四班汇总-车辆培训空调系统

CommissioningCommissioningCOPYRIGHTBYSHANGHAIFAIVELEYRAILWAYTECHNOLOGY所所Essentialparts arecopyrightedandalltherights maynot,inwholeorinpart,becopied,photocopiedorreproducedwithoutwrittenpermissionfromSHANGHAIFAIVELEYRAILWAYTECHNOLOGYCo.该文件的总体或部分法维莱交通车辆不被拷贝，影印或ReleasePreparedby：HeCheckedby：YanCheckedby：WeiWangWeiRevisionTable：修订修日Revised修正部issue初版公部WolfgangWeiTableofGeneral概 Introduction说 Procedure基本过 Preparations准 SaloonPreconditionsforcommissioning调试准 SaloonVisualcheck机组外观检 SaloonOverviewaboutcomponentsanddevices机组设备及原 SaloonVisualcheckofmechanicalcomponents机组机械部件的检 SaloonVisualcheckofelectricalcomponents机组电气部分的检 SaloonInstruction机组指 SaloonCheckingsoftwareversionsandSettingtheRealTimeClockru版本及控制器的时的检查和设 Saloon og 检查机组模拟量输 SaloonCheckingDigitalOutputs检查机组数字量输 InstructionDatasheettofillin(returntoSFRT)（返回 General概Thepurposeof istotestfollowingsystem-ConnectionbetweenPLCandsystemcomponents(carwiring)控制系统与空调Introduction说Safetyinstruction安全说明Operation,maintenanceandrepairworkontheequipmentaretobecarriedoutsolelycompetent al.设备的操作、、维修需由合格的技术工人执行Validstandardsandsafetyspecificationsaretobeobserved!遵守有效的标准和Theserviceprogrammayonlybeoperatedbyskilledandnelthesystem'ssafetydevicesareoffintheSERVICEMODEandoperatingmaydamagecomponentsorthesystemasa空调系统运行模式”时，系统的安全保护功能失效，任何误操作将会损坏设备至整个系统，因此只有熟悉系统或者经过培训 才能使 进 Purposeofthefunctionalcheckisthetestofeachsinglecomponentanditsrighectricalconnectiontothepowersupplyandtothecontrollingdevices.检测各功能块的目的是为了测试每个独立的部件及其电气原件是否正确连接到电源盒控制系Basisofthischeckisadetailedinstructionforeachtest-step(setintooperationinstruction).Allstepswillbedonebyusingaservice-PC(laptop),whichisconnectedtotheFAIVELEY每个部件的检测都有详细的说明，所有的测试需使用电脑来连接到法维莱的控制Maincontentsofthefunctionalcheckare主要部件功能测试Checkofsensors检查温度感应Checkofmonitoringfunctionsanddigitalinputs检查和数字量输入模Checkofdigitaloutputsandcontactorsandfunctionalcontrolofeachcomponents检查数字Checkofmanualfunctions检测手动Checkofsafetydevices检查ProcedureACsystemsincorporateclimatecontrollersandrequirecomponenttestsforproperstartupusingalaptop/PConwhichaspecificserviceprogram(monitor)formaintenanceandcommissioninghasbeeninstalled.TheprograminteractswiththecomputerviaanEthernetcable(NormalRJ45).了空调PTE的笔记本电脑,其与控制器的接口为RS232或RJ45。Preparations准Wiringbetweencontrollerandthecontrolpanelisincompletedandhasbeentested.Therefrigerantcircuithasbeenchargedwithspecifiedrefrigerant.Tools工Technicalpreconditionsandtoolsare调试开始前需要准备下列工具Multi-meterneededrangeofcurrent万用表(测试范围Current0.1Ato50AAC0.1Ato20ADC交流电流0.1Ato50A,直流电流0.1AtoVoltage0.1Vto500VAC0.1Vto150VDC0.1Vto500V，直流电压0.1Vto150VClampmeter钳型表Current0.1Ato50AAC0.1Ato20ADC交流电流0.1Ato50A直流电流0.1AtoPCLAPTOPwithreadyinstalledmaintenancesoftwareinminimalConfiguration准备Pentium200MHzorequal,32MBRAM奔腾200MHzorequal,32MB内Display256colors800x600256色显示器Serialport,UART串行端口CD-ROMdriveforinstallation)光Windows98secondedition)orhigherNT4.0,2000XP)Windows98系统或者更Internetexplorer5.5orhigher(internet5.5或者更高Externalmouseoptional)鼠标（可选Maintenancesoftware(tobeupdated)（可更新onewirelinktoconnectterminalsonswitchboard(1.5sqmm,wirewithferrule20cmortestleads)用于连接端子的跳接线(1.5sqmmEthernetCable(normalRJ45)网screwdriver3mmisolatedrequiredsetofscrewdriveroptional螺丝3mm,带绝缘(必须),最好有一套螺丝刀ApplicationSoftware应用File文件名TobeMaintenanceCD,last 光Electricalinterface电气接口文件:KA57-Electricschematic电气原理图KA57_WiringEquipmentsoverview设备概述KA57_BlockSoftwarespecification规范:KA57-SaloonPreconditionsforcommissioning调试准Required1380VAC=OFFAllcomponentsoftheairconditioningsystem,includingductsystemmust connectionsandgroundingmust□ 所有和空调系统有关的设备，括风道已完全安装固定好。电气连接及接已完成2Theinsulationcheckofcarwiringtestedsuccessful空调机组经过检successfulfinished检验合格□告3Theelectricalsystemsupplymustavailable(110VDC,3x380VAC)电源系Commissioningreportavailableandsuccessful□正常(直流110V，交流finished检验4380VAC=OFFThecomponentsoftheairconditioningalsototheaccessibilityofthe□unitontopofthe 空调系统须能够。这也适用于车顶部的空调机无5MaintenancecoversopenedbyHVACunit ThecoverscanbeopenedonlywhentheHVACunitpoweredoff.机组盖只有在空□terminals)机组盖通过空调机组和控机组关闭的时候才能打开柜打开6Ambienttemperatureofthecarisatleast10°C,nocondensationonelectricalcomponents/terminals车厢□温度不低于10°C，没有凝结的电气原件/子SaloonVisualcheckForvisualcheck,allsupplyvoltageshallbeswitchedOFF(3x380VAC,110V检查外观是所有的电源必须关闭（3x380VAC,110VSaloonOverviewaboutcomponentsanddevicesFigure2-1:GeneraloverviewoftheComponents部Components部1热力膨胀48单向22通风29避震软23蒸发2干燥过滤24液路电磁2低压开25压缩2冷凝26高压开2冷凝风27针6Location/7380VAC=OFFHVACunit空调机Unitwellmounted,safetypartsOK(novisibledamages)可靠安装固定，正常（无可见损坏□8Checkforfreeroof□9Compressors压缩OillevelisOKcomparefigure可靠安装固□Cornershut-offvalve(usedoubleopenendwrench)(comparefigure)□Condenserfans冷凝风Freerunpossible可转□Location/Returnairfans回风Freerunpossible转□Supplyfans送风Freerunpossible转□Generally一般Checkforfixationofallparts.检查所有部件安装Lookforlosttoolsorfottenmaterialproductio.检查现场是否有生产遗留。□Ductsystem管道系Tightnessoftheducts,break-freepipes,isolationcompley管道过紧，管裂，密封分离□SaloonVisualcheckofelectricalcomponentsLocation/380VAC=OFFHVACunit空调机PlugsofHVACunitareconnected空调机组□EarthconnectionofHVACunit空调机组接正□Controlpanelinterfaceinthecar车厢内的控制接Powersupplyfromelectricalsystemofcar接口端子:(T01:1,2,□EarthconnectionofcontrolpanelVACareconnected控制板接地正□Controllerplugsandearthconnection控制器连接器和接Plugofcontrollerunitareconnected控制器好□PTEconnectionisreadyforTCcarsPTE连客户□Earthconnectionofcontrolleris控制器接地正□Earthconnectionofcontrolpanelisconnected.控制盘接地正确□SaloonInstruction机组指步Activity动Response/PC-display响应/显AC=Requirements要求Supplyvoltagefor VDC)isavailable控制器电源可□380VAC=380VACavailableoncar,switchedOFF交流380V可用且关110VDCavailableoncar,switchedOFF直流110V可用且关LaptopconnectedviaCable膝上电□Checkphasesequenceforsupply380VAC检查交流380V电源T01:1isT01:2isL2T01:3isL3Makesurephasesequenceis□CheckAC380Vphasesequenceeveryequipment检查每个部件交流电源380VForexample,forU1QF11:1isL1QF11:3isL2QF11:5isL3KM11:1isL1KM11:3isL2KM11:5isMakesurealltheequipmentshavebeenchecked.确保所有设备已检Makesurephasesequenceis□□Checkpolarity检查正负极:Polarityiscorrect极性正□T03:2=(-)110Vvoltageis110VDC电压为直流110V,thenswitchon110Vfromtrain开来自车体Checkpower检查电源LEDofthecontroller控制器的LED灯If110VDCsupplyforcontrollerisavailable,thepowerLEDofthecontrollerwillbeON.如果□电源可用，LED灯亮步Activity动Response/PC-display响应/显CheckiffollowingallprotectivedeviceareswitchedONandsetinstateON检查以下保护器打开且设定Checkifallareactivated.检查所有□SaloonCheckingsoftwareversionsandSettingtheRealTimeClockru 步Activity动Response/PC-display响应/显Requirements要求SupplyvoltageforcontrollerVDC)isavailable控制器110V电SwitchON110Vfromtrain.打的电可Howtofindactualsoftware如何PleaserefertoVersionDescription(KA57_VDDlastestvalidissue,请参考版本描述文件Tofindatbasketofsoftwarequalitys找到质量件到的Checkifmaintenancesoftwarehasalreadybeeninstalledo/检查已经安装到电脑Pleasereferto“maintenancesoftwarecustomerhandbook”,Tofindatbasketofsoftwarequalitys请参考客□380VAC=CheckifinterfacecablebetweenIPswitchandPCisOK检查IP开□ChecksoftwarestatusSelectSerialPort选择用户端口状startmaintenancesoftware开Password□操Press点CheckPLCsoftwareversionis检查PLC版本为“1.00”□ComparetoFigure3-1比较图3-Ifapplicationsoftwareversionisnotcorrect如果版本不正确latestapplicationsoftwareshouldbedownloadedintothecontroller.需要的应用程□Figure3-1OverviewofsystemandapplicationFigure3-2I/OSaloon og 步Activity动Response/PC-display响应/显380VAC=OFFCheckofogueinputswithFigure3-IBSview)检查模拟量输入如图示3-AI_01_U1_RAS(U1ReturnairT°sensor机组1的回风温度传感Checktemperature查看温Usecoolingspray使用冷却喷Checktemperatureagain再次查看温Theresultshallberealinsidetemperaturevalue.温度值为真实ForexampleTendency趋势Temperaturegoesdown温度降□AI_02_U1_SAS(U1SupplyairT°sensor机组1的送风温度传感Checktemperature查看温Usecoolingspray使用冷却喷Checktemperatureagain再次查看度Theresultshallberealinsidetemperaturevalue.温度值为真实ForexampleTendency趋势Temperaturegoesdown温度下□步Activity动Response/PC-display响应/显AI_04_U1_FAS(U1FreshairT°sensor机组1新风温度传感Checktemperature查看温Usecoolingspray使用冷却喷Checktemperatureagain再次查看温Theresultshallberealinsidetemperaturevalue.温度值为真实ForexampleTendency趋势Temperaturegoesdown温度下□AI_05_U2_RAS(U2ReturnairT°sensor机组2的回风温度传感Checktemperature查看温Usecoolingspray使用冷却喷Checktemperatureagain再次查看温Theresultshallberealinsidetemperaturevalue.温度值为真实ForexampleTendency趋势Temperaturegoesdown温度下□AI_06_U2_SAS(U2SupplyairT°sensor机组2的送风温度传感Checktemperature查看温Usecoolingspray使用冷却喷Checktemperatureagain再次查看温Theresultshallberealinsidetemperaturevalue.温度值为真实ForexampleTendency趋势Temperaturegoesdown温度下□AI_08_U2_FAS(U2FreshairT°sensor机组2的新风温度传感Checktemperature查看温Usecoolingspray使用冷却喷Checktemperatureagain再次查看温Theresultshallberealinsidetemperaturevalue.温度值为真实ForexampleTendency趋势Temperaturegoesdown温度下□步Activity动ResponsePC-display响应/显Checkofrelayoutputs检查继电器输出:(ATTENTION主要!alllogicalsafetyfunctionsareduringservicemode所有的逻辑安全功能模Justgetready□步Activity动ResponsePC-display响应/显SetOP_Levelto设定操作等级ClickButton点击按钮“ForceI/OModeCheckLEDofthebuttonisgreen检查按钮的LED灯为绿色CheckcurrValueiscuurValue“10”ThatmeansPLCisinForcingMode表示PLC是处于强制模□□Checkforstatusofeachfollowdevice检查OnlyifallcontactorsareswitchedOFF,realizenextstep.只有接触器是处于断开状□Switchon380VAC打开交380V电□380VAC=Connect短接–T04:9-10Connect短接–T04:25-26Turnon打开QF11ForceDQ_01_U1_CPR1=1L(Unitcompressor1contactorKM11机组1压缩1接触器KM11输出Check检查DI_01_U1_HP1Check检查DI_06_U1_CPR1ForceDQ_01_U1_CPR1=Check检查DI_01_U1_HP1CheckDI_06_U1_CPR1Removeconnectionon移除短接–T04:9-10Removeconnectionon移除短接ContactorKM11isONandcompressorrunningdirectionisright(alignwitharrowdirectiononthesheetmetal)接触器KM11吸合且压缩机直接DI_01_U1_HP1=DI_06_U1_CPR1=ContactorKM11isOFF接触器KM11断开DI_01_U1_HP1=0LDI_06_U1_CPR1=0L□□□□□□步Activity动ResponsePC-display响应/显Connect短–T04:11-12Connect短接–T04:27-28Turnon打开QF12ForceDQ_02_U1_CPR2=1L(Unitcompressor2contactorKM12机组1压缩机2接触器KM12输Check检查DI_02_U1_HP2Check检查ForceDQ_02_U1_CPR20LCheck检查DI_02_U1_HP2Check检查Removeconnectionon移除短–T04:11-Removeconnectionon移除短接–T04:27-ContactorKM12isONandcompressorrunningdirectionisright(alignwitharrowdirectiononthesheetmetal)接触器KM12吸合且压缩机直接DI_02_U1_HP2=1LDI_07_U1_CPR2=1LContactorKM12is接触器KM12断开DI_02_U1_HP2=0L□□□□□□380VAC=Turnon打ForceDQ_03_U1_CDF1=1L(Unitcondenserfan1contactorKM13output)冷机组1凝风机1接触器KM13输出CheckForceDQ_03_U1_CDF1=0LCheck检查DI_03_U1_CDF1ContactorKM13isON.接触器KM13吸合DI_03_U1_CDF1=1LContactorKM13isOFF接触器KM13断开DI_03_U1_CDF1=0L□□□□Turnon打ForceDQ_04_U1_CDF2=1L(Unit1condenserfan2contactorKM14output)机组1凝风机1接触器KM14输出CheckForceDQ_04_U1_CDF20LCheck检查ContactorKM14isON.接触器KM14吸合DI_04_U1_CDF2=1LContactorKM14is接触器KM14断DI_04_U1_CDF2=□□□□步Activity动ResponsePC-display响应/显380VAC=Turnon打ForceDQ_05_U1_SAF1=1L(Unit1supplyairfan1contactorKM15output)机组1送风机1接触器KM15输CheckForceDQ_05_U1_SAF1=0LCheck检查DI_08_U1_SAF1ContactorKM15isON.接触器KM15吸合DI_08_U1_SAF1=1LContactorKM15is接触器KM15断DI_08_U1_SAF1=□□□□Turnon打ForceDQ_06_U1_SAF2=1L(Unit1supplyairfan2contactorKM16output)机组1送风机2接触器KM16输CheckForceDQ_06_U1_SAF20LCheck检查ContactorKM16is接触器KM16吸DI_09_U1_SAF2=ContactorKM16is接触器KM16断DI_09_U1_SAF2=□□□□contactorKA1output)紧急控制继电器KA1输Turnon打QF17andCheck检查DI_05_U1_EMTurnoff关闭QF17orQF18Check检查DI_05_U1_EMTurnon打开QF37andCheck检查DI_19_U2_EMTurnoff关闭QF17orQF18CheckForceDQ_07_EM=ContactorKA1is继电器KA1动作DI_05_U1_EMDI_05_U1_EM=DI_19_U2_EM=1LDI_19_U2_EM=□□□□步Activity动ResponsePC-display响应/显380VAC=ForceDQ_08_U1_FADO=Check检查–T04:2and–T04:1ForceDQ_08_U1_FADO=0LCheck检查–T04:2and–T04:1RelayKA2isON继电器KA2动作DC110Visdetected110VRelayKA2is继电器KA2关NoDC110Vis110V断□□□□380VAC=ForceDQ_09_U1_FADC=Check检查–T04:3and–T04:1ForceDQ_09_U1_FADC=0LCheck检查–T04:3andRelayKA3is继电器KA3动作DC110Visdetected110VRelayKA3is继电器KA3关NoDC110Vis110V断□□□□ForceDQ_10_U1_RADC=Check检查–T04:4and–T04:1ForceDQ_10_U1_RADC=0LCheck检查–T04:4andRelayKA4is继电器KA4动作DC110Visdetected110VRelayKA4is继电器KA4关NoDC110Vis110V断□□□□380VAC=Connect短接–T06:9-10Connect短接–T06:25-26Turnon打开QF31ForceDQ_11_U2_CPR1=1L(Unitcompressor1contactorKM31机组2压缩机1接触器KM31输Check检查DI_26_U2_HP1ForceDQ_11_U2_CPR1=0LCheck检查DI_20_U2_CPR1Check检查DI_26_U2_HP1Removeconnectionon移除短接–T06:9-10Removeconnectionon移除短接ContactorKM31isONandcompressorrunningdirectionisright(alignwitharrowdirectiononthesheetmetal)DI_20_U2_CPR1=1LDI_26_U2_HP1=1LContactorKM31is接触器KM31关闭DI_26_U2_HP1=0L□□□□□□Connect短–T06:11-12Connect短接–T06:27-28Turnon打开QF32ForceDQ_12_U2_CPR2=1L(Unitcompressor2contactorKM32机组2压缩机2接触器KM32输Check检查DI_21_U2_CPR2Check检查ForceDQ_12_U2_CPR20LCheckDI_21_U2_CPR2Check检查DI_27_U2_HP2Removeconnectionon移除短–T06:11-Removeconnectionon移除短ContactorKM32isONandcompressorrunningdirectionisright(alignwitharrowdirectiononthesheetmetal)接触器KM32吸合压缩机直接运DI_27_U2_HP2=1LContactorKM32isOFF接触器KM32关闭DI_21_U2_CPR2=0LDI_27_U2_HP2=0L□□□□□□Turnon打ForceDQ_13_U2_CDF1=1L(Unit2condenserfan1contactorKM33output)机组2冷暖风机1接触器KM33输出Check检查DI_17_U2_CDF12ForceDQ_13_U2_CDF10LCheck检查ContactorKM33isON.接触器KM33吸合DI_17_U2_CDF1=1LDI_17_U2_CDF1=0L□□□□Turnon打ForceDQ_14_U2_CDF2=1L(Unit2condenserfan2contactorKM34output)机组2冷凝风机2接触器KM34输出Check检查DI_18_U2_CDF2ForceDQ_14_U2_CDF20LCheck检查ContactorKM34isON.接触器KM34吸合DI_18_U2_CDF2=1LContactorKM34isOFF接触器KM34断开DI_18_U2_CDF2=0L□□□□Turnon打ForceDQ_15_U2_SAF1=1L(Unit2supplyairfan1contactorKM35output)机组2送风机2接触器KM35输CheckForceDQ_15_U2_SAF10LCheck检查ContactorKM35isON.接触器KM35吸合DI_22_U2_SAF1=1LContactorKM35isOFF.接触器KM35断开DI_22_U2_SAF1=0L□□□□380VAC=Turnon打开ForceDQ_16_U2_SAF2=1L(Unit2supplyairfan2contactorKM36output)机组2送风机2接触器KM36输CheckForceDQ_16_U2_SAF20LCheck检查ContactorKM36isON.接触器KM36吸合DI_23_U2_SAF2=1LContactorKM36isOFF.接触器KM36断开DI_23_U2_SAF2=0L□□□□ForceDQ_17_U2_FADO=Check检查–T06:2and–T06:1ForceDQ_17_U2_FADO=0LCheck检查–T06:2and–T06:1RelayKA6isON继电器KA6动作DC110Visdetected110VRelayKA6is继电器KA6关NoDC110Vis110V断□□□□ForceDQ_18_U2_FADC=Check检查–T06:3and–T06:1ForceDQ_18_U2_FADC=0LCheck检查–T06:3and–T06:1RelayKA7isON继电器KA7动作DC110Visdetected110VRelayKA7is继电器KA7关NoDC110Vis110V断□□□□ForceDQ_19_U2_RADC=Check检查–T06:4and–T06:1ForceDQ_19_U2_RADC=0LCheck检查–T06:4and–RelayKA8is继电器KA8动作DC110Visdetected110VRelayKA8is继电器KA8关NoDC110Vis110V断□□□□ForceDQ_20_U1_RADO=Check检查–T04:5and–T04:1ForceDQ_20_U1_RADO=0LCheck检查–T04:5andRelayKA5is继电器KA5动作DC110Visdetected110VRelayKA5is继电器KA5关NoDC110Vis110V断□□□□ForceDQ_21_U2_RADO=Check检查–T06:5and–T06:1ForceDQ_21_U2_RADO=Check检查–T06:5and–RelayKA9is继电器KA9动DC110Vis110VRelayKA9is继电器KA9关NoDC110Vis110V断□□□□380VAC=Connect短接–T04:13,14Removeconnection移除短CheckDI_10_U1_LP1=1LDI_10_U1_LP1=□□Connect短接–T04:15,16Removeconnection移除短Check检查DI_11_U1_LP2=DI_11_U1_LP2=□□Connect短–T04:17T03:2Check检查DI_12_U1_FADRemoveconnection移除短Chec