德国沃马WOMA操作和维护手册1

进口正品德国沃玛WOMA高压泵清洗原装_进口正品德国沃玛WOMA高压泵 联 系  人： 纪 先生 (品牌事业部 网络营销) 和我联系 电      话： 86 0595 28767850 移动电话： 15159510350 传      真： 86 0595 28767802 地      址： 中国 福建 泉州市鲤城区 福建省泉州市展览城A座 邮      编： 362000 公司主页： http://www.twindisc.cc 德国沃马WOMA操作和维护 手册 华为质量管理手册 下载焊接手册下载团建手册下载团建手册下载ld手册下载 OPERATING AND MAINTENANCE INSTRUCTIONS HIGH-PRESSURE PLUNGER PUMP 1000 Z 纪：15159510350 Edition Date of modification TN 06/03 11/04 C O N T E N T S 4 1. GENERAL 4 1.1 PREFACE 5 1.2 GUARANTEE 6 1.3 SERVICE 7 2. TRANSPORT AND ERECTION 7 2.1 TRANSPORT 7 2.2 ERECTION 9 2.3 OPERATING REQUIREMENTS ON THE SUCTION SIDE 10 2.4 HIGH‑PRESSURE LINES 10 2.5 ELECTRICAL CONNECTION 11 3. APPLICATION 13 4. FUNCTIONING AND OPERATION OF THE PLUNGER PUMP 14 5. DESIGN AND DESCRIPTION OF THE PUMP COMPONENTS 14 5.1 Pump type - pump components 15 5.2 GEAR END 19 5.3 WECHSELSATZ 20 5.4 PUMP HEAD 21 5.5 TYPE PLATE 22 6. STARTUP 22 6.1 INITIAL OPERATION 25 6.2 OTHER STARTUPS 26 6.3 SPECIAL OPERATING CONDITIONS 27 7. SHUTDOWN 27 7.1 FROST PRECAUTIONS 28 7.2 PRESERVATION 29 8. IMPERMISSIBLE OPERATION AND WORKING METHODS 31 9. MAINTENANCE AND OPERATION CHECKING 31 9.1 GEAR END (WHEELWORK) 31 9.1.1 OIL CHANGE 32 9.1.2 FORCED OIL LUBRICATION 32 9.1.3 CHECKING OF FASTENING SCREWS 33 9.2 CONVERSION SET 34 9.3 PUMP HEAD 35 9.4 SPILL VALVE 36 9.5 WATER FILTER 37 10. MOUNTING AND REPAIR INSTRUCTIONS 37 10.1 Conversion Set 39 10.1.1 DISMOUNTING OF CONVERSION SET 40 10.1.2 MOUNTING OF CONVERSION SET 43 10.1.3 SEAL WATER SYSTEM 44 10.2 PUMP HEAD 46 10.2.1 DISMOUNTING OF PUMP HEAD 47 10.2.2 MOUNTING OF PUMP HEAD 49 11. TECHNICAL DATA 50 11.1 TIGHTENING TORQUES 51 12. REQUIREMENTS ON THE WATER USED FOR HIGH PRESSURE PUMPS 52 13. LUBRICATION CHART 53 14. FAILURES,CAUSE AND REMEDY 56 15. MAINTENANCE SCHEDULE 1. GENERAL 1.1 PREFACE WOMA products are high-quality machines which will give you excellent service provided that they are correctly operated and maintained. Our units and accessories are manufactured in accordance with the safety requirements for “Pumps and pump units for liquids” as per EN 809 , and in accordance with the German “Regulations for Liquid Sprayers“ (ZH 1/406) and BGV D 15 “Working with Liquid Sprayers“ issued by the Liability Insurance Association. Their design and construction are state of the art and they are operationally reliable. However, high-pressure water jet machinery and its connected accessories may cause danger if they are not properly operated by trained and authorized persons or if they are improperly used. - Danger to the bodies and lives of the operators or third persons - Damage to the machine or other property Any person concerned with the erection, commissioning, operation, maintenance and repair of the machine and/or its accessories must have read and fully understood the corresponding operating instructions. Read the operating instructions completely and carefully. Only a good knowledge of the operating instructions can avoid mistakes and will guarantee troublefree operation. So the operating instructions do not belong in the office but must always be available to the operating personnel and must be visibly fixed on the high-pressure water jet unit. The technical information and data contained in this publication are the latest at the time of printing. Changes in design will be made from time to time to serve the further development and improvement of our products. No claims shall be made on account of the data, illustrations and descriptions in these operating instructions. Any reprint or photomechanical reproduction - also in extracts - is subject to our explicit approval. All rights reserved in accordance with the copyright. Subject to alterations. 1.2 GUARANTEE These operating instructions contain all necessary information. They must be carefully read before commissioning the machine. WOMA shall not be liable for any damage and failure resulting from non-observance of these operating instructions. Wear parts are not covered by our guarantee. Claims under guarantee shall be made immediately after finding a defect. Mention the order number in your claim. The guarantee does not apply in case of improper handling of the machine in case of improper use of the machine in case of use of impermissible operating material in case of incorrect erection in case of wrong or faulty laying of the pipes, cables and hoses or wrong connections in case of tampering with or removing or breaking the lead seals in case of use of spare parts other than original WOMA spare parts ATTENTION WOMA original spare parts and WOMA accessories are specially designed for WOMA high-pressure water jet machines and are tested in a most extensive series of tests. We expressly point out that any spare parts and accessories not supplied by us are not tested, approved and released by us. The installation and use of non-original products may negatively change the design-based properties of the high- pressure water jet machine and may thus cause danger to man, machine or other property. The manufacturer shall not be liable for damage due to the use of non-original spare parts or accessories or damage resulting from unauthorized changes or conversion of the high-pressure water jet machine or its connected accessories. 1.3 SERVICE Our world-wide SERVICE AGENCIES will be at your disposal for all technical information about WOMA products and their use in technical systems. Should there be any trouble with our products, please contact our service stations or the authorized agencies or the manufacturer's works. They will all be glad to assist you. Quick help and a correct handling of your order can only be guaranteed if you always mention the order number and the serial number. WOMA Apparatebau GmbH Postfach 14 18 20 47208 Duisburg or Werthauser Str. 77 - 79 47226 Duisburg Telephone: 02065/304-0 Telex: 85 56 60 Fax: 02065/304-200 e-mail: sales@woma.de http:// www.woma.de 2. TRANSPORT AND ERECTION 2.1 TRANSPORT All openings on the pump must be closed for transport and storage. ATTENTION For the transport of the unit all valid regulations for the prevention of accidents must be strictly observed. The pump must be transported without causing any risk. All hitches on individual components, e. g. pump, engine, etc., must not be used to transport the whole machine. They only serve to transport these individual components. When the pump is put down, make sure that it has a safe stand. After transporting the unit and before commissioning it, it is advisable to check the play of the clutch and readjust it if necessary. The alignment must be done as carefully as possible. The permissible misalignment depends on the tolerances allowed by the manufacturer of the clutch. 2.2 ERECTION When erecting the high‑pressure water jet machine, the recognized rules of engineering must be observed. High-pressure water jet machines must never be erected or operated in fire-hazardous or explosion-hazardous areas unless they are specially designed for that purpose. All safety requirements of the relevant range of operation must be strictly observed, e. g. in power plants and refineries. In case of operation at petrol stations or other hazardous areas the special provision "Technical Rules for Inflammable Liquids" (TRbF) must be observed. Furthermore, any existing local regulations governing the erection and operation of high‑pressure water jet machines are to be observed. Basically, all machines are suitable for erection in the open air under normal ambient temperatures Unusual local ambience conditions such as high or low temperatures, corrosive atmosphere, sand storms etc. for which the machine must be specially designed must be mentioned by the client. If possible, the high‑pressure unit should be erected in a safe place, in dry atmosphere and protected against frost. It should also be easily accessible to maintenance work. It must be taken into account that the following maintenance and checking work has to be carried out: oil level check oil change venting the water‑hydraulic parts of the pump draining the pump (in case of imminent frost) free visibility of the pressure gauge (manometer) sufficient free space for pulling off the pump head visual inspection of the high‑pressure seals on the conversion set work on the engine and the clutch If high-pressure units driven by combustion engines are erected in closed rooms, sufficient ventilation and a sufficient removal of the combustion gases into the open air must be guaranteed. Dissipating heat or cooling air must be carried off or absorbed. This applies to high-pressure units which are either driven by an electric motor or by a combustion engine. In any case, the manufacturer's instructions are to be observed. The water supply required for the high-pressure unit as well as the current supply required for the drive motor must be rated for continuous operation. The required amount of water and the required electric power must constantly be available. All dimensions and data for the erection can be seen from the corresponding technical documentation. Before erecting high-pressure water units in plants or vehicles it is advisable to consult the manufacturer. ATTENTION The surface on which a base frame is fixed must be level. The permissible angles of inclination in all planes are max. 8° if it is guaranteed that even under specific operating conditions of the system, the maximum angle of inclination of the pump is not exceeded during operation. In case of erection on a vehicle, possible inclinations of the road must be taken into account. Furthermore, care must be taken that no twisting occurs through the holding down bolts. In order to avoid vibrations in the floor or in the ceiling, it is advisable to fix the base frame on rubber‑metal feet to the ground. The correct selection of the rubber‑metal feet and their correct points for fixing them on the base frame should be left to an expert. 2.3 OPERATING REQUIREMENTS ON THE SUCTION SIDE The proper functioning of the high‑pressure water jet machine depends not least on the sufficient dimensioning, the correct selection and proper laying of the suction, supply, pressure and return pipes and their connections. The water supply line must be equipped with a shut‑off device and must be connected with the high‑pressure unit by means of a flexible pressure hose. The connection of the water supply to the drinking water line network must be carried out in accordance with DIN 1988. A check valve must guarantee that the flow medium cannot get into the drinking water network. All suction and supply lines must be designed and installed in such a way that no air can be sucked in. All removable connections must be carefully sealed. It must be ensured that no leakages occur due to vibrations. In case of fixed piping, mechanical vibrations must be avoided by inserting a sufficiently long hose as a compensating link. Depending on the operating conditions, the hose and the coupling must be rated for internal excessive and negative pressures. Suction lines must be installed as rising lines and air pockets must be avoided. It must be made sure that the water supply on the pressure side is continuous and trouble-free. In the suction and supply lines the maximum flow speed must not exceed 1.4 m/sec. The line should be as short as possible. It is advisable to avoid elbows, sudden sharp-edged changes in the cross section and installations of all kinds in order to keep the flow resistance as low as possible. For the same reason screens and filters must be sufficiently dimensioned with regard to their effective surfaces if polluted liquids are to be conveyed. The mesh size of the filter should be at least 0.1 mm. The flow resistance at a corresponding flow rate must not be greater than 0.15 bar. This applies to clean filter inserts. Shut-off devices in the suction and supply lines must be completely open during operation, must not shut on their own due to vibration or other influences and must not be used for control purposes. Shut-off devices in the suction line should be installed with a horizontal or vertical spindle to avoid air pockets in the spindle or valve cover. 2.4 HIGH‑PRESSURE LINES All components must withstand the occurring mechanical, chemical and thermal stresses. If quick‑shutting valves are used, e. g. in a spray gun, the occurring pressure peaks must be considered when rating the pipes. This is done by suitably dimensioning the pipes, installing pulsation dampers or other measures. Note: Hydraulic dampers must be in accordance with the regulations governing pressure tanks and the corresponding technical rules with respect to their design, equipment and checking. 2.5 ELECTRICAL CONNECTION For the connection and operation of the electrical switch plants and relevant installations strictly observe the regulations and standards EN 60204 - 1. Control cabinets must at least be in accordance with IP 55 regarding their system of protection. The high‑pressure unit must be connected to the electric supply in accordance with the electrical documentation concerning the specific machine. 3. APPLICATION WOMA high‑pressure water pumps, extended to a high‑pressure water jet machine, can be employed for the most extensive range of tasks in almost all branches of industry. Examples: Construction industry ‑ laying open reinforcing steel ‑ removing sick concrete ‑ removing coatings, e. g. paints, plastic on concrete and stone Chemical industry ‑ inside and outside cleaning of tanks and heat exchangers Automobile industry ‑ removing paint from gridirons and body carriers Shipbuilding industry ‑ cleaning ship's hulls by removing the shells, removing varnish and rust Aviation ‑ cleaning of airports ‑ removing the varnish from airplanes Power industry ‑ cleaning of turbines and pipes ‑ decontamination of power plants Special properties Depending on their mode of application, high‑pressure water jet machines can be driven by electric motors or combustion engines. One distinguishes between: ‑ Mobile high‑pressure water jet machines which are designed for operation in various places and are equipped with an undercarriage, with skids or similar or which are mounted on a trailer and are equipped with removable, flexible connecting lines. ‑ Stationary high‑pressure water jet machines whose drive and pressure generator are fixed on a part of a building or on a foundation and which have permanently laid connecting lines for power and water supply. This also includes machines which are operated as a component of a permanently installed high‑pressure water jet system. 4. FUNCTIONING AND OPERATION OF THE PLUNGER PUMP Plunger pumps are preferably used where high water pressures are required. Water from the header tank is supplied to the high‑pressure pump via a booster pump or is directly supplied from the water mains (hydrant). A water filter removes undesirable polluting particles which might lead to a premature wear of the parts. The rotary movement of the drive motor is converted into an oscillating movement of the plunger in the pump by means of a crank mechanism. The suction and lifting movements of the plunger (piston) cause the water to reach a higher pressure by means of the suction and pressure valves. High operational pressures can be achieved via a pressure control device, depending on pump type and plunger diameter. The water leaves the pump through a high‑pressure hose and is conveyed to a spraying device. Spraying devices can be spraying guns with nozzles, lance pipes or hoses with nozzles etc. T H E W A T E R B E C O M E S A T O O L ATTENTION For each pump the conditions on the supply side call for special attention. Pipe and hose arrangements, NPSH, temperature of the liquid and other factors have a direct influence on the pump operation. Only after full consideration of all influences a trouble‑free operation can be expected. The design and rating of the pump should therefore be entrusted to the expert. 5. DESIGN AND DESCRIPTION OF THE PUMP COMPONENTS 5.1 Pump type - pump components The pump 1000 Z is a horizontal plunger pump with two flanged-on, one-piece pump heads in central valve design and easily changeable plunger conversion sets. The main parts of the pump are: Gear end (driving gear) 2 Plunger conversion set 3 Pump head in central valve design Pressure regulator Check valve Intake port with integrated water filter 4 3 6 2 1 5 6 4 picture 1 5.2 GEAR END The gear end is equipped with an internal gear reducer unit consisting of a drive shaft (2/2) and a crankshaft (2/4) with two helical gears which are screwed onto the crankshaft. The crankshaft is interchangeable and supported by two cylindrical roller bearings (2/21). The connecting rods (2/11) are supported by sliding bearings (2/10) and are driven via the crankshaft journal. The oil supply for the sliding bearings (2/10, 13), the guide piston (picture 2/15) and the connecting rod pin (picture 2/14) is achieved by means of an oil pump (picture 3/26) which is mounted to the pinion shaft. The oil pressure, which is set by means of the spill valve (picture 3/28), is indicated by the pressure gauge (picture 3/29). The oil is continuously cleaned by a single filter (picture 3/27). The gearbox (picture 2/1) contains the oil supply for the gear. The aeration of the gearbox is achieved by means of a wet‑type breather (5). A heat exchanger (cooling coil) (picture 2/12) provides for the cooling of the gear oil. The cooling water can be supplied either internally from the suction side of the pump or externally from the water mains. Gear End- REPAIR SURVEY Figure 2 Legend (see figure 2) 1 Gear box housing 11 Connecting rod 21 Cylinder roller bearing 2 Pinion shaft 12 Heat exchanger 22 - 3 Cylinder roller bearing 13 Slide bearing 23 Nut 4 Crankshaft 14 Gudgeon pin 24 Socket head cap screw 5 Breather 15 Guiding rod 25 Socket head cap screw 6 Gear housing cover 16 Connecting nut 26 Oil pump 7 Lateral cover driving side 17 Cover 8 Lateral cover oil pump side 18 Gear-wheel 9 Oil drain 19 Lantern 10 Slide bearing 20 Locking ring (complete) Fig.-No. Part-No. Tightening torque 20 240.1150 100 Nm 23 240.1112 1200 Nm 24 240.0151 195 Nm 25 240.0124 23 Nm Forced oil lubrication - REPAIR SURVEY 30 26 27 29 31 32 S 35 28 33 34 Picture 3 Legend 26 Oil pump 31 Oil pressure line 27 Oil filter 32 Oil pressure control 28 Spill valve 33 Oil temperature control 29 Oil pressure gauge 34 Nozzle pipe 30 Oil supply line 35 oil level sight glass 5.3 WECHSELSATZ Pumps can be equipped with other sizes of conversion sets of the same type. By means of different plunger conversion sets (fig. 8) it is possible to vary the operating pressure and the flow rate of the pump within the scope of the drive power is shown in the performance chart. When changing the conversion set, it must be considered that the pressure/volume ratio of the pump changes. In this case, the complete pressure system from the pump pressure flange onwards must be checked for its compatibility with the new maximum operating pressure, and all impermissible components must be replaced! These parts include, for example, the safety valve, pressure dampers, hoses, adapters, pres