Functional Design Specificationcoastlubricants.com/wp-content/uploads/2020/11/... · 1.1 Autol Functional Design Specification The Autol centralized lubrication systems are new generations

Functional Design Specification

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Contents

Autol Automated Lubrication System ...........................................................................2

1.1 Autol Functional Design Specification .................................................................2

1.1.1 Autol Mechanical & Hardware Overview .......................................................2

1.1.2 Project Design Layout ................................................................................5

1.1.3 Equipment List ..........................................................................................8

1.1.4 Bill of Materials ....................................................................................... 13

1.1.5 Electrical Design and Layout ..................................................................... 16

1.1.6 Functional Control ................................................................................... 18

1.1.7 Maintenance & Troubleshooting ................................................................ 26

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Autol Automated Lubrication System

1.1 Autol Functional Design Specification

The Autol centralized lubrication systems are new generations of centralized lubrication systems developed by Autol Technology & World Focus after a long-term market research & technology innovation, with a number of technical invention patents. The systems deliver

metered amount of grease volume to each lube point via distribution valve blocks through a pipework system.

The system plays an important role in reducing friction resistance, decreasing contact damage and lowering surface temperature of friction as well as anti-rust, shock absorption and sealing.

The system works automatically according to the pre-set settings inputted by the user. This

pre-set parameter is based on either a Pause countdown and Run Time or number of cycles required on specific days or a 24/7 period.

1.1.1 Autol Mechanical & Hardware Overview

The Autol Automated lubrication system consists of the following:

• Reservoir (size vary from 2; 4; 6; 8; 10; 12; 20 kg based on the design requirement)

• DC24V Motor

• Gear reduction

• Stirring Paddle

• Pumping element – Spring Piston (4.5 cm³ / minute)

• Visual Pressure Gauge (0 to 400 bar)

• Distribution valve blocks

• Piping (Stainless, Mild steel or Polyamide hose)

• Various Fittings

• Various Instruments

• PLC control unit

This combination completes a full centralized progressive multi-point lubrication system with

full automated and condition monitoring capabilities.

Operating Temperature: ( -20 °C to +70 °C)

Max operation pressure: 350 bar

Grease: NLGI 0; 1 & 2

Relative Humidity: ≤95%

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Autol ALP Pump

Reservoir

Pressure Relief Valve

Grease Outlet

Filling Port

Return Inlet

Stirring Paddle Motor Location

Wire Port 3

Wire Port 2

Typical Installed System

Layout

Wire Port 1

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Distribution Valve Block

The pistons of a progressive distributor operate in order, discharge the grease into lube

points one by one in a progressive way. The indicator stem can be used to observe the

operating state of all the distributors. Through a piston (pin) detector mounted on the

primary distributor, the operating state of the distributors can be detected automatically. In

case of blockage, the alarm on the PLC will be triggered. According to the solution demand,

the grease into the lube points can be multiplied through combining several outlets of the

distributor.

Pin Detection

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1.1.2 Project Design Layout

1.1.2.1 LCM 1

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1.1.2.2 LCM 2

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1.1.2.3 LCM 3

Each system consists of a series of lubrication distribution blocks design to supply each bearing with the correct amount of lubrication as

prescribed by the bearing manufacturer / OEM.

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1.1.3 Equipment List

1.1.3.1 Drives & Outputs

TAG Description PLC address

Send data

LCM1_Q Autol Lube Pump 1 Output Q48.0 DB#. SendData.Bool_0



LCM1_FAULT Autol Fault light indication 1 (optional) Q48.3 DB#. SendData.Bool_3



1.1.3.2 Digital Inputs

TAG Description PLC address

Send data

LCM1_US001 Lubrication Running Feedback #1 I48.0 DB#. SendData.Bool_6

LCM1_XS001 Distribution block Feedback #1 I48.1 DB#. SendData.Bool_7





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LCM3_ES001 Lubrication System emergency Stop I49.0 DB#. SendData.Bool_10

LCM3_RS001 Lubrication System alarm Reset I49.1 DB#. SendData.Bool_11

1.1.3.3 Analog inputs input

Autol Sensors

TAG Description PLC address Inter PLC Coms Send data

Eng. min

Eng. Max

HH H L LL

LCM1-LT001 Autol reservoir level PIW600 DB#. SendData.Val_0 0% 100% 95% 90% 15% 5%

R1S4C0 4mA 20mA N/A N/A Alarm Trip





LCM1-PT001 Autol Distribution

pressure

PIW606 DB#. SendData.Val_3 0Bar 400Bar 350Bar 300Bar 10bar 5bar

R1S4C3 4mA 20mA Trip Alarm N/A N/A

LCM2-PT001 Autol Distribution

pressure



LCM3-PT001 Autol Distribution pressure



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Condition monitoring

LCM_001

TAG Description PLC address Inter PLC Coms Send

data

Eng.

min

Eng.

Max

HH H L LL

LCM1_TT001 Yard Conv Snub Top temperature 1

PIW612 DB#. SendData.Val_6 -50°C 150°C 100°C 85°C 20°C 10°C


LCM1_TT002 Yard Conv Snub Top

temperature 2



LCM1_TT003 Yard Conv Snub bottom temperature 3



LCM1_TT004 Yard Conv Snub bottom temperature 4



LCM1_TT005 Yard Conv NDE left temperature 5



LCM1_TT006 Yard Conv NDE Right

temperature 6



LCM1_TT007 Boom Conv NDE left

temperature 7



LCM1_TT008 Boom Conv NDE Right temperature 8



LCM1_TT09 Boom Conv DE left temperature 9



LCM1_TT10 PIW630 DB#. SendData.Val_15 -50°C 150°C 100°C 85°C 20°C 10°C

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Boom Conv DE Right temperature 10


LCM_002


Eng. min

Eng. Max

HH H L LL

LCM2_TT11 Bogey wheel front Right temperature 11

PIW632 DB#. SendData.Val_16 4mA 20mA Trip Alarm N/A N/A

R1S6C0 -50°C 150°C 100°C 85°C 20°C 10°C

LCM2_TT12 Bogey wheel front Right temperature 12



LCM2_TT13 Bogey wheel front left temperature 13



LCM2_TT14 Bogey wheel front left

temperature 14



LCM_003


Eng. min

Eng. Max

HH H L LL

LCM3_TT15 Bogey wheel middle right temperature 15



LCM3_TT16 PIW642 DB#. SendData.Val_21 -50°C 150°C 100°C 85°C 20°C 10°C

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Bogey wheel middle right temperature 16


LCM3_TT17 Bogey wheel middle left temperature 17



LCM3_TT18 Bogey wheel middle left temperature 18



LCM3_TT19 Bogey wheel Back

Right temperature 19



LCM3_TT20 Bogey wheel Back Right temperature 20









LCM3_TT23 Bogey wheel Back left

temperature 24



LCM3_TT24 Bogey wheel Back left

temperature 25



LCM3_TT25 Bogey wheel Back left temperature 25



LCM3_TT26 Bogey wheel Back left temperature 26



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1.1.4 Bill of Materials

The live condition monitoring system has various components that are integrated to provide the full solution. The overall view of the Autol system consists of:

• 3 x Automated Autol systems with positive feedback

• Main PLC Control Panel

• Condition monitoring temperature sensors

1.1.4.1 Detail:

1. 8 kg Autol lubrication pump (LCM-001)

1.1. 1x 3-point distribution block 1.2. 3x 2- point distribution block 1.3. Pressure Gauge 1.4. Polyamide tubing 1.5. Fittings 1.6. Level transmitter 1.7. Pressure transmitter 1.8. Grease distribution block inductive sensor

2. 4 kg Autol lubrication pump (LCM-002)

2.1. 1x 4-point distribution block 2.2. Pressure Gauge 2.3. Polyamide tubing 2.4. Fittings 2.5. Level transmitter 2.6. Pressure transmitter 2.7. Grease distribution block inductive sensor

3. 6 kg Autol lubrication pump (LCM-003) 3.1. 1x 3-point distribution block 3.2. 1x 4-point distribution block 3.3. 2x 6-point distribution block 3.4. Pressure Gauge 3.5. Polyamide tubing 3.6. Fittings 3.7. Level transmitter 3.8. Pressure transmitter 3.9. Grease distribution block inductive sensor

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1.1.4.2 Detailed breakdown of PLC

Quantity Part nr. Description Article nr.

1 6ES7507-0RA00-0AB0 System power supply, PS 60W 120/230VAC/DC

1 6ES7511-1AK02-0AB0 CPU 1511-1 PN

1 6GK7 543-1AX00-0XE0 CP 1543-1

1 6ES7523-1BL00-0AA0 Digital input/digital output DI/DQ 16x24VDC/16xDC24V/0.5A BA; incl. front connector push-in

5 6ES7 531-7KF00-0AB0 AI 8xU/I/RTD/TC ST

1 6AV6 647-0AD11-3AX0 KTP600 Basic colour PN

1 6GK5 208-0BA10-2AA3 SCALANCE X208

2 Phoenix Power supply 10 A power supply

1 6ES7590-1AE80-0AA0 Mounting rail S7-1500 rail, 482 mm

5 6ES7592-1AM00-0XB0 Front connector, Screw in system for 35mm modules, 40-pin

1 3x2 point wall plug Plug and wall mount

3 Motor relay & base To drive Autol motor

8 6GK1901-1BB10-2AA0 Profinet connectors

1 Wlink Gprs communication module

1 Raspberry pi Web interface

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1.1.4.3 PLC topology

1.1.4.4 Detailed breakdown of Instrumentation

Quantity Part nr. Description Article nr.

3 UGT582 Ultrasonic level Transmitter

3 PT5500 Pressure transmitter 0-400 bar

26 TS2229 Bolt type pt100/pt1000

26 TP3231 Temp converter

3 MS5013 Magnetic pickup sensor

3 IE5317 Inductive Proxy 24v 8mm n/o

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1.1.5 Electrical Design and Layout

1.1.5.1 Stacker cable block diagram and equipment layout

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1.1.5.2 Cable schedule and termination schedule

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1.1.6 Functional Control

1.1.6.1 General

The LCM main function is to lubricate all the required lubrication points in addition to the

lubrication function the system also does condition monitoring.

The system will also provide the following features:

1. List viewing of multiple systems on one network 2. Live animated Scada graphics 3. Configuration setup page 4. 3 modes

a. Auto b. Manual c. Purge d. Bearing protection operation

5. Monitor and historical data

a. Live Real time monitoring b. Live trending of all interlocks on system c. Reporting d. Alarming e. SMS and email notification

6. 3 lubrication function setups a. 24/7 operation at cycle intervals b. TOD (time of day) cycle operation c. Bearing protection operation

7. Actual true monitoring of system conditions

a. Level (%) b. Pressure (bar) c. Grease distribution block pulse monitoring (blockage detection) d. Pump rotor rotation (mechanical check on pump) e. Grease consumption (meter via distribution blocks ±95% accuracy) f. Cycle intervals (cycle counter) g. Bearing temperature (optional) h. Vibration analysis (optional)

8. Remote access support 9. System Security and access control. 10. Actual true monitoring of system conditions

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1.1.6.2 List viewing of multiple systems on one network

In the event of having more than one Autol pump the system will display the systems on a list view format for easy access and viewing.

1.1.6.3 Live animated Scada graphics

The system has an HMI for viewing and configuration. The system is also accessible from any

mobile device or remote station (computer) by using a unique IP Address.

1.1.6.4 System configuration page

The system configuration page allows the user to configure the system to lubricate in various modes to ensure that we comply to the manufactures lubrication specifications. various

modes, intervals and time settings can be configured on this setup page

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1.1.6.5 Monitor and historical data 1. Live Real time monitoring

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2. Live trending of all interlocks on system

3. Alarming

4. SMS and email notification

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1.1.6.6 3 modes

1.1.6.6.1 Auto mode

In auto mode the system will adhere to functional settings in the setup select menu. The auto mode enables the system to stop and start by means of the device running feedback received

from the machine.

When to run lubrication cycles

In auto mode each Autol system will act differently due to the lubrication frequencies and intervals

• LCM-001

A running counter must keep track of the number of minutes the system has been active. Every time that the conveyors start the system will be provided with an input signal from the reclaimer PLC via inter PLC coms to activate the Autol lubrication system. The Autol lubrication system will be programed to greases at the correct relubrication intervals.

• LCM-002 & LCM-003

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A running counter must keep track of the number of minutes the system has been active. Every time that the bogey wheels travel the system will be provided with an input

signal from the reclaimer PLC via inter PLC coms to activate the Autol lubrication system. The Autol lubrication system will be programed to greases at the correct relubrication

intervals. The running feedback signal from the reclaimer must be retained for 20min on the negative edge trigger to prevent unnecessary and frequent stop and start of the systems.

➢ Alarms (all parameters are displayed in RAT (Range Alarm and Trip list)

• An additional timer is required to monitor the lubrication frequency. If no lubrication was applied for a period longer than 4 consecutive accumulated hours,

an alarm needs to be displayed on the machines’ s Scada (Lube system frequency Alarm)

• Low level on Autol grease dispenser

• High pressure on pump element port

• High temperature where applicable

• High vibration where applicable

➢ Trips (optional) under circumstances may the lubrication system trip the equipment unless requested by the client. The system is designed for condition monitoring and not process control.

• An additional timer is required to monitor the lubrication frequency. If no lubrication was applied for a period longer than 8 consecutive accumulated hours, an alarm needs to be displayed on the reclaimer Scada (Lube system frequency

Alarm)

• Low-Low level on Autol grease dispenser

• High-High pressure on pump element port

• High-High temperature where applicable

• High-High vibration where

➢ Interlocks • If no lubrication was applied for a period longer than 4 consecutive accumulated hours

on any of the above lubrication systems (Lube system frequency failure)

• Fault statuses and alarm conditions can be drawn from the lubrication PLC via profinet

1.1.6.6.2 Manual mode

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In manual mode all the above functions apply except for the signal from the machine. The system will no longer be controlled by the feedback from the plant equipment.

It requires the enable button on the Scada to be activated and then the system will run according to the system intervals configured in the configuration page.

1.1.6.6.3 System purge

System purge is a function that is used when the system needs to be purged or flushed.

this is only a maintenance function and can only be done by a lubrication technician.

1.1.6.6.1 Bearing protection mode

Bearing protection mode is activated when a bearing is in a high-high stare for longer than 1 mi. If the system restores to operating temperature the bearing protection mode will restore

to default

1.1.6.7 lubrication function setup

24/7 operation at cycle intervals

Cycle ➢ Cycles are time based ➢ One cycle consists of a complete on and off time interval.

• Running time + Standing time = One cycle

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TOD (Time of day function) ➢ The time of day allows the operator to select the operating days as well as hours that the

system may function

1.1.6.8 Actual true monitoring of system conditions

1.1.6.8.1 Level (%)

A very accurate ultrasonic level transmitter provides Realtime actual level of the lubrication cylinder

1.1.6.8.2 Pressure (bar)

Hi pressure precision pressure transmitter indicates the port pressure from 0 up to 400bar

1.1.6.8.3 Grease distribution block pulse monitoring (blockage detection)

An inductive sensor monitors the distribution block for pulses. This will indicate when there is a flow of lubricant through the system to all the required

lubrication points

1.1.6.8.4 Pump rotor rotation (mechanical check on pump)

A magnetic pickup sensor has been installed at the motor driver gear to detect motor rotation and to determine if the spindle is turning and that the pump is

pumping

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1.1.6.8.5 Grease consumption (meter via distribution blocks

±95% accuracy)

Grease consumption is calculated to monitor and control the grease

consumption on each system. A standard pumping element dispenses 4.5 ml grease per min

1.1.6.8.6 Bearing temperature (optional)

Temperature sensors are mounted on the bearing to monitor the bearings temperature.in the event that a bearing should go over temperature, the

bearing protection mode activates and continuously applies a lubricant untick the condition restores to normal

1.1.6.9 Remote access support

A secure remote support system is in place allowing the client to view the plant

from any location

Stacker URL: [email protected]:81

1.1.7 Maintenance & Troubleshooting

1.1.7.1 Maintenance

a. Activate the grease system manually (purge activation); check that the operation is normal

and no fault codes / alarms appear;

b. Check whether there is any leakages or ruptures in any of the pipelines, ensure you follow

the entire route of the pipeline, check whether each point is receiving grease by taking off

the fitting located on the plumber bock / grease point;

c. Check all pipe bundles and wiring harness are connected securely and firm;

d. Clear all dirt built up on or near the systems, this includes the pipework, distribution blocks,

cables etc, any greased leaked must be cleaned and disposed of;

e. Check grease level inside reservoir of the system and fill if required;

f. Ensure maintenance records are kept and completed

Contact World Focus for any queries or assistance.

mailto:[email protected]:81

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1.1.7.2 Troubleshooting

Basic troubleshooting problems, for more involved problems please contact a World Focus

Technician.

Fault :

The pump does not work

Analysis :

a. The motor does not rotate

b. There is some air in the pump

Possible solution :

a) Check the motor and power, ensure power is on

b) Exhaust air

Fault :

The outlet pressure of the pump is insufficient

Analysis :

a. Low piston / pumping element pressure (Motor is turning and piston is moving)

b. Safety relief valve failure (Grease is bypassing main line into the reservoir)

Possible solution :

a) Replace pumping element

b) Replace Safety relief valve

Fault :

No pressure

Analysis :

a. Pressure sensor is damaged

b. Pressure sensor wires are loose

c. Grease leakage

Possible solution :

a) Replace pressure sensor

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b) Firmly secure wires

c) Fix grease leak and ensure there are no other leaks

Fault :

No pressure

Analysis :

a. Pressure sensor is damaged

b. Pressure sensor wires are loose

Possible solution :

a) Replace pressure sensor

b) Firmly secure wires

Documents

Functional Design Specificationcoastlubricants.com/wp-content/uploads/2020/11/... · 1.1 Autol Functional Design Specification The Autol centralized lubrication systems are new generations