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1、 XGD-A2.5/40使用说明书 04B01199A1-SYXGD-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 : 2XGD-C200/600 Product Manual 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
2、 Installation, test and trial operation6维护与安全技术 Maintenance 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 111、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。
3、This H.P&L.P oil lubrication station consists of a gear pump 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 pane
4、l.2、 主要性能参数Main specifications：2.1低压供油系统Low pressure oil supply system：2.1.1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 2.1.2过滤器Filter
5、：型 号Model： SPL80X SPL65X 过滤精度Filtering accuracy： 0.08 mm 0.04mm 过滤面积Filtering area: 1.31 m2 0.83m2 2.1.3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/h2.1.4电加热器Electric heater：型 号Model： HR
6、Y5-220/6功 率Power： 6kW6=36kW2.1.5油箱外形尺寸Oil box outline dimension： （LWH）37002300 1260 油箱有效容积Effective volume of the oil box： 6.5m32.1.6油站外形尺寸Oil station outline dimension： （LWH）4700220026002.2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 pressur
7、e： 40MPa 系统工作压力System work pressure： 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 detachab
8、le structure (please refer to the 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 lubricatin
9、g oil to the gears, but also supply 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8
10、0m，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。 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 a
11、utomatic start /halt outlet of electromagnetic 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 oi
12、l after cooling unit partly goes to 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 qua
13、lity lubricating oil. By this way 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.
14、P system is controlled by the electro 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
15、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 requi
16、rements.The work pressure of high 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.
17、4.2低压系统工作时，最高压力0.4Mpa，最低压力0.12Mpa，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 low
18、er than 0.12Mpa, a standby pump starts 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 pre
19、ssure of L.P oil comes to 0.2 Mpa, 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
20、工（自动）打开油冷却器.Before the oil station 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 o
21、il temperature at the oil outlet reduces 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 t
22、he system for 35 minutes, then supply 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
23、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
24、）; manually exchange the working cartridge 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
25、 the maxmum, minimum, normal oil level, 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 te
26、sted in the producing workshop, so 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 re
27、quirement. 5.3现场安装后，首先要检查润滑油是否与设计牌号符合，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.
28、 After all, trial operation can be 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
29、pump body, the hand stick of double 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
30、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。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 t
31、he main body, when operation is in 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 tr
32、ail run, attention to the pressure 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
33、find out the reason, on condition 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
34、 noise in the oil supplying system 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,
35、after one hour operation, generally 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 w
36、ill generate a large amount of heat, 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 pump6.1.1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
37、灵活。A flexible connection is adopted between 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.6.1.2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
38、 box, suction height should be less than 500 mm.6.1.3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.6.1.4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 sh
39、ould be clean, and without corrosive substances and mechanical impurities, a filter should be set at the inlet of oil pump.6.1.5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.6.1.6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 ne
40、ar as possible, better directly connect to the oil pump.6.1.7油封是易损件,如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.6.1.8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
41、 of gear pump will increase, power function reduced, then replacement of rolling bearing is needed.6.1.9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, othe
42、rwise it can not work normally.6.1.10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 gear 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.6.1.11停止工作时先关闭电动机开关，然后再关闭油管中的阀。Up
43、on 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Operation and maintenance of cooler6.2.1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 equipmen
44、t. Check whether pressing size is in accordance with the specified size. If not, twist the bolt 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 si
45、des. Testing pressure is one and a quarter times as much as operating pressure. Retaining time is 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 n
46、eed hing requirements for sanitation. Clean out oil dirt and foreign matter in the equipment.4) 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 function 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 h