TI001dc

IndustrialElectricalServices(I.E.S.)LtdRegisteredAddress:Unit2,TeybrookCentreBrookRoad,GreatTeyColchester,Essex,CO61JEPhone:+44(0)1206211222Fax:+44(0)1206211251Email:sales@iesworks.co.ukBOSKERRAKINGMACHINEFUNCTIONALDESIGNSPECIFICATIONRef:BrackettGreenTitle:RakeScreenFunctionalDesignSpecificationIESRef:ADMIN1\IES\PRODUCTS\BRACKETT\BOSKER-RAKE\MICROLOGIXPLC\TI001-DCCONTENTS1.Introduction2.SystemArchitecture2.1Overview2.2Systemconfiguration2.3Hardwarespecifications2.4Programmingmethod3.ControlPhilosophy3.1MotorControl3.2Interlocks4.PlantControl(HMI)4.1Off/Auto/Remote/Manual4.2Login/Logout4.3HomeMenuScreen4.4HoursRunScreen4.5ZoneSelectionScreen4.6LightConfigurationScreen4.7TimerConfigurationScreens4.7.1SystemTimers4.7.2AlarmTimers4.8ParameterConfigurationScreen4.9TimeClockConfigurationScreen5.HMIGeneral5.1Alarms5.2DumpPosition5.3OptionalItems6.SettingsList1.IntroductionTheFunctionalDesignSpecification(FDS)coversthedesignoftheControlSystem.TheaimoftheFDSistoprovideanunambiguousviewofhowthefinalControlSystemwilloperate.2.SystemArchitecture2.1OverviewTheControlsystemconsistsofanAllenBradleyProgrammableLogicController(PLC)andMagelisHumanmachineinterface.(HMI)2.2SystemConfigurationTheHMIislinkedtothePLCviatheRS232Serialinterface,communicatingatapproximately19200KbBaudviatheAllenBradleyDF1Protocol.ThePLCcontrolstheplantasdescribedlaterintheControlPhilosophy.TheHMIprovidesthefront-endinterfacefortheoperatorandisusedtoinitiate/monitorplantandnotifiestheoperatorofplantalarmsetc.2.3PLCHardwareSpecificationsDeviceTechnicalSpecificationsPartNumberAllenBradleyMicrologix1200PLCMemory6KWords1762-L40BWAMaxIO88CommunicationthroughOn-BoardPortDH+RS-232-CPowerSupplyUnitInputFreq47-63Hz24VdcUserPowerVoltageRange18-30VdcDiscreteInput-32ptOperatingVoltage(SourceLoad)24SinkDiscreteOutputModule–16ptOperatingVoltage24-250ac2.4ProgrammingMethodThePLCisprogrammedusingRockwellRSLogix500software(Windows95&NTbased).ThisisastandardLadderLogicprogramminglanguage.ThePLCprogramisdocumentedthroughouttoallowforeasyfollowingofthecontrolmethod.TheHMIsystemusedisCompactterminalsoftwareXBTP021010fromTelemecanique(Windows95&NTbased).3.ControlPhilosophy3.1MotorControlTheControlSystemoperatesinthreemodes,namelyAutomatic,Remote,orManual.InAutomaticandRemotemodetherakewillstartandstopautomatically.InManualmodeitispossiblefortheoperatortostart/stopmotors(open/closevalvesetc)outsideofanysequences.AutomaticandRemotemodes:Therakeisnowstartedandstoppedaccordingtotheautomaticsignals(instrumentation,timers,startandstopsequences,etc).Thestopalwayshaspriorityoverthestartsignals.InterlocksignalsstayactivateduntiltheoperatorhasacknowledgedthembymeansofaresetfromtheHMIManualmode:Themotorisnowstartedandstoppedinfunctionofthecommandsfromtheoperatorviatheremovablependant.3.2Interlocks(Alarms)Interlocksignalsstopandprotecttheequipmentagainstunsafesituations.Iftheyareactivated,theoperatormustalwaysacknowledgeaninterlocksignalbeforetheequipmentcanbere-started.Aninterlockconditionactsasastopcondition.4.PlantControlHMITheHMIsystemconsistsofasetoffunctionkeysF1toF12,astandardkeypad,andasetofcursorkeys.Theseareallusedtoperformcertaintasksandaccessthevariousscreens.Mostofthescreensrequiredtobeviewedonaday-to-daybasisareaccessedviatheF1toF12functionkeysasdescribedoneachbutton.TheKeypadandcursorkeysareusedprimarilyforadjustingparametervaluesandsettingupoftherakemachine.4.1Off/Auto/Remote/ManualThe4modespossiblewiththerakemachineareasfollows:Off,Auto,RemoteandManual.Offmode:Iftherakemachineshouldfailduetoanyalarminterlock,itautomaticallyrevertstothe‘Off’mode.Themachinewillthenrequireattentiontoplaceitbackinto‘Auto’mode.Automaticmode:InAutomaticmodetherakemachinewillrunaspertheautosequence,andwillstartonreceivingaHighdifferentialsignal,aTimeperiodsignal,oraPumpstartsignal.Inaddition,whenInAutomode,themachinewillstartusingthe‘Start’buttonontheHMI,buta‘Remote’startisnotpossible.Remotemode:InRemotemodetherakemachinewillrunaspertheautosequence,andwillstartonreceivingaHighdifferentialsignal,aTimeperiodsignal,oraPumpstartsignal.Inaddition,wheninRemotemode,aremotestartsignalcanbeappliedtostartthemachinebuttherakemachinecannotbestartedfromthe‘Start’buttonontheHMI.Manualmode:InManualmodeitispossiblefortheoperatortostart/stopmotors(open/closevalvesetc)outsideofanysequences.Manualmodeisachievedbyinsertingthependantintoitssocket.Whenthependantisremovedtherakemachinerevertsto‘Off’mode.4.2Login/LogoutTologintothesystemtheoperatorhastopushF12,‘Login/Logout’button.Iftheoperatorisnotloggedinandthemachineisnotinanautosequence(cleaning),theLoginscreenwillbedisplayedaskingforapassword.Oncethecorrectpasswordhasbeenentered,theoperatorhasaccesstotheZoneSelectscreen,Timersscreen,andParametersscreen,andoperatorhastheabilitytomodifysettingsaswellasviewingthem.Iftheoperatorisalreadyloggedin,thenpressingthiswillinstantlylogthemout.Ifthemachineisrunninganautosequenceandthelogin/logoutbuttonispressed,amessagewillbedisplayedaskingtheoperatortowaitfortheautosequencetofinish.4.3HomeMenuScreenThe‘HomeScreen’isthede