46381-1003 CFDS Caster R00

46380
ARCONIC Kunshan China

Pit 2 Upgrade
46380-1003
Casting Machine & MMLC Control
Functional Design Specification
Revision 00
4th May 2017
ARCONIC Kunshan, China
Pit 2 Casting Machine Upgrade
Document History
Revision Description/Changes Author Checked Approved
00 Preliminary Martin Langham Brian Bussey Nigel Walker
Document Number 46381-1003 Rev 00 Page 2 of 151

SAFETY CONTROL ..................................................................................... 7
C_100 POWER AND SAFETY SYSTEM GROUP MONITOR .................................... 8

EY_100A CASTING MACHINE SAFETY SUPPLY RELAY .......................................................................... 8
UPS_100 UPS CONTROL SUPPLY ............................................................................................... 10
EY_100C_A CONTROL SUPPLY ON RELAY ..................................................................................... 10
EY_100D PLC WATCHDOG PULSED OUTPUT RELAY ......................................................................... 11
OPERATOR CONTROL .............................................................................. 13
C_105 CASTING MACHINE OPERATOR CONTROL ................................................ 14

C_105_MODE CAST MODE CONTROL ............................................................................................. 15
C_105_PREM CAST PERMISSIVE CONTROL ...................................................................................... 17
C_105_ABORT CAST ABORT CONTROL ........................................................................................... 20
EY_105 CAST ABORT AND TILT INTERLOCK RELAY ............................................................................. 24
C_106 CASTING MACHINE RECIPE CONTROL ..................................................................................... 25
C_412 MOULD METAL LEVEL GROUP FUNCTIONS .............................................. 29

VY 412A PIN ACTUATOR CALIBRATE VIRTUAL RELAY ............................................................................ 30
VY 412B MOULD LASER CALIBRATE VIRTUAL RELAY............................................................................. 31
LAUNDER AND FURNACE EQUIPMENT CONTROL ..................................... 34
Z_317C CASTING LAUNDER DAM GROUP ..................................................... 35

EVH_317C CASTING LAUNDER DAM RAISE SOLENOID ...................................................................... 35
EVL_317C CASTING LAUNDER DAM LOWER SOLENOID ...................................................................... 37
ZSH_317C CASTING LAUNDER DAM RAISE LIMIT ............................................................................ 38
ZSL_317C CASTING LAUNDER DAM LOWER LIMIT ........................................................................... 39
Z_317E CFF LAUNDER DAM GROUP ........................................................... 40

EVH_317E CFF LAUNDER DAM RAISE SOLENOID ............................................................................ 40
EVL_317E CFF LAUNDER DAM LOWER SOLENOID............................................................................ 42
ZSH_317E CFF LAUNDER DAM RAISE LIMIT .................................................................................. 43
ZSL_317E CFF LAUNDER DAM LOWER LIMIT ................................................................................. 43
Z_317D DRAIN LAUNDER DAM GROUP ........................................................ 45

EVH_317D DRAIN LAUNDER DAM RAISE SOLENOID ......................................................................... 45
EVL_317D DRAIN LAUNDER DAM LOWER SOLENOID ........................................................................ 47
ZSH_317D DRAIN LAUNDER DAM RAISE LIMIT ............................................................................... 48
ZSL_317D DRAIN LAUNDER DAM LOWER LIMIT .............................................................................. 48
L_361 LAUNDER METAL LEVEL CONTROL GROUP ......................................... 50

LT_361_X LAUNDER METAL LEVEL TRANSMITTER ............................................................................ 51
EV_361_X LAUNDER LASER COOLING AIR SOLENOID CONTROL ........................................................... 52
LC_361 FURNACE LAUNDER METAL LEVEL CONTROLLER ....................................................................... 54
FV_361 FURNACE TILT CONTROL VALVE .......................................................................................... 55
Z_361 FURNACE TILT GROUP .................................................................. 57

VV_361 FURNACE TILT HOLD VIRTUAL OUTPUT ................................................................................. 57

VVHH_361 FURNACE TILT UP FAST VIRTUAL OUTPUT ....................................................................... 58
VVH_361 FURNACE TILT UP CAST VIRTUAL OUTPUT ......................................................................... 60
MOULD WATER EQUIPMENT CONTROL ................................................... 62
F_230 MOULD WATER FLOW CONTROL GROUP ........................................... 63

FT_230 MOULD WATER FLOW TRANSMITTER .................................................................................... 64
PT_230 MOULD WATER PRESSURE TRANSMITTER ............................................................................... 65
TT_230 LAUNDER METAL LEVEL TRANSMITTER .................................................................................. 66
FC_230 MOULD WATER FLOW CONTROLLER ..................................................................................... 67
FV_230 MOULD WATER FLOW CONTROL VALVE ................................................................................. 69
M 044 STEAM EXTRACTION FAN MOTOR GROUP .......................................... 71

EY_044 STEAM EXTRACTION FAN MOTOR CONTRACTOR ....................................................................... 71
EQ_044 STEAM EXTRACTION FAN MOTOR CIRCUIT BREAKER .................................................................. 72
M 051 CASTING PIT LIFT PUMP MOTOR GROUP .......................................... 74

EY_051 CASTING PIT LIFT PUMP MOTOR CONTRACTOR ........................................................................ 74
EQ_051 CASTING PIT LIFT PUMP MOTOR CIRCUIT BREAKER .................................................................. 75
L_240 CASTING PIT WATER LEVEL CONTROL GROUP ................................... 77

LT_240 MOULD WATER FLOW TRANSMITTER .................................................................................... 77
PLATEN EQUIPMENT CONTROL ............................................................... 79
F_310 CAST SPEED CONTROL GROUP........................................................ 80

FC_310 PLATEN CAST SPEED CONTROLLER ...................................................................................... 81
EY_310 PLATEN LIFT MOTOR VSD SAFE TORQUE OFF CONTROL ............................................................. 82
SC_310 PLATEN LIFT VARIABLE SPEED DRIVE ................................................................................... 84
EQ_310 PLATEN LIFT MOTOR CIRCUIT BREAKER ................................................................................ 85
M 310_A PLATEN DRIVE COOLING AIR FAN MOTOR GROUP .............................. 87

EY_310_A PLATEN DRIVE COOLING AIR FAN MOTOR CONTRACTOR ....................................................... 87
EQ_310_A PLATEN DRIVE COOLING AIR FAN MOTOR CIRCUIT BREAKER ................................................ 88
M 310_B PLATEN DRIVE BRAKE MOTOR GROUP ............................................. 90

EY_310_B PLATEN DRIVE BRAKE MOTOR CONTRACTOR ..................................................................... 90
EQ_310_B PLATEN DRIVE BRAKE MOTOR CIRCUIT BREAKER .............................................................. 91
Z 310 PLATEN POSITION GROUP ............................................................. 93

VVHH_310 PLATEN UP FAST VIRTUAL OUTPUT ............................................................................... 94
VVH_310 PLATEN UP SLOW VIRTUAL OUTPUT ................................................................................ 95
VVLL_310 PLATEN DOWN FAST VIRTUAL OUTPUT ............................................................................ 96
VVL_310 PLATEN DOWN SLOW VIRTUAL OUTPUT ............................................................................ 97
ZT_310 CAST LENGTH ENCODER ................................................................................................... 99
ZSH_310 PLATEN FULLY RAISE LIMIT ........................................................................................ 100
ZS_310 PLATEN ZERO HOME LIMIT .............................................................................................. 100

MECHANICAL EQUIPMENT CONTROL .................................................... 102
M 011 MAIN HYDRAULIC OIL PUMP MOTOR GROUP ................................... 103

EY_011 MAIN HYDRAULIC OIL PUMP MOTOR CONTRACTOR ................................................................. 103
EQ_011 MAIN HYDRAULIC OIL PUMP MOTOR CIRCUIT BREAKER ............................................................ 104
C_250 HYDRAULIC POWER PACK GROUP ................................................. 106

Z_315 MOULD TILT TABLE CONTROL GROUP ............................................ 107
EVH_315 MOULD TILT TABLE RAISE SOLENOID ............................................................................ 107
EVL_315 MOULD TILT TABLE LOWER SOLENOID ............................................................................ 109
ZSH_315 MOULD TILT TABLE RAISE LIMIT .................................................................................. 110
ZSL_315 MOULD TILT TABLE LOWER LIMIT ................................................................................. 111
ZS_311_A CASTING LAUNDER IN CASTING POSITION LIMIT ............................................................. 111
ZS_311_B CASTING LAUNDER IN MAINTENANCE POSITION LIMIT ....................................................... 112
CASTING LAUNDER PRE-HEAT EQUIPMENT CONTROL .......................... 113
M 061 LAUNDER COOLING AIR SUPPLY FAN MOTOR GROUP ........................ 114
EY_061 LAUNDER COOLING AIR SUPPLY MOTOR CONTRACTOR ............................................................. 114
EQ_061 LAUNDER COOLING AIR SUPPLY MOTOR CIRCUIT BREAKER ....................................................... 115
M 062 LAUNDER HEATING AIR SUPPLY FAN MOTOR GROUP ........................ 117
EY_062 LAUNDER HEATING AIR SUPPLY MOTOR CONTRACTOR ............................................................. 117
EQ_062 LAUNDER HEATING AIR SUPPLY MOTOR CIRCUIT BREAKER ........................................................ 118
H 063X LAUNDER HEATER GROUP ........................................................... 120

EY_063X LAUNDER HEATER CONTRACTOR .................................................................................. 120
EQ_063X LAUNDER HEATER CIRCUIT BREAKER ............................................................................ 121
ZS_063X LAUNDER HEATER IN POSITION LIMIT SWITCH ................................................................. 122
HC _063X LAUNDER HEATER TEMPERATURE CONTROLLER ................................................................ 122
H 412X SPOUT HEATER GROUP ............................................................... 124

EY_412X LAUNDER HEATER CONTRACTOR .................................................................................. 124
EQ_412X LAUNDER HEATER CIRCUIT BREAKER ............................................................................ 125
MOULD METAL LEVEL CONTROL EQUIPMENT OPERATION .................... 127
L_412X MOULD METAL LEVEL CONTROL GROUP .......................................... 128

LT_412X_TT MOULD METAL DEPTH TRANSMITTER INTERNAL TEMPERATURE .......................................... 130
LT_412X_A MOULD TOP LEVEL TRANSMITTER.............................................................................. 131
LT_412X_B MOULD METAL LEVEL TRANSMITTER .......................................................................... 132
LT_412X MOULD METAL DEPTH CALCULATION ............................................................................. 133
LC_412X MOULD METAL DEPTH CONTROLLER .............................................................................. 134
ZV_412X MOULD METAL FLOW PIN POSITION ACTUATOR ................................................................ 137
ZV_412X_EY MOULD METAL LEVEL FLOW CONTROL PIN POSITION ACTUATOR ELECTROMAGNET CHARGED CONTROL 138
ZV_412X_TSH MOULD METAL FLOW PIN POSITION ACTUATOR OVER TEMPERATURE SWITCH ..................... 139
EV_412X_A MOULD BAG SHAKER SOLENOID CONTROL .................................................................. 140

EV_412X_B MOULD LASER COOLING AIR DISABLE SOLENOID CONTROL .............................................. 141
PLC PROGRAMMING ............................................................................. 143
PLC PROGRAM STRUCTURE ......................................................................... 144

INTERLOCKS ............................................................................................ 145
BASIC CONTROL ....................................................................................... 146
AUTO/MANUAL ........................................................................................ 147
ALARMS 148
HMI EV/ZS STATUS................................................................................. 150
HMI LOOP STATUS ................................................................................... 151

Safety Control
This section will describe the safety features of the control system to ensure safe operation.

C_100 Power and Safety System Group Monitor

The primary function of this loop is to control, protect and monitor the electrical control supply to all the casting machine equipment.
The machine control supply is protected and distributed to different areas and different items of equipment via control circuit breakers.
The machine controls include a number of illuminated pushbuttons, indicators and sirens. To ensure these are functioning there are a
number of test facilities available to the operator.
Tag C_100
Description Machine Supply and Safety Group Control
UDT GROUP_STATUS
User Functions
TAG Description Settings SAT
1 EPB_100A_A (CP100) Safety and alarm reset, the safety circuit reset can be done from these ☐
EPB_100A_B (CP102) pushbuttons; also, any current alarms can also be reset from the pushbutton.
EPB_100A_D (CP100_ROD) The illumination will flash when it requires a reset (when all emergency stop
pushbuttons and watchdog timers are healthy), the illumination will hold
steady once the safety circuit itself has been reset.
2 EPB_100B_A (CP100) On each control panel and most control pushbutton stations will be ☐
EPB_100B_B (CP102) emergency pushbuttons
EPB_100B_D (CP100_ROD)
EY_100A Casting Machine Safety Supply Relay

This PLC output is used to reset the electrical safety circuit after power cycle or emergency stop.
Tag EY_100A, EY_100B
Description Casting Machine Safety Supply Relay
Rod Feeder Safety Supply Relay
UDT OBJ_EY01
User Control
TAG Description Access Unit Max Min Value SAT
1 hmi_EPBH Hand start operation virtual pushbutton L0 ☐
positioned on the HMI, for an operator to
initiate the device operation
2 hmi_EPBL Hand stop operation virtual pushbutton L0 ☐
stop the device operation
3 am.Select.hmi_On Will put device in to manual control L1 ☐
4 am.Select.hmi_Off Will put device in to automatic control L0 ☐
5 am.Run.hmi_On Will start device in manual control Hand ☐
6 am.Run.hmi_Off Will stop device in manual control Hand ☐
7 lock.hmi.Latch.hmi_On Will put interlock latch on, if the device L2 ☐
loses an interlock only the first failed
interlock will show and remain on until reset
manually
8 lock.hmi.Latch.hmi_Off Will put interlock latch off L0 ☐
9 lock.hmi.Reset Will reset any tripped interlocks, when L0 ☐
interlock latch is on allowing the device to
start
Interlocks
TAG Description Interlock Position SAT
0 "EY_100A".plc_Dout.Com IO Healthy Available ☐
1 "EY_100A".plc_Dout.Status Safety Status Healthy (If Applicable) Available ☐

2 "EPB_100B_A".plc_Din.On Emergency Stop Pushbutton Main Panel (CP100) Available ☐

3 "EPB_100B_B".plc_Din.On Emergency Stop Pushbutton Operator Desk (CP102) Available ☐
4 "EPB_100B_C".plc_Din.On Emergency Stop Pushbutton Water Panel (CP230) Available ☐
29 .con_PB.Hand Device hand mode control active Indication ☐
30 .con_PB.Auto Device Automatic mode control active Indication ☐
31 .con_PB.Auto Device Automatic mode control tripped requiring to be reset Indication ☐
Control Functions
1 con_PB.Start All pushbuttons real or on the HMI that will manually initiate the device ☐
operation
2 con_PB.Stop All pushbuttons real or on the HMI that will manually stop the device ☐
operation
3 con_PB.Auto.Active Device Automatic mode active. ☐
 Automatic mode always disabled
4 con_PB.Auto.Reset Device Automatic mode reset, device automatic on is tripped, reset from ☐
Device hand mode stop any pushbutton or Safety Circuit Reset Pushbutton
 Device manual mode stop pushbutton pressed
 Device hand mode stop any pushbutton pressed
5 con_PB.Auto.On Device Automatic mode Trigger. ☐
 none
6 con_PB.Hand.Active Device Hand mode active ☐
 Device not in manual control
7 con_PB.Hand.Reset Device Hand mode disable latch ☐
 Device always latched
8 con_PB.Hand.On Device Hand mode Trigger, set and reset from the device start, stop ☐
pushbuttons
9 con.enable All interlocks are made and either auto on request or hand on request are ☐
set.
10 con.Run Motor running signal is set from a timer allowing the motor to run up to ☐
speed before enabling other functions in the PLC
11 hmi_EPBH Device HMI start button illumination control ☐
12 hmi_EPBL Device HMI Stop button illumination control ☐
Alarms
TAG Description Type Settings SAT
1 alm_Make PLC Output to contactor is made but PLC input from Warning 0 Seconds ☐
contactor auxiliary remains not made
2 alm_Break PLC Output to contactor is not made but PLC input from Fault 0 Seconds ☐
contactor auxiliary remains made
3 alm_Safety_Out PLC Safety output to device has failed, single safe output with Fault Not used ☐
pulse check continuity and feedback from auxiliary
4 alm_Safety_In PLC Safety input from the auxiliary contract has failed, two Fault Not used ☐
complementary safe inputs with safety pulse to check
continuity
5 EPB_100Bx Emergency Stop Pushbutton Pressed Fault 0 Seconds ☐
alm_Make
6 EPB_100Bx Emergency stop Pushbutton PLC input from the auxiliary Fault 0 Seconds ☐
alm_Safety_In contract has failed, single safe inputs with safety pulse to
check continuity
7 EPB_100Bxy Emergency Stop Pull Cord Pressed Fault 0 Seconds ☐
alm_Make
8 EPB_100Bxy Emergency stop Pull Cord PLC input from the auxiliary Fault 0 Seconds ☐
alm_Safety_In contract has failed, single safe inputs with safety pulse to
check continuity

UPS_100 UPS Control Supply

In the motor control section will have a UPS control supply, this will be sized to supply all the PLC, HMI and SCADA equipment, all PLC
digital and analogue inputs, and all equipment necessary for the safe shut down of the machine in the event of a power failure. The
machine has three types of control supply.
Control Supplies
Type Supplying Supplying SAT
1 UPS The UPS unit will be in the motor control panel, it has a 240 volt input and a PLC Modules ☐
battery backed 240 volt output which will supply power for a minimum of 15 HMI
minutes. SCADA
PLC analogue field
devices
PLC digital Input devices
2 Standard The transformer will be in the motor control panel, it has a 2 phase 240 volt input UPS unit ☐
and a 240 volt output All PLC outputs
3 Safety Were the ups supply is used in conjunction with a PLC safety input or the All PLC safety modules ☐
standard supply is used in conjunction with a PLC safety output.
Safety PLC inputs will be double contact either complementary or equitant high,
both inputs need to change within a discrepancy time and inputs are supplied by
the module safe supply so switches cannot be bypassed with a standard supply.
Safety PLC outputs will be wired through the PLC module which will monitor of
wire break.
Alarms
1 BYPASS UPS running on Bypass HMI Warning Warning 5 Seconds ☐
alm_Make
2 BYPASS NA Fault 0 Seconds ☐
alm_Safety_In
3 FAIL UPS healthy signal to the PLC is not Made Fault 5 Seconds ☐
alm_Make
4 FAIL NA Fault 0 Seconds ☐
alm_Safety_In
EY_100C_A Control Supply On Relay

Tag EY_100C_A, EY_100C_B
Description Casting Machine Control Supply On Relay
Rod Feeder Control Supply On Relay
UDT OBJ_XS01
User Control
1 NA ☐
Interlocks
1 ☐
Control Functions
1 ☐
Alarms, Failures and Warnings


1 alm_Make limit PLC input from the auxiliary contact is not made Fault 0 Seconds ☐
2 alm_Safety_In limit PLC input from the auxiliary contact has failed, two Fault Not used ☐
continuity
EY_100D PLC Watchdog Pulsed Output Relay

The CPU is monitored by an external watchdog circuit, the PLC sends a pulse to the watchdog to proof that the CPU is running, when
running the watchdog energises the relay EY100D. If the pulse stops and the watchdog circuit fails, the relay de-energises and the safety
circuit will fail; this will abort any cast in operation, cut the control supply to the MCC and all solenoids.
Tag EY_100D
Description PLC Watchdog Pulsed Output Relay
UDT OBJ_EY01
User Control
manually
start
Interlocks
0 "EY_100D".plc_Dout.Com IO Healthy Available ☐
Control Functions
operation
operation

 Output is driven from the PLC clock 2 second pulse

pushbuttons
set.
Alarms
continuity

Operator Control
This section details operator control functions

C_105 Casting machine operator control

The description of system process is meant to provide an insight into the proposed control of the system. This section is intended to
provide the highest level of control functionality from which all further design documents stem.
An integrated control system will be provided to control one vertical direct-chill casting machine in manual and automatic operation.
The casting machine will produce ingot to a pre-prepared recipe based on the mould size and cast identification. The cast recipe must be
selected by the operator, but once selected, will automatically configure the system ready for cast.
The control system, once initiated, shall check the casting machine for readiness through the use of pre-cast interlocks, one of these shall
require the operator to manually check the casting machine based on a list of manual pre-checks.
Once pre-cast interlocks are passed, the casting machine is ready for casting. The cast start, run and end cast will all be primary a fully
automatic processes, there are pushbuttons situated on the desk to allow the operators to initiate casting processes manually.
 To begin the cast process the operator will put the furnace into cast tilt from a pushbutton on the operator desk.
The furnace will tilt up fast until the level in the furnace outlet launder reaches a flood level, the furnace stops
tilting, there is now a set time to allow the complete flooding of the launder up to the mould table dam. All the
dams between the furnace and casting machine will open on a timed process or metal level basis one after the
other. The grain rod feed will start when the launder metal level reaches a set level.
 The mould table dam will rise automatically or the operator can raise it from a pushbutton on the desk, allowing the
metal to flood the distribution launder and start filling the moulds, the mould pin actuators are at a pre-defined
position to allow the correct flow of metal to the mould. During this time the automatic mould bag shakers will run.
 Once the metal level in each mould has risen to a set level the cast will start automatically and the platen will start
to move down or the operator can start the cast from a pushbutton on the desk. When the cast starts the furnace
will resume tilting to control the launder metal level and all casting function water flow, cast speed, grain rod feed,
mould metal level control and mould lubrication will follow the pre-defined setpoints set from the casting recipe.
 The cast will run until a pre-set cast length is reached and the furnace will tilt back automatically, the operator can
tilt the furnace back from a pushbutton on the desk. Prior to this length being reached a bell will sound to alert the
operators that the end of cast is approaching. The grain rod feed will stop.
 The cast will continue unchanged until the metal level in the launder drops to a set level and initiate end of cast is
automatically selected, the operator can select initiate end of cast from a pushbutton on the desk. Usually the cast
recipe will include slow cool cast parameters, which will slow the cast speed and water flow in preparation for the
end of cast.
 The cast will continue at the slow cool cast parameters until the metal level in the mould drops to a set level when
the cast will be stopped automatically or the operator can stop the cast from a pushbutton on the desk. The platen
will stop and the water will continue for a set time after which it will also stop (if the water run on timer is set to
zero then the water must be stopped manually).

 All casting processes are monitored if there is a serious failure of one or more parameters the cast will abort
automatically and safely. The machine will run through a pre-defined cast abort sequence there is no need for
operator intervention, leaving them free to leave the casting area.
Pre Cast Mode

All the movement functions are enabled such as carriage, platen and dams and are in manual control only. The operator can prepare the
casting machine ready for the next cast.
• Position all the launder units in to the launder at the raised position
• Check dam seals and close all the dams at the degasser, both filters and on the distribution launder.
• Bring platen up and clean, dry the oil the starter heads
• Move carriage over casting pit and lock in position.
• Bring platen into moulds, this can be done manually and the position checked or it can be done automatically where
the PLC will position the platen to level feedback from the mould level control lasers.
• Fit spout heaters into the distribution launder and ensure all launder lids are closed allowing the full launder system
to be pre heated.
Casting Mode
Casting mode is initiated by the operator from the pre-cast check pushbutton on the desk, at this point the manual control of the platen
and carriage will be disabled.
 The operator must select and confirm the casting recipe
 The operator will confirm all manual visual checks before cast
 Switch on the water, mould lubrication and refining rod to run (water will start if the recipe has been accepted; the mould
lubrication and grain refining rod start when metal is filling the launder).
 Allow the machine to run through all automatic pre-cast checks when complete the casting machine is ready for casting.
 The casting process is started from initiating cast tilt on the holding furnace.
 The auto flood sequence will run and the table will be flooded with metal, when the system is ready the platen will start to
lower at the predetermined recipe speed setpoint, the bell will sound to indicate the cast has started. The cast process will now
run automatically until it is complete.
Post Cast Mode

All the movement functions are enabled such as carriage, platen and dams and are in manual control only. The operator can move the
casting machine to allow the rolling ingot to be removed from the casting pit.
 The operator will manually drop the platen until the rolling ingot is below the level of the carriage
 Move the carriage to the service position and lift the platen until the rolling ingot is in position for the crane to remove them
from the casting pit.
Tag C_105
Description Casting Control Group
UDT GROUP_STATUS
C_105_MODE Cast Mode Control

The casting machine system will control the casting mode, the MMLC system will monitor the metal level in the mould to start or stop the
casting process automatically.
Tag C_105_Mode
Description Casting Control Mode
UDT GROUP_CAST

User Control
1 EPB_105A Pre-Cast Check Illuminated Pushbutton NA ☐
To initiated all the pre-cast checks that must been done
prior to the cast starting, the illumination flashes during
pre-cast checks and goes steady once all check have
been passed. The final pass will not occur unless the
furnace has started tilting, at this point the checks are
latched on so if one of the checks is lost the overall
check is not lost.
2 hmi_Check Pre-Cast Check Start HMI Poke Point L0 ☐
Situated on the operator interface the function is as the
pushbutton above
3 hmi_Cancel Pre-Cast Check Cancel HMI Poke Point L0 ☐
Situated on the operator interface the if the pre-cast
checks have not finished then they can be cancelled
from this pock point.
4 EPB_105B Cast start illuminated pushbutton NA ☐
The cast start will start automatically when the metal in
the mould reaches a set level this though can be
overridden though pressing the cast start pushbutton on
the operator desk, the cast can only be started once all
the pre-cast checks have been passed. The illumination
will flash during the initial hold time (if there is one) and
go steady when the platen starts to move down.
After the hold time has started pressing the cast start
pushbutton again will bypass the hold time and start the
platen immediately.
5 EPB_105C Initiate end of cast illuminated pushbutton NA ☐
At the end of the cast, the furnace will tilt back
automatically when the recipe specified cast length is
reached, the remaining metal in the launder and the
degasser can be cast out. Initiate end of cast will be
triggered automatically when the any mould level drops
below a set level and the slow cool descent cast speed
and water flow will be applied. This can be overridden
though pressing the initiate end of cast button on the
operator desk.
6 EPB_105D Cast stop pushbutton NA ☐
After the initiate end of cast has been pressed the cast
will continue for a set length before it is stopped
automatically, the platen will stop and the water stop is
initiated, the water will stop a set time from the platen
stopping. Again this can be overridden by pressing the
stop cast pushbutton on the casting desk, to stop the
cast the initiate end of cast must have been started first.
7 hmi_stop Pre-Cast Check stop HMI Poke Point L0 ☐
Situated on the operator interface the function is as the
pushbutton above
Interlocks
0 C_105_Abort Casting machine abort sequence has been initiated Available ☐
Control Functions
1 EPB_105B The cast can be manually started if precast checks are running and the cast ☐
start pushbutton is held for 5 seconds, this is an emergency function to use if
the safest action is to start casting metal at the table and precast checks are
not fully completed.
2 con_check Casting machine pre-cast check control ☐
.request (Pre-cast checks have started)
.enable (Pre-cast checks have all passed)
.run (Pre-cast checks is complete at locked on ready to start casting)

3 con_cast Casting machine cast start control ☐

.request (cast start primed waiting for metal flow to the moulds)
.enable (manual start from button or auto start from mould metal level)
.run (cast running after any hold time complete)
4 Auto start Metal level in one mould has reached the cast start threshold and the metal ☐
level in the remaining moulds are within a set percentage of the start set
point.
5 con_stop Casting machine cast stop control ☐
.request (cast length reached or initiate end of cast is pressed, the furnace
tilt is disabled)
.enable (mould metal level has dropped, cast freeze flow is initiated)
.run (cast complete and platen has now stopped)
6 Auto stop Metal level in one mould has reached the cast stop threshold. ☐
7 con_hold Casting machine hold time, this will hold the platen from moving at the start ☐
of a cast, the time is set from the recipe and can be overridden by pressing
the cast start pushbutton.
C_105_PREM Cast Permissive Control

The casting machine system will go through a series of automatic pre-cast checks before it will allow casting to start, from the HMI if
required a supervisor can log in and override these checks.
Tag C_105_PREM
Description Casting Permissive Check
UDT GROUP_PERM
User Control
1 hmi_EPBH From the HMI the pre-cast checks can be overridden by L0 ☐
a high level user, this function is for the purpose of
allowing dummy casts to be run so setpoint ramps and
control to be checked
Interlocks Water
0 Mould Water Line Flow in Tolerance Available ☐
lock_Water.con.State.0
1 lock_Water.con.State.1 Mould Water Line Flow Control Running Available ☐
2 Main Water pressure in main line Available ☐
Mould water pressure in tolerance
3 Mould water temperature in tolerance Available ☐
Water Temperature is within acceptable levels
4 lock_Water.con.State.4 Steam Extraction Air Fan Motor Running in Automatic Available ☐
5 lock_Water.con.State.5 Casting Pit Well Water Level Above Low Limit Available ☐
6 lock_Water.con.State.6 Pit Lift Pump Available in Automatic Available ☐
7 lock_Water.con.State.7 Available ☐
16 lock_Water.con.State.16 ☐

Interlocks Machine
0 Cast Speed Flow Control Available in Automatic with Control Valve Available ☐
lock_Machine.con.State.0
Prepositioned for Cast Start Speed
1 lock_Machine.con.State.1 Cast Speed Flow Transmitter in Range & ECB On Available ☐
2 lock_Machine.con.State.2 Platen Motor VSD Ready in Automatic Mode Available ☐
3 lock_Machine.con.State.3 Compressed Air Available for Furnace Launder Dam Control Available ☐
4 lock_Machine.con.State.4 Distribution Trough Compressed Air Available Pressure Switch Available ☐
5 lock_Machine.con.State.5 Platen at Cast Start Position and All Platen Movement in Automatic Mode Available ☐
6 lock_Machine.con.State.6 Launder Distribution Trough on Casting Machine Available ☐
7 Mould Carriage Lowered Limit Made (in Casting Position) and in Automatic Available ☐
lock_Machine.con.State.7
Mode
8 lock_Machine.con.State.8 CFF Launder Dam Lowered and in Automatic Mode Available ☐
9 lock_Machine.con.State.9 Casting Table Inlet Dam Lowered and in Automatic Mode Available ☐
10 lock_Machine.con.State.10 Drain Dam Lowered and in Automatic Mode Available ☐
11 lock_Machine.con.State.11 Available ☐
Interlocks External
0 lock_External.con.State.0 Furnace Safety Circuit Healthy Available ☐
1 lock_External.con.State.1 Furnace Tilt Control Ready for Use by Casting Machine Available ☐
2 lock_External.con.State.2 Available ☐
3 Safety check list acknowledged Available ☐
lock_External.con.State.3
Operator has acknowledged the casting safety check list
4 Cast Practice accepted Available ☐
Operator has accepted the current cast practice
5 lock_External.con.State.5 Cast Abort Not Active Available ☐

7 Casting Table Inlet Launder Thermocouple Available ☐

lock_External.con.State.7 In Range and In Tolerance
10 lock_External.con.State.10 Furnace Launder Metal Level Transmitter Healthy signal Made Available ☐
11 lock_External.con.State.11 Casting Table Inlet High Metal Level Transmitter Healthy signal Made Available ☐
12 Selected Degasser Ready for Casting Available ☐
Communication Healthy, Safety Circuit Healthy
13 Grain Rod Feeder Ready for Casting Available ☐
Communication Healthy, Safety Circuit Healthy
14 lock_External.con.State.14 ☐
Interlocks mmlc
0 lock_MMLC.con.State.0 Laser check complete, Platen at start position Available ☐
1 Pin Actuators calibration complete, pins fitted and actuators in correct Available ☐
lock_MMLC.con.State.1
position
2 lock_MMLC.con.State.2 At least one mould position Selected Available ☐
3 lock_MMLC.con.State.3 Simulation Mode Not Selected Available ☐
4 lock_MMLC.con.State.4 Mould 1, laser is healthy and in range Available ☐
5 lock_MMLC.con.State.5 Mould 1, laser On and temperature in tolerance Available ☐
6 lock_MMLC.con.State.6 Mould 1, Metal level controller running interlocks made and in auto control Available ☐
7 Mould 1, pin actuator running interlocks made and in auto control, position Available ☐
feedback within tolerance.
8 lock_MMLC.con.State.8 Mould 1, pin actuator charge cylinder in position and not over temperature Available ☐
Control Functions
1 C_105_Perm_Interlock If either the permissive or the override are made set the perm interlock on ☐
2 Lock.Water If all the water control permissive interlocks are made set the interlock ☐
available
3 Lock.Machine If all the machine control permissive interlocks are made set the interlock ☐
available
4 Lock.External If all the external control permissive interlocks are made set the interlock ☐
available (furnace, degasser and grain refining rod)

5 Lock.MMLC If all the mould metal level control permissive interlocks are made set the ☐
interlock available
C_105_ABORT Cast Abort Control

The primary function of this loop is monitor all casting parameters during a cast if there is a major fault the cast is aborted automatically in
a set sequence. The cast abort is split into two categories, automatic were the machine will abort the cast automatically without any
operator intervention and semi-automatic were the operator has a set time to assess the fault, override the cast abort signal if safe and
remain casting.
Automatic Cast abort

If the abort is automatic then by the time the popup is displayed the cast will have aborted.
Semi-Automatic Cast abort

In the case of a semi-automatic abort, the Operator has 10 seconds to assess the fault and override the cast abort signal by selecting the
Override pushbutton. Aborts that can be overridden are listed in the Abort Trigger Table; these are defined as Semi-Automatic Type. An
example of a semi-automatic abort: there might be a high or low tolerance failure, which has triggered the abort but has then gone or
started to go back into tolerance, in this situation the operators might deem it safe to continue.
Cast Abort sequence

In the event of a cast abort the following sequence will run:
1. The holding furnace will tilt back automatically
2. The mould pin actuators will close by de-energising the internal charge cylinder
3. The platen will stop (regardless of whether water is still running or not)
4. The distribution launder will rise and angle down toward the furnaces, allowing the metal in the MMLC to Drain into the spill
trays
5. The launder Drain dam will open
6. If the water is running, it will continue to run and can be switched off once the run-on timer has expired.
Tag C_105_ABORT
Description Casting Abort Control
UDT GROUP_ABORT
User Control
1 HMI_Override.PB The operator has a set time to override semi cast L0 ☐
abort alarms
Control Functions (Standard)

1 StanAbort.con_Active The automatic cast abort is active after all the pre-cast checks are complete ☐
or during casting
2 StanAbort.con_Override If the abort has been overridden from the HMI, this must be sent to the ☐
safety program and acknowledge reset set by the safety program to say the
override has been received.
3 StanAbort.con_Mould Map to the safety program the mould positions being used for casting ☐
4 HMI_Abort Map from safety program the state of all aborts ☐
5 ☐
6 ☐
7 ☐
8 ☐
Control Functions (Safety)


1 HMI_SemiAbort Set which alarms are semi abort"C_105_ABORT".HMI_State_0 0110 0110 0110 0110 ☐
[0] 0000 0101 1011 0110
[1] 0000 0100 0011 0000
[2] 0000 0100 0011 0000
[3] 0000 0100 0011 0000
[4] 0000 0100 0011 0000
[5] 0000 0100 0011 0000
2 S_105_ABORT.Semi Compare all active aborts to determine if they are semi aborts and can 10 seconds ☐
be overriden, if a semi abort is on set the override timer running. If a
semi abort has been overridden then the auto abort will ignore it,
otherwise it will trigger the abort sequence once the semi abort timer
(usually 10 seconds) has expired.
3 S_105_ABORT.Auto Compare all active aborts, first with those already overridden, then if 10 minutes ☐
aborts are still on set the auto abort active, this will remain active for a
set time. The auto abort latches in for 10 minutes so it cannot be
overridden by anyone.
4 con_Override If operator has overridden an abort set the corresponding override bit ☐
5 HMI_Abort Update the abort alarms displayed on the HMI, after abort is triggered ☐
disable this update so the HMI will display the last alarm that triggered
the abort
6 ☐
7 ☐
8 ☐
Alarms Water
1 con_Abort[0].0 Water Flow Transmitter Failure Full Auto Standard ☐
Abort
2 con_Abort[0].1 Water Flow Transmitter High Failure Full Auto Standard ☐
Abort
3 con_Abort[0].2 Water Flow Transmitter Low Failure Full Auto Standard ☐
Abort
4 con_Abort[0].3 Water Flow Control Valve Failure Full Auto Standard ☐
Abort
5 con_Abort[0].4 PSL_252 Compressed Air On Pressure Switch Not Made Automatic Standard ☐
6 con_Abort[0].5 PSL_252 Compressed Air On Pressure Switch Safety Input Automatic Standard ☐
Failure
7 con_Abort[0].6 Casting Pit Water Level Transmitter Failure Full Auto Standard ☐
Abort
8 con_Abort[0].7 Casting Pit Water Level Transmitter High Failure Full Auto Standard ☐
Abort
9 con_Abort[0].8 Casting Pit Water Level Transmitter Low Failure Full Auto Standard ☐
Abort
10 con_Abort[0].9 Spare Full Auto Standard ☐
Abort
11 con_Abort[0].10 Full Auto Standard ☐
Abort
Abort
13 con_Abort[0].12 End Cast Standard ☐
Abort
15 con_Abort[0].14 ☐
Alarms Machine
1 con_Abort[0].0 Abort 28: Platen Stopped Full Auto Standard ☐
Abort

2 con_Abort[0].1 Abort 29: Platen Speed Transmitter Failure Full Auto Standard ☐
Abort
3 con_Abort[0].2 Abort 30: Platen Speed Transmitter High Failure Full Auto Standard ☐
Abort
4 con_Abort[0].3 Abort 31: Platen Speed Transmitter Low Failure Full Auto Standard ☐
Abort
5 con_Abort[0].4 Abort 32: Platen Dive Motor VSD Failure Full Auto Standard ☐
Abort
Abort
Abort
Abort
9 con_Abort[0].8 Abort 36: Platen At Bottom Limit Full Auto Standard ☐
Abort
10 con_Abort[0].9 Abort 37: Mould Carriage At Casting Position Limit Failure Full Auto Standard ☐
Abort
Abort
Abort
13 con_Abort[0].12 Abort 40: Emergency Stop Circuit Full Auto Standard ☐
Abort
14 con_Abort[0].13 Abort 41: Mains Supply Circuit Full Auto Standard ☐
Abort
Alarms External
1 con_Abort[0].0 Abort 42: Tilt Enable/Abort Relay Not Healthy End Cast Standard ☐
Abort
3 con_Abort[0].2 Abort 44: Furnace Tilt Failure End Cast Standard ☐
Alarms Mould 1
1 con_Abort[0].0 LT412A_A Mould 1 Top Level Transmitter Input Failure Automatic Standard ☐
2 con_Abort[0].1 LT412A_A Mould 1 Top Level Transmitter Healthy Signal Not Automatic Standard ☐
Made
3 con_Abort[0].2 LT412A_B Mould 1 Metal Level Transmitter Input Failure Automatic Standard ☐

4 con_Abort[0].3 LT412A_B Mould 1 Metal Level Transmitter Healthy Signal Automatic Standard ☐
Not Made
5 LT412A Mould 1 Metal Depth Calculation High High Semi- Standard ☐
con_Abort[0].4
Automatic
6 LT412A Mould 1 Metal Depth Calculation Low Low Semi- Standard ☐
con_Abort[0].5
Automatic
7 con_Abort[0].6 ZV_412A Mould 1 Metal Flow Pin Position Actuator Command Automatic Standard ☐
Signal Open Circuit
8 con_Abort[0].7 ZV_412A_ZSH Mould 1 Metal Flow Pin Position Actuator Air Automatic Safety ☐
Cylinder Spring Charged Limit Not Made
9 con_Abort[0].8 ZV_412A_ZSH Mould 1 Metal Flow Pin Position Actuator Air Automatic Safety ☐
Cylinder Spring Charged Limit Safety Input Failure
10 con_Abort[0].9 ZV_412A Mould 1 Metal Flow Pin Position Actuator Pin Fitted Automatic Standard ☐
Too High (no flow control)
11 ZV_412A Mould 1 Metal Flow Pin Position Actuator Pin Froze Semi- Standard ☐
con_Abort[0].10 In Spout (no flow) Automatic
12 con_Abort[0].11 Mould 1 Spare Automatic Standard ☐
Alarms Mould 2
1 con_Abort[0].0 LT412B_A Mould 2 Top Level Transmitter Input Failure Automatic Standard ☐
2 con_Abort[0].1 LT412B_A Mould 2 Top Level Transmitter Healthy Signal Not Automatic Standard ☐
Made
3 con_Abort[0].2 LT412B_B Mould 2 Metal Level Transmitter Input Failure Automatic Standard ☐
4 con_Abort[0].3 LT412B_B Mould 2 Metal Level Transmitter Healthy Signal Automatic Standard ☐
Not Made
5 LT412B Mould 2 Metal Depth Calculation High High Semi- Standard ☐
con_Abort[0].4
Automatic
6 LT412B Mould 2 Metal Depth Calculation Low Low Semi- Standard ☐
con_Abort[0].5
Automatic
7 con_Abort[0].6 ZV_412B Mould 2 Metal Flow Pin Position Actuator Command Automatic Standard ☐
Signal Open Circuit
8 con_Abort[0].7 ZV_412B_ZSH Mould 2 Metal Flow Pin Position Actuator Air Automatic Safety ☐
9 con_Abort[0].8 ZV_412B_ZSH Mould 2 Metal Flow Pin Position Actuator Air Automatic Safety ☐
10 con_Abort[0].9 ZV_412B Mould 2 Metal Flow Pin Position Actuator Pin Fitted Automatic Standard ☐
11 ZV_412B Mould 2 Metal Flow Pin Position Actuator Pin Froze Semi- Standard ☐
Alarms Mould 3
1 con_Abort[0].0 LT412C_A Mould 3 Top Level Transmitter Input Failure Automatic Standard ☐

2 con_Abort[0].1 LT412C_A Mould 3 Top Level Transmitter Healthy Signal Not Automatic Standard ☐
Made
3 con_Abort[0].2 LT412C_B Mould 3 Metal Level Transmitter Input Failure Automatic Standard ☐
4 con_Abort[0].3 LT412C_B Mould 3 Metal Level Transmitter Healthy Signal Automatic Standard ☐
Not Made
5 LT412C Mould 3 Metal Depth Calculation High High Semi- Standard ☐
con_Abort[0].4
Automatic
6 LT412C Mould 3 Metal Depth Calculation Low Low Semi- Standard ☐
con_Abort[0].5
Automatic
7 con_Abort[0].6 ZV_412C Mould 3 Metal Flow Pin Position Actuator Command Automatic Standard ☐
Signal Open Circuit
8 con_Abort[0].7 ZV_412C_ZSH Mould 3 Metal Flow Pin Position Actuator Air Automatic Safety ☐
9 con_Abort[0].8 ZV_412C_ZSH Mould 3 Metal Flow Pin Position Actuator Air Automatic Safety ☐
10 con_Abort[0].9 ZV_412C Mould 3 Metal Flow Pin Position Actuator Pin Fitted Automatic Standard ☐
11 ZV_412C Mould 3 Metal Flow Pin Position Actuator Pin Froze Semi- Standard ☐
EY_105 Cast Abort and Tilt Interlock Relay

This relay is used as a hardwired interlock to the third party furnace tilt control, the third party should use this relay to enable the tilt
control circuit. When the relay is de-energised, the tilt control should de-activate and the furnace should tilt back. The correct use of this
relay is critical to the safety of the casting process.
Tag EY_105
Description Cast Abort and Tilt Interlock Relay
UDT OBJ_EY01
User Control
manually
start
Interlocks


0 EY_105 Relay Emergency Stop Healthy Available ☐
1 EY_105 Relay PLC output Module Healthy Available ☐
2 Spare NA ☐
3 F_105_ABORT.con_Time Cast Abort Not Active Available ☐
4 "LSH_361C".plc_Din.On Furnace Metal Level Detection Healthy Available ☐
Control Functions
operation
operation
 Output is driven from all the interlocks being healthy
 Mode always disabled
pushbuttons
set.
Alarms
continuity
C_106 Casting Machine Recipe Control

The primary function of this loop is to select, edit and store casting practices.
A database of casting recipes/practises is held on the datalogging PC. The database is accessed by the SCADA stations on CP102 and
recipes can be selected for casting, new recipes can be added and saved.
A practice will be differentiated by Alloy and Mould Size, and is captured by a three digit version number, when a practice is selected the
information will be displayed visually in the form of a graph as well as parameters.

Tag C_106_EDIT, C_106_RUN

Description Casting Recipe Control
UDT GROUP_RECIPE
User Control
1 hmi_Alloy Select Alloy input field L0 ☐
The operator must select the alloy of the material used
in the next cast.
2 hmi_Mould Select Mould Size input field L0 ☐
The operator must select the mould size used for the
next cast
3 hmi_Accept Accept Casting Recipe pushbutton L0 ☐
After the alloy and mould size has been set the operator
is presented with a single recipe.
The operator must accept a casting practise before the
start of each cast. The operator can then edit some of
the cast parameters to within 10% of their maximum
values, these edits are for the current cast only and are
only allowed after the practice has been accepted.
Permanently editing a practice is not possible once pre-
cast checks have completed
Recipe Functions
1 PracticeVersion Practise Version String (###) ☐
2 PracticeName Practise Name (Customer reference number for the recipe) String(254) ☐
3 AlloyNumber Alloy Number Double Integer ☐
4 MouldSize Mould Size Double Integer ☐
5 CastNumber Cast Number Double Integer ☐
6 LengthCast Cast Length (required casting length) mm ☐
7 FURNACE_TILTBACK Furnace tilt back length mm ☐
8 CAST_START_HOLD Cast Start Hold Time seconds ☐
9 CAST_STOP_FREEZE Slow cool descent length (cast length for slow cool descent) mm ☐
10 COOLING_RUNON Cooling Run On (Water run-on time after cast) min ☐
11 LAUNDER_LEVEL Launder metal level setpoint at casting machine mm ☐
12 CFF_DAM_TRIGGER Furnace dam open trigger metal level mm ☐
13 TABLE_DAM_TRIGGER Degasser dam open trigger metal level mm ☐
14 ROD_FEEDER_TRIGGER Rod feeder start run trigger metal level mm ☐
15 ROD_FEEDER_SPEED Rod Feeder speed mm/min ☐
16 WATER_TEMP_SP Water temperature (monitor only) ˚C ☐
17 WATER_PRESS_SP Water Pressure (monitor only) mbar ☐
18 WATER_FLOW_FILL Water Flow during Fill L/min ☐
19 WATER_FLOW_PRC[1].Target Water Flow ramp 1 target rate L/min ☐
20 WATER_FLOW_PRC[1].Duration Water Flow ramp 1 duration to reach target mm ☐
21 WATER_FLOW_PRC[1].Trigger Water Flow ramp 1 trigger length mm ☐


46 WATER_FLOW_END.Trigger Water Flow at the end of a cast L/min ☐
47 PLATEN_SPEED_FILL Cast Speed starting rate mm/min ☐
48 PLATEN_SPEED_PRC[1].Target Cast Speed ramp 1 target rate mm/min ☐
49 PLATEN_SPEED_PRC[1].Duration Cast Speed ramp 1 duration to reach target mm ☐
50 PLATEN_SPEED_PRC[1].Trigger Cast Speed ramp 1 trigger length mm ☐


75 PLATEN_SPEED_END.Trigger Cast Speed at the end of a cast during Slow cool descent length mm/min ☐
76 MOULD_DEPTH Depth of the mould, to allow the metal depth in the mould to be mm ☐
calculated.
77 MOULD1_SEL Mould 1 has been selected for this cast NA ☐

80 PLATEN_STARTPOS Platen Start position, during laser checks the platen should mm ☐
automatically move to this position. #1
81 PIN_STARTPOS Pin Start Position, this is the percentage position for all the pin actuators % ☐
before casting starts
82 CAST_DEPTHSTART Mould Metal level required in all the moulds, before the cast mm ☐
automatically starts
83 CAST_DEPTHSTOP Mould Metal level required in only one mould, before the cast mm ☐
automatically stops
84 FILL_FLOW[0].Target Mould Metal Fill Rate Before Cast Start, Initial setpoint fill Rate mm/min ☐
85 FILL_FLOW[1].Trigger Mould Metal Fill Rate Before Cast Start, Setpoint ramp 1 trigger level in sec ☐
time since mould fill has begun.
86 FILL_FLOW[1].Target Mould Metal Fill Rate Before Cast Start, Setpoint ramp 1 target fill rate mm/min ☐
94 FILL_FLOW[5].Target Mould Metal Fill Rate Before Cast Start, Setpoint ramp 5 target fill rate mm/sec ☐
95 METAL_LEVEL[0].Target Mould Metal Level setpoint required at the start of a cast mm ☐
96 METAL_LEVEL[1].Trigger Mould Metal Level setpoint ramp 1 trigger point in mm of cast length mm ☐
97 METAL_LEVEL[1].Duration Mould Metal Level setpoint ramp 1 duration in mm of cast length mm ☐
98 METAL_LEVEL[1].Target Mould Metal Level setpoint ramp 1 target level after ramp is complete. mm ☐

C_412 Mould Metal Level Group Functions

The distribution launder will have fitted to it all the mould metal level control equipment.
Tag C_412
Description Launder MMLC Group
UDT GROUP_MOULDS
User Control
1 hmi_PrcStartCastDepth This is the level of metal required in each mould L2 mm 300 0 NA ☐
for the cast to start, usually set from the casting
machine recipe but if this is set to zero it can be
manually set from the HMI
2 hmi_PrcStopCastDepth This is the level of metal required in any mould L2 mm 300 0 NA ☐
for the cast to stop, usually set from the casting
machine recipe but if this is set to zero it can be
3 hmi_PrcStartSetpoint This is the level of metal setpoint at the start of L2 mm 300 0 NA ☐
the cast, usually set slightly higher than the start
cast metal level to avoid any overshooting of the
metal level. Usually set from the casting machine
recipe but if this is set to zero it can be manually
set from the HMI
4 hmi_PinStartPosition This is the pre-position for the pin actuator prior L2 % 100 0 60 ☐
to casting, set to ensure that the metal will not
freeze initially at the start of a cast, usually set
from the casting machine recipe but if this is set
to zero it can be manually set from the HMI
5 hmi_PlatenStartPosition This is the pre-position for the platen prior to L2 mm 100 -100 -30 ☐
casting, set to ensure that the mould starter
blocks are positioned correctly in the mould,
usually set from the casting machine recipe but if
this is set to zero it can be manually set from the
HMI
6 hmi_PlatenMaximum The maximum position the platen can be raised L2 mm 100 -100 -10 ☐
to, as measured by the mould metal lasers
7 hmi_StartOffset The offset above the mould start block the mould L2 mm 100 0 5 ☐
level controller will start controlling metal flow
8 hmi_BypassPrePos Bypass platen preposition sequence L0 ☐
The platen positioning can be overridden before
casting from an HMI button on the platen screen
or MMLC Sensor Calibration screen. The platen
will not run the auto position routine, the platen
can be positioned manually. This button is not
active during casting
9 hmi_PinFitted During pin actuator calibration the actuator will L0 ☐
stop at its fit pin position, this then requires the At
operator to press the pin fitted pushbutton for
the calibration sequence to complete Seq
Pos
10 hmi_SimMod_On Will put caster into simulation mode, this is to L2 ☐
allow dummy casts as the mould metal level will Not
be simulated to stop the dummy cast from
aborting due to no metal in the mould cast
11 hmi_SimMode_Off Will take the caster out of simulation mode L0 ☐
Control Functions
1 con_PVhighest The highest mould metal depth, used before the flow of metal into the ☐
mould to set a common start controller setpoint across all moulds

VY 412A Pin Actuator Calibrate Virtual Relay

Before every cast the actuators must be calibrated to check feedback and positional control, this calibration routine must be initiated from
the Check Mould Actuators popup.
The calibration sequence is initiated from the HMI by pressing the check calibration button.
The pin positions are lowered to the zero position where the actuators are reset. Once reset the pin positions are raised to the maximum
position where the position is read. The pin positions are then lowered to their start position and the pins are fitted. Each stage of this
sequence is indicated by a green light. When the pin positions have been lowered to their start position, a green light appears against Cal
Fit Pin indicating to the Operators that the pins may be fitted.
At this point all final preparations should be done, such as removing launder and spout heaters.
Once the pins are fitted the Operator from the HMI presses the Pin Fitted Button.
When the calibration sequence is completed the Complete check box changes from grey to green and the Operator selects OK to close down
the Check Mould Actuators popup.
Tag VY_412A
Description Pin Actuator Calibrate Virtual Relay
UDT OBJ_EY00
User Control
1 hmi_EPBH Prior to casting the pin actuators must be L0 ☐
calibrated. This is initiated from a button on
the actuator calibration popup
2 hmi_EPBL If a pin requires re-calibrating before L0 ☐
casting, then the existing calibration Not
complete can be reset from this pushbutton cast
manually
start
Interlocks
0 L_412A,B,C,D,E At least one mould has been selected for casting Available ☐
1 ZV_412A_ZSH Mould 1 Level Pin Actuator Air Cylinder Spring Charged Limit Made Available ☐
2 ZV_412B_ZSH Mould 2 Level Pin Actuator Air Cylinder Spring Charged Limit Made Available ☐
3 ZV_412C_ZSH Mould 3 Level Pin Actuator Air Cylinder Spring Charged Limit Made Available ☐
4 L_412A Mould 1 Level Pin Actuator Calibration Check Failed Available ☐
5 L_412B Mould 2 Level Pin Actuator Calibration Check Failed Available ☐
6 L_412C Mould 3 Level Pin Actuator Calibration Check Failed Available ☐
7 C_105 Casting Machine has started pre-cast check prior to casting Required ☐
Control Functions
1 con_PB.Start Group all pushbuttons that will operate the movement ☐
Device HMI start button

EPBH 104 cycle start button

2 con_PB.Stop Group all pushbuttons that will disable the movement ☐
Device HMI stop button
EPBH 104 cycle hold button
 always inactive
 Always enabled
 always active
 device always latched
pushbuttons
9 con.Run Either Device Automatic mode Trigger or Device Hand mode Trigger is set ☐
and all interlocks are made
10 con_CalMovMin Actuator Calibration Sequence Step 1, actuator moves to minimum position 15 Seconds ☐
11 con_CalZeroAcuator Actuator Calibration Sequence Step 2, actuator Zero Drive output is enabled 15 Seconds ☐
12 con_CalMinRead Actuator Calibration Sequence Step 3, short delay from disabling Zero Drive 1 second ☐
output and setting actuator feedback to 0
13 con_CalMaxRead Actuator Calibration Sequence Step 4, actuator moves to maximum position 20 Seconds ☐
and sets actuator feedback to 100
14 con_CalFitPin Actuator Calibration Sequence Step 5, actuator moves to fit pin pre-position 10 Seconds ☐
and waits for the pin to be fitted
15 con_CalCheck Actuator Calibration Sequence Step 6, initiated from the pin fitted 5 Seconds ☐
pushbutton, actuator moves to minimum position to check position feedback
is reading zero
Alarms
1
VY 412B Mould Laser Calibrate Virtual Relay

In the recipe will be the platen start position, during the pre-cast checking process this value can be used to position the platen
automatically using the mould metal level laser measuring the position on the bottom of the mould starting blocks.
If the platen can be automatically prepositioned to a set value the process is initiated from the casting routine screen. Firstly, the Operator
presses the Platen Up pushbutton on the Operator Control Desk to raise the platen to its near top limit. Once the platen is raised, the
calibration sequence is started by the Operator selecting the “Go” button. The platen is then raised automatically in slow speed to just
above its start position then lowered using a very slow cast speed until with the help of level feedback from the mould level control lasers,
the platen reaches the correct position for the start of cast.
Tag VY_412B
Description Mould Laser Calibrate Virtual Relay
UDT OBJ_EY00
User Control
1 hmi_EPBH Prior to casting the laser can be used to pre- L0 ☐
position the platen so the mould start
blocks are in the correct position. This is
initiated from a button on the laser
calibration popup

2 hmi_EPBL If the platen requires positioning again L0 ☐

before casting then the existing calibration Not
complete can be reset from this pushbutton cast
manually
start
Interlocks
0 L_412A,B,C,D,E At least one mould has been selected for casting Available ☐
1 LT_412A_A Mould 1 Top Level Transmitter Healthy Available ☐
2 LT_412A_B Mould 1 Metal Level Transmitter Healthy Available ☐
3 LT_412B_A Mould 2 Top Level Transmitter Healthy Available ☐
4 LT_412B_B Mould 2 Metal Level Transmitter Healthy Available ☐
5 LT_412C_A Mould 3 Top Level Transmitter Healthy Available ☐
6 LT_412C_B Mould 3 Metal Level Transmitter Healthy Available ☐
7 LT_412D_A Mould 4 Top Level Transmitter Healthy Available ☐
8 LT_412D_B Mould 4 Metal Level Transmitter Healthy Available ☐
9 LT_412E_A Mould 5 Top Level Transmitter Healthy Available ☐
10 LT_412E_B Mould 5 Metal Level Transmitter Healthy Available ☐
11 C_412 Platen reached its fully raised position Required ☐
12 C_412 Platen already at pre position Required ☐
13 ZSL_412 Distribution Launder In Position Required ☐
Control Functions
1 con_PB.Start Group all pushbuttons that will operate the movement ☐
Device HMI start button
EPBH 104 cycle start button
2 con_PB.Stop Group all pushbuttons that will disable the movement ☐
Device HMI stop button
EPBH 104 cycle hold button
 always inactive
 Always enabled
 always active
 device always latched
pushbuttons
9 con.Run Either Device Automatic mode Trigger or Device Hand mode Trigger is set ☐
and all interlocks are made
10 con_CalPlatenRaise Laser Calibration Sequence Step 1, Platen raises at slow speed until just 5 Seconds ☐
below its preposition setpoint, the delay in the laser reading will mean the

platen should have overshot. (the .Active bit is to be tied in to platen slow up
Solenoid)
11 con_CalPlatenLower Laser Calibration Sequence Step 2, platen lowers at a slow cast speed until 5 Seconds ☐
just above preposition setpoint. (the .active bit is to be tied into cast down
solenoid)
12 con_CalPlatenHigh Not part of the Laser Calibration Sequence but the limit is there to protect 0 second ☐
the platen rising too high during the calibration process.
Alarms
1

Launder And Furnace Equipment Control

This section details all launder equipment such as launder dams and the furnace tilt and launder control .

Z_317C Casting Launder Dam Group

The primary function of this loop is to control the launder dam it is operated primarily via a local pushbutton station or during an
automatic cast it will open automatically when the launder level reaches a set level, the head of metal before the dam is great enough to
allow the distribution launder to be flooded quickly so reducing the effect of metal cooling from the launder walls.
The launder dam will be controlled using a pneumatic cylinder.
Automatic Control
The dam will be automatically opened during the lauder flood routine before the cast has begun and the level of metal in the launder has
reached a set level.
Manual Control
On the operator main desk the operator can access manual control pushbuttons to operate the dam, all interlocks will still be in circuit
before any movement is enabled
Tag Z_317C
Description Casting Launder Dam Group
UDT GROUP_STATUS
User Control
1 EPBH_317C The dam can be opened fully from a single push of the button; the ☐
illumination will flash when the dam is opening and go steady when the dam
is fully open
2 EPBL_317C e dam can be closed fully from a single push of the button; the illumination ☐
will flash when the dam is closing and go steady when the dam is fully closed
Control Functions
1
EVH_317C Casting Launder Dam Raise Solenoid

The Dam raise valve is a spring to centre pneumatic valve. In the event of power failure or the safety circuit being tripped the valve de-
energises but the Dam will remain in its current position
Tag EVH_317C
Description Casting Launder Dam Raise Solenoid
UDT OBJ_EV01
User Control
1 hmi_EPBH Casting launder dam Raise start virtual L0 ☐
pushbutton Positioned on the HMI, the
casting launder dam will raise fully when
pressed
2 hmi_EPBL Casting launder dam stop virtual L0 ☐
Casting launder dam will stop moving when
pressed


manually
start
Interlocks
0 EVH_317C Casting Launder Dam Raise solenoid Emergency Stop Healthy Available ☐
1 EVH_317C Casting Launder Dam Raise solenoid PLC output Module Healthy Available ☐
2 EVH_317C Casting Launder Dam Raise solenoid PLC safety output status NA ☐
3 ZSH_317C Casting Launder Dam Raised Limit Switch failed to break Available ☐
4 EVL_317C Casting Launder Dam Lower Solenoid Energised Running ☐
5 ZSH_317C Casting Launder Dam Raised Limit Switch failed to make Running ☐
Control Functions
operation
operation
5 con_PB.Auto.On Device Automatic mode Trigger ☐
 Launder flooded dam 2 is set (L_361)
6 con_PB.Hand.Active Device Hand mode active. ☐
pushbuttons
set.
10 con.Run Device output has been enabled ☐
11 con_ZS Position limit allow the use of a run on time before the output needs to be 1 Seconds ☐
stopped, and is also interlocked with the opposite limit is not made
Alarms
1 alm_Fail Casting launder dam raise fails to leave its lowered limit in a Fault 5 Seconds ☐
set time

2 alm_Safety_Out PLC Safety output to device has failed, single safe output with Fault 0 Seconds ☐
EVL_317C Casting Launder Dam Lower Solenoid

The Dam lower valve is a spring to centre pneumatic valve. In the event of power failure or the safety circuit being tripped the valve de-
energises but the dam will remain in its current position.
Tag EVL_317C
Description Casting Launder Dam Lower Solenoid
UDT OBJ_EV01
User Control
1 hmi_EPBH Casting Launder Dam Lower start virtual L0 ☐
pushbutton
Positioned on the HMI, the Casting Launder
Dam will Lower fully when pressed
2 hmi_EPBL Casting Launder Dam Lower stop virtual L0 ☐
pushbutton
Positioned on the HMI, the Casting Launder
Dam Lower will stop moving when pressed
manually
start
Interlocks
0 EVL_317C Casting Launder Dam lower solenoid Emergency Stop Healthy Available ☐
1 EVL_317C Casting Launder Dam lower solenoid PLC output Module Healthy Available ☐
2 EVL_317C Casting Launder Dam lower solenoid PLC safety output status Available ☐
3 ZSL_317C Casting Launder Dam Lowered Limit Switch failed to break Available ☐
4 EVH_317C Casting Launder Dam Raise Solenoid Energised Running ☐
5 ZSL_317C Casting Launder Dam Lowered Limit Switch failed to make Running ☐
Control Functions
operation
operation
 Mode Always disabled

5 con_PB.Auto.On Device Automatic mode Trigger ☒
 None
6 con_PB.Hand.Active Device Hand mode active. ☒
7 con_PB.Hand.Reset Device Hand mode disable latch ☒
8 con_PB.Hand.On Device Hand mode Trigger, set and reset from the device start, stop ☒
pushbuttons
9 con.enable All interlocks are made and either auto on request or hand on request are ☒
set.
10 con.Run Device output has been enabled ☒
11 con_ZS Position limit allow the use of a run on time before the output needs to be 1 Seconds ☒
12 hmi_EPBH Device HMI start button illumination control ☒
13 hmi_EPBL Device HMI Stop button illumination control ☒
Alarms
1 alm_Fail Mould tilt table lower fails to leave its raised limit in a set Fault 5 Seconds ☒
time
2 alm_Safety_Out PLC Safety output to device has failed, single safe output with Fault 0 Seconds ☒
ZSH_317C Casting Launder Dam Raise Limit

The Dam is fitted with a proximity switch which will indicate the dam is fully raised.
Tag ZSH_317C
Description Casting Launder Dam Raise Limit
UDT OBJ_XS02
User Control
1
Interlocks
1
Control Functions
1
Alarms
1 alm_Make The casting launder dam fails to reach the raise limit in a set Fault 5 Seconds ☒
time
2 alm_Break The casting launder dam its lower limit and the raised limit is Fault 5 Seconds ☒
still made.
3 alm_Safety_In PLC Safety input from the auxiliary contract has failed, single Fault Not used ☐
safe inputs with safety pulse to check continuity

ZSL_317C Casting Launder Dam Lower Limit

The Dam is fitted with a proximity switch which will indicate the dam is fully lowered.
Tag ZSL_317C
Description Casting Launder Dam Lower Limit
UDT OBJ_XS02
User Control
1
Interlocks
1
Control Functions
1
Alarms
1 alm_Make The casting launder dam fails to reach the lower limit in a set Fault 5 Seconds ☒
time
2 alm_Break The casting launder dam reach its raised limit and the Fault 5 Seconds ☒
lowered limit is still made.

Z_317E CFF Launder Dam Group

The primary function of this loop is to control the launder dam. It is operated primarily via a local pushbutton station or during an
automatic cast it will open automatically when the launder level reaches a set level, the head of metal before the dam is great enough to
allow the launder to be flooded quickly so reducing the effect of metal cooling from the launder walls.
The launder dam is controlled using a pneumatic cylinder.
Automatic Control
The dam will be automatically opened during the lauder flood routine before the cast has begun and the level of metal in the launder has
reached a set level.
Manual Control
Tag Z_317E
Description CFF Launder Dam Group
UDT GROUP_STATUS
User Control
1 EPBH_317E The dam can be opened fully from a single push of the button; the ☐
is fully open
2 EPBL_317E e dam can be closed fully from a single push of the button; the illumination ☐
Control Functions
1
EVH_317E CFF Launder Dam Raise Solenoid

Tag EVH_317E
Description CFF Launder Dam Raise Solenoid
UDT OBJ_EV01
User Control
1 hmi_EPBH CFF launder dam Raise start virtual L0 ☐
pushbutton Positioned on the HMI, the CFF
launder dam will raise fully when pressed
2 hmi_EPBL CFF launder dam stop virtual pushbutton L0 ☐
Positioned on the HMI, the CFF launder dam
will stop moving when pressed


manually
start
Interlocks
0 EVH_317E CFF Launder Dam Raise solenoid Emergency Stop Healthy Available ☐
1 EVH_317E CFF Launder Dam Raise solenoid PLC output Module Healthy Available ☐
2 EVH_317E CFF Launder Dam Raise solenoid PLC safety output status NA ☐
3 ZSH_317E CFF Launder Dam Raised Limit Switch failed to break Available ☐
4 EVL_317E CFF Launder Dam Lower Solenoid Energised Running ☐
5 ZSH_317E CFF Launder Dam Raised Limit Switch failed to make Running ☐
Control Functions
operation
operation
 Launder flooded dam 2 is set (L_361)
pushbuttons
set.
Alarms
1 alm_Fail CFF launder dam raise fails to leave its lowered limit in a set Fault 5 Seconds ☐
time

EVL_317E CFF Launder Dam Lower Solenoid

Tag EVL_317E
Description CFF Launder Dam Lower Solenoid
UDT OBJ_EV01
User Control
1 hmi_EPBH CFF Launder Dam Lower start virtual L0 ☐
pushbutton
Positioned on the HMI, the CFF Launder
2 hmi_EPBL CFF Launder Dam Lower stop virtual L0 ☐
pushbutton
Positioned on the HMI, the CFF Launder
manually
start
Interlocks
0 EVL_317E CFF Launder Dam lower solenoid Emergency Stop Healthy Available ☐
1 EVL_317E CFF Launder Dam lower solenoid PLC output Module Healthy Available ☐
2 EVL_317E CFF Launder Dam lower solenoid PLC safety output status Available ☐
3 ZSL_317E CFF Launder Dam Lowered Limit Switch failed to break Available ☐
4 EVH_317E CFF Launder Dam Raise Solenoid Energised Running ☐
5 ZSL_317E CFF Launder Dam Lowered Limit Switch failed to make Running ☐
Control Functions
operation
operation


 None
pushbuttons
set.
Alarms
time
ZSH_317E CFF Launder Dam Raise Limit

Tag ZSH_317E
Description CFF Launder Dam Raise Limit
UDT OBJ_XS02
User Control
1
Interlocks
1
Control Functions
1
Alarms
1 alm_Make The CFF launder dam fails to reach the raise limit in a set time Fault 5 Seconds ☒
2 alm_Break The CFF launder dam its lower limit and the raised limit is still Fault 5 Seconds ☒
made.
ZSL_317E CFF Launder Dam Lower Limit


Tag ZSL_317E
Description CFF Launder Dam Lower Limit
UDT OBJ_XS02
User Control
1
Interlocks
1
Control Functions
1
Alarms
1 alm_Make The CFF launder dam fails to reach the lower limit in a set Fault 5 Seconds ☒
time
2 alm_Break The CFF launder dam reach its raised limit and the lowered Fault 5 Seconds ☒
limit is still made.

Z_317D Drain Launder Dam Group

The primary function of this loop is to control the drain dam. It is operated primarily via a local pushbutton station or during an automatic
cast abort; it will open automatically when the abort is initiated, this will allow the metal in the launder to drain away from the table.
A pneumatic cylinder controls the launder dam.
Automatic Control
The dam will be automatically opened during a cast abort to allow the molten metal to be quickly drained from the casting machine
launder
Manual Control
Tag Z_317D
Description Drain Launder Dam Group
UDT GROUP_STATUS
User Control
1 EPBH_317D The dam can be opened fully from a single push of the button; the ☐
is fully open
2 EPBL_317D e dam can be closed fully from a single push of the button; the illumination ☐
Control Functions
1
EVH_317D Drain Launder Dam Raise Solenoid

Tag EVH_317D
Description Drain Launder Dam Raise Solenoid
UDT OBJ_EV01
User Control
1 hmi_EPBH Drain launder dam Raise start virtual L0 ☐
Drain launder dam will raise fully when
pressed
2 hmi_EPBL Drain launder dam stop virtual pushbutton L0 ☐
Positioned on the HMI, the Drain launder
dam will stop moving when pressed


manually
start
Interlocks
0 EVH_317D Drain Launder Dam Raise solenoid Emergency Stop Healthy Available ☐
1 EVH_317D Drain Launder Dam Raise solenoid PLC output Module Healthy Available ☐
2 EVH_317D Drain Launder Dam Raise solenoid PLC safety output status NA ☐
3 ZSH_317D Drain Launder Dam Raised Limit Switch failed to break Available ☐
4 EVL_317D Drain Launder Dam Lower Solenoid Energised Running ☐
5 ZSH_317D Drain Launder Dam Raised Limit Switch failed to make Running ☐
Control Functions
operation
operation
 Cast abort triggered
pushbuttons
set.
Alarms
1 alm_Fail Drain launder dam raise fails to leave its lowered limit in a set Fault 5 Seconds ☐
time

EVL_317D Drain Launder Dam Lower Solenoid

Tag EVL_317D
Description Drain Launder Dam Lower Solenoid
UDT OBJ_EV01
User Control
1 hmi_EPBH Drain Launder Dam Lower start virtual L0 ☐
pushbutton
Positioned on the HMI, the Drain Launder
2 hmi_EPBL Drain Launder Dam Lower stop virtual L0 ☐
pushbutton
Positioned on the HMI, the Drain Launder
manually
start
Interlocks
0 EVL_317D Drain Launder Dam lower solenoid Emergency Stop Healthy Available ☐
1 EVL_317D Drain Launder Dam lower solenoid PLC output Module Healthy Available ☐
2 EVL_317D Drain Launder Dam lower solenoid PLC safety output status Available ☐
3 ZSL_317D Drain Launder Dam Lowered Limit Switch failed to break Available ☐
4 EVH_317D Drain Launder Dam Raise Solenoid Energised Running ☐
5 ZSL_317D Drain Launder Dam Lowered Limit Switch failed to make Running ☐
Control Functions
operation
operation


 None
pushbuttons
set.
Alarms
time
ZSH_317D Drain Launder Dam Raise Limit

Tag ZSH_317D
Description Drain Launder Dam Raise Limit
UDT OBJ_XS02
User Control
1
Interlocks
1
Control Functions
1
Alarms
1 alm_Make The Drain launder dam fails to reach the raise limit in a set Fault 5 Seconds ☒
time
2 alm_Break The Drain launder dam its lower limit and the raised limit is Fault 5 Seconds ☒
still made.
ZSL_317D Drain Launder Dam Lower Limit


Tag ZSL_317D
Description Drain Launder Dam Lower Limit
UDT OBJ_XS02
User Control
1
Interlocks
1
Control Functions
1
Alarms
1 alm_Make The Drain launder dam fails to reach the lower limit in a set Fault 5 Seconds ☒
time
2 alm_Break The Drain launder dam reach its raised limit and the lowered Fault 5 Seconds ☒

L_361 Launder Metal Level Control Group

The primary function of this loop is to control the furnace tilt to allow the molten Aluminium to be cast.
All physical tilt control equipment is supplied by a third party; the control signals in this section should be mapped to the furnace CPU over
the Level 2 network. The truth table below shows how the equipment should be controlled to fit with tilt control software. The hydraulic
tilt system is spool back, so the proportional valve is controlling the oil flow back to tank, rather than the supply to the cylinders. This
means the control variable output to the proportional valve should be inverted: the valve is fully closed when 100% tilt is required and
fully open when no tilt is required.
Automatic Control
The furnace can be put into cast mode from a single push of the button, the illumination will flash slowly as the furnace tilt fast to flood
the launder system up to the casting machine, it will flash quickly while the furnace is holding after the launder is flooded and before the
casting machine starts. The illumination goes steady when the casting machine is running and the furnace is tilting in cast mode..
Manual Control
Tag L_361
Description Launder Metal Level Control Group
UDT GROUP_TILT
User Control
1 EPBHH_361 Furnace Tilt Up Illuminated Pushbutton ☐
The furnace can be fast tilted up with a
continual push of button; the illumination
will flash when the furnace is moving up
fast
2 EPBH_361 Furnace Tilt Cast Illuminated Pushbutton ☐
The furnace can be put into cast mode from
a single push of the button, the illumination
will flash slowly as the furnace tilt fast to
flood the launder system up to the casting
machine, it will flash quickly while the
furnace is holding after the launder is
flooded and before the casting machine
starts. The illumination goes steady when
the casting machine is running and the
furnace is tilting in cast mode
3 EPBL_361 Furnace Tilt Down Illuminated Pushbutton ☐
The furnace can be tilted down from a
single push of the button, the illumination
will flash when the furnace is moving down
fast and go steady when the furnace has
reached the fully down limit.
4 EPB_361 Furnace Tilt Hold Illuminated Pushbutton ☐
The furnace can be stopped from tilting up
or down from a single push of the button,
the illumination will go steady when the
furnace tilt is in hold mode
5 HMI_Override When cast tilt is selected and the metal L2 mm 300 0 100 ☐
level in the launder is above the flood
launder override setpoint then automatic
level control will start directly.
6 HMI_FloodDam1 At the start of a cast the furnace tilts up fast L2 mm 300 0 ?? ☐
automatically flooding the launder until the

level reaches the set flood launder level

setpoint for the first dam in the launder.
When this level is reached the furnace will
stop tilting and wait for the cast to be
started, the automatic level control will
start when the cast has begun and the
metal level has dropped back to the
controlling setpoint.
7 HMI_FloodDam2 After the first launder dam is raised the L2 mm 300 0 ?? ☐
furnace will still remain stationary but metal
will still continue to flood the launder up to
the second dam, when the metal reaches
this level the dam will be opened.
8 hmi_onelaser With one laser set launder metal control L2 ☐
will be to the furnace metal level with no
correction from the casting launder laser
9 hmi_LaunderOffset The difference in level between the furnace L2 mm 300 0 ?? ☐
launder metal level transmitter and the
casting launder metal level transmitter
Control Functions
1 con_OverrideFlood Furnace tilt cast enable and the launder metal level is above the override 2 seconds ☐
flood setpoint.
2 con_Flooded Furnace tilt cast enable and the launder metal level is above the flood 2 seconds ☐
setpoint.
3 con_TiltRelease Furnace tilt will be released to the furnace metal level controller when the ☐
casting machine is running and the metal level has dropped below the
controller setpoint
4 con_TiltHold Furnace launder metal level controller is running and the controller deviation 5 seconds ☐
high alarm is on, set furnace hold which will momentarily stop the furnace
tilting.
5 Two laser control For two laser control is enable after launder level control has reached steady 10 minuets ☐
SteadyState.On state conditions
6 Two laser control If the metal level at the casting machine is not in a set tolerance of the level 2 minuets ☐
AdjustLevel.Run setpoint, a setpoint adjustment at the furnace will be made after a set time
7 Two laser control After a setpoint adjustment then the control is given a set time for the control 5 minuets ☐
AdjustLevel.Enable to stabilise again
8 Two laser control An average on the casting machine launder metal level is taken over a 10 ☐
con_AdjustFIFO second period
9 Two laser control When a setpoint adjustment is due, the current error between caster metal ☐
AdjustLevel.Value[1] level setpoint and process variable is calculated and added to the furnace
launder level controller
10 con_SPEdit.On This allows the operator control of the mould level setpoint, it is off during ☐
the launder flood process then is enabled during steady state casting.
Alarms
1 ☐
LT_361_x Launder Metal Level Transmitter

Launder metal level transmitter will measure the metal level in the launder system close to the furnace. This will act as the process
variable input for the launder level controller
Tag LT_361_A, LT_361_C, LT_361_E
Description Furnace Launder Metal Level Transmitter
Casting Launder Metal Level Transmitter
CFF Launder Metal Level Transmitter
UDT OBJ_XT02

Type Laser distance transmitter

Range 0 to 300 mm range with a 400mm blocking distance, actual measuring range is 700 to 400 mm (0 to 20ma)
User Control
1 data.AlarmUnitAsPer Transmitter Deviation Setpoint display as L2 ☐
percentage of range
2 data.AlarmUnitAsEng Transmitter Deviation Setpoint display as L2 ☐
engineering units
3 hmi_data.UserHigh Transmitter user setpoint high, if the L2 mm NA NA NA ☐
transmitter has an operating band such as a
tank level this will be the upper band limit
4 hmi_data.UserLow Transmitter user setpoint low, if the L2 mm NA NA NA ☐
tank level this will be the lower band limit
5 hmi_data.Control Transmitter user deviation setpoint for L2 mm/% 100% 0% NA ☐
control, this will trigger high low deviation
to be used in the program for control
6 data.AlarmWarning Transmitter user deviation setpoint for L2 mm/% 100% 0% NA ☐
warning, this will trigger high low deviation
to be used in the program for warning alarm
7 hmi_data.AlarmFailure Transmitter user deviation setpoint for L2 mm/% 100% 0% NA ☐
Failure, this will trigger high low deviation to
be used in the program for failure alarm
Control Functions
1 plc_Dout.Enable Transmitter Enable Not Used ☐
2 Enable_alm_HH Enable transmitter high failure alarm On ☐
Enable_alm_H Enable transmitter high warning alarm On
Enable_con_H Enable transmitter high control On
Enable_con_L Enable transmitter low control On
Enable_alm_L Enable transmitter low warning alarm On
Enable_alm_LL Enable transmitter low failure alarm On
3 con_high Transmitter Process variable has deviated above the high setpoint plus the 5 Seconds ☐
control deviation setpoint for a set time.
4 con_low Transmitter Process variable has deviated below the low setpoint minus the 5 Seconds ☐
5 con_Delay Transmitter Process variable alarm delay, all alarms are delayed from being 5 Seconds ☐
activated for a set time from the start of the process to avoid nuisance
tripping of alarms as the process goes through an initial settling down period.
6 plc_Dout.Enable The laser level transmitter is enable when being prepared for casting NA ☐
Alarms
1 alm_Make Transmitter Healthy PLC input is off after the laser has been Fault 5 Seconds ☐
enabled
2 alm_Input Transmitter PLC input is open circuit or transmitter has failed Fault 5 Seconds ☐
3 alm_HighFailure Transmitter Process variable has deviated above the high Fault 15 Seconds ☐
setpoint plus the failure deviation setpoint for a set time.
4 alm_HighWarning Transmitter Process variable has deviated above the high Warning 30 Seconds ☐
setpoint plus the warning deviation setpoint for a set time.
5 alm_LowFailure Transmitter Process variable has deviated below the low Fault 15 Seconds ☐
setpoint minus the failure deviation setpoint for a set time.
6 alm_LowWarning Transmitter Process variable has deviated below the low Warning 30 Seconds ☐
setpoint minus the warning deviation setpoint for a set time.
EV_361_x Launder Laser Cooling Air Solenoid Control

The laser air cooling solenoid valve will operate automatically when the laser is enabled or the furnace is off the tilt down limit.

Tag EV_361_A, EV_361_C, EV_361_E
Description Furnace Launder Metal Level Transmitter Cooling Solenoid

Casting Launder Metal Level Transmitter Cooling Solenoid
CFF Launder Metal Level Transmitter Cooling Solenoid
UDT OBJ_EV01
User Control
manually
start
Interlocks
0 EV_361_x Launder Laser Cooling Air Disable Solenoid Emergency Stop Healthy Available ☐
1 EV_361_x Launder Laser Cooling Air Disable Solenoid PLC output Module Healthy Available ☐
2 EV_361_x Launder Laser Cooling Air Disable Solenoid Safety Status Healthy NA ☐
29 .con_PB..Hand Device hand mode control active Indication ☐
30 .con_PB..Auto Device Automatic mode control active Indication ☐
31 .con_PB..Auto Device Automatic mode control tripped requiring to be reset Indication ☐
Control Functions
1 con_PB. Start All pushbuttons real or on the HMI that will manually initiate the device ☐
operation
operation
 The laser cooling is enable all the time the laser is on and when
the laser is indicating a high temperature.
 Always inactive
pushbuttons

set.
Alarms
1 alm_Fail Device Failed To Energise in time Fault Not used ☐
LC_361 Furnace Launder Metal Level Controller

The launder metal will be controlled by tilting the furnace at a controlled speed. A laser by the furnace measures the metal depth in the
launder and a control valve on the hydraulic power pack will control the furnace tilt speed.
Tag LC_361
Description Launder Metal Level Controller
UDT OBJ_XC
Range Set to LT_361 range
User Control
3 hmi_data.SPMin Controller Minimum Setpoint L2 mm 200 0 0 ☐
4 hmi_data.SPMax Controller Maximum Setpoint L2 mm 200 0 200 ☐
5 hmi_data.SPuser Controller User Setpoint L0 mm max min NA ☐
6 hmi_data.CVuser Controller Output Variable User Setpoint Hand % 100 0 NA ☐
7 hmi_data.CVpre1 Controller Preposition Output 1, pre-set tilt L2 % 100 0 NA ☐
control valve before cast tilt enabled
8 hmi_data.CVpre2 Controller Preposition Output 2 L2 % 100 0 NA ☐
9 hmi_data.Pgain Controller proportional gain setpoint L2 none 100000 0 5.5 ☐
10 hmi_data.Igain Controller integral gain setpoint L2 none 100000 0 15 ☐
11 hmi_data.Dgain Controller derivative gain setpoint L2 none 100000 0 0 ☐
manually
start
Interlocks
0 LC_361 Launder Metal Level Controller Faulted Not Active Available ☐
1 LC_361 Launder Metal Level Controller in program mode Available ☐
2 LC_361_PID Launder Metal Level Controller Control variable Windup high alarm not Running ☐
active
3 LC_361_PID Launder Metal Level Controller Control variable Windup low alarm not active Running ☐
4 LT_361 Launder Metal Level Transmitter PLC input Module Healthy Available ☐

5 LT_361 Launder Metal Level Transmitter analogue signal Healthy Available ☐

6 LT_361 Launder Metal Level Transmitter Healthy signal Made Available ☐
7 FV_361 Furnace tilt control valve Required Interlock Healthy Available ☐
8 EV_361 Furnace Tilt Enable Solenoid Output Enabled Required ☐
9 PID_361 Launder Metal Level Controller High Deviation Hold Tilt Running ☐
Control Functions
1 Healthy Launder Metal Level transmitter is in range ☐
2 Mode Launder Metal Level Controller, switch back to program control on PLC first ☐
scan
3 Enable The PID will automatically run from power on. Each PID controlled loop is 1 Second ☐
tuned to give good control of the process variable to the setpoint by
manipulating the control variable
4 PV Select The Launder Metal Level transmitter is used all the time for the PV ☐
5 SP Select User setpoint only is used ☐
6 CV Select In the following conditions the control loop is automatically set to manual ☐
control and the tilt control valve is positioned directly.
Pre-position when the furnace is not is casting tilt mode the control variable
is set to a pre-position based on the known tilt rate at the start of a cast.
Freeze position, output returns to the last known output when the metal
level process variable input was healthy after the process variables has
failed.
7 CV User Update User control variable is updated when loop is not in manual control to enable ☐
bumpless transfer when manual control selected.
8 CV Limits Mould metal flow pin position actuator calibration not complete, control ☐
variable limits are set to 0 to 100.
Mould metal depth control process not started, control variable limits are set
to Fill limits for maximum and minimum.
Mould metal depth control process started, control variable limits are set to
Run limits for maximum and minimum.
Alarms
1 alm_PIDE Controller Internal Fault Fault 0 Seconds ☐
FV_361 Furnace Tilt Control Valve

The furnace tilt control valve will be a hydraulic proportional valve working of an analogue signal to control the tilt speed of the furnace,
the valve has feedback to ensure to has moved to the correct position.
Tag FV_361
Description Furnace Tilt Control Valve
UDT OBJ_XV01
User Control
3 hmi_data.CVMin Device Output Minimum Setpoint L2 % 100 0 0 ☐
4 hmi_data.CVMax Device Output Maximum Setpoint L2 % 100 0 100 ☐
5 hmi_data.CVuser Device Output Variable User Setpoint Hand % max min NA ☐


manually
start
Interlocks
0 FV_361 Furnace Tilt Control Valve Emergency Stop Healthy Available ☐
1 FV_361 Furnace Tilt Control Valve output command signal open circuit Available ☐
2 FV_361 Furnace Tilt Control Valve output command PLC module healthy Available ☐
Control Functions
1 Enable The valve will automatically run from power on ☐
2 CV Select Manual Enabled, set from User control variable ☐
Manual disabled, set control variable to 0 (damper fully open)
4 CV Position The device command signal and position feedback are compared, to a set 5% ☐
tolerance to indicate the device is at position
Alarms
1 alm_Open The analogue command signal to the actuator is open circuit Fault 0 Seconds ☐
2 alm_Input The signal from the transducer has failed, either the Fault 5 seconds ☐
transducer or the analogue input module could be faulty
3 alm_Error The valve position feedback has deviated from the valve Warning 20 seconds ☐
control variable output by set value

Z_361 Furnace Tilt Group

The furnace will be tilted hydraulically, with pre-set speeds; up, down, and hold. The operator can control the furnace tilt manually from
pushbuttons on the operator desk or tilt pushbutton station.
Automatic Control
The tilt hold solenoid is used by the auto-tilt sequence, it is enabled at the start of the sequence and remains enabled until the cast
completes. The hold can also be enabled by pressing fast tilt up or hold pushbuttons, the hold will latch on until the cast completes/aborts
or the tilt lower is pressed.
The fast tilt up (both tilt up valves and both motors operating) is used by the auto-tilt sequence to flood the launder up to the flood
setpoint (Z_361 Flood SP), this auto function will only enable if the interlocks are satisfied and the required level transmitter is enabled
and healthy.
The slow/auto/cast tilt up (just one up valve and one motor operating) is used once the cast has started and the auto tilt is active, the tilt
up supplies oil to the cylinders and the auto tilt proportional valve regulates the supplied oil flow back to tank.
The cast tilt virtual solenoid is used to enable the automatic tilt control. The control valve regulates the hydraulic oil flow determined by
the metal level (and the launder level control); the cast tilt virtual solenoid will enable the tilt control function once the launder flood
sequence has completed and the metal level has settled below the launder level control setpoint
Manual Control
No Manual Control
Tag Z_361
Description Furnace Tilt Group
UDT GROUP_STAUS
User Control
1 ☐
Control Functions
1 ☐
VV_361 Furnace Tilt Hold Virtual Output

The hold tilt valve is a spring to off hydraulic valve, energised it will prevent oil from the tilt cylinders retuning to tank, this solenoid must
remain energised to allow the furnace to tilt. In the event of power failure or the safety circuit being tripped the valve de-energises and
the furnace will lower at the normal lower speed of the furnace..
Tag VV_361
Description Furnace Tilt Hold Virtual Output
UDT OBJ_EV00
User Control


manually
start
Interlocks
0 Available ☐
1 Available ☐
Control Functions
operation
operation
 For the furnace to tilt up or hold in its current position the tilt
hold valve must be energised, if this valve is off the furnace will
tilt down
 Always inactive
pushbuttons
set.
Alarms
1 ☐
VVHH_361 Furnace Tilt Up Fast Virtual Output

The furnace fast tilt solenoid valves are supplied by a third party, it is expected to be a spring to centre hydraulic valve. In the event of
power failure or the safety circuit failing the valve de-energises but the furnace will continue or start to return to the down position.
Tag VV_361

Description Furnace Tilt Up Fast Virtual Output
UDT OBJ_EV00
User Control
manually
start
Interlocks
0 Available ☐
1 Available ☐
Control Functions
operation
operation
 For the furnace tilt up at maximum speed combined with the tilt
hold will tilt the furnace up at its fast speed enabled for the
flooding section of the auto-tilt sequence
pushbuttons
set.
Alarms


1 ☐
VVH_361 Furnace Tilt Up Cast Virtual Output

The cast tilt valve is a spring to off hydraulic valve, energised it will oil through the tilt control valve which controls the speed of the
furnace tilt during a cast. In the event of power failure or the safety circuit being tripped the valve de-energises and the furnace will lower
at the normal lower speed of the furnace.
Tag VV_361
Description Furnace Tilt Up Fast Virtual Output
UDT OBJ_EV00
User Control
manually
start
Interlocks
0 Available ☐
1 Available ☐
Control Functions
operation
operation
 For the furnace cast tilt speed both the tilt hold solenoid and cast
solenoid are energised. This function is used when the launder
level control is active; the furnace tilt speed is controlled via the
furnace tilt speed control valve described in the next section
 Mode Always Inactive


pushbuttons
set.
Alarms
1 ☐

Mould Water Equipment Control

This section details all mould water control equipment such as water flow control and pit water level control.

F_230 Mould Water Flow Control Group

The primary function is to control the casting machine mould water flow to a setpoint; the setpoint is either derived from a casting
practise or set by the operator.
The mould water flow must be controlled to give the correct amount of cooling water during the cast, the cast rolling ingot will crack if
there is too much cooling and not solidify before it leaves the mould with too little cooling.
Pre-position is used when the water has not started. The control variable is pre-positioned based on the current setpoint. Pre-position is
expressed as a polynomial equation, the values for the polynomial are derived during commissioning by mapping water flow against valve
position.
Automatic Control
The mould water flow will automatically start once the water on is selected from the casting operator desk.
Manual Control
On the operator main desk the operator can access manual control pushbuttons to enable or disable the mould water flow, after precast
checks have started the water cannot be switched off.
Tag F_230
Description Mould Water Flow Control Group
UDT GROUP_PROCESS
User Control
1 EPBH_230 Mould Water On Illuminated Pushbutton ☐
The water flow will start from a single push
of the button, the illumination will flash as
the water flow ramps up to the current
flow setpoint and goes steady when the
water flow reaches setpoint.
2 EPBL_230 Mould Water Off Pushbutton ☐
The water flow will stop from a single push
of the button, as long as casting has been
completed
3 hmi_SPwindow During casting the water flow setpoint can L2 l/min 5000 0 500 ☐
be altered by an operator, this setpoint will
set the limit of change from the original
setpoint that an operator can make, if set
to 0 the flow setpoint cannot be changed.
4 hmi_SProc This is the maximum rate of change in L2 l/min/sec 500 0 100 ☐
water flow setpoint
5 hmi_Polynomial_C0 Pre-position Polynomial Offset Constant L2 none 100000 0 ?? ☐
6 hmi_Polynomial_C1 Pre-position Polynomial Proportional L2 none 100000 0 ?? ☐
Constant
7 hmi_Polynomial_C2 Pre-position Polynomial Squared L2 none 100000 0 ?? ☐
Proportional Constant
Control Functions
1 con_Process Mould water supply has been selected on from the main casting desk ☐
Run
2 con_Process After the current cast has completed the water will continue to run on for a ☐
Request set time before the request to stop the water flow is set.

3 con_Startflow If the mould water flow setpoint has been set to water flow start flow from ☐
the recipe the start flow set, will reset after the cast has started.
4 con_StageLevel The current stage in the water flow section of the recipe is loaded into this 10 minuets ☐
Data data area when the current stage has been completed and the setpoint is
released back to the operator
5 con_StageLevel Apart from stage 0 each stage of the water flow section of the recipe has a 2 minuets ☐
SPcontrol.Run trigger when the cast length reaches the trigger setpoint in the current water
flow section of the recipe. If the cast is running and there are none zero
Latch values in the recipe the current cast length and current water flow setpoint
are stored. The water flow control setpoint is now ramped from the stored
staring setpoint to the recipe target setpoint over the cast length duration
set in the recipe.
6 con_StageLevel When the water flow setpoint reaches the target setpoint of the current 5 minuets ☐
SPcontrol.Run stage of the recipe, the stage running bit is reset and the current recipe stage
pointer is incremented.
unlatch
7 con_SPEdit.On This allows the operator control of the water flow setpoint, it is off during ☐
the mould fill process and when running a stage from the mould water flow
recipe section.
8 con_StageLevel When the cast is complete the current stage counter is set back to zero ☐
Current
9 con_Check Before the start of each cast the water flow is automatically ramped up to ☐
the maximum setpoint, this flow has to be checked before a cast can be
started
Recipe Functions
1 Mould Water flow during Fill (L/min). Water flow at the start of a cast and ☐
during the time it takes to tilt the holding furnace and fill the launder system
and moulds with metal.
2 Mould Water flow during slow cool descent (L/min). The water flow is ☐
ramped down to this flow at the end of a cast when end of cast has been
initiated.
3 Mould Water flow ramp 1 to 9 target rate (L/min) ☐
4 Mould Water flow ramp 1 to 9 trigger length (mm of cast length) ☐
5 Mould Water flow ramp 1 to 9 duration to reach target (mm of cast length) ☐
6 Mould Water flow during end of cast run-on time (L/min). Water flow at the ☐
end of a cast and during the time between the platen stopping and the water
flow stopping.
Alarms
1 ☐
FT_230 Mould Water Flow Transmitter

Positioned in the mould water supply line to casting table is a flow transmitter, this will measure the mould water flow to the casting table
when the water is running and alert the operators in the event of an out of tolerance situation, the monitoring is also used by the
automatic cast abort should there be a failure
Tag FT_230
Description Mould Water Flow Transmitter
UDT OBJ_XT01
Type Flow transmitter
Range 0-5650L/min
User Control


percentage of range
engineering units
3 hmi_data.UserHigh Transmitter user setpoint high, if the L2 l/min ☐
4 hmi_data.UserLow Transmitter user setpoint low, if the L2 l/min ☐
5 hmi_data.Control Transmitter user deviation setpoint for L2 l/min 100% 0% ☐
control, this will trigger high low deviation /%
6 data.AlarmWarning Transmitter user deviation setpoint for L2 l/min 100% 0% ☐
warning, this will trigger high low deviation /%
7 hmi_data.AlarmFailure Transmitter user deviation setpoint for L2 l/min 100% 0% ☐
Failure, this will trigger high low deviation to /%
Control Functions
Alarms
PT_230 Mould Water Pressure Transmitter

Positioned after the mould water hand valve is a static pressure transmitter, this will prove that when the hand valve is open there should
be water pressure in the line
Tag PT_230
Description Mould Water Supply Pressure Transmitter
UDT OBJ_XT01
Type Static pressure transmitter
Range 0-6 bar
User Control


percentage of range
engineering units
Control Functions
1 Enable_alm_HH Enable transmitter high failure alarm Off ☐
Enable_alm_H Enable transmitter high warning alarm Off
Alarms
2 alm_HighFailure Transmitter Process variable has deviated above the high Fault Not Used ☐
3 alm_HighWarning Transmitter Process variable has deviated above the high Warning Not Used ☐
TT_230 Launder Metal Level Transmitter

Positioned in the mould water supply is a temperature transmitter, this will monitor the water temperature when the water is running and
alert the operators in the event of an out of tolerance situation
Tag TT_230
Description Mould Water Supply Main Line Temperature Transmitter
UDT OBJ_XT01
Type Temperature transmitter
Range 0-100degC
User Control


percentage of range
engineering units
3 hmi_data.UserHigh Transmitter user setpoint high, if the L2 °C 100 0 NA ☐
4 hmi_data.UserLow Transmitter user setpoint low, if the L2 °C 100 0 NA ☐
5 hmi_data.Control Transmitter user deviation setpoint for L2 °C 100% 0% NA ☐
6 data.AlarmWarning Transmitter user deviation setpoint for L2 °C 100% 0% NA ☐
7 hmi_data.AlarmFailure Transmitter user deviation setpoint for L2 °C 100% 0% NA ☐
Control Functions
Alarms
FC_230 Mould Water Flow Controller

Water flow PID loop uses the process variable of the water to the casting machine and will control to a setpoint, the control variable from
the controller will position a water control valve, which is regulating the water flow to the casting machine mould.
Tag FC_230
Description Mould Water Flow Controller
UDT OBJ_XC
Range Set to FT_230 range
User Control


3 hmi_data.SPMin Controller Minimum Setpoint L2 l/min 1470 0 ☐
4 hmi_data.SPMax Controller Maximum Setpoint L2 l/min 1470 0 ☐
5 hmi_data.SPuser Controller User Setpoint L0 l/min max min ☐
6 hmi_data.CVuser Controller Output Variable User Setpoint Hand % 100 0 ☐
7 hmi_data.CVpre1 Controller Preposition Output 1, pre-set L2 % 100 0 ☐
flow control valve before water has started
manually
start
Interlocks
0 FC_230 Mould Water Flow Controller Faulted Not Active Available ☐
1 FC_230 Mould Water Flow Controller in program mode Available ☐
2 FC_230_PID Mould Water Flow Controller Control variable Windup high alarm not active Running ☐
3 FC_230_PID Mould Water Flow Controller Control variable Windup low alarm not active Running ☐
4 FT_230 Mould Water Flow Transmitter PLC input Module Healthy Available ☐
5 FT_230 Mould Water Flow Transmitter analogue signal Healthy Available ☐
6 FV_230 Mould Water Flow control valve Required Interlock Healthy Available ☐
Control Functions
1 Healthy Transmitter Input in Range ☐
Controller Process Variable Rate of Change alarm not active.
2 Mode Controller, switch back to program control on PLC first scan ☐
4 Fill Flow setpoint Set in the casting recipe is the water fill flow this can be used to give low ☐
water flow at the start of a cast before metal enters the mould then usually
ramp1 will increase the water flow at the start on the cast as soon as the
platen starts moving.
5 Slow cool descent flow When end of cast is initiated the cast speed is reduced rapidly at the same ☐
time the water flow is reduced to the slow cool decent flow, this is to slow
cool the cast slab once the cast is complete to freeze the remaining metal in
the mould.
6 Control Variable Select In the following conditions the control loop is automatically set to manual ☐
Pre-position is used when the water has not started. The control variable is
pre-positioned based on the current setpoint. Pre-position is expressed as a
polynomial equation, the values for the polynomial are derived during
commissioning by mapping water flow against valve position.

Freeze position, output returns to the last known output when the mould
water flow process variable input was healthy after the process variables has
failed.
7 Ramp control The mould water flow ramp control is done using a scaling block. The input ☐
to the scaling block will be the cast length and it is controlled between the
trigger point and the trigger point plus the duration. The output from the
scaling block will be mould water flow controlled between current mould
water flow and mould water flow at end of ramp.
8 Automatic control The PID will automatically run from power on. Each PID controlled loop is ☐
manipulating the control variable.
9 Process Variable Select Process variable is fixed as there is only one input. PV is always the FT input ☐
value.
10 Process Setpoint Select Setpoint is controlled by the casting recipe after a ramp is complete the ☐
setpoint control is released to the operator when adjustment 10% of
operating range can be made.
Alarms
FV_230 Mould Water Flow Control Valve

Positioned in the mould water supply line is a ¼ turn proportional control valve working of an analogue signal to control the water flow to
the casting machine mould table, the valve has feedback to ensure to has moved to the correct position.
Tag FV_230
Description Mould Water Supply Control Valve
UDT OBJ_XV01
User Control
manually
start
Interlocks
0 FV_361 Mould water flow control Valve Emergency Stop Healthy Available ☐
1 FV_361 Mould water flow control Valve output command signal open circuit Available ☐
2 FV_361 Mould water flow control Valve output command PLC module healthy Available ☐

Control Functions
1 Enable The valve will automatically run from power on ☐
Alarms

M 044 Steam Extraction Fan Motor Group

The primary function of this loop is to extract steam from the casting table though ducts around the casting machine.
Automatic Control
the fan will start and stop automatically with the mould water supply.
Manual Control
No Manual Control
Tag M_044
Description Steam Extraction Fan Motor Group
UDT GROUP_STATUS
User Control
1 ☐
Control Functions
1 ☐
EY_044 Steam Extraction Fan Motor Contractor

A direct online motor contactor for controlling the motor; sized to suit motor rating.
Tag EY_044
Description Steam Extraction Fan Motor Contactor
UDT OBJ_EY01
User Control
manually
start
Interlocks
0 EY_044 Steam Extraction Fan Motor Contactor Emergency Stop Healthy Available ☐

1 EY_044 Steam Extraction Fan Motor Contactor PLC output Module Healthy Available ☐
2 EY_044 Steam Extraction Fan Motor Contactor Safety Status Healthy NA ☐
3 EY_044 Steam Extraction Fan Motor Contactor Failed to break alarm not active Available ☐
4 EQ_044 Steam Extraction Fan Motor Circuit Breaker On Available ☐
Control Functions
operation
operation
 Output set on when the mould water process is set on
pushbuttons
set.
Alarms
continuity
EQ_044 Steam Extraction Fan Motor Circuit Breaker

Motor circuit breaker sized to suit motor.
Tag EQ_044
Description Steam Extraction Fan Motor Circuit Breaker
UDT OBJ_XS01
User Control

1 NA Motor circuit breaker setting will be set NA ?? ☐

during commissioning
Interlocks
1 ☐
Control Functions
1 ☐

1 alm_Make Circuit Breaker PLC input from the auxiliary contract is not Fault 0 Seconds ☐
made

M 051 Casting Pit Lift Pump Motor Group

The primary function of this loop is to pump water from the casting pit.
Automatic Control
The pump motors will start automatically once the pit water level deviates by a pre-set amount above the pit water level setpoint. Only
one pump will run at a time in a duty/standby setup, the duty/standby pump selection is controlled by L_240 (Casting Pit Water Lift Pump
Control). The pump motor will stop automatically once the pit water level deviates by a pre-set amount below the pit water level setpoint
and the cooling water supply has stopped.
Manual Control
No Manual Control
Tag M_051
Description Casting Pit Lift Pump Motor Group
UDT GROUP_STATUS
User Control
1 ☐
Control Functions
1 ☐
EY_051 Casting Pit Lift Pump Motor Contractor

A direct online motor contactor for controlling the motor; sized to suit motor rating.
Tag EY_051
Description Casting Pit Lift Pump Motor Contactor
UDT OBJ_EY01
User Control
manually
start
Interlocks


0 EY_051 Casting Pit Lift Pump Motor Contactor Emergency Stop Healthy Available ☐
1 EY_051 Casting Pit Lift Pump Motor Contactor PLC output Module Healthy Available ☐
2 EY_051 Casting Pit Lift Pump Motor Contactor Safety Status Healthy NA ☐
3 EY_051 Casting Pit Lift Pump Motor Contactor Failed to break alarm not active Available ☐
4 EQ_051_A Casting Pit Lift Pump Motor Circuit Breaker On Available ☐
5 EQ_051_B Casting Pit Lift Pump Motor Overload On Available ☐
Control Functions
operation
operation
 Output set on, off from the casting pit water level control C_240
pushbuttons
set.
Alarms
continuity
EQ_051 Casting Pit Lift Pump Motor Circuit Breaker

Tag EQ_051
Description Casting Pit Lift Pump Motor Circuit Breaker

UDT OBJ_XS01
User Control
Interlocks
1 ☐
Control Functions
1 ☐

made

L_240 Casting Pit Water Level Control Group

The primary function of this loop is to control the water level in the casting machine pit.
The water level must be maintained at a set level for safety reasons, there is a minimum water level allowed to casting aluminium, also the
level must remain above the height of the bottom of the service pit wall or the steam extraction fan will not work properly as steam can
escape into the service pit area.
Automatic Control
The mould water flow will automatically start once the water on is selected from the casting operator desk.
Manual Control
On the operator main desk the operator can access manual control pushbuttons to drain the casting pit
Tag F_230
Description Mould Water Flow Control Group
UDT GROUP_PROCESS
User Control
1 EPB_240 Pit Drain Illuminated Pushbutton ☐
To initiate the pit drain operation, the
illuminated PB must be pressed, it can be
disabled with a second press. The
illumination flashes during the drain and
goes steady completed.
2 hmi_PBdrain Pit Drain pock point on HMI Screen ☐
Function as above pushbutton
3 hmi_SPpumpOff Pit drain enable setpoint, if the pit water L2 mm 5000 0 500 ☐
level is below this level the pit drain cycle
cannot be initiated
4 hmi_SPpumpRunOn After the pit water level drops below the L2 sec 5000 0 500 ☐
SPpumpOFF setpoint during the pit drain
cycle, the pump will run on for this set
time
Control Functions
1 con_DrainPit Activated by pushbutton EPB 240, this function will drain the pit, running the ☐
duty pump until the water level has dropped below the pump off setpoint
"L_240".HMI_SPpumpOff and the run on time "L_240".HMI_SPpumpRunOn
has expired
LT_240 Mould Water Flow Transmitter

In the casting pit there is a water level transmitters one is selected as the process variable input for the water level controller
Tag LT_240
Description Casting Pit Water Level Transmitter
UDT OBJ_XT01
Type Water Level transmitter
Range 0-9500mm
User Control


percentage of range
engineering units
3 hmi_data.UserHigh Transmitter user setpoint high, if the L2 mm ☐
4 hmi_data.UserLow Transmitter user setpoint low, if the L2 mm ☐
5 hmi_data.Control Transmitter user deviation setpoint for L2 mm 100% 0% ☐
6 data.AlarmWarning Transmitter user deviation setpoint for L2 mm 100% 0% ☐
7 hmi_data.AlarmFailure Transmitter user deviation setpoint for L2 mm 100% 0% ☐
Control Functions
Alarms

Platen Equipment Control

This section details all casting machine platen equipment.

F_310 Cast Speed Control Group

The primary function is to control the speed of decent of the platen during casting to a setpoint, the setpoint is either derived from a
casting practise or set by the operator.
Pre-position is used when the platen has not started the cast descent. The control variable pre-positioned based on the current setpoint,
this pre-position is expressed as a polynomial equation. The equation is derived during commissioning by mapping cast speed against valve
position.
Automatic Control
The cast speed control will automatically start once the cast start is initiated.
Manual Control
No manual control.
Tag F_310
Description Cast Speed Control Group
UDT GROUP_PROCESS
User Control
1 hmi_SPwindow During casting the cast speed setpoint can L2 l/min 5000 0 500 ☐
be altered by an operator, this setpoint will
set the limit of change from the original
setpoint that an operator can make, if set
to 0 the speed setpoint cannot be
changed.
2 hmi_SProc This is the maximum rate of change in cast L2 l/min/sec 500 0 100 ☐
speed setpoint
3 hmi_Polynomial_C0 Pre-position Polynomial Offset Constant L2 none 100000 0 ?? ☐
4 hmi_Polynomial_C1 Pre-position Polynomial Proportional L2 none 100000 0 ?? ☐
Constant
5 hmi_Polynomial_C2 Pre-position Polynomial Squared L2 none 100000 0 ?? ☐
Proportional Constant
Control Functions
1 con_Process Cast speed control process is started as soon as the platen cast down is ☐
Run initiated
2 con_Startflow If the cast speed setpoint has been set to cast start speed from the recipe ☐
the start flow set, will reset after the cast has started.
3 con_StageLevel The current stage in the cast speed section of the recipe is loaded into this 10 minuets ☐
4 con_StageLevel Apart from stage 0 each stage of the cast speed section of the recipe has a 2 minuets ☐
SPcontrol.Run trigger when the cast length reaches the trigger setpoint in the current cast
speed section of the recipe. If the cast is running and there are none zero
Latch values in the recipe the current cast length and current cast speed setpoint
are stored. The cast speed control setpoint is now ramped from the stored
staring setpoint to the recipe target setpoint over the cast length duration
set in the recipe.
5 con_StageLevel When the cast speed setpoint reaches the target setpoint of the current 5 minuets ☐
unlatch
6 con_SPEdit.On This allows the operator control of the cast speed setpoint, it is off during the ☐
mould fill process and when running a stage from the mould water flow
recipe section.

Current
Recipe Functions
1 Platen Cast Speed Start (mm/min). cast speed at the start of a cast. ☐
2 Platen Cast Speed during slow cool descent (mm/min). the cast speed is ☐
ramped down to this speed at the end of a cast when end of cast has been
initiated.
3 Platen Cast Speed ramp 1 to 9 target rate (mm/min) ☐
4 Platen Cast Speed ramp 1 to 9 trigger length (mm of cast length) ☐
5 Platen Cast Speed ramp 1 to 9 duration to reach target (mm of cast length) ☐
Alarms
1 alm_CheckFail No platen movement measured the alarm is set to say the Failure 2 seconds ☐
platen has stopped
FC_310 Platen Cast Speed Controller

The platen speed during a cast is controlled using a motor and hoist arrangement controlled from a variable speed drive as there will be a
fixed linear correlation between motor speed and cast speed the controller will use open loop control the controller setpoint will drive the
motor speed directly, it will not require feedback
Tag FC_310
Description Platen Cast Speed Controller
UDT OBJ_XC
Range NA will be open loop control
User Control
3 hmi_data.SPMin Controller Minimum Setpoint L2 mm/min 150 0 ☐
4 hmi_data.SPMax Controller Maximum Setpoint L2 mm/min 150 0 ☐
5 hmi_data.SPuser Controller User Setpoint L0 mm/min max min ☐
6 hmi_data.CVuser Controller Output Variable User Setpoint Hand % 100 0 ☐
7 hmi_data.CVpre1 Controller Preposition Output 1, pre-set L2 % 100 0 ☐
flow control valve before water has started
interlock will show and remain on until
reset manually
start
Interlocks


0 FC_310 Platen Cast Speed Controller Faulted Not Active Available ☐
1 FC_310 Platen Cast Speed Controller in program mode Available ☐
2 SC_310 Platen Variable Speed Drive Required Interlock Healthy Available ☐
Control Functions
3 Slow cool descent flow When end of cast is initiated the cast speed is reduced rapidly at the same ☐
time the water flow is reduced to the slow cool decent flow, this is to slow
cool the cast slab once the cast is complete to freeze the remaining metal in
the mould.
4 Control Variable Select In the following conditions the control loop is automatically set to manual ☐
Pre-position is used when the cast has not started. The control variable is
pre-positioned based on the current setpoint. Pre-position is expressed as a
polynomial equation, the values for the polynomial are derived during
commissioning by mapping water flow against valve position.
5 Ramp control The cast speed ramp control is done using a scaling block. The input to the ☐
scaling block will be the cast length and it is controlled between the trigger
point and the trigger point plus the duration. The output from the scaling
block will be cast speed controlled between current mould cast speed and
cast speed at end of ramp.
6 Automatic control The PID will automatically run from power on. Each PID controlled loop is ☐
manipulating the control variable.
7 Process Setpoint Select Setpoint is controlled by the casting recipe after a ramp is complete the ☐
setpoint control is released to the operator when adjustment 10% of
operating range can be made.
Alarms
EY_310 Platen Lift Motor VSD Safe Torque Off Control

The platen lift drive is controlled using the variable speed drive, there is no Motor Contactor fitted, physically the EY PLC output is wired to
the VSD safety input terminals which will stop the motor in the case of an emergence. For convenience the PLC will still refer to the EY PLC
output as a motor contactor, the function is the same.
Tag EY_310
Description Platen Lift Motor VSD Torque Off Output
UDT OBJ_EV (no actual contractor so no feedback)
User Control


manually
start
Interlocks
0 EY_310 Platen Lift Motor Safe Torque Off Output Emergency Stop Healthy Available ☐
1 EY_310 Platen Lift Motor Safe Torque Off Output PLC output Module Healthy Available ☐
2 EY_310 Platen Lift Motor Safe Torque Off Output Safety Status Healthy Available ☐
3 EQ_310 Platen Lift Motor Circuit Breaker On Available ☐
Control Functions
1 con_PB.Start All pushbuttons real or on the HMI that will manually initiate the device ☒
operation
2 con_PB.Stop All pushbuttons real or on the HMI that will manually stop the device ☒
operation
3 con_PB.Auto.Active Device Automatic mode active. ☒
4 con_PB.Auto.Reset Device Automatic mode reset, device automatic on is tripped, reset from ☒
5 con_PB.Auto.On Device Automatic mode Trigger. ☒
 Always enabled
6 con_PB.Hand.Active Device Hand mode active ☒
 Always inactive
pushbuttons
set.
10 con.Run Motor running signal is set from a timer allowing the motor to run up to ☒
speed before enabling other functions in the PLC , will include VSD running at
speed Signal

Alarms
SC_310 Platen Lift Variable Speed Drive

The platen lift motor is controlled from a VSD is drive which will give maximum torque at zero speed to control the platen speed during
casting, it will need maximum torque to overcome the weight of the platen and cast slabs to hold the platen in position
Tag SC_310
Description Platen Lift Variable Speed Drive
UDT OBJ_SC01
User Control
3 am.fwd.hmi_On If the drive is manual control it can be L3 ☐
driven forward by pressing this pock point
on the HMI
4 am.fwd.hmi_Off If the drive is manual control it can be L0 ☐
stopped from being driven forward by
pressing this pock point on the HMI
5 am.rev.hmi_On If the drive is manual control it can be L3 ☐
driven in reverse by pressing this pock point
on the HMI
6 am.rev.hmi_Off If the drive is manual control it can be L0 ☐
stopped from being driven in reverse by
pressing this pock point on the HMI
manually
start
10 hmi_data.CVMin Device Output Minimum Speed Setpoint L2 % 100 0 0 ☐
11 hmi_data.CVMax Device Output Maximum Speed Setpoint L2 % 100 0 100 ☐
12 hmi_data.CVuser Device Output Variable User Setpoint None ☐
Interlocks
0 SC_310 Motor VSD communication Healthy Available ☐
1 SC_310 Motor VSD Faulted Available ☐
2 EY_310 Motor VSD Safe Torque Off enabled Required ☐
3 EY_310_B Motor VSD break de-energised Running ☐
4 ZSHH_310 Platen Fully Raised Limit Switch On when platen raise request is enabled Running ☐
Control Functions
1 con.Enable Platen Lift Motor VSD is controlled from trolley in/out request described in ☐
the following sections

2 End_Position Depending on the direction of the trolley movement the final stop position is ☐
moved to a local memory tag.
3 hmi_Data.CV.Value Speed setpoint of 0% is selected when the drive is off ☐
Speed setpoint Slow (CVMin) is selected when the platen slow up or slow
down are selected or when the platen is being raised and is within 200mm of
its top limit
Speed setpoint Fast (CVMax) is selected when the platen fast up or fast down
are selected.
Speed setpoint is set from the platen speed controller during casting (FC310)
4 CV Update The device command signal is moved to the plc output ☐
5 CV Position The device command signal and speed feedback are compared, to a set ☐
6 plc_com.Fwd Forward direction is selected when platen lift request is made and all the ☐
VSD interlocks are heathy
7 plc_com.Rev Reverse direction is selected when platen lower request is made and all the ☐
VSD interlocks are heathy
8 plc_com.Reset Fault reset is set if the VSD has an active fault and the resulting alarm in the ☐
PLC has been acknowledged by the operator
9 hmi_Current.Value Will read VSD output current ☐
10 hmi_Voltage.Value Will read VSD output voltage ☐
11 hmi_Power.Value Will read VSD output power ☐
12 hmi_Fault Will read VSD last fault code ☐
Alarms
1 alm_Communication VSD communication to PLC has failed Fault 10 Seconds ☒
2 alm_Fault VSD Faulted, active fault will be displayed on VSD HMI Fault 5 Seconds ☒
3 alm_Warn VSD Warning, active warning will be displayed on VSD HMI Warning 0 Seconds ☒
4 alm_Error The VSD speed feedback has deviated from the control Warning 10 Seconds ☒
variable output by 5%
EQ_310 Platen Lift Motor Circuit Breaker

Tag EQ_310
Description Platen Lift Motor Circuit Breaker
UDT OBJ_XS01
User Control
1 NA Motor circuit breaker setting will be set NA ☒
Interlocks
1
Control Functions
1
Alarms


1 alm_Make Circuit Breaker PLC input from the auxiliary contact is not Fault 0 Seconds ☒
made
2 alm_Safety_In PLC Safety input from the auxiliary contract has failed, single Fault 0 Seconds ☒

M 310_A Platen Drive Cooling Air Fan Motor Group

The platen drive cooling air fan provides cooling for forced air cooling for the platen drive motor.
Automatic Control
The fan will start automatically and run continuously while the platen drive is running.
Manual Control
No Manual Control
Tag M_310_A
Description Platen Drive Cooling Air Fan Motor Group
UDT GROUP_STAUS
User Control
1 ☐
Control Functions
1 ☐
EY_310_A Platen Drive Cooling Air Fan Motor Contractor

The Platen Drive Cooling Air Fan Motor is controlled from a motor contactor.
Tag EY_310_A
Description Platen Drive Cooling Air Fan Motor Contactor
UDT OBJ_EY01
User Control
manually
start
Interlocks
0 EY_310_A Platen Drive Cooling Air Fan Motor Contactor Emergency Stop Healthy Available ☐

1 EY_310_A Platen Drive Cooling Air Fan Motor Contactor PLC output Module Healthy Available ☐
2 EY_310_A Platen Drive Cooling Air Fan Motor Contactor Safety Status Healthy NA ☐
3 EY_310_A Platen Drive Cooling Air Fan Motor Contactor Failed to break alarm not Available ☐
active
4 EQ_310_A Platen Drive Cooling Air Fan Motor Circuit Breaker On Available ☐
Control Functions
operation
operation
 Output set on when SC_310 platen drive is running
pushbuttons
set.
Alarms
continuity
EQ_310_A Platen Drive Cooling Air Fan Motor Circuit Breaker

Tag EQ_310_A
Description Platen Drive Cooling Air Fan Motor Circuit Breaker
UDT OBJ_XS01
User Control


Interlocks
1 ☐
Control Functions
1 ☐

made

M 310_B Platen Drive Brake Motor Group

The platen drive brake motor will control the platen drive brake when running the brake will be driven off.
Automatic Control
The fan will start automatically and run continuously while the platen drive is running.
Manual Control
No Manual Control
Tag M_310_B
Description Platen Drive Brake Motor Group
UDT GROUP_STAUS
User Control
1 ☐
Control Functions
1 ☐
EY_310_B Platen Drive Brake Motor Contractor

The Platen Drive brake Motor is controlled from a motor contactor.
Tag EY_310_B
Description Platen Drive Brake Motor Contactor
UDT OBJ_EY01
User Control
manually
start
Interlocks
0 EY_310_B Platen Drive Brake Motor Contactor Emergency Stop Healthy Available ☐

1 EY_310_B Platen Drive Brake Motor Contactor PLC output Module Healthy Available ☐
2 EY_310_B Platen Drive Brake Motor Contactor Safety Status Healthy NA ☐
3 EY_310_B Platen Drive Brake Motor Contactor Failed to break alarm not active Available ☐
4 EQ_310_B Platen Drive Brake Motor Circuit Breaker On Available ☐
Control Functions
operation
operation
 Output set on when SC_310 platen drive is running
pushbuttons
set.
Alarms
continuity
EQ_310_B Platen Drive Brake Motor Circuit Breaker

Tag EQ_310_B
Description Platen Drive Brake Motor Circuit Breaker
UDT OBJ_XS01
User Control


Interlocks
1 ☐
Control Functions
1 ☐

made

Z 310 Platen Position Group

The primary function of this loop is to control the casting machine platen to allow the operator to position before a cast, cast and lift cast
billet/slab out of the casting pit at the end of a cast.
The platen is moved using one a 15kw drive controlled from a variable speed drive.
Automatic Control
The platen will be automatically controlled during a cast, refer to section F_310 for the full description. The platen can also be controlled
automatically during the calibration sequence, refer to section VVY_412_B laser calibration sequence.
Manual Control
Manual control will be from pushbuttons on the operator casting desk, or from a wireless handheld pendant
Tag Z_310
Description Platen Position Group
UDT GROUP_STAUS
User Control
1 EPBHH_310_A Platen fast raise illuminated pushbutton ☐
(caster operator Desk)
The platen can be raised at fast speed from
a continual push of the button; the
illumination will flash when the platen is
moving up fast and go steady when the
platen has reached the platen high position
limit. If the mould table carriage is at its
service position then the platen can be
raised at fast speed from a single push of
the button, the illumination will flash when
the platen is moving up fast and go steady
when the platen has reached the platen
high position limit. This button is not active
during casting
2 EPBH_310 Platen slow raise illuminated pushbutton ☐
The platen can be raised at slow speed from
a continual push of the button on the
casting machine desk. This button is not
active during casting.
3 EPBLL_310_A Platen fast lower illuminated pushbutton ☐
The platen can be lowered at fast speed
from a single push of the button, the
illumination will flash when the platen is
moving down fast and go steady when the
platen has reached the platen low position
limit. The platen will continue to lower until
the cylinder bottoms out. This button is not
active during casting
4 EPBL_310 Platen stop pushbutton (caster operator ☐
Desk)
the platen can be lowered at slow speed
from a continual push of the button on the
casting machine desk. This button is not
active during casting.
5 EPB_310_A Platen stop pushbutton (caster operator ☐

Desk)

The platen can be stopped from moving up

or down from a single push of the button..
This button is not active during casting.
6 EPBL_310_B Platen lower pushbutton (hand held ☐

pendant)
The platen can be lowered at fast speed
from a continual push of the button on the
radio-controlled pendant if the platen is
below its top limit. The platen can be
lowered at slow speed from a continual
push of the button on the radio controlled
pendant if the platen is above its top limit
.This button is not active during casting.
7 EPB_310_B Platen stop pushbutton (hand held pendant) ☐
The platen can be stopped from moving up
or down from a single push of the button.
This button is not active during
Control Functions
1 ☐
VVHH_310 Platen Up Fast Virtual Output

The platen direction and speed control is via a variable speed drive, this will be a virtual controlled output which will be used to set the
speed and direction in the variable speed drive.
Tag VVHH_310
Description Platen Up Fast Virtual Output
UDT OBJ_EV00
User Control
manually
start
Interlocks
0 C_105_Mode Pre-cast checks not active Required ☐
1 VVH_310 Platen Slow Up virtual output not Active Available ☐
2 VVL_310 Platen Slow down virtual output not Active Available ☐
3 VVLL_310 Platen fast down virtual output not Active Available ☐

Control Functions
operation
operation
 None
 Device latched if the platen is below the top 200mm of travel
pushbuttons
set.
Alarms
1 ☐
VVH_310 Platen Up Slow Virtual Output

Tag VVH_310
Description Platen Up Slow Virtual Output
UDT OBJ_EV00
User Control
manually
start
Interlocks


1 VVHH_310 Platen Fast Up virtual output not Active Available ☐
3 VVLL_310 Platen fast down virtual output not Active Available ☐
Control Functions
operation
operation
 The laser calibration sequence to drive the platen up slow to the
platen start cast position
 Device is always unlatched
pushbuttons
set.
Alarms
1 ☐
VVLL_310 Platen Down Fast Virtual Output

Tag VVLL_310
Description Platen Down Fast Virtual Output
UDT OBJ_EV00
User Control


manually
start
Interlocks
1 VVH_310 Platen Slow Up virtual output not Active Available ☐
3 VVHH_310 Platen fast up virtual output not Active Available ☐
Control Functions
operation
operation
 None
pushbuttons
set.
Alarms
1 ☐
VVL_310 Platen Down Slow Virtual Output

Tag VVL_310
Description Platen Down Slow Virtual Output

UDT OBJ_EV00
User Control
manually
start
Interlocks
1 VVHH_310 Platen Fast Up virtual output not Active Available ☐
3 VVH_310 Platen slow up virtual output not Active Available ☐
Control Functions
operation
operation
 The laser calibration sequence to drive the platen down slow to
the platen start cast position
 Device is always unlatched
pushbuttons
set.
Alarms


1 ☐
ZT_310 Cast Length Encoder

The encoder pulse output is connected to a PLC high speed counter module, in the PLC this pulse count will be converted to engineering
units.
Tag ZT_310
Description Cast Length Encoder
UDT OBJ_XT01
Type Pulse encoder
Range 0-8100mm
User Control
percentage of range
engineering units
Control Functions
Enable_con_H Enable transmitter high control Off
Enable_con_L Enable transmitter low control Off
Enable_alm_L Enable transmitter low warning alarm Off
Enable_alm_LL Enable transmitter low failure alarm Off
Alarms
1 alm_Input Transmitter PLC input is open circuit or transmitter has failed Fault Not used ☐
2 alm_HighFailure Transmitter Process variable has deviated above the high Fault Not used ☐
3 alm_HighWarning Transmitter Process variable has deviated above the high Warning Not used ☐

4 alm_LowFailure Transmitter Process variable has deviated below the low Fault Not used ☐
5 alm_LowWarning Transmitter Process variable has deviated below the low Warning Not used ☐
ZSH_310 Platen Fully Raise Limit

Fitted to the platen is fully up limit switch, this is there to protect the drive .
Tag ZSH_310
Description Platen Fully Raise Limit
UDT OBJ_XS01
User Control
1
Interlocks
1
Control Functions
1
Alarms
1 alm_Make The platen has reached this final end of travel limit Fault 5 Seconds ☐
ZS_310 Platen Zero Home Limit

The platen is fitted with a platen zero limit, this limit will be used to set the platen drive variable speed drive to its home position.
Tag ZS_310
Description Platen Zero Home Limit
UDT OBJ_XS01
User Control
1
Interlocks
1
Control Functions
1
Alarms
1 alm_Make fails to reach the raise limit in a set time Fault Not used ☐


Mechanical Equipment Control

This section details all casting machine mechanical equipment other than the platen.

M 011 Main Hydraulic Oil Pump Motor Group

The primary function of this loop is to generate pressure when required by the hydraulic functions of the casting machine.
Automatic Control
The pump will automatically start when one of the mechanical functions has been initiated.
Manual Control
No Manual Control
Tag M_011
Description Main Hydraulic Oil Pump Motor Group
UDT GROUP_STAUS
User Control
1 ☐
Control Functions
1 ☐
EY_011 Main Hydraulic Oil Pump Motor Contractor

The main hydraulic oil pump motor is controlled from a motor contactor.
Tag EY_011
Description Main Hydraulic Oil Pump Motor Contactor
UDT OBJ_EY01
User Control
manually
start
Interlocks
0 EY_011 Main Hydraulic Oil Pump Motor Contactor Emergency Stop Healthy Available ☐

1 EY_011 Main Hydraulic Oil Pump Motor Contactor PLC output Module Healthy Available ☐
2 EY_011 Main Hydraulic Oil Pump Motor Contactor Safety Status Healthy NA ☐
3 EY_011 Main Hydraulic Oil Pump Motor Contactor Failed to break alarm not active Available ☐
4 EQ_011 Main Hydraulic Oil Pump Motor Circuit Breaker On Available ☐
Control Functions
operation
operation
 Output set on when one pump run request is set on from C_250
pushbuttons
set.
Alarms
continuity
EQ_011 Main Hydraulic Oil Pump Motor Circuit Breaker

Tag EQ_011
Description Main Hydraulic Oil Pump Motor Circuit Breaker
UDT OBJ_XS01
User Control


Interlocks
1 ☐
Control Functions
1 ☐

made

C_250 Hydraulic Power Pack Group

The primary function of this loop is to control and monitor tank level, duty standby and pumps selection and common load and enables
valves.
Automatic Control
No automatic control.
Manual Control
No operator manual control.
Tag C_250
Description Hydraulic Power Pack Group
UDT GROUP_HYD
User Control
1 ☐
Control Functions
1 .con_Main.RunOn After the hydraulic demand has gone off the pump will remain running for a 300 Seconds ☒
set time to avoid excessive starts each time a hydraulic function is selected
2 .con_Main.RunReq1 run one hydraulic pump request is set from specific hydraulic valves being ☒
enabled.
EVH_315 Mould Carriage Raise Solenoid Valve enable set
EVL_315 Mould Carriage Lower Solenoid Valve enable set
3 .con_Main.RunSelect1 Run one pump requested will set select 1 pump to run and reset select 2 ☒
pumps to run, the select pump will be reset after the pump run on timer has
timed out.

Z_315 Mould Tilt Table Control Group

The Scrap Saw First Stop has a hydraulically operated lift cylinder which will raise it and lower it to act as a stop as the scrap is fed into the
scrap saw then is raised to allow the cut scrap to be cleared from the scrap saw.
Automatic Control
No automatic control.
Manual Control
On the operator main desk the operator can access manual control pushbuttons to operate the mould tilt table, all interlocks will still be in
circuit before any movement is enabled
Tag Z_315
Description Mould Tilt Table Control Group
UDT GROUP_STATUS
User Control
1 EPBL_315 Mould table lower pushbutton positioned on the operator desk ☐
The operator will lower the table manually from a single push of the button.
The button illumination will flash when the table is lowering and will remain
on when the table is lowered fully
2 EPBH_315 Mould table raise pushbutton positioned on the operator desk ☐
The operator will raise the table manually from a single push of the button.
The button illumination will flash when the table is raising and will remain on
when the table is raised fully
Control Functions
1
EVH_315 Mould Tilt Table Raise Solenoid

Operating this hydraulic valve will raise the mould table
Tag EVH_315
Description Mould Tilt Table Raise Solenoid
UDT OBJ_EV01
User Control
1 hmi_EPBH Mould Tilt Table Raise start virtual L0 ☐
Mould Tilt Table will raise fully when
pressed
2 hmi_EPBL Mould Tilt Table raise stop virtual L0 ☐
Mould Tilt Table raise will stop moving when
pressed


manually
start
Interlocks
0 EVH_315 Mould Tilt Table Raise solenoid Emergency Stop Healthy Available ☐
1 EVH_315 Mould Tilt Table Raise solenoid PLC output Module Healthy Available ☐
2 EVH_315 Mould Tilt Table Raise solenoid PLC safety output status NA ☐
3 ZSH_315 Mould Tilt Table Raised Limit Switch failed to break Available ☐
4 ZS_311_B Casting Launder in maintenance position Required ☐
5 EY_011 Main Hydraulic Pump Running Running ☐
6 EVL_315 Mould Tilt Table Lower Solenoid Energised Running ☐
Control Functions
operation
operation
 None
pushbuttons
set.
Alarms
1 alm_Fail Mould tilt table raise fails to leave its lowered limit in a set Fault 5 Seconds ☐
time

EVL_315 Mould Tilt Table Lower Solenoid

Operating this hydraulic valve will lower the mould table
.
Tag EVL_315
Description Mould Tilt Table Lower Solenoid
UDT OBJ_EV01
User Control
1 hmi_EPBH Mould Tilt table Lower start virtual L0 ☐
pushbutton
Positioned on the HMI, the Mould Tilt table
will Lower fully when pressed
2 hmi_EPBL Mould Tilt table Lower stop virtual L0 ☐
pushbutton
Positioned on the HMI, the Mould Tilt table
Lower will stop moving when pressed
manually
start
Interlocks
0 EVL_315 Mould Tilt table lower solenoid Emergency Stop Healthy Available ☐
1 EVL_315 Mould Tilt table lower solenoid PLC output Module Healthy Available ☐
2 EVL_315 Mould Tilt table lower solenoid PLC safety output status Available ☐
3 ZSL_315 Mould Tilt table Lowered Limit Switch failed to break Available ☐
4 ZS_311_B Casting Launder in maintenance position Required ☐
5 EY_011 Main Hydraulic Pump Running Running ☐
6 EVH_315 Mould Tilt Table Raise Solenoid Energised Running ☐
Control Functions
operation
operation

 None
pushbuttons
set.
Alarms
time
ZSH_315 Mould Tilt Table Raise Limit

The mould table tilt is fitted with a limit to show the stop has been fully raised.
Tag ZSH_315
Description Mould Tilt Table Raise Limit
UDT OBJ_XS02
User Control
1
Interlocks
1
Control Functions
1
Alarms
1 alm_Make The mould tilt table fails to reach the raise limit in a set time Fault 5 Seconds ☒
2 alm_Break The mould tilt table reach its lower limit and the raised limit is Fault 5 Seconds ☒
still made.

ZSL_315 Mould Tilt Table Lower Limit

The mould table tilt is fitted with a limit to show the stop has been fully lowered.
Tag ZSL_315
Description Mould Tilt Table Lower Limit
UDT OBJ_XS02
User Control
1
Interlocks
1
Control Functions
1
Alarms
1 alm_Make The mould tilt table fails to reach the lower limit in a set time Fault 5 Seconds ☒
2 alm_Break The mould tilt table reach its raised limit and the lowered Fault 5 Seconds ☒
ZS_311_A Casting Launder In Casting Position Limit

Fitted to the casting launder is a proximity switch which is made when the casting launder is in its casting position, this will be used as an
interlock to allow casting.
Tag ZSL_311_A
Description Casting Launder In Casting Position Limit
UDT OBJ_XS01
User Control
1
Interlocks
1
Control Functions
1
Alarms
1 alm_Make Casting process check have been initiated and the casting Fault 5 Seconds ☒
launder is not in the casting position

ZS_311_B Casting Launder In Maintenance Position Limit

Fitted to the casting launder is a proximity switch which is made when the casting launder is in its maintenance position, this will be used
as an interlock to allow launder heating to be used.
Tag ZSL_311_B
Description Casting Launder In Maintenance Position Limit
UDT OBJ_XS01
User Control
1
Interlocks
1
Control Functions
1
Alarms
1 alm_Make Launder heating process have been initiated and the casting Fault 5 Seconds ☒
launder is not in the Maintenance position

Casting Launder Pre-Heat Equipment Control

This section details all launder pre-heat control functions.

M 061 Launder Cooling Air Supply Fan Motor Group

The primary function of this loop is to supply cooling air to the launder during casting to help reduce thermal expansion; the fan will be
automatically controlled from the PLC, start is initiated by an operator when launder heating is required.
Automatic Control
The fan will automatically start when the cooling water table is started and will switch off after the cooling water to the table is switched
of.
Manual Control
No Manual Control
Tag M_061
Description Launder Cooling Air Supply Fan Motor Group
UDT GROUP_STAUS
User Control
1 ☐
Control Functions
1 ☐
EY_061 Launder Cooling Air Supply Motor Contractor

The Launder cooling Air Supply motor is controlled from a motor contactor.
Tag EY_061
Description Launder Cooling Air Fan Motor Contactor
UDT OBJ_EY01
User Control
manually
start
Interlocks


0 EY_061 Launder Cooling Air Fan Motor Contactor Emergency Stop Healthy Available ☐
1 EY_061 Launder Cooling Air Fan Motor Contactor PLC output Module Healthy Available ☐
2 EY_061 Launder Cooling Air Fan Motor Contactor Safety Status Healthy NA ☐
3 EY_061 Launder Cooling Air Fan Motor Contactor Failed to break alarm not active Available ☐
4 EQ_061 Launder Cooling Air Fan Motor Circuit Breaker On Available ☐
5 EY_100CA Power On to distribution panel Required ☐
6 ZS_315AA Mould carriage in casting position limit Required ☐
7 ZS_315BAA Mould carriage LHS clamp on limit Required ☐
8 ZS_315BBA Mould carriage RHS clamp on limit Required ☐
Control Functions
operation
operation
 Automatic control is tied to the mould water flow, when the
water starts so will the cooling fan
pushbuttons
set.
Alarms
continuity
EQ_061 Launder Cooling Air Supply Motor Circuit Breaker


Tag EQ_061
Description Launder Cooling Air Fan Motor Circuit Breaker
UDT OBJ_XS01
User Control
Interlocks
1 ☐
Control Functions
1 ☐

made

M 062 Launder Heating Air Supply Fan Motor Group

The primary function of this loop is to supply air to all launder heaters; the fan will be automatically controlled from the PLC, start is
initiated by an operator when launder heating is required.
Automatic Control
The fan will automatically start when a launder heater has been selected to run.
Manual Control
No Manual Control
Tag M_062
Description Launder Heating Air Supply Fan Motor Group
UDT GROUP_STAUS
User Control
1 ☐
Control Functions
1 ☐
EY_062 Launder Heating Air Supply Motor Contractor

The Launder cooling Air Supply motor is controlled from a motor contactor.
Tag EY_062
Description Launder Heating Air Fan Motor Contactor
UDT OBJ_EY01
User Control
manually
start
Interlocks

0 EY_062 Launder Heating Air Fan Motor Contactor Emergency Stop Healthy Available ☐
1 EY_062 Launder Heating Air Fan Motor Contactor PLC output Module Healthy Available ☐
2 EY_062 Launder Heating Air Fan Motor Contactor Safety Status Healthy NA ☐
3 EY_062 Launder Heating Air Fan Motor Contactor Failed to break alarm not active Available ☐
4 EQ_062 Launder Heating Air Fan Motor Circuit Breaker On Available ☐
5 EY_100CA Power On to distribution panel Required ☐
6 ZS_311_A or ZS_311_B Table launder in casting position or in maintenance position Required ☐
Control Functions
operation
operation
 Output is set on when any of the three launder heater are
selected to run
pushbuttons
set.
Alarms
continuity
EQ_062 Launder Heating Air Supply Motor Circuit Breaker

Tag EQ_062
Description Launder Heating Air Fan Motor Circuit Breaker

UDT OBJ_XS01
User Control
Interlocks
1 ☐
Control Functions
1 ☐

made

H 063x Launder Heater Group

The primary function of this loop is to control the launder heaters which will produce hot air at a pre-set temperature up 650˚C to heat the
launder system before casting.
Automatic Control
No Automatic Control
Manual Control
From the heater panel (CP063) the operator can insert the launder heaters in to the launder, the heaters are then switched on from a the
“start heater” illuminated pushbutton on the heater panel.
Tag H_063A, H_063B, H_063C

Description Launder Heater Group
UDT GROUP_STAUS
User Control
1 EPB_063x Launder Heater x Select On illuminated Pushbutton ☐
Will start the selected heater when all the required interlocks are healthy
Control Functions
1 ☐
EY_063x Launder Heater Contractor

The Launder Heater is controlled from a contactor.
Tag EY_063A, EY_063B, EY_063C
Description Launder Heater Contactor
UDT OBJ_EY01
User Control
manually
start
Interlocks


0 EY_063x Launder Heater Contactor Emergency Stop Healthy Available ☐
1 EY_063x Launder Heater Contactor PLC output Module Healthy Available ☐
2 EY_063x Launder Heater Contactor Safety Status Healthy Available ☐
3 EQ_063x Launder Heater Circuit Breaker On Available ☐
4 ZS_063x Launder Heater In Position Limit Required ☐
5 EY_062 Launder Heater Air Fan Running Running ☐
Control Functions
operation
operation
 none
pushbuttons
set.
Alarms
continuity
EQ_063x Launder Heater Circuit Breaker

Heater circuit breaker sized to suit heater.
Tag EQ_063A, EQ_063B, EQ_063C
Description Launder Heater Circuit Breaker
UDT OBJ_XS01

User Control
1 NA Heater circuit breaker setting will be set NA ?? ☐
Interlocks
1 ☐
Control Functions
1 ☐

made
ZS_063x Launder Heater In Position Limit Switch

The launder lid is fitted with a limit switch indicating the launder heater is in position. This limit is wired to a safety input to disable the
heater until it is in position.
Tag ZS_063A, ZS_063B, ZS_063C
Description Launder heater in position Limit Switch
UDT OBJ_XS01
User Control
1 NA ☐
Interlocks
1 ☐
Control Functions
1 ☐

1 alm_Make limit PLC input from the auxiliary contact is not made Fault 0 Seconds ☐
2 alm_Safety_In limit PLC input from the auxiliary contact has failed, two Fault Not used ☐
continuity
HC _063x Launder Heater Temperature Controller

The launder heater has an internal temperature controller, the PLC supplies a setpoint for the controller as a 4 to 20 ma signal, there is no
feedback from this controller apart from a fault signal.
Tag HC_063A, HC_063B, HC_063C
Description Launder Heater Temperature Controller

UDT OBJ_XV02
User Control
3 hmi_data.CVMin Device Output Minimum Setpoint None ˚C max 0 0 ☐
4 hmi_data.CVMax Device Output Maximum Setpoint, this L0 ˚C 650 0 650 ☐
setpoint will be used when the spout
heaters are not in position.
5 hmi_data.CVuser Device Output Variable User Setpoint, this L0 ˚C max min NA ☐
reduced setpoint will be used when the
spout heaters are in position to protect
them from high air temperatures.
manually
start
Interlocks
0 HC_063x Launder Heater Temperature Controller Emergency Stop Healthy Available ☐
1 HC_063x Launder Heater Temperature Controller output command signal open circuit Available ☐
2 HC_063x Launder Heater Temperature Controller output command PLC module Available ☐
healthy
3 HC_063x Launder Heater Temperature Controller Launder heater fault signal feedback Available ☐
is not made
4 EY_063x Launder Heater contactor energised Required ☐
Control Functions
1 con.Enable The valve will automatically run from when the Scrap Saw Head Speed ☐
Proportional Valve Enable Signal is energised
4 CV Position The device command signal and position feedback are compared, to a set ☐
Alarms
1 alm_Open The analogue command signal to the damper is open circuit Fault 0 Seconds ☐
2 alm_Input The signal from the transducer has failed either the Fault Not used ☐
3 alm_Error The valve position feedback has deviated from the valve Warning Not used ☐
4 alm_Make Controller Fault Signal PLC input from the auxiliary contact is Fault 1 Seconds ☐
not made

H 412x Spout Heater Group

The primary function of this loop is to control the spout heaters which is an element type heater that is inserted in to the mould poring
spout to pre-heat before casting.
Automatic Control
No Automatic Control
Manual Control
From the SCADA screen the spout heaters can be switch on or off if all the required interlocks are healthy
Tag H_412A, H_412B, H_412C

Description Spout Heater Group
UDT GROUP_STAUS
User Control
1 ☐
Control Functions
1 ☐
EY_412x Launder Heater Contractor

The Launder Heater is controlled from a contactor.
Tag EY_412A, EY_412B, EY_412C
Description Launder Heater Contactor
UDT OBJ_EY01
User Control
manually
start
Interlocks

0 EY_412x Spout Heater Contactor Emergency Stop Healthy Available ☐

1 EY_412x Spout Heater Contactor PLC output Module Healthy Available ☐
2 EY_412x Spout Heater Contactor Safety Status Healthy NA ☐
3 EQ_412x Spout Heater Circuit Breaker On Available ☐
Control Functions
operation
operation
 none
pushbuttons
set.
Alarms
continuity
EQ_412x Launder Heater Circuit Breaker

Heater circuit breaker sized to suit heater.
Tag EQ_412A, EQ_412B, EQ_412C
Description Launder Heater Circuit Breaker
UDT OBJ_XS01
User Control

1 NA Heater circuit breaker setting will be set NA ?? ☐

Interlocks
1 ☐
Control Functions
1 ☐

made

Mould Metal Level Control Equipment Operation

This section details all mould metal level control functions
.

L_412x Mould Metal Level Control Group

The metal flow rate to each mould can be controlled from an electrically actuated control pin for each mould. The pin is positioned based
on the level of molten metal in the individual mould. The system consists of one close loop PID controller based on the metal level in the
mould.
Prior to cast start the pin actuator must be calibrated; after the calibration is complete the pin will move to its start position.
During automatic abort the pin actuator can be closed automatically by releasing a pneumatic valve which will operate a pneumatic
cylinder in the electrical actuator closing the pin fully.
Automatic Control
The mould metal level control will automatically starts as the metal level in the mould rises above a set threshold.
Manual Control
No operator manual control.
Tag L_412A, L_412B, L_412C, L_412D, L_412E

Description Mould Metal Depth Control Group
UDT GROUP_MOULDL
User Control
1 hmi_Deselect_On If the mould position is not required for the L2 ☐
next cast it can be de-selected, by pressing
this button on the HMI
2 hmi_Deselect_Off If the mould position is now required for L2 ☐
the next cast it can be re-selected, by
pressing this button on the HMI
3 hmi_Depth This is the depth of the mould to allow the L2 mm 300 0 NA ☐
PLC to calculate the metal depth in the
mould, usually set from the casting machine
recipe but if this is set to zero it can be
4 hmi_SPwindow During casting the Mould Metal Level L2 mm 50 0 5 ☐
setpoint can be altered by an operator, this
setpoint will set the limit of change from
the original setpoint that an operator can
make, if set to 0 the level setpoint cannot
be changed.
5 hmi_PVrateChange This is the maximum rate of change in metal L2 mm/sec 5 0 2.5 ☐
level that can be accepted as normal, above
this limit it will be assumed that the laser is
not seeing the actual metal level due to
excessive smoke or secondary reflections
6 hmi_FillLimits.hmi_On As metal is filling the moulds, the mould L2 % 100 Off SP 60 ☐
level controller, control variable maximum
will be limited to this value
7 hmi_FillLimits.hmi_Off As metal is filling the moulds, the mould L2 % On SP 0 15 ☐
level controller, control variable minimum
will be limited to this value, this to ensure
that there is always fresh metal coming into
the mould
8 hmi_RunLimits.hmi_On When the mould has been filled and the L2 % 100 Off SP 80 ☐
cast has started, the level controller, control
variable maximum can be set to a normal
control level.
9 hmi_RunLimits.hmi_Off When the mould has been filled and the L2 % On SP 0 5 ☐
cast has started, the level controller, control
variable minimum can be set to a normal
control level.

Control Functions
1 hmi_Deselect The mould position can be de-selected or re-selected from the casting ☐
recipe, the switch control is put in to manual and then switched on or off
based on the data from the recipe
2 con_StartSP Once all the casting machine pre-cast checks are complete and the machine ☐
is ready to cast the mould level controlling setpoint is set to just above the
level at the bottom of the mould start block.
3 con_Process During filling the mould, the controller will start controlling when the metal ☐
Run level in the mould is above the start setpoint, the mould metal level control
process for that mould has started. This is only reset when the cast has
stopped.
4 con_Process This is set when any one of the selected moulds, mould metal level control ☐
Request process has started, this is to enable the setpoint for all the mould metal
level controllers to ramp together even if metal has not actually started fill
this mould yet.
5 con_Process This is set when the mould reaches a steady state after the initial fill and the ☐
Enable cast has started, at this point the pin actuator position limits are set to the
cast running limits
6 con_PVROC The mould metal controller monitors the Level transmitter rate of change, if 2 seconds ☐
this exceeds a set value then the controller is put to manual and the output
frozen for a set time
Control Functions (Fill)

1 con_StageFill The current stage in the mould fill section of the recipe is loaded into this ☐
Data data area
2 con_StageFill Apart from stage 0 each stage of the mould fill section of the recipe has a ☐
Data.Trigger trigger when the mould metal level setpoint reaches this value. The new fill
rate is set when this trigger is reached and the control process has been
requested and this is a new stage with none zero values. The current stage is
incremented.
3 con_StageFill When the cast is complete the current stage counter is set back to zero ☐
Current
Control Functions (Cast)

1 con_StageLevel The current stage in the mould level section of the recipe is loaded into this ☐
2 con_StageLevel Apart from stage 0 each stage of the mould level section of the recipe has a ☐
SPcontrol.Run trigger when the cast length reaches the trigger setpoint in the current
mould level section of the recipe. If the cast is running and there are none
Latch zero values in the recipe the current cast length and current mould level
setpoint are stored. The mould level control setpoint is now ramped from
the stored staring setpoint to the recipe target setpoint over the cast length
duration set in the recipe.
3 con_StageLevel When the mould level setpoint reaches the target setpoint of the current ☐
unlatch
4 con_SPEdit.On This allows the operator control of the mould level setpoint, it is off during ☐
the mould fill process and when running a stage from the mould metal level
recipe section.
Current
Alarms

1 alm_CalCheck During the pin actuator calibration sequence the pin is fitted Fault 0 Seconds ☐
and the actuator moves to its minimum position to check the
feedback also shows minimum
2 alm_SpoutReplace A spout will degrade over time allowing more metal through Warning 10 minutes ☐
as it does, if during the cast the pin actuator position is at
minimum for a period the alarm is set, the operator must
replace the spout before the next cast
3 alm_PinFroze The mould metal level is checked every second, if this level Fault 5 seconds ☐
remains constant or starts to drop and the pin actuator
position is at maximum for a period the alarm is set. The pin
is likely to have got stuck in the mould due to cold metal
temperature, this alarm will cause a semi-automatic abort. It
is possible with operator intervention to free the pin.
4 alm_PinFitHigh The mould metal level is checked every second, if this level Fault 5 seconds ☐
continues to rise and the pin actuator position is at minimum
for a period the alarm is set. The pin is likely to have been
fitted too high in the spout so no metal flow control is
possible, this alarm will cause an automatic abort.
LT_412x_TT Mould Metal Depth Transmitter Internal Temperature

Each mould position has two laser level transmitters, measuring the distance to the metal in the mould and to top of the launder, both
lasers are mounted in a single housing with the internal temperature being retransmitted back to the PLC.
Tag LT_412A_TT, LT_412B_TT, LT_412C_TT
Description Mould Metal Level Transmitter Internal Temperature
UDT OBJ_XT01
Range 0 to 100 ˚C
User Control
percentage of range
engineering units
3 hmi_data.UserHigh Transmitter user setpoint high, if the None ˚C 100 0 30 ☐
4 hmi_data.UserLow Transmitter user setpoint low, if the None ˚C 100 0 25 ☐
5 hmi_data.Control Transmitter user deviation setpoint for None ˚C/% 100% 0% 2.5% ☐
6 data.AlarmWarning Transmitter user deviation setpoint for None ˚C/% 100% 0% 5% ☐
7 hmi_data.AlarmFailure Transmitter user deviation setpoint for None ˚C/% 100% 0% 10% ☐
Control Functions

3 con_high Transmitter Process variable has deviated above the high setpoint plus the 60 seconds ☐
4 con_low Transmitter Process variable has deviated below the low setpoint minus the 60 seconds ☐
5 con_Delay Transmitter Process variable alarm delay, all alarms are delayed from being NA ☐
Alarms
2 alm_HighFailure Transmitter Process variable has deviated above the high Fault 10 minutes ☐
3 alm_HighWarning Transmitter Process variable has deviated above the high Warning 5 minutes ☐
4 alm_LowFailure Transmitter Process variable has deviated below the low Fault Not Used ☐
5 alm_LowWarning Transmitter Process variable has deviated below the low Warning Not Used ☐
LT_412x_A Mould Top Level Transmitter

Each mould position has one laser level transmitter measuring the distance to the top of the mould, this is a distance laser unit mounted in
combined laser housing along with the laser level transmitter that measures the metal level in the mould.
Tag LT_412A_A, LT_412B_A, LT_412C_A
Description Mould Top Level Transmitter
UDT OBJ_XT02
User Control
percentage of range
engineering units
3 hmi_data.UserHigh Transmitter user setpoint high, if the None mm NA NA NA ☐
4 hmi_data.UserLow Transmitter user setpoint low, if the None mm NA NA NA ☐
5 hmi_data.Control Transmitter user deviation setpoint for None mm/% 100% 0% NA ☐
6 data.AlarmWarning Transmitter user deviation setpoint for None mm/% 100% 0% NA ☐
7 hmi_data.AlarmFailure Transmitter user deviation setpoint for None mm/% 100% 0% NA ☐
Control Functions


3 con_high Transmitter Process variable has deviated above the high setpoint plus the NA ☐
4 con_low Transmitter Process variable has deviated below the low setpoint minus the NA ☐
Alarms
enabled
LT_412x_B Mould Metal Level Transmitter

Each mould position has one laser level transmitter measuring the distance to the metal in the mould, this is a distance laser unit mounted
in combined laser housing along with the laser level transmitter that measures the level to the top of the mould.
Tag LT_412A_B, LT_412B_B, LT_412C_B
Description Mould Metal Level Transmitter
UDT OBJ_XT02
User Control
percentage of range
engineering units
3 hmi_data.UserHigh Transmitter user setpoint high, if the None mm NA NA NA ☐
4 hmi_data.UserLow Transmitter user setpoint low, if the None mm NA NA NA ☐
5 hmi_data.Control Transmitter user deviation setpoint for None mm/% 100% 0% NA ☐
6 data.AlarmWarning Transmitter user deviation setpoint for None mm/% 100% 0% NA ☐
7 hmi_data.AlarmFailure Transmitter user deviation setpoint for None mm/% 100% 0% NA ☐
Control Functions


3 con_high Transmitter Process variable has deviated above the high setpoint plus the NA ☐
4 con_low Transmitter Process variable has deviated below the low setpoint minus the NA ☐
Alarms
enabled
LT_412x Mould Metal Depth Calculation

Each mould is fitted with a mould level transmitter, the transmitter has two transmitted level signals, one gives the distance to the top of
the mould which is fixed and the second gives the distance to the bottom of the mould or metal in the mould if casting.
As there are two lasers the difference between both levels will always be the level in the mould, if the distribution launder should distort
during a cast both laser levels will change by the same amount so the measured level will remain the same.
Tag LT_412A, LT_412B, LT_412C
Description Mould Metal Depth Calculation
UDT OBJ_XT00
Type Internally calculated value
Range -100 to 300 mm range
User Control
percentage of range
engineering units
3 hmi_data.UserHigh Transmitter user setpoint high, if the None mm ?? 0 Set ☐
transmitter has an operating band such as a from
tank level this will be the upper band limit PID
4 hmi_data.UserLow Transmitter user setpoint low, if the None mm ?? 0 Set ☐
transmitter has an operating band such as a from
tank level this will be the lower band limit High
5 hmi_data.Control Transmitter user deviation setpoint for L2 mm/% 100% 0% 2.5% ☐
6 data.AlarmWarning Transmitter user deviation setpoint for L2 mm/% 100% 0% 5% ☐
7 hmi_data.AlarmFailure Transmitter user deviation setpoint for L2 mm/% 100% 0% 10% ☐

Control Functions
1 Level calculation The mould metal depth is calculated from knowing the thickness of the ☐
mould and subtracting the difference between the two laser levels, i.e if the
mould thickness is 200mm and the distance to the top of the mould is
550mm and inside the mould is 700mm then mould depth is 200 –(600-
750)=50mm
2 plc_Dout.Enable Transmitters are Enabled when the distribution launder is in position and the ☐
compressed air has been enabled
4 con_high Once the metal level in each mould reaches the recipe set parameter the 2 seconds ☐
automatic cast start signal is set which will allow the platen to start
descending.
5 con_low At the end of the cast the holding furnace will tilt back so stopping feeding 1 seconds ☐
the launder with metal, the level in the whole launder system will start to
drop, the metal flowing into the moulds will reduce so the metal level in the
moulds will drop. When the metal level in any mould drops below the recipe
set parameter the automatic cast stop signal is set which will put the casting
machine into slow cool decent, cast speed is reduced, water flow is reduced,
the distribution launder is lifted.
Alarms
LC_412x Mould Metal Depth Controller

Metal Level PID loop uses the process variable metal level in the mould and will control to a setpoint, the control variable from the
controller will position an electrical actuator with a pin attached, which is regulating the metal flow through a spout in the distribution
launder.
Tag LC_412A, LC_412B, LC_412C,
Description Mould Metal Depth Controller
UDT OBJ_XC
Range Set to LT_412 range
User Control
3 hmi_data.SPMin Controller Minimum Setpoint L2 mm 200 0 0 ☐
4 hmi_data.SPMax Controller Maximum Setpoint L2 mm 200 0 200 ☐
5 hmi_data.SPuser Controller User Setpoint L0 mm max min NA ☐
6 hmi_data.CVuser Controller Output Variable User Setpoint Hand % 100 0 NA ☐

7 hmi_data.CVpre1 Controller Preposition Output 1, will be set L2 % 100 0 NA ☐

to fit Pin position
Fit pin position is the position the pin
actuator drives to during the pin actuator
calibration sequence to allow the operator
to fit the pin
8 hmi_data.CVpre2 Controller Preposition Output 2, will be set L2 % 100 0 NA ☐
to start pin position
Start pin position is the position the pin
actuator drives to at the end of the pin
actuator calibration sequence ready to
receive metal.
manually
start
Interlocks
0 LC_412X Mould Metal Depth Controller Faulted Not Active Available ☐
1 LC_412X Mould Metal Depth Controller in program mode Available ☐
2 LC_412X_PID Mould Metal Depth Controller Control variable Windup high alarm not active Running ☐
3 LC_412X_PID Mould Metal Depth Controller Control variable Windup low alarm not active Running ☐
4 LT_412X_A Mould Top Level Transmitter PLC input Module Healthy Available ☐
LT_412X_B Mould Metal Level Transmitter PLC input Module Healthy
5 LT_412X_A Mould Top Level Transmitter Input In Range Available ☐
LT_412X_B Mould Metal Level Transmitter Input In Range
6 ZV_412X Mould Metal Flow Pin Position Actuator Available Interlock Healthy Available ☐
7 LT_412X_A Mould Top Level Transmitter Healthy Signal Made Required ☐
LT_412X_B Mould Metal Level Transmitter Healthy Signal Made
8 ZV_412X Mould Metal Flow Pin Position Actuator Calibration Complete Required ☐
9 ZV_412X_ZSH Mould Metal Flow Pin Position Actuator Air Cylinder Spring Charged Required ☐
10 L_412X Mould Position Not Disabled Required ☐
11 LC_412X_PID Mould Metal Depth Controller Process variable Rate Of Change alarm not Running ☐
active
Control Functions
1 Healthy Mould Top Level Transmitter Input In Range ☐
Mould Metal Level Transmitter Input In Range
Mould Metal Depth Controller Process variable Rate Of Change alarm not
active.
4 PV Select The mould metal depth calculation is used all the time for the PV ☐
5 con.Control[0].0 Enable setpoint fil rate when the metal level control has been requested, the ☐
cast has not started and the current setpoint has not reached the start cast
level in the mould.

6 SP Select The setpoint can be set directly from the HMI or from the casting recipe, ☐
while a stage from the recipe is running the operator user setpoint is being
updated with the current setpoint.
If Setpoint Edit enable is on, the setpoint will be controlled from the HMI
Mould metal depth control process not running, the setpoint is fixed to start
setpoint, set from the position of mould starter block.
Mould metal depth has not reached the start cast metal depth, the setpoint
is controlled from the mould fill section in the casting recipe, the setpoint
will continue to increment until it reaches the Start cast Metal depth
Mould metal depth has reached the start cast metal depth for less than half
a second, the setpoint is set to the first target value from the metal depth
section of the casting recipe.
Mould metal depth has reached the start cast metal depth for set time, the
setpoint will be controlled from the metal depth section of the casting
recipe, when a stage has been triggered from the casting length
7 SP Edit Window When the mould metal depth setpoint control is being controlled from the ☐
user setpoint, the maximum and minimum setpoints are set to a window
around this setpoint so HMI control of the setpoint is only available within
set limits.
When the casting recipe is controlling the metal depth setpoint, the
maximum and minimum setpoints are set back to the original values
8 CV Select In the following conditions the control loop is set to manual control and the ☐
None Calibration mould metal depth control variable is set directly.
Sequence Manual control selected, control variable will be set from the HMI.
Mould position not selected, control variable will be set to minimum
Pre-cast Checks not started, control variable will be set to maximum
Mould Metal Flow Pin Position Actuator calibration sequence complete but
mould metal depth process not started, control variable will be set to pre-
position 2 (start cast position)
Mould metal depth process started, control variable will be frozen in current
position
9 CV Select In the following conditions the control loop is set to manual control and the ☐
Calibration mould metal depth control variable is set directly.
Sequence Mould metal flow pin position actuator calibration process not started,
control variable will be frozen in current position
Mould metal flow pin position actuator calibration move to minimum

running, control variable will be set to minimum.
Mould metal flow pin position actuator calibration move to maximum

running, control variable will be set to maximum.
Mould metal flow pin position actuator calibration move to pit pin running,
control variable will be set to pre-position 1 (fit pin position)
Mould metal flow pin position actuator calibration check minimum running,
control variable will be set to minimum.
11 CV Limits Mould metal flow pin position actuator calibration not complete, control ☐
variable limits are set to 0 to 100.

Mould metal depth control process not started, control variable limits are set
to Fill limits for maximum and minimum.
Mould metal depth control process started, control variable limits are set to
Run limits for maximum and minimum.
Alarms
ZV_412x Mould Metal Flow Pin Position Actuator

The mould metal fill is controlled with a vertical Pin Position Actuator which has 50mm of vertical movement.
Tag ZV_412A, ZV_412B, ZV_412C
Description Mould Metal Flow Pin Position Actuator
UDT OBJ_XV02
User Control
manually
start
Interlocks
0 ZV_412X Mould Metal Flow Pin Position Actuator Emergency Stop Healthy Available ☐
1 ZV_412X Mould Metal Flow Pin Position Actuator output command signal open circuit Available ☐
2 ZV_412X Mould Metal Flow Pin Position Actuator output command PLC module Available ☐
healthy
3 ZSL_412 Distribution Launder In Position Required ☐
4 L_412x Mould position selected for casting Required ☐
Control Functions
1 Enable The valve will automatically run from power on. ☐
Manual disabled, in the event of losing an interlock the process will switch to
manual control and the control variable is frozen in last known position.
5 plc_Dout.Enable Mould metal flow pin position actuator calibration sequence zero actuator, ☐
the output is to the actuator servo motor which will drive to its minimum
position regardless of what the command signal is set to.

6 con_CalPin.Enable Mould metal flow pin position actuator calibration sequence is complete for ☐
this mould position
7 plc_Ain.Scale. Mould metal flow pin position actuator calibration read minimum complete, ☐
con_ModuleZero set analogue zero value to current analogue reading to reset position
feedback to 0%
8 plc_Ain.Scale. Mould metal flow pin position actuator calibration read maximum complete, ☐
con_ModuleRange set analogue range value to current analogue reading to reset position
feedback to 100%
9
10
11
Alarms
4 alm_Safety_Out PLC Safety output to device has failed, single safe output with Fault Not Used ☐
ZV_412x_EY Mould Metal Level Flow Control Pin Position Actuator Electromagnet
Charged Control
The pin electrical actuator is connected to a electromagnet, for normal operation this electromagnet is energised fully raised, but during a
cast abort the pin electrical actuator can be lowered by de-energising the electromagnet and allowing gravity to lower the pin electrical
actuator, the pin will be lowered, stopping metal flow to the mould even if the electric actuator part of the pin position control is fully
raised.
Tag ZV_412A_EY, ZV_412B_EY, ZV_412C_EY
Description Mould Metal Level Flow Control Pin Position Actuator Electromagnet Charged
UDT OBJ_EY01
User Control
manually
start
Interlocks

0 ZV_412x_EV Mould Metal Flow Pin Position Actuator Electromagnet Charged Emergency Available ☐
Stop Healthy
1 ZV_412x_EV Mould Metal Flow Pin Position Actuator Electromagnet Charged PLC output Available ☐
Module Healthy
2 ZV_412x_EV Mould Metal Flow Pin Position Actuator Electromagnet Charged Safety Not used ☐
Status Healthy
3 ZV_412x_EV Mould Metal Flow Pin Position Actuator Electromagnet Failed to break alarm Available ☐
not active
4 C_105_ABORT Casting Machine Automatic Abort not active Required ☐
Control Functions
operation
operation
 Always active
 Always inactive
pushbuttons
set.
Alarms
1 alm_Make PLC Output to Electromagnet is made but PLC input from Warning 0.5 Seconds ☐
actuator position remains not made
2 alm_Break PLC Output to Electromagnet is not made but PLC input from Fault 0.5 Seconds ☐
actuator position remains made
4 alm_Safety_In PLC Safety input from the auxiliary contact has failed, two Fault Not used ☐
continuity
ZV_412x_TSH Mould Metal Flow Pin Position Actuator Over Temperature Switch
The pin actuator is fitted with a thermal switch which will indicate the actuator is overheating.
Tag ZV_412A_TSH, ZV_412B_TZSH, ZV_412C_TSH
Description Mould Metal Flow Pin Position Actuator Over Temperature Switch
UDT OBJ_XS01
User Control


1 NA ☐
Interlocks
1 ☐
Control Functions
1 ☐

1 alm_Make Thermal Switch PLC input from the auxiliary contact is not Fault 10 Seconds ☐
made
2 alm_Safety_In Thermal Switch PLC input has failed, two complementary safe Fault Not Used ☐
inputs with safety pulse to check continuity
EV_412x_A Mould Bag Shaker Solenoid Control

At the start of the cast and the end the filter bag in each mould will require shaking to initiate metal flow through it. The start and duration
Tag EV_412A_A, EV_412B_A, EV_412C_A
Description Mould Bag Shaker Solenoid
UDT OBJ_EV01
User Control
manually
start
Interlocks
0 EV_412X_A Mould Bag Shaker Solenoid Emergency Stop Healthy Available ☐
1 EV_412X_A Mould Bag Shaker Solenoid PLC output Module Healthy Available ☐
2 EV_412X_A Mould Bag Shaker Solenoid Safety Status Healthy Available ☐

Control Functions
operation
operation
 At the start of the cast the shaker is enable automatically for a
time, this time is set from the recipe
 Always active, expect during a cast and the cast length is greater
than a set threshold
 Device always unlatched
pushbuttons
set, the solenoid is pulsed to produce the shake.
Alarms
EV_412x_B Mould Laser Cooling Air Disable Solenoid Control

The mould metal level lasers are fitted with a vortex cooler, this cooling and be enabled or disabled depending on the temperature of the
laser via the cooling air disable solenoid.
Tag EV_412A_B, EV_412B_B, EV_412C_B
Description Mould Laser Cooling Air Disable Solenoid
UDT OBJ_EV01
User Control


manually
start
Interlocks
0 EV_412X_B Mould Laser Cooling Air Disable Solenoid Emergency Stop Healthy Available ☐
1 EV_412X_B Mould Laser Cooling Air Disable Solenoid PLC output Module Healthy Available ☐
2 EV_412X_B Mould Laser Cooling Air Disable Solenoid Safety Status Healthy Available ☐
Control Functions
operation
operation
 The cooling air to the laser is enabled during the start of pre-cast
checks and will remain running if the internal laser temperature
remain above the lower control setpoint.
 Always inactive
pushbuttons
set.
Alarms

PLC Programming
New HMI screens will be added to the existing touch screen operator interface.

PLC Program Structure

This section breaks down the structure of the PLC program and objects used within the program.
Various objects will be used to demonstrate the tag structures, the principles used in these examples are duplicated throughout the
program on all other objects.
The examples shown in this section are to demonstrate Mechatherm software design principles, to allow a user to navigate and
understand Mechatherm code.
The Routine/function structures follow the same structure so each Sub Group of each Object will have a section in the Object
Routine/Function. This table shows the sub sections for a basic object function:

Interlocks
The interlocks are split into three distinct groups.
Availability Interlocks are for the object itself, usually the first availability interlock will be the safety circuit being energised, then any
electrical supplies to the object and IO modules linked to the object IO.
The Required Interlocks are usually other objects which affect the operation of the object.
The Running Interlocks are usually other objects which must change state before running of the object is possible. For example, on the
door raise solenoid valve a Running Interlock is door clamps off, because the raise movement cannot happen until the door is unclamped.
Each Interlock is given a state which is “Off” when healthy, when all interlock states in one group are off then the Interlock Group
(Available, Required, Running) is energised.

Basic Control
The basic control section contains the start/stop functions of the object. Direct pushbutton controls will be used here; commands for
Auto/Manual control from the A/M Subsection are executed here.
The “con.Request” and “con.Enable” tags are used to request or enable other object functions before this functions object can run.
A starting timer will monitor the object output or feedback to determine when the object can be considered “Running”, at which point the
“con.Run” tag will energise

Auto/Manual
This section switches the object enable between automatic and manual control. When “am_Select” Enable is energised the object is in
Manual control, when “am_Select” Enable is de-energised the object is in Automatic control.
Other running processes or object positions may inhibit the change of object operating mode. For example a valve operating mode might
need to be in automatic when certain motors are running.
The Select PB can only be enabled if the conditions of the SUB_SW are met. A SecLevel tag in the SUB_SW is used to restrict access to the
HMI/SCADA PB. Only users with the correct security access can switch to manual operation. For example if the “Off” PB is unrestricted so
any user can switch to auto, but the “On” PB might require a level 2 access to switch to manual.
The “am_Run” On follows the same principle, the PB operation is restricted in SUB_PB so that Manual must be enabled before the object
can be started or stopped from the HMI/SCADA.

Alarms
This section shows three different alarms for a typical solenoid valve with limit switch to confirm position.
Example 1 - The first alarm with the relevant IO Modules healthy (“EVH_360A".plc_Dout.Int, “ZSL_360A".plc_Dout.Int), if the lowered limit
("ZSL_360A".plc_Din.On) stays on when the raise solenoid ("EVH_360A".plc_Dout.Enable) is energised then the alarm timer will activate. If
the flag is on for more than the monitoring time (Preset = 5S) then the fail alarm ("EVH_360A".alm_Fail.On) will activate and trigger an
alarm in the alarm handling routine C_102.
Example 2 – This is a positional alarm and will only activate if the solenoid alarm alm_Fail.On is not already active. With the relevant IO
Module healthy (“EVH_360A".plc_Dout.Com), if the raised limit ("ZSH_360A".plc_Din.On) fails to energise when the raise solenoid
("EVH_360A".plc_Dout.Enable) is energised then the alarm timer will activate. If the flag is on for more than the monitoring time (Preset =
30S) then the failed to make alarm ("ZSH_360A".alm_Make.On) will activate and trigger an alarm in the alarm handling routine C_102.

Example 3 – This is a positional alarm monitoring for the valve Raise limit ("ZSH_360A".plc_Din.On) to go off. If the Raise limit and the
Lower limit ("ZSL_360A".plc_Din.On) are on at the same time, then the Raise limit failed to break alarm ("ZSH_360A".alm_Break.On) will
energise and trigger an alarm in the alarm handling routine C_102. No timers are used for this alarm, it is instantaneous.

HMI EV/ZS Status

The HMI Status for each object is split into five status flags #Com, #Fault, #Warn, #Avail, #Run. These flags are then used in the SUB_Status
subroutine to derive the status number for the HMI status display.
#Com is energised when the objects associated IO Modules are healthy; this means that Communication is healthy. #Fault is energised
when no faults are present for the object; it indicates that the objects fault state is healthy. #Warn is energised when no Warnings are
present for the object; it indicates that the objects fault state is healthy. #Avail is energised when the Availability Interlock is on and the
object is in automatic control. #Run is energised when the object is in a running/enabled/energised state.
The
status of these five flags is analysed in the SUB_STATUS and an integer “hmi_Status” is generated with the following characteristics:
0 = Object not running, object available for automatic control (HMI Status Colour = Display Background)
1 = Object running in automatic, object available for automatic control (HMI Status Colour = Green)
2 = Object not running, object not available for automatic due to interlocks or manual mode selected (HMI Status Colour = Yellow)
3 = Object running, object not available for automatic due to interlocks or manual mode selected (HMI Status Colour = Flashing Yellow)
4 = Object not running, object warning present (HMI Status Colour = Cyan)
5 = Object running, object warning present (HMI Status Colour = Flashing Cyan)
6 = Object not running, object fault present (HMI Status Colour = Red)
7 = Object running, object fault present (HMI Status Colour = Flashing Red)
8 = Object not running, object communication failure present (HMI Status Colour = White)
9 = Object running, object fault present (HMI Status Colour = Flashing White)

HMI Loop Status

The HMI Status for each Loop follows the same principles as for an object, the only difference is that it checks all objects for the loop
number and summarises the state of the loop, this is used on the HMI/SCADA overview screens in place of multiple objects, to prevent
screens from appearing too complicated.
The HMI Status for each loop is split into five status flags #Com, #Fault, #Warn, #Avail, #Run. These flags are then used in the SUB_Status
subroutine to derive the status number for the HMI status display. #Com is energised when the loop objects associated IO Modules are
healthy; this means that Communication is healthy.
#Fault is energised when No faults are present for any loop object, it indicates that the loops fault state is healthy.
#Warn is energised when No Warnings are present for any loop object, it indicates that the loops fault state is healthy. #Avail is energised
when all objects in the loop are available for automatic control. #Run is energised when all loop objects are in a
running/enabled/energised state.

46381-1003 CFDS Caster R00

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ARCONIC Kunshan China

Document Number 46381-1003 Rev 00 Page 2 of 151

SAFETY CONTROL ..................................................................................... 7

C_100 POWER AND SAFETY SYSTEM GROUP MONITOR .................................... 8

OPERATOR CONTROL .............................................................................. 13

C_105 CASTING MACHINE OPERATOR CONTROL ................................................ 14

C_412 MOULD METAL LEVEL GROUP FUNCTIONS .............................................. 29

LAUNDER AND FURNACE EQUIPMENT CONTROL ..................................... 34

Z_317C CASTING LAUNDER DAM GROUP ..................................................... 35

Z_317E CFF LAUNDER DAM GROUP ........................................................... 40

Z_317D DRAIN LAUNDER DAM GROUP ........................................................ 45

L_361 LAUNDER METAL LEVEL CONTROL GROUP ......................................... 50

Z_361 FURNACE TILT GROUP .................................................................. 57

Document Number 46381-1003 Rev 00 Page 3 of 151

VV_361 FURNACE TILT HOLD VIRTUAL OUTPUT ................................................................................. 57

MOULD WATER EQUIPMENT CONTROL ................................................... 62

F_230 MOULD WATER FLOW CONTROL GROUP ........................................... 63

M 044 STEAM EXTRACTION FAN MOTOR GROUP .......................................... 71

M 051 CASTING PIT LIFT PUMP MOTOR GROUP .......................................... 74

L_240 CASTING PIT WATER LEVEL CONTROL GROUP ................................... 77

PLATEN EQUIPMENT CONTROL ............................................................... 79

F_310 CAST SPEED CONTROL GROUP........................................................ 80

M 310_A PLATEN DRIVE COOLING AIR FAN MOTOR GROUP .............................. 87

M 310_B PLATEN DRIVE BRAKE MOTOR GROUP ............................................. 90

Z 310 PLATEN POSITION GROUP ............................................................. 93

Document Number 46381-1003 Rev 00 Page 4 of 151

MECHANICAL EQUIPMENT CONTROL .................................................... 102

M 011 MAIN HYDRAULIC OIL PUMP MOTOR GROUP ................................... 103

C_250 HYDRAULIC POWER PACK GROUP ................................................. 106

CASTING LAUNDER PRE-HEAT EQUIPMENT CONTROL .......................... 113

H 063X LAUNDER HEATER GROUP ........................................................... 120

H 412X SPOUT HEATER GROUP ............................................................... 124

MOULD METAL LEVEL CONTROL EQUIPMENT OPERATION .................... 127

L_412X MOULD METAL LEVEL CONTROL GROUP .......................................... 128

Document Number 46381-1003 Rev 00 Page 5 of 151

PLC PROGRAMMING ............................................................................. 143

PLC PROGRAM STRUCTURE ......................................................................... 144

Document Number 46381-1003 Rev 00 Page 6 of 151

Document Number 46381-1003 Rev 00 Page 7 of 151

C_100 Power and Safety System Group Monitor

EY_100A Casting Machine Safety Supply Relay

Document Number 46381-1003 Rev 00 Page 8 of 151

2 "EPB_100B_A".plc_Din.On Emergency Stop Pushbutton Main Panel (CP100) Available ☐

Document Number 46381-1003 Rev 00 Page 9 of 151

UPS_100 UPS Control Supply

EY_100C_A Control Supply On Relay

Alarms, Failures and Warnings

Document Number 46381-1003 Rev 00 Page 10 of 151

TAG Description Type Settings SAT

EY_100D PLC Watchdog Pulsed Output Relay

Document Number 46381-1003 Rev 00 Page 11 of 151

 Output is driven from the PLC clock 2 second pulse

Document Number 46381-1003 Rev 00 Page 12 of 151

Document Number 46381-1003 Rev 00 Page 13 of 151

C_105 Casting machine operator control

Document Number 46381-1003 Rev 00 Page 14 of 151

Pre Cast Mode

Post Cast Mode

C_105_MODE Cast Mode Control

Document Number 46381-1003 Rev 00 Page 15 of 151

Document Number 46381-1003 Rev 00 Page 16 of 151

3 con_cast Casting machine cast start control ☐

C_105_PREM Cast Permissive Control