Appendix No. 24
Guidance Document
"Guide overhaul freight wagons"
1. Introduction
1.1 This manual establishes uniform requirements to the overhaul of 1520 mm gauge freight cars by repair enterprises of the Commonwealth Member States, Georgia, the Republic of Latvia, the Republic of Lithuania, the Republic of Estonia and applies to all types of freight cars having the right to enter the track common use regardless of the form of ownership.
1.2 This guide contains general mandatory technical requirements, safety and industrial hygiene requirements, indicators and standards that must be met by freight cars that have undergone major repairs at car repair enterprises, regardless of their form of ownership and have permission to this type activities.
1.3 The terms for the overhaul of freight cars are established by the regulation on the system Maintenance and repair of freight cars admitted to circulation on public railways in international traffic, approved at the 47th meeting of the Council for Railway Transport of the States Members of the Commonwealth. The telegram put into effect dated December 25, 2007. 32941TsCV-3429T.
2 Requirements for repairs
2.1 Overhaul (CR) of freight cars is carried out at specialized car repair enterprises that have the right to this type of activity. The overhaul is carried out in order to restore the operating life of the car with the repair of car components and parts according to the repair documentation developed in accordance with the requirements of the guidelines approved by the Council for Railway Transport of the States Members of the Commonwealth, and agreed by the Commission of the Council of Authorized Carriage Specialists.
2.2 Works on the overhaul of freight cars must be carried out in accordance with the technological processes for the overhaul of each type of wagon under repair and technological processes work of production sites developed by car repair enterprises and approved by the head of this enterprise.
2.3 Non-removable, defective parts of the wagon are repaired directly on the wagon. Faulty removable units and parts are replaced with repaired or new ones that meet the technical requirements and characteristics of this car model.
2.4 Materials, semi-finished products, spare parts and accessory equipment used in the overhaul of freight cars must meet the established standards and specifications, and are made in the climatic version UHL category 1 in accordance with GOST 15150-69. Relevant documents (certificate, declaration, etc.) must be submitted for spare parts and component equipment subject to mandatory confirmation of conformity. must have appropriate stamps indicating the place and date of manufacture, repair and testing. On the frame, wheels, cast parts of the wagon bogies, there must be codes of the state-owner.
2.5 Car parts are tested in accordance with the list and requirements of the Technological instructions for tensile testing No. 656-2000.
2.6 The list of car parts subject to non-destructive testing is given in the Guiding document RD 32.174-2001 (as amended No. 1 and No. 2)
Ultrasonic control welds when repairing tank cars, they are carried out in the presence of a methodology approved in the prescribed manner.
2.7 Details and assemblies of wagons: wheel sets, axlebox assemblies, assemblies and parts of bogies - are repaired and manufactured in accordance with the requirements of the relevant standards, rules, instructions, specifications, instructions.
2.8 Preparation for surfacing and welding operations, welding, surfacing, as well as acceptance of car parts and assemblies after surfacing and welding are carried out in accordance with the requirements of the Instructions for welding and surfacing during the repair of freight cars, approved by the Council for Railway Transport of the Commonwealth Member States on May 29-30, 2008, Khujand.
2.9 Newly supplied wooden parts must comply with the drawings for their manufacture, and in terms of wood quality and moisture content meet the requirements of GOST 3191. It is allowed to put glued wooden parts on the car, manufactured according to the manufacturer's specifications. Wooden parts to be further painted are primed.
2.10 During the QD, all unusable bolts and nuts are replaced with new ones. The threaded part of the bolts, on which cotter pins are not installed, must protrude from the nut by at least three threads, but not more than by the size of the bolt diameter.
Cotter pins and checks for bolts or rollers put new, typical (standardized). In the absence of special requirements, they must be separated from the nut or washer by no more than 3 mm. The ends of the cotter pins and the check are bred at an angle of at least 90 °. Loose and non-standard rivets are replaced.
replace the riveted joints provided for by the design with welded or bolted ones;
put simple nuts instead of castle nuts, provided for by the drawing (technical conditions);
to produce caulking, welding and tightening of rivets;
Driving screws instead of driving them;
burn holes in metal parts;
leave without a primer the metal parts of the body and frame in the places where the parts removed for replacement fit;
Use materials that do not have a certificate of conformity.
2.12 During the QD, newly installed rubber products must comply with the manufacturer's specifications, and also have a certificate of conformity.
I approve
Deputy Minister
means of communication
A.N.KONDRATENKO
December 31, 1998 N TsV-627
FREIGHT CARS OF 1520 MM RAILWAYS
OVERHAUL GUIDE
1. INTRODUCTION
1.1. This Guide is mandatory when carrying out major repairs of freight cars railways Russian Federation, the list of which is given in Appendix 1.
1.2. This Guide contains general technical requirements, safety measures and industrial sanitation, indicators and standards that must be met by freight cars that have undergone a major overhaul.
1.3. Specialized wagons owned commercial organizations or individuals allowed for circulation on the railway network of the Russian Federation and not specified in this Guide are repaired according to separate guidelines or specifications developed for such cars.
2. GENERAL PROVISIONS
2.1. Overhaul of freight cars is carried out within the time limits established by the Ministry of Railways of Russia and in accordance with the requirements of this Guide.
2.2. Non-removable faulty parts are repaired directly on the car. Faulty removable units and parts are replaced with repaired or new ones of the appropriate type that meet technical requirements and characteristics of this series of wagons.
2.3. Materials, semi-finished products, spare parts and accessories used in the overhaul of freight cars must have the appropriate certificates and meet the established standards and specifications.
2.4. After the repair of the car, all critical parts of the car: wheelsets, bogie parts, automatic coupler, auto-braking equipment, tank boilers, etc. must have the appropriate stamps (marking marks or stencils indicating the place and date of manufacture, repair and testing). The frame, wheels of wheelsets, cast parts of the wagon bogies must bear the codes of the state-owner.
2.5. Critical car parts are tested in accordance with the list and requirements of the Technological Instruction for tensile testing and non-destructive testing of car parts.
2.6. Details and assemblies of cars: wheel pairs, spring suspension, axlebox assemblies - are repaired and manufactured in accordance with the requirements of the relevant standards, rules, instructions, specifications, guidelines.
2.7. Preparation for surfacing and welding work, welding, surfacing, as well as acceptance of car parts and assemblies after surfacing and welding are carried out in accordance with the Instructions for welding and surfacing during the repair of freight cars.
2.8. When setting overlays on rivets, the thickness of one- or two-sided overlays should be 10% more than the thickness of the repaired part in total, and the width and length of the overlay should cover the corrected place, ensuring the setting of the calculated number of rivets.
Rivets must have a diameter corresponding to the thickness of the fastened parts, and their number must be such that the cross-sectional area of the rivets on each side of the weakened place is not less than the cross-sectional area of the linings. Rivets are placed in a checkerboard pattern with a distance between the centers of the rivets equal to three to four of their diameters.
2.9. Newly supplied wooden parts must comply with the drawings, and in terms of wood quality and moisture content, meet the requirements of GOST 3191-82. It is allowed to install on the car glued wooden parts manufactured according to the specifications approved by the Ministry of Railways of Russia.
2.10. Wooden parts to be further painted are not primed.
2.11. Bolts for fastening car parts are fixed. The ends of the bolts on which cotter pins are not placed must protrude from the nut by at least three threads.
Cotter pins and checks are set to standard, new ones, in the absence of special requirements, they must be separated from the nut or washer by no more than 3 mm. The ends of the cotter pins and the check are bred at a right angle. Unusable bolts and nuts must be replaced.
Bolts and rollers are placed outside with nuts and cotter pins, with the exception of those whose heads are provided for by the design.
2.12. Loose and non-standard rivets are replaced.
It is forbidden:
Replace the riveted joints provided for by the design with welded or bolted ones;
Install simple nuts instead of castellated nuts provided for in the drawing ( specifications);
To produce caulking, welding and tightening of rivets;
Driving screws instead of driving them;
Burn holes in wood and metal parts;
Leave or reinstall bolts or nuts that have a developed thread or clogged edges, as well as install bolts that do not correspond to the size of the holes and the parts to be connected or have threads of a different type with the nut;
Leave without a primer the metal parts of the body and frame in the places where the parts removed for replacement fit;
Use materials that do not meet the technical requirements, assortments and standards, the requirements of the current sanitary rules and instructions for safety and industrial sanitation.
2.13. Assembly of wagons during repair shall be carried out in accordance with this Manual, drawings and technical requirements of the manufacturer.
3. SAFETY PRECAUTIONS
The administrations of car repair plants and car depots are obliged to properly equip all workplaces and create conditions for them that comply with the legislation of the Russian Federation and the Rules for labor protection during the repair of rolling stock and the production of spare parts at car repair plants and the Rules for labor protection during the maintenance and repair of freight cars and refrigerated rolling stock.
4. ACCEPTANCE FOR REPAIR
4.1. The procedure for sending and handing over freight cars for overhaul is determined by the Basic Conditions for the Repair and Modernization of Freight Cars at Repair Plants of the System of the Ministry of Railways of the Russian Federation.
4.2. Freight cars damaged or having increased wear and tear with an unexpired overhaul period may be sent for overhaul only with the permission of the Department of Carriage Facilities of the Ministry of Railways of Russia.
For a wagon with increased wear, an act is drawn up confirming the need for a major overhaul, and for a damaged wagon, there must be an act of the VU-25 form and approval of the plant to which the wagon is supplied for repair.
4.3. Before putting into repair, the wagons must be cleaned of dirt, debris and washed.
4.4. It is prohibited to accept and repair tanks whose boilers have not been cleaned, steamed and degassed in accordance with the requirements of the Rules for labor protection during the maintenance and repair of freight cars and refrigerated rolling stock (when repairing wagons in a depot) and the Rules for labor protection during the repair of rolling stock and the production of spare parts (when repairing at factories).
4.5. Works on the modernization of freight cars are carried out in accordance with the plan approved annually by the Ministry of Railways of Russia and the technical documentation approved by the Department of Carriage Facilities of the Ministry of Railways of Russia.
4.6. Technological processes for the dismantling and repair of cars and their components, the distribution of work by position and the sequence of their implementation are developed in accordance with the requirements of the regulatory documentation given in Appendix 2 to this Guide.
5. DISASSEMBLY, PREPARATION FOR TROUBLESHOOTING AND REPAIR
5.1. During a major overhaul, all removable parts are removed and disassembled.
5.2. The bogies are rolled out from under the wagons, washed in a washing machine and delivered to the workshop for repair.
5.3. The coupler is removed for repair.
5.4. Nodes ( Assembly units) brake equipment: air distributors, control devices for automatic linkage regulators and automatic regulators of the braking mode and its drive, limit and disconnect valves, connecting sleeves, exhaust valves, brake line, brake cylinders, spare and two-chamber tanks are removed from the cars and sent for repair.
5.5. The order and extent of disassembly of individual types of wagons are indicated in the 10th and 15th sections of this Guide.
6. DISASSEMBLY, DEFECT AND REPAIR OF TROLLEYS
6.1. Dismantling, flaw detection and repair of bogies must be carried out in accordance with the requirements of the Instructions for the repair of freight car bogies.
6.2. Repair and complete examination of wheel sets is carried out in accordance with the Instructions for the inspection, examination, repair and formation of wheel sets.
6.3. Dismantling, repair and installation of axle boxes are carried out in accordance with the Instructions for the operation and repair of carriage axle boxes with roller bearings.
7. DEFECT AND REPAIR OF THE COUPLING DEVICE
7.1. Removable components and parts of the automatic coupler are removed from the car and completely disassembled in accordance with the Instructions for the repair and maintenance of the automatic coupler of the rolling stock of the railways of the Russian Federation. Carefully check all welded and riveted connections of the coupler with riveting of loose rivets. Installation of an automatic coupler on a wagon must meet the requirements of GOST 3475-81 and the manufacturer's drawings.
7.2. The stops of the main beam, cast together with the impact rosette, are repaired in accordance with the Instructions for the Repair and Maintenance of the Automatic Coupler of the Rolling Stock of the Railways of the Russian Federation and the Instructions for Welding and Surfacing in the Repair of Cars.
7.3. If there are defects beyond repair in the coupler socket molded together with the front thrust squares, the socket may be replaced. At the same time, the thrust squares remain on the car. The new rosette is attached with six 22mm diameter rivets to the end brackets. The end brackets must be made from an angle with flanges 100 x 100 mm and 9 mm thick and welded to the main beam (Figure 1 - here and below the figures are not shown).
7.4. After repair and verification, the following are subject to branding: a lock, a lock holder, a fuse, a hoist, a hoist roller, a traction collar, a roller, a traction collar wedge, a shock socket, a centering device beam, pendulum suspensions, a thrust plate, a draft gear body, an assembled automatic coupler, an insert and a centering device support plate.
Parts that do not have the manufacturer's marking are not subject to repair and are sold as scrap metal.
8. DEFECT AND REPAIR OF BRAKING EQUIPMENT
8.1. Brake equipment is repaired in accordance with the Instructions for the repair of brake equipment of wagons.
8.2. The lever transmission of the automatic and parking brakes is completely disassembled, regardless of its condition, all parts are inspected for wear and cracks. Details that protect parts of the brake linkage from falling onto the track, and checks are standard, corresponding to GOST 1203, and cotter pins are new. Safety brackets are inspected and, if necessary, removed for repair and replacement. It is forbidden to install safety brackets with deviations from the manufacturer's drawings.
8.3. Upon receipt of the wagon for the first overhaul, it is allowed to repair:
With removal from the car, inlet pipes made of thick-walled pipes;
Without dismantling from the car, a two-chamber tank according to TU 32 TsTVR 32-93;
Without removing the brake line from the car, made of seamless pipes and in the absence of faults (wear, thread wear in the tee).
It is allowed to repair the shoe with the restoration of the jumper to the dimensions indicated in the working drawings.
Repair brake devices and fittings in accordance with the repair documentation approved by the Department of Carriage Facilities of the Ministry of Railways of Russia.
When installing repaired brake equipment on a wagon, the presence of tags indicating the date of repair and the conditional number of the enterprise that carried out the repair should be checked.
9. DEFECT, REPAIR OF FRAMES AND PYATNIKS OF CARS
9.1. Frame inspection and repair
9.1.1. Before repair, all parts of the frame are cleaned of dirt, collapsed paintwork, peeling rust and inspected. The thickness of the wall and horizontal shelves are also controlled, the thickness of the metal of closed structures is checked by an ultrasonic thickness gauge of the UZT-93 type.
9.1.2. Welding and surfacing work during the repair of the car frame and its parts is carried out in accordance with the Instructions for welding and surfacing during the repair of freight cars.
9.1.3. Metal beams of the frame, damaged by corrosion of no more than 15% of the cross section, provided that their individual elements (horizontal shelves, vertical walls) are damaged by corrosion of no more than 1/5 of the maximum thickness, are left without repair. Metal frame beams with corrosion damage from 15 to 30% of the cross section and the thickness of individual elements (horizontal shelves, vertical walls) of at least 0.5 of the structural thickness are repaired by welding.
Metal beams of the frame, damaged by corrosion more than 30% of the cross section or the thickness of individual elements is less than 0.5 of the limiting dimensions in a section 500 mm long or more, are replaced with new ones; in case of damage at a length of less than 500 mm, they are repaired with the installation of reinforcing linings.
9.1.4. The frame spine beams that have cracks that do not extend to the vertical walls, as well as abrasions in the places where the draft gears of the automatic coupler are installed with a depth of more than 4 mm, are repaired by placing reinforcing pads 8–10 mm thick on the vertical and horizontal walls.
The overlay is placed on rivets that secure the front and rear thrust squares of the coupler.
In the middle part between the thrust squares, the linings are fastened with five staggered rivets with countersunk heads on the inside of the main beam.
9.1.5. If, due to design features, one end of the lining cannot be strengthened with all the rivets of the rear or front square, it is allowed to fasten it with two rows of rivet joints of the thrust squares.
9.1.6. Wear or misalignment of the bearing surfaces of the supports of the center beam, not more than 3 mm, may be left without correction. Surfaces with high wear are restored by surfacing with subsequent processing. With a wear depth of more than 5 mm, it is allowed to weld strips of appropriate sizes. Repair of the socket of the automatic coupler, cast at the same time with the front thrust squares, is carried out in accordance with the technical documentation approved by the Department of Carriage Facilities of the Ministry of Railways of Russia.
9.1.7. Spinal beams with no more than two breaks or two cracks with a length of no more than 2/3 of the cross section in the middle part between the center supports are subject to repair by welding, followed by reinforcement of the damaged area with overlays.
The crack in the lower flange of the center beam, which passes to the vertical wall by less than 10% of the height of the center beam in the middle part of the car between the center supports, is welded with the setting of a reinforcing corner plate.
A crack in the main beam between the rear thrust square and the pivot beam, passing to the vertical wall, but not more than 50% of the height of the main beam, and at a distance of at least 200 mm from the pivot beam, is welded with the installation of a reinforcing profile lining.
A crack in the center beam in the area of the pivot assembly, which passes to the vertical wall, but not more than 50% of the height of the center beam, and at a distance of less than 200 mm from the pivot beam, is welded with the setting of a reinforcing profile lining after cutting out a part of the vertical sheet of the pivot beam.
The overlay on the spinal beam must be at least 500 mm long. It is installed symmetrically to the crack, if necessary, on the rivets of the rear thrust square and the thrust bearing assembly, and welded. An overlay or an insert with welding around the perimeter is installed on the cut-out part of the vertical sheet of the pivot beam.
PHASE-5|
1. |
Introduction |
2 |
|
2. |
General repair instructions |
2 |
|
3. |
List of required works |
4 |
|
4. |
Possible malfunctions and ways to eliminate them |
5 |
|
5. |
Disassembly of the PHASE-5 ventilator |
12 |
|
5.1. |
Disassembly of the electronics unit |
13 |
|
5.1.1. |
Front panel disassembly |
13 |
|
5.1.2. |
Top panel disassembly |
14 |
|
5.1.3. |
Bottom Panel Disassembly |
15 |
|
5.2. |
Disassembly of the working block |
16 |
|
5.3. |
Dismantling the power unit |
17 |
|
5.4. |
Blower disassembly |
18 |
|
5.5. |
Distribution board disassembly |
19 |
|
6. |
Fault detection of the ventilator PHASE-5 |
20 |
|
6.1. |
Detection of components of the electronics unit |
20 |
|
6.1.1. |
Characteristics of the product as an object of repair |
20 |
|
6.1.2. |
Method for determining defects in a product |
20 |
|
6.2. |
Detection of units of the working block |
22 |
|
7. |
Assembly of the PHASE-5 ventilator |
23 |
|
7.1. |
Blower Assembly |
23 |
|
7.2. |
Assembly of the energy block |
25 |
|
7.3. |
Distribution Board Assembly |
27 |
|
7.4. |
Working block assembly |
30 |
|
7.5. |
Assembly of the electronics unit |
33 |
|
7.5.1. |
Assembly of the top panel |
33 |
|
7.5.2. |
Front panel assembly |
35 |
|
7.5.3. |
Assembly of the bottom panel |
36 |
|
7.5.4. |
Assembly of the electronics unit |
37 |
|
7.6. |
Assembly of the PHASE-5 ventilator |
38 |
|
8. |
Electronics block. general characteristics, description of work |
39 |
|
8.1. |
General characteristics of the electronics unit |
39 |
|
8.2. |
Main technical data |
39 |
|
8.3. |
Brief description of the operation of the electronics unit |
40 |
|
8.3.1. |
Bottom panel |
40 |
|
8.3.2. |
power unit |
41 |
|
8.3.3. |
Control block |
43 |
|
8.3.4. |
Amplifier block |
48 |
|
8.3.5. |
Front panel |
55 |
|
8.3.6. |
Top panel |
59 |
|
8.3.7. |
Display block |
60 |
|
Annex 1. Instructions for the use of lubricant in the product |
62 |
|
|
Appendix 2. Instructions for locking and sealing threaded connections in the assembly units of the PHAZA-5 ventilator |
64 |
|
|
Appendix 3. Instructions for soldering with tin-lead solders |
67 |
|
|
Annex 4. Instructions for additional verification And adjustment of the working unit |
72 |
|
|
Appendix 5. List of spare parts for overhaul |
73 |
|
|
Annex 6. List binding documents and drawings |
78 |
|
|
Annex 7. Annexes to RP5.00-00.000 TU |
79 |
|
PHASE-5
1. INTRODUCTION
This manual has been developed for the overhaul of the PHAZA-5 ventilator. The manual is a document containing instructions for organizing repairs, technical and technological information and is a guide when repairing a product to restore its reliability after the end of a resource.
The manual determines the scope and sequence of work to repair the product.
2.GENERAL INSTRUCTIONS FOR REPAIR
2.1. The assembly room, assembly conditions and assembly should exclude the possibility of dust, moisture, dirt, oil and other substances getting into the working cavities and on the outer surfaces of parts, assembly units and products.
2.2. The assembly must ensure the cleanliness of workplaces, tools, fixtures and overalls.
2.3. The relative humidity of the air in the room should be no higher than 70%, and the temperature should not be lower than 15 0 С and not higher than 30 0 С.
2.4. Alcohol and gasoline used for flushing should be stored in a clean, sealed container made of stainless materials.
2.5. Compressed air used for washing cavities and external surfaces of parts and products must be clean and must not contain any mechanical impurities of oils, vapors, etc. Check the purity of the compressed air at least once a week.
2.6. When assembling, washing, drying, use coarse calico or cotton napkins.
2.7. Lubricate parts of assembly units according to the instructions (Appendix 1). Lubricate rubber rings with VNIINP-282 OST 3801405-86 grease before installation.
PHASE-5
OVERHAUL GUIDE
2.8. Twisting rubber rings is not allowed.
2.9. In all assembly units, all threaded connections that are not locked with lock washers, lock wire, punching and other methods, should be countered with red enamel EP-51 GOST 9640-85 (Appendix 2).
2.10. When tightening hexagonal parts, measures must be taken to exclude the possibility of their shape breaking (twisting of the edges).
2.11. During assembly, tighten fasteners on flange connections alternately in diametrically opposite places (crosswise) with a gradual increase in the tightening torque in several steps.
2.12. Materials for parts made of felt, felt, cloth, etc. must be treated with an antiseptic.
2.13. When checking the product and its units, the requirements of the safety instructions must be strictly followed. When testing for strength and tightness, filters must be installed on the lines supplying the test benches with water or air, and at the inlet to the tested parts and products, to protect the cavities of the parts and products from clogging.
2.14. Measurement of pressure, flow (leakage) of water or air during testing or verification should be carried out with pressure gauges or rotameters of any accuracy class, while the error of the measuring instruments should not exceed 30% of the tolerance, unless a specific type of device is indicated. The accuracy of electrical measuring instruments must be no worse than class 1.5.
2.15. In the process of flaw detection and disassembly of nodes, in order to maintain the relative arrangement of parts in the nodes and ensure subsequent assembly, it is allowed to make technological marks on the mating parts, as well as attach tags to the ends of the mounting wires indicating which terminal the wire is soldered to. During assembly, all screws and nuts that are not locked by spring washers should be locked with red locking compound AK-070.
PHASE-5
OVERHAUL GUIDE
3.LIST OF COMPULSORY WORKS
3.1. Checking the device (preliminary fault detection).
3.2. Disassembly of the PHASE-5 ventilator.
3.3. Detection of the working block (functioning).
3.4. Defection of the electronics unit (functioning).
3.5. Disassembly of the electronics unit for fault detection.
3.6. Dismantling of the block of the worker on defect detection.
3.7. Detection of parts and assemblies of the working block.
3.8. Finding a defect on the boards.
3.9. Assembly of the working block.
3.10. Assembly of the PHASE-5 ventilator.
PHASE-5
OVERHAUL GUIDE
4. POSSIBLE FAULTS AND SOLUTIONS
Table 4.1.
|
Name of the malfunction, external manifestation and additional signs |
Probable Cause |
Remedy |
|
1 |
2 |
3 |
|
1. No gas flow, motor running |
Blower drive belts torn |
Remove the front panel of the working unit, replace the belts |
|
2. The gas flow is weak, the electric motor is running. |
Blower furs torn |
Pick up the apparatus and blower. Replace the failed fur (in accordance with the method of disassembling and assembling the blower). |
|
3. No gas flow, motor not running. When the device is connected to the 220 V network (the S1 knob on the front panel is in the “Apparatus off” position), the indicators turn on for a short time. |
Fuses F1 or F2 blown. Failed optothyristor V2 or rectifier bridge V5 on the bottom panel RP5.05-00.100 The engine has failed. |
Replace fuses *. Call to identify a faulty element. Replace from the spare parts kit. Check the presence of rectangular pulses at the input of the optothyristor (Х1/4А). Frequency - 1280 Hz, pulse duration 50 μs, amplitude - 1.5 V. |
|
PHASE-5 OVERHAUL GUIDE Continuation of the table. 4.1. |
||
|
1 |
2 |
3 |
|
|
Check the presence of pulses on the base and collector of the transistor V10. The amplitude of the pulses on the V10 collector is + 27 V. If there are pulses on the V10 base and no pulses on the collector, replace the faulty V10. Check the presence of pulses on the base and collector of transistor V9. Replace defective element V9. Check the operation of the reference frequency generator 20480 Hz per m/s D1. Replace defective element. Check the passage of pulses of 1280 Hz along the circuit D10.1-D10.2. Check the arrival of the logical “0” level allowing the engine to work at the output D10.2/6, the logical level “1” on D4.4/9 in all positions of the type of work switch S1, except for the position “The device is off”. |
|
|
PHASE-5 OVERHAUL GUIDE Continuation of the table. 4.1. |
||
|
1 |
2 |
3 |
|
4. There is no water heating in the humidifier jar. |
Fuses F5 or F6 blown. The heater burned out. The optothyristor V3 or V4 failed on the bottom panel RP5.05-00.100. The power amplifier of the amplifier unit RP5.05-00.150 is faulty The front panel RP5.05-00.200 is faulty. |
Replace fuses *. Ring the humidifier heater circuit. Replace heater. Check the presence of rectangular pulses at the input of X1/8A optothyristors. Frequency 1280 Hz, pulse duration 50 μs, amplitude 3 V. Check the passage of impulses along the V15-V14 circuit. Check the passage of pulses with a frequency of 1280 Hz along the circuits D1.6-D3.1-D2/7. Check the operation of the reference frequency generator 20480 Hz per m/s D1. Replace defective element. Check the passage of 1280 Hz pulses through the circuit D10.3-D10.1. |
|
PHASE-5 OVERHAUL GUIDE Continuation of the table. 4.1. |
||
|
1 |
2 |
3 |
|
Open circuit or malfunction of one or two thermistors located in the humidifier cover. |
Check the receipt of the logical “0” level allowing the heater to be switched on at the input D10.3/9. Check the operation of the elements of the logic block D8.4, D8.3, D1.3, D3.2, D3.1, D1.1, D4.3, in accordance with the truth tables for describing the operation of the front panel RP5.05-00.200. Replace defective element. |
|
|
5. The gas flow is constant in all modes of the device. There is no characteristic click of the valve actuation. The indicators light up. |
The power amplifier of the “Inhale” valve of the amplifier unit RP5.05-00.150 is faulty. |
Check the passage of control signals for the “Inspiration” valve along the V7-V6 circuit. Replace defective element. Check the passage of control signals on circuits D9 / 8-D9 / 9-D7 / 31. Replace defective element. If the fault cannot be found, contact the manufacturer. |
|
6. when the device is working, no exhalation occurs. The pressure protection is activated. |
The power amplifier of the “Exhalation” valve of the amplifier unit RP5.05-00.150 is faulty. |
Check the passage of control signals for the “Exhalation” valve along the V12-V11 circuit. Replace defective element. |
|
PHASE-5 OVERHAUL GUIDE Continuation of the table. 4.1. |
||
|
1 |
2 |
3 |
|
Faulty control unit RP5.05-00.120 |
Check the passage of control signals on circuits D9 / 10-D9 / 11-D7 / 30. Replace defective element. If it is impossible to find a malfunction, contact the manufacturer. |
|
|
7. The gas flow is constant in all modes of the device. An audible alarm is triggered. The indicators do not light up. When the device is connected to the 220 V mains (handle S1 on the front panel in the “Apparatus off” position), the indicators do not turn on for a short time. |
The control unit RP5.05-00.120 is faulty. |
There is no communication on buses D. Check m / s D7, D10, D11, D8. Replace defective element. If it is impossible to find a malfunction, contact the manufacturer. |
|
8. The device does not work, the “Network” indicator does not light up. |
Fuses F3 or F4 blown. The stabilizer 5V of the power supply RP5.05-00.130 came out of the store. |
Replace fuses *. Disconnect the amplifier unit RP5.05-00.150 and the control unit RP5.05-00.120 from the device. Ring the connectors of these blocks for the absence of a short circuit in the +5 V supply circuits. Check the operation of the stabilizers V3, V5, V6 and the transistor V1 on the bottom panel |
|
PHASE-5 OVERHAUL GUIDE Continuation of the table. 4.1. |
||
|
1 |
2 |
3 |
|
RP5.05-00.100 in accordance with the description of the power supply. Replace defective items. |
||
|
9. The gas flow is constant in all operating modes of the apparatus. The indicators do not light up. When the device is connected to the 220 V network (the S1 knob on the front panel is in the “Apparatus off” position), the indicators turn on for a short time. |
The power supply unit RP5.05-00.130 is faulty. The secondary power converter has failed. |
Disconnect the amplifier unit RP5.05-00.150 and the control unit RP5.05-00.120 from the device. Ring the connectors of these blocks for the absence of a short circuit in the supply circuits +15 V, -15 V. Control the supply of + 5V power to the emitters of transistors V8, V9. Check the operation of the converter in accordance with the description of the operation of the power supply 9the presence of generation, the operation of the rectifier bridge V10 ... V13. Replace defective element. |
|
10. No indication. The device is working. |
The control unit Rp5.05-00.120 is faulty. |
Check the supply of voltage +5 V to the emitters of transistors V1 ... V9. Check the operation of the decoder D2 in accordance with the truth table of the description of the operation of the display unit. Replace defective element. Check the passage of pulses through the tires Ind. (1,2,4,8) from interface D10/(40,39,38,37) to decoder D2 of the display unit. Check the receipt of the “Reset” command at the input R m / s D10 / 35 in accordance with the description of the control unit. Replace defective element. |
|
PHASE-5 OVERHAUL GUIDE Continuation of the table. 4.1. |
||
|
1 |
2 |
3 |
|
11. No indication of one or more digits. The device is working. |
The display unit RP5.05-00.310 is faulty. |
Check the operation of the corresponding transistors V1 ... V9. Replace defective element. |
|
12. There is no indication of some segments of digital indicators. |
The display unit RP5.05-00.310 is faulty. |
Ring the faulty segments with a tester. Check the operation of the decoder D1 in accordance with the truth table of the description of the operation of the display unit. |
|
13. Extraneous noise. |
The springs are broken, the blower bearings are loose. |
Dismantle the apparatus and blower. Replace springs, fix bearings. |
|
14. Uneven gas flow. |
Loose or deformed valves in the blower. |
Dismantle the apparatus and blower. Replace valves in blower. |
* Note. The fuses are located under the right side cover of the PHAZA-5 ventilator.
PHASE-5
OVERHAUL GUIDE
5. DISASSEMBLY OF THE VENTILATOR PHASE-5 RP5.01-00.000
Turn out ten screws poz.12, fixing the false panel and block
2. Remove the electronics unit pos.2 from the frame of the working unit pos.1.
Unscrew the twelve screws pos. 12, fixing the lining pos. 5, 6 to the frame
PHASE-5
OVERHAUL GUIDE
5.1. DISASSEMBLY OF THE ELECTRONICS UNIT RP5.05-00.000
1. Unscrew the locking screw from the handle pos.3. Remove the handle pos.3.
2. Unscrew the three nuts pos.9. Remove the false panel pos.5.
3. Remove the five screws pos. 14, fastening the top panel pos.4 to the bottom
panel pos. 1. Unscrew the four screws securing connectors X 2, X 4,
unplug connectors. Remove the top panel pos. 4.
4. Remove the four screws pos. 13, fixing the front panel pos. 2 k
bottom panel pos. 1. Unscrew the two screws securing the connector X 1,
unplug the connector. Remove the front panel pos. 2.
5. Unscrew the four screws pos.13 securing the back wall pos.6 to the frame.
Remove the back wall pos. 6.
5.1.1. DISASSEMBLY OF THE FRONT PANEL RP5.05-00.200
Remove the six handles pos.4, 5 with force. Loosen six nuts
2. Unscrew the locking screw from the handle pos.6. Remove the handle pos.6.
Remove the sealing sleeve with the remote control cord from the false panel pos.11.
Remove false panel.
3. Remove six screws pos.18 with washers pos.22, 23, securing the board
pos.2 and front panel pos.10.
4. Remove two screws pos.20 with nuts pos.21 and washers pos.23, 22,
fixing the bracket pos.12 to the front panel pos.10.
5. When replacing the switch poz.30, unscrew the nut with a washer that secures
switch poz.30 to the bracket poz.12. Remove switch pos.30.
PHASE-5
OVERHAUL GUIDE
5.1.2. DISASSEMBLY OF THE TOP PANEL RP5.05-00.300
Unsolder the four wires from the block X5 coming from the converter
Unscrew the nut that secures the rubber tube pos.10 coming from
3. Unscrew the nut pos.54 with a washer that secures the pressure transducer to
bracket. Break the thread that secures the wires B1.
Remove pressure transducer.
4. Unscrew the four screws poz.35, fixing the board poz.25 to the panel poz.1.
5. Disconnect connector X 3. Remove board pos.25.
6. Remove the tube pos.9 from the fitting pos.11. Remove the four screws securing
pressure and vacuum gauge pos.19 to the panel pos.1. Remove the pressure gauge.
7. Unsolder four wires from the switch contacts poz.56.
8. Unscrew the nut securing the switch poz.56 to the panel.
Remove switch.
9. Unsolder six wires from the contacts of the buttons pos. 54.55,
10. Unscrew the nuts that fasten the buttons pos.54,55 to the panel pos.1.
Remove buttons.
11. Unsolder eight wires from the outputs of the LEDs V1, V2, V3,
after removing the insulating tubes poz.65.
12. Unscrew the two nuts poz.40, fastening the bar poz.31 to the panel poz.1.
Remove the bar pos.31.
PHASE-5
OVERHAUL GUIDE
5.1.3. DISASSEMBLY OF THE LOWER PANEL RP5.05-00.100
1. Remove the boards pos.1,2,3 from the guides pos.22, 23.
2. Break the thread that secures the tourniquet to the post pos. 17.
3. Loosen the nuts pos. 38, fixing the panel pos. 20 on racks pos. 17.
4. Unscrew the screws poz.35, fixing the board poz.19 to the casing poz.11.
5. Unsolder the wires from the outputs of the optothyristors pos. 60, previously
removing the insulating tubes.
6. Unscrew the nuts poz.38, fixing the optothyristors poz.60 to the board poz.19.
Remove optothyristors.
7. Unsolder the wires from the terminals of the rectifier bridge V5 pos. 61,
having previously removed the insulating tubes.
8. Unscrew the screw poz.34 that secures the rectifier bridge to the board poz.19.
Remove rectifier bridge V5.
PHASE-5
OVERHAUL GUIDE
5.2. DISASSEMBLY OF THE UNIT WORKING RP5.02-00.000
1. Unscrew the four screws poz.40, fixing the rear wall poz. 4 to the frame of the working unit. Remove the rear wall pos. 4.
2.Remove the locking screws pos. 60 of the handles pos. 5. Remove two handles pos.5.
Unscrew the five screws pos. 40, fixing the panel pos. 29 to block frame
Unscrew the four screws pos. 62, fixing the four legs pos. 34 to the bottom cover pos. 43. Remove the legs pos. 34. Unscrew the two decorative nuts securing the buttons pos. 102 to the bottom cover. Remove the bottom cover pos. 43.
5. Using force, remove the four covers pos. 51, 52, 53, 54 from nozzles.
Remove the rubber rings pos. 85. Unscrew the four screws poz.40, fixing the panel poz. 25 to the frame of the working unit. Remove panel pos.25.
Unscrew the two screws pos. 66. fixing the bracket pos. 1 to spigot
7. Unsolder the three wires on the block pos.100 from the electromagnets.
Remove distribution board pos.12.
8. Unsolder the three wires on the block pos. 101 from the engine pos. eleven.
9. Break the thread connecting the two bundles.
10. Unscrew five nuts poz.72 with washers poz. 81 fixing the base
pos. 24 to the base of the energy block pos. eleven.
Remove the energy block pos.11.
11. Remove gears pos. 38, 39, with great effort.
PHASE-5
OVERHAUL GUIDE
5.3. DISASSEMBLY OF THE ENERGY UNIT RP5.03-00.000
1. Unscrew two nuts poz.45 with washers poz.56. Remove clamp pos.1.
2. Unsolder the wires from the capacitors pos.63,64.
3. Remove the belts pos.28 from the pulleys pos.7.8.
Unscrew four nuts poz.46 with washers poz.58. Remove base pos.10
5. Remove four screws poz.38 with washers poz.57 and nuts poz.46.
Remove the motor pos.68 from the base pos.10.
6. Unscrew six screws poz.39 with washers poz.57, fixing the clamps
pos.25. Remove clamps pos.25.
7. Unscrew the six screws pos.37, fixing the blower pos.3 to
base pos.9. Remove blower pos.3.
8. Unscrew the four screws pos.40, fixing the frame pos.5 to the base pos.9.
Remove frame pos.5.
9. Unscrew the pulley pos.8. Remove the pulley and spring from the shaft pos.6.
10. Remove four screws poz.35 with nuts poz.45 and washers poz.56,
fastening washers poz.26, bearing poz.52 to the frame poz.5.
Remove four rings poz.48 from two bearings poz.52. Take off one
bearing poz.52.
11. Remove six rings poz.49 from the eccentrics poz.12. Remove with force three
bearing poz.53 with eccentrics poz.12. Knock out the pins pos.14.
Release the shaft pos.6, the frame pos.5.
PHASE-5
OVERHAUL GUIDE
5.4. DISASSEMBLY OF THE BLOWER RP5.08-00.000
1. Cut the safety wire poz.54. Remove eighteen screws pos.44 with washers pos. 50, fastening the strap poz.19 to the strap poz.12. Remove three strips pos.19.
2. Unscrew twelve bolts poz.42 with washers poz.51, fastening poz.27 bar, poz.29 spring, poz.12 strap, poz.8 insert, poz.25 flange. unscrew the twelve nuts poz.53 with washers poz.51, fixing the bar poz. 28, spring poz.29 to the channels poz. 5.6.
3. Remove the twelve screws pos. 46, fastening liners pos.8, bellows pos.21, flanges pos.25. Remove six inserts pos.7,8.
4. Unscrew the nut pos. 23 with gasket poz.24 together with connecting rod poz.22. Release three inserts pos.8.
5. Remove the sixteen screws pos. 45 with nuts pos. 53 and three screws poz.47, fixing the channel poz. 5.6, covers pos.10.11, gaskets pos. 13, board pos.9. Remove six bellows pos.21.
6. Loosen the three nuts pos. 53 with washers poz.52, fixing pipes poz. 3.4 to the board pos. 9. Remove two branch pipes pos.3,4.
7. Remove one screw pos. 42 with a nut poz.53, fixing the covers poz.10,11 with gaskets poz.19 to the board poz.9. Remove two covers pos.10,11.
8. Remove the twelve valves pos.16 from the caps pos. 10.11.
PHASE-5
OVERHAUL GUIDE
5.5. DISASSEMBLY OF THE DISTRIBUTION BOARD RP5.04-00.000
1. Remove the tube pos.25.
2. Remove the sixteen screws pos. 54 with nuts pos. 57 and washers pos. 59, fixing the adapter pos. 28, adapter pos. 20, adapter pos. 29, throttle pos. 4, two electromagnets. Remove two membranes pos.46. Remove the two gaskets pos. 15 and bar pos. 16. Remove valve pos. 52 from the bar pos. 16.
3. Unscrew the rod in the throttle poz.4. Remove rubber ring.
4. Remove the four screws pos. 33 with nut pos. 57 and washer poz.59, fixing the body poz. 10 with base pos. 9 to the board pos. 8. Remove the housing, take out the diaphragm pos. 3. Unscrew the stem poz.65. Remove ring pos.35 and spring pos. eleven.
5. Remove the base pos.10, remove the gasket.
6. Unscrew the nut poz.63. Remove diaphragm pos.3.
7. Disassemble the solenoid valve. Unscrew the supports pos. 24 with great effort. Unscrew the anchors pos. 49, 51, with an effort. Pull out two coils pos. 5.
PHASE-5
OVERHAUL GUIDE
6. DEFECT OF THE PHASE-5 VENTILATOR
6.1. ELECTRONICS UNIT DEFECT
6.1.1. CHARACTERISTICS OF THE PRODUCT AS A REPAIR OBJECT
1. The design of the electronics unit is technological, made of separate independent interchangeable boards (see clause 1.3). This design makes it possible to repair the electronics unit not only by replacing failed assembly units with standard ones, but also by restoring them in appropriate cases.
2. In the technical documentation for the electronics unit, materials, devices, elements that require special permission are not used. All materials used in the electronics block are mass-produced by the industry.
3. When repairing the electronics unit RP5.05-00.000, additional requirements that differ from the requirements of the technical specifications are not provided.
6.1.2. METHOD FOR DETECTING DEFECTS IN A PRODUCT
1. After accepting the product for repair and after carrying out an external inspection in assembled form, it is necessary to eliminate the malfunction of the product using the "List of possible defects, methods for their elimination".
2. Repair of the product is carried out by replacing failed assemblies with standard ones and, in technically feasible cases, by replacing failed ERE.
3. Check the defective blocks and boards removed from the product for compliance with the technical requirements of the drawings and setup instructions.
4. When inspecting defective blocks and boards (panels), check:
There are no cracks, traces of corrosion on the cases and boards, leading to the failure of the unit;
reliability of fastening parts and radio elements (capacitors, diodes, microcircuits, transistors) to the block boards;
OVERHAUL GUIDE
The quality of the desoldering of elements;
Integrity of printed wiring of blocks and boards;
Lack of curvature, corrosion and pollution of contacts of sockets RP15, GRPMSh, RP14;
The absence of foreign objects in the block.
5. If the blocks and boards removed from the product do not comply with the technical requirements of the drawings and instructions, it is necessary to determine the failed element, part. Defective elements, parts of a faulty block must be replaced with elements, parts indicated in the spare parts list (Appendix 5), guided by the technological process for the repair of the corresponding block.
PHASE-5
OVERHAUL GUIDE
6.2. DEFECT OF ASSEMBLY AND PARTS
UNIT WORKING RP5.02-00.000.
1. External inspection to make sure that there are no signs of corrosion, nicks, dents, mechanical damage. Flared parts - for the absence of swings and distortions.
2. Having found corrosion, clean the places of corrosion and cover with glue.
3. Changes in geometric shape that do not affect the nature of mating and performance, minor local violations of coatings and roughness caused by normal effects of parts during assembly (tightening, fit, etc.) are allowed on the parts.
4. Carefully review all rubber parts: bellows, valves, gaskets. Rubber wear, cracks, deformations are not allowed.
5. Re-use of retaining rings and safety wire is not allowed.
6. Check the condition of the wiring, the integrity of the insulation of the wires, the absence of breaks.
7. Carefully inspect all gears of the work unit. Chips, cracks, deformations are not allowed. If defective parts are found, replace with new ones.
8. Minor thread chipping is allowed with a depth of not more than 20% of the profile height. Chipping of individual threads should not exceed half the length of the thread. Replace if defective screws are found.
PHASE-5
OVERHAUL GUIDE
7. ASSEMBLY OF THE PHASE-5 VENTILATOR
7.1. BLOWER ASSEMBLY
1. Wash rubber parts in alcohol:
gasket pos.13 - 2 pcs.
valve pos.16 - 12 pcs.
gasket pos.12 - 2 pcs.
bellows pos. 21 - 6 pcs.
2. Wash the following parts with an alcohol-petrol mixture:
nozzles pos. 3.4 - 2 pcs.
board pos. 9 - 1 pc.
covers pos.10, 11 - 2 pcs.
inserts pos. 7, 8 - 2 pcs.
Blow out parts with compressed air.
3. Clean the parts and assembly units from the locking composition by repeated thorough wiping with a cloth of coarse calico soaked in solvent. Rinse parts in gasoline and blow with compressed air.
4. Perform quality control of degreasing. If there are no traces of oil and dirt on the napkin, the surface is considered fat-free. Dry the parts on a cotton napkin.
5. Insert the bellows pos.21 into the channels pos.5,6.
6. Fasten to the board pos.9 gaskets pos.13, covers pos.10.11 with valves, channels pos.5.6 with screws, washers and nuts pos.47, 45, 53. Bellows pos.21, installed on opposite sides of the board, should be located along the same axis.
Channels must be at the same level. Lock the screws according to the instructions (Appendix 2).
7. Put on the bellows pos.21 flanges pos.25.
8. Put the gasket poz.24 in the bushing poz.8 and screw the nut poz.23 with the connecting rod poz.22. Install the connecting rod vertically, while the nut pos. 31 must be adjacent to the gasket poz.24.
PHASE-5
OVERHAUL GUIDE
9. Install inserts pos.7, 8 into flanges pos.25. Fasten with screws.
10. Fix the flange poz.25 with inserts poz.7,8, poz.12 strap, poz.29 spring, poz.27 strap poz.42 bolt with washer poz.51. Turn the bars poz.27 to the springs poz.29 with a radius R 1+ 0.5 (see B - B, A - A).
11. Fix the spring poz.29 with the strap poz.28 on the channels poz.5,6 nut poz.53 with washer poz. 51. Turn the bars poz.28 to the springs poz.29 with a radius R 1 + 0.5 (see B - B). Spring pos. 29 must be tensioned evenly.
12. Fix the branch pipes pos. 3.4 with gaskets pos.18 nuts pos.53 with washers pos. 52. Screw the bolt poz.42 with the nut poz.53, lock according to the instructions (Appendix 2).
13. Rubber parts in assembly units must be aligned with the edges, sit tightly in the grooves, grooves and must not have cracks or folds. When assembling the assembly, tighten the fasteners until the tightness requirements of the assembly are met. Clamping of rubber parts is not allowed.
14. Fix the strips pos.19 with screws pos.44,43 with washers pos.50. Lock the screw heads with wire poz.54.
15. There should be no touching of the moving parts of the assembly on the fixed ones.
16. Check blower for leaks. It must be airtight when tested with air at a pressure of 50 + 10 cm of water. Art. under the water. Bring air to the branch pipe pos.4, and close the branch pipe pos.3. Air leakage within 1 min. not allowed.
17. Put technological plugs on the nozzles. Blow out the blower with compressed air.
18. Wipe the springs pos.29 with an oiled cotton cloth or a soft brush. Oil industrial I12A or I20A.
COMPILED by the Chisinau department of the Central Design Bureau of Glavenergoremont
Authors engineers S.A. Fridman, V.I. Smolyak, R.D. Mirsoyapov, I.M. Chernyakhovsky, Yu.Ya.Agapov, Yu.I.
Editor Eng. L.F. Tafipolsky
AGREED by Chief Engineer production association"Uralelektrotyazhmash" A. Kazantsev March 29, 1974
APPROVED by Chief Engineer of Glavenergoremont V. Kurkovich on September 26, 1974
INTRODUCTION
INTRODUCTION
The organization manual for the overhaul technology of the VMD-35/600 oil circuit breaker provides for the use by repair personnel of energy enterprises and other specialized enterprises of the most rational forms of organization of repair work and advanced technological methods for their implementation.
The manual was developed based on the drawings and instructions of the manufacturer and the best repair experience in a number of enterprises.
The Manual defines a strict sequence and scope of repair operations, provides regulatory materials on the technology and labor costs for repairs, the qualifications of the repair personnel, as well as recommendations for identifying defects in parts. A list of means (tools, fixtures, fasteners, etc.) necessary for the repair work is given (Appendices 1, 2, 3 and 4).
The total cost of overhaul of one circuit breaker is 28.2 man-hours, including 24.0 man-hours directly for repairs, 4.2 man-hours for setting up the circuit breaker.
The labor costs indicated in the operating cards cannot be used to determine the timing and cost of repair work, since they do not take into account the time for preparatory and final work, downtime, breaks, rest, etc. This time is approximately 8.5% of the total breaker repair time.
I. GENERAL PROVISIONS
This Guide is intended for manufacturing enterprises as a regulatory document in the planning, preparation and production of repair work.
Since the Manual provides for the repair of all circuit breaker components, the total labor costs are higher than the standard ones. The volume of repair work can be reduced or increased by the decision of the persons responsible for the operation and repair of equipment, but the actual labor costs should not exceed the normative ones.
Further improvement of this Guide, aimed at improving the quality, level of organization and production of repair work, at reducing the repair time, will be carried out as new technological solutions are accumulated and adopted.
The overhaul technology provides for the replacement of damaged or worn parts with spare parts.
Repair of parts that lengthen the downtime of equipment in repair is not recommended. Repair of such parts is carried out during the overhaul period with their further use as an exchange fund of spare parts.
The manual provides for the verification and repair of relay protection devices, automation, secondary switching circuits and electrical testing by personnel of the relevant services.
The labor costs given in the Guidelines are determined on the basis of the "Time Standards for Capital, Current Repairs and Operational Maintenance of 35-500 kV Substation Equipment", approved by the USSR Ministry of Energy in 1971, and can be further reduced by improving the organization and technology of repair work.
During the production of works, the repair personnel must strictly comply with current rules safety technology.
Ensuring the conditions for the safe production of repair work is assigned to the operational (operational) personnel of the electric grid enterprise and power plant.
II. PREPARATION FOR OVERHAUL
Preparation for overhaul should be carried out in accordance with the specific scope of work provided for this equipment.
The most rational is the following order of preparatory work:
- familiarization with the statement of the volume of repair work;
- familiarization with the measures recommended by the factory instructions, circulars of the Main Technical Directorate of the USSR Ministry of Energy to improve the reliability of equipment operation;
- familiarization with the documentation of previous repair work or installation;
- determination of the qualification and quantitative composition of the repair team;
- study with the maintenance personnel of instructions on the organization and technology of the overhaul of the circuit breaker;
- development of a plan for equipping workplaces and placing parts, assemblies, fixtures and tools.
Before starting repair work, check:
- availability of necessary spare parts;
- availability of technical documentation;
- availability of devices, tools, inventory and means of mechanization of work;
- availability of lifting and transport mechanisms and rigging devices and their suitability for operation in accordance with the rules of the USSR Gosgortekhnadzor (together with operating personnel);
- suitability of premises for mobile storerooms for storing tools, fixtures and materials for equipment repair.
III. ORGANIZATION OF REPAIR WORKS
The repair is managed by a representative of the repair unit (repair manager).
Acceptance of equipment from repair is carried out by operational services in accordance with existing regulations.
The terms of repair of equipment should be determined taking into account the following organizational measures:
- the composition of the team is determined by the circuit breaker overhaul technology scheme (Appendix 5 - see insert). A change in the composition of the brigade before the completion of work at individual nodes is not allowed;
- the mode of operation of the repair personnel should be subject to the maximum reduction in the terms of repair work;
- to ensure the performance of repair work, it is recommended to issue standardized task plans, use the assembly-nodal repair method and use the exchange fund of parts.
The completion of repair work is documented by a technical act (Appendix 6) and signed by representatives of repair and maintenance enterprises (services).
IV. MAIN TECHNICAL DATA OF OIL SWITCH VM-35/600 (GOST 687-67)
|
Rated voltage, kV |
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Maximum operating voltage, kV |
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Rated current, A |
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Limit through current, kA: |
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effective value |
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amplitude |
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Thermal stability current (kA) for a period of time, s: |
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Breaking current, kA |
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Breaking power, MVA |
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Breaking speed of moving contacts (m/s) at: |
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opening |
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leaving the cells |
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maximum |
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Circuit breaker opening time |
Not more than 0.06 |
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Weight of circuit breaker without drive, kg |
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Oil mass, kg |
V. MAIN TECHNICAL DATA OF DRIVE PE-11 (GOST 688-67)
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Rated voltage of switching and disconnecting electromagnets, V |
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Rated current of electromagnet windings, A: |
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including |
116 (at 110 V) |
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shutting down |
2,5
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Rated current of the switching winding of the KMV-521 contactor (A) at voltage, V: |
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Shaft rotation angle, deg. |
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Drive mass, kg |
VI. BREAKER OVERHAUL TECHNOLOGY
OPERATION 01
OUTSIDE INSPECTION OF THE SWITCH AND DRIVE
Node 01. Switch
Labor costs - 1.0 man-hour
01.1*. Carry out a test cycle of switching on and off the switch, paying attention to the correct position of all levers and rods, as well as the position indicator.
_________________
* The numbers before the dot - the number of the operation, after the dot - the number of the transition.
01.2. Clean the switch inputs from dirt and dust. Identify defects (Appendix 7).
Equipment: rags.
01.3. Make sure there are no oil leaks. If there is a leak, identify the cause and eliminate during the repair process.
01.4. Check the correct installation of the frame 28 (Fig. 1) of the circuit breaker and the horizontal position of its upper base, on which the cover 32 is fixed. In case of deviation from the horizontal plane, align the frame by installing a lining under the support legs.
Fig.1. Oil switch BM-35/600
Fig.1. Oil switch VM-35/600:
1 - cap; 2 - steel wire with a diameter of 0.5 mm (GOST 3282-46*); 3 - plate; 4 - rivet
diameter 3x8 mm; 5 - washer pr.20N; 6 - nut M20; 7 - bolt M20x1015; 8 - washer 10.5/22x2; 9 - bolt M10x20;
10 - washer pr.16N; 11 - bolt M16x70; 12 - nut M16; 13 - pipe; 14 - screw M6x12; 15 - puck
diameter 6.5 (14x15); 16 - nut M6; 17 - washer; 18 - restrictive screw; 19 - nut M12; 20 - gasket;
21 - fastening of the insulator and current transformer; 22 - bracket; 23 - bolt M10x30; 24 - washer pr.10N;
25 - nut M20; 26 - washer pr.20N; 27 - arc extinguishing device; 28 - frame; 29 - tank; 30 - removable
winch; 31 - casing; 32 - cover; 33 - capacitor input; 34 - axis with a diameter of 10x40 mm;
35 - cotter pin 3.2x40 mm; 36 - rod; 37 - nut M10; 38 - ear; 39 - spring; 40 - glass; 41 - spring;
42 - bolt M10x18; 43 - washer 11/18x1.5; 44 - cylinder; 45 - nut M30; 46 - connecting pipe
________________
* GOST 3282-74 applies. - Note "CODE".
Equipment: bar level.
01.5. Inspect the fastening of the frame to the foundation. Anchor bolts must have locknuts. The frame must be securely grounded.
01.6. Inspect the cabinet with the drive (Fig. 2), clean it from dust. Pay attention to the condition of the seals, the absence of smudges, rust and mechanical damage.
Fig.2. Drive cabinet
Fig.2. Drive cabinet:
1 - heating PST; 2 - nut M10; 3 - bolt M10x20; 4 - washer 11/22x2 mm; 5, 32 - spring; 6, 15 - axis;
7, 34 - cotter pin 3.2x20 mm; 8 - bolt M12x30; 9 - drive PE-11; 10 - frame; 11 - contactor KMV-521; 12 - washer;
13, 23 - washer 6.5 / 14x1.5 mm; 14 - finger; 16 - cotter pin 1.5x16 mm; 17, 39 - M6x16 bolt; 18, 40 - washer pr.6N;
19 - contact row KR-10; 20 - plate; 21 - rivet with a diameter of 3x8 mm; 22 - screw M6x18;
24 - contact row KR-12; 25, 36 - strap; 26 - bolt M8x25; 27 - washer pr.8N; 28 - nut M8; 29 - handle;
30 - cable fittings; 31 - stock; 33 - washer 8.5 / 18x1.5; 35 - contact row KR-16; 37 - collar;
38 - screw M6x12; 41 - wiring
Equipment: brush, rag.
01.7. Inspect contactor 11, clean it from dust, check the condition of the contacts.
01.8. Inspect and clean the contact rows 19, 24, 35 of dust. Make sure that there is no oxidation of the contacts, burn marks and loosening of the screws.
Equipment: brush, rag.
01.9. Inspect power circuits and secondary switching circuits. Pay attention to the quality of cutting, termination and insulation condition. Check fastening of power circuits and secondary switching circuits.
Equipment: brush, rag.
01.10. Inspect cabinet heating device 1. Remove dust, check the condition of the contacts on the terminals of the heating element.
Equipment: brush, screwdriver.
01.11. Check operation of the manual override device. The rod should not have distortions along the entire length, burrs and nicks in the working part. The spring must not have cracks, breaks and residual deformation. Under the action of the spring, the rod should freely return to its original position.
01.12. Clean the drive mechanism 10 (Fig. 3) from dust, dirt and old grease, inspect, paying attention to:
a) correct installation and fastening of the drive;
b) state of lubrication in friction units;
c) the degree of corrosion of parts.
Fig.3. Drive mechanism PE-11
Fig.3. Drive mechanism PE-11:
1, 7, 23, 37, 39, 42, 43 - axes; 2, 8, 17, 22 - cotter pins 3x20 mm; 3, 31, 33 - springs; 4 - holding dog;
5, 6, 11 - earrings; 9 - lever; 10 - assembled mechanism; 12, 16, 21, 27 - washers 12.5 / 25x2 mm; 13 - shaft; 14 - body
mechanism; 15, 24, 28 - washers 13.5 / 20x0.5 mm; 18, 26, 34, 35 - bushings; 19 - retaining ring; 20 - stopper;
25, 29, 36 - cotter pin 3x30 mm; 30 - trip dog; 32, 38 - roller; 40 - hairpin M8x60 mm;
41 - handle; 44 - cotter pin 3.2x20 mm; 45 - washer pr.8N; 46 - nut M8; 47 - M8x30 bolt
Equipment: brush, rag.
01.13. Make sure that there are no jams in the lever mechanism, for which, without dismembering the lever mechanism with a gear mechanism or a gear mechanism with a switch, turn on the drive manually, and then, retracting the lever or manual jack to turn it off, slowly turn off the mechanism. In this case, the shaft of the lever mechanism 13 must rotate freely in the bearing, and the earrings 5, 6, 11 - on the axles; pawls 4, 30 can be easily rotated on their axes, and springs 3, 31 of pawls 4, 30 must be securely fastened.
01.14. Check the integrity of the cotter pins and washers, make sure that there are no dents and cold hardening on the ends of the axle 37, lying on the shoulders of the holding pawl 4 and on the roller 32, lying on the shoulder of the disconnecting pawl 30.
01.15. Check the absence of burrs and saddles on the working surfaces of pawls 4, 30.
01.16. Visually check the wear of parts, determine the required amount of disassembly and repair of the drive mechanism.
01.17. Inspect, clean from dust and grease auxiliary contacts 1 (Fig. 4) of the tripping electromagnet, check the clamps and the condition of the gasket 14.
Fig.4. Shutdown solenoid
Fig.4. Shutdown solenoid:
1 - block contact; 2 - hairpin M8x80; 3 - nut M8; 4 - washer pr.8N; 5 - washer 11/18x1.5 mm; 6 - stock;
7, 12 - cover; 8 - casing; 9 - coil; 10 - screw M4x10; 11 - sleeve; 13 - core; 14 - gasket;
15 - bracket; 16 - textolite washer; 17, 20 - spring; 18 - fixed contact;
19 - moving contact; 21 - cotter pin; 22 - thrust
Equipment: brush, rag.
01.18. Manually check the operation of cores 1 with rods 10 (Fig. 5) and 13, 6 (see Fig. 4) of the turning on and off electromagnet. The absence of distortion and jamming of the core with the rod is checked by raising the core to the upper position with its simultaneous rotation by 10-20 ° around the vertical axis and subsequent free fall to its original position. Check the condition of the rubber buffers 21 (Fig. 5) at the base of the switching electromagnet.
Fig.5. Electromagnetic drive PE-11
Fig.5. Electromagnetic drive PE-11:
1 - core; 2 - nut M12; 3, 18 - washer pr.12N; 4 - hairpin M12x160; 5 - base; 6 - gasket;
7 - switching coil; 8 - magnetic circuit; 9 - spring; 10 - stock; 11 - sleeve; 12 - washer; 13 - screw
M6x10; 14 - bushing; 15 - KSA; 16 - switching mechanism; 17 - bolt M12x35; 19 - disconnecting
electromagnet; 20 - contact row KR-10; 21 - rubber buffer (gasket); 22 - stopper; 23 - casing
01.19. Remove dust, grease and inspect the contacts of the KBV, KBO to the KSA (Fig. 6). Pay attention to the condition of moving and fixed contacts, springs, clamps, contact screws, rods and levers.
Fig.6. Installation of auxiliary contacts
Fig.6. Installation of auxiliary contacts:
1, 6 - levers; 2, 4, 7 - thrust; 3 - signal contact KSA; 5 - cotter pin 2x15 mm; 8 - nut M8;
9 - fork; 10 - high-speed contacts of the KBV to the OBE
Equipment: brush, rag.
Based on the results of the inspection, determine the final extent of the drive repair.
OPERATION 02
REPAIR OF THE CLOSING MECHANISM*
________________
* Disassemble the drive only if a malfunction is detected that interferes with further normal operation. When performing repairs with partial disassembly, the repair technology is described in the future for individual mechanisms, into which the drive is conditionally divided.
Node 02. Drive PE-11
Labor costs - 0.5 man-hours
The composition of the link: electrician of the 4th category - 1 person.
02.1. Unfasten and remove axle 37 (see Fig. 3) with bushings 35 and roller 38. Unpin and remove axle 7 with washers 12; remove the earring 6. Unpin the rods 2, 4, 7 (see Fig. 6) and disconnect them from the lever 6. Knock out the conical screw and remove the fork from the drive shaft.
Equipment: hammer, pliers.
02.2. Unscrew the stopper 20 (see Fig. 3) and remove the retaining ring 19.
Equipment: screwdriver.
02.3. Remove shaft 13 with lever 9 from the bearing.
02.4. Clean the removed parts from dirt and old grease. If necessary, rinse with gasoline (unleaded).
Equipment: rags.
02.5. Identify defects and make the necessary repairs of shaft 13, axles 7 and 37, roller 38, holes in earring 6 and lever 9.
Equipment: metal ruler, micrometer, caliper, hammer, file, sandpaper.
02.6. Clean the shaft bearing 13 from dirt and old grease. Make sure there are no burrs or nicks on the friction surfaces. Existing burrs and notches should be cleaned with a file or sandpaper.
Equipment: file, sandpaper.
02.7. Fill the shaft bearing with CIATIM-203 grease (3 volume parts) and silver crystalline graphite GOST 5279-61* (1 volume part). Apply the same lubricant to the friction surfaces.
________________
* GOST 5279-74 applies. - Note "CODE".
02.8. Assemble parts according to steps 5-1 paying attention to:
- lack of distortions;
- compliance of details with the original position;
- the presence and serviceability of washers and cotter pins.
The use of copper wire for cotter pins is unacceptable!
02.9. Disconnect the leads of the closing coil 7 (see Fig. 5) from the clamps in the contact row KR-10.
Equipment: screwdriver.
02.10. Unscrew nuts 2 from studs 4 and remove electromagnet.
Equipment: wrench 17x19.
02.11. Remove dust and old grease from the removed parts, inspect, paying attention to:
- the state of the magnetic circuit and the base. Cracks should be welded, rusted areas should be cleaned and painted over. Clean the joints of the magnetic circuit and the base from paint, varnish, dirt;
- the state of the brass washer 12 and its fastening with screws 13. The screws must be tightened to failure and punched into the slot in two places;
Bushing surface condition 14. Carefully remove burrs and nicks with a file or sandpaper;
- state of the sleeve 11. Align dents, eliminate ellipticity;
- state of the surface of the core 1. Remove rust, paint with a file, sandpaper. Wipe the core with a cloth soaked in gasoline and grease with a thin layer of CIATIM-203 lubricant;
- the condition of the rubber pads 21 in the lower part of the base and their fastening. Rubber pads should be attached to the base using metal strips and two screws flared into the holes in the base. The height of the rubber gaskets with metal strips should provide a distance between the brass washer and the upper end of the core, equal to 81 mm.
Equipment: rags, brush, file, sandpaper.
02.12. Identify defects and make the necessary repair of the rod 10 and spring 9 in accordance with Appendix 8 (clauses 7 and 8).
Rod 10 is screwed into the core and locked. If necessary, the length of the rod can be adjusted by screwing it in or out of the core body.
Equipment: pliers, file, screwdriver.
02.13. Check the resistance of the switching coil, which should be 3.096-4.101 ohms at 220 V = and 0.874-1.028 ohms at 110 V =.
Rigging: MMV bridge.
02.14. Check the insulation resistance of the closing coil and the supply wires with a megger (resistance must be at least 1 MΩ).
Equipment: megohmmeter 1000 V.
02.15. Assemble the switching electromagnet according to transitions 10-9, paying attention to the tight fit at the joints of the parts of the magnetic system.
OPERATION 03
REPAIR OF THE DISCONNECTING MECHANISM
Node 02. Drive PE-11
Labor costs - 0.8 man-hour
The composition of the link: electrician of the 4th category - 1 person.
03.1. Unpin and remove axle 43 (see Fig. 3), while releasing roller 32 with washers 27.
Equipment: pliers.
03.2. Unpin and remove the axle 39, while releasing the trip dog 30 with the spring 31, washers 28 and the manual release handle 41.
Care must be taken as the spring is pre-compressed!
03.3. To clear the removed details of dirt and old greasing, if necessary to wash out gasoline.
Equipment: rags.
03.4. Identify defects and make the necessary repair of axles 39, 43, roller 32, trip dog 30, spring 31 and holes in earring 11.
Equipment: skin, metal ruler, micrometer, caliper, hammer, round nose pliers, file.
03.5. Apply a thin layer of CIATIM-203 lubricant to the friction points.
03.6. Assemble parts in reverse order.
The position of the tripping pawl is not adjustable and it occupies working position under the influence of a spring mounted on the axle.
The gap in the engagement process between the shoulder of the tripping pawl 30 and the roller 32 is regulated by the restrictive bolt 47.
03.7. Disconnect the terminals of the disconnecting coil 9 (see Fig. 4) and the circuit of auxiliary contacts 1 from the clamps in the contact row KR-10 (20, see Fig. 5).
Equipment: screwdriver.
03.8. Unscrew nuts 3 (see Fig. 4) from studs 2, disconnect and move aside KP-10, remove electromagnet.
Equipment: wrench 12x14.
03.9. Remove cotter pin 21 and remove core 13 from sleeve 11, while releasing textolite washers 16, springs 17 and 20, movable contact 19.
Equipment: pliers.
03.10. Remove dust and old grease from the removed parts, inspect, paying attention to:
- condition of covers 7 and 12, casing 8 and bracket 15, fixed 18 and movable 19 contacts. Clean rusty and oxidized parts. Clean the joints of the casing and covers from paint, varnish, dirt.
Eliminate mechanical damage, replace unusable parts;
- condition of the sleeve 11.
Align dents, eliminate oxidation. Remove dirt and dried grease by washing with gasoline, wipe dry;
- the state of the surface of the core 13 and thrust 22.
Remove rust, paint, notches and burrs with a file, sandpaper. Wipe the core and rod with a cloth soaked in gasoline. Check the reliability of locking rod 22 with screw 10;
- condition of the felt pad 14, textolite washers 16.
Washers should not have breaks, cracks and chipping.
Replace defective washers.
Replace the felt pad if it loses its shape and elasticity. Glue the new gasket to the bracket 15 with bakelite glue.
Equipment: file, sandpaper, brush and rags.
03.11. Identify defects and make the necessary repairs of stem 6, springs 17 and 20 in accordance with Appendix 7.
Equipment: pliers, screwdriver, file.
03.12. Check the resistance of the trip coil, which should be 80.96/95.04 ohms at 110/220V.
Rigging: MMV bridge.
03.13. Check the insulation resistance of the opening coil and the supply wires, which must be at least 1 MΩ, with a megger with a voltage of 1000 V.
03.14. Lubricate metal parts, including the core, with a thin layer of CIATIM-203 grease.
03.15. Assemble the electromagnet in reverse order and check:
a) the full stroke of the core, which should be 18-20 mm.
The stroke of the core is regulated by changing the thickness of the felt pad 14 or washer 5.
Equipment: metal ruler;
b) the length of the rod 6, which should be 38 mm.
It is allowed to set the final length of the rod when adjusting the limits of the electromagnet;
c) the full stroke of the auxiliary contact (18.5 mm) and the gap between the end face of the spring 20 and the movable contact 19, which should be 2-3 mm. The adjustment is made by changing the thickness of the washer under the cotter pin 21 or by screwing in or out of the rod 22 from the core body. After adjusting the stroke of the auxiliary contact with a rod, drill the rod under screw 10 in order to screw it flush with the core.
Equipment: screwdriver.
OPERATION 04
REPAIR OF THE LOCKING MECHANISM
Node 02. Drive PE-11
Labor costs - 0.4 man-hour
The composition of the link: electrician of the 4th category - 1 person.
04.1. Unpin and remove the axle 1 (see Fig. 3), while releasing the retaining pawl 4 with the spring 3 and washers 15; 16. Be careful as the spring is pre-compressed!
Equipment: pliers.
04.2. Unpin and remove axle 37, while releasing roller 38 with bushing 35.
Equipment: rags.
04.3. Clean the removed parts from dirt and old grease. Rinse with petrol if necessary.
04.4. Identify defects and make the necessary repairs to axle 37, roller 38, holes in earrings 5 and 6, retaining pawls 4 and spring 3 in accordance with Appendix 7.
Equipment: skin, plasticine, hammer, metal ruler, micrometer, caliper, file.
04.5. Apply a thin layer of CIATIM-203 lubricant to the friction units.
04.6. Assemble parts in reverse order.
Notes: 1. The position of the locking pawl is not adjustable, it takes the working position under the influence of the spring mounted on the axle. 2. The position of the stop (axis 37) of the locking pawl is not adjustable.
OPERATION 05
REPAIR FREE RELEASE MECHANISM
Node 02. Drive PE-11
Labor costs - 0.4 man-hour
The composition of the link: electrician of the 4th category - 1 person.
05.1. Unpin and remove axle 42 (Fig. 3) with bushings 26, 34, spring 33, washers 24 and axle 37 with bushings 35 and roller 38, while releasing the free disengagement mechanism consisting of shackles 5 and 11 connected by axle 23.
Be careful as the spring is pre-compressed!
Equipment: pliers.
05.2. Unpin and remove axle 23 with washers 21.
05.3. Clean the removed parts from dirt and old grease. Rinse with petrol if necessary.
Equipment: rags.
05.4. Identify defects and make the necessary repair of axles 23, 37, 42 holes in earrings 5, 11 and spring 33 in accordance with Appendix 7.
Equipment: metal ruler, micrometer, caliper, hammer.
05.5. Check the condition of the stop bolt 47 with nut 46 and washer 45.
The bolt must not have distortions along the length, damage to the working surface of the head and the threaded part.
Replace defective bolt and nut.
05.6. Apply a thin layer of CIATIM-203 grease to the friction points.
05.7. Assemble parts.
OPERATION 06
REVISION OF ASSEMBLY, WHICH HAVE NOT BEEN DISASSEMBLED
Node 02. Drive PE-11
Labor costs - 0.5 man-hour
The composition of the link: electrician of the 4th category - 1 person.
06.1. Remove old grease from friction units. Moisten the cloth with gasoline if necessary.
06.2. Check and retighten any loose drive bolt connections.
Equipment: wrench 12x14, 17x19, screwdriver.
06.3. Check the correct position and fastening of the parts of the drive mechanisms.
06.4. Apply a thin layer of CIATIM-203 lubricant to the friction units.
06.5. Check the operation and adjustment of the drive and auxiliary contacts.
06.6. Remove the arc chutes from the switching contactor 11 (see Fig. 2) and check:
- cleanliness of contacts, symmetry of the location of movable contacts in relation to the fixed ones;
- reliability of pressing contacts, free movement of the armature and its fit to the core;
- spring stiffness and reliability of fastening of the contactor and all connections to it;
- state of the contactor coil.
If the winding or terminals are damaged, replace the coil.
Equipment: file, sandpaper.
06.7. Put on the arc chutes, make sure that there are no stuck contacts.
06.8. Eliminate the detected defects in power circuits and secondary switching circuits.
06.9. Eliminate defects in the drive cabinet and paint it.
OPERATION 07
DRIVE ADJUSTMENT
Node 02. Drive PE-11
Labor costs - 0.8 man-hour
The composition of the link: electrician of the 4th category - 1 person.
07.1. In the drive position "Off." adjust the gap between the roller 32 and the shoulder of the tripping pawl 30 with the bolt 47 (see Fig. 3).
Equipment: wrench 12x14.
07.2. Measure the size of this gap with a plate probe (it should be 0.5-1 mm).
Equipment: probe.
07.3. After adjustment, set the limiting bolt 47 with its edges along the axis of the mechanism and fix it with a nut 46.
Equipment: wrench 12x14.
07.4. Raise the core 1 (see Fig. 5) with the stem 10 to the upper extreme position with the manual engagement lever.
Equipment: manual switch lever.
07.5. Measure the gap between the shoulders of the holding pawl 4 (see Fig. 3) and the axis 37 with a plate probe, which should be 1-1.5 mm. If the gap deviates from the norm, adjust by screwing in or out of the rod 10 (see Fig. 5) of the core 1. After setting the required gap, drill the rod and lock it with stoppers 22.
Equipment: probe.
07.6. In the drive position "On." measure the gap between the head of the bolt 47 (see Fig. 3) and the axle 23 with a plate probe, which should be 0.5-1 mm.
07.7. Check visually (with actuator "On"):
- engagement between the shoulder of the disconnecting pawl 30 to the roller 32, which should be located in the middle part of the shoulder;
- engagement between the shoulders of the holding pawl 4 and the axle 37, which must be at least 1/4 of the length of the shoulder.
07.8. Check the opening angle of the opening mechanism (see fig. 5). Release angle =15°, full handle angle =60°.
07.9. Check the stroke of the core 13 (see Fig. 4) with the rod 6, for which, slowly moving the core by hand (for example, with a screwdriver), notice the position at which the tripping mechanism is disengaged. After that, the core should have a power reserve of at least 2-3 mm.
In case of discrepancy, adjust the length of the rod 6 by screwing or unscrewing it from the core body. After setting the size, drill the stem under screw 10 in order to screw it flush with the core.
Equipment: screwdriver.
07.10. Adjust the auxiliary contacts KBV and KBO (see Fig. 6), in which the on position of the drive corresponds to the disconnected position of the KBV contact and the on position of the KBO contact;
Equipment: screwdriver, pliers, wrench 12x14.
To ensure the normal operation of the drive, the gaps between the pawls and ratchets at the auxiliary contacts must correspond to the gaps indicated in Fig. 7.
Fig.7. Adjustable Quick Contact Clearances
Fig.7. Adjustable Quick Contact Clearances:
A - block contact KBV; I - enabled; II - disabled; b - block contact OBE; I - disabled; II - enabled.
The value of the pawl 2-3 mm
Equipment: probe.
Block-contact KBV in the contactor winding circuit opens at the end of switching on [with a stroke of the rod 10 (see Fig. 5) 78 mm].
The shutdown circuit is closed when turned on at the stroke of the EV rod 52 mm.
Equipment: ruler.
Adjustment of the moment of closing and opening of auxiliary contacts of KBV and KBO is to be carried out with slow (manual) turning on and off of the drive. The adjustment is made by changing the length of the rods or levers connecting the auxiliary contacts with the drive shaft.
In the open position, the gap between the moving and fixed contacts should be 4-5 mm on each side of the moving contact.
07.11. Adjust block contacts KSA, for which:
- check the fixation of the closing and opening of the moving and fixed contacts in both positions of the drive. In the off position, the gap between the contacts must be at least 3-5 mm;
- connect the rods to the KSA after preliminary testing of the closure of the corresponding contacts of the KSA in both extreme positions of the drive;
- set the rotation angle of the KSA shaft (~90°) by selecting the length of the rod or the length of the lever arm;
Equipment: pliers, screwdriver.
07.12. At the end of the adjustment of KBV, KBO and KSA:
- tighten the locknuts on all threaded connections of the transmission links;
- check that the lever 6 (see Fig. 6) is screwed into the drive shaft by at least 5 threads;
- check that the threaded part of the rods enters the nuts to the full height of the nuts;
- check the reliability of the circuits through all contacts;
- lubricate with TsIATIM-203 grease the axes of the hinges of the transmission mechanisms and all rubbing parts of the drive mechanism and auxiliary contacts.
Attention! In order to avoid accidents in the process of adjusting the drive with a switch, strengthen the opening pawl of the drive with a steel bar 6x20x60 and bolt 17 (see Fig. 5).
When disconnecting, remove the bar.
OPERATION 08.
SWITCH LAYOUT
Node 01. Switch
Labor costs - 1.0 man-hour
The composition of the link: electrical fitters of the 3rd category - 1 person, 2nd category - 1 person.
08.1. Unscrew nuts 45 (see fig. 1).
When screwing nuts 45, in order to prevent the rod from turning in the bushings, it is necessary to hold the tip with a wrench by sawed places on the tip of the rod, or screwing should be done with the switch on.
Tooling: wrench 46.
08.2. Lower the loops and tie them to the metal structures.
Equipment: rope.
OPERATION 09
OIL DRAIN. GENERAL DISASSEMBLY OF THE SWITCH
Node 01. Switch
Labor costs - 4.0 man-hours
09.1. Remove wire 2 (see Fig. 1) on cap 1, remove the cap from the oil drain plug, open the oil drain hole.
Equipment: pipe lever wrench, pliers.
09.2. Drain the oil into a prepared container. At the same time, check the operation of the oil indicators.
Equipment: container for oil.
09.3. Unscrew the flue pipe 13 from the connecting pipe 46, check the tightness of the cover and gasket on the pipe outlet.
Equipment: pipe lever wrench.
09.4. Unscrew earth bolt 9 with washer 8.
Equipment: wrench 17.
09.5. Install removable winch 30.
Tooling: wrench 17x19.
09.6. Hook the winch cable 30 to the tank rollers 29, pull the cable slightly with the winch, unscrew the washer 6 from the bolt 7, remove the washer 5, lower the tank 29 until the cable is completely loosened, remove the cable from the tank rollers.
09.7. Unscrew bolt 23 with washer 24, remove bracket 22.
Equipment: wrench 17.
09.8. Loosen bolts 9 (Fig. 9) with washers 10, remove contact with quenching chamber 3, screen 18 and complete shoe 16.
Equipment: wrench 17.
09.9. Unscrew nuts 12 (see Fig. 1) from bolts 11, remove capacitor bushing 33 and gasket 20 (transition 9 is performed only if necessary).
Equipment: wrench 22, 24.
09.10. Unscrew nut 37 (see Fig. 1), remove spring 39 from lug 38.
Equipment: wrench 17, screwdriver, pliers.
09.11. Unscrew bolt 42, lower cylinder 44 with cup 40 and spring 41.
Equipment: wrench 17.
09.12. Unpin the cotter pin 35, remove the axle 34, remove the rod 36 from the fork lever 56 (Fig. 8); transition 12 is performed only when necessary.
Fig.8. Complete cover
Fig.8. Complete cover:
1 - bar;
2 - bolt M10x25; 3 - washer pr.10N; 4 - key 10x8x63 mm; 5 - cork; 6, 45, 53, 58 - gaskets;
7, 10 - M8x16 screw; 8, 60 - washers; 9 - screw M4x10; 11 - adjusting ring; 12, 28, 38, 57 - shafts;
13 - fork; 14 - key 8x10x40 mm; 15 - screw M8x30; 16, 24 - M8 nuts; 17 - bolt M16x35; 18 - bearing;
19 - washer pr.16N; 20 - nut M16; 21 - bolt M16x90; 22 - washer pr.12N; 23, 67, 71 - M12x40 bolts;
24 - nut M8; 25 - screw M8x20; 26, 31 - covers; 27, 33, 37 - double levers; 29 - coupling;
30 - thrust; 32, 42, 50, 54 - axes; 34, 62, 64, 66, 68, 70, 72, 74, 76 - M12 nuts; 35 - restrictive screw;
36 - blind nut; 39 - plug; 40 - washer 14/28x1 mm; 41 - felt (technical fine wool
10x20x1585 mm GOST 288-61); 43, 51 - rollers; 44, 52 - axes of the rollers; 46 - cotter pin 3.2x20 mm;
47 - axle with a diameter of 12x50 mm; 48 - earring; 49 - lever; 55 - box; 56 - fork lever; 59 - screw M4x10;
61, 75 - M12x30 bolt; 63, 73 - bolt M12x60; 65, 69 - bolt M12x80; 67, 71 - M12x40 bolt
Transitions 1-12 are performed for the other two phases.
Equipment: pliers, drift, metalwork hammer.
OPERATION 10
DISASSEMBLY AND REVIEW OF THE EXTINGUISHING DEVICE.
REPAIR OF CONTACTS
Node 01. Switch
Labor costs - 2.0 man-hours
The composition of the link: electric fitters of the 2nd category - 1 person, 3rd category - 1 person.
10.1. Unscrew nut 12 (Fig. 9) from screw 13, release conductor 23.
Fig.9. arc extinguishing device
Fig.9. Arcing device:
1 - bolt M8x16; 2 - washer 9/16x1.5 mm; 3 - quenching chamber; 4 - traverse; 5 - nut M20; 6 - washer pr.20M;
7 - screw M6x20; 8 - fixed contact; 9 - bolt M10x55; 10 - washer pr.10N; 11 - nut M10; 12 - nut M6;
13 - screw M6x30; 14 - spring; 15 - flexible connection; 16 - complete shoe; 17 - screw M6x10; 18 - screen;
19 - axis; 20 - bolt M8x20; 21 - bar 9 / 18x23 mm; 22 - nut M6; 23 - conductor; 24 - nut M8x20;
25 - nut М6х15
Equipment: wrench 10.
10.2. Unscrew the bolts 1 that fasten the screen 18 to the chamber 3, remove the screen. Place the pieces on a baking sheet.
Equipment: wrench 14, baking tray.
10.3. Unscrew the bolts 11 (Fig. 10), 16 with washers 17, remove the bar 12, clamp 14, block 15, flexible connection 13, put all the parts on a baking sheet.
Equipment: wrenches 14, 17, baking sheet.
Fig.10. Extinguishing chamber
Fig.10. Extinguishing chamber:
1 - bottom pad; 2, 4, 5 - gaskets; 3 - plate; 6 - top pad; 7 - screw M6x10; 8 - axis;
9 - contact; 10 - shoe; 11 - bolt M8x20; 12 - locking bar 9/18-23 mm; 13 - flexible connection;
14 - collar; 15 - block; 16 - bolt M10x55; 17 - washer pr.10N; 18 - cap; 19, 21 - M20 bolt; 20 - nut M20
10.4. Unscrew the locking screw 7, knock out the axle 8, remove the contact 9, place the parts on a baking sheet.
Equipment: screwdriver, punch, hammer, baking sheet.
10.5. Carefully inspect the screen 18 (see Fig. 9) of the arc extinguishing device. To avoid accidental damage to the metal lining, do not remove the outer insulating sheet. Inspect the metal lining only if necessary. The lining (framework, aluminum foil, shoping) should not have tears and cracks. In case of such defects, install a new frame lining or a shop screen. In the absence of these details, it is allowed to install a lining made of tin, previously tinned at the points of contact. Slots are made in such a lining and petals are bent, with the help of which the lining is attached to a sheet of electric cardboard (Fig. 11).
Fig.11. Tin lining for VMD-35 switch screen
Fig.11. Tin lining for VMD-35 switch screen
10.6. Check the correct location of the mounting holes on the screen sheets. The centers of the upper pair of holes should be 110 ± 2 mm from the top edge, and the centers of the lower holes - 20 ± 2 mm.
Equipment: ruler 150 mm.
10.7. Clean chamber 3 (see Fig. 9) from dirt, rinse in clean "dry" transformer oil. Make sure that there are no burns, traces of electrical discharges, delaminations or warping. If there are defects, disassemble the damping chamber according to steps 9-10.
Equipment: rags.
10.8. Unscrew nuts 20 (see Fig. 10), remove gaskets 2, 4, 5; plate 3; pads 1, 6. Detect defects according to appendix 7. Replace defective parts.
Equipment: wrench 30.
10.9. Select a set of gaskets 2, 4, 5, plates 3 and linings 1, 6. Install the above parts on the bolts 21 in strict sequence according to Fig. 10, while maintaining a dimension of 125 mm. Screw nuts 20.
Equipment: caliper, wrench 30.
Note. Steel coupling bolts 21 (installed on some switches) should be replaced with textolite ones.
10.10. Inspect rod 36 (see Fig. 1), make sure that there are no cracks or chips; replace the defective rod. Hang the rod to the fork lever 56 (see fig. 8) using the axle 34 (see fig. 1), install the cotter pin 35, spread the ends of the cotter pin.
Equipment: pliers, hammer.
10.11. Check moving contacts. If there are fusions and shells on the contact surfaces, file them with a file so that the profile of the contacts is not disturbed during filing.
Clean contact surfaces made of copper or its alloys from dirt and oxidation using a file, sanding paper or card tape. After stripping, remove sawdust, rinse parts in gasoline, wipe. After filing, no shells deeper than 0.5 mm should remain on the contact surfaces.
Moving contacts are inspected and repaired without removal from the rod. If necessary, remove the moving contact according to transitions 12, 13.
Equipment: sanding paper, rags, card tape, files N 2, 4.
10.12. Unscrew the nut 5 (see Fig. 9), loosen the nut 25, unscrew the locking screw 7 and remove the traverse 4 with the knife.
Equipment: wrenches 30 and 10, screwdriver.
10.13. Put the traverse 4 on the rod, screw in the locking screw 7, screw on the nut 25, screw on the nut 5 with washer 6, adjust the contact stroke to 235 mm.
Equipment: wrenches 30 and 10, screwdriver, ruler 1000 mm.
10.14. Inspect the fixed contacts, make sure there are no melting, shells. If the latter are found, file them with a file. Remove dirt and oxidation. Remove sawdust, wash contacts in gasoline, wipe.
Equipment: files N 2, 4, sanding paper, rags.
10.15. Inspect contact springs 14 (see Fig. 9) in normal (uncompressed) and compressed states. Find defects in springs according to Appendix 7. Replace defective springs with new factory-made ones.
10.16. Check the condition of the insulating cap 18 (see Fig. 10). If there are tears or cracks on the cap, replace it.
10.17. Inspect the lower edges of the side faces of the fixed contacts 8 (see Fig. 9) and the upper edges of the tides on the shoe 16. If these edges do not have an oval, then they must be filed.
Equipment: files N 2, 4, sanding paper.
10.18. Inspect fork lever 56 (see Fig. 8), earring 48, double levers 27 and 33, lever 49, roller 43 for cracks, breaks. In the presence of significant defects in the above parts, their repair on site is not recommended. It is recommended to replace the circuit breaker phase or the entire circuit breaker and then repair the circuit breaker mechanism in a workshop.
10.19. Lubricate all rubbing parts with a thin layer of CIATIM-203 lubricant.
Equipment: brush.
10.20. Unscrew nut 16, unscrew screw 15, knock out key 14, remove fork 13.
Equipment: punch, hammer, screwdriver, wrench 14.
10.21. Unscrew bolts 17 and remove bearing 18.
Tooling: wrench 24.
10.22. Inspect yoke 13, bearing 18, shaft 12 and make sure that there are no cracks, breaks, spalling. If significant defects are found, replace the parts. Remove traces of corrosion with sandpaper. Lubricate all rubbing parts with a thin layer of CIATIM-203 lubricant.
Equipment: sandpaper, brush.
10.23. Install bearing 18, screw in bolts 17.
Tooling: wrench 24.
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Appendix No. 24
Guidance Document
"Manual for the overhaul of freight cars"
1. Introduction
1.1 These guidelines establish uniform requirements for the overhaul of 1520 mm gauge freight wagons by repair enterprises of the Commonwealth Member States, Georgia, the Republic of Latvia, the Republic of Lithuania, the Republic of Estonia and apply to all types of freight wagons that have the right to exit on public tracks, regardless of the form of ownership.
1.2 This guide contains general mandatory technical requirements, safety and industrial hygiene requirements, indicators and standards that freight cars that have undergone major repairs at car repair enterprises, regardless of their form of ownership and have permission for this type of activity, must satisfy.
1.3 The terms for the overhaul of freight cars are established by the regulation on the system for the maintenance and repair of freight cars admitted to circulation on public railways in international traffic, approved at the 47th meeting of the Council for Railway Transport of the States Members of the Commonwealth. The telegram put into effect dated December 25, 2007. 32941TsCV-3429T.
2 Requirements for repairs
2.1 Overhaul (CR) of freight cars is carried out at specialized car repair enterprises that have the right to this type of activity. The overhaul is carried out in order to restore the operating life of the car with the repair of car components and parts according to the repair documentation developed in accordance with the requirements of the guidelines approved by the Council for railway transport Member States of the Commonwealth, and agreed by the Commission of the Council of Plenipotentiary Specialists of the Carriage Industry.
2.2 Works on the overhaul of freight cars must be carried out in accordance with the technological processes for the overhaul of each type of car being repaired and the technological processes for the work of production sites developed by car repair enterprises and approved by the head of this enterprise.
2.3 Non-removable, defective parts of the wagon are repaired directly on the wagon. Faulty removable units and parts are replaced with repaired or new ones that meet the technical requirements and characteristics of this car model.
2.4 Materials, semi-finished products, spare parts and accessories used in the overhaul of freight cars must meet the established standards and specifications, and are made in climatic version UHL category 1 according to GOST 15150-69. Relevant documents (certificate, declaration, etc.) must be submitted for spare parts and component equipment subject to mandatory confirmation of conformity. After the repair of the car, all critical parts of the car: wheel pairs, bogie parts, automatic coupler, automatic braking equipment, pivot beam, tank boilers, etc. must have appropriate stamps indicating the place and date of manufacture, repair and testing. On the frame, wheels, cast parts of the wagon bogies, there must be codes of the state-owner.
2.5 Wagon parts are tested in accordance with the list and requirements Technological instructions according to tensile test No. 656-2000.
2.6 The list of car parts subject to non-destructive testing is given in the Guiding document RD 32.174-2001 (as amended No. 1 and No. 2)
Ultrasonic testing of welds during the repair of tank cars is carried out in the presence of a methodology approved in the prescribed manner.
2.7 Parts and assemblies of wagons: wheelsets, axlebox assemblies, assemblies and de trolley hoists - repair and manufacture in accordance with the requirements of relevant standards, rules, instructions, specifications, etc. structural guidelines.
2.8 Preparation for surfacing and welding works, welding, surfacing ku, as well as the acceptance of parts and assemblies of the car after surfacing and welding is carried out, guided by the requirements of the Instructions for welding and surfacing during the repair of freight cars, approved by the Council for Railway Transport of the Commonwealth Member States on May 29-30, 2008, Khujand.
2.9 Newly supplied wooden parts must comply with the drawings for their manufacture, and in terms of wood quality and moisture content meet the requirements of GOST 3191. It is allowed to put glued wooden parts on the car, manufactured according to the manufacturer's specifications. Wooden parts to be further painted are primed.
2.10 During the QD, all unusable bolts and nuts are replaced with new ones. The threaded part of the bolts, on which cotter pins are not installed, must protrude from the nut by at least three threads, but not more than by the size of the bolt diameter.
Cotter pins and checks for bolts or rollers put new, typical (standardized). In the absence of special requirements, they must be separated from the nut or washer by no more than 3 mm. The ends of the cotter pins and the check are bred at an angle of at least 90°. Loose and non-standard rivets are replaced.
2.11 It is forbidden:
- replace the riveted joints provided for by the design with welded or bolted ones;
- put simple nuts instead of castle nuts, provided for by the drawing (technical conditions);
- to produce caulking, welding and tightening of rivets;
Driving screws instead of driving them;
- burn holes in metal parts;
- leave without a primer the metal parts of the body and frame in the places where the parts removed for replacement fit;
Use materials that do not have a certificate of conformity.
2.12 During the QD, newly installed rubber products must comply with the manufacturer's specifications, and also have a certificate of conformity.
3 Rules for acceptance of freight wagons for repair
3.1 Freight wagons are sent for overhaul:
With the used limit of operation before overhaul;
Damaged or having wear more than allowed, established by regulatory documents, the elimination of which is impossible in the current or depot repairs. An act of form VU-25 is drawn up for a damaged wagon.
Freight wagons that have not expired before overhaul may be sent for overhaul only with the permission of the wagon owner.
3.2 It is prohibited to accept and repair tanks whose boilers have not been subjected tochickpeas cleaning, steaming and degassing in accordance with the requirements of labor protection regulations. The wagons are delivered for repair, cleaned of cargo residues and dirt.
3.3 During the overhaul of freight cars, the main work on the modernization of units is carried out in accordance with the projects given in Appendix A.
4 Fault detection of components and parts of freight cars
4.1 Detection of assembly units and parts of freight cars is carried out by the method visual control using instrumentation.
4.2 When defecting, it is allowed to use non-destructive testing (ND) methods if there is a non-destructive testing methodology for this part, developed in accordance with the requirements of the guidelines approved by the Council for Railway Transport of the Commonwealth Member States. Based on the results of the measures taken, the amount of repair is determined with filling in the defective statement of the VU-22 form.
4.3 Cleaned assembly units and wagon parts are subject to comprehensive control and sorting into the following groups:
Suitable, retaining their original size and shape;
Requiring repair, having wear or damage, the elimination of which is technically possible;
Unsuitable to be replaced, having wear, corrosion or mechanical damage, the elimination of which is impossible for technical reasons.
4.4 The list of parts of freight cars subject to mandatory non-destructive testing, indicating the methods and means of control, is given in Guiding Document No. RD 32.174-2001 (as amended No. 1 and No. 2).
4.5 The list of components and parts of wagons intended for the carriage of dangerous goods and checked by non-destructive testing methods is established by the railway administration in agreement with authorized body established order.
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