1

Z-MillAutomation & Drives Upgrade

2

Z-Mill Automation UpgradeProject Goals

• Replace the Following Equipment:

– Reliance AutoMax Mill Master

– Reliance Distributed Power Drives

– Herb PC based AGC

– Main Operator Desk and Local Mill-Stand Control Stations

– Reliance Shark Remote I/O

– Level 1 Human-Machine Interface (HMI) Systems

3

Z-Mill Automation UpgradeNew System Configuration

KVM

Wind-On MasterWind-Off Master

EAD MCC(existing)

EAH MCC(existing)

X-Ray GaugeCabinet (IRM)

Mill

Operator Station

FLEX I/O

Right Reel

Operator Station

FLEX I/O

Mill Master/AGC

CP

U

PS

Power

32-D

I

HS

C

16

-DO

C-N

ET

Bla

nk

C-N

ET

4A

I-2A

O

HS

CH

SC

4A

I-2A

O

Computer Cabinet

Eth

ern

et

CP

U

EW

EB

Eth

ern

et

Wind-On Rewind

Operator Station

FLEX I/O

HMI

Wind-On Payoff

Operator Station

FLEX I/O

Wind-Off Rewind

Operator Station

FLEX I/O

HMI

Wind-Off Payoff

Operator Station

FLEX I/O

Eth

ern

et

CP

U

PS

Power

Bla

nk

Bla

nk

Bla

nk

Bla

nk

Eth

ern

et

Bla

nk

Bla

nk

Bla

nk

Bla

nk

Bla

nk

Bla

nk

C-N

ET

C-N

ET

Bla

nk

M

DCS800

E

DCS800

ME

Wind-Off Drives

Thickness Gauge Network

Eth

ern

et

CP

U

PS

Power

Bla

nk

Bla

nk

Bla

nk

Bla

nk

Eth

ern

et

Bla

nk

Bla

nk

Bla

nk

Bla

nk

Bla

nk

Bla

nk

C-N

ET

C-N

ET

Bla

nk

M

DCS800

E

DCS800

ME

Bla

nk

Bla

nk

Bla

nk

Bla

nk

Brake

Supply

(New)

(existing cabinet, new

drive sub-panels)

Wind-On Drives(existing cabinet, new

drive sub-panels)

Payoff DiameterFeedbackB

Brake

Supply

(New)

B

Brake

Supply

(New)

Brake

Supply

(New)

B B

FLEX I/O

FLEX I/O

DCS800 DCS800

E

Wind-Off

Rewind Motor

Wind-Off

Payoff Motor

Wind-On

Rewind Motor

Wind-On

Payoff Motor

Payoff DiameterFeedback

Left DeflectorRoll Tensiometers

(OS/DS)

Left Reel Drives(existing cabinet,

new drive sub-panels)

Right Deflector RollTensiometers (OS/DS)

M

SR6 Power

Modules

1500 HP

(existing)

DCS800 DCS800

E

Main Mill Drives(existing cabinet,

new drive sub-panels)

M

SR6 Power

Modules

1500 HP

(existing)

DCS800 DCS800

E

Right Reel Drives(existing cabinet,

new drive sub-panels)

M

SR6 Power

Modules

1500 HP

(existing)

EAH MCC

Remote I/O

(Bkt. BJ1)

FLEX I/O

DI: 17DO:12

EAD MCC

Remote I/O

(Bkt. AJ1)

Pump & Motor

Starters

Pump & Motor

Starters

HMI Client PCs (3)KVM

Extenders

HMI Server PC

HMI KVM

iba Data

Acquisition PC

Main Desk

HMI HMI HMI

Level 2 PC

Patch Panel

Network Switch

HMI

Server

Cooling Tower Control

- Water Temperature AI

- Oil Temperature AI

- Oil Valve AO

DI: 27DO: 25AI: 2AO: 1

FLEX I/O

Mill Master I/O

Screwdown HPU

Inputs

Maintenance PC

iba PC

Maintenance

PCLevel 2

Network

Printer

Level 3 Database

(by customer)

PDI

Process Data

Network

Switch

Pro

fib

us

Brake

Supply

(New)

B

Brake

Supply

(New)

B

DCSLink DCSLink DCSLink

Wind-On Valve

Stand I/O

FLEX I/O

DI: 7DO:28

Wind-Off Valve

Stand I/O

FLEX I/O

DI: 4DO:20

Right Reel

Valve Stand I/O

FLEX I/O

DI: 8DO:22

Left Reel

Valve Stand I/O

FLEX I/O

DI: 9DO:20

iba Data Acquisition Network

Drive Programming Network

HMI/Inter-processor Network

Wind-Off I/O Wind-On I/O

Profibus

A

Gauge Status I/O

Left/Right Deviation Feedbacks (2)

Left Deflector Roll Encoder

Right Deflector Roll Encoder

Left Strip Encoder

Right Strip Encoder

Lower Intermediates LVDT Fdbk.

Upper Intermediates LVDT Fdbk.

Lower Intermediates Servo Valve

Upper Intermediates Servo Valve

Upper Screwdown Servo Valve

Upper Screwdown Pressure Xdcrs. (2)

Screwdown System Pressure Xdcr.

Screwdown Position Feedback

B

C

D

E

F

G

H

J

K

L

M

Left Reel

Operator Station

FLEX I/O

N Crown Adjust Solenoids (12)

Crown LVDT Feedbacks (6)P

421 420

221 222 223

220

201

300200400

430232 233

230

231

330

310212211210410

321320

1

1

1

1

23

23

4

2 3 4 5 6 7

2 3 4

5 6 78 9

10

11

2

1

1

23

3

4

.20

.30.40

4

Z-Mill Automation UpgradeNew System Configuration

Remote I/O (ControlNet)

New DC Drives

DC Drive Digital Front End Retrofit

New Setup Model (T. Sendzimir)

Pyramid Hierarchy

Distributed Processing

Common Implementation Platform

Common L1/L2 HMI

Setup

Mill Master/AGC

Stand Control Sub-Masters

Drives and Auxiliary I/O

Level 1

Level 2

5

Z-Mill Automation UpgradeMain Operator Screen

6

Z-Mill Automation UpgradePass Schedule Screen

7

Z-Mill Automation UpgradeCrown Control Screen

8

Z-Mill Automation UpgradeAnnunciator Screen

9

Z-Mill Automation UpgradeDrive Fault Screen

10

Z-Mill Automation UpgradeServo Diagnostic Screen

11

Z-Mill Automation UpgradeRoll Setup Screen