R O L C O X®

Intelligent
Controlling and monitoring system
for the

ROLLER PRESS

DATA TRANSFER LIST

SCADA  PLC, ROLCOX

Plant/Client:

El Brocal
Peru
Contract No.:
B.03.0731.3.001

ROLLER PRESS RPS 13 - 170/140 B

Machine No.:
502

Cologne, March 2012

Rev.: 0

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List of content

1 SCADA OUTPUT...................................................................................................................................... 3

1.1 SCADA to PLC ROLCOX: PARAMETER Roller Press...................................................................3

1.1.1 SCADA to PLC ROLCOX: CONTROL SIGNAL 1............................................................4
1.2 SCADA to PLC ROLCOX: RETURN SIGNAL 1.............................................................................5

2 SCADA INPUT.......................................................................................................................................... 6

2.1 PLC ROLCOX to SCADA: MEASURING DATA.............................................................................6

2.2 PLC ROLCOX to SCADA: ROLLER PRESS DATA.......................................................................7
2.3 PLC ROLCOX to SCADA: STATUS SIGNAL 1..............................................................................8
2.4 ALARM SIGNALS............................................................................................................................. 9
2.4.1 PLC ROLCOX to SCADA: ALARM SIGNAL 1.................................................................9
2.4.2 PLC ROLCOX to SCADA: ALARM SIGNAL 2.................................................................9
2.4.3 PLC ROLCOX to SCADA: ALARM SIGNAL 3...............................................................10
2.4.4 PLC ROLCOX to SCADA: ALARM SIGNAL 4...............................................................10
2.4.5 PLC ROLCOX to SCADA: ALARM SIGNAL 5...............................................................11
2.4.6 PLC ROLCOX to SCADA: ALARM SIGNAL 6...............................................................12
2.4.7 PLC ROLCOX to SCADA: ALARM SIGNAL 7...............................................................12
2.5 PICTURE SIGNALS........................................................................................................................ 13
2.5.1 PLC ROLCOX to SCADA: PICTURE SIGNAL 1............................................................13
2.5.2 PLC ROLCOX to SCADA: PICTURE SIGNAL 2............................................................14
2.5.3 PLC ROLCOX to SCADA: PICTURE SIGNAL 3............................................................15
2.5.4 PLC ROLCOX to SCADA: PICTURE SIGNAL 4............................................................16
2.5.5 PLC ROLCOX to SCADA: PICTURE SIGNAL 5............................................................16
2.6 PLC ROLCOX to (SCADA): START SIGNALS 1.........................................................................17

3 SCADA: CRT input field: Parameter Roller Press............................................................................18

4 SCADA: CRT input field: SWITCHES................................................................................................ 19

5 SCADA: CRT input field: PUSH BUTTON - function........................................................................19

6 SCADA: CRT: Status indication field for groups and input field "Switches".................................19

7 Limit values............................................................................................................................................. 20
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1 SCADA OUTPUT
1.1 SCADA to PLC ROLCOX: PARAMETER Roller Press

PARAMETER
PLC ROLCOX input
DB 41 Description Range PWL
DBW2 Op.pressure 30 - 150 bar
DBW4 Op.pressure increase max 10 - 99 bar
DBW6 Pressure ratio (10*) 0.0 - 8.0 bar/mm
DBW8 Pressure tolerance +/- 5 - 25 bar
DBW14 Pressure difference max (x) 20 - 70 bar
DBW16 Bearing distance Lmin (x) (10*) 1.0 - 12.0 mm
DBW18 Press.corr. Factor K3 0 - 100 %
DBW20 Gap setpoint ( L2 ) (x) (10*) 15.0 - 35.0 mm
DBW22 Gap difference permit (x) (10*) 2.0 - 7.0 mm
DBW24 Roller distance L/R min (x) (10*) 0.0 - 30.0 mm
DBW26 Grease distrib. pulsrate (x) 10 - 200 pulses/h
DBW28 Pressure incr. delay time (x) 0 - 180 sec
DBW30 Prop. Valves, P-highpoint 0 - 100 %
DBW32 Prop. Valves, P-low, lowpoint 0 - 100 %
DBW34 Prop. Valves, P-low, highpoint 0 - 100 %
DBW46 Bear.distance L2increase (x) (10*) 5.0 - 20.0 mm
DBW48 Excess current, drives (x) 900 - 1150 A
DBW50 Operation current, drives (x) 700 - 900 A
DBW52 Current difference, drives (x) 50 - 200 A
DBW54 Setpoint pre-bin level max 20 - 95 %
DBW56 Setpoint pre-bin level min 2 - 50 %
DBW58 Setpoint feed regulating gate (10*) 0 - 100 %
DBW60 Hysteresis for feed regulating gate (10*) 1-5 %
DBW62 Heater off, tank oil lubrication 30 - 50 °C
DBW64 Heater on, tank oil lubrication 25 - 40 °C
DBW66 5312MD1.J01 Power fixed roll 0 - 1000 kW
DBW68 5312MD2.J01 Power move roll 0 - 1000 KW
DBW70 5312MD1.I01 Current fixed roll 0 - 1000 A
DBW72 5312MD2.I01 Current move roll 0 - 1000 A
DBW74 Temperature recycle material 0
DBW76 Humidity fresh feed 0
DBW78 Fresh feed total 0
DBW80 Signal from metal detector 0
DBW82 Siganl flap to metal container 0
DBW84 Recycle feed total 0
Definition (10*): value will be transferred with factor 10; for example value 10.0 = 100

PWL= Pass Word Level

0 = No password required; free access to shift operator
1 = Access to Process engineer
2 = Access to System engineer (electrical)
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1.1.1 SCADA to PLC ROLCOX: CONTROL SIGNAL 1

CONTROL SIGNAL 1
PLC ROLCOX input
DB 41 Bit Description
DBX1 0 DI=Pl > Manual pressure increase left 1)
(F44.0)
1 DI=Pl < Manual pressure decrease left 1)
(F44.1)
2 DI=Pr > Manual pressure increase right 1)
(F44.2)
3 DI=Pr < Manual pressure decrease right 1)
(F44.3)
4 DI=Pl+r > Manual pressure increase left + right 1)
(F44.4)
5 DI=Pl+r < Manual pressure decrease left + right 1)
(F44.5)
6 DI=PCON Pressure controller automatic /manual 1)
(F44.6)
7 DI=BLC Shut-off gate, controller on 1)
(F44.7)
DBX0 0 DI=ALR Alarm acknowledgement 1)
(F45.0)
1 Spare
2 Spare
3 Spare
4 Spare
5 Spare
6 DI=WATCHDOG Ind. Ethernet Watchdog SCADA (F45.6)
7 Spare (F45.7)

1)
Definition of signals: The command will be executed, when the signal is 1.
The execution stops, when the signal is 0.
2)
The command will be executed, when the signal is 1.
The reverse action will be executed, when the signal
is 0.
3)
Upon receive of this signal (1) from SCADA the
corresponding watchdog signal from ROLCOX will
be set (1) and provided for SCADA. This signal shall
then be inverted (0) in SCADA. Consequently, the
watchdog signal from ROLCOX will also be inverted
(0).
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1.2 SCADA to PLC ROLCOX: RETURN SIGNAL 1

RETURN SIGNALS 1
PLC ROLCOX input
DB 41 type Description
DBX 100.0 BOOL Lubr_comm Command for Lubrication system group – start/stop
DBX 100.1 BOOL RP_comm Command for Roller press group – start/stop
DBX 100.2 BOOL Loc_oper Permission for local operation ( Roller press group )
DBX 100.3 BOOL GAP_ALR Alarm reset local
DBX10 0.4 BOOL R_5312MD1.M01 Return signal, main motor fixed roll
DBX 100.5 BOOL R_5312MD2.M01 Return signal, main motor move. roll
DBX 100.6 BOOL R_5312LQ1.M01 Return signal, motor gear oil pump fixed roll
DBX 100.7 BOOL R_5312LQ2.M01 Return signal, motor gear oil pump move. roll
DBX 101.0 BOOL R_5312LQ3.M01 Return signal, motor grease pump
DBX 101.1 BOOL R_5312HD1.M01 Return signal, motor hydraulic pump
DBX 101.2 BOOL Loc_oper_oil Permission for local operation (Oil lubrication group)
DBX 101.3 BOOL R_5312HD1.H01 Return signal, tank heater, hydraulic oil tank
DBX 101.4 BOOL R_5312LQ4.H01 Return signal, tank heater, oil lubr. system
DBX 101.5 BOOL TRANSP_R Material discharge on – return signal
DBX 101.6 BOOL R_5312SG2.M01_cl_on1 Return signal, feed regulating gate, closing on
DBX 101.7 BOOL R_5312SG2.M01_opn_on1 Return signal, feed regulating gate, opening on
DBX 102.0 BOOL R_5312LQ4.M01 Return signal, motor for circulation pump
DBX 102.1 BOOL R_5312LQ5.M01 Return signal, motor for feed pump
DBX 102.2 BOOL R_5312MX1.M01 Return signal, motor for stirrer
DBX 102.3 BOOL R_5312FN01.M01 Return signal, lube oil cooler FR
DBX10 2.4 BOOL R_5312FN02.M01 Return signal, lube oil cooler MR
DBX 102.5 BOOL R_5312FN03.M01 Return signal, oil to air cooler
DBX 102.6 BOOL Spare
DBX 102.7 BOOL Spare

Definition of signals: The command will be executed, when the signal is 1.

The execution stops, when the signal is 0.
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2 SCADA INPUT
2.1 PLC ROLCOX to SCADA: MEASURING DATA

MEASURING DATA
PLC ROLCOX output
DB 40 Description Range
DBW28 5312RP1.G01 Bearing distance left (10*) 0.0 - 100.0 mm
DBW30 5312RP1.G02 Bearing distance right (10*) 0.0 - 100.0 mm
DBW32 5312HD1.P02 Hydraulic pressure left 0 - 400 bar
DBW34 5312HD1.P03 Hydraulic pressure right 0 - 400 bar
DBW36 5312MD1.J01 Power FR drive 0 - 1000 KW
DBW38 5312MD2.J01 Power MR drive 0 - 1000 KW
DBW40 5312FB1.W01 Level pre-bin roller press 0 - 100 %
DBW42 5312RP1.T11 Bearing temp. MR drive site (10*) -20.0 ..+100.0 °C
DBW44 5312RP1.T12 Bearing temp. MR non drive site (10*) -20.0 ..+100.0 °C
DBW46 5312RP1.T01 Bearing temp. FR non drive site (10*) -20.0 ..+100.0 °C
DBW48 5312RP1.T02 Bearing temp. FR drive site (10*) -20.0 ..+100.0 °C
DBW50 5312LQ2.T01 Gear box bearing temp. MR (10*) -20.0 ..+100.0 °C
DBW52 5312LQ1.T01 Gear box bearing temp. FR (10*) -20.0 ..+100.0 °C
DBW54 Spare
DBW56 Spare
DBW58 Spare
DBW60 5312SG2.G01 Feed regulating gate (10*) 0.0 - 100.0 %
DBW62 Spare
DBW62 5312LQ4.T02 Temp. Oil lubrication tank (10*) -20.0 ..+100.0 °C
DBW66 5312LQ5.T04 Temp. in front of bearings- left (10*) -20.0 ..+100.0 °C
DBW68 Spare
DBW70 Spare
DBW72 5312LQ5.T06 Oil temp behind oil to air cooler -20.0 ..+100.0 °C
(10*)
DBW74 Spare
DBW76 5312MD1.I01 Current FR drive 0 - 1000 A
DBW78 5312MD2.I01 Current MR drive 0 - 1000 A
DBW80 5312HD1.T01 Temp. Hydraulic oil tank (10*) 0.0 ..+100.0 °C
DBW82 5312LQ5.T05 Temp. in front of bearings- right (10*) -20.0 ..+100.0 °C
DBW84 5312LQ4.T03 Temp. return line to tank (10*) -20.0 ..+100.0 °C
DBW86 5312RP1.S11 Speed movable roll (10*) 0.0 ... 21.0 1/min
DBW88 5312RP1.S01 Speed fixed roll (10*) 0.0 ... 21.0 1/min

Definition (10*): value will be transferred with factor 10; for example value 10.0 = 100
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2.2 PLC ROLCOX to SCADA: ROLLER PRESS DATA

ROLLER PRESS DATA

PLC ROLCOX output
DB 40 description Range
Spare
Spare
DBW128 PLC Grease distributor, counter left side 0 – 200 pulses
DBW130 PLC Grease distributor, counter right side 0 – 200 pulses
DBW132 PLC Operating time, hour – with load 0 - 29999 h
DBW134 PLC Operating time, minute- with load 0 - 59 min
DBW136 PLC Setpoint pressure left/right 0 - 245 bar
DBW138 PLC Setpoint pressure+correct. left 0 - 270 bar
DBW140 PLC Setpoint pressure+correct. right 0 - 270 bar
DBW142 PLC Bearing distance left + roller distance min (10*) 0.0 - mm
130.0
DBW144 PLC Bearing distance right + roller distance min (10*) 0.0 - mm
130.0
DBW146 PLC Current difference, roller drives 0 - 200 A
DBW148 PLC Operating time, hour 0 - 29999 h
DBW150 PLC Operating time, minute 0 - 59 min
PLC Spare
PLC Spare
PLC Spare
PLC Spare

Definition (10*): value will be transferred with factor 10; for example value 10.0 = 100
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2.3 PLC ROLCOX to SCADA: STATUS SIGNAL 1

STATUS SIGNAL 1
PLC ROLCOX output
DB 40 Bit Description
DBX127 0 DO=PCON Pressure controller automatic on (F46.0)
1 DO=PACT Pressure controller active (F46.1)
2 DO=BIN Shut-off gate, controller on (F46.2)
3 DO=WD Ind. Ethernet Watchdog ROLCOX 1) (F46.3)
4 DO=ALARM General alarm (F46.4)
5 RP_NSTOP RP Normal stop (F46.5)
6 RP_FASTSTOP RP Fast stop (F46.6)
7 RP_Emergency stop ROLCOX local panel ( +V4 ) (F46.7)
DBX126 0 DO=GAP_ALARM GAP_ALARM ( +V4 ) (F47.0)
1 DO=RP RUN Release Material transport (RP run) (F47.1)
2 DO=RP AVAIL Roller Press available (F47.2)
3 Spare (F47.3)
4 Spare (F47.4)
5 Spare (F47.5)
6 Spare (F47.6)
7 Spare (F47.7)

These signals are provided for indication on client’s operator’s station and interlocking.

3)
Definition of signals: Upon receive of this signal (1) from SCADA the
corresponding watchdog signal from ROLCOX will
be set (1) and provided for SCADA. This signal shall
then be inverted (0) in SACDA. Consequently, the
watchdog signal from ROLCOX will also be inverted
(0).
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2.4 ALARM SIGNALS

2.4.1 PLC ROLCOX to SCADA: ALARM SIGNAL 1

ALARM SIGNAL 1.1/1.2 -oil lubrication-

PLC ROLCOX output
DB 40 bit Description
DBX 3 0 5312LQ5.L01 Level tank 2 – oil lubr. system (0) - min
1 5312LQ4.L01 Level tank 1 – oil lubr. system (0) - min
2 5312LQ4.L02 Level tank 1 – oil lubr. system (0) – max2
3 5312LQ4.L03 Level tank 1 – oil lubr. system (0) - max
4 5312LQ4.T01 Thermo limiter oil lubr. system
5 5312LQ4.H01_FLT Trouble, Heater oil lubrication system - tank
6 5312MX1.M01_FLT Trouble, stirrer, oil lubric. system
7 5312LQ4.M01_FLT Trouble, Circulation pump, oil lubric. system
DBX 2 0 5312LQ5.M01_FLT Trouble, Feed pump, oil lubric. system
1 5312LQ4.T02_HH_1 Temp. oil lubr. system, tank
2 5312LQ4.T02_LL_1 Temp. oil lubr. system, tank
3 5312LQ4.T02_LP Loop oil temp. tank, oil lubrication system
4 5312LQ5.T04_LP Loop oil temp. in front of roller bearing - left
5 5312LQ5.T05 _LP Loop oil temp. in front of roller bearing - right
6 5312LQ4.T03_LP Loop oil temp. return line to tank
7 5312HD1.H01_FLT Trouble, Heater hydraulic oil tank

2.4.2 PLC ROLCOX to SCADA: ALARM SIGNAL 2

ALARM SIGNAL 0.1/0.2 -roller press-

PLC ROLCOX output
DB 40 Bit Description
DBX 5 0 5312LQ4.P02>1 Trouble, Filter 5312LQ4.P02>1
1 220VAC Power fail 220V AC
2 24VDC Power fail 24V DC
3 F 29.7 Trouble, trip greasing
4 F 21.4 Pressure difference max ( Gap correction )
5 F 21.3 Trouble, trip, pressure min
6 F 25.1 Trouble, Gap difference max
7 BCON.ALA Trouble, trip, bearing distance control
DBX 4 0 PMAXOFF Pressure >170bar, open emergency valve
1 F 32.4 Trouble, trip, both drive running
2 F 32.5 Trouble, trip, both drive start
3 F 32.6 Trouble, Current difference (MR-FR) abs.
4 F 43.0 Start-up time exceeded
5 5312SG2.V01_FLT Trouble shut-off gate
6 5312RP1.S01_LP Loop Speed FR
7 5312RP1.S11_LP Loop Speed MR
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2.4.3 PLC ROLCOX to SCADA: ALARM SIGNAL 3

ALARM SIGNAL 0.3/0.4 -roller press-

PLC ROLCOX output
DB 40 Bit Description
DBX 7 0 F 28.1 Trouble, grease transport
1 F 28.4 Trouble, grease distribution left
2 F 29.1 Trouble, grease distribution right
3 F 27.3 Trouble, trip, end limit left, QUITT EXT
4 F 27.2 Trouble, trip, end limit right, QUITT EXT
5 F 21.6 Excess power MR
6 F 21.5 Excess power FR
7 5312SG2.M01_FLT Trouble feed regulating gate
DBX 6 0 F 33.1 Trouble, trip, speed control MR
1 F 33.0 Trouble, trip, speed control FR
2 5312MD2.M01_FLT Trouble, main drive MR
3 5312MD1.M01_FLT Trouble, main drive FR
4 5312LQ2.M01_FLT Trouble, motor gear oil pump MR
5 5312LQ1.M01_FLT Trouble, motor gear oil pump FR
6 5312LQ3.M01_FLT Trouble, motor grease barrel pump
7 5312HD1.M1_FLT Trouble, motor hydraulic pump

2.4.4 PLC ROLCOX to SCADA: ALARM SIGNAL 4

ALARM SIGNAL 0.5/0.6 -roller press-

PLC ROLCOX output
DB 40 bit
DBX 9 0 5312LQ5.F01
1 5312LQ5.F02
2 5312LQ5.F03
3 5312LQ5.F04
4 5312LQ5.F06
5 5312LQ5.F07
6 5312LQ5.F08
7 5312LQ5.F09
DBX 8 0 5312LQ5.F05
1 5312LQ5.F10
2
3
4 5312LQ05.T06
5 5312FN03.M01_FLT
6 5312FN01.M01_FLT
7 5312FN02.M01_FLT
Description
Oil flow bear.No.1 MR drive side (0)
Oil flow bear.No.2 MR drive side (0)
Oil flow bear.No.3 MR non-drive side (0)
Oil flow bear.No.4 MR non-drive side (0)
Oil flow bear.No.6 FR drive side (0)
Oil flow bear.No.7 FR drive side (0)
Oil flow bear.No.8 FR non-drive (0)
Oil flow bear.No.9 FR non-drive side (0)
Oil flow axial bear.No.5 MR non-drive side (0)
Oil flow axial bear.No.10 FR non-drive side (0)
Loop oil temp. behind oil cooler
Trouble, fan oil to air cooler
Trouble, fan gear lubrication FR
Trouble, fan gear lubrication MR
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2.4.5 PLC ROLCOX to SCADA: ALARM SIGNAL 5

ALARM SIGNAL 0.7/0.8 -roller press-

PLC ROLCOX output
DB 40 Bit Description
DBX11 0 5312FB1.W01_LP Loop Pre-bin level
1 F29.6 Grease trouble since – 1 hour -
2 F29.5 Grease trouble since – 2 hours -
3 F29.4 Grease trouble since – 3 hours -
4 5312HD1.G01_opn Limit switch, bladder accumulator 1,left, not closed
5 5312HD1.G03_opn Limit switch, bladder accumulator 2,left, not closed
6 5312HD1.G02_opn Limit switch, bladder accumulator 1,right, not closed
7 5312HD1.G04_opn Limit switch, bladder accumulator 2,right, not closed
DBX10 0 5312HD1.L01 Level tank hydraulic system (0)
1 5312HD1.P01 Diff. pressure filter hydraulic oil
2 5312LQ2.P01>1 Trouble, Filter gear oil MR 5312LQ2.P01>1
3 5312LQ1.P01>1 Trouble, Filter gear oil FR 5312LQ1.P01>1
4
5
6
7
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2.4.6 PLC ROLCOX to SCADA: ALARM SIGNAL 6

ALARM SIGNAL 0.9/0.10 -roller press-

PLC ROLCOX output
DB 40 Bit Description
DBX 13 0 5312RP1.T11D_H Bearing temperature MR drive side
1 5312RP1.T11_HH Bearing temperature MR drive side
2 5312RP1.T12_H Bearing temperature MR non drive side
3 5312RP1.T12_HH Bearing temperature MR non drive side
4 5312RP1.T01_H Bearing temperature FR non drive side
5 5312RP1.T01_HH Bearing temperature FR non drive side
6 5312RP1.T02_H Bearing temperature FR drive side
7 5312RP1.T02_HH Bearing temperature FR drive side
DBX 12 0 5312LQ2.T01_H Gear box bearing temp. MR roller
1 5312LQ2.T01_HH Gear box bearing temp. MR roller
2 5312LQ1.T01_H Gear box bearing temp. FR roller
3 5312LQ1.T01_HH Gear box bearing temp. FR roller
4 5312HD1.T01_L Temperature hydraulic tank
5 5312HD1.T01_H Temperature hydraulic tank
6 5312HD1.T01_HH Temperature hydraulic tank
7 5312HD1.T02 Thermo limiter, hydraulic oil tank

2.4.7 PLC ROLCOX to SCADA: ALARM SIGNAL 7

ALARM SIGNAL 0.11/0.12 -roller press-

PLC ROLCOX output
DB 40 Bit Description
DBX 15 0 5312RP1.G01_LP Loop bearing distance left
1 5312RP1.G02_LP Loop bearing distance right
2 5312MD1.J01_LP Loop power FR
3 5312MD2.J01_LP Loop power MR
4 5312HD1.P02_LP Loop hydraulic pressure left
5 5312HD1.P03_LP Loop hydraulic pressure right
6 5312MD1.I01_LP Loop current FR
7 5312MD2.I01_LP Loop current MR
DBX 14 0 5312HD1.T01_LP Loop temperature hydraulic tank
1 5312SG2.G01_LP Loop feed regulating gate
2 5312RP1.T11_LP Loop bear. temp. MR drive side
3 5312RP1.T12_LP Loop bear. temp. MR non drive side
4 5312RP1.T01_LP Loop bear. temp. FR non drive side
5 5312RP1.T02_LP Loop bear. temp. FR drive side
6 5312LQ2.T01_LP Loop gear box bearing temp. MR
7 5312LQ1.T01_LP Loop gear box bearing temp. FR
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2.5 PICTURE SIGNALS

These signals are provided for indication on client’s operator’s station.
Additionally, all measuring values (see 2.1), Roller Press data’s (see 2.2)
and the measuring values provides by the client (see 1.3) shall be indicated
as numerical values.
All process values shall be available as historic trend data’s.

2.5.1 PLC ROLCOX to SCADA: PICTURE SIGNAL 1

PICTURE SIGNAL 1
PLC ROLCOX output
DB 40 Bit Description
DBX19 0 DO=PCON Pressure Controller automatic on
1 DO=PCACT Pressure Controller active
2 DO=BIN Shut off gate automatic on
3 Spare
4 DO=ALARM General alarm
5 Spare
6 GRO/OFF Group Roller press off
7 F 109.4 Group Roller press runs
DBX18 0 GRO/ONAC Group Roller press on active
1 GRO/ONRO Group Roller press delay off
2 GRO/LOC Group Roller press local
3 GR1/OFF Group Aux. heater off
4 F 57.4 Group Aux. heater runs
5 GR1/ONAC Group Aux. heater on active
6 GR1/ONRO Group Aux. heater delay off
7 GR1/LOC Group Aux. heater local
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2.5.2 PLC ROLCOX to SCADA: PICTURE SIGNAL 2

PICTURE SIGNAL 2
PLC ROLCOX output
DB 40 Bit description
DBX21 0 5312MD1.M01_R Main motor FR on
1 5312MD1.M01_FLT Trouble Main drive FR
2 5312MD2.M01_R Main motor MR on
3 5312MD2.M01_FLT Trouble Main drive MR
4 5312LQ1.M01_R Gear oil pump FR on
5 5312LQ1.M01_FLT Trouble Gear oil pump FR
6 5312LQ2.M01_R Gear oil pump MR on
7 5312LQ2.M01_FLT Trouble Gear oil pump MR
DBX20 0 5312LQ3.M01_R Grease barrel pump labyrinth sealing on
1 5312LQ3.M01_FLT Trouble Grease barrel pump labyrinth sealing
2 5312HD1.M01_R Hydraulic pump on
3 5312HD1.M01_FLT Trouble Hydraulic pump
4 5312LQ4.H01_R Heater oil lubrication system – tank on
5 5312LQ4.H01_FLT Trouble Heater oil lubrication system - tank
6 5312LQ4.M01_R Circulation pump, oil lubrication system on
7 5312LQ4.M01_FLT Trouble Circulation pump, oil lubrication system
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2.5.3 PLC ROLCOX to SCADA: PICTURE SIGNAL 3

PICTURE SIGNAL 3
PLC ROLCOX output
DB 40 Bit description
DBX23 0 5312LQ5.M1_R Feed pump, oil lubrication system on
1 5312LQ5.M1_FLT Trouble Feed pump, oil lubrication system
2 5312MX1.M1_R Stirrer, oil lubrication system on
3 5312MX1.M1_FLT Trouble stirrer, oil lubric. system
4 5312HD1.H1_R Hydraulic oil tank heater on
5 5312HD1.H1_FLT Trouble, hydraulic oil tank heater
6 5312SG2.V1_STAT Shut off gate opened
7 5312SG2.V1_FLT Trouble shut off gate
DBX22 0 5312HD1.V05 Solen. valve pressure decrease left
1 5312HD1.V06 Solen. valve pressure decrease right
2 5312HD1.V07 Solen. valve retraction cylinder
3 5312HD1.V09 Bypass valves hydraulic system - left
4 5312HD1.V10 Bypass valves hydraulic system - right
5 5312LQ5.V2 Valve bypass bearing right
6 5312LQ5.V3 Valve bypass bearing left
7 5312LQ5.V1 Solen. valve bypass behind feed pump

1)
Valve type is "fail open" (closed when energized).
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2.5.4 PLC ROLCOX to SCADA: PICTURE SIGNAL 4

PICTURE SIGNAL 4
PLC ROLCOX output
DB 40 Bit description
DBX25 0 5312HD1.V8 Emergency-off valve
1 F 53.0 SCADA: Grease flow at pump
2 F 53.1 SCADA: Grease flow progressive distributor left
3 F 53.2 SCADA: Grease flow progressive distributor right
4 5312HD1.V11 Bypass valves hydraulic system – left – 2. set -
5 5312HD1.V12 Bypass valves hydraulic system – right – 2. Set -
6 5312SG2.M1_LL Feed regulating gate
7 5312SG2.M1_HH Feed regulating gate
DBX24 0 5312LQ3.H1/2_C Aux. trace oil heater on
1 5312LQ5.H1/3_C Aux. trace grease heater on
2 F 36.0 Prop. valve, flow control left, close
3 P_DECR_L Flag: pressure decrease left
4 P_INCR_L Flag: pressure increase left
5 F 35.7 Prop. valve, flow control right, close
6 P_DECR_R Flag: pressure decrease right
7 P_INCR_R Flag: pressure increase right

2.5.5 PLC ROLCOX to SCADA: PICTURE SIGNAL 5

PICTURE SIGNAL 5
PLC ROLCOX output
DB 40 Bit description
DBX27 0 5312FN01.M01_R Fan gear lubrication FR on
1 5312FN01.M01_FL Trouble, fan gear lubrication FR
T
2 5312FN02.M01_R Fan gear lubrication MR on
3 5312FN02.M01_FL Trouble, fan gear lubrication MR
T
4 5312FN03.M01_R Fan oil to air cooler on
5 5312FN03.M01_FL Trouble, fan oil to air cooler
T
6 Spare
7 Spare
DBX26 0 Spare
1 Spare
2 Spare
3 Spare
4 Spare
5 Spare
6 Spare
7 Spare
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2.6 PLC ROLCOX to (SCADA): START SIGNALS 1

START SIGNALS 1
PLC ROLCOX OUTPUT
DB 40 type Description
DBX 100.0 BOOL C_5312MD1.M01 5312MD1.M01 Start order from
ROLCOX
DBX 100.1 BOOL C_5312MD2.M01 5312MD2.M01 Start order from
ROLCOX
DBX 100.2 BOOL C_5312LQ1.M01 5312LQ1.M01 Start order from
ROLCOX
DBX 100.3 BOOL C_5312LQ2.M01 5312LQ2.M01 Start order from
ROLCOX
DBX 100.4 BOOL C_5312HD1.M01 5312HD1.M01 Start order from ROLCOX
DBX 100.5 BOOL C_5312LQ3.M01 5312LQ3.M01 Start order from
ROLCOX
DBX 100.6 BOOL C_5312LQ3.H01/02 5312LQ3.H01/H02 Start order from ROLCOX
DBX 100.7 BOOL RELMAT Release material transport
DBX 101.0 BOOL RPAVAILA Roller press available
DBX 101.1 BOOL GENFAULT General fault
DBX 101.2 BOOL GAP_ALARM GAP alarm
DBX 101.3 BOOL C_5312SG2.M01_close Feed regulating gate, end limit – close -
DBX 101.4 BOOL C_5312SG2.M01_open Feed regulating gate, end limit – open -
DBX 101.5 BOOL C_5312MX1.M01 5312MX1.M01 Start order from
ROLCOX
DBX 101.6 BOOL C_5312LQ5.M01 5312LQ5.M01 Start order from
ROLCOX
DBX 101.7 BOOL C_5312LQ4.M01 5312LQ4.M01 Start order from
ROLCOX
DBX 102.0 BOOL C_5312LQ5H01/02/03 5312LQ5.H01/02/H03 Start order from ROLCOX
DBX 102.1 BOOL C_5312LQ4.H01 5312LQ4.H01 Start order from ROLCOX
DBX 102.2 BOOL C_5312HD1.H01 5312HD1.H01 Start order from
ROLCOX
DBX 102.3 BOOL C_5312FN01.M01 5312FN01.M01 Start order from
ROLCOX
DBX 102.4 BOOL C_5312FN02.M01 5312FN02.M01 Start order from
ROLCOX
DBX 102.5 BOOL C_5312FN03.M01 5312FN03.M01 Start order from
ROLCOX
DBX 102.6 BOOL Spare
DBX 102.7 BOOL Spare

Definition of signals: The command will be executed, when the signal is 1.

The execution stops, when the signal is 0.
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3 SCADA: CRT input field: Parameter Roller Press

PARAMETER (see also chapter 1.1)

Inputs on SCADA operator’s station
Description Default value PWL
Op.pressure 80 bar 0
Op.pressure increase max 10 bar 1
Pressure ratio 0.0 bar/mm 1
Pressure tolerance +/- 10 bar 0
Pressure difference max 60 bar 1
Press. corr. factor K3 50 % 1
Pressure delay time (incr.) 0 sec 1
Roller distance l/r min 10.0 mm 1
Bearing distance Lmin 5.0 mm 1
Gap setpoint ( L2 ) 25.0 mm 1
Bear. distance L2increase 10.0 mm 1
Gap difference permit 4.0 mm 1
Grease distrib. Pulsrate 40 pulses/h 1
Prop. valves, P-increase 100 % 1
Prop. valves, P-decr., lowpoint 50 % 1
Prop. valves, P-decr., highpoint 80 % 1
Excess current, drives 11590 A 2
Operation current, drives 900 A 2
Current difference, drives 200 A 1
Setpoint pre-bin level - max 55 % 1
Setpoint pre-bin level - min 15 % 1
Setpoint feed regulating gate 65 % 0
Hysteresis for feed regulating gate 1 % 0
Heater off, tank oil lubrication 45 °C 0
Heater on, tank oil lubrication 37 °C 0

PWL= Pass Word Level

0 = No password required; free access to shift operator
1 = Access to Process engineer
2 = Access to System engineer (electrical)
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4 SCADA: CRT input field: SWITCHES

CONTROL SWITCHES FUNCTION

Pressure controller manual/auto
Shut-off gate controller off/on
Group Roller Press stop/start
Group Aux. heaters stop/start
Release local operation off/on

Output definition:
manual / off / stop flag = 0
automatic / on / start flag = 1

5 SCADA: CRT input field: PUSH BUTTON - function

CONTROL SWITCHES FUNCTION

Manual pressure increase left on
Manual pressure decrease left on
Manual pressure increase right on
Manual pressure decrease right on
Manual pressure increase left + right on
Manual pressure decrease left + right on
Alarm acknowledgement on

The function shall be executed (output flag = 1) as long as the template at the
display is selected with the mouse curser and the mouse button is pressed.

6 SCADA: CRT: Status indication field for groups and input field "Switches"

INDICATION FIELDS TEXT

Pressure controller MANUAL / AUTO / ACTIVE
Shut-off gate controller ON / OFF
Group Roller Press OFF / ON / ACTIVE / DELAY OFF
/ LOCAL
Group Aux. heaters OFF / ON / ACTIVE / DELAY OFF
/ LOCAL
Release local operation REMOTE / LOCAL

The status text shall be indicated in the respective area at the display.
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7 Limit values

LIMIT VALUES
PLC ROLCOX output
description value
PLC Gap difference max. (10*) 14,0 mm
PLC Bearing temp. move./fixed roll H 55 °C
PLC Bearing temp. move./fixed roll HH 60 °C
PLC Gear box bearing temp. move./fixed roll H 85 °C
PLC Gear box bearing temp. move./fixed roll HH 100 °C
PLC Hydraulic oil temp. H 60 °C
PLC Hydraulic oil temp. HH 70 °C
PLC Lube oil temp. ( tank ) LL 10 °C
PLC Lube oil temp. ( tank ) L 30 °C
PLC Lube oil temp. ( tank ) H 55 °C
PLC Lube oil temp. ( tank ) HH 60 °C
PLC Lube oil temp. roller bear. left/right L 25 °C
PLC Lube oil temp. roller bear. left/right H 30 °C
PLC Hydraulic pressure min. left/right 30 bar

Limits are included within the ROLCOC program, and will not be transferred