rp presentation Ünye cimento v 05.07

7/30/2019 RP Presentation NYE CIMENTO v 05.07

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PrincipleSpecial anti-friction bearings and the fact that the

machine features one movable and one

stationary roll permit the two rolls to adjust

themselves obliquely to each other during

material feeding. This means that varying gap

widths are established at the two roll ends (being

the maximum and minimum distance between

the roll shell surfaces) and different hydraulic

pressures in the two cylinders of the movable

roll. Consequently, two sensors each have to be

installed for measuring gap width and pressure.

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Roller Press on SCADA

.

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+ Bearing dist. = 0 mm

RP - Frame

Gap sensor Limit switch

Press cylinder

Fixed Bearing

Roller dist. = 10 mm fix

Gap = 10 mm

Movable Bearing

Retraction cylinder

measured by

Distance block

5

Roller Press


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Pressure acting on the rolls

The pressure inside the gap witch has vital importance for the quality of theproduct is set via the hydraulic cylinders relative to the material properties

The gap width adjusts itself as a function of the resistance to compactionoriginating from the material.

The pressure in the cylinders is measured and controlled with the controlsystem - by way of automatic re-adjustment - warranting that the pressure willneither fall below the minimum level required for the operating point nor

exceed the maximum pressure permitted for the system.

A pressure loss will occur if the gap width - being a function of materialhardness and granulometry- is reduced.

The bearing distance is measured continuously on both sides of the movableroll with two sensors. The program, stored in the controller, permanentlycalculates the difference between the two values with correct sign indication

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Components Roller Press 1 hydraulic set consists of hydraulic pump and;

2 proportional valves for pressure control, a number of solenoid valves forpressure decrease, bypass valves, valves for the retraction cylinder and valvefor pressure release in case of an emergency shut-down, 1 resistance

thermometer PT100 for monitoring of the hydraulic oil temperature in thereservoir accumulator, 1 temperature limiting switch for the hydraulic oilreservoir

2 pressure sensors for the pressure acting on the rolls

2 position sensors for the bearing distance

4 resistance thermometers PT100 for monitoring the bearing temperatures at

the rolls 2 resistance thermometers PT100 for monitoring the temperature of the gear

box bearings and 2 resistance thermometers PT100 for monitoring thetemperature of the oil gear box bearings.

2 limit switches for monitoring the permitted operating range of the roll

1 Solenoid valve for the shut-off gate and 2 Sensors for monitoring shut-offgate position

1 pump for grease lubrication of the roller bearings and

1 heating unit for the grease barrel including temperature

controller

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2 Sensors for monitoring shut-off gate position Grease lubrication system consisting of 1 Pump for of the roller

bearings, 1 heating unit for the grease barrel including temperaturecontroller, 1 heating unit for the grease pipes including temperaturecontroller and resistance thermometer PT100, 1 signalling contact for

monitoring the minimum grease flow rate behind the grease pump, 2signalling contacts (one each at the two progressive distributors) of thegrease lubrication unit for the roller bearings.

2 differential pressure monitoring of the gear oil filter

2 speed sensors for under speed monitoring of the rolls

1 Lubrication oil system with circulation pump, 1 feed pump, 1 Heaterfor oil in the reservoir ( oil tank ), 1 Stirrer within the oil reservoir ( oiltank ), 3 Solenoid valves, 4 Resistance thermometers PT100 formonitoring oil temperatures, 10 Oil flow sensors for monitoring the oilflow and 3 heating units for the oil pipes including temperature

controller and resistance thermometer PT100 1 Servo drive for feed regulating gate

1 ROLCOX control panel with control system, power supply andterminals for all external cable connections

local junction boxes for the collection of all signals at the Roller Press

1 local operating panel for the operation of the hydraulic valves inlocal mode

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The control unit isdesigned as closed

system for the Roller

Press based on thehardware platform S7-

300. The interface to

the client control

system is performedvia discrete I/O`s and a

Profibus DP - standard

interface.

Control cabinet with

ROLCOX software

The application software is stored in the micromemory card of the CPU. The micro memory

card is plugged-in in the CPU unit and shall

not be removed.

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Local operation box

Local operation box for the operationof the Roller Press hydraulic system inLOCAL mode during trouble-shooting and maintenance activities,

consisting of: 4 push buttons for manual control of

the hydraulic pressures at the movableroll

1 push button with signal lamp foralarm acknowledgement. The signallamp is energized at specific,unacknowledged alarms.

1 mushroom push button foremergency stop

4 digital indicators for indication thehydraulic pressures and the bearingdistances at the left and the right sideof the roller press.

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Control unit The control unit is designed to control the following drives of the

Roller Press:

2 Roller drives 2 Gear oil pumps

1 Grease barrel pump

1 Hydraulic pump

2 Proportional valves for pressure control of the hydraulic system 1 Solenoid valve for emergency shut-down

2 Solenoid valves for pressure decrease

2 Solenoid valves ( bypass valves for pressure release )

1 Solenoid valve for moving the two rolls apart by the help of theretraction cylinder

1 Servo drive for the feed regulating gate

1 magnetic valve for the pre-bin shut-off gate

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5312HD1.V 3/4 Prop. valve right

5312HD1. V 1/2 Prop. valve left

5312HD1 V 08 Emergency valve

5312HD1.V 05 Pressure decrease valve left

5312HD1.V 06 Pressure decrease valve right

5312HD1.V 07 Retraction cylinder valve

5312HD1.M01 Hydraulic pump

5312HD1.V 10 Bypass valve right

5312HD1.V 09 Bypass valve left

Left Right

Retraction cylinder

Fixed Roller

Retract. cylinder

Hydraulic oil tank

Movable Roller

Press cylinder

V 08

V 07

Pump 5312.HD1

V 10V 09

V 05 V 06

V 1/2 V 3/4V 10

V 09

V 08

M01

V 07

V 06

V 05

V 1/2

V 3/4

Hydraulic system of the

roller press

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HYDRAULIC SYSTEM13

Hydraulic set consists of :

1 hydraulic pump, 2 proportionalvalves for pressure control, anumber of solenoid valves for

pressure decrease, bypassvalves, valves for the retractioncylinder and valve for pressurerelease in case of an emergency

shut-down, 1 resistancethermometer PT100 formonitoring of the hydraulic oiltemperature in the reservoiraccumulator, 1 temperature

limiting switch for the hydraulicoil reservoir


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Hydraulic control equipment of the roller press

5312HD1.V 3/4 Prop. valve right

5312HD1. V 1/2 Prop. valve left 5312HD1.V 05 Pressure decrease valve left

5312HD1.V 06 Pressure decrease valve right

5312HD1.H01 Tank heater

5312HD1.T02

Temperature measurement

T > 70 C RP STOP with ALARM

T > 50 C Alarm

T < 20 C Heating OFF

T < 15 C Heating ON

5312HD1.T01 Tank temperature > 40C

5312HD1.V07 For valve retraction cylinder5312HD1.L01 Tank level

5312HD1.M01 Hydraulic pump

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Hydraulic layout:15

Fixed value: 50 C for Hydraulic oil temperature (warning) Fixed value: 70 C for Hydraulic oil temperature (fault, group Roller

Press STOP)

If the temperature exceeds the above fixed value, the roller press is

stopped with an alarm.


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Oil circulating lubrication ( Woerner)

The pump station includes the oil tank divided in twosections with a heating device and an external mountedoil circulation pump

The heating device, temperature safety switch, PT100temperature detectors,

and oil filling level meters, a duplex filter is installed on the pressure side of the

circulation pump,

oil-to-water heat exchanger,

the delivery pipe is routed over two distributingbranches leading to the rollers,

bypass valves controlled by PT100 resistors.

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5312LQ5. M01 Feed Pump 5312LQ55 M01Oil Circulation

pump Pump

5312LQ4.P02Filter with

pressure switch

Oil level indication

Tank T1

L > Max 3

L > Max 2 (Early morning)

L < Min Pump LQ4.M01 OFF

5312LQ5.T03Oil return

temperature

Oil level indication

Tank T 2L < Min Pump LQ5.M01 OFF

5312LQ4.P02 Filter

5312MX1.M01 Mixer

Terminal box Oil re/filling pipe

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OIL LUBRICATION SYSTEM

Site view of the oil reservoir

5312LQ5.T02 Tank oil temperature

5312LQ5.T01Heating with oil

temperature controller

5312LQ5.T03

Oil return line with

temperature

measurement

Roller press bearing lubrication

Bypass-Valve

5312LQ5.V01

Oil circulation pump

5312LQ4.M01

5312MX1.M01 Stirrer motor

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Longitudinal / radial oil lubrication of

Roller Press bearings Behind the heat exchanger, the delivery oil

pipe is routed over two distributing branchesto the bearing lubrication points of themovable and the fixed roll. The bypassvalves 3212LQ5.V02 and V03 located at theends of the distributing branches are openedduring the heating up phase. As soon as theoil temperature in the pipeline reaches a limitvalue (approx. 40C) - measured with thePT100 resistor directly in front of thedistributing branches at the roller press. Both

bypass valves 3212LQ5.V02 and V03 areclosed thereby clearing the way for the oil tothe different bearing lubrication points.

As soon as the oil temperature in front of thebearing decrease below 10C, both bypass

valves will open and after approx. 15 min.the roller press group will be stopped.

All pipelines branched to these locationshave been equipped with flow governors;their flow switches are used for monitoring.

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Oil Lubrication governors for Longitudinal bearingAdjusted for 3,75 l/minMeasuring range 0 10 l/min

Oil Lubrication governor for radial bearingAdjusted for 1,5 l/minMeasuring range 0 5 l/min

1 Flow NOK max 3 ours, 2 Flows NOK max 15 min, then stop Roller Press


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Roller Press bearings20

Bearing- Oil-

Flow- Meters

Oil Lubrication governors for LongitudinalbearingsAdjusted for 3,75 l/minMeasuring range 0 10 l/min

Oil Lubrication governor for radial bearingsAdjusted for 1,5 l/minMeasuring range 0 5 l/min


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Roller Press bearings21

Bypass valve LQ5.V02

Oil return line

PT100 in one ofthe oil lubrication

lines for bearinglubrication


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Grease lubrication for roller bearings

The grease lubrication consists of a grease tankwith grease pump and two progressivedistributors each mounted on the left- andright-hand side of the roller press. Greaseconveying of the pump is monitored by apressure switch. In case of a failure an alarm iscreated. In addition, each progressivedistributor has been provided with a switchwhich is operated at each stroke of the pistonof the progressive distributor at the cycle ofgrease distribution.

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Grease lubrication barrel with pump

In order to guarantee a sufficient greasesupply to the roller bearings, the signalsfrom the pressure switch and the

progressive distributors are analyzed.

Level switch at grease barrel

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Monitoring of the bearing lubrication

The required amount of grease is determined by the amount of pulses sentfrom the progressive distributors. A preset difference (40 pulses) of both

pulse rates shall not be exceeded.

If the pulses are not reached within one hour, the pulse difference (8)

exceeds the permissible limit or no pressure signal is monitored within 180sec after pump start, an alarm is generated

The remaining operating time for the Roller Press is now reduced to 2hours.

Occurred another grease lubrication fault after the next hour of operation,

the remaining operating time is now reduced to 1 hour. After 3 hours of continuous alarms the Roller Press will be shut-down

(normal stop). The indication of the remaining operating time will betemporarily set to "0".

The highest fault memory will be reset in case the fist hour of operation

ends without fault. The indication of the remaining operating time will beincreased by 1 hour. With undisturbed grease distribution system aremaining operating time of 3 hours will be indicated

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Bearing distance measurement

The bearing distance is measured at theleft- and right-hand side of themovable roll. Since the distance

between the roll surfaces insidethe gap cannot be measureddirectly, the distance between thehousings of fixed and movable

bearing is used as a measure.

The sensors are inductive positionsensors with integratedtransducers.

The transducer is of a four-wiretype. The measuring range is

0 -100mm.

The output signal is 4 ... 20 mA.

In case of wire breakage, a fault signalis generated and the roller press

group will be stopped.

Bearing distance MAX switch

Bearing distance measurement

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Pressure measuring The pressure is measured with

one pressure sensor each on theleft- and right-hand side of the

movable roll. The correspondingtransducer is of a two-wire type.

The measuring range is 0 ... 400bar, the output signal 4 ... 20 mA.

Sensor and transducer areaccommodated in one housing.

In case of wire breakage a faultsignal is generated and the roller

press group will be stopped.

Pressure transmitter

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Temperature measuring The roller bearing temperatures

and the gear box bearingtemperatures are measured at

every test point with oneresistance thermometer PT100each. These thermometers have

been connected in three-wiretechnique to the temperature

transducer. The transducer is of atwo-wire type. The measuringrange is 20 +100 degC, theoutput signal is 4 ... 20 mA.

In case of wire breakage a faultsignal is generated and the rollerpress group will be stoppedimmediately.

Temperature PT100 sensorof one bearing measurement

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Pre-bin level measurement and Shut-Off Gate control

The Roller Press requires alwayssufficient material between andabove the rolls. This is achieved byswitching-on the pre-bin shut-offgate control.

This function can be switched on oroff via switching template atSCADA

During operation and de-activatedpre-bin shut-off gate control theshut-off gate will open when the

bin level exceeds the set maximumlimit, e.g. 50% and stays open evenwhen the bin level drops below theset minimum limit. The gate closesonly at stop of the Roller Press.

During operation and activated pre-bin shut-off gate control will openthe shut-off gate when the bin levelexceeds the set maximum limit,e.g. 50% and closes when the pre-

bin level drops below the set

minimum limit, e.g. 5%

Pre- bin level transmitter

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Pre-bin shut-off gate


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Pre-Bin - Shut-Off - Gate control

During operation and activated pre-bin shut-off gate control theshut-off gate will open when the bin level exceeds the setmaximum limit, e.g. 50% and closes when the pre-bin level drops

below the set minimum limit, e.g. 5%. Exceeds the pre-bin levelagain the maximum limit the gate will be opened again.

The pressure control function is not active and the movable rollwill be positioned to limit L2 at closed shut-off gate. This willlimit the amount of uncrushed material passing the Roller Presswhen the gate opens. The pressure control is activated again when

the gate is open. When the shut-off gate closes the pressure reducing valves are

energized and the gap increases. This procedure continues until themovable roll reaches the limit L3 at any side or the delay time (10sec) is elapsed.

Then, the movable roll is moved back to the start position L2. Themovable roll is now parallel the stationary roll and ready for thenext start.

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Control of the feed

regulating gate

The purpose of the feed regulating

gate is the adjustment of thematerial flow to the Roller Press.

The positioning is done in

AUTOMATIC MODE by setting a

position set point at SCADA and

in LOCAL MODE with thecontrol switch

At shut-down of the Roller Press

the feed regulating gate is moved

to a start set point pre-defined in

ROLCOX (e.g. 20%). The feedregulating gate opens to the

position set at SCADA after start

of the material feeding.

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min. Pos.

open

close

Dosing

Gate in

Movable

Roller

Fixed

Roller

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RP - Bin

Slide Gate.

max. Pos.

Dosing

Gate

Start Roller Press


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Start Group Roller Press Following conditions must be considered in the client control system:

No failures causing a pre-alarm or a stop.

The signal MATERIAL DISCHARGE ON must be present.

Pressure control functions must be switched ON in order to allow a

complete start of the Roller Press with its start-up procedure. Upon every start of the group Roller Press, a startprogram BCON is

started.

At first, the solenoid valve for emergency off(V08) will be energized(the valve is fail open) and the hydraulic system closed. The pressurereducing valves (V05 and V06) will be energized (opened) and theRoller drives started. The pressure reducing valves will be closed timedelayed or when any bearing distance has reached the limit L3.

If the bearing distances are >L2 after the start-up time, the pressureincrease valves and the hydraulic pump will be energized and the

movable roll will be positioned to the limit L2. In case the pressure exceeds the limit 40barthe group start will be

terminated with an alarm message.

After some delay time the feed belt will be started, the material feed isreleased and the pressure control function is activated.

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Start Group Roller Press33


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RP Trouble, trip,

Group off, automatic

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SCADA35RP Trouble, trip, Fast stop automatic


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36RP Trouble, trip, Loop alarm

Start RP group


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MovbleRoller

V 09

V 07

Hydraulic oil tank

Pump 5312.HD1

Press cylinder

Af ter reaching of L2 + 10 mm, the main dr ives wi ll be

started one by one.

Start RP group

At every start the emergency

valve V08 is energizedto close the hydraulic circuit.

The movable roller will be moved

by the retraction cylindersto L2 + 10 mm = 45 mm

To release the oil of the maincylinders the bypass valves(V09 and V10) and the

pressure decrease valves areenergized (opened).

This will occur with standingrollers.

V 06V 06 V 07V 07V 08

Movable

Roller

Left

Fixed

Roller Right

Gap = 45 mm

L min

L2

+ 10 mm

V 11

V 3/4

V 10

V 1/2

V 05

V 06V 06 V 07V 07

V 3/4V 1/2

V 07V 07V 07V 10V 06V 06V 06V 09

V 06

Valve closed

Valve open

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Bearing distance Lmin, (L2, L3)

Lmin= 1.0 ... 12.0 mm

minimum limit for a gapreduction at activatedpressure control function.

The control system stopsany pressure increase

when the bearing distancedrops below this limit.

A limit violation is notshown as fault alarm. Theinput has to be madecarefully to avoidincorrect function of the

pressure control system.

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Bearing distance L2, L3 L2= 5.0 ... 30.0 mm

At the start of both rollerdrives start of the roller pressgroup, the start programBCON is activated. Herebythe movable roll as opposed to

the fixed roll is moved to L2with running roller drives.

After stopping the feed beltthe movable roll will be

positioned again to this value.

A limit violation is notsignalized as fault alarm.

L3= 5.0 ... 20.0 mm

With activated pressurecontrol system, the sum fromBEARING DISTANCE L2 +BEARING DISTANCEL2increase = L3 serves as

maximum limit for a bearingdistance increase duringoperation.

Any pressure relief measureswill be stopped when the

bearing distance reaches this

limit.

The sum of L3= (L2 + L2incr.) must never exceed the maximum travel

range of the hydraulic pistons.

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V 08

Start RP group

Retraction cylinders are drawn back by springs.

After L2 will be reached - the shut off Gate will be openedto release material flow to the rollers.

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L2 Gap = 35 mm

In case if during moving back the movable roller an oil pressureis measured of more than 40 bar ( normal < 40 bar ), the start willbe interrupted by an alarm signal.Fault has to be acknowledged at the roller press after checking.

Possible causes:Material between the rollers.

Disturbance in the hydraulic circuit.Roller can not move free.

After bearing distance is on both sides L2 the roller press group willbe released and feeding of the pre bin can be started.

MovbleRoller

V 09

Press cylinder

V 06V 06 V 07V 07V 07

Movable

Roller

Left

Fixed

Roller Right

Gap = 45 mm

V 10

V 3/4V 1/2

V 07V 07V 07V 07V 06V 06V 06V 06

V 11

Af ter th is the movable roller wil l be pushed back to

L2 by the main cylinders from 45 mm to 35 mm.

This happens with running rollers.

V 07

V 06V 09 V 07V 10

V 06V 05

V 1/2 V 3/4V 1/2 V 3/4

Gap = 35 mm

Pump stops and valves will be closed.

Hydraulic oil tank

Pump 5312.HD1


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V 3/4V 1/2 V 3/4V 1/2

V 08

V 07

V 10V 09

Press cylinder

Left RightFixed Roller

The proportional valves will increasepressure to the main cylinders upuntil the set point. Hydraulic pump

start.

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Start Pressure control

After the start program is readythe pressure control will start

automatically.

After opening of the shut off gate therewill get material between the rollers.

Movable Roller

V 06V 05

Hydraulic oil tank

Pump 5312.HD1


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Pressure control

By the intake behaviour of therunning rollers combined with thepressure of the column ( gap )of material on the rollers the materialflow will tend to press the rollers

apart.

V 3/4V 1/2

V 07

V 08 V 10V 09

Left Right

Press cylinder

Movable Roller

Fixed Roller

When the hydraulic reaches thevalue set point-tolerancethe proportional valves will be

closed and the pump will stop.

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Pres.Set point

At this value the material counterpressure and the cylinder pressurewill be on balance.

- 10 bar

+ 10 bar

V 1/2 V 3/4

V 06V 05

Hydraulic oil tank

Pump 5312.HD1

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Accumulator

Gas ( N2 ) Pressure = 90 bar100 bar

135 bar

125 bar

115 bar

Set point 125 bar

Hydraulic oil tank

V 3/4V 1/2

V 07

Pump 3212HD1.M01

V 08 V 10V 09

Left RightFixed Roller

Press cylinder

Movable Roller

90

bar

Start up

< 90 bar

Pressure control

Pressure variations with intolerance will be compensatedby the N2 accumulators.

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V 1/2 V 3/4

100

bar

V 06V 05

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Pressure control

When the hydraulic gets beneath the pressure (value)

set point tolerance the proportional valves will beopened and the pump will start.

V 3/4V 1/2

V 07

Hydraulic oil tank

Pump 28 HD 41 M 01

V 08 V 10V 09

Fixed Roller

Left Right

Press cylinder

Movable Roller

44

This will remain so until set point operation pressure tolerance

has been reached.After this the valves will close again and pump will stopped.

In this example on one side.

135 bar

125 bar

115 bar

Characteristics proportional valves.

100

%

100

%

12 m Amp

0 %

4 m Amp

Proportion valve

pressureincrease

20 m Amp

Proportion valve

pressuredecrease

80 %

80 %

18,4 m Amp

V 3/4

V 06V 05

Proportional valves


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Proportional valves

The proportional valves act in two flow directions

which are activated by two solenoids:a) Pressure increase: Analogue PLC output:

12 - 20mA corresponding to 0 - 100%opening

b) Pressure decrease: Analogue PLC output

12 - 4mA corresponding to 0 - 100% openingThe neutral position (both ways closed is

determined at I = 12mA ).The activation of the solenoids is organised via

valve amplifier installed on top of theproportional valve.

V 3/4V 1/2

V 07

Hydraulic oil tank

Pump 28 HD 41 M 01

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Characteristics proportional valves.

100

%

100

%

12 m Amp

0 %

4 m Amp

Proportion valve

pressure

increase

20 m Amp

Proportion valve

pressuredecrease

80 %

80 %

18,4 m Amp

V 3/4

Set points

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This is the point where the bearing distance is 0.For the gap measuring this point is 4 m Amp.

The bearing blocks are fixed in a way that therollers can never touch each other physically

Fixed Roller

Movable Roller

Left Right

Distance pieces

Movble

Roller

Fixed Roller

Left Right

Distance between the bearings used as lowerlimit for the pressure control.If distance is less pressure control will bedeactivated.

Roller distance 10 mm = Gap 10 mm

Roller distance 10 mm

+ Bearing dist. 15 mm

-----------------------------

= Gap 25 mm

Gap = 10 mm

Set points

0 mm ( Bearing distance )L 0mm

GAP > L min Pressure contro l ON

normal operation

L min 15 mm ( Bearing distance )

Movable Roller

GAP < L min Pressure contro l OFFGap = 25 mm

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LOCAL CONTROL PANEL:

One push button with signallamp is used foracknowledgement of alarms

which require a visualinspection at the Roller Pressfor the reason of followingalarms:

Pressure >40bar during start

programme (BCON) Pressure >180bar during

operation

Movable roll end limitposition has been reached

Under speed monitoring After local acknowledgement

these alarms have to beacknowledged at the SCADAtoo!

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Start program BCON (RP GROUP = START)

With the group Roller Pressstart command both pressuredecrease valves are energizedto allow the movable roll tomove backwards. This isimportant after a restartfollowing an emergency stopwith uncrushed material

above the rolls. Is the bearing distance left or

right


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Start program BCON Program Step 1 and 2

BCON Program Step 1

If the bearing distance left or right is

L3 or after a delay time the start ofthe roller drives in parallel mode orsequential mode is performed.

BCON Program Step 2

The movable roll will be movedtowards the fixed roll byenergizing both pressure increasevalves, when both roller drivesare in operation and the run-uptime is elapsed. Both pressureincrease valves are to becontrolled independently.

Exceeds any hydraulic pressurethe limit 40bar the group startsequence will be stopped withalarm.

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Start program BCON Program Step 3

BCON Program Step 3

The program BCON stops and theshut-off gate opens when the binlevel reaches the maximum limitset at SCADA, e.g. 50% and the

pressure control function isactivated in case the operationmode "AUTOMATIC" isselected.

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The delayed energising of pressure reducing valves takes place when the

shut-off gate is closed. This causes the movable roll to move apart from the

fixed roll. This action is terminated when the bearing distance has reachedthe limit L3 or latest after 5 sec.

Now, the movable roll will be positioned to the limit L2 (start position)

using the pressure increase valves.

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L min

Movable

Roller

Fixed

RollerLeft Right

Gap = 35 mm

Movable

Roller

Fixed

RollerLeft Right

Gap = 45 mm

L2Parameter set in the PLC. Set only once.

Range from 5.0 to 30.0 mm

Actual set point 20 mm

( Set point for material feeding )


p

L min

+ L2 + 10 Bearing dist. 30 mm

51

= Gap 30 mm

+ L2 Bearing dist. 20 mm

L2+ 10 mmUntil this value the rollers are pushed back

by retraction cylinders

during start up the main motors.

= Gap 40 mm


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Movable

Fixed

RollerLeft Right

Gap = 65 mm maximum


+ Bearing dist. > 50 mm

= Gap > 60 mm

Limit switchMaximum distance allowed

between the bearings. ( 65 mm Gap )

Determined by a mechanical switch.Over 65 mm gap the roller press will

stop with max. gap alarm.

Set points52

Normal operation

Movable

Roller

L2

L min

+ 10 mm

Movable

RollerMovable

Roller

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Normal Stop of the group Roller Press

This command starts the shut-down procedure with:

- stopping of the feed belt, - the pressure reduction by opening of the pressure reducing valves

until the limit L3 has been reached or for max. 5sec,

- the run-off of the roller drives for 1min.

This procedure can be released by:

STOP command from SCADA

Drive fault

Instrument loop fault

Over temperature roller bearings

Over temperature gear box bearings Over temperature hydraulic oil

Disturbance BCON

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Fast stop of the group Roller Press

This command stops the group Roller Press immediately

- stopping the feed belt,

- Stop of the roller drives and all other drives of the Roller Press, - de-energising of the hydraulic valves.

This procedure can be released by:

EMERGENCY STOP command from the local control panel

Loss of control voltage

Activation of the movable roll end position

Hydraulic pressure >180bar

Under speed monitoring of any roll

Fault of any roller drive

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Group Aux. Heater = Start / Stop The commands Start/Stop and LOCAL are sent from SCADA to the

ROLCOX system. This signal starts the heating system for the

grease pipe and oil pipes. The heating units are self-controlling.

No temperature control is required in ROLCOX.

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3212LQ5.H01 3212LQ5.H02 3212LQ5.H03

Current control56


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By means of to much adjusting ofoperationpressure or due to changing materialproperties the electr ical load of the maindrives can become to high.If this load exceeds a preset maximum thepressure will be reduced.

V 07

Hydraulic oil tank

Pump 28 HD 41 M 01

V 08 V 10V 09

Left Right

Fixed Roller

After this the pressure control will be reactivated.

V 1/2V 1/2 V 3/4V 3/4

This will last until the movable roller reachesL2 + 10 mm = 45 mm gapor until the drives get below operation load.

Press cylinder

Movable Roller

V 11V 06V 10V 05

RP Group stop

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V 10V 11

The Pressure decrease valves will

open, the proportional valves willopen,and the emergency valve willopen.

Hydraulic oil tank

Pump 28 HD 41 M 01

Left RightFix Roller

Press cylinder

Movble

Roller

Fixed Roller

Movable Roller

V 07

V 09 V 10V 09

V 1/2V 1/2 V 3/4

V 08

The rollers will due to material pressure move apartuntil L2 is reached on both sides or after time limit.Roller press will stop after 60 sec.

At a stop of the roller press (desiredor undesired) the RP - slide gate willclose and stopped the material feedto the RP.

The Pressure decrease valves willclose, the proportional valves willclose, and the emergency valve willopen.

V 06

V 3/4

V 10V 05

ROLCOX Parameters58


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SCADA59


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SCADA59

OPERATION CURRENT

Adjusting range:

70 ... 90% of the nominal current In

EXCESS CURRENT

Adjusting range:


This value corresponds to the upper

limit of the standard operating

current. As soon as that value isreached, the overload pressure

reliefing measure is terminated.

This value corresponds to the upper limit

of the standard operating current. As

soon as that value is reached, the

overload pressure reliefing measure isterminated.

CURRENT DIFFERENCE

Adjusting range:


In case the current difference

between the drives exceeds the set

limit, an alarm will be generated

without further consequences for the

operation of the Roller press.

SCADA60


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SCADA60

With activated gap-dependent pressurecontrol, the SETPOINT PRESSURE islimited to the sum ofOPERATINGPRESSURE + PRESSUREINCREASE MAX. An internal pressure

limit (150 bar) cannot be exceeded!

OP.PRESSURE INCREASE MAX,

10-99bar

With activated gap-dependent pressurecontrol, the SETPOINT PRESSURE islimited to the sum ofOPERATING

PRESSURE + PRESSUREINCREASE MAX. An internal

pressure limit (150 bar) cannot beexceeded!


10-99bar

With activated gap-dependent pressure

control, the SETPOINT PRESSURE islimited to the sum ofOPERATINGPRESSURE + PRESSUREINCREASE MAX. An internal

pressure limit (150 bar) cannot beexceeded!


10-99bar

SCADA60


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SCADA

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rp presentation Ünye cimento v 05.07

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