電氣控制系統(tǒng)用戶手冊

安全措 控制 、啟 安 接 調試和培 啟動和操 故障與處 保養(yǎng)與檢 環(huán) 參數 附 Safety Control Transportationand Installation Wiring Commissioningand Start-upand TroubleShootingand 9Maintenanceand Environmental Parameters Appendix 安全措 Safety（BeforeinstallationandoperationpleasereadthesesafetyinstructionandThisequipmenthashighvoltageatitsmovingpartsduringoperation.Pleasereadthismanualandotherrelevantmanualscarefullybeforeoperatingthemachines.Thesafetyprecautionlevelsare“HAZARD”and!表示不正確的操作可能造成情況，引起或重傷事! referstopotentialdangerofdeathorseriousinjurycausedby!警告 據情況不同，標示為!警告的步驟也可能引起嚴重。! referstopotentialdangerofmediumorslightinjuryorlossofcausedbyincorrectoperation;dependonsituationsometimesitmayleadtograve只有具備資格的，在他們完全熟悉了本手冊中所有警告和安全注意事項及步驟Thisequipmentmustbeinstalled,operatedandmaintainedbysuitablyqualifiednelonly,afterbeingfamiliarizedwithallwarnings,safelyaspectsandproceduresinthisThesafelyoperationofthissystemissubjecttothecorrecttransportation,installation,operationandmaintenance.!注 ! thosepartsinthismanualmarkedwiththeword“Caution”mustbespecial!接 ! allequipmentrequiredbythismanualtohavegroundaccordingtheinstructiontopreventdangerand定義：Qualifiedpeople:“qualifiedpeople”mentionedinthismanualrefersto nelwhoarefamiliarwiththecompletesysteminstallation,operationandpotentialdanger.Theymusthavethefollowingqualifications:·1Theyhavebeentrainedandareabletoconnectpowersupply,disconnectpowersupplyandequipmentgroundingandwiring.·2經過培訓、能按照制定地安全規(guī)范，正確使用和、保護裝置。在緊急救護方面受過Theyhavebeentrainedandareabletooperateandmaintaintheequipmentproperlyandhavecompleted-aidtraining.Undernocircumstances,shallsafetybecompromised.Themanualinstructionsmustbestrictlyobserved.Pleasekeepthismanualinproperplaceforeasilyaccess. mustbemadeavailableforuseroftheequipments.控制柜ControlStandardcontrolcabinetasshownOverallDimensionoftheCabinet(mm)andApprox.WeightWHDNote:Theabovearereferential 、啟封TransportationandTheelectricalcontrolcabinetisdeliveredaccordingtotherequirementsoftheorderandpackedwithnecessarylabelonthepackage.Shakingandbumshallbeavoidedduringtransportation.Thecabinetshallbekeptawayfrommoistureandhandledwithcarewhenloadingandunloading.Pleasecheckandtallythedeliveredgoodsaccordingtothepackinglist.Afterconfirmationofnodamagedgoodspleaseproceedtounpack. Ifthereisanydamageduringtransportationormissingcomponents,sparepartsorationafterunpacking,pleaseinformtheforwarderorKeyachemicalmachineryAfterunpacking,pleasekeepthe ation.Makecopiesforfrequentlyusedand 安裝 PreparationandPleaselayoutthecompletemachinesetaccordingtotheprovidedlayoutdrawing,determinethepowersupplyandwiringrequirementsstatedonthepanelandrelevantspecificationprovided.Ifinstructionisnotfollow,itmightresultindanger.供電系統(tǒng)的設計及引入。PowersupplysystemdesignandThepowersupplyistobefurnishedbyenduser,pleaseseedetailspecificationforthepowersupply.控制柜到設備間的接線布置。Wiringbetweencontrolcabinetand整套系統(tǒng)中按照科亞成套裝備公司配線標準進行配線，沒有配線的所有設備，要求ThewiringofthecompletesystemshallfollowKeyachemicalmachinery’swiringstandard.Forequipmentswithoutconnectionwiring, userisrequestedtoprovidethesewiresandcables.Theenduserneedtofollowasperdrawing,alongwithrelevantspecificationprovidedandactualsitesituationtoprovidewiresandcables,beforethearrivalofourcommissioningengineer.整套系統(tǒng)安裝就位完全好以后，請按照有關要求固定好所有設備及電儀系統(tǒng)。Afterinstallationandlayoutofthecompletesystem,pleasefollowrelevantspecificationprovidedtosecureallequipment.接線5.1接線準備Wiring!警告系統(tǒng)接線需具有資格的進行接線，該必須獲得有關方面的工作證，或具!WARNINGSystemwiringrequiresqualified neltohandlewireconnection,theyneedstobecertifiedorshouldbespecialistwhopossessescompetency,uponmasteringthesystem.Otherwiseitmayresulttoseriousinjuryandequipmentdamages.!在接線以前，必須確保整套系統(tǒng)的總電源開關沒有合上，只有在確保系統(tǒng)斷電的!HAZARDAllelectricalpowersupplyshouldnottobeswitchonbeforewiring.Systemwiringcanonlybecarriedonrefertotherelevantwiringdiagramswhenthemachineispoweroff.Otherwiseitmayresulttoseriousinjuryandequipmentdamages..接線端子 Wira!注 ! Pleasefollowterminaldiagramtoconnectallwire,theactualwiringterminaldiagramwillbeprovidetogetherwiththe5.3檢查!警告系統(tǒng)接線完成后，必須經專業(yè)或具有相關資格的進行全面檢查。檢查!WARNINGSpecialistorqualified nelmustrunacompletecheckafterthesystemisconnected.Theinspectorneedstocarefullycheckforanyloose,dampedandpoorconnection,checkifallterminalsarewiredcorrectly,andcheckforbarewires,especiallyallgroundingcircuit.Allelectricalequipmentsneedtobeproperlygrounded.!!WARNINGEnsuresafety,electricinsulatingofallmotors,heatersneedtobechecked,undernormaltemperature,unlessspecify,theinsulating notlessthan0.5M?.Speedcontroller,frequencyinverter,controlinstrumentstrictlyprohibittouseofmegaohmmeter;insteadmultimetercanbeusefortesting.6調試與培訓Commissioningand.1調試準備Commissioning!總電源合閘：在整套系統(tǒng)安裝完成并經過檢查后，在雙方共同認為滿足系!HAZARDmainElectricalPowerSupplySwitch：Afterthecompletesystemhavebeeninstalledandchecked,onlywhenbothsides’ nelareconsiderthatallconditionshavebeenmet;themainelectricalpowersupplyswitchcanbeturnedon.Theexternalpowersupplyneedstobechecked(whetherrunningproperly)beforethewholesystem6.2Commissioning!按照一般系統(tǒng)配置，本系統(tǒng)主要分為主機輔機兩大系統(tǒng)。其中主機系統(tǒng)主要包!HAZARDaccordingtostandardsystemsetup,thewholesystemconsistsofmainmachineandauxiliaryequipments.Themainmachineconsistsoftemperaturecontrolsystem,maindrivesystemandlubricatingsystem;theauxiliaryequipmentsconsistoffeedingsystem,vacuumsystem,conveyingsystem,pelletizingsystemanddryingpacking主機系統(tǒng)MainMachine溫度控制系統(tǒng)TemperatureControlTemperaturecontrolsystemusedfeedbacktemperaturecontrollerfortemperaturecontrol,theheatingsystemconsistsoftemperaturecontroller’soutputsignal,solidstaterelayandelectricheater;thecoolingsystemconsistsoftemperaturecontroller’soutputsignal,solidstaterelayandwatercoolingpump.Alltemperaturecontrollerparameterareproperlysetaccordingtorequirement,seerelevantspecificationprovided.Heating/coolingsystemandcontrolfeedbackfunctionAllheatingandcoolingfunctionshouldbecheckedaccordingtoOptimizationoftemperaturecontrollerparameterandvalveDuringactualcontrolsituation,itispossibletooptimizesomeofthetemperatureBeforeactivatetheoilpump,allvalveistobe設置斷路器斷路電流根據需要設置好其保護電流。Accordingtorequirementsetsafetycurrentvalueforfuse.SystemcheckforcoolingoflubricationCheckforlubricatingoilsystemoperatingcondition:Forexamplerotation,temperature,pressure,oilleveletc.主機傳動系統(tǒng)：MaindriveControllerparametersettingandinspectionshallbeaccordingtotherequirement,seerelevantspecification傳動系統(tǒng)的負荷檢查根據實際情況和相關的工藝要求可以通過手動盤車來評估負荷Checkdrivesystemload,accordinglytorequirement,thejiggerismovedbyhandtoestimatetheload,andiftheloadexceedsrequirement,donotstartupthemotor.3)Checkmaindrivesystemoperation:forexamplerotationdirection,temperature,current,voltage,rotationspeedetc.輔機系 Supplementequipment加料系統(tǒng)：FeedingControllerparametersetupandinspection,accordingtotherequiredsetupandcheckothercontrollerparameter,pleaserefertooperatingmanualforactualsetup.feedingsystemoperation:forexamplerotationdirection,temperature,current,voltage,feedingfrequency,dischargecapacityetc.真空處理系統(tǒng)：VacuumManagement管路閥門的位置檢查CheckallpiandAccordingtorequirementsetsafetycurrentvalueforfuse.3)真空系統(tǒng)的運行狀況檢查:如電機轉向、溫度、真空度大小等。Checkforvacuumsystemoperatingcondition:forexamplerotation,temperature,vacuumpressureetc.管道、輸送風機等閥門的位置檢查Pipe,conveyingbloweretc.valvesposition2）設置各保護用斷路器斷路電流根據需要設置好其保護電流值。Accordingtorequirementsetsafetycurrentvalueforfuse.3)Checkforconveyingsystemoperatingconditionforexamplemotorrotationtemperatureconveyingcapacityetc.切粒系統(tǒng)Pelletizing控制器參數設置和檢查根據需要設置并檢查其控制器參數，具體設置請見相關說明書。Controllerparametersetupandinspectionforcontrolleraccordingtotherequiredsetup,pleasecheckitandrefertooperatingmanualforactualsetup.systemoperatingcondition:forexamplerotation,temperature,current,voltage,cuttingspeedetc.干燥包裝系統(tǒng)DryingPacking控制器參數設置和檢查根據需要設置并檢查其控制器參數，具體設置請見相關說明書。Controllerparametersetupandinspectionforcontrolleraccordingtotherequiredsetup,pleasecheckitandrefertooperatingmanualforactualsetup.設置各保護用斷路器斷路電流根據需要設置好其保護電流值。Accordingtorequirementsetsafetycurrentvalueforfuse.干燥包裝系統(tǒng)的運行狀況檢查:如轉向、溫度、包裝量大小等。Checkfordryingpackingsystemoperatingcondition:forexamplerotation,temperature,packingoutputetc.聯(lián)鎖及功能檢查：Interlockingand潤滑系統(tǒng)與主機傳動系統(tǒng)和加料系統(tǒng)的聯(lián)鎖。Interlockingoflubricationsystem,mainmachinedrivesystemandfeedingsystem.主機過電流、熔體過壓力、控制器故障等功能檢查。Alarmformainmachineoverload,meltpressureexceedlimit,controllerfaultyetc.3)有聲光系統(tǒng)的摘除功能等。DeactivatealarmsirenandwarningAfterdebuggingandbeforeproductionofthesystem,theserviceengineerisrequiredtoproviderelevanttrainingtotheoperatorsandmaintenance nel,sothat canoperate,manageandmaintainthecompletesystemafteracceptanceofthesystem.ElectriccontrolsystemandoperatingIntroductiontoallcontrolsystem操作規(guī)則培訓Trainingonoperatingregulations3）操作注意事項Cautionproceedingduringoperating4）緊急事件處理Handlingofemergencysituation機械系統(tǒng)的操MechanicalsystemoperatingIntroductiontoallmechanicalsystemTrainingonoperatingCautionproceedingduring緊急事件處理HandlingofemergencyStart-upandAlloperatorshavebetrainedandequippedwiththeskillsbeforeoperating,withreferencetotheelectricalcontroldiagram,pleasefollowthebelowsteps:合上總電源保護開關。Switchonmainelectricalpower打開電源開關，給系統(tǒng)控制柜上電自檢。Switchonthepowersupplyby系統(tǒng)，對溫度進行控制。Accordingtothetechnicalrequirementsetalltemperaturevaluesforallbarrelsections,atthesametimeactivatedthewatercoolingsysteminordertocontrolthetemperature.Aftersystemtemperatureparameterreachtechnicalrequirement,thesystemneedtomaintainthetemperaturefor0.5hour.根據工藝需要啟動換網系統(tǒng)。Thescreenchangerneedstobeactivatedwhen啟動潤滑系統(tǒng)，檢查傳動裝置的油位、油壓等。Activaubricationsystemandcheckdrivesetupoillevel,oilpressureetc.啟動輸送系統(tǒng)、干燥包裝系統(tǒng)。Activateconveyingsystemanddryingpackingsetcuttingspeed.systemthensetrotationspeed.下緩慢加大加料量。Activatefeedingsystemandadjustfeedingcapacityaccordingtoactualsituationandtechnicalrequirement.再停掉真空泵電機。Tostartupvacuumsystem, activatethevacuumpumpmotorandadjustthevacuumpressurewithvacuumcontrolvalve.Toturnoffthevacuum,closethevacuumcontrolvalveandstopthevacuumpumpmotor.停車順序Stop正常停NormalShut停加料系統(tǒng)，對于有幾套加料系統(tǒng)的設備，根據工藝要求決定其停止順序。Stopfeedingsystem,forsystemwithseveralfeeders,shutdownsequenceshallbebasedontheprocessingrequirement.料排掉以后再停主機，參考標準為熔體的壓力和機頭出料情況。Stopthemainmachine,formachinerunningathighrotationspeed,themachineneedtoslowdownforafewminutestillthematerialinsidethemachineisremoved,whichcanbeindicatedbythemeltpressureandproductoutput.停潤滑系統(tǒng)、真空系統(tǒng)、切粒系統(tǒng)、輸送系統(tǒng)和干燥包裝系統(tǒng)等。Stoplubricationsystem,vacuumsystem,pelletizingsystem,conveyingsystem,anddryingpackingsystemetc.停車AbnormalShut決問題后方可再次開車。Whenthemainmachineisshutdownaftergivinganalarmduetofaultycontroller,overloadandmeltoverpressureetc.itisnecessarytofindouttheproblembeforethemachinestartsupagain.須查明原因并解決問題后方可再次開車。Whenthereisanabnormalnoiseandvibrationetc.Pleasepushtheemergencybuttonimmediay.Itisnecessarytofindouttheproblembeforethemachinestartsupagain.partofthesystemisfaultyornotrunningbutthemainmachinestilloperates,thepartofthesystemshouldberepairedaftertheelectricpoweriscutoffbyqualifiednelwhilethemainmachinestill!注 !CAUTION Itisrequiredthattheallspeedcontrollershouldbereturntozeropositionaftermachineisstopped.故障與處理Faultycoolingsystem(watercooling)Thesolenoidvalveisnotworking.Thecontrolvalveis FaultycoolingsystemairTheventilatorisnotdirectionisincorrect.Theoverload 3、溫控表或PLC調節(jié)失靈FaultytemperaturecontrollerorPLCFaultysolidstaterelayorThescrewelementsandkneadingblocksstrong1、(waterCheckwiringofsolenoidvalvecheckorreplacethesolenoidvalve.Openthestopvalveandregulatethevalveforsuitablerateofflow.Clearupthewater2、(AirCheckthewiringofventilatorcheckorreplacetheventilator.ReplacethewiringofResetoverloadAlterregulatingdataoftemperaturecontrollerandcontinueobservation. Replacesolidstaterelayor kneadingblocksagain.1、溫控表或PLCAlterregulatingdataofthetemperaturecontrollerandcontinueReplacetheIncreasethetemperatureofcoolingwaterandcontinueobservation.CheckandrepairthesolenoidCheckthecontrolvalvethenregulatetheflowrateofcoolingwater. kneadingblocks.RegulatescrewspeedandcontinueFaultytemperatureThepowerratingofheaterisnotenough.FaultyofwatercoolingwaterisThesolenoidvalveisTheflowrateofcoolingwateristoobig.ThescrewelementsandkneadingblocksdonotproduceenoughThescrewspeedistooThecoolingfanofmainmotorstopped.ThepressureofliberationoilisMeltFaultyofspeedcontroller.(phaseshortage,voltage1、查明停止原因，處理解決后重新啟動Findoutthecause 2、查明停止原因，處理解決后重新啟動Findoutthecause Cleanorreplacethefileroftheliberationoil.4（1）檢查熔體壓力設定值是否合適Checkwhetherthealarmsetvalueofmelt-pressureiscorrect.ReplacetheCheckwhetherthetemperatureofthedie-headislow.Checkwhethertheholesofdie-plateareblocked.Refertothemanualinstructionofspeedcontroller.Forthecauseofoverload,toAbruptoverheat,etc.)FaultyofcomplementmainWhetherforeignobjectsarefeedintothebarrel.WhetherthetemperaturesetvalueofisWhetherthefeedrateistoofast;orwhethertherawmaterialssizeistooWhetherthescrewelementsandgearboxbearingsaredamaged.Findoutthecause AbruptMainmotorFaultyspeedFaultyCheckandrepairthemainmachine2、對照調速器使用說明書處理解決Refertothemanualinstrumentofspeed3、請機械、電氣檢查處理(喂料機中是否有異物，喂料顆粒是否過大，喂料機Techniciansfindoutthecauseandresolvethestoppage.(suchasWhetherforeignobjectsarefeedintothebarrel;whether ofrawmaterialsistoobig;whetherfeedingmethodissuitableforrawpumpisnotMainmotorFaultyFindoutthecauseandresolvetheAsktechnicianstofindoutthecauseandresolveit.OilshortageinoilFilteroftheoilisblocked3、油壓設定過低Thesetvalueofoilpressureislow.isAskmechanic nelfindoutthecauseandsolveit.CleanorreplacetheResettheoilpressureUseacorrectlubricationisnotMainmotorFaulty1、查明泵停原因，處理解決后重新啟動Findoutthecause AsktechnicianstofindoutthecausesolveThewaterpumpisnotatThesolenoidvalveisnotThehandvalveisnotCoolingwaterisshortageinthewater TheinletofwaterpumpisFaultywaterCheckthewiringCheckorreplacethesolenoidCheckorreplacet