OPERATING INSTRUCTION

使用说明书

Twin Co-rotating Screw Extruder

同向双螺杆挤出机
同向双螺杆挤出机

Edition 10/2012
版本 10/2012
 Contents 内容

1 General notes 概述 ........................................................................................... 5

1.1 Introduction 导言................................................................................................. 5
1.2 Intended purpose 指定用途 ................................................................................ 5
1.3 Copyright 版权 .................................................................................................... 5

2 Technical data 技术参数 ................................................................................... 6

2.1 Processing task 加工任务 ................................................................................... 6
2.1.1 Process description 加工过程描述........................................................................... 6
2.1.2 Application 使用范围 ............................................................................................... 7
2.2 Technical data 技术参数 ..................................................................................... 7
2.3 Standard parameters 标准参数........................................................................... 7
Notice: Some parameters will be adjusted according to process requierment and will be
different from the parameters on the running machine. 注
意：某些参数可能根据工艺需求进行调整，会与得到设备的实际参数有所不同 ................... 8
2.4 Water specification设备用水的详细说明 .............................................................. 8
2.5 Tightening torques for screw connections 螺纹连接的预紧力矩........................ 10

3 Plant description 设备描述 ............................................................................. 11

3.1 Drive section 驱动部分...................................................................................... 11
3.2 Processing section 加工部分 ............................................................................ 11
3.2.1 General 概述 ......................................................................................................... 11
3.2.2 Design and function 设计和功能............................................................................ 12
3.2.3 Supervision and checking监督和审核 .................................................................... 16
3.3 Discharge section 挤出部分.............................................................................. 16
3.4 Gearbox lubrication cooling system 齿轮箱的油润滑系统 ................................. 16
3.5 Screw barrel cooling system 筒体冷却系统....................................................... 18
3.5.1 Manifold 筒体冷却管路 .......................................................................................... 18
3.5.2 Water tempering unit 水温控制单元 ...................................................................... 18
3.6 Vacuum exhaust system 真空排气系统 ............................................................ 20
3.7 Feeding system 喂料系统 ................................................................................. 20
3.8 Electrical equipment 电气设备 .......................................................................... 21

4 Safety 安全 ...................................................................................................... 22
4.1 Warnings and symbols 警告和标记................................................................... 22
4.2 Designated purpose 指定用途 .......................................................................... 22
4.3 Signalling of dangers 危险标识......................................................................... 23
4.4 Safety advices 安全建议 ................................................................................... 24
4.5 Obligations of the manufacturer 制造商的责任 ................................................. 24
4.6 Safety equipment 安全装置 .............................................................................. 25
4.6.1 Heat insulation 绝热性........................................................................................... 25
4.6.2 EMERGENCY STOP 紧急停车 ............................................................................. 25
4.7 Operating phases 运行阶段 .............................................................................. 25
4.7.1 Start-up 启动 ......................................................................................................... 26
4.7.2 Operation 运转 ...................................................................................................... 26
4.7.3 Service and maintenance 保养和维护 ................................................................... 26
 Contents 内容
4.8 Remaining hazards 残留危险............................................................................ 28

5 Transport, storage and preservation 运输、

运输、存储和保存 .............................. 33
5.1 Scope of delivery and notice of shipping damage 交付范围和运输损坏通知..... 33
5.2 Transport 运输.................................................................................................. 33
5.2.1 Transportation vehicle 运输工具............................................................................ 33
5.2.2 Transport and hoisting 运输和起吊........................................................................ 33
5.3 Storage area requirements 储藏室的要求......................................................... 35
5.4 Storage conditions 存储条件............................................................................. 35
5.5 Preservation 保存 ............................................................................................. 35
5.5.1 Preservation at factory 在工厂里保存 .................................................................... 35
5.5.2 Short-term preservation 短期保存 ......................................................................... 36
5.5.3 Preservation for long-term storage 长期保存......................................................... 36
5.5.4 Removal of the preservative 清除防腐剂 ............................................................... 36

6 Installation 安装 .............................................................................................. 37
6.1 General conditions for installation 安装的基本条件 ........................................... 37
6.2 Customer participation 用户的责任 ................................................................... 37
6.2.1 Safety regulations at installation site 安装场地的安全规则 .................................... 37
6.2.2 Prerequisites for installation 安装的先决条件 ........................................................ 37
6.2.3 Keya Chemical Machinery assistance for installation is requested 安装工作必须由科亚成套
装备公司协助完成................................................................................................................. 38
6.2.4 Installation tools and means of transport 安装和运输工具 ..................................... 38
6.3 Installation sequence 安装顺序......................................................................... 43
6.3.1 Installation of the screw shaft seal 螺杆密封装置的安装........................................ 43
6.3.2 Installation of the screw tip 螺杆背帽的安装 .......................................................... 43
6.3.3 Installation of the screw shafts with screw shaft coupling 螺杆的安装 ................. 44
6.3.4 Information concerning transport lock运输的锁定说明 ........................................... 46
6.3.5 Installation of the heater and heat insulating hoods 加热器和热保护罩的安装....... 46
6.3.6 Electric equipment电气设备 ................................................................................... 46

7 Start-up and operation 启动和操作

启动和操作 ................................................................ 47
7.1 Important general information 概述................................................................... 47
7.1.1 Basic conditions for function tests, adjustment work, and first start-up of the extruder 功
能检测，调节工作和第一次启动的基本条件....................................................................... 47
7.1.2 First start-up 第一次启动 ....................................................................................... 47
7.1.3 Operating parameters 运行参数 ............................................................................ 47
7.1.4 Energy, utilities, auxiliary products 设备设施条件 .................................................. 48
7.1.5 Information on the documentation “Commissioning and Operation” 试车和操作 ... 48
7.2 Required manpower for start-up 启动设备所需的人力 ...................................... 48
7.2.1 Required manpower from Keya Chemical Machinery 所需的科亚成套装备公司的援助人
力 48
7.2.2 Personnel to be provided by the user of the plant 用户方需要提供的人员............. 48
7.3 Training of the plant operating and maintenance personnel 设备操作、维修人员的培训.. 49
7.4 Start-up and operation of the processing section 加工段的启动和操作............. 49
7.4.1 Information on start-up 启动.................................................................................. 49
 Contents 内容
7.4.2 Preparations Before Start 启动前的准备工作 ........................................................ 50
7.4.3 Test Items 测试 ..................................................................................................... 50
7.4.4 Co-operation of the user 用户的协作..................................................................... 51
7.4.5 Start Up 启动......................................................................................................... 52
7.5 Stop the machine 停车...................................................................................... 53
7.5.1 Normal stop 正常停车 ........................................................................................... 53

8 Service and maintenance 维修和保养............................................................

维修和保养 55
8.1 General notes 概述........................................................................................... 55
8.2 Cleaning of parts contaminated with plastic被塑料污染的零部件的清洗 ............ 55
8.3 Maintenance and inspection schedule of the processing section 加工段的保养和检查
时间表 55
8.4 Dismantling and reinstallation of the cartridge heater 加热器的拆卸和重新安装 56
8.5 Dismantling of the screw shafts. 螺杆的拆卸 .................................................... 57
8.6 Dismantling and fitting of the screw elements 拆卸和安装螺杆元件 .................. 59
8.7 Service and maintenance for gearbox 齿轮箱的维护和检查 ................................... 60
8.7.1 Servicing table 维护表 ...................................................................................... 61
8.7.2 Topping up the oil 补充加注润滑油........................................................................ 62
8.7.3 Changing the oil 换油 .......................................................................................... 62
8.7.4 Inspection 检查 ..................................................................................................... 64
8.7.5 Malfunctions—causes and rectification 故障—原因及处置 .................................. 64
For the trouble and trouble shooting ,pls see chapter 9.1.................................................. 65
8.7.6 Maintenace for plate heat exchager 板式热交换器的清理维护................................. 65
8.8 Table of lubricants 润滑油列表 ................................................................................. 67

9 Trouble-shooting 故障排除.............................................................................
故障排除 70
9.1 Gearbox with oil circulating lubrication 油润滑齿轮箱........................................ 70
9.2 Processing section 加工段................................................................................ 75
9.3 Die head 机头 ................................................................................................... 81
9.4 Pelletizing section 切粒部分.............................................................................. 82
9.5 Screw shaft seals 螺杆尾部密封 ....................................................................... 83

10 Spare parts 备件 ............................................................................................. 84

10.1 Spare parts inventory 备件清单 ........................................................................ 84
10.2 Ordering spare parts 备件的订购 ...................................................................... 84
Operating Instructions 使用说明书

1 General notes 概述

1.1 Introduction 导言
These operating instructions are intended to be read and fully adhered to by the persons who
responsible for operation, servicing and maintenance of the plant. 这些使用说明用来指导用户
对我公司设备进行操作、维护和保养，操作者必须熟读并遵守本说明。

The complete operating instructions must be kept in the vicinity of the plant at all times. This
assures that they can be quickly consulted whenever necessary. 为了保证在需要的时候能得到
及时的参考，必须将本使用说明书置于设备的附近。
Reading these operating instructions carefully before starting up the plant is mandatory. Keya
Chemical Machinery shall not be liable for damage and malfunction resulting from non-
observance of these operating instructions. 在启动设备之前必须仔细阅读这些使用说明，对不
遵守本手册造成损害和故障，科亚成套装备公司将不承担任何责任。

The operating instructions and the safety notes must be read and adhered
to prior to starting up the plant.
在启动设备前必须熟读并遵守操作说明和安全事项。
在启动设备前必须熟读并遵守操作说明和安全事项。

1.2 Intended purpose 指定用途

The processing section is limited to the intended application specified in chapter 2 ”Technical
data”. 加工段只限于加工2节的“技术资料”中指定的物料。

If the units are used outside the specified application range, Keya Chemical Machinery shall not
be liable for damage or malfunction, and the warranty shall be void. 如果此设备被用来加工指定
范围之外的物料，科亚成套装备将不负责因此造成的损伤或故障，并将取消担保。

Modifications to the units after start-up which would result in deviation

from the data sheet are impermissible. If such a modification should
become necessary, it must be approved by Keya Chemical Machinery
beforehand. 设备启动后，
设备启动后，如果某些改动可能会造成背离参数表指定范围的
情况，
情况，那这种改动是不允许的。
那这种改动是不允许的。如果这样的改动是必需的， 如果这样的改动是必需的，须预先得到科亚成 须预先得到科亚成
套装备的批准
套装备的批准。
的批准。

1.3 Copyright 版权
For certain reasons causing the difference from this documents, our company will not inform
and explain seperately. All rights are reserved by Keya Chemical Machinery . 由于某种原因造
成实际与本说明书不符的情况，我公司不另行通知和说明。本资料的最终解释权归科亚成套装备
所有。

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Operating Instructions 使用说明书

2 Technical data 技术参数

2.1 Processing task 加工任务

2.1.1 Process description 加工过程描述

Filling and reinforcing of thermoplastic polymers 热塑性聚合体的填充和增强
The polymer and the additive Premix are continuously fed into the first barrel section of the twin
screw extruder by suitable metering feeding devices. 聚合体和添加剂预混后，通过合适的计量
喂料装置连续地加入双螺杆挤出机的第一节筒体。

The first extruder barrel is typically cooled continually with water, the other barrels are cooled or
heated electrically during production depending on process requirements and the temperature
regulation of the different zones. The co-rotating, closely intermeshing twin screws pick up the
product, transport and compact it. Finally, the product is melted mainly by the kneading
elements. 挤出机的第一节筒体通过水冷却的方式不断地进行冷却，这是它与其它筒体不同的地
方。其它筒体在生产的过程中根据生产工艺的需要和各区的温度调节，通过电加热或冷却。两根
螺杆是同向旋转、紧密啮合的，这使得物料崛起、传送并压缩。然后，物料开始熔融，物料的熔
融主要是通过捏合元件来实现的。

During the melt process, the additives and stabilizers are worked into the polymer melt
homogeneously. A variable speed drive allows to choose the appropriate range of screw
speeds (maximum up to 600 rpm or 900rpm) for the process. 在熔融的过程中，将添加剂和稳
定剂均匀地加入高聚物熔体中。调速驱动系统使得加工过程可选择适当的螺杆转速（最大可达到
600rpm或900rpm）。

Via side feeder additives or mineral fillers can be fed to the extruder. This side feeder has to be
fed itself by one or several gravimetric feeders. 可以通过侧向喂料机加入添加剂或矿物质，侧向
加料机有一个或多个计量系统。

Via liquid injection bores, liquid additives can be fed into the extruder. 通过液体加注口，可以将
液体添加物加入挤出机。

Openings for atmospheric venting in open barrels allow to evacuate air and moisture from the
melt.开口筒体上的自然排气口可以将熔体中的气体和湿气排出去。

Volatiles can be evacuated from the machine in the degassing zone barrel. For this purpose a
vacuum pump may be connected to the vacuum vent installed on the top opening of the barrel.
In the last barrel the machine builds up the pressure that is needed to extrude the product via
die head. 物料中的挥发物通过排气室排放，排气室是连接在排气筒体的开口上的，排气口和真
空泵相连。在最后一节筒体中，设备通过足够的压力，将物料从机头中挤出。

A melt temperature and melt pressure gauge on the discharge unit enables to check for stable
and reproducible process condition. 通过装在挤出部分上的熔体温度表和熔体压力表，可以检测
物料是否稳定，可否再加工。

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Operating Instructions 使用说明书

2.1.2 Application 使用范围

Filling and modification, such as PE, PP, ABS, PC, EVA filled with CaCO3, Talc and
TiO2, etc.
填充改性。如PE、PP、ABS、PC、EVA等填充CaCO3、 Talc、 TiO2等。

Rubber and plastic compounding, plastic alloy, such as PC+ABS, PA+EPDM,
PBT+PET, PP+NBR, etc.
橡塑共混、塑料合金。如PC＋ABS、PA＋EPDM、PBT＋PET、PP＋NBR等。

Masterbatch, such as PE, PP, ABS, PC, EVA and PET, etc.
色母粒。PE、PP、ABS、PC、EVA、PET等

Flame retardant, degradable plastic, anti-static and anti-bacteria masterbatches.
阻燃母粒、可降解塑料、抗静电母料、抗菌母粒等。

Glass fiber (carbon fiber) reinforcement, such as PA, PP, PC, ABS, PBT, POM +
glass fiber.
玻纤（碳纤）增强：如PA、PP、PC、ABS、PBT、POM等＋Gf

Thermoplastic elastomer, such as TPR, TPE, TPV and TPU, etc.
热塑性弹性体。TPR、TPE、TPV、TPU等。

Cable material, such as PE, PP, EVA, PVC, XLPE.
电缆料。PE、PP、EVA、PVC、XLPE。

Reaction extrusion, such as PA, PU, POM, PMMA and PC, etc.
反应挤出。如PA、PU、POM、PMMA、PC等。

Devolatilization after process, such as CPP, CPE, SBS, EPDM, SEBS, fluorubber and
PBT, etc.
排气脱挥后处理。如CPP、CPE、SBS、EPDM、SEBS、氟橡胶、顺丁橡胶等。

Powder coating, such as epoxy, polyester and mixed type.
粉末涂料。环氧型、聚酯型、混合型等。

2.2 Technical data 技术参数

About the technical data for a certain machine, please see attached data sheet.
关于某一设备的技术参数，请查看附加的参数表。

2.3 Standard parameters 标准参数

Machine Screw Max. Max. Screw
type diameter permissible speed
机型 螺杆直径 axial pressure 螺杆最大转速
轴向最大压力
mm bar rpm
-22 Ф21.7 150 600/900
-36 Ф36.0 150 600/900
-53 Ф50.6 150 600/900
-63 Ф62.6 150 600/900
-73 Ф72.2 150 600/900
-96 Ф93.6 150 600/900

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Operating Instructions 使用说明书

Notice: Some parameters will be adjusted according to process requierment and will be
different from the parameters on the running machine.
注意：
注意：某些参数可能根据工艺需求进行调整，
某些参数可能根据工艺需求进行调整，会与得到设备的实际参数有所不同

2.4 设备用水的详细说明
Water specification设备用水的详细说明
Conditions Barrel cooling and Underwater Cooling water from
条件 screw shaft cooling pelletizer, water- cooling tower
(condensate or ring pelletizer 冷却站的冷却水
demineralized water) and knife rotor
筒体和螺杆芯轴冷却 pelletizer
冷凝物或软化水)
冷凝物或软化水
(冷凝物或软化水 水下造粒，
水下造粒，水环切
粒和水冷拉条切粒
Circuit Adm. Circuit Adm. Circuit Adm.
Pressure [bar]压力 3-7 3–7 4.5–7
Temperature [°C]温度 10–80 10–60 Max. 28
Max. temperature 10 10 8
increase [°C]最大温升
Permissible _ _ 1.5
Pressure drop [bar]
容许的最大压降
Analysis 分析
PH value [at 20 °C] 8–9.5 8–9.5 7.5–9
PH值
Total hardness [°dH ] ≤ 0.3 ≤ 0.3 ≤4 ≤2 ≤ 18 ≤4
总硬度
Conductivity [µs/cm ] ≤ 0.2*
传导率
Oxygen – O2 [mg/l] ≤ 0.02 ≤ 0.02
氧气
Chlorides – Cl- [mg/l] ≤5 ≤5 ≤ 50 ≤ 25 ≤ 200 ≤ 50
氯化物
Sulfate-SO42- [mg/l] ≤5 ≤5 ≤ 100 ≤ 50 ≤ 300 ≤ 70
硫酸盐
Oil [mg/l] 含油量 ≤1 ≤1 ≤1
Germ forming [KBE/m] ≤ 1000 ≤ 10000
units 微生物构成
Setting solids[mg/l] ≤1 ≤2 ≤2
(after appr. 2 hours)
凝固指数
Comments 注释 a) b) c)

*For checking of the ion exchanger if demineralized water is used. If this value is exceeded
after the acid cation exchanger, regeneration of the ion exchanger becomes necessary. 软
化水是用来检测离子交换剂的，如果检验因酸性导致数据偏高，将有必要更换离子交换剂。

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Operating Instructions 使用说明书

To avoid instructions and corrosion, the water circuits are to be checked to ensure that the
above values are not exceeded. For preparing additional water for boiler feeding and process
water, steam condensate or drinking water is to be used. 为了避免腐蚀，应保障水循环不超过
上表中的数值。另外备选用蒸馏冷凝水或饮用水。

推荐使用的添加剂
Note on recommended additives推荐使用的添加剂
a) Easily alkalizing, organic oxygen fixing agent which is not volatile in steam, or film forming
additives on a basis of alkalizing amines and aliphatic polyamines. Stability in the steam
phase above 350 °C. When using film forming media, there is no oxygen limit. 有机的固态
氧在气体状态下，或成膜添加剂在作为碱性胺和聚胺酯的主要成分时，不具有挥发性，易成
碱性。当温度达到350摄氏度以上时，在气体状态下性质是稳定的。当使用成膜媒介时，用氧
不受限制。
b) Of necessary, add hydrogen peroxide-no other biocides. 需要添加氧化氢。
c) We recommend adding anti-corrosion agents with calcium stabilizing effect as well as
biocides which must be biological degradable. 推荐使用带有环保性质的防腐剂。
The material for the machine parts (heat exchangers, pump etc.) were chosen on the basis of
the stated water analyses. Water with different values may make it necessary to use different
material. 设备零部件（如热交换器、泵等）的材质是在规定的水分析的基础上选择的，不同的水
要配不同的材质。

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Operating Instructions 使用说明书

2.5 Tightening torques for screw connections 螺纹连接的预紧力矩

Machine Screw barrel Screw tip Screw shaft seal
机型
type机型 筒体连接
connections筒体连接 螺杆背帽 螺杆尾部密封
Screw size MA (Nm) Screw size MA (Nm) Screw size MA (Nm)
螺纹型号 力矩 螺纹型号 力矩 螺纹型号 力矩
-22 M8 30 M6x0.75 9 M4 5
-36 M12 103 M10x1.5 15 M6 7
-53 M12 103 M14x1.5 60 M6 7
-63 M14 150 M20x1.5 115 M6 7
-73 M16 252 M20x1.5 130 M6 7
-96 M20 480 M30x1.5 260 M12 61

Discharge parts 挤出部分

螺纹型号
Screw size螺纹型号 Tightening torque(Nm)
预紧力矩
M6 7
M8 18
M 10 35 At a temperature
M 12 61 of approx. 250 °C
M 16 149 温度约为250℃的条件下
M 20 290
M 24 500
M 30 1000
M 36 1750
M 42 2800

All bolts to be coated with high temperature paste, like Molykote, at

thread and contact surfaces. 所有的螺栓都需要涂上一层耐高温润滑剂,
所有的螺栓都需要涂上一层耐高温润滑剂 比
如二硫化钼润滑剂,
如二硫化钼润滑剂 把它涂在螺纹和接触表面上。
把它涂在螺纹和接触表面上。

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Operating Instructions 使用说明书

3 Plant description 设备描述

An extruder plant consists of a number of individual units. All the units not supplied by Keya
Chemical Machinery that are required to make the plant completely functional are to be
provided by Customer. Adherence to the process specifications contained in chapter 2 is
mandatory. 一套挤出机组包括很多部件，不是所有部件都是由科亚成套装备公司提供的。
为了确保整套机组功能更全面，某些部件需要客户自己准备。必须遵守第2节关于加工的详细规
定。

The extruder is mainly consists of 3 sections: drive section, processing section, discharge
section. 挤出机主要由三部分组成：驱动部分、加工部分和挤出部分。

3.1 Drive section 驱动部分

The drive section of the twin screw extruder consists of 3 parts: motor, clutch, gearbox.
驱动部分由三个部件组成：电机、联轴器和传动箱。

The reduction and distribution gear unit reduces the motor speed to the screw shaft speed and
distributes the input torque to the two output shafts. Clutch is installed between the drive motor
and the gearbox drive shaft. 传动箱将电机的转速变速到螺杆的转速，并将输入转矩分配到两根
输出轴上。联轴器安装在电机和传动箱之间，用来连接电机的输出轴和传动箱的输入轴。

3.2 Processing section 加工部分

3.2.1 General 概述
The processing section of the twin screw extruder consists of individual barrel sections which
are replaceable. Depending on the process tasks, a hopper connection, devolatilization ports or
bores for lateral connection of twin screw side feeders are provided.双螺杆挤出机的加工段由单
个的筒体组成并可以更换。根据生产物料的不同，可以选择预留喂料接口、液体加注口或双螺杆
侧喂料接口。

Owing to the modular design of the screw elements and screw barrels, conveying, plasticizing,
homogenizing, pressure build-up and devolatilization zones can be established, depending on
the process task. 螺杆元件和筒体是模块化的标准组件，根据不同的生产物料就可以确定输送、
塑化、均化、挤压、熔融等各个区段。

For product intake and conveying, screw elements are used. The extruder can be fed with
powder, pellets, chips, melt, paste, etc. 螺纹元件是用来喂入并传送物料的。挤出机可以喂入粉
末、颗粒、片状、熔融状、糊状物等。

Plasticizing, mixing and dispersing are done by the kneading elements. By varying the
thickness of the kneading disks and their angle of stagger, their mixing, shearing and
dispersing action can be adjusted to the individual requirements. 物料的塑化、混合和分散是靠
捏合块来实现的，对不同的物料，可以通过改变捏合盘的厚度和角度，来调节混合、剪切和分散
的效果。

The screw elements are arranged on screw shafts. The co-rotating and closely intermeshing
screw shafts have a sealing profile. This means: 螺杆元件安装在螺杆芯轴上。同向旋转并紧密
啮合着的两根螺杆形成一个密闭的截面，这意味着：

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• self-cleaning of the screw elements; 螺杆元件的自洁性；

• no excessive stress on individual product particles; 物料颗粒不会受到过大压力；
• narrow residence time distribution; 物料停留时间分布较短；
• uniform load on product; 物料受力均匀；
• short times for color change. 易于换色。

At the end of each screw shaft, a screw tip is fitted by which the elements are held in position
axially on the screw shaft. Each screw shaft is connected with the power output shafts of the
gearbox by means of a screw shaft coupling. A screw shaft sealing system ensures that no
product will leave the processing section and flow toward the gearbox. 在每根螺杆芯轴的尾
部，装有一个螺杆背帽，它把螺杆元件固定在芯轴上，阻止它们轴向移动。每根芯轴通过花键套
和传动箱的输出轴相联接。在螺杆的尾部配有一套螺杆密封装置，防止物料朝传动箱方向回流。

The screw barrels are supported by barrel supports. Axial displacement of the processing
section resulting from thermal dilatation is absorbed by these supports. 筒体靠支架支撑着，这
些筒体支架也可以缓冲由热膨胀引起的加工段的轴向位移。

3.2.2 Design and function 设计和功能

Screw barrel 筒体
By means of the replaceable screw barrel sections, the processing section is divided into
individual zones. The barrels are heated electrically. In addition, the barrels are provided with
longitudinal bores for cooling with water. Uniform temperature distribution, namely on the
circumference of the eight-shaped barrel bore, is achieved by a reverse force-flow temperature
control circuit. Connections of pipes for temperature control are in groove-tongue design to
balance alternating thermal stress and avoid leakage. 根据筒体的可更换性，加工段分为多个单
独的区。筒体是电加热、水冷却的。在筒体内部开有纵向的孔，用来通冷却水，通过温度控制回
路可达到温度在八字孔表面的均匀分布。温度控制管路的连接采用舌状沟槽设计，可以平衡相互
间的热应力挤压，防止泄漏。

The screw barrels are covered with heat insulating hoods to reduce heat dissipation. At the
same time, these hoods are a protection against burns caused by the screw barrel. 筒体外围加
有隔热外罩，一方面减少了热量的散发，另一方面又可以避免烫伤发生。

The screw barrels are made of nitrided steel. In order to increase the service life of the screw
barrels, these are provided with wear resistant inserts.筒体材质采用优质氮化钢，如果要增加其
使用寿命，也可镶入耐磨衬套。

Machine base frame 底座

The single components of the machine are fixed to a distortion-free base frame. The following
loads/forces are transmitted to the base frame: 设备的主机部分安装在一个不易变形的底座上
面，下述这些力矩/力都将传送到底座上：

• Vertical loads from the dead weight and the force couples resulting from the screw shaft
torques.
垂直方向的静载荷和因螺杆轴的转动形成的合成力矩。
• Moments and horizontal forces in both directions resulting from the supporting reactions of
machine components lying on the base frame.
由支撑物的反作用力引起水平方向的变载荷。

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• Proportions of dynamic loads resulting from residual unbalance and gearing influences. In
addition to motor and gear shaft rotating frequencies, gearing frequencies will occur. The
dynamic proportion from the drive shaft is considerably greater than from all other moving
parts.
残留的不平衡性；传动装置引起的均衡动载荷；电机和齿轮轴高频率旋转所产生的高频率振
动；由驱动轴产生的相当大的动力。
• All these forces are absorbed by the base frame.
所有这些力都被底座吸收。

Screw barrel support 筒体支架

The screw barrels are supported by the screw barrel supports. Axial displacement of the
processing section resulting from thermal dilatation is absorbed by these supports. 筒体支架用
来支撑筒体（图1），它可以缓冲因热膨胀造成的加工段的轴向位移。

The screw barrel supports are screwed to the base frame. The base frame is placed on the
floor. 筒体支架用螺钉紧固在底座上，底座置于地面。

For reason of transport the bolts (Fig.1, item 7) are tightened. The bolts must be loosened
before the first start-up. Otherwise, heat expansion can damage the processing section. The
loosened bolts must be locked with the locknuts again, so that they cannot work loose totally,
but still allow heat expansion. 为了确保运输过程的安全，（图1，件7）所示的螺栓是紧固的。
在设备第一次启动前，必须先松开螺栓，否则热膨胀可能会导致加工段的变形。松开的螺栓必须
用防松螺母重新锁紧，防止在运转过程中完全松开，但仍要保留热膨胀间隙。

Fig. 1: Screw barrel support 筒体支架

Screw shaft coupling 花键套

The screw shaft coupling (Fig. 2) connects the output shafts of the gearbox with the screw
shafts and thus transmits the torque. The rings (item 1) on each screw shaft coupling are in
split design. The coupling sleeve has involute gear teeth on the inside. Involute gear teeth are
also provided at the end of the output shafts of the gearbox and the screw shafts, on the
outside. 花键套（图2）是用来联接齿轮箱输出轴和螺杆芯轴并传递扭矩的，套在两根螺杆轴端
的环（件1）是剖分设计的。它们之间采用渐开线花键连接，花键套开有内花键，齿轮箱输出轴
和螺杆轴的尾部开有外花键。

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Fig. 2: Screw shaft coupling 花键套

Screw shaft seal 螺杆尾部密封

The screw shaft seal (Fig. 3) prevents product from flowing out of the processing section, in the
direction of the gearbox. Sealing is achieved by means of a gland packing. 螺杆尾部密封的作
用是防止物料从齿轮箱的方向流出加工段（图3），它是通过一个密封填料来密封的。

Fig. 3: Srew shaft seal 螺杆尾部密封

Screw shafts 螺杆芯轴

螺杆芯轴
To transmit higher torques, the screw shafts are equipped with a special gearing system
(involute gear teeth). 为了传递更高的扭矩，我们采用一种特殊的传动方式（渐开线花键传动）
来安装螺杆。

The special profile of the screw shaft allows positive fitting of the screw elements. The elements
are clamped axially by means of the screw tip. The screw shafts are connected to the output
shafts of the gearbox by means of the screw shaft couplings. 特殊的芯轴剖面易于螺杆元件的
安装，依靠螺杆背帽把螺杆元件轴向夹紧在芯轴上，采用花键套把螺杆跟传动箱输出轴联接在一
起。

Screw elements 螺杆元件

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The double-flighted screw profile (Fig. 4) distinguishes itself mainly by a greater flight depth,
compared with the triple-flighted profile. This results in a higher free volume per unit of length
and a lower mean shearing rate, at same screw speed. Due to these differences, the following
processing features are typical of the double-flighted profile: 从螺纹的剖面来看，双头螺纹的螺
槽要比三头的深，这意味着在相同的螺杆转速下，双头螺纹单位长度内的容量空间较大而剪切速
度较小。根据上述差别，接下来主要介绍一下双头螺纹剖面的特征：

• good feed characteristic便于物料喂入

• high conveying capacity输送能力强
• stress-free product treatment对物料的压力小

Consequently, the high-volume screw design is to be chosen:

因此，以下这些情况都会选择大容量的螺纹：

• for products which are difficult to feed (e.g., fibre-filled mixes)

喂料比较难的物料（例如：加纤维的混合物料）
• for powdery raw materials, especially those having a low buld density
粉状原料，特别是低密度的
• for processes where no high shearing forces are required
不需要强剪切力的物料
• for shear and temperature sensitive products.
对剪切和温度比较敏感的物料。

In all these cases the double-flighted profile is advantageous for the process, not least because
of the higher throughput and, considering that the investment and operating costs are almost
the same, it represents the more profitable solution. 在这些情况下，双头螺纹的优势不仅仅体现
在产量高，而且可以用相同的成本获得更高的利润，是一个很好的选择。

Fig. 4: Screw elements 螺纹元件

Screw tip 螺杆背帽

The screw tips form the transition zone from the processing section to the discharge parts. The
screw tips rotate at high circumferencial speed in the polymer melt which is conveyed in axial
direction at relatively low speed. High local shearing rates lead to strong heating of the melt
whereas there is no significant temperature change of the product that flows along the barrel
wall. 螺杆背帽形成了加工部分和挤出部分的过渡区。螺杆背帽在聚合物熔体中以很高的线速度
旋转，而聚合物熔体的轴向传送速度相对比较慢，很高的局部剪切速度使得熔体温度快速升高，
但沿筒壁流动的物料温度不会有明显的升高。

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In case of the concentric cone shaped screw tip (Fig. 5), a streamline flow in axial direction is
predominant. There is no mixing of hot product from the inner flow with the colder product from
the area of the barrel wall. 螺杆背帽是同心、锥形的，物料主要是沿轴向顺滑流动的，所以中间
的高温物料和边缘的低温物料是不混合的。

Fig. 5: Screw tip 螺杆背帽

3.2.3 监督和审核
Supervision and checking监督和审核
The fixed process parameters and plant-specific requirements must be supervised and checked
by the operating personnel. For this, openings for various measurements, e.g. melt pressure,
barrel temperature, etc. are provided on the barrels of the processing section. 操作人员必须监
督和审核固定的工艺参数和设备特殊的要求。为此，在筒体上预留了熔体压力，筒体温度等参数
的测量位置。

3.3 Discharge section 挤出部分

The discharge section of the twin screw extruder consists of die head and screen changer.
There are several types of die heads and screen changers to meet the requirements of different
polymers and processing technology. 挤出部分主要分为机头和换网。根据物料和加工工艺的不
同可以选配不同的机头和换网器。

3.4 Gearbox lubrication cooling system 齿轮箱的油润滑系统

The gearbox lubrication cooling system is mainly consists of three parts: Oil pump, Heat
exchanger and filter. About the cooling circuit please see lubrication system diagram (Fig. 6)
齿轮箱的油润滑系统主要由三个部分组成：油泵、热交换器和过滤器，请参照油润滑的原理图
（图6）。

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Fig. 6 : Lubrication system diagram 油润滑系统原理图

The forced oil lube system has two purposes: 油润滑系统有两个目的：

• to lubricate the bearing and gears with oil 润滑齿轮和轴承

• to pump oil of a controlled temperature into the gearbox. 将恒温的油送入齿轮箱

The oil is pumped into the gearbox through the oil cooler and an oil filter by a pump. 油经过过
滤器过滤，再经过油泵抽入冷却器冷却，最后进入齿轮箱。

★Lubrication oil code: ISO-VG220 The details can be found in chapter 8.8
润滑油系统牌号：ISO-VG220工业齿轮油具体牌号请见8.8节润滑油列表。

Main parameters of oil pump for lubrication system 油泵的主要参数

机型
Machine type机型 Oil pump power Flow rate
油泵功率 流量
kW L/min
-36 0.37 5
-53 0.55 8
-63 0.55 8
-73 0.75 13
-96 1.1 20

Planned service and maintenance is required for plate heat exchanger in lubrication system.
The details can be found in chapter 8.7 《Maintenance for plate heat exchanger》 油润滑系统
中的板式热交换器应当定期予以维护，具体内容请见 8.7 章节《板式热交换器的清理维护》

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3.5 Screw barrel cooling system 筒体冷却系统

The screw barrel cooling system (Fig. 7) has 2 units: 筒体冷却系统（图7）分为两个单元：

• Manifold 筒体冷却管路
• Water tempering unit 水温控制单元

Fig. 7 : Screw barrel cooling system diagram 筒体冷却系统原理图

3.5.1 Manifold 筒体冷却管路

The purpose of the manifold is to cool the processing section. It is arranged under the barrels
and supported by pump holder. The manifold is mainly consists of: water inlet pipe(stainless
steel), water return pipe(stainless steel), branch pipes(red copper)、pipe adaptor and valves.
筒体冷却管路的作用是将加工段冷却。它安装在筒体的下方，靠水管夹来支撑，主要由进水管
（不锈钢）、回水管（不锈钢）、支路管（紫铜）、管接头和阀门组成。

The design of the manifold corresponds to the process conditions. The first screw barrel section
(feed section) is controlled manually by means of needle valves. The other screw barrel
sections are controlled via automatic 2/2 Valves. 筒体冷却管路在设计上附合加工条件的要求。
第一节筒体（喂料区）是用手阀来控制的，其它筒体是通过二位二通电磁阀来自动控制的。

3.5.2 Water tempering unit 水温控制单元

The water tempering unit has 2 circuits 水温控制单元有两个回路：

• the consumer circuit (process water circuit) 消耗回路（工艺用水回路）

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• the cooling water circuit 冷却水回路

This unit pumps process water into the processing section and cools the heated process water
in the heat exchanger. The consumer circuit is unpressurized。水泵把工艺用水送到加工段筒体
中，回流的热水在热交换器中冷却。消耗回路的水循环系统是不需增压的。

Main parameters of water pump for barrel cooling system 水泵的主要参数

Machine type Water pump power Flow rate Head
机型 水泵功率 流量 扬程
kW L/min m
-22 0.55 25 35
-36 0.55 25 35
-53 0.55 25 35
-63 0.75 30 40
-73 0.75 30 40
-96 1.5 60 52

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3.6 Vacuum exhaust system 真空排气系统

Through the vacuum exhaust system, volatiles can be evacuated from the machine. The
vacuum exhaust system is mainly consists of three parts: vacuum chamber, vacuum pump and
closed water tank, see the diagram of vacuum exhaust system (Fig. 8). 通过真空排气系统，可
以将气体挥发物从设备中排出。真空排气系统主要包括：排气室、真空泵和冷凝罐。

Fig. 8 : vacuum exhaust system diagram 真空系统原理图

Main parameters of vacuum pump for vacuum system 真空泵的主要参数

Machine type 机型 Vacuum pump power Vacuum speed
真空泵功率 抽真空速度
kW L/min
-22 0.75 0.15
-36 0.75 0.15
-53 1.5 0.4
-63 2.2 0.8
-73 2.2 0.8
-96 2.2 0.8

3.7 Feeding system 喂料系统

Keya Chemical Machinery ’s volumetric feeder include co-rotating twin screw feeder and single
screw feeder. The twin screw feeder is equipped with -36~-96, and the single screw feeder is
designed specially for -22. 科亚成套装备公司的容积式喂料机分为同向旋转的双螺杆喂料机和单
螺杆喂料机。双螺杆喂料机适用于-36~-96，单螺杆喂料机专用于-22设备。

The twin screw feeder can be used both for main feeder and side feeder. The side feeder can
be two stage. 双螺杆喂料机可以被用作主喂料机，也可以被用作侧向喂料机。侧向喂料机也可
以是双阶式的。

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The screws of the twin screw feeder has three types: intermeshing type, spring type and non-
intermeshing type. Users can choose diffrent feeding screw according to the shape of the
polymer to be process. 双螺杆喂料机的螺杆分为三种：啮合型、弹簧型和非啮合型。用户可以
根据要加入的物料的形状来选择不同的喂料螺杆。

The intermeshing type is used for all sorts of powder and granule, the spring type is mainly
used for recycled material. 啮合型的螺杆可用于各种粉状物料和颗粒，弹簧螺杆主要用于回收
料。

About the detailed instruction of the volumetric feeder, please see the operating manual
specially made for it. 关于喂料系统的详细描述，请查看专门为其编写的操作手册。

Main parameters for valumetric feeder 喂料机的主要参数（

喂料机的主要参数（标准配置） 标准配置）
For the details ,pls see TWIN SCREW VOLUMETRIC FEEDER OPERATION INSTRUCTION
chapter 2.1. According to different process requirement ,it is possilbe to choose nonstandard
volumetric feeder,the parameters will be different accordingly.具体内容详见容积式喂料机说明书
2.1 章节。根据工艺要求，也有可能配置非标准的喂料机，参数将有所不同。
3.8 Electrical equipment 电气设备
The equipment of the electric system is limited to the contractually agreed scope of supply.
电气设备仅限于合同中规定的供应范围。

The power customer used should be have the over voltage protect device.
用户的电源在接到我公司设备之前应该装一个过电压保护装置。

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4 Safety 安全

4.1 Warnings and symbols 警告和标记

The following signs and designations are used in the manual to designate instructions of
particular importance.下面的标志在本操作手册里用来表示特别重要的内容。

Refer to special information and /or orders and prohibitions directed

towards preventing damage.
表示特殊的提示和/或规定
表示特殊的提示和 或规定， 或规定，以及预防损坏的禁止标志。
以及预防损坏的禁止标志。

Refers to orders and prohibitions designed to prevent injury or extensive

damage.
表示会造成损伤或严重损害的规定和禁止标志。
表示会造成损伤或严重损害的规定和禁止标志。

Safety signs which are attached to the extruder are listed in the operating instructions for the
individual extruder components, in the chapter on “safety”. These signs refer to dangers which
might occur notwithstanding a safe design. 挤出机上的安全标记在“安全”这一章中将逐个列
出，这些标记表明可能会发生的危险，尽管已经采用了安全的设计。

4.2 Designated purpose 指定用途

The extruder and/or individual units are allowed to be used only for the process described in
the chapter "Technical data". Any other use shall be considered to be not in accordance with
the designated purpose. If the extruder and/or individual units are not used in accordance with
the designated purpose, Keya Chemical Machinery shall not be liable for any personal injury,
material damage or malfunction and any warranty shall be void. 无论是整套挤出机组还是单个
的设备单元都要按照“技术参数”来操作，如用作它用，应该先考虑它是不是符合本来的指定用
途。如不符合，科亚成套装备公司恕不承担所有因此造成的人身伤害、物资损失或设备故障，任
何担保都将无效。

The following materials are not allowed to be processed in the extruder and/or individual units:
本套挤出机组不允许加工如下几种物料：

• explosive base materials

爆炸性物料
• base materials that release explosive matter during the process
加工过程中可能会释放爆炸性物质的物料
• base materials that become explosive by the process.
加工过程中会变为爆炸性物质的物料

The processing section is installed between the gearbox and the discharge section. It may be
used only for continuous production of thermoplastic melt. 加工段位于传动箱和挤出段的中间，
加工段
只能用于热塑性熔体的连续生产。

The die head may only be used for extruding and filtering the thermoplastic melt compounded
in the twin screw compounder. The die head is mounted on the end barrel of the processing
section. 机头只能用来挤出和过滤从加工段出来的热塑性熔体，机头安装在最后一节筒体上。
机头

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Any other use shall be considered to be not in accordance with the designated purpose. If the
unit is not used in accordance with the designated purpose, Keya Chemical Machinery shall not
be liable for any personal injury, material damage or malfunction and any warranty shall be
void. 任何其它用途都是不符合规定的，如果本设备被用来加工不符合规定用途的物料，所造成
的任何人身伤害、物资损失或设备故障，我公司均不承担责任，所有的担保都属无效。

The use in accordance with the designated purpose implies also that all operating instructions,
in particular the safety instructions, are complied with. The operating instructions must always
be kept ready at hand at the extruder and/or individual units. 即使是用来加工指定的物料，也必
须遵守整个操作说明，尤其是安全防范部分。本操作说明必须时刻放在设备附近以便随时取用。

Generally, no modifications to the extruder and/or individual units are permissible after start-up.
Should modifications become necessary, prior approval shall be obtained from Keya Chemical
Machinery. 通常情况下，挤出机启动后不允许做任何改动。如果必须修改，要事先取得科亚成套
装备公司的批准。

4.3 Signalling of dangers 危险标识

The following labels are attached to the twin screw extruder: 双螺杆挤出机上贴有这些标识：

Disconnect the power supply, before opening the terminal boxes!

打开端子盒之前，
打开端子盒之前，必须断开电源！ 必须断开电源！

Wear gloves!
戴上手套！
戴上手套！

Risk of burns!
有烫伤危险！
有烫伤危险！

Can’t be move away!

不能将它移走！
不能将它移走！

Risk of getting seized and risk of injury!

存在被旋转部件卷入的危险，
存在被旋转部件卷入的危险，小心受伤！ 小心受伤！

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4.4 Safety advices 安全建议

The following information is given for your personal safety and for the protection of the extruder
or individual units, or of devices and machines connected, against damage. If this information is
not clear to you, please ask a superior. 以下内容是关于个人安全、挤出机及相关辅机部件的保
护以及安全设施的。如果对此项内容留有疑点，请咨询相关专家。

All information on dangers in these operating instructions is identified by

the symbol in the margin.
本操作说明中所有关于安全的内容在旁边都注有标记。
本操作说明中所有关于安全的内容在旁边都注有标记。

Protect extruder against water.

设备必须防水。
设备必须防水。

4.5 Obligations of the manufacturer 制造商的责任

The extruder and/or individual units have been designed and built by Keya Chemical Machinery
in accordance with the applicable directives and laws. After delivery of the plant and/or
individual units, essential obligations pass to the user. 整套挤出机组由科亚成套装备公司根据一
定的标准和法规设计制造，交付使用后，主要的责任也随之转移给用户。

The manufacturer has the duty of information and instruction for the user. The remaining
hazards from individual units are documented in the corresponding operating instructions. 制造
商有责任为用户提供资料和使用说明，某些仍然存在的危险在相关的文件中也备有说明。

The user has the following obligations: 用户的责任如下：

• He must ensure that the extruder and/or individual units are kept and operated in a
technically perfect condition.
必须保证整套挤出机的保管和操作在技术上处于理想状态。
• He must ensure that the product fed into the extruder and/or individual units is not
contaminated and contains no foreign matter (e.g. screws, stones, etc.).
必须保证喂入挤出机的物料没有被污染，不包含杂质（螺钉、石块等）。
• He must ensure that the prescribed checks and maintenance work are carried out at regular
intervals.
必须保证对挤出机进行定期的检查和维护。
• Checks and maintenance work he doesn't carry out himself shall be entrusted by him in due
time to authorized persons.
如果用户自己做不了，应及时委托权威人士来检查和维护。
• He must ensure that any modifications, maintenance work and repairs performed on the
extruder and/or the individual units are recorded in a log.
必须保证每次对挤出机所做的修改、维护和维修工作都有明确的记录。
• He must ensure that, after every check and maintenance intervention, all protection and
safety devices are checked for perfect functioning.
必须保证每次检查和维护后，对所有保护装置及安全设施的功能进行检查。
• He must ensure that none of the protection and safety devices is removed during operation.
必须保证操作中不得移开安全保护设施。

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• He must ensure that the extruder and/or individual units are used only in accordance with the
designated purpose. Modifications to the extruder and/or individual units are only permissible
upon agreement with Keya Chemical Machinery.
必须保证挤出机只用来加工规定的物料，对设备的改造必须经过科亚成套装备公司的批准。
• He must ensure that all work on the extruder and/or individual units is performed only by
qualified and authorized personnel.
必须保证操作人员要受过专门的培训并取得相应的资格。
• He must clearly specify the competences of his personnel with regard to the extruder and
individual units.
必须明确提出负责机组和独立单元的工作人员应该具备的能力。
• He must inform his personnel about all remaining hazards.
必须告知操作人员所存在的危险。
• He must ensure that work on the extruder and/or individual units is performed by his
personnel only on the basis of these operating instructions.
必须保证操作人员按照本操作说明进行操作。
• He must ensure that his personnel has available all necessary protective equipment against
hazards existing even in case of proper use, e.g. in case of maintenance work, installation
work, etc..
必须保证操作人员在任何时候（即使是在正常的操作，如，维修、安装等情况下）都要采取安
全保护措施。

4.6 Safety equipment 安全装置

The extruder and/or individual units are equipped with safety devices. The safety devices are to
protect persons and the extruder and/or individual units and must not be removed. The safety
devices must never be made inoperative by modifications to the extruder and/or individual units.
See also “7.4.1 Information on start-up”. 本挤出机组配有安全设施，用来保障人员和设备不受
伤害，不得随意拆卸。必须保证这些安全设施的作用，不得改造设施使之失去应有的功能。另外
请参考“7.4.1 启动说明”。

4.6.1 Heat insulation 绝热性

The processing section is provided with cover panels. 采用外罩对加工段进行隔热保护。

4.6.2 EMERGENCY STOP 紧急停车

The complete extruder is integrated in a safety system. If a malfunction within the extruder
requires that an EMERGENCY STOP is tripped, all EMERGENCY STOP pushbuttons provided
for this purpose in the immediate vicinity of the extruder are to be actuated.
整套机组拥有一套完整的安全系统。如果出现故障需要紧急停车，请启动急停按钮。

Before restarting, this malfunction must be eliminated. Only then the EMERGENCY STOP
pushbutton and the EMERGENCY STOP system are allowed to be unlocked by an authorized
person. 重新启动前，必须排除此故障。排除故障后，也只有专业人员才可以解开急停系统和急
停按钮。

4.7 Operating phases 运行阶段

For all work to be performed during the various operating stages, the safety instructions and the
information on remaining hazards given in the individual operating instructions must be
observed. 在各个运行阶段，各项操作必须遵守相关的残余危险情况以及安全说明。

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All modifications, maintenance work and repairs performed are to be recorded by the user in a
log book. 用户必须用一个记事本把所有做过的修改、保养以及维修工作都记录下来。

4.7.1 Start-up 启动
The extruder and individual units are only allowed to be started up if the following conditions are
fulfilled: 要启动挤出机或个别单元，必须满足下列条件：

• All safety devices have been installed and are operative.

所有的安全设施已经安装好并有效运行。
• All signalling and lighting installations are operative.
所有信号指示灯或照明灯都有效运行。
• The product fed into the processing section is not contaminated and contains no foreign
matter (e.g. screws, stones, etc.).
喂入加工段的物料没有污染，不含杂质（螺钉、石块等）。

If the product is contaminated or contains foreign matter, the following troubles can occur:
如果物料被污染或含有杂质，将会引发下面的故障：

• Failure of the extruder设备故障

• Increased wear of extruder components设备零件的额外磨损
• Destruction of extruder components. 设备零件的破坏
4.7.2 Operation 运转
In case of malfunctions, the extruder and individual units are to be immediately stopped and
safeguarded. 设备出现故障时，挤出机及所有的独立单元都要立刻停车并采取安全措施。

4.7.3 Service and maintenance 保养和维护

Before starting any service and maintenance work, the following must be done:
在进行保养和维护前，必须履行下列事宜：

• Inform the operating personnel in due time about the service and maintenance work.
及时通知操作人员相关保养和维护事宜。
• Amply guard the service and maintenance area.
给保养和维护区域做充分的防护措施。
• Cut off the power supply to the extruder and individual units.
切断设备电源。
• Lock the main controls and take out the keys.
锁上主控制器并拔出钥匙。
• Attach a warning sign to the mains switch.
在主开关上附注标记。
• Protect the extruder and individual units against accidental switching on.
防止挤出机的意外通电。

For cleaning of the extruder and individual units, the following must be observed:
清洗挤出机时，要遵守下列几条：

• Don't use extruder components as climbing aid.

不得借助挤出机的零部件来攀登，禁止踩踏设备。

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• Cover/tape all openings where - for safety and/or functional reasons - no

water/steam/cleaning agent or foreign matter (e.g. screws, stones, etc.) are allowed to enter.
处于安全或功能上的考虑，盖上所有开口，以避免水、蒸汽、清洗剂或杂质（如螺钉、石子
等）的进入。
• Don't use aggressive cleaning agents.
不得使用腐蚀性的清洗剂。
• Make sure that the temperature and pressure sensors don't get in contact with cleaning
agent.
热电偶和压力传感器不得接触清洗剂。

After cleaning of the extruder and individual units, the following work is to be performed:
挤出机清洗后，要遵守下列事宜：

• Remove all covers/tapes.

取下所有的保护罩。
• Check all oil pipes for leakage, loose screw connections, scours and damage.
检查油管是否漏油，螺纹连接是否松动，是否擦洗干净，是否有损坏部件。
• Immediately repair any damage found.
一旦发现有损坏，必须马上修理。

Upon completion of the service and maintenance work, the following must be done:
完成保养和维护工作后，必须完成下列事宜：

Re-install all safety devices that were removed for maintenance and repair work.
重新安装好所有因为维护工作而拆卸下来的保护装置。
Check all safety devices for correct functioning.
检查所有保护装置的功能是否正常。
Replace any defective safety devices.
更换有缺陷的保护装置。

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4.8 Remaining hazards 残留危险

危险来源 危险 危险的排除
Source of hazard Hazard Avoiding the hazard
未安装机头 • 旋转的螺杆引起危险（卷入） • 维修前先给设备断电。未经许可不能重
No discharge part Danger of crushing (pulling-in) 新合上主断路器。
installed at the end of by rotating screw shafts Switch the plant off before starting any
the processing section maintenance work. Secure the main
breaker against unauthorized reclosing
• 给突出的螺杆部件安装防护装置。
Attach a guard to the protruding screw
shafts
• 穿防护衣，戴防护手套。
Wear protective gloves and protective
clothing
打开联轴器的防护罩后 • 如果电机没有停转就打开联轴 • 等主机停下来的时候才可以拆下安全护罩
电机仍然运转 器的防护罩，转动部分容易产 Guard must only be removed after the
Motor runs on after the 生危险 machine has come to a stop
clutch guard has been Injury hazard at rotating parts • 必须经常指导操作人员有关危险的防护
opened if the clutch guard is opened Operators must be constantly instructed
before the motor has come to regarding the hazards
a stop • 联轴器罩上有“旋转部件”警示牌。
“Rotating parts” warning plate on the
clutch guard.

Processing section 加工段

The processing section is integrated in the overall safety system. The unit has been designed
to eliminate hazards to operating personnel. However, the following hazards for personnel
remain: 加工段有一套完整的安全系统，虽然设计上尽量排除设备对操作人员造成伤害，仍然存
在下面这些危险：

危险来源 危险 危险的排除
Source of hazard Hazard Avoiding the hazard
旋转的螺杆可能将人的 • 如果没有安装落料管，存在伸 • 落料筒的设计要保证不能随便移开，只
肢体从喂料口卷入设备 入螺杆的危险 有使用工具才能打开。
Hazard of parts of the If no feed funnel is fitted, Design the feed funnel / feed tube so
body can be pulled in there is a hazard of reaching that it cannot be removed without tools.
by the rotating screws into the screws. • 不要伸进落料管或喂料口。
– at material feed port Do not reach into the funnel or the feed
port.
• 如果料斗或下料管没有安装就位，请不
要启动设备。
Machine must not be run unless the
feed funnel or feed tube is in position.

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危险来源 危险 危险的排除
Source of hazard Hazard Avoiding the hazard
加工段的末端开口，没 • 可能会被卷入旋转的螺杆 • 开始维护工作之前，一定要断开电源。
有安装模板或拉条机头 Items can be pulled into the 未经许可不要重新闭合主断路器。
Processing section rotating screws Before starting any maintenance work,
end open without switch off the entire line. Secure the
profile die or strand die main switch against unauthorised
switching on.
• 对操作人员进行培训。
Train operators
• 保持安全距离。
Maintain safety distance
从开口筒体拿走堵块 • 清理工具或身体的部分会被从 • 用适当的工具清除排气口的障碍物！
Attempting to remove 筒体开口处卷入 Only use suitable tools to unblock
a blockage from a Clearance tools and parts of vents!
devolatilization port the body can be pulled in • 应该用可靠的方式萃取气体或蒸汽。
through the devolatilization Gases and vapours should be reliably
port extracted.
• 清理工具可能被卷入 • 穿防护衣，带防护面罩、手套
Clearance tool can be pulled Wear protective clothing, face mask
in and gloves
• 被冒出的气体或物料烫伤 • 培训操作人员 Train operators.
Burns due to gas or product
emerging
• 被气体或蒸汽灼伤
Cauterisation due to gases
and vapours
抽出和插入螺杆 • 锋利的边缘和巨大的重量会对 • 穿防护衣，戴防护手套
Extracting and 人体造成伤害 Wear protective clothing and gloves
inserting the screw Injuries to parts of the body • 保证使用正确的悬吊和提升装置
shafts due to sharp edges and heavy Always use only the correct slings and
weight lifting gear
• 如果搬运螺杆的方法不正确， • 在螺杆被拔出的时候不要站在它的下面
可能会对人体造成伤害 Do not go under the screw shafts whilst
Injury hazard to parts of the they are extracted
body if screw shafts not • 保持安全距离
correctly handled Maintain safety distance
• 禁止非专业人员进入工作区域
Prevent unauthorised access to the
working area
螺杆元件 • 对人体造成切伤、压伤、烧伤 • 穿防护衣，戴防护面罩、手套
Screw elements 等危险 Wear protective clothing, face mask
Cut hazard, crush hazard, and gloves
burn hazard to parts of the • 防止螺杆滚离固定位置
body Prevent the screw shafts rolling away
• 禁止非专业人员进入工作区域
Prevent unauthorised access to the
working area

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危险来源 危险 危险的排除
Source of hazard Hazard Avoiding the hazard
松开螺杆背帽（预紧力 • 阻力的慢慢减小使扳手转动速 • 对操作人员进行培训
大，左旋螺纹） 度加快，可能对人体造成伤害 Train operators
Undoing the screw tips Injury to parts of the body due • 安全地夹紧螺杆
(relatively high to the wrench slipping Clamp the screw shafts securely.
tightening forces, left- • 注意旋转方向
hand thread) Note the direction of rotation
• 穿防护衣，戴防护手套
Wear protective clothing and gloves
筒体 • 筒体坠落造成伤害 • 利用吊绳和提升机保护筒体，避免坠落
Screw barrel Injury due to the screw barrel Use slings and lifting gear to secure
falling screw barrel against falling
• 对操作人员进行培训
Train operators
• 穿防护衣，戴防护手套
Wear protective clothing and gloves
电加热器 • 电缆缺陷造成的电击 • 使加热器绝缘
Electric heaters Electric shock due to Make heaters electrically dead
defective cabling • 穿防护衣，戴绝缘手套
Wear protective clothing and insulating
gloves
损坏的电缆造成的电击 • 不正确的安装造成的电击 • 保证等电位连接性能良好
Electric shock due to Electric shock due to incorrect Ensure that the equipotential bonding is
damaged power installation functioning correctly
cables
加热器的接线盒 • 接线盒进水造成触电危险 • 保护挤出机不要沾水
Terminal boxes for Electric shock due to water Protect the extruder against water.
heater shells penetration • 挤出机上标有“远离水”的警示牌
“Keep water away” warning plate on the
extruder.
• 培训操作人员
Train operators.
电加热器 • 很热的表面会造成烫伤 • 等加热板冷却下来以后再对其进行维护
Electric heaters Burns at hot surfaces Only work on heater plates after they
have cooled down
• 使加热器对电绝缘
Make heaters electrically dead
• 穿防护衣，戴防护手套
Wear protective clothing and gloves
筒体温度很高，约达 • 拆除防护罩时，加工段的上面 • 戴防护手套
250－350°C 和下面也可能会造成烫伤 Wear protective gloves
High temperatures on Burns on the processing • 不要伸到筒体的上面或下面
the screw barrel section from below and above Do not reach on to or under the screw
(processing section) and when removing the barrel
approx. (200–350 °C) guards • 标记 “热表面”
Sign “Hot surface”
• 保持安全距离
Maintain safety distance
• 没有安全护罩的情况下不要启动挤出机
Do not run the extruder without guards.

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危险来源 危险 危险的排除
Source of hazard Hazard Avoiding the hazard
筒体和其附属零件的连 • 漏出的物料可能会烫伤人体 • 定期检查螺栓联接处和密封部位
接部分漏料 Burns to parts of the body due Regularly check bolted connections and
Leaks between screw to product escaping at the gaskets
barrel and attached leakage points in the • 穿防护衣，戴防护面罩、手套
parts processing section Wear protective clothing, face mask
and gloves
• 保持安全距离
Maintain safety distance
拆卸传感器或液体加注 • 漏出来的物料可能会烫伤人体 • 不要在机器运行时清理漏出的物料
接头 Burns to parts of the body due Do not remove whilst the machine is
Removal of material to product escaping running
sensor or injection • 穿防护衣，戴防护面罩、手套
nozzle Wear protective clothing, face mask
and gloves
• 保持安全距离
Maintain safety distance
物料在加工的过程中会 • 产生的有毒气体可能会危害人 • 在挤出机上安装排气装置
产生有毒气体并从排气 体健康 Install stationary air extraction
口或液体加注口排出 Toxic gases can be generated equipment above the extruder
Toxic gases can be by the processed product • 穿防护衣，戴防护面罩、手套
generated by the which pose a health hazard Wear protective clothing, face mask
processed product and and gloves
escape from the vent
ports or open
devolatilization ports.
筒体开口处的泄漏 • 漏出的物料或有毒气体会造成 • 穿防护衣，戴防护面罩、手套
Leaks around the 危害 Wear protective clothing, face mask
devolatilization port on Hazard due to product and and gloves
the screw barrel, toxic gases escaping • 在挤出机上安装排气装置
whether at an insert or Install stationary air extraction
a devolatilization equipment above the extruder
connector
液体加注连接器的管道 • 气体会从管道和液体加注连接 • 在挤出机上安装排气装置
连接 器之间的空隙，或在拆卸管道 Install stationary air extraction
Pipework connection 的时候溢出 equipment above the extruder
to devolatilization Escape of gas at leak • 穿防护衣，戴防护面罩、手套
connector between pipework and Wear protective clothing, face mask
devolatilization connector, or and gloves
at removal of pipework
拆卸熔体传感器或液体 • 漏出的物料或有毒气体会造成 • 不要在机器运行时清除漏出的物料
加注接头 危害 Do not remove whilst the machine is
Removal of material Hazard due to product and running
sensor or injection toxic gases escaping • 穿防护衣，带防护面罩、手套
nozzle Wear protective clothing, face mask
and gloves
• 在挤出机上安装排气装置
Install stationary air extraction
equipment above the extruder

Manifold 筒体冷却管路系统
危险来源 危险 危险排除
Source of hazard Hazard Avoiding the hazard

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电缆受损或错误的连接会 • 错误的安装造成电击 • 确保连接正确无误

造成电击 Electric shock due to incorrect Ensure that the equipotential
Electric shock due to installation bonding is functioning correctly
damaged power cables
and lack of equipotential
bonding
水管温度太高，约90°C； • 水管会烫伤人体 • 穿防护衣，戴防护面罩和手套
回水管的温度甚至可达到 Burns to parts of the body on Wear protective clothing, face
120°C pipework mask and gloves
High temperatures at the • 保持安全距离
pipework, approx. 90 °C, Maintain safety distance
especially the return • 开始维修工作前先冷却水管
pipework approx. 120 °C Allow pipework to cool down
before starting any maintenance
work
水管压力低于5－6bar，水 • 从回水管泄漏出来的蒸汽会造成 • 开始维修工作之前先释放配水系
温约为90°C ，回水温度 烫伤 统的压力
大约为120°C Scalding due to steam escaping Release the pressure on the
Pipework is under 5–6 bar from the return pipework distribution system before
pressure, water flow starting any maintenance work
approx. 90 °C and return • 保持安全距离
approx. 120 °C Maintain safety distance
• 水管接头有渗漏 • 穿防护衣，戴防护面罩和手套
Leaks at pipework Wear protective clothing, face
connections mask and gloves
• 更换组件Exchanging
components
保养与维修工作 • 热水或水蒸汽造成烫伤 • 释放压力
Maintenance and repair Scalding due to hot water or Release the pressure
work steam • 穿防护衣，戴防护手套
• 清洗/更换过滤器 • 烧伤 Wear protective clothing and
Cleaning / exchange of Burns gloves
the strainer
• 在运行的过程中调节阀
门
Control valves during
operation
• 更换所有老化零件，如
水管和螺纹连接件
Exchanging all
pressurised parts such
as pipes and screwed
connections
在渗漏的螺纹连接处，存 • 热水或水蒸汽会造成烫伤 • 确保螺纹连接紧密且密封
在被水或水蒸汽烫伤的危 Scalding due to hot water or Ensure screwed connections are
险 steam tightened and sealed
In the case of leaky • 烧伤Burns • 穿防护衣，戴防护手套
screwed connections • 更换零件时需参考“保养和维 Wear protective clothing and
there is a scald hazard 修”中的内容 gloves
due to hot water or steam See “Maintenance and repair
work” for exchanging parts

Also see the information given in the operating instructions for the
individual units/machines.
同时请参考本操作说明中关于单个部件的说明
同时请参考本操作说明中关于单个部件的说明。
说明中关于单个部件的说明。

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5 Transport, storage and preservation 运输、

运输、存储和保存

5.1 Scope of delivery and notice of shipping damage 交付范围和运输损坏通知

The machine is delivered completely assembled. Loose subassemblies and accessories are
stated in the packing list.设备交付前是完全装配好的，其它散件或附件在装箱单中列出。

The purchaser must inspect the plant for transport damage before they are placed in storage.
Any damage is to be recorded by an independent average surveyor and to be communicated to
Keya Chemical Machinery in the form of a damage survey. Guarantee or insurance claims can
only be asserted in this manner. 买方将设备放入储存室之前必须检查有无损坏，在运输过程中
造成的任何损坏必须由一个中立的检查员记录并以鉴定损坏的形式呈交给科亚成套装备公司，只
有在这种形式下，才能进行保修和保险索赔。

The temperature during the transportation should be in the range of –25~55℃。运输过程中的

温度范围：–25~55℃

5.2 Transport 运输

5.2.1 Transportation vehicle 运输工具

The transportation vehicle of extruder can be truck, train or vessel. 挤出机的运输方式可以是汽
车、火车或者船。

For china inland transportation, normally use the truck. Mechanical part of the machines without
packaging, and electrical control cabinet with simple packaging, steadiness must be ensured
during transportation. 中国地区内, 一般采用汽车运输。机器的机械部分为裸装，电气控制柜为
简易包装。运输途中要保证平稳。

Train or vessel transportation of machines shall have all parts packed, and ensure steadiness
during transportation. 火车和船运均有包装，运输途中要求平稳。

Machines for export shall be packed according to China export packaging standard, and ensure
correspond transport standard during transportation. 所有出口设备都按中国出口包装标准包
装。运输途中保证遵守相关的运输标准。

5.2.2 Transport and hoisting 运输和起吊

Centre of gravity and weight must be taken into account for the use of transport and hoisting
equipment. 运输和起吊设备的时候必须考虑地心引力和重量

The means of transport, hoisting equipment and associated auxiliary

equipment must be selected according to local conditions and the weights
to be handled.
运输、
运输、起吊和其它相关的辅助设备必须根据当地的条件和需承担的重量来选择。
起吊和其它相关的辅助设备必须根据当地的条件和需承担的重量来选择。

Adherence to local safety regulations for hoisting equipment and to the

lifting regulations contained in the applicable standards is mandatory.
必须严格遵守当地的起重设备安全规则和相关的起吊标准。
必须严格遵守当地的起重设备安全规则和相关的起吊标准。

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For transportation of the machine (Fig. 9) two round steel bars are required which have to be
inserted in the bores (item 1) provided for this purpose in the base frame. 设备的运输（图9）
需要两根铁棒，并将它们插入底座上的吊装孔中（件1）。

The steel bar must project at least 500 mm on each side of the base frame. 铁棒插在底座上之
后两侧应该各伸出500mm，所以在准备铁棒的时候要比底座的宽度长1000mm。

The width of the base frame is indicated in the installation drawing. 底座的宽度在装配图中有显
示。

Fig. 9: Bores in the base frame 底座上的吊装孔

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5.3 Storage area requirements 储藏室的要求

Building • weather-resistant building shell 不受天气影响
厂房 • secured against access by unauthorized persons
禁止非专业人员进入
Floor • hard-surfaced, water drainage assure 表面坚硬，排水良好
地面 • for load capacity, please refer to the applicable foundation and
installation drawing
请根据我们提供的安装图和地基要求来确定承载能力
• free from vibrations 消震
• accessible to means of transport and lifting/hoisting equipment
易接近运输和起吊设施
Ambient conditions • well-ventilated 通风良好
环境条件 • dry 干燥
• dust-free in as far as possible 尽量无尘埃
• max. humidity 50 % 最大湿度50％
• temperature approx. -20 °C to +40 °C 温度范围：-20 °C to +40 °C
• altitude <1000m 海拔<1000m

Heater cartridges which are stored longer than 4 weeks must be packed in air-sealed plastic
bags. 加热器如果要存放四个星期以上，必须保存在密封塑料袋里。

5.4 Storage conditions 存储条件

Packed • packages must be protected against penetration of water
包装的 包装箱必须防水
• do not stack packages, assure stability
不要把包装箱叠放在一起，保证它的稳定性
• package number must be visible包装箱的数量必须一目了然
Unpacked • units must be placed in clear arrangement, stability must be assured
未包装的 设备各部件必须按序摆放，并保证其稳定性
• do not stack units不能堆放
• individual parts and tools must be stored in lockable room
个别零件和工具必须存放在封闭的空间

5.5 Preservation 保存

5.5.1 Preservation at factory 在工厂里保存

Preservation is intended to maintain the value, condition and operativeness of the units
concerned. All machine parts requiring preserved at the factory for a period of 6 months. If
machine parts must be stored for more than 6 months, contact the Customer Service
Department at Keya Chemical Machinery regarding the preservation measures required to
extend the preservation period. 保存是为了维持设备的价值，状态和可运转性，所有的设备零部
件在工厂最多只能存放为6个月，如果需要存放更长的时间，请联系科亚成套装备公司售后服务
部，以确定延长保存期限的办法。

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5.5.2 Short-term preservation 短期保存

Proceed as follows when the machine is installed but not operated after installation:
在设备已经安装好还没有运转的情况下，请按下述说明进行操作：

• The extruder operator must take all the safety-related measures required by national
legislation and regulations in the case of delayed start-up.
在需要延迟启动的情况下，挤出机操作人员必须依照国家的法规和标准采取所需要的安全保护
措施。
5.5.3 Preservation for long-term storage 长期保存
All parts must be preserved on the inside and the outside before their storage. Please contact
the Customer Service Department at Keya Chemical Machinery regarding the measures to be
taken for long-term preservation. 在长期保存之前，所有的零件的内外表面都应保护起来。关于
长期保存的方法，请联系科亚成套装备公司的客户服务部。

5.5.4 Removal of the preservative 清除防腐剂

For removal of the preservative, Keya Chemical Machinery recommends to use a cold
cleansing agent (type 4 form FINE ORGANICS). A cold cleansing agent is a solvent that is
suitable for cleaning of cold metal parts which are contaminated with grease, oil, tar or wax.
Such cold cleansing agent should be environment-friendly so that a stable emulsion will form in
conjunction with water and a quick separation in accordance with the requirements of DIN 1999
(separators for light fluids) be achieved. 要去除防腐剂，科亚成套装备公司推荐使用冷清洗剂
（type 4 form FINE ORGANICS）。冷清洗剂具有可溶性，适用于被油脂、油、焦油和蜡等污染
过的冷金属部件。根据德国工业标准1999的要求，冷清洗剂应该选用环保型的，这样可以使得稳
定乳状液与水结合并迅速分解。

The cold cleansing agent can be applied to the preservative-coated surfaces by means of a
brush or by spraying. Subsequently, these surfaces are to be cleaned with suitable materials
such as cleaning wool or cloths. 冷清洗剂也可用来作防腐涂层，可以用喷雾或用刷子刷的方式
把它涂在物体的表面。然后，这些表面可以用合适的毛料或衣料来清洗。

In order to avoid excessive removal of fat from the skin, protective gloves must be used when
handling cold cleansing agents and also safety boots be worn. 为避免对皮肤造成意外的损伤，
在使用冷清洗剂时请戴上防护手套，并穿防护鞋。

When handling cold cleansing agents, sufficient ventilation of the working rooms must be
ensured. 在使用冷清洗剂的时候，必须保证工作室内的空气流通状况良好。

Typical characteristics 特性

25 °C 时的动粘度 Kinematic viscosity at 25 °C 1.57 mm2/s (cSt)

15 °C时的密度 Density at 15 °C 0.775–0.79 g/ml
闪点 Flash point > 61 °C
20 °C 时在水中的溶解性 Solubility in water at 20 °C 几乎不溶 Almost insoluble
喷射清洗 Spray cleaning 4–6分钟 4–6 minutes
浸洗 Dip cleaning 15–30分钟 15–30 minutes
危险等级 Hazard class A lll

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6 Installation 安装

6.1 General conditions for installation 安装的基本条件

The work to be carried out by the customer in connection with the installation is prerequisite for
the proper installation of the extruder. If this work is not executed at all or executed improperly
or incompletely by the customer, this may:
安装挤出机之前，用户必须先完成与安装相关的事宜，如果这些事宜完全没有执行或执行不正确
或不全面，将会造成下列后果：

• cause damage to the parts and components of the extruder;

损坏挤出机零部件；
• prevent the installation work from progressing according to the installation schedule, causing
delays; and
延误安装进度；
• increase the installation costs beyond the planned installation costs.
安装费用超支。

If the conditions stipulated below as listed in 6 are fulfilled by the customer not at all or only in
part, Keya Chemical Machinery shall be entitled to charge the resulting additional expenses to
the customer. 如果用户没有执行或只有部分执行了第6节规定的条款，科亚成套装备公司将有权
收取因此而额外增加的费用。

6.2 Customer participation 用户的责任

6.2.1 Safety regulations at installation site 安装场地的安全规则

The customer is obligated to make the site rules accessible to the Keya Chemical Machinery
installation personnel or instruct the personnel regarding the contents of these rules. Keya
Chemical Machinery shall not be liable for damage to the plant or delayed installation resulting
from a lack of knowledge of the installation site rules or the working regulations. 用户必须通知
并提示科亚成套装备公司的安装人员关于场地的规则以及相关的要求，如果因为不了解安装场地
规则或操作规章而造成设备的损坏或安装的延误，科亚成套装备公司将不承担责任。

6.2.2 Prerequisites for installation 安装的先决条件

The customer or his representative must assure that the following conditions exist:
用户或其代表必须保证满足以下条件：

• The buildings must be completed to a degree permitting the installation work to be properly
performed, particularly as far as the safety-related aspects are concerned. Provisions must
be taken to enable the transport of heavy and/or bulky parts into the building and within the
building.
厂房建设必须达到执行安装工作的要求，尤其要达到安全部分的要求。另外，必须预备好把设
备运进厂房并安置在厂房内的设施。
• The foundations must already be constructed and inspected according to the relevant
foundation and installation plans.
基础设施必须已经按照相关的安装计划建好并检查完毕。

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• The proper static/dynamic design and execution of the foundations is the customer’s
responsibility.
基础设施的静态、动态设计以及最终的实施都是用户的责任。
• The utilities required for proper installation, e.g. electrical power, water and compressed air,
must be available in the building in sufficient quantities. Adequate illumination of the
installation site must be assured.
必须提供充足的电、水、压缩空气等相应设施。另外，必须保证厂房内的照明设施。
• The room where the extruder is to be installed must be adequately protected from the
influence of the weather. At ambient temperatures below 0 °C in the installation room,
continuation of the work is not ensured.
安装挤出机的厂房必须保证不受天气的影响。如果厂房内的温度低于0 °C ，将不能保证机器
继续工作。
• Adherence to the regulations for the prevention of accidents and to the installation site rules
is mandatory. Special regulations valid at the installation site are to be brought to the
attention of the Keya Chemical Machinery personnel in written form.
除了必须遵守事故预防的规则和安装场地的规则外，其它特殊的规则必须以书面形式告知科亚
成套装备公司人员。

6.2.3 Keya Chemical Machinery assistance for installation is requested 安装工作必须由

安装工作必须由科
须由科
亚成套装备公司协助完成
亚成套装备公司协助完成
The request must be made early as possible, at least 6-8 weeks ahead of startup. The
customer and its contractor will provide qualified personnel to assist Keya Chemical Machinery
staff to perform the work. 必须尽早提出安装邀请，最迟也要在试车前的6－8周提出。用户需要
提供有资格的操作人员来协助科亚成套装备公司人员进行安装。

6.2.4 Installation tools and means of transport 安装和运输工具

The means of transport (see chapter 5 and 6 of the operating instructions of the unit in
question) are to be selected as required to assure safe transport. The means of transport
required must be available at the agreed time during installation and must correspond to the
applicable safety regulations. 运输方式（如有疑问请参照第5节和第6节的相关内容）要根据安
全运输的要求来选择，必须在规定的时间内提供运输工具并要符合安全规则。

The extruder parts and components are to be secured at the indicated pointed to prevent
transport damage. Hosting equipment is required to load the means of transport at the place of
storage, for unloading at the installation site and for installing the extruder parts and
components. The weights to be hoisted are specified in the list of the units to be installed. The
hoisting equipment must be approved for the specified weights. 要将挤出机零部件上标明的尖
锐部分包装好，防止在运输过程中损坏。在储存挤出机的场所，需要准备安装运输工具，用来卸
载设备并安装就位。起吊的重量在安装部件列表中有详细的说明。起重设备必须能承受规定的重
量。

Ropes must be attached at the points provided and/or marked. The rope must be adequately
secured at the points of attachment. 吊绳必须系在预留位置或作有标记的地方，系点附近要有
充分的安全保护措施。

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Auxiliary installation equipment and consumables 辅助安装设备和消耗品

Unless agreed otherwise by contract, auxiliary installation equipment and consumable items are
to be provided by the customer or his representative. See chapter 6 of the operating
instructions of the unit in question. 辅助的安装设施和消耗品均由用户或其代表提供，除非在合
同中有特殊的协议。如有疑问请查看第6节中的相关内容。

Transport openings 运输通路

The dimensions of the individual extruder parts and components or units are specified in the list
of units. These dimensions do not include the packaging materials. If the extruder parts and
components or units are to be transported in the packaging materials, the dimensions specified
in the list of units are increased by approx. 0.5 m on each side. 设备零部件的尺寸在清单里有详
细的说明，这些尺寸不包括包装箱的尺寸，如果挤出机的零部件要包装后运输，清单中列出的尺
寸则要在两侧各加0.5m左右的距离。

The dimensions of the transport openings must take into account the intended means of
transport; this is the customer’s responsibility. 用户必须根据运输方式来选定运输通路的尺寸。

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Installation tools and transport means 安装工具和运输方式

The customer must have the following installation tools and means of transport ready in time at
the beginning of installation work:
在安装之前，用户必须准备好下面的安装工具和运输设备：

数量
Qty.数量 Designation 名称 用途
Application用途
4 each 钢索和麻绳，不同长度，可起吊2000kg 重量 Installation of machine
各4件 Steel and hemp ropes, different lengths, up to 2000 kg 设备的安装

4 固定枷锁和操作滑车，负载1500kg Installation of machine

Shackles and guide pulleys, load 1500 kg 设备的安装
2 撬棍，大约1.5 m x Ø30 mm Installation of machine
Crow bars, approx. 1.5 m x Ø30 mm 设备的安装
1 工具箱 Installation of machine
Tool box 设备的安装
1 钻床和钻头 Installation of machine
Drilling machine and several twist drills 设备的安装
1 扭矩扳手 Installation of machine
Torque wrench 设备的安装
1 钢条卷尺，50m Installation of machine
Steel tape rule, 50 m 设备的安装
1 氧气焊 Installation of machine
Oxyacetylene welder with various burner tips 设备的安装
2 精密的水平仪，精确度达 0.04 mm/m Alignment work
Precision spirit level, accuracy 0.04 mm/m 调整工作
1 精确的直尺 Alignment work
Precision straight edge 调整工作
2 塞规测量仪 0.03–1 mm Alignment work
Feeler gauges 0.03–1 mm 调整工作
1 一卷钢丝线，Ø1 mm Alignment work
Roll of steel tensioning wire, Ø1 mm 调整工作
1 深度计 0–250 mm Alignment work
Depth gauge 0–250 mm 调整工作
1 深度千分尺0-25和25-50 mm Alignment work
Depth micrometer 0–25 and 25–50 mm 调整工作
1 外用千分尺 0–25 mm Alignment work
External micrometer 0–25 mm 调整工作
1 磁吸式百分表，测量精度0.01 mm Alignment work
Magnetic holder with dial gauge, reading 0.01 mm 调整工作

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Auxiliary installation means and consumables 辅助安装工具和消耗品

The customer must have the following auxiliary installation equipment and consumables ready
in time at the beginning of installation work:
用户必须在安装前准备好下列辅助安装设备和消耗品：

数量 重量 名称 用途
Qty. Weight Designation Application
kg
4 金属薄片，400 x 400 x 10 支撑撬棍
Sheet-steel plates, 400 x 400 x 10 Supports for crow bars
1 机器油脂 日常维护
Machine grease General work
10 机械油 日常维护
Machine oil General work
50 清洗剂，如汽油、煤油等 清洗工作（防腐蚀）
Cleaning agent, e.g. benzine Cleaning work (corrosion protection)
substitute, kerosene, etc.
25 抹布 清理工作（防腐蚀）
Cleaning rags Cleaning work (corrosion protection)
50 砂布 安装工作
Emery cloth Installation work
1 延长电线，长50 m ，110/220 V 清洗工作（防腐蚀）
Extension cord, length 50 m, for Cleaning work (corrosion protection)
110/220 V
1 手提灯，110/220 V/100 W 检查工作
Hand lamp, 110/220 V/100 W Inspection work
3 钢刷，宽50mm 清洁工作
Steel brushes, width 50 mm Cleaning work
1 二硫化钼润滑剂（耐热润滑剂） 安装工作
Molykote fitting paste (temperature- Installation work
resistant lubricant)

Conditions for installation 安装条件

The twin screw compounder is delivered as a completely assembled unit mounted on a base
frame and is ready to be installed by customers. Additional horizontal supports prevent
displacement of the extruder. These horizontal supports are fixed after the extruder has been
completely installed and aligned. There must be left enough space for installation and repair
work. 双螺杆挤出机是完全安装好后交付的，客户只需将其就位。另外，为防止在水平方向上的
移动，设备的下面装有水平固定装置。必须预留足够的空间，以便于安装和维修。

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Concrete groundwork is not necessary for the installation of Keya Chemical Machinery twin
screw extruder. Keya Chemical Machinery extruders can be installed on leveled ground of
cement thickness at 100–150 mm, no need for second time grouting. Please locate the main
machine and auxiliaries with reference to the measurements on the layout drawing we provide.
When installing the main machine, please use a gradienter on the frame and adjust the
levelness at the tolerance of 0.1 mm/m, finally fix it with pads. 科亚成套装备公司设备的安装通
常不需要混凝土的地基，只需安装在水泥厚度约100－150mm的水平地面上。请按照我公司提供
的布置图安装主机和辅机，在安装主机时，请将一个水平仪放在底座上，利用调整垫片来调整它
的水平度，误差不能大于0.1mm/m。

Insert shims to adjust the machine. Then fix the machine with anchor bolts or horizontal
supports. 调节好设备，然后用地脚螺栓或水平支架将设备固定。

The water pipe work starts after the main machine and auxiliaries are installed. The main hard
pipes include: cooling water input and output pipes for the chiller of the barrel cooling system
and gearbox lubrication oil system. In consideration of some movable auxiliaries, there are also
some soft hoses including: input and output hoses of water-ring vacuum pump, input and output
hoses of cooling water tank, input and output hoses of pelletizer cover cooling. The above pipes
and hoses are prepared by the user and installed according to our requirement. 在主机和辅机
安装就位后，开始安装水管管路。主要的硬水管有：筒体冷却系统和减速箱的润滑油系统冷却器
的进水管和回水管。对于那些辅助的可移动管道，还包括一些软管：如真空水循环系统的进回水
软管，冷却水箱的进回水软管，冷却切粒罩（风冷模面热切粒粒机）的进回水软管。这些水管都
是由用户自备并按我们的要求安装的。

Please clean the dirt inside the pipes and hoses before using them. Please note that heat
exchanger input pipe diameter should be no smaller than output pipe, vacuum system output
pipe diameter should be no smaller than venting pipe diameter. If the vacuum venting pipe
diameter is bigger than 5 mm, the user shall use an even bigger output pipe. 在使用水管之前请
将其内部清洗干净。请注意热交换器的进水管的直径不能小于回水管的直径；真空系统回水管的
直径不能小于排气管的直径，如果真空排气管的直径大于5mm，出水管的直径将要更大。

The general power supply is 3 phase 5 wire AC 3P/N/PE, 380V. Any different requirements
must be mentioned in the contract. Please see “Electrical Control Manual” for power distribution
capacity. The power supply cable is prepared by the user. And the user is recommended to use
a suitable over-load protective switch before the extruder, so as to prevent the components
from being damaged by power supply failure. 供电电源一般为交流380V，3相5线电源，任何不
同的需求都应在合同中注明。供电电缆由用户准备，建议用户将电通到挤出机前安装一个过流保
护开关，避免因供电错误造成设备零件的损坏。

The connecting wires of the extruder set with the electrical control units and auxiliaries shall be
inspected in accordance with our provided diagrams. 挤出设备和电控单元以及辅机之间的电线
连接要经过检查，确保和我们的图纸一致。

• All powered equipment shall be well grounded.

所有通电设备都要有良好的接地。
• Please note that for equipment by inverter control, the user shall NEVER switch on the
equipment before the cover is well grounded.
请注意由转换开关控制的设备，在表面接地之前千万不要打开开关。

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6.3 Installation sequence 安装顺序

Alignment of the processing section, if necessary 必要时，
必要时，对加工段进行调整
Normally, an alignment of the processing section is no longer necessary. Should extraordinary
conditions (alignment precision towards discharge parts) make an alignment necessary, such
correction can be made. 一般不需要再对加工段进行调整，如果需要特殊调整（有助于挤出的校
整精度），可以做相应的校准。

6.3.1 Installation of the screw shaft seal 螺杆密封装置的安装

Install the screw shaft seal as shown in Fig.10. The screws of the sealing block are to be
tightened uniformly and crosswise. For tightening torque please see chapter 2.5. 螺杆尾部密封
的安装如图10所示，用均衡的力矩将密封压盖上螺钉紧固。关于预紧力矩，请参照第2.5节。

Fig. 10: Screw shaft seal

6.3.2 Installation of the screw tip 螺杆背帽的安装

Before installation, fitting paste is to be applied to all threads and to the contact surfaces of the
screw tips(Fig.11, item 1). Screw in the screw tip bolts and tighten. The contact surfaces of all
the screw elements must be flush. For tightening torque please see chapter 2.5. 安装前，在螺
纹表面和所有接触表面上涂上一层耐高温润滑脂。装上螺杆背帽并紧固螺栓。螺纹元件的接触表
面必须是磨平的。关于螺杆背帽的预紧力矩，请查看第2.5节的参数。

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Fig. 11: Screw tip 螺杆背帽

The thread on screw tips is left-hand. 螺杆背帽上是左旋螺纹。

螺杆背帽上是左旋螺纹。

6.3.3 Installation of the screw shafts with screw shaft coupling 螺杆的安装
The screw shafts are generally supplied completely assembled. After they have been
unpacked, the screw shafts are placed on three wooden trestles of equal height.
螺杆通常是事先组装好的，当它被拆下来的时候，要放在三个等高的木制三角凳上。

1. Remove the anticorrosive agent from the screw shafts with a suitable solvent.
用适当的溶剂将螺杆芯轴上的防腐剂除掉。
2. Thoroughly clean the involute gear teeth of the coupling sleeve and the screw shaft and
check them for damage. The coupling sleeve must slide easily over the teeth of both, the
screw shaft and the gearbox output shaft.
彻底清洁花键套和螺杆芯轴上的齿，并检查有无损坏。花键套通过花键与螺杆和传动箱输出
轴连接，花键连接必须保证轻松的滑动。
3. Apply Molykote fitting paste to the coupling teeth. Push the coupling sleeves with screwed-
on ring nut onto the output shafts of the gearbox.
在花键套的齿上涂上二硫化钼耐高温润滑油，然后用并帽固定到齿轮箱的输出轴上。
The screw shaft coupling has right-handed threads on the gearbox side
and left-handed threads on the processing section side.
花键套上靠近传动箱的一端是右旋螺纹，
花键套上靠近传动箱的一端是右旋螺纹，靠近加工段的那一端是左旋螺纹。 靠近加工段的那一端是左旋螺纹。

4. Turn the drive shaft of the gearbox until the offset of the cam pins (wider teeth gap, if any)
is 90º(Fig.12). 旋转传动箱的输出轴直到两根输出轴的相位相差90º（如图12所示）。

Fig. 12: Srew shafts 螺杆

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5. Carefully place the screw shafts close together and turn until the adjusting device slides
over both screw shafts.
轻轻地将两根螺杆靠拢并旋转，直到校准块能够同时在两根螺杆上滑动。
6. Lift manually the screw shafts up to the height of the center of the machine. Check the
position of the screw shafts with a spirit level and correct as necessary.
用手将螺杆举起到设备中心高度，然后利用水平仪检测它们的位置。
7. Push the screw shafts into the processing section until the involute gear teeth project from
the screw shaft seal.
把螺杆推进加工段，直到渐开线齿轮穿过螺杆尾部密封压盖。
8. Thoroughly clean the faces of the screw shafts and gearbox output shafts and slide the ring
nut (Fig., item2) onto the screw shafts.
彻底清理螺杆和传动箱输出轴的花键表面，并将并帽（图13，件2）旋紧到螺杆上。
9. Lift the screw shafts slightly and slide them into the coupling sleeves (item 4) very carefully.
Minor adjustments are possible by manually moving the gearbox drive shaft.
稍稍把螺杆抬起，并将其轻轻推进花键套（图13，件4）。如果调整较小，旋转传动箱的传动
轴就可以了。
Do not use force!
不能太用力！
不能太用力！

10. Push the screw shafts against the gearbox output shafts paying attention to close fitting of
the shaft faces.
推动螺杆，使螺杆尾部端面和传动箱输出轴贴合，要注意使轴端面连接紧密！
The split rings (Fig.13, item 3) are marked by pairs and must therefore
also be installed in pairs.
剖分环（
剖分环（图 13， ，件 3） ）是成对标记的，
是成对标记的，因此也必须成对安装。
因此也必须成对安装。

11. Coat the split rings (item 3 and item 8) with Molykote fitting paste and install. Screw the
threaded rings (item 2 and item 9)) onto the coupling sleeve (item 4) and tighten firmly with
a hook wrench. The screw shaft coupling should not allow axial movement after installation.
在剖分环上涂上二硫化钼耐高温润滑油并安装上去，把并帽拧到花键套上并用钩型扳手紧
固，安装后花键套不能移动。

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Fig.13: Screw shaft coupling 花键套

After installation turn the screw shafts manually several times to ensure easy-running.
安装后，用手盘动联轴器转动螺杆数次，确保运行良好。

Cover the barrel openings of the processing section! Make sure that no
dirt or foreign matter can get into the processing section!
封上筒体的开口！
封上筒体的开口！避免脏物或杂质进入加工段！
避免脏物或杂质进入加工段！

6.3.4 运输的锁定说明
Information concerning transport lock运输的锁定说明
Loosen the bolts on the barrel guide of the screw barrel support before commissioning to allow
the screw barrels and the barrel guide to move against each other due to thermal dilatation.
试车之前松开筒体支架上的紧固螺钉，保证筒体由于热膨胀产生的位移。

6.3.5 Installation of the heater and heat insulating hoods 加热器和热保护罩的安装

1. The heater must closely fit to the screw barrels to ensure good heat transfer. Coat the
screw with Molykote fitting paste before installation. Tightening torque for the screw of the
heater: 10 Nm.
加热器必须贴紧安装在筒体上，以保证有效的热传递。安装前在螺钉上涂上一层二硫化钼耐
高温润滑油，螺钉的预紧力矩应为10Nm 。

2. Place the heat insulation hoods on the screw barrels.

把隔热罩安装到筒体上。

6.3.6 电气设备
Electric equipment电气设备
Electric connection of the heater shells, the temperature sensors, and the material pressure
sensors is to be carried out by qualified personnel, in accordance with the enclosed wiring
diagram, taking into consideration all applicable safety regulations. 加热器、热电偶、压力传感
器等的电气接线都要由有资格的人员，依照配备的接线图纸来完成，并要考虑到所有的安全规
则。

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7 Start-up and operation 启动和操作

7.1 Important general information 概述

7.1.1 Basic conditions for function tests, adjustment work, and first start-up of the
extruder 功能检测，
功能检测，调节工作和第一次启动的基本条件
Conditions for start-up 启动的条件
The start-up is carried out after termination of the work described in chapter 6 “Installation”.
启动设备要等第6章所描述的“安装”工作结束后才能进行。

The first function tests, checking and setting of information function, interlocking, and control
parameters of the plant or parts thereof, as well as its first start-up are always to be supervised
or carried out by a commissioning engineer/specialist of Keya Chemical Machinery. This is one
of the prerequisites for the guarantee for the relevant scope of supply and, in the wider sense,
for any guaranteed production parameters to remain valid. 本套挤出机的首次功能测试、参数设
定以及第一次启动，必须由科亚成套装备公司调试工程师或专家来执行或监督执行。这是保证相
关供应范围的一个先决条件，进一步说，是保证生产参数是否有效的先决条件。

The acceptance certificate will be considered as an evidence of the fact that commissioning
was carried out in the prescribed form. This document is always to be filled in, even in case of
partial acceptance, and to be signed by the responsible company representative.“验收证明”
是证明设备已经按照规定格式进行了试车的一个证据。用户必须填写这份证明文件（即使在部分
验收的情况下），并且要由公司负责人的签字。

7.1.2 First start-up 第一次启动

Due to the fact that the necessary settings have to be made and process-specific parameters
have to be determined, the procedure during first start-up of the plant may differ from the
standard start-up instructions. 第一次启动的程序与正常启动不同，因为第一次启动不但要设定
必要的参数，还要将特殊的工艺参数确定下来。

Should it become necessary- due to specific polymer or process parameters and /or to
conditions which are beyond the scope of our supply-to complete or to modify the standard
start-up sequence, this will be carried out by our personnel. 如果因为特殊的物料或工艺参数和/
或超出我公司提供范围的情况，要完善或更改标准启动的程序，必须由我公司的专业人员来执
行。

Exceptions: Customer-specific designations of units and devices are excluded from such
completions/modifications. 例外：
例外：用户自己所做的特殊设计不适用于上述情况。
用户自己所做的特殊设计不适用于上述情况。

7.1.3 Operating parameters 运行参数

The operating parameters set during the acceptance run and/or a possible guarantee run, are
entered for each polymer in data sheets. 在验收运行或合理的担保运行过程中，设定的运行参
数要按物料的不同详细地记录下来。

In case of complaint, these data sheets will be considered to be the basic

data at which the acceptance and /or the test run were carried out. As a
principle, a copy of these data sheets is to be enclosed to the acceptance

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certificate. 出现纠纷时，
出现纠纷时，这份数据表将作为验收设备和试车的原始数据，
这份数据表将作为验收设备和试车的原始数据，同时
根据规定在验收证明书的后面附上备份数据表。
根据规定在验收证明书的后面附上备份数据表。

7.1.4 Energy, utilities, auxiliary products 设备设施条件

If not otherwise stipulated in the contract, the required energy and media are to be provided by
the user in the sufficient quantity and the specified quality. Filling of the units and devices must
take place before carrying out the function test and /or first start-up. 如果合同中没有特别的说
明，则由用户方按规定的质量标准充分准备所需的能源或介质，设施设备在验收和调试之前应当
备妥。

7.1.5 Information on the documentation “Commissioning and Operation” 试车和操作

The precondition for correct commissioning and future operation of the extruder is that the
user’s personnel has received the needed information contained in these operating instructions
regarding the individual units, the functional sequences, and the plant as a whole. In addition,
the relevant information in the function and interlocking diagrams and the control documents,
training of the operating personnel (an option) on the site already at the installation and start-up
stage is particularly recommended. 用户自己的员工完全掌握本操作说明中关于单个部件、运行
顺序以及整套挤出机组的详细资料，是正确试车和将来正常操作的前提。另外，要重视相关资
料、图表、控制资料以及对操作人员进行安装和启动的现场培训。

7.2 Required manpower for start-up 启动设备所需的人力

7.2.1 Required manpower from Keya Chemical Machinery 所需的科亚成套装备

所需的科亚成套装备公司
科亚成套装备公司的援
公司的援
助人力
Scheduling 行程安排
As a rule, if a paid startup assistance from Keya Chemical Machinery, an option, is needed, the
dates for dispatch and the number of personnel required are mutually agreed upon between the
user or his representative and the Project Manager or Service Department of Keya Chemical
Machinery approx. 6-8 weeks before the beginning of the function test as scheduled. Address
of Service Department: See chapter 10. 按规定，如果需要科亚成套装备公司提供有偿的的协助
试车，就需要在预定调试日期前的6～8周，用户方或他的代表跟科亚成套装备公司的项目负责人
或服务部门之间进行协商来确定需派遣调试人员的人数和日期。服务部门的地址，请查看第10
章。

7.2.2 Personnel to be provided by the user of the plant 用户方需要提供的人员

For the function tests, at the least, however, for first start-up, at least one qualified and
responsible person from the following specialties must be available:
第一次试车，用户方必须至少各准备一个专业人员负责下列各项。

• production产品
• control technology技术控制
• maintenance/repair维修

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7.3 Training of the plant operating and maintenance personnel 设备操作、

设备操作、维修人员的培训
Training on site and on the plant itself is the most effective way to familiarize the personnel with
the start-up procedure and with all other requirements for the extrusion operation. It is therefore
most advantageous to start the training of the extruder operating and maintenance personnel
already during the start-up and then to further strengthen know how after regular production
has been started. 对操作人员进行现场培训是使之快速掌握启动过程和设备操作的最有效方法。
所以，在验收和调试阶段对操作和维修人员进行培训，然后再进一步巩固其正常的生产操作知
识，是非常有利的。

7.4 Start-up and operation of the processing section 加工段的启动和操作

7.4.1 Information on start-up 启动

Grease the lubrication points. Check oil levels and refill oil, if necessary. 给需要润滑的地方涂上
油脂，检查油位，如有需要，请补足油量。

Open valves for water, stream, and compressed air and check pipes for leakages. 打开水、气
流或压缩空气的阀门，检查管道是否泄漏。

Carry out a functional test and check the direction of rotation taking into account that most
pumps are designed for only one direction of rotation, i.e. they may be started only shortly for
this purpose. 功能和旋转方向的检测，鉴于大部分泵都是单向旋转的，所以只需很短的时间。

Chech all screw connections, include mechanical connections and the connections inside the
control cabinet. Retighten any loosening connections during the transportation. 检查所有的螺纹
连接，包括机械部分和电气柜内部。如果在运输过程中松动，必须在启动设备前将它们重新紧
固。

Furthermore, make sure, before start-up, that all mechanical and electrical safety devices are
installed and tested and that their performance is ensured. 此外，在启动设备前必须确保机械和
电气的所有安全设施都已装好并通过检验。

Check interlock, before start-up. 启动前，检查联锁功能。

Extruder alarm and interlock functions: 挤出机的报警和联锁功能：

挤出机的报警和联锁功能：
• When the main machine current reaches or exceeds the nominal current, the alarm lights up
and main machine and feeder stop automatically;
如果主机电流达到或超过了设定值，报警器发出警报，主机和喂料机自动停车。
• When the die head melt pressure exceeds the preset value, the alarm lights up and the
extruder stops automatically;
当机头的熔体压力超过了设定值，报警器发出警报，挤出机自动停车。
• The main motor and its cooling fan (for DC motor), oil pump motor are interlocked in order,
i.e., if the cooling fan and oil pump motor do not start, the main machine cannot start;
主电机、主电机风机（只有直流电机才有）、油泵按照顺序联锁，比如，主电机风机和油泵没
有启动，主机也不能启动。
• The main motor is interlocked with feeder motor, i.e., if the main motor does not start, the
feeder motor cannot start.
主电机和喂料机联锁，比如：如果主电机没有启动，喂料机也不能启动。

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7.4.2 Preparations Before Start 启动前的准备工作

Add oil amount to reach a level between min and max. of the level indicator. 油量加到油位计的
最大值和最小值之间。

Clean the main water tank and input water to it to reach 2/3 of the tank. Start the water pump to
check if it rotates in correct direction. If yes, check if the water pressure is 0.3–0.4 Mpa. All
input and output pipes shall be smooth without leakage, and all valves shall work well. 清洁水
箱，往里面加水至水箱容积的2/3，启动水泵，检查水泵的旋转方向，如果方向正确，检查水压
值是否在0.3–0.4 Mpa之间。所有的输入输出水管都应该平滑无渗漏，所有的阀门都完好无缺。

For vacuum venting process, the user shall add clean city water to reach 1/3～2/3 of the
condenser tank. Start the vacuum pump to check if it rotates in correct direction; close vacuum
pipe and condenser tank valves to check if the seal of vacuum chamber is good. 冷凝器中需要
加入 1/3 ~2/3 容积的纯净饮用水，作为抽真空用水。启动真空泵检查它的旋转方向是否正确。
关闭真空泵，合上冷凝器阀门，检查真空室的密封是否良好。

The twin screws and barrels shall not interfere with each other or make any abnormal noise. 双
螺杆和筒体之间不能互相刮擦，也不能有不正常的声音。

Clean the silo and hopper and input raw material. If the user has automatic loading machine,
start the loading machine and check if it rotates in correct direction. 清理料仓和料斗，加入原
料。如果用户有自动装料机，启动装料机并检查它的旋转方向是否正确。

For extruder working with water-cooling strand pelletizing system, start the pelletizer to check if
the knife rotates in correct direction.如果设备配备的是水冷拉条切粒系统，启动切粒机，检查切
刀的旋转方向是否正确。

Start the cooling fans or conveying fans to check if they rotate in correct direction. 启动冷却风
扇和输送风扇，检查它们的旋转方向是否正确。

Prepare necessary tools and articles for start-up. 准备所需的工具。

7.4.3 Test Items 测试

• Are wires connect correctly? 接线是否正确？
• Do all motors rotate in correct direction? 所有的电机旋转方向是否正确？
• Are the motors’ fixing bolts fastened? 电机的固定螺栓是否紧固？
• Does the oil input reach the required levels? 加油量是否达到标准？
• Do all valves, pressure and temperature indicators work well?
所有的阀门、压力传感器、热电偶是否正常工作？
• Is the distance between the screws correct? 螺杆之间的距离是否正确？
• Are the screw end bolts fastened? 螺杆背帽上的螺栓是否紧固？
• Is there any foreign material in the processing part? 加工部分有无杂质？
• Can the couplings be turned by hand smoothly? 是否能够用手平稳地转动联轴器？
• Is the gearbox noise normal? 传动箱是否有噪音？
• Is there any abnormal big vibration of the machine? 设备有无异常振动？
• Is the sealing block at the screw shaft put correct and pressed?
螺杆尾部密封压盖是否安装正确，有无压紧？
• Is the die plate installed correctly? 口模是否安装合适？
• Is the feeding unit inspected? 喂料部件是否已检查？

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• Are the downstream units for the pellets inspected? 切粒的下游设备是否已检查？

7.4.4 Co-operation of the user 用户的协作

For start-up, the following must be ensured by the user: 启动前，用户必须保证：

• The supply lines for all media must be connected and available in accordance with chapter 2
“Technical data”
能源供应设施必须完善，参照第2章“技术资料”。
• All the other units must have been mounted and their function be ensured.
其它所有的部件都应当安装好并经过性能检验。
• The components required for the thermoplastic melt must be available in sufficient quantity
(for at least 1 hour operation).
物料的成分必须准备足量（至少要满足1个小时的生产）。

Start-up / Preparations for operation 启动/预备运行

启动 预备运行

In order to ensure a normal service life of the heater shells and to evacuate
any humidity which might have penetrated during transportation, heating-
up to operating temperature should always be made in two or three steps,
with intervals of approx. 15 min. between the steps.
为了保证加热器的使用寿命和排掉设备运输过程中产生的湿气，
为了保证加热器的使用寿命和排掉设备运输过程中产生的湿气，加热的过程可以
分两个或三个阶段来进行，
分两个或三个阶段来进行，每个阶段之间间隔约为 15 分钟。 分钟。
When the operating temperature is reached, retighten the turnbuckle and
fastening screws!
当达到运行温度的时候，
当达到运行温度的时候，需要再次紧固加热器连接螺钉！
需要再次紧固加热器连接螺钉！

Start of production 开始生产

After the operating temperature has been achieved (depending on the product), the extruder
can be started for production. 达到工作温度（根据物料而定）后，就可以开始生产。

Risk of burns by hot surfaces and hot product!

小心被热表面和物料烫伤！
小心被热表面和物料烫伤！
Wear safety gloves. Wear protective clothing.
戴防护手套，
戴防护手套，穿防护衣。 穿防护衣。

Risk of intoxication by product vapours!

小心被物料排出的毒气所伤！
小心被物料排出的毒气所伤！
Wear a breathing mask. Wear a face guard.
戴防毒面具或防护面罩。
戴防毒面具或防护面罩。

The extruder is then switched off, the die strip sealing surfaces have to be cleaned with an
appropriate tool (a brass spatula, or the like), and the unit is closed. After the fastening screws
have been tightened with the correct torque, normal operation of the extruder can start and the
extruded strands are conveyed to the downstream equipment. 当挤出机停车后，要用适当的工
具（黄铜刮刀或类似的工具）清理出条口的物料，并关闭整套设备。当以合适的力矩重新上紧紧
固螺钉后，又可以进行正常的生产。

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7.4.5 Start Up 启动
Heating up: preset value of each zone according to the processing requirements. 加热：根据工
艺的需要设定各区的温度。

After each zone reaches the preset value, keep temperature for another 50 minutes. Further
check if all temperature controllers and solenoid valves work well. 在每个区的温度达到设定值
后，保持恒温50分钟。进一步检测温控表和电磁阀是否正常。

Start lubrication oil valve to further confirm there is no leakage. Turn on the lubrication chiller
cool water switch. 打开油润滑阀门进一步确认没有漏油。开启润滑油的水冷却器开关。

Turn the main motor coupling by hand and ensure the screws rotate in correct direction to at
least 3 circles (Correct direction means: seeing from the motor end, it should turn clockwise;
seeing from die head end, it should turn counter-clockwise). Reset the main machine speed,
start the main motor and increase screw speed gradually for free load test, keeping the speed
below 20 rpm for less than 1 minute to check if the main machine free load current is stable. 用
手盘动主电机的联轴器至少三圈，确认螺杆的旋转方向是否正确（正确方向：从电机的尾部看，
它是顺时针旋转的，从机头方向看，它应当是逆时针旋转的）。设定主机转速，启动主电机并在
空转的状态下逐渐增速，保持转速20 rpm下转动约1分钟，检测主机的空转电流是否稳定。

If the main machine runs well, start the feeder motor from low speed and input material. When
there is material extruded at the die head, increase the extruder screw speed, then increase
feeder screw speed gradually. First increase extruder screw speed till the current decreases to
stable level, then increase feeder screw speed and increase feeding quantity so that feeder
runs in matching with the extruder speed. It is reasonable to keep every increase of speed
below 50 rpm. If the processing needs the increase of feeder and the extruder current increase
too fast, the user shall reduce the feeding quantity accordingly, and increase the extruder screw
speed gradually to reach the processing requirement. 如果主机运行良好，低速启动喂料电机并
加入物料。当有物料从机头挤出的时候，加快螺杆转速并逐渐加快喂料速度。首先加快螺杆转速
直到电流降至标准值，然后加快喂料速度使得它和主机的转速相匹配，每次增加值不能超过
50 rpm 。如果工艺上要求增大喂料速度但挤出机电流上升过快时，用户应该适当减小喂料量，
并逐渐增加螺杆速度来达到工艺的要求。

For multi-feeding system, the user shall first adjust the extruder and main feeding system to
work well, then start the other feeders in order. During the adjustment the user shall pay close
attention to extruder current, generally keep it below 85 % of the maximum current value. In the
meantime shall pay attention to the complete extruder operation, and stop the machine if there
is any abnormal noise or vibration. 如果是多喂料系统，用户应该首先调节主喂料，使之运行良
好，然后再按顺序启动其它喂料机。在调节的过程中，用户要特别注意主机电流，通常保持在最
大电流值的85％以下。同时也要注意整套设备的运转状况，如有任何噪音或不正常的振动，立刻
停机。

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Each barrel zone cooling pipe is equipped with manual throttle and solenoid valve. Feeder
barrel only has manual throttle. Before start up, the user shall not use the tempered water
cycling system until the extruder runs stable for some time. Then open the throttle for required
zone slightly (not suddenly or open too much). After some minutes when there is no obvious
reduce trend or reduce to a stable value beyond the normal range, the user can open a little
more the manual throttle. This procedure may repeat several times. When the best valve switch
is fixed, the user does not have to change it for the same material production. But for a new
material production, the user has to adjust the switch of the valve again. 每节筒体的冷却水管上
都配有手动截止阀和电磁阀，喂料筒体只配手动截止阀。启动前，不要使用水循环系统，等设备
运转稳定一段时间以后才能使用。稍微开启需要冷却区的截止阀（不能开的太快、太大），几分
钟后如果温度没有明显下降的趋势或下降到仍然高于正常范围的一个稳定值，可以把手阀开得稍
微大一点。以上程序可以多次操作，直到手阀的开度达到最佳状态，这样对于相同的物料就不用
再次调节。但对于不同的物料，需要再次调节手阀的开度。

For extruder with water-cooling strand pelletizing system, start the cooling water cycling system,
blower and pelletizer. If this system works well, adjust the pelletizer speed to match the
extruding linear speed; pelletizer speed varies when the extruder output changes so that the
pellets diameter can meet the requirement. 如果设备配的是水冷拉条切粒系统，启动水循环系
统，吹干机和切粒机。如果这个系统工作正常，调节切粒机的速度使之和挤出条料的速度相匹
配。根据挤出机产量的变化来改变切粒机的速度，这样才能保证料粒直径的均匀。

Venting unit works after the extruder works stable. First close the valve between vacuum
system and vacuum chamber, then open the input valve of vacuum pump. Pay attention to the
material at the screws from the venting port. If the material is completely plasticized and does
come out, close the venting chamber cover and open the valve of vacuum pipe to keep a high
vacuum degree. 挤出机运行稳定之后再打开抽真空系统。首先要关闭真空系统和真空室之间的
阀门，然后打开真空泵的进水阀。注意排气口处的物料，如果已经完全塑化并没有冒料情况，合
上真空室盖子并打开真空管的阀门，保持高的真空度。

7.5 Stop the machine 停车

7.5.1 Normal stop 正常停车

• Close vacuum pipe valve and open vacuum chamber cover.
关闭真空管道阀门并打开真空室盖子。
• Note: DO NOT first stop the vacuum pump, because this may cause water inside
accumulator to enter barrels if the valve is still open.
注：禁止 禁止先停真空泵，因为如果没有关闭阀门，可能会造成冷凝罐内的水流入筒体。
禁止
• Stop the feeder. For multi-feeding system, first stop liquid feeder, then side feeder, finally
main feeder.
停喂料机。对于多喂料系统，先停液体加注，其次是侧喂料，最后是主喂料。
• Reduce the extruder screw speed gradually and discharge the remaining material inside
barrels. For easy-decomposing thermoplastic materials like PBT, POM, SPVC high filler,
degradable material and so on, input polyolefin, like PE, PP and so on, to replace the
remains. Stop the extruder when the remains is almost discharged, i.e., reset the speed and
push the extruder motor stop button. For two-stage extruder set, first stop twin screw
extruder, then stop single screw extruder.
逐渐降低螺杆转速，挤出筒体内的残余物料。对那些容易分解的物料，如：PBT、POM、
SPVC高填充以及可降解物料等，加人PE、PP等聚烯烃等来清除残留物料。当物料基本清除
干净的时候才可以停机，使螺杆停止转动，再按下挤出机停止按钮。对于双阶机，应当先停双
螺杆，再停单螺杆。

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• Stop the main motor fan, oil pump, vacuum pump and water pump in order. Switch off all
heating zones on the control panel.
按照顺序停主电机风机，油泵，真空泵和水泵。切断控制面板上所有的加热区。
• Stop pelletizer and all other auxiliaries. 停切粒机和其它下游辅机。
• Close each water pipe valve, including valves for barrels cooling water, gearbox oil lubrication
system cooling water, vacuum pump and water tank cooling water (Don’t close the throttles
of tempered water pipe for barrels).
关闭所有水管阀门，包括筒体冷却水管，齿轮箱油润滑系统冷却水管，真空泵和水箱冷却水管
（不要关闭筒体冷却水管的截至阀）。

EMERGENCY STOP 紧急停车

For EMERGENCY STOP please push the red EMERGENCY STOP button, then switch off
power supply. Reset the speed button of extruder and all feeders. When the problem is solved,
start the machine in above-mentioned steps. 需要紧急停车时，请先按下红色的急停按钮，再切
断电源开关，使挤出机和所有喂料机的速度复位。当故障排除后，就可以按上述的步骤重新启
动。

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8 Service and maintenance 维修和保养

8.1 General notes 概述

These maintenance instructions are based on efficient maintenance and repair. Planned
service and maintenance performed at the correct intervals can largely eliminate trouble and
breakdowns and guarantees economically efficient machine operation. 本保养说明建立在有效
的保养和维修上，定期对设备进行维修和保养可以很大程度上避免故障发生，并保证设备运行的
经济效益。

The intervals specified in the schedule below are based on experience under normal operating
conditions typical for this type of industry. These intervals may be changed depending on the
product to be processed and company-specific requirements. Experience gained during
operation is to be duly considered. Especially in case of machines with wear protected
processing section, the process tasks and conditions are to be taken into consideration and
maintenance intervals corrected accordingly. 下列时间表中规定的时间间隔是根据这种机型正常
生产状态的经验所定的。这种间隔可根据物料的不同和用户的特定要求进行改变。适当地参考操
作中的经验，要综合考虑设备的筒体是否有耐磨衬套，所加工的物料情况等来决定相应的维修时
间表。

8.2 被塑料污染的零部件的清洗
Cleaning of parts contaminated with plastic被塑料污染的零部件的清洗
Various methods are used to clean parts contaminated with plastic, such as screw elements,
die plates, screen plates, screen inserts, tools, etc. the screw barrels must be slowly pre-heated
to 300 °C. 可以运用各种不同的方式清洗被塑料污染的部件，如螺杆元件、口模、换网装置、工
具等等。筒体必须慢慢预热到300 °C ，以便于清理。

8.3 Maintenance and inspection schedule of the processing section 加工段的保养和检

查时间表
时间间隔 检查/保养部位
检查 保养部位
Interval Inspection point / maintenance note
Daily • 在操作过程中检查温度、压力的控制和加热系统。
每天 Check the temperature and pressure control and heating system during
operation.
• 排除加工过程中出现的故障，如：泄漏和机械故障。
Eliminate all defects observed during operation, e.g. leaks and mechanical
defects.
• 在设备运行时检查螺杆尾部密封(图10), 如果需要的话，进行调整或更换。
Check the screw shaft seal (Fig.10). While the machine is running and readjust
or replace as necessary.

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时间间隔 检查/保养部位
检查 保养部位
Interval Inspection point / maintenance note
Every 2000 • 检查加热器的安装和功能是否合适，螺钉是否松动。
hours of Check the fit and operation of the heater shells/ heater cartridges.
operation • 如果需要，检查所有加热和冷却线路，排气装置、法兰连接和阀门是否泄漏，密
每运转2000 封状况如何。
个小时 Check all heating and cooling connections, exhausts, flanges and valves for
leakage and seal, if necessary.
• 在设备运行的时候检查螺杆尾部密封（图10），如果需要，进行适当的调整或更
换。Check the screw shaft seal (Fig. 10) while the machine is running and
readjust or replace, as necessary.
• 在操作的过程中检查温度和压力控制装置。
Check the temperature and pressure control devices during operation.
Every 6,000 • 拔出螺杆，把螺杆元件和背帽拆卸下来，检查它们的磨损、腐蚀或损坏状况，更
hours of 换已损坏的零件。重新安装螺杆元件的时候采用特殊的耐高温安装油——参照第
operation 8.8“润滑油脂表”
每运转6,000 Pull out the screw shafts. Dismantle the screw elements as well as the screw
个小时 tips and check all parts for wear, corrosion or damage. Replace damaged parts
according to the findings. Use special heat-resistant grease when refitting the
screw elements – see chapter 0 “8.8 Table of lubricants”.
• 检查温度和压力控制装置。
Check the temperature and pressure control devices.
• 更换密封圈。
Replace the gland packing.
• 拆除加热器，清洁连接表面后重新安装并检测其功能，保证安装适当。安装时采
用特殊耐高温油脂（请查看第8.8节“润滑油脂表”）。
Dismantle the heater shells/heater cartridges and clean the contact surfaces.
Reinstall the heater shells and test their function. Make sure that the heater
shells are properly fitted. Use special heat-resistant grease (see chapter 0 “8.8
Table of lubricants” ).
• 检查加热和冷却连接管道，排气装置、法兰和阀门是否有泄漏，密封状况是否良
好。
Check all heating and cooling connections, exhausts, flanges and valves for
leakage and seal if necessary.

8.4 Dismantling and reinstallation of the cartridge heater 加热器的拆卸和重新安装

Dismantling 拆卸
The heater must be switched off at least 30 minutes before dismantling them. They are allowed
to be dismantled only when the screw barrel is cold. 拆加热器之前，必须先断电至少30分钟。
必须等筒体冷却后才能进行拆卸。

Reinstallation 重新安装
Thoroughly clean the bore in the screw barrel, e. g. with a brass wire brush.
彻底清洁筒体上的螺纹孔，可以用铜刷来清理。
Apply Molykote fitting paste to the bore in the screw barrel.
给螺纹孔里涂上二硫化钼润滑油。
The heater must fit easily into the screw barrel.
装上加热器。
Lock the heater with a locking screw.

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用锁紧螺钉紧固。
Lay the cable such that is cannot get in touch with hot parts, e.g. the screw barrel.
安全布置电线，避免接触筒体等受热零部件。

8.5 Dismantling of the screw shafts. 螺杆的拆卸

Tools and appliances 工具
• Tools for loosening the screw tips 松开螺杆背帽的工具
• Extraction device for pulling the screw shafts out of the processing section 将螺杆拔出的工具
• A grab winch or pulley block for pulling of the screw shafts 拉出螺杆的绞盘或滑轮
• Hook wrench for loosening the screw shaft coupling 松开花键套的钩型扳手
• General fitter’s tools (hammer, wrenches, etc.) 普通的安装工具（锤子，扳手等）
• Supports for the screw shafts, 2 or 3 depending on the length and weight of the screw shafts.
螺杆的支架，根据螺杆的长度和重量来选择用2个或者是3个。

Dismantling of the screw shafts 螺杆的拆卸

The screw shafts may only be dismantled while the processing section is hot. When sticky
products are processed, operate the extruder for approx. 10 min with a cleaning product before
dismantling. Then stop the extruder and the auxiliaries. 螺杆要趁加工段还热的时候拔出来。如
果加工的黏性物料，拆卸之前先开10分钟的清洗料，然后停掉双螺杆主机和其他辅机。

All discharge parts must be dismantled. The area in front of the machine required for
dismantling the screw shafts must be cleared. Make hoisting equipment available for
dismantling and suspending the screw shafts. 拆除所有的挤出零部件，清理设备前方用来拆卸
螺杆的场地，准备起重设备。

Switch off the die head heater, and keep the heaters of other zones working.Take out the
pressure and temperature sensor at the die head. Put on thick asbestos gloves and remove the
die head and screen changer, and the heater if necessary. Clean the die head, screen changer
and the melt remains at screw ends. 先将机头加热器断电，其他加热区持续加热。拆下机头上
的温度和压力传感器，戴上厚石棉手套，将机头和换网拆下来。清理机头、换网器和螺杆端部的
残余物料。

Remove the screw tip (left-hand thread) with the screw tip wrench, and fix on special bolts to
draw the screws out from the barrel. See Fig. . 用扳手将螺杆背帽（左旋螺纹）拆下来，然后把
螺杆吊环旋入螺杆端部，把螺杆拉出筒体。如图14所示：

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Fig. 14: Dismantling of screw shafts 螺杆的拆卸

Loosen the threaded rings (Fig.13, item 2) on the screw shaft couplings with a hook wrench and
remove the split rings (Fig.13, item 3). Pull the screw shafts out of the processing section.先用
钩型扳手将花键套两端的并帽（图13，件2）松开，把剖分环（图13，件3）拿下来，然后从加工
段抽出螺杆。

Remember the marks on the screw ends with spline couplings. While assembling the user shall
fix the screws on the original marks, ie., the two screws cannot shift the position each other.
Note: spline coupling to the gearbox direction is right-hand thread, to die head direction
is left-hand thread. 要记住螺杆尾部的标记，这样重新安装的时候可以按原来的位置安装，两
根螺杆不可以互相掉换位置。 。注：花键套的并帽靠近传动箱那端的是右旋螺纹
花键套的并帽靠近传动箱那端的是右旋螺纹，而靠近机头那
端的是左旋螺纹。
端的是左旋螺纹。

Continue to pull the screw shafts out until screw shaft project from the processing section. Lift
the screw shafts up evenly. 持续将螺杆拔出来，然后将其平稳地提升。

If only one hoisting device is used to dismantle the screw shafts, the projecting screw shaft
ends must be supported when passing over from the processing section. While partly
disassembled, the screw shafts are not allowed to be suspended. 如果只用一个起重设备来拆
卸螺杆，当螺杆被抽出到尾端地时候应该用支架将尾端架起来。拆卸到一半的时候，是不容许停
下来的。

Level the screw shafts with the hoisting gear and pull them completely out of the processing
section. Place the screw shafts on 3 wooden supports and secure them. 用起重机将螺杆保持水
平，并完全抽出。然后把螺杆放在3个木制支架上面，并保护起来。

The melt remains on the surface of shafts should be cleared away thoroughly. If the screw shaft
is not in use for some time, the user shall hang it vertically to avoid deforming. 螺杆表面残留的
熔体要彻底清理干净，如果有一段时间不使用螺杆，用户必须将它们垂直挂起来，防止变形。

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Item to be observed for screw shafts 必须遵守的条款

In any case, local heating of the screw shafts with a flame is to be avoided since this could
affect the hardened layer. At uniform heat distribution, the max. permissible surface
temperature is 450 °C for the screw shafts. Hard knocks and blows are to be avoided during
dismantling and transportation of the screw shafts to prevent deformation. 无论如何，应当避免
用火局部加热螺杆，因为这样可能会影响它的表面硬度，在正常加热的情况下，螺杆的最大允许
温度为450 °C 。螺杆在拆卸和运输的过程中应尽量避免敲打和撞击，防止变形。

8.6 Dismantling and fitting of the screw elements 拆卸和安装螺杆元件

Auxiliary equipment for dismantling and testing 辅助工具
• Wire brushes 金属丝刷子
• Spatula 抹刀
• Emery cloths of different grain size 不同粒度的纱布
• Oil stone 油石
• Mould separating oil or Molykote fitting paste 隔离油或二硫化钼润滑油
• Crack testing agent (Met-L-Check, Diffutherm or similar) 裂缝检测仪

Preparatory work 准备工作

The screw shafts and the screw tips must be dismantled before the screw elements can be
dismantled. 拆卸螺纹元件之前必须先拆下螺杆，并将螺杆背帽去掉。

Dismantling of the screw elements 螺杆元件的拆卸

Remove the eye bolts and disassemble the screw elements when they are warm. Use only
wooden hammer or copper bar to knock on thick edges of the screw elements slightly, but
never use shaft and rigid tools. If the material is too sticky or flows to the surface of shaft and
the screw elements are difficult to take out, the user can put the screw elements back into the
barrel again for heating up or heat them up with a blowtorch, until the material is melt and easy
to take out the screw elements. 拆下螺杆吊环，趁热将螺杆元件拆下来，不允许采用尖利淬硬的
工具击打，可用木棰、铜棒对螺杆元件有螺棱厚度的位置轻轻敲击。若物料过粘或渗入芯轴表面
致使拆卸困难，可将其重新放入筒体内加热升温，或用喷灯加热，待缝隙中物料软化后一般即可
将元件趁热拆下。

It is necessary to emphasize here that the last screw element should

never be removed from the shaft, because it is the benchmark for future
assembly.
有必要强调的是，
有必要强调的是，螺杆上的最后一个螺纹元件永远不能拆下来，
螺杆上的最后一个螺纹元件永远不能拆下来，因为它是重新
安装的基准。
安装的基准。

Cooling and cleaning of the screw elements 螺杆元件的冷却和清理

Remove any plastic material adhering to the screw elements after dismantling and allow them
to cool down slowly in calm air. 拆下螺杆元件后将残余的物料清理干净，然后让它们在空气中自
然冷却。

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The end surfaces inside splines of the screw elements should also be cleaned and put of shelf
without touching each other (use anti-rust grease on the surface of screw elements not in use).
拆下的螺杆元件端面及内孔键槽也应及时清理干净，整齐放置在备品架上，严禁互相碰撞（对暂
不使用的螺杆元件应涂防锈油脂）。

Checking of screw elements and screw shafts 螺杆和螺杆元件的检测

Should any elements prove to be difficult to remove, notwithstanding the measures described
above, they are to be marked. In addition, they are to be subjected to a crack test immediately
after cleaning. Magnetic crack testing is to be preferred. If this is not possible, a dye penetration
test can be carried out with agents such as Met-L-Check, Differential Thermal Analysis, etc. 虽
然上面介绍了拆卸方法，如果仍有螺杆元件很难拆卸，就要做上标记。另外，清理之后要对它们
进行裂缝检测，最好用磁性检测，但如果条件达不到，也可采用金属染色探裂,差热分析等检测方
法。

In case of long intervals between screw set changes, we urgently recommend that, in addition
to the above-mentioned elements, also the screw elements located in the melting zone or
immediately upstream or downstream thereof be checked. The area checked should cover not
only the element surface but also the fitting keyways. 如果螺杆更换的时间间隔很长，我们需要
提醒的是，除了上面所说的螺纹元件外，还包括融化段的元件或反向元件，检测范围不仅仅是螺
纹元件表面，还包括安装键槽。

If screw elements are warmed with a flame or if the intervals between screw set changes are
long, the screw shafts must also be checked for cracks. The teeth of the shaft coupling should
be included in this check. This does not affect the maintenance instructions for the machine
concerned. 如果螺杆元件直接是用火来加热的，或者螺杆元件更换的周期太长的话，需要检查
螺杆芯轴是否有裂缝检测，也需要检查联接芯轴的花键套。这不影响相关的保养说明。

Fitting of double-flighted screw elements 双头螺杆元件的安装

Screw elements are allowed to be fitted only after positioning of the screw
shafts!
安装螺杆元件之前，
安装螺杆元件之前，先将螺杆芯轴的位置固定
先将螺杆芯轴的位置固定！
螺杆芯轴的位置固定！

When fitting the double-flighted screw elements, pay attention to the mid-crest position of the
screw element with regard to start-screw which will never be removed. 在安装双头螺纹元件的
时候，要注意使螺纹元件的中顶部和起始元件对齐，每根螺杆的起始元件不可以拿下来。

Double-flighted screw elements are to be fitted congruently.

安装双头螺杆元件的时候要注意一致性。
安装双头螺杆元件的时候要注意一致性 。

8.7 Service and maintenance for gearbox 齿轮箱的维护和检查

Malfunctions that are caused by inadequate or improper maintenance can result in high repair
costs and unnecessarily long gearbox down times. Regular servicing and inspection work are
therefore imperative.
不充分的或不正确的维护造成的故障将导致高昂的维修费用和不必要的停机。定期维护和检查是
必须的！

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All servicing and repair work is only allowed to be performed with the
gearbox stationary and by trained, authorized and appropriately instructed
personnel. It is imperative that all safety instructions (chapter 4) are
observed.
维修和维护工作只能在减速箱停机状态下，
维修和维护工作只能在减速箱停机状态下，由被授权的， 由被授权的，经适当培训的人员进
行。必须遵守安全说明(第
必须遵守安全说明 第4章 章)。。

8.7.1 Servicing table 维护表

Work to be Frequency Comment

performed 次数 说明
需完成的工作
Check the oil Daily Excessively high temperatures are a sign of
temperature 每天 malfunctions or damage to the gearbox or the oil
检查油温 system. They reduce the service life of the oil and
can result in the premature failure of the gearbox.
过高的温度是故障，减速箱损坏或油润系统故障的
标志，将降低润滑油的使用寿命，缩短减速箱使用
寿命。
Check the noise Daily Changes in the noises made by the gearbox can
made by the gearbox 每天 be indicative of damage to the parts inside the
for changes gearbox
检查是否有异常噪声 异常噪声表示减速箱内部有零部件损坏。
Check the oil level Weekly An oil level that is too low can result in
检查油位 每周 inadequate lubrication of the gearbox and thus to
failure of bearing or gears
油位过低导致减速箱不能被充分润滑，导致轴承和
齿轮失效。
Check the gearbox Monthly Leaks that go unnoticed can result in inadequate
for leaks 每月 lubrication
检查是否有漏油 忽视漏油问题将导致润滑不充分。
First oil change After approx.250 See section 8.7.3
第一次换油 operating hours 见第8.7.3章节
大约在运行250小
时后
Subsequent oil Every 4,000 to See section 8.7.3
change 6,000 operating 见第8.7.3章节
后续换油 hours, at the
latest however
after 12 months
每4,000至6,000运
行小时后，但至少
每12个月
Visual inspection of Quarterly The visual inspection of the gears can be
the gears 每季度 performed by removing the inspection hole
目测检查齿轮 covers. In case of damage or irregularities, the
manufacturer must be consulted
打开检查视窗盖目测检查齿轮，如有损坏或异常，
应同制造商联系。

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Check used oil for Quarterly Unusually high quantities of foreign bodies, e.g.
foreign bodies and 每季度 metal particles can be indicative of damage.
coloration Coloration is a sign of reduced quality oil.
检查使用的油中是否 发现大量异常外来物，如金属颗粒，显示可能有损
有外来物或变色 坏。油变色表示油的品质已经降低。
Clean the air filter Quarterly Regular cleaning with suitable cleaning agents
清洁空气过滤器 每季度 prevents clogging of the filter
定期采用适当的清洁介质清洁，防止阻塞。
Check the oil filter quarterly Unusually high quantities of foreign bodies, e.g.
检查油过滤器 每季度 metal particles can be indicative of damage, it is
then necessary to replace the filter
如发现大量异常外来物，如金属颗粒，显示可能有
损坏，当然也需要更换过滤器。
Check the oil Before every oil The viscosity is to be found in the manual of
viscosity class change gearbox data sheet
检查油粘度等级 在每次换油前 油的粘度标注在说明书的减速箱参数说明中。
Clean the gearbox After every oil Prevents premature aging and undesirable
housing change corrosion
清洁减速箱箱体 在每次换油后 防止油过早老化和腐蚀。
Check all fastening Annually Checking all fastening bolts for tightness
bolts 每年 increases safety and reliability
检查所有紧固螺栓 检查所有紧固螺栓提高安全性和可靠性。
Service the complete Every 2 years Regular servicing by Keya Chemical Machinery
gearbox 每2年 after sales service enables worn parts to be
减速箱整机维护 replaced in a timely manner and thus ensures
long gearbox service life
定期由科亚成套装备售后服务人员维护并即时更换
磨损部件，延长减速箱使用寿命。

8.7.2 Topping up the oil 补充加注润滑油

The oil level is to be checked regularly. It must never be below the bottom mark. In the case
that the oil level drops below the minimum, it is imperative that the lubricant is topped up. The
oil is only allowed to be topped up with the drive units shut down.
定期检查油位。油位永远不能低于油低位标志线，如果油位低于最低线，必须补充加油。加油时
设备必须停机。
 A funnel with a filter is to be used for topping up (filter mesh 40um).
加油时，要采用带过滤器漏斗(40um过滤器精度)。

 The gearbox is always to be filled with the same type of oil as used previously (see section
8.1), It is not allowed to mix different oils or oils from different manufacturers.
始终采用同一种型号的润滑油(见8.1章节)，不允许混合使用不同牌号的油或不同制造商制造
的油。

8.7.3 Changing the oil 换油

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The effectiveness of the oil reduces with increasing use due to soiling (foreign bodies and
water) and chemical changes (ageing products). When the soiling and/or ageing is/are
excessive, it is necessary to change the oil. Regular oil analyses provide information on the
effectiveness of the gearbox oils. For larger quantities of oil it is recommended to make oil
changes dependent on the results of an oil analysis. A missed oil change increases the risk of
damage and can result in premature failure of the gearbox.
The first oil change should be made at approx. 250 operating hours. Subsequent oil changes
depend on the state of the oil and are to be performed every 4,000 to 6,000 operating hours,
however at the latest after one year.
由于污染物的增加(外来物和水)以及化学变化(老化)将降低润滑油的效率。当污染或老化超过一定
程度，就需要换油。定期对润滑油质量进行分析将提供润滑油润滑效率的信息。当使用大量润滑
油的情况下，是否换油取决润滑油分析结果。忽略定期换油将增加损坏的危险并导致减速箱过早
失效。
在减速箱首次运行250小时后需换油。以后换油时间将取决于油的状态，在运行4,000至6,000小
时内更换，但最晚在一年后更换。
 As a matter of principle the gearbox is always to be filled with the type of oil used
previously. It is not allowed to mix different oils or oils from different manufactures.
作为减速箱一重要原则，始终采用同一品牌，同一型号的润滑油。不允许将不同品牌或不同
型号的润滑油混用。
 A funnel with a filter must be used to fill the gearbox (filter mesh 40um). Dirt can result in
premature damage to bearings and gears.
采用带过滤器的漏斗加注润滑油(过滤器过滤精度为40um)。污染物将导致轴承或齿轮过早损
坏。
 When changing the oil ,the old gearbox oil is to be drained, if possible when still warm,
using the oil drain plug provided for this purpose.
当换油时，原齿轮箱中的润滑油应排出。如果齿轮箱处于热太并可能的话，从排油塞处排
油。
 The drained gearbox is to be cleaned of oil sludge, dirt and remnants of old oil using
flushing oil. The same type of oil is to be used here.
排完油后的减速箱应采用同种牌号的润滑油对其冲洗，清楚油泥和污物。
 On every oil change the oil drain plug is to be cleaned. If the plug is very dirty, the source of
the dirt is to be determined. There may be damage.
每次换油时，应清洗排油塞。如果排油塞很脏，必须对污染物进行辨认，可能有损坏发生。
 Also, on every oil change the filter element in the oil filter is to be cleaned or replaced, as a
dirty filter can degrade the reliable function and expected service life of the gearbox and the
oil system.
同样，每次换油时必须清洁油过滤器或更换。被污染的过滤器会降低可靠性及减速箱性能，
油润滑系统的寿命。
 The gearbox vent filter is also to be cleaned.
减速箱排气过滤器也应清洁。
 All instructions in section 8.1 are to be observed.
遵守章节8.1中的所有说明。
 When the oil is changed, all tooth flanks are to be visually inspected. In case of damage or
irregularities, the manufacturer is to be consulted.
当换油时，所有齿面均需检查，如果有损坏或有异常时，应同制造商联系。
 When refilling the gearbox, it is to be ensured that the oil level is in the area marked on the
oil sight glass. To ensure that the oil level is correct, after filling the oil system is to be
placed in operation for approx. 5 minutes so that the fresh oil can fill the pipes and the
cooler. If the oil level drops, the oil is to be topped up.

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重新加注润滑油时，油位必须处于油位视窗中的油位线范围内，确认油位正确。在加注润滑
油后，让减速箱运行大约5分钟以使新油能充满管道和冷却器。如果油位下降，必须补加
油。

It is imperative to ensure that no dirt enters the gearbox during the oil
change.
在换润滑油时必须确保无污染物进入减速箱。
在换润滑油时必须确保无污染物进入减速箱。

8.7.4 Inspection 检查

To counteract damage on the gearbox, regular inspections should be performed. The after
sales service department at Keya Chemical Machinery offers the following checks:
为防止损坏齿轮箱，应对减速箱进行定期检查。科亚成套装备公司服务部门将提供以下检查服
务。
 Checking the contact pattern on the individual teeth.
检查每一齿接触情况。
 Checking whether there is any damage to the parts of the gears, e.g.:
检查是否有损坏的齿轮部件。
- Pittings and micro pittings on the tooth flanks (due to gearbox overloading)
齿面上的点蚀和微点蚀(由于齿轮过载)。
- Scratches and indentations (due to the action of dirt)
擦伤和凹痕(由污物造成)。
- Fretting (due to inadequate lubrication or overload)
磨损(由于润滑不良或过载造成)。
 Visual inspection of the roller bearings
目测检查滚子轴承。
 Checking the oil supply to the meshing gears and to the roller bearings in the gearbox
检查润滑油对啮合齿轮和滚子轴承的润滑情况。

In case of damage, the related parts are replaced. Malfunctions are rectified. Please contact
our after sales service department.
如有损坏，相应的零部件将被更换，请同我们售后服务部门联系。

8.7.5 —causes and rectification 故障—

Malfunctions— 故障—原因及处置

Regular servicing of the gearbox, as described in section 12, is imperative. It is only in this way
that irregularities can be detected and more serious consequent damage avoided. If
malfunctions occur during the warranty period and repair is necessary, the after sales service
department at Keya Chemical Machinery is to be contacted. For repairs that were not approved
by Keya Chemical Machinery, no warranty or guarantee for the subsequent operation of the
gearbox can be provided.
按第12章所述定期对减速箱进行维护，只有这样才能发现异常，避免发生严重损坏。如果故障发
生在保修期内或需要维修，同科亚成套装备公司售后服务人员联系。对于未经科亚成套装备公司
批准的维修，将对接下来的运行问题不保修。

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The rectification of malfunctions is only allowed to be performed with the gearbox stationary
and by trained personnel. It is imperative that all safety instructions (section “3 Safety
instructions” ) are observed.
当对减速箱进行维修时，减速箱必须处于停机状态，并由经培训的人员进行。必须遵守所有安全
规则(第3章)。

For the trouble and trouble shooting ,pls see chapter 9.1
关于故障以及排除说明请见9.1 章节

8.7.6 Maintenace for plate heat exchager 板式热交换器的清理维护

If the cooling water contain a number of impurity, pls install at least 60 mesh Y shape filter in
front of inlet pipe of plate heat exchager. If the cooling water hardness is high, pls reduce the
hardness of water beforehead .对于含杂质较多的循环冷却水，在肋板换热器循环冷却水的进口
前应配置60目丝以上的y型过滤器。如果循环冷却水的硬度偏高，应预先将循环冷却水进行软化
处理。

Water way should be cleaned once per year. In high hardness water area,(e.g
shangdong ,Northeast of China district),every 3 months is recommend to clean water way 肋板
式冷却器循环冷却水侧一般每一年清洗一次。对于北方水质较硬的地区（如山东，东北等地
区），如使用未经水处理软化的循环冷却水，建议每3个月清洗一次。

After long time running, when the pressure difference between inlet and outlet was increased,or
low heating efficiency occurs,it is possible that the water way was built up by begrime.Cleaning
work is required immediately. 长时间运行后，水侧出现进出口压差增大或者传热情况不好时，
可能为循环冷却水通道积垢所致,应立即对其进行清洗。

Cleaning lotion ingredient percentage is (consistence and ingredient percetage are mass
percentage proportion) nitric acid corrosion remove lotion: 5% nitric acid solution=6：100,5%
(mass percentage) nitric acid solution, add 2 litre 68% nitric acid into 40 litre water. Flux
should be increased step bu step. First, wash through reverse direction.2 hours is required
according to output.Second ,wash through normal direction 2 hous,until the output is
enough.After acid wash, input pure water 1 hous until no turbid liguid come out. : 清洗液配方
为（所有浓度和配比均为质量百分比）：硝酸缓蚀剂：5％的硝酸溶液＝6：100， 5％（质量百
分比）的硝酸溶液配方为40升水加入2升浓度为68％ 的硝酸调配，清洗循环泵的流量由小逐步加
大，首先反向冲洗，根据出水流量的大小，循环2小时左右；其次正向冲洗2小时左右，直到出水
满意。酸洗结束后，置换清水清洗，时间约1小时，无混浊液体流出结束。

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Fig 15 cleaning chart 图15 除垢清洗示意图

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8.8 Table of lubricants 润滑油列表

Keya Chemical Machinery does not assume any responsibility with regard to the quality terms used by the above-mentioned companies for their standard lubricants.
Any liability is expressly excluded. The composition and name of the lubricants of the individual producers are subject to modification.The lubricants above-
mentioned are recommended by Keya Chemical Machinery. For further information see operating instructions of the suppliers. 科亚成套装备公司对下面提到的各公
司润滑油质量问题不承担任何责任。个别生产厂家的润滑油的成分和名称可能会有更改。更多信息请查看具体供应厂商的操作说明书。
Pos. ISO Mean viscosities
no. Description viscosity class mm²/s
EXXON
identification 40°C 100°C MOBIL
Lubricating oil CLP ISO VG 100 11 Blasia Degol Energol Mobilgear Spartan Renolin
1 acc. to DIN 51519 100 BG 100 GR-XP 100 627 EP 100 100
acc. to DIN 51502
Lubricating oil CLP ISO VG 220 19 Blasia Degol Energol Mobilgear Spartan Renolin
2 acc. to DIN 51519 220 BG 220 GR-XP 220 630 EP 220 220
acc. to DIN 51502
Lubricating oil CLP ISO VG 320 24 Blasia + Degol + # Energol Mobilgear * Spartan * + # Renolin *
3 acc. to DIN 51519 320 BG 320 GR-XP 320 + # 632 EP 320 320
acc. to DIN 51502
Dego BG * GR-XF 320 Mobilgear + # Renolin +
320PLUS* * XMP 320 320 PLUS
Hydraulic oil HLP ISO-VG 46 6.5 Oso Vitam Energol Mobil Nuto Renolin
4 acc. to DIN 51519 46 GF 46 HLP -HM 46 DTE 25 H 46 B 15
acc. to DIN 51502
Compressor oil VDL acc. to DIN ISO-VG 100 11 Dicrea Motanol Energol Rarus --- Renolin
5 acc. to DIN 51519 100 HE 100 RC 100 427 504
51502
Standard values acc. to DIN 51506
Hardly inflammable hydraulic fluid ISO-VG 46 4.5 Arnica --- Enersyn Pyrogard 53 T ---- Renosafe
6 acc. to DIN 51519 S 46 SF-D 0302 M Pyrotec DU 46
acc. to DIN 51502: GOM-20
HFD-U HFD 46
Hardly inflammable hydraulic fluid ISO-VG 46 10 --- --- --- Quaker --- Renosafe DU46
7 acc. to DIN 51519 or Quintolubric
acc. HFDU 7 (Hydraulic centeral
unit for underwater pelletizer) ASTM D-45 822-220

Fire XX FDU46 Plantoflux-AT-S

(FM-approval) 46 (FM-approval)
Fluid gear grease EP 0/00 DIN Constistency class Consistency class GR-LF 0 Aralub Energrease Mobilux --- Renolit
8 DIN 51818 0/00 GR SLL FDP 00 PR-EP 00 EP 004 SO GFB
51502 and DIN 51825/51826
Li-base grease 3 acc. to DIN 51502 Constistency class Consistency class GR-MU 3 Aralub Energrease Mobilux EP 3 --- Renolit
9 DIN 51818 3 GR-MU HL 3 LS 3 FWA 220
Performance
acc. to DIN 51825 EP 3 Beacon EP 3
Li-base grease 2 acc. to DIN 51502 Constistency class Consistency class GR-SM Multipurpose Energrease Mobilgrease Mehrzweck- Renolit
10 DIN 51818 2 GR-MU Grese F L 21 M Spezial Fett FLM 2
Performance acc. to DIN 51825
EP 2
Li-base grease 2 acc. to DIN 51502 Constistency class Consistency class --- --- Energrease Unirex EP2 --- Urethyn MP2
11 DIN 51818 2 MM-EP2
Performance acc. to DIN 51825
(Knife shaft bearing for underwater
Energrease SY Unirex S2
pelletizer)
2202

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Pos. ISO Mean

no. Description viscosity class viscosities
identification mm²/s
40°C
100°
C
CASTROL Shell / DEA TEXACO
Lubricating oil CLP ISO VG 100 11 Tribol Optigear Omala Meropa compound Meropa
1 acc. to DIN 51519 1100/100 BM 100 100 100 EP 100 100
acc. to DIN 51502
Lubricating oil CLP ISO VG 220 19 Tribol Optigear Omala Meropa compound Meropa
2 acc. to DIN 51519 1100/220 BM 220 220 220 EP 220 220
acc. to DIN 51502
Lubricating oil CLP ISO VG 320 24 Tribol * Optigear * + Omala * # Meropa + # Compound + Meropa
3 acc. to DIN 51519 1100/320 BM 320 320 320 EP 320 320
acc. to DIN 51502
Omala F +
320
Hydraulic oil HLP ISO-VG 46 6.5 Tribol Hydo Tellus Oil Rando Oil EP Hydrauliköl Rando Oil
4 acc. to DIN 51519 772 46 46 HD 46 46 HD 46
acc. to DIN 51502
Compressor oil VDL acc. to DIN ISO-VG 100 11 Tribol 890 Copo Corena Compressor EP Industrial oil Compressor
5 acc. to DIN 51519 Tribol ET 100 P 100 Oil EP 100 Oil EP
51502
Standard values acc. to DIN 1555/100 VDL 100 VDL 100
51506
Hardly inflammable hydraulic ISO-VG 46 4.5 --- --- Turbo Synstar --- ---
6 acc. to DIN 51519 HFD 46 Hydraulic
fluid
acc. to DIN 51502: GOM-20 HFD-U 46
Hardly inflammable hydraulic ISO-VG 46 10 Anvol SWX --- Irus DU 46 --- --- ---
7 acc. to DIN 51519 or FM 46 (FM-
fluid acc. HFDU 7 (Hydraulic
centeral unit for underwater ASTM D-45 approval)
pelletizer)
Fluid gear grease EP 0/00 DIN Constistency class Consistency Molub Alloy Onagel Alvania Marlak CP Grease Marlak
8 DIN 51818 class 0/00 00 GL 00 0/00 00 0/00
51502 and DIN 51825/51826
Li-base grease 3 acc. to DIN Constistency class Consistency --- Olit 3 EP Alvania Multilak Duralith Grease Multilak
9 DIN 51818 class 3 Olista RL 3 Premium 3 EP 3 EP 3
51502 Performance
acc. to DIN 51825 Longtime 3 Starplex EP 3
Li-base grease 2 acc. to DIN Constistency class Consistency Molub Alloy Olislamoly 2 Retinax Molylex Moly Grease Multifak
10 DIN 51818 class 2 BRB 572 EPX 2 EP 2 EP 2 EP 2
51502 Performance acc. to DIN
51825 Multilak EP 2 Dura Lith Greas
Li-base grease 2 acc. to DIN Constistency class Consistency --- Optitemp Albida HD2 --- --- ---
11 DIN 51818 class 2 HT2
51502 Performance acc. to DIN
51825 (Knife shaft bearing for
Olista Albida EP2
underwater pelletizer)
Longtime 2

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Pos. ISO Mean viscosities

no. Description viscosity class mm²/s
identification 40°C 100°C KLÜBER Sentinel
Lubrication Lubricants
Lubricating oil CLP ISO VG 100 11 Carter Gearmaster Klüber-Oil Wintershall ECO Gear ---
1 acc. to DIN 51519 EP 100 CLP 100 GEM 1-100 Ersolan 100 100 M
acc. to DIN 51502
Lubricating oil CLP ISO VG 220 19 Carter Gearmaster Klüber-Oil Wintershall Eco Gear ---
2 acc. to DIN 51519 EP 220 CLP 220 GEM 1-220 Ersolan 220 220 M
acc. to DIN 51502
Lubricating oil CLP ISO VG 320 24 Carter + Gearmaster Klüber-Oil + Wintershall * Eco Gear * ---
3 acc. to DIN 51519 EP 320 CLP 320 GEM 1 320 Ersolan 320 320 M
acc. to DIN 51502
Hydraulic oil HLP ISO-VG 46 6.5 Azolla Renolin Lamora Wintershall ---
4 acc. to DIN 51519 ZS 46 B 15 HLP 46 Wiolan HS 46 HLP 46
acc. to DIN 51502
Compressor oil VDL acc. to DIN ISO-VG 100 11 Dacnis Renolin --- Wintershall ---
5 acc. to DIN 51519 P 100 504 Wiolan CD 100 VDL 100-
51502
Standard values acc. to DIN VDL 100
51506
Hardly inflammable hydraulic ISO-VG 46 4.5 Hydronsafe Renosafe --- --- ---
6 acc. to DIN 51519 HFD-U 46 DU 46 ---
fluid acc. to DIN 51502: GOM-20

Hardly inflammable hydraulic ISO-VG 46 10 --- --- --- --- --- S-FRH 46
7 acc. to DIN 51519 or
fluid acc. HFDU 7 (Hydraulic
centeral unit for underwater ASTM D-45
pelletizer)
Fluid gear grease EP 0/00 DIN Constistency class Consistency class Multis Gearmaster Microlube --- Fliessfett ---
8 DIN 51818 0/00 EP 00 LI 400 GB 00 SGA 600
51502 and DIN 51825/51826
SGR 4-00-9 P
---
Li-base grease 3 acc. to DIN Constistency class Consistency class Multis Stabyl Centoplex --- Mehrbereichsfett ---
9 DIN 51818 3 3 L 120 3 LM 3 EP
51502 Performance
acc. to DIN 51825
Li-base grease 2 acc. to DIN Constistency class Consistency class Multis Lagermeister Unimoly --- Mehrbereichsfett ---
10 DIN 51818 2 MS 2 BF 2 GL 402 LM 2 EP
51502 Performance acc. to DIN
51825 Longlife -
GreaseHP 2
Li-base grease 2 acc. to DIN Constistency class Consistency class Ceran WR2 --- --- --- --- ---
11 DIN 51818 2
51502 Performance acc. to DIN
51825 (Knife shaft bearing for Multis Complex
EP2
underwater pelletizer)

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9 Trouble-shooting 故障排除
In the following tables, only those troubles of the units are described which can arise in
connection with the extruder operation. 在下面的表格中，将列出所有在机器运行过程中可能会
发生的问题。

9.1 Gearbox with oil circulating lubrication 油润滑齿轮箱

故障Trouble
故障 可能原因Possible
可能原因 cause 解决措施Action
解决措施
产生大量油沫 • 进气管漏气 • 重新紧固螺纹和法兰连接，必要时可以使
Great amount of oil Leakage of suction 用漏油监测器（噪音频率很高）
foam covering the oil pipe(air intake). Retighten screw or flange connections. If
in the gearbox • 防腐剂的残渣与齿轮油不 necessary, a leakage detector is to be
相容 used (high-frequency noise)
Residues of anticorrosive • 进行一次彻底的冲洗、换油
agents incompatible with Carry out an overall oil change. Flush
the gear oil used. the system.
• 采用另外一种型号的油
Use another type of oil.
• 添加抑泡剂，添加之前必须和润滑油的生
产厂家进行协商
Add foam depressant, however only
after having conferred with the oil
producer
• 油被杂质（尤其是化学物 • 请润滑油的生产厂家或有资格的实验室进
品）污染 Oil polluted 行红外线光谱分析，然后根据他们的意见
with foreign substance (in 进行处理
particular chemical Infrared spectral analysis to be made by
substances) oil producer or a qualified laboratory and
then proceed as recommended.
• 润滑油使用太久 • 换油Carry out an oil change.
Oil has excessively aged.
油变黑 • 使用太久 • 换油，最好在换油前经过分析
Oil is getting darker Oil has excessively aged Carry out an oil change. It is
recommended to have an analysis made
beforehand.
油变成乳状 • 油中含有水分 • 换油，找出掺水的原因并排除
Oil looks “milky” Water in oil (dispersed) Carry out an oil change. Find out and
eliminate the cause of water presence.
轴隙漏油 • 油位太高 • 将油位降低到规定的位置
Oil leakage at the Oil level too high Reduce oil level to values as specified
shaft passages • 回油管因沉淀物而变窄 • 检查回油管是否畅通并进行清理
Oil return pipe narrowed Check oil return pipe for free passage
down by deposits and clean them, if necessary.
轴隙漏油 • 密封问题 • 更换密封圈
Oil leakage at the Defective seals Remove seals and replace them.
shaft passages
• •

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故障Trouble
故障 可能原因Possible
可能原因 cause 解决措施Action
解决措施
• 油温太低 • 检测油温，按照需要升温
Oil temperature too low Check temperatures and increase them,
as necessary.
• 检查加热功能 Check heater function.
其他部位漏油 • 漏油部位：Leakage at: • 重新紧固螺纹或法兰连接，必要时更换密
Other leakage – 管接头pipe joints 封圈
– 连接件connections Retighten screw or flange connections
– 配件fittings replace seals if necessary.
• 密封或更换配件
Seal or replace fittings.
油过滤压差太高 • 过滤器堵塞：轴承、齿轮 • 检查清理过滤器并更换过滤网，如含杂质
Differential pressure at 或油泵内部磨擦产生的金 应分析其成分
oil flow filter too high 属屑 Clean filter or insert new filter element. If
Filter clogged with: there are mainly metallic particles
Rubbed-off particles from retained in the filter, have an analysis of
bearings and/or gear the components made.
teeth or from the oil pump
itself.
• 换油或更换过滤器时带入 • 检查维护过程
杂质 Review maintenance procedure.
Foreign matter introduced
during an oil change or
filter change.
• 油老化或沉淀引起成分上 • 缩短换油周期，彻底冲洗齿轮箱和润滑系
的改变 统
Oil components resulting Oil change to be carried out more
from aging and taken in frequently. Thoroughly flush the gearbox
from the oil sump. and the lubricating system.
• 油冷却器和管道的积留物 • 清洗或更换过滤器，必要时清洗油冷却器
Dirt and loose deposits Clean the filter or insert a new filter
from pipes and oil cooler. element. Clean oil cooler, if necessary.

• 油温太低或粘度太大 • 使用适当粘度的油
Oil too cold or basic Use oil with the prescribed viscosity.
viscosity of oil too high.
• Overflow valve stuck • 根据需要检查阀门并重新调节或更换
(damaged) Check valve and readjust or replace, as
溢流阀损坏 necessary.
油压太低 • 油过滤器堵塞 • 清洗油过滤器
Oil pressure too low Oil filter clogged. Clean oil filter.
• 润滑油的温度太高 • 检查油冷却器
Lube oil temperature too Check oil cooler.
high (sump temperature) • 检查冷却水的流量、温度等，必要时清理
油冷却器通水的那一端
Check cooling water flow/quantity/
temperature and, if necessary, clean oil
cooler on the water side.

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故障Trouble
故障 可能原因Possible
可能原因 cause 解决措施Action
解决措施
• 油的粘度不符合规格 • 使用粘度合适的润滑油
Viscosity of oil is not in Use oil with correct viscosity.
accordance with
specification.
• 油泵磨损，流速降低 • 拆卸油泵并进行检查，必要时更换其零件
Wear of oil pump, i.e. 或整个油泵。
reduced flow rate. Dismantle pump and check. Replace
pump parts or the whole pump, as
necessary.
油温太低 • 冷却水的量太大 • 检查冷却水控制器，必要时更换
Oil temperature too Cooling water quantity too Check function of cooling water
low great. controller and replace, if necessary.
• 冷却水控制器故障
Cooling water controller
defective.

油温太高 • 冷却水量不足或流速太低 • 检查冷却水循环系统

Oil temperature too Insufficient cooling water Check cooling water circuit for the
high quantity/flow rate defects described
• 冷却水温度过高 • 排除主要故障，清洗相关设备，必要时可
Cooling water 更换新的。检查测量系统。
temperature too high Eliminate the primary causes. Clean the
• 冷却水控制阀门故障 devices concerned or install a new one,
Defective cooling water as necessary. Check the measuring
control valve system.
• 热交换器有污积
Oil heat exchanger dirty
• 环境温度过高
Extreme ambient
temperature
传动箱的振动加剧 • 主电机和齿轮箱之间的连 • 在设备运转的时候检查主电机和传动箱之
Increasing 接不好 间的联接，必要时进行调节
deterioration in the Change in the alignment Check alignment of main drive motor to
vibrational behaviour between main drive motor gearbox with the machine at operating
of the gearbox and gearbox. temperature and the clutch engaged.
Realign, if necessary.
• 轴承或齿轮损坏 • 配备必要的检查设备，必要时更换损坏部
Bearing defect or gear 件As far as possible, examine through
teeth defect. the inspection operating, using an
endoscope, if necessary. Replace
defective parts, if necessary.
• 与底座间的连接松弛。 • 检查紧固元件并重新紧固，必要时考虑排
Loose connection to 列上的移动
foundation. Check the fastening elements and
retighten them, if necessary (take in to
account a possible change in alignment)

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故障Trouble
故障 可能原因Possible
可能原因 cause 解决措施Action
解决措施
• 外界震动通过机座传入传 • 通常可以通过振动的频率来判断问题原因
动箱 In general, this can be determined only
Ingress of external by a vibration or frequency analysis
vibrations in the gearbox,
via the foundation
震动 • 齿轮的齿或轴承损坏 • 通过齿轮箱上的视察口检查旋转部件
Knock Gear-teeth or bearing If necessary, visual check of rotating
defect. parts through the inspection openings in
the gearbox.
• 分析油的成分（通过光谱分析的方法），
要特别注意残留在过滤器上的金属屑的组
成，进而确定它们的来源。必要时更换有
缺陷的部件
Oil analysis (spectroscopic method). In
particular, check the composition of
rubbed-off metallic particles retained in
the filter (alloying constituents ) to
determine their origin. Replace defective
parts, as necessary.
• 从加工段传递过来的噪 • 这种情况通常发生在有大量颗粒或薄片混
音，比如：塑化段的捏合 合在一起的时候，它可以造成筒体温度升
块因塑化不完全产生噪音 高。检查螺杆元件的组合是否合适。
Noise transmitted from This occurs usually if a greater amount
the processing section, of pellets or flakes is mixed in. Increase
e.g. “knocking” of the the barrel temperatures before and in the
kneading block in the plasticizing zone. Check whether the
plasticizing zone, due to screw configuration is suitable.
insufficient plastification.
• 电机为变频调速 • 请教电机控制方面的专家，减小震动。
Speed pulsations in Confer with a specialist for motor control.
frequency-controlled In any case, pulsations are to be
variable-speed motor (if eliminated/reduced.
provided)

Elevated oil Oil level is too high Check oil level and adjust
temperature 油位太高 检查油位并调节
温度提高 Oil is too old Check when the oil was last changed and
油使用时间太长 if necessary have the oil analyzed and
change the oil
Oil is very dirty 检查上次换油时间，如果需要对油进行分析
油很脏 和换油
Cooling is insufficient Change the oil
冷却不充分 换油
Check the cooling system feed and return,
if necessary increase the cooling (higher
flow of cooling water, lower temperature)
Oil flow rate is inadequate 检查冷却系统输入和输出，如果需要增强冷
冷却水流量不足 却(提高水流量，降低冷却水温度)
Oil pump is faulty Check the feed and return, clean oil filter
油泵故障 or replace

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检查润滑油输入/输出，清洁油过滤器或更
换
Check pump, if necessary replace
检查油泵，如果需要进行更换。
Elevated bearing Oil level is too low Check oil level and adjust
temperature 油位太低 检查油位并调节
轴承温升 Oil is too old Check when the oil was last changed and
油使用时间太长 if necessary have the oil analyzed and
change the oil
Bearing faulty 检查上次换油时间，如果需要对油进行分析
轴承故障 和换油
Seek advice from Keya Chemical
Oil pump faulty Machinery after sales service
油泵故障 科亚成套装备售后服务联系咨询
Check pump, if necessary replace
检查油泵，如需要应更换
Noises Bearing or gear damage Seek advice from Keya Chemical
噪声 轴承或齿轮损坏 Machinery after sales service
Inadequate fastening to 科亚成套装备售后服务联系咨询
the foundation Re-tighten bolts, if necessary replace
基础未紧固 重新紧固螺钉，如果需要进行更换
Leaks Inadequate sealing Check radial shaft seals and other seals, if
泄露 密封不良 necessary replace, renew sealing of joints
(on this topic seek advice from Keya
Chemical Machinery after sales service)
检查轴轴向密封和其他密封，如果需要进行
更换，更换结合处密封(同科亚成套装备公
司售后服务联系)
Water in the oil Oil cooler faulty Repair/replace oil cooler
油中有水 油冷却器故障 维修/更换油冷却器
Condensed water Fit suitable thermal insulation, close vent,
冷凝水 moist air filter
安装适当隔热装置，关闭排气，空气过滤器
Elevated quantity of Bearing or gear damage or Seek advice from Keya Chemical
particles in the oil faulty oil pump Machinery after sales service
油中颗粒物增加 轴承或齿轮损坏或油泵故障 科亚成套装备服务部门联系
Oil foaming Oil incompatible with oil Change the oil
油起泡沫 residue 换油
油型号不同混合产生油渣
Operating temperature too Shut down plant, leave oil to de-gas, pre-
low heat oil to operating temperature (if
运行温度太低 necessary shut off cooling water feed
briefly)
关闭设备，让润滑油处于排气，预热至操作
Water in the oil 温度(如果需要，短暂关闭冷却水)
油中有水 Have the oil analyzed, if necessary change
the oil
分析油质量，如果需要进行换油

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Operating Instructions 使用说明书

9.2 Processing section 加工段

故障
Trouble故障 导致原因
Possible cause导致原因 Action 解决措施
螺杆或筒体磨损 • 运转过程中的磨损 • 正常现象
Wear /metal abrasion Running-in wear during Normal phenomenon.
on screws or barrels commissioning. • 检测过滤网前的金属碎屑，如果是试运
转造成的磨损，金属碎屑的数量将会不
断减少
Check magnetic fines in the screen. In
case of running-in wear, the amount of
metallic fines will constantly decrease.
• 无规律的加热或冷却会造 • 检测加热电路和加热器是否完好，如有
成加工段的变形 必要，检查冷却回路是否通畅
Distortion of the Make sure that heater shells to the
processing section due barrels. Check function of the (electr.)
to irregular heating/ heating elements. If necessary, check
cooling. the cooling circuit of the barrels for free
passage.
• 适当地减小或增大冷却水的流量
Shorted or extend the cooling pulse, as
applicable.
• 螺杆塑化效率低 • 升高温度或加强塑化段的螺杆组合，必
Insufficient plasticizing 要时请联系科亚成套装备公司的工艺工
performance of screw. 程师Rise temperature level for
processing section. Reinforce screw in
the plasticizing zone. If necessary,
confer with Keya Chemical Machinery
processing engineers.
• 粉末物料中的颗粒比例太 • 增加螺杆塑化段的背压，根据需要排列
大，螺杆组合不合适 捏合元件，并相应地升高温度
High percentage of Increase the screw back pressure in the
pellets with screw plasticizing zone. Kneading block
configuration for arrangement to be matched to
powders. requirements. Rise temperature level.
• 物料中含有因磨损造成的 • 使用耐磨的螺杆和筒体，优化螺杆组
掺杂成分。Abrasive 合。对于不同的情况，请咨询科亚成套
additives/ components 装备公司的工艺工程师
contained in the product. Use suitable screws and barrel sections
with wear protection. Optimize screw
configuration. For each individual case,
confer with Keya Chemical Machinery
processing engineers.
螺杆和筒体磨损 • 螺杆组合不合适 • 对于不同的情况，请咨询科亚成套装备
Wear/metal abrasion Screw configuration in 公司的工艺工程师
on screws or barrels general not suitable for For each individual case, confer with
the specific process or Keya Chemical Machinery processing
polymer. engineers.

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故障
Trouble故障 导致原因
Possible cause导致原因 Action 解决措施
• 螺杆元件安装错误 • 对于不同的情况，请咨询科亚成套装备
Wrong fitting of screw 公司的工艺工程师
elements. For each individual case, confer with
Keya Chemical Machinery processing
engineers.
喂料过程中出现的问题 • 容积密度太低。 • 增大容积密度。
Problems during intake Bulk density is too low Increase bulk density.
of components • 设备转速太低。Speed of • 增大转速。
the extruder is too low. Increase speed of the extruder.
• 挤出速度太高。 • 减小挤出速度。
Throughput rate is too Reduce throughput rate.
high.
• 气体逆流。 • 调整螺杆组合。
Backflow of gases. Adapt screw configuration.
• 在喂料区液化。 • 减少气膜
Fluidization in the feed Reduce gas blanketing.
zone.
• 喂料筒体粘料。 • 对喂料筒体进行冷却。
Sticking of components Provide cooling for feed barrel.
in the feed barrel.
• 料斗中发生架桥现象。 • 在料斗里面装上搅拌器。
Bridging of components Provide a vibrator on the hopper.
in the hopper.
螺杆摩擦筒体内孔 • 筒体对中不太好。 • 等加工段冷却后再对筒体重新对中。
Screw shafts “scrape” Processing section not Align processing section while “cold”.
the barrel bores. perfectly aligned
加工段产生爆燃 • 加工太潮湿的粉料。 • 使用干的粉料。
Extreme deflagration in Moist powder is Use dry powder.
processing section processed.
加工段弯曲变形 • 不规则的加热或冷却。 • 检查加热或冷却系统。
Processing section in Irregular heating/cooling Check heating/cooling system.
warped.
加工段振动 • 速度范围不合适。 • 轻微调整速度。
Vibration at processing Unfavorable speed range Change speed slightly.
section • 产量太低。 • 增大产量。
Throughput too low. Increase throughput.
筒体和螺杆元件被腐蚀 • 聚合物或其添加剂中含有 • 虽然加工段的腐蚀不是经常发生的，但
Corrosion on screw 腐蚀剂。 这是一个非常复杂的问题。对于不同的
elements and/or screw Corrosive constituents in 情况，请咨询科亚成套装备公司相关专
barrels the polymer or in 家。Corrosion attack in the extruder
additives. processing section does not occur very
often. However, this is a very complex
matter with reciprocal effects. In each
specific case, confer with Keya
Chemical Machinery specialist
regarding the measures to be taken.

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故障
Trouble故障 导致原因
Possible cause导致原因 Action 解决措施
噪音较大 • 设备空转（未润滑；干 • 喂入物料或及时切断开关。
Loud noise in the 转） Feed in product or switch the machine
processing section, for Machine running without off in good time.
example knocks, product (no lubrication;
rattling, creaking. dry running).
• 粉末物料中的颗粒太多。 • 减小颗粒比例；适当升高温度；增加塑
Too high percentage of 化段捏合块的背压。
pellets for a “powder Reduce percentage of pellets. Rise
screw”. temperature level before and in the
plasticizing zone by external heating.
Increase back pressure of the kneading
block in the plasticizing zone.
• 螺杆元件安装不正确。 • 检查并校正。
Screw set elements not Check and correct, if necessary.
correctly fitted on the
shaft
• 花键套松动。 • 检查花键套，使得螺杆和传动箱输出轴
Coupling between screw 之间紧密连接。
Shafts and output shafts Check screw shaft coupling. Retighten
of gearbox is loose. union nuts until the screw shafts fit close
• 螺杆偏移。 to the gear shafts.
Offset of screws.
筒体温度变化较大 • 没有设好温度控制器的脉 • 纠正控制器或控制程序。
Barrel temperature 冲持续时间。 Correct controller or controller program
varies considerable Temperature controller: accordingly.
around the set value cooling or heating pulse
duration not optimized.
• 聚合物有水分，塑化不稳 • 检测并减小湿气，特殊情况也可考虑改
定。 变螺杆组合。
Polymer contains Check polymer moisture and reduce it,
moisture, thus producing if necessary. In exceptional case,
pulsations in the reconsider and change screw
plasticizing zone. configuration.
• 排气系统不好。 • 检查排气口。
Vent system partly does Check vent port.
not function.
• 聚合物粉末中含有太多空 • 减小容积密度的变化，检查喂料系统的
气或容积密度变化较大。 排气；如有需要调整螺杆组合，请与科
Bulk density of polymer 亚成套装备公司协商。
varies strongly or too Reduce bulk density variation. Check
much air contained in the venting of polymer feed system (vent
polymer powder. lines and/or filter equipment). Adjust
screw configuration .For this, please
confer with Keya Chemical Machinery.
输入功率变化较大 • 短期内的喂料不均匀。 • 检查喂料机并优化喂料精度。
Major variations in Polymer feed varies Check feeder and optimize feed
power input. within short cycles. precision, if necessary.

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故障
Trouble故障 导致原因
Possible cause导致原因 Action 解决措施
• 物料较潮湿。 • 检测湿度，减少含水量。
Feed product is wet. Determine the degree of moisture. Take
measures to reduce moisture.
• 喂料段物料液化。 • 减小压力；改善喂料系统的排气状况；
“Fluidization” of feed 加强喂料筒体的冷却；特殊情况下，也
product. 可以优化螺杆组合或排气系统。
If necessary, reduce nitrogen blanketing
and pressure. Optimize venting for
polymer feed line. Provide more
intensive cooling for feed barrel. In
exceptional cases, optimize screw or
vent system.
• 喂料系统发生架桥。 • 用适当的方法消除架桥。
Bridging in the feed Bridging to be eliminated by suitable
system. measures.
筒体连接处漏料 • 螺栓的预紧力不够或因长 • 清洗筒体端面，更换新的螺栓。在第一
Polymer leakage at 期的加热和负载的变化所 次加热后，需要重新拧紧螺栓。如果没 如果没
barrel section joints. 引起的应力减小。 有清除掉所粘的物料，
有清除掉所粘的物料，只拧紧螺栓不能
Tightening torque for 解决问题。Clean
解决问题 barrel faces and
bolts too low/initial stress remove any polymer adhered. Place
diminished due to long- new bolts. After first heating-up, these
term temperature bolts are to be retightened.
influence and load Retightening of bolts without revoval
changes. of polymer will not solve the
problem!

• 筒体端面有损坏或不平 • 在磨床上重新磨平筒体端面。
滑。 Regrind the barrel faces on a grinding
Barrel faces damaged or machine.
uneven.

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故障
Trouble故障 导致原因
Possible cause导致原因 Action 解决措施
不能很好的排出聚合体 • 未连接真空泵。 • 连接真空泵。
中的挥发物 No vacuum pump Connect vacuum pump.
Degassing of volatile connected.
matter in polymer not • 真空不够：真空系统有泄 • 用泄漏探测器查找泄漏部位并进行紧密
satisfactory. 漏。 处理。
Insufficient vacuum due Localize leakage with a leakage
to: Leakage in vacuum detector and make tight.
system
• 进气管堵塞。 • 清理进气管。
Clogging in suction pipe Clean suction pipe.
• 真空泵故障。 • 检查泵的抽气管路。
Defect of vacuum pump. Check pump suction line.
• 维修有缺陷的管道。
Repair any defect found.
• 熔体温度太低。 • 升高熔体温度。
Temperature of polymer Increase melt temperature.
melt is too low.
• 挤出速度太快。 • 渐渐减小挤出速度，并检测结果。
Polymer throughput rate Reduce throughput rate gradually and
is too high. check the result.
• 螺杆组合不合适。 • 调整螺杆组合。
Screw configuration is If necessary, change screw
not suitable. configuration.
排气筒体直接通向空气 • 喂料量太高。 • 降低喂料量。
是不安全的。物料从开 Throughput rate of Reduce throughput rate.
口漏出。 extruder too high.
Vent barrel open to • 挤出压力太高。 • 根据情况降低产量或调整螺杆组合，必
atmosphere is not safe. Pressure built-up too 要时请先计算一下背压。
Product comes up. high downstream. Reduce throughput rate or adapt screw
configuration accordingly. If necessary,
a backpressure calculation is to be
made beforehand.
• 排气口接头不合适。 • 安装合适的排气口接头，必要时请咨询
Unsuitable vent insert. 科亚成套装备公司。
Mount a suitable vent insert; if
necessary, confer with Keya Chemical
Machinery.
• 日常清理工作不够。 • 保证日常清理工作。
Insufficient cleaning Optimize cleaning routine.
routine.
• 螺杆转速太低。 • 在可变速驱动的情况下，选择更高的转
Screw speed too low. 速。
In case of shiftgears or variable-speed
drives, use a higher speed.

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故障
Trouble故障 导致原因
Possible cause导致原因 Action 解决措施
筒体温度开始保持正 • 加热器或保险丝故障。 • 检查加热器、保险丝。检查加热器和筒
常，然后突然降低。 Heater shells/heater or 体的连接，换掉损坏了的加热片。
Electric heater. The fuses defective. Check electric function of heater
indicated barrel shells/heater. Check fuses. Check
temperature level, heater shells for good contact with
which first has been barrel. Replace defective heater shells.
correctly maintained, • 控制器故障 • 检查控制器并进行调节，必要时更换新
drops. Controller defective. 的。
Check controller and readjust or
replace, as necessary.
• 热电偶和筒体之间的接触 • 检查热电偶，使之与筒体接触良好。
不好。 Check thermocouple for good contact.
Faulty contact between
thermocouple and barrel.
• 筒体冷却系统的阀门未关 • 检查阀门；按需要清理或更换阀门。必
闭；阀门有脏物。 要时也要检查旁边筒体上的阀门。
Valve of barrel cooling Check solenoid valve; clean or replace
system does not close valve as necessary. If necessary, also
and continuous cooling check valves of the adjacent barrels.
water flow is possible.
Valve is dirty or valve
seat is defective.
• 控制阀故障。 • 检查控制阀。
Pilot valve defective. Check pilot valve.
• 聚合物的吞吐量增加，而 • 相对这样的吞吐量，螺杆强度不够，尤
相应的机械强度不够。 其是塑化段的强度。
Increased polymer Screw is too weak for this throughput,
throughput rate and thus especially in the plasticizing zone.
insufficient input of
mechanical energy.

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Operating Instructions 使用说明书

9.3 Die head 机头

故障
Trouble故障 导致原因
Possible cause导致原因 解决措施
Action解决措施
密封面漏料 • 螺纹联接预紧力不足。 • 以正确的力矩紧固螺钉。
Leakage on the Screw tightening torque Retighten with specified torque.
sealing surfaces not correct.
• 密封表面损坏或弄脏。 • 拆开进行清洗或维修。
Sealing surface damaged Open unit and clean or repair.
or dirty.
未达到操作温度 • 加热设备连接不正确。 • 参照接线图检查电路连接。
Operating temperature Heating equipment not/ Check electrical connection - see wiring
not reached not correctly connected. diagram.
• 加热器有缺陷。 • 检查加热器，必要时更换。
Defective heater shell. Checking and, if necessary, replace
heater shell.
• 加热器功率太低。 • 更换加热器。
Heaters with too low Replace heater.
capacity installed.
• 加热控制器故障。 • 更换控制器。
Heater control Check heater control.
defective/not adjusted
挤出物料不均匀 • 温度控制不正确。 • 纠正温度控制。
Non-uniform melt flow Temperature control not Correct temperature control.
at the die strip correct.
• 设备内部有脏物。 • 打开并清理。
Dirt in the unit Open and clean.
高背压 • 过滤网堵塞。 • 更换过滤网。
High back-pressure Screen clogged Change screen.
• 温度未达到：塑料没有完 • 等待温度升高。
全熔融。 Wait until operating temperature is
Operating temperature reached.
not yet reached: plastic
material not completely
molten

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9.4 Pelletizing section 切粒部分

Pelletizing method Trouble Possible cause and Action
切粒方式 故障 可能的原因和解决措施
Strand pelletizing • Strands are too thin or too • Reduce or increase the pelletizer speed,
Ø3 x 3 column shape thick. clean the die plate.
pellets3 料条太细或太粗 减小或增大切粒速度，清理模板。
水冷拉条切粒
Ø3 x 3 圆柱形 • Lengths of pellets are • Fix the position of feeding strands, avoid
not in uniform. strands to sway.
切出的粒子长短不均匀 固定料条的喂入位置，避免摇摆。
• End of pellets is not • Adjust the clearance between rotating
smooth. knife and fixed knife.
粒子端面不光滑 调整动刀和定刀之间的间隙。
• Pellets shape is flat. • The pressure of roller is too heavy.
切出的粒子成扁平状 Adjust the air pressure or spring
pressure.
压辊的压力太大，调节气压或弹簧压力。
• Strands cannot be cut off. • The temperature of strands is too high.
料条不能切断 Increase the distance between main
machine and pelletizer, or add another
air knife, or increase cooling water
circulation in the tank.
料条温度太高，增加主机和切粒机之间的
距离，或增加一个风刀，或加快水槽冷却
水的循环速度。
• Strands broken easily. • Materials are not well plasticized or too
容易断条 many contaminations, or change screw
configuration.
物料塑化不完全或含太多的杂质，或考虑
螺杆组合是否合适。
Air-cooling • Lengths of pellets are not • Some holes of die plate are blocked,
pelletizing in uniform stop the machine and clean die-head.
Φ3×3mm 粒子长度不一 When the melt comes out in same
Tablet or ball speed, start up the pelletizer at low
风冷热切 speed and increase to normal speed.
Φ3×3 药片状或球状 局部出条孔堵塞，停机，拆下模头快速
清理。等模头出料均匀再从低速启动切
粒机至正常转速。
• Pellets stick to each • Check if the knives touch close to die-
other. face and if the knife stick shakes. If the
粒子粘在一起 melt temperature is too high, reduce the
temperature of each zone or spray
water.
检查刀具是否紧贴模面，刀杆是否摆
动。料温过高，适当降低各区设定温度
或补喷水雾。

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Pelletizing method Trouble Possible cause and Action

切粒方式 故障 可能的原因和解决措施
• Products cannot come • Take off the first elbow pipe to clean,
out from the cyclone keep the pipes smooth.
separator. 拆下风管第一节弯头，及时清理，保持
旋风分离器不出料 管道畅通。
• End of pellets is not • Mill or change the knives. Check if all
smooth. knives touch close to the die-face.
粒子端面不光滑 修磨或更换切刀，检查是否所有的刀片都
贴紧模面。
Water-ring • Lengths of pellets not in • Could be some holes of die plate may
pelletizing uniform. blocked, so clean the die plate.
Similar to small balls 粒子长短不一 可能是部分出料孔堵塞，清理模板。
of φ3mm
水环造粒
近似φ3球形
• Pellets stick to each • Check if the knives touch closed to the
other. die-face or melt temperature is too high.
粒子粘在一起 So reduce the temperature of each zone.
检查切刀是否紧贴模面或者熔体温度太
高，降低各区温度。
• End of pellets is not • Mill or change the knives. Check if all
smooth. knives touch close to the die-face.
粒子端面不光滑 修磨或更换切刀，检查是否所有的刀片都
贴紧模面。
Under-water • Pellets stick each other • The temperature of die-head too high,
pelletizing and block the pipe. adjust the pelletizer speed and cooling
Similar to small balls 粒子粘在一起并堵塞了管 waterflow to match the output.
of Φ3mm 道 模头温度太高，调节切粒速度和冷却水的
水下造粒 流量，与主机的产量匹配。
近似Φ3 mm球形
• Melt does not come out in • Some heater pipes are not working
same speed. properly. Contamination in the melt.
模头出料不均匀 Main machine output too low.
局部加热管损坏；物料中含有杂质堵塞模
孔；主机产量过低。

9.5 Screw shaft seals 螺杆尾部密封

Trouble Possible cause Action
故障 导致原因 解决措施
Screw shaft seal is • Stuffing box packing is • Retighten screws on stuffing box
getting too hot or leaks. defective. packing. Replace stuffing box packing if
螺杆尾部密封过热或泄 密封压盖或填料环的问 necessary.
漏。 题。 拧紧密封压盖上的螺丝，必要时更换密封
填料环。

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10 Spare parts 备件

10.1 Spare parts inventory 备件清单

The operator must keep an inventory of needed spare parts in stock in order to assure that the
unit operates smoothly and without unnecessary downtimes. 为了保证设备的正常运行，避免不
必要的停工，操作人员必须对需要的备件做一些库存。

We will only warrant the original spare parts supplied by Keya Chemical Machinery . Installation
and use of spare parts not supplied by us will void the warranty on the part of Keya Chemical
Machinery 我们只担保科亚成套装备提供的原始备件，如果安装或使用了非科亚成套装备所提
供的备件，科亚成套装备将不承担任何责任。

SPARE PARTS SUPPLY AND SERVICE ADDRESS 备件供应和服务地址

NANJING KY CHEMICAL MACHINERY Co., Ltd. 南京科亚化工成套装备有限公司
No.9 Liquan road, Jiangning science park, jiangning, Nanjing, China
地址：中国南京江宁科学园醴泉路9号 邮编：211103

Sevice Phone售后热线电话: +86-25-52706158

Fax传真: +86-25-52706166
10.2 Ordering spare parts 备件的订购
To ensure quick and smooth handling of your spare parts orders, we request you to provide us
with the following data: 为了便于我们快速、顺利地处理贵公司的备件订单，请提供下列资料：

1. Machine type 机型
2. Year of construction of unit 生产年月
3. Machine’s order number 设备编号
4. Part designation (Name) 零件描述

You will find the data regarding points1, 2 and 3 on the name plate of the corresponding unit.
The data regarding point 4 can be found on the spare parts list, or you can send photos of the
damaged parts to us to confirm. 关于1，2，3点的内容可以从设备的铭牌上得到，第4点的内容
可以参考备件清单，您也可以将损坏零件的照片发给我们，以便确认。

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备忘录 Memo ：

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