1014(;314 TE201513565
13565 Masch,nenbuch
1
SE=iVOLiFT
Machine Book for: Container Blender
Manufacturer: Customer:
Table of contents
.,
1. Masterdata 3
1.1. General information 3
2. Description of Product 4
3. Technical Data 5
3.1. General data 5
3.2. Fixings 5
3.3. Material and surface 5
3.4. Blending drive 6
3.5. Horizontal clamping system consisting of: 6
3.6. Lifting device 6
a.7. Electricity 6
3.8. Control 6
3.9. Control cabinet 6
3.10. Safety 7
3.11. Interface 7
3.12. Safety installations and Components 8
3.13. Securing of the hydraulics against excess pressures 8
3.14. Factory adjustment with nominal load 8
3.15. Securing of the pneumatics against excess pressures 8
3.16. Attachment to Machine Book 9
3.17. Changes in design and major repair work 9
4. Test certificates 10
4.1. Factory Acceptance Test 10
4.2. Acceptance test at the user 11
4.3. Repeat test on site 12
S. Carrying out regular tests by competent persons of Servolift
5.1. 13
(
5.2. Supporting structure and wearing parts 13
5.3. Hydraulics 13
5.4. Electrics 14
5.5. Safety equipment and technical documents 14
Test report 14
1. Master data
Delivery date:
Initial operation
Datel: T3565::_MaChine Book.docx--- .-- .----.-- - Verslon:1--'---' -_.. -..-.- -._.----- _. 3/14
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2. Description of Product
The blender is exclusively destined to take the descript containers with a maximum load of 1000 kg
and to blend them.
Operation is done on a separate operating terminal as touch display.
The controls are located at a separate stainless steel control cabinet
The danger zone is protected by customer with safe potential free contacts on process site door
switch.
The machine is not designed for any other use than that listed above.
For all for injury to persons and damage to property which occur from inappropriate use, the liability
is only subject to the user off the machine and not to the manufacturer.
(
2.2. Overview of the System
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3. Technical Data
3.2. Fixings
3.7. Electricity
energy supply 380V, 60Hz, 3Ph, PE
power consumption 13 kW
electric supply to be installed on site to the control cabinet by customer
connecting cable between the top of the control cabinet and the separate operator panel:
- cable 20 m length, cabling and installation are not in our supply.
control voltage 24 VDC
class of electrical components IP 54
Ex-protection
- no ATEX requirements
electric installation ace. EN 60204, with single core labelling
{
3.8. Control
Control PLC-control Siemens S7-300 into control cabinet
Main switch on the door of the control cabinet
Separate operator panel outside of the blending room with:
- operator terminal Touch 12" colour
- laser printer for DIN A 4 paper sheets
- HMI for: lifting / lowering and clamping / unclamping
- pushbutton for emergency stop
- pushbutton "Agreement for rotation function"
lifting device
- lifting range mechanically limited
- with relockable check valve for safety reason
clamping
- safety valve fixed on the cylinder to protect against loss of pressure
- in case of damage, the clamping device remains closed
overload protection
for all the load related functions, no movement possible
overload protection for lifting movement
adjustable pressure control valve, no movement possible
safety device
monitoring of clamping pressure
3.11. Interface
DateE':i"3t@:i:_Machine- Book.docx-- ---- ----------------version: r'- -- .- _. o__ ---. _. " - .--.- _-- ...... --- - . -- ---7714
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Pressure limiting valve for lifting movement factory adjusted and sealed.
the operating instructions with the documents listed below must be assigned to the machine book
Date: Description
The design engineer responsible decides whether a new machine book needs to be prepared.
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4. Test certificates
4.1. Factory Acceptance Test
'Test carried out by the expert at Servolift premises before initial operation
The SERVOLIFT unit has successfully stand Factory Acceptance Test on 4--1, 0v7.. 2 (;? --7 t
After site erection, check of anchoring and connection to energy by an expert no concerns are seen to put
the unit into operation.
test before initial operation at user's site can be recorded on the following page.
(
"
Expert:
(
The Servo lift unit was subjected to a test for readiness for service on
Dowel report about correct setting of anchors is existing and filled out.
yes 0 no o
( The machine is marked by CE- label and Declaration of Conformity is available and signed.
yes 0 no [gI
There are reservations about putting the unit into operation: yes 0 no o
Repeat test is necessary yes 0 no o
Expert:
Result of the test carried out by the specialist before initial operation
the Servolift unit was subjected to a test for readiness for service on
There are reservations about putting the unit into operation: yes 0 no o
Repeat test is necessary yes 0 no o
Expert:
instructions for carrying out tests within the context of regular or exceptional tests
Visual inspection of all supporting parts for corrosion and deformations, this applies particular
for weld seams.
Check of all chains, in particular the chain locks and connecting links.
Check of lubrication of all bearing parts. (Some of the ball bearings are lifetime lubricated)
Check of all ball and slide bearings.
Check of attachment elements, in particular anchors, screws with safety functions etc.
( Functional test
with 90 ... 100 % of the perm issible load
Function and wear of the cover bands
Check of the rotary and tilt drives (motors, gear rims, stops etc.)
Check of the load suspension device
Tightness and condition of gears
Function
State
5.2. Hydraulics
Checking the hydraulic system (power pack, valves, fittings, pipes, brake):
a) Tightness and function
b) Check of pressure limiting and safety valves e.g. check valves with release,
line rupture valves and settings of pressure limiting valves
5.3. Electrics
Check of the safety-related functions and signal equipment of the electric, hydraulic and pneumatic
circuits and/or switching elements (sensors).
14/14
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The Servolift unit was subjected to a test for readiness for service on
There are reservations about putting the unit into operation/ continuing to use it: yes D no D
Repeat test is necessary: yes D no D
Next inspection according to test badge:
,
Expert:
Name and address of the competent person:
Faults acknowledged: *)
Inspector
Sig: I Y..
{ Approved by:
Sig:
Approved by:
Sig:
Approved by:
Sig:
I
Blender
Date of Version: 107. Jan. 2016 I
Version: Table of Contents
1.1. Document History - Change Control 3
2. Identification 4
2.1. General Data 4
2.2. Reference Documents 4
Check of Order 5
3.1. Check of unit against the offered and ordered positions 5
4. Installation 6
5. Labelling 6
5.1. Labelling added to machine 6
6. Interlocks 7
6.1. in general: 7
6.2. for manual functions: 8
<,
7. Operation 10
'7.1. Control ON - general test 10
1.2. Password Management - general test. 11
7.3. LOGIN procedure, in example for OPERATOR level 11
1.4. LOGOUT procedure (manually actuated), for example for OPERATOR level. 12
1.5. LOGIN procedure, in example for ADMINISTRATOR level 13
7.6. LOGOUT procedure (automatic, if set time elapsed), for example for SUPERVISOR level 14
7 .7. Operating Terminal - general test offunctions at HMI 16
-
7.8. Check MANUAL MODE functions (positioning for blending) 18
7.9. Check BLEND PARAMETER functions 19
7.10. Check BLEND MENU functions 22
7.11. Check MANUAL MODE functions, moving back to start position 23
7.12. Check MAINTENANCE MENU functions 24
8. Documentation Check 25
I
Blender
Date of Version: 107. Jan. 2016 I Version: 1
The following list registers the execution of changes for this document.
Remarks
IBlender
Date of Version: I 07. Jan. 2016 I Version: 1
2. Identification
Remarks
I, r,
Servolift I Sig Customer I Signature
3.1.2.
Operating Terminal i<
Receipe Management )(
3.1.3.
3.1.5.
Potential free contact 'I-
Qualification documentation for blender (IQ, OQ, FAT, FS/FDS)
3.1.6. '1<
3.1.7.
SERVOLIFT Standard Documentation y
(
Other non-listed items as service work, packaging and transport are
not relevant for qualification, and thus not included in this table.
INFORMATION
File: 13565_FAT_1.docx
1.1/,
Servolift I Customer I Signature
File: 13565_FAT_1.docx
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I Factory Acceptance Test (FAT)
4. Installation
5. Labelling
5.1. Labelling added to machine
5.1.3. Symbol
5.1.4. )<
Remarks
, L1 4, .>
1.1/, if
Servolift / Stbnature Customer / Signature
SE=iVOLiFT
I Factory Acceptance Test (FAT)
6. Interlocks
6.1. in general:
YES NO
confirm,
the control at HMI-terminal of Blender 13565 is only possible:
- if general power supply at electric cabinet is switched ON
6.1.1. - if HMI-terminal is initialized and y
- user is logged in to one of available 4 user groups
( (ADMINISTRATOR, SUPERVISOR, MAINTENANCE OR OPERATOR)
confirm,
6.1.2.
after initializing of HMI-terminal the operating language PORTUGUESE is
loaded, means it is indicated by national flag on first screen,
y
and it can be changed by tapping the symbol with national flag, e.c. to ENGLISH
confirm,
after an interrupt of running sequence, e.g. by a disturbance (E-Stop, blend
6.1.3. room access, etc.) the displayed fault message(s} has to be remedied, ~
confirmed and reset in separate menu ALARMS
confirm,
any interruption in movement can only be started again, if the cause for the
6.1.4. interruption is remedied, the fault message is reset, and the safety circuit is >(
activated by function key ACTIVATE SAFETY CIRCUIT
Remarks
I. 1/.
Servolift I Customer I Signature
SE=iVOLiFT
I Factory Acceptance Test (FAT)
'" . '7/28
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I Factory Acceptance Test (FAT)
YES NO
confirm,
- with activated operating language ENGLISH,
- logged in user "OPERATOR" and starting from MAIN MENU:
- if pressed key OPERATOR MENU and then MANUAL MODE
6.2.1. - the menu is opened and manual functions become visible in dark grey, -c
but cannot be started at this moment,
there are: LIFT I LOWER, CLAMP I UNCLAMP and TURN LEFT I RIGHT
confirm,
only after having pressed key ACTIVATE SAFETY CIRCUIT the manual ')(
function can be operated, these will be shown light grey, means function
6.2.2.
released
confirm,
LIFT I LOWER function (with inserted container in arm) is possible,
6.2.3.
- if supporting arm is in 0 turn position (= upright)
- if supporting arm is unclamped (means swivel clamps unclamped and y
centering cylinders retracted)
confirm,
CLAMP function is possible,
6.2.4.
- with container in position y
- supporting arm in max. height (= blend height)
confirm,
UNCLAMP function (with inserted container in arm) is possible,
6.2.5.
- if supporting arm is in 0 turn position (= upright) y
- if supporting arm is in max. height (= blend height)
confirm,
TURN LEFT I RIGHT function (with inserted container in arm) is possible,
- if supporting arm is in 0 turn position (= upright)
)<
6.2.6. - and in max. height (= blend height)
- and container is clamped
- blend room access - here safety door is closed
Remarks
File: 13565_FAT_1.docx
SE~VOLiFT
'I Factory Acceptance Test (FAT)
YES NO
confirm,
start blend cycle in BLEND MENU is only possible,
if following conditions are fulfilled:
- if supporting arm is in 0 turn position (= upright)
6.3.1. -
-
and in max. height (= blend height)
and inserted container is clamped
><
- blend room access - here safety door is closed
- and blend parameter are entered or selected
YES NO
:
confirm,
the activation of MAINTENANCE MODE is possible on HMI-terminal,
- if user is logged in as member of MAINTENANCE level
- or logged in for a higher group level, e.g. as ADMINISTRATOR,
6.4.1.
- if MAINTENANCE MODE is opened (submenu in MAINTENANCE MENU), ~
in opened menu it will be possible to start each displayed function of the blender
without regarding current position or other interlocks, that's why user has to be
careful when starting any movement and consider the given warnings on HMI
Remarks
Customer / Signature
YES NO
confirm,
by turning main switch located at electric cabinet to ON position 'X
7.1.1.
the control to operate the machine is ON
7.1.2.
confirm,
with general control on the initialization of HMI-terminal starts :
confirm,
the operating language PORTUGUESE is loaded, .--/
7.1.3.
it can be changed by tapping the symbol with national flag, e.g. to ENGLISH
confirm,
7.1.4. with operating language changed the MAIN MENU is displayed .:X
confirm,
at this moment no user is logged in or indicated at the head line
7.1.5. t 'f
y
~~R HAlH MfNU
c .. I
confirm,
only communication status between PLC and HMI
X
7.1.6.
is shown by green blinking symbol: IO~IIIIl!. I
confirm,
installed version of PLC and HMI can be read at MAIN MENU screen:
(
7.1.7. HMI YEn.IOl X
1 PLCVEII., 01 :1
Remarks
Group enter into entry field: User . enter into entry field: Password
ADMINISTRATOR ADMIN1 ADMIN1
SUPERVISOR SUPERVISOR SUPERVISOR
MAINTENANCE MAINTENANCE MAINTENANCE
OPERATOR OPERATOR OPERATOR
(
the following test shows how to log in for a user group and which functionality is assigned. Here it will
only be tested to login for user group OPERATOR, the procedure to login as for the 3 other user groups /
levels will then be the same.
YES NO
confirm,
('
7.3.1. with pressed key LOGIN. ~ X
the user Logon dialogue and the screen keyboard are displayed
confirm,
in opened dialog the cursor is blinking in input field "User" and expects ";x
7.3.2.
input
confirm,
after entering the user name "OPERATOR"
7.3.3.
and Confirmation with ENTER the user name is it is shown
?<
confirm, )<
7.3.4. with touch to input field "Password" the cursor is blinking and expects input
confirm,
after entering user password "OPERATOR"
7.3.5. and Confirmation with ENTER it is shown as " " , X
confirm, the password is not readable at the screen, it is hidden
confirm,
7.3.6. with pressed key OK the disQlayed Logon dialog is closed )<.
confirm,
user's name "OPERATOR" is indicated at the head line,
7.3.7.
means log in procedure was successful
and 'I
now user can start all assigned functions, e.g. in MANUAL MODE menu
test is continued on next page
Remarks
Customer / Signature
YES NO
confirm,
7.3.8.
if pressed key OPERATOR MENU,
the menu is opened and several submenus become visible
><
confirm,
7.3.9.
if pressed key MANUAL MODE,
the corresponding menu is opened, showing available manual functions
X
confirm,
if pressed key ACTIVATE SAFETY CIRCUIT here in the menu (key either
dark grey or light grey, doesn't matter) y
7.3.10.
an advice message, blue framed is given, showing that safety circuit is
activated and user is assigned here to start any function
confirm,
if pressed key EXIT (door symbol) the current menu is closed, OPERATOR X
7.3.11. MENU is displayed again and can also be closed by pressing key EXIT,
then the MAIN MENU is displayed again
confirm, y.
7.3.12. if pressed key EXIT again, the MAIN MENU is indicated again
7.4. LOGOUT procedure (manually actuated), for example for OPERATOR level
YES NO
confirm,
7.4.1. with pressed key LOGOUT 1 the current indicated user "OPERATOR" 'X
is logged out manually and at this moment no user is logged in
( confirm,
7.4.2.
when input of valid user identification (as described in "Login procedure")
is repeated user's name "OPERATOR" is indicated again at head line and v:
sequences can be continued by selecting needed menus and function
Remarks
I, r.
Servolift / Customer / Signature
File: 13565_FAT_1.docx 12 i 28
SE=iVOLiFT
I Factory Acceptance Test (FAT)
YES NO
(. ;
7.5.1.
confirm, with pressed key LOGIN. J
the user Logon dialog and the screen keyboard are displayed
><
confirm,
7.5.2. with touch to input field "User" the cursor is blinking and eX_Q_ecitnsput X
confirm,
after entering the user name "ADMIN1"
7.5.3. and confirmation with ENTER the user name is it is shown
X
(
confirm,
7.5.4. with touch to input field "Password" the cursor is blinking and expects input 'X
confirm,
after entering user password "ADMIN1"
7.5.5. and confirmation with ENTER it is shown as "***" , -
confirm, the password is not readable at the screen, it is hidden
confirm,
7.5.6. with pressed key OK the displayed Logon dialog is closed X
confirm,
7.5.7. now user's name "ADMIN1" is indicated at the head line
-
Remarks
Customer / Signature
File: 13565_FAT_1.docx
SE=lVOLiFT
I Factory Acceptance Test (FAT)
7.6. LOGOUT procedure (automatic, if set time elapsed), for example for SUPERVISOR level
YES NO
confirm,
7.6.1. user is still logged in as ADMIN1, the name is indicated at the head line y
confirm,
7.6.2. with pressed key ADMIN. MENU the menu is oQ_ened X
(, l
confirm,
7.6.3.
X
with pressed key" the menu USER MANAGEMENT is opened
confirm,
here the overview of pre-defined user and user groups is given,
Remarks
I. t>,
Servolift / Si Customer / Signature
confirm,
if doing following steps in described order
the modified logoff time is reset back to 5 minutes of user "SUPERVISOR":
therefore do following steps:
1. press key LOGIN
2. login as ADMIN1
3. call ADMIN. MENU ')(
7.6.11.
4. call USER MANAGEMENT menu.
.' ~
5. search user SUPERVISOR in overview list
6. and move to 4th column with value 1 minute for automatic logoff time
7. touch value, and change to 5 minute
( 8. confirm change by ENTER
9. close menu by EXIT key, ADMINISTRATOR MENU is displayed
10. press key EXIT again and return to MAIN MENU
Remarks
I. 1/. ./r~
Servolift ~ignature
A >:
Customer / Signature
YES NO
confirm,
7.7.1. control is ON and HMI-terminal is initialized, MAIN MENU is indicated '>(
confirm,
7.7.2.
operating language ENGLISH is selected and active,
indicated by national flag at MAIN MENU
-
confirm,
7.7.3. user is logged in as "OPERATOR", user's name is shown at head line y:
( confirm,
with pressed key OPERATOR MENU and then key MANUAL MODE
7.7.4.
the menu is opened and available manual functions become visible
'?<
confirm,
with pressed emergency stop push button beside HMI-terminal
a message bar "ALARM" is indicated -.,<.
7.7.5.
and no function can be executed until pressed E-Stop is unlocked,
if unlock the pressed E-Stop the test can be continued with next step
confirm,
7.7.6. pressed e-stop is unlocked and message bar ALARM was pressed X
test continued on next page
Remarks
I. V.
Servolift / Customer / Signature
File: 13565_FAT_1.docx
- "16/28
SE=lVOLiFT
I Factory Acceptance Test (FAT)
confirm,
in separate menu "ALARMS" the fault message(s) is(are) displayed with
date and time stamp in clear text, the fault message
7.7.7. V
can be confirmed by key ~; (Acknowledge) and key (Ai!it:! i
(Reset), confirm,
7.7.8. if pressed key EXIT current menu "ALARMS" is closed, menu MANUAL y
( MODE is shown again and key ACTIVATE SAFETY CIRCUIT is blinking
confirm,
7.7.9.
if pressed key ACTIVATE SAFETY CIRCUIT the safety module is on,
and manual functions (enabled functions are light grey) are released
.X-
confirm,
in case of communication error between PLC and HMI-terminal
7.7.10. by disconnecting the connection line (MPI-cable) no movement is possible, 'X
even if function keys at menu MANUAL MODE are pressed
confirm,
if connection line (removed MPI plug) between PLC and HMI )<'
7.7.11.
is re-connected again the test can be continued with next step
confirm,
in separate menu "ALARMS" the fault message(s) is(are) displayed with
date and time stamp In clear t~xt. the fault message 1 K
7.7.12.
can be confirmed by key
confirm, I
JJ . and key; .
' Af.'&T
(Reset),
(Acknowledge)
7.7.13.
if pressed key EXIT (door symbol) X
current menu "ALARMS" is closed, menu MANUAL MODE is shown again
('
Remarks
_,-
/. Y.
/ y / l
---
Servolift / Sigrfature Customer / Signature
YES NO
confirm,
Container Blender 13565 is in defined start position: means,
- arm is in min. height and clamps are open
- in 0 turn position (= upright) )<
7.8.1.
- with no container inserted in arm
- and safety door closed
- all openinQs (e.q. vent, lid) at the container must be closed
confirm,
(
7.8.2.
if safety door is opened, 'j
the container can be inserted into the arm by help of a hand pallet truck
confirm,
if container is in position, pallet truck can be removed
7.8.3.
and y
if leaving blending area and closing door from outside
the user is back at HMI to continue the sequence
confirm,
7.8.4. user is still logged in as "OPERATOR", name is displayed in head line .X"
confirm,
starting in MAIN MENU, if pressed key OPERATOR MENU
7.8.5. ~
the menu is opened and further submenus become visible
confirm,
7.8.6.
with pressed key MANUAL MODE
the menu is opened and available manual functions will be displayed Y
confirm,
if pressed key ACTIVATE SAFETY CIRCUIT, safety module is switched on, X
7.8.7.
all possible manual functions are released and displayed light grey
confirm,
( with pressed and hold key LIFT,
7.8.8.
lifting starts, it stops if pick up height big container is reached ><
confirm,
7.8.9.
with pressed and hold key LIFT again,
liftinQ starts, it stops if max. height is reached
><
confirm,
with pressed and hold key CLAMP,
7.8.10. X
clamping starts, it stops when container is clamped
confirm,
with pressed key EXIT (door symbol) the menu MANUAL MODE is closed,
y!'
7.8.11. OPERATOR MENU is displayed again and
PARAMETER MENU or TEST RECIPE menu are selectable
Remarks
File: 13565_FAT_1.docx 18 /
28
1Type of Machine: 1Container Blender 1 Project No. 13565
YES NO
confirm,
as checked in previous section
7.9.1. container is positioned into arm and container is clamped => means it is 'x
positioned for blending
confirm,
7.9.2. with pressed key TEST RECIPE the menu is opened X
confirm,
current logged in user "OPERA TOR" is not assigned to enter blend data,
therefore
7.9.3.
change user to "SUPERVISOR",
X
member of this group are enabled to enter blend data in this menu
confirm,
if pressed input box PRODUCT NAME
7.9.4.
screen keyboard is shown, input is possible
'<
confirm,
with input value "ABX-1 ", confirmed by ENTER key,
7.9.5. x
value will be displayed and contains not more than 40 characters
confirm,
with pressed input box PRODUCT NUMBER ')(
7.9.6.
screen keyboard is displayed, input is possible
confirm,
with input value "4711" and confirmed by ENTER key, )(
7.9.7.
value will be display_ed and contains not more than 40 characters
confirm,
7.9.S. if pressed input box BLEND TIME screen keyboard is shown, input is possible 't(
confirm,
input of blend time is limited and value must be within defined range:
{ '?(
7.9.9. if input value "0" min and confirmed by ENTER key,
value will not be acce~ted, value is out of range, input have to be repeated
confirm,
7.9.10.
if input value "100" min and confirmed by ENTER key it will not be accepted, v;
value is out of range, input have to be repeated
confirm,
if input value "5" min and confirmed by ENTER key, value will be accepted ')(
7.9.11.
and shown, it is within possible range of 1 to 99 [minutes]
Remarks
I. t .
Servolift Customer / Signature
SE=iVOLiFT
I Factory Acceptance Test (FAT)
YES NO
confirm,
with pressed input box BLEND REVERSE TIME
7.9.12.
screen keyboard is displayed, input is possible
'<
confirm,
input of blend reverse time is limited and value must be within defined range:
7.9.13. if input value "100" min and confirmed by ENTER key it will not be accepted, y
value is out of range, input have to be repeated
confirm,
(
7.9.14.
with input value "2" min and confirmed by ENTER key <:
value will be displayed, it is within possible range of 0 to 99 [minutes]
confirm,
if pressed input box BLEND SPEED
7.9.15.
screen keyboard is displayed, input is possible
X'
confirm,
input of blend speed is limited and value must be within defined range:
7.9.16. if input value "4" rpm and confirmed by ENTER key it will not be accepted, -c
value is out of range, input have to be repeated
confirm,
input of blend speed is limited and value must be within defined range:
7.9.17. if input value "16" rpm and confirmed by ENTER key it will not be accepted, y:
value is out of range, input have to be repeated
confirm,
if input value "8" rpm and confirmed by ENTER key
7.9.18. X
value will be accepted and shown, it is within possible range of 5 to 15 rrpml
confirm,
with pressed input box for LEVELLING ....,{
7.9.19.
screen keyboard is displayed, input is possible
( confirm,
input of levelling (time) is limited and value must be within defined range:
7.9.20. if input value "5001" ms and confirmed by ENTER key it will not be accepted, 'X
value is out of range, input have to be repeated
confirm,
if input value "2500" ms (milliseconds) and confirmed by ENTER key, the
7.9.21.
value will be displayed and is within possible range of 0 to 5000 [millisecondl
X
Remarks
/J ./J .>
I. t<
IY -
Servolift I S~nature Customer I Signature
SE=iVOLiFT
File: 13565_FAT_1.docx 20/28
I Factory Acceptance Test (FAT)
Date
YES NO
confirm,
7.9.22.
if pressed input box for BATCH ''1<
the screen keyboard is shown, input is possible
confirm,
with input value "13565-FAT-1" and confirmed by ENTER key, X
7.9.23.
value will be displayed and contains not more than 40 characters
confirm, => if input of BATCH is successful all entered values are shown,
here as summary:
( - PRODUCT NAME set ABX-1
- PRODUCT NUMBER set 4711
- BLEND TIME set 5 min X
7.9.24. - BLEND REVERSE TIME set 2 min
- and
- BLEND SPEED set 8 RPM
- LEVELLING set 2500 ms
- and with BATCH lnamel set "13565-FAT-1"
confirm,
if pressed key EXIT (door symbol) the TEST RECIPE menu is closed,
7.9.25. OPERATOR MENU is indicated again,
X
blend cycle is prepared and can be started in BLEND MENU, => see next test
Remarks
I. 1/.
Sarvolift / Customer / Signature
YES NO
confirm,
7.10.1.
starting at HMI-terminal in OPERATOR MENU :
if pressed key BLEND MENU the menu with blend data is displayed
check and confirm,
7.10.2. user is logged in, user's name is displayed in head line, here "SUPERVISOR" ,K
confirm,
7.10.3. loaded blend data are indicated, entered BATCH value "13565-FAT-1" too .X
( confirm,
7.10.4.
with all start conditions fulfilled the blend cycle can be started,
the key START in BLEND MENU is indicated light grey
-
confirm,
with pressed key START
7.10.5. the rotation starts and blend speed accelerates to selected value, here "8" 'K
rpm (as set before)
confirm,
with pressed key STOP
7.10.6. the running rotation is interrupted, blend speed decelerates to positioning -
speed and arm stops then in 0 turn position, the blend data keep remain
confirm,
with pressed key START again
7.10.7. the interrupted rotation starts with remaining blend time, X
and blend speed accelerates to "8" rpm (as set before)
confirm,
blend process stops after run down of "blend time", here set to "5" min,
)(
7.10.8. positioning starts and then the arm with inserted container stops in 0 turn
position
confirm,
( with finished blend cycle the blend report is printed
(on installed and configured printer),
7.10.9. or printout can be started by touching printer symbol in opened menu,
check and confirm, the report contains preset blend data, as well as time of >'-
start and end of blend sequence, and the interruption by pressed key STOP
confirm,
with blend cycle finished (or interrupted without finishing)
7.10.10. the current menu can be closed: if pressed key EXIT (door symbol), X
the BLEND MENU is closed, OPERATOR MENU become visible
confirm,
7.10.11.
if pressed key MANUAL MODE the submenu with manual functions is
opened
"><
Remarks
Customer / Signature
YES NO
confirm,
blend cycle is finished and supporting arm with inserted container
is still in blend position,
7.11.1. y
means with container clamped in 0 turn position (upright)
and safety door is closed
confirm,
(
in displayed MANUAL MODE menu:
if pressed and hold key UNCLAMP,
7.11.2. )<
unclamping starts, it stops when container is unclamped
confirm,
in displayed MANUAL MODE menu:
7.11.3. if pressed and hold key LOWER, X
lowering starts, it stops when pick up height big container is reached
confirm,
in displayed MANUAL MODE menu:
7.11.4. if pressed and hold key LOWER again, ')<
lowering starts, it stops when min. height is reached
confirm,
7.11.5.
if opened safety door, enter blend area y
the unclamped container can be removed by hand pallet truck
confirm,
7.11.6.
with pressed key EXIT (door symbol)
menu MANUAL MODE is closed, OPERATOR MENU is visible again ><
confirm,
( 7.11.7. if pressed key EXIT again MAIN MENU is displayed '!(
Remarks
YES NO
confirm,
y
7.12.1. general power supply is ON (main switch is at ON position)
confirm,
7.12.2. at HMI-terminal the operating language ENGLISH is loaded 'X
confirm,
7.12.3. the MAIN MENU is displayed, and user is still logged in as SUPERVISOR K
confirm,
with pressed key LOGIN in head line,
7.12.4. user identification can be changed to MAINTENANCE, )<
and if entry confirmed the user is logged in, name is shown in head line
confirm,
7.12.5. with pressed key MAINTENANCE MENU the submenus become visible X
confirm,
with pressed key MAINTENANCE MODE
7.12.6.
the menu is indicated with blinking warning and service functions '><
NOTE!
indicated service functions can be operated without any interlocks, therefore
7.12.7. user has to be careful when pressing any key and starting any movement, X
e.g. TURN LEFT/RIGHT may possible without having clamj)_ed the containerl
confirm,
if working in maintenance mode is finished, return the machine back
to its defined start position,
machine then can be operated in "normal" manual mode: 'K
7.12.S.
=> defined start position is reached with following positions fulfilled:
- arm is in 0 turn position (= upright) and in min. height
- swivel clamps unclamped and center cylinder retracted
( confirm,
all fault messages are acknowledged, reset and confirmed
so that closing the displayed MAINTENANCE MODE menu is possible
7.12.9. by pressed key EXIT,
previous menu is displayed and red framed message bar is disappeared and
"normal" operating mode is j)ossible
confirm,
7.12.10 if pressed key EXIT displayed MAINTENANCE MODE menu is closed X
confirm,
with pressed key EXIT again current shown MAINTENANCE MENU is closed,
7.12.11
and the MAIN MENU becomes visible again
'X
Remarks
Customer / Signature
8. Documentation Check
7.14. Installation Instruction and Safety Data Sheet of Compound Anchors HILTI )<
Remarks
The documents listed below are available only on CD-Rom after FAT
Remarks
I. c-:
Servolil Customer / Signature
File: 13565_FAT_1.docx
Type of Machine: I Container Blender I Project No. 13565
L
/
L
V
/
/
/
/
-:
/
//
/
/
L
(
.:
/
/
-:
/
Remarks
I. "".
Customer / Signature
Date
10. Final Statement
Remark:
/
.>
/
/'
/'
/'
/'
/'
/'
/'
/'
/'
/'
/'
/'
{
-:
I~
YES NO
Remarks
I. 1/,
Servolift / Customer / Signature
File: 13565_FAT_1.docx 28/28
SE=iVOLiFT
Operational Qualification (OQ)
OPERATION QUALIFICATION
for
Container- Blender
Written by:
Mr. R. ~~er
Sig:
/' 1', ~
~
.
, Electrical
i-'programming dept.
22. Dec. 2015
Reviewed by:
Sig:
Reviewed by:
Sig:
Approved by:
Sig:
13565_OQ_1_E.docx 1/
66
SE=...lVOLiFT
!' ':,' ~ i .~!.... ...;;.. .~.. ,': .
this page will be revised each time the specification is revised and re-issued, to record the dates and
reason for issue. All changes of this document (either for review or approval) are registered in this list.
13565_OQ_1_E.docx 2/
66
SE=tVOLiFT
Operational Qualification (OQ)
Table of Contents
1. Introduction 6
1.1. Author 6
1.2. Objective of this document 6
1.3. Reference Document(s} 6
2. Control ON 7
2.1. Control ON, general procedure 7
13565_OQ_1_E.docx 3/
66
SE=lVOLiFT
r:: .: I "~ ~ ~l""''' : .:/ ....)."
7. Functional Sequence(s) 45
7.1. Blending (with 1600L container) .45
1.2. Maintenance mode / sequence 48
8. Adjustments 51
8.1. SUPERVISOR MENU - RECIPE MANAGEMENT 52
8.2. ADMINISTRATOR MENU - PASSWORD I USER MANAGEMENT 57
8.3. TERMINATE I SHUTDOWN RUNNING APPLICATION 64
13565_OQ_1_E.docx 4/
66
SE=JVOLiFT
Operational Qualification (OQ)
Responsible
Person:
.'
1. Introduction
1.1. Author
This document is the Operational Qualification (OQ). It presents the basic test procedures
to carry out the single functional tests of the Container Blender 13565 as given in the contract.
This document is written and approved by SERVOLIFT GmbH, Germany.
"
1.3. Reference Document(s)
(
SE=iVOLiFT
Operational Qualification (OQ)
2. Control ON
The following test is a general test and it shows that functional sequences can be started
from operator panel located outside blend room, after having switched ON general power supply.
2.1. Control ON, general procedure
I.~
and HMI is indicated
confirm, at head line ...
/ 2.1.5. only communication status ... by blinking green symbol:
I
between PLC and HMI is shown
IlDlS
defined position means:
2.1.6.
check and confirm, - arm is in min. height
blender is in "defined" position - safety door is closed
- container type 1600L is available
2.1.7. TEST FINISHED
Remarks
(user-) Group enter into entry field: User enter into entry field: Password
ADMINISTRATOR ADMIN1 ADMIN1
SUPERVISOR SUPERVISOR SUPERVISOR
MAINTENANCE MAINTENANCE MAINTENANCE
OPERATOR OPERATOR OPERATOR
,
The following tests show how to log in for each user group and which functionality is assigned.
Remarks
Remarks
3.2.7.
check, if key with arrow down c:J] displayed dialog is closed, blend data
is pressed of "Sample RECIPE" become visible
an recipe dataset can be selected
menu RECIPE MANAGEMENT is
closed,
3.2.8. press key EXIT
SUPERVISOR MENU is displayed
again
3.2.9. press key EXIT again MAIN MENU is indicated again
Remarks
Remarks
c
3.4.6. is opened, an overview of preset user
the submenu will opened and user groups is displayed
check and confirm, with touch input field
if touched any input field, screen keyboard is shown
e.g. logoff time and value is changeable,
3.4.7. of user "SUPERVISOR" e.g. to 1 minute,
which shows "5" min, if pressed ENTER change is saved,
modification is possible if pressed EXIT menu is closed
press key EXIT (door symbol) menu is closed,
3.4.8. in the end MAIN MENU is shown
to close displayed menu
3.4.9. TEST FINISHED
Remarks
Remarks
SE=iVOLiFT
Operational Qualification (OQ)
Type of Machine: I Container Blender I Servo lift Project No. I 13565
Remarks
lifting starts
4.1.5. press and hold key LIFT and stops
at pick up height big container
Remarks
,
item Description I Start condition Acceptance criteria YES NO
at HMI panel:
4.1.9. press key (blue, blinking) safety module is switched on
ACTIVATE SAFETY CIRCUIT
Remarks
Remarks
_. _
Remarks
5.1.9.
press key 0 [CONFIRM]
message is confirmed,
key RESET will be enabled, is light grey
Remarks
Remarks
Operational Qualification (OQ)
Remarks
confirm
5.3.1. submenus become visible
MANUAL MENU is still dis la ed
defined position means:
arm is at blend height
check and confirm,
5.3.2. in 0 turn position
b~nder~in"~end"posWon
inserted container is clamped
safet door is closed
confirm, user is logged in,
user's name "SUPERVISOR"
5.3.3. if not, please put in user 10
is shown in the head line
as described in cha ter 2
BLEND MENU is indicated with blend
in displayed OPERATOR MENU:
5.3.4. data as entered, key START
press key BLEND MENU
is shown enabled =
Ii ht re
rotation starts and
5.3.5. press key START
accelerates to selected blend seed
simulate communication error MPI-plug is disconnected,
between PLC and HMI-terminal but no message is displayed
5.3.6. => disconnect MPI-plug at HMI-terminal,
at PLC (15A2) located inside elec-
tric cabinet and wait 15 seconds
wait 15 seconds and
5.3.7.
then re-connect MPI- lu to PLC
message is confirmed,
5.3.9.
press key [[J [CONFIRM] key RESET will be enabled, is light grey
5.4.6.
press key 0 [CONFIRM]
message Is confirmed,
key RESET will be enabled, is light grey
Remarks
Remarks
Remarks
Operational Qualification (OQ)
Type of Machine: I Container Blender I Servolift Project No. I 13565
Remarks
Remarks
SE=lVOLiFT ". : '!..-:~ ~ '; '. -, :J ",
Remarks
SE=iVOLiFT
~"i":'i::'
::, ',;, (.F:-)".: f'!;,
return
5.7.10. press key EXIT (door symbol)
from menu ALARMS to BLEND MENU
( press key (blue, blinking)
5.7.11. safety module is switched on
ACTIVATE SAFETY CIRCUIT
rotation starts and
5.7.12. press key START
accelerates to selected blend speed
Remarks
SE=iVOLiFT
.1.;..... _',;,
:.7: .: ;".!.J';.
simulate malfunction
of protection components after having switched off
(e.g. fuse, circuit breaker) the motor circuit breaker
5.8.4. caused by over current,
the rotation stops
and
a message bar shows "ALARM"
=> tum off motor circuit breaker (5Q3)
5.8.7.
press key Q [CONFIRM]
message is confirmed,
key RESET will be enabled, is light grey
5.8.9. press key EXIT (door symbol) return from menu ALARM
to BLEND MENU
Remarks
SE=tVOLiFT
Operational Qualification (OQ)
Type of Machine: I Container Blender I Servolift Project No. I 13565
Remarks
Remarks
message is confirmed,
5.10.7.
press key .ll.J. [CONFIRM] key RESET will be enabled, is light grey
Remarks
.v.
5.11.7.
press key _ ~
[_J [CONFIRM]
message is confirmed,
key RESET will be enabled, is light grey
Remarks
Remarks
message is confirmed,
5.13.7.
press key [[J [CONFIRM] key RESET will be enabled, is light grey
Remarks
5.14.7.
press key tJ [CONFIRM] message is confirmed,
key RESET will be enabled, is light grey
Remarks
5.15.6.
press key 0: [CONFIRM) message is confirmed,
key RESET will be enabled, is light grey
Remarks
SE=lVOLiFT
Operational Qualification (OQ)
message is confirmed,
5.16.7.
press key q. [CONFIRM]
key RESET will be enabled. is light
grey
5.16.8. press key RESET message is confirmed and cleared
return from menu ALARM
5.16.9. press key EXIT (door symbol)
to BLEND MENU
5.16.10. press key START sequence is continued
Remarks
Remarks
Remarks
Remarks
Remarks
SE=lVOLiFT
Operational Qualification (OQ)
7. Functional Sequence(s)
At this section the "normal" operational sequences is checked. Possible sequences is Blending with all
lnterlocks activated, and Maintenance for setting up the machine without interlocks.
7.1.1.
check and confirm, - arm is at min. height
blender is in "defined" position - in 0 turn position
- container type 1600L is available
check and confirm,
user's name "SUPERVISOR"
7.1.2. user is logged in as described
in chapter "Access control" is shown in the head line
go to HMI terminal and screen changes and
7.1.3. submenus will be displayed
press key OPERATOR MENU
7.1.4. press key MANUAL MODE menu MANUAL MODE is displayed
press key (blue, blinking) safety module is switched on,
7.1.5.
ACTIVATE SAFETY CIRCUIT sequence can be continued
lifting starts and
7.1.6. press and hold key LIFT
stops at pick UP heloht bia container
go into blend room, insert availa-
7.1.7. ble container container is in position
( into supporting arm
remove hand pallet truck, leave hand pallet truck is removed, safety
7.1.8.
blend room and close safety door door is closed
at HMI panel:
safety module is switched on,
7.1.9. press key
sequence can be continued
ACTIVATE SAFETY CIRCUIT
press and hold key LIFT until
lifting starts
7.1.10. max. height (=blend height) is
and stops at max. height
reached
7.1.11. press and hold key CLAMP inserted container will be clamped
Remarks
5E~VOLiFT ,l '.' :." ~ .' ',_ ',.
STEP I
Remarks
7.1.25. press and hold key LOWER arm is lowered to pick-up height 1600L
go into blend room, position hand
container is removed from arm,
7.1.26. pallet truck under the container in
arm is free
arm and remove it
close safety door and go to HMI
7.1.27. safety door is closed
panel
at HMI panel:
safety module is switched on,
7.1.28. press key (blue, blinking)
sequence can be continued
ACTIVATE SAFETY CIRCUIT
7.1.29. press and hold key LOWER again lowering starts and stops at min. height
Remarks
( 7.2.2.
starting from MAIN MENU - SERVICE INTERVAL
press key MAINTENANCE MENU - STATE INDICATION
BY SYMBOL 6d
- ARCHIVE ALARMS
BYSYMBOL~
menu is shown with flashing warning
7.2.3. press key MAINTENANCE MODE and available manual functions
for setting-up the machine
... continued on next page
Remarks
Remarks
all messages
7.2.10. press key RESET
are confirmed and cleared
7.2.11. press key EXIT (door symbol) return to MAIN MENU
Remarks
h. Adjustments
Following sections are used to check how the user can execute modifications of machine set points
and to edit or modify user identifications.
Remarks
For access to functions of this menu user needs authorization for SUPERVISOR or ADMINISTRATOR
(
ieve!. The call of this menu is independent of current machine position, but it is recommended it should
be in defined start position.
Remarks
product number
move to PRODUCT NUMBER, is entered and confirmed,
8.1.9.
put in "13565001", it contains maximum 40 characters
( confirm input by ENTER key
Remarks
SE=tVOLiFT
Operational Qualification (OQ)
recipe is selected,
8.1.29. select recipe "TEST-1" from list
blend data loaded and displayed
Remarks
Eurofarma Laboratories SA, Itapevi - C t R f 4500233630
Customer: Sao Paulo, Brazil us omer e erence
Remarks
( 8.1.42.
press key DELETE
IX I which must be implicitly confirmed
in recipe BLEND DATA?"
to avoid unintended deletion
Remarks
--
8.2.1. blender is in "defined" position in 0 turn position
with clamp system unclamped
check and confirm, user is logged in
user's name "ADMIN1"
8.2.2. as described in chapter "Access
is indicated in the head line
control", change it to "ADMIN1"
( ADMINISTRATOR MENU is opened,
starting from MAIN MENU
8.2.3. function keys and available submenus
press key ADMIN. MENU
become visible
menu USER MANAGEMENT
8.2.4.
press key:::;' is displayed showing user overview list
Remarks
Remarks
Remarks
SE=lVOLiFT
Operational Qualification (OQ)
8.2.27. )()tINI'lH'tIC
,...
'''"
HQ.I fl'"
Remarks
.8.2.31. to change single parameter of new user identification and check if it works
in ADMINISTRATOR MENU
(. menu USER MANAGEMENT is dis-
( 8.2.32.
press key i:,l played showing user overview list
Remarks
( 8.2.48.
. user Log on dialogue
press key LOGIN and screen keyboard are displayed
Remarks
press key LOGIN and put in after successful input user's name
8.2.52. user identification of IADMIN1" IADMIN1" is indicated at head line
8.2.53, press key EXIT (door symbol) MAIN MENU is displayed again
Remarks
Remarks
SE=JVOLiFT ~ . ..
)
.,
13565_OQ_1_E.docx 65 /
66
SE=iVOLiFT
Operational Qualification (OQ)
reviewed by:
Sig:
reviewed by:
Sig:
approved by:
Sig:
- END of document-
13565_OQ_1_E.docx 66 /
66
Software Design Specification (SDS)
,,-;tp
Mr. R. ~hri.n$;ler/ ,
Electrical
Written by:
Sig:
~ /I. <proqrarnrninq dept.
23. Dec. 2015
Reviewed by:
Sig:
Reviewed by:
Sig:
Approved by:
Sig:
13565_SDS_1_E.docx 1/
58
SE=iVOLiFT
'.. . ". ~:1'"
this page will be revised each time the specification is revised and re-issued, to record the dates and
reason for issue. All changes of this document (either for review or approval) are registered in this list.
(
Change Date Editor Reason for Change
13565_SDS_1_E.docx 2/
58
SE=JVOLiFT
Software Design Specification (50S)
Table of Contents
1. Introduction 6
1.1. Author/Authority 6
1.2. Objective of document 6
1.3. Contractual Status 6
1.4. Reference Docu ment( s) 6
2. Overview 7
2.1. Program Development 7
2.1.1. PLC development 7
2.1.2. HMI Development 7
2.1.3. Software development list. 7
2.2. Version Control 8
2.2.1. PLC version 8
2.2.2. HMI version 8
2.3. HMI and PLC Interface Design 9
3. System Description 10
3.1. PLC 10
( 3.1.1. Siemens S7 PLC Program Structure 10
3.1.2. Program Description 10
3.1.3. Symbolic Conventions 10
3.1.4. Program Block Specification Descriptions 11
3.1.4.1. Siemens S7 - OB _ Organisation Blocks 11
3.1.4.2. Siemens S7 - Fe _ Functions 11
:t 1.4.3. Siemens S7 - FB _ Function Blocks 12
3.1.4.4. Siemens S7 - DB _ Data Blocks 12
3.1.5. Siemens S7 PLC Program Blocks Listing 13
3.2. HMI 15
3.2.1. HMI Access Security 15
3.2.1.1. User Groups and Authorizations 15
3.2.1.2. Assignment of functions to user groups 16
3.2.1.3. Users and Passwords 18
3.2.1.4. Logoff Times 18
3.2.1.5. Backup and Restore 18
3.2.1.6. Limits of users and passwords 18
3.2.1.7. Extended security and access control requirements, deviations from SL standard 18
13565_SDS_1_E.docx 3/
58
SE=iVOLiFT
/":> :;'!!'.,,; ';.n: : ~
4. System data 44
4.1. System/ Machine Parameter 44
4.1.1. 0 proxim ity switch settings 44
4.1.2. batch entry setting 45
4.1.3. system settings, general 46
4.1.4. printer settings 47
4.1.5. customer specific machine definition 47
4.1.6. Message Handling 48
4.1.6.1. Alarm messages 48
4.2. Communication to extern systems 49
4.3. Recipe data 49
4.4. Recorded data 50
"
13565_SDS_1_E.docx 4/
58
Software Design Specification (SDS)
6. Glossary 55
..
7. Attachments 56
7.1. PLC Structure 56
7.2. Operational Sequences 58
13565_SDS_1_E.docx 5/
58
5E~VOLiFT
~ ,.., . ...,
. .. . '. .
1. Introduction
The blender will be designed and manufactured to conform to the following standards:
GAMP Guidelines (current version)
all components will be CE certified
(
1.4. Reference Document(s)
13565_SDS_1_E.docx 6/58
SE=iVOLiFT
f,:' -: ., 1 ,j _ ." . ~.: ,', ".; ..
2. Overview
The two main elements of the software design are the S7 PLC program and the WinCC HMI
program. The HMI program contains the visualization for operating the machine.
The PLC and HMI program design will be based on SERVOLIFT programming standards.
(
2.1. Program Development
configuration GAMP
software version manufacturer version
software category
V13.0 SP1
SIMATIC TIA Portal SIEMENS 4
13565.zap13 Update 5
1
(PLC/HMI) SIMATIC V13.0 SP1
M ENS
SIE 4
WinCC Advanced Update 5
13565_SDS_1_E.docx 7 I 58
SE=lVOLiFT
Software Design Specification (50S)
,'"
Example:
IJSt'II MAIN M~NU
()pfllAIOIt _f' ~
IIMlvtn.:QJ
"l(I/E~.:OI +--t----'
13565_SDS_1_E.docx 8/58
SE=tVOLiFT
Software Design Specification (50S)
CMD
block function
( DB1 CMD
CMD_POS
DB2 CMD_POS
DB3 COMMON
COMMON
DB5 DB STATE INDICATION
DB STATE DB9 DB HMI SETIINGS
INDICATION
DB99 DB DISTURBANCE
DBHMI DB180 DB SETIINGS MAINTENANCE COMMON
SETIINGS
DB190 DB SETIINGS SUPERVISOR
DB DB92 DB ADVICE MESSAGES
DISTURBANCE
DB68 DB RECIPE COMMON
DBSmlNGS DB66 DB RECIPE SET
MAINTENANCE
COMMON DB67 DB RECIPE ACTUAL
DB90 DB SERVICE INTERVAL
DBSmlNGS
SUPERVISOR DB85 DB FNCT SPEED CALIBRATION
DB ADVICE
MESSAGES
HMI
DB RECIPE
COMMON
DB RECIPE SET
DB RECIPE
ACTUAL
DB SERVICE
INTERVAL
DB FNCTSPEED
CALIBRATION
."
3. System Description
3.1. PLC
13565_SDS_1_E.docx 10 /
58
SE~VOLiFT
Software Design Specification (SDS)
Type of Machine: I Container Blender I Servolift Project No. I 13565
.
program processing, that means the cyclic program
processing can be interrupted by certain events I Paw ",,,,, I
(interrupts). If such an event occurs, the block / i>11J11<1i'
l '-
-
~~.Jiim,
currently being executed is interrupted at a command
boundary and a different organization block that is
assigned to the particular event is called. Once the
organization block has been executed, the cyclic ~
program is resumed at the point at which it was klrdlmupl1 -
interrupted.
Application
A FC contains a program section that is always executed if the FC is called by a different logic
block. FC's can be used for the following purposes:
To return a function value to the calling block (example: math functions).
To execute a technological function (example: single control function with a bit logic
operation).
The description in the PLC program blocks listing illustrates the function of each FC.
13565_SDS_1_E.docx 11 /
58
SE=iVOLiFT
if /:1;'.',;:.
J.
Application
A FB contains a program section that is always executed if the FB is called by a different logic
block. FB's can be used for the following purposes:
Complex functionalities
Multiple use of a function
The description in the PLC program blocks listing illustrates the function of each FC.
Data blocks will be designed to store data of FB's, providing interface data to other equipment
(HMI). The structure of the blocks will be individually defined as to what the data areas do,
or predefined by calling of a FB.
SE=tVOLiFT
:Jt .. ;
1,1...' .. ,',
13565_SDS_1_E.docx 13 /
58
SE=lVOLiFT
I, : . ~ .... " "i.::
.:..:.-~:.
Software Design Specification (SDS)
Type of Machine: I Container Blender 1Servolift Project No. I 13565
function
group module I family address comment I description
HMI DATA BLOCK DBx DB99 DB DISTURBANCE
HMI DB98 DB DISTURBANCE MANAGEMENT
HMI DB9 DB HMI SETTINGS
HMI DB181 DB LIFT ENCODER
DB SETTINGS MAINTENANCE
HMI DB180
COMMON
DB
HMI #NOT USED IN 13565 OB182
SETTINGS MAINTENANCE SLEW
HMI DB190 DB SETTINGS SUPERVISOR
HMI #NOT USED IN 13565 DB185 DB SLEW ENCODER
HMI DB5 DB STATE INDICATION
SERVICE
INTERVAL FUNCTION BLOCK FBx FB90 SERVICE INTERVAL
SERVICE
DATA BLOCK DBx DB90 DB SERVICE INTERVAL
INTERVAL
..
- end of listing -
13565_SDS_1_E.docx 14 /
58
SE=iVOLiFT
Software Design Specification (SDS)
i2. HMI
Logoff time
User name Password Group in minutes
ADMIN1 ADMIN1 ADMINISTRATOR 60
MAINTENANCE MAINTENANCE MAINTENANCE 5
OPERATOR OPERATOR OPERATOR 5
The project-specific user groups are created by the configuration engineer. The "Administrators"
and "PLC User" groups are included by default, these groups cannot be changed whether by the
engineer, nor by the customer. User groups are assigned to authorizations. Authorization required
( for an operation is specifically defined for each individual object and function in the project.
Accessibility which is given to a group with a lower access level, is also given to all groups with
higher access level, e.g. functions of "OPERATOR" level are enabled for user assigned to
"ADMINISTRATOR" level.
Software Design Specification (50S)
User group
(
...
Function -- .. .
0
r a ~
ra
e ... 0
...0
-
.~
1/1
.!!! e
e Q) e
c 'co
.!!
'E Q. Q)
Q.
::::I
~ :il t/) 0
maintenance mode
maintenance settings
calibration of blend speed
service interval settings
service interval confirmation
state indication / diagnosis of pic periphery
recipe management-
to edit, modify and delete recipe data sets
call predefined recipe (if recipe management is selected)
PARAMETER MENU function
input of blend parameter (if no recipe management is available)
TEST RECIPE function
input of batch number
PARAMETER MENU and TEST RECIPE function
Software Design Specification (SDS)
User group
.. ..
Function
-
e! 0
til
'
'E
CJ
e
IV
C
se
0
til
.~
Q)
Q.
- 0
E
Q)
..
'C 'iii :;, Q.
:!l: I/) 0
No. of characters
minimum 3 character, maximum 40,
Length of user name
not "key sensitive", that means "MAX" and "max" are one user
minimum 3 character, maximum 40
Length of password "Key sensitive", that means "operator" and "OPERATOR" are two
password
User entries per user group minimum 1, maximum 50
User entries maximum 50 (system limitation)
The min. and max. parameters for user names, user passwords, max user entries are fixed.
The logoff time is configurable by users with administrator authorization only.
3.2.1.7. Extended security and access control requirements, deviations from SL standard
There are no deviations from Servolift standard configuration for password and user management.
5E~VOLiFT
Software Design Specification (SDS)
The picture below shows the general layout of menus and submenus, displayed during operation
of the machine, divided into 3 parts. Generally, a menu consists of 3 information and actuating areas:
1 2 3 4 5 6 7
\ /
$1[[. SE=lVOLiFT
EUROFARMA
13565
23/12/2015 10:10,54
no. function
1 to show communication status between PLC and HMI terminal, blinking green symbol means "OK"
2 to show current logged in user by indication of user's name, e.g. here "ADMIN1"
3 to show screen name,
here in selected operating language PORTUGUESE, e.g. here "MENU PRINCIPAL"
4 to show project / machine number, e.g. here "13565",
5 if available the customer specific machine definition is displayed too, here "Merck, Brasil"
(this is only a recommendation, input is changeable by specific user groups)
6 to operate function keys LOGIN / LOGOUT, to enable operation of the machine after login
7 to show time / date, to enable modification
13565_SDS_1_E.docx 19 /
58
Software Design Specification (SDS)
information line:
Here the indication of messages (advise messages, alarm messages, etc.), current of PLC and HMI
version are indicated. Also you can find the current state of working hour counter and select which
operating language should be used. The indication of message depends on message type. For showing
fault message they will be framed with red bar. To be able to confirm alarm messages the coloured
message bar has to be touched to open a separate menu.
USER MAIN MENU
ADMIN!
ALARM
Advice messages occur during the whole operation and be in plain text framed with a blue bar to indicated
machine end positions or missing start conditions. An acknowledgment of those messages is not
necessary. As soon as the movement is continued or a function is selected by pressing the corresponding
the dis will disa automati
13565_SDS_1_E.docx 20 /
58
SE=iVOLiFT
~ilt::.'.
' 'L, ,.:i .. _ .. :'
function line:
_~ _j I-~~ J MENU
SUPERVISOR MENU
~~-
1
will be shown graphically either as active (light-grey) : ""'" or inactive (dark grey)
This shows, if the implementation of the chosen function will be possible.
After initializing of the HMI-terminal the PORTUGUESE language is loaded as operating language.
Now the user has to enter a valid user identification, consisting of name and password. After successful
login it is possible to operate the machine according to the assigned menus and functions.
To change indicated language on the HMI repeat activation of the button with national flag in MAIN MENU
(first screen after initialization is finished) until required language is signalized by the corresponding
national flag. Afterwards, all messages, labels and legends will be displayed in selected language. After
translation work during programming period all texts, messages, alarms, etc. are available in this
language at the HMI-terminal. Further selectable operating languages will be ENGLISH or GERMAN.
13565_SDS_1_E.docx 21 /
58
SE=lVOLiFT
Software Design Specification (SDS)
The following scheme gives an overview of the general screen / menu structure.
Here it is displayed in ENGLISH and PORTUGUESE.
When initialization of HMI is finished successfully the PORTUGUESE language
will be the loaded as operating language.
(
I. ,
1 .t.;J4'" i
.i
l'
j
_L
. . ..
i'f l
,..
t.
'
~
~.. Ii"'
~II~
...i i
.. _ j -" , ,"'.- ,
. I
I
i
,...~-r...~.'."~.-~..."'1- .....~.....-..-
i----l :I
i~ ...'4:- ( ._._.'-._._
A ~ ~tl
.. "'-""
hI I!
*-
t
'----.~~
I ~ lo(!(1<
s;.' .,.,,, ....
i ! '"
l' .'U ..V ." I
!
i
r .... . .
""-"'1
! ~ .\ 'O~I ... '.~
L.
, Vt\dj 1' - ...~' _._ ~ .., ,.,,~ - . ..--)
1.
Vil,.
4 ~"'I.u.:.ft
,
i !
.
..
NIP
'>' ... r
!,
n.",,,tl
... fro..,..,
I
:-..::
SE=JVOLiFT
" .' " .l. ";;..',,'.
->.
Software Design Specification (50S)
HMIVER.,OI
PlCVfR.: 01
IIORAS O~ OI'flUlCAO, 4106
n r
.:...~. :.
- C .~
_UDO
0Pf1lAOOR 1
I_
IilfNU
SUPERVISOR
]
2 3 4 5
no. function
1 change operating language, => here PORTUGUESE is loaded after first start of application
2 selection of OPERADOR MENU which contains further sub-menus and functions
3 selection of MENU MANUTENCAO which contains further sub-menus and functions
4 selection of MENU SUPERVISOR which contains further sub-menus and functions
5 selection of MENU ADMINISTRADOR which contains further sub-menus and functions
SE=iVOLiFT
.",.. I; ,". :',
.~ "
MENU
TEsn NENUDl
PARAMIElRO
RfalTA
J _ 1(15lURA
1 2 3 4 5 6
no. function
1 selection of MODO MANUAL menu to start any manual actuated function / movement
2 selection of MENU PARAMETRO to select an defined blend recipe
3 selection of TESTE RECEITA to enter single blend parameter, which will NOT be stored
4 selection of MENU DE MISTURA to start and stop the blend cycle / the rotation
5 selection of ARCHIVO GRUPO to load archived batches
6 function key EXIT to close current menu / return to previous menu
13565_SDS_1_E.docx 24 /
58
SE~VOLiFT
Software Design Specification (50S)
Type of Machine: I Container Blender I Servolift Project No. I 13565
(
SERVOUFT Gfllbn
Service: Ilotllne:
Em"ll: servlce@scrvollh.de
t
www.scrvollft.de
Finnwarc UMI: 4
Hrrnware Ple: 4
1-
c
.V' (1:_ :; 6
MAN~NCAO j MIAJUN5uTnA
NM(Al:ON
J 7
lOS
1 2 3
no. function
1 call MODO MANUTENCAO menu to start manual actuated function without interlocks
2 call MENU CALIBRACAO to calibrate blend speed
3 call menu MANUTENCAO AJUSTAMENTOS
for setnnqs 1 modifications of correct horizontal positioning of supporting arm
4 call menu SERVICE INTERVAL
for indication and confirmation of service interval messages, or to reset service intervals manually
5 call menu STATE INDICATION
for display and supervision of data input! output channels, data sets, and flaas from or to the PLC
6 call menu ALARM HISTORY
to call overview list for indication of all occurred alarm messaoes after switchinc on power supply
7 function key exit to close current menu 1 return to previous menu
SE=-1VOLiFT
Software Design Specification (50S)
~
I
,
.~
1 2 3
no. function
1 selection of ADMINISTRACAO RECEITA menu to edit, modify or delete defined recipes
2 selection of AJUST A A SISTEMA menu to activated / deactivate starting of printout
3 function key EXIT to close current menu / return to previous menu
SE=iVOLiFT
Software Design Specification (SOS)
ADMIN!
'NO.,
TIME
TEXT 1
IlHil!lI"iiiNe'U_"ijI"Ul!I"I_lnail~I.ttttftt1tffiti'f'ii'il'ili!;','ij!liifi ..i.Ui.iUli
(
7 , 13 I
2 3 4 5 6
no. function
1 display system messages,
messages will be logged continually, max. 500 messages, then the first will be overwritten
2 calibration of touch screen
3 adjust tap "beeper"
4 to call USER MANAGEMENT menu
to edit, modify or deactivate user assignments to functions / menus
5 shut down application and return to control panel system settings, e.g. for backup/restore
6 function key EXIT to close current menu / return to previous menu
5E~VOLiFT
Software Design Specification (50S)
Now will follow the sub-menus of the main previously shown menus:
After having called the OPERATOR MENU from MAIN MENU and pressed key MANUAL MODE
fpllowing menu is displayed. It shows and contains all manual functions which are needed e.g. to position
( supporting arm with inserted container to correct height position to enable blending or discharging cycle.
r
Following functions can be done by users:
;':LlSH as operating language is loaded~""M'o"
jI
1 3 5
2 4 6
(
7 8
no. function
1 function key LIFT, to move to next height position until mechanical end position is reached
2 function key LOWER, to next height position until mechanical end position is reached
3 function key CLAMP, to fix inserted container in the supporting arm to enable rotation
4 function key UNCLAMP, to unfasten inserted container to enable removing it
5 function key TURN LEFT, to enable manually activated rotation in anti-clockwise direction
e function key TURN RIGHT, to enable manually activated rotation in clockwise direction
7 function key ACTIVATE SAFETY CIRCUIT,
to switch on safety module and continue cycle
8 function key EXIT to close current menu / return to previous menu
1356S_SDS_1_E.docx 28/58
SE=iVOLiFT
': e. f ". ';..:
( RECIPE
PRODUCT NANE,
PRODUCT NUNOI;R,
SHI'l
OL[NDTIN[ ININ)
u- 3
( no. function
1 selection of recipe (dataset with predefined blend parameter) without modification
13565_SDS_1_E.docx 29 /
58
Software Design Specification (SDS)
'.
(
TEST RECIPEI ONLY fOR TEST PURPOSES
_j
PROOUCT NAME,
1
PROOUCT NUM8Rl
STtP I
BAlCHI
...-. 2
{j-+ 3
no. function
1 input of single blend parameter which will not be stored, only be valid for next blend cycle
2 input of BATCH, it is a needed start condition for blend cycle
3 function key EXIT to close current menu I return to previous menu
5E=JVOLiFTr."...... 1 _ .. :;~:.)
_lI.L.l'~'p_I~!\!WtJl~IHQ~~Q _
( ___ ____ ___________________
_
_____ _ _
0,00
1
BLEND nME (MINI I MIN AOUAL> MIN
10 20 30 40 50 60 70 80 90 100
10 20 30 40 )0 60 70 80 90 100
10 11 U J3 14 IS 16
BATCH, 4/11"1
-
START
2 3 4 5 6
no. function
1 summary of blend parameter,
loaded either from PARAMETER MENU or entered in TEST RECIPE menu
2 control blend cycle - key START,
if shown light grey all start conditions are fulfilled, start is possible
3 control blend cycle - key STOP,
if shown dark grey, function cannot be started, here stop is only possible if it was started
4 function key ACTIVATE SAFETY CIRCUIT to switch on safety module and continue cycle
5 function key PRINTER to start printing batch report, manual actuated
6 function key EXIT to close current menu / return to previous menu
13565_SDS_1_E.docx 31 /
58
SE=iVOLiFT
Software Design Specification (SDS)
RECIPE,
( PRODUCT NAME.
PROOUCT NUMBER:
BATCH,
1 2 3
no. function
1 function key PRINTER to start printing batch report of reloaded batch
2 call of ARCHIVE INDEX menu to ease the selection / reloading of finished batches
3 function key EXIT to close current menu / return to previous menu
13565_SDS_1_E.docx 32 /
58
SE=tVOLiFT
-,:"',i.:; ".('t .. , :":,'
S:'
[]~
NO NAMEI
( (
(
t! J
1
(
( SELECTION.
2
( 0
(
OVERALL:
I 0 3
u
u
0
"'1 -t. j:
1
. I
4
no. function
1 the chart shows the index of available and reloadable batch reports,
it contains maximum of 16 datasets, if more than 16 datasets exist
the keys "up" and "down" have to be pressed to scroll through it
2 entry field for directly input of dataset number of selected finished batch to reload it
3 indication field to show the full amount of existing datasets
4 function key EXIT to close current menu I return to previous menu
13565_SDS_1_E.docx 33 /
58
SE~VOLiFT
Software Design Specification (SDS)
IrJ
ATTENTION DANGER:
OPERATION WITHOUT SAFETY INTERLOCKS. OPERATING
ONLY FOR TRAINED PERSONNEL ALLOWED.
ClAMP
UlliN
lIFT UH
lUAN
RlGHr
1 3 5 7
2 4 6 8
9 10
no. function
1 function key LIFT to move to different height positions until end position is reached
2 function key LOWER to move to different height positions until end position is reached
3 function key CENTER CYLINDER OUT
to move centerinq cylinder out, included in function clamp
4 function key CENTER CYLINDER IN
to move centering cylinder in, included in function unclarno
5 function key CLAMP
to fix inserted container in the supporting arm to enable rotational movement
6 function key UNCLAMP to unfasten inserted container to enable removing it from cage
7 function key TURN LEFT to enable manually activated rotation in anti-clockwise direction
8 function key TURN RIGHT to enable manually activated rotation in clockwise direction
9 function key ACTIVATE SAFETY CIRCUIT to switch on safety module and continue cycle
10 function key EXIT to close current menu / return to previous menu
13565_SDS_1_E.docx 34 /
58
5E~VOLiFT
i .. :,.':'.::",,':.i'c .J. :ri'".i~
USER
CALIBRATION MENU
AOMINI
(
BlE~D ,FEEO 11\Pfo1) 05 RFN .\CTUAl a 0 RP'"
to 11 II 15 Lo
ENTRV,
1 2 3 4 5
.no. function
1 control blend cycle - key START,
if shown light grey all start conditions are fulfilled, start is possible
2 control blend cycle - key STOP,
if shown dark grey, function cannot be started, here stop is only possible if it was started
3 change direction of rotation during calibration sequence - key REVERSE
4 function key ACTIVATE SAFETY CIRCUIT
to switch on safety module and continue cycle
5 function key EXIT to close current menu I return to previous menu
13565_SDS_1_E.docx 35 /
58
SE=iVOLiFT
Software Design Specification (SDS)
AITENTION DANGER:
OPERATION WITHOUT SAFETY INTERLOCKS.
..
~ OPERATING ONLY FOR TRAINED PERSONNEL ALLOWED.
00 PROXIMITY
SETIINGS
swnca 1
TURN R1GHl't 8 loiS
lURN LEFTI
tuRH
LEfT 2
BLum:
CALIBRATION TURN
RIGHT
3
OISlUR8ANCE:
4
5
no. function
1 key CONFIRM MESSAGE,
to confirm warning to enable oQerating displayed function
2 parameter values and function keys, as long as warning is displayed
and NOT confirmed the parameter values and function keys are blocked,
input boxes for adjustment of 0 prox. switch position at supporting arm
3 parameter values and function keys, as long as warning is displayed and NOT confirmed the
parameter values and function keys are blocked, keys TURN RIGHT and TURN LEFT,
function keys to rotate supporting arm manually in anti-clockwise direction or in clockwise
direction to adjust prox. switch of 0 turn position, in general keys have the same functionality
as in menu maintenance mode
4 function key ACTIVATE SAFETY CIRCUIT
to switch on safety module and continue cycle
5 function key EXIT to close current menu / return to previous menu
SE=iVOLiFT
. Software Design Specification (SDS)
I USER
ADMINI
SERVICE INTERVAL
j---------------------------------------------------------------------------
, III TEXT
. .
STATE
----I
I ilfdldlSM'hilUMI'II9"dii'"" 1 :
Fil' NUtt
lIur
I
I
!, lL~ I
I
~I'================================~~~======================~
I I
I
I
---I
I PRESElECT
I
I
. INTERVAL
2:
I SERVICE INTERVAl [)(PIRE.OI
: I], MAINTENANCE EVERY 6 MONTH 24/10/2015
I I., MAINTENANCE EVERY YEAR 13/"4/1016
!
:_I~,~I~T~'!.A~<:.E~V~~Y!!~A~ '~J_04-'~I!?~ _
r--------------------------------------------------------------------------- ---,
3: I
I
I
( I
4: ,
I
~--------------------------------------------------------------~
I
no. function
1 to display current SERVICE INTERVALS, to show present messages in the overview list and
the functions keys to confirm and reset messages,
to display upcoming service intervals in text-in-clear and to give possibility to confirm and to
reset indicated messages when activities done, if current date corresponds with upcoming
rj~l
interval date the icon 1.;C1 will be shown flashing at head line, if pressinq this icon, this menu will
INPUTS OUTPUTS
2
, BYTEI 124 IBVTE! 124
Blli 0 0 ern 0 0
10 10 3
...2 0
sO
20
3
40
50
60
o
4
no. function
1 monitoring of pic periphery
after having selected the connection type In first column, e.g. the used cpu type
2 function key to activate "monitoring mode" and to show current status value in last column
3 indication of current state of input and output of selected byte, e.g. 124
4 function key EXIT to close current menu / return to previous menu
13565_SDS_1_E,docx 38/58
SE=iVOLiFT
Software Design Specification (SDS)
( no. function
1 summary and indication of all occurred alarms after having turned the main control on,
overview is only readable, modifications impossible
indication of different states:
- "K" means incoming alarm, message line shown red
- "KQ" means incoming and quit, incoming alarm is confirmed, line shown in yellow
- "KQG" means incoming, quit and gone, incoming alarm is confirmed and reset, line is
shown in green
2 function key EXIT to close current menu / return to previous menu
13565_SDS_1_E.docx 39 /
58
SE=lVOLiFT
Software Design Specification (SDS)
( I - - - .---.-----.-----
R E C IP E
--. -- --.-.---.--.-------.---- .-._.---- --_.--:; 1
PRODUCI Nl\Mlo
AAOOUCT NUMBERt
I------------+-c-------------.------------l
r.234~
BL~NI) IIMC (MINI
lusn
* _J ~ J ~ J
~l.J
2 3 4 5 6 7 8
no. function
1 select defined recipe dataset by designation from drop down list or
create recipe dataset and put in new designation after having pressed key (2) NEW
2 function key NEW, to create new recipe dataset and enter new designation in field RECIPE
3 function key MODIFY, to modify / change single parameter of an existing recipe dataset
function key SAVE, to store new created recipe dataset or changed recipe parameter
4 function key DELETE. to delete an selected recipe dataset completely
5 function key PRINTER, to start printing selected recipe dataset
6 function key to export recipe
7 function key to import recipe
8 function key EXIT to close current menu / return to previous menu
SE=iVOLiFTr-r.I, "" .::' 'I, '
the following screens shows only a recommendation, modifications are possible but only
by users which are members of user group SUPERVISOR or ADMINISTRATOR:
~ STOP BY DISTURBANCE
X ENABLE SCREENSHOT
no. function
1 function for setting up the entry of new blend parameter, can be activated or deactivated
2 function for proof of batch entry, can be activated or deactivated
3 function for printer settings and the selection when the print out should start
4 entry field for input of customized project number, maximum of 40 characters, if something is entered
it will be displayed on each menu in the head line above the project number and it will be on protocols
5 function key EXIT to close current menu / return to previous menu
SE~VOLiFT
'.-i_,.:.; '. ; _ .. ,:,: " :.'., '.
The following menu shows a chart with 4 columns, each must be filled when creating a new user:
USER USER MANAGEMENT
ADMIN I
(
"'---_~~~ o-............c'_..,....
........... f I)",IN'''II{''''J( 5
....,.
ADMINl f ADMINISTRATOR 60
MAINTENANCE I MAINTENANCE 5
OPERATOR
f.......... 1USER
- :\1,. mltltl
[5
:~:~-~-
t/ If 5
ADMINISTRATOR 5
SUPERVISOR 5
~-.._.R_._.._-.-._-.
I
i i
-.--r:::::::
------ ..-- - .. - - - ..._-.---. - ..... - '-'1
I.
1 2 3 4
no. function
1 column 1: "User",
contains the user name as displayed in the head line of each menu and
which gives the possibility to operate the aSSigned function in the corresQonding menus
( 2 column 2: "Password",
contains the user specified password, is shown hidden
3 column 3: "Group",
contains and shows assigned user group and
determines therefore the possibility to control corresponding functions
4 column 4: "Logoff time",
contains and shows the time value at which time the current logged in user
will be logged out automatically_if now function key or other control is done on the HMI
5 function key EXIT to close current menu I return to previous menu
SE=iVOLiFT
Software Design Specification (SDS)
3.2.5.21. Alarms
After having touched the red framed alarm message bar ...
USER MAIN MENU
ADMIN I
(
HMIVER.,01
PlCVER.,OI
ALARM
L ... _ _ ~_ _ _ ........ _ _
2 3 4
no. function
1 to display fault / alarm message in text-in-clear with time and date stamp
2 function key CONFIRM, to enable confirmation occurred alarm / fault message
3 function key RESET,
to enable reset of confirmed alarm message and to continue functional sequence
4 function key EXIT to close current menu / return to previous menu
l ....;:.'.;,~.,. , .. ,
..
Software Design Specification (SDS)
4. System data
4.1. Systeml Machine Parameter
Following system / machine parameter settings used in this design:
data
parameter unit min. value max. valu e
type
0 PROXIMITY SWITCH
SETTINGS:
TURN RIGHT integer ms 0 990
TURN LEFT integer ms 0 990
BLEND integer ms 0 990
CALIBRATION integer ms 0 990
DISTURBANCE integer ms 0 990
Ell
ATTINTlON DANGER:
OPERATION WITHOUT SAFETY INTERlOCKS.
OPERATING ONLY FOR TRAINED PERSONNEL ALLOWED.
- - -
IUItH HIlI"'l
IUHNI''': IUIH
UYT
BliND;
...........,
fAllIUIAllIHI
1U.,11j1U'IAN('1
Detailed description of how to use this menu and modify the values
will be given in owner's manual document at a later time (if the programming is finished).
SE=&VOLiFT
Software Design Specification (SDS)
Here in this menu it is oossib e to de f ine the handling 0f entr, for blend
data. parameter data type activated deactivated
LxJ
ENTER NEW BLEND DATA
- BATCH AGAIN check mark
- PRODUCT DATA AGAIN II v' II
,- --- -------
: BLEND PAAAM1ER SEnlHGS
------ ----------- PAINTER SnIHGS
: fNTRy NEW BlEND PAAAMETEASI PRINTOUT START ATt
::'
,
../
_ ENTERBATCHAGAIN I ;_
!..-..!
1 8lENO FINJSHEO
i _.:{
I
fNTfA PAOOUCT OATA AGAIN ~ &10.. Y.,..RATO.
CUSlOMER SPECIFIC
"ACHINE DfINllIONI
PAOOf BAlCH ENlRYt
13565_SDS_1_E.docx 45 /
58
5E~VOLiFT
Software Design Specification (50S)
Here it is possible to define the minimum and maximum number of characters which the batch
number should consist of. It is also possible to activate a checkmark, so that batch number will
be checked when input is finished and confirmed.
~ fNtRJ'flOOuCTDATA"QAJN
~ STOP8VOl'{RATOQ
X ,! ENABlE SCRrENSHOT
:,. ..
.,
:i 1 MINNUM8ROfSI<lNS
II
L.
40 MAX NUMBER OF SIGNS
_
13565_SDS_1_E.docx 46 /
58
SE~VOLiFT
1,':;,".1:.'.',"',:"::",
,
4.1.4. printer settings
Within this menu it is possible to select general system settings, as well as printer settings.
This menu is also used for adjustment of system functions, e.g. for activation / deactivation of
functions for handling input of data.
l._..I' _
f
! ../
....... BUND rlNISH(O
! 'oTt. BATell..... 0
,
i~ I [H1ERPROOUCTOATAAG.\I,N : )\ STOP BY OHRA1OA
'--'
l---:
: X STOP BY DISlUABAN(f
:-
: X
:_ -_ ---~.. -_ .... _-_ ..--- -----
EHAIlE SCA[[N~OT
i -.i ., '.OOH"TRY
1"'-
I
1 NIHNUMBlROFSIGNS
fO. -.~ ..
, 040 MAX NUN&R Of.SIGNS,
Here it is possible to define an additional labelling if project number alone is not enough. The
range for input of alphanumeric characters is maximum of 20. If entered an additional labelling it
will be shown at the head line and on each report, which can be printed from BLEND MENU or
from RECIPE MANAGEMENT.
I ~LENDER 1
~
...
..--- ' ,
~------~.~L~~Nb~eR-l-------------------'
SE=tVOLiFT 1356, t:. 'l/I'IlOIS W15,5S
SYSTlM SUTIHGS
13565_SDS_1_E.docx 47 /
58
SE=iVOLiFT
~::.:"':.: " .:~:~,,-.:.~/.":j} ..
.. . .
PLC message
number in block displayed alarm message
DISTURBANCE ,
MANAGEMENT
FB99 I DB99
.n. ....
.,.C("
~. : ''I 'nm~
1 FUSE 24V DC GENERAL SWITCHED OFF
3 E-STOP HMI PRESSED
4 E-STOP BLEND ROOM PRESSED (SPARE, FOR FUTURE E-STOP)
20 SAFETY DOOR 1 OPEN
24 FUSE I OVERLOAD RELAY SWITCHED OFF
26 E-STOP MODULE NOT ACTIVE
27 E-STOP MODULE READY
(
30 LASER SCANNER MODULE NOT OK
33 ARM NOT AT BLEND HEIGHT
35 BLEND SPEED OUT OF RANGE
41 TIMEOUT 0 PROXIMITY SWITCH FLAG
42 FAILURE 0 PROXIMITY SWITCH
48 MAIN POWER SUPPL Y LOST
49 TIMEOUT SENSOR AT SPROCKET
50 FAILURE MAINS CONTACTOR HYDRAULIC PUMP
54 COMMUNICATION PLC - HMI DISTURBED
55 HMI MEMORY CARD READ I WRITE ERROR
65 CONTAINER NOT IN POSITION
66 CONTAINER NOT CLAMPED
72 CENTERING CYLINDERS COMPLETELY EXTENDED
74 TIMEOUT AUTO CLAMP
82 TEMPERATURE HYDRAULIC OIL EXCEED
84 TEMPERATURE BLEND MOTOR 1 EXCEED
88 FAILURE FREQUENCY CONVERTER BLEND MOTOR
End of list. Find description to each fault in owner's manual, section "Troubleshooting"
13565_SDS_1_E.docx 48 /
58
SE=tVOLiFT
Software Design Specification (SDS)
1 -
_~.
.,, ._~ _. ._ N'_" _ _.~. _ ..
i~~~::=~:~=~~~~~:=::~=_==:-
'ItOOVCfNAMe, fADcorF
2 - ~~~~~~ .
=:~~~~ SUPl
--_---.----------._-
data
line parameter unit minimum value maximum val ue
type
1 PRODUCT NAME string 0 40 characters
2 PRODUCT NUMBER string 0 40 characters
3 BLEND TIME string minute 1 99
(
BLEND
4 REVERSE TIME
integer minute 0 99
13565_SDS_1_E.docx 50 I
58
/1 ,_'.. _ .;,. ""':.
This is an example of a blend report protocol with assignment of each parameter according to
previous page. Here selected operating language is ENGLISH, but it can also printed in
PORTUGUESE language, if it was changed by key with flag in MAIN MENU:
RfCIP~:
PRODUCl NAr'IE: PRUDUCT
NUMBER: PROOUc:r
lEVr.llING [~ISJ o MS
PRrSET: AcnJAL:
DlEND TIIIE (~IINl
BLEND REVliRSE TI~IE [~lIN]
o : 00
~lIN 0 : 00 NIN
0: 00 MIN
ULEND SPEeD [RPM] 00 RPM
BLEND STIIRTED: 01/01/199912,00:00
BLEND STOPPED: 01/01/199912:00:00
BLEIID STIITE: BUND NOT STARTID
OP:RIITOR:
DAlE SIGNATURE
RENARK:
ALARM
NO.1 nH STATE DATE
PAGE: 1
FRUIT DATE: 10/06/1015
07:15,51
13565_SDS_1_E.docx 51 /
58
SE=tVOLiFT
i ,::;~.,::':..
(
SE=tVOLiFT
Software Design Specification (50S)
13565_SDS_1_E.docx 54 /
58
5E~VOLiFT
I:. i " ,.-'.;.'" I
6. Glossary
The following is a list of terms used throughout this document:
13565_SDS_1_E.docx 55 /
58
SE=iVOLiFT
[ii'u i ;1. .. .;.
,t';......:
Software Design Specification (SDS)
Type of Machine: I Container Blender J Servolift Project No. I 13565
Attachments
7.1. PLC Structure
This scheme shows graphically the described and used modules which form the complete pic program,
given as table in section "Siemens S7 PLC Program Blocks Listing".
.... 13565
.....::;:dd~~;.;d~.::i~~.......................... ~ ..................................
it Devices So networks
II !.I Asem Ubiquity (CPU 414-3 PNJDP)
.... rI CPU 313C (CPU 313C)
Y De'. ICe configura tion
~~.Online Sc diagnostics
.... ~ Prcgra III blocks
.;. Add new block
ORGr.NlSr.ll0N [OB 1 J
PLC FIRSTCYCLE(OBtOOI
..
DB ','.oRKltIGHOUI\S ioBSI J - 1
..
'1:: auto
t:: Hr.U
- 2
3
..
t:: 1\4anual 4
i:: outputs
.. '1:: service
-interve I
5
Find on next page(s) the detailed information of enlarged modules "AUTO"; "HMI"; "Iift_encoder";
"MANUAL"; "OUTPUTS" and "SERVICE INTERVAL", which form the complete pic program.
13565_SDS_1_E.docx 56 /
58
," ,. _ .. ," ....
DB FNCTBLEND JDB6")
.. DB RECIPE ACTUAL (DB67)
CMD_POS iDB2)
.. COMMON iDB3)
.. DB ADVICE MESSAGES (DB9::1]
.. DB DISTURBANCE (DB99)
III DB DISTURBANCE MANAGEtl.tENTjDB98)
1
Eurofarma Laboratories SA,
Customer: Customer Reference 4500233630
Ita evi - Sao Paulo, Brazil
4 ...............~....~.~?~~p.~~~
.. Here find the detailed information of module
.. i-.O BLEND SPEED IFCtOl] "OUTPUTS",
.. OUTPUTS iFB10D]
DB OUTPUTS 106100)
5 :::::::::::::::::::::::~;:::~:~~~~)~i~:~:~C::::::::::::::::::::::::::::::::::::::::::::::::
.. SERVICE_INTERVAL !FB90] Here find the detailed information of module
DB SERVICE INTERVAL {DB90I "SERVICE INTERVAL" .
- END of document -
13565_SDS_1_E.docx 58 /
58
SE=iVOLiFT
HOS 1/0 List
Type of Machine: I Container Blender I Servolift Project No. I 13565
Mr. R. ~hri.llger/ ,
Electrical
Written by:
Sig:
.~ /I./~, programming dept.
21. Dec. 2015
Reviewed by:
Sig:
Reviewed by:
Sig:
Approved by:
Sig:
13565_HDS-IO_1_E.docx 1 110
SE=1VOLiFT
HOS 1/0 List
this page will be revised each time the specification is revised and re-issued, to record the dates and
reason for issue. All changes of this document (either for review or approval) are registered in this list.
13565_HDS-IO_1_E.docx 2/
10
5E=iVOLiFT
:;'; s, r; ;/" ;' .:':,))
1 table of Contents
1. General Introduction 4
1.1. Author I Authority 4
1.2. Purpose and Method of Use 4
1.3. Reference Document(s} 4
2. Digital Inputs 5
2.1. module 15A2 (Byte 124, 125, 126) 5
2.2. module 15A7 (Byte 0, 1) 6
2.3. module 15A8 (Byte 4, 5) 7
3. Digital Outputs 8
3.1. module 15A2 (Byte 124, 125} 8
3.2. module 15A7 (Byte 0, 1) 9
4. Analogue Inputs 10
4.1. module 15A2 (PEW 752 - PEW 760) 10
5. Analogue Outputs 10
5.1. module 15A2 (PAW 752 - PAW 754) 10
13565_HDS-IO_1_E.docx 3/
10
SE=iVOLiFT
HOS 1/0 List
1. General Introduction
1.1. Author I Authority
This document is the I/O List as additional document to the Hardware Design Specification (HDS).
It presents the assignment of sensors and actuators to the pic cards and it is the basis
for programming and assigning the visualization of the HMI-terminal which is used for control of
the blender. This document is written and approved by SERVOLIFT GmbH, Germany.
2. Digital Inputs
PLC and periphery modules are installed in electric cabinet.
3. Digital Outputs
4. Analogue Inputs
5. Analogue Outputs
- END of document -
13565_HDSIO_1_E.docx 10/10
SE=iVOLiFT
Hardware Design Specification (HDS)
y
Mr. R. ~hri.~er~ ,
Electrical
Written by:
Sig:
/4. programming dept.
22. Dec. 2015
( Mr. C. .Harms
Asst. manager
Approved by:
Sig:
fi l'4_" t,
V' electrical dept.
22. Dec. 2015
/
Reviewed by:
Slg:
Reviewed by:
Sig:
Approved by:
Sig:
13565_HDS_1_E.docx 1/
49
Hardware Design Specification (HDS)
This page will be revised each time the specification is revised and re-issued, to record the dates and
reason for issue. All changes of this document (either for review or approval) are registered in this list.
Table of Contents
1. General Introduction 4
1.1. Author I Authority 4
1.2. Purpose and Method of Use 4
1.3. Contractual Status 4
1.4. Reference Document(s) 4
2. Overview 5
2.1. Intended Use of the Machine 5
2.2. System Components 5
2.3. Machine overview 6
2.4. General control system 8
3- Control System 9
3.1. Main Control System Components 9
3.2. Storage and retentivity of memory 12
3.3. Peripherals 13
3.4. Interconnections 37
3.5. Configuration 40
(
4. Inputs & Outputs 41
4.1. Digitallnputs 41
4.2. Digital Outputs 44
4.3. Analogue In-/Outputs 45
4.4. I/O Listing 46
5. Environment 46
6. Electrical Supplies 47
6.1. Filtering 47
"
6.2. Loading 47
6.3. Earthing protection 47
6.4. Uninterruptible power supply (UPS) 47
7. Glossary 48
7.1. Definitions 48
8. Attachments 49
5E~VOLiFT
Hardware Design Specification (HDS)
1. General Introduction
/ The blender will be designed and manufactured to conform to the following standards:
!
GAMP Guidelines (current version)
all components will be CE certified
2. Overview
2.1. Intended Use of the Machine
The blender is exclusively destined to take the descript containers with a maximum load of 1000
kg and to blend them.
Operation is done on a separate operating terminal as touch display. The controls are located at
a separate stainless steel control cabinet. The danger zone is protected by customer with safe
potential free contacts on process site door switch.
The machine is not designed for any other use than that listed above. For all for injury to persons
and damage to property which occur from inappropriate use, the liability is only subject to the user
off the machine and not to the manufacturer.
13565_HDS_1_E.docx 6/
49
SE=iVOLiFT
-.', a ,' ._to, ~ ,;
I
Eurofarma Laborat6rios SA,
Customer: Ita evi - Sao Paulo, Brazil Customer Reference 4500233630
"-. Xl
\ electric cabinet
including the pic and
periphery,
on front side the main
switch is installed for
general power supply of
the blender
ROOl"I06S
13565_HDS_1_E.docx 7/
49
SE=tVOLiFT
Hardware Design Specification (HDS)
The main hardware is built up on a Siemens PLC type 300 and a Siemens touch panel HMI type
( "TP1200 comfort" as operator interface. Communication between HMI and PLC is done via
Siemens MPI protocol.
Rack 0 HMI
~MPI_1
13565_HDS_1_E.docx 8/
49
SE=-1VOLiFT
: I ~ -', ~: '1 r- :,;
3. Control System
In the following the most important used hardware components are described.
3.1.1. PLC
The machine is controlled by a PLC, type SIEMENS S7-300 CPU 313C.
It is installed in the electric cabinet onto corresponding DIN rail.
Manufacturer Siemens
Specification
general description:
SIMATIC S7-300, CPU 313C,
COMPACT CPU WITH MPI,
2401116 DO, 4AI, 2AO 1
( design
PT100, 3 FAST COUNTERS
(30 KHZ), INTEGRATED 24V
DC POWER SUPPLY, 128
KBYTE WORKING MEMORY
current
in no-load operation: typo 150mA rated value: 650mA
consumption
13565_HDS_1_E.docx 9/
49
SE=iVOLiFT
.." . ;.1:.;.>' . t:l
Specification
",
.................... ~
..
"
... r
design
Main memory
_.... ._-- _. -
....
Note: The Micro Memory Card must have inserted into the CPU to
enable the download of user programs and operation of the CPU.
( The RAM system memory is integrated in the CPU and cannot be
expanded.
It contains
System memory the address areas for address area memory bits,
timers and counters
the process image of the II0s
local data
The work memory is integrated in the CPU and cannot be extended.
Work memory It is used to run the code and process user program data.
Programs only run in the work memory and system memory.
13565_HDS_1_E.docx 10 I 49
SE=tVOLiFT
Hardware Design Specification (HDS)
Specification
PG/OP communication
integrated functions
Global data communication
S7 basic communication
S7 communication (server only)
[excerpt from siemens.corn website]
3.1.1.3. Clock
Specification
----------- ------------ -- -- ---_-
Clock
Behavior 01 the clock following expiry 01 backup Clock continues to run with the time at which the power
period fal1ur6 occurred
- ----------------- ---------- ----
Operating hours counter
Number
features NumberiNumber range
-- - - Granularity 1 hour
Yes ; Must be restarted at each restart
------------
re tent ive
s_u;._pp_ort_e_d Yes
t_o_M_PIm_,_a_.t_e' Ve~
In AS, slave No
13565_HDS_1_E,docx 11 /49
",
v
.
Specification
retentive data. the program in load memory is always retentive: it is stored on the
Micro Memory Card, where it is protected against power failure or
in load memory
CPU memory restart
in accordance with the configuration (properties of CPU, retentivity
tab), parts of memory bits, timers and counters are kept retentive
retentive data and are to be initialized with "0" on restart (warm restart)
in system memory the diagnostics buffer, MPI address (and transmission rate) and
operating hour counter data are generally written to the retentive
memory area on the CPU
the contents of retentive DBs are always retentive at restart and
retentive data POWER ON/OFF. Retentive data blocks can be uploaded to the
in work memory work memory in accordance with the maximum limit allowed by the
work memory
Specification
retentive data the program in load memory is always retentive: it is stored on the
in flash memory internal flash memory, where it is protected against power failure
the following data will be stored:
retentive data Archives and recipes
in external memory User management data
Data for operating system backup and restore
13565_HDS_1_E.docx 12 /
49
5E=lVOLiFT
;'....'!(,.~:;e .:,:'1 .::....: ...
3.3. Peripherals
This section describes the configuration of the peripheral elements:
Model self-made by SL
I
Ref. e-schematics X3
Specification
front view:
design 2
13565_HDS_1_E.docx 13 /
49
SE=iVOLiFT
~;'\ I... ~,~.: ,. ; f'
3.3.1.1. HMI
To operate the machine an operator terminal type "SIEMENS TP1200 COMFORT" with touch
screen is installed in the operator panel. The operating application is running
( on a Windows CE 6.0 operating system. The connection between PLC and HMI is done via MPI.
Manufacturer Siemens
Model TP1200, 12" Comfort 1615279
Ref. e-schematics 17A3
Specification
bottom view
(1) X80 power supply connector
(2) Connection for equipotential bonding (ground)
(3) X2 PROFIBUS (Sub-D RS422/485)
(4) X61 1 X62 USB type A
(5) X1 PROFINET (LAN), 10/100 Mb
(6) X90 Audio Line IN lOUT
(7) X60 USB type Mini B
13565_HDS_1_E.docx 14 /
49
SE=lVOLiFT.. ) "
~"'" t.
3.3.1.2. Printer
Manufacturer Brother
Specification
The following section shows the general components installed in the electrical cabinet
which will be needed to enable the control of the blender:
The main power supply is switched ON by a main switch, coloured red-yellow with emergency
function. This device is installed at the front of the electric cabinet. To interrupt the general power
supply this main switch has to be turned to OFF position (1 => 0).
Specification
example
design
current 32A
power 16 kW
mounting single hole mounting 22mm with square escutcheon plate 64x64mm
In order to prevent dangerous currents in the event of an error, a residual current circuit
breaker is used, which disconnects the main supply as a result of an error after a leakage
current of >30mA occurs.
Manufacturer Siemens
Specification
e.4C
(;.(.!-
- To prevent dangerous
currents in the event of a fault
a residual-current circuit
design / function III breaker is used, which
separates the main supply
--
A~.<.t when an error occurs at a
leakage current of> 30mA.
Specification
power 5,5kW
voltage 220/380V
frequency 60 Hz
Manufacturer KGenle
( Model KTE .... I 8015856
Ref. e-schernatics 5M3
Specification
power 3,OkW
voltage 220/380 V
frequency 60 Hz
brake no
temperature contact no
speed, adjustable no
Manufacturer Danfoss
Specification
power rating 5,5kW
voltage 380-500V
frequency 50 Hz
~:i
t. ItlH\Uel it\. ,llle
- RFI Fill.,
{hnk 5Mt! Sltll'
(lit) RFI OI... AtlB (e,)
(0) BlOke choppol
LCP (G) Graphical tee. Coni. Panul
("h\till'JPC:U (lO Not COBtQa PCO
M.lllI,OIdol1 (Xl No MaiM Option
A;I"pM1Iolt/\ (Xl ~tantll1d Cabl& 1:"10'"
A11.lpt.ldn .. B (X) No :adapl';lion
$,lltw",e "elt"'o t$~ UJf'1 reI UtI ';;N.
Manufacturer Koch
( Model 2xBWDS00160 16902290
Specification
I.
BWD 50 0 function:
short-circuit-proof, resistor for
design '~.
~-.:r~:
ti'
~~~;::;:;~.~
'!!' I lL
operation on converters (brake
transistors)
aluminium
in an anodized
casing, protection
. ~.~
..r...i .. ~ ;?;J
- class IP65.
1IlIIIfi~' example
resistance 80 Ohm
Specification
input: 200-500V AC
technical data output: 115/230V AC
1000VA
(
5E~VOLiFT ';) .Io~ ",
1,.[
Specification
',\'J".h"
INPlIT OA1A
". Jp\"~""",,,l.
~ 1"";;'1",1"'''''
~'1~1 J"":'.'
..S 16 ,'f"')\'
OUTPUT DATA
OCZ4V
~o Ii""" 'r-
.,,.,.;u.r
I...-='~:In'J::.f~Ullil"r:
I} 10
We (,,~
SE=iVOLiFT
Hardware Design Specification (HDS)
Manufacturer GAT
(
Model ESR60/12 1614607
Ref. e-schematics 27E1
Specification
design
13565_HDS_1_E.docx 24 /
49
5E=iVOLiFT
; .;~: '. ; '. I .,' :~: '{ . : '
Manufacturer Elobau
(
Model 471 M41 H31 1614823
Ref. e-schematics 10A1
Specification
To ensure a safe operation of the
system, this safety module I control unit
for the use with max. 4 sensors will be
installed at the main electric cabinet.
. The condition of the device will be
design t5 monitored at all times and any change
.2 will result in a shutdown of the
equipment. In case of a system failure
or interruption of the general power
supply, the machine will stop into a safe
condition.
indication LED
[excerpt from datasheet]
13565_HDS_1_E.docx 25 /
49
SE=-1VOLiFT
Hardware Design Specification (HDS)
The following safety protection component(s) is used to observe the conditions for starting any
( movement, e.g. hydraulic functions or rotation. The operational sequence is immediately stopped
in case of interruption of one of these safety components.
The blend cycle, calibration cycle or manual rotation is continued only again if the present fault is
cleared, the corresponding fault message is confirmed and reset, and the corresponding function
key is pressed again.
Entrance to blender room need to be closed by a safety door with includes safety contacts which
have to be closed during blending or rotational sequence. The contacts will be hard-wired as
potential free contact (signal exchange from customer to blender's control) to the emergency stop
module. Then this module switches the release contact to continue functional sequence only if
door is correctly closed.
3.3.9. Interfaces, communication with external components, using potential free contacts
(
To handle and operate the machine in a safe manner and to prevent personal from dangerous
situations there are several feedback signals:
13565_HDS_1_E.docx 26 /
49
5E=lVOLiFT
:";r.-:(!.~t1r-; .' /,:~J...: !".:
( describes used elements like emergency stop push button, key switches, push buttons,
indication lamps, membrane keypad, etc.
Manufacturer Eaton
Model M22-PV with contact elements 1613438
Ref. e-schematics 10S6
Specification
13565_HDS_1_E.docx 27 /49
SE=tVOLiFT
Hardware Design Specification (HDS)
Specification
~,
~I"'"
connection:
design
(P ~~;
~
E2
-~
I
<{l>
--. 1:BN
r'r-"--l+
) 4'BK
~f}JL'
operating voltage 10- 30V DC
assured
operating distance O ... 4,05mm
installation embeddable connection type I connector M 12 x 1, 4-pin
[excerpt from datasheet]
13565_HDS_1_E.docx 28 /
49
SE=iVOLiFT
: :<. ,
Specification
~, connection:
I
- c- .
T
I
"f
V
;:>
-e
design 2.~
I ._ .~~ ~/~L' BK
~\
1'-. LEO :~
_BU L..
~
_.f-:-:--
M'2~1
assured
operating distance 0 ... 4,OSmm
Specification
~ connection:
r+ sf I I" I
design ~-~'Fr:Er:#1t?,~: .!!
~
f ~. '~Al~;
i
---L+
I ,,12,
t ! ! BK
-~~~---
~~
IEu)fEl 1
a 11;i.~~
(4;.:) C(,
t ,
I
~H2.J. ~
operating
distance 20mm
assured
operating distance 0 ... 16,2mm
installation embeddable connection type I connector M12 x 1, 4-pin
[excerpt from datasheet]
5E~VOLiFT
" r
: 'l ~,''::
Manufacturer Turck
Specification
connection:
design
\
"..
M12x I
---.-.-.- ..~
l-4B.G ._.J
OpOrOtlng'vollogo iO:::-3OVtjC-'-' ._
Rosldual rlpplo ,10% U.
DC rctod operatio",,1 .' 150mA
current ._ 1SmA
No-load current I. -0.1 mA
technical data Residual curront < 0.5 kV
Rated tnsutauon voltage yesl cyclic
Shortclrcull protocncn ,: 1.SV
Vollago drop ot I.
Wlro brookugo I Roverse polarity protoctlon yo:JI complete
Output function 3wlro. NO contact. PNP
Switching froquency 1 kHz
Indication by ... LED yellow, included in scope of supply => cable clip
Specification
_~l_ connection:
...-;
)-. J
i"1= ~ 'f :~:tl
E2
design ~~J
1~1~ '~Lt
'BK
%;;;;""
:;'
LEO'
~
r-- ~~ ~~'--t L
1~ ~
M1:lx1
I .
- I
Manufacturer tecsis
( Model SC420 1131556
Ref. e-schernatlcs 27B4,27B10
Specification
design
I
ow., conlultl hun '. r- ....1.-.1' j'
't.VI r 'r "~I
( !Outfl'll"
Swllchlny Qulput.
_.
r ~,tw "lIurlllJ tt \Ill Itlt! d'S... .If
"'/JOt ('t'''Ojl rl(!(Jr1 324 HI
" , . ~ , .. ., .
"unjet S24;l(:
NIII'::~" ~IWJ "o'ilW1nl9 oU!....!s !)no 'S."i!:I1I.~ out: .. 1nr,'J r ...Q. ''I;1tCh1f1!J o .. !put Mil
_ .---~-.- .. _--'. _._- -- ._~~~'I.:':C'l~cl_O.UI._.!:'._ .'\:I_~I~.!IO.'.JLJ~_eu~...!..
SW't..:hlf'lD !lItlllllJII ....
O!'lInt"~" ( C'::'llo" , lIonf"l:~ c;lm..co(t\t;1 ~r mlnlh\Uy fJ~\lr11:NOJ
~~:ilY' t o..:~,on , 1 n ?,\:CPI'I"I
i'9{i'HI,,.iM 1(1 (l1lt''9t1
!r.,., [I ! ~
1'1II,w.1.I\lal\ j p ..;. n "..,.11 11111',
nominal pressure
'<:1)<".'.'
'11)161;:0'"
i
' ..'~" ofl~:i.n
I {J it,j/to 01 '.4i.ln
.~~t;r.;:"!."1;II.IiII"~
-; -.-.. _:.-t-!:P;.~:'. '''_._-
AnaiQQut outPui
lil.thJl1d i .11: V. ;; .,'hl
I
()t,I'u't :l
S~.ll"j 20 .. lIJl1'!-, o(t~~r';
\....OOdW~5!O,.CC. Cunl.tnt 1.!:,I;,)ul '"( <. ~~.:. ~1:1., ...
I
CUllt~l1tlJl,'.tllll ] \il',1114mr.;,
n 11l"J
r.1in Inttn~'1
~.J Ii. c~ -spiln for ccra:TUC Cof'
I
:) 2 ,.~ I~ !D(!!l 'j)t (1,111 I r" ~o"jll
.,'.:., v , 'I.11I11rllq
IIi \0' .. I.lll
arnper.lun, '.11\1".
":"llltnn ~tI ~j t.:
Vr"" :., &') <.:
An'I~(!nt 'n 7"\ I:
I r.," '...'11'1'"
Flactrl(::tt Cf)IIr.t:(;tiQf1 t IDUlI~ r.Olll~1 (., t.I ' .. _ I Jill'
Platedhl" clau' II? r,~'I.,t:r.o'~~ ,~ fG t:?11
LO;ldin9 c:::tp:aC.11y
Shot~ (r.:o:~h.:mll;.tll
~~~;~:l'~h"i1l1
5U9 w:;:ulllhlCj IQ 1t:~;'GCc:t!!! ~.::7
Vil'l:fol:iOI) , ... Ni' ,e~en.:'" ~t~",C,,~.;..~-,O; ~ ..
Wt:1 ht
3.3.11.7. Temperature sensor 1, "GN 650.6 ... " - monitoring hydraulic oil temperature
Specification
.... connection:
-
l-c fIn N/~~
:)11'1(:11<1:,,1,,111
design
'.
~
-
LCd
technical data
max. current 5A
for monitoring and indication of hydraulic oil fluid level, but also for
triggering an electric pulse once a certain temperature is reached,
function
a sensor switches / opens a contact if temperature increases over
70C, this contact is provided as type 1xNC
[excerpt from datasheet]
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; I
13565_HDS_1_E.docx 35149
SE=iVOLiFT
Hardware Design Specification (HDS)
Specification
13565_HDS _1_E.docx 36 /
49
Type of Machine: I Container Blender I Servolift Project No. _j 13565
3.4. Interconnections
Sensors:
(
Most of the used sensors are connected via M12 plug cables, type V1-W-SM-PVC (611749).
7000-18021-2160300,
Model valve connector 1606903
Ref. e-schematics => hydraulic valves and electric valve (=> 127325, includes 129499)
Specification ,
features:
design form A (18 mm) => (28x28mm)
24 V AC/DC with LED and suppression
operating voltage 24 V AC 20 % I DC 25 %
operating current
per contact max.4A
( (40C)
protection IP65 and IP67 when plugged and screwed down (EN 60529)
temperature
range -25 ...+85 C, depending on cable quality
cable PVC, 3xO,75 mm"
[excerpt from datasheet]
Pneumatic Valves:
Item is not applicable (n/a). There are no pneumatic valves used.
Terminals:
Most of the connectors used in the system will be tension clamp connectors from manufacturer
'Weidmuller".
Alternatively connectors used in the system will be clamp connectors secured by screws.
3.4.2. Cables
All main power and 24V DC supply cables are flexible types. Each cable end is labelled
with a unique cable number (Wxx). The cable number refers to the electrical component
see screenshot as example:
( e.g. sensor is labelled 23B2,
corresponding cable
is labelled W23B2
- Front page
- T able of contents
- Change control I Modification Index
- Terminal diagram(s)
3.5. Configuration
Configuration and setting points of electrical components (motor circuit, pressure switches,
temperature switches, etc.) are mentioned directly at the appropriate device in the electrical
drawing. If devices are programmable, a separate configuration file exists and will be included
( on the documentation CD.
-
W5S~_ ~
.'JJ.J
,
~,
5S3~_1
o.s
",!"
w~~~_
r.
X!/91 I.
ju
Manufacturer Siemens
Model 57-300, CPU 313C 1613950
Ref. e-schematics 15A2
Specification
n
X11 X12
r- ---,
,,_ r--' ~ -
>.. ...
1,\.J.
"".'
!ol~'
I ~J
~",.'.~,. 2 a) :3
design I!I
(
!J'at.
r ~
'I
,.... .. , ,....
bloc diagram of CPU313C
- with integrated II0s
To expand the amount of further digital in-/outputs the modules type "Helmholz 700- 323"
and/or "Helmholz 700- 321" are used. For detailed information see following pages.
13565_HDS _1_E.docx 41 /
49
SE~VOLiFT
Hardware Design Specification (HDS)
Type of Machine: I Container Blender I Servolift Project No. I 13565
Specification
# digital inputs convert the external
binary signals from the process into the
c:: internal signal level of the
.Q programmable controller...
design t5
c:: # digital outputs convert the internal
~ signal level of the programmable
controllers into the external binary signal
level required for the process
700 12 118l00
Input vultol9l'
IlCUI'l,\':lhlt' : l)f .!I \'
hll SI'I1.lIn~ \ ,:i, , ..:-\0
" l"l:;~jl~I"l" i ..1.1" ~ll)\'
tnllut C'unP.nt
fu~_"I" si!.ln~~ "V .. im,\
In ', 1 . 2 , .. .. ,::;1 1I~
('01111",'''(.111 01 t-wtrc ililhOllrtl _ . :\. ~ , ! > , .. - -_ ....
~~~~I,I . ' 1I: '~i~.I:~'I~:~lh,'.~I.I.tI.~~~~.\)'~:.~! 1)1.t". I.:'m.\
JI.,.H
C"IJlc'h:ncJlh
1111", :u11l111l
, UI\',hitldtd
'i1M;, IOU;lr'!I
~hh:hl~\d
1(.
hI)1~t10a ~UUlll1J;lci.?IJ1Wbtl:,
technical data ill
o~il~;u~~t ~~.._.
II,!>,'
Ilnm,\".llu('
l:]"",uvrll('
~Jll~~I.dl<~II~! !Uh:\'!~~)_I1_ _
: ~O \;
\'olt:'l&,' ilHt~~,~,:,t?~I'I~I:lt Itneu
11vtin~III~i.ltr<1",'
1111\ :6ll(Jllt
C,,~lr IcnUlh
1:11\ U)uOm
UI1>;ll1thJ('d
~lIlt'ld,'d
: i)C)-I\'
SUltply vnl!;J9p. V,.. V:
tlW:'13,6\'
1\9n1,\.1111t"
: .'O,.. 30r
11~'VI('\';,
Ilt'III1I;'/ll'l~ ,.u\:~.\wlill I ippl\")
m.M', i .~oy,
,',llm",ltt' llJltI~
Cutrl:nt VJMUnllltiOIl
-
hOI1l .) 1 \'J
_''',Id,
-- -
,,'~I\'U1 ~1 tW hhont
._
_ .111':.: J.J~~~~,
t)'I" :v.U\'
-11).1\'.1:-'
13565_HDS_1_E.docx 42 /
49
SE=1VOLiFT
;,,~..,:.: ~.,~:. j~)( .~":
Specification
, 700321IBH02
.-.- ..- .....- ..- 1-.- .-...- _..-.,- -_ .. -.- ..-.-.! .-
I
..- ...--- - .-.....- ..- ..- --
- .'_ ... - - - - . . . - .. .... - ".- ..-._. -- .... --- .. _. '.'1!'"16 ----' .. -.' .... '- "-".- - - .....--I
o li l l PU I S :
ISl,j.ltiUIlIIf()tU h;ld;PI'H.I'.' bUil ! i
\".~ 8 IOphJfl1Ilph:c,
1t' u ps
- - .
j
i
I ~ P ; ~ '~ ~"a-9_~._-'. --" ..- .. _....
I I I
lh
(If
-'-'1"-
( IlI.lIl'- \":,h:..: U(, .!4 v I
i
.. " I ~..1.:,:''~'!I~y.. _.'._ .. " ". _ '"
I ' 1111.,,,,11\bad;plillWUIII)
.. :
I~I'.2 n m A
,~:~!~~~t~~!~:l_~~_~~.~-,~,_..-_. _ .. J:l~~. 1 4 1 )""\
I
v ~
II ( , (If) \
~:. ( '. -, l
13565_HDS_1_E.docx 43 /
49
SE=-1VOLiFT
Hardware Design Specification (HDS)
Manufacturer Siemens
( Model S7-300, CPU 313C 1613950
Ref. e-schematics. 15A2
Specification
X12
-
X11
r--
'-
. --' ._ r--'
,,
~t\.l.'
",
.
."
~ - ;),
"
"1
~.~
HJ
:.J""
I
:l
~
design II!!
1
If further digital outputs are necessary the module type "Helmholz 700- 323" is used.
SE=-1VOLiFT
Hardware Design
For detailed Specification
information (HDS)
see following chapter. All modules are installed in main electric cabinet.
Manufacturer Siemens
Model S7-300, CPU 313C 1613950
Ref. e-schematics 15A2
Specification
X11 X14!
---,
~~ -
."...,-
._
I ~~ 'N:,
i ,J
"'!'\~
~
~. " .
design
f t "
r ~
!I!
.~ ,.
\ ) '
-
bloc diagram of CPU313C
..._, r-- with Integrated II0s
1
-- ..-
The flol)ro~s show the follOWIn~Integrated II0s
I (1) Analog liOs
(2) each wi\l1 8 cigl!al inputs
(3) each ~vi:n8 d!gi:31 outpias
The detailed assignment (function, description, labelling) of the used sensors and actuators can
be taken from the separate document, called "13565_HDS-IO". This will be used as basis for the
programming and for testing purposes, e.g. the functionality or signal exchange. Each revision of
assignment of sensors and/or actuators, which will be added are removed, or renamed by tag
( number is only done in this "HDS-IO" document itself.
5. Environment
This section shows the minimum and maximum environmental conditions
that the PLC equipment will be suitable for.
1. Temperature o -40 C
2. Humidity 10 to 65% RH
4. Radio frequency,
see technical data of the appropriate device
electro-magnetic and UV-interference
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< .
6. Electrical Supplies
The section describes minimum of supply requirements for the configured hardware system.
6.1. Filtering
To avoid electromagnetically interference a filter is integrated in the VFD according EN55011-1A.
6.2. Loading
The general power can be switched on/off with the main switch on the electric cabinet's door.
A power supply unit breaks down the voltage onto 24V DC to supply the PLC with additional
periphery also as for sensors and other devices too. The main power supply should match
following requirements:
fuse 25 A
7. Glossary
1.1. Definitions
The following definitions apply to corresponding terms which may be unfamiliar to the readership:
Term Definition
PLC Programmable Logic Controller
E-Stop Emergency stop
LED Light Emitting Diode
EMC Electro-motive compatibility
FAT Factory Acceptance Tests
FS Functional Specification(suRplier prepared documents)
HDS Hardware Design Specification (supplier prepared documents)
HMI Human- machine interface
Hz Frequency (Hertz) Cycles/second
I/O Input/output
AI Analogue input
AO Analogue output
DI Digital input
DO Digital output
protection
IP54
against splashing water from all directions, limited ingress of dust permitted
IP65 protection against splashing water from all directions, total protection from dust
KW Kilowatt (Electrical power)
MMC Micro Memory Card
MPI Multi- point interface
n.a. not applicable
N/C Normally closed
N/C Normally opened
PLC Programmable Logic Controller
printer command language, developed by HP as a printer protocol which has
PCL6 become an industry standard
RAM Random access memory
RH Relative Humidity
SDS Software design specification
CPU Central Processing Unit
URS User re_guirement specification
USB Universal serial bus
V voltage (Volts)
V voltage (volts)
VAC volts alternating current
VDC volts direct currents
SE=tVOLiFT
:. :l.ti'!J/l(: :.;).(,;+-i'_ .'
8. Attachments
Main components of the electrical parts
1. Datasheet DB_CPU313C_E.pdf
separate on CD
5. electrical schematics
13565_EP, current version
~ END of document -
13565_HDS_1_E.docx 49 /
49
SE=lVOLiFT
tijetime solutions
Installation Qualification
for
Container - Blender
13565
(
Eurofarma Laboratcrlos S.A.
M . r A.7~L Technical
Written by: Sl g : OB.Jan.2016
editorial dept.
k.
. I
Reviewed by:
Sig:
Reviewed by:
Sig:
Approved by:
Sig:
SE=lVOLiFT
tijetime solutions
I Date of Version
Blender 108. Jan. 2016 I Version 1
table of Contents
List of persons, involved in qualification: 3
3. Identification 5
3.1. General Data 5
3.2. Reference Documents 5
4. Scope of Delivery 6
5. Installation 7
5.1. Assembly 7
6. Utilities 8
6.1. Mains 8
9. Final Statement 12
File: 13565_IQ_1_E.docx
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lifet iiue SO/lit ions
Responsible
Person:
File: 13565_IQ_1_E.docx
.... _._ -'3T12
SE=iVOLiFT
lifetime solution:
I Date of
Machine 108. Jan. 2016 I Version
No. 1
Version
the following list registers the execution of changes for this document.
File: 13565_IQ_1_E.docx
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lifetime solution:
File: 13565_IQ_1_E.docx
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tijct ime solutions
I Date of Version
Blender 108. Jan. 2016 1 Version 1
3. Identification
Remarks
IMachine
Date of Version 108.Jan.2016 I Version 1
4. Scope of Delivery
4.6. Qualification documentation for blender (IQ, OQ, FAT, FS/FDS, SDS, HDS)
Other non-listed items as service work, packaging and transport are not
relevant for qualification, and thus not included in this table.
INFORMATION
Remarks
I Date of Version
Machine 108. Jan. 2016 I Version 1
5. Installation
~.1.Assembly
Operator terminal outside blend Siemens terminal 12"- installed into built-
5.1.9. room in panel
Sensors for positions and installed and adjusted into the column
5.1.12. temperat res
Remarks
File: 13565_1Q_1_E.docx
5E=iVOLiFT
lif~?Z.iln(' solutions
5.1.13. Hydraulic powered pivoting clamps Installed at supporting arm ace. schemes
,
6. Utilities
6.1. Mains
Power supply
6.1.1. Supply to the electric cabinet
380 V, 60 Hz, 3Ph, PE, 13 kW
Remarks
File: 13565_IQ_1_E.docx
SE=lVOLiFT
Hid-lin", soiutions
Installation Qualification (IQ)
I Date of Version
Blender lOB. Jan. 2016 I Version
7.1B. Safety Data Bulletin of blend drive gearbox oil SHELL OMALA 6BO
7.19. Qualification Documentation consisting of FAT, OQ, IQ, FS, FDS, SDS, HDS
Remarks
File: 13565_1Q_1_E.docx
SE=iVOLiFT
litl: lime sotutions
The documents listed below are available only on CD-Rom after FAT
Remarks
All defects, which are detected during FAT tests, are listed below together with the necessary actions
to eliminate the defects.
(
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tijetime solutions
9. Final Statement
Reviewed by:
Sig:
(
Reviewed by:
Sig:
Approved by:
Sig:
File: 13565_IQ_1_E.docx