Sub Control System HY-AM-10

1.
01
List of Contents 80009161 Ver.: 1.0
List of contents
1. Contents
.01 Lists of contents
.10 Lists of references
2.
3. Operating Instructions and System Description

.01 Lists of contents
.10 General description
4. Layout
.10 Flow diagram
.20 Block diagram 1/2

.21 Block diagram 2/2
.40 Panel, outline

.41 Panel, parts location
.42 Panel front signs
5. Interconnection Diagrams
.05 Power (incl. ventilator, fuses, light, air-con etc.)
.06 Power (incl. Control Display, power supply, PLC etc.)
.08 Power (48VDC)
.10 Emergency stop circuits
.11 Emergency stop circuits, Expansion
.30 Interlocks from/to gear lubrication unit
.40 Oil tank temperature, grinding pressure & grinding layer thickness
.41 Main valve supervision and roller position
.42 Pressure Transmitters for accumulators
.43 Diff. pressure for oil filter, oil tank levels
.44 Solenoid valve -Y01, -Y02, -Y03 and -Y04
.60 Circulation pump -M01
.61 Hydraulic pump -M02
.62 Heating element -E01
6. Parts Lists
.01 Parts list
7.
8. Remote Control Interface

.05 Signals list
9. I/O Addressing Arrangement

.05 PLC I/O address location
12/03/2008 KHP/SVo/FleJ
08:53:0025
Local control panel 1.10
List of references 80009161 Ver.: 1.0
List of references
Sub supplier instructions No.: 60049966
Sub supplier instructions No.: 60050023
Programming software and equipment:
PLC, Allen Bradley:

Rslogix5000, V16, 4 CD-ROM’s and License Disk 9324RLD300ENE
RS232 Programmer Cable, 3 meter 1756-CP3
ControlNet Communication Card, incl. Cable 3 meter 1784-PCC
Control Display, Pro-face:

GP-PRO/PBIII C-Package 03, V7.26E, 2 CD-ROM’s PFE-GPPRO-CNT01EU-P06
Incl. Screen data transmission cable for USB, 2 meter GPW-CB03
Digital amplifier (Hydraulic cooler drive), Bosch Rexroth:

Connection cable; additionally for BODAC (RS232) VT-HACD DEMO-1x/
Interface modules, PR-electronics:

Loop Link for USB:
Configuration software kit incl. Preset V5.20.1042, CD-ROM 5909
ECS License for Sub control Systems:

SCS1362 Sinai Grey
20-Aug-08 KHP/KHP/MRSc
Local control panel HY-AM-1011 3.01
System structure and operation procedure 80009161 Ver.: 1.0
LIST OF CONTENTS
GENERAL DESCRIPTION..................................................................................................... 10
OPERATION............................................................................................................................ 11
Operation of the heating system .......................................................................................... 11
Hydraulic system ................................................................................................................. 11
Lifting the rollers ................................................................................................................. 11
Grinding control................................................................................................................... 12
OPERATING PROCEDURE, CONTROL DISPLAY ............................................................ 13
Main menu picture ............................................................................................................... 14
Mode of operation................................................................................................................ 15
Central Control Mode ..................................................................................................... 15
Local Control Mode ........................................................................................................ 15
Local Test Mode ............................................................................................................. 15
Mimic diagram..................................................................................................................... 16
Control menu ....................................................................................................................... 17
Control picture No. 1 - Local control, Hydraulic unit..................................................... 17
Control picture No. 2 - Local control, Heating ............................................................... 19
Control picture No. 3 - Central control, Change filter .................................................... 20
Control picture No. 4 - Local test, Pumps....................................................................... 21
Control picture No. 5 - Local test, Heating element ....................................................... 22
Alarm list ............................................................................................................................. 23
CCS signals status, digital ................................................................................................... 27
CCS signals status, analogue ............................................................................................... 28
Parameter menu ................................................................................................................... 29
Parameter picture No. 1 - Alarm limits........................................................................... 30
Parameter picture No. 2 - Override CCS signal.............................................................. 31
Parameter picture No. 3 - Setpoint and Delaytime ......................................................... 32
Parameter picture No. 4 - Control limits......................................................................... 33
Parameter picture No. 5 - Water cooling system ............................................................ 34
Parameter picture No. 6 - Empty/filling oil tank............................................................. 35
Parameter picture No. 7 - Local test valves .................................................................... 36
Parameter picture No. 8 - Local test pressure systems.................................................... 37
GENERAL SPECIFICATION ................................................................................................. 40
COMMUNICATION WITH CCS ........................................................................................... 80

Digital signals to CCS.......................................................................................................... 80
Digital signals from CCS ..................................................................................................... 81
Analog signals to CCS ......................................................................................................... 81
Analog signals from CCS .................................................................................................... 81
21-Apr-08 KHP / SVo / MRSc

GENERAL DESCRIPTION
The purpose of the local control panel is to:
- Control the operation of the hydraulic system.

- Process and display various measuring points.
- Perform test and adjustment during commissioning.
- Alarm abnormal conditions.
- Communication with the central control system (CCS).
A flow diagram for the hydraulic system is shown on page 4.10.
The hydraulic systems main function is to maintain the grinding pressure within a set range, and to
control the position (up/down) of the grinding rollers.
The hydraulic system consists of a hydraulic pump unit (oil tank, valves and a hydraulic pump), 3
hydraulic controlled cylinders and one set of connections between the pump unit and the
cylinders.
The oil tank is equipped with a heating element(s) and a circulation pump to heat the oil to a
proper operation temperature.
In the circulation string is build in a filter to clean the oil, and a water-cooled heat exchanger to
cool the oil if necessary.
The heating and circulation are, based on a temperature measurement in the oil tank, controlled
from the local control panel; the water-cooled heat exchanger is likewise controlled by the
temperature sensor in the oil tank.
The hydraulic pump supplies through the valve block oil to the cylinders. The grinding pressure
and the position of the grinding rollers are controlled by starting and stopping the hydraulic pump
and by opening and closing the valves.
A full description of the functions and maintenance of the hydraulic system can be obtained in
FLS instruction manual.

OPERATION
The operation of the hydraulic system is divided in two parts:

- Operation of the heating system
- Hydraulic system
Operation of the heating system
Before start, the heating system must be ready i.e. no alarms must be present in the system.
When a start command to the heating system is given, the heating element will be energized and
the temperature in the oil tank will rise.
When the tank oil temperature > 1°C, the circulation pump will start and oil circulation will take
place.
When the tank oil temperature > 40°C , the heating element will be de-energized, and when the
temperature has dropped below 35°C , the heating element will again be energized.
When the tank temperature exceeds the temperature t-max (see parameter picture) for water
cooling ON, the valve Y04 will be energized. When the temperature has dropped below t-min, the
temperature for water cooling OFF, Y04 will be de-energized.
If the tank temperature drops below 1°C, the circulation pump will stop.
Hydraulic system
Before start, the hydraulic system must be ready i.e. no alarms must be present in the system, and
the tank oil temperature > 17°C.
The main relief valve Y03 is energized as soon as the system is powered up, and will relieve the
system in case of power failure.
The mill has always to be started with the rollers in lifted position to minimize the breakaway
torque of the mill motor.
Lifting the rollers
When the command to lift the rollers "Rollers up" is given the hydraulic pump will be started and
the hydraulic pressure will rise.
When the pressure exceeds min.1, the solenoid valves Y01 and Y02 will be energized and the
rollers will be lifted.
When the rollers reach their top position the mill motor can be started.

Grinding control
When the mill motor and the mill feed system is in operation and the command "Start grinding
control" is given (and the signal "rollers up" removed), the hydraulic pump will start if not already
started and the solenoid valves Y01 and Y02 will be de-energized.
The rollers will now be lowered onto the grinding table, and the grinding pressure will start to rise.
When the grinding pressure has reached the setpoint value and a delaytime is expired, the signal
"grinding in operation" is send to CCS.
The grinding pressure will be kept on the setpoint value in the following way.
Around the setpoint is programmed 4 limits P1, P2, P3 and P4.
When the grinding pressure reaches the value Setpoint + P1, the hydraulic pump will be stopped,
if the pressure continues to raise the solenoid valve Y2 will be energized and the pressure starts to
be relieved, when the pressure exceeds setpoint + P3.
If the grinding pressure drops below setpoint - P2, the solenoid valve Y02 will be de-energized
and relieve of the pressure will stop. If the pressure drops below setpoint - P4, the hydraulic
pump will start again.
The setpoint can be set from the Central Control system, or when in Local Control mode from the
local control panel.
The 4 limits P1, P2, P3 and P4 can be adjusted as parameters in the local control panel.

OPERATING PROCEDURE, CONTROL DISPLAY
General
The local control panel is equipped with a control display (CD), which acts as a communication
interface between the PLC and the operator. The CD's touch screen functions make it possible for
the operator to operate the system, monitor various functions, change parameters and display
actual values. The various pages and functions on the display have been designed and
programmed to suite the operational needs of this unit.
Operating functions and changing of parameters, which should be protected against intervention
by unauthorised personnel, are protected by a password.
Display design
Information and functions are to be looked for in screen pictures with the following headlines:
-Main menu
-Mode selection
-Mimics
-Control
-Local test
-Alarms
-Alarm history
-Parameters
-CCS signal status
Top menu bar

On top of all screen pictures there is a menu bar with the following information/functions:
-Indication of actual control mode (CC, LC or LT mode).
-Direct access to the main mimic (press the FLS-logo)
-Direct access to the main menu and alarm pictures.
-Indication of alarm present in the system (present alarms are indicated by a red coloured alarm
key).
Touch function
Touch sensitive key areas are shown as push buttons. Use a light pressure with a finger to activate.
Screen saver function

To extend the lifetime of the control display, a "screen saver function" is incorporated.
When no touch has been made on the screen for more than 10 minutes, the control display will go
into standby mode.
The control display is activated by touching the screen in any position.
Detailed description
On the following pages a description of each screen picture and explanations of the various
functions etc. that appears on the screen will follow.

Main menu picture
Main menu picture shows the different pictures that can be selected by activating the appropriate
touch key. The pictures are placed in groups by type as listed below:
SELECTION Selection between the different operational modes.
MIMIC Mimic diagram showing status of the process.
CONTROL Local operation/regulation of the machines and various test functions

can take place from these pictures.
PARAMETER When the touch key SET VALUE is pressed a numeric keyboard will
appear. When the correct password (=number) is entered in the numeric
keyboard a menu of the parameter pictures will appear.
(PASSWORD = 3618)
STATUS When the touch key CCS SIGNAL is pressed a status of signals between
CCS and local control panel (LCP) will appear.
ALARM List of all active alarms in the system.
On the top of all pictures, a ”Top menu bar", is shown. From the ”Top menu bar" other pictures
can be selected, further the actual control mode and alarm status are shown.
.

Mode of operation
Three different modes of operation for the machine can be selected. The actual selected mode will
be indicated with light in the appertaining touch key.
Central Control Mode

In this mode the machine is controlled from the Central Control System (CCS). It means that
the machine is started, stopped and regulated from the CCS.
The central control mode is the basic mode as the system always will be in this mode when the
system is powered up and as the system automatically will go to this mode when local test is
not selected.
“CC mode” will be shown in the mode-key in the "top menu bar"
Local Control Mode

In this mode the machine is controlled from the local control panel.
The mode can only be selected when the signal "local permission" is present.
A green dot in the LOCAL CONTROL button will indicate that the function can be selected.
“LC mode” will be shown in the mode-key in the "top menu bar"
Local Test Mode

In this mode system test of the machine and test of the individually parts of the Hydraulic unit
can take place.
The mode can only be selected when the signal "local permission" is present.
A green dot in the LOCAL TEST button will indicate that the function can be selected.
“LT mode” will be shown in the mode-key in the "top menu bar"

Mimic diagram
The mimic is a simplified flow diagram for the Machine showing:

- Status of motors, valves etc.
- Process values
- Alarm indication points
The mimics are for monitoring only.
A manually operated valve (Inlet valve) is shown with a symbol showing the following status:
Green (Open), red (Closed) Alarm.
The control valves (Y01, 02, 03 & 04) are shown with a composed symbol an icon with the letter
“S” inside showing the following status: Green (Activated), white (De-activated), and the valve
symbol showing the following status: Green (Passage), white (Closed).
A motor (M01) is shown as an icon with the letter “M” inside and a heating element (E01) is
shown as a rectangular symbol showing the following status:
White (Stopped), green (Running/Activated), red (Alarm).
Digital alarms are shown as a red circle with a letter within when in alarm state with the following
letters applied otherwise invisible:
"L" (Level), "P" (Pressure)
A flashing "T" next to a heating element indicates that a preset temperature (thermostat inside
heating element) is reached and de-energize the heating element. The flashing “T” disappears
when the temperature has dropped below hysteresis of the thermostat and the heating element is
re-energized.
A filer is indicated as a squared box with a dotted horizontal line inside showing the following
status: White (OK), red (blocked) alarm.

An analogue signal displayed is represented by the actual engineering unit.

If an alarm on the analogue signal occurs the displayed value will be highlighted with a red colour.
Control menu
From Control Menu tree test modes can be chosen:
Local Control Mode - Hydraulic unit
Local Control Mode - Heating system
Central Control Mode - Changing oil filter
Control picture No. 1 - Local control, Hydraulic unit
From control picture Local Control Hydraulic unit, it is possible in Local Control mode
“LC MODE” to select two modes:
ROLLERS UP
GRINDING CONTROL
Rollers up:
When the system is ready to start, a green dot will appear in the “START” push button. When the
start button is activated, the hydraulic pump will start.
The hydraulic pressure will raise and when it reaches MIN.1, the solenoid valves Y01 and Y02
will be energized, and the rollers will start to lift. The rollers will remain in top position as long as
the button is indicating green
To stop, press the “STOP” button.
The rollers will be lowered against the table.

Grinding control:
When the gear unit is in operation and the system is ready, a green dot will appear in the
“START” button and the grinding pressure control can be started.
Before start a proper setpoint range for the grinding pressure has to be set (ref. FLS instruction).
A green frame around the set point value field below the bar graph indicates that the set point
value can be changed.
Activating the set point value field and using the up-/down- keys sets the setpoint value until the
wanted set point value is obtained.
(The up-down keys can only be used in a period of 30 sec after activation of the value field.)
The range for the setpoint can be checked from parameter picture no. 3.
The upper/lower control limits for the hydraulic pressure can be set at parameter picture no. 4.
Activate the “START” button and the grinding pressure will start to rise. When the hydraulic
pressure is within the setpoint range and the delay time adjusted at parameter picture no. 3 has
expired, the system is In Operation.
During operation, the set point for the hydraulic pressure can be changed.
To stop, press the “STOP” button.
Remark!
In the control system is build in limits for the permissible range for the set point for the hydraulic
pressure.
If a set point value outside the range is selected, it will automatically be changed to the nearest
permissible value, see parameter picture no. 3.

Control picture No. 2 - Local control, Heating
From control picture No.2, the heating system can be started and stopped, when the system is in
Local Control Mode “LC MODE”.
On the mimic diagram the actual status of the system is monitored.
A green dot in the “ON” button will indicate that the heating can be selected.
Press the “ON” button and the heating will be started as long as the button is indicating green.
Press the “OFF” button to stop the heating.

Control picture No. 3 - Central control, Change filter
From control picture No. 3, it is possible to stop the circulation pump if the filter in the circulation
line is blocked and the system is in “CC MODE”.
The circulation pump must be restarted within one hour; otherwise the lubrication unit and the
heating unit will be stopped due to an A2-alarm.
The following conditions must be present in order to stop the circulation pump:
1. Oil filter blocked.

2. Lubrication unit in central control mode.
If the circulation pump has been stopped for changing of the filter, it can only be restarted from
the control picture.

Control picture No. 4 - Local test, Pumps
From this picture the pumps can be started and stopped, when the system is in Local Test Mode
“LT-MODE”.
A green dot in the “START” button will indicate that the pump can be started.
Activate the “START” button (colour changes from white to green) and the pump will be running
as long as the button is green.
Activate the “STOP” button to stop the pump (colour changes from green to white).

Control picture No. 5 - Local test, Heating element
From this picture the Heating elements can be activated and de-activated, when the system is in
Local Test Mode “LT-MODE”.
A green dot in the “START” button will indicate that the Heating element can be activated.
Activate the “START” button (colour changes from white to green) and the Heating element will
be active as long as the button is green.
Activate the “STOP” button to de-activate the Heating element (colour changes from green to
white).

Alarm list
Whenever an alarm occurs, the alarm key in the top menu bar will change to red colour.
Switch to the alarm list by pressing the “ALARM” key. In the alarm list is shown all active
alarms, in chronological order.
For each alarm is shown: date, time, error number, alarm type (A1 = pre-warning and A2 = alarm
which will stop the machine), signal number and an alarm description.
When an alarm situation is corrected, the alarm can be removed by pressing the “RESET” key. If
there are more than one page with alarms, (15 alarms = 1page), it is possible to scroll up/down. In
order to scroll, press the “arrow” keys”.
A more detailed description of the alarms can be obtained by pressing the “?” key. When it is
pressed, a description of all alarms in the system, arranged by error number, will be shown on the
screen.
Further a screen, alarm history, showing the last 300 alarms is available. On this
Screen is all active alarms shown in yellow and corrected alarms are shown in Green. The screen
layout is identical with the alarm list.
All alarms will be latched in the control system and when the cause for an alarm has disappeared,
the alarm indication can be removed from the alarm list by activating the “RESET” key on the
screen.
The alarms for the Hydraulic Unit are:

No. Alarm text and description
00 A2 A01X41 EMERGENCY STOP

Alarm is set if an emergency stop is activated.
01 A1 A01X42 LOCAL PERMISSION OVERRIDE

If local permission override is selected in the parameter picture, this pre-warning will
occur.
02 A1 S05C41 Local control panel door open

The Panel Door(s) is opened keep closed to avoid dust.
04 A1 A01X44 Backup battery low

Change the battery, see PLC instruction.
05 A2 A01X45 DATA BUS ERROR

Network communication has failed.
06 A1 M01C41 CIRCULATION PUMP STOPPED

Circulation pump is stopped from the control panel, for filter change
07 A1 D09L41 TANK LEVEL < MINIMUM 1

If the tank level drops below range, a pre-warning will occur.
08 A1 D08P41 FILTER BLOCKED

The filter is blocked, change the filter.
09 A1 A01X46 EMPTY/FILL OIL TANK

Emptying or filling of oil tank is selected from the control panel.
11* A1 N01P01 GRINDING PRESSURE < MINIMUM 1

The hydraulic pressure is still below minimum, even the hydraulic pump has been in
operation for 20 seconds.
12* A1 N01P01 GRINDING PRESSURE > MAXIMUM 1

The hydraulic pressure is above maximum.
14 A1 N02T01 OIL TANK TEMPERATURE > MAXIMUM 1 (>55°c)

The oil tank temperature is above 55°C.
15 A1 N02T01OIL TANK TEMPERATURE < MINIMUM 3 (<5°c)

The oil tank temperature is below 5°C.
16 A1 N02T01OIL TANK TEMPERATURE < MINIMUM 1 (<17°c)

The oil tank temperature is below 17°C, and the hydraulic system is started.
20 A1 E01C41 READY FAULT E01

If the temperature in the oil tank is above control range (40°C), and the MCC for E01 is
not ready, this pre-warning will occur.

21 A1 E01C61 RETURN FAULT E01

If the temperature in the oil tank is above control range (40°C), and the E01 return
signal from the MCC is not given after the command is given, or the E01 return signal
from the MCC is given but not the command, this pre-warning will occur.

If the temperature in the oil tank is above control range (40°C), and the MCC for E02 is
not ready, this pre-warning will occur.

If the temperature in the oil tank is above control range (40°C), and the E02 return
signal from the MCC is not given after the command is given, or the E02 return signal
from the MCC is given but not the command, this pre-warning will occur.
30 A2 D07Z41 INLET VALVE TO M02 CLOSED

The main oil valve is closed.
31 A2 M01C41 TIME OUT FOR CIRCULATION PUMP STOPPED

The circulation pump has been stopped for more than 1 hour for changing filter (during
normal operation of the lubrication system).
32 A2 N01P01 TIME OUT FOR PRESSURE CONTROL

The pressure has been outside limit for 5 minutes.
34 A2 D10L41 TANK LEVEL < MINIMUM 2

The oil level is below minimum 2.
36 A2 N02T01 OIL TANK TEMPERATURE > MAXIMUM 2 (>60°c)

The oil tank temperature is above 60°C.
38 A2 N02T01 OIL TANK TEMPERATURE < MINIMUM 2 (<15°c)

The hydraulic system is started and the oil tank temperature drops below 15°C.
40* A2 N01P01 GRINDING PRESSURE < MINIMUM 2

The hydraulic pump has been in operation for 20 seconds, but the pressure is still below
minimum 2.
50 A2 M01C41 READY FAULT M01

Missing ready signal from M01
51 A2 M01C61 RETURN FAULT M01

Disagreement detected between motor command and return signal.
53 A2 M02C41 READY FAULT M02

Missing ready signal from M02
54 A2 M02C61 RETURN FAULT M02


Missing ready signal from E01


62 A2 N01P01 INSTRUMENT FAULT

Transmitter fault, broken wire or short circuit detected. Check fuse in terminal.
63 A2 N02T01 INSTRUMENT FAULT

64 A2 B01L01 INSTRUMENT FAULT

65 A2 A01P01 INSTRUMENT FAULT




80* A2 N11P01 ACCUMULATOR PRESSURE CYL. 1 > MAXIMUM

The accumulator pressure is above maximum.
81* A2 N11P01 ACCUMULATOR PRESSURE CYL. 1 < MAXIMUM

The accumulator pressure is below minimum.




*) The alarm limit can be changed from parameter picture No.1

CCS signals status, digital
On the picture is indicated the status of the digital signals between the local control panel (LCP),
and the central control system (CCS).

CCS signals status, analogue
On the picture is indicated the status of the analogue signals between the local control panel
(LCP), and the central control system (CCS).

Parameter menu
When the correct password has been entered on the numeric keyboard, the parameters menu
picture is shown.
From the picture the listed functions can bee selected.
General:
If a value has to be changed, press the field showing the value, a numeric keyboard will appear,
and the new value can be entered.
Pressing the ESC button will remove the numeric keyboard, and the old value will be used.
When pressing the ENT button, the entered value will be checked to see if it is inside the allowed
limits, if it is outside the allowed limits the new value will not be accepted and the numeric
keyboard will stay on the screen. If the entered value is inside the allowed limits it will be
accepted, the numeric keyboard will disappear, and the field will show the new value.
Some values are checked against each other to check that they have the right proportions (one
value must be greater than the other). If the proportions are correct they will be accepted as above.
If the proportions are not correct the value input will be accepted and the input field will show the
new value, but a text “Fault! Enter new limit” will pop up. As long as the text is on the screen the
proportions are not correct, and the old values will be used by the PLC. As soon as one of the
values is changed to make the proportions correct the text will disappear and the input values will
be used by the PLC.

Parameter picture No. 1 - Alarm limits
Parameter picture Alarm limits comprises adjustable alarm limits for the hydraulic pressure and
scaling factor for the layer thickness measurement.
Change of limits must only be done by authorized personal.
The below specified values are for guidance only, the final adjustment is to be done during
commissioning.
Hydraulic pressure min.1 ( A1 prewarning ) Default value 50 bar

Hydraulic pressure min.2 ( A2 alarm ) Default value 45 bar
Hydraulic pressure max.1 ( A1 prewarning ) Default value 170 bar
If the limit is illegal Minimum 1 < Minimum 2, the text “FAULT: ENTER NEW LIMIT” will
appear, but the value will not change in the PLC. New values are only valid when no error text is
present.
Accumulator pressure common maximum Default value 240 bar

Accumulator pressure common minimum Default value 40 bar
Above limits for the accumulator pressures are as named common for all applied accumulator
pressures.
If the limit is illegal Accumulator pressure common maximum < Accumulator pressure
common minimum, the text “FAULT: ENTER NEW LIMIT” will appear, but the value will not
change in the PLC. New values are only valid when no error text is present.
Parameter picture No. 2 - Override CCS signal
In parameter picture Override CCS signal it is possible to override the Local Permission signal
from CCS.
Local Permission:
When this signal is overridden it is possible to select Local Test Mode “LT MODE”,
or Local Control Mode “LC MODE” even if the Local Permission signal is not present from CCS.
The facility is foreseen to be used for system test and test of the individual components when CCS
is not installed.
In this mode the machine is only be operated by authorized personnel.
A green dot in the “ENABLE” button will indicate that the function can be selected.
Selection procedure:
Press the “ENABLE” button and the function will be active as long as the button is indicating
green.
Reset of selection:
Press the “RESET” button.
A power up of the cabinet will disable any selections made in this Parameter picture.

Parameter picture No. 3 - Setpoint and Delaytime
From parameter picture setpoint and delay time the allowable range for the set point for hydraulic
Grinding Mode pressure can be adjusted (ref. FLS instruction).
As initial values the following limits are set:
Upper limit: 150 bar

Lower limit: 60 bar
Delay time: 60 sec.
If the limit is illegal Upper limit < Lower limit, the text “FAULT: ENTER NEW LIMIT” will
appear, but the value will not change in the PLC. New values are only valid when no error text is
present.
The signal Grinding In Operation to CCS is delayed by the preset number of seconds keyed in on
the numeric keyboard.
The final adjustment has to be done during commissioning.

Parameter picture No. 4 - Control limits
From parameter picture Control limits the control limits for the hydraulic Grinding mode can be
set.
If P3<P1 or P4<P2 the text “FAULT: ENTER NEW LIMIT” will appear on the screen,
but the value will not change in the PLC. New values are only valid when no error text is present.
commissioning.
Range
P1 2 bar -10 to 10 bar
P2 1 bar -10 to 10 bar
P3 7 bar 0 to 20 bar
P4 5 bar 0 to 20 bar

Parameter picture No. 5 - Water cooling system
Parameter picture Water cooling system comprises adjustable temperature limits for the water
cooling system on the Hydraulic unit.
commissioning.
Water cooling ON: 50°C
Water cooling OFF: 47°C.
If the on limit < off limit the text “FAULT: ENTER NEW LIMIT” will appear on the screen,
but the value will not change in the PLC. New values are only valid when no error text is present.

Parameter picture No. 6 - Empty/filling oil tank
When the system is in Local Test Mode “LT MODE” it is possible to use the circulation pump for
filling or emptying of the oil tank.
The circulation pump can afterwards be started from the start/stop buttons.
REMARK! If the ENABLE function is selected, the safety interlocks from oil level and oil
temperature are cancelled.
A green dot in the “ENABLE” button will indicate that the function can be selected.
Press the “ENABLE” button and the function will be active as long as the button is indicating
green.
Reset of selection:
Press the “RESET” button.

Parameter picture No. 7 - Local test valves
From parameter picture Local test valves opening and closing of the solenoid valves Y01, Y02
and Y04 can be tested, when the system is in Local Test Mode “LT MODE”.
A green dot in the “ON” button will indicate that the function can be activated.
Press the “ON” button and the function will be active as long as the button is indicating green.
Press the “OFF” button to de-activate the function.

Parameter picture No. 8 - Local test pressure systems
From parameter picture Local test pressure systems venting and test of the grinding pressure side
and of the lifting pressure side can be done. (Ref.: FLS instruction).
The system is ready for venting and tests when:

-The system is in Local Test Mode “LT MODE”
-No alarm 2 is present
-The gear unit is in operation (ONLY for test of grinding pressure side)
-The oil temperature > 17°C
A green dot in the “START” button will indicate that the function can be selected.
Venting and test of grinding pressure side:

When the “START” button is activated the function will be active as long as the button is
indicating green, the solenoid valves Y01 and Y02 will be de-energized and the hydraulic pump
will start.
Reset of selection, press the “STOP” button.
Venting and test of lifting pressure side:

When the “START” button is activated the function will be active as long as the button is
indicating green, the solenoid valves Y01 and Y02 will be energized and the hydraulic pump will
start.
Reset of selection, press the “STOP” button.

GENERAL SPECIFICATION
Storage
Temperature -5 - 60°C
Humidity 0 - 75% non condensing
Operating
Temperature -5 to 40°C
Humidity 20 - 90% non condensing
Altitude above sea level < 1000 meters
Class and protection IP54
Power supply 380V 2ph 50Hz
Power consumption 1,0 kVA
Dimensions and weight
HxWxD 2000 x 1200 x 400 mm

Weight 200 kg

COMMUNICATION WITH CCS
Digital signals to CCS
Heating ready Heating ready = 1, when:

(-E01C41) All alarm 2 interlocks are fulfilled for heating
Heating ready = 0, when:
An alarm 2 (alarm which causes stop of the heating)
is present or the unit is in LOCAL mode.
Heating started Signal = 1 when:

(-E01C61) The heating system is started,
(Return signal).
Oil temperature OK Signal = 1 when:

(-E01T41) The oil temperature is inside limits,
(Safety interlock for hydraulic unit).
Hydraulic ready Unit ready = 1, when:

(-A01C41) All alarm 2 interlocks are fulfilled
Unit ready = 0, when:
An alarm 2 (alarm, which causes stop of the unit) is present
or the unit is in LOCAL mode.
Lift rollers started Signal = 1 when:

(-A01C62) The rollers up movement are started.
(Return signal)
Rollers in top position Signal = 1, when:

(-A01Z41) The hydraulic unit is started and rollers are in upper position.
Grinding started Signal = 1 when:

(-A01C61) The grinding control is started.
(Return signal).
(Interlock to other machinery)
Grinding in operation Signal = 1 when:

(-A01C69) The grinding control is started and the hydraulic pressure is
within normal range, and the oil temperature is inside limits.
(Interlock to other machinery)
Alarm 1, No pre-warning Alarm signal = 0, when:

(-A01U41) A pre-warning alarm is present.

Digital signals from CCS
Local permission Local permission = 1,

(-A01C39) permits the unit to be tested from the local control panel.
Start/Stop heating Start = 1

(-E01C31) Stop = 0
Up/down rollers Signal = 1, up.

(-A01C36) Signal = 0, down.
Start/Stop grinding Start = 1

(-A01C31) Stop = 0
Analog signals to CCS
Grinding pressure 0 - 400 bar

(-A01P01)
Layer thickness 0 - 400 mm

(-A01L01)
Analog signals from CCS
Grinding setpoint 0 - 400 Bar

(-A01P11)

Local control panel type ATOX-HY 6.01
Parts list 80009161 Ver.: 1.0
Tag Qty. Designation Type/model Manufacturer
Panel
-A1 1 HxWxD 1800x1200x400mm 8284.500 Rittal
1 Panel sides 8184.235
1 Plinth H=200 8602.200
1 Plinth H=200 8602.040
1 Utility lectern 4638.600
1 Diagram pocket 2514.000
2 Cable flange FMC25-M Fibox
-A2 1 CPU, Compact Logix 1769-L32C Allen Bradley

1 Memory module, 64Kb 1784-CF64
2 Digital input, 16 ch. 1769-IQ16
2 Digital output, 8 ch. 1769-OW8I
1 Analog input, 8 ch. 1769-IF8
1 End terminator 1769-ECR
-A20 1 Emergency stop relay PNOZ-X3, 774318 Pilz

230VAC
-A21 1 Emergency stop relay exp. PZE9, 774148 Pilz

230VAC
-B01 1 Layer thickness sensor UC2000-30GM-IUR2- Pepperl & Fuchs

V15
1 Cable for sensor V15-G-2M-PUR
-E01 1 Fluorescent lamp 230VAC 4138.140 Rittal

1 Supply cable 4315.100
-E03 1 Heating element 50-120W 3116.000 Rittal

230V
-E05 1 Ventilation fan DP201A-220VAC Sunon

2 Protection Cover FG
-E06 1 Ventilation fan DP201A-220VAC Sunon

2 Protection Cover FG
-F01 1 Manual motor starter 4,0-6,3A GV2-ME10 Schneider
-F02 1 Circuit breaker, 1ph, 6A, C 24309 Schneider
-F03 1 Circuit breaker, 1ph, 6A, C 24309 Schneider
-G1 1 Power Supply, 2A, 230V 1769-PA2 Allen Bradley
-G2 1 Power supply 230/24VDC 6EP1334-2BA01 Siemens

10A
17-07-07

2,5A
2,5A
2,5A
-K1 1 Auxiliary relay, 1P, 24VDC 8533640000 Weidmüller
MRS

MRS

MRS

MRS (X60)

MRS (X60)

MRS (X60)

MRS (X60)

MRS (X60)

MRS (X60)
-K99 1 Auxiliary relay, 1P, 230VAC 8556020000 Weidmüller

MRS

MRS
-N3 1 R/I Transmitter 1 Channel 5131A-A PR-Electronics
-P01 1 Touch screen panel ProFace GP2500-SC41-24V Proface

1 HMI communication cable HMI-CAB-D015 ABB
1 Inspection Window FT5492704.SPEC Rittal
17-07-07
-Q01 1 Manual motor starter 13-18A GV2-ME20 Schneider
-Q02 1 Circuit breaker, 2ph, 4A, C 24334 Schneider
-S01 1 Emergency stop button 3SB3000-1HA20 Siemens

1 Sign: Emergency stop 3SB3921-0AD
1 Auxiliary contact NC 3SB3400-0C
-S02 1 Selector switch 1P 20A 5TE8111 Siemens
-S03 1 Thermostat 3110.000 Rittal
-S04 1 Thermostat 3110.000 Rittal
-S05 1 Door operated switch 4127.000 Rittal
-T01 1 Transformer, 380/230V, 4AM6142-8JD40-0FA0 Siemens

1,6KVA
-X00 3 Terminals WDU4 1020100000

3 Earth terminals WPE4 1010100000

-X08 22 Terminals WDU4 1020100000

-X15 12 Terminals WDU4 1020100000
-X19 20 Terminals WDU4 1020100000
-X20 62 Terminals WDU4 1020100000

3 Fuse terminals WSI6 1011000000
-X30 1 Socket with earth, 230VAC, PC16/2 Schupa

16A
-X31 1 Socket with earth, 230VAC, PC16/2 Schupa

16A
-X60 24 Terminals WDU4 1020100000
17-07-07

17-07-07
Local control panel type HY-AM-11 8.05
Signals list 80009161 Ver.: 1.0
FROM: Local control panel TO: CCS

PLC Node: 52 PLC No:
PLC ref.: 321HY110A01
PLCtoPLC_BUFFER[17,1].
Element_1. [Bit]
Digital signals: Digital signals:
Bit No: Bit No:
0
1
2
3
4
5
6
7

Bit No: Bit No:
8 Heating ready -E01C41
9 Heating started -E01C61
10 Oil temperature OK -E01T41
11 Hydraulic unit ready -A01C41
12 Lift Rollers started -A01C62
13 Rollers in top pos. -A01Z41
14 Grinding started -A01C61
15 Grinding in operation -A01C69

Bit No: Bit No:
16 No pre-warning -A01U41
17
18
19
20
21
22
23
Analogue signals: Analogue signals:

Real: Real:
Element Grinding pressure PV, -A01P01
_21 0-400 bar (0-400.0)
Element Layer Thickness, -A01L01
_22 0-400 mm (0-400.0)
08:35:00
Local control panel type HY-AM-11 8.06
Signals list 80009161 Ver.: 1.0
FROM: CCS TO: Local control panel

PLC No: PLC Node: 52
PLC ref.: 321HY110A01
PLCtoPLC_BUFFER[17,0].
Element_1. [Bit]
Bit No: Bit No:
0
1
2
3
4
5
6
7

Bit No: Bit No:
8 Local permission -A01C39
9 Start/stop heating -E01C31
10 Command rollers up -A01C36
11 Start/stop grinding -A01C31
12
13
14
15
Analogue signals: Analogue signals:

Real: Real:
Elemen Grinding pressure SP, -A01P11
t _21 0-400 bar (0-400.0)
Elemen
t _22
08:35:00
STD: ED INT: KHP / KHP / FleJ DATE: 12-03-08 VER.: 1.0
Slot No. 0 Slot No. 1 Adr. Slot No. 2 Adr. Slot No. 3 Adr. Slot No. 4 Adr. Slot No. 5 Adr.
CPU Digtal input Digtal input Digital output Digital output Analog input
16 x 24 VDC 16 x 24 VDC 8 x Relay 8 x Relay 8 x 4-20mA
Term. Term. Term. Term. Term.
24VDC Supply Data.0 Circ. pump M01 Data.0 Hydraulic in Out.0 Circ. pump M01 Out.0 Oil tank temp. Ch 0
OK Ready operation Command 0-150 °C
IN 0 IN 0 VAC- VAC- I in 0+
-G02C41 -M01C41 -HY110A01C68 VDC 0 -M01C31 VDC 0 -N02T01 V/I in 0-
Panel Door closed Circ. Pump M01 Hyd. pump M02 Grinding pressure
Data.1 Return signal Data.1 Out.1 Command Out.1 0-400 bar Ch 1
-S05C41 -M01C61 -M02C31 VDC 1 -N01P01 V/I in 1-
VDC 1
Main valve Water cooling Heating E01 Layer thickness
Position Data.2 Data.2 command Y04 Out.2 Command Out.2 Ch 2
-D07Z41 -Y04C31 -E01C31 VDC 2 -B01L01 V/I in 2-
VDC 2
Roller 1 Hydr. pump M02 Heating E02
top Data.3 Ready Data.3 Out.3 Command Out.3 Ch 3
-D01Z41 -M02C41 -E02C31 VDC 3 V/I in 3-
VDC 3
Roller 2 Hyd. pump M02 Roller position
top Data.4 Return signal Data.4 command Y01 Out.4 Out.4 Ch 4
-D02Z41 -M02C61 -Y01C31 VDC 4 V/I in 4-
VDC 4
Roller 3 Pressure relief. Acc. press. cyl. 1
top Data.5 Data.5 Command Y02 Out.5 Out.5 0-400 bar. Ch 5
-D03Z41 -Y02C31 VDC 5 -N11P01 V/I in 5-
VDC 5
Heating E01 Acc. press. cyl. 2
Data.6 Ready Data.6 Out.6 Out.6 0-400 bar. Ch 6
-E01C41 VDC 6 -N12P01 V/I in 6-
VDC 6
Heating E01 Reset Acc. press. cyl. 3
Data.7 Return signal Data.7 Emergency Out.7 Out.7 0-400 bar. Ch 7
Circuit VAC- VAC- I in 7+
IN 7 -E01C61 IN 7 -A01X31 VDC 7 -N13P01 V/I in 7-
VDC 7
Data.8 Data.8
IN 8 IN 8
Heat protection
Data.9 E01 Data.9
IN 9 -E01T41 IN 9
Data.10 Data.10
IN 10 IN 10
Data.11 Data.11
IN 11 IN 11
Oil filter blocked
Data.12 Data.12
-D08P41 IN 12 IN 12
Oil Level
MIN 1 Data.13 Data.13
-D09L41 IN 13 IN 13
Oil Level
MIN 2 Data.14 Data.14
-D10L41 IN 14 IN 14
Data.15 Emergency
circuit OK Data.15
IN 15 -A01X41 IN 15
321HY110
I/O Addressing arrangement
80009161 9.05

Sub Control System HY-AM-10

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Sub Control System HY-AM-10

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1.

3. Operating Instructions and System Description

.20 Block diagram 1/2

.40 Panel, outline

8. Remote Control Interface

9. I/O Addressing Arrangement

Sub supplier instructions No.: 60049966

Sub supplier instructions No.: 60050023

Programming software and equipment:

PLC, Allen Bradley:

Control Display, Pro-face:

Digital amplifier (Hydraulic cooler drive), Bosch Rexroth:

Interface modules, PR-electronics:

ECS License for Sub control Systems:

COMMUNICATION WITH CCS ........................................................................................... 80

21-Apr-08 KHP / SVo / MRSc

The purpose of the local control panel is to:

- Control the operation of the hydraulic system.

A flow diagram for the hydraulic system is shown on page 4.10.

21-Apr-08 KHP / SVo / MRSc

The operation of the hydraulic system is divided in two parts:

Operation of the heating system

Lifting the rollers

21-Apr-08 KHP / SVo / MRSc

21-Apr-08 KHP / SVo / MRSc

OPERATING PROCEDURE, CONTROL DISPLAY

Top menu bar

Screen saver function

21-Apr-08 KHP / SVo / MRSc

Main menu picture

SELECTION Selection between the different operational modes.

MIMIC Mimic diagram showing status of the process.

CONTROL Local operation/regulation of the machines and various test functions

ALARM List of all active alarms in the system.

21-Apr-08 KHP / SVo / MRSc

Central Control Mode

Local Control Mode

Local Test Mode

21-Apr-08 KHP / SVo / MRSc

The mimic is a simplified flow diagram for the Machine showing:

21-Apr-08 KHP / SVo / MRSc

An analogue signal displayed is represented by the actual engineering unit.

Control picture No. 1 - Local control, Hydraulic unit

21-Apr-08 KHP / SVo / MRSc

To stop, press the “STOP” button.

21-Apr-08 KHP / SVo / MRSc

Control picture No. 2 - Local control, Heating

On the mimic diagram the actual status of the system is monitored.

Press the “OFF” button to stop the heating.

21-Apr-08 KHP / SVo / MRSc

Control picture No. 3 - Central control, Change filter

1. Oil filter blocked.

21-Apr-08 KHP / SVo / MRSc

Control picture No. 4 - Local test, Pumps

On the mimic diagram the actual status of the system is monitored.

21-Apr-08 KHP / SVo / MRSc

Control picture No. 5 - Local test, Heating element

On the mimic diagram the actual status of the system is monitored.

21-Apr-08 KHP / SVo / MRSc

The alarms for the Hydraulic Unit are:

21-Apr-08 KHP / SVo / MRSc

No. Alarm text and description

00 A2 A01X41 EMERGENCY STOP

01 A1 A01X42 LOCAL PERMISSION OVERRIDE