CBK型空气预热器传动变频控制系统使用说明书航天科工哈尔滨风华有限公司电站设备分公司目 录1 主要用途与适用范围 (1)2 系统组成与功能 (1)3 主要技术参数 (2)4 工作原理 (2)5 安装 (3)6 使用与操作 (5)7 维护与保养 (6)检修空预器时,必须将柜内"运行投入和运行抑制"旋钮切到"运行抑制"。
检测电机绝缘时，必须全部脱开电机与变频器之间的导线。
1 主要用途与适用范围空气预热器传动变频控制系统是应用变频器对空气预热器的传动进行软启动的控制设备。
它具有启动力矩大、设备冲击小、运行可靠、结构简单等优点，是针对空气预热器这类大惯性负载较为理想的控制系统。
空气预热器传动变频控制系统适用于65MW、135MW、300MW、600MW、1000MW等火电机组空气预热器的配套。
2 系统组成与功能2.1 系统组成空气预热器传动变频控制系统包括控制柜2台（A、B侧各1台），每台控制柜中配置主、辅两台变频器分别对主、辅电机进行控制；每台控制柜配置1台制动控制箱，用以进行过压保护。
系统同时包括转子停转检测装置2套（A、B侧各1套），每套配置3个探头及作用板，对转子停转进行监测。
（图1：单侧系统构成示意图）图1：单侧系统构成示意图2.2 系统功能a) 具有高速、低速、调试档，以满足设备运行的不同需要。
b) 具有主、辅电机之间自动切换的功能，当主电机出现变频器故障，电机卡死等故障时，可以自动切换为辅电机运行，反之亦可。
c) 系统具有远方控制和就地操作两种途径，在控制柜内设有切换开关。
d) 系统可以分别给出每台变频器DC 4～20mA的电机运行电流信号。
e) 当变频器故障、电源故障、转子停转时，发出报警信号。
3 主要技术参数a) 主、辅变频器功率:≥7.5kWb) 供电电源：AC 380V 50Hz 三相四线 两路（厂用、保安）c) 输出继电器负载能力：5A /AC 240V 5A /DC 28Vd) 环境温度：－10℃～50℃e) 相对湿度：＜85％4 工作原理系统（单侧、以下同）采用两台变频器分别驱动主、辅电机，可使主、辅电机分别具有高速、低速两档驱动电机功能，其中高速档为正常工作档，低速档为清洗空预器时使用。
系统还具有调试档，可由用户通过变频器人机接口（HIM）在线设定所需运转速度。
系统启动时可先启动主电机，也可以先启动辅电机（建议先启动主电机），电机可按所设定的速度软启运行，当所启动的电机出现故障时，系统可以自动启动另一台电机，起到互备的作用。
系统可以就地控制，即在控制柜操作面板进行操作或应急处理，也可以在控制室内进行运行操作。
系统可向中控发出主、辅电机启/停；远程/就地状态；主、辅变频器故障；转子停转报警等信号，以及运行电机DC 4～20mA输出电流信号。
两台变频器联锁信号是由故障信号发出的，即正常启/停电机不发出故障信号，则不需要联锁启动下一台电机。
当发出故障信号时，系统自动联锁启动下一台电机。
转子停转报警装置是利用“接近开关”作为检测传感元件，在空预器支撑轴承上方的转子转盘上安装有金属作用板，当转子旋转时，作用板周期性地接近和离开检测传感元件，这样就给出了有规律的开关信号，当转子停转时，系统发出转子停转报警信号。
在本系统中变频器作为控制核心，集成了变频启动、热保护、运行指示输出、报警输出等功能于一身，相当于一个具有智能的软继电器，具有元件集成化程度高、事故几率小等特点。
其中故障输出及保护内容包括；过电流、对地短路、过电压、久电压、电源缺相等（详见变频器使用说明书）。
以上保护功能已基本包括了所有事故出现的工况，是一般控制系统所无法比拟的。
5 安装安装前按装箱单清点各部分设备,检查有无损坏，并按安装说明进行安装。
a) 控制柜、制动控制箱：控制柜与制动控制箱相邻就地安装，安装地点应通风良好, 避免日晒、雨淋,并应避免腐蚀气体、尘埃，远离振动、冲击激烈的场所，控制柜、制动控制箱底部应与平台焊接牢固。
（图2：控制柜、制动控制箱外形尺寸）图2：控制柜、制动控制箱外形尺寸b) 电气接线：按图纸规定进行。
所有线缆要求外置金属管（金属管接地），加以保护并防干扰。
注意：有极性的线缆，不应接错。
c) 转子停转检测装置：一套转子停转检测装置包含3个作用板、3个接近开关和一个安装支架。
作用板焊接在转子转盘上且圆周方向均匀分布，3个作用板至转子中心的距离应保持一致；安装支架与预热器中心绗架焊在一起，现场尺寸大于调节尺寸时，现场制作过渡连mm，调整完毕接件。
接近开关的作用平面与作用板之间的距离为50-1后将接近开关锁紧。
具体安装方式参考图3：转子停转检测装置安装示意图。
图3：转子停转检测装置安装示意图6 使用与操作系统启动之前应先将动力电源(厂用、保安)正确投入,再将主、辅电机运行开关切到“运行投入”档,并确定主、辅电机均为“高速”档。
“远方/就地”选择开关切到需要位置。
主、辅电机处于准备好状态，即面板上的故障灯灭，变频器控制盘显示00Hz。
1、正常工况下，系统应先启动主电机。
按“启动”按钮，“运行”灯亮，电机将慢速启动，约需60秒系统达到设定频率，变频器控制盘显示从0Hz上升到设定频率，电机达到额定转速。
2、当主电机发生故障时（故障原因及排除见变频器使用说明书），变频器发出故障信号，“运行”灯灭“故障”灯亮，主变频器停止运行，同时自动切换到辅变频器启动，主变频器故障信号发往中控，以便中控做出相应的处理。
在主变频器故障修复后，可通过主变频器控制盘“EXIT/RESET”按钮复位，也可通过断主变频器电源断路器“Q1”复位。
如果此时需要主变频器工作，应先按下辅变频器“停止”按钮，然后再按下主变频器“启动”按钮，主变频器即可启动，辅变频器回复到准备好状态即“运行”灯、“故障”灯灭。
如果不需要主变频器工作，则主变频器将作为辅变频器的备用，当辅变频器出现故障时，自动切换到主变频器启动。
系统运行时，“高速”、“低速”两档切换时需要掌握一条原则：即尽量不要由“高速”档切至“低速”档，否则由于转子惯性较大，可能减速时间过长从而造成变频器报警。
系统检修时，如果维修人员进入空预器内检修，必须将柜内“运行投入和运行抑制”旋钮切到“运行抑制”。
如果进行吹灰等检修时人员不进入空预器时，应将选择开关切为“调试”档，通过变频器控制盘上的相关按键进行操作（见变频器使用说明书）。
系统正常投入运行时，不允许将选择开关切为“调试”档。
变频器正常工作时，可由变频器面板监视输出频率，相应各运行指示灯亮；单侧变频器发生故障时，故障指示灯亮。
同时将运行状态发往中控。
7 维护与保养7.1 千万不要把动力线接至变频器输出端子，否则会烧坏变频器。
7.2检测电机绝缘时，必须全部脱开电机与变频器之间的导线，不要用MΩ表检测变频器，否则可能损坏变频器。
7.3 如果变频器发生故障报警时，请查阅变频器使用手册，排除故障后再恢复运行，不要采用外部电路进行自动复位。
7.4 考虑到现场环境恶劣，所以在系统长时间运行时应经常检查柜内温度。
7.5 系统两台电机切换时应尽量避免由高速到低速，否则可能损坏变频器。
另外，只有检修时，才应切到调试档操作。
7.6 系统应安全接地，否则可能造成不必要的事故。
7.7 系统断电后待变频器电压降至安全电压以下时方可进行检查或维修，否则可能造成人员伤害。
7.8 系统由于故障报警而自动启动另一台电机时，应先将故障排除复位后，才能停止运行的电机。
7.9 系统操作人员应详细了解变频器使用说明书和系统使用说明书后才能操作本系统。
7.10 信号指示灯、位置（点动）开关、中间继电器等电器件如有锈蚀、接触不良或其它异常，视情况定期予以更换。
7.11 定期检查转子停转报警装置的探头与作用板间不允许有杂物。
CBK ModelAir PreheaterDrive Control System Instruction ManualPOWER STATION EQUIPMENT FILIALEHARBIN FENGHUA CO., LTD.CHINA AEROSPACE SCIENCE&INDUSTRY CORP.CONTENTS1. Main uses and apply range (1)2 System composing and function (1)3. Main technical parameters (3)4. Working principle (3)5. Installation and adjustment (4)6. Operation (6)7. Maintenance (9)To avoid any damage or injury, verify that the position switch being at the status of "Run Prohibited" when the air preheater is being overhauled.Be sure to disconnect the wires between the motor and the transducer when testing the insulation of the motor.1. Main uses and apply rangeThe transducer control system of the air preheater is equipment that using transducer to control the air preheater’s running. It has many virtues, for example big torque, running credibly, simple structure, etc. It is a good system for the air preheater driving.The transducer control system of the air preheater is applicable for 65MW、135 MW、300 MW、600 MW boiler，etc.2 System composing and function2.1 System composingThe air preheater includes two control cabinets which are on the A and B sides of the air preheater separately. There are primary and standby transducers in each control cabinet to control the primary and standby motors. There are one brake control box that is configured with each control cabinet and two sets of rotor stop detecting devices. (There is one set on A and B side each.) There are three detectors and function boards in every set of rotor stop detecting device to detect the rotor stopping. (Fig 1: System compose sketch map of single side).Fig 1: System compose sketch map of single side2.2 Function：a) The system has three options of high speed, low speed and debugging so that sufficing user’s requirements.b) It can automatically change between the primary motor and the standby motor. It can automatically switch to the standby motor when the main motor is fault. Also it can automatically switch to the primary motor when the standby motor is fault.c) The system has two operate mode. One is remote and the other is local. There is a changing switch in the control cabinet.d) Every transducer can output 4-20mA current signal.e) The system can output the alarm signal when the transducer is fault orrotor stopping.3. Main technical parametersa) Transducer’s power: ≥7.5KWb) Power supply: AC380V 50Hz Three phases and four lines. Two kinds of power supplies(primary and standby）c) Loading ability of output relays: 5A /AC 240V 5A / DC 28Vd) Ambient temperature: Min.-10℃~Max.50℃e) Relative humidity: <85%4. Working principleThe system has one transducer and every transducer controls one of the two motors .The motor can run with high speed or low speed .The high speed is the normally work status and the low speed is used when washing the air preheater .The system has debugging station. The user can set the speed on HIM. The system can start the primary motor first. Also it can start the standby motor first ( First starting the primary motor is advised.) . The motor can run in setting speed .The system can start the other motor when one of them is fault .The system can control in local .It means the system can be operated on the panel. It also can be controlled in remote.The signal outputted to the DCS include the main motor start, the standby motor start, the main motor stop, the standby motor stop, the main motor fault, the standby motor fault, the rotor stop and the signal of current monitor .If the system sent out each of the motor fault signal thenthe other motor start. The system will not send out the motor fault signal when the motor normal start or stop, the other motor will not start .The system auto interlock the other motor when it sends out the signal of fault.The device of rotor stops detecting use the proximity switch as the sensor. There are function boards on the rotor of the air preheater .The function boards are close to the sensor periodically when the rotor turns. Then the system can receive the on-off signal regularity .The system judges the rotor whether stopping or not by the program .The system sends out the fault signal of the rotor stopping when the “rotor stopping’’ happens.The transducer is the controlling core of the system. It integrates the functions as frequency conversion start, heat protect, running designation output, fault output and so on .The system’s integration is well and the accident’s probability is less. Fault output and protection’s function includes over current, over voltage and under voltage .The protection’s function is provided with the work’s status mostly .So we can say the system is better than others.5. Installation and adjustmentPlease check the equipment before installing, and then please install according to the explain of installation.a)Control cabinet and brake control box:The placing site of the control cabinet and brake control box should be airiness , avoid sunning and raining , evade caustic air and dust ,keep away from shaking .The foot of the control cabinet and brake control box be joined firmly with the flat. Mounting dimensions as the Fig 2: Formal size of the control cabinet and the brake control box.Fig 2: Formal size of the control cabinet and the brake control boxb) Install wiring:Please install wiring according wiring diagram. All of the cable need install metallic pipe for protecting cables and preventing disturb.Note: cables with polarity don’t connect wrong.c) Rotor stop detecting deviceThe rotor stop detecting device has three function boards, one sensor and one bracket .The function boards are jointed on the rotor , and the board are distributed equally. The distance of every board to the rotor’s center should keep on the same .The bracket is jointed on the air preheater’s center truss. When the sensor’s function distance is out of place, adjust the transition’s device make it on the function field .There is 60-1mm from the sensor to the board .Fix up the sensor after adjusting.Fig3: Rotor stop detecting device install sketch map6. OperationBefore the system running, turn-on the power supply correctly, make sure that the gear of the main motor and the standby motor on the high speed. Put the switch on the needed place between “Remote” and “Local”. Make sure the primary and the standby motors are ready that the light of fault is off and the control panel shows “00Hz”.1. Normally, the system should start the primary motor first. Press the start button then the motor will start slowly. About in 60 seconds the frequency will from 0Hz reaches the setting value，the main motor will reach the rated rev.2. When the primary motor fault occurs (the fault reason and fault removing are in user manual of transducer), the transducer sends out the fault signal, at the same time, the “Running” light is off and the “Fault” light is on, then the standby motor starts. The primary transducer sends the fault signal to DCS, and then DCS treat with the information. After the primary transducer has been repaired, press the “EXIT/RESET” button or cut off the breaker “Q1”, which controls the power supply of primary transducer, to reset the primary transducer. If the primary transducer needs to run here, please press the stop button of the standby transducer first and then press the start button of the primary transducer. Then the primary transducer will run and the standby transducer will return to the ready state, viz, both the “Running” light and the “Fault” light are off. If the primary motor needn’t to work, the primary transducerwill be the standby of the other transducer. When the standby transducer is fault, the system would start the primary transducer automatically.When the system is running，auto-switching between the high speed and the low speed has a principle. The principle is that don’t switch from the high speed to the low speed. Or else the time of slowdown is too long, accordingly the system will give an alarm of fault because the rotor’s inertia is very large.When the system is being overhauled, if there are any service personnel in the air preheater, must turn the “Running Prohibited/Allowed” switch at the “Running Prohibited” position. When just need to do some overhauls like blowing dust that the service personnel needn’t to enter into the air preheater, the select switch should switched at “Debugging” position, operating with the panel of the transducer(according to the user manual of the transducer). When the system is normally running, switching the switch at the ‘Debugging” position is prohibited.The output frequency is shown on the control panel of the transducer when the transducer is normally running. At the same time the corresponding indicator light is on. When the single side of the transducers is fault, the “Fault” indicator light is on, at the same time the state of the system is sent to the DCS.7. Maintenance7.1 Never connect the power wire on the output terminals of the transducer, or else the transducer may be broken-down.7.2 When test the insulation of the transducer, must disconnect all the wires between motor and transducer, and do not detect the transducer with “MΩ” meter or else the transducer may be broken-down.7.3Please refer to the user manual when the transducer is fault .The system will restart when the fault is removed. Don’t reset the transducer with the external circuit.7.4Considering the execrable environment, check the temperature of the control box after the system run through a long time.7.5When the two motors auto-change, avoid change from the high speed to the low speed, or the transducer may be broken-down. By the way, put the switch on the debugging only when the system is examined and repaired.7.6The system should be well earthed, or there will be unnecessary accident.7.7After the system’s power shut down, If any overhaul is needed, must wait the voltage reduces to a safe value, or it may injure some one.7.8When the system start the next motor for fault, you should remove the fault and reset the system first. and then you could stop the running motor.7.9The operator should operate the system after reading the user manual of transducer and the system detailedly.7.10Please change the electric components like the indicator light, the station switch and relay regularly when they don’t work correctly.7.11Please check the sensor and the function board of the rotor stop detecting device regularly. Sundries is not allowed to be there.。