Operating manual - somatec- · PDF fileOrder‐No. 000000 Turret Rewinder ATW 1‐2 General...

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Transcript of Operating manual - somatec- · PDF fileOrder‐No. 000000 Turret Rewinder ATW 1‐2 General...

  • CopyrightSOMATECSondermaschinenGmbH2010HorstDieterWelzelTechnischeDokumentation

    Allrightsreserved.Copying,processingandtranslationisprohibitedwithoutpriorwrittenpermission.

    OperatingmanualTurretRewinderATW

    withautomaticReelchangesystemTAC

    Customer : SamplecustomerOrderNo. : 000000Issued : March2010

  • OrderNo.000000 TurretRewinderATW

    12General

    Importantdirectionsfortheuseroftheoperatingmanual

    Fortechnicalreasons,thedeliveredmachine,typeTurretRewinderATW,willbecalledlineinthefollowingdocumentation.

    Someoftheappliedpicturesanddrawingsinthedescriptionorinstructionserveasanexplanationoftheline,becauseapictureoradrawingtellsyoumorethananywords.

    Becauseofmanybuildinstandardcomponentsintheline,thetranslateddetailsinthecolouredperformanceofthebuildincomponentscouldbevarying.

    Somepicturesshowthelinewithdisassembledsafetydevices,likebarriers,panelling,safetyclosings,orsafetydoors,therewiththedetailsofthelinecanbeperformedbetter.

    Technicalalterationsandaddingoftheexplanation./.explanationarereserved.

    Noresponsibilitywillbetakenforthecontents,especiallyfordamagesthroughexistent,notexistent,orincorrectdeclarations.

    Itisnotallowedtopassonthisdescription./.operatingmanualtothirdpartiesinprintedorelectronicallyformatortoamendsomethingtothisdescription./.operatinginstruction,unlessthisisspeciallyauthorizedbySOMATEC.

    SOMATECSondermaschinenGmbH March2010

    Withinthissamplemanualonlysomeselectedchaptersarepresentedinordertokeepthissamplemanualwithinareasonable size.

  • TurretRewinderATW OrderNo.000000

    General13

    Tableofcontents

    1. General _________________________________________________________________ 161.1 GENERALDATAOFTHEPROJECT 16

    1.2 INITIATIONFORTHEOPERATORSMANUAL 17

    1.3 INSTRUCTIONANDEDUCATIONALHELP 18

    1.4 SYMBOLSINTHEOPERATORSMANUAL 18

    1.5 EXAMPLEFOREDUCATIONALTHEMES 19

    2. Safety__________________________________________________________________ 2112.1 GENERAL 211

    2.2 APPLICATIONASSPECIFIED 211

    2.3 ATTENTIONANDWARNINGSIGNS 212

    2.4 SIGNSATTHEMACHINE 213

    2.5 SAFETYDEVICES 214

    2.5.1 SAFETYDEVICESSIDEVIEW 2142.5.2 SAFETYDEVICESTOPVIEW 2152.5.3 STATIONARYPROTECTIVEGRATINGSATTHEREAROFTHELINE 2162.5.4 EMERGENCYSTOPPUSHBUTTONS 2162.5.5 SAFETYLIGHTBARRIER 2162.5.6 ALARMMESSAGESYSTEM 2172.5.7 SAFETYDOORS 2172.5.8 SAFETYAREAS 2182.5.9 MECHANICALMAINTENANCEAREAS 2182.5.10 ELECTRICALMAINTENANCEAREAS 218

    2.6 PROTECTIONOFLABOUR 219

    2.7 SAFETYINSTRUCTIONSFORTHEOPERATINGPERSONNEL 220

    2.8 SAFETYINSTRUCTIONSFOROPERATINGTHELINE 221

    2.9 UPKEEPANDOPERATINGINSTRUCTIONS 222

    3. TechnicalData___________________________________________________________ 324

    4. StructureandModeofOperation ___________________________________________ 4254.1 TERMINOLOGY 425

    4.2 GENERAL 428

  • OrderNo.000000 TurretRewinderATW

    14General

    4.3 DESCRIPTIONOFTHESUBASSEMBLIES 429

    4.3.8 CONTACTROLLERSYSTEM 4294.3.8.1 ContactWinding 4304.3.8.2 GapWinding 431

    4.3.9 REELCHANGESYSTEMTAC 4324.3.10 REELCHANGECYCLE 434

    4.3.10.1 NormalWindingProcess 4344.3.10.2 Indexingprocess 4354.3.10.3 IndexingprocesscompletedCutting 4364.3.10.4 ReturntoNormalWindingOperation 437

    4.3.11 WINDINGSYSTEM(WINDINGDRIVE) 4384.3.12 INDEXINGSYSTEM 439

    5. TransportandInstallation _________________________________________________ 5405.1 TRANSPORT 540

    5.2 INSTALLATION 542

    5.2.1 LOCALISATION 5425.2.2 ALIGNMENT 5425.2.3 FASTENING 5435.2.4 DISASSEMBLY/SHUTDOWN 543

    5.3 ELECTRICALCONNECTION 544

    5.3.1 CHECKUPOFTHEELECTRICALEQUIPMENT 5445.3.2 MAINSCONNECTION 5455.3.3 PROTECTIVEMEASURES 545

    5.4 FIRSTSTARTUP 545

    6. Operatingtheline________________________________________________________ 6466.1 GENERAL 646

    6.2 DESCRIPTIONOFOPERATINGELEMENTS 647

    6.2.1 OPERATINGTHESWITCHCABINET 6476.2.2 MAINOPERATINGPANEL(+P) 6486.2.4 PNEUMATICOPERATING 6546.2.5 PANELOPERATINGBYSIEMENSSIMATICMP370 657

    6.2.5.1 GeneralDescription 6576.2.5.2 PasswordProtection 6586.2.5.3 DescriptionoftheScreenMasks 659

  • TurretRewinderATW OrderNo.000000

    General15

    6.3 SCREENMASKS 660

    6.3.1 STARTPICTURE 6606.3.2 SYSTEMFUNCTION 6616.3.3 REWINDER/OVERVIEW 6626.3.4 REWINDER/PARAMETERACTUAL 6636.3.5 REWINDER/PARAMETERWINDER1 6666.3.6 REWINDER/PARAMETERWINDER2 6706.3.7 REWINDER/OPERATIONAUTOMATIC 6746.3.8 REWINDER/WEBLENGTH 6776.3.9 REWINDER/PARAMETERRECIPE 6786.3.10 REWINDER/DIAGNOSIS 680

    6.3.10.1 Rewinder/Diagnosis 6826.3.11 SCREENMASKMESSAGESARCHIVES 6886.3.12 SCREENMASKMESSAGES 6896.3.13 REWINDER/SETUP 690

    6.3.13.1 Rewinder/SetupContactsledge(Contactroller) 6916.3.13.2 Rewinder/SetupServiceCutsystem(TAC) 6936.3.13.3 Rewinder/SetupServiceIndexing/Chucks 6946.3.13.5 Rewinder/SetupfrictiontestWinder1&2 6966.3.13.6 Rewinder/SetupServiceEncoder 6986.3.13.7 Rewinder/ServicePLCMonitoring 699

    6.4 OPERATINGTHELINE 6100

    6.4.1 ELECTRICALSUPPLY 61006.4.2 PNEUMATICSUPPLY 61016.4.3 PREPARATIONOFWINDING 6102

    6.4.3.1 EquipmentwithWindingShafts 61036.4.3.2 ManualSetting 61066.4.3.3 SettingsRecipes 6108

    6.4.4 INLINEPRODUCTION 61096.4.4.1 ProductionLine 61096.4.4.2 SettingspriortoOperation 61096.4.4.3 JoinPreparation 61116.4.4.4 Threadup 6112

    6.4.5 REELCHANGEATTHEOPERATINGMODEMANUAL 61146.4.6 REELCHANGEATTHEOPERATIONMODE'AUTOMATIC'WITHMANUALINITIATION 61166.4.7 AUTOMATICWITHAUTOMATICINITIATION 61176.4.8 REELUNLOADING 6118

    7. UpkeepandMaintenance ________________________________________________ 71197.1 EXPLAINING 7119

    7.2 LUBRICANTTABLE 7121

    7.3 LUBRICATIONINSTRUCTION 7122

    7.4 MAINTENANCEPLAN 7124

  • OrderNo.000000 TurretRewinderATW

    16General

    1. General1.1 GeneralDataoftheProject1. DesignationoftheProject:

    TypeofLine/ Machinetype:

    TurretRewinder ATWwithautomaticreelchangesystemTAC

    PlaceofErection :

    Supplieror/and Seller :

    SOMATECSondermaschinenGmbH

    Customer/Buyer: Samplecustomer

    OrderNo.: 000000

    ElectricalNo.: 000000

    3. Thefollowingfaultshavebeenconfirmedattheacceptanceofthedocumentation.(Debatablefaultshavetobenoted.):

    Faults: Notes:

    4. Thedocumentationofthelineisacceptedbythefollowingsignatures,becauseoftheabovementionedarrangements.

    5. Place: Date:

    Samplecustomer Customer(Orderer) (AuthorizedPerson)

    SOMATECSondermaschinenGmbH Supplier(Manufacturer) (AuthorizedPerson)

    LineManager(Customer) (AuthorizedPerson)

  • TurretRewinderATW OrderNo.000000

    General17

    1.2 InitiationfortheOperatormanualThemanagerofthelineisobligedtoproduceoperatinginstructionsfortheoperatingpersonnel,toprotecttheirhealthorothersafetytechnicaldanger.

    Besidesthemanagerisobligedtoinstructtheoperatingpersonnelaboutthesafeandorderlyoperating,upkeeping,maintenance,andoperatingthelinerelevant.

    Thisoperatorsmanualbookcanbeusedasaconstantpartofaserviceinstruction,butinnowayitisaserviceinstruction.

    Themanagertakescare,thattheoperatingpersonneltakenoticeofthisserviceinstruction.

    ThisoperatormanualbookisaconstantpartofthelineandanessentialhelpforasuccessfulanddangerlessoperatingofthelinefromSOMATEC

    Theoperatorsmanualbookwillhelpkeepingthelineonahighefficiencycapacityduringalongdurationoflife,andtotakethenecessarymoderationstoavoidaccidents.

    Attheendofmaintenanceandbeforecommissioningtheline,themanagerhastostartatrialrunwithcheckingallsafetydevicesatthemachine,toconvincehimselfthatthelineissafetooperateaswellasthepersonneloperatingthelineiscapabletooperateorderlyandsafe.

    Themachinehasbeenbuilttotheregularstandardoftechniqueandtheacknowledgedsafetytechnicalrules.

    Themanagerisobligedalwaystokeepupthenewestvalidsafetymodifications.

    Shouldyouneedanyfurtherinformation,youcanreachatthefollowingtelephoneandfaxnumbersacompetentpartnertospeakto:

    CustomerService&Spareparts:Phone: +495151106520Fax: +4951511065210

  • OrderNo.000000 TurretRewinderATW

    18General

    1.3 InstructionandEducationalHelpAsacontractor/manageryouareobligedtoinformandinstructtheoperatingpersonnelabouttheexistinglegalandpreventionofaccidentsorder,aswellasthesafetydevicesattheline.

    Theoperatingpersonnelhavetounderstandtheinstructions,andithastobemadesure,thattheinstructionshavetobetakennoticeof.

    Onlythroughthiswayyouwillreachthatyourpersonnelisworkingconsciouslyforsafetyanddanger

    Onthefollowingpagesyouwillfindexampleswitheducationalthemes,aswellasaformula,whichconfirmsthecourseofinstruction.

    1.4 SymbolsintheOperatorsManualUsedsymbolswithinthedocumentation

    Symbol Explanation

    Information

    Additionalinformationbesidesthemanualoperatorsbook.

    Danger

    Dangerofsufferingdeathandinjuries.

    Attention

    Dangerofdestroyingordamagingthelineorlineparts.

    PointingtoPointstoanadditionaltextpassagewithinthedocumentation.

  • TurretRewinderATW OrderNo.000000

    General19

    1.5 ExampleforEducationalThemes1. ForSafety

    Accidentpreventioninstructions.

    Generallegalinstructions.

    Generalsafetyadvises.

    Modeofactingduringanemergency.

    Thepersonalsafetyequipment.

    Safetyadvisesforoperatingtheline.

    Proceedingwithsafetydevicesattheline.

    Safetydevicesatthesurroundingoftheline.

    Meaningofsymbolsandsigns.

    2. OperatingtheLine

    Proceedingwiththeoperatingelementsoftheline.

    Explanationoftheoperatinginstructionfortheoperatingpersonnel.

    Specialexperienceofthemanagerwithproceedingtheline.

    Theuseofmaterialdeposit,expedientsandhelpingdevices.

    Experiencewithregardtotheproduction.

    3. UpkeepingandMaintenanceinstructions

    Proceedingaccordingtoinstructionswiththecleaningmaterial,lubrications.

    Specialexperiencesofthemanagerformaint