Procedimiento de Comisionado
Secuencia de re-energización y arranque (55 pasos) — 55 registros.
| STEP | PHASE | TASK | CIRCUIT IDs | DETAIL | VERIFICATION | HOLD POINT | RESPONSIBLE |
|---|---|---|---|---|---|---|---|
| 1 | 1-RECEIVING | Inspect ALL equipment for shipping damage | ALL | Visual inspection of panels P-01, P-03, P-04, P-05, AC890PX, DL-205. Check for bent enclosures, loose components, broken connectors. | Document damage with photos. Compare to deinstallation photos. | YES | Field Tech |
| 2 | 1-RECEIVING | Inspect FireWire cables (IRREPLACEABLE) | FW-001 to FW-006 | Locate all 6 IEEE 1394a FireWire segments in P-03 AC890 rack. Check each 6-pin connector for bent pins, cracked housing, damaged shielding. | Photograph each connector. Log condition. If any cable damaged, STOP and contact Parker. | YES | Field Tech |
| 3 | 1-RECEIVING | Photograph all unreadable motor nameplates | PWR-DECO, PWR-HPU1, PWR-HPU2, ROLL-01-06 | Decoiler motor, HPU M-10 and M-11, all 6 roll motors. Record: HP, V, FLA, RPM, S/N, Frame. | Update Master Cable Schedule with confirmed data. | YES | Field Tech |
| 4 | 1-RECEIVING | Insulate all bare copper immediately | DISC-08, DISC-04 | DISC-08 has bare copper hanging from aux panel — short circuit risk during handling. DISC-04 has bare wire ends. | Heat shrink or tape all exposed conductors. Photograph before and after. | NO | Field Tech |
| 5 | 1-RECEIVING | Assess DISC-03 contaminated junction box | DISC-03 | Floor-level JB severely contaminated. UL sticker degraded. | Evaluate: clean and reuse vs replace entire NEMA 12 box. Order replacement if needed. | NO | Field Tech |
| 6 | 2-GROUND | Install main ground bus and building ground | FD-007, all GND circuits | Establish Houston facility ground system. Connect main ground bus. | Verify ground resistance <5 ohm with ground resistance tester. | YES | Electrical Eng. |
| 7 | 2-GROUND | Bond all panel frames to ground bus | P-01, P-03, P-04, P-05, AC890PX, DL-205 | #6 AWG green/yellow from each panel frame to ground bus through JBOX-05 distribution. | Verify continuity from each panel frame to main ground. <1 ohm bonding resistance. | YES | Field Tech |
| 8 | 2-GROUND | Bond motor frames to ground system | FD-003, FD-004, all motor GND | Connect ground conductor to MTR-01, MTR-02, MTR-300, and all motor frames. | Verify bonding continuity motor frame to ground bus. | YES | Field Tech |
| 9 | 3-MOUNT | Position and anchor P-01 (Main Panel) | N/A | Mount P-01 at machine centerline. Level. Anchor to floor/structure. Verify all internal components secure from shipping. | Visual inspection. Door operation. DIN rail components seated. | NO | Mechanical + Electrical |
| 10 | 3-MOUNT | Position and anchor P-03 (AC890 VFD Rack) | N/A | Mount P-03 adjacent to P-01. Ensure adequate ventilation clearance per Parker specs. | Visual. Ventilation clearance measured. | NO | Mechanical + Electrical |
| 11 | 3-MOUNT | Position and anchor P-04 (DC Drive Cabinet) | N/A | Mount P-04 adjacent to P-01. Verify Shawmut fuses present and intact. | Visual. Fuse check. | NO | Mechanical + Electrical |
| 12 | 3-MOUNT | Position P-05 (Operator Console) | N/A | Mount at operator station. Verify PanelView screen intact. | Visual. | NO | Mechanical |
| 13 | 3-MOUNT | Position AC890PX (Flattener drive) | N/A | Mount standalone cabinet near P-03. Ventilation clearance per Parker specs. | Visual. | NO | Mechanical |
| 14 | 3-MOUNT | Position DL-205 Cabinet | N/A | Mount separate cabinet. Verify DirectLOGIC 205 rack intact. | Visual. | NO | Mechanical |
| 15 | 4-CONDUIT | Install cable tray MCC → P-01 → P-03/P-04 | SU-002, DC-PWR-01/02/03, SU-010, AC-PWR-PX | Main power cable tray from MCC location to panel lineup. | Route verified against deinstallation photos. Supports rated for cable weight. | NO | Electrical |
| 16 | 4-CONDUIT | Install conduit P-04 → pit → JBOX-01 → JBOX-02 → motors | DC-MTR-01/02, DC-FLD-01/02, DC-ENC-01/02 | Subterranean conduit route for DC motor power and signal cables. ~15m per route section. | Conduit continuity. Pull string installed. Verify pit access. | NO | Electrical |
| 17 | 4-CONDUIT | Install safety conduit P-01 → P-03 | STO-002, AC890-STO | Dedicated conduit for STO safety wiring. MUST be separate from power conduit. | Separation verified from power cables per NEC. | NO | Electrical |
| 18 | 4-CONDUIT | Install field conduit P-01 → JBOXes 01-08 | JBF-001, JBF-002, JBF-003, FD-005-010 | Conduit runs to all 8 field junction boxes. | Routes match deinstallation documentation. | NO | Electrical |
| 19 | 4-CONDUIT | Replace damaged conduit sections | DISC-01, DISC-04 | DISC-01 conduit disconnected at base leveler. DISC-04 flexible conduit disconnected. | New conduit installed. Connectors secured. | NO | Electrical |
| 20 | 5-POWER-AC | Pull MCC → P-01 main feed cables | SU-002 | L1/L2/L3 + GND. Cable size per MCC engineering (3/0 AWG+ XHHW-2). | Megger test >1 MΩ at 1000V. Phase identification labeled. | YES | Electrical |
| 21 | 5-POWER-AC | Pull MCC → P-04 drive feed cables (PF20P #1 and #2) | DC-PWR-01, DC-PWR-02 | 2/0 AWG XHHW-2 per circuit. L1/L2/L3 + GND per drive. | Megger test. Phase ID. Cable label at both ends. | YES | Electrical |
| 22 | 5-POWER-AC | Pull MCC → P-04 decoiler drive feed | DC-PWR-03 | Cable size PENDING motor nameplate confirmation (OI-003). | HOLD — Cannot execute until OI-003 resolved. | YES | Electrical |
| 23 | 5-POWER-AC | Pull MCC → P-03 AC890 rack feed | SU-010, AC890-PWR-RACK | Through TCI reactors KDRH3L/KDRF2L. 250A+ estimated. | Megger test. Reactor connections verified. | YES | Electrical |
| 24 | 5-POWER-AC | Pull MCC → AC890PX flattener feed | AC-PWR-PX | ~250 MCM estimated. Size PENDING Parker documentation (OI-014). | Megger test. | YES | Electrical |
| 25 | 5-POWER-AC | Land 480VAC at P-01 main breaker CB-001 | SU-002 | L1/L2/L3 at CB-001 line side 1-3-5. Verify CB-001 function (OI-002). | Torque to manufacturer spec. Verify phase rotation with meter. | YES | Electrical |
| 26 | 6-POWER-DC | Pull armature cables P-04 → JBOX-01 → JBOX-02 → MTR-01 | DC-MTR-01 (cable E315270) | 4/0 AWG XHHW-2. Route through pit subterranean. | Megger test. Cable label E315270 verified. Polarity marked A+/A-. | YES | Electrical |
| 27 | 6-POWER-DC | Pull armature cables P-04 → JBOX-01 → JBOX-02 → MTR-02 | DC-MTR-02 | 4/0 AWG XHHW-2. Same route as MTR-01. | Megger test. Polarity marked. | YES | Electrical |
| 28 | 6-POWER-DC | Pull field cables to MTR-01 and MTR-02 | DC-FLD-01, DC-FLD-02 | #10 AWG shielded. Bundled with armature conduit. | Measure field resistance before connecting: MTR-01 = 11.3 ohm, MTR-02 = same. | YES | Electrical |
| 29 | 6-POWER-DC | Land armature cables at JBOX-02 TB70-72 | FD-002 | TB-70, TB-71, TB-72 terminal blocks. Power/control separation point. | Verify TB labeling matches deinstallation photos. Torque to spec. | YES | Electrical |
| 30 | 6-POWER-DC | Land armature A1/A2 at MTR-01 and MTR-02 | FD-003, FD-004 | A1=+, A2=−. DO NOT INVERT — reverse causes reverse rotation + possible runaway. | Polarity verified with voltmeter (brief bump test at low voltage if possible). | YES | Electrical |
| 31 | 6-POWER-DC | Pull flattener motor cables AC890PX → MTR-300 | AC-MTR-300 | 350 MCM per phase. U/V/W at drive, T1/T2/T3 at motor. | Megger test. Phase sequence verified. | YES | Electrical |
| 32 | 7-SAFETY | Wire E-stop circuit P-05 → P-01 Banner relay | STO-001 | #16 AWG 2C safety grade. S31/S32/S34 inputs at Banner ES-UA-5A. | Continuity test. Dual-channel function verified. | YES | Electrical |
| 33 | 7-SAFETY | Wire STO circuits P-01 → P-03 (6 AC890 drives) | STO-002 | 6 separate runs #16 AWG shielded. X11 STO A/STO B at each AC890. | Test each: press E-stop → drive must NOT enable. Release → drive enables. | YES | Electrical |
| 34 | 7-SAFETY | Wire STO circuit P-01 → AC890PX | STO-003 | #16 AWG shielded to AC890PX X11 STO A/STO B. | Same test as Step 33 for flattener drive. | YES | Electrical |
| 35 | 8-CONTROL | Verify 24VDC power supplies in P-01 | 24V-001, 24V-002, 24V-003 | Phoenix QUINT 30A (primary), PULS ML30 (secondary), SOLA SDN (tertiary). Verify all present and undamaged. | Measure output voltage on each PSU before connecting bus. | NO | Electrical |
| 36 | 8-CONTROL | Wire 24VDC distribution to field JBOXes | 24V-004, JBF-002 | 24V/0V/ENA signals to JBOX-04 and JB-FIELD-02. | Verify 24VDC present at each JB. Measure voltage. | NO | Electrical |
| 37 | 8-CONTROL | Wire JB-FIELD-01 (confirmed wire labels) | JBF-001 | Wire labels: 2561,2561A,1025,702,3161,3121,3081,M25,4025. Panel-side destinations require tone-test (OI-010). | Tone-test each wire. Map to panel terminal. Document. | YES | Field Tech |
| 38 | 8-CONTROL | Wire JB102 motor control (FWD/REV/COM) | JBF-003 | Terminals 1-9: FWD(1), REV(2), COM(3), MOTOR(4-9). Check for corrosion. | Inspect terminals. Replace if corroded. Verify continuity. | NO | Electrical |
| 39 | 8-CONTROL | Wire solenoid valve circuits (110/120VAC) | SOL-001 to SOL-005 | #16 AWG 2C+GND from transformer secondary. Rexroth E33 @110V, Parker @120V. | Verify transformer tap matches required voltage (OI-012). Test each solenoid energizes. | NO | Electrical |
| 40 | 8-CONTROL | Wire encoder cables to drives | PLC-002, PLC-003, PLC-004 | FSI encoder to L24ER HSC. UNICO transducers to PF20P #1/#2. | Verify encoder signals with oscilloscope or drive diagnostic. | NO | Electrical |
| 41 | 9-NETWORK | Verify FireWire daisy chain in P-03 | FW-001 to FW-006 | Check all 6 segments. Node sequence: AC890PX(3)→Roll#1(1)→Roll#2(4)→Roll#3(5)→Roll#4(6)→Roll#5(7)→Roll#6(8). End terminator at Node 8. | Visual inspection of each connection. Node 2 must remain empty. | YES | Controls Eng. |
| 42 | 9-NETWORK | Connect Ethernet cables at Hirschmann switch | ENET-01 to ENET-09 | Cat5e/6 STP RJ45 to each device. Requires IP plan (OI-008) and port map (OI-009). | HOLD until IP plan complete. Then: ping each device from Hirschmann. | YES | Controls Eng. |
| 43 | 9-NETWORK | Verify DL-205 Ethernet connection | ENET-07 | Cable CB-0178/CB-1920. IP: 192.168.84.101. | Ping 192.168.84.101 from Hirschmann network. | NO | Controls Eng. |
| 44 | 10-DISC | Tone-test and map DISC-01 (leveler area) | DISC-01 | Red/Green/Yellow/White cut ends at base leveler. | Each wire identified, labeled, and mapped to destination. New conduit installed. | YES | Field Tech |
| 45 | 10-DISC | Tone-test and map DISC-06 (MCC floor area) | DISC-06 | Pink/Red AND Blue cut cables — mass on floor in front of MCC. | Each conductor identified. May include interlock or safety wiring. | YES | Field Tech |
| 46 | 10-DISC | Process remaining DISC-02 to DISC-05, DISC-07, DISC-08 | DISC-02-05, DISC-07-08 | Tone-test, label, map, re-terminate each group. Replace thermally damaged cables (DISC-07). | All conductors identified and reconnected or documented as spare. | NO | Field Tech |
| 47 | 11-VERIFY | Megger test ALL power cables | ALL PWR-AC, PWR-DC circuits | Insulation resistance >1 MΩ at 1000V DC for each power circuit. | Log results per circuit. Fail = do not energize that circuit. | YES | Electrical Eng. |
| 48 | 11-VERIFY | Verify ALL ground bonds | FD-007, all GND circuits | Continuity test from every motor frame, panel frame, and equipment frame to main ground bus. | <1 ohm bonding resistance for each connection. | YES | Electrical |
| 49 | 11-VERIFY | Verify phase rotation at P-01 | SU-002 | Phase rotation meter on L1/L2/L3 at P-01 main bus. | Correct rotation confirmed (CW or as required by drives). | YES | Electrical |
| 50 | 11-VERIFY | Verify ALL safety circuits functional | STO-001, STO-002, STO-003 | Press E-stop → ALL drives must de-energize STO. Release → drives ready. | Test with each drive individually AND all simultaneously. | YES | Safety Eng. |
| 51 | 12-ENERGIZE | Energize 24VDC control power only | 24V-001, 24V-002, 24V-003 | Turn on 24VDC PSUs. Verify voltage at all field distribution points. | 24VDC ±2% at each JB and I/O module. | YES | Electrical Eng. |
| 52 | 12-ENERGIZE | Energize P-01 main 480VAC (CB-001) | SU-002 | Close MCC breaker feeding P-01. Verify 480V L-L at P-01 bus. | Voltage measured. No smoke, arcing, or abnormal sounds. | YES | Electrical Eng. |
| 53 | 12-ENERGIZE | Energize P-04 drives one at a time | DC-PWR-01, DC-PWR-02 | Close dedicated breaker for PF20P #1 first. Verify drive powers up with no faults. Then PF20P #2. | Drive display shows normal. No fault codes. Parameters verified. | YES | Electrical Eng. |
| 54 | 12-ENERGIZE | Energize P-03 AC890 rack | SU-010, AC890-PWR-RACK | Close rack input breaker. Verify all 6 drives power up. Check FireWire sync status. | All drives show normal. FireWire communication confirmed. | YES | Electrical Eng. |
| 55 | 12-ENERGIZE | Energize AC890PX flattener drive | AC-PWR-PX | Close dedicated breaker. Verify drive powers up. | Drive display normal. Base freq = 84Hz confirmed in parameters. | YES | Electrical Eng. |