夏普搅拌器操作手册最新版-中英文-图文

OPERATION&MAINTENANCEMANUALFORSHARPEMIXERSLIQUIDAGITATIONEQUIPMENTREADBEFOREUNPACKINGMIXERYOURMIXERHASBEENTESTEDANDSHAFTSTRAIGHTNESSVERIFIEDPRIORTOSHIPMENT.CAREFULHANDLINGOFSHAFTPRIORTOANDDURINGINSTALLATIONWILLENSUREPROPEROPERATION.THEFOLLOWINGCRITERIAMUSTBEADHEREDTOINORDERTOPREVENTDAMAGETOEQUIPMENTORSERIOUSINJURYTOOPERATINGPERSONNEL:WARNING•HIGHVOLTAGEANDROTATINGPARTSCANCAUSESERIOUSORFATALINJURY.ONLYEXPERIENCEDPERSONNELMUSTOPERATEORSERVICETHISEQUIPMENT.•NEVERENTERTANKWITHOUTLOCKING-OUTPOWERTOMIXER.•LOCKOUTPOWERPRIORTOREMOVINGANYGUARDSORSERVICINGANYPARTOFTHISEQUIPMENT,INCLUDINGINITIALINSTALLATIONAND/ORINSPECTION.•THISMANUALMUSTFIRSTBEFULLYREADANDUNDERSTOODPRIORTOINSTALLATIONBYALLPERSONNELINSTALLINGAND/OROPERATINGTHIS,ORNEARTHISEQUIPMENT.•NEVERUSETHISEQUIPMENTFORANYUSEOTHERTHANDESCRIBEDINTHEORIGINALPROPOSALANDAPPLICATIONBOXONTHEDATASHEET.•MODIFICATIONSUNAUTHORIZEDBYSHARPEMIXERSTOTHISEQUIPMENTMAYDAMAGEEQUIPMENTORCAUSESERIOUSINJURYTOPERSONNEL.CAUTION•ALWAYSREADTHESERVICEMANUALTHOROUGHLYBEFOREINSTALLATIONANDSTART-UP.•OPERATIONOFMIXERINAIRISNOTRECOMMENDED.•ALWAYSFOLLOWMOUNTINGRECOMMENDATIONSDESCRIBEDINORIGINALPROPOSAL.MIXERPLATFORMMUSTBESTABLE.•EXTENDEDOPERATIONOFMIXERWHENLIQUIDLEVELISATORNEARBOTTOMIMPELLERISNOTRECOMMENDED.•ALWAYSROTATETHESHAFTBYHANDTOVERIFYSTRAIGHTNESSPRIORTOOPERATIONINLIQUID.•ALWAYSCHECKASSEMBLYDRAWINGANDDATASHEETFORSPECIALOPERATINGSPEEDREQUIREMENTSIFUSINGAVARIABLESPEEDDRIVE.•ALWAYSFLUIDIZESETTLEDSOLIDSBEFORESTARTINGMIXER.•NEVERLIFTMIXERBYSHAFT.ANYEXCEPTIONSTOTHEABOVEMUSTBEAGREEDUPONINWRITINGBYSHARPEMIXERSANDNOTEDONTHEASSEMBLYDRAWING.SHARPEMIXERSP.O.BOX3906SEATTLE,WA98124(206767-5660•FAX(206767-9170(800237-8815M5QuoteProgram,LOGO,052202.xls目录A部分搅拌器数据表、图和部件数据A-1(前面部分B部分初始检查、接收和存放B-1,pg1驱动安装B-2,pg2安装搅拌器叶轮B-3,pg3电机连接和润滑B-4,pg3机械密封启动准备B-5,pg4启动和操作B-6,pg5启动检查清单B-7,pg6C部分V系列维护和润滑C-1,pg7V系列维护和润滑C-1,pg8外部轴承移动C-2,pg8轴缩回C-3,pg9重新组装C-4,pg13V-皮带维护C-5,pg16故障查询向导C-6,pg18推荐备件C-7,pg20D部分其它资料和说明(需要时D-1B1.1发货前此搅拌器在工厂经过检查。收到设备后马上检查包装和里面所装的设备,看是否有任何损坏(运输过程中可能会造成损坏。对照装箱单和A部分里的检验图纸,确定收到了所有的部件。如有任何损坏或缺少部件,请立即通知运输公司和沙普公司。保留运输包装,以便将来存放或运输。B1.2提起设备时,使用非金属吊索,环绕搅拌器框架固定好。提起前要确定所有负荷量是平衡的。不要站在提起的搅拌器下,不要通过提搅拌器的轴来提起搅拌器,不要用电机提升拖动提升搅拌器。见图B1.1。B1.3存放:存放是指:a搅拌器交货到工作场地,等待安装,b搅拌器已经安装,但是启动被推迟,c运行周期之间有很长的闲置时间。将搅拌器存放在干净、干燥的地方,空气要流通,温度变化不能太大。电机容易受潮。将整台机器离开地面存放,用塑料覆盖,用干燥剂降低湿度。如果启动前电机显示出受潮的信号,那么在两根导线上用10%电压烘干电机(如果有疑问,测量线圈电阻,一到三兆欧姆是正常的。存放达到或超过6个月时,启动前要重新润滑电机。V形皮带的存放:最好将它们从皮带轮上取下存放。在皮带轮上或者其它任何没有保护的软钢零件上喷金属保护剂。重新安装皮带前除掉所有金属保护剂。存放时,搅拌器轴轴承需要额外的保护。加润滑脂,直到密封上出现润滑脂,转动轴承,使润滑脂分散、覆盖住轴承。每6个月转动一次轴承,以防止在轴承上产生“平台”。图B1.1用吊索环绕搅拌器框架固定好,将搅拌器提起不要通过提轴来提起搅拌器MANUALV-SERIESFGDSHORTRETSCB428CN-1-B2.1支撑结构必须足够稳定和牢固,能够应付扭转、弯曲,重量在装配图上给出。在搅拌器运行当中,此结构一定不能弯曲或振动。如果安装到不稳定的结构上,搅拌器的负荷会对设备、罐造成损坏,或者带来其它危险。也可以用下面的选项。将搅拌器用螺栓连接到管口前,法兰面之间都要使用垫圈,以便正确的密封。见图B2.1–B2.3。安装选项B2.2底座支撑推荐脱硫应用。见图#A12005。底座支撑的基础一定要附到罐基础上(见图B2.1A。底座一定要在跟罐一样的基础上,以防止搅拌器框架应力的影响,罐装好后装接口。应力造成的扭曲变形会导致搅拌器密封不能调正,从而使密封过早磨损坏掉。装好法兰安装螺栓之后,调节底座,直到搅拌器的重量在底座和接口之间达到平衡。具体安装,见图B2.1A。B2.3墩状支撑推荐用于大马力搅拌器。混凝土墩在V系列机架的底座之下。混凝土墩必须浇注在罐基础的顶部或者说附在罐基础上,防止罐运行时对搅拌器和安装接口产生的机械压力。安装法兰装配螺栓之后,用垫片调整墩,直到搅拌器的重量在接口和墩之间平均分配。螺栓的位置见A部分的装配图。见图B2.3。S图B2.1A可选安装方法外部底座支撑V系列侧进式搅拌器墩状支撑图B2.3MANUALV-SERIESFGDSHORTRETSCB428CN-2-B3.1-参照手册前面的搅拌器装配和叶轮详图,正确旋转、定位和放置叶轮。B3.2-1-片叶轮:根据装配图(见图B3.2在轴上朝着正确的方向滑动叶轮。对于带键类装置的叶轮,在键上拧紧固定螺丝。不要用锤子击打零件。如果键不合适,修整到合适的尺寸。上紧固定螺丝,固定好带帽/底螺栓。见12页的扭矩额定值。警告:维护叶轮前一定要切断能源。图B3.21片式水翼II警告:高压电和旋转零件可能导致严重的甚至致命的伤害。电气设备具有危险性,它们的安装、操作和维护必须由合格人员完成。需要完全了解国家电气规范和当地建筑规范。MANUALV-SERIESFGDSHORTRETSCB428CN-3-B5.1-通常搅拌器从工厂发出时带适当上紧的密封固定螺丝#411和转到“运输”位置的定位片#417,如下图所示在启动搅拌器前,确定所有的密封固定螺丝#411已经正确上紧,定位片#417已被取下并存放好(存放到工具包里以备将来使用。B5.2-在启动搅拌器前,用油脂灌满机械密封。密封设计将多余油脂从在密封顶部的弯管“口”清除出去。在注油脂之前拿掉所有为运输而安装到弯管“口”里的塞子和配件,否则会对密封造成损坏。用不含钼的NGL-1润滑油。从#421zirc油嘴灌入油脂,直到油脂从顶部的弯管口溢出。注:以前的密封可能将油嘴放在侧面。而SCB-428密封设计zric油嘴在密封底部,一个开“口”弯管在密封顶部。如果密封位置不正确,转动到正确位置。油脂用来润滑并清理运行过程中密封腔里累积的灰尘。每两周定期重新润滑密封,检查溢出闷头螺丝处油脂的情况,如果油脂脏了,那么油脂的更换要更为频繁一些。注意:在准备机械密封前,不要启动电动机,否则会损坏密封。密封一定要用油脂润滑过,定位片拿走并存放好,启动前,所有固定螺丝都要正确拧好。居中夹特殊合金固定螺丝整体轴承碳化硅面合金轴套自动居中SCB-428脱硫浆液密封每两周一次定期润滑密封。必须用NGL-1润滑油(不含钼注意:-叶轮埋在固体里或者在罐里有多余固体时不要启动搅拌器,否则会造成损坏。-在叶轮浸入之前不要启动搅拌器,否则可能对密封造成损坏。B7.0启动检查清单在启动前和启动期间,检查下列事项是外侧支撑被垫起来并调直,这样搅拌器法兰和罐法兰平衡______________________________否完成:看过手册并完全理解__________看过所有核定图纸__________传动皮带调直并张紧__________所有防护已安装好__________轴承已用油脂润滑,固定螺丝已上紧__________叶轮安装正确(见核定图纸检查并上紧所有装配螺栓__________拿掉机械密封定位夹并将其存放好____________________机械密封用油脂正确润滑过/锥形环(见12页____欧姆拧好机械密封固定螺丝_____正确布线、接线、绝缘__________检查电机是否受潮(电阻必须小于3兆___________根据核定图纸检查轴旋转___________________安培正确:______每端测量实际线电压(每端:运行期间,检查机械密封上的多余热量__________搅拌器支撑或者法兰有没有过多的振动?_________________________________________________________检查员_________________日期项目组件名00103电机轴套键23130电机安装板13132•300内侧轴承02307轴承卡环308轴承顶进螺栓(2314轴承固定螺320轴承REM•371V-带372电机皮带轮373传动皮带轮74375传动轴套77378皮带防护罩螺栓、螺母、垫圈79传动轴套螺栓和垫圈(3键411密封固定螺丝413密封安装螺栓/夹子(4417密封定位片421密封zirc油嘴436密封锥形环螺丝475轴支撑支架(没有示出551搅拌器框架552安装法兰固件(他人供货•600(没有示出密封轴环密封轴环杯677回缩轴环顶进螺栓(2螺栓731叶轮螺丝50叶轮推荐备件V-系列组件图C1.11电机382传动轴套•400机械密封1电机安装螺栓、螺母和垫圈电机调整螺栓(41电机调整螺母(16•3外侧轴承306轴承安装螺栓和垫圈丝O板559安装法兰紧搅拌器轴672回缩轴环673回缩轴环紧固螺栓3电机轴套674•675376皮带防护罩3皮带防护罩底座678回缩轴环安装730叶轮键3皮带防护罩底座安装螺母、垫圈(8380电机轴套螺栓和垫圈(37381555系杆装置(没有示出556管腿支撑(示出•=2.1此程序是从搅拌器上移走外侧轴承302。如果内侧轴承#300也要移走,那么必须要用轴回缩程序。见C3.1部分“轴回缩”。只移动外侧轴承时,不需要轴回缩。C2.2断开搅拌器电机电源并锁住以防止启动。警告:在移动防护或者维修前锁定能源。高压和旋转部件可能导致严重甚至致命的伤害。C#图C2.2外侧轴承和REMO板搅拌器轴滑轮端注:上图中防护被移走C3.3-断开搅拌器电机电源并锁住以防止设备意3.4-移走皮带防护罩#376。松开电机调节螺母如有必要转动搅拌器轴,避免定位片遮住密封固定C3.6-取下(4个密封安装螺栓和压块413。松开在轴承#300和#302里的两个固定螺丝314。从内侧轴承#300上拿下四个安装注:此时切勿螺丝和锥形压紧环依然跟安装合紧密。3.7-在轴下两个轴承之间安装轴支撑支架#475(此工具用单独的工具盒装运,工具盒上面标着时梁要和轴接触的。将工具定位在离内侧轴承卡环后面大约40MM处。见图。工具底部的四个顶进螺钉可能需要松开,以使支架适合轴。上紧底部螺丝升起支架直到它紧紧地撑起搅拌器轴。不要将底部螺丝上的太紧,否则轴和/或密封可能受到破坏。切勿过紧。向后移动。轴会一直回缩(~10-15mm,取决于搅拌器缩。这说明密封轴环杯#675#552罐内物注意:密封很容易被破坏。小心处理。切勿敲打密封!移走轴支撑支架。外启动。C#132,放低电机。移走皮带#371。C3.5在机械密封上重新安装密封定位片#417,在移动过程中保护密封。转动定位片固定住套环。螺丝。对着密封套上紧定位片到合适的位置。##螺栓。松开密封固螺丝,密封固定好的定位片#411定接C“servicetoolkit维护工具包”。将油脂涂到支架的顶部梁上,升起C3.1用轴支撑支架将轴校直,消除密封的负荷。C3.8-现在,轴可以回缩了。相对内侧轴承#300上的法兰,上紧两个轴回缩螺栓#308,将轴从罐里顶出来。轴会向后滑过外侧轴承(确定所有轴承固定螺丝是松开的,密封和轴一起型号,直到很难再进一步回跟安装法兰的罐面顶得很紧,阻止了质的泄漏。定位片#411密封压块#413注意:回缩过程中,密封壳必须和轴一起回缩。如果密封不能和轴一起移动,停下来重新调整支架。图3.1注意:切勿从密封本体或任何O形圈部分撬动密封。如一定要撬,从移动密封可能要用力,zirc油嘴那或是润滑油通风口那撬。调整轴支撑支架,帮助密封移动。C3.9-松开机械密封上的(6个固定螺丝#411,取下锥形压紧环上的螺丝#436,装到锥形环的回缩孔里。移动锥形环,滑离密封,以防止密封和锥形环在回缩过程中卡住(见下图。向后内侧轴承方向移动密封。或许要在轴上抹一些润滑油脂以帮助密封移动。密封时,如发生泄漏,再次拧紧顶进,使密封轴环杯#675和搅拌器法兰结合更为将法兰上凸起的轴颈内外清理干净。将回缩轴环的轴颈嵌入到法兰中,当轴承被取走后,回缩轴环保持C3.10-在法兰上最初安装密封的地绕轴安装回缩轴环#672,见图C3.3和上面片。两个紧固螺栓#673,将轴环紧紧固定到轴上。稍稍松开四个轴环安装螺栓#678,上紧轴环里的两个顶进螺丝#677,将轴上的张紧力传递到轴环。现,即便轴承被,回缩轴环#672会轴保持在原位。C3.11-将(2个顶进螺丝#308从中间的板上动外侧轴承#302,将移动板#320从轴端取下。如果板和轴承卡住了,将两个螺栓拧到移动板的螺纹孔里并上紧,用作顶进螺丝。切勿用锤子锤击或剧烈震动零件,否则搅拌器组件可能损坏。用卡环钳取下靠着内侧轴承的卡环。片411(NLG#1向后移动螺丝#308紧密。轴居中。确定轴和轴环孔是干净的,否则轴可能被刮伤和损坏。将轴环上的轴颈安装到法兰的中心凹处。用手指拧上两个紧固螺栓#673,将轴环上的四个孔和法兰上的螺纹孔对齐,安装所提供的四个安装螺栓(在工具包里。上紧安装螺栓,使轴环紧靠法兰面。切勿使用密封安装螺栓,它们太长了会损坏搅拌器法兰。方,环的照牢牢上紧重新上紧四个固定螺栓#678。拿掉时在将松开。C3.12-现在可以移动外侧轴承#302了。在移动轴承之前,清理轴承端部。移动轴承时,可能会需要轻质油。从轴承移动板#320上取下安装螺栓,滑C3.13-417定位密封固定螺丝411锥形环螺丝内侧轴承卡环回缩轴环密封钳子对搅拌机框架的现在可以从轴上取下机械密封进行维护了。在在移动过程中用胶带覆盖键槽可以保护密封。C3.3C3.14-从轴上取下内侧轴承#300。为使拆卸顺利,可能要将轻质油抹到轴上。可能要使用支撑支架将轴更好的对直并移走轴承。移动密封和轴承尽可能远离罐,将支架直接放在这些零件的后面。将支架安装到轴上,这样支架就会上半部分施加压力,将轴向下推以便校直。轴的键槽上滑动密封时要小心,否则密封的O形圈可能会被损坏。图C4.1-重新组装,将程序反过来即可。越键槽和轴台阶安装密封时要小心。用透明胶带住轴上键槽锋利的边缘和卡环槽,避免密封受。法兰轴颈和轴一定要没有毛刺、碎片和锋利C4.2-滑动机械密封#400(不带锥形环轴的中部。确定O形圈在密封套的正确位置。一定要安装密封定位片#417以持密封的高度。在轴承的较小部分,密封移动以很方便。在轴较大的部分,也就是要放密封的地,涂NLG#1润滑油脂。将密封小心的滑动到轴直径较大的部分上。需用点力将O形圈越过轴台阶。将密封锥形环装到轴上,如下图所示,但是不C4.3-将防卡油(推荐航海级抹到每个轴承的内部,以防止腐蚀并且日后便于拆卸。用同样的方法处理机加工的轴颈,轴承从此处被安装到搅拌器框架里和搅拌器轴上。C4.4-将内侧轴承#300安装到轴上,可能必须使用支撑支架调直轴以便从后板安装轴承。在轴上向轴承方向滑动卡环。C4.5-在搅拌器框架上的适当位置安装外侧轴承、Remo板#302#320和螺栓装置。从轴上拿走支撑支架,将内侧轴承#300滑动到正确位置。将卡环安装到槽上。进行下一步前,确定卡环完全安装到了位置上。C4.6-在轴下、两个轴承之间安装轴支撑支架#475,见图C3.1。将油脂涂到支架的顶部梁上,升起时梁要和轴接触的。将工具定位在离内侧轴承卡环后面大约40MM处。见图C3.1。工具底部的四个支撑螺钉可能需要松开,以使支架适合轴。上紧底部螺丝升起支架直到它紧紧地器轴。不要将底部螺丝上的太紧,否则轴和/或密封可能会受到破坏。丝#308装到中板上,对着内侧C4从回缩轴环#672上取下(4个安装回缩轴环#672里的(2个顶进螺丝轴承顶进螺丝#308和法兰结合更为紧密。取下回缩轴环里的紧固螺栓#673,取下轴环。用防止生锈的包装材料包好零件,放入到维护工具过盖损边缘。到上,在安装面上保来方要要用螺栓连接到密封上。#677。如果发生泄漏,重新上紧增大张紧力将密封轴环杯#675撑起搅拌C4.7-将顶进螺轴承#300上紧。.8-螺栓。松开包里。C4.10-安装密封之前,检查清理轴和杯区(要装机封的区域。杯#675滑动机械密封到法兰中,安放好。如果密封有滑入法兰中,可以通过调整轴支架将轴调直。密封螺纹么是密封和法兰之间形兰有丝,。将(2个轴承顶进螺丝重新装到中板上以便存放。4.12-个密封压块螺栓,拧紧到对O,密封紧靠法兰,密封的金属之间接合紧密。密封体里锥形环槽上抹上薄薄一层航海级防卡油,如下图所示。(安装锥形环之前域里必须彻底清理干净,一点浆液不能有。没会完全插入到法兰中。只安装密封压块#413,手动拧紧螺栓。切勿过紧。C4.11-将回缩工具包里所提供的(4个超长轴承安装螺栓通过内侧轴承法兰安装到中板的孔里。松开并取下(2个顶进螺丝#308。小心上紧(4个轴承安装螺栓,将内侧轴承放回到搅拌器框架上合适的位置。轴滑过密封轴套,和轴承一起向后移动到正确的位置。现在,如果发生泄漏,要的O圈密封出了故障,要么是密封轴套里的法了问题。必须取下密封检查。执行C3.8步。牢牢拧紧四个轴承安装螺栓。使用新的固定螺拧紧内侧和外侧轴承上的固定螺丝,拧到扭矩值为52英尺-磅(71N-mC再次上紧(4将密封拉到靠着法兰的运行位置。将密封压块螺栓形圈形成足够的压缩力在417定位片411密封固定螺丝锥形环螺丝411图C4.12为两个轴承注入润滑油。使用FLGI级#2者认处溢出。C4.21-重新安装皮带轮、皮带和皮带防护。调整电机调节螺栓,正确张紧皮带。见C-5部分的调整说明。重新连接能源到电机。完整的启动程序,见手册里的启动说明。C4.19-十二羟基硬脂酸锂托辊轴承润滑油脂或可的等同物。将油脂灌入到ZIRC油嘴,直到轴承上密封的周围形成一个珠子或者从zirc油嘴对面的溢流嘴C4.20-将一滴硅树脂密封剂涂到两个轴承如下图所示区域,将轴承孔密封好防止腐蚀。锥形环锥形压紧环图C4.18开始运行的最初24-28小时之内,要频繁检查张力。C5.2-通过升起或降低电机拉紧皮带,使用在电机安装板正下方的四个大的电机螺栓调节螺母完成这一步骤。注:测量电机板和托架顶部的距离。每个角都要保持正确尺寸以保证正确对直。C5.3-周期性检查V-皮带。有滑脱或者不可调节现象时,上紧。不要用喷洒式皮带油,它会破坏皮带,导致皮带过早老化。C5.4-保持皮带清洁,不会受到外界物质C5.5-根据C5.2中推荐的步骤拉紧皮带。测量跨度距离‘K’。见图C5.1。在跨度距离‘’中心施加力量。拉紧皮带,直到此力量将皮带在跨度距离每英寸弯曲1/64”。例如:48”跨度的弯曲是48/64”或者3/4”。件螺纹孔里(或者轴衬法兰,轮,确定皮带摇晃。C5.7-皮带轮调直:需要检查调节以保证C5.2。将直边穿过皮带轮面,这样它就能碰到四个接触点。通常,坏拉断这一侧的皮带。C5.8-皮带的安装安装一套新皮带前–检查皮带轮情况。脏的或者生锈的皮带轮会降低驱动效率,磨损皮带,导致皮带过早老化。5.2警告:在启动或者维修前锁定能源。旋转零件可能导致严重甚至致命的伤害。C5.1-理想张紧力是最低张紧力,在这种张紧力下,皮带不会在最大荷载情况下滑脱。过大张力会缩短皮带和轴承寿命。在(可能造成皮带滑脱的侵扰。KC5.6-皮带轮的安装QD轴衬,可以安装到两边的任一位置,轴衬法兰向着电机或者远离电机。最终安装之前,确定最好位置,这样安装了皮带防护后,就不会发生机械接口问题。不管那种情况,都要从外侧装皮带轮安装螺栓,穿过外面的孔进入到靠着电机的零或者皮带轮轴心。确保钥匙在位置上帮助扭矩传递。转动皮带转动正常(没有皮带轮和皮带的最大寿命(见图1/2º未调直(1/8”/英尺就会缩短皮带和/或皮带轮寿命。不正确的皮带轮调直会使皮带的一侧不均衡磨损,导致皮带在皮带轮上反侧,或者将所有的复合都压到了皮带一侧,拉图皮带弯曲力(磅皮带弯曲每英尺跨度1/64”力量跨度“K”图C5.2正确调直直线偏离角度偏离横截面最小滑轮直径范围Dyna-V无齿轮PolybandDyna-V齿轮Polyband通常新皮带通常新皮带C5.9-换掉磨损的皮带轮。磨损的皮带轮C5.1前面的核定图纸上找到中心距离。遵循缩短皮带寿命50%。如果槽被磨损到皮带底部,能会导致滑脱,烧灼皮带。如果侧壁“坏掉”,那么底肩。0-皮带安装和张紧公差:在此手册C5.5部分的说明。能单条替换。过的皮带通常在交叉部分都有磨损,并被拉长,不能跟新皮带配套。不同生产厂家的皮带不能混合使用,避免不配套问题。C5.12-将上轮的中心距离,直到可以毫不费力的安装皮带。可就会磨掉底角,破坏皮带使其过早老C5.11-皮带要整套替换,不用了化皮带放到皮带轮,缩短皮带问题可能的原因解决方法z轴不适合传动z固定螺丝伸到了孔里z轴超尺寸z轴损坏z键超尺寸(正确的直径=0.001”-0.002”低于额定标准z修理/换掉轴z打磨键,使其合适z松开固定螺丝z测量并咨询工厂z搅拌器不能启动z布线不正确z连接器松散z熔断器损坏z电压不正确z叶轮干扰z水对电机造成损坏z启动器里加热器尺寸错误z根据布线图正确布线z上紧连接z换掉熔断器z电线电压正确z除掉所有碎屑,以便旋转z修理或换掉电机z换掉加热器z搅拌器不能达到正确的速度z电机超负荷z皮带或皮带轮松掉/坏掉z对着名牌数据检查安培数z上紧皮带/换掉皮带或皮带轮z见“搅拌器不能启动”z电机运行发热/电量超载z电压低/高z产品粘度过大z通风受限z频繁启动和停止z相间电压不平衡z旋转不正确z产品粘度过大z叶轮安装靠后z叶轮太靠近罐底z润滑不够或不正确z输出速度不正确z罐底部积了沉淀物z加热器尺寸过小z电线电压正确z检查粘度和产品比重(咨询工厂z清理通风口z和工厂核实-可能需要特殊电机z咨询电工z检查电机导线z检查粘度和比重-(咨询工厂z对着装配图检查-如有必要纠正z提升叶轮/管口z增加或改换润滑油z确定速度-(咨询工厂z清理或冲掉沉淀物z换上正确的加热器z有噪音z皮带和皮带防护间机械干扰z皮带滑脱z皮带轮没有调直z搅拌器轴弯曲z轴轴承坏了z检查皮带拉紧是否正确z重新拉紧皮带传动z调直皮带轮z弄直/换掉轴承z换掉轴承z轴承故障z皮带拉的过紧z皮带轮太小z皮带轮离轴承太远z皮带轮没调直/电机z见“有噪音”里多包含项目z正确拉紧z咨询工厂z将皮带轮靠近轴承z调直-见C-5部分警告:在搅拌器带能量运行之前换掉皮带的,可能导致严重甚至防护。旋转部件是危险致命的伤害。问题解决方法可能的原因皮带滑脱z驱动超负荷z皮带“油”破坏了皮带z咨询工厂z换掉皮带zz皮带轮磨损z油、灰尘、油脂过多z皮带轮尺寸不正确z换掉皮带轮z提供更好的防护z咨询工厂皮带磨损很快z皮带轮没有调直z电机支撑松了机械干扰驱动超负荷(弹簧过紧入传动上有油或油脂致拉紧组件损z重新调直皮带轮-除掉“弯曲”z换掉过小的螺丝或者断裂的zz消拉力-用酒精清洗zz刻槽/皮带轮损坏/磨损z温度过高zzz皮带绳断裂z灰尘/砂子进z皮带轮太小z皮带或皮带轮z安装不正确导坏基部z换掉皮带轮给皮带防护通风除干扰-移动皮带轮z咨询工厂z减小皮带轮马里/弹簧z给皮带防护通风z咨询工厂z清除油或油脂皮带/槽z用新的配套组件替换,安装要正确z振动z弯曲搅拌器轴法兰面除掉油z叶轮损坏z皮带轮不平衡z皮带跳动z修理/换掉叶轮z找到原因-咨询工厂z皮带侧面磨光-换掉;从皮带轮z修理/换掉轴z密封泄漏z润滑不够/不正确z密封装置过热坏密封装置中有固体运行部分z了-清理和润滑z洗(见B5部分时罐必须是满的z密封O-环损z密封垫破裂/磨损zz轴刮伤z过热z轴出位z密封面烧坏(干z正确润滑(见B5检查零件有无刮伤密封腔脏z换掉O-环z改造/换掉机械密封正确冲z换掉轴和/或密封z正确润滑z见“轴振动”z改造密封(不要干运行-润滑密封问零件价格时,要参号和型号。序列前面和沙普搅拌器的铭牌上。C7.1-根据个人需求不同,同。使用者手里应该有哪些零件的存货,主要影响因素是停机时间(允许搅拌器部停机时间段。尽叶轮通常不损零件,但是也可能损坏,需要修理/替换。这些零件交货期长,如果不允许长时间停机,那么应该及早考虑这些因素。所有的易磨损零件是通常的推荐备件,适用于下订单或询记着照搅拌器序列号在此服务手册推荐备件也不注:管算磨任何停机时间:轴承、套环、填料、垫圈V皮带、易磨损皮带轮和标准发货时间根据交货时间为维护准备的推荐备件。包括、轴。12到14周-完整的搅拌器尺寸到-完整的搅拌器尺寸-硬化轴、殊6到7周-机械零件、易磨损轴套、叶轮、填料函节流阀搅拌器轴、皮带防护2周-标准电机5到7天-备用电机、填料函包装、V皮带、轴承、皮带轮、轴衬V40及以上(如用特殊合金交货期更长1012周8周V30及以下(如用特殊合金交货期更长特电机、机械密封/轴衬、SECTIONB-TableofContentsSECTIONAMIXERDATASHEET,DRAWINGS&COMPONENTDATAA-1(previoussectionSECTIONBINITIALINSPECTION,RECEIVINGANDSTORAGEB-1,pg1MOUNTINGTHEDRIVEB-2,pg2INSTALLINGTHEMIXERIMPELLERB-3,pg3MOTORCONNECTIONS&LUBRICATIONB-4,pg3MECHANICALSEALSTARTUPPREPARATIONB-5,pg4STARTUP&OPERATIONB-6,pg5START-UPCHECKLISTB-7,pg6SECTIONCV-SERIESPARTSDETAILC-1,pg7V-SERIESMAINTENANCE&LUBRICATIONC-1,pg8OUTERBEARINGREMOVALC-2,pg8SHAFTRETRACTIONC-3,pg9REASSEMBLYC-4,pg13V-BELTMAINTENANCEC-5,pg16TROUBLESHOOTINGGUIDEC-6,pg18RECOMMENDEDSPAREPARTSC-7,pg20SECTIONDMISCELLANEOUSDETAILS&INSTRUCTIONS(whenrequiredD-1B1.1Thismixerhasbeeninspectedatthefactorypriortoshipment.Immediatelyuponreceiptoftheequipmentinspectthecratingandcontentsforanydamagethatmayhaveoccurredintransit.CheckagainstthepackingslipandthecertifieddrawingsinsectionAtomakesurethatallpartswerereceived.ReportanydamageormissingitemsimmediatelytothecarrierandtoSharpeMixers.Keepshippingcontainersforpossiblefuturestorageorshipping.B1.2WHENLIFTINGTHEEQUIPMENTUSENON-METALLICSLINGSTIGHTENEDAROUNDTHEMIXERHOUSING.Verifyallloadsarebalancedbeforelifting.Donotstandunderneathsuspendedloads.Donotliftthemixerbytheshaft.Donotliftthemixerusingthemotorliftinglug.SeefigureB1.1B1.3STORAGE:Storageiswhenamixerhasbeendeliveredtothejobsiteandisawaitinginstallation,bmixerhasbeeninstalled,butstartuphasbeendelayed,ctherearelongidleperiodsoftimebetweenoperatingcycles.Storethemixerinaclean,drylocation,withcirculatingair,freefromwidevariationsintemperature.Electricmotorsareeasilydamagedbymoisture.Storetheentireunitoffthefloor,coveredwithplastic,andusedesiccantstoreducemoisturebuildup.Ifthemotorshowssignsofmoistureabsorptionbeforestart-up,drythemotoroutbyapplying10%voltageontwoleads(ifindoubt,measureresistanceinwindings,onetothreemeg-ohmsisnormal.Relubricatemotorbeforestart-upwheninstoragesixmonthsormore.V-Beltsarebeststoredbyremovingthemfromthesheaves.Sprayametalprotectantonthesheavesoranyotherunprotectedmildsteelpart.Removeallthemetalprotectantbeforereinstallingbelts.Mixershaftbearingsrequireextraprotectionwhenstored.Addgreaseuntilitshowsattheseals,rotatebearingstodistributegrease,andcoverthebearings.Rotateshaftevery6monthstopreventcreating“flats”onbearings.FigureB1.1B2.1Mountingstructuremustbestableandstrongenoughtohandletorque,bendingmoment,andweightshownonassemblydrawings.Thestructuremustnotflexorvibratewhenthemixerisinoperation.Ifmountingtoanunstablesupport,mixerloadsmaycausedamagetotheequipment,tank,orotherhazards.Thefollowingoptionsmaybeused.Alwaysusegasketsbetweenflangefacesbeforeboltingthemixertothenozzleforpropersealing.SeefiguresB2.1–B2.3formountingdetails.MOUNTINGOPTIONSB2.2PedestalSupportRecommendedforFGDapplications.Seedrawing#A12005forcompletedetail.Thepedestalfoundationmustbeattachedtothetankfoundation(seeillustrationinfigureB2.1A.Thepedestalmustrestonthesamefoundationasthetanktopreventstressonthemixerframeandmountingnozzlewhenthetanksettles.Distortionfromthisstresscancausemis-alignmentofthemixersealandmaycreateprematuresealwearandfailure.Afterinstallingtheflangemountingbolts,adjustthepedestaluntiltheweightofthemixerhasbeentransferredequallybetweenthepedestalandthenozzle.SeefigureB2.1Aformountingdetails.B2.3Piersupportsarerecommendedforlarger-horsepowermixers.TheconcretepierisbuiltunderthebaseoftheV-Serieshousing.Theconcretepiermustbepouredontopof,orotherwiseattachedto,thetankfoundation,topreventstressingthemixerframeandthemountingnozzlewhenthetanksettles.Afterinstallingtheflangemountingbolts,shimthepieruntiltheweightofthemixerhasbeentransferredequallybetweenthepierandthenozzle.SeetheassemblydrawinginSectionAforstudlocation.SeefigureB2.3formountingdetailsSFigureB2.1AALTERNATEMOUNTINGMETHODB3.1-Refertomixerassemblyandimpellerdetaildrawingsinthefrontofthemanualforproperimpellerrotation,positioning,andplacement.B3.2-1-PieceImpellers:Slidetheimpellerontheshaftfacingthecorrectwayaccordingtotheassemblydrawings(SeefigureB3.2.Forimpellerswithkeys,tightenthesetscrewsecurelyoverthekey.Donothammerpartsinplace.Ifkeysdonotfit,grindtosize.Tightensetcrew,jamnut/endboltsecurely,seetorqueratingpage12.B4.1-Wiring:Startingandoverloadcontroldevicesmustbematchedtomotorrating.Followcontrolmanufacturer'sinstructionsforproperconnectionsandinstallation.B4.2-ElectricalconnectionsmustconformtoNationalElectricalcodeandalllocalregulations.Linevoltageandwirecapacitymustmatchmotorratingsonmotornameplate.Motorsmustbewiredaccordingtothewiringdiagramsonthemotor.B4.3-Testlineresistancetocheckforpossiblemoistureinthemotor.Donotapplypowerifanyresistanceexceedsonetothreemeg-ohms.B4.4Rotation:MECHANICALSEALMUSTBEPREPAREDBEFOREAPPLYINGPOWERTOTHEMOTOR.Rotationoftheimpellermustbeaccordingtotheassemblydrawinganddatasheet.Commonrotationisclockwisewhenlookingfromthebeltdriveintothetank.Interchangelinesifnecessaryforproperrotation.B4.5-ElectricACVariableSpeed:ElectricmotorsusinganACvariablefrequencycontrollermustbewiredfollowingtheinstructionssuppliedwiththecontroller.SeedatasheetandassemblydrawingsforpossibleRPMlockoutranges.Operateonlyatspeedsoutlinedonthosesheets.Damagetoequipmentorseriousinjurytopersonnelcanresult,Ifspeedlimitationsarenotfollowed.B4.6-Motorlubrication:Electricmotorbearingsareoftensealedandneednorelubrication.Whenzircfittingsarepresent,relubricatewithaNo.2consistencylithiumsoapbaseandpetroleumcompound.Relubricateevery6monthsto1yeardependingonusage.Openandcleandrains.Addgreaseuntilnewgreaseisforcedoutdrain.Removeexcessgreaseandreplaceinputplugs.Runmotoronehalfhourbeforereplacingdrainplugs.B4.7-GreasetheMechanicalSealSeeSectionB-5.2WARNING:Alwayslockoutpowerbeforeservicingimpeller.FigureB3.2WARNING:Highvoltageandrotatingpartscancauseseriousorfatalinjury.Electricmachinerycanbehazardous.Installation,operation,andmaintenanceofelectricmachinerymustbeperformedbyqualifiedpersonnel.FullunderstandingofNationalElectricalCodeandlocalbuildingcodesisrequired.WARNING:Groundthemixermotorproperlytoavoidseriousinjurytopersonnel.GroundingneedstobeinaccordancewiththeNationalElectricalCodeandconsistentwithlocalbuildingcodes.CAUTION:MechanicalSealsuseSealRetainingClipsthatmustberotatedintooperatingpositionbeforeapplyingpowertothemixer.DonottestmotorrotationbeforepreparingMechanicalSealorsealdamagewilloccur.SeeSectionB5B5.1-TypicallythemixerwillbeshippedfromthefactorywiththeSealSetscrews#411,properlytightened,andtheRetainingClips#417,rotatedintothe“shipping”position,asshowninthephotobelow.ConfirmallSealSetscrews#411,aretorquedproperlyandtheRetainingClips#417areremovedandstored(intoolkitforfutureusebeforestartingmixer.B5.2-FilltheMechanicalSealwithgreasepriortostartingthemixer.Thesealisdesignedtopurgeexcessgreaseoutoftheelbow“vent”locatedatthetopoftheseal.Removeanyplugsorfittingsthatmaybeinstalledforshippingpurposesintheelbow“vent”beforeapplyinggreaseorsealdamagemayoccur.UseNGL-1greasecontainingNOMolybdenum.Pumpgreaseintothezircfitting,#421,untilgreaseexitstheelbowventatthetopoftheseal.Note:Previoussealsmayhavepositionedthegreasefittingonthesideofthesealifaventfittingwasused.TheSCB-428sealisdesignedtooperatewiththezircfittingpositionedatthebottomofthesealandanopen“vent”elbowonthetop.Rotateifthesealisinincorrectposition.Thegreaseisusedtolubricateandcleanthesealofdirtthatbuildsupinthesealcavityduringoperation.Re-greasethesealperiodicallyevery2weeksandchecktheconditionoftheoldgreaseasitispurgedouttheoverflowplug.Re-greasemoreofteniftheoldgreaseisdirty.CAUTION:DonotstartmixerbeforepreparingMechanicalSealorsealdamagewilloccur.SealMUSTbegreased,RetainingClipsremovedandstored,andallsetscrewsproperlytorquedpriortoStart-Up.SealsmustbegreasedregularlyEVERY2WEEKSwithNGL-1(ContainingNOMolybdenumpreviouslyauthorized.CAUTION:-Donotstartmixerwithimpellerburiedinsolidsorifexcessivesolidsareontankfloorordamagewilloccur.-Donotrunmixerunlessimpellerissubmergedorsealdamagewilloccur.B7.0Start-UpChecklistPriorandduringstart-upcheckthatthefollowingthingshavebeencompleted:Manualwasreadandfullyunderstood__________AllCertifieddrawingshavebeenreviewed__________Outboardsupporthasbeenshimmedandleveledsothatthemixerflangeisparalleltotankflange____________________Drivenbeltshavebeenalignedandtensioned__________Allguardshavebeeninstalled__________Bearingshavebeengreasedandsetscrewstightened__________Impellerhasbeeninstalledcorrectly(seecertifieddrawings__________Allassemblyboltshavebeencheckedandtightened__________MechanicalSealRetainingClipsremovedandsaved__________MechanicalSealproperlygreased__________Mechanicalsealsetscrews/driveringtorqued(seepage12_________Wiringcorrectlyinstalled,groundedandinsulated__________Motorcheckedformoistureabsorption(Resistancemustmeasurelessthan3meg-ohms___________Checkshaftrotationagainstcertifieddrawings__________Impellerimmersedinliquidbeforeoperation_________Correctvoltage/amperage@start-up:Actuallinevoltagemeasured(eachlead__________CheckforexcessiveheatduringoperationatMechanicalSeal__________Excessivevibrationatmixersupportorflange?_______________Mixeroperatingtodesignspecifications___________________________________________________________________________INSPECTORDATEITEMPARTNAME100Motor103Motorbushingkey123Motormountingbolts,nuts,&washers130Motormountingplate131Motoradjustmentstuds(4132Motoradjustmentnuts(16•300Inboardbearing•302Outboardbearing306Bearingmountingbolts&washers307Bearingsnapring308Bearingjackingbolts(2314Bearingsetscrews320BearingRemoPlate•371V-Belts372Motorsheave373Drivensheave374Motorbushing375Drivenbushing376Beltguard377Beltguardbase378Beltguardbolts,nuts,&washers379Beltguardbasemountingnuts&washers(8380Motorsheavebushingbolts&washers(3381Drivensheavebushingbolts&washers(3382Drivenbushingkey•400MechanicalSeal411SealSetscrews413SealMountingBolts/Clamps(4417SealRetainingClips421Sealzircfitting436SealDriveRingScrews475ShaftSupportCradle(notshown551MixerFrame552MountingFlange555Tierodassembly(notshown556Pipelegsupports(shown559MountingFlangefasteners(byothers•600MixerShaft672RetractionCollar(notshown673RetractionCollarclampbolts674SealCollar•675SealCollarCup677RetractionCollarJackingScrews(2678RetractionCollarMountingBolts730Impellerkey731Impellersetscrew750Impeller•=RecommendedsparepartC2.1ThisprocedureistoremovetheOutboardBearing#302fromthemixer.IftheInboardBearing#300isalsotoberemovedtheShaftRetractionproceduremustbeused.See"ShaftRetraction",SectionC3.1.Shaftretractionisnotrequiredtoremoveoutboardbearing.FigureC2.2C3.3-Disconnectthepowerfromthemixermotorandlocktopreventaccidentalstart-upofequipment.C3.4-RemovetheBeltGuard#376.Lowerthemotorbylooseningthemotoradjustmentnuts#132.RemovetheBelts#371.C3.5Re-installtheSealRetainingClips#417ontheMechanicalSealtoprotectandholdthesealpositionduringremoval.Rotatetheclipsaroundsotheyholdthesleevecollar.Rotatethemixershaftifnecessarytoavoidcoveringthesealsetscrewswiththeclips.PushtheRetainingClipstightagainstthesealsleeveandtighteninplace.C3.6-Removethe(4sealmountingboltsandclamps#413.Loosenthetwosetscrews#314intheBearings#300Į.RemovethefourmountingboltsfromtheInboardBearing#300.Note:DoNOTloosenthesealsetscrewsatthistime,SealSetScrewsanddrivecollarareStillTightwiththeretainingclips#411installed.C3.7-InstalltheShaftSupportCradle#475undertheshaftbetweenthebearingandseal(thistoolisshippedinaseparatetoolboxmarked“ServiceToolKit”.ApplygreasetothetopsaddleoftheCradlewhereitwillcontacttheshaftwhenraised.Positionthetoolapproximately40mmbackfromtheMechanicalSeal,SeeFigure3.1.ThefourjackingscrewsinthebaseofthetoolmayneedtobeloosenedtoallowtheCradletofitundertheshaft.TightenthebasescrewstoraisetheCradleuntilitfitssnugunderthemixershaft.Donotover-tightenthebasescrewsortheshaftand/orthesealmaybedamaged.UsetheShaftSupportCradletoalignshaftandremoveloadfromseal.DONOTOVERTIGHTENC3.8-Theshaftmaynowberetracted.TightenthetwoshaftRetractionBolts#308againsttheflangeontheinboardbearing#300topushtheshaftoutwardsfromthetank.Theshaftwillslidebackwardsthroughtheoutboardbearing(makesureallBEARINGsetscrewsarelooseandthesealwillmovebackwiththeshaft.Theshaftandsealwillretract(~10-15mmdependingonmixermodeluntilfurtherretractionbecomesdifficult.Thisindicatesthesealcollarcup#675istightagainstthetanksideofthemountingflange#552,sealingofftankcontentsfromleakage.CAUTION:Thesealcanbeeasilydamaged.Handlewithcare.DONOTHAMMERTHESEAL!RemovetheShaftSupportCradle.CAUTION:Thesealcanrequiresomeefforttoremove,DONOTpryonthesealbodyoranyo-ringarea.IfneededGENTLYpryonthezircfittingandgreasevent.Adjustingtheshaftsupportcradlewillassistinsealremoval.CAUTION:DURINGRETRACTION,THESEALHOUSINGMUSTRETRACTWITHTHESHAFT.STOPANDRE-ADJUSTCRADLEIFSEALDOESNOTMOVEWITHSHAFT.RemoveC3.9-Loosenthe(6sealsetscrews#411,removetheDriveCollarScrews#436andinstallthescrewsinthe