COOLER MANUAL 2 (Process)

Local control panel type RK-SFHY-04/SBC-13 0.
01
List of contents 80001695 Ver.:1.0
List of contents
0. Contents
.01 List of contents
.10 List of references
3. System structure and operating procedure

.01 Description
4. Layout
.01 Block diagram 1/9
.20 Layout of local control panel

.21 Parts location, local control panel
.22 Panel front door signs
5. Unit diagrams
6. Parts list
.01 Parts list
.02 Parts list
8. Data communication
.05 CCS data communication
.06 CCS data communication
9. PLC program documentation

.05 I/O addressing arrangements
D:\Fls_edoc\Root\Users\Hape\Convert\80001695_001_1.doc 26.01.05 MSOffice/ MiC / FleJ

Local Control panel type RK-SFHY-04/SBC-13. 0.10
List of references 80001685 Ver.:1.0
List of references
Instructions :
FLS sub supplier instructions: No.: 60013431
Programming software and equipment :
PLC, Siemens
Control Display, Proface
D:\Fls_edoc\Root\Users\Hape\Convert\80001695_001_1.doc 26.01.05 MSOffice/ MiC / FleJ

Settings 2.10
Hydraulic drive system, clinker cooler 80001695 Ver.: 1.0
Control display settings:
Parameters Drive No. 1 Default As built

Reverse stop 25mm
Forward stop 175mm
Forward up ramp 250ms
Forward down ramp 250ms
Reverse up ramp 250ms
Reverse down ramp 250ms
P-setting 0.050
I-setting 0.100 sec
Min output 8%

Reverse stop 25mm
Forward stop 175mm
P-setting 0.050
I-setting 0.100 sec
Min output 8%

Reverse stop 25mm
Forward stop 175mm
P-setting 0.050
I-setting 0.100 sec
Min output 8%

Reverse stop 25mm
Forward stop 175mm
P-setting 0.050
I-setting 0.100 sec
Min output 8%
Parameters for hydraulic pressures Default As built

Pressure alarm 250
11-06-05 ToLo / SvG / FleJ

Settings 2.11
Parameters for Cooling valve Default As built

Open 52°C
Close 50°C
Parameters, Shock Blaster Sequence No.1 Default As

build
Off-set time 6 min
Cycle time 100 min
Step time 10 s
Pulse time 500ms

build
Off-set time 2 min
Cycle time 100 min
Step time 15 s
Pulse time 500ms

build
Off-set time 4 min
Cycle time 100 min
Step time 5s
Pulse time 500ms

build
Off-set time 6 min
Cycle time 100 min
Step time 100 s
Pulse time 500ms

build
Off-set time
Cycle time
Step time
Pulse time

build
Off-set time
Cycle time
Step time
Pulse time

Settings 2.12
Parameters, Shock Blaster Selection Default As

build
SBD1 (-Y81) 11
SBD2 (-Y82) 12
SB1 (-Y83) 21
SB2 (-Y84) 22
SB3 (-Y85) 23
SB4 (-Y86) 24
SB5 (-Y87) 25
SB6 (-Y88) 26
SBH2(L) (-Y90) 31
SBH4(L) (-Y91) 32
SBZ1(L) (-Y92) 0
SBZ2(L) (-Y93) 0
SBH2(R) (-Y94) 41
SBH4(R) (-Y95) 42
SBZ1(R) (-Y96) 0
SBZ2(R) (-Y97) 0

Settings 2.13
Hardware settings:
Pump cards settings

-N10, Main Pump –M01:
Data set name : VT-VSPD-1-1X

User :
Date : 26.1.2005
Comment :
Configuration :
COMMAND VALUE : E6 (b22/24)
:
VALVE TYPE : Userdef. 1
SOLENOIDS : 2 solen.>4 Ohm
ENABLE INPUT : HIGH
SEQUENT. CONTROL : off
RAMP FUNCTION : normal ramp
Settings :
frequency 100.0 Hz
pre current 0.02 A
jump curr. a 0.23 A
jump curr. b 0.23 A
max. current 0.60 A
Normalizations :
ampl. + E6 1.00
offset E6 + 1.0 %
ampl. - E6 1.00
Command call-ups :
0 : com.value 0 + 0.0 %
ramp 0 0.200 s
1 : 2 : 3 : 4 : 5 : 6 : 7 : 8 : 9 : 10 : 11 : 12 : 13 : 14 : 15 :

Settings 2.14
Pump cards settings

-N20, Main Pump –M02:

User :
Date : 28.1.2005
Comment :
Configuration :
:
ENABLE INPUT : HIGH
Settings :
frequency 100.0 Hz
pre current 0.02 A
jump curr. a 0.23 A
jump curr. b 0.23 A
max. current 0.60 A
Normalizations :
ampl. + E6 1.00
offset E6 + 1.5 %
ampl. - E6 1.00
Command call-ups :
0 : com.value 0 + 0.0 %
ramp 0 0.200 s
1 : 2 : 3 : 4 : 5 : 6 : 7 : 8 : 9 : 10 : 11 : 12 : 13 : 14 : 15 :

Settings 2.15
Pump cards settings

-N30, Main Pump -M03:

User :
Date : 28.1.2005
Comment :
Configuration :
:
ENABLE INPUT : HIGH
Settings :
frequency 100.0 Hz
pre current 0.02 A
jump curr. a 0.23 A
jump curr. b 0.23 A
max. current 0.60 A
Normalizations :
ampl. + E6 1.00
offset E6 + 3.5 %
ampl. - E6 1.00
Command call-ups :
0 : com.value 0 + 0.0 %
ramp 0 0.200 s
1 : 2 : 3 : 4 : 5 : 6 : 7 : 8 : 9 : 10 : 11 : 12 : 13 : 14 : 15 :

Settings 2.16
Pump cards settings

-N40, Main Pump -M04:

User :
Date : 31.1.2005
Comment :
Configuration :
:
ENABLE INPUT : HIGH
Settings :
frequency 100.0 Hz
pre current 0.02 A
jump curr. a 0.23 A
jump curr. b 0.23 A
max. current 0.60 A
Normalizations :
ampl. + E6 1.00
offset E6 + 2.6 %
ampl. - E6 1.00
Command call-ups :
0 : com.value 0 + 0.0 %
ramp 0 0.200 s
1 : 2 : 3 : 4 : 5 : 6 : 7 : 8 : 9 : 10 : 11 : 12 : 13 : 14 : 15 :

Settings 2.17
Pump cards settings

-N70, Backup Pump -M07:

User :
Date : 19.1.2005
Comment :
Configuration :
:
ENABLE INPUT : HIGH
Settings :
frequency 100.0 Hz
pre current 0.02 A
jump curr. a 0.23 A
jump curr. b 0.23 A
max. current 0.60 A
Normalizations :
ampl. + E6 1.00
offset E6 + 0.0 %
ampl. - E6 1.00
Command call-ups :
0 : com.value 0 + 0.0 %
ramp 0 0.200 s
1 : 2 : 3 : 4 : 5 : 6 : 7 : 8 : 9 : 10 : 11 : 12 : 13 : 14 : 15 :

Settings 2.18
Pump card replacement procedure:

1) Replace pump card module during power off;
2) Power on;
3) Connect pump card module to a PC with Rexroth/Bodiv user interface;
4) Bodiv-Data set: Load from amplifier;
5) Bodiv-Options: Select language; English – current amplifier;
6) Bodiv-Data set: Load from file (select backup file to be used);
7) Bodiv-Data set: Save to amplifier;
Pump card adjustment procedure:

1) Connect pump card module to a PC with Rexroth/Bodiv user interface;
2) Bodiv-Data set: Load from amplifier;
3) Adjust the “ampl. + E6” to 1.00, “ampl. – E6” to 1.00 and “offset E6” to +1.00 and “press
send to amplifier”;
4) Set the local control panel into “local control mode”;
5) Start the oil conditioning system on the local test screen picture;
6) Start the main pump in question on the panel front push button;
7) Select the local test screen picture for the drive in question;
8) Select the info screen picture and observe the values of position transmitter 1 and 2;
9) Adjust the “offset E6” in positive direction in steps of 0.1% until movement is observed on
the position transmitters. Then decrease until no movement. Make a note of the value (the
offset range min. to max. is usually app. 4%).
10) Adjust the “offset E6” in negative direction in steps of 0.1% until movement is observed on
the position transmitters. Then increase until no movement. Make a note of the value (the
offset range min. to max. is usually app. 4%).
11) Then adjust the “offset E6” to the center value of values noted;
12) Select the local test screen picture for the drive in question and press the start button;
13) On the local test screen picture: Increase the controller OV to 20%;
14) Select the info screen picture for the drive in question and observe the “Pump controller
offset value”;
15) Increase the value of “ampl. + E6” or the “ampl. – E6” (leaving the other value on 1.00) to
reduce the “Pump controller offset value” to be in the range of -50 to +50:
16) Bodiv-Data set: “Save in file” (save a backup file).
17) Stop the pumps, disconnect Bodiv user interface and “remove” local test permission for the
local control panel to select “central control mode”.

Local control panel type HD-SF-4 3.01
System structure and operating procedure 80001695 Ver.: 1.0
CONTENTS
GENERAL.................................................................................................................................. 2
The hydraulic concept............................................................................................................ 2
The control system................................................................................................................. 3
Drives Control........................................................................................................................ 4
OPERATING PROCEDURE..................................................................................................... 5
Cooler drives.......................................................................................................................... 5
Air Blasters ............................................................................................................................ 6
Control display....................................................................................................................... 7
Main menu ........................................................................................................................ 8
Mode of operation ............................................................................................................. 9
Mimic, oil tank ................................................................................................................ 10
Mimic, drives .................................................................................................................. 10
Mimic, Backup pump...................................................................................................... 11
Mimic, air blasters........................................................................................................... 14
Pump selection picture .................................................................................................... 15
Local test, valves............................................................................................................. 16
Local test, heating system ............................................................................................... 17
Local test, drive No. 1 ..................................................................................................... 18
Local test of drive No. 2, 3 & 4...................................................................................... 18
Local test, air blasters...................................................................................................... 19
Local test, flushing .......................................................................................................... 20
ALARM LIST...................................................................................................................... 21
Alarm History.................................................................................................................. 22
Help Screen ..................................................................................................................... 22
Parameters menu.................................................................................................................. 36
Parameters, Drive No. 1 .................................................................................................. 37
Parameters, Drive No. 2 & 3........................................................................................... 37
Parameters, General Control ........................................................................................... 38
Parameters, overriding CCS signals................................................................................ 39
Parameters, position signal selection .............................................................................. 40
Parameters, Air Blaster Sequence 1 & 2 (similar to sequence 3 & 4, 5 & 6) ................. 41
Parameters, Air blasters selection -Y81 to -Y88 (similar to -Y90 to -Y97) ................... 42
CCS digital signals, hydraulic system ................................................................................. 43
CCS digital signals, Air Blasters ......................................................................................... 43
CCS analog signals, Hydraulic System ............................................................................... 44
COMMUNICATION WITH CCS ........................................................................................... 45
Digital signals to CCS:.................................................................................................... 45
Digital Signals from CCS: .............................................................................................. 46
Analog signals to CCS: ................................................................................................... 48
Analog signals from CCS: .............................................................................................. 48
GENERAL SPECIFICATIONS............................................................................................... 80

GENERAL
The purpose of the local control system is to:

- Control the operation of the hydraulic drives;
- Process and display various measuring points;
- Perform test and adjustments during commissioning;
- Alarm abnormal conditions;
- Exchange data with the central control system (CCS).
A full description of the function and maintenance of the hydraulic drive system can be obtained
in a separate instruction for the hydraulic system.
The hydraulic concept

The movement of a drive is controlled by a piston oil pump, which is able to deliver oil flow in
two directions.
Oil flows from port A resulting in forward movement of the drive cylinders or from port B
resulting in reverse movement of the drive cylinders. The oil flow amount and the oil flow
direction are controlled by an electrically controlled proportional servo oil valve.
A shuttle valve is located by the cylinders. The purpose of this valve is to drain a part of the oil
from the main oil circuit to the oil tank, at the beginning of each cylinder movement. Through this
system the oil in the main circuit is replaced little by little by conditioned oil from the oil tank.
A smaller pump is mounted on the same shaft as the main pump. This servo oil pump is used to
supply oil to the pilot system, which by use of the proportional valve controls the oil flow from the
main pump. Furthermore the pump takes care of refilling the main pump circuit with the amount
of oil drained by the shuttle valve.
Principle sketch of a main pump with servo pump, cylinder connections and shuttle valve:

The control system

The aim of the control system is to control the drive movement with a stroke speed according to
the speed set-point from CCS and ensure that the selected stroke length is maintained. The stroke
of the drive is max. 150 mm (from 25 to 175 mm).
To maintain the selected stroke length under varying clinker load four stop limits are defined:
0 RS RAS FAS FS 200
RS Reverse Stop
RAS Reverse Auto Stop
FAS Forward Auto Stop
FS Forward Stop
The stroke length is the distance between RS and FS. The two limits are adjustable for each drive
from a parameter picture on the control display.
RAS and FAS are limits, which are controlled by two PID controllers to initiate stop ramps in time
to reach RS and FS.
When a start command to a drive is given, the pump will start, and 2 seconds later the proportional
valve will be released thus enabling the pump to produce oil flow.
If the cylinder position is less than or equal to 100mm the cylinder will start moving forward (oil
flow from port A); if the cylinder position is more than 100mm the cylinder will start moving
reverse (oil flow from port B).
When the drive is started e.g. in forward direction the oil flow is ramped up to a level determined
by a speed PID controller, and when the FAS limit is reached the oil flow is ramped down.
When the oil flow is zero or the FS limit is reached the oil flow direction is changed and the oil
flow will be ramped up to the level determined by the speed PID controller, thus moving the
cylinder in reverse direction.
When the RAS limit is reached the oil flow will be ramped down and when the oil flow is zero or
the RS limit is reached the oil flow direction is changed and the oil flow will be ramped up again,
- and so on.
Principle sketch of how the oil flow and the oil flow direction are controlled:

The ramps are introduced to make the acceleration and de-acceleration smooth.
For each drive four ramps are defined:
Forward up ramp
Forward down ramp
Reverse up ramp
Reverse down ramp
The ramps have a ramp time which is adjustable in the range of 50 to 500 ms from a parameter
picture.
FS and RS are used as set-points for the FAS - and RAS PID position controllers.
The actual maximum FS - and the actual minimum RS positions for each stroke are used as
process variables.
The two PID controllers for FAS and RAS will compensate for the system tendency to increase
the total stroke length, when the speed is increased.
The speed set-point for the drives is limited to the range of 4 to 30 strokes/minute.
The actual speed of the drive, in the range of 0 to 30 strokes/minute, is updated each time the drive
has finished a full stroke (a full cycle).
If the cylinder position is detected to be out of allowed range, i.e. less than 2mm or more than
198mm, a pre-warning will be given.
The current signal from each of the cylinder position transmitters is constantly monitored and if
the signal drops below 3.5mA or exceeds 20.5mA, an instrumentation alarm is given and the drive
is stopped immediately.
Drives Control
The drives control facilitates selection between three different transport patterns:
1) Random Mode (transport- and reverse strokes are individually controlled for each drive);
2) Shuttle Mode (synchronized transport strokes and two step reverse strokes; - at first the
central drive and when in reversed position the outer drives);
3) Synchro Mode (Synchronized transport strokes and synchronized reverse strokes).
In, “Random Mode”, the three hydraulic drives are working position-wise independently, but
speed-wise coordinated with the central drive as the reference drive and the outer drives running
in ratio to that.
The speed ratio control provides control of different transport capability across the cooler.
To establish similar control ability in the “Shuttle- and Synchro Modes”, the length of the strokes
of the outer drives must be set in ratio to the stroke length of the central drive.
(Stroke lengths to be adjusted by altering the minimum position only).
The drives start individually and always in “Random Mode”; - if “Shuttle-” or “Synchro Mode”
is selected, the actual mode is initiated when all drives are running. Then if during operation in
“Shuttle-” or “Synchro Mode” one of the drives stops, the mode switches to “Random Mode”.
Control modes can be selected freely during the run.
The stroke lengths can be preset via the touch panel in the local control panel only.
The control mode can be preset via the touch panel in the local control panel or from CCS.
The control mode selected is signalized to the Central Control System

OPERATING PROCEDURE
Cooler drives
Normal start/stop of the oil conditioning system and the hydraulic drive system can only take
place from the Central Control System (CCS).
Start/stop of the oil conditioning system

The interlocks required to operate the oil conditioning system are:
No emergency stop ALARM
No oil temperature max.2 ALARM
No oil tank level min2 ALARM
No oil temperature instrumentation ALARM
No inlet valve ALARM on the oil conditioning pump
No ready ALARM on the oil conditioning pump
No return signal ALARM on the oil conditioning pump
Start/stop of the drives

The interlocks required to operate the drive No.1 are:
Interlocks as for the oil conditioning system and
Oil temperature OK (t>25°C with hysteresis to t<18°C (E01T41))
The actual hydraulic pump ready comprising of:
no cylinder position transmitter A2 ALARM
no valve position ALARM,
no pump card failure ALARM and
no motor ALARM on selected pump.
When the above described interlocks are OK, it will be possible to start and run the drive.
When A01C31 (start command to drive No.1) is received from CCS, the main pump will start and
the signal A01C61 (Drive No.1 is running) will be sent to CCS.
Operation of the other drives is similar to drive No.1.

Operating procedure
Air Blasters
The normal start of the air blaster control system takes place from the Central Control System.
In order to start the system the following is required:

Unit ready (A09C41).
Unit ready comprises:
- The compressed air pressure must be sufficient (D81P41 and D82P41)
- A number (>1) of blasters must be selected to operate
When the above conditions are fulfilled the local control system will send the signal “Unit
Ready” to CCS. When the start signal from CCS is received the local control system will start
the blaster sequences and send the signal "In operation" to CCS.
The air blasters operate by the four built in sequence controllers or they can be released
manually.
For each sequence the following parameters can be adjusted in the “Parameters” section:
Off-set time: The time delay between start of the blaster system and starting of the first cycle
of a sequence
Cycle time: The time delay between each cycle
Step time: The time delay between each step (9 in total) in a cycle
Pulse time: The duration of the blaster pulse
Each sequence shows the following pattern:
Start Step Pulse

time time
1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9
Off-set Cycle Cycle
time time time
The air blasters are each connected to one of four sequences and can be activated by a pulse in a
sequence by specifying a single digit number (1-9) in the “Parameters” section.

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

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

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

Main menu
The main menu picture shows the different groups of pictures that can be selected:
-Selection: Access to mode selection picture
-Mimic: Access to mimic pictures
-Control: Access to control pictures
-Parameters: Access to parameter menu (enter via password)
-Status: Access to various information pictures

Mode of operation
Two different modes of operation can be selected. The actual selected mode is indicated in the
top menu bar, and with a green colour on the selected key.
Central control mode

In this mode the unit is controlled from the Central Control System (CCS). This means that the
unit is started, stopped and regulated from the CCS.
The central control mode is the default mode, the system will unconditional change to this mode
when powered up.
Removing the signal “local permission” returns the LCP to CCS mode from local test mode.
Local test mode

In this mode an individually equipment test can be executed.
The mode can only be selected when the signal "local permission" is present.
When the signal “local permission” is present a green dot will light up in the local test key.

Mimic, oil tank
Mimic, drives

Mimic, Backup pump
The mimic pictures display status of active components on the hydraulic system.
For the oil tank the status of the oil temperature, level indications, filters, valves and pump are
displayed.
For the drives mimic, the cylinder positions, cylinder pressures, drive speeds, valve positions,
motor status and filters are displayed.
Motor status:
White: Stopped, no alarm
Green: Running, no alarm
Red: Stopped, alarm
Filter status:
White: No alarms
Red: Alarm (filter is blocked)
Status of inlet valves:

White: Closed, no alarm
Green: Open, no alarm
White/red: Alarm with closed indication
Green/red: Alarm with open indication
Heating/cooling solenoid valves:

White: No flow
Green: Flow
Change over valves:

Green: Flow
Red: Alarm (i.e. illegal position with the current pump selection)
Digital alarms are shown as a red dot with:

“L” for level alarm.
“P” for pressure alarm
The analog signals displayed are:

Position: Main- and backup transmitters, indicated as bar graphs
Speed: 0-30 strokes/minutes
Pressure: 0-400 bar
Oil temperature: 0-150°C
If an alarm on an analog signal occurs the displayed value will be highlighted with a red colour.
The buttons labelled “INFO” give access to separate pictures with more detailed operational
information for each drive (see next page).

Info, drive No. 1
This picture is used for information purposes only.
“Cylinder speed” is the actual speed in strokes/minute. The calculation is made by measuring the
time the cylinder uses to complete one cycle i.e. a forward and a reverse stroke.
The strokes/minutes vary with the cylinders speed and the actual length of a stroke.
The actual “total stroke length” is displayed.
“Cylinder Min position” and “Cylinder Max position” positions indicate lowest and highest
position the cylinder obtained in the last stroke. These values are used as feedback for the PID
loops controlling the “Reverse Auto Stop” (RAS) and “Forward Auto Stop” (FAS) limits.
“Cylinder 1 position” and “cylinder 2 position” indicate the value of the two cylinder position
transmitters. To see which is selected as “Primary”, please refer to the parameter picture.
For maintenance purposes two stroke counters are displayed. One of these is resetable from the
parameter picture.

Mimic, air blasters
The mimic diagram is a simplified diagram of the system showing:

- Indication of each blaster selection
- Status of each air blaster
- Alarm points
- Status of the compressed air system
The mimic is for monitoring only.
The sequence selection as well as adjustment of the sequence controllers can be done in the
“Parameters” section.
Compressed air pressure alarm is indicated with the letter “P” shown inverted with red
background.

Pump selection picture
At first time power up the main pumps are pre-selected as default.

The backup pump can replace only one of the main pumps at a time.
Replacement of a main pump with the backup pump can only take place if the following condi-
tions are fulfilled:
All pumps in question must be stopped, i.e. backup pump and main pump for the drive in
question.
Press the de-select button for the pump to be replaced (the button will have a green dot indicating
that replacement is allowed).
A selected pump is indicated by a green button with the text: “SELECTED”.
A de-selected pump is indicated by a green button with the text: “DESELECTED”
It is necessary to manually operate the two 3-way valves related to the pump selection, every
time a pump selection has been performed. The mimic display and alarm list will indicate any
illegal valve positions.
Please note that the backup pump button is for information only and is not active at any time.

Local test, valves
In Local test mode it will be possible to activate and de-activate the solenoid valves for
commissioning or fault tracing purposes only.
When Local test mode is present and a green dot is lit in the “ON” button the valve can be
activated. When activated, the “ON” button changes colour from white to green and the “OFF”
button from green to white.
All pumps are started from the push buttons on the panel front.
To run the main pumps for the drives and the backup pump, the oil temperature must be OK.
Please ensure correct direction of rotation before running for prolonged periods.
The oil conditioning pump M08, can be started at all times. Only interlocks are, “no MCC fault”
and “emergency stop circuit OK”.

Local test, heating system
In Local Test Mode the heating system can be started as a system from this picture.
If the unit is ready a green dot is lit in the “START” button and if pressed the system will start and
the button change colour from white to green.
The system is ready if there is no Alarm 2 (A2) on the oil temperature, oil level or the circulation
pump (M08).
If any of the valves are activated in Local Test Mode on the previous picture, the heating system
can not be started.

Local test, drive No. 1

This picture comprises monitoring of a drive speed PID controller, cylinder position and hydrau-
lic oil pressures and comprises control buttons for Local test mode operations.
Speed control
The drive speed PID controller displays the actual speed of the drive (PV) 0..30 strokes/minute,
the speed setpoint (SP) 4..30 strokes/minute and the PID output (OV) min..100 %. The output
will correspond directly to the oil flow from the pump.
When CCS mode is selected this picture can only be used for monitoring.
Local test of the drive no. 1

In Local Test mode it is possible to move the drive forward or reverse from this picture by
pressing the left or right arrow key, providing that the selected pump has been locally started by
the push button on the front of the panel. The oil flow is determined by the OV value. The OV
can be adjusted by the use of arrow keys initiated by pressing the digital reading of the OV.
Be aware that the cylinder will not stop even if it reaches FS or RS limits. The pressure will rise
to the limit adjusted manually on the pump. This function can be used when the maximum
pressure of the pump is to be set or verified.
When the selected pump is running, it will be displayed on the mimic part, indicating that the
drive is ready to be operated locally. The drive is started by pressing the “START” button.
When the drive is moving and the PID is in “MANUAL” it is possible to control the oil flow and
subsequently the speed, by adjusting the OV value. When the PID is in “AUTOMATIC”, the
speed can be controlled via the SP value. The SP can be adjusted by the use of arrow keys
initiated by pressing the digital reading of the SP. Change between PID modes is possible when a
green dot is lit in the button in question.
Local test of drive No. 2, 3 & 4

is similar to local test of drive no. 1.
Local test, air blasters
From this picture the individual air blaster can be activated.
It is a pre-condition that the “Local Test Mode” has been selected.
The blasters will be activated with the “Pulse” time, which has been selected on the parameter
picture.

Local test, flushing
In local test mode flushing of the piping can be controlled from this picture.
To flush the piping the valves for a certain string must be open for the pump backup pump M07,
which can then be started.
A green dot appears in the start button and the unit is ready.
Press start.
It is now possible to increase the oil flow by adjusting the OV value. The OV can be adjusted by
the use of arrow keys initiated by pressing the digital reading of the OV.
Attention:
Before using the flushing program read the instruction for the hydraulic system.
If the pressure rises to a continually value over 200 bar, the station must be stopped at once.

ALARM LIST
Whenever an alarm occurs, the alarm key in the top menu bar will change to red colour.
Switch to the alarm list by pressing the “ALARM” key. In the alarm list, the alarms are shown,
in chronological order.
For each alarm is shown: date, time, error number, alarm type (A1 = pre-warning, or A2 = alarm
which will stop the machine), signal number and an alarm description.
When an alarm situation is corrected, the alarm can be removed by pressing the “RESET” key.
If there are more than one page with alarms, (15 alarms = 1page), it is possible to scroll up/down
by use of the “Arrow” keys.
A more detailed description of the alarms can be obtained by pressing the “HELP” key. When
help is pressed, a description of all alarms in the system, arranged by error number, will be
shown on the screen.

Alarm History
Further a screen with the alarm history, showing the latest 300 alarms is available. On this screen
all active alarms are shown in yellow and the corrected alarms are shown in green.
Help Screen
When help is pressed, a description of all alarms in the system, arranged by error number, will be
shown on the screen.

The alarms for the system are as follows:
Error Alarm Signal Alarm

No. type No. Description
00 A2 A01X41 Emergency stop has been activated

An emergency stop on the panel, on the
hydraulic unit or by the clinker cooler has
been activated.
01 A1 A01X42 Local permission overridden

Local permission override has been selected
from the parameters section in the CD.
04 A1 A01X44 Replace PLC backup battery

There has been detected low voltage on the
backup battery.
05 A2 A01X45 Data network fault

The 30s watchdog timer has run out of time.
06 A2 N01T01 Oil temperature, oil tank < minimum (15°C)

The oil temperature in the oil tank has to
be heated up to 22°C before start is ready.
07 A1 N01T01 Oil temperature, oil tank > maximum 1

If the oil temperature reaches maximum 2 the
hydraulic system will stop. Control the
functioning of the water cooling system.
Check for clogged water filter.
08 A2 N01T01 Oil temperature, oil tank > maximum 2

Control the functioning of the water cooling
system. Check for clogged water
filter.
09 A2 N01T01 Instrumentation fault

The 4-20mA current signal has been out of
the range of 3.6 to 21.2 mA.
Possibly a broken wire or a short circuit.
10 A1 D09Z41 Local control panel door open

The control panel door has been opened.
Keep doors closed when power on.
11 A2 D01Z41 Inlet valve closed

Inlet valve must be open to run the oil
conditioning pump.
12 A1 D01Z41 Inlet valve closed

Inlet valve must be open to run the oil
conditioning pump.

14 A1 D02L41 Oil level, oil tank < minimum 1
15 A2 D02L42 Oil level, oil tank < minimum 2

Check hydraulic system for leakage.
Apply hydraulic oil with the oil conditio-
ning pump to release start of the system.
16 A1 D04P41 Replace return oil filter 1

Diff. pressure, return oil filter 1, > max.
17 A1 D05P41 Replace return oil filter 2

Diff. pressure, return oil filter 2, > max.
18 A1 D03P41 Replace oil feed filter

Diff. pressure, oil feed filter, > max.
21 A1 M08C41 Ready signal fault

The stop button on the panel door or the
emergency stop has been activated, or the
the main switch is off (overloaded).
22 A1 M08C61 Return signal fault

After command to the motor starter the feed
back signal is missing or the feed back
signal is on with no command.
28 A1 N11P01 Instrumentation fault


30 A2 N11P01 Hydraulic pressure > max

Hydraulic pressure, drive No.1, port A > max

Hydraulic pressure, drive No.1, port B > max
32 A1 D11Z41 Inlet valve closed and –M01 not selected

Inlet valve must be open to run the
hydraulic pump.
33 A1 N13/14 Drive 1 position transmitters displacement.

The difference in the process value from
the two position transmitters on drive 1 is
more than 10 mm.
In local test mode: move the drive to the
outer positions to test or adjust the

fastening of the position transmitters.
35 A2 D11Z41 Inlet valve closed and –M01 selected

hydraulic pump.
36 A1 D12P41 Replace booster oil filter

Diff. pressure, booster oil filter, > max.
37 A2 D13P41 Booster oil pressure < min

Check for clogged oil filter.
38 A2 D14Z41 Main valves open and –M07 selected

Close the valves or select –M01.
39 A2 D15Z41 Main valves closed and –M01 selected

Open the valves or deselect –M01.
40 A2 D16Z41 Backup valves open and –M01 selected

Close the valves or deselect –M01.
41 A2 D17Z41 Backup valves closed and M07 selected

Open the valves or select –M01.

43 A2 N10U41 Pump card fault

Error code 4: Input cable break
Error code 5: Under voltage
Error code 12: No configuration
44 A2 N13Z01 Instrumentation fault





48 A1 N13/14 Drive 1, strokes outside limits (Auto reset)

The process value from the position
transmitter selected “primary” has been
outside the range of 2 to 198 mm.
fastening of the position transmitter.




55 A1 D19F41 Drain oil flow sensor fault

Possibly a broken wire or a faulty sensor.
56 A1 D19F41 Drain oil flow < min.

The drain oil flow sensor has not been
activated for 15s.







hydraulic pump.

more than 10 mm.

hydraulic pump.


















86 A1 D29F41– Drain oil flow sensor fault


activated for 15s.








hydraulic pump.

more than 10 mm.

hydraulic pump.





















activated for 15s.






hydraulic pump.

more than 10 mm.

hydraulic pump.





















activated for 15s.


Hydraulic pressure, backup, port A > max

Hydraulic pressure, backup, port B > max







hydraulic pump.

hydraulic pump.







220 A2 D81P41 Compressed air pressure < min

The compressed air supply valve is closed or
air compressor fault.
221 A2 D82P41 Compressed air pressure < min

The compressed air supply valve is closed or

air compressor fault.

Parameters menu
This picture gives access to overriding CCS signals, parameter pictures for the drives and pictures
which displays digital and analogue signals between CCS and the local panel.

Parameters, Drive No. 1
This picture comprises all adjustable parameters for Drive no. 1:

The parameters are entered by highlighting the parameter to change, a numeric keyboard will
appear and the control display is ready for input. Please note that the value of some parameters has
been limited to prevent illegal values to be entered.
For default settings, please refer to chapter 2.
Warning:
Great care must be taken when changing the different values and this should only be done by
authorised personnel.
If the down ramps are increased too much during operation of the grate, the grate will move too
far and hit mechanical limits with the possibility of damaging the frame or the cylinder.
Increasing the down ramps during operation must be done in the following way:
Increase the ramp in steps of 10ms. Wait and see that the total stroke is back at the selected stroke
length and the cylinder min. and max. positions are back at the FS and RS values, before increas-
ing with another 10ms.
Stroke counter reset:

This feature enables the user to reset one of the two stroke counters for the drive.
Parameters, Drive No. 2 & 3

Drive no. 2 and 3 have the similar parameters as for drive no. 1.

Parameters, General Control
In this picture parameters for hydraulic pressure limits and temperature control limits are to be set.
For default parameters, please refer to chapter 2.

Parameters, overriding CCS signals
From this picture it is possible to override Local Permission from CCS:

Press the "ENABLE" button (Possible if the green dot in the button is lit)
When Override Local Permission is selected a prewarning will be generated.

From the mode selection picture it is now possible to select Local Test Mode.
Disable override Local Permission:

Press the "RESET" button (possible if the green dot in the button is lit).
A power up of the local control panel will also disable the “override” function.

Parameters, position signal selection
In this picture the operator can select which of the two transmitters on each drive is to be used as
the primary transmitter.
Selection is possible when the drive in question is stopped, indicated by a green dot in the button.

Parameters, Air Blaster Sequence 1 & 2 (similar to sequence 3 & 4, 5 & 6)
These parameter pictures comprise the adjustment of air blaster sequences. For each sequence the
following parameters can be adjusted:
Off-set time: The time delay between start of the blaster system and starting of the first
cycle of the sequence
Cycle time: The time delay between each cycle
Step time: The time delay between each step (9 in total) in a cycle
Pulse time: The duration of the blaster pulse
Each sequence shows the following pattern:
Start Step Pulse

time time
1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9
Off-set Cycle Cycle
time time time
The parameter pictures comprise further the selection of the air blasters by use of select-/deselect
buttons, and selection of the step number in the sequence in question to activate the air blaster.

Parameters, Air blasters selection -Y81 to -Y88 (similar to -Y90 to -Y97)
This parameter picture comprises the selection of the Air blasters –Y81 to –Y88 by use of a 2-
digit number.
The following parameters can be adjusted:
The first digit: Sequence No. (0-6)

The second digit: Step No. (0-9) in the selected sequence
Key:
0 =deactivated
10= (1) sequence No.; (0) manually only (pulse duration from sequence No.1 settings)
20= (2) sequence No.; (0) manually only (pulse duration from sequence No.2 settings)
13= (1) sequence No.1; (3) step No.3 & manually
69= (6) max. sequence No.; (9) max. step No.

CCS digital signals, hydraulic system

This picture displays the status of the digital communication with CCS.
CCS digital signals, Air Blasters

This picture displays the status of the digital communication with CCS.

CCS analog signals, Hydraulic System

This picture displays the status of the analog communication with CCS.

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

All alarm 2 interlocks are fulfilled.
Unit ready = 0, when:
An alarm 2 is present or the unit is in LOCAL TEST mode.
Heating running Heating Running = 1, when:

The heating system is in operation. This signal is an
operational interlock for the drives.
Oil temp. OK Signal = 1 when:

The oil temperature has reached an operational value (18°C).
This signal is a safety interlock for the drives.
Drive No.1, ready Unit ready = 1, when:

All alarm 2 interlocks for the left drive are fulfilled.
Drive No.1, running System running = 1, when:

The hydraulic system for the drive No.1 is in operation.
Drive No, 2, ready Unit ready = 1, when:

All alarm 2 interlocks for the centre drive are fulfilled.
Drive No.2, running System running = 1, when:

Drive No. 3, ready Unit ready = 1, when:

All alarm 2 interlocks for the right drive are fulfilled.
Drive No. 3, running System running = 1, when:

Drive No. 4, ready Unit ready = 1, when:

All alarm 2 interlocks for the right drive are fulfilled.
Drive No. 4, running System running = 1, when:

No prewarning Signal = 1, when:

No prewarning is present.

Air blasters ready Unit ready = 1, when:

All alarm 2 interlocks for the air blasters are fulfilled.
Air blasters, running System running = 1, when:

The air blaster system is in operation.
Digital Signals from CCS:
Local test permission Local permission = 1, permits:

The unit to be tested locally without any interlocks
Start/stop heating Start = 1

Stop = 0
Start/stop hydraulic system Start = 1

for drive No. 1 Stop = 0




Start/stop air blaster controller Start = 1

Stop = 0
Force firing blaster –Y81 Fire = 1

Stop = 0

Stop = 0

Stop = 0

Stop = 0

Stop = 0

Stop = 0

Stop = 0

Stop = 0

Stop = 0

Stop = 0

Stop = 0

Stop = 0

Stop = 0

Stop = 0

Stop = 0

Analog signals to CCS:
Speed, drive No. 1 0 - 300 --> 0 - 30.0 strokes/min
Hydraulic pressure, drive No. 1 0 - 400 --> 0 - 100 % (0-400 Bar)
Speed, drive No. 2 0 - 300 --> 0 - 30.0 strokes/min
Speed, drive No.3 0 - 300 --> 0 - 30.0 strokes/min
Speed, drive No.4 0 - 300 --> 0 - 30.0 strokes/min
Analog signals from CCS:
Set point for speed, drive No. 1 0 - 300 --> 0 - 30.0 strokes/min

GENERAL SPECIFICATIONS
Storage
Temperature -5 - 60°C
Humidity 0 - 75% non condensing
Operating
Temperature -5 to 45°C
Humidity 20 - 90% non condensing
Altitude above sea level < 1000 meters
Degree of protection IP 54
Power supply 400 V 50Hz
Power consumption 1.0 kVA
Dimensions and Weight

wxhxd 1200 x 2000 x 400 mm
Weight app. 200 kg

6.01
Parts List 80001695 Ver.: 1.0
0012015 3-72814 1 COMPLET PANEL
CABINET 2 Control Cabinet 1200x1800x400 Rittal TS8284.600

2 Cabinet Socket Front/Back Rittal TS8602.200
2 Cabinet Socket Sides Rittal TS8602.040
1 Cabinet Side Panels Rittal TS8184.200
1 Diagram Pocket Rittal SZ2514.000
P01 1 Touch Panel, Pro Face Brodersen GP2500 TC41 24V

1 MPI-Cable Brodersen GP000-MPI21-PFE
1 Inspection Window 430x355x34mm Rittal FT5492704-SPEC.
A2 1 Backplane Siemens 6ES7390-1AJ30-0AA0
G1 1 Power Supply 230/24VDC 5 Amp. Siemens 6ES7307-1EA00-0AA0
G2,G3 2 Power Supply Module 24VDC/10Amp. Siemens 6EP1 334-2BA00
A2 1 CPU Siemens 6ES7315-2AG10-0AB0

1 Memory Module Siemens 6ES7953-8LG00-0AA0
SLOT0/ 4,5,6,7, 5 Dig. Input Module Siemens 6ES7 321-1BH02-0AA0

8
SLOT0/ 9,10,11 6 Dig. Output Module Siemens 6ES7 322-1HF01-0AA0

SLOT1/4,5,6
SLOT1/ 7,8,9 3 Analog Input Module Siemens 6ES7 331-7KF02-0AB0
SLOT1/ 10,11 2 Analog Output Module Siemens 6ES7-332-5HD01-0AB0
SLOT0,1/3 1 Interface module Siemens 6ES7-365-0BA01-0AA0
16 Front Connector Siemens 6ES7 392 1AJ00-0AA0
T1 1 Transformer 415/230VAC, 1,6 KVA Siemens 4AM61428JD400FA0
A20 1 Emergency Stop Relay 230VAC Pilz PNOZ-X3, (774318)
B10 1 Thermostat Rittal SK3110.000
E1,E1.1 2 Heating Element 50-120W 230VAC Rittal SK3116.000
E2,E3 2 Panel Light 230VAC Rittal PS4109.000
E4,E5,E6,E7 4 Ventilator Sunon DP201A-230VAC

8 Protection Cover For Ventilator Sunon FG
X30,X31 2 Socket With Earth 16 Amp Schupa PC16/2
Q1 1 Circuit breaker 500 Amp. Siemens 3VF6211-1BK44-0AA0

1 Terminal Cover Siemens 3VF9624-1NB10
1 Bus Bar System:
3 Rail Holder for Cubber Rail 800 Amp. Rittal SV3000.000

2 End Cover Rittal SV3080.000
1 Cover for Unused Slots Rittal SV3092.000
1 Supply Adaptor 800 Amp. Rittal SV3441.000
5 Outlet Adaptor 250 Amp. Rittal SV3442.000
2 Outlet Adaptor 63 Amp. Rittal SV3443.000
F1 1 Manual Motor starter 5,5-8,0 Amp Siemens 3RV1021-1HA10
F2 1 Cirquit Breaker, 1P, 6 Amp, C-kar. Siemens 5SX2106-7
F3 1 Circuit Breaker, 1P, 10 Amp, C-kar. Siemens 5SX2110-7
F70,F71,F72, 5 Manual Motor starter 70-90 Amp Siemens 3RV1041-4LA10
D:\Fls_edoc\Root\Users\Hape\Convert\80001695_601_48.doc 24-01-05 HaPe / ToLo / FleJ

6.02
Parts List 80001695 Ver.: 1.0
F73,F74 5 Auxiliary Switch 2 NO Siemens 3RV1901-1F
F75 1 Manual Motor starter 3,5-5,0 Amp Siemens 3RV1021-1FA10

1 Auxiliary Switch 2 NO Siemens 3RV1901-1F
K70,K71,K72 5 Contactor 230V Siemens 3RT1054-6AP36

K43,K74 5 Auxiliary Switch 1NO Siemens 3RH1921-1CA10
K75 1 Contactor 4 kW/230VAC Siemens 3RT1017-1AP01
K01 to K99 16 Relay 10A 3P 24VDC Schrack MT323024

16 Socket Schrack MT78740
K98 1 Relay 10A 3P 230VAC Schrack MT328230

1 Socket Schrack MT78740
N10,N20,N30, 5 Card Guides for Hydraulic Cards Phönix SKBI 64/F48

N40,N70 5 DIN-Rail Fixing Phönix SF-SKBI 64
S01 1 Emergency Stop Push Button Siemens 3SB3000-1HA20

1 Aux. Switch (NC) Siemens 3SB3400-0C
1 Label Emergency Stop Siemens 3SB3921-0AD
S2,S3,S4,S5, 6 Double Push Button Siemens 3SB310D-BAC21

S6,S7 6 Aux. Switch (NO) Siemens 3SB3400-0B
6 Aux. Switch (NC) Siemens 3SB3400-0C
S02 1 Selector Switch 1P. 16 Amp Siemens 5TE7111
270 Terminals scr/scr WDU4 Weidmüller 102010

22 Earth Term. WPE 4 GR/YE Weidmüller 101010
19 Fuse terminal WSI6 Weidmüller 101100
D:\Fls_edoc\Root\Users\Hape\Convert\80001695_601_48.doc 24-01-05 HaPe / ToLo / FleJ

Remote Control Interface 8.05
Hydraulic Drive System, Clinker Cooler 80001695 Ver.: 1.0
From: Local control panel To: CCS

PLC Node No.: 15 PLC Node No.:
Panel Tag: 441MD140A01 Panel Tag:
Digital Signals: Digital Signals:
Q96
0 Handshake bit 0
1 1
2 2
3 3
4 4
5 5
6 6
7 7
Q97
0 Heating ready -E01C41 0
1 Heating running -E01C61 1
2 Oil temperature OK -E01T41 2
3 Drive No.1 ready -A01C41 3
4 Drive No.1 running -A01C61 4
Q98
3 No prewarning -A01U41 3
4 Filters OK -A01U42 4
5 Air blasters ready BQ110 5
-A01C41
6 Air blasters running BQ110 6
-A01C61
7 7
Analog signals: Analog signals:
QB102 Drive No.1 speed PV -A01S01

+ [0-30.0 strokes/min]
QB103
QB104 Drive No.1 pressure PV -A01P01
+ [0-400 bar]
QB105
QB107
+ [0-400 bar]
QB109


QB111
+ [0-400 bar]
QB113
QB115
+ [0-400 bar]
QB117
QB120 Drives Control Mode -A01Z01
+ (1-3)
QB121
From: CCS To: Local Control Panel

PLC Node No.: PLC Node No.: 15
Panel Tag: Panel Tag: 441MD140A01
Digital Signals: Digital Signals:
I96
0 0 Handshake bit
1 1
2 2
3 3
4 4
5 5
6 6
7 7
I97
0 0 Local permission -A01C39
1 1 Start/stop heating -E01C31
2 2 Start/stop drive No.1 -A01C31
6 6 Start/stop air blasters BQ110C
31
7 7
I98
0 0 Manual firing BQ110
Y81 SBD1 -Y81C31
Y82 SBD2 -Y82C31
Y83 SB1 -Y83C31
Y84 SB2 -Y84C31

Y85 SB3 -Y85C31
Y86 SB4 -Y86C31
Y87 SB5 -Y87C31
Y88 SB6 -Y88C31
I99
0 Manual firing BQ110-
Y90 SBH2(L) Y90C31
Y91 SBH4(L) Y91C31
Y92 SBZ1(L) Y92C31
(OPTIONAL)
Y93 SBZ2(L) Y93C31
(OPTIONAL)
Y94 SBH2(R) Y94C31
Y95 SBH4(R) Y95C31
Y96 SBZ1(R) Y96C31
(OPTIONAL)
Y97 SBZ2(R) Y97C31
(OPTIONAL)
Analog signals: Analog signals:
IB102+ Drive No.1 speed SP

IB103 [0-30.0 strokes/min] -A01S11
IB110+ Drives Control Mode -A01Z11
IB111 (1-3)

COOLER MANUAL 2 (Process)

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COOLER MANUAL 2 (Process)

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Local control panel type RK-SFHY-04/SBC-13 0.

3. System structure and operating procedure

.20 Layout of local control panel

9. PLC program documentation

D:\Fls_edoc\Root\Users\Hape\Convert\80001695_001_1.doc 26.01.05 MSOffice/ MiC / FleJ

FLS sub supplier instructions: No.: 60013431

Programming software and equipment :

Control Display, Proface

D:\Fls_edoc\Root\Users\Hape\Convert\80001695_001_1.doc 26.01.05 MSOffice/ MiC / FleJ

Control display settings:

Parameters Drive No. 1 Default As built

Parameters Drive No. 2 Default As built

Parameters Drive No. 3 Default As built

Parameters Drive No. 4 Default As built

Parameters for hydraulic pressures Default As built

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Parameters for Cooling valve Default As built

Parameters, Shock Blaster Sequence No.1 Default As

Parameters, Shock Blaster Sequence No.2 Default As

Parameters, Shock Blaster Sequence No.3 Default As

Parameters, Shock Blaster Sequence No.4 Default As

Parameters, Shock Blaster Sequence No.5 Default As

Parameters, Shock Blaster Sequence No.6 Default As

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Parameters, Shock Blaster Selection Default As

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Pump cards settings

Data set name : VT-VSPD-1-1X

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Pump cards settings

Data set name : VT-VSPD-1-1X

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Pump cards settings

Data set name : VT-VSPD-1-1X

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Pump cards settings

Data set name : VT-VSPD-1-1X

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Pump cards settings

Data set name : VT-VSPD-1-1X

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Pump card replacement procedure:

Pump card adjustment procedure:

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The purpose of the local control system is to:

The hydraulic concept

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The control system

0 RS RAS FAS FS 200

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Start/stop of the oil conditioning system

Start/stop of the drives

Operation of the other drives is similar to drive No.1.

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In order to start the system the following is required:

Each sequence shows the following pattern:

Start Step Pulse