Main Pusher

Tunnel-Kiln

Main Pusher System Control

From Kiln Switchboard

Rev. 1.0 02/04/2012

Electro-mechanic Main Pusher

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Summary :

1. Pushing Time Setting

2. Pushing Time Configuration and Commissioning Parameters
3. Alarms and Messages

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1. Pushing Time Setting :

The pushing time setting is performed by the kiln management control system called ‘Praktico’.

The opening screen of Praktico is shown in figure 1.1. It displays the Main Menu, which gives you access to
all the program functions.

Fig. 1.1 – Praktico Main Menu

To access a specific function (Kiln Management, Programs, Autoset or other) just “touch” the screen at the
point where the key indicating the function you wish to use is located.

To enter the section where Pushing Time is setting is available, on Main Menu press ‘Kiln Management’
(central key) to open the related screen.

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 Cycle Time

Fig. 1.2 – Kiln Management

From this screen the Pushing Time (Detected and Setted) is shown with all other process data
(temperatures, Pressures, Flows, etc) in a specific Regulator box :

Regulator code

Cycle Time Detected value (Min)

Cycle Time Set-point (Min)

Actuation percentage (0-100%)

Automatic/Manual Mode

It is possible to change the Cycle Time Set Point (in the same way for temperature and pressure set-
points) directly on the kiln management screen for the program that is running without accessing the
program screen.

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To change a the Set Point, press key on the menu in the background on the screen.

At the top of the management screen, a window opens for data entry similar to the one shown in figure 6.3
representing a regulator and a numeric keyboard.

1.3 Kiln Management – Set Point Modification

The panel for entering and editing the set-point shows the current detected value (at the top) and the
current setting (at the bottom) marked “SP”. This is the value that can be changed using either the numeric
keyboard on the left or the arrows on the regulator.

Press , to cancel the change.

Press , to confirm the change and go on to the next regulator.

The field relative to the set-point of the selected regulator changes color to indicate that you are changing its
value, as shown in Fig. 1.3. You can also edit the set-point of any regulator, without necessarily reviewing all
of them. Just touch the screen on the regulator whose set-point you want to change.

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To save the new values press . To exit without saving press .

The dialogue window shown in the figure appears and asks

you to confirm.

If you answer , you confirm the changes.

Praktico saves and exits the function.

If you answer , Praktico exits the function

without saving the changes.

When you confirm saving data, this makes the changes effective in the current program and the set-points
are transmitted to the regulators (in case single loop controllers are installed) or to the PLC.

The changed set-point is also saved in the program archive.

WARNING!
When you change the kiln settings on the kiln management screen, this effectively changes the
firing program currently running. (*)

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2. Pushing Time Configuration and Commissioning Parameters :

The parameters used for Pushing time configuration and adjustment are setted in a section called ‘Timers’.
Press “Configuration” on the main menu screen to access the Configuration screen, shown in figure 2.1.

Fig. 2.1

From this screen you can access Configuration of the system timers.

To access the timers screen press , then .

Access to this screen is controlled by a Password, so the dialogue window shown in Figure 2.2 appears.

Fig. 2.2

Enter the Password and press .

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If the Password is accepted the required screen appears :

Figure 2.3

On this screen you can enter the time values described on each line of the table.

For every element you can enter the value expressed in the unit of measurement indicated, with the specified
number of decimals (the number of decimals and unit of measurement cannot be modified

The meaning of each timer is illustrated in the “Description” field of the table.

To make a setting press .

This displays a numeric keyboard where you can edit the settings of all the timer.
After selecting the desired Timer, enter the new setting :

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 Figure 2.4

To select the desired timer use the keys (to scroll the Timers one by one).

To scroll more quickly, one screen at a time, use and .

Press to cancel the change.

Press to confirm the change and move on to the next timer.

Introduce the values with the keyboard panel, then press to save the new values. or press

to exit without saving press .

The dialogue window shown in the figure appears and asks

you to confirm.

If you answer , you confirm the changes.

Praktico saves and exits the function.

If you answer , Praktico exits the function

without saving the changes.

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2.1 Settings in Special Configuration, table PARAMETRI CANALE 1:

314_8 Function
1 Enable chain pusher

2.2 Timer List for Pushing Time Configuration and Commissioning :

Some parameters in timer section are used to adapt and modify the reaction of the pushing time regulation
algorithm The following data (divided by function) are setted by commissioning technician (not by final
customer).

MEM 684 - Pusher driver minimun frequency (Hz)

Set the minimum frequency of pusher driver inverter.

MEM 685 - Pusher driver maximun frequency (Hz)

Set the maximum frequency of pusher driver inverter.

MEM 686 - Pusher speed at driver minimum frequency (mm/min)

Set the the detected speed while pusher driver inverter is at its minimum frequency.

MEM 687 - Pusher speed at driver maximum frequency (mm/min)

Set the the detected speed while pusher driver inverter is at its maximum frequency.

MEM 688 - Pusher torque limit for alarm (%)

Set the torque limit of the pusher driver inverter. Over this limit its over-torque alarm is activated.

MEM 689 - Pusher backward frequency (Hz)

Set the frequency of pusher drive inverter during backward operation.

MEM 690 - Pusher feeding driver minimum frequency (Hz)

Set the minimum frequency of pusher feeding inverter.

MEM 691 - Pusher feeding driver maximum frequency (Hz)

Set the maximum frequency of pusher feeding inverter.

MEM 692 - Pusher feeding speed at driver minimum frequency (mm/min)

Set the the detected speed while pusher feeding inverter is at its minimum frequency.

MEM 693 - Pusher feeding speed at driver maximum frequency (mm/min)

Set the the detected speed while pusher feeding inverter is at its maximum frequency.

MEM 694 - Pusher feeding torque limit for alarm (%)

Set the torque limit of the pusher feeding inverter. Over this limit its over-torque alarm is activated.

MEM 695 - Pusher feeding torque limit for slowdown (%)

Set the torque limit of the pusher feeding inverter to slowdown speed.

MEM 696 - Pusher feeding forward additional frequency (Hz)

Set the additional frequency of pusher feeding inverter during forward operation.

MEM 697 - Pusher feeding backward frequency (Hz)

Set the frequency of pusher feeding inverter during backward operation.

MEM 698 - Pusher feeding backward slowdown frequency (Hz)

Set the frequency of pusher feeding inverter during backward slowdonw operation.

MEM 699 - Pusher feeding slowdown time (sec)

Set the time after which pusher feeding inverter slowdonw speed during backward operation.

MEM 700 - Wagon hook failure time (sec)

Set the time after which wagon hook failure alarm is activated.

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2.3 Corrispondence Praktico Timers – Siemens TP project :

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3. Alarms and Messages :

During the operation in case alarms or failures happen at main pusher management or regulation, some
messages are shown in the Alarm section.

On the Main Menu screen press ‘ALARM’, to go directly to the screen of active alarms, shown in figure 3.1.
This screen displays all the ACTIVE alarms only.

Figure 3.1

For every active alarm the following data are displayed:

Start: Instant in which the alarm started.

Where: Part of the kiln where the alarm occurred.
ID: Identification code of the alarm.
What happened: Description of the alarm.

To scroll the list of active alarms use . If the list of active alarms does not fit on a

signal screen, to scroll the other screens use or

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3.1 Alarms list for Main Pusher Management :

ID1703 - EMERGENCY PRESSED ON PUSHER PANEL

Emergency push-botton has been pressed on main-pusher switchboard.
Release the emergency push-button.
Press reset emergency on main-pusher swichboard.
Reset the alarm on kiln switchboard (from Praktico) or use push-button on main pusher switchboard.

ID1705 - MOTION IN EMERGENCY STATE

Emergency circuit on trasfert system has been activated.
Check and remove the cause.
Reset the alarm on kiln switchboard (from Praktico) or use push-button on main pusher switchboard.

ID1717 - ALARM MODULE PROFIBUS

Profibus station in the main-pusher switchboard is out of order.
Check 24Vcc power supply, check the cable connection, check or replace CPU or station units.
Reset the alarm on kiln switchboard (from Praktico) or use push-button on main pusher switchboard.

ID1724 – PUSHER 1 OVER-CURRENT

Pusher drive inverter detect too high current.
Check current limit into inverter parameters, check the drive system.
Reset the alarm on kiln switchboard (from Praktico) or use push-button on main pusher switchboard.

ID1748 - INPUT/OUTPUT ANOMALY PROFIBUS NODE

A profibus inputs-outputs module in the profibus station is out of order.
Check 24Vcc power supply, check the connection, check or replace the module.
Reset the alarm on kiln switchboard (from Praktico) or use push-button on main pusher switchboard.

ID1907 - PUSHER POWER FAILURE

24V power supply is missing.
Check 24V power supply.
Reset the alarm on kiln switchboard (from Praktico) or use push-button on main pusher switchboard.

ID1908 – PUSHER SWITCHBOARD OVER-TEMPERATURE

Temperature inside pusher switchboard is too high.
Check thermostat setting (must be within 35-45 °C), check the switchboard cooling system (fan or
conditioner).
Reset the alarm on kiln switchboard (from Praktico) or use push-button on main pusher switchboard.

ID1909 – WAGON HOOK FAILURE

Hooking failure of incoming wagon at kiln entrance.
Check the position of incoming wagon.
Reset the alarm on kiln switchboard (from Praktico) or use push-button on main pusher switchboard.

ID1910 – PUSHER DRIVE OVER-TEMPERATURE

Pusher drive thermistor detect too high temperature.
Check thermistor setting, check the drive system.
Reset the alarm on kiln switchboard (from Praktico) or use push-button on main pusher switchboard.

ID1911 – PUSHER DRIVE OVER-TORQUE

Pusher drive detected torque exceed the limit set in Praktico (MEM 688).
Check over-torque limit, check the drive system.
Reset the alarm on kiln switchboard (from Praktico) or use push-button on main pusher switchboard.

ID1912 – PUSHER SAFETY SWITCH OFF

Pusher safety switch is switched-off.
Check pusher safety switch.
Reset the alarm on kiln switchboard (from Praktico) or use push-button on main pusher switchboard.

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ID1913 – PUSHER FEEDING OVER-CURRENT
Pusher feeding drive inverter detect too high current.
Check current limit into inverter parameters, check the drive system.
Reset the alarm on kiln switchboard (from Praktico) or use push-button on main pusher switchboard.

ID1914 – PUSHER FEEDING OVER-TORQUE

Pusher feeding detected torque exceed the limit set in Praktico (MEM 694).
Check over-torque limit, check the drive system.
Reset the alarm on kiln switchboard (from Praktico) or use push-button on main pusher switchboard.

ID1915 – PUSHER FEEDING SAFETY SWITCH OFF

Pusher safety switch is switched-off.
Check pusher safety switch.
Reset the alarm on kiln switchboard (from Praktico) or use push-button on main pusher switchboard.

ID1916 – PUSHER LEFT SIDE EMERGENCY

Left-side emergency push-botton has been pressed.
Release the emergency push-button.
Press reset emergency on main-pusher swichboard.
Reset the alarm on kiln switchboard (from Praktico) or use push-button on main pusher switchboard.

ID1917 - PUSHER RIGHT SIDE EMERGENCY

Right-side emergency push-botton has been pressed.
Release the emergency push-button.
Press reset emergency on main-pusher swichboard.
Reset the alarm on kiln switchboard (from Praktico) or use push-button on main pusher switchboard.

ID1923 – NO CAR SPACE AT KILN INPUT

Wagon size too big at kiln entrance.
Check incoming wagon.
Reset the alarm on kiln switchboard (from Praktico) or use push-button on main pusher switchboard.

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