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									FLUID BED GRANULATOR AND
         DRYER
      MODEL: DBL1
   OPERATION MANUAL




                         CIMA Industries Inc.
                    Pharmaceutical Equipment
                                          CONTENTS


      1、SAFETY INFORMATION .............................................................. 1

      2、MAIN SPECIFICATIONS AND TECHNICAL PARAMETERS ........... 3

      3、MAIN FEATURES ......................................................................... 4

     4、WORKING PRINCIPLE .............................................................. 12

     5、INSTALLATION & DEBUGGING ................................................. 16

     6、OPERATION & USE .................................................................... 20

     7、MAINTENANCE.......................................................................... 47

     8、TROUBLESHOOTING ................................................................. 48




1. SAFETY INFORMATION
     In order to avoid any accident, you must understand the operation and maintenance of
 this machine fully. Please read it carefully and understand all the contents of this manual, as
 well as all the safety warning messages.
   For example:
                                           !
                                          !!Warning!!   !
                         Please cut off the power supply before disassembly.


   Read and understand the warning content carefully
   Before operation, please confirm that all the accessories are installed rightly
    Before operation, please confirm that all the movable components have no contact and
friction with the sensor.
   If it is thought that there is some trouble, please don’t try to operate the machine.


   Working Process
  In the process of using the equipment
                                         !
                                        !!Warning!!    !
     Please pay attention to clean the hard substance in the powder material and bond, to
     avoid destroying the peristaltic pump head, silicone tube, sieve, etc. in the process of
                                             work.

   Installation
                                         !        !
                                        !!Warning!!
    If the installation of equipment is done in places with explosion danger, please check the
parameter panel,
    and confirm that the machine has been done the protection setup for explosion
                                         !        !
                                        !!Warning!!
   Before electrifying the machine, please confirm that the voltage and rating frequency of
power supply is right.
   The installation of circuit must be done by the qualified electrician who has a proficiency
certifícate




                                            Important

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                                                 1
  After finishing the installation, please check whether the rotating direction of induced draft
blower is right.
 Through fair and foul, to prize, beat and knock on the outside surface of this machine with
something hard is strictly forbidden.


      Assemble
                                         !
                                        !!Warning!!      !
                        Before assembling it, please cut off the power supply
      Disassemble
                                         !
                                       !!Warning!!      !
                      Before disassembling it, please cut off the power supply
      Cleaning
     All the incompact components must be washed with clear water and suited detergent
     Wipe the shell of this machine with wet cloth (which doesn’t lose hair)


                                       !
                                      !!Warning!!     !
         Please don’t wash the components in the control cabinet using the tube directly,
                                 which will lead to short circuit




2、MAIN SPECIFICATIONS AND TECHNICAL PARAMETERS


Fluid Bed Granulator and Drier DBL1                                              Operation Manual
                                                 2
Throughput                 L                                        0.2~1

Air volume              M3/h                                          170

Pressure                  Pa                                        14000

Voltage                   V           three-phase 220V            frequency Hz                  60

Fan power                Kw           0.85 KW                     Rating speed r/min           2850
Electric heating          ℃           Normal temperature      ~ Power Kw                        2.4
                                      120℃                        Consumption
Compressed air          Mpa           0.4~0.6                                                  0.25
                                                                  m3/min
Air inlet
                          ℃           automatic control, automatic display
temperature

 Noise                  db            Less than 63 db
outline
                        mm            1300×650×1700
dimension
(L×B×H)
Net weight        of
                        Kg            250
equipment




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                                                     3
3. MAIN FEATURES


    Multi-function Fluid bed lab machine DBL1 is a newly developed multi-purpose fluid bed
device. The apparatus integrates flexibility and applicability into its design, able to realize
processes of drying, granulating, spheronization, coating and dressing in the same equipment.
It is applicable to two various processing approaches in accordance with different processing
purposes, that is top spray and bottom spray, and the difference lies in modes in material
fluidization and spray liquid supply. Therefore each process has its distinctive capability, wide
application range, and the whole process is intuitionistic and foreseeable.

  Note: this equipment is only equipped with top spray technology, so only
needing to consult the section of the top spray technology.


3.1 Top spray process
     Upon the push action of inlet air flow, the material makes up and down movement
  repeatedly in the chute, to form a fluid state. But this state is irregular and not under strict
  control. The spray liquid is supplied into the system via a spray nozzle of the extension
  chamber. The material, spray liquid and hot air flow then take shape and get dried. (Image
  1)




                                                      Imag 1




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Main application of top spray

     1) Drying and spraying

     The fluid bed is a good drying facility. The granule floats in the air in the process of
fluidization, and its surface is in full contact with hot air, to reach the best heat exchange
status, which ensures the granule to be evenly heated and surplus moisture can then equably
evaporate, avoiding excessive heat on partial areas. When the material temperature is a bit
above the room temperature, higher inlet air temperature can be used to quicken the drying
speed.

     Compared with bottom spray and tangent spray, top spray is more suitable for drying. If
only for the purpose of drying, the equipment becomes a fluid bed dryer when the spray gun
is removed off.



     2) Granulating

      Purposes of granulating are as follows:

     To reduce fine dust;
     To improve fluidity;
     To avoid delaminating;
     To improve the compressibility of granules;
     To change bulk density.
     To improve breakup, help to dissolve.
    With higher requirement over medicine quality, stricter control has been placed on the
parameters related with quality information. To speak of troche, these key parameters for final
control are: weight, brittleness, breakup, and dissolution, etc., which are directly related with
the quality of manufactured granule. If the granule is of even distribution and good fluidity, and
the difference in weight is small, which helps to improve the hardness, to lower brittleness and
to facilitate breakup and dissolution, etc.

   In the process of granulating, to ensure even granularity of final granules, the spraying
range of the spray gun must meet the maximum range in material fluidization, so as to avoid
excessively dry or damp spraying liquid on the wall or in the material and to form uneven
granularity of final products.



  3) Making instant granule

   Fine powder is easy to dissolve, but dust is bigger with poor fluidity. To eliminate those
drawbacks, it is better to make powder into instant granules.
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   Instant granule is a substance easy to dissolve in water or other solvents in soon time,
which must possess the features below: a. higher dispersibility;b. Wide hole clearance in
granules, easy for water infiltration. It has been widely used in pharmacy industry like dosage
and in food industry like instant drinks.



    Fluid bed granulating: the inlet air flow pushes the material to move upward. In top spray,
the bond is sprayed in via the spray gun from upper to lower, atomized into very fine liquid
drops, and its spray direction is opposite to that of material movement. The material is
conglutinated together upon action of the bond, thus causing a bigger and bigger bulk, finally
forming sizable granules. Surface of these granules is very rough, with much hole clearance
inside, and it is easy for solvents like water to penetrate into, so as for possible instant
dissolution.

      4) Coating

      On top spray coating, mainly applicable to the following aspects:

a. To separate heat;
b. To cover flavor, to improve poor medicine taste;
c. Resistant to oxidization and dampness, to extend storing time of medicine;
d. To improve appearance.
e. To hot melt coating.
    In the process of coating, spray the liquid to the densest area of moving material to be
coated, so that the distance between the spray liquid and the granule can be minimized, able
to make the spray liquid well paved on the granule surface, to form into even and continuous
coatings without any broken layer




3.2 Bottom spray

    Bottom spray is additionally configured in the chute with a distance spacer ,whose upper
and lower ends are open cut and a corresponding
screen of various pores, so as to control the material
movement in orderly fluidization. The liquid is sprayed
into the system by means of a pneumatic nozzle


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                                               6
                                                                                      Image 2
mounted in the center of the sifter plate, and the spray direction is opposite to that of material
movement. There is some distance between the distance spacer and the sifter plate to ensure
the material smoothly form a circular flowing movement state from the outside of the distance
spacer to the inside, (Image 2)

It coated granule passes by distance spacer, and begins to slow down at the extension chamber.

When the granule rises to the extension chamber, surplus media will be evaporated. When the
air flow speed is not enough to push the granule in movement, the granule will again return to
the clearance between the distance spacer and the chute, where the air flow is just enough to
push the granule in downward movement and to remain a weightless floating state. The
granule moves horizontally from the area between the distance spacer and the chute to the
coating area, thus forming a movement cycle, which is realized by means of correctively
adjusting the clearance between the bottom of distance spacer and the sifter plate. The
granule passes through the coating area in several seconds, and finishes a complete movement
cycle.

     It is of great significance to make good adjustment on flow of fluidizing air, height of the
distance spacer, atomizing pressure and flux, as well as temperature of the coated material
during the process.

   The spray gun is mounted on the central bottom of the sifter plate with the head upward,
spraying liquid from upper to lower. The spray direction is same as that of material movement.
The bottom spray device is mainly suitable for coating.

    The bottom spray is to spray liquid in same direction, and the spray direction of coating
liquid is in compliance with the direction of particle movement, fast, constant and even in
general case. As the coating liquid is sprayed on the particle surface which moves regularly
around the nozzle, the spay liquid is in a close distance from the nozzle to the coated material,
and the formed coating is good, continuous and compact.



   The material moves to and fro in the bottom spray device, whose fluidized state is very
regular. The interval for fluidized granule to pass through the spray liquid fog is also regular.
The pavement of liquid fog is also uniform, and the formed coating is homogeneous without
any bore, unlike top spray, which causes coatings in poor performance due to out-of-order
movement.

   The bottom spray is mainly applied in all films: covering film, taste masking film, enteric
coating, slow release coating, etc. Moreover, the coating is of good quality, evenly distributed
and taste-masked as well as with improved appearance.



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3.3 Tangent spray process

    Due to the unique construction, the tangent spray has certain obvious advantages in certain
applications. It is applied more and more in
production and scientific researches nowadays.
Tangent spraying device adopt a rotating wheel
without opening that can move up and down to
replace mesh plate. The rotating wheel locates at the
bottom of material bin, while stops, the edge of
rotating wheel clings to inner wall of material bin,
                                                                                         Image 3
while starts, the rotating wheel is elevated to
generate a clearance between rotating wheel and
material bin wall to allow air flow passing. (Image 3) The clearance between rotating wheel
edge and material bin wall can be adjusted by adjusting the elevation of rotating wheel, thus to
adjust the air flow entering material bin without changing the speed of air flow.

   This essential feature ensures direct granulation or coating with powder, because in these
two production processes, the inlet air is required to have min. drying to material thus to make
material bind closely under rather wet conditions, and the drying speed/ratio must be kept
under low level. However, in granulation or coating, the medium is required to be quickly
evaporated, which can be realized by raise the elevation of rotating wheel and increase air flow
volume.

   Spraying liquid is supplied into the system through the nozzle on the sidewall of the Chute,
whose direction is the same as that of material movement, spraying in tangent shape.




      The movement of material in Chute is twist / coil, even, order. It is formed depending on
the action of three forces: material moves downwards upon the action of its own gravity; the
upwards airflow through the clearance of turntable and Chute let materials move upwards; the
centrifugal force of turntable while revolving makes materials move around the turnplate, the
resultant force of three forces make materials move helically.

   Tangent spray is quite similar to bottom spray; they share three major physical features:
a) same direction spray, nozzle is buried inside material; therefore, the travel of liquid drop is
the shortest. b) The probability of fluidized particle passing atomized liquid is equal. c) In
spray area, the particles are highly concentrated.


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                                                8
   Due to these features, the coat formed in tangent spray is even and continuous in quality, it
has the same good quality coat as the bottom spray, and it has been successfully applied
Tangent spray is mainly used in following aspects:
   a) Granulation:Tangent spray granulation is a process of granulation by putting in binding
agent, the huge friction force produced in movement of rotating wheel has made the density of
particle is much higher than that of particle formed in common fluidized bed facility (top spray).
Besides, due to the movement of rotating wheel, the wheel bottom keeps rubbing the particle
surface, which forms round and smooth surface particles.

    b) Pellet spheronization: Compare pellet spheronization with granulation, the former has
higher intensity and more compact than granulation. The difference with granulations:
Humidity increased in production process while controlling parameters, and changed bigger
rotating wheel with larger friction at the same time, the main purpose of pellet spheronization
with tangent spray is: to improve density, spheronization and make surface smooth.

    c) Solvent & suspension coating: Coating indicates coat a layer of material onto a small
pellet, such as blank pellet or regular crystal, so as to obtain certain weight, grain size or
content. Material will be made solvent or suspension, added in via spray unit. This solvent or
suspension can be also used as binding agent.The purpose: Mainly for making high efficacy
pellet or carrying on slow release coat.

   d) Powder coat: The difference between powder coat and solvent or suspension coat is:
the active medicine is added in by form of solid powder, additional binding agent is
required.The active powder and binding agent is sprayed into material bin simultaneously, the
binding agent is sprayed onto the surface of pellet, making it wet and adhesive and the active
powder will be stuck onto the pellet, so as to dry the pellet surface, as well as avoid binding.



   The optimum status of the coating process is: the spray of binding agent and active powder
shall be in proportion, excess binding agent or less powder will cause wet, and lead to binding
among pellets. Less binding agent and excess powder will cause excessive dry and lead to
excess powder residue inside material bin. Apart from these, the adding speed of both
materials must not be slow, it will prolong the production cycle. Correctly control each
parameters in process is able to produce super high efficacy pellet or carry out slow release
coating in a short period of time.

    Coating: Its process is similar to solvent and suspension coating, often used in slow
release coat, enteric coat, release control coat, on time release coat, thermal fusion coat, etc.



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3.4 Fluid bed coating

    For some solid preparations in pharmacy industry, some leechdom needs coating to
provide the required feature of release. Coatings to crystal and granule cam be slow release or
control release films, taste masking, enteric, enhance stability or improve appearance.

     Coating means applying a layer of film around the material of certain shapes for some
purpose. The basic process is: when the granule passes by coating area, the coating liquid is
sprayed on its surface, forming small blocks of coating films, finally to coating the whole
surface. During the whole process, different procedures happen almost at the same time, such
as liquid drop forming, granule contacting, paving and extending on granule surface, joining
between liquid drops, as well as media evaporation. As small block of film continuously and
repeatedly be coated on the granule surface, the coating thickness increases steadily. (Image
4) Evaporating and dehydrating




                                         Evaporating and dehydrating

                        Granule Core
                                                     Coating liquid,drop preparation
                       Penetrating
                                            Contacting
                                            Paving and Extending
                                            Coagulating




                         Illustration of coating movement (Image 4)




   The coating liquid is sprayed on the surface of material to be coated by means of different
technologies, like top/bottom spray. For a specifically given material, application of different
technologies will bring about distinctive difference in final release characteristic. In addition,
you will design and improve the recipe in the process of development, and it is essential for
you to learn about the features of these technologies.

     In the process of coating with the fluid bed technology, all granules are floated in the
fluidized air with the surface fully exposed. Various coating liquid can be sprayed for heat
exchange. In the fluid bed, the fluidization state is determined by characteristics of the
fluidized material and structure of equipment. Since each technology has different structure,
Fluid Bed Granulator and Drier DBL1                                             Operation Manual
                                                10
the fluidization state is also variant.

    When the two fluid bed technologies—top/bottom spray—are used in coating, to obtain
even and continuous coating, you should try your best to reduce the stroke of liquid drop, that
is the distance from nozzle outlet to granule surface, so as to reduce the drying effect on
liquid drop by hot air. In such case, when the liquid drop reaches the material surface to be
coated, it can basically keep its initial features, and minimize the evaporation of media in the
liquid drop, thus to have equal and ideal extending ability, forming continuous and even
coatings.

   Because the fluid bed equipment has a high evaporating efficiency, the granule floats in
the air flow for coating, which enables this technology widely applied in coating granule core.

   The two fluid bed technologies can both be used in coating, providing wide applicability.
These methods are generally same while with dissimilarities. In the process of studying for a
product, some essential factors needs to be considered in selection of specific technology like:
benefit, material dosage, recipe, purpose of coating, and control on process parameters.




4. WORKING PRINCIPLE

  Under the pumping action of Fan, through the air collecting filter, air inlet valve, purifying
filter, heater, blast pipeline, through the air distribution plate, the airflow enters into the fluid-
bed granulating chamber, and then agitates and suspends the seminal powder or pellet core
into a fluid state ( the seminal powder can be various material like raw powder, forming
preparation, absorbent and western medicine and food), meanwhile mixing them.

  The liquid state material and the Compressed air pass through their individual channels to
enter into the spray nozzle, the compressed air atomizes the liquid state material into fogdrop,


Fluid Bed Granulator and Drier DBL1                                                Operation Manual
                                                  11
which are sprayed in the fluid-bed granulating chamber to mix with the seminal powder or
pellet core, and then felt into granules or dressed, coated, at the same time, the granules will
be dried by the heated air, a part of the fine powder goes up to the filter chamber and is
collected, and cleaned by the compressed air spouted by the working pulse valve. The powder
which is cleaned returns to the fluid bed to make granule again.
For further details, please see:
 Working Schematic graph of Top spray (Image 5)
 Working Schematic graph of bottom spray (Image 6)
 Working Schematic graph of tangent spray (Image 7)




Fluid Bed Granulator and Drier DBL1                                           Operation Manual
                                               12
                                                                               12
                  To Air supply                                    11

                                              10
                                              9
                                              8
                                              7




                            5         6            4




                        1        2        3




  Note:
  1. Collecting air filter      2. Air purifying filter              3. Electric Heater
  4. Airflow distribution plate 5. Constant temperature mixing heate 6. Peristaltic pump
  7. top spray gun              8. Fluid bed                         9. Filter
 10. Blowing windpipe          11. Air outlet filter                12. Induced draft fan



                 Working Schematic graph of Top spray (Image 5)




Fluid Bed Granulator and Drier DBL1                                         Operation Manual
                                                   13
                                                                                    12
            To Air supply                                                 11

                                              10
                                              9
                                              8
                                              7




                     5                6




                 1          2             3                  4


Note:

1. Collecting air filter          2. Air purifying filter                  3. Electric Heater

4. Bottom spray gun               5. Constant temperature mixing heater    6. Peristaltic pump
7. Top spray guide cartridge 8. Fluid bed                                 9. Filter
10. Blowing windpipe         11. Air outlet filter                        12. Induced draft fan




                Working schematic gragh of bottom spray(image6)




Fluid Bed Granulator and Drier DBL1                                             Operation Manual
                                                   14
                                                                                      12
         To Air supply                                                       11

                                              10
                                              9
                                              8




                    5                 6   7




                1             2               3                       4




Note:



1. Collecting air filter                           2. Air purifying filter         3. Electric Heater

4. tangent spray turnplate 5. Constant temperature mixing heater                   6. Peristaltic pump
7. side spray gun          8. Fluid bed                                            9. Filter
10. Blowing windpipe       11. Air outlet filter                                  12. Induced draft fan




              Working Schematic graph of tangent spray (Image 7)

Fluid Bed Granulator and Drier DBL1                                                     Operation Manual
                                                          15
5. INSTALLATION AND DEBUGGING

5.1 Equipment Installation

      DBL1 fluid bed lab machine is mainly composed of general systems of the technical
processes like machine case body, fluidizing device, top cover unit, filtering facility, heating
facility, pulse powder cleaning facility, pneumatic control mechanism and electric control
mechanism. In accordance with requirement of specific process, it is specially configured with
a set of top spray facility, a set of bottom spray facility, a set of side spray facility, respectively.
Top spray gun and bottom spray gun are a set of spray gun compounding which can be
disassembled and assembled. If you select the bottom spray process or top spray process, the
technical requirements can be satisfied simply only by changing relevant matching facilities
and the right spray gun.

     Mechanisms matched with the main machine including: peristaltic pump, Meanwhile the
user needs on his own to configure such facilities as 220V AC ( 3 phase ) power and
compressed air at 0.4~0.6 MPa, so as to form a complete process flow control system. The
equipment and its matching facility should be horizontally placed on a platform, and the outlet
air pipe of main machine is connected to outside of test room. The machine cabin must be
reliably and safely grounded, the grounding resistance should not be bigger than 100Ω.
Connect the electric power and compressed air, and you can adjust and run the equipment.

5.1.1 Installation of filter chamber

    Put the round mounting socket disc on filter chamber on the right position corresponding
to work table, thread the control pipe into the hole, then erect the filter chamber, and connect
the holes by means of mounting screw.

5.1.2 Installation of top, bottom, tangent spray device

   Select the top, bottom or tangent spray device in accordance with the process operation
(one process only for each time)

a) Top spray device

      Install the pulse powder cleaning device on the top spray transition section device well
firstly, and then connect it with the filter chamber. Before its installation, embed the seal bar
(if already connected with the bottom spray device, please remove it first); next Install the
transition section and top spray gun on the top spray material container; finally put the whole
top spray material container into the base groove, and adjust the observe point according to
the position of sight glass



b) Bottom spray device
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                                                   16
   Install the pulse powder cleaning device on the bottom spray transition section device well
firstly, and then connect it with the filter chamber. Before its installation, embed the seal bar
(if already connected with the top spray device, please remove it first); next Install the
transition section and top spray gun on the bottom spray material container; finally put the
whole bottom spray material container into the base groove, and adjust the observe point
according to the position of sight glass

c) Tangent spray device

    When needing to use the Tangent spray function, installing the pulse powder cleaning
device well firstly, and then clamping its straight connecting section on the filter chamber, after
the material container device is put into the base, and confirming the connecting shaft is
connected and lifted well, screwing down the handle nut.


5.1.3 Installation of pulse powder cleaning device
     This installing program must be carried out, after the debugging for the empty machine is
right.
    Demount the straight connecting section from the filter chamber; take out the mounting
plate, and then let the cleaned metal filter (4 pieces) aim at the mounting hole, screw them
down with the special aluminous nut; Finally connect them on the filter chamber.

5.2 Equipment adjustment


5.2.1 Up/down adjustment of top/bottom spray device

    Select a process mode, connect through the power and air supply, as per operation
procedure, and click Container Up/down repeatedly, to adjust rising/falling sequence and
movability.

5.2.2 Tangent spray device

    The height of turnplate in the Tangent spray device, can be adjusted discretionarily by
hand within 0~6mm.
Between the turnplate and chute wall, the space exists, so that the air flow can pass through,
adjusting the height of turnplate to adjust the air inlet volume. When the turnplate is still, the
edge of turnplate sticks to the chute wall, to provent the material in the chute leaking
downwards.



This action is done by adjusting the handwheel. Before the turnplate rotates, adjusting the
handwheel clockwise, and at the same time, pulling the link rod device to make the turnplate
Fluid Bed Granulator and Drier DBL1                                              Operation Manual
                                                17
lift to the set height; after the turnplate stops rotating, adjusting the handwheel link rod
device anticlockwise, to restore it , the turnplate lowers and sticks to the chute wall. As for the
rotating speed of turnplate, it is able to set the frequency of rotating motor at any time,
according to the quantity of material and fluidized state. As for the setting method, see the
explanation of touch screen operation interface in detail.
5.2.3 Adjusting the atomization effect of spray gun

    Connect the compressed air to spray gun, start the system to the atomizing state, adjust
the pumping frequency and the atomizing pressure to change the atomizing effect
Molding principle of granule:
   The size of fogdrop is in direct ration to the liquid flux, and inverse ration to the
atomizing pressure.

    The atomizing angle ( micro-adjust ) can be regulated by means of adjusting the
atomizing pressure and the air cap of the spray gun.

5.2.4 Installation and adjustment of spray gun

a) Place the top spray gun into the socket, the nozzle vertical downward pointed to the
container center, and fix the spray gun. The spray angle and spray coverage should meet the
maximum range of material fluidization.

b)    Place the bottom spray gun into the socket, the nozzle spraying from lower to upper in
same direction as material movement. Manually adjust the clearance between the distance
spacer and sifter plate, so as to ensure that the material can form a circular flowing state upon
action of push force from inlet air.

Several points in starting spray state:

a) Preliminarily dry the material for some time before starting atomization. When the material
temperature reaches the permitted value for spraying, you can then carry out by spray
granulating or coating.

b) In the process of granulating or coating, you can at any time adjust fan frequency, the
rotating speed of pulse pump, the atomizing pressure in accordance with the fluidized state,
granulating or coating, to maintain a relative balance state of water evaporation in the fluid
bed, and can obtain proper granules or coatings by adjusting size of fog drops.




c) In case abnormalities (such as rill flow, clogging, bed sinking) appear in the fluid bed even
after adjustment on such parameters as fan frequency, liquid supply volume, you should stop
spraying immediately. Start function of agitating to deal with the problem, resume spraying till
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                                                18
after the fluidized state goes normal again.

Several points after completion of spray:

     When the agglutinating liquid is used up, spray with purified water for some time, so as to
clear off the agglutinating liquid left in the liquid supply pump, liquid supply pipe and spray
gun, thus achieving the purpose of cleaning the spray gun.

5.2.5Material charge

    Manual charge:Operate as per stop procedure, fall down the material container, take
away the test tube for differential pressure across beds, and take out material temperature
sensor, screw out material container for charge.

5.2.6 setting of air inlet temperature

    You can set the air inlet temperature in accordance with the technical requirements at
any time, before and after the program is started

     As for the setting method, see the Para. Setting Image in detail

5.2.7 Setting of Fan flow

    Set the fan flow in accordance with the quantity of material and the fluidization status at
any time, before and after the program starts.

     As for the setting method, see the Para. Setting Image in detail

5.2.8 Setting of liquid supply speed

     Set the liquid supply frequency in accordance with the quantity of material and the
fluidization status at any time, before and after the program starts.

     As for the setting method, see the Para. Setting Image in detail

5.2.9 Setting of turnplate speed

     Set the turnplate speed in accordance with the quantity of material and the fluidization
status at any time, before and after the program starts.

5.2.10 stop the machine
    After the above procedures are finished, start the program system to exit from work
preparation status, take out the power key by turning anticlockwise.



6. OPERATION AND USE

     Alarm:Connect the compressed air to control system before operation, and

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                                               19
check whether the seal bar on the cartridge body of main machine is inserted in
the right position.

6.1 Function introduction

6.1.1 On the touch screen operation panel
    Control Power
    Key switch when rotating clockwise, the power supply of control system is put through;
when rotating anticlockwise, the power supply of control system is cut off.
    Emergency The program puts back, when the equipment is running, coming along
urgent condition, needing to stop the equipment quickly. Beating this key-press with hand can
achieve it. When needing to renew it, rotating this key clockwise
    Adjustment of atomizing pressure adjust the spraying atomizing pressure manually
    Display of atomizing pressure display the current spraying atomizing pressure
6.1.2 Start the machine to enter welcome image :( all keys are plain button type)
6.1.2.1 Operation image automatically shifts from welcome image to indication image as
below
           User Login Image




F9— Start Work 〈F9〉         press < F9>, to start the work
       Note: All of the grade password can do this operation
F10—Parameter selection 〈F10〉 press < F10>, to choose the required parameters
     a) Press〈F9〉for manual setting Press〈F9〉, to choose the manual parameters
         setting mode Enter into the manual parameters setting screen directly, to set and
         adjust the parameters operated manually
     b) Press〈F11〉to select the prescription parameters
Enter into the memorized prescription parameters screen, to choose the required technical
operating mode and various parameters, according to the hint.

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      Annotations: as long as having grade password of level 2~9, can all carry out
this operation.
      F11—Parameter modification 〈F11〉 press < F11>, to modify the parameters.
In this operating screen, it is able to modify the existing parameters, also can work in the new
ripe operating parameters, so that there are more prescription parameters supplied to choose.
      Annotations : Only having grade password of level 9 can carry out this
operation
      F12—Change password 〈F12〉 press < F12>, to modify the operating password.
 It is able to modify your own grade password.
      Annotations: Only having grade password of level 9 can carry out this operation
6.1.2.2 The hint screen: After choosing the operation, needing to key in the user name and
the password of the user with this grade




    For example: Now a user named USER 3 (password: 333 the grade is higher) will
operate this equipment, in spite of he uses which function in the F9、F10、F11、F12. Key in
USER 3 in the User item, after the confirmation, key in 333 in the Password item, after the
confirmation, to enter the required operation screen.




  6.1.2.3 Change Password



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         Type                     Password                  Group
         Admin(cannot be modified)*********(can          be administrator
                                  modified)
         PLC admin ( cannot be *********(can             be PLC administrator
         modified)                modified)
         USER 1(can be modified)) 111(can be modified)      USER 1
         USER 2(can be modified)) 222(can be modified)      USER 2
         USER 3(can be modified)  333(can be modified)      USER 3
         …….. USER 9




6.1.2.4 Parameter selection


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     a) Press〈F9〉for manual setting Press〈F9〉, to choose the manual parameters
setting mode
     Enter into the manual parameters setting screen directly, to set and adjust the parameters
operated manually
     b) Press〈F11〉to select the prescription parameters
     Enter into the memorized prescription parameters screen, to choose the required technical
operating mode and various parameters, according to the hint.
     Note: Only having the level 2~9 grade password can carry out this operation




6.1.2.5 Hand Parameters set



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    Available manual parameter includes:
    Inlet Temperature This setting value is needed when automatic control in the heating
unit:℃
    Fan Flow This setting value is frequency value of fan work         unit:m3/h
    Time of Bag Shaking This setting value is the work time of pulse blowing valve, in the
work program for automatic pulse blowing powder cleaning unit: Sec.
    Interval Time of Bag Shaking This setting value means that: in the work program for
automatic pulse blowing powder cleaning, after a group of pulse blowing valve is put through,
how long will it delay the next group of pulse blowing valve starts to work, after that, turning
back to the first group to do the blow work. unit:Sec.
    Air Control Mode Set the control mode of fan:

Open-loop control namely control the air volume value, through the air velocity sensor to
measure
Close-loop control namely control the air volume value, not through the wind speed sensor
measure, here the setting function of air volume value is still effective, this function is
applicable to use when the air velocity sensor has a screw loose
Back Turn back to the operation screen to start the equipment, to carry out the start
operation.
Monitor Image Turn back to the dynamic monitor Image.
XSTS Series Digital Controller AT In the work process, it is able to carry out the self-
tuning operation of Inlet Temperature.


    But this operation cannot be used continually. Click this key to start the self-tuning. When
doing the self-tuning, using position adjustment, the output will flop and change between the

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following direction      and      ( such as 0% and 100% ),after 2~3 weeks, the PID
parameter will be figured out automatically, finishing the self-tuning, and entering the normal
PID control. The sketch map of the whole course as follows:




                                      The sketch map of the self-tuning

     When the self-tuning is stopt/ closed, the AT indicator light on the controller (DTC1000)
panel goes out.
     When starting the self-tuning, the AT indicator light on the controller (DTC1000)panel
lights. When the self-tuning finishes, the      value will change to       automatically,the AT
indicator light on the panel lights, now entering into the normal PID control process.
   ★ The length of the self-tuning process lies on the responding speed of the controlled
     process.
       For the slow system, sometimes may need several hours.
   ★ Choose an appropriate time to carry out the self-tuning, such as the prophase of the
     heating stove rises in temperature. If the gained parameters will be used in steady-
     state control, then choose the time when the system is relative steady, to carry out the
     self-tuning.
     ★ In the different phases, the system has different characteristics, therefore, in the
          different phases, the gained PID parameters are different after the self-tuning.
     As for the special system such as the Large Delay and frequency-change control system,
etc., if the gained control effect is not satisfying through operating the self-tuning rightly,
     You can consult the following experience, and modify the PID parameters manually, to
improve the adjustment precision further:
    Too Excessive Adjustment, before getting to the steady-state, if the requirement for the
adjustment time is not high, can enlarge the proportion zone properly.
        If needing to shorten the time to steady-state, and allowing a little excessive
         Adjustment, can reduce the proportion zone properly.
        When the measured value fluctuates up and down slowly at the set value, it is able to


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          increase the integral time or enlarge the proportion zone.
         When the measured value fluctuates up and down frequently at the set value, it is able
          to reduce the rate time properly.
        (P)—— proportion zone             producer value: 5.0
      Proportion operation parameters, the bigger the is, the weaker the proportion action is.
        (i)—— integral time             producer value: 850
      0 second shows that there is no integral action, the bigger the value is, the weaker the
      integral action is.
        (d) ——Derivative Time             producer value: 24
       If it is “0”, the function is not in use. The bigger the setting value is, the greater the
    effect will be.




6.1.2.6 Prescription— choose and download the parameters.
    (Equivalent to extract the required parameters group from the formulation parameters
data group, and download the parameters to the work parameters)




    Choose the required formulation parameters group, according to the displayed entry name,
and download it, then the control procedures works on the basis of this data.




6.1.2.7 Prescription modification— modification of formulation parameters (equivalent
to set or modify the formulation parameters data group)



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     The screen will be set to adjust or modify the existing ripe formulation parameters or
increase the formulation parameters group. After that, click the Save button, to memorize the
formulation parameters. Also can clicking the cancel button to cancel it.

6.1.3 Mach. Start Image




F1—START Program ON Start the inner control program of equipment, let the equipment
be in the state of preparing to operate
F2—Stop Stop Machine            Start equipment stop program, operate as per instruction.
F3—Container Up Container Up, top lift the movable section of equipment, and then sealed
it.
F4—Container Down Container down, lower the movable section of equipment, and then

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cancel the sea
F5—Fan on Starts the fan

This equipment has two kinds of fan control mode:
Open-loop control and Close-loop control



 Open-loop control namely control the air volume value, through the air velocity sensor to
measure
 Close-loop control namely control the air volume value, not through the wind speed sensor
measure, here the setting function of air volume value is still effective, this function is
applicable to use when the air velocity sensor has a screw loose
F6—Fan off Stops the fan



6.1.4 Ready to work once preparations finished




  6.1.5 Start work confirmation




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      6.1.6 Monitor Image




Function introduction:
Fan Flow          m3/h set and display the air flow when fan works. Only when using Manual
Work can set the fan’s flux; after using Prescription, cannot change its parameters.

Inlet Temperature            ℃ set and display the air inlet temperature. Only when using
Manual Work can set the air inlet temperature; after using Prescription, cannot change its
parameters.

Materiel Temp.             ℃ Display the current value of material temperature

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Outlet Temp.       ℃ Display the current value of outlet air temperature
Current      A Display the current work current
HEAP(P1)          Pa Differential pressure display of Air inlet filter
P2       Pa Differential pressure display of Bed layer
P3       Pa Differential pressure display of air exhaust filter

Alarm Indication Click this key, display the current failure alarm content, for reference
when eliminating the failure.
Temp. Curve Look over the temperature Curve, and provide reference data of Temperature
change. Including air inlet temperature, material temperature, and air outlet temperature; also
can enter into the corresponding curve menu separately, according to the following hint, to
look over the change condition of curve
HAND Parameter            Click this key, to enter manual Parameter setting. This setting will be
displayed in this screen, only when using the Manual Work. After using the Prescription,
this screen will be hided
K3—Heat On Start heating, then control heating automatically in accordance with the set
value of inlet air temperature and the actual value detected by inlet air temperature sensor
K4—Heat Off Heat off
F7—Lamp On Work lamp on/off
K5—Spray On Click this key, to start the spraying granulating function. After spraying is
started, automatically judging whether the heating is started, according to current condition,
after time delay, the liquid feed pump started automatically; click this key again, to stop
spraying. Peristaltic pump (rotating speed 0~100rpm)can be started and stoppt separately.
If needing to stop spraying, pressing K6—Spray Off, stop feeding liquid first, after 10
seconds delay, stopping atomizing pressure
The size of atomizing pressure can be adjusted with the manual valve.
K6—Spray Off To stop function of spraying and granulating
K7—Pump On To start liquid pump for operation.
K8—Pump Off Stop operation of liquid pump.
Alarm Timer Enter into the alarm parameter setting screen, to carry out the setting of listed
item, according to the item requirement.




6.1.7 Alarm Timer

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Back Turn back to the Monitor Image menu, to monitor the changing condition of various
parameters



               actual value             Interlock process parameter
            process parameter
                                                                  delay
                                                                  time



             MAX                                                          NO ALARM
             BAND




              MIN                                                                 ALARM
                                           ALARM



                                                                                          time

                     setting    delay                                     delay
                      time      time                                      time




Alarm work curve drawing
    As for the setting and modification of the Upperlimit Lowerlimit value, only the person
who has the grade password of Level 2~9 can carry out this operation.
    As for the setting and modification of the delay time value, only the person who has the
grade password of Level 3~9 can carry out this operation



Setting time has been solidified in the control program, including:

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    a) The Setting time of the air volume alarm is 10 minutes after the fan works.
    b) The Setting time of the temperature and some other alarms is 10 minutes after the fan
works, the heating work is started



6.1.8 TEMP. Curve




F9—Monitor Image             when in the temperature timing curve screen, click this key to enter
                             into the dynamic menu of equipment.
F11— P* Curve                differential pressure timing curve screen
F12— Air Curve               air volume timing curve screen




6.1.9 Air Curve

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F9—Monitor Image When in the screen of Air Curve, click this key to enter the dynamic
screen of equipment
F11—TEMP. Curve Real-time temperature curve
F13— P2 P3 Curve Curve of differential pressure across beds and exhaust air.
F14— P1 Curve Differential pressure timing curve screen of air inlet filter




6.1.10 Real-time Curve of HEPA (P1)

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F9— Monitor Image         When in the P1 differential pressure timing curve screen, click this
key to enter into the dynamic screen of equipment.
F11—TEMP. Curve Temperature timing curve screen
F12—Air Curve Air volume timing curve screen
F14—P2 P3 Curve P2 P3 Timing curve screen




6.1.11 Real-time Curve of P2 and P3

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F9— Monitor Image In the P2 P3 differential pressure timing curve screen, click this key
to enter into the dynamic screen of equipment.
F11—TEMP. Curve Temperature timing curve screen
F12—Air Curve Air volume timing curve screen
F14—P1 Curve P1 Timing curve screen




6.1.12 Stop mach. as per instruction

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                                           35
     Function key F1、F2、F3、F4、F5、F6、F7、K1、K3、K4、K5、K6、K7、K8 keep
the intrinsic functions,
     There are other three function keys’ functions as follows:
K2—Shake bag synchronously Before stopping the machine, start the final powder
cleaning program for the collection bag
F8—Stop shake bag synchronously Before stopping the machine, stop the final powder
cleaning program for the collection bag
K10—Stop program Do not work continuously, stop the machine. When there is no need to
work continuously, click this key,
     all the working program stops, the operation screen turns back to the User Login Image




6.1.13 Help

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                                            36
     Only when in the Monitor Image, clicking the key HELP can display the operation hint
text, inside there are the function hints of other operating button; after finishing seeing, click
the key HELP again, the screen turns back to Monitor Image.




6.1.14 The alarm information hint which is set for this equipment

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 PLC inner alarm information as follows:

 No.     alarm information
 1       Emergency!
 2       Fan Faulty!
 3       Compressed Air Faulty!
 4       Inlet Air Temp. Faulty!
 5       Material Temp. Faulty!
 6       Lower limit of air flow!
 7       Upper limit of air flow!
 8       Lower limit of inlet air temperature!
 9       Upper limit of inlet air temperature!
 10      Lower limit of material temperature!
 11      Upper limit of material temperature!
  12     Lower limit of exhaust air temperature!
  13     Upper limit of exhaust air temperature!
  14     Lower limit of inlet air HEPA!
  15     Upper limit of inlet air HEPA!
  16     Lower limit of differential pressure of material container!
  17     Upper limit of differential pressure of material container!
  18     Lower limit of differential pressure of exhaust air!
  19     Upper limit of differential pressure of exhaust air!
  20     Operating Error! Please lift the Material Container.
  21     Operating Error! Please start the Fan, before heating.
  22     Operating Error! Please stop the Spray, before stopping the Fan.
  23     Operating Error! Please stop Spraying, before stopping Heating.
         Operation protection: the Air inlet temperature is bigger than 50℃, cannot stop the
  24
         machine, please stop heating first, stop the machine till the temperature lowers.




Explanation:

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1) The program is restored!
     The Emergency stop button is pressed, the equipment is in abnormal state, please check
it and restore it.
     Alarm when the Emergency stop button is pressed; at the same time, all the operation
programs is stopt.

2) Fan failure!
    The alarm information, when the induced draft fan or the transducer which controls the
induced draft fan have fault; at the same time, all the operation programs is stopt.

3) Air supply failure!The compressed air is on the low side, please check it and restore it.
    This equipment uses the B work port of the digital pressure switch (SDE1-D10-G2-H18-
L-P2-M8) from Germany FESTO as the alarm port for monitoring the air supply pressure; the
producer value is 2.5bar. If the outer air supply pressure is higher than this value, don’t give
an alarm; when the outer air supply pressure is lower than this value, give an alarm.
    After giving an alarm, spraying and heating program are stopt; but other functions of
equipment can still work normally. If within 3 minutes, this failure isn’t eliminated, the other all
control programs are stopt.
    Alarm will occur under two conditions:
    a) The pressure supplied by the system is lower than this value;
    b) The air pipe in the equipment leaks badly, the pressure is lower than this value
    Please see the manual of digital pressure switch (SDE1-D10-G2-H18-L-P2-M8) from
Germany FESTO in detail.

4) Alarm when the temperature goes beyond! Air inlet temperature is bigger than 120℃
    The hot source used by this equipment is electric heating device, the alarm when the
temperature goes beyond (>120 ℃) is set in the control program .
    After the alarm, heating stops automatically, and the key-press K3—Heat On is cut off, if
needing to heat, click the K3—Heat On again.

5) Operation protection: The air inlet temperature is bigger than 50 degrees, cannot stop the
machine, please stop heating first, do it till the temperature lowers.
     The hot source used by this equipment is electric heating device, the air inlet
temperature is bigger than 50 degrees, cannot stop the machine, please stop
heating first, do it till the temperature lowers, which is set in the control program .
     After stopping heating, the air inlet temperature is still bigger than 50℃, when stopping
the fan, it will warn.After the warning occurs, the fan cannot stop working, now needing to
click the function key manual on, open the air door, and continue to lower the temperature.
6.2 Operating procedure(recommended to use)

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                                                 39
1) Open the manual valve of compressed air, place it on the position of ON, and put through
the compressed air.

2) Place the general power switch 《QF1》on the control cabinet on the position of ON ,
and put through the general power

3) Press the Control power key switch, the operating screen is connected with power,
   Automatically entering into the《User Login Image》controlled by the system;

    a) Adopting the function of User Login Image “F9— Start Work 〈F9〉” directly
       Click the key-press〈 F9〉 on the operating screen,the requirement to input the
password is on the display screen, after inputting the user name and password on the numeric
keyboard, separately click the key “ENTER” at the lower right corner of operating screen to
confirm, the screen turns back to the User Login Image. In the 《User Login Image》,
click the key-press 〈F9〉on the operating screen again,automatically entering into the
operation screen controlled by system—— namely: 《Mach. Start Image》and 《Operate
as per the instruction》
       When adopting this mode of operation, the system automatically defaults the
parameters after the manual work.

b) Adopting the function of “F10—Parameter selection 〈F10〉 ” in the User Login
Image
       Click the key-press〈F10〉 on the operating screen,the requirement to input the
password is on the display screen, after inputting the user name and password on the numeric
keyboard, separately click the key “ENTER” at the lower right corner of operating screen and
confirm it, the screen turns back to the User Login Image。In the《User Login Image》,
click the key-press 〈 F10 〉 on the operating screen again, the screen enters into the
“Parameter selection ”. There are two parameters mode to choose.
      A Press〈F9〉for manual setting Press〈F9〉, to choose the manual parameters
setting mode
Enter into the manual parameters setting screen directly, to set and adjust the parameters
operated by hand.

      B Press〈F11〉to select prescription parameters
Press 〈 F11 〉 to enter into the stored prescription parameters screen to make choice, to
choose the required technical operation mode and various parameters, according to the hint.
       Click the key-press〈F9〉 on the operating screen,the screen is manual parameters
setting screen, carry out the adjustment and modification of parameters, according to the hint.

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                                              40
Finally, shift the cursor to “Back”, click the key “ENTER” at the lower right corner of
operating screen and confirm it, the screen turns back to the Mach. Start Image, it is able
to carry out the starting operation.
       If clicking the key-press 〈 F11 〉 on the operating screen , the screen is
“Prescription ” screen, to choose the required ripe formulation and technical operation mode,
according to the hint, shift the cursor to “download”, click the key “ENTER” at the lower right
corner of operating screen and confirm it, the selected various parameters cover with the
former formulation parameters automatically, the system recognizes it and implement the
current parameters. In the course of operation, these parameters will not be able to be
modified once again. Then click the key=press "<F14> Back" on the operating screen, the
screen turns back to the Mach. Start Image screen, you can start the operation.

c)  Adopting the function of User Login Image “F11—Parameter modification
〈F11〉”

       Click the key-press 〈F11〉on the operating screen, the requirement to input the
password is on the display screen ( Annotations:Only having the grade password of
level 9 can carry out this operation), after inputting the user name and password on the
numeric keyboard, click the key “ENTER” at the lower right corner of operating screen and
confirm it, the screen turns back to the User Login Image. In the《User Login Image》,
click the key-press 〈 F11 〉 on the operating screen again, the screen enters into the
“Parameter modification ”.

      In the “Parameter modification" image, it is able to change, adjust, add, and delete
the parameters, according to the exact circumstances, after that, store and download them.
And then click the key-press 〈F14〉Back on the operating screen again, the screen turns
back to the User Login Image.
      On the basis of the operational requirement, in accordance with the above 3)-a) or 3)-b)
steps to operate.




d) Adopting the function of User Login Image “F12—Change password 〈F12〉”

       (Annotations:Only having the grade password of level 9 can carry out this operation)
It is able to modify the following password requirement according to requirement:

           Type                            Password                   Group
           Admin( cannot be modified)      ********* ( can         be administrator

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                                              41
                                    modified))
           PLC admin ( cannot be *********                   ( can      be PLC administrator
           modified)                modified))
           USER 1(can be modified)) 111(can be               modified))     USER 1
           USER 2(can be modified)) 222(can be               modified))     USER 2
           USER 3(can be modified)) 333(can be               modified))     USER 3
           …….. USER 9

4) The screen shows Press <F1> to start Image
    After Clicking the key 〈F1〉, the hint operation Machine is started! occur, at the same
time, display the next step.

5) The screen shows Install the bag filter and its transtion section in the filter
chamber.
      Namely: Install the filter and its transition section in the filter chamber, and check whether
 it is connected well. And t hen click the key “       ” in the right of operating screen, the cursor
 is moved on the block Yes, click the key “ENTER” and confirm it; the screen displays the
 next step.

6) The screen shows Put material container in place, Press <F3> to lift material
    container and press <F4> to lower it.
a) Install the spray gun in position according to the installation requirement of spray gun on
the material container.
b) Put the material container in the right place, and click the key-press <F3> to lift the
material container, and make each moving part between containers is sealed.In the process of
lifting the material container, if the movable top ring, material container, and filter chamber are
not sealed well, clicking the <F3> 、<F4> again and again is ok
c) Connect and plug the material temperature sensor and the earth wire well.
d) Connect and plug the bed layer differential pressure detecting windpipe well.
e) Click the key “      ” in the right of operating screen, the cursor is moved on the block Yes,
click the key “ENTER” and confirm it; the screen displays the next step.



7) The screen shows Press <F5> to start Fan; press <F6> to stop Fan;
a) Click the key <F5>, to start the fan. In the right of this row displays Fan is started!
b) Click the key “  ” in the right of operating screen, the cursor is moved on the block Yes,
click the key “ENTER” and confirm it; the operation screen enters into Ready to work once
preparations finished.



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8)    Click the key 〈 K1 〉 , the function is confirmed, the screen shows Start work
      confirmation

9)   Click the key 〈 F9 〉 , ( Start work confirmation ) It is able to begin the work
                                                           ,
     confirmation, the screen shows the next step Monitor Image

10) Enter into the various monitor menu and Alarm Time menu, according to the hint in the
    below pane of operating screen, to set the alarm parameters.

11) After the fan works steadily, and the air duct draughts normally, click the key 〈K3〉,
    start heating, dry the equipment

12) After drying the equipment, charging material—— Charging method of material, manual
     charging
a) Click the key 〈K4〉, stop heating, lower the temperature (inlet air temperature<50℃)
b) Click the key〈 F2〉 ,stop the machine,enter into the Stop machine as per the
instruction
c) The screen shows Stop manual operation?
d) Click the key “ ” in the right of operating screen, the cursor is moved on the block Yes,
click the key “ENTER” and confirm it; the screen displays the next step.
e) The screen shows Press <F6> to stop Fan
Click the key <F6>,the fan stop working, the right of screen shows Fan is stopped! The
screen shows the next step.
f) The screen shows Press <K2> to shake bag synchronously, Press <F8> to stop
after bag shaking finished, Click the key <F8>,overleap the synchronous bag shaking .
The screen shows the next step.
g) The screen shows press <F4> to lower material container.
Click the key <F4>,lower the material container. Click the key “     ” in the right of operating
screen, the cursor is moved on the block Yes, click the key “ENTER” and confirm it; the
screen displays the next step.




h) The screen shows Mach. for reproduction?
Click the key “  ” in the right of operating screen, the cursor is moved on the block Yes, click
the key “ENTER” and confirm it, the screen turns back to the step 1.5 of the operation step.
i) Take down the material temperature sensor and bed layer differential pressure detecting
pipe, take down the material container, charge the prepared powder material into the material
groove.

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j) According to the step 1.5;1.6; 1.6.2;1.6.3;1.6.4;1.6.5;1.7;1.7.1;1.7.2;1.8;
1.9;2.0 in the above steps to operate.

13) Click the key-press〈K3〉, to start heating, and dry the equipment.

14) Click the key〈K5〉,to start the spraying function
a) Click the key 〈K5〉,the system starts the spraying atomizing pressure first.
b) After a few seconds delay, the peristaltic pump starts, namely the function of 〈K7〉 is
started automatically. Here needing to stop the peristaltic pump’s work, pressing the key
〈K8〉 is ok. Only when needing to use peristaltic pump to supply liquid can start it. Click the
key 〈K7〉 is ok.
c) In the operating choice, if the operating manner Manual parameters is adopted, various
parameters can be adjusted in the dynamic image; the adjustment of spraying atomizing
pressure can be adjusted on the panel of control operation box。 If the Prescription is
adopted, then except the adjustment of spraying atomizing pressure can be done on the
panel of control operation box, the other all parameters can not be adjusted
d) Put through the Spray atomizing pressure to the outer spray nozzle of spray gun, to
prevent building up the spray nozzle because of the boil of material.

15) After the material is dried, able to carry out spraying and granulating of prepared
adhesive fluid.

16) The shaking time and shaking frequency value needn’t to be adjusted frequently.

17) Observe the change of various parameters in the “Monitor Image”

18) After starting the equipment, record the parameters, preparing for inspection and
reference use

19) After Spraying Granulating has been completed, spray into a small amount of purified
water; to clean the adhesive fluid remained in the pipeline wall of liquid supply system



20) In the granulating work process, you can adjust the air volume, liquid supply volume
(rotate speed of liquid supply), and the fogdrop size, the height of spray gun, time, frequency,
time interval of shaking bag, etc. according to the fluidized state, size of sample granules,
humidity at any time, to keep the relative balance state of moisture evaporation in the fluidized
bed to get the particles you satisfied with. Once these parameters are determined, do not
change it easily; the state of fluidized bed can be observed from the sight glass of spraying

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                                               44
chamber on the mainframe, general fluidized height is better not to exceed the height of sight
glass of spraying chamber. When there is abnormal condition in fluidized bed, adjust the
parameter such as air volume, and rotate speed of liquid supply, atomizing pressure, etc. when
there is some abnormal condition unable to change (such as channeling, agglomeration,
collapse of bed, etc.), you can start the agitating function, until the state of fluidized bed tends
to be normal, resume Spraying Granulating operation again.

21) After stopping spraying granulating, turning to do the drying work.

22) After the material drying moisture reached the technological requirement, able to stop the
machine and discharge the material according to the operation steps of stopping the machine

23) Procedure to stop the machine
a) Click the key 〈 F2 〉 , stop the machine , to enter into the Stop mach. as per
instruction
b) If the heating and spraying are not stopt, there is the hint in the operation process
c) The screen shows Stop manual operation?
d) Click the key “    ” in the right of operating screen, the cursor is moved on the block Yes,
click the key “ENTER” and confirm it; the screen displays the next step.
e) The screen shows Press <F6> to stop Fan
Click the key <F6>,the fan stop working, the right of screen shows Fan is stopped! The
screen shows the next step.
f) The screen shows
Press <K2> to shake bag synchronously, Press <F8> to stop after bag shaking
finished
Click the key <K2>,to carry out the final powder cleaning work. <F8> can stop this
operation. The screen shows the next step
g) The screen shows Press <F4> to lower material container.
Click the key <F4>,to lower the material container. Click the key “       ” in the right
of operating screen, the cursor is moved on the block Yes, click the key “ENTER”
and confirm it; the screen displays the next step.



h) The screen shows Mach. for reproduction?
Need reproduction: Click the key “ ” in the right of operating screen, the cursor is moved on
the block Yes, click the key “ENTER” and confirm it; the screen turns back to the step 1.5 in
the operation steps.
i) If there is no need to reproduce, then stop the program, press the key <K10>
j) Take out the material temperature sensor, the earth wire and the bed layer differential

Fluid Bed Granulator and Drier DBL1                                              Operation Manual
                                                 45
pressure detecting windpipe, pull out the material container.
k) Discharge the material
l) Disassemble the metal filter and its transition section from the filter chamber
m) Close the key switch of Control power——turn the switch anticlockwise, stop it.
n) Set the general supply switch in the control cabinet into OFF,to close the general supply.
o) Close the compressed air manual valve,set the valve into OFF,Close the compressed air
p) Clean the collecting bag and some other parts needed to be cleaned.




7. MAINTENANCE

      Correct maintenance may better keep the performance of equipment, prolong the
    service life or equipment, thus routine maintenance is necessary for equipment.
 7.1 The inner and outer air draught fan shall be cleaned, as well as the air pass of fan, to
   clean the visible dusts. The accumulation of dust may affect heat radiation, cause

Fluid Bed Granulator and Drier DBL1                                         Operation Manual
                                              46
    temperature to rise, reduce the air volume, increase vibrating and cause failure. The
    bearing, oil seal, silencer and blades of fan are consumables, which have certain period of
    service life. Therefore, they are required to be changed termly.

  7.2 The inlet air filter sieve, outlet air filter sieve and filtering cartridge shall be periodically
    cleaned or changed. Large amount of dust accumulation will lower down the ventilation
    volume and affect normal work of fluidization state.

  7.3 The atomized lubricator of air supply treatment triple parts shall be done frequent
    inspection, check the lubricating oil, lube must be added before it is exhausted, the lube
    should be 5#, 7# machine oil (gear oil or transformer oil is also ok), if lacking oil, which
    may cause cylinder failure or damage, water accumulated in water separator & gas strainer
    shall be drained in time.

  7.4 Regarding cleaning of elements and parts of fluidized system, the fluidized system can be
    easily disassembled and cleaned separately (such as metal filter, fluidized cartridge, air
    distributor plate, top/bottom/tangent spray stand, etc.), after cleaning, heating, they can
    be replaced or stocked for future use.

  7.5 If equipment is unused, should start it once every 10 days and each operation time shall
    be no less than 2 hours, thus to prevent air valve lube from drying due to long time unused,
    and consequently damage air valve or cylinder. In the mean time, should prevent electric
    control unit from being affected with damp and being damaged




 8. TROUBLESHOOTING




Status                           Possible reason                                    solutions
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                                                   47
                          1. No powder cleaning for a long time, too
                             much powder adhered onto the filter         1. Check the blowing magnetic valve &
                             cartridge                                     metal filter cartridge
                          2. High bed layer negative pressure,           2. Reduce the frequency of fan, shake the
Bad fluidization state
                             powder adhered onto filter bag                  bag and clean the powder
                          3. Air inlet filter is blocked, too high air   3. Check, clean or change the filter
                             resistance                                  4.Add lube for atomized lubricator
                          4. Atomized lubricator lacks lube.
                                                                   1. Check the metal filter cartridge, to
                          1. the metal filter cartridge is cracked   see if there is break or holes, it must be
Discharge the fine
                          2.Too high bed layer negative pressure,    mended before use
powder in air
                              the fine powder is drawn out         2. Reduce the fan frequency
                                                                   3. Change filter bag
                                                                  1. Decrease water content in pellet
                                                                  2. Charge partial of total quantity, wait till
                          1. Too high water content in pellet
Channeling or dead                                                   it is drier than feed in wet pellet; Don’t
                          2. The wet pellet has stayed in the raw
corner appears when                                                  keep the pellet in container too long,
                            material container too long
granulating                                                          start the agitate button to shake and
                          3. Temperature is too low
                                                                     loosen the granule
                                                                  3. Rise the temperature
Agglomeration occurs      1. Some wet pellet were pressed in raw 1. start the agitation function to loose the
while drying the            material container                     pellets by shaking
granules                  2. The bag shaking cycle is too short  2. lengthen the bag shaking time
                                                                   1. Check if the open/close of nozzle
                          1. Pressure of compressed air too low
                                                                      smooth or reliable.
Caking on distribution    2. Nozzle obstructed by lump
                                                                   2. Adjust atomization pressure
plate while               3. The atomized angle is not good at the
                                                                   3. Adjust delivery volume, check nozzle to
granulating                   spray nozzle
                                                                      exclude any       lumps, adjust the
                          4. The position of spray gun is lower.
                                                                      atomization angle of nozzle.
Bean size particle                                                       1. Adjust liquid delivery volume; adjust
                          1. Bad atomization quality
occurs while                                                                atomization pressure
                          2. the fluidity of bond is bad
granulating                                                              2. improve the fluidity of bond
                                                                         1. check the electric heater
The inlet temperature     1. electric heater’s failure
                                                                         2. check the solid state relay
cannot meet the           2. failure of the solid state relay
                                                                         3. check the meter of control part and
requirement               3. the control part has some problem
                                                                         other control components
        Status                           Possible reason                                solutions
The inlet temperature,
material temperature,                                               Check the Temperature sensor or its
                          Temperature sensor or its connecting line
and outlet                                                          connecting line or its Process Module, and
                          or its Process Module has some problems
temperature                                                         deal with the failure.
displays wrong



         Fluid Bed Granulator and Drier DBL1                                            Operation Manual
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