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WPJ5 bottle warming machine

Instruction

Zhangjiagang JINRI Beverage Machinery Co.,Ltd

catalogues

一、GENERAL SAFETY REFERENCE................................................2

二、MIDWAY STORAGE..........................................................3

三、SAFETY NOTICE...........................................................3

四、OVERVIEW................................................................4

1、PRODUCT USE AND SCOPE OF APPLICATION.....................................4

2、COLD BOTTLE SITUATION....................................................4

3、PRODUCT MAIN SPECIFICATIONS AND TECHNICAL PARAMETERS..........5

4、TRANSMISSION..........................................................6

5、SAFETY DEVICES...........................................................6
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五、WORKING PRINCIPLE AND STRUCTURE.........................................6

六、INSTALLATION AND COMMISSIONING AND COMMISSIONING........................7

七、MACHINE OPERATION AND MAINTENANCE.......................................9

八、BACKUP LIST............................................................11

九、RANDOM TECHNICAL FILE..................................................11

一、General safety reference

Before the machine is put into operation for the first time, important information about

safety must be read and understood.

The safety of the machine complies with the regulations of professional associations, as

well as relevant applicable safety laws and currently known

machine guidelines.

As long as the operation is proper and within the allowed range, the danger to the

operator and the machine will be reduced to a low level that modern technology can

achieve.

Use the
emergency
shutdown
switch only in
critical
situations!

The emergency shutdown switch on the operation panel and the machine can

only be used when the operator or the machine is in danger. Under normal
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circumstances, the emergency shutdown switch cannot be used to turn off

the machine!

Please pay attention to the use of emergency stop switch!

The emergency shutdown switch cannot be used during normal shutdown!

Once activated, the emergency shutdown switch is automatically locked.

The machine can only be restarted after eliminating the safety threat to

the operator and the machine!

二、Midway storage

If storage is needed in the middle, the storage site must meet the following

requirements to prevent damage and corrosion of some temperature and humidity

sensitive parts:

Keep the machine and its parts away from dirt, dust and paint molecules. Cover

the machine with plastic film.

The ambient temperature must be between minus 10 degrees and 50 degrees.

Prevent condensation inside and outside the machine. Ensure that the storage

site has good ventilation.

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There should be no volatilized vapors of solvents, acids, lyes in the area around

the machine.

Ensure that the machine is placed at the level of the ground, and the weight of the

machine is evenly distributed on each spiral foot.

After a long period of storage (more than 4-5 months), check

whether the battery in the PLC controller is intact and whether

all program units still exist. If you have any questions, please notify our staff.

The above practices also apply in the following situations：

The program unit is completely or partially lost due to too long storage time or

insufficient buffer battery capacity.

三、Safety instructions

This machine is built in accordance with corresponding safety regulations.

Its structure allows it to operate without danger in adjustment, maintenance,

maintenance, repair and elimination of temporary faults. During these kinds

of work, the machine must only be turned by hand, or use a jog switch.

If the switch is located outside the reach of the person doing this kind of

work, or if there are several people working on or in the machine at the

same time, then a person must be specially assigned for this purpose. This

person must be able to observe the work and Operate the machine at a

position where the machine can be stopped immediately, and the person

must not leave this position while the work is in progress.

Before any connection, check that there are no tools, cleaning

utensils, etc. on the passage of the bottle.

It is especially important to carefully read all safety regulations and

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instructions for safety professionals. In addition, the main thing is to see

the following points:

a)Do not wear any loose work clothes.

b)To protect long hair, use a hairnet or some other form of work cap.

c)When handling chemicals, hot water and steam, in order to prevent corrosion burns,

scalds and injuries, wear protective clothing (protective glasses, rubber aprons, boots,

gloves) according to regulations.

d)When the machine is running normally, it is not allowed to cut off the power

suddenly.

四、overview

1 . Product overview and scope of application

This machine is an auxiliary equipment for the polyester bottle beverage

line. After the cold filling of the polyester bottle and glass bottle, the

machine is used to raise the temperature to the process temperature while

ensuring the color, fragrance and nutritional ingredients of the beverage

remain unchanged, so as to facilitate the labeling machine The labeling

ensures that the container can be clean and dry into the carton.

2.Warming bottle situation

Spraying The first spray the Second

area area spray area

Spray
2.3㎡ 2.3㎡
area
Temperat
15℃ 30-40℃
ure ℃
Spray
10min 10min
time
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3.Product main specifications and technical parameters

3.1.Main product specifications：

model：WPJ5

Type ： This machine is a double-end chain plate conveying spray type

bottle warming machine

3.2 technical parameter

2.1、max speed：3000b/h 500ml

2.2、Inlet temperature：0-5℃
2.3、output temperature：36～40℃
2.4、Cold water spray time：15-25minute
2.5、Consumption quota
a.electric power
Total power：7.1KW
include：main motor：1.5KW
The third spray zone pump：3KW
The fourth spray zone pump：3KW
b.Water consumption：0.2m³/hour(pressure：0.3MPa)
2.8、Overall dimensions and total weight：
size：5000㎜×1500㎜×1650㎜
weight：about 2T

4.transmission

The main drive adopts stepless variable frequency reduction motor drive.
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5.safety devices

Operators should be familiar with all safety devices and their use methods to

avoid personal injury and machine damage.

五、Working principle and structure

1、working principle

The bottle warming machine takes the low-temperature filling and capping

and sealing of the container bottle through the circular plastic chain

transportation into the spray area of different temperature to complete the

heating process, and raise the beverage in the bottle to a certain

temperature to ensure the beverage The color, fragrance, taste and nutrition

of the product are convenient for labeling, labeling and packing after the

whole line.

2、structure

This equipment is composed of body, transmission part, spray area and

electrical control.

2.1、airframe：

The whole body is made of stainless steel, which consists of spray area,

adjustment base and other parts.

2.2、Transmission part

a、In-machine conveying

The conveying inside the machine is composed of a set of ring-shaped

plastic modular chain plates. The transmission system is a continuously

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variable motor to drive the active shaft to rotate. Several tooth pitch

sprockets mounted on the main drive shaft drive the plastic modular chain

plates. Circulating operation, so as to carry out the transportation of

polyester bottles in the machine. The bottle guide part is arranged in the

body to prevent the bottle from touching the frame during operation and

causing the bottle to fall. An open hole is provided on the conveyor belt, and

the water during spraying can flow into the water tank from the hole.

b、Spray device

There are two spray areas in the machine. The water heated by the

steam is pumped to the corresponding spray pipe, and the warm water is

sprayed from the pipe cone nozzle onto the polyester bottle to spray the

bottled beverage. The sprayed water flows into the sump at the bottom of

the body, and then circulates by the pipeline pump. The first and second

areas are independent spray areas. Before work, open the manual valve at

the upper end of the steam pipe to heat the water in the water tank to a

predetermined temperature (as can be seen from the temperature gauge on

the water tank), and turn on the water pump for heat exchange. Speed up

the warm-up time. Then the pneumatic valve will automatically supplement

the heat (close the manual valve) to maintain the process temperature and

ensure the purity of the beverage. The first and second zone pipeline pumps

respectively drive into the spray pipeline in their own area. Spray the

polyester bottles in this area, and the sprayed water flows into the water

collection tank at the bottom of the body, and is heated by steam and

sprayed and sterilized by a water pump.

2.3、Electrical control

a.The electrical control box of the machine is placed on the left side

panel of the machine body with operation buttons.

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b.There is an emergency stop button in the circuit to prevent the

machine from being stopped for inspection under abnormal conditions.

六、Installation and commissioning and commissioning

1、Installation and debugging：

1.1 ready

Draw the reference line with ink according to the basic drawing of the

bottle warming machine, including the center line of the bottle cooling

machine, the parallel lines on both sides and the two front and back end

lines.

1.2 Bring the cold bottle machine to the site

Due to the large volume of the equipment, it is necessary to check

whether the direction of the equipment in and out of the bottle is consistent

with the plan before transporting in to avoid errors. Pay attention to safety

during transportation to avoid damage to the machine.

1.3 installation

a.First, it is required to place the body on the reference line, and align

the center of the body to the ground centerline, and the front and rear ends

to the ground reference line.

b.Adjust the height and horizontal plane of the body, and adjust the

height to about 1100 mm based on the upper surface of the flat-top chain on

the bottle feeding and discharging machine, and then calibrate the body

level to avoid deformation caused by the height of the body.

c.After confirming that the machine body is installed correctly, check all

piping systems and remove debris before connecting all external piping.

1.4 adjustment

Adjust the positions of the pallets on the side plates of the bottle in and out
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and the plastic ring conveyor chain to the correct position. The bottle inlet

plate is higher than the ring conveyor chain by 0.2 ～ 0.5mm, and the bottle

end pallet is slightly lower than the ring chain plate by 0.2 ～ 0.5㎜.

Commissioning

2、Preparation for test run

2.1、Precautions before trial operation:

a、Check for dirt in the warm water pipe and keep the pipe clean.

b、Check whether the body and sink are clean.

c 、 Check whether all valve switches are flexible, whether the safety

protection device is reliable, and whether the supplied water and electricity

technical parameters meet the requirements of this machine.

2.2、start up

a.Fill the two water tanks with water.

b.Check whether the nozzles of the cone-shaped water jets in the two

spray areas are spraying smoothly. If you find that it is not smooth or

blocked, it should be cleared.

c.Turn the main switch to the position open position, and the power

indicator light is on and enters the running state.

d.Turn on the main drive operation key to make the main motor run, the

circular plastic chain in the machine body starts to run, and adjust the main

motor speed to match the actual production capacity.

e.Turn on the operation key of the bottle delivery section to make the

bottle delivery conveyor run.

f.Switch on the operation key of the bottle feeding section to make the

bottle feeding conveyor belt run. Adjust the speed of the bottle feeding

section to meet the output requirements of the host.

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g.Press the operation key to switch on the water pump.

h.Manually adjust the manual valve to control the flow of warm water, so

that the temperature of the bottled beverage reaches the temperature

required by the production within the specified processing time, and then the

production operation can be carried out.

i.First, manually open the manual valve at the top of the pneumatic

valve to heat the water in the water tank in the sterilization area, and wait

until the temperature is reached (displayed on the dial on the water tank).

Close the manual valve and open the pneumatic valve to automatically

control the temperature in the water tank. Ensure that the water temperature

meets the process requirements.

2.3 Shutdown after trial run

a 、 Turn off the operation keys of the bottle feeding section to stop the

bottle feeding conveyor belt.

b、Turn off the main drive operation key to stop the circular plastic chain

in the machine.

c 、 Turn off the bottle-out section conveying operation key and stop the

bottle-out conveying operation.

d 、 Close the operation key of the water valve to stop the flow of clean

water.

e 、 Close the inlet and outlet valves of the cooling water and the steam

valve.

f、Turn off the operation key of the water pump to stop the water pump.

g、Turn the switch to the off position-stop.

h 、 Perform a comprehensive inspection of the inside and outside of the

machine, find out the cause of the problem, and troubleshoot.

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七、Machine operation and maintenance

1.Machine operation

1.1 Before operation, empty the water tank in the machine, clean up the

dirt from the bottle, and then fill the water tank with spray water.

1.2 Follow the startup procedure above.

1.3 Pay attention to the following items during production operation:

a 、 Monitor the correct startup, operation and shutdown of the whole

machine.

b 、 Monitor the speed of the production process and shut down at any

time.

c、Monitor the spraying conditions of all nozzles and make corrections at

any time.

d、Monitor the operation of each transmission part.

e 、 Monitor the remaining water in each water tank, and adjust the

shut-off valves to prevent the pump from running empty.

1.4Shutdown is operated according to the shutdown procedure after trial

run.

2、Repair and maintenance

Repairs and maintenance should be unconditionally coordinated with

production and carried out within the specified time.

It is possible to put the machine in a safe and normal state.

2.1 Repair and maintenance of each shift

a、When repairing, drain the water in the tank, rinse the tank with clean

water, and remove the debris in the tank (including the circular plastic

chain).

b、Clean the water tank.

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c、Unblock or replace blocked or damaged nozzles.

d、Remove the debris on the conveyor belt and rinse it.

e 、 Lubricate the lubrication points. (Active and passive end bearings,

active motor)

2.2 Weekly repair and maintenance

a 、 Check whether the circular plastic chain is damaged, and repair or

replace the damaged part.

b、Check the tightness of the connection and the tightness of all valves,

re-tighten the loose part or replace the seal.

c 、 Check whether the performance of the original parts of the electrical

control box is normal, and replace the damaged parts.

2.3 Repair and maintenance every 3 months

In addition to the weekly repair and maintenance work, the ventilation

hoods and heat sinks of all motors are purified.

2.4 Repair and maintenance once a year

a 、 Disassemble and wash the water pump, check the degree of friction

of the moving parts and the degree of corrosion of the rotating wheel and

the pump body, and replace the damaged parts.

b、Check the wear condition of the transmission belt (plastic chain) and

the conveyor belt of the bottle in and out section, and replace the damaged

parts.

3. Fault analysis and troubleshooting：

malfunction the reason Method of exclusion

Bottle-out The bottle is Stop the bottle-in conveyor belt

conveyor is squeezed or until the bottle-out conveyor belt is

blocked poured conveyed smoothly before starting

the bottle-in conveyor belt.

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The temperature Pneumatic angle The solenoid valve is damaged,

is outside the valve is not open replace the solenoid valve.

normal range

八、backup list：

Code Assembly
item Name material quantity remark
name part
Spray
1 Nozzle Nylon 20
pipe
Master
Mesh belt
2 and slave 2
sprocket
shaft
3 Comb plate Transition 3
Mesh belt
transmiss
4 chain 0.5m
ion

九、Random technical file

1、user's Guide 1 serving

2、Certificate of conformity 1serving

3、Packing List 1serving

4、Electrical diagram 1serving

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合 格 证

（ZJ—7.5—06） NO：

产品型号：

产品名称：

出厂编号：

本产品经检验合格，准予出厂。
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检 验 员：

质检部长：

日期： 年 月 日

装 箱 单
（ZJ—7.5—01） NO：
包装箱号： 箱体尺寸：
净 重： 毛 重：
一、主机及辅机
序号 代号 名 称 规格 数量 备注
1
2
3
4
二、随机备件
见使用说明书
三、随机技术文件
序号 代号 名 称 规格 数量 备注
1
2 `
3
4
5
四、随机工具清单
序号 代号 名 称 规格 数量 备注
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1
2
3
4
5