User manual

User manual

Revision: Date: Issued: Date: Checked:

Copyright reserved: This documentation is the property of Andritz AG and must not be copied or used for manufacture without their
permission.

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Table of Content

1 Controlling on touch panel ....................................................................................................................................................3

1.1 Navigation .......................................................................................................................................................................3

1.1.1 General ........................................................................................................................................................................3

1.2 Popup Typicals ................................................................................................................................................................3

1.2.2 Motor ...........................................................................................................................................................................4
1.2.3 Valve ...........................................................................................................................................................................5
1.2.4 Analog .........................................................................................................................................................................5
1.2.5 PID Controller .............................................................................................................................................................6
1.2.6 Binary ..........................................................................................................................................................................7

1.3 Sequence Start / Stop .......................................................................................................................................................8

1.4 Alarm Handling ...............................................................................................................................................................8

1.5 Operating hours counter ................................................................................................................................................10

1.6 Trend ..............................................................................................................................................................................11

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1 CONTROLLING ON TOUCH PANEL

1.1 NAVIGATION

In the Top of the screen the navigation bar is located, from where it is possible to navigate
between different windows: General, Pellet mill – Overview, Pellet mill – Alarmlist, Pellet mill –
Trend.

1.1.1 General

In the general screen the systems general parameter and configuration can be changed. For
example you can change the user level, calibrate the panel or go to the desktop.

1.2 POPUP TYPICALS

On the overview picture of the PCPS you will find different symbols (Motor, Valve, Analog
signal, Controller, Binary signal). By clicking on the symbol, a popup will automatically open.

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1.2.2 Motor

Interlock

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Each motor has two modes: Automatic and Manual. In the Manual Mode the motor can
be started and stopped by clicking the buttons. In the Auto Mode the PLC is controlling
the motor.

Interlocks are taking care for the security. The motor will start flashing in case of fault.

1.2.3 Valve

Each valve has two modes: Automatic and Manual. In the Manual Mode the valve can
be opened or closed by clicking the buttons. In the Auto Mode the PLC is controlling the
valve.

The valve will start flashing in case of fault.

1.2.4 Analog

On each analog signal the setpoints (HIHI, HI, LO, LOLO) can be configured. If the
actual value (PV) is higher or lower than the setpoint an alarm (HIHI and on LOLO) or at
least a warning on the screen will be shown, if available.

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1.2.5 PID Controller

Each PID – Controller has 2 modes: Auto and Manual. In the Manual Mode the output of
the controller (M CV) can be set (For example on the load current control, M CV means
the reference Speed for the Feed screw). In the Auto Mode the PID Controller is
controlling the output automatically according to the process SP (For example on the load
current control, AUTO SP means a SP for the load current for the main motor).

By pressing the red framed button, a popup with all controller parameters opens.

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On each PID controller are alarm setpoints (HIHI, HI, LO, LOLO, DEV H, DEV L) can be
configured. If the actual value (PV) is higher or lower than the setpoint an alarm (HIHI
and LOLO) or a warning (HI and LO) will be shown on the screen, if available. If the
deviation between the setpoint and the actual value is higher or lower than the
Setpoints, there will be an alarm.
There are limits for the setpoint of the PID controller (SP H and SP L). Also the Output
of the controller is limited (OUT H, OUT L).

The parameters for the PID controllers are: KP, TI, TD, TF, DZ.
KP: Direct gain
TI: Integral time
TF: Differential time
DZ: Dead zone

1.2.6 Binary

On the Binary popup shows the status of the signal.

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The alarm square will start flashing in case of fault.

1.3 SEQUENCE START / STOP

Before starting the pellet mill make sure that there are no alarms on the system. You also
need to put the right Setpoints for the controllers (Load current control: 40 – 80% from
nominal current; Temperature control: 80°C) and switch the controllers into the Auto
Mode. Then the system is ready for start.

Now you can start in Semi or Auto, like it is described in point 2.2.

1.4 ALARM HANDLING

There are the following typical alarms on the system: Motor fault, Valve fault, Binary
signal fault, Analog signal warning, alarm, wire broken and overflow, Controller warning,
alarm wire broken and overflow.

Motor:

The reason why a motor has a fault is that the PLC system did not get the run feedback
or the ready signal is not OK. To solve this fault check the motor protection and the
power supply in the MCC cabinet. Then reset the alarm.

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Valve:

The reason why a valve has a fault is that the PLC system did not get the feedback for
the end position. To solve this problem check the air pressure and the position of the
valve. Then reset the alarm

Binary signal:

If the system did not get right input status of the signal then there will be an alarm. To
solve this problem check the signal on side (For example any overflow switch is
activated), check if you get the right signal on the HMI and then reset the alarm.

Analog signal:

If there is a warning or an alarm then the value is out of his normal operation range. To
solve this problem you need to check the process (For example any temperature is not
OK  Probably the cooling system is not working).

If there is a wire broken alarm, then please check the cabling of the sensor.

If there is an overflow alarm, then please check the sensor, the cabling and the
converter of the sensor.

After solving the problems just reset the alarms.

Controller:

If there is a warning or an alarm then the process value is out of his normal operation
range. To solve this problem you need to check the setting of the controller and the
process (For example the load current is not OK  Maybe any mechanical problem).

If there is a wire broken alarm, then please check the cabling of the measurement unit.

If there is an overflow alarm, then please check the measurement unit.

After solving the problems just reset the alarms.

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1.5 OPERATING HOURS COUNTER

There is for each motor an operating hours counter and an overall hours counter. If the
operating hours (ACT) are more then the setpoint (MAX) then there will be an alarm. The alarm
has no influence in the process, it is just for indication. To stop the alarm you need to reset the
operating hours and then you can make a normal alarm reset.

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1.6 TREND

There are 5 parameters which need to be trended:

- Load of Main motor (PP-50-03.01)

- Speed of Feed screw (AG-50-07.02)

- Temperature of Conditioner (AG-50-09.05)

- Position of Motorized Steam valve (AG-50-09.11)

You have two different time ranges for the Trend: 20min and 24h.

There is also the possibility to scan in the Trend. This scan function allows finding out any value
on any time.

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