GXYZB高低压稀油站说明书样本
63L高低压稀油站使用说明书
MGKZ-63L高低压稀油站使用说明书一、用途：MGKZ-***型高低压稀油站主要用于装有动静压轴承的各种主机、轧钢机、大型电机、磨机等设备的润滑系统中；根据动静压原理在低速、停车、启动时用高压系统，正常运行时用低压系统，也可以正常运行时高低压系统同时使用。
从而提高了静压轴承的使用寿命，保证了主机的正常运转，其工作介质为粘度N32—N460的工业润滑油。
本油站通常安装在附近地面。
二、技术参数：稀油站型号：MGKZ-63 低压泵流量：63L/min低压泵压力：0.63MPa 电机功率（低压）：2.2Kw高压泵流量：2.5L/min 电机功率（高压）：2.2Kw高压泵压力：32MPa 冷却面积：10平面工作形式：连续工作制（一用一备）加热器功率：12Kw油箱容积：1.25立米冷却水耗量：6.0立米/小时三、工作原理及结构特征：MGKZ型高低压稀油站主要由油箱、高压油泵装置、低压油泵装置、双筒网式过滤器、冷却器及仪表盘、电气控制装置、管道、阀门等组成，其结构见附图。
高低压稀油站的工作原理是：本稀油站具有两种控制方式：一种是集中控制方式，由中央计算机系统（DCS）进行远程控制；一种是机旁控制方式。
其中集中控制方式时中控启停稀油站，当中控给出启动信号后稀油站电控柜自动启动被设定为主泵的低压泵装置；等低压泵装置正常工作后延时几秒启动被设定为主泵的高压泵装置，当压力传感器采集到系统高压从一个高值降低到一个比较低的值，同时较低的值保持相对稳定，这时电控系统默认为轴承被浮起，电控柜给出允许主机启动信号；在主机正常运行过程中，当液位低于低限、液位高于高限、油温大于50度但低于60、油温低于20度、过滤器堵、低压油压力低、高压油压力低时电控柜给出报警信号但不停主机；当低压油的压力低时备用泵（低压）自动启动（同时报警），等低压油压力正常时停止有故障的低压泵装置，如果两台低压泵装置同时启动还不能满足压力要求，系统故障停车（故障停车时高压泵装置正常工作）；当高压油的压力低时备用泵（高压）自动启动（同时报警），等高压油压力正常时停止有故障的高压泵装置，如果两台高压泵装置同时启动还不能满足压力要求，系统故障停车（故障停车时低压泵装置正常工作）；当油温低于20度时加热器自动工作，等油温达到38度时加热器停止工作，当油温高于45度时冷却器水阀自动接通，等油温降到40度时冷却器水阀关闭，当油温高于60度时系统故障停车。
稀油润滑站说明书
High-low Oil Lubricating StationOperating ManualCompiled ByChecked ByStandardApproved ByCITIC Heavy Machinery Company, LtdOct. 2005Catalogue1. Summary2. Product Specification and Performance Pedigree3. Operation Principle4. Structural Features5. Main Control Function6. Debug and Operating Regulations7. Daily Operation and Maintenance8. Swing and Setting9. Storage Conditions and Time10.System Schematic Diagram11.Spare Parts List12.Excursus1. Summary：This high and low pressure thin oil lubritory is used for the principal axletree of the ball mill. Each ball mill equips such a lubritory. The high and low pressure oil lubritory is made up of high and low pressure oil supply systems. The high-pressure oil supply system provides static pressure support to the principal axletree at both ends of the ball mill separately while the low one is split in two after effusing the oil to provide the dynamic pressure lubrication.The high pressure oil supply system: the ball mill has to transport the high pressure oil before starting or stopping so that the principal axletree of it floats and the oil film at a certain thickness is formed between the principal axletree and the spherical tile. With the aim to debase the starting moment, otherwise the tile kilning accident, caused by the direct tangency of the principal axletree and the spherical tile, will occur when the ball mill stops if the rotate speed of it is too low to form the required oil filmThe low pressure oil supply system: when the ball mill runs normally, the dynamic pressure lubrication will form between the principal axletree and the spherical tile, which debases the wearing, reduces the power consumption, carries away the generating heat, refrigerates the principal axletree and lengthens the service life of the equipments.The operating environment of this lubritory requires indoor, dry air, no damp, lustration, no noxious gases, no explosivity gases, no aggressive gases wrecking metal and insulation, no conducting dust, no more than 1500 meters altitude and around the 5-40 Celsius degrees.2. Product Specification and Performance Pedigree：The viscosity trademarks used by the working medium of this high and low pressure thin oil lubritory are shown in the operating specification of the main frame.Performance Pedigree：High-pressure oil supply system Normal mode voltage31.5 Mpa （The operating oil pressure is determined by load.）Norminal flow rate 6.0×2 1/minElectromotor Power 5.5×2 KWLow-pressure oil supply system Normal mode voltage0.6 Mpa （The operating oil pressure is determined by load.）Norminal flow rate 63.0 1/minElectromotor Power 3.0×2 KWCooler Cooling water capacity 95-130.0 1/minPressure of the cooling water 0.2-0.3 MPaArea of cooling surface 6.0 ㎡Latus rectum of water intake and water outlet 32.0 mmOil filter Filter precision 80.0Electrical heater Power 2.0×3 KWOil product Viscosity rangeN46-N150 Industrial gear lubrication or antiwear hydraulic oilRecommend N100 antiwear hydraulic oilOil tank Cubage 2.15 Weight2100 Kg3. Operation Principle：The high and low pressure thin oil lubritory is mainly made of oil tank, high-pressure oil pump, high-pressure relief valve, high backpressure valve, electromagnetical diversion valve, high-pressure valve; low-pressure oil pump, low-pressure safety valve, low backpressure valve, oil filter, cooler; pressure controller, humidity controller, electrical crunode thermometer, pressure instrument, pipeline, low-pressure valve and so on.The low-pressure oil pump electromotor has to be started first when the ball mill starts or stops. Then the low-pressure oil pump will draw out the dubbing from the oil tank through diversion valve, oil filter, cooler, low-pressure valve, intermediate piping and flow control device sending to the oil site of the principal axletree at both ends of the ball mill. At the same time, the dubbing drawn out is sent to the input port of the high-pressure oil pump. After the low oil pressure achieves the normal value, the high-pressure oil pump electromotor has to be started. Then the high-pressure oil pump will draw out the high-pressure dubbing changed from the low-pressure one through high backpressure valve and high-pressure valve to the principal axletree of the ball mill. Effusing from the oil site, the lubrication will pass through the oil return port at the principal axletree of the ball mill, the intermediate piping, the oil return filter setted in the oil tank and reflow the oil tank after filtration.This cycle process will ensure the lubricating system work normally.The over-oil-pressure protection to the high and low pressure of the system isfinished by the relief valve and safety valve. When the oil pressure exceeds the setup oil pressure value at the working condition, the relief valve and safety valve will automatically open to step down the pressure in order to realize the overload protection.The operating pressure value of the low pressure system depends on the factors of the opening level of the oil site, the difference of elevation between the lubritory outlet and the oil site, the length of pipeline, the quantity of elbow, and the valve opening and so on.The operating pressure value of the high pressure system is mainly determined by the load and depends on the weight of the ball mill itself and the load, the clearance between the spherical tile and the journal of the principal axletree. The other influential factors are the same as that of the low pressure system.The drain contamination valve on the lubritory is used for quickly eliminating the waste oil which reaches the renewal date and can’t be used ever in the oil tank.Two high-pressure gauges are used for directly observing the oil pressure of the high pressure system. Four high-pressure controllers are used for controlling the oil pressure of the high pressure system. Two low-pressure gauges are used for directly observing the maximum oil temperature warning of low-pressure oilout.One electrical crunode thermometer is used for high oil temperature warning in the oil tank. Two temperature controllers are used for controlling the operation of the electrical heater and electromagnetical gate valve.The oil tank of the lubritory is enclosed type. The supercharged air cleanser setted on it will meet the working condition that the altitude difference from the oilout to the oil site is less than 6.0 meters.If some accident occurs and the oil supply has to be stopped to fix, the main generating room or the designing institute don’t allow the U type of pipeline for connection when doing the design of tubing and the users’construction. The connected caliber should be greater than or equal to that of oilout. The valve on one side of the oil tank must be closed when fixing in order to ensure the maintenance work under no oil condition.4. Structural Features：4.1 The lubritory has three high-pressure oil pumps, the two of which work at thesame time and supply the oil to one principal axletree of the ball mill separately while the rest one is for standby. It also has two low-pressure oil pumps, one of which is for working and the other one is for standby too.4.2 The oil filter of the low pressure system is setted on the front of columnwisecooler. The filtration effects will be good if filtrating first and then cooling. (The oil’s through capacity represented in the oil filter has something to do with the viscosity temperature characteristic. When the temperature is high, the oil viscosity is low and the through capacity is great. Contrariwise, the through capacity is low.)4.3 The oil filter of the low pressure system adopts twin-cylinder network-pattern oilfilter and one filter element is for working while the other one is for standby.When the working filter element is jammed and warning, we should let the standby one to work by moving the switching hand onto it. The jammed filter element can be taken out to cleanout or replacement when doing the normal maintaining but not to stop the host.4.4 The oil filter of the low pressure system adopts the GLC type of shell-and tube oilcooler, which adopts finned tube. The water side channel adopts double monitor framework, which puts up the advanced technology and distinct heat exchange effect.4.5 The oil return magnetism filter is setted at the back of the oil return port in the oiltank, which will adsorb the scrap iron from the oil return and filter the oil return.4.6 The meter is to be setted on the pipeline at the observed-tend position, whichlooks beautiful.4.7 A by-path valve connected to the oil return tank is setted at the outlet piping on thelow pressure system, which is used for the low-pressure oilout distributary and filtering circularly.4.8 The lubritory has the electric cabinet which can be ordered with the lubritory bythe users if required. And the electric cabinet has its individual operating specification.5. Main Control Function：5.1 Oil Pressure ControlEach high-pressure oilout has two pressure controllers and four ones in total. The pressure controller is used for monitoring the oil pressure and separately controlling the standby oil pump electromotor whether to be electrified, over high-pressure warning and the starting of the ball mill.The first group of the second high-pressure oilout port：After the high-pressure oil pump works, when the oil pressure achieves to the first setting value (the setting value is determined by the actual oil pressure when the ball mill is lifted.) of the pressure controller (the range of it is 2.5-25MPa), the system will enter the normal operating condition. The indicator light shows the high pressure normally. After the pressure stabilizes, the ball mill can be started.When the oil pressure can’t achieve the setting value, the sound-light warning signature will represent that the high-pressure oil-pressure is low, which is used the switching difference of the pressure controller. The electromagnetical diversion valve will be electrified first and then will the standby high-pressure oil pump after 1-2s. The operating high-pressure pump electromotor is cut. When the oil pressure is achieving or over the normal value, the ball mill can be started. If the oil pressure can’t achieve the normal value yet, the electronic control cabinet will send the sound-light warning signature representing that the high pressure is failure and the ball mill can’t be started.When the oil pressure achieves the second setting value (the range of it is4.0-40MPa) of the pressure controller, the electronic control cabinet will send thesound-light warning signature representing that high-pressure oil-pressure is high or the ball mill is forced to stop.The second group of the first high-pressure oilout port：After the high-pressure oil pump works, when the oil pressure achieves to the first setting value (the setting value is determined by the actual oil pressure when the ball mill is lifted.) of the pressure controller (the range of it is 2.5-25MPa), the system will enter the normal operating condition. The indicator light shows the high pressure normally. After the pressure stabilizes, the ball mill can be started. When the oil pressure can’t achieve the setting value, the indicator light will send the sound-light warning signature representing that high-pressure oil-pressure is low, which is used the switching difference of the pressure controller. The electromagnetical diversion valve will be cut first and then the standby high-pressure oil pump will be electrified after 1-2s. The operating high-pressure pump electromotor is cut. When the oil pressure is achieving or over the normal value, the ball mill can be started. If the oil pressure can’t achieve the normal value yet, the electronic control cabinet will send the sound-light warning signature representing that the high pressure is failure and the ball mill can’t be started.When the oil pressure achieves the second setting value (the range of it is 4.0-40MPa) of the pressure controller, the electronic control cabinet will send the sound-light warning signature representing that high-pressure oil-pressure is high or the ball mill is forced to stop.When the ball mill is started normally and after a period of time delay, the high pressure system will stop automatically.When the ball mill stops, the high-pressure oil supply system will start automatically at the same time. When the temperature of the principal axletree of the ball mill falls to the room temperature or achieves to the appropriate one, the high-pressure oil supply system should stop first and then will the low-pressure oil supply system.When the ball mill is in the slow-drive operation, high and low pressure oil supply system should always be in the normal operation until achieving the meet of the operator. The high-pressure oil supply system will be stopped first and then will the low-pressure oil supply system.Generally, in the normal stop situation, the high and low pressure system should last working for another 15-30min and then stop supplying oil.The low-pressure oil supply system has two pressure controllers which are used for monitoring the oil pressure of the oilout. The oil pressure of the oilout reduces to the first setting value (the recommendation value is 0.08-0.15MPa) of the pressure controller (the range of it is 0.02-0.2MPa) in the operation, the sound-light warning signature will represent that the low-pressure oil-pressure is low and the standby oil pump at the same time will be started and the operating one will be stopped. When the pressure of the system renews the normal value, that sound-light warning signature should be cancelled by use of the switching difference of the pressure controller. As the standby oil pump is in the operationand the oil pressure still can’t achieve the required value, the sound-light warning signature will represent that low-pressure oil-pressure is failure and the ball mill will be stopped at the same time.When the pressure is achieving or over the setting value (the recommendation value is 0.6MPa) of the other pressure controller (the range of it is 0.05-0.8MPa), the sound-light warning signature will represent that low pressure is high or the ball mill will be stopped.5.2 Flow ControlOn the oil supply pipeline close to the principal axletree at both ends in the low-pressure oil supply system, each flow switch is set actinically which is used for monitoring the flow change in the pipeline. When the flow in the pipeline reduces to its setting value, the sound-light warning signature will represent that the oil flow is cut or the ball mill will be stopped.5.3 Oil Temperature ControlThe oil tank has two temperature controllers and one electrical crunode thermometer which are used for monitoring the temperature change in the oil tank and controlling the electrical heater and oil valve. When the oil temperature in the oil tank is under the setting value (the recommendation value is 10 Celsius degrees) of the first temperature controller (the range of it is 10-40 Celsius degrees), the electrical heater will be electrified automatically and take the operation of heating dubbing, while the oil pump for operating can’t be started.When the oil temperature is higher the setting value (above the 10 Celsius degrees and the switching difference is 3-5 Celsius degrees), the electrical heater will be cut automatically and the oil pump for operating will be allowed to start.The electrical heater can be also controlled electrified and cut manually on the control cabinet.The other temperature controller’s temperature probe is set nearby the high-pressure oil pump. When the oil temperature here achieves to the setting value, the electromagnetical gate valve used for controlling the water intake of the cooler will be electrified and opened automatically. The cooling water enters into the cooler. When the oil temperature here is under the setting value, the electromagnetical gate valve will be cut and closed automatically. The cooling water can’t enter into the cooler.The one electrical crunode thermometer on the oil tank is used for monitoring the oil temperature in the oil tank. When the temperature in the oil tank achieves to the maximum setting value, the sound-light warning signature will represent that the oil temperature is high in the oil tank and the corresponding indicator light on the control cabinet will show it.An electrical crunode thermometer is set on the low-pressure oilout. When the oil temperature achieves to the maximum setting value, the sound-light warning signature will represent that the oil temperature is over-high or the ball mill is forced to stop.5.4 Liquid Level ControlThe oil tank has a liquid level controller which is used for monitoring the liquid level in the oil tank. When the liquid level reaches to the maximum level, there isa light represented it. When the liquid reaches to the minimum level, thesound-light warning signature will represent that the liquid level in the oil tank is low.5.5 The Control to the Differential Pressure of Oil FilterThere are two differential-pressure switches on the twin-cylinder network-pattern oil filter. When the differential pressure between the filter’s oilin and oilout is over the setting value, the sound-light warning signature will represent that the filter element is jammed. We should let the standby one to work manually. The jammed filter element should be cleaned out or replaced in time.6. Debug and Operating Regulations：The debug to the lubricating system should be affirmed by the engineering departments such as civil engineering, machinery, electricity, heat, instrument and safetyguard that the qualifications of the trial run is prepared and then can be carried. Make sure that the connection to the electricity and heat instrument is absolutely right. The system to supply cooling water can work normally. The connection to the intermediate piping between the ball mill and the lubritory should be finished, cleaned out and achieve the standard requirement.Debug is to regulate the operating oil-pressure to the normal operation range and to adjust out the setting values of every control elements.6.1 The Operation before DebugCharging up the lubrication：The ordered lubrication will be filled by the oil filter vehicle from the lubrication hole on the oil tank into the oil tank at the maximum liquid level. The oil filter vehicle can repeat filtering the lubrication and examine the cleanliness of the lubrication. Indeed, the oil filter vehicle can keep on filtering for 60min, so there will be no solid pollutant viewed on the oil filter and the oil filter vehicle will examine whether the cleanliness of the dubbing has reached the standard requirement.Open the stopcock on the cover board of the oil tank. Let the top of the oil tank connect to the atmosphere. When opening the lubritory for the first time and there is lubrication flowed from the oil site to the oil tank, and then the lubritory can be closed. The liquid level in the oil tank will fall down after starting the lubritory at the first time, so the oil should be added to the required maximum level in time 6.2 The Debug to the Oil Pressure Control Value：The high and low pressure oil pumps are operating normally. The high and low pressure oil-pressure should operate in the normal range by regulating the relief valve and safety valve which are adjusted well before leaving the factory.According to the operating pressure, the setting value of the pressure controllerwill be adjusted on the appropriate position. The detailed elements are as below：There are two setting value of the high-pressure pressure controller (the range of it is 2.5-25MPa). Generally, it is the actual oil-pressure value when the ball mill is lifted.There are two setting value of the high-pressure pressure controller (the range of it is 4.0-40MPa).The setting value of the low-pressure pressure controller (the range of it is0.02-0.2MPa) is 0.2MPa. (It is generally a little lower the normal operatingpressure.)The setting value of the low-pressure pressure controller (the range of it is0.05-0.8MPa) is 0.6MPa.6.3 The Debug to the Temperature Control Value：The setting value of the temperature controller and the electrical crunode thermometer should be adjusted on the appropriate position. The detailed setting values are as below：The setting value of the temperature controller (the range of it is 10-40 Celsius degrees) is 10 Celsius degrees. The differential value of it is 3-5 Celsius degrees.The setting value of the temperature controller (the range of it is 40-80 Celsius degrees) is 10 Celsius degrees. The differential value of it is 3-5 Celsius degrees.The setting value of the electrical crunode thermometer on the oil tank：The minimum value is 10 Celsius degrees and the maximum one is 55 Celsius degrees.The setting value of the electrical crunode thermometer on the low-pressure oilout：The minimum value is 10 Celsius degrees and the maximum one is 60 Celsius degrees.6.4 Adjustment Method：The adjustment to the electrical crunode thermometer：Insert the small key or screwdriver on the electrical crunode thermometer to the dial hole in the middle.Dial the driving lever in the meter to make the upper or lower pointer at the required value.The adjustment to the temperature controller：Unbolt the lock nut on the regulating lever of the setting value at the left-upside. Use screwdriver to rotate the regulating lever. Make the pointer at the temperature setting value required to be controlled. Then screw down the lock nut. Rotate the switching differential knob to make some value between one and three aiming at the red dot in the middle, which is to get the required switching differential value.Notice：Don’t allow to rotate the switching differential knob. The lock nut on the regulating lever of the setting value at the left-upside must be screwed down, because any looseness will cause the setting value changed and affect the control function.The adjustment to the low-pressure pressure controller：Connect one end of the wire to the plug, while the other end is connected to the multimeter. Open the oil pump electromotor and keep the oil pressure at 0.15/0.6MPa. Loose the lock nutof the pressure controller. Use the 5mm socket head screw spanner to rotate clockwise the setting value in order to adjust the hexagon groove. The setting value is from small to big until the contact is switch here. Screw down the lock screw. The oil pressure of the system will change around there values. Examine whether the switching difference of the contact will be at some value when the oil pressure reduces. The value is to be set.The adjustment to the high-pressure pressure controller：Connect one end of the wire to the plug, while the other end is connected to the multimeter. Open the oil pump electromotor and keep the oil pressure at ……. Loose the lock nut of the pressure controller. Use the 5mm socket head screw spanner to rotate clockwise the setting value in order to adjust the hexagon groove. The setting value is from small to big until the contact is switch here. Screw the lock screw. The oil pressure of the system will change around there values. Examine whether the switching difference of the contact will be at some value when the oil pressure reduces. The value is to be set.Notice：Don’t be allowed to loose the lock screw which is screwed down, because any looseness will cause the setting value changed and affect the control function.6.5 The debug process should be followed as below：The oil pressure should be kept above 10 Celsius degrees. Switch the reversing handle of the twin-cylinder network-pattern oil filter to one of the filter elements.Debug the low-pressure system：Shut the discharge hole and oilout valve. Open the switches of the other valves and pressure gauge. Turn each shaft coupling set on the electromotor pump manually separately. No emphraxis feeling. Inch examination. The turning of the electromotor should be right.Open two low-pressure oil pump electromotor separately. Shut the by-path valve on the exit piping slowly. Observe the two pressure gauges that represent the oil pressure climbing slowly. When the valve is shut totally, the oil pressure should be kept at the 0.6MPa which is adjusted by safety valve. Run for 10min and the low-pressure oil pump electromotor should be with no exceptional sound. No oil leaks and other phenomenon on each jointing and interface.Open the oilout valve. The dubbing through the intermediate piping flows into each oil site of the ball mill and back to the oil tank. Observe the two pressure gauges that represent the oil pressure falling correspondingly and keep at a certain value which is the normal operating oil-pressure (Generally, it is 0.2-0.4MPa.).The low-pressure system enters into the normal operating situation at this time.Debug the high-pressure system：(Now the low-pressure should be in the normal operating situation, otherwise the high-pressure oil pump will be broken.)Shut the oilout valve. Open the switch of the pressure gauge. Turn each shaft coupling set on the electromotor pump manually separately. No emphraxis feeling.Inch examination. The turning of the electromotor should be right. Open the No.one and two high-pressure oil pump electromotor separately. The oil pressure should be kept at 31.5MPa which is adjusted by the relief valve. Run for 10minand the low-pressure oil pump electromotor should be with no exceptional sound.No oil leaks and other phenomenon on each jointing and interface.Open the oilout valve. No one and two high-pressure oil pump electromotor is electrified. Observe the two high-pressure pressure gauge. The oil pressure will ascend and fall back at a steady value which is the normal operating oil-pressure (Generally, it is at the range of 6.0-20.2MPa.). Run for 10min and use the meter to measure the lifted value of the principal axletree at the ball mill. The high-pressure system enters into the normal operating situation at this time.Debug the standby high-pressure oil pump：(Now the low-pressure should be in the normal operating situation, otherwise the high-pressure oil pump will be broken.)No. 3 high-pressure oil pump electromotor is electrified while No. 1 is cut. The electromagnetically diversion valve is cut too. Observe the high-pressure pressure gauge at the oilout. The oil pressure will ascend and fall back at a steady value.Run for 10min.No. 3 high-pressure oil pump electromotor is electrified while No. 2 is cut. The electromagnetically diversion valve is cut too. Observe the high-pressure pressure gauge at the oilout. The oil pressure will ascend and fall back at a steady value.Run for 10min.The lifted oil-pressure of the ball mill will be higher at the heavy-duty situation than the empty-duty. That of the principal axletree is low.6.6 After the low and high pressure system all enter into the normal operatingsituation, the ball mill can be started. The electricity and heat instrument personnel can take the analogue interlocking experiment. When finishing the analogue interlocking experiment, the ball mill will enter the test run.7. Daily Operation and Maintenance：7.1 All the lubrication should be assayed and examined at a particular time. It shouldbe replaced in time if disqualification. The process of changing oil should repeat the 6.1 operation.7.2 After finishing the debug, any valve can’t be rotate optionally.7.3 When the lubritory is working, if the oil pressure, temperature and liquid level areabnormal, there will be the corresponding signature lighted and some of them have sound warning. Turn off the warning first and mend according to the position represented by the signature.7.4 The seal ring at the oil pump axletree should be examined frequently and replacedimmediately when occuring the oil seepage or broken phenomenon.7.5 According to the situation of the water qualification, the columnwise coolershould be taken an inner examination and cleanout every six to twelve months.And replace the inner seal ring when necessary.7.6 The oil filter should be unpicked and washed every three months in order to wipeoff the accumulated filth in it. Clean out or replace the filter element in time。
稀油站使用说明书
一、概述标准XYZ-63G电气控制柜采用继电器控制，不间断向系统循环供油的电控系统。
标准XYZ-63G电气控制柜具有功能强，使用寿命长，故障率低的等一系列优点。
二、使用条件2.1主回路电源:3N4Φ 50HZ AC380V2.2控制电路电源:50HZ AC2202.3海拔高度不超过1000米.2.4周围空气温度:不高于40摄氏度,不低于负10摄氏度.2.5周围空气湿度:最湿月平均最大相对湿度为90%,同时该月平均最低温度为25摄氏度.并考虑到温度变化发生在元器件表面的凝露.2.6在无爆炸危险的介质中,且介质中无足以腐蚀金属和破坏绝缘气体和尘埃.(包括导电尘埃)2.7无显著震动和冲击的地方.2.8垂直安装,安装倾斜度不大于5度.三、电气控制原理标准XYZ-63G电气控制原理如图.本装置有单动,自动两种状态.1. 单动工作:把转换开关SA1打到单独,并将转换开关SA2打到机旁,按下启动按钮SB2(或SB4),一号泵(二号泵)单动启动,按下停止按钮SB1(或SB3),一号泵(二号泵)单动停止,此工作状态用于安装完毕用于机旁调试和故障情况下.2.自动工作:把转换开关SA1打到一号泵为主(或二号泵为主),并将转换开关SA2打到机旁,一号泵和二号泵互为主泵,按下启动按钮SB2(或SB4),启动一号泵(或二号泵)，如果压力低于正常值,备用泵自动启动,到压力正常时停止备用泵.此工作状态用于正常工作情况下.本装置加热器有手动,自动两种状态.1.手动工作:转换开关SA3打到加热手动,按钮SB6启动加热器,按钮SB5停止加热器.2.自动工作:转换开关SA3打到加热自动,油温低时启动加热器,油温高时停止加热器.故障:1.压力过低:压力低于下限报警。
2.油位低:油位低于下位时不能起泵并报警.3.油位高:油位高上位时发轻故障信号.4.压差高:压差高于上限报警.5.出口油温高:出口油温高于上限报警.四、注意事项4.1控制柜在使用前必须校对电压。
油站使用说明
P—PLC 控制；省略--继电器、接触器控制 流量：L/min 稀油润滑装置
2、XGD-A 型 高低压稀油润滑装置主要用于水泥磨、煤磨机主轴承的润滑。 向水泥磨、煤磨机主轴承（简称主机）等的磨擦部位强制供送润滑油，在相 对运动的机器零件之间形成油膜，减少零件的摩擦、磨损。同时对摩擦部位 进行冲洗，带走摩擦产生的热量，保证机器正常运转，延长机器寿命。XGD-A 型高低压稀油润滑装置高压油泵待主机形成油膜后停止运行，短时工作。 该油站工作介质为粘度等级 N22～N320 极压工业齿轮油或油膜轴承油以及其 它机械润滑油。
动作
中控死机，造成 油站停止运行， （1）硬联锁未完善 但主机还在运行
（1） 将允许主机启动的长闭 点并入主机跳闸回路； 将主机运行由硬联锁提 供
第 14 页 共 16 页
螺杆泵故障及消除方法
序号
故障
1
流量减少
2
吸油减少
3
压力不够
4
异常的噪音和振动
螺杆泵磨损加快
5
可能引起故障的原因 系统元件故障
泵内进入空气 泵的转速太低 错误的旋转方向
二、 稀油润滑装置 1、稀油润滑装置外形及各部件：
过滤器
冷却器
安全阀
回油口
润滑油泵 组
单向阀
加油孔 油箱
XRZ 型
第 2 页 共 16 页
高压泵组
回油口
过滤器 安全阀 低压泵组
油箱
XGD-A
高压泵组
补偿装置
低压泵组
安全阀
止回阀
空气过滤器
油箱 板式冷却器
加热器 液位控制器
XGD-C
铂热电阻
温度计
吊耳
（1） 循环水量低于我公司要
立磨减速机油站使用说明
XGD-B-120-350高低压稀油站使用说明书贵州黔沪水泥有限责任公司2013年2月26日整理缪维纲注意事项1、安装、使用前，请仔细阅读说明书。
2、油箱和电柜外壳必须可靠接地，以确保人身安全。
3、现场手动通常用于调试或应急运行。
此时，备用泵不能自动启动，加热器不能自动恒温，操作人员不得离开现场。
4、本装置及电控柜不能露天使用，如需露天使用，请在订货时说明。
5、海拨高度小于1500米、无振动、无腐蚀性气体、无明火、无爆炸的环境。
6、、环境温度0-40℃，相对湿度：≤90%（25℃时）7、电压波动小于10%，冷却水温度≤32℃，压力0.2-0.3MPa,8、不得将220V及以上的电源线接入控制柜的信号回路，否则会烧坏PLC.目录概述 (1)主要性能参数 (1)工作原理 (3)试运转、调试 (4)维护和安全技术 (5)概述：本高低压稀油站，主要用于立磨减速机，对静压油膜与齿轮箱提供润滑。
稀油站主要由齿轮泵（低压两台）、柱塞泵（高压两台）、双筒网片式过滤器（两台）、油冷却器、油箱、阀门、管道等组成，稀油站为分体式结构。
本润滑装置由稀油站、仪表盘、补偿装置、电控柜组成。
1、主要参数XGD-C120/350参数型号参数型号低压齿轮泵2台CB-BM 公称压力1MPa公称流量L/MIN 350 电机功率11KW电机转速r/min 1450 低压工作压力0.2-0.4MPa低压过滤精度mm 0.08 高压柱塞泵4台63SCY14-1D高压公称流量l/min 2×60 高压公称压力MPa 25高压电机功率KW 22 电机转速r/min 9700.04高低压工作压力MPa 14（暂定可调节）高压油过滤精度mm冷却面积为m228 冷却水耗量m3/h 31油箱外形尺寸mm 2700×1500×1290 油站外形尺寸mm 2950×2150×2400 油站重量kg 4000 工作介质N220-N320工作温度℃38-422、工作原理：2.1油站为整体式结构（见外型图），油站工作原理见（系统图）,油站由低压供油系统与高压系统组成，低压油出口除直接提供齿轮润滑外，同时以高压泵吸油口供油，两台高压泵形成分十六路高压，供油系统直接将高压油输送至主机各供油点。
XYZ稀油站通用说明书
XYZ系列稀油站说明书一、简介本装置主要适用于水泥、冶炼、轧制、矿山、能源、轻工、交通、运输、石化和电力等机械设备的稀油循环润滑系统中，向主机齿轮箱的齿轮和轴承等摩擦部位供送润滑油，起减摩擦和冷却润滑作用，保证供油和润滑质量，使主机设备连续正常运行。
其工作介质为N220～N320中负荷工业齿轮油或其它机械润滑油。
本装置由稀油润滑站,仪表盘,电控柜配套组成。
型号说明: 选型时采用XYZ- ※※P： PLC控制省略：继电器、接触器控制流量：L/min稀油站如：稀油站，公称流量125L/min，用PLC控制，则选型：XYZ-125P三、工作原理与结构特点稀油站由油箱、油泵装置、油冷却器、油滤器以及电控柜、仪表盘、管道、阀门等组成。
工作时，油液由齿轮泵从油箱吸出，经单向阀、双筒网片式油滤器、列管式油冷却器，被直接送到设备的润滑点进行润滑，然后经系统回油管流回油箱。
油站的最高工作压力为0.4MPa,最低工作压力为0.2MPa（视现场情况可重新设定），根据润滑点的要求，通过调节安全阀确定使用压力。
当油站的工作压力超过安全阀的调定压力时，安全阀将自动打开，多余的油液流回油箱。
稀油站具有过滤、冷却、加热等装置和安全、自控、报警等功能。
本稀油站有以下结构特点：1.设有备用油泵。
稀油站有两台油泵，一台工作，一台备用，正常情况下工作油泵运行，当系统压力低于压力调节器调定值时，备用泵投入运行，保证向主机继续供送润滑油。
2.采用双筒网片式油滤器。
双筒网片式油滤器有两组过滤滤芯。
一组滤芯工作，一组滤芯备用。
当工作滤芯需要更换时，可不停机，用转换阀使备用滤芯工作，即可取出原工作滤芯，更换滤片。
此油滤器结构紧凑，接管简单，不设旁路，更换方便。
3.采用GLCQ、GLLQ型列管式油冷却器。
换热管为紫铜管，冷却效果较好，体积小，重量轻，阻力降大大小于板式换热器，在工作压力本身不高的稀油润滑系统中使用是比较合理的。
4．回油口设有磁性过滤器。
GXYZ-63G型双高低压稀油站的使用、常见故障及维护进行简要的介绍
高低压稀油站的使用、常见故障及维护我厂5#窑系统稀油站主要有低压稀油站、单高低压稀油站、双高低压稀油站三种，低压稀油站由于结构简易，控制简单，设备运行过程中很少出现故障，而高低压油站结构复杂，控制烦琐，时有故障影响生产。
单高低压与双高低压油站相比，其工作原理基本相同，但控制稍微简单，下面就我厂GXYZ-63G型双高低压稀油站的使用、常见故障及维护进行简要的介绍。
一、结构与工作原理1、结构：双高低压稀油站有低压润滑系统和高压润滑系统组成。
低压润滑系统主要由两台立式齿轮泵装置、油箱、过滤器、冷却器、安全阀、阀门、管道等组成；高压润滑系统主要由两台高压泵装置（煤磨单高低压稀油站为一台高压泵）、高压溢流阀、单向阀、高压管道等组成。
2、工作原理：在主机起动前，先起动低压泵，当低压泵运行稳定后（2分钟），再起动高压泵，高压泵的润滑油由低压管道吸入，再送到滑履轴承，当压力达到一定值，使静止的轴和轴承之间充入足够的油膜，主轴将在压力油作用下浮起，以减小摩擦，此时即可开动主机运转，主机运转平稳后（10分钟，煤磨单高低压油站为3分钟），自动停止高压泵，由低压泵供油润滑。
在主机停机前，先将高压泵开启，压力达到一定的稳定值时，方可停主机，待主机完全停稳后，再停止高压泵，3、低压润滑系统设有两台泵，正常情况下，一台工作，一台备用，遇有意外，低压润滑系统压力降到低压于第一压力调节器调定值时，备用油泵投入工作，保证向轴承继续供送润滑油。
压力达到0.3 Mpa 备用油泵自动停止，若此时压力继续下降到第二压力调节器调定的最低压力时，报警器将发出压力过低事故信号。
4、过滤器采用双筒网式过滤器，稀油站运行时，一筒工作，一筒备用，在进出口外接有一只压差控制器，当压差超过0.1Mpa，报警器将发出压差过大信号，可进行人工换向，备用筒工作，取出滤芯进行清洗，然后放入滤筒备用。
5、油箱中设有电加热器，用来加热油箱中的润滑油，加热温度可进行自动控制，当油温低于某一设定温度时，加热器自动投入工作，当油温高于某一设定温度时，加热器自动停止工作，电加热器是由装于油箱上的电接点双金属温度计来控制的。
稀油站说明书
1．用途XYZ200-L立式稀油站是北京电力设备总厂设计制造的，为ZGM95型磨煤机用SXJ140型立式螺伞-行星减速机配套的专用润滑装置，用于润滑减速机中的齿轮和轴承，起到润滑、冷却和清洗的作用。
2．工作原理稀油站在正常工作时，电机螺杆泵将润滑油从磨煤机减速机下箱内吸出，送入加热器，经管路进入双室过滤器的一个滤筒，再沿管路进入冷却器，然后被送到各个润滑点，润滑油经过润滑部位后汇集于减速机下箱，再经电机螺杆泵吸出，如此循环往复，使润滑油在系统中循环，确保系统各部位的正常润滑。
3．结构特点XYZ200-L立式稀油站由电机螺杆泵、电加热器、双室过滤器、冷却器以及阀门、管道、仪表和底座等组成。
所有零部件均安装在底座上组成整体式结构，稀油站无自带油箱，减速机下箱体就作为稀油站的油箱。
各部分的结构特征如下：3.1电机及三螺杆泵：立式，配双速电机，带安全阀。
驱动采用YD160M-8/4 V1型双速电动机，其功率为5.0/7.5kW，对应转速为720/1450 r/min。
若稀油站启动时油温<25℃时，先令电机720r/min运转，直到油温达到28℃时，再改用1450r/min运转。
油泵上装有对油泵和系统起过载保护作用的安全阀，阀的调节压力为0.63MPa，可保证安全运行。
3.2电加热器：带纵向折流。
纵向折流板将加热管分隔为三个区间，油和加热管间的相对流速增加，可避免因油流死角导致的油温过高区；加热管温度均衡减少了结炭现象；同时采用了能放尽空气的放气结构，保证油加热管温度最高的上部能浸入油液中；这些都提高了加热效率和延长了加热管的使用寿命，同时也减少了顶罩部分的温升，并且油液不易氧化变质，延长了油液的使用寿命。
3.3双室过滤器：采用纵向导流和上下磁过滤结构，带三位六通换向阀。
油液由换向阀进入过滤器中部后，由导向套引入下部，先均匀地经过下部磁过滤装置并由下而上均衡地通过滤网，再同样均衡地流过上部磁过滤装置，最后经换向阀进入下一个循环装置。
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GXYZ-B2×5/40
高低压稀油润滑装置
使用说明书
重庆诺普信液压润滑设备制造有限公司
目录
1、概述
2、主要性能参数
3、工作原理
4、试运转、调试
5、维护和安全技术
1、概述:
本高低压稀油润滑装置, 用于电机主轴承, 对静压油膜轴承提供高压支撑及润滑。
稀油站主要由齿轮泵( 低压) 装置( 两台) 、轴向柱塞泵( 高压) 装置( 两台) 、双筒网片式过滤器、油冷却器、油箱、阀门、管道等组成, 稀油站为整体式结构。
本润滑装置由稀油站、仪表、电控柜配套组成。
2、主要性能参数:
2.1低压供油系统:
2.1.1齿轮泵( 低压) 装置
-40( 2台)
型号: LBZ
1
公称流量: 40 L/min
公称压力: 0.6 MPa
电机型号: Y100L1-4B5
转速: 1430 r/min
功率: 2.2 kW
2.1.2过滤器
型号: SPL32C/SPL25C
过滤精度: 0.08 mm/0.025 mm
2.1.3油冷却器
-4/0.63
型号: GLCQ
3
工作压力: 0.63 MPa
热交换系数: ≥300 Kcal/m2.h.℃
2.1.4电加热器
型号: SRY2-220/3
功率: 3kW×3=9 kW
2.1.5油箱
有效容积: 1.6 m3
2.1.6油站外形尺寸: ～1830×1455×1880( 长×宽×高)
2.1.7工作介质: L-TSA46
2.1.8油站净重: 约1200Kg
2.2 高压系统:
轴向柱塞泵( 高压) 装置
型号: 10SCY14-1B
公称流量: 5 L/min
公称压力: 25 MPa
系统最高工作压力: ≤16MPa( 暂定)
电机型号: Y112M-4B35
电机转速: 1430 r/min
功率: 4 kW
3、工作原理:
3.1该油站为整体式结构( 见外形图) , 稀油站工作原理图( 见系统图) , 稀油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润滑外, 同时对高压泵吸油口供油。
3.2 低压系统由两台齿轮泵( 一台工作, 一台备用) 组成, 齿轮泵出油口压力经安全阀调定约0.4MPa, 流经过滤器, 过滤精度≤80μm, 再流经油冷却器, 由冷却水的启停控制出口油温为38～42℃范围。
冷却器后低压油出口, 一部份通向主机提供润滑, 一部份向高压泵吸口供油, 高、低压系统工作压力均由压力变送器控制, 保证高低压系统的正常工作。
3.3油站启动前, 油温低于38℃时, 电加热器可自动先启动加热润滑油, 油温达到25℃后, 启动低压泵, 运行3～5分钟, 使润滑油在系统中循环后, 再提供给主机润滑, 在正常运行中, 出油口油温为40±3℃, 出油口油温高于43℃冷却器运行, 低于38℃时冷却器停止工作。
3.4当低压油压力达到0.2MPa时, 高压泵才能启动, 当高压泵出口压力达到一定值, 主电机才能起动, 当工作台未浮起时, 不得强行启动主电机。
当高压泵出油口压力达到20MPa( 暂定) 时, 声光报警, 主机停车。
3.5主机正常运行中, 低压供油压力低于0.12MPa时, 备用泵自动启动, 同时声光报警, 油压升至0.4MPa时, 备用泵自动停机, 当压力继续下降至0.1MPa时, 停车报警, 高于0.5MPa时, 发出报警讯号。
3.6油箱油位由油位发讯器控制, 最高或最低油位发出报警讯号, 若油位过低时,
发出停车讯号, 主机停车。
3.7主机停车后, 供油系统的延续时间为1分钟。
3.8当稀油站过滤器前后压差高于0.1MPa时, 声光报警。
4、调试、试运转:
4.1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。
4.2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。
4.3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。
4.4启动油泵电机前, 应采用点动方式, 观察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。
4.5压力设定值及压力联锁的动作和信号应与设定相符。
4.6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。
4.7在调试过程中, 应及时注意高压系统的压力变化, 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。
4.8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。
4.9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40～50℃, 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。
5、维护和安全技术
5.1齿轮油泵使用与维护
5.1.1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。
转动联轴器是否灵活。
5.1.2油泵应尽量接近油箱, 吸入高度不得大于500毫米。
5.1.3油泵应牢固地加以固定, 进出口管接头, 不得有松动现象。
5.1.4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。
5.1.5油泵使用时应按标牌所指示方向转动。
5.1.6溢流阀应尽可能靠近油泵, 最好是直接与油泵相连。
5.1.7油封是易损件,如果主动轴出现漏油现象,应更换油封。
5.1.8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。
5.1.9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。
5.1.10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。
5.1.11停止工作时先关闭电动机开关, 然后再关闭油管中的阀。
5.2冷却器使用与维护
5.2.1操作规程
a使用前检查所有附件与仪表, 并查看各连接处是否紧固。
b将冷却器热侧排气阀打开, 再缓缓开启热进阀门( 此时热介质排出阀处于关闭状态) , 当热介质充满后, 关闭热进阀门及热侧排气阀。
c将冷却器冷侧排气阀打开, 再缓缓开启冷进阀门( 此进冷介质排出阀处于关闭状态) , 当冷介质充满后, 关闭冷进阀门和冷侧排气阀。
此时两种介质均成静止状态, 经热交换后, 温差逐渐减小。
d冷侧介质温升5～10℃后, 打开冷热介质的进出阀, 使冷热介质均处于流动状态, 然后调整两种介质流量, 使温度达到工艺要求。
e冷却器因故或正常停止工作时, 其操作步骤应按启动的逆过程进行。
5.2.2使用中的注意事项
a在开动冷却器时, 切忌快速打开冷进阀门, 因为冷介质大量流过冷却器时, 会使换热管表面形成一层导热性很差的”过冷层”, 即使以后冷介质流量很大, 也起不到良好的换热作用。
b如果冷介质为水, 当发生电化腐蚀时, 能够自行在水侧选择适当位置安装防电化腐蚀的锌棒。
c冷介质一般采用净化的淡水, 为防止水垢形成, 水的温度尽可能要低些,水流量要大些。
5.2.3维修、保养
冷却器经过长期工作后, 有腐蚀生成物、沉积物及水垢等附着于管壁, 会降低传热系数、影响传热效率及增大压降, 因此, 视具体情况, 及时清洗, 以保证冷却器性能。
a拆装方法
a.1关闭冷、热介质的进出口阀门, 排尽冷却器内剩余的介质, 然后从系统中拆卸下来。
a.2打开冷却器, 拆去两端头盖, 取下密封垫。
a.3由固定管板侧将管束从壳体中抽出来, 注意轻拿轻放, 以免损坏换热管。
a.4装配顺序应按拆开的逆过程进行, 要特别注意密封垫的装配, 密封垫不得扭曲或损伤。
a.5装配完毕, 应按1.25倍工作压力进行水压试验, 合格后排尽积水装入系统中。
b清洗方法
b.1用软管引洁净水高速冲洗头盖、后盖、壳体内壁及换热管内、外表面, 同时用清洗通条洗刷换热管内表面, 洗毕后, 用压缩空气吹干。
b.2清洗液冲洗法: 用泵将清洗液强制经过冷却器, 并不断进行循环, 清洗液压力不大于0.5MPa, 流向最好与工作介质流向相反, 清洗时间视结垢情况而定。
清洗完。