Ecps C Manual Afb - Master v1 05

Andritz Feed & Biofuel – ECPS Manual
ECPS Manual
PLC ver. 1.05
HMI ver. 1.05
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Andritz FB - Automation dep. Page 1 1/3/2012
PREFACE ..........................................................................................................................................................................................4
INTRODUCTION ...............................................................................................................................................................................4
System Description .................................................................................................................................................................................. 4
Terminology ............................................................................................................................................................................................. 4
GRAPHIC OVERVIEW. .....................................................................................................................................................................5
Start – Stop Icons. ................................................................................................................................................................................... 5

Auto Start..............................................................................................................................................................6
Auto Stop. .............................................................................................................................................................6
Step Start. .............................................................................................................................................................6
Step Stop...............................................................................................................................................................6
Antiplug. ...............................................................................................................................................................6
Process icons. ......................................................................................................................................................................................... 6
TREND. .............................................................................................................................................................................................7
Zoom.....................................................................................................................................................................7
Trend “Scan” ........................................................................................................................................................8
Trend 1..................................................................................................................................................................8
Trend 2..................................................................................................................................................................9
Trend 3..................................................................................................................................................................9
Trend 4................................................................................................................................................................10
Trend 5................................................................................................................................................................10
CONFIGURATION ...........................................................................................................................................................................11
Autostop configuration ........................................................................................................................................................................... 11
Feeding Configuration............................................................................................................................................................................ 12
Extruder Configuration ........................................................................................................................................................................... 13
Temperature / Pressure Configuration ................................................................................................................................................... 15
Steam Configuration .............................................................................................................................................................................. 16
Additive 1 water to conditioner Configuration ......................................................................................................................................... 17
Additive 2 oil Configuration .................................................................................................................................................................... 18
Additive 3 water to extruder Configuration ............................................................................................................................................. 19
Autostart Configuration .......................................................................................................................................................................... 20
Main Configuration................................................................................................................................................................................. 21
GENERAL........................................................................................................................................................................................22
Login ..................................................................................................................................................................................................... 22
Calibration ............................................................................................................................................................................................. 23
System .................................................................................................................................................................................................. 23
Touch screen ......................................................................................................................................................................................... 23
Language .............................................................................................................................................................................................. 23
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COUNTERS.....................................................................................................................................................................................24
ALARMLIST .....................................................................................................................................................................................25
Troubleshooting alarms ......................................................................................................................................................................... 26
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Preface
This manual describes the functionality of the ECPS system and provides thorough instructions about set-
up, operation and troubleshooting of the system.
This manual is created for the ECPS system alone.
Furthermore, this manual gives the reader a general knowledge of Extruded feed production, as well as
comprehensive knowledge about the machines, of which this system will be controlled. The reader is
referred to the mechanical documentation of the relevant machines for any mechanical questions.
Enjoy!
Introduction
The ECPS control is a “Stand alone” system for controlling an extruder line (from prebin to or a part of it.
It is a simple system but with the capability of carrying out advanced automatic instructions.
System Description
The ECPS is based around a PLC, which handles all electrical signals to and from the machines. The PLC
communicates with the B&R 10.4” touch panel PC running Windows XP embedded and Zenon 6.51
SCADA software from Copa-Data (A-SCADA).
A-SCADA allows the operator to monitor, operate the process.
The Panel pc and PLC is connected via an Ethernet connection and it is therefore possible to add it to a
Local network and/or an internet connection so that remote support is possible.
Terminology
Absolute Interlock An absolute interlock is a safety interlock which can not be

bypassed in the PLC software.
Group The plant is divided into technological groups which represent a
functional unit within the plant.
Hard wired interlock A hard wired interlock is an electrical interlock without PLC
software influence.
HMI Human Machine Interface (Operation Terminal)
Limited Interlock A limited interlock is a process interlock which can be bypassed
at SCADA for maintenance purposes at a high access level.
MCC Motor Control Centre
PLC Programmable Logic Controller
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Graphic Overview.
The graphic overview is found in the Extruder-Detail tab. It shows the entire installation with all
components indicated. Icons for Motors, switches etc. changes color to show which state they are in.
Motors are red when stopped, green when running, and flashing to indicate an error status.
Switches are green when OK, i.e. in a state which does not prevent operation. A red switch means it is in
a state that prevents operation, and flashing signifies the switch has triggered an alarm.
There are 2 types of Parameter windows:
 Process value: The actual process value is indicated.

 Set point value: Set point values can be changed to optimize the process.
Example of a Graphic overview:
Start – Stop Icons.
The Graphic overview also contains the operation buttons for starting and
stopping the extruder equipment. The control starts each part of the machine in
preprogrammed steps that makes sure the machines start in the correct order.
During steps, the clicked button will blink green. When a sequence is started the
button will be constantly green.
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Auto Start.
When clicking “Auto Start” the extruder will make the start up as configured. (See configuration Auto start)
If extruder bypass valve is opened, the first click on “Auto Start” will start Forced feeder in reverse (if
available) then conditioner etc. When feed screw is running, the next click will start from knife motor.
When all machines are running operator must click on extruder bypass to move bypass to extruder.
Auto Stop.
Pressing Auto stop the extruder line stops as you set up the timers in the “auto stop configuration” section.
Step Start.
Step start is a start sequence, which allows you to start the extruder line backwards from the knife motor
to feed screw, in steps one by one.
Step Stop.
Step stop is a stop sequence, which allows you to stop the extruder line backwards from the feed screw to
the knife motor, in steps one by one.
Antiplug.
When clicking “Antiplug” the antiplug on/off valve will open for a preset time, and oil will be added into the
extruder barrel.
Process icons.
In general all setup of icons shown on the screen, can be configured

individual depending on the physical installed components.
This is done dynamic during startup from Andritz technician, and also possible
to change if further components are installed later.
(For further information see configurations).
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Trend.
The ECPS has real time and historical trend curves for a large number of variables.
The trend curve is accessed clicking Trend in the lower tab.
There are 5 different trend pages. The process values shown as trends are set for a full configured
control, and some might not be used on the specific machines installed.
On each trend bar there is a scale bar and 2 arrows. The bars fill color indicates the input value of the
variable, the small arrow indicates the Set Point of the process value and the big arrow indicates the
output.
Zoom
There are 3 zoom levels on the trend
10 min.
30 min.
24 hours.
The zoom level is selected in the dropdown box.
The trend curves are stored in the memory for 5 days.
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Trend “Scan”
Click on the “Scan” button (1) open a popup window “Trend Status” (2) where its possible to see the
trending values in historic mode, and go back to see old values, a vertical line (3) marks the value there is
selected on the trend. If the “Stop” button is pressed the time bar below the marker (3) can be moved
using the arrow keys on the window, (“<<” “<” “>” “>>”),
Click on “Play” button change time back to real time.
The “Trend Status” window can be closed by pressing the “Scan” (1) button again.
Trend 1
(Extruder load, Temperature outlet conditioner, Conditioner steam valve & Feed screw speed)
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Trend 2
(Barrel Zone 1 temperature, Barrel Zone 2 temperature & Barrel Zone 3 temperature)
Trend 3
(Barrel Zone 1 pressure, Barrel Zone 2 pressure & Barrel Zone 3 pressure)
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Trend 4
(Extruder gear oil temp & Extruder gear oil flow (pulse))
Trend 5
(Water flow to conditioner, Oil flow to extruder & Water flow to extruder)
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Configuration
The ECPS has adjustable parameters for each part of the machinery. They are usually adjusted by an
Andritz Feed & Biofuel technician before or during commissioning.
To open the configuration pages, click on “Config” in the lower menu bar.
The configuration variables can only be changed if the user is logged on as “Programmer”
Autostop configuration
The first configuration page, from where all the other configuration pages can be opened and you can
configure the settings for “Auto Stop”.
Parameter Explanation Typical setting / Notes

Step 1: The speed of the feed screw is reduced to 5%
the selected value, and steam to conditioner is
Feed screw + Close Steam
closed.
Time delay for next step 30 sec.
If Step selected.
Bypass valve after extruder is moved to Bypass
Bypass
dryer
If Step selected.
Antiplug + Conditioner Stop Select “Open antiplug valve” & “stop conditioner”
Conditioner additives stop in this step, (Before stop of Extruder)
This step will always be selected
Extruder, Forced feeder + Extruder
Stops Extruder, Forced feeder & Extruder
additives stop
additives.
Antiplug + Conditioner Stop
And Conditioner and Conditioner additives if not
Conditioner additives stop
stopped before
10 sec.
Time delay for next step
If selected or available
Knife motor Stop Stops the Knife motor
If selected or available
Oil Pump Stop Stops the Extruder gear lubrication Oil pump
Time delay for next step (Line stopped) 1 sec.
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Feeding Configuration
Configuration page for set-up of feeder screw and conditioner.

[110LS01] Low level available Low level sensor in pre bin installed Selected
[110LS01] Delay alarm time Delay time before alarm 5 sec.
Depending on level
Pre bin empty delay before autostop Time from alarm to activating “Autostop” sensor position
10 sec.
[110M02] Feed screw available Feed screw installed Selected
[110M02] Running alarm delay time Max feedback time on running signal 5 sec.
Feed screw calibration 100% speed Capacity of feed screw at full speed (100%) 5.000 – 15.000 kg/h
Feedback signal from frequency inverter on
[110SI01] PV (input) 4-20mA Selected
feed screw (0-20 or 4-20mA)
Output (control) signal to frequency inverter
[110SI01] CV (output) 4-20mA Selected
on feed screw (0-20 or 4-20mA)
[120M01] Conditioner 1available Conditioner 1 installed Selected
[120SS01] Speed guard alarm delay time Delay time before alarm after motor start 5 sec.
[120M02] Conditioner 2 available Conditioner 2 installed Selected if installed
[130M01] Forced feeder available Forced feeder installed Selected if installed
Forward and reverse on motor (reverse on
[130M01] Forced feeder reverse available Selected if installed
EX1250)
[130SS01] Speed guard available Speed guard installed on forced feeder Selected if installed
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Extruder Configuration
Configuration page for set-up of extruder main machine.

[140M01] Extruder available Extruder installed Selected
[140SS01] Speed guard available / alarm Speed guard installed on extruder main Selected if installed
delay time motor / Delay time before alarm 10 sec.
Back flange sensor installed (depending on
[140GS01] Back flange sensor available Selected if installed
extruder type)
Extruder load signal (0-20 or 4-20mA) Select
[140EI01] PV (input) 4-20mA Not selected
if 4-20mA
Calculated value from Ampere max and
[140EI01] Scale max
Ampere nominal.
[140M01] Ampere max Full scale signal (20mA) motor load See CT name plate
[140M01] Ampere nominal Extruder nominal load See motor name plate
[140M01] Voltage supply Motor voltage 400 V
[140M01] Cos phi Motor Cos phi 0,89
[190OV01] Bypass available 2-way distributor for Bypass dryer installed Selected
[190OV01] Position switch available Position switch on 2-way distributor Selected
Max feedback time from pos. switch on
[190OV01] Position alarm delay time 5 sec.
change position.
Alarm time on downstream machines after
[190GS01] Downstream alarm time 5 sec
extruder.
[141M01] Knife available Knife installed at extruder die plate Selected if installed
Output (control) signal to frequency inverter
[141SI01] CV (output) 4-20mA Selected
on knife (0-20 or 4-20mA)
Minimum speed on knife, low speed setting
[141SI01] Minimum speed for knife, if operator try to set a lower speed 25 %
set point it will be changed to this value.
[141GS01] Door switch available Door switch for knife installed Selected
Lubrication pump for extruder main gear.
[142M01] Gear oil pump available Selected if installed
Only available on some extruder models.
[142FS01] Flow switch alarm delay time Alarm time on oil lubrication flow switch 10 sec.
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[142PS01] Oil pressure alarm delay time Alarm time on oil lubrication pressure switch 10 sec.
Gear oil temperature (0-20 or 4-20mA)
[142TI01] Gear oil temp. 4-20mA Selected
Select if 4-20mA
[142TI01] Scale min / max Scale on gear oil temperature transmitter 0 – 150 °C
Max. temperature before alarm on gear oil
[142TI01] Max oil temp. 70 °C
temperature
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Temperature / Pressure Configuration

Configuration page for the extruder barrel temperature and pressure sensors.
For zone 1 – 3 where zone 3 is close to the die plate.

[156TI01] Temperature Zone 1 available Temperature sensor in Zone 1 installed Selected
[156TI01] PV (input) 4-20mA Temperature signal (0-20 or 4-20mA) Selected
[156TI01] Scale min Temperature at min signal 0 °C
[156TI01] Scale max Temperature at max signal 150°C
[156PI01] Pressure Zone 1 available Pressure sensor in Zone 1 installed Selected
[156PI01] PV (input) 4-20mA Pressure signal (0-20 or 4-20mA) Selected
[156PI01] Scale min Pressure at min signal 0 Bar
[156PI01] Scale max Pressure at max signal 150 Bar
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Steam Configuration
Configuration page for steam to conditioner & extruder barrel.

[150OV01] Conditioner steam valve
Steam to conditioner on/off valve installed Selected
available
Feedback signal (position switch) for steam
[150OV01] Position switch available Not selected
valve installed
[150OV01] Position switch alarm delay Max feedback time from pos. switch on
0 sec. (Not used)
time change position.
Steam to extruder barrel on/off valve
[152OV01] Extruder steam valve available Selected
installed
Feedback signal (position switch) for steam
valve installed
0 sec. (Not used)
Temperature conditioner signal
[150TIC] PV (input) 4-20 mA. Selected
(0-20 or 4-20mA)
Conditioner steam modulation valve signal
[150TIC] CV (output) 4-20 mA. Selected
(0-20 or 4-20mA)
[150TIC01] Scale min Temperature at min signal 0 °C
[150TIC01] Scale max Temperature at max signal 150°C
[150TIC01] Gain P value for Steam conditioner PID regulator 2.0
[150TIC01] I-time I value for Steam conditioner PID regulator 10.0
[150TIC01] Deviation delay alarm Delay time on the regulators deviation alarm 200 sec.
Feedbag signal type for conditioner steam
[150SI01] PV (input) 4-20 mA. Selected
modulation valve (0-20 or 4-20mA)
Parking position for conditioner steam
modulation valve, (position when on/off
Steam valve parking position 20 %
valve is closed) value depends on start set
point for feed screw, steam pressure etc.
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Additive 1 water to conditioner Configuration

Configuration page for additive 1 Water to conditioner.

[160M01] Water to cond. pump available Water pump for water to conditioner installed Selected
[160OV01] Water to cond. valve available Water to conditioner on/off valve installed Selected
Feedback signal (position switch) water
valve installed
0 sec. (Not used)
Flow meter for water to conditioner available
[160FIC] PV (input) available / 4-20 mA Selected - Selected
/ signal type (0-20 or 4-20mA)
Frequency inverter on pump for water to
[160FIC] CV (output) available / 4-20 mA conditioner available / signal type (0-20 or 4- Not available
20mA) (Option for future use)
[160FIC01] Scale min Flow meter min signal 0 kg/h
[160FIC01] Scale max Flow meter max signal 500 – 2500 kg/h
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Additive 2 oil Configuration

Configuration page for additive 2 Oil to extruder / Antiplug.

[161M01] Oil to Ext. pump available Pump for oil to extruder installed Selected
Load level on extruder motor for start of
Extruder amp. level start anti plug 105 %[A]
Antiplug.
Time where Antiplug valve is open when
Antiplug time Antiplug amp level is reach or a Antiplug 10 sec.
command is send
Time before checking of Antiplug amp.
Delay Antiplug at extruder startup 30 sec.
Level.
[161OV01] Oil to Ext. valve available Oil to extruder on/off valve installed Selected
valve installed
0 sec. (Not used)
[161OV02] Antiplug valve available Oil to extruder on/off valve installed Selected
valve installed
0 sec. (Not used)
Flow meter for oil to extruder available /
signal type (0-20 or 4-20mA)
Frequency inverter on pump for oil to
[161FIC] CV (output) available / 4-20 mA extruder available / signal type (0-20 or 4- Not available
[161FIC01] Scale max Flow meter max signal 125 –1500kg/h
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Additive 3 water to extruder Configuration

Configuration page for additive 3 Water to extruder.

Water pump for water to extruder installed
[162M01] Water to ext. pump available If not installed pump for additive 1 can be Selected
used. If valve 162OV01 is selected
[162OV01] Water to ext. valve available Water to extruder on/off valve installed Selected
valve installed
0 sec. (Not used)
Flow meter for water to extruder available /
signal type (0-20 or 4-20mA)
Frequency inverter on pump for water to
[162FIC] CV (output) available / 4-20 mA extruder available / signal type (0-20 or 4- Not available
[162FIC01] Scale max Flow meter max signal 500 – 2500 kg/h
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Autostart Configuration
Configuration page for auto start settings.

Select if gear oil pump is installed. Selected
Oil motor running
Delay time from pump running to next step 5 sec.
Select if knife motor is installed. Selected
Knife motor running
Delay time from knife running to next step 5 sec.
Always selected
Selected
Extruder motor running Delay time from extruder motor running to
5 sec.
next step
Select if installed
Selected
Extruder additives running Delay time from extruder additives running
5 sec.
to next step
Select if installed (only available on some
machines) Selected
Forced feeder running
Delay time from forced feeder running to 5 sec.
next step
Always selected
Selected
Conditioner + Additive running Delay time from conditioner and additive
20 sec.
pump running to next step
Always selected
Selected
Feed screw + Steam running Delay time from feed screw + steam running
10sec.
to machine in started / running step
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Main Configuration
Configuration page for general settings.

If selected an alarm will be generated if on of
Operation counter timer alarm on/off the operation hours counters reach the Not Selected
alarm set
Delay communication timer alarm Delay time before a communication alarm 100 sec.
Delay time from a alarm to activate an Auto
Delay start autostop at alarm 20 sec.
stop sequence
Read only. Show the version of software in
PLC ver. 1.05
the PLC.
PLC Firmware Read only. Show the firmware in the PLC 19.11
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General
The general window can be opened by pressing the “General” tap on the top bar.
From the general window the operator can select different function or find some system information.
In the bottom of the window the following is shown:
HMI version, Zenon runtime version & Computer name.
Login
The first button is for login of a different user.
The next button is for logout of current user.
Display below show current user.
Change user.
Tap on the login button - Login window open.
Tap on the input field below User identification - the onscreen keyboard open.
Tap the user id on the keyboard.
Tap on the field below the password, and tap the password on the keyboard.
Tap on ok, the user change and the window and keyboard close.
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Calibration
This function is for calibrating the Touch screen, at tap on the button a new screen is shown, follows the
instruction on the screen carefully.
System
First button: opens the Windows Task Manager.
Second button: opens Windows Desktop.
Last button: close the Zenon runtime.
Touch screen
Select “Popup keyboard” on/off at tap on a set-point.
Language
Select “Customer” or “Andritz” language.
Customer: can be the country language, or a customer special translated language file.
Andritz: English standard language file for this control.
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Counters
The ECPS has some build in service timers / counters, there is counting running hours for all the motors.
There are 2 counters: Standard service timer & Total counter.
For the service timer, the “ACT” count the hours. The “MAX” is a set-point where the operator can set a
value when he wants an alarm to be generated. When the “ACT” reach this value there is generated an
alarm (shown in the alarm log if selected) this alarm informs the operator that’s its time to check, calibrate,
adjust or ex change oil on a gear, etc. When the service is done the operator can reset the timer, by
pressing “RESET” and it will start again from 0.
There is a Total counter that not can be reset (Zero adjusted) by the operator. This Total counter count the
total running time, for the selected motor.
The square after the “MAX” indicate the status of the counter, whit the following indications:
Gray: Counter not active or not counting
Green: Counter active and counting.
Red: Counter have reach max value, and have generated an alarm.
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Alarmlist
The Alarm list has 2 list forms: History & Actual.
The History alarm list is selected by pressing the “History” button at the Filter section on the page.
This list shows all alarms for the last month.
In the “Option” section the total no. of alarms is shown, and also no. of not acknowledge alarms.
By pressing the “Acknowledge” button the selected alarm is acknowledge.
The “Acknowledge all” button acknowledges all pending alarms.
An alarm display is shown on all full screens windows, and a reset button is located right of the display.
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Troubleshooting alarms
Alarm Explanation Possible Solutions

[100HS01] Reset the Emergency stop button,
The Emergency stop is activated
Emergency stop [Alarm] and or relay
[110LS01] Be sure of machines before extruder
Prebin empty.
Prebin low level [Alarm] can follow the extruder flow.
[190GS01] Machines after extruder not running, ex. Check machines after the extruder
Downstream [Alarm] Dryer stopped. backwards.
Check doors on conditioner, check
[120GS01]
Door on conditioner 1 or 2 open. door switch, check safety relay,
Conditioner door switch [Alarm]
check cables.
Check about extruder barrel is fully
[140GS01] Back flange sensor on extruder not
assembled, check sensor, check
Ext. backflange sensor [Alarm] activated.
cables.
[141GS01] Close knife, check switch, check
Knife on extruder not closed.
Knifehouse door switch [Alarm] cables
Check motor protection relay,
frequency inverter, motor
[110M02] Motor not running / no feedback from motor
temperature, service breaker at
Feeder screw motor running [Alarm] starter
motor and fuse at PLC output
module
service breaker at motor and fuse at
Conditioner 1 motor running [Alarm] starter
PLC output module
Conditioner 2 motor running [Alarm] starter
PLC output module
frequency inverter (if installed, motor
Forced feeder motor running [Alarm] starter
module
[140M01] Motor not running / no feedback from motor service breaker at motor, motor
Extruder motor running [Alarm] starter temperature and fuse at PLC output
module
frequency inverter, motor
Knife motor running [Alarm] starter
module
Gear oil motor running [Alarm] starter
PLC output module
Water to cond. motor running [Alarm] starter
PLC output module
Oil to extruder motor running [Alarm] starter
PLC output module
[162M01] Water to extruder motor running Motor not running / no feedback from motor
[Alarm] starter
PLC output module
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Check air supply to solenoid and

valve, check position switch, check
[130OV01] Extruder bypass valve not in closed position
the bypass gate can move to the 2
Extruder Bypass valve not closed (Material to extruder)
end positions and activate the
position switch.
[130OV01] Extruder bypass valve not in opened position
the bypass gate can move to the 2
Extruder Bypass valve not opened (Material to bypass)
position switch.
[190OV01]
Dryer bypass valve not in dryer position the bypass gate can move to the 2
Ext. outlet bypass valve close [Fault]
position switch.
Dryer bypass valve not in bypass dryer
[190OV01] Ext. outlet bypass open [Fault] the bypass gate can move to the 2
position
position switch.
Check V-belts on motor, check
conditioner for overflow (level of
[120SS01]
Speed guard on conditioner 1 not ok material inside), check adjustment of
Conditioner 1 speedguard [Alarm]
sensor (switch level and sense
distance)
conditioner for overflow (level of
[120SS02]
Speed guard on conditioner 2 not ok material inside), check adjustment of
Conditioner 2 speedguard [Alarm]
sensor (switch level and sense
distance)
[130SS01] screw for blocked outlet, check
Speed guard on forced feeder not ok
Forced feeder speedguard [Alarm] adjustment of sensor (switch level
and sense distance)
Check V-belts on motor, check if
[140SS01] screw is blocked, check adjustment
Speed guard on extruder not ok
Extruder speedguard [Alarm] of sensor (switch level and sense
distance)
To high feed rate, liquid addition not
ok, material temperature not ok,
[140M01]
High load on extruder main motor screw or barrel worn out, If at start or
Ext. max ampere load [Alarm]
stop balance of dry material, steam
and liquids not in balance
[140M01] Check gear oil filter, check gear oil
Oil flow on gear oil below selected limit
Ext. gear oil flow [Alarm] temperature, check gear oil pump.
[142LS01]
Low level on gear oil. Check gear oil level
Gear oil level [Alarm]
[142PS05]
Low pressure on gear oil system Check gear oil filter
Gear oil pressure [Alarm]
[142TI01]
High temp on gear oil Check oil cooler
Gear oil temp. HI [Alarm]
Fault on cable or connection to frequency Check analog connections to
[110SI01]
inverter for feed screw, output (control frequency inverter, and try to reset
Feeder screw speed wirebroken [Fault]
signal) or input (feedback signal) alarm
[140EI01] Fault on connection to extruder main motor Check analog connections to load
Extruder amp. load wirebroken [Fault] load transmitter. transmitter
[141SI01]
inverter for knife motor, output (control frequency inverter, and try to reset
Knife speed wirebroken [Fault]
signal) alarm
____________________________________________________________________
Check connection to temperature

[142TI01] Fault on connection to temperature transmitter, check temperature
Gear oil temp. wirebroken [Fault] transmitter, no 4-20mA sensor, check temperature
transmitter.
Check connection to steam
[150SI01] Cond. steam position wirebroken Fault on feedback signal from steam modulation valve. Check output from
[Fault] modulation valve steam modulation valve.
Check power supply to valve.
Fault on connection to temperature transmitter, check temperature
[150TIC01] transmitter, no 4-20mA sensor, check temperature
Cond. Temp. PID wirebroken [Fault] Fault on analog control signal to Steam transmitter.
modulation valve. Check connection to steam
modulation valve
Check connection to pressure
[156PI01] Fault on connection to pressure transmitter,
transmitter, check pressure
Ext. barrel press. 1 wirebroken [Fault] no 4-20mA
transmitter.
Ext. barrel temp. 1 wirebroken [Fault] transmitter, no 4-20mA sensor, check temperature
transmitter.
transmitter.
transmitter.
transmitter.
transmitter.
[160FIC01]
inverter for water pump, output (control frequency inverter, and try to reset
Additive 1 PID wirebroken [Fault]
signal) alarm
Check analog connections to
[161FIC01] Fault on cable or connection to frequency
frequency inverter, and try to reset
Additive 2 "Oil" PID wirebroken [Fault] inverter for oil pump, output (control signal)
alarm
[162FIC01]
inverter for water pump, output (control frequency inverter, and try to reset
Additive 3 PID wirebroken [Fault]
signal) alarm
[110M02] When necessary service done reset
Service timer for feed screw.
Feeder operation time counter timer and alarm
Service timer for conditioner 1
Conditioner 1 operation time counter timer and alarm
Service timer for conditioner 2
Conditioner 2 operation time counter timer and alarm
Service timer for forced feeder
Forcedfeeder operation time counter timer and alarm
Service timer for extruder main machine.
Extruder operation time counter timer and alarm
Service timer for knife motor
Knife operation time counter timer and alarm
Service timer for gear oil pump
Gearoil pump operation time counter timer and alarm
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[160M01] Service timer for water to conditioner pump. When necessary service done reset
Water to cond. operation time counter (Additive 1) timer and alarm
[161M01] Service timer for Oil pump. When necessary service done reset
Oil to ext. operation time counter (Additive2) timer and alarm
[162M01] Service timer for water to extruder pump. When necessary service done reset
Water to ext. operation time counter (Additive3) timer and alarm
Check for power fault, check PLC
Alarm for indication of bad or no
Communication alarm to plc [Alarm] CPU for error, Check Ethernet
communication to PLC
switch, check communication cables
An alarm has been generated, if it not is
Acknowledge the alarm and take
If alarm not ack. Autostop is started acknowledged, auto stop will begin Auto
care of it, or let the machine stop
stop sequence
Simulation ON One of the components is in simulation Switch off the simulation
One of the components is in dynamic

Dynamic Simulation ON Switch off the simulation
simulation
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Ecps C Manual Afb - Master v1 05

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Andritz Feed & Biofuel – ECPS Manual

System Description .................................................................................................................................................................................. 4

GRAPHIC OVERVIEW. .....................................................................................................................................................................5

Start – Stop Icons. ................................................................................................................................................................................... 5

Autostop configuration ........................................................................................................................................................................... 11

Extruder Configuration ........................................................................................................................................................................... 13

Temperature / Pressure Configuration ................................................................................................................................................... 15

Steam Configuration .............................................................................................................................................................................. 16

Additive 1 water to conditioner Configuration ......................................................................................................................................... 17

Additive 2 oil Configuration .................................................................................................................................................................... 18

Additive 3 water to extruder Configuration ............................................................................................................................................. 19

Autostart Configuration .......................................................................................................................................................................... 20

Touch screen ......................................................................................................................................................................................... 23

Troubleshooting alarms ......................................................................................................................................................................... 26

Absolute Interlock An absolute interlock is a safety interlock which can not be

There are 2 types of Parameter windows:

 Process value: The actual process value is indicated.

Example of a Graphic overview:

Start – Stop Icons.

In general all setup of icons shown on the screen, can be configured

The zoom level is selected in the dropdown box.

The trend curves are stored in the memory for 5 days.

Parameter Explanation Typical setting / Notes

Parameter Explanation Typical setting / Notes

Parameter Explanation Typical setting / Notes

Temperature / Pressure Configuration

Parameter Explanation Typical setting / Notes

Parameter Explanation Typical setting / Notes

Additive 1 water to conditioner Configuration

Parameter Explanation Typical setting / Notes

Additive 2 oil Configuration

Parameter Explanation Typical setting / Notes

Additive 3 water to extruder Configuration

Parameter Explanation Typical setting / Notes

Parameter Explanation Typical setting / Notes

Parameter Explanation Typical setting / Notes

Alarm Explanation Possible Solutions

Check air supply to solenoid and

Check connection to temperature

Simulation ON One of the components is in simulation Switch off the simulation

One of the components is in dynamic

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