Knowledge about slag breakers

At present, there is only one manufacturer of slag breakers in China, and that is Beijing Aerospace Petrochemical Technology Equipment Engineering Company. Therefore, the operating procedures and troubleshooting information for slag breakers that I have uploaded are intended for those manufactured by this company. Since they contain images, they cannot be pasted directly; they must be uploaded instead. Please download them for reference.

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Hydraulic power unit for slag breaker 1. Hydraulic power unit: Before debugging, turn off the main switch, cut off the power voltage and control voltage, and close the inlet ball valve. ①The power unit requires petroleum-based hydraulic oil; this system uses N46 anti-wear hydraulic oil. After purchase, it is subjected to circulation filtration and purification (with a filtration precision of no less than 20μm), then poured into clean oil drums and sealed, ensuring that the drums are clean and airtight. The parameters of the hydraulic oil are as follows: Density, Viscosity, Operating Temperature, Flash Point, Ignition Point, Water Content, Vapor Pressure – 0.87 g/cm3, 41.4–50.6 cSt, -5°C–74°C, 222°C, 298°C; Water content: 0%. Low viscosity index, Viscosity, Pressure coefficient, Maximum allowable pressure, Suitable sealing materials, Corrosion resistance, Flammability – 10622, 22–2735 MPa. BN, N, V, T; Good, Fair. Note: BN – Nitrile rubber; N – Polychloroprene rubber; V – Fluoroplastics; T – PTFE. ② Pressure resistance test for hose assemblies: The hoses should be pressurized to twice the operating pressure and held at that pressure for over 60 seconds, with no leakage or other abnormal phenomena occurring. ③Cleaning treatment: Hydraulic components such as pumps and motors are used for cleaning the hydraulic oil through circulation ； The pipes are pickled. Clean the interior of the hydraulic system before filling it with oil. The main lines A and B of the power unit are connected to the cleaning circuit, allowing the system to operate at maximum flow rate so that the entire system can be filtered and cleaned for 2 hours. Then. Connect interfaces A and B to the motor’s oil inlet and outlet, and connect interface D to the motor’s oil drain port, making sure the connectors are clean first. Self-circulating filtration can also be used; run the system without a load for a period of time to check the cleanliness of the oil. During self-circulating filtration, connect a filter (with a rating of no less than 20μm) to the return line of the hydraulic pump. To change the direction of the motor, be sure to swap the filter back to the hydraulic pump return line to prevent dirt in the filter from entering the system. ④Oil filling: Before filling with oil, clean the oil filler tube and connectors to ensure they are free from water or other contaminants. Use a dedicated oil pumping filtration device equipped with a filter (with a minimum pore size of 20μm) to pour the oil into the clean fuel tank through the air filter opening. Before the first start-up, fill the fuel tank to the maximum level, then remove the oil leakage pipes from the pump and motor and fill the pump and motor housings with clean oil. During the first start-up, if the system cannot build pressure, air can be released from the pump’s oil outlet until a bubble-free flow is achieved, thereby facilitating filling and reducing noise. ⑤Testing site: The testing site must be cleaned thoroughly before testing to ensure it is dust-free and clean; the testers are required to carry out their work in a clean and orderly manner. 2. Operation 2.1 Visual and electrical inspection Starting from the oil level, going through the pipeline connections to the motor. Check all pipeline connections to ensure that the flange screws are tightened. Check the voltage of the motor and other electrical components to ensure that the wiring is correct. 2.2 Ensure unobstructed pipelines: Open the pump and the pipeline valves as soon as possible. Before the first start-up, the oil supply lines on both sides of the pump must be unobstructed (check that all valves are fully open). 2.3 Powering on the system: Open the control cabinet door and sequentially turn the switches for the power supply, control power supply, motor power supply, and heater power supply to the “ON” position. At this point, looking at the text display, the words “******Slag Disintegrator, Aerospace Institute 11 (Beijing)” will be shown, indicating that the system is working properly. If the message “Oil temperature below minimum level” appears, it means that the oil temperature in the hydraulic system is below 5°C; in such cases, the control system automatically activates a 380V/1.5KW heater to heat the oil. Press the “Reset” button until the display shows a temperature of >5°C, after which the system can be started again. 2.4 System startup: Press the “Motor Start” button; at this point, the “Motor Running” indicator light on the front panel will light up. The text display will show “Wait 7 seconds for pressure to build up”, and after 7 seconds it will indicate “Hydraulic system ready”, signaling that the hydraulic motor can be started. Set the \"Manual/Automatic\" selector switch to the \"Automatic\" position to start the hydraulic motor; at this point, the \"Automatic Mode\" indicator on the front panel will light up, indicating that the drive system has entered automatic operation mode. The rotation direction is forward, and this state represents normal operation of the drive system. This display shows the normal operating oil temperature value. Check the fuel supply pressure, system pressure, and oil level. If the oil level drops after startup, this is because the motor’s working chamber and other system components such as the main fuel lines are filled with oil during the first start-up; in such cases, oil should be added to the tank from the air filter promptly. With the hydraulic system ready, set the \"Manual/Automatic\" selection switch to the \"Manual\" position; the \"Manual Mode\" indicator light on the front panel will then light up. At this point, the automatic operation mode is stopped, and the system enters manual adjustment mode. Press the “Forward” button to make the drive system rotate in the forward direction. Conversely, pressing the “Reverse” button causes the drive system to rotate in the opposite direction. Viewed from the motor shaft end, clockwise rotation of the motor is considered the forward direction. Whenever a shutdown is required, press the “Motor Stop” button to cut off the power to the motor; the “Motor Running” indicator light on the front panel will go out, and the hydraulic motor will stop rotating. Adjust the pump’s maximum discharge limiter to keep the motor speed stable at 10 r/min. The displacement limiter setting value is predetermined before the power unit leaves the factory, and generally no further adjustment is required. If readjustment is needed, follow these steps: ① Loosen the lock nut ； ② Manually rotate the adjustment screw to adjust the displacement. Adjusting counterclockwise will increase the displacement. Be careful not to adjust the displacement while the motor is rotating ； ③ Adjust so that the motor rotates at approximately 1010 r/min ； ④ After setting the displacement, tighten the lock nut. 2.5 Operation: When testing the power unit in conjunction with the main slag crusher, a cooling water pipe must be connected for cooling purposes. Inspect all pipe joints, flanges, and other connection points for oil leakage, and tighten them or replace the seals as necessary based on the actual condition. During operation, internal contaminants are removed; monitor the filter pressure difference indicator to replace the filter element in a timely manner. Check the oil level and determine whether to top it up based on the time of day. Check the pressure value. The hydraulic system is operated without any load applied, in order to check whether the servo pressure and the supply pressure match the values specified by the pump. The servo pressure is set before the system leaves the factory, and generally no adjustment is required ； The fuel supply pressure is adjusted using the fuel supply pressure adjustment screw. If the hydraulic system operates properly under no-load conditions, a load can be applied to it. The fuel supply pressure setting value is predetermined before the power unit leaves the factory, and generally no further adjustment is required. If readjustment is needed, the steps are as follows: ① Remove the nut ； ② Use a 5/32” hex screwdriver to loosen the lock nut and adjust the pressure. Adjusting in a clockwise direction will increase the pressure. Note that the pressure will vary with different viscosities/work temperatures. ③ The fuel supply pressure can be read from the fuel pressure gauge. The allowable pressure range is 1.0 to 2.0 MPa. ④ After setting the fuel supply pressure, tighten the lock nut and screw nut. ⑤ Revise the fuel supply pressure setting in the technical documents or logbook. Check whether the pump compensator control pressure and pressure switch are set at a level suitable for operation. The check is carried out by closing a ball valve in the high-pressure pipeline to raise the system pressure to the set value; the control pressure of the pump compensator is adjusted using the adjustment screw of the pump compensator. The pressure setting for the pump compensator is predetermined before the power unit leaves the factory, and generally no further adjustment is required. If readjustment is needed, the steps are as follows: ① Remove the nut ； ②Use a 5/32” hex screwdriver to loosen the lock nut and adjust the pressure. Adjusting in a clockwise direction will increase the pressure. Note that the pressure will vary with different viscosities/work temperatures. ③Confident that the piping system and mechanisms can withstand higher pressures and torques from the hydraulic motor. ④After setting the pump’s compensation pressure, tighten the lock nut and screw nut. ⑤Revise the fuel supply pressure setting in the technical documents or logbook. 2.6 Automatic reverse function: When the “automatic mode” indicator is on, the control system has an automatic reverse function. The control of this reverse operation is carried out by a PLC programmable controller, which ensures that even if the slag crusher gets blocked, the blockage can still be removed through multiple crushing attempts, allowing the system to operate continuously automatically. Its working process is as follows: When the slag breaker is operating in \"forward\" mode, it gets blocked, and the pressure in the high-pressure hydraulic pipeline connecting the hydraulic pump to the hydraulic motor reaches its maximum value (220 bar/22 MPa). The pressure switch on its pipeline activates (with the activation point set at 210 bar/21 MPa); the maximum pressure is maintained for 2 seconds, after which the hydraulic motor is automatically driven to rotate in the \"reverse\" direction. “After rotating in the “reverse” direction for 10 seconds, it automatically returns to operating in the “forward” direction. If it remains blocked while operating in reverse, it will stay at the highest reverse pressure point for 2 seconds before automatically switching to forward rotation. If three alternating cycles of “forward” and “reverse” occur within 70 seconds, the drive system shuts off automatically. The control system determines that the slag breaker is blocked, activates the \"Fault\" indicator light on the front panel, and displays the message \"Slag breaker blocked\" on the screen. 2.7 Emergency Stop Function In an emergency, pressing the “Emergency Stop” button shuts down the system and then cuts off all power supplies. After the fault is resolved, first reset the \"Emergency Stop\" button, then restart the system. 3. Operations 3.1 Configuration and functions of the control panel buttons and indicators are shown in the table below: Button Function Power Supply – Turns on the voltage supply for the motor. Motor Power Supply – Turns on the voltage supply for the motor. Control Power Supply – Turns on the control voltage, allowing or preventing operation. Motor Start – Starts the pump motor. There are automatic and manual modes; once the hydraulic system is ready, turn this knob to the “Automatic” position, and the slag crusher will operate in automatic mode. At this time, the slag breaker is rotating in the forward direction. Once the hydraulic system is ready, by turning the knob to the “manual” position, the slag breaker enters manual operation mode; at this point, manual control is used to determine whether the slag breaker rotates forward or backward. Forward: In manual mode, pressing the “Forward” button causes the slag crusher to rotate in the forward direction; lifting the button stops this forward rotation. Reverse: In manual mode, pressing the “Reverse” button causes the slag crusher to rotate in the reverse direction; lifting the button stops this reverse rotation. Motor stop: The power supply to the motor is cut off, the “Motor Running” indicator light on the front panel goes out, and the hydraulic motor stops rotating. Reset: Alarms and fault signals are cleared. Emergency stop: The control voltage is activated. Light test: Before starting the machine, a light test should be conducted. The 380V motor power supply is turned off, the “Manual/Automatic” selector switch is set to the middle position, and the “Light Test” button is pressed; all indicator lights on the front panel should light up. If any light does not illuminate, that light needs to be replaced. Use the “Reset” button to end the light test mode; if the “Motor Running” indicator light is still on, press the “Motor Stop” button to disable this indicator. The Motor Running indicator light indicates that the hydraulic system’s motor is operating normally. The Automatic Mode indicator light shows that the system has entered automatic cycle mode, with the motor running in forward direction. The Manual Mode indicator light indicates that the system is in manual mode. The Alarm indicator shows that there is an alarm signal, while the Fault indicator indicates that a fault has occurred. The High Pressure indicator light comes on when the forward pressure exceeds the set value during forward operation. 3.2 Operation Procedures: Automatic cycle operation sequence: ① Turn on the main power switch, so that both power and control signals are supplied to the control box ； ② Set the switches for the power supply, control power supply, motor power supply, and heater power supply to the “ON” position ； ③ Press the “Motor Start” button, the “Motor Running” indicator light will turn on, and the motor will start. After 7″, the text display shows “Hydraulic system ready”” ；

Control device for the slag breaking machine: 1. Functions of the control system: Command function, display function, switching function, automatic control function, detection function, output signal function, explosion-proof function. 2. Functions of indicator lights and buttons: 2.2 Functions of the indicator lights on the front panel of the control cabinet: ① Motor operation indicator light: This light comes on when the 30KW motor in the hydraulic system is operating normally. ② Automatic mode indicator light: This light comes on when the control system is operating in automatic mode. ③ Manual mode indicator light: This light comes on when the control system is operating in manual mode. ④ High pressure indicator light: This light comes on when the hydraulic system is operating in forward or reverse mode and the system pressure exceeds the set value of the pressure switch. ⑤ Alarm indicator light: This light turns on when the control system issues an alarm message. (This includes: the oil level dropping to the lowest level) ； Filter clogged ； Reaches maximum oil temperature) ⑥ Fault indicator light: This light comes on when the control system sends a fault message. (This includes: oil level below the minimum oil level) ； The oil refill pressure is too low ； Clogging of the slag breaker ； Exceeding the maximum oil temperature; motor overloaded ； Heater overload 2.2 Functions of the control cabinet panel buttons: ① Manual/automatic selection knob: Once the hydraulic system is ready, turn this knob to the “automatic” position, and the slag breaker will operate in automatic mode. At this time, the slag breaker rotates automatically in the forward direction. Once the hydraulic system is ready, by turning the knob to the “manual” position, the slag breaker enters manual operation mode; at this point, manual control is used to determine whether the slag breaker rotates forward or backward. ②Forward button: When the operation mode of the slag breaker is set to “manual”, each time the “Forward” button is pressed, the slag breaker rotates in the forward direction; lifting the button stops this forward rotation. ① Reverse button: When the operation mode of the slag breaker is set to “manual,” each time the “Reverse” button is pressed, the slag breaker rotates in the reverse direction; lifting the button stops this reverse rotation. ② Motor start button: First, connect the power supply for the control system, the control power supply, and the motor power supply in sequence, then press the “Motor Start” button. This will start the 30KW motor in the hydraulic system; the “Motor Running” indicator light on the front panel will light up, and the display will show “Waiting 7 seconds for pressure to build up”. After 7 seconds, it will display “Hydraulic system ready”. ③ Motor stop button: Pressing the “Motor Stop” button at any time shuts down the 30KW motor, and the “Motor Running” indicator light on the front panel goes out. ④ Light test button: Use this button regularly to check whether the indicator lights are functioning properly. Perform a light test before turning the device on: turn off the power supply to the 380V motor, set the \"Manual/Automatic\" selector switch to the middle position, and press the \"Light Test\" button. All the indicator lights on the front panel should light up; if any light does not illuminate, that indicator light needs to be replaced. Use the “Reset” button to end the light testing mode; if the “Motor Running” indicator light is still on, press the “Motor Stop” button to turn it off. ⑤ Reset button: When the “Alarm” or “Fault” indicator lights are on, press the “Reset” button after resolving the fault to clear the fault indication. ⑥ Emergency stop button: In the event of an abnormality in the system, press the “Emergency Stop” button promptly to shut down the control system. 3. Control system operation procedure ① System power-on: Open the cabinet door and sequentially turn the switches for the power supply, control power supply, motor power supply, and heater power supply to the “ON” position. At this point, looking at the text display, the words “H1301 slag breaker, Aerospace Institute 11 (Beijing)” will be shown, indicating that the system is operating normally. If the message “Oil temperature below minimum level” appears, it means that the oil temperature in the hydraulic system is below 5°C; in such cases, the control system automatically activates a 380V/1.5KW heater to heat the oil. Press the “Reset” button until the display shows a temperature of >5°C, after which the system can be started again. ②Start/stop of the control system: First, open the valve switches MK1 and MK2 for the oil pipeline, then press the “Motor Start” button. At this point, the “Motor Running” indicator light on the front panel will light up, and the 30KW hydraulic motor will be started. The text display will show “Waiting 7 seconds for pressure to build up”; after 7 seconds, it will indicate “Hydraulic system ready”, signaling that the hydraulic motor can now be started. Set the \"Manual/Automatic\" selector switch to the \"Automatic\" position to start the hydraulic motor; at this point, the \"Automatic Mode\" indicator light on the front panel will light up, indicating that the drive system has entered automatic operation mode. The rotation direction is forward, and this is the normal operating state of the drive system. With the hydraulic system ready, set the \"Manual/Automatic\" selector switch to the \"Manual\" position; the \"Manual Mode\" indicator light on the front panel will light up. At this point, the automatic operation mode is stopped and the system enters manual adjustment mode. Press the \"Forward\" button to make the drive system rotate in the forward direction. Conversely, pressing the “Reverse” button causes the drive system to rotate in the opposite direction. Whenever shutdown is required, press the “Motor Stop” button to cut off the power supply to the 30KW motor; the “Motor Running” indicator light on the front panel will go out, and the hydraulic motor will stop rotating. 4. Automatic reverse function: When the “automatic mode” indicator light is on, the control system has an automatic reverse function. This reverse operation is controlled by a PLC programmable controller, which ensures that even if the slag crusher gets clogged, the blockage can still be removed through multiple crushing attempts, allowing the system to continue operating automatically. Its working process is as follows: When the slag breaker is operating in \"forward\" mode, it gets blocked, and the pressure in the high-pressure hydraulic pipeline connecting the hydraulic pump to the hydraulic motor reaches its maximum value (220 bar/22 MPa). The pressure switch on its pipeline activates (with the activation point set at 210 bar/21 MPa); the maximum pressure is maintained for 2 seconds, after which the hydraulic motor is automatically driven to rotate in the \"reverse\" direction. “After rotating in the “reverse” direction for 10 seconds, it automatically returns to operating in the “forward” direction. If it remains blocked while operating in reverse, it will stay at the highest reverse pressure point for 2 seconds before automatically switching to forward rotation. If three alternating cycles of “forward” and “reverse” occur within 70 seconds, the drive system shuts off automatically. The control system determines that the slag breaker is blocked, activates the \"Fault\" indicator light on the front panel, and displays the message \"Slag breaker blocked\" on the screen. 5. Alarm and fault troubleshooting: When an alarm or fault occurs in the control system, the alarm indicator light or fault indicator light will turn on. At the same time, detailed information is provided by the text display screen. When there is more than one alarm or fault message, the text display will show them in turn. The system can provide 3 types of alarm messages; the device can continue to operate even when an alarm is triggered, prompting relevant personnel to check the device and eliminate the cause of the alarm using the methods provided below. Once the potential issues with the device are resolved, the alarm messages on the display are automatically cleared. Press the “Reset” button to clear the front-panel alarm indicator lights. When the oil level drops to the minimum level, top up the hydraulic oil in the tank to the specified level. Filter clogged – replace the filter element. Reach the maximum oil temperature – check whether the cooling water valve is open, and operate the manual bypass water valve. In the event of a fault, the equipment stops working; based on the fault information displayed on the screen, appropriate measures are taken to resolve the issue. After verification that everything is correct, the “Reset” button is pressed to erase the fault information from the screen as well as the fault indicator lights on the front panel, allowing the motor to restart. Oil level is below the minimum level – top up the hydraulic oil in the tank to the specified level. The refilling pressure is too low – check the oil filling pump and oil circuit, and increase the refilling pressure. Slag crusher clogged – shut down the machine and turn off all power supplies. Exceeding maximum oil temperature – Check whether the water valve is open; operate the manual bypass water valve. If the water valve is faulty, replace it. Motor overload – Identify the cause of the fault and eliminate it. If it is necessary to open the explosion-proof control box, be sure to cut off all power supplies before proceeding; this can only be done after 45 minutes. Heater overload – Identify the cause of the fault and address it. If it is necessary to open the explosion-proof control box, be sure to cut off all power supplies first; this can only be done after 45 minutes. 6. Emergency shutdown function: In an emergency, pressing the “Emergency Stop” button shuts down the system, after which all power supplies are turned off. After the fault is resolved, first reset the \"Emergency Stop\" button, then restart the system. 7. Output function: This device provides the user with the following output signals: Motor operation ； Motor running in forward direction ； Motor reversal ； Call the police ； Fault ； Emergency stop. 8. System maintenance: ① The explosion-proof connection tubes between various explosion-proof boxes in the control cabinet should be inspected once a year; if any signs of aging or deterioration are detected, they should be replaced promptly. ② If the message “Battery failure; please replace it” appears on the text display screen, all power supplies must be turned off, and the explosion-proof box must be opened to replace the PLC battery, which typically has a lifespan of 5 years. The green light turns on when NT31C is in operation mode. If the NT31C is used at an ambient temperature of 25°C, its battery life is approximately 5 years. If the operating temperature is higher than 25°C, the battery’s lifespan will be reduced. If the “Voltage too low” message appears when the NT31C is powered on or restarted, or if the status light is orange, the battery of the NT31C needs to be replaced.

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