1

Principle
Special anti-friction bearings and the fact that the machine features one movable and one stationary roll permit the two rolls to adjust themselves obliquely to each other during material feeding. This means that varying gap widths are established at the two roll ends (being the maximum and minimum distance between the roll shell surfaces) and different hydraulic pressures in the two cylinders of the movable roll. Consequently, two sensors each have to be installed for measuring gap width and pressure.

4 .

Roller Press on SCADA

Roller Press
Roller dist. = 10 mm fix + Bearing dist. = 0 mm Gap = 10 mm
measured by Limit switch Gap sensor

RP - Frame

Retraction cylinder

Press cylinder

Fixed Bearing
Distance block

Movable Bearing

Pressure acting on the rolls

The pressure inside the gap witch has vital importance for the quality of the product is set via the hydraulic cylinders relative to the material properties The gap width adjusts itself as a function of the resistance to compaction originating from the material. The pressure in the cylinders is measured and controlled with the control system - by way of automatic re-adjustment - warranting that the pressure will neither fall below the minimum level required for the operating point nor exceed the maximum pressure permitted for the system. A pressure loss will occur if the gap width - being a function of material hardness and granulometry- is reduced. The bearing distance is measured continuously on both sides of the movable roll with two sensors. The program, stored in the controller, permanently calculates the difference between the two values with correct sign indication

Components Roller Press

1 hydraulic set consists of hydraulic pump and; 2 proportional valves for pressure control, a number of solenoid valves for pressure decrease, bypass valves, valves for the retraction cylinder and valve for pressure release in case of an emergency shut-down, 1 resistance thermometer PT100 for monitoring of the hydraulic oil temperature in the reservoir accumulator, 1 temperature limiting switch for the hydraulic oil reservoir 2 pressure sensors for the pressure acting on the rolls 2 position sensors for the bearing distance 4 resistance thermometers PT100 for monitoring the bearing temperatures at the rolls 2 resistance thermometers PT100 for monitoring the temperature of the gear box bearings and 2 resistance thermometers PT100 for monitoring the temperature of the oil gear box bearings. 2 limit switches for monitoring the permitted operating range of the roll 1 Solenoid valve for the shut-off gate and 2 Sensors for monitoring shut-off gate position 1 pump for grease lubrication of the roller bearings and 1 heating unit for the grease barrel including temperature controller

2 Sensors for monitoring shut-off gate position Grease lubrication system consisting of 1 Pump for of the roller bearings, 1 heating unit for the grease barrel including temperature controller, 1 heating unit for the grease pipes including temperature controller and resistance thermometer PT100, 1 signalling contact for monitoring the minimum grease flow rate behind the grease pump, 2 signalling contacts (one each at the two progressive distributors) of the grease lubrication unit for the roller bearings. 2 differential pressure monitoring of the gear oil filter 2 speed sensors for under speed monitoring of the rolls 1 Lubrication oil system with circulation pump, 1 feed pump, 1 Heater for oil in the reservoir ( oil tank ), 1 Stirrer within the oil reservoir ( oil tank ), 3 Solenoid valves, 4 Resistance thermometers PT100 for monitoring oil temperatures, 10 Oil flow sensors for monitoring the oil flow and 3 heating units for the oil pipes including temperature controller and resistance thermometer PT100 1 Servo drive for feed regulating gate 1 ROLCOX control panel with control system, power supply and terminals for all external cable connections local junction boxes for the collection of all signals at the Roller Press 1 local operating panel for the operation of the hydraulic valves in local mode

9
The control unit is designed as closed system for the Roller Press based on the hardware platform S7300. The interface to the client control system is performed via discrete I/O`s and a Profibus DP - standard interface.

Control cabinet with ROLCOX software

The application software is stored in the micro memory card of the CPU. The micro memory card is plugged-in in the CPU unit and shall not be removed.

10

Local operation box

Local operation box for the operation of the Roller Press hydraulic system in LOCAL mode during troubleshooting and maintenance activities, consisting of: 4 push buttons for manual control of the hydraulic pressures at the movable roll 1 push button with signal lamp for alarm acknowledgement. The signal lamp is energized at specific, unacknowledged alarms. 1 mushroom push button for emergency stop 4 digital indicators for indication the hydraulic pressures and the bearing distances at the left and the right side of the roller press.

11

Control unit

The control unit is designed to control the following drives of the Roller Press: 2 Roller drives 2 Gear oil pumps 1 Grease barrel pump 1 Hydraulic pump 2 Proportional valves for pressure control of the hydraulic system 1 Solenoid valve for emergency shut-down 2 Solenoid valves for pressure decrease 2 Solenoid valves ( bypass valves for pressure release ) 1 Solenoid valve for moving the two rolls apart by the help of the retraction cylinder 1 Servo drive for the feed regulating gate 1 magnetic valve for the pre-bin shut-off gate

Left
Fixed Roller
Retraction cylinder

Right
V 1/2

Hydraulic system of the roller press

5312HD1. V 1/2 Prop. valve left

Retract. cylinder
V 3/4

5312HD1.V 3/4

Prop. valve right

Movable Roller

V 05

5312HD1.V 05

Pressure decrease valve left

Press cylinder
V 06 V 09 V 08 V 10 V 07 V 05 V 06 V 09

5312HD1.V 06

Pressure decrease valve right

5312HD1.V 07

Retraction cylinder valve

5312HD1.V 09

Bypass valve left

V 1/2

V 3/4

V 10

5312HD1.V 10

Bypass valve right

V 07

V 08

5312HD1 V 08

Emergency valve

M01

5312HD1.M01

Hydraulic pump

12

Pump 5312.HD1

Hydraulic oil tank

13

HYDRAULIC SYSTEM
Hydraulic set consists of : 1 hydraulic pump, 2 proportional valves for pressure control, a number of solenoid valves for pressure decrease, bypass valves, valves for the retraction cylinder and valve for pressure release in case of an emergency shut-down, 1 resistance thermometer PT100 for monitoring of the hydraulic oil temperature in the reservoir accumulator, 1 temperature limiting switch for the hydraulic oil reservoir

14
5312HD1. V 1/2

Hydraulic control equipment of the roller press

5312HD1.M01 Hydraulic pump Prop. valve left 5312HD1.V 05 Pressure decrease valve left

5312HD1.V 3/4

Prop. valve right

5312HD1.V 06

Pressure decrease valve right

5312HD1.L01

Tank level

5312HD1.V07

For valve retraction cylinder

5312HD1.H01

Tank heater

Temperature measurement T > 70 C RP STOP with ALARM 5312HD1.T01 Tank temperature > 40C 5312HD1.T02 T > 50 C Alarm T < 20 C Heating OFF T < 15 C Heating ON

15

Hydraulic layout:

Fixed value: 50 C for Hydraulic oil temperature (warning) Fixed value: 70 C for Hydraulic oil temperature (fault, group Roller Press STOP) If the temperature exceeds the above fixed value, the roller press is stopped with an alarm.

16

Oil circulating lubrication ( Woerner)

The pump station includes the oil tank divided in two sections with a heating device and an external mounted oil circulation pump The heating device, temperature safety switch, PT100 temperature detectors, and oil filling level meters, a duplex filter is installed on the pressure side of the circulation pump, oil-to-water heat exchanger, the delivery pipe is routed over two distributing branches leading to the rollers, bypass valves controlled by PT100 resistors.

5312LQ5. M01

Feed Pump

5312LQ55 M01

Oil Circulation pump Pump

17
Terminal box Oil re/filling pipe

5312MX1.M01 5312LQ4.P02 Filter with pressure switch 5312LQ5.T03 5312LQ4.P02 Filter

Mixer Oil return temperature

Oil level indication Tank T1

L > Max 3 L > Max 2 (Early morning) L < Min Pump LQ4.M01 OFF

Oil level indication Tank T 2

L < Min Pump LQ5.M01 OFF

Site view of the oil reservoir

18
OIL LUBRICATION SYSTEM
Roller press bearing lubrication

Oil circulation pump 5312LQ4.M01

Bypass-Valve 5312LQ5.V01

5312MX1.M01 Stirrer motor

5312LQ5.T03

Oil return line with temperature measurement

5312LQ5.T02

Tank oil temperature

5312LQ5.T01

Heating with oil temperature controller

19

Longitudinal / radial oil lubrication of Roller Press bearings

Behind the heat exchanger, the delivery oil pipe is routed over two distributing branches to the bearing lubrication points of the movable and the fixed roll. The bypass valves 3212LQ5.V02 and V03 located at the ends of the distributing branches are opened during the heating up phase. As soon as the oil temperature in the pipeline reaches a limit value (approx. 40C) - measured with the PT100 resistor directly in front of the distributing branches at the roller press. Both bypass valves 3212LQ5.V02 and V03 are closed thereby clearing the way for the oil to the different bearing lubrication points. As soon as the oil temperature in front of the bearing decrease below 10C, both bypass valves will open and after approx. 15 min. the roller press group will be stopped. All pipelines branched to these locations have been equipped with flow governors; their flow switches are used for monitoring.

Oil Lubrication governors for Longitudinal bearing Adjusted for 3,75 l/min Measuring range 0 10 l/min

Oil Lubrication governor for radial bearing Adjusted for 1,5 l/min Measuring range 0 5 l/min

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

20

Longitudinal / radial oil lubrication of Roller Press bearings

Bearing- OilFlow- Meters

Oil Lubrication governors for Longitudinal bearings Adjusted for 3,75 l/min Measuring range 0 10 l/min

Oil Lubrication governor for radial bearings Adjusted for 1,5 l/min Measuring range 0 5 l/min

21

Longitudinal / radial oil lubrication of Roller Press bearings

PT100 in one of the oil lubrication lines for bearing lubrication

Bypass valve LQ5.V02

Oil return line

22
Grease lubrication for roller bearings
The grease lubrication consists of a grease tank with grease pump and two progressive distributors each mounted on the left- and right-hand side of the roller press. Grease conveying of the pump is monitored by a pressure switch. In case of a failure an alarm is created. In addition, each progressive distributor has been provided with a switch which is operated at each stroke of the piston of the progressive distributor at the cycle of grease distribution.

23

Grease lubrication barrel with pump

Level switch at grease barrel

In order to guarantee a sufficient grease supply to the roller bearings, the signals from the pressure switch and the progressive distributors are analyzed.

24

Monitoring of the bearing lubrication

The required amount of grease is determined by the amount of pulses sent from the progressive distributors. A preset difference (40 pulses) of both pulse rates shall not be exceeded. If the pulses are not reached within one hour, the pulse difference (8) exceeds the permissible limit or no pressure signal is monitored within 180 sec after pump start, an alarm is generated The remaining operating time for the Roller Press is now reduced to 2 hours. Occurred another grease lubrication fault after the next hour of operation, the remaining operating time is now reduced to 1 hour. After 3 hours of continuous alarms the Roller Press will be shut-down (normal stop). The indication of the remaining operating time will be temporarily set to "0". The highest fault memory will be reset in case the fist hour of operation ends without fault. The indication of the remaining operating time will be increased by 1 hour. With undisturbed grease distribution system a remaining operating time of 3 hours will be indicated

25

Bearing distance measurement

The bearing distance is measured at the left- and right-hand side of the movable roll. Since the distance between the roll surfaces inside the gap cannot be measured directly, the distance between the housings of fixed and movable bearing is used as a measure. The sensors are inductive position sensors with integrated transducers. The transducer is of a four-wire type. The measuring range is 0 -100mm. The output signal is 4 ... 20 mA. In case of wire breakage, a fault signal is generated and the roller press group will be stopped.

Bearing distance MAX switch

Bearing distance measurement

26

Pressure measuring
The pressure is measured with one pressure sensor each on the left- and right-hand side of the movable roll. The corresponding transducer is of a two-wire type. The measuring range is 0 ... 400 bar, the output signal 4 ... 20 mA. Sensor and transducer are accommodated in one housing. In case of wire breakage a fault signal is generated and the roller press group will be stopped.
Pressure transmitter

27

Temperature measuring
The roller bearing temperatures and the gear box bearing temperatures are measured at every test point with one resistance thermometer PT100 each. These thermometers have been connected in three-wire technique to the temperature transducer. The transducer is of a two-wire type. The measuring range is 20 +100 degC, the output signal is 4 ... 20 mA. In case of wire breakage a fault signal is generated and the roller press group will be stopped immediately.
Temperature PT100 sensor of one bearing measurement

28

Pre-bin level measurement and Shut-Off Gate control

The Roller Press requires always sufficient material between and above the rolls. This is achieved by switching-on the pre-bin shut-off gate control. This function can be switched on or off via switching template at SCADA During operation and de-activated pre-bin shut-off gate control the shut-off gate will open when the bin level exceeds the set maximum limit, e.g. 50% and stays open even when the bin level drops below the set minimum limit. The gate closes only at stop of the Roller Press. During operation and activated prebin shut-off gate control will open the shut-off gate when the bin level exceeds the set maximum limit, e.g. 50% and closes when the prebin level drops below the set minimum limit, e.g. 5%

Pre-bin shut-off gate

Pre- bin level transmitter

29

Pre-Bin - Shut-Off - Gate control

During operation and activated pre-bin shut-off gate control the shut-off gate will open when the bin level exceeds the set maximum limit, e.g. 50% and closes when the pre-bin level drops below the set minimum limit, e.g. 5%. Exceeds the pre-bin level again the maximum limit the gate will be opened again. The pressure control function is not active and the movable roll will be positioned to limit L2 at closed shut-off gate. This will limit the amount of uncrushed material passing the Roller Press when the gate opens. The pressure control is activated again when the gate is open. When the shut-off gate closes the pressure reducing valves are energized and the gap increases. This procedure continues until the movable roll reaches the limit L3 at any side or the delay time (10 sec) is elapsed. Then, the movable roll is moved back to the start position L2. The movable roll is now parallel the stationary roll and ready for the next start.

30 Control of the feed

regulating gate
The purpose of the feed regulating gate is the adjustment of the material flow to the Roller Press. The positioning is done in AUTOMATIC MODE by setting a position set point at SCADA and in LOCAL MODE with the control switch At shut-down of the Roller Press the feed regulating gate is moved to a start set point pre-defined in ROLCOX (e.g. 20%). The feed regulating gate opens to the position set at SCADA after start of the material feeding.

33

Start Roller Press

RP - Bin Slide Gate.

open close

Dosing Gate in max. Pos. min. Pos.

Dosing Gate

Fixed Roller

Movable Roller

32

Start Group Roller Press

Following conditions must be considered in the client control system: No failures causing a pre-alarm or a stop. The signal MATERIAL DISCHARGE ON must be present. Pressure control functions must be switched ON in order to allow a complete start of the Roller Press with its start-up procedure. Upon every start of the group Roller Press, a start program BCON is started. At first, the solenoid valve for emergency off (V08) will be energized (the valve is fail open) and the hydraulic system closed. The pressure reducing valves (V05 and V06) will be energized (opened) and the Roller drives started. The pressure reducing valves will be closed time delayed or when any bearing distance has reached the limit L3. If the bearing distances are >L2 after the start-up time, the pressure increase valves and the hydraulic pump will be energized and the movable roll will be positioned to the limit L2. In case the pressure exceeds the limit 40bar the group start will be terminated with an alarm message. After some delay time the feed belt will be started, the material feed is released and the pressure control function is activated.

33

Start Group Roller Press

34
RP Trouble, trip, Group off, automatic

35

SCADA
RP Trouble, trip, Fast stop automatic

36

RP Trouble, trip, Loop alarm

37
Left Fixed Roller Gap = 45 mm

Start RP group
At every start the emergency valve V08 is energized to close the hydraulic circuit.

Right
To release the oil of the main cylinders the bypass valves (V09 and V10) and the pressure decrease valves are energized (opened). This will occur with standing rollers. The movable roller will be moved by the retraction cylinders to L2 + 10 mm = 45 mm
11 V 06

Movble Movable Roller Roller

Press cylinder

V 06 09 10 V 05

08 V 09

V 10 07

L min L2 + 10 mm

V 1/2 V 07

V 3/4

After reaching of L2 + 10 mm, the main drives will be started one by one.

Pump 5312.HD1

Hydraulic oil tank

Valve closed Valve open

38

Bearing distance Lmin, (L2, L3)

Lmin= 1.0 ... 12.0 mm minimum limit for a gap reduction at activated pressure control function. The control system stops any pressure increase when the bearing distance drops below this limit. A limit violation is not shown as fault alarm. The input has to be made carefully to avoid incorrect function of the pressure control system.

39

Bearing distance L2, L3

L2= 5.0 ... 30.0 mm At the start of both roller drives start of the roller press group, the start program BCON is activated. Hereby the movable roll as opposed to the fixed roll is moved to L2 with running roller drives. After stopping the feed belt the movable roll will be positioned again to this value. A limit violation is not signalized as fault alarm. L3= 5.0 ... 20.0 mm With activated pressure control system, the sum from BEARING DISTANCE L2 + BEARING DISTANCE L2increase = L3 serves as maximum limit for a bearing distance increase during operation. Any pressure relief measures will be stopped when the bearing distance reaches this limit.

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

40
Left Fixed Roller Gap = 35 45 mm Right

Start RP group
Retraction cylinders are drawn back by springs. After this the movable roller will be pushed back to L2 by the main cylinders from 45 mm to 35 mm. This happens with running rollers.

L2

Gap = 35 mm

Movble Movable Roller Roller

Press cylinder

In case if during moving back the movable roller an oil pressure is measured of more than 40 bar ( normal < 40 bar ), the start will be interrupted by an alarm signal. Fault has to be acknowledged at the roller press after checking. Possible causes: Material between the rollers. Disturbance in the hydraulic circuit. Roller can not move free. After bearing distance is on both sides L2 the roller press group will be released and feeding of the pre bin can be started. Pump stops and valves will be closed.

V 06 09 V 10 05

07 V 09

V 10 07 06 V 11

V 1/2 V 07 08

V 3/4

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

Pump 5312.HD1

Hydraulic oil tank

41
Left Fixed Roller Right

Start Pressure control

After the start program is ready the pressure control will start automatically.

Movable Roller
Press cylinder

After opening of the shut off gate there will get material between the rollers.
V 10

V 09

V 08

V 05

V 06

V 1/2 V 07

V 3/4

The proportional valves will increase pressure to the main cylinders up until the set point. Hydraulic pump start.

Pump 5312.HD1

Hydraulic oil tank

42
Left Fixed Roller Right

Pressure control
By the intake behaviour of the running rollers combined with the pressure of the column ( gap ) of material on the rollers the material flow will tend to press the rollers apart. When the hydraulic reaches the value set point-tolerance the proportional valves will be closed and the pump will stop.
V 06

Movable Roller
Press cylinder

V 09

V 08

V 10

V 05

V 1/2 V 07

V 3/4

+ 10 bar Pres.Set point - 10 bar

Pump 5312.HD1

At this value the material counter pressure and the cylinder pressure will be on balance.

Hydraulic oil tank

43
Left Fixed Roller Right

Pressure control
Pressure variations with in tolerance will be compensated by the N2 accumulators.
Accumulator Gas ( N2 ) Pressure = 90 bar

100 90 bar
100 bar

Movable Roller
Press cylinder Start up < 90 bar Set point 125 bar
135 bar 125 bar 115 bar

V 09

V 08

V 10

V 05

V 06

V 1/2 V 07

V 3/4

Pump 3212HD1.M01

Hydraulic oil tank

44
Fixed Roller Left Right

Pressure control
When the hydraulic gets beneath the pressure (value) set point tolerance the proportional valves will be opened and the pump will start.
135 bar 125 bar 115 bar

Movable Roller
Press cylinder

This will remain so until set point operation pressure tolerance has been reached. After this the valves will close again and pump will stopped. In this example on one side.

V 09

V 08

V 10 20 m Amp

V 05

V 06

18,4 m Amp

Proportion valve pressure increase

80 %
Characteristics proportional valves.
V 1/2 V 3/4 100 % V 07

Proportion valve pressure decrease

12 m Amp 0%

80 %

100 %

Pump 28 HD 41 M 01

Hydraulic oil tank

4 m Amp

Proportional valves
The proportional valves act in two flow directions which are activated by two solenoids: a) Pressure increase: Analogue PLC output: 12 - 20mA corresponding to 0 - 100% opening b) Pressure decrease: Analogue PLC output 12 - 4mA corresponding to 0 - 100% opening The neutral position (both ways closed is determined at I = 12mA ). The activation of the solenoids is organised via valve amplifier installed on top of the proportional valve.

20 m Amp

18,4 m Amp

Proportion valve pressure increase

80 %
Characteristics proportional valves.
100 % V 1/2 V 3/4

V 07

Proportion valve pressure decrease

12 m Amp 0%

80 %

100 %

Pump 28 HD 41 M 01

45

4 m Amp

Hydraulic oil tank

46
Fixed Roller
Gap = 10 mm

Set points

Distance pieces

L 0mm

0 mm ( Bearing distance )

Left Movable Roller

Right

This is the point where the bearing distance is 0. For the gap measuring this point is 4 m Amp. The bearing blocks are fixed in a way that the rollers can never touch each other physically

Roller distance 10 mm = Gap 10 mm

L min
Fixed Roller Left Gap = 25 mm Movble Movable Roller Roller Right

15 mm ( Bearing distance )

Distance between the bearings used as lower limit for the pressure control. If distance is less pressure control will be deactivated. GAP < L min Pressure control OFF GAP > L min Pressure control ON normal operation

Roller distance 10 mm + Bearing dist. 15 mm ----------------------------= Gap 25 mm

47

LOCAL CONTROL PANEL:

One push button with signal lamp is used for acknowledgement of alarms which require a visual inspection at the Roller Press for the reason of following alarms: Pressure >40bar during start programme (BCON) Pressure >180bar during operation Movable roll end limit position has been reached Under speed monitoring After local acknowledgement these alarms have to be acknowledged at the SCADA too!

48
Start program BCON (RP GROUP = START)
With the group Roller Press start command both pressure decrease valves are energized to allow the movable roll to move backwards. This is important after a restart following an emergency stop with uncrushed material above the rolls. Is the bearing distance left or right <L3 the movable roll will be moved using the retraction cylinder until one side has reached L3 The retraction cylinder then is deenergized.

49
Start program BCON Program Step 1 and 2
BCON Program Step 1 If the bearing distance left or right is L3 or after a delay time the start of the roller drives in parallel mode or sequential mode is performed.

BCON Program Step 2

The movable roll will be moved towards the fixed roll by energizing both pressure increase valves, when both roller drives are in operation and the run-up time is elapsed. Both pressure increase valves are to be controlled independently.

Exceeds any hydraulic pressure the limit 40bar the group start sequence will be stopped with alarm.

49
Start program BCON Program Step 3
BCON Program Step 3

The program BCON stops and the shut-off gate opens when the bin level reaches the maximum limit set at SCADA, e.g. 50% and the pressure control function is activated in case the operation mode "AUTOMATIC" is selected. The delayed energising of pressure reducing valves takes place when the shut-off gate is closed. This causes the movable roll to move apart from the fixed roll. This action is terminated when the bearing distance has reached the limit L3 or latest after 5 sec. Now, the movable roll will be positioned to the limit L2 (start position) using the pressure increase valves.

51
Left Fixed Roller Gap = 35 mm

Set points
Roller distance 10 mm + L2 Bearing dist. 20 mm = Gap 30 mm L min L2
Parameter set in the PLC. Set only once. Range from 5.0 to 30.0 mm Actual set point 20 mm

Right

Movable Roller

( Set point for material feeding )

Left

Fixed Roller Gap = 45 mm

Right

Roller distance 10 mm + L2 + 10 Bearing dist. 30 mm = Gap 40 mm L min L2 + 10 mm

Until this value the rollers are pushed back by retraction cylinders during start up the main motors.

Movable Roller

52

Set points

Left

Fixed Roller Normal operation Gap = 65 mm maximum Movable Movable Roller Movable Roller Movable Roller

Right

L min L2 + 10 mm

Roller distance 10 mm + Bearing dist. > 50 mm = Gap > 60 mm

Limit switch
Maximum distance allowed between the bearings. ( 65 mm Gap ) Determined by a mechanical switch. Over 65 mm gap the roller press will stop with max. gap alarm.

53
Normal Stop of the group Roller Press
This command starts the shut-down procedure with: stopping of the feed belt, the pressure reduction by opening of the pressure reducing valves until the limit L3 has been reached or for max. 5sec, the run-off of the roller drives for 1min. This procedure can be released by: STOP command from SCADA Drive fault Instrument loop fault Over temperature roller bearings Over temperature gear box bearings Over temperature hydraulic oil Disturbance BCON

54
Fast stop of the group Roller Press
This command stops the group Roller Press immediately stopping the feed belt, Stop of the roller drives and all other drives of the Roller Press, de-energising of the hydraulic valves. This procedure can be released by: EMERGENCY STOP command from the local control panel Loss of control voltage Activation of the movable roll end position Hydraulic pressure >180bar Under speed monitoring of any roll Fault of any roller drive

55
Group Aux. Heater = Start / Stop
The commands Start/Stop and LOCAL are sent from SCADA to the ROLCOX system. This signal starts the heating system for the grease pipe and oil pipes. The heating units are self-controlling. No temperature control is required in ROLCOX.

3212LQ5.H01

3212LQ5.H02

3212LQ5.H03

56
Left Fixed Roller Right

Current control
By means of to much adjusting of operation pressure or due to changing material properties the electrical load of the main drives can become to high. If this load exceeds a preset maximum the pressure will be reduced.

Movable Roller
Press cylinder

V 09

V 08

V 10

V 05 10

V 11 06

This will last until the movable roller reaches L2 + 10 mm = 45 mm gap or until the drives get below operation load.

V 1/2

V 3/4

V 07

After this the pressure control will be reactivated.

Pump 28 HD 41 M 01

Hydraulic oil tank

57
Fixed Roller Fix Roller Left Right

RP Group stop
At a stop of the roller press (desired or undesired) the RP - slide gate will close and stopped the material feed to the RP. The Pressure decrease valves will open, the proportional valves will open,and the emergency valve will open.
V 10

Movble Movable Roller Roller

Press cylinder

V 09

09 V 08

V 05 10

V 06 11

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

V 1/2

V 3/4

V 07

Pump 28 HD 41 M 01

Hydraulic oil tank

The Pressure decrease valves will close, the proportional valves will close, and the emergency valve will open.

58

ROLCOX Parameters

59
OPERATION CURRENT Adjusting range: 70 ... 90% of the nominal current In

SCADA
This value corresponds to the upper limit of the standard operating current. As soon as that value is reached, the overload pressure reliefing measure is terminated. This value corresponds to the upper limit of the standard operating current. As soon as that value is reached, the overload pressure reliefing measure is terminated.

EXCESS CURRENT Adjusting range: 70 ... 90% of the nominal current In

CURRENT DIFFERENCE Adjusting range: 5 ... 20% of the nominal current In

In case the current difference between the drives exceeds the set limit, an alarm will be generated without further consequences for the operation of the Roller press.

60

SCADA
With activated gap-dependent pressure control, the SETPOINT PRESSURE is limited to the sum of OPERATING PRESSURE + PRESSURE INCREASE MAX. An internal pressure limit (150 bar) cannot be exceeded! With activated gap-dependent pressure control, the SETPOINT PRESSURE is limited to the sum of OPERATING PRESSURE + PRESSURE INCREASE MAX. An internal pressure limit (150 bar) cannot be exceeded! With activated gap-dependent pressure control, the SETPOINT PRESSURE is limited to the sum of OPERATING PRESSURE + PRESSURE INCREASE MAX. An internal pressure limit (150 bar) cannot be exceeded!

OP.PRESSURE INCREASE MAX, 10-99bar

OP.PRESSURE INCREASE MAX, 10-99bar

OP.PRESSURE INCREASE MAX, 10-99bar

60

SCADA

62