GEA SIMATIC C7-623 User manual

8164-9001-400
1198
Control Unit
C7-623
WMS
01
Program
0Program
1L-Test SMS
36 SMS
96
78 9
45 6
12 3
.0
ESC
INS
DEL
DIR
HARD
COPY
SHIFT
HELP ENTER
SF
BAF FRCE
DC5V STOP
RUN
DEF
ABC
SIMATIC C7-623
ACK
DOWN ALARMS
SERIES
1 2
CHECK
Sep. FEED SLUDG
E
PARTIAL HEATER
RELEASE
UP


III
8164-9001-400 / 1198
Subject to modification!

IV
8164-9001-400 / 1198
For your safety
•Strictly adhere to instructions marked with this symbol.
This avoids damage to the separator and other units.
•Take special care when carrying out operations marked with
this symbol -
otherwise danger to life.
•Observe accident prevention regulations.
The local safety and accident prevention regulations apply uncondi-
tionally to the operation of the separator.
•When operating electrical apparatus, certain parts carry
dangerously high voltage.
Non-compliance with the protective measures can therefore result in
serious injury or damage.
For this reason, only suitably qualified specialists are allowed to work
on the units.
Protectivemeasuresshouldbetakeninline withnationalandlocalreg-
ulations.
•Instruction manuals
Follow the instructions given in this manual and the separator manual.
Proper and safe operation is conditional on appropriate transport and
storage conditions, correct operation and assembly as well as careful
operation and maintenance.
•Operate the separator only in accordance with agreed pro-
cess and operating parameters.
•Maintain the separator as specified -
in the separator manual.
•Carry out safety checks on the separator -
as described in chapter ”Safety” in the separator manual.
ÁÁ

V
8164-9001-400 / 1198
•Liability for the function of the unit passes to the owner.
Liability for the function of the unit passes unconditionally to the owner
oroperator irrespective of existingwarranty periods in sofar as the unit
is improperly maintained or serviced by persons other than Westfalia
Separator service personnel or if the machine is not applied in accor-
dance with the intended use.
Westfalia Separator AG shall not be liable for damage which occurs as
a result of non-compliance with the above. Warranty and liability condi-
tions in the Conditions of Sale and Delivery of Westfalia Separator AG
are not extended by the above.

VI
8164-9001-400 / 1198
Foreword
This instruction manual is primarily intended for persons assigned the task
of operating and maintaining the control unit. To assure safe operation it is
therefore imperative that the manual is indeed handed over to these per-
sons.
In the event of any queries please state the model designation and the se-
rial number (see nameplate inside the control unit).
When ordering spare parts, it aids the rapid and correct processing of your
order if you also state the circuit diagram number specified.
Typenschild / Name plate

VII
8164-9001-400 / 1198
1 General description 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1 Application 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2 Equipment 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3 Control cabinet 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4 General layout plan 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 Control system 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1 Design 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2 Classification specifications 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3 Special designs 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4 Assembly 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4.1 Control unit 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4.2 Electrical connection 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4.3 Fuse terminals 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.5 Installing the control unit in the control cabinet 12. . . . . . . . . . . . . . . . .
2.5.1 Loosening the fixing bracket 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 Control unit 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1 Technical specifications 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2 Getting acquainted with the operating elements 19. . . . . . . . . . . . . . . .
3.2.1 Function keys 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2.2 Softkeys 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2.3 System keyboard 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3 Overview of display pages 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.4 Selecting operating modes 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.4.1 Calling up the system function menu 26. . . . . . . . . . . . . . . . . . . . . . . . . .
3.4.2 Calling up the system function menu 27. . . . . . . . . . . . . . . . . . . . . . . . . .
3.4.3 Exiting the system function menu 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.5 Password protection 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.5.1 Entering the password 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.6 The start screen 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.7 Interfaces 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 Operation 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1 Switching on the control unit 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2 Start screen 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3 Calling up separator data 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4 Calling up the process text page 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.5 Calling up the separator data page 41. . . . . . . . . . . . . . . . . . . . . . . . . . .
4.6 Calling up system times 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.6.1 Determining the separating time 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.7 Timer overview 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.8 Calling up the timer table 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.9 Calling up digital inputs 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.10 Calling up digital outputs 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.11 Calling up analog inputs 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.12 Calling up analog outputs 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.13 Calling up service addresses 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.14 Calling up operator times 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.15 Calling up the system settings 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.16 Loading a new program 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.16.1 The UD 700 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.16.2 Loading data from the UD 700 to the C7-623 61. . . . . . . . . . . . . . . . . .

VIII
8164-9001-400 / 1198
4.16.3 Text transfer OP-part 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.16.4 Loading configured data from the programming device into
the UD 700 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 Programs and settings 71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1 Separator-specific operating modes 72. . . . . . . . . . . . . . . . . . . . . . . . . .
5.1.1 OSA-/OSB separators with VARIZONE system 72. . . . . . . . . . . . . . . . .
5.1.2 OSA-/OSB separators with UNITROL system – WMS function 73. . .
5.1.3 OSA-/OSB separators with UNITROL system – SMS function
for HFO 74. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1.4 OSC separators in -02- design 76. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1.5 OSC separators with UNITROL system – WMS system 79. . . . . . . . .
5.1.6 OSC separators with UNITROL system – SMS function 82. . . . . . . . .
5.1.7 OSC separators with UNITROL system – SMS function for
lube oil treatment 85. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2 Setting the counters 89. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.1 Flush ejection (counter 1) 89. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.2 Partial ejections (counter 2) 89. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3 Entering freely assignable times 90. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 Error messages / maintenance 91. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1 Error messages 92. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1.1 Status and error indicators 92. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2 Alarm descriptions 93. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2.1 Separator motor protection (input 0.1) 93. . . . . . . . . . . . . . . . . . . . . . . . .
6.2.2 PSL Clean oil discharge (input 0.2) 95. . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2.3 PSH Clean oil discharge (input 0.3) (special design) 97. . . . . . . . . . . .
6.2.4 FSH water discharge (input 0.4) (special design) 99. . . . . . . . . . . . . . .
6.2.5 LSHH Sludge tank (input 0.7) 100. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2.6 Fault feed pump (input 1.1) (optional) 102. . . . . . . . . . . . . . . . . . . . . . . . .
6.2.7 Fault sludge pump (input 1.3) (optional) 103. . . . . . . . . . . . . . . . . . . . . . .
6.2.8 Vibration monitoring stage 1 (input 1.6) (additional equipment) 105. . .
6.2.9 Vibration monitoring stage 2 (input 1.7) (additional equipment) 107. . .
6.2.10 SMS – System errors (input 0.6) 109. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2.11 SMS – Minimum separating time not exceeded (Input 0.6) 111. . . . . . .
6.2.12 HFO series operation: Selection errors 113. . . . . . . . . . . . . . . . . . . . . . . .
6.2.13 Ejection monitoring (analog output 0.0) 115. . . . . . . . . . . . . . . . . . . . . . . .
6.2.14 Temperature monitoring (analog output 0.2) 119. . . . . . . . . . . . . . . . . . .
6.3 Causes and action 124. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.3.1 Separator monitoring systems 124. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.3.2 Separator – optional auxiliaries 126. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.3.3 Separator 128. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.3.4 Control unit C7-623 129. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.4 Maintenance 131. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.4.1 Storing batteries 131. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.4.2 Changing the battery 131. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 Appendix 135. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 General description
1
8164-9001-400 / 1198
1.1 Application 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2 Equipment 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3 Control cabinet 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4 General layout plan 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2
8164-9001-400 / 1198
The C7-623 control unit is used for the automatic ejection control and condition
monitoring of mineral oil separators of the series
•OSA
•OSB
•OSC
With the electronic C7-623/A control unit total ejections of the centrifuge bowl, with
or without previous displacement of the product, are triggered at preset intervals.
The following ejection modes can be selected on the OSC separators:
•partial ejections
•total ejections
•preselectable partial ejections followed by total ejection
With the time-dependent program cycle it is important in respect of high clarifying
efficiency and avoiding desludging losses that the separable solids content in the
product does not fluctuate widely.
Thecentrifuges withUNITROL systemare provided with two basic monitoring sys-
tems:
•Water content monitoring system - WMS
•Sludge space monitoring system - SMS
Series operation is also available for two-stage HFO treatment.
Software assignment to the specific separator is carried out in the factory using a
password function.
Detailed information on the special functions is given in the respective chapters of
this manual.
The illuminated four-line LC display provides information about the operating and
malfunction condition of the separator and, depending on the programming, dis-
plays relevant process data.
The control system comprises, in addition to the control cabinet, all complete line
fittings incorporating electrical components which are controlled or monitored by
the control unit.
These include:
•the dirty oil connection,
•the water connection,
•the operating water connection,
•additionally on UNITROL centrifuges:
- the circuit and water discharge valve
- the water sensor
- and/or the pressure switch for the bypass line in SMS function.
Optional extras:
•multi-purpose thermometer PT 100 for minimum / maximum monitoring in the
dirty oil
•level switch for monitoring the water discharge
•process-dependent control of an external feed pump
•level switch for monitoring the sludge tank
•minimum and maximum level switch for controlling a sludge pump
•klaxon for audible alarm
ThestandardC7-623controlunitisdesignedforsingleoperationofpurifiersorclar-
ifiers.
If required, series operating mode can be pre-selected for two-stage HFO opera-
tion after entering a password. The MPI interfaces (Multi Point Interface) must be
cabled accordingly (cf. chapter 6.2.12 page 113 ff.).
1.1 Application
1.2 Equipment

3
8164-9001-400 / 1198
Fig. 2
TheC7-623controlunitisbuiltintothedoorofthecontrolcabinetreadyforconnec-
tion.
An order-specific drawing is in the appendix to this manual.
1.3 Control cabinet

4
8164-9001-400 / 1198
1.4 General layout plan
Fig. 3
9
1
8
14
11
13
10
12
7
3
2
A
C6
5
4
B
D
AWater
BCompressed air
CDirty oil feed
DClean oil discharge
1Control unit C7-623 and motor control for centrifuge
Motor control feed pump
Motor control sludge pump
2Water pressure reducer
3Feed assembly with solenoid valve for
filling, displacement and operating water
4Compressed air control unit
5Pneumatic 3/2-way valve with
manual adjustment and solenoid valve for control air
(fitted in the dirty oil line of the separator)
6PT 100 oil feed min./max. temperature monitoring
7Pressure switch (for monitoring the clean oil discharge)
8Connections for electrical power supply
9Klaxon
10 Water discharge valve
11 Circuit valve
12 Pressure switch - sludge space monitoring
13 Water sensor
14 Terminal box (fitted to separator)
On special order only.

2 Control system
5
Westfalia Separator AG
8164-9001-400 / 1198
2.1 Design 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2 Classification specifications 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3 Special designs 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4 Assembly 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4.1 Control unit 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4.2 Electrical connection 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4.3 Fuse terminals 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.5 Installing the control unit in the control cabinet 12. . . . . . . . . . . . . . . . .
2.5.1 Loosening the fixing bracket 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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