SPJ150 English Manual

OPERATING INSTRUCTION
SPJ-150 Batch Pre-expander
1.Generalization
SPJ150 automatic pressurized intermittent batch pre-expander is newly designed and made
by our company according to the latest international and domestic marketing
requirements,used for first and second expansion. This type of EPS machine is an
automatic expanding system, composed of pressurized batch pre-expander, fluidized bed
drier, sieving, delumpling ,screw conveyor and etc making an fully automatic cycle foam
system. It is an essential machine for EPS factory.
Expanded EPS beads through aging under normal pressure can be provided for EPS
molding machine to make different shapes of packing products as well as different sized
blocks. They are ideal packing materials for household appliance, gauges, instruments,
chinaware, glassware and all sorts of valuable and fragile things. Blocks can be used in
house construction, cars, ships, refrigerators etc, because they are good material of sound
insulation, heat insulation and vibration proof.
Main features:
1. Use PLC control system to fulfill automatic working
cycle.
2. Pipe system is simple, which is convenient for
maintaness and repair.
3. Using a 2.2kw mortor for filling and discharging
makes the filling and discharging much faster than before and reduces energy
consumption.
4. The applying of screw conveyer for filling and
electronic weighting scale relieves working density and improves the production
efficiency.
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5. The chamber is totally closed which ensures high

thermal efficiency and steam saving and excels consistant pre-expander in energy
saving with 50 percent of energy using.
6. With electronic weighing system and level sensor to
control material position, so as to control expanded density. We control density
tolerance within 3 %.
7. With fluidized bed drier, we can carry out automatic
cycle of drying, sieving, deplumping and transporting to silos (with blower).
8. The electronic appliances, pneumatic components and
valves are all international and domestic famous brand which ensures good
perfomance, stability, reliability and long life.
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2. Main Specification and Technical Data

NO. NAME UNIT PARAMETERS
1500internal
1 Expansion chamber mm
diameter2480height
2 Effective volume m3 3
Entry port mm DN50
3 steam
Working pressure Mpa 0.6-0.8
Entry port mm DN50
Compressed Working
4
air Mpa 0.6-0.8
pressure
Upper drainage mm DN 80
5 Draining port
Lower drainage mm DN 80
Main axis motor kW 7.5
Discharging motor kW 2.2
Drying motor kW 5.5
Transporting blower kW 5.5
Connected
6 De-lumping motor kW 0.55
load
Vibration motor kW 0.18
First filling motor kW 2.2
Second filling motor kW
Secondary
foaming / 600Kg/h
efficiency
7
12 g/l 600Kg/h
First foaming 15 g/l 900 kg/h
efficiency
20 g/l 1200 kg/h
30 g/l 1500 kg/h
8 Density tolerance within 3%
9 Dimension (lwh) M 431041505120
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10 weight T 5
Note: 1.With the constant development and improvement of machine technique, machine
structure and accessories may have some difference from that on operating
instruction, We keep the right of changing and explaining.
2.If you found the annex not match with the packing list in machine acceptance or there are
questions about operation, please contact with the QC department of our company.
You should send us main specifications and serial number and so on.
3. Company reserves the final interpretation of the company's products.
3. Shape of the machine
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4.For Running Machine

1. Be sure to check the spindle speed reducer is full of the gear oil or not before starting. Oil-
free operation is strictly prohibited.
2. Saturated steam, steam pressure 0.6-0.8Mpa, dynamic pressure 0.12-0.15Mpa. To use
saturated steam is very important, since if steam pipe too long and too thin, boiler pressure
not enough, aqueous vapor will occur. If unsaturated steam enter expansion chamber, EPS
material will have more water content and easy to form lump, and the expanded density
cannot be even. So for better expansion, the diameter of steam pipe inlet should be over
40mm, and machine near boiler or steam holder.
3. Compressed air should be purified, no water and no dust, working pressure 0.6-0.8Mpa, In
batch pre-expander, compressed air is used for controlling valves and air cylinders,
cleaning chamber and pipes. Centers of solenoid valve are highly sensitive, they are easy to
be block when meeting dirty air and valves burnt from overloading. So compressed air
should be filtered through 40um filter before entering machine to make sure of normal
working.
4. EPS material should be dried no-powder material within period of validity. If material
exceed time of validity, patent in material escaped out, then they cannot be expanded to the
desired density. Powder is easy to block filling port and steam holes of expansion chamber,
leading to lumps and uneven density.
5. Supplied power 3 phase 4 lines, 50HZ, 380V, connected load 26kW. Machine should be
earth-connected. Before connected with intermittent pre-expander, user should mount an
air control switch near machine for controlling general power
5.Preparation for Running Machine
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. To check electric system

1. Supply power 380V, connected load 26kW. Electric box has a wire hole at the bottom for
connecting power supplier. Its shell should be well earth connected. When power supplied,
be sure that indicating light on control panel is on. Check rotating direction of motors, such
as screw conveyor motor, backpressure filling motor, main shaft motor, discharging motor,
drying motor, transporting motor, delumping motor and vibration motor. Check motors
action and noise.
2. Check positions of level sensor, discharge gate sensor, light sensor. Check whether their
positions are right and in correspondence to PLC.
3. Check pressure gauge switch, turn the pin with hand to see if PLC input light on and wire
connection is correct.
. To check piping system
1. Check oil lubricator, keeping enough 10# engine oil (must use light oil) in it.
2. Check steam pipe and compressed air pipe. Fill compressed air in machine, open all
solenoid valves with touch screen. Check whether NO, NC valves are compliant with
piping diagram.
3. Adjust steam pressure relief valve, making its outlet pressure 0.12Mpa. Open steam valve
via touch screen, check whether valve outlet pressure is steady. When pressure comply
with set value, tighten the adjusting screw.
4. Adjust compressed air pressure gauge upper limit to 0.75Mpa, lower limit to 0.45Mpa,
pressure gauge on chamber upper limit 0.05Mpa (chamber protective pressure).
6.Batch Pre-expander Working Steps

Check piping system, level sensors, weighing system and steam proportional valve system
before operating the machine.
1. First remove condensate in steam pipes and in compressed air filters.
2. Turn on Power, startup main shaft motor through touch screen, close discharge gate and
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start all motors in fluidized bed drier.

3. Switch to single step picture, decide EPS raw material volume according to Parameter
Reference Table. Enter values of raw material volume, fast discharge, slow discharge and
balance on touch screen
4. In single step, preheat expansion chamber to around 100.
5. Limit the upper temperature under 120.
6. Filling and filling port clean, filling time should be lasting until all material in loader are
poured out into chamber.
7. Open the gate.
8. Discharge and clean: discharging time is set until all material in chamber poured out.
Bottom clean: after discharging, fill compressed air from chamber bottom to blow out
material in steam holes, time is 2-4 seconds.
9. Windows clean start from begin heating and end until finish bottom cleaning, it is
discontinuous blowing, usually 0.5-1.5 seconds each time.
10.Close discharge gate (controlled by a stroke sensor).
11.When first clean discharging gate, transporting motor, vibration motor and delumping
motor start to run (drying motor starts when expander main agitator run). To get to know
expansion density, measure material at dryer outlet.
Measuring EPS density with electronic scale, if density has great tolerance, try the following
solutions:
1. Increase or decrease EPS raw material
2. Change position of level sensor.
3. Increase or decrease warming time.
When expanded density is adjusted near the desired density, turn to auto and run automatic
expanding.
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12.You can select manual, single step, semi-auto and auto on touch panel. Usually manual is
for testing actions of all valves, motors and level sensors. Single step and semi-auto are for
adjusting expanding density, while auto is for automatically running.
7. Touch screen
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8.Electrical diagrams
9.Pipe system
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10.Machine Maintenance
1. Clear all material in expansion chamber and in fluidized bed drier before every shift ends.
2. Cut off power supply of screw conveyor, electronic scale, fluidized bed drier and
preexpander.
3. Close compressed air and steam valves.
4. Everyday before working, check chamber to remove lumps and other objects, and check
agitating rods.
5. Everyday before working, check air filter and oil lubricator. Remove water in filter and add
oil (light engine oil) in lubricator if necessary, usually add to 2/3 of the cup.
6. Check vent port and trap to remove blocks. Make sure water flow out of drain port when
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working.
7. Often check actions of pressure gauge, temperature gauge, current gauge, volt gauge and
motors. If finding breakage or malfunction, change or repair immediately, ensuring their
reliability and sensitivity.
8. Often check all valves and pipes, especially copper tube of safety valve and pressure gauge
switch. Before machine delivery, safety valve is set to 0.5Mpa, usually users neednt adjust
again, but every week manually test it in case of malfunction. Pressure of expansion
chamber is controlled by pressure gauge switch, while copper tube is the connection
between chamber and pressure gauge switch. So once copper tube blocked, pressure gauge
switch cannot display chamber pressure correctly and cannot control pressure correctly,
easy to cause chamber breakage. In view of the importance of copper tube, try to protect it
carefully, especially in winter days since it is easy to break in cold area.
9. Check electronic scale periodically, if its not precise, ask professional person to adjust or
repair it.
10.Check earth connection periodically.
11.Often check sealing of 80 butterfly valve on filling port and vent port. Remove sealing
immediately when finding breakage or leakage.
12.Keep windows clean and no dust, otherwise, sensitivity of level sensor will be influenced.
11.Safety Notice and Attention

1. If power fails, steam valve will automatically close and compressed air valve open for
cooling, avoiding lumps in chamber. Open discharge gate manually, drive material out with
blower or compressed air.
2. When using the preexpander, make sure that compressed air working pressure more than
0.5Mpa (5kg). All valves are controlled by compressed air, especially the discharge gate.
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Discharge gate is locked by air cylinder, air pressure decrease will cause gate open. To run
machine normally, compressed air pressure should be ensured.
3. Before reparation, main power must be cut off. After repairing, remember to take all tools
and accessories out of machine, since they tend to break steam plate and plough plate in
chamber.
4. When producing, prevent objects (small stones or iron chips) from entering in chamber
with material, since they are easy to break steam plate.
5. In producing, often check sensitivity of pressure gauge switch, repair or change in time
when finding problems.
6. Machine warning light on in following cases:
A. motor overload, thermal relay released
B. no material for filling in loader
C. discharge gate switch not in right position
D. compressed air pressure lower than set value of pressure gauge switch.
E. Expansion chamber pressure higher than set value of pressure gauge switch.
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SPJ150 English Manual

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OPERATING INSTRUCTION

SPJ-150 Batch Pre-expander

5. The chamber is totally closed which ensures high

2. Main Specification and Technical Data

3. Shape of the machine

4.For Running Machine

5.Preparation for Running Machine

. To check electric system

. To check piping system

6.Batch Pre-expander Working Steps

start all motors in fluidized bed drier.

11.Safety Notice and Attention

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