ML20中速磨主减速机说明书

Date of issue Jan 2005 Version number 05A ML20 vertical roller mill reducer Manual instruction Executive standard Q 3201NGC009 2005 Driving device the axial run out may be increased accordingly 2 Installation and aligning between the reducer and the mill Confirm the rotation direction before connecting to the machine of other side Otherwise the wrong rotation direction may cause injury or machine damage Avoid imposing impact force or too much load on the shaft when installing the coupling Otherwise it may cause broken or fallen off to bearing or seal ring ML20 vertical roller mill reducer Manual instruction 6 The installation of the reducer and the mill should be carried out correctly and delicately Clean the disc mill and thrust pillow block without any inclusion The fitting rabbet dimension between the disc mill and thrust pillow block must be recorded in details Tighten the connection bolts between the disc mill and thrust pillow block and make sure the thrust pillow block is free from deformation or distortion The tolerance of axial run out is no more than 0 13mm During installing the reducer if no oil or lubricate system doesn t work the reducer mustn t run slowly VI The records of field installation debugging and commissioning 1 The type of the reducer 2 The delivery Serial No of the reducer 3 The specification of mill 4 The specification type power revolution pressure current of the main drive motor 5 Rotation direction from motor end 6 Detailed records during installation and aligning The result of the aligning between the reducer and the motor The result of the aligning between the reducer and the mill 7 Test run record The beginning time Month Day Year The ending time Month Day Year The load on the mil Month Day Year Running time Start up Current of electric machine stator A Temperature C Oil tank temperature RemarkItem Beginning time Ending time Load on main motor T Voltag e of electric machine stator V Max Min Work current of electric machine statorRoom temperature Before test After test Operation and Maintenance 1 Start up 1 Preparation work before start up Lubrication oil has been discharged from the reducer before delivery so recommended ML20 vertical roller mill reducer Manual instruction 7 lube must be filled in before operation Assemble the external lubrication piping completely The pipes should be clean and free of any cotton or chips inside before fitting Make sure by inspection that the safety controlling and automatic protection systems function reliably Check oil level in the tank Check whether all instruments gauges apparatus and meters have been installed completely Check the oil leakage of the lubrication system after 1 hr lubricating Check the oil level of the thrust bearing and housing if oil is less than required refill to normal level Heat up the oil temperature over 25 by the oil heater when the temperature of the bearing is lower than 25 2 Preparatory work before the start up of oil pump Check if the oil pump work properly Check the oil pressure Outlet pressure of the low pressure pump 0 25 0 4 Mpa Inlet pressure of the reducer 0 15 0 25 Mpa 3 Preparatory work before the start up of reducer In the case that the high pressure is not turned on the reducer should be started up without load It is forbidden to start up the motor when the high pressure is in loading which is able to protect the thrust bearing from damaging under the conditions of none oil Observe the rising of the bearing temperature without load At all hours it is not allowed to load continually until the temperature rise of the bearing is steady It is strictly prohibited to load unevenly and the two loading cylinder must work at the same time Check if any abnormal noise or vibration exists in the reducer Check the temperature of the thrust block is normal and it must be shut down when exceeding 75 One cannot start up the main motor when outlet temperature of the oil cooler is below 25 or above 50 ML20 vertical roller mill reducer Manual instruction 8 4 Preparatory work before the startup of main motor One can carry out the test run according to the test program with load or without load Check if any abnormal noise or vibration exists Check the temperature of the thrust block is normal and it must be shut down when exceeding 75 One cannot start up the main motor when outlet temperature of the oil cooler is below 25 or above 50 2 Shut down Precautions before shut down and its process The mill disc must be unloaded before the mill stop working shutdown with load is strictly forbidden 1 Unload of the mill disc 2 Shutdown of the main motor 3 Stop filling water to the oil cooler During the frozen winter do not shut off the cooling water completely or drain the cooling water completely Take notice that the main motor can be started only when the lubrication oil is in liquid state in winter it is difficult to form oil film with the starchy lubrication oil for it is easily to damage the thrust bearing 4 Stop the oil pump Let the pump work for about 10 minutes after the mill stop working If the mill only stop for a short time it is not necessary to shut off the oil pump in order to let the mill can start up at any time After shutting off the oil pump if one needs to restart the mill he must turned on the oil pump first and then inspect the oil level o in the thrust bearing oil tank which should be higher than the prescribed scale line or it is not allowed to start the mill 3 Maintenance In order to keep the good operating situation regularly check the following items during the continuous operation 1 Check and record the data of the pressure temperature and other indicated parameter at the stipulated time every day 2 Compare the recorded data with the following table data and find out the reason for the abnormal things if necessary stop for inspection ML20 vertical roller mill reducer Manual instruction 9 ItemRated valueLimited valueRemark Inlet temperature25 50 C Inlet pressure0 15 0 25Mpa Outlet pressure0 25 0 4MPa Oil level of the tank Above 1 2 Temperature of the thrust bearing bushing 70 C80 C Thrust bearing bushing temperature in the house 60 C75 C 3 Take notice of the overload to the reducer 4 Oil filtering 3 4 hrs after the first operation clean the filter Normally clean the filter once after 200 hours work Pay attention to the type and origin of the impurity during the cleaning 5 Check the connection bolts After 20 hours initial operation or subsequent 1000 hours running carefully check the tightening of the bolts and nuts which connect the housing and framework of the foundation If necessary tighten it 6 Relative position inspection between the thrust pillow block and housing Check the relative position dimension a between the thrust pillow block and house every 2000 hours see the assembly drawing Compare the present data with former data if great change happen stop the operation and check the reason 7 Frequently check the noise and vibration if abnormal situation occur analyze the reason and solve it 8 Frequently check oil leakage in each part if it happen solve it 9 Frequently check the oil level When the oil level is below the 1 3 refill the oil to the stipulated level If the oil level is rising may be the cooling water drain into the oil tank take the oil sample form the oil plug position at the tank bottom If necessary change the oil Regular inspection 1 The entire inspection should be carried out after running 2000 hrs or more generally no more than 1 year and can be processed at stop period or maintenance period 2 The inspection items ML20 vertical roller mill reducer Manual instruction 10 Inspection pointsInspection itemsNotes The relative position dimension a between the thrust pillow block and housing Compare the recorded data with the delivery data Check the connection of the thermal coupling which measure the thrust bushing temperature Thrust bearing If any dirt at the house bottom of the thrust bearing Dismounting the observation hole cover on the thrust bearing housing Check teeth the contact pattern Dismounting the observation hole cover on the lower housing Bevel gear If nozzles are blocked or loose occur to connection bolts House and pipingCheck tightening of the following components 1 Bolts tightening between the thrust bearing housing and the reducer 2 Bolts tightening between the lubrication piping and housing 3 Bolts tightening between the reducer and foundation 4 Bolts tightening between the mill and thrust pillow block Input couplingCheck the bolts tightening Clean the internal tankIf necessary drain old oils form tank Oil station and auxiliary device Check the following devices 1 Oil pump 2 Cooling device 3 Heater 4 Relay of the oil temperature and pressure and other instruments Check devices when the oil flow and pressure is not enough Check devices when the cooling ability decline or water drain into the oil tank Ensure the value should be right Comment ngc1 页 11 ML20 vertical roller mill reducer Manual instruction 11 3 The first oil replaroller must be processed after the 2000 hrs operation and later regular inspection of the oil should be carried out frequently If the oil quality does not meet the requirement change the oil normally change the oil every 5000 hrs during changing the oil and carefully check the nozzle if nozzles are blocked should immediately solve them The new oil should comply with the requirement Attention for the assembly and disassembly It is necessary to check and maintain the whole reducer after a period work Inform the NANJING HIGH SPEED ACCUATE GEAR CO LTD to get help when the reducer needs to be maintained and remounted 1 Dismount 1 Dismount shall carry out at special place where must be clean and without other sundries 2 Wrap the both end of the dismounted pipes with the plastic paper to prevent dirty after dismounting the outside pipes 3 During the dismounting take note of the assembly No and position of the locating pin so as to recover them to the original position when it is reassembled 4 Prevent gearbox form any dirty keep the house clean 5 Use the hydraulic tool to dismount the thrust pillow block if necessary contact the supplier 2 Inspection After disassembling the drive parts check and record the parts in detail contact pattern of the tooth face bearing worn check the worn situation of the thrust pillow block the permissible height tolerance is no more than 0 025mm The spherical surface must be grinded and amended Change the worn out parts 3 Reassembly The reassembly of the gearbox must meet the requirement of the drawing and carry out according to the technological situation Clean all the parts before the reassembly Connect the all bolts and nuts if necessary change the worn out tightening parts During reassembling house clean the old sealing glue change the new one during the major maintenance one shall change the lubrication oil and align the gearbox X Guarantee ML20 vertical roller mill reducer Manual instruction 12 The guarantee range is limited to products manufactured by our company Guarantee period and content Note Our company reserves the right to update this instruction at any time and don t take the responsibility of renewing the delivered instruction Guarantee period 18 months after delivery or the shortest period within the 12 month after operation Guarantee contentWithin the guarantee period please carry out installation connection and maintenance in strict accordance with operation instruction or any other agreement accepted If the abovementioned conditions are met in case of malfunction our company will provide basing on our judgement maintenance or substitute products free of charge with exception of the following cases When this product is connected with other device of the customer we won t pay for dismantlement and reconnection between the product and such dev