凱馬CCFJ系列船用柴油發(fā)電機組安裝使用及維護說明書

1、CCFJ系列船用柴油發(fā)電機組安裝使用及維護說明書CCFJ series Marine Diesel Engine Generator UnitsInstallation Usage and Maintenance Manual 南昌凱馬柴油機有限公司NanChang Kama Diesel Engine Co., Ltd.安全告示 Safety Warning使用及安裝CCFJ系列柴油發(fā)電機組前，請詳細閱讀本說明書、以及柴油機、發(fā)電機、附件的說明書（或手冊），以了解機組、發(fā)電機、柴油機和有關(guān)設(shè)備的情況。Before operating and installing CCFJ series Di

2、esel Engine Generator Units, Please carefully read the Notebook, and Diesel Engine, Generator, Accessoriess notebook (or manual) to know the condition of Engine, Generator, Diesel Engine and related equipments.請記住安全第一，當(dāng)你不甚明白所作的說明或操作程序時，應(yīng)向?qū)I(yè)人員請教后再進行正確操作和保養(yǎng)設(shè)備才能達到安全、有效的運行。Pls remember safety first. If

3、you are not sure of the instructions or procedures contained herein, seek qualified help before continuing.·確保安裝能滿足所有適用的安全標(biāo)準(zhǔn)和地方性電氣標(biāo)準(zhǔn)。所有安裝要有合格的電工和機械工來實施。Ensure installing can meet all available safety standard and local electric standard. All installation should be attempted by qualified electri

4、cian and machinist. ·確保使用能正常、安全，必須具有電氣、機械安全知識的合格的操作人員來操作使用。Ensure operation can be in order, safety, it should be attempted by the qualified, electrical, mechanism safety knowledges personnel.·勿在機組、燃油箱、蓄電池附近抽煙、點火。Please not Smoking, lighting near the Engine, Fuel Tank and Storage Battery.&

5、#183;勿在機組運行時打開散熱器、或熱交換器的壓力蓋，要待機組停機并冷卻后才可打開壓力蓋、及放冷卻水（液）。Please do not open the Radiator, or heat exchangers pressure lid while engine running, only can open the pressure lid and put cooling water until the engine stops and cools·起吊發(fā)電機組時，必須使用長度適當(dāng)和起吊能力適當(dāng)?shù)匿撍骰虼掷K。在起吊時，機組可能有一定傾斜，必須小心操作，以避免人員受傷或設(shè)備損壞。Wh

6、en lifting the generator, need to apply proper length and suitable lifting ability of tightwire or rope. While lifting, the engine maybe a little slant, must be operating carefully, avoid personal injury or equipment damnification. ·機組周圍的通道應(yīng)寬暢，確保機組出現(xiàn)重大事故時，以便操作人員可以迅速安全撤離。The engine around door s

7、hould be wide, in case of the engine occurs big accident, the operating personnel can retreat promptly. ·勿在機組運行時，開啟防護溫蓋、維修蓋、出線盒進行維修、操作。Please do not open defence lid, maintenance lid, repair or operate outlet box while the engine is running.·在進行維修前應(yīng)將柴油機起動回路切斷、切斷和電網(wǎng)或其它機組閉合回路，在斷路開關(guān)上置警告牌，以免意外

8、的提示操作（閉合）。Before any maintenance, disconnect all power sources and lock out all controls to prevent an unexpected notice operation (close). ·遵守機組中所有重要、小心、警告和危險牌上的提示。Comply with all engines important, cautious, warning and dangerous notice.由于本產(chǎn)品技術(shù)的提高，本說明書的內(nèi)容在印刷時是正確的。隨時間推移本說明書所述內(nèi)容可能與產(chǎn)品稍有出入，望用戶諒解。

9、如有疑問，請與本公司聯(lián)系。With the constant modification and improvement, the engine delivered maybe slightly different from content in this manual., please understanding. Any of doubt, please inform of our company. 第一章 機組型號簡要說明Chapter 1 Engine Type Brief JCCF不同發(fā)電機組裝機組變型代碼，蘭州產(chǎn)相復(fù)勵電機同“X”；三波產(chǎn)的諧波電機用“S”；蘭州產(chǎn)無刷相復(fù)勵電機用“W

10、X”；無刷諧波電機用“WS”；馬拉松電機用“M”；斯坦福電機用“N”表示。不同柴油機組裝機組變型代碼，一般用柴油機生產(chǎn)廠廠名的聯(lián)想字符加·，若缺省則柴油機為本公司的X105及X110柴油機。機組分類代號：無符號為普通性機組；“Z”為應(yīng)急發(fā)電機組；“K”為帶監(jiān)控儀的機組；“YA”為蒂帶轉(zhuǎn)速遙控機組，“S”為前端輸出機組。機組的額定功率（KW），用數(shù)字表示。電流種類代碼，交流用“J”表示船用柴油發(fā)電機組代碼a. The code sample of the generator, Lanzhou generator of phase compound excitation use X; S

11、anBo harmonic generator use S; Lanzhou generator of brushless phase compound excitation use WX; Brushless harmonic generator use WS; Marathon generator use M; Standford generator use Nb. The code sample of the diesel engine, this part is the using diesel engines code with the association words of ma

12、nufacturer and a point. Or it shall be our X105 and X110 diesel engine if omited.c. Engine Function Code: No any symbol is Ordinary generator units; Z is contingency generator units; K is the generator units with monitor; YA is remote control generator units, S is front fan-out generator units.d. Ra

13、ted Power (kW) showed by number.e. Current type code, J means alternating current. f. The code of marine diesel generator units型號示例：（1）CCFJ24YA-X：24KW船用柴油交流發(fā)電機組（發(fā)電機是蘭州產(chǎn)的相復(fù)勵，柴油機是本公司產(chǎn)的X4105BCF柴油機），帶轉(zhuǎn)速遙控裝置；（2）CCFJ40-C·W：40KW船用柴油交流發(fā)電機組，柴油機是東康產(chǎn)的康明斯柴油機，電機是無刷諧波發(fā)電機；（3）CCFJ75Z-S·M：75KW船用應(yīng)急柴油交流發(fā)電機組，

14、柴油機是上海柴油機股份有限公司生產(chǎn)的，電機是馬拉松發(fā)電機；（4）CCFJ100K-N·WX：100KW帶監(jiān)控儀的柴油交流發(fā)電機組，柴油機是我公司生產(chǎn)的NC6110ZLCF柴油機，發(fā)電機用蘭州無刷相復(fù)勵發(fā)電機；（5）CCFJ150- S·N：150KW船用交流發(fā)電機組，柴油機用上海柴油機股份有限公司生產(chǎn)的柴油機，發(fā)電機用無錫新時代斯坦福發(fā)電機。Type Illustration:(1) CCFJ24YA-X：24kW marine diesel alternating current generator unit (generator is Lanzhou generator

15、 of phase compound excitation, diesel engine is our own X41105BCF), and equipped remote control device;(2) CCFJ40-C·W: 40kW marine diesel alternating current generator unit, diesel engine is Cummins diesel engine, generator is Brushless harmonic generator.(3) CCFJ75Z-S·M: 75kW contingency

16、marine diesel alternating current generator unit, diesel engine is the product of ShangHai Diesel Engine Joint-Stock Limited Co., generator is Marathon generator.(4) CCFJ100K-N·WX: 100kW marine diesel alternating current generator unit with monitor, diesel engine is our own NC6110ZLCF, generato

17、r is Lanzhou brushless generator of phase compound excitation.(5) CCFJ150- S·N: 150kW marine diesel alternating current generator unit, diesel engine is the product of ShangHai Diesel Engine Joint-Stock Limited Co., generator is Wuxi Standford generator. 第二章 機組基本技術(shù)規(guī)格及主要技術(shù)性能的使用工作環(huán)境、Chapter 2 Ope

18、ration conditions, main technical specification, and major performance characteristics2.1 使用工作環(huán)境 、環(huán)境溫度：+5+40；海拔高度：4000； 、空氣相對濕度：95（+25時）； 、長期橫傾：15°； 、長期縱傾：7°30； e、周期橫傾(橫搖)：22°30； f、空氣中有凝露、鹽霧、油霧； g、有正常營所產(chǎn)生的振動和沖擊 h、沒有導(dǎo)電塵埃、沒有破壞金屬和絕緣介質(zhì)的腐蝕性氣體以及無爆炸危險的場所。2.1 Operation Conditionsa. Ambient te

19、mperature . +5+40b. Relative humidity 95%(at 25 ambient temperature)c. Long-term horizontal incline 15° d. Long-term vertical incline7°30e. Period horizontal incline22°30f. Congealed dew, salt fog and oil fog in the airg. Normal libration and impulsione. No conductive dust, corrosive

20、gases or explosive hazards.2.2 基本技術(shù)規(guī)格 、額定功率 （注） 見銘牌 、額定電壓 400/230V 、額定電流 見銘牌 、功率因數(shù) 0.8（滯后） 、額定頻率 50H 、額定轉(zhuǎn)速 1500 、相數(shù)與接法 三相四線（星形） 、調(diào)壓方式 自動 、起動方式 直流電起動 、冷卻方式 水冷閉式循環(huán) 、質(zhì)量 見銘牌2.2 Main technical data and specifications a. Rated Power See brandb. Rated voltage 400/230Vc. Rated currency See brandd. Power fac

21、tor 0.8 (lag)e. Rated frequency 50HZ f. Rated speed 1500r /min g. Phase and connection 3-phase, four wire system h. Voltage regulation automatic i. Method of starting electric j. Method of cooling water-cooling, closed type k. N. Weight See nameplate 注：在環(huán)境溫度318K（45）、絕對大氣壓力100P、空氣相對濕度60，初級冷卻水溫度32條件下可

22、長期運行的功率，其中允許以110%額定功率運行1小時。超出上述環(huán)境條件下輸出功率按GB1105規(guī)定修正柴油機功率再折算機組輸出修正功率值。Note: the set can operate for long-term continuously at power output under the following operating conditions: the specified condition of 318K (45) in ambient temperature,100 P in atmospheric pressure, 60% in relative humidity and

23、32 of primary cooling water, use of 110% output power for an hour is permitted. Pls refer to GB1105 Standard under the other operating conditions.2.3 主要技術(shù)性能Main Technical Performance2.3.1 穩(wěn)態(tài)電壓偏差（穩(wěn)態(tài)電壓調(diào)整率） 不大于±2.52.3.1 Steady Voltage Windage (Steady Voltage Regulation Ratio) ±2.5% 2.3.2 瞬態(tài)電壓

24、偏差（瞬態(tài)電壓調(diào)整率） 100突減功率 +20突減功率 -152.3.2 Transient Voltage Windage (Transient Voltage Regulation Ratio) 100% Anticlimactic Power +20% Anticlimactic Power-15% 2.3.3 電壓穩(wěn)定時間 1.52.3.3 Voltage Stability Time (s) 1.5 s2.3.4 電壓波動率 0.52.3.4 Voltage Fluctuation Ratio 0.5%2.3.5 穩(wěn)態(tài)頻率調(diào)整率 52.3.5 Steady Frequency Reg

25、ulation Ratio 5%2.3.6頻率波動率 0.52.3.6 Frequency Fluctuation Ratio 0.5%2.3.7瞬態(tài)頻率調(diào)整率 100突減功率 +10突減功率 -102.3.7 Transient Frequency Regulation Ratio100% Anticlimactic Power +10%Anticlimactic Power -10%.2.3.8 頻率穩(wěn)定時間 52.3.8 Frequency Stability Time (s) 5 s2.3.9 空載電壓整定范圍 95105額定電壓2.3.9 Unloading Voltage regu

26、lation range 95% - 105% Rated Voltage2.3.10 冷熱態(tài)電壓變化 可控勵磁裝置的機組應(yīng)不超過±2額定電壓 不可控勵磁裝置的機組應(yīng)不超過±5額定電壓2.3.10 Cold and Hot Voltage Variety Controllable excitation settings engine should be no more than ±2% rated voltage.Uncontrollable excitation settings engine should be no more than ±5% ra

27、ted voltage.2.3.11 空載額定電壓、額定頻率時, 線電壓波形畸變率 無刷發(fā)電機組5 有刷發(fā)電機組102.3.11 Unloading Rated Voltage, Rated Frequency, Voltage Wave Aberration Ratio Brushless Generator Units 5%Brush Generator Units 10%2.3.12 不對稱負載要求：機組帶一定的三相對稱負載，在其中一相加上25額定相功率的純阻性負載，當(dāng)該相的總負載電流不超過額定值時應(yīng)能正常工作，線電壓的最大（或最?。┲蹬c三線電壓平均值之差應(yīng)不超過三線電壓平均值的

28、7;5。2.3.12 Dissymmetry Load Requests: The generator has definite 3 phase symmetry load, add the pure resistance load of 25% rated power on any of one phase, it shall work well when total load electric current of it is no more than rating. Wire voltages maximum (or minimum) minus average of 3 wires v

29、oltage should be no more than 5% of 3 wires voltage average. 2.3.13 機組在額定空載電壓、頻率額定時能直接起動下表規(guī)定的空載四極長鼠籠型三相異步電動機。2.3.13 The generator unit can directly drive empty load quadrupole long rat type 3 phase asynchronism electromotor as stated of following list under rated empty load voltage and rated frequen

30、cy. 表1 List 1機組額定功率PH(kW)Rated Power PH (kW)四級三相鼠籠式異步電動機（kW）（國家標(biāo)準(zhǔn)）quadrupole 3 phase rat type asynchronism electromotor (kW) (National Standard)四級三相鼠籠式異步電動機（kW）（可達水平）quadrupole 3 phase rat type asynchronism electromotor (kW) (Available Level)PH40 0.7 PH相近容量 Close Capacity50PH7530相近容量 Close Capacity7

31、5PH12055相近容量 Close Capacity150PH250750.8 PH300PH3201102202.3.14 具有并聯(lián)運行功能的機組，二臺同型號、同功率的機組在額定功率因數(shù)的20100總額定功率范圍內(nèi)應(yīng)能穩(wěn)定地并聯(lián)運行，且能平穩(wěn)相互轉(zhuǎn)移負載的有功功率和無功功率，其有功功率和無功功率的分配差度均不大于±15。2.3.14 The generator units of parallel connection running function, 2pcs homotype, same power can steadily parallel connection runni

32、ng at 20%-100% total rated power range, also can stable transfer loads power and powerless, and the distributed balance between power and powerless is no more than ±15%.第三章 機組結(jié)構(gòu)簡介Chapter 3 Generator Units Structure Brief機組由柴油機、發(fā)電機、控制屏、聯(lián)軸器和公共底座（機架）等組件構(gòu)成，柴油機與發(fā)電機之間彈性聯(lián)軸器連接，由柴油機飛輪通過聯(lián)軸器來驅(qū)動發(fā)電機。柴油機的飛輪殼

33、與發(fā)電機的端蓋采用凸緣定位，用螺栓連成一體。這種連接方式既保證了柴油機飛輪與發(fā)電機轉(zhuǎn)子有較好的同軸度，又能對柴油機在起動、停機及負載突變時所產(chǎn)生的沖擊起到緩沖減震作用。柴油機、發(fā)電機與公共底盤之間均裝有減震器。Generator Units consists of Diesel Engine, Generator, Connection Shaft and General Mudsill (engine frame) etc., the diesel engine and generator are linked by elastic connection, and the connectio

34、n drive the generator by diesel engine flywheel. The flywheel shell of diesel engine and end lid of generator are adopted flange orientation, linked by bolt. This connection method not only ensure the good same-spindle for flywheel of diesel engine and rotor of generator, it also can shock absorptio

35、n while the diesel engine starts, stops and load changes impact. The absorber is equipped on diesel engine, generator and general mudsill.柴油機采用95系列、105系列、135系列、康明斯、斯太爾、曼海姆、道依茨、奔馳、富豪遍達等國內(nèi)外著名品牌柴油機。發(fā)電機采用馬拉松、斯坦福、西門子、蘭州相復(fù)勵、諧波勵磁等國內(nèi)外著名品牌發(fā)電機。本主系列產(chǎn)品具有體積小，重量輕，結(jié)構(gòu)緊湊，安裝使用方便等特點。柴油機帶有充電發(fā)電機及充電調(diào)節(jié)器，機組在正常運行時能對蓄電池充電，并能

36、自動保持和調(diào)節(jié)輸出電壓在規(guī)定范圍內(nèi)。船用柴油機的冷卻系統(tǒng)一般采用雙閉式循環(huán)水冷卻。Our diesel engine adopts 95 series, 105 series, 135 series, Cummins, Styer, Mannheim, Deutz, Benz, Volvo-Penta, and many domestic or oversea famous brand diesel engine. Generator units adopts many domestic or oversea famous brand, such as marathon, standford,

37、 Siemens, Lanzhou gengerator of phase compound excitation, harmonic excitation generator. This series products has small volume, light weight, compact in structure, convenient in installation and operation. The diesel engine has electrification generator and electrification adjustor, and it can elec

38、tricize to accumulator, automatic holding, adjust regulated output voltage when the generator unit is running. The cooling system of marine diesel engine is dual closed circulation water cooling. 31 柴油機與發(fā)電機的聯(lián)接柴油機和發(fā)電機采用柴油機罩與發(fā)電機機蓋止口突緣結(jié)合方式使發(fā)電機與柴油機組成一個剛性組合體。這種聯(lián)接方式使發(fā)電機與柴油機兩者軸線的同心度的要求得到了可靠的保證，裝配時不需校調(diào)軸中心。3

39、.1 The connecting way of diesel engine and generatorThrough the connecting way of diesel engine cover and generator cover slot flange, make the generator and engine form a rigid combination. This connecting way ensures that the axes concentric degree of the generator and the engine can get a nice gu

40、arantee, not to adjust when assembly.還有部分機組不采用柴油機與發(fā)電機機蓋止口突緣結(jié)合方式，這種聯(lián)接方式在組裝機組時，必須對發(fā)電機與柴油機的軸線中心進行調(diào)校。保證兩者之間軸線同軸度在0.1范圍內(nèi)，柴油機飛輪端面與結(jié)合器盤端面間平行度不大于0.25mm。由制造廠組裝出廠的機組，其軸線中心已校調(diào)好了。如經(jīng)拆卸則需對軸線中心重新校調(diào)才能投入運行。軸線中心校調(diào)方法：The other part generator units are not adopted the above connecting way, and this connecting way must

41、adjust the axes center when assembly. Ensure the axes concentric degree both of them is in the range of 0.1, the parallel degree between the end plane of diesel engine and the end plane of connecting tray is no more than 0.25 mm. The axes center of generator unit was adjusted fine after leaving the

42、manufacturer, please readjust it if disassembly. The adjustive way of axes center:a. 將專用的校正定心器按圖1所示安裝a. Install the generator unit by using the special adjustor according to Figure 1.b. 盤動柴油機的飛輪，檢查定心器在上端、下端、左端、右端四個位置測得徑向間隙、平面間隙。在調(diào)試過程中的徑向間隙的1/2，不超過0.5 mm，上、下端的平面間隙差的1/2R，左、右端的平面間隙差的1/2R不超過0.25 mmb. Tu

43、rn the engine flywheel, check the adjustor position of top end, bottom end, left end and right end and measure the radial space, plane space. Make sure the 1/2 of radial space is no more than 0.5 mm, the 1/2R of plane space between top end and bottom end, between left end and right end is no more th

44、an 0.25 mm.c.緊固柴油機、發(fā)電機與機架的聯(lián)接螺栓c. Fix the connecting bolt between diesel engine, generator and mudsilld.按b要求重復(fù)檢查，若不符合b的要求則松動柴油機、發(fā)電機與機架的聯(lián)接螺栓，對發(fā)電機底腳墊片及移動位置，直至緊固螺栓后的同軸度、端面平行度達到要求為止。d. Repeat check the generator unit according to b, if not you must loosen the connecting bolt, move the generator bottom ga

45、sket until the axes degree meet the above request.徑向間隙: The radial clearance 平面間隙: Plane clearance校正定心器: center revising 迥回半徑: Returning radius不同軸度(偏移)不平行度(曲折與交錯): different axis degree (excursion) no parallel degree (twist and interleaving)A向: A direction 上端:Upper 下端: Down 左端: Left 右端: Right圖1 聯(lián)軸器校

46、正示意圖: Fig. 1 Coupling revising sketch3.2柴油機與發(fā)電機組合體的安裝3.2 Installation of diesel engine and generator3.2.1 采用止口突緣結(jié)合方式的柴油機與發(fā)電機的組合件的安裝3.2.1 Installation of slot flange connecting way這種組合體與機架之間有六個或八個支承點。對2缸柴油機的發(fā)電機組，在發(fā)電機底腳支承蘭裝有E型橡膠減震器為彈性支點。對四、六缸柴油機的發(fā)電機組所有支承點裝有EA型橡膠減震器，使整個組合體裝在彈性支承上。為使組合體裝上減震器后軸上變形小，軸心線同軸

47、度好，減少飛輪罩因安裝產(chǎn)生附加力矩，工作可靠，要求各減震器合理承擔(dān)載荷，通過對機組安裝、正確墊調(diào)可以達到目的。There are 6 or 8 supporting point between this combination and the mudsill. Equipped E-type rubber absorber as flexibility supporting point on the bottom supporting point of generator for 2-cylinder diesel engine. Equipped EA-type rubber absorbe

48、r as flexibility supporting point for 4 or 6 cylinder diesel engine to ensure the entire combination flexible support. Through the good installation and adjustment to make the absorber bear the load in reason, so to reduce the distortion of combination rear shaft and affixation moment, to improve wo

49、rk reliability.A、CCFJ12型機組的安裝、調(diào)整方法A. Installation and adjustment way of CCFJ12 a. 將減震器裝上機架，其緊固件暫不緊固a. Assemble the absorber on the mudsill, dont fit the tightened part b. 將柴油機吊裝于機架上，檢查柴油機安裝腳是否與機架安裝面貼合，而不貼合用墊片墊調(diào)，直至貼合為止，這時緊固柴油機的安裝螺栓。b. Lay the diesel engine on the mudsill, check whether the fixed feet

50、 of diesel engine and the fixed side of mudsill are joint, use the gasket to adjust, dont tighten the installation bolt until both of them are joint.c.將發(fā)電機座落在減震器上，緊固柴油機飛輪罩與發(fā)電機連接環(huán)的連接螺栓，這時注意調(diào)節(jié)發(fā)電機安裝腳。c. Lay the generator on the absorber, tighten the connecting bolt between the flywheel cover of diesel

51、engine and the connecting plate of generator, meanwhile adjust the fixed feet of generator.d.對發(fā)電機底腳的減震器與機架間用墊片進行調(diào)墊，直至減震器與機架之間的間隙為零，然后加0.60.7 mm厚的墊片，最后緊固發(fā)電機與減震器之間，減震器與機架間的緊固件，到此裝調(diào)完畢。d. Adjust the space of absorber of generator bottom feet and the mudsill by using the gasket, make the space to 0, then

52、 add gasket of 0.60.7 mm, then tighten the fixed parts between the generator and absorber, between absorber and the mudsill, hereto the installation is over.B、CCFJ24100型機組的安裝、調(diào)整方法B. Installation and adjustment way of CCFJ24100調(diào)節(jié)螺栓: Adjusting Bolt拼緊螺母: Tightening nut減震器: damper柴油機前支承: diesel engine f

53、ront supporting柴油機后支承: diesel engine rear supporting發(fā)電機支承: generator supporting圖2: 減震器支承位置: Fig. 2 Damper supporting positiona.將全部減震器裝上機架，緊固件暫不緊固，對中間2只裝柴油機后底腳的減震器裝上調(diào)節(jié)螺栓、調(diào)節(jié)螺栓支承臺肩的支承面用直尺初步定位，使其與裝柴油機前底腳的減震器的支承面在同一水平上。a. Assemble the entire absorber on the mudsill, dont tighten the fixed parts briefly,

54、assemble the adjustment bolts of the 2 absorbers on the middle of the rear bottom feet and adjust the supporting side, measure the position by using ruler to make the absorber supporting side of front bottom feet and it of rear bottom feet are parallel.b.裝上柴油機和發(fā)電機。將發(fā)電機和柴油機聯(lián)接好，然后扳松2只支承柴油機后底腳的調(diào)節(jié)螺栓，使其支承臺肩與柴油機后底腳安裝面脫離，這時兩只減震器不承受載荷。b. Install the diesel engine and the generator. Connect the diesel engine and the generator, then loosen the 2 adjustment bolts of diesel engine rea