8164-9001-600 C7 Booster en

Westfalia Separator Mineraloil Systems GmbH
Business Unit Mechanical Separation Technology
Instruction manual
No. 8164-9001-600
Edition 0501
Control Unit for Visco Booster Plants Type C7-623
SIMATIC C7-623 7 4
DOWN
ALARMS
8
D
9
E
5 2 0
6 3
UP
1 .
SF BAF
DC5V FRCE
RUN STOP
DIR HARD COPY
DEL INS
ESC
ACK
MDO
HFO
Feeder pump 1
Feeder pump 2
Circul. pump 1
Circul. pump 2
Autom. filter
Vicosity alarm
SHIFT
Manual
FEED Ventilate
Filter cleaning
SLUDGE
HEATER LAL RELEAS tank
LAH tank
Lamp test
HELP
ENTER
III
Subject to technical modifications!
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IV
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 marked with this symbol otherwise, danger to life!
Observe accident prevention regulations. The local safety and accident prevention regulations apply unconditionally to the operation of the Visco Booster unit.
When operating electrical apparatus, certain parts carry dangerously high voltage. Non-compliance with the protective measures can therefore result in serious injury or damage. For this reason, only suitably qualified specialists are allowed to work on these units. Protective measures should be taken in line with national and local regulations.
Instruction manuals Follow the instructions given in this manual and in the Visco Booster unit manual. Proper and safe operation is conditional on appropriate transport and storage conditions, correct installation and assembly as well as careful operation and maintenance.
Operate the Visco Booster plant only in accordance with agreed process and operating parameters. Maintain the Visco Booster plant as specified in the instruction manual of the Visco Booster plant.
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Carry out safety checks on the Visco Booster plant as described in the chapter "Safety" in the Visco Booster plant instruction manual.
Liability for the function of the unit passes to the owner. Liability for the function of the unit passes unconditionally to the owner or operator irrespective of existing warranty periods in so far as the unit is improperly maintained or serviced by persons other than Westfalia Separator Service personnel, or if the unit is not applied in accordance with the intended use. Westfalia Separator AG shall not be liable for damage, which occurs as a result of non-compliance with the above. Warranty and liability conditions in the General Conditions of Sale and Delivery of Westfalia Separator AG are not extended by the above.
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VI
Preface
This instruction manual is intended for the persons entrusted with operation and maintenance of the control unit. To assure safe operation it is therefore essential that the manual is indeed handed over to these persons. In the event of any queries please state the model designation and the serial no. (see name-plate inside the control unit). When ordering spare parts, it aids the rapid and correct processing of your order if you also state the circuit diagram number specified.
Name-plate
Mechanical Separation Division
Type Type Prf-Nr. Control No. Bemessungsspannung Nominal voltage Control voltage Control voltage
............................................................................................ ............................................................................................ ......... V, 3/AC .............. VAC ................... A ................. Hz .............. Hz .............. VDC
Vollaststrom Full-load current Bemessungsstrom (grter Motor/Verbraucher) Nominal current (largest motor/consumer) Kurzschluausschaltvermgen Icn Short-circuit breaking capacity Schaltplan-Nr. Wiring diagram No. Programm-Nr. Program No. Teil-Nr. Part No.
................... A
................. kA ......................................................................... ......................................................................... .........................................................................
A company of mg technologies group Installations- und Schutzmanahmen sind nach den Bestimmungen des VDE bzw. des zustndigen EVU auszufhren. Installation and protective measures are to be taken in accordance with national and local electric rules and regulations.
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VII
General
1.1 1.2 1.3
Application and operating principles ........................................................2 Equipment ................................................................................................2 Control cabinet .........................................................................................3
Control system
2.1 2.2
2.3
2.4
2.5
2.6 2.7 2.8 2.9
Construction .............................................................................................9 Classification specifications .....................................................................9 Design versions ........................................................................................10 Mounting ................................................................................................11 Control unit...............................................................................................11 Electrical connection ..............................................................................12 Fuse terminals........................................................................................12 Installing the control unit in the control cabinet......................................13 Loosening the fixing bracket ..................................................................16
Control unit
3.1 3.2 3.2.1 3.2.2 3.2.3 3.3 3.4 3.4.1 3.4.2 3.4.3 3.5 3.5.1 3.6 3.6.1
17
Technical data........................................................................................18 Getting acquainted with the operating elements....................................19 Function keys .........................................................................................20 Softkeys .................................................................................................23 System keyboard ...................................................................................24 Overview of display pages .....................................................................27 Selecting operating modes ....................................................................29 Calling up the system function menu .....................................................29 Calling up the system function menu .....................................................30 Exiting the system function menu ..........................................................31 Password protection...............................................................................32 Enter password ......................................................................................32 The start screen .....................................................................................33 Interfaces ...............................................................................................34
Operation
4.1 4.2 4.3 4.4 4.4.1 4.4.2 4.4.3 4.4.4 4.4.5 4.4.6 4.5
37
Switching on the control unit ..................................................................38 Start screen............................................................................................39 Calling up the process text pages.........................................................40 Detail settings.........................................................................................47 Fuel selection .........................................................................................47 Feed pumps ...........................................................................................49 Automatic filter .......................................................................................51 Mixing / degassing tank ........................................................................54 Circulation pumps ..................................................................................56 Viscosity measuring ...............................................................................58 Calling up digital inputs ..........................................................................60
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VIII

4.6 4.7 4.8 4.9 4.9.1 4.10 4.10.1 4.10.2 4.10.3 4.10.4 Calling up digital outputs ........................................................................62 Calling up analog inputs.........................................................................63 Calling up analog outputs ......................................................................63 Calling up service addresses .................................................................64 Calling up the system settings ..............................................................66 Loading a new program ........................................................................69 The UD 700............................................................................................69 Loading data from the UD 700 to the C7-623........................................70 Text transfer OP part..............................................................................74 Loading configured data from the programming device into the UD700 .......................................................................................76
Commissioning
5.1 5.1.1 5.1.2 5.1.3 5.1.4 5.1.5
81
How to proceed on the control cabinet ..................................................82 Product selection "MDO........................................................................82 Product selection "HFO ........................................................................83 Feed pumps ...........................................................................................83 Circulation pumps ..................................................................................85 Manual operation ...................................................................................87
Fault signals / Maintenance

6.1 6.1.1 6.2 6.2.1 6.2.2 6.2.3 6.2.4 6.2.5 6.2.6 6.2.7 6.2.8 6.2.9 6.2.10 6.2.11 6.2.12 6.2.13 6.2.14 6.2.15 6.2.16 6.2.17 6.2.18 6.2.19 6.2.20 6.2.21 6.2.22 6.2.23 6.2.24 6.2.25 6.2.26 6.2.27 6.2.28
89
Fault signals ...........................................................................................90 Status and fault indication.....................................................................90 Alarm descriptions..................................................................................91 Feed pumps ...........................................................................................91 DPSH Automatic filter (input 32.2) .........................................................93 LAL mixing tank (input 32.3) ..................................................................95 Motor protection switch of circulation pump 1........................................97 Circulation pump 1 .................................................................................99 Motor protection switch of circulation pump 2......................................100 Circulation pump 2 ...............................................................................102 PSL Circulation pumps (input 32.5) .....................................................103 End position error "MDO.....................................................................105 End position error "HFO......................................................................107 Motor adjustment valve ........................................................................109 Motor protection switch of feed pump 1 ...............................................110 Feed pump 1 ........................................................................................112 Motor protection switch of feed pump 2 ...............................................113 Feed pump 2 ........................................................................................115 PSL Feed pumps (input 32.0) ..............................................................116 Product selection "MDO or "HFO ......................................................118 Bypass filter - input 32.1.......................................................................120 Viscosity below limit .............................................................................121 Viscosity above limit.............................................................................124 Temperature below limit.......................................................................127 Temperature above limit ......................................................................129 Delay time ............................................................................................131 Circulation pumps ................................................................................132 Level switch / mixing tank ....................................................................134 Mixing tank is not filled .........................................................................135 Automatic filter .....................................................................................137 Power-supply monitoring......................................................................139
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6.3 6.3.1 6.4 6.4.1 6.4.2
IX
Causes and action ...............................................................................141 Control unit ...........................................................................................141 Maintenance.........................................................................................143 Storing batteries ...................................................................................143 Changing the battery............................................................................143
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Note Notes Notizen Anotaciones Notizen Notes Note
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General
1.1 1.2 1.3 Application and operating principles ........................................................2 Equipment ................................................................................................2 Control cabinet .........................................................................................3
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1.1
Application and operating principles
Proper functioning of diesel engines operating aboard ships or in power stations requires perfect fuel supply. This vital task is performed by the new Visco Booster plants developed by Westfalia Separator Mineraloil Systems for fuel conditioning. This is a processing system meeting the quality requirements for the fuel between clean oil tank and injection system of main drive engine and auxiliary engine with regard to injection viscosity and temperature. Booster pumps specially designed for this application ensure the required system pressure. The modules are adapted to the individual consumption behaviour of the motors depending 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 availability of the plant and extremely low installation demand. A powerful PLC system with optional bus technology allows optimum process control and supervision. The components of the primary and secondary stages are controlled and monitored by the electronic control unit C7-623/P. Abnormal conditions occurring in the plant are memorised in the control unit and can be retrieved or, optionally, printed at any time. Software allocation to the corresponding Visco Booster plant is done at the factory, using a password-protected function. Detailed information on the specific functions can be found in the corresponding sections of this instruction manual. The illuminated LC display provides information on the functional conditions or troubles prevailing in the Visco Booster plant and - depending on program adjustment - visualises the corresponding process data.
1.2
Equipment
Beside the control cabinet, the control system comprises all component assemblies which, due to built-in electrically actuated equipment, are subject to the control 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
Fig. 1
The control unit C7-623 is incorporated in the door of the control cabinet, ready for connection A project-related view is found in the electro-technical documentation.
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Control system
2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 Construction .............................................................................................9 Classification specifications .....................................................................9 Design versions......................................................................................10 Mounting ................................................................................................11 Control unit.............................................................................................11 Electrical connection ..............................................................................12 Fuse terminals........................................................................................12 Installing the control unit in the control cabinet......................................13 Loosening the fixing bracket ..................................................................16
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16 15
2 3
14
4 5
13 12 6 11
7 10 9
Fig. 2 - Front view of the C7-623 control unit
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Selection local - remote Viscosens / viscosity regulator Feed pump 2 Stand-by - 0 - Automatic Feed pump 2 Stand-by - 0 - Automatic Circulation pump 2 Hand 0-1 Feed pump 2 Hand 0-1 HFO operation MDO operation Main switch mains 2 Main switch mains 1 Lock Circulation pump 1 Hand 0-1 Feed pump 1 Hand 0-1 Feed pump 1 Stand-by - 0 - Automatic Feed pump 1 Stand-by - 0 - Automatic Electronic control unit C7-623/P
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Fig. 3 - Inside view of the C7-623 control unit
1 2 3 4 5 6 7
Electronic control unit C7-623/P Terminal strip Connecting terminals for lead Main switch Circuit breaker Interface relay 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 characters and cursor control. The display is equipped with continuous background illumination. The contrast of 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 adjust the LC display for optimum readability during commissioning. The main switches for redundant supply are installed underneath the electronic unit. Installed on the mounting plate inside the control unit, above terminal strip X1 for connection 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 specifications The C7-623/P control unit complies with the VDE regulations (IEC) and has been 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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Design versions
2.3
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 cabinet with pump motor controls, automatic filter control, mixing/degassing tank control, as well viscosity and temperature regulating devices. Special design: Project-dependent extra equipment such as heater controls and external pump controls, are available at extra cost. For Visco Booster plants installed in potentially explosive areas, operation can be assured by means of an explosion-protected control panel fitted near the 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 operated according to FM in explosion-hazarded zones.
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2.4
Mounting
1 Gasket 10.5x23x5 (part-No. 0007-2278-750) 2 Threaded bolt M 8 (let into wall) 3 Washer 4 Rear panel of control unit 5 Washer 6 Wall
Fig. 5
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 chosen so that the sun cannot shine on the front panel impairing the readability of the display. Heating of the electronic control unit by solar radiation must also be avoided. If the control unit is mounted on a wall, a clearance of approx. 20 mm must be observed. The fixing dimensions are given in the dimensioned drawing in the project-related electrical documentation. The fixing holes at the rear of the control unit must be sealed means of the gaskets supplied. In case of shipboard installations, the unit should be mounted in a lowvibration arrangement and must not be within the vicinity of hot pipelines. Although the electronic control unit is protected against moisture by the protective foil and door seal, the cabinet must not, however, be installed in an 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 Visco Booster plant is at standstill. If the Visco Booster plant is installed in an explosion-hazarded area, the control 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 nameplate inside the control cabinet. The required control voltages, 230 VAC and 24 VDC, are auto-generated. Before operating the control unit, check the rated voltage indicated on the name-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 the fuses specified in the project-related circuit diagram. External voltages: The potential-free contacts of the output modules carry external voltage (even when the main switch is off!). They can be identified by the orange coloured wiring. 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 mm , copper, is adequate for all cables. The arrangement of the terminals on terminal strip X1 is shown in the terminal diagram included in the electrical documentation). The screwed glands for the electrical cables should be properly tightened and packed with sealing compound.
2
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 terminal will respond. This failure is signalled by the corresponding red LED. This single fuse arrangement guarantees the full functionality of the C7-623/P control unit, as the operating voltage 24 VDC is still available. The electronic fuse in the power supply module is not activated. Attention! When the safety system has responded, the functionality of the plant is restricted. 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 control unit in the control cabinet
The C7-623/P control unit has been prepared for fixed installation in a control panel or cabinet door. Housing dimensions Mounting depth Control panel cutout 240 mm x 168 mm 69 mm 230.5 mm x 158.5 mm
69
240
168
230,5 +0,5 1 158,5 +0,5
Fig. 6
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).
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Fig. 7
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.
Fig. 8 - Fixing bracket before engaging
Insert the four fixing brackets (3) (see Fig. 8) into the guides provided for this purpose. Push the fixing brackets in until the spring engages.
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Fig. 9 - Fixing bracket engaged
Screw the four fastening screws enclosed with the control unit into the four fixing brackets (4) (see fig. 9). Tighten the four screws with the Torx screwdriver (torque 0.6 Nm).
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2.9
Loosening the fixing bracket
Proceed as follows when loosening the fixing bracket:
Fig. 10
Loosen the screw (1). Lift the fixing bracket (2). Push the fixing bracket out of the guide (3).
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Control unit
3.1 3.2 3.2.1 3.2.2 3.2.3 3.3 3.4 3.4.1 3.4.2 3.4.3 3.5 3.5.1 3.6 3.6.1 Technical data........................................................................................18 Getting acquainted with the operating elements....................................19 Function keys .........................................................................................20 Softkeys .................................................................................................23 System keyboard ...................................................................................24 Overview of display pages .....................................................................27 Selecting operating modes ....................................................................29 Calling up the system function menu .....................................................29 Calling up the system function menu .....................................................30 Exiting the system function menu ..........................................................31 Password protection...............................................................................32 Enter password ......................................................................................32 The start screen .....................................................................................33 Interfaces ...............................................................................................34
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3.1
Technical data Ordering number WSMS No. Dimensions Installation/cutout dimensions Weight C7-623/P EWK: P4 623 A000 11 303 0005-4050-340 240 x 168 x 69 mm (H x B x T) 230.5 x 158.5 1 350 g
+0.5
mm
Display STN LC display, 4 lines of 20 characters, LED background illumination 5 mm character height Keypad Inputs Outputs Serial interface MPI interface Buffer battery foil-protected keyboard with metal domes 44 keys with 26 integrated LEDs 16 digital, 24 VDC, Range: 11-30 VDC 4 analog 4-20 mA / 0-10 VDC, 4 quick counters 16 digital, 0.5 A each, max. total current A 4 A 4 analog 4-20 mA V.-24 for printer connection Standard Buffer time approx. 1 year
Flash memory / configuration 128 KB memory RAM Configuration software B+B software Power supply Input voltage with polarity reversal protection Current consumption Safety standard Enclosure 128 KB Step 7 ProTool / ProTool Lite digital 24 VDC, Range: 30.2 t0 20.4 VDC yes 2.4 A max. DIN EN 61131-2/IEC 1131-2 Front of unit: IP 65 acc. to IEC 529 housing: IP 20 acc. to IEC 529 Tested as per DIN IEC 68-2-1/ 68-2-2 0 C to 55 C, vertical installation -20 C to +70 C Tested as per DIN / IEC 68-2-3 595% at 25 C vibration: acc. to DIN IEC 68-2-6 operation: 1058 Hz, amplitude 0.075 mm, 58500 Hz, acceleration 9.8 m/s storage: 5 Hz, amplitude 3.5 mm, 58500 Hz, acceleration 9.8 m/s shocking: as per DIN IEC 68-2-29 Semi-sinusoidal 100 m/s2 (10 g), 16 ms, 100 shocks
o o o o o
Electromagnetic compatibility EN 50081-2 / EN 50082-2 Climatic conditions Operation: Storage: Humidity: Operation/storage: Mechan. ambient conditions
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3.2
Getting acquainted with the operating elements
SIMATIC C7-623 7 4
DOWN
ALARMS
8
D
9
E
5 2 0
6 3
UP
1 .
1
SF BAF DC5V FRCE RUN STOP
DIR HARD COPY
DEL INS
ESC
2
MDO HFO
Feeder pump 1 Feeder pump 2 Circul. pump 1 Circul. pump 2 Autom. filter Vicosity alarm
ACK
SHIFT
3
Manual
FEED Ventilate
Filter cleaning
SLUDGE
HEATER LAL RELEAS tank
LAH tank
Lamp test
HELP
ENTER
Fig. 11
The operating interface consists of: 1 2 3 4 5 Display Softkeys Status and fault indicator Function keys System keys
Section 2.1 3.2.2 6.1.1 3.2.1 3.2.3
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3.2.1 Function keys
The function keys have a global function: The actions which can be triggered are independent of the picture indicated by the display. They each incorporate an LED which gives information on the state of the respective function.
Key
MDO
Key designation Fuel selection: Diesel oil operation
Description By actuating this key, the motor adjusting valve is positioned to "MDO fuel". The valve position is monitored by end position switches and 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.
Fuel selection:
HFO
Heavy fuel oil operation
By actuating this key, the motor adjusting valve is positioned to "HFO fuel". The valve position is monitored by end position switches and 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.
Feeder pump 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 of the LED. Faults are signalled by flashing of the LED.
Feeder pump 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" and - the operating mode switch "1S1 is set to "stand-by" mode. Operation of the pump is indicated by continuous light of the LED. Faults are signalled by flashing of the LED.
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Key
Circul. pump 1
Key designation Circulation pump selection: Circulation pump 1 - operation
Description 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" and - the operating mode switch "4S1 is set to "stand-by" mode. Operation of the pump is indicated by continuous light of the LED. Faults are signalled by flashing of the LED.
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" and - the operating mode switch "2S1 is set to "stand-by" mode. Operation of the pump is indicated by continuous light of the LED. Faults are signalled by flashing of the LED.
Autom. filter
Automatic filter
This key has no function. When the filter is in automatic operation, the cleaning cycles are signalled by lighting up of the LED.
Viscosity alarm
Viscosity alarm
This key has no function. Values lower than the preselected min. setpoint or higher than the preselected max. setpoint of viscosity are signalled by flashing of the LED. Details are shown in the display.
Preselection of manual tank degassing

Manual
This key, when operated, will - interrupt automatic degassing of the tank assured by the level switches and - allow manual de-aeration. The LED indicates the "hand" mode.
Valve actuation for tank degassing

Ventilate
When actuating this key in "hand" mode, the degassing valve is opened for pre-set 5 sec. The LED shows the valve to be open. By means of this key, a cleaning cycle is manually triggered. The LED shows the filter to be cleaned.
Filter cleaning
Chamber cleaning - automatic filter
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Key
Key designation Special function
Description The function of this key is programmed as specified in the order and described in the project-related electrical documentation. The function of this key is programmed as specified in the order and described in the project-related electrical documentation. The LED signals the min. level of the tank to be exceeded and, hence the required volume to be available. The LED signals the max. level of the tank to be exceeded
Special function
LAL tank
Min. level mixing / degassing vessel
LAH tank
Max. level mixing / degassing vessel
Lamp test
Lamp test
LEDs of the control unit and external signal lamps are checked for proper functioning.
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3.2.2 Softkeys
The softkeys have local function: The functions that can be triggered depend on the picture currently shown in the display and are marked by a symbol on the display, above the key. Example of triggering an action in the softkey "menu:
MODE: STOP MEN

ALARMS
DOWN
UP
Fig. 12
UP
Press 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. Softkey "ALARMS Picture-dependent function key acc. to display figure. On the process pages (display pages 2/1 - 2/9) you can use this key to call up the alarm message buffer. Picture-dependent function key acc. to display figure. 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.
ALARMS
UP
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Note: Pressing several keys at the same time may lead to incorrect entries.
3.2.3 System keyboard
7
D
8
E
9
F
4 1 .
DIR
5
A B
6 3
C
2 0
DEL INS
ESC
HARD COPY
ACK
SHIFT
HELP
ENTER
Fig. 13
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 is repeated after a short delay until the key is released.
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Numeric ....
0
... .... key block for inputting values When the SHIFT key is pressed you can enter alphanumeric characters A to F. Change-sign key This key is used to alternate between the plus and minus sign. Shift key This key is used to activate the alternate function of double-function keys. The LED goes on when the changeover function is activated. 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. Confirm This key - accepts and exits an entry, - switches from message level to picture level. Acknowledgement key Acknowledges the currently indicated alarm message or all messages of an acknowledgement group; this does not eliminate the fault. The LED remains on as long as at least one unacknowledged alarm message is queued. Insert / delete key This key is used to enter a blank at the cursor position for alphanumeric entries. All following characters are shifted to the right by one position. When you simultaneously press the SHIFT key, you can delete the character at the cursor position for alphanumeric entries. All following characters are shifted to the left by one position. Info key Opens 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 selected object. Displays contents This key is used to call up the screen directory.
DIR
+/-
SHIFT
ESC
ENTER
ACK
INS
DEL
HELP
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Print (hardcopy) This key serves to output the content of the current display via a connected printer (optional).
HARD COPY
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3.3
Overview of display pages
The control functions can be seen in the different display pages. Proceed as follows to view the display pages: Press the "DIR key to get a display of all configured pages
DIR
or ...
... select the desired screen.
Open the desired screen.

ENTER
The following table gives an overview of the available display pages Display Page 1/1 Start menu Display Page 1/2 1/3 2/1 - 2/9 Process information 2/2 2/3 2/4 2/5 2/6 2/7 2/8 2/9 3/1 - 3/3 Fuel selection 3/2 3/3 4/1 - 4/3 Feed pumps 4/1 4/2 4/3 5/1 - 5/10 Automatic filter 5/1 5/2 5/3 5/4 5/5 5/6
Main menu
Submenu Unit no. / Commissioning date Program no./ Unit version Selection of product Feed pumps PAL alarm - feed pumps Automatic filter Mixing tank Circulation pumps PAL alarm - circulation pumps Viscosity Adjustment of setting time for "MDO Adjustment of setting time for "MDO Feed pump 1 Feed pump 2 Pressure monitoring - feed pumps 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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Display Page
Main menu
Display Page 5/7 5/8 5/9 5/10
Submenu Number of total cleaning cycles Number of timed and manual cleaning operations 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 Circulation pump 1 Circulation pump 2 Pressure monitoring - circulation pumps 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 Fault indication - components
7/1 - 7/3
Circulation pumps
7/1 7/2 7/3
8/1 - 8/7
Viscosity measurement
8/1 8/2 8/3 8/4 8/5 8/6 8/7
9/1 - 9/14
Fault statistics
9/1 - 9/14
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 15/1 - 15/5 System settings Service information Language setting, transfer, alarms
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3.4
Selecting operating modes
You can call up the system function menu from every operating level. The following menus are available in the system function menu: C7-CPU operating mode selection RUN-P RUN STOP MRCSs
3.4.1 Calling up the system function menu
DI/DO (Digital-Input/Output) status indication ...
SHIFT
... Simultaneously press the shift key and the help key.
HELP
Note: The LED in the shift key goes out again when you press the help key. The display shows the system functions menu:
SIMATIC C7 SYSTEM FUNCTIONS KEY

DOWN
ALARMS
DI/DO
UP
Fig. 14
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3.4.2 Calling up the system function menu
DOWN
Press the "DOWN key.
The display shows the menu "C7-CPU operating modes :
MODE: STOP RUNP

DOWN
RUN
ALARM
STOP
MRES
UP
Fig. 15
Key
DOWN
Operating mode RUNP
Description The CPU processes the user program. Using a programming device (PD) programs and data can be uploaded from the C7-CPU ( C7 PG), transferred to the C7-CPU (PG C7). The CPU processes the user program. Programs and data in the C7-CPU can be uploaded with the PG/UD 700 ( C7 PG/UD). The program and data can neither be loaded nor modified.
ALARMS
RUN
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 C7CP, not for the C7-OP. Further processing with the C7OP is possible.
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Operating mode MRCSs
31
Key
UP
Description Booting: Booting of the C7-CPU requires a specific sequence of "STOP" and "MRCSs modes. This function needs special knowledge.
3.4.3 Exiting the system function 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
... Enter the password using the numerical keys. For security reasons, the entered digits are displayed as asterisks "*. Confirm the entry or ...
ENTER
... cancel the entry.

ESC
After you have entered a valid password, you can use the password-protected function for two minutes. After this time your access right is "cancelled and the password must be re-entered if necessary. This symbol is used in the manual to refer to the procedure described above, that means: Enter the password as described above. Multiple password-protected entries during the 2 minute session do not require you to enter the password again.
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3.6 The start screen
33
1 2 3 4
22.10.98 10:35:28 Visco Booster Unit Westfalia Separator << LOGOUT LOGIN >>
8
DOWN
ALARMS
UP
5
Fig. 16
1 2 3 4 5 6 7 8
Current date Plant designation Company name Exit start picture level ("DOWN key) Terminate password function ("ALARMS key) Call up password ("" key) Call up start picture level ("UP key) Current time
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3.6.1 Interfaces
The plug and socket connectors (interfaces) required for connecting the various inputs and outputs of the C7 are provided. Attention! Use only approved shielded cables for wiring the analog inputs and outputs as well as the IM, V.24 and MPI interfaces.
o l r u
6 7
Fig. 18
Fig. 17 1 2 3 4 5 6 7 8 l o u r IM interface for external input-/output extension Analog inputs Analog outputs Digital AUX inputs, quick counters Serial port V.24 (e.g. for printer) Digital inputs (top) Digital outputs (bottom) DI/DO 24 VDC power supply left top bottom right
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Fig. 18
MPI interface
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Operation
4.1 4.2 4.3 4.4 4.4.1 4.4.2 4.4.3 4.4.4 4.4.5 4.4.6 4.5 4.6 4.7 4.8 4.9 4.9.1 4.10 4.10.1 4.10.2 4.10.3 4.10.4 Switching on the control unit ..................................................................38 Start screen............................................................................................39 Calling up the process text pages..........................................................40 Detail settings.........................................................................................47 Fuel selection .........................................................................................47 Feed pumps ...........................................................................................49 Automatic filter .......................................................................................51 Mixing / degassing tank ........................................................................54 Circulation pumps ..................................................................................56 Viscosity measuring ...............................................................................58 Calling up digital inputs ..........................................................................60 Calling up digital outputs ........................................................................62 Calling up analog inputs.........................................................................63 Calling up analog outputs ......................................................................63 Calling up service addresses .................................................................64 Calling up the system settings ..............................................................66 Loading a new program ........................................................................69 The UD 700............................................................................................69 Loading data from the UD 700 to the C7-623........................................70 Text transfer OP part..............................................................................74 Loading configured data from the programming device into the UD700 .......................................................................................76
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4.1
Switching on the control 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
Press "ENTER to switch to the start screen:

ENTER
22.11.97 Booster plant
16:30:11
Display page 1/1 (start screen)
Westfalia Separator << LOGOUT LOGIN >>
Contrast adjustment Press the shift key. The LED goes on. Press the "+/- key to adjust the contrast.
SHIFT
+/Press the shift key. The LED goes out.
SHIFT
Calling up display pages Press the "DIR key to call up the directory.
DIR
...
... navigate to the desired display page using the cursor keys.
Press "ENTER to open the desired display page (overview see page 27).
ENTER
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4.2
Start screen
When the control unit has started correctly, you enter the start menu (display page 1/1): 22.11.97 Booster plant Westfalia Separator << >> Press the "Cursor down key to call up the next submenu: 16:30:11 Display page 1/1
Unit no.: ............... Commissioning date 20.10.2000
Display page 1/2
Press the "Cursor down key to call up the next submenu:
Prog: 8104-0623-754 Version: 03.2000 Unit version: P
Display page 1/3
Always state the current program version when contacting Westfalia Separator for 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 the process 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: Press the "MDO key

MDO
or Press the "HFO key.

HFO
Line Description The display shows the selected fuel, currently used. Possible states are: MDO The motor adjustment valve is in MDO position, confirmed by the limit switch. Fuel is supplied from the MDO tank. 2 HFO The motor adjustment valve is in MDO position, confirmed by the limit switch. Fuel is supplied from the HFO tank. No preselection No preselection has been done by means of function keys. - MDO: Marine Diesel Oil operation - HFO: Heavy Fuel Oil operation Fault The motor protection device of the control valve has responded.
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Line Description 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 MDO The motor control valve has duly reached the preselected MDO position within the monitoring time. 4 Limit switch HFO The motor control valve has duly reached the preselected HFO position within the monitoring time. Fault MDO The motor control valve has not duly reached the preselected MDO position within the monitoring time. Fault HFO The motor control valve has not duly reached the preselected HFO position within the monitoring time. Position unknown The 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 Line Description
Display page 2/3
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. 2 Fault Motor protection of feed pump 1 has responded. Preselection "Automatic" Preselector switch "1S1 is in automatic position, and feed pump 1 can be started by means of function key "Feed pump 1. Preselection "stand-by" Preselector switch "1S1 is in stand-by position, feed pump 1 is started automatically if the current operation pump 2 fails to operate or to build up delivery pressure.
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Line Description The current status of feed pump 2 is indicated. Possible states are: Off Feed pump 2 is out of operation. On Feed pump 2 is in operation. 4 Fault Motor protection of feed pump 2 has responded. Preselection "Automatic" Preselector switch "3S1 is in automatic position, and feed pump 2 can be started by means of function key "Feed pump 2. Preselection "stand-by" Preselector switch "3S1 is in stand-by position, feed pump 2 is started automatically if the current operation pump 2 fails to operate or to build up delivery pressure. Press the "Cursor down key to call up the next submenu:
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Feed pump: PAL - pressure alarm Status: 0
Display page 2/4
Line Description The delivery pressure downstream of the feed pumps is monitored by means of pressure switches and is shown in the display. Possible modes are: 3 0 The pumps are out of operation. The preselected pump fails to build up delivery pressure. 1 The preselected pump is operating and builds up pressure. Press the "Cursor down key to call up the next submenu:
Automatic filter Status Ready for operation
Display page 2/5
Line Description 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 are cleaned at cyclical intervals via the differential-speed monitoring system or timer T24. 3 Fault Motor protection of the filter or too dense a cleaning sequence lead to fault signalling. Cleaning The cleaning cycles are indicated in the display. Manual cleaning Manual cleaning is indicated in the display when function key "Manual on the C7 unit has been actuated. Press the "Cursor down key to call up the next submenu:
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Tank level: Tank filled Degassing: open
Display page 2/6
Line Description 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. 2 Tank filled The fuel level has exceeded the level of the "LSL switch. LAL alarm The fuel level has dropped below the level of the "LSL switch when the "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. Press the "Cursor down key to call up the next submenu:
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Circulation pump 1 On Circulation pump 2 Off Line Description
Display page 2/7
The current status of circulation pump 1 is indicated. Possible states are: Off Circulation pump 1 is out of operation. On Circulation pump 1 is in operation. 2 Fault Motor protection of circulation pump 1 has responded. Preselection "Automatic" Preselector switch "2S1 is in automatic position, and circulation pump 1 can be started by means of function key "Circulation pump 1. Preselection "stand-by" Preselector switch "2S1 is in stand-by position, circulation pump 1 is started automatically if the current operation pump 2 fails to operate or to build up delivery pressure. The current status of circulation pump 2 is indicated. Possible states are: Off Circulation pump 2 is out of operation. On Circulation pump 1 is in operation. 4 Fault Motor protection of feed pump 2 has responded. Preselection "Automatic" Preselector switch "4S1 is in automatic position, and circulation pump 1 can be started by means of function key "Circulation pump 1. Preselection "stand-by" Preselector switch "4S1 is in stand-by position, feed pump 2 is started automatically if the current operation pump 1 fails to operate or to build up delivery pressure. Press the "Cursor down key to call up the next submenu:
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Circulation pumps: PAL pressure alarm: Status: 0
Display page 2/8
Line Description The delivery pressure downstream of the feed pumps is monitored by means of pressure switches and is shown in the display. Possible modes are: 3 0 The pumps are out of operation. The preselected pump fails to build up delivery pressure. 1 The preselected pump is operating and provides the required working pressure. Press the "Cursor down key to advance to the next display stage.
Viscosity measurement Status indication Measurement active Viscosity: 11.5mPas Line Description
Display page 2/9
The current viscosity value is transferred from the Viscosens to the control 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 operating. 3 Viscosity OK The viscosity value is within the preselected range. Viscosity alarm The viscosity value is outside the preselected range. The following faults 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 the process sequence menu. Individual adjustment for each component is described in detail on the next pages of this instruction manual. When starting the Visco Booster plant, the fuel to be used must be selected. For this purpose: press the "MDO key for operating with marine diesel oil,
MDO
4.4.1 Fuel selection
or press the "HFO key for operating with heavy fuel oil.
HFO
When the key has been actuated the motor adjustment valve moves into the desired position, the running time and the end position being monitored. The corresponding display shows: Medium selection: MDO operation Status limit switch: MDO Line Description The display shows the selected fuel, currently used. Possible states are: MDO The motor adjustment valve is in MDO position, confirmed by the limit switch Fuel is supplied from the MDO tank. 2 HFO The motor adjustment valve is in HFO position, confirmed by the limit switch Fuel is supplied from the HFO tank. No preselection No fuel preselection has been made by means of the "MDO or "HFO function keys. Fault The motor protection device of the control valve has responded. Display page 3/1
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Line Description 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 MDO The motor control valve has duly reached the preselected MDO position within the monitoring time. 4 Limit switch HFO The motor control valve has duly reached the preselected HFO position within the monitoring time "T10". Fault MDO The motor control valve has not duly reached the preselected MDO position within the monitoring time. Fault HFO The motor control valve has not duly reached the preselected HFO position within the monitoring time "T11". Position unknown The motor control valve is in no defined end position. Press the "Cursor down key to advance to the next display stage.
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 actuation up to reaching the "MDO" end position, plus 5 sec, must be entered. Press the "Cursor down key to advance to the next display stage.
Delay time Limit switch in HFO position: 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 actuation up 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: Feed pump 1 is switched on or off.
Feeder pump 1
or Feed pump 2 is switched on or off.

Feeder pump 2
The corresponding display shows: Feed pump 1 Status On Oper time: 12345h Display page 4/1
Line Description 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. 3 Fault Motor protection of feed pump 1 has responded. Preselection "Automatic" Preselector switch "1S1 is in automatic position, and feed pump 1 can be started by means of function key "Feed pump 1. Preselection "stand-by" Preselector switch "1S1 is in stand-by position, feed pump 1 is started automatically if the current operation pump 2 fails to operate or to build up delivery pressure.
The operating hours of feed pump 1 are registered. Make sure that the two pumps are equally loaded.
Press the "Cursor down key to advance to the next display stage.
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Feed pump 2 Status On Oper time: 12345h
Display page 4/2
Line Description
The current status of feed pump 2 is indicated. Possible states are: Off Feed pump 2 is out of operation. On Feed pump 2 is in operation. 3 Fault Motor protection of feed pump 2 has responded. Preselection "Automatic" Preselector switch "2S1 is in automatic position, and feed pump 2 can be started by means of function key "Feed pump 2. Preselection "stand-by" Preselector switch "2S1 is in stand-by position, feed pump 2 is started automatically if the current operation pump 2 fails to operate or to build up delivery pressure. The operating hours of feed pump 2 are registered. Make sure that the two pumps are equally loaded. Press the "Cursor down key to advance to the next display stage.
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 pressure switches. In case of pressure drop, the stand-by pump is automatically switched on when the delay time has elapsed. The delay time is to be entered in the display. Line Description Signal status: 3 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 operated backflush filter is used, proper functioning of same is controlled and monitored by the C7 system. Emptying of the filter chambers is initiated by means of differential-pressure monitors or by an overriding timer. The following display pages give a functional overview of the automatic filter status and allow entering the individual time functions. Automatic filter Status Ready for operation Diff. pressure: 0 Line Description 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 are cleaned at cyclical intervals via the differential-speed monitoring system or timer. 3 Fault Motor protection of the filter or a dense cleaning sequence lead to fault indication. Cleaning The cleaning cycles are indicated in the display. Manual cleaning Manual cleaning is indicated in the display when function key "Manual on the C7 unit has been actuated. Diff.-pressure definitions: 4 0 = Normal operation 1 = Signal for chamber flushing Display page 5/1
Flush ejection Pre: 7200 sec Act: 0.00 sec
Display page 5/2
If no flush process-dependent ejection is triggered by a differential-pressure switch, a time-dependent forced ejection can be programmed. In case of system-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 respected after the latest chamber flushing cycle. If, during this period, a new signal is gin by the differential-pressure switch, the message "Flushing frequency too dense" will appear. No further cleaning cycle will be performed. Press the "Cursor down key to advance to the next display stage.
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 Press the "Cursor down key to advance to the next display stage.
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 of approx. 3 sec for pressure build-up in the air vessel are preselected. Press the "Cursor down key to advance to the next display stage.
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 flushing and 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 total being shown in the display. Press the "Cursor down key to advance to the next display stage.
Amount of cleaning by timer : 23 Amount of cleaning by hand 11 Line Description 2 4
Display page 5/8
The sum total of time-dependent ejections is displayed. The sum total of manual ejections is displayed. Press the "Cursor down key to advance to the next display stage.
Amount of cleaning via diff. pressure: 1234 4
Display page 5/9
The sum total of filter ejections triggered by the differential pressure switch is displayed here. Press the "Cursor down key to advance to the next display stage.
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 be preselected here.
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4.4.4 Mixing / degassing tank
For mixing the "cold" heavy fuel oil obtained from the day tank with the hot heavy oil returning from the motor, and for degassing the system, an adequately sized mixing and degassing tank is installed. The following electric components fitted to the tank are connected to the control unit: Level switch - Max. Level switch - Min. Degassing valve Adjustment of and display values for these components are described here below: Mixing tank Tank level: Tank not filled Degassing valve: open Line Description The current state prevailing in the mixing / degassing tank is indicated Possible states are: 3 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. The current status of the degassing valve in the tank is indicated. Possible states are: 4 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 connection. Detailed information can be read from the circuit diagram and from the data sheet included in the project-related electrical documentation. Manual operation - degassing valve After actuating the function key "Manual (LED lights up), the degassing valve can be opened by means of the key "degassing ". The opening time for the valve is adjusted on timer 32. Display page 6/1
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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 signalling can be entered. Press the "Cursor down key to advance to the next display stage.
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 signalling can be entered. Press the "Cursor down key to advance to the next display stage.
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 valve can be entered. Press the "Cursor down key to advance to the next display stage.
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 functioning. If the level is first under LSH and later under LSL level, the LSH level must 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 circulation pump. The second pump is in "stand-by" mode and starts automatically in case of pressure drop on the pump in operation. Circulation pump 1 is switched on or off.
Circul. pump 1
or Circulation pump 2 is switched on or off.

Circul. pump 2
The corresponding display shows: Circulation pump 1 Status On Oper time: 12345h Display page 7/1
Line Description The current status of circulation pump 1 is indicated. Possible states are: Off Circulation pump 1 is out of operation. On Circulation pump 1 is in operation. 3 Fault Motor protection of circulation pump 1 has responded. Preselection "Automatic" Preselector switch "3S1 is in automatic position, and circulation pump 1 can be started by means of function key "Circulation pump 1. Preselection "stand-by" Preselector switch "3S1 is in stand-by position, circulation pump 2 is started automatically if the current operation pump 1 fails to operate or to build up delivery pressure. The operating hours of circulation pump 1 are registered. Make sure that the two pumps are equally loaded.
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Circulation pump 2 Status Off Oper time: 12345h
Display page 7/2
Line Description The current status of circulation pump 2 is indicated. Possible states are: Off Circulation pump 2 is out of operation. On Circulation pump 2 is in operation. 3 Fault Motor protection of circulation pump 2 has responded. Preselection "Automatic" Preselector switch "4S1 is in automatic position, and circulation pump 2 can be started by means of function key "Circulation pump 2. Preselection "stand-by" Preselector switch "4S1 is in stand-by position, circulation pump 1 is started automatically if the current operation pump 2 fails to operate or to build up delivery pressure. 4 The operating hours of circulation pump 2 are registered. Make sure that the two pumps are equally loaded. Press the "Cursor down key to advance to the next display stage.
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 of pressure switches. In case of pressure drop, the stand-by pump is automatically switched on when the delay time has elapsed. The delay time is to be entered in the display. Line Description Signal status: 3 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 heating flow is effected by means of an external Viscosens unit. For optimizing the supervision of viscosity and temperature, the corresponding 4-20mA signals are transmitted to the C7 control unit. Individual preliminary alarm can be set by the following adjustment. Viscosity measurement Status indication Viscosity: 11.5mPas Temperature: 135 C Press the "Cursor down key to advance to the next display stage. 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 monitoring. As soon as the values are under or above the preset values, the corresponding fault message appears on the display, and collective alarm is activated. Press the "Cursor down key to advance to the next display stage.
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. Press the "Cursor down key to advance to the next display stage.
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. Press the "Cursor down key to advance to the next display stage.
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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 temperature monitoring. As soon as the values are under or above the preset values, the corresponding fault message appears on the display, and collective alarm is activated. Press the "Cursor down key to advance to the next display stage.
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. Press the "Cursor down key to advance to the next display stage.
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 digital inputs
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. DI 0.0 DI 0.1 DI 0.2 DI 0.3 DI 0.4 DI 0.5 DI 0.6 DI 0.7 DI 1.0 DI 1.1 DI 1.2 DI 1.3 DI 1.4 DI 1.5 DI 1.6 DI 1.7 DI 32.0 DI 32.1 DI 32.2 DI 32.3 DI 32.4 DI 32.5 DI 32.6 DI 32.7 DI 33.0 DI 33.1 DI 33.2 DI 33.3 DI 33.4
Functions Feed pump 1 - Stand-by Feed pump 1 - Automatic Feed pump 1 - Fault Feed pump 1 - Operation Circulation pump 1 - Stand-by Circulation pump 1 - Automatic Circulation pump 1 - Fault Circulation pump 1 - Operation Feed pump 2 - Stand-by Feed pump 2 - Automatic Feed pump 2 - Fault Feed pump 2 - Operation Circulation pump 2 - Stand-by Circulation pump 2 - Automatic Circulation pump 2 - Fault Circulation pump 2 - Operation PAL feed pumps DPAH - Diff. pressure, filter by-pass DPAH - Diff. pressure, backflush filter LSL - Level switch, mixing tank LSH - Level switch, mixing tank PAL - Circulation pumps Limit switch - Filter chamber not assigned Motor adjustment valve / DO fuel Motor adjustment valve / HFO fuel 24-V-monitoring Local / Remote control (option) Injection system 1 / Main switch ON
Connection 1S1 / 24 1S1 / 14 1Q1 /22 1K1 / 14 2S1 / 24 2S1 / 14 2Q1 / 22 2K1 / 14 3S1 / 24 3S1 / 14 3Q1 / 22 3K1 / 14 4S1 / 24 4S1 / 14 4Q1 / 22 4K1 / 14 X2. 05 / 06 X2. 07 / 08 X2. 09 / 10 X2. 11 / 12/13 X2. 14 / 15/16 X2. 17 / 18 X2. 19 / 20 X2. 21 / 22 X2. 23 / 24 X2. 25 / 26 X2. 27 / 28 S114 X2. 31 / 32
Status 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
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Input-No. DI 33.5 DI 33.6 DI 33.7
Functions Injection system 2 / Main switch ON Digital alarm from Viscosens not assigned
Connection X2. 33 / 34 U10 / J4:9/10 X2. 37 / 38
Status 0 0 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 digital outputs
All digital outputs are shown on display pages 11/1 to 11/16. Scroll through the list below by pressing the "Cursor down key.
Input-No. DO 0.0 DO 0.1 DO 0.2 DO 0.3 DO 0.4 DO 0.5 DO 0.6 DO 0.7 DO 1.0 DO 1.1 DO 1.2 DO 1.3 DO 1.4 DO 1.5 DO 1.6 DO 1.7
Functions Feed pump 1 Circulation pump 1 Feed pump 2 Circulation pump 2 Motor adjustment valve OPEN / fuel Motor adjustment valve CLOSED / fuel Automatic filter - flushing valve Automatic filter - chamber valve Mixing tank - degassing valve Viscosity-control release not assigned Lamp test Temperature signal Viscosity signal Collective alarm signal Actuation of external klaxon
Connection 1K10 2K10 3K10 4K10 K10 K11 K12 K13 K14 K15
Status 0 0 0 0 0 0 0 0 0 0 0
K17 K18 K19 K20 K21
0 0 0 0 0
UP
Press the "UP key to access display page 12/1 (analog inputs).
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4.7
Calling up analog inputs
All analog inputs are shown on display pages 12/1 to 12/2. Scroll through the list below by pressing the "Cursor down key.
Input-No. AI 0.0 AI 0.1 AI 0.2 AI 0.3
Functions Viscosity signal from Viscosens Temperature signal from Viscosens not assigned Temperature bypass (option)
Connection U10 J41/2 U10 J3 4/5
UP
Press the "UP key to access display page 13/1 (analog outputs).
4.8
Calling up analog outputs
All analog outputs are shown on display pages 13/1 to 13/2. Scroll through the list below by pressing the "Cursor down key.
Input-No. AO 0.0 AO 0.1 AO 0.2 AO 0.3
Functions Viscosity indication for control center (option) Temperature indication for control center (option) not assigned not assigned
Connection
UP
Press the "UP key to access display page 14/1 (service addresses).
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4.9
Calling up service addresses
The operating hours of the separator are shown on display page 14/1; the main service addresses with phone and fax numbers are shown on display pages 14/2 to 14/8. Further service information as well as spare parts orders are available in the Marine After-Sales Service Center, Hamburg, on: Phone.: Fax: ++49 (0) - 73 93 36 - 0 ++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 the system 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 entry see 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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Passwords Edit | <|>

DOWN
Display page 15/3 Logout | <|> Time Date
Login <|>
Define password level 0 to 9.
ALARMS
Call up password entry.
Back to start screen after password entry.
UP
Set time and date.
German | | <|>
DOWN
Display page 15/4 | <|> Spanish <|> SELECT
English
Language selection German
ALARMS
Language selection English
Language selection Spanish or French
UP
Display of the selected language
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MPI transfer | | <|>

DOWN
Display page 15/5 Online <|>
Offline | <|>
Transfer configured OP software into the control.
ALARMS
Offline operation
Online operation
UP
no function
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4.10 Loading a new program
The UD 700 (WS part-no.: 0005-4040-190) can be used to load S7 user programs and OP configurations into the control unit without needing a programming device. The UD 700 replaces the previous EPROMs. In addition, new programs can be loaded into an existing UD 700 via modem connection and be displayed.
4.10.1 The UD 700
SIEMENS
UD 700
2
ESC
OK
Fig. 19
1 2 3
MPI connection (9-pole) RS232 interface (6-pole) 24 VDC supply voltage
ESC
-
exits current function, returns to next highest menu level. confirms a setting, starts the selected function, selects the next lower menu level, acknowledges error messages. moves the cursor up.
OK
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 RS232 cable (C79451-A3437-B122).
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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 from The UD 700 is connected to the control unit via the MPI port (1). the UD 700 to the C7623 Attention! The following steps may only be carried out when the separator is at standstill and with closed media feed. Proceed as follows on the control unit: ... ... Simultaneously press the shift key and the help key.
HELP
SHIFT
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
DOWN
DI/DO 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
... Exit the password entry. The menu "C7-CPU operating modes is displayed again:
ESC
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.
MPI Transfer
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
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 the start 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 control unit) is marked by " Confirm the marked transfer process. The display shows the following selection menu:
OK
! CPU download YES
CPU download
NO
The selection item "CPU Download YES is marked by "! When you want to transfer the CPU program: Start the transfer process. The following message is briefly displayed:
OK
Preparing download
Attention! Do not press any key on the UD 700 or on the control unit after you have started the transfer. Otherwise the transfer will be faulty. You can then no longer feed data to the control unit with the UD 700; you must 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 loading progress. After completion of data transfer the C7 control unit must be switched back to operating 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: Call up the directory.

DIR
Scroll to the menu "System setting (display page 15/1).
Press the "ENTER key.

ENTER
System setting Language Alarms Transfer
Display page 15/1
Scroll to the menu "MPI transfer (display page 15/5).
MPI transfer | | <|>

DOWN
Display page 15/5 Online <|>
Offline | <|>
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 account different 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.
Confirm your selection.
OK
The display switches to the following screen:
! OP download YES
OP download
NO
The selection item "OP download YES is marked by "! Start the data transfer of the configured texts and graphics.
OK
The following messages are displayed: UD --> OP OPG0019 -------The number is counted during the transfer, the bar "--- indicates the loading progress. When this program has been transferred, the UD 700 beeps. On the control unit: The control system restarts. Acknowledge the restart. The LED "RUN goes on signalling that the control system is functional again.
ENTER
Disconnect the cable between UD 700 and control unit.
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4.10.4 Loading configured You can load configured data from the programming device PG 740 into the data from the proUD 700. gramming device into For this purpose you need the following connecting cables: the UD 700 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 MiR crosoft 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 of the SIMATIC Manager. This procedure need not be repeated for subsequent transfers.
Setting user parameters The following description refers to the PC program "SIMATIC Manager; the keys described are the keys of the PC keyboard not the control unit or UD 700 keys. 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. Confirm with the "OK button. 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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Confirm with the "OK button. Always enter the value UD Address= 0. Confirm with the "OK button. 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. Confirm with the "OK button. 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. Confirm with the "OK button. 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. Confirm with the "OK button. 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. Confirm with the "OK button. Select Label DB . Confirm with the "OK button. 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 with the "OK button.
77
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 Communication UD ---> S7/C7. The programming device is ready for data transmission. main menu
Transfer configuration data When the user parameters have been saved you can transfer the configuration data from the programming device to the UD 700 as follows: On the PG 740: Switch on the PG 740. Start Microsoft Windows until the start screen with the program overview appears.
R
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. "COM 2, 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 successfully. 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 the RAM 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
79
--> S7/C7 S7/C7 --> UD !
Connect the serial data transfer cable to the serial port of the PG 740 and to the RS232 port of the UD 700. Use the "Cursor down key to select the transfer mode "PG/PC <--> UD on the UD 700.
Confirm your selection.
OK
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 process at 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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Commissioning
5.1 5.1.1 5.1.2 5.1.3 5.1.4 5.1.5 How to proceed on the control cabinet ..................................................82 Product selection "MDO........................................................................82 Product selection "HFO ........................................................................83 Feed pumps ...........................................................................................83 Circulation pumps ..................................................................................85 Manual operation ...................................................................................87
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5.1
How to proceed on the 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 pressure settings to be done in the Visco Booster plant are described in the project-relating start-up instructions. Set the selector switches for the feed and circulation pumps, provided under the control unit, to zero position. In case of unique supply, set the corresponding main switch of the control cabinet to "on" position. In case of redundant supply, turn on both main switches; if, then, one supply system fails, immediate switch-over will be secured without interruption of 100% availability of the plant. The C7 control unit undergoes a self-test of approx. 15 sec, and then the display signals "ready-for-operation" as follows: Start screen after start-up
SIMATIC C7-623 V1.23 4 x 20 Characters 5 mm
Acknowledge all alarm signals by actuating the ACK key one or several times.
ACK
Confirm start-up by pressing the ENTER key, Then the display shows:
ENTER
22.11.99 Booster unit
16:30:11
Basic screen
Westfalia Separator << 5.1.1 Product selection "MDO

MDO
>> Press the "MDO key to set the motor adjusting valve to "MDO position.
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 Status limit switch: MDO Position of control valve
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The display changes from "Control valve running" to "MDO" as soon as the end position is reached. 5.1.2 Product selection "HFO
HFO
Press the "HFO key to set the motor adjusting valve to "HFO position.
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 Status limit switch: HFO The display changes from "Control valve running" to "HFO" as soon as the end position is reached. 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. Position of control valve
5.1.3 Feed pumps
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
Feeder pump 1
Actuate the start button of the pump preselected under automatic operation on the C7 control unit (example: feed pump 1).
The display output changes from "off to "on, the LED in the key lights up, confirming 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 monitoring" display, where you can check the current pressure build-up of the selected pump.
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Feed pumps PAL status
Feed pumps PAL - pressure alarm: Status 1
Line Description Possible states are: 0 Delivery side of pump is not o.k. Delay time prior to switch-on of stand-by pump starts 1 Delivery side of pump is o.k. When a feed pump is switched on, the corresponding automatic filter is started at 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 from section 4.4.3 of this manual. The selected feed pump conveys the selected fuel is from the corresponding tank to the degassing / mixing vessel, through the automatic filter. Press the "Cursor down key to proceed to the "Mixing tank display for checking the filling level and the degassing-valve position for this tank.
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 same time a monitoring time starts which is intended to register abnormal filling cycles and to trigger alarm, if required. Adjustment of the mixing tank functions is done in the "mixing tank display, as described in section 4.4.4 of this manual.
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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 automatic operation on the C7 control unit (example: circulation pump 2).
The display output changes from "off to "on, the LED in the key lights up, confirming 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 monitoring" display, where you can check the current pressure build-up of the selected pump.
Circulation pumps PAL - pressure alarm Status 1
Circulation pumps PAL status
Line Description Possible states are: 0 Delivery side of pump is not o.k. Delay time prior to switch-on of stand-by pump starts 1 Delivery side of pump is o.k. When a circulation pump is switched on, the viscosity control is started in the external Viscosens at the same time, in order to control the temperature of the fuel sent to the main motor according to the preset viscosity value. Adjustment and parameter setting of the Viscosens has to be done in accordance 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 of the 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 tendencies in 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 this purpose: Press the "DIRECTORY key
DIR
Use the "Cursor down key to select the display pages 8/2 - 8/7 "Viscosity measuring, and
Press the "ENTER" key.

ENTER
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 a wire. In case of temporary failure of the Viscosens check whether the viscosity and temperature values can be read on the corresponding display page of the C7 control unit. Then adjust the desired viscosity by setting the heating circuit valve at constant flow, by hand.
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Fault signals / Maintenance

6.1 6.1.1 6.2 6.2.1 6.2.2 6.2.3 6.2.4 6.2.5 6.2.6 6.2.7 6.2.8 6.2.9 6.2.10 6.2.11 6.2.12 6.2.13 6.2.14 6.2.15 6.2.16 6.2.17 6.2.18 6.2.19 6.2.20 6.2.21 6.2.22 6.2.23 6.2.24 6.2.25 6.2.26 6.2.27 6.2.28 6.3 6.3.1 6.4 6.4.1 6.4.2 Fault signals ...........................................................................................90 Status and fault indication.....................................................................90 Alarm descriptions..................................................................................91 Feed pumps ...........................................................................................91 DPSH Automatic filter (input 32.2) .........................................................93 LAL mixing tank (input 32.3) ..................................................................95 Motor protection switch of circulation pump 1........................................97 Circulation pump 1 .................................................................................99 Motor protection switch of circulation pump 2......................................100 Circulation pump 2 ...............................................................................102 PSL Circulation pumps (input 32.5) .....................................................103 End position error "MDO.....................................................................105 End position error "HFO......................................................................107 Motor adjustment valve ........................................................................109 Motor protection switch of feed pump 1 ...............................................110 Feed pump 1 ........................................................................................112 Motor protection switch of feed pump 2 ...............................................113 Feed pump 2 ........................................................................................115 PSL Feed pumps (input 32.0) ..............................................................116 Product selection "MDO or "HFO ......................................................118 Bypass filter - input 32.1.......................................................................120 Viscosity below limit .............................................................................121 Viscosity above limit.............................................................................124 Temperature below limit.......................................................................127 Temperature above limit ......................................................................129 Delay time ............................................................................................131 Circulation pumps ................................................................................132 Level switch / mixing tank ....................................................................134 Mixing tank is not filled .........................................................................135 Automatic filter .....................................................................................137 Power-supply monitoring......................................................................139 Causes and action ...............................................................................141 Control unit...........................................................................................141 Maintenance.........................................................................................143 Storing batteries ...................................................................................143 Changing the battery............................................................................143
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6.1
Fault signals
6.1.1 Status and fault indication
The control unit is equipped with the adjacent status and error indicators. They are explained in the following table (see also chapter 6.3 page 141).
Fig. 21
Display SF (red)
Meaning C7 CPU summary error
Explanations 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 device and display the diagnostic buffer.
BAF (red)
Battery error
This LED lights up when the battery is too weak defective missing This LED lights up when the internal 5V power supply is ok. 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 then also lights up; when the STOP LED goes out the outputs are released). This LED lights up when the control unit is not processing the user program. This LED flashes at one second intervals when the CPU requests "memory reset.
DC5V (green) FRCE (yellow) RUN (green)
5V DC supply for C7 Reserved Operating mode RUN of CPU
STOP (yellow)
Operating mode STOP of the CPU
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6.2
Alarm descriptions
In the case of abnormal machine or process situations the following is initiated after 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 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 position, and selector switch "3S1 for the stand-by pump has to be set to stand-by position. In case of incorrect selection, the following message flashes on the display when the pump is started: Failure Preselection of Feed pumps not OK The collective alarm of the control system is activated immediately. The alarm is indicated by flashing of the LED on the "Feed pump ... " key. Viewing the help text Press the "HELP key to call up information on trouble-shooting:
HELP
6.2.1 Feed pumps
Fault message 0001
>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 preselection of pumps.
Fault message (help text, page 2)
Press the "ESC key to return to the display page with the alarm cause.
ESC
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Confirm fault Press the "ACK key when you have registered the alarm. The display switches back to the previous standard mode.
ACK
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.
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6.2.2 DPSH Automatic filter The chambers are monitored for due emptying by means of timer function and (input 32.2) differential-pressure switch. If, after flushing of the automatic-filter chambers and expiry of a delay time, no pressure drop occurs and, hence, the flushing frequency is very high, the following message flashes on the display: Failure Automatic filter amount of cleaning cycles too high The collective alarm of the control system is activated immediately. Viewing the help text Press the "HELP key to call up information on trouble-shooting:
HELP
Fault message 0002 (automatic filter)
>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
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ACK
Eliminate the cause of the fault. The alarm is stored in the alarm message buffer together with date and time.
ALARMS
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6.2.3 LAL mixing tank (input 32.3)
In the continuously operating Visco Booster plant, the min. level of the mixing/degassing tank is permanently monitored by "Liquiphant" level switches. If the level is below min. limit and a delay time has elapsed, the following message flashes on the display: Failure LAL level Mixing tank The collective alarm of the control system is activated immediately. Viewing the help text Press the "HELP key to call up information on trouble-shooting:
HELP
Fault message 0003 (LAL mixing tank)
>Please check both level switches >Valves BV43,44,45 must be closed
Check position >Check automatic degassing valve
>Check automatic filter and FQ counter for flow rate
ESC
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ACK
ALARMS
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6.2.4 Motor protection switch of circulation pump 1
Circulation pump 1 responded - input 1.2 If the motor protection switch of circulation pump 1 responds due to an electrical or mechanical trouble, the system is automatically switched over to circulation pump 2, and the following message flashes on the display: Failure Feed pump 1 motor protection switch 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. Viewing the help text Press the "HELP key to call up information on trouble-shooting:
HELP
Fault message 0004 (motor protection)
Check the setpoint on the motor protection switch
>Motor protection switch must be set to rated current. >Check for
free run of pump with simultaneous check of
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motor temperature
ESC
ACK
Eliminate the fault by checking the mechanical and electrical function of the pump. The alarm is stored in the alarm message buffer together with date and time.
ALARMS
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99
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 operation signal is received from the power contactor of the pump, the following message flashes on the display: Failure Operating signal from Circulation pump 1 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. Viewing the help text Press the "HELP key to call up information on trouble-shooting:
HELP
Fault message 0005 (operation signal)
Check for correct wiring of motor contactor and interface relay
from SPS For details, see circuit diagram
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6.2.6 Motor protection switch of circulation pump 2
Circulation pump 2 responded - input 1.6 If the motor protection switch of circulation pump 2 responds due to an electrical or mechanical trouble, the system is automatically switched over to feed pump 1, and the following message flashes on the display: Failure Circulation pump 2 Motor protection switch The collective alarm of the control system is activated immediately. The alarm is indicated by flashing of the LED on the "Circulation pump 2" key. Viewing the help text Press the "HELP key to call up information on trouble-shooting:
HELP
>Check for setpoint on the motor protection switch
Motor protection switch must be set to rated current. >Check for
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motor temperature
ESC
ACK
ALARMS
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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 operation signal is received from the power contactor of the pump, the following message flashes on the display: Failure Operating signal from Circulation pump 2 The collective alarm of the control system is activated immediately. The alarm is indicated by flashing of the LED on the "Circulation pump 2" key. Viewing the help text Press the "HELP key to call up information on trouble-shooting:
HELP
>Check for correct wiring of motor contactor and interface relay
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6.2.8 PSL Circulation pumps (input 32.5)
The circulation pumps are monitored for proper functioning by means of a pressure guard on he delivery side of the pumps. If pressure drop occurs on the pump selected for operation and a delay time has elapsed, the stand by pump is started automatically, and the faulty pump is stopped. The following message is flashing in the display: PAL Fault pressure alarm for circulation pump The collective alarm of the control system is activated immediately. Viewing the help text Press the "HELP key to call up information on trouble-shooting:
HELP
Fault message 0008 (PAL - Circulation pumps)
>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
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ACK
ALARMS
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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 motor adjustment valve get into the desired position. Arrival at end position has to be confirmed within the defined adjustment period, by means of the local limit switch. If this acknowledgement is not given, the following message flashes on the display: Fault message 0009
No preselection MDO or HFO
The collective alarm of the control system is activated immediately. The alarm is indicated by flashing of the LED on the "ACK" key. Viewing the help text Press the "HELP key to call up information on trouble-shooting:
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
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connection, direction of rotation. >Check smooth run of spindle.
ESC
ACK
Eliminate the fault by checking adjustment time and functioning of motor adjustment valve. The alarm is stored in the alarm message buffer together with date and time.
ALARMS
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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 motor adjustment valve get into the desired position. Arrival at end position has to be confirmed within the defined adjustment period, by means of the local limit switch. If this acknowledgement is not given, the following message flashes on the display: Fault message 0010
No preselection MDO or HFO
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
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connection, direction of rotation. >Check smooth run of spindle.
ESC
ACK
Eliminate the fault by checking adjustment time and functioning of motor adjustment valve. The alarm is stored in the alarm message buffer together with date and time.
ALARMS
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6.2.11 Motor adjustment valve
In case of logically faulty interpretation of the end positions of the motor adjustment valve (1 signal, both feedbacks) the following message flashes on the display: 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
ACK
Eliminate the fault by checking adjustment time and end-position functioning of motor adjustment valve. The alarm is stored in the alarm message buffer together with date and time.
ALARMS
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6.2.12 Motor protection Circulation pump 1 responded - input 0.2 switch of feed pump 1 If the motor protection switch of circulation pump 1 responds due to an electrical or mechanical trouble, the system is automatically switched over to feed pump 2, and the following message flashes on the display: Fault Feed pump 1 Motor protection switch 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. Viewing the help text Press the "HELP key to call up information on trouble-shooting:
HELP
>Motor protection switch must be set to rated current. >Check for
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motor temperature
ESC
ACK
ALARMS
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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 signal is received from the power contactor of the pump, the following message flashes on the display: Fault Operating signal from Feed pump 1 The collective alarm of the control system is activated immediately. The alarm is indicated by flashing of the LED on the "Feed pump 1" key. Viewing the help text Press the "HELP key to call up information on trouble-shooting:
HELP
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6.2.14 Motor protection Feed pump 2 responded - input 1.2 switch of feed pump 2 If the motor protection switch of feed pump 2 responds due to an electrical or mechanical trouble, the system is automatically switched over to feed pump 1, and the following message flashes on the display: Fault Feed pump 2 Motor protection switch The collective alarm of the control system is activated immediately. The alarm is indicated by flashing of the LED on the "Feed pump 2" key. Viewing the help text Press the "HELP key to call up information on trouble-shooting:
HELP
>Motor protection switch must be set to rated current. Check
motor temperature
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ESC
ACK
ALARMS
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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 signal is received from the power contactor of the pump, the following message flashes on the display: Failure Operating signal from Feed pump 2 The collective alarm of the control system is activated immediately. The alarm is indicated by flashing of the LED on the "Feed pump 2" key. Viewing the help text Press the "HELP key to call up information on trouble-shooting:
HELP
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6.2.16 PSL Feed pumps (input 32.0)
The feed pumps are monitored for proper functioning by means of a pressure guard on he delivery side of the pumps. If pressure drop occurs on the pump selected for operation and a delay time has elapsed, the stand by pump is started automatically, and the faulty pump is stopped. The following message is flashed in the display: PAL Fault pressure alarm for feed pump Please press help key The collective alarm of the control system is activated immediately. Viewing the help text Press the "HELP key to call up information on trouble-shooting:
HELP
Fault message 0016 (PAL feed pumps)
>Check prefilter 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
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ACK
ALARMS
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6.2.17 Product selection "MDO or "HFO
Fuel selection is done by actuating the "MDO" or "HFO" function key to make the motor adjustment valve get into the corresponding position. If this preselection is not done, and a feed pump is started, the following message flashes on the display: No preselection MDO or HFO Fault message 0017
HELP
>No preselection MDO or HFO Please make preselection
of product.
ESC
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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.
ALARMS
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6.2.18 Bypass filter - input 32.1
When carrying out service work or in case of failure of the automatic filter, operation of the Visco Booster plant can be continued by switching over to the bypass filter. Filter fouling is monitored by means of a differential-pressure switch which activates collective alarm and the following message on the display: Failure Differential pressure in automatic bypass filter too high Fault message 0019 (DPSH bypass filter)
Viewing the help text Press the "HELP key to call up information on trouble-shooting:
HELP
Check bypass filter Clean filter by hand
ESC
ACK
ALARMS
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6.2.19 Viscosity below limit
The viscosity controller sends the current viscosity value of the fuel to the control unit as 4-20mA signal. It is possible to set a preliminary alarm for decreasing viscosity in the "Viscosity" display pages. The preliminary alarm allows to react 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 values is selected.
Viscosity measurement Status indication Viscosity: 13.5 mPas Temperature: 135 C
Operation signal (viscosity / temperature)
Setpoint entry (min./max. viscosity)
Place the flashing cursor on the desired min. position and ...
1
0
... use number keys to enter the preliminary-alarm setpoint.
Confirm the entry.

ENTER
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Alarm signalling: While a circulation pump is operating, the viscosity monitoring system is activated. As soon as the viscosity is below the preset lower limit, collective alarm is triggered, 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
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ACK
ALARMS
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6.2.20 Viscosity above limit
The viscosity controller sends the current viscosity value of the fuel to the control unit as 4-20mA signal. It is possible to set a preliminary alarm for rising viscosity in the "Viscosity" display pages. The preliminary alarm allows to react to decreasing viscosity in time. Adjustment:
Setpoint entry (min./max. viscosity)
Place the flashing cursor on the desired max. position and ...
1
0
Confirm the entry.

ENTER
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Alarm signalling: While a circulation pump is operating, the viscosity monitoring system is activated. 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
ESC
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ACK
ALARMS
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6.2.21 Temperature below limit
The viscosity controller sends the current temperature value of the fuel to the control unit as 4-20mA signal. It is possible to set a preliminary alarm for decreasing temperature in the "Viscosity" display pages. The preliminary alarm allows to react to decreasing temperature in time. Adjustment:
Setpoint entry (min./max. temp.)
1
0
Corfirm the entry.

ENTER
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Alarm signalling: While a circulation pump is operating, the viscosity monitoring system is activated. As soon as the viscosity is below the preset lower limit, collective alarm is triggered, and the following message is shown in the display: Viewing the help text Press the "HELP key to call up information on trouble-shooting:
HELP
ESC
ACK
ALARMS
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6.2.22 Temperature above limit
The viscosity controller sends the current temperature value of the fuel to the control unit as 4-20mA signal. It is possible to set a preliminary alarm for rising temperature in the "Viscosity" display pages. The preliminary alarm allows to react to rising temperature in time. Adjustment:
Setpoint entry (min./max. temp.)
1
0
Corfirm the entry.

ENTER
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Alarm signalling: While a circulation pump is operating, the viscosity monitoring system is activated. As soon as the viscosity exceeds the preset limit, collective alarm is triggered, and the following message is shown in the display: Viewing the help text Press the "HELP key to call up information on trouble-shooting:
HELP
ESC
ACK
ALARMS
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6.2.23 Delay time
Individual delay times between setpoint level and alarm signalling can be set for the viscosity and temperature alarms here described. For this purpose: call up the corresponding menu in the display ...
1
0
Enter the desired time using the numerical keys.
9
Confirm your entry.
ENTER
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)
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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 position. In case of incorrect selection, the following message flashes on the display when the pump is started: Fault message 0025
Failure Preselection of circulation pumps not OK
HELP
>Only one feed pump is allowed to be preselected as stand by or
automatic. >Please check preselection of pumps.
ESC
ACK
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Eliminate the fault by setting the selector switch correctly. The alarm is stored in the alarm message buffer together with date and time.
ALARMS
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6.2.25 Level switch / mixing tank
The level switch functions are logically monitored for signalling. In case of wire break or switch failure, the following message appears in the display : Failure Level switch of mixing tank defective The collective alarm of the control system is activated immediately. Viewing the help text Press the "HELP key to call up information on trouble-shooting:
HELP
Fault message 0026 (level switch)
>Please check both level switches for Electr. connection and the
correct position of Y connector
ESC
ACK
ALARMS
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6.2.26 Mixing tank is not filled
Inputs: 32.3/4 When using a feed pump, filling and degassing of the mixing vessel is monitored by means of the level switch provided and via the preset monitoring time. The monitoring time has to be adjusted in the display menu "Mixing tank. When alarm is triggered, the following message is shown on the display: Failure Tank is not filled. The collective alarm of the control system is activated immediately. Viewing the help text Press the "HELP key to call up information on trouble-shooting:
HELP
Fault message 0027 (tank filling not ok)
>Please check both level switches Valves BV 43,44,45 must be closed
Check position >Check automatic degassing valve
>Check the automatic filter and FQ counter for flow rate
ESC
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ACK
ALARMS
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6.2.27 Automatic filter
If the cleaning time for emptying of the filter chambers is exceeded, the following message is shown on the display:
Failure Cleaning time for automatic filter over limit Viewing the help text
Fault message 0028 (automatic filter)
Press the "HELP key to call up information on trouble-shooting:

HELP
>Check pneumatic filter for compressedair supply 4 bar
>Check for electrical drive the function
of motor protection switch, wiring
>Check the limit switch for correct function
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ESC
ACK
ALARMS
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6.2.28 Power-supply monitoring
In order to ensure perfect availability of the Visco Booster plant, a redundant power supply system is provided for the control unit. When carrying out service work the required power supply source can be selected or both sources can be switched on by hand, so that the Visco Booster plant can be mains-supplied uninterruptedly if one system fails. Abnormal conditions well cause collective alarm and to the following fault message: Failure of power supply system - input 33.4 Failure power supply system 1 Voltage supply failed The collective alarm of the control system is activated immediately. Viewing the help text Press the "HELP key to call up information on trouble-shooting:
HELP
Fault message 0029 (failure power supply system 1)
Check on-site power supply system -main switch -protection system
ESC
ACK
ALARMS
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Failure of power supply system - input 33.5 Failure power supply system 2 Voltage supply failed The collective alarm of the control system is activated immediately. Viewing the help text Press the "HELP key to call up information on trouble-shooting:
HELP
Fault message 0030 (failure power supply system 2)
Check on-site power supply system -main switch -protection system
ESC
ACK
ALARMS
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6.3
Message
Explanations
Causes
Action
Text display dark
No supply voltage at C7 unit
8164-9001-600/0501
6.3.1 Control unit
Causes and action
Status LEDs dark
Check whether: main switch in position "ON. automatic circuit breakers are switched on. green LED "OK is on on the power supply unit. Plug connector for power supply to the C7 unit is plugged in properly.
Switch on main switch. Activate circuit breakers. Switch on power supply unit. Replace power supply unit if required. Check plug connector.
Text display lights up
When power is supplied the unit C7 unit is in mode "STOP. Status LED "STOP lights performs a self-test, signals "start- CPU of control disabled. up complete and is in the prelimiup CPU for text display enabled. nary setting "STOP. Status LED "RUN dark
Press keys "Shift and "Help. Press "KEY. Press "RUN key. Unit prompts password. Enter password. Press "ENTER to confirm. Press "ESC key. Press "RUN key. LED "RUN flashes and lights continuously after 5 s. C7 unit is ready for operation. LED "STOP goes out. Press the "ESC key to return to the start screen.
141
142
Message C7 CPU summary error
Explanations
Causes
Action
Text display lights up
Status LED "SF lights up
SF-LED lights up in case of: module errors in the unit Firmware errors programming errors timer errors faulty internal memory battery failure or no buffering when "POWER ON internal peripheral faults Replace the unit. In the case of special programs, consult the electrical engineering department in Oelde.
To precisely diagnose the fault a specialist must upload the diagnostic buffer of the C7 unit for evaluation, using a programming unit.
Text display lights up. LED "BAT lights up because: battery is too weak, battery is defective, battery is missing.
Battery error
Status LED "BAT lights up
If it can be avoided, do not disconnect the unit from the power supply and replace the buffer battery as per chapter 6.4.2 (page 143ff). Attention: Incorrect handling will lead to data loss!
Text display lights up.
Internal supply voltage failed
Status LED "DC5V dark
Unit failure due to internal power Replace the unit. supply unit.
Text display signals various Diverse system alarms that are system alarms, e.g. defined by the manufacturer and "$ 114 new start registered in the diagnostic memory.
System alarms that register ab- Try to acknowledge with the ESC key. normal control functions. Code shown can be identified by Otherwise contact the electrical engineering department in Oelde means of the manufacturer list. or the manufacturer's hotline.
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6.4
Maintenance Store the batteries in a dry, cool place. Batteries can be stored for up to 5 years.
6.4.1 Storing batteries
6.4.2 Changing the battery
In an inactivated state data loss in the internal user memory is prevented by a buffer battery. Change the battery at least once a year.
When the LED "BAF (1) goes on, the battery must be replaced immediately. Part-No.: 0005-4057-020
Fig. 22
When changing the battery do not switch off the power supply to the control unit! Replace the battery only when "POWER ON. Otherwise data in the user memory can be erased during the battery change.
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-circuit batteries Note: Do NOT touch the inside of the unit or slip metal parts (e.g. screwdriver) into the unit. Electrical components and printed circuit boards are accessible and might be damaged.
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Proceed as follows:
The battery is located in a compartment in the power supply unit.
Fig. 23
Unscrew cover (2) of the battery compartment.
Fig. 24
Pull the cover up and to the right. Make sure you raise the cover only as far as the length of the battery connections (3) allow.
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Remove the connector (4) of the old battery (5).
145
Loose the cable binders (6) with which the battery (5) is attached to the cover. 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 in the 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 screw the cover (2) tight again. Dispose of the battery according to the pertinent local regulations and guidelines.
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8164-9001-600/0501

Business Unit Mechanical Separation Technology A company of mg technologies group Westfalia Separator Mineraloil Systems GmbH Werner-Habig-Strae 1 D-59302 Oelde Phone +49 (0) 25 22 / 77-0 Fax +49 (0) 25 22 / 77-2394
http://www.westfalia-separator.com / mailto: info@gea-westfalia.de

8164-9001-600 C7 Booster en

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Westfalia Separator Mineraloil Systems GmbH

Business Unit Mechanical Separation Technology

Control Unit for Visco Booster Plants Type C7-623

DIR HARD COPY

HEATER LAL RELEAS tank

Westfalia Separator Mineraloil Systems GmbH

Subject to technical modifications!

Westfalia Separator Mineraloil Systems GmbH

For your safety

Westfalia Separator Mineraloil Systems GmbH

Westfalia Separator Mineraloil Systems GmbH

................. kA ......................................................................... ......................................................................... .........................................................................

Westfalia Separator Mineraloil Systems GmbH

2.6 2.7 2.8 2.9

Westfalia Separator Mineraloil Systems GmbH

Fault signals / Maintenance

Westfalia Separator Mineraloil Systems GmbH

Westfalia Separator Mineraloil Systems GmbH

Note Notes Notizen Anotaciones Notizen Notes Note

Westfalia Separator Mineraloil Systems GmbH

Westfalia Separator Mineraloil Systems GmbH

Application and operating principles

Westfalia Separator Mineraloil Systems GmbH

Westfalia Separator Mineraloil Systems GmbH

Note Notes Notizen Anotaciones Notizen Notes Note

Westfalia Separator Mineraloil Systems GmbH

Westfalia Separator Mineraloil Systems GmbH

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

Westfalia Separator Mineraloil Systems GmbH

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

Westfalia Separator Mineraloil Systems GmbH

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

Westfalia Separator Mineraloil Systems GmbH

Westfalia Separator Mineraloil Systems GmbH

Westfalia Separator Mineraloil Systems GmbH

Westfalia Separator Mineraloil Systems GmbH

Westfalia Separator Mineraloil Systems GmbH

Installing the control unit in the control cabinet

230,5 +0,5 1 158,5 +0,5

Westfalia Separator Mineraloil Systems GmbH

Fig. 8 - Fixing bracket before engaging

Westfalia Separator Mineraloil Systems GmbH

Fig. 9 - Fixing bracket engaged

Westfalia Separator Mineraloil Systems GmbH

Loosening the fixing bracket

Proceed as follows when loosening the fixing bracket:

Westfalia Separator Mineraloil Systems GmbH

Westfalia Separator Mineraloil Systems GmbH

Westfalia Separator Mineraloil Systems GmbH

Getting acquainted with the operating elements

DIR HARD COPY

HEATER LAL RELEAS tank

Section 2.1 3.2.2 6.1.1 3.2.1 3.2.3

Westfalia Separator Mineraloil Systems GmbH

3.2.1 Function keys

Key designation Fuel selection: Diesel oil operation

Heavy fuel oil operation

Feed pump selection: Feed pump 1 - operation

Feed pump selection: Feed pump 2 - operation

Westfalia Separator Mineraloil Systems GmbH

Key designation Circulation pump selection: Circulation pump 1 - operation

Circulation pump selection: Circulation pump 2 - operation