[原文]
LSS型全自动燃油（气）蒸汽锅炉
安装使用说明书
江苏省东台市舒乐锅炉厂
厂址：东台市六灶街西首
电话：0515-5830029 5830030
安装说明
一、安装前准备工作
1、锅炉房平面布置等设计工作应由专门设计单位完成，锅炉房布置应符合中华人民共和国劳动部《蒸汽锅炉安全技术监察规程》第八章的规定。
2、锅炉安装必须有专业技术人员负责，并配备管工、钳工、起重工、电焊工、电工及辅助工等各类专门工种的技术工人。
3、组织有关人员学习《蒸汽锅炉安全技术监察规程》、锅炉安装使用
说明书等技术文件，熟悉图纸，以了解和掌握安装、起重、运行、操作本锅炉的各种技术事项。
4、地基必须保证能承受锅炉全部重量。
二、锅炉安装
   本锅炉为快装锅炉、安装极其简便，只要将锅炉水平置于预定的地基上即可。
三、水泵、燃烧器安装
   水泵、燃烧器安装比较简单，（均在本厂试装过）对其只需紧固件连接固定即可。
四、电控箱安装
   安装时，电控箱与固定支架或底板应安装按牢固，并按电控箱使用说明书中电气接线图与燃烧器、水泵、压力控制器等接线。
五、管道、阀门仪表及附件安装
1、安装前应校验好仪表，检查阀门、弯头等零件是否完好。
2、按照管道、阀门、仪表图纸安装。
3、安全阀应预先调整好整定压力，并在水压实验后安装，其排气管应通向锅炉室外安全处。
4、排污管接至排污箱或其它安全处，管道应固定，防止排污时移位或发生反击烫伤等事故。
5、主蒸汽管道上至少有一个弯头，否则应加装伸缩管，管道外壁应保温。
6、水位表下部泄水管必须接入安全处，水位表考克旋转要灵活，不得漏水，水位表处必须安装照明设备。
7、锅炉水位自控报警器，按锅炉电控箱接线图接线。
8、压力表刻度盘应垂直，刻度盘上应画红线，以示锅炉最高许可工作压力，压力表考克旋转灵活，不得漏水，压力表管禁止保温。
9、燃料供给系统管道附件的安装按照燃料器配备的安装使用说明书。
六、烟囱安装
  烟囱要垂直，其水平方向引出不应过长。
七、水压实验
1、待锅炉各种仪表，阀门管道安装完毕后，检查和清理锅炉内部，检查各连接处的边接情况，关闭入孔、手孔及其它有关部件后，就可以进行水压实验。
2、水压实验压力按下表：
名称        锅壳工作压力MPa   实验压力MPa
锅炉本体     ＜0.8            1.5P但不小于0.2
3、水压实验应在周围气温高于5℃时进行，低于5℃时必须有防冻措施，水压实验用水应保持高于周围露点的温度，以防锅炉表面结露，但也不宜温度过高，以防引起汽化和过大温差应力，水温一般为20-70℃。
4、进水应均匀，不宜过快，边进水边排空气，直到灌满水为止。
5、水压实验时，升压速度应缓慢，当压力升至0.1MPa时，即进行一次严密性检查，必要时可紧一次法兰，人孔门和手孔的螺栓。
6、当压力上升至工作压力时，应暂停升压，检查有无漏水或异常现象，然后再升到实验压力，保持20分钟，若压力没有下降，再降至工作压力进行检查，检查期间压力应保持不变。
7、发现任何渗漏情况都应做上记录，以便降低到大气压力时进行修理。
8、水压实验符合下列情况认为合格：
①在受压元件金属壁上和焊缝上没有水珠和水雾。
②水压试验后，没有发现残余变形。

                   使 用 说 明
   锅炉的启动、停炉操作详细参阅电控箱使用说明书。
一、煮炉
    锅炉安装后，要对单项设备逐个进行试运转，需加润滑油的部位是否都加点油，电控箱能否正常使用，供给燃料用小火煮炉，煮炉投药量为：
    氢氧化钠（NaOH）   2-3kg/t(炉水)
    磷酸三钠（Na3PO4） 2-3kg/t(炉水)
如缺少磷酸三钠时，可用无水碳酸钠（Na2CO3）代替，数量为3-4.5kg/t(炉水)。
    煮炉所用的上述药物配制成浓度为20%的均匀溶液，不得将固体药品直接加入锅炉。
    当锅炉内产生压力时，可冲洗水位表，当锅炉压力为0.1MPa时应对入孔、手孔及锅炉范围内的法兰螺栓进行一次坚固，检查所有接口有无渗漏。待压力升至75%工作压力时，维持此压力24小时，然后停止燃烧，让压力逐渐隆至0.1MPa以下，开启排污阀，将炉水全部放出，待锅炉自然冷却后，应按上述办法再行煮炉，直至锅壳内无油垢，金属表面无锈斑，管道与阀门清洁无堵塞，煮炉才算合格。
二、给水要求
  用户应按GB1576《低压锅炉水质》的规定，根据本地区的水质情况和生产要求，选用水处理设备。没有采取可靠的给水处理措施的锅炉，不得投入运行。锅炉运行期间给水和炉水水质应符合上述标准要求。
三、安全闸调整
    安全闸应在出次点火时进行调整。
    按照“规程”第143条规定进行调整和检验。
1、 安全闸调整方法
拆去开口销和铅封，卸掉顶盖，拧松六角螺丝母，然后拧动调节螺杆，使弹簧放松或拧紧，来达到安全阀要求的排气压力，调整后拧紧锁紧螺母，再将其余零件装妥并铅封。
2、 安全阀经校验后不准乱动。
3、 在校验安全阀时，锅壳内之水位应较平常水位略低，并预备在安全阀开启后能随时给水。
4、 切勿敲击安全阀上的任何部分，开启安全阀只能用阀上的控制杆。
5、 在安全阀为校验前锅炉绝对禁止运行。
四、供汽
    当锅炉气压接近工作压力，准备向外供汽时，供汽前锅壳内水位不宜超过正常水位，供汽时炉内燃烧应稳定。
五、正常运行
    锅炉运行时要求做到：锅炉内水位正常，蒸汽压力稳定，保持锅炉房的整洁，做好交接班工作，加强对各机械设备和仪表的监察，特别是电控设备的正常，确保安全可靠，防止事故发生。
1、 给水要求
锅炉给水须进行处理，按GB1576“低压锅炉水质”的要求。
2、 给水设备
锅炉配用给水泵，给水是自动控制的，水位控制范围是由水位控制器里的电极棒插入水中位置高低所决定，锅炉运行时，当水位低于设定的低水位值时，水泵起动上水；当水位升高至设定的高水位值时，水泵自动停止上水。
3、蒸汽压力
锅炉内的蒸汽压力控制器选择一个压力范围，燃烧器在这个压力范围内启动和停炉，保证正常供器。
4、 自动报警
电控设备自动进行声光报警；当水位低于极限低水位时，或锅炉内蒸汽压力达到设定的允许最高值，电控设备自动声光报警并联锁保护。
5、 压力表
压力表接管要定期冲洗，检验压力是否正常，如损坏，应立即停炉修理或更换。为了保证压力表准确性，应按国家计量部门的规定进行检验和维护。
6、 压力控制器
压力控制器的调整值应与压力表一致，调整数值关系到锅炉的正常运行，因此，要经常注意压力控制器的性能。
7、 安全阀
注意安全阀的工作是否正常，为了防止安全阀的芯盘和阀座粘信，应定期拉动安全阀提升手柄，作排汽实试验，每隔2—4星期应升高汽压一次，作排汽试验以校验安全阀能否正常动作。
8、 排污阀
定期排污（参阅六条“排污”）
9、 正常操作
锅炉全自动控制。司炉人员只须值勤，尤其要经常观察汽压和水位是否在要求的工作范围水内。
六、排污
一般给水内含有或多或少的矿物质，给水进入锅炉汽化后，矿物质留在锅内，浓缩到一定程度后就在锅内沉淀下来。蒸发量越大，运行时间越长，沉积物就越多。为了防止由于水垢、水渣引起损坏，必须保证炉水质量，应对炉水进行排污，每天一次或每班一次等。
排污应在低负荷、高水位是进行，在排污时应密切注意炉内水位的变化。
七、维护保养
1、 锅炉是正压燃烧的，锅炉不允许有漏风、漏烟现象。
2、 锅炉燃烧器与电控箱要经常检查，保证完好。
3、 锅炉运行2—3个月，应进行检查一次。
4、 锅炉运行半年，应停炉进行检查维修。打开手孔，检查水垢情况超过2mm，则必须洗炉。
5、 锅炉保温尘罩壳（外包皮）及锅炉底座（包括炉子附件），每个至少要油漆一次。
6、 锅炉长期不用的，保养方法有干保养法和湿保养法二种。
湿保养法：锅炉停炉放出炉水，将内部污垢彻底除、冲洗干净，重洗注入已处理的水至全满，将炉水加热到100C,让水中的气体排出炉外，然后关闭所有阀门。 气候寒冷的地方不可采用湿保养法，以免炉水结冻、损坏锅炉。

[译文]
Manual of Installation and Usage of
Model LSS Full-automatic Fuel( Gas)  Steam Boiler

      Dongtai Shule Boiler Factor
      Factory Site:No.63 Fuming Westroad Liuzao Dongtai City
      Telephone:0515-5830029 5830030

Instructions of Installation
Ⅰ.Preparations before installation
    1.The plan layout of the boiler room and other design work should be completed by a specialized design agency. All the arrangements in the room should meet the specification in Chapter 8 of  Censorial Rules for Steam Boiler Safety Techniques
by China Labor Department .
    2.The installation of the boiler should be done by professional technicians with plumbers,fitters,hoisters,welders,electricians, auxiliary workers and other techincians in various types of specialized work.
    3.Organize related workers to study  Censorial Rules for Steam Boiler Safety Techniques, the manual of installation and usage of the steam boiler and other technical documents, and to get familiar with drawing sheets,so as to know and master the installation,hoist. operation and other techincal items of the boiler.
    4. The foundation must be guaranteed to bear all the  weight of the boiler.
Ⅱ.Installation of the boiler
    This boiler for quick and easy installation only needs to be placed on the pre-arranged foundation without an inclination.
Ⅲ.Installation of the water pump and burner
    The simple installaton has been tested in the factory with the firmwares only joined and fastened .
Ⅳ.Installation of the electric control box
    While installed the box should be fixed firmly with the steady rest or the bottom board with wire connection to the burner,bump,pressure controller etc. following the connecting diagram in the usage manual of the electric control box.
Ⅴ.Installation of the pipes,valves, gauges and accessories
    1.Check the gauges ,valves,bends and other parts before installation.
    2.Follow the  diagrams of  the pipes, gauges and valves to carry out the installation.
    3.The safety valve should be adjusted to the pre-set pressure in advance,and installed after the water pressure experiment with its windpipe leading to the safe place outside the boiler room.
    4.The blow-off pipe should be connected to the blow-off box or other safe places,
and fixed securely in case of any shift or accidents like counter-attack scald in the boiler blowdown hour.
    5.There must be at least one bend on the main jet pipe.Otherwise the expansion pipe should be added.The outside of the jet pipe should preserve heat.
    6.The discharge pipe below the water gauge must be led to a safe place.The cock spin of the gauge must be flexible from water leak.There must be lighting equipment at the gauge.
    7. Follow the connecting diagram of the electric control box to connect the automatic alarm of the boiler water .
    8.The dial of the pressure gauge should be upright with a red line on it to show the highest permitted working pressure.The cock must be revolve smoothly from water leak.The pipe of the pressure gauge is forbidden to preserve heat.
    9.The pipe accessories of the fuel supplying system are installed by the manual of the burner installation.
Ⅵ. Installation of the chimney
    The chimney should be set vertically with its horizontal lead-out not overlong.
Ⅶ. The water pressure experiment
    1．After installing all the gauges and valve pipes of the boiler,examine and clean the inside,check every joint and connection,and then close the access and hand holes and other relevant parts to conduct  the water pressure experiment.
    2．The water pressure experiment is undertaken after the following table:
   3.The water pressure experiment should be carried out with the surrounding temperature above 5 ℃.Measures should be taken to avoid freezing below 5 ℃.The water in the   experiment should be kept above the temperature of the surrounding dewdrops to prevent the boiler surface from condensation of moisture ,but not too high in case of vaporization and too big thermal stress .The general water temperature is 20 ℃-70 ℃.
    4.The feedwater should be equable at a normal speed with air being evacuated at the same time till the boiler is filled.
    5.The pressure should be raised slowly during the water pressure experiment with a very strict check made when up to 0.1 MPa.The flanges,access and hand holes must be fastened when necessary.
    6.Pause the pressure from rising when up to the working pressure for a check that there is no water leak or abnormal phenomena.Raise it to the experimental pressure and keep it 20 minutes for a check that there is no decline.And then reduce it to the working pressure again for a check.During the examinations the pressure should be kept  unchanged.
    7.Records of any leak must be made for repairs to be done at the atmosphere pressure.
   8.The water pressure experiment is considered acceptable if matching the following conditions:
    ①There is no water drops or mist on the metal wall and welding lines of the components under pressure.
    ②No remaining deformation is discovered after the water pressure experiment.

Directions for Use
    Refer to the usage manual of the electrical control box for detailed information of the startup and blowout of the boiler.
Ⅰ.Boiling out
    After the installation all the equipment need testing one by one to see whether enough lubrication is added to its place and whether the electric control box can be used properly.Small fire is used for the supplied fuel during the boiling out.The drugs used are:
                           NaOH                                          2-3kg/t (boiler water)
                           Na3PO4·12H2O                          2-3kg/t (boiler water)
     Na2CO3 can be used to replace the lacked Na3PO4·12H2O with the amount of 3-4.5kg/t(boiler water).
    The above drugs used during the boiling out should be dispensed into the symmetric solution with the consistency of 20%.The solid drugs mustn't be put into the boiler without being processed.
    With the pressure arising the water gauge can be rinsed .Under the pressure of 0.1 MPa all the flange bolts at the access and hand holes and other places should be fastened and all the joints should be checked in case of a leak.When up to 75% of the working pressure keep the pressure  for 24 hours and then without burning lower it below 0.1MPa with the blow-off valve opened to discharge all the boiler water.After the natural cooling of the boiler repeat the above steps until the desirable state without any oil sludge inside the boiler and rust on the metal surface and blockage at the pipes and valves.
Ⅱ. Water supply requirements
    The user should select wate processing equipment according to the regulations of  Water Quality for Low Pressure Boilers (GB1576), the conditions of the local water quality and the requirements of production. The boiler without any dependable measures to process supplied water can't be put into service. During the boiler service , the water supply and  quality should match the above standard.
Ⅲ.Adjustment of  the  safety valve
    The safety valve should be adjusted at the first time of ignition. The adjustment and check should be made by Item 143 of  Censorial Rules for Steam Boiler Safety Techniques .
    1.Method to adjust the safety valve
    Dismantle the cotter pin and seal lead,remove the cover , unscrew the hexagonal nuts, then turn the temper screw to loosen or  fasten the spring to reach the required exhaust pressure by the safety valve.After the adjustment screw down the nuts and pack other parts with lead seal.
      2.The safety valve cant be changed after being checked.
    3.The water level in the boiler should be a little lower than usual when the safety valve is checked. Prepare that the water can be supplied at any moment after the valve is opened.
    4.Never knock at any places on the safety valve. Only the control lever on the valve can be used to open it.
    5.The boiler is absolutely forbidden to work before safety valve is checked.
Ⅳ.Steam supply
    When the boiler air pressure comes near the working pressure to supply steam outward, the combustion in the boiler should be stable with the water level not
beyond the normal before the supply.
Ⅴ.Normal operation
    The boiler should run with the water level in the boiler in a normal state, the
steam pressure  stable , the boiler room tidy ,the shifts exchanged well, all the mechanical equipment and instruments especially the electric control equipment monitored more carefully to keep safe away from accidents.
     1.Water  supply requirements
     The boiler supplied water need processing following the requirements of  Water Quality for Low Pressure Boilers(GB1576).
    2.Water supply equipment
    The boiler is equipped with the water bump with the water supply automatically controlled. The control range of the water level is decided by the underwater height of the electrode inserted into the water. During the operation if the water level is lower than the designed lowest, the bump starts to feed water. If the water level goes up to the designed highest, the bump will stop the water filling automatically.
    3.Steam pressure
    The range of the steam pressure inside the boiler is choosen by the pressure controller . The burner starts up and blows out the boiler automatically within this range to guarantee the normal provision of steam.
    4.Automatic alarms
    The electric control equipment can give automatic alarms in light and sound. When the water level is lower than the lowest or the steam pressure inside the boiler reaches the designed highest value , the electric control equipment gives the automatic alarms with interlock protection.
    5.The pressure gauge
    The pressure gauge should be washed up periodically and checked to make sure the pressure is in the normal state. If not the boiler should be blown out immediately for the gauge to be mended or changed.In order to guarantee the accuracy of the gauge the examination and maintenance should be carried through by the rules of the national metrological service department.
    6.The pressure controller
    The adjusted value of the pressure controller should accord with that of the
pressure gauge. The value relates to the normal operation of the boiler so that  the function of the pressure controller should frequently be paid attention to.
    7.The safety valve
    Pay attention to the normal function of the safety value. To prevent the conglutination of the core and valve base the hoisting handle of the safety valve should be periodically pulled  to do the exhaust experiment with the pressure raised every 2 to 4 weeks to check that the safety valve can work normally.
    8.The blowoff valve
    The blowoff should be carried out periodically. (Refer to  Ⅵ.Blow off.)
     9.Normal operation
    The boiler is controlled ful-automatically.The stoker on duty especially needs to watch the steam pressure and water level regularly to make sure they are within the required working ranges.
Ⅵ.Blow off
    Normally the supplied water contains more or less mineral substance which will remain inside the boiler  and deposit when condensed to a certain degree after the vaporization. The deposits increase as the quantity of evaporation rises and the running time lasts.In case of the damage caused by incrustation and scum the water quality must be garanteed .The blow off should be conducted every day or on every shift at the time of  low burden and high water level.In the meanwhile pay close attention to the change of the water level inside the boiler.
Ⅶ.Maintenance
    1.The burning should be under positive pressure without any air or smoke leak.
  2.The burner and electric control box should be examined frequently to remain in good condition.
    3.The check should be made every 2-3 months when in service.
    4.The boiler should be checked and maintained after half a year of service.Open the hand hole to check that the depth of incrustation exceeds 2mm at which the washup should be done.
  5.The heating and dirt cover casting(the outer pack) and the boiler base(including the accessories of the boiler) should be painted at least once.
    6.There are dry and wet preservations to maintain the boiler if not used for a long
time.Model LSS can adopt the wet method.
    The wet method:After blowing out the boiler let off the water, completely clear away the incrustaton and clean up the boiler.Then refill the processed water and heat it up to 100 ℃ to discharge the air out of the boiler. And then turn off all the valves. In wet places the wet method is not allowed in case of water freezing to cause damge to the boiler.