Andritz Feed & Biofuel – BCMS Manual

BCMS Manual

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Preface 3

Introduction 4

System Description 4

Graphic Overview 5

Start – Stop Icons 6

Trend 7

Lubrication 8

Operation Hour Counters

Counters (OPH) 9

Report 10

Wearpart 11

Alarmlist 12

Configuration 13

Alarms 21

Material flow
flow / System operation 22

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Preface

This manual describes the functionality of the BCMS system and provides thorough instructions about set-
up, operation and troubleshooting of the system.
This manual is created for the BCMS system alone.

Furthermore, this manual assumes that the reader has general knowledge of biofuel production as well as
comprehensive knowledge about the machines of which this system will be controlling. The reader is
referred to the mechanical documentation of the relevant machines for any mechanical questions.

Enjoy!

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Introduction

The BCMS control is a system for controlling an entire pelleting line or a part of it.
It is a modular system, making it possible to construct a control for any Andritz Feed & Biofuel bio pellet
fuel production machine.
The system may also be configured to control a range of third-party machines.
Due to the flexibility of the BCMS system, Customization and optimization must be carried out by an
authorized Andritz Feed & Biofuel technician.

System Description

The BCMS is based around an Allen-Bradley CompactLogix PLC, which handles all electrical signals to
and from the machines. The PLC communicates with a computer running the A-Scada system.
A-Scada allows the operator to monitor, manage the process, and also saves production data for retrieval
at any time.
Computer and PLC is connected via an Ethernet connection.
The A-Scada system is network-based and it is possible to connect more than one client to the same
Server. Client and server do not have to be installed on the same PC, as long as they are connected via
the same network. This means that there can be several operating stations for controlling the machinery.

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Graphic Overview

The graphic overview is found in the Detail tab. It can show the entire installation as well as single
installations depending of the numbers of elements in the control. Motors, switches etc. change color to
show which state they are in. Motors are red when stopped, when running, and blinking to indicate an error
state.
Switches are green when they are OK, i.e. in a state that does not prevent operation. A red switch means
that it is in a state that prevents operation, and blinking signifies that the switch has triggered an alarm.

There may be fields for adjusting Recipe parameters or fields that display current values.

Example of a Graphic overview:

Single Pellet press.

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Start – Stop Icons

Icons

The Graphic overview also contains the buttons for starting and stopping
the pelleting equipment.
The control starts each part of the machine in preprogrammed semi steps
that makes sure the machines start in the correct order.
During semi steps, the clicked button will blink green. When a sequence is
finished/ready the button will be constantly light yellow.

Start and Stop

When clicking Auto Start;
Start all steps initiate automatically. Clicking Auto
Stop will reverse this sequence.

Semi Start and Semi

Semi Stop
By clicking Semi Start,
Start the machine will start in steps.
For each time the button is clicked, next section will initiate.
By clicking Semi Stop,
Stop the active step will stop and the preceding step will
be active.

Cooler Start
This button will start the Cooler operation, and it is possible to fill and
empty the cooler if the machines before and after the Cooler are running.

Start Empty
Empty cooler will discharge the cooler for a configured amount of time
(see Cooler configuration page)

Pregrinding / Grinding Start Auto CW / CCW

This button will start the grinding process and the machines belonging to
the grinding process. The green square around the button indicates which
direction the mill has been running least amount of time. When the
grinding mill is running a indication on the button shows which direction
the mill is running in.

Auto Stop
This button will stop the grinding process in a controlled shut down,
making sure the mill and transportation elements to the next bin are empty
before stopping.

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Trend
The BCMS has trend curves for a large number of variables, and more are added constantly. The trend curve is accessed clicking
Trend in the lower tab.. Grinding mills and Pellet mills can have a special trends with only a few curves showing.

The variables shown as trends depend on the specific machines installed, and may be adjusted by an Andritz Feed & Biofuel
technician, but this table demonstrates the most common ones. Your specific installation may differ from this description.
On each trend bar you have a scale and 2 arrows. The bars fill color indicates the input value of the variable, the small arrow
indicates the Set Point of the variable and the big arrow indicates the output value.

Parameter Explanation
Steam pos. The opening of the Steam Motor valve, 0 – 100%

Conditioner [C] The temperature at the end of the Conditioner, 0-100° C

Main Motor % [A] The load of the Main motor, 0 – 100% of motor capacity in Amperes

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Lubrication

The lubrication system is taking care of lubricating the Main shaft and the rollers of the Pellet mill.

To make sure that each machine gets the correct

Amount of lubrication, please follow the below
Scheme developed by Andritz Feed & Biofuel,
when configuring your system.

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Operation Hour Counters (OPH)

The BCMS system has operation hour counters for some of the motors. If some motors need service after running an amount of
hours the MAX time can be set. When actual (ACT) time is greater them the MAX time a B alarm is set. The total counter is
counting the total hours a motor has been running and is often reset when a motor is being replaced. Both counters can be reset.

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Report
The BCMS system has a report system. The system is recording the changes made by the operator during operation of the plant.

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Wearpart
The BCMS system contains a Wearpart handling. It is possible to make a listing of actual wearparts for the plant. The counters are
counting the actual time the wearparts have been used.

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Alarmlist
The BCMS system alarm list shows actual alarms as well as historic alarms. It is possible to setup a filter to sort in the list.

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Configuration
(Configuration pages may vary from plant to plant)

The BCMS has adjustable parameters for each part of the machinery. They are usually adjusted by the Andritz Feed & Biofuel technician during
commissioning.
In some cases it is needed to change these parameters later on and for that a special administrator login is needed.
The login will be given to a chief operator or similar.
The configuration parameters can be found by mouse click on the motor,
motor then clicking the CONFIG button in the popup window.

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Main Configuration
Configuration

The Main Configuration is to ease setting or resetting

multiple functions at the same time and to backup or
restore the configuration of all equipment.

Parameter Explanation
All equipment in Simulation Switch simulation of all
equipment ON or OFF

All equipment in Dynamic Switch dynamic simulation of

Simulation all equipment ON or OFF

All equipment Bypass Switch off all bypassed

functions

All equipment Inhibit Switch off all inhibited

functions

All equipment in Auto Switch all equipment to Auto

mode

Back up Configuration
By pressing Backup config on the main configuration
page a pop-up window will allow you to save your
current configuration of the system. It is also possible
to load and/or delete earlier saved configurations.

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Configuration of a Feed
screw

Checkbox
Cross a checkbox to indicate an
existing component, signal type
or motor.

Signal delay time

The delay before a component
triggers the alarm.

Feedback time
The delay before loss of a motors
running signal trigger the alarm.

4...20mA
Check this if the signal is 4 –
20mA

Parameter Explanation Typical setting

[410LS01] – Feed screw – Prebin empty level Switch Indicates product available in systems without DWC (Extension 3). 3.00 sec

[410LS02] – Feed screw – Prebin full level Switch Indicates upstream that the prebin is full. 3.00 sec

[410GS01] – Feed screw – Overflow Switch Blocking sensor located at the feed screws outlet. 3.00 sec

[410M01] – Feed screw – Motor The motor for the feed screw. 3.00 sec

[410EIC01] – Feed screw – Process value (PV) Feedback of feed screws speed. -

Scaling Span of the ampere feedback – 100 % = Main Motors nominal current

[410EIC01] – Feed screw – Control value (CV) Set point of feed screws speed. -

Scaling The minimum - maximum output speed to the frequency drive. 0-100%

KP The gain of the speed controller. Higher = More aggressive 1

TI The integral time of the controller. Higher = less aggressive 20

The Dead band of the controller. The span around the set point with no
TD 1
regulation.
Deviation alarm delay time The delay before the deviation in the controller triggers the alarm. 10 sec

Deviation high value Maximum deviation between actual and set point before alarm. 15 %

Deviation low value Minimum deviation between actual and set point before alarm. -15%

Production of Feed screw on 100% Speed Kilos of production pr. hour with 100% speed on the feed screw. -

Calibration density Density of the product used when calculating the above capacity. -

Sequence waiting time after stop of Feed screw Waiting time before it is possible to stop the next step after the feed screw. 3
The delay between the empty sensors signal is lost and the alarm is
Prebin empty delay time 3
triggered.
Auto stop line at empty prebin Stop down the line if the prebin is empty. -

Stop feed screw at high PM amp Stop the feed screw in case of overload on the main motor. -

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Configuration of a Conditioner

General explanation

Checkbox
Cross a checkbox to indicate an existing component,
signal type or motor.

Signal delay time

The delay before a component signals “Alarm”.

Feedback time
The delay before loss of a motors running-signal
signals “Alarm”.

Position available
Position switches indicating the position of a valve.

4...20mA
Check this if the signal is 4 – 20mA

Parameter Explanation Typical setting

[411M01 – Conditioner 1 - Motor The motor for the conditioner. 3.00 sec

[411GS02] – Conditioner 1 – Overflow Switch Blocking sensor located at the conditioners outlet. 3.00 sec

[411SS01 – Conditioner 1 – Speed Switch Speed switch indicating correct speed of the conditioner. 3.00 sec

[411SI01] – Conditioner 1 - Speed Speed control of the conditioner motor. -

Scaling The scaling of the speed control in percentage. 0-100%

Min Output The minimum speed output in percentage. -

[411EI01] Conditioner 1 - Load Ampere feedback of the conditioner. -

Nominal Current The nominal current, read of the motors tag plate. -

Trend scale max Maximum amperes on the trend scaling. -

Max amp alarm The ampere needed to trigger the alarm. -

[411OV01] – Conditioner - PT100 Cleaning The air cylinder that cleans the PT100 thermostat. 3.00 sec

[411OV02] – Conditioner - Inlet valve Special inlet shot for CM902PH. 3.00 sec

[411OV03] – Conditioner – Outlet valve 1 Special outlet shot for CM902PH (left). 3.00 sec

[411OV04] – Conditioner – Outlet valve 2 Special outlet shot for CM902PH (right). 3.00 sec

[413OV01] – Steam to Conditioner 1 - Valve On/off valve for supply of steam to the conditioner. 3.00 sec

[413TIC01] – Steam to Conditioner 1 – Process Value(PV) Feedback of the motor valves position (steam controller). -

Scaling Scaling of the PT100 thermostats span in degrees. 0-200°C (read tag plate)

Control Value (CV) Set point of the motor valves position (steam controller). -

KP The gain of the steam controller. Higher = More aggressive. 1

TI The integral time of the steam controller. Higher = less aggressive. 20

The Dead band of the steam controller. The span around the set
TD 1
point with no regulation.

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Continued…
Parameter Explanation Typical setting
Deviation alarm delay time The delay before the deviation in the controller triggers the alarm. 10 sec.

Deviation high value Maximum deviation between actual and set point before alarm. 15%

Deviation low value Minimum deviation between actual and set point before alarm. -15%

Sequence waiting time after start/stop of Conditioner Waiting time for next step after start/stop of the conditioner 5 sec.

Steam to conditioner on delay When to open the steam supply after starting the feed screw. 3-5 sec.

Parking position of steam motor valve In what position to “park” the motor valve after stop. -

Steam to Conditioner off delay When to close the steam supply after stop of the feed screw. 3-5 sec.

PT100 cleaning open time The opening time of the PT100 cleaning cylinder before closing. 2 sec.

PT100 cleaning close time The closing time of the PT100 cleaning cylinder before opening. 200 sec.

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Configuration of a Pellet mill

General explanation

Checkbox
Cross a checkbox to indicate an
existing component, signal type
or motor.

Signal delay time

The delay before a component
signals “Alarm”.

Feedback time
The delay before loss of a
motors running-signal signals
“Alarm”.

Position available
Position switches indicating the
position of a valve.

4...20mA
Check this, if the signal is 4 –
20mA

Parameter Explanation Typical setting

[550M01] – Pellet Mill – Main Motor The main motor of the Pellet mill 20 sec.

[550SS01] – Pellet Mill – Main Motor Speed Switch Speed switch indicating correct speed of the Pellet mill main motor. 10 sec.
Read of the tag plate
Nominal current The main motors Current
located on the motor.
Read of the tag plate
Voltage The main motors Voltage
located on the motor.
Read of the tag plate
Cos fi The main motors Cosinus fi
located on the motor.
[550M02] – Pellet Mill – Inlet Screw Motor A screw located in front of the Pellet chamber. 3 sec.

[550SS02] – Pellet Mill – Inlet Screw Motor Speed Switch Speed switch indicating correct speed of the Inlet screw. 3 sec.

[550M03] – Pellet Mill – Hydraulic Pump Pump controlling the brake pressure and tension of the belts. 3 sec.

[550PS01] – Pellet Mill – Pressure Switch Indicator for the brake pressure. 3 sec.

[550PS02] – Pellet Mill – Pressure Switch Indicator for the belt tension 3 sec.

[550M04] – Pellet Mill – Gearbox Oil Pump Circulation pump for oil in cog driven Pellet mills 3 sec.

[550PS03] – Pellet Mill – Gearbox Pressure Switch Switch indicating the pressure of the oil flow. 0 sec.
[550OV01] – Pellet Mill – Bypass Pellet mill (Dump
Bypass in front of the Pellet Chamber. 3 sec.
Shute)
In case the Dump Shute opens due to overload of the main motor, the bypass
Manual Close Dump Shute -
will not close automatically.
Depending on the
Restart delay Time before the Pellet mill main motor will be able to start again after stopping.
size of the motor.
Sequence waiting time after stop of Pellet Mill Waiting time after the stop sequencer has stopped the Pellet mill. 10 sec.

Lubrication alarm delay Time for registering pulses after each lubrication cycle. Check lubrication pt.

Lubrication cycle time Time between each cycle of lubrication Check lubrication pt.

Lubrication number of pulses Pulses requested in each lubrication cycle. Check lubrication pt.

Blocking sensor outlet Switch indicating that that the space after the Pellet mill is blocked. 1 sec.

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Configuration of the Cooler

General explanation

Checkbox
Cross a checkbox to indicate an existing
component, signal type or motor.

Signal delay time

The delay before a component signals
“Alarm”.

Feedback time
The delay before loss of a motors running-
signal signals “Alarm”.

Position available
Position switches indicating the position of
a valve.

4...20mA
Check this if the signal is 4 – 20mA

Parameter Explanation Typical setting

[412FIC01] – Cooler 1 – Air flow control System that controls the airflow of the cooler outlet. 0-100 %

Deviation alarm delay time Time before the below mentioned deviation triggers the alarm. 5 sec.

Deviation high value Accepted + Deviation between actual position and set point. +10 %

Deviation low value Accepted - Deviation between actual position and set point. -10 %

[421M01] – Cooler 1 – Inlet airlock Airlock located on top of the cooler. -

[421M02] – Cooler 1 – Distributer Distributor located in the top of the cooler on the inside. 3 sec.

[421M03] – Cooler 1 – Discharger The moving floor in the cooler. 3.sec.

[421M04] – Cooler 1 – Fan The fan that circulates the air in the cooling system. ̴ 20 sec. (dep. on size)

[421M05] – Cooler 1 – Cyclone Airlock Airlock located in the bottom of the cyclone. 3 sec.

[421GS01] – Cooler 1 – Door switch Switch making sure that the door is closed. 0 sec.

[421GS02] – Cooler 1 – Blocking sensor outlet Switch located after the floor of the cooler, activated if the outlet is blocked. 3 sec.
Switch located at the “arm” of the moving floor, activated when the floor is
[421GS03] – Cooler 1 – Discharger bottom closed 0 sec.
mechanically closed.
Switch located at the “arm” of the moving floor, activated when the floor is
[421GS04] – Cooler 1 – Discharger bottom opened 0 sec.
mechanically opened.
[421XS01] – Cooler 1– Fire sensor or fire gate pos. Temperature switch and/or position switch indicating the fire gate open. 0 sec.

[421LS01] – Cooler 1 – Full level switch Top level switch of the cooler main chamber. 5-10 sec.

[421LS02] – Cooler 1 – Empty level switch Low level switch of the cooler main chamber. 3 sec.

[421LS03] – Cooler 1 – Start level switch Middle level switch of the cooler main chamber. 3 sec.

[421LS04] – Cooler 1 – Blocking level switch in cyclon Level switch located just above the cyclone airlock. 3 sec.

[421SS01] – Cooler 1 – Fan Speed guard Switch indicating correct speed of the cooler fan. ̴ 10 sec. (dep. on size)

[421OV01] – Cooler 1 – Grid Valve Valve for total opening of the cooler floor 3 sec.

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Continued…
Parameter Explanation Typical setting
[421OV02] – Cooler 1 – Midriff Valve Extra floor located in the middle of the cooler chamber. 3 sec.

Ambient Temperature The temperature outside the cooler. 0-200°C (read tag plate)

Outlet Temperature Temperature in the outlet, after the bottom floor. 0-200°C (read tag plate)

Material Temperature Temperature inside the cooler chamber, in material level. 0-200°C (read tag plate)

Cooler emptying time The time it takes to empty a full cooler with grid half open. (Experienced value)
If the grid valve is available, the end of the above cycle will open
Cooler emptying time with open grid valve (Experienced value)
completely these seconds.
Cooler discharging time The discharging time when reaching the start level (Experienced value)
The alarm delay, If the discharging arm doesn’t stop on the parking
Parking switch alarm delay 3 sec.
switch

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Alarms

(The alarm messages and Element numbers [Elemet name] may differ from plant to plant)

There is alarm indication on the main screen and in the Alarm list tab.
Here you will find the current alarms, when they where received, cleared and acknowledged.

The usual alarm consist of 3 - 4 different information’s

Example:
Example: [620] - Cooling - Main equipment - Door switch - Fault

• [620] The position and internal name of the faulted element

• Cooling The main part of the machine where the faulted element is located
• Door switch The exact element where the fault is located
• Fault The reason why the element is signaling alarm

You will find some specific explanations in the list below. All alarms are not listed.

Alarm Name Explanation Possible Solutions

[410] - Feed screw - Speed Control - Deviation
PV is deviating higher than allowed compared to the SP -
high alarm
[410] - Feed screw - Speed Control - Deviation
PV is deviating lower than allowed compared to the SP -
low alarm

[410] - Feed screw - Speed Control – Fault Controller has faulted Check unit supplying mA feedback

[410] - Feed screw - Speed Control – High

The PV has reached the HIHI level set in the configuration -
alarm
[410] - Feed screw - Speed Control – High
The PV has reached the HI level set in the configuration -
warning

[410] - Feed screw - Speed Control - Low alarm The PV has reached the LOLO level set in the configuration -

[410] - Feed screw - Speed Control - Low

The PV has reached the LO level set in the configuration -
warning
[410] - Feed screw - Speed Control – Wire
The PV feed back is more or less than 4-20mA Check mA circuit and mA unit
broken alarm

[410] - Feed screw - Overflow Switch – Fault Overflow switch has been activated Make sure that overload opening is closed.

[410] - Feed screw - Prebin empty level Switch

The empty switch is not activated Fill material into to the bin.
– Fault
[410] - Feed screw - Prebin full level Switch –
The full level switch is activated -
Fault
The motor has tried to start but the system hasn’t received a Check repair switch, overload relay, frequency drive
[M 410] - Feed screw - Motor - Fault
running signal. or soft starter.
The motor has been running longer than set in the “Operation Reset the operation counter on the “Operation
[M410] - Feed screw - Motor - OPH Alarm
Counter” Tab Counters” tab

[410] - Feed screw - Speed - High alarm The PV has reached the HIHI level set in the configuration -

[410] - Feed screw - Speed - High warning The PV has reached the HI level set in the configuration -

[410] - Feed screw - Speed - Low alarm The PV has reached the LOLO level set in the configuration -

[410] - Feed screw - Speed - Low warning The PV has reached the LO level set in the configuration -

[410] - Feed screw - Speed - Wire broken alarm The PV feed back is more or less than 4-20mA Check mA circuit and mA unit

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[550] - Pellet Mill - Load - High alarm The PV has reached the HIHI level set in the configuration -

[550] - Pellet Mill - Load - High warning The PV has reached the HI level set in the configuration -

[550] - Pellet Mill - Load - Low alarm The PV has reached the LOLO level set in the configuration -

[550] - Pellet Mill - Load - Low warning The PV has reached the LO level set in the configuration -

[550] - Pellet Mill - Load - Wire broken alarm The PV feed back is more or less than 4-20mA Check mA circuit and mA unit

[550] - Pellet Mill - Overload Switch - Fault Overload switch has been activated Make sure that overload opening is closed.

[550] - Pellet Mill - Door Switch - Fault Door switch is not activated Check that the Door is closed.

Clean area around blocking sensor and make sure

[550] - Pellet Mill - Blocking Sensor Inlet - Fault Blocking sensor activated
that the sensor can rotate.
[550] - Pellet Mill - Blocking Sensor Outlet - Clean area around blocking sensor and make sure
Blocking sensor activated
Fault that the sensor can rotate.
[550] - Pellet Mill - Lubrication Pulse Sensor - Lubrication system hasn’t reached its number of pulses with
Check level in lubrication barrel and pulse sensor.
Fault in the cycle time.
Low level in the lubrication barrel or no pulses from
[557] - Pellet Mill - Lubrication - Fault Check level in lubrication barrel
lubrication
The motor has tried to start but the system hasn’t received a Check repair switch, overload relay, frequency drive
[550M01] - Pellet Mill - Main Motor - Fault
running signal. or soft starter.
[550M01] - Pellet Mill - Main Motor - OPH The motor has been running longer than set in the “Operation Reset the operation counter on the “Operation
Alarm Counter” Tab Counters” tab
The motor has tried to start but the system hasn’t received a Check repair switch, overload relay, frequency drive
[550M02] - Pellet Mill - Inlet Screw - Fault
running signal. or soft starter.
The motor has been running longer than set in the “Operation Reset the operation counter on the “Operation
[550M02] - Pellet Mill - Inlet Screw - OPH Alarm
Counter” Tab Counters” tab
The motor has tried to start but the system hasn’t received a Check repair switch, overload relay, frequency drive
[550M03] - Pellet Mill - Hydraulic Pump - Fault
running signal. or soft starter.
[550M03] - Pellet Mill - Hydraulic Pump - OPH The motor has been running longer than set in the “Operation Reset the operation counter on the “Operation
Alarm Counter” Tab Counters” tab
[550M04] - Pellet Mill - Gearbox Oil Pump - The motor has tried to start but the system hasn’t received a Check repair switch, overload relay, frequency drive
Fault running signal. or soft starter.
[550M04] - Pellet Mill - Gearbox Oil Pump – The motor has been running longer than set in the “Operation Reset the operation counter on the “Operation
OPH Alarm Counter” Tab Counters” tab
[605OV01] - Pellet Mill - Bypass Pellet mill The valve has tried to close but haven’t received signal from
Check air supply to the valve.
(Dump shute) - Close fault the position switch “Closed”
[605OV01] - Pellet Mill - Bypass Pellet mill The valve has tried to Open but haven’t received signal from
Check air supply to the valve.
(Dump shute) - Open fault the position switch “Opened”
[557OV01] - Pellet Mill - Lubrication Grease The valve has tried to close but haven’t received signal from
Check air supply to the valve.
Valve - Close fault the position switch “Closed”
[557OV01] - Pellet Mill - Lubrication Grease The valve has tried to Open but haven’t received signal from
Check air supply to the valve.
Valve - Open fault the position switch “Opened”
[557OV02] - Pellet Mill - Lubrication Air Valve - The valve has tried to close but haven’t received signal from
Check air supply to the valve.
Close fault the position switch “Closed”
[557OV02] - Pellet Mill - Lubrication Air Valve - The valve has tried to Open but haven’t received signal from
Check air supply to the valve.
Open fault the position switch “Opened”

[550PS01] - Pellet Mill - Pressure Switch - Fault Hydraulic brake pressure not ok. Check hydraulic pump for oil level and pressure

[550PS02] - Pellet Mill - Pressure Switch - Fault Belt tension pressure not ok. Check hydraulic pump for oil level and pressure

[550PS03] - Pellet Mill - Gearbox Pressure

Oil Lubrication pressure not ok. Check hydraulic pump for oil level and pressure
Switch - Fault
[550SS01] - Pellet Mill - Main motor Speed
The motor speed is not activating the speed switch Check if the motor is stuck.
Switch - Fault
[550SS02] - Pellet Mill - Inlet Screw Speed
The motor speed is not activating the speed switch Check if the motor is stuck.
Switch - Fault
[620OV01] - Cooler - Bypass Valve - Close The valve has tried to close but haven’t received signal from
Check air supply to the valve.
fault the position switch “Closed”
The valve has tried to Open but haven’t received signal from
[620OV01] - Cooler - Bypass Valve - Open fault Check air supply to the valve.
the position switch “Opened”

[620GS01] - Cooler 1 - Door Switch - Fault Door switch is not activated Check that the Door is closed.

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[620GS02] - Cooler 1 - Blocking Sensor Outlet - Clean area around blocking sensor and make sure
Blocking sensor activated
Fault that the sensor can rotate.
[620GS03] - Cooler 1 - Discharger bottom Discharger has tried to close, but the system hasn’t received Check mechanical adjustment of the discharge
closed - Fault “closed” position. bottom
[620GS04] - Cooler 1 - Discharger bottom Discharger has tried to open, but the system hasn’t received Check mechanical adjustment of the discharge
opened - Fault “open” position. bottom

[620LS01] - Cooler 1 - Full level Switch - Fault The full level switch is activated Check that downstream machines are running.

[620LS02] - Cooler 1 - Empty level Switch - The empty level switch is not activated -

The motor has tried to start but the system hasn’t received a Check repair switch, overload relay, frequency drive
[640M01] – Cooler - Inlet Airlock - Fault
running signal. or soft starter.
The motor has been running longer than set in the “Operation Reset the operation counter on the “Operation
[640M01] – Cooler - Inlet Airlock - OPH Alarm
Counter” Tab Counters” tab
The motor has tried to start but the system hasn’t received a Check repair switch, overload relay, frequency drive
[620M02] – Cooler - Distributer - Fault
running signal. or soft starter.
[M310] - Transport to Dryer - Conveyor
The overflow switch is activated. Check if material is stocked in the conveyor
Overflow Switch
[M600] - Transport - To Cooler - Speedguard
Speedguard fault. The elevator is not running Check why the elevator is not running
for Elevator - Fault

[[M650] - Cooler Fan Fault The Fan for the cooler has stopped. Check why it is stopped.

[M650] - Cooler Speedguard Fault The Fan for the cooler has stopped. Check why it is stopped.

[Valve705.1] - Outtake - Storage Silo Slidegate

The slidegate has not reached the closed position. Check if something is stocked at the slidegate.
- Closed fault
[Valve705.1] - Outtake - Storage Silo Slidegate
The slidegate has not reached the open position Check if something is stocked at the slidegate.
- Open fault
[Valve750] - Outtake - Storage Silo Slidegate -
The slidegate has not reached the closed position. Check if something is stocked at the slidegate.
Closed fault
[Valve750] - Outtake - Storage Silo Slidegate -
The slidegate has not reached the open position Check if something is stocked at the slidegate.
Open fault

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Last saved by esbn083 22-11-2010 23-25
Andritz Feed & Biofuel – BCMS Manual

Material flow
flow / System operation

Systems may vary in the way they are controlled, depending of types of elements, feeding of material, grinding and pelleting
elements. This is a short description of the basics in BCMS controlled plants.

Due to the flexibility of the BCMS system, Customization and optimization must be carried out by an
authorized Andritz Feed & Biofuel technician. Operators are teached how to keep a constant material flow
and maximum capacity during commissioning of the plant.
Bins, prebins, coolers, silos and other kind of bins are the main objects, either to fill or to empty. Elements filling the bins are
started and stopped according to the full and empty sensors in the bins. Elements emptying/taking material from the bins are
started and stopped according to the empty level sensor in the bin. Some elements are both taking material from one bin to fill the
next bin.

The Andritz Feed & Biofuel technician is optimizing the process and teaching the operators how to keep a constant material flow
with a very few starts and stops of the elements / motors.

The filling of the bin after a mill is optimized by the set point / speed of the associated feed screw (Load Control).

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Last saved by esbn083 22-11-2010 24-25
Andritz Feed & Biofuel – BCMS Manual

Pellet mills are controlled by the Set point for the Load control and compared to the actual process load value. The control system
is regulating the associated feed screw speed to obtain the load set point for the pellet mill.

The steam temperature set point is compared to the actual temperature measured and regulating the steam valve opening degree
to obtain the temperature.

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Last saved by esbn083 22-11-2010 25-25