00 B&R HydSt HCS-Si BED EN 01

Hydraulic control system HCS
Operating instruction
00_B&R_HydSt_HCS-Si_BED_EN_01.docx Page 2 of 28
Content
1. Safety ........................................................................................................................................................... 4
1.1 General ....................................................................................................................................................... 4
1.2 Responsibilities of the operator .................................................................................................................. 4
1.3 Proper use .................................................................................................................................................. 5
1.4 Improper use .............................................................................................................................................. 5
1.5 Obvious improper use ................................................................................................................................ 5
1.6 Person-related information ......................................................................................................................... 5
1.6.1 Personnel qualifications ........................................................................................................................... 5
1.6.2 Target group ............................................................................................................................................ 6
1.7 Required personal protective equipment ................................................................................................... 6
1.8 Safety instructions ...................................................................................................................................... 7
1.9 Product-specific hazards or product safety ................................................................................................ 7
1.10 Storing documentation ............................................................................................................................... 8
2. General instruction ..................................................................................................................................... 8

2.1 Delivery condition ....................................................................................................................................... 8
2.1.1 Colour marking......................................................................................................................................... 8
2.1.2 Liability ..................................................................................................................................................... 8
2.2 Spare and wear parts ................................................................................................................................. 9
2.3 Transportation ............................................................................................................................................ 9
2.3.1 Loading and transporting further .............................................................................................................. 9
2.3.2 Lifting equipment.................................................................................................................................... 10
2.4 Storage ..................................................................................................................................................... 10
2.4.1 Conditions .............................................................................................................................................. 10
2.4.2 Short-term storage ................................................................................................................................. 11
2.4.3 Long-term storage and preservation...................................................................................................... 11
2.4.4 Storage conditions for rubber products ................................................................................................. 11
2.5 Waste disposal ......................................................................................................................................... 12
3. Characteristics .......................................................................................................................................... 13
3.1 Circuit concept .......................................................................................................................................... 13
3.2 Electrical switchgears ............................................................................................................................... 13
3.3 PLC ........................................................................................................................................................... 13
3.4 Additional characteristics .......................................................................................................................... 13
3.5 Optional functions ..................................................................................................................................... 13
4. Program description ................................................................................................................................. 14

4.1 Start-up screen ......................................................................................................................................... 14
4.1.1 Quick information section (1) ................................................................................................................. 14
4.1.2 Status section (2) ................................................................................................................................... 14
4.1.3 Command section (3) ............................................................................................................................ 15
4.2 Setup ........................................................................................................................................................ 16

4.2.1 Feed-in 400 V / pump control ................................................................................................................ 16
4.3 Pressure, temperature and level switch points ........................................................................................ 17
4.3.1 Pressure switch points ........................................................................................................................... 18
4.3.2 Temperature switch points ..................................................................................................................... 18
4.3.3 Level switch points ................................................................................................................................. 18
4.4 System setting / Operating hours ............................................................................................................. 19
4.4.1 System setting ....................................................................................................................................... 19
4.4.2 Operating hours ..................................................................................................................................... 19
4.5 Administration section .............................................................................................................................. 20
4.5.1 Monitoring times / settings / monitoring ................................................................................................. 20
4.5.2 Analogue inputs ..................................................................................................................................... 23
4.5.3 Binary level ............................................................................................................................................ 23
5. Messages ................................................................................................................................................... 24
5.1 Warning messages touch panel ............................................................................................................... 24
5.2 Alarm messages touch panel ................................................................................................................... 25
5.3 Group message, processing fault............................................................................................................. 25
5.4 Group message, E-process control equipment fault ................................................................................ 25
5.5 Receiving module DB20 of the DCS via Profibus .................................................................................... 26
5.6 Transmitter block DB30 to the DCS via Profibus ..................................................................................... 26
1. Safety
1.1 General
To ensure general safety, the following documentation must be
thoroughly read and understood. All regulations and information
must be adhered to.
Please contact the manufacturer if difficulties should arise which
cannot be resolved with the aid of the operational
documentation.
Failure to comply may result in injury and property damage!
This operational documentation has been prepared in
accordance with the requirements of the EU Pressure
Equipment Directive 97/23/EC.
Only qualified Bopp & Reuther personnel may carry out any work
NOTICE on the control!
Any of the operator's installation staff involved, the operator is
also responsible for compliance with local safety regulations.
1.2 Responsibilities of the operator

 The operator must have the necessary qualifications
 The operator must have access to the appropriate technical
documentation materials at all times
 The operator must have read and understood the information
contained in the operating manual before putting the machine
into operation for the first time
 The piping system is to be professionally designed and
installed so that the control can be fitted and operated free of
stress
 The control must be installed correctly and correctly
positioned
 Only competent, trained personnel may install, operate and
service the control. Competent in the sense of these
instructions are those who on the basis of their training,
knowledge and professional experience are capable of
correctly assessing and properly executing their appointed
tasks and are able to recognize and eliminate potential
hazards.
 It is to be ensured that the control is installed only if the
function, pressure and temperature range, housing material,
connection types and dimensions are appropriate for the
particular operating conditions
 Newly installed tanks and/or piping sections must be carefully
flushed out and cleaned before operating the valve
1.3 Proper use

After installation and connection of the actuation to the
controlled system, Bopp & Reuther controls are intended only for
conveying and regulating media within permissible pressure and
temperature limits.
The type of the medium stipulated in the purchase contract for
each control must be adhered to and is not be substituted or
altered. Refer to the planning documents for information on the
permissible pressure and temperature ranges.
1.4 Improper use

Modifications, attachments or conversions are not to be made
without prior approval from the manufacturer.
The materials used in the control are only compatible with
certain types of media. The materials comprising the controls
could be damaged.
Using a medium that is unsuitable for the controls will invalidate
the terms and conditions of liability. Any other use is not in
accordance with the intended purpose.
Always contact Bopp & Reuther.
1.5 Obvious improper use

Carry out all work on Bopp & Reuther controls as described in
the technical documentation. Failure to comply cause serious
injury and/or property damage!
In addition, it must be ensured that the control is implemented
only where the type of medium, operating pressure and
temperature coincide with the design criteria defined in the order
and specified on the type plate. Take appropriate measures to
prevent any potential hazards originating from the medium of the
control system or from moving parts. Proper transport and
storage are prerequisite.
Operational reliability and quality assurance can no longer be
ensured if this machine is randomly combined with third-party
machines.
1.6 Person-related information

1.6.1 Personnel qualifications
Transport, installation, commissioning, maintenance, or repair
must be only performed by Bopp & Reuther personnel.
Staff must have the required qualifications based on their
technical knowledge and experience. They must be capable of

correctly assessing their appointed tasks and recognizing
possible hazards on the basis of their professional education,
experience and knowledge of relevant standards. Furthermore,
personnel must be familiar with accident prevention regulations,
generally recognized safety regulations, EU directives and
national standards and regulations, as well as all regional and
in-house regulations and requirements related to operational
conditions.
Training or instruction in accordance with established safety
practices in the care and use of appropriate safety and
protective equipment is necessary.
Bopp & Reuther always offers training and instruction courses.
1.6.2 Target group

The technical documentation addresses those persons who
have been entrusted with installation planning, installation,
operation, servicing and maintenance. These persons must
have the qualifications that correspond to their activities and
functions, i.e. must be capable of assessing their appointed
tasks and recognizing possible hazards on the basis of their
professional education, knowledge and experience as well as
knowledge of relevant standards.
This also includes knowledge of relevant accident prevention
regulations, generally recognized safety regulations, EC
directives and regional standards and regulations.
1.7 Required personal protective equipment

Measures for personal occupational safety and health protection
apply in addition to technical and organizational measures. All
persons who are in the vicinity of the control are required to
wear the prescribed personal protective equipment. These must
comply with the relevant national standards and accident
prevention regulations.
Wearing and using the following safety equipment minimizes the
risk of injury and can help to avoid accidents and increase the
level of safety.
The following personal protective equipment must always be
worn when working in the area of the system:
 Hearing protection
 Safety goggles
 Protective gloves
 Safety shoes
 Welding suit
 Safety helmet
 Anti-fall device
1.8 Safety instructions

The following symbols are used to point out hazardous areas or
important information in the technical documentation.
Danger
Consequence: serious or even fatal injury
Warning
Consequence: minor injury, major property damage
Caution
Consequence: minor property damage
Note pertaining to special conditions
Consequence: damaging situation
Tip / Info
General information for the operator
1.9 Product-specific hazards or product safety

The control is designed only for the permissible pressure load of
the medium!
Dispose of hazardous materials without endangering humans and

the environment!
Additional mechanical load will cause malfunctions or

overloading!
Inspect the individual components and piping systems to ensure

that they are clean before installation!
Inspect the control for shipping damage before installation!
Protect control installed outdoor against the effects of weather!
Effectively cover the control when working on them!
This technical documentation does not replace national accident

prevention regulations and local operator safety regulations,
which are to have priority in all instances!
Always keep the technical documentation available at the

workstation!
Refer to the type plate for the information required for

identification!
Unauthorized modifications and the use of non-original spare

parts exclude the manufacturer from liability for any resulting
damage!
1.10 Storing documentation

The technical documentation materials must be kept available at
the workstation for reference at all times!
The manufacturer of partly completed machinery or his

authorized representative shall keep the original declaration of
incorporation after the last date of manufacture of the partially
completed machine for a period of at least ten years (DIRECTIVE
2006/42/EC on Machinery).
2. General instruction
2.1 Delivery condition
The controls supplied by Bopp & Reuther are tested from
factory, adjusted to the required set pressure, marked and lead-
sealed.
Removing the lead seal without permission of Bopp & Reuther
voids the agreed warranty!
2.1.1 Colour marking

Important fittings and connections on the control are identified
after assembly and testing by colour markings.
Breaking the colour markings without the consent of Bopp &
Reuther voids the agreed warranty!
2.1.2 Liability
Bopp & Reuther shall not be liable for any work not carried out by
qualified Bopp & Reuther personnel, even if the work is performed
on the basis of this documentation!
2.2 Spare and wear parts

Procure all spare parts only from Bopp & Reuther. The purpose is
to ensure the safety of the product.
The use of other parts may invalidate the liability for the resulting
consequences.
The manufacturer's recommendation for spare part stock
keeping can be seen in the list of spare and wear parts.
The following details are required when placing an order:
 Manufacturer’s order number
 Specification of the type
 Part information identifying the part (part no.) from the
drawing and part list
2.3 Transportation
Only transport pallets or containers, which are clean and in
perfect condition are to be used for transporting purposes. Pay
particular attention to ensuring that the products are packed so
that they will not damage each other.
Transport the control horizontally.

Cover the following openings before transporting:
 Supply air connection
 Loading air connection
 Lifting air connection
 Control connections
 Pressure relief connections
2.3.1 Loading and transporting further

In agreement with the customer, dismantling of individual
components may be necessary for the following purposes:
Note the markings on the packaged product with regard to the top
and bottom sides!
 To facilitate handling of the product

 To decrease the packing volume
 To protect protruding or sensitive parts
 To avoid damage to the packaging
Take utmost care when unpacking the control unit. Inspect the
equipment for shipping damage after unpacking.
2.3.2 Lifting equipment

Devices for lifting and moving loads and in general lifting tackle
and chains are referred to as lifting equipment.
Comply with the general transport conditions, such as the
securing, suspension and hoisting instructions for the relevant
control units. Use only suitable lifting equipment.
When transporting, ensure that load-securing, suspension and
lifting devices are available for the control units, which are
always used and properly implemented. To ensure the adequate
load-bearing capacity for a control unit.
Only use lifting equipment, which specifies the maximum
permitted load!
This equipment is to be designed according to generally

recognized rules of technology in such a manner to ensure that
the pulling capacity used as the basis for the size of the lifting
equipment cannot be exceeded. Pay particular attention to the
centre of gravity and prevent the load from slipping and falling
over! When lifting control units, take the in some cases
considerable dead weight of the valves into consideration and
only use appropriate lifting equipment such as wire ropes, cross-
members and lifting equipment.
Comply with the general transport conditions, such as the
securing, suspension and hoisting instructions for the relevant
control units!
Only permissible hoisting equipment must be used for lifting!
While lifting and loading the control units, reverse movements

and uncontrollable movements of the lifting tool should be
avoided, so that slippage of the supporting cable or tilting of the
control unit to one side may be prevented!
2.4 Storage
2.4.1 Conditions
Store the control units in a clean dry place and leave them in their
original packaging until they are to be installed in the system.
This also applies to spare and wear parts.
Storage room The storage room should be cool, dry, clean, dust-free and
moderately ventilated. Outdoor storage even when protected
against weather is not permitted. Store the parts so that they are
protected against damage.
Temperature The temperature for storing products made of caoutchouc and
rubber is between +15 and +25°C. Avoid storing at higher
temperatures.
Heating Secure the sources of heat in heated storage rooms. The
distance between the heat source and the stored product must
be at least 1 metre. A greater distance is required in rooms
heated by forced air.
Moisture Avoid storing in damp storage rooms. It is important to ensure
that there is no condensation. A relative humidity of less than
65% is best.
Lighting Protect the products from light, especially against strong artificial
light with a high UV content. For this reason, provide the
windows of storage rooms with a red or orange (never blue)
protective coating. The preferred lighting is with standard
incandescent lamps.
Oxygen and ozone Protect the products from circulating air and in particular
draughts by storing them in the supplied packaging.
2.4.2 Short-term storage

When stored in a dry room, preserving the parts in shipping
packaging materials protects them for a period of three months.
Avoid exposure to rain/snow and moisture from the floor.
This procedure protects the control unit for three months.
After welded in, the control unit can be kept under these
conditions for three more months before use.
2.4.3 Long-term storage and preservation

Special measures must be taken for storage over a period longer
than six months that vary from case to case.
Cover openings to protect housings against foreign particles!
2.4.4 Storage conditions for rubber products

The following guidelines (extract from DIN 7716) apply for pure
rubber products or in composite form with other materials,
namely for elastomers made from natural rubber and/or
synthetic rubber as well as for adhesives and solutions. The
guidelines in accordance with sections 3 and 4 of DIN 7716
apply primarily as the requirements for long-term storage
(generally longer than 6 months). For short-term storage (less
than 6 months) - such as in production and distribution
warehouses with a constant turnover of materials - the
requirements of DIN 7716 shall apply in the sense of the
requirements with the exception of the general requirements for
storage rooms in accordance with sections 3 and 3.1, as long as
there is no adverse change in the appearance and function of

the products (see section 2, DIN 7716 and as long as no
contradiction to the special requirements of this standard arises
for explicitly short storage periods of rubber products (see
section 4.2.b, DIN 7716).
DIN 7716 (rubber products; requirements for storage, cleaning
and maintenance) always apply for storing components such as
O-rings. Proper storage is important. The service life of O-rings
can be affected and changed by many influences such as light,
heat, moisture, oxygen, ozone, etc. The ideal storage
temperature is between + 5 and + 20 °C. In general, storage in
sealed polyethylene bags is considered ideal.
We recommend that the following storage periods not be
significantly exceeded:
Acrylnitrile-Butadiene-Rubber (NBR) 4 years
Fluor-Polymer-Rubber (FKM/FPM) 10 Years
Perfluorized rubber (FFKM/FFPM) 10 Years
Silicone rubber (MVQ) 10 Years
Ethylen-Propylen-Dien-Rubber (EPDM) 6 years
Chloropren-Rubber (CR) 4 years
2.5 Waste disposal

When disposing of any kind of waste, comply with the waste
laws, directives and regulations governing waste disposal
measures and methods currently in effect at your site. All
components have component-related instruction manuals.
Those indicate substances possibly requiring waste disposal.
Proper waste disposal can also pertain to rubbish, packaging
materials, and residue from operating materials.
Follow the instructions regarding:
 Personal protective equipment

 Disposal containers
 Absorbents, neutralizers, and fire extinguishants
 Traffic regulations
Personnel are to receive instruction on and be advised of laws
and regulations in effect at their site at regular intervals so that
they are able to conduct themselves correctly in case of an
actual health threat from hazardous substances. The emphasis
in this case is on effective immediate action and clearly defined
responsibilities.
3. Characteristics
3.1 Circuit concept
The distribution of the electric lines to the power consumers is
accomplished in so-called "fuseless design" protection with
power circuit breakers. Likewise, in the control voltage cut-outs
are used instead of safety fuses.
3.2 Electrical switchgears

All used switchgears are based on the applicable DIN, VDE, EN
and IEC standards.
The monitoring and control of the individual unit functions is
achieved by a Simatic S7 PLC.
3.3 PLC
The heart of this unit is an S7-3xx or S7-4xx control unit from
Siemens or Vipa combined with a 6" touch panel KTP600 Basic
from Siemens. The Siemens S7-4xx control unit can also be
implemented redundantly if desired.
3.4 Additional characteristics

 Oil pressure control and monitoring
 Pump runtime monitoring
 Monitoring of the oil level (binary or analogue)
 Monitoring of the oil temperature (analogue)
 Filter monitoring (binary)
 Triggering of two pumps with 100% power each
 Alternating pump operation
 Operation using 6" touch panel
 Operating hours meter
3.5 Optional functions

 Redundant input of the 400 V supply
 Automatic input switching of the 400 V supply
 Redundant input of the control voltage 24 VDC or 110-
240 VAC/DC
 Redundant sensors
 Oil heating
 Oil cooler
4. Program description
The control is operated and setup via a touch panel. The setting
options are distributed across several screen pages and are
separated into a user section and an administration section.
The most important messages and settings can be viewed and
changed in the user section.
The administration section is used to troubleshoot and setup the
hydraulic unit. Incorrect settings here can lead to hydraulic unit
malfunctions. Therefore, this section is password protected.
4.1 Start-up screen

The start-up screen provides a general overview of the hydraulic
unit status.
4.1.1 Quick information section (1)

All main operating parameters can be viewed here. Among other
things, important errors, warnings and alarms are displayed in
groups.
Detailed information can be viewed here with the messages
button.
4.1.2 Status section (2)

Ready for Service Ready for Service is indicated when the unit has successfully
run through the initial start, no alarms are pending and the
hydraulic control is in the automatic mode! It is also indicated by
a green signal lamp on the control cabinet door and reported
through a relay at zero potential to the DCS.
Warning A warning signal is triggered when one of the warnings listed in
Chapter 5 occurs. The Warning is also indicated by flashing of a
yellow signal lamp on the control cabinet door and reported
through a relay at zero potential to the DCS. If the error
disappears, the signal lamp goes out. However, the warnings
are saved in the PLC message memory.5
A pending warning does not lead to the unit stopping.
NOTICE
alarm An alarm is indicated when an error is present that leads to the stop of
the unit. The operational readiness expires. The Alarm is also indicated
by flashing of a red signal lamp on the control cabinet door. When the
error disappears, the signal lamp does not go out. The alarm is also
saved in the PLC message memory.
These three messages are reported to the DCS via permanent

NOTICE wiring!
Auto This indicates that the control is in automatic mode. If no faults

are present the oil pressure is autonomously provided. This is
indicated by operational readiness.
Manual This indicates that the hydraulic unit is not in automatic mode.
That means oil pressure is not provided. At the same time, a
warning is issued to the process control technology. This mode
is used when maintaining the hydraulic power unit.
Furthermore, additional information is displayed in the lower part
NOTICE of the Status section!
Flushing mode active This message signals the pipeline flushing operation and can be
selected while commissioning the unit in the administration
section.
Hydraulic inactive The warning signal is displayed if the hydraulic power unit has
been switched off.
Auxiliary systems like oil heating and oil cooling are not affected!
NOTICE They need to be switched off separately!
Processing fault / Both of these messages group the errors into mechanical and
E-processing failure: electrical errors. Please refer to chapter 5 for a list of faults.5
Depending on the requirements, these messages are issued via
a relay at zero potential to the DCS.
4.1.3 Command section (3)

You can reach the various functional and display areas in the
control through this section.
Hyd. On This button switches the hydraulic control "On" and "Off".
Auxiliary systems like oil heating and oil cooling are not
NOTICE affected! They need to be switched off separately!
Setup You can reach the setup section with this button.
Graph Temp This button displays a two-hour trend of the hydraulic
temperatures.
Graph Hyd This button displays a two-hour trend of the hydraulic
temperatures.
Messages This button retrieves message list of the control in which the
warning and alarm messages are displayed in detail. The fault
messages can be acknowledged with the OK button as soon as

a fault is no longer pending.
ACK/ Lighting test This button resets the control error memory and lights up all
connected signal lamps for testing purposes. When this button is
pressed, both pumps can start-up in automatic mode to ensure
that the hydraulic power unit is immediately ready for service
after an error.
After reaching P5, operational readiness is indicated!
NOTICE
4.2 Setup
The setup section separated into a user section and an
administration section. The performance of the control can be
changed in these sections.
4.2.1 Feed-in 400 V / pump control
4.2.1.1 Feed-in 400 V
The desktop changes its appearance depending on the

hydraulic power unit equipment.
Monitoring feed-in A Monitoring feed-in A+B Monitoring with feed-in switching
The errors and the selected feed-in are displayed in the upper
section.
In the middle section, the delay time for switchback after return
of the voltage is defined. By touching the time value a screen

keyboard appears. The corresponding value has to be typed in.
The preferred supply can be preselected via the "select power
source" button.
4.2.1.2 Pump control
Automatic mode Manual mode
Use the upper button to change between the manual and

automatic pump mode.
The pumps and the circulation valve can be tested in the manual
mode.
Hydraulic Auto / Manual This button changes between manual and automatic mode
Circulation valve test The circulation valve is activated as long as the button is
pressed.
Hyd On Switch the hydraulics on and off with this button. This switch
corresponds to the start-up screen.
Test pump 1/2 Jog mode for the hydraulic pumps. The selected pump switches
on as long as one of these buttons is being pressed!
Pump 1/2 On/Off This button switches the hydraulic pumps on and off:
4.3 Pressure, temperature and level switch points

In this screen you can set the fluid-level switch points and the
temperature switch points.
Touch the numerical value to open a screen keyboard to enter the

values.
4.3.1 Pressure switch points

P1 = Alarm The pump control goes into fault mode
P2 = Warning A message is send to the DCS
P3 = Start 2nd pump The unit supplies 200% oil pressure
P4 = Start pump A pump is started to increase the pressure again
P5 = Stop pump All started pumps switch off
During normal operation, the pumps are started alternating!
NOTICE
4.3.2 Temperature switch points
T1 = oil temp. H Value for oil temperature "high". Starting from this value, a
warning is output to the DCS. This value is factory-set to 55 °C.
T2 = oil temp. HH Value for oil temperature alarm. The pump control goes into fault
starting from this value. This value is factory-set to 70 °C.
Optional:
T3 = oil cooler Set temperature at which the oil cooler turns on.
The cooling switches off 5 K above the set value!
NOTICE
T4 = oil heating Set temperature at which the oil heating turns on.
A second power stage is connected 5 K below the set value.
NOTICE
The heating switches off again 5 K below the set value!
NOTICE
4.3.3 Level switch points
If the hydraulic power unit has an analogue oil level
measurement, this button can be used to show the Level switch
points with the following screen.
This button is only available with analogue level

NOTICE measurement!
Oil level - Warning Value for oil level low. A warning message is sent to the DCS
when this value is reached.
Oil level - Alarm Value for oil level too low. By reaching this value the pump
control switches to fault!
The level value for the warning must not lie below the alarm
NOTICE value!
4.4 System setting / Operating hours

In this screen the system settings can be set. Here also the
operating hours are shown.
4.4.1 System setting

Button language Use this button to switch between German and English.
Button contrast Use this button to change the display contrast.
Calibr. Display Starts the calibration function of the touch panel.
Display cleaning Locks the touch panel against accidental operation during a
screen cleaning.
4.4.2 Operating hours

In this part of the display, the operating hours are shown. The
runtimes for each pump and those of the unit are counted when
one or both pumps are running.
The Hydraulic operating hours serves as the criterion for
changing the hydraulic oil.
The operating hours pump 1/2 should be about the same.
NOTICE
Check the pumps, if a too large difference is found here!
NOTICE
4.5 Administration section

The software for the control is mostly a standard program. To be
able to customize the software to the hydraulic power unit without
changing the software, the program has option switches.
Furthermore, in this section there is also a facility to adapt the
connected sensors.
1. In the system settings / operating hours screen, press the

"Next" button
2. You will then be requested to enter the user name and
password.
User name Password

admin 100
By touching the text boxes a screen keyboard will be shown!

NOTICE
3. After entering, press the "OK" button
4. Then press the "Next" button again
5. The following page appears
4.5.1 Monitoring times / settings / monitoring

4.5.1.1 Monitoring times
Filter delay This value states how long the filter warning signal must queue
before a filter warning is issued.
The filter warning is always suppressed if one of the two
NOTICE pumps is running!
Initial start to P1 This time determines how much time is allowed to pass during
the initial start before the hydraulics start to generate pressure.

If this time is exceeded, the hydraulic goes into fault mode!
NOTICE
Initial start to P5 This time determines how much time is allowed to pass during
the initial start before the hydraulic has generated full pressure.
If this time is exceeded, the hydraulic goes into fault mode!
NOTICE
Runtime warning During normal pump operation, the pumps are subject to
constant runtime monitoring
If this time is exceeded, the second pump is started and a
NOTICE warning message is issued!
Runtime alarm If this value is exceeded, the unit goes into fault mode and
an alarm is issued!
NOTICE
4.5.1.2 Settings
Heating yes / no This option switch defines if an oil heater is installed.

Cooling yes / no This option switch defines if an oil cooler is installed.
Level binary / analogue This option switch defines if a level sensor or a level switch is
installed!
Temp. PT100 / external This option switch defines whether the oil temperature sensor in
an S7-313C control is read via the internal PT100 input or
through a 4-20 mA input.
If a different control is installed, this option switch must be
NOTICE set to "external"!
Sensors normal / redundant This option switch enables the control redundant mode. The
type of redundancy can be defined in the following screens.
If a measurement is executed redundant, this mode must be
NOTICE selected in the program.
View "normal“: View "redundant“

These views can differ depending on the selected options!

NOTICE
Button flushing On/Off While commissioning a hydraulic power unit, all pipelines must
be purged with hydraulic oil.
When this mode is enabled, all hydraulic monitoring except
the monitoring of P4 and P5, temperature and level are
switched off and both pumps are started.
The P1, P2 and P3 pressure switch points and all
monitoring times are terminated!
This mode is shown in the start screen!
NOTICE
4.5.1.3 Monitoring
P1-Off On/Off In some cases, it can be desirable to switch off the monitoring of
the P1 pressure action point.
If this option is selected, there is no longer any error
NOTICE analysis!
24 VDC On/Off: Monitoring of the 24 VDC control voltage, path A and B
230 VAC/DC On/Off Monitoring of the 230 VAC/DC supply voltage for the control
voltage, paths A and B
If the supply feeds and the control voltages are only
NOTICE designed singly, monitoring is omitted because an error
would mean the loss of the control, making monitoring
meaningless!
400 VAC-A/B On/Off Monitoring of the 400 V supply for the motors, path A and B
If both 400 V monitors are activated, it is also possible to
NOTICE enable feed-in switching. The option switch appears with
the activation of both monitors!
Special application
P-Save On/Off: If a second secure pressure line is installed, the block valve of
one of the bladder-typed accumulators is controlled through this
monitoring.
Normally, this function is not used!
NOTICE
4.5.2 Analogue inputs

This screen is used to configure the analogue sensors and,
depending on the options selected in the previous screen, has a
different appearance.
Upper measurement range Reading at 20 mA
Lower measurement range Reading at 4 mA
Permitted deviation Enter the permitted error deviation in the redundant mode. All
redundant measurements are then checked for this error. If the
various measurements lie too far apart from each other, an error
message is issued. The control automatically attempts to isolate
the error. If only one of the 3 valid measurements deviates, this
measurement is detected as incorrect and is excluded from
logging!
Actual values 1-3 Displays the single measurements
Switch O/I Switches the measurement to the redundancy evaluation on or

off.
If the measurement is connected, it is error controlled!
NOTICE
Mean value Transfer value to the control.
4.5.3 Binary level

If the options binary level switch and redundancy are selected,
the following screen can be selected. This screen allows
selecting the redundancy mode and indicates the status of the
level switch for maintenance purposes.
Mode Select the redundancy mode.

5. Messages
The messages are displayed in the message screen.
In addition to the messages, group alarms are also created,

NOTICE displayed and issued to the DCS!
5.1 Warning messages touch panel

Byte address Bit Message
DB1.DBW44 1 Warning - filter clogged
DB1.DBW44 2 Warning - breaker tripping
DB1.DBW44 3 Warning - Pump 1 failed
DB1.DBW44 5 Warning - Oil pressure Min
DB1.DBW44 7 Warning - Oil temperature Max
DB1.DBW44 9 Warning - Oil level Min
DB1.DBW44 11 Warning - Pumps runtime
DB1.DBW44 13 Warning - Manual
DB1.DBW44 14 Warning - Hydraulics off
DB1.DBW46 2 Warning - 400 VAC feed-in A failed
DB1.DBW46 3 Warning - 400 VAC feed-in B failed
DB1.DBW46 4 Warning - 24 VDC feed-in A failed
DB1.DBW46 5 Warning - 24 VDC feed-in B failed
DB1.DBW46 10 Warning - Oil heating defective
DB1.DBW46 11 Warning - Oil cooling defective
DB1.DBW46 12 Warning - 230 VAC/DC feed-in A failed
DB1.DBW46 13 Warning - 230 VAC/DC feed-in B failed
DB1.DBW194 3 Warning - Pressure sensor 1 defective
DB1.DBW194 6 Warning - Impermissible deviation of the pressure measurements
DB1.DBW194 11 Warning - Temperature sensor 1 defective
DB1.DBW194 14 Warning - Impermissible deviation of the temperature measurements
DB1.DBW196 3 Warning - Level sensor 1 defective
DB1.DBW196 6 Warning - Impermissible deviation of the level measurements

5.2 Alarm messages touch panel

DB1.DBW44 0 Alarm - Initial start runtime to P1 too long
DB1.DBW44 6 Alarm - Oil pressure MinMin
DB1.DBW44 8 Alarm - Oil temperature MaxMax
DB1.DBW44 10 Alarm - Oil level MinMin
DB1.DBW44 12 Alarm - Pumps runtime
DB1.DBW44 15 Alarm - Initial start too long
DB1.DBW46 0 Alarm - Both pumps failed
DB1.DBW46 1 Alarm - Critical power failure
DB1.DBW46 9 Alarm - Critical failure of the temperature sensors
DB1.DBW194 7 Alarm - Critical failure of the pressure sensors
DB1.DBW196 7 Alarm - Critical failure of the level sensors
5.3 Group message, processing fault


DB1.DBW44 1 Warning - filter clogged
DB1.DBW44 6 Alarm - Oil pressure MinMin
DB1.DBW44 5 Warning - Oil pressure Min
DB1.DBW44 7 Warning - Oil temperature Max
DB1.DBW44 8 Alarm - Oil temperature MaxMax
DB1.DBW44 9 Warning - Oil level Min
DB1.DBW44 10 Alarm - Oil level MinMin
DB1.DBW44 11 Warning - Pumps runtime
DB1.DBW44 12 Alarm - Pumps runtime
DB1.DBW44 15 Alarm - Initial start too long
DB1.DBW46 0 Alarm - Both pumps failed
5.4 Group message, E-process control equipment fault

DB1.DBW44 2 Warning - breaker tripping
DB1.DBW44 13 Warning - Manual
DB1.DBW44 14 Warning - Hydraulics off
DB1.DBW46 1 Alarm - Critical power failure
DB1.DBW46 2 Warning - 400 VAC feed-in A failed


DB1.DBW46 3 Warning - 400 VAC feed-in B failed
DB1.DBW46 4 Warning - 24 VDC feed-in A failed
DB1.DBW46 5 Warning - 24 VDC feed-in B failed
DB1.DBW46 9 Alarm - Critical failure of the temperature sensors
DB1.DBW46 10 Warning - Oil heating defective
DB1.DBW46 11 Warning - Oil cooling defective
DB1.DBW46 12 Warning - 230 VAC/DC feed-in A failed
DB1.DBW46 13 Warning - 230 VAC/DC feed-in B failed
DB1.DBW194 6 Warning - Impermissible deviation of the pressure measurements
DB1.DBW194 7 Alarm - Critical failure of the pressure sensors
DB1.DBW194 14 Warning - Impermissible deviation of the temperature measurements
DB1.DBW196 6 Warning - Impermissible deviation of the level measurements
DB1.DBW196 7 Alarm - Critical failure of the level sensors
5.5 Receiving module DB20 of the DCS via Profibus

Byte address Message
DB20.DBW 0 Live counter
DB20.DBX 2.0 IN - Hydraulic ON (Impulse)
DB20.DBX 2.1 IN - Hydraulic OFF (Impulse)
DB20.DBX 2.2 IN - AKN (Impulse)
DB20.DBX 2.3 IN - oil cooling ON (Impulse)
DB20.DBX 2.4 IN - oil cooling OFF (Impulse)
DB20.DBX 2.5 IN - oil heating ON (Impulse)
DB20.DBX 2.6 IN - oil heating OFF(Impulse)
5.6 Transmitter block DB30 to the DCS via Profibus

DB30.DBW 0 Live counter

DB20.DBX 2.0 OUT - Message hydraulic Auto
DB20.DBX 2.1 OUT - Message hydraulic Ready
DB20.DBX 2.2 OUT - Message warning
DB20.DBX 2.3 OUT - Message alarm
DB20.DBX 2.4 OUT - Message pump 1 in service
DB20.DBX 2.5 OUT - Message pump 2 in service
DB20.DBX 2.6 OUT - Message circulation valve in service
DB50.DBX 2.7 OUT - Message oil cooler in service
DB50.DBX 3.0 OUT - Message oil heating in service
DB50.DBX 3.1 OUT - Message time initial start to P1 too long
DB50.DBX 3.2 OUT - Message filter warning
DB50.DBX 3.3 OUT - Breaker tripping
DB50.DBX 3.4 OUT - Failure pump 1
DB50.DBX 3.5 OUT - Failure pump 2
DB50.DBX 3.6 OUT - Message oil pressure low
DB50.DBX 3.7 OUT - Message oil pressure low
DB50.DBX 4.0 OUT - Message oil temp. High
DB50.DBX 4.1 OUT - Message oil temp. too high
DB50.DBX 4.2 OUT - message oil level low
DB50.DBX 4.3 OUT - Message oil pressure too low
DB50.DBX 4.4 OUT - Message warning runtime
DB50.DBX 4.5 OUT - Message alarm runtime
DB50.DBX 4.6 OUT - Message hydraulic in manual
DB50.DBX 4.7 OUT - Message hydraulic Off
DB50.DBX 5.0 OUT - Message time initial start too long
DB50.DBX 5.1 OUT - Message power failure 400 VAC feed-in A
DB50.DBX 5.2 OUT - Message power failure 400 VAC feed-in B
DB50.DBX 5.3 OUT - Message power failure 24 VDC feed-in A
DB50.DBX 5.4 OUT - Message power failure 24 VDC feed-in B
DB50.DBX 5.5 OUT - Failure heating
DB50.DBX 5.6 OUT - Message failure cooling
DB50.DBX 5.7 OUT - Message power failure 230 VAC feed-in A
DB50.DBX 6.0 OUT - Message power failure 230 VAC feed-in B
DB50.DBX 6.1 OUT - Message oil drip tray full
DB50.DBX 6.2 OUT - Failure pressure sensor
DB50.DBX 6.3 OUT - Failure temperature sensor
DB50.DBX 6.4 OUT - Failure level sensor


DB50.DBD 8 OUT - Pressure (analogue)
DB50.DBD 12 OUT - Temperature (analogue)
DB50.DBD 16 OUT - Level (analogue)
DB50.DBD 20 OUT - Hour meter (analogue)

IMI Bopp & Reuther
Bopp & Reuther Sicherheits-
und Regelarmaturen GmbH
Carl-Reuther-Straße 1
68305 Mannheim
Deutschland
Tel: +49 (0)621 76220-100
Fax: +49 (0)621 76220-120
www.imi-critical.com
imibur.sales@imi-critical.com
IMI Critical Engineering

Lakeside, Solihull Parkway
Birmingham Business Park
Birmingham B37 7XZ
United Kingdom
Tel: +44 (0)121 717 3700
Fax: +44 (0)121 717 3701
www.imi-critical.com

00 B&R HydSt HCS-Si BED EN 01

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Hydraulic control system HCS

2. General instruction ..................................................................................................................................... 8

4. Program description ................................................................................................................................. 14

4.2 Setup ........................................................................................................................................................ 16

1.2 Responsibilities of the operator

1.3 Proper use

1.4 Improper use

1.5 Obvious improper use

1.6 Person-related information

technical knowledge and experience. They must be capable of

1.6.2 Target group

1.7 Required personal protective equipment

1.8 Safety instructions

Consequence: serious or even fatal injury

Consequence: minor injury, major property damage

Consequence: minor property damage

Note pertaining to special conditions

Consequence: damaging situation

General information for the operator

1.9 Product-specific hazards or product safety

Dispose of hazardous materials without endangering humans and

Additional mechanical load will cause malfunctions or

Inspect the individual components and piping systems to ensure

Inspect the control for shipping damage before installation!

Protect control installed outdoor against the effects of weather!

Effectively cover the control when working on them!

This technical documentation does not replace national accident

which are to have priority in all instances!

Always keep the technical documentation available at the

Refer to the type plate for the information required for

Unauthorized modifications and the use of non-original spare

1.10 Storing documentation

The manufacturer of partly completed machinery or his

2.1.1 Colour marking

2.2 Spare and wear parts

Transport the control horizontally.

2.3.1 Loading and transporting further

 To facilitate handling of the product

2.3.2 Lifting equipment

This equipment is to be designed according to generally

Only permissible hoisting equipment must be used for lifting!

While lifting and loading the control units, reverse movements

This also applies to spare and wear parts.

2.4.2 Short-term storage

2.4.3 Long-term storage and preservation

Cover openings to protect housings against foreign particles!

2.4.4 Storage conditions for rubber products

there is no adverse change in the appearance and function of

2.5 Waste disposal

 Personal protective equipment

3.2 Electrical switchgears

3.4 Additional characteristics

3.5 Optional functions

4.1 Start-up screen

4.1.1 Quick information section (1)

4.1.2 Status section (2)

These three messages are reported to the DCS via permanent

Auto This indicates that the control is in automatic mode. If no faults

4.1.3 Command section (3)

messages can be acknowledged with the OK button as soon as

4.2.1 Feed-in 400 V / pump control

4.2.1.1 Feed-in 400 V

The desktop changes its appearance depending on the