空冷风机说明书_.doc

空 冷 器 风 机使 用 维 护 说 明 书保定航技风机制造有限公司TEL:AX:EMAIL: 目 录一、总述21风机简介22风机铭牌说明23平衡方法2二、风机的安装31轴及轴承座的安装32三角带轮及三角带的安装（联组带） 33轮毂的安装54叶片的安装65叶尖与风筒间隙7三、运行前的准备工作8四、风机的维护8五、风机故障原因及其排除方法9一总述1风机简介： 风机总成含叶轮及传动系统。叶轮由锻铝合金叶片碳钢轮毂两部分组成。传动系统包括电机架、驱动带轮、从动带轮、轴承座、主轴及传动带。风机的构架或基础均应有足够的强度、刚度和稳定性，能吸收和隔离振动，防止发生共振。2 风机铭牌说明：在所有风机轮毂上都有一风机铭牌, 以便快速准确地识别。风机铭牌显示如下信息：* 风机型号 : F 电机功率 (kw)安装形式： e、n、f、z、 g, 叶片数：4,6 叶片材质：L：铝 B：玻璃钢 T或S：手调角 风机直径：风机直径(mm)/100 J：机械调角 调角形式： G：鼓风 B：半自调 Y：引风 Z：自调3平衡方法：除非特别指出，所有风机叶轮均按如下方法平衡：轮毂及叶片均采用静平衡。这种部件的分体平衡使组装后的组件仍符合6.3级平衡精度。同批交付的叶片有相同的大矩值，允许与轮毂随机组装。这样省略了打配套标记。二、风机的安装1. 轴及轴承座的安装：图1轴承座安装应找正、找平，并使主轴与风筒同轴，同轴度误差5mm（在安装叶片时，可从叶尖与风筒间隙差来调整）。同时，注意轴承座上压注油杯的朝向，以便于加注润滑脂，见图1。2. 三角带轮及三角带的安装（联组带）图2 2.1 三角带轮的安装将大、小皮带轮分别装于轴承座及电机轴上，电机、风机轴分别涂抹油脂，装锥套于电机、风机轴上。（螺孔向外便于拧紧锥套上的内六角顶丝）拧紧锥套螺栓确保安装稳定见图2，最终拧紧力矩见表1。（锥套规格见锥套上标识）表1锥套规格25173020303035253535403040404535454550405050螺钉拧紧扭矩（N.M）5090901151151701701901902702702.2带轮调整皮带轮装上后，调整主、从动皮带轮的对称面偏移不大于（1/400）a（a为两皮带轮中心距），利用皮带轮上的锥形轴套调整皮带轮固定在电机轴的轴端或传动轴轴端的轴向位置，以达到两皮带轮对称面在同一平面的要求。检查方法见图3，用一根线绳在两皮带轮端面拉紧，如果A、B、C、D、4点没有同时碰上绳子说明没有调整好，需要继续调整，直到A、B、C、D、4点同时碰上绳子，说明调整合适。 图32.3三角带（联组带）的安装安装三角带（联组带）时，必须先将带轮的中心距缩短，装上三角带（联组带），再使中心距复位。严禁用螺丝刀撬三角带（联组带）的方法安装，以防止皮带损伤。2.4皮带预紧力的控制 联组带比单根带传动有更高的传动效率。为了保证皮带正常传动工作，皮带要有适当的预紧力，可通过调整螺栓把电机板和电机拉到一定位置，以达到皮带预期张紧程度。检查预紧力是通过在皮带与两皮带轮的切点跨距的中点M加载荷（见附图4）测量皮带的挠度y，跨距a每100mm产生的挠度为1.6mm图4时的预紧力为恰当值，载荷大小：G=（2835）Z （N） Z为皮带根数3轮毂的安装：3.1 分解视图及零件列表图5序号名称材质及标准号数量1轮毂板碳钢12下压块碳钢1/叶片3锥套座45#14锥套45#15U形螺栓碳钢2/叶片6叶片铝合金7上压块碳钢1/叶片8垫圈GB97.1-2002 164/叶片9螺母GB/T889.1-2000 M16 4/叶片10弹簧垫圈GB/T93-1987 20 611螺栓GB5783-2000 M2050 612键45#113螺栓GB5783-2000 M1245 414主轴45#13.2安装准备a) 清理主轴、锥套及轮毂的配合表面。b) 检查主轴是否垂直。如果垂直误差超过0.5则必需加以校正c) 确保主轴与风筒同轴，同轴度误差不大于5mm。3.3安装步骤在任何风机组装前，要确保电机不会被意外启动。切断电机电源并按如下步骤安装：a) 将锥套（4）滑装到主轴（14）上。b) 将轮毂板（1）及锥套座（3）（出厂前以组装好）安装到锥套（4）上。c) 确保锥套（4）法兰边上的螺栓孔与锥套座（3）上的螺纹孔对齐。穿上螺栓逐步拧紧，最终拧紧力矩40-50NM。使轮毂抱紧在传动轴上。4叶片的安装：a) 将上压块（7）从轮毂上移开，将叶轴放入下压块（2）槽中。b) 叶片前缘（厚边）必需朝向指定的旋转方向。c) 扣上上压块（7）穿入U形螺栓（5）并安装垫圈（8）及锁紧螺母（9），手动拧紧螺母。在最终拧紧螺母前，向外拉叶片使叶轴轴肩靠紧下压块（2），见图6、7。d) 将一钢板尺或一足够硬的直板（长度至少与叶片型面宽度相等）放置于距叶尖60mm的叶片工作面上，将角度尺置于其上，见图8。e) 在叶尖提起叶片并使其绕自身轴线旋转直到达到设计指定角度，角度互差0.5。f) 重新检查叶轴轴肩是否靠紧下压块。 g) 用力矩扳手按对角对称原则拧紧U形螺栓。拧紧力矩为80N/M100N/M。叶尖应尽可能在同一旋转平面。叶尖高度互差应小于10mm。h) 对其它叶片重复上述步骤。 叶片安装错误 叶片安装正确 图6 图7图85叶尖与风筒间隙：叶尖间隙“S”是指叶尖到风筒的距离(图9)。 基于通常风筒的加工公差，叶尖间隙在风筒圆周上是变化的。图9我公司推荐的叶尖间隙“S”值见下表2 表2风机直径, DD2.4M D2.4M最小间隙6mm9mm最大间隙19mm19mm为确保叶尖间隙在任何地方不小于最小间隙，我们建议采取如下步骤： a) 通过测量所有叶片与风筒上一固定点的叶尖间隙来确定最长的叶片。b) 手动缓慢旋转最长的叶片，测量叶尖与风筒上均布的12个测点的距离。c) 假使发现叶尖与风筒间隙太小，则找正叶轮与风筒的同心度后重复上述步骤。三运行前的准备工作1. 手动旋转叶轮，检查是否运转自如，与风筒壁有无碰撞及刮蹭。2. 确认轴承内加足润滑脂3. 确保所有工具及安装辅助工具例如：支架、梯子等，被清理出现场。4. 重新联接电机电源。5. 点动电机，检查叶轮旋向是否为迎风看顺时针旋转。四. 风机的维护1. 风机首次运转48小时后，要检查风机各部件紧固件是否有松动，如发现松动应重新拧紧。2. 主轴轴承应每隔三个月加注一次润滑脂，采用3#锂基润滑脂（GB7324-1994）.3. 每年检修一次风机五. 风机故障原因及其排除方法问题产生原因解决办法振动剧烈轮毂上的平衡块脱落或检修后未校准平衡。轮毂重新平衡叶片角度互差大于0.5重设叶片角度叶片表面出现不均匀附着物清理叶片表面轴承损坏更换轴承基础或机座的刚度不够或不牢固查明原因，施以适当的修补和加固，拧紧螺母，加强支撑电机额定电流过大叶片出始安装角过大减小叶片安装角气流量低叶片安装角过小在电机允许功率范围内增加初始叶片安装角皮带太松，转速低调整皮带松紧叶片前后缘装反重新装叶片叶轮转向相反调整电机转向皮带向一边偏拉风机轴与电动机轴不平行调整两轴使之平行主、从动皮带轮位置偏离调整皮带轮，使两皮带轮径向中心线处在同一直线位置。 AIR COOLING FANINSTALLATION & MAINTENANCE MANUALBaoding HJ Fan Manufacturing Co., Ltd.Tel:ax:mail: CONTENTSI. General information 121. Fan Components122. Fan Nameplate 123. Balancing 13II. Installation 131. Shaft and Bearing hous installation 132. Installation of V belt and pulleys 133. Hub installation154. Blades installation175. Check Tip Clearance18III. Start-up Preparation19IV. Maintenance19V. Trouble Shooting20I. General information1Fan ComponentsA fan unit consists of rotor and transmission system. The rotor consists of extruded aluminum blade and carbon steel hub. Transmission system includes fan shaft, motor mount, driving pulley, driven pulley, belt, bearing housing, top & bottom bearings. The structure or base of fan shall have enough intensity, rigidity and stability, so that it can absorb and segregate vibration, avoid resonance, which may influences fan efficiency. 2Fan NameplateAll rotors have a nameplate attached on the hub. The nameplate indicates the following information:*Fan Type : F Motor power rating (kw)Mounting type： e, n, f, z, g, Number of Blades：4,6 Blade material： L：Aluminium B：FRPFan Diameter： Fan Diameter : fan diameter (in mm)/100 T or S：manually blade pitch adjustment at standstill J：manually blade pitch adjustment during operationType of pitch variation G：forced draft B：semi-auto-variable blade pitch during operation Y：induced draft Z:：auto-variable blade pitch during operation3BalancingUnless otherwise specified, all Hangjiang fan rotors are balanced as follows：- The hub, as well as blades, is statically balanced.- This components are balanced separately so that the assembled unit will correspond to a degree Q=6.3.Blades of the same batch have same torque value.II. Installation1. Shaft and bearing house installationFig. 1Align the bearing house with shaft, and make sure the shaft and fan ring are coaxial with coaxiality error 5mm, which can be reduced by adjusting tip clearance during blade installation. Make the direction of grease nozzle on bearing house convenient for greasing, see Fig. 1.2. Installation of V belt and pulleys Fig. 22.1 Installation of pulleySmear oil on the fan and motor shaft. Slip the taper bushings onto the drive shaft and motor shaft. (Make sure that bolt hole towards outward, so its easy to tight the bushing bolt.) Install pulleys. Tighten bushing bolts evenly to assure proper fit. See Fig.2. Please refer to the final tightening torque listed in Table 1. (Type of taper bushing is marked on the bushing.)Table 1Taper Type25173020303035253535403040404535454550405050Tightening Torque of Bolt (N.M)5090901151151701701901902702702.2 Adjusting pulleysAfter the pulleys are installed, set the parallels excursion within (1/400) x a (a is central distance of the two pulleys.) Adjust the axial position of pulleys on shafts with taper bushing to meet the requirement. Check method refers to Fig. 3. Strain a rope on the parallel of the two pulleys. If the rope doesnt touch the four spots of A, B, C, D at the same time, the pulleys need adjusting until the rope touches the four spots. Fig. 32.3 Installation of banded V beltShorten central distance of the pulley, and install the belts. After that reset central distance of the two pulleys and tighten tension pulley. Do not pry the belt with screwdriver to avoid damage to the belt.2.4 TensionThe transmission efficiency of banded belt is higher than single belt. Set proper belt tension to assure the target transmission efficiency. To adjust the tension, move the bolt to adjust the position of motor frame to apply tension to the belt until the proper tension is achieved. Check the tension by add force “G” on the center “M” of span “a” to measure deflection “y”. The tension is proper if deflection “y” is 1.6mm at each 100mm of span. Fig. 4G=（2835）Z （N） Z Number of band3Hub installation：3.1Exploded view and part list：Fig. 11ItemDescriptionMaterial (standard construction)Quantity1Hub plateCarbon steel 12Lower clamping pieceCarbon steel1/blade3Coupling flange45#14Split tapered bushing45#15U-boltCarbon steel2/blade6BladeAluminium 7Upper clamping pieceCarbon steel1/blade8WasherGB97.1-2002 164/blade9NutGB/T889.1-2000 M16 4/blade10BoltGB5783-2000 M2050611WasherGB/T93-1987 20 612Key45#113BoltGB5783-2000 M1245 414Shaft45#13.2 Preparationa) Clean all mating surfaces between shaft，tapered bushing and fan hub.b) Check if the shaft is vertical. A correction must be made if there is a discrepancy exceeding 0.5.c) Make sure the shaft is properly centered with respect to the fan casing with discrepancy less than 5mm.3.3 Installation StepBefore assembling the fan, make sure the motor will not be inadvertently started up at any time. Disconnect the motor from power supply and assemble the fan as follows:a) Slip the Split tapered bushing (4) onto the drive shaft (14).b) Lift or pull the hub (The hub plate (1) and Coupling flange (3) are supplied pre-assembled ) onto the taper of the bushing (4).c) Make sure that the bolt holes in the bushing flange (4) line up with the threaded holes in the Coupling flange (3). Insert bolts into holes and tighten each bolt to finger tightness. Then torque the bolt in rotation, to 40-50NM to maintain squareness of the hub on shaft .d) Install retaining plate with washer and bolts after the Split tapered bushing and hub have been installed.4Blades installation：a) Remove blade top clamping piece (7) from hub. Place the blade stem into the hub bottom clamp (2) sockets.b) The blades leading edge (thick side) must be installed toward the direction of the specified rotation .c) Replace the top clamping piece and install U-bolts and elastic stop nuts and tighten lightly, Before tightening locknuts. pull the blade outward to set the blade stem collar is resting firmly against the shoulder of the bottom clamping piece (figur12、13).d) Place a rigid steel rule or a sufficiently stiff strip (at least as long as the profile width) on top of the blade (discharge side) at about 60mm (1 inches) from the blade profile end. Place an inclinometer on top of the straight edge (figur14).e) Lift the blade at the tip and rotate the blade around its axis until the desired angle is set, within a maximum tolerance of 0.5degrees.f) Re-check if the blade stem collar is flush against the lower clamping piece.g) Tighten the U-bolts with a torque wrench. The U-bolts must always be tightened in diagonal order. The U-bolts must be torqued to 80N/M100N/M. The blade tips should be reasonably located on the same plane. The maximum tolerable deviation is 10 mm. ade installation incorrect Blade installation correct Fig.12 Fig.13Fig.145Check Tip ClearanceTip clearance “S” is the distance between the blade tip and the impeller casing (figure 15). Due to normal impeller casing tolerances the tip clearance is not constant around the impeller casing. Fig.15We recommend a tip clearance as Table 3.Table 3Fan Diameter, DD2.4M D2.4MMin. Clearance6mm9mmMax. Clearance19mm19mmMake sure that the tip clearance is nowhere less than the min. clearance. We recommend the following steps to be taken:a) Determine the longest blade by measuring the tip-clearance for all blades at a fixed point in the fan casing.b) Now measure the tip clearance of the longest blade at 12 measuring points. Slowly rotate the impeller by hand to the different measuring point.c）Center the impeller in the casing in case the tip clearance is found too small and repeat the previous steps.III Start-up Preparationa) Rotate the impeller by hand, check if it runs freely and does not rub or strike the impeller housing.b) Make sure that all tools and assembly aids such as supports, ladders, are cleared from the site.c) Reconnect motor power supply.d) Bump the motor to check clockwise rotation of the impeller, when viewed into the air stream.I