干灰散装机说明书.doc

SZJ-100 型干灰散装机SZJ-100 Model Dry Dust Bulk Machine使用说明书Operation Instruction江苏国能环保设备有限公司Jiangsu Guoneng Environment Protection Equipment Co., Ltd.一、前言1. Foreword 本产品适用于电力、建材、冶金、煤炭以及化工等其它行业的无腐蚀、低研磨性粉粒状物料的装车或装船作业。在火力发电厂主要用于灰斗或贮灰库下装车、装船。本产品可与料库下给料设施联锁运行，通过控制系统的控制，实现了装卸过程的自动化。其装车效率高，密封性能好，无粉尘污染。是散装粉状物料装车、装船的理想设备。The product is applicable to the loading or shipment work of non-corrosion, low abrasiveness powder materials in such industry as power, construction, metallurgy, coal and chemical industry. If it uses in thermal power plant, it is mainly applied to the loading, shipping under dust hopper or dust bunker. The product is interlocking operated with material storage feeding facility, to carry out automatic loading and unloading process via control system. It is the ideal equipment for loading and shipping bulk powder materials with such characteristics as high efficiency loading, good sealing performance and without dust contamination.二、技术参数2. Technical parameters2.1干灰散装机型号含义：结构形式 I：不带轴尘风机 II：带抽尘风机 III：带就地除尘器Structural form I: without dust exhaust fanII: with dust exhaust fanIII: with in site dust collector2.1 Model and signification of dry dust bulk machine:SZJ 100 Structural form I: without dust exhaust fan II: with dust exhaust fan III: with in site dust collector出力100m3/hOutput 100m3/h干灰散装机Dry dust bulk machine2.2控制方式：设半自动和自动2.2 Control mode: setting semi-automatic and automatic2.3散装头升降行程：1300mm（亦可按用户需要而定）2.3 Lifting stroke of bulk head: 1300mm (decided as per users demand)2.4散装头升降速度：0.1m/s2.4 Lifting speed of bulk head: 0.1m/s2.5配带升降电动机参数：2.5 Lifting motor parameters: 型号：YEJ 90S 6 Model: YEJ 90S 6 功率：0.75kw Power: 0.75kw 电压：380V Voltage: 380V 转速：910 r/min Rotating speed: 910 r/min2.6减速机参数：2.6 Reducer parameters: Model: WHT08-VII 型号：WHT08-VII Reduction ratio: 1:63 减速比：1:632.7抽尘风机参数：2.7 Dust exhaust fan parameters: 型号：9-19 No 4.5 Model: 9-19 No 4.5型号：4-72 No 3.6Model: 4-72 No 3.6 流量：2817m3/h Flow rate: 2817m3/h流量：2930m3/hFlow rate: 2930m3/h 风压：4.04kPa Wind pressure: 4.04kPa风压：1.65kPaWind pressure: 1.65kPa 抽尘风机电机型号：Y112M-2 Motor model of dust exhaust fan: Y112M-2抽尘风机电机型号：Y100L-2Motor model of dust exhaust fan: Y100L-2 抽尘风机电机功率：4.0kW Motor power of dust exhaust fan: 4.0kW抽尘风机电机功率：3.0kWMotor power of dust exhaust fan: 3.0kW 抽尘风机电机电压：380V Motor voltage of dust exhaust fan: 380V抽尘风机电机电压：380VMotor voltage of dust exhaust fan: 380V 抽尘风机电机转速：2890r/min Rotating speed of motor of dust exhaust fan: 2890r/min抽尘风机电机转速：2870r/minRotating speed of motor of dust exhaust fan: 2870r/min2.8料位计形式：电容式料位开关2.8 Material level meter type: capacitance type level switch2.9料位计型号：TLK-C15A1-4C2.9 Material level meter model: TLK-C15A1-4C2.10散装机下料管直径：3502.10 Diameter of blanking tube of bulk machine: 3502.11散装机吸尘管直径：5582.11 Diameter of dust suction pipe of bulk machine: 558注：带为III型散装机参数。Note: indicates the parameters of III model bulk machine.三、结构与工作原理3. Structure and working principle3.1主要结构3.1 Main structure3.1.1可伸缩散装头3.1.1 Extensional bulk head 散装头由底座、伸缩管、吸尘管、套箍、钢丝绳、绳卡等主要部件组成，通过吸尘管、钢丝绳把它们连接起来，形成可伸缩的结构。Bulk head is composed of base frame, extension tube, dust suction pipe, hoop, steel cable, cable head, etc., which are connected by dust suction pipe and steel cable to form an extensional structure.3.1.2卷扬装置3.1.2 Hoisting unit 卷扬装置由电动机、减速机（带有计数器）、滑轮装配、钢丝绳等组成，它是控制散装头伸缩的装置。Hoisting unit is composed of motor, reducer (with counter), pulley assembly, steel cable, etc. It is the unit for controlling the extension of bulk head.3.1.3控制系统3.1.3 Control system 控制系统是散装机的心脏，直接完成散装机整个卸料过程。它由控制拒、计数器、接近开关以及料位计、支架、电线等元件组成。计数器和接近开关控制散装头的下降位置，通过反馈信号打开给料机和抽尘风机，散装机进行装料；料位计控制料位的高低，当料位达到指定位置后，它反馈给控制系统电信号，使控制系统关闭给料机和抽尘风机，并打开卷扬电机，提升散装头；同时计数器控制散装头的上升位置，当散装头接近预定位置时，关闭卷扬电机，从而完成物料的装卸。本控制系统设有“自动、手动”操作切换开关，手动操作供检修及特殊情况下使用。Control system is the core of bulk machine, which may complete full unloading process of bulk machine. It consists of control cabinet, counter, approach switch and material level meter, support, wires. The counter and approach switch are to control the descending position of bulk head, start feeder and dust exhaust fan through feedback signal, then bulk machine carries out loading; the material level meter controls the height of material level. When the level is up to the specified position, it will feed back an electrical signal to control system so that the control system may close the feeder and dust exhaust fan, and start hoisting motor to lift bulk head; meanwhile, the counter controls the lifting position of bulk head, when bulk head approaches the presetting position, close hoisting motor so as to complete the unloading of materials. The control system has “automatic, manual” operation to change over the switches. The manual operation is only for inspection and special situations.3.1.4脉冲除尘器3.1.4 Pulsed dust collector III型散装机自带一就地DMC型电脉冲除尘器，由抽尘风机、喷吹系统、箱体和滤袋组成。箱体设有吸尘口，把从散装机吸来的含尘气体经滤袋后得到净化，净化后的气体经由抽尘风机出风口排空，滞阻在滤袋外壁的灰尘经由喷吹系统循环处理以后被清除。这样一来，现场可实现无尘作业。III model bulk machine has an in site DMC electrical pulsed dust collector, which is composed of dust exhaust fan, blowing system, tank and filter bag. The tank has a dust suction inlet to purify the dusty gas absorbed from bulk machine via filter bag, then empty the purified gas via the air outlet of dust exhaust fan, remove the dust retained at external wall of filter bag by circular processing of blowing system, so that the site can carry out dust free work.3.2工作原理3.2 Working principle 当散装头锥面下降到与汽车（或船）入灰口上部密合时，钢丝绳变松，计数器上的到位开关发出电信号反馈给控制系统，关闭卷扬电机，并打开抽尘风机和给料机，开始装料；当物料装满料罐时，料位计发出信号，反馈给控制系统，控制系统自动关闭给料机和抽尘风机并提升散装头；当散装头提升到预定位置时，计数器上的到位开关发出电信号，反馈给控制系统，自动关闭卷扬电机，完成一次物料的装卸过程。When the conical surface of bulk head descends to be sealed together with the top of dust inlet of vehicle (or ship), the steel cable will be loose, the limit switch on the counter sends out an electrical signal to feed back to control system, close hoisting motor and start dust exhaust fan and feeder, then start loading; when material tank is full of materials, the material level meter will send out a signal to feed back to control system, then control system automatically closes feeder and dust exhaust fan as well as lift bulk head; when bulk head is lifted at presetting position, the limit switch on the counter will send out an electrical signal to feed back to control system, then hoisting motor is automatically closed so that a completed material loading and unloading process is finished.四、安装、调试与运行4. Installation, commissioning and operation4.1安装4.1 Installation4.1.1设备到现场后，先整体检查，看有无因运输而损坏部件的情况，如有，则应拆卸更换；4.1.1 Check if any part is damaged due to transportation, after the equipments are arrived at the site, if any, it should be removed and replaced;4.1.2然后吊装散装机并与预留孔对位；对好位后，按现场管道情况把散装头底座与预埋件用螺栓联结好（也可直接焊接）。安装过程中注意不要刺破或烧伤吸尘管（挂胶帆布），以免影响吸尘管的透气性。4.1.2 Lift the bulk machine and direct to preserved hole; after positioning, connect the base frame of bulk head with pre-embedded parts by bolts (or welding) according to the piping in site. During installation, notice that do not break or burn the dust suction pipes (rubberized canvas) so as not to affect the air permeability of dust suction pipes.4.1.3按电气图纸资料连接电缆，并注意各电缆的走向。4.1.3 Connect cables according to electrical drawing and pay attention to the direction of each cable.4.2调试4.2 Commissioning4.2.1空载调试4.2.1 No-load commissioninga) 调试前检查所有接线是否正确，安装是否合格，经检验确认，方可进行调试；a) Check if all wirings are correct, installation is qualified before commissioning. Do not carry out commissioning until passing the inspection.b）调试时，关闭手动检修门（位于散装机进料口最上方），先手动操作，看电动机转向是否符合要求，转向正确后，方可进行上、下限位以及料位计的动作调试；b) Close manual access door (located at the topmost part of feed inlet of bulk machine) during commissioning, manually operate at first, and observe the turning of motor is conformity with the requirement. Carry out commissioning of the action of upper, lower limit and material level meter after the turning is correct;c）启动“自动按钮”，卷扬电机打开，散装头下降，下降到位后给料机打开；当全部联动投入运行，空运转数分钟，把功能开关置于“满料指示”位置时，报警铃声响后运行设备自动停机；提升散装头到上限位置，计数器上的到位开关自动切断卷扬电机电源，整个联动过程空试完毕。c) Start “automatic button”, to start hoisting motor and descend bulk head, after descending to reach the designated position, feeder will start; when inputting operation fully, and place function switch in “full indication”, after no-load operation for several minutes, the equipment will stop automatically after alarm bell sounds; lift the bulk head to upper limit position, the limit switch on the counter will cut off the power of hoisting motor automatically, so that a full interlocking commissioning process is completed.4.2.2负载调试4.2.2 Load commissioninga）空载调试正常后，将散装机的管路、阀门置于工作状态位置，让散装粉煤灰车或其它运载设施到位，即可进行负载调试；a) Place the pipes and valves of bulk machine under operating condition after no-load commissioning is normal, and bulk dry dust vehicle or other transporting equipments are in position, it can carry out load commissioning.b）正常情况下，散装下料锥斗与装载容器进料口结合部位及吸尘管均处于负压工作状态，负压大小可由抽尖风机前的手动调节门来调节，当吸尘管往外鼓胀及进料口结合部位向外冒灰时，表示抽尘风机出现故障，如不及时排除则会引起料位计误发报警信号而停机；b) Under normal condition, the joint part of bulk unloading cone hopper and feed inlet of container and dust suction pipe are under negative pressure condition, the negative pressure may be adjusted by manual adjustable gate in front of dust exhaust fan. When dust suction pipe expands and the joint part at feed inlet spreads dust, it shows the dust exhaust fan occurs failure, if do not eliminate in time, the material level meter may send out wrong alarm signal and stop the machine;c）料满报警停机后，将散装下料锥斗复位，并检查装载容器中物料装满程度状况，过满或过浅可通过调节料位计的位置来满足，并固定好料位计的最终位置。c) After alarm to stop machine due to full of materials, reset bulk feeding hopper and check the materials in the container, if it is too full or too shallow, it may adjust the position of material level meter and fix its final position. 4.3运行4.3 Operation4.3.1散装粉煤灰车或其它运载设施到位后，手动操作，使散装头下降接近罐口，然后停下来，罐口对准散装头后，将切换开关打向自动操作位置，按下启动按钮，使散装头的锥斗与罐口结合严密；4.3.1 After bulk dry dust vehicle or other transporting equipments are in position, manually operate to descend the bulk head close to the port of tank, then stop, after the port of tank centers on bulk head, place change-over switch in automatic operation, press start button so that the cone hopper of bulk head connects with the port of tank closely;4.3.2当料已装满，料位计发出信号（料位指示灯亮），给料机自动停止给料，延时一段时间以后（一般为46秒），关闭抽尘风机，提升散装头。延时长短以下料管内物料落净为准。4.3.2 When there are full of materials, the material level meter will send out a signal (level indicator is on), the feeder automatically stop feeding, after delay a few times (generally 46 seconds), close dust exhaust fan, lift bulk head. The delay time is based on the material emptying in loading pipe.五、使用注意事项与维护5. Usage notice and maintenance5.1使用前必须给减速机加油至合适位置，运行一个月后更换新油，以后每年换油一次；5.1 Fill the reducer with oil to applicable position before using, replace with new oil after operating one month, and change oil once a year.5.2在装料时，务必把散装机对准罐口，否则散装头可能下降不到规定位置或被绳卡卡住，发生堵料事故，甚至损坏料位计；5.2 The bulk machine should be centered on the port of tank when loading, otherwise, the bulk head may not descend to the specified position or be blocked by cable head resulting in plugging, even breaking the material level meter.5.3当装料时，突然发生极大的扬尘，说明排料不畅通，应马上停止下料，千万不要立即提升散装头；5.3 Large dust emission happens suddenly when loading, which shows that material discharge is not smooth, it shall stop loading at once and do not lift bulk head immediately.5.4在装料过程中，如果发生溢料，应立即停止下料。千万不要在散装头内积满料的情况下，提升散装头，应把吸尘管套箍卸下，排除一部分积存物料后，再慢慢把下料管的积料排除，然后再提升散装头；5.4 If materials are surplus during loading, it shall stop loading at once. Do not lift bulk head when there are full of materials in bulk head, after removing the hoop from dust suction pipe and cleaning out a part of accumulative materials, eliminate the accumulative materials in feed pipe slowly and then lift bulk head. 5.5松尘开关装置、计数器的到位开关应常检查，一旦失灵要及时更换，以免造成设备损坏；5.5 Check dust switch unit and limit switch of counter regularly. Once it fails, it shall be replaced in time so as not to damage the equipment.5.6滑轮装置及钢丝绳注意定期检查，若有损坏要马上更换；5.6 Pay attention to check pulley device and steel cable regularly. If it has any damage, replace it at once.5.7吸尘管会因老化或尖锐物品的碰挂而损坏，需定期更换，破损处应及时补牢以免影响收尘效果；5.7 The dust suction pipe may be damaged due to aging or touching of sharp objects, so it needs to be replaced regularly. The breakage should be repaired in time so as not to affect the dust collection.5.8散装机在装料过程中应处于负压状态工作，故应保证抽尘风机的正常运转和维护。5.8 The bulk machine works under negative pressure condition during loading, so it shall ensure the normal operating and maintenance of dust exhaust fan.5.9罐车或其它装运设备应注意其运行高度，不要撞坏散装头。5.9 Pay attention to the height of tank car or other transporting equipments. Do not hit the bulk head.6故障分析与处理措施6. Failure analysis and handling measures故障现象Failure故障分析Failure analysis处理措施Handling measures卷扬电机不动作Hoisting motor fails to act1线路故障；1. Wiring failure;2制动片未脱开2. Brake disc does not disconnect.1排除线路故障；1. Eliminate wiring failure;2取出电机后罩，松开制动片螺栓，再通电正、反运转几次后拧紧制动螺栓。2. Take off rear cover of motor, loosen the bolt of brake disc, after operating in positive and negative direction for several times with power, then screw down the bolt of brake disc.散装头上、下位置到位后，减速机不能适时停运After upper and lower position of bulk head are both in place, reducer can not stop running timely.1线路故障；1. Wiring failure;2计数器到位开关损坏。2. Limit