I. Safety Precautions

Attention

The equipment manufactured by our company, if used without due regard for safety, could pose significant risks of injury to individuals. Therefore, at all times and under all operating conditions, users must strictly adhere to the operational guidelines and remain vigilant about 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, cite, or redistribute any part of it without our company’s prior written authorization; otherwise, our company will pursue legal action against the offender.

This manual may not describe certain device features; however, the company assumes no responsibility for these features during actual use, as they are provided solely for informational purposes.

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.

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

-- The equipment is not properly installed and secured;

-- The device is not properly connected to the power source;

-- The gas unit failed to secure a stable gas supply;

-- Safety devices of the equipment are not properly installed;

--The equipment is 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 device itself;

-- Equipment status related to inspection, maintenance, and upkeep;

-- The electrical components of the equipment were wetted by cleaning water;

Attention

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 any of the following circumstances, our company will suspend the warranty obligations.

-- Equipment improperly installed due to failure to follow the manual or lack of technical support from our company;

– Removing pre-installed safety devices on 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-original parts without the company's permission or approval resulted in equipment malfunction;

– During warranty service, it is impossible to provide repair conditions that ensure personal safety;

-- Do not use the equipment in high-risk, hazardous, 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, ensuring both the operator's safety and the reliable operation of the equipment.

To better illustrate the device's structure, this manual includes several detailed illustrations of local components, as well as equipment diagrams that conceal certain parts. When using the device, please carefully inspect—especially the safety components and ensure the integrity of all other 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 products; however, the equipment you’ve purchased may not include all of them. Since your device was customized according to your specific requirements, the information provided in the manual might differ from the actual features of the equipment you received.

This manual reflects the latest technical standards at the time the product is sold. While the company may subsequently introduce technical updates to the product, this manual will remain valid. Additionally, the company reserves the right to revise the manual as needed to align with new standards—without providing prior notice or replacing previous versions of the manual.

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

Attention

1. Sources of harm to avoid

The equipment has three main sources of harm:

1. Mechanical Injury

1. The mechanical hazards of the equipment come from its various transmission components, and we will specifically mark the relevant areas in the manual.

2. Electric Motor Impeller Guard

From equipment installation through to the start of production, there is no need to remove the motor impeller guard. The guard 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 completed, the guard should be promptly reinstalled and reset—never operate the equipment with the guard removed.

Second, electric shock injuries

1. Electrical shock hazards from the equipment originate from the motor, control cabinet, cables, and cable connections.

2. A complete grounding system must be installed to prevent accidental leakage currents, short circuits, and potential electrostatic hazards that could harm individuals.

Third, temperature damage

The temperature-related damage to the equipment can originate from the temperature control kit, the fluid coupling device, or potentially from the various transmission components as well.

2. Basic Principles for Safe Operation

1. Absolutely no touching of moving transmission parts on the human body, and be mindful of potential hazards such as accidental falls or collisions.

2. When performing maintenance or cleaning operations on the equipment, ensure that the main power supply is turned off and take precautions to prevent anyone else from accidentally turning it back on.

3. Electrical connection, wiring inspection, and maintenance of the control section must be performed by qualified electricians; non-professionals are strictly prohibited from operating these tasks.

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. For all moving parts, ensure that no pinching injuries occur during rotation.

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

II. Basic Information on the Equipment

1. Scope of Application

Cooling tanks are widely used in water bath cooling processes for materials such as chemicals and modified plastics.

Features:

1. The cooling tank meets the high-standard requirement of providing non-contaminating cooling for materials.

2. The adjustable guide roller allows for convenient adjustment of the cooling distance and bath water depth.

3. The control valves installed at the cooling tank heat exchange station allow for easy adjustment of the tank temperature.

2. Working Principle

Cooling water inside the cooling tank is pumped in through multiple inlet points located along the tank's sides, driven by a water pump. As materials cool and exchange heat within the tank, return and overflow ports are strategically placed at the bottom and front of the tank. After absorbing heat, the warmed cooling water is drawn back into the system via these return and overflow ports, then routed through a filter before entering a plate-type heat exchanger. There, it exchanges heat with external cooling water, effectively lowering its temperature. Finally, the cooled water re-enters the tank through the multi-point inlets on the side, completing the continuous cooling cycle within the tank.

3. Equipment Configuration

1. Install a 40-mesh basket-type filter on the pipeline, and a basket-style strainer is required for the side overflow of the sink.

2. Materials: SUS304 sink, 2B finish, 2.5mm thick; carbon steel frame, 40mm x 40mm x 2/Q235B square tubing.

3. Water Refill: Float valve automatically refills water

4. Adjustable-angle nylon guide rollers: 6 per trough; brushes: 2 per trough

5. On both sides of the machine head are handwheel gear racks and stainless steel tool boxes. Near the extruder end on both sides of the sink, there are filter mesh baskets. At the front of the sink, a material-receiving tray is positioned to catch cut-off material strips, along with a capacitive sensor.

6. Casters with universal wheels and brakes, featuring adjustable height.

7. Adjustable front-to-back movement distance of the sink: 500mm (varies depending on the specific model).

8. The first and second sections are connected by a hose, with a valve controlling the flow.

9. Water enters from the side of the rear section of the sink; each sink features four inlet ports.

10. The first sink is movable, with the sink body able to slide back and forth, and equipped with two handwheels—one on each side. The second sink is fixed; its body cannot be moved.

11. Cables are routed through a grid bridge at the bottom of the water tank, and the cables in the tank use aviation connectors.

12. Install waterproof junction boxes for sinks and heat exchange stations.

13. The water pump is placed beneath the sink, and a check valve is installed at the pump's outlet to prevent backflow of water from the pipes, which could otherwise cause overflow into the sink.

4. Special Notes

Device configurations may vary depending on the specific model.

During the equipment configuration process, the following situations either exist or need to be configured. The cooling equipment being configured will differ from conventional cooling units and must be explicitly noted:

1. Those requiring cooling tanks with a single section longer than 6 meters;

2. The sink temperature must be automatically controlled;

3. The cooling water inside the sink is isolated from the external cooling water;

4. Environments where the minimum temperature exceeds -35°C;

5. Used at temperatures below 0°C;

6. The materials have special properties such as exothermic reactions, steam generation, flammability, explosiveness, and tendency to stick or adhere.

The following factors highlight the differences in equipment:

Equipment materials, equipment surface treatments, startup methods, motor power, power supply characteristics, protective measures, and more

III. Equipment Installation

1. Equipment Loading and Unloading

1) Cooling tanks must be loaded and unloaded using forklifts, and all operations must follow specific procedures. These tasks should be carried out exclusively by professionally trained personnel qualified to operate special equipment.

2) The cooling tank is equipped with a dedicated fork-lift positioning area. During loading and unloading operations, the fork arms should avoid equipment pipes—using the pipes to bear weight is strictly prohibited!

3) Use forklifts equipped with appropriate capabilities and adhering to safety standards for loading and unloading operations, as shown in the diagram. Ensure proper control of the center of gravity, and after lifting, operate at a slow pace while maintaining stable movement.

4) Personnel should work from a safe location and are prohibited from standing directly beneath the equipment.

2. Equipment Installation Foundation

1) The cooling tank, as an intermediate process equipment, typically requires a flooring surface with sufficient load-bearing capacity, ensuring the ground is level and smooth.

2) Each cooling tank is supported by 4 sets of adjustable foot cups to ensure equipment leveling, while each tank is equipped with 4 casters for easy mobility. During operation, the foot cups are used to fine-tune the equipment’s level and securely support the entire unit, keeping it firmly in place.

4) The installation of the large cooling tank should take into account the tank's length when moving it within the overall factory layout.

3. Precautions During Installation

During the installation process of the flow system, the various pieces of equipment within the system should be arranged in an appropriate sequence for installation.

When fabricating the equipment's foundation structure, attention should be paid to ensuring the horizontal alignment and smoothness of the installation area. During equipment placement, adjustable foot cups can be used to fine-tune the level, preventing potential malfunctions caused by unevenness.

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 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, ensuring proper anti-slip measures and maintaining a stable, balanced position for secure operation.

4. Installation of the equipment's power supply

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.

When installing the equipment's power supply, the power lines must be thoroughly inspected to avoid issues such as incorrect phase or voltage mismatches.

The cooling tank pump has a fixed rotation direction. During equipment debugging or after power installation, briefly press the start button to check whether the pump's rotation direction matches the label sticker on the equipment. If the rotation is reversed, swap any two of the three-phase wires connected to the motor junction box, then perform another brief test to confirm 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 equipment.

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

Attention

Your equipment, as per the contract agreement, may not include the electrical control box. Please proactively request the equipment control circuit diagram from our company, and ensure that only qualified companies or personnel carry out any customization work. Additionally, all components and the enclosure must comply with the relevant safety standards.

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 shared by the inverter and the variable-frequency motor. Otherwise, the motor may easily overheat and burn out.

4. Equipment Debugging

1. Instructions Before Debugging

At the time of出厂, all equipment has undergone sealing tests and met quality inspection standards. After reviewing the equipment's manufacturing requirements, it is then released for shipment.

After users have completed the installation of the equipment, they must carefully clean out any remaining debris and dust inside the device and then perform a sealing test. 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, it should be thoroughly inspected and cleaned before powering up and starting to run.

Attention

During all types of debugging, please use the raw materials required for production for testing; do not substitute them with other materials.

After the equipment installation and debugging are completed, it is still necessary to clean the inside of the equipment.

During all types of commissioning, operators and on-site inspectors should not leave their posts until the commissioning is complete.

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

2. Prepare the assignment

Inspect the equipment interior for any potential debris or tools, and proceed to clean the inside of the device.

Check whether the equipment's power supply is functioning properly, including the main motor power supply, safety device power supply, and more.

Check whether all equipment valves are opening and closing properly, and ensure that each valve is operated according to the corresponding label.

Check whether the device accessories are functioning properly.

Check whether the water pump is rotating correctly.

Check whether each connecting pipe is properly connected.

3. Functional Component Testing

After the equipment is powered on, you should first check whether the functional accessories are operating properly.

Test whether the signal from the broken-bar detection device is correct (if applicable).

After the attachment has been inspected, start the equipment and verify whether the rotation of its pump matches the markings on the pump. If not, make adjustments promptly.

4. Run and Debug

After the equipment completes preparation and functional debugging, it enters the operational commissioning phase.

Proceed step by step according to the following method:

1. Open the tank filling valve and the pipeline filling valve to fill both the tank and the pipeline with water.

2. Start the equipment for 5 minutes, and monitor closely at all times for any unusual or disruptive noises during operation. If such noises are detected, immediately stop the equipment. Also, check each connecting pipe for leaks—if any leaks are found, promptly shut down the equipment and reconnect the seals securely. Finally, verify that the operating current remains within normal limits; if not, immediately use the stop button or emergency stop button to cut off the power supply.

3. During normal operation, after running continuously for 1 hour, inspect all parts of the equipment for leaks, vibrations, abnormal noises, or any other irregularities. If any issues are detected, take immediate action to address them.

4. Verify whether the broken-bar detection and alarm function are working properly (if applicable).

5. Post-debugging Inspection

1. During the debugging process and after it concludes, the following components must be inspected:

2. The temperature of all water pumps should be below 50°C;

3. The pipe connections show no signs of leakage;

4. Instrument readings in each section match the actual conditions;

5. All connecting bolts and anchor bolts on the equipment show no signs of loosening.

V. Occupational Safety and Health

1. Safety Precautions in Production

1) When operating the equipment, pay attention to all the warning areas indicated on the device.

2) Equipment with removed safety devices must not be used.

3) While the equipment is running, do not use any tools to probe into the sink drain opening.

4) When cleaning or repairing 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.

2. Planning and Responsibility

1) Use equipment that has been properly debugged and qualified for production, and establish a series of pilot production plans to better coordinate and align the various stages of the manufacturing process.

2) Establish a job responsibility system and assign trained professionals to perform all equipment operations. Ensure rational division of tasks to guarantee the smooth completion of production activities.

3. Pre-production Preparation

1) Before powering on the electrical control system, ensure the sink and pipes are fully filled with water, verify that the equipment is ready for production conditions, and remove any obstructions or debris.

2) Turn on the electrical control box switch and check whether the supply voltage and phase count are normal.

3) Inspect the equipment interior for any potential debris or tools, and thoroughly clean the inside of the device.

4) Check whether the equipment's power supply is functioning properly, including the main motor power supply, safety device power supply, and others.

5) Check whether all equipment valves open and close properly, and ensure that each valve is operated according to its corresponding label.

6) Check whether the device accessories are functioning properly.

7) Check whether the water pump is rotating correctly.

4. Production Operations

Production Operation Process:

Equipment Startup Operation

1) Check whether each valve is opening and closing correctly.

2) Open the tank filling valve and the pipeline filling valve to fill both the tank and the pipeline with water.

3) Close the pipeline make-up water valve.

4) Open the external cooling water inlet and outlet valves on the plate heat exchanger.

5) Start the device.

6) Set the sink temperature (or adjust the manual control valve).

Equipment stops operation

1) Close the tank's water supply valve.

2) Close the external cooling water inlet and outlet valves on the plate heat exchanger.

3) Stop the equipment

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

1. If the stroke of the broken-bar detection device configured on the equipment does not reach its designated position, triggering a连锁 signal, the equipment will enter an alarm state.

2. While the equipment is running, unless there is an emergency requiring shutdown, do not arbitrarily open or close any valves at the heat exchange station except for the control valve. Otherwise, the tank's cooling function will be interrupted, leading to pump overload and potentially causing the pump to burn out directly.

3. If the equipment's filter is clogged with excessive debris, it will create a pressure difference between the two sides of the filter. When the pressure difference becomes too high, the equipment will trigger an alarm. At this point, you should stop the machine and clean the filter promptly.

6. Equipment Structure

1. Equipment Diagram

7. Maintenance and Care

1. The Basic Principles of Maintenance

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

2) When repairing or maintaining the equipment, use components that are consistent with the equipment itself. Each maintenance and upkeep plan should be assigned to a dedicated person in charge and carried out by trained personnel.

3) During normal operation of the equipment, necessary maintenance measures should be taken for items such as keeping the exterior clean and checking the tightness of all fastening bolts, with a scheduled plan established accordingly.

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

2. Equipment Cleaning

After continuous operation of the equipment, impurities generated during the production process will accumulate in pipelines, filters, and plate heat exchangers, necessitating equipment cleaning after a certain period of use.

When cleaning, please note the following points:

1) Please do not leave any of the cleaning tools used inside the equipment—after cleaning, they should be collected and stored together.

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

3) When cleaning the heat exchange station 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 plate heat exchanger, strictly follow the operating instructions provided for the plate heat exchanger.

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

6) When cleaning, ensure the equipment is not turned on and the electrical control box is powered off to prevent others from accidentally activating the power. Appropriate warning measures should also be implemented.

7) Do not use cleaning agents that are corrosive to the material of the device itself.

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

9) Do not use blunt or sharp tools for cleaning operations, as this may easily damage the inner surface of the equipment.

10) After cleaning the equipment, the safety devices should be reset.

3. Equipment Maintenance Plan

4. Possible Equipment Failures and Troubleshooting