keli
Note: 1. Parts manufactured by Muyang; 2. Parts purchased from Muyang suppliers; Replacement frequency: A. within one year; B. One year or longer; Note6：The codes in this spare part list and those in the following component parts lists only suitable for the mixers made of carbon steel. Mixers made of #304stainless steel, #304 stainless steel wiring plate and 316L anti-acid stainless steel are also available, but the codes for parts will be different and the exact codes depend on the Contract.
57
1
3
2
5
6
4
Fig.6-2 Schematic diagram of Spare parts of TWLD Belt Feeder
Table 6-9 Schematic list of Spare parts of TWLD Belt Feeder
No.
Model
SYPL35C 1 SYPL15C,25C
Part code
Part name
4×560×2834( e
PVC Belt
dge width 80)
with edge
4×440×2834( e
PVC Belt
dge width 80)
with edge
SYPL35C
GB/T1243
SYPL15C,25D
GB/T1243
SYPL35C
R57DT90L4/VS
2
Chain 16A-1×54 Chain 10A-1×80
Muyang code
Qty
U150109001
1
U150109002
1
KAA160054
1
KAA100080
Supplier Taizhou
Classificatio n
Deliver y cycle (month)
Replacemen t frequency
2
1
B
2
1
B
General
2
1
B
1
General
2
1
B
R03040068
1
SEW
2
1
B
R01030007
1
2
1
B
Taifeng Taizhou Taifeng
Bevel wheel reducing motor
3 SYPL15C,25C
BWVP11-29-1.1
SYPL35C
TWLD45.0-10
Cycloidal reducer Small sprocket wheel
4
Small SYPL15C,25C
TWLD20-4
sprocket wheel
SYPL35C
TWLD45.0-06
SYPL15C,25D
TWLD20-5
SYPL35C
UCF209
5
TWLD0041001 0 TWLD0021000 1
Big sprocket
TWLD0041000
wheel
6
Big sprocket
TWLD0021000
wheel
2
Rexnor d
1
Muyang
1
1
B
1
Muyang
1
1
B
1
Muyang
1
1
B
1
Muyang
1
1
B
Ball bearing with square
DAE09050901
4
2
1
B
DAE09050601
4
2
1
B
pedestal
6
Ball bearing SYPL15C,25C
UCF206
with square pedestal
58
1
3
2
4
6
5
Fig.6-3 Schematic diagram of SYPL liquid adding pipeline
Table 6-10 List of SYPL liquid adding pipeline
No.
Model
Part code
SYPL15 1
C、25C、
3
SYPL15 C、25C
SYPL15
Qt
code
y
H04050003
1
Muyang
1
Muyang
gauge
S010114001
Y-filter DN15
Filter
D101H004
Pneumatic ball
G02010100
（DN15）
valve
001
Switch solenoid
G02020100
valve
007
Flowmeter
H04040059
35C
02
SYPL15
LC-WBU151/
C、25C
D1
02
4 C
LC12-A15
Flowmeter( incl ude filter)
SYPL15 5
C、25C、
QQ41M-16
Ball valve
35C
6
SYPL15 C、25C
Replacem
cycle(mon
ent
th)
frequency
2
1
B
2
1
B
2
1
B
2
1
B
ation
(0-2.5MPa)
C、25C、 VF3130-4D-
SYPL35
Supplier
Deliver
Classific
Pressure YPF100A
35C 2
Part name
Muyang
A-liquid adding system
Blowing
1
1
Italy OMAL Wuxi Hengli
1
Muyang
2
1
B
1
Muyang
2
1
B
2
1
B
H04040031
S010102001 91
G02029900 001
59
1
Wuxi Hengli
Fig.6-4 Schematic diagram of spare parts of SYPL Liquid storing and delivering system Table 6-11 List of spare parts of SYPL Liquid storing and delivering system No.
1
2
Model SYPL15C、 25C、35C SYPL15C、 25C、35C
SYPL15C、 25C 3
4
SYPL15C、 25C、35C
SYPL25C SYPL35C
6
Part name
Muyang code
Qty
Supplier
Classification
Deliver cycle (month)
Replacement frequency
Solenoid valve 9016
Solenoid valve
H03020011
1
Italy OMAL
2
1
B
GB/T3287
Ball valve D15 carbon steel (screw fitting)
S01010201501
1
Muyang
2
1
B
GB/T3287
Ball valve D25 carbon steel (screw fitting)
S01010202501
Ball valve D32 carbon steel (screw fitting)
3
Muyang
2
1
B
S01010203201
Q11F-16
Ball valve DN50
S01010205001
1
Muyang
2
1
B
CB-B10JZ
Oil pump assembly
M08010007
CB-B16
Gear pump
M08010099
1
Dali
2
1
B
CB-B32JZ
Gear pump assembly
M08010022
CB-B40
Oil absorption gear pump
S01011204001
1
Dali
2
1
B
SYPL35C
SYPL15C 5
Part code
SYPL15C、 25C、35C
60
·
Fig.6-4 Schematic diagram of spear parts of SYPL15C, 25C Drum coater
Table 6-11 List of spear parts of SYPL15C, 25C Drum coater No .
1
2
Model
SYPL15C , 25C SYPL15C , 25C SYPL15C
3
5
Part name
Muyang code
SYPL15C , 25C SYPL15C , 25C
Qty
Vertical EA-225-D
hold-dow
Q02010016
1
n handle SYPL25A.01.05
Roller
BWD11-11-2.2-B 3
Cycloidal
SYPL0029001 3
BWD12-17-3 GB/T11544-1997
SYPL15A.01.15
4
R01050001 1
reducer SYPL25C
4
Part code
Replaceme
Suppli
Classificati
Delivery
er
on
cycle(month)
2
1
B
2
1
B
2
1
B
2
1
B
2
1
B
Easyto ol Muya ng
Rexno rd
nt frequency
R01060005 V-belt B3912
PAB3912
Side
SYPL0049000
wheel
4
61
1
1
Muya ng Muya ng
Fig.6-5 Schematic diagram of spear parts of SYPL35C Drum coater
Table 6-12 List of spear parts of SYPL35C Drum coater
No.
Part code
Part name
Model
Qt
code
y
Q02010016
1
Easytool
2
1
B
4
Muyang
2
1
B
JX00000940
1
Tongli
2
1
B
PAE5380
1
2
1
B
2
1
B
Supplier
Classificati
Delivery
Muyang
on
cycle(mont h)
Replacemen t frequency
Vertical 1
SYPL35C
EA-225-D
hold-down handle
2
SYPL35C
3
SYPL35C
SYPL35.01-07
Supporting
SYPL00910
wheel
083
TR78-Y5.5-4P-15.
Gear
6-M6
reducer
V-belt 4
SYPL35C
(triangle-belt)-SPB
V-belt
5380 5
SYPL35C
SYPL15A.01.15
Side wheel
SYPL00490 004
62
1
Samsun g
Muyang
3
2
1
Fig.6-6 Schematic diagram of spear parts of SYPL coating pipeline
Table 6-13 List of spear parts of SYPL coating pipeline
No .
1
Model SYPL15 C SYPL25 C
Part code
Part name
Muyang
Qty
PVC_three-way_D2 0
Three-way
S021202002
1
KQ2T12-10
Three-way
G0401020005 2
1/4 JN-SS+SUE45-SS
Air atomizing spraying nozzle
SYPL15 C 2
SYPL25 C
SYPL25 C
Deliver cycle (month )
2
1
B
Muyang
2
1
B
ＳＭＣ
2
1
B
Supplier
Replacement frequency
ＳＭＣ
2
SYPL35 C 3
1
Classificati on
Q2101050005
3 5
KQ2T10-12
Quick connector
G0401020002 0
63
1
Fig.6-7 Schematic diagram of spear parts of SYPL side wheel
Table 6-14 List of spear parts of SYPL side wheel No.
Part code
Part name
Qty
Material
Muyang code
1
SYPL15A.01.15.01-02
Rubber wheel
1
Polyurethane
SYPL00410018
2
GB/T5783
Bolt M8×16
1
3
SYPL15A.01.15-05
Shaft end retaining ring
1
Q235-A
SYPL00111303
4
SYPL15A.01.15.01-01
Iron core wheel
1
HT200
SYPL00410017
5
GB/T 292
Bearing 7205B
2
6
SYPL15A.01.15-04
Shim
1
-2/Q235-A
SYPL00410016
7
SYPL15A.01.15-02
Retaining ring
1
Q235-A
SYPL00410014
8
SYPL15A.01.15-01
Shaft
1
20
SYPL00410013
Remark
AAD0801601
DAA00720502
No.
Part code
Part name
Qty
1
NPT1/4×φ12
Sleeve type rectangular connector
1
2
SYPL15A.01.03.01-03
Connecting tube
1
3
1/4 JN-SS+SUE45-SS
Air spraying nozzle
1
Q2101050005
4
PC10-02
Quick connector
1
G04010100014
5
Quick connector_PUL10
Quick connector
1
G04010103010
64
Material
Muyang Q1903000001
Φ20/Q235-A
SYPL00110030
Remark
Fig.6-8 Schematic diagram of spear parts of roller Table 6-15 List of spear parts of roller No.
Part code
Part name
Qty
Material
Muyang code
1
SYPL25A.01.05-01
Shaft
1
φ60/45
SYPL00210045
2
GB/T276
Bearing 6010-RS
2
DAA00011000
3
SYPL25A.01.05.01
Wheel
1
SYPL00291300
4
GB/T894.1
Retaining ring 50
1
GAH05001
Remark
Fig.6-9 Schematic diagram of spear parts of V-belt Table 6-16 List of spear parts of V-belt No.
Part code
Part name
Qty
1
GB/T11544
V-belt B3150
6
2
SYPL25A.01-07
Belt pulley
1
65
Material
Muyang code PAB3912
HT200
SYPL00211008
Remark
6.6.3 Ordering list of spare parts Ordering list of spare parts Model of Coating
Power
System No.
Part code
Muyang code
Part name
Note: This list can be copied or made into electronic form.
66
Ex-works No. Qty
Remarks
7 Appendix 7.1 Attached documents No.
Designation
Unit
Qty
Remarks 1.Drum
1
Operation manual of reducing motor
Copy
2
assembly 2. Belt feeder
2
Operation manual
Copy
1
3
Attached documents
Copy
1
4
Quality certificate of product
Copy
1
5
Sheet of customer's feedback information
Copy
1
7.2 Contract information
Company name
Address/telephone/fax Add: 1, Muyang Road, Yangzhou, Jiangsu, China
Jiangsu Muyang Group Co., Ltd
P. C.: 225127 Tel: +86-514-87848880 Fax: +86-514-87848686
67
7.3 Muyang SYPL(C) Continuous Type Liquid Coating System (list of operation manuals) Equipment designation: Muyang SYPL(C) Continuous Type Liquid Coating System. REV of the original edition: September, 2010 Revised version
Item
Description
Pages
Revision date
Original edition
All
September, 2010
number 0
I
a 3D and Principle diagram, form
a 2-3~2-8
content 1
II
b 4-4~4-6
b Revise flange and scaled drawing c Revise electric principle diagram d Renew spare parts list
June, 2012 c 4-8~4-14 d 6-8~6-17
2
3
4
5
6
7
8
9
10
68
Revision person
Remarks
