XGDC200600两台高压泵说明书中英文083618

1、XGD-C20/600高低压稀油润滑装置High-Low Pressure Thin Oil Lubrication Equipment 使 用 说 明 书Operation Instruction 编号：1008034-ZY-SM Serial No : 目 录CONTENT1用 途General2主要性能参数The main specifications3结 构 特 点structure feature4工 作 原 理Working principle5安装、调试、试运转 Installation, test and trial operation6维护与安全技术 Maintenance

2、and safety technique7稀油润滑装置系统图principle drawing of lubrication station8稀油站润滑装置形图 contour dimension drawing of lubrication station 1、用途General application：本高低压稀油润滑装置主要由低压齿轮泵装置（2台）、高压柱塞泵、双筒网式过滤器、板式冷却器、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、仪表配套组成。 This H.P&L.P oil lubrication station consists of a gear pu

3、mp unit(2sets), high pressure plunger pump, double tube mesh filter, oil cooler, oil box, valves, pipes. The whole system is in a detachable structure. This lubrication unit can be divided into lubrication station, a gauge and instrument panel.2、 主要性能参数Main specifications：2.1低压供油系统Low pressure oil s

4、upply system：齿轮泵型号gear wheel pump model： CB-B600 公称流量Nominal flow rate： 600L/min公称压力Nominal pressure： 0.6MPa系统工作压力System work pressure： 0.2-0.4MPa电机型号Nominal pressure： Y180M-4B5转 速Rotation speed： 1430 r/min功 率Power： 18.5kW 过滤器Filter：型 号Model： SPL80X SPL65X 过滤精度Filtering accuracy： 0.08 mm 0.04mm 过滤面积

5、Filtering area: 1.31 m2 0.83m2 板式冷却器Oil cooler： 型 号Model： C6-1.0/60-NB 冷却面积Cooling area： 60m2 工作压力Operation pressure： 1.0 MPa热交换系数Heat exchange ratio： 300 kacl/m2.h.水耗量Water consume： 53 m3/h电加热器Electric heater：型 号Model： HRY5-220/6功 率Power： 6kW×6=36kW油箱外形尺寸Oil box outline dimension： （L×W

6、15;H）3700×2300 ×1260 油箱有效容积Effective volume of the oil box： 6.5m3油站外形尺寸Oil station outline dimension： （L×W×H）4700×2200×26002.2高压系统HP system：2.2.1 高压泵型号High pressure pump model： SC-108 公称流量Nominal flow-rate： 108 L/min 公称压力Nominal pressure： 40MPa 系统工作压力System work pressur

7、e： 14Mpa（暂定interim） 电机型号Motor type： Y250M-6/b35 转 速Rotation speed： 970r/min 功 率Power： 37kW3、结构特点structure feature：3.1油站为分体式结构（见外形图），油站工作原理图（见系统图），润滑站由低压供油系统与高压供油系统组成，低压油出口除直接提供齿轮润滑外，同时对高压泵吸油口供油，两台高压泵将高压油提供给补偿装置形成十六路高压供油系统直接将高压油输送至各油腔。The oil station is in a detachable structure (please refer to the

8、contour drawing ). The graphic operation principle please refers to the system drawing. The lubrication station includes two units - one oil high-pressure supply unit and one low-pressure oil supply unit. The outlets of L.P oil supply unit not only supply lubricating oil to the gears, but also suppl

9、y oil to the inlet of H.P pumps. 2 sets of HP pumps offer H.P oil give 1 set of compensate set, Offer 16 HP oil supplying outlets forming whole HP oil system that directly pumps the H.P oil to oil reservoirs.3.2油站在正常工作时，低压泵一台工作，一台备用，齿轮泵出油口压力经安全阀调定约0.7MPa，流经过滤器，过滤精度80m，再流经油冷却器，由电磁水阀的自动启停控制出口油温为3842范围

10、。 At normal operation ,one low pressure pumb will work and another will be spare. The oil outlet pressure of gear wheel pump is set to 0.7Mpa by safety valve. The oil flows through a oil filter whose filtering accuracy 80m, a oil cooler. The oil temperature at the automatic start /halt outlet of ele

11、ctromagnetic water valve is controlled between 3842.3.3冷却器后低压油出口，一部份通向齿轮箱提供润滑，一部份向高压泵吸口供油，在高压泵进口安装有过滤器，过滤精度40m，保证提供给高压泵工作的润滑油为高清洁度的润滑油，以提高高压泵的工作寿命。两台高压泵同时工作，两台高压泵与两台补偿装置的十六路出口与静压油膜轴承各油腔连接。高压系统工作压力由压力变送器通过数显控制仪控制，低压系统工作压力由压力变送器通过数显控制仪进行控制，保证高低压系统的正常工作。Low pressure oil after cooling unit partly goes t

12、o the gear box as lubrication oil , the other part of it goes to the oil inlet of high pressure pump as inlet oil. At the oil inlet pipe of H.P pump a filter with filtering accuracy 40m is mounted to guarantee the oil supplying to the HP pump as high cleanliness quality lubricating oil. By this way

13、the working life of the HP pump is improved. 24 sets of HP pump work together, 2 sets of HP pump and 2 sets compensate set so 16 sets of HP oil outlet pipes connect to the oil reservoirs of static pressure oil membrane bearings. The unit operating pressure of the H.P system is controlled by the elec

14、tro connecting pressure gauges. A digital control gauge through a pressure transducer controls the unit operating pressure of the L.P system in order to guarantee the normal operation of HP unit.4、工作原理Working principle：4.1低压供油系统工作压力0.4Mpa，高压系统公称压力为31.5Mpa，高压系统可根据工作需要调整高压系统的工作压力，高低压系统工作压力由溢流阀调节，在运行中由

15、电接点压力表和压力继电器（或压力开关、或压力变送器和数显表）控制，保证高低压系统的正常工作。The working pressure of the Low pressure oil system is 0.4 Mpa, The Nominal pressure of the high pressure oil system is 31.5MPa, The operating pressure of high pressure system may be adjusted according to operation requirements.The work pressure of high

16、pressure oil system which is adjusted by overflow valve , During operation, it is controlled by a electro-connecting pressure gauge and a pressure relayr( or pressurecontrolle 、orpressure transducer). The normal operation of whole unit can be guaranteed by this way.4.2低压系统工作时，最高压力0.4Mpa，最低压力0.12Mpa，

17、压力低于0.12Mpa时，备用泵自动投入工作，当供油压力达到0.3MPa时，原工作泵自动停车，当备用泵起动1分钟后压力仍低于0.12MPa时，主机停车报警。当低压供油压力高于0.2Mpa时，启动高压泵，高压泵启动10分钟后，当高压出口油压力达到4MPa时由压力控制主机启动， During low system operating, the maximum of pressure is 0.4 Mpa and the minimum is 0.12 Mpa, if oil supplying pressure drops lower than 0.12Mpa, a standby pump st

18、arts automatically; when it reaches 0.3 Mpa, the original pump stops working automatically. during standby pump automatically starts to work 1 minute oil supplying pressure still drops lower than 0.12Mpa, the unit will halt and start alarm. On condition that the pressure of L.P oil comes to 0.2 Mpa,

19、 the H.P pump can be initiated. during high pressure pump automatically starts to work 10 minute，high pressure oil supply reaches 4 Mpa, by pressure cortrol main engine start.4.3 油站在启动前,油站油温低于38，先开动电加热器.油温到38时,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时再开动电加热器,低压供油出口温度达到45时,人工（自动）打开油冷却器.Before the oil station

20、 start, if the oil temperature is lower than 38, 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 r

21、educes to 35, electric heater starts automatically. if the temperature in the LP oil supplying outlet rises up to 45, start the oil cooler manually(automatic).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 sup

22、ply to the main bearing for lubrication.4.5主机停机后,供油系统的延续时间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,由差压开关控制,当压差超过差压开关的发讯值时（粗过滤：0.15MPa，精过滤

23、0.2MPa）,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 excess alarm numerical（rough filtrate：0.15MPa，fine filtrate：0.2MPa）; manually exchange the working c

24、artridge 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 l

25、evel, when oil level at the maximum or minimum position the alarm initiates, if it is in oil minimum position, try to complement oil manually. 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

26、 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，首先要检查润滑油是否与设计牌

27、号符合，油液的清洁度是否良好。润滑油应过滤后再加入油箱，方可进行试车。After installation, a check shall be carried out to see if the lubricant is conforming to the design type and brand, also the cleanliness degree of oil right or not. The lubricant shall be filled into the oil box after a filtering. After all, trial operation can be

28、 done.5.4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 doubl

29、e tube filter should be moved to one cartridge operating position. 5.5 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.5.6试车启动，首先按2.3与2.4条进行，高压泵启动后，工作台浮起形成油膜后，只要用较小的力，就能使工作台移动，再开始一开一停地启动主机，运转正常后方可连续运转，若有故障，应及时排除，不允许强行启动主机

30、。Trail start, first do the steps according to 2.3 and 2.4, after the start of the H.P pump, the working platform floats up and forming oil membrane, only a little force can move the working platform by now. Then one start-one halt operation can be done to initiate the main body, when operation is in

31、 a normal condition, continuous operation can be initiated, if some trouble, shoot the trouble first, force start is not allowed.5.7在调试过程中，应及时注意高压系统各路的压力变化，如出现压力不稳定，首先判断是否因载荷变化所引起，其次应检查油路系统中有无空气，以及油中的较多的气泡。如发现油腔压力下降很多，应及时停车检查原因，停车时要先停主机，待主机停止转动，才可停油泵电机。During the trail run, attention to the pressure

32、 varieties of HP system should be paid, if unstable pressure occurs, try to judge if it is caused by load varieties, or air existing in the oil system line, or unallowable bubbles in the oil. If the pressure of the oil reservoir drops down largely, halt the unit to find out the reason, on condition

33、of halting the system, the main body should be halted first, when rotating parts in the main body stop working, the motor of oil pump can be halted.5.8如发现异常现象，例如转动不灵活，供油系统噪音大等，立即停车检查，排除故障。If there are some abnormal phenomena such as inflexibility of rotation, louder noise in the oil supplying system

34、 and etc., please halt the unit instantly to solve the trouble.5.9主机运转后应注意发热问题，经过一小时运转后，一般轴承壳体温度为4050，则说明工作正常，若温度达到70左右，应停车检查原因：主要是工作台与轴瓦产生局部接触，形成半液体摩擦而产生很大的热量，只有在温度正常情况下，才能测试静压轴承的主要性能指标。When the main body is under operation, temperature rising should be inspected, after one hour operation, generall

35、y the temperature of bearing shells between 4050 means the unit working normally, if the temperature reaches around 70, a halt should be done to find out the reason: mainly the partial contact of working platform and bearing bush forms a semi-liquid friction, this will generate a large amount of hea

36、t, only under normal temperature, the main specifications of static pressure bearing can be examined and tested.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 bet

37、ween 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.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

38、 mm.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.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 me

39、chanical impurities, a filter should be set at the inlet of oil pump.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.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.油封是易损件,如

40、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.油泵采用的是滚动轴承，如果磨损，齿轮泵的噪声增大，压力有所下降，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 r

41、olling bearing is needed.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.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 ge

42、ar 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.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Op

43、eration and maintenance of cooler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

44、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 i

45、s 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)

46、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 funct

47、ion 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

48、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 i

49、n 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 permit

50、s (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。W

51、hen 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.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 effi

52、ciency 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

53、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 b

54、etween 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 prop

55、er or not before assembling. Wipe up excessive detergent.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 si

56、ze, 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

57、 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 pi