Professional Documents
Culture Documents
Technical
bar
production
line
mechanical
equipment
Purpose:
the
continuous
casting
square
billet
of
raw
material
(the
continuous
casting
billets)
will
be
For the cold continuous casting billets from outside, they will be
hanged to the
through the transporting roll table and after the centering of the
the centering roll table the continuous casting billets will be
sent to the reheating furnace for heating.
The
heating
furnace
heats
the
square
billet
to
the
roller.
and centered by guide. Then it comes into 550 rolling mill for
repeating milling.
Before entering the cold bed, the rolled profile bars need
to be sawed into two pieces first and then be sent to the cold
beds for cooling. After cooling, the straightening will be made.
And the straightened profile bars will be fixed-scale saw cut in
the cold sawing group with 11 cold saws. After this process the
profile bars will be detected and then bundled, weighed and
packed.
According
to
the
size,
determine
the
straightening
100X100X3000
120X120X3000
5.0mm
5.0mm
80mm
3
150X150X3000
Angle
steel No.
2.5
3
3.5
4
4.5
5
6
7
8
Size
d
25
30
35
40
45
50
60
70
80
3
3
3.5
4
5
5
6
7
8
3.5
4.5
4.5
5
5
5.5
7
8
9
Cm2
Section
area
Cm2
Kg/m
Theoretic
quantity
Kg/m
1.432
1.749
1.124
1.373
M2/m
Outside
surface
area
M2/m
0.098
0.117
3.086
4.292
4.803
2.422
3.369
3.770
0.157
0.176
0.196
9.424
12.303
7.398
9.658
0.275
0.314
+/-
+50/0 .
>8000
+80/0
Channel steel
Model
5
6
6.5
8
10
12
14
16
Size
h
r1
50
60
65
80
100
120
140
160
37
30
42
45
50
55
60
65
5
6
6
6.5
7
7
8
8
7
7.5
7.5
8
8.5
9
9.5
10
7
7.5
7.5
8
8.5
9
9.5
10
3.5
3.75
3.75
4
4.25
4.5
4.75
5
Cm2
Section
area
Cm2
Kg/m
Theoretic
quantity
Kg/m
8.444
10.24
12.74
6.63
8.04
10
21.31
25.15
16.73
19.74
+/-1.5
+/-2.5
5
100<h<200
+/-1.5
+/-2
100<b<150
+/-0.4
100<d<200
+/-
0.5
Total length tolerance of channel: 8000
+50/0 .
>8000
+80/0
Flat steel
Width
Thickness
Nominal
Nominal
size
10~25
25~40
size
+0.5/-1.0
+0.5/-1.0
4000
10
12~20
+30/0 . 4000~6000
+0.2/-0.4
+0.2/-0.4
+50/0
6000
+70/0
Total length tolerance of flat steel: 4000
+50/0
+30/0 . 4000~6000
4. Auxiliary
3 sets
Function: receive the billet from the hot transporting and sent
them to feeding port of furnace.
Max. weight for sending: 4526.5Kg/time
Roller size: 300X800mm
Roller face elevation: according to metallurgy furnace conditions
Roller speed: 1.5m/s
Roller distance: 850mm
n=20
3X22KW
720r/min
2 sets
n=12
15KW
1 group
n=12
8
15KW
1 set
n=12
15KW
Max. 610mm;
Regulation stroke:
A=1400mm Mn=20
i=6.887reference value
Mn25
i=1
Mn25
i=1
face
elevation:
about
800mm
(according
to
aperture
conditions)
Roller speed: 3m/s
Operation mode: clockwise rotating and anti-clockwise rotating
10
n=120
22KW
720r/min
5.2) Working roller table before the roughing mill and the tilting
plate: 1 set
Function: used to receive and send billet for roughing role
process
Max. weight for rolling billet: 2X1450Kg
Roller dimension: 300X1900mm (solid roller)
Roller
face
elevation:
about
800mm
(according
to
aperture
conditions)
Roller distance: 850mm
n=5
n=10
30KW
725r/min
1 set
Function:The rolling mill with three rollers has the upper and the
lower rolling line. The lower rolling line is transported the
rolled pieces by the roll tables, while the upper rolling line is
transported the rolled pieces by this lifting table behind the
roughing mill. And the rise-and-fall and the rotation of the
lifting table are all carried out by the machinery.
Rolled piece weight: 2X526.5kg
Swing angle: about 415
Time for one swing: about 2 S
Roller size: 300X1900mm (4 solid roller in front)
Roller elevation: lower part about 800mm; upper part about
1420mm (according to aperture conditions)
Roller distance: 600X3/850X1/800X9
11
63KW
585r/min
63KW
585r/min
1 set
face
elevation:
about
800mm
(according
to
aperture
conditions)
Roller speed: 3m/s
Operation mode: clockwise and anticlockwise rotating
Roller distance: 850mm
n=10
2X22KW
720r/min
1 set
Intermediate
rolling
mill:
450X4
with
layout
Rolling mill: 4 pcs
Type: two-roller semi-closed port type
Nominal size of roller: 450x800mm
Max. diameter: 480mm
continuous
600KW
500-1200r/min
7.1)
of
machine/The
Front
roller
K6
4 sets
roll
table
behind
the
1 set
face
elevation:
about
800mm
(according
conditions)
Roller speed: 2m/s
Roller distance: 1000 mm
n=18
15KW
720r/min
Min. diameter:380 mm
Max. 390mm;
to
aperture
600KW
500-1200r/min
6 sets
face
elevation:
about
800mm
(according
to
aperture
conditions)
Roller speed: 4.2-6.4m/s
Roller distance: 1000mm
n=57
2.5#-8#
flat steel
14
angle
Function: fixed on the side of front roller of cold bed, used for
pulling the rolling part to cold bed quickly to avoid blocking.
Type: multi-claw pusher (or adopt companys horizontal carrier
organ type)
Stroke of pusher claw: 700mm
Distance of pusher claw: 6000mm
Pusher claw higher than roller: 120mm
Max. transferring time: 30 times/min
Driven mode: motor drive
10.4) The output roller table behind the cold bed: 1 set
Function: for transferring the cold-rolled part to straightening
machine for straightening
Roller dimension: 250X600mm
Roller distance: about 1000 mm
Roller quantity: 77 pcs (in 11 groups, driven by DC motor)
Roller speed: 2-4m/s (adjustable)
Roller elevation: 700mm
11.500 straightening machine: 1 piece
11.1 The roller table behind the 500 straightening machine: 1
group
Function: used to receive the rolling parts from 500 straightening
machine and send them into 300 straightening machine.
Roller dimension: 250X400mm
Roller face elevation: about +700mm
Roller speed: 2.5-4.5m/s
Roller distance: 1000mm
n=2
5KW
group
Function:
used
to
receive
the
rolling
parts
from
the
300
n=2
5KW
n=43
11KW
Structure requirement:
a. For structure design roller, the installation between cold
sawing units and horizontal movable machine shall be considered.
b. The upper of roller shall be equipped with pneumatic lifting
pressing positioning device to ensure the stable sawing.
c. The end of roller shall be set with positioning baffle.
1 set
1 set
Function: used to receive the rolling materials from the chaintype conveyer and convey them to the packing stage.
Roller size: 250X400mm
Roller elevation: about+700mm
Roller speed: 2m/s
Roller distance: 2000mm
n=41
18
1 piece
2 pieces
1 group
19
cooling
bed,
cooling
bed
flat
carrier;
cooing
bed
rolling
line
is
by
DC
motor,
installed
capacity
of
450
based
on
full
consideration
of
the
realization
of
minimum
tension
control
of
intermediate
and
finishing
rolling
3.2.6 logic control of rolling mill start/stop
3.2.7 human-computer interface:
a) equipment operating status parameter display
b) setting of rolling parameter
c) faults, display and alarm of events
d)
dynamic
simulation
display
of
rolling
lines
and
various
equipments
3.3 Technical functions of intermediate mill and finishing mill
drive system
3.3.1 General requirements of intermediate mill and finishing mill
drive system
For the equipment supplied, it shall ensure realization of various
control functions and satisfaction of the performances required by
production, and stable as well as stable and reliable operating in
a variety of environments, with convenient maintenance, low fault
rate and simple operation.
3.3.2 Characteristics of intermediate mill and finishing mill
drive cabinet
3.3.2.1 drive cabinet is reversible excitation system;
3.3.2.2 static property satisfies 0.1%, and dynamic property
satisfies 0.5%.
3.3.2.3
protection
requirement:
drive
fan,
power
components
temperature protection.
3.3.2.4 insulation of incoming line zone.
3.3.2.5
with
such
hardware
with
~220V
socket
for
Profibus-DP
communication
as
required
3.3.2.6
in
the
lighting.
22
cabinet
and
self-provided
device
or
EUROTHERM
companys
SSD590
reversible
No.
1
2
Equipment
name
550 Roughing
mill
450
Intermediate
mill
350
Finishing
mill
Electrical Qty.
equipment
Power
supply
Model
Main motor
YR1250
1250
585
10000
AC
Main motor
Z5003A
4x600=2400
532-1200
660
DC
Main motor
Z5003A
6x600=3600
532-1200
660
DC
Subtotal
11
7250
continuous
service,
it
is
comprehensive
test
to
the
up
by
computer
network,
which
fully
reflects
the
proportion
automatically
according
to
the
principle
that
between
frames
for
an
instant
of
biting,
and
to
compensation
value
(0.98~1.02),
multiplied
by
speed
setting value of this frame, as the speed value when biting, after
completion
of
dynamic
speed
drop
compensation value.
26
of
biting,
withdraw
the
Full pinch
Head and tail pinch
Tail pinch
The selection of pinch method is completed by the operation
station.
6.3.2.6 Interlocking of rolling line and hydraulic, lubrication
station and water treatment system
As an independent system of hydraulic station and lubrication
station and water treatment system, it must have such signal as
ready, fault and so on sending to PLC. As an integral part of
ready for whole line, if the whole line is not ready, it cannot
run. If the whole line runs, but hydraulic station or lubrication
station or water treatment system fails: for light fault, stop
tapping of heating furnace immediately; send out alarm signal; if
the fault is still existed after three minutes (this period of
time is waiting for completion of rolling in current rolling
line), shut down in corresponding area. For major fault, the whole
production line should be stopped.
6.3.2.7 Operation of rolling line equipments
There are normally two operating modes of automatic and manual for
rolling line equipments. For drive system, it is fitted with
inching operation (generally, inching setting value is 510%).
When
selecting
automatic
mode,
all
equipments
automatically
condition
and
process
control
requirement.
When
speed-regulating
drive
equipments
are
operated
by
of
the
operation
with
low
real-time
requirement
is
by
appliances
on
the
operating
board
(such
as:
tension
transmitting
operating
control,
between
board
and
there
regulation
local
are
large
cabinets.
operation
cabinet
number
The
of
control
will
carry
data
for
out
regulating devices:
PLC
DC speed-regulating device:
Start/stop signal
Inching command signal
forward and reverse signal
Specified
setting
signal
(including:
general
setting,
single
realization
of
start/stop
control,
logic
control
and
connection
between
electrical
terminals
can
be
and
signal,
so
it
can
complete
commissioning
of
the
relays,
contactors,
indicator
lamps
and
other
simulation
of
such
process
as
start/stop,
steel
on
and
self-check
the
system,
after
network
contact
of
main
parameters,
total
setting,
single
machine
quality
centralized
of
the
monitoring
system,
management
which
for
greatly
facilitates
operating
maintenance
personnel;
I. Rolling schedule
Establish complete rolling procedure, apply scientific management
to produce and improve the precision and efficiency;
J. Operating report
Record
the
operation
situations
of
machine
unit
and
main
the
operation
situations
33
of
machine
unit
and
main
3. Site positioning
3.1 The dilute oil tank is better to be installed in ground
channel, thus the oil may flow smoothly and freely and the oil
liquid of speed reducer will not overflow.
Capacity: 600ml/r
Working pressure: 5bar
Max. working pressure: 8bar
Summary
complete set.
This item is a turnkey project and we are the general contractor
for design, equipment supply, construction, installation, baker,
commissioning and production.
circuit
system,
water,
electricity,
nitrogen
and
2.Scope of supply
(1)Reheating furnace body(steel structure, masonry work,etc.)
(2) The whole combustion system(including oil circuit system,
steam system, air system, fume exhaust system, etc.)
(3)The whole instrument control and electric control systems for
the reheating furnace.
(4)Evaporated cooling system
(5)Equipments for the reheating furnace(nozzle, door for the input
and output of material, peep-hole, access door, etc.)
(6)Steel pusher, discharge machine, etc.
(7)Hydraulic and lubrication system
37
3. Design condition
(1) Fuel and calorific value: heavy oil, 96004.18KJ/kg
(2) Billet bloom size: 1501506000mm1501503000mm
(3) Steel species: carbon structural steel, low-alloy structural
steel, etc.
(4) Charge and discharge temperatures of billet:
charge temperature of billet: 700 800 the cold charged
temperature20
discharge temperature of billet: 1150-1250
(5) Rating output: 25t/h (cold charged)
(6) Cross-section difference in temperature: 30
(7) Unit heat consumption: (rating condition)32kg oil/t billet
(8) Bottom beam cooling method: evaporation cooling, adding valve
before water level gauge
(9) Input and output method of billet: end charge, end out
(10) Billet distribution method: 3m double-row billet; 6m single
row billet
Second
(1) The top and bottom of the furnace supply heat, with heath
temperature uniformity in furnace area. Setting partition in
furnace to control furnace temperature and furnace press easily,
and to reduce interference in segments.
(2) The reheating furnace sets 4 vertical water pipes to satisfy
the request of
preheated
temperature
is
450,
and
steam
overheated
bottom part with the height of 10m and the diameter of 1.6m
(welded by the steel plate of 20mm); the middle part with the
height of 12m and the diameter of 1.2m (welded by the steel
plate of 10mm); the top part with the height of 6m and the
diameter of 0.8m (welded by the steel plate of 6mm). The
connections of the three parts are connected by the flanges and
integrally assembled to fit the condition of the 150km/h wind
speed. The outlet diameter of the outside chimney is 0.8m and
the natural discharge of the smoke is taken use of for the
furnace. The temperature of the flue inside the furnace is
600~700, and the temperature of the bottom of the outside
chimney is 200~300.
(6) Oil supply system uses main pipe for returning oil(before
heater) to stabilize oil press, and does not set oil return device
in other segments.
(7) Designing light oil system which imports from main pipe and
only is used for starting and stoping the furnace.
(8) Water girder in furnace adopt evaporative cooling.
39
(9) Roof and wall of the reheating furnace adopt the masonry
structure with whole cast and complex layer, strengthen the
adiathermance of the furnace masonry work, reduce radiating loss
and improve the furnace life.
10 2 segments furnace temperature control are taken used
including soaking segment and heating segment. And dual cross
amplitude limit control is adopted in the furnace temperature
control, as the oil and the fogging agent using proportion
control.
11 Equipping practical, reliable, advanced thermotechnical
automatic control system to ensure heating quality; controling the
air-fuel ratio and reasonable
Third
the
furnace
1. Furnace model
Adopting a three-section consecutive pusher-type reheating furnace
with billet end charge and side out. The reheating furnace uses
floor water pipes with overhead structure in preheating and
heating segments, heating double sides of billet; leave certain
length of true floor in soaking zone to balance the cross-section
difference in temperature of billet and eliminate water pipe
black marking. Soaking zone uses true floor with pink fused
alumina.
The reheating furnace takes use of two-segment furance temperature
control for the soaking segment and the heating segment. The roof
of the furnace takes the screwdown structure, and all nozzles are
installed on the wall of the upper
furnace.
The combustion control system of the reheating furance has two
40
can
satisfy
the
request
of
heating
temperature
and
support.
Taking natural draft and down draught as the flue gas exhausting
method.
2. Main size of the reheating furnace:
Total length of the reheating furnace masonry:
16300mm
15300mm
6800mm
1400mm
1800mm
3
4
5
6
7
8
9
Name
purpose of the furnace
Heating steel species
Unit
Billet specification
Furnace approach
temperature of billet
Heating temperature
mm
Furnace output
Steel pressure
intensity of furance
floor
Fuel & low calorific
value
Rated specific
C
C
Data
Billet heating before rolling
Carbon construction steel, carbon
construction quality steel, lowalloy high-tensile structural
steel
1501506000 1501503000
20 as cold installed
700-800as hot installed
1150-1250
t/h
Rated 25Cold installed
Kg/ Cold installed 230rated
2
mP P.h
KJ/mP3
GJ/t
41
Heavy oil96004.18
Cold installed
1.296GJ/t
10
11
12
13
14
15
16
17
consumption
Rated fuel consumption
Rated air capacity
Rated fume capacity
Oxidation burnout rate
Air preheating
temperature
Cooling method for
floor water pipe
Air pressure before
furnace
Cooling water pressure
18
Cooling water
consumption
19
Pressure of the
evaporation cooling
system
Steam output
20
21
kg/h
mP3P/h
mP3P/h
%
C
800
9000
9300
1.0
450
Evaporation cooling
7000Pa
0.3MPa
Clean circulating water 100t/h,
turbid circulating water 30t/h,
soft water 7t/h
0.78Mpa
2.5-5.0t/hadiabatic 100%-90%
and entering
The roof wall of the reheating furnace adopts the complex masonry
work structure with monolithic cast, and the furance floor takes
the complex masonry construction; the furnace body has good
performance on heat insulation and good air tightness.
42
five years.
230mm
100mm
Total thickness
330mm
264mm
116mm
120mm
500mm
116mm
Clay brick
272mm
Light brickr=1.0
136mm
Diatomite brick
136mm
Total thickness
660mm
20mm
Self-flowing castable
60mm
43
Thickness
Fifth
80mm
platforms
are
set
around
the
furnace
and
in
the
slag removal.
There are many peepholes on the wall of the charge end and the
discharge end of the furnace, which are used to observe the
furnace condition in the daily producting operation.
Peephole specification: 135mm
cooling,
and
the
furance
floor
water
pipes
are
heat
resistant
steel
slider,
and
the
adiabatic
Combustion system
combustion
system
adopts
two-segment
furance
temperature
products flow from the flue located at the bottom of the charging
end to the flue at the back of the furance, then through the steam
superheater, the air preheater and the flue adjusting valve to the
chimney with the height of 50m and the exit dia. of 2.2m, and then
will be delivered outside of the workshop. The flue has the cold
wind mixed device to pretect the heat exchanger.
To recycle the heat from the fume, the air preheater is installed
at the discharge to preheat the combustion air to 450. The
preheater is the two-cycle metal-tube shape type with twist plugin piece, with the steam superheater in the fume entrance side.
Pluging twist metal sheet in the inside of the metal pipes, on one
hand, can increase the air speed and journey in pipes. on the
other hand, because of producing continuous backset and on the
effection of centrifugal force, the air in the center of pipes
will be mixed sufficiently with the gas at the boundary layer of
the wall surface to reduce the bottom of laminar flow, strengthen
the convective heat transfer and reduce the pipe wall temperature.
To protect the heat exchanger, the hot blast automatic exhale
device is set at the main pipe.
The steam superheater is the U-type psse preheater, which can
superheat the atomizing steam heat around 250280.
The reheating furnace takes use of the furnace end downdraught.
The
fume
passes
through
the
air
heat
exchanger,
the
steam
The rehearting furnace floor pipes and end wall of furnace cooling
pipes are all using the evaporatiom cooling natural circulation
system.
The design pressure of the drum(steam header) for the evaporation
48
1. Design scope
Automatic control system includes the process detect and control
of the main and assistant installations for the reheating furnace.
2. Operation mode and interface
Operation mode for this system: hand keyboard, PLC autocontrol.
PLC autocontrol is used in general condition.
Switch input and output usually use voltage of AC220V or DC24V,
and
analog input and output use 420mADC. The signal of RTD hot
main
principle
of
design
49
is
that
according
to
the
room
by
the
method
of
communication),
and
the
and
record
two-segment
furnace
temperature,
and
indicationof
the
atomizing
temperature
cooling water main pipe pressure indication
51
air
preheated
cutting
down
heavy
oil
systems
of
each
segments when the the pressure of heavy oil and air is low
The fuenace pressure automatically controls the flue valve
Emergency water automatically input
(3)Evoporstion cooling system detection and autocontrol items:
Manual and automatic control of the pressure of the steam
header and the water level
Pressure detection for soft water supply
Flow
indication
and
autocontrol
of
the
steam
header
feedwater
Over high and low water level alarm for the steam header
Over high and low pressure for the steam header
Water supply valve automatically pumping water
Manual and automatic control of the steam pressure
7. Equipment selection
The main function of the automatic instrument is the logic control
about processing equipment action and
52
the detection
about
technical process
transmitter.
Ninth
1. Fuel
Adopting heavy oil
heavy oil thermal value: 96004.18kJ/mP3
contact pressure: 0.8MPa
rating wastage: 800 Kg/h
contact flow: 960Kg /h
adopting large back oil, and the back oil rate is not less than 1.51.
2. Electrical source
Three phase AC: 50HZ
Voltage: AC380V, AC220V
Power: about 30kW
There will be one 0.2t oil buring steam boiler, and the drawing of
the boiler will be supplied by the seller.
3. Cooling water
For the discharge furnace door, hydraulic station, etc.
Water quality: clean circulating water
Water temperature: inleting32, yielding 45
Contact pressure:0.3MPa
Contact flow: 30t/h
Emergency water: according to two electrical sources switch
time 0.5h;Consumption: 50t/h
53
4Compressed air
Pressure: 0.6MPa
Flow: 20m3/h
5. Light diesel oilFor the start and stop of the furnace
The quantity should satisfy the continuous 10 hours comsuption
for the reheating furnace.
Comsuption: 1000kg/h
Pressure :0.8Mpa
6. Power supply
Electric motor for the combustion fan of the reheating
furnace: 1 piece 75 kW,
380 V
Tenth
run and inform the buyer about the test content, the precept, time
and place of the test, and the requirement for the buyer about the
test preparations in 48 hours before the test run The buyer should
make preparations according to the requirement of the seller and
send
representative
to
take
part
54
in
the
test
andcheck
and
supervise it. The seller should make the test run record. Only
after the test run is passed and both sides sign on the test
recoed, the project can be put into the head load test run stage.
1.3 If it is the seller matter that causes the failure of the
test run, the seller should afresh the test run after amending the
equipment and afford the expanse of amending and afreshing. If it
is the seller matter that affects the test running process, the
project duration will be postponed.
1.4 During debug and test run period, the seller takes charge of
turnover pieces and wearing pieces; the buyer takse charge of the
expanse of medium(oil, fuel), fuel used for baker, human and tool.
2. detection
2.1
The
project
final
detection
is
the
production-qualified
detection. The seller makes the precept for the heat load test run
and the both sides confirm the
devices
and
low
energy
consumption
to
obtain
6m
2 passes
Pass distance
1.30m
Ladle turret
Tundish car
Four
wheel
type
with
traverse
function
Pouring mode
Secondary cooling
Water
cooling,
auto
adjusting
straightening
Roller table
Dummy bar
Billet cutting
Flame cutting
Billet conveying
table
The set pouring speed and correct pouring process can guarantee
high-quality products.
The automatic control system can ensure the correct and safe
equipment running.
The overall technical characteristics of the machine are
guaranteed by the design of seller, especially the experience in
production of equipment.
The type slection of equipment is closely related to the following
high target values:
Limited investment costs;
High-quality products;
High productivity;
Operation as simple as possible;
Reliability of operation;
Meet the different market demands to the maximum extent.
To ensure the normal operation and maintenance, we will provide
trainings for buyers operators and maintenance personnel on both
theory and practical operation at site or sellers school factory
during installation and commissioning.
If necessary, after handing over the equipment, we will further
supply technical assistance of equipment running and maintenance
57
updating
its
products
in
order
to
improve
the
Item
Representative
steel grade
Q235
Proportion
Remark
50%
Tentative
50%
Tentative
is
equipped
with
150X150mm
Dummy
bar
head
and
10T
Melting cycle
90min
30 heats/day
330 days/year
2) Production capacity
Working days
330 days/year
30heats/day
Nominal capacity
10/furnace
Production capacity
99000t/year
100X100
120X120
1.8
1.2
150X150
Pass 1
1.8
10t
Passes
2 stand
Cutting length
Automatic 3m/6m
Pass 1
15 times
Pass 1
Total (kg)
300
300
10
156
156
20
312
312
20
312
312
972
150000
99%
bar. This time is measured from the end of last pass to the
beginning of the first pass of the next pouring cycle.
Machine radius
Angle
Bending length form the meniscus to the vertical
6.0
79.9
9.56
6.5
point of cutting
Distance from the starting point of cutting to the
m/min
m/min
mm
m/min
m
min
m
mm
m/min
mm
t/Stand
mm
m/min
min
min
min
min
min
min
min
28.0
5.0
4
2.2
1.7
1.28
9.42
450.0
1.5
300.0
5
3.0
0.0
0.8
10
2.85
2.0
1.0
0.5
2.0
16.05
of pouring radius.
Therefore, the main pouring radius is determined to be 6m and
with gradual straightening function.
In the design of straightening zone, the straightening with
liquid core shall be completed to reduce the pressure on the
billets (internal and surface). Even if the pouring speed further
increases, no cracks will occur.
Gradual straightening ensures that the continuous deformation
of billets, and the elongation percentage of each straightening
point is maintained below the critical value at which crack
occurs.
The
factors
influencing
steel
cracks
are
the
initial
If
the
straightening
force
on
the
solid
liquid
product
cracks
will
be
formed
during
liquid-core
precisely
adjusted
to
ensure
the
surface
temperature
is
Billet section;
Basic radius of continuous caster;
Pouring speed;
Critical elongation percentage decided by steel grade.
The actual billet straightening deformation rates are calculated
as the table below:
Steel grade
Straight carbon
steel
Low alloy steel
(m/min)
Pouring speed
(m/min)
1.02.2
0.82.0
Efficient
deformation rate
()
Referred to the
tabular statement.
Referred to the
tabular statement.
Allowable
deformation rate
(RmaxR)
0.25
0.150.2
Max.
life
of
refractory
materials
for
long-time
continuous casting;
Low temperature drop during pouring process;
Safe pouring of multi-pass caster
No nozzle eddy flow during the replacement of ladle.
Tundish design of shape can prevent refractory materials
from peeling from tundish due to heat elongation percentage.
It is recommended to use high-quality insulating boards and
covering agents to reduce temperature drop and ensure the steel
quality.
Characteristics of refractory materials recommended:
Working lining material: insulting boards
Working lining thickness: 40mm.
It is recommended to use synthetic covering agents for tundish.
The compositions shall be able to adsorb slag inclusion and reduce
oxygen activity.
Basic features of covering agent:
Compositions
SiOR2R=2124%
62
AlR2ROR3R=810%
(CaO+MgO)=3638%
(CaO+MgO)/SiOR2R=2
1300
Alkalinity
Melting point
based
on
the
cost
and
organization
of
production,
Mold water slit design is for high water speed to keep low tube
temperature and avoid water boiling, especially near the meniscus
of molten steel in the mold.
The discontinuous changes in the temperature of copper tube wall
and unstable heat transmission will lead to cooling water boiling,
causing
permanent
tube
deformation,
furthermore,
high
wall
result
when
mold
has
high
water
speed
and
lower
pressure.
In order to ensure the water slit size, the water jacket has
stringent tolerance limits to ensure that the water slit is
constant in all cases. Main cooling parameters:
Steel grade
Water flow velocity
Max. inlet pressure
Water speed
Group
2000Lmin/pass
Bar
m/sec
12
6.0
10
CuAg
10mm
Cr
0.1mm
The
basic
factor
taken
into
account
for
the
selection
of
has
proved
that
the
best
negative
strip
time
is
0.10~0.12s.
Depending on different pouring speed, the frequency shall be
changed to ensure constant negative strip time. The results of
changes are automatically controlled by continuous casting and
recorded by the computer.
Oscillation frequency and amplitude are determined by the negative
strip time and pouring speed.
Pouring parameters are controlled by the basic automatic system.
2.2.9 Billet support
Seller recommends the mold with foot rollers.
The purpose of foot rollers is to guide the billet after getting
out of mold and guide the introduction of dummy bar head when
resetting the dummy bar. If the billet/dummy head is without
guidance, it may scratch the bottom copper tube wall of mold,
shorten the service life of mode and result billet surface
defects.
Practice has proved that the proper use of foot rollers can reduce
65
mold wear, and reduce the impact on the billet surface under
different pouring conditions.
Foot roller number and distance considered in design:
Section
Number of rows
Roller number of
Roller diameter
each row
mm
60
mm
150150
Item
Foot roller
Fixed section
Length (m)
0.20
2.4
1
Fixed section
2
Nozzle number
16
56
Cooling mode
water
cooling
380
50
200
V
Hz
Kw
power
2.3.2 Water
1) Cooling water classification
Indirect cooling water: the cooling water that does not directly
contact the cooled objects, such as the water for the primary
cooling circuit of a continuous caster.
Direct cooling water: the cooling water that directly contacts the
cooled objects, such as the water for the secondary cooling
circuit of a continuous caster.
Emergency water: the cooling water for protecting devices from the
hazards of power down.
Direct and indirect cooling water has own independent systems. The
recirculation is in two ways: closed circuit and open circuit.
When the equipment is running, it shall always guarantee the
quality characteristics of water to avoid the impact of debris and
corrosion.
Technical requirements for water are shown in the following table:
Cooling system
Device
Soft
Secondary
Emergency
Water type
PH
Ca hardness (mg/1CaCCOR3R)
Mg hardness (mg/1CaCCOR3R)
Alkalinity (mg/1CaCCOR3R)
Max. chloride (mg/1CCl)
Max. sulfide (mg/1SOR4R)
Max. iron (mg/1Fe)
Max. silicon oxide
water
a
79
30240
080
50200
200
150
0.5
50
water
aa
79
060
020
20200
50
40
0.5
10
cooling water
b
79
30360
0120
50300
250
200
0.5
75
water
c
79
30240
080
50200
200
150
0.5
50
(mg/1SiOR2R)
67
1000
500
1500
1000
(mg/1)
Total suspended solid
1020
1020
5080
1020
(mg/1)
Max. suspended solid size
100
50
200
100
(m)
Max. oil content (mg/1)
10
Type
aa
a
b
Q
mP3P/h
240
100
50
Ti
Te
Pi
Mpa
DP
Mpa
35
35
35
50
50
/
0.8
0.3
0.8
0.50
0.3
/
Qem
mP3P/h
Pem
Mpa
0.3
/
/
68
User
General
user
Pressure
head
Instrume
nt air
Q
(NmP3P/h
)
10
Pi
(Mpa)
(mg/mP3
P)
(mg/NmP3P)
(mg/mP3P)/
(mm)
0.6
20
5000
15/0.05
180
0.6
5.000
15/0.05
0.6
(dew point
-20)
5/1pm
2.3.4 Oxygen
Pressure required: 1.2Mpa
User
Oxygen lance
2.3.5 Fuel
Fuel type and user
Continuous caster
oxygen lance
Continuous caster
230t
Slewing radius
3300mm
By
operation)
69
hydraulic
motor
(normal
1r/min
1r/min
Rotation angle:
270
Equipment weight:
18000Kg
Equipment Quantity:
1 set
1) Drive unit
Slewing bearing
131.50.1800
M=20
z=174
M=20
z=174
Slewing motor:
CD03477W
Speed:
50r/min
Pressure difference:
10MPa
1 set
3.2 Tundish
For receiving the molten steel in the ladle and pouring it to
the mold.
The cover on the tundish is mainly for the heat preservation
of molten steel.
1) Main tundish technical parameters
Tundish structure: T-type, with retaining wall and retaining
weir, overall pouring tamped Tlining
Nozzle quantity:
2Pcs
Nozzle interval:
1300mm
160mm
1800Kg/set
Equipment quantity:
2 sets
Manual
Equipment weight:
200Kg/set
20t
1600mm
Equipment Quantity:
2 sets
Equipment weight:
2500Kg/set
mm
Travel speed:
1.210m/min
Wheel diameter:
250mm
Gear motor
Model:
Power:
2.2KW
Output speed:
12.7r/min
Frequency:
350Hz
Working stroke:
50mm
1800mm
Equipment weight:
60Kg/set
Equipment quantity:
2 sets
Manual
Quantity:
1 set
3.7 Mold
It is for the initial setting of shells. After initial setting,
billets are continuously drawn out from the lower outlet of the
mold, then come into the secondary cooling zone. It includes steel
tubes, internal water jacket, external water jacket, drainage
pipe, water ring, foot roller, bottom and top flanges, lubricating
flange and other components.
Main technical parameters:
Type:
Mold type:
Chromeplated
CuAg
tube
with
length/pouring
section/fillet
radius:
850mm/150150mm/3~6mm
Copper tube cooling:
Closed
primary
cooling
system
Water seam size:
Approx 5mm
Flow rate:
Approx 8~10m / s
0.6~0.8MPa
40/48
St52-3
2/set
One
row
above,
three
2 sets
order
to
maintain
certain
negative
strip
rate,
the
VVVF
Amplitude range:
29mm
Frequency:
30~250 times/min
Oscillation mode:
Sine
73
Amplitude adjustment:
Shutdown regulation
Frequency regulation:
Automatic
adjustment
according
to
casting speed
Oscillator quantity:
2 sets
The
cooling
intensity
and
the
structure
and
Simplified structure
pass distnce:
1300mm
Nozzle type:
Nozzle model:
3/8 PZ6065Q24
1000Kg
billet
guiding
and
straightening.
The
drawing
speed
is
Integrated
rack
five-roller
withdrawal straightener
Driving mode/TscrewdownT mode:
Electric
drive/Thydraulic
screwdown
Straightening radius:
6000mm-12000mm-
Straightening temperature:
9501050
Drawing speed:
0.33.0m/min
Roller size:
300mm
Motor power:
11KW
340
230mm
Variable (5-50Hz)
10Mpa
Hydraulic medium:
Mineral oil
LA-200X80X60
LA-200X80X225
Equipment weight:
5000kg/set
Equipment quantity:
2 sets
R6m
Angle of contact:
92
200140mm
Drawing speed:
0.55mmin
Power:
1.5KW
Output power:
5.1rmin
Constant speed
Platform size:
Approx 12m3.4m2m
1667kg/set
10000kg
Centralized
(electric)
drive
Llinear velocity of roller surface:
2.5mmin
5000500450 mm
Roller (diameter/length):
240230 mm
Roller distance:
1060 mm
Roller quantity:
5/pass2 passes=10
1.5KW
Motor speed:
1500rmin
Rotation direction:
Motor quantity:
1300mm
Roller (diameter/length):
240230mm
Roller distance:
1060mm
Roller quantity:
5/pass
Table speed:
15mmin
240230mm
Roller distance:
1060mm
Table distance:
1300mm
Roller quantity:
5/pass
Power:
4.0KW
Velocity ratio:
59
Motor speed:
1450rmin
Constant speed
1 set/pass
1000mm
77
Cutting seam:
7mm
150180
Centralized drive
50KN/pass2 passes=100KN
15 mmin
Roller (diameter/length):
240230 mm
Roller distance:
1300 mm
Roller quantity:
5/pass2 passes=10
Motor type:
4.0KW
Motor speed:
1450rmin
Motor quantity:
Hydraulic
TC1251800
1800mm
Mineral oil
2 pcs
78
Equipment quantity:
1 set
1500kg
10T
20KN
1501506000mm
60003000mm
Equipment quantity:
1 set
Equipment weight:
2000kg
200KN
Weight:
1490kg
Qty:
1 set
50KN
Weight:
300kg
Quantity:
1seat
of
the
rotating
components.
79
device,
platform
and
other
The mold can turn to any angle though the rotating device for
maintenance.
Main technical parameters:
Motor power:
0.4KW
1003
Equipment weight:
350kg/set
Equipment quantity:
1 set
372kg/group
Equipment quantity:
2 groups
6000mm
Equipment weight:
14kg
Equipment quantity:
1 set
model
3.19 Hydraulic system
Mainly for the driving and control of the body of continuous
caster and off-line devices.
In order to ensure safe and reliable continuous running of the
equipment, domestic brand-name components are to be adopted as the
main components of the hydraulic system. The main pump is an axial
plug pump to adapt to the needs of high pressure and large flow
rate.
Due
to
the
transmission
requirements
and
different
control
station is designed.
Hydraulic station.
To supply power to the withdrawal straightener, ladle turret,
roll table flap, pusher, etc.
System pressure:
8MPa
44KW
Tank capacity:
2000L
Hydraulic medium:
Mineral oil
control
technology,
electronic
instrument
control
experience
accumulated
during
the
installation
and
cooling
water,
and
select
the
safe
and
reliable
software
of
control
system
includes
the
system
control
from
objects.
The
man-machine
interface
is
accessible,
can zoom out and in. By observing the real-time and historical
trend curves, we can get full information of the control process,
and use the historical trend treatment to collect, store and
display real-time process data. The data obtained can be filed, so
that it can be made into reports for comparison.
Alarm function: Be able to continuously monitor the process, and
alarm as soon as failure occurs.
Database function: The stronger database management function can
not only establish a production database and store the raw
production data for statistics and analysis, but also establish a
fault database to record system errors and failures.
4.2.2 Inspection and control items and control mode
1) Mold
Inlet branch tube pressure and temperature detection of cooling
water, and low-pressure alarm
Inlet temperature and pressure detection of cooling water inlet
manifold and low-pressure alarm
Inlet and outlet temperature difference detection of cooling
water, and high-temperature alarm.
2) Secondary cooling zone
Inlet pressure and flow rate detection of the manifold, and
low-pressure alarm.
Flow rate and pressure detection of each pass of branch tubes.
3) Withdrawal straightener
Drawing speed inspection
Billet length inspection
5. Design scopes and work division of both parties
5.1 Party As design scope
5.1.1 Design of plant related to the continuous caster.
5.1.2 Design of off-line pipeline related to the continuous
83
caster.
5.1.3 Design of common and auxiliary facilities (including
water, electricity, wind, gas) related to the continuous caster.
5.1.4 Design of the gas supply system and gas pipeline of gas
bus.
5.1.5 Design of the power line of oxygen and compressed air.
5.1.6 Design of the tubing of gases (oxygen, gas, compressed
air) for continuous casting.
5.1.7
Design
of
the
power
cable
feeding
for
continuous
Design
of
the
air
conditioning,
ventilation,
fire
Automatic
control
system
84
design
of
the
continuous
caster.
5.2.6 Hardware configuration of computer system
5.2.7 Programming of application software.
5.2.8 Design of the cable laying of on-line equipment.
5.2.9 Technical requirements and parameters related to the
energy medium system, water, electricity and gas of the continuous
caster, which shall be provided for Party A.
5.2.10 Design of the continuous caster and relevant civil
construction requirements.
5.2.11 Design of the water supply system requirements of the
continuous caster.
5.3 Nodes of pipeline plans of both parties:
5.3.1 The node of the compressed air pipeline: for the
compressed air, Party A is responsible to design the pipeline form
the gas source to the dedicated gas tank (including gas tank) of
the continuous caster, and Party B is responsible to design the
pipeline from the gas tank to equipment.
5.3.2 The node of the energy medium pipeline: for the gas
pipeline, Party A is responsible to design the pipeline from the
gas source to the master valve (including the master valve) of the
continuous caster, and Party B is responsible to design the
pipeline from the valve to the point of use.
5.3.3
The
design
of
lubricating
pipeline
and
hydraulic
The
node
of
the
power
supply
line:
Party
is
responsible to design the line from the power source to the power
receiving cabinet in the main electric room of the continuous
caster, and Party B is responsible to design the line from the
power receiving cabinet (including the power receiving cabinet) to
the use point of equipment..
5.4 Handing over of drawings and data
85
5.4.1 Drawings and data that Party A shall provide for Party
B.
5.4.1.1 Civil construction drawings of plant in connection
with the continuous caster; Crane outline and hook movement
location drawing, as well as hook head outline drawing, ladle
drawing, ladle slide gate nozzle assembly drawing.
5.4.1.2 Other date related to the design of the continuous
caster.
5.4.2 Date which Party B shall provide for Party A.
5.4.2.1
Provide
detailed
basic
equipment
data
of
the
continuous caster.
5.4.2.2 Provide the civil construction data of internal cable
trenches, pipe tunnels and embedded parts of the continuous
caster.
5.4.2.3 Provide the civil construction design data of the main
electric room, each control room, and hydraulic station.
5.4.2.4 Technical requirements of the three-water system and
energy medium consumption of the continuous caster; Location
coordinate drawing of the master three-water feed and return
valve, master gas tank valve, gas tank, etc.
5.4.2.5 Other data related to Party As design.
5.4.2.6 Two complete sets of installation and maintenance
drawings of equipment, electric and instruments of this project.
5.4.2.7
Technical
documents
and
data
attached
with
the
(including
the
delivery, including:
Equipment delivery list (packing list);
Outsourced
parts
and
standard
parts
list
Designed
complete
sets
of
electric
and
instrument
automation equipment.
7. Others
7.1 Electromagnetic stirring, automatic liquid level control
and
aerosol
cooling
system
are
not
taken
into
account
for
R6
two-pass
continuous
caster
Wuxi Qiangsheng Iron & Steel Co., Ltd.
R6
two-pass
R6
two-pass
continuous caster
Guangxi Mingang Iron & Steel Co., Ltd.
continuous caster
Ningde Rongxing Steel Industry Co., Ltd.
R6
three-pass
continuous caster
Jiangsu Changjiang Runfa (Suqian) Group R6 two-pass continuous
caster
Changzhou Xingyu Iron & Steel Co., Ltd.
R6 two-pass continuous
caster
Guangdong Xiaoheng Huidong Steel-casting Foundry
R8 two-pass continuous caster
Jiangsu Jiangyin Xinshengang Iron & Steel Co., Ltd.
R6 two-pass continuous caster
88
R4 two-pass continuous
caster
Jiangxi Shangrao Steel Mill
R6 two-pass continuous
caster
Zhejiang Mingtai Iron & Steel Co., Ltd.
R6
two-pass
continuous caster
Chongqing Pengcheng Iron & Steel Co., Ltd.
R6 two-pass continuous caster
Guangdong Fengshun Agricultural Machinery Continuous Casting
Factory
R6 two-pass continuous caster
Guangdong Yongshun Steel-casting Foundry
R6 two-pass continuous caster
Sichuan Fufeng Iron & Steel Co., Ltd.
R6
two-pass
continuous
caste
Shandong Liaocheng Steel Mill
R6
two-pass
continuous
caste
Jiangxi Shangrao Metal Products Co., Ltd. R6
two-pass
continuous caste
Guangdong Huafa Metal Products Co., Ltd.
R6
two-pass
continuous caste
Indonesia Delong Steel Mill
R6
two-pass
continuous
caste
Zhejiang Mingtai Iron & Steel Co., Ltd.
R6
two-pass
continuous caste
Guangxi Qinzhou Hengrong Iron & Steel Co., Ltd.
R6 two-pass continuous caste
Guangdong Zhongrun Steel Industry Co., Ltd.
R6 four-pass continuous caster
Indonesia
First
Source
Steel
continuous caster
89
Co.,
Ltd.
R6
three-pass
R6 two-pass continuous
caste
Thailand Taifengrong Steel Mill
R6
three-pass
continuous
caster
Shandong Dazong Machinery Casting Co., Ltd.
R6 three-pass continuous caster
Chongqing Yonghang Metal Products Co., Ltd.
R8 four-pass continuous caster
Technical Specification For The 10T Electrical Furnace
with Variable Frequency and Energy Conservation
1. General description
1.1 KGPS series integrated thyristor medium frequency power supply
is to rectify 50 Hz or 60 Hz alternating current into direct
current fully controlled by an ordinary thyristor, after the
ripple
is
filtered,
inverted
to
be
150HZ~10000HZ
by
fast
1250
50
Controlled
Controlled
Rated output Power (Hz)
Frequency converter
Water cooling
inverter
trigger
circuit
adopts
automatic
frequency-
adopts
large-scale
phase-shifting
90
rectifying
trigger
Mechanical
characteristics:
transparent,
clear,
deposit
free
(screen size of 0.38 inch), total solid content not over 250ml/L.
Chemical characteristics: at hardness of 8DH, PH value is 7.8;
Chloride
100 mg/L;
Nitrite (NOR2R)
0.04 mg/L;
Iron sulfur
0.3mg/L;
Mn
0.05 mg/L;
250 mg/L;
Resistivity: 2500.cm
Water inlet temperature: not lower than 5, not higher than 35,
the internal part of water cooling component is not scaled. When
supplying
water
on
hot
day,
it
is
important
to
avoid
following table:
Medium
frequenc
y
melting
furnace
Rectifor
mer
ton
ton/h
ton/h
MPa
1012
1600
6.5
100
0.2
40
water
Temperature rise
The inductor voltage
The inside diameter
The total height of the inductor
Power consumption for steel of per
V
mm
mm
Degree/ton
20
3200
1400
2000
660
ton(continuous casting)
Turndown mode
Hydraulic turndown
Model
Winding structure
ZS-6300
D/d/yRnR11
Secondaly
side
/Y
duplex
Total capacity
KGPS
6300
Primary voltage
Secondary voltage
KV
A
20
1000
Power range
Inlet wire voltage
Maximum inlet wire voltage
Rectification pulse
Cooling
Flow capacity
Pressure
water
Temperature of the inlet
KW
V
A
pulse
ton/h
MPa
35005300
1000
1820
12
50
0.1
35
water
Temperature rise
Intermediate frequency voltage
IF-FRE
V
Hz
15
1600
500+50
working.
4. Structural description
4.1 Series structure and appearance of power supply cabinet
The series structure of the medium frequency device comprises of
four parts, as shown in Fig. 1: rectifier cabinet, inverter
cabinet, capacitor cabinet and melting furnace, of which the
rectifier cabinet and inverter cabinet are the core of the whole
system, collectively known as power supply cabinet that plays the
role of converting power frequency voltage to medium frequency
voltage.
Input
AC
Invert
er
cabin
et
Rectif
ier
cabin
et
Capa
citor
cabin
et
Meltin
g
furna
ce
uses
indicator
parallel
lamps,
dual-cabinet.
operating
Corresponding
buttons
and
instruments,
power-regulation
94
Protection lamp
Control ON
Control OFF
Energy storage
Main power supply ON
Main power supply OFF
Power measuring knob
Reset
2 Incmoing line voltage 2
1 Incmoing line voltage 1
4.2 Description of operation door components
Totally 8 monitoring instruments,
Upper row from left to right:
DC voltmeter of rectifier 1 output;
DC ammeter of rectifier 1 output;
Medium frequency ammeter of inverter 1 output;
Medium frequency voltmeter of inverter synthetic output;
Lower row from left to right:
DC voltmeter of rectifier 2 output;
DC ammeter of rectifier 2 output;
Medium frequency ammeter of inverter 2 output;
Medium-frequency frequency meter of inverter synthetic output;
Totally 4 indicator lamps:
From left to right:
Control power lamp; main switch lamp 1; main switch lamp 2;
protection lamp
Totally 6 operating buttons:
From left to right, from up to down:
Control ON (green)
Energy storage (green)
Main power supply ON (green)
Reset (red)
Frequency meter
Control Panel
Locking
hole
Water
inlet
pressure
of
medium
frequency
cabinet
and
Resistance
between
primary
and
secondary
sides
of
98
6. Operating sequences
* The device is strictly prohibited starting with empty furnace,
and the furnace must be charged in order to start properly.
* It is prohibited that the furnace can not be emptied when there
is output power, that is to say, when discharging molten steel,
the potentiometer must be adjusted anti-clockwise back to zero.
6.1 Turn anticlockwise the power-regulation potentiometer on
the door of medium frequency power supply cabinet to the end, then
press Control power ON button, so that the control system is
powered on. Observe that the indication of +24V voltmeter on
control cabinet panel is between 18V and 28V, and that inverter
pulse lamp should be fully lighted.
6.2 Press Reset button, then the red lamp on the control panel
shall be extinguished, but the red lamp on the door is still
bright, this is because KP inspection board locks the rectifier
pulse and lightens the protection lamp.
6.3 Press and hold the Pre-storage energy button, then the
protection lamp is extinguished, and rectifier pulse lamp is
fully bright. After releasing the button, the storage motor
actuates, with energy storage in place. If the motor fails to
actuate after releasing the Pre-storage energy button and
the protection lamp is re-lighted, it shall check if KP and its
resistance-capacitance absorption components are normal, if
there are problems on lack of phase, phase-to-phase short
circuit or short circuit to ground at the joint of main switch.
6.4 Press the Main power supply ON button, then the main
switch is turned on. Now DC voltmeter shall be reversal of
biasing.
6.5 Turn clockwise Power-regulation potentiometer slowly, to
observe that the Fmin lamp (frequency low lamp) in the control
cabinet should be flashing, which indicates startup of inverter
99
output
also
will
oscillate
up
and
down,
silicon
is
extinguished.
If
any,
please
ask
the
electrician to check.
After protection is presented, it shall be aware of whether there
is any ignition, water leakage and other abnormal phenomenon, if
no abnormity, and the status indicator lamp of controlled silicon
and pulse lamp are normally lighted, then press the "Reset" button
so that the protection lamp is off, re-test the machine. If there
will be repeated several times to protect, it should shut down and
ask the electrician to check the problem.
During operating of the device, if such phenomenon as water
leakage or blocking in water circuit and water cooling components
are detected, it shall shut down and check and repair immediately,
after the problems are eliminated, it can be continued to use.
In order to ensure safety in production, the power operators
should put a dry wood plate at the feet, and the furnace operators
should put a rubber insulating mat at the feet to prevent electric
shock accident caused by electrical leakage.
7. Introduction to functions of control circuit board:
For following introduced component names and their distribution
positions on the control panel, please refer to hereinafter
attached control circuit board function distribution drawing.
Functions of potentiometer:
P2: over-current 2 potentiometer, set the protection value
of over-current 2, increased in clockwise rotation, in reverse
reduced.
P3: 2=0potentiometer, angle is reduced in clockwise
rotation and pulse moves forward; angle is increased in
anticlockwise rotation and pulse moves backward.
P5: current limiting potentiometer, current limiting value
101
increased
in
clockwise
rotation
and
reduced
in
anticlockwise rotation.
Introduction to functions of control panel:
L1: over-current 2 protection lamp of rectifier 2;
L2: current limiting 2 lamp of rectifier 2;
L3: emergency stop lamp: when pressing the emergency stop
button, the equipment stops emergently in the condition of
protection.
L4: KP protection lamp;
L5: water circuit protection lamp: when water pressure is
too low or water temperature is too high, the equipment will
shut down automatically, and this lamp will be lightened.
L6: +12V indicator lamp;
102
oscillator
is
drawn
back
to
the
highest
frequency.
L16: large angle lamp: when the phase-locked angle of
inverter is more than the set value, this lamp will be
lighted. Meanwhile, the current limiting value will be
reduced to an appropriate value, so that the phase-locked
tracking circuit may be returned to the stable condition.
103
over-current
halving
inspection
switch,
when
current
sharing
switch,
over-current
halving
inspection
switch,
when
inverter
starting
switch,
when
switching
on,
the
Frequency-sweeping
self-starting
switch,
the
self-
During
normal
working,
it
should
regularly
check
the
eliminate it immediately.
2. A drainage valve is normally mounted on the end of water
inlet pipe. Drain off the water regularly so as to remove the
solid sundries and sludge accumulated in the pipes.
3. For hard water or with more solid particles (i.e. more
turbid), the surface inside of water circuit and component
radiator is liable to scale, so it must flush the water circuit
and replace the radiator regularly.
Circuit:
1. During normal working, regularly check the conditions of
relevant indicator lamps (such as resistance-capacitance
absorption
board,
pulse
transformer)
in
the
electrical
During
normal
working
process,
regularly
test
the
Check
and
electrical
see
if
cabinet
the
are
electrical
loose,
connections
heating
or
in
the
discharging
frequently.
5.
Under
the
condition
of
shutdown,
regularly
check
the
Arrange
full-time
personnel
to
be
responsible
for
2. Use air pump to blow off the conductive dust on the surface
of sensor; use magnet to absorb the iron chips between coils of
sensor.
3. Check the fixed screws of bakelite column of sensor and see
if they are loose, and check whether the magnetic yoke post rod
is loose.
4. Check the water circuit, if the water flow of some circuit
is too small, or if water connector leaks.
5. During production process, if the sensor has discharge
ignition, resulting in carbonizing and darkening on the edge of
mica plate, on the side of bakelite column and on the surface
of coated sludge, it must use a knife to shave the blackening
layer clearly. The bare copper exposed on the surface of copper
pipe due to discharge shall be brushed a layer of insulating
paint after worn flat by sand paper.
6. When deslagging or tapping every time, providing that the
furnace panel is not set level, it shall turn off the fan on
the furnace platform, so as to prevent the iron chips being
blown into the sensor.
7. Steel tapping must be carried out after shutdown. After
tapping, it shall charge completely before starting. Starting
with empty machine is prohibited.
9. Reference waveform
9.1 Rectifying pulse:
Characteristics: dual modulation pulse, interval 60 between
two pulses, each modulating pulse is a sequence composed of 4~8
small pulses, with total width of about 1000S. As general
pulse amplitude of 3~6V, the width of small pulse should be
more than 80S.
106
the
power-regulation
potentiometer
increases
to
the
lamp
on
KP
inspection
board
is
extinguished.
After
oscillating
and
point
to
the
appropriate
position,
to check.
10.7 Shutdown sequence:
10.7.1
Turn
back
the
power-regulation
potentiometer
anti-
clockwise;
10.7.2 Press the Main power supply OFF button, the main switch
is disconnected;
10.7.3 Press the Control power supply OFF button, the control
power supply is powered off.
Instructions:
For this device, after main circuit is powered on, each working
status lamp of controlled silicon (located on the resistancecapacitance absorption board) should be lighted, otherwise, please
ask the electrician to check.
During working process, when the protection lamp on the door
is light, it shall record which red lamp is lighted on the control
panel, and observe if the status indicator lamp of controlled
silicon is extinguished. If any, please ask the electrician to
check.
After protection is presented, it shall be aware of whether there
is any ignition, water leakage and other abnormal phenomenon, if
no abnormity, and the status indicator lamp of controlled silicon
and pulse lamp are normally lighted, then press the "Reset" button
so that the protection lamp is off, re-test the machine. If there
will
be
repeated
several
times
to
protect,
please
ask
the
109
Circui
Synchr
111
Rectifying
phase-shifting
angle
Rectifier
bridge
voltage waveform
output
112
Spare
L3
Water
pressure L5
Overcurrent 2
Sub-lower
limit
Abnormal
medium
frequency
Medium
frequency
Voltage
limiting
Trigger pulse
Trigger pulse
114