干灰散裝機說明書

-.z.SZJ-100型干灰散裝機SZJ-100ModelDryDustBulkMachine使用說明書OperationInstruction國能環(huán)保設(shè)備JiangsuGuonengEnvironmentProtectionEquipmentCo.,Ltd.一、前言1.Foreword本產(chǎn)品適用于電力、建材、冶金、煤炭以及化工等其它行業(yè)的無腐蝕、低研磨性粉粒狀物料的裝車或裝船作業(yè)。在火力發(fā)電廠主要用于灰斗或貯灰?guī)煜卵b車、裝船。本產(chǎn)品可與料庫下給料設(shè)施聯(lián)鎖運行，通過控制系統(tǒng)的控制，實現(xiàn)了裝卸過程的自動化。其裝車效率高，密封性能好，無粉塵污染。是散裝粉狀物料裝車、裝船的理想設(shè)備。Theproductisapplicabletotheloadingorshipmentworkofnon-corrosion,lowabrasivenesspowdermaterialsinsuchindustryaspower,construction,metallurgy,coalandchemicalindustry.Ifitusesinthermalpowerplant,itismainlyappliedtotheloading,shippingunderdusthopperordustbunker.Theproductisinterlockingoperatedwithmaterialstoragefeedingfacility,tocarryoutautomaticloadingandunloadingprocessviacontrolsystem.Itistheidealequipmentforloadingandshippingbulkpowdermaterialswithsuchcharacteristicsashighefficiencyloading,goodsealingperformanceandwithoutdustcontamination.二、技術(shù)參數(shù)2.Technicalparameters2.1干灰散裝機型號含義：構(gòu)造形式I：不帶軸塵風(fēng)機 II：帶抽塵風(fēng)機 III：帶就地除塵器StructuralformI:構(gòu)造形式I：不帶軸塵風(fēng)機 II：帶抽塵風(fēng)機 III：帶就地除塵器StructuralformI:withoutduste*haustfanII:withduste*haustfanIII:withinsitedustcollectorSZJ–100StructuralformI:withoutduste*haustfanII:withduste*haustfanIII:withinsitedustcollector出力100m3Output100m3干灰散裝機Drydustbulkmachine2.2控制方式：設(shè)半自動和自動2.2Controlmode:settingsemi-automaticandautomatic2.3散裝頭升降行程：1300mm〔亦可按用戶需要而定〕2.3Liftingstrokeofbulkhead:1300mm(decidedasperuser’sdemand)2.4散裝頭升降速度：0.1m/s2.4Liftingspeedofbulkhead:0.1m/s2.5配帶升降電動機參數(shù)：2.5Liftingmotorparameters:●型號：YEJ90S–6●Model:YEJ90S–6●功率：0.75kw●Power:0.75kw●電壓：380V●Voltage:380V●轉(zhuǎn)速：910r/min●Rotatingspeed:910r/min2.6減速機參數(shù)：2.6Reducerparameters:●Model:WHT08-VII●型號：WHT08-VII●Reductionratio:1:63●減速比：1:632.7抽塵風(fēng)機參數(shù)：2.7Duste*haustfanparameters:●型號：9-19No4.5●Model:9-19No4.5※型號：4-72No3.6※Model:4-72No3.6●流量：2817m3●Flowrate:2817m3※流量：2930m3※Flowrate:2930m3●風(fēng)壓：4.04kPa●Windpressure:4.04kPa※風(fēng)壓：1.65kPa※Windpressure:1.65kPa●抽塵風(fēng)機電機型號：Y112M-2●Motormodelofduste*haustfan:Y112M-2※抽塵風(fēng)機電機型號：Y100L-2※Motormodelofduste*haustfan:Y100L-2●抽塵風(fēng)機電機功率：4.0kW●Motorpowerofduste*haustfan:4.0kW※抽塵風(fēng)機電機功率：3.0kW※Motorpowerofduste*haustfan:3.0kW●抽塵風(fēng)機電機電壓：380V●Motorvoltageofduste*haustfan:380V※抽塵風(fēng)機電機電壓：380V※Motorvoltageofduste*haustfan:380V●抽塵風(fēng)機電機轉(zhuǎn)速：2890r/min●Rotatingspeedofmotorofduste*haustfan:2890r/min※抽塵風(fēng)機電機轉(zhuǎn)速：2870r/min※Rotatingspeedofmotorofduste*haustfan:2870r/min2.8料位計形式：電容式料位開關(guān)2.8Materiallevelmetertype:capacitancetypelevelswitch2.9料位計型號：TLK-C15A1-4C2.9Materiallevelmetermodel:TLK-C15A1-4C2.10散裝機下料管直徑：φ3502.10Diameterofblankingtubeofbulkmachine:φ3502.11散裝機吸塵管直徑：φ5582.11Diameterofdustsuctionpipeofbulkmachine:φ558注：帶※為III型散裝機參數(shù)。Note:※indicatestheparametersofIIImodelbulkmachine.三、構(gòu)造與工作原理3.Structureandworkingprinciple3.1主要構(gòu)造3.1Mainstructure可伸縮散裝頭E*tensionalbulkhead散裝頭由底座、伸縮管、吸塵管、套箍、鋼絲繩、繩卡等主要部件組成，通過吸塵管、鋼絲繩把它們連接起來，形成可伸縮的構(gòu)造。Bulkheadisposedofbaseframe,e*tensiontube,dustsuctionpipe,hoop,steelcable,cablehead,etc.,whichareconnectedbydustsuctionpipeandsteelcabletoformane*tensionalstructure.卷揚裝置Hoistingunit卷揚裝置由電動機、減速機〔帶有計數(shù)器〕、滑輪裝配、鋼絲繩等組成，它是控制散裝頭伸縮的裝置。Hoistingunitisposedofmotor,reducer(withcounter),pulleyassembly,steelcable,etc.Itistheunitforcontrollingthee*tensionofbulkhead.控制系統(tǒng)Controlsystem控制系統(tǒng)是散裝機的心臟，直接完成散裝機整個卸料過程。它由控制拒、計數(shù)器、接近開關(guān)以及料位計、支架、電線等元件組成。計數(shù)器和接近開關(guān)控制散裝頭的下降位置，通過反應(yīng)信號翻開給料機和抽塵風(fēng)機，散裝機進展裝料；料位計控制料位的上下，當(dāng)料位到達指定位置后，它反應(yīng)給控制系統(tǒng)電信號，使控制系統(tǒng)關(guān)閉給料機和抽塵風(fēng)機，并翻開卷揚電機，提升散裝頭；同時計數(shù)器控制散裝頭的上升位置，當(dāng)散裝頭接近預(yù)定位置時，關(guān)閉卷揚電機，從而完成物料的裝卸。本控制系統(tǒng)設(shè)有“自動、手動〞操作切換開關(guān)，手動操作供檢修及特殊情況下使用。Controlsystemisthecoreofbulkmachine,whichmaypletefullunloadingprocessofbulkmachine.Itconsistsofcontrolcabinet,counter,approachswitchandmateriallevelmeter,support,wires.Thecounterandapproachswitcharetocontrolthedescendingpositionofbulkhead,startfeederandduste*haustfanthroughfeedbacksignal,thenbulkmachinecarriesoutloading;themateriallevelmetercontrolstheheightofmateriallevel.Whenthelevelisuptothespecifiedposition,itwillfeedbackanelectricalsignaltocontrolsystemsothatthecontrolsystemmayclosethefeederandduste*haustfan,andstarthoistingmotortoliftbulkhead;meanwhile,thecountercontrolstheliftingpositionofbulkhead,whenbulkheadapproachesthepresettingposition,closehoistingmotorsoastopletetheunloadingofmaterials.Thecontrolsystemhas“automatic,manual〞operationtochangeovertheswitches.Themanualoperationisonlyforinspectionandspecialsituations.脈沖除塵器3.1.4PulseddustcollectorIII型散裝機自帶一就地DMC型電脈沖除塵器，由抽塵風(fēng)機、噴吹系統(tǒng)、箱體和濾袋組成。箱體設(shè)有吸塵口，把從散裝機吸來的含塵氣體經(jīng)濾袋后得到凈化，凈化后的氣體經(jīng)由抽塵風(fēng)機出風(fēng)口排空，滯阻在濾袋外壁的灰塵經(jīng)由噴吹系統(tǒng)循環(huán)處理以后被去除。這樣一來，現(xiàn)場可實現(xiàn)無塵作業(yè)。IIImodelbulkmachinehasaninsiteDMCelectricalpulseddustcollector,whichisposedofduste*haustfan,blowingsystem,tankandfilterbag.Thetankhasadustsuctioninlettopurifythedustygasabsorbedfrombulkmachineviafilterbag,thenemptythepurifiedgasviatheairoutletofduste*haustfan,removethedustretainedate*ternalwalloffilterbagbycircularprocessingofblowingsystem,sothatthesitecancarryoutdustfreework.3.2工作原理3.2Workingprinciple當(dāng)散裝頭錐面下降到與汽車〔或船〕入灰口上部密合時，鋼絲繩變松，計數(shù)器上的到位開關(guān)發(fā)出電信號反應(yīng)給控制系統(tǒng)，關(guān)閉卷揚電機，并翻開抽塵風(fēng)機和給料機，開場裝料；當(dāng)物料裝滿料罐時，料位計發(fā)出信號，反應(yīng)給控制系統(tǒng)，控制系統(tǒng)自動關(guān)閉給料機和抽塵風(fēng)機并提升散裝頭；當(dāng)散裝頭提升到預(yù)定位置時，計數(shù)器上的到位開關(guān)發(fā)出電信號，反應(yīng)給控制系統(tǒng)，自動關(guān)閉卷揚電機，完成一次物料的裝卸過程。Whentheconicalsurfaceofbulkheaddescendstobesealedtogetherwiththetopofdustinletofvehicle(orship),thesteelcablewillbeloose,thelimitswitchonthecountersendsoutanelectricalsignaltofeedbacktocontrolsystem,closehoistingmotorandstartduste*haustfanandfeeder,thenstartloading;whenmaterialtankisfullofmaterials,themateriallevelmeterwillsendoutasignaltofeedbacktocontrolsystem,thencontrolsystemautomaticallyclosesfeederandduste*haustfanaswellasliftbulkhead;whenbulkheadisliftedatpresettingposition,thelimitswitchonthecounterwillsendoutanelectricalsignaltofeedbacktocontrolsystem,thenhoistingmotorisautomaticallyclosedsothatapletedmaterialloadingandunloadingprocessisfinished.四、安裝、調(diào)試與運行4.Installation,missioningandoperation4.1安裝4.1Installation設(shè)備到現(xiàn)場后，先整體檢查，看有無因運輸而損壞部件的情況，如有，則應(yīng)拆卸更換；Checkifanypartisdamagedduetotransportation,aftertheequipmentsarearrivedatthesite,ifany,itshouldberemovedandreplaced;然后吊裝散裝機并與預(yù)留孔對位；對好位后，按現(xiàn)場管道情況把散裝頭底座與預(yù)埋件用螺栓聯(lián)結(jié)好〔也可直接焊接〕。安裝過程中注意不要刺破或燒傷吸塵管〔掛膠帆布〕，以免影響吸塵管的透氣性。Liftthebulkmachineanddirecttopreservedhole;afterpositioning,connectthebaseframeofbulkheadwithpre-embeddedpartsbybolts(orwelding)accordingtothepipinginsite.Duringinstallation,noticethatdonotbreakorburnthedustsuctionpipes(rubberizedcanvas)soasnottoaffecttheairpermeabilityofdustsuctionpipes.按電氣圖紙資料連接電纜，并注意各電纜的走向。Connectcablesaccordingtoelectricaldrawingandpayattentiontothedirectionofeachcable.4.2調(diào)試4.2missioning空載調(diào)試No-loadmissioninga)調(diào)試前檢查所有接線是否正確，安裝是否合格，經(jīng)檢驗確認，方可進展調(diào)試；a)Checkifallwiringsarecorrect,installationisqualifiedbeforemissioning.Donotcarryoutmissioninguntilpassingtheinspection.b〕調(diào)試時，關(guān)閉手動檢修門〔位于散裝機進料口最上方〕，先手動操作，看電動機轉(zhuǎn)向是否符合要求，轉(zhuǎn)向正確后，方可進展上、下限位以及料位計的動作調(diào)試；b)Closemanualaccessdoor(locatedatthetopmostpartoffeedinletofbulkmachine)duringmissioning,manuallyoperateatfirst,andobservetheturningofmotorisconformitywiththerequirement.Carryoutmissioningoftheactionofupper,lowerlimitandmateriallevelmeteraftertheturningiscorrect;c〕啟動“自動按鈕〞，卷揚電機翻開，散裝頭下降，下降到位后給料機翻開；當(dāng)全部聯(lián)動投入運行，空運轉(zhuǎn)數(shù)分鐘，把功能開關(guān)置于“滿料指示〞位置時，報警鈴聲響后運行設(shè)備自動停機；提升散裝頭到上限位置，計數(shù)器上的到位開關(guān)自動切斷卷揚電機電源，整個聯(lián)動過程空試完畢。c)Start“automaticbutton〞,tostarthoistingmotoranddescendbulkhead,afterdescendingtoreachthedesignatedposition,feederwillstart;wheninputtingoperationfully,andplacefunctionswitchin“fullindication〞,afterno-loadoperationforseveralminutes,theequipmentwillstopautomaticallyafteralarmbellsounds;liftthebulkheadtoupperlimitposition,thelimitswitchonthecounterwillcutoffthepowerofhoistingmotorautomatically,sothatafullinterlockingmissioningprocessispleted.負載調(diào)試Loadmissioninga〕空載調(diào)試正常后，將散裝機的管路、閥門置于工作狀態(tài)位置，讓散裝粉煤灰車或其它運載設(shè)施到位，即可進展負載調(diào)試；a)Placethepipesandvalvesofbulkmachineunderoperatingconditionafterno-loadmissioningisnormal,andbulkdrydustvehicleorothertransportingequipmentsareinposition,itcancarryoutloadmissioning.b〕正常情況下，散裝下料錐斗與裝載容器進料口結(jié)合部位及吸塵管均處于負壓工作狀態(tài)，負壓大小可由抽尖風(fēng)機前的手動調(diào)節(jié)門來調(diào)節(jié)，當(dāng)吸塵管往外鼓脹及進料口結(jié)合部位向外冒灰時，表示抽塵風(fēng)機出現(xiàn)故障，如不及時排除則會引起料位計誤發(fā)報警信號而停機；b)Undernormalcondition,thejointpartofbulkunloadingconehopperandfeedinletofcontaineranddustsuctionpipeareundernegativepressurecondition,thenegativepressuremaybeadjustedbymanualadjustablegateinfrontofduste*haustfan.Whendustsuctionpipee*pandsandthejointpartatfeedinletspreadsdust,itshowstheduste*haustfanoccursfailure,ifdonoteliminateintime,themateriallevelmetermaysendoutwrongalarmsignalandstopthemachine;c〕料滿報警停機后，將散裝下料錐斗復(fù)位，并檢查裝載容器中物料裝滿程度狀況，過滿或過淺可通過調(diào)節(jié)料位計的位置來滿足，并固定好料位計的最終位置。c)Afteralarmtostopmachineduetofullofmaterials,resetbulkfeedinghopperandcheckthematerialsinthecontainer,ifitistoofullortooshallow,itmayadjustthepositionofmateriallevelmeterandfi*itsfinalposition.4.3運行4.3Operation散裝粉煤灰車或其它運載設(shè)施到位后，手動操作，使散裝頭下降接近罐口，然后停下來，罐口對準散裝頭后，將切換開關(guān)打向自動操作位置，按下啟動按鈕，使散裝頭的錐斗與罐口結(jié)合嚴密；Afterbulkdrydustvehicleorothertransportingequipmentsareinposition,manuallyoperatetodescendthebulkheadclosetotheportoftank,thenstop,aftertheportoftankcentersonbulkhead,placechange-overswitchinautomaticoperation,pressstartbuttonsothattheconehopperofbulkheadconnectswiththeportoftankclosely;當(dāng)料已裝滿，料位計發(fā)出信號〔料位指示燈亮〕，給料機自動停頓給料，延時一段時間以后〔一般為4~6秒〕，關(guān)閉抽塵風(fēng)機，提升散裝頭。延時長短以下料管物料落凈為準。Whentherearefullofmaterials,themateriallevelmeterwillsendoutasignal(levelindicatorison),thefeederautomaticallystopfeeding,afterdelayafewtimes(generally4~6seconds),closeduste*haustfan,liftbulkhead.Thedelaytimeisbasedonthematerialemptyinginloadingpipe.五、使用考前須知與維護5.Usagenoticeandmaintenance5.1使用前必須給減速機加油至適宜位置，運行一個月后更換新油，以后每年換油一次；5.1Fillthereducerwithoiltoapplicablepositionbeforeusing,replacewithnewoilafteroperatingonemonth,andchangeoilonceayear.5.2在裝料時，務(wù)必把散裝機對準罐口，否則散裝頭可能下降不到規(guī)定位置或被繩卡卡住，發(fā)生堵料事故，甚至損壞料位計；5.2Thebulkmachineshouldbecenteredontheportoftankwhenloading,otherwise,thebulkheadmaynotdescendtothespecifiedpositionorbeblockedbycableheadresultinginplugging,evenbreakingthemateriallevelmeter.5.3當(dāng)裝料時，突然發(fā)生極大的揚塵，說明排料不暢通，應(yīng)馬上停頓下料，千萬不要立即提升散裝頭；5.3Largedustemissionhappenssuddenlywhenloading,whichshowsthatmaterialdischargeisnotsmooth,itshallstoploadingatonceanddonotliftbulkheadimmediately.5.4在裝料過程中，如果發(fā)生溢料，應(yīng)立即停頓下料。千萬不要在散裝頭積滿料的情況下，提升散裝頭，應(yīng)把吸塵管套箍卸下，排除一局部積存物料后，再慢慢把下料管的積料排除，然后再提升散裝頭；5.4Ifmaterialsaresurplusduringloading,itshallstoploadingatonce.Donotliftbulkheadwhentherearefullofmaterialsinbulkhead,afterremovingthehoopfromdustsuctionpipeandcleaningoutapartofaccumulativematerials,eliminatetheaccumulativematerialsinfeedpipeslowlyandthenliftbulkhead.5.5松塵開關(guān)裝置、計數(shù)器的到位開關(guān)應(yīng)常檢查，一旦失靈要及時更換，以免造成設(shè)備損壞；5.5Checkdustswitchunitandlimitswitchofcounterregularly.Onceitfails,itshallbereplacedintimesoasnottodamagetheequipment.5.6滑輪裝置及鋼絲繩注意定期檢查，假設(shè)有損壞要馬上更換；5.6Payattentiontocheckpulleydeviceandsteelcableregularly.Ifithasanydamage,replaceitatonce.5.7吸塵管會因老化或鋒利物品的碰掛而損壞，需定期更換，破損處應(yīng)及時補牢以免影響收塵效果；5.7Thedustsuctionpipemaybedamagedduetoagingortouchingofsharpobjects,soitneedstobereplacedregularly.Thebreakageshouldberepairedintimesoasnottoaffectthedustcollection.5.8散裝機在裝料過程中應(yīng)處于負壓狀態(tài)工作，故應(yīng)保證抽塵風(fēng)機的正常運轉(zhuǎn)和維護。5.8Thebulkmachineworksundernegativepressureconditionduringloading,soitshallensurethenormaloperatingandmaintenanceofduste*haustfan.5.9罐車或其它裝運設(shè)備應(yīng)注意其運行高度，不要撞壞散裝頭。5.9Payattentiontotheheightoftankcarorothertransportingequipments.Donothitthebulkhead.6．故障分析與處理措施6.Failureanalysisandhandlingmeasures故障現(xiàn)象Failure故障分析Failureanalysis處理措施Handlingmeasures卷揚電機不動作Hoistingmotorfailstoact1．線路故障；1.Wiringfailure;2．制動片未脫開2.Brakediscdoesnotdisconnect.1．排除線路故障；1.Eliminatewiringfailure;2．取出電機后罩，松開制動片螺栓，再通電正、反運轉(zhuǎn)幾次后擰緊制動螺栓。2.Takeoffrearcoverofmotor,loosentheboltofbrakedisc,afteroperatinginpositiveandnegativedirectionforseveraltimeswithpower,thenscrewdowntheboltofbrakedisc.散裝頭上、下位置到位后，減速機不能適時停運Afterupperandlowerpositionofbulkheadarebothinplace,reducercannotstoprunningtimely.1．線路故障；1.Wiringfailure;2．計數(shù)器到位開關(guān)損壞。2.Limitswitchofcounterdamages.1