合肥中亚XRZ-16(25)说明书(中英文).doc

XRZ-16（25） 稀油润滑装置Thin Oil Lubrication Equipment使 用 说 明 书Operation Instruction编号：04 B03191-ZY-SM SERIAL No: 目 录CONTENT1. 用 途General application2. 主要性能参数main specifications3. 结 构 特 点structure feature 4. 工 作 原 理Working principle 5. 安装、调试、试运转Installation, test and trial operation 6. 维护与安全技术 Maintenance and safety technique7. 稀油站原理图 principle drawing of lubrication station8. 稀油站外形图 contour dimension drawing of lubrication station 1. 用途General application： XRZ-16（25）型稀油站主要用于冶金、矿山、建材、石化和电力等机械设备的稀油循环润滑系统中，向减速机和电机轴承等摩擦部位供送润滑油。本稀油站主要由齿轮泵装置（2台）、双筒网片式过滤器、油冷却器、油箱、阀门、管道等组成，油站为整体式油站，本装置由稀油润滑站和仪表配套组成。XRZ-16（25）Thin oil lubrication equipment is widely applied to supply lubricant to friction sections such as reducing mechanism, bearings of a main motor and so on in metallurgical, mineral, building material, petro-chemical and electrical fields. This oil lubrication station consists of a gear pump unit(2sets), a double tube mesh filter, oil cooler, oil box, valves and some pipes. The lubrication station is in integral structure, A lubrication station and a gauge and instrument panel forms as a whole system.1、 2. 主要性能参数Main specifications： 2.1齿轮泵型号gear pump model： CB2-16（25） 公称流量nominal flow rate ： 16（25） l/min 公称压力nominal Pressure： 0.6Mpa 系统工作压力system working pressure： 0.4 Mpa 电机型号Motor type： Y90S-4B5 转 速Rotation speed： 1440 r/min 功 率Power： 1.1KW 2.2过滤器filter： 型 号Model： SPL25C过滤精度Filtering accuracy： 0.12 mm过滤面积Filtering area： 0.13m2 2.3冷却器cooler： 型 号Model； C2-1.0/4 冷却面积Cooling area： 4 m2 工作压力Operation pressure； 0.63 Mpa 热交换系数Heat exchanging efficient： 300 kcal /m2.h. 耗 水 量Water consumption ： 1.5m3/h 2.4 电加热器electric heater： 型 号Type ： SRY2-220/4 功 率Power： 4KW 3=12KW 2.5 油箱 Oil box 油箱外形尺寸oil box dime3nsion： 12001000800 mm 油箱有效容积Effective volume of the oil box： 0.63 m3 2.6 油站外形尺寸contour size of lubrication station (LxWxH) ： 1410x1155x1500 3. 结构特点structure feature： 3.1油站为整体式，见外形图。the lubrication station is a integral type, please refer to the contour drawing. 3.2油站在正常工作时，低压泵一台工作，一台备用，油站具有过滤，加热，冷却以及安全，自控，报警等功能。under normal operation, one low pressure pump works, the other standby, the lubrication station has functions of filtering, heating, cooling, safety, self control, alarm and etc. 4. 工作原理Working principle： 4.1系统工作压力0.4MPa，系统工作压力由安全阀调节，在运行中由电接点压力表（压力控制器或压力变送器）控制，保证系统的正常工作。The working pressure of the system is 0.4 Mpa, which is adjusted by the safety valve. During operation, it is controlled by a electro-connecting pressure gauge( a pressure controller or pressure transducer). The normal operation of whole unit can be guaranteed by this way. 4.2系统工作时，最高压力0.4MPa，最低压力0.12MPa，压力低于0. 12MPa时，备用泵自动投入工作，当供油压力达到0.4MPa时，原工作泵自动停车。The maximum operating pressure is 0.4 Mpa and the minimum is 0.12 Mpa during operation, if oil supplying pressure drops lower than 0.12Mpa, a standby pump starts automatically; when it reaches 0.4 Mpa, the original pump stops working automatically. 4.3油站在启动前，油站油温低于25，先开动加热器，油温到38时，自动停止电加热器，启动低压泵，在主机正常运行中，供油出口油温降到35时再自动开动电加热器，低压供油出口温度达到45时，人工打开油冷却器。Before the oil station start, if the oil temperature is lower than 25, then start the electric heater first to heat lubrication oil. When the oil temperature rises to 38, the electric heater will stop automatically and initiate the LP pump. During the normal operation of main body, the oil temperature at the oil outlet reduces to 35, electric heater starts automatically. if the temperature in the LP oil supplying outlet rises up to 45, start the oil cooler manually. 4.4当低压泵启动后，应使润滑油在低压供油系统中循环35分钟，再提供给主轴承润滑。after LP pump start and lubricant should be kept circulation in the system for 35 minutes, then supply to the main bearing for lubrication. 4.5主机停机后，供油系统的延续时间，可根据主机的运动特性及现场具体情况决定。 when the main body stop working, oil supplying system should have a delay time, the time delayed depends the properties of the main body and the site condition. 4.6油站双筒网式过滤器，一筒工作，一筒备用，由压差发讯器控制，当压差为0.1MPa时报警，不停机由手动切换阀更换工作筒。the oil station installed a double cartridge mesh filter, one in work, the other standby. The signal generator for pressure difference controls it. When the pressure difference is 0.1 Mpa, alarm sounds; manually exchange the working cartridge without stopping the machine. 4.7回油磁过滤器能吸收油中钢铁细粒，保证油的清洁度。 magnetic filter of reflux oil can absorb the metallic particles to assure the cleanliness of oil. 4.8油箱上装有油位发讯器，控制最高、最低、正常工作油位，最高最低时发出报警讯号，最低位时由人工加油。a oil level signal generator is installed to control the maxmum, minimum, normal oil level, when oil level at the maximum or minimum position the alarm initiates, if it is in oil minimum position, try to complement oil manually. 4.9油箱中位设放油阀，可采油取样，油箱底部两边有球阀放水，放油。a discharge oil valve is designed in the middle part of the oil box, there a sampling of oil can be done. Two ball valves installed in the two sides of the oil box bottom for releasing water and oil. 5. 安装、调试、试运转Installation, test and trial operation： 5.1润滑装置出厂前，已在制造厂进行性能试验，在现场安装平稳后，即可连接油管、电控线路。The lubrication system is tested in the producing workshop, so if it is installed on site stably, oil pipes and electric wires can be connected. 5.2接管前，应将管子按酸洗要求去锈、中和、温水清洗、干燥后再进行连接。Before the connection of pipes, rust cleaning, neutralizing, hot water washing, drying of the pipes should be done according to the acid washing requirement. 5.3现场安装后，润滑油应过滤后再加入油箱，方可进行试车。After site installation, the lubricant should be filled into the oil box after filtering, the test run will be done after filling.5.4油位发讯器的油位定位应按最高最低设定要求定位，超过设定位置应立即发出报警。The set value of oil level signal generator should be set according to maximum oil level value and minimum oil level value, any exceeding of the set position will causes alarm sound. 5.5启动油泵电机前，应先采用点动方法，观查高低压油泵启动方向，转向应符合泵体上箭头所指方向。双筒过滤器手柄搬到一个过滤芯的工作位置上。Before the start of oil pump motor, some dot-start should be done to examine the rotating direction of the HP and LP oil pumps, the rotating direction must conform to the arrows marked on the pump body, the hand stick of double tube filter should be moved to one cartridge operating position. 5.6压力设定值及压力联锁的动作和信号应与设定相符。The set pressure value, signal and action of linkage assembly should conform to the required set values.5.7系统调试完毕后，油温、油压、油位等所有调整参数及联锁均应符合设定值；所有管道和设备应无漏油和不允许的振动，在工作压力下运转2小时后，泵体应无漏油及异常噪声和振动。after test run, oil temperature, oil pressure, oil level, other adjustable parameters and action of linkage assembly should conform to the designed values, no leakage, unallowable vibration occur in the pipes and unit. After the system runs in the operating pressure for 2 hours, leakage, abnormal noise and vibration should not happen to the pump body.6维护与安全技术 Maintenance and safety technique： 6.1 齿轮油泵使用与维护The maintenance and operation of oil gear pump 6.1.1齿轮油泵头与电动机采用弹性联接，齿轮油泵中心线与电动机中心线误差不得大于0.1毫米。转动联轴器是否灵活。A flexible connection is adopted between the oil gear pump and the motor, the error value of oil gear pump central line to electric motor central line should be less than 0.1 mm, rotating the coupling to check if it is flexible. 6.1.2油泵应尽量接近油箱，吸入高度不得大于500毫米。The oil pump should be nearer to the oil box, suction height should be less than 500 mm. 6.1.3油泵应牢固地加以固定，进出口管接头，不得有松动现象。The oil pump should be fixed stably, no looseness occurs on the connectors for inlets and outlets. 6.1.4为保证油泵长期使用，其抽送的油液必须清洁，不应有任何腐蚀性物质和机械杂质，油泵吸入口应设置滤油器。In order to assure long term operation of oil pump, the oil pumped should be clean, and without corrosive substances and mechanical impurities, a filter should be set at the inlet of oil pump. 6.1.5油泵使用时应按标牌所指示方向转动。 The rotation direction should conform to the direction marked by the nameplate. 6.1.6溢流阀应尽可能靠近油泵，最好是直接与油泵相连。Overflow valve should be near the oil pump as near as possible, better directly connect to the oil pump. 6.1.7油封是易损件,如果主动轴出现漏油现象,应更换油封。 Oil sealing is a wearing part, if a leakage occurs in the driving axle, oil sealing should be replaced. 6.1.8油泵采用的是滚动轴承，如果磨损，齿轮泵的噪声增大，出力有所下降，应更换轴承。Rolling bearings are used in the oil pump, if it worn out, the noise of gear pump will increase, power function reduced, then replacement of rolling bearing is needed. 6.1.9检修齿轮后，从新装配时应严格控制泵的轴向间隙，同心度，不能超差，否则不能正常工作。 After repairing of a gear, during assembly the axial clearance, concentricity of a pump should be controlled strictly, no out-of-tolerance is allowed, otherwise it can not work normally. 6.1.10齿轮泵严禁在周围环境度过高（超过电机允许温度）的地方工作和露天工作，以免电动机受潮。The gear pump is not permitted to operate in higher environmental temperature( exceeding the allowable temperature of motor) places or out door environment to avoid the wetting of a motor. 6.1.11停止工作时先关闭电动机开关，然后再关闭油管中的阀。 Upon a halt, first stop the motor, then close the valve in the oil pipe circuit.6.2冷却器使用与维护Operation and maintenance of cooler6.2.1设备操作及维修保养Equipment Operation and Maintenance1) 设备使用前应检查压紧螺栓是否松动，压紧尺寸是否符合规定尺寸，如不符合规定，应均匀把紧螺栓，使其达到规定尺寸。Check whether pressed bolts are loose or not before using the equipment. Check whether pressing size is in accordance with the specified size. If not, twist the bolt to tight equally to the specified size.2)使用前应对设备进行水压试验，对冷热两侧分别试压，试验压力为操作压力的1.25倍，保压时间为30分钟，各密封部位无泄漏方可投入使用。Take water pressure test of the equipment before using it. Test pressure for both cold and hot sides. Testing pressure is one and a quarter times as much as operating pressure. Retaining time is 30 minutes. It can be used without any leaking of each sealed part.3)当设备用于卫生要求较高的食品工业或医药工业时，使用前应对设备进行清洗和消毒，消除设备内的油污和杂物。Clean and sterilize the equipment when used in food or medicine industries which need hing requirements for sanitation. Clean out oil dirt and foreign matter in the equipment.4)当操作介质含有大量泥沙或其它杂物时，设备前应置有过滤装置。Install filter unit when there is much mud or other sundries in the operating medium.5)冷热介质进出口接管应按设备压紧板上的标示进行连接，否则，会影响设备操作性能。Joint pipes of hot and cold media should be connected according to the designation on pressed flat. Otherwise it will affect the operating function of the equipment.6)设备操作时，应缓慢注入低压侧液体，然后再注入高压侧液体；停车时应缓慢切断高压侧流体，再切断低压侧流体。When operating the equipment, first fill in liquid with low pressure slowly, then fill in liquid with high pressure, then cut off liquid with low pressure.7)设备长期运行后，板片表面将产生不同程度的水垢或沉物，这样会降低传热效率并增加流阻，因此设备应定期打开检查，清除污垢。清洗板片时，不得用金属刷子，以免划伤板片，降低耐腐蚀性能。Some scale or deposit will appear on the flat surface after long-time using. Thus heat exchanging efficiency will be reduced and flow resistance will be increased. Therefore equipment should be opened and checked regularly. Clean scale. When washing plctes, dont use metal brush in case it scratches plates. Thue reduce corrosion-resistance.8) 损坏的板片应及时进行更换，若没有备用片，在操作允许的情况下，可以拆下两张相邻的板片（注意：拆下的板片不应是换向板片，而应是带四孔的板片），同时相应减少压紧尺寸（每拆一对板片，BR0.3型设备压紧尺寸减少13mm，BR0.5型设备压紧尺寸减少9mm）。Chang the damaged plate in time. With no spare plates, disassemble two side-by-side plates if operation permits (disassembled plates should not be reversing plates, but ones with four holes). At the same time reduce pressing size (pressing size of BR0.3 should be reduced by 13mm when disassembling a pair of plates. BR0.5 should be reduced by 9mm). 9) 维修时，对于已经老化的密封垫片应进行更换，脱落的垫片应重新粘接，粘接时应清洗垫片槽，涂上粘接剂，将垫片摆正粘牢。When repairing, change the ageing sealed spacers. Rebond the fallen spacer. Clean spacer groove when bonding. Smear bonding agent and bond spacer to tight in the proper position.6.2.2设备清洗Equipment Cleaning1)板式换热器应定期检修，热效率明显降低、压降明显变化时应进行清洗。Check plate-type heat exchanger reqularly. Clean it when heat efficiency is obviously reduced and pressure decrease changes apparently.2) 清洗工作可将设备打开，逐张板片冲洗，如果结垢严重，应将板片拆下，放平清刷。Open the equipment when cleaning, wash one flate after another, dismantle plates when there is much scale and brush them in a horizontal position.3)如果使用化学清洗剂，可在设备内部打循环，若用机械清洗，要使用软刷，禁止使用钢刷，避免划伤板片。Cycle inside the equipment if using chemical detergent. Use soft brush if using machine to clean. Forbid using steel brush in case it damage flat.4)设备冲洗后，须用干净布擦干，板片及胶垫间不允许存有异物颗粒及纤维之类杂物。Use clean cloth to wipe up affter cleaning. Dont allow any foreign matter such particle and fibre to exist between plate and spacer.5) 清洗完毕后，应对板片、胶垫仔细检查，发现问题及时处理。Check plate and spacer carefully after cleaning. Solve the problem in time when finding one.6)在清洗过程中，对于要更换的胶垫和脱胶胶垫应粘牢固，并在组装前仔细检查是否贴合均匀，将多余的粘合剂擦干净。Bond the changed and fallen spacer tightly in the course of cleaning. Check whether bonding is proper or not before assembling. Wipe up excessive detergent.6.2.3故障处理Solutions to Breakdown1)设备在运行过程中常出现的故障有渗漏、泄漏、串液。The common breakdowns in the process of operating are transudation, leakage and mixed liquid.2)产生渗漏的原因有夹紧尺寸不够，垫圈粘接不好，垫圈表面有异物颗粒或缺陷。应根据情况夹紧螺栓或拆装设备。Reasons of transudation are less pressing size, bad bonding of pad loop, foreign matter and defect on the surface of the pad loop. Twist bolts to tight or dismantle the equipment depending on circumstance.3)若在运行过程中出现少量渗漏，应将压力降至零，拧紧螺栓，每次拧紧量23mm，不可过多，若拧紧后仍然渗漏则需要更换胶垫。If there appears a little leakage in the process of operating, reduce pressure to zero. Twist bolt to tight. Twist 2-3mm each time, not more than that, If there is still leakage after twisting, chang glue pad.4)长期运行后出现泄露或渗漏，尺寸夹紧后仍不能解决，证明胶垫老化，应重新更换胶垫。Twisting bolt cannot solve transudation or leakage proves glue pad to be ageing. Chang it.5)设备出现串液现象，原因是板片裂纹或穿孔。应打开设备，检查板片情况，个别板片出现问题应更换板片。若使用年限过长，应更换设备。Reason of mixed liquidis plate crack or piercing. Open the equipment, check the condition of the plate. Change the plate if there exists some problem. Change the equipment if using time is too long.6.3过滤器的使用与维护Service and operation of filter 在正常工作情况下，油滤器的清洗压降0.15MPa，如压差超过应迅速转换滤芯腔，对原滤芯腔进行检查清洗。Under normal operation, the pressure drop of washing of oil filter0.15 Mpa, if it exceeds this value, turn to use the other filtering cartridge immediately, washing and inspecting should be done to replaced old cartridge.6.3.1使用要点Operation instructiona. 在壳体转换阀体腔两侧有两对进出油口，油系下进上出，不得误装，有四种接管方式，由用户根据工况自选。There are two couple of inlet and outlet connectors on the cartridge and chamber, the upper ones for output, lower ones for oil inlet, dont misassemble them, there are four types of connecting measure, the buyer can choose upon their own condition.b. 转换手柄必须处于左开或右开的极限位置，以保证油路畅通。The hand stick must be in the maximum right or maximum left position to guarantee the flow of oil.c. 滤器开始通油时，应开启放气阀，待油液充满滤芯腔，排尽空气后关闭放气阀，以免油液外溢。At the beginning of filling oil of a filter, gas discharge valves should be open, when the oil filled full of the filtering core chamber, all air is put out, then close the gas discharge valve to voiding oil overflowing.d. 当压差超过要求或在系统运转中拆洗滤芯组件时，必须迅速转动手柄，转换结束时手柄应处于极限位置，严禁中途停留。When the pressure drop exceeding the set value or a disassembly and wash of the filtering core unit is needed, a rapid move of hand stick should be done, after transforming, the hand stick must be in the up most position for one cartridge, remaining in middle pos