Equipment Operation&Maintenance Manual

设备运行维护手册Equipment Operation&Maintenance Manual
第三篇 设备运行维护手册
Part 3 Equipment Operation&Maintenance Manual
一、 安全提示和警告
Safety Tips and Warnings

● 在任何维护或维修之前，必须严格遵守操作规程。
● Before any maintenance repair, you must strictly observe the rules。
● 只有专业人员才能安装、操作、检修和维护该设备，专业人员指“熟悉设备
结构、操作以及危险的人”。
● Only the operators who are familiar with the equipment, structure, operations and
risk, can install, operate, repair and maintenance of the equipment,
● 不要带电连接或断开任何表计、电缆和印制线路板。
● Don’t connect or disconnect any meter, cables and printed circuit boards in
charged state
● 在箱内靠近或接触元器件时要消除静电（ESD）。印制线路板上有许多元件对
静电很敏感。接触或维护 对静电敏感元器件的工作只能由阅读并理解专门静
电技术的专业人员完成。
● Before close to or operate the Main Unit, eliminate static electricity. Because there
many PCB components are very sensitive to static electricity.
● 手持PC板时，尽量握住边缘部分。
● Handing PCB, hold the edge of some as far as possible
● 不要使印制线路板与任何表面（桌面或工作台面）发生摩擦。如可能，进行
PC板维护时在 具有导电表面（通过1M欧电阻接地）的工作台上进行。如没
有合适的导电工作台，可用干净的钢板或铝 板代替。
● Stop PCB chafing on the surface of anything(desk or workbench).
● 不要将易燃材料放在机箱里面、上面或附近，包括设备图和用户手册。
● Do not put flammable materials inside the chassis, or in the vicinity of the above,
including equipment, maps and user manual.
● 接触或测量箱内元件时必须十分小心，千万注意防止表棒引起短路。
● When touch or maintain the component of the main unit carefully, avoid a short
circuit caused by sheet rod.
● 现场维护时，应注意防止接触取样器和测试箱内加热部件烫伤和触电。
● When maintain the device,take care to prevent contacting with the
sampling and being scalded by the heating component and electric shock

二、 常规检查维护事项
Routine Maintenance Checks

装置应安排专人定期进行维护，主要检查事项如下：

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设备运行维护手册Equipment Operation&Maintenance Manual
Devices should be arranged the regular follow:
? 测试箱内器件之间连接是否松脱，螺丝螺母紧固件是否松动；
Whether the components of the main unit and the screw nut fasteners
become loosened
? 箱内工作温度是否异常,当环境温度为5℃--30℃时，调节左温控仪为100℃
左右，调节右温控仪 为130℃左右；环境低于5℃（高于30℃）时，将两温
控仪分别调至110℃和140℃（90℃和 120℃）。
Whether the temperature of the main unit is the
circumstance temperature is in the range of 5℃--30℃,the left
Temperature Controller should be adjust to about 100℃,and the right
Temperature Controller should be adjust to about 130℃. If it’s beneath
5℃（above 30℃）,the both should be adjust to 110℃ and 140℃（90℃
and 120℃）。
? 观察一个完整的测量周期，检查收、排灰情况是否正常；
Observed a complete measurement cycle, and check the collection and
ejection of ash whetherit is normal.
? 加热套是否加热；
Whether heating pad is heating
? 飞灰取样器喷射嘴是否有堵塞；
Whether sampler’s ash intake nozzle is jamed
? 检查油雾器是否有油;
Check whether there is oil in Oil mist device
? 收油器定期清理；
Oil closed must be regularly clean-up
? 前置单元中WBA 4.2的“吹扫”“换向”“振动”开关控制是否正确无误；
Whether the “Purge”、”Swerve” and ”Vibration” Switch of WBA 4.2 Card
in the Pre-Unit box can operate correctly.
? 各减压阀压力表是否指示正常；
Whether each pressure relief valve show normally
? 软件界面含碳量显示是否显示正常；
Whether the show of carbon content on soft interface is normal
如果遇到无法自行解决的问题，应及时和厂方技术人员取得联系，避免事故
进一步扩大。
If you experience problems that are unable to solve , contact our
Technical Support Engineer to prevent furthering more accidents.


三、 常规维护指导

Routine Maintenance guidance
1） 取样器的维护

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设备运行维护手册Equipment Operation&Maintenance Manual
The Maintenance of Sampler
飞灰装置作为在线式取样测量装置，一般安装于空预器后除尘器前烟道内，在
The device which is the on-line sampling measurement device,is installed on the
Flue between the Dust Cleaner and the Air Preheater. In the course of sampling,

the
装置取样工作过程中，高温烟气对伸入烟道的取样管以及取样管路进行冲刷，在长期
high-temperature flue gas is eroding the internal and external sampling tube inside
工作过程中，取样单元的器件会出现磨损情况，主要是旋流集尘器、取样管、取样器
The components of sampler will be wore each day as time go by. That mainly concentrate
in the cyclone dust collector, sampling tube, sampler exhaust pipe.d
排气管的磨损，图1所示为取样单元结构图。取样器由吸气嘴、取样管、引射管、连
Picture 1 is the structure picture of sampler. The sampler is composed of Ash Intake Nozzle
接板、排气管、调节喷嘴、螺母、压圈、旋流集尘器腔等组成。
Sampling Tube、Ejector Tube、Exhaust Pipe 、Connection Plate and so on


图1 飞灰取样器结构示意图
Picture 2 Fly Ash Sampler Structure Diagram

取样器排气管是飞灰取样器的重要部件，它承担了取样时的排气和灰样返回烟
The Exhaust pipe which is the important component of sampler,assumes the role of
道通路的作用。当装置工作一段时间后，在取样器的调节喷嘴和排灰管内壁上会沾结
exhausting gas and sample back to flue. When the device works for some time,adjust
nozzle and exhaust pipe will particle agglomerate in tube inside-wall.

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设备运行维护手册Equipment Operation&Maintenance Manual
一些灰 尘和结焦，如果长期不进行清理，会造成排灰管灰路变细，甚至堵死，从而
使取样器不能收集灰样。
If not being clean-up for long time,

it will block the road of ash exhausting out,so that the
sampler is not able to collect sample.
如果取样排气管发生堵灰，进入旋流集尘器的飞灰并不能排到烟道里，导致旋
If exhaust pipe block up, the ash entering the cyclone dust collector will not be
流集尘器发生堵灰，取样管发生轻微的堵灰，长期不维护，取样管中飞灰越积越多，
ejected to flue, so that it was block up. If no long-term maintenance, ash in the sampling
tube will accumulate more cumulative,so that it make a serious clogging.
发生严重堵灰。
如图2所示，排灰管由锁紧螺栓、调节喷嘴、弯管、螺母、压圈组成，维护时
Ash excluder is comosed of screw fastening、adjust nozzle、bend tube、nut、washer.
用扳手将螺母旋下，将排气管从集尘器帽上取下，用金属器械捅去管内的沾结物。如
In the maintenance,use spanner to rotate nut out, and take exhaust pipe out of the cyclone
dust collector , and then stab coagulation stick.
发现磨损，需及时更换。
If discover abration, replace it timely.

Screw
Fastening

Exhaust Pipe


Nut

Copper
hoop
Adjust
Nozzle
Cavity
Cap

图2 排灰管装配图
Ash Excluder Assembly Drawing
拆卸时的几点注意事项：
Some disassembly notice as follow:
a) 不要将压圈掉落，否则弯管固定不紧。
Don’t lose the ring, otherwise the exhaust pipe will fasten loosely.
b) 由于旋流集尘器表面温度较高，维护时要注意带手套工作，以防烫伤。
As a result of higher surface tmperatures of cyclone dust temperature, glove must
be wore in time of maintenance to prevent scald.

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设备运行维护手册Equipment Operation&Maintenance Manual
c) 安装完毕时要调整调节喷嘴，使之位于引射管轴线的位置上。
After installation, the adjust nozzle should be adjust to the front axis of the ejector tube
d) 调节弯管上喷嘴，使之与喇叭口间保持适当间隙。
Ajuctthe adjust nozzle to maintain an appropriate gap between nozzle and the mouth
of the adjetor tube.
f) 调节完成后，请拧紧锁紧螺栓。
Finish that,wrest the nut tightly
g) 如果弯管发生堵灰，清理后下灰仍不正常，请清理集尘器腔和取样管。
If ash collection is irregulary after cleaning up coagulation inside the exhaust
pipe,just clean up cavity of the dust collector and sampling tube.

2）单向阀的维护
Maintenance for Unilateralism Valve
Picture 3 is unilateralism valve structure diagram，










Nut
Filter Ne
t
Filter Core
Copper
hoop Fastness Frame
图 3 单向阀结构图
Unilateralism Valve Structure Diagram


由安装座、压片、XQ110601型单向阀、接头、螺母等组成。当压缩空气中的杂
Unilateralism valve components is composed of Fastness Frame、Pressed Article、
XQ110601 unilateralism valve、Joint、Nut and so on. When impurities within
质或管路中的污垢渗入单向阀中过滤器滤芯后，会增加空气阻力，从而使吹扫测量管
compressed air or dirt in the unilateralism valve infiltrate filter core,that will increase air
Pressed
Article

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设备运行维护手册Equipment Operation&Maintenance Manual
的压缩空气流量变小，有时会造成测量管中的灰样吹不干净，甚至测量管中的灰样不
resistance, so that the flow of air compressed air purging measurement tube reduce.
Sometime it will cause sample within measurement tube purging uncleanly, and forcing
能更新；如果单向阀漏气会导致装置下灰少或无法下灰；以上两种情况就需要更换单
to keep the same. Once unilateralism valve leak, it will cause the device to collect ash less
or collect ash hardly. If that will happen,it has to been changed
向阀。

3）测量管的维护
Maintenance for Measurement Tube
图4为测量管和单向阀安装图，测量管与上下管接头一体连接。当测量管被磨
Picture 4 is Measurement Pipe and Unilateralism Valve Assembly Drawing. The
measurement tube connect with upper and nether joint s. When the measurement tube
损导致气密性不良时，装置不能正常采集灰样，此时需要更换测量管。
ware to cause seal badly, the device can not collect sample normally. At the same
time,replace the measurement tube.







单向阀

Unilateralism Valve
下管接头
Nether Connector
谐振腔
上管接头
Upper Connector
测量管
Unilateralism Valve
Resonant Avity

图4 单向阀与测量管安装图
方法是：把测量管从中间剪断，分别旋下上、下管接头并取出两截测量管；换用
As follow: The measurement tube is sniped from center into two parts. And then, screw
off upper joint and nether joint , and take off them. Next replace new
新的测量管和压圈（铜箍）将其与上管接头连接好，从上端穿入谐振腔后用新的压圈
measurement tubes and use a Copper hoop to connect them with the new joint s. And then,
put it through the resonant avity and connect it with the nether joint. At last,

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设备运行维护手册Equipment Operation&Maintenance Manual
与下管接头连接；重新将上下管接头固定于相应位置。
re-fixup upper and nether joint s to the corresponding position.


4）油雾器加润滑油及收油器的清理
Lubricating to Oil mist device and Cleaning up Oil recovery devices
图5为油雾器的外形示意图。
Picture 5 is oil mist device’s structure diagram

Refueling
knob
cover

adjustment knob
Bottle
图5 油雾器外型示意图
Oil Mist Device’s Structure Diagram


给油雾器加润滑油的方法如下：先将振动器的气源关闭，再将油瓶旋下，加进
How to lubricating to oil mist device,as follow: First, shut off gas source of the
润滑油至最大刻度处（max），然后将油瓶装上，最后将振动器的气源压力调整到原
vibrator and screw off the bottle . Second, pour grease into

the max scale of the bottle. Last,
来的大小。另外，也可从加油旋纽处加油，但需要使用内六角扳手工具。进油量的大
Gas source will be restored to original state. Otherwise,you can pour oil from the cover.
But it need Hexagon Spanners. The size of refueling capacity can be adjusted by the
小可以通过调节油量调节旋纽来控制，顺时针方向调节 为减小进油量，逆时针调节
adjustment knob. The clockwise direction. is to reduce refueling capacity; and the
为加大进油量。调节方法是先将调节旋纽顺时针方向调至最小，然后再逆时针旋转
1~2圈。

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设备运行维护手册Equipment Operation&Maintenance Manual
anti-clockwise direction is to increase refueling capacity. The method is that first ajust
the bottle by refueling capacity to the minimum, and netx ajust the bottle by anti- refueling
capacity to 1-2 circle.





]








收油瓶


Oil Recovery Device



图6收油器外型示意图
Oil recovery devices’s Structure Diagram

若发现测试箱体内有油污染，可以检查油帽是否断裂或油帽密封圈是否移位，
Discoving oil dirt inside the main unit,you check whether the cover has broken or
the airproof ring shift the position. If it have to be deal with,replac with a new one.
必要时进行更换处理；也可检查接头a和振动器接头b否漏气（图7中）。
And you can check Joint
a or vibrator’s Joint b whether it leaked
装置采用收油器收集振动器排出的废油，需要维护人员定期清理收油器，以免
The device use oil recovery device made by SMC to collect waste oil discharged from the
vibrator. It require that the operator should clean up oil recovery devices regularly to avoid
影响装置正常工作，一般在油雾器加油的同时把收油器下端的收油瓶旋下进行清理。
affecting the work of device normally.



5）振动器恢复起振
Vibrator Recovering Vibration

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设备运行维护手册Equipment Operation&Maintenance Manual
记住振动气源减压阀压力值，然后将其压力调至0，将振动器右出气管从振动器
Record the pressure value of the pressure relief valve, and adjust the pressure value to
0. And then take off a right windpipe from the vibrator and a windpipe from the Current
上拔下，再拔下限流器的出气管，将限流器出气管直接插入振动器右出气口，将振动
limiter. Next, put the windpipe of the current limiter to right outlet of the vibrator and
器减压阀压力调到0.4Mpa（或者更高）,打开前置处理箱，将DKFHB-4.2电路板上
adjust the pressure relief valve to 0.4Mpa. And then opening the pre-processing box, the
vibration button switch should be turn to upside,that make vibrator to it
vibrate,turn the button switch adown, and it restored to original state.
“振动”钮子开关拨向上方（见图8），使振动器在高压力、大流量 的情况下强迫起
振，一旦起振，则将DKFHB-4.2电路板上“振动”钮子开关拨向下方，然后恢复 振
源减压阀压力以及气管连接原样，参见振动器连接图7。

振动器右出气管

振动器接头b
Right windpipe of viabrator

Connector b
振动器

Vibrator
限流器
current limiter
限流器出气管
currentlimite windpipe

三通接头
Three- channel
connector
振动器减压阀
pressure relief valve


图7 振动器连接图


Vibration Connection Graph


注意事项：
Notice：
请注意振动器固定螺母是否松动。如发现松动须立即锁紧。

If the nut fixing vibrator is loose, it must be fastened tightly
并帽knob
接头b Joint b
接头a joint a
螺母

下灰管Ash dip tube
Nut

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设备运行维护手册Equipment Operation&Maintenance Manual
6）测试箱内电路板和微波组件的连接
The connection of microwave components and circuit board within the main unit


下图是电路板DKFHB-3.2、DKFHB-4.2外形图8
Below picture is
DKFHB-3.2 card & DKFHB-4.2 Card


图8 电路板DKFHB-3.2、DKFHB-4.2外形图
DKFHB-3.2 card & DKFHB-4.2 Card

DKFHB-4.2电路板是控制继电器板，DKFHB-3.2电路板是信号前置处理板，其
DKFHB-4.2 card is control card for the relay. DKFHB-3.2 circuit card

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设备运行维护手册Equipment Operation&Maintenance Manual
is a signal pre-processing card. The SMA joint connect with the microwave
中的SMA连接器和微波源相连，Q9连接器和检波器相连。电路板同微波组件的电缆
source. And the Q9 joint connect with the microwave component
connection picture of circuit board and cable as picture 9
连接如图9。如果没有信号时，应检查电路连接电缆是否接触不良。
If there is no signal ，circuit connecting cables should be checked .



SMA Joint
Air Joint

谐振腔
Resonant cavity
微波源
Microwave source
WBA3.2
电路板
Circuit board

检波器
Microwave Detector
SMA Joint
Q9 Joint




图9 微波组件电缆连接图
The connection of microwave components








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