Please read the manual carefully before use

QSM-4.5-18.5-B

Instruction manual for chemical water cutting machine

Binzhou Senjie Machinery Technology Co., Ltd

Table of Contents

Preface II

1 Overview1

2 Precautions for safe use2

3 Table 3 of the basic performance parameters

4 Working principle and structural characteristics 4

5 Installation and commissioning6

6 Use and Operation9

7 Maintenance and maintenance of equipment10

8 Transport and storage12

9 Common Faults and Troubleshooting Methods 12

Foreword

Dear users,

Thank you very much for choosing our product, please read carefully and keep this manual properly before use.

QSM-4.5-18.5-B flameproof water cutting machine is specially designed for the coal mining field, whether it is explosion-proof grade, spark test or electrostatic detection are up to standard, please feel free to use.

This manual provides instructions for the installation, commissioning, use and maintenance of QSM-4.5-18.5-B flameproof water cutting machine, and details its use conditions, precautions for safe use, structure and working principle, technical parameters, troubleshooting, etc., please read carefully before use, and operate in accordance with the relevant instructions in the manual.

Since the date of purchase, our company promises the following after-sales service:

——Quality and safety assurance;

——Training on the use of the whole machine;

——After-sales technical guidance;

——After-sales repair and maintenance;

- Provision of accessories and abrasives.

You are welcome to supervise our services and put forward your valuable opinions, and related questions can be consulted by telephone to our company.

QSM-4.5-18.5-B flameproof water cutting machine

1 Overview

1.1 Product Use

QSM-4.5-18.5-B flameproof water cutting machine (hereinafter referred to as "water cutting machine") water cutting machine can cut any material with a thickness of 0~100mm (except fiberglass, diamond and special cemented carbide).Cutting operations in the process of dismantling and maintenance of chemical and underground equipment.

Note: The water cutting machine belongs to the main engine part, and it needs an auxiliary cutter to assist it in completing the cutting operation.

1.2 Product implementation standards

GB/T 26136-2018 "Ultra-high pressure water cutting machine".

GB/T 13306-20 11 signs

1.3.1 Working conditions

The working conditions of the water jet cutting machine are as follows:

(a) The ambient temperature is 0~40°C, and the minimum ambient temperature during non-working period is not lower than -40°C;

(b) Relative humidity not exceeding 95% (at a temperature of 25°C)

(c) The voltage fluctuation shall not exceed ±10%, and the frequency fluctuation shall not exceed ±2%.

1.3.2 Power Requirements

Voltage; 380V/660V； POWER: 18.5KW

1.3.3 Working Media Requirements

The medium used in the system is clean water after the mine water has been filtered; Acidic, alkaline, or corrosive liquids are not allowed. The specific water quality requirements are shown in Table 1.

1.3.4 Water inlet requirements: water inlet temperature: 0°C~ 45°C;

1.3.5 Abrasive requirements

The abrasive mentioned by our company, special garnet sand abrasive, 80 mesh.

Table 1 Abrasive requirements

2 Precautions for safe use

2.1 General Requirements

——Equipment operators must be trained in professional operation;

- Do not point the muzzle of the gun at the surrounding personnel or equipment;

——When using the equipment, it is necessary to strictly follow the operation steps, and wear protective equipment, and it is strictly forbidden to play and play on the job site;

——The performance of the equipment must be carefully checked before use to ensure that the system has no leakage and no abnormal noise;

- The workpiece to be cut must be fixed firmly, and it is strictly forbidden to cut the workpiece if it is not fixed in place;

- When cutting, the operator must stay away from the front end of the nozzle to prevent injury from abrasive water jets;

- During the use of the equipment, it is strictly forbidden to place any object on the equipment;

——High and low pressure hoses are strictly forbidden to bend excessively (bending radius greater than 0.5m) and intertwined with each other;

- If there is any abnormality during the operation of the equipment, it should be stopped immediately and overhauled after the pressure is relieved;

——It is strictly forbidden to disassemble and overhaul the equipment during work, and it is strictly forbidden to overhaul the equipment with electricity;

——During the use of the equipment, the inclination angle should be less than 5° to ensure the best lubrication adjustment of the pump operation.

Injuries that may be caused by mishandling

——Do not start the power supply of the equipment without water to prevent the high-pressure water pump components from being damaged and the pressure from missing

- Before starting the equipment, the air in the pump should be exhausted to ensure that the parts of the pump are not damaged during operation

3 Basic performance parameter table

The basic parameters of the water cutting machine are shown in Table 2

Table 2 Basic parameters

4. Working principle and structural characteristics

4.1 How it works

The working medium flows into the high-pressure piston pump through the low-pressure hose after filtration, and the flameproof three-phase asynchronous motor provides power for the high-pressure piston pump, pressurizes the working medium, and the high-pressure water flows into the abrasive tank through the high-pressure hose, fully mixed with the abrasive, and drives the abrasive to accelerate, and finally through the Φ1.02mm cutting gun nozzle, a high-pressure abrasive jet is formed for cutting operations.

The pressure regulator realizes stepless adjustment of system pressure through the principle of flow limiting; The safety valve realizes overpressure protection through overflow action; The check valve can prevent the backflow of water and sand, further ensuring the safety performance of the system.

4.1 Equipment Composition

4.1.1 Equipment composition and functional principle

The water cutting machine is mainly composed of a drive system, a pressurization system, an abrasive supply system, a control system, a water circulation system, etc., and the schematic diagram of the structure of the water cutting machine is shown in Figure 1.

Fig.1. Schematic diagram of the structure of the water cutting machine

- Drive system (prime mover, coupling): supercharged power provided by the prime mover;

- Filters (water storage tanks, filters): filter and store a certain volume of working medium;

- Pressurization system (high-pressure piston pump): high-pressure piston pump pressurizes the working medium;

- Abrasive supply system (abrasive tank): store abrasive, realize the full mixing of abrasive and working medium, and control the flow of abrasive;

- Control system (frequency conversion cabinet, safety valve): adjust the pressure of the system, and at the same time carry out overpressure protection;

- Water circulation system (high and low pressure hoses): pipelines for the flow of working medium.

4.1.2. Description of the main components

The pressurization system, control system and abrasive supply system are the core components of the water cutting machine, and their quality determines the overall performance of the water cutting machine, as detailed in Table 2.

Table 2 Performance of the whole machine

5 Installation and commissioning

5.1 Preparation before installation

5.1.1 Place the equipment in a relatively flat area on the ground and place it safely.

5.1.2 Ensure that the inlet water pressure is 0.1~0.3MPa.

5.1.3 Selection of cables:

——According to the current size, the use of the conditions of correct selection;

- The diameter of the cable entering the junction box should be consistent with the aperture of the sealing ring.

5.1.3 Prepare high and low pressure hoses.

5.1.5 Prepare the matching auxiliary cutter.

5.2 Installation Instructions

5.2.1 Connection of Cables

- Open the upper cover of the water cutting machine, thread the cable through the hole in the left side panel, and connect it with the motor.

Make sure that there is no gap between the sealing ring and the cable and junction box holder.

5.2.2 Connection of low-pressure hoses

- Ensure the inlet water pressure;

- Connect the external water source to the low-pressure hose with a pipe clamp;

——Remove the dustproof plug at the water inlet valve, insert the low-pressure hose joint, and pull the pull rings on both sides to realize the connection between the low-pressure hose joint and the quick tie rod at the water inlet valve of the equipment.

5.2.3 Connection of high-pressure hoses

- Insert the high-pressure quick coupling at one end of the high-pressure hose into the high-pressure quick coupling of the equipment;

——Connect the high-pressure quick coupling at the other end of the high-pressure hose with the high-pressure quick coupling at the cutting gun of the auxiliary machine.

5.2.4 Filling of abrasives

——Unscrew the upper valve body of the abrasive tank (tight clockwise, loose counterclockwise), and fill the funnel frame at the mouth of the tank;

——Clean the tank mouth, tighten the upper valve body and pressure relief valve.

Figure 5.2.4

The surface of the tank mouth and the groove of the sealing ring should be washed clean to prevent the leakage of the working medium and the influence of the O-type

the service life of the rubber seal; At the same time, it ensures that no debris enters the system to prevent the muzzle from clogging.

5.2.5 Installation Precautions

- If the length of a single high-pressure hose is insufficient, the high-pressure hose in the spare parts can be used to connect the wires.

——High and low pressure hoses are strictly forbidden to bend excessively or intertwine with each other.

5.3 Commissioning work

5.3.1 Preparation for commissioning

- Open the water inlet valve, the water inlet pressure gauge (low pressure gauge) shows that the water inlet pressure is between 0.1MPa-0.3MPa, and there is a water flow from the nozzle without blockage;

- Open the exhaust valve, exhaust the air, until there is a smooth flow of water, close the valve;

- Make sure the abrasive control valve is in the closed position;

- Make sure the pressure relief valve is tightened.

5.3.2 Debugging

Starting the motor, the equipment acceptance items are as follows:

- There is no abnormal noise or vibration of the equipment;

- No leakage or leakage in the system;

- Smooth jet flow without blockage;

- The pressure is adjustable, stable and up to the rated pressure;

5.3.3 Debugging Considerations

If there is an abnormality or fault in the equipment, please step down the voltage, turn off the power supply, and deal with it after the pressure is relieved.

6 Use and Operation

Preparation before use

6.1.1 After the equipment is debugged normally, the cutting operation can be carried out.

6.1.2 In order to ensure safety, two operators are required when cutting, one is responsible for cutting, and the other is responsible for observing the operation of the host.

6.1.3 Open the inlet valve, observe the inlet pressure gauge (low pressure gauge), and the inlet pressure is between 0.1MPa-0.3MPa before it can be ready to start.

Boot of the device

6.2.1 Turn on the power: After completing the operation of 5.3.1, you can turn on the power switch.

6.2.2 Pressure regulation: adjust the speed of the inverter cabinet, and gradually adjust the pressure to the working pressure (40MPa).

6.2.3 Sand addition: Rotate the abrasive control valve 90°.

6.2.4 When the abrasive jet is basically formed, the cutting begins.

6.2.5 Cutting Precautions:

- The operator needs to be far away from the direction of the abrasive water jet and reflection to prevent injury.

- When cutting, judge the cutting condition according to the reflection of the jet (the reflection of the jet is very high, indicating that the workpiece has not been cut through; The diagonal downward state of the jet is the best cutting state; If the jet is straight down, it means that the cutting speed can be increased).

6.3 Shutdown of the Device

6.3.1 Close the abrasive control valve

After the cutting operation is completed, first close the abrasive control valve (pull the handle of the sand control valve back to its original position), and the equipment runs for about 1min to drain the remaining abrasive in the high-pressure hose.

6.3.2 Turn off the power switch

6.3.3 Pressure relief: The handle of the left-handed pressure relief valve releases the pressure in the system.

6.3.4 Turn off the water inlet

6.4 Dismantling and cleaning of equipment

6.4.1 Remove the power supply connected to the equipment and coil the cable.

6.4.1 Remove the high and low pressure hoses connecting the equipment and the auxiliary equipment, and plug the joints at both ends with plugs.

6.4.3 Dismantle the auxiliary machine and clean it.

6.4.4 Open the exhaust valve, drain the water in the system, and close the valve until there is no water flowing out.

6.4.5 Plug the low-pressure water inlet and high-pressure water outlet with plugs to prevent debris from entering the system.

6.4.6 Precautions:

- If the equipment is not used frequently, the abrasive tank needs to be drained;

- Pay attention to dustproof at the pipe joint and plug it with a plug;

——When removing the low-pressure hose, pay attention to the sealing ring at the quick pull rod to prevent it from falling and losing;

7 Maintenance and maintenance of equipment

7.1 High Pressure Piston Pumps

——Regularly check whether the lubricating oil level of the crankcase of the high-pressure plunger pump is normal, the oil level should not be lower than the scale mark of the oil level indicator ruler, but at the same time, it should not be higher than 5mm of the scale line, and add No. 30 oil according to the oil level.

- The lubricating oil of the high-pressure pump should be replaced after 50 hours of first use, and then every 500 hours.

- High pressure pumps are not allowed to use acidic, alkaline or corrosive liquids.

7.2 Electric Motors

——The motor should be checked at least once every 2500 hours (about half a year), if the bearing grease is found to be deteriorated, it must be replaced in time, and the bearing must be cleaned with gasoline before replacement, and the grease is ZL3 lithium grease (SY142-75).

——Before starting the machine, check whether the connection of various parts is firm, confirm that there is no loosening, and whether the pressure gauge is normal; Correctly connect the power supply line and grounding according to the requirements of the use of explosion-proof motors.

——When dismantling the motor, pay attention to protecting the flameproof surface, and when assembling, the flameproof surface must be coated with 204-1 anti-rust grease.

——The motor is damp and must be dried.

7.2 Filter Bags

The filter barrel should be cleaned at least once for half a month and replaced if necessary.

7.3 Pressure gauges

The pressure gauge is used for half a year and needs to be calibrated once.

7.4 Pressure relief valves, high-pressure quick connectors, etc

Pressure relief valves, high-pressure quick connectors, etc., are often disassembled, and are cone sealed parts, which need to be cleaned when used to avoid abrasive wear and sealing cone; When the cone is worn and cannot be sealed, it needs to be replaced.

8 Transportation and storage

8.1 Transportation

On the way, it needs to be handled gently, not upside down, and wooden packaging boxes are required for long-distance transportation.

8.2 Storage

- The equipment should be properly placed and kept dry and ventilated.

- Safe storage of high-pressure pumps in colder environments (below 0°C) requires the removal of residual water from the pump body; The method is that the high-pressure pump does not run for more than 5 seconds in the case of water supply.

- The device cannot be inverted.

9 Common faults and troubleshooting methods

Table 4 Common faults and troubleshooting methods

Note: If there are other abnormal situations, or the fault cannot be solved, please consult the relevant personnel of our company.