干灰散装机说明书

-.z.SZJ-100型干灰散装机SZJ-100ModelDryDustBulkMachine使用说明书OperationInstruction国能环保设备JiangsuGuonengEnvironmentProtectionEquipmentCo.,Ltd.一、前言1.Foreword本产品适用于电力、建材、冶金、煤炭以及化工等其它行业的无腐蚀、低研磨性粉粒状物料的装车或装船作业。在火力发电厂主要用于灰斗或贮灰库下装车、装船。本产品可与料库下给料设施联锁运行，通过控制系统的控制，实现了装卸过程的自动化。其装车效率高，密封性能好，无粉尘污染。是散装粉状物料装车、装船的理想设备。Theproductisapplicabletotheloadingorshipmentworkofnon-corrosion,lowabrasivenesspowdermaterialsinsuchindustryaspower,construction,metallurgy,coalandchemicalindustry.Ifitusesinthermalpowerplant,itismainlyappliedtotheloading,shippingunderdusthopperordustbunker.Theproductisinterlockingoperatedwithmaterialstoragefeedingfacility,tocarryoutautomaticloadingandunloadingprocessviacontrolsystem.Itistheidealequipmentforloadingandshippingbulkpowdermaterialswithsuchcharacteristicsashighefficiencyloading,goodsealingperformanceandwithoutdustcontamination.二、技术参数2.Technicalparameters2.1干灰散装机型号含义：构造形式I：不带轴尘风机 II：带抽尘风机 III：带就地除尘器StructuralformI:构造形式I：不带轴尘风机 II：带抽尘风机 III：带就地除尘器StructuralformI:withoutduste*haustfanII:withduste*haustfanIII:withinsitedustcollectorSZJ–100StructuralformI:withoutduste*haustfanII:withduste*haustfanIII:withinsitedustcollector出力100m3Output100m3干灰散装机Drydustbulkmachine2.2控制方式：设半自动和自动2.2Controlmode:settingsemi-automaticandautomatic2.3散装头升降行程：1300mm〔亦可按用户需要而定〕2.3Liftingstrokeofbulkhead:1300mm(decidedasperuser’sdemand)2.4散装头升降速度：0.1m/s2.4Liftingspeedofbulkhead:0.1m/s2.5配带升降电动机参数：2.5Liftingmotorparameters:●型号：YEJ90S–6●Model:YEJ90S–6●功率：0.75kw●Power:0.75kw●电压：380V●Voltage:380V●转速：910r/min●Rotatingspeed:910r/min2.6减速机参数：2.6Reducerparameters:●Model:WHT08-VII●型号：WHT08-VII●Reductionratio:1:63●减速比：1:632.7抽尘风机参数：2.7Duste*haustfanparameters:●型号：9-19No4.5●Model:9-19No4.5※型号：4-72No3.6※Model:4-72No3.6●流量：2817m3●Flowrate:2817m3※流量：2930m3※Flowrate:2930m3●风压：4.04kPa●Windpressure:4.04kPa※风压：1.65kPa※Windpressure:1.65kPa●抽尘风机电机型号：Y112M-2●Motormodelofduste*haustfan:Y112M-2※抽尘风机电机型号：Y100L-2※Motormodelofduste*haustfan:Y100L-2●抽尘风机电机功率：4.0kW●Motorpowerofduste*haustfan:4.0kW※抽尘风机电机功率：3.0kW※Motorpowerofduste*haustfan:3.0kW●抽尘风机电机电压：380V●Motorvoltageofduste*haustfan:380V※抽尘风机电机电压：380V※Motorvoltageofduste*haustfan:380V●抽尘风机电机转速：2890r/min●Rotatingspeedofmotorofduste*haustfan:2890r/min※抽尘风机电机转速：2870r/min※Rotatingspeedofmotorofduste*haustfan:2870r/min2.8料位计形式：电容式料位开关2.8Materiallevelmetertype:capacitancetypelevelswitch2.9料位计型号：TLK-C15A1-4C2.9Materiallevelmetermodel:TLK-C15A1-4C2.10散装机下料管直径：φ3502.10Diameterofblankingtubeofbulkmachine:φ3502.11散装机吸尘管直径：φ5582.11Diameterofdustsuctionpipeofbulkmachine:φ558注：带※为III型散装机参数。Note:※indicatestheparametersofIIImodelbulkmachine.三、构造与工作原理3.Structureandworkingprinciple3.1主要构造3.1Mainstructure可伸缩散装头E*tensionalbulkhead散装头由底座、伸缩管、吸尘管、套箍、钢丝绳、绳卡等主要部件组成，通过吸尘管、钢丝绳把它们连接起来，形成可伸缩的构造。Bulkheadisposedofbaseframe,e*tensiontube,dustsuctionpipe,hoop,steelcable,cablehead,etc.,whichareconnectedbydustsuctionpipeandsteelcabletoformane*tensionalstructure.卷扬装置Hoistingunit卷扬装置由电动机、减速机〔带有计数器〕、滑轮装配、钢丝绳等组成，它是控制散装头伸缩的装置。Hoistingunitisposedofmotor,reducer(withcounter),pulleyassembly,steelcable,etc.Itistheunitforcontrollingthee*tensionofbulkhead.控制系统Controlsystem控制系统是散装机的心脏，直接完成散装机整个卸料过程。它由控制拒、计数器、接近开关以及料位计、支架、电线等元件组成。计数器和接近开关控制散装头的下降位置，通过反应信号翻开给料机和抽尘风机，散装机进展装料；料位计控制料位的上下，当料位到达指定位置后，它反应给控制系统电信号，使控制系统关闭给料机和抽尘风机，并翻开卷扬电机，提升散装头；同时计数器控制散装头的上升位置，当散装头接近预定位置时，关闭卷扬电机，从而完成物料的装卸。本控制系统设有“自动、手动〞操作切换开关，手动操作供检修及特殊情况下使用。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.脉冲除尘器3.1.4PulseddustcollectorIII型散装机自带一就地DMC型电脉冲除尘器，由抽尘风机、喷吹系统、箱体和滤袋组成。箱体设有吸尘口，把从散装机吸来的含尘气体经滤袋后得到净化，净化后的气体经由抽尘风机出风口排空，滞阻在滤袋外壁的灰尘经由喷吹系统循环处理以后被去除。这样一来，现场可实现无尘作业。IIImodelbulkmachinehasaninsiteDMCelectricalpulseddustcollector,whichisposedofduste*haustfan,blowingsystem,tankandfilterbag.Thetankhasadustsuctioninlettopurifythedustygasabsorbedfrombulkmachineviafilterbag,thenemptythepurifiedgasviatheairoutletofduste*haustfan,removethedustretainedate*ternalwalloffilterbagbycircularprocessingofblowingsystem,sothatthesitecancarryoutdustfreework.3.2工作原理3.2Workingprinciple当散装头锥面下降到与汽车〔或船〕入灰口上部密合时，钢丝绳变松，计数器上的到位开关发出电信号反应给控制系统，关闭卷扬电机，并翻开抽尘风机和给料机，开场装料；当物料装满料罐时，料位计发出信号，反应给控制系统，控制系统自动关闭给料机和抽尘风机并提升散装头；当散装头提升到预定位置时，计数器上的到位开关发出电信号，反应给控制系统，自动关闭卷扬电机，完成一次物料的装卸过程。Whentheconicalsurfaceofbulkheaddescendstobesealedtogetherwiththetopofdustinletofvehicle(orship),thesteelcablewillbeloose,thelimitswitchonthecountersendsoutanelectricalsignaltofeedbacktocontrolsystem,closehoistingmotorandstartduste*haustfanandfeeder,thenstartloading;whenmaterialtankisfullofmaterials,themateriallevelmeterwillsendoutasignaltofeedbacktocontrolsystem,thencontrolsystemautomaticallyclosesfeederandduste*haustfanaswellasliftbulkhead;whenbulkheadisliftedatpresettingposition,thelimitswitchonthecounterwillsendoutanelectricalsignaltofeedbacktocontrolsystem,thenhoistingmotorisautomaticallyclosedsothatapletedmaterialloadingandunloadingprocessisfinished.四、安装、调试与运行4.Installation,missioningandoperation4.1安装4.1Installation设备到现场后，先整体检查，看有无因运输而损坏部件的情况，如有，则应拆卸更换；Checkifanypartisdamagedduetotransportation,aftertheequipmentsarearrivedatthesite,ifany,itshouldberemovedandreplaced;然后吊装散装机并与预留孔对位；对好位后，按现场管道情况把散装头底座与预埋件用螺栓联结好〔也可直接焊接〕。安装过程中注意不要刺破或烧伤吸尘管〔挂胶帆布〕，以免影响吸尘管的透气性。Liftthebulkmachineanddirecttopreservedhole;afterpositioning,connectthebaseframeofbulkheadwithpre-embeddedpartsbybolts(orwelding)accordingtothepipinginsite.Duringinstallation,noticethatdonotbreakorburnthedustsuctionpipes(rubberizedcanvas)soasnottoaffecttheairpermeabilityofdustsuctionpipes.按电气图纸资料连接电缆，并注意各电缆的走向。Connectcablesaccordingtoelectricaldrawingandpayattentiontothedirectionofeachcable.4.2调试4.2missioning空载调试No-loadmissioninga)调试前检查所有接线是否正确，安装是否合格，经检验确认，方可进展调试；a)Checkifallwiringsarecorrect,installationisqualifiedbeforemissioning.Donotcarryoutmissioninguntilpassingtheinspection.b〕调试时，关闭手动检修门〔位于散装机进料口最上方〕，先手动操作，看电动机转向是否符合要求，转向正确后，方可进展上、下限位以及料位计的动作调试；b)Closemanualaccessdoor(locatedatthetopmostpartoffeedinletofbulkmachine)duringmissioning,manuallyoperateatfirst,andobservetheturningofmotorisconformitywiththerequirement.Carryoutmissioningoftheactionofupper,lowerlimitandmateriallevelmeteraftertheturningiscorrect;c〕启动“自动按钮〞，卷扬电机翻开，散装头下降，下降到位后给料机翻开；当全部联动投入运行，空运转数分钟，把功能开关置于“满料指示〞位置时，报警铃声响后运行设备自动停机；提升散装头到上限位置，计数器上的到位开关自动切断卷扬电机电源，整个联动过程空试完毕。c)Start“automaticbutton〞,tostarthoistingmotoranddescendbulkhead,afterdescendingtoreachthedesignatedposition,feederwillstart;wheninputtingoperationfully,andplacefunctionswitchin“fullindication〞,afterno-loadoperationforseveralminutes,theequipmentwillstopautomaticallyafteralarmbellsounds;liftthebulkheadtoupperlimitposition,thelimitswitchonthecounterwillcutoffthepowerofhoistingmotorautomatically,sothatafullinterlockingmissioningprocessispleted.负载调试Loadmissioninga〕空载调试正常后，将散装机的管路、阀门置于工作状态位置，让散装粉煤灰车或其它运载设施到位，即可进展负载调试；a)Placethepipesandvalvesofbulkmachineunderoperatingconditionafterno-loadmissioningisnormal,andbulkdrydustvehicleorothertransportingequipmentsareinposition,itcancarryoutloadmissioning.b〕正常情况下，散装下料锥斗与装载容器进料口结合部位及吸尘管均处于负压工作状态，负压大小可由抽尖风机前的手动调节门来调节，当吸尘管往外鼓胀及进料口结合部位向外冒灰时，表示抽尘风机出现故障，如不及时排除则会引起料位计误发报警信号而停机；b)Undernormalcondition,thejointpartofbulkunloadingconehopperandfeedinletofcontaineranddustsuctionpipeareundernegativepressurecondition,thenegativepressuremaybeadjustedbymanualadjustablegateinfrontofduste*haustfan.Whendustsuctionpipee*pandsandthejointpartatfeedinletspreadsdust,itshowstheduste*haustfanoccursfailure,ifdonoteliminateintime,themateriallevelmetermaysendoutwrongalarmsignalandstopthemachine;c〕料满报警停机后，将散装下料锥斗复位，并检查装载容器中物料装满程度状况，过满或过浅可通过调节料位计的位置来满足，并固定好料位计的最终位置。c)Afteralarmtostopmachineduetofullofmaterials,resetbulkfeedinghopperandcheckthematerialsinthecontainer,ifitistoofullortooshallow,itmayadjustthepositionofmateriallevelmeterandfi*itsfinalposition.4.3运行4.3Operation散装粉煤灰车或其它运载设施到位后，手动操作，使散装头下降接近罐口，然后停下来，罐口对准散装头后，将切换开关打向自动操作位置，按下启动按钮，使散装头的锥斗与罐口结合严密；Afterbulkdrydustvehicleorothertransportingequipmentsareinposition,manuallyoperatetodescendthebulkheadclosetotheportoftank,thenstop,aftertheportoftankcentersonbulkhead,placechange-overswitchinautomaticoperation,pressstartbuttonsothattheconehopperofbulkheadconnectswiththeportoftankclosely;当料已装满，料位计发出信号〔料位指示灯亮〕，给料机自动停顿给料，延时一段时间以后〔一般为4~6秒〕，关闭抽尘风机，提升散装头。延时长短以下料管物料落净为准。Whentherearefullofmaterials,themateriallevelmeterwillsendoutasignal(levelindicatorison),thefeederautomaticallystopfeeding,afterdelayafewtimes(generally4~6seconds),closeduste*haustfan,liftbulkhead.Thedelaytimeisbasedonthematerialemptyinginloadingpipe.五、使用考前须知与维护5.Usagenoticeandmaintenance5.1使用前必须给减速机加油至适宜位置，运行一个月后更换新油，以后每年换油一次；5.1Fillthereducerwithoiltoapplicablepositionbeforeusing,replacewithnewoilafteroperatingonemonth,andchangeoilonceayear.5.2在装料时，务必把散装机对准罐口，否则散装头可能下降不到规定位置或被绳卡卡住，发生堵料事故，甚至损坏料位计；5.2Thebulkmachineshouldbecenteredontheportoftankwhenloading,otherwise,thebulkheadmaynotdescendtothespecifiedpositionorbeblockedbycableheadresultinginplugging,evenbreakingthemateriallevelmeter.5.3当装料时，突然发生极大的扬尘，说明排料不畅通，应马上停顿下料，千万不要立即提升散装头；5.3Largedustemissionhappenssuddenlywhenloading,whichshowsthatmaterialdischargeisnotsmooth,itshallstoploadingatonceanddonotliftbulkheadimmediately.5.4在装料过程中，如果发生溢料，应立即停顿下料。千万不要在散装头积满料的情况下，提升散装头，应把吸尘管套箍卸下，排除一局部积存物料后，再慢慢把下料管的积料排除，然后再提升散装头；5.4Ifmaterialsaresurplusduringloading,itshallstoploadingatonce.Donotliftbulkheadwhentherearefullofmaterialsinbulkhead,afterremovingthehoopfromdustsuctionpipeandcleaningoutapartofaccumulativematerials,eliminatetheaccumulativematerialsinfeedpipeslowlyandthenliftbulkhead.5.5松尘开关装置、计数器的到位开关应常检查，一旦失灵要及时更换，以免造成设备损坏；5.5Checkdustswitchunitandlimitswitchofcounterregularly.Onceitfails,itshallbereplacedintimesoasnottodamagetheequipment.5.6滑轮装置及钢丝绳注意定期检查，假设有损坏要马上更换；5.6Payattentiontocheckpulleydeviceandsteelcableregularly.Ifithasanydamage,replaceitatonce.5.7吸尘管会因老化或锋利物品的碰挂而损坏，需定期更换，破损处应及时补牢以免影响收尘效果；5.7Thedustsuctionpipemaybedamagedduetoagingortouchingofsharpobjects,soitneedstobereplacedregularly.Thebreakageshouldberepairedintimesoasnottoaffectthedustcollection.5.8散装机在装料过程中应处于负压状态工作，故应保证抽尘风机的正常运转和维护。5.8Thebulkmachineworksundernegativepressureconditionduringloading,soitshallensurethenormaloperatingandmaintenanceofduste*haustfan.5.9罐车或其它装运设备应注意其运行高度，不要撞坏散装头。5.9Payattentiontotheheightoftankcarorothertransportingequipments.Donothitthebulkhead.6．故障分析与处理措施6.Failureanalysisandhandlingmeasures故障现象Failure故障分析Failureanalysis处理措施Handlingmeasures卷扬电机不动作Hoistingmotorfailstoact1．线路故障；1.Wiringfailure;2．制动片未脱开2.Brakediscdoesnotdisconnect.1．排除线路故障；1.Eliminatewiringfailure;2．取出电机后罩，松开制动片螺栓，再通电正、反运转几次后拧紧制动螺栓。2.Takeoffrearcoverofmotor,loosentheboltofbrakedisc,afteroperatinginpositiveandnegativedirectionforseveraltimeswithpower,thenscrewdowntheboltofbrakedisc.散装头上、下位置到位后，减速机不能适时停运Afterupperandlowerpositionofbulkheadarebothinplace,reducercannotstoprunningtimely.1．线路故障；1.Wiringfailure;2．计数器到位开关损坏。2.Limitswitchofcounterdamages.1