The equipment manufactured by our company, if used without due regard for safety, could pose significant risks of personal injury. Therefore, whenever and under any operating conditions you use our company's equipment, please strictly adhere to the operating guidelines and always prioritize your personal safety.
Please read this manual carefully!

Attention

The copyright of this manual, as well as all illustrations and images used herein, is owned by our company. No individual or organization may reproduce, modify, quote, or reprint any part of it without our company’s prior written authorization; otherwise, our company will pursue legal action against such unauthorized use.

This manual may not describe certain device features, but the company assumes no responsibility for these features during actual use.

During the review and editing process of this manual, we conducted a thorough examination; however, inconsistencies and inaccuracies may still exist. We will periodically check the content within the manual and reserve the right to make revisions without prior notice.

Attention

This manual explains the latest technology of our company's product series and summarizes the key technical features of each device. The product line features a variety of designs, including different sizes, distinct functional roles, diverse installation methods, and varying component configurations. If you need to determine the appropriate model for your equipment, please contact our company.

This product series features numerous components designed for specific functions, which can be easily added and assembled—such as flying blades, spray nozzles, and other functional parts.

Installing additional components requires separate specification for retrofitting, in order to manufacture according to the requirements.

As an equipment manager, the following situations will result in the equipment being taken out of use:

-- The equipment is not properly installed and secured;
-- The device is not properly connected to the power source;
-- The equipment's gearbox has not been lubricated;
-- The circulating oil pump for the gearbox is not properly connected to the power supply;
-- The gas unit failed to secure a stable gas supply;
-- The safety device of the equipment is not installed correctly;
– The cooling fan for the variable-frequency motor is not properly connected to an independent power source; – The equipment is currently in the installation and construction phase.
-- After installation, the integrity of the equipment was not checked;
--The equipment includes various installation tools and lifting devices stored within the equipment cylinder;
-- Equipment status related to inspection, maintenance, and upkeep;
-- The electrical components of the equipment were wetted by cleaning water;
--The equipment is used to mix materials that do not meet the requirements for the equipment's material, such as corrosive, flammable, or explosive substances;
-- Filling the equipment cylinder or jacket with pressure that does not meet manufacturing standards, or creating a vacuum.

Attention

This manual also records the results of various equipment debugging sessions, detailed maintenance and upkeep logs for each phase, as well as comprehensive records of repair outcomes. Therefore, please keep this manual safely stored so that our company’s after-sales personnel can promptly understand the equipment’s status and respond swiftly.
This manual can serve as the basis for product after-sales service, as well as a record for repairs and maintenance.

Under normal usage, our company will fulfill the warranty obligations stipulated in the contract. However, if the user makes unauthorized modifications to the equipment, fails to follow the instructions outlined in this manual, or in the following circumstances, our company will suspend the warranty obligation:

-- Equipment improperly installed due to failure to follow the manual or lack of technical support from our company;
– Removing safety devices preset on the equipment or disabling equipment that shields safe operation features;
-- Equipment used in serious violation of operational guidelines, failing to follow the manual's requirements;
– Beyond the agreed warranty period;
-- Equipment whose components have been privately modified, with or without the company's approval, or where parts have been added or removed;
-- Unauthorized replacement of non-genuine parts without the company's permission or approval resulted in equipment malfunction;
– Replacing materials required for production with materials produced without the necessary manufacturing license;
– During warranty service, it is impossible to provide repair conditions that ensure personal safety;
-- Do not use the equipment in high-risk, toxic, or outdoor environments without our company's approval;

If the device is transferred for sale, please pass this manual on to the new user. If this manual is lost, you may request a replacement directly from our company.

Attention

This manual outlines the product's various performance features and highlights essential safety guidelines and precautions for proper usage.
Ensure the safety of operators and the stable operation of equipment.

To better illustrate the device's structure, this manual includes detailed illustrations of certain components, as well as equipment diagrams that conceal some parts. When using the device, be sure to inspect—especially its safety components—as well as the integrity of other key parts.

This manual uses text and images to inform users about the product's performance, installation, usage, maintenance, and troubleshooting.
This manual introduces the current model products.

This manual outlines the various configurations available for the current model of product. Please note that the equipment you’ve purchased may not include all of these features, as your device was customized according to your specific requirements. Therefore, the information provided in this manual might differ slightly from the actual equipment you’ve acquired.
This manual reflects the latest technical standards at the time the product is sold. Although the company may subsequently update the product’s technology, this manual will remain valid.

At the same time, the company reserves the right to revise the manual as needed to meet new standards—without prior notice and without replacing the previous version of the manual.

Our company's equipment is suitable for altitudes below 2,000 meters and operates under normal temperature and atmospheric pressure conditions. If users have special requirements, they should specify them before placing an order and clearly indicate these details in the purchase contract.

Our company will continuously optimize our products, and we would appreciate any feedback or suggestions aimed at improving either the product or this manual.

Safety Precautions

Attention

Sources of harm to avoid

The mixer has three main sources of harm:

1. Mechanical Injury

Mechanical hazards from the mixer originate from various transmission components, agitators, hinged doors, and other areas—specific locations will be clearly marked in the manual.

2. Electric Shock Injuries

The electrical shock hazards of the mixer come from the motor, control cabinet, cables, and cable connections.

Third, temperature damage

The temperature-related damage to the mixer can originate from the temperature control kit, the fluid coupling unit, and potentially from various transmission components as well.

Basic Principles for Safe Operation

1. Absolutely no touching of moving transmission parts or mixers with the human body, and be cautious of hazardous behaviors such as accidental falls or collisions.

2. The mixing equipment is a forced-mixing device; during maintenance and cleaning operations, ensure that the main power supply is switched off, and take precautions to prevent anyone else from turning the main power back on.

3. Electrical connection, wiring inspection, and maintenance of the control section must be performed by qualified electricians; unauthorized personnel are strictly prohibited from operating.

4. Do not remove the safety protection devices that come with the equipment itself, and perform safety checks according to the notes in this manual.

5. Avoid all heat source areas and strictly prohibit direct physical contact. Also, ensure that no one stands in the potential splash paths of any components.

6. Ensure that all hinged moving parts are protected against pinching or injury when opening and closing.

7. Users should establish a post responsibility system and strengthen their awareness of safe production.

Safety warning areas on the equipment

Attention

This manual uses line drawings to illustrate the external appearance of the vertical mixer under different structural configurations. While the drawings may vary slightly from the user’s custom-designed equipment, this does not diminish the importance of safety considerations applicable across all structural designs.
Our company customizes equipment according to requirements, selecting or omitting certain safety devices and protective measures based on different manufacturing (or usage) standards. However, during operation, such risks should still be avoided.

1. Electric Motor Impeller Guard

From the equipment installation to the start of production, there is no need to remove the motor impeller guard; it may only be taken off temporarily during maintenance for calibration purposes. Therefore, unauthorized or non-professional maintenance personnel must not dismantle this guard. After maintenance is complete, the guard should be promptly reinstalled and secured—never operate the equipment with the guard removed.

2. Grounding electrical appliances or equipment

A complete grounding system must be installed to prevent accidental leakage, short circuits, and static electricity from causing harm to individuals.

3. Emergency Stop Button

In the design of electrical control systems, an emergency stop button should be included and installed near the mixing equipment, ensuring it is easily accessible so that the equipment can be immediately shut down in case of malfunction.
If the control cabinet is installed near the mixing equipment, an emergency stop button can be directly mounted on the control cabinet.

4. Protection for the Feeding and Cleaning Ports

The manually operated door installed on the cylinder features direct feed-in and cleaning openings, along with corresponding safety measures such as safety switches or barrier grids.
On equipment equipped with safety switches, two measures are in place to ensure personal safety: 1. When the door is opened, the mixer cannot operate. 2. If the door is opened while the mixer is running, the mixer will immediately stop. This functionality must be implemented in conjunction with the electrical control cabinet.
The hybrid device, which starts under no-load conditions, features a densely packed load-bearing grid or a dedicated manual feeder fitted at its manual feeding port, effectively preventing personal injury.
The safety grilles on cleaning doors or feed openings must not be removed during the production process.

Basic information about the equipment

Scope of Application

Conical mixers are widely used in mixing processes involving powders with powders, granules with granules, or powders combined with liquids—in industries such as chemicals, pesticides, dyes, food, battery materials, rare earths, and rubber-plastic materials.

1. The conical mixing drum boasts a high standard requirement for ensuring no residue remains when discharging the mixed materials.
2. Gentle stirring methods prevent damage to fragile materials such as crystalline substances.

3. The conical mixer delivers superior mixing performance and better compatibility with material chemical reactions, especially in terms of low energy consumption.
The drive system of the double-helix conical mixer can simultaneously deliver independent output shafts rotating at two different speeds, while the helix on the cantilever arm creates a combination of orbital and rotational motion during mixing.
The ribbon-type conical mixer and the paddle-type conical mixer both utilize a single-output shaft drive, with a sealed isolation device installed at the output shaft position of the drive unit to completely prevent any leakage or contamination.

How it works

The double-helix conical mixer features two asymmetrical helices mounted on an internal cantilever, which rotate both around their own axes and are driven by the cantilever to revolve around the central axis of the mixing vessel.

The double-helix conical mixer can generate forces acting in four directions:

1. Two asymmetrical helical screws rotate on their own axes, lifting the material upward.
2. The cantilever performs slow, circular rotation, causing the material to move in a continuous, cyclical motion.
3. The spiral revolution and rotation work in harmony, drawing materials into the spiral while simultaneously dispersing them outward in a circular direction.
4. The two material streams, elevated to the upper section, then converge toward the center, creating a downward flow that fills the empty zone at the bottom, thus establishing an overall circulating flow pattern.

The ribbon-type conical mixer and the paddle-type conical mixer both feature a dual-layer force system, where the central screw interacts with either the outer ribbon or the outer paddles, creating extensive circulating motion of the material.

Special Note

The double-helix conical mixer is designed for blending bulk materials, fine-particle materials (particle size less than 1mm), small amounts of liquids, or similar types of materials.

The paddle-type conical mixer can handle the mixing of various forms of composite materials, including powders, granules, and liquids.

During the device configuration process, the following situations either exist or need to be configured. The configured hybrid device will differ from a standard hybrid device and must be explicitly noted:

1. The raw materials contain hard particles with a particle size exceeding 2 mm;
2. Material density is greater than 2;
3. Material particle size exceeds 500 mesh;
4. The dry powder material has a relatively high moisture content, appearing damp, hygroscopic, or exhibiting adhesive properties;
5. When equipment needs to be heated to temperatures exceeding 120 degrees;
6. The materials have special properties such as exothermic reactions, steam generation, flammability, explosiveness, and tendency to stick or adhere.
7. When mixing two materials with a specific gravity difference exceeding 1 to 20 or a particle size difference exceeding 1 to 100;
8. Requires equipment capable of vacuuming or maintaining a negative pressure state;
9. When compressed gas is introduced into the equipment cylinder, creating pressure;
10. Material properties such as particle size, hardness, and irregular shapes can easily lead to equipment wear;
11. Processes where materials cannot come into direct contact with metal;
12. When mixing materials, first add the materials and start the equipment at full load. Do not stir non-fluid materials such as pastes, solid oils, or substances with no flowability. Avoid mixing materials that are excessively viscous, and never directly handle materials with a formulation ratio lower than 1:1000. Additionally, do not process materials that rapidly harden or solidify within a short time, nor should you handle unstable substances like explosives.

The following factors highlight the differences in equipment:

Equipment materials, surface treatments, startup methods, motor power, gear reducer configurations, spindle sealing, equipment speed, cylinder inspection openings, discharge valves, temperature-controlled jacket systems, maintenance access doors, liquid spray mechanisms, liquid addition flow rates, power supply characteristics, and protective measures, among others.

Equipment Installation

Equipment lifting and installation

The conical mixer standard employs suspension lifting, and all operations must follow specific procedures, carried out exclusively by professionally trained personnel qualified to operate specialized equipment.
The cone-shaped mixer is equipped with dedicated lifting holes on its cylinder. Use lifting devices that comply with relevant safety standards, and employ lifting equipment capable of handling the load—refer to the illustration for proper lifting procedures. Ensure the center of gravity is carefully controlled during the lift, and after hoisting, operate at a slow pace to maintain stable movement.
Personnel should remain in a safe area during operations and are prohibited from standing directly beneath lifting equipment.

Equipment Foundation Installation

As an intermediate process equipment, hybrid devices typically require a supporting structure to elevate and position the equipment at a height above the ground, ensuring it meets the process design requirements of the production workflow.
The conical mixer is supported by four ear brackets and horizontally fixed to a steel-structure platform.
The platform's design should account for resonance phenomena caused by operating hybrid equipment, ensuring that it does not interfere with the performance of other devices or the weighing equipment itself.
The platform's design capacity typically ranges from 2 to 3 times the weight of the equipment—specifically, the equipment's own weight plus the weight of the materials being mixed, as well as any additional attachments mounted on the device.
The installation of the large conical mixer should take into account the mixer's diameter and height, particularly when it comes to lifting and hoisting during the overall plant construction process.

Precautions during installation

During the installation process of the flow system, the various pieces of equipment within the flow must be arranged in a specific sequence for installation.

When fabricating the equipment's foundation structure, attention should be paid to ensuring the installation position is level and properly aligned. During equipment placement, shims can be used to adjust the levelness of the equipment, helping to prevent potential malfunctions caused by improper alignment.

The equipment's safety bolts and the foundation bolts for the platform columns do not use spring washers for anti-loosening; instead, they employ a double-nut system to prevent loosening, while also reserving approximately 3 to 5 threaded positions for future bolts.

When the equipment needs to be installed on a steel-structure platform, a rubber plate can be added between the equipment base and the mounting plate to reduce vibrations during operation.

When installing the equipment, pay attention to its orientation, ensuring that the installation adheres to safety principles while also optimizing production efficiency, facilitating maintenance and repairs, and enabling easy cleaning and upkeep.

The steel-structure platform should be equipped with comprehensive protective measures, such as fences.

When installing the equipment, ensure that no installation tools or other debris fall into the equipment cylinder, and take precautions to prevent them from getting stuck in the various transmission parts of the spindle.

The installation components used during installation are either provided by the user or prepared by the installation company.

If the equipment is not installed or used for an extended period, it must be stored in a dry, well-ventilated, and cool environment, with proper measures taken to prevent slipping and ensure stable operational balance.

Equipment power installation

All operations related to the circuit must be carried out by qualified professionals. Ensure strict adherence to standards by selecting high-quality electrical components and cables of appropriate capacity for circuit installation.

The starting control systems for mixing equipment come in a variety of configuration structures, including star-delta start, variable-frequency start, reduced-voltage start, and direct-on-line start, depending on the operational conditions and environment.

The dual-helix conical mixer features a separate-type design for revolution and rotation, requiring simultaneous connection of both the revolution motor and the rotation motor, with separate control mechanisms. Specifically, you must first independently start the rotation motor before activating the revolution motor.

When installing power supplies for hybrid devices, the power lines must be thoroughly inspected to ensure no phase or voltage mismatches occur.

All hybrid devices have a fixed rotation direction. During equipment debugging or after power installation, briefly press the start button to check whether the device's rotation direction matches the label sticker on the equipment. If the rotation is in the opposite direction, simply swap any two of the three-phase wires connected to the motor junction box, then perform another brief test to verify the correct rotation direction.
After installing the power supply, all buttons and indicator lights on the electrical control box should be checked for proper functionality. If any component fails, address the issue promptly—do not proceed with direct use of the mixed equipment.

The basic configuration of the electrical control box should include the following components: a 3-phase ammeter, a voltmeter, a converter, 3-phase power-in indicator lights, a start button, a start indicator light, a stop button, and a stop indicator light.

Attention

Your equipment, as stipulated in the contract, may not include an electrical control box. Please proactively request the equipment control circuit diagram from our company, and ensure that installation or customization is carried out by a qualified company or personnel. All components and the enclosure provided must comply with the relevant safety standards.
If equipped with a dedicated circulating oil pump for the gearbox, it should be powered on simultaneously with the motor’s startup; otherwise, the gearbox may end up operating without proper lubrication, directly leading to its damage.
If the equipment is equipped with a variable-frequency-specific motor, the motor fan should be powered independently and must not be connected in parallel with the main power line supplying the inverter and the variable-frequency motor. Otherwise, the motor is likely to overheat and burn out.

Equipment debugging

Instructions Before Debugging

At the time of出厂, all equipment has undergone a one-hour no-load test to meet quality inspection standards. After reviewing the equipment's manufacturing requirements, it is then released for shipment.

After users have completed the equipment installation, they still need to perform an unloaded trial run. If the equipment has been left unused for an extended period, or if more than 3 months have passed since it was manufactured before being put into operation, a low-speed, unloaded trial run should be conducted—or alternatively, the mixer blades of the blending unit can be manually rotated by hand to test their functionality. Regarding the debugging process, this includes functional accessories such as shear knives; however, if the blending equipment lacks these configured components, the corresponding steps for this part can be skipped altogether.

Attention

During all types of debugging, please use the raw materials required for production for testing—do not substitute them with other materials. The materials used must fall within the operational range of the mixing equipment. If hard, blocky materials or installation tools happen to drop into the mixing device and become trapped inside, they could cause severe damage, potentially leading to the complete failure and scrapping of the equipment.

After the mixed equipment installation and debugging are completed, it is still necessary to clean the inside of the equipment. Additionally, before formal production begins, multiple cycles of material mixing can be performed to thoroughly remove any residual powder impurities that aren’t part of the raw materials. Equipment requiring high hygiene standards should undergo sterilization procedures.
During all types of debugging, operators and on-site inspectors should not leave their posts until the debugging is complete.

Various types of debugging cannot be performed out of sequence, nor can they span across time.

When the equipment leaves the factory, the gearboxes have not been lubricated with oil. Users should add lubricant themselves before using the equipment; otherwise, operating the gearbox without proper lubrication will directly cause damage to the unit.

Prepare homework

Follow the lubrication guidelines outlined in the Maintenance and Care section of this manual to correctly add lubricant to the gearbox, and ensure that all lubrication points of the equipment are properly greased and inspected.
If the equipment's gearbox is equipped with a lubrication oil circulation pump, ensure that it powers on and operates properly; otherwise, it may easily lead to localized lack of lubrication within the gearbox, resulting in damage to the reducer.
Inspect the inside of the simplified equipment and check for any potential debris or tools in its various transmission parts, and clean the exterior of the equipment. Ensure that any inspection doors installed on the equipment are securely closed and locked.
Check whether the equipment's power supply is functioning properly, including the main motor power, discharge valve power, safety device power, and more.
Turn on the gas supply valve and check whether the gas sources used by the equipment—such as the discharge cylinder and the air-sealing device—are functioning properly, including the pressure levels and the power supply to each solenoid device.
Adjust the device's startup parameters, such as the star-delta start method's switching time and the variable-frequency start method's starting frequency, among others.

Functional Component Testing

After the equipment is powered on, you should first check whether the functional accessories are operating properly.
Open and close the mixer discharge valve, adjust the appropriate compressed air flow rate, and ensure stable opening and closing performance.
Test whether the signals from each safety device are correct.

All accessories installed on the equipment, such as sampling valves, level indicators, thermometers, and others, must be verified before the equipment's main shaft is started for no-load testing.
After the attachment has been inspected, briefly press the main motor’s start button to check whether its rotation direction matches the label indicated on the equipment cylinder. If not, make adjustments promptly.

No-load commissioning

After the equipment completes preparation and functional debugging, it enters the no-load commissioning phase.

Proceed step by step according to the following method:

1. Power on the main motor of the pneumatic mixer. (If it’s a separate planetary and rotating-type unit, first start the rotating motor, then the planetary motor.)
2. Run the mixer for 5 minutes, continuously monitoring for any unusual or disruptive noises during operation. If such noises are detected, immediately stop the equipment. Also, check whether the operating current is within the normal range; if not, promptly use the stop button or emergency stop button to cut off the power.
3. Ensure the mixer is running normally. After operating continuously for 1 hour, inspect all parts of the mixing equipment for overheating, vibration, or unusual noises. If any of these issues are detected, take immediate action.
4. Before stopping the operation of each motor in the mixing equipment, simulate the discharge process by opening and closing the discharge valve multiple times to verify proper functionality.
5. If safety devices, such as limit switches, are specifically installed for the equipment, they should be verified at this time. When the protected component is triggered, all power sources of the hybrid equipment must be able to shut off immediately; otherwise, power supply should be halted right away, and the control circuit should be inspected promptly.

Check after debugging

During debugging and after the debugging period concludes, inspections will be conducted on the following areas:
The temperatures of the main motor and main gearbox should both be below 50 degrees Celsius.
The inner surface of the cylinder, the edges of the ribbon, and the paddles show no signs of friction;
Current conditions during no-load commissioning of motors in each component;
All connecting bolts and anchor bolts on the equipment show no signs of looseness.

Load Testing and Debugging

The equipment has completed preparatory work and undergone functional and no-load debugging; only after confirming no abnormalities can it proceed to the load testing phase.
To smoothly complete the equipment's load commissioning, operators should familiarize themselves with all of the equipment's controls during the no-load debugging phase. Additionally, multiple no-load test runs can be conducted to master the operational sequence and emergency stop procedures.
Load debugging requires adding materials to the mixing equipment, so either feeding equipment needs to participate in the debugging process, or materials must be added manually. The materials used must be free of any foreign objects, and their properties in all aspects should align with the operational range of the mixing equipment.
Please follow these steps:
1. Start the main motor of the mixer; (if it’s a separate planetary and rotating type, first start the rotating motor, then the planetary motor.)
2. After observing no abnormalities, proceed with filling and adding materials;
3. The added materials should be within the operational range of this equipment.
Additionally, it can be tested with 50% and 100% of the rated mixing capacity, with each trial run lasting at least 1 hour.
4. During the test run, if any abnormal conditions occur, the equipment should be immediately stopped using either the stop button or the emergency stop button in case of an emergency.
5. After a normal test run, open the discharge port to empty the material from the mixing equipment, then stop the mixing device.

Check after debugging

During the load debugging process and after the debugging period ends, checks are conducted on the following aspects:

The temperatures of the main motor and main gearbox should both be below 60 degrees Celsius.
The inner surface of the cylinder, the edges of the ribbon, and the paddles show no signs of friction;
Current conditions during no-load commissioning of motors in each component;
There are no signs of looseness in any of the connecting bolts or anchor bolts on the equipment.

Re-trimming initiated for commissioning

At this stage, only specially designed equipment capable of overload startup can perform the task. During commissioning, the process should follow these steps: preparatory work, functional accessory testing, no-load testing, and finally, loaded testing—only after completing all these stages is the overload startup performance test permitted.
Hybrid devices equipped with overload-start capabilities will have corresponding structural differences in their configuration. During debugging, operations should be performed based on the actual configuration method used.

Please follow these steps:
1. Load the mixing equipment with materials that meet the specified requirements.
2. Start the spindle motor of the hybrid device. (If it’s a separate rotation and revolution type, first start the rotation motor, then the revolution motor.) If the device fails to perform revolution mixing immediately after power is turned on, stop the power supply right away and notify our company’s after-sales service personnel for assistance. Do not continue supplying power blindly, as this could lead to motor burnout.
3. After the hybrid equipment is running normally, please directly apply the loaded commissioning method for all types of inspections.

Occupational Safety and Health

Safety Precautions During Labor

When operating mixed equipment, pay attention to the designated warning areas marked on the devices.

Equipment with removed safety devices must not be used.

When operating mixed equipment, climbing on the equipment for any purpose is strictly prohibited.

When the mixed equipment is running, no tools may be used to reach into the equipment through the feed opening.

When cleaning, repairing, or lubricating equipment, be sure to disconnect the power supply and use warning signs or lockout/tagout procedures to prevent unauthorized personnel from turning the power back on.
When personnel enter the mixer for operations, they should adopt appropriate protective measures, including wearing a filtering respirator and protective goggles. For large-scale equipment, ensure adequate ventilation inside; if necessary, use a blower to facilitate air exchange.
Establish safety production regulations and implement reasonable measures to ensure personal safety.

Plans and Responsibilities

Use equipment that has been properly debugged for production, and establish a series of pilot production plans to better coordinate and align the various stages of the manufacturing process.
Establish a job responsibility system and assign trained professionals to perform all equipment operations. Implement a rational division of labor to ensure the smooth completion of production tasks.

Preparation before material feeding for production

Before powering on the electrical control system, check whether the cylinder has the necessary production conditions, verify if the surrounding equipment is ready for operation, and clear away any obstructions or debris.
Check whether the maintenance doors installed on the equipment and the safety devices are properly in place. After completing the hardware inspection, turn on the switch of the electrical control box and verify that the supply voltage and phase sequence are normal.
Check whether the lubrication oil circulation pump for the accelerator is energized properly. If the mixing equipment is equipped with pneumatic discharge or pneumatic sealing devices, first power on the compressed air source and verify the air supply pressure at each point.

The pneumatic discharge valve requires an air pressure of at least 6 kg (0.6 MPa).
The pneumatic sealing device uses air pressure of approximately 4 kg (0.4 MPa).
Pre-production no-load simulation test
Start the mixer spindle motor and check for noise-free operation to determine the prerequisites for production of the mixing equipment.
Activate the circulating oil pump for the reducer's lubricating oil.
The hybrid device is running; open and close the discharge valve.
Performing the basic discharge operation for mixed equipment.
Testing additional supporting equipment, such as dust collectors.
Test whether the finished material handling equipment is operating properly.
Only after the no-load simulation is completed are operators permitted to proceed with normal production involving material feeding.
Material Feeding Production Operation

The single batch weight of the horizontal mixer should meet two criteria:

1. The volume of the materials submitted should be 20% to 50% of the mixing equipment cylinder's storage capacity;
II. The weight of the materials submitted must be within the capacity of this mixer.
Initially, the configuration of the mixing equipment is determined by first selecting the size of the equipment cylinder based on the volume of material to be mixed in a single batch. Then, according to the material's specific gravity, the weight of the material per batch is calculated to determine the required load capacity of the mixing equipment—such as motor power and spindle size.
The specific gravity of the materials added to the equipment must not exceed the originally preset allowable weight.
The load-carrying capacity of a hybrid device cannot be determined solely by the specific gravity of the material—factors such as the material's coefficient of friction and particle size can also significantly influence the equipment's operational performance.

The production feeding operation for conventional equipment should be:

↓ Close the equipment discharge valve
↓ Operate the equipment's stirring shaft
↓Perform material feeding operations
↓ Conduct mixed operations
↓Mixing time completed
↓ Open the equipment discharge valve
↓ Material discharge completed
↓ Turn off the machine spindle
↓ Finish homework

In actual production operations, the following aspects should be noted:

1. If the mixing equipment is equipped with a manual discharge valve or lacks a stroke-position interlock signal for the discharge valve, ensure that the discharge valve is closed before feeding materials into the system.
2. The mixing equipment is currently running with material inside. Unless there’s an unexpected issue requiring immediate shutdown, the equipment should not be stopped arbitrarily. Otherwise, equipment not designed with robust overload-start capabilities may fail to restart altogether. If an emergency stop occurs, it will be necessary to remove some of the material from the mixing unit until the equipment can resume operation smoothly. During this restart process, care must be taken to avoid continuously overloading the motor, as doing so could directly lead to motor burnout.
3. The discharge valve configured for the equipment has different material-specific discharge times; therefore, during trial production, a reasonable material-release time should be estimated.
4. When adding liquids during the mixing process, it is recommended to do so in a spray form; otherwise, uneven mixing or clumping may easily occur.

Maintenance and Care

The basic principles of maintenance

Implementing a regular maintenance plan can effectively extend the lifespan of equipment and better ensure safe production.

When repairing or maintaining the equipment, please use the components provided by our company, or procure them yourself under the guidance of our company's technical staff. Each maintenance and upkeep plan should be assigned to a dedicated person in charge and carried out by trained personnel.

When the equipment is running normally, necessary maintenance measures should be taken for the following items: keeping the exterior clean, lubricating the gearbox, checking the tightness of all fastening bolts, and establishing a regular schedule for these tasks.

When performing equipment maintenance and inspections, follow the safety operating procedures.

Equipment lubrication

Lubrication of the gearbox

Lubricate the reducer of the homogenization equipment. The reducer is equipped with an oil level sight glass or oil level indicator tube. Add lubricating oil gradually until the level reaches the midpoint of the sight glass or indicator tube.

Add Gear Oil No. 320–460 to the gear reducer, and use No. 40 engine oil for the harmonic drive reducer.

When adding lubricant for the first time—before the equipment is running—the oil level indicated by the sight glass or dipstick may not accurately reflect the actual amount of lubricant added inside the gearbox. Instead, you should monitor the oil level after the gearbox has been properly run and allowed to circulate the lubricant evenly throughout the housing. Therefore, when adding lubricant, it’s best to do so in multiple small increments.

Adding excessive lubricant can easily lead to oil overflow, compromising sealing performance and even causing environmental pollution or contamination of materials; conversely, insufficient lubricant will result in severe wear of the gearbox, significantly reducing its service life.

When adding lubricant, the machine should be stopped for operation.

After the equipment has run for 1,500 hours, the lubrication inside the gearbox should be replaced. When performing this task, first drain the old oil completely before adding new oil. For gearboxes equipped with a circulating oil pump, proper lubrication can only be achieved when the pump is operating correctly.

Equipment cleaning

After continuous production on the mixing equipment, if it's necessary to switch material types or clean out materials that are prone to spoilage, the interior of the mixing equipment must be thoroughly cleaned.

When cleaning, please note the following points:

1. Please do not leave any cleaning tools used inside the equipment; they should be collected and organized uniformly after cleaning.

2. Use clean compressed air for cleaning and take appropriate protective measures to prevent eye injuries from particles blown up by the compressed air.

3. When cleaning with water, be sure to wipe away any accumulated water afterward. Alternatively, you can use compressed air to dry the equipment thoroughly.

4. When cleaning the equipment with water, pay attention to electrical safety and take appropriate isolation measures for the motor, control box, and solenoid valves.

5. When cleaning, ensure that the equipment is not turned on and the electrical control box is disconnected from power to prevent others from accidentally activating the power supply. Appropriate warning measures should also be implemented.

6. Do not use cleaning agents that are corrosive to the materials of the hybrid device itself.

7. Equipment requiring hygiene standards should be cleaned using appropriate cleaning methods that meet the necessary requirements.

8. The internal structure of the mixing equipment is complex; when cleaning, gently rotate the equipment’s main shaft by hand to remove any adhered materials from the reverse side.

9. Do not use blunt or sharp tools for cleaning operations, as this may easily damage the inner surface of the equipment. After cleaning the equipment, be sure to reset its safety devices.

Possible Equipment Failures and Troubleshooting