MMD Design and Consultancy Ltd

A Member of the MMD Group of Companies

Cotes Park Lane, Cotes Park Industrial Estate, Somercotes, Derbyshire, DE55 4NJ

T: +44 (0) 1773 835533 E: sales@mmdsizers.com

F: +44 (0) 1773 835593 W: www.mmdsizers.com

Hardware And Control Philosophy

MMD
Sizing Stations

On Behalf of
REBASA
Project Number: J64461

Document Number: J64461-CP-01

Prepared By:

Prame Siva

MMD Design and Consultancy

Ltd
January 2015

Revision Reason For Issue Date Signature

A First Draft 19/01/2016

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This document(s) and any document(s) contained herein is deemed to be a confidential document(s) by the MMD Group of Companies and is intended for the sole use of the addressee(s).
This document(s) may not be disclosed (either wholly or in part), reproduced or distributed to any third parties without first obtaining the expressed written consent of the originator. All
intellectual property rights in respect of contained and/or attached information are reserved.

Registration No.: 01396760 (England and Wales)

Table of Contents
Hardware And Control Philosophy ....................................................................................... 1
1. Introduction ................................................................................................................... 3
2. Electrical System Parameters ...................................................................................... 4
2.1 Electrical Supply ........................................................................................................ 4
3. Electrical Control Philosophy: Automatic Operation of Drives ............................... 5
3.1 Start and Stop, Processing Material ......................................................................... 5
3.2 Emergency Stop ....................................................................................................... 5
3.3 Normal Processing Operation .................................................................................. 5
3.4 Auto Sequence Start (Forward) ................................................................................ 6
3.5 Auto Sequence Stop ................................................................................................. 6
3.6 Plant Fault (Trip Stop) .............................................................................................. 6
3.7 Sizer Stall (Recovery procedure) ............................................................................. 7
3.8 Customer Takeaway Conveyor System ................................................................... 7
4. Electrical Control Philosophy: Manual Operation Of Drive .................................... 8
4.1 Start and Stop Sizer motors from its associated motor controller keypad display unit
in Local operating mode: .................................................................................................... 8

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MMD Sizer Station - Hardware and Control Philosophy

1. Introduction

This document has been produced to provide an outline of the proposed control philosophy for the
operation of the new Sizer station from an Electrical prospective and in conjunction with MMD
standard requirements. This document does not detail mechanical, personnel, material handling or
any other control that may be required to operate the entirity of the new plant. We recommend that
this document is in part or in full incorporated into the complete design of the plant.

Note: This document is for MMD equipment only and not intended to supersede site
specifications or standards.

The control philosohpy should be read in conjunction with the following

J64461-BCD-001 Block Cable Diagram

J64461-PID-001 Process and Instrumentation Diagram

List of Abreviations

PLC = Programmable Logic Controller

LCP = Local Control Panel
MCCB = Molded Case Circuit Breaker

There are two available methods of operation, manual and automatic; the preferred method of
operation is automatic and controlled by the main plant PLC. On occasions it may be necessary to
operate the the Sizer in manual mode, to facilitate clearing of to blockages, carry out maintenance
etc.

Automatic Control:

The purpose of automatic control is to provide the facility to start the plant remotely via the main
plant PLC, to acheive sequence control for processing material. Selecting between automatic and
manual is done by a three position selector switch mounted on the auxiliary cabinet door. When in
automatic mode, a remote run signal from the main plant PLC will be required to initiate start up.

The motor must be in Remote Operating Mode on the drive controller keypad mounted on the
cubicle door. Only authorised personnel should carry out any alterations to the Drive
Controller.

1. On the keypad, press until Operating Mode is displayed

2. Press Remote inputs (2 of 3) is displayed
3. Press to store this mode.

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Manual Control:

The purpose of Manual control is to provide the facility to start and stop the Sizer via start and stop
push buttons located on the Local Control Panel door. Manual control must only be used to clear
materials from the Sizer in the event of blockages or for maintenance purposes only. Manual control
must not be used for normal operation.

2. Electrical System Parameters

2.1 Electrical Supply

The electrical power and control specification for the MMD Sizer station is as follows.
 Power 3 Phase - 460V AC, 60Hz
 Power 1 Phase - 230V AC, 60Hz
 Control - 24V DC
 Instruments - 24V DC.

The Sizer Local Control Panel, generally comprise of the following listed items:

Incomer / Auxiliary Cabinet:

The main incomer is a 500A rated Isolator, door interlocked, mounted inside the
Auxiliary/Marshalling Cabinet.
All electrical power to devices on the Sizer have this as the single point of distribution & isolation.

1. 230V AC & 24V DC Circuit distribution & protection

2. Common controls, PLC & Marshalling Section
3. Rotation sensor relay for Sizer.

The Auxiliary Cabinet door indication and control generally comprises of the following:

1. WHITE PLC power supply healthy lamp

2. RED Sizer motor common fault detected lamp
3. RED Emergency Stop pressed lamp
4. GREEN Takeaway conveyor running lamp
5. Amber Sizer rotation under speed lamp
6. 3 position selector switch for Sizer Auto-Forward/OFF/Manual-Reverse
7. GREEN Plant sequence start push button
8. BLACK Plant sequence stop push button
9. BLUE fault reset push button
10. Emergency stop push button.

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PLC

The PLC is an Allen-Bradley Micrologix 1200 24VDC 40 point and 2 x RS232 outputs.

1. PLC Micrologix 1200 AB1762L40BXBR

All inputs and outputs including spares will be wired to terminals within the marshalling section.

Drive:
Sizer Motor Compartment

The MMD Sizer Motor Controller generally comprises of the following.

1. Motor rated power converter with individual MCCB

2. Door mounted key pad
3. Protection for local 460V,230V & 24VDC control wiring
4. Associated wiring, trunking and terminals.

3. Electrical Control Philosophy: Automatic Operation of Drives

3.1 Start and Stop, Processing Material

The Sizer plant must be operated in Automatic Mode for processing material. In Automatic mode,
the Sizer drive will start and stop in sequence and all safety control devices are activated.

3.2 Emergency Stop

The emergency stop protection on the plant and Sizer Local Control Panel, irrespective of Manual or
Automatic control, will shutdown all of the 24V DC control circuits within the local control panel.
In the event of an emergency stop pressed, the sizer drive control circuitry will be de-energised
immediately and shutdown the sizer plant operation.

3.3 Normal Processing Operation

The operator, prior to operating the sizer and associated equipment, must carry out the following
checks:

External/Internal to the Sizing Plant:-

1. Sizer discharge chute not blocked
2. Gearbox oil level ok
3. No oil leaks
4. Sizer rotation sensor ok
5. Takeaway Conveyor (by others) must be running before Sizer plant starts

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Controls:-

1. The local control panel electrical supply isolator is switched on

2. All faults are cleared
3. Emergency Stop fault lamp off
4. All relevant circuit breakers are switched on
5. Sizer drive on “StandBy”.

3.4 Auto Sequence Start (Forward)

When the plant is started in Automatic Sequence Start from the LCP door; the selector switch in the
“Auto” position, the sequence of events will be as follows:

1. Pre-Start Siren for 10 Seconds (Optional)

2. Sizer main motor starts ( MMD-M1)
3. Sizer plant now ready for material.

3.5 Auto Sequence Stop

When the plant is shut down in Automatic Sequence from the LCP door by pressing the stop
pushbutton , the sequence of events will be as follows:

1. The operator should initiate sequence stop by pressing the Sequence Stop pushbutton on
the LCP door
2. Sizer main motor stops.
3. After 20seconds customer conveyor stops.

3.6 Plant Fault (Trip Stop)

A plant fault will occur in the event of any of the following developing a fault, the Sizer LCP
common fault detected lamp comes on:

1. Customer Takeaway Conveyor Fault

2. Sizer Loss of Rotation
3. Sizer Drive Fault
4. Emergency stop operated.

The sizer drive preceding the specific fault will immediately stop,and the drive after the fault will
continue to run until either the plant is shut down or re-started.

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Checks to carry out when Sizing:

External to the panels, mounted on the sizer plant:

1. Sizer discharge chute not blocked
2. LED on Sizer rotation sensor illuminates on and off.

View Local Control Panel:-

1. No Red fault lamps are on
2. No Common Fault/Underspeed faults (Loss of Rotation Amber lamps are not on).

3.7 Sizer Stall (Recovery procedure)

In the event that the sizer motor has stalled the operator should proceed as follows.
1. Inspect the sizer shafts to determine the reason for the stall
2. If there is metal located within the shaft, this needs to be removed prior to re-starting.
3. If there is no metal identified, then the sizer should be prepared for Manual-Reverse
operation.
4. Place the Sizer position selector switch to the Manual- Reverse position. This will allow
the Sizer to run in reverse.
5. If the sizer runs in reverse, run for no more than two minutes at a time to remove as much
of the material as possible.
6. If the sizer remains stalled or only reverses slightly, the motor will stop again
automatically after 6 seconds due to loss of rotation. In this event wait a further 90
seconds and start the Sizer forward. Again if the Sizer stalls and does not remove the
blockage then isolate the motor (LCP) and proceed to remove the blockage by hand.
7. Re-energise the LCP only when clear and press RESET.
8. Upon clearing of any blockage and the Sizer drive moves freely in either forward or
reverse, then switch the Sizer direction selector switch to Automatic-forward and press
the sequence start pushbutton to bring the sizer motor online.

3.8 Customer Takeaway Conveyor System

The clients takeaway conveyor system, if provided, must always be running before the MMD 850
Sizer Starts and remains running for a time after the MMD 850 Sizer stops. This is to enable material
to be cleared off the takeaway conveyor and to avoid depositing material from the sizer discharge
chute on to a stationary belt.

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4. Electrical Control Philosophy: Manual Operation Of Drive

4.1 Start and Stop Sizer motors from its associated motor controller keypad display
unit in Local operating mode:

Follow the below steps to start an individual motor independently from the drive controller door key
pad.

1. On the keypad, press until Operating Mode is displayed

2. Press Remote inputs (2 of 3) is displayed
3. Press or until Local panel (1 of 3) is displayed
4. Press to store this mode
5. Press to start the motor
6. Press to stop the motor
7. Press button to choose direction of motor (ONLY USE THIS BUTTON FOR THE
SIZER MOTOR)
8. To return settings to original state, follow the same steps above and store the Remote
inputs (2 of 3) option.

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