I. Pre-commissioning Safety Checks
1. Mechanical Safety Verification: Manually rotate the rollers 3–5 times to ensure smooth rotation without binding or abnormal noise; clear away any tools or debris from the surrounding area.
2. Safety Device Verification: Test the emergency stop button, movable safety guards, and mechanical interlocks one by one to ensure the equipment immediately cuts power and stops when triggered.
3. Electrical Safety Inspection: Confirm the power supply voltage is 380V ±10% and the equipment grounding resistance is ≤4Ω; ensure no cable connections are loose or have exposed/damaged insulation.
II. Basic No-Load Commissioning
1. Control System Self-Test: Power on the equipment, wait for the control system to complete its self-test, and confirm that no fault codes appear and all indicator lights and displays are functioning normally.
2. Function Key Testing: Operate function keys-such as speed regulation, temperature control, tension adjustment, and automatic reversing-individually to ensure responsive and effective operation.
3. No-Load Run Test: Run the equipment without a load for 10–15 minutes; observe the drive system for smooth operation and the absence of abnormal vibration or noise, confirming that mechanical repairs were successful.
III. Core Process Parameter Commissioning
1. Temperature Control System Calibration: Set a standard dyeing temperature and compare it with the actual dye liquor temperature using an independent thermometer; keep the temperature deviation within ±2°C to ensure uniformity throughout the vat.
2. Tension System Calibration: Calibrate tension sensors and keep operating tension fluctuations within 5%; automatically reduce tension by 20% when dyeing chemical fiber fabrics at temperatures above 100°C to prevent fabric stretching or stiffening.
3. Circulation System Commissioning: Start the dye liquor circulation pump and adjust valve openings to ensure uniform and stable flow without dead zones, maintaining consistent dye concentration throughout the vat.
4. Roll Diameter Matching: Test linear speed consistency across different roll diameters to ensure the fabric moves at a constant linear speed throughout the process, preventing shade differences between the fabric ends caused by changing roll diameters.
IV. Verification via Trial Production with Load
1. Selection of Trial Fabric: Select low-value greige fabric of the same specifications for trial dyeing; complete 3–5 dyeing cycles using the standard process to verify the equipment's operational stability.
2. Dyeing Quality Check: Inspect the fabric surface after trial dyeing to confirm the absence of defects such as color difference, uneven dyeing (color mottling), or creases, thereby verifying the effectiveness of the repairs.
3. Full-Process Confirmation: Perform standard shutdown and fabric unloading procedures for the trial-dyed fabric; confirm that the startup, shutdown, and unloading processes operate smoothly without jamming.
V. Final Commissioning Tasks
1. Cleanup of Residues: Drain the trial dyeing liquor and clean away any residual stains from the dye vat and equipment surfaces to maintain a tidy work area.
2. Parameter Archiving: Save the optimized process parameters into the equipment control system to create a dedicated process profile, facilitating direct retrieval for future production.
3. Trial Run Confirmation: Once the equipment operates stably and without anomalies for two consecutive hours, it is ready to be officially put into mass production.
