Professional Documents
Culture Documents
Sand mill
Gear unit
Sand mill
Gear unit Clinker
Silo
Separator
2 3
Cement
Raw meal silo
silo
5 Cement mill
3 4 Gear unit
1 2
Raw mill
1. INTRODUCTION...................................................................................................................................... 4
4. SUB-SYSTEMS........................................................................................................................................ 10
4.1 EXAMPLE OF LOCAL CONTROL PLC NODES, ON PROFIBUS ................................................................ 10
4.2 EXAMPLE OF COMMUNICATION LAYOUT FOR SIEMENS S7.................................................................. 11
4.3 PROGRAM EXAMPLE .......................................................................................................................... 14
4.4 GENERAL FOR CONTROLLOGIX AND SLC 5/04.................................................................................. 15
4.5 COMMUNICATION LAYOUT ................................................................................................................ 15
4.6 DATA FILES........................................................................................................................................ 15
4.7 NODE DEFINITIONS AND MEMORY LAYOUT ........................................................................................ 15
4.8 PRINCIPLE OF RECEIVING DATA .......................................................................................................... 16
4.9 PRINCIPLE OF SENDING DATA ............................................................................................................. 16
4.10 WATCHDOG FUNCTION ...................................................................................................................... 16
4.11 GENERAL PLC FAULT ........................................................................................................................ 16
4.12 SUB PLC PROGRAM........................................................................................................................... 17
4.13 DATA SHEET SUB PLC TO MAIN PLC ............................................................................................... 19
4.14 DATA SHEET MAIN PLC TO SUB PLC ............................................................................................... 20
5. ECS / SDR................................................................................................................................................. 21
5.1 DEPARTMENT COMMANDS ................................................................................................................. 21
5.1.1 Emergency stop............................................................................................................................ 22
5.2 ALARM PHILOSOPHY .......................................................................................................................... 22
5.2.1 Alarms on analog signals ............................................................................................................. 22
5.2.2 Alarms on digital signals.............................................................................................................. 23
5.3 MIMIC COLOURS ................................................................................................................................ 24
5.4 MIMIC LAYOUT, TYPICAL................................................................................................................... 25
6. PLC AND I/O CABINET LAYOUT ...................................................................................................... 27
6.1 STANDARD CABINET LAYOUT “ACEDOC” ....................................................................................... 27
6.1.1 Cabinets ....................................................................................................................................... 27
6.1.2 General layout.............................................................................................................................. 27
6.1.3 Three basic cabinet layouts:......................................................................................................... 27
6.1.4 Terminal block marking:.............................................................................................................. 28
6.1.5 Emergency Stop/Plant Stop: ........................................................................................................ 29
6.1.6 Incoming cable fixation: .............................................................................................................. 29
6.1.7 Miscellaneous: ............................................................................................................................. 30
6.2 TERMINAL BLOCK ASSIGNMENT ......................................................................................................... 39
1. Introduction
It has been decided that a general design manual for process control systems should
be written. The general design manual should be a thorough detailed basis for the
project manuals written by FLSA, in co-operation with FLS in connection with
new projects. Hereby, it should not be necessary to discuss general control
principals when starting a new project. The project manual forms the basis of all
project work with FLSA. Therefore, the manual should be the first step in any
project co-operation.
Unless there are contractual specific requirements differing from the general
design manual, the general design manual is to be used as basis for the project
manual.
A work group and a managing group should co-operate, update and maintain the
design manual.
1.1.1
An overall time schedule for the project has been agreed upon. (If a split of the freezing
dates is possible, the number of possible splits are defined in the overall time schedule).
Variations (changes) are handled according to the FLS/FLSA general agreement for
control systems.
The basic design criteria are discussed and agreed upon. (Special client requirements are
clarified, any deviation from the FLSA-standard panel layout is clarified, interface to
local control systems, exact edition of FLS Key to Interlock to be used in the project is
agreed upon, etc).
1.1.4 PLC-freeze
The number of PLC-panels is agreed upon based on a preliminary I/O list and the
number of PLC’s for each department are frozen.
As each PLC basically contains only the central rack with CPU-unit, communication
module, power supply and if space available, some analogue I/O’s, FLSA can start
design and purchase of the PLC-panels after the PLC-freeze date. FLS will inform
FLSA about numbers of standard terminal blocks (analog blocks) required in each of the
PLC-panels.
A revised edition of the preliminary I/O list in digital format with PLC-addresses, etc. is
returned to FLS, after receiving the revised edition FLS will check the readability of the
list.
The purpose of this exercise is to check the conformity in the data formats used by FLS
and FLSA.
If agreed in the start up meeting the I/O freeze could be split into 2 or 3 freeze-
dates, each covering a number of departments.
FLSA can start design and purchase of the I/O-panels after the I/O-freeze date
based on the signal lists that are nearly final. The numbers of actual I/O’s are
compared to the contractual number of I/O’s and a deviation list is made for the
plus/minus account.
Changes caused by FLS after the I/O freeze will delay the design and
manufacture of the I/O-panels. Changes will be priced according to agreed Unit
price for I/O-changes after I/O freeze as defined in the FLS/FLSA general
agreement for control systems, (variations).
If agreed at the start-up meeting the interlock freeze could be split into 2 or 3
freeze-dates, each covering a number of departments.
Changes caused by FLS after the interlock freeze will delay the programming.
Changes will be priced according to agreed Unit price for Interlock-changes
after interlock- freeze as defined in the FLS/FLSA general agreement for control
systems (variations).
Changes caused by FLS after the interlock freeze will delay the programming,
changes will be priced according to agreed Unit price for I/O-changes after
interlock- freeze as defined in the FLS/FLSA general agreement for control
systems (variations).
1.1.8 FAT
The purpose of the Factory Acceptance Test is that FLSA shall demonstrate to FLS that
the PLC-program acts as described in the FLS-interlock diagrams. Before starting the
FAT-test FLSA states that the total system is completed according to the FLS interlock
diagrams.
Further the FAT-test gives FLS the possibility to check the overall function of the FLS-
interlocking.
1. A raw mill with two mills will physical typically be placed in two PLC’s.
PLC 1 with joint raw material transport to both mills and mill no. 1.
PLC 2 with joint transportation of manufactured goods to silo from both mills
and mill no. 2.
2. Many plants have a PLC, which deals with various equipment such as plant air
and water treatment. If parts of the equipment logically belong to another
department, such as rotary blowers to airlifts for kiln feeding, the rotary blowers
should be controlled from the same department as the rest of the kiln feeding.
There should be no doubt that a start in one ECS department must not under any
circumstances start a group in any other ECS department than the one selected,
all though a group may have been selected in another ECS department.
It is of great importance that the above mentioned is observed from the
beginning, as it is almost impossible to change once installed. Therefore there
should be an agreement between those involved on this issue as early in the
process as possible.
4. Sub-Systems
Input
Handshake constant "1" send from Bridge PLC please check program example
I 96.0 FC100
I 96.1 Start status bits
I 101.7 End status bits
I 102.0 IW 102 Start status word
FC100 DP communication OK
This manual contains information about communication between FLSA main PLC’s and
Sub-PLC’s from other suppliers, using Data Highway network (DH+). Main PLC’s are
Allen Bradley type ControlLogix, and Sub-PLC’s are Allen Bradley type SLC 5/04.
For each Sub-PLC 10 integer words are allocated for receiving data and 10 words for
sending data. The first two words in each block are predefined for sending digital
information (32 bits), followed by eight integer variables for analog information.
The request for sending data is trigged by any change in the digital data (the two first word
in the data block). If the data in N213:000/N214:000 or N213:001/N214:001 are not equal,
a transfer is executed. If the data have not been sent within 5 seconds trigged by change in
the digital data bits, the data are send anyway to insure that the analog signal are transferred
at least every 5 seconds.
The first bit in the data block from the Sub PLC to the Main PLC is also allocated for
watchdog function. The only thing to be done in the Sub PLC is to insure that the bit is
constant low.
Plant TamDiep
Comm. direction Sub PLC ® Main PLC Date
Sub PLC no. xx Decimal / xx Octal Rev.
Sub PLC Ref. Init.
Sub PLC Name
Address Tagcode Description
N213:000/00 Watchdog bit (constant low)
N213:000/01 General PLC fault (1=OK)
N213:000/02
N213:000/03
N213:000/04
N213:000/05
N213:000/06
N213:000/07
N213:000/08
N213:000/09
N213:000/10
N213:000/11
N213:000/12
N213:000/13
N213:000/14
N213:000/15
N213:001/00
N213:001/01
N213:001/02
N213:001/03
N213:001/04
N213:001/05
N213:001/06
N213:001/07
N213:001/08
N213:001/09
N213:001/10
N213:001/11
N213:001/12
N213:001/13
N213:001/14
N213:001/15
N213:002
N213:003
N213:004
N213:005
N213:006
N213:007
N213:008
N213:009
Plant TamDiep
Comm. direction Main PLC ® Sub PLC Date
Sub PLC no. xx Decimal / xx Octal Rev.
Sub PLC Ref. Init.
Sub PLC Name
Address Tagcode Description
N211:000/00 Watchdog bit (constant low)
N211:000/01
N211:000/02
N211:000/03
N211:000/04
N211:000/05
N211:000/06
N211:000/07
N211:000/08
N211:000/09
N211:000/10
N211:000/11
N211:000/12
N211:000/13
N211:000/14
N211:000/15
N211:001/00
N211:001/01
N211:001/02
N211:001/03
N211:001/04
N211:001/05
N211:001/06
N211:001/07
N211:001/08
N211:001/09
N211:001/10
N211:001/11
N211:001/12
N211:001/13
N211:001/14
N211:001/15
N211:002
N211:003
N211:004
N211:005
N211:006
N211:007
N211:008
5. ECS / SDR
http://www.flsadev.dk
Username: FLSmidth
Password:
The following commands are all issued from the common task bar shown on top of each
screen on the ECS-Opstation and is only logical “1” in one PLC cycle.
MMI Presentation:
The following symbols are a part of the FLSA standard library for use with digital
alarms.
The above shown symbols are changing colour according to status of the process. These
symbols are used on the process flow pictures clicking with the right hand mouse on the
text or symbol will bring up a faceplate for the alarm e.g.:
Static colours
Colour coding.
6.1.1 Cabinets
All cabinets will be of the same size, 2100x1200x500 mm (HxWxL), where H includes
a 100 mm base frame.
1) Make: Rittal
2) Type: TS8205
3) Colour: RAL 7032. Base frame: RAL 7022.
4) Each cabinet will be supplied with side covers.
5) Cabinet will be supplied with Rittal’s standard handle/lock, unless otherwise
specified.
c. The X6 block has a version for DC supply and a version for AC supply.
d. The block X6.0 is predefined for power distribution to the other X6
blocks.
3) One cabinet with 4 unit/motor blocks (X7).
a. 4 X7 blocks are the maximum for one cabinet.
b. The X7 block is for unit/motor control.
One X7 block is designed to handle 16 motors; i.e. maximum 64 motors
in same cabinet.
c. The block X7.0 is predefined for power distribution to the other X7
blocks.
d. The X7 block has 4 versions:
1 DO and 3 DI with DC supply.
1 DO and 3 DI with AC supply.
1 DO and 4-5 DI with DC supply.
1 DO and 4 to 5 DI with AC supply.
Combination of X5, X6 & X7 blocks can be made in the same cabinet for minor process
departments.
The blocks X0, X1, X2 & X3 are dedicated for internal power distribution.
Example for X6
X6.xx:n z where X6 is the terminal block type (digital)
where xx is the terminal block number (01…10)
where n is the signal terminal number (1…16 for digital
input; 17…24 for digital output)
where z is terminal extension (+/- for dc voltage, L/N for
Example for X7
X7.xx.yy:n where X7 is the terminal block type (unit/motor)
where xx is the terminal block number (01…04);
where yy is the unit/motor terminal block section
(01…16);
where n is the signal terminal number (+ -, 1…4 for 3
digital inputs, 1 digital output, dc voltage);
where n is the signal terminal number (+ -, 1…6 for 5
digital inputs, 1 digital output dc voltage);
where n is the signal terminal number (L N, 1…4 for 3
digital inputs, 1 digital output ac voltage);
where n is the signal terminal number (L N, 1…6 for 5
digital inputs, 1 digital output ac voltage);
(Refer to Appendix B, -X7.x).
6.1.7 Miscellaneous:
1) Cabinet lighting can be installed.
Basic installation, i.e. circuit breaker, terminals and wiring will always be prepared.
Terminal 1 - 8 are used for field connection of emergency stop push buttons.
Wires are connected at top and middle level.
Terminal 11 & 12 are used for field connection from next cabinet emergency
stop push buttons. Wires are connected at top and middle level.
Terminal 20 is used for connection from next X4 block emergency stop push
buttons. Wires are connected at top and middle level.
Terminal 21 & 22 are used for field connection to next cabinet emergency stop
orders. The 2 terminals are preferred for cabinets with push buttons, but can also
be used for auxiliary cabinets. Wires are connected at top and bottom level.
Terminal 23 - 29 are used for field connection to auxiliary cabinet emergency
stop orders. Wires are connected at top and bottom level.
Terminal 30 is used for connection to next X4 block emergency stop order.
Wires are connected at top and middle level. If no next X4 block is needed, the
terminal can be used for field connection to auxiliary cabinet emergency stop
order.
Terminal 31 & 32 are in remote cabinets/next X4 blocks, used for field/internal
connection of collected push buttons to previous cabinet/block. Wires are
connected at top and bottom level.
Terminal 33 & 34 are in remote cabinets/next X4 blocks, used for field/internal
connection of common stop order from previous cabinet/block . Wires are
connected at top and bottom level.
Terminal 35 & 36 are used for field connection from next cabinet OLM/Surge
supervision. Wires are connected at top and bottom level.
Terminal 37 & 38 are only used on X4.9 blocks.
Terminal 39 – 58 are used for internal connection of the emergency stop
circuits.
Terminal 21 is used for field connection to next cabinet emergency stop orders.
Wires are connected at top and bottom level.
Terminal 33 & 34 are used for field connection of common stop order from
previous cabinet. Wires are connected at top and bottom level.
Terminal 35 & 36 are used for field connection from next cabinet OLM/Surge
supervision. Wires are connected at top and bottom level.
Terminal 37 & 38 are used for field connection to previous cabinet OLM/Surge
supervision. Wires are connected at top and bottom level.
Terminal 39 – 42 are used for internal connection of the emergency stop
circuits.
X7.01.03.+ + (Supply for digital inputs: Ready, local start, return etc.)
X7.01.03.- - (0 ref. for digital output: Command)
X7.01.03.1 C31 (Command)
X7.01.03.2 C41 (Unit/Motor Ready)
X7.01.03.3 C51 (Local start)
X7.01.03.4 C61 (Return)
Other signal combinations/descriptions may occur, but connection will be as above with
the Command (digital output) on terminal .1, and the inputs in logical order (alphabetic).
Example:
Special applications with limit/torque switches may require the use of 3 consecutive
motor terminal blocks.
Units typically interfaced with X7 are: Motors, Dampers (reversible motor starter), EP-
filters (rectifiers and rapping) etc.
Units, which include motor driven parts typically interfaced with X6 are:
Feeders (Dosax-, Pfister-, Schenck-), Compressors, Actuators etc.
7. FA Test Procedure
FLSA shall conduct tests to verify that the functional operation of all systems and
equipment meets the requirements from FLS.
Wiring Check
By panel manufacturer
Wiring Insulation Test
Visual Inspection
By FLSA
Hardware Test
System Functional Test By FLS and FLSA
7.3.1 Checklist
A checklist shall document the results of visual inspections.
Workmanship of wiring;
Location of components;
Adequacy component supports;
Tightness of all components;
Nameplates and wire tags;
Electrical wiring and terminal block layouts, using the latest or as-built system
drawings;
If one or more signals fail FLS is entitled to carry out a full test where all inputs
and outputs are checked one by one.
The test is performed from the terminals in I/O cabinet to the operator station,
where possible – otherwise to PLC level.
7.5.4.3 Network
¡ Network redundancy and change over functionality is verified.
It is recommended that the names of the test personnel appear after <Date> and <the
premises> in the first page.
7.5.7 Checklists
<Buyer's name>
(Buyer's name)
and the representative of FLS Automation A/S (the Seller) to certify that the following items:
<list of items>
During the test, the Buyer has examined each item to verify it's compliance with the agreed
specifications. The Buyer has searched for and not found any reason to refuse, and with the
exceptions notified and enclosed to this FACTORY ACCEPTANCE TEST DOCUMENT,
the Buyer accepts the tested functions of the equipment to perform properly.
After verified correction of the enclosed exceptions, the Buyer shall hereby accept the
equipment as ready for packing and shipping.
This document does not relieve the Seller from any obligation of guarantee stated in the
Sellers order confirmation above.
<Location>, <date>
___________________________ ____________________________
For the Seller For the Buyer
and the representative of FLS Automation A/S (the Seller), and shall be understood as the
commitment of any of the parties (Seller/Buyer) noticed as the responsible party to remedy
each of the exceptions observed and listed below:
<Location>, <date>
____________________________ __________________________
For the Seller For the Buyer
The document has been divided into two parts. The first part briefly describes the
placement of responsibility for data exchange. The second part consists of two sections,
describing the layout for de various exchange databases.
The data exchange is done in dBase file format, as it is the approved industrial standard.
8.1.1 Model 1
8.1.2 Model 2
8.1.3 Model 3
It will be decided during the first kick-off meeting, which model should be
used for the project.
8.2.1 Import
Two different imports can be made into EDOC depending on the information to be
imported. The two import files are EdocSiIO and EdocXTIO.
These import files can be in either Microsoft Excel format (with the extension ‘xls’) or
in Dbase format (with the extension ‘dbf’).
The first row in the files has to contain the field names and they must be spelled in the
way shown below.
8.2.2 EdocSiIO
This file can be used for importing connections between tag-signals and PLC terminals
or PLC addresses or both.
Field Required Type Size Description
Itemno X Text 18 Tagcode (with or without succeding
signalcode)
Signaltype (X) Text 6 Signalcode (required if this is not part
of the Itemno (tagcode))
PLCID X Text 7 PLC name/code
CabinetID (X) Text 12 Cabinet name/code (required if no
address is written)
RackID (X) Text 3 Rack code/number (required if no
address is written)
CardID (X) Text 4 PLC card number (slot number)
(required if no address is written)
Address (X) Text 10 PLC Address (required if no cabinet,
rack and card is written)
Subport (X) Numbe Integer PLC card terminal number (required if
r no address is written)
8.2.3 EdocXTIO
This file can be used for importing connections between X-terminals and PLC-
terminals.
Field Required Type Size Description
PLC X Text 25 PLC name/code
Cabinet X Text 12 Cabinet name/code
XRow X Text 20 X-Row name
XTerm X Text 12 X-terminal name
Rack X Text 5 Rack code/number
Card X Text 5 PLC card number (slot number)
Term X Numbe Integer PLC card terminal number
r
Address X Text 25 PLC Address
8.3 Export
Three different exports can be made from EDOC depending on the information to be
exported. The three export files are EdocSiIO, EdocSig and EdocSiTe.
These export files can be in either Delimited text format (with the extension ‘txt’ and
delimitor ‘;’) or in Dbase format (with the extension ‘dbf’).
The first row in the files contains the field names as shown below.
8.3.1 EdocSiIO
This file can be used for exporting connections between tag-signals and PLC terminals
or PLC addresses or both.
Field Type Size Description
Itemno Text 18 Tagcode
Signaltype Text 6 Signalcode
PLCID Text 7 PLC name/code
CabinetID Text 12 Cabinet name/code
RackID Text 3 Rack code/number
CardID Text 4 PLC card number (slot number)
Address Text 10 PLC Address
Subport Number Integer PLC card terminal number
8.3.2 EdocSig
This file is used for exporting information about signals with alarms.
Field Type Size Description
Itemno Text 18 Tagcode
Signaltype Text 6 Signalcode
Parent Text 18 Tagcode (same as Itemno)
Templatetype Text 20 Not used
Descript Text 22 Tag description
Purpose Text 22 Signal purpose
Subdepart Text 7 Department
IOType Text 5 Signal type (DI / DO / AI / AO / …)
IONode Text 12 Not used
Indicator Text 1 N: No indication or recording on CS
Y: Indication on CS
Recorder Text 3 No of hours to record (ie. ‘24h’) (Blank = no
recording)
ElRange Text 20 Electrical range (normally 4 to 20 mA, written:
‘4-20 mA’)
PhyRanMin Text 10 Physical range, minimum
PhyRanMax Text 10 Physical range, maximum
PhyRanUnit Text 15 Physical range, unit
AILLTime Number Double Alarm/Indication low-low - timedelay
AILLLim Text 20 Alarm/Indication low-low - limit
AILTime Number Double Alarm/Indication low – timedelay
AILLim Text 20 Alarm/Indication low – limit
AIHTime Number Double Alarm/Indication high – timedelay
AIHLim Text 20 Alarm/Indication high – limit
AIHHTime Number Double Alarm/Indication high-high – timedelay
AIHHLim Text 20 Alarm/Indication high-high – limit
RevDate Date - Date of last change
RevVer Text 2 Revision
RevInit Text 10 Initials of person making last change
8.3.3 EdocSiTe
This file is used for exporting information about signals with corresponding X-
terminals.
Field Type Size Description
Itemno Text 18 Tagcode
Signaltype Text 6 Signalcode
CTName Text 22 Cabinet name
CTGroup Text 8 X-Row
CTTeName Text 15 X-Terminal
· “A” Documents are the documentation necessary for installation, operation and
maintenance of equipment. This is typical documentation elaborated and generated
by FLSA (documentation for panels, layout of bus cabling, installation instructions,
etc), however it can also be documentation from one or more of FLSA's sub-
suppliers.
· “B” Documents are the documentation that is needed for FLS/FLSA specialists on
site. Typically this is valuable documentation from FLSA's sub-suppliers such as
repair manuals for QCX - spectrometer.
Programme documentation is normally regarded as “B” documents; FLS will accept
the program documentation in one preliminary copy for installation and
commissioning and one preliminary "electronic file" file copy.
FLSA will be in charge of copying the agreed number of copies and places every copy in
a folder with the appropriate 7.000000 no.
One folder is marked "original" and floppy disk, or CD ROM, is placed in a plastic
pocket inside the folder.
The FLS purchaser in charge will receive the agreed number of copies of each document
from FLSA.
The FLS purchaser in charge registers the documentation as received and delivers both
originals and copies of the documentation to the FLS-EE co-ordinator.
The FLS-EE co-ordinator will see to the reporting into the MCS system prior to the
forwarding of the documentation to REP for dispatch and filing of the original
document.
· FLSA shall supply the same number of copies of the documentation "B" together
with the equipment as received from the FLSA-sup-supplier. The documents shall
be packed in the original packing together with the equipment.
· Documentation "B" is not a part of the official documentation and is not registered
in FLS's introduction registration system.