Technical Guidelines for Machinery and Equipment...EN 1037:2008 Safety of machinery – Prevention...

voestalpine Tubulars GmbH & Co KG

Technical Guidelines for Machinery and Equipment

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Technical Guidelines for Machinery

and Equipment

Version January 23, 2018

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

24.04.2015 1.3, 5.3.4, 5.5, 5.7

30.04.2015 1.3

01.12.2015 2.5, 3.1, 3.6.2, 3.6.3, 3.6.4, 3.6.6, 3.7.4, 3.7.6, 3.8, 3.9.2

23.01.2018

1.3, 1.4, 1.5, 1.6, 1.7, 2.2, 2.5, 2.6, 3.6.1, 3.6.2, 3.6.3, 3.6.4, 3.6.6, 3.6.7, 3.7.4,

3.7.6, 3.8, 3.9.3, 4.1.1, 4.1.2, 4.2.2, 4.2.3, 4.2.4, 4.2.5, 4.2.6, 4.2.7, 4.2.8, 4.2.9,

4.2.10, 4.2.11, 4.3.8, 4.4.1, 4.4.2, 4.5.1, 4.5.6, 5.3.1, 5.5.4, 5.8, 5.9, 5.10, 6, 7.1,

7.2, 7.3, 7.4, 8.2, 8.3.1, 8.3.3, 8.3.3.1-8, 8.4, 8.4.1-8, 8.5, 8.6, 8.7, 9



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Table of Contents

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

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

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

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

1.4 Applicable standards and regulations ................................................................................................. 8

1.5 CE-marking for concatenated machinery or equipment .............................................................. 10

1.6 Subcontractor adherence to guidelines ............................................................................................ 10

1.7 Additional conditions .............................................................................................................................. 10

2 Tasks .............................................................................................................................................................. 10

2.1 Duty to obtain information .................................................................................................................... 10

2.2 Risk assessment ......................................................................................................................................... 10

2.3 Functional test ........................................................................................................................................... 11

2.4 Training ....................................................................................................................................................... 11

2.5 Technical documentation ...................................................................................................................... 11 2.5.1 General .......................................................................................................................................................... 11 2.5.2 Documentation of electrical equipment ........................................................................................... 13

2.6 Additional documentation documents for instrumentation and control of Furnaces........... 14

3 Mechanical specifications ......................................................................................................................... 15

3.1 General ....................................................................................................................................................... 15

3.2 Screws .......................................................................................................................................................... 15

3.3 Drives ........................................................................................................................................................... 15

3.4 Lubrication ................................................................................................................................................. 16 3.4.1 Oil and grease filling, Oil sight glass ................................................................................................... 16 3.4.2 Lubrication lines ......................................................................................................................................... 16 3.4.3 Manufacturers of small and medium-sized systems ..................................................................... 16

3.5 List of mechanics manufacturers ......................................................................................................... 16

3.6 Hydraulics .................................................................................................................................................. 17 3.6.1 General .......................................................................................................................................................... 17 3.6.2 Hydraulic pipes/tubes ............................................................................................................................. 17 3.6.3 Hydraulic tank, Oil level indicator ....................................................................................................... 17 3.6.4 Hydraulic accumulator ............................................................................................................................ 17 3.6.5 Inscription ..................................................................................................................................................... 18 3.6.6 List of hydraulics manufacturers .......................................................................................................... 18 3.6.7 Measurements ............................................................................................................................................ 19

3.7 Pneumatics................................................................................................................................................. 19 3.7.1 Air oiling ........................................................................................................................................................ 19 3.7.2 System separation ..................................................................................................................................... 19 3.7.3 Valves ............................................................................................................................................................ 19 3.7.4 Pipes and hose connection .................................................................................................................... 20 3.7.5 Inscription ..................................................................................................................................................... 20 3.7.6 List of pneumatics manufacturers ....................................................................................................... 20



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3.8 Pipelines ...................................................................................................................................................... 21

3.9 Operating data......................................................................................................................................... 21 3.9.1 Compressed air .......................................................................................................................................... 21 3.9.2 Central hydraulics WT1, WT2, SRA ....................................................................................................... 22 3.9.3 Water ............................................................................................................................................................. 22

4 Electrical specifications.............................................................................................................................. 23

4.1 Installation of switch cabinets ............................................................................................................... 23 4.1.1 General .......................................................................................................................................................... 23 4.1.2 Identification system ................................................................................................................................ 23 4.1.3 Location of parts ....................................................................................................................................... 24 4.1.4 Location of terminal strips/cable fittings .......................................................................................... 24 4.1.5 Free space .................................................................................................................................................... 24 4.1.6 Switch cabinet climate control .............................................................................................................. 24 4.1.7 Protection class .......................................................................................................................................... 25 4.1.8 Service socket and switch gear cabinet lighting ............................................................................ 25

4.2 Installation guidelines ............................................................................................................................. 25 4.2.1 Cables and conductors ........................................................................................................................... 25 4.2.2 Standard cables ......................................................................................................................................... 26 4.2.3 Special cables ............................................................................................................................................. 26 4.2.4 Movable cable routing ............................................................................................................................ 26 4.2.5 Terminal strips ............................................................................................................................................. 27 4.2.6 Connection of sensors .............................................................................................................................. 27 4.2.7 Identifying parts and cables .................................................................................................................. 27 4.2.8 Switching devices ....................................................................................................................................... 27 4.2.9 Electrical drives and associated equipment .................................................................................... 27 4.2.10 Signalling devices ...................................................................................................................................... 27 4.2.11 Conductor colors ....................................................................................................................................... 28

4.3 Electrical supply, protective measures ............................................................................................... 28 4.3.1 Main voltage ............................................................................................................................................... 28 4.3.2 Protective measures ................................................................................................................................. 28 4.3.3 Control circuits ............................................................................................................................................ 29 4.3.4 Power supplies and control transformers .......................................................................................... 29 4.3.5 Potential equalization .............................................................................................................................. 29 4.3.6 Protecting transformers from overloading ....................................................................................... 29 4.3.7 Switching inductive loads ....................................................................................................................... 30 4.3.8 EMC-conform installation ....................................................................................................................... 30 4.3.9 Operation and protection of induction motors .............................................................................. 31

4.4 Control equipment, operator interface .............................................................................................. 31 4.4.1 EMERGENCY STOP device ...................................................................................................................... 31 4.4.2 Operating modes ...................................................................................................................................... 31 4.4.3 Faults and alarms ...................................................................................................................................... 32

4.5 Programmable control systems ............................................................................................................ 32 4.5.1 Selection and setup .................................................................................................................................. 32 4.5.2 Installation ................................................................................................................................................... 33 4.5.3 Interfaces ...................................................................................................................................................... 33 4.5.4 Decentralization ........................................................................................................................................ 33 4.5.5 ASI bus ........................................................................................................................................................... 33 4.5.6 Programming languages ........................................................................................................................ 33 4.5.7 Program structure...................................................................................................................................... 33 4.5.8 Simatic S7 protection levels ................................................................................................................... 34 4.5.9 Safety controllers ....................................................................................................................................... 34



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4.6 CNC systems and industrial computers .............................................................................................. 34

5 Specifications for instrumentation and control of Furnaces ............................................................... 35

5.1 Accessibility ................................................................................................................................................ 35

5.2 S7/Software ............................................................................................................................................... 35 5.2.1 Structure........................................................................................................................................................ 35 5.2.2 General Information ................................................................................................................................. 36

5.3 Pipes............................................................................................................................................................. 36 5.3.1 Impulse pipes .............................................................................................................................................. 36 5.3.2 Grounding and paintwork ...................................................................................................................... 37 5.3.3 Pipes for Ignition Burner .......................................................................................................................... 37

5.4 UV-Sensor and Ignition burner ............................................................................................................. 37

5.5 Measurements .......................................................................................................................................... 37 5.5.1 Quantity Measurements ......................................................................................................................... 37 5.5.2 Oxygen Measurements ........................................................................................................................... 37 5.5.3 Exhaust Measurements ........................................................................................................................... 37 5.5.4 Pyrometer Measurements ...................................................................................................................... 38

5.6 Switch cabinets ......................................................................................................................................... 38

5.7 Limit values ................................................................................................................................................ 38

5.8 Thermocouples ......................................................................................................................................... 38

5.9 Cooling of electrical components ........................................................................................................ 39

5.10 Water cooling on industrial furnaces .................................................................................................. 39

6 Industrial Computers .................................................................................................................................. 39

7 APPENDIX A: Electrical parts (approved list) and documentation specifications ........................... 40

7.1 Electrical parts .......................................................................................................................................... 41

7.2 Selection list of the Phoenix modules .................................................................................................. 44

7.3 TIA approved list ....................................................................................................................................... 45

7.4 Documentation requirements ............................................................................................................... 49

8 APPENDIX B: voestalpine Tubulars S7 software specifications .......................................................... 51

8.1 Liability disclaimer .................................................................................................................................... 51

8.2 Hardware configuration / device view ............................................................................................... 51

8.3 Structuring .................................................................................................................................................. 52 8.3.1 Programming languages and standard software ......................................................................... 52 8.3.2 Program structure...................................................................................................................................... 52 8.3.3 Folder structure .......................................................................................................................................... 53

8.4 PLC variables ............................................................................................................................................. 57 8.4.1 Input / output variables .......................................................................................................................... 58 8.4.2 FU input / output variables / other fieldbus devices .................................................................... 59 8.4.3 Flag assignment: general ....................................................................................................................... 60 8.4.4 Flag assignment: operating mode ...................................................................................................... 61 8.4.5 Flag assignment: drive ............................................................................................................................. 61 8.4.6 Bypass Flag .................................................................................................................................................. 62 8.4.7 “Don’t know yet” ........................................................................................................................................ 62 8.4.8 Parameters ................................................................................................................................................... 62

8.5 Structure of functions .............................................................................................................................. 63



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8.5.1 Safety program .......................................................................................................................................... 63 8.5.2 General .......................................................................................................................................................... 66 8.5.3 Equipment areas ........................................................................................................................................ 69 8.5.4 Messages ...................................................................................................................................................... 72

8.6 PLC data types .......................................................................................................................................... 73 8.6.1 Safety data type: Not_Halt ................................................................................................................... 73 8.6.2 Safety data type: Schutztuer_ohne_Anford_entr ......................................................................... 74 8.6.3 Safety data type: Schutztuer_mit_Anford_entr ............................................................................. 74 8.6.4 Safety data type: Lichtgitter .................................................................................................................. 74 8.6.5 Safety data type: F_Signal_Allgemein ............................................................................................... 74 8.6.6 Safety data type: Sicherheitskreis_ohne_RUECKF ........................................................................ 74 8.6.7 Safety data type: Sicherheitskreis_mit_RUECKF ............................................................................ 74 8.6.8 Drive ............................................................................................................................................................... 75 8.6.9 Analogwerte_Typ ...................................................................................................................................... 76 8.6.10 Rampenbildner_Typ ................................................................................................................................. 76 8.6.11 Regler_Typ ................................................................................................................................................... 77 8.6.12 Betriebsstundenzaehler_Typ ................................................................................................................. 78 8.6.13 Mittelwert_Typ ............................................................................................................................................ 78 8.6.14 RACK_FLT_Typ ............................................................................................................................................ 78 8.6.15 Antrieb FU PPO4 (z.B. PDrive) ................................................................................................................ 78 8.6.16 Sinamics ........................................................................................................................................................ 79

8.7 Visualization .............................................................................................................................................. 86 8.7.1 Time synchronization ................................................................................................................................ 86 8.7.2 Operator logon .......................................................................................................................................... 86 8.7.3 Alarm messages ......................................................................................................................................... 86 8.7.4 Archiving ....................................................................................................................................................... 86 8.7.5 Display ........................................................................................................................................................... 87 8.7.6 Color regulations WinCC-OA ................................................................................................................. 89

9 APPENDIX C: VAT-Dokumentationsstruktur_Rev.0 .............................................................................. 90



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1 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:

» Applicable EU guidelines and those regulations that have been adopted into Austrian law,

especially:

» Machine Safety Regulation MSV2010

» Low Voltage Equipment Regulation in accordance with Low Voltage Directive 2014/35/EU

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

» Harmonized European standards

» Recognized rules of engineering

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

» Official requirements

» voestalpine Tubulars identification system (equipment abbreviations and location codes, will

be issued by the CP)

» Crane - Safety - Non-fixed load lifting attachments DIN EN 13 155



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1.4 Applicable standards and regulations

PED 2014/68/EU

Pressure Equipment Directive

DGÜW-V Pressure Equipment Control Order

DIN 20066 Fluid technology – hose lines, dimensions, specifications

DIN 2403 Identification of pipelines according to the fluid conveyed

DIN 51524-3 Pressure fluids – Hydraulic oils – Part 3: HVLP hydraulic oils, Minimum

requirements

DIN 7991 Hexagon socket countersunk head cap screws (DIN EN ISO 10642)

DIN 912 Hexagon socket head cap screws (DIN EN ISO 4762)

DIN 916 Hexagon socket set screws with cup point (DIN EN ISO 4029)

DIN 931 Hexagon cap screws partially threaded

EN 1037:2008 Safety of machinery – Prevention of unexpected start-up

EN 1090 Execution of steel structures and aluminium structures

EN 12952, EN 12953 Water-tube boilers and auxiliary installations, Shell boilers

EN 13445 Unfired pressure vessels according to AD2000/HP0

EN 13480 Metallic industrial piping

EN 13675:2004+A1:2010 Safety of machinery – Safety requirements for tube forming and rolling

mills and their finishing line equipment

EN 50110 Operation of electrical installations

EN 60204-1 :2006 Safety of machinery – Electrical equipment of machines – Part 1:

General requirements

EN 61000-6-1 Electromagnetic compatibility (EMC) Generic standards – Immunity to

interference


interference for industrial environments

EN 61000-6-3 Electromagnetic compatibility (EMC) Generic standards – Emission

standard for residential, commercial and light-industrial environments


interference for industrial environments



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EN 61439-1 :2013 Low-voltage switchgear and controlgear assemblies – Part 1: General

rules

EN 61439-2 :2011 Low-voltage switchgear and controlgear assemblies – Part 2: Power

switchgear and controlgear assemblies

EN 61496-1 :2013 Safety of machinery – Electro-sensitive protective equipment – Part 1:

General requirements and tests

EN 61784 Industrial communication networks - Profiles - Part 3-6: Functional safety

fieldbuses – Additional specifications for CPF 6 (IEC 61784-3-6: 2007)

EN 61800-3 Adjustable speed electrical power drive systems – EMC requirements

EN 61918 Industrial communication networks – Installation of communication

networks in industrial premises

EN 746-1 and EN 746-

2

Industrial thermoprocessing equipment

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

programmable electronic control systems

EN ISO 12100:2010 Safety of machinery – General principles for design – Risk assessment

and risk reduction

EN ISO 13849-1:2008 Safety of machinery – Safety-related parts of control systems – Part 1:

General principles for design

EN ISO 13849-2:2012 Safety of machinery – Safety-related parts of control systems – Part 2:

Validation

EN ISO 13850 Safety of machinery – Emergency stop function – Principles for design

EN ISO 13855:2010 Safety of machinery – Positioning of safeguards with respect to the

approach speeds of parts of the human body

EN ISO 13857:2008 Safety of machinery – Safety distances to prevent hazard zones being

reached by upper and lower limbs

EN ISO 14119:2014 Interlocking devices associated with guards – Principles for design and

selection

EN ISO 14120 Safety of machinery – General requirements for the design and

construction of fixed and movable guards

ISO 1219-1 Fluid power systems and components – Graphical symbols and circuit

diagrams – Part 1: Graphical symbols for conventional use and data-

processing applications

ÖNORM EN 7010 Graphic symbols; Safety colours and safety signs

ÖVE/ÖNORM

E 8001-6-61

Erection of electrical installations with low voltages

Part 6-61: Verification – Initial verification

ÖVE/ÖNORM

E 8001-6-63

Erection of electrical installations with low voltages

Part 6-63: Verification – Certification and reporting



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1.5 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.

1.6 Subcontractor adherence to guidelines

The CO is fully responsible to the CP for adherence to these guidelines. If the CO uses third parties to

fulfil the contracted services, then the third parties must be included in the obligation to adhere to

these guidelines.

1.7 Additional conditions

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 CO is obliged to obtain information about these

conditions.

2.2 Risk assessment

The documentation of the risk assessment must be handed over to the contracting party’s Basic

Engineering. 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.

If access to the hazardous areas during operation is required, the protective devices and the signal

processing equipment must meet at least a performance level PL = d / category 3 (EN13675-A.2).



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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 CP is to receive a written

test report.

In general, each CO 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 CP.

It is agreed that both the CO and the CP will name a contact who will be responsible for all training

and educational activities.

The CO 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

2.5.1 General

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.

All documents must be created by the contractor in German.

The “preliminary documentation” must be delivered at least 2 weeks before commissioning 1 x on

disk (CD or DVD) and the e-plans 1 x on paper. The “as-built documentation” is part of the positive

acceptance and must be delivered 1 x on disk (CD or DVD) and 2 x on paper.

The disk documentation must correspond 1:1 to the paper documentation.

The documentation must be delivered in the form of the stipulated voestalpine Tubulars

documentation structure (Appendix C: VAT-Dokumentationsstruktur_Rev.0) including table of

contents. The file formats to be delivered can be found in the “VAT-Dokumentationsstruktur_Rev.0”

table.

The folder to be populated is available at http://www.voestalpine.com/tubulars/de/downloads/ .

http://www.voestalpine.com/tubulars/de/downloads/



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All documents must be clearly named.

e.g.: Assembly and operating instructions for helical gearboxes and bevel helical gearboxes of the

X_20284535 series.

Only short names are permitted (e.g. 20284535) is not allowed!

The following contents are required in the documentation:

» Precise installation plans including all machine parts and modules

» Production drawings including all wear parts

» Hydraulic and pneumatic schematics in accordance with ISO 1219-1 and ISO 1219-2

» Lubrication plans with lubrication point position numbers and corresponding lubrication

instructions or lubrication chart!

» List of the delivered production drawings

» Parts list for all assemblies. The delivered drawings are to be marked with yellow in the parts

lists!

» For conversions of existing systems, the contractor’s existing parts lists must be updated by

the contracting party!

» Handbook and instruction manual

» Maintenance and repair instructions with the necessary engineering plans

» Data sheets of all purchased parts

» Spare parts lists for a three-shift operation, unless otherwise stipulated by the contracting

party.

» The following information is required:

o Position number

o Drawing number

o Material

o Installed quantity

o Recommended spare parts quantity

o Manufacturer

o Manufacturer type

o Item number

» 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.



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2.5.2 Documentation of electrical equipment

2.5.2.1 Reports and documents

The following contents are required in the documentation:

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 machines:

» 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 or design verification in accordance with ÖVE EN 60439 Low voltage switching

device combinations

» Risk assessment 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 of all Movements

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

door tumblers

» Power circuit diagrams are to be created in EPLAN P8 V2.6, 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

The structure of the documentation is shown in Appendix A by means of an example = 4MAA.

2.5.2.2 PLC software documentation

PLC programs are to be submitted to the CP on a CD-ROM. The list format is A4 portrait. The software

version must be the latest version available at acceptance. Changes made by 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 (KOP, FUP, AWL, S7-SLC)

» Listing of data blocks (commented)

» Cross-reference list of all operands

» Assignment list for inputs, outputs, flags



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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.

2.5.2.3 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.

2.5.2.4 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.

2.6 Additional documentation documents for instrumentation and

control of Furnaces

» Flow schema

» Plan of measuring points

» 3D CAD drawings of the pipes

» Equipment list (including calculations)

» Burner documentation including pressure curves for combustion air and fuel gas



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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).

In order to keep the contracting party's storage costs low, components identical to the ones presently

used by the contracting party are to be used if possible. Function or technical progress should not be

restricted. For this reason, the contracting party must be informed about the planning progress at

regular intervals.

Contractor and contracting party must agree on the use of spare and wearing parts.

Hydraulic power units, control elements and valve stands (hydraulic / pneumatic), as well as

lubrication systems are to be installed outside of protective fences.

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.



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3.4 Lubrication

All lubrication points must be marked on the machinery and equipment as specified in the lubrication

and maintenance schedule.

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.

Manual lubrication points are not permitted.

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)

The connection for lubricating lines can be made using a cutting ring connection.

3.4.3 Manufacturers of small and medium-sized systems

Material Supplier

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, NORD

Pumps for industrial water EGGER, KSB, Xylem

Cooling tower COFELY Kältetechnik



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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.

The equipment for the pressure generating system with redundant main pump unit, or the use of a

circulation system and filter system (e.g. with differential pressure monitoring) is requirement-specific

and is to be agreed upon with the contractor in the course of the project.

3.6.2 Hydraulic pipes/tubes

Installation and layout of hose lines must be performed according to DIN 20066.

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.

In the case that rust-free metals are not used for pipelines, they must be painted thoroughly in the

colour of the hydraulic medium.

The pipe connections to the consumers are to be made with pipe threads according to ISO 228-1 or

with SAE flanges.

3.6.3 Hydraulic tank, Oil level indicator

In principle there is hydraulic oil in accordance to ISO VG 46, DIN 51524/Teil 2 to use.

If the tank has a capacity of 1000l or more the tank has to be equipped with to additional

connections (R 2”) and stopcock. (additional draining, filtering, emptying)

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.

If no circulating system with flow heater is included, a tank heater is to be provided. For tank volumes

> 1000l, a water content warning must be installed. For the tank, a collection tray with half the tank

volume should be provided.

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. Only

storage reservoirs of test level 1 should be used. Bubble accumulators are preferred. The

accumulators have to be equipped with an automatic relief valve at the oil side.

The pressure vessel and the safety valve must be mounted so that the manufacturer's instructions can

be read without any aids. The storage capacity must be determined during the design process.



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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. Function labels and type plates may not

be painted over.

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

labelling

pressure switch position number, pressure and electrical labelling

filter position number, manufacturer product name

hydraulic cylinders serial number

hydraulic accumulator manufacturer, year of manufacture, gas

pressure, volume

other components position number

All symbols are to be executed according to ISO 1219-1.

3.6.6 List of hydraulics manufacturers

Material Description Supplier

Hydraulic components and

accessories

Hydraulic cylinders

Series CDH1 or CDH2,

Seal version: M = standard

sealsystem

Bosch Rexroth

Float switch Type ABZMS-41, level and

temperature measurement (RTA) Bosch Rexroth

Valves

Switch valves with manual override

Proportional valves: Manual

overrides must be defined together

with the contracting party

Bosch Rexroth

Hydraulic fittings

DIN fittings, 24° sealing cone cutting

ring threaded connections are not

permitted

Ermeto, Walform

Hydraulic flanges for pressure lines SAE flange, AVIT square flanges GS-Hydro

Hydraulic flanges for tank lines DIN 2633 (low pressure flange PN 16)

Manometer With glycerine filling

Hydraulic cooling With plate heat exchanger To be defined with

the contractor

Hose lines 24° sealing cone connection for DIN

fittings



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3.6.7 Measurements

Pressure transmitters with digital display to monitor the pressure generating system must be provided.

Minimess connections (G ¼") are to be applied as follows:

» Before each pressure control valve

» After each pressure reduction valve

» In the P, T, A, B lines

» Parallel to each pressure transducer and pressure switch

All values measured on the system must be wired into an intermediate terminal box. The

measurement of the values is to be coordinated with the contracting party.

The use of a particle counter with remote monitoring of oil quality in systems with proportional valves

must be defined separately with the contracting party.

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.

The sealing elements of the components must be equipped with the appropriate material.

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.

Ensure that all connections and adjustment screws are accessible.

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.



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3.7.4 Pipes and hose connection

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

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

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

In the case that rust-free metals are not used for pipelines, they must be painted thoroughly in the

colour of the hydraulic medium.

3.7.5 Inscription

The labelling is carried out as in the hydraulics (see 3.6.5).

3.7.6 List of pneumatics manufacturers

Material Description Supplier

Pneumatic components and

accessories

Pneumatic valves ISO sizes 1 to 4

(base mounting valves)

Festo, Norgren,

Aventics, Stasto

Pneumatic cylinders

ISO cylinder

Line connection

Pipe thread ISO 228-1

Festo, Norgren,

Aventics, Stasto

Pneumatic fittings DIN fittings 24° sealing cone

or push-in fittings



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3.8 Pipelines

The pipelines are to be designed according to “voestalpine execution standards for pipe classes”.

These are available for download at http://www.voestalpine.com/tubulars/de/downloads/ .

An overview of the valid pipe classes is shown below.

max. Druck min. Temp. zul. Druck max. Temp. Druck Temp.

abgegeben am [bar] [°C] [bar] [°C] [bar] [°C]

1 EN-E10P abgegeben 23.10.2017 Heizkreisläufe ND 7,2 -10 6 90 6 90

2 EN-D16HG abgegeben 23.10.2017 Schmieröl Vorlauf 14 -20 10 100 10 70

3 EN-E16P abgegeben 23.10.2017Abwärme DF, Dampfkondensat nach

Kondensomat, Kühlwasser (geschlossener

Kreislauf)

16 -10 13 180 14,3 140

4 EN-E25PD abgegeben 23.10.2017Sattdampf nach Speicher, Prozeßdampf 12barü,

Dampfkondensat PD, Dampfkondensat SD25 -10 16 300 16 300

5 EN-E40P abgegeben 23.10.2017 Kesselspeisewasser 35 -10 30 150 30 150

6 EN-F100PK abgegeben 23.10.2017 Sattdampf vor Speicher, Dampfkondensat SD HD 95 -10 60 300 60 300

7 EN-F160PK abgegeben 23.10.2017 Dual Fuel 125 -10 116 150 116 150

8 EN-E16FH abgegeben 23.10.2017 Erdgas Werksnetz, Erdgas Betrieb Halle 10 -10 9,5 50 9,5 50

9 EN-E25NH abgegeben 23.10.2017 Stickstoff, Argon 25 -20 20 50 25 20

10 EN-E40NH abgegeben 23.10.2017Stickstoff 25bar GAN(rein), Stickstoff 14bar CGAN,

Argon25 -20 25 50 25 50

11 EN-R16AM abgegeben 23.10.2017 Ammoniakwasser 16 -10 9 25 9 25

12 EN-G100PK abgegeben 23.10.2017 Mitteldruckdampf, Dampfkondensat MD 100 -10 62 500 62 500

13 EN-R10CH abgegeben 23.10.2017Brunnenwasser, Trinkwasser,

Kreislaufkühlwasser10 -10 9 90 10 20

14 EN-R16DE abgegeben 23.10.2017 Deionat 16 -10 15 70 15 70

15 EN-R25CH abgegeben 23.10.2017 VE-Wasser 25 -10 21 100 25 20

16 EN-R40XT abgegeben 23.10.2017 Sauerstoff 25bar GOX 25 -10 20 100 25 40

17 EN-R16HG abgegeben 23.10.2017 Druckluft 6bar, Instrumentenluft 6bar 11 -10 9,5 100 10 50

18 EN-R16HV abgegeben 23.10.2017 Schmieröl Rücklauf 11 -10 10 100 10 70

19 EN-F040PK abgegeben 23.10.2017 DF-Kesselspeisewasser, DF-Dampf 40 -10 21 450 21 450

20 EN-E25FW abgegeben 23.10.2017 Fernwärme, Abwärme HBO 25 -10 20 140 20 140

21 EN-E040PK abgegeben 23.10.2017 DF-Kesselspeisewasser 40 -10 35 180 35 180

22 EN-E100PK abgegeben 23.10.2017 SD-Dampf, SD-Kondensat 100 -10 85 150 85 150

23 EN-E160PK abgegeben 23.10.2017 Kesselspeisewasser 130 -10 116 150 116 150

24 EN-D10JC-10bar abgegeben 23.10.2017 Kühlwasser, Nutzwasser, Reinwasser, Abwasser 10 -10 10 20 10 20

26 EN-R250PY abgegeben 23.10.2017 Hydrauliköl mineralisch 250 -10 250 80

27 EN-R3215PY abgegeben 23.10.2017 Hydrauliköl mineralisch 315 -10 315 80

(1) Einstufungen, Prüfungen, Anzugsmomente und Rohranbauteile, die in der Rohrklasse aufgelistet sind, beziehen sich auf Berechnungstemperatur

Berechnung (1)

lfd. Nummer Rohrklasse StatusDatum:

Medium

Gültigkeitsgrenzen der Rohrklasse

For requirements that deviate from the valid pipe classes, consult the contracting party.

The use of plastic pipes for service water distribution must be coordinated separately with the

contracting party.

3.9 Operating data

3.9.1 Compressed air

Site grid: p=6bar

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

Oilcontent: 0,1mg/m³

Dew point: +3°C

Particle size: 0,3µm

http://www.voestalpine.com/tubulars/de/downloads/



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3.9.2 Central hydraulics WT1, WT2, SRA

The use of the central hydraulics is to be agreed with the contracting party.

Operating pressure: 120bar

Temperature: 40°C – 60°C

3.9.3 Water

Pressure Temperature Water hardness

Drinking water 3,5 bar 10°C 7,5°dH

Industrial water 5 bar 10°C 12°dH

Open circuit 4 bar 25°C 12°dH

Closed circuit 4 bar 21°C 12°dH

Chemical testing of groundwater containment probes from June 20, 2017

Groundwater BEFORE filling – results (depth 8.87 m)

Sample description: clear, colourless, odourless

Parameter Analysis method Unit Measure value Parameter value (Guide value)

#

Temperature DIN 38 404 - C 4 °C 10,4 (25)

pH value DIN 38 404 - C 5 -- 7,58 (6,5 - 9,5)

Electrical conductivity

conductivity

ÖNORM EN 27888 µS/cm 565 (2500)

Oxygen content DIN EN 25814 O2

mg/l

7,90 --

Oxygen saturation DIN EN 25814 % 75,7 --

Acid capacity up pH 4,3 DIN 38 409 - H 7 mmol/l 4,0 --

Carbonate hardness DIN 38 409 - H 7 °dH 11,2 --

Total hardness DIN 38 409 - H 6 °dH 11,4 --

Ammonium (NH4+) DIN 38 406 - E 5 mg/l 0,019 (0,5)

Nitrate (NO3) DIN 38 405 - D 9 mg/l 8,02 50

Nitrite (NO2) DIN EN 26777 mg/l <0,01 0,1

NO3 NO2 1

50 3

--

mg/l

0,16

≤ 1

Chloride (Cl) DIN 38 405 - D 1 mg/l 35,8 (200)

Sulfate (SO42-

) DIN 38 405 - D 5 mg/l 22,8 (250)

Iron (as Fe) analog DIN 38 406 –

E 28

mg/l 0,010 (0,2)

Manganese (as Mn) ÖNORM ISO 8288 mg/l 0,0010 (0,05)

TOC (as C) DIN EN 1484 mg/l <1,0 --

KW-index ÖNORM EN ISO

9377-2

mg/l <0,08 --

* On-site measurement, #parameter value (maximum permissible concentration) and standard values (indicator parameter)

acc. Appendix I to the drinking water ordinance, BGBl. II No. 304/2001 as amended.



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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 signalling devices, text displays, and

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

» Exceptions must be expressly agreed to by the CP. 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.

» A rotating field monitor as well as a combined surge arrester type 1/2 (DEHN TNS 255 FM)

with remote signalling contact must be installed on the machine feed switching cabinets.

4.1.2 Identification system

Voestalpine Tubulars has defined company-specific definitions for implementing the standard:

» Plant and function identification

» Location marking (control cabinets, operating console and terminal boxes, etc.)

» Terminal block labelling

» Cable labelling

» EPLAN resource and structure labelling specifications

These are described in Appendix A with an example = 4MAA and in the EPLAN sample project as well

as in the EPLAN base project.

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.



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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

150mm. 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 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 CP can follow. The climate control system is to be controlled

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

signalled 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.



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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 trailing, oil-proof and/or acid-proof

insulation, depending on the environment. The ambient temperatures are also to be taken into

account when selecting cables.

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.



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4.2.2 Standard cables

Standard cables Designation

Control cable YSLY-JZ, YSLY-OZ

Shielded control cable YSLCY-JZ, YSLCY-OZ

Hydraulics and exterior control cables H07RN-F, H05RN-F

Oil-resistant cables H05VVS-F (NYSLYö), S90

Oil-resistant, shielded cables H05VVC4V5-K (NYSLYCYö), S90C

Cables for high ambient temperatures SiHF

Cables for high ambient temperatures. Shielded SiFCuSi

Drag chain cables S80

Shielded drag chain cable S80C

Reeling cables NSHTöu(K)-J

Power cables NYY-J 3x ....

Power cables for motors NYY-J 4x ....

Shielded power cables for motors (Siemens drives) 2YSLCYK-J 4x..., 2YSLCY-J 4x....

Power cables for mobile devices SLM

Shielded power cables for mobile devices SLCM

Compensation line NiCrNi

Simatic inputs / outputs installation cable without power JE-LiYCY nx2x0,5 Bd Si gr; n=2, 4, 8 ….

4.2.3 Special cables

Special cables Designation

Profinet cable CAT 7

Profibus cable 6FX1830-0EH10

Profibus cables for mobile devices 6FX1830-0FH10

Cable for weighing HBMKAB09/00/-2/2/2

Fibre optic cable

Network cable CAT7

4.2.4 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.



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4.2.5 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.

4.2.6 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.

4.2.7 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

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 labelled with conductor numbers in

accordance with the connecting terminal designation. PLC I/O cards must be labelled with the

absolute address of the respective part designation.

4.2.8 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.

4.2.9 Electrical drives and associated equipment

To be agreed

4.2.10 Signalling 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. See appendix A.



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4.2.11 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:

Wire color Description

BLACK (RAL 9005) Main circuit for DC and AC, Secondary circuit for transformers

LIGHT BLUE (RAL 5015) Neutral conductor only

GREEN / YELLOW (RAL

6018/1021) Protective conductor

RED (RAL 3000) 230VAC Control circuits

GREEN (RAL 6018) Control circuits up to 120V AC

BROWN (RAL 8003) Control voltage up to 220VDC (except 24VDC)

DARK BLUE (RAL 5010) Control voltage 24VDC, binary signals, internal auxiliary circuits (e.g.

controller enable signals, monitoring circuits, ...)

ORANGE (RAL 2003) External voltage for locks, supplies and enabling.

Exchange signals with other systems.

WHITE (RAL 9010) Conductor for analog signals: transducers (temperature, humidity,

pressure, etc.)

YELLOW (RAL 1021)

All leads for safety-relevant functions. E.g. leads that are connected to

F-modules or safety circuits of safety switchgear. Feedbacks routed to

standard inputs must be wired blue.

4.3 Electrical supply, protective measures

4.3.1 Main voltage

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

Frequency: ~50 Hz 1%

Type: TN-S and TN-C-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.



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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 24VDC 10%

Switching elements, valve coils, optical and acoustic signalling devices,

PLC output potential

output potential

24VDC 10%

Auxiliary contactors and power contactors 24VDC 10%

Emergency stop switches, supplying monitoring relays for safety circuits 24VDC 10%

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

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

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.



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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 61000-1,-2. With respect to emissions, EMC-conform installation must

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

with

EN 61000-2 and EN 61800-3/A11.

The installation and cabling of frequency-controlled drives must be carried out in accordance with

the corresponding installation instructions manual. This manual includes the dimensioning of cables

and fuses.

In addition, a motor output choke and, if required, a mains choke or DC reactor must be installed.

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.



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4.3.9 Operation and protection of induction motors

Efficiency classes:

» All motors from 0.75 kW must meet the minimum efficiency IE3 or alternatively IE2 with

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

The display of the EMERGENCY STOP state is required and must be signalled with a continuous red

indicator light and logged in the control system.

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.

The minimum required stop category is category 1.

Stop category 1:

» Controlled stop with maintenance of the power supply during the stop process

The power supply is switched off after stopping the machine.

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.

For adjustment and repair work, a corresponding operating mode (MAINTENANCE OPERATION) and

a set-up mode must be provided (safe speed).



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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

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

For new machines, the SIMATIC S7 1500 system with the TIA Version 14 Service Pack 1 programming

software must be used.

Without exception, only the products listed in the parts list (appendix A) are allowed.

For reasons of rational spare parts management, the SIMATIC S7 1500 system initially has the

following restrictions:

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

» 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)

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.

All the above restrictions are valid for the SIMATIC S7 1500 as well.

If deviations from this delivery specification are unavoidable, then they must be expressly agreed to

by the CP.



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For small and micro systems, SIEMENS S7-1200 components may be installed after consultation with

the contracting party. LOGO, EATON controllers, or similar small controllers may not be used.

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 CP. The current standards are Profinet and Profibus (Siemens Profibus plug).

Profibus is only permissible if Profinet is not applicable.

4.5.4 Decentralization

To reduce the cabling effort, it is recommended that PROFINET 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 CP is required.

4.5.6 Programming languages

Preferably, the function block diagram (FBD) and graph 7 are to be used. For complex problems, the

S7-SCL high-level language tool is necessary.

TIA Portal is to be used.

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.



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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 CP

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 CP. The make and version of any programmable

safety controllers used must be coordinated with the CP.

4.6 CNC systems and industrial computers

The CP 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

» 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 CP and the CO.



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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

» Measurements with doesn’t belong to a zone DB and FC 814-860

» Measurements 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 (e.g.: 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 Measurements DB and FC x45-x49

» Controllers DB and FC x61-x79

» Burner General 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



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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 CP.

» 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.

» (Computer is provided by the company )

» 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.

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

» The 3-way valve should have a lever for switching and no turning wheels

» 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.



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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 to be 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 neighbour burners. Our experience of the best possibility is shown in the

graphic. The ignition burner should have at least 10 kW.

5.5 Measurements

5.5.1 Quantity Measurements

All quantity Measurements have to be a temperature and pressure compensated differential

pressure measurement with a restrictor.

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.

UV-Sonde

Ignition-Burner



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5.5.4 Pyrometer Measurements

In addition to the mA loop, the serial interface (RS485) or network interface of the pyrometers must

also be routed to a converter so that the pyrometer can be configured via a network connection.

Furnace outlet pyrometers should be mounted as close as possible to the furnace outlet and

equipped with suitable cooling (water). This should reduce the falsification of the outlet temperature.

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 gas outlet temperature from

the chimney without the addition of fresh

air using a central recuperator or

regenerative burner. In all other cases, the

value should be noted in the project

description.

130 – 200 °C

The max. surface temperatures for the

following points are to be noted in the

project description:

Ceiling

Wall

Insulated cables

Exhaust compounding Austrian Law „Begrenzung der Emission von

luftverunreinigenden Stoffen“, last version

5.8 Thermocouples

The choice of thermocouple must be made in accordance with the contracting party. Thermocouples

of at least one higher grade type must be used.

The temperature ranges are specified in the table below:

From 1200 °C Type B

1000 – 1199 °C Type S

Below 1000 °C Type K

» In addition, it is necessary that the thermocouple offers the possibility of a comparative

measurement.

» The cable on the thermocouples must be left so long that the thermocouple can be pulled out

completely

» A holder for the thermocouple must be provided in the immediate vicinity of the measuring

point



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5.9 Cooling of electrical components

All electrical components must be secured in such a way that the electronics are not affected by the

radiant heat.

» Oxygen measurements in the furnace – do not install the electronics on the furnace

» Equip the light sensor with protective plate and protective glass and, if necessary, with water

cooling

5.10 Water cooling on industrial furnaces

If water-cooled dividers monitored by measurements and switches are installed in an industrial

furnace, a bypass line with the necessary shut-off device must be provided at the measurement points

so that replacement or maintenance of the built-in sensors is possible. The furnace must not

immediately lower the furnace temperature or turn off the heating after being triggered by such a

monitoring device.

6 Industrial Computers

The industrial computers have to be sent to the CP 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 PDF-XChange Editor

o Hardcopy

o NTP Service

o Empirum Advanced Agent

o End Point Security (Ego Secure)

» User configuration

» Network configuration



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Industrial computers and KVM Industrial Computer B&R APC910

- 5PC910.SX02-00

- 5PC900.TS77-00

- 5AC901.HS00-00

- 5MMDDR.8192-03

- 5AC901.FA02-00

- 5AC901.BX02-02

- 5AC901.CSSD-C00

- 54C901.SSCA-00

- 5AC901.FF02-00

- 5AC901.IRDY-00

- 5AC901.ISIO-00

- 0TB2104.8000

- 0TB103.91

- 5SWWI7.1200-GER

2-Slot APC910 System Unit

CPU Board Intel Core i7 3615QE

APC910 Heatsink

RAM SO-DIMM DDR3, 8192 Mbyte

APC910 Fan Kit

APC910 2-Slot BUS – 2x PCI Express (x4)

1 TByte SSD MLC (Slide-In HD) 2x

Front Flap orange

Slide-in compact Adapter

Interface Card Ready Relays

Interface Card System I/O

Plug 24 VDC

Plug 24 VDC

Operating System

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++

7 APPENDIX A: Electrical parts (approved list) and

documentation specifications

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 CP.



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7.1 Electrical parts

Part Preferred product Alternative products

Manufacturer Type Manufacturer Types

Schaltschränke u. Gehäuse, Stromverteilung Distribution cabinets

Equipment cabinets

Control cabinets

Terminal boxes

Console enclosure Power distribution parts Switch cabinet climate

control

Rittal

TS

AE

CP

EB

Connectors Terminals Phoenix Contakt 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, 24VDC

Siemens

Thermal motor protection

relay Siemens

Relays, semiconductor switches Time relay 22,5mm Siemens Industrial relay Schrack RT series Relay and semiconductor switching elements

Phoenix Contact

Emergency stop switching devices

Siemens, 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



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Proximity sensor Proximity sensor, inductive, DC, 24 V M12x1mm pluggable

Balluff BES Euchner All products

Proximity sensor, capacitive, DC, 24 V M12x1mm pluggable

Balluff BES Euchner All products

Proximity sensor, magnetic sensing

(cylinder sensor)

Balluff BMF Sick MZ series

Photoelectric sensors

DC, 24 V

Sick Wenglor Keyence

To be agreed

Safety switches Safety

light curtains

Sick To be agreed

Safety

interface

Sick To be agreed

Control and indicating devices Indicator lights Swisstac Siemens 3SB3

Mushroom pushbutton switch for emergency stop switching devices

Swisstac Siemens 3SB3

Power supplies Single-phase, 230VAC, 24VDC

Phoenix Contact Quint 24V

Three-phase, 380VAC, 24VDC

Phoenix Contact Quint 24V

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

Servo-/Frequency converter Frequency converter Siemens Sinamics S120 To be agreed

Safety components Safety switches EUCHNER CET3-AR-CRA-AH

-50..-SG-SG To be agreed

Safety light curtain SICK To be agreed

CNC controllers Drives SIEMENS Sinamics S120 CNC controller SIEMENS 840D sl Control panels SIEMENS To be agreed Machine control panel SIEMENS MCP 483C



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Measurement and regulation technology for furnaces



Quantity measurement

Differential pressure

ABB

266CST

Gauge pressure ABB 266GST Differential pressure ABB 266MST Temperature (furnace chamber)

ABB TTF300

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

gas)

ABB PME 120 –

AN (100Nm)

Power electronics, small ABB EAN 823 Safety thermocouple Günther GmbH see 05-99050064-0830 Air and exhaust flaps Jasta GD-6 E/S 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 Druckregler Kromschröder GDJ High-temperature

monitoring

Jumo

b70.1150.0

Repeater pr electronics 9106B Universal transmitter (To be agreed)

pr electronics 4114

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 with mounting

accessories

AS-Schneider

S345.06.202.02+S006.38.106. +S006.42.103.04 Oxygen Measurement Oxitec SME5 Oxitec Economy

Key switch

Siemens 3SB3000-3AH01 (high temperature), 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



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7.2 Selection list of the Phoenix modules



Selection list Phoenix Modules for S7-1500 SCALANCE Switch X208 Siemens 6GK5208-0BA10-2AA3

+ C-Plug Siemens 6GK1900-0AB00

Power supply module PS 60W Siemens 6ES7507-0RA00-0AB0

Repeater RS 485 Siemens 6ES7972-0AA02-0XA0

Act. RS485 termination

element Siemens 6ES7972-0DA00-0AA0

Central module CPU 1517F-3

PN/DP Siemens 6ES7517-3FP00-0AB0

+ SIMATIC Memory Card 12

MB Siemens 6ES7954-8LE02-0AA0

Communication proc. CP

1543-1 Siemens 6GK7543-1AX00-0XE0

Interface module IM 155-6 PN

HF Siemens 6ES7155-6AU00-0CN0

+ BusAdapter BA 2×RJ45 Siemens 6ES7193-6AR00-0AA0

Digital input module F-DI

8x24VDC HF Siemens 6ES7136-6BA00-0CA0

+ BaseUnit BU15-P16+A0+2D Siemens 6ES7193-6BP00-0DA0

Digital input module DI

16x24VDC ST Siemens 6ES7131-6BH00-0BA0

+ BaseUnit BU15-

P16+A10+2D Siemens 6ES7193-6BP20-0DA0

Digital output module F-DQ

4x24VDC HF Siemens 6ES7136-6DB00-0CA0

+ BaseUnit BU15-P16+A0+2D Siemens 6ES7193-6BP00-0DA0


32x24VDC HF Siemens 6ES7521-1BL00-0AB0

+ Front plug-in module for 4 x

8 I/O Siemens 6ES7921-5AH20-0AA0

+ 4 pcs. round cable Phoenix FLK 14/16/EZ-DR/

200/S7

Digital output module DQ

32x24VDC ST Siemens 6ES7522-1BL01-0AB0

+ Front plug-in module for 4 x

8 I/O Siemens 6ES7921-5AH20-0AA0

+ 4 pcs. round cable Phoenix FLK 14/16/EZ-DR/

200/S7



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VARIOFACE transfer module Phoenix VIP-2/PT/FLK14/PLC

V8-OUTPUT-Adapter Phoenix PLC-V8/FLK14/OUT

+ 8 pcs. relay modules Phoenix PLC-RPT- 24DC/21

V8-OUTPUT-Adapter Phoenix PLC-V8/FLK14/OUT

+ 8 pcs. solid state relay

modules

Phoenix PLC-OPT- 24DC/

24DC/2

Patch panel RJ45-LSA Phoenix FL-PP-RJ45-LSA

7.3 TIA approved list



TIA Portal approved assemblies for VAT dated 25 July 2017 Digital input module. DI

8x24VDC ST Siemens

6ES7 131-6BF00-0AB0

ET200SP 8xDI


16x24VDC ST Siemens

6ES7 131-6BH00-0AB0

ET200SP 16xDI

Digital output module, DQ 8x

24VDC/0,5A ST Siemens

6ES7 132-6BF00-0AB0

ET200SP 8xDO

Digital output module DQ

4x24VDC/ 2A ST Siemens

6ES7 132-6BD20-0AB0

ET200SP 4xDO 2A

Digital output module. DQ

16x24VDC/0.5A ST Siemens

6ES7 132-6BH00-0AB0

ET200SP 16xDO

Analog input module. AI

4xU/I 2-wire ST Siemens

6ES7 134 6HD00-0BA1

ET200SP 4xAI U/I 2-wire

Analog input module. AI

2xU/I 2-wire ST Siemens

6ES7 134 6HB00-0BA1

ET200SP 2xAI U/I 2-wire

Analog input module. AI 4xI 2-

/4-wire ST Siemens

6ES7 134 6GD00-0BA1

ET200SP 4xAI 4-wire

Analog output module AQ 4xU/I

ST Siemens

6ES7 135 6HD00-0BA1

ET200SP 4xAO U/I ST

Digital input module F-DI

8x24VDC HF Siemens

6ES7 136-6BA00-0CA0

ET200SP 8xF-DI

Digital output module F-DQ

4x24VDC/ 2A PM HF Siemens

6ES7 136-6DB00-0CA0

ET200SP 4xF-DO

1x 24V counter module,

1 channel for 24V incremental Siemens

6ES7 138-6AA00-0AB0

TM Count 24V

Technology module TM Pulse 2x

24V PWM and pulse output, 2

channels 2A

Siemens 6ES7 138-6DB00-0BB1

TM Pulse 2x24V

Interface-Module

IM 155-5 PN HF Siemens

6ES7 155-5AA00-0AC0

ET200MP IM155-5 PN HF



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Interface-Module

IM 155-6 PN ST Siemens

6ES7 155-6AU00-

0BN0 ET200SP IM155-

6 PN ST

Interface-Module

IM 155-6 PN HF Siemens

6ES7 155-6AU00-

0CN0 ET200SP IM155-

6 PN HF

PN/PN coupler Siemens 6ES7 158-3AD01-

0XA0 PN/PN Coupler

Bus adapter BA 2xRJ45, 2

RJ45 sockets for PROFINET Siemens

6ES7 193-6AR00-0AA0

ET200SP Profinet

interface

Base-unit BU15-P16+A0+2B,

BU-Type A0, push-in

terminals, without ...

Siemens

6ES7 193-6BP00-0BA0

ET200SP Base-unit

type A bridged to the

left without AUX

Base-unit BU15-P16+A0+2D,

BU-Type A0, push-in

terminals, without ...

Siemens

6ES7 193-6BP00-0DA0

ET200SP Base-unit

type A new load group

without AUX

Base-unit BU15-

P16+A10+2B, BU-Type A0,

push-in terminals, with 10 ...

Siemens

6ES7 193-6BP20-0BA0

ET200SP Base-unit

type A bridged to the

left with 10 AUX

Base-unit BU15-

P16+A10+2D, BU-Type A0,

push-in terminals, with 10 ...

Siemens

6ES7 193-6BP20-0DA0

ET200SP Base-unit

type A new load group

with 10 AUX

Server module for ET 200SP Siemens

6ES7 193-6PA00-0AA0

ET200SP Server

module

Power supply module PS

60W. 120/230V AC/DC Siemens

6ES7 507-0RA00-0AB0

PS 60W

Central module with 200 KB

main memory for program

and 1Mbyte for data, 1.

Interfaces: PROFINET IRT with

3 Port Switch, 48 NS Bit-

Performance, SIMATIC

Memory Card required, Bus

adapter required for ports 1

and 2

Siemens 6ES7 512-1DK01-0AB0

CPU1512SP-1 PN

Central module with 300 KB

main memory for program

and 1Mbyte for data, 1.

Interfaces: PROFINET IRT with

3 Port Switch, 48 NS Bit-

Performance, SIMATIC

Memory Card required, Bus

adapter required for ports 1

and 2

Siemens

6ES7 512-1SK01-0AB0

CPU1512SP F-1 PN F-

CPU



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Central module with 1MByte

main memory for program and

5Mbyte for data, 1. Interfaces:

PROFINET IRT with 2-port switch,

2. Interfaces: PROFINET RT, 3.

Interfaces: PROFIBUS, 10 NS Bit

performance, SIMATIC Memory

Card required

Siemens 6ES7 516-3AN01-0AB0

CPU1516

Central module CPU 1517F-3

PN/DP Siemens

6ES7 517-3FP01-0AB0

FCPU1517


32x24VDC HF Siemens

6ES7 521-1BL00-0AB0

DI32

Digital output module. DQ

32x24VDC/0.5A ST Siemens

6ES7 522-1BL00-0AB0

DO32

Digital input / output module. DI

16x24VDC/

DQ 16x24VDC/0.5A BA

Siemens

6ES7 523-1BL00-0AA0

DI 16/DQ

16x24CDC/0.5A BA_1

Analog input module AI

8xU/I/RTD/TC ST Siemens

6ES7 531-7KF00-0AB0 AI

8xU/I/RTD/TC ST

Analog input module AI

4xU/I/RTD/TC ST Siemens

6ES7 531-7QD00-0AB0

AI 4xU/I/RTD/TC ST


ST Siemens

6ES7 532-5HD00-0AB0

AO 4xU/I ST


HS Siemens

6ES7 532-5HF00-0AB0

AO 8xU/I ST


ST Siemens

6ES7 532-5NB00-0AB0

AO 2xU/I ST_1

Front connector with push-in

technology, 40-pole, for 35mm

width assemblies incl. 4 potential

bridges and ...

Siemens 6ES7 592-1BM00-0XB0

front connector 40pol

Front plug-in module with 4x16

pol. IDC connection for digital 32

I/O modules of the S7-1500 ...

Siemens

6ES7 921-5AH20-0AA0

front plug-in module

4x16

Memory Card fur S7-1x 00

CPU/SINAMICS, 3, 3V Flash, 12

MByte.

Siemens

6ES7 954-8LE02-0AA0

MEM CARD 12MB for

CPU15xx

C-Plug/Memory Card Siemens 6GK1 900-0AB00 C-Plug

Card for Scalance

IRT switch, 4x 10/100 Mbit/s

RJ45 ports, fault signalling

contact with set button,

redundant power supply, ...

Siemens 6GK5 204-0BA00-2BA3

Scalance X204 IRT

IE switch, 8x 10/100 Mbit/s RJ45

ports, fault signalling contact

with set button, ...

Siemens 6GK5 208-0BA00-2AF2

Scalance XF208

IE switch, 8x 10/100 Mbit/s RJ45

ports, LED diagnosis, fault

signalling contact with ...

Siemens 6GK5 208-0BA10-2AA3

Scalance X208

IWLAN Access Point Siemens

6GK5 788-2GD00-0AA0

Scalance W788-2

Wireless LAN



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Communication processor Siemens

6GK7 543-1AX00-0XE0

Communication proc.

Ethernet

Comfort Panel, touch control, ... Siemens 6AV2 124-0GC01-0AX0

TP700 7"

Comfort Panel, touch control, ... Siemens 6AV2124-0JC01-0AX0

TP900 9"

Comfort Panel, touch control, ... Siemens 6AV 2124-0MC01-0AX0

TP1200 12"

Comfort Panel, touch control, ... Siemens 6AV2 124-0QC02-0AX0

TP1500 15"

Protective foil 7” wide screen for

KTP700 Basic Siemens

6AV2 124-6GJ00-0AX0

protective film 7” wide

screen

Protective foil 15” wide screen

for KTP700 Basic Siemens

6AV2 124-6QJ00-0AX1

protective film 15” wide

screen

HMI memory card 2 GB Siemens 6AV2 181-8XP00-0AX0

HMI SD 2GB

HMI connection box Siemens

6AV2 125-2AE23-0AX0

advanced connection

box

HMI Mobile Panel

7.0" TFT-Display Siemens

6AV2 125-2GB23-0AX0

KTP700F Mobile Panel 7"

Mobile Panel 277

with confirmation button and

STOP button

Siemens 6AV6 645-0CB01-0AX0

Mobile Panel 277 8"

Connection cable PN for Mobile

Panels (PROFINET)

Length 5m

Siemens 6XV1 440-4BH50 cable

for PN (4MAA, 4TGA)

Connection box PN plus for

Mobile Panels (PROFINET). Siemens

6AV6 671-5AE11-0AX0

connection box PN

(4MAA, 4TGA)

Charging station for

Mobile Panel 277(F) IWLAN Siemens

6AV6 671-5CE00-0AX1

Charging station for

Mobile Panel 277

Main battery 7.2V for

Mobile Panel 277 IWLAN, Mobile

Panel 277F IWLAN,

Siemens

6AV6 671-5CL00-0AX0

main battery for Mobile

Panel 277

Protective foil 8” touch devices,

type 10, for Mobile Panel 277 8" Siemens

6AV6 671-5BC00-0AX0

protective foil for 8"

Mobile Panel

Mobile Panel 277F IWLAN (RFID),

with integrated confirm /

emergency stop button, hand

wheel, key switch and two

illuminated pushbuttons

Siemens

6AV6 645-0EF01-0AX1

Mobile Panel 277F 8"

IWLAN

Measuring instrument

7KM PAC3200, optional Modbus

RTU / PROFINET / PROFIBUS,

apparent / active / reactive

energy

Siemens 7KM2111-1BA00-3AA0

Sentron PAC 3200



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7.4 Documentation requirements

For EPLAN, the VAT sample project and base project are to be used, which are also stored in the

download section.

VAT standard for terminal blocks and cable labelling

Terminal

block

diagram

Condu

ctor

colours

Description Description Cable

labelling Manual

-XD0 -

XD99 BK

Voltage level

400VAC

Supplies, motor outgoing

feeders, etc. W1-W99

Number ranges,

expand to. E.g.

W99.1 and

W99.2 for

motors with

brakes,

encoders, 2

directional

motors, forced

cooling fans

.1 for first

direction of

rotation

(rotational

speed)

-XD100 -

XD199 YE, BU Safety technology

Sensors, e.g. emergency

stop, light curtains.

ATTENTION: the actuators

are to be drawn in relation

to their voltage!

All leads for safety-

relevant functions are

yellow. E.g. leads that are

connected to F-modules

or safety circuits of safety

switchgear. Feedbacks

routed to standard inputs

must be wired blue.

W101-W199

Expand number

ranges if two or

more cables

lead to one

electrical device.

E.g. W199.1 and

W199.2

-XD200 -

XD299 RD

Voltage level

230VAC W201-W299

Expand number

ranges if two or

more cables

lead to one

electrical device.

E.g. W299.1 and

W299.2

-XD300 -

XD349 GN

Voltage level

< 230VAC W301-W399

Expand number

ranges if two or

more cables

lead to one

electrical device.

E.g. W499.1 and

W499.2



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Terminal

block

diagram

Condu

ctor

colour

s

Description Description Cable

labelling Manual

-XD350 -

XD399

YE,

GN,

BU,

RD,

BN,

WH,

BK,

YE/G

N

400VAC/230VAC/

24VDC...

For special cables with

different voltage levels

(e.g. for servomotors ...)

W301-W399

Expand number

ranges if two or

more cables

lead to one

electrical device.

E.g. W499.1 and

W499.2

-XD400 -

XD499 BN

Control voltage up

to 220VDC (except

24VDC)

W401-W499

Expand number

ranges if two or

more cables

lead to one

electrical device.

E.g. W299.1 and

W299.2

-XD500 -

XD599 BU

Voltage level 0-

24VDC (including

digital signals)

Supplies, signals, sensors,

actuators W501-W599

Expand number

ranges if two or

more cables

lead to one

electrical device.

E.g. W599.1 and

W599.2

-XD600 -

XD699

Reserve for later

use

-XF700 -

XF799

Network cable

(Ethernet)

Operating computer,

SASI, Video LAN,

connections between the

controllers

W701-W799

-XF800 -

XF899 Fieldbus cable

Profibus, Profinet,

Modbus, DALI ... W801-W899

-XG900 -

XG999

WH,

BU

Analog values and

encoder signals

Analog signals, encoders

(absolute value, resolver,

incremental encoder ...),

thermistors, PTC, NTC, KTY

...

W901-W999

Expand number

ranges if two or

more cables

lead to one

electrical device.

E.g. W999.1 and

W999.2

-XE YE/G

N

Ground and shield

terminals

For terminal blocks that

are used exclusively for

earthing or shielding

function.



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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.

8.2 Hardware configuration / device view

The equipment and safety functions are generally executed on an S7-1500 CPU 1517F-3 PN/DP

(1517-3FP00-0AB0):

Any data exchange with other controllers may be implemented via a separate network based on

ProfiNet (I-Device) or via PN/PN coupler.

For ProfiNet networks, a topology must be created in order to make it easier for maintenance to

replace the device in the event of a fault:



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8.3 Structuring

8.3.1 Programming languages and standard software

The standard programming language function block diagram (FBD) from the TIA Portal must

preferably be used. The representation in statement lists (STL) and ladder diagrams (LAD) is not

allowed.

For complex problems, the programming language SCL is allowed. A GRAPH sequence must be used

for configuring and programming sequential processes with sequence cascades, e.g. sequences for

automatic processes. Only the use of the WinCC-Advanced configuration software from the TIA Portal

is required to configure the user menus for the touch panels.

Exceptions are allowed only when absolutely necessary and only with the express agreement of the CP.

The versions of the programming tools are to be agreed with the CP.

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 CP.

All global variables (inputs, outputs, flags, data points, etc.) are to be clearly labelled 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

CP.



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8.3.3 Folder structure

An overview structure for folders and groupings is to be used:

8.3.3.1 00_Fehler_OB

The required error OB is stored here (“Rack or station failure”, ...)

8.3.3.2 01_Standardbausteine

Standard blocks may only be used for general, recurring functions (NOT for drives):



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8.3.3.3 05_Sicherheitsprogramm

8.3.3.3.1. 01_Allgemein

» FB “F_Allgemein”: Safety program, general

» DB “Sicherheit_DB”: Safety data block

8.3.3.3.2. 02_Not_Halt

For each emergency stop, an FB is created here in which the signals are processed.

8.3.3.3.3. 03_Schutztueren

For each safety door, an FB is created here in which the signals are processed.

8.3.3.3.4. 04_Lichtgitter

For each light grid, an FB is created here in which the signals are processed.

8.3.3.3.5. 05_Sonstige_Signale

For all other clear signals, an FB is created here in which the signals are processed.

8.3.3.3.6. 10-99 Safety circuits

The safety circuits / drives are stored in groups depending on the structure of the safety concept

(drive or safety circuit related). If the safety concept is drive related, the grouping must be the same

as the equipment areas in the standard program. An FB is created for each safety circuit or drive

(e.g. ProfiSafe).



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8.3.3.4 10_Allgemein

» FC “Allgemein”: General functions

» FC “Allgemein_xxx”: Own FC per controller console for general functions

» FC “Austausch_xxx”: Own FC per controller with which data is exchanged

» FC “Busfehler”: Calling the “DeviceStates” function for each bus system

» FC “Datenaufb_HMI”: Data preparation for HMI (counters, light barriers, …)

» FC “Materialverfolgung”: Material tracking (walking beam allocation, pipes in

tester, ...)

» FB “Analog”: Analog value processing

» DB “Analog_DB”: Analog values (if analogue values available)

» DB “Antriebe_DB”: Drives (if visualization necessary)

» DB “Betriebsstunden_DB”: Operating hours (if required)

» DB “Datum_Zeit_DB”: Date and time

» DB “HMI_DB”: Data for HMI (one DB per HMI device)

» DB “Materialverfolgung_DB”: Data for material tracking (if required)

» DB “Multimessgeraet_DB”: Data from the system power supplies (PAC3200)

» DB “RACK_FLT_DB”: Profibus failures

» DB “Rampenbildner_DB”: Ramp generator (if proportional valves available)

» DB “Regler_DB”: Controller (if needed)

8.3.3.5 11-19 Sonstige Allgemeine Ordner

e.g.: Safety doors, Allgemein_Sinamics, ...

8.3.3.6 21-89 Anlagenbereiche

A folder is created for each equipment or operating area (in the material flow direction):



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Each area contains the operating mode and the drive functions:

In case it is required for clarity purposes, it is also necessary to subdivide material tracking from

equipment areas, so that a block is created for each area. In this example, it would be FC

“5TRA010_01_Materialverfolgung”. The “Materialverfolgung” block in the “10_Allgemein” folder is

then omitted.

8.3.3.7 91_Betriebsrechner

Here all signals for the higher-level master computer are generated in the “Betriebsrecher” FC. These

are stored in the “Betriebsrechner_DB” DB.

This DB must not be set to “optimierter Bausteinzugriff” because the “WinCC OA” master computer

cannot access symbolic operands. Furthermore, the option “Zugriff über PUT/GET-Kommunikation

durch entfernte Partner erlauben” must be set in the hardware configuration of the CPU.

8.3.3.8 99_Meldungen

» FC “Betriebsmeldungen”: Operating messages (No start possible: …)

» FC “STOER”: Enter general fault messages Drive related messages

o are recorded directly in the drive block

» FB “STOERAUS”: Evaluate error messages (new error, horn)

» DB “Meld_HMI_xxx:DB”: Error messages for HMI (one DB per HMI device)

» DB “Meld_PVSS_DB”: Error messages for electrical fault indicator (PVSS/WinCC-OA)

» DB “STOER_DB”: Fault messages / operating messages

The DB for WinCC-OA must not be set to “optimierter Bausteinzugriff” because this system cannot

access symbolic operands. Furthermore, the option “Zugriff über PUT/GET-Kommunikation durch

entfernte Partner erlauben” must be set in the hardware configuration of the CPU.



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8.4 PLC variables

The program logic is handled by flags (not via DB or instances), so that program changes can be

imported at any time during operation, without shutting down the system for loading and reinitializing

(instance) data blocks!

The PLC variables are created in the following, separate variable tables:

» 00_Ausgaenge

» 00_Ausgaenge_Analog

» 00_Ausgaenge_FU

» 00_Eingaenge

» 00_Eingaenge_Analog

» 00_Eingaenge_FU

» 00_PNPN

» 05_Parameter_Sicherheitsprogramm

» 10_Allgemein

» 11-19 Sonstige Allgemeine Variablen

» 21-89 Variablen Anlagenbereiche

» 91_Betriebsrechner

» 98_Ueberbrueckungsmerker

» 99_Weiß_ich_noch_nicht

The names of these variables tables correspond with the folder names in the program blocks and also

contain the variables of these folders.

e.g.: In the variables table “21_Trsp_vor_KBA” the variable from the blocks are in the folder

“21_Trsp_vor_KBA”.



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8.4.1 Input / output variables

The symbol must contain the following information:

» “E_” or “A_”

» Equipment / drive code

» Part

The comment must contain the following information:

» Location code

» Equipment / drive code

» Part

» Type:

o SM…error message

o K ...contactor / relay

o Y...valve

o QS...transverse signal

o BE...Bero switch

o ES...limit switch

o LS...light barriers

o P...pressure switch

o Q...flow switch

o L...level switch

o DT...pushbuttons

o LDT…illuminated pushbuttons

o LDS...illuminated push switches

o PDTV…locked mushroom pushbuttons

o ML...signal lamp

o H...horn / summer

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 SLS...safety light barrier

o SQS...safety transverse signal

o SES...safety limit switch

o …

» Text

Examples of symbols and comments:

E_5TRA021-FC11

+5S2E104 =5TRA.021-FC11 SM dispensing trough 1 chain drive motor error



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E_5TRA027-BG202

+5TRA.027 =5TRA.027-BG202 BE flap transfer lowered to AM 1

E_5TRA021-SF11

+5ST1P02 =5TRA.021-SF11 LDT dispensing trough 1 lift chain drive

8.4.2 FU input / output variables / other fieldbus devices

Variables for fieldbus devices are always defined using data types.

e.g. FU PPO type 4:

This enables direct access to the status and control values, without having to use various send and

receive blocks (DPRD_DAT, DPWR_DAT SFC14 / SFC15 for Simatic S7-300/400).

The same applies to variables in connection with a data exchange with another controller.



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8.4.3 Flag assignment: general

Here it is evident that in the hardware configuration, the clock flag byte is set to 0 and the system flag

byte is set to 1.

The start-up flags are used to easily find (using cross-references) everything that had to be bridged /

blocked during start-up.



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An acknowledgment flag is created for each equipment area.

The following variables are defined for each control voltage range:

» Acknowledgment pulse (e.g. for acknowledgment FU use)

» Delayed control voltage on / off

» General approval

Variables for lamp test and screen blanking are defined for each control console.

The dark switching is linked to each signal lamp directly in front of the output and has the purpose of

dark switching the whole control panel with a flag. This flag is generally generated with the key switch

“Control voltage on”.

8.4.4 Flag assignment: operating mode

As shown in the screenshot, always first add the name of the area and then describe the function in the

comment in order to have a better overview see the red border line.

The same applies to the symbol (Nummer_Funktion) see the blue border line.

8.4.5 Flag assignment: drive

Example of 2-direction drive:

As shown in the screenshot, always first add the name of the drive and then describe the function in the

comment in order to have a better overview see the red border line.

The same applies to the symbol (Antriebsnummer_Funktion) see the blue border line.

For flexibility reasons, end positions are always set on flags in case, for example, the sensor is linked

differently (normally closed, normally open contact, exchange with analogue sensor, ...).



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Example FU:

8.4.6 Bypass Flag

Here, flags are defined with which various functions are deactivated.

Examples:

» Temporary bypass of a defective sensor

» Preparations for a future conversion

» Tests performed by the production department

These flags make it possible to quickly find changes via cross-reference. In addition, a textual

description is stored in the comment of the flag.

8.4.7 “Don’t know yet”

The “Don’t know yet ...” signals are to be used for open points to make them easy to find.

8.4.8 Parameters

For fixed parameters in the equipment, the possible “user constants” in the TIA Portal must be used.



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8.5 Structure of functions

8.5.1 Safety program

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 / HW-config).

» F_FDBACK: Monitor feedback circuit

» F_ESTOP1: Emergency stop – also used for door contacts

8.5.1.1 Parameter safety program (user constants)

These values are stored as user constants so that they can be easily globally changed in one

location.

8.5.1.2 DB “Sicherheit_DB”

All relevant signals for the safety program are generated in this DB.

e.g. passivity messages, feedback circuit messages, safety door OK / discrepancy / open, …

8.5.1.3 FB “F_Allgemein”

» Generation of secure 0/1 signals

» Passivity messages

» Reintegration

» Read acknowledgment buttons



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8.5.1.4 Emergency Stop FB “NH_xxx”

Reading all emergency stops with F_1oo2DI discrepancy analysis in each corresponding FB:



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8.5.1.5 Safety doors FB “T_xxx”

Reading all safety doors with F_1oo2DI discrepancy analysis in each corresponding FB:

8.5.1.6 Light grid / light curtain FB “LS_xxx”

Reading all light grids / light curtains F_1oo2DI discrepancy analysis and acknowledgment with

F_ESTOP1 in each corresponding FB:

8.5.1.7 Other safety signals FB904

Reading all other safety signals with F_1oo2DI discrepancy analysis in each corresponding FB:

8.5.1.8 Safety circuits FB “SK_xxx”

Safety-related functions in the following sequence:

» Safety circuit OK

» Acknowledge / release safety circuit

» Relay or Profisafe-Bits

» Monitor feedback circuit



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Example of safety circuit with F output:

Example of Profisafe FU (drive HO task chain conveyor 1):

8.5.2 General

8.5.2.1 FC “Allgemein”

The following signals are generated in the FC:

» Start-up flag 0/1

» Timing pulses

» Control voltage range x on

» Error acknowledgment buttons are placed on flags or acknowledgment pulses are

generated

» Lamp tests for each operating console are placed on flags

» “Screen blanking” is generated for each operating console e.g. with key switch control

voltage for all lamps, these flags will be connected such that nothing lights up when the

equipment is off.

» Date / time will be read from PLC



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8.5.2.2 FC “Allgemein_xxx”

Own FC per operating console for general functions / signalling:



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8.5.2.3 FC “Austausch_xxx”

Own FC per controller with which data is exchanged:

8.5.2.4 FC “Datenaufb_HMI”

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

» …

8.5.2.5 FC “Materialverfolgung”

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 the FC “pipe tracking” in SCL.



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8.5.2.6 FB “Analog”

All analogue inputs are scaled here.

8.5.2.7 FC for calculations, pipe tracking

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

8.5.2.8 Profibus / Profinet error evaluation

Is realized with the function “DeviceStates”:

8.5.3 Equipment areas

8.5.3.1 FC “xxx_Betriebsart”

All functions for the given automatic area:

» Automatic start conditions

» Automatic off

» Automatic pre-selection

» Automatic on / off

» Manual pre-selection

» Operating mode: manual

» Various pre-selections and program modes

» All drives started automatically

» Calling up GRAPH step processes

» Signalling

» Sum error



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8.5.3.2 Drives

Drive-related functions:

Example of 2-direction drive:



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Example of FU:



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Example of valve:

8.5.4 Messages

8.5.4.1 FC “Betriebsmeldungen”

Generation of messages that keep a machine / automation from starting.

e.g.:

» No start possible: Walking beams not in starting position

» Feeding not enabled

» Hydraulic device not on

» …

8.5.4.2 FC “STOER”

Generation of general fault messages Drive-related messages are generated directly in the drive

block.



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8.5.4.3 FB “STOERAUS”

This evaluates which messages have arrived or which have not yet been acknowledged.

For this, the data type “STOER_Typ” is used repeatedly (current / old / edges / not acknowledged

messages) in the static interface.

In addition, the messages are routed in the direction of WinCC-OA and TPs.

Furthermore, event messages of type “BM_Typ” are also declared here.

8.5.4.4 DB “STOER_DB”

The error message DB is the instance DB of FB “STOERAUS” and contains operating and error

messages of the data type “BM_Typ” or “STOER_Typ”.

The error message type is to be set up similar to the symbols:

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

8.6 PLC data types

The same folder names as in the PLC program are again also found in the PLC data types:

8.6.1 Safety data type: Not_Halt



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8.6.2 Safety data type: Schutztuer_ohne_Anford_entr

Required if safety door lock is triggered with standard output.

8.6.3 Safety data type: Schutztuer_mit_Anford_entr

Required if safety door lock is triggered with safe output.

8.6.4 Safety data type: Lichtgitter

8.6.5 Safety data type: F_Signal_Allgemein

8.6.6 Safety data type: Sicherheitskreis_ohne_RUECKF

8.6.7 Safety data type: Sicherheitskreis_mit_RUECKF



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8.6.8 Drive

Only required if drives are visualized in detail on the factory visualization of type WinCC-OA.

In this case, VAT provides an Excel list in which all drives with DB number and offset are entered and

provided with additional information. E.g.: Which alarm is displayed in the detail screen or which text

have the used free alarms, ...

8.6.8.1 Antrieb_Status_Typ

8.6.8.2 Antrieb_Befehle_Typ

8.6.8.3 Antrieb_Alarme_Typ



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8.6.8.4 Antrieb_Typ

8.6.9 Analogwerte_Typ

8.6.10 Rampenbildner_Typ



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8.6.11 Regler_Typ



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8.6.12 Betriebsstundenzaehler_Typ

8.6.13 Mittelwert_Typ

8.6.14 RACK_FLT_Typ

8.6.15 Antrieb FU PPO4 (z.B. PDrive)

8.6.15.1 PDrive_PPO4_RCV_Typ:



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8.6.15.2 PDrive_PPO4_SND_Typ:

8.6.15.3 PDrive_PPO4_Istwerte_Typ:

8.6.16 Sinamics

8.6.16.1 Sinamics_Einspeisung

8.6.16.1.1. Sinamics_Einsp_T371_08W_RCV_Typ (Starter Standardtelegramm 371)



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8.6.16.1.2. Sinamics_Einsp_T371_05W_SND_Typ (Starter Standardtelegramm 371)

8.6.16.1.3rd Sinamics_Einsp_Istwerte_Typ

8.6.16.1.4th Sinamics_Einsp_Typ


8.6.16.2 Sinamics_CU

The time synchronization between PLC and CU takes place via the ping bit in control word 1 and

acyclic services (write parameter).

Procedure:

1. Set parameter 3100 to 1

2. Set ping bit

3. Write parameter 3101 / index 1 (current date in days)

4. Write parameter 3101 / index 0 (current time in milliseconds)

5. Reset ping bit

6. Finished



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8.6.16.2.1. Sinamics_CU_T394_03W_RCV_Typ (Starter Standardtelegramm 394)



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8.6.16.2.2. Sinamics_CU_T394_03W_SND_Typ (Starter Standardtelegramm 394)

8.6.16.2.3rd Sinamics_CU_Typ




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8.6.16.3 Sinamics_Antrieb

The following telegrams cover both the positioning mode and the speed-controlled mode.

8.6.16.3.1. Sinamics_Antr_10W_RCV_Typ (Starter freies Telegramm)

8.6.16.3.2. Sinamics_Antr_10W_SND_Typ (Starter freies Telegramm)



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8.6.16.3.3. Sinamics_Antr_Anw_02W_RCV_Typ (Starter freies Telegramm)

This data type represents an extension of the Sinamics telegram that can be freely used. The

telegram is then expanded to 12 words in the starter. These 2 additional words do not appear in the

visualization.

8.6.16.3.4. Sinamics_Antr_Anw_02W_SND_Typ (Starter freies Telegramm)

This data type represents an extension of the Sinamics telegram that can be freely used. The

telegram is then expanded to 12 words in the starter. These 2 additional words do not appear in the

visualization.



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8.6.16.3.5th Sinamics_Antr_Istwerte_Typ

8.6.16.3.6th Sinamics_Antr_Sollwerte_Typ

8.6.16.3.7th Sinamics_Antr_Typ


The status, commands and alarm elements are the same data types as described in chapter 8.6.8

"Drive".

8.6.16.4 Sinamics_ProfiSafe

8.6.16.4.1. Sinamics_ProfiSafe_T30_2W_RCV_Typ (Starter Standardtelegramm 30)



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8.6.16.4.2. Sinamics_ProfiSafe_T30_2W_SND_Typ (Starter Standardtelegramm 30)

8.7 Visualization

Normally, individual drives are not visualized in detail for unit loaders in the case of VA-Tubulars, since

they are operated by means of push-buttons (console or touch buttons) and thus already represented

(lamp or touch button).

Point 8.7.6 is extracted from a PC visualization (Siemens WinCC-OA).

8.7.1 Time synchronization

The time synchronization between PLC and control panel is done via an area pointer which accesses

the local time in the DB “Datum_Zeit_DB”.

The automatic mechanism for time synchronization from WinCC-Advanced (HMI time synchronization

mode) is not used because in this case the time zone of the panel must match the PLC. After

replacement of the (defect) panel, the time zone would then need to be set manually each time. This is

not desired by VAT.

8.7.2 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 with TIA-Portal by the maintenance personnel.

8.7.3 Alarm messages

Standard alarm window from WinCC flexible.

8.7.4 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.



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8.7.5 Display

Only standard graphical elements from WinCC-Advanced with simple dynamic properties can be used.

Manual mode is only executed via TP if there is no console operation for the respective drive at this

control point.

8.7.5.1 Sample image settings



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8.7.5.2 Sample image overview

8.7.5.3 Sample image manual mode



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8.7.6 Color regulations WinCC-OA

Operating modes:

Operating mode: undefined (off)

Operating mode: manual

Operating mode: setup

Operating mode: automatic

Status:

Drive ready

Automatic started / drive ready

Automatic restart required

Drive running

Switched off for safety

Fault (blinking: not acknowledged / continuous: acknowledged)



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9 APPENDIX C: VAT-Dokumentationsstruktur_Rev.0

VAT-Dokumentationsstruktur_Rev.0 Dateiformat Erläuterung

01 Anleitung Dokumentation Dokumentationen der Lieferanten, Herstel ler, interne

Dokumentationen, Anlei tungen welche für den Betrieb der

Anlage relevant s ind.

Alle pdf's sind in OCR-Ausführung zu liefern!

0101 pdf

0105 Betriebsanleitung pdfBetriebs- Bedien- Montage- Inbetriebnahme- Einbau- Wartungsanleitung,

Funktions- Steuerungsbeschreibung

0110 Handbuch, Datenblatt pdf Geräte- Betriebshandbuch, Datenblatt

0115 Fehlerbehebungsanleitung pdf

0120 Parametrieranleitung pdf

0125 Technische Berechnung pdf

0130 Schulungsunterlagen pdf

0135 Fotos jpg od. pdf

0140 Beschriftungen pdf

05 Behörde (Genehmigung, Bescheid) Dokumente, welche für die Behörde (Einreichung,

Baugenehmigung, Betrieb) maßgebl ich s ind.

0501 Diverse pdf

0505 Anlagen- Betriebsmittelbeschreibung pdf Kurze Anlagen-(Projekt)bezogene Anlagen bzw. Funktionsbeschreibun.

0510 CE Erklärung pdf Konformitätserklg., Einbauerklg., alt Herstellerklg.

0515 Prüfbefund, Gutachten pdf Für behördliche Überprüfungen, Abnahmen

0520 Baurecht pdf Einreichplan, …

0525 Gewerberecht pdf

0530 Wasserrecht pdf

0535 Abfallrecht pdf

10 Listen Dokumente, die "Lis ten" im Namen enthalten.

1001 Diverse xlsx od. docx

1005 Stückliste Mechanik xlsx

1010 Stückliste Elektrik xlsx

1015 Zeichnungsliste xlsx od. docx

1020 Ersatzteilliste xlsx od. docx

1025 Antriebs- Komponentenliste xlsx od. docx

1030 Geräteliste xlsx od. docx Schaltschrank

1035 Feldgeräteliste xlsx od. docx Instrumentierungs- Messkreis- Feldgeräteliste

1040 Kabelliste xlsx od. docx

1045 Parameterliste xlsx od. docx

1050 E/A Liste xlsx od. docx Rangierliste - E/A Liste

1055 Verbraucherliste xlsx od. docx

15 Pläne / Schemata Dokumente, die "Pläne" oder "Schemata" im Namen enthalten.

1501 Diverse pdf u. dwg-dxf Orientierungsplan, …

1505 Infrastruktur pdf u. dwg-dxf Gas, Wasser, Kanal, Strom, …

1510 Einrichtungsplan pdf u. dwg-dxf

1515 Einrichtungsplan - Bau pdf u. dwg-dxf Inntere Planung: Werkstätten und Büro

1520 Geometerplan pdf u. dwg-dxf Bestandserhebungs- Vermessungsplan, …

1525 Gleisplan pdf u. dwg-dxf

1530 Baubestandsplan pdf u. dwg-dxf

1535 Ausführungsplan pdf u. dwg-dxf inkl. Detailpläne

1540 Statikplan pdf u. dwg-dxf Bewehrungs- Schalungs- Belastungs- Fundamentplan

1545 HKLS-plan pdf u. dwg-dxf

1550 Elektroinstallationsplan pdf u. dwg-dxf

1555 Brandschutzplan pdf u. dwg-dxf

1560 Evakuierungsplan pdf u. dwg-dxf Evakuierungs- Beschallungsplan, …

1565 Betriebsmittellageplan pdf u. dwg-dxf Betriebsmittellage- Schaltschrankaufstellungsplan

1570 Aufbauplan pdf, dwg u. zw1

1575 Einlinienschaltplan pdf u. zw1

1577 Erdungsplan pdf u. dwg-dxf

1579 MSRT-Schema pdf u. zw1MSRT = Mess- & Regeltechnik / Funktionsschema, R+I Schema, MSRT Schema,

PID Diagramm

1581 Anschlußplan pdf u. zw1 Klemmen- Kabelanschluss- Steckerübersichts- Kabelübersichtsplan

1583 Verkabelungsplan pdf u. zw1

1585 Steuerungskonfiguration pdf u. zw1 Steuerung- Übersichtssplan (Steuerungskonfiguration)

1587 Stromlaufplan pdf u. zw1 PDF und EPLAN

1589 Fluidschema pdf u. dwg-dxf

1591 Rohrleitungsschema pdf u. dwg-dxf

1593 Pneumatikschema pdf u. dwg-dxf

1595 Hydraulikschema pdf u. dwg-dxf

1597 Schmierplan pdf u. dwg-dxf

20 Prüfprotokolle Prüfprotokol le beginnend von der Montage, über die IBN, den

Betrieb der Maschine bzw. Anlage bis zur Demontage.

2001 Diverse pdf

2005 Gesetzliche Überprüfungen pdf Prüfbuch (Kran…)

2010 Prüfmatrix pdf

2015 ÖVE Anlage pdfÖVE E 8001-6 Erstprüfung, Wiederholungsprüfung, Anlagenbuch, Exschutz,

Geräteüberprüfung (Notlicht, Brandmeldeanlage, Blitzschutz...)

2020 Einstellwerte der Schutzeinrichtungen pdf

2025 MSV Maschine pdfNach EN60204, EN61439, MSV2010 (Maschinenprüfprotokoll,

Erwärmungsnachweis…)

2030 Sichere Geschwindigkeit pdf Nachweis der Einhaltung der sicheren Geschwindigkeit

2035 Wartungsberichte pdf

2040 Inspektionsbericht pdf

2045 Kalibrierung pdf, xlsx

25 Sicherheitstechnik Dokumente, welche die Sicherheits technik betreffen.

Beginnend von der Planung, über den Betrieb bis zur

Demontage der Maschine/Anlage.

2501 Diverse pdf

2505 Begehungsprotokoll pdf

2510 Risikobeurteilung pdf

2515 Schutzzonenplan pdf u. dwg-dxf

2520 Sicherheitsdatenblatt pdf

2525 Abschaltmatrix pdf, docx, xlsx

2530 Validierung pdf, docx, xlsx Sistema Berechnungen

30 Zeichnungen/Layouts Dokumente, die "Zeichnungen" im Namen enthalten.

3001 Diverse pdf u. dwg-dxf

3005 pdf u. dwg-dxf Verknüpfung aus Ordner "3015 Maschinenbauzeichnungen"

3010 Stahlbauzeichnung pdf u. dwg-dxf Gebäude

3015 Maschinenbauzeichnung pdf u. dwg-dxfAlle Zeichnungen Maschinenbau (Layout, Übersicht, Baugruppe, Bauteil,

Einzelteil)

3020 Medienzeichnung pdf u. dwg-dxf

3025 Elektrik pdf u. dwg-dxf

3030 3D Datenipt, iam, idw,

step

Diverse

Anlagenübersicht

Technical Guidelines for Machinery and Equipment...EN 1037:2008 Safety of machinery – Prevention...

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Transcript of Technical Guidelines for Machinery and Equipment...EN 1037:2008 Safety of machinery – Prevention...