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JRJZJRJZJRJZJRJZ----V06PV06PV06PV06P Brake Fluid Filling Machine
Operating Instruction
JINAN CJIERUI ELECTRIC CO.,LTD. OF CHINA Adress:No.56 General Road in Jinan, Shandong province Post Code:250108
Tel: 0531-88266622 (General Phone)
Fax: 0531-88772200 0531-81206707
E-mail: [email protected] Web Site: www.cjierui.com
JRJZ-V vacuum filling machine instruction
Company Introduction
JINAN JIERUI ELECTRIC CO., LTD. OF CHINA, that is JINAN
CJIERUI ELECTRIC CO., LTD, which integrates design and development,
manufacture, installation and sales services as one. This manufacture has higher
competitive in intelligence professional electromechanical equipment in China.
Also it is certified high-tech enterprises in Shandong Province.
JINAN JIERUI ELECTRIC CO., LTD. was established in October 1995
and its register fund was one million yuan; JINAN CJIERUI ELECTRIC CO.,
LTD. was established in June, 2003 and its register fund was five million yuan.
The enterprise is located No.56 in General Road of Jinan city and covers 8700
㎡. In 2010 the company's income of annual sales was more than 80 million
yuan, with an annual taxes was more than 6 million yuan, and fixed assets was
50 million yuan, and current assets was over 38 million; The company has
maintained a 40% average annual growth since it was founded.
At present, the numbers of employees are 156 persons, 53 technical
engineers who have rich experience in the application of vacuum technology,
automatic control, gas and liquid transmission technology, electro-hydraulic
integration technology and other field’s professionals. CJIERUI ELECTRIC
CO., LTD. establishes expedite communication and business contacts with
well-known domestic and foreign enterprises and institutions such as the U.S.
GRACO. Germany BURKERT, LEYBOLD, WILO, Britain SPIRAX likelihood,
Sweden ORION, Shandong University, Harbin Institute of Electrical and
Mechanical College, Tianjin Industrial University of Technology and so on.
From 1999 to 2001, JIERUI ELECTRIC CO., LTD. made the first
completely automatic power steering vacuum filling machine of China
proprietary intellectual property rights with China First Automobile Group and
the Chinese Automobile Research institute, which supplied prologue of the
automobile assembly line to high, fine, excellent on mechanical and electrical
JRJZ-V vacuum filling machine instruction
numerical control equipment domestically; And it seized the domestic and
foreign markets rapidly in afterwards several years.
Currently, the brand of JIERUI and CJIERUI vacuum filling equipment,
quantitative filling equipment and automobile assembly line of mechanical and
electrical equipment have occupied more than 60% market share in domestic
market. In Volkswagen, Hongqi, FAW, DFAC, Chery, Chang'an, Great Wall
Changfeng, HuaTai, KIA, Nissan and other famous auto company's product line
to replace the imported equipment, and successfully exported to Russia,
Vietnam and other foreign markets. It received customers’ recognization at
home and abroad as a stable quality, excellent cost performance and improved
customer service system.
When consolidating the existing products and markets, CJIERUI
ELECTRIC CO., LTD. always sticks to technology and quality as top of the
enterprise development, continuously improves products system and explores,
develops new products; gradually transfers to non-standard industry. In 2006 the
company successfully developed hermetic leak detection, attack started, Helium
recycling etc. a series of automatic electrical and mechanical equipment for
Emerson Group, and quality of products transcended the Emerson Group of the
United States suppliers, and successfully exported to the Vietnamese company
of Emerson Group. At present, the company has already established business tie
with foreign-funded enterprise of the Yangtze River Delta, Pearl River Delta and
the Bohai - rim areas and successfully operates a large number of non-standard
equipment items.
The concept of JIERUI ELECTRIC CO., LTD. is "integrity, dedication,
efficiency, innovation". The company adheres to the people-oriented,
market-oriented, innovative technology standpoint, and reliable products quality
management system to provide our customers with high performance and low
cost of products and first-class technical services, which will become best
Intelligent electromechanical equipment suppliers in China.
JRJZ-V vacuum filling machine instruction
JIERUI Products Brief
Standard Products::::
� JRJZ-V series Vacuum Filling products
� JRBJ series Intelligence Industrial Identification products
� JRBJ series Intelligence Industrial Gelatinizing products
� JRJZ-N series Quantitative Filling products
� JRJZ-S Concentrated Fluid Transportation system
� JRJZ-H series Lubricant Coating system
� JRJL series Hermetic Leak Detectors
� JR-XX series information gathering of production lines,
monitoring system.
Non-standard products::::
� Industrial non-standard equipment, engineering and construction solutions
consulting, design, production, services on site
� Automobile assembly line specialized non-standard work, clamp, and
automation solutions
� Various production lines specialized non-standard equipment, automation
solutions
� Various production lines used to retrofit, manufacture and sale solutions in
China with imported equipment
Special Notice: “CJIERUI”, “JIERUI ELECTRIC”, “JIERUI” etc. relating
brand, mark, trademark are CJIERUI’S register brand, its property and
ownership governed by CJIERUI ELECTRIC CO., LTD., and protected by the
relevant laws and regulations.
JRJZ-V vacuum filling machine instruction
CJIERUI Sales Services Introduction
CJIERUI ELECTRIC CO., LTD. not only provides high-class products, but
also provides top-notch service for customers from various levels; during
pre-market, performance, sale provides elaborate technical services and
meticulous, effective, comprehensive communication with customers to ensure
that manufacturers of products are to customers and themselves satisfaction. As
for sold products, we grant whatever is requested and reply whatever is asked
and overall track, in order to pursuit dual-perfect of products quality and
technical services.
★★★★ Service Concept
Sincerity, specialty, prompt, careful
★★★★Service support
After-sales service department directly is responsible for customers and the
general manager, with implementing Initial Consultation system to ensure that
the service got an effective response;
Perfect services database, the maturity clients, equipment archives, digital and
network management, which effectively coordinate the relevant departments,
and to ensure timely and accuracy;
In In In In Nationwide distribute after-sales service Office and to ensure service
response timely and efficiency;
The 24-hour direct dial service hotline and complaint hotline, inspect and
supervise services to ensure customers satisfaction
★★★★ Service team
Make a good use of talents and establish a high standard, high quality, efficient
service team, and use a full service system;
Specialty engineers president over replying technical problems from
customers.
The leader, technical deputy and professional maintenance staff of the
company regularly or irregularly visit customers;
JRJZ-V vacuum filling machine instruction
We set permanent office in FAW (Changchun), DFAC (Shiyan), Chongqing,
Suzhou, etc. area, specialty personnel are responsible for after sales service.
★★★★ Service promise
All the sold equipments are used for warranty within one year and lifetime
maintenance.
We can guide installation on-site according to the needs of its customers and
ensure the correct installation of equipment;
To ensure that users have qualified personnel to operate and maintain with
systematic operation training.
Receipt of a notice should be given treatment response within one hour.
Service personnel serve on-site with the average area 12-hour and special area
within 24 hours
Make a customer archives to provide regular visit.
JRJZ-V vacuum filling machine instruction
Introduction of other area agencies
Office in China First Automobile Group
Address: FAW factory No. 665, 38 blocks
Tel: 0431-5986108 13944179631
Office in DFAC Group
Address: Dongfeng Group office, Shiyan city
Tel: 0719-8264988 13617195365
Office in Chongqing
Office in Suzhou
Office in Tianjin
JRJZ-V vacuum filling machine instruction
Caution before using
Safety Note
� Misuse Equipment hazardous:
� The equipment used exclusively for professional use and avoid misusing of
equipment.
� Please read carefully manual equipment instructions and all components
instructions, warning etc before using.
� No moving or changing equipments.
� All the equipment parameters are set before leaving factory, and
non-professionals avoid amending.
� Before changing parameters, please record original parameters.
� Check and maintain the equipments daily, and replace the worn components
immediately.
� Fire and Explosion hazardous
� The equipment is the three-phase 4-wire 380V AC power equipment, which
should be grounded line before using, solidly and reliably connect to the safety
standards protection grounded line after electricity switched on.
� No smoking in the working area.
� Keep well ventilation of equipments.
� If accidents occur, please immediately shut down, until maintain equipment
to normal before the boot.
� Spraying hazardous
1. Avoid any part of the body close the pipeline system components during
JRJZ-V vacuum filling machine instruction
operations and maintenance.
2. Do not use hands and any other part of the body to prevent the leakage.
3. Please carefully check equipment pipeline and connecting whether to be
normal, when you find the worn parts and replace them immediately. When
maintaining equipments, you must keep the pressure relief.
� Personal Safety
1. Working uniform: Workers must wear protective uniform, do not
wear earrings, bracelets, necklace and other jewelry ornaments!
2. Protective gloves: Workers must wear protective gloves to prevent
danger.
3. Protective glasses: Workers must wear protective glasses to protect
their eyes from harming!
4. Safety boots: Workers are required to wear protective boots!
JRJZ-V vacuum filling machine instruction
JRJZ-V06P Brake fluid filling machine
Operating Instruction
CONTENTS
1. EQUIPMENT OVERVIEW---------------------------------------------------------------------------1
1.1 CONSTITUTION AND FUNCTION OF EQUIPMENT ----------------------------------------------1 1.2 CONTROL PANEL: ---------------------------------------------------------------------------------3 1.3 PNEUMATIC CONTROL UNIT:--------------------------------------------------------------------4 1.4 THE ELECTRIC CONTROL SYSTEM: -----------------------------------------------------------4 1.5 FILLING GUN AND ITS HOUSE GROUP: ----------------------------------------------------------5
2. PRINCIPAL OF WORKING--------------------------------------------------------------------------5
3. MAIN TECHNICAL INDEX -------------------------------------------------------------------------6
4. VACUUM FILLING EQUIPMENT OPERATION PROCESS----------------------------------7
4.1 PREPARATION-----------------------------------------------------------------------------------------7 4.2 EVACUATION -----------------------------------------------------------------------------------------7 4.3 LEAKAGE CHECK-------------------------------------------------------------------------------------8 4.4 RE-EVACUATION -------------------------------------------------------------------------------------8 4.5 FILLING PROCESS------------------------------------------------------------------------------------8 4.6 SUCTION PROCESS-----------------------------------------------------------------------------------8 4.7 COMPLETE--------------------------------------------------------------------------------------------8 4.8 SUCTION AGAINST DROP----------------------------------------------------------------------------8 4.9 SYSTEM SUPPLY--------------------------------------------------------------------------------------8
5. OPERATION --------------------------------------------------------------------------------------------9
5.1 START/STOP OPERATING SYSTEM ------------------------------------------------------------------9 5.2 SYSTEM PARAMETERS SET ----------------------------------------------------------------------- 10 5.3 VACUUM FILLING OPERATION-------------------------------------------------------------------- 13 5.4 SYSTEM MONITOR--------------------------------------------------------------------------------- 16 5.5 MANUAL DEBUGGING----------------------------------------------------------------------------- 17 5.6 DATE FUNCTION------------------------------------------------------------------------------------ 18 5.7 WARNING RELATING OPERATIONS--------------------------------------------------------------- 19
6 FAULTS AND REMEDY ---------------------------------------------------------------------------- 20
7 MAINTENANCE AND REPAIR ------------------------------------------------------------------- 24
7.1 SYSTEM MAINTENANCE DAILY ------------------------------------------------------------------ 24 7.2 SYSTEM MAINTENANCE:-------------------------------------------------------------------------- 26
ANNEX ONE TWO CONJOINED / TRIPLE-USE (COMPRESSED AIR SOURCE PROCESSOR) INSTRUCTION----------------------------------------------------------------------- 27
ANNEX TWO MAIN COMPONENTS LIST------------------------------------------------------- 29
JRJZ-V vacuum filling machine instruction 1
1. Equipment Overview
JRJZ-V06P brake fluid filling machine
is for the needs of auto brake fluid in
production Line, designed and
manufactured by WUHU CHERY
EQUIPMENT CO., LTD, as
a new type of mechanical-electrical
integration, special vacuum quantitative
filling equipment.
Fig 1.1.1
JRJZ-V06P Brake fluid filling machine can synchronous detect brake fluid
pipeline system pressure reliably and deal with statistics about the filling volume,
vacuum and pressure data parameters when filling powering steering oil. It provides
reliable quality assurance for production management and performance testing.
1.1 Constitution and Function of Equipment
1.1.1 The internal pipeline and components of the equipment is shown in Figure
1.1.3, internal piping system consists of vacuum tube, fill pipe, suction pipe
and fluid tube and so on. The symbol of pipelines indicated in Figure 1.1.2.
Vacuum pipeline Red
Exhaust pipes Yellow
Compressed air Orange
Fluid Pipeline White
Suction line Blue
1) Vacuum System: mainly for vacuum, realize high vacuum effect within little
time by import vacuum pump, including vacuum pump, vacuum sensor and
JRJZ-V vacuum filling machine instruction 2
control and adjustment valves with visual position control etc. D30C vacuum
pump is used mainly for find vacuum.
2) Filling system: system completes filling by constant current electric pump ,
which can shorten the fluctuate time in pipeline during pressure holding process
and can give the filling pressure more exactly. Adjust pressure with fluid valve.
This system consists of the storage tank, filling pump, regulator valve, flow
meter, pressure sensor, pressure meter and control and adjustment valves with
visual position control etc.
Fig 1.1.3 inter pipe
3) Supply system: Two roads for supply, automatics switch, and decide supply by
time delay. This system consists of supply pump and control and adjustment
valves with visual position control etc.
4) Suction system: the main function is to adjust fluid level and suction fluid
remained in pipeline to storage tank after filling complete. The pressure in
tank is controlled by pressure switch. Make tank in vacuum state by D16B.DOT
Vacuum pump D30C
Vacuum pump D16B
Filling tank
Storage tank
Fluid valve
JRJZ-V vacuum filling machine instruction 3
vacuum pump, so system can suction fluid into tank due to pressure difference.
This system consists of control and adjustment valves with visual position
control etc.
1.2 Control panel:
The main operating control panel, Operator can make man-machine
conversation on control panel.
Main operating control panel mainly consists of switch indication control panel,
process indication lamp panel and touch screen. When vacuum filling equipment is
running and instructed by indicator light in addition to color LCD display relevant
data to ensure that operators in remote monitor the state of filling.
Switches control panel is composed of 【Emergency stop】、【Power on】(with
light)、【Power stop】、【Manual/Auto】、【Start】、【Stop】、【Supply】、【Reset】、
【1-ABS-0】.
Switching indicator panels is composed of “Ready→First vacuum→Vacuum
leak→Post vacuum→Filling→Suction→Over”.
Type selection button is composed of【High low】、【Type 1】、【Type 2】、【Type
3】、【Type 4】、【Type 5】.
Fig 1.1.4
JRJZ-V vacuum filling machine instruction 4
1.3 Pneumatic Control Unit:
Located on the left door of cabinet, the main function is to provide an effective
source of compressed air. Before compressed air coming into the equipment, firstly
processes unit (triplet) filter, lubrication etc., and then gas sources will be available to
provide to the aerodynamic components. Control the sol valves by PLC to achieve
pneumatic control functions. Mainly consists of solenoid valve group, valve board,
air disposal unit (triplet), and regulator etc.
Fig 1.1.5
1.4 The electric control system:
The main electric control loop. Inside electric cabinet there are PLC, A/D module,
mini breaker, motor protective switches, mini relay, contactor, switch electric source,
connection terminal etc. PLC shall make logic operation of whole system to assistant
each control component action to ensure normal working of system. A/D module
shall translate the simulation signal of each sensor(pressure, vacuum) into digital
and input them to PLC, then PLC shall compare every parameter and program to
control filling system and vacuum system. Mini breaker can be used for manual
switch under debugging mode, and protect each loop form over current under normal
mode. Motor protection switch mainly protects each pump motor form over current
JRJZ-V vacuum filling machine instruction 5
and under voltage. Mini relay complete logic operation with contactor.
1.5 Filling gun and its house group:
1.5.1 Gun and the main pipeline joints connecting rapid routing and coated with
plastic covers.
1.5.2 The gun head is designed with anti-leak, after filling finishes; there is no
leakage when plucking gun head.
1.5.3Gun is set with start and stop button and indicator lighters. Green button if for
filling and red button is for stop.
1.5.4Gun head cooperated with oil tank are connected with pneumatic clamping type.
1.5.5Filling oil gun is seated right side of equipment for use, which is made from
aluminum (not including handle), the part of easy-worn connected with oil tank is
considered intension, durability and corrosive resistance.
1.5.6 Gun head cooperated with the oil tank, oil tank mouth is without deformation or
injury, and the body without interference.
2. Principal of Working
JRJZ-V06P brake fluid vacuum filling machine is composed of fluid control,
pneumatic control and electric control three parts: Fluid control mainly real-time
check and quantitative controls Antifreeze filling and system vacuum pressure;
pneumatic control part mainly finishes the fluid valve supplying pilot gas supply and
controls filling gun clamping; electrical control system mainly finishes system
process control and testing, also deal with process parameters data, preservation and
the system monitoring, data display and failure alarm, etc.
JRJZ series common vacuum filling equipment working principle is based filled
system with vacuum check, vacuum filling, and suction of filling line and purification
etc. process technology integration of intelligent control. And complete vacuum,
checking and filling process with higher operating rhythms.
Vacuum process of JRJZ - V06P Brake fluid vacuum filling machine, including
low vacuum and then high vacuum stage; while suction process, including suction,
ventilation, etc. several stages. Filling process of quantitative vacuum filling
equipment consists of preparation, vacuuming and leakage detection, re-evacuation,
JRJZ-V vacuum filling machine instruction 6
filling, suction and completing, etc. several sequential process.
Refer to system diagram, see the attached figure.
3. Main Technical Index
1) Technical Parameters
� Max system vacuum capability(filling gun head)::1mbar under temperature
25℃
� Max displacement of vacuum pump::30 m3 /h more than 400mabr under
temperature 25℃
� Filling mode :in-line
� Filling medium: brake fluid
� filling pressure: 1-10bar,adjustable
� filling speed:1-15L/ min , adjustable
� filling accuracy:level±2mm
� Filling cycle : ≤120s/vehicle
� moving pipe length:8m
� moving mode:moving arm
� supply mode:two pails auto exchange
� Equipment shape dimensions: length×width×height 1700×800×1600mm
2) working environment
� gas source:6.5bar(静态);
� power: three-phase 380V±10% 50Hz±1%;
� power consumption:3.5KW;
� environment temperature:-5~45℃;Environment humidity:55~99%;
� noise:70db;
JRJZ-V vacuum filling machine instruction 7
4. Vacuum Filling Equipment Operation Process
The process of vacuum filling equipment consists of preparation, evacuation,
leakage check, re-evacuation, filling process, suction and complete .
4.1 Preparation
After power on, then system shall enter into working state.
4.2 Evacuation
When first evacuation, vacuum pump M1 runs, vacuum pressure holding valve
No Process Content
1 Preparation Electrified, equipment enters preparation after self-check
2
Automatically
clamp Press the green button on the gun, seal complete
3 Evacuation
Big leakage checking
If failure to withdraw from filling cycle, sound and light alarm
4
Constant
pressure,
leakage check
Small leakage checking
If failure to withdraw from filling cycle, sound and light alarm
5 Re-evacuation Gun head reach the lowest vacuum
6 Pressure
filling
Constant pressure filling, pressure, flow and time triple control. If failure
to withdraw from filling cycle, sound and light alarm
7 Keep pressure Make the filling pressure constant to ensure fill up
8 Suction
process Inflatable, and suction to complete level treatment
9 Filling
complete State initialization, sound and light alarm
10 Pneumatic
loosening Press red button on the gun and unclamp
11 Manually
take guns Suction against drop.
JRJZ-V vacuum filling machine instruction 8
V601and gun vacuum valve V622 opens, a few seconds later, vacuum sensor
V604.1 opens, until preset time.
4.3 Leakage check
After first evacuation, vacuum pressure holding valve V601 closes, system
begins leakage checking, until preset time.
4.4 Re-evacuation
Generally, system enters into re-evacuation process after leakage checking, and
opens vacuum pressure holding valve V601 again. The re-evacuation is to repeat
evacuation process, until preset time.
4.5 Filling process
When filling, filling pump M3 runs, and gun filing valve V621 and filling valve
V602 act, filling process start until preset pressure. Then keep to preset times, the
filling process ends.
4.6 Suction process
After filling, the oil in pipeline shall be sucked back into tank. During this process,
Tank vacuum valve V612 opens, the vacuum air pump D16B.DOT start to
evacuation for tank. suction valve V603, gun suction valve V621 and blowing
valve V509 act, until preset time.
4.7 Complete
After suction, the whole filling process ends, system shall give indication signal
for s few seconds.
4.8 Suction against drop
Then, press stop button, vacuum pump M2 runs. The system opens tank vacuum
valve V612 again, suction valve V603 acts to suction against drop until preset
time or after gun returns into its house. The suction against time can be set on
man-machine interface. See details in fig 5.2.2.
4.9 System supply
During the system supply process, supply valve V610or V611 acts and use the
JRJZ-V vacuum filling machine instruction 9
negative pressure in tank to supply oil into tank.
5. Operation
Check Before Power On
1. Check the pipeline and joints whether to leak and damage or not, if so, please
replace or repair them immediately.
2. Check the gas source valve whether to open or not, whether gas supply range
is within the scope of(0.5-0.6Mpa)or not。
3. Check whether the vacuum pump oil is within the indicator line, if inadequate,
please add immediately.
4. Observe the vacuum pump oil color whether to become pale or not, verify the
use of time and replace vacuum pump oil immediately.
5. Check the contact line whether to peel or not and repair immediately.
6. Check supply oil mix whether to insert on line within the oil drum or not. .
7. Check emergency stop button whether to pluck off or not and make
emergency stop button at spring state.
5.1 Start/stop Operating System
5.1.1 Power On:
Connect with the main power of the JRJZ-V06P brake fluid filling machine ;
Push the 【power on】button in the control panel ,The indication light shines and the
touch screen enters the original interface(fig 5.1.1)
JRJZ-V vacuum filling machine instruction 10
Fig5.1.1 system original interface
5.1.2 Power off Operation: Shut off the main electric source switch and main air
valve.
5.2 5.2 5.2 5.2 System Parameters Set
System parameters set is completed on the touch screen.
5.2.1 Selection of Working Mode
Switch the 【manual / automatic】switch to manual location on the control panel,
system enters manual mode; If switching the switch to automatic location, the system
enters automatic work mode.
5.2.2 Operating Parameters Set
NNNNote: this item must be operated by professional persote: this item must be operated by professional persote: this item must be operated by professional persote: this item must be operated by professional person or authorized person by on or authorized person by on or authorized person by on or authorized person by
our our our our company, strictly prohibit other pcompany, strictly prohibit other pcompany, strictly prohibit other pcompany, strictly prohibit other person amend.erson amend.erson amend.erson amend.
1)Technical Parameters Set
In figure 5.1.1 window, press "Parameter set" to access the interface shown as
figure 5.2.1. After inputting the process password (system default password 1), press
ENT and system firstly enters current parameter set interface (Figure 5.2.2), in which
you can set each control parameters of vacuum filling process; press DOWN to enter
“Technics parameter two(fig 5.2.3)”.
JRJZ-V vacuum filling machine instruction 11
Fig 5.2.1 password input interface
Fig 5.2.2 Technics parameter set interface
JRJZ-V vacuum filling machine instruction 12
1
Fig 5.2.3 technics set interface 2
List 5.2.1:
No. Parameter name unit Meaning Set value
1 Rough vacuum time S The time to check whether there is big leakage in vacuum pipe and break pipe.
2 Rough vacuum value Mbar The vacuum limit value for rough
vacuum process
3 Fine vacuum time S The time to check whether there is
small leakage in vacuum pipe and break pipe.
4 Fine vacuum value mbar The vacuum limit value for farther
vacuum process
5 Vacuum leakage checking time S Vacuum leakage checking time
6 Vacuum checking
value mbar
Checking whether there is small
leakage
7 Re-evacuation time S Time time for second vacuum process
8 Filling pressure Bar The pressure value for full filling
9 Filling volume L The max filling volume
10 Filling tolerance L The filling volume range
11 The shortest filling
time s The shortest filling time
12 Max time S The longest filling time
13 Pressure keep time S Pressure keep time after filling to
JRJZ-V vacuum filling machine instruction 13
ensure filling full.
14 Suction time S Time of suction process
15 Barrel empty time S The time to check barrel empty.
16 Suction against drop
time S
Suction against drop time after taking
gun form filling point.
2) System parameter set
System parameters are for system measurement to ensure the filling accuracy.
Input system parameter password (system default password 1) in the interface shown
as fig 5.2.1, press ENT key and system enters “system parameter set” interface (fig
5.2.4 ). User can modify the measure parameter, also can set new password.
Fig 5.2.3 system parameter set interface
NNNNote : before delivery, system parameters have been set right, do not amend ote : before delivery, system parameters have been set right, do not amend ote : before delivery, system parameters have been set right, do not amend ote : before delivery, system parameters have been set right, do not amend
them .them .them .them .
5.3 5.3 5.3 5.3 Vacuum Filling Operation
5.3.15.3.15.3.15.3.1 Automatic Filling
1. First, switch【manual / automatic】switch to the automatic position on the panel,
filling equipment enters preparation state, preparation indicator lights on.
JRJZ-V vacuum filling machine instruction 14
2. on monitor interface, select vehicle type.
3. Take the gun from bracket and point to the filled pot, push the green FILLING
button on the top of the gun or press the remote control locking button, the three
claws in the gun clamps the lip of the pot, and the entire vacuum filling cycle
starts as follow. The indication lamps will indicate the each process; the whole
cycle is going on automatically:
Ready→First vacuum→Vacuum leak→Post vacuum→ Filling→Suction→Over
4. After filling, press stop button to unclamp claws, then system starts suction
against drop until preset time or gun returns into its house.
5. Put the gun into its house.
5.3.2 5.3.2 5.3.2 5.3.2 Manual Filling
1. First,switch the 【manual/automatic】switch to the “manual” position ,the
system enters to the manual work mode, the “preparation” indicator lights on..
Each time pressing the filling button, system shall enter into evacuation, leakage
checking, re-evacuation, filling, suction step by step. You can get the changing and
result of each parameter during every process, to make the fault judge more easy and
full. Generally, in normal produce line, for user we do not recommend this mode.
Ready→First vacuum→Vacuum leak→Post vacuum→ Filling→Suction→Over
� NNNNote ote ote ote ::::
a) System shall sync-output fault alarm with the indicator on panel when fault.
b) With automatic mode filling, if press【filling stop】 key on the gun or the stop
button on the operation panel, system stops current operation, and then return the
initial state.
c) During filling process, operators can observe the current fill volume, the current
pressure and current vacuum degree by system monitor interface. Detailed
monitoring interface see 5.4.
d) Any filling state, users can adjust filling pressure by the filling pipeline regulating
valve RF1 to regulate the speed of the filling.
5.3.3 Supply fluid to tank by hand
1. First, switch 【manual / automatic】 switch to the manual position on the panel,
JRJZ-V vacuum filling machine instruction 15
filling equipment enters manual state.
2. Press【manual supply】button on the panel, supply indicator lights are on, supply
fluid valve open, the system begins supplying oil to the storage tank from. to fill
the required level, again press on the panel【manual supply】button, and stop
supplying.
Note: Note: Note: Note: DuringDuringDuringDuring manual manual manual manual supplysupplysupplysupply, , , , until until until until systemsystemsystemsystem set set set set the the the the high high high high level, level, level, level, you need not you need not you need not you need not presspresspresspress
【【【【manual manual manual manual supplysupplysupplysupply】】】】buttonbuttonbuttonbutton , the system will automatically stop , the system will automatically stop , the system will automatically stop , the system will automatically stop supplying.supplying.supplying.supplying.
5.3.45.3.45.3.45.3.4 Automatically supply fluid to tank
System monitors the level of the fluid in the storage tank by the fluid level
switch. When the storage tank level reaches the low level, system will
automatically open the valve SV10or SV11 to supply with level alarm interface( see
details in 6 fault and remedy), when reach to high level, the system automatically
stop supplying, supply valve closed.
5.3.55.3.55.3.55.3.5 State Indicator Instructions
1. Three-color Lamps indicator
1) A red warning light constant on indicated system with malfunction, when
checking generally electricity or equipment preparation state. This warning,
system does not start filling operations. Mainly in the following circumstances
lit :
A. Gas source is smaller than set smallest pressure, which is to protect pneumatic
valve dependable motion.
B. The Trip situation of filling pump, vacuum pump motor protector.
C. The liquid level is too low or too high.
2) A red warning light frequent flashes indicating filling process with failure, in this
case, you can choose complete mandatory or restoration re-operation. Mainly in
the following circumstances:
A. Filling time exceeds longest filling time set.
B. When evacuation, you can not vacuum the largest leak vacuum degree in set
time, the system reckons there is big leakage.
C. During leakage check, find leakage greater than the set.
JRJZ-V vacuum filling machine instruction 16
D. When filling, the pipe-distance exceed journey.
3) A yellow light constant on shows system with problem, need to solve with
manual intervention, mainly in the following circumstances:
A. Filters plug, regardless of supply filters or filling filters
B. When complete filling, the actual filling volume is less than the preset least
filling volume.
C. When the edge of oil drum empty.
2) The green light is on expressed filling, extinguishing indicates completing.
2. Sound warning : the following two situations :
A. After filling completed, the buzzer will call a period of time to remind the
operator complete filling. 1HZ frequency, time out or press the "stop" button
on the gun to stop.
B. System with malfunction, with a red light for state instructions, buzzer
frequency 5HZ, until troubleshooting or by pressing the "alarm reset" button.
5.4 System Monitor
Systems with real-time monitoring function, users can fully understand
equipment current work state by this picture.
Touch "system monitor” in any interface, you can access to the main monitor
window of system (Figure 5.4.1), press the “pipe monitor” to the pipe monitor
interface (fig 5.4.2). The operators can observe the current filling volume, the current
cycle time, the current pressure and the current vacuum value and the current filling
state.
JRJZ-V vacuum filling machine instruction 17
Fig 5.4.1main system monitor interface
Fig 5.4.1 system pipe monitor interface
5.5 5.5 5.5 5.5 Manual Debugging
Only super manager can operate this function. When system debugging and fault
judge, under this mode, you can operate pump and valves directly on man-machine
interface without PLC control, which makes judge and operation more easily. But this
must be completed by very professional person, otherwise, it can bring unexpected
fault with wrong interlocking of pump and valves. This function must be used
usefully.
JRJZ-V vacuum filling machine instruction 18
In 5.1.1 window after input “manual debugging password”, press the ENT key,
the system enters manually debugging window (Figure 5.5.1), users can manually
debugging in this window, "the manual debugging" functions for system service/
maintenance, an online debugging functions of the main system components
individually, or a combination check.
Fig 5.5.1 manual debugging window
5.6 Date function
Data query function is about statistics about the total filling volume and time of
filling, users can access this function window for data inquiries.
5.6.1 In the main menu select "Data Query", the system accesses data query interface
(fig 5.6.1).
JRJZ-V vacuum filling machine instruction 19
Fig 5.6.1 data query window
User can press “ clear” to clear filling times and filling quantity manually.
Note: The data will not automatically clear and only manually cleared.
5.7 5.7 5.7 5.7 Warning Relating Operations
(1) During systems operation, before operators carry out the next phase of the
operation or change the setting, must complete ongoing operation, or will
result in system disorder or system failures.
(2) In all touch-screen interfaces "return" buttons are return the initial interface.
(3) In case of emergencies, you can beat 【emergency stop】 on the panel,
equipment stop.
(4) For any system fault alarm , you can press【alarm reset】button to cancel alarm.
Unless an emergency situation, you can not press【emergency stop】 button,
frequently use 【emergency stop】 button to stop power would affect some
components of life, even damage some electrical components.
JRJZ-V vacuum filling machine instruction 20
6666 Faults and Remedy
The system has fault diagnosis and alarm instructions function. In any working
state, failure, the alarm buzzers ring with failure, while red indicator light on of the
top three-color, the operator can query the current buzz content on the screen, the
specific alarm Table see 6.1.
When alarm interface appears, press【alarm reset】on the panel to cancel alarm.
Repairing equipment must be made under stopped state. Only after all alarms
have been eliminated, equipment can be started. Do not repair equipment with
electric.
Table 6.1 detailed alarm items and treatment
alarm content reason treatment
level too low
alarm
Level switches may be
damaged or infusion pump
damage
1、check level switch
2、adjust infusion pump and filter
level too high
alarm
level switch may be
damaged or infusion speed
too fast
1、check level switch
2、adjust throttle valve of infusion
pressure shortage
alarm
pressure switch may be
damaged or Under voltage
gas supply circuit
1、check pressure switch
2、Check pressure of the gas supply loop
whether to be enough
filling pump
alarm
load may be too large or
system power failure
1、protective switch current set whether to
be too small
2、check system load whether to be too
large
3、 check system distribution electricity
circuit
vacuum pump
alarm
load may be too large or
system power failure
1、protective switch current set whether to
be too small
2、check system load whether to be too
large
JRJZ-V vacuum filling machine instruction 21
3、 check system distribution electricity
circuit
big leakage
alarm
Seal system not well, filling
head unclamp, pipeline
leakage, or large leakage
check parameter set too
small
1、remove filling head and clamp
2、check system pipeline whether to be leak
3、adjust large leakage parameters
small leakage
alarm
pipeline with small leakage
or small leakage parameters
set too small
1、choose compel filling or cancel filling
2、check system pipeline
3、 adjust system small leakage check
parameters
drum empty
alarm
level switch damage
drum empty
1、check level switch
2、change drum prompt
filter alarm filter damage
pipeline unsmooth
1、check filter
2、check clean pipeline
filling overtime
alarm
set filling volume too large
filling pipeline leak
1、check set filling volume and filling
protective
2、check and maintain pipelie
Note: any of the foregoing alarm, according to the screen prompts for the
corresponding inspection and operation. If that does not succeed, please contact with
the manufacturers.
Equipment Common Faults and Remedy :
1. Vacuum failure (large leakage and small leakage alarm).
1) Seal damage: check seal loop of gun muzzle whether to damage or not, if
damaged, replace new seal loop;
2) Vacuum pump failure: start vacuum pump and check vacuum pump whether
to normally operate or not, if normally operate, block gunpoint by hand and
directly vacuum, and then observe vacuum gauge whether it is below 20mbar
or not, if not reach, denoting that pipeline is leaking or vacuum pump
performance decline;
JRJZ-V vacuum filling machine instruction 22
3) Car assembly loops or oil drum leaks: if such testing can vacuum below
20mar, denoting circuit assembly or oil drum leaks;
2. Press filling without action.
1) Check gas source on site and observe triplet of the equipment whether to have
compressed air or not.
2) Press the button to observe input dot of the PLC corresponding button
whether it is light, if not light denoting button damage.
3) If light on to observe input dot of the PLC corresponding button whether it is
light, if not light denoting PLC or the internal process with problem.
4) Observation stops button corresponding PLC lights and whether it is lighting,
lighting denoting button damage.
5) After obviating power issues, observe output dot corresponding fluid valve
whether to correctly open or not, if not open, pull out the windpipe to check
whether ventilate or not, ventilation denoting fluid valve damage;
6) Not ventilating, measure the corresponding sol valve whether to have 24V
power input or not, if no inputting, denoting PLC solenoid valve connecting
line with problem. If inputting, and solenoid valve without action, denoting
solenoid valve with failure. When you can remove the windpipe, repeatedly
open and close solenoid valve by the manual button, to see whether to
resume normally or not, if ineffective, denoting solenoid valve damage;
3. Filling process without vacuuming
1) Observe this process whether to activate the vacuum air pump or not, if not
starting, check whether contactor is Pick-up and whether the thermal
protection switch is Takeoff;
2) Pump starts normally, and observe vacuum valve of this process whether to
open or not, if not opening, connect 2.6
3) Valve open normally without filling, showing that the pneumatic control valve
of filling gun did not open, and check the corresponding sol valve whether it
is normal, if work normally, when press corresponding sol valve manual
switch a minute then loose and repeated operation, then observe whether to
JRJZ-V vacuum filling machine instruction 23
fill normally or not.
4. During filling process, evacuation without filling
1) Observe this process whether to activate the filling pump or not, if not starting,
check whether contactor is Pick-up and whether the thermal protection
switch is Takeoff;
2) Pump starts normally, and observe filling valve of this process whether to
open or not, if not opening, connect 2.6. Valve open normally without filling,
showing that the pneumatic control valve of filling gun did not open, and
check the corresponding sol valve whether or not normal, if work normally,
when press corresponding sol valve manual switch a minute then loose and
repeated operation, then observe whether to fill normally or not.
5. Filling Inadequate
1) During evacuation observations, vacuum instrumentation shows whether to
reach 20mbar around or not, if not reaching, denoting vacuum failure, refer
to 1.
2) If not evacuation, observe set value of pressure display gauge or "filling
pressure stable time" and "suction time " of PLC parameters set value
whether to be changed or not , if altered, revise original setting values;
3) If no changed, observe pressure gauge pressure of filling pipeline whether is
above the two kilograms during filling, if not, gently shake regulating valve
to reach above two kilograms of pressure and adjust pressure until filling
pressure satisfied;
6. Level Failure (Level too low, Level too high alarm)
1) If level is below lowest limit, firstly observe liquid pipelines whether to have
power steering fluid or not.
2) Pipeline has no problem, observe four level reference point of the PLC
whether it is normal, if not normal, denoting Level Meter or connectors with
problem, test connections and troubleshooting Level Meter
3) If input point is correct to observe whether the fluid valve is opened, if not
opening, connect 2.6)
JRJZ-V vacuum filling machine instruction 24
4) If level is above level higher limit;observe four level reference point of the
PLC whether it is normal, if not normal, denoting Level Meter or connectors
with problem, test connections and troubleshooting Level Meter
If output point is normal to observe whether the fluid valve is opened, if opening,
connect 2.6
7 Maintenance and Repair
7.1 System Maintenance Daily
1. System Pipeline Maintenance: check equipment pipelines daily and tie-in whether
to leak or not, and ensure that equipment is clean and tidy. Carrying out
maintenance every three months with cleaning dust and check whether pipeline
and circuit are normal.
2. Vacuum pump maintenance:
1) Check vacuum oil daily, if necessary you must check oil volume and top up it.
Suggestion: you should always keep oil level be in the middle of oil level
observing window.
2) Normally, system shall first check vacuum oil level after turn on, and shall
open SV11 valve to supply with shortage. However, operator also should
check oil level every day one time, to avoid vacuum pump being damaged
and affecting filling with oil shortage due to system failure.
3) Change vacuum oil immediately and you must replace vacuum pump oil in
follow circumstances during using equipment.
a) The equipment has been used more than one month.
b) Observe that oil color has becoming white.
c) The equipment has already filled more than 7000 vehicles.
d) Changing oil type: LEBOLD N62
Tool required: Allen key 8mm
Oil changing must be done with a switched off and still warm pump.
Open the oil drain plug and let run out the used oil into an appropriate container.
Refasten the oil drain plug when oil runs slower, start up the pump briefly (10 sec.
max) and switch off immediately. Reopen the oil drain plug and drain the rest of the
JRJZ-V vacuum filling machine instruction 25
oil. Before refastening the oil drain plug, inspect the O-ring and if necessary replace
it. Open the oil fill plug and pour in clean oil; refasten the oil fill plug.
4) Cleaning the filter:
A wire-mesh filter is located in the intake port of the pump to act as a dirt trap for
impurities. It should be kept clean in order to avoid reduction of the pumping speed.
For this purpose, remove the dirt trap from the intake port and rinse it in a suitable
vessel using a solvent. Then thoroughly dry it with compressed air. If the dirt trap is
defective, replace it. The cleaning intervals depend on requirements.
5) If the limit pressure of pump is affected because any air or fluid melted into
oil, you can run pump for 30min to exhaust under the condition of gas ballast
valve opened and inlet closed.
6) If vacuum pump has been set aside for one year, the oil must be replaced
before it is used again.
7) The open times of pump can’t exceed six to avoid motor over loading.
8) The vacuum pump oil must be LEYBOLD oil. The damaged due to other oil
doesn’t be included in warranty.
3. System Maintenance:
System checks vacuum value and flux parameters every half year and makes
them optimization.
4. You should keep fingers clean, slightly touch and press, forbid touching with
finger nail during using of various operation keyboards equipped in the
equipment system (especially LCD touching screen keyboard).
5. Electric Maintenance: regularly inspect whether connection terminal line loosens
and whether the relay contacts badly and every valve plug contacts badly in order
to ensure signal reliably input and output.
6. Maintaining Filter: Check whether supply filter and filling pipe filter are blocked
every month and clean filter sieve. Filter should be rinsed and changed when
system fault for filter is blocked during normally using.
7. Filling gun maintenance: Seal ring of filling nozzle is easy-damageable and you
should check regularly every month. If damaged you should replace it
JRJZ-V vacuum filling machine instruction 26
immediately.
8. Moving system maintenance: you should regularly fill the lubricant oil for mobile
arm parts every year.
9. Maintenance of gas disposal unit:
1) Oil level of oil tank should keep between upper limit and lower limit, if
shortage you should supply oil immediately. Use viscosity 2.5~7°E lubricant
and 22 engineer oil is recommended.
2) Filter adopted with manually drainage device should advert to drain and keep
level below level sign, at least drain once every shift.
10. Maintaining air desiccator:
1) You should change desiccant in the drier every four years, when changing you
just remove four screws of below cover and unfix connect pipe.
Desiccant type: modified aluminum:A5
2) Carrying out maintenance every four months and cleaning dust and checking
whether gas pipeline and electric line are normal.
11. Ensure that power supply and gas source are switched off you can carry out
various maintenance.
12. you can know the detailed content on the main parts instructions.
7.2 System Maintenance:
1. Fluid control circuit maintenance: every fluid valve can open manual in the
fluid control circuit, during maintenance if you want to operate a valve, you
can press white point in the sol valve manually, and check and maintain the
relevant pipelines, you can operate manually sol valve only on the power off
conditions.
2. Electric loop maintenance: Total system logic controls are in the PLC control,
after checking trapezium and know the logic relation, observe each input and
output state in the “PLC”, confirm that interior logic failure, or exterior
connector and valve or its perform components problem, maintenance process
you can refer to system theory chart and electric control chart.
JRJZ-V vacuum filling machine instruction 27
Annex one
Two conjoined / triple-use (compressed air source processor) instruction
(for reference only difference between models)
一、 Installation
1、Blow the pipeline by compressed air before installation.
2、Triplet required install vertical, and water cup and oil cup are adown, but
pressure relief valve knob install up or adown.
3、Arrowhead direction refers to air compress direction, pay attention to it when
installation.
二、 Environment
1、Avoid exposure in the sun。
2、As a result of water cup and oil cup are made from creosote; Avoid using in
circumstances containing the following chemistry: compound oil, thinner,
chloroethylene, kerosene, acid or aroma hydrocarbon.
三、 Operation
1、The filter should advert to release water with drainage manually, level does not
exceed level symbol, at least set water once every number of runs
2、When adjusting pressure, firstly pull the knob, right rotate with pressure
ascending and left rotate with pressure descending, and then push the knob and
clock on the adjusted pressure.
3、The oil level of oil tank should keep between upper limit and lower limit, oil
deficiency, supply oil prompt. use mucosity 2.5~7ºE lubricate, we commend
use number 22 steamer oil.
4、The minimum air flux in the normally operating should content the minimum
flux request of oil tank.
5、Cup and cup cover removed should be operated without pressure.
(1)Clutch shield cover by hands and press orientation device and rotate right
JRJZ-V vacuum filling machine instruction 28
or left 45º by thumb, and then make the arrowhead of orientation device
versus the arrowhead of valve and pull adown to remove.
(2)Some models can directly tweak down.
6、Oil tank can fill oil with stop gas or non stop gas, fill oil step as follows:
(1)Usually directly fill by opening oil stuff.
(2)Some model: a. open the block of oil tank and dropt air of cup →b. tweak
down oil cup→ c. add the cup proper oil→ d. tweak up oil cup→e. tweak
up stuff.
四、 Maintenance:
Abstersion of cup and sieve should choose litmusless scour, after washing with rinsing and cool.
JRJZ-V vacuum filling machine instruction 29
Annex two
Main Components List
NO Name Type Manufactures Mark
1 Vacuum pump D16B.DOT Germany
LEYBOLD
2 Vacuum pump D30C Germany
LEYBOLD
3 Vacuum sensor PTX610 DURCK
4 Pressure sensor A-10 WIKA
5 Flow sensor 8030 Germany
BURKERT
6 Fluid valve G1/2 Germany
BURKERT
7 Filling pump TOP-2MY400-206HBM Japan NIPPON
8 Vacuum pressure
siwtch ZSE30-01-25-ML SMC
9 Pressure meter with
switch
GP46-10-01L5 SMC
10 PLC 1766-L32BWA AB
11 I/O extending unit 1762-IQ16 AB
12 A/D extending unit 1762-OW16 AB
13 Air dryer KGA-250 YSC
14 Touch screen 2711P-T6C20A AB
15 Triple AC30-03 SMC
16 Pressure meter Y60 Shanghai
17 Electric components SCHNEIDER
JRJZ-V vacuum filling machine instruction 30
18 Fluid hose 10X12 fluorine Japan DMZ
19 Ripple pipe jacket AD42.5 nylon Germany FLEX
20 Fluid filter 500目,150目 Haideke
21 Supply oil
combination Self-made
22 Storage tank 50Lstainless steel China
23 Cabinet 1700X800X1800 China
24 Air-condition LA-03-H Leibo
25 Mobile arm JR010 Self-made
26 Balancer 1.5-3KG Aotuo
27 Filling gun J812D-03 Self-made
SSSSpare list pare list pare list pare list
NO Name Type Manufactures
1 Button on panel XB2B SCHNEIDER
2 Button on gun 49112 American ICW
3 Fluid valve TYPE2000 BURKERT
4 Sol valve VQZ1115 SMC
5 Seal toop KF25 LEYBOLD
6 Filter core G1/2