HWS造型线电气说明书.docx

DOCUMENTATIONEFA-SD 5P-10-SChongqing Qinan foundry Co. LTDOPERATING INSTRUCTIONSJob No.: 11 288page:104of1045.ELECTRICS电气部分5.0 INTRODUCTION35.0.1 Overview display of the moulding plant45.0.2 Technical data85.1 SAFETY ADVICE95.1.1 Behaviour in case of failure of the moulding plant95.1.2 Safety advice for the automatic operation105.1.3 Master switch115.1.4 Emergency-stop equipment115.1.5 Repair mode125.1.6 Alarm equipment145.1.7 Safety equipment (refer to 5.3.1)145.2 STRUCTURE OF THE SWITCH AND CONTROL PLANT155.2.1 Power cabinet165.2.2 Electronic cabinet175.2.3 Local hand control boxes185.2.4 Terminal boxes of the limit switches205.2.5 Terminal boxes of the valves215.2.6 Location code225.2.7 Assignment list235.2.8 Circuit diagrams and user software245.3 PLANT RELATED OPERATING ADVICE265.3.1 Safety equipment265.3.2 Operator panels295.3.3 Selector switches and pushbuttons305.4 SWITCH ON OF THE MOULDING PLANT345.4.1 Operating modes345.4.2 Visual inspection385.4.3 Starting and operation of the hydraulic system405.4.4 Central lubrication (optional)435.4.5 Start of the automatic mode for the complete plant445.4.6 Start of production455.4.7 Restart after power failure or emergency-stop455.5 OPERATION OF THE MOULDING PLANT465.5.1 General information about the operation of the moulding plant465.5.2 Breaks due to operational reasons465.6 STOPPING OF THE MOULDING PLANT475.6.1 Require basic position475.6.2 Stopping of the automatic mode475.6.3 Stopping of the hydraulic system475.6.4 Stop due to emergency-stop or power failure475.7 FUNCIONAL DESCRIPTIONS495.7.1 Proportional valves495.7.2 Index and damping unit515.7.3 Quantity reached525.7.4 Bad mould525.7.5 Clean pattern525.7.6 Working with/without machine525.7.7 Metal on running strip525.7.8 Core setter stop535.7.9 Pouring stop535.7.10 Basic position535.7.11 Initializing pulse545.7.12 Check lamps555.7.13 Filling moulding sand into machine hopper555.7.14 Pattern and machine parameter management555.7.15 Hydraulic aggregate565.8 MAINTENANCE / SERVICING595.8.1 Technical documents605.8.2 Signals and displays605.8.3 Operation advice for parameterization of installed equipment.615.8.4 What to do in case of:665.8.5 Advice for fault detection685.8.6 Preventive maintenance745.8.7 Exchange of equipment755.8.8 Signal transfer to the customer785.8.9 Installation795.9 DATA ACQUISITION AND PROCESSING805.9.1 Plant monitoring system ALS 2010805.10 AMENDMENT825.10.1 Reference to the circuit diagrams865.10.2 Reference to the operating instructions875.0 简介35.0.1 造型线示意图45.0.2 技术参数85.1 安全条例95.1.1 造型线发生故障的措施95.1.2 自动运行的安全条例105.1.3 主开关115.1.4 紧急停机设备115.1.5 维修模式125.1.6 报警设备135.1.7 安全装置 (参阅 5.3.1)135.2 控制开关和控制柜结构155.2.1 电源柜155.2.2 电气柜165.2.3 就地手动控制柜175.2.4 接近开关接线箱195.2.5 阀块接线箱205.2.6 编号215.2.7 代号清单225.2.8 电气原理图和用户软件235.3 有关设备的操作指导265.3.1 安全设备265.3.2 操作面板295.3.3 选择开关和按钮开关305.4 造型线启动345.4.1 运行模式335.4.2 目视检查365.4.3 液压系统的启动和运行385.4.4 集中润滑（选择件）405.4.5 造型线自动运行模式启动415.4.6 生产开始425.4.7 断电或紧急停机后的再启动425.5 造型线的运行465.5.1 造型线运行的常用信息465.5.2 操作原因引起的停机465.6 造型线的停机475.6.1 要求恢复原始位置475.6.2 自动模式的停机475.6.3 液压系统的停机 475.6.4 由于紧急停机或断电引起的停机475.7 功能描述495.7.1 比例阀465.7.2 推送和缓冲装置475.7.3 达到设定数量485.7.4 坏模485.7.5 清扫模板485.7.6 带主机/不带主机运行485.7.7 砂箱粘铁485.7.8 下芯暂停485.7.9 浇铸暂停495.7.10 原始位置495.7.11 程序复原按钮505.7.12 指示灯检查515.7.13 造型机砂斗加砂515.7.14 模板和设备参数管理515.7.15 液压阀块525.8 维修/服务595.8.1 技术文件555.8.2 信号和显示555.8.3 参数设置的操作指导.565.8.4 故障处理605.8.5 故障诊断指导625.8.6 预防性维修625.8.7 设备更换635.8.8 信号传输675.8.9 安装685.9 参数设置和处理805.9.1 设备监控系统ALS 2010695.10 修订825.10.1 关于电气原理图815.10.2 关于操作手册825.0 Introduction简介1. These operating instructions serve as functional description of the electric plant whereby we reserve to ourselves deviations in the technical design, particularly those redounding to the technical progress. The functions of the plant aggregates are described in the mechanical instructions (mechanics) and in the structure of the sequencers (plant software).这些操作手册作为电气设备的功能描述我们保留在我们技术设计时的差别，特别是在技术进步方面的改进。设备总体的功能则在机械(机构)说明书和工序（设备软件）的结构里进行描述。2. Even if a maximum degree of conceptional safety has been reached during the project planning of an electronic control system, it is still essential to strictly respect the advices contained in the operating instructions as any faulty behaviour might possibly cause the lapse of precautions and devices, which serve to avoid dangerous plant states, or even create additional sources of danger.即使在电气控制系统项目设计的过程中已经最大程度上考虑了安全性，但仍须严格遵守操作手册里的有关规定。任何的错误行为都将导致为了避免危险的设备状态而设置的预防性措施和装置的失效，甚至产生其他的危险苗子。3. Other important advices and information can be found in the instruction manuals, technical documents as well as the information sheets of the electric diagrams delivered at the same time.其他重要的建议和资料可以在指导手册、技术文件以及同时提供的电气原理图信息栏里查阅。4. Data carriersWe recommend you to create at least one back-up copy of your control program and of your production monitoring system (if existing) in regular intervals.In addition, the data stages should be saved at least once a week.The back-up copies are to be labelled, to be provided with the date and stored at a safe place.If you need any assistance for the data save, please do not hesitate to contact the electronics department of hws.数据载体我们建议您至少应该定期地建立一套控制程序和生产监视系统（若有的话）的备份。此外，至少每周一次将数据情况进行存盘。该备份必须进行标注，标明制作的日期，并在安全的地方存放。假如您在数据存盘方面需要帮助的话，请与hws公司的电气部门联系。5.0.1 Overview display of the moulding plant造型线示意图 The moulding plant is splitted into the above marked functional areas. The drive units of the area can be controlled by a local operating panel. A listing of the drive units belonging to each area with the assignment of symbolic and absolute designations can be found in the assignment list of the programmable controller. 造型线可以分解为上图标注的不同功能区域； 不同的功能区域可以用就地操作面板进行控制； 每一个区域带有符号和绝对名称的设备在可编程序控制器的配置表 里可以查阅 5.0.1.1 HvO 15.0.1.2 HvO 25.0.1.3 HvO 35.0.1.4 HvO45.0.1.5 HvO 55.0.1.6 HvO65.0.1.7 HvO75.0.2 Technical data技术参数Energy requirement moulding plantapprox. 540 kWOperating voltage3 400 VACSystem frequency50 HzValve voltage24 VDCLimit switch voltage24 VDCControl voltage of the power part230 VACControl voltage of the electronics24 VDCVoltage fluctuations 5 %造型线功率要求约 540 kW运行电压 3 400 VAC系统频率50 Hz控制阀电压24 VDC接近开关电压24 VDC动力元件控制电压230 VAC电子元件控制电压24 VDC电压波动 5 %5.1 Safety advice安全条例5.1.1 Behaviour in case of failure of the moulding plant造型线发生故障的措施1.Trespassing of the plant is as a general principle only permitted when the hydraulic pumps are switched off! 2.Additional safety advice for pushing lines and roller conveyorsThere is a high risk of accidents at the end of pushing lines or roller conveyors (wherever pattern, moulding box cars, pallets or moulding boxes are taken by lifting devices, inclined elevators or transfer trucks).Here, prior to starting the maintenance works, it must be sure that any risk of injury or damages of plant parts is prevented by mechanical protection.It is possible that there are residual risks caused by potential energy of the components (lifting devices). In case of a repair, these components have to be protected correspondingly.3.First, a failure is to be located via the text display system and the possible cause of failure is to be traced from a point outside the plant with switched-on automatic system. If the failure can be located, the automatics and the hydraulic pumps are switched off and the failure is repaired by suitable staff.For this purpose the personnel has to actuate a repair switch before entering the plant, to lock it by a padlock and to pocket the key. This avoids an acknowledgement of the emergency-stop and a possible switching-on of the plant by third persons. If plant parts have been displaced when repairing the failure, the plant must be moved again to the stage found when the failure occurred. Afterwards, the plant is switched on again and the production continues.4.If, however, the plant stoppage resulted from a failure of the CPU, and after exact verification a deletion and a repeated transmission of the application software should be required, an initializing pulse for the control will be necessary before a restart of the automatic mode of the plant.1.通常只有在液压油泵停机的时候方可进入造型线！2.推送线和辊道输送线的安全条例在输送线或辊道的尾端是非常危险的（无论是在模板更换、砂箱输送、铸型小车或是砂箱提升机构，包括升降机构或转运小车）。为此，在开始维修工作时必须确认所有可能由于设备造成伤害或危险的地方已经由机械保护机构预防。也有一种可能是由于设备（升降装置）里的残余压力造成伤害，这些设备假如要进行维修的话也必须做好相应的保护。3.首先通过文字显示系统确定故障的位置，通过自动系统查找设备以外可能产生故障的原因。假如确定了故障位置的话，就应关闭自动系统和液压油泵，由合适的人员对故障进行修理。 维修人员进入到设备之前必须启动维修开关，用挂锁将开关锁定并将钥匙保管在自己的口袋里。这是为了防止第三者重新启动紧急停机开关和设备上的开关。在维修的时候假如设备的位置有所移动的话，必须将该设备重新移动到故障发生时的位置，然后再启动设备和继续生产。4. 假如设备的停机是由于CPU故障产生的话，在完全确认故障已经删除和反复传送应用软件之后，在重新启动设备的自动模式之前，必须将系统的程序恢复原位5.1.2 Safety advice for the automatic operation自动运行时的安全条例During the automatic mode a trespassing of the plant as well as of the dangerous zones is forbidden.Before starting the automatic mode, the operator has to convince himself that there are no persons inside the plant area or dangerous zones.It has further to be controlled whether any damage has occurred since the latest operation of the plant which could hinder the run of the plant or lead to an endangering of persons.When the total automatics is started, an acoustic warning signal (horn) sounds and the moulding plant changes into the automatic operation after expiry of the pre-warning period.The flashing alarm lamp is illuminated as long as the automatic mode is switched on.However, this does not release the operator from the duty to monitor the plant.Besides the advices of the responsible security organization are strictly to be observed.在自动模式下运行时禁止进入设备以及危险区域！在启动自动模式之前，操作人员必须确认在设备里面和危险区域里没有人员滞留。此外操作人员还须注意检查从最后一次运行以来设备是否有损坏，它们有可能阻碍设备运行或危及人员安全。当整个的自动模式启动后，警报（喇叭）开始鸣笛，预先报警阶段过了之后造型线转变为自动运行模式。只要自动模式在运行，闪烁警灯就一直工作。但这并不意味着操作人员可以逃避监视设备的责任。此外安全负责部门的意见应该得到严格地遵守。5.1.3 Master switch主开关Every plant is equipped with a mechanically actuated master switch. It can be secured in the off position by a padlock.每台设备都设置了机械驱动的主开关，它们可以用挂锁将开关锁定在断开位置。5.1.4 Emergency-stop equipment紧急停机设备All local hand control boxes HvO of the individual plant areas are equipped with an emergency-stop pushbutton according to VDE 0113.Further, a red pilot lamp showing the current situation is placed over the specific emergency-stop pushbutton.根据VDE 0113的规定每个设备区域的所有就地手动控制柜HvO都配置了紧急停机按钮。表示目前状况的红色指示灯设置在特制的紧急停机按钮上方。Lamp off: Emergency-stop circuit in orderLamp flashes: The associated emergency-stop pushbutton or repair switch is actuated. Failure in this plant area.Lamp permanent light: Emergency-stop is actuated. Failure in another plant area.指示灯“关”：紧急停机电路正常指示灯“闪烁”：相应的紧急停机按钮或维修开关工作，在这个设备区域有故障。指示灯“常亮”：紧急停机开关工作，其他的设备区域有故障。When the red mushroom button emergency-stop is actuated, the moulding plant is shut down in case of danger in a way that the shut-down shall exclude any danger for persons or machine parts, as far as this is possible. (Drives are not stopped abruptly but leaded by a emergency-stop ramp function.)The hydraulic pumps are switched off and the hydraulic accumulator discharges.当红色的“紧急停机”蘑菇按钮工作的时候，造型线将立即停机，但有可能，应排除任何人员和设备危险（由于“紧急停机减速的作用”，动作不会突然停止）。液压油泵停机，液压蓄能器卸荷。If an emergency-stop pushbutton has been actuated in any section of the moulding plant, this one must first be unlocked for restarting the plant and additionally the complete emergency-stop equipment has to be acknowledged centrally at the HvO 2.1 by a key-operated switch.造型线上任何一个区域的紧急停机按钮假如工作的话，在重新启动设备时这个按钮必须首先解锁，其他所有的紧急停机按钮必须在HvO 2.1控制柜通过钥匙开关集中复位。Attention: Before manual interventions or repairs all concerned plant parts must be secured against further risks resulting from potential energy.注意： 在手动操作或维修之前都应确保所有有关的设备不会因为剩余的压力造成进一步的危险。5.1.5 Repair mode维修模式1. In case of extensive repair or maintenance works, the master switch is always to be switched off, even if the works can be carried out from outside the plant area.在进行广泛的维修和维护保养时，即使是这些工作是在线外进行，主开关通常是切断的。2. Refer to 5.1: Safety advice参阅5.1: 安全条例In addition to the existing emergency-stop pushbutton, a lockable step switch is installed at the local control box (HvO) in the machine section and the hydraulic station”.This switch allows to switch off the whole moulding plant in case of occurring repair works (function as emergency-stop).If a repair switch has been actuated in any part of the moulding plant, this one has to be unlocked first for restart of the plant and additionally the complete emergency-stop equipment has to be acknowledged centrally by a key-operated switch at HvO 2.除了现有的紧急停机开关之外，在设备和液压站就地控制柜（HvO）上还装有可以加锁的选择开关。在进行维修工作时这个开关可以切断整个的造型线（作用就像紧急停机开关）。假如在造型线的任何地方维修开关工作的话，在重新启动造型线时这个开关必须首先打开，此外整个的紧急停机装置必须由HvO 2上的钥匙开关集中进行确认。Description of functions:a)Off-switching of the hydraulic pumpsb)Relieving of the storage basinc)Off-switching of the supply voltage for the digital output cards(except the pilot lamps)As the supply voltage for the digital input cards holds on, the necessary messages can also be displayed by the signalling system.功能描述a)切断液压油泵b)卸荷c)切断数字输出卡上的电源（除了指示灯之外）当保留数字输入卡上的电源时，必要的信息还可以在信号系统上显示。5.1.6 Alarm equipment报警设施The moulding plants are equipped with an optical and an acoustic signal as starting alarm.When the entire automatics is started, an acoustic alarm signal (hooter or horn), which is limited in time, sounds.All-round lights indicate in addition the start of the automatic operation.The orange pilot lamp on each manual local control box (HvO) is lighting and indicates the automatic operation.造型线配置了声光信号作为设备启动的警报。当全线自动运行启动时由时间控制的报警信号（汽笛或喇叭）就会报警。另外旋转灯光表示设备在自动模式下运行。在每一个手动控制柜（HvO）上面的黄色指示灯一直亮着，表示设备正在自动模式下运行。Starting alarm启动警报In case the moulding plant is started after a longer process-related stoppage, e.g. core setter stop, or started from basic position or automatic mode on, there is an automatic starting alarm. It is also possible to make a starting alarm sound manually by actuating one of the function keys at the operators panel of local control box 2.假如造型线由于工艺的原因停顿了较长时间需要重新启动，例如，下芯暂停，或从原始位置启动，或“自动模式启动”，造型线会自动启动报警。也可以由操作人员在就地控制柜2按下功能键发出启动报警5.1.7 Safety equipment (refer to 5.3.1)安全设备 (参阅 5.3.1)5.2 Structure of the switch and control plant控制开关和控制柜结构The automatic green sand moulding plant is equipped with a freely programmable control which ensures that the operation is achieved step by step.湿砂造型自动线配备可编程序控制用来保证自动线可以一步一步地进行运行。TypeS7MakeSiemens型号S7制造西门子The control comprises the following subassemblies:-Power cabinet-Electronic cabinet-Local hand control boxes (HvO)The complete control has got a retentive-memory version, i.e. after a power failure or a stop of the automatics and an emergency-stop, the plant logically continues its run after having restarted it.控制系统包含以下部件：-电源柜-电气柜-就地手动控制箱（HvO）整个的控制系统有很强的记忆功能，例如在断电或自动和紧急停机后，设备在重新启动后能够继续运转。The electric control has an automatic mode, which ensures that the operation is achieved step by step, a locked manual mode and a non-locked setting-up mode (inching mode). In automatic and manual mode safety interlocks are programmed directly before the outputs. These are only jumpered by a seal-in after completion of the movement.This measure serves to secure the drives against an unintended leaving of the end position.The complete electric and electronic control is installed in dust-tight closed switch cabinets.电气控制系统具有能保证设备能够一步一步地进行运行的自动模式，锁定的手动模式和为锁定的调整模式（缓慢移动模式）。在自动和手动模式里，安全连锁在输出前就已经直接编写在程序里。在整个动作完成之后这些程序仅仅隐藏连接。这个方法用来避免设备预想不到地从最终位置自行偏移。整个的电气和电子控制系统都安装在防尘的密闭开关柜里。5.2.1 Power cabinet电源柜At this cabinet the master switch (lockable) for the input to the network of the whole moulding plant (480 V / 50 Hz).在电源柜里，主开关（可以锁定）用于整个造型线电源的输入（480V/50Hz）。Furthermore the cabinet contains are the following components and subassemblies:电源柜还包括以下的元器件和部件：-power drives-voltage supply and distribution 120 VAC-voltage generation and distribution 24 VDC-配电部分-120 VAC 电源和分配-24 VDC电源和分配Furthermore the power cabinet contains the safety block for the emergency chain.此外，电源柜还包括用于紧急链的安全块。Input field with master switch (example)带主开关的输入部分（实例）5.2.2 Electronic cabinet电气柜This switch cabinet comprises the central controller of the freely programmable control (CPU = Central Processing Unit) as well as the switching devices for the safety equipment.电气柜包括可编程序控制的中央控制器（CPU）以及安全设施的开关装置。 5.2.3 Local hand control box就地手动控制柜For the control system, the moulding plants are subdivided in individual plant sections, e.g. moulding line, pouring line, cooling house, shake-out line, etc.There are local control boxes in these sections not far away and of easy access by which the plant parts can be moved in manual or set-up mode and/or repair mode.There is an operators panel in the front of the specific hand control box in order to operate single plant parts / movements (instead of pushbuttons) in