ABB Industries

PLC

Gearless Mill Drive

Training Course
© ABB Industries - 1 -
 Table of contents

„ General structure
„ Controllers
„ Program overview
„ Systems
„ System operation
„ VMS
„ Transient recorder
© ABB Industries - 2
 PLC

„ General Structure
MILL DRIVE

„ Drive LUBRICATION SYSTEM

„ Systems LOW PRESSURE SYSTEM

„ Subsystems DEVICES

SENSOR 1
„ Devices
SENSOR 2

„ Aux. Equipment etc.

TRANSMITTER 1
etc.
AUXILIARY EQUIPMENT

PUMP 1

PUMP 2
etc.
HEATER 1
etc. etc.
SWITCH 1
etc.
BREAKE SYSTEM
etc.
© ABB Industries - 3

RINGMOTOR
etc.

etc.
 PLC

„ Control / interlocks
„ Signals are physically inputs/ outputs of the Drive Controller/ PLC as
well as internal calculated values or Boolean values as a result of logical
conjunctions.
„ Signals will be described in control/ interlocks of the particular
subsystems
„ Physical inputs/ outputs can be find in the I/O list of the referring mill
„ All significant Boolean and analogue values will be sent to the DCS
system. They can be find in the DCS list.
„ Interlocks are defined as an input/ output signal or a PLC/ DCS internal
logic condition that automatically prevents the operation of an individual
device/ auxiliary. Interlocks are listed in the interlock list.
© ABB Industries - 4
 PLC
„ Different types of interlocks
„ Safety interlocks

Safety interlocks are those interlocks that prevent damage to that

associated piece of equipment.

e.g.: Safety interlock for a pump would be “no high-high bearing

temperature”.
„ Start interlocks

Start interlocks are those interlocks that prevent a individual or function

group of equipment from being started. Once individual or function
group is running, the start interlock no longer inhibits operation.

e.g.: Safety interlock for a fixed speed fan would be “damper is

closed”.Process interlocks
© ABB Industries - 5
 PLC

„ Process interlocks

Start interlocks are those interlocks that prevent a individual or

function group of equipment from starting or running. The term
“process” is commonly used because these interlocks are often
dependent on another individual or function group of equipment
within the process.

e.g.: Process interlock for a belt conveyor would be “downstream

conveyor is running”.
© ABB Industries - 6
 PLC
„ e.g.: Interlocks of a Ball Mill

CYCLONE
UNDERFLOW
LAUNER

BALL MILL

BALL MILL
LUBRICATION
SYSTEM

BALL MILL
BRAKING
SYSTEM
CYCLONE
© ABB Industries - 7

FEED PUMPBOX CYCLOCONVERTER

AND RING MOTOR
COOLING
© ABB Industries - 8 PLC
 PLC

„ Controller
„ General
„ Time critical tasks

All time critical tasks will be processed in the drive control system
(PSR)

None time critical tasks will be processed in the PLC system

„ Functionality

If a certain functionality is part of the drive controller standard

package that package will be used as much as possible
© ABB Industries - 9
 PLC
„ Drive Control System (PSR)
„ Time critical tasks
„ Gate control thyristors
„ Excitation control
„ Motor/ Converter protection
„ Current voltage detection
„ Protection logic thyristor
„ Control and supervision of main circuit breakers
„ Current & speed control of the drive

„ Functionalities
„ Brake control logic
„ Cyloconverter cooling pump control logic
„ Ringmotor air gap detection
© ABB Industries - 10

„ Alarm/ Fault handling of complete cycloconverter system

„ MV circuit breaker control
 PLC

„ PLC System
„ Mode control
„ Communication from / to DCS system
„ Communication from / to PRS
„ Control lubrication system
„ Control ringmotor auxiliary system
„ Supervising and I/O control of cycloconverter cooling pumps
„ Supervising and I/O control of brake system
„ Alarm/ Fault handling of auxiliary drives/ devices
© ABB Industries - 11
 General overview

DCS
see DCS Signal List

VMS Ethernet
OperatelT Profibus
RSView ControlNet
Modbus
serial communication
DF1(Allen Bradley) or
Modbus
PLC PSR
Ethernet
OPC

PLC specific
Serialbus

I/O
see I/O Signal List
© ABB Industries - 12
 Overview of signal flow
23kV / 50Hz / 3ph -15/+5% Legend
380V / 3ph / 50Hz
1. MCC LV Power Supply
Client Proxy Server 2. Synchronisation Transformer HV Supply

4. HV Power Supply stator

5. Excitation Transformer Power Supply
Option 2
1 22 4 6. Stator Transformer 1 Power Supply
7. Stator Transformer 2 Power Supply
DCS 8. Stator Transformer 3 Power Supply
24
Distributed
VMS 9. Synchronisation Voltage
No Load Main Circuit
2 Power
VAR Control System Tower 10. Excitation Converter Power Supply
Disconnect Synchronisation Telephone
Breaker Stator Transformer Volt 11. Stator Phase (R) Power Supply
Switch Amp
Others 12. Stator Phase (S) Power Supply
4
Protect.Relay 13. Stator Phase (T) Power Supply
SR745 ABB CHIND
5 38 39a 14. Motor Excitation Power Supply
Option 1
Stator Stator
Transformer 2
Stator
Transformer 3
15. Motor Phase U,V,W Power Supply &
Transformer 1 44
Motor Starpoint
43
Excitation Hub/ 16. Converter Auxiliary LV Power Supply
Transformer Switch 17. Space Heater, Motor Fans Power Supply
18. Mill Brake Power Supply
next client 19. Cycloconverter Recooling System
Auxiliary Power Supply
39
23 25 26 27
20. Mill Lubrication System
Auxiliary Power Supply
10
21. MCC Control and Supervision
11 12 13 9 45
22. Excitation Breaker Control and Supervision
120VAC / 50Hz/ 1ph
Fire Fighting 23. Excitation Transformer Supervision

125VDC
MCC-supplied
Air condition UPS 24. Main Breaker Control and Supervision
redundant 40 System
Supply 25. Stator Transformer 1 Supervision
+F14
40
26. Stator Transformer 2 Supervision
MCC +CA +CB +CC
27. Stator Transformer 3 Supervision
+F05...+F08 PSR +F02 PLC Video Monitoring 28. Serial Interface PSR to PLC (RS 232 / DH+)
30
Control & Regulation +F03 System +F04 29. Motor Winding temperature Supervision
Water inlet / outlet temp. supervision by PT100
Cyclo-Converter 12-Pulse 30. Cycloconverter control & supervision
16 Excitation 31. Cycloconverter Recooling System
+F01 Cycloconv.Recooling Supervision
19 redundant 31 28 32. Mill Lubrication system Supervision
+F15 VMS Tower Data Logger
33. Excitation converter control
33 34. Air Gap Supervision
35. Air temp., water flow/ leakage, filter superv., dust
sealing
14 15 36. Interconnection MLCB to PLC
21 E-House
37 Arcnet Interface MLCB to PSR
42 38. Interface PLC to DCS
39. Serial Interace VMS to PLC
Knife switches 39a.Serial Interace VMS to Monitor in DCS
34 37 40. UPS Power Supply (PSR,PLC, VMS)
17 36 41. Mill Brake Control & Supervision
2 x Make up Fan

V
Ringmotor W
water leakage

U MLCB
dust sealing

42. Knife switch (rotor/stator) Control & Supervision

* x Motor Fans

PT100

Y
9x Probe

2x heat Motor Local Control

water flow

43. Line current, line power, line VAR signals to PLC

air temp.

exchanger
Excitation

Box
M 44. Transformer Differential Protection
Heater

air gap

29 45. 125VDC Supply voltage for Switch Gear

35
DF1(Allen Bradley) or Modbus
32
20
Mill Lubrication System Hardwired connections
© ABB Industries - 13

41
(scope of mill supplier) Mill Brake Ethernet, Profibus, ControlNet, Modbus
System
(scope of mill supplier)
Ethernet
18 Phoneline
© ABB Industries - 14

I/O interface

Fieldbus Module,
Profibus-DP

AC 800F (Master)
HUB CCR

Ethernet
Communication
Module

LOCAL HUB
Fieldbus Module,
Profibus-DP

Fieldbus Module,
Modbus Serial
VMS

PLC
PSR DRIVE
CONTROLLER

PSR
SAG MILL

AC 800F

Fieldbus Module,
DCS

VMS
Profibus-DP
BALL MILL 1

Ethernet
Communication
Module
BALL MILL 2

Fieldbus Module,
Printer

Profibus-DP

I/O interface
OPTION

I/O interface
Network PLC physical connection

ABB

I/O interface
ABB
ABB
DCS SYSTEM
CLIENT
© ABB Industries - 15

RS232

RS485

PSR Controller
ABB E- House Panel +F02 (PRS)

Allen Bradley DF1 or Modbus

Bus
PLC specific

17 5 6 - P A 7 2
Rack 0

1756-PA72 1756-PA72 1756-PA72 1756-PA72

1 7 5 6 -C N B R

17 56 -L5 5M 14

Rack 5
Rack 4
Rack 3
Rack 2

1756-CNBR 1756-CNBR 1756-CNBR 1756-CNBR

17 5 7-S R M

1756-IA16 1756-IA16 1756-ENET

R ESER VE
1756-IR6I 1756-IA16 1756-IA16 1756-MVI
R ESER VE

1756-IR6I 1756-IA16
R ESE RVE
R ESE RVE

1756-IR6I 1756-OW16I 1756-IA16

R ESE RVE

Ana log Outp ut

1756-IR6I 1756-OW16I 1756-IA16

R ESER VE

Ana lo g Outp ut

1756-IR6I 1756-OW16I 1756-IA16 1756-IA16

Ana lo g Outp ut

1756-IR6I 1756-OW16I 1756-IA16 1756-IA16

Ana log Outp ut

1756-OW16I 1756-IA16 1756-IA16

17 5 6 - P A 7 2
R ESE RVE
Ana log Outp ut

1756-IF16 1756-OW16I 1756-IA16 1756-IA16

Ana lo g Output

1756-IF16 1756-IA16 1756-IA16

R ESER VE
ABB E- House Panel +F03 (PLC)

1756-IF16 1756-OF6CI 1756-IA16 1756-IA16

1 7 5 6 -C N B R
Ana lo g Outp ut

1756-OF6CI 1756-IA16 1756-IA16

R ESE RVE
Ana log Outp ut

17 56 -L5 5M 14
Option

17 5 7-S R M
Local PLC physical connection

Rack 1

Ethernet

VMS
LOCAL HUB
ABB E- House

to DCS system

ABB TOOL
Commissioning notebook
 Ethernet

LEVEL 7 APPLICATON LAYER

APPLICATION example RSLOGIX, RSView,
PRESENTATION
LEVEL 6 LAYER
APPLICATION example RSLinx,
LEVEL 5 SESSION LAYER

LEVEL 4 TRANSPORT LAYER TCP SECURITY

LEVEL 3 NETWORK LAYER IP SOURCE,DESTINATION,

ETHERNET
LEVEL 2 DATA LAYER CSMA/CD

ETHERNET, CONTROLNET,…
LEVEL 1 PHYSICAL LAYER
© ABB Industries - 16
 Modbus

PLC SSV PSR

MVI Modul Modbus Modul

Port 1 Channel A

RS232 RS232
Port 2
RS485
RS485
Channel B
Port 3
© ABB Industries - 17
 Modbus
PSR PLC
Slave
Device Nr 6
MODBUS MODULE MCM.P2Cmd[1].IntAddress =0
Master
MCM.P2Cmd[1].Device = 6
MCM.P2Cmd[1].Func = 16
300H aaaa 0 MCM.ModDef.WriteStartReg 0 aaaa

301H bbbb 1 1 bbbb

302H cccc 2 2 cccc

303H dddd 3 3 dddd

00
MCM.ModDef.WriteRegCnt = 600

un ce = s = 6
s
6
d[0 Dev dre

3
C m d [ 0 ] . I n t Ad

c=
i
M. 2Cm [0].

].F
MC M.P Cmd
WRITE

2
MC M.P

P2
MC

MCM.P2Cmd[0].Count = 100
MCM.P2Cmd[1].Count = 100
598

599

600 MCM.ModDef.ReadStartReg 47

601 48 AAAA

602 49 BBBB

50 CCCC
MCM.ModDef.ReadRegCnt = 600

51

READ
© ABB Industries - 18

32FH gghh 96

330H AAAA 1197 97

331H BBBB 1198 98

332H CCCC 1199 99

 PLC

„ Program overview
„ Systems
„ Lubrication system (supplied by mill supplier)
„ Brake system (supplied by mill supplier)
„ MV (Medium Voltage) system
„ Excitation system
„ Cycloconverter system
„ Ringmotor system
„ E-House

„ System startup sequence

„ System shutdown sequence
© ABB Industries - 19
 PLC

„ Reference documents
„ Cat. 1 - SAG Mill Drive Operation Manual
- BALL Mill Drive Operation Manual

„ Cat. 2 - I/O Signal List – SAG

- I/O Signal List – BALL1
- I/O Signal List – BALL2

„ Cat. 3 - DCS Signal List – SAG

- DCS Signal List – BALL1
- DCS Signal List – BALL2
© ABB Industries - 20
 PLC
„ Cat. 4 - Mill Local Control Box Layout & Specification

„ Cat. 5 - Motor Maintenance Manual SAG

- Motor Maintenance Manual BALL 1-2

„ Cat. 6 - Network Architecture diagram for GMD

„ Cat. 7 - PLC Bill of Material

- VMS Bill of Material
© ABB Industries - 21
 PLC

„ I/O and DCS Signal List

„ Customer Tagname acc. ISA Letter
„ Equipment or System
„ Subsystem
„ Measured value
„ State
„ Address
„ Engineering unit
© ABB Industries - 22
 PLC

„ State
„ State
Alarm, Command, Control, Fault, High, Indication, Low, Normal,
Release, Selected, Value

„ Type
DI, DO, AIT, AIV, AIP, DIP, AOP, DOP, DIC, AIC
© ABB Industries - 23
 Lubrication system

„ Subsystem
„ General lube system
„ Oil reservoir system
„ Low pressure pump system
„ High pressure pump system
„ Emergency accumulator system
© ABB Industries - 24
 Lubrication System
DISCHARGING
FEED END
END

FLOW
DIVIDER

OIL
FILTER
INDIVIDUAL
NITROGEN
FLOW
CHARGING
DIVIDER
COOLING
WATER FLOW
DIVIDER
HEAT
EXCHANGER FLOW
DIVIDER
COOLING
WATER

FLOW
DIVIDER

LOW PRESSURE
PUMPS

RELIEF
RELIEF VALVE FLOW FLOW
VALVE DIVIDER
RELIEF DIVIDER
FLOW
VALVE
DIVIDER

HIGH PRESSURE
PUMPS
OPERATING OPERATING STANDBY
FLOW UNLOAD EMERGENCY
CONTROL RELIEF LUBRICATION
VALVE VALVE CIRCUIT
HEATERS
HEATER
ACCUMULATOR
© ABB Industries - 25

CHARGE/ RUNDOWN
SETTLING RETURN CONDITIONED
PUMP
COMPARTMENT COMPARTMENT COMPARTMENT
 Brake system

„ Subsystem
„ Hydraulic system brake
„ Reservoir system brake
„ Caliper system brake
© ABB Industries - 26
 MV (Medium Voltage) system

„ Subsystem
„ Disconnect system stator
„ Main circuit breaker stator (controlled by PSR)
„ Stator transformer 1
„ Stator transformer 2
„ Stator transformer 3
© ABB Industries - 27
 MV (Medium Voltage) system
23kV / 50Hz / 3ph -15/+5% Legend
380V / 3ph / 50Hz
1. MCC LV Power Supply
Client Proxy Server 2. Synchronisation Transformer HV Supply

4. HV Power Supply stator

5. Excitation Transformer Power Supply
Option 2
1 22 4 6. Stator Transformer 1 Power Supply
7. Stator Transformer 2 Power Supply
DCS 8. Stator Transformer 3 Power Supply
24
Distributed
VMS 9. Synchronisation Voltage
No Load Main Circuit
2 Power
VAR Control System Tower 10. Excitation Converter Power Supply
Disconnect Synchronisation Telephone
Breaker Stator Transformer Volt 11. Stator Phase (R) Power Supply
Switch Amp
Others 12. Stator Phase (S) Power Supply
4
Protect.Relay 13. Stator Phase (T) Power Supply
SR745 ABB CHIND
5 38 39a 14. Motor Excitation Power Supply
Option 1
Stator Stator
Transformer 2
Stator
Transformer 3
15. Motor Phase U,V,W Power Supply &
Transformer 1 44
Motor Starpoint
43
Excitation Hub/ 16. Converter Auxiliary LV Power Supply
Transformer Switch 17. Space Heater, Motor Fans Power Supply
18. Mill Brake Power Supply
next client 19. Cycloconverter Recooling System
Auxiliary Power Supply
39
23 25 26 27
20. Mill Lubrication System
Auxiliary Power Supply
10
21. MCC Control and Supervision
11 12 13 9 45
22. Excitation Breaker Control and Supervision
120VAC / 50Hz/ 1ph
Fire Fighting 23. Excitation Transformer Supervision

125VDC
MCC-supplied
Air condition UPS 24. Main Breaker Control and Supervision
redundant 40 System
Supply 25. Stator Transformer 1 Supervision
+F14
40
26. Stator Transformer 2 Supervision
MCC +CA +CB +CC
27. Stator Transformer 3 Supervision
+F05...+F08 PSR +F02 PLC Video Monitoring 28. Serial Interface PSR to PLC (RS 232 / DH+)
30
Control & Regulation +F03 System +F04 29. Motor Winding temperature Supervision
Water inlet / outlet temp. supervision by PT100
Cyclo-Converter 12-Pulse 30. Cycloconverter control & supervision
16 Excitation 31. Cycloconverter Recooling System
+F01 Cycloconv.Recooling Supervision
19 redundant 31 28 32. Mill Lubrication system Supervision
+F15 VMS Tower Data Logger
33. Excitation converter control
33 34. Air Gap Supervision
35. Air temp., water flow/ leakage, filter superv., dust
sealing
14 15 36. Interconnection MLCB to PLC
21 E-House
37 Arcnet Interface MLCB to PSR
42 38. Interface PLC to DCS
39. Serial Interace VMS to PLC
Knife switches 39a.Serial Interace VMS to Monitor in DCS
34 37 40. UPS Power Supply (PSR,PLC, VMS)
17 36 41. Mill Brake Control & Supervision
2 x Make up Fan

V
Ringmotor W
water leakage

U MLCB
dust sealing

42. Knife switch (rotor/stator) Control & Supervision

* x Motor Fans

Y
PT100
9x Probe

2x heat Motor Local Control

water flow

43. Line current, line power, line VAR signals to PLC

air temp.

exchanger
Excitation

Box
M 44. Transformer Differential Protection
Heater

air gap

29 45. 125VDC Supply voltage for Switch Gear

35
DF1(Allen Bradley) or Modbus
32
20
© ABB Industries - 28

Mill Lubrication System Hardwired connections

41
(scope of mill supplier) Mill Brake Ethernet, Profibus, ControlNet, Modbus
System
(scope of mill supplier)
Ethernet
18 Phoneline
 Excitation System

„ Subsystem
„ Disconnect system rotor
„ Excitation transformer
„ Excitation control
© ABB Industries - 29
 Cycloconverter System

„ Subsystem
„ Power part
„ Recooling unit
„ Control & supervision
© ABB Industries - 30
 Ringmotor system

„ Subsystem
„ Knife switches
„ Motor space heater
„ Overpressure air fans
„ Main motor fans
„ Motor winding temperature
„ Air gap monitoring
„ Motor local control box
© ABB Industries - 31
 E- House

„ Subsystem
„ Air condition system
„ Fire fighting system
„ UPS system
„ MCC system
„ Lighting system
© ABB Industries - 32
 System Operation

„ General
„ Main circuit breaker stator
„ Disconnect switch rotor
„ Cycloconverter power part
„ Cycloconverter cooling system
„ Knife switch stator
„ Knife switch rotor
„ Lubrication system
„ Brake system
„ Ringmotor auxiliary system
„ Ringmotor
© ABB Industries - 33
 Modes

„ Remote Mode
„ Normal mode of operation for SAG/ BALL mills.
„ Mill will be controlled by clients DCS.
„ E- House Mode
„ This mode will be provided mainly for commissioning or in case
of adjusting of regulation parameter/ measuring values for
optimizing the system.
„ MLCB Mode
„ This mode will be provided for local operation. Mill will be
controlled by the control unit in front of the respective mill.
„ All local operation like: Mill Inching, Mill creeping, Mill manual
lowering etc will be executed in this mode
© ABB Industries - 34
 Mode
PRIORITY 1: PRIORITY 2:
CONTROL DCS CONTROL MLCB

LOCAL CONTROL PANEL

MLCB

REMOTE = 0

REMOTE
?
RE S ER VE
DCS
DCS/ E-
MLCB HOUSE
1 7 5 6 -L 5 5 M 1 4
1 7 5 6 -P A 7 2

1756-ENET

MLCB
I/O Boards
1756-MVI

E-
HOUSE
PLC I/O INTERFACE

NO PRIORITY:
CONTROL E- HOUSE

CONTROL E- HOUSE

ABB ARCNET

PLC I/O INTERFACE

PLC PSR SERIAL COM

RE S ER VE
1 7 5 6 -L 5 5 M 1 4
17 5 6 -P A 7 2

1756-ENET

I/O Boards
1756-MVI

PSR Controller

Physical Connections
© ABB Industries - 35

Signal Flow
 Start-up sequence
„ Start auxiliary drives
„ Step 1.1 Start cycloconverter cooling system
„ Step 1.2 Start lubrication system
„ Step 1.3 Activate brake system
„ Step 1.4 Start ringmotor auxiliary system

„ Step 2 Switch on disconnect system (MV & excitation)

„ Manual switch on knife switches

„ Step 3 Start ringmotor

„ Horn
„ Release Excitation Rotor
© ABB Industries - 36

„ Release Cyclo converter

„ Ramp up to speed reference value
 Operation

„ During operation the motor will get the reference value from
selected control location. The drive will follow the reference
speed value as best as possible. Under extreme high load
condition's the regulation principle of the drive permits an
permanent offset between actual and reference speed. The drive
keeps running until reaching the overload current setting.
„ All systems will be supervised by the drive Controller/PLC
controller to act in case of any Alarms/ Faults
© ABB Industries - 37
 Shutdown sequences
„ Normal stop sequence
„ Ringmotor
„ Lubrication system
„ Ringmotor auxiliary drives

„ Drive system caused stop by:

„ Lubrication System caused stop
„ Brake System caused stop
„ Cyclo cooling caused stop
„ Ringmotor aux drives caused stop
„ MV System / Excitation system caused stop
„ Cyclo power / control part caused stop
© ABB Industries - 38
 Shutdown sequences

„ Emergency stop sequence

„ Ringmotor
„ Lubrication system
„ Ringmotor
„ Brake system
„ Cycloconverter cooling system
© ABB Industries - 39