JINAN CJIERUI ELECTRIC CO., LTD. Integrates design and development, manufacture, installation and sales services as one. In 2010 the company's income of annual sales was more than 80 million yuan.
JINAN CJIERUI ELECTRIC CO., LTD. Integrates design and development, manufacture, installation and sales services as one. In 2010 the company's income of annual sales was more than 80 million yuan.
JINAN CJIERUI ELECTRIC CO., LTD. Integrates design and development, manufacture, installation and sales services as one. In 2010 the company's income of annual sales was more than 80 million yuan.
JINAN CJIERUI ELECTRIC CO.,LTD. OF CHINA Adress:No.56 General Road in Jinan, Shandong province Post Code:250108 Tel: 0531-88266622 General Phone Fax: 0531-88772200 0531-81206707 E-mail: cjierui@cjierui.com Web Site: www.cjierui.com
JRJZ vacuum filling machine instruction
Company Introduction
JINAN JIERUI ELECTRIC CO., LTD. OF CHINA, that is JINAN CJIERUI ELECTRIC CO., LTD, which integrates design and development, manufacture, installation and sales services as one. This manufacture has higher competitive in intelligence professional electromechanical equipment in China. Also it is certified high-tech enterprises in Shandong Province. JINAN JIERUI ELECTRIC CO., LTD. was established in October 1995 and its register fund was one million yuan; JINAN CJIERUI ELECTRIC CO., LTD. was established in June, 2003 and its register fund was five million yuan. The enterprise is located No.56 in General Road of Jinan city and covers 8700 . In 2010 the company's income of annual sales was more than 80 million yuan, with an annual taxes was more than 6 million yuan, and fixed assets was 50 million yuan, and current assets was over 38 million; The company has maintained a 40% average annual growth since it was founded. At present, the numbers of employees are 156 persons, 53 technical engineers who have rich experience in the application of vacuum technology, automatic control, gas and liquid transmission technology, electro-hydraulic integration technology and other fields professionals. CJIERUI ELECTRIC CO., LTD. establishes expedite communication and business contacts with well-known domestic and foreign enterprises and institutions such as the U.S. GRACO. Germany BURKERT, LEYBOLD, WILO, Britain SPIRAX likelihood, Sweden ORION, Shandong University, Harbin Institute of Electrical and Mechanical College, Tianjin Industrial University of Technology and so on. From 1999 to 2001, JIERUI ELECTRIC CO., LTD. made the first completely automatic power steering vacuum filling machine of China proprietary intellectual property rights with China First Automobile Group and the Chinese Automobile Research institute, which supplied prologue of the automobile assembly line to high, fine, excellent on mechanical and electrical JRJZ vacuum filling machine instruction
numerical control equipment domestically; And it seized the domestic and foreign markets rapidly in afterwards several years. Currently, the brand of JIERUI and CJIERUI vacuum filling equipment, quantitative filling equipment and automobile assembly line of mechanical and electrical equipment have occupied more than 60% market share in domestic market. In Volkswagen, Hongqi, FAW, DFAC, Chery, Chang'an, Great Wall Changfeng, HuaTai, KIA, Nissan and other famous auto company's product line to replace the imported equipment, and successfully exported to Russia, Vietnam and other foreign markets. It received customers recognization at home and abroad as a stable quality, excellent cost performance and improved customer service system. When consolidating the existing products and markets, CJIERUI ELECTRIC CO., LTD. always sticks to technology and quality as top of the enterprise development, continuously improves products system and explores, develops new products; gradually transfers to non-standard industry. In 2006 the company successfully developed hermetic leak detection, attack started, Helium recycling etc. a series of automatic electrical and mechanical equipment for Emerson Group, and quality of products transcended the Emerson Group of the United States suppliers, and successfully exported to the Vietnamese company of Emerson Group. At present, the company has already established business tie with foreign-funded enterprise of the Yangtze River Delta, Pearl River Delta and the Bohai - rim areas and successfully operates a large number of non-standard equipment items. The concept of JIERUI ELECTRIC CO., LTD. is "integrity, dedication, efficiency, innovation". The company adheres to the people-oriented, market-oriented, innovative technology standpoint, and reliable products quality management system to provide our customers with high performance and low cost of products and first-class technical services, which will become best Intelligent electromechanical equipment suppliers in China.
JRJZ vacuum filling machine instruction
JIERUI Products Brief Standard Products JRJZ-V series Vacuum Filling products JRBJ series Intelligence Industrial Identification products JRBJ series Intelligence Industrial Gelatinizing products JRJZ-N series Quantitative Filling products JRJZ-S Concentrated Fluid Transportation system JRJZ-H series Lubricant Coating system JRJL series Hermetic Leak Detectors JR-XX series information gathering of production lines, monitoring system. Non-standard products Industrial non-standard equipment, engineering and construction solutions consulting, design, production, services on site Automobile assembly line specialized non-standard work, clamp, and automation solutions Various production lines specialized non-standard equipment, automation solutions Various production lines used to retrofit, manufacture and sale solutions in China with imported equipment
Special Notice: CJIERUI, JIERUI ELECTRIC, JIERUI etc. relating brand, mark, trademark are CJIERUIS register brand, its property and ownership governed by CJIERUI ELECTRIC CO., LTD., and protected by the relevant laws and regulations. JRJZ vacuum filling machine instruction
CJIERUI Sales Services Introduction CJIERUI ELECTRIC CO., LTD. not only provides high-class products, but also provides top-notch service for customers from various levels; during pre-market, performance, sale provides elaborate technical services and meticulous, effective, comprehensive communication with customers to ensure that manufacturers of products are to customers and themselves satisfaction. As for sold products, we grant whatever is requested and reply whatever is asked and overall track, in order to pursuit dual-perfect of products quality and technical services. Service Concept Sincerity, specialty, prompt, careful Service support After-sales service department directly is responsible for customers and the general manager, with implementing Initial Consultation system to ensure that the service got an effective response; Perfect services database, the maturity clients, equipment archives, digital and network management, which effectively coordinate the relevant departments, and to ensure timely and accuracy; In In In In Nationwide distribute after-sales service Office and to ensure service response timely and efficiency; The 24-hour direct dial service hotline and complaint hotline, inspect and supervise services to ensure customers satisfaction Service team Make a good use of talents and establish a high standard, high quality, efficient service team, and use a full service system; Specialty engineers president over replying technical problems from customers. The leader, technical deputy and professional maintenance staff of the company regularly or irregularly visit customers; JRJZ vacuum filling machine instruction
We set permanent office in FAW (Changchun), DFAC (Shiyan), Chongqing, Suzhou, etc. area, specialty personnel are responsible for after sales service. Service promise All the sold equipments are used for warranty within one year and lifetime maintenance. We can guide installation on-site according to the needs of its customers and ensure the correct installation of equipment; To ensure that users have qualified personnel to operate and maintain with systematic operation training. Receipt of a notice should be given treatment response within one hour. Service personnel serve on-site with the average area 12-hour and special area within 24 hours Make a customer archives to provide regular visit.
JRJZ vacuum filling machine instruction
Introduction of other area agencies
Office in China First Automobile Group Address: FAW factory No. 665, 38 blocks Tel: 0431-5986108 13944179631 Office in DFAC Group Address: Dongfeng Group office, Shiyan city Tel: 0719-8264988 13617195365 Office in Chongqing Office in Suzhou Office in Tianjin
JRJZ vacuum filling machine instruction
Caution before using
Safety Note Misuse Equipment hazardous: The equipment used exclusively for professional use and avoid misusing of equipment. Please read carefully manual equipment instructions and all components instructions, warning etc before using. No moving or changing equipments. All the equipment parameters are set before leaving factory, and non-professionals avoid amending. Before changing parameters, please record original parameters. Check and maintain the equipments daily, and replace the worn components immediately. Fire and Explosion hazardous The equipment is the three-phase 4-wire 380V AC power equipment, which should be grounded line before using, solidly and reliably connect to the safety standards protection grounded line after electricity switched on. No smoking in the working area. Keep well ventilation of equipments. If accidents occur, please immediately shut down, until maintain equipment to normal before the boot. Spraying hazardous 1. Avoid any part of the body close the pipeline system components during JRJZ vacuum filling machine instruction
operations and maintenance. 2. Do not use hands and any other part of the body to prevent the leakage. 3. Please carefully check equipment pipeline and connecting whether to be normal, when you find the worn parts and replace them immediately. When maintaining equipments, you must keep the pressure relief. Personal Safety 1. Working uniform: Workers must wear protective uniform, do not wear earrings, bracelets, necklace and other jewelry ornaments! 2. Protective gloves: Workers must wear protective gloves to prevent danger. 3. Protective glasses: Workers must wear protective glasses to protect their eyes from harming! 4. Safety boots: Workers are required to wear protective boots!
JRJZ vacuum filling machine instruction
JRJZ-V04/N11P Coolant and Washer fluid filling machine Operating Instruction CONTENTS
1 EQUIPMENT OVERVIEW.................................................................................................... 1 1.1 Constitution and Function of Equipment -------------------------------------------------------- 1 2 PRINCIPAL OF WORKING................................................................................................... 6 3 MAIN TECHNICAL INDEX.............................................................................................. 6 4 COOLANT VACUUM FILLING EQUIPMENT OPERATION PROCESS...................... 7 4.1 Preparation------------------------------------------------------------------------------------------- 7 4.2 Evacuation ------------------------------------------------------------------------------------------- 7 4.3 Leakage check--------------------------------------------------------------------------------------- 7 4.4 Re-evacuation --------------------------------------------------------------------------------------- 8 4.5 Filling process --------------------------------------------------------------------------------------- 8 4.6 Suction process-------------------------------------------------------------------------------------- 8 4.7 Complete --------------------------------------------------------------------------------------------- 8 4.8 Suction against drop-------------------------------------------------------------------------------- 8 4.9 System supply --------------------------------------------------------------------------------------- 8 5 OPERATING........................................................................................................................ 9 5.1 Start/stop Operating System----------------------------------------------------------------------- 9 5.2 System Parameters Set ----------------------------------------------------------------------------- 9 5.3 Filling operation----------------------------------------------------------------------------------- 13 5.4 System Monitor ----------------------------------------------------------------------------------- 16 5.5 Manual Debugging ------------------------------------------------------------------------------- 17 5.6 Date Query Function ----------------------------------------------------------------------------- 18 5.7 Warning Relating Operations ------------------------------------------------------------------- 19 6 FAULTS AND REMEDY ..................................................................................................... 20 7 MAINTENANCE AND REPAIR.......................................................................................... 21 7.1 System Maintenance Daily ---------------------------------------------------------------------- 21 7.2 System Maintenance:----------------------------------------------------------------------------- 21 ANNEX ONE........................................................................................................................... 22 MAIN COMPONENTS LIST.................................................................................................. 24 JRJZ vacuum filling equipment 1
1 Equipment Overview JRJZ-V04/N11P coolant and washer fluid filling machine is for the needs of filling coolant and washer fluid in production Line, designed and manufactured by JINAN CJIERUI ELECTRIC CO., LTD, as a new type of mechanical-electrical integration, special vacuum quantitative filling equipment. Fig 1.1.1 When filling coolant , JRJZ-V04/N11P coolant and washer fluid filling machine can synchronous detect power steering fluid pipeline system pressure reliably and deal with statistics about the filling volume, vacuum and pressure data parameters when filling powering steering oil. It provides reliable quality assurance for production management and performance testing. 1.1 Constitution and Function of Equipment The equipment consists of coolant proportion vacuum filling and clear fluid ration filling two parts. 1.1.1 The internal pipeline and components of the equipment as shown in Figure 1.1.3, internal piping system consists of vacuum tube fill pipe, suction pipe and fluid tube for coolant filling unit and the fill pipe, supply pipe for clear fluid filling. The symbol of pipelines indicated in Figure 1.1.2.
Vacuum pipeline Exhaust pipes Compressed air Fluid Pipeline Suction line
1.1.1.1coolant vacuum filling system JRJZ vacuum filling equipment 2
1) Vacuum systemmainly is used for vacuuming with imported vacuum pump in shortest time, which consists of vacuum pump, vacuum tank, water and air separated tank, vacuum sensor, vacuum pressure gauge , The control and adjustment valves with visual position control. Use SV25B pump as vacuum pump to complete system vacuuming. 2) Filling System: system filled using constant-current electric vane pump and shorten fluctuations time in the pipeline system under pressure and can more accurately reflect filling pressure. Regulating pressure by fluid regulate valve. Mainly consists of the storage tank, filling pump, regulator valve, flow meter, filters, pressure sensor, pressure gauges, the control and adjustment valves with visual position control. The main water tank filling is controlled by pressure, and the subsidiary water tank is controlled by flow. 3) Supply system: including original fluid pipe and storage tank, water supply and storage tank, and decide supply by time delay and flow switch. This system consists of supply pump and control and adjustment valves with visual position control etc. Suction system: the main function is to adjust fluid level and suction fluid remained in pipeline to storage tank after filling complete. This system consists of control and adjustment valves with visual position control etc.
JRJZ vacuum filling equipment 3
Fig 1.1.3 inter pipe 1.1.1.2 Cleaning fluid filling system 1Filling system: make filling by American GRACO dissepiment pump, regulate pressure with manual gate valve. This system mainly consists of storage tank, filling gun ,gate valve, pressure meter, control and adjustment valves with visual position control etc. 2Supply system: there are two roads for supply with automatic switch. Supply fluid by American GRACO dissepiment pump. This system mainly consists of supply pump, control and adjustment valves with visual position control and flow switch etc. 1.1.2 Control panel: the main operating control panel. Operator can make man-machine conversation on control panel.
Coolant filling Coolant vacuum pump Cooling unit Coolant proportion tank Original fluid, water, proportion fluid supply pump Clear fluid Supply pump
Fig 1.1.4 Main operating control panel mainly consists of switch indication control panel, process indication lamp panel and touch screen. When vacuum filling equipment is running and instructed by indicator light in addition to color LCD display relevant data to ensure that operators in remote monitor the state of filling. Switch control panel is composed of Emergency stopPower onwith lightPower stopManual/AutoStartStopSupplyResetFormula type1Formula type2. Switch indicator panels is composed of ReadyFirst vacuumVacuum leakPost vacuumFillingSuctionOver. Type selection button is composed of High lowType 1Type 2Type 3Type 4Type 5. 1.1.3Pneumatic Control Unit: located on the right door of cabinet, the main function is to provide an effective source of compressed air. Before compressed air coming into the equipment, firstly processes unit (triplet) filter, lubrication etc., and then gas sources will be available to provide to the aerodynamic components. Control the sol valves by PLC to achieve pneumatic control functions. Mainly consists of solenoid valve group, valve board, air disposal unit (triplet), and regulator etc. JRJZ vacuum filling equipment 5
1.1.4The electric control systemthe main electric control loop. Inside electric cabinet there are PLC, A/D module, mini breaker, motor protective switches, mini relay, contactor, switch electric source, connection terminal etc. PLC shall make logic operation of whole system to assistant each control component action to ensure normal working of system. A/D module shall translate the simulation signal of each sensor pressure, vacuum into digital and input them to PLC, then PLC shall compare every parameter and program to control filling system and vacuum system. Mini breaker can be used for manual switch under debugging mode, and protect each loop form over current under normal mode. Motor protection switch mainly protects each pump motor form over current and under voltage. Mini relay complete logic operation with contactor. 1.1.5Filling gun and its house group: the equipment is equipped with one coolant vacuum filling gun and one cleaning ration filling gun and one coolant filling gun transition adapter. The vacuum filling gun can be used solely or with transition adapter to complete filling to complete different vehicle type. Cleaning fluid ration filling gun completes ration filling of cleaning fluid. The gun houses are located on the ground. Mainly has the following functions: A. Gun and the main pipeline joints connecting rapid routing and coated with plastic covers. B. The gun head is designed with anti-leak, after filling finishes; there is no leakage when plucking gun head. C. Gun is set with start and stop button and indicator lighters. D. Gun head cooperated with oil tank are connected with pneumatic clamping type. E. Filling oil gun is seated right and left sides of equipment for use, which is made from aluminum (not including handle), the part of easy-worn connected with oil tank is considered intension, durability and corrosive resistance. F. Gun head cooperated with the oil tank, oil tank mouth is without deformation or injury, and the body without interference.
JRJZ vacuum filling equipment 6
2 Principal of Working JRJZ-V04/N11P coolant and washer fluid filling machine is composed of fluid control, pneumatic control and electric control three parts: Fluid control mainly real-time check and quantitative controls Antifreeze filling and system vacuum pressure; pneumatic control part mainly finishes the fluid valve supplying pilot gas supply and controls filling gun clamping; electrical control system mainly finishes system process control and testing, also deal with process parameters data, preservation and the system monitoring, data display and failure alarm, etc. JRJZ series common vacuum filling equipment working principle is based filled system with vacuum check, vacuum filling, and suction of filling line and purification etc. process technology integration of intelligent control. And complete vacuum, checking and filling process with higher operating rhythms. Vacuum process of JRJZ-V04/N11P coolant and washer fluid filling machine includes low vacuum and high vacuum stages; suction process includes suction, ventilation etc. several stages. Filling process of quantitative vacuum filling equipment consists of preparation, evacuation and leakage detection, re-evacuation, filling, suction and completing, etc. several sequential process. Refer to system diagram, see the attachedfigure. 3 Main Technical Index 1) Technical Parameters system vacuum value (filling gun mouth):20mbar filling pressure:0.10.4mpa adjustable filling volume 120L adjustable coolant filling accuracy: level height2mm clear fluid filling accuracy1% Filling cycle :8set /hour Storage tank90L Noise <80dB Equipment shape dimensions: lengthwidthheight: 32008001800mm 2) working environment JRJZ vacuum filling equipment 7
4.1 1 1 1 Preparation After power on, then system shall enter into working state. 4.2 2 2 2 Evacuation When first evacuation, vacuum pump M1 runs, vacuum pressure holding valve V401and gun vacuum valve V422 opens, a few seconds later, vacuum sensor V404.1 opens, until preset time. 4.3 3 3 3 Leakage check No Process Content 1 Preparation Electrified, equipment enters preparation after self-check 2 Automatically clamp Press the green button on the gun, seal complete 3 Evacuation Big leakage checking If failure to withdraw from filling cycle, sound and light alarm 4 Constant pressure, leakage check Small leakage checking If failure to withdraw from filling cycle, sound and light alarm 5 Re-evacuation Gun head reach the lowest vacuum 6 Pressure filling Constant pressure filling, pressure, flow and time triple control. If failure to withdraw from filling cycle, sound and light alarm 7 Keep pressure Make the filling pressure constant to ensure fill up 8 Suction process Inflatable, and suction to complete level treatment 9 Filling complete State initialization, sound and light alarm 10 Pneumatic loosening Press red button on the gun and unclamp 11 Manually take guns Suction against drop. JRJZ vacuum filling equipment 8
After first evacuation, vacuum pressure holding valve V401 closes, system begins leakage checking, until preset time. 4.4 Re-evacuation Generally, system enters into re-evacuation process after leakage checking, and opens vacuum pressure holding valve V401 again. The re-evacuation is to repeat evacuation process, until preset time. 4.5 Filling process When filling, filling pump M2 runs, and gun filing valve V421 and filling valve V402 act, meantimes, tank breath valve V507 acts to accelerate filling process, until preset pressure. 4.6 Suction process After filling, the oil in pipeline shall be sucked back into tank. During this process, suction valve V403,gun suction valve and blowing valve V509 act, until preset time. 4.7 Complete After suction, the whole filling process ends, system shall give indication signal for s few seconds. 4.8 Suction against drop Then, press stop button, suction valve V403 acts to suction against drop until preset time or after gun returns into its house. The suction against time can be set on man-machine interface. See details in fig 5.2.3. 4 44 4.9 System supply Auto supply mode, supply valve V410or V411 acts and supply pump P3 runs to supply oil into tank.
N NN Note: all parameters of each vacuum filling process can be set on man ote: all parameters of each vacuum filling process can be set on man ote: all parameters of each vacuum filling process can be set on man ote: all parameters of each vacuum filling process can be set on man- -- -machine interface. machine interface. machine interface. machine interface. JRJZ vacuum filling machine instruction 9
5 55 5 Operating 5.1 Start/stop Operating System 5.1.1 Power On: Connect with the main power of the JRJZ-V04/N11P coolant and washer fluid filling machine ; Push the power onbutton in the control panel The indication light shines and the touch screen enters the original interface(fig 5.1.1)
Fig5.1.1 system original interface 5.1.2 Power off Operation: Shut off the main electric source switch. 5.2 System Parameters Set System parameters set is completed on the touch screen. 5.2.1 Selection of Working Mode Switch the manual / automaticswitch to manual location on the control panel, system enters manual mode; If switching the switch to automatic location, the system enters automatic work mode. 5.2.2 Operating Parameters Set N NN Note: this item must be operated by professional person or authorized pers ote: this item must be operated by professional person or authorized pers ote: this item must be operated by professional person or authorized pers ote: this item must be operated by professional person or authorized person by our on by our on by our on by our company, strictly prohibit other person amend. company, strictly prohibit other person amend. company, strictly prohibit other person amend. company, strictly prohibit other person amend. 1)Technical Parameters Set In figure 5.1.1 window, press "Parameter set" to access the interface shown as JRJZ vacuum filling machine instruction 10
figure 5.2.1. After inputting the process password (system default password 1), press ENT and system firstly enters current parameter set interface one (Figure 5.2.2), press DOWN to enter technic parameter two(fig 5.2.3) , you can set each control parameters of vacuum filling process, including the coolant vacuum filling process parameters and clear fluid ration filling process parameters. The definition of each parameter can be fund in list 5.2.1.
Fig 5.2.3 technics set interface 2 List 5.2.1 No parameters title units parameters signification Current set 1 Rough vacuum time S Evacuation process, the time to check vacuum pipe and coolant pipe whether there is big leakage.
2 Rough vacuum value mbar The big leakage checking value, if it not to reach the preset vacuum value in first vacuum time , system will give big leakage alarm
3 Fine vacuum time S Evacuation process, the time to check vacuum pipe and vehicle coolant pipe whether there is leakage.
4 Fine vacuum value mbar Evacuation process, base on the vacuum degree to judge vacuum pipe and vehicle coolant pipe whether there is leakage.
5 Leakage check time S The system leakage checking time 6 leakage check value mbar Estimate whether or not have small leakage value when vacuum checking
7 Re-evacuation time S The second vacuum time 8 Filling protection time S the longest time of fill during filling 9 Main tank filling volume L The preset value for main coolant tank ration filling
10 Filling quantity error L The main coolant tank filling quantity error. 12 Filling pressure Bar Judge pressure value of fill pipeline with topping up during filling process
13 Filling pressure keeping time S The time of keeping the filling pressure preset value.
14 Secondary tank filling volume L The preset value for secondary coolant tank ration filling
JRJZ vacuum filling machine instruction 12
15 Secondary filling protection time S the longest time of secondary tank filling. 16 Suction time S suction process time 17 The original coolant filling quantity L The preset filling quantity of original coolant 18 Drum empty check time S Supply drum empty check time 19 Alarm screen time S The alarm screen time after pressing reset button.
20 Suction against drop time S pick up gun and anti-leakage, suction time after completing filling
21 The preset value of clear fluid filling quantity. L The preset value of clear fluid filling quantity. 22 The filling protect time S the longest time of fill during clear fluid filling 23 Drum exchange time S Drum exchange time after achieving system drum empty information.
2)System parameter set System parameters are for system measurement to ensure the filling accuracy. Input system parameter password (system default password 1) in the interface shown as fig 5.2.1, press ENT key and system enters system parameter set interface (fig 5.2.4 ). Continue to flip to enter into system parameter set interface2 (fig 5.2.5).
A AA Attention: the system parameters have been set right, ttention: the system parameters have been set right, ttention: the system parameters have been set right, ttention: the system parameters have been set right, do not change them without do not change them without do not change them without do not change them without professional person professional person professional person professional person. .. .
Fig 5.2.4 system parameter set interface JRJZ vacuum filling machine instruction 13
Fig 5.2.5 system parameter set interface 5.3 5.3 5.3 5.3 Filling operation 5.3.1 5.3.1 5.3.1 5.3.1 Coolant vacuum filling 1. First, switchmanual / automaticswitch to the automatic position on the panel, filling equipment enters preparation state, preparation indicator lights on. 2. Filling operation: base on vehicle type, Take the gun from bracket and point to the filled nozzle. Push the green FILLING button on the top of the gun or press the remote control locking button, the three claws in the gun clamps the lip of the pot and the entire vacuum filling cycle starts as follow. The indication lamps will indicate the each process; the whole cycle is going on automatically without person. The order is shown as following: ReadyFirst vacuumVacuum leakPost vacuum FillingSuctionOver After the filling of main water tank, start filling secondary water tank with certain quantity until preset value. 3. After both main water and secondary water tank have completed, press stop button to unclamp claws, then system starts suction against drop until preset time or gun returns into its house. 4. Put the gun into its house. 5.3.2 5.3.2 5.3.2 5.3.2 Cleaning fluid automatic ration filling 1. First, switch manual / automatic switch to the manual position on the panel, JRJZ vacuum filling machine instruction 14
filling equipment enters preparation state, preparation indicator lights on. . 2. Take the gun from bracket and point to the filled pot, press filling button to start filling until preset value. 3.Put filling gun into its house, the whole filling process completes. 5.3.3 5.3.3 5.3.3 5.3.3 Manual filling 1. First, switch manual / automatic switch to the manual position on the panel, filling equipment enters preparation state, preparation indicator lights on. . 2. Un-quantitative manual filling: take filling gun and point to filling nozzle, press filling button to start main water tank, and press stop filling button to stop filling, the filling quantity can be controlled by operator himself. Note a) System shall sync-output fault alarm with the indicator on panel when fault. b) With automatic mode filling, if pressfilling stop key on the gun or the stop button on the operation panel, system stops current operation, and then return the initial state. c) During filling process, operators can observe the current fill volume, the current pressure and current vacuum degree by system monitor interface. Detailed monitoring interface see 5.4. d) Any filling state, users can adjust filling pressure by the filling pipeline regulating valve RF1 to regulate the speed of the filling. 5.3. 5.3. 5.3. 5.3.4 44 4 Supply fluid to tank by hand 1. First, switch manual / automatic switch to the manual position on the panel, filling equipment enters manual state. 2. Pressmanual supplybutton on the panel, supply indicator lights are on, supply fluid valve open, the system begins supplying oil to the storage tank from. to fill the required level, again press on the panelmanual supplybutton, and stop supplying. Note: Note: Note: Note: During During During During manual manual manual manual supply supply supply supply, , , , until until until until system system system system set set set set the the the the high high high high level, level, level, level, you need not you need not you need not you need not press press press press manual manual manual manual supply supply supply supply button button button button , the system will automatically stop , the system will automatically stop , the system will automatically stop , the system will automatically stop supplying. supplying. supplying. supplying. 5.3. 5.3. 5.3. 5.3.5 55 5 Automatically supply fluid to tank JRJZ vacuum filling machine instruction 15
System monitors the level of the fluid in the storage tank by the fluid level switch. When the storage tank level reaches the low level, system will automatically open the valve V410or V411(VB10 or VB11 for cleaning fluid)to supply, when reach to high level, the system automatically stop supplying, supply valve closed. 5.3.6 5.3.6 5.3.6 5.3.6 State Indicator Instructions 1. Three-color Lamps indicator 1) A red warning light constant on indicated system with malfunction, when checking generally electricity or equipment preparation state. This warning, system does not start filling operations. Mainly in the following circumstances lit : A. Gas source is smaller than set smallest pressure, which is to protect pneumatic valve dependable motion. B. The Trip situation of filling pump, vacuum pump motor protector. C. The liquid level is too low or too high. 2) A red warning light frequent flashes indicating filling process with failure, in this case, you can choose complete mandatory or restoration re-operation. Mainly in the following circumstances: A. Filling time exceeds longest filling time set. B. When evacuation, you can not vacuum the largest leak vacuum degree in set time, the system reckons there is big leakage. C. During leakage check, find leakage greater than the set. D. When filling, the pipe-distance exceed journey. 3) A yellow light constant on shows system with problem, need to solve with manual intervention, mainly in the following circumstances: A. Filters plug, regardless of supply filters or filling filters B. When complete filling, the actual filling volume is less than the preset least filling volume. C. When the edge of oil drum empty. 2) The green light is on expressed filling, extinguishing indicates completing. 2. Sound warning : the following two situations : A. After filling completed, the buzzer will call a period of time to remind the operator complete filling. 1HZ frequency, time out or press the "stop" button JRJZ vacuum filling machine instruction 16
on the gun to stop. B. System with malfunction, with a red light for state instructions, buzzer frequency 5HZ, until troubleshooting or by pressing the "alarm reset" button.
5.4 5.4 5.4 5.4 System Monitor Systems with real-time monitoring function, users can fully understand equipment current work state by this picture. Touch "system monitor in the initial interface 5.1.1, you can access to the main monitor window of system (Figure 5.4.1), the operators can observe the current filling volume, the current cycle time, the current pressure and the current vacuum value and the current parameters of the changes by this interface etc.
Fig 5.4.1 system monitor interface In addition, system also has pipeline monitor function through monitor interface. Press pipe monitor to enter pipeline monitor interface shown as fig 5.4.2, which can give you the realtime working state of each valve. JRJZ vacuum filling machine instruction 17
Fig 5.4.2 pipeline monitor interface1 5.5 5.5 5.5 5.5 Manual Debugging The function reserves the use of super administrator. During the system adjusting or failure checking, divorcing from any PLC mode control, easy to operate and judge the valve operation more directly on the man-machine interface. But professional personnel are needed to complete, otherwise you can not properly handled the valve interlocked relationship and brought the unexpected failure. This function absolutely is used cautiously. In 5.5.1 window after input manual debugging password, press the ENT key, and then the system enters manually debugging window (Figure 5.5.1), users can manually debugging in this window, "the manual debugging" functions for system service/ maintenance, an online debugging functions of the main system components individually, or a combination check. JRJZ vacuum filling machine instruction 18
Fig 5.5.1 manual debugging window 1
5.6 5.6 5.6 5.6 Date Query Function Data query function is about statistics about the total filling volume and time of filling, users can access this function window for data inquiries. In the main menu select "Data Query", the system accesses data query interface(fig 5.6.1), on which, you can query the latest filling time, vacuum value and whole filling time.
Fig 5.6.1 data query window.
JRJZ vacuum filling machine instruction 19
5.7 5.7 5.7 5.7 Warning Relating Operations 1 During systems operation, before operators carry out the next phase of the operation or change the setting, must complete ongoing operation, or will result in system disorder or system failures. 2 In all touch-screen interfaces "return" buttons are return the initial interface. 3 In case of emergencies, you can beat emergency stop on the panel, equipment stop. Unless an emergency situation, you can not pressemergency stop button, frequently use emergency stop button to stop power would affect some components of life, even damage some electrical components.
JRJZ vacuum filling machine instruction 20
6 6 6 6 Faults and Remedy The system has fault diagnosis and alarm instructions function. In any working state, the alarm buzzers ring with failure, while red indicator light on of the top three-color, the operator can query the current buzz content on the screen, the specific alarm Table see 6.1. Failure Alarm, pressalarm reseton the panel to cancel alarm ,users can handle relating alarm by alarm picture. Table 6.1 detailed alarm items and treatment alarm content reason treatment level too low alarm Level switches may be damaged or infusion pump damage 1check level switch 2adjust infusion pump and filter level too high alarm level switch may be damaged or infusion speed too fast 1check level switch 2adjust throttle valve of infusion pressure shortage alarm pressure switch may be damaged or Undervoltage gas supply circuit 1check pressure switch 2Check pressure of the gas supply loop whether to be enough filling pump alarm load may be too large or system power failure 1protective switch current set whether to be too small 2check system load whether to be too large 3check system distribution electricity circuit vacuum pump alarm load may be too large or system power failure 1protective switch current set whether to be too small 2check system load whether to be too large 3check system distribution electricity circuit big leakage alarm Seal system not well, filling head unclamp, pipeline leakage, or large leakage check parameter set too small 1remove filling head and clamp 2check system pipeline whether to be leak 3adjust large leakage parameters small leakage alarm pipeline with small leakage or small leakage parameters set too small 1choose compel filling or cancel filling 2check system pipeline 3adjust system small leakage check parameters drum empty alarm level switch damage drum empty 1check level switch 2change drum prompt filter alarm filter damage pipeline unsmooth 1check filter 2check clean pipeline filling overtime alarm set filling volume too large filling pipeline leak 1check set filling volume and filling protective 2check and maintain pipelie JRJZ vacuum filling machine instruction 21
Note: any of the foregoing alarm, according to the screen prompts for the corresponding inspection and operation. If that does not succeed, please contact with the manufacturers. 7 7 7 7 Maintenance and Repair 7.1 7.1 7.1 7.1 System Maintenance Daily 1System Pipeline Maintenance: check equipment pipelines daily and tie-in whether to leak or not, and ensure that equipment is clean and tidy. Carrying out maintenance every three months with cleaning dust and check whether pipeline and circuit are normal. 2Electric Maintenance: regularly inspect whether connection terminal line loosens and whether the relay contacts badly and every valve plug contacts badly in order to ensure signal reliably input and output. 3System Maintenance:System checks vacuum value and flux parameters every half year and makes them optimization. 4Vacuum Maintenance: perform use methods, safety and maintenance stated in the operating manual of pump to ensure pump running safely. Regularly checking and maintain to eliminate possible fault and hidden trouble. Refer to details see the operating manual. 5Air disposal unit( triple): see appendix one. 7.2 System Maintenance: 1. Fluid control circuit maintenance: every fluid valve can open manual in the fluid control circuit, during maintenance if you want to operate a valve, you can press white point in the sol valve manually, and check and maintain the relevant pipelines, you can operate manually sol valve only on the power off conditions. 2. Electric loop maintenance: Total system logic controls are in the PLC control, after checking trapezium and know the logic relation, and then observe each input and output state in the PLC to confirm interior logic with failure or exterior connector and valve or its perform components problem. During maintenance process you can refer to system theory chart and electric control chart. JRJZ vacuum filling machine instruction 22
Annex one Two conjoined / triple-use (compressed air source processor) instruction (for reference only difference between models)
Installation 1Blow the pipeline by compressed air before installation. 2Triplet required install vertical, and water cup and oil cup are adown, but pressure relief valve knob install up or adown. 3Arrowhead direction refers to air compress direction, pay attention to it when installation. Environment 1Avoid exposure in the sun 2As a result of water cup and oil cup are made from creosote; Avoid using in circumstances containing the following chemistry: compound oil, thinner, chloroethylene, kerosene, acid or aroma hydrocarbon. Operation 1The filter should advert to release water with drainage manually, level does not exceed level symbol, at least set water once every number of runs 2When adjusting pressure, firstly pull the knob, right rotate with pressure ascending and left rotate with pressure descending, and then push the knob and clock on the adjusted pressure. 3The oil level of oil tank should keep between upper limit and lower limit, oil deficiency, supply oil prompt. use mucosity 2.57E lubricate, we commend use number 22 steamer oil. 4The minimum air flux in the normally operating should content the minimum flux request of oil tank. 5Cup and cup cover removed should be operated without pressure. 1Clutch shield cover by hands, press orientation device and rotate right or JRJZ vacuum filling machine instruction 23
left 45 by thumb, make the arrowhead of orientation device versus the arrowhead of valve and pull adown to remove. 2Some models can directly tweak down. 6Oil tank can fill oil with stop gas or non stop gas, fill oil step as follows: 1Usually directly fill by opening oil stuff. 2Some model: a. open the block of oil tank and dropt air of cup b. tweak down oil cup c.add the cup proper oil d. tweak up oil cupe.tweak up stuff. Maintenance: Abstersion of cup and sieve should choose litmusless scour, after washing with rinsing and co JRJZ 24
Main Components List NO Name Type Quantity Manufactures Mark 1 Vacuum pump 2BV2070 1 SIEMENS 2 Atmospheric ejector 2BP107 1 SIEMENS
7 Regulator Reference 11 1 France AD 8 Coolant filling pump MHI-206 1 Germany WILO
9 Coolant supply pump H716 3 GRACO
10 Cleaning filling pump H716 1 GRACO
11 Cleaning supply pump H716 1 GRACO
12 Condensation TFHSZ4531FHR 1 France taikang 13 Flow switch FB21-020GK 3 Shanghai 14 Freezing point measurement LCC3T 1 Guangzhou china 15 PLC 1766-L32BWA 1 AB 16 I/O extending unit 1762-IQ16 2 AB
17 I/O extending unit 1762-OW16 4 AB
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18 A/D extending unit 1762-IF4 1 AB
19 Touch screen 2711P-T6C20A 1 AB 20 Sol valve VQZ115-5G-C6 20 Japan SMC 21 Reducing valve AR20-02 11 Japan SMC 22 Triple AC30-03 1 Japan SMC 23 Pressure meter 0-2.5MPa 2 Shanghai china 24 Electric components 1 SCHNEIDER
25 Pipeline, connecter, valve Stainless steel 1 American PARKER
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