Decanter 2Touch Commissioning Guide

61211297

Version: 5
Decanter 2Touch Comissioning Guide
61211297

Revision 5 released on Jan 20, 2010. Updates are as follows:

- revised communication cables requirements,
- added log in sequence description.

Revision 4 released on Dec 8, 2009. Updates are as follows:

- PVI transfer tool software reference was removed from special tools list,
- added reference to Remote Stop 1222 NC contact wiring to the wiring check list,
- added note about REPL-01 adapters use with ACS550 drives,
- added paragraph about 2Touch components inspection,
- added pictures illustrating EPL node address settings on REPL-01 adapters and IO modules

Revision 3 released on Oct 23, 2009

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WARNING
To avoid communication problems the following rules
are to be observed:

- The cables used for Ethernet and Ethernet PowerLink networks are to be
S/FTP type (foil-shielded twisted pairs surrounded by an overall braided
shield) with shielded RJ45 jacks on both ends. Cable external diameter is
4.5 - 8 mm. The diameter of the core insulation must not exceed 1.6 mm.

- Both attached to the HMI cover grounding wires are to be connected.

The 4 mm2 wire connects to the screw on HMI chassis and the 2.5 mm2
wire – to the HMI panel 24VDC power plug terminal.

- Use the screened cable with twisted wires to bring 24VDC power to the
HMI.

- Network cables parallel runs with power cables are not allowed.

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Contents

WARNING ............................................................................................................................... 3
Contents .................................................................................................................................. 4
Preface .................................................................................................................................... 5
Prior to Commissioning ............................................................................................................ 5
Inspect the 2Touch components .............................................................................................. 5
Check the Power Wiring .......................................................................................................... 5
Check the Ethernet Network Wiring and IP Address Settings.................................................. 6
Check the Ethernet Powerlink Network Wiring and Node Address Settings ............................ 7
Check versions of software loaded into Controller, firmware and software in the HMI ............ 8
Check Status LEDs on Controller, Remote IO Islands, Other Modules ................................... 8
Conduct 2Touch Parameters Setup ......................................................................................... 9
Log in into 2Touch ................................................................................................................... 9
Initialize 2Touch Parameters ................................................................................................... 9
Enable Optional Remote IO Islands ....................................................................................... 10
Set up MD and BD VFD for EPL Communication .................................................................. 10
Conduct MD and BD VFD Motor ID Runs ............................................................................. 10
Conduct Units Setup ............................................................................................................. 10
Install Mechanical Filters Between Bearing Housing and Vibration Sensor ........................... 11
Acknowledge Active Alarms................................................................................................... 11
Test Run Decanter in LSFlush mode ..................................................................................... 11
Set up Decanter Full Speed Flush and Rundown Flush modes............................................. 11
Decanter First Start ................................................................................................................ 11
Check on Feed System Ready signal from the customer ...................................................... 12
Special Startup ...................................................................................................................... 12
Commission Adaptive Torque Control ................................................................................... 12
Set up Maintenance Timers ................................................................................................... 12
Set up Decanter Automatic Transitions ................................................................................. 12
Test and Demonstrate Decanter 2Touch Alarms ................................................................... 13
Insert and Check Operation of the HMI External CF Card ..................................................... 13
Backup Parameters to USB Memory Stick ............................................................................ 13
Conduct Training for Customer’s Operation Personnel ........................................................ 13
Provide Your Feedback to CAT ............................................................................................. 13
2Touch Manuals List .............................................................................................................. 14

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Preface

Use this manual when you commission a new decanter with 2Touch.
For old machines controls upgrade to 2Touch see the manual 61211287, that contains more details on parts
order, sensors installation and other upgrade related issues.

Prior to Commissioning

Find out who has built the VFD panel and try to obtain the copy of electrical drawings.

Contact the customer or contractor involved in machine installation to make sure:

- they have sufficient information on how the HMI installation and wiring are to be done, including
mounting options on the wall or on the floor stand and hardware required,
- they know that type of communication cables and type of RJ45 connectors to be used,
- they know how to wire the decanter feed permission and pump running status feedback,
- they know how to wire the decanter flush valve,
- they know how to wire the decanter additive permission and pump running status feedback,
- they know how to wire the decanter feed interlock (if required),
- the installation and wiring will be complete prior to Alfa Laval service engineer arrival on site for
commissioning.

Contact CAT to find out:

- what are the current Controller and HMI application software versions to be used,
- if and how many mechanical filters for vibration sensors are needed,
- for any other important news and updates.

Prepare 2Touch special tools:

- RJ45 connectors. We recommend Phoenix Contact order #1656725. A crimping tool may also be
required if different type connectors are going to be used,
- Torx 10 screwdriver (for HMI cover assembly),
- CF card reader,
- USB memory stick.

Get the latest 2Touch manuals that are available in Sally. Have the manuals printed. You can use it during
startup and leave with the customer after commissioning is complete.

Inspect the 2Touch components

- Inside the Controller panel check if the CPU is of the correct type CP1484, make sure the CF card and
the battery are inserted, check controller IO cards for correct nomenclature and assembly order,
- Inside the VFD panel check if all Standard Remote IO module cards are of correct type and are fit in
correct places,
- Check if all optional IO modules ordered by the customer are present, fit with correct type cards that are
placed in correct order

Check the Power Wiring

- Incoming power wiring to the VFD panel,

- MD motor and motor thermistors wiring,
- BD motor and motor thermistors wiring,
- 24VDC to the Controller panel,

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- 24VDC to the HMI panel, ground wire link from the HMI power connector to the grounding screw on the
back of the HMI,
- Flush water valves control wiring,
- Feed permissive and feed pump running status feedback,
- Additive permissive and poly pump running status feedback,
- Feed System Ready 1114 customer feed interlock (or jumper),
- Remote Stop 1222 NC contact wiring (or jumper)

Check the Ethernet Network Wiring and IP Address Settings

Ethernet network cables are connected to the Ethernet switch located in the Controller panel. Internal
connections inside the Controller panel have been already made. During installation the contractor installs the
network cables between the connector X21 on the bottom of the controller panel and the 2Touch HMI.

The Decanter 2Touch Controls Ethernet network uses SFTP type line cables. RJ45 connectors pinout is shown
below.

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To be checked:
- Contractor’s installed network cables have correct shield connections at both ends,
- There is no strain on the cables,
- The RJ45 plugs did not get loose during transportation,
- The x1 rotating switch on the Controller just to the left from the ETH plug is set to 1 and the x16 rotating
switch right above it is set to 0.
- The left rotating switch on SVU (Speed and Vibration unit) is pointing at 0, the right one – to F,
- The network cables are fit correctly through the cable glands, are not on the way of people or other
machinery.
- The 2Touch HMI IP address is shown in the screen bottom left corner when it’s boots up. For
procedures of changing HMI IP address consult the manual 61211285.

Check the Ethernet Powerlink Network Wiring and Node Address Settings

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The Decanter 2Touch Controls Ethernet PowerLink network uses SFTP type crossover cables. RJ45
connectors pinout is shown below.

One end of the Ethernet PowerLink (EPL) network cable is plugged into connector X23 on the bottom of the
Controller panel, the other end - into Standard Remote IO inside the VFD panel. All optional Remote IO
modules are chain linked as shown.

MD and BD VFD require REPL-01 adapters to connect to the network. Adapters are
supported with ACS800 standard software version ASXR7350 onwards. All ACS800
converters produced after 3rd of March 2009 are delivered with correct software version.
REPL-01 adapters are also supported with ACS550 standard software
version v3.13d onwards. All ACS550 converters produced after 30th of June 2009 are
delivered with correct software version.

REPL-01 adapters have dip switches that are used to set the EPL node address. Dip
switch settings are 32 for BD VFD and 33 for MD VFD as shown on 2Touch drawings.

Node address settings for Standard and Optional remote IO modules are set with the
rotating switches on the BC0083 or BC8083 Bus Controller modules. The top switch
marked x16 has to be left always in position 0. The switch underneath marked x1 has
to be set as follows: 1 - Standard Remote I/O island, 2 - Option HW VFD Remote I/O
island, 3 - Option CIP Remote I/O island, 4 - Option HW REMOTE Remote I/O island, 5
- Option PROCESS Remote I/O island, 7 - Option OCTOPUS Remote I/O island, 8 -
Option POWER MONITOR Remote I/O island.

Check versions of software loaded into Controller, firmware and software in the HMI

Screen 5.2: Check what software versions are currently loaded into Controller and HMI.

HMI firmware version is displayed in the screen left bottom corner (e.g. as “built 321”) when the HMI starts up.

Check Status LEDs on Controller, Remote IO Islands, Other Modules

Light Emitting Diodes (LED’s) provide valuable information on system components operating status.

Observe the LEDs near the Ethernet or EPL plugs – steady frequent flushing of green light is confirming that the
communication goes well.

Green and yellow steady lights on the modules that are part of the main controller and Remote IO islands are
generally a good sign. Red flashing lights on PS2100 modules right after the system has been powered up
indicate that the 24VDC from the Safety Relay output circuit is not present – the Safety Relay has to be reset.

For more details on modules troubleshooting using the status LEDs refer to the manual 61211280 Appendix.

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Conduct 2Touch Parameters Setup

To prepare for 2Touch parameters setting up you need to collect the following data:
- Decanter type, serial number, max bowl speed and bowl diameter as stamped on the nameplate,
- GB size, type and ratio are stamped right on the gearbox,
- Torque arm length has to be measured,
- Decanter and MD motor pulleys are to be measured,
- Remove the MD motor terminal box cover and note the type of connection made. Record the motor
nameplate data corresponding to connection type, voltage and frequency levels.

When several identical decanters are commissioned, there is no need to enter all parameters for all machines
manually. When the first decanter setup is complete, you can insert your USB memory stick into HMI slot and
execute parameters Backup, then transfer the memory stick to each other machine and execute parameters
Restore.

When setting up the 2Touch parameters and Alarm setpoints use the manual 61211290.

Log in into 2Touch

Access to 2Touch configuration parameters is restricted. For access the username and the password need to
be entered. Log in done in a following way:
- Touch located in the screen right top corner little button with the arrow pointing down in order to make
log in tab appear,
- Touch the username entry field to call the popup keyboard window,
- Key in the username (e.g. “alse” for Alfa Laval service engineer),
- Hit Enter button to move the cursor to the password entry field,
- Key in the password (e.g. “d2-th” for Alfa Laval service engineer),
- Hit Enter button for 2Touch to accept the entry,
- Hit Login button to log in,
- If log in was successful, you will observe the log in tab hiding and entered username appear nearby
login icon.

Alfa Laval service engineer username and the password are intended for service engineers use.
Customer is expected to use the following usernames and passwords:
For basic operators: username “operator”, password “1113”.
For advanced operators and foremans: username “advoper”, password “2412”.
For technical personnel responsible and administration: username “operator”, password “.2-3”.

Initialize 2Touch Parameters

To facilitate 2Touch parameters setting up, there are several options available to initialize groups of parameters
with one simple action.

Screen 7.5: Using virtual buttons on the you can set all parameters to default at once, initialize related
to the GearBox parameters just by selecting the gearbox size, or initialize lubrication system related
parameters depending on the lube system type selected.

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Enable Optional Remote IO Islands

Screen 8.1: In order to use the Optional Remote IO Islands need to be enabled. It is done with the
parameters P112-P119. Power reset is required to be done for the controller and HMI on order to accept
a new EPL network configuration.
Screen 5.1: clearly indicates enabled optional modules with dark colour.

Set up MD and BD VFD for EPL Communication

In order to enable VFD communication on the EPL network both MB and BD VFD parameters need to be set:

ACS800
COMM PROFILE 98.07 = ABB DRIVES
COMM. MODULE LINK 98.02 = FIELDBUS
TRANSPARENT MODE 51.02 = 1
FBA PAR REFRESH 51.27 = REFRESH

Please remember that every time parameters initialization is requested, all VFD parameters are reset to default
values and therefore will require to have the above parameters set again.

Conduct MD and BD VFD Motor ID Runs

In order to operate the MD and BD motors, both VFD will require motor ID runs to be conducted.
Motor ID runs are done initially and have to be repeated every time after the motor related parameters have
been changed.

With the MD and BD VFDs on the EPL network the types of motors identification runs are set with the
parameters that 2Touch transfers to the VFDs. If the MD and BD VFDs are connected to 2Touch using the
Option HW VFD – the types of motor ID runs are set manually.
In case of MD motor it is Magnetising. No drive belts removal is needed. The motor model is calculated at first
start by magnetising the motor for 20 to 60 seconds at zero speed.
The BD motor required the Standard ID run to guarantee the best possible control accuracy. Lift decanter cover
and open the coupling that connects the BD motor and the GB pinion shafts. During ID run the motor will run at
50 to 80% of it’s nominal speed. Make sure the rotation direction is correct as it has to run Forward. Assemble
the coupling when the ID run is complete.

Links to the Motor ID runs are found on the HMI screens 8.5 and 9.1. Pushing dark blue Motor
Identification Start button will call another popup screen asking to confirm the action. Clock symbol
appears on the screen during the run. Another message will tell when it’s complete.
Note that Motor ID run will not start if there are any active alarms on the VFD,

Once the Motor ID run is complete and accepted, the Motor Identification Start button will turn grey. Now you
can visit the Active Alarms page and acknowledge the ID Run related alarms.

Conduct Units Setup

Screen 7.4: Depending on the country the units displayed on the HMI screens may need to be converted
to those that are more convenient for use. Units can be selected for Time, Flow, Torque, Temperature,
Distance, Mass and Vibration.

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Install Mechanical Filters Between Bearing Housing and Vibration Sensor

It has been noticed that the accuracy of measurement by acceleration type vibration sensors can be affected by
high frequency vibrations. In order to eliminate that effect, mechanical filers are installed between the bearing
housing and the acceleration sensors. Smaller diameter decanter centrifuges require only one mechanical filter
installed under the MD end bearing sensor. Large machines need two mechanical filters under each of the
vibration sensors to be installed.

Acknowledge Active Alarms

Note, investigate and acknowledge any outstanding alarms that appear during machine commissioning. Alarms
provide valuable information about possible installation or wiring mistakes, incorrectly set parameters, losses of
communication between various system components.

For alarms description and settings refer to the manual 61211290.

Test Run Decanter in LSFlush mode

Decanter Back Drive operation can be checked when machine is started in Low Speed (LS) Flush mode.

Parameters to be set for the LS Flush mode:

P206 Max Rev Bowl Speed,
P501 Low Flush Bowl RPM,
P505 Low Flush Time Rev,
P506 Low Flush Time Fwd,
P507 Low Flush Cycles.

Set up Decanter Full Speed Flush and Rundown Flush modes

Depending on type of produst run through decanter, different time and differential speed settings may be
required for different applications. To set up Full Speed Flush and Rundown Flush modes use the following
parameeters:
P502 Full Speed Flush Time,
P503 Rundown Flush Time,
S301 Flushing Diff.

Decanter First Start

To confirm the ratio between the bowl pulley (P204) and the MD motor pulley (P203), you can start decanter
with the Bowl RPM Reference (P207) set to reduced number, e.g. 1000 RPM and watch if the measured bowl
speed value will be significantly different from the set reference.
The ratio (P203) has to be increased if measured bowl speed value is higher then the reference set by P207
and decreased if it is lower.

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Check on Feed System Ready signal from the customer

Customer is given an option to use a hardwired input to 2Touch in order to prevent feed pump from automatic
start on some plant specific conditions, e.g. sludge tank empty, or polymer tank empty, or cake bin full, or
conveyor system stopped, etc. If customer doesn’t want to use that option, a jumper is required to be installed to
set the DI 1114 (input #7 on card 11) of Standard Remote IO True. On SMG built panels the jumper is installed
between terminals X5:76 and X5:77

Otherwise if the above jumper is not in place the 2Touch will nor be able to issue the Feed Permission signal,
Needed to start the feed pump.

Note: Once the Feed Permission has been issued, the 2Touch system is waiting for the Feed Pump Running
feedback to set the DI 1121 True, or algorithm will prevent decanter from going into Production mode and it will
remain in Standby.

Special Startup

A special startup function is enabled with the parameter P111. Diff speed setpoint at Filling is set with the
parameter S303. Mode ends when actual torque value reaches the value set in P701 Stop Divert Torque.

Commission Adaptive Torque Control

An adaptive Torque control function is enabled with the parameter P379. It starts after certain delay set by the
parameter P376 Core Start Delay and in course of adaptation analyzes the effect of the torque control and
automatically changes the control parameters P362, P363, P364. The parameters are calculated by analyzing
Dn (differential speed) and T (conveyor torque) over a period of time.

Adaptive Torque Control is advised backdrive torque control algorythm. It is able to start with standard control
parameters and then, in the first hours of operation, calculates the best control parameters.

Set up Maintenance Timers

Screen 7.3 is used for setting up maintenance timers.

Recommended maintenance intervals can be found in the Decanter Operator Manual.

Set up Decanter Automatic Transitions

A number of 2Touch decanter operationg modes can be automated to reduce need for operator´s intervension:

Parameters P122 Production Mode and P110 Production Stop Condition set the automatic termination of
Production mode and decanter shutdown after duration of production time has expired

Parameter P106 Feed Wait Time limits amount of time machine stays in Offline mode before it shuts down
automatically.

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Automatic transition to Production mode after decanter has been started is made possible with the parameter
P812 Auto Feed Request.

The LSFlush starts automatically after machine shutdown is complete when enabled with the parameter P508
Low Flush Auto Start.

Test and Demonstrate Decanter 2Touch Alarms

It’s very important to test the most important decanter alarms and safety interlocks. Quite often a demonstration
of system alarms and 2Touch response has to be made for the customer.

Screen groups 10 and 11 contain alarm set/reset setpoints and delay timer values essential for
alarms testing. For alarms description and settings refer to the manual 61211290.

Insert and Check Operation of the HMI External CF Card

Insert external HMI CF card into HMI slot. Test and demonstrate the customer access to the manuals and
service movies.

Backup Parameters to USB Memory Stick

Insert the USB memory stick into HMI USB slot. Back up the parameters.

You can also take a screenshots from any 2Touch screens including parameters and alarm setpoints setup
screens using the Print button located on the bottom Control Buttons Bar.

Conduct Training for Customer’s Operation Personnel

Spend time with the customer operators to demonstrate how to operate the machine.
Make sure they get answers to the questions asked.

Provide Your Feedback to CAT

After successful startup completion, please send your notes to 2Touch designers in Core Automation Team
(CAT). We shall appreciate your feedback on noticed problems, important observations, further improvement
suggestions.

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2Touch Manuals List

61211280 Decanter 2Touch Controls Hardware Introduction

61211281 Decanter 2Touch Controls Electrical Drawings
61211282 Decanter 2Touch VFD Panel Recommendations
61211283 Decanter 2Touch Interconnection Diagrams
61211284 Decanter 2Touch Controller Panel Drawings
61211285 Decanter 2Touch HMI Instructions
61211286 Decanter 2Touch HMI Screens Overview
61211287 Decanter Controls Upgrade to 2Touch Guide
61211289 Decanter 2Touch Parameters and Alarms List
61211290 Decanter 2Touch Parameters and Alarms
61211292 Decanter 2Touch VFD Panel Drawings
61211293 Decanter 2Touch Controls FAQ
61211295 Decanter 2Touch Operator Manual
61211296 Decanter 2Touch "How to …" Guides
61211297 Decanter 2Touch Commissioning Guide
61211298 Decanter 2Touch Data Exchange and Signal Mapping

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