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MAIN BURNER

OPERATION MANUAL
BURNER MANAGEMENT SYSTEM

IM151-8F PN/DP CPU

with
HMI KTP1000

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CONTENT

Orientation HMI (Human Machine Interface) ...................................................................... 3

Used symbols .................................................................................................................... 4
Inside screens ................................................................................................................ 4
Status of group ............................................................................................................... 5
Description of functions...................................................................................................... 6
Screen selection with “F” function key ............................................................................ 6
Select screen with softkey .............................................................................................. 7
Basics of operation ............................................................................................................ 8
Password - level ................................................................................................................ 8
Change parameter values .................................................................................................. 8
Set time and date............................................................................................................... 8
ACKNOWLEGE / RESET .................................................................................................. 9
Change LOCAL – REMOTE .............................................................................................. 9
Change set point in LOCAL mode...................................................................................... 9
START and STOP fuel’s .................................................................................................... 9
Screen START..................................................................................................................10
Screen MAIN BURNER ....................................................................................................11
Screens Interlocking MAIN BURNER ............................................................................11
Screen IGNITOR ..............................................................................................................13
Screens Interlocking IGNITOR ......................................................................................14
Screen Parameter IGNITOR .........................................................................................16
Screen HFO VALVE TRAIN ..............................................................................................17
Screens Interlocking HFO .............................................................................................18
Screens Parameter HFO ...............................................................................................20
Screen COAL....................................................................................................................22
Screen MESSAGES .........................................................................................................23
Screen SYSTEM...............................................................................................................24
Screen FAILSAFE MODULS .........................................................................................25
LOGIC ..............................................................................................................................26
PROFIBUS DP – COMMUNICATION...............................................................................26

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Orientation HMI (Human Machine Interface)

F1 – F8 the function keys are for screen selection – see “description of function”

Other functions or selection of screens have to be done for each screen inside the screen
with touch keys.

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Used symbols

Inside screens

ERROR / STATUS Error is present

Signal is present – good condition

Signal not present

Signal is present but not acknowled

ACTORS No limit is present

Closed/off position

Open/on position

Both limits are present

Actor is faulty

ANALOG VALUES 12345 Analog value ok

12345 Analog value faulty

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Status of group

Operation interlock

starting interlock

Operation

Actual step no.

OI SI OP STEP
Operation and starting interlock not OK – no operation
0 possible

OI SI OP STEP
Operation interlock OK but starting interlock not OK – no start
0 possible

OI SI OP STEP
0 Operation and starting interlock OK – start possible

OI SI OP STEP
1-16 Group is in start sequence

OI SI OP STEP
16 Group is started sucessfull and in operation

OI SI OP STEP
51-66 Group is in stop sequence

OI SI OP STEP
66 Group is stopped sucessfull – ready to start

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Description of functions

Screen selection with “F” function key

START Go to screen „START“ (always screen after start HMI)

IGN Go to screen „IGNITOR“

HFO Go to screen „HFO VALVE TRAIN“

COAL Go to screen „COAL“

INT Go to screen „INTERLOCKS“

PARA Go to screen „PARAMETERS“

à Go to next screen

ß Go to previous screen

MES Go to screen „MESSAGES“

SYS Go to screen „SYSTEM“

FS-MOD Go to screen „FAILSAFE MODULS“

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Select screen with softkey

START Start push button

STOP Stop push button

INT Go to screens of interlocking

PARA Go to screens for parameter

à Go to next screen

ß Go to previous screen

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Basics of operation

The controller watches and controls the ignition and operation of fuels on a safe way.

In REMOTE mode the commands start and stop and the set points will give from central control room
(CCR). In LOCAL mode the commands start and stop and the set points will control from the local
HMI (human machine interface).

Additional for the regulating of fuel flow a possibility to switch between automatic control and manual
control is given.

Password - level

To change any settings or parameter a password with the right user is necessary. The default setting
of password is :

password user purpose

555 5 change settings, parameter and configuration

Change parameter values

If it is necessary to write a new value in the desired parameter field user have to touch the parameter
field à a key board and the login screen is automatically open and the user can write by touching the
soft keys the user name and password and after the new value.
If the value is right press ENTER à new set point will transferred to the controller and the screen
switch back to origin screen. Is the value wrong press ESC à old value is shown in the field.

Set time and date

Normally if the data interchange to CCR is ok the time and data will synchronised all the time to the
time and date of CCR.

If the communication is disturbed you can set time and/or date manually via HMI.

To set time and date you have to go to screen SYSTEM.

If you have written in the actual time and date you have to press CLOCK .

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ACKNOWLEGE / RESET

If a fault is present in the controller a fault memory is activated and the group goes in safe position
(closed valves).

By each new fault a signal – new fault - is activated. To reset the signal you have to press the ACK
button.

For acknowledging of 1 or more faults you have to press ACK button.

Is the reason of the fault solved you have to reset the fault memory by pressing again ACK button.
Otherwise the starting interlock of the group give not the enable signal for starting.

Change LOCAL – REMOTE

If the communication to remote system run successful you can switch the operation mode from
LOCAL to REMOTE by using the KEY SWITCH.

If the communication is disturbed (the feedback of LIVE signal does not come back in adjusted time)
automatically the controller goes in LOCAL mode – so the operator can react immediately.

Change set point in LOCAL mode

If the controller is in LOCAL mode the operator can write a new value in the desired set point field.
Operator have to touch the set point field à a key board is automatically open and the operator can
write by touching the soft keys the new value.
If the value is right press ENTER à new set point will transferred to the controller and the screen
switch back to origin screen. Is the value wrong press ESC à old value is shown in the field.

If the controller is in REMOTE mode the set point from remote system is shown in the field. Any
change of set point is not possible.

START and STOP fuel’s

All fuel’s and the ignitor are able to start and stop from the relevant screen if the controller is in
LOCAL mode. In REMOTE mode the commands are given from central control room (CCR).

Before you start any fuel or Ignitor call the relevant picture.
A stopping of any fuel or ignitor is always possible. To start a fuel or ignitor the starting interlock has to
be fulfilled.

The starting interlock is fulfilled if operation and starting interlock is green (see “Status of group”)

For start you have to press in same time START (see “Select screen with softkey”).

For stop you have to press in same time STOP (see “Select screen with softkey”).

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Screen START

After a successful start of controller this screen will shown automatically.

LOCAL REMOTE Indication of actual operation mode

FS MODUL it means 1 or more failsafe module are passivated

ACK it means a new fault is present

KILN T > 750°C it means kiln temperature is greater as MIN

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Screen MAIN BURNER

Screens Interlocking MAIN BURNER

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Screen IGNITOR

The starting interlock is fulfilled if operation and starting interlock is green (see “Status of group”)

For start you have to press in same time START (see “Select screen with softkey”).

For stop you have to press in same time STOP (see “Select screen with softkey”).

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Screens Interlocking IGNITOR

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Screen Parameter IGNITOR

Safety time XXXX failsafe parameters – not possible to change

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Screen HFO VALVE TRAIN

The starting interlock is fulfilled if operation and starting interlock is green (see “Status of group”)

For start you have to press in same time START (see “Select screen with softkey”).

For stop you have to press in same time STOP (see “Select screen with softkey”).

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Screens Interlocking HFO

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Screens Parameter HFO

Setting of regulator parameter:

dead band – DEAD inside of dead band the regulator does not react to any changes of actual
value
dimension: same as set point and actual value

proportional factor – GAIN with proportional factor you make regulator slower or faster
increase factor à regulator is faster
decrease factor à regulator is slower
dimension: less

integral time – TI with integral time you make the regulator more or less sensitive
dimension: seconds

max output – LMN_H limit of max output signal

dimension: %

min output – LMN_L limit of min output signal

dimension: %

IGN-POS position for start HFO firing

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Safety time XXXX failsafe parameters – not possible to change

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Screen COAL

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Screen MESSAGES

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Screen SYSTEM

THE FOLLOWING SCREENS AND POSSIBILITIES ARE

FOR WELL TRAINED PERSONAL!

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Screen FAILSAFE MODULS

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LOGIC

The start and Stop of fuel is realised by sequences. For trouble shooting the indication of the steps
is very important.

STEP = 0 operation interlock is not ok

STEP 1 - 49 starting steps
STEP 51 - 99 stopping steps

Definition of operation and start interlock:

- OPERATION INTERLOCK the operation interlock have to be always 1 (OK – green

indication); by loosing operation interlock all valves goes in
safe position (closed valves)

- START INTERLOCK the start interlock has to be 1 in time of activating start; a

change to 0 after has no influence

PROFIBUS DP – COMMUNICATION

For the data interchange between GRECO controller and DCS-system (scada system) there is a
communication device installed.

1 DP-DP Koppelung Ord.No. 6ES7-158-0AD01-0XA0

Baud rate max 12 Mbit/s

To DCS system
Start address Q 100.0 (outputs)
Length 64 bytes consistent

From DCS system

Start address I 100.0 (inputs)
Length 32 Byte consistent

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