Training Material PCS System
Training Material PCS System
Training Material PCS System
Paint circulation
system is mainly to
ensure that the paint in
the pipeline in circulation
and provide a certain
pressure and temperature
of the paint to the spray
gun to meet the spraying
process requirements.
The system is
powered by an electric
pump. The operation
status of each module,
including liquid level,
temperature, stirrer start
and stop, solenoid valve
open and close, electric
pump start and stop and
work mode, outlet
pressure, work pressure
flow can be displayed on
the system monitor
screen.
上汽通用五菱印尼汽车有限公司 PT. SGMW MOTOR INDONESIA
Network Communication
❑ Networking
Between the PLC master station
and the slave station uses between the
ethernet, the PLC and the agitator
frequency changer uses between the
ethernet, PLC and the GRACO
network management uses between the
ethernet, the gateway module and the
ACS module uses the double line 485
communication way, uses MODBUS
agreement. The whole network is a
ring network structure. PLC and clean
room between which the use of fiber-
optic remote communication station.
The electric pump control system in PCS is designed to Hazardous Area Non-Hazardous Area
meet explosion proof safety standards, so that all devices
used have the required safety standards. Functionally, the Inverter
E-Flo pump functions to circulate paint and ensure FREQUENCY SIGNAL IN
pressure and flow are in accordance with the parameters Pressure FREQUENCY SIGNAL OUT
set, as follows is an electric pump control system. tranducer
Safety barrier ACS Module
a. Electric pump Electric
TDC Sesor
RS485
POS Sensor
explosion proof design which is used to circulate paint Thermistor
Rellay
PTC Sensor
from the mix room to the robot.
b. Sensor Gateway
• Top dead center (TDC) sensor is used to measure
motor speed,
• position sensor (POS) is used to determine the position 1763 - ETAP
of the motor
• pressure transducer (PT) is used to measure paint
pressure at the pump outlet Ehernet IP
DIGITAL OUTPUT
PLC
DIGITAL INPUT
motor is overheating,
• These three sensors will send feedback to the ACS 1756-L72
Control
module through the safety barrier and the PTC sensor logix5572
for safety from the motor will be connected to the PLC controller
via the thermistor relay.
Circulation
Circulation tank agitator and mix circulation pump agitator
function to keep the paint in the tank circulating or not
settling to avoid paint clumping, as well as the agitator Mix
Inverter Inverter
control device. circulation
pump
Ethernet Cable
❑ Motor Agitator
Limit switch
0,37 KW 3 phase motor tersertifikasi ATEX explosion proof level sensor 1783-US08T
Ethernet Switch
❑ Inverter/ VFD (Schnieder ATV32HU22N4)
Is a device that functions to regulate the speed of a 3 Phase AC
motor by changing the frequency, in the agitator system, the VFD is 1763 - ETAP
connected to the PLC via an ethernet cable, which functions for real
time monitoring of VFD parameters and also regulates the output Ehernet IP
frequency of the VFD via PLC.
❑ Limit switch level sensor PLC
DIGITAL OUTPUT
DIGITAL INPUT
The limit switch level sensor on the agitator pump system is to 1756-L72
provide feedback to the PLC level on the tank, which will later Control
logix5572
become a reference for the agitator rotation speed. When the level in controller
the tank is low, the agitator speed will decrease and when the tank
level is high, the agitator rotation speed will increase.
上汽通用五菱印尼汽车有限公司 PT. SGMW MOTOR INDONESIA
Robot Interlock
The interlock system between the robot and the PCS is in the form of a digital signal via a DC
rellay, and also PLC module
DIGITAL OUTPUT
DIGITAL INPUT
1756-L72
The temperature control system on the PCS functions to maintain the paint
temperature in accordance with predetermined parameters. PLC
❑ Cooling water system Rellay
DIGITAL OUTPUT
Selenoid valve
Basically, the CW system is in charge of providing cooling water supply that
DIGITAL INPUT
1756-L72
will be used to control the paint temperature. Control
Contactor
logix5572
The cooling water temperature is set to 20°C, the electrical devices in the
Temp controller
CW system are: Valve
RTD sensor : The RTD sensor provides feedback to the PLC temperature Circulation
Pump
from the cooling water. Circulation
Tank
Automatic valve : automatic valve regulates the supply of chiller water that
ANALOG OUTPUT
ANALOG INPUT
enters the heat exchanger, the automatic valve opening itself is regulated RTD RTD Automatic
AO
input Valve
by the PLC using PID by calculating the feedback temperature data from module
MODULE
1734-
the RTD sensor. 1734-IR2 OE2C
Pump Circulation: serves to circulate cooling water to the mixing room RTD
tank.
❑ Circulation Mix tank cooling system CW system
To maintain the paint temperature, the circulation tank has a heat
exchanger that uses a cooling water supply, the device that regulates the
temperature parameters of the paint in the circulation tank are:
RTD sensor : The RTD sensor provides feedback on the PLC temperature of
the paint in the circulation tank.
Selenoid Valve : a valve controlled by PLC to move the temperature valve.
Temperature Valve : is a valve that uses air to open and close the valve, this
valve serves to regulate the cooling water that enters the heat exchanger in
the circulation tank.
❑ Schnieder ATV32H037N4 and ATV320U04N4B is use for mix agitator and circulation agitator.
Drawing
SoMove Software
SoMove software incorporates various functions for the device setup phases, such as:
• configuration preparation
• testing and start-up
• Maintenance
• Backup Parameter
To facilitate setup and maintenance, SoMove software
can use a direct USB/RJ45 cable (Modbus serial) link.
5. Set Configuration
❑ Output to ACS
1 2