.

MACHINE CONTROL SYSTEM

431MD140A01

Plant Name: DG Khan Cement Company Ltd.

Contract Number: 1545366_900

Created by: SHAKS

Approved by: SVG
Approved date: 6-Feb-17

Doc. No.: 80041598 - 2.0

 0.01
Kiln Speed & - Angular Position Transmitter 80041598 Ver.: 1.0

Contents List

Ver.
0. Contents
.01 Table of contents 1.0

2. Description and Settings

.00 Description 1.0
.01 Parameters for the kiln angular transmitter 1.0
.02 Programming of the kiln angular transmitter 1.0

.05 Parameters for the kiln angular transmitter 1.0

.06 Programming of the kiln angular transmitter 1.0

5. Panel Documentation
.002 Table of contents 1.0
.030 Panel layout 1.0
.900 Parts lists 1.0

30-Nov-16 svg/SVG
 2.00
Kiln Speed & - Angular Position Transmitter 80041598 Ver.: 1.0

Description:

The kiln speed & -angular position transmitter generates 2-wire, 4-20mA, active signals for
the kiln speed as well as for the kiln angular position. The signals are based on a 15 pulse
per revolution encoder placed on the kiln motor or the kiln gear shaft.

A kiln angular position reference signal is generated by use of a proximity switch detecting
a bracket on the kiln shell. The reference signal is used to reset the angular position signal
and is available as a potential free contact for external use (kiln shell temperature scanner).

30-Nov-16 svg/SVG
 2.01
Kiln Speed & - Angular Position Transmitter 80041598 Ver.: 1.0

3.01 Parameterizing of the kiln speed transmitter:

Calculations:
Ratio in planetary gearbox: i= 84,2410
Ratio, supporting roller/kiln tyre: i= 3,2227
Total ratio: i= 271,4835
Kiln speed max.: 5,00 min‾¹
Drive speed max.: Total ratio x max.kiln speed = 1357,417 min‾¹

15 pulses per revolution from an encoder on the kiln motor shaft results in:
Total ratio x 15/60 = 339,354 pulses/s = 339,354 Hz

Transmitter type: f/I-Converter, PR-Electronics 2255

Configuration according to instruction manual for PR 2255 - see next page.

The following parameters to be entered:

2.1: 0
2.2: 339
2.3: 354

3.1: 4.0
3.2: 20.0
3.3: 002
3.4: 0.06 [s]

5.1: 001
5.2: PnP
5.3: HI
5.4: 040

30-Nov-16 svg/SVG
 2.02
Kiln Speed & - Angular Position Transmitter 80041598 Ver.: 1.0

30-Nov-16 svg/SVG
 2.05
Kiln Speed & - Angular Position Transmitter 80041598 Ver.: 1.0

3.05 Parameterizing of the kiln angular transmitter:

Calculations:
Ratio in planetary gearbox: i= 84,2410
Ratio, supporting roller/kiln tyre: i= 3,2227
Total ratio: i= 271,4835

15 pulses per revolution from an encoder on the kiln motor shaft results in:
Total ratio x 15 = 4072,25 pulses/kiln revolution

Transmitter type: Ramp Generator, PR-Electronics 2281

The resolution of the applied 2-phase encoder is doubled, as both the leading and
the trailing edges on the pulses are countered:
Pulses/rev. x 2 = 8144,50 pulses/kiln revolution

Configuration according to instruction manual for PR 2281 - see next page.

The following parameters to be entered:

1.1: rES
1.2: 0 [%]
1.3: 1

2.1: 8
2.2: 145

4.1: 4.0
4.2: 20.0
4.3: 002
4.4: OFF

5.1: 002
5.2: EFS
5.3: HI
5.4: 040

30-Nov-16 svg/SVG
 2.06
Kiln Speed & - Angular Position Transmitter 80041598 Ver.: 1.0

30-Nov-16 svg/SVG
 0 1 2 3 4 5 6 7 8 9

Vigerslev Allé 77
2500 Valby
Denmark
Tel +45 36 18 10 00
Fax +45 36 44 11 46
info@flsmidth.com

Customer D. G. Khan HUB

FLSmidth order number 15-45366

Panel ID 431MD140A01
Panel description Kiln Speed and Angular Position
Panel type KL-SA-02
Drawing number 80041598

Project start 07.09.2015

Latest change 21.09.2016
Document revision 1.0
Print date 21.09.2016

Customer: D. G. Khan HUB Drawing No: 80041598 Front page

Project: 15-45366 Version: 1.0
Print date: 21.09.2016
This drawing may not be copied or disclosed to a third party Edited by IL : 18.03.2016 Kiln Speed and Angular Position 431MD140A01 Page 5.001
 0 1 2 3 4 5 6 7 8 9

Table of contents
Page Page description Date Edited by
431MD140A01/ 5.001 Front page 18.03.2016 IL
431MD140A01/ 5.002 Table of contents 31.03.2016 IL
431MD140A01/ 5.021 Specification label 18.03.2016 IL
431MD140A01/ 5.030 Panel Layout 600x600 panel 31.03.2016 IL
431MD140A01/ 5.031 Panel Layout 600x600 panel 31.03.2016 IL
431MD140A01/ 5.100 Main Power Supply 18.03.2016 IL
431MD140A01/ 5.102 Grounding layout 18.03.2016 IL
431MD140A01/ 5.116 24VDC Supply 18.03.2016 IL
431MD140A01/ 5.400 =341+MD140A01-U4000, U4002 Kiln Speed and Angular position transmitters 18.03.2016 IL
431MD140A01/ 5.401 =341+MD140-D02, -B01 Kiln Motor Shaft Encoder and Position Sensor 18.03.2016 IL
431MD140A01/ 5.900 Bill of materials 18.03.2016 IL

Customer: D. G. Khan HUB Drawing No: 80041598 Table of contents

Project: 15-45366 Version: 1.0
Print date: 21.09.2016
This drawing may not be copied or disclosed to a third party Edited by IL : 31.03.2016 Kiln Speed and Angular Position 431MD140A01 Page 5.002
 0 1 2 3 4 5 6 7 8 9

TAG ID

Panel ID : 431. MD140A01

Panel Type : KL-SA-02
Panel Description : Kiln Speed and Angular Position Tag No.: 431.MD140A01

70 mm
Order : 15-45366 Type: KL-SA-02
Field Wiring Diagram : 80041598 Order: 15-45366
Enclosure Type : IP54 Instructions: 80041598
Min.-Max. Ambient Temperature : 0-45°C Power: 230 VAC 1Ph+PE 50 Hz
In 6 A Icp 6 kA
Supply Voltage : 230 VAC
Phases : 1Ph+PE 110 mm

Frequency : 50 Hz
System Earthing : TN-C
Switchboard Load : 6A
Prospective short-circuit current, Icp : 6 kA
Control Voltage : 230VAC/24VDC
Nominal heat dissipation : xxx W
Manufacturing date : 05.2016

Min. character height 3.5mm

Customer: D. G. Khan HUB Drawing No: 80041598 Specification label

Project: 15-45366 Version: 1.0
Print date: 21.09.2016
This drawing may not be copied or disclosed to a third party Edited by IS : 07.09.2016 Kiln Speed and Angular Position 431MD140A01 Page 5.021
 0 1 2 3 4 5 6 7 8 9

Customer: D. G. Khan HUB Drawing No: 80041598 Panel Layout 600x600 panel
Project: 15-45366 Version: 1.0
Print date: 21.09.2016
This drawing may not be copied or disclosed to a third party Edited by IL : 31.03.2016 Kiln Speed and Angular Position 431MD140A01 Page 5.030
 0 1 2 3 4 5 6 7 8 9

354 mm

300 mm

25*80

-T1161
-F1161

-U4000

-U4002
120 mm

25*80
400 mm

423,53 mm
200 mm
25*80

-K4007
-K4008
-K4009
-X1001

-X4001

-X4004
267,5 mm

315 mm PE

335 mm Shield

375 mm

213 mm
227 mm

35 mm

45 mm

80 mm

115 mm

150 mm

185 mm

220 mm

260 mm
Customer: D. G. Khan HUB Drawing No: 80041598 Panel Layout 600x600 panel
Project: 15-45366 Version: 1.0
Print date: 21.09.2016
This drawing may not be copied or disclosed to a third party Edited by IL : 31.03.2016 Kiln Speed and Angular Position 431MD140A01 Page 5.031
 0 1 2 3 4 5 6 7 8 9

230VAC / 116.0
0VAC / 116.0

1,5 mm²

1,5 mm²
RD

RD

Field Field
-X1001 1 2 PE
PE

1 2 PE

=431+MD140A01
-M01

1 2 PE

L N PE

Power
Supply

System Earthing TN-C

Voltage 230 VAC 50 Hz

Customer: D. G. Khan HUB Drawing No: 80041598 Main Power Supply

Project: 15-45366 Version: 1.0
Print date: 21.09.2016
This drawing may not be copied or disclosed to a third party Edited by IL : 18.03.2016 Kiln Speed and Angular Position 431MD140A01 Page 5.100
 0 1 2 3 4 5 6 7 8 9

Mounting Panel Door

Plate PE Frame PE PE

16 mm²

16 mm²
GNYE

GNYE
16 mm²
GNYE

PE PE PE

Customer: D. G. Khan HUB Drawing No: 80041598 Grounding layout

Project: 15-45366 Version: 1.0
Print date: 21.09.2016
This drawing may not be copied or disclosed to a third party Edited by IL : 18.03.2016 Kiln Speed and Angular Position 431MD140A01 Page 5.102
 0 1 2 3 4 5 6 7 8 9

100.9 / 230VAC
100.9 /0VAC

24VDC / 400.0

1 3
-F1161
Siemens
5SY6203-7 2 4
1,5 mm²

1,5 mm²
RD

RD

L1 N
AC AC
-T1161
IN: 120/230 V AC
OUT: 24 V/2.5 A DC
- - +

PE - +
0,75 mm²
1,5 mm²

1,5 mm²
GNYE

GNYE

BU
0,75 mm²
BU

0VDC / 400.0
Field Field
-PE-PE

24VDC 24VDC
Supply Supply
Internal

Customer: D. G. Khan HUB Drawing No: 80041598 24VDC Supply

Project: 15-45366 Version: 1.0
Print date: 21.09.2016
This drawing may not be copied or disclosed to a third party Edited by IS : 07.09.2016 Kiln Speed and Angular Position 431MD140A01 Page 5.116
 0 1 2 3 4 5 6 7 8 9

116.2 / 24VDC 24VDC / 401.0

0,75 mm²

0,75 mm²
BU

BU
-U4000 JP1: OFF -U4002 JP1: OFF
PR Electric PR Electric
9 JP2: ON 9 JP2: OFF
2255B1 2281
JP3: ON JP3: ON

10 6 3 1 5 10 3 1 4 6 11
0,75 mm²

0,75 mm²

0,75 mm²

0,75 mm²

0,75 mm²

0,75 mm²

0,75 mm²

0,75 mm²

0,75 mm²

0,75 mm²
BU

BU

BU

BU

BU

BU

BU

BU

BU

BU
11 / 401.0
6 / 401.0
4 / 401.0

116.2 / 0VDC 0VDC / 401.0

Field Field
-X4001
1 2 SH 3 4 SH
1 2 1 2

=431+MD140A01 =431+MD140A01
-C01 -C02

1 2 1 2

+Factory +Factory
Kiln Speed Kiln Angular Pos.
4-20mA 4-20mA

Customer: D. G. Khan HUB Drawing No: 80041598 =341+MD140A01-U4000, U4002

Project: 15-45366 Version: 1.0 Kiln Speed and Angular position transmitters
Print date: 21.09.2016
This drawing may not be copied or disclosed to a third party Edited by IS : 21.09.2016 Kiln Speed and Angular Position 431MD140A01 Page 5.400
 0 1 2 3 4 5 6 7 8 9

400.4 / 24VDC

400.4 / 11
400.4 / 6
400.4 / 4

-K4007 A1+ A2- -K4008 A1+ A2- -K4009 A1+ A2-

Encoder [1] Encoder [2] Kiln
Angular
+ - + - Pos. ref. + -
pulse

+ + +

0' 0'

+' +'

+ 0 A + 0 A + 0 A

400.4 / 0VDC
Field Field
-X4004 1 2 3 4 5 6 7 8 SH 9 10 11 12 13 SH SH
1 2 3 4 5 6 7 8 1 2 3 3 4 1 2 7 8 5

=431+MD140A01 =431+MD140A01 =431+MD140A01

-D02C01 -X38C01 -KPEC01
Twisted pair

1 2 3 4 5 6 7 8 1 2 3 3 4 1 2 7 5 8
=431+MD140
-D02 =431+MD140 -KPE (OPTIONAL)
1 2 3 4 5 6 7 8 1 2 3
-X38
BK BU BN 5VDC 0VDC A+ A- B+ B- 24VDC PULSE 0VDC
L1 1 2 3 4 5 6 24 25 26 27
TO CEM Scanner
=431+MD140A01
-D03C01

=431+MD140
-D03
Rechner IAS-10-250-S-BB

=431+MD140A01
-B01C01
=431+MD140
-B01
+E V 0 V 1 -1 2 -2 0 -0
Kiln motor shaft encoder Kiln angular position reference
L&L 865-1024/0015 sensor Rechner IS250-M32-5m

Customer: D. G. Khan HUB Drawing No: 80041598 =341+MD140-D02, -B01

Project: 15-45366 Version: 1.0 Kiln Motor Shaft Encoder and Position Sensor
Print date: 21.09.2016
This drawing may not be copied or disclosed to a third party Edited by IS : 21.09.2016 Kiln Speed and Angular Position 431MD140A01 Page 5.401
 0 1 2 3 4 5 6 7 8 9

Parts list
Device designation Quantity Description Type No Order No Manufacturer
-A01 1 Compact enclosures AE , whd 300x400x210 mm AE.1034500 1034500 Rittal
-A01 1 FLS LOGO PLATE FLS-LOGO PLATE FLS-LOGO PLATE AE PARTNER
-A01 1 Wall mounting bracket SZ.2508010 2508010 Rittal
-F1161 1 CIRCUIT BREAKER 400V 6KA, 2-POLE, C, 3A, D=70MM 5SY6203-7 5SY6203-7 Siemens
-K4007 1 Solid-state relay module PLC-OPT- 24DC/24DC/100KHZ 2902970 Phönix Contact
-K4008 1 Solid-state relay module PLC-OPT- 24DC/24DC/100KHZ 2902970 Phönix Contact
-K4009 1 Solid-state relay module PLC-OPT- 24DC/24DC/100KHZ 2902970 Phönix Contact
-T1161 1 SITOP PSU100L 24 V/2.5 A 6EP1332-1LB00 6EP1332-1LB00 Siemens
-U4000 1 Relay socket RIF-3-BPT/3X21 2900938 Phönix Contact
-U4000 1 Programmable f/I converter 2255 2255B1 PR ELECTRONICS
-U4000 1 Relay retaining bracket EL3-M52 2833628 Phönix Contact
-U4002 1 Relay socket RIF-3-BPT/3X21 2900938 Phönix Contact
-U4002 1 Ramp Generator 2281 2255B1 PR ELECTRONICS
-U4002 1 Relay retaining bracket EL3-M52 2833628 Phönix Contact
-X1001 2 End clamp CLIPFIX 35 3022218 Phönix Contact
-X1001 2 Feed-through terminal block PT4 PT 4 3211757 Phönix Contact
-X1001 1 End cover D-ST 4 3030420 Phönix Contact
-X4001 2 End clamp CLIPFIX 35 3022218 Phönix Contact
-X4001 4 Feed-through terminal block PT4 PT 4 3211757 Phönix Contact
-X4001 1 End cover D-ST 4 3030420 Phönix Contact
-X4004 2 End clamp CLIPFIX 35 3022218 Phönix Contact
-X4004 13 Feed-through terminal block PT4 PT 4 3211757 Phönix Contact
-X4004 1 End cover D-ST 4 3030420 Phönix Contact

Customer: D. G. Khan HUB Drawing No: 80041598 Bill of materials

Project: 15-45366 Version:
Print date: 21.09.2016
This drawing may not be copied or disclosed to a third party Edited by IL : 18.03.2016 Kiln Speed and Angular Position 431MD140A01 Page 5.900