4.1概述Summarization

4.2安装Installation(4.2.1概述Summarization 4.2.2安装顺序Installation Sequence)

4.3液压系统 Hydraulic System(4.3.1技术参数Technical Parameter 4.3.2注意事项Note 4.3.4空载试运行No-load Commissioning 4.3.5保养及维护Maintenance)

4.4电控系统Electronic Control System(4.4.1概述Summarization 4.4.2控制功能Control Function)

1.液压破碎关断门为干式除渣系统的主要产品之一。

2.液压破碎关断门与湿式除渣系统的液压关断门类似，系统位置基本相同。

3.主要工作原理，是依靠液压油缸，实现水平挤压破碎的设备

4.详细介绍

4.1概述Summarization

液压破碎关断门又叫大渣破碎装置或液压挤渣关断门。主要作用有两个：一是对大渣进行预冷却后破碎的作用；二是在设备检修时起关断门的作用。

The Hydraulic Cut-off Gate is also known as large slag crushing machine or hydraulic slag crushing gate. There are two main functions of it: first, large slag can be pre-cooled and crushed; second, the gate will be closed during equipment maintenance, so slag can not be directly into the following equipment.

产品优点：①设置在渣井下面，冷空气进入炉膛时可以充分预热，有利于热量回收。②设置在干渣机上级，有利于冷却。干式除渣冷却的困难就是大渣块，渣块内外温差梯度大，需要较长的冷却时间。而限于空间布置和锅炉进风量要求限制，很难保证此时间。在干渣机上部预破碎后，渣块变小，内部高温可直接与冷空气换热，有利于冷却，同时增加了设备使用寿命。③挤渣门体多，无堵塞问题。对应不同的机组，渣井采用1～4口布置；对应破碎关断门也有1～4口，每口由2～3对门。在任何一对门进行挤压破碎时，另外的挤渣门处于打开状态，可以继续排渣，不影响系统的正常运行。

The Hydraulic Cut-off Gate has many advantages, for example, first heat can be effectively reclaimed. Because it is under the Bottom Slag Hopper, cold air can be effectively preheated when it into the furnace. Second, it is installed before the Air-cooled DSC, good for cooling. In Bottom Ash/Slag Dry Handing System, big slag as large temperature difference between its inside and outside is need a longer cooling time. However, it is difficult to ensure this time because the space layout and wind-inlet flow requirement. But when the slag is pre-crushing by the Hydraulic Cut-off Gate, high temperature can directly change with the cold air, not only conducive to cooling but also extend the equipment life. Third, the Hydraulic Cut-off Gate has many doors, without blocking problems. For different units/funnels, the Bottom Slag Hopper has 1 to 4 parts, so the corresponding Hydraulic Cut-off Gate also has 1 to 4 parts, and every part with 2 to 3 pairs of doors. When one of the doors operates, the others will be opened to discharge, not effect the normal operation of whole system.

液压破碎关断门安装于渣井的下面，采用自支撑式结构，与渣井间采用金属膨胀节连接，与干式排渣机间采用高强度螺栓连接。

Hydraulic Cut-off Gate installs blow the Bottom Slag Hopper, adopt self-supporting structure, connect Slag Hopper with metal expansion joint, and connect DSC with high strength bolt.

每台炉的渣井布置有1～4个落渣口，每个落渣口配有高温摄像头，用于观察落渣情况；设有观察孔和捅焦孔。每个挤渣门由2个油缸驱动，在液压缸的驱动下，挤渣门沿着其下部的耐热钢蓖管导轨做往复直线运动。每扇挤渣门都可根据实际情况单独进行操作。全部挤渣门使用一个液压站控制。每个液压站配套2台油泵，一备一用，可以相互切换。

Bottom Slag Hopper for each of boiler furnished 1 ~ 4 slag-falling units, each slag-falling unit is equipped with high-temperature camera used to observe the slag-falling situation; with observation holes and slag-poked holes. Every Gate/Door driven by two cylinders, it does reciprocating linear motion along the heat-resisting steel tube guide at the bottom of it. Every Slag Cut-off Gate may operate separately according to the actual situation. All Slag Cut-off Gates are control by one hydraulic station. Every hydraulic station sets 2 oil pumps, one use and the other stand by. They can switched with each other.

在锅炉正常运行时，挤渣门全部处于开启位置，小于200×200mm的底渣通过挤渣门下部的蓖板落至干式排渣机的输送带上；大于200mm的渣快被密集格栅拦截。此格栅具有两个作用：阻挡>200mm的渣块和承受大渣块冲击。密集格栅下面设置有大型钢结构，可承受巨大渣块从炉膛高处下落的冲击。保证除渣系统的正常运行。参见图4-2。

During normal operation of boilers, Hydraulic Cut-off Gate is in open position, all slag less than 200 × 200mm fall into the conveyor belt of DSC through the gate grid; slag more than 200mm are intercepted by the dense grid. There has been large steel structure below the dense grid. This grid also can withstand impact of large slag, to ensure the normal operation of the Bottom Ash Dry Handing System. Show in Fig.4-2.

当通过摄像头观察到有大于200×200mm的底渣落至蓖管上时，延迟一段时间（5～10分钟左右），待落下的大渣初步得到冷却后，在控制系统点击相应的挤渣门关闭按钮，挤渣门对大渣进行预破碎，破碎后的渣落至干式排渣机的输送带上。若遇到内部高温大渣快，则需要多次挤压破碎。任何一扇挤渣门可独立运动，且有3个位置响应监测点。

Observe through the camera, more than 200 × 200mm bottom slag fall on the grid, delay some times (about 5~10 minutes), after large falling slag are initially cooled, control the corresponding Slag Cut-off Gate closed button in the control system, the large slag pre-broken by Slag Cut-off Gate and then fall into the conveyor belt of DSC. Because hot sticky, it need several times to cooling & broken the big slag which high temperature inside. Any Slag Cut-off Gate can be independence movement, and three locations respond to the monitoring point.

当后续除渣系统遇到故障，故障设备发出报警信号，需要临时停机进行检修时，在控制系统将挤渣门全部关闭。使渣斗形成一封闭容器。检修完毕后，按下面步骤开启挤渣门。

When the follow-up device failures, faulty equipment sends a warning signal, when need to temporarily shut down for maintenance, control Slag Cut-off Gates to closed. Slag Hopper forms a closed container. After maintenance, open the Slag Cut-off Gate according to the following steps.

开启挤渣门步骤：

① 首先将干式排渣机输送带的变频器调到额定频率，即运行速度调至最快速度；

② 点动接近干式排渣机头部（弧段）的第一对挤渣门，置于较小的开口位置，大量存渣落到干渣机上被冷却并输送，此时大渣检测装置可能报警，可以忽略报警，干渣机运行一段时间，待大渣检测装置处于正常位置，说明渣量减少；

③ 将此挤渣门慢慢打开，直到完全打开；

④ 同理，将所有挤渣门依次全部打开；

Steps of open the Slag Cut-off Gate:

① First, the transducer of DSC(Dry Slag Conveyor) belt adjust to rated（60Hz）, the fastest operation speed;

② Jog control, make the first pair of Slag Cut-off Gate which is close to the arc/head of DSC on smaller opening position, many slag will fall on DSC and be cooled and conveyed, this time large slag detection device may alarm, alarms can be ignored, when DSC runs for some times, with big slag detection device in the normal position, slag quantity reduced.

③ Open the Slag Cut-off Gate slowly, until to open fully.

④、Similarly, open all doors in turn.

在打开每对挤渣门过程中，如发现有大渣，视其渣块的大小，适时进行挤压。

When opening the Slag Cut-off Gate, if there are large slag, timely extrusion depending on the size.

特别注意：

①. 正常运行时每对挤渣门每月要进行一次全开、半开、全关操作。

②. 事故关断后处理后，慢慢开启每对挤渣门，待渣量减小大渣检测回复正常后再进行操作。否则可能会引起干渣机过载。

③. 如果开启挤渣门时，大量灰渣排泄到干渣机上，可能引起过载；此时允许干渣机倒转，将渣从其尾部排出。如图4-3。

Special Note:

①. during normal operation, every Slag Cut-off Gate should do a whole-open, half-open and whole-closed operation once a month.

②. Be carefull, when open all closed gates after maintenance, must care & jog control, allowed & smaller Slag fall on DSC. After DSC runs for some times, with big slag detection device in the normal position, allowed another operation.

③. There are too much slag to DSC may over loading, when you open the gate quickly. At this point, DSC is allowed to reverse. Slag discharged from the end of DSC. Show in Fig.4-3.

4.2安装Installation

4.2.1概述Summarization

请参考国家相关规定和7.3.1钢结构安装技术要求，严格按照随机图纸要求进行安装。

Please refer to relevant national regulations and 7.3.1 steel structure installation technique requirements, strictly in accordance with the drawings for installation.

设备本体重量>10吨，应特别注意安全；在起吊时，设备下面禁止站人；因为每扇门重达1吨多，仅靠下方导轨支撑，所以起吊之前应确保所有挤渣门已捆绑固定牢固，起吊过程中不得出现滑动；起吊时不得倾斜，严禁直立和倒置。

The weight of equipment body more than 10 tons, you should special pay attention to safety; in lifting, prohibits anybody standing under the equipment; Because every door weighed more than 1 ton, only support by the bottom guide, so it should ensure that all Slag Cut-off Gates have been fixed firmly before lifting, and must not appear sliding during lifting process; when lifting it shall not be titled, strictly prohibited erection and inversion.

安装时应保证油缸与其接管的同轴性，从而保证两根油缸平行推动一扇挤渣门体。任何的偏差将影响挤渣门的推动，从而增大磨损，减小设备的使用寿命。

When installation should ensure that the oil cylinder and its connecting tube is in the same axis, thereby ensuring two oil cylinder parallel to promote a Slag Cut-off Gate. Any deviation will affect the door pushing, increased the wear and tear, reduce equipment life.

安装完毕后，应对液压管路进行排气，煤油清洗；然后按照4.1中挤渣门开启步骤进行试车。若发现任何问题，请咨询现场服务人员。

After installation, should exhaust and kerosene wash the hydraulic pipe; then commissioning the Slag Cut-off Gate according to the 4.1 steps. If you have any questions, please contact the on-site service personnel.

4.2.2安装顺序Installation Sequence

检查基础→立柱→本体、膨胀节→油缸支架→平台围栏→油缸、液压管路→电控系统→清洗管路、检查→试车。

Check foundation →pillar→ body, expansion joints→oil cylinder support→platform fence→oil cylinder, hydraulic pipe→electric control system→cleaning pipe, inspection→ commissioning.

4.3液压系统 Hydraulic System

4.3.1技术参数Technical Parameter

电机功率：2×5.5Kw；

Motor Power：2×5.5Kw；

油　泵：流量14.3 ml/rev；系统流量：21L/min

Oil Pump: flow 14.3 ml/rev; system flow: 21L/min

油箱容积：400L；

Volume of Oil Tank: 400L；

工作介质：N46号普通液压油或同等级抗磨液压油；

Working Medium: common hydraulic oil for N46 type or the same level anti-wear hydraulic oil;

系统清洁度：NAS9级

System Cleanliness: NAS9 class

系统额定工作压力：10Mpa；最大≤16MPa

System Rated Working Pressure: 10Mpa；Max ≤16MPa

正常工作油温：25-55℃

Working oil temperature: 25-55℃

加油量：6～8L×油缸数量。

Fill oil ：6～8L×the number of Hydraulic cylinder

4.3.2注意事项Note

设备安装、使用前，请详细阅读说明书。

Read the instructions carefully before equipment installation and using.

设备在使用前，必须对所有紧固件进行检查、紧固。

All fasteners must be checked and fasted before equipment using.

设备在使用前清洗，注油；不得在载油情况下吊装。

The equipment must be filled with oil and cleaned before use, and it is not lifting contain oil.

电气接入前，请检查供电电源和地线是否符合要求。

Check whether the power source and ground line meet requirements before electrical access.

供电电源接入后，请立即检查设备是否有漏电。

Please check whether the equipments have electricity leakage after power supply access.

设备调试、使用期间，请远离可能由压力作用造成元件脱离飞出的位置。

Please stay away from the position where the components fly out caused by pressure during the equipment debugging and use time.

设备使用压力不得超过要求。

The use pressure shall not exceed the manual instructions.

设备检修时、必须对设备压力泄载。

The equipment pressure must be let out during equipment maintenance.

按中国人民共和国和企业的电气和液压安全标准，检查和操作。

Inspect and operate according to the China electrical and hydraulic safety standards.

设备应在安全的情况下，安装、使用、操作、维护。

Installation, use, operation and maintenance of equipment should be in safe conditions.

对不按说明和安全要求产生的事故，本公司不负任何责任。

Our company is not responsible to the accidents those resulting from fail to note and security requirements.4.3.2试运行前准备Preparing before Commissioning　①.清洁油箱管路；检查管接头和法兰是否拧紧（必须在无压的状态下拧紧接头）；检查电机转向。

Cleaning the oil tank pipeline; check if the pipe joint and flange are tighten (the joint must be tighten without pressure); check motor rotation direction.

②.检查液压站与各个管路、油缸连接。

Check the connections of hydraulic station with pipeline and oil tank.

③.检查各阀门的接口是否正确。

Check if every valve interface is right.

④给油箱加油，单油缸需要约4L；为了降低油温，建议加入两倍以上。

Fill oil in oil tank, and single cylinder need 4L. Please twice the oil for get a lower oil temperature.

4.3.4空载试运行No-load Commissioning

①.注意安全，非专业人员须远离现场。

To ensure safety, no-professional staff must be far away from the scene.

②.确认各电气接点无误，常开常闭点的位置正确，可以正确的发讯，DC24V电源的供给无衰减。

Make sure all electrical contacts are correct, the usually open & close point in the right position and can sent right signal, supply of DC24V power without reduction.

③.点动电机、进一步确认转动方向。

Start motor, and further confirm its rotation direction.

④.给系统排气，将较高位置的接头及排气螺丝小心的拧送，排放气体，当泄露的液体中不再含有气泡时，重新拧紧接头及排气螺丝。

System exhausts. Carefully twist the high position joint and exhaust screw to exhaust gas, when the leaked liquid without air bubbles you can twist tighten them again.

⑤.空载起动系统后，运行一段时间，采取手动的方式控制各电磁阀，验证动作是否正确。

Manually control all electromagnetic valves and verify the action is right or not when the system no-load operation for some time.

⑥.逐渐加载，缓慢的提高系统压力，注意观察电磁阀、仪器仪表，压力、温度、油位、噪音等是否异常。

Gradually increase load and improve system pressure, observe electromagnetic valve, instruments, pressure, temperature, oil level and noise are normal or not.

⑦.关掉电动机，重新拧紧所有接头；即使管接头无泄漏也需拧紧。

Stop motor, re-tighten all joints even if the joints without leaking;

4.3.5保养及维护Maintenance

①.正常运行后每周至少检查一次油箱液位的高度。

After normal operation, the height of oil tank level must be checked at least once a week.

②.液压油的保养周期和程度与下列因素有关：油液的老化程度、含水量、温度、充液量等。油液应在冷却状态排放更换。老化非常的严重或污染非常严重的油不能通过注入新油来改善其状况；给系统加油一定要经过过滤，且过滤精度不低于系统的要求；在加油时必须使用同一厂家同一品牌及型号的液压油；并定期从油液中取样，检验其含有颗粒、杂质的状况，对油液的成分进行分析，并记录在案。

Maintenance period and extend of hydraulic oil are relate with the oil aging, water content of oil, oil temperature, oil amount and etc. Oil should be replaced in the cooling status. The serious aging or pollution oil should not change its situation from filling new oil; oil must be filter, and its filtering accuracy can not be less than the system requirement; when oil filling, the hydraulic oil must be the same manufacturer, brand and mode; periodically sampling from the oil, test its situation with particles and impurities, analyze its composition and record.

③.工作温度随时测量，油温的升高意味着，内部的磨损及泄漏的增加。

Measure the working temperature at any moment, oil temperature rise means the internal wear and leakage increase.

④.管路系统应无泄漏，若存在泄流，尤其是地下管路的泄漏，意味着油料的损失，同时也对地面及元器件造成损坏及环境的污染。

Pipeline system should not leak. If there is any leakage, especially for the underground pipeline leak, which not only means oil loss but also can cause ground and components damage or environmental pollution.

⑤.检测主回路压力:设备正常运行后，定期检测系统压力，并记录；压力的频繁调整意味着溢流阀的磨损加剧。

Check main circuit pressure. After normal operation, check system pressure regularly and record; frequent adjustment of pressure means the wear of relief valve increased.

⑥.蓄能器的充气（若有）：正常运行后，一周检查一次充气压力，并做好记录；若压力不断的下降意味着气体的泄漏，必须及时的更换维修；只允许用氮气作为使用气体，且氮气为4.0级，最纯的。

Accumulator charging (if has): after normal operation, check the charging pressure once a week and record; if pressure decline means gas leak, accumulator must be replaced and maintenance in time; only nitrogen as the use gas, and it is for 4.0 class, the most pure.

⑦. 油液的污染是导致系统元件损坏一个重要因素，过滤器是清洁度的一个重要保障，若滤芯已经污染时，要及时的更换滤芯，更换滤芯时必须保持周围环境的清洁，避免更换过程中的二次污染；纤维或纸制滤芯不能清洗再次使用。

The oil pollution is an important factor of system components damage, the filter is an important guarantee for cleanliness. If filter core has been polluted, the core must be replaced in time. In the replacement, we must keep the surrounding environment clean to avoid secondary pollution; fiber or paper filters can not be washed and use again.

4.4电控系统Electronic Control System

4.4.1概述Summarization

中国大陆使用电源：

Power source used in China:

动力电源：380V/220V AC 50Hz；

Power supply: 380V/220V AC 50Hz；

接触器、继电器、指示灯：220V AC / 24V DC；

Contactor, relays, indicator light: 220V AC / 24V DC；

电磁阀：24VDC；

Electromagnetic valve：24VDC；

按钮──220VAC/24VDC。

Button－220VAC/24VDC。

国外请参照技术协议要求。

In abroad please refer to the technology agreement.

4.4.2控制功能Control Function

4.4.2.1 就地、远程控制转换Local, Remote Control Conversion

通过"就地V集控"转换开关实现液压挤渣门就地与远程控制的转换。

Switch the local and center control of Slag Cut-off Gate through “local V center control” button.

4.4.2.2油泵电机过载保护

当油泵电机长时间过载时，空气开关动作，系统将立即停车，同时发出报警信号。

When the pump motor overload a long time, the air button moving, the system will immediately stop, while give an alarm signal.

4.4.2.3 安装Installation

将控制柜落地安装在基础上，安装基础应在液压站的旁边，便于调试及检修维护，参照互连图要求提供电源，油路上接有各挤渣门动作控制的电磁阀，其支撑框架上有挤渣门开度检测用限位开关，对照互连图从控制柜端子排引线至上面的各个控制部件，完成设备接线。

Control cabinet is installed on the foundation which is installed near the hydraulic station, easy debugging and maintenance, the power is provided according to the requirement of wiring diagram. There are several electromagnetic valves which control action of every Slag Cut-off Gate in the oil pipeline, and detection limit switches for Slag Cut-off Gate opening is on the supporting frame of oil pipeline. Wiring from the cabinet terminal to all control components according to the wiring diagram, equipment wiring is completed.

4.4.2.4 调试Debugging

送电前，检查控制盘面，将选择开关打到就地位置，操作方式选择开关打到中间位置，其余选择开关全部打到左侧停止位；然后逐个合上动力电源开关观察有无异常，直流电源的冷却风扇是否工作正常，测量确定直流电源输出电压为24V，消除盘面异常报警。

Before switching on the current, check the control panel, turn select switch to local position, turn operation select switch to middle position, and turn all the other select switches to the left stopping position; then close the power supply switches one by one and observe if it is any abnormal, check if DC power cooling-fan normally work and make sure its DC power output voltage is 24V, remove abnormal alarm of control panel.

检查液压动力站油箱是否加满液压油，确定油泵吸油球阀打开，泄压球阀关闭；挤渣门油站有两套动力系统，可分别控制打压，调试时先起动油泵电机打压，观察压力表油压，减压阀出厂设定工作压力为10MPa，几乎没有压力则电机反转，调整电机电缆相序。

Check if oil tank of hydraulic station fill with hydraulic oil, make sure the oil-pumpingoil pumping ball valve open and pressure-release ball valve close; the oil station of Slag Cut-off Gate has two power systems which can control the pressure separately. In debugging, start the oil pump motor to open the pressure, observe oil pressure of pressure gauge, and working pressure of decompression valve is set to 10MPa in the factory. If almost no pressure, motor will be reversal. Adjust motor cable phase sequence.

4.4.2.5 操作说明Operation Instruction

挤渣门的操作必须遵循一定的规则，才能使其动作灵敏，工作有效。控制面板上每个选择开关都对应设备上一个电磁阀、两个液压缸、一扇挤渣门，每扇门有全关、中间、全开三个限位开关，对应盘上三个指示灯；对照液压原理图和电气原理图检查液压管路连接是否正确，各个电磁阀及相应位置检测限位开关与端子排连线说明是否一一对应，发现错误立即纠正，然后可以操作验证；

Operation of Slag Cut-off Gate must follow certain rules to make its action sensitive, work effectively. Every select switch in the control panel is corresponding to an electromagnetic valve, two hydraulic cylinders and a Slag Cut-off Gate. Each gate has whole-closed, half-open, whole-opened three limit switches and corresponding to the three indication lamps in the control panel; check if the connection of hydraulic pipeline is right according to the hydraulic and electrical schematic diagram, check if the wiring of each electromagnetic valve and the corresponding limit switch with terminal correspond one by one. If any wrong, correct it immediately, and then operate to verify;

由于电磁阀较多，且为直流24V，电压低电流大，建议每次操作的挤渣门不超过即3对门，以免控制回路负载过大，加速线路老化。操作时，先要明确要操作哪对门，启动油泵打压，将相应的选择开关打到运行位置，然后按“操作选择”开关，则相应的挤渣门关闭或打开动作，每次动作到位应及时将操作选择打到中间位置，然后重新选择需要动作的挤渣门，再选择动作方式，如此重复；操作完毕后，先将操作选择开关打到中间位置，然后将挤渣门运行选择开关打到左边停止位，完成整个过程。

Because there are many electromagnetic valves with DC 24V, low voltage and large current, so we suggest every operation of Slag Cut-off Gate can not exceed 3×2 doors to avoid the control loop with large load and accelerating the lines aging. In the operation, first make sure to open which door, start oil pump to give the pressure, turn the corresponding select switch to the operation position, press the “operation select” switch and the corresponding Slag Cut-off Gate will close or open, turn the “operation select” switch to intermediate position in time after every action in place, and then re-select the Slag Cut-off Gate and select the operation mode, repeat in this manner; after the operation, first turn the operation select switch to intermediate position, then turn the operation select switch of Slag Cut-off Gate to the left stopping position, now a whole process is completed.

远程操作时，只要接线正确，只需将选择开关打到远程位置，就能在上位机操作。

In remote operation, if the wiring is correct, turn the select switch to a remote position, you can operate in the PC machine.

4.4.2.6 注意事项Notes

每次操作完成离开前应立即停止油泵，检查确认盘面各个选择开关都在停止位，以免下次油泵启动时液压缸直接动作；

After each operation, the oil pump should be stopped immediately before leaving. Check if all select switches on the control panel is on the stop position, avoid the oil cylinder direct acting when oil pump start for the next time.

操作的挤渣门到位后，先将“操作选择”开关打到中间的停止位，再将挤渣门运行选择开关打到左边停止位，防止挤渣门误动作；

When the Slag Cut-off Gate is in the specified location, turn “select switch” to the middle stop position, then turn operation select switch to the left stop position, avoid the gate wrong action.

油泵电机未启动时，操作电磁阀，电磁阀不能得电。

When oil pump motor doesn’t start, electromagnetic valve can be operated without current.