Siemens PLC - Control For Grinding Mills General Description

PLC - Control
for Grinding Mill Drives
General Description
PLC CONTROL
g Technologies
Project Execution
San Cristobal / Bolivia
Gearless Drives
SAG Mill / 13050 kW
Ball Mill / 7830 kW
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SIEMENS PLC - Control
SERVICE REPORT
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General Description
General Description PLC - Control

Gearless Drive / Twin Drives
Overview / Index
1 INTRODUCTION 6
1.1 PLC – Software general 6

1.1.1 Special features 6
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2 MILL OPERATION FUNCTIONS / OVERVIEW 8
2.1 Operation Modes: 8

2.1.1 REMOTE Normal 8
2.1.2 LOCAL Normal 8
2.1.3 LOCAL Balancing 8
2.1.4 LOCAL Inching 9
2.1.5 LOCAL Creeping 10
2.2 MLCP Operation Instructions: 11

2.2.1 Selecting REMOTE Mode 11
2.2.2 Selecting LOCAL Disabled Mode 11
2.2.3 Selecting LOCAL Mode 11
2.2.4 Changing Speed Setpoint 11
2.2.5 Changing Rotation Sense 12
2.2.6 Fault Acknowledgement 12
2.2.7 Emergency Stop push button 12
2.3 Start Procedure Mill: 13

2.3.1 Start Trunnion Bearing Lubrication System 13
2.3.2 Start Mill Drive Auxiliaries 14
2.3.3 Start High Voltage Switchgear 14
2.3.4 Start Mill Motor 15
2.4 STOP Procedure Mill 16
2.5 Cyloconverter Cooling System : 17
2.6 Motor Cooling System / Twin Drive Systems 17
2.7 Anticondensation Heating System: 18
2.8 Mill Drive Auxiliaries: 18
I&S IP PEP PE2/Schiffer Page 2 of 113

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General Description
2.9 Brake System: 19
2.10 Lube System: 22

2.10.1 Low Pressure System: 22
2.10.2 High Pressure System: 22
2.10.3 Rundown Emergency System: 23
2.11 E-House Airconditioning: 25
2.12 Data Exchange Plant Control System DCS<-> Siemens Mill Control PLC 26
3 QUICK OVERVIEW MILL INTERLOCKING CONDITIONS 27
3.1 Existing Mill Interlocking Levels 27
3.2 Interlocking Conditions with Memory 27

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4 TECHNOLOGICAL FUNCTION GROUPS 28
4.1 Function Group Overview 28
4.2 Function Group Details 29

4.2.1 = .A INTERFACE WITH OTHERS 29
4.2.2 = .B POWER AND CONTROL VOLTAGE 30
4.2.3 = .C CONVERTER TRANSFORMER 31
4.2.4 = .G CYCLOCONVERTER 32
4.2.5 = .H CYCLOCONVERTER COOLING SYSTEM 33
4.2.6 = .J EXCITATION RECTIFIER 34
4.2.7 = .K MOTOR AND MONITORING 35
4.2.8 = .L MOTOR AUXILIARIES / Gearless Drives / Twin Drives 36
4.2.9 = .M MOTOR SPACE HEATERS 37
4.2.10 = .N GENERAL MONITORING 38
4.2.11 = .P MILL LOCAL CONTROL PANEL (MLCP) 39
4.2.12 = .R BRAKE SYSTEM 40
4.2.13 = .U CLOSED LOOP CONTROL Simadyn D 41
5 PCS7 GENERAL PROGRAM STRUCTURE 42
5.1 Introduction 42
5.2 PCS7 Plant View 43

5.2.1 Internal Group Structure 44
5.3 PCS7 Run Sequence 45
5.4 CFC-Charts: 46
5.4.1 CFC-Chart: Common functions 46
5.4.2 CFC-Chart Drive 47
5.4.3 CFC-Chart Analog Value 48

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General Description
5.4.4 CFC-Chart Operation Messages 49

5.4.5 CFC-Chart Single Faults 50
5.5 PCS7 Further Info´s 51

5.5.1 Overview of used blocks and flag areas 51
5.5.2 Block Structure within a Group 53
5.5.3 Example: Block list for Group = .A to = .H: 53
5.5.4 Allocation Flags <-> Mill Interlockings 54
5.5.5 Example: CFC-Chart with Interlockings of Group = .H: 54
5.5.6 Flag Bits for the Group = .A and a Part of Group = .B: 55
6 WINCC 56
6.1 WIN CC Pictures 56

6.1.1 Start Picture: 56
6.1.2 Plant Communication Overview: 57
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6.1.3 Overview: 58
6.1.4 Lube System: 59
6.1.5 Brake System: 60
6.1.6 Air Cooling Motor: 61
6.1.7 Cycloconverter Cooling System: 62
6.1.8 External Cooling System (Option): 63
6.1.9 Bearing Temperatures Mill: 64
6.1.10 Winding Temperatures Motor: 65
6.1.11 Single Line: 66
6.1.12 E-House: 67
6.1.13 Air Gap Supervision: 68
6.1.14 Group Interlockings: 69
6.1.15 Faceplate Measuring Value: 70
6.1.16 Measuring Value Fault: 71
6.1.17 Faceplate Measuring Value: 71
6.1.18 Faceplate Drive: 73
6.1.19 Status Indication 75
6.1.20 Help: 76
6.1.21 Change Language: 77
6.1.22 System Date and Time: 78
6.1.23 WIN CC Clock Settings: 79
6.1.24 Optional Functions Selection: 80
6.2 WIN CC Curves 81

6.2.1 Winding Temperatures 1: 82
6.2.2 Winding Temperatures 2: 83
6.2.3 Cooling Water: 84
6.2.4 Cooling Air: 85
6.2.5 Converter Cooling: 86
6.2.6 Bearing Temperatures: 87
6.2.7 Bearing Oil Flow: 88
6.2.8 Bearing Oil Pressure: 89
6.2.9 Converter Transformer Temperatures: 90
6.2.10 E-House Temperature: 91

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General Description
6.2.11 Brake System: 92

6.2.12 Lube System: 93
6.2.13 Motor Values in Normal Mode (Start and Stop sequence): 94
6.2.14 Motor Data in Normal Mode (Start and Stop sequence): 95
6.2.15 SIMEAS Q / Part 1 (Option) 96
6.2.16 SIMEAS Q / Part 2 (Option) 97
6.2.17 Printout of Trends: 98
6.2.18 Print screenshot: 98
6.2.19 Online Trend Control: 99
6.2.20 The Selection of a Curve: 100
6.2.21 The Selection of the Curves from the Archive: 100
6.2.22 Definition of the Name and Selection of the Tag of the Curve: 101
6.2.23 General Settings: 102
6.2.24 Selection of Trend Groups: 102
6.3 WIN CC Message System 104

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6.3.1 Incoming Alarm List: 104

6.3.2 Outgoing Alarm List: 105
6.3.3 Process List: 106
6.3.4 Operation List: 107
6.3.5 Journal List: 108
6.3.6 First Fail Alarm List: 109
6.3.7 Tag List: 110
6.3.8 Tag Selection: 111
6.3.9 Message Type: 112

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General Description
1 INTRODUCTION
1.1 PLC – Software general
The PLC-Plant-Software for Ringmotor control is based of the Siemens

Standard-Ringmotor-Control Software Packet, and is already running in
several plants around the world.
This software packet includes software modules (Grinding Mill specific) for
the typical different control tasks of a Grinding Mill and Siemens standard
function packets for specific common tasks as basic auxiliaries drive control,
reading and processing of measuring values, supplying of information for the
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visualization system WinCC and so on.
=> The Grinding Mill specific software packet has to be adapted for each
project because of mill specific requirements.
1.1.1 Special features
are available and assist the customer to reduce downtime because of

shutdowns / plant problems
- No limitation in drive starts, after a mill stop is no waiting time necessary

before the next time the mill can be started
- Monitoring / supervision devices with two alarm levels, warning and trip, so
the operator has the possibility to react , analyze and solve if possible, a
problem before a faulty situation leads to a shutdown and loss of production
time
- Message system where all operation and fault messages be stored of the
last three months, several options and sort criteria available for analyzing /
faultfinding purposes
- all operator actions of the last three months are stored too
- separate access levels to the system are prepared for several personnel
groups as operator, maintenance, service
- All status and fault information is available for the plant control system too
- First out detection system to assist maintenance personal in analyzing mill

shutdowns

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General Description
- All analog values available as trends, trends are stored over 30 days, also
the operator can use his own selection of trend groups for analyzing purposes
- PLC with implemented hardware-diagnostic, the visualization system gives

detailed information in case of faulty modules / field PLC-equipment
- Software-changes / modifications can be done quickly, and online during

operation of sag mill
- field bus for field signals installed as optical ring, so one break does not
influence the operation of the mill
- critical part of cyclo-converter cooling system redundant, additional hot

swapping to standby system included
- e-house air-condition system redundant, each system is capable to take over

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every time the function of the other system
- special logic control for accumulator charging pumps of brake and lube
system.
Switch-on frequency and operation duration are supervised. Too high switch
on frequency would indicate leakages in the piping system or anywhere else in
the system (pressure losses).
Increasing operation duration would indicate any problems with pumps / dirt /
big leakage (brake of a pipe for example). In all cases the operator gets
information about the situation and has therefore the chance to act
immediately to check / solve the situation and avoid mill shutdowns
- the PLC-Software can be adapted easily to satisfy special customer

requirements / duties

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General Description
2 MILL OPERATION FUNCTIONS / OVERVIEW
2.1 Operation Modes:
Selection of Operation modes is possible at the Mill Local Control Panel

(MLCP)
(only if the mill is out of service)
2.1.1 REMOTE Normal

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Operation via DCS,

Speed Range between 3 and 11 rpm for Gearless Drives and
150 and 210 rpm for Twin Drives, adjustable from the DCS System.
2.1.2 LOCAL Normal
Operation from the Local control panel,

Speed Range between 3 and 11 rpm for Gearless Drives and
100 and 210 rpm for Twin Drives, adjustable with "Speed lower/raise"
pushbuttons on the local control panel in Steps of +/- 0.5 rpm (Gearless
Drive) or +/- 5 rpm (Twin Drives)
[DCS and Lube System must be in operation !!]
2.1.3 LOCAL Balancing
As in inching mode the mill can be rotated back to a balanced position.
The maintenance personnel can select this mode of operation on the MLCP
by turning the selector switch “NORMAL – BALANCING – INCHING –
CREEPING” into the “BALANCING” position. The Gearless Drive opens the
brake and turns, torque-controlled, the mill back to balanced position, without
oscillations.
Start procedure is the same as for a normal mill start, external process
interlock is inactive, operator needs feedback MILL READY TO START to be
able to start balancing with the MILL START pushbutton.

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General Description
2.1.4 LOCAL Inching
Operation from the Local control panel,

Fixed speed 1.2 rpm for Gearless Drives and 20 rpm for Twin Drives, Inching
angle selectable with the 2-digit Contraves switch on the LCP, 1 digit is equal
to one bolt, is equal to 5 degree, e.g. 36 = 36 bolts = 180 degree.
Inching operation is performed by the Mill Drive via the MLCP at a speed of
approximately 1.2 rpm for Gearless Drives and 20 rpm for Twin Drives.
Inching mode and the direction of rotation is selected by the operator at the
local control panel. A thumbwheel (Contraves) switch is then used to select
the “Requested Angle” of rotation. The unit of measurement for the rotation
angle is the number of bolts around the mill circumference.
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The “MILL READY FOR OPERATION” indication lamp provides the operator
with feedback that all is in readiness to push the MILL START pushbutton at
the MLCP.
The drive accelerates slowly and rotates the mill. When the charge cascades
for the first time, this so called ”Cascading Angle” is measured and
memorized by the system.
The Mill Drive rotates the mill to the “Requested Angle” setted on the Local
Control Panel and it overturns the “Requested Angle” by the “Cascading
Angle”.
Reaching the calculated summary value of requested angle plus cascading
angle, the Mill Drive stops and rotates the mill back to the “Requested Angle’,
stopping the mill with a balanced charge. Then the mill motor will be switched
off electrically.
This automatic procedure avoids any mill oscillations after inching and
considerably reduces downtime, because operation can start faster with the
maintenance tasks or initiate without delay further mill starts.

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General Description
2.1.5 LOCAL Creeping
Operation with the creeping panel, which is stored in a box nearby the local
panel. Fixed speed 0.3 rpm for Gearless Drives and 6 rpm for Twin Drives,
the mill turns as long as the RUN pushbutton is pushed. Start and operation
of the Mill is enabled, when the white lamp is on.
The creeping panel is equipped with

- An indication lamp READY
- A pushbutton RUN
- An EMERGENCY OFF pushbutton
The operator changes the NORMAL - BALANCING – INCHING –

CREEPING selector switch on the Local Control Panel to CREEPING.
Pushing RUN on the creeping panel will start the gearless drive and will turn
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the mill slowly at 0.3 rpm in the direction selected on the MLCP. This speed is
slow enough to allow a detailed inspection of the shell surface or the liners
coming out of the grinding material (with the feed chute removed).
Creep mode allows the operator to move the mill charge up to the
“Cascading Angle”. As the charge cascades, mill liners are then exposed for
inspection or exchange.
As in inching mode the system measures and memorises the “Cascading
Angle”.
The operator can stop the mill by releasing the RUN pushbutton.
The Gearless Drive stops the mill in unbalanced position and applies the
brake.
The brake holds the mill in the unbalanced position.
The operator can continue turning the mill even out of unbalanced position by
pressing the RUN pushbutton again.
Also the direction of rotation can be changed in unbalanced position.
Running and stopping the mill with this means, that the operator has the
possibility to get exactly the requested liner on a certain place.
The brake is closed and the mill remains in unbalanced position.

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General Description
2.2 MLCP Operation Instructions:
2.2.1 Selecting REMOTE Mode

(Operation by DCS)
Mill Operation Mode NORMAL must be selected,

Mill must be balanced and Pinion/Mill Speed = 0
Selector switch Normal/-Inching on LCP in position NORMAL
Selector-Switch Local/Remote on LCP in position REMOTE
Signal “Remote Control” from DCS present
2.2.2 Selecting LOCAL Disabled Mode

(Any Operation disabled)
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Mill must be balanced, Pinion/Mill Speed = 0,

Selector-Switch Local/Remote on LCP in position LOCAL DISABLED.
Used for maintenance purposes, the selector switch can be locked, in this
position it is not possible to start the mill motor neither in local nor in remote
mode.
2.2.3 Selecting LOCAL Mode

(Operation from MLCP)
Mill must be balanced, Pinion/Mill Speed = 0,

Selector-Switch Local/Remote on MLCP in position LOCAL
2.2.4 Changing Speed Setpoint
Normal mode:
Depending on whether the mill is running in local or remote mode, the speed
reference is coming from the DCS-System (remote) or has to be changed at
the MLCP using the “-“ and “+” pushbuttons.
With pushing one of these buttons the speed indication changes from actual
speed value to speed reference.
When the pushbutton is pressed longer than 5s, the speed reference gets
changed in steps of 0.5 rpm (for Gearless Drive) or 5 rpm (for Twin Drives)
each 2s.
Inching/Creeping:
Fixed speed setpoints, not changeable by operator.

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General Description
2.2.5 Changing Rotation Sense
Clockwise / counterclockwise
Is only possible from the DCS-System (Twin Drives only)

Operation mode REMOTE and NORMAL must be selected
Mill must be balanced and Pinion/Mill Speed = 0
Is only possible from the MLCP (Gearless Drives)

Operation mode LOCAL and NORMAL must be selected, Mill balanced and
switched off
or
Operation mode LOCAL and INCHING/CREEPING selected, Brake closed
and Drive switched off.
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2.2.6 Fault Acknowledgement
Possibility to acknowledge any fault in the mill drive system locally from the
MLCP, if Local Mode is active
2.2.7 Emergency Stop push button
Always active, pushing this button trips the main circuit breakers, stops the mill
drive and the related auxiliary drives on the mill floor level

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General Description
2.3 Start Procedure Mill:
The following guidelines are designed to be a general help to Mill Drive

Operations and Maintenance personnel involved in re-starting of Mill Drive
equipment. It is assumed that all auxiliary equipment including trunnion
bearing lube system has been shut-off for maintenance reasons. Procedures
for re-starting the Mill Drive with auxiliary equipment still running become
then simplified versions of the following general procedure by leaving out the
unnecessary steps.
2.3.1 Start Trunnion Bearing Lubrication System
(Twin Drives: Lube system controlled by DCS-System)

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The low and the high pressure lube system for the Mill trunnion bearings
should be re-started first when preparing for a return to operation. It generally
makes sense to re-start the lube system as soon as possible (i.e. after
completion of any maintenance activities on lube units) to avoid unnecessary
cooling of piping and bearings.
Unnecessary pump standstills should be avoided.

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General Description
2.3.2 Start Mill Drive Auxiliaries
These consist of all cooling equipment for the Mill Drive(s) itself, the cooling
equipment for the cycloconverter
(Twin Drive: and the hydraulic jacket pumps for the pinion lubrication).
(Gearless Drive: and excitation rectifier fan).
These auxiliaries can be group started from the DCS in REMOTE Mode or
via the AUXILIARIES START pushbutton on the MLCP in LOCAL Mode, if the
auxiliary systems are ready to start, otherwise a start command will not be
accepted.
(Gearless Drives: A further pre-condition for a successful GROUP START is

that all the motor cooling fan selector switches on the mill panel +.U21
(former +.U22) are in REMOTE position. The LOCAL position setting for
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these selector switches is used only for maintenance applications to allow

controlled on/off testing of individual motor fans.)
After triggering a GROUP START the warning horn will sound for 20
seconds.
Twin-Drives: Time-delay for 10 sec before the cycloconverter cooling unit, all
the motor cooling fans and the hydraulic jacking pumps are switched on.
Gearless-Drives: Time-delay for 10 sec before the first four motor cooling
fans are started, 5sec later the second group of fans and cycloconverter
cooling system as well as the excitation cubicle fan are started
Further delays may occur before all feedbacks are satisfied to give a MILL
DRIVE AUXILIARIES RUNNING display on the MLCP and in the DCS.
2.3.3 Start High Voltage Switchgear
The next step is to request closing of the main circuit breaker.
Before that it is recommended to close the motor disconnector switches.

These motor disconnectors isolate the Mill Drive motors from the
cycloconverter unit (power conditioner) in the E-house. These switches must
be opened, grounded and secured before any Maintenance or Operations
personnel enter the Mill body.
After all appropriate switches have been closed the availability of the main
power will be indicated on the MLCP and in the DCS system.

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General Description
2.3.4 Start Mill Motor
At this stage the DRIVE TROUBLE lamp on the MLCP should be off if no
faults remain in the control system. It may be necessary to ACKNOWLEDGE
the controls to reset any stored faults in the system. If a Trouble still persists,
electrical maintenance must check in the E-room for cause of problem.
When no DRIVE TROUBLE exists, it is still possible that a MILL DRIVE

READY signal is not indicated on the MLCP lamp and in the DCS. This can
be because of one of the following reasons.
-.The 3 Minutes Time Delay initiated after opening the brakes has still not
elapsed. This time-delay is to ensure that the Mill Drive rocks out before a re-
start is applied.
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-.The EXTERNAL PROCESS INTERLOCK I/II signal is not satisfied as

indicated by the off status of the control lamp on the MLCP.
This hardwired signal to the Siemens PLC is the operation permissive to the
Mill Drive from the external grinding equipment (ball mills, conveyors,
screens, lube system (Twin Drives only!)...) and is active in both REMOTE
and LOCAL Modes of operation.
This signal has no meaning during INCHING and CREEPING operation
which can be performed only in LOCAL Mode (Gearless Drives).
Therefore in the case of a missing EXTERNAL PROCESS INTERLOCK an
external!! fault causes inhibit mill operation.
If this signal disappears during mill operation, it will cause a shutdown of the
Mill Drive(s).
- no ROTATION DIRECTION SELECTED
The control system stores the actual active rotational direction. Under normal
circumstances no re-selection of rotational direction is required unless
explicitly desired by the Operators. If however an overall reset has been
carried out on the Mill control systems as part of some maintenance
procedure, the stored rotational sense will be reset and a new selection will
be necessary to obtain a MILL DRIVE READY. The lack of a stored rotational
sense is indicated by flashing of both COUNTERCLOCKWISE and
CLOCKWISE lamps on the MLCP.
When a MILL DRIVE READY has been achieved, the mill can be started from
the DCS if in REMOTE Mode or with a pushbutton command from the MLCP
when operating in LOCAL Mode.
The Mill Drive will slowly accelerate to Inching Speed (Twin Drive: 20 rpm)
after starting and hold this speed for one half revolution (180 deg.
mechanical) to perform continuously the frozen charge test. The Mill will then
ramp to the setpoint speed as sent by the DCS in REMOTE Mode or
selected locally by the Operator with SPEED RAISE and LOWER commands

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General Description
at the MLCP when operating in LOCAL Mode within the permitted mill
specific speed range
(Note: Normal Speed Range 3 - 11 rpm for Gearless Drive and

100 – 210 rpm for Twin Drives).
.
2.4 STOP Procedure Mill
A single operator command stops the Mill. There are two stop modes.
NORMAL STOP, brings the mill to standstill with a speed ramp of 40
seconds, FAST STOP will bring the mill to standstill in 20 seconds.
The Mill Drive(s) controls the stopping of the Mill to standstill, however at
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zero speed the load is still unbalanced. To avoid unwanted oscillations and to
balance the load, the implemented torque control automatically turns the Mill
back and stops with balanced load.
=> This has the benefit, that there is no mayor waiting time till the Mill is
balanced, the operator can immediately restart the Mill again.
Note: Under emergency stop situations forced by faults which trigger an

emergency stop with gate blocking cyclo-converter or emergency off main
circuit breaker, a controlled stop of the Mill is not possible, the following
further reactions depend of the individual situation.

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General Description
2.5 Cyloconverter Cooling System :
CONTROL function and supervision of the water cooling system for the
cycloconverters.
The cycloconverter cooling system consists of 2 pumps as well as 2 solenoid

or motorized valves. A pump/valve pair will be switched on/off (with the
common auxiliary drive start/stop command by DCS or in LOCAL Mill
operation from MLCP) as selected by the selector switches located at a small
panel directly beside this cooling unit.
From this small panel it is also possible to operate the pumps/valves in
LOCAL Mode for testing purposes (only if Mill is not in operation).
The system is a redundant one, any fault in pump or heat exchanger-circuit
(flow low, pressure low, drive fault) will cause an automatic switch-over to the
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other valve or pump. It is also possible to trigger a manual switch-over to the

other valve or pump by changing the selection with the selector switch.
Water conductivity is monitored. If the conductivity cranks a certain limit, a

further solenoid valve behind the pump-circuit opens and steadily a part of
the de-ionized water goes back through the de-ionize unit till the conductivity
drops below the limit.
Severe faults of the system trigger a Mill shutdown (refer to mill interlockings
below)
2.6 Motor Cooling System / Twin Drive Systems
Control of Mill Motor Cooling, fan control, oil jacking pumps control, status
monitoring of motor cooling and bearing pressure
Bearing pressure monitoring is only active in INCHING/CREEPING Mode or

NORMAL Mode with Pinion Speed below 70 rpm, pressure too low is a
normal stop interlock and leads to a Mill shutdown.
Pressure low as start permit interlock is only relevant for INCHING and
CREEPING operation of the oil jacking pumps is monitored if the pinion
speed is < 50 rpm, failure of one pump in this speed range triggers a mill
shutdown with gate blocking
All 4 primary and 2 secondary fans are running is a start permit condition for
the mill, during operation only the internal and external air temperatures are
monitored, any temperature too high triggers a NORMAL STOP shutdown of
the Mill.
In Standstill of the Mill the fans and the oil jacking pumps can be started and
stopped individually for testing purposes, furthermore the whole group can be

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General Description
started together from the DCS System with the Mill in REMOTE Mode or
from the Mill LCP with the Mill in LOCAL Mode.
2.7 Anticondensation Heating System:
Anticondensation heating is achieved by heating elements with a three-phase

supply. During periods of motor standstill, the motor temperature is
automatically kept above dew point.
2.8 Mill Drive Auxiliaries:

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These consist of all cooling equipment for the Mill Drive motor itself, the
cooling equipment for the cycloconverter and for the excitation rectifier in the
E-house. These auxiliaries can be group started from the DCS in REMOTE
Mode or via the MILL DRIVE AUXILIARIES START pushbutton on the MLCP
in LOCAL Mode.
A pre-condition for a successful GROUP START is that all the motor cooling
fan selector switches on the mill panel +.U21 (former +.U22) are in REMOTE
position. The LOCAL position setting for these selector switches is used only
for maintenance applications to allow controlled on/off testing of individual
motor fans.
After enacting a GROUP START the warning horn will sound for 20 seconds.
There is then a time-delay for 10 sec before the cycloconverter cooling unit,
the external water/air cooling circuit and 4 SAG motor fans are switched on. A
further 5 sec time-delay elapses before the excitation rectifier and the
remaining motor fans are automatically switched on. Further delays may
occur before all feedbacks are satisfied to give a MILL DRIVE AUXILIARIES
RUNNING display on the MLCP and in the DCS.

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General Description
2.9 Brake System:
Twin Drive System
control function and supervision of the brakes for each pinion

- includes a Dual Brake System, working with oil pressure, with 2-way
solenoid valves, oil tank, hydraulic pump, one oil pressure sensor for
common oil pressure monitoring, and wear sensors at each brake for brake
position monitoring.
Opening and closing of the brakes will be monitored by oil pressure, also the
brake position is monitored with the wear sensors.
The brake opens with oil pressure applied.
With oil pressure low starts automatically the hydraulic pump to increase the
oil pressure, oil pressure low for more than 5 sec leads to a Mill shutdown.
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With Mill balanced and Pinion Speed = 0 for longer than 30 sec the 2-way-
valve will be closed (energized) and therefore the brakes too.
The brakes open again automatically with the next MILL START command.
Gearless Drive Brake-System Design
The Brake-System consists of two Caliper Brakes, located at the

discharge end of the Mill, a hydraulic unit with accumulator charging
pump, immersion heater, SVR and SVC valves, and of a local control
panel, located at the front side of the hydraulic unit. Furthermore is
there at each brake a selector switch to close and open the brakes in
LOCAL Mode of the brake system.
The position of the brake will be monitored by limit switches, also the
oil pressure in the accumulators, the oil pressure in the main line and
the oil pressure for each brake will be monitored.
The immersion heater is controlled by a thermostat and monitored by a
further temperature switch.
Oil level is monitored too, oil level too low will stop the accumulator
charging pump.
The isolating valves are monitored, closing of one of the valves will
lead immediately to a shutdown of the mill.

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General Description
Brake System in REMOTE Mode is a precondition for the

operation of the Mill Drive
Overview Operation Modes / Status Brake System:
Operation Mode Mill Drive Operation Mode Brake Status Brake

Normal mode, remote always open
Normal mode, SP/SF Fault remote closed
Inching mode, Mill stopped remote closed
Creeping Mode, Mill stopped remote closed
Stop rocking remote closes
manual lowering remote opens
no operation possible local open /closed
Mill Drive Brake System: Operation

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The caliper brakes will be applied if the Mill Drive is in NORMAL Mode
operation, in the following cases:
1. Loss of power to or any electrical tripping of the selected trunnion

bearing supply pumps (high pressure pumps and thrust pump,
pinion).
2. Signalling of any FSLL flow low low switch or any PSLL pressure
low low switch on thrust, feed or discharge bearings.
3. Loss of pressure in lube accumulator system.

This would imply no emergency lube oil back-up system available
and would endanger trunnion bearings by simultaneous tripping
of high pressure pumps.
4. Manual actuation of any EMERGENCY STOP pushbutton at

various local control panels or E-house container. An
EMERGENCY STOP activation will trip high voltage main circuit
breakers, cut Mill Drive motor, switch-off all Mill Drive auxiliary
cooling equipment, discharge lube accumulator system by de-
energizing (opening) dumping valves and finally will set or close
the caliper brakes by the two-way control de-energizing valve.
The EMERGENCY STOP pushbutton at the lube control panel will in

addition switch-off all lubrication pumps in the system.

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In the case of a lube unit shutdown for maintenance, the brake will
have set on the Mill Drive. The brake will automatically open in
NORMAL Mode after 10 sec sounding of warning horn,
when all oil flows and pressures have been restored to the trunnion
bearings and when the emergency accumulator system has signalled
its re-charged condition.
We assume also that any E-STOPs have been removed and
acknowledged in the control system and that the brake unit is in
AUTOMATIC Mode as selected at the brake panel.
It is therefore imperative that the caliper brake assembly is isolated,
including stored energy in its accumulator bladder circuit, to avoid any
undesired opening of the brake during maintenance activities. This is
absolutely vital to protect Maintenance and Operations personnel who
wish to enter the Mill body.
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The brake system fast braking valve is only energized during

INCHING, CREEPING or STOP ROCKING modes and is never
energized during a NORMAL Mode brake application. This valve
provides a fast braking capability and is used only for very low speed
applications. Brake opening in NORMAL Mode is exclusively obtained
by energizing the brake control valve and closing by switching this
same valve off. If the brake refuses to open despite energizing this
valve (a brake fault will be indicated by the BRAKE TROUBLE lamp on
the MLCP) the most likely problem is a "forgotten" closed isolating
hand-valve at the brake supply lines. An ACKNOWLEDGE signal from
the MLCP or from the DCS after opening the hand valve will allow a re-
try by the control system to open the brake.
After successful start-up of lubrication system and after achieving a

released brake condition, the Mill Drive auxiliaries are the next in line.

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General Description
2.10 Lube System:
The Lube-System is separated in 3 parts, the Low Pressure System, The

High Pressure System, and the Rundown Emergency System.
The Lube-system has two operation modes, LOCAL and REMOTE, which
can be chosen from the local control panel besides the lube system.
Changing an operation mode is only possible during the Mill is out of
operation. Generally local operations can be performed only, if LOCAL Mode
is active. Only STOP commands are always allowed, independent of the
selected operation mode.
To operate the Lube System from the MLCP or from the DCS-System,
REMOTE Mode has to be selected at the Lube Local Control panel.
2.10.1 Low Pressure System:

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The low pressure system has the function to clean the oil and cool the
temperature down. The oil will be pumped from the return oil section of the
oil tank through the low pressure pump, the selected oil filter and heat
exchanger to the clean oil section of the tank.
Oil level, oil flow and filter differential pressure will be monitored.
Oil flow too low, oil level too low or a given STOP command (included
emergency off lube system) will stop the operating pump.
2.10.2 High Pressure System:
The high pressure system consists of 3 high pressure pumps (two in

operation, one standby), which supply the feed end and discharge end
bearing.
For some High Pressure Lube Systems the following drives are also existing:
Two piston pumps, which are both in operation, if the mill is running with low
speed, and boost the oil pressure for feed / discharge end bearing, and two
thrust rail pumps (one in operation, one standby), which supply the thrust
rails and feed the accumulators of the rundown emergency system.
Monitored are oil flow of feed end/discharge end bearing and thrust rails, and
oil pressure for feed end / discharge end bearing. Precondition for the start of
a high pressure pump is, that conditioned oil flow and lube reservoir oil level
are ok. Interlocks for the high pressure pumps are electrical fault of the
pump, emergency stop lube system, active stop commands, and lube
reservoir oil level low, or conditioned oil flow low or no LP-pump in operation
(everything delayed).
In the clean oil section are two (or three) heaters mounted, which are
controlled by the measured oil temperature (RTD). The heaters will be turned
on with a temperature below 40 degree, with a temperature higher than 47
degree the heaters will be turned off.
The HP-Pumps are always started in a certain sequence. It is not possible to

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General Description
start two high pressure pumps at the same time in LOCAL Mode for
example. A green flashing indication at the local control panel means either
´drive fault´ or during a start sequence, that the start of this pump is
interlocked for a certain time.
2.10.3 Rundown Emergency System:
This system consists of accumulators, pressure relief and unloading valve.

The function of this system is to keep the oil pressure in the piping in the
case of a pressure drop or oil flow too low until the Mill is in a standstill
position. In such a situation the unloading valve will be opened and
discharge the accumulators. As soon, as the faulty situation is cleared, and
oil flow and pressure are ok for the bearings, the unloading valve will be
closed and the pressure relief valve opens, so that the accumulators can be
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charged again by the thrust rail pump or the separate Accumulator charge
pump. The pressure of the accumulators will be monitored. With pressure
low starts the charging sequence automatically.
The lube system for the Mill Drive trunnion bearings should be re-
started first when preparing for a return to operation. It generally
makes sense to re-start the lube system as soon as possible (i.e. after
completion of any maintenance activities on lube units) to avoid
unnecessary cooling of piping and bearings. The heater elements in
the lube oil tanks switch-on automatically if the oil temperature drops to
40 deg. C. but any unnecessary pump standstill should be avoided.
The lube pumps can be re-started locally at the lube control panel or
remotely by the DCS operator. Pre-condition for local starting is that
the main selector switch at the Mill Local Control Panel (MLCP) is in
LOCAL Mode, for DCS operator starting it must be in REMOTE Mode.
Firstly, one low pressure pump should be started. A selector switch at
the lube control panel selects between two pumps = .S11 and = .S12.
Operations must however check that the selector switch setting agrees
with the hand-valve arrangements in the low pressure circuit. With one
of these pumps started, the lube oil will be circulated and conditioned
(cooled and cleaned) in preparation for starting the high pressure
pumps.
Next, a pair of the three available high pressure pumps = .S21, = .S22,
= .S23 must be started. Again coordination with Operations is
necessary to ensure that only those 2 pumps which are correctly hand-
valved into the system are actually started. One of these pumps will

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General Description
then supply high pressure oil to the feed end bearing, the other pump
to the discharge end bearing. The third pump remains in a stand-by
condition.
Next (if available), one of the thrust pumps, = .S31 or = .S32, must be
started to provide oil supply to the trust rail. Again a selector switch is
provided to select operating pump, again this switch setting must
agree with hand-valve arrangements in the circuit.
The accumulator charging pump = .S41 or = .S42 (if redundancy

available) must never normally be manually started from the lube panel
or from the DCS. The selected charging pump (selector switch at lube
panel) will be automatically switched on by pressure control.
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Precondition for automatic switch-on is that the accumulator dumping

valves are energized to direct oil flow into accumulator bottles. These
valves will close automatically (energized state) when high pressure oil
supply has been fully restored to the trunnion bearings. This requires 2
high pressure pumps and one thrust pump to be running and all PLL
(pressure low low) and FLL (flow low low) switches on thrust, feed and
discharge pads to be satisfied. Only then will the valves close to
enable charging of the accumulator bottles. The charging process
takes about 15 min and provides another reason to re-start the lube
unit as soon as possible.
Finally the piston pumps = .S33, = .S34 (if available) are started to
provide an additional lifting force and oil cushion to the piston pads.
They always run together and reduce wear and tear on the bearings
during ramp-up's. These pumps will be automatically stopped after 5
minutes Mill DRIVE RUNNING by the control system.
A MAINTENANCE/RUN RELEASED switch is provided at the lube
control panel. When this switch is in the MAINTENANCE position, the
pumps will stay on indefinitely after MILL DRIVE START. This enables
measurements or checks to be performed at the piston pads.
When all pumps have been started as above and the accumulator
bottles have been re-charged as indicated by clearing of the pressure
switch PSL, a LUBE SYSTEM READY (no LUBE SYSTEM TROUBLE)
should be indicated at local panels with indicator lamps and in the DCS
system.

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General Description
2.11 E-House Airconditioning:
includes two separate airconditioner systems for the control and the
cycloconverter room of the E-house
Each airconditioner consists of an internal circulation fan, two compressors
and one (or two) external fan. Flow monitors are installed in the E-House
bottom for monitoring the operation of the airconditioner. The temperature of
each room is monitored by one RTD.
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General Description
2.12 Data Exchange Plant Control System DCS<-> Siemens Mill Control PLC
The standard communication is an Industrial Ethernet connection,

with TCP/IP Protocol:
- TCP/IP communication SIMATIC PCS7 <-> DCS
- Control Signals / Setpoints from DCS
- Drive Status to DCS

- Measuring Values to DCS
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- Faults / Limits to DCS

- First Fail Signal to DCS
Optional a Modbus connection can be provided also:
- Modbus communication SIMATIC PCS7 <-> DCS

Settings: Modbus RTU-Format
Interface: RS422/485
Baud-Rate: 9600
Data-Bits: 8
Stop-Bit: 1
Parity: even
The SIMATIC S7-400 is Modbus Slave and stores the information for DCS
(Modbus Master) in a Data Block.
The communication area consists of 512 Words (Registers):
The Master reads via Function Code 03 (Read Holding Registers) the information
from Register 0 - 251.
The Master writes via Function Code 06 (Modify Register Contents) the information
to Register 252 - 511.

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General Description
3 QUICK OVERVIEW MILL INTERLOCKING CONDITIONS
3.1 Existing Mill Interlocking Levels
“Emergency Stop” triggers trip of Main Circuit Breaker(s)
“Gate blocking” triggers an immediate stop of pulse firing to the thyristors,

cyloconverters are immediately deenergized, Mill starts rocking
“Fast stop” triggers a controlled Mill stop with a shorter ramp time [20s]
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“Normal stop” stops the Mill with the normal ramp down time (40s)
“Start permit” brings up an alarm, but doesn't stop the Mill during operation.
Note: The Mill won't start without start permit.
3.2 Interlocking Conditions with Memory
- requires an alarm acknowledge in fault case

(by operator via WinCC or with a local pushbutton, if mentioned)
Faults of the Brake System

Faults of Auxiliary Drives
After activation of an Emergency stop button
Stator Earth Fault (locally in CCV room)
Transformer Overcurrent (locally in CCV room)
The Most Faults of the Battery Charger (locally in CCV room)
MCC Faults (locally in CCV room)
Pressure/Flow low Cylcoconverter Cooling System
Closed Loop Control (Simadyn D) indicates Summary Fault

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General Description
4 TECHNOLOGICAL FUNCTION GROUPS
4.1 Function Group Overview
The used Hardware and Software for Siemens Grinding Mill Drives (Gearless
Drives and Twin Drives) is subdivided in special Groups for the different
technological functions of a grinding mill:
Group overview
Group = .A Interface with others

Group = .B Power and Control Voltage
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Group = .C Converter Transformer

Group = .D Spare
Group = .E Excitation Transformer (optional)
Group = .F Harmonic Filter (optional)
Group = .G Cycloconverter
Group = .H Cycloconverter Cooling
Group = .J Excitation
Group = .K Ring Motor and Monitoring
Group = .L Motor Auxiliaries
Group = .M Motor Space Heating
Group = .N General Monitoring
Group = .P Local Control Panel
Group = .R Brake System
Group = .S Lube System (Twin Drives: by others)
Group = .T Spare
Group = .U Closed Loop Control (Simadyn-D)
Group = .V Spare
Group = .W Spare
Group = .X E-House, Air Condition (optional)
Group = .Z E-House Lighting (optional)

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General Description
4.2 Function Group Details
In the following detailed information about the different function groups for
each function group is shown
- Short description =>a brief description of the group functions
- Includes => which equipment / functions are included in this group
- Mill Interlockings => which devices /signals/conditions leads to a

Mill Shutdown
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4.2.1 = .A INTERFACE WITH OTHERS
Short description:
Monitors the status of the main circuit breaker and handles the
communication with the DCS-System
Supervises the status of the harmonic filters and includes the release-logic
Includes
Interface to Main Circuit Breaker
Interface to Excitation Circuit Breaker
Industrial Ethernet via TCP/IP protocol or Serial link (MODBUS) to DCS
Part of Control Logic for Harmonic Filter Equipment
Mill Interlockings
Gate Blocking
Main Breaker off or not on

Excitation Breaker off or not on
DCS Mill Permissive II missing
Harmonic Filter not on
Synchronizing voltage fault
Normal stop
DCS Mill permissive I missing

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General Description
4.2.2 = .B POWER AND CONTROL VOLTAGE
Short description:
No control sequences, monitors the status of low voltage (LV) and medium
voltage (MV) distribution
Includes
Battery 24V DC
Battery charger
24V DC Distribution
115V AC Control voltage
230V AC Control voltage
Feeder Excitation 1 and 2 (for Twin Drives)
400V AC Main incoming supply feeder
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Mill Interlockings
Emergency Stop
Trip of a 24V DC, 110/230V AC circuit breaker triggers mostly an emergency

stop
Any fault of the 400V feeder
Gate blocking
400V synchronizing voltage fault

Feeder excitation fault
Normal stop
Feeder battery charger fault

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General Description
4.2.3 = .C CONVERTER TRANSFORMER
Short description:
Temp. Control Logic for transformer fans (if applicable - >55°C Fans on),
monitors the status of the Cycloconverter-Transformer 1-3 and some
transformer protection equipment
Includes
Transformer 1-3, fans (if applicable), and some transformer protection
equipment
Mill Interlockings
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Emergency off
Buchholz tripped
Winding temperature tripped
Oil temperature tripped
Normal Stop
Hardware fault oil temp. supervision
Start Permit
Buchholz warning
Oil level low warning
Winding temperature warning
Oil temperature warning

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General Description
4.2.4 = .G CYCLOCONVERTER
Short description:
No control sequences, monitors the status of the Cycloconverter- 1, 2
(signals to PLC via Closed Loop Control)
Includes
Cycloconverter and signals from protection devices
Mill Interlockings
Emergency off
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Feeder converter electronic fault

Branch fuse / voltage fault
Pulse voltage fault
Thyristor fault
Overvoltage fuse fault

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General Description
4.2.5 = .H CYCLOCONVERTER COOLING SYSTEM
Short description:
includes
- two heat-exchanger systems, one in operation, one standby
- two water-pumps, one in operation, one standby
- one ion exchanger unit
- water tank with level monitoring, conductivity-measurement, several RTDs,
flow and pressure switches
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Mill Interlockings
Emergency off
Water conductivity too high
Gate blocking
No valve open or no pump running

Internal flow/pressure low and standby circuit not ready
Internal water return temperature too high or disturbed
Tank level too low
Start permit
Tank level low alarm

Internal / external water cooling temperature high

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General Description
4.2.6 = .J EXCITATION RECTIFIER
Short description:
No control sequences, monitors the status of the excitation rectifiers (signals
to PLC via Closed Loop Control)
Includes
Excitation rectifier and supervision devices
(2 Excitation rectifier for Twin Drives)
Mill Interlockings
Emergency off
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feeder excitation electronic fault

incoming fuse off
overvoltage overload or fuse fault
17,5/24V fault
auxiliary circuit breaker tripped

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General Description
4.2.7 = .K MOTOR AND MONITORING
Short description:
Monitors the status of the isolator cubicles which are located at Stator or
nearby the Mill, monitors the winding temperatures and the bearing shell
temperatures (only for Twin Drive Motors).
Includes a mill start supervision, if 10s after a given start command to
Simadyn D there is still feedback “Mill balanced” present, a reset of the start
command will be initiated.
Includes
monitoring of winding temperatures
monitoring of bearing shell temperature (only for Twin Drive Motors)
supervision of isolator cubicles
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Mill Interlockings
Gate blocking
isolator stator open or not closed

isolator excitation open or not closed
isolator switch operating handle inserted
Fast Stop
bearing temperature too high or hardware fault
Normal Stop
winding temperature too high or hardware fault

speed not > 0 10s after mill start
Start permit
winding temperature alarm high
bearing temperature alarm high (only for Twin Drive Motors)

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General Description
4.2.8 = .L MOTOR AUXILIARIES / Gearless Drives / Twin Drives
Short description:
Includes for Twin Drive Motors
4 Fans of primary and 2 secondary circuit for each motor

2 Hydraulic oil jacking pumps for each motor
Includes for Gearless Drive Motors
8 or 6 Fans for a Ringmotor

4 or 3 Air to Water Coolers with RTDs and Flow Monitors
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Mill Interlockings
Gate blocking (only for Twin Drive Motors)
Hydraulic jacking oil pumps not running in Operation Mode inching/creeping

or in Operation Mode normal and speed lower than 70rpm
Fast Stop (only for Twin Drive Motors)
Oil pressure hardware fault
Normal stop
Oil pressure too low (under hydrodynamic level) (only for Twin Drives)
External / internal circuit temperature too high or hardware fault
Start permit
External/internal circuit air temperature alarm

Not all fans in operation
Oil pressure not reached (under hydrostatic level) (only for Twin Drives)

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General Description
4.2.9 = .M MOTOR SPACE HEATERS
Short description:
Motor Space Heaters control and Status monitoring,
Motor bearing temperature supervision (only for Twin Drive Motors).
If the mill is not in operation and the average temperature in a motor drops
below 30°C, the space heater of this motor will be turned on.
Includes
Motor space heaters
Bearing oil heaters (only for Twin Drives)
Bearing oil temperature supervision (only for Twin Drives)
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Mill Interlockings (only for Twin Drives)
Normal stop
Bearing oil temperature measurement hardware fault

Bearing oil temperature too high
Start permit
Bearing oil temperature low alarm

Bearing oil temperature high alarm

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General Description
4.2.10 = .N GENERAL MONITORING
Short description:
No control sequences, monitors cyloconverter / transformer protection
devices, internal earth faults, PLC-Operation, and the Status of the
emergency stop buttons
Includes
Transformer overcurrent protection
Transformer differential protection
Earth fault monitoring
Supervision PLC and emergency stop buttons
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Mill Interlockings
Emergency Stop
Transformer overcurrent
Transformer differential protection tripped
Overcurrent monitoring unit not in operation
Diff.protection monitoring unit not in operation
Stator/converter diff. protection tripped
Stator monitoring system not in operation
Stator earth fault
Emergency off electrical room
High voltage room door open
Gate blocking
PLC air flow low (only for Simatic S5 155U PLC)

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General Description
4.2.11 = .P MILL LOCAL CONTROL PANEL (MLCP)
Short description:
Control logic for Mill Operation Modes Remote/Local,
Normal/Balancing/Inching/Creeping, Start/Stop for Mill Motor and Auxiliary
Drives, reading and supply for the MLCP
Start/Stop pushbuttons and Running Indicator Light for Trunnion Bearing
LP and HP Lube system (only Gearless Drives).
Includes
All operation modes of the Mill Drive
Emergency Stop button Mill area
Creeping panel
Indications / pushbuttons / switches MLCP (Mill Local Control Panel)
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Mill Interlockings
Emergency off
Pushing MLCP/Creeping panel EMERGENCY OFF button or one of the

EMERGENCY STOP buttons besides the mill.
Normal Stop
Auxiliary stop command DCS/MLCP

Mill drive stop DCS/MLCP
Start up warning feedback missing

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General Description
4.2.12 = .R BRAKE SYSTEM
Short description:
Includes
control and monitoring of the brake system
Mill Interlockings
Gate blocking
Brake not open after time

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Brake not closed after time

Oil pressure low > 5s
Brake position failure
Motors turning and 2-way valve energized or electrical fault
Fast stop
Hydraulic pump electrical fault and oil pressure low
Start permit
Hydraulic pump faulty

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General Description
4.2.13 = .U CLOSED LOOP CONTROL Simadyn D
Short description:
Data-Exchange with Closed Loop Control Simadyn D, link monitoring, sends
several Mill Operation Commands to the CLC, receives Status/Fault
information
Includes
Interface to Simadyn D
Supervision of Simadyn D Status/Operation
Supervision of Simadyn D Voltage Supply and Distribution
Mill Interlockings
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Emergency off
Interface to Simadyn D fault

One of the power supplies for Simadyn D tripped
Simadyn D not in operation
Gate blocking
Inching / Creeping fault

Digital tacho fault
Normal stop
Summary fault indication of Simadyn D

Start permit
Summary warning indication of Simadyn D
Note: Simadyn D takes care of a lot of protections for the operation of the
transformers, the cycloconverters and the motors and is also able to trigger a
shutdown of the mill with ‘Emergency Stop’ or ‘Gate Blocking’.

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General Description
5 PCS7 GENERAL PROGRAM STRUCTURE
for Gearless Drives and Twin Drives
5.1 Introduction
Hardware and Software for Siemens Grinding Mill Motors (Gearless Drives
and Twin Drives) is subdivided in special Groups for the different
technological functions of a Grinding Mill
Group = .A Interface with others

Group = .B Power and Control Voltage
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Group = .C Converter Transformer

Group = .D Spare
Group = .E Excitation Transformer (not Twin Drives)
Group = .F Harmonic Filter (not Twin Drives)
Group = .G Cycloconverter
Group = .H Cycloconverter Cooling
Group = .J Excitation
Group = .K Ring Motor and Monitoring
Group = .L Motor Auxiliaries
Group = .M Motor Space Heating
Group = .N General Monitoring
Group = .P Local Control Panel
Group = .R Brake System
Group = .S Lube System (not Twin Drives)
Group = .T Spare
Group = .U Closed Loop Control (Simadyn D)
Group = .V Spare
Group = .W Spare
Group = .X E-House, Air Condition (not Twin Drives)
Group = .Z E-House Lighting (not Twin Drives)

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General Description
5.2 PCS7 Plant View
The same structure is also used in the PCS7 Plant View:

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General Description
5.2.1 Internal Group Structure
Each Group has the following components / CFC Charts:

(as maximum, some groups have less components, depends of the
technological function in a group)
Common functions xCOMMON

Drives xDRIVE
Analog Values xMEAS
Operation Messages xMESSAGE/xOPERATION
Single Fault Messages xMESSAGE/xSINGLEFAULT
Here is an example of the Group = .H Cycloconverter Cooling:

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General Description
5.3 PCS7 Run Sequence
The Run Sequence of the PCS7 Program has the same structure, sorted by
Groups:
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H_COMMON General functions Group = .H

H_DRV Drives Group = .H
H_OP Operation Messages Group = .H
H_SF Single Fault Messages Group = .H

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General Description
5.4 CFC-Charts:
5.4.1 CFC-Chart: Common functions
E.g. for Group = .H:

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Sheet 1 Spare
Sheet 2 Block Calls
Sheet 3 Group Interlockings
Sheet 4 Mean-/Max-Values for the Group
Sheet 5 Operation / Fault Messages
Sheet 6 Acknowledge, Group Status and
First Fail Function for the Group

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General Description
5.4.2 CFC-Chart Drive
For each Drive of the System exists an own CFC-Chart, with an Input FC
(IN), a Drive Block (M) and an Output FC (OUT).
Example CFC-Chart Drive for Group = .H:

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The Input FC's for Drives start with FC1001 for Drive No. 1.
For a complete list of the Drives for this plant, refer to DCS_Interface /
Drives document in the PLC Project-documentation.

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General Description
5.4.3 CFC-Chart Analog Value
For each Analog Value exists also an own CFC-Chart, with a Driver Block
(Driver), Input FC (IN), Measuring Value Block (X) and an Output FC (OUT).
The Driver Block detects automatically faults of the Analog Modules.
Example CFC-Chart Analog Value for Group = .H:

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For a complete list of the Measuring Values for this plant, refer to
DCS_Interface / MV-List in the PLC Project-documentation.

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General Description
5.4.4 CFC-Chart Operation Messages
Example for Group = .H:
The Operation Messages for the Group will be detected in the Operation
CFC-Chart.
These Messages will be collected in a special Function (FC777), and then
transferred to the Message Block.
This MESSAGE Block transfers the Operation Messages to WIN CC.

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General Description
5.4.5 CFC-Chart Single Faults
Example of the Group = .H:
The Single Fault Messages for the Group will be detected in the Single Fault
CFC-Chart.
These Messages will be collected in a special Function (FC779), and then
transferred to the related Message Block.
This MESSAGE Block transfers the Fault Messages to WIN CC.

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For a complete list of the Single Faults for this plant,

refer to DCS_Interface / Faults in the PLC Project-documentation.

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General Description
5.5 PCS7 Further Info´s
Further information regarding the use of Blocks and Flag Bits. For each
Group a special area of Blocks (FC's, DB's) and Flag Bits is reserved.
5.5.1 Overview of used blocks and flag areas
Group = .A Functions FC700 - FC709 / Data Blocks DB700 - DB709

Flag Bytes MB 700 - MB 709
Group = .B Functions FC710 - FC719 / Data Blocks DB715 - DB719
Group = .C Functions FC720 - FC729 / Data Blocks DB720 - DB729
Group = .D Functions FC730 - FC739 / Data Blocks DB730 - DB739
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Group = .E Functions FC740 - FC749 / Data Blocks DB740 - DB749

Group = .F Functions FC750 - FC759 / Data Blocks DB750 - DB759
Group = .G Functions FC760 - FC769 / Data Blocks DB760 - DB769
Group = .H Functions FC770 - FC779 / Data Blocks DB770 - DB779
Group = .J Functions FC780 - FC789 / Data Blocks DB780 - DB789
Group = .K Functions FC790 - FC799 / Data Blocks DB790 - DB799
Group = .L Functions FC800 - FC809 / Data Blocks DB800 - DB809
Group = .M Functions FC810 - FC819 / Data Blocks DB810 - DB819
Group = .N Functions FC820 - FC829 / Data Blocks DB820 - DB829
Group = .P Functions FC830 - FC839 / Data Blocks DB830 - DB839
Group = .R Functions FC840 - FC849 / Data Blocks DB840 - DB849
Group = .S Functions FC850 - FC859 / Data Blocks DB850 - DB859
Group = .T Functions FC860 - FC869 / Data Blocks DB860 - DB869
Group = .U Functions FC870 - FC879 / Data Blocks DB870 - DB879
Group = .V Functions FC880 - FC889 / Data Blocks DB880 - DB889
Group = .W Functions FC890 - FC899 / Data Blocks DB890 - DB899

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General Description
Group = .X Functions FC900 - FC909 / Data Blocks DB900 - DB909

Group = .Z Functions FC910 - FC919 / Data Blocks DB910 - DB919
The use of blocks and flags in a group is always the same

(as far as possible), therefore the reference between a Group in the Plant
and the PCS7-Program is clear and easy.
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General Description
5.5.2 Block Structure within a Group
Also a special structure of Blocks is used in the PCS7-Program for each

Group, this structure is equal for all Groups, in Groups with few or less
functions only some of the blocks are used.
FCxy0 General
FCxy1 Interlock
FCxy2 }
FCxy3 }
FCxy4 } => free available,
FCxy5 } e.g. for communication tasks
FCxy6 }
FCxy7 Operation Messages
FCxy8 Status
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FCxy9 Single Fault Messages

xy - consecutive counting number, equal within one group, for one group
always a range of 10 blocks is reserved
5.5.3 Example: Block list for Group = .A to = .H:

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General Description
5.5.4 Allocation Flags <-> Mill Interlockings
For each Group exists an area of Flag Bits with the same signification for
mill interlocking.
All these signals must have signal state High to enable operation of Mill Drive !!
(Exception: Start permit only for starting the mill, during operation does not matter).
M xyz.0 Emergency Off EO

M xyz.1 Gate Blocking GB
M xyz.2 Fast Stop FS
M xyz.3 Normal Stop NS
M xyz.4 Start Permit SP
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The Mill is ready for operation, when all Groups have Start Permit
(High signal = OK).
5.5.5 Example: CFC-Chart with Interlockings of Group = .H:

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General Description
5.5.6 Flag Bits for the Group = .A and a Part of Group = .B:
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General Description
6 WINCC
6.1 WIN CC Pictures
6.1.1 Start Picture:

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General Description
6.1.2 Plant Communication Overview:

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General Description
6.1.3 Overview:
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General Description
6.1.4 Lube System:

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General Description
6.1.5 Brake System:

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General Description
6.1.6 Air Cooling Motor:

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General Description
6.1.7 Cycloconverter Cooling System:

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General Description
6.1.8 External Cooling System (Option):

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General Description
6.1.9 Bearing Temperatures Mill:

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General Description
6.1.10 Winding Temperatures Motor:

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General Description
6.1.11 Single Line:

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General Description
6.1.12 E-House:
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General Description
6.1.13 Air Gap Supervision:

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General Description
6.1.14 Group Interlockings:

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With the function 'Disable Message Suppression' it is possible to display

fault messages immediately, without any interlockings. This makes sense only for
signal check during commissioning.
The same purpose has the function 'Enable extended Op. Messages'.
It shows detailed commands during commissioning, but makes no sense for
normal operation.

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General Description
6.1.15 Faceplate Measuring Value:

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For detailed information the Faceplate can be enlarged.

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General Description
6.1.16 Measuring Value Fault:

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6.1.17 Faceplate Measuring Value:
The sign AH (Alarm High) announces a Fault Message and WH (Warning High)
announces a Warning for this Measuring Value.

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General Description
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The operator can change, in the Faceplate above, the limits for the Analog Value.

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General Description
6.1.18 Faceplate Drive:
This Faceplate displays a Drive On in Simulation Mode ( ! ), which is used for

Test only.
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General Description
For detailed information the Faceplate can be enlarged.

The Sign AH (Alarm High) announces a Fault Message for this Drive.
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It is not provided in this plant to operate the Drives from WIN CC.
Therefore the buttons are not active.
This box allows only setting or resetting the operation hours of this Drive.

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General Description
6.1.19 Status Indication
For Status information purposes in WIN CC each message has additional an

identifier for the Alarm-Mode.
Value 1 ==> Warning Low (WL)

Value 2 ==> Warning High (WH)
Value 4 ==> Alarm Low (AL)
Value 8 ==> Alarm High (AH)
This Information will be displayed in the WIN CC Picture as follows:

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General Description
6.1.20 Help:
The following picture shows the different color combinations for Drives,
Valve, Circuit Breaker, Transformer, Converter and Monitoring symbols.
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General Description
6.1.21 Change Language:
The operator is able to change the Language of the WIN CC Displays

between English <--> Spanish.
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After selecting 'spanish' button it takes a few seconds for changing the Language.
Then the Language changes to Spanish.

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General Description
6.1.22 System Date and Time:
The PCS7 V6.0 is based on Coordinated Universal Time (UTC) Date/Time

settings.
To set this System Date/Time, the Operator has to change "Date/Time"

in the WINDOWS Control Panel.
This Date/Time will be set in WIN CC (UTC or LOC) and also in the PLC (UTC).
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General Description
6.1.23 WIN CC Clock Settings:

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General Description
6.1.24 Optional Functions Selection:
Depending on Logon permissive, the operator can select different PCS7 or

WINDOWS functions.
Change Keyset:
WINDOWS 2000 / PCS7 Selections:

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General Description
6.2 WIN CC Curves
The selection of Trends (curves) will be done via 'Trend' key:
It appears a keyset with the different selection keys for the curves:
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Change keyset:
It appears the next keyset with more selection keys for the curves:

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General Description
6.2.1 Winding Temperatures 1:

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General Description
6.2.2 Winding Temperatures 2:

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General Description
6.2.3 Cooling Water:

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General Description
6.2.4 Cooling Air:

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General Description
6.2.5 Converter Cooling:

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General Description
6.2.6 Bearing Temperatures:

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General Description
6.2.7 Bearing Oil Flow:

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General Description
6.2.8 Bearing Oil Pressure:

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General Description
6.2.9 Converter Transformer Temperatures:

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General Description
6.2.10 E-House Temperature:

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General Description
6.2.11 Brake System:

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General Description
6.2.12 Lube System:

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General Description
6.2.13 Motor Values in Normal Mode (Start and Stop sequence):

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General Description
6.2.14 Motor Data in Normal Mode (Start and Stop sequence):

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General Description
6.2.15 SIMEAS Q / Part 1 (Option)

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General Description
6.2.16 SIMEAS Q / Part 2 (Option)

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General Description
6.2.17 Printout of Trends:
The background color of Trend Pictures has been designed in white to

save printer ink.
Independent of Logon permissive, the Operator is able to printout a screen

hardcopy, via screenshot button.
6.2.18 Print screenshot:

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General Description
6.2.19 Online Trend Control:
The selection will be done via key 'trend group':
It appears a selection box, with a list of the trend groups:

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The function 'New' allows the operator to define groups of different curves from
the archive.
The function 'Create' opens the Properties of WIN CC Online Trend Control,
for the definition of the Curves.

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General Description
With the + button a curve can be added or with the - button a curve can be deleted
from the curve picture.
With up or down the position of a special curve can be changed.
6.2.20 The Selection of a Curve:

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6.2.21 The Selection of the Curves from the Archive:

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General Description
6.2.22 Definition of the Name and Selection of the Tag of the Curve:
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General Description
6.2.23 General Settings:

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6.2.24 Selection of Trend Groups:

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General Description
The selected Trend Group will be displayed online:

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For detailed information refer to WIN CC Help function:

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General Description
6.3 WIN CC Message System
The Message System will be selected by the key 'alarm logging'.

After pushing the button, appears the incoming alarm list.
6.3.1 Incoming Alarm List:
This list displays all fault messages, which are still active.
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General Description
6.3.2 Outgoing Alarm List:
This list displays all fault messages, which are already gone.
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General Description
6.3.3 Process List:
This list displays all messages, which are generated by the system.
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General Description
6.3.4 Operation List:
This list displays the operation messages.

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General Description
6.3.5 Journal List:
This list displays all messages, which are stored in the message archive
(ring buffer).
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General Description
6.3.6 First Fail Alarm List:
This list displays the first fail signals, which caused a mill shutdown.
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General Description
6.3.7 Tag List:
This list displays all messages of the ring buffer, which can be sorted via Tagname
selection.
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General Description
6.3.8 Tag Selection:
The operator can select an individual Tagname, searching for a special message.
The input of the Tagname has to be confirmed with Return key.
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General Description
6.3.9 Message Type:
Alarms:
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Warnings:

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General Description
Operation Messages:
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Process Messages:

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Siemens PLC - Control For Grinding Mills General Description

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Siemens PLC - Control For Grinding Mills General Description

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PLC - Control

for Grinding Mill Drives

Mining Technologies Your Success is Our Goal

General Description PLC - Control

1.1 PLC – Software general 6

2 MILL OPERATION FUNCTIONS / OVERVIEW 8

2.1 Operation Modes: 8

2.2 MLCP Operation Instructions: 11

2.3 Start Procedure Mill: 13

2.4 STOP Procedure Mill 16

2.5 Cyloconverter Cooling System : 17

2.6 Motor Cooling System / Twin Drive Systems 17

2.7 Anticondensation Heating System: 18

2.8 Mill Drive Auxiliaries: 18

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2.9 Brake System: 19

2.10 Lube System: 22

2.11 E-House Airconditioning: 25

3 QUICK OVERVIEW MILL INTERLOCKING CONDITIONS 27

3.1 Existing Mill Interlocking Levels 27

3.2 Interlocking Conditions with Memory 27

4 TECHNOLOGICAL FUNCTION GROUPS 28

4.1 Function Group Overview 28

4.2 Function Group Details 29

5 PCS7 GENERAL PROGRAM STRUCTURE 42

5.2 PCS7 Plant View 43

5.3 PCS7 Run Sequence 45

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5.4.4 CFC-Chart Operation Messages 49

5.5 PCS7 Further Info´s 51

6.1 WIN CC Pictures 56

6.2 WIN CC Curves 81

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6.2.11 Brake System: 92

6.3 WIN CC Message System 104

6.3.1 Incoming Alarm List: 104

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1.1 PLC – Software general

The PLC-Plant-Software for Ringmotor control is based of the Siemens

visualization system WinCC and so on.

1.1.1 Special features

are available and assist the customer to reduce downtime because of

- No limitation in drive starts, after a mill stop is no waiting time necessary

- First out detection system to assist maintenance personal in analyzing mill

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- PLC with implemented hardware-diagnostic, the visualization system gives

- Software-changes / modifications can be done quickly, and online during

- critical part of cyclo-converter cooling system redundant, additional hot

- e-house air-condition system redundant, each system is capable to take over

every time the function of the other system

- the PLC-Software can be adapted easily to satisfy special customer

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2 MILL OPERATION FUNCTIONS / OVERVIEW

2.1 Operation Modes:

Selection of Operation modes is possible at the Mill Local Control Panel

2.1.1 REMOTE Normal