Technical Guidelines for Machinery and Equipment · 1/20/2015 · voestalpine Tubulars GmbH & Co...

voestalpine Tubulars GmbH & Co KG

Technical Guidelines for Machinery and Equipment

Technical Guidelines for Machinery

and Equipment

Version January 20, 2015

Applicability:

These guidelines for machinery and equipment are an integral part of agreements when purchasing

machinery and equipment.

If the CO deems that deviations from these specifications are necessary or appropriate, then these are

to be agreed separately in writing with the CP.

Abbreviations:

CP = Contracting Party

CO = Contractor



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Change Index

Date of Change Chapter

14.01.2015 3.1, 3.3, 3.4.1, 3.4.2, 3.6.2, 3.6.3, 3.6.4, 3.6.5, 3.7.1, 3.7.2, 3.7.3, 3.7.4, 3.7.5,

3.8.1, 4.2.8, 5.7, 7



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1 General information ................................................................................................................................ 7

1.1 Rules of engineering ..................................................................................................... 7

1.2 Spare parts stock .......................................................................................................... 7

1.3 General conditions ....................................................................................................... 7

1.4 CE-marking for concatenated machinery or equipment ................................................. 8

1.5 Subcontractor adherence to guidelines ......................................................................... 8

1.6 Other terms ................................................................................................................. 8

2 Tasks ....................................................................................................................................................... 8

2.1 Duty to obtain information ........................................................................................... 8

2.2 Risk assessment ........................................................................................................... 8

2.3 Functional test ............................................................................................................. 9

2.4 Training ....................................................................................................................... 9

2.5 Technical documentation ............................................................................................. 9

3 Mechanical specifications ..................................................................................................................... 10

3.1 General ...................................................................................................................... 10

3.2 Screws ....................................................................................................................... 10

3.3 Drives ........................................................................................................................ 10

3.4 Lubrication ................................................................................................................. 10

3.4.1 Oil and grease filling, Oil sight glass .............................................................................................. 11 3.4.2 Lubrication lines ............................................................................................................................ 11 3.4.3 Manufacturers of small and medium-sized systems ..................................................................... 11

3.5 List of mechanics manufacturers ................................................................................. 11

3.6 Hydraulics .................................................................................................................. 11

3.6.1 General .......................................................................................................................................... 11 3.6.2 Hydraulic pipes/tubes ................................................................................................................... 11 3.6.3 Hydraulic tank, Oil level indicator ................................................................................................. 12 3.6.4 Hydraulic accumulator .................................................................................................................. 12 3.6.5 Inscription ..................................................................................................................................... 12 3.6.6 List of hydraulics manufacturers ................................................................................................... 12

3.7 Pneumatics ................................................................................................................ 14

3.7.1 Air oiling ........................................................................................................................................ 14 3.7.2 System separation ......................................................................................................................... 14 3.7.3 Valves ............................................................................................................................................ 14 3.7.4 Pipes and hose connection............................................................................................................ 14 3.7.5 List of pneumatics manufacturers ................................................................................................. 14

3.8 Operating data ........................................................................................................... 14

3.8.1 Compressed air ............................................................................................................................. 14 3.8.2 Central hydraulics .......................................................................................................................... 14 3.8.3 Water ............................................................................................................................................ 15

4 Electrical specifications ......................................................................................................................... 16

4.1 Installation of switch cabinets .................................................................................... 16



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4.1.1 General .......................................................................................................................................... 16 4.1.2 Identification system ..................................................................................................................... 16 4.1.3 Location of parts ........................................................................................................................... 17 4.1.4 Location of terminal strips/cable fittings ...................................................................................... 17 4.1.5 Free space ..................................................................................................................................... 18 4.1.6 Switch cabinet climate control ...................................................................................................... 18 4.1.7 Protection class ............................................................................................................................. 18 4.1.8 Service socket and switch gear cabinet lighting ............................................................................ 18

4.2 Installation guidelines ................................................................................................ 18

4.2.1 Cables and conductors .................................................................................................................. 18 4.2.2 Movable cable routing .................................................................................................................. 19 4.2.3 Terminal strips ............................................................................................................................... 19 4.2.4 Connection of sensors ................................................................................................................... 19 4.2.5 Identifying parts and cables .......................................................................................................... 19 4.2.6 Switching devices .......................................................................................................................... 20 4.2.7 Electrical drives and associated equipment .................................................................................. 20 4.2.8 Signaling devices ........................................................................................................................... 20 4.2.9 Conductor colors ........................................................................................................................... 20

4.3 Electrical supply, protective measures ........................................................................ 20

4.3.1 Mains voltage ................................................................................................................................ 20 4.3.2 Protective measures ...................................................................................................................... 21 4.3.3 Control circuits .............................................................................................................................. 21 4.3.4 Power supplies and control transformers ..................................................................................... 21 4.3.5 Potential equalization ................................................................................................................... 21 4.3.6 Protecting transformers from overloading ................................................................................... 21 4.3.7 Switching inductive loads .............................................................................................................. 22 4.3.8 EMC-conform installation ............................................................................................................. 22 4.3.9 Operation and protection of induction motors ............................................................................ 22

4.4 Control equipment, operator interface ....................................................................... 23

4.4.1 EMERGENCY STOP device ............................................................................................................. 23 4.4.2 Operating modes ........................................................................................................................... 23 4.4.3 Faults and alarms .......................................................................................................................... 23

4.5 Programmable control systems................................................................................... 24

4.5.1 Selection and setup ....................................................................................................................... 24 4.5.2 Installation ..................................................................................................................................... 24 4.5.3 Interfaces ...................................................................................................................................... 24 4.5.4 Decentralization ............................................................................................................................ 24 4.5.5 ASI bus ........................................................................................................................................... 25 4.5.6 Programming languages ................................................................................................................ 25 4.5.7 Program structure ......................................................................................................................... 25 4.5.8 Simatic S7 protection levels .......................................................................................................... 25 4.5.9 Safety controllers .......................................................................................................................... 25

4.6 CNC systems and industrial computers........................................................................ 25

4.7 Documentation of electrical equipment ...................................................................... 26

4.7.1 Reports and documents ................................................................................................................ 26 4.7.2 PLC software documentation ........................................................................................................ 26 4.7.3 Documentation for CNC controllers and industrial computers ..................................................... 27 4.7.4 Installed components and systems ............................................................................................... 27

5 Specifications for instrumentation and control of Furnaces ................................................................... 28

5.1 Accessibility ............................................................................................................... 28



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5.2 S7/Software ............................................................................................................... 28

5.2.1 Structure ....................................................................................................................................... 28 5.2.2 General Information ...................................................................................................................... 28

5.3 Pipes .......................................................................................................................... 29

5.3.1 Impulse pipes ................................................................................................................................ 29 5.3.2 Grounding and paintwork ............................................................................................................. 29 5.3.3 Pipes for Ignition Burner ............................................................................................................... 29

5.4 UV-Sensor and Ignition burner .................................................................................... 29

5.5 Measurements ........................................................................................................... 30

5.5.1 Quantity Measurements ............................................................................................................... 30 5.5.2 Oxygen Measurements ................................................................................................................. 30 5.5.3 Exhaust Measurements ................................................................................................................. 30 5.5.4 Pyrometer Measurements ............................................................................................................ 30

5.6 Switch cabinets .......................................................................................................... 30

5.7 Limit values ................................................................................................................ 30

5.8 Documentation .......................................................................................................... 30

6 Industrial Computers ............................................................................................................................. 30

7 APPENDIX A: Electrical parts (approved list) ......................................................................................... 31

8 APPENDIX B: voestalpine Tubulars S7 software specifications .............................................................. 37

8.1 Liability disclaimer...................................................................................................... 37

8.2 Hardware configuration ............................................................................................. 38

8.3 Structuring ................................................................................................................. 39

8.3.1 Programming languages and standard software .......................................................................... 39 8.3.2 Program structure ......................................................................................................................... 39 8.3.3 General functions .......................................................................................................................... 39 8.3.4 Equipment functions ..................................................................................................................... 40

8.4 Marker organization ................................................................................................... 40

8.4.1 Marker assignment: general ......................................................................................................... 40 8.4.2 Marker assignment: automatic block ............................................................................................ 41 8.4.2.1 Without safety control ............................................................................................................. 41 8.4.2.2 With safety control ................................................................................................................... 41 8.4.3 Marker assignment: drive ............................................................................................................. 41 8.4.4 Marker assignment: controller ...................................................................................................... 41

8.5 Structure of functions ................................................................................................. 42

8.5.1 General .......................................................................................................................................... 42 8.5.1.1 General FC200 .......................................................................................................................... 42 8.5.1.2 Data preparation HMI FC202 .................................................................................................... 42 8.5.1.3 Operating messages FC204 ...................................................................................................... 42 8.5.1.4 Material tracking FC206 ........................................................................................................... 42 8.5.1.5 Preselection/operating modes FC208 ...................................................................................... 42 8.5.1.6 Analog value processing FC190: ............................................................................................... 42 8.5.1.7 Calculations, material tracking (FC170-179) ............................................................................. 43 8.5.1.8 Profibus error analysis .............................................................................................................. 43 8.5.2 Equipment areas ........................................................................................................................... 43 8.5.2.1 Automatic (e.g. FC210) ............................................................................................................. 43 8.5.2.2 Modules (e.g. FC220) ................................................................................................................ 43



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8.5.4 Safety technology .......................................................................................................................... 44 8.5.4.1 Parameter safety program DB899 ............................................................................................ 44 8.5.4.2 DB safety DB900 ....................................................................................................................... 44 8.5.4.3 General FC902 .......................................................................................................................... 44 8.5.4.4 Emergency stop FB901 ............................................................................................................. 44 8.5.4.5 Safety doors FB902 ................................................................................................................... 44 8.5.4.6 Light grid/light curtain FB903 ................................................................................................... 44 8.5.4.7 Other safety signals FB904 ....................................................................................................... 44 8.5.4.8 Safety circuits FB911, 912, … .................................................................................................... 44

8.6 Symbols ..................................................................................................................... 45

8.7 Error messages ........................................................................................................... 46

8.8 Data structures for HMI and Profibus .......................................................................... 47

8.8.1 Drive UDT101 ................................................................................................................................ 47 8.8.2 Analog values UDT102 .................................................................................................................. 48 8.8.3 Ramp generators/target value selection UDT103 ......................................................................... 48 8.8.5 Controller UDT104 ........................................................................................................................ 49 8.8.7 Drive structure for Profibus control UDT110 (e.g. PPO4) ............................................................. 50

8.9 Visualization .............................................................................................................. 51

8.9.1 Operator logon .............................................................................................................................. 51 8.9.2 Icons .............................................................................................................................................. 51 8.9.3 Alarm messages ............................................................................................................................ 51 8.9.4 Archiving ........................................................................................................................................ 51 8.9.5 Color regulations ........................................................................................................................... 51

8.10 Notes on the example project ..................................................................................... 52

8.10.1 Equipment control .................................................................................................................... 52 8.10.2 Safety controller ....................................................................................................................... 52



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1 General information General information

If it is not possible to adhere to these guidelines, then the voestalpine Tubulars project contact is to be

informed immediately. Modifications or additions must be approved in writing.

1.1 Rules of engineering The supplier guarantees that the machinery and equipment that is to be offered or delivered meets the

specified and listed requirements for machinery and equipment and the features and properties

defined therein. Such machinery and equipment is to be implemented in accordance with the generally

acknowledged state of the art.

1.2 Spare parts stock After the required number of drives, switching devices, hydraulic and pneumatic devices, etc. has

been defined, the Contracting Party is to be consulted so that we have the opportunity to adjust them

to our internal spare parts stock.

1.3 General conditions All delivered machinery, machine parts, switch cabinets, and equipment must meet the guidelines,

standards, regulations and state of the art at the time they are introduced on the market.

It is especially important to adhere to the latest version of the following regulations:

1. Applicable EU guidelines and those regulations that have been adopted into

Austrian law, especially:

2. Machine Safety Regulation MSV2010

3. Low Voltage Equipment Regulation in accordance with Low Voltage Directive 2006/96/EC

4. Electromagnetic Compatibility Regulation (in accordance with EMC Directive 2004/108/EC)

5. ÖVE, VDE Directives to be applied, especially:

6. ÖVE E 8001-6-61 Erection of electrical installations with rated voltages – Verification – Initial

verification

7. ÖVE E 8001-6-63 Erection of electrical installations with rated voltages – Verification –

Certification and reporting

8. ÖVE EN 60 204-1 Electrical equipment of machines

9. ÖVE EN 60 439 Low voltage switching device combinations

10. ÖVE EN 50 081-2 EMC emission – Part 2: Industrial sector

11. ÖVE EN 50,082-2 EMC immunity – Part 2: Industrial sector

12. ÖNORM EN ISO 12100 Safety of machinery – General principles for design – Risk

assessment and risk reduction

13. EN ISO 13849 Safety of machinery – Safety-related parts of control systems

14. EN IEC 62061 Safety of machinery – Functional safety of electrical, electronic, and

programmable electronic control systems

15. Harmonized European standards



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16. Recognized rules of engineering

17. CE marking and any necessary declarations of conformity are to be applied

18. Official requirements

19. voestalpine Tubulars identification system (equipment abbreviations and location

codes will be issued by the Contracting Party)

20. Industrial thermoprocessing equipment EN476-1 and EN476-2

1.4 CE-marking for concatenated machinery or equipment Machinery and equipment that is concatenated with other machinery and equipment also has to have

a CE marking or a declaration of conformity. If the safety of the entire installation is dependent on the

interfaces to other parts (e.g. locks, emergency stop circuits), all specifications must be given to the

purchaser and the supplier of the connected parts in order to ensure the conformity of the entire

machinery/equipment chain.

In the case of machine parts, all information necessary to perform any required conformity tests and

risk assessment (in accordance with the EU machinery guideline or machine safety regulations) must

be made available to the purchaser.

1.5 Subcontractor adherence to guidelines

The Contractor is fully responsible to the Contracting Party for adherence to these guidelines. If the

Contractor uses third parties to fulfill the contracted services, then the third parties must be included in

the obligation to adhere to these guidelines.

1.6 Other terms If there is reason to believe that the CO did not fully or only partly adhere to the electrical guidelines,

then the CP reserves the right to have the machinery/equipment audited by an independent

organization (e.g. TÜV, etc.) to determine whether the electrical installation adheres to the

guidelines. If any deficiencies are found, then the cost of the external audit and the costs of fully

remedying the deficiencies shall be borne by the CO.

2 Tasks

2.1 Duty to obtain information The electrical equipment used must take into account the operating environment, the climatic

conditions, and any special existing conditions. The Contractor is obliged to obtain information about

these conditions.

2.2 Risk assessment



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The risk assessment must be submitted to the CP together with the documentation. The assessment

must state which performance level or SIL level was implemented. When placing the order, the CP

wants to know which protection level is planned since the operating modes also need to be defined at

this point in time.

2.3 Functional test

Before it is put into operation, the equipment should undergo a functional test. All settings must be

equivalent to the operating state after the functional test is completed. The Contracting Party is to

receive a written test report.

In general, each Contractor is responsible for his scope of delivery. This also includes proper

functioning across interfaces (e.g. overall functional of locking must work).

2.4 Training Appropriate training for planning, operating, and maintenance personnel is to be defined in due time in

consultation with the Contracting Party.

It is agreed that both the Contractor and the Contracting Party will name a contact who will be

responsible for all training and educational activities.

The Contractor is to train the Contracting Party’s employees such that they are theoretically and

practically capable of supervising, operating, and maintaining the delivered equipment. The training

will not only cover service and operating tasks during normal, problem-free operation. It will also

include activities related to start up, shut down, and what to do in the case of failures and problems.

The Contracting Party’s personnel will complete the necessary external and internal theoretical

training and when possible take the exams and take part in putting the equipment into operation. The

Contractor’s personnel will provide the necessary information and consulting services. If possible, the

practical training will take place during the installation and test operation under the supervision of the

Contractor’s experts.

The specific dates of the training activities will be jointly defined based on the availability and working

hours of the Contracting Party’s personnel.

2.5 Technical documentation The technical documentation is an integral part of each piece of machinery/equipment. The execution

and scope must meet the applicable European standards included all cross-references to IEC

publications as well as the scope of delivery at acceptance.

In general, the following content must be included:

• Precise installation plans including all machine parts and modules

• Maintenance and repair instructions with the necessary engineering plans

• Hydraulic and pneumatic schematics

• Spare parts lists

• Electrical documentation



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• When using explosive substances (gases, solvents, dust), any necessary information needed

to create an explosion protection document (in acc. with VEXAT) must be submitted to the

purchaser.

• In the case of machinery and equipment that is concatenated with other machinery and

equipment, all specifications for the connected parts must be given to the purchaser and

supplier in order to ensure conformity of the entire machinery/equipment chain (e.g.

information about locks, emergency stop circuits).

• In the case of machine parts, all information necessary to perform any required conformity

tests and risk assessment (in accordance with the EU machinery guideline or machine safety

regulations) must be made available to the purchaser.

3 Mechanical specifications

3.1 General

All machine parts must be easy and safe to access for repair. Every piece of the equipment must

function properly and be made of the material best suited for the intended use. The materials must be

coordinated so that they function well together.

All equipment parts that need to be operated, regularly inspected or maintained must be safely

accessible using appropriate walkways or platforms.

Mounting aids for inaccessible assemblies have to be in scope of supply. ( special lifting device,

slings)

3.2 Screws The following screws should preferably be used:

• Hexagon socket cap screws DIN 912

• Hexagon screws DIN 931

• Socket set screws DIN 916

• Countersunk head screws DIN 7991

3.3 Drives If only one turning direction is allowed for drive shafts and spindles, then this must be indicated with a

conspicuous arrow.

Every gear box and gear motor has to have a nameplate on which you can read gear ratio, number of

revolution and serial number.

3.4 Lubrication If technically feasible, maintenance-free elements are to be used. Automatic central lubrication is to be

used where it makes sense or is expressly requested.

When connecting to an existing dual-line central lubrication system, ZV-B or ZV-C distributors from

Bijur Delimon are to be used.

Single lubrication points must be marked and arranged such that they are easy to access.



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3.4.1 Oil and grease filling, Oil sight glass

Sight glasses of gear boxes, lubricant container and so on should be readable without entering the

safety area. The three levels for min, max and operating condition must be easy to read.

The filling and refilling should be possible without technical aids (ladder) and from outside the safety

area.

3.4.2 Lubrication lines The guidelines for lubrication lines refer to the guidelines for hydraulic lines. (3.6.2)

3.4.3 Manufacturers of small and medium-sized systems

Progressive distributors Bijur Delimon, BekaLube

Single line distributors Bijur Delimon, BekaLube

3.5 List of mechanics manufacturers

Material Supplier

Rolling bearings SKF, INA, FAG, NSK, TIMKEN

Cardan shafts Voith, Elbe, GWB

Gear couplings Malmedie, Flender

Elastic couplings KTR, Stromag, Rexnord, Flender

Gear motors Bauer, SEW Eurodrive

Pumps for industrial water EGGER, KSB

Cooling tower COFELY Kältetechnik

3.6 Hydraulics 3.6.1 General

Hydraulic equipment is to be installed in accordance with the currently valid DIN standards. Only

original parts (e.g. valves, devices, etc.) that have not been changed whatsoever can be installed and

used. The connection to the central hydraulic system must be equipped with safety valves.

3.6.2 Hydraulic pipes/tubes

Tubes are to be installed such that they cannot be kinked, trapped, or abraded. The inside walls of

pipes and tubes must be cleaned before final installation. Pipelines that end (P/T/L) are to be closed

with plugs.

If pipes have contact with water and scale they have to be made of stainless steel (1.4571, 1.4541).

Hoses which are exposed to radiant heat have to be delivered with protection coat. Hose dimensions

and fittings must be written down in the documentation.

The marking of pipes must be in accordance to DIN 2403.



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3.6.3 Hydraulic tank, Oil level indicator In principle there is hydraulic oil in accordance to ISO VG 46, DIN 51524/Teil 3 to use. The tank has to

be equipped with to additional connections (R 2”) and stopcock. (additional draining, filtering)

The three levels for min, max and operating condition must be easy to read. Also there has to be a

marking for those three levels.

3.6.4 Hydraulic accumulator The usage of hydraulic accumulators shall be in accordance to the pressure vessel regulation DGVO

and DGÜW-VO. All required documents and the proof for fatigue strength are to deliver. Bubble

accumulators are preferred. The accumulators have to be equipped with an automatic relief valve at

the oil side.

3.6.5 Inscription The hydraulic unit is named with an inscription plate which contains the name of the machine, plant

etc. and the drawing number of the hydraulic plan.

The plate is mounted at the associated valve stand or table.

All hydraulic components are lettered, as shown in the table below, on not removable plates in

accordance to the hydraulic plan.

Component description electrically operated valve function, direction, position number and electrical

labeling pressure switch position number, pressure and electrical labeling Filter position number, manufacturer product name hydraulic zylinders serial number hydraulic accumulator manufacturer, year of manufacture, gas

pressure, volume other components position number 3.6.6 List of hydraulics manufacturers Material Description Supplier

Hydraulic components and accessories Bosch Rexroth

Hydraulic cylinders Series CDH1 or CDH2

Seal version: M = standard sealsystem

Float switch Bosch Rexroth

Typ ABZMS-41,

level and temperature measurement (RTA)

Line connection ISO 228-1 pipe threads or Bosch Rexroth SAE flange

Hydraulic fittings DIN fittings (24° sealing cone) Ermeto

Hydraulic flanges for pressure lines SAE flange or AVIT square flanges

Hydraulic flanges for tank lines DIN 2633



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Hose lines 24° sealing cone connection for DIN fittings or SAE

flange



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3.7 Pneumatics 3.7.1 Air oiling In case of pneumatic operated device is an air oiling possible. Preferred are pneumatic maintenance

units including filter, regulator and oiler with automatic condensate outlet.

Ensure that all connections and adjustment screws are accessible.

3.7.2 System separation Every assembly that has its own decentralized controller can be separated from the system manually

and has to be depressurized by an electrically operated valve. (monitoring with pressure switch)

A sharp and sudden increase of the pressure must be prevented.

3.7.3 Valves Valves which are electro pneumatically actuated or pneumatically actuated have to have a manually

emergency function. Valve voltage 24V DC.

All Valves should be mounted in a cabinet with a view window.

3.7.4 Pipes and hose connection All connections between valves and actuators are made with hydraulic tubes or hydraulic hoses. If

they are in contact with water and scale they have to be made of stainless steel. (1.4571, 1.4541)

The marking of pipes must be in accordance to DIN 2403.

For connections in dry area are polyamide pipes with plug-connection are possible.

3.7.5 List of pneumatics manufacturers

Material Description Supplier

Pneumatic components and accessories Festo, Norgren

Pneumatic valves ISO sizes 1 to 4 Festo, Norgren

(base mounting valves)

Pneumatic cylinders ISO cylinder Festo, Norgren

Pneumatic fittings 24° light series DIN fittings or push-in fittings

3.8 Operating data 3.8.1 Compressed air Site grid: p = 6 bar

Compressed air is technically dry with less content of oil and water.

Dew point: +3°C

Oilcontent: 0,1mg/m³

Particle size: 0,3µm

3.8.2 Central hydraulics

Operating pressure: 120 bar

Temperature: 60 °C



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3.8.3 Water Drinking water

Pressure: 3.5 bar

Temperature: 10 °C

Water hardness: 7.5 °dH

Industrial water

Pressure: 5 bar

Temperature: 10 °C

Water hardness: 12 °dH

Open circuit

Pressure: 4 bar

Temperature: 25 °C

Water hardness: 12 °dH

Closed circuit

Pressure: 4 bar

Temperature: 21 °C

Hardness: 12 °dH

Deep well water analysis, November 2013 Parameter Analysis

method Unit Measured value Limit

values1 Guide values2

Color DIN EN ISO 7887 (C1)

-- colorless -- --

Odor DIN 38 403 – B 1/2

-- odorless -- --

Turbidity qualitative -- clear -- -- Taste DIN 38 403 – B

1/2 -- none -- --

Temperature DIN 38 404 – C 4

°C 9.9 -- 25

pH value DIN 38 404 – C 5

-- 7.34 -- 6.5 - 9.5

Electrical conductivity

ÖNORM EN 27 888

µS/cm 552 -- --

Total hardness DIN 38 409 – H 6

°dH 10.4 -- --

Carbonate hardness

DIN 38 409 – H7

°dH 10.0 -- --

Oxidizability (as KMnO4 index)

EN ISO 8467 mg/l 0.12 -- 5.0

Ammonium DIN 38 406 – E 5

mg/l < 0.01 -- 0.5

Iron DIN EN ISO 17294 – 2

mg/l < 0.010 -- 0.2

Manganese DIN EN ISO 17294 – 2

mg/l < 0.001 -- 0.05



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Nitrate DIN EN ISO 10304 – 1

mg/l 5.9 50 --

Nitrite DIN EN 267777

mg/l < 0.01 0.1 --

Chloride DIN EN ISO 10304 – 1

mg/l 26.6 -- 200

Sulfate DIN EN ISO 10304 – 1

mg/l 20.9 -- 250

Calcium DIN EN ISO 17294 – 2

mg/l 54.5 -- --

Potassium DIN EN ISO 17294 – 2

mg/l 1.75 -- --

Magnesium DIN EN ISO 17294 – 2

mg/l 12.0 -- --

Sodium DIN EN ISO 17294 – 2

mg/l 14.0 -- --

1Parameter values, 2Indicator parameter values in acc. with Drinking Water Ordinance 304/2001 following 254/2000 n.a. = not analyzed

4 Electrical specifications

4.1 Installation of switch cabinets 4.1.1 General

• Switch cabinets can only contain electrical parts, modules, or systems.

• The doors on the cabinets are not to be wider than 800 mm and are to be equipped with a

double-bit key lock. The depth of the cabinet is not to exceed 600 mm.

• The switch, control and distribution cabinets, including all installed components, must be easy

to access for maintenance and servicing.

• Control cabinets are to be used for command and signaling devices, text displays, and control

consoles. It is prohibited to use control cabinets as switch cabinets.

• Exceptions must be expressly agreed to by the Contracting Party. In cabinets that are 200 mm

x 200 mm or larger, terminal boxes and junction boxes with hinges must have a cover that

opens 170 degrees.

• Wiring is to be done using plastic conduits on mounting plates.

• Devices in cabinets with hinged doors are to be connected using a protective tube or

multiconductor lines. If protective tubes are used, an extra spare wire is to be inserted for use

as a pulling wire.

• The wiring must adhere to the specified power circuit diagram.

• The wiring must be done with flexible conductors.

• Switching devices can have no more than two conductors per terminal point.

4.1.2 Identification system



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voestalpine Tubulars has defined company-specific definitions for implementing the standard.

Electrical designations such as

• Equipment abbreviations e.g. for pipe cutting machine = RTM1 and a

• Function group (=RTM1.00; =RTM1.01; etc.)

• Location designation for switch cabinets, control cabinets, and terminal boxes, e.g. +12E302,

will be jointly defined by the CO and the CP (electrical department).

The designation will be placed in a suitable location near the circuit symbol. It represents the

relationship between the part, the equipment, and the various circuit documents (circuit diagram, parts

list, electrical wiring diagrams, instructions). For easier servicing, the designations can be placed

completely or partially on or near the part.

Cable designations are to include: From location, to location and corresponding number

1-100 400 V cables

101-199 Cables for emergency power off (switches)

201-299 230 V cables

500-509 24 V cables

510 Cables for 24 V valves

901 - 999 Signal and measuring cables (0-10 V, 4-20 mA, PT100,

analog values) e.g. 12E305-12E403/.501

4.1.3 Location of parts Electrical parts that are not meant for panel mounting are not to be mounted on cabinet doors or walls.

They are only to be mounted on mounting plates and top hat rails designated for this purpose.

The parts should be arranged in clear, functional groups. Care must be taken to ensure adequate

space between the parts. The installed switching devices must be at least 0.2 m above the cabinet

floor. Devices that emit a lot of heat are to be mounted in the upper part of the cabinet.

4.1.4 Location of terminal strips/cable fittings The spacing between the cable routing in the cabinet and the terminal strip above must be at least

150 mm. A cable duct is to be installed below the terminal strip (see appendix).

The cables in the cabinet must be routed in accordance with the protection class of the cabinet and

must relieve tensile stress (C-rails). Any cable fittings must be plastic.

Each terminal strip can have no more than one conductor per terminal point. The use of loose

terminals is not permitted. All connections must be clamped or plugged connections. With the

exception of data and measuring conductors, no solder connections are allowed.

Screw terminals on all devices are to be equipped with a thrust piece, clamping bracket or sleeve to

protect the conductor.

Interconnections between adjacent terminals must be carried out using jumper bars (no jumper wires).

Differing potentials and control signals are to be placed on separate terminal strips. At least 10% free

space is to be maintained between the terminal blocks. Cable trays are to be mounted on both ends of



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the terminal strips. Enough space must be left between the cable trays to replace a defective device or

terminal.

4.1.5 Free space In switch cabinets and control cabinets, at least 20% of the available mounting space must be

reserved as free space. This space is to be divided into areas for the later mounting of terminals,

switching devices, and components.

4.1.6 Switch cabinet climate control The climatic conditions for all parts, modules, and systems contained in a switch cabinet must adhere

to the respective manufacturer specifications. Under no circumstances should the air temperature

exceed 40 °C. The determination of the required climate control system must be calculated based on

a dissipation power calculation that the Contracting Party can follow. The climate control system is to

be controlled and monitored using a thermostat and door switches. Defects and overtemperatures

must be signaled to prevent electronic systems from failing due to overtemperature.

In a worst case situation, the ambient temperature in halls can reach 40 °C. For switch cabinets in

which there is high power dissipation, suitable cooling measures must be taken to make sure the

above-mentioned maximum temperature is not exceeded. Switch cabinets in the field are to be

equipped with water/air heat exchangers.

4.1.7 Protection class Cabinets that are to be installed in the vicinity of the equipment/machine must have at least protection

class IP54. Cable conduits, fans, and other openings subsequently added to the cabinet must not

degrade the protection class. In general, open switch cabinets with a wooden block to prevent

stumbling are to be installed in the switch rooms.

4.1.8 Service socket and switch gear cabinet lighting Internal cabinet lighting is required for cabinets that are at least 1,500 mm high. A door switch is to be

used to turn off the lighting when the cabinet is closed. A 230 V 50 Hz socket is required for repair and

servicing. This socket must be fed from the main switch and be protected with an LS-FI 13A circuit

breaker.

4.2 Installation guidelines 4.2.1 Cables and conductors Only flexible conductors (stranded wire) are to be used to install machinery and equipment. Outside

the cabinets, the conductors and cables are to be equipped with oil-proof and/or acid-proof insulation,

depending on the environment. The ambient temperatures are also to be taken into account when

selecting cables.



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Cables and conductors outside the cabinets are to be routed in designated cable trays, protective

tubes or hoses, or metal cable ducts. Under no circumstances are cables to be routed to equipment or

machine parts just as they are, or with easily disconnected connections, or in plastic ducts.

Each part is to be connected to the cabinet, terminal box, or fieldbus distributor using a separate,

flexible cable. Conductors from stranded conductors must have end sleeves for screw connections.

Soldered connections are not allowed. Shielded, twisted pair conductors are to be used for data lines.

Only shielded conductors are to be used for motor lines to frequency-controlled drives or servo drives.

Suitable, highly flexible conductors are to be used for connections to frequently moved parts. They are

to be mounted such that the conductor is subject to as little bending or tensile stress as possible,

especially at the fixing points. The conductor loop must be large enough that the minimum permissible

bending radius is maintained when moved. Conductors that are frequently moved must be installed

such that they can be plugged in before and after they are moved. All connections for electrical parts

(e.g. initiators, valve coils) must be plugged connections. If this is not possible, the connecting

conductor must be routed to the distribution board or control cabinet using the shortest possible cable.

4.2.2 Movable cable routing Cables that are bundled or routed in energy chains and often moved must be equipped with plugs

before and after the interfaces to the movable section so that only the movable part of the cable has to

be replaced in the case of wear. Energy chains have to be open on one end to make it easier to

replace defective cables. Cables and conductors must be specified for routing in energy chains or

regular movement. A terminal box can be alternatively used.

4.2.3 Terminal strips Terminal strips are to be divided according to main or auxiliary electrical circuits. Each energy cable

must have a zero and protective earth output. Terminals and terminal strips are to be permanently and

clearly marked in agreement with the power circuit diagram. The terminals are to be sequentially

numbered from left to right. Each conductor is to have a terminal point. It is prohibited to have two

conductors in a single terminal.

4.2.4 Connection of sensors For inductive or optical proximity sensors, only M8 and M12 round plug connectors for straight or 90 °

4-pin sockets are allowed. If there is no function or voltage display on the sensor, or it is installed such

that the display cannot be seen, then the cable sockets should each have an LED to indicate the

function and voltage display.

4.2.5 Identifying parts and cables All electrical parts must be designated in accordance with the power circuit diagram. In the case of

cables, the designation must be located in a very visible location using label holders on cable ties and

must be resistant to abrasion, UV, water, oil, and solvents.

Part designations are to be mounted on machinery using oil-proof screwed or riveted plates (type to

be defined in the order confirmation) and must conform to EN/IEC 61346. Switching device



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designations must be in accordance with the circuit diagram and are to be mounted on both the device

and the mounting plate. Internal cabling must be labeled with conductor numbers in accordance with

the connecting terminal designation. PLC I/O cards must be labeled with the absolute address of the

respective part designation.

4.2.6 Switching devices Only approved standard electronics products listed in the voestalpine Tubulars approved list are to be

used. All devices such as contactors, power supplies, transmitters, etc. are only to be installed in their

original state, i.e. without changing electrical or mechanical characteristics. For switching devices such

as contactors and circuit breakers, snap-on mounting is to be used on hat rails.

4.2.7 Electrical drives and associated equipment

To be agreed

4.2.8 Signaling devices

For several functions switches (temperature, pressure, differential pressure) shouldn’t be used, the

signals should be implemented as an analogue value (4-20 mA) to the PLC. In the PLC the switch

point is deposited. The only exception for using switches is, if it is used for a safety function and a

special SIL or PL level has to be reached.

According to the voestalpine Tubulars approved list

4.2.9 Conductor colors In addition to the definitions in EN 60204-1 Section 13.2 – Identification of conductors – the following

internal rules apply to the colors of conductors:

LIGHT BLUE Neutral conductor only

BLACK Main circuit for DC and AC

Secondary circuit for transformers

RED 230 VAC control voltage

BROWN 24 VAC control voltage

DARK BLUE 24 VDC control voltage

ORANGE External voltage for locks and enabling.

VIOLET Internal auxiliary electrical circuit (e.g. enabling controllers, monitoring

circuits, etc.)

WHITE Conductor for analog transducers (temperature, humidity, pressure, etc.)

4.3 Electrical supply, protective measures 4.3.1 Mains voltage



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Power supply: Operating voltage: 230/400 VAC ± 10%

Frequency: ~50 Hz ± 1%

Type: TN-C and TNC-S

One of the circuit breakers listed in the voestalpine Tubulars approved list is to be used to disconnect

the mains power supply.

4.3.2 Protective measures Zeroing is used for protection in the production area. In offices and sanitary rooms, zeroing plus

residual current protection are used. Earthed sockets in the hall area and in switch cabinets (service

sockets) are to be protected using residual current protection devices with a nominal residual

current/IN < 0.03 A. Control circuits are usually implemented in the IT system.

4.3.3 Control circuits Control circuits must be implemented in accordance with EN60204-1. It must be easy to separate

(disconnect terminal) the one-sided earthing of the control voltage.

To make troubleshooting easier, circuit breakers are to be used to divide control circuits into functional

groups for the given equipment/machinery in accordance with the categories in the following table.

Sensors, command devices, transmitters, PLC input potential 24 VDC ± 10% Switching elements, valve coils, optical and acoustic signaling devices, PLC output potential

24 VDC ± 10%

Auxiliary contactors and power contactors 24 VDC ± 10% Emergency stop switches, supplying monitoring relays for safety circuits

24 VDC ± 10% Large power contactors, magnetic clutches and brakes 24 VDC; 230 VAC

± 10% Electrical circuits for fans, lighting, service sockets, etc. 230 VAC ± 10%

4.3.4 Power supplies and control transformers Control voltage ripple: max. 5 % effective

Voltage tolerance: ± 10%

Three-phase power supplies or switching power supplies are to be used for load currents greater than

2.5 A. Power supply transformers must be implemented as safety transformers in accordance with

EN 60 742 and ±5% switchable on the primary end.

4.3.5 Potential equalization Potential equalization is to be implemented in accordance with EN 60204-1, i.e. all

machine/equipment parts made of metal must have the same electric potential (are conductive with

each other) and connected to operational earth. The machine/equipment/switch cabinets are to have

their own ground terminal for connecting to operational earth. The ground terminal is to be marked

with the 417-IEC-518 symbol.

4.3.6 Protecting transformers from overloading



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Control transformers are to be designed so that primary fusing is safely activated when a secondary

short circuit or overload occurs. Circuit breakers with adjustable thermal or direct overcurrent trip are

to be used for overload protection. Small transformers must be either permanently short-circuit-proof

or protected by fuses.

4.3.7 Switching inductive loads Inductive loads with a coil power > 12 W or high switching rate (valves, large contactors, clutches, and

brakes) should be electronically switched. Electronic switching elements with the appropriate power

are to be used.

Electromagnetic brakes for brake motors are to be activated with a brake control that is supplied by

the motor voltage. If it is necessary to switch between DC and AC, then a contactor with the

appropriate power or an electronic brake control is to be used. For operational safety reasons,

electronic circuit breakers are also preferred in the case of only AC switching. It is not permitted to use

auxiliary contacts for power contactors to switch brakes and clutches. Brake rectifiers must contain an

integrated protection circuit.

4.3.8 EMC-conform installation The development and spreading of disturbance voltages resulting from self-induction of inductive

loads or from modulators (converters, power supplies) is to be prevented through the use of protection

circuits and special installation measures.

Protection circuits vary depending on the part and application:

• Polarity-proof protection circuits in junction boxes or directly on valves, clutches, brakes, holding

magnets, etc.

• Interference suppressors for contactor and relay coils

• RC combinations or varistors for motors and transformers

The inducted induction voltage must be safely limited to values less than the control voltage. For

motor starters with a high switching rate, the motor must have an RC circuit to protect the contactor

contacts.

The interference immunity of electrical devices in machinery and equipment must conform with

EN 61800-3 and EN 50082-1,-2. With respect to emissions, EMC-conform installation must ensure

adherence to the generally applicable standards for the industrial segment in accordance with

EN 5081-2 and EN 61800-3/A11. In the case of frequency converters, a smoothing coil or an

intermediate circuit coil and motor output choke is to be installed.

The manufacturer specifications for installing speed-controlled drives must be complied with. Shielded

cables must be used to connect the frequency converter output and the motor. Suitable shield

terminals are to be used to ground the cable shield (as much area as possible) on or near the output

of the frequency converter. Twisted shielded pairs (pigtails) with ground terminals for round

conductors are not permitted.

4.3.9 Operation and protection of induction motors Efficiency classes:



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• From 1.1.2015 motors from 7.5 kW to 375 kW have to comply EU efficiency class IE3 or IE2

with a frequency converter.

• From 1.1.2017 motors from 0.75 kW to 375 kW have to comply EU efficiency class IE3 or IE2

with a frequency converter.

Motor outputs up to 15 kW are to be implemented with circuit breakers (fuse-less). For motors with an

output power of 15 kW or more, or when special operating conditions make it necessary (e.g. heavy

starting, S7 operation, etc.), full motor protection using thermistors is required (electronic motor

protection relay is recommended). For motors with an output power of 5.5 kW or more, the motor

current must be displayed. In the case of frequency converter operation, the power at the analog

output is to be displayed. In speed-controlled operation, the thermal stress on the motors is to be

monitored and limited through the use of external fans.

4.4 Control equipment, operator interface 4.4.1 EMERGENCY STOP device Display of the EMERGENCY STOP state is required if the EMERGENCY STOP device has several

activators. The EMERGENCY STOP state is to be signaled with a permanently on red indicator light.

The signal must be visible from the operator’s usual working position. The system must recognize

when contact blocks fall down or they are to be installed such that this problem cannot occur. Each

electrical control must have at least one EMERGENCY STOP button with unavoidable latching and

blocking capabilities.

4.4.2 Operating modes Each piece of equipment/machinery is to have a conventional operating mode that allows the operator

to manually control all movements and states required to achieve a defined starting position, to freely

move in the case of a collision, or when there are material flow problems.

In automatic mode, there must be a START/STOP function to stop the flow control. Changing

operating modes cannot cause the machinery/equipment to move. The required operating modes are

to be clarified in advance. An operating mode for alignment and maintenance work must be provided

(safe speed).

4.4.3 Faults and alarms Faults and alarms should help operators and maintenance personnel during troubleshooting, indicate

critical states, and help avoid error conditions.

In addition to a central group alarm, alarms and faults are to be grouped and displayed according to

the following criteria:

• Warnings from protection and monitoring systems (e.g. circuit breaker, thermal contact)

• Exceeding or falling below limits for physical properties (current, pressure, temperature, fill level,

etc.)

• Monitoring the time and sequence of control sequences

• Internal monitoring of devices and systems (PLC, servos)

• Alarms from safety equipment for the protection of persons



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We prefer alphanumeric text displays for visualizing faults and alarms. A single optical indicator light is

sufficient for simple control systems. Function displays on modules (e.g. hydraulic motor, main drive)

should blink when the group alarm is active. Critical alarms must be supported by alarm sounders or

flashing lights.

4.5 Programmable control systems 4.5.1 Selection and setup Without exception, only the products listed in the parts list are allowed.

For reasons of rational spare parts management, the SIMATIC S7-300 system initially has the

following restrictions:

• Only central modules that can be fully replaced by the CPU 315-2 DP are allowed. This means

that CPU 312 IFM and CPU 314 IFM cannot be used. Special integrated functions that come

with these modules have to be achieved using standard S7-300 modules.

• Only 24 VDC digital input and output modules are allowed.

• Combination input/output modules (SM323) cannot be used.

• The fully modular TOP connect connection cannot be used to connect to I/O modules.

• At least 80 mm of space must be left free on the module carrier.

• I/O cards are to be connected using preassembled system cables with transfer modules that

make it possible to directly connect to external signal lines.

• Input/output modules, relay, and optocoupler modules (Phoenix)

• Isolation amplifiers (Knick) are to be used for analog signals.

The manufacturer’s setup guidelines are to be strictly followed. We especially call your attention to the

measures for grounding, shielding, and interference voltage protection. The thermal stress on the

modules cannot exceed 75% of the specified limit.

If the electrical control system, i.e. PLC input and power supply, requires a switch cabinet area that is

more than 1200 mm wide, then the PLC is to be installed in a separate cabinet area.

For all new installations the system SIMATIC S7 1500 with the software tool TIA Portal hast to be

used. All restriction from above keep their validation. If deviations from this delivery specification

are unavoidable, then they must be expressly agreed to by the Contracting Party.

4.5.2 Installation All digital inputs and outputs that connect PLC modules to the outside must be installed on

input/output modules in the switch cabinet as approved by voestalpine Tubulars. The part designation

must correspond to the I/O operands.

4.5.3 Interfaces All equipment interfaces to higher-order systems (HMI, server services, and data loggers) are to be

clarified with the Contracting Party. The current standards are Profinet and Profibus (Siemens Profibus

plug).

4.5.4 Decentralization



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To reduce the cabling effort, it is recommended that a fieldbus system be used to decentralize the I/O

levels. Copper or fiber optic conductors can be used for the bus cabling. The Profibus shield is to be

used where the cabling enters the housing. Only the approved parts in Appendix A can be used for

passive distributors and decentral I/O systems.

4.5.5 ASI bus When using ASI bus components (especially to control open, fuse-less motor starter combinations),

technical clarification with and the approval of the Contracting Party is required.

4.5.6 Programming languages Preferably, the standard PLC language STEP 7 is to be used in function block diagrams (FBD) and

Graph 7. For complex problems, programming in statement lists (STL) and the S7 SCL high-level

language tool is allowed. TIA Portal will be the new standard as of 2015.

4.5.7 Program structure

The control program is to be created in accordance with the specifications (voestalpine Tubulars S7

software specifications). Any deviations are to be clarified in advance between the CO and CP

(electrical department).

The programming tools’ features are to be used to develop clear, structured PLC programs, especially

for FBDs. To promote clearly structured programming, the use of the same operands for assignment,

set and reset operations or for different purposes should be avoided. High-level language elements in

SCL should be used in complex function blocks to improve the readability of these program

components.

4.5.8 Simatic S7 protection levels Setting protection levels for modules and S7 blocks is only allowed for:

• Siemens standard function blocks

• In the case of justified know-how protection with the agreement of the Contracting Party

4.5.9 Safety controllers In the case of concatenated equipment where overriding EMERGENCY STOP circuits or safety

circuits are required or for single pieces of equipment with several EMERGENCY STOP or safety

circuits, the technical safety concept is to be clarified with the Contracting Party. The make and

version of any programmable safety controllers used must be coordinated with the Contracting Party.

4.6 CNC systems and industrial computers The Contracting Party is to be fully informed about the use of CNC controllers and industrial

computers in electrical equipment for machinery/equipment.

In particular, the following points must be clarified in technical discussions before the contract is

awarded:

• Make and type according to the approved list

• Availability of spare parts and service



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• Response time in the case of failure

• Remote maintenance via network

• Technical documentation

Industrial computers (B&R) as part of the electrical equipment for machinery or equipment must be

designed to meet the environmental conditions (protection class, mechanical and thermal stress,

interference immunity, type, etc.).

Desktop models for offices are not allowed. Screens, keyboards, and output devices must also be

suitable for industrial applications and for installation in switch cabinets.

Industrial computers and all peripheral devices are to be installed in a separate switch cabinet area,

with the exception of compact devices with a protection class higher than IP54 and a fully RF shielding

metal enclosure. They must comply with the EN 500852-2 3/94 standard for interference immunity.

Customer-specific applications and solutions can only be implemented based on a written, agreed

specification between the Contracting Party and the Contractor.

4.7 Documentation of electrical equipment 4.7.1 Reports and documents Here, a short summary of the required documents:

For electrical installations:

• Initial verification report in accordance with ÖVE/ÖNORM E 8001-6-61 Erection of electrical

installations Section 6-61 – Verification – Initial verification

• Installation log book in accordance with ÖVE/ÖNORM E 8001-6-63 Erection of electrical

installations Part 6-63 – Verification – Certification and reporting

For electrical equipment:

• Start-up report; cold, warm, and function tests of the CO’s safety equipment.

• Technical documentation, ÖVE EN 60204 test report and stop category in accordance with

ÖVE EN 60204-1 Electrical equipment of machines

• Test report in accordance with ÖVE EN 60439 Low voltage switching device combinations

• Risk assessment report in accordance with EN 12100

• Indication of the performance level in accordance with EN 13849 or the SIL level in

accordance with EN 62061 for safety shutdown

• Assignment list of drives to control voltage switches, emergency stop buttons, and safety door

tumblers

• Power circuit diagrams are to be created in ELCAD (preferred) or EPLAN, saved as an

archived project (incl. symbols and parts management) on a CD-ROM and submitted with the

above documents.

• All documentation is to be in electronic form on data storage devices and in PDF format.

4.7.2 PLC software documentation PLC programs are to be submitted to the Contracting Party on a CD-ROM. The list format is A4

portrait. The software version must be the latest version available at acceptance. Changes made by



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the manufacturer after acceptance are to be immediately updated on the data storage device and in

the customer’s written documentation.

Documentation of the control system must include the following list in the order presented here:

• List of blocks and objects

• Symbol table

• Listing of the source program in the original representation (LAD, FBD, STL, S7-SLC)

• Listing of data blocks (commented)

• Cross-reference list of all operands

• Assignment list for inputs, outputs, markers

The data storage device must contain all original data and source code generated when developing

the program, compiled executable programs, and a dump of the Contractor’s latest valid version.

4.7.3 Documentation for CNC controllers and industrial computers If not provided in the standard scope of delivery, the following information must be submitted for CNC

controllers:

• Operating instructions

• Programming instructions

• Description of interfaces

• Documentation of the PLC and NC programs

• Machine data, R parameter lists

• Ghost of the hard drive including relevant ghost versions as a data backup on DVD

CD-ROM is the approved data storage device. If available, technical manuals for the hardware and

operating systems of industrial computers are to be submitted as well as the licenses for installed

software, including all manuals and data storage devices.

4.7.4 Installed components and systems If available, technical documentation and data sheets for electronic components and subsystems that

suffice for required maintenance and servicing are to be submitted. Purchased parts that do not have

service documents or for which service cannot be guaranteed cannot be used. A list of manufacturers

for OEM parts with information about national service locations must be contained in the technical

documentation.



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5 Specifications for instrumentation and control of Furnaces

5.1 Accessibility Every equipment (transducers, gears) and electrical equipment should be access able without

resources (e.g. ladder).

5.2 S7/Software 5.2.1 Structure Following structure has to be used for the PLC, the “x” place holder for the number of the zone.

• Furnace General DB and FC 800

• Furnace General error messages DB and FC 804

• Fans DB and FC 60 – 69

• Measuremants with doesn’t belong to a zone DB and FC 814-860

• Measuremants and controllers with doesn’t belong to a zone General DB and FC 860

• controllers with doesn’t belong to a zone DB and FC 861-879

• Zone general DB and FC x00 (z.B.: Zone 1 Allgemein = DB100)

• Error Messages DB and FC x04

• Temperature Measurements DB and FC x11 – x19

• Fuel Gas Measurements DB and FC x21-x24

• Air Measurements DB and FC x25-x29

• Exhaust Measurements DB and FC x41-x44

• Other Messungen DB and FC x45-x49

• Controllers DB and FC x61-x79

• Brenner allgemein DB and FC x80

• Burner DB and FC x81-x89

• Safety Control General DB and FC 901

• Safety Control zone General DB and FC 9x1

• Safety Control zone analogue DB and FC 9x2

• Safety Control zone burner DB and FC 9x4

5.2.2 General Information The software has to include following points:

• Inert rendering with a consistent key switch.

• All measurements have to be visible in the GUI.

• The GUI has to be in German and agreed to by the Contracting Party.

• The PDM software from Siemens has to be used, to get access to the transducers (S7

components have to support the HART communication).

• 2 Touchpanels with at least 19“ and a WinnCC flexible station is necessary.

• All safety functions have to be implemented into the S7, no additional equipment is allowed.

• For service a mobile panel (WLAN) is necessary.

• 24 volts supply has to be redundant.



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5.3 Pipes 5.3.1 Impulse pipes All Impulse Pipes have to be executed with following points:

• Shut-Off device at the extraction point

• 3 way valve in front of the transducer, to set the 0 point

• Impulse pipes have to be as short as possible. At least all transducers of one zone should be

together.

• If it is possible the transducer should be higher than the extraction point, if it is not possible the

impulse pipe should have a drainage.

5.3.2 Grounding and paintwork Every pipe, which is not isolated (also impulse pipes) have to be colored correctly. At least 150µm grounding and 80µm paint is necessary.

Natural gas RAL1018 Air for Ignition burner RAL5021 Air for Main Burner RAL5005 Cooling Air RAL5018 Exhaust/Furnace pressure RAL3020

5.3.3 Pipes for Ignition Burner The pipes (air and natural gas) for the ignition burner have tob e build without connections until the

shut-off device.

5.4 UV-Sensor and Ignition burner The UV-sensors have to be integrated into the burner that they are not able to see the flame of the ignition burner or one of the neighbor burners. Our experience of the best possibility is shown in the graphic. The ignition burner should have at least 10 kW.

Ignition-Burner



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5.5 Measurements 5.5.1 Quantity Measurements All quantity Measurements have tob e a temperature and pressure compensated differential pressure measurement with a restrictor. To verify the restrictor measuring a thermal mass flowmeter has to be implemented as well. 5.5.2 Oxygen Measurements In every zone (logical configurations) and in the exhaust (chimney) an oxygen measurement is necessary. 5.5.3 Exhaust Measurements In every chimney a quantity measurement and a temperature measurement is necessary. An extraction point to check the exhaust should be provided. If the exhaust is pulled back via the burner, every zone should have a quantity measurement. 5.5.4 Pyrometer Measurements The serial interface of every pyrometer has to be connected to the network with the help of a transducer, to able to configure the pyrometer.

5.6 Switch cabinets One Cabinet has to be planed for general part and for each zone a separate cabinet is necessary (logical configuration e.g. heating zones is possible).

5.7 Limit values Max. exhaust temperature in the chimney without adding fresh (cool) air

130 – 200 °C

Max. furnace surface temperature 80 °C Max. temperature of isolated pipes 50 °C Exhaust compounding Austrian Law „Begrenzung der Emission von

luftverunreinigenden Stoffen“, last version

5.8 Documentation Following documents have to written in German and hand over to the contracting party in time.

• Flow schema • Plan of measuring points • 3D CAD drawings of the pipes • Technical Description • Handbook and instruction manual • Equipment list (including calculations) • Maintenance plan • List of spare parts

6 Industrial Computers The industrial computers have to be sent to the contracting party for doing a first installation. After this installation the computer will be send back. The first installation includes:

• Software: o Virus protection – Office Scan (Trendmicro) o Remote Maintenance – Fast Viewer (Matrix42) o Windows 7 64 bit German with actual Windows Patches o Office 2010 o Acrobat Reader 11 o Hardcopy o NTP Service



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o Empirum Advanced Agent o End Point Security (Ego Secure)

• User configuration • Network configuration

7 APPENDIX A: Electrical parts (approved list)

The following lists contain a selection of parts that we prefer to use and that we therefore stock as

spare parts.

Suppliers and manufacturers of electrical equipment are obliged to use the electrical parts in these

lists. Exceptions are allowed when parts from different manufacturers are compatible based on

standards, technical data, size, and connections. When parts are replaced due to a failure, this cannot

result in any changes in the mechanical structure, design, or electrical connections. It also cannot

cause any changes in electrical wiring diagrams. If deviations from this delivery specification are

unavoidable, then they must be expressly agreed to by the Contracting Party.



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Part Preferred product Alternative products

Manufacturer Type Manufacturer Types

Switch cabinet and housing, power distribution Distribution cabinets Equipment cabinets Control cabinets Terminal boxes Console enclosure Power distribution parts Switch cabinet climate control

Rittal CP EB

Connectors Terminals Phoenix Contact Multiple terminals To be agreed Initiator terminals To be agreed Actuator terminals To be agreed Multi-pin plug connectors Harting All series Phoenix Contact All series

Cable routing Energy chains for metalworking machinery

Henning Stabiflex Quality G

Power circuit breakers, safety parts Circuit breakers and accessories

Schneider Multi9 Siemens To be agreed

Residual current circuit breaker

Siemens

Motor circuit breaker Siemens Fuse terminals Phoenix Contact UK 5 Monitoring module LÜTZE LOCC-Box

Power and auxiliary contactors Power contactors with AC/DC drive

Siemens

Auxiliary contactors with DC drive, 24 VDC

Siemens

Thermal motor protection relay

Siemens



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Relays, semiconductor switches Time relay, 22.5 mm Siemens Industrial relay Schrack RT series Relay and semiconductor switching elements

Phoenix Contact

Emergency stop switching devices

Pilz PNOZelog

Interference suppressor for switching devices

Siemens

Position switches Single hole fixing limit switch Euchner All products Siemens All

products Multiple position switch Euchner All products Balluff All products

Proximity sensor Proximity sensor, inductive, DC, 24 V M12x1 mm pluggable

Balluff BES Euchner All products

Proximity sensor, capacitive, DC, 24 V M12x1 mm pluggable

Balluff BES Euchner All products

Proximity sensor, magnetic sensing (cylinder sensor)

Balluff BMF Sick MZ series

Photoelectric sensors DC, 24 V

Sick W12 metal W24, W34, ELG1; MLG

Safety switches Safety light curtains

Sick

Safety interface

Sick



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Control and indicating devices Indicator lights Swisstac Siemens 3SB3 Mushroom pushbutton switch for emergency stop switching devices

Swisstac Siemens 3SB3

Power supplies Single-phase, 230 VAC, 24 VDC

Phoenix Contact Quint 24 V

Three-phase, 380 VAC, 24 VDC

Phoenix Contact Quint 24 V

Text displays and control terminals Displays and control units Siemens To be agreed

S7 interface – initiators and actuators Input module Phoenix Contact FLKM50/PLC Relay module Phoenix Contact UMK Optocoupler module for valve control

Phoenix Contact UMK

System cable Phoenix Contact FLK 50

Frequency converter Frequency converter without positioning

Schneider Electric Power Drives

pDRIVE MX To be agreed

Safety components Safety switches Euchner CET1 To be agreed Safety light curtain Sick

CNC controllers Drives Siemens Simodrive 611 Siemens Sinamics S120 CNC controller Siemens 840D Siemens 840D sl Control panels Siemens OP010 Siemens OP012 Machine control panel Siemens MCP 483C

Measurement and regulation technology for furnaces

Quantity measurement ABB 266CST Gauge pressure ABB 266GST Differential pressure ABB 266MST Temperature (furnace chamber) ABB TTF300

Temperature ABB TTR200 Swing drive, large ABB RHD250 (250 Nm) Power electronic unit, large ABB EBN 853 Swing drive, small (air and gas) ABB

PME 120 AN (100 Nm)

Power electronics, small ABB EAN 823 Safety thermocouple Günther GmbH see 05-99050064-0830



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Air and exhaust flaps Jasta GD-6 E/S with stop bar and seal insert Drives Flowserve S085D, S100D Burner control unit Kromschröder BCU480-5/3/1LW3GBD2B1/1 UV sensor Kromschröder UVS 10L1G1 Motorized valve for gas Kromschröder VK Solenoid valve for gas Kromschröder VAS, VCS (double solenoid valve) Pressure switches Kromschröder DG…UG Test valve, combustion air Bürkert BA0335-EU High-temperature monitoring Jumo b70.1150.0 Repeater pr electronics 9106B Universal transmitter pr electronics 4114 Pressure regulating valve Kromschröder GDJ Safety contactors Phoenix Contact PSR-SCP- 24DC/ESP4/2X1/1X2 Safety contactors (multichannel) Phoenix Contact PSR-SCP- 24UC/ESAM4/8X1/1X2 24V redundancy supply Phoenix Contact QUINT-DIODE/12-24DC/2X20/1X40 Contactors Phoenix Contact PR1-RSP3-LDP-24DC/2X21 3 way valve AS-Schneider S345.06.202.02+S006.38.106. +S006.42.103.04 Oxygen Measurement Oxitec SME5 Oxitec Economy

Schlüsselschalter Siemens 3SB3000-3AH01 (high temperature > 750°C), 3SB3000-3AG01 (Inert rendering)

Mobile Panel Siemens 6AV6645-0DD01-0AX01 Access Point for Mobile Panel Siemens 6GK5788-1GD00-0AA0 Pyrometer <700°C Lumasense IMPAC IPE 140/39 MB7 Vario-Optik 3-PE Pyrometer 600 – 1400°C Raytek MR1SASFW

Industrial computers and KVM Industrial Computer B&R APC910 KVM Remote Unit IHSE IHSE BE-R477-1SHC KVM Local Unit IHSE IHSE BE-R477-1SHC KVM Switch IHSE BE-K480-16C (Standard) BE-K480-48C TCP/IP – Serial Interface WuT 58665 Com-Server++



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8 APPENDIX B: voestalpine Tubulars S7 software specifications

8.1 Liability disclaimer

The authors have taken every care to publish complete and accurate information in this user manual and any other accompanying information media. The authors neither guarantee nor assume legal liability for the use of this information, its economic viability or error-free function for a specific purpose. Moreover, the authors accept no liability for damages, for any misinterpretation of the content, nor for any resulting violation of patent rights and other titles of third parties.



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8.2 Hardware configuration The equipment functions are usually executed on an S7-400 CPU 414-2XK05:

The safety functions are usually outsourced to an ET200S-CPU (IM151-8):

Data exchange between equipment and safety control is implemented on a separate Profinet (I device) based network.



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8.3 Structuring 8.3.1 Programming languages and standard software

Preferably, the standard language STEP 7 is to be used in function block diagrams (FBD). Statement lists (STL) and ladder diagrams (LAD) are only to be used as an exception. For complex problems, programming in S7 SCL high-level language tool is allowed. The S7-GRAPH engineering software is to be used to design and program sequential processes, e.g. step processes for automatic sequencing. The WinCC flexible HMI software has to be used to design the user menus for the touch panels. Exceptions are allowed only when absolutely necessary and only with the express agreement of the Contracting Party. The versions of the programming tools are to be agreed with the Contracting Party.

8.3.2 Program structure The programming tools’ features are to be used to develop clear, structured PLC programs, especially for functional block diagrams (FBDs). To promote clearly structured programming, the same operands should not be used for assignment, set, and reset operations. The program structure is to be agreed with the Contracting Party. All global variables (inputs, outputs, markers, data points, etc.) are to be clearly labeled according to their function. All block headers and networks are to be given comments on their use. Complex functions must be verbally described in the block to make them easier for service personnel to understand. All drive-related functions must be implemented with simple logic without using function blocks. Functions that were not included in this document or in the example project are to be agreed with the Contracting Party.

8.3.3 General functions - FC0-110: Standard blocks Siemens/Sprecher - FC170-179: General calculations, material tracking in SCL - FC185: Data from counter cards - FC186: Differences - FC190: Analog value processing - FC192-199: Data exchange with other equipment parts - FC200: General functions - FC202: Data preparation for touch panel (counters, light barriers, …) - FC204: Operating messages (No start possible: …) - FC206: Material tracking (walking beam allocation, pipes in tester) - FC208-209: Preselections/operating modes that depend on a switch

� are then saved in the DB208 - FC800: Recording of error messages - FC810: Evaluate error messages (new error, horn) - DB86: Profibus failures - DB90: Date and time - DB101: Drives - DB102: Analog values - DB103: Ramp generators - DB104: Controllers - DB170: Error messages for electrical fault indicator (WinCC) - DB171: Error messages for TP - DB172: Operating messages - DB180-189: Data for TP, parameters, plant computer, material tracking



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- DB800: Error messages - DB801-803: Evaluation of error messages - FC900: Safety program - FC901: Safety program, F-OB1 - FC902: Safety program, general - FB901: Safety program, EMERGENCY STOP - FB902: Safety program, safety doors - FB903: Safety program, light grids - FB910: Safety program, voltage controlled switches - FB911-929: Safety program, safety circuits - DB899: Parameter safety program - DB900: Safety data block

8.3.4 Equipment functions

Equipment parts are divided into groups of 100: e.g.: - FC210-298: Feeding - FC310-398: Straightening machine - FC410-498: Outgoing transport A group is subdivided as follows: e.g.: - FC310-318: Automatic block - FC320-398: Drive block

8.4 Marker organization

Marker numbers are to be chosen so that they match the number of the FC. To make sure that there are enough available markers, only even FC numbers are used. FC220: M220.0 – M221.7 FC432: M432.0 – M433.7 If there are still not enough, then simply multiply the FC number by ten: FC210: M2100.0 – M2119.7 FC212: M2120.0 – M2139.7

8.4.1 Marker assignment: general M 0.0: Logical 0 M 0.1: Logical 1 M 0.2: Start-up 0 M 0.3: Start-up 1 M 0.4: 100 ms – pulse M 0.5: Edge marker 100 ms M 1.x: Clock marker byte M 2.x: Error acknowledgements M 3.x: Lamp tests M 4.x: Screen blanking M 8.x: Horn acknowledgements M 10-19.x: Control voltages/safety circuits M 80-81.x: Error marker for OB errors incl. group alarm



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MW990: “Don’t know yet INT” M 999.6: “Don’t know yet output” M 999.7: “Don’t know yet” MD1000: Cycle time (read out from OB1) The start-up markers are used to easily find (using cross-references) everything that had to be bridged/blocked during start-up. The “Don’t know yet ...” signals are to be used for open points to make them easy to find.

8.4.2 Marker assignment: automatic block

8.4.2.1 Without safety control

x.0 Enable automatic x.1 Automatic started x.2 Operating mode: automatic x.3 Operating mode: manual x.4 Operating mode: jog/manual on-site (if available) x.5 Interrupt in automatic mode (if available)

8.4.2.2 With safety control

x.0 Enable automatic x.1-5 Automatic started, safety circuit x x.6 Operating mode: manual x+1.1-5 Operating mode: automatic, safety circuit x

8.4.3 Marker assignment: drive x.0 Ready x.1 Enable x.2 On/forward/lift, manual x.3 Back/lower, manual x.4 On/forward/lift, manual x.5 Back/lower, automatic x+1.0 On/forward/lift, when drive not controlled by the output (proportional valve control, frequency converter from Profibus) x+1.1 Back/lower, when drive not controlled by the output (proportional valve control, frequency converter from Profibus)

8.4.4 Marker assignment: controller x.0 Enable controller x.2 Automatic selected x.3 Automatic



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8.5 Structure of functions 8.5.1 General

8.5.1.1 General FC200

The following signals are generated in the FC200: - Log.0 / Log.1 / Start-up marker 0/1 - Control voltage/safety circuit x on - Error acknowledgement buttons are placed on markers or acknowledgment pulses are

generated - Lamp tests for each operating console are placed on markers - “Screen blanking” is generated for each operating console � e.g. with key switch control

voltage � for all lamps, these markers will be connected such that nothing lights up when the equipment is off.

- Date/time will be read from PLC (DB90) - Spare lamps - …

8.5.1.2 Data preparation HMI FC202

Signals that were stored in a DB for the HMI: - Counter preparation (piece counter, good/bad pipe counter, …) - Sensors for displaying on overview display - Safety doors/safety light grids for displaying on overview display - Target values from HMI - …

8.5.1.3 Operating messages FC204

Generation of messages that keep a machine/automatic from starting. e.g.: - No start possible: walking beams not in starting position - Feeding not enabled - Hydraulic device not on - …

8.5.1.4 Material tracking FC206

Generation of signals for material tracking e.g.: - Location of good/bad pipes - Detection and marking of pipe faults - … Material tracking is then processed collectively, e.g. in FC175 in SCL.

8.5.1.5 Preselection/operating modes FC208

If an operating mode can be changed from different operating points, then it cannot be done using a switch. In FC208, operating mode signals are reproduced with buttons (sometimes also from HMI) and saved in DB208.

8.5.1.6 Analog value processing FC190:



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All analog inputs are scaled here.

8.5.1.7 Calculations, material tracking (FC170-179)

Complex calculations and material logistics with large data structures are processed in SCL.

8.5.1.8 Profibus error analysis

Can be implemented using the following methods: - OB86 - FB125 - FB126 - SFC51

8.5.2 Equipment areas 8.5.2.1 Automatic (e.g. FC210)

All functions for the given automatic area: - Automatic start conditions - Automatic on/off - Automatic started signal - Various preselections and program modes - Automatic links to the individual modules - Calling up GRAPH step processes

8.5.2.2 Modules (e.g. FC220)

Drive-related functions in the following sequence: - Drive ready/enable - Read drive data (for Profibus – e.g. SFC14) - Selection, if available - Manual function forward/on/off/… - Drive forward/on/off/… - Manual function back/down/ … - Drive back/down/ … - Various Profibus commands (e.g. on, acknowledge, …) - Speed selection and preparation - Send data to drive (for Profibus – e.g. SFC15) - Signaling lamps / HMI



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8.5.4 Safety technology In the safety program, the following SIEMENS standard functions are used: - F_ACK_GL: Reintegration of all modules - F_1oo2DI: Discrepancy analysis (NOT implemented on the module) - F_FDBACK: Monitor feedback circuit - F_ESTOP1: Emergency stop – also used for door contacts Settings for F-CPU in hardware configuration: Basis for Profisafe addresses: 2000 F data blocks: 1000-1099 F function blocks: 1000-1099 If it is necessary to use Profisafe (safety functions via Profibus or Profinet), then the drives (in this case SINAMICS) must be operated as shared devices based on Profinet.

8.5.4.1 Parameter safety program DB899

- Time, discrepancy monitoring - Time, feedback circuit monitoring - Time, safety circuit delayed off These values are stored in a DB so that they can be easily globally changed in one location.

8.5.4.2 DB safety DB900

All relevant signals for the safety program are generated here. e.g. passivity messages, feedback circuit messages, safety door OK / discrepancy / open, …

8.5.4.3 General FC902

- Generation of secure 0/1 signals - Passivity messages - Reintegration - Read acknowledgement buttons - Parameters

8.5.4.4 Emergency stop FB901

Reading all emergency stops with F_1oo2DI discrepancy analysis.

8.5.4.5 Safety doors FB902 Reading all safety doors with F_1oo2DI discrepancy analysis.

8.5.4.6 Light grid/light curtain FB903 Reading all light grids/light curtains F_1oo2DI discrepancy analysis and acknowledgement with F_ESTOP1.

8.5.4.7 Other safety signals FB904

Reading all other safety signals with F_1oo2DI discrepancy analysis.

8.5.4.8 Safety circuits FB911, 912, …



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Safety-related functions in the following sequence: - Safety circuit OK - Acknowledge safety circuit - Safety circuit enabled/delayed - Monitor feedback circuit

8.6 Symbols

Symbols must contain the following information: - Location code - Equipment/drive code - Part - Type:

o SM…error message o K…contactor/relay o QS…transverse signal o BE…Bero switch o ES…limit switch o LS…light barriers o DT…pushbuttons o LDT…illuminated pushbuttons o PDTV…locked mushroom pushbutton o SS…rotary switch o SSS…rotary switch with key o STZ…safety door (locking device) o SLG…safety light grid o SLV…safety light curtain o …

- Text e.g.: +RMH1 =RMH1 V01.N01-B32 BE pipe before infeed channel +21E802 =PSH1 M04.F01-Q12 SM excenter walking beam in front of motor protection testing line +HST1 P10 =RMH2 M02.N02-S12 LDT chain conveyor in front of RMH



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8.7 Error messages

The error message DB (DB800) is to be set up similar to the symbols:

This DB will be entered in a central error message system.



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8.8 Data structures for HMI and Profibus 8.8.1 Drive UDT101



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8.8.2 Analog values UDT102

8.8.3 Ramp generators/target value selection UDT103



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8.8.5 Controller UDT104



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8.8.7 Drive structure for Profibus control UDT110 (e.g. PPO4)



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8.9 Visualization In the case of a piece goods machine like the reeler, voestalpine Tubulars GmbH & Co KG

does not usually visualize the individual drives in detail since they are operated via buttons (console or touch key) and are therefore already represented (lamp or touch key). � The figures in section 8.8.1 and 0 are from a PC visualization (Siemens WinCC OA).

8.9.1 Operator logon Not usually used at voestalpine Tubulars GmbH & Co KG. Only functions that are relevant for maintenance personnel (e.g. end runtime) are password-protected. Parameters that the user is not allowed to change are not shown on the HMI. If they need to be changed, this will be done directly in STEP7 by the maintenance personnel.

8.9.2 Icons Only standard graphical elements from WinCC flexible with simple dynamic properties can be used.

8.9.3 Alarm messages Standard alarm window from WinCC flexible.

8.9.4 Archiving If archiving is required, then a standard variable archive (memory card) is to be created. Message archives are not necessary since there is a central error message system with archiving.

8.9.5 Color regulations

Operating modes:

Operating mode: undefined (off)

Operating mode: manual

Operating mode: setup

Operating mode: automatic Status:

Drive ready



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Automatic started / drive ready

Drive running

Emergency off or control voltage turned off

Fault (blinking: not acknowledged / continuous: acknowledged)

8.10 Notes on the example project 8.10.1 Equipment control

- This project serves to familiarize the user with the structure. Much of the program logic

has been removed. - Drive example for:

o Frequency converter: e.g.: FC220, FC422 o One-directional drive, conventional: e.g.: FC224, FC524 o Two-directional drive, conventional: e.g.: FC540, FC334 o Valve, 1 coil: e.g.: FC354, FC454 o Valve, 2 coils: e.g.: FC352, FC424 o

8.10.2 Safety controller

- This project serves to familiarize the user with the structure. Much of the program logic

has been removed.

Technical Guidelines for Machinery and Equipment · 1/20/2015 · voestalpine Tubulars GmbH & Co...

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Transcript of Technical Guidelines for Machinery and Equipment · 1/20/2015 · voestalpine Tubulars GmbH & Co...