Failsafe Docu.

Operating Instruction
En-16052.707-A
Control system “failsafe plant interlocking“

with operator panel TP 177 B
Code Word
Order Number
POLYSIUS Order Code (POC)

Operating Instruction Contents
Control system “failsafe plant interlocking“ with operator panel TP 177 B
Contents
1 Technical Data......................................................................................... 1-1
2 Safety ....................................................................................................... 2-1
3 Systems description............................................................................... 3-1
3.1 Introduction ............................................................................................... 3-1
3.2 Configuration possibilities ......................................................................... 3-4
4 Control system SIMATIC S7-300F ......................................................... 4-1
4.1 Requests ................................................................................................... 4-1
4.2 Hardware................................................................................................... 4-2
4.3 Software .................................................................................................. 4-13
5 Operator panel TP 177 B ........................................................................ 5-1
5.1 General description ................................................................................... 5-1
5.2 Display areas ............................................................................................ 5-3
5.3 Operating objects ...................................................................................... 5-8
5.4 Operating displays .................................................................................. 5-10
5.5 Signalling system .................................................................................... 5-32
5.6 System .................................................................................................... 5-53
5.7 User administration ................................................................................. 5-56
5.8 Saving and restoring the project ............................................................. 5-58
6 Electrical commissioning....................................................................... 6-1
6.1 Checks prior to commissioning ................................................................. 6-1
6.2 Checks after commissioning ..................................................................... 6-2
6.3 Handing-over............................................................................................. 6-2
7 Maintenance ............................................................................................ 7-1
8 Spare Parts .............................................................................................. 8-1
9 Appendix.................................................................................................. 9-1
9.1 Firing system interlocks ............................................................................ 9-1
9.2 Communication ......................................................................................... 9-2
9.3 Test log ..................................................................................................... 9-5
9.4 Handing-over record ............................................................................... 9-15
9.5 Glossary .................................................................................................. 9-16
En-16052.707-A
Operating Instruction Technical Data
Control system “failsafe plant interlocking“ with operator panel TP 177 B 1-1
1 Technical Data
Specification of the intended use

The safety interlocks for the firing system and the efilter of a kiln plant according
to the standard operating procedure 118 (SOP 118, status 02.06.1982) are im-
plemented in the control system “failsafe plant interlocking“. More detailed infor-
mation on the intended use is shown in the section System description.
Basic data
Year of manufacture.................................................................................................
Programmable logic controller ....................................................SIMATIC S7-300F
Control cabinet
Ambient temperature of control cabinet ..................................... 0 °C to max. 60 °C
Relative humidity ....................................................................... max. 95 % at 25 °C
Power supply to control cabinet

Voltage ................................................................................................................... V
Frequency ............................................................................................................ Hz
Voltage fluctuation................................................................................... max. 10 %
Control voltage in control cabinet........................................................................... V
Control voltage in plant........................................................................................... V
Measurement signals .......................................................................................... mA
Interface to the master control system .............................................PROFIBUS-DP
Interface to the burner control systems...................... PROFIBUS-DP (PROFIsafe)
En-16052.707-A
Operating Instruction Safety
2 Safety
NOTE
Be sure to comply with the general safety instructions in the supplement
Important notes on the documentation.
Use
The control system “failsafe plant interlocking“ is exclusively provided for the
safety interlocks for the firing system and the efilter of a kiln plant. Be sure to
comply with the specification of the intended use in section Technical data.
Any use other than the intended use is forbidden. POLYSIUS AG is not responsi-
ble for damage resulting from any use other than the intended use. Any other use
is at the owner's own risk.
The intended use also includes compliance with the operating instructions and
the maintenance instructions.
Transport and assembly

All transport instructions in this manual refer exclusively to transportation of the
system at the plant site.
Only use suitable hoisting and load-carrying equipment which is in serviceable

order and has a sufficient load bearing capacity.
Never work under a suspended load.
Operation
It is strictly forbidden to make program alterations (software) to the programma-
ble control system without prior consultation with POLYSIUS AG.
Any safety checks before or during operation depend on the relevant national
regulations. The plant management is responsible for the performance and re-
cording of such checks.
Be sure to comply with all warning signs and safety instructions on and around
the systems, as well as in the machine manuals and operating instructions.
The control system is specially designed for the planned system and may, there-
fore, not be used for any other machine without the express consent of
POLYSIUS AG.
If changes in the plant or its operating behaviour relevant to safety occur, shut it
down immediately.
En-16052.707-A
Operating Instruction Systems description
3 Systems description
3.1 Introduction
The safety interlocks for the firing system and the efilter in the plants are imple-
mented in accordance with the standard operating procedure 118 (SOP 118,
status 02.06.1982).
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The gas analysis for O2 and CO after cyclone stage 2 or 3 and after the DOPOL
exhaust gas fan is the most important instrument for setting and monitoring the
correct fuel-air-mixture.
The correct setting of the fuel-air mixture is monitored by means of the CO analy-
sis after cyclone stage 2 or 3 and is corrected if necessary by manual adjustment
of the fuel quantity and/or the combustion air volume (speed of the kiln exhaust
gas fan or position of the damper in the kiln exhaust gas duct).
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The CO analysis after the DOPOL exhaust gas fan is primarily a safety device
for monitoring the gas atmosphere after the kiln system.
If the combustion air volume is insufficient, i.e. if the CO concentration increases,

the complete fuel supply to the kiln system and also the precipitator's high-
voltage supply are shut down and the efilter is earthed.
The system is also switched off if events occur that do not exclude the formation
of exhaust gases containing CO. This includes e.g. failure of the primary air fan,
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the DOPOL exhaust gas fan or of the filter fan, simultaneous failure of more than
two cooling air fans in the recuperation section of the clinker cooler or serious ex-
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ceeding of the pressure after the DOPOL exhaust gas fan or at the kiln hood
(e.g. due to incorrect operator command or similar).
After a direct CO-shutdown of the firing system and the efilter the plant has to be
purged for at least three minutes (air exchange 5 times) before restart of the firing
system and the efilter is enabled. The time monitor purging of the system is not
started before the CO concentration in the exhaust gas is below the limit of MAX1
and all other purging conditions are fulfilled.
The limit values for the CO concentration are defined as follows:

• MAX1 = 0.4 % by volume
En-16052.707-A
Systems description Operating Instruction
3-2 Control system “failsafe plant interlocking“ with operator panel TP 177 B
All safety interlocks for the firing system and the efilter are shown in the section
Firing system interlocks. This table is based on the standard operating procedure
118 and is used as basis for writing the program for the control system "failsafe
plant interlocking". The table is divided into the following working folders:
• Glossary
Explanations of the designations used
• List of signals
General list of signals (type, use of interlocks)
• 1.0 Conditions for PURGING the system
Conditions for purging the system after a CO-shutdown has occurred
• 2.1 Starting conditions SZ
Switch-on conditions for starting the SZ burner
• 2.2 Operating conditions SZ
Permanent conditions for operating the SZ burner
• 3.1 Starting conditions PC
Switch-on conditions for starting the PC burner
• 3.2 Operating conditions PC
Permanent conditions for operating the PC burner
• 4.1 Starting conditions CC
Switch-on conditions for starting the CC burner
• 4.2 Operating conditions CC
Permanent conditions for operating the CC burner
• 5.1 Starting conditions KI
Switch-on conditions for starting the KI burner
• 5.2 Operating conditions KI
Permanent conditions for operating the KI burner
• 6.0 Conditions bypass PURGING
Conditions for purging the bypass system
• 6.1 Starting conditions bypass
Conditions for starting up the bypass system
• 6.2 Operating conditions bypass
Permanent conditions for the bypass system
• 7.1 Starting conditions efilter
Conditions for starting up the efilter high voltage supply
• 7.2 Operating conditions efilter
Permanent conditions for the efilter high voltage supply
• external interlocks
Machine protection conditions of the kiln system (are NOT implemented in the
fail-safe control system)
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Hot gas generator

If hot gas generators are used, exclusively the control system of the respective
supplier is used. To ensure a fail-safe design in accordance with the specifica-
tions the following signals are wired in this control system:
• Pressure before mill
• Enable signal of the kiln plant (only during interconnected operation)
• Main contactor of motor of the mill system fan
• Speed control of the mill system fan:
• speed monitor on fan impeller shaft (n > Min = log1) or
• tacho-generator (4...20 mA) (n > 20% of the rated speed = log1) or
• actual value from the frequency converter (4...20 mA) (n > 20% of the rated
speed = log1)
• Damper control of the mill system fan:
• external limit switch at damper (position > Min = log1) or
• position feedback transmitter in the actuator (4…20 mA) (position > 20%
opening = log1)
It is not necessary that the two process temperatures "temperature before mill"
and "temperature after mill" are fail-safe. However, the two signals must be made
available by the master process control system as start and permanent conditions
at the hot gas generator control system. This means: no burner enable signal for
the hot gas generator if T > Max and burner stop if T > MaxMax.
En-16052.707-A
Systems description Operating Instruction
3.2 Configuration possibilities
The complete configuration of the system consists of the following components

depending on the quantity of burners:
• Fail-safe control system of the burner supplier for the SZ burner
• Fail-safe control system of the burner supplier for the PC/CC burner
• Fail-safe control system of the burner supplier for the KI burner
• Control system “failsafe plant interlocking“ for monitoring the kiln plant and
controlling and monitoring the fuel feeding system
The control system “failsafe plant interlocking“ is the only connection of the differ-
ent burner control systems to the master process control system.
Communication to the master process control system

Communication to the master process control system is as a rule via a
PROFIBUS connection for each plant section (kiln, cooler), in which the control
system is the slave. All signals generated in the control system (safety interlocks)
and all signals from the burner control systems are transmitted. All control and
enable signals (START, not STOP, external interlocks,…) and the setpoint values
and required parameters (burner setpoints, fuel parameters,...) from the master
process control system are also transmitted via this PROFIBUS connection to the
control system.
Communication to the burner control systems

The communication to the burner control systems can be in the three different
ways listed below.
Master-master-communication
During master-master-communication all fail-safe control systems are active as

master at the PROFIBUS. To connect two master systems, DP/DP couplers have
to be used for this communication.
Master-slave-communication
During master-slave-communication the control system "fail-safe plant interlock-

ing" is active as master at the PROFIBUS. The fail-safe control systems of the
burner suppliers act as slave at the PROFIBUS and cannot set up an active con-
nection. This means an enquiry from the master is always necessary for this
communication.
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Parallel communication
All fail-safe control systems are connected in parallel for this communication, i.e.
the data are wired as inputs and outputs in the respective control system.
For the different types of communication see the diagrams in section Communi-
cation.
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Operating Instruction Control system SIMATIC S7-300F
4 Control system SIMATIC S7-300F
4.1 Requests
Fail-safe automation systems (F-systems) are used in plants with high safety re-
quirements. F-systems are used to control processes with a safe state that can
be achieved immediately after shutdown. That is, F-systems control processes in
which an immediate shutdown does not endanger humans or the environment.
Functional safety
The functional safety is implemented principally through safety functions in the
software. Safety functions are executed by the S7 Distributed Safety system to
place or maintain the system in a safe state in case of a dangerous occurrence.
Safety functions are contained mainly in the following components:
• in the F-capable CPU (F-CPU)
• in the fail-safe inputs and outputs (F-I/O)
The fail-safe I/O ensure safe processing of field information (flap positions, tem-
peratures,...). They contain all of the required hardware and software components
for safe processing in accordance with the required safety class.
Safety interlocks
The safety interlocks for the firing system and the efilter are implemented in the
safety program of the control system “failsafe plant interlocking“. The operating
statuses are diversely monitored, i.e. one plant condition is defined with two dif-
ferent signals. Example: A damper is signalised as “damper in position” by the ex-
ternal limit switch and the analog signal from the position feedback transmitter in
the actuator, the signal statuses always being scanned for signal "1".
Diverse monitoring of an operating status and use of the control system SIMATIC
S7-300F fulfill the requirements according to IEC 61508 SIL2 and EN 954-1 cate-
gory 3. These are the requirements of the TÜV Hannover as regards monitoring
systems for fuels in the report of 13.12.2001 "Hazard analysis for cement rotary
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kiln firing systems and PREPOL -AS-CC calciners with respect to explosion haz-
ards".
En-16052.707-A
Control system SIMATIC S7-300F Operating Instruction
4.2 Hardware
The control system SIMATIC S7-300F consists of the following hardware compo-
nents:
• F-capable CPU (F-CPU)
• fail-safe inputs and outputs (F-I/O)
A CPU with fail-safe capability is a central processing unit that fulfills certain
safety requirements and is permitted for use in S7 Distributed Safety. A standard
program and a safety program can be processed at the same time on a F-CPU. A
standard program can coexist with a safety program in a F-CPU because the
safety-related data of the safety program are protected from being affected unin-
tentionally by data of the standard program.
The main distinction between fail-safe signal modules and standard modules in
the S7-300 module family is that fail-safe modules have a two-channel internal
design. The two integrated processors monitor each other, automatically test the
input and output wiring and place the fail-safe signal module in a safe state in the
event of a fault. The F-CPU communicates with the fail-safe signal module by
means of the PROFIsafe safety-related bus profile.
The hardware components for S7 Distributed Safety (F-CPU, F-I/O, batteries,...)

are replaced like in standard automation systems.
The actuators relevant for the safety interlocks have to meet the SIL2 require-
ments if possible (e.g. PNOZ contactors). Monitoring of the static pressure after
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the DOPOL exhaust gas fan and at the kiln hood is extremely important for the
purging process because this is the way the main gas route is monitored. Imple-
mentation of these sensors is therefore either redundant or in SIL2 absolutely
necessary.
The pages below show the fail-safe signal modules used in the control system.
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Digital input module SM326; DI 24 x DC 24V

The SM 326; DI 24 x DC 24V has the following features:
• 24 inputs, isolated in groups of 12
• 24V DC rated input voltage
• 4 short circuit-proof sensor supplies for 6 channels in each case, isolated in
groups of 2
• Group error display (SF)
• Safety mode display (SAFE)
• Sensor supply indicator (Vs)
• Status indicator for each channel (green LED)
Figure 1 Front view SM326; DI 24 x DC 24V
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Figure 2 Connection and block diagram of the SM326; DI 24 x DC 24V
One sensor is connected via one channel (1oo1 evaluation) for each process sig-
nal. Power supply to the sensors is via the internal sensor supply of the module. If
a channel fault occurs, the inadequate channel is passivated and the substitution
value “0“ is called up.
Figure 3 Wiring diagram of the SM326; DI 24 x DC 24V
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Digital output module SM326; DO 10 x DC 24V/2A

The SM 326; DO 10 x DC 24V/2A has the following features:
• 10 inputs, isolated as two groups of 5
• 2A output current
• 24V DC rated load voltage
• Status indicator for each channel (green LED)
Figure 4 Front view SM326; DO 10 x DC 24V/2A
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Figure 5 Connection and block diagram of the SM326; DO 10 x DC 24V/2A
One actuator is connected via a single pin for each process signal. If a channel
fault occurs, the inadequate channel is passivated and the substitution value “0“
is called up.
Figure 6 Wiring diagram of the SM326; DO 10 x DC 24V/2A
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Analog input module SM336; AI 6 x 13Bit

The SM 336; AI 6 × 13Bit has the following features:
• 6 analog inputs with electrical isolation between the channels and the back-
plane bus
• Current measurement 4 to 20 mA in safety mode
• Short circuit-proof power supply of 2- or 4-wire measuring transducers over
the module
• External sensor supply is possible
• Sensor supply indicator (Vs)
Figure 7 Front view SM336; AI 6 x 13Bit
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Figure 8 Connection and block diagram of the SM336; AI 6 x 13Bit
6 process signals can be connected to an analog module. The sensor supply Vs

is provided for 6 channels by the analog module. The sensors can also be sup-
plied by means of an external sensor supply (example: AUMA actuators, CO
analysis). The inputs are configured as current measurement inputs from 4 to 20
mA. If a channel fault (the inadequate channel is passivated) or oversteering or
understeering (AI > 21 mA or AI < 3.8 mA) occurs, a corresponding substitution
value is called up.
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Figure 9 Wiring diagram of the SM336; AI 6 x 13Bit (2-wire measuring transducer)
Figure 10 Wiring diagram of the SM336; AI 6 x 13Bit (4-wire measuring transducer)
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Analog output module SM332; AO 4 x 16Bit

An analog output module is necessary when coal is used as fuel. An analog value
sets the respective dosing amount. As fail-safe analog output modules do not ex-
ist, a standard module of the S7-300 module family is used.
The analog output module 332; AI 4 × 16Bit has the following features:
• 4 outputs in 4 channel groups
• Outputs configured as current outputs
• Resolution of 16 bits
Figure 11 Connection and block diagram of the SM332; AO 4 x 16Bit
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The two figures below show the hardware configuration in the control cabinet and
the hardware configuration of the decentral I/O level.
Figure 12 Example of hardware configuration in the control cabinet
Figure 13 Example of hardware configuration of the decentral I/O level
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Detailed information is shown in the Siemens manuals

• Automation System S7-300 Fail-Safe Signal Modules
• SIMATIC S7 Distributed Safety - Configuring and Programming
• Safety Engineering in SIMATIC S7.
The manuals are included in the documentation package 6ES7998-8XC01-8YE0.
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4.3 Software
Safety program
The safety interlocks for the firing system and the efilter are implemented in the
safety program. It consists of fail-safe blocks that are created using the F-FBD or
F-LAD programming languages or are selected from an F-library and fail-safe
blocks that are automatically added when the safety program is compiled. Fault
control measures are automatically added to the safety program, and additional
safety-related tests are performed.
After the safety program has been compiled, it can be downloaded to the F-CPU.
The safety program must be consistent, i.e. the collective signature of all fail-safe
blocks with F-attribute in the block container and the collective signature of the
safety program must be identical. For the present collective signature of the
safety program see the section Handing-over record.
Standard program
In addition to the safety program, a standard program can be run on the F-CPU.
The communication to the master process control system, generation of the
alarm messages etc. are implemented in the standard program. A standard pro-
gram can coexist with a safety program in a F-CPU because the safety-related
data of the safety program are protected from being affected unintentionally by
data of the standard program. Data are exchanged between the safety program
and the standard program in the F-CPU by means of bit memory or by accessing
the process input and output images.
Safety mode
The safety program runs in the F-CPU in safety mode. This means that all safety
mechanisms for fault detection and fault reaction are activated. The safety pro-
gram cannot be modified during operation in safety mode. Safety mode of the
safety program in the F-CPU can be deactivated and reactivated occasionally.
So-called "deactivated safety mode" enables the safety program to be tested
online and changed as needed while the F-CPU is in RUN mode. For S7 Distrib-
uted Safety, you can switch back to safety mode only after an operating mode
change from RUN to STOP to RUN.
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In safety mode, data are transmitted consistently between the F-CPU and F-I/O in
a safety message frame. The safety message frame in accordance with PROFIs-
afe consists of the following:
• Process data (user data)
• Status byte / control byte (coordination data for safety mode)
• Sequence number
• CRC signature
To meet the demands on the control system, the safety mode in the F-CPU must
be activated.
Password protection
In addition to the standard password for the F-CPU or CPU, F-systems require a
password for the safety program. The password for the F-CPU protects the F-
systems from unauthorized downloads to the F-CPU from the engineering system
or programming device. The password for the safety program protects from unau-
thorized changes to the configuration and parameter settings of the F-CPU and
F-I/O. For the respective passwords see the section Handing-over record.
Detailed information is shown in the Siemens manuals

• Automation System S7-300 Fail-Safe Signal Modules
• SIMATIC S7 Distributed Safety - Configuring and Programming
• Safety Engineering in SIMATIC S7.
The manuals are included in the documentation package 6ES7998-8XC01-8YE0.
En-16052.707-A
Operating Instruction Operator panel TP 177 B
5 Operator panel TP 177 B
To operate and monitor the control system "failsafe plant interlocking", a operator
panel TP 177 B is used. This device has a touch screen, i.e. a programmable
touch-sensitive screen.
5.1 General description
Figure 14 Operator panel TP 177 B, display with touch screen
A touch screen is a bidirectional human machine interface.

• Output from the system to the user is possible via the touch screen (the touch
screen functions as a screen).
• Input into the system via the touch screen is possible (the touch screen func-
tions as a keyboard).
You can operate the device using operating objects, which are illustrated on the
touch screen after the operating program has started.
In the following, "quotation marks" are used for the output to the user. Buttons are
highlighted in bold print.
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Operator panel TP 177 B Operating Instruction
Operate operating objects on the touch screen

Operating objects are touch-sensitive display images on the screen of the opera-
tor panel, such as buttons, input/output fields and message windows. Basically,
there is no difference between operating the buttons and pressing mechanical
keys. The operating objects are operated using the finger or a stylus with a
rounded tip.
NOTE
When operating with the touch screen, always touch only one operating object.
By touching more than one operating object at the same time, unintended
actions can be activated.
Causing damage to the touch screen

Touching the touch screen with pointed or sharp objects as well as abruptly
touching it with hard objects severely reduces the service life of the touch screen
or damages it. Touch the touch screen of the operator panel only with the finger
or a appropriate stylus with a rounded tip.
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5.2 Display areas
All operating displays of the touch screen are always - from top to bottom - di-
vided into three areas:
• Overview area
• Process operating area
• Display changing area
Overview area
Process operating
area
Display changing area

Figure 15 Display areas
Overview area
Figure 16 Overview area
In the upper section of the overview area, the name of the recent display, and
under this, the last received, not yet acknowledged message is displayed. You
select the message picture by touching the overview area.
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Process operating area

The process operating area displays the operating displays. They are arranged in
the following hierarchy:
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Start display
System
User
Menu
Process values
Fans
Cooler air fan(s)
SZ primary air fan(s)
DOPOL waste gas fan(s)
Filter fan(s)
Flaps
Fresh air damper(s)
Damper(s)
CO analysers
DOPOL stage 2/3
DOPOL waste gas fan(s)
Bypass*
Kiln inlet*
Temperature values
Pressure values
Bypass*
Hot gas flap
Waste gas fan
Fresh air fan
Efilter*
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Efilter*
Kiln plant status
Kiln plant
SZ burner
PC/CC burner
KI burner*
Bypass*
Efilter*
Control cabinet
Interlocks
Kiln plant purging
SZ burner startup
SZ burner operation
PC/CC burner startup
PC-/CC burner operat.
KI burner startup*
KI burner operation*
Bypass purging*
Bypass startup*
Bypass operation*
Efilter startup*
Efilter operation*
Parameter
Kiln plant
SZ burner
PC/CC burner
KI burner*
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Operating displays consist of static objects, e.g. texts, as well as dynamic objects
for displaying process values and operating conditions and for operation (but-
tons).
The operating displays marked * are integrated depending on the system configu-
ration.
Display changing area

In this area you can find button symbols for selecting the individual operating dis-
plays in the process operating area.
Figure 17 Display changing area
When operating the button Back you jump to the next higher hierarchical level. In
the message picture the user can jump to the last displayed process diagram by
touching this button.
With the arrow buttons and you can select a neighbouring picture of the
same hierarchical level.
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5.3 Operating objects
Operating objects are

• Buttons (key symbols) and
• Input/Output fields (I/O fields)
Buttons
Figure 18 Button
In the process operating area, buttons are used amongst others for acknowledg-
ing fault messages or setting parameters.
Input/Output fields
Figure 19 Input/Output field
In the process operating area, pure output fields display process values for ex-
ample. Input/Output fields are used for entering and displaying parameters.
After touching an input/output field the following input dialog opens on the screen:
Figure 20 Input dialog field
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Cursor (flashing text cursor, not shown in Figure 20): A flashing text cursor in the
upper field indicates that entries can be made on the left of the text cursor. In
Figure 20 the total display "0.00" is marked. Each new entry deletes the marked
part and displays the new sign entered.
For entering, press the individual buttons:

• Letters A, B, C, D, E, F: inactive depending on the program blocks. Inactive
buttons are flat, active buttons are raised and shaded.
• Digits 0, 1, 2, 3, 4, 5, 6, 7, 8, 9
• Sign changing + / -
• Decimal separator (comma or point - depending on the selected language)
• By pushing the Enter button (arrow pointing down and left; at the
right side at the bottom), the entry is finished and the input dialog is closed.
• With this button (ESCape) you can cancel the entry without changing
the value and close the input dialog.
• By pushing this button (BackSPace), a single sign left of the text cur-
sor is deleted.
• / By touching this buttons, the text cursor is moved one position

to the left or one to the right.
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5.4 Operating displays
After the run up of the "WinCC Flexible“ runtime application (operating program)
the following start display appears:
Figure 21 Start display
After an hour, this operating display is automatically called up again if no opera-

tion on the touch screen has been made.
Button symbols in the display changing area
Button Selected operating display

System System; "administration" authorisation necessary
User User; "administration" authorisation necessary
Language Change into another language (no picture change);
"operate" authorisation necessary
Menu Menu
The following is a list of extracts from operating displays that can vary depending
on the system configuration.
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Process values: fans (digital signals)
Figure 22 Process values of fans (digital signals)
Output field "drive"
This field indicates whether the fan drive is switched on. Main contactor of motor
(statuses: ON / OFF)
Output field "speed"
This field indicates whether the fan speed is n > MIN. Speed monitor on fan
impeller shaft (statuses: n > MIN / n < MIN)
Output field "damper"
This field indicates whether the fan damper is closed. External limit switch at
damper (statuses: Closed / Not closed)
Output field "SZ primary air pressure“
This field indicates whether the pressure after the damper in the primary air
channel of the SZ burner is p > MIN. Pressure switch in the primary air duct
(statuses: p > MIN / p < MIN)
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Process values: fans (analog signals)
Figure 23 Process values of fans (analog signals)
Output field "volume flow"
This field indicates the flow rate of the fan (% of the nominal flow rate).
Output field "speed"
This field indicates the fan speed (% of the rated speed). Tacho-generator or ac-
tual value of frequency converter
This field indicates the position of the damper (% open). Position feedback
transmitter in the actuator
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Process values: dampers (digital signals)
Figure 24 Process values of dampers (digital signals)
This field indicates whether the damper is closed. External limit switch at damper
(statuses: Closed / Not closed / Open / Not open)
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Process values: dampers (analog signals)
Figure 25 Process values of dampers (analog signals)
This field indicates the flap / damper position (% open). Position feedback trans-
mitter in the actuator
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Process values: CO analysers
Figure 26 Process values of CO analysers
Output field "maintenance"
This field indicates whether the CO analysis is being serviced. Maintenance

switch in the local analysis cabinet (statuses: Being serviced / Not being serviced)
Output field "alarm"
This field indicates whether the CO analysis is signalling an alarm. Automatic

checking of the gas analysis system (including monitoring of the test gas flow rate
and the static pressure after the test gas pump) (statuses: Alarm / No alarm)
Output field "measuring position"
This field indicates whether the measuring lance of the AURETRAC analysis in
the kiln inlet is in measuring position. Limit switch of the measuring lance
(statuses: In measuring position / Not in measuring position)
Output field "COMAX1"
This field indicates whether the limit value of the CO analysis MAX1 = 0.4 % by
volume is exceeded. Digital output of the CO analyser (statuses: CO < MAX1 /
CO > MAX1)
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CO > MAX2)
CO > MAX3)
CO > MAX4)
Output field "CO concentration"
This field indicates the CO concentration (% by volume). Analog output of the CO

analyser
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Process values: temperature values
Figure 27 Process values of temperature
Output field "temperature"
This field indicates the temperature in °C.
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Process values: pressure values
Figure 28 Process values of pressure
Output field "pressure"
This field indicates the pressure in mbar.
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Process values: bypass hot gas flap
Figure 29 Process values of bypass hot gas flap
Output field "limit switch"
This field indicates whether the hot gas flap is closed. External or integrated limit
switch at hot gas flap (statuses: Closed / Not closed / Open / Not open)
Output field "slack rope switch"
This field indicates whether the slack rope switch has been operated and if so,
that the rope or the chain of the hot gas flap is not in good condition. Slack rope
switch (statuses: Operated / Not operated)
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Process values: efilter
Figure 30 Process values of efilter
Output field "high voltage"
This field indicates whether the high voltage of the efilter is switched on. Main
contactor of the ESP high voltage transformer (statuses: ON / OFF)
Output field "earthing"
This field indicates whether the efilter is earthed. Earthing switch of the efilter
(statuses: Active / Not active)
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Kiln plant status: kiln plant
Figure 31 Kiln plant status kiln plant
Output field "Kiln plant purging"
This field indicates whether the kiln plant must be purged, e.g. after a shutdown
(see section Firing system interlocks) (statuses: Requested / Not requested).
Output field "Preconditions"
This field indicates whether the preconditions for purging the kiln plant, e.g. cool-
ing air fans in operation, CO < MAX1,… are fulfilled (see section Firing system in-
terlocks) (statuses: / ).
Output field "Section 1 purged"
This field indicates whether the first section of the kiln plant (main exhaust gas
route from clinker cooler to filter fan) has been purged (statuses: / ) or indi-
cates during the purging period the remaining purging time for the first section.
Output field "Section 2 purged"
This field indicates whether the second section of the kiln plant (main exhaust gas
route from damper in kiln exhaust gas duct to filter fan) has been purged
(statuses: / ) or indicates during the purging period the remaining purging
time for the second section. The position of the fresh-air flap in the kiln exhaust
gas duct is no longer monitored in the second section. This means that the fresh-
air flap can be opened and the damper in the kiln exhaust gas duct can be partly
closed. This prevents excessive heat from being dissipated from the kiln system
during the purging process.
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Output field "Hot gas generator operation"
This field indicates whether the control system has enabled operation of the hot
gas generator (statuses: Blocked / Released).
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Kiln plant status: burner (digital values)
Figure 32 Kiln plant status burner (digital values)
Output field "Ctrl mode"
This field indicates whether the burner is controlled locally or from the master
process control system (statuses: LOCAL / REMOTE).
Output field "Oper. mode"
This field indicates whether the burner is in the operating mode "Automatic" or
"Manual". In the "Automatic" operating mode, a setpoint value for the fuel quantity
is set; in the "Manual" operating mode, a setpoint value for the control device is
set (statuses: AUTO / MAN).
Output field "Operation"
This field indicates whether the burner is in operation (statuses: ON / OFF).
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Kiln plant status: burner (analog values)
Figure 33 Kiln plant status burner (analog values)
Output field "SP from PCS"
This field indicates the setpoint value set by the master process control system.
Output field "SP to XX"
This field indicates the setpoint value that is transferred to the burner control sys-
tem after calculation of the heat quantities in the control system.
Output field "AV from XX"
This field indicates the actual value that is transferred from the burner control sys-
tem to the control system.
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Kiln plant status: bypass
Figure 34 Kiln plant status bypass
Output field "Bypass purging"
This field indicates whether the bypass system must be purged, e.g. after a fail-
ure of the bypass exhaust gas fan (see section Firing system interlocks)
(statuses: Requested / Not requested).
This field indicates whether the preconditions for purging the bypass system, e.g.
bypass filter fan in operation, bypass hot gas flap closed,… are fulfilled (see sec-
tion Firing system interlocks) (statuses: / ).
Output field "Bypass purged"
This field indicates whether the bypass system has been purged
(statuses: / ) or indicates during the purging period the remaining purging
time.
Output field "Bypass operation"
This field indicates whether the control system has enabled operation of the hot
gas generator (see section Firing system interlocks) (statuses: Blocked / Re-
leased).
Output field "Bypass efilter operation"
This field indicates whether the control system has enabled operation of the by-
pass efilter (see section Firing system interlocks) (statuses: Blocked / Released).
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Kiln plant status: efilter
Figure 35 Kiln plant status efilter
Output field "Efilter operation"
This field indicates whether the control system has enabled operation of the efilter
(see section Firing system interlocks) (statuses: Blocked / Released).
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Kiln plant status: control cabinet
Figure 36 Kiln plant status control cabinet
Output field "Operating mode of control system"
This field indicates whether the control system is running in safety mode or in
standard mode (see section Control system SIMATIC S7-300F) (statuses:
FAILSAFE / STANDARD).
Output field "State of control system"
This field indicates the status of the control system (statuses: Ok / Disturbed).
Output field "State of IO modules"
This field indicates the statuses of the I/O modules (statuses: Ok / Disturbed).
Output field "State of circuit breakers"
This field indicates whether all circuit breakers in the control cabinet are switched
on (statuses: Ok / Disturbed).
Output field "Acknowledgement for reintegration"
This field indicates whether an I/O module can be reintegrated after a fault has
been eliminated (statuses: Requested / Not requested).
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Button Acknowledgement for reintegration
An acknowledgement for reintegration of the respective IO module or the respec-

tive channel can be sent to the control system via this button. "Operate" authori-
sation necessary.
Reintegration of I/O modules and channels
I/O modules are passivated after the following events:

• When errors occur during safety-related communication between the F-CPU
and the F-I/O using the safety protocol in accordance with PROFIsafe
• When F-I/O faults occur (e.g. parameter assignment error, overtemperature)
If the F-system detects an error, the entire F-I/O affected is passivated and sub-
stitution values are called up ("0" in the case of digital input and digital output
modules and a substitution value in the case of analog input modules).
Individual channels are passivated after the following event:

• When channel faults occur (e.g. short circuit, overload)
If the F-system detects a channel fault, the channels affected are passivated and
substitution values are called up ("0" in the case of digital input and digital output
modules and a substitution value in the case of analog input modules).
The affected F-I/O and the affected channels are reintegrated when:
• communication errors, F-I/O faults and channel faults no longer exist
• the F-system has requested acknowledgement (see output field "Acknowl-
edgement for reintegration") and
• the user has touched the button Acknowledgement for reintegration.
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Interlocks
Figure 37 Interlocks
This field indicates whether the respective preconditions e.g. for starting the SZ
burner are fulfilled (see section Firing system interlocks) (statuses: / ).
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Parameter: Heat quantities
Figure 38 Parameter heat quantities
Input / output field "Heat quantity"
After touching the input/output field referred to the burner, the input dialog opens
on the screen. You can enter the required parameter with the input dialog. The
following preconditions must have been fulfilled:
• The respective burner must be switched off.
• "Administration“ authorisation necessary.
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Parameter: Heat capacities
Figure 39 Parameter heat capacities
Output field "From PCS"
Indicates the heat capacity set by the master process control system. This pa-
rameter must be between the entered lower and upper limits ("LL" ≤ "From PCS"
≤ "UL") in order to ensure that it is accepted by the control system.
Input / output field "LL"
After touching the input/output field the input dialog opens on the screen. You can
enter the required lower limit for the specific heat capacity with this input dialog.
The following preconditions must have been fulfilled:
• The burner must be switched off.
Input / output field "UL"
After touching the input/output field the input dialog opens on the screen. You can
enter the required upper limit for the specific heat capacity with this input dialog.
The following preconditions must have been fulfilled:
• The burner must be switched off.
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5.5 Signalling system
Latest messages
Figure 40 Latest messages
The operating display "Latest messages" is selected by touching the overview

area.
Message display
Figure 40 shows the message display that contains the two last current mes-
sages. The message lines are three-spaced. When you select the picture, the
cursor is automatically moved to the upper message line of this display.
The selected message, operable for acknowledging, appears in the colours text:
white, background: blue. The other messages appear in colour, depending on the
message class and the message status, see table Message classes.
Message blocks
The message lines consist of the following message blocks:
Upper line: Message number: consecutive number (max. 400)
Time: Format: hh:mm:ss
Date: Format: dd/mm/yyyy
Status: C=Come, G=Gone, Ack=Acknowledged
Lower line: Message text
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Message classes
Message Status Text col- Background Comment
class our colour
Error C Black Red
CG Black Red
CAck Black Grey
CGAck --- ---
System C Black Yellow No acknowledge-
ment demanded
CG --- ---
CAck --- ---
CGAck --- ---
Messages, with the statuses Come, Acknowledged and Gone are automatically
deleted from this message display.
Button
When this button is pressed, the cursor moves upwards in the message display.
Button
When this button is pressed, the cursor moves downwards in the message dis-
play.
Acknowledge button
This button acknowledges the message, selected in the message display using
the cursor. "Operate" authorisation necessary.

Current Latest messages
(only relevant in the "Message archive" operating
display)
Archive Message archive
Back Last shown operating display
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Message archive
Figure 41 Message archive
The operating display "Message archive" is called up pushing the archive button
in the display "Latest messages".
Message display
Figure 41 shows the message display that contains the two last current mes-
sages. The message lines are three-spaced. When you select the picture, the
cursor is automatically moved to the upper message line of this display.
The selected message appears in the colours text: white, background: blue. The
other messages appear in colour, depending on the message class and the mes-
sage status, see table Message classes.
Message blocks
The message lines consist of the following message blocks:
Upper line: Message number: consecutive number (max. 400)

Time: Format: hh:mm:ss
Date: Format: dd/mm/yyyy
Status: C=Come, G=Gone, Ack=Acknowledged
Lower line: Message text
En-16052.707-A
Message classes
Message Status Text col- Background Comment

class our colour
Error C Black Red
CG Black Red
CAck Black Grey
CGAck --- ---
System C Black Yellow
CG --- ---
CAck --- ---
CGAck --- ---
In contrast to the latest messages, here the messages are shown and saved with
all three statuses, that means also acknowledged messages relating to expired
events. This applies to max. 64 different messages with max. 256 statuses.
Button
When this button is pressed, the cursor moves upwards in the message display.
Button
When this button is pressed, the cursor moves downwards in the message dis-
play.
Delete button
This button deletes all messages visible in the message display and saved in the
message buffer. "Administration" authorisation necessary.

Current Latest messages
Archive Message archive
(only relevant in the "Latest messages" operating
display)
Back Last shown operating display
En-16052.707-A
Message texts
General
To allow a detailed error analysis, the control system "failsafe plant interlocking"
provides fault messages.
If one or more errors occur, you can call up these fault messages on the operator
panel.
En-16052.707-A
Fault messages of the control system
The following is a list of all fault messages of the control system "failsafe plant in-
terlocking". The messages vary depending on the system configuration.
No. Message text

1 Acknowledgement request for reintegration of I/O cards in cabinet
1K1.BU01.XFS01
2 Fault of I/O cards in cabinet 1K1.BU01.XFS01
3 Fault - AI slot 1K1.BU01.XFS01-K9301
9 Control system not in safety mode
10 Fault of control system in cabinet 1K1.BU01.XFS01
11 Spare
12 Spare
13 Spare
14 Spare
15 Spare
16 Spare
17 Spare
18 Spare
19 Spare
20 Spare
21 Spare
22 Spare
23 Spare
24 Spare
25 Fault - DI slot 1K1.BU01.XFS01-K9101
28 Fault - DO slot 1K1.BU01.XFS01-K9201
29 Spare
30 Spare
En-16052.707-A
No. Message text

31 Spare
32 Spare
33 Spare
34 Spare
35 Spare
36 Spare
37 Spare
38 Spare
39 Spare
40 Spare
41 Spare
42 Spare
43 Spare
44 Spare
45 Spare
46 Spare
47 Spare
48 Spare
49 PII 016: Analog input > 29376 (> 21 mA) (over nominal range)
50 PII 016: Analog input < -346 (< 3.8 mA) (under nominal range)
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No. Message text

En-16052.707-A
No. Message text

En-16052.707-A
No. Message text

113 Spare
114 Spare
115 Spare
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No. Message text

116 Spare
117 Spare
118 Spare
119 Spare
120 Spare
129 Spare
130 Spare
131 Spare
132 Spare
133 Spare
134 Spare
135 Spare
136 Spare
137 Spare
138 Spare
139 Spare
140 Spare
En-16052.707-A
No. Message text

141 Spare
142 Spare
143 Spare
144 Spare
145 Spare
146 Spare
147 Spare
148 Spare
149 Spare
150 Spare
151 Spare
152 Spare
153 Spare
154 Spare
155 Spare
156 Spare
157 Spare
158 Spare
159 Spare
160 Spare
161 Spare
162 Spare
163 Spare
164 Spare
165 Spare
166 Spare
167 Spare
168 Spare
169 Spare
170 Spare
En-16052.707-A
No. Message text

171 Spare
172 Spare
173 Spare
174 Spare
175 Spare
176 Spare
177 Spare
178 Spare
179 Spare
180 Spare
181 Spare
182 Spare
183 Spare
184 Spare
185 Spare
186 Spare
187 Spare
188 Spare
189 Spare
190 Spare
191 Spare
192 Spare
193 Fault - purging: Cooler fans of recuperation zone are not operating
194 Fault - purging: SZ primary air fan is not operating
195 Fault - purging: Flaps are not in right position (analog values)
196 Fault - purging: Flaps are not in right position (digital values)
197 Fault - purging: DOPOL waste gas fan and/or filter fan are not
operating
198 Fault - purging: CO analyser: CO >= Max1 (0.4 % by volume) or
one analyser disturbed
199 Fault - purging: Pressure values are not ok
200 Fault - purging: Spare
En-16052.707-A
No. Message text

201 PROFIsafe communication fault from/to SZ
202 PROFIsafe communication fault from/to PC/CC
203 PROFIsafe communication fault from/to KI
204 Spare
205 Spare
206 Spare
207 Spare
208 Spare
209 Fault - operation SZ: SZ burner is not in REMOTE
210 Fault - operation SZ: Firing release from PCS (operator) is not ok
211 Fault - operation SZ: Firing release from PCS is not ok
212 Fault - operation SZ: SZ firing reduced to MIN
213 Fault - operation SZ: Button for heating startup is active
214 Fault - operation SZ: Kiln plant is disturbed
215 Fault - operation SZ: Request for purging
216 Fault - SZ: SZ burner EMERGENCY-OFF
218 Fault - purging: Request for purging => no release for all burner
219 Fault - purging: Bypass hot gas flap is not ok
225 Fault - heat startup: CO analyser: CO >= Max1 (0.4 % by volume)
or both analysers disturbed
226 Fault - heat startup: Spare
227 Fault - heat startup: Cooler fans of recuperation zone are not op-
erating
228 Fault - heat startup: SZ primary air fan is not operating
En-16052.707-A
No. Message text

229 Fault - heat startup: DOPOL waste gas fan and/or filter fan are not
operating
230 Fault - heat startup: Pressure values are not ok
233 Fault - operation SZ: Fault of cooler fans of recuperation zone
234 Fault - operation SZ: SZ primary air fan is not operating
235 Fault - operation SZ: Spare
236 Fault - operation SZ: Spare
237 Fault - operation SZ: DOPOL waste gas fan and/or filter fan are
not operating
238 Fault - operation SZ: CO analyser: CO >= Max3 (0.8 % by vol-
ume) or both analysers disturbed
239 Fault - operation SZ: Pressure values are not ok
240 Fault - operation SZ: Bypass waste gas fan is not operating and
bypass hot gas flap is open
241 Fault - SZ: Spare
249 Fault - SZ: Group error (see alarm buffer on HMI of SZ burner
control system)
En-16052.707-A
No. Message text

273 Fault - start PC/CC: CO analyser: CO >= Max1 (0.4 % by volume)
or one analyser disturbed
274 Fault - start PC/CC: SZ burner is not operating
275 Fault - start PC/CC: Temperature values are not ok
En-16052.707-A
No. Message text

276 Fault - start PC/CC: PC/CC primary air fan is not operating
277 Fault - start PC/CC: Spare
289 Fault - operation PC/CC: PC/CC burner is not in REMOTE
290 Fault - operation PC/CC: Firing release from PCS (operator) is not
ok
291 Fault - operation PC/CC: Firing release from PCS is not ok
292 Fault - PC/CC: Spare
296 Fault - PC/CC: PC/CC burner EMERGENCY-OFF
297 Fault - operation PC/CC: CO analyser: CO >= Max2 (0.5 % by
volume) or both analysers disturbed
298 Fault - operation PC/CC: SZ burner is not operating
299 Fault - operation PC/CC: Temperature values are not ok
300 Fault - operation PC/CC: PC/CC primary air fan is not operating
En-16052.707-A
No. Message text

301 Fault - operation PC/CC: Spare
313 Fault - PC/CC: Group error (see alarm buffer on HMI of PC/CC
burner control system)
321 Fault - operation KI: CO analyser CO >= Max2 (0.5 % by volume)
or both analysers disturbed
322 Fault - operation KI: PC burner is not operating
323 Fault - operation KI: Temperature values are not ok
324 Fault - operation KI: KI primary air fan is not operating
325 Fault - operation KI: Spare
En-16052.707-A
No. Message text

329 Fault - start KI: CO analyser: CO >= Max1 (0.4 % by volume) or
one analyser disturbed
330 Fault - start KI: PC burner is not operating
331 Fault - start KI: Temperature values are not ok
332 Fault - start KI: KI primary air fan is not operating
333 Fault - start KI: Spare
337 Fault - KI: Group error (see alarm buffer on HMI of KI burner con-
trol system)
338 Fault - KI: Spare
345 Fault - operation KI: KI burner is not in REMOTE
346 Fault - operation KI: Firing release from PCS (operator) is not ok
347 Fault - operation KI: Firing release from PCS is not ok
En-16052.707-A
No. Message text

352 Fault - KI: KI burner EMERGENCY-OFF
353 Fault - general: Control system not in safety mode
354 Communication fault from/to PCS (L)
355 Communication fault from/to PCS (K1)
356 Communication fault from/to PCS (K2)
357 Fault - general: Group error I/O cards
358 Fault - general: Spare
En-16052.707-A
No. Message text

385 Fault - operation BP: Request for purging bypass => no release
for bypass
386 Fault - operation BP: Kiln inlet temperature is not ok
387 Fault - operation BP: Bypass waste gas fan is not operating
388 Fault - operation BP: Bypass fresh air fan is not operating
389 Fault - operation BP: Bypass CO analyser: CO >= Max3 (0.8 % by
volume) or analysers disturbed
390 Fault - operation BP: COMAX3 => close hot gas flap or kiln will
disturbed in 5 min
391 Fault - BP: Spare
393 Fault - purging BP: Bypass hot gas flap is not ok
394 Fault - purging BP: Bypass waste gas fan is not operating
395 Fault - purging BP: Bypass fresh air fan is not operating
396 Fault - purging BP: Spare
397 Fault - purging BP: Bypass CO analyser: CO >= Max1 (0.4 % by
volume) or analysers disturbed
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5.6 System
Figure 42 System
In this operating display you can set some system functions.
System time
After touching the input field the input dialog for entering date and time opens on
the screen.
Offline button
This button finishes the "WinCC Flexible“ runtime application. The desktop
(graphical user interface) of the Windows CE operating system appears.
Clean TP button
After pressing this button, the touch screen is grey for 30 seconds. The functions
of the operating display are ineffective for this period of time and the screen can
be cleaned.
NOTE
For cleaning the screen, use a wet cleaning tissue with a cleaning agent. Only
use washing-up liquid or foaming cleaning agent for the screen.
En-16052.707-A
Calibration button
Depending on installation position and viewing angle, during normal work with the
operator panel a parallax can occur. To avoid operating errors based on this par-
allax, you can recalibrate the touch screen during operation with this function.
After pushing the button, proceed as follows:
1. At first, a dialog with the following text appears:
Carefully press and briefly hold stylus on Message text: "Carefully press and briefly
the center of the target. Repeat as the target hold stylus on the center of the target. Re-
moves around the screen.
peat as the target moves around the
screen."
Target
2. Carefully press the centre of the target.
3. After that, the target appears on four other positions. In each position
briefly touch the centre of the target. If you miss the centre of the target,
the procedure will be repeated.
En-16052.707-A
If you have touched the target in every position, the following dialog is displayed:
New calibration settings have been measured. Message text: "New calibration settings
Tap the screen to register saved data.
Wait for 30 seconds to cancel saved data and
have been measured. Tap the screen to
keep the current setting. register saved data. Wait for 30 seconds to
cancel saved data and keep the current
setting."
Remaining time until data is discarded

Time limit : 30 sec (max. 30 seconds) is displayed
4. Touch the screen within 30 seconds. The new calibration is stored. If you
wait longer than 30 seconds, the new calibration is discarded and the
previous calibration remains active.
Set clock button
By pushing this button the displayed value will be sent to the subordinated control
system. Date and time of touch screen and control system are cyclically synchro-
nised per minute by the control system.
Back Start display
En-16052.707-A
5.7 User administration
Figure 43 User administration
In this operating display the administrator who has "administration" authorisation

can provide a new password. Moreover, the logoff time can be changed. The
logoff time is the time, after which the login becomes invalid. It is started after the
last operation on the touch screen. The input dialog can be opened by double
clicking on the respective buttons.
Administrators / Persons of group 9 Admin
Administrators have "operate", "monitor" and "administration" authorisations. With

the "administration" authorisation, these people can call up the operating display
"system" and "user" and delete the message archive. With the "operate" authori-
sation a different projected language can be selected and other password pro-
tected buttons e.g. acknowledgement of fault messages can be actuated.
User / Persons of group 1 User
These persons have "operate" authorisation.
En-16052.707-A
Back Start display
En-16052.707-A
5.8 Saving and restoring the project
The entire "WinCC Flexible“ project can be saved on the supplied memory card
after finishing the commissioning. If the operator panel TP 177 B is damaged, you
can restore the project on a new operator panel with this card according to the
following procedure.
After the runtime application has quit (see operating display "system") the follow-
ing dialog appears:
Figure 44 Dialog for Loader
En-16052.707-A
By pushing the Control Panel button you will call up the control panel of the op-
erator panel.
Figure 45 Control Panel
Subsequently, you can open the Backup/Restore dialog by double clicking.
Figure 46 Backup/Restore
1. BACKUP button for saving data on the memory card
2. RESTORE button for restoring data from the memory card
En-16052.707-A
Procedure for saving

1. Insert the memory card
2. Touch the BACKUP button
The message “Starting Backup“ is displayed. The first step is a check by pro-
gramming if a suitable memory card is inserted.
Memory card missing or damaged:

The message "No storage card detected!" appears if no memory card is inserted
in the card slot or if the memory card is damaged.
Figure 47 Fault message during backup
Then perform the steps 3 to 4 below.
3 Confirm with OK.
The message "Backup aborted" is displayed.
4. Also confirm with OK. The control panel is displayed again.
Memory card ok:
The message "Storage card successfully detected" is displayed.
If the memory card contains data, the message "You may have an old backup on
the storage card. Do you want to delete it?" is displayed.
3. Touch Yes if you want to delete the data. Touch No if you want to retain the
data.
The messages "Checking Registry" and "Saving CE-Image" are displayed in se-
quence when the backup begins. A progress bar shows the status of the process.
The backup ends with the following message: "Backup successfully completed.
Press OK and remove your storage card."
4. Confirm with OK.
The control panel is displayed. The data is saved on the memory card. Now you
can remove the memory card and store it on a suitable place.
En-16052.707-A
Procedure for restoring

1. Insert the memory card
2. Touch the RESTORE button.
The message “Starting restore“ is displayed. The first step is a check by pro-
gramming if a suitable memory card is inserted.
Memory card missing or damaged:
If no memory card is inserted in the card slot or if the memory card is damaged
the message "Storage card couldn't be detected. Try restore again? Insert stor-
age card and press OK or abort restore with CANCEL." is displayed.
Figure 48 Fault message during restoring
Then perform the steps 3 to 4 below.
3. Abort with CANCEL.
The message "Abort restore. Remove your storage card!" is displayed.
4. Confirm with OK. The control panel is displayed again.
Memory card ok:
The message "Checking data" is displayed.
When the data has been checked, the message "You are starting RESTORE
now. All files (except files on storage cards) and the registry will be erased. Are
you sure?" is displayed.
3. If you want the data to be restored, touch the Yes button. If you do not want
the data to be restored, touch the No button.
The messages "Deleting files on flash" and "Restore CE-Image" are displayed in
sequence once the restore process begins. A progress bar shows the status of
the process.
En-16052.707-A
The restore ends with the following message: "Restore of CE Image finished. The
device will be rebooted now. Don`t remove the storage card."
4. Confirm with OK.
The operator panel will be restarted; Loader and control panel open one after an-
other. Two messages are following. Then the final message appears: "Restore
successfully finished. Press ok, remove your storage card and reboot your de-
vice."
5. Confirm with OK.
The operator panel will be restarted. The control panel is displayed. The data
from the memory card are on the operator panel. Existing licenses remain on the
operator panel, all other data which already existed are deleted.
En-16052.707-A
Operating Instruction Electrical commissioning
6 Electrical commissioning
6.1 Checks prior to commissioning
Control cabinet and power supply

Is the control cabinet located in "permissible environment" (dust free, ambient
temperature)?
Is the control cabinet free from mechanical damage and damaged paintwork?
Are all cables connected and the clamping screws properly tightened?
Are all earth connections properly connected and screwed tight?
Check the power supply and supply system configuration and write the respec-
tive information on the cabinet plate.
Switch on the control cabinet power supply and measure at the terminal strip
whether the values are within the permissible range.
Switch on the control voltage for the control cabinet and measure whether the
values are within the permissible range.
Is the fan to the control cabinet functioning correctly? Is an adequate overpres-
sure generated in the control cabinet?
Is an air filter installed in the control cabinet wall and is it clean?
Switch on the control voltage 24 V and measure whether the voltage is in the
permissible range.
Control system and signal exchange

Control system SIMATIC S7-300F
Are all S7 modules installed and properly set in the hardware profile?
Switch on the S7 control system and load and start the control program.
Does the light-emitting diode "RUN" light up?
If not, determine the reason for the failure via CPU diagnosis.
Start the operator panel TP 177 B and load the operator panel program.
Does the Profibus operate correctly?
If not, localise and eliminate the fault via fault LEDs and system diagnosis.
Set the system parameters.
En-16052.707-A
Electrical commissioning Operating Instruction
Signal exchange to the master process control system

Check the Profibus connection to the higher-level control system.
When the signal exchange with the higher-level control system is active, test
all signals.
Check the displays in the master process control system for completeness and
correctness.
Signal exchange to the burner control systems

Check the Profibus connection to the subordinate control systems.
When the signal exchange with the subordinate control systems is active, test
all signals.
If the signal exchange is via hardware DI/DO/AI/AO:
test all signals.
6.2 Checks after commissioning
For checking the safety interlocks for the firing system and the efilter the commis-
sioning manager has to perform a test routine in co-operation with the customer
After a successful test of the safety functions (e.g. switching off if CO > MAX3,
failure of a system fan,...) a test log is drawn up and signed by both parties (see
the section Test log).
6.3 Handing-over
At the end of commissioning the software and the associated passwords are
handed over to the customer. This is noted in a handing-over record that has to
be signed by the commissioning manager and the customer (see the section
Handing-over record).
En-16052.707-A
Operating Instruction Maintenance
7 Maintenance
Make absolutely sure that the entire working area is cordoned off during mainte-
nance work to prevent unauthorised persons from gaining access.
Make absolutely sure that all machines and motors whose operation might en-
danger persons or equipment are switched off and safeguarded against restarting
for the entire duration of the maintenance work.
Switch off the power supply to the electrical components before starting any
maintenance work.
Keep the plant free of oily and combustible substances and materials! Be careful
with cleaning agents! Never use gasoline or other easily inflammable substances
for cleaning!
Work on the electrical equipment of the machine/plant may only be performed by

a qualified electrician or by authorised persons under the supervision of a quali-
fied electrician in accordance with the electrotechnical regulations.
Remount all protection devices when maintenance work has been finished.
En-16052.707-A
Operating Instruction Spare Parts
8 Spare Parts
Guidelines for ordering spare parts

Dear Customer,
POLYSIUS AG want to make spare part enquiries and spare part order place-
ment as easy and efficient as possible. For this purpose we have prepared a form
sheet containing all data required by our spare parts department to ensure opti-
mum processing in the most speedy and troublefree manner.
Please provide all the data mentioned below in every enquiry or order for spare
parts or copy this sheet and enclose the copy with your order or enquiry.
Keep the original sheet as a master for photocopying!
We hope that this will ensure quick and smooth cooperation between you and our
spare parts department.
Data for ordering spare parts

• Code word
• Order number
• POLYSIUS Order Code (POC,
Itemisation of the principal machines in the order structure)
En-16052.707-A
Spare Parts Operating Instruction
Code Word: Order No.: POC:

Item No. Designation Qty. Unit Order Enquiry
En-16052.707-A
Operating Instruction Appendix
9 Appendix
9.1 Firing system interlocks
En-16052.707-A
9-2
Appendix
Monitor
Visualisation General Arrangement Drawing
Failsafe Control Units for Kiln Firing
(with MASTER - MASTER communication)
(by ?????) OLM
* failsafe I/O‘s Optical Link Module
Server/Client
* FOC (fibre optical cable)
(by ?????) (by ?????)
Controller Controller
(kiln aerea) (cooler area)
OLM OLM Profibus DP

Profibus DP
Control Level
9.2 Communication
(by ?????) *
OLM OLM
INTERLOCKING
MPI
TP177B failsafe PLC
S7-315F (Master)
OLM
*
Master-master-communication
Process
(digital and analog signals)
Profisafe (187.5 kBit/s)
Profibus DP * Profibus DP
(by ?????) (by ?????) (by ?????) (by ?????) (by ?????) (by ?????)
Profisafe Profisafe Profisafe
* * * *
OLM OLM OLM OLM OLM OLM
serial serial serial serial
DP / DP parallel parallel DP / DP parallel parallel
coupler Profisafe coupler Profisafe
* *
OLM OLM
Precalcination Sintering Zone

failsafe PLC failsafe PLC
S7-315F (Master) S7-315F (Master)
For interlockings For interlockings
necessary signals necessary signals
(by ?????) (by ?????)
Profisafe Profisafe
OLM OLM
serial serial
parallel
OP170B parallel
OP170B
Process Process Process Process Process Process

Process Level (digital and analog (digital and analog (digital and analog (digital and analog
(digital and analog (digital and analog
signals) signals) signals) signals)
signals) signals)
From: xxxx From: xxxx
From/to : xxxx (burner) From/to : xxxx (burner)
En-16052.707-A
Monitor
En-16052.707-A
(with MASTER - SLAVE communication)
* failsafe I/O‘s
Server/Client
* Profibus FOC by ABB
OLM OLM
Profibus DP
Control Level
(by Polysius)
OLM OLM
POLYSIUS
Master-slave-communication
MPI
TP177B S7-315F (Master)
Address: x
OLM *
3K1Nxxx Process
(digital and analog signals)
Profisafe (187.5 kBit/s) to: xxxx
* *
(by xxxx) (by Polysius ) (by xxxx ) (by xxxx) (by Polysius ) (by xxxx )
* * * *
OLM OLM OLM OLM
Typ: xxxx OLM OLM
serial serial serial serial
parallel parallel parallel parallel
S7-315F (Slave) S7-315F (Slave)
Addr:3 Address: 20 Addr: 4
Address: 10 * *
* KxNxxx KxNxxx KxNxxx * LxNxxx LxNxxx LxNxxx
binary (parallel) analog (parallel) MPI (serial)
binary (parallel) analog (parallel)
(by xxx) (by xxx) (by xxx) (by xxx)
Terminal OP170B Terminal OP170B

Cabinet For interlockings
Cabinet For interlockings
necessary signals necessary signals

KxCxxx KxCxxx LxCxxx LxCxxx
Process Process Process Process

Process Level Process Process (digital and analog
(digital and analog (digital and analog (digital and analog (digital and analog
signals) (digital and analog signals) signals) signals)
signals) signals)
From/to : xxxx (burner) From: xxxx From: xxxx
From/to : xxxx (burner)
Appendix
9-3
9-4
Appendix
Monitor
(with PARALLEL communication)
* failsafe I/O‘s
Server/Client
* Profibus FOC
parallel
OLM OLM
Profibus DP
Control Level Profibus DP
Parallel communication
(by ?????)
OLM OLM
Failsafe PLC (Master) MPI

TP177B
Address: x
parallel parallel
*
(digital and analog
signals)
Process
(by ?????) (by ?????) (digital and analog signals)
to: xxxx
OLM OLM
DP / DP DP / DP
coupler coupler
OLM OLM

S7-315F (Master) * S7-315F (Master)
Address: x Address: x *
For interlockings
necessary signals
(by ?????)
(by ?????)
Profisafe
OLM Profisafe
OLM
serial
OP170B serial
parallel OP170B
parallel
LxNxxx
* LxNxxx
(by ?????) * (by ?????)
Process Process Process

Process Level Process (digital and analog (digital and analog
(digital and analog
(digital and analog parallel signals) parallel signals)
signals)
signals) From: xxxx
From/to : xxxx (burner) From/to : xxxx (burner)
En-16052.707-A
9.3 Test log
9.3.1 Electrical signal checking Comment Done

All digital signals installed and wired □
Signals lacking:
□
□
□
□
□
□
□
□
□
□
All analog signals installed and wired □

Signals lacking:
□
□
□
□
□
□
□
□
□
□
En-16052.707-A
Appendix Operating Instruction
9.3.2 Interlock test "Purging the system" Comment Done

Start the purging process, then simulate a fault
Failure of more than x cooling air fans (point 2.1.1.1) □
Cooling air flow rate < MIN (point 2.1.1.2) □
Failure of primary air fan (point 2.1.2.1) □
Damper of primary air fan closed (point 2.1.2.1) □
Speed of primary air fan < MIN (point 2.1.2.1) □
Primary air flow rate < MIN (point 2.1.2.1) □

Pressure after damper in the primary air channel < MIN (point
2.1.2.1) □
Pressure at kiln hood > MAX (point 2.1.3.1) □
Failure of DOPOL exhaust gas fan (point 2.1.3.2.1) □
Speed of DOPOL exhaust gas fan (point 2.1.3.2.1) □
Pressure after DOPOL exhaust gas fan > MAX (point 2.1.3.3) □
Damper in kiln exhaust gas duct closed (point 2.1.3.4) □
Fresh-air flap in kiln exhaust gas duct open (point 1.0.3.3) □
Damper in mill bypass not open (point 2.1.3.5) □
Failure of filter fan (point 2.1.3.6.1) □
Damper of filter fan closed (point 2.1.3.6.1) □
Speed of filter fan < MIN (point 2.1.3.6.1) □
Efilter is ON or not earthed (point 2.1.3.7) □
Bypass hot gas flap not closed (point 2.1.3.8) □

Slack rope switch of bypass hot gas flap actuated (point
2.1.3.9) □
CO analysers are faulty or in maintenance (point 2.1.4.1) □
CO > MAX1 (0.4 % by volume) (point 2.1.4.2) □
En-16052.707-A
9.3.3 Interlock test "SZ burner operation" Comment Done

Start the burner, then simulate a fault
CO analysers are faulty or in maintenance (point 2.2.1.1) □
Failure of more than 1 cooling air fan in 2 min (point 2.2.3.1) □
Failure of more than x cooling air fans (point 2.2.3.1) □
Cooling air flow rate < MIN (point 2.2.3.2) □
Failure of primary air fan (point 2.2.3.4.1) □
Damper of primary air fan closed (point 2.2.3.4.1) □
Speed of primary air fan < MIN (point 2.2.3.4.1) □
Primary air flow rate < MIN (point 2.2.3.4.1) □

2.2.3.4.1) □
Pressure at kiln hood > MAX (point 2.2.4.3) □
Failure of filter fan (point 2.2.4.4.1) □
Damper of filter fan closed (point 2.2.4.4.1) □
Speed of filter fan < MIN (point 2.2.4.4.1) □
Failure of bypass exhaust gas fan (point 2.2.4.5.1) □
Speed of bypass exhaust gas fan < MIN (point 2.2.4.5.1) □

2.2.4.6.1) □
Oil pressure < MIN (point 2.2.5.1) □
Fuel quantity of SZ burner > 100 % (point 2.2.6.1) □
Fuel input > 10 % Qmax of the kiln (point 2.2.9.1) □
En-16052.707-A
9.3.4 Interlock test "SZ burner operation"

Comment Done
PCS interlocks
Kiln feed system failure (raw meal feeding) (point 8.2.1) □
Failure or manual operation of clinker cooler (point 8.2.2) □
Failure of cooler exhaust air fan (point 8.2.3) □
Failure of main kiln drive (point 8.2.4) □
Failure of primary air fan (point 8.2.5) □
Temperature after preheater > MAX2 (450 °C) (point 8.1.1) □

Temperature after preheater > MAX1 (420 °C) (point 8.1.1.1)
□
(20 min delayed)
Temp. after DOPOL exhaust gas fan > MAX2 (point 8.1.2) □
Temperature before kiln filter > MAX2 (point 8.1.3.1) □
Temperature after kiln efilter > MAX2 (point 8.1.3.2) □

Temperature before cooler exhaust air filter > MAX2 (point
8.1.4.1) □
Temperature after cooler exhaust air efilter > MAX2 (point

8.1.4.2) □
Failure of kiln outlet cooling system (30 min delayed) (point

8.1.5) □
9.3.5 Interlock test "SZ burner to MIN"

Comment Done
PCS interlocks
Failure of kiln feed system (raw meal feeding) (point 8.2.1) □
En-16052.707-A
9.3.6 Interlock test "PC burner operation" Comment Done

Failure of SZ burner (point 3.2.1.1) □
Reduction of SZ burner to MIN (point 3.2.1.1) □
All temperatures < 750 °C (point 3.2.1.2) □
Fuel quantity PC burner > 100 % (point 3.2.4.2) □
Failure of ignition or pilot burner (point 3.2.6.1) □
Failure of flame monitor (point 3.2.6.1) □
9.3.7 Interlock test "CC burner operation" Comment Done

All temperatures < 750 °C (point 4.2.1.2) □
Fuel quantity CC burner > 100 % (point 4.2.4.2) □
En-16052.707-A
9.3.8 Interlock test "PC/CC burner operation"

Comment Done
PCS interlocks
Temperature after preheater > MAX2 (450 °C) (point 8.1.1) □
Temperature after preheater > MAX1 (420 °C) (point 8.1.1.1)
□
(20 min delayed)
Temp. after DOPOL exhaust gas fan > MAX2 (point 8.1.2) □
Temperature before kiln filter > MAX2 (point 8.1.3.1) □
Temperature after kiln efilter > MAX2 (point 8.1.3.2) □

Temperature before cooler exhaust air filter > MAX2 (point
8.1.4.1) □
Temperature after cooler exhaust air efilter > MAX2 (point

8.1.4.2) □
Failure of kiln outlet cooling system (30 min delayed) (point

8.1.5) □
Kiln feed system failure (raw meal feeding) (point 8.2.1) □
En-16052.707-A
9.3.9 Interlock test "KI burner operation" Comment Done

Failure of PC/CC burner (point 5.2.1.1) □
Fuel quantity of KI burner > 100 % (point 5.2.4.2) □
En-16052.707-A
9.3.10 Interlock test "Release bypass" Comment Done

Start bypass:
Bypass hot gas flap not closed (point 6.1.2.1.1) □

6.1.2.1.1) □
Damper bypass exhaust gas fan closed (point 6.1.2.2.1) □
Failure of bypass fresh air fan (point 6.1.2.3.1) □
Damper of bypass fresh air fan closed (point 6.1.2.3.1) □
Speed of bypass fresh air fan < MIN (point 6.1.2.3.1) □
9.3.11 Interlock test "Bypass operation" Comment Done

Bypass in operation, then simulation of a fault
Damper of bypass exhaust gas fan closed (point 6.2.2.1.1) □
Bypass hot gas flap closed (point 6.2.2.2.1) □

6.2.2.2.2) □
Bypass gas analysis: CO > MAX3 (0.8 % by volume) (point

6.2.3.1) □
Bypass gas analysis: changeover to kiln inlet (point 6.2.3.2) □
En-16052.707-A
9.3.12 Interlock test "Efilter operation" Comment Done

Start the efilter, then simulate a fault
Analysers are faulty or in maintenance (point 7.2.1.1) □
Failure of more than 1 cooling air fan in 2 min (point 7.2.2.1.1) □
Failure of more than x cooling air fans (point 7.2.2.1.1) □
Cooling air flow rate < MIN (point 7.2.2.1.2) □
Failure of primary air fan (point 7.2.2.2.1) □
Damper of primary air fan closed (point 7.2.2.2.1) □
Speed of primary air fan < MIN (point 7.2.2.2.1) □
Primary air flow rate < MIN (point 7.2.2.2.1) □

7.2.2.2.1) □
Failure of the efilter fan (point 7.2.4.1) □
Damper of the efilter fan closed (point 7.2.4.1) □
Speed of the efilter fan < MIN (point 7.2.4.1) □
Failure of bypass exhaust gas fan (point 7.2.5.1) □
Damper of bypass exhaust gas fan closed (point 7.2.5.1) □
Speed of bypass exhaust gas fan < MIN (point 7.2.5.1) □
Bypass hot gas flap not closed (point 7.2.5.2) □

7.2.5.2.1) □
Oil pressure < MIN (point 7.2.7.1) □
Fuel quantity of burner > 100 % (point 7.2.6.1) □
En-16052.707-A
9.3.13 Hardware information Comment Done

Version of
- CPU .................................................................... □
- CP modules ........................................................ □
- AI modules ........................................................ □
- AO modules ........................................................ □
- DI modules ........................................................ □
- DO modules ........................................................ □
- IM modules ........................................................ □
- DP/DP coupler ........................................... □
Program signature □
.................................................................................
Note site modifications according to "comments" □
(modification of documentation)
The performed test of the manufactured part shall not release the manufacturer from his Release for operation Yes No
responsibility for appropriate manufacture in conformity with the drawings.
Customer: Manufacturer's works POLYSIUS AG

No.
Stamp and Signature Stamp and Signature
Place Date Place Date
En-16052.707-A
9.4 Handing-over record
9.4.1 Hardware Comment

Version of
- CPU .............................................................................................. □
- CP modules ................................................................................. □
- AI modules ................................................................................. □
- AO modules ................................................................................. □
- DI modules ................................................................................. □
- DO modules ................................................................................. □
- IM modules ................................................................................. □
- DP/DP coupler .................................................................... □
9.4.2 Software Comment

Version of
- Documentation Manual Collection ........................................... □
- Documentation HMI .................................................................... □
- S7 Distributed Safety .................................................................... □
- WinCC flexible .................................................................... □
Collective signature of safety program: ..............................................................................................
9.4.3 Passwords
- Operator panel user: ....................................................................................................................................
- Operator panel password: ....................................................................................................................
- Control system standard password: ...........................................................................................................
- Control system password safety program: ..............................................................................................
Customer: Manufacturer's POLYSIUS AG

works No.
Stamp and Signature Stamp and Signature
Place Date Place Date
En-16052.707-A
9.5 Glossary
AV Actual value
BP Bypass
CC Combustion chamber
KI Kiln inlet
LL Lower limit
PII Process input image

PC Precalciner
PCS Process control system
SIL Safety integrity level

SP Setpoint
SZ Sintering zone
TP Touchpanel (Touchscreen)
UL Upper limit
En-16052.707-A

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Operating Instruction

Control system “failsafe plant interlocking“

POLYSIUS Order Code (POC)

Specification of the intended use

Power supply to control cabinet

Transport and assembly

Only use suitable hoisting and load-carrying equipment which is in serviceable

Never work under a suspended load.

If the combustion air volume is insufficient, i.e. if the CO concentration increases,

The limit values for the CO concentration are defined as follows:

Hot gas generator

3.2 Configuration possibilities

The complete configuration of the system consists of the following components

Communication to the master process control system

Communication to the burner control systems

During master-master-communication all fail-safe control systems are active as

During master-slave-communication the control system "fail-safe plant interlock-

4 Control system SIMATIC S7-300F

The hardware components for S7 Distributed Safety (F-CPU, F-I/O, batteries,...)

Digital input module SM326; DI 24 x DC 24V

Figure 1 Front view SM326; DI 24 x DC 24V

Figure 2 Connection and block diagram of the SM326; DI 24 x DC 24V

Figure 3 Wiring diagram of the SM326; DI 24 x DC 24V

Digital output module SM326; DO 10 x DC 24V/2A

Figure 4 Front view SM326; DO 10 x DC 24V/2A

Figure 5 Connection and block diagram of the SM326; DO 10 x DC 24V/2A

Figure 6 Wiring diagram of the SM326; DO 10 x DC 24V/2A

Analog input module SM336; AI 6 x 13Bit

Figure 7 Front view SM336; AI 6 x 13Bit

Figure 8 Connection and block diagram of the SM336; AI 6 x 13Bit

6 process signals can be connected to an analog module. The sensor supply Vs

Figure 9 Wiring diagram of the SM336; AI 6 x 13Bit (2-wire measuring transducer)

Figure 10 Wiring diagram of the SM336; AI 6 x 13Bit (4-wire measuring transducer)

Analog output module SM332; AO 4 x 16Bit

Figure 11 Connection and block diagram of the SM332; AO 4 x 16Bit

Figure 12 Example of hardware configuration in the control cabinet

Figure 13 Example of hardware configuration of the decentral I/O level

Detailed information is shown in the Siemens manuals

Detailed information is shown in the Siemens manuals

5 Operator panel TP 177 B

5.1 General description

Figure 14 Operator panel TP 177 B, display with touch screen

A touch screen is a bidirectional human machine interface.

Operate operating objects on the touch screen

Causing damage to the touch screen

5.2 Display areas

Display changing area

Figure 16 Overview area

Process operating area

Cooler air fan(s)

SZ primary air fan(s)

DOPOL waste gas fan(s)

Fresh air damper(s)

DOPOL stage 2/3

DOPOL waste gas fan(s)

Hot gas flap

Waste gas fan

Fresh air fan

Kiln plant status

Kiln plant purging

PC/CC burner startup

PC-/CC burner operat.

Display changing area