SKLN A Series

Counter-flow Cooler

Operation Manuall

Prior to use, please read through this operation manual

carefully and keep it properly for reference in the future.

CONTENTS1

CONTENTS

1 Safety attention points .......................................................................................... 1

1.1Environmental conditions ..................................................................................... 1

1.2 Description of warning marks .............................................................................. 1

1.3Description of safety marks .................................................................................. 3

1.4General safety attention points .............................................................................. 5

1.5 Safety attention points in transport, storage and installation ................................. 6

1.6 Safety attention points in operation, inspection and maintenance ......................... 6

1.7Personal protection ............................................................................................... 9

1.8Explosion Protection: Countermeasures against dust explosion and fire hazard ....11

1.9Other attention points (environmental protection measurements) ........................ 13

2 General .................................................................................................................13

2.1 Application and adaptability .............................................................................. 13

2.2 Main features and functions ............................................................................... 13

2.3 General outline and main structure feature ......................................................... 15

2.3.1Main components (see Fig.2-1) .........................................................................15

2.3.2General outline .................................................................................................16

2.3.3Structure and features of main working components ............ 错误!未定义书签。

3 Cooler specifications ............................................................................................17

3.1 Basic Specification ............................................................................................ 17

3.1.1 Working condition ...........................................................................................17

3.2Main technical parameters .................................................................................. 19

3.2.1 Technical parameters of various coolers .............................. 错误!未定义书签。

4 Transport, installation and adjustment ..............................................................20

4.1Transport ............................................................................................................ 20

4.2Mechanical installation ....................................................................................... 21

4.3 Electric installation ............................................................................................ 23

5 Running................................................................................................................25

CONTENTS2

5.1Attention points for operations ............................................................................ 25

5.2Functional inspection prior to test-run ................................................................. 25

5.3Commissioning ................................................................................................... 26

5.4Use and operation ............................................................................................... 26

5.5Emergency stop and restart method..................................................................... 27

6Inspection, repair and maintenance .....................................................................27

6.1Attention points for inspection, repair and maintenance ...................................... 27

6.2Daily inspection items and methods .................................................................... 29

6.3Regular inspection items and methods ................................................................ 30

6.4Malfunction and troubleshooting ........................................................................ 31

6.5Tools for repair and maintenance ........................................................................ 32

6.6Spare parts List ................................................................................................... 32

6.6.1Spare parts List: ................................................................... 错误!未定义书签。

6.6.2Exploded diagram of different parts ..................................... 错误!未定义书签。

6.6.3Schematic diagram of some common spare parts ................. 错误!未定义书签。

6.6.4Ordering list of spare parts ................................................................................33

7Appendix .................................................................................. 错误!未定义书签。

7.1 Attached documents ............................................................... 错误!未定义书签。

7.2 Contact information ............................................................... 错误!未定义书签。

7.3 Muyang SKLN A Series Counterflow Cooler（List of Operation Manual）错 误 !

未定义书签。

7.4 Packing list ............................................................................ 错误!未定义书签。

1

1 Safety attention points

1.1Environmental conditions

In order to operate this equipment safely, please install it according to following operating

conditions.

(1) Please install this equipment indoors according to following conditions:

① Ambient temperature range:(-10～+40℃)

② Relative humidity range: 30%～85%.

③ Altitude: less than1000.

④ Guarantee indoor cleaning and ventilation

⑤ Guarantee that the equipment is far away from the corrosive gas,

inflammable and explosive gas as well as steam

(2) Power source: as for Voltage and Frequency, please refer to the nameplate; air

pressure ≧0.4Mpa.

(3) For easy use, operation and maintenance, please check this equipment and reserve

enough space for it.

1.2 Description of warning marks

(1) In order to well understand this operation Manual, the safety warning marks are

divided into following kinds.

(2) These warning marks have been worked out according to the operating regulations

and safety attention points for this equipment. In order to avoid dangerous accidents, this

Operation Manual also includes concrete preventive measures. Please operate this

equipment according to the instructions based on sufficient understanding of warning

marks.

2

Table 1-1

This mark expresses that in order to avoid death and serious

injury accidents, please be sure to operate this equipment

according to relevant stipulations of safety attention points.

This mark expresses that in order to avoid potential dangerous

accidents and serious injury accidents, please operate this

equipment according to relevant stipulations of safety attention

points.

This mark expresses that in order to avoid slight wound and

potential moderate injury accidents, please operate this

equipment according to relevant stipulations of safety attention

points.

3

1.3Description of safety marks

(1)Relevant safety marks are pasted on different corresponding positions of this

equipment, which are property dangerous to personal safety. See Table 1-1.

(2) All the safety marks are indicatedin Table 1-1. Please carefully understand and install,

adjust, operate, maintain and inspect this equipment according to the contents in Table

1-1.

(3) Please place these safety marks near the equipment.

(4) When these safety marks have fallen off or been damaged, please replace them with

new marks.

(5) If you want to order new marks, please contact our company.

Table1-1 Safety signs used for this extruder

No. Part name Ordering cod Description

1 Beware of electric shock COMM65010010 Do not open the junction box until the power supply is cut off.

2 Do not remove the guard

shield COMM65010012

Do not remove the guard when the machine is in

running

3 Beware of injury

bymechanical movement COMM65010008

Do not open the access door when the machine is in

running and not completely stopped.

4 The protective gloves

must be worn COMM65010015

Wear protective gloves when inspecting and

repairing the equipment

Beware of electric shock Do not remove the guard shield

Beware of injuries by mechanical movement Protective gloves must be worn

4

Fig.1-1 position of safety signs on the principal machine

1,、2

1、2

3、

4

5

1.4General safety attention points

(1) The here said equipment operators refer to all personnel who participate

in operation, inspection and maintenance etc.

(2) The equipment operator must carry out the operation on the basis of

sufficient understanding on the Operation manual.

(3) For safety attention points, the owner has the duty and obligation to

deliver the contents of the Operation Manual for the equipment to all working

personnel.

(4) At the same time when obeying all the safety attention points, the users

also must obey the safety regulations and stipulations to prevent accidents.

(5) All related employees should receive safety education. The enterprise

management should be in charge of it and respect the national, local and the

other enterprise’s safety regulations of the users.

(6) This equipment is suitable for cooling granular feed. All the

responsibilities for any accidents or damage to the equipment shall not be

borne by manufacture and commission agent if the equipment is not operated

according to the stipulations.

(7) Please install, use and operate the equipment correctly. Whoever takes

off guard or makes it dysfunctional should be responsible for the safety result.

(8) Any reformation of the equipment may not affect the functions and

safety performances of the equipment.

(9) Be sure to run the cooler under strict obeying all regulations for prevention

of accidents.

(10)If any accidents are caused due to not obeying the stipulations in the

Operation Manual and the control system for Muyang equipment is not used

as per the conditions mentioned above, the Muyang Group will refuse to take

6

any responsibility. If the Muyang Group is required to take responsibility, the

Group will reserve the right to investigate and affix the responsibility of the

operator.

1.5 Safety attention points in transport, storage and installation

(1)The equipment must be placed and handled by professionals.

(2)Please use designated tools (steel cable, crane, hoisting machine etc.) for

hoisting, and carry out the hoisting according to designated sequence and

method.

(3) Staff only when carrying out hoisting.

(4) In order to prevent serious injury accidents, no one is allowed to be under

the equipment when carrying out hoisting.

(5)The permissible load of hoisting tools should be more than total weight of

the equipment.

(6)When the equipment is stored temporarily, please place the equipment

horizontally and keep a normal temperature and clean indoors.

(7) For transportation and handing, it is not allowed to damage the equipment

by binding. It should be reported to the manager immediately in case of any

machine damage and missing of parts in transporting.

(8)In installation, enough space should be reserved for future maintenance

and replacement of the equipment.

(9)Prior to installation, all machine parts must be kept in their original package.

The machine parts and packing boxes should be properly covered and stored

in places sheltered from rain, sunning and damp.

(10)The protecting hood or guard grating are usually installed and delivered

together with the machine. They can only be disassembled with tools. And the

machines with such kind of devices can never put into work until the

above-mentioned devices have been properly installed.

1.6 Safety attention points in operation, inspection and maintenance

(1)The operation, inspection, repair and maintenance of the equipment shall

7

be carried out only by the trained technical personnel according to

specifications provided together with the equipment. Electric installation shall

be carried out only by professional persons according to relevant electric

safety standards.

(2)Whenever maintenance or repairing is to be done the power must be cut off

so as to prevent the motor from accidental staring.

(3)Operation and installation should be done after shutdown, Please be sure to

cut off and lock the main supply switch, and place the execution mark plates

on the workshop gateway, in front of the electric control cabinet in the control

room and near the cooler respectively, so as to prevent the motor from

accidental staring. Be sure there is no personnel lingering and no items

missing in cooling bin when closing the access door after completing

maintenance works.

(4)In operation, a special attention shall be paid to the positions with attached

safety marks.

(5)Do not operate when the safety protection device and operating gate are

open. It is prohibited to open the operating gate until the machine has been

fully stopped.

(6)If any troubles occur in the operating gate and safety protection device,

please repair or replace them at once.

(7) The safety protection devices can never be dismounted, covered or

overlapped at will. It can never be opened until the machine has completely

stopped. And the machine can only be started when these safety protection

devices are in good order.

(8) The security mechanism of the operating gate is equipped with the travel

switch for opening, it must be correctly wired as per requirement to ensure the

power-off when the access door is opened, and additionally in such case the

machine cannot be started. Owing to the fact that this safety mechanism is

related to life safety, it can never be removed or discarded! Whenever there is

anything wrong with this mechanism, it should be repaired or renewed

8

promptly.

(9) When the machine is under stoppage, attention must be taken to prevent

the cooler from being started by any accidental starting mode.

(10)Except the maintenance of the equipment, it is not allowed to take off the

guard shields of the chain pulley

(11) When the safety guard shields or operating gates have to be opened or

the safety devices have to be disassembled in order to inspect, adjust, repair

and maintain the equipment or replace the parts, please well negotiate about

the required safety attention measures and work out the safety

countermeasures prior to the operations and then carry out the inspection

work.

(12) When the machine is running, it is strictly forbidden to put fingers near the

running components, such work as inspection, maintenance and cleaning etc

cannot be done until the cooler and spreader have been completely stopped.

(13) In case maintenance and inspection work should be done with a welder or

other tools that can generate sparks, strict safety precautions must be taken

against dust explosion and combustion (see "Explosion protection").

(14)If the parts are damaged, please repair or replace them immediately.

(15)Guarantee the safety of the electric system. Before the electric circuit is

cut off, it is strictly prohibited to open the junction box for avoiding electric

shock.

(16)The electric control system of the cooler must follow the following points.

Otherwise, it will not be the supplier's responsibility if any loss occur.

① The electric control system of the cooler must be supplied by Jiangsu

Muyang Group.

② The equipment must be checked up by an expert from Muyang Group

before commissioning.

③ The electric control is a component part of the safety regulations for

accident precaution.

④ Prior to commissioning the control system must be tested by an expert from

9

Jiangsu Muyang Group in light of the testing list and a permit will be signed by

him.

⑤If the control system for Muyang machinery equipment is not used as per the

conditions mentioned above, the Muyang Group will refuse to take any

responsibility. If the Muyang Group is required to take responsibility, the Group

will reserve the right to investigate and affix the responsibility of the operator.

1.7Personal protection

(1) All the mechanical equipments manufactured by Jiangsu Muyang Group

are equipped with safety devices, which are consistent with modern technical

level and universally effective safety rules prior to ex works, so that the

customers can use the machines in accordance with the regulations.

(2)If the operators employed cannot read or write, the owner has the duty to

explain to them clearly where dangers exist and warn them that special

attention should be paid.

(3) In order to guarantee the safety and health of labors during production

process, it is necessary to use labor protection articles (such as gloves,

breathing masks and labor shoes) during operation.

(4)Please execute the special regulations on accidents prevention in the

operation manual provided by us.

(5)The enterprises are obligated to execute following regulations to guarantee

operators' safety.

①The guard shield should be amounted and keep close at any moment. It is

very dangerous when they are opened or disassembled. It may cause casualty

accident. This is also applicable for the preventive device of the manipulator.

②The safety limit switches should always be kept in good order. Overlap or

discard of the safety limit switches is not allowed.

③The driving motor must be switched off completely to make the machine

stop when carrying out inspection, commissioning, repair and maintenance.

This can be done through a full-phase separating and lockable switch which is

10

installed near the machine or on the operation desk, or the control panel on the

site. It is not enough only to screw off the fuse wire!

④If the machine needs other energy like pneumatic, hydraulic, steam and hot

water energy, it is necessary to cut off their energy supply or turn off the switch,

and eliminate the pressure in the internal pipeline system of the machine.

⑤As for handling heated or cooled parts and components of the machine,

especial care should still be taken for the danger of burning, to prevent any

scald.

⑥If you have pressed the emergency stop switch to stop the machine and you

want to reset the switch, so it is not permissible to only re-press this button to

restart the machine. And the machine can only be started by re-closing the

main switch first.

⑦If some machines are equipped with a local shutdown system, especial care

should be taken. Read the instruction manuals attached with the machine

carefully. In such machines with a local shutdown system, temperature will rise

because pressure or vacuum will occur after they have been used for a period.

⑧The cleaning, lubricating and oiling of the machine or its parts and

components may be carried out only when the machine is stopped. If you have

to climb on or enter the machine to do such work, the mandatory provisions

shall be made without exception: the power supply of motors must be cut off

completely and the switch must be locked, fix the rotor of the spreader before

entering the cooler. Attention must be paid to safety measures for climbing.

⑨Be careful, sampling from inside the machine can never be carried out

unless there is not any danger. Usually, the samples can be taken from suction

inlets of tipping plate and hopper instead of inside machine.

⑩Clear off the deposited dust, dirties and materials frequently. Keeping the

machine clean can enhance production safety and the cleaning level of

workshop, and is also beneficial to prevent dust explosion.

(11) If oil (grease) leakage occurs, clean it immediately and seal well the place

where leakage occurs. For oil or grease leaked on the floor will easily bring

11

about hazards to the operators.

(12)In production operation, the machine must be equipped with safety

devices, which may be neither removed and abandoned nor reduced in

functions. Otherwise, we are not responsible for any accidents resulted here

from, and reserve the right to ascertain where the responsibility lies.

1.8Explosion Protection: Countermeasures against dust explosion and

fire hazard

（1）Common cleaning work

①Keeping the working site with combustible dust clean is an important

condition for safe production.

② Try not to pile bagged or bulk materials between machines.

③ In order to reduce dust emission to surrounding areas, all conveying

devices, air pipe for pressure balance, filtering bag should be kept in good

condition. Especially, the unsealing of pipes or top covers should be avoided.

④ In order to reduce dust explosion hazard, dust everywhere must be cleaned

out frequently and effectively.

⑤ Keep all motors free of deposited dust.

（2）Regular inspection and maintenance

① Check the safety devices such as speed monitor or the like regularly, at

least once a week.

②Check and clean the connection of direct-coupling speed reducing motor

and machine body, at least once a day.

③ In order to avoid heat generation, it is necessary to regularly check the

functions of all main shafts and bearings, at least once a week, and to

regularly fill up lubricating oil.

（3）Electric apparatus

Regularly check the electric apparatus and articles, and special

attention should be paid to the following points:

①It is forbidden to use any flashlights and other lamps without shielding or

explosion-proof glass.

12

②It is forbidden to use any lengthened cable or electric furnace.

③It is necessary to immediately repair or replace the electric apparatus and

equipment if any failure occurs.

④The cables without conduits are not allowed to be installed on the floor.

⑤ Cut off the power supply of the machine after work.

⑥An electrician should be assigned to check the insulation of all the lines of

electric network according to relevant regulations on heavy current, at least

once a year.

（4）Smoking and welding

① Smoking is forbidden, which is applicable to all workers and staff of the

enterprise as well as guests, customers, foreigners and drivers visiting the

factory.

②If the tools such as welding machine or soldering lamp (flame soldering lamp)

etc. are required for repair or installation, do as best as possible to arrange the

work in a special workshop or on a special site.

③If it is necessary to carry out welding or the like directly in production area or

storehouse once in a while, written applications must be submitted to a related

supervisor in advance for written approval. The above mentioned operations

can be carried out only when special safety measures have been taken, such

as laying pieces of water soaked canvas or canvas special for covering on the

surrounding area and preparing fire extinguishers. After completion of the

operation, the welding site and the surrounding area are to be monitored at

least for 10h.

④The gas cutting sparks are very dangerous for people who can't see where

they will fly on earth. They can cross through the narrow clearance of walls

and drop downstairs or to the next rooms, or even fly off 10m away in distance.

If the sparks drop in dusts, fire accidents may occur at any time.

⑤Welding is prohibited on a running conveyor. If the welding work is

necessary, shut down the machine first, and then make a thorough cleaning

and isolate both sides of the welding site tightly with materials like mineral wool

13

to avoid connecting with other conveying devices, silos or tanks. If the work is

to be done on the chutes or conveying pipes, it is necessary to disassemble

them or divert their lower ends and seal them to avoid welding sparks entering

the conveying pipes or silos.

（5）Effect of static electricity

①In order to ensure the safety of electric circuits and avoid explosion resulted

from spark discharge.

② The paint coat at the electric connections must be removed.

1.9Other attention points (environmental protection measurements)

If you decide not to use the machine any longer after it is used for a certain

number of years (about8-10years),the measures for environmental protection

and reutilization should be taken.

(1) Drain the liquids inside the machine (like motor oil, gearbox oil, brake oil

and coolant etc.) into special containers and send them to the preparation

workshop.

(2) The plastic parts shall be picked out for reutilization.

(3) The metal parts shall be sorted out so as to be ground or scraped.

13

2 General

2.1 Application and adaptability

SKLN A Series Counter-flow Cooler (improved model) is used widely for cooling process

in feed industry. It is applicable for cooling all kinds of pellet feeds such as pelletized feeds,

expanded feeds, extruded feeds flakes and other granular feeds, especially applicable for

cooling expanded pellets.

SKLNA Series Counter-flow cooler(improved model) hereinafter is referred to as the

"cooler" in this Operation Manual.

2.2 Main features and functions

(1) It is characterized by vertical layout, concise and beautiful appearance;

(2) Advanced counter-flow cooling principle, fence type discharging mechanism making

reciprocating rectilinear movement is adopted, fluent discharge and uniform discharging

volume.

(3) The cooling bin with an octagonal section can avoid dead angles of cooling and this is

favorable for material cooling.

(4) The new rotary spreader ensures that materials can be evenly and thoroughly cooled,

and can decrease the breaking ratio obviously. The material-distributing range is

adjustable and the power consumption is low;

(5) Several pressure reducing plates are mounted on the top of discharging mechanism,

which can greatly improve the working load of discharging mechanism and reduce

distortion, prolong service life of components.

(6) The driving device uses a geared motor to drive the eccentric shaft, it provides stable

and reliable driving and the noise is small, and it makes the installation and repair

convenient.

(7) The temperature of material after cooling is not+3 ～ 5℃ higher than room

temperature, the dehydration rate is in scope of 2%～3.0％,so the storage time of

high-quality pellets is prolonged.

Note:

i. The above mentioned scenario is applicable for normal temperature (≥15℃）. When the

ambient temperature below the normal temperature (＜15℃）, the dehydration rate of cooler will

14

drop to within 1.0％～2.0％, if therefore bringing about finished products without required

moisture content, it is suggested that: ① Decrease as much conditioning moisture amount as

possible;② Add an thermal insulation layer on cooler bin body, top cover and air pipe;③

Complement auxiliary heating device around cooler or on the position of air inlet.

ii. The cooling effect of this cooler will be reduced sharply when the external ambient

temperature is ≥40℃ and the relative humidity is≥85％, Which will cause the severe result in

safety storage of feeds.

(8) The equipment is complemented with access door on the front face for convenience

of daily maintenance and repair. The side face is equipped with observation windows to

facilitate the observation of running status of the equipment.

15

2.3 General outline and main structure feature

2.3.1Main components (see Fig.2-1)

1.Top cover 2. Spreader 3.Cooling bin 4.Driving device for discharging 5.Base 6.Flow adjusting

and pneumatic emptying device 7.Discharging hopper 8.Access door

Fig.2-1 Schematic diagram of overall structure

The cooler is mainly composed of a base, atop cover, a spreader, a cooling bin, a

discharging fence, a flow adjusting fence, a driving device for discharging, a flow regulator,

a hopper and so on. See Fig.2-1 Overall structure diagram Fig.2-1Schematic diagram of

overall structure

16

2.3.2General outline

Hot pellet materials pile up gradually after entering the cooling bin through the rotary

feeder, till reach a certain height, the materials level sensor of cooling bin will send out

signals to make the discharge motor work when the material contacts the upper level

indicator. The motor drives the discharging fence to reciprocate through the speed reducer

and eccentric mechanism for discharging At this point, the time relay goes into operation,

and set a delayed discharging time for automatic discharge. The discharging amount of

materials in the cooling bin is more than the feed rate during discharging, if the delayed

discharging time of time relay ends up when materials in the bin dropped down to a certain

level, and when the limit indicator board on the discharging fence approaches the

horizontal level indicator mounted on the Base, the motor will stop at once, and the

discharging fence will stay in a fixed position. When the layer height reaches the upper

level indicator again, the discharging fence resumes movement and discharging. Repeat

the above discharging process over and over. Repeat the above discharging process

over and over.

17

3 Cooler specifications

3.1 Basic Specification

3.1.1 Working condition

(1)Material characteristics

① Particle size of materials: Length of edge shall be less than40mm.

② Bulk density: 0.5～0.8 t/m3

③ Moisture content of material: less than15%.

(2) Environment conditions

① Ambient temperature range:(-10～+40℃)

② Relative humidity range:30%～85%内

③ Altitude: less than1000m

④ Temperature range for normal transportation is:(-25～55℃)

⑤ Air supply for normal use is above0.4Mpa.

⑥ Voltage for normal use: AC380V

Note: If the actual condition fails to accord with the environment condition ①, the

temperature shall be adjusted properly. If it fails to accord with conditions ② and ③, a

speed reducing motor shall be customized. If it fails to accord with condition ⑥, please

refer to the motor nameplate.

(3) Configuration conditions

① The cooler should match the equipments before and after it in process flow.

②The power supply range for normal use (permissible voltage deviation±5% , and

frequency deviation±1Hz).

③The user must configure an over-voltage protection device for the power supply.

(4) Noise testing during normal production

Table3-1Noise testing condition and method

18

Noise—pressure level LP≤ - dB （A）

Idling noise —power level LW≤ 90 dB （A）

Noise on test-surface—pressure level LP= 74 dB （A）

Test-surface specification LS= 16 dB （A）

Equivalent noise—power level Lweq= - dB（A）

19

3.2Main technical parameters

Model composition and its meaning

S KL N □×□ A

Improved model: after major improvement

Spec of product: sectional dimensions of cooling bin(dm)

Model Code: counter-flow

Variety Code: pellet cooler

Industry code: Feed processing equipment

20

4 Transport, installation and adjustment

4.1Transport

(1) Hoisting

When hoisting is carried out through lifting devices, the rope shall be capable to bear the

weight of the hoisted equipment (see nameplate for the weight of equipment) and not be

too short in order to avoid any damage to the equipment. The angle between every two

ropesis not necessarily equal to60°; actually an angle less than 60° is better, but it

requires a much longer rope. The bearing capacity of the hoisting equipment shall

be1.2times larger than the weight of the equipment to be hoisted.

(2) Transport

① When leave the factory, whether to use a packing case is determined according to

actual conditions.

②If a packing case is not used in transport, rain-proof measures shall be taken and it shall

be prevented against collision and overturn of the equipments.

③If a packing case is used, the complete machine and accessories shall be fixed securely

in the case and a certain distance shall be reserved from the plate of the packing case, so

as to avoid collision and damage in transport. If the height is in excess of the standard, the

whole packing shall be separated into parts.

④During transport, any overturn, intense pressure or collision are not allowed on the

machine body.

⑤ Due to larger volume of the complete cooler and the outline dimension restriction on

transportation, the machine has been disassembled into several functional components

prior to leaving the factory, and for the list see Table4-1.

(3) Storage

①When the machine equipment is to be stored in the open air, the facilities for prevention

of rain, sunshine and water accumulation should be available. When the machine

equipment is to be stored indoors, the measures for ventilation and damp proof shall be

taken.

②The equipment should be stored in ventilated, dry and cool place for long-time storage,

and damp proof measures should be taken, the exposed surface without painting should

be painted with rust-proof oil.

21

4.2Mechanical installation

(1) Unpacking and inspection

① When the machine arrives at the destination, unpack it and check careful if there is any

phenomenon like collision or friction during the transportation.

② Count the documents and accessories attached compared with the packing list.

(2) Equipment installation

① Installation of the cooler

The extruder is delivered generally as a complete set. It is fixed through base anchor of

the supporting legs on firm foundation by foundation bolts.

Sometimes due to larger volume of the complete cooler and transportation restriction on

the outline dimension, the machine has been disassembled into several functional

components prior to leaving the factory, and for the list see Table4-1. After the installation

position of the cooler is confirmed, these components shall be assembled again under the

guidance of Muyang specialized technical personnel and technical documents or by

reference to "Fig.4-1Scaled drawing of equipment installation and Table4-2 Installation

dimension for equipment

22

②Installation requirements

a) The pellet mill is delivered generally as a complete set. Firstly check if

there is any damage during transportation when unpacking;

b) Fabrication yard should be strong and spacious, and enough space

around should be reserved for operation and maintenance. It is suggested

that to reserve a space of1.2m～2.0m around the equipment in accordance

with the dimension as shown in scaled drawing of equipment installation so

as to avoid inconvenience of maintenance and operation caused by narrow

space.

c) Please refer to the scaled drawing of cooler installation provided when

ordering;）

d) The proper maintenance platform and staircase should be provided if

necessary, the staircase shall be equipped with guardrails.

e) The cooler should be placed horizontally. The floor and frame

instruction for cooler installation is required to be strong and level, and

should be of enough stability and bearing capacity to afford the weight at full

capacity of equipment and the impact arising from the action of moving

elements. The machine body should be tightly jointed with anchor bolts,

otherwise it will cause vibration of equipment, even worse lead to accident.

The foundation should be connected with the base by pre-embedded anchor

bolts. （Fig.4-2 Pre-embedding of the anchor bolt）

Fig.4-2 Pre-embedding of the anchor bolt

③Matched feeder

Requirements to matched feeder

Besides ensuring the material for smooth entering into the cooling bin, the feeder should

serve a certain function of air locking, so as to ensure all the cold air is used for cooling.

So, a universal airlock can be chosen.

When a matched air lock used, the discharge rate of the airlock shall be calculated

according to the following formula:

23

(3) Equipment adjustment

① Spreader adjustment

a) Generally, the spreader is already pre-installed on top cover before ex-works.

b) The distributing scope can be changed by adjusting the vertical position of the

throwing disc on the vertical shaft.

c) The distributing amount everywhere in radial can be controlled by adjusting the

position of dividing plate on throwing disc. （see Fig.2-6）

② Adjustment of material level indicator

Due to the uneven material layer surface, of which the highest point is liable to hit to the

spreader plate and damage it, the production will be influenced thereby. So it is best to

adjust the position of level indicator properly under the premise of satisfying production to

prevent the spreader from getting hit by materials.

③ Adjustment of discharging flow

Adjust the discharging amount according to the requirement of throughput control to keep

the material layer at a certain height. To adjust the discharging amount, turn the hand

wheel of flow-control device right for increasing the discharging amount, and turn it left for

decreasing the discharging amount.

④ Adjustment of cooling time

a) The material thickness in cooling bin and the cooling time can be controlled by

adjusting the position of level indicator on cooling bin.

b) Generally, the commended cooling time is10min. The thicker the material, the cooling

time should be prolonged.

4.3 Electric installation

(1) Electric connection

① The wiring chute in central control room must be protected.

② The central control room should be kept clean and free of dust.

Attention:

1. All cables shall be with a specification of0.75mm2;

2. The user must configure an over-voltage protection device for the power supply.

3. In order to ensure safety, it is necessary to install a safety switch nearby the cooler (an

emergency stop switch or a lock-up maintenance switch).

4. The above schematic diagrams are only for the independent operation of the cooler and

24

matched airlock, the interlocking of the cooler with its upstream and downstream

processing equipment should be taken into account in process design.

5. Ensure the cooling bin is closed and the safety switch is normally working prior to

running.

6. Check the wiring at least once a year to ensure the insulation of the electric wiring in

good condition.

25

5 Running

5.1Attention points for operations

Note: When operation is implemented on the machine, besides the safety points specified in

Chapter 1, the regulation items of the owner's enterprise shall also be obeyed.

(1) Pay attention to the place where the dangerous marks are attached when

operating.

(2) The safety protection devices can never be dismounted, covered or

overlapped at will.

5.2Functional inspection prior to test-run

(1) Before leaving the manufacture plant, a perfect test-run has already been conducted to the

machine.

(2) The initial test run in the user’s factory cannot be done until following checks have been

conducted.

① Check whether there are abnormal phenomenon such as blockage, collision and

scratch of discharging fence and driving device and other moving parts.

② All connecting points must be checked carefully to ensure there is not any

looseness.

③ Check the rotor of airlock for smooth rotation, and there should be free of

abnormal noise, foreign material winding and scraping.

④ Check whether the driving chain of spreader is in proper tension condition and

whether the rotation direction of spreader is correct. Therefore, it may need to start the

motor for a short time. Meanwhile, check for obvious eccentricity phenomenon in

rotating process of spreader.

⑤ Check for the correct installation and smooth rotation of material level indicator

⑥ Emergency stop switch

Check whether the emergency stop switch is in good working condition or not.

⑦ Safety switch of the access door

As a part of the safety control of the machine, whether the safety switch of the access

door works normally or not is directly related with the safety of the cooler, so the safety

switch should be frequently checked for its functioning.

⑧ Check before closing the access door

Be sure there is no personnel lingering and no items missing in cooling bin when

closing the access door after completing maintenance works.

26

5.3Commissioning

(1) The material in bin should be emptied before each commissioning.

(2) Only when the access door is closed can the cooler run.

5.4Use and operation

(1) The operator should well know the structure, performance and operating methods

of the machine, and have received the training organized by Jiangsu Muyang Group.

(2) Throughput of each batch should be as even as possible so as to avoid quality

fluctuation of final products due to different feeding amount.

(3) After working, idle run the fence for several times so that all feeds be discharged

out of the cooler.

(4) The spreader should operate smoothly and enable feed to be distributed evenly

in the cooling bin.

(5) The blades of rotary hiding level indicator run smoothly, level detecting is

accurate and no fault.

(6) Adjust the flow adjusting mechanism to allow appropriate amount of feed

discharged through fence, ensuring neither blockage nor inconsistent end products

quality because of large discharging amount.

(7) The bearing temperature raise(refers to the risen temperature above ambient

temperature)of the bearings for main shaft should not be higher than35℃，and the

maximum temperature should not be higher than80℃(ambient temperature should

not be higher than40℃)；

(8) When every shift production finishes, the inside of equipment and the surrounding

environment shall be cleaned, and the residual materials and dusts shall be removed

for next shift production.

(9) When stopping the machine, close the fan motor not until the material be

emptied.

(10) Metal or other large impurities should not be included in the material, or else the

airlock and the fences may be damaged.

(11) The speed reducer, cylinder and other accessories should be used in accordance

with the relevant stipulations in their operating instruction manuals.

(12) After a period of usage, appropriately fasten the connecting bolt between speed

reducer and rotor, the loosen extent is as shown in Table4-2，and furter check other

fasten;

27

(13) It is forbidden to run the equipment with overload to prevent blockage and

damage.

5.5Emergency stop and restart method

(1) If the equipment makes abnormal noise when running, the machine shall be

stopped immediately; At the same time, stop feeding of upstream equipment, clean

the flow adjusting fence, discharging fence and other mechanic links for any blockage,

impact and friction.

(2) Only when the fault cleared and verified can the stopping status be resolved.

(3) Close the access door and ensure the signal of safety switch in place.

(4) Reset emergency stop switch, and the power supply of cooler is recovered in the

control room.

(5) The cooler can enter into working status.

6Inspection, repair and maintenance

6.1Attention points for inspection, repair and maintenance

Besides those mentioned in Chapter 1, following attention points should be obeyed when

carrying out inspection, repair and maintenance:

(1) Whenever inspection, commissioning, repair and maintenance is to be

done the power must be totally cut off first.

(2) Only trained technical personnel is allowed to do works with

danger-potential such as parts replacement and repair.

(3) The replacement or maintenance of electric control system, circuit and

other components should only be done by trained personnel.

(4) Make sure the cooler has completely stopped when lubrication and

maintenance are carried out for discharging device.

(5) Make sure the power supply of airlock has be cut off and the blades has

completely stopped when maintenance of airlock and impurity removing work

are done.

(6) It is allowed to start equipment not until the access door is closed and

the signal of safety switch in place

(7) When the safety guard shields or access doors have to be opened or

28

the safety devices have to be disassembled in order to inspect, adjust, repair

and maintain the equipment or replace the parts, please well negotiate about

the required safety attention measures and work out the safety counter

measures prior to the operations and then carry out the inspection work.

(8) Be sure that the above said safety devices and guards are installed to

their positions after inspection, adjustment, repair and maintenance.

(9) When operation, installation, repair and maintenance, please be sure

the execution mark boards [In Process of Maintenance and Inspection] are

placed on the workshop gateway, so as to let other people know about it.

(10) Attention! Improper operation and maintenance may cause accident.

(11) The equipment should be stored in ventilated, dry and cool place for

long-time storage, and damp proof measures should be taken, the exposed

surface without painting should be painted with rust-proof oil.

Note:

The machine must be operated in the light of operating regulations, and

necessary checking and cleaning should be conducted for each working shift.

The internal of conditioner could be cleaned by flushing with material such as

corn. It can also be cleaned by blowing with air if an air-sac blowing device is

adopted.

29

6.2Daily inspection items and methods

In daily and regular inspection, stop the machine rapidly and take on proper

measures in case of any abnormality in machine operation.

Re-use the machine after confirming that the machine is recovered to normal

operation.

Table6-1List of daily inspection items (prior to each running or during each running)

No. Position Inspection item Cycle Method Solution

1 Air-pressure

system

Check whether the air pressure is higher than0.4Mpabefore entering

into the cylinder Everyday Inspection

Increase air

pressure

2 Machine (including airlock)

Check for any abnormal noise Everyday Listening Checking

3 Bearing Check for temperature lower

than80℃. Everyday Thermometer Checking

4

Motor Check for temperature lower

than80℃. Everyday Thermometer Checking

Motor Lubricating amount Everyday Inspection Checking

Motor Check for any abnormal noise Everyday Listening

Reducing motor Check whether current within rated

current value(Table6-2) Everyday Ammeter Checking

5 Material level

indicator Check for normal running Everyday Inspection

Repair and

correct it

6 Over-travel limit

switch Check for sensitiveness Everyday Inspection

Repair and

correct it

7 Spreader Check for normal spreading of

material Everyday Inspection

Repair and

correct it

Table6-2Check list of rated power and current of motor

Rated power （KW） Rated current （A） Remarks

0.75 0.197

Note1) The above-mentioned cycle applies 12h12a day and 2525days a month. Customers can adjust it

by themselves according to actual conditions

Note2) Three frequently-used greases for lubricating bearing:

① LITEAEP6-077（ASEOL）

② BEACOMPZ（ESSO）

③ ARALUBHLP(ARAL)

Reducing motor: Shell HD- 220, or MOBIL SCH-630

30

6.3Regular inspection items and methods

Regularly check various coupling bolts for loose, fall off and broken-down, if

there are, repair should be done immediately.

Overhaul should be carried out once every equipment running for1000h.

Table6-3 List of regular inspection items

No. Position Inspection item Cycle Method Solution

1 Bearing

Sliding bearing

Cleaning Once a half

year Cleaning

Filling grease Once a half

year Filling grease

2 connection of

reducing motor Check whether fastening state in good condition

Every two weeks

Screw down

3 Safety device

Check the warning marks for missing or abrasion

Every month Inspection

Safety switch on the access door

Every month Cleaning

4 Chain Check for proper tension Every month Inspection Repair and correct it

31

6.4Malfunction and troubleshooting

Trouble Cause Solution

Poor cooling effect

1. Insufficient cooling time caused by too much

feeding material.

1. Choose another type of cooler

according to the specified

situation or consult with relevant

technicians.

2. Insufficient cooling time caused by low

material layer.

2. Determine the level indicator

position again.

3. Large pellets, or the air gate is not opened

enough.

3. Determine the opening

position of the air gate again.

Hollow space in

the material

1. The material is distributed unevenly and

causes airflow short circuit.

1. Refer to the solutions in this

Instruction.

2. When the pellets are small, the air gate is

opened too extensively and the air speed is

fast.

3. Determine the opening

position of the air gate again.

3.Unsmooth

movement of

discharging fence

with noise

6. Bearings damaged 6. Replace the bearing

2. Roller wheel failure 2. Change roller wheel

3. Guide rail failure 3. Change guide rail

4. discharging fence abrades flow adjusting fence

4. Adjust the clearance between these two fences

4. Motor cannot be

started up

1. Wiring trouble 1. Check and clear away the

wiring trouble

Motor damaged Replace the motor

3. Induction signal output of level indicator has

malfunction

3. Repair or change level

indicator

32

6.5Tools for repair and maintenance

Table6-8 Tools for repair and maintenance

No. Tool name Spec. Function

1 Monkey wrench Max. opening width(mm)46

Bolt for connection of machine base and body

2 A group of socket

wrench Common bolt

3 Chain block (2T) for heavy parts

4 Steel rope for heavy parts

5 Scissors Cutting

6 Screwdriver Tightening bolts

7 Ammeter Measuring the current of motor

8 Thermometer Measuring the temperature of motor and

bearing

9 Knife Cutting

10 Flexible ruler Length measuring

11 Oil gun Filling oil

12 Iron hammer Knocking

13 Rubber hammer Knocking

14 Portable electric

driller(0～13mm) Drilling hole

15 Electrical heating device for bearing

Heating bearing

16 Retainer pliers Retaining rind disassembling

17 Glass cement gun Filing glass cement

18 Multimeter Resistance,

voltage Measuring

6.6Spare parts List

Some parts and components in this equipment are worn off gradually when in use. If these

parts are still used after worn to a certain degree, the property of equipment will be

affected and dangerous accidents will occur probably. Therefore, these parts and

components shall be replaced timely after used for a certain period. The spare parts in this

Operation Manual is also called wearing parts.

Whether the spare parts can be ordered timely and accurately will influence your

production. So in order to purchase right spare parts, when place an order, please

mention the corresponding serial number, code, description of the spare part and the

quantity needed in the order list. And provide us the order list (seeTable6.5.4)

And provide us the order list via mailing or e-mail. If it is possible, please attach a sketch of

the spare part to be ordered.

33

6.6.4Ordering list of spare parts

Type of

cooler Power

Ex-works

No.

No. Part code Part code Part name Qty Remarks