skln a series counter-flow cooler -...
TRANSCRIPT
SKLN A Series
Counter-flow Cooler
Operation Manuall
Prior to use, please read through this operation manual
carefully and keep it properly for reference in the future.
CONTENTS1
CONTENTS
1 Safety attention points .......................................................................................... 1
1.1Environmental conditions ..................................................................................... 1
1.2 Description of warning marks .............................................................................. 1
1.3Description of safety marks .................................................................................. 3
1.4General safety attention points .............................................................................. 5
1.5 Safety attention points in transport, storage and installation ................................. 6
1.6 Safety attention points in operation, inspection and maintenance ......................... 6
1.7Personal protection ............................................................................................... 9
1.8Explosion Protection: Countermeasures against dust explosion and fire hazard ....11
1.9Other attention points (environmental protection measurements) ........................ 13
2 General .................................................................................................................13
2.1 Application and adaptability .............................................................................. 13
2.2 Main features and functions ............................................................................... 13
2.3 General outline and main structure feature ......................................................... 15
2.3.1Main components (see Fig.2-1) .........................................................................15
2.3.2General outline .................................................................................................16
2.3.3Structure and features of main working components ............ 错误!未定义书签。
3 Cooler specifications ............................................................................................17
3.1 Basic Specification ............................................................................................ 17
3.1.1 Working condition ...........................................................................................17
3.2Main technical parameters .................................................................................. 19
3.2.1 Technical parameters of various coolers .............................. 错误!未定义书签。
4 Transport, installation and adjustment ..............................................................20
4.1Transport ............................................................................................................ 20
4.2Mechanical installation ....................................................................................... 21
4.3 Electric installation ............................................................................................ 23
5 Running................................................................................................................25
CONTENTS2
5.1Attention points for operations ............................................................................ 25
5.2Functional inspection prior to test-run ................................................................. 25
5.3Commissioning ................................................................................................... 26
5.4Use and operation ............................................................................................... 26
5.5Emergency stop and restart method..................................................................... 27
6Inspection, repair and maintenance .....................................................................27
6.1Attention points for inspection, repair and maintenance ...................................... 27
6.2Daily inspection items and methods .................................................................... 29
6.3Regular inspection items and methods ................................................................ 30
6.4Malfunction and troubleshooting ........................................................................ 31
6.5Tools for repair and maintenance ........................................................................ 32
6.6Spare parts List ................................................................................................... 32
6.6.1Spare parts List: ................................................................... 错误!未定义书签。
6.6.2Exploded diagram of different parts ..................................... 错误!未定义书签。
6.6.3Schematic diagram of some common spare parts ................. 错误!未定义书签。
6.6.4Ordering list of spare parts ................................................................................33
7Appendix .................................................................................. 错误!未定义书签。
7.1 Attached documents ............................................................... 错误!未定义书签。
7.2 Contact information ............................................................... 错误!未定义书签。
7.3 Muyang SKLN A Series Counterflow Cooler(List of Operation Manual)错 误 !
未定义书签。
7.4 Packing list ............................................................................ 错误!未定义书签。
1
1 Safety attention points
1.1Environmental 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:
① Ambient temperature range:(-10~+40℃)
② Relative humidity range: 30%~85%.
③ Altitude: less than1000.
④ Guarantee indoor cleaning and ventilation
⑤ 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; air
pressure ≧0.4Mpa.
(3) For easy use, operation and maintenance, please check this equipment and reserve
enough space for it.
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.
2
Table 1-1
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.
3
1.3Description of safety marks
(1)Relevant safety marks are pasted on different corresponding positions of this
equipment, which are property dangerous to personal safety. See Table 1-1.
(2) All the safety marks are indicatedin 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.
Table1-1 Safety signs used for this extruder
No. Part name Ordering cod Description
1 Beware of electric shock COMM65010010 Do not open the junction box until the power supply is cut off.
2 Do not remove the guard
shield COMM65010012
Do not remove the guard when the machine is in
running
3 Beware of injury
bymechanical movement COMM65010008
Do not open the access door when the machine is in
running and not completely stopped.
4 The protective gloves
must be worn COMM65010015
Wear protective gloves when inspecting and
repairing the equipment
Beware of electric shock Do not remove the guard shield
Beware of injuries by mechanical movement Protective gloves must be worn
4
Fig.1-1 position of safety signs on the principal machine
1,、2
1、2
3、
4
5
1.4General 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 on 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 regulations 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 suitable for cooling granular feed. 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 cooler under strict obeying all regulations for prevention
of accidents.
(10)If any accidents are caused due to not obeying the stipulations 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
6
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.
(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 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
7
be carried out only by the trained technical personnel according to
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)Operation and installation should be done after shutdown, Please be sure to
cut off and lock the main supply switch, and place the execution mark plates
on the workshop gateway, in front of the electric control cabinet in the control
room and near the cooler respectively, so as to prevent the motor from
accidental staring. Be sure there is no personnel lingering and no items
missing in cooling bin when closing the access door after completing
maintenance works.
(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 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
8
promptly.
(9) When the machine is under stoppage, attention must be taken to prevent
the cooler 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 chain pulley
(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 cooler and spreader have 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 junction box for avoiding electric
shock.
(16)The electric control system of the cooler must follow the following points.
Otherwise, it will not be the supplier's responsibility if any loss occur.
① The electric control system of the cooler 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
9
Jiangsu Muyang Group in light of the testing list and a permit will be signed by
him.
⑤If 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.
1.7Personal 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.
①The guard shield should be amounted and keep close at any moment. 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.
②The safety limit switches should always be kept in good order. Overlap or
discard of the safety limit switches is not allowed.
③The 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
10
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!
④If 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.
⑤As 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.
⑥If 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. And the machine can only be started by re-closing the
main switch first.
⑦If 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.
⑧The cleaning, lubricating and oiling of the machine or its parts and
components may be 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 rotor of the spreader before
entering the cooler. Attention must be paid to safety measures for climbing.
⑨Be careful, sampling from inside the machine can never be carried out
unless there is not any danger. Usually, the samples can be taken from suction
inlets of tipping plate and hopper instead of inside machine.
⑩Clear 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.
(11) 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
11
about hazards to the operators.
(12)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.
1.8Explosion Protection: Countermeasures against dust explosion and
fire hazard
(1)Common cleaning work
①Keeping 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 for pressure balance, 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.
②Check 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 main shafts and bearings, at least once a week, and to
regularly fill up lubricating oil.
(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.
12
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 who 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 10m 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
13
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.
(5)Effect of static electricity
①In 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.
1.9Other 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 (about8-10years),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.
13
2 General
2.1 Application and adaptability
SKLN A Series Counter-flow Cooler (improved model) is used widely for cooling process
in feed industry. It is applicable for cooling all kinds of pellet feeds such as pelletized feeds,
expanded feeds, extruded feeds flakes and other granular feeds, especially applicable for
cooling expanded pellets.
SKLNA Series Counter-flow cooler(improved model) hereinafter is referred to as the
"cooler" in this Operation Manual.
2.2 Main features and functions
(1) It is characterized by vertical layout, concise and beautiful appearance;
(2) Advanced counter-flow cooling principle, fence type discharging mechanism making
reciprocating rectilinear movement is adopted, fluent discharge and uniform discharging
volume.
(3) The cooling bin with an octagonal section can avoid dead angles of cooling and this is
favorable for material cooling.
(4) The new rotary spreader ensures that materials can be evenly and thoroughly cooled,
and can decrease the breaking ratio obviously. The material-distributing range is
adjustable and the power consumption is low;
(5) Several pressure reducing plates are mounted on the top of discharging mechanism,
which can greatly improve the working load of discharging mechanism and reduce
distortion, prolong service life of components.
(6) The driving device uses a geared motor to drive the eccentric shaft, it provides stable
and reliable driving and the noise is small, and it makes the installation and repair
convenient.
(7) The temperature of material after cooling is not+3 ~ 5℃ higher than room
temperature, the dehydration rate is in scope of 2%~3.0%,so the storage time of
high-quality pellets is prolonged.
Note:
i. The above mentioned scenario is applicable for normal temperature (≥15℃). When the
ambient temperature below the normal temperature (<15℃), the dehydration rate of cooler will
14
drop to within 1.0%~2.0%, if therefore bringing about finished products without required
moisture content, it is suggested that: ① Decrease as much conditioning moisture amount as
possible;② Add an thermal insulation layer on cooler bin body, top cover and air pipe;③
Complement auxiliary heating device around cooler or on the position of air inlet.
ii. The cooling effect of this cooler will be reduced sharply when the external ambient
temperature is ≥40℃ and the relative humidity is≥85%, Which will cause the severe result in
safety storage of feeds.
(8) The equipment is complemented with access door on the front face for convenience
of daily maintenance and repair. The side face is equipped with observation windows to
facilitate the observation of running status of the equipment.
15
2.3 General outline and main structure feature
2.3.1Main components (see Fig.2-1)
1.Top cover 2. Spreader 3.Cooling bin 4.Driving device for discharging 5.Base 6.Flow adjusting
and pneumatic emptying device 7.Discharging hopper 8.Access door
Fig.2-1 Schematic diagram of overall structure
The cooler is mainly composed of a base, atop cover, a spreader, a cooling bin, a
discharging fence, a flow adjusting fence, a driving device for discharging, a flow regulator,
a hopper and so on. See Fig.2-1 Overall structure diagram Fig.2-1Schematic diagram of
overall structure
16
2.3.2General outline
Hot pellet materials pile up gradually after entering the cooling bin through the rotary
feeder, till reach a certain height, the materials level sensor of cooling bin will send out
signals to make the discharge motor work when the material contacts the upper level
indicator. The motor drives the discharging fence to reciprocate through the speed reducer
and eccentric mechanism for discharging At this point, the time relay goes into operation,
and set a delayed discharging time for automatic discharge. The discharging amount of
materials in the cooling bin is more than the feed rate during discharging, if the delayed
discharging time of time relay ends up when materials in the bin dropped down to a certain
level, and when the limit indicator board on the discharging fence approaches the
horizontal level indicator mounted on the Base, the motor will stop at once, and the
discharging fence will stay in a fixed position. When the layer height reaches the upper
level indicator again, the discharging fence resumes movement and discharging. Repeat
the above discharging process over and over. Repeat the above discharging process
over and over.
17
3 Cooler specifications
3.1 Basic Specification
3.1.1 Working condition
(1)Material characteristics
① Particle size of materials: Length of edge shall be less than40mm.
② Bulk density: 0.5~0.8 t/m3
③ Moisture content of material: less than15%.
(2) Environment conditions
① Ambient temperature range:(-10~+40℃)
② Relative humidity range:30%~85%内
③ Altitude: less than1000m
④ Temperature range for normal transportation is:(-25~55℃)
⑤ Air supply for normal use is above0.4Mpa.
⑥ Voltage 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 cooler should match the equipments before and after it in process flow.
②The power supply range for normal use (permissible voltage deviation±5% , and
frequency deviation±1Hz).
③The user must configure an over-voltage protection device for the power supply.
(4) Noise testing during normal production
Table3-1Noise testing condition and method
18
Noise—pressure level LP≤ - dB (A)
Idling noise —power level LW≤ 90 dB (A)
Noise on test-surface—pressure level LP= 74 dB (A)
Test-surface specification LS= 16 dB (A)
Equivalent noise—power level Lweq= - dB(A)
19
3.2Main technical parameters
Model composition and its meaning
S KL N □×□ A
Improved model: after major improvement
Spec of product: sectional dimensions of cooling bin(dm)
Model Code: counter-flow
Variety Code: pellet cooler
Industry code: Feed processing equipment
20
4 Transport, installation and adjustment
4.1Transport
(1) Hoisting
When hoisting is carried out through lifting devices, the rope shall be capable to bear the
weight of the hoisted equipment (see nameplate for the weight of equipment) and not be
too short in order to avoid any damage to the equipment. The angle between every two
ropesis not necessarily equal to60°; actually an angle less than 60° is better, but it
requires a much longer rope. The bearing capacity of the hoisting equipment shall
be1.2times larger than the weight of the equipment to be hoisted.
(2) Transport
① When leave the factory, whether to use a packing case is determined according to
actual conditions.
②If 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.
③If 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 parts.
④During transport, any overturn, intense pressure or collision are not allowed on the
machine body.
⑤ Due to larger volume of the complete cooler and the outline dimension restriction on
transportation, the machine has been disassembled into several functional components
prior to leaving the factory, and for the list see Table4-1.
(3) Storage
①When 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.
②The 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.
21
4.2Mechanical 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 during the transportation.
② Count the documents and accessories attached compared with the packing list.
(2) Equipment installation
① Installation of the cooler
The extruder is delivered generally as a complete set. It is fixed through base anchor of
the supporting legs on firm foundation by foundation bolts.
Sometimes due to larger volume of the complete cooler and transportation restriction on
the outline dimension, the machine has been disassembled into several functional
components prior to leaving the factory, and for the list see Table4-1. After the installation
position of the cooler is confirmed, these components shall be assembled again under the
guidance of Muyang specialized technical personnel and technical documents or by
reference to "Fig.4-1Scaled drawing of equipment installation and Table4-2 Installation
dimension for equipment
22
②Installation requirements
a) The pellet mill is delivered generally as a complete set. Firstly check if
there is any damage during transportation when unpacking;
b) Fabrication yard should be strong and spacious, and enough space
around should be reserved for operation and maintenance. It is suggested
that to reserve a space of1.2m~2.0m around the equipment in accordance
with the dimension as shown in scaled drawing of equipment installation so
as to avoid inconvenience of maintenance and operation caused by narrow
space.
c) Please refer to the scaled drawing of cooler installation provided when
ordering;)
d) The proper maintenance platform and staircase should be provided if
necessary, the staircase shall be equipped with guardrails.
e) The cooler should be placed horizontally. The floor and frame
instruction for cooler installation is required to be strong and level, and
should be of enough stability and bearing capacity to afford the weight at full
capacity of equipment and the impact arising from the action of moving
elements. The machine body should be tightly jointed with anchor bolts,
otherwise it will cause vibration of equipment, even worse lead to accident.
The foundation should be connected with the base by pre-embedded anchor
bolts. (Fig.4-2 Pre-embedding of the anchor bolt)
Fig.4-2 Pre-embedding of the anchor bolt
③Matched feeder
Requirements to matched feeder
Besides ensuring the material for smooth entering into the cooling bin, the feeder should
serve a certain function of air locking, so as to ensure all the cold air is used for cooling.
So, a universal airlock can be chosen.
When a matched air lock used, the discharge rate of the airlock shall be calculated
according to the following formula:
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(3) Equipment adjustment
① Spreader adjustment
a) Generally, the spreader is already pre-installed on top cover before ex-works.
b) The distributing scope can be changed by adjusting the vertical position of the
throwing disc on the vertical shaft.
c) The distributing amount everywhere in radial can be controlled by adjusting the
position of dividing plate on throwing disc. (see Fig.2-6)
② Adjustment of material level indicator
Due to the uneven material layer surface, of which the highest point is liable to hit to the
spreader plate and damage it, the production will be influenced thereby. So it is best to
adjust the position of level indicator properly under the premise of satisfying production to
prevent the spreader from getting hit by materials.
③ Adjustment of discharging flow
Adjust the discharging amount according to the requirement of throughput control to keep
the material layer at a certain height. To adjust the discharging amount, turn the hand
wheel of flow-control device right for increasing the discharging amount, and turn it left for
decreasing the discharging amount.
④ Adjustment of cooling time
a) The material thickness in cooling bin and the cooling time can be controlled by
adjusting the position of level indicator on cooling bin.
b) Generally, the commended cooling time is10min. The thicker the material, the cooling
time should be prolonged.
4.3 Electric installation
(1) Electric connection
① The wiring chute in central control room must be protected.
② The central control room should be kept clean and free of dust.
Attention:
1. All cables shall be with a specification of0.75mm2;
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 cooler (an
emergency stop switch or a lock-up maintenance switch).
4. The above schematic diagrams are only for the independent operation of the cooler and
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matched airlock, the interlocking of the cooler with its upstream and downstream
processing equipment should be taken into account in process design.
5. Ensure the cooling bin is closed and the safety switch is normally working prior to
running.
6. Check the wiring at least once a year to ensure the insulation of the electric wiring in
good condition.
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5 Running
5.1Attention 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 when
operating.
(2) The safety protection devices can never be dismounted, covered or
overlapped at will.
5.2Functional 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 Check whether there are abnormal phenomenon such as blockage, collision and
scratch of discharging fence and driving device and other moving parts.
② All connecting points must be checked carefully to ensure there is not any
looseness.
③ Check the rotor of airlock for smooth rotation, and there should be free of
abnormal noise, foreign material winding and scraping.
④ Check whether the driving chain of spreader is in proper tension condition and
whether the rotation direction of spreader is correct. Therefore, it may need to start the
motor for a short time. Meanwhile, check for obvious eccentricity phenomenon in
rotating process of spreader.
⑤ Check for the correct installation and smooth rotation of material level indicator
⑥ Emergency stop switch
Check whether the emergency stop switch is in good working condition or not.
⑦ Safety switch of the access door
As a part of the safety control of the machine, whether the safety switch of the access
door works normally or not is directly related with the safety of the cooler, so the safety
switch should be frequently checked for its functioning.
⑧ Check before closing the access door
Be sure there is no personnel lingering and no items missing in cooling bin when
closing the access door after completing maintenance works.
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5.3Commissioning
(1) The material in bin should be emptied before each commissioning.
(2) Only when the access door is closed can the cooler run.
5.4Use 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) Throughput of each batch should be as even as possible so as to avoid quality
fluctuation of final products due to different feeding amount.
(3) After working, idle run the fence for several times so that all feeds be discharged
out of the cooler.
(4) The spreader should operate smoothly and enable feed to be distributed evenly
in the cooling bin.
(5) The blades of rotary hiding level indicator run smoothly, level detecting is
accurate and no fault.
(6) Adjust the flow adjusting mechanism to allow appropriate amount of feed
discharged through fence, ensuring neither blockage nor inconsistent end products
quality because of large discharging amount.
(7) The bearing temperature raise(refers to the risen temperature above ambient
temperature)of the bearings for main shaft should not be higher than35℃,and the
maximum temperature should not be higher than80℃(ambient temperature should
not be higher than40℃);
(8) When every shift production finishes, the inside of equipment and the surrounding
environment shall be cleaned, and the residual materials and dusts shall be removed
for next shift production.
(9) When stopping the machine, close the fan motor not until the material be
emptied.
(10) Metal or other large impurities should not be included in the material, or else the
airlock and the fences may be damaged.
(11) The speed reducer, cylinder and other accessories should be used in accordance
with the relevant stipulations in their operating instruction manuals.
(12) After a period of usage, appropriately fasten the connecting bolt between speed
reducer and rotor, the loosen extent is as shown in Table4-2,and furter check other
fasten;
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(13) It is forbidden to run the equipment with overload to prevent blockage and
damage.
5.5Emergency stop and restart method
(1) If the equipment makes abnormal noise when running, the machine shall be
stopped immediately; At the same time, stop feeding of upstream equipment, clean
the flow adjusting fence, discharging fence and other mechanic links for any blockage,
impact and friction.
(2) Only when the fault cleared and verified can the stopping status be resolved.
(3) Close the access door and ensure the signal of safety switch in place.
(4) Reset emergency stop switch, and the power supply of cooler is recovered in the
control room.
(5) The cooler can enter into working status.
6Inspection, repair and maintenance
6.1Attention 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 is to be
done the power must be totally cut off first.
(2) Only trained technical personnel is allowed to do works with
danger-potential such as parts replacement and repair.
(3) The replacement or maintenance of electric control system, circuit and
other components should only be done by trained personnel.
(4) Make sure the cooler has completely stopped when lubrication and
maintenance are carried out for discharging device.
(5) Make sure the power supply of airlock has be cut off and the blades has
completely stopped when maintenance of airlock and impurity removing work
are done.
(6) It is allowed to start equipment not until the access door is closed and
the signal of safety switch in place
(7) When the safety guard shields or access doors have to be opened or
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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 counter
measures prior to the operations and then carry out the inspection work.
(8) Be sure that the above said safety devices and guards are installed to
their positions after inspection, adjustment, repair and maintenance.
(9) 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, so as to let other people know about it.
(10) Attention! Improper operation and maintenance may cause accident.
(11) 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.
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 conditioner 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.
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6.2Daily inspection items and methods
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.
Table6-1List of daily inspection items (prior to each running or during each running)
No. Position Inspection item Cycle Method Solution
1 Air-pressure
system
Check whether the air pressure is higher than0.4Mpabefore entering
into the cylinder Everyday Inspection
Increase air
pressure
2 Machine (including airlock)
Check for any abnormal noise Everyday Listening Checking
3 Bearing Check for temperature lower
than80℃. Everyday Thermometer Checking
4
Motor Check for temperature lower
than80℃. Everyday Thermometer Checking
Motor Lubricating amount Everyday Inspection Checking
Motor Check for any abnormal noise Everyday Listening
Reducing motor Check whether current within rated
current value(Table6-2) Everyday Ammeter Checking
5 Material level
indicator Check for normal running Everyday Inspection
Repair and
correct it
6 Over-travel limit
switch Check for sensitiveness Everyday Inspection
Repair and
correct it
7 Spreader Check for normal spreading of
material Everyday Inspection
Repair and
correct it
Table6-2Check list of rated power and current of motor
Rated power (KW) Rated current (A) Remarks
0.75 0.197
Note1) The above-mentioned cycle applies 12h12a day and 2525days a month. Customers can adjust it
by themselves according to actual conditions
Note2) Three frequently-used greases for lubricating bearing:
① LITEAEP6-077(ASEOL)
② BEACOMPZ(ESSO)
③ ARALUBHLP(ARAL)
Reducing motor: Shell HD- 220, or MOBIL SCH-630
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6.3Regular inspection items and methods
Regularly check various coupling bolts for loose, fall off and broken-down, if
there are, repair should be done immediately.
Overhaul should be carried out once every equipment running for1000h.
Table6-3 List of regular inspection items
No. Position Inspection item Cycle Method Solution
1 Bearing
Sliding bearing
Cleaning Once a half
year Cleaning
Filling grease Once a half
year Filling grease
2 connection of
reducing motor Check whether fastening state in good condition
Every two weeks
Screw down
3 Safety device
Check the warning marks for missing or abrasion
Every month Inspection
Safety switch on the access door
Every month Cleaning
4 Chain Check for proper tension Every month Inspection Repair and correct it
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6.4Malfunction and troubleshooting
Trouble Cause Solution
Poor cooling effect
1. Insufficient cooling time caused by too much
feeding material.
1. Choose another type of cooler
according to the specified
situation or consult with relevant
technicians.
2. Insufficient cooling time caused by low
material layer.
2. Determine the level indicator
position again.
3. Large pellets, or the air gate is not opened
enough.
3. Determine the opening
position of the air gate again.
Hollow space in
the material
1. The material is distributed unevenly and
causes airflow short circuit.
1. Refer to the solutions in this
Instruction.
2. When the pellets are small, the air gate is
opened too extensively and the air speed is
fast.
3. Determine the opening
position of the air gate again.
3.Unsmooth
movement of
discharging fence
with noise
6. Bearings damaged 6. Replace the bearing
2. Roller wheel failure 2. Change roller wheel
3. Guide rail failure 3. Change guide rail
4. discharging fence abrades flow adjusting fence
4. Adjust the clearance between these two fences
4. Motor cannot be
started up
1. Wiring trouble 1. Check and clear away the
wiring trouble
Motor damaged Replace the motor
3. Induction signal output of level indicator has
malfunction
3. Repair or change level
indicator
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6.5Tools for repair and maintenance
Table6-8 Tools for repair and maintenance
No. Tool name Spec. Function
1 Monkey wrench Max. opening width(mm)46
Bolt for connection of machine base and body
2 A group of socket
wrench Common bolt
3 Chain block (2T) for heavy parts
4 Steel rope for heavy parts
5 Scissors Cutting
6 Screwdriver Tightening bolts
7 Ammeter Measuring the current of motor
8 Thermometer Measuring the temperature of motor and
bearing
9 Knife Cutting
10 Flexible ruler Length measuring
11 Oil gun Filling oil
12 Iron hammer Knocking
13 Rubber hammer Knocking
14 Portable electric
driller(0~13mm) Drilling hole
15 Electrical heating device for bearing
Heating bearing
16 Retainer pliers Retaining rind disassembling
17 Glass cement gun Filing glass cement
18 Multimeter Resistance,
voltage Measuring
6.6Spare parts List
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. And provide us the order list (seeTable6.5.4)
And provide us the order list via mailing or e-mail. If it is possible, please attach a sketch of
the spare part to be ordered.
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6.6.4Ordering list of spare parts
Type of
cooler Power
Ex-works
No.
No. Part code Part code Part name Qty Remarks