homogenizer均质机英文说明书.doc

High pressure homogenizerOperation instructionJiangyin Gang Lite Mechanical Manufacturing Co.LtdContentsOne、Use and characteristicsTwo、Main technical parametersThree、Installment and useFour、Easily damaged partsFive、Attachment1、 outside view2、 high pressure transmission and high pressure homogeneous device3、 pump body unit construction4、 homogenizer structure diagram5、 pressure gauge schematic6、 explosion-proof device structure diagram7、 stripping attachment usage sketch mapOne、Use and characteristicsAs the usage of high pressure homogenization, high pressure homogenizer is the special equipment for homogenizing or refining liquids and transferring high pressure, which is widely used in production, research and technique development of food, dairy, beverage, pharmaceutical, fine chemical, biotechnology and other fields. This equipment can make liquids being mixed and refined in the three effects of crowd and grind, strong impact, and inflation. This equipment is of great importance in food, dairy products, beverage and other industrial equipment.For the soybean milk and other kinds of dairy liquids, homogenization is done in high pressure, which can help refine fat globules in the liquids, make products easy to be digested or absorbed, and improves edibleness.For the production of ice cream and other products, the equipment can help improve the cleanness and make its quality be improved significantly.For the production of emulsion, glue, fruit juice, slurry and other products, the equipment can help prevent or decrease the liquid delamination, improve liquid appearance, and make products brighter in color, thicker in fragrance, and purer in taste.As the high pressure pump： by being highly pressured , liquids can be made into power through the spraying drying equipment, which is an important equipment of powder production.Two、Main technical parameters（Figure 1）Three、Architecture OverviewThis machine consists of frame, pump body, transmission case，pressure gauge, homogenizer and other parts. This machine is vertical layout. The motor is installed in the frame and the transmission box is installed on the frame. The pump body connects the transmission boxMotor, belt, transmission case, and big gear make bent axle rotate and drive the plunger reciprocating motion. The plunger actions in the pump body form axial inlet and contraction. Pressure can be formed by the liquids control of the combination valve.When the machine is used for homogeneity, the homogenizer should be equipped with.（See attached figure 2 when assembly）. The material liquid was fully homogenized to refine material liquid molecular mass and uniform material liquid ingredients by the effect of homogenizing valve.This machine is used as a high-pressure pump. The homogeneous valve should be opened entirely, and the valve is not allowed to be installed in the high-pressure output pipeline.HomogenizerSpecificationFlow (m3/h)Operating pressure (Mpa)Motor power (KW)Weight (Kg)FOB price(yuan)DHB0.5-250.5255.567023500DHB1-251257.570028000DHB2-2522518120043000DHB3-2532530140057000DHB4-2542537140058500DHB5-2552545220079000DHB0.6-400.6401180033000DHB1-4014015120045000DHB2-4024022123054000DHB3-4034037200079000DHB4-40440552500113000DHB5-40540652500140000DHB0.2-600.2605.570028000DHB1-6016022120063000DHB2-6026045230097000DHB3-60360602500140000Four、Installation and Usage1、Installation：This machine is vertical fixed installation, and has four legs at the bottom that can be adjusted up and down, which is used to leveling and fixation.（1）Foundation which the equipment is lay in requires ground flat solid.（2）Four pieces of stainless steel gasket are at the bottom of the arm-braces. If there are rubber rails under the gaskets, noises can be reduced and stability can be improved.（3）When installing，the level ruler should be used to leveling for ensuring usability.（4）The equipment requires clean cooling water.（5）The feed liquid tank should be higher than the material inlet. The storage tank should be installed next to the equipment.（6）The valve is not allowed to be installed in the outlet of the pipeline, in order to prevent nausea cars and the breakdown.2、Usage：（1）Preparation before starting：Wipe out protection grease.Check whether bolts and nuts are screwed in the drive part and the pump body. Before starting , the belt pulley should be turned by hand, and check whether there are jams, blocking or loose phenomenon in the rotational parts.Clean engine oil should be injected to the oil level line in the transmission box. HJ40 engine oil is used in general and HJ50 engine oil is used in the high temperature workplace.The pressure regulating hand shank should be turned to the loosest position. Get through to cooling water in the plunger.Open the valve in the feed pipe for keeping the pipeline unblocked. Check the electrical device，and check whether the motor steering is correct.（2）Start the operation：After the above preparation，open the motor for light running.Unscrew bleeder screw for discharging air in the feed pipe and the pump body. Screw bleeder screw after liquids flowing from air release pipe.Tighten the hand shank of the homogenizer step by step. Observe whether the response of pressure gage is sensitive and observe the response of the ampere meter. The indicated value of the pressure gage and the ampere meter should synchronous rise. Otherwise, it should be checked whether the pressure gage is out of order or other reasons. Do not blindly pressurize that may cause overpressure accidents. The usage of the homogenizer: the machine is equipped with the secondary homogenizer. When in use, appropriate homogeneous method can be chosen according to the requirements of the products. First Grade homogenizer is suitable for most of the products. When using the secondary homogenization, please adjust the first level to two-thirds of homogeneous pressure to the required pressure and adjust the secondary homogeneous pressure to the required pressure, or adjust the secondary homogeneous pressure to one-third of homogeneous pressure to the required pressure and then adjust the first level of homogeneous pressure to the required pressure.When in load running，the biggest pressure shall not exceed 110% rated worth a short time.Material liquid should be filtered through stainless steel wire mesh in case that the debris in the liquids will block the pipeline or valve. （3）ParkingBefore parking, loosen the pressure regulating hand shank for removing pressure.After parking，close the valve at the feed pipeline. After parking , please clean the machine immediately. The equipment can be washed by cleaning fluid with low pressure circulation, in case that liquids deposit and go bad in the pump body and the pipeline for effecting the normal operation. Cleaning methods and use of cleaning fluid can be selected according to the requirement of the product. High pressure steam is not allowed. The following is a general cleaning method of dairy products for your reference.a、hot water（8090）washingb、15Nitric acid aqueous solution washing（removing protein gelling fluid）.c、15Caustic soda solution washing（neutralizing pickling solution and remaining lubricity）.（4）Matters need attention：Never start equipment under pressure，so unscrew the hand shank of the homogenizer after parking the equipment.Never start equipment under insufficient lubricating oil. The minimum oil level line is in the rear window of the equipment. The low oil level line will cause bent axle losing oil.No countermotions. The correct direction is facing the big belt wheel with clockwise rotation.Before the operation and maintenance of this machine, users should be familiar with the machine specification, and unprofessional operation is not allowed. Before using the new machine，check that all the nuts should be screwed.Within a week run-in period of new machine usage, cleansing oil should be changed in order to avoid foreign matter flowing into the slip part causing the bent axle and the bearings being burnout.The machine adopts advanced vibration-proof pressure gauge and special pressure gauge seat. When the machine is in normal operation and the pressure gauge is out of order, users should firstly check whether there is oil in the seat. If the oil is drying, edible oil or glycerol should be filled up.After a period of usage, please check and frap the triangle belt.Five、Maintenance1、Transmission case parts：When in operation, abnormal noises or rushing sounds should not appear in the transmission case. After a long period of operation, please check the space between the moving parts, and repair it when necessary.The space between pitman box and bent axle should not be larger than 0.3mm.The space between small end of connecting rod bushing and dowel should not be larger than 0.2mm.2、Pump body parts：（1）Valve（Structure as shown in figure 3）Hard particles in liquids will accelerate the valve wear. The dent or line generating from the valve face wear will result in forming leakage and decreasing work efficiency, insufficient flow, pressure oscillation and，bad noise in the valve operation and so on.Small hurts in the valve face can be removed by the grind. If the large hurt cannot be removed by the grind, the valve can be turned over for using or changed a new one.After 100 hours usage, check and grind the valves, valve seats and homogenizer valves. When installing, pay more attention to the check for avoiding missing the seal ring.（2）Plunger（Structure as shown in figure 3）The plunger in high pressure, liquids and the seal elements do reciprocating friction when the plunger is in operation. The plunger will suffer wear and leakage after a long time usage. If the plunger is worn out, change it in time for assuring normal operation.（3）Seal elementsThe seal is one of the important parts to prevent leakage. It plays its role depending on the elasticity of the material and surface shape. Therefore , please do as follows：The contact surface for installing the seal elements should be flat and smooth. Any burr or injury is not allowed.In order to avoid skew and damage during installation, please pay more attention to installation. Do not allow force installation. Lubricating grease can be drawn when necessary.3、Lubrication：（1） Transmission box is self-lubrication. Engine oil should be filtered at the 150 mesh for assuring the oil clearness.（2） The oil should be changed after 100-hour operation. The changed oil can be reused through precipitation and filtration. After then, change oil per 1000 hour, and drain off water and discharge pollution once. Open transmission tank and clean tank wall once a year.（3） Regularly check the oil level and oil luster, if it is abnormal, please check immediately.4、Attention：（1）The new valve, valve seat, or homogenizer valve parts should be matched and grinded when new parts are changed. And coating should be used to check the contact surface in order to ensure that the contact area can be sealed, and improve the performance of the whole machine with prolong service life.（2）When installing the nuts and bolts, thick grease should be painted and the screw power should be proper.（3）Adjust correctly the flow of cooling water in the plunger to prevent that large water flow causes splash.（4）The bouncing of the gauge hand should be within 1.（5）If it is found abnormal sound or hot in the part, the machine should be stopped in time to check and repair（6）It is strictly prohibited that screwing the bolts or repairing in operation.（7）It is strictly prohibited running without cooling water.Chart 1 the elimination methods of general breakdown Order numberBreakdownGeneral causeElimination method1Lack of flow, pressure is not highLeakage and loss of the valve, damage of seal, leakage and loss of the homogeneous valveCheck, repair, and replace2Over beating of the gauge hand Leakage and loss of the valve, damage of seal、Poor pressure gauge componentCheck, repair, and replace3Voice uneven in the valve operation, high pressure brakingDamage and leakage of the part of the valve, spring damageCheck, repair, and replace4Material liquid in the plungerThe plunger ring wear, plunger wearRenew5Rushing sound in the pump bodyGas and debris in the pump bodyEliminate by air bleed screw and disassemble to check 6Knock noise in the transmission boxPitman box and bushing wear、connecting rod bolt looseness 、The valve leakage and lossReplace, tight and repair7crankcase bearing heatingbearing failure、debris in the bearing、poor assembly of the bearingInspection, renew, replace, clean, assembly8Sliding block heatingDebris between sliding block and box , block of lubrication hole disassembly、check、clean9Motor heatingDamage of electrical appliances、too high room temperatureCheck、Action of repairing and replacing、reduce