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1、Spunbond nonwoven production line electrical controlInstruction manualWenzhou ouhai second light industrial machinery factoryContents1、product introduction - 22、system requirements - 33、electric control system introduction - 44、 touch screen introduction - 75、 normal trouble shooting - 116、 590 DC d
2、rive trouble table list - 187、 FUJI inverter trouble protection action list - 208、 RKC parameter specification table - 229、Pre-filter pressure controller inner parameter table（PW206）- 2510、Post-filter pressure controller inner parameter table (F900) - 2611、Post-filter pressure controller inner param
3、eter(FB900) - 2712、 maintenance notes - 2813、 wearing parts list - 29Product introductionOur spunbond nonwoven line uses polymer directly melted ,push and extracted into small filaments, stretching in the flow field using the air dynamic theory, then decelerates in the way of air diffuse and stick t
4、ogether as a web on the spin belt. Our machines have three specification, 1.6 M,2.4M,3.2M.The entire machine consists of following parts:Main extruder, co-extruder, material auto-suction system, master batch and additive blending device, filter, spin pump, monomer fan, upper stretching unit, bottom
5、stretching unit, spin belt carriage, calendar, winder, die heater, calendar heater, AC system, cooling air blower, suction blower, air-compressor, slitter, oven, etc. Processing steps as followAdditive(scrap recycled) Material supply-melting and extruding-filtering-measuring volume and pushing-spinn
6、ing-cooling-stretching- deposition on the web-embossing and formation-slitting and packingThe products mainly apply in packing, medical field, clothing interlining, etc.System requirements 1. Power voltage: three-phase five-wire, 3*380+N+PE2. Power frequency: 50HZ3. The maximum current system needs
7、1.6m width 350A 2.4m width 450A 3.2m width 550A 4. Earthing : the earthing wire is half size of the any phase of power line. The earthing resistance should be less than 4. 5. Working site: in the room 6. temperature: -5t45 7. Humidity: 20%80% 8. Latitude: lower than 1000 m 9. Circumstance requiremen
8、ts: no medal dust, corrosive gas and smog. Electric control system introductionPLC(programmable logic controller)is the main part of electric control system for this machine .The touch screen is the main operation interface, AC or DC drives as the speed smoothing control part, RKC temperature contro
9、ller as the high precise temperature controller. System working stably, easy operation, simple maintenance.The system has three control options: line low speed, line high speed, not-synchronized mode, the three modes can be switched to each other by press the touch screen or switching the mode switc
10、h under the touch screen. There is a linked settings(synchronized settings) for all the high speed settings for entire parts of the machine , a low speed settings for all the low speed settings for entire parts of machine and a unlinked settings (not-synchronized settings) for all the separate runni
11、ng speed settings for drives.The main extruder is droved by DC drive which melt and extruder the material from hopper through filter to spin pump. The RPM of main extruder is close-circuitly controlled by post-filter pressure. When the spin pump speed increases, so does the extruder, this is for ens
12、ure the stable post-filter pressure. The extruder only can be started after the spin pump. At the same time, the master batch, additive and co-extruder motors can only start after the main extruder. Otherwise the machine parts maybe damaged.The post-filter pressure controller for controlling main ex
13、truder speed has two control options: manual and auto. First start the main extruder by manually increase the pressure to the suitable pressure for spinning, then turn to auto mode.Wait until all the heater zones of co-extruder is above lowest temperature point and make sure the main extruder is als
14、o running, then start the co-extruder.When running on the linked settings, the line speed is dominated by spin belt speed. The calender and winder speed fluctuate with the spin belt at certain proportion. The way for controlling spin belt and calenders speed is high-precise encoder feedback control.
15、 Winders speed is controlled by tachogenerator speed feedback. Spin belt is adjusting left wise or right wise by web-guiding system. When the spin belt exceed the super limit, the winder, calender and spin belt speed goes into line low speed settings to avoid damage to spin belt.The lubricant oil pu
16、mp starts with the calender motor. The position of upper roller is fixed; bottom roller is controlled by hydraulic pump. When switch to bottom roller up, the hydraulic pump starts, solenoid valve electrify to get up the bottom roller until presses the upper roller at certain stable pressure, and the
17、n the hydraulic pump stopped. It will start again when the pressure between the two rollers below bottom limits. The winder speed fluctuates with the spin belt speed at the linked settings, controlled by tension close-circuit. When the tension is higher than the set value, speed goes down until to a
18、 stop; when the tension is lower than set value, speed goes up until to 20% of the speed. The winder first starts without tension until web comes into it.Main extruder, 6 heater zones for 1.6M machine, heating voltage single phase 220 volt ; 6 heater zones for 2.4M machine, heating voltage double ph
19、ases 380 volt; 7 heater zones for 3.2M machine, heating voltage double phases 380 volt.Co-extruder, 5 hearer zones, heating voltage single phase 220 volt.Die heater, there are two sets heaters, basic and temperature control heater. Heating voltage is three phases 380 volt. The cycling oil pump shoul
20、d be start before the heater, and then start the basic and temperature control heater. The basic heater stops when the temperature approaches the set value, only the temperature control heater will be running. For 1.6M machine, there is only one heater for calender and two heaters for calender two r
21、ollers respectively. The control way for die and calender heaters is same.Pressure roller, heater is three-phase 380 volt.Upper feeding unit, has two types, granule feeder or vacuum powder material feeder. Granule feeder is controlled by PLC cabinet, taking switch to control material suctions motor
22、on or off, the suction interval can be set on the touch screen. Vacuum powder material feeder has a separate control system which can be used for 0.5g/CM3density 3.0g/CM3 additive, not adhesive, powder like. The system uses high pressure air to blow it down, shake down the powder in a short moment v
23、ery effectively. Cooling air, suction, master batch, additive, all these speeds is controlled by the touch screen separately. AC set, for detailed information, refer to the AC manual.Notes for AC set:1No alien objects beside the AC set within 1 M distance for easy maintenance .2There should be some
24、filters for filtering cooling water and freezing water from outlet. Protect the machine from damage.3There should be a expansion tank for freezing water pipes, to make up the freezing water and condensated water when starts the machine. It is forbidden for start the machine without waters.4. There s
25、hould be good insulation for freezing water pipes, for not necessary energy loss.5. The earthing should be good, be ware of electric shock.6. Make sure the power voltage is in accordance with the rated voltage before starting.7. Wait at least 3 minutes to restart the machine in case of compressor da
26、mage.8. Wash the condenser regularly in case of jammed by dirt. 9.Please read the manual carefully before using. Not to change the temperature controllers parameter casually, set it only according to the requirements, not lower than 7.Touch screen introductionThe touch screen has five operation disp
27、lay, initial display, linked settings display, alarm settings display, low speed settings display, unlinked settings display. 1. Start up, choose the English version, and enter into the linked settings.2. Enter into the linked settings; there are eight buttons on the top. If you want to start coolin
28、g tower motor, need to start the water pump 2 first.3. Seven set inputs. One is for winder tension, off the tension when just start the machine, turn it on after winding. Other six is for high speed settings for spin pump, monomer, etc. The button at the top of the frame is for control on/off of mac
29、hine parts, the input below is for directly enter the speed value. The up/down button is for fine adjustment. 4. There are three high speed inputs for spin belt, calendar, and winder at the bottom. The spin belt speed is the master speed. Spin belt input calender input percentage= calender input, sp
30、in belt input winder input percentage=winder input, the maximum value for calender and winder input percentage is 100%.5. The five buttons at the bottom is for switch the setting display.6. The counter meter shows the actual length of the roll. When the roll length nears the set length, the doffing
31、performs automatically. There are two types of doffing, manual doffing and auto-doffing. Press the manu doffing button below the touch screen to change the roll at anytime when it is in manual mode. Press the winder reset to let the doffing system go back to original position.7. Alarm settings, if a
32、ny part has trouble, the related indication light will be on.8. Low speed settings, set for all drives low speed.9. Unlinked settings, “Counter amendment para” can calibrate the actual meter read. Normal the value is 0.221.“Cutter delay “is for adjusting the time need for cutter to act.“Roller holde
33、r back delay” is for adjusting the stop time for roller holder to go back.“material-suction input delay” is for adjusting the interval for suction.“material-suction output delay” is for adjusting the time suction last.“Roller down delay” is for adjusting the time roller remains in the holder before
34、it comes down. When we are making the light GSM, the “roller down delay” time should be longer to ensure the enough pressure against the windering roller.The following inputs are for spin belt, calender and winders unlinked setting and start up parameters.The five buttons on the left only effect whe
35、n presses unlinked setting button under the linked settings.Normal trouble shootingbreakdown partHow breakdown showsCauses ofBreakdown Main extruderA.over-current protection1.V-belt too tight2.heater zones temp low, too much load on the extruder motor3. not enough gear oil in the gearbox4.screw scra
36、tches the out-core 5.field current setting is lower than rated field currentB. extruder motor speed has big fluctuationPost-filter pressure controllers parameters wrongC. motor temp high1.motor cooling fan not running or running reversely2.cooling fan jammed3.actural current bigger than rated curren
37、tD. extruder high temp1. solid relay short-circuit2. temp testing senor not workingE. extruder low temp1.solid relay open-circuit2. temp testing senor short-circuit3.heater open-circuitF. extruder temp controller display “0000”1. temp testing senor open-circuit2. temp testing senor parameters not ma
38、tch with the controllerCo-extruderA. co-extruder can not start1. heater temp low2. motor over-load protectionB. temp controller troubleLike the main extruderC. scrap feeding motor not running1.scrap feeder jammed2. inverter protectionMaster batchA. not precise adding percentageThe set RPM and actual
39、 RPM has difference2.wrong g/min value for master batch3.inverter parameter set wrong, not stable speedB. motor temp high, over-current protection 1.master batch motor shaft resistance high2.inverter parameter wrongC. master batch over-flowMotor runs reversely or extruder stopsMaterial suctionA.extr
40、uder starvation alarm1. not enough material in the material tank2. extruder starvation senor error, material powder on the sensorB .material suction not working1.low suction2.sensor breakdown3.vacuum pump overloadSpin pump A. not precise measuring on the volume1.RPM/min testing error2.inverter param
41、eter set wrong, speed not in a direct ratio with settingB. no melt come out from spin pump 1. inverter protection2.spinning chamber has no melt3. spin pump troubleSpin belt troubleA. spin belt can not start1. spin belt motor fan overload2.spin belt drive trouble3.spin belt motor trouble4.motor encod
42、er connection shaft breaksB. spin belt speed not stable1.spin belt encoder loose connection2. spin belt motor loose chain 3.spin belt motor foundation plate loose4.spin belt driving roller alignment not good5.spin belt driving roller bearing tight6.spin belt drive parameters wrongC. spin belt speed
43、suddenly decreases to 10m/min when running at high speedSpin belt leans asideCaldender troubleA. calender can not start1. calender motor fan overload2.calender drive trouble3.caledender motor trouble4.motor encoder connection shaft breaksB.calender speed not stable1.calender motor encoder loose conn
44、ection2.calender motor loose chain 3.calender driving roller bearing tight4. calender drive parameters wrongC. spin belt speed suddenly decreases to 10m/min when running at high speedSpin belt leans asideDcalender up/down inflexible1. up/down oil pump overload protection2.up/down valve not electrifi
45、ed, fuse burnt or solenoid burntE. calender oil level low1.lubricant oil pump protection2.oil routes jammed, valve not open to the most3.caledender stopsF. calender temp highCalender oil heater temp sets too highG. calender temp low1. calender heating solid relay burnt2.heater open-circuit3. oil heater over-pressureWinder troubleA. winder can not start1. winder motor fan overload2.winder drive trouble3.winder motor trouble4.speed testing trouble ,no voltage outputB.winder speed not stable1.winder s
