1、 株洲威森機車配件有限公司司機控制器TKS520Master controller TKS520第一版 Issue: - 1.0 -批準 Released: 桂勇 GuiYong R & D depart 2010-02-04 Sgd. GuiYong 校核 Checked: 凌錦燦LingJinCan R & D depart 2010-02-04 Sgd. LingJinCan編制 Created: 全湘乾 QuanXiangQian R & D depart 2010-02-04 Sgd. QuanXiangQian姓 名 Name 部門 Devision 日期 Date 簽 名 Sig

2、nature更改清單List of changes版本號Issue日期Date更改理由Reason for change頁面Page(s)1 04.02.2010第一版First issue 全部All234567891011121314151617181920目錄Table of contents1 用途/功能Purpose / function.52 說明Description.52.1 技術參數Purposes of use/ technical data.62.2 技術說明Technical description .73 安全說明Safety instructions .173.1

3、與安全有關的擰緊轉矩Safety relevant tightening torque.174 操作手冊Instruction manual.174.1 操作Operation .185 組裝和調試Assembly and commissioning .185.1 運輸/裝船/儲存Transportation / shipment / storage .185.1.1 運輸/裝船Transportation / shipment.185.1.2 儲存Storage.185.2 安裝Installation .195.3 調試Commissioning.215.3.1 調試前檢查Check-up

4、 before commissioning.215.3.2 調試Commissioning.225.4 維修Maintenance.235.4.1 維修等級Maintenance steps .235.4.2 維修計劃Maintenance plan .245.4.3 維修工作Maintenance works.255.5 故障處理、更換設計維修Trouble shooting, exchange concept / maintenance.265.5.1 故障處理Trouble shooting.265.5.2 組裝Assembly.285.5.3 投入使用/功能試驗Return to se

5、rvice / Function test.285.6 專用工具、設備，測量和試驗設備Special tools, devices, measuring and test devices .285.6.1 測量和試驗設備Measuring and test devices.285.6.2 易損件和備件Wearing und spare parts .295.7 廢棄物處理方案Waste management concept .291 用途/功能Purpose / function司機控制器是機車的主令控制電器，用來轉換機車的牽引與制動工況，改變機車的運行方向，設定機車運行速度，實現機車的起動和

6、調速等工況。Master controller is a kind of master apparatus used to control locomotive running.It used to convert the locomotives working modes of traction and braking, to change its direction, to set its velocity, to perform locomotive starting and speed regulation.122 說明Description31Traction/brake contr

7、oller2Direction switch3Key switch圖 1：司機控制器總圖Figure 1: Master controller overview 司機控制器是機車的主令控制電器，用來轉換機車的牽引與制動工況，改變機車的運行方向，設定機車運行速度，實現機車的起動和調速等工況。各主要部件的功能參看表2.2。Master controller is a kind of master apparatus used to control locomotive running.It used to convert the locomotives working modes of tract

8、ion and braking, to change its direction, to set its velocity, to perform locomotive starting and speed regulation. The function of each components see table2.2.2.1 技術參數 technical data司機控制器的機械壽命 2106 次Master controllers mechanical lifetime 2106cycles輔助觸頭盒電壽命 2105 次Auxiliary contacts Electrical life

9、2105 cycles司機控制器的質量 10kgMaster controllers mass 10kg輔助觸頭盒的防護等級 IP67（依照IEC60529）Auxiliary contacts degrees of protection IP67(according to IEC60529)輔助觸頭盒標稱電壓 DC 110VAuxiliary contacts nominal voltage DC 110V輔助觸頭盒約定發熱電流 10AAuxiliary contacts rated thermal current 10A最小電氣間隙 3mmMin electrical clearance

10、3mm最小爬電距離 4mmMin creeping length 4mm2.2 技術說明Technical description 司機控制器的結構見圖2和表2.2。The structure of master controller see Fig 2 and table2.2.8721121615141317111069345圖 2：司機控制器結構 Fig 2:Structure of master controller序號Item名稱Designation備注Remarks1面板panel2牽引/制動控制器Drive of power-/brake controller3牽引/制動控制器

11、油浸電位器Oil potentiometer of power-/brake controller與株洲威森機車配件有限公司聯系Contact Zhuzhou VEE.SUN motor accessories Co.，Ltd4螺釘及彈墊Set of screws and spring lock washers包含在序3 中Included in item35聯軸器Coupling包含在序2 中Included in item26沉頭螺釘Set of countersunk screws包含在序2 中Included in item27方向轉換開關Direction switch8螺釘及彈墊S

12、et of screws and spring lock washers包含在序2、7 中Included in item2、79圓柱齒輪Spur gear 包含在序2、7 中Included in item2、7 10VS847 輔助觸頭盒Auxiliary contact type VS847 與株洲威森機車配件有限公司聯系Contact Zhuzhou VEE.SUN motor accessories Co.，Ltd11螺釘及彈墊Set of screws and spring lock washers包含在序10中Included in item1012鑰匙開關Key switch1

13、3聯鎖機構Mechanical interlocking system包含在序12中Included in item1214螺釘及彈墊Set of screws and spring lock washers包含在序13中Included in item1315電阻Resistance包含在序2中Included in item216警惕按鈕輔助觸頭盒Alert buttonAuxiliary contact type17警惕按鈕Alert button18電連接器和連接電纜Connector and connecting cables 表 2.2 司機控制器部件清單 Table 2.2 Co

14、mponents list of Master controller2.2.1 牽引/制動控制器Drive of power-/brake controller牽引/制動手柄（圖2，序2）位于司機控制器右側，用于調節機車的牽引和制動工況。可前后推動，具有“T” （牽引）、“0”（停止）、“B”（制動）和“快制”四個區域。牽引/制動手柄（圖2，序2）垂直時為“0”位，向前推進入“牽引”區，推動41后到達“牽引”最大位；向后拉進入“制動”區，拉動36后到達“制動”最大位；拉動41后到達“快制”位。牽引/制動手柄上的警惕按鈕在任何角度都可以操作。Driving/braking lever（Fig 2

15、,list 2） is at the right of master controller, used to convert thelocomotives working modes of traction and braking. Driving/braking lever（Fig 2,list 2）can bepushed forward and be draught backward, and it has four positions: “T”(Traction) 、“0”(Coast)、“B”(Braking) and Quick braking. When it is vertic

16、al, indicating “0” (Coast). If push forward, driving/brakinglever in driving range, and after be pushed forward 41, driving/braking lever will arrive theposition of driving max; If draw backward, driving/braking lever in braking range, and after bedraught backward 36,driving/braking lever will arriv

17、e the position of braking max. and after bedraught backward 41,driving/braking lever will arrive the position of Quick braking.Driving/braking levers vigilance button in any Angle can operate.2.2.2 牽引/制動控制器油浸電位器 Oil potentiometer of power-/brake controller牽引/制動控制油浸電位器（圖2，序3）共有一個，外形結構如圖3所示：There is o

18、ne Oil potentiometer （Fig 2,list 3）of the Drive-/brake controller.The structure of Oil potentiometer see Fig 3.圖3 油浸電位器外形圖 Fig 3 The structure of Oil potentiometer牽引/制動手柄（Fig 2,list 2）在各位置的手柄角度及油浸電位器輸出值見表2.2.2：輸入電壓：15VDC Driving/braking levers position and its deflection and Oil potentiometer output

19、 valeues see table 2.2.2 ：The input voltage: 15VDC牽引/制動手柄（圖2，序2）位置Driving/braking levers（Fig 2,list2） position手柄角度deflection of lever油電位器輸出數值Oil potentiometer output values牽引最大位Driving max+418.30.15VDC0 位Coast 0 30.1VDC制動最大位Braking max -3680.1VDC快制位 Quick braking-418.30.15VDC 表 2.2.2 牽引/制動手柄角度及油浸電位器

20、輸出Table 2.2.2 Driving/braking levers position and Oil potentiometer output valeues2.2.3 方向轉換開關控制器Direction switch方向轉換開關（圖2，序7）位于司機控制器左側，方向轉換開關有三個位置：向前、0、向后，且每個位置均有定位。每個位置之間開關的轉動角度為20。鑰匙開關（圖2，序12）具有“ON”和“OFF”兩個位置。 Direction switch（Fig 2,list 7） is at the left of master controller, The direction switc

21、h has 3 positions namely ：”forward”, ”0”and “backward” , and each location are positioning. The switch turned 20from one position to another. Keyswitch（ Fig 2,list 12） has two positions: “ON”、“OFF”.機械聯鎖要求：Mechanical interlocking system：2.2.3.1 鑰匙開關（圖2，序12）在“OFF”位置時，方向轉換開關（圖2，序7）和牽引/制動手柄（Fig 2,list 2

22、）被鎖在”0“位。 鑰匙開關（圖2，序12）在“ON”位置時，方向轉換開關（圖2，序7）可在“F”（向前）、“N”（關閉）、“B”（向后）之間轉換。Keyswitch（ Fig 2,list 12）in “OFF”-position Direction switch（Fig 2,list 7）anddriving-/braking lever（Fig 2,list 2） blockedin Coast. Keyswitch（ Fig 2,list 12）in “ON”-position Direction switch（Fig 2,list 12）can be transformed amon

23、g “F”、 “N”and “B”.2.2.3.2 當方向轉換開關（圖2，序7）在“0”（關閉）位時，牽引/制動手柄（圖2，序2）被鎖在“0”（停止）位。Direction switch（Fig 2,list 7） in 0-position driving-/braking lever（Fig 2,list 2） blockedin Coast.2.2.3.3 當方向轉換開關（圖2，序7）在“F”（向前）位或“B”（向后）位時，牽引/制動手柄（圖2，序2）可自由推動。Direction switch（Fig 2,list 7）either in F-or in B-position Driv

24、ing-/braking lever（Fig 2,list2） free to move.2.2.3.4 牽引/制動手柄（圖2，序2）在“0”（停止）位時，方向轉換開關（圖2，序7）可在“F”（向前）、“N”（關閉）、“B”（向后）之間轉換。Driving-/braking lever（Fig 2,list2） blocked in Coast Direction switch（Fig 2,list7） can be transformed among “F”、 “N”and “B”.2.2.3.5 牽引/制動手柄（圖2，序2）在“T”（牽引）或“B”（制動）區域時，方向轉換開關（圖2，序7）

25、被鎖在“F”（向前）位或“B”（向后）位。Driving-/braking lever （Fig 2,list 2） either in driving-or in braking range-Direction switch （Fig2,list 7） blocked either in F-or in B-position.2.2.4 電連接器和連接電纜Connector and connecting cables所有觸頭盒的接線都連接到46 芯的Harting電連接器, 電連接器外罩型號為HAN16B,電連接器型號為HAN46EE，見圖4，導線長1.1m。電位器導線接到5芯的Hartin

26、g電連接器, 電連接器型號為HAN3HPR。All switches are wired to a 46-pole Harting connector according to wiring diagram ,the type of the Hood is HAN16B and the Harting connector is HAN46EE and the configuration ofconnector see Fig 4, cable length is 1.1m. Potentiometer wires to a 5-pole Harting connector.the Hartin

27、g connector is HAN3HPR.圖4 電連接器 Fig 4 Connector3 安全說明Safety instructions注意 NOTE司機控制器連接插頭未連接時，觸頭可能無電。Not with the master controller connected plugs may lead in the contacts novoltage.嚴重警告CAUTION輔助觸頭盒（圖2，序10）的額定工作電壓為DC110V，小心觸電。The auxiliary contacts （Fig 2,list 10） rate voltage is DC110V, be careful!3

28、.1 與安全有關的擰緊轉矩Safety relevant tightening torque位置Location螺紋公稱尺寸Screws size擰緊轉矩(Nm)Tighteningtorque (Nm)扳手尺寸Wrenchsize (SW備注Remark面板（ 圖2 ，序1）panel（Fig 1,list 1）M82613所標明的擰緊轉矩取決于緊固方式(螺紋連接等級)，并根據德國25202 標準化機構制定。制動柜部件的螺紋連接：參見Knorr 檢修手冊The indicated tighteningtorques are depending onthe method of tighteni

29、ng(screw connection class) to German Institute forStandardization 25202.Screw connections ofcomponents of the brakepanel: see respective overhaulinstructions Knorr其余 OthersM5M66,310,8810表 3.1 與安全有關的擰緊轉矩實例 Table 3.1 Sample safety relevant tightening torque4 操作手冊Instruction manual4.1 操作Operation 用鑰匙打開

30、鑰匙開關（圖2，序12），旋轉方向轉換開關（圖2，序7），選擇“向前”或“向后”，向牽引方向推動牽引/制動手柄（圖2，序2），機車將起動，并隨著推動角度的增大，機車速度將增大。機車需要制動時，可將牽引/制動手柄（圖2，序2）拉向制動區域。在行車過程中，如需要改變機車的工況時，必須將控制手柄放回“0”位后，才可進行換向手柄的操作。如司機需要進行異端操作時，必須將本端司控器的控制手柄置“0”位，鎖閉機械鎖拔出鑰匙，方可進行異端操作。 Use the key to open key switch（Fig 2,list 12）, then operate direction switch（Fig 2,

31、list7）, select F(forward) or B(backward),push driving/braking lever（Fig 2,list 2） to“T”(Traction),locomotive will start, and the speed will rise with the pushing angle up.Whenlocomotive need brake,only draw driving /braking lever（Fig 2,list 2） to “B”(Braking). In driving process, such as the need to

32、 change the operation condition of the locomotive, must will driving/braking lever（Fig 2,list 2） to put it back after a 0, they are the reversing handle operation. If the driver to heresy operation, the company will have to the control device driving/braking lever（Fig 2,list 2） buy 0, a mechanical l

33、ock key lock out, can heresy operation.5 組裝和調試Assembly and commissioning5.1 運輸/裝船/儲存Transportation / shipment / storage5.1.1 運輸/裝船Transportation / shipment 司機控制器在運輸時的環境條件（根據DIN EN 60721-3-2 的環境條件分級）： Ambient conditions of Master controller during transport（Classification of environmentalconditions a

34、ccording to DIN EN 60721-3-2）： 溫度等級 Temperature class：2K4； 其他環境條件Other environmental conditions：2B2，2C3，2S3，2M3。 司機控制器由制造商進行包裝和發貨。在收到包裝后，客戶必須檢查交貨是否受損和有故障，包括因運輸而受損的，并把可能出現的問題通知制造商和轉運商。如果通知遲了將不再考慮索賠。 Master controller is packed and dispatched by the manufacturer. After receiving the packing the custom

35、er is obliged to check the delivery for damaged and defects, including transport damaged and notify the manufacturer and forwarder about possible shortcomings. Claims are not considered in cases of later notifications.5.1.2 儲存Storage 司機控制器必須儲存在下列條件下的封閉的空間內： Master controller must be stored in enclos

36、ed spaces under the following conditions: 儲存溫度的范圍: -40到+50 Range of storage temperature : from 40 to +50 最大相對濕度（該月月平均最低溫度不低于25）： 95 Max. relative humidity：95 (the average lowest temperature of the month is above 25)5.2 安裝Installation圖5 開孔和安裝尺寸圖 Fig 5 The diagram of openings and installation 將司機控制器安裝

37、到司機操縱臺上前，無需要先拆下牽引/制動控制器和速度設定控制器的控制手柄。（圖5）直接從司機操縱臺下部向上安裝即可。鎖開關安裝要卸下后面的凸輪，取出鎖芯才可以安裝。 Before the Master Controller can be installed into the operators panel, the grip of thetraction power / brake control unit and speed setting-selector unit has not to be removed（Fig 5）.The installation can be directly

38、from the operators panel upward. Lock switch installed to remove the back of the CAM, remove lock core can be installed.圖6 司機控制結構圖Fig 6 Schematic diagram of structural profile for S335 master controller 司機控制器 (圖6)需要從司機操縱臺上側用螺釘連接。因此司機操縱臺需要預留四個安裝螺釘的接口。在安裝中將用到以下連接件： 內六角沉頭螺釘M8 （GB/T70.3-2000） 4 個 As enl

39、ightens from Figure 6 the Master controller (Fig 64) has to be bolted against the desk platestop side. For that purpose the desk plate is to be provided with the cutouts aswell as four thread screws as shown in dimensioned drawing no. TKS520. For thescrew joint the following elements are recommended

40、: _ 4 x M8 Hex head sink screws according to GB/T70.3-2000 安裝或拆卸時必須注意以下事項：1、司機控制器鎖閉側是通過鎖來安裝的，組裝或拆卸時需注意：鎖后面的凸輪必須移走，如果必要的話，可以移動拉絲組件。2、司機控制器的拉絲組件在發貨之前已經調到合適的位置，如果在組裝或者拆卸司機控制器的時候將其分開了，必須重新再作調整。要保護司機控制器的鑰匙可以靈轉動，鎖牢固可靠。Install or remove must pay attention to the following items:1, the driver controller is

41、through the lock to lock in the installation, assembly or remove the need to note: lock the back of the CAM must be moved, if necessary, you can move the wire drawing components.2, the driver of the controller drawing components prior to shipment has been transferred to the right position, if in the

42、 assembly or remove the driver of the controller time to separate, have to be adjusted. To protect the driver controller can be the key to spirit rotation, lock strong and reliable.5.3 調試Commissioning5.3.1 調試前檢查Check-up before commissioningNo.序號部件Components方法Measures注意NOTE交叉引用Crossreference1 牽引/ 制動手

43、柄（ 圖2 ， 序2 ）driving/braking lever（Fig 2,list 2）方向轉換開關（圖2，序7）direction switch（Fig 2,list 7）鑰匙開關（圖2，序12），key switch（Fig 2,list 12）操作各手柄及開關，檢查是否動作良好。Operate all levers andswitches, check themwhether they work well.2 機械聯鎖機構mechanical interlocking system檢查機械聯鎖機構的聯鎖關系是否滿足2.2.3的要求。Check mechanicalinterlock

44、ing systemwhether meet therequirements of 2.2.3.2.2.3 機械聯鎖要求2.2.3mechanicalinterlockingsystem表5.3.1 調試前檢查實例 Table 5.3.1 Sample checkups before commissioning5.3.2 調試CommissioningNo.序號部件Components方法Measures結果/指示器Effect / Indicator交叉引用Crossreference1油浸電位器（ 圖2，序3）Oil potentiometer （ Fig2,list 3 ）調節油浸電位器

45、（圖2，序3）的聯軸器，使得輸出碼值滿足表2.2.2 和2.2.4的要求。Regulate coupling of Oil potentiometer（Fig 2list 3 and 8）, make Oil potentiometer output values meet therequirements of table 2.2.2and table 2.2.4.油浸電位器測試儀Oil potentiometertesting pparatus2.2.2、2.2.4表5.3.2 調試實例 Table 5.3.2 Sample commissioning5.4 維修Maintenance5.4

46、.1 維修等級Maintenance steps維修等級Maintenance stage說明Description運行里程數Running performance (km)間隔期Interval(Period)VI目檢Visual inspection10.000 km 2 周 2 weeksI1檢查1 級Inspection 1100.000 km6 個月6 month I2 檢查2 級Inspection 2200.000 km 1 年1 yearI3檢查3 級Inspection 3400.000 km 2 年2 yearsR1 修正1 級Revision 1800.000 km 1.

47、200.000 km 4 6 年4 6 yearsR2 修正2 級Revision 21.600.000 km 2.400.000 km 8 12 年8 12yearsR3 修正3 級Revison 33.200.000 km 3.600.000 km 16 18 年16 18yearsUM 計劃外維修Unscheduled maintenance 表 5.4.1 中國機車項目維修等級 Table 5.4.1 Maintenance steps for Project China Sprinter5.4.2 維修計劃Maintenance planNo.序號部件Components維修Main

48、tenance維修等級Maintenance stage1牽引/制動手柄（圖2，序2）driving/braking lever（Fig 2,list 2）方向轉換開關（圖2，序7）direction switch（Fig 2,list7）鑰匙開關（圖2，序12），key switch（Fig 2,list 12）操作各手柄及開關，檢查是否動作良好。Operate all levers and switches,check them whether they work wellI12 油浸電位器（圖2，序3）Oil potentiometer（Fig 2,list 3）檢查油浸電位器輸出值是否

49、滿足表2.2.2和表2.2.4的要求。CheckOil potentiometer output values whether meetthe requirements of table 2.2.2 andtable 2.2.4.3 機械聯鎖機構mechanicalinterlocking system拆解機械聯鎖機構，對疲勞部件進行更換dismantle mechanicalinterlocking system,replace theweariness components.I2 表5.4.2 維修計劃實例 Table 5.4.2 Sample maintenance plan5.4.3 維修工作Maintenance worksI1 級檢修Maintenance stage I1No.序號部件Components檢查Inspection交叉引用Cross reference1 牽引/制動手