PERATOR. HYDRA Operator's Manual Volume 1 issue 4 revision TEC-TCC/ /OB page 1 of 23. document title/ titre du document

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1 page 1 of 23 document title/ titre du document ANUAL PERATOR OLUME S prepared by/préparé par Otto Brunner reference/réference issue/édition 4 revision/révision 5 date of issue/date d édition status/état Approved/Applicable Document type/type de document Distribution/distribution

2 page 2 of 23 APPROVAL Title Titre issue issue 4 revision revision 5 author auteur O. Brunner date date approved by approuvé par O. Brunner/TEC-TCC date date

3 page 3 of 23 USER INTERFACES Operations of the hydraulic shaker HYDRA are facilitated by the following user interfaces: PLC & VDU PC HYDRA user shell WADO user shell PLC & VDU PC The PLC1 and VDU1 PCs are the user interface for operation the hydraulic power supply and contain 18 following graphic pages described below. Because both PC run on different operating systems and use different programs for the graphical user interface, there is a small difference in appearance and in the display of confirmation requests and errors. PLC1 running on Windows XP Professional uses Iris (software name) for the PLC interface, while VDU1 running on Windows 3.11 uses Intellution. PLC1 makes use of standard Windows XP confirmation windows, while VDU1 uses Intellution programming for this purpose. PLC1 shall be used for all PLC commands during Hydra operation with VDU1 only used as backup. Graphic page Welcome Screen System Overview Status Diagram Oiltank Pump Control Leak Oil & Lubr. Oil Stats Is used to activate modes, buttons and display. Refer to chapter Is used to select the desired hydraulic subsystem and to monitor the status of the hydraulic units. refer to chapter Is used for system overview and to monitor pressures, temperatures and states of the assemblies. It is also possible to change over directly to each shown hydraulic unit. Refer to chapter Is used to operate and monitor the oil tank. Refer to chapter Is used to operate and monitor the main pumps. Refer to chapter Is used to operate and monitor the leakage and lubrication oil station. Refer to chapter Seq. Block X1/Z1 Is used to operate and monitor sequence block [20.00]. Refer to chapter Seq. Block Y2/Z1 Is used to operate and monitor sequence block [21.00]. Seq. Block X2/Z3 Is used to operate and monitor sequence block [22.00]. Seq. Block Y1/Z4 Is used to operate and monitor sequence block [23.00]. Control Block X1 Is used to operate and monitor control block [61.00] (actuator X1). Refer to chapter

4 page 4 of 23 Control Block Z1 Control Block Y2 Control Block Z2 Control Block X2 Control Block Z3 Control Block Y1 Control Block Z4 Is used to operate and monitor control block [62.00] (actuator Z1). Is used to operate and monitor control block [63.00] (actuator Y2). Is used to operate and monitor control block [64.00] (actuator Z2). Is used to operate and monitor control block [65.00] (actuator X2). Is used to operate and monitor control block [66.00] (actuator Z3). Is used to operate and monitor control block [67.00] (actuator Y1). Is used to operate and monitor control block [68.00] (actuator Z4) Graphic page: Welcome Screen Figure Error! No text of specified style in document.-1 Graphic page: Welcome Screen (PLC1) The screens at PLC1 feature an error message area at the top of the screen while VDU1 would open an extra window for error messages. Art system start both Local Mode and Central Mode indicators are red. Only when System On is selected the active mode is indicated in green.

5 page 5 of 23 Figure Error! No text of specified style in document.-2 Graphic page: Welcome Screen (VDU1) Local Mode Alarm Display Alarm log Green indicates that local mode is selected via key switch on control cabinet R9 and the VDU system 2 is connected. Changes to System Overview graphic page. Red indicates that local mode is not active. If both are red, the PLC interface is off. Activates alarm display function. If an alarm has occurred, a window describing the alarm opens automatically. (not at PLC1) Calls the FIX Alarm list. (not at PLC1) Historical Display The temperature and pressure is recorded during the entire heating phase and the curve is subsequently displayed. (not at PLC1) Pushbuttons Calls up hydraulic buttons on the button bar. Password protection is possible. (not at PLC1) Central Mode Green indicates that Central mode is selected via key switch on control cabinet R9 in the hydraulic room. Changes to System Overview graphic page. Red indicates that Central mode is not active.

6 page 6 of 23 In Central Mode all virtual buttons below apart from System On/, Quit Horn and Accept Alarm, need to be confirmed. If a button is selected a standard Windows confirmation window (Yes, No, Cancel=No) appears on PLC1, but on VDU1 a confirm button bar appears. After a single click on the Confirm button the selected function is starting. The buttons listed below are displayed on the button bar for all graphic pages: System On System Reci. Pu 1 Reci. Pu 2 Cool. Pu 1 Cool. Pu 2 Pu 1 Pu 2 Pu 3 Pu 4 Pu 5 Lub O-Pu Leak O-Pu Heating Phase Cooling Phase Mainten. Phase Quit Horn Accept Alarm Switches VDU system on. Switches VDU system off. After confirming switches recirculation pump 1 [1.24] on. After confirming switches recirculation pump 1 off. After confirming switches recirculation pump 2 [1.25] on. After confirming switches recirculation pump 2 off. After confirming switches cooling pump 1 [1.20] on. After confirming switches cooling pump 1 off. After confirming switches cooling pump 2 [1.21] on. After confirming switches cooling pump 2 off. After confirming switches main pump 1 [3.00] on. After confirming switches main pump 1 off. After confirming switches main pump 2 [4.00] on. After confirming switches main pump 2 off. After confirming switches main pump 3 [5.00] on. After confirming switches main pump 3 off. After confirming switches main pump 4 [6.00] on. After confirming switches main pump 4 off. After confirming switches main pump 5 [7.00] on. After confirming switches main pump 5 off. After confirming switches lubrication oil pump [11.12] on. After confirming switches lubrication oil pump off. After confirming switches leakage oil pump [11.13] on. After confirming switches leakage oil pump off. After confirming starts heating phase. After confirming stops heating phase. After confirming starts cooling phase. After confirming stops cooling phase. After confirming starts maintenance phase. After confirming stops maintenance phase. Silences the horn in the hydraulic room. Stops flashing of the activated alarm symbol in the corresponding assembly and its associated assemblies. Accept an acknowledged alarm and the message in the alarm display disappear.

7 page 7 of 23 Figure Error! No text of specified style in document.-3 Graphic page: Confirmation window (PLC1) Cancel and No behave in the same way.

8 page 8 of 23 Figure Error! No text of specified style in document.-4 Graphic page: Confirm button bar (VDU1) In Central Mode all selected functions need to be confirmed. The buttons listed below are displayed on the Confirm button bar for all graphic pages in Central mode: Confirm Cancel The selected function is starting Closed the appeared window without any function

9 page 9 of 23 Figure Error! No text of specified style in document.-5 Graphic page: Confirm button bar for Heating Phase (VDU1) The confirm button bar for start heating phase contains additional the buttons Activate and temperature control for Heating Phase. Activate Confirm Cancel Activate temperature control for Heating Phase temperature control for Heating Phase The selected function is starting Reset the selected function and switch back to the last called picture This is slightly different at PLC1: Confirmation of the heating phase starts already the pumps for the heating phase. The request for temperature control is processed in a different window subsequently.

10 page 10 of 23 Figure Error! No text of specified style in document.-6 Graphic page: Active Temperature control for Heating Phase (PLC1)

11 page 11 of Graphic page: System Overview Figure Error! No text of specified style in document.-7 Graphic page: System Overview (VDU1) Status Diagram Welcome Screen Changes to Status Diagram graphic page. Changes to Welcome Screen graphic page. The virtual buttons listed below indicate alarms of the corresponding subsystems. Alarm messages are displayed on all VDU graphic pages, the corresponding graphic element flashes red. After the alarm has been acknowledged, the flashing changes to steady red which only goes out when the fault has been successfully rectified. Oiltank Pump Control Leak Oil & Lubr. Oil Stats Changes to Oiltank graphic page. Changes to Pump Control graphic page. Changes to Leak Oil & Lubr. Oil Stats graphic page.

12 page 12 of 23 Seq. Block X1/Z1 Seq. Block Y2/Z2 Seq. Block X2/Z3 Seq. Block Y1/Z4 Control Block X1 Control Block Z1 Control Block Y2 Control Block Z2 Control Block X2 Control Block Z3 Control Block Y1 Control Block Z4 Changes to Seq. Block X1/Z1 graphic page. Changes to Seq. Block Y2/Z2graphic page. Changes to Seq. Block X2/Z3 graphic page. Changes to Seq. Block Y1/Z4 graphic page. Changes to Control Block X1 graphic page. Changes to Control Block Z1 graphic page. Changes to Control Block Y2 graphic page. Changes to Control Block Z2 graphic page. Changes to Control Block X2 graphic page. Changes to Control Block Z3 graphic page. Changes to Control Block Y1 graphic page. Changes to Control Block Z4 graphic page. In Local Mode the buttons listed below are displayed on the button bar. System On System Quit Horn Accept Alarm Switches VDU system on. Switches VDU system off. Silences the horn in the hydraulic room. Stops flashing of the activated alarm symbol in the corresponding assembly and its associated assemblies. Accept an acknowledged alarm and the message in the alarm display disappear.

13 page 13 of Graphic page: Status Diagram Figure Error! No text of specified style in document.-8 Graphic page: Status Diagram (VDU1) Overview Screen Graphic element e.g. Pump Control Changes to Overview Screen graphic page. Status or alarm indication. Yellow: Pump not running Green: Pump running Flashing red: Pump fault or alarm Steady red: Alarm acknowledged, but pump fault not rectified Click to change to the Pump Control graphic page. In Local Mode the buttons listed below are displayed on the button bar. System On System Quit Horn Accept Alarm Switches VDU system on. Switches VDU system off. Silences the horn in the hydraulic room. Stops flashing of the activated alarm symbol in the corresponding assembly and its associated assemblies. Accept an acknowledged alarm and the message in the alarm display disappear.

14 page 14 of Graphic page: Oil tank Figure Error! No text of specified style in document.-9 Graphic page: Oil tank (VDU1) Status Diagram Overview Screen Changes to Status Diagram graphic page. Changes to Overview Screen graphic page. In Central Mode the buttons are displayed on the button bar as described in the chapter

15 page 15 of 23 In Local Mode the buttons listed below are displayed on the button bar. System On System Cooling Valve Cooling Pump 1 Cooling Pump 2 Recirc. Pump 1 Recirc. Pump 2 Quit Horn Accept Alarm Switches VDU system on. Switches VDU system off. Opens cooling valve. Closes cooling valve. Switches cooling pump 1 [1.20] on. Switches cooling pump 1 off. Switches cooling pump 2 [1.21] on. Switches cooling pump 2 off. Switches recirculation pump 1 [1.24] on. Switches recirculation pump 1 off. Switches recirculation pump 2 [1.25] on. Switches recirculation pump 2 off. Silences the horn in the hydraulic room. Stops flashing of the activated alarm symbol in the corresponding assembly and its associated assemblies. Accept an acknowledged alarm and the message in the alarm display disappear.

16 page 16 of Graphic page: Pump Control Figure Error! No text of specified style in document.-10 Graphic page: Pump Control (VDU1) Status Diagram Overview Screen Changes to Status Diagram graphic page. Changes to Overview Screen graphic page.

17 page 17 of 23 System On System V8.04 V8.05 Pu 1 Pu 2 Pu 3 Pu 4 Pu 5 V3.27 V4.27 V5.27 V6.27 V7.27 V13.03 Quit Horn Accept Alarm In Local Mode the buttons listed below are displayed on the button bar. Switches VDU system on. Switches VDU system off. Activates medium pump pressure valve solenoid [8.04]. s medium pump pressure valve solenoid. Activates low pump pressure valve solenoid [8.05]. s low pump pressure valve solenoid. Switches main pump 1 [3.00] on. Switches main pump 1 off. Switches main pump 2 [4.00] on. Switches main pump 2 off. Switches main pump 3 [5.00] on. Switches main pump 3 off. Switches main pump 4 [6.00] on. Switches main pump 4 off. Switches main pump 5 [7.00] on. Switches main pump 5 off. Activates swivel angel valve [3.27] of main pump 1. s swivel angle valve of main pump 1. Activates swivel angel valve [4.27] of main pump 2. s swivel angle valve of main pump 2. Activates swivel angel valve [5.27] of main pump 3. s swivel angle valve of main pump 3. Activates swivel angel valve [6.27] of main pump 4. s swivel angle valve of main pump 4. Activates swivel angel valve [7.27] of main pump 1. s swivel angle valve of main pump 1. Activates relief valve p-line [13.03]. s relief valve p-line. Silences the buzzer in the control room and the horn in the hydraulic room. Stops flashing of the activated alarm symbol in the corresponding assembly and its associated assemblies. Accept an acknowledged alarm and the message in the alarm display disappear.

18 page 18 of Graphic page: Leak Oil & Lubr. Oil Stats Figure Error! No text of specified style in document.-11 Graphic page: Leak Oil & Lubr. Oil Stats (VDU1) Status Diagram Overview Screen Changes to Status Diagram graphic page. Changes to Overview Screen graphic page.

19 page 19 of 23 In Local Mode the buttons listed below are displayed on the button bar. System On System LUB Oil Valve LUB Oil Cooler LUB Oil Pump Leak Oil Pump Quit Horn Accept Alarm Switches VDU system on. Switches VDU system off. Opens lubrication oil valve. Closes lubrication oil valve. Switches lubrication oil cooler (air heat exchanger) [11.37] on. Switches lubrication oil cooler (air heat exchanger) [11.37] off. Switches lubrication oil pump on. Switches lubrication oil pump off. Switches leakage oil pump on. Switches leakage oil pump off. Silences the horn in the hydraulic room. Stops flashing of the activated alarm symbol in the corresponding assembly and its associated assemblies. Accept an acknowledged alarm and the message in the alarm display disappear.

20 page 20 of Graphic page: Seq. Block X1/Z1 Figure Error! No text of specified style in document.-12 Graphic page: Seq. Block X1/Z1 (VDU1) Graphic pages Seq. Block Y2/Z2, X2/Z3 and Y1/Z4 are identical in structure. Status Diagram Overview Screen Changes to Status Diagram graphic page. Changes to Overview Screen graphic page.

21 page 21 of 23 In Local Mode the buttons listed below are displayed on the button bar. System On System V20.12 V20.02 V20.06 V20.04 V20.13 V20.03 V20.07 V20.05 V20.53 V20.54 V20.49 Quit Horn Accept Alarm Switches VDU system on. Switches VDU system off. Activates bearing pilot valve [20.12] for pilot oil supply of actuator X1. s bearing pilot valve for pilot oil supply of actuator X1. Activates set up valve [20.02] for hydraulic oil supply of actuator X1. s set up valve for hydraulic oil supply of actuator X1. Activates flow control valve [20.06] for hydraulic oil supply of actuator X1. s flow control valve for hydraulic oil supply of actuator X1. Activates reversing valve [20.04] for hydraulic oil supply of actuator X1. s reversing valve for hydraulic oil supply of actuator X1. Activates bearing pilot valve [20.13] for hydraulic oil supply of actuator Z1. s bearing pilot valve for hydraulic oil supply of actuator Z1. Activates set up valve [20.03] for hydraulic oil supply of actuator Z1. s set up valve for hydraulic oil supply of actuator Z1. Activates flow control valve [20.07] for hydraulic oil supply of actuator Z1. s flow control valve for hydraulic oil supply of actuator Z1. Activates reversing valve [20.05] for hydraulic oil supply of actuator Z1. s reversing valve for hydraulic oil supply of actuator Z1. Activates heating valve high pressure solenoid [20.53]. s heating valve high pressure solenoid. Activates heating valve low pressure solenoid [20.54]. s heating valve low pressure solenoid. Activates accumulator dump valve [20.49]. s accumulator dump valve. Silences the horn in the hydraulic room. Stops flashing of the activated alarm symbol in the corresponding assembly and its associated assemblies. Accept an acknowledged alarm and the message in the alarm display disappear.

22 page 22 of Graphic page: Control Block X1 Figure Error! No text of specified style in document.-13 Graphic page: Control Block X1 (VDU1) Graphic pages Control Block X2, Y1, Y2 and Z1 to Z4 are identical in structure. Status Diagram Overview Screen Changes to Status Diagram graphic page. Changes to Overview Screen graphic page. In Local Mode the buttons listed below are displayed on the button bar. System On System V61.44 Quit Horn Accept Alarm Switches VDU system on. Switches VDU system off. Activates the flush valve actuator X1 [61.44]. s the flush valve actuator X1 [61.44]. Silences the horn in the hydraulic room. Stops flashing of the activated alarm symbol in the corresponding assembly and its associated assemblies. Accept an acknowledged alarm and the message in the alarm display disappear.

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