8164-9001-600_c7_booster_en

Business UnitMechanical Separation Technology

Westfalia SeparatorMineraloil Systems GmbH

Instruction manual

No. 8164-9001-600

Edition 0501

Control Unit for Visco Booster Plants

Type C7-623

FEED SLUDGE HEATERRELEAS

ALARMSDOWN UP

SIMATIC C7-623

987

6F

5E

4D

3C

2B

1A

0.

ESC

ACKHARDCOPY

ENTER

SHIFT

HELP

INSDEL

DIRSFBAF FRCE

DC5VSTOPRUN

MDO HFO Feederpump 1

Feederpump 2

Circul.pump 1

Circul.pump 2

Autom.filter

Vicosityalarm

VentilateManual Filtercleaning

LALtank

LAHtank

Lamptest

Westfalia SeparatorMineraloil Systems GmbH III

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Subject to technical modifications!

Westfalia SeparatorIV Mineraloil Systems GmbH

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For your safety

• Strictly adhere to instructions marked with this symbol.This avoids damage or destruction of pumps or of other units.

• Take special care when carrying out operations markedwith this symbol -otherwise, danger to life!

• Observe accident prevention regulations.The local safety and accident prevention regulations apply un-conditionally to the operation of the Visco Booster unit.

• When operating electrical apparatus, certain parts carrydangerously high voltage.Non-compliance with the protective measures can thereforeresult in serious injury or damage.For this reason, only suitably qualified specialists are allowedto work on these units.Protective measures should be taken in line with national andlocal regulations.

• Instruction manualsFollow the instructions given in this manual and in the ViscoBooster unit manual.Proper and safe operation is conditional on appropriate trans-port and storage conditions, correct installation and assemblyas well as careful operation and maintenance.

• Operate the Visco Booster plant only in accordance withagreed process and operating parameters.

• Maintain the Visco Booster plantas specified in the instruction manual of the Visco Boosterplant.

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• Carry out safety checks on the Visco Booster plantas described in the chapter "Safety" in the Visco Booster plantinstruction manual.

• Liability for the function of the unit passes to the owner.Liability for the function of the unit passes unconditionally to theowner or operator irrespective of existing warranty periods inso far as the unit is improperly maintained or serviced by per-sons other than Westfalia Separator Service personnel, or ifthe unit is not applied in accordance with the intended use.Westfalia Separator AG shall not be liable for damage, whichoccurs as a result of non-compliance with the above. Warrantyand liability conditions in the General Conditions of Sale andDelivery of Westfalia Separator AG are not extended by theabove.

Westfalia SeparatorVI Mineraloil Systems GmbH

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PrefaceThis instruction manual is intended for the persons entrusted with opera-tion and maintenance of the control unit. To assure safe operation it istherefore essential that the manual is indeed handed over to these per-sons.In the event of any queries please state the model designation and theserial no. (see name-plate inside the control unit).When ordering spare parts, it aids the rapid and correct processing ofyour order if you also state the circuit diagram number specified.

Name-plate

Mechanical SeparationDivision


TypeType ............................................................................................

Prüf-Nr.Control No. ............................................................................................

BemessungsspannungNominal voltage ......... V, 3/AC ................. Hz

Control voltageControl voltage .............. VAC .............. Hz .............. VDC

VollaststromFull-load current ................... A

Bemessungsstrom(größter Motor/Verbraucher)Nominal current(largest motor/consumer)

................... A

Kurzschlußausschaltvermögen IcnShort-circuit breaking capacity ................. kA

Schaltplan-Nr.Wiring diagram No. .........................................................................

Programm-Nr.Program No. .........................................................................

Teil-Nr.Part No. .........................................................................

A company of mg technologies group

Installations- und Schutzmaßnahmen sind nach den Bestimmungen des VDEbzw. des zuständigen EVU auszuführen.Installation and protective measures are to be taken in accordance with nationaland local electric rules and regulations.

Westfalia SeparatorMineraloil Systems GmbH VII

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1 General 1

1.1 Application and operating principles ........................................................21.2 Equipment ................................................................................................21.3 Control cabinet .........................................................................................3

2 Control system 5

2.1 Construction .............................................................................................92.2 Classification specifications .....................................................................92.3 Design versions ........................................................................................102.4 Mounting ................................................................................................112.5 Control unit...............................................................................................112.6 Electrical connection ..............................................................................122.7 Fuse terminals........................................................................................122.8 Installing the control unit in the control cabinet......................................132.9 Loosening the fixing bracket ..................................................................16

3 Control unit 17

3.1 Technical data........................................................................................183.2 Getting acquainted with the operating elements....................................193.2.1 Function keys .........................................................................................203.2.2 Softkeys .................................................................................................233.2.3 System keyboard ...................................................................................243.3 Overview of display pages .....................................................................273.4 Selecting operating modes ....................................................................293.4.1 Calling up the system function menu.....................................................293.4.2 Calling up the system function menu.....................................................303.4.3 Exiting the system function menu ..........................................................313.5 Password protection...............................................................................323.5.1 Enter password ......................................................................................323.6 The start screen .....................................................................................333.6.1 Interfaces ...............................................................................................34

4 Operation 37

4.1 Switching on the control unit ..................................................................384.2 Start screen............................................................................................394.3 Calling up the process text pages.........................................................404.4 Detail settings.........................................................................................474.4.1 Fuel selection .........................................................................................474.4.2 Feed pumps ...........................................................................................494.4.3 Automatic filter .......................................................................................514.4.4 Mixing / degassing tank ........................................................................544.4.5 Circulation pumps ..................................................................................564.4.6 Viscosity measuring ...............................................................................584.5 Calling up digital inputs ..........................................................................60

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4.6 Calling up digital outputs ........................................................................624.7 Calling up analog inputs.........................................................................634.8 Calling up analog outputs ......................................................................634.9 Calling up service addresses .................................................................644.9.1 Calling up the system settings ..............................................................664.10 Loading a new program ........................................................................694.10.1 The UD 700............................................................................................694.10.2 Loading data from the UD 700 to the C7-623........................................704.10.3 Text transfer OP part..............................................................................744.10.4 Loading configured data from the programming device

into the UD700 .......................................................................................76

5 Commissioning 81

5.1 How to proceed on the control cabinet ..................................................825.1.1 Product selection "MDO“........................................................................825.1.2 Product selection "HFO“ ........................................................................835.1.3 Feed pumps ...........................................................................................835.1.4 Circulation pumps ..................................................................................855.1.5 Manual operation ...................................................................................87

6 Fault signals / Maintenance 89

6.1 Fault signals ...........................................................................................906.1.1 Status and fault indication.....................................................................906.2 Alarm descriptions..................................................................................916.2.1 Feed pumps ...........................................................................................916.2.2 DPSH Automatic filter (input 32.2) .........................................................936.2.3 LAL mixing tank (input 32.3) ..................................................................956.2.4 Motor protection switch of circulation pump 1........................................976.2.5 Circulation pump 1 .................................................................................996.2.6 Motor protection switch of circulation pump 2......................................1006.2.7 Circulation pump 2 ...............................................................................1026.2.8 PSL Circulation pumps (input 32.5) .....................................................1036.2.9 End position error "MDO“.....................................................................1056.2.10 End position error "HFO“......................................................................1076.2.11 Motor adjustment valve........................................................................1096.2.12 Motor protection switch of feed pump 1...............................................1106.2.13 Feed pump 1 ........................................................................................1126.2.14 Motor protection switch of feed pump 2...............................................1136.2.15 Feed pump 2 ........................................................................................1156.2.16 PSL Feed pumps (input 32.0) ..............................................................1166.2.17 Product selection "MDO“ or "HFO“ ......................................................1186.2.18 Bypass filter - input 32.1.......................................................................1206.2.19 Viscosity below limit .............................................................................1216.2.20 Viscosity above limit.............................................................................1246.2.21 Temperature below limit.......................................................................1276.2.22 Temperature above limit ......................................................................1296.2.23 Delay time ............................................................................................1316.2.24 Circulation pumps ................................................................................1326.2.25 Level switch / mixing tank ....................................................................1346.2.26 Mixing tank is not filled .........................................................................1356.2.27 Automatic filter .....................................................................................1376.2.28 Power-supply monitoring......................................................................139

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6.3 Causes and action ...............................................................................1416.3.1 Control unit ...........................................................................................1416.4 Maintenance.........................................................................................1436.4.1 Storing batteries ...................................................................................1436.4.2 Changing the battery............................................................................143

Westfalia SeparatorX Mineraloil Systems GmbH

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NoteNotes

NotizenAnotaciones

NotizenNotesNote

Westfalia SeparatorMineraloil Systems GmbH 1

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1 General

1.1 Application and operating principles ........................................................21.2 Equipment ................................................................................................21.3 Control cabinet .........................................................................................3

Westfalia Separator2 Mineraloil Systems GmbH

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1.1 Application and op-erating principles

Proper functioning of diesel engines operating aboard ships or in power stationsrequires perfect fuel supply.This vital task is performed by the new Visco Booster plants developed byWestfalia Separator Mineraloil Systems for fuel conditioning.This is a processing system meeting the quality requirements for the fuel be-tween clean oil tank and injection system of main drive engine and auxiliaryengine with regard to injection viscosity and temperature. Booster pumps spe-cially designed for this application ensure the required system pressure.

The modules are adapted to the individual consumption behaviour of the motorsdepending on their capacity and to the required injection viscosities (approx. 10- 24 cSt) and injection temperatures (approx. 135 - 150 °C).

The common control cabinet with redundant inputs assures optimum availabilityof the plant and extremely low installation demand. A powerful PLC systemwith optional bus technology allows optimum process control and supervision.

The components of the primary and secondary stages are controlled andmonitored by the electronic control unit C7-623/P.

Abnormal conditions occurring in the plant are memorised in the control unit andcan be retrieved or, optionally, printed at any time.

Software allocation to the corresponding Visco Booster plant is done at thefactory, using a password-protected function.Detailed information on the specific functions can be found in the correspondingsections of this instruction manual.

The illuminated LC display provides information on the functional conditions ortroubles prevailing in the Visco Booster plant and - depending on program ad-justment - visualises the corresponding process data.

1.2 Equipment Beside the control cabinet, the control system comprises all component assem-blies which, due to built-in electrically actuated equipment, are subject to thecontrol or supervision by the control unit.

These include:• the product feed valve, automatically closed, or• the product feed pump provided on site, automatically shut down• the "MDO“ or "HFO“ fuel selection• the duplex filter• the redundant feed pump system with pressure monitoring• the automatic backflush filter with differential pressure / position monitoring• the level switches of the mixing vessel• the degassing valve of the mixing vessel• the redundant circulation pump system with pressure monitoring• the heating-rate control• the interlocking with the viscosity metering device


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1.3 Control cabinet

The control unit C7-623 is incorporated in the door of the control cabinet, readyfor connection

A project-related view is found in the electro-technical documentation.

Fig. 1


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NoteNotes

NotizenAnotaciones

NotizenNotesNote


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2 Control system

2.1 Construction .............................................................................................92.2 Classification specifications .....................................................................92.3 Design versions......................................................................................102.4 Mounting ................................................................................................112.5 Control unit .............................................................................................112.6 Electrical connection ..............................................................................122.7 Fuse terminals........................................................................................122.8 Installing the control unit in the control cabinet......................................132.9 Loosening the fixing bracket ..................................................................16


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2

11

10

3

4

6

5

9

1

7

8

12

13

14

15

16

Fig. 2 - Front view of the C7-623 control unit

1 Selection local - remote2 Viscosens / viscosity regulator3 Feed pump 2 – Stand-by - 0 - Automatic4 Feed pump 2 – Stand-by - 0 - Automatic5 Circulation pump 2 – Hand 0-16 Feed pump 2 – Hand 0-17 HFO operation8 MDO operation9 Main switch mains 2

10 Main switch mains 111 Lock12 Circulation pump 1 – Hand 0-113 Feed pump 1 – Hand 0-114 Feed pump 1 – Stand-by - 0 - Automatic15 Feed pump 1 – Stand-by - 0 - Automatic16 Electronic control unit C7-623/P


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1

2 4 3 3

5

7

6

Fig. 3 - Inside view of the C7-623 control unit

1 Electronic control unit C7-623/P2 Terminal strip3 Connecting terminals for lead4 Main switch5 Circuit breaker6 Interface relay7 Power supply module


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Fig. 4 - Rear view of the C7-623/P control unit - input/output definitions


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2.1 Construction The electronic control unit C7-623/P is installed in the front door.

The foil-protected keyboard allows IP 65 protection.

The control unit incorporates an illuminated LC display with 4 x 20 charactersand cursor control.

The display is equipped with continuous background illumination. The contrastof the LC display can be altered with the keyboard.

SHIFT. . .

+ ... The contrast is adjusted by pressing the shift key and the "+/-“key.

As the control units can be installed at various heights, it is advisable to adjustthe LC display for optimum readability during commissioning.

The main switches for redundant supply are installed underneath the electronicunit.

Installed on the mounting plate inside the control unit, above terminal strip X1 forconnection of all external lines, are the following devices:• 24 VDC power supply unit• S7 input modules for C7 extension• power switches for pump-motor protection

• power contactors for pump drives

• hour counters for registering the operating hours of the pumps

• control transformer with fuses

• series terminals for external wiring

Cable entry is from below through cable glands.

The control unit is assembled ready for operation and is wired ready to hook up.It complies with the EN 60204 regulations.

2.2 Classification speci-fications

The C7-623/P control unit complies with the VDE regulations (IEC) and hasbeen granted acceptance certificates by the following classification societies:

• Germanischer Lloyd (certificate No. 10050-98HH)

• Lloyds Register of Shipping (certificate No. 98/20058)

• Det Norske Veritas (certificate No. A-6626)

• American Bureau of Shipping (certificate No. 9-MU3355-8-A1)

• Bureau Veritas (certificate No. 09048 / A1 BV)

+/-


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2.3 Design versions Special versions differing from the one described in this manual are available:

Standard design:

• The electronic control unit C7-623/P is supplied in a compact control cabinetwith pump motor controls, automatic filter control, mixing/degassing tankcontrol, as well viscosity and temperature regulating devices.

Special design:

• Project-dependent extra equipment such as heater controls and externalpump controls, are available at extra cost.

• For Visco Booster plants installed in potentially explosive areas, operationcan be assured by means of an explosion-protected control panel fitted nearthe plant. The control unit is then installed in a room outside the danger area.Optionally, the control system can be supplied in explosion-proof design.

• In accordance with US regulations, the C7-623/P control unit can be operatedaccording to FM in explosion-hazarded zones.


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2.4 Mounting

Fig. 5

1 Gasket 10.5x23x5(part-No. 0007-2278-750)

2 Threaded bolt M 8(let into wall)

3 Washer4 Rear panel of control unit5 Washer6 Wall

2.5 Control unit • The control unit has to be fitted to a framework on the Visco Booster plant.

• If possible, the installation site for land-based installations must be chosenso that the sun cannot shine on the front panel impairing the readability ofthe display. Heating of the electronic control unit by solar radiation mustalso be avoided.

• If the control unit is mounted on a wall, a clearance of approx. 20 mm mustbe observed. The fixing dimensions are given in the dimensioned drawing inthe project-related electrical documentation.

• The fixing holes at the rear of the control unit must be sealed means of thegaskets supplied.

• In case of shipboard installations, the unit should be mounted in a low-vibration arrangement and must not be within the vicinity of hot pipelines.

• Although the electronic control unit is protected against moisture by theprotective foil and door seal, the cabinet must not, however, be installed inan excessively humid environment or damp area.

• To keep the temperature inside the unit constant, the main switches"Mains 1" and "Mains 2" should be kept turned on even when the ViscoBooster plant is at standstill.

• If the Visco Booster plant is installed in an explosion-hazarded area, thecontrol unit must be located outside the hazardous area.


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2.6 Electrical connection The control unit is designed for a connected voltage as indicated on the name-plate inside the control cabinet. The required control voltages, 230 VAC and 24VDC, are auto-generated.Before operating the control unit, check the rated voltage indicated on thename-plate inside the cabinet.

Make sure that the solenoid valves of the plant are rated for 24 VDC.

The lead-in wires towards the control unit have to be secured by means of thefuses specified in the project-related circuit diagram.

External voltages:The potential-free contacts of the output modules carry external voltage (evenwhen the main switch is off!). They can be identified by the orange colouredwiring. They can be included in circuits with any voltage 250 VAC.

Switching capacity of the contacts: see 3.1

A wire cross-section of 1.0 mm2, copper, is adequate for all cables. The ar-rangement of the terminals on terminal strip X1 is shown in the terminal diagramincluded in the electrical documentation).

The screwed glands for the electrical cables should be properly tightened andpacked with sealing compound.

2.7 Fuse terminals Valve actuation is via fuse terminals with LED indicators.

In case of short-circuit in the valve control circuit, the fuse of the relevant termi-nal will respond. This failure is signalled by the corresponding red LED. Thissingle fuse arrangement guarantees the full functionality of the C7-623/P controlunit, as the operating voltage 24 VDC is still available. The electronic fuse in thepower supply module is not activated.

Attention!When the safety system has responded, the functionality of the plant is re-stricted.Eliminate the cause of trouble immediately!Spare fuses "0.5 A - semi-time lag" are supplied with the control cabinet.


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2.8 Installing the controlunit in the controlcabinet

The C7-623/P control unit has been prepared for fixed installation in a controlpanel or cabinet door.

Housing dimensions 240 mm x 168 mm

Mounting depth 69 mm

Control panel cutout 230.5 mm x 158.5 mm

168

24069

230,5 +0,5

158,5 +0,5

1

Proceed as follows:

• Preferably use a Torx screwdriver, size T10.

• Make a cutout in the control panel (1) (dimensions 230.5 x 158.5 mm).

Fig. 6


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2

• Insert the enclosed sealing ring behind the front panel (2) (see fig.7).

• Insert the control unit into the cutout provided in the control panel.

3

• Insert the four fixing brackets (3) (see Fig. 8) into the guides provided forthis purpose.

• Push the fixing brackets in until the spring engages.

Fig. 7

Fig. 8 - Fixing bracket before engaging


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4

• Screw the four fastening screws enclosed with the control unit into the fourfixing brackets (4) (see fig. 9).

• Tighten the four screws with the Torx screwdriver (torque 0.6 Nm).

Fig. 9 - Fixing bracket engaged


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2.9 Loosening the fixingbracket

Proceed as follows when loosening the fixing bracket:

1

3

2

• Loosen the screw (1).

• Lift the fixing bracket (2).

• Push the fixing bracket out of the guide (3).

Fig. 10


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3 Control unit

3.1 Technical data........................................................................................183.2 Getting acquainted with the operating elements....................................193.2.1 Function keys .........................................................................................203.2.2 Softkeys .................................................................................................233.2.3 System keyboard ...................................................................................243.3 Overview of display pages .....................................................................273.4 Selecting operating modes ....................................................................293.4.1 Calling up the system function menu.....................................................293.4.2 Calling up the system function menu.....................................................303.4.3 Exiting the system function menu ..........................................................313.5 Password protection...............................................................................323.5.1 Enter password ......................................................................................323.6 The start screen .....................................................................................333.6.1 Interfaces ...............................................................................................34


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3.1 Technical dataOrdering number C7-623/P

EWK: P4 623 A000 11 303WSMS No. 0005-4050-340Dimensions 240 x 168 x 69 mm (H x B x T)Installation/cutout dimen-sions

230.5 x 158.5+0.5 mm

Weight 1 350 gDisplayLED background illumination

STN LC display, 4 lines of 20 characters,5 mm character height

Keypad foil-protected keyboard with metal domes44 keys with 26 integrated LEDs

Inputs 16 digital, 24 VDC, Range: 11-30 VDC4 analog 4-20 mA / 0-10 VDC, 4 quick counters

Outputs 16 digital, 0.5 A each, max. total current A 4 A4 analog 4-20 mA

Serial interface V.-24 for printer connectionMPI interface StandardBuffer battery Buffer time approx. 1 yearFlash memory / configurationmemory

128 KB

RAM 128 KBConfiguration software Step 7B+B software ProTool / ProTool LitePower supply digital 24 VDC, Range: 30.2 t0 20.4 VDCInput voltage with polarityreversal protection

yes

Current consumption 2.4 A max.Safety standard DIN EN 61131-2/IEC 1131-2Enclosure Front of unit: IP 65 acc. to IEC 529

housing: IP 20 acc. to IEC 529Electromagnetic compatibility EN 50081-2 / EN 50082-2Climatic conditions Tested as per DIN IEC 68-2-1/ 68-2-2Operation: 0 oC to 55 oC, vertical installationStorage: -20 oC to +70 oCHumidity: Tested as per DIN / IEC 68-2-3Operation/storage: 595% at 25 oCMechan. ambient conditions vibration: acc. to DIN IEC 68-2-6

operation: 1058 Hz, amplitude 0.075 mm,58500 Hz, acceleration 9.8 m/sstorage: 5 Hz, amplitude 3.5 mm,58500 Hz, acceleration 9.8 m/sshocking: as per DIN IEC 68-2-29Semi-sinusoidal 100 m/s2 (10 g), 16 ms, 100shocks


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3.2 Getting acquainted with the operating elements

FEED SLUDGE HEATERRELEAS

ALARMSDOWN UP

SIMATIC C7-623

987

6F

5E

4D

3C

2B

1A

0.

ESC

ACKHARDCOPY

ENTER

SHIFT

HELP

INSDEL

DIRSFBAF FRCE

DC5VSTOPRUN

1

3

5

2

4

MDO HFO Feederpump 1

Feederpump 2

Circul.pump 1

Circul.pump 2

Autom.filter

Vicosityalarm

VentilateManual Filtercleaning

LALtank

LAHtank

Lamptest

Fig. 11

The operating interface consists of: Section1 Display 2.12 Softkeys 3.2.23 Status and fault indicator 6.1.14 Function keys 3.2.15 System keys 3.2.3


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3.2.1 Function keys The function keys have a global function: The actions which can be triggeredare independent of the picture indicated by the display. They each incorporatean LED which gives information on the state of the respective function.

Key Key designation Description

MDOFuel selection:

Diesel oil operation

By actuating this key, the motor adjusting valve is posi-tioned to "MDO fuel".The valve position is monitored by end position switchesand is shown in the display.Operation of the motor adjustment valve and the "MDO"end position are signalled by continuous light of the LED.Faults are signalled by flashing of the LED.

HFOFuel selection:

Heavy fuel oil operation

By actuating this key, the motor adjusting valve is posi-tioned to "HFO fuel".The valve position is monitored by end position switchesand is shown in the display.Operation of the motor adjustment valve and the "HFO"end position are signalled by continuous light of the LED.Faults are signalled by flashing of the LED.

Feederpump 1

Feed pump selection:

Feed pump 1 - operation

By means of this key, feed pump 1 is started.Actuating this key a second time will switch off the pump,provided that:- the operating mode switch "1S1“ is set to "automatic"

and- the operating mode switch "3S1“ is set to "stand-by"

mode.Operation of the pump is indicated by continuous light ofthe LED.Faults are signalled by flashing of the LED.

Feederpump 2

Feed pump selection:

Feed pump 2 - operation

By means of this key, feed pump 2 is started.Actuating this key a second time will switch off the pump,provided that:- the operating mode switch "3S1“ is set to "automatic"




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Circul.pump 1

Circulation pump selection:

Circulation pump 1 - operation

By means of this key, circulation pump 1 is started.Actuating this key a second time will switch off the pump,provided that:- the operating mode switch "2S1“ is set to "automatic"



Circul.pump 2

Circulation pump selection:

Circulation pump 2 - operation

By means of this key, circulation pump 2 is started.Actuating this key a second time will switch off the pump,provided that:- the operating mode switch "4S1“ is set to "automatic"



Autom.filter

Automatic filter This key has no function.When the filter is in automatic operation, the cleaningcycles are signalled by lighting up of the LED.

Viscosityalarm

Viscosity alarm This key has no function.

Values lower than the preselected min. setpoint or higherthan the preselected max. setpoint of viscosity are sig-nalled by flashing of the LED.Details are shown in the display.

ManualPreselection of manual tank degassing This key, when operated, will

- interrupt automatic degassing of the tank assured bythe level switches and

- allow manual de-aeration.The LED indicates the "hand" mode.

VentilateValve actuation for tank degassing When actuating this key in "hand" mode, the degassing

valve is opened for pre-set 5 sec. The LED shows thevalve to be open.

Filtercleaning

Chamber cleaning - automatic filter By means of this key, a cleaning cycle is manually trig-gered.The LED shows the filter to be cleaned.


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Special function The function of this key is programmed as specified inthe order and described in the project-related electricaldocumentation.

Special function The function of this key is programmed as specified inthe order and described in the project-related electricaldocumentation.

LALtank

Min. level mixing / degassing vessel The LED signals the min. level of the tank to be ex-ceeded and, hence the required volume to be available.

LAHtank

Max. level mixing / degassing vessel The LED signals the max. level of the tank to be ex-ceeded

Lamptest

Lamp test LEDs of the control unit and external signal lamps arechecked for proper functioning.


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3.2.2 Softkeys The softkeys have local function: The functions that can be triggered depend onthe picture currently shown in the display and are marked by a symbol on thedisplay, above the key.

Example of triggering an action in the softkey "menu“:

MODE: STOP

MENÜ

DOWN UPALARMS

UPPress the "UP“ key to execute the "Menu“ function.

The individual soft keys are described at the corresponding display figures.

DOWN Softkey "DOWN“This key is normally used in the display to access the previous level.Other functions are picture-dependent and are shown in the display.

ALARMS Softkey "ALARMS“Picture-dependent function key acc. to display figure.On the process pages (display pages 2/1 - 2/9) you can use this keyto call up the alarm message buffer.

Picture-dependent function key acc. to display figure.

UP Softkey "UP“This key is normally used in the display to access the next level.Other functions are picture-dependent and are shown in the display.

Fig. 12


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987

6F

5E

4D

3C

2B

1A

0.

ESC

ACKHARDCOPY

ENTER

INSDEL

SHIFT

HELP

DIR

3.2.3 System keyboard

Fig. 13

Note:Pressing several keys at the sametime may lead to incorrect entries.

Moves cursor to the left

Moves cursor to the right

Moves cursor upwards

Moves cursor downwards

Note:The cursor keys have repeat function: When the key is depressed the entry isrepeated after a short delay until the key is released.


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0 Numeric ....

...

9 .... key block for inputting valuesWhen the SHIFT key is pressed you can enter alphanumeric charac-ters A to F.

+/-Change-sign keyThis key is used to alternate between the plus and minus sign.

SHIFT

Shift keyThis key is used to activate the alternate function of double-functionkeys.The LED goes on when the changeover function is activated.

ESC

Cancel key (Escape)This key- cancels already started functions,- deletes already entered characters for a value input,- switches back to previous menu,- changes operating levels.

ENTER

ConfirmThis key- accepts and exits an entry,- switches from message level to picture level.

ACK

Acknowledgement keyAcknowledges the currently indicated alarm message or all messagesof an acknowledgement group; this does not eliminate the fault.The LED remains on as long as at least one unacknowledged alarmmessage is queued.

DELINS

Insert / delete keyThis key is used to enter a blank at the cursor position for alphanu-meric entries. All following characters are shifted to the right by oneposition.When you simultaneously press the SHIFT key, you can delete thecharacter at the cursor position for alphanumeric entries. All followingcharacters are shifted to the left by one position.

HELP

Info keyOpens a help text for the selected object (e.g. message, entry field).The LED only goes on when a help text is available for the selectedobject.

DIR

Displays contentsThis key is used to call up the screen directory.


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HARDCOPY

Print (hardcopy)This key serves to output the content of the current display via a con-nected printer (optional).


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3.3 Overview of displaypages

The control functions can be seen in the different display pages. Proceed asfollows to view the display pages:

DIR

Press the "DIR“ key to get a display of all configured pages

or ...

... select the desired screen.

ENTER

Open the desired screen.

The following table gives an overview of the available display pages

DisplayPage Main menu Display

Page Submenu

1/1 Start menu 1/2

1/3

Unit no. / Commissioning date

Program no./ Unit version

2/1 - 2/9 Process information 2/2

2/3

2/4

2/5

2/6

2/7

2/8

2/9

Selection of product

Feed pumps

PAL alarm - feed pumps

Automatic filter

Mixing tank

Circulation pumps

PAL alarm - circulation pumps

Viscosity

3/1 - 3/3 Fuel selection 3/2

3/3

Adjustment of setting time for "MDO“

Adjustment of setting time for "MDO“

4/1 - 4/3 Feed pumps 4/1

4/2

4/3

Feed pump 1

Feed pump 2

Pressure monitoring - feed pumps

5/1 - 5/10 Automatic filter 5/1

5/2

5/3

5/4

5/5

5/6

Indicating function and status "DPSH“

Flush ejection

Forced filling, filter chamber

Flushing time, filter chamber

Impulse / Pause - chamber valve

Monitoring time - cleaning


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DisplayPage Main menu Display

Page Submenu

5/7

5/8

5/9

5/10

Number of total cleaning cycles

Number of timed and manual cleaningoperations

Number of cleaning operations via diff.pressure

By-pass filter

6/1 - 6/5 Mixing / degassing tank 6/1

6/2

6/3

6/4

6/5

Level signal / degassing status

Delay time, LAL alarm

Delay time, LAH alarm

Manual opening time, degassing valve

Monitoring time - tank filling

7/1 - 7/3 Circulation pumps 7/1

7/2

7/3

Circulation pump 1

Circulation pump 2

Pressure monitoring - circulation pumps

8/1 - 8/7 Viscosity measurement 8/1

8/2

8/3

8/4

8/5

8/6

8/7

Status: viscosity and temperature

Setpoints: Min./Max. viscosity

Delay time: Min.-viscosity

Delay time: Max.-viscosity

Setpoints: Min./Max. temperature

Delay time: Min.-temperature

Delay time: Max.-temperature

9/1 - 9/14 Fault statistics 9/1 - 9/14 Fault indication - components

10/1 - 10/32 Digital inputs overview

11/1 - 11/16 Digital outputs overview

12/1 - 12/2 Analog inputs overview

13/1 - 13/2 Analog outputs overview

14/1 - 14/8 Service Service information

15/1 - 15/5 System settings Language setting, transfer, alarms


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3.4 Selecting operatingmodes

You can call up the system function menu from every operating level. The fol-lowing menus are available in the system function menu:

• C7-CPU operating mode selection- RUN-P- RUN- STOP- MRCSs

• DI/DO (Digital-Input/Output) status indication

3.4.1 Calling up the sys-tem function menu

SHIFT

...

HELP

... Simultaneously press the shift key and the help key.

Note:The LED in the shift key goes out again when you press the help key.

The display shows the system functions menu:

SYSTEM FUNCTIONS

KEY DI/DO

SIMATIC C7

DOWN UPALARMS

Fig. 14


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3.4.2 Calling up the sys-tem function menu

DOWN Press the "DOWN“ key.

The display shows the menu "C7-CPU operating modes“ :

MODE: STOP

RUNP RUN STOP MRES

DOWN UPALARM

Key Operatingmode Description

DOWN RUNP The CPU processes the user program.Using a programming device (PD) programs and datacan be• uploaded from the C7-CPU ( C7 → PG),• transferred to the C7-CPU (PG → C7).

ALARMS RUN The CPU processes the user program.

Programs and data in the C7-CPU can be uploadedwith the PG/UD 700 ( C7 → PG/UD).

The program and data can neither be loaded nor modi-fied.

STOP The C7 CPU does not process a user program.Programs can• be uploaded from the C7 CPU with the programming

device ( C7 → PG),• transferred to the C7-CPU (PG → C7).

Note:The operating mode "STOP“ is valid only for the C7-CP, not for the C7-OP. Further processing with the C7-OP is possible.

Fig. 15


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Key Operatingmode Description

UP MRCSs Booting:Booting of the C7-CPU requires a specific sequence of"STOP" and "MRCSs“ modes. This function needsspecial knowledge.

3.4.3 Exiting the systemfunction menu

ESC

Press the "ESC“ key to exit the system function menu or the menu"C7-CPU operating modes“.


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3.5 Password protection Certain entries and functions require prior entry of a password.

You will be prompted to enter a password if you• press a key to which a password-protected function is assigned,• write in password-protected input fields.

Note: You can obtain the password from Westfalia Separator AG.

3.5.1 Enter password PASSWORD ENTRY

* * * * *

0...

9 ... Enter the password using the numerical keys.For security reasons, the entered digits are displayed as asterisks "*“.

ENTER

Confirm the entry or ...

ESC

... cancel the entry.

After you have entered a valid password, you can use the password-protectedfunction for two minutes. After this time your access right is "cancelled“ and thepassword must be re-entered if necessary.

This symbol is used in the manual to refer to the procedure describedabove, that means:

• Enter the password as described above.Multiple password-protected entries during the 2 minute session donot require you to enter the password again.


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3.6 The start screen

Visco Booster Unit

<< LOGOUT LOGIN >>

22.10.98 10:35:28

Westfalia Separator

DOWN UPALARMS

1

8

2

3

4

5 6

7

1 Current date

2 Plant designation

3 Company name

4 Exit start picture level ("DOWN“ key)

5 Terminate password function ("ALARMS“ key)

6 Call up password ("" key)

7 Call up start picture level ("UP“ key)

8 Current time

Fig. 16


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3.6.1 Interfaces The plug and socket connectors (interfaces) required for connecting the variousinputs and outputs of the C7 are provided.

Attention!Use only approved shielded cables for wiring the analog inputs and outputs aswell as the IM, V.24 and MPI interfaces.

Fig. 18

o

u

l

r

6

2

4

5

1

78

3

Fig. 171 IM interface for external input-/output extension2 Analog inputs3 Analog outputs4 Digital AUX inputs, quick counters5 Serial port V.24 (e.g. for printer)6 Digital inputs (top)7 Digital outputs (bottom)8 DI/DO 24 VDC power supply

l lefto topu bottomr right


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1

1 MPI interface

Fig. 18


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NoteNotes

NotizenAnotaciones

NotizenNotesNote


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4 Operation

4.1 Switching on the control unit ..................................................................384.2 Start screen............................................................................................394.3 Calling up the process text pages..........................................................404.4 Detail settings.........................................................................................474.4.1 Fuel selection .........................................................................................474.4.2 Feed pumps ...........................................................................................494.4.3 Automatic filter .......................................................................................514.4.4 Mixing / degassing tank ........................................................................544.4.5 Circulation pumps ..................................................................................564.4.6 Viscosity measuring ...............................................................................584.5 Calling up digital inputs ..........................................................................604.6 Calling up digital outputs ........................................................................624.7 Calling up analog inputs.........................................................................634.8 Calling up analog outputs ......................................................................634.9 Calling up service addresses .................................................................644.9.1 Calling up the system settings ..............................................................664.10 Loading a new program ........................................................................694.10.1 The UD 700............................................................................................694.10.2 Loading data from the UD 700 to the C7-623........................................704.10.3 Text transfer OP part..............................................................................744.10.4 Loading configured data from the programming device

into the UD700 .......................................................................................76


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4.1 Switching on thecontrol unit

When you switch on the power supply the C7 control unit performs a self-test.When the control unit has started correctly the following message is displayed:

SIMATIC C7-623 V1.23

4 x 20 Characters 5 mm

ENTER

Press "ENTER“ to switch to the start screen:

22.11.97 16:30:11

Booster plant

Westfalia Separator

<< LOGOUT LOGIN >>

Display page 1/1 (start screen)

Contrast adjustment

SHIFT

Press the shift key.The LED goes on.

+/-Press the "+/-“ key to adjust the contrast.

SHIFT

Press the shift key.The LED goes out.

Calling up display pages

DIR

Press the "DIR“ key to call up the directory.

...

... navigate to the desired display page using the cursor keys.

ENTER

Press "ENTER“ to open the desired display page (overview see page 27).


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4.2 Start screen When the control unit has started correctly, you enter the start menu (displaypage 1/1):

22.11.97 16:30:11

Booster plant

Westfalia Separator

<< >>

Display page 1/1

Press the "Cursor down“ key to call up the next submenu:

Unit no.:

...............

Commissioning date

20.10.2000

Display page 1/2


Prog: 8104-0623-754

Version: 03.2000

Unit version: P

Display page 1/3

Always state the current program version when contacting Westfalia Separatorfor support.

Press the "Cursor up“ key to return to the start menu.

UP Press the "UP“ key to access display page 2/1 (Plant data).


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4.3 Calling up theprocess text pages

Process screen of

plant:

Navigate with

arrow keys

Display page 2/1


Medium selection:

MDO operation

Status limit switch:

MDO

Display page 2/2

Select the desired fuel:

MDO

Press the "MDO“ key

or

HFO

Press the "HFO“ key.


Line Description

2

The display shows the selected fuel, currently used.

Possible states are:• MDO

The motor adjustment valve is in MDO position, confirmed by the limitswitch. Fuel is supplied from the MDO tank.

• HFOThe motor adjustment valve is in MDO position, confirmed by the limitswitch. Fuel is supplied from the HFO tank.

• No preselectionNo preselection has been done by means of function keys.- MDO: Marine Diesel Oil operation- HFO: Heavy Fuel Oil operation

• FaultThe motor protection device of the control valve has responded.


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Line Description

4

The current position of the motor control valve is indicated

Possible states are:• Control valve running

The motor control valve has been actuated by means of the "MDO“or "HFO“ function key and moves to the desired position.The running time is monitored by a timer.

• Limit switch MDOThe motor control valve has duly reached the preselected MDO posi-tion within the monitoring time.

• Limit switch HFOThe motor control valve has duly reached the preselected HFO posi-tion within the monitoring time.

• Fault MDOThe motor control valve has not duly reached the preselected MDOposition within the monitoring time.

• Fault HFOThe motor control valve has not duly reached the preselected HFOposition within the monitoring time.

• Position unknownThe motor control valve is in no defined end position.

Press the "Cursor down“ key to call up the submenu:

Feed pump 1

On

Feed pump 2

Off

Display page 2/3

Line Description

2

The current status of feed pump 1 is indicated.

Possible states are:• Off

Feed pump 1 is out of operation.• On

Feed pump 1 is in operation.• Fault

Motor protection of feed pump 1 has responded.• Preselection "Automatic"

Preselector switch "1S1“ is in automatic position, and feed pump 1can be started by means of function key "Feed pump 1“.

• Preselection "stand-by"Preselector switch "1S1“ is in stand-by position, feed pump 1 isstarted automatically if the current operation pump 2 fails to operateor to build up delivery pressure.


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Line Description

4










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Feed pump:

PAL - pressure alarm

Status: 0

Display page 2/4

Line Description

3

The delivery pressure downstream of the feed pumps is monitored bymeans of pressure switches and is shown in the display.

Possible modes are:• 0

The pumps are out of operation.The preselected pump fails to build up delivery pressure.

• 1The preselected pump is operating and builds up pressure.


Automatic filter

Status

Ready for operation

Display page 2/5

Line Description

3

Current function of the automatic filter is displayed.

Possible modes are:• Ready for operation

The automatic filter is ready for operation, and the filter chambers arecleaned at cyclical intervals via the differential-speed monitoringsystem or timer T24.

• FaultMotor protection of the filter or too dense a cleaning sequence leadto fault signalling.

• CleaningThe cleaning cycles are indicated in the display.

• Manual cleaningManual cleaning is indicated in the display when function key "Man-ual“ on the C7 unit has been actuated.



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Tank level:

Tank filled

Degassing: open

Display page 2/6

Line Description

2

The current state prevailing in the mixing / degassing tank is indicated

Possible states are:

• Tank not filledThe fuel level has not yet exceeded the level of the "LSL“ switch.

• Tank filledThe fuel level has exceeded the level of the "LSL“ switch.

• LAL alarmThe fuel level has dropped below the level of the "LSL“ switch whenthe "LSH“ has been left approx. 5 minutes before.

3 The current status of the degassing valve in the tank is indicated.Possible states are:• Closed

The degassing valve is closed• Open

The degassing valve is open.



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Circulation pump 1

On

Circulation pump 2

Off

Display page 2/7

Line Description

2

The current status of circulation pump 1 is indicated.


Circulation pump 1 is out of operation.• On

Circulation pump 1 is in operation.• Fault

Motor protection of circulation pump 1 has responded.• Preselection "Automatic"

Preselector switch "2S1“ is in automatic position, and circulationpump 1 can be started by means of function key "Circulation pump1“.

• Preselection "stand-by"Preselector switch "2S1“ is in stand-by position, circulation pump 1 isstarted automatically if the current operation pump 2 fails to operateor to build up delivery pressure.

4










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Circulation pumps: PALpressure alarm:

Status: 0

Display page 2/8

Line Description

3

The delivery pressure downstream of the feed pumps is monitored bymeans of pressure switches and is shown in the display.

Possible modes are:• 0

The pumps are out of operation.The preselected pump fails to build up delivery pressure.

• 1The preselected pump is operating and provides the required workingpressure.

Press the "Cursor down“ key to advance to the next display stage.

Viscosity measurement

Status indication

Measurement active

Viscosity: 11.5mPas

Display page 2/9

Line Description

3

The current viscosity value is transferred from the Viscosens to thecontrol unit as 4 - 20 mA and can be read from the display.

Possible modes are:• Measurement not active

The Viscosens only sends a signal when the circulation pump is op-erating.

• Viscosity OKThe viscosity value is within the preselected range.

• Viscosity alarmThe viscosity value is outside the preselected range. The followingfaults are possible:- Min.-Setpoint is not reached.- Max.-Setpoint is exceeded.- No viscosity signal from Viscosens.

UP Press the "UP“ key to access display page 3/1 (fuel selection).


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4.4 Detail settings The operation and alarm states of the components in use can be checked in theprocess sequence menu. Individual adjustment for each component is de-scribed in detail on the next pages of this instruction manual.

4.4.1 Fuel selection When starting the Visco Booster plant, the fuel to be used must be selected. Forthis purpose:

MDO

press the "MDO“ key for operating with marine diesel oil,

or

HFO

press the "HFO“ key for operating with heavy fuel oil.

When the key has been actuated the motor adjustment valve moves into thedesired position, the running time and the end position being monitored.

The corresponding display shows:

Medium selection:

MDO operation


MDO

Display page 3/1

Line Description

2

The display shows the selected fuel, currently used.

Possible states are:• MDO

The motor adjustment valve is in MDO position, confirmed by the limitswitchFuel is supplied from the MDO tank.

• HFOThe motor adjustment valve is in HFO position, confirmed by the limitswitchFuel is supplied from the HFO tank.

• No preselectionNo fuel preselection has been made by means of the "MDO“ or"HFO“ function keys.

• FaultThe motor protection device of the control valve has responded.


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Line Description

4

The current position of the motor control valve is indicatedPossible states are:• Control valve running

The motor control valve has been actuated by means of the "MDO“or "HFO“ function key and moves to the desired position.The running time is monitored by a timer.

• Limit switch MDOThe motor control valve has duly reached the preselected MDO posi-tion within the monitoring time.

• Limit switch HFOThe motor control valve has duly reached the preselected HFO posi-tion within the monitoring time "T10".

• Fault MDOThe motor control valve has not duly reached the preselected MDOposition within the monitoring time.

• Fault HFOThe motor control valve has not duly reached the preselected HFOposition within the monitoring time "T11".

• Position unknownThe motor control valve is in no defined end position.


Delay time

Limit switch

in MDO position:

Pre: 40.0 s Act: 30.9 s

Display page 3/2

In this menu, the running time of the motor adjustment valve from its actuationup to reaching the "MDO" end position, plus 5 sec, must be entered.


Delay time

Limit switch in HFO po-sition:

Pre: 40.0 s Act: 30.0 s

Display page 3/3

In this menu, the running time of the motor adjustment valve from its actuationup to reaching the "HFO" end position, plus 5 sec, must be entered.


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4.4.2 Feed pumps The fuel is conveyed from the tank by means of feed pumps; for this purpose,one of the following function keys has to be actuated:

Feederpump 1

Feed pump 1 is switched on or off.

or

Feederpump 2

Feed pump 2 is switched on or off.


Feed pump 1

Status

On

Oper time: 12345h

Display page 4/1

Line Description

3




Feed pump 1 is in operation.

• FaultMotor protection of feed pump 1 has responded.

• Preselection "Automatic"Preselector switch "1S1“ is in automatic position, and feed pump 1can be started by means of function key "Feed pump 1“.


4 The operating hours of feed pump 1 are registered.Make sure that the two pumps are equally loaded.



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Feed pump 2

Status

On

Oper time: 12345h

Display page 4/2

Line Description

3








4 The operating hours of feed pump 2 are registered.Make sure that the two pumps are equally loaded.


Delay time for

PAL feed pumps

Signal: 0

Pre: 30.0 s Act: 15.3 s

Display page 4/3

The function downstream of the feed pumps is monitored by means of pressureswitches.In case of pressure drop, the stand-by pump is automatically switched on whenthe delay time has elapsed. The delay time is to be entered in the display.

Line Description

3

Signal status:• 0

no pressure• 1

pressure available


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4.4.3 Automatic filter For separating the dirt particles contained in the oil, a compressed-air operatedbackflush filter is used, proper functioning of same is controlled and monitoredby the C7 system.Emptying of the filter chambers is initiated by means of differential-pressuremonitors or by an overriding timer.

The following display pages give a functional overview of the automatic filterstatus and allow entering the individual time functions.

Automatic filter

Status

Ready for operation

Diff. pressure: 0

Display page 5/1

Line Description

3

Current function of the automatic filter is displayed.

Possible modes are:• Ready for operation

The automatic filter is ready for operation, and the filter chambers arecleaned at cyclical intervals via the differential-speed monitoringsystem or timer.

• FaultMotor protection of the filter or a dense cleaning sequence lead tofault indication.

• CleaningThe cleaning cycles are indicated in the display.

• Manual cleaningManual cleaning is indicated in the display when function key "Man-ual“ on the C7 unit has been actuated.

4

Diff.-pressure definitions:0 = Normal operation1 = Signal for chamber flushing


Flush ejection

Pre: 7200 sec

Act: 0.00 sec

Display page 5/2

If no flush process-dependent ejection is triggered by a differential-pressureswitch, a time-dependent forced ejection can be programmed. In case of sys-tem-dependent ejections, this timer is reset to zero.


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Forced chamber filling

Pre: 720 sec

Act: 0.00 sec

Display page 5/3

The filter manufacturer specifies a min. 720 seconds' settling time to be re-spected after the latest chamber flushing cycle.If, during this period, a new signal is gin by the differential-pressure switch, themessage "Flushing frequency too dense" will appear. No further cleaning cyclewill be performed.


Chamber flushing:

Pre: 10.0 sec

Act: 0.00 sec

Display page 5/4

Here, the flushing time for the filter chamber is preselected; it should• not be shorter than 10 sec and• not be longer than 30 sec


Chamber valve:

Impulse: 1.5 sec

Pause: 3.00 sec

Display page 5/5

Here, an impulse time of approx. 1.5 sec for chamber rotation and a pause ofapprox. 3 sec for pressure build-up in the air vessel are preselected.


Controlling time

Cleaning process:

Pre: 240 sec

Act: 0.00 sec

Display page 5/6

The approx. 246 sec monitoring time is the period in which chamber flushingand chamber rotation, with subsequent pressure build-up, must be finished.


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Amount of cleaning

total

Automatic filter

12345

Display page 5/7

The total amount of cleanings is registered in the control system, the sum totalbeing shown in the display.


Amount of cleaning

by timer : 23

Amount of cleaning byhand 11

Display page 5/8

Line Description

2 The sum total of time-dependent ejections is displayed.

4 The sum total of manual ejections is displayed.


Amount of cleaning

via diff. pressure:

1234 4

Display page 5/9

The sum total of filter ejections triggered by the differential pressure switch isdisplayed here.


Automatic filter

bypass line

Diff. pressure: 234

Pre: 15.0 s Act: 0.00 s

Display page 5/10

When using a bypass filter, an alarm delay time of approx. 15 sec has to bepreselected here.


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4.4.4 Mixing / degassingtank

For mixing the "cold" heavy fuel oil obtained from the day tank with the hotheavy oil returning from the motor, and for degassing the system, an adequatelysized mixing and degassing tank is installed.

The following electric components fitted to the tank are connected to the controlunit:• Level switch - Max.• Level switch - Min.• Degassing valve

Adjustment of and display values for these components are described herebelow:

Mixing tank

Tank level:

Tank not filled

Degassing valve: open

Display page 6/1

Line Description

3

The current state prevailing in the mixing / degassing tank is indicated

Possible states are:• Tank not filled

The fuel level has not yet exceeded the level of the "LSL“ switch.• Tank filled

The fuel level has exceeded the level of the "LSL“ switch.• LAL alarm

The fuel level has not yet exceeded the level of the "LSL“ switch.

4

The current status of the degassing valve in the tank is indicated.Possible states are:• Closed

The degassing valve is closed• Open

The degassing valve is open.

Min./Max. level switch:The liquid switches are designed as 24-VDC liquiphants in 3-conductor connec-tion. Detailed information can be read from the circuit diagram and from thedata sheet included in the project-related electrical documentation.

Manual operation - degassing valveAfter actuating the function key "Manual“ (LED lights up), the degassing valvecan be opened by means of the key "degassing ".

The opening time for the valve is adjusted on timer 32.


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Delay time

LAL - mixing tank

Pre: 05.0 s Act: 0.00 s

Display page 6/2

Here, the individual delay time between below-min. level and alarm signallingcan be entered.


Delay time

LAH - mixing tank

Pre: 05.0 s Act: 0.00 s

Display page 6/3

Here, the individual delay time between above max. level and alarm signallingcan be entered.


Time, valve actuation

in hand operation

Pre: 05.0 s Act: 0.00 s

Display page 6/4

Here, the individual opening time for manual operation of the degassing valvecan be entered.


Delay time:

Filling time of tank

exceeded

Pre: 240.0 s Act: 0.00 s

Display page 6/5

Here, the max. tank-filling time can be preselected for system security reasons.This is to supervise the first stage of the Visco Booster plant for proper func-tioning. If the level is first under LSH and later under LSL level, the LSH levelmust be reached again after a preselected period (max. 20 min).


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4.4.5 Circulation pumps Supply to the injection pumps of the motor is effected by the preselected circu-lation pump. The second pump is in "stand-by" mode and starts automatically incase of pressure drop on the pump in operation.

Circul.pump 1

Circulation pump 1 is switched on or off.

or

Circul.pump 2

Circulation pump 2 is switched on or off.


Circulation pump 1

Status

On

Oper time: 12345h

Display page 7/1

Line Description

3








4The operating hours of circulation pump 1 are registered. Make surethat the two pumps are equally loaded.



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Circulation pump 2

Status

Off

Oper time: 12345h

Display page 7/2

Line Description

3








4 The operating hours of circulation pump 2 are registered.Make sure that the two pumps are equally loaded.


Delay time

PAL feed pumps

Signal: 0

Pre: 30.0 s Act: 15.3 s

Display page 7/3

The function downstream of the circulation pumps is monitored by means ofpressure switches.In case of pressure drop, the stand-by pump is automatically switched on whenthe delay time has elapsed. The delay time is to be entered in the display.

Line Description

3

Signal status:• 0

no pressure• 1

pressure available


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4.4.6 Viscosity measuring Supervision of the preselected viscosity values and controlling of the heatingflow is effected by means of an external Viscosens unit. For optimizing the su-pervision of viscosity and temperature, the corresponding 4-20mA signals aretransmitted to the C7 control unit. Individual preliminary alarm can be set by thefollowing adjustment.


Status indication

Viscosity: 11.5mPas

Temperature: 135 °C

Display page 8/1


Lower viscosity limit:

Setpoint: 9.5mPas

Upper viscosity limit:

Setpoint: 15.5mPas

Display page 8/2

In this display, individual preliminary alarms can be defined for viscosity moni-toring. As soon as the values are under or above the preset values, the corre-sponding fault message appears on the display, and collective alarm is acti-vated.


Delay of alarm

Viscosity

under limit:

Pre: 5.00 s Act: 0.00 s

Display page 8/3

The delay time for "Viscosity under limit“ (Setpoint-Min.) is entered here.


Delay of alarm

Viscosity

over limit

Pre: 5.00 s Act: 0.00 s

Display page 8/4

The delay time for "Viscosity over limit“ (Setpoint-Max.) is entered here.



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Lower temperature limit:

Setpoint: 120 °C

Upper temperature limit:

Setpoint: 150 °C

Display page 8/5

In this display, individual preliminary alarms can be defined for temperaturemonitoring. As soon as the values are under or above the preset values, thecorresponding fault message appears on the display, and collective alarm is ac-tivated.


Delay of alarm

Temperature

under limit:

Pre: 5.00 s Act: 0.00 s

Display page 8/6

The delay time for "Viscosity under limit“ (Setpoint-Min.) is entered here.


Delay of alarm

Temperature

over limit

Pre: 5.00 s Act: 0.00 s

Display page 8/7

The delay time for "Viscosity over limit“ (Setpoint-Max.) is entered here.


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4.5 Calling up digitalinputs

All digital inputs are shown on display pages 10/1 to 10/32.

Scroll through the list below by pressing the "Cursor down“ key.

Input-No. Functions Connection Status

DI 0.0 Feed pump 1 - Stand-by 1S1 / 24 0

DI 0.1 Feed pump 1 - Automatic 1S1 / 14 0

DI 0.2 Feed pump 1 - Fault 1Q1 /22 0

DI 0.3 Feed pump 1 - Operation 1K1 / 14 0

DI 0.4 Circulation pump 1 - Stand-by 2S1 / 24 0

DI 0.5 Circulation pump 1 - Automatic 2S1 / 14 0

DI 0.6 Circulation pump 1 - Fault 2Q1 / 22 0

DI 0.7 Circulation pump 1 - Operation 2K1 / 14 0

DI 1.0 Feed pump 2 - Stand-by 3S1 / 24 0

DI 1.1 Feed pump 2 - Automatic 3S1 / 14 0

DI 1.2 Feed pump 2 - Fault 3Q1 / 22 0

DI 1.3 Feed pump 2 - Operation 3K1 / 14 0

DI 1.4 Circulation pump 2 - Stand-by 4S1 / 24 0

DI 1.5 Circulation pump 2 - Automatic 4S1 / 14 0

DI 1.6 Circulation pump 2 - Fault 4Q1 / 22 0

DI 1.7 Circulation pump 2 - Operation 4K1 / 14 0

DI 32.0 PAL feed pumps X2. 05 / 06 0

DI 32.1 DPAH - Diff. pressure, filter by-pass X2. 07 / 08 0

DI 32.2 DPAH - Diff. pressure, backflush filter X2. 09 / 10 0

DI 32.3 LSL - Level switch, mixing tank X2. 11 / 12/13 0

DI 32.4 LSH - Level switch, mixing tank X2. 14 / 15/16 0

DI 32.5 PAL - Circulation pumps X2. 17 / 18 0

DI 32.6 Limit switch - Filter chamber X2. 19 / 20 0

DI 32.7 not assigned X2. 21 / 22 0

DI 33.0 Motor adjustment valve / DO fuel X2. 23 / 24 0

DI 33.1 Motor adjustment valve / HFO fuel X2. 25 / 26 0

DI 33.2 24-V-monitoring X2. 27 / 28 0

DI 33.3 Local / Remote control (option) S114 0

DI 33.4 Injection system 1 / Main switch ON X2. 31 / 32 0


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DI 33.5 Injection system 2 / Main switch ON X2. 33 / 34 0

DI 33.6 Digital alarm from Viscosens U10 / J4:9/10 0

DI 33.7 not assigned X2. 37 / 38 0

Press the "Cursor up“ key to scroll back to the previous display stage.

UP Press the "UP“ key to access display page 11/1 (digital outputs).


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4.6 Calling up digitaloutputs

All digital outputs are shown on display pages 11/1 to 11/16.



DO 0.0 Feed pump 1 1K10 0

DO 0.1 Circulation pump 1 2K10 0

DO 0.2 Feed pump 2 3K10 0

DO 0.3 Circulation pump 2 4K10 0

DO 0.4 Motor adjustment valve OPEN / fuel K10 0

DO 0.5 Motor adjustment valve CLOSED / fuel K11 0

DO 0.6 Automatic filter - flushing valve K12 0

DO 0.7 Automatic filter - chamber valve K13 0

DO 1.0 Mixing tank - degassing valve K14 0

DO 1.1 Viscosity-control release K15 0

DO 1.2 not assigned 0

DO 1.3 Lamp test K17 0

DO 1.4 Temperature signal K18 0

DO 1.5 Viscosity signal K19 0

DO 1.6 Collective alarm signal K20 0

DO 1.7 Actuation of external klaxon K21 0


UP Press the "UP“ key to access display page 12/1 (analog inputs).


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4.7 Calling up analoginputs

All analog inputs are shown on display pages 12/1 to 12/2.


Input-No. Functions Connection

AI 0.0 Viscosity signal from Viscosens U10 – J41/2

AI 0.1 Temperature signal from Viscosens U10 – J3 4/5

AI 0.2 not assigned

AI 0.3 Temperature bypass (option)


UP Press the "UP“ key to access display page 13/1 (analog outputs).

4.8 Calling up analogoutputs

All analog outputs are shown on display pages 13/1 to 13/2.


Input-No. Functions Connection

AO 0.0 Viscosity indication for control center (option)

AO 0.1 Temperature indication for control center(option)

AO 0.2 not assigned

AO 0.3 not assigned


UP Press the "UP“ key to access display page 14/1 (service addresses).


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4.9 Calling up serviceaddresses

The operating hours of the separator are shown on display page 14/1; the mainservice addresses with phone and fax numbers are shown on displaypages 14/2 to 14/8.

Further service information as well as spare parts orders are available in theMarine After-Sales Service Center, Hamburg, on:

• Phone.: ++49 (0) - 73 93 36 - 0

• Fax: ++49 (0) - 73 80 585


Marine After-Sales

Service-Center Hamburg

Phone:++49(0)40 739336-0

Fax: ++49(0)40 7380585

Display page 14/2


Great Britain:

Phone: ++44 1908-576503

Fax: ++44 1908-311384

Display page 14/3


Netherlands:

Phone: ++31 485 395911

Fax: ++31 485 322211

Display page 14/4


Norway:

Phone: ++47 22 021606

Fax: ++47 22 021601

Display page 14/5



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Singapore:

Phone: ++65 283 6834

Fax: ++65 283 2349

Display page 14/6


Japan:

Phone: ++81 3 5443 3761

Fax: ++81 3 5443 3767

Display page 14/7


USA:

Phone: ++01 201 784 4355

Fax: ++01 201 784 6485

Display page 14/8


UP Press the "UP“ key to access display page 15/1 (system adjustment).


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4.9.1 Calling up thesystem settings

UP You can alter the system settings on display pages 15/1 to 15/5.

System setting

Language

Alarms

Transfer

Display page 15/1


Alarm message

buffer

| Text

<|> <|> Amount

Display page 15/2

The following functions are password-protected (for password entrysee page 32).

DOWN no function

ALARMS Reading of the alarm message buffer.The following information is displayed here:- the alarm messages with code number- date and time of the faults and acknowledgements.

List of the programmed alarm messages with code number

UP Overview of the number of faults



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4.10 Loading a newprogram

The UD 700 (WS part-no.: 0005-4040-190) can be used to load S7 user pro-grams and OP configurations into the control unit without needing a program-ming device. The UD 700 replaces the previous EPROMs. In addition, newprograms can be loaded into an existing UD 700 via modem connection and bedisplayed.

4.10.1 The UD 700

ESC OK

UD 700SIEMENS

1

2

3

1 MPI connection (9-pole)2 RS232 interface (6-pole)3 24 VDC supply voltage

ESC exits current function, returns to next highest menu level.

OK- confirms a setting,- starts the selected function,- selects the next lower menu level,- acknowledges error messages.

moves the cursor up.

moves the cursor down.

The symbol "!" at the left in a display line marks the selected function.

A power supply unit (220 mA) is required for operating the programming device.

Download from the programming device to the UD 700 is normally via an RS232cable (C79451-A3437-B122).

Fig. 19


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Download from the UD 700 to the C7 CPU is normally via an MPI cable(6ES7705-0AA00-7BA0).

4.10.2 Loading data fromthe UD 700 to the C7-623

The UD 700 is connected to the control unit via the MPI port (1).

Attention!The following steps may only be carried out when the separator is at standstilland with closed media feed.

Proceed as follows on the control unit:

SHIFT...

HELP

... Simultaneously press the shift key and the help key.

Note:The LED in the shift key goes out again when you press the help key.

The display shows the system function menu:

SIMATIC C7

SYSTEM FUNCTIONS

KEY DI/DO

DOWN Switch to the menu "C7-CPU operating modes“.

MODE: RUN

RUNP RUN STOP MRES

Select the operating mode "STOP“.

Enter the password (cf. page 32).


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PASSWORD LEVEL: 9

...

ESC

Exit the password entry.The menu "C7-CPU operating modes“ is displayed again:

MODE: RUN

RUNP RUN STOP MRES

Switch the CPU to STOP mode.The CPU switches to "Stop“; the LED "STOP“ goes on.The control unit is ready for data download.

MPITransfer

Switch to the "MPI Transfer“ operating mode.Wait until "MPI DOWNLOAD“ appears in the display:

Proceed as follows on the UD 700:

• Check the UD 700 for the software to be downloaded. The label specifies:- Device type (must be "C7-623 “)- Software number to be downloaded- Configuration date of the program

2

Fig. 20


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• Use the cable provided to connect the UD 700 to the jack "MPI“(2) on the rear panel of the control unit (in the cabinet door).

The UD 700 tests the function of RAM and EPROM. It then briefly displays thestart screen:

SIMATIC S7 UD700

V1.00

It then displays the selection menu:

!UD --> S7/C7

S7/C7 --> UD !

The transfer process "UD --> S7/control unit“ (transfer from UD 700 to controlunit) is marked by "►“

OKConfirm the marked transfer process.The display shows the following selection menu:

!CPU download YES

CPU download NO

The selection item "CPU Download YES“ is marked by "!“

When you want to transfer the CPU program:

OKStart the transfer process.The following message is briefly displayed:

Preparing download

Attention!Do not press any key on the UD 700 or on the control unit after you havestarted the transfer. Otherwise the transfer will be faulty.You can then no longer feed data to the control unit with the UD 700; youmust return the control unit to Westfalia Separator for reprogramming.The following messages are displayed:

UD --> CPU FCB0019

--------

The number is counted during the transfer, the bar "---“ indicates the loadingprogress.

After completion of data transfer the C7 control unit must be switched back tooperating mode:

ALARMS Press the "RUN“ key.


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If applicable, enter the password (cf. page 32).

The control unit will start and signals proper functioning by means of the LED"RUN“.


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4.10.3 Text transfer OP part On the control unit:

DIR

Call up the directory.

Scroll to the menu "System setting“ (display page 15/1).

ENTER

Press the "ENTER“ key.

System setting

Language

Alarms

Transfer

Display page 15/1

Scroll to the menu "MPI transfer“ (display page 15/5).

MPI transfer

| Offline

| | Online

<|> <|> <|>

Display page 15/5

DOWN Start the MPI transfer.

The display switches over to:

MPI transfer

Addr. 1

Attention!In the case of configured series operation, you must take into accountdifferent MPI addresses (3 / 5 / 7).


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On the UD 700:

!CPU download YES

CPU download NO

Select the entry "CPU download NO“.

OK Confirm your selection.

The display switches to the following screen:

!OP download YES

OP download NO

The selection item "OP download YES“ is marked by "!“

OK Start the data transfer of the configured texts and graphics.

The following messages are displayed:

UD --> OP OPG0019

--------

The number is counted during the transfer, the bar "---“ indicates the loadingprogress.

When this program has been transferred, the UD 700 beeps.

On the control unit:The control system restarts.

ENTER

Acknowledge the restart.The LED "RUN“ goes on signalling that the control system is func-tional again.

• Disconnect the cable between UD 700 and control unit.


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4.10.4 Loading configureddata from the pro-gramming device intothe UD 700

You can load configured data from the programming device PG 740 into theUD 700.

For this purpose you need the following connecting cables:• RS 232 adapter cable (Part-No. C79451-A3437-B25) or• RS 232 zero modem cable (Part-No. 6ES7901-1BF00-0XA0)

In the following descriptions it is assumed that you know and can use Mi-crosoftR Windows™ and that you are familiar with the SIMATIC Manager.

Attention!Prior to the first transfer you must set the user parameters in the setup menu ofthe SIMATIC Manager.This procedure need not be repeated for subsequent transfers.

Setting user parametersThe following description refers to the PC program "SIMATIC Manager“; thekeys described are the keys of the PC keyboard not the control unit or UD 700keys.

• Press the "Cursor down“ key 6 times until the cursor is positioned on Setup.

• Confirm with the "OK“ button.The cursor is on Menu Setting.

• Confirm with the "OK“ button.The cursor is on No Restrictions.

• Confirm with the "OK“ button.The cursor jumps back to Menu Setting.

• Position the cursor with the "Cursor down“ key on MPI Parameter.

• Select the entry HSA = 15.

• Confirm with the "OK“ button.The cursor jumps back to Modify HSA.

• Position the cursor with the "Cursor down“ key on Modify CPU addr..

• Confirm with the "OK“ button.

• In the case of standard configurations use the "Cursor up“ or "Cursor down“keys to enter the value Address = 2.Exceptions:HFO series operation or integration in existing MPI networks.

• Confirm with the "OK“ button.The cursor jumps back to Modify CPU addr.

• Position the cursor with the "Cursor down“ key on Modify OP addr.


• In the case of standard configurations use the "Cursor up“ or "Cursor down“keys to enter the value Address = 1.Exceptions:HFO series operation or integration in existing MPI networks.

• Confirm with the "OK“ button.The cursor jumps back to Modify OP addr.

• Position the cursor with the "Cursor down“ key on Modify UD addr.


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• Always enter the value UD Address= 0.


• Press the "ESC“ key to return to the main menu Setup.The MPI parameters are set.

• Use the "Cursor down“ key to select the entry Target Device.


• Select the entry C7-623.

• Confirm with the "OK“ button.The cursor jumps back to Target Device.

• Use the "Cursor down“ key to position the cursor on CPU Memory.

• Confirm with the "OK“ button.The cursor jumps to Clear before download.

• Confirm with the "OK“ button.The cursor jumps back to CPU Memory.

• Use the "Cursor down“ key to position the cursor on CPU RAM to ROM.


• Use the "Cursor down“ key to position the cursor on Copy.

• Confirm with the "OK“ button.The cursor jumps back to CPU RAM to ROM.

• Use the "Cursor down“ key to position the cursor on Operating Language.


• Select the desired language.

• Confirm with the "OK“ button.The cursor jumps back to Operating Language.

• Use the "Cursor down“ key to position the cursor on Version Label.


• Select Label DB .


• Select the value Number = 0.

• Confirm with the "OK“ button.The cursor jumps back to Version Label.

• Use the "Cursor down“ key to position the cursor on RS232 Connection.


• Confirm the transmission speed Direct 38400 bit/s as per PG specification.

• Confirm with the "OK“ button.The cursor jumps back to RS232 Connection.

• Press the "ESC“ key to return to the main menu Setup.

• The modifications will be accepted by the UD 700.

• Setup is now complete.


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• Press the "ESC“ key to return to the main menuCommunication UD ---> S7/C7.The programming device is ready for data transmission.

Transfer configuration dataWhen the user parameters have been saved you can transfer the configurationdata from the programming device to the UD 700 as follows:

On the PG 740:

• Switch on the PG 740.

• Start MicrosoftR Windows™ until the start screen with the program overviewappears.

• Start the SIMATIC Manager.

• Open the desired file or configuration, e.g. "SIMATIC 300-623_1“.

• In the menu bar select "Extras → PG/PC Interface Selection“.

• Set the entry from MPI/ISA on Board to PC Adapter.

• Define the COM port and transmission speed under Properties, e.g. "COM2, 38.400“.

• Confirm with the "OK“ button.You return to the main menu.

• Go to CPU Program.

• Open the S7 program to be transferred, e.g. "SIMATIC 300-623_1“.

• Open the configuration "S7 Program (1)“.

• Click on the display "AP off“.The S7 configuration is available for download.

• Go to OP Program.

• Open the OP program by double-clicking "op623_1“.

• Start the transfer mode via the menu "File → Transfer“.The configuration data are synchronised.The Windows window "Transfer MPI“ is opened.

• Start data transfer with the "OK“ button.The transfer window is open and the data transfer shown as a block diagram.Correct transmission is indicated with the message "Transfer completed suc-cessfully“.

On the UD 700:

• Connect the power supply unit for 24 VDC power supply.

The display of the UD 700 lights up and the UD 700 tests the function of theRAM and EPROM. It then briefly displays the start screen:

SIMATIC S7 UD700

V1.00

It then displays the selection menu:


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! UD --> S7/C7

S7/C7 --> UD !

• Connect the serial data transfer cable to the serial port of the PG 740 and tothe RS232 port of the UD 700.

Use the "Cursor down“ key to select the transfer mode "PG/PC <-->UD“ on the UD 700.

OK Confirm your selection.

If the connection is not correct, the display outputs the message:

Waiting for connection

On the PG 740:

• Click in the button bar on the "Transfer“ button to start the download processat the programming device.

The display of the UD 700 shows the following message:

Connected

The program is loaded into the UD 700.


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NoteNotes

NotizenAnotaciones

NotizenNotesNote


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5 Commissioning

5.1 How to proceed on the control cabinet ..................................................825.1.1 Product selection "MDO“........................................................................825.1.2 Product selection "HFO“ ........................................................................835.1.3 Feed pumps ...........................................................................................835.1.4 Circulation pumps ..................................................................................855.1.5 Manual operation ...................................................................................87


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5.1 How to proceed onthe control cabinet

In the following, it is described how to proceed on the control cabinet only.

• The manual operations to be performed on the shut-off devices and the pres-sure settings to be done in the Visco Booster plant are described in the proj-ect-relating start-up instructions.

• Set the selector switches for the feed and circulation pumps, provided underthe control unit, to zero position.

• In case of unique supply, set the corresponding main switch of the controlcabinet to "on" position.

• In case of redundant supply, turn on both main switches; if, then, one supplysystem fails, immediate switch-over will be secured without interruption of100% availability of the plant.

The C7 control unit undergoes a self-test of approx. 15 sec, and then the displaysignals "ready-for-operation" as follows:

SIMATIC C7-623 V1.23

4 x 20 Characters 5 mm

Start screen after start-up

ACK

Acknowledge all alarm signals by actuating the ACK key one or sev-eral times.

ENTER

Confirm start-up by pressing the ENTER key,Then the display shows:

22.11.99 16:30:11

Booster unit

Westfalia Separator

<< >>

Basic screen

5.1.1 Product selection"MDO“

MDO

Press the "MDO“ key to set the motor adjusting valve to "MDO“ posi-tion.

For manual adjustment:• set the 3/2-way valve towards MDO tank and• check that the end position of MDO operation is confirmed in the display.

Medium selection:

MDO operation


MDO

Position of control valve


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The display changes from "Control valve running" to "MDO" as soon as the endposition is reached.

5.1.2 Product selection"HFO“

HFO

Press the "HFO“ key to set the motor adjusting valve to "HFO“ posi-tion.

For manual adjustment:• set the 3/2-way valve towards HFO tank and• check that the end position of HFO operation is confirmed in the display.

Medium selection:

HFO operation


HFO

Position of control valve

The display changes from "Control valve running" to "HFO" as soon as the endposition is reached.

5.1.3 Feed pumps • Set the selector switch of the desired feed pump to automatic position and• the selector switch of the spare feed pump to stand-by position.

Actuate the "Cursor down" key to proceed to the feed pump display,where you can check the status of the pumps.

Feed pump 1

Off

Feed pump 2

Off

Feed pump status

Feederpump 1

Actuate the start button of the pump preselected under automaticoperation on the C7 control unit (example: feed pump 1).

The display output changes from "off“ to "on“, the LED in the key lights up, con-firming that feed pump 1 is operating.

When using feed pump 2, proceed accordingly, as described here above.

Actuate the "Cursor down" key to proceed to the "pressure monitor-ing" display, where you can check the current pressure build-up of theselected pump.


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Feed pumps

PAL - pressure alarm:

Status 1

Feed pumpsPAL status

Line Description

3

Possible states are:• 0

Delivery side of pump is not o.k.Delay time prior to switch-on of stand-by pump starts

• 1Delivery side of pump is o.k.

When a feed pump is switched on, the corresponding automatic filter is startedat the same time in order to separate the dirt particles contained in the oil.

Actuate the "Cursor down“ button to proceed to the "Automatic filter“display allowing to check the current status of the filter.

Automatic filter

Status

Ready for operation

Automatic filter status

Adjustment of the time functions for the automatic filter should be read fromsection 4.4.3 of this manual.

The selected feed pump conveys the selected fuel is from the correspondingtank to the degassing / mixing vessel, through the automatic filter.

Press the "Cursor down“ key to proceed to the "Mixing tank“ displayfor checking the filling level and the degassing-valve position for thistank.

Mixing tank

Tank level:

Tank filled

Degassing: closed

Mixing tank

When the tank filling is below min. level, the degassing valve opens.When the tank level exceeds the max. limit, the valve is closed. At the sametime a monitoring time starts which is intended to register abnormal filling cyclesand to trigger alarm, if required.

Adjustment of the mixing tank functions is done in the "mixing tank“ display, asdescribed in section 4.4.4 of this manual.


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5.1.4 Circulation pumps In order to supply the injection pumps of the main motor with fuel,• Set the selector switch of the desired circulation pump to automatic position

and• the selector switch of the spare circulation pump to stand-by position.

Actuate the "Cursor down" key to proceed to the feed pump display,where you can check the current status of the pumps.

Circulation pump 1

Off

Circulation pump 2

Off

Circulation pump status

Circul.pump 2

Actuate the start button of the pump preselected under automaticoperation on the C7 control unit (example: circulation pump 2).

The display output changes from "off“ to "on“, the LED in the key lights up, con-firming that feed pump 2 is operating.

When using feed pump 1, proceed accordingly, as described here above.

Actuate the "Cursor down" key to proceed to the "pressure monitor-ing" display, where you can check the current pressure build-up of theselected pump.

Circulation pumps

PAL - pressure alarm

Status 1

Circulation pumpsPAL status

Line Description

3

Possible states are:• 0

Delivery side of pump is not o.k.Delay time prior to switch-on of stand-by pump starts

• 1Delivery side of pump is o.k.

When a circulation pump is switched on, the viscosity control is started in theexternal Viscosens at the same time, in order to control the temperature of thefuel sent to the main motor according to the preset viscosity value.

Adjustment and parameter setting of the Viscosens has to be done in accor-dance with the relevant separate manual.


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Use the "Cursor down" key to proceed to the "Viscosity measuring“display where you can check the current viscosity and temperature ofthe fuel.

Viscosity measurement:

Status indication

Measurement active

Viscosity: 13.5 mPas

Viscosity display

In order to optimize the operating reliability of the plant and to detect tendenciesin fuel quality, it is possible to enter individual preliminary alarm settings for

- Viscosity- Temperature

in view of values dropping below or rising above the setpoints provided. For thispurpose:

DIR

Press the "DIRECTORY“ key

Use the "Cursor down“ key to select the display pages 8/2 - 8/7 "Vis-cosity measuring“, and

ENTER

Press the "ENTER" key.

Further details on adjustment are found in section 4.4.5 of this manual.


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5.1.5 Manual operation Failure of the C7 control unit means stopping of the following functions:- process-dependent interlocking- automatic control and monitoring of pumps- control of the mixing vessel and- automatic alarm activation

In these cases, the plant can however be operated manually.

This means• fuel selection has to be done by manual operation,• the required pumps have to be started using the hand position of the selector

switches• the chambers of the automatic filter must be cleaned by hand• the degassing valve of the mixing vessel has to be opened manually from

time to time

Viscosity control is still by the Viscosens with connected heating-circuit control,provided that the contact of the "K19“ interface relay is bridged by means of awire.

In case of temporary failure of the Viscosens check whether the viscosity andtemperature values can be read on the corresponding display page of the C7control unit. Then adjust the desired viscosity by setting the heating circuit valveat constant flow, by hand.


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NoteNotes

NotizenAnotaciones

NotizenNotesNote


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6 Fault signals / Maintenance

6.1 Fault signals ...........................................................................................906.1.1 Status and fault indication.....................................................................906.2 Alarm descriptions..................................................................................916.2.1 Feed pumps ...........................................................................................916.2.2 DPSH Automatic filter (input 32.2) .........................................................936.2.3 LAL mixing tank (input 32.3) ..................................................................956.2.4 Motor protection switch of circulation pump 1........................................976.2.5 Circulation pump 1 .................................................................................996.2.6 Motor protection switch of circulation pump 2......................................1006.2.7 Circulation pump 2 ...............................................................................1026.2.8 PSL Circulation pumps (input 32.5) .....................................................1036.2.9 End position error "MDO“.....................................................................1056.2.10 End position error "HFO“......................................................................1076.2.11 Motor adjustment valve........................................................................1096.2.12 Motor protection switch of feed pump 1...............................................1106.2.13 Feed pump 1 ........................................................................................1126.2.14 Motor protection switch of feed pump 2...............................................1136.2.15 Feed pump 2 ........................................................................................1156.2.16 PSL Feed pumps (input 32.0) ..............................................................1166.2.17 Product selection "MDO“ or "HFO“ ......................................................1186.2.18 Bypass filter - input 32.1.......................................................................1206.2.19 Viscosity below limit .............................................................................1216.2.20 Viscosity above limit.............................................................................1246.2.21 Temperature below limit.......................................................................1276.2.22 Temperature above limit ......................................................................1296.2.23 Delay time ............................................................................................1316.2.24 Circulation pumps ................................................................................1326.2.25 Level switch / mixing tank ....................................................................1346.2.26 Mixing tank is not filled .........................................................................1356.2.27 Automatic filter .....................................................................................1376.2.28 Power-supply monitoring......................................................................1396.3 Causes and action ...............................................................................1416.3.1 Control unit ...........................................................................................1416.4 Maintenance.........................................................................................1436.4.1 Storing batteries ...................................................................................1436.4.2 Changing the battery............................................................................143


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6.1 Fault signals

SF

BAF FRCE

DC5V

STOP

RUN

6.1.1 Status and faultindication

Fig. 21

The control unit is equipped with theadjacent status and error indicators.They are explained in the followingtable (see also chapter 6.3 page 141).

Display Meaning Explanations

SF (red) C7 CPU summary error This LED lights up in case of:• Hardware errors• Firmware errors• Programming errors• Parameter errors• Computing errors• Timer errors• Faulty internal memory• Battery failure or no buffering when "POWER ON“.• Periphery error at internal periphery functions

For precise troubleshooting you must use a programming deviceand display the diagnostic buffer.

BAF (red) Battery error This LED lights up when the battery is• too weak• defective• missing

DC5V(green)

5V DC supply for C7 This LED lights up when the internal 5V power supply is ok.

FRCE(yellow)

Reserved -

RUN(green)

Operating mode RUN ofCPU

This LED lights up when the CPU is processing the user program.

This LED flashes (2 Hz) during the C7 start-up (the STOP LED thenalso lights up; when the STOP LED goes out the outputs are re-leased).

STOP(yellow)

Operating mode STOP ofthe CPU

This LED lights up when the control unit is not processing the userprogram.

This LED flashes at one second intervals when the CPU requests"memory reset“.


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6.2 Alarm descriptions In the case of abnormal machine or process situations the following is initiatedafter a preset delay time• the collective alarm is activated• the fault is indicated in the display• the LED of the ACK key for acknowledging the alarm lights up

6.2.1 Feed pumps Pump preselector switch in wrong position:

The pumps are preselected for operation by means of selector switches.For this purpose,• selector switch "1S1“ for the operational pump has to be set to automatic po-

sition, and• selector switch "3S1“ for the stand-by pump has to be set to stand-by posi-

tion.

In case of incorrect selection, the following message flashes on the displaywhen the pump is started:

Failure

Preselection of

Feed pumps

not OK

Fault message 0001

The collective alarm of the control system is activated immediately. The alarm isindicated by flashing of the LED on the "Feed pump ... " key.

Viewing the help text

HELP

Press the "HELP“ key to call up information on trouble-shooting:

>Only one feed pump

is allowed to

be preselected as

stand by or

Fault message (help text, page 1)

Press the "Cursor down“ key to call up the next display page.

automatic.

>Please check pre-

selection of

pumps.

Fault message (help text, page 2)

ESC

Press the "ESC“ key to return to the display page with the alarmcause.


8164-9001-600/0501

Confirm fault

ACK

Press the "ACK“ key when you have registered the alarm.The display switches back to the previous standard mode.

• Eliminate the fault by setting the selector switch correctly.The alarm is stored in the alarm message buffer together with date and time.

ALARMS Press the "ALARMS“ key to call up the alarm message buffer.


8164-9001-600/0501

6.2.2 DPSH Automatic filter(input 32.2)

The chambers are monitored for due emptying by means of timer function anddifferential-pressure switch.If, after flushing of the automatic-filter chambers and expiry of a delay time, nopressure drop occurs and, hence, the flushing frequency is very high, the fol-lowing message flashes on the display:

Failure

Automatic filter

amount of cleaning

cycles too high

Fault message 0002 (automatic filter)

The collective alarm of the control system is activated immediately.


HELP


>Check the

local differential

pressure

monitor. If

Fault message 0002 (help text, page 1)


monitor shows pressure

all time clean filter

cartridge manually.



>Manual cleaning

triggered too early or

too often



>Check for

leakages on

pump suction side



8164-9001-600/0501

Confirm fault

ACK


• Eliminate the cause of the fault.The alarm is stored in the alarm message buffer together with date and time.



8164-9001-600/0501

6.2.3 LAL mixing tank (in-put 32.3)

In the continuously operating Visco Booster plant, the min. level of the mix-ing/degassing tank is permanently monitored by "Liquiphant" level switches.If the level is below min. limit and a delay time has elapsed, the following mes-sage flashes on the display:

Failure

LAL level

Mixing tank

Fault message 0003 (LAL mixing tank)

The collective alarm of the control system is activated immediately.Viewing the help text

HELP


>Please check both

level switches

>Valves BV43,44,45

must be closed



Check position

>Check

automatic de-

gassing valve



>Check auto-

matic filter

and FQ counter for

flow rate


ESC



8164-9001-600/0501

Confirm fault

ACK





8164-9001-600/0501

6.2.4 Motor protectionswitch of circulationpump 1

Circulation pump 1 responded - input 1.2If the motor protection switch of circulation pump 1 responds due to an electri-cal or mechanical trouble, the system is automatically switched over to circula-tion pump 2, and the following message flashes on the display:

Failure

Feed pump 1

motor protection switch

Fault message 0004 (motor protection)

The collective alarm of the control system is activated immediately.The alarm is indicated by flashing of the LED on the "Circulation pump 1" key.


HELP


Check the

setpoint

on the




>Motor protection switch

must be set to

rated current.

>Check for



free run of

pump with

simultaneous

check of



8164-9001-600/0501


motor temperature Fault message 0004 (help text, page 4)

ESC


Confirm fault

ACK


• Eliminate the fault by checking the mechanical and electrical function of thepump.The alarm is stored in the alarm message buffer together with date and time.



8164-9001-600/0501

6.2.5 Circulation pump 1 Circulation pump 1: no operation signal - input 0.7

If, in case of program-dependent actuation of circulation pump 1, no operationsignal is received from the power contactor of the pump, the following messageflashes on the display:

Failure

Operating signal from

Circulation pump 1

Fault message 0005 (operation signal)



HELP


Check for

correct wiring of

motor contactor and

interface relay



from SPS

For details, see

circuit diagram



8164-9001-600/0501

6.2.6 Motor protectionswitch of circulationpump 2

Circulation pump 2 responded - input 1.6If the motor protection switch of circulation pump 2 responds due to an electri-cal or mechanical trouble, the system is automatically switched over to feedpump 1, and the following message flashes on the display:

Failure

Circulation pump 2

Motor protection switch




HELP


>Check for

setpoint

on the





must be set to

rated current.

>Check for



free run of

pump with

simultaneous

check of



8164-9001-600/0501



ESC


Confirm fault

ACK





8164-9001-600/0501

6.2.7 Circulation pump 2 Circulation pump 2: no operation signal - input 1.7

If, in case of program-dependent actuation of circulation pump 2, no operationsignal is received from the power contactor of the pump, the following messageflashes on the display:

Failure


Circulation pump 2




HELP


>Check for

correct wiring of

motor contactor and

interface relay



from SPS

For details, see

circuit diagram



8164-9001-600/0501

6.2.8 PSL Circulationpumps (input 32.5)

The circulation pumps are monitored for proper functioning by means of a pres-sure guard on he delivery side of the pumps.If pressure drop occurs on the pump selected for operation and a delay timehas elapsed, the stand by pump is started automatically, and the faulty pump isstopped. The following message is flashing in the display:

PAL Fault

pressure alarm for

circulation pump

Fault message 0008(PAL - Circulation pumps)



HELP


>Check pressure

switch P6 for proper

functioning

(setting,



>wire break,

mechanics)

>Check position

of ball valve at



pressure gauge.

Check for leakage

on pump suction

side




8164-9001-600/0501

Confirm fault

ACK





8164-9001-600/0501

6.2.9 End position error"MDO“

Motor adjustment valve after MDO selection - input: 33.0

Fuel selection is done by actuating the "MDO" function key to make the motoradjustment valve get into the desired position. Arrival at end position has to beconfirmed within the defined adjustment period, by means of the local limitswitch. If this acknowledgement is not given, the following message flashes onthe display:

No preselection

MDO or HFO

Fault message 0009

The collective alarm of the control system is activated immediately. The alarm isindicated by flashing of the LED on the "ACK" key.


HELP


>Adjustment time

too short; please

check. See

instruction manual



>Limit switch defective

Check for

wire break and

correct setting



>Valve actuator

defective

>Check the

electrical




8164-9001-600/0501

connection, direction

of rotation.

>Check smooth run

of spindle.



ESC


Confirm fault

ACK


• Eliminate the fault by checking adjustment time and functioning of motor ad-justment valve.The alarm is stored in the alarm message buffer together with date and time.



8164-9001-600/0501

6.2.10 End position error"HFO“

Motor adjustment valve after HFO selection - input: 33.1

Fuel selection is done by actuating the "HFO" function key to make the motoradjustment valve get into the desired position. Arrival at end position has to beconfirmed within the defined adjustment period, by means of the local limitswitch. If this acknowledgement is not given, the following message flashes onthe display:

No preselection

MDO or HFO

Fault message 0010



HELP


>Adjustment time

too short; please

check. See

instruction manual



>Limit switch defective

Check for

wire break and

correct setting



>Valve actuator

defective

>Check the

electrical




8164-9001-600/0501

connection, direction

of rotation.

>Check smooth run

of spindle.



ESC


Confirm fault

ACK


• Eliminate the fault by checking adjustment time and functioning of motor ad-justment valve.The alarm is stored in the alarm message buffer together with date and time.



8164-9001-600/0501

6.2.11 Motor adjustmentvalve

In case of logically faulty interpretation of the end positions of the motor adjust-ment valve (1 signal, both feedbacks) the following message flashes on thedisplay:

Failure adjustment valve Fault message 0011



HELP


>End position signals

not logic.

Please check:

Signal MDO end position



>Signal HFO end position

>Wire connection to

control cabinet

>Switching contacts


ESC


Confirm fault

ACK


• Eliminate the fault by checking adjustment time and end-position functioningof motor adjustment valve.The alarm is stored in the alarm message buffer together with date and time.



8164-9001-600/0501

6.2.12 Motor protectionswitch of feed pump 1

Circulation pump 1 responded - input 0.2

If the motor protection switch of circulation pump 1 responds due to an electricalor mechanical trouble, the system is automatically switched over to feed pump2, and the following message flashes on the display:

Fault

Feed pump 1



The collective alarm of the control system is activated immediately. The alarm isindicated by flashing of the LED on the "Circulation pump 1" key.


HELP


>Check for

setpoint

on the





must be set to

rated current.

>Check for



free run of

pump with

simultaneous

check of




8164-9001-600/0501


ESC


Confirm fault

ACK





8164-9001-600/0501

6.2.13 Feed pump 1 Feed pump 1: no operation signal - input 0.3

If, in case of program-dependent actuation of feed pump 1, no operation signalis received from the power contactor of the pump, the following messageflashes on the display:

Fault


Feed pump 1


The collective alarm of the control system is activated immediately. The alarm isindicated by flashing of the LED on the "Feed pump 1" key.


HELP


>Check for

correct wiring of

motor contactor and

interface relay



from SPS

For details, see

circuit diagram



8164-9001-600/0501

6.2.14 Motor protectionswitch of feed pump 2

Feed pump 2 responded - input 1.2

If the motor protection switch of feed pump 2 responds due to an electrical ormechanical trouble, the system is automatically switched over to feed pump 1,and the following message flashes on the display:

Fault

Feed pump 2





HELP


>Check for

setpoint

on the





must be set to

rated current.

Check



free run of

pump with

simultaneous

check of





8164-9001-600/0501

ESC


Confirm fault

ACK





8164-9001-600/0501

6.2.15 Feed pump 2 Feed pump 2: no operation signal - input 1.3

If, in case of program-dependent actuation of feed pump 2, no operation signalis received from the power contactor of the pump, the following messageflashes on the display:

Failure


Feed pump 2




HELP


>Check for

correct wiring of

motor contactor and

interface relay



from SPS

For details, see

circuit diagram



8164-9001-600/0501

6.2.16 PSL Feed pumps (in-put 32.0)

The feed pumps are monitored for proper functioning by means of a pressureguard on he delivery side of the pumps.If pressure drop occurs on the pump selected for operation and a delay timehas elapsed, the stand by pump is started automatically, and the faulty pump isstopped. The following message is flashed in the display:

PAL Fault

pressure alarm for

feed pump

Please press help key

Fault message 0016(PAL feed pumps)



HELP


>Check pre-

filter for

soiling



>Check pressure switch

P3 for proper

functioning

(setting, wire break)



>Check position

of ball valve at

pressure gauge.



>Check for leakage

on pump

suction

side



8164-9001-600/0501

Confirm fault

ACK





8164-9001-600/0501

6.2.17 Product selection"MDO“ or "HFO“

Fuel selection is done by actuating the "MDO" or "HFO" function key to makethe motor adjustment valve get into the corresponding position.If this preselection is not done, and a feed pump is started, the following mes-sage flashes on the display:

No preselection

MDO or HFO

Fault message 0017



HELP


>No preselection

MDO or HFO

Please make

preselection



of product. Fault message 0017 (help text, page 2)

ESC



8164-9001-600/0501

Confirm fault

ACK


• Eliminate this fault by preselecting the fuel by means of the "MDO“ or "HFO“key on the control unit.The alarm is stored in the alarm message buffer together with date and time.



8164-9001-600/0501

6.2.18 Bypass filter - input32.1

When carrying out service work or in case of failure of the automatic filter, op-eration of the Visco Booster plant can be continued by switching over to thebypass filter. Filter fouling is monitored by means of a differential-pressureswitch which activates collective alarm and the following message on the dis-play:

Failure

Differential pressure in

automatic bypass

filter too high

Fault message 0019(DPSH bypass filter)


HELP


Check bypass filter

Clean

filter by

hand


ESC


Confirm fault

ACK





8164-9001-600/0501

6.2.19 Viscosity below limit The viscosity controller sends the current viscosity value of the fuel to the con-trol unit as 4-20mA signal. It is possible to set a preliminary alarm for decreas-ing viscosity in the "Viscosity" display pages. The preliminary alarm allows toreact to decreasing viscosity in time.

Adjustment:

By means of the "Cursor up“ or "Cursor down“ key ...

the display page indicating the current viscosity and temperature val-ues is selected.


Status indication



Operation signal (viscosity / temperature)



Setpoint: 10.0mPas


Setpoint: 17.5mPas

Setpoint entry (min./max. viscosity)

• Place the flashing cursor on the desired min. position and

1 0...

9... use number keys to enter the preliminary-alarm setpoint.

ENTER

Confirm the entry.


8164-9001-600/0501

Alarm signalling:While a circulation pump is operating, the viscosity monitoring system is acti-vated.As soon as the viscosity is below the preset lower limit, collective alarm is trig-gered, and the following message is shown in the display:

>Warning

Viscosity

under limit

Fault message 0020(Min. viscosity)


HELP


>Check settings

of the

SPS

>Check the



complete heating

circuit.

>Check electrical

and mechanical



function of motor

control valve in

steam or thermal oil

heating


ESC



8164-9001-600/0501

Confirm fault

ACK





8164-9001-600/0501

6.2.20 Viscosity above limit The viscosity controller sends the current viscosity value of the fuel to the con-trol unit as 4-20mA signal. It is possible to set a preliminary alarm for risingviscosity in the "Viscosity" display pages. The preliminary alarm allows to reactto decreasing viscosity in time.

Adjustment:




Status indication



Operation signal (viscosity / temperature)



Setpoint: 10.0mPas


Setpoint: 17.5mPas

Setpoint entry (min./max. viscosity)

• Place the flashing cursor on the desired max. position and

1 0...


ENTER

Confirm the entry.


8164-9001-600/0501

Alarm signalling:While a circulation pump is operating, the viscosity monitoring system is acti-vated.

As soon as the viscosity exceeds the preset limit, collective alarm is triggered,and the following message is shown in the display:

>Warning

Viscosity

over limit

Fault message 0021 (Max. viscosity)


HELP


>Check settings

of the

SPS

>Check the



complete heating

circuit.

>Check electrical

and mechanical



function of motor

control valve in


heating


ESC



8164-9001-600/0501

Confirm fault

ACK





8164-9001-600/0501

6.2.21 Temperature belowlimit

The viscosity controller sends the current temperature value of the fuel to thecontrol unit as 4-20mA signal. It is possible to set a preliminary alarm for de-creasing temperature in the "Viscosity" display pages. The preliminary alarmallows to react to decreasing temperature in time.

Adjustment:




Status indication



Operation signal(viscosity / temperature)



Setpoint: 120 °C


Setpoint: 150 °C

Setpoint entry (min./max. temp.)


1 0...


ENTER

Corfirm the entry.


8164-9001-600/0501

Alarm signalling:While a circulation pump is operating, the viscosity monitoring system is acti-vated.As soon as the viscosity is below the preset lower limit, collective alarm is trig-gered, and the following message is shown in the display:


HELP


>Check settings

of the

SPS

>Check the



complete heating

circuit.

>Check electrical

and mechanical



function of motor

control valve in


heating


ESC


Confirm fault

ACK





8164-9001-600/0501

6.2.22 Temperature abovelimit

The viscosity controller sends the current temperature value of the fuel to thecontrol unit as 4-20mA signal. It is possible to set a preliminary alarm for risingtemperature in the "Viscosity" display pages. The preliminary alarm allows toreact to rising temperature in time.

Adjustment:




Status indication



Operation signal(viscosity / temperature)



Setpoint: 120 °C


Setpoint: 150 °C

Setpoint entry (min./max. temp.)


1 0...


ENTER

Corfirm the entry.


8164-9001-600/0501

Alarm signalling:While a circulation pump is operating, the viscosity monitoring system is acti-vated.As soon as the viscosity exceeds the preset limit, collective alarm is triggered,and the following message is shown in the display:


HELP


>Check settings

of the

SPS

>Check the



complete heating

circuit.

>Check electrical

and mechanical



function of motor

control valve in


heating


ESC


Confirm fault

ACK





8164-9001-600/0501

6.2.23 Delay time Individual delay times between setpoint level and alarm signalling can be set forthe viscosity and temperature alarms here described.For this purpose:

• call up the corresponding menu in the display

1 0...

9Enter the desired time using the numerical keys.

ENTER

Confirm your entry.

The following example is applicable to all time entries :

Delay of alarm

Viscosity

under limit:

Pre: 15.0 s Act: 0.00 s

Delay time (min. viscosity)


8164-9001-600/0501

6.2.24 Circulation pumps Pump preselector switch in wrong position:The pumps are preselected for operation by means of selector switches.For this purpose,• selector switch "2S1“ for the operational pump has to be set to automatic

position, and• selector switch "4S1“ for the stand-by pump has to be set to stand-by posi-

tion.In case of incorrect selection, the following message flashes on the displaywhen the pump is started:

Failure

Preselection of

circulation pumps

not OK

Fault message 0025

The collective alarm of the control system is activated immediately.The alarm is indicated by flashing of the LED on the "ACK" key.


HELP


>Only one feed pump

is allowed to

be preselected as

stand by or



automatic.

>Please check pre-

selection of

pumps.


ESC


Confirm fault

ACK



8164-9001-600/0501

• Eliminate the fault by setting the selector switch correctly.The alarm is stored in the alarm message buffer together with date and time.



8164-9001-600/0501

6.2.25 Level switch / mixingtank

The level switch functions are logically monitored for signalling. In case of wirebreak or switch failure, the following message appears in the display :

Failure

Level switch of

mixing tank defective

Fault message 0026 (level switch)



HELP


>Please check both

level switches for

Electr. connection

and the



correct

position of

Y connector


ESC


Confirm fault

ACK





8164-9001-600/0501

6.2.26 Mixing tank is notfilled

Inputs: 32.3/4

When using a feed pump, filling and degassing of the mixing vessel is monitoredby means of the level switch provided and via the preset monitoring time. Themonitoring time has to be adjusted in the display menu "Mixing tank“. Whenalarm is triggered, the following message is shown on the display:

Failure

Tank is not

filled.

Fault message 0027(tank filling not ok)



HELP


>Please check both

level switches

Valves BV 43,44,45

must be closed



Check position

>Check

automatic de-

gassing valve



>Check the

automatic filter

and FQ counter for

flow rate


ESC



8164-9001-600/0501

Confirm fault

ACK





8164-9001-600/0501

6.2.27 Automatic filter If the cleaning time for emptying of the filter chambers is exceeded, the follow-ing message is shown on the display:

Failure

Cleaning time for

automatic filter

over limit

Fault message 0028 (automatic filter)


HELP


>Check

pneumatic filter

for compressed-

air supply 4 bar



>Check for

electrical

drive the

function



of motor protection

switch,

wiring



>Check the

limit switch

for correct

function



8164-9001-600/0501

ESC


Confirm fault

ACK





8164-9001-600/0501

6.2.28 Power-supply moni-toring

In order to ensure perfect availability of the Visco Booster plant, a redundantpower supply system is provided for the control unit. When carrying out servicework the required power supply source can be selected or both sources can beswitched on by hand, so that the Visco Booster plant can be mains-supplieduninterruptedly if one system fails.

Abnormal conditions well cause collective alarm and to the following fault mes-sage:

Failure of power supply system - input 33.4

Failure

power supply system 1

Voltage supply

failed

Fault message 0029(failure power supply system 1)



HELP


Check on-site

power supply system

-main switch

-protection system


ESC


Confirm fault

ACK





8164-9001-600/0501

Failure of power supply system - input 33.5

Failure

power supply system 2

Voltage supply

failed

Fault message 0030(failure power supply system 2)



HELP


Check on-site

power supply system

-main switch

-protection system


ESC


Confirm fault

ACK





8164-9001-600/0501

6.3 Causes and action6.3.1 Control unit

Actio

n

• Sw

itch

on m

ain

switc

h.•

Activ

ate

circ

uit b

reak

ers.

• Sw

itch

on p

ower

sup

ply

unit.

• R

epla

ce p

ower

sup

ply

unit

if re

-qu

ired.

• C

heck

plu

g co

nnec

tor.

• Pr

ess

keys

"Shi

ft“ a

nd "H

elp“

.•

Pres

s "K

EY“.

• Pr

ess

"RU

N“ k

ey.

• U

nit p

rom

pts

pass

wor

d.•

Ente

r pas

swor

d.•

Pres

s "E

NTE

R“ t

o co

nfirm

.•

Pres

s "E

SC“ k

ey.

• Pr

ess

"RU

N“ k

ey.

• LE

D "R

UN

“ fla

shes

and

ligh

tsco

ntin

uous

ly a

fter 5

s.

• C

7 un

it is

read

y fo

r ope

ratio

n.•

LED

"STO

P“ g

oes

out.

• Pr

ess

the

"ESC

“ key

to re

turn

toth

e st

art s

cree

n.

Cau

ses

Che

ck w

heth

er:

• m

ain

switc

h in

pos

ition

"ON

“.•

auto

mat

ic c

ircui

t bre

aker

s ar

esw

itche

d on

.•

gree

n LE

D "O

K“ is

on

on th

epo

wer

sup

ply

unit.

Plug

con

nect

or fo

r pow

er s

uppl

y to

the

C7

unit

is p

lugg

ed in

pro

perly

.

C7

unit

is in

mod

e "S

TOP“

.C

PU o

f con

trol d

isab

led.

CPU

for t

ext d

ispl

ay e

nabl

ed.

Expl

anat

ions

No

supp

ly v

olta

ge a

t C7

unit

Whe

n po

wer

is

supp

lied

the

unit

perfo

rms

a se

lf-te

st, s

igna

ls "

star

t-up

com

plet

e“ a

nd is

in th

e pr

elim

i-na

ry s

ettin

g "S

TOP“

.

Mes

sage

Text

dis

play

dar

kSt

atus

LED

s da

rk

Text

dis

play

ligh

ts u

pSt

atus

LED

"ST

OP“

lig

hts

up Stat

us L

ED "R

UN

“ dar

k


8164-9001-600/0501

Actio

n

To p

reci

sely

dia

gnos

e th

e fa

ult

asp

ecia

list

mus

t up

load

the

di

ag-

nost

ic

buffe

r of

th

e C

7 un

it fo

rev

alua

tion,

usi

ng a

pro

gram

min

gun

it.R

epla

ce th

e un

it.In

the

case

of s

peci

al p

rogr

ams,

cons

ult t

he e

lect

rical

eng

inee

ring

depa

rtmen

t in

Oel

de.

If it

can

be a

void

ed, d

o no

t dis

con-

nect

the

unit

from

the

pow

er s

uppl

yan

d re

plac

e th

e bu

ffer

batte

ry a

spe

r cha

pter

6.4

.2 (p

age

143

ff).

Atte

ntio

n:In

corre

ct h

andl

ing

will

lead

to d

ata

loss

!

Rep

lace

the

unit.

Try

to a

ckno

wle

dge

with

the

ESC

key.

Oth

erw

ise

cont

act

the

elec

trica

len

gine

erin

g de

partm

ent

in O

elde

or th

e m

anuf

actu

rer's

hot

line.

Cau

ses

SF-L

ED li

ghts

up

in c

ase

of:

• m

odul

e er

rors

in th

e un

it•

Firm

war

e er

rors

• pr

ogra

mm

ing

erro

rs•

timer

erro

rs•

faul

ty in

tern

al m

emor

y•

batte

ry fa

ilure

or n

o bu

fferin

gw

hen

"PO

WER

ON

“•

inte

rnal

per

iphe

ral f

aults

LED

"BAT

“ lig

hts

up b

ecau

se:

• ba

ttery

is to

o w

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8164-9001-600/0501

6.4 Maintenance

6.4.1 Storing batteries • Store the batteries in a dry, cool place.Batteries can be stored for up to 5 years.

6.4.2 Changing the battery In an inactivated state data loss in the internal user memory is prevented by abuffer battery.

SFBAF FRCE

DC5VSTOPRUN

1

Fig. 22

Change the battery at least once ayear.When the LED "BAF“ (1) goes on, thebattery must be replaced immedi-ately.Part-No.: 0005-4057-020

When changing the battery do not switch off the power supply to the con-trol unit!Replace the battery only when "POWER ON“.Otherwise data in the user memory can be erased during the batterychange.

Warning!The use of batteries may result in injury and damage.Wrongly handled batteries can explode or cause serious burns.

Do NOT• recharge• heat• burn• drill• crush• short-circuitbatteries

Note:Do NOT touch the inside of the unit or slip metal parts (e.g. screwdriver) into theunit.Electrical components and printed circuit boards are accessible and might bedamaged.


8164-9001-600/0501

Proceed as follows: The battery is located in a compartment in the power supply unit.

2

• Unscrew cover (2) of the battery compartment.

6 3 4

5

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• Pull the cover up and to the right.Make sure you raise the cover only as far as the length of the battery con-nections (3) allow.

Fig. 23

Fig. 24


8164-9001-600/0501

• Remove the connector (4) of the old battery (5).

• Loose the cable binders (6) with which the battery (5) is attached to thecover.

• Attach the new battery (5) with the cable binders (6) to the cover.

• Plug the connector (4) of the new battery (5) into the corresponding socket inthe battery compartment.The notch on the connector (4) must point to the left.

• Place the cover (2) with the springs to the left onto the control unit and screwthe cover (2) tight again.

• Dispose of the battery according to the pertinent local regulations and guide-lines.


8164-9001-600/0501

NoteNotes

NotizenAnotaciones

NotizenNotesNote


Business UnitMechanical Separation Technology

A company of mg technologies group

Westfalia Separator Mineraloil Systems GmbH • Werner-Habig-Straße 1 • D-59302 Oelde •Phone +49 (0) 25 22 / 77-0 • Fax +49 (0) 25 22 / 77-2394 •

http://www.westfalia-separator.com / mailto: [email protected]

8164-9001-600_c7_booster_en

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