楚天燧道烘箱說明書機(jī)械部分

1、機(jī)械部分 目錄1. 目錄2. 設(shè)備的名稱和型號(hào)3. 設(shè)備的外形及安裝示意圖4. 設(shè)備的主要用途和適用范圍5. 設(shè)備的主要技術(shù)參數(shù)6. 設(shè)備的工作原理及主要結(jié)構(gòu)7. 設(shè)備的吊運(yùn)安裝與調(diào)整8. 設(shè)備的操作與使用9. 設(shè)備的維護(hù)與保養(yǎng)10. 設(shè)備的電器操作說明11. 設(shè)備的一般故障排除2. 設(shè)備的名稱和型號(hào)Equipment Name and Model2.1 名稱：滅菌隧道Name: Sterilization Tunnel2.2 型號(hào)：AL-D400Model: HM AL-D4003. 設(shè)備的外形及安裝示意圖Equipment Outline and Installation Drawing4

2、. 設(shè)備的主要用途和適用范圍Main Use and Applicable Scope of Equipment4.1 主要用途 Main use本機(jī)用于容器瓶的干燥，滅菌和冷卻。它利用層流原理和熱空氣高速消毒工藝，使容器在潔凈度A級(jí)的密封隧道內(nèi)完成干燥，滅菌，去熱原和冷卻的無菌生產(chǎn)工藝流程。它可與洗瓶機(jī)，灌封機(jī)組成一條完整的洗，烘，灌，封自動(dòng)生產(chǎn)線。This machine is used for drying, sterilization and cooling of containers .It adopts LF principle and hot air high speed ste

3、rilization process, which can make the containers in the closed tunnel of Cleanliness Grade A complete the sterile production process of drying, sterilization, depyrogenation and cooling. This machine can form a complete compact line along with washing machine and filling and sealing machine for was

4、hing, drying, filing and sealing of containers.4.2 適用范圍Applicable scopeHM AL-D400型隧道式滅菌干燥機(jī)的隧道設(shè)計(jì)主要適合安瓿，口服液，抗生素瓶的干燥，滅菌處理。HM AL-D400 is mainly applicable for drying and sterilization of ampoule, oral liquid and vial.Main specification:4.3 主要規(guī)格：Main specification:4.3.1 容器直徑：8mm-64mmDiameter of container

5、: 8mm-64mm4.3.2 容器高度：40-180mmHeight of container: 40-180mm4.3.3 隧道寬度(B) :600mmWidth of conveying tunnel(B) :600mm4.3.4 預(yù)熱段(LE)有效長度: 580mmEffective length of preheating zone(LE): 580mm4.3.5 加熱段(LH)有效長度: 1320mmEffective length of heating zone(LH):1320mm4.3.6 冷卻段(LK)有效長度:860mm Effective length of cooli

6、ng zone(LK): 860 mm5. 設(shè)備的主要技術(shù)參數(shù)Main Technical Parameter of Equipment5.1 輸瓶網(wǎng)帶有效寬度:600mm Effective width of conveyor belt: 600mm5.2 干燥滅菌最高溫度: 350 The highest temperature of sterilization and drying zone:3505.3 潔凈度:達(dá)到國標(biāo)A級(jí) Cleanliness: national standard Grade A5.4 動(dòng)力能耗總電功率: 47.55KW Total power consumpti

7、on: 47.55Kw5.4.1預(yù)熱層流電機(jī): 1.1kW 1set LF motor in preheating zone 1.1kW 1set5.4.2加熱層流電機(jī): 1.5kW 2sets LF motor in heating zone 1.5kW 2sets5.4.3冷卻層流電機(jī): 1.1kW 1sets LF motor in cooling zone 1.1kW 1sets5.4.4 抽濕排風(fēng)電機(jī): 0.18kW 1set Dehumidify & exhaust motor 0.18kW 1set5.4.5 冷卻排風(fēng)電機(jī): 1.8kW 1set Exhaust moto

8、r in cooling zone 1.8kW 1set5.4.6 輸瓶網(wǎng)帶電機(jī): 0.37kW 1set Bottle conveyor belt motor 0.37kW 1set5.4.7 不銹鋼翅片電熱管耗能: 1.2kW×36=43.2kW Power consumption of stainless steel fin electric heating pipe: 1.2kW×36=43.2kW 正常工作能耗: 25kw Normal working power consumption : 25kw5.5 網(wǎng)帶超聲波清洗: 1.2kW 1臺(tái) Ultrasonic

9、 cleaning : 1.2kw 1set5.6 輸瓶網(wǎng)帶清洗耗氣量: 90m3h 0.3MPa(保證1小時(shí)) Water consumption for conveyor belt cleaning : 90m3h 0.3MPa (to ensure 1hour)5.7 輸瓶網(wǎng)帶清洗耗水量: (0.51)t/次 0.2MPa Water consumption for conveyor belt cleaning : (0.51)t/time 0.2MPa5.8 排風(fēng)量: 3500 m3/h Exhaust volume: 3500 m3/h5.9 加熱層流風(fēng)機(jī)冷卻耗水量: 0.2t/h(

10、自來水) Water consumption for LF fan cooling in heating zone: 0.2t/h(tap water )5.10 設(shè)備外形尺寸: 2760mm×1555mm×2450mm Overall dimension: 2760mm×1555mm×2450mm5.11 設(shè)備包裝尺寸: 3610mm×1900mm×2810mm Package dimension: 3610mm×1900mm×2810mm 5.12 設(shè)備檢修空間:前面0.9m,上部0.3m,后面1m The m

11、aintenance space of equipment: front part 0.9m, upper part 0.3m, rear part 1m.5.13設(shè)備凈重: 3000kg(含電器箱) Net weight: 3000Kg(including electric cabinet)5.14 設(shè)備毛重: 3500Kg (含包裝箱) Gross weight: 3500Kg(including package carton)5.15 干燥機(jī)產(chǎn)量表:見附錄表2 Tunnel output: see attachment 26. 設(shè)備的工作原理及主要結(jié)構(gòu)Working Princ

12、iple and Main Structure of Equipment6.1 概述 General description本設(shè)備應(yīng)用層流原理和熱交換原理,完成對(duì)經(jīng)過密封隧道內(nèi)的容器瓶進(jìn)行干燥,滅菌和冷卻.正常工作過程中,溫度,風(fēng)壓等均設(shè)有自動(dòng)監(jiān)控,實(shí)現(xiàn)了自動(dòng),連續(xù)的完成容器瓶的輸入,預(yù)熱,干燥,滅菌,冷卻和輸出的無菌生產(chǎn)工藝流程.本設(shè)備整個(gè)輸送隧道是一個(gè)密閉的整體組合件,按結(jié)構(gòu)可分為三部分,第一部分為預(yù)熱段,第二部分為干燥,滅菌段,第三部分為冷卻段.This equipment adopts LF principle and heat exchange principle to finish

13、 drying, sterilization and cooling of containers inside the tunnel. When the machine is working normally, the temperature and air pressure both are configured with auto monitor, which can realize the sterile production process for the containers of automatic and continuous input, preheating, sterili

14、zation, drying, cooling and output. The whole conveying tunnel of this equipment is a closed integral combined part. According to the structure, this machine consists of three parts, preheating zone, sterilization and drying zone and cooling zone.6.2 預(yù)熱部分(LE) Preheating part (LE)序號(hào)No.名稱Name代號(hào)Code數(shù)量Q

15、ty.備注Remark1預(yù)熱粗效過濾器Coarse efficiency filter in preheating zone1459×620×702預(yù)熱層流LF frame in preheating zone13預(yù)熱層流風(fēng)機(jī)LF fan in preheating zoneYDF-2.8-4S11.1kW4風(fēng)罩Air hood15偏心壓緊裝置Eccentric clamping device26預(yù)熱主效過濾,器HEPA filter in preheating zone2001610×457×1507Pr接近感應(yīng)開關(guān)Proximity switch1外

16、圓M11Outer circle M128信號(hào)板Signal plate1如圖2所示”預(yù)熱部分(LE)主要由預(yù)熱粗效過濾器(1),預(yù)熱層流框(2),預(yù)熱層流風(fēng)機(jī)(3),風(fēng)罩(4),偏心壓緊裝置(5),預(yù)熱高效過濾器(6),接近感應(yīng)開關(guān)(7), 信號(hào)板(8)等組成.As Figure 2, preheating part(LE) mainly consists of coarse efficiency filter (1) of preheating zone, LF chamber of preheating zone(2), LF fan of preheating zone(3), air

17、 hood (4), eccentric clamping device(5), HEPA filter of preheating zone(6), proximity switch(7), and signal plate(8), etc.工作時(shí),預(yù)熱層流箱體中的預(yù)熱層流風(fēng)機(jī)從上腔開孔處吸入從干燥滅菌段經(jīng)粗效過濾器后過濾后的空氣,壓入層流箱體下腔,經(jīng)過風(fēng)罩,高效過濾器,將潔凈的空氣壓向容器瓶，對(duì)容器瓶進(jìn)行層流風(fēng)保護(hù)，然后由設(shè)備底部抽風(fēng)機(jī)抽走。預(yù)熱段層流腔室相對(duì)洗瓶間為正壓，使外面的低級(jí)別空氣不能進(jìn)入隧道內(nèi)，以保持容器的潔凈度。預(yù)熱段對(duì)藥瓶預(yù)熱的熱量主要來自于干燥滅菌段向預(yù)熱段溢出的熱風(fēng)。為

18、保證干燥滅菌段的干燥，滅菌效果；同是又使干燥滅菌段的熱風(fēng)不至于大量流向預(yù)熱段，在壓力設(shè)置中需將干燥滅菌段內(nèi)的風(fēng)壓調(diào)至高于預(yù)熱段的風(fēng)壓并為正壓。6.3 干燥，滅菌部分（LHDrying & sterilization part(LH) 如圖3所示：干燥，滅菌部分（LH）主要由箱體（7），加熱層流風(fēng)機(jī)（2），電加熱管（13），高溫高效過濾器（15），風(fēng)罩（16）和粗效過濾器（11）等組成。As Figure 3, drying and sterilization part (LH) mainly consists of chamber (7), heating LF fan (2), el

19、ectric heating pipe (13), high temperature HEPA filter (15), air hood (16) and coarse efficiency filter (11) etc.工作時(shí)，少量空氣由粗效過濾器進(jìn)入，按箭頭方向向上經(jīng)過不銹鋼電熱管，經(jīng)電加熱管加熱后，被加熱層流風(fēng)機(jī)吸入，再按箭頭方向經(jīng)過高溫高效過濾器過濾潔凈后進(jìn)入隧道內(nèi)，進(jìn)入隧道內(nèi)的高溫潔凈空氣對(duì)容器進(jìn)行干燥和滅菌；其中，箱體前端部分高溫高濕空氣沿著箱體底部箭頭方向被抽濕排風(fēng)風(fēng)機(jī)抽走。在干燥滅菌箱體的結(jié)構(gòu)中，將過濾與加熱用隔離板分開，使氣流形成如圖示箭頭方向所示的明顯的層流風(fēng)道。而且不

20、使紊亂；因而此結(jié)構(gòu)可使容器瓶在箱體隧道內(nèi)始終處于潔凈均勻的層流保護(hù)之下，避免容器被箱體外低級(jí)別空氣的污染，可始終保持容器瓶的潔凈度，從而達(dá)到滿足無菌生產(chǎn)工藝的要求。 為保證滅菌效果，干燥，滅菌區(qū)的風(fēng)壓相對(duì)于預(yù)熱區(qū)和冷卻區(qū)為正壓。圖3 干燥,滅菌部分的(LH)箱體結(jié)構(gòu)示意圖Figure 3 Structure schematic drawing of the chamber in sterilization and drying zone (LH)序號(hào)No.名稱Name代碼Code數(shù)量Qty.備注Remark1水冷接口Connector for water coolingKSZ620/60-12

21、-16-06-002熱風(fēng)機(jī)冷水出口Cooling water outlet of hot fan2加熱層流電機(jī)LF motor in heating zone420型YS0-2S420Type YS0-2S21.5kW3接近開關(guān)Proximity switch2外徑M12Outer diameter M124感應(yīng)片Sensor chip25DOP入口DOP inlet26預(yù)留驗(yàn)證口Reserved validation port37箱體Chamber18封板Sealing plateKSZ620/60-12-12-3819排濕口Dehumidify port110塞塊Plug211粗效過濾器C

22、oarse efficiency filter汽車過濾器1706Auto filter 1706212壓塊Pressing blockKSZ620/75-12-11-001213電加熱管Electric heating pipeKSZ620/60-12-10-04-00A361.2Kw14偏心壓緊裝置Eccentric clamping device215高溫高效過濾器High temperature HEPA filter216風(fēng)罩Air hood117加熱器出口溫度探頭Temperature probe in heater outlet118DOP入口DOP inlet16.4 冷卻部分(

23、LK) Cooling part (LK) 圖4 冷卻部分(LK)箱體結(jié)構(gòu)示意圖Figure 4Structure schematic drawing of cooling zone (LK)序號(hào)No.名稱Name代碼Code數(shù)量Qty.備注Remark1冷卻層流箱體LF chamber in cooling zone12冷卻層流風(fēng)機(jī)LF fan in cooling zoneYDF-2.8-4S11.1kW3接近感應(yīng)開關(guān)Proximity switch1外圓M12Outer circle M124高效過濾器HEPA filter801762×762×1505中效過濾器Me

24、dium efficiency filter11235×550×706表冷器進(jìn)水管Water inlet pipe of radiator11.5快換卡箍1.5quick-to-change joint7角座閥Angular seat valveGET-200018表冷器Radiator19箱體Chamber110排風(fēng)管Exhaust pipe1如圖4所示:冷卻部分(LK)采用了空氣熱交換原理,在冷卻層流箱體(1)中裝有中效過濾器(5),表冷器(8),冷卻層流風(fēng)機(jī)(2)吸入經(jīng)中效過濾器(5),表冷器(8)交換后的冷空氣壓入風(fēng)罩,流經(jīng)高效過濾器(4)后對(duì)容器瓶進(jìn)行冷卻,使容器

25、瓶在經(jīng)過冷卻部分后的瓶溫不高于室溫+5,以滿足制藥工藝的要求,方便下道工序進(jìn)行灌裝封口.表冷器(8)熱交換使用7-12冷凍水.冷凍水通過角座閥(7)控制流量大小,以調(diào)節(jié)冷卻段內(nèi)層流風(fēng)的溫度.冷卻段內(nèi)的層流風(fēng)溫工一般設(shè)定為25.注意: 在冷卻段裝有溫度探頭,在溫控儀上有冷卻溫度顯示,要求溫度不能低于20.6.5 容器瓶輸關(guān)機(jī)構(gòu)Container conveying structure圖5 容器輸送機(jī)構(gòu)示意圖Figure 5 Container conveying structure如圖5所示: 容器瓶輸送機(jī)構(gòu)是一條兩邊帶有側(cè)擋邊的鏈條輸送通道,在輸送過程中兩 邊不至于倒瓶,通道的有效寬度為600

26、mm6.6 輸瓶網(wǎng)帶減速機(jī)構(gòu)Speed reducing structure of conveyor belt圖6 輸瓶網(wǎng)帶減速機(jī)構(gòu)示意圖Figure 6 Speed reducing structure of conveyor belt序號(hào)No.名稱Name代碼Code數(shù)量Qty.備注Remark1電機(jī)Motor0.37kW1非穿越(序號(hào)1)Non-crossing(NO.1)2蝸輪蝸桿減速機(jī)Worm gear boxNMRV40/75-2400-Y0.371非穿越(序號(hào)2)Non-crossing(NO.2)3傳動(dòng)軸Transmission shaftKSZ620/60-09-011非穿越

27、(序號(hào)3)Non-crossing(NO.3)4傳動(dòng)鏈輪Transmission sprocketKSZ620/60-09-021非穿越(序號(hào)4)Non-crossing(NO.4)如圖6所示:輸瓶網(wǎng)帶減速機(jī)構(gòu)是由電機(jī)(1)通過二給蝸輪蝸桿減速機(jī)(2)傳動(dòng)到傳動(dòng)軸(3),通過與傳動(dòng)軸(3)固聯(lián)的傳動(dòng)鏈輪(4),鏈條,驅(qū)動(dòng)與從動(dòng)鏈輪固聯(lián)的從動(dòng)軸,帶動(dòng)與從動(dòng)軸的鏈輪驅(qū)動(dòng)輸瓶網(wǎng)帶,完成輸送容器的任務(wù).6.7 排氣結(jié)構(gòu) Exhaust structure6.7.1 冷卻段排風(fēng)結(jié)構(gòu)Exhaust structure in cooling zone圖7 冷卻段排風(fēng)結(jié)構(gòu)示意圖Figure 7 Schemat

28、ic drawing of exhaust structure in cooling zone序號(hào)No.名稱Name代碼Code數(shù)量Qty.備注Remark1冷卻排風(fēng)風(fēng)機(jī)Exhaust fan in cooling zoneYDFW 1.8-411.8kW2風(fēng)門軸Shaft of air shutterKSZ620/60-07-05-0513船體2Hull 2KSZ620/60-04-04-00A14排風(fēng)箱Exhaust boxKSZ620/60-07-05-001如圖7所示:冷卻段排風(fēng)機(jī)構(gòu)主要由冷卻排風(fēng)機(jī),調(diào)節(jié)桿,排風(fēng)漏斗,排風(fēng)管等組成.工作時(shí),冷卻排風(fēng)機(jī)運(yùn)轉(zhuǎn),產(chǎn)生如箭頭所示的方向,抽走冷卻

29、隧道內(nèi)經(jīng)熱交換后變熱空氣,空氣沿箭頭方向經(jīng)排風(fēng)管道排出;調(diào)節(jié)手柄5可調(diào)節(jié)風(fēng)門開啟大小,通過調(diào)節(jié)風(fēng)門開啟大小可輔助調(diào)節(jié)此排風(fēng)量.6.7.2 預(yù)熱抽濕排風(fēng)機(jī)構(gòu)Dehumidify and exhaust structure圖8 預(yù)熱抽濕排風(fēng)結(jié)構(gòu)示意圖Figure 8 Schematic drawing of dehumidify and exhaust structure in preheating zone序號(hào)No.名稱Name代碼Code數(shù)量Qty.備注Remark1導(dǎo)風(fēng)管Air ductKSZ620/60-15-03-0012抽濕風(fēng)機(jī)Dehumidify fanDF-1.3A-2(左進(jìn)風(fēng))D

30、F-1.3A-2(Air coming from left)10.18kW3排風(fēng)管Exhaust pipeKSZ620/75A-15-14-001如圖8所示:預(yù)熱抽濕排風(fēng)機(jī)構(gòu)主要由法蘭墊,導(dǎo)風(fēng)管(1),抽濕排風(fēng)機(jī)(2),排風(fēng)管(3)等組成.預(yù)熱抽濕排風(fēng)機(jī)(2)安裝在干燥滅菌段箱體的初始部分的左下方,一端與法蘭墊,導(dǎo)風(fēng)管(1)連接,并用排風(fēng)管插入至干燥滅菌段箱體的內(nèi)底面,使風(fēng)排向船體.工作時(shí),預(yù)熱抽濕排風(fēng)機(jī)(2)從干燥滅菌段箱體的進(jìn)口處透過網(wǎng)孔板吸入充滿水蒸汽的濕熱空氣排往室外.6.8 預(yù)熱段容器瓶進(jìn)入信號(hào)裝置Infeed signal device in preheating zone圖9 預(yù)

31、熱段容器瓶進(jìn)入信號(hào)裝置Figure 9 Infeed signal device in preheating zone序號(hào)No.名稱Name代碼Code數(shù)量Qty.備注Remark1進(jìn)瓶臺(tái)板Infeed plate12信號(hào)板Signal plateKSZ620/60-02-01-0013限位板Limit blockKSZ620/60-02-081A-B接近感應(yīng)開關(guān)Proximity M162施耐德Schneider如圖9所示:信號(hào)裝置由信號(hào)板,信號(hào)裝置固定座及接近開關(guān)A,B等組成.信號(hào)裝置用于控制烘箱輸送網(wǎng)帶的開啟和洗瓶機(jī)的聯(lián)動(dòng).工作時(shí),由洗瓶機(jī)洗完的瓶子經(jīng)進(jìn)瓶過渡板進(jìn)入隧道預(yù)熱段內(nèi),隨著隧道

32、內(nèi)的瓶子數(shù)量的增加,瓶子開始推動(dòng)信號(hào)板繞信號(hào)板固定桿轉(zhuǎn)動(dòng);同時(shí),固定在信號(hào)板固定桿上的信號(hào)感應(yīng)桿也隨之轉(zhuǎn)動(dòng),當(dāng)其轉(zhuǎn)動(dòng)到一定角度時(shí),感應(yīng)桿接近開關(guān)A,啟動(dòng)輸瓶網(wǎng)帶移動(dòng);當(dāng)進(jìn)瓶數(shù)量減少時(shí),信號(hào)板受瓶子擠壓力減少,則其依靠自身的彈力逐漸復(fù)位,使開關(guān)A斷開,停止輸瓶網(wǎng)帶移動(dòng).如果輸瓶網(wǎng)帶上容器瓶過多或其它情況堵塞時(shí),輸送網(wǎng)帶上瓶子擠壓力增大,推動(dòng)信號(hào)板轉(zhuǎn)動(dòng)至接通開關(guān)B時(shí),可自動(dòng)停止前面的洗瓶機(jī)的動(dòng)轉(zhuǎn),避免瓶子擠壓破碎.6.9 DOP port structure圖11 DOP煙霧測(cè)試示意圖Figure 11 DOP smoke test drawing如圖11所示:本設(shè)備設(shè)置有DOP接口裝置,是為用戶

33、提供一個(gè)驗(yàn)證(高溫)高效過濾器是否合格,而進(jìn)行煙霧測(cè)試或者塵埃粒子測(cè)試用的接口裝置,該裝置還可用來作為測(cè)量烘箱內(nèi)部溫度或者風(fēng)速的接口.6.10 停電保護(hù)裝置Power failure protection structure圖12 停電保護(hù)裝置Figure 12 Power failure protection structure序號(hào)No.名稱Name數(shù)量Qty.備注Remark1入口接口Inlet joint12過濾減壓閥Filtration and depressurization 13面板panel14手扭開關(guān)Manual switch15出口接頭Outlet joint1如圖12所示:

34、停電保護(hù)裝置主要由過濾減壓閥(2),手扭開關(guān)(4)等組成,均安裝在主機(jī)前端面板(3)上.As figure 12, power failure protection structure mainly consists of filtration and depressurization valve (2), manual switch (4) etc., which are installed on the panel in the front part of machine.要求將壓縮空氣氣源接至入口接頭(1)上;再將出口接頭(5)接至烘箱箱體停電保護(hù)入口(共2處);并將過濾減壓閥(2)的壓

35、力調(diào)定到0.3MPa即可.本設(shè)備在正常運(yùn)行中若發(fā)生突然斷電后,各個(gè)層流風(fēng)機(jī)都會(huì)停止運(yùn)轉(zhuǎn),干燥,滅菌箱內(nèi)的空氣溫度較高,時(shí)間過長會(huì)中會(huì)加劇高溫高效過濾器老化,此時(shí)可打開備用氣源,轉(zhuǎn)動(dòng)手扭開關(guān)(4),通過過濾減壓閥(1),將經(jīng)過過濾,減壓后的常溫潔凈壓縮空氣連續(xù)吹入干燥,滅菌箱體內(nèi)使其溫度降低,起到保護(hù)高溫高效過濾器不會(huì)因停電溫度過這而引起高溫高效過濾器燒壞.7. 設(shè)備的吊運(yùn)安裝與調(diào)整Handling, Installation and Adjustment7.1 運(yùn)輸和安裝 Transport and Installation本機(jī)為木箱包裝,運(yùn)輸前和到達(dá)場(chǎng)地后需按包裝箱上起吊位置吊裝.到達(dá)場(chǎng)地打

36、開包裝箱,按圖13將機(jī)器吊起.,卸下機(jī)器底部木方,運(yùn)送到安裝地點(diǎn).圖13 起吊位置示意圖Figure 13 Schematic drawing of hoisting position7.2 安裝指南 Installation guide 在安裝設(shè)備之前,必須研究安裝圖.檢查消毒室口和壁厚的尺寸,保證他們相符合.指隧道緊靠消毒室口,縱橫向水平對(duì)中,把水平儀放在隧道的基架上,在正常情況下,工作高度為900mm.安裝需要分兩步,一般是先將烘干機(jī)就位,連線,使灌裝間隔離板緊貼連接筒內(nèi)邊.然后將水氣管路,電源電壓,排風(fēng)管路等布置好,待房間凈化做好后再安裝過濾器,以免過濾器因房間塵埃不合格而損壞,房間高

37、度必須大于2.7m.拆下后面進(jìn),出口層流箱體的蓋板,真空吸去松散微粒,用酒精清洗金屬板,然后裝上中,高效過濾器,蓋上蓋板.拆開烘箱后面的加熱器,取下里面的內(nèi)蓋板,以及底問抽屜,排渣孔,清理隧道內(nèi)的灰塵,真空吸去松散微料,用酒精清洗 金屬板.裝上高溫高效過濾器,用高溫紙棒和耐高溫密封膠密封,裝上內(nèi)蓋板并檢查加熱器上所有加熱系統(tǒng)的接觸處,然后重新蓋上.再將所有其他零件按原樣裝上.關(guān)上加熱座的時(shí)候也要注意安裝密封條.注意:安裝過濾器時(shí)不要接觸過濾器表面!Caution: Dont touch surface of filter when the filter is being installed.7

38、.3 安裝場(chǎng)地要求 Requirement of installation field:能源條件:Power condition:電源與電器柜相連,主機(jī)各部分參數(shù)為:Power supply connects with electric cabinet, and parameters of each part of machine:電源總功率最大為47.55KW,三相五線制:Total power of power supply: 47.55 KW, there-phase-five-wire system;室內(nèi)環(huán)境潔凈度為10萬級(jí);Cleanliness in the room is Gra

39、de 100000;灌裝間與洗瓶間的壓力差為+15MPa+30MPa;Pressure difference between filing room and washing room is +15MPa+30MPa;用戶需另接排風(fēng)引風(fēng)機(jī),計(jì)算公式如下:User should connect additional air-inducing fan, calculation formula as follows:排風(fēng)引風(fēng)機(jī)風(fēng)量=排風(fēng)機(jī)風(fēng)量×(1+50%+W×0.5%+L×0.5%)Air volume of air-inducing fan=air volume of

40、 exhaust fan×(1+50%+W×0.5%+L×0.5%)式中:In formula:W為彎道數(shù)量,L為管道長度/10W is number of curve, L is the pipe length/10排風(fēng)引風(fēng)機(jī)全壓=排風(fēng)機(jī)全壓+50 MPa;Total pressure of air-inducing fan=total pressure of exhaust fan+50Pa.經(jīng)計(jì)算排風(fēng)引風(fēng)機(jī)風(fēng)量4000m3/h,全壓350Pa.;The calculated air volume of air-inducing fan 4000m3/h, t

41、otal pressure 350Pa.排風(fēng)引風(fēng)機(jī)直接接到主排風(fēng)管路上,因?yàn)榉块g相對(duì)于管路必須保持正壓(由空調(diào)系統(tǒng)保證),所以不必安裝防倒流閥,粗效過濾器就起到防倒流作用,而且排風(fēng)引風(fēng)機(jī)是與每個(gè)房間空調(diào)系統(tǒng)配套,處于常開狀態(tài),不倫排風(fēng)機(jī)是否變頻,當(dāng)排風(fēng)機(jī)頻率變小時(shí),排風(fēng)引風(fēng)機(jī)會(huì)使管路產(chǎn)生一個(gè)負(fù)壓,使得排風(fēng)順暢.其排風(fēng)管路布置示意圖14.圖14 排風(fēng)管道布置示意圖Figure 14 Layout drawing of exhaust pipeline7.4 調(diào)整試車Adjusting and commissioning7.4.1 加熱層流風(fēng)機(jī)運(yùn)行指示的調(diào)整:Adjustment of runni

42、ng indication of LF fan in heating zone圖15 加熱層流風(fēng)機(jī)運(yùn)行指示的調(diào)整Figure 15 Adjustment of running indication of LF fan in heating zone序號(hào)No.名稱Name代碼Code數(shù)量Qty. 備注Remark1接近感應(yīng)開關(guān)Inductive proximity switch1外圓M12Outer circle M122信號(hào)板Signal plateKSZ620/60-01-12-041如圖15所示:加熱層流風(fēng)機(jī)是否運(yùn)轉(zhuǎn),在箱體外表面是無法看出的,這時(shí)可啟動(dòng)加熱層流風(fēng)機(jī),觀察電器柜控制面板上的

43、”熱風(fēng)電機(jī)”信號(hào)是否處于工作狀態(tài),如此時(shí)此信號(hào)沒有顯示處于工作狀態(tài),可調(diào)節(jié)干燥滅菌段箱體背后接近開關(guān)1,使信號(hào)板2離接近開關(guān)1最近距離約1mm左右,待信號(hào)顯示穩(wěn)定后,將信號(hào)板用螺絲固定.其風(fēng)壓可通過面板上的壓差表讀出,需改變風(fēng)壓時(shí),可調(diào)節(jié)控制加熱層流風(fēng)機(jī)的變頻器的工作頻率來達(dá)到所要求的風(fēng)壓.在機(jī)器啟動(dòng)前,加熱層流風(fēng)機(jī)未開啟時(shí),信號(hào)板2應(yīng)遠(yuǎn)離接近開關(guān)1,即接近開關(guān)應(yīng)處于關(guān)閉狀態(tài),否則將會(huì)報(bào)警.7.4.2 預(yù)熱層流風(fēng)機(jī)與冷卻層流風(fēng)機(jī)運(yùn)行指示的調(diào)整Adjustment of running indication of LF fan in preheating zone and cooling zon

44、e如圖2所示:預(yù)熱段,冷卻段的層流風(fēng)機(jī)是否運(yùn)轉(zhuǎn),可先啟動(dòng)層流風(fēng)機(jī),觀察電器控制柜的面板上”預(yù)熱段層流電機(jī)”,”冷卻段層流電機(jī)”信號(hào)是否處于工作狀態(tài),按照7.4.1所描述的調(diào)節(jié)熱風(fēng)機(jī)工作狀態(tài)的方法,調(diào)節(jié)與之相對(duì)應(yīng)的接近開關(guān),讓風(fēng)機(jī)處于工作狀態(tài)下.其風(fēng)壓可通過面板上的壓差表讀出,并通過調(diào)節(jié)加熱層流風(fēng)機(jī)的變頻器來達(dá)到所要求的風(fēng)壓,風(fēng)速.7.4.3 抽濕排風(fēng)電機(jī),冷卻排風(fēng)電機(jī)是否運(yùn)轉(zhuǎn),可觀察控制面板上的”抽濕電機(jī)”,”排風(fēng)電機(jī)”信號(hào)是否處于工作狀態(tài)確定.7.4.4 調(diào)整好干燥機(jī)的各段壓差,洗瓶間與灌裝間的壓差,使之符合附錄表1中所限范圍,才能組織正常生產(chǎn).注意:灌裝間對(duì)洗瓶間的壓差直過35Pa時(shí)報(bào)警!

45、并停止加熱,輸瓶網(wǎng)帶停止運(yùn)轉(zhuǎn).8. 設(shè)備的操作與使用Operation and Use8.1 電源開關(guān)柜面板操作說明Operation instruction of electric cabinet8.1.1 將開關(guān)柜里的斷路器全部合上Close all breaker in electric cabinet.8.1.2 用鑰匙打開電源柜電源開關(guān).Turn on the power switch of electric cabinet with key.8.1.3 在觸摸屏輕觸”操作畫面”按鍵, 進(jìn)入操作畫面,按”網(wǎng)帶手動(dòng)”,觀察輸瓶網(wǎng)帶的運(yùn)行情況,最少運(yùn)轉(zhuǎn)1小時(shí).再”按網(wǎng)帶自動(dòng)”按鈕. 輕觸

46、”溫度設(shè)定”按鍵,進(jìn)入濕度設(shè)定畫面,設(shè)定干燥滅菌溫度.使干燥機(jī)在正常運(yùn)轉(zhuǎn)過程中:當(dāng)干燥滅菌溫度低于設(shè)定溫度時(shí),電加熱管將會(huì)自動(dòng)加熱.注意:設(shè)定停機(jī)溫度可實(shí)現(xiàn):當(dāng)干燥機(jī)內(nèi)各層流風(fēng)機(jī)在溫度低于設(shè)定停機(jī)溫度時(shí)就會(huì)自動(dòng)停機(jī),調(diào)好后可固定,不必經(jīng)常調(diào)整.8.1.4 在觸摸屏輕觸”操作畫面”按鍵,進(jìn)入操作畫面,啟動(dòng)”日間工作”按扭,各層流風(fēng)機(jī)開始運(yùn)轉(zhuǎn),電加熱管開始加熱.8.1.5 檢查電加熱管加熱情況,轉(zhuǎn)動(dòng)”電源開關(guān)”,觀察”電流指示”表電流指示狀態(tài).注意:當(dāng)順時(shí)針轉(zhuǎn)動(dòng)電流開關(guān),三擋分別為每一相的電流測(cè)試,觀察三擋電流是否相等,如果不相等,說明電加熱管中有的已經(jīng)損壞,需重新更換.8.1.6. 輸瓶網(wǎng)帶起帶

47、控制選擇” 自動(dòng)”方式.Select “automatic mode” for the control of conveyor belt moving.注意:可使干燥機(jī)輸瓶風(fēng)帶走帶與清洗機(jī),灌裝機(jī)動(dòng)作匹配,由洗瓶機(jī)清洗干凈的空瓶遂只進(jìn)入干燥機(jī)預(yù)熱段進(jìn)口過渡板上,當(dāng)過渡板上聚集到有一定數(shù)量的瓶子后,就會(huì)推動(dòng)信號(hào)板彈片動(dòng)作,從而使接近開關(guān)接通,啟動(dòng)輸瓶網(wǎng)帶減速電機(jī)運(yùn)轉(zhuǎn),輸瓶網(wǎng)帶就會(huì)載著瓶子移動(dòng);當(dāng)預(yù)熱段進(jìn)口處的瓶子數(shù)量減少,信號(hào)板彈片就會(huì)回彈,使接近開關(guān)斷開,輸瓶網(wǎng)帶就會(huì)停止移動(dòng).如此循環(huán)就形成了輸瓶網(wǎng)帶走帶自動(dòng)控制.8.1.7 輕觸”日間啟動(dòng)”按鍵后,整個(gè)干燥機(jī)處理自動(dòng)狀態(tài),溫度自調(diào)節(jié)到設(shè)定溫度

48、值.電機(jī)過載,風(fēng)壓過高,風(fēng)門沒打開,會(huì)立即彈出報(bào)警畫面,并停止干燥滅菌段加熱.8.1.8 輕觸”日間啟動(dòng)”,按下”夜間啟動(dòng)”鍵,輸瓶網(wǎng)帶電機(jī)停止,干燥滅菌段加熱停止.預(yù)熱層流電機(jī),加熱層流電機(jī),冷卻層流電機(jī),抽濕排風(fēng)電機(jī),冷卻排風(fēng)電機(jī)的信號(hào)指示燈都亮,表示都在運(yùn)行.當(dāng)干燥滅菌段箱體內(nèi)溫度低于100,加熱層流風(fēng)機(jī),抽濕排風(fēng)電機(jī)停止.其它風(fēng)機(jī)繼續(xù)運(yùn)行,保持干燥機(jī)隧道內(nèi)部處于層流屏蔽狀態(tài),以免外部空氣進(jìn)入隧道內(nèi).一般緊急停機(jī)時(shí)間不宜超過半小時(shí),以免箱體內(nèi)的熱量不能及時(shí)排出,使得溫度過高而損壞高溫高效過濾器.如果是停電故障,則可開啟停電保護(hù)裝置.8.2 正確使用Correct use8.2.1 空車運(yùn)

49、行,檢查所有電機(jī)是否運(yùn)轉(zhuǎn),有無異常響聲.The machine runs in empty load. Check whether all motors are running or not and whether there is abnormal noise.8.2.2 測(cè)量并調(diào)整干燥機(jī)各段箱體內(nèi)的風(fēng)速和風(fēng)壓:Measure air speed and air pressure of each zone 預(yù)熱段箱體內(nèi)的風(fēng)速為0.45m/s,相對(duì)于房間為正壓.Air speed in preheating zone 0.45m/s and it is positive pressure co

50、mpared with room.干燥滅菌段箱體內(nèi)的風(fēng)速為0.55 m/s,相對(duì)于房間為正壓.Air speed in drying and sterilization zone 0.55m/s, and it is positive pressure compare with room . 冷卻段箱體內(nèi)的風(fēng)速為0.45m/s,相對(duì)于房間為正壓.Air speed in cooling zone 0.45m/s, and it is positive pressure compare with room. 并應(yīng)防止或減少因人流,物流開關(guān)房門而引起風(fēng)壓與風(fēng)速的變化.If should preve

51、nt the air pressure and air speed from changing when the door is opened or closed due to human flow and material flow.8.2.3 當(dāng)容器瓶由洗瓶機(jī)出口進(jìn)入本機(jī)預(yù)熱段進(jìn)瓶臺(tái)板時(shí),可用鏈條(普通單排或雙排鏈條,藥廠自備)放置在洗瓶機(jī)的出瓶軌道口上,擋住洗瓶機(jī)的出瓶嘴,以防止輸送到本機(jī)輸瓶帶上的容器倒瓶.輸入的容器瓶排列聚集到一定數(shù)量后,就會(huì)形成一定的壓力,使限位彈片移動(dòng),從而接通接近開關(guān),啟動(dòng)輸瓶網(wǎng)帶電機(jī),輸瓶網(wǎng)帶開始移動(dòng).8.2.4 清洗機(jī)停機(jī)后,在電源柜控制面板上輕觸”手動(dòng)走帶”后可以不斷推動(dòng)瓶子補(bǔ)充給下道工序.洗瓶機(jī)停機(jī)后,可用推瓶板將剩余的瓶了隨輸送網(wǎng)帶送到下道工序.8.2.5 使用,操作本設(shè)備應(yīng)嚴(yán)格按照說明書上要求的額定產(chǎn)量,包裝材料等組織進(jìn)生生產(chǎn);本設(shè)備的操作,維護(hù)必須是經(jīng)過培訓(xùn),考核合格的人員.8.3 瓶規(guī)格更換的調(diào)整,Repla