High pressure foaming equipment Repairs and maintenance
1、Repairs operating rage
1.1 repairs work is everyday or begin work shift
------- Check the components temperature, when necessary to re-adjustment
------- Check the silica filter if the filer changes to red and need to exchange the dry silica
------- Exclude the residual water in the water separator (only that the cooling or dry equipment)
------- Exclude the line clearance filter,
------- Check the meter pump and pressure
--------Check hydraulic pressure, mixing head and hydraulic exclude air
------- Check the equipment function parameter, installed injection time
--------Check mixing ratio
--------The experimental injection
-------- Check the tank of safely valve if is effectively
1.2 Repairs of everyday or off duty
--------- Check the pump of seals, if the install is manual seal and exclude one third DOP that increase fresh DOP. If discovery the DOP was changed color that should be exchange DOP or exchange the pump axis.
1.3 Product control
-------- Keep the mixing head hole clean
-------- Check the components temperature
---------Check the meter pump pressure
-------- Exclude the air of meter pump when stop or intermittent
1.4 safeguard every week
-------- Check the oil level
-------- Clean hydraulic oil filter
-------- Check tank of safely valve
-------- Check safely valve of all fringes functional
-------- Check meter pump of 250bar over pressure valve right functional
-------- Check all the pipe of connecting
-------- Check the cable of balancers weather damage
1.5 more detailed to requirement maintenance, security the next section and chapter < Components unit function and specification> with content of corresponding unit
%1、 Main parts of unit maintenance
2.1 Hydraulic unit, meter unit maintenance
NO. | Name | Content | Periodic maintenance | Medium | Consumption | Units as follows |
1 | Manometer | Check work pressure | Everyday |
|
| Hydraulic Unit |
2 | Return-filter | Clean | Every week or change oil |
| About 500CM3 | Hydraulic Unit |
3 | Meter pump with DOP lubrication | Driven draining, liquor level checking | Everyday | DOP |
| Meter unit |
4 | Relief valve | Relief pressure | Before maintenance |
|
| Hydraulic Unit |
5 | Pressure switch | Checking | Everyday |
|
| Meter unit |
6 | Oil gauge | Check oil level | Everyday |
|
| Hydraulic Unit |
7 | Hydraulic tank | Change oil | First use50hours and after 1000 hours | Hydraulic oil | About | Hydraulic Unit |
8 | Exhaust valve | Exhaust | Everyday |
|
| Meter unit |
9 | Overpressure safely valve | Check | Every week |
|
| Meter unit |
2.2 250//1000Ltank maintenance plan
NO.
| Name | Content | Maintenance | Medium | Consumption | Units as follows |
1 | Sealed tank | Check about sealed | Everyday |
|
| Tank |
2 | Tank safely | Check functional | Everyday |
|
| Tank |
3 | Agitating speed reducer | Check oil of filling | First, work 50hours, and last is 6months |
|
| Tank |
4 | Hydraulic safely valve | Check functional | Every week |
|
| Tank |
5 | Cut off valve | Close and check | Before tank of exhaust |
|
| Tank |
6 | Exhaust valve | Open | Stop, before maintenance |
|
| Tank |
7 | Relief | Check pressure | Staring shit work |
|
| Tank |
8 | Silicon filter | Check (color) | Every day |
|
| Tank |
2.3 components filter maintenance plan
NO. | Name | Content | Maintenance | Medium | Consumption | Units as follows |
1 | Handle | Clockwise rotation | Everyday |
|
| Components filter |
2 | Ball valve | Exhaust | Everyday |
|
| Components filter |
3 | Bolt | Exhaust, clean | Everyday |
|
| Components filter |
2.4 Test valve maintenance plan
NO. | Name | Content | Maintenance | Medium | Consumption | Units as follows |
1 | Test valve and DOP | Check level | Before test | DOP | About 3
| Return test unit |
3Stop and clean
3.1. machine stop
------ Cutting the power switch
------ Cutting compressed air provide pipe
------ Relief pressure
------ Relieving pressure hydraulic system
3.1 as follow clean two components pipe of system
----- Machine need to long time stop
----- Change the different nature different color material
Cautions
Prohibit using impregnant for cleaning, otherwise, cleaning process will be likely to damage the cleaning of airproof and soft tube.
1) Relief pressure and exhaust tank
2) Removed the under of pump bolt, and then tighten the bolt
3) Exhaust and clean Poly and Isocyanate filter
Filling the cleaning agent (DOP), material charging lies on tank volume
4) Demolition return pipe of tank and exhaust into the scrap barrel
6) Wall up with plug the circumfluence interface
7) Rotate automatic/manual choice switch to "manual" position
8) Star the pump of Poly until circumfluence pipe outflow the clean DOP
%1) Pressure relief tank and connecting circumfluence pipe
%1) Newly add pressure and staring Poly pump that the DOP recalculation
%1) Repeat the fifth and clean the Isocyanate pipe
%1) The DOP in the two pump of recalculation about 30 minute
%1) Stop, pressure relief, cut power
%1) If long time stop, should be the clean agent stay in internal machinery
4 Malfunction & resolve guide
Malfunction | Analysis | Resolve guide |
The pump can not star | The wrong voltage Not enough pressure of tank The filter is plug Rotate automatic/manual choice switch to wrong position The hydraulic unit not star | Check the voltage if necessary Increase the pressure of tank 0.4MpaHigh viscosity components increase the 0.4Pa Clean the filter check and correct Star the hydraulic unit |
Production the machine stop | The filter is plug The provide components not enough The pump overpressure Components switch is plug The mixing head nozzle is plug or the diameter is small | Cleaning, filling and checking Clean the pressure switch and pipe Clean the mixing head nozzle or change it |
The pump instability function (impact sound | Provide components of pump is not enough and the not enough air | Checking, and increase pressure of pump if necessary Clean the filter Filling and exhaust |
Pressure decline from circulation to foaming | circumfluence trough of mixing head jam flux of mixing head excessive large Pipeline jam due to the small diameter of circumfluence pipe | cleaning mixing head ,maintain and retest replace mixing head of bigger specification check pipeline and replace if necessary |
Pressure increase from circulation to foaming | pressure difference between two components | eplace spraying nozzle to balance pressure |
program can run but mixing head fail to open | check malfunction display working pressure malfunction of Isocyanateor Poly injection solenoid valve failure | Check pressure switch or pipeline, maintain or replace solenoid valve |
machine mixing ratio run away | circulation switching valve failure pump worn ,inner leakage | Replace valve airproof elements, maintain or replace pump |
short circuit and leakage of pump pressure limiting valve | pressure limiting valve fail airproof fail | replace pressure limiting valve replace airproof unit |
foaming pressure of two sides increase | mixing head fail to withdraw fully hydraulic by pass fail gas entry into hydraulic system | check injection solenoid valve replace O type airproof loop do venting of hydraulic system |
The working pressure of hydraulic system can not achieve preset valve | leakage exist in hydraulic pipeline and joint pressure increasing fail hydraulic pipeline crack pressure switch fail pump fail | retighten connection unit replace pressure increasing valve replace pipeline calibrate contact point or replace switch replace pump |
Temperature increasing of hydraulic unit excessively | oil cooling not working efficiently oil lack hydraulic pressure lack switch enactment difference of hydraulic pressure | check oil temperature controlling device charge oil
Handle pressure relief valve not screw tightly or pressure switch not adjust well .do appropriate adjustment |
Efficiency of temperature controlling become bad | pump jam, impurity or furring accumulation water strainer jam refrigeration or heating malfunction | disassemble and clean pump disassemble and clean filtering screen check and maintain |
water lack alarm of temperature controlling | switch of water level not moved water pressure lack water pressure too low | check water level switch charge water |
High pressure foaming equipment Repairs and maintenance
1、Repairs operating rage
1.1 repairs work is everyday or begin work shift
------- Check the components temperature, when necessary to re-adjustment
------- Check the silica filter if the filer changes to red and need to exchange the dry silica
------- Exclude the residual water in the water separator (only that the cooling or dry equipment)
------- Exclude the line clearance filter,
------- Check the meter pump and pressure
--------Check hydraulic pressure, mixing head and hydraulic exclude air
------- Check the equipment function parameter, installed injection time
--------Check mixing ratio
--------The experimental injection
-------- Check the tank of safely valve if is effectively
1.2 Repairs of everyday or off duty
--------- Check the pump of seals, if the install is manual seal and exclude one third DOP that increase fresh DOP. If discovery the DOP was changed color that should be exchange DOP or exchange the pump axis.
1.3 Product control
-------- Keep the mixing head hole clean
-------- Check the components temperature
---------Check the meter pump pressure
-------- Exclude the air of meter pump when stop or intermittent
1.4 safeguard every week
-------- Check the oil level
-------- Clean hydraulic oil filter
-------- Check tank of safely valve
-------- Check safely valve of all fringes functional
-------- Check meter pump of 250bar over pressure valve right functional
-------- Check all the pipe of connecting
-------- Check the cable of balancers weather damage
1.5 more detailed to requirement maintenance, security the next section and chapter < Components unit function and specification> with content of corresponding unit
%1、 Main parts of unit maintenance
2.1 Hydraulic unit, meter unit maintenance
NO.
Name
Content
Periodic maintenance
Medium
Consumption
Units as follows
1
Manometer
Check work pressure
Everyday
Hydraulic
Unit
2
Return-filter
Clean
Every week or change oil
About 500CM3
Hydraulic
Unit
3
Meter pump with DOP lubrication
Driven draining, liquor level checking
Everyday
DOP
Meter unit
4
Relief valve
Relief pressure
Before maintenance
Hydraulic
Unit
5
Pressure switch
Checking
Everyday
Meter unit
6
Oil gauge
Check oil level
Everyday
Hydraulic
Unit
7
Hydraulic tank
Change oil
First use50hours and after 1000 hours
Hydraulic oil
About
Hydraulic
Unit
8
Exhaust valve
Exhaust
Everyday
Meter unit
9
Overpressure safely valve
Check
Every week
Meter unit
2.2 250//1000Ltank maintenance plan
NO.
Name
Content
Maintenance
Medium
Consumption
Units as follows
1
Sealed tank
Check about sealed
Everyday
Tank
2
Tank safely
Check functional
Everyday
Tank
3
Agitating speed reducer
Check oil of filling
First, work 50hours, and last is 6months
Tank
4
Hydraulic safely valve
Check functional
Every week
Tank
5
Cut off valve
Close and check
Before tank of exhaust
Tank
6
Exhaust valve
Open
Stop, before maintenance
Tank
7
Relief
Check pressure
Staring shit work
Tank
8
Silicon filter
Check (color)
Every day
Tank
2.3 components filter maintenance plan
NO.
Name
Content
Maintenance
Medium
Consumption
Units as follows
1
Handle
Clockwise rotation
Everyday
Components filter
2
Ball valve
Exhaust
Everyday
Components filter
3
Bolt
Exhaust, clean
Everyday
Components filter
2.4 Test valve maintenance plan
NO.
Name
Content
Maintenance
Medium
Consumption
Units as follows
1
Test valve and DOP
Check level
Before test
DOP
About 3
Return test unit
3Stop and clean
3.1. machine stop
------ Cutting the power switch
------ Cutting compressed air provide pipe
------ Relief pressure
------ Relieving pressure hydraulic system
3.1 as follow clean two components pipe of system
----- Machine need to long time stop
----- Change the different nature different color material
Cautions
Prohibit using impregnant for cleaning, otherwise, cleaning process will be likely to damage the cleaning of airproof and soft tube.
1) Relief pressure and exhaust tank
2) Removed the under of pump bolt, and then tighten the bolt
3) Exhaust and clean Poly and Isocyanate filter
Filling the cleaning agent (DOP), material charging lies on tank volume
4) Demolition return pipe of tank and exhaust into the scrap barrel
6) Wall up with plug the circumfluence interface
7) Rotate automatic/manual choice switch to "manual" position
8) Star the pump of Poly until circumfluence pipe outflow the clean DOP
%1) Pressure relief tank and connecting circumfluence pipe
%1) Newly add pressure and staring Poly pump that the DOP recalculation
%1) Repeat the fifth and clean the Isocyanate pipe
%1) The DOP in the two pump of recalculation about 30 minute
%1) Stop, pressure relief, cut power
%1) If long time stop, should be the clean agent stay in internal machinery
4 Malfunction & resolve guide
Malfunction
Analysis
Resolve guide
The pump can not star
The wrong voltage
Not enough pressure of tank
The filter is plug
Rotate automatic/manual choice switch to wrong position
The hydraulic unit not star
Check the voltage if necessary
Increase the pressure of tank
0.4MpaHigh viscosity components increase the 0.4Pa
Clean the filter check and correct
Star the hydraulic unit
Production the machine stop
The filter is plug
The provide components not enough
The pump overpressure
Components switch is plug
The mixing head nozzle is plug or the diameter is small
Cleaning, filling and checking
Clean the pressure switch and pipe
Clean the mixing head nozzle or change it
The pump instability function (impact sound
Provide components of pump is not enough and the not enough air
Checking, and increase pressure of pump if necessary
Clean the filter
Filling and exhaust
Pressure decline from circulation to foaming
circumfluence trough of mixing head jam
flux of mixing head excessive large
Pipeline jam due to the small diameter of circumfluence pipe
cleaning mixing head ,maintain and retest
replace mixing head of bigger specification
check pipeline and replace if necessary
Pressure increase from circulation to foaming
pressure difference between two components
eplace spraying nozzle to balance pressure
program can run but mixing head fail to open
check malfunction display
working pressure malfunction of Isocyanateor Poly
injection solenoid valve failure
Check pressure switch or pipeline, maintain or replace solenoid valve
machine mixing ratio run away
circulation switching valve failure
pump worn ,inner leakage
Replace valve airproof elements, maintain or replace pump
short circuit and leakage of pump pressure limiting valve
pressure limiting valve fail
airproof fail
replace pressure limiting valve
replace airproof unit
foaming pressure of two sides increase
mixing head fail to withdraw fully
hydraulic by pass fail
gas entry into hydraulic system
check injection solenoid valve
replace O type airproof loop
do venting of hydraulic system
The working pressure of hydraulic system can not achieve preset valve
leakage exist in hydraulic pipeline and joint
pressure increasing fail
hydraulic pipeline crack
pressure switch fail
pump fail
retighten connection unit
replace pressure increasing valve
replace pipeline
calibrate contact point or replace switch
replace pump
Temperature increasing of hydraulic unit excessively
oil cooling not working efficiently
oil lack
hydraulic pressure lack
switch enactment difference of hydraulic pressure
check oil temperature controlling device
charge oil
Handle pressure relief valve not screw tightly or pressure switch not adjust well .do appropriate adjustment
Efficiency of temperature controlling become bad
pump jam, impurity or furring accumulation
water strainer jam
refrigeration or heating malfunction
disassemble and clean pump
disassemble and clean filtering screen
check and maintain
water lack alarm of temperature controlling
switch of water level not moved
water pressure lack
water pressure too low
check water level switch
charge water
