OPERATING INSTRUCTIONS ELECTRONIC LOW
Contents
1. nntnnennnenen vanana nnne nn nene nennen nennen 57 Management of casting control programs nnnrnnennnnenennenennnnennnan annan 59 Page 3 of 60 CAST POWERED BY Fil The electronic casting control consists of an industrial PC with a 15 inch TFT screen with 1 Introduction membrane keyboard or touch a separate electronics component integrated in a 19 inch housing and or a PLC module The electronics component and industrial PC can be installed up to 100m apart The communication between the two devices takes place via two serial RS 422 interfaces Communication between the industrial PC and the PLC takes place It s main purpose is 1 To monitor the pressure in the holding furnace i e mould filling according to a predefined profile taking into account the leakage losses of the furnace the fluctuations in system pressure and to control and or regulate either time or temperature dependently the pressure compensation for the amount of metal removed 2 To control and or regulate either time or temperature dependently the mould cooling process according to predefined target values 3 To store a variety of programs recipes and data All the necessary programs and data are stored in the PC Whenever the program is started the PC transfers the selected programs to the casting control electronics unit This program is executed independently Changes made to the program parameters2. 4 This area shows the cooling zones controlled by the temperature sensor Clicking on a cooling zone number takes you to the configuration window for the selected cooling zone see Chapter 9 2 4 5 Displays the parameters for the temperature controlled pressure holding phase Clicking this area displays the configuration window for casting parameter settings see Chapter 9 2 3 a un Ve an El RE Temperaturgesteuerte Druckhaltephase J Temperatur C 250 Zeit Min Sek 10 Zeit Max Sek 25 Temperaturgesteuerte Maschine ffnen Te 6 Displays the parameters for temperature controlled opening of the machine Clicking this area displays the configuration window for casting parameter settings see Chapter 9 2 3 g AA Ten akg aiias gesteuerte Druckhaltephase Temperaturgesteuerte Maschine ffnen Temperatur C 190 Zeit Min Sek 15 Zeit Max Sek 25 SE 7 Here you can set the operational limits for the temperature sensor 2 rm N Page 56 of 60 9 2 6 Mould and machine parameters SN 09 11 32 ee BASIS Maschine Nr 1 Ausfahren vareae Name Car testing A ON GEOFFNET GESCHLOSSEN Real Position Ge ffnet Dez er Sehe P GE FFNET o GESCHLOSSEN Ne Fr GE FFNET i GESCHLOSSEN ol Sim 5 GE FFNET o GESCHLOSSEN Tie Geschlossen 1065 6 GEOFFNET o GESCHLOSSEN aj EE STEUERUNGSPROGRAMM TIEK MASCHIN
3. 2 a r er Here the individual cooling zones can be activated through clicking In the above example e The 2 3 6 water cooling circuits and 3rd air cooling circuits are switched off manually e The ist and 6th air cooling circuits are switched on manually e All other cooling circuits are in Automatic mode The cooling circuit is switched in the following order gt ON gt OFF gt AUTO gt ON gt In the event that a cooling zone does not switch in Automatic mode it can be checked here whether Manual switch off is possible Page 31 of 60 9 1 5 Status of the temperature controlled cooling zones Ss Werkzeugname l Test die Maschine Nr 100 Ofen Nr Programm 1 Ofenf llung Nr Gesamtst ckzahl 11125 Guss Nr d 160 C E 70 C OTT u 70 C RRRANANANAN EB 145 C usc RS onal tye 1 145 C H 145 C 350 Soon 150 C 350 500 C E 150 C 350 500 C Ji 450 C 350 500 C 8 150 C 350 500 C TEE 150 C 350 500 C jun 150 C CAST POWERED BY FILL Displays the adjusted parameters and the real differences between the target and actual values 9 1 6 Progression of temperatures Werkzeugname l Test die Maschine Nr 100 Ofen Nr Programm 1 Ofenf llung Nr Gesamtst ckzahl 11127 Guss Nr Page 32 of 60 13 07 2012 CAST POWERED BY FILL 1 Chart di
4. 9 1 10 Exporting reports Browse For Folder 3 314 Floppy 4 H we System C a Data D CastingProtocols CcS_VentilTest O ControlPrograms EwF O temp working 1 Clicking button 1 launches the export of casting reports A memory location should be selected for the reports Clicking the OK button copies all of the machine s casting reports to the selected location Page 36 of 60 CAST POWERED BY FILL 9 2 Configuring the casting process User interface To perform the custom control of the casting and cooling process a suitable administration panel operated with an industrial PC must be used The various graphical user interfaces are described in the following sections 9 2 1 General display Via the buttons on the right side of the interface all other screens can be accessed C E SS 06 07 2012 11 25 14 Test die 111 KALTSTART Ablaufkette Programm PASSWORD at STEUERUNGSPROGRAMM Schritt des Ablaufs Zu gieRende Gesamtstiickzahl 500 OFEN FULLEN ZAHLER GESAMTZAHLER LOSCHEN LOSCHEN DEAKTIVIERT DEAKTIVIERT St ckzahl f r Ofen nachf llen Blinken f r Metall nachf llen Leckverluste Anzeige Grenzwert Beginn 06 01 M Ende 14 00 Beginn 14 01WW Ende 22 00 Beginn 22 01WW Ende 06 00 Page 37 of 60 CAST POWERED BY FILL 9 2 1 1 Description of the left menu bar m a Page 38 of 60 Switch the operating lang
5. M Schritt des Ablaufs M A asd The ON and continuous time of cooling for air water cooling circuits is to be set Parameter entry starts with a click in the top area 1 for the air cooling circuit and in the bottom area 2 for the water cooling circuit A number pad is shown Here the delay time of the cooling zone and in the 1st and 2nd number block the cooling time can be entered Accept the entry by clicking Enter The cooling zone can then be left and the next cooling zone can be configured Air cooling circuit electron OMINAL COOLING PROCESS PARAMETERS OOO a No 8 ___________________ _ js jo Na 4 Is lo MN an mudi 1 i 000 000 Kusel 2 Enter M gt ratta aa Taga poega N TI mr Page 51 of 60 CAST POWERED BY FILL u 4 Water cooling circuit JOMINAL COOLING PROCESS PARAMETERS KIE SECTION No 8 Temperature 1 Entering the ON time for the cooling circuit 2 Entering the continuous time for the cooling circuit 9 2 4 3 Temperature controlled cooling zone ee 09 07 2012 Test die 111 _ K HLUNGS PROZESS SOLL PARAMETER Kl Nr 12 o STEUERUNGS 5a 340 C 4 BETRIEBSART WASSER STEUERUNGSPROGRAMM a M Schritt des Ablaufs M amp A BA Le E With the temperature controlled cooling zone the following entries can be parameterised 1 Temperature sensor Selection by the select menu with temperature sensor
6. Displays 1 In the top area the temperature difference of the thermocouples to detect any thermal stress in the mould Inthe middle area the accumulated cooling status In the bottom area the target and actual pressurisation curve the target curve is grey the actual curve blue 4 Displays current casting parameters Admission pressure nominal valve width metal temperature time of the pressure holding phase or time until the machine is opened current pressure Page 29 of 60 CAST POWERED BY FILL 9 1 3 Status of the cooling zones Werkzeugname Test die 100 OfenNr 1 Ofenf llung Nr 11124 Guss Nr K HLUNGS PROZESS BERWACHUNGS PARAMETER I l i A 1 C EN SSS SSeS essed N SENNA ee SSS SSS 1 Here the temperature difference of the thermocouples is displayed 2 Status of the individual cooling zones e Left light blue for air cooling e Right light green for water cooling e In the middle area the activations of the cooling zones can be controlled in the diagram Here the current temperatures of all connected an used thermocouples are displayed Click in this area to launch manual control of cooling zones See chapter 9 1 4 Page 30 of 60 CAST POWERED BY FILL 9 1 4 Setting the cooling mode AUTO ON OFF Werkzeugname l Test die 100 Ofen Nr 1 Ofenf llung Nr 11125 Guss Nr K HLUNGS PROZESS u 1 PEA 1 ja s a 1 ra
7. Page 25 of 60 CAST POWERED BY FILL 9 Low pressure casting control system 9 1 Monitoring of the casting process User interface To perform the custom control of the casting and cooling process a suitable administration panel operated with an industrial PC must be used The various graphical user interfaces are described in the following sections 9 1 1 General display The header bar see figure below includes general information about the process and control seguence By clicking in the individual fields you can enlarge them or zero in on specific monitoring areas ea Werkzeugname Test die 100 Ofen Nr 1 Ofenf llung Nr 11124 Guss Nr KUHLUNGS PROZESS UBERWACHUNGS PARAMETER e 1 AAA A ee 1 y CA 6 5 m A 80 100 126 140 EES RENNENS 7 00000 00000 00000 KASKA KAIRIAKARAKIKKKAKIRAKAKIKAKAIKA KI KARSI KKI 0000 00000 00000 00000 00000 0000 00000 3 A ef Page 26 of 60 9 1 1 1 Header bar __ Werkzeugnime Test die gt 13 34 13 42 07 2012 Maschine Nr 100 Ofen Nr 123 CN 177 cy 594 gt 621 Proaramm 1 Ofenf llung Nr 3306 a vo cc BENENNEN 10865 Guss Nr 30 28 5 TEE a 103 s 100 1 Shows the status of the existing connection to the data server control Shows red when the machine s control system reports a new fault Shows light blue when all reported faults have been acknowledged Clicking this button opens a wi
8. 3 4 Open the machine CAST POWERED BY FILL The end of the pressure holding time is preset by an external timer The following settings can be made for the opening conditions Temperature Nr 10 T C 250 Zeit Min Sek 010 Zeit Max Sek 025 Machine ffnen TEMPERATUR Verz gerung Sek 005 Page 46 of 60 Machine is opened at a set temperature However at least the set minimum time must have expired In addition the set maximum time must not be exceeded After the maximum time has lapsed the machine is also opened Machine is opened after a set time 9 2 3 5 Pressure control DRUCKREGELUNG Ventilnennweite bis Vord 035 9 2 3 6 Pressure compensation CAST POWERED BY FILL During pressure control the nominal valve width is specified until the admission pressure is reached Pressure compensation has the following operating modes and possible settings Pressure compensation DRUCKKOMPENSATION MIT STEIGROHRREGELUNG ind METALLSONDE METALLSONDE MIT STEIGROHRREGELUNG DRUCKKOMPENSATION pro Guss mbar Grundvordruek mbar DRUCKKOMPENSATION DRUCKKOMPENSATION MIT STEIGROHRREGELUNG METALLSONDE MIT STEIGROHRREGELUNG METALLSONDE Max Sonde Druck mbar f r den 1 Guss mbar Page 47 of 60 s Chap 5 Explanation of operating mode 1 Compensation per cast Compensation of furnace filling by the drai
9. MACH11 MASCHINEN FEHLER ENDSCHALTER ZUR BESTIMMUNG DER MASCHINENPOSITION ANDER SCHALTERLEISTE SIND NICHT ZUL SSIG MASCHINE IM HANDBETRIEB FFNEN UND FEHLER QUITTIEREN Page 34 of 60 CAST POWERED BY FILL This screen displays current machine faults New fault messages are shown in red Fault messages once read can be acknowledged with a click Acknowledged messages are shown in light blue This screen appears when clicking button 1 when the control system reports any kind of fault 9 1 9 Fault report Werkzeugname l Test die Maschine Nr 100 Ofen Nr lt Programm 1 Ofenf llung Nr Gesamtst ckzahl 11118 Guss Nr KUHLUNGS PROZESS UBERWACHUNGS PARAMETER ___ bac EE Date Type No Description bl 7 13 2012 11 25 MACH 11 MASCHINEN FEHLER ENDSCHALTER ZUR BESTIMMUNG DER MASCHINENPOSITION AN DER SCHALTERLEI 7 13 2012 11 25 MACH 15 7 13 2012 11 26 MACH 11 MASCHINEN FEHLER ENDSCHALTER ZUR BESTIMMUNG DER MASCHINENPOSITION AN DER SCHALTERLEI 7 13 2012 11 26 MACH 15 7 13 2012 11 26 MACH 11 MASCHINEN FEHLER ENDSCHALTER ZUR BESTIMMUNG DER MASCHINENPOSITION AN DER SCHALTERLEI 7 13 2012 11 27 MACH 15 7 13 2012 11 27 MACH 11 MASCHINEN FEHLER ENDSCHALTER ZUR BESTIMMUNG DER MASCHINENPOSITION AN DER SCHALTERLEI 7 13 2012 11 27 MACH 15 7 13 2012 11 28 MACH 11 MASCHINEN FEHLER ENDSCHALTER ZUR BESTIMMUNG DER MASCHINENPOSITION AN DER SCHALTERLEI 7 13 2012 11 28 MACH 15 7 13 2012 11 2
10. dP Pressure compensation for the amount of metal removed The admission pressure depends on the operating mode See also the various modes of operation Whenever the furnace is refilled the button Furnace refilled must be pressed so that the admission pressure is reset The button Furnace refilled must only be pressed if the casting program is not running to Time starting from the zero point of the casting curve t1 t8 Time steps corresponding to the pressure levels P1 to P8 tstep Time difference between 2 time steps always starting from zero tmp Pressure holding time During this time the final pressure P8 is kept constant Page 13 of 60 CAST POWERED BY Fil This time specification is required in the operating mode Temperature dependent pressure tmp min Minimum pressure holding time holding phase During this time the pressure is not released regardless of the temperature tmp max Maximum pressure holding time At the end of the maximum pressure holding time the pressure is released regardless of the temperature top Delay time When this time has lapsed and the furnace pressure is zero the casting program is complete and the machine can be opened top min Minimum delay time During this time the machine must not be opened regardless of the temperature top max Maximum delay time When this time has lapsed the casting program is stopped regardless of the temperature Total This is the time from the beginn
11. during program execution will only be applied to the following program cycle i e after the transfer to the control unit In these operating instructions the functions for a full expansion stage are explained The functions are dependent on the expansion stage of the control unit and must be specified when placing an order Page 4 of 60 CAST POWERED BY Fil 1 1 Intended use Please note the following information Prerequisite for intended use of the control unit is knowledge of these operating instructions These operating instructions must be observed by all staff working with the control unit This control unit is intended exclusively for controlling the pressure in the furnace and for mould cooling Any other or additional use is considered improper use Warranty and liability claims for personal injury and property damage are excluded if they are the result of one or several of the following causes o Improper use o Failure to follow operating manual o Unauthorised modifications to hardware or software or presettings to the electrical equipment You must not use the control unit if it is obviously malfunctioning or has any kind of damage Never stand in the vicinity of the furnace while the furnace is under pressure Only open the furnace door or furnace lid when you are sure the furnace is no longer under pressure Only remove the casting when you are sure the furnace is longer under pressure Switch off the main s
12. furnace is always filled to a certain level zero point Page 17 of 60 6 Explanation of operating mode 2 WITH PRESSURE CONTROL WITH METAL SENSOR 1 NO RISER CONTROL Bild 6 1 MS 1 EEA AA ZZ PO A mbar P8 630 P7 185 PMS admission pressure 20 30 t7 t8 1 Guss 2 Guss n Guss Total furnace pressure Admission pressure P8 Page 18 of 60 al A O O CAST POWE WERED BY FILL All numerical values are exemplary MS1 Metal sensor As soon as the metal comes into contact with the metal sensor the sensor sends an electrical signal The metal sensor should be installed at the lowest point in the mould e g side core It must always be ensured that the metal sensor is not covered with oxyden and thus sends a false signal The operating mode with metal sensor is recommended for highly complex moulds that reguire precise mould filling switching between different filling speeds during the filling process and for moulds that cannot be filled under pressure or if the fill level of the furnace cannot be controlled when refilling the metal Advantage Accurate determination of the zero point of the casting curve independent of the fill level of the furnace Disadvantage Metal sensors are prone to interference and can lead to production losses In this operating mode the default pressure compensation and the furnace refilling level
13. parameters with a separate electronics component 0nnnnennnnennnenennanennnne annan nnene nne 39 9 2 1 4 SCIEEN KeYBBAl ds re 40 9 2 2 Define basic parameters of the machine rnvinennnennennnanen avane nene nn 41 9 2 3 Input of target parameters for casting nnirnnenennenennnaen nenne nennen nennen 43 9 2 3 1 The pressure 0181 oli 6 SETE ee ee ee 43 9 2 3 2 Monitoring th casting UNE 45 Page 2 of 60 9 2 3 3 9 2 3 4 9 2 3 5 9 2 3 6 9 2 4 9 2 4 1 9 2 4 2 9 2 4 3 9 2 4 4 9 2 9 9 2 6 9 2 CAST POWERED BY FILL Pressure holding phase es montana akuutne eher Jamie 45 Oben theimachine ae kami Ola slate 46 Pressure SONO lesen einen en rear 47 Pressure COMDCMSAUION aaa ee NEE 47 Parametrisation of the cooling ZONES nnrnnnenennnnen nenne nenne nenne nennen 49 Switching on the cooling ZONE nnirrernnnennennnnnnen ennnnnnnnnnennnennnen 50 Time controlled cooling zone n nnninennenennnnennnaen nennen nenn mane nennen 51 Temperature controlled cooling zone n nnnuennenennenennene nunnu nne 52 Cooling zone with proportional valves rnnnnernnnennennnnnnne enne 53 Definition of the temperature monitoring parameters 0 rrnennnnenenena 55 Mould and machine parameters
14. until the metal reaches the metal sensor MS1 From this MS1 pressure e g 130 the PMSST pressure indicated in the operating mode menu e g 50 mbar is deducted and the result 130 50 80 mbar is entered into the admission pressure display field When the metal has reached the metal sensor the pressure time curve starts immediately In the example the pressure is increased within 20 seconds to 185 mbar then within 10 seconds from 185 mbar to 630 bar 630 mbar is the final pressure This pressure is kept constant during the tmp time adjustable internally externally or temperature dependently After the time tmp has lapsed the furnace is vented to 50 mbar Y16 to 80 mbar vented This residual pressure of 80 mbar in the furnace is kept constant until the next casting cycle riser control After the time tmp has lapsed the delay time begins When the time top has lapsed and the residual furnace pressure is at 80 mbar the casting process is completed and the machine is opened Page 24 of 60 CAST POWERED BY FILL The pressure in the furnace is increased from these 80 mbar using the set nominal width until the metal reaches the metal sensor 1 The remaining sequence is identical to Cast No 1 Since the furnace is constantly under pressure in this operating mode it must be fully vented before the furnace door can be opened This is done by pressing the button Stop riser control on the control panel or on the control cabinet door
15. 1 operating Mode issin a a ae 23 Low pressure casting control system nviernrnennvnnnnnene nenn nenne nennenennn nenne nennen 26 9 1 Monitoring of the casting process User interface nn nennnunennnanennnnnnennnnnna 26 Od Generaldisplay secrets a GUAM E ee 26 9 1 1 1 SAAD AI se are ee A E aal een 27 9 1 1 2 STE IMCL DAT mergen ee ee ee re 28 9 12 Casting process SEALUS messen rer een 29 91 3 Stat s of the coolng ZONES zu nee 30 9 1 4 Setting the cooling mode AUTO ON OFF nnnirrnnnneveennnvnvvannnnanen nennen nennen 31 9 1 5 Status of the temperature controlled cooling zones n rnnnennnnnennnea 32 9 1 6 Progression of temperatures 0nnnnnnnnenennnnennnnun navn nenne neuen namen namen nennen 32 9 1 7 Temperature values 0nninvnntunentunennnnun navn navn nnnnunnnnen nenne nnnnennnnnnnnnnnnnnnnnn 34 Salve FAUST rennen Te ee ee EEE 34 IES EAU DON een ait 35 9 110 Exp rting repols kama a ne are ren 36 9 2 Configuring the casting process User interface nnnnvenennnnennennnnnnneennnnnnena 37 921 6115 lol e ee ee ee ee 37 9 2 1 1 Description of the left menu bar nmimeenneneennnanennnanne nennen nennen 38 9 2 1 2 Description of the general control buttons uu0444004enn nennen ennn nennen 39 9 2 1 3 Synchronisation of the configuration
16. 8 MACH 11 MASCHINEN FEHLER ENDSCHALTER ZUR BESTIMMUNG DER MASCHINENPOSITION AN DER SCHALTERLEI 7 13 2012 11 29 MACH 15 7 13 2012 11 29 MACH 11 MASCHINEN FEHLER ENDSCHALTER ZUR BESTIMMUNG DER MASCHINENPOSITION AN DER SCHALTERLEI 7 13 2012 11 29 MACH 15 7 13 2012 11 30 MACH 11 MASCHINEN FEHLER ENDSCHALTER ZUR BESTIMMUNG DER MASCHINENPOSITION AN DER SCHALTERLEI 7 13 2012 11 30 MACH 15 7 13 2012 11 30 MACH 11 MASCHINEN FEHLER ENDSCHALTER ZUR BESTIMMUNG DER MASCHINENPOSITION AN DER SCHALTERLEI 7 13 2012 11 31 MACH 15 7 13 2012 11 31 MACH 11 MASCHINEN FEHLER ENDSCHALTER ZUR BESTIMMUNG DER MASCHINENPOSITION AN DER SCHALTERLEI 7 13 2012 11 31 MACH 15 7 13 2012 11 32 MACH 11 MASCHINEN FEHLER ENDSCHALTER ZUR BESTIMMUNG DER MASCHINENPOSITION AN DER SCHALTERLEI 7 13 2012 11 32 MACH 15 7 13 2012 11 32 MACH 11 MASCHINEN FEHLER ENDSCHALTER ZUR BESTIMMUNG DER MASCHINENPOSITION AN DER SCHALTERLEI 7 13 2012 11 33 MACH 15 7 13 2012 11 33 MACH 11 MASCHINEN FEHLER ENDSCHALTER ZUR BESTIMMUNG DER MASCHINENPOSITION AN DER SCHALTERLEI 7 13 2012 11 33 MACH 15 7 13 2012 11 34 MACH 11 MASCHINEN FEHLER ENDSCHALTER ZUR BESTIMMUNG DER MASCHINENPOSITION AN DER SCHALTERLEI 1 in eee te ce nd sal T gt Clicking button 1 displays the machine fault messages which were saved most recently Clicking button 2 closes this window Page 35 of 60 CAST POWERED BY FILL
17. AKL P7 jtmpmin P6 mpma opma P5 l l P4 l l a P3 P Ofen P2 l l P1 l l l l 0 l _ 1 t 2 B u 56 6 78 tO Zeit l l Stufe l l 1 Guss 2 Guss t Stufe n Guss giesse esamtgie zei Einstellung der K hlzeiten z 15 Absolut Verz gerungszei K hlzei Einstellung der K hlzeiten Verz gerungszeit R Relativ K hlzei Page 12 of 60 CAST POWERED BY Fil The following rules of thumb can be of great help when you need to determine the correct filling curve This information is supplied without liability 1 1 mbar pressure in the furnace causes the metal in the riser to rise by about 4 mm e g aluminium specific weight 2 5 g cm Rule of thumb 10 Specific weight of the metal 2 Rule of thumb for calculating the required pressure compensation in mbar for 1 kg of removed metal Rule of thumb Bath height in mm Furnace content in kg Bee Ee Se pases Pee AA X mbar 10 Specific weight of the metal EXPLANATION OF THE TERMS AND ABBREVIATIONS USED See Figure 4 1 H1 Bath height or height or metal when furnace is completely filled O Zero point of the casting curve This is the point where the furnace is completely filled Po Furnace pressure from the zero point of the casting curve P1 P8 Pressure levels P1 to P8 P open Progression of furnace pressure from the zero point of the casting curve
18. CK STEUERLUFT DRUCKSCHALTER DRUCKWANDLER A ABLUFT STEUERLUFT REGELUNG WERKSEITIGE EINSTELLUNG ca 100 mbar ENTSPRICHT ETWA EINER METALLHOHE ALUMINIUM VON 400 mm DRUCKSCHALTER BERWACHUNG DES OFEN MAXIMALDRUCKES WERKSEITIGE EINSTELLUNG ca 950 mbar DRUCKSCHALTER BERWACHUNG DES NETZDRUCKES WERKSEITIGE EINSTELLUNG ca 4 bar SONDERAUSSTATTUNG DRUCKWANDLER ae ios O 2000 mbar USGANG 4 20 mA NUR ABGESCHIRMTE LEITUNG VERWENDEN Page 9 of 60 lt lt FILTER DRUCKSCHALTER BERWACHUNG DES OFENDRUCKS BEI STEIGROHR ZULUFT CAST POWERED BY FILL VENTILBLOCK BILD 3 2 Sole Hegel Venti Yii Y12A E D ZUM OFEN VB 200 AR AN Ventilblock Komplett wy WY VB 200 Y14 Hauptventil ie N LI H VB 200 Y15 Ablassventil Wird nur bei der Betriebsart Mit Steigrohr regelung verwendet o Ei ZULUFT VB 200 Y14 SP 24V Spule Page 10 of 60 CAST POWERED BY Fil The three pressure switches and the pressure transducer monitor the pressure in the furnace 3 2 Pressure switches and pressure transducer Pressure switch 1 here 5B1 factory setting about 50 mbar In the operating mode Without riser control the signal to open the machine is only generated if the casting control unit has completed the program and the pressure switch has switched to zero As long as the pressure switch has not switche
19. ENPOSIT Schritt des Ablaufs On this screen the basic core pulling settings can be predefined 1 Run in core pulls Here you can define in what sequence and in which machine position the core pulls should run in CLOSED gt The core pulls run in when the machine is closed OPEN gt The core pulls run in when the machine is open No gt Specifies the sequence The core pulls run in according to the sequence entered If the core pulls should run in at the same time identical numbers must be entered here If they should run in one after each other the appropriate seguence must be selected here Page 57 of 60 CAST POWERED BY FILL 2 Run in core pulls Here you can define in what seguence and in which machine position the core pulls should move out CLOSED gt The core pulls move out when the machine is closed and the casting process has completed The delay time can be setin the Sec column The core pulls move out following this delay after the end ofthe casting process OPEN gt The core pulls move out when the furnace pressure has triggered the pressure switch 5B1 0 mbar and the Delay time or Machine open time has lapsed The Machine open time is of higher priority REMOVAL gt The core pulls move out when the machine is in the removal position and the removal plate has run in No gt Specifies the sequence The core pulls run in according to the defined seguence 3 Machine po
20. NAL mp O PO A mbar P8 630 Bild 8 1 P7 185 rr Z AED GE A A A 20 30 t7 t8 PMS u Total furnace pressure PMS P8 PMSST PMS PMSST pressure for riser control The metal is held at this pressure after casting PMS admission pressure Page 23 of 60 Sec CAST POWERED BY Fil In this operating mode the furnace is not vented completely after the pressure holding time has lapsed rather it is vented when a certain residual pressure level is reached The metal can thus be kept at acertain level and the next cast cycle can be started from the same level Since the height at which MS1 is installed is too high for holding the metal level an additional pressure PMSST must be subtracted from this special pressure The calculated pressure is the pressure at which the metal is kept constant Advantages Less air consumption Less oxidation of the metal Accurate determination of the zero point of the casting curve regardless of the fill level of the furnace Disadvantages Different metal temperatures in the riser and furnace Danger of overflowing metal when machine is open Metal sensors are susceptible to interference PROCESS The process is explained by the above numerical example The starting point furnace is fully vented 1 Cast The pressure in the furnace is initially increased using the set nominal valve width e g 20
21. OPERATING INSTRUCTIONS ELECTRONIG LOW PRESSURE CASTING CONTROL PC VERSION Version 4 0 The contents and excerpts from these operating instructions may only be copied or disclosed with the explicit permission of amTec Trading GmbH The manufacturer and or author of these operating instructions shall not be held liable for the accuracy of the content The data referred to in these operating instructions describe functions and characteristics but do not represent guaranteed properties Subject to technical modifications Contents 4 oO CO N O O A INIIOOUCLION sa iial tal ua ee eee eee 4 ja a0 210 E E E E A N ee e 5 MAMM AGE and repair Seemann heran 6 Pneumatic diagram and valve bank n nernnrnnennnanenn nene nn nnnnennna nen nene anname nennen 8 3 1 Pneumatic diagram PIPING notes rnnuernnenennneneennnanannnane nn nnne nn nnanannnanenna 8 3 2 Pressure switches and pressure transducer 5 0 nnonnnennnennnnennnannneenennnneenenna 11 Explanation of the basic progression of the casting curve and abbreviations used 12 Explanation of operating mode 1 cccceccccssececceececceeececcueeecseeeessueeeesuueesseueeessaeeesseeeessaneeseas 16 Explanation of operating mode 2 n rnnnrunennnane nn nene en nennen nennnnnnnnne nennen ernennen 18 Explanation o operating MORE Denen ee ene een 20 EXBlanallon 0
22. Z 15 07 48 OO KUN BEIETEIIIIIIIT SS TTT SUR ET RRA The number of air and water cooling installations is bound to the order Upon delivery the software is configured accordingly 1 Configuration of the individual cooling zones e Light blue for air cooling e Light green for water cooling e Light blue light green cross hatched for mix cooling 2 Here the adjusted temperatures of all connected thermocouples are displayed 3 Displays the configured thermocouple numbers for the cooling circuits Clicking on a bar takes you to the configuration window for the selected cooling zone Page 49 of 60 CAST POWERED BY FILL En EEE 7 15 28 18 9 2 4 1 Switching on the cooling zone Test die 111 STEUERUNGS BETRIEBSART Zeit STEUERUNGSPROGRAMM a j PA M Schritt des Ablauf M 8 The program for mould cooling starts when the admission pressure i e the zero point of the casting curve is reached The system makes a distinction between two cooling modes for the cooling zone 1 Time controlled Select by clicking in Zone 1 Temperature controlled Select by clicking in Zone 2 Description of cooling zone Clicking in Zone 3 starts the entry mode for the description and opens the alphanumeric keyboard Page 50 of 60 CAST POWERED BY FILL 9 2 4 2 Time controlled cooling zone lt 09 07 2012 15 26 04 D _ STEUERUNGS BETRIEBSART Zeit Temperatur WASSER le
23. agram for accumulated temperature variation of the thermocouples or temperature variations up to 8 first temperature sensors 2 Bar chart showing temperatures By clicking on a screen in this area you can zero in on the bar chart See figure chapter 9 1 7 3 Selection zone for displaying chart diagrams There are two displays a Displays the temperature difference between minimum and maximum value of the temperature sensor b Displays the temperature values of up to eight initial temperature sensors Werkzeugname Test die Nr E MAET F iM 46 07 2012 Maschine Nr 100 OfenNr gt 34 fc 244 lt s 270 Programm 1 Ofenf llung Nr ir ar f 5 Hr Sesamtst ekzahl 413013 Guss Nr ie 29 4 af 105 4 21 102 Page 33 of 60 CAST POWERED BY FILL 9 1 7 Temperature values Werkzeugname Test die Nr Maschine Nr 100 Ofen Nr Programm 1 Ofenf llung Nr Gesamtst ckzahl 11128 Guss Nr 501 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 T 204060801 1 L 11 22 1 2 3 4 5 6 7 8 s Tm 3 12 14 t amp WV 98 18 BS 20 22 24 N mi TI rei 849 Vordruck 70 2 Ventil NW 1 Bar chart with current readings of temperature sensor 2 Chart diagram for accumulated temperature variation of the thermocouples or temperature variations up to 8 first temperature sensors 9 1 8 Fault list Aq MAO TRITT ANT Ss L U bac EES
24. are of no importance The zero point of the casting curve is determined by MS1 PROCESS The process is explained by the above numerical example The pressure in the furnace is initially increased using the set nominal valve width e g 20 until the metal reaches the metal sensor MS1 This pressure referred to as admission pressure or MS1 pressure is stored and displayed internally Subseguently the pressure time curve starts immediately In the example the pressure is increased within 20 seconds to 185 mbar then within 10 seconds from 185 mbar to 630 bar 630 mbar is the final pressure This pressure is kept constant during the tmp time adjustable internally externally or temperature dependently After the tmp time has lapsed the furnace is vented and the top time starts After the top time has lapsed and when the furnace pressure 0 the casting program is complete Page 19 of 60 CAST POWERED BY FILL 7 Explanation of operating mode 3 WITH PRESSURE CONTROL WITH PRESSURE COMPENSATION WITH RISER CONTROL OPTIONAL PO A mp O mbar P8 760 Bild 7 1 P7 315 P6 130 0 7 5 25 35 t0 t6 17 t8 sec dP1 Grundvorduck 7 Page 20 of 60 Eguation Total furnace pressure basic admission pressure n 1 dp P8 Furnace pressure with riser control basic admission pressure n 1 dP where n number of castings dP1 pressure compensation
25. d the lamp Casting in progress on the control cabinet door will be on and the machine will not be unlocked for opening Pressure switch 2 here 5B2 Factory setting about 180 mbar This pressure switch has two functions 1 In the operating mode With riser control the signal to open the machine is only generated if the casting control unit has completed the program and the pressure switch has switched 2 If the signal Start casting is not present when the machine is open but the furnace pressure exceeds the set value or if the furnace pressure exceeds the set value during riser control the furnace is immediately fully vented In this case the lamp Excessive pressure on the control cabinet door goes on and must be acknowledged by pressing the Excessive pressure button Pressure switch 3 here 5F3 Factory setting of standard furnaces about 950 mbar This pressure switch monitors the maximum furnace pressure Regardless of this pressure switch there must always be a suitable safety release valve present at the furnace When the pressure switch is activated the furnace is immediately fully vented In addition the following lamps on the control cabinet door go on and must be acknowledged by pressing the buttons 1 Max furnace pressure exceeded 2 Excessive pressure Page 11 of 60 4 Explanation of the basic progression of the casting curve and abbreviations used PO Druck A Stufe Bild 4 1 a i TT
26. dely used operating mode because no measuring sensors are required in the moulds PROCESS The process is explained by the above numerical example The starting point Metal refilled button Metal refilled pressed Admission pressure display 0 1 Cast The pressure is increased within 5 seconds to 180 mbar then within 20 seconds from 180 to 365 mbar and then within 10 seconds from 365 to 810 mbar 810 mbar is the final pressure This pressure is kept constant during the tmp time adjustable internally externally or temperature dependently After the tmp time has lapsed the furnace is vented and the time top starts After the top time has lapsed the casting program is stopped when the furnace pressure is 0 2 Cast The pressure in the furnace is initially increased by dP1 1 8 mbar using the set nominal valve width e g 20 Admission pressure 1 8 mbar When this admission pressure has been reached the pressure time curve starts The remaining sequence is identical to Cast No 1 3 Cast First the pressure in the furnace is increased by another 1 8 mbar Admission pressure 1 8 mbar 1 8 mbar 3 6 mbar When this admission pressure has been reached the pressure time curve starts The remaining sequence is identical to Cast No 1 This continues like this up to the last cast By pressing the button Metal refilled the admission pressure is reset to zero In this operating mode it must be ensured that the
27. dialog window is opened where the program name can be changed Page 60 of 60 CAST POWERED BY FILL The selected process program is cleared from the system and the CF card A selection dialogue is launched for the program search PROGRAM LOAD Look in ControlPrograms DIE delta narrow 6 2 DIE FAGOR TEST My Recent DIE FAGOR TEST COPY 0 Documents My Network Files of type System Control Smart Files v The selected process program can now be picked out and loaded into the system This function generates copies of all existing process programs to selected external drives selected directory A selection dialogue is launched Browse For Folder Please select a folder to export of all existing casting programs E L My Documents 4 My Computer E My Network Places 2 Recycle Bin
28. e changed by clicking the corresponding parameter for time 1 and pressure 2 with number key pad and for temperature sensor 3 with selection menu Te No Eps pt Existing temperature sensor in the system Clearing temperature sensor 2 To delete a curve point enter a time of 0 seconds for this point KS 3 Create a new curve point after ho the button Then enter the time 4 Clicking the i button to pre select the parameters in the system and close the dialog window Page 44 of 60 CAST POWERED BY FILL The total casting time or maximum casting time can be set with the dialog window here 9 2 3 2 Monitoring the casting time Gisamt Giesszeit deaktiviert Gesamt Giesszeit aktiviert BEsamt Giesszeit aktiviert cy Gesamt Giesszeit 2 deaktiviert 9 2 3 3 Pressure holding phase The pressure holding phase can be controlled using one of three operating modes Temperature Druckhaltephase End of pressure holding time at a set temperature However the pressure holding time lasts for at least the set minimum time and ZEIT at most for the set maximum time re EXTERN TEMPERATUR Nr 16 T C 250 Zeit Min Sek 010 Zeit Sek 025 pressure holding timeEnd of the pressure holding time according CG TEMPERATUR to set internal clock EXTERN Page 45 of 60 External Druckhaltephase TEMPERATUR EXTERN 9 2
29. ing of the casting curve to the end of the time top casting time Total casting time t8 tmp top t giessen This is the time from the casting start to end signal In other words the time when the machine remains closed t casting time until admission pressure is reached zero point t8 tmp to BASIC ADMISSION PRESSURE The function of the basic admission pressure depends on the respective operating mode It can be used to artificially shift the zero point of the casting curve If for example too little metal is refilled into the furnace this can be compensated with the basic admission pressure so that the casting curve does not need adjusting from the zero point The basic admission pressure that has been entered will only be used when the button Metal refilled has been pressed on the control panel NOMINAL VALVE WIDTH OR VALVE CROSS SECTION The pressure in the furnace is reduced with the help of the valve bank The control valves Y6 to Y13 are integrated on the valve bank all valves closed Valve cross section 0 equals 0 opening no additional pressure build up in the furnace all valves open Valve cross section 255 equals 100 opening maximum possible pressure build up in the furnace Between 0 and 255 the valve bank opens linearly Page 14 of 60 GENERAL PROGRESSION OF A CASTING PROCESS Once the machine has closed and all the reguirements for casting are met the casting program starts First the pressu
30. ion time with pressure temp is running the furnace is checked for leakage losses If the furnace were completely sealed the pressure would not drop during this phase But since every real furnace has leakage losses the escaped air must be compensated by the supply air This pressure compensation during the pressure holding phase is a measure of the leakage losses of the furnace which is displayed on the display Valve cross section A value between 0 20 indicates that the leakage losses are within the limits of the furnace Starting from the value 20 the lamp Excessive leakage loss on the door of the control cabinet or on the control panel goes on and indicates that the furnace or the entire pipe system should be checked for leakage Page 6 of 60 CAST POWERED BY FILL Disadvantages due to high leakage losses include Oxide formation Heat loss cold air is blown continuously into the furnace Material stress caused by uneven distribution of heat in the furnace Page 7 of 60 3 Pneumatic diagram and valve bank 3 1 Pneumatic diagram piping notes All the eguipment abbreviations refer to Figure 3 1 Figure 3 1 shows the complete pneumatic diagram Figure 3 2 shows the valve bank The following units are installed in the pneumatic cabinet Valve bank consisting of 8 control valves here Y6 to Y13 and the 2 control valves here Y14 and Y15 3 pressure switches here 5B1 5B2 and 5B3 and pressure transd
31. n 10 seconds to 760 mbar 760 mbar is the final pressure This pressure is kept constant during the pressure holding time tmp adjustable internally externally or temperature dependently After the time tmp has lapsed the furnace is vented to 50 mbar Y16 to 50 mbar vented The residual pressure of 50 mbar in the furnace is kept constant until the next casting cycle riser control After the 50 mbar have been reached and the delay time top has lapsed the casting process is complete and the machine is opened 2 Cast The furnace pressure is increased by dP 1 8 mbar in other words 50 1 8 mbar 51 8 mbar using the set nominal valve width e g 20 When the admission pressure is reached the pressure time curve starts The remaining sequence is identical to Cast No 1 The furnace is vented to 51 8 mbar and the pressure is held until the next casting cycle This process is repeated until the last cast Then the furnace is refilled with metal and the button Metal refilled on the control panel is pressed This resets the admission pressure to the basic pressure value 50 mbar Since the furnace is constantly under pressure in this operating mode it must be fully vented before the furnace door can be opened This is done by pressing the button Stop riser control on the control panel or on the door Page 22 of 60 8 Explanation of operating mode 4 WITH PRESSURE CONTROL WITH METAL SENSOR 1 WITH RISER CONTROL OPTIO
32. ndow with the current fault messages from the machine see Chapter 9 1 8 No connection to the data server Flashes indicating an existing connection to the data server Displays machine and program number Shows the current mould name and number 4 Displays the process times a Current casting cycle time b Maximum cycle time C Time between start times of the two last casting cycles 5 status of the connections to a Mould filling control block b Mould cooling control block C Mould control block d Machine control e SQL based documents management system 6 Displays total number of castings Clicking on this field toggles the display between Gesamtst ckzahl 10865 continuous total casting number and Gesamtstiickzahl 0 deletable total casting number Page 27 of 60 CAST POWERED BY FILL 7 Casting data a Furnace number b Furnace filling number 6 Cast number for current furnace 8 Production quantity for early late and night shifts 9 1 1 2 Left menu bar Switch the operating language T Displays the history of faults in the machine See chapter 9 1 9 Exports casting program See chapter 9 1 10 Fa Ir N Setting the configuration parameters See chapter 9 2 J wi i Page 28 of 60 CAST POWERED BY FILL 9 1 2 Casting process status Werkzeugname Test die 100 Ofen Nr 1 Ofenf llung Nr 10891 Guss Nr
33. ning after every casting Specification of the basic admission pressure to compensate the differences when filling the furnace s Chap 6 Explanation of operating mode 2 Pre set the max pressure for the metal sensor Upon reaching this pressure without the sensor having generated a signal the casting process is terminated with an alarm If MS1 is mounted at the top of the mould the target pressure in mbar for the first cast is set here CAST POWERED BY FILL Pressure compensation with riser control DRUGKKOMPEMSATIOM METALLSONDE METALLSONDE MIT STEIGROHRREGELUNG pro Guss mbar Grundvordruek mbar Sort AeA Py DRUCKKOMPENSAT ION DRUCKKOMPENSATION MIT STEIGROHRREGELUNG METALLSONDE Page 48 of 60 s Chap 7 Explanation of operating mode 3 Specification of the basic admission pressure to compensate the differences when filling the furnace Compensation per cast Compensation of furnace filling by the draining after every casting s Chap 8 Explanation of operating mode 4 Specification of the basic admission pressure for the first casting Specification of the correction pressure Pre set the max pressure for the metal sensor Upon reaching this pressure without the sensor having generated a signal the casting process is terminated with an alarm CAST POWERED BY FILL 9 2 4 Parametrisation of the cooling zones lt 09 07 2012
34. p Zeit Temperatur Sensor Nr 14 STEVERUNGS BETRIEBSART o Let Temperatur Sensor Nr 10 e r CAST POWERED BY FILL 9 2 5 Definition of the temperature monitoring parameters i 072012 AAN 15 36 19 bac F UEEIEREIENKIENEIEIEIESESEREIESEIEJEIEIEI 711117 m M E m n m TC11 EFE E K hlung SAAT ETTA TT dk EEEE Canes Einstellunge m OOO Druckhaltey 5 JAA dh in 100 a raturgesteuerte Maschine ffnen E 800 s STEUERUNGSPROGRAMM M gy M SPEICHERN Schritt des Ablaufs A a s This screen gives an overview of the reference and the settings of the thermocouples 1 Displays overviews of thermocouples present in the system and also which parts are controlled by which thermocouple in the system a Number of temperature sensor b When the pressure holding phase and or the opening of the system is controlled by the temperature a green box appears under the corresponding number of the temperature sensor c Green box is underneath the number of the temperature sensor when this sensor is used for the control of one or more cooling zones d Clicking the column displays detailed information about the controlled machine parts in the bottom area 2 Control elements for switching the displayed temperature sensor Page 55 of 60 3 Description of the temperature sensor Clicking in this area launches the edit mode where you can correct re enter a description
35. per casting 1 8 mbar Basic admission pressure 50 mbar All numerical values are exemplary In this operating mode the furnace is not vented completely after the pressure holding time has lapsed rather it is vented when a certain residual pressure level is reached The metal can thus be kept at a certain level and the next cast cycle can be started from the same level Advantages Less air consumption Less oxidation of the metal Disadvantages Different metal temperatures in the riser and furnace Danger of overflowing metal when machine is open PROCESS They process is explained by the above numerical example With the parameter Basic admission pressure the metal level is determined at which the metal should be kept constant Please note 1 mbar pressure corresponds to about 4mm metal movement in the riser aluminium After pressing the button Metal refilled the basic admission pressure 50 mbar is displayed on the admission pressure display The starting point Metal refilled Metal refilled button has been pressed Admission pressure 50 mbar furnace is fully vented Page 21 of 60 1 Cast The pressure in the furnace is initially increased using the set nominal width e g 20 until 50 mbar have been reached Subseguently the pressure time curve starts immediately In the example the pressure is increased within 5 seconds to 130 mbar then within 20 seconds from 130 to 315 mbar and then withi
36. re in the furnace is increased in an uncontrolled fashion with the predefined valve cross section until the admission pressure has been reached zero point of the casting curve Then the furnace pressure display is set to zero and the pressure in the furnace increased in a controlled fashion according the pressure time curve until the final pressure P8 has been reached Then the pressure holding phase begins During this phase which can be time or temperature dependent the final pressure P8 is kept constant At the end of this phase the furnace is vented and at the same time the final time starts i e the delay time When this time has lapsed and the furnace pressure has dropped below 50 mbar the casting process is complete and the machine can be opened again The mould cooling systems are started when the admission pressure is reached i e from the zero point of the casting curve Page 15 of 60 5 Explanation of operating mode 1 WITH PRESSURE CONTROL WITH PRESSURE COMPENSATION NO RISER CONTROL PO A mbar Bild 5 1 aa P7 365 P6 180 E E LEE N n Number of castings oul 25 t7 35 t8 Total op 1 Guss 2 Guss n Guss furnace pressure Page 16 of 60 By n D O n 1 dp PE CAST POWERED BY FILL dP1 pressure compensation per casting 1 8 mbar All numerical values are exemplary This is the most wi
37. s in the system 2 Control mode Control mode selected by clicking the arrow The following two control modes are implemented in the system Page 52 of 60 CAST POWERED BY FILL Me Cooling zone is switched ON OFF constantly when the temperature has reached the set value during the cooling time y Single automatic de activation when preset temperature is reached On and continuous time of cooling for air cooling circuit Switch off temperature for the air cooling circuit On and continuous time of cooling for water cooling circuit Switch off temperature for the water cooling circuit HLUNGS PROZESS SOLL PARAMETER E ZONE Nr 8 ele sensor 8 Ben ce E d KO La W AS S E 9 2 4 4 Cooling zone with proportional valves The flow quantity input field is shown on the parameter setting screen The flow quantity is controlled by proportional valves The values are edited using the number pad Proportional technology for air and water cooling circuits ele Nr 8 STEVERUNGS BETRIEBSART Zeit Temperatur Sensor Nr 8 Page 53 of 60 Proportional technology or air cooling circuit g ZONE Nr 9 KIE P 55 vn EN 100 c o u i n 25 0 Wig 350 C Proportional technology or water cooling circuit Input mode Page 54 of 60 i Cee Nr 10 gA JE D Moor vl mw WASSER WASSER STEUERUNGS BETRIEBSART o
38. sition Here you can define the position in mm for the machine as open close and ready for removal Page 58 of 60 CAST POWERED BY FILL 9 2 7 Management of casting control programs Werkzeugname 701112007analog 701112007analog 701112007digital gt 70111200 7digital delta narrow 6 2 delta052 Test die 0 1 0 1 0 1 8 1 52 2 1 1 Erstellt 02 05 2012 15 36 51 10 04 2012 15 55 54 21 05 2012 15 32 48 10 04 2012 16 26 43 22 05 2012 16 02 04 09 04 2012 23 59 34 05 07 2012 09 46 29 Geandert LADEN PARAMETER ANDERN 11 05 2012 13 20 43 12 07 2012 i 10 20 10 ____ Dac tr ic electronic 26 04 2012 11 22 51 nn 22 05 2012 15 59 11 23 04 2012 13 43 17 e KOPIEREN 03 07 2012 13 08 26 09 04 2012 23 59 35 NAME NDERN i 09 07 2012 15 07 16 VON SPEICHERMEDIUM LADEN AUF EXTENAL MEDUIM SPEICHERN E This screen displays all of the casting cooling programs on this screen The following functions exist for managing the process program LADEN PARAMETER The selected process program is loaded into the system The program ANDERN parameters can now be modified or transferred into the control component Name is started WERKZEUG Test die 002 Page 59 of 60 All parameter values are set to zero and the setting of a new process program A copy of the selected program is generated and activated for editing A
39. sting 99 07 2012 10 22 03 le FORM F LLUNG PROZESS SOLL PARAMETER E AR ee GBS m gt gt mzm zzzzg moar Ba On Druc Kk TEUERUNGS BETRIEBSART Fu 5 DRUCKREGELUNG DRUCKKOMPE ON 6 39 pro Guss mbar 0 8 Grundvo STEUERUNGSPROGRAMM M Al GA M nennweite bis Vordr mbar u SPEICHERN a Schritt des Ablaufs The description of each mode can be found in Chapters 5 8 In this screen the following operating modes and parameters can be set 1 Pressurisation target parameters for the casting process Switch to monitor the casting time Mode and target parameters for pressure holding phase Mode and target parameters for opening of the machine er Pressure control with specification of nominal valve width until the admission pressure is reached 6 Mode and target parameters for pressure compensation 9 2 3 1 The pressure build up Parametrisation is launched by clicking on the table The following dialog window is activated A casting curve with up to 8 points of the combination of time 1 in secs and pressure 2 in mbar can be set Each pressure point can also be controlled by the temperature sensor 3 Page 43 of 60 CAST POWERED BY FILL The temperature sensor needs to be highly precise as the control only responds to momentary changes of temperature of more than 10 degrees 1 Parameters ar
40. thout ZURUCK applying the changes With the selection the changes are deleted and the existing data ABBRUCH ja OK With the selection the modified data is transferred to the control x mi are read out from the control Page 39 of 60 CAST POWERED BY FILL 9 2 1 4 Screen keyboards Two variants of screen keyboards are used in the program 1 Number pad The appropriate keyboard is activated automatically during parameter edit The parameter editing process is launched when the user has the right to edit parameters and clicks the reguired parameter box using the mouse or a finger Page 40 of 60 CAST POWERED BY FILL 9 2 2 Define basic parameters of the machine BASIS KALTSTART Maschine Nr 11 Ablaufkette SIGNALISIERUNG Zu gie ende Gesamtstiickzahl 500 OFEN FULLEN ZAHLER GESAMTZ HLER LOSCHEN LOSCHEN DEAKTIVIERT DEAKTIVIERT St ckzahl f r Ofen nachf llen 30 Blinken f r Metall nachf llen 5 Erstellund 10 2011 2 nderung 49 07 2012 Leckverluste Anzeige Grenzwert 20 PASSWORD SCHICHTZEITEN Fr hschicht Beginn 06 01 Ende 14 00 Sp tschicht 5 Beginn 14 01 Ende 22 00 Nachtschicht Beginn 22 01 nde 06 00 STEUERUNGSPROGRAMM m m Schritt des Ablaufs ANA 1 Login form Some functions are password protected in the application To log in the user should click in the password field PASSWORD Caster This person can monitor the casting process but m
41. uage Synchronisation of the configuration parameters with a separate electronics component Management of casting control programs See chapter 9 2 7 Input of target parameters for casting process pressure holding time etc See chapter 9 2 3 Input of cooling target parameters definition of the individual zones See chapter 9 2 4 Definition of the temperature monitoring parameters See chapter 9 2 5 Setting the machine parameters core pulls See chapter 9 2 6 Setting the basic parameters shift times guantities etc See chapter 9 2 2 Switch to monitor the casting process See chapter 9 1 CAST POWERED BY FILL To save modified recipes the following symbols appear in the bottom menu box 9 2 1 2 Description of the general control buttons Save recipe Save a changed newly created recipe on the hard disc or any other storage medium The dialog window for parameter entry Pre select the parameters in the system and close the dialog window 9 2 1 3 Synchronisation of the configuration parameters with a separate electronics component a m m When clicking on a control element the question Would you like to transfer the modified parameters to the control appears with the following selection options M chten Sie die ge nderten Parameter in die Steuerung bernehmen gt ap ZURUCK fez OK fey ABBRUCH y With the selection the next higher menu level is opened wi
42. ucer here 15B1 2 control valves here Y3 and Y16 for the two main release valves here Y3 and Y16 For the connection of the pneumatic cabinet to the furnace the following pipe lines should be installed see Figure 3 1 Supply air line 1 inch Sensing line Y inch Connection to the furnace 1 inch Control air for release valves 1 8 inch The main release valves and the hand throttle must be installed as close as possible to the furnace The length of each pipe line except supply air must not exceed 10 0 metres The pressure switch 5B2 is only required for the option With riser control Page 8 of 60 SCHEMATISCHE DARSTELLUNG DES PNEUMATIKPLANES BILD 3 1 ABLUFT 1 _ 2 min 1 NZ 16 X 14 1Y3 14 1Y16 Y6 Y13 Y18 Y14 Y15 5F1 TOTAL ENTL FTUNG DES OFENS IN RUHESTELLUNG OFFEN ENTL FTUNG DES OFENS BER HANDDROSSEL R BEI BETRIEBSART MIT STEIGROHRREGELUNG x HNADDROSSEL BESTIMMT DIE ENTLUFTUNGSZEIT DES OFENS IN RUHESTELLUNG OFFEN REGELVENTILE IN RUHESTELLUNG GESCHLOSSEN NOT AUS VENTIL SONDERAUSSTATTUNG HAUPTZULUFTVENTIL IN RUHESTELLUNG GESCHLOSSEN LUFTABLASSVENTIL BEI STEIGROHRREGELUNG IN RUHESTELLUNG GESCHLOSSEN DRUCKSCHALTER BERWACHUNG DES OFENDRUCKS AUF P 0 WERKSEITIGE EINSTELLUNG ca 45 mbar 5F2 5F3 5F4 15B1 LUFT ZUM OFEN VENTILBLO
43. ust not change anything Shift supervisor This person can load and select programs Can change all data except operating modes during casting Must not save changes Casting director This person is logged in above This person can modify everything and has all access rights Page 41 of 60 CAST POWERED BY FILL 2 Here the machine number can be defined The user should also enter a mould name here The mould name and number then appears atthe top of the menu 3 Here the program number can be entered The decimals are reserved for future functions 4 Signalling e Expected total casting No Indicates how many parts are to be cast e Expected castings for one filling Indicates after how many castings the furnace must be refilled e Metal filling flashing Indicates after how many castings before the maximum number of producible parts the respective indicator light shall flash e Limit for display of leakage loss If the leakage loss value is exceeded for more than 30 seconds during the time tmp the respective signalling lamp on the screen goes on 5 Shift times Here the shift times can be entered SSS WE 06 07 2012 EA 15 35 06 Test die 1 1 nn sikei ecr onic 91 92 93 94 FURNACE FILLING CASTING COUNTER COUNTER RESET OFF RESET OFF Ser 22 01 ens 06 00 CONTROL EINS a M E SAVE 1 operation Step Gi gt m Page 42 of 60 CAST POWERED BY FILL 9 2 3 Input of target parameters for ca
44. witch of the control unit before carrying out repairs Any repairs on electrical equipment must only be carried out by trained personnel The set pressure values at the pressure switches in the pneumatic system cabinet must only be changed by trained personnel within the limit values of the furnace When replacing parts it is important to ensure that only original parts recommended by us are installed Page 5 of 60 CAST POWERED BY FILL 2 Maintenance and repair Please perform the following checks once per month on a regular basis The pressure sensing line between the furnace and control must be absolutely clean They must contain no foreign particles or condensation water The openings of the control valve bank must be clean and the springs must be in working order uninstall control valves then perform visual check Ensure proper functioning of the release valves mounted to the furnace Check pressure release time Functioning of the furnace pressure switches 5B1 5B2 and 5B3 The EMERGENCY STOP function SAFETY EQUIPMENT The following safety equipment has been tested by the German Technical Control Board and must not be tampered with or modified in any way EMERGENCY STOP devices Two hand control device Lowering monitor When replacing these devices it is essential that the same or equivalent devices be used Checking for leakage losses During the pressure holding phase when the time Solidificat
Download Pdf Manuals
Related Search