AMPP Requirements Before Comissioning - 2.8

Requirements
before commissioning.
Index
Foreword.................................................................................................................................................. 2
Chapter 1 ................................................................................................................................................. 3
General findings .................................................................................................................................................. 3
Chapter 2 ................................................................................................................................................. 5
Cable connections ............................................................................................................................................... 5
Chapter 3 ................................................................................................................................................. 7
PT100 – Temperature sensor .............................................................................................................................. 7
Chapter 4 ................................................................................................................................................. 8
PICA – Pressure sensors ..................................................................................................................................... 9
Chapter 5 ............................................................................................................................................... 10
Motors and fans................................................................................................................................................. 10
Chapter 5.1 ............................................................................................................................................ 12
EMC .................................................................................................................................................................. 12
Example for correct EMC cabling and connections: ............................................................................. 12
Chapter 6 ............................................................................................................................................... 14
PLC Cabinet ...................................................................................................................................................... 14
Chapter 7 ............................................................................................................................................... 15
Burner ............................................................................................................................................................... 16
Author : M. van Hattum

Date : 04 November 2019
Version : 2.8
Requirements before comissioning AMPP Industrial Automation (NL)
Foreword
This document explains the most common mistakes for TEMA Process installation.
Please read this document carefully.
By doing these things correctly you can shorten the commissioning time.
This way a startup can be done quicker and faster.
If you have any questions about this document or the installation, please do not
hesitate to give us a call. We can help you step by step on the phone with what you
should do.
Doing so will eventually save you a lot of time and money.
Do not activate the power supply to the control panel!

BY DOING SO YOU WILL LOSE YOUR WARRANTY!!!
Overview of an installed dryer.
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The Netherlands email: info@ampp.nl
AMPP Requirements before comissioning_2.8.doc 4-11-19 12:21
Chapter 1
General findings
This chapter contains some explanations for some common devices. Like the air bellows, filter, in feed
etc.
Are all utilities available?

 For starting up the burner several things are needed.
o Gas, Oil or both.
o Compressed air.
o Check the TEMA Process drawing for the specifications.
 For the Dryer air bellows and filter (baghouse) compressed air is needed.
 For the cabinet, motors and instruments electricity is needed.
o One phase, and three phase is needed
o Check the AMPP documentation for the specifications.
 Product should be available to configure the dryer.
 Some installations need water or other products, are these available as well?
Are the emergency buttons and pull cords installed?

The emergency buttons and pull cords are double pole switched, SIL3 (category 4). 2NC (normally
closed) contacts parallel.
Is the product flow detection switch installed and working?

The product flow detection switch, FSA7405, should be installed.
There are several options for these sensors. See the pictures below.
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Are the air bellows grounded?

The air bellows should be grounded with a flexible cable.
Using a stiff cable shortens the life span of the ground cable, because the dryer will move up and
down continuously. Better to use a type like a battery cable.
Not all bellows have to be grounded, only minimum one bellow in the corner will suffice.
See the picture below how to connect the grounding cable.
Is the filter installed and tested?

 Is there compressed air available for the filter unit (baghouse)?
o See the TEMA Process drawing for specifications.
 Are all the hoses connected with an airtight seal?
 Are all valves connected to the control box?
 Are the filter sacks installed?
 DPICA3200 need to be installed outside the compartment to prevent overheating.
 Airlines need to be installed from DPICA3200 to the connectors which are inside the compartment.
 Between the Hesch boxes (extension and main board) a cable for the 2 alarm contacts is needed.
See the picture below for an example of the filter.
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Chapter 2
Cable connections
This chapter explains how to correctly connect a wire and what to use.
Use bootlaces/wire terminals.

All wires should have bootlaces/wire terminals on each end before connecting it to the control cabinet
and field equipment. This is to make sure you have a good connection between the cabinet and the
instruments.
Exception is if you use AWG wires or massive copper wires.
Use shielded cables.

Most sensors use a shielded cable.
See the electrical diagrams which instruments need a shielded cable.
Use heat resistant cable.

A few sensors need special flexible heat resistant silicone cable.
See the electrical diagrams which instruments.
(Mostly TICA1113 and TIA1120)
Tape off not used cables and wires.

Tape off all cables that are connected to the control cabinet but not connected in the field.
Also tape off all other wires that are not connected.
(in the control cabinet and in the field)
Shield/ground and earth.

Connect device as per manual. If not specified connect the earth or ground or shield on the panel side
to create a star point. Earth, ground and shield are important to connect in the correct way!
Shield only connected on the panel side must be taped off on the field side!
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Network cables Profinet and Modbus TCP/IP.

Used for HMI/SCADA/VSD’s/Siemens network Used for E12 Burner panel
Profinet cable shielded Cat5 (e6,7) shielded SFTP cable
Use profinet connectors ! Use shielded connectors!
Profinet connector Shielded connector

Example 6GK1901-1BB10-2AA0 Example 6GK1901-1BB11-2AA0
Profinet cable SFTP cable
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Chapter 3
PT100 – Temperature sensor
This chapter explains how to install and connect the PT100 temperature sensors.
These are the TICAxxx (Temperature indicator controller alarm) and TSAxxx (Temperature switch
alarm) sensors.
Use AMP rings/ring terminals.

Wires connected to the PT100 should have an AMP ring/ring terminal to make a good connection.
Also AWG wires and massive copper wires.
Placing the 400 and 600 degree sensors.

There are two types of PT100’s. A 400 degree and a 600 degree PT100.
The 600 degree PT100’s can withstand more heat and need to be placed in a different location.
(Mostly TICA101 and TSA3110)
Installing PT100 inside the dryer.

A few PT100’s need to be installed inside the dryer. This is to measure the product temperature.
(Mostly TICA1113 and TIA1120)
The cables to these sensors need to be installed in a round pipe. This is to remove movement and
pressure from the cable and extending its live span. (like a swans neck).
Use the specified cable for the PT100’s as per drawing (heat resistant silicon flexible shielded cable)
See the pictures below how to do this.
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Installing PT100 inside the dryer.

A few PT100’s need to be installed inside the dryer. This is to measure the product temperature.
 In the dryer are several anchor points for the PT100’s. Special brackets have been shipped with
the system for installing these sensors.
 Use special flexible heat resistant silicone shielded cable as per drawing.
 Adjust the cable op top of the horizontal bars. This is so the cable wont damage from jumping
product and creating a longer life time for the cable.
 See the pictures below how to correctly install these PT100’s.
 The last picture shows how the product temperature is being measured.
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Chapter 4
PICA – Pressure sensors
This chapter explains how to install and connect the pressure sensors.
These are the PICAxxx (Pressure indicator controller alarm) and PSAxxx (Pressure switch alarm)
sensors.
Placing of the sensor.

 The sensor is never connected directly to the dryer. Inside the sensor is a sensitive membrane.
When the dryer is moving up and down, this membrane will brake within a short time and a new
sensor is needed.
 The PICA1210 sensor is located on top of the dryer. This sensor should be higher than the dryer
and connected to it using a flexible (red) hose.
It should be done in that way, that no metal pipes are needed and no water can get stuck inside
the hose. If that happens, the sensor will not be able to work correctly.
 Below is a picture showing how to correctly install the PICA1210. Note that the sensor is higher
than the dryer and not attached to any moving part.
Install this PICA1210 on the hood of the dryer closest to the product inlet socket.
Filter pressure sensor.

The PDICA3200 is a pressure difference sensor. It measures two pressured sides and calculates the
difference.
This sensor must be installed outside the compartment
One side of the sensor is installed above the filter sacks and the other side below.
See the pictures below how to best install this sensor.
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Chapter 5
Motors and fans
This chapter explains how to install and connect the motors and fans.
Connecting the wires.

 Use cable shoes, rings or AMP’s for a good connection to the motor.
 Connect the ground cable with a ring at the ground terminal inside the junction box.
 Make sure you connect the motor correctly according electrical drawing and the motor plate. This
should be star, delta, star/delta or direct on line. See the next paragraph for more information.
Connecting the motor as delta or star.

 Check the motor information plate how to connect the motor. Star, delta, star/delta or direct on
line.
 Use the copper plates inside the motor connection box of remove them if you don’t use any of
them. If you use only one instead of three, keep the other two plates inside the motor box. This is
to be able to connect the motor from star to delta in the future.
 Don’t mix up the connections of the motor. Measure the cables to make sure Cable1 = U1, V1 and
W1 and Cable2 = U2, V2 and W2.
 See the picture below how to connect a star/delta motor.
Connecting frequency controlled motors.

Check the motor information plate how to connect the motor. Use EMC glands according EMC
regulations. The shield/screen of the cable most be connected to the EMC gland, otherwise connect
the ground to PE inside the motor box, see chapter 5.1 for more EMC details.
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Connecting frequency controlled motor cables inside the panel.
Use right torque and AMP ring terminals to connected the wires to the drives!
PTC/Thermistor goes directly to the VSD terminals.
Check the table for the correct Tightening torques

(Nm) of the VSD connections
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Chapter 5.1
EMC
Example for correct EMC cabling and connections:
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Chapter 6
PLC Cabinet
This chapter explains how to install the PLC cabinet and connect all the cables.
Do not activate the power supply to the control panel. By doing so you will lose your warranty!
General subjects.
 Do not drill holes in the control panel.
 Watch out for iron particles falling into relays and motor starters. This can damage the control
panel.
 Connect the control panel to the wall or floor, so it can’t fall over.
Use wire “jumpers” on not used terminals.

 Some terminals (X2, X4, X5, X7) need a connection to get the PLC running correctly. A wire
jumper is needed for this connection.
 Leave the wire jumpers long enough to go through the cable ducts.
 Do this for all instrument and devices which are not used. E.g. no thermistors used in the motors,
no isolation switches used, etc.
Grounding.
 Check if all the cables that need grounding are connected to the ground bar. E.g. shielded cables
and green/yellow cables, etc.
Circuit breakers and power supply.

 Use the correct amps for the three face power supply circuit breaker. See the electrical drawings
for the required amps.
 Set the correct voltage for the power supply to the cabinet. See the electrical drawings for the
correct power supply.
 Check if a three or one face power supply is needed or both.
 Connect a separate power supply for the lights and fans of the cabinet. 230/110/120Vac.
External communication.
 Connect the external communication cables to the PLC if required. E.g. Profinet, Ethernet
(Modbus TCP/IP for burner E12), internet (eWon) etc. Check the electrical drawings for more
information.
1. Check wire jumpers on connection terminals X2, X4, X5, X7 in control panel and in field
equipment (E07 Filter unit, valves e.g. and burner), “release product and dust output”.
2. Look for the right isolating switches + auxiliary contacts, see electrical diagrams.
3. Check communication signals with in- and out feed systems by others, check our electrical
diagrams.
4. Check if customer want to mount/install alarm horn/buzzer 24Vdc or 230/110/120Vac and failure
lamp, check our electrical diagrams.
Wiring.
 When putting the cables in the control panel fix it at the bottom with tie-wraps. Fix maximum three
cables together with one tie-wrap. (See picture)
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 Put away the cables in the gutters.

 All wires should have bootlaces/wire terminals on each end before connecting it to the control
cabinet and field equipment.
Exception is if you use AWG wires or massive copper wires.
 See pictures below how to correctly connect all the cables to the control panel.
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Chapter 7
Burner
This chapter explains burner and the burner panel.
Do not activate the power supply to the control panel. By doing so you will lose your warranty!
CombuServe burner:
General subjects.
 Check the burner schematics for the cable work, (E.g. 2 power cables and 1 Ethernet
SFTP cable for Modbus communication, also see chapter 2 Cable connections)
 Check if the right shielded ethernet RJ45 connectors has been used! (also see chapter 2 Cable
connections)
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Maxon burner:
General subjects.
 Check the burner schematics for the cable work, (E.g. burner cable TSA1102 and TSA3110)
terminal connection and wire jumpers.
 Make sure all products for the burner are available.
o Gas, Oil or both.
o Compressed air.
o Correct gas or oil pressure (eg. 300mB gas)
o Regulators and protection valves (OPSO valve)
o Check the TEMA Process drawing for the specifications.
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Requirements

Author : M. van Hattum

Do not activate the power supply to the control panel!

Overview of an installed dryer.

Are all utilities available?

Are the emergency buttons and pull cords installed?

Is the product flow detection switch installed and working?

Are the air bellows grounded?

Is the filter installed and tested?

See the picture below for an example of the filter.

Use bootlaces/wire terminals.

Use shielded cables.

Use heat resistant cable.

Tape off not used cables and wires.

Shield/ground and earth.

Network cables Profinet and Modbus TCP/IP.

Profinet connector Shielded connector

Profinet cable SFTP cable

Use AMP rings/ring terminals.

Placing the 400 and 600 degree sensors.

Installing PT100 inside the dryer.

Installing PT100 inside the dryer.

Placing of the sensor.

Filter pressure sensor.

Connecting the wires.

Connecting the motor as delta or star.

Connecting frequency controlled motors.

Connecting frequency controlled motor cables inside the panel.

Check the table for the correct Tightening torques

Use wire “jumpers” on not used terminals.

Circuit breakers and power supply.

 Put away the cables in the gutters.

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