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OPERATION & MAINTENANCE MANUAL FOR WEIGH FEEDER
OPERATION & MAINTENANCE MANUAL FOR WEIGH FEEDER
FLSmidth Pfister India Ltd.
FPIL JOB NO : 90.1291 CUSTOMER : SAIL-ROURKELA STEEL PLANT EQPT : WEIGH FEEDER (WF) TABLE OF CONTENTS DESCRIPTION
SR. NO. 1.0 2.0 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9
PAGE NO.
OPERATION & MAINTENANCE MANUAL FOR TUC-6 CONTROLLER MECHANICAL DATA. ASSEMBLY & STARTUP INSTRUCTION. MAINTENANCE INSTRUCTION. LUBRICATION CHART. TESTING / ADJUSTING MANUAL. ERECTION INSTRUCTION MANUAL. SAFETY & STORAGE MANUAL. OPERATION & MAINTENACE MANUAL FOR AC MOTOR. INSTALLATION & MAINTENANCE MANUAL FOR GEAR BOX. OPERATION & MAINTENACE MANUAL FOR VIBRATORY MOTOR
100
01 10 04 02 04 02 20 21 62
3.0 3.1 3.2 3.3
TECHNICAL DATA. TACHOMETER TECHNICAL LITERATURE. LOADCELL SPECIFICATION WF. DATA SHEET
01 03 01
4.0
ELECTRICAL DRAWING
53
5.0
MECHANICAL GAD
01
6.0
INVERTER MANUAL FOR ACS 550
322
FLSmidth Pfister India Ltd.
TUC 6 OPERATION & MAINTENANCE MANUAL
TUC 6 OPERATION & MAINTENANCE MANUAL
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL - INDEX Weigh Feeder with TUC-6CAN Electronics Page 1 of 1
1.0
Technical data............................................……………………………………10 TUC6CAN-010-EE23.0-R0
2.0
Functional Description....................................……………………………… 06 TUC6CAN-010-EE23.1-R0
3.0
Operator's Manual.........................................…………………………………12 TUC6CAN-010-EE23.2-R0
4.0
Commissioning Instructions................................………………………….. 26 TUC6CAN-010-EE23.3-R1
5.0
Menu Operations...........................................…………………………………11 TUC6CAN-010-EE23.4-R1
6.0
Parameter Listing.........................................………………………………….06 TUC6CAN-010-EE23.5-R1
7.0
PLC Program...............................................…………………………………..16 TUC6CAN-010-EE23.6-R0
8.0
Appliance Description.....................................……………………………… 12 TUC6CAN-010-EE23.10-R0
9.0
Front Facia Layout........................................…………………………………01 TUC6CAN-010-EE25-R0
Software_version: 4.1 (onwards) 2010-11-29
TECHNICAL DATA Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.0-R0 1.0
System
1.1 1.2
Microprocessor Memory
2.0
Construction
2.1
Housing
2.2 2.3 2.4 2.5 2.6
Page 1 of 10
: :
8xC51FA 64K EPROM 16K Data EEPROM 32K RAM with integral Battery Backup.
Colour Dimensions (W*H*D) Control cutout Control thickness Mounting space
: : : : : : :
2.7
Wall clearance
:
2.8 2.9 2.10
Weight Mounting Protection type
: : :
Aluminum enclosure in DIN format Silver anodized 144 * 72 * 245 mm 138 * 68 mm Min. 1 mm, max. 15 mm Approx. 300 mm deep with connectors Min. 100 mm upwards. Min. 60 mm on each side with natural convection Approx. 1.0 Kg 2 Grub screws at the sides IP 54 (Front)
3.0
Display
3.1
Display
:
3.2 3.3 3.4 3.5 3.6
Colour Type Digit height Reading angle Dimension sign
: : : : :
4.0
Control
4.1
Type
Software_version: 2.0 (onwards) 2008-05-17
:
2 lines * 16 Characters Vacuum Fluorescent Display Blue VFD, alphanumeric 5.5 mm legible to approx. 2 m Approx. 40 °. kg, t ( selectable)
Membrane foil with pressure sensitive keyboard.
TECHNICAL DATA Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.0-R0 5.0
Environment
5.1 5.2 5.3
Operating temperature Storage temperature Humidity
6.0
Measurement Input - Loadcell
6.1 6.2 6.3
Page 2 of 10
: : :
0 ° C to +55 ° C -20 ° C to +85 ° C Max 85 % relative, without condensation
Terminal Measurement input range Supply voltage
: : :
6.4
Measuring cable
:
9 pole, DB connector 0 to 28 mV Internal 12 V ± 5 %, Max. 110mA (e.g. 3 loadcells of 350 ohms in parallel) 6 core, shielded (min. 80% optical cover) Isolation resistance min.120 Mohm/Km Core cross-section min. 0.34 mm² to 0.5 mm² solderable directly to connector. Cable diameter up to 8mm mountable in connector. Connect greater cross-sections with solderable connectors.
6.5
Cable length
:
l = 5.1 * R * A / n R = Loadcell resistance in ohm A = Cable cross-section in mm² n = no. of loadcells in parallel l = Cable length , max. 1000 m
7.0
Measurement Input - Tacho
7.1
Terminal
:
7.2 7.3 7.4 7.5
Input signal Measurement input range Supply voltage Measuring cable
: : : :
Software_version: 2.0 (onwards) 2008-05-17
Screw clamped terminals. Conductor size 0.14 to 1.5 mm2. Max. 15 V 10 - 2500 Hz, 12 V Internal 12 V ± 5 %; max. 10 mA 3 core, shielded (min. 80%
TECHNICAL DATA Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.0-R0
Page 3 of 10
7.6
Cable length
8.0
Digital Outputs
8.1
Output type
:
8.2
Terminal
:
8.3
Functions
:
9.0
Power supply
9.1
Terminal
:
9.2 9.3
Voltage Power consumption
: :
10.0
Analog output
10.1
Function
Software_version: 2.0 (onwards) 2008-05-17
:
:
optical cover) Isolation resistance min.120 Mohm/Km Core cross-section min. 0.34 mm² to 1.5 mm2. Max. 1000 m
4 Nos. Relay s, 220Vac, 2 Amp rating Screw clamped terminals Conductor size from 0.5 to 1.5 mm2 2 Nos. outputs can be assigned as totaliser outputs. Non-assigned outputs can be used in SPSS program for any desired function.
Screw clamped terminals Conductor size 0.14 to 1.5 mm2. 18-36 Vdc 12 VA max.
0 -20 mA / 4-20 mA isolated o/p corresponding to any of the following functions, -Actual feedrate -Belt Load -Belt Speed -Weigh Feeder drive setpoint -Pre-feeder drive setpoint -Current setpoint -Pre-Hopper Level -Control measurement error
TECHNICAL DATA Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.0-R0
Page 4 of 10
10.2 10.3 10.4
Isolation type Load Terminal
: : :
10.5
Cable type
:
11.0
Impulse outputs
11.1
Function
:
11.2
Terminal
:
12.0
RS-485 Interface (X2)
12.1 12.2
Terminal Transmission
: :
12.3 12.4 12.5
Baud rate Format Cable type
: :
12.6
Function
:
13.0
RS-485 Interface (X4)
13.1 13.2
Terminal Transmission
: :
13.3 13.4
Baud rate Format
:
13.5
Cable type
:
Software_version: 2.0 (onwards) 2008-05-17
Galvanic 500 Ohm Screw clamped terminals Conductor size 0.14 to 1.5 mm2. 2 core ,shielded. Individual core connectable directly to connector.
2 relay outputs corresponding to either Totaliser1 or Totaliser2. 50mSec to 500mSec programmable ON time pulses Screw clamped terminals Conductor size 0.14 to 1.5 mm2.
5 pole DIN socket Half duplex, serial bit, asynchronous mode 19200 baud 8 bite, 1 stop, No Parity 2 core ,shielded ,max 0.5 mm2 individual core connectable directly to connector. Used to interface I/O cards to TUC-6 unit.
9 pole, DB connector Half duplex, serial bit, asynchronous mode 4800,9600,19200 baud 8 bits, 1 stop bit, None, Even or Odd Parity 2 core ,shielded ,max 0.5 mm2 individual core connectable
TECHNICAL DATA Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.0-R0
13.5
Function
14.0
Profibus-DP Interface (X4)
14.1 14.2 14.3 14.4
Terminal Transmission mode Baud rate Station Address
15.0
CANBUS Interface (X7)
15.1 15.2 15.3
Terminal Baud rate Cable Type
Page 5 of 10
:
directly to connector. Modbus-RTU
: : : :
9 pole, DB connector RS 485 9600 bps to 12 Mbps max 01 to 99
: : :
5 pole, DIN socket 10 kbps to 1 Mbps max Circular cable, 2x2 core, twisted pair, plus total shield, max 0.56mm2 connectable directly. to connector.
8 Nos, opto-coupled, 24 Vdc positive logic, max. 5 mA. 8 Nos. Relay s, 220Vac, 2 Amp rating Screw less Terminals. Conductor size from 0.5 to 1.5 mm2. Inputs/Outputs can be assigned any desired function through SPSS program. 2 Nos maximum
Optional Interface Modules 16.0
Digital I/O Interface Card (F-866)
16.1
Input type
:
16.2
Output type
:
16.3
Terminal
:
16.4
Functions
:
16.5
Max. cards ed
:
17.0
Digital I/O Interface Card (F-889/F-890)
17.1
Input type
:
17.2
Output type
:
Software_version: 2.0 (onwards) 2008-05-17
8 Nos, opto-coupled, 24 Vdc positive logic, max. 5 mA. 8 Nos. Relay s, 220Vac,
TECHNICAL DATA Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.0-R0
Page 6 of 10
17.3
Terminal
:
17.4
Functions
:
17.5
Max. cards ed
:
18.0
Analog I/O Interface Card (F- 868 card)
18.1
Input Type
:
18.2
Output Type
:
18.3 18.4
Isolation type Load - Input
: :
18.5 18.6
Load - Output Terminal
: :
18.7
Cable type
:
18.8
Max. cards ed
:
Software_version: 2.0 (onwards) 2008-05-17
2 Amp rating Screw less Terminals. Conductor size from 0.5 to 1.5 mm2. Inputs/Outputs can be assigned any desired function through SPSS program. 1 No. F889 card along with 1 No. F890 card
2 Channels. 0/4-20 mA/0-10 V isolated Inputs corresponding to, -Feeder Setpoint. -Gate Position for Flow Control Gates 1 Channel 0/4-20 mA isolated output corresponding to any of the following functions, -Actual feedrate -Belt Load -Belt Speed -Weigh Feeder drive setpoint -Pre-feeder drive setpoint -Current setpoint -Pre-Hopper Level -Control measurement error Optical. 4 - 20 mA - 100 Ohm 0 -10 V < 1 mA 4 - 20 mA - 500 Ohm (max.) Screw less terminations Conductor size 0.14 to 1.5 mm2. 2 core ,shielded. Individual core connectable directly to connector. Max. 3 cards can be interfaced
TECHNICAL DATA Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.0-R0
Page 7 of 10 to TUC-6 unit.
19.0
Analog I/O Interface Card (F- 875 card)
19.1
Input Type
:
19.2
Output Type
:
19.3 19.4
Isolation type Load - Input
: :
19.5 19.6
Load - Output Terminal
: :
19.7
Cable type
:
19.8
Max. cards ed
:
2 Channels. 0/4-20 mA/0-10 V isolated Inputs corresponding to, -Feeder Setpoint. -Gate Position for Flow Control Gates 2 Channels 0/4-20 mA isolated output corresponding to any of the following functions, -Actual feedrate -Belt Load -Belt Speed -Weigh Feeder drive setpoint -Pre-feeder drive setpoint -Current setpoint -Pre-Hopper Level -Control measurement error Optical. 4 - 20 mA - 100 Ohm 0 -10 V < 1 mA 4 - 20 mA - 500 Ohm (max.) Screw less terminations Conductor size 0.14 to 1.5 mm2. 2 core ,shielded. Individual core connectable directly to connector. Max. 2 cards can be interfaced to TUC-6 unit.
20.0 Field Interface Module (F- 892) 20.1
Power supply (X1) 20.1.1
Terminal
Software_version: 2.0 (onwards) 2008-05-17
:
Screw clamped terminals
TECHNICAL DATA Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.0-R0
20.1.2 20.1.3 20.2
20.3
20.4
Voltage Power consumption
Page 8 of 10
: :
Conductor size 0.14 to 1.5 mm2. 18-36 Vdc 12 VA max.
Measurement Inputs – Loadcell (X10, X11) 20.2.1 Terminal 20.2.2 Measurement input range 20.2.3 Supply voltage
: : :
20.2.4 Measuring cable
:
9 pole, DB connector 0 to 28 mV Internal 12 V ± 5 %, Max. 110mA (e.g. 3 loadcells of 350 ohms in parallel) 6 core, shielded (min. 80% optical cover) Isolation resistance min.120 Mohm/Km Core cross-section min. 0.34 mm² to 0.5 mm² solderable directly to connector. Cable diameter upto 8mm mountable in connector. Connect greater cross-sections with solderable connectors.
Measurement Inputs – Tacho (X9) - 2 Nos 20.3.1 Terminal
:
20.3.2 20.3.3 20.3.4 20.3.5
Input signal Measurement input range Supply voltage Measuring cable
: : : :
20.3.6
Cable length
:
Screw clamped terminals. Conductor size 0.14 to 1.5 mm2. Max. 15 V 10 - 2500 Hz, 12 V Internal 12 V ± 5 %; max. 10 mA 3 core, shielded (min. 80% optical cover) Isolation resistance min.120 Mohm/Km Core cross-section min. 0.34 mm² to 1.5 mm2. Max. 1000 m
:
0-20mA/ 4-20mA/ 0-10V input
Anaputs (X9) -2 Nos 20.4.1
Input Type
Software_version: 2.0 (onwards) 2008-05-17
TECHNICAL DATA Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.0-R0
20.5
20.4.2
Terminal
:
20.4.3
Cable Type
:
20.7
corresponding to setpoint Screw clamped terminals Conductor size 0.14 to 1.5mm2. 2 core shielded. Individual core connectable directly to connector.
Analog outputs (X8) -2 Nos 20.5.1
20.6
Page 9 of 10
Function
:
20.5.2 Isolation type 20.5.3 Load 20.5.4 Terminal
: : :
20.5.5 Cable type
:
0/4-20 mA isolated o/p corresponding to any of the following functions, -Actual feedrate -Belt Load -Belt Speed -Weigh Feeder drive setpoint -Pre-feeder drive setpoint -Current setpoint -Pre-Hopper Level -Control measurement error Optical 500 Ohm Screw clamped terminals Conductor size 0.14 to 1.5 mm2. 2 core ,shielded. Individual core connectable directly to connector.
Digital Inputs (X3) -12 Nos 20.6.1 Input Type 20.6.2 Terminal
: :
20.6.3 Function
:
12 Nos, opto-coupled 24Vdc Screw clamped terminal Conductor size 0.5 to 1.5mm2. Inputs can be assigned any desired function through SPSS program.
Digital Outputs (X2) -8 Nos 20.7.1
Output Type
Software_version: 2.0 (onwards) 2008-05-17
:
8 Nos, opto-coupled, 24Vdc, 250 mA max load
TECHNICAL DATA Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.0-R0
20.8
20.9
Page 10 of 10
20.7.2 Terminal
:
20.7.3 Function
:
Screw clamped terminal Conductor size 0.5 to 1.5mm2. Outputs can be assigned any desired function through SPSS program.
RS-485 Interface (X4) 20.8.1 Terminal 20.8.2 Transmission
: :
20.8.3 Baud rate 20.8.4 Format 20.8.5 Cable type
: :
20.8.6 Function
:
9 pole, DB connector Half duplex, serial bit, asynchronous mode 19200 baud 8 byte, 1 stop, No Parity 2 core ,shielded ,max 0.5 mm2 individual core connectable directly to connector. Modbus-RTU, can be used to Interface to local display
RS-485 Interface (X5) 20.9.1 Terminal 20.9.2 Transmission
: :
20.9.3 Baud rate 20.9.4 Format
:
20.9.5 Cable type
:
20.9.6 Function
:
9 pole, DB connector Half duplex, serial bit, asynchronous mode 9600 to 19200 baud 8 bits, 1 stop bit, None, Even or Odd Parity options 2 core, shielded, max 0.5 mm2 individual core connectable directly to connector. Modbus-RTU
20.10 CANBUS Interface (X6) 20.10.1 Terminal 20.10.2 Baud rate 20.10.3 Cable Type
Software_version: 2.0 (onwards) 2008-05-17
: : :
9 pole, DB connector 10 kbps to 1Mbps max. Circular cable, 2x2 core, twisted pair, plus total shield, max 0.56mm2 connectable directly to connector.
FUNCTIONAL DESCRIPTION Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.1-R0
Page 1 of 6
TABLE OF CONTENTS 1.0
Principle.................................................………………………………………... 2 1.1 TUC-6 Weigh Feeder system, Overview..................……………………. 2 1.2 System Features......................................………………………………... .. 2
2.0
Functions.................................................………………………………………. 3 2.1 Modes of operation...................................…………………………………. 3 -Interlock - Gravimetric Mode.......................………………………………. 3 -Interlock - Volumetric Mode.........................……………………………….3 -De-Interlock - Gravimetric Mode.....................……………………………. 3 -De-Interlock - Volumetric Mode......................……………………………. 3 -Local Mode..........................................……………………………………..3 2.2 Belt off-track monitoring............................…………………………………. 4 2.3 Zero Setting.........................................……………………………………... 4 2.4 Linearization of belt load...........................…………………………………. 4 2.5 Programmable Scale Control...........................……………………………. 4 2.6 Error Messages.......................................…………………………………... 4 2.7 Scale types..........................................……………………………………... 4 2.7.1 Directly extracting Weigh Feeder................………………………… 4 2.7.2 Weigh Feeder with pre-feed regulation...........……………………… 4 2.7.3 Flow metering device............................………………………………5 2.7.4 Batch operation.................................………………………………… 5 2.7.5 Control Measuring…............................……………………………… 5 2.7.6 Measuring Mode…............................…………………………………5
3.0
Interfaces................................................……………………………………….. 6 3.1 Computer Interface...............................…………………………………….. 6 3.2 Modbus Interface...............................………………………………………. 6 3.3 Canbus Interface...............................………………………………………. 6 3.4 Pulse outputs........................................……………………………………. 6 3.5 Analog outputs.......................................…………………………………… 6 3.6 Digital I/O..........................................……………………………………….. 6
Software_version: 2.0 (onwards) 2008-11-15
FUNCTIONAL DESCRIPTION Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.1-R0
1.0
Page 2 of 6
Principle
The Weigh Feeder consists of a conveyor belt whose material load is continuously weighed with a measuring device. The mass flow is calculated from the product of Belt Load (Loadcell value) and belt speed (Tacho frequency). The amount of material being conveyed is controlled by controlling the belt speed. This is done by generating the setpoint and control signals to control a suitable drive controller. Belt speed is monitored to ensure that the required speed is being achieved by the drive controller. In addition to controlling the material flowrate, the system can also control a Pre-feeder to control the material bed-height 1.1
TUC-6 Weigh Feeder System, Overview:
The unit is operated using the TUC-6 keypad and the 2 line * 16 digit VFD display. The display values are called using fixed keys or displayed through pull-down selection. The Configuration of the system is determined by the parameter values. To do this, a selection is made from the fixed values in the configuration menus or a parameter is entered using the front keypad. 1.2
System Features
- Fail safe EEPROM memory for configuration parameters - Battery buffered RAM for working data - Date/Time in battery buffered Real Time Clock - Integrated keyboard and display - Data memory even with replacement of interface cards - Up to 36 inputs / 28 outputs - 2 Impulse outputs - Analog to Digital and Digital to Analog signal interfaces - Auto-Calibration - Curve correction - Zero correction - Inbuilt PLC for easy adaptation to different control schemes - Alphanumeric Text displays for Fault diagnosis
Software_version: 2.0 (onwards) 2008-11-15
FUNCTIONAL DESCRIPTION Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.1-R0
2.0
Functions
2.1
Modes of operation
Page 3 of 6
The system can operate in any one of the following 5 modes, i)
Interlock - Gravimetric Mode
In this mode, the system operates through External setpoint in the form of analog 4-20 mA signal or setpoint through the serial interface. Start/Stop to the system is either through external digital Inputs or through the serial Interface. ii)
Interlock - Volumetric Mode
In this mode, the system operation is un-regulated (Volumetric). Setpoint in this mode is from an external 4-20 mA signal and Start/Stop to the system is through external digital Inputs. iii)
De-Interlock - Gravimetric mode.
In this mode, the system operates through setpoint entered through the TUC keypad. System Start/Stop is through the keys provided on the keypad. iv)
De- Interlock - Volumetric mode.
In this mode, the system operation is un-regulated (Volumetric). Setpoint and Start/Stop is from the TUC keypad. v)
Local Mode.
In this mode, Setpoint & Start/Stop commands to the system are from the Local Control station. In this mode, system operation is un-regulated (Volumetric) i.e. the setpoint from the Local control station directly varies the belt speed.
Software_version: 2.0 (onwards) 2008-11-15
FUNCTIONAL DESCRIPTION Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.1-R0 2.2
Page 4 of 6
Belt off-track monitoring
Off-track running of the belt can be monitored via an external signal from the Belt tracking sensors to the control unit. 2.3
Zero setting
Belt related influences on the belt load can be compensated by means of zero correction. To do this, the correction process is started with the belt running idle. The zero correction value, with which the belt load is set off, is calculated automatically after the zero correction process. The zero correction is initiated from the front keypad. 2.4
Linearization of belt load
If the load on the measuring cell is not linear in the whole range, the load can be laniaries by entering up to ten correction points. 2.5
Programmable Scale Control
To achieve optimum adjustment of the dosing control as per the customer's requirements, a PLC is built into the Controller. This enables digital signals within the control unit and to the process to be freely defined. Standard PLC programs are implemented internally for standard configurations. These may be called directly and used or modified to suit diverse application needs. 2.6
Error Messages
Faults/Errors caused by incorrect operations are displayed in clear text in the control display. Faults are also made available at the output in the form of potential free s. 2.7
Scale types
2.7.1 Directly extracting weigh feeder Material is extracted directly from a hopper, without a pre-feeding device. 2.7.2 Weigh Feeder with pre-feed regulation
Software_version: 2.0 (onwards) 2008-11-15
FUNCTIONAL DESCRIPTION Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.1-R0
Page 5 of 6
As a result of variation of belt speed, required for output regulation, a varying bed-height of material may occur on the conveyor belt. If a constant bed-height of material is required or in the event of unfavorable material properties which do not permit direct extraction, pre-feed regulation is necessary. For this purpose, an output setpoint can be generated to control a pre-feed device. This output value is coupled to the flow regulator i.e. changes in flow setpoint automatically adjusts the pre-feed device. 2.7.3 Flow metering device With flow metering devices no speed tachometer is available. Regulation of mass flow is realized by regulation of material load. In this mode, system operation is with fixed internal tachometer. 2.7.4 Batch operation By specifying a target quantity, it is possible to proportion individual batches. In this mode, proportioning is done as per the prescribed setpoint. After the target quantity of material has been conveyed, an alarm or automatic belt stop command can be generated. 2.7.5 Control measuring If a hopper with a measuring device is present on the weigh feeder, it is possible to perform control measuring. In this case, the material volume removed from the hopper within a defined period of time is compared with the volume of material which the weigh feeder has recorded for the corresponding period. In the event of a difference, a correction value is calculated, which is taken into when measuring the belt loading. Thus, it is possible to compensate zero point fluctuations, which may have occurred during operation. 2.7.6 Measuring Mode It is possible to by feed regulation and operate the unit only in measuring mode, for equipments like Belt Weighers.
Software_version: 2.0 (onwards) 2008-11-15
FUNCTIONAL DESCRIPTION Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.1-R0 3.0 3.1
Page 6 of 6
Interfaces Computer Interface
It is possible to enable remote monitoring and control of the system, by connecting the unit to a master controller through the serial interface. Modbus RTU and Profibus protocol options are ed through use of optional modules. 3.2
Modbus Interface
The controller can be directly connected to PLC through this MODBUS interface. It is possible to enable remote monitoring and control through this interface.
3.3
CAN bus Interface
The controller can communicate to the Field Interface Module (FIM) through CAN protocol. Data collected locally at the field can be communicated to the controller through a single cable. 3.4
Pulse Output
Two pulse outputs are available from the system corresponding to the quantity being conveyed. The resolution & pulse width of the Totaliser pulses are configurable. 3.5
Analog outputs
Analog outputs are available for display and/or measurement tasks. Up to 4 analog current outputs can be generated from the system. Each individual output can be selected to various measurement/control variables, such as Feeder setpoint, Pre-feeder setpoint, Material Feedrate, Belt loading, Belt Speed. 3.6
Digital I/O
A maximum of 36 inputs and 28 outputs are available for controlling the weigh feeder and other plant interlocks. Outputs are available corresponding to various status and fault conditions in the system.
Software_version: 2.0 (onwards) 2008-11-15
OPERATOR’S MANUAL Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.2-R0
Page 1 of 12
TABLE OF CONTENTS 1.0
Keypad and display..........................................……………………………... 2 1.1 Keypad...............................................…………………………………….. 2 1.2 Display..............................................……………………………………... 4
2.0
Functions.................................................…………………………………….. 5 2.1 Start................................................……………………………………….. 5 2.2 Stop.................................................………………………………………. 5 2.3 Zero setting.........................................……………………………………. 6 2.4 Interlock/De-Interlock...............................………………………………... 6 2.5 Batch Operation......................................………………………………… 7 2.6 Control Measurement................................……………………………. 7 2.7 Error Acknowledgement................................……………………………. 8 Modes.....................................................….........................................…….. 9 3.1 Local mode...........................................….........................................…..9 3.2 Remote mode.....................................................................................…9 3.2.1 Interlock - Gravimetric Mode.....................................................… 9 3.2.2 De-Interlock - Gravimetric Mode................………………………... 9 3.2.3 Interlock - Volumetric Mode....................………………………….. 9 3.2.4 De-Interlock - Volumetric Mode.................………………………... 10
3.0
4.0
Parameter input...........................................…………………………………. 10 4.1 Control Parameters (SET1)............................…………………………… 10 4.2 Setpoint (SET2)................................................................................….. 10 4.3 PF parameters (SET3).................................…………………………….. 10
5.0
Error Messages............................................………………………………… 10
6.0
Abbreviations.............................................………………………………….. 12
Software_version: 2.0 (onwards) 2008-11-15
OPERATOR’S MANUAL Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.2-R0 1.0
Keypad and display
1.1
Keypad
Page 2 of 12
TUC-6 has a multi-function keypad; the definition of keys change as per the menu operations. Some keys have alphabets in the lower left hand corner. These are used in editing the PLC programs. The numbers 0 to 9 in the upper right hand corner of some keys are used for numeric entries. Characters/Symbols used in the keys have following meaning,
Display current setpoint
BB - Display Belt Load in %
Switch between Gravimetric / Volumetric selections
Display Actual Flowrate
Display Totaliser 1
Switch between Interlock/De-interlock modes Display Tacho Frequency Software_version: 2.0 (onwards) 2008-11-15
OPERATOR’S MANUAL Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.2-R0
Page 3 of 12
Display Totaliser 2 Start Zeroing in Manual/Local modes
Call online menus within Main_Program Cancel (CL) -In Main_Program, S1 value displayed in Line 2 is cleared -Used to Clear Fault displays -When used with 'Esc' key, is used to exit from menu. -Used to accept values modified in the SET menu. HOR -Selection of options from list. -'ENTER' key to accept value Start/Stop ESC -Used in combination with 'CL' key to exit from menu. -Used to discard values modified in the SET menu. -Display mV value in Calibration menu UP/DOWN - Scroll Menu/parameter list being displayed.
Software_version: 2.0 (onwards) 2008-11-15
OPERATOR’S MANUAL Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.2-R0 1.2
Page 4 of 12
Display
When the TUC-6 is powered on from the mains, the display "Transweigh" is shown for 5 secs. The system then displays either the Online Menu or the Offline menus, depending on the status of keypressed during the 5 secs. delay. -Press 'VER' to by 5 sec. delay & jump to Main_Program menu. -Press 'CL'to by 5 sec. delay & jump to Offline menus. If no key is pressed, the system enters Main_Program menu at the end of 5 sec. delay. a)
In the Online menu - Main_Program, the following parameters can be displayed by selecting keys from the keypad, 'W','BB','X', 'S1','S2','T': Wc BB X S1 S2 Ta
Current setpoint in units selected Belt load value in % Actual flowrate value in units selected Totaliser1 value Totaliser2 value Weigh Feeder Tacho frequency in Hz.
Other Values are selectable with the '↑↓' key. These values are shown below with their designated names. W1 W2 W3 Wm Xd L L F W D Sk
De-Interlocked setpoint Interlocked setpoint Interlocked setpoint through X4 Manual mode setpoint Deviation in % Weight of pre-hopper in units selected Weight of pre-hopper in % Weighed quantity during control measuring Quantity extracted during control measuring Difference between F and W Control measuring error
BS Date
Belt Speed in m/sec In format yy-mm-dd
Software_version: 2.0 (onwards) 2008-11-15
OPERATOR’S MANUAL Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.2-R0 Time Q q GATE b)
Page 5 of 12
In format Hour:Minute Quantity Setpoint Dribble setpoint Gate position in % (For Flow Control Gates)
Error messages The error messages have the highest priority, i.e. they are not overwritten by any other display and remain in display until they are acknowledged. The error messages are listed in section 5.0 "Errors Messages" of this manual.
2.0
Functions
2.1
Start
Conditions - Interlock input high Mode
Start trigger
De-Interlock-Gravimetric De-Interlock-Volumetric Interlock-Gravimetric Interlock-Gravimetric
'Start' from TUC 'Start' from TUC 'Start' from external digital input ‘Start' from superior computer (For configuration with Computer) 'Start' from external digital input Local pushbutton
Interlock-Volumetric Local Display - LED 'START' on. 2.2
Stop
Stop trigger for all modes -An Error condition leading to stop -Interlock input removed Mode Stop trigger De-Interlock-Gravimetric De-Interlock-Volumetric Interlock-Gravimetric
'Stop' from TUC 'Stop' from TUC 'Stop' from external digital input
Software_version: 2.0 (onwards) 2008-11-15
OPERATOR’S MANUAL Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.2-R0 Interlock-Gravimetric Interlock-Volumetric Local Display - LED 'START' off. 2.3
Page 6 of 12
'Stop' from superior computer (For configuration with Computer) 'Stop' from external digital input Local pushbutton
Zero setting With this key, Zero correction process is initiated.
Conditions - System in Local/De-Interlock-Volumetric mode - Belt started Display - LED over '>0<' flashing. Note: Zero setting operation can be canceled by pressing '>0<' key during zeroing process. With canceling, the old zero setting value is not lost. Operation: The zero setting runs for one belt revolution determined by the belt revolution time set in configuration. After zero setting operation, the mean value over the zero curve is calculated and the belt load is re-calculated with the zero correction value. An error message occurs when the correction limit is exceeded. 2.4
Interlock/De-Interlock With this key, it is possible to switch between the two modes.
Display: Interlock : LED over 'Int./De-Int.' ON De-Interlock: LED over 'Int./De-Int.' OFF Note: Switching between the modes is only possible in Weigh Feeder Stop mode. Software_version: 2.0 (onwards) 2008-11-15
OPERATOR’S MANUAL Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.2-R0 2.5
Page 7 of 12
Batch Operation
The Feeder can be selected for Batch mode operation. In this mode, a fixed quantity of material can be delivered by the Feeder and an alarm generated or the system stopped, if required. The quantity setpoint values are entered in SET2 menu. Two Setpoint parameters, 'Q1' & 'Q2', are provided in the system. Selection between 'Q1' and 'Q2' is through marker 'M024'. Each Quantity setpoint (Qx) is associated with a corresponding Dribble value (qx). When operating in the Batch mode, an alarm is generated after delivering 'Q-q' quantity of material. 'q' is usually the amount of material overfed by the feeder after it is stopped. Conditions: - Weigh feeder configured for Batch mode operation Operation : When the feeder is started in Batch mode, Totaliser, S1 is cleared if greater than 'Q'. Totaliser, S1 increments up to 'Q-q' and "Quantity Over!" is displayed. Marker 'M059' is set. This marker can be used in SPSS to stop the feeder if requried. Pressing 'CL' key clears the alarm display and resets 'M059' marker if set. 2.6
Control measurement With this key, it is possible to initiate a control measurement cycle.
Conditions : - Feeder configured with pre-hopper scale - Started in automatic mode. Display : LED over >O< flashing Note: During the control measurement, no level regulation will take place. The control measurement is aborted if, ™ the hopper weight falls below the pre-hopper Limit1. Software_version: 2.0 (onwards) 2008-11-15
OPERATOR’S MANUAL Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.2-R0
Page 8 of 12
™ the hopper is being filled. ™ an abort request is received from the keypad or super-ordinate system. ™ System is switched to manual operation. Operation: ™ Initiate control measurement via front keyboard, Master computer or external input. ™ Automatic filling of pre-hopper to pre-hopper Limit3 if the hopper weight is lower than Limit2 at the time of starting the control measurement. ™ Wait for the damping period. ™ Control measurement is started for time defined by Parameters "Belt_Revolution_Time" * "No_of_Belt_Rev". ™ Values, "F"-Material conveyed by feeder and "W"-Material extracted from Hopper, are calculated. ™ On completion of control measurement, the following values are calculated, D =F-W Sk = D x 100 x Current Setpoint , % error F System capacity ™ The error value can be corrected via front keyboard (' 'key), Master computer or external input. ™ The correction can be applied to either Feeder ‘Tare’ or ‘Span’ value. ™ The correction for control measurement error is limited by the maximum correction limit parameter entered in TUC-6. 2.7
Error Acknowledgment key is used to acknowledge errors.
Display The Error text message is displayed in line 2. All Error texts are characterized with "!" in the last column Note: If an error is already in the display, further errors will not be displayed until this error has been acknowledged. 3.0
Modes
Software_version: 2.0 (onwards) 2008-11-15
OPERATOR’S MANUAL Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.2-R0 3.1
Page 9 of 12
Local mode
This mode is invoked by a "Low" signal on the 'Local/Remote' digital input. In this mode, Setpoint & Start/Stop commands to the system are from the Local Control Station. System operation in this mode is unregulated. Zero setting operation is possible in this mode. 3.2
Remote mode
This mode is invoked by a "High" signal on the 'Local/Remote' digital input. This mode is further sub-divided into the following four modes. 3.2.1 Interlock - Gravimetric mode This mode is invoked by a "Low" signal on the 'Int/De-Int' digital input & "High" signal on 'Vol/Grav. Select' digital input or selected through TUC-6 keypad. Selection either from External Inputs or from Keypad is defined in the Configuration Menu. In this mode, Start/Stop & Setpoint are through external I/Os 3.2.2 De-Interlock - Gravimetric mode This mode is invoked by a "High" signal on the 'Int/De-Int' digital input & "High" signal on 'Vol/Grav. Select' digital input or selected through TUC-6 keypad. Selection either from External Input or from Keypad is defined in the Configuration Menu. In this mode, Start/Stop & Setpoint are through the keypad. 3.2.3 Interlock - Volumetric mode This mode is invoked by a "Low" signal on the 'Int/De-Int' digital input & "Low" signal on 'Vol/Grav. Select' digital input or selected through TUC-6 keypad. Selection either from External Input or from Keypad is defined in the Configuration Menu. System operation in this mode is unregulated. In this mode, Start/Stop & Setpoint are through external I/Os. 3.2.4 De-Interlock - Volumetric (Manual) mode This mode is invoked by a "High" signal on the 'Int/De-Int' digital input & "Low" signal on 'Vol/Grav. Select' digital input or selected through TUC-6 keypad. Selection either from External Input or from Keypad is defined in the Configuration Menu. System operation in this mode is un-regulated. Software_version: 2.0 (onwards) 2008-11-15
OPERATOR’S MANUAL Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.2-R0
Page 10 of 12
In this mode, Start/Stop & Setpoint are through the keypad. Zero setting operation is possible in this mode. 4.0
Parameter input
Operating the menus via the TUC keys is described in the Operating Instructions section of this manual (see Menu Operations, section 2.0) 4.1
Control Parameters (SET1)
In this menu, control parameters related to the PI regulator are set. 4.2
Setpoint (SET2)
In this menu, it is possible to input the setpoints for system operation. The setpoints are entered with the units and decimal points as selected in configuration. Operating mode De-Interlock - Volumetric De-Interlock - Gravimetric 4.3
Valid setpoint Wm W1
Pre-feeder parameters (SET3)
Parameters for Pre-feeder control are set in this menu. 5.0
Error Messages
Errors are characterised by "!" display in the last position of the messages occurring during operation are shown below. " Message
!"
" Tacho Fault
!"
"Drive Int. Err.
!"
Software_version: 2.0 (onwards) 2008-11-15
= > = > = >
Meaning Help Tacho freq. input missing Check tacho, tacho cable external drive disturbance check drive interlocks
display. Error
OPERATOR’S MANUAL Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.2-R0 "Belt Tracking "Corr.>set-limit
!"
=
!”
> = >
"Corr. Aborted
!”
=
"Deviation
!"
> =
" AIO1 Commun.
!"
"EEProm read
!"
"EEProm write
!"
"Integration Off
!"
" Overload
!"
> = > = > =
!"
> =
" Underload "Emergency Stop
!"
"Anal. i/p Error
!"
" No PLC File
!"
"In-correct Inst
!"
Software_version: 2.0 (onwards) 2008-11-15
> = > =
> = > =
> = > = >
Page 11 of 12 Belt off track message at input for time greater than permissible time Set belt Zero correction or control measurement error, greater than permitted Check load, repeat zero correction or control measuring Zero correction or Control Measurement cycle aborted Check Tacho input, Drive Interlock input. Actual capacity outside the tolerance band longer than =deviation time= check load, setup Communication error AIO card Check AIO connection, interface, setup Data and checksum in EEProm do not match Enter parameters anew. Not possible to write to EEProm Hardware fault. Replace unit. Downstream Interlock input not present Check input. BB > MAX. LOAD value set in Measuring param. Check material on belt BB < MIN. LOAD value set in Measuring Param. Check material on belt Emergency stop switch pressed Check Switch status, cable. This error occurs during AIO scaling if Max_Value selected is lower than Min_Value or Communication error with Anaput module Check anaput value, Interface No assembled PLC file in memory. Enter PLC program, Assemble Error found in PLC file during assembly. Check line indicated.
OPERATOR’S MANUAL Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.2-R0 "Quantity Over
!"
"Inverter1 Comm.
!"
"Inverter2 Comm.
!"
" DIO 1 Commun.
!"
" DIO 2 Commun.
!"
" SIO Communicat.
!”
" Master Commun.
!"
= > = > = > = > = > = > =
" Belt Slip
!"
> =
" CAN Communicatn
!"
> =
" Loadcell Fault
!"
“ Zero Correction
!"
" Bin LC Fault
!"
" Error Scaling
!"
> = > = > = > = >
6.0 '....' =....= LED VFD SPSS
Page 12 of 12 Totaliser S1 greater than Q-q value set. Check set values Communication error with Inverter1 Check connection, interface, setup Communication error with Inverter2 Check connection, interface, setup Communication error with DIO card 1 Check connection, interface, setup Communication error with DIO card 2 Check connection, interface, setup Communication error with SIO module Check connection, interface, setup Communication error between TUC & master (Modbus/Profibus) Check connection, interface, setup Tail Pulley tacho input missing for time greater than permissible time Set belt Communication error between FIM & CAN master (TUC) Check connection, power, baudrate Hopper Loadcell not connected Check Loadcell connection. BB > limit value set in config. Check material on belt Bin Loadcell not connected Check Loadcell connection. Dimensions of weigh feeder and hopper do not match. Check parameters
Abbreviations key... Parameter in configuration Light emitting diode Vacuum Fluorescent display (16 characters X 2 line) PLC program
Software_version: 2.0 (onwards) 2008-11-15
COMMISSIONING INSTRUCTIONS Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.3-R1
Page 1 of 26
TABLE OF CONTENTS 1.0
First start...............................................………………………………………. 2
2.0
Parameters................................................…………….…….……………….. 2
3.0
OFFline parameters........................................………………………………. 2 3.1 .............................................…………….……………………..2 3.2 Measuring Parameters................................…………………………….. 3 3.3 Configuration Parameters............................……………………………. 4 3.4 Interface...........................................…………………….……………….. 7 3.5 Anaput........................................…………….…………………….. 9 3.6 TUC Analog Output............................…………….…………………….. 10 3.7 AIO Analog Output………………………………………………………… 11 3.8 Calibration - Feeder...........................……………………………………. 11 3.8.1 Calibration using weights.......................……………………….. 12 3.8.2 Calibration without weights.....................………………………. 13 3.9 Calibration correction ….………………………………………….………..13 3.10 CAN Configuration…..............................……………….……………….. 14 3.11 Hopper Parameters…………………………………………………………15 3.12 Calibration - Hopper……………………………………………………….. 16 3.13 Anaputs – FIM……………………………………………………….. 16 3.14 Analog Outputs – FIM………………………………………………………17 3.15 System data.........................................………………………………….. 18
4.0
ONline parameters.........................................……………………………….. 18 4.1 Main program........................................…………………………………. 18 4.1.1 SET1...........................................………………………………….. 19 4.1.2 SET2...........................................………………………………….. 21 4.1.3 SET3...........................................………………………………….. 22 4.1.4 SET4...........................................………………………………….. 23 4.1.5 SET5...........................................………………………………….. 24 4.1.6 Zero Correction................................………………………………. 25 4.1.7 Control Measuring............................……………………………… 25
Software_version: 4.1 (onwards) 2010-29-11
COMMISSIONING INSTRUCTIONS Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.3-R1
1.0
Page 2 of 26
First start
When starting for the first time the following procedure must be followed: Steps 1.1 1.2 1.3 1.4 1.5 1.6 1.7 2.0
Check jumpers Connect peripheral appliances Enter parameters Enter PLC Program Calibrate system Zero setting Calibration correction Parameters
See "Menu Operations" (section 2.0) for description about menu parameters and operations. 3.0
OFFline parameters
3.1
== When power is turned ON and 'CL' key is pressed during the 5 sec. delay, the system comes to this option Press '↑/↓' keys to scroll through the different menus. To select any menu,Press '→' key with that menu being displayed in the 2nd display line. =Enter = Enter the 5 digit and press '→' key. The OFFline parameter access is disabled if the wrong is entered. The same can be accessed only on right entry. Once enabled, the parameters can be accessed till the ONline menu is accessed or power to the system is turned 'Off'. Display: "Y" - On right entry "N" - On wrong entry Software_version: 4.1 (onwards) 2010-29-11
COMMISSIONING INSTRUCTIONS Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.3-R1 3.2
Page 3 of 26
Measuring parameters
=M. RANGE= Measuring Range The voltage rise is defined as the voltage difference which the measuring cell delivers between a belt loaded with 100% load and an empty belt.The value to be set is the next lowest setting value to this value. Select : 1.0 / 3.0 / 6.0 / 12 mV =Units,X= Units,Capacity Designation of all capacity displays. If "t/h" is selected as designation,all other values are automatically defined with "t". Select : kg/h, t/h =D. Pt,X= Decimal point,capacity Definition of the position of the decimal point within the 4 digit capacity display. Select : 000000 / 00000,0 / 0000,00 / 000,000 =Nom. Cap.= Nominal capacity Flow rate with 100% belt load and nominal tacho frequency = 100% capacity. Input : Numerical value of capacity =D. Pt,S1=Decimal point, Totaliser 1 Definition of the position of the decimal point within the 6 digits display of Totaliser 1 Select : 000000 / 00000,0 / 0000,00 / 000,000 =Units,S1= Units ,Totaliser 1 Definition of designation for resettable Totaliser 1 Select : kg / t =D. Pt,S2= Decimal point, Totaliser 2 Definition of the position of the decimal point within the 6 digits display of Totaliser 2 Select : 000000 / 00000,0 / 0000,00 / 000,000 =Units,S2 = Units ,Totaliser 2 Software_version: 4.1 (onwards) 2010-29-11
COMMISSIONING INSTRUCTIONS Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.3-R1
Page 4 of 26
Definition of designation for non-resettable Totaliser 2 Select : kg / t =Freq. I/P= Frequency input source Select : Fixed - Tacho frequency is simulated internally (1000 Hz) Tacho - Tacho frequency is read from tacho input Inv. – Tacho frequency is read from the inverter (Requires inverter to be connected to TUC-6 on the RS-485 serial bus) =Tacho Freq= Nominal tacho frequency Input : 0-9999 Hz (Only used for fixed frequency = "No") =Belt Speed= Nominal Belt speed in m/sec at nominal tacho frequency Input : 0-0,000 m/s (Only used for fixed frequency = "No") =Max. Load= Limit maximum load Maximum limiting value causing error message "Overload!". Input : Numerical value in % =Min. Load= Limit minimum load Minimum limiting value causing error message "Underload!". Input : Numerical value in % 3.3
Configuration Parameters
=Block mode= Block mode Definition of the weigh feeder as a Block system i.e with or without Control Measuring. Selection: Yes = Weigh feeder with pre-hopper and control measuring No = Weigh feeder without pre-hopper =Reg. mode= Regulation mode Definition of 2nd regulator Selection : Direct Removing = no 2nd regulator Feed regulation = With supplementary regulation of load =Batch mode= Batch mode Software_version: 4.1 (onwards) 2010-29-11
COMMISSIONING INSTRUCTIONS Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.3-R1
Page 5 of 26
In Batch mode operation feeder can be made to generate an alarm or stop, after delivering a set quantity of material. Quantity setpoints for this operation are entered in SET2 menu in Main_Program. Selection :Yes = Weigh feeder selected for Batch operation No = Weigh feeder not selected. =Rev. Time= Belt revolution time Time for one revolution of the belt with nominal tacho frequency. Input : Numerical value in 0,1 s steps =No. of Rev.= No. of belt revolutions Number of revolutions for control measurement. Input : numerical value with 2 digits =Zero Limit= Zero correction limit This parameter determines the number of percentage points by which the zero correction value may differ from the zero value. If the difference is greater, the error message "CORR.>SET-LIMIT!" is displayed and the zero value calculated is discarded. Input : numerical value in % =Belt track= Belt tracking monitoring time Time for monitoring the belt tracking input. Input : numerical value in 0,1 sec. steps =Run Time= Tacho supervision time Time for monitoring the tacho input pulses. Input : 0-999.9 s in 0.1s steps (No monitoring with input "0") =Impulse1= The impulse output can be assigned to Totaliser 1, Totaliser 2 or kept Off. Select : ϊ1 / ϊ2 / Off =On_Time= The impulse ON time can be set using this parameter. Select : 50mS / 100mS / 250mS / 500mS =Impulse2= Software_version: 4.1 (onwards) 2010-29-11
COMMISSIONING INSTRUCTIONS Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.3-R1
Page 6 of 26
A 2nd Inpulse output can be enabled/disabled with this parameter. Select : NO / YES =I1 value= I1 value Definition of analog output type at I1 Select : TPH/BB/Ta/Wc/WFsp/PFsp/Sk/LEVEL NOTE : TPH - Actual Material Flowrate BB - Instantaneous Belt Load Ta - Weigh feeder Tacho frequency (Belt speed) Wc - Current setpoint WFsp - Weigh feeder drive setpoint PFsp - Prefeeder drive setpoint Sk - Control measurement error LEVEL- Hopper level =Limit 1= Limit value 1 The potential free output for Belt load value above this value. Select : Numerical value in % =Limit 2= Limit value 2 The potential free output for Belt load value above this value. Select : Numerical value in % =L_Delay= Hysteresis time Time after which the output goes high when Belt load remains above limit values 1 or 2 Input : Numerical value in 0,1 sec steps. =Clear,S2= Clear Totaliser2 value Input : No / YES =Meas_Filt= Meas_Filt provides Loadcell input signal filtering. Select ‘0’ to de-select filtering. Select: 0/ 1 / 2 / 3 / 4 / 5 steps
Software_version: 4.1 (onwards) 2010-29-11
COMMISSIONING INSTRUCTIONS Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.3-R1
Page 7 of 26
=Display_Step= Digit step provides damping of display and analog output values. Select : 1 / 2 / 3 / 4 / 5 / 6 steps =Mode_Sel= This parameter defines the selection for switching between Interlock/Un-Interlock & Gravimetric/Volumetric modes. Selecting "External" defines mode selections from external digital inputs. Selecting "Internal" defines mode selections through TUC-6 keypad. Select : External/Internal =Setpoint %= Multiplying factor for setpoint to Drive in Volumetric modes. Select : Numerical value in % =CTRL_Mode= Selects the control mode for WF drive. Selecting "PI" selects PI control action. Selecting "tCTRL" selects "TRANScontrol" action for WF drive control. In this mode, the drive setpoint is automatically adjusted by the controller based on an internal algorithm. Selecting “Off” for this parameter, TUC-6 works in measuring mode, bying corrective action on drive setpoint. With “Off”, SET1, SET2, SET3 menus are disabled. Select : PI / tCTRL / Off 3.4
Interface
=No_Of_Inv= Inverter selection Inverters can be connected to TUC-6 serial interface. When connected to serial interface, drive setpoint, start/stop, signals are exchanged between TUC & Inverters via the serial interface only. The number of inverters connected to TUC-6 is selected with this parameter. Select : 0 / 1 / 2 NOTE : i) The address for each Inverter interfaced with TUC-6 should be separate. Address for Inverters are selected with the help of =Address= parameter in Inverter.
Software_version: 4.1 (onwards) 2010-29-11
COMMISSIONING INSTRUCTIONS Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.3-R1
Page 8 of 26
ii) The =Address= parameter in Inverter should be set to '01' for the 1st Inverter and '02' for the 2nd Inverter. iii) TUC-6 communicates with Inverters at 19200 baud, 8 bits, 1 stop, NO parity. =Inv_Type= Select Inverter type Select the Inverter type with this parameter. Select : ATV28 / MM4 / J7/V7 / ATV31 / PF4/40 / ACS550 =No_Of_DIO= Digital I/O card interface The number of DIO cards interfaced TUC-6 is selected with this parameter. Select : 0 / 1 / 2 NOTE: i) The address for each DIO card interfaced with TUC-6 should be separate. ii) Address for DIO cards are selected with the help of jumper plugs on the DIO card. (Refer "Appliance Description" for jumper selection details) =No_Of_AIO= Analog I/O card interface The number of AIO cards interfaced TUC-6 is selected with this parameter. Select : 0 / 1 / 2 / 3 NOTE: i) The address for each AIO card interfaced with TUC-6 should be separate. ii) Address for AIO cards are selected with the help of jumper plugs on the AIO card. (Refer "Appliance Description" for jumper selection details) =AIO_Type= Select AIO type Select the type of AIO interfaced in the system. Select : F868 / F875 =Ext_SP= External setpoint Selects source of external analog setpoint Select : OFF / AIO1 / Inverter =SP_Filter= Filter step provides damping for anaput setpoint value. Select : 0 / 1 / 2 in seconds =AIO1_OP= Definition of analog output (4-20mA) type from the 1st AIO card Select : TPH/BB/Ta/Wc/WFsp/PFsp/Sk/LEVEL Software_version: 4.1 (onwards) 2010-29-11
COMMISSIONING INSTRUCTIONS Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.3-R1
Page 9 of 26
=AIO2_OP= Definition of analog output (4-20mA) type from the 2nd AIO card Select : TPH/BB/Ta/Wc/WFsp/PFsp/Sk/LEVEL =AIO3_OP= Definition of analog output (4-20mA) type from the 3rd AIO card Select : TPH/BB/Ta/Wc/WFsp/PFsp/Sk/LEVEL =SIO_INT= SIO Interface Selection of the peripheral device at the serial interface Select: Off / Modbus / Profibus =SIO_BAUD= SIO baud rate Setting the baud rate at serial interface Select: 4800 / 9600 / 19200 baud =SIO_SETUP= SIO data format Definition of data format at serial interface Select: Data Stop Parity 8 1 None 8 1 Even 8 1 Odd =SIO_ADDR= SIO address Address of controller when connected to a multi-drop bus on the Serial network Input: Numerical value from 00-99. =SIO_MONITOR= SIO monitoring time Monitoring time for communication. Input: Numerical value in 1 sec. steps Note: IF "00" selected, SIO communication monitoring is disabled. In systems, where "Remote Interlock" mode of operation is used, i.e. Setpoint & Start/Stop through SIO, this parameter should not be set to "00". =CAN_Int= Selection of Field Interface Module via CAN is selected through this parameter. Select: Off / On
Software_version: 4.1 (onwards) 2010-29-11
COMMISSIONING INSTRUCTIONS Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.3-R1 3.5
Page 10 of 26
AIO AnalgInp Cal
=Re-Calibrate?= AIO1 anaput re-calibration The calibration menu is released on selecting '→' for this parameter.Pressing '↓' key will not affect the existing values stored in memory. Selection : → / ↓ =CHANNEL1= Recalibration of anaput for AIO1 channels =CHANNEL2= The Channel for calibration is selected by '→' key. Press '↓' key for scrolling to next channel Selection : → / ↓ =Min_Value= AIO Min. value With the anaput at the minimum value, Press '→' key to accept the value as 0% value for the channel selected. =Max_Value= AIO Max. value With the anaput at 100%, press '→' key to accept the value as 100% for the channel selected. 3.6
TUC AnalgOut Cal
=Re-Calibrate?= Analog output re-calibration The analog output calibration menu is released on selecting '→' for this parameter.Pressing '↓' key will not affect the existing values stored in memory. Selection : → / ↓ =Min_Value= I1 Output Min. value This is used to adjust the minimum output value at the Analog output I1. The present analog output count value is displayed. Press '→' key to increase/decrease the analog output value. ‘Esc’ key is used to toggle assignment of '→' key as increase or decrease key. Press ‘↓’ to save value and proceed further. =Max_Value= I1 Output Max. value
Software_version: 4.1 (onwards) 2010-29-11
COMMISSIONING INSTRUCTIONS Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.3-R1
Page 11 of 26
This is used to adjust the maximum output value at the Analog output I1. The present analog output count value is displayed. Press '→' key to increase/decrease the analog output value. ‘Esc’ key is used to toggle assignment of '→' key as increase or decrease key. Press ‘↓’ to save value and proceed further. 3.7
AIO AnalgOut Cal
=Re-Calibrate?= AIO card Analog outputs re-calibration The analog output calibration menu is released on selecting '→' for this parameter.Pressing '↓' key will not affect the existing values stored in memory. Selection : → / ↓ =OUTPUT1= AIO card output1 recalibration =OUTPUT2= =OUTPUT3= The enter key will proceed for recalibration of selected Output. The down key will give options for other channel outputs. Selection : → / ↓ =Min_Value= AIO Output Min. value This is used to adjust the minimum output value at the Analog output. The present analog output count value is displayed. Press '→' key to increase/decrease the analog output value. ‘Esc’ key is used to toggle assignment of '→' key as increase or decrease key. Press ‘↓’ to save value and proceed further. =Max_Value= AIO Output1 Max. value This is used to adjust the maximum output value at the Analog output1. The present analog output count value is displayed. Press '→' key to increase/decrease the analog output value. ‘Esc’ key is used to toggle assignment of '→' key as increase or decrease key. Press ‘↓’ to save value and proceed further. 3.8
Calibration - Scale Calibration of the scale can be carried out in 2 ways, i) Using Calibration weights
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ii) Using previous calibration values. In this mode, previous calibration values , viz 'COUNT_DL' and 'COUNT_BL', are used to calibrate the scale. =Re-calibrate? ->= Recalibrate? The 2 modes in calibration menu are initiated by the following procedure, i)
Mode 1 - Calibration using Weights Press '→'. Pressing '↑↓' key will exit the menu without recalibration.
ii)
Mode 2 - Calibration without weights Press keys '1','2','3' and '→' in sequence. Pressing '↑↓' key will exit the menu without recalibration. Input : As above 3.8.1 Mode 1 - Calibration using Weights =Dead load= The actual value is displayed in of "d" in the lower display line.With a completely empty belt , delete the dead load with the '→' key.The actual value displayed then shows 0000 d; the dead load is compensated.Press '↑↓' key to switch further. Input : None TIP : Press 'ESC' key to display the actual value in mV. =Calibration load= Calibration load The actual value is displayed in of "d" in the lower display line. Load a known weight and wait for a steady display. The display then shows the actual value on the left and is ready to accept the new value. CALIBRATION LOAD 1230 => 0000 Enter the calibration load value on the right hand side. A value of 2000 corresponds to 100% Belt load. Scale the input value according to the calibration load. Conclude the calibration procedure with '↓' key.The value entered is saved on exit.
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Input : Numerical value of calibration load in of "d". TIP : Press 'ESC' key to display the actual value in mV. 3.8.2 Mode 2 - Calibration without Weights =Count_DL= Dead Load Count The Dead Load is displayed in of internal calibration counts. The numerical keys can be used to change this value. Press '↑↓' key to switch further. Input : Numerical value =Count_BL= Belt Load Count The Belt Load corresponding to 100% load is displayed in of internal calibration counts. The numerical keys can be used to change this value. Press '↑↓' key to switch further. Input : Numerical value 3.9
Calibration correction
If measurement of the momentary load shows non-linear characteristics, correction in order to increase the linearity is possible. For this upto 10 measuring points can be taken and stored from 0....100% capacity. Between these measuring points, the curve is then linearized. To start the calibration correction process, calibrate the system. Take a measuring point e.g at 20% capacity and operate the system at 20% of nominal capacity. Switch on the capacity display on the unit and note the average indicated capacity. By a determined quantity (at completed belt revolutions) and reweigh it using a static weigher. Take the measurement time by a stop watch. From the actual conveyed capacity and the time taken, calculate the true conveying capacity. Conveying capacity (t/h) = Reweighed quantity (t) Time (sec)
x 3600
Input the displayed value (S1)and the measured value in the unit. Repeat the procedure for other calibration points,if necessary. Software_version: 4.1 (onwards) 2010-29-11
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=Curve_Correction= =Edit ->= Press '→' key to enter the curve correction menu. Press '↑↓' key to exit the menu. Pressing '→' key will display the correction points as shown, N DISP →MEASURED 0 0123,0→0000,0 "N"
- The correction point number,from 0 to 9
"DISP." - Input for quantity of conveyed material as displayed Input : Numerical value in units & resolution of S1. "MEASURED" - Input for measured quantity of material using a static scale. Input : Numerical value in units & resolution of S1. Press '↑↓" key to increment to the next correction point. After 10 correction points are displayed, next '↑↓" press will display the following in the lower line, "Exit ->" Press '→' to exit the menu and '↑↓' to move to correction point number 0 3.10
CAN Configuration
This menu is displayed only if =CAN_Int= is selected as ‘Yes’ in “Interface menu” =CAN_Baud= The Baud rate for communication between TUC6 and FIM can be selected through this parameter. Select: 10K / 20K / 50K / 100K / 125K / 250K / 500K / 1000K. =X5_Int= Modbus Interface Selection of MODBUS interface Select: Off / Modbus =X5_Baud= Modbus Baudrate Setting the baud rate for Modbus Software_version: 4.1 (onwards) 2010-29-11
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Select: 4800 / 9600 / 19200 baud =X5_Setup= Modbus data format Definition of data format at modbus interface Select: Data Stop Parity 8 1 None 8 1 Even 8 1 Odd =X5_Addr= Modbus Address Address of FIM when connected to a multi-drop bus through MODBUS Input: Numerical value from 00-99. =X5_Monitor= Modbus monitoring time Monitoring time for modbus communication. Input: Numerical value in 1 sec. steps Note: IF "00" selected, communication monitoring is disabled. =AO1_output= Definition of analog output type from channel 1 (X8) of FIM. Select: TPH/BB/Ta/Wc/WFsp/PFsp/Sk/LEVEL =AO2_output= Definition of analog output type from channel2 (X8) of FIM. Select: TPH/BB/Ta/Wc/WFsp/PFsp/Sk/LEVEL 3.11 CAN HopperParam This menu is displayed only if =CAN_Int= is selected as ‘Yes’ in “Interface menu” =M. RANGE= Measuring Range The voltage rise is defined as the voltage difference which the measuring cell delivers between a belt loaded with 100% load and an empty belt. The value to be set is the next lowest setting value to this value. Select1.0 / 3.0 / 6.0 / 12 mV =Units, L= Units, Hopper Software_version: 4.1 (onwards) 2010-29-11
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Designation of capacity display. Select: kg, t =D. Pt, L= Decimal point, Hopper Definition of the position of the decimal point within the 5 digit capacity display. Select: 000000 / 00000,0 / 0000,00 / 000,000 =Nom. Cap, L= Nominal capacity, Hopper Input: Numerical value of capacity =L_MIN= Limit Value Minimum Marker M061 set high, if Hopper level below this limit Input: Numerical value in % =L_NOM= Limit Value Nominal Marker M062 set high, if Hopper level below this limit Input: Numerical value in % =L_MAX= Limit Value Maximum Marker M063 set high, if Hopper level below this limit Input: Numerical value in % =Meas_Damp, L= Meas_Filt provides Loadcell input signal filtering. Select: 1 / 2 / 3 steps 3.12 Calibration – Hopper This menu is displayed only if =CAN_Int= is selected as ‘Yes’ in “Interface menu” The calibration procedure for hopper is similar to that explained in section 3.7 for Feeder. 3.13
CAN AnalgInp Cal
This menu is displayed only if =CAN_Int= is selected as ‘Yes’ in “Interface menu”
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=Re-Calibrate?= AIO re-calibration The calibration menu is released on selecting '→' for this parameter. Pressing '↓' key will not affect the existing values stored in memory. Selection: → / ↓ =Channel1= Channel Selection =Channel2= The Channel for calibration is selected by '→' key. Press '↓' key for scrolling to next channel Selection: → / ↓ =Min_Value= AI Min. value With the anaput at the minimum value, Press '→' key to accept the value as 0% value for the Channel selected. =Max_Value= AI max. value With the anaput at 100%, press '→' key to accept the value as 100% for the Channel selected 3.14
CAN AnalgOut Cal
This menu is displayed only if =CAN_Int= is selected as ‘Yes’ in “Interface menu” =Re-Calibrate?= Analog output re-calibration The analog output calibration menu is released on selecting '→' for this parameter. Pressing '↓' key will not affect the existing values stored in memory. Selection: → / ↓ =Channel1= Channel Selection =Channel2= The Channel for calibration is selected by '→' key. Press '↓' key for scrolling to next channel Selection: → / ↓ =Min_Value= Output Min. value This is used to adjust the minimum output value at the Analog output. The present analog output count value is displayed. Software_version: 4.1 (onwards) 2010-29-11
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Press '→' key to increase/decrease the analog output value. ‘Esc’ key is used to toggle assignment of '→' key as increase or decrease key. Press ‘↓’ to save value and proceed further. =Max_Value= Output Max. Value This is used to adjust the maximum output value at the Analog output. The present analog output count value is displayed. Press '→' key to increase/decrease the analog output value. ‘Esc’ key is used to toggle assignment of '→' key as increase or decrease key. Press ‘↓’ to save value and proceed further. 3.15
System data
=U crystal= U crystal frequency is displayed Input : None =S/W Ver.= Software version Display of software version Input : None =Date= The date can be changed through this parameter. Input : Numerical value in format YY:MM:DD =Time= The system time can be changed through this parameter. Input : Numerical value in format HH:MM:SS 4.0
ONline parameters
If 'CL' key is not pressed during the 5 sec. power on delay, system goes to the ONline mode when power is switched ON. 4.1
Main Program
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The display in the ONline mode can be switched directly by using keys 'W','BB','Ta','X', 'S1' and 'S2'. Other parameters are called by pressing '↑↓' key. The following parameters can be displayed in this mode, X S1 S2 BB Ta BS W1 W2 W3 Wm Wc Xd Y0 Y1 L L F W D SK Date Time Q q GATE
Actual flowrate value in units selected Totaliser1 value Totaliser2 value Belt load value in % Weigh Feeder Tacho frequency in Hz. Belt Speed in m/sec Un-Interlocked setpoint Interlocked setpoint Remote, Interlocked setpoint Manual mode setpoint Current setpoint Deviation in % WF drive setpoint in % PF drive setpoint in % Weight of pre-hopper in units selected Weight of pre-hopper in % Weighed quantity during control measuring quantity deducted during control measuring difference between F and W Control measurement error in % In format yy-mm-dd In format Hour:Minute Quantity setpoint. Dribble setpoint. Gate Position in % (for Flow Control gates)
4.1.1 SET1 This menu allows access to the PI regulator of the system. The P-share of the regulator is represented by =Amplification P1= and the I-share by =Reset Time I1=.
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For Weigh Feeders with Feeding regulation or level regulation, a second regulator is implemented in the system to regulate the material on the belt or the pre-hopper content to a defined level. The parameters for second regulator are represented by =Reset Time I2= and =Amplification P2=. Since regulator1 and regulator2 mutually influence each other,an evaluation factor =Regulator Tracking= must be entered. This establishes a coupling between the output value for the drive speed setpoint and the output value for the feeding device. A setpoint change can thus be followed quickly. Note: SET1 menu is disabled if =CTRL_Mode= parameter in Configuration menu is selected “Off”.
=Reset Time I1= "I" time of the PI regulator for belt speed setpoint.If this value is zero, the "I" part is ignored in the regulator action. Input : Numerical value in 0,1 sec steps =Amplification P1= "P" part of the PI regulator for belt speed setpoint. Input : Numerical value in 0,1 steps =Deviation Limit= Tolerance range around the actual flow rate. Input : Numerical value in percent =Deviation Time= Maximum time that the actual flow rate is allowed to remain outside the tolerance range. At the end of this time, the scale trips due to "Deviation" error. Input : Numerical value 0,1 sec steps =Reset Time I2= Similar to =Reset Time I1= =Amplification P2= Similar to =Amplification P1= =Dead Band= % Error band for which no control action takes place on the drive setpoint. Software_version: 4.1 (onwards) 2010-29-11
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Input : Numerical value 0,1 % steps 4.1.2 SET2 This menu allows access to setpoints effective in different modes. The actual setpoint for system operation is dependent on the operational mode. Note: SET1 menu is disabled if =CTRL_Mode= parameter in Configuration menu is selected “Off”. =W1= De-Interlock - Gravimetric setpoint Setpoint W1, can be entered in the units and resolution selected in config. Input : Numerical value,4 digit number =Wm= De-Interlock-Volumetric (Manual) setpoint Setpoint Wm, can be entered in the units and resolution selected in config. Input : Numerical value, 4 digit number =Capacity Limitation= The setpoint input can be scaled from 0 to 100% using this parameter. Input : Numerical value in % =Q1= Quantity setpoint1 Setpoint Q1, can be entered in the units and resolution selected of S1. Input : Numerical value, 6 digit number =q1= Dribble setpoint1 Setpoint q1, can be entered in the units and resolution selected of S1. Input : Numerical value,6 digit number =Q2= Quantity setpoint2 Setpoint Q2, can be entered in the units and resolution selected of S1. Input : Numerical value, 6 digit number =q2= Dribble setpoint2 Setpoint q2, can be entered in the units and resolution selected of S1. Input : Numerical value, 6 digit number
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4.1.3 SET3 This menu allows access to pre-feeder control parameters. Note: SET1 menu is disabled if =CTRL_Mode= parameter in Configuration menu is selected “Off”. =BB_Limit= Used for Weigh Feeder with "Feed regulation" mode selected. When Belt Load value is less than this value, the pre-feeder is started with a fixed setpoint, for time defined by parameter =BB_Delay=. After this time period, the setpoint value changes as per the 2nd PI regulator settings. The initial setpoint for Pre-feeder is defined by parameter =BB_Setpnt=. Input : Numerical value in % =BB_Delay= Description as above. Input : Numerical value in seconds. =BB_Setpnt= Description as above. Input : Numerical value in % =BB_Control= This parameter determines the level about which Belt Load regulation takes place. Input : Numerical value in % =BB_Band= Percentage Belt loading band within which no correction of the 2nd PI regulator takes place. Input : Numerical value in 0,1 % steps
=PF_Limit= Multiplying factor for limiting maximum setpoint to prefeeder drive. Set value equal to 100,0 % for maximum PF setpoint equal to 10 Vdc; set correspondingly lower values for clamping maximum PF setpoint value. Input : Numerical value in % Software_version: 4.1 (onwards) 2010-29-11
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=Reg_Type= PI / WSP / DSP This parameter selects the control action of 2nd regulator. Select, PI - Pre-feeder drive control as per PI control action WSP - pre-feeder drive setpoint tracks the current WF setpoint,Wc DSP - pre-feeder drive setpoint tracks the WF drive setpoint Select : Use '→' key to select =Regulator Tracking= When WSP or DSP is selected for parameter =Reg_Type=, pre-feeder drive setpoint tracks the selected variable by a multiplying factor defined by this parameter. Input : Numerical value in 0,1 % steps 4.1.4 SET4 This menu allows access to certain offline parameters. These paramters may be viewed/edited in this menu. Entry to this menu is allowed only after entry of the 5 digit system . =Count_DL= The Dead Load count value is displayed in of internal calibration counts. Input : Numerical value =Span_Cnt= The Belt Load corresponding to 100% load is displayed in of internal calibration counts. Input : Numerical value in count =AI_Tare= The Tare value is displayed in of internal calibration counts for the Anaput. Input: Numerical value =AI_Span= The Anaput corresponding to 100% value is displayed in of internal calibration counts. Software_version: 4.1 (onwards) 2010-29-11
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Input : Numerical value in count =Rev. Time= Belt revolution time Time for one revolution of the belt with nominal tacho frequency. Input : Numerical value in 0,1 s steps =Drv_Const= Used with "tCTRL" control mode for WF drive. Select the initial drive setpoint value with this parameter. Input : Numerical value in %. =tCTRL_Cnt= Used with "tCTRL" control mode for WF drive. Select the speed of control action with this parameter. Input : Numerical value in 01 step 4.1.5 SET5 This menu displays the status of Digital Inputs, Digital Outputs, Markers and Timer bits.
E00_ 9 ■ ■ ■ ■ ■ ■ 2 ■ ■ A00_ ■ ■ ■ ■ 5 ■ ■ ■ ■ 0
Bit status ‘0’ is indicated by ‘■’ and Bit status’1’ is indicated by the corresponding bit number. Example: In the above display, E002, E009, A000 & A005 are with status ‘1’ while all remaining bits are with status ‘0’ Press ‘→’ key to switch the 2nd line display to next block Press ‘↓’ or ‘↑’ to scroll the display lines Press either ‘Esc’ or ‘CL’ to exit and return to Main_Program
Software_version: 4.1 (onwards) 2010-29-11
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4.1.6 Zero correction Since the belt conveyor scale shows system related oscillation around the zero position, the zero point is corrected during one belt revolution in order to improve the measuring precision. The deviation of the zero point is measured and stored with a plus or minus prefix. This value is used to correct the momentary load during each measuring cycle. Zeroing can be started with the system in "Local" or "Manual" mode and in "Start" condition. Press key to initiate the zero correction cycle. When zero correction is in progress, deviation of zero point is displayed continuously. At the end of the zero correction cycle, the average deviation is displayed in percent. If the deviation is greater than the =Zero_limit= parameter, an error message is displayed and the value calculated is discarded. Zero correction has to be repeated. Press
key to stop zeroing in progress.
4.1.7 Control Measurement Feeders with pre-hopper scale can be selected to operate as a "Block" system. In this mode, material conveyed by the feeder for a fixed time can be compared with the amount of material extracted from the hopper for the same time period. The difference between can be measured and used to correct the feeder calibration automatically. Control Measuring (CM) can be started with the system in "Gravimetric" mode and in "Start" condition. Press key to initiate the zero correction cycle. When CM is in progress, "F"-Material conveyed by feeder and "W"-Material extracted from Hopper are displayed continuously. At the end of the CM cycle the following results are calculated and displayed, “D” – Difference between “F” and “W” “Sk” – Control Measurement error in %. The feeder calibration can be corrected on the basis of the error value calculated by pressing the key. The correction can be applied to either Feeder ‘Tare’ or ‘Span’ value.
Software_version: 4.1 (onwards) 2010-29-11
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If deviation is greater than the =Zero_limit= parameter, an error message is displayed and the value calculated is discarded. Press
key to stop Control Measuring in progress.
Control Measurement can also be initiated and controlled through Serial I/O or Digital I/O.
Software_version: 4.1 (onwards) 2010-29-11
MENU OPERATIONS Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.4-R1
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TABLE OF CONTENTS 1.0
General...............................................………………………………………… 2 1.1 Parameter save...................................………………….……………….. 2
2.0
Parameter menus.......................................………………………………….. 2 2.1 OFFline parameters...............................………………………………… 2 2.2 ONline parameters................................…………………………………. 2 2.3 Parameter label..................................…………………………………… 2 2.4 Menu structure...................................…………………………………… 3 2.5 Keys inside the menu.............................………………………………… 8 2.6 Calling and operating the menus..................…………………………… 8 2.7 Menu operation example...........................……………………………… 11
Software_version: 4.1 (onwards) 2010-11-29
MENU OPERATIONS Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.4-R1 1.0
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General
The Parameters are entered using the keypad and a 16 digit x 2 line display. The arrangement of parameters within the menus, options available for each parameters and writing the parameters are explained in the commissioning instructions. 1.1
Parameter save
The parameters of the system are stored in an EEPROM. On each power ON, the data in the EEPORM is checked with the contents of the Battery Buffered RAM. If a mismatch occurs, error message is displayed. Acknowledging the error, reloads the RAM from EEPROM. Instantaneous values during system operation are stored in the Battery buffered RAM. The parameters in a menu are automatically saved when the display is scrolled to display the next parameter. When the Online menu "Main_Program" is called,the parameters set in various menus are checked for logical settings.In case of mismatch, error message is generated.The corresponding parameter should then be correctly set. 2.0
Parameter Menus
The menu structure is divided into 2 categories, 2.1
OFFline parameters
These parameters can be changed only when the measuring mode is "OFF". 2.2
ONline parameters
These parameters can be changed even when the system is in operation. 2.3
Parameter Label
A differentiation is made between 2 types of parameters: Parameter label 1. Parameter whose value is entered numerically 2. Parameter whose value is selected from a list Software_version: 4.1 (onwards) 2010-11-29
Display xxxxxxx Selection →
MENU OPERATIONS Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.4-R1 2.4
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Menu structure
The parameters are arranged in different menus. The menus and the parameter listing is as shown below. Power ON ¾ • Enter ¾ Measuring Parameters • Measuring range • Units, Capacity • Decimal point, Capacity • Nominal capacity • Decimal point, S1 • Units, S1 • Decimal point, S2 • Units, S2 • Frequency Input • Nominal Tacho frequency • Belt Speed • Limit max. load • Limit min. load ¾ Configuration • Block mode • Regulation mode • Batch mode • Belt revolution time • No. of Belt Revolutions • Zero correction limit • Belt track monitoring time • Tacho supervision time • Impulse1 (S1,S2,OFF) • On_Time for Impulse output • Impulse2 • I1-Output Value • Limit value1 • Limit value2 • Limit delay time • Clear Totaliser2 Software_version: 4.1 (onwards) 2010-11-29
MENU OPERATIONS Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.4-R1 • • • • •
Measurement Filter Display Filter Step Mode selection (Internal/External) Setpoint %, Wm Ctrl_Mode
¾ Interface • No of Inverter • Inverter Type • No of DIO • No of AIO • AIO Type • Ext. Setpoint source • Ext. SP filter • AIO1 output • AIO2 output • AIO3 output • SIO Interface • SIO Baud • SIO Setup • SIO address • SIO monitor • CAN Interface ¾ AIO Anaput • Re-Calibrate? ¾ Channel1 ¾ Channel2 ƒ Min_Value ƒ Max_Value ¾ TUC Analog Output • Re-Calibrate? • Min_Value • Max_Value ¾ AIO Analog output • Re-Calibrate? ¾ Channel1 ¾ Channel2 ¾ Channel3 ƒ Min_Value ƒ Max_Value Software_version: 4.1 (onwards) 2010-11-29
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MENU OPERATIONS Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.4-R1 ¾ Calibration - Scale • Recalibrate? • Dead load set • Calibration load set ¾ PLC Program ¾ Calibration correction • Edit? • N Displayed_value Measured_value ¾ CAN Configuration • CAN Baudrate • X5 Interface • X5 Baudrate • X5 setup • X5 Addr • X5 Monitor • AO1 output • AO2 output ¾ CAN Hopper Parameters • Measuring Range • Units, L • Decimal Point, L • Nominal Capacity • Limit Min • Limit Nom • Limit Max • Measurement Damp, L ¾ Calibration - Hopper • Recalibrate? • Dead load set • Calibration load set ¾ Anaputs - FIM • Recalibrate? o Channel1 o Channel2 ƒ Min_Value ƒ Max_Value ¾ Analog Outputs - FIM • Recalibrate? o Channel1 Software_version: 4.1 (onwards) 2010-11-29
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MENU OPERATIONS Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.4-R1
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o Channel2 ƒ Min_Value ƒ Max_Value ¾ System data • • • • ¾ Main Program • • • • • • • • • • • • • • • • •
U crystal frequency Software version Date Time
• • • • • • •
Display Actual Flowrate Display S1 Display S2 Display belt load, BB Display WF Tacho frequency, Ta Display belt speed in m/sec, BS Display Internal setpoint, W1 Display External setpoint, W2 Display setpoint through X4, W3 Display Manual setpoint, Wm Display current setpoint, Wc Display Deviation, X0 Display WF drive setpoint, Y0 Display PF drive setpoint, Y1 Display Pre-hopper level, L Display material weighed during control measuring, F Display material extracted from hopper during control measuring, W Display D, difference between F & W Display Sk, control measurement error Display Date Display Time Display Quantity setpoint, Q Display dribble setpoint, q Display Gate Position
• • •
Reset Time I1 Amplification P1 Deviation Limit
¾ SET1
Software_version: 4.1 (onwards) 2010-11-29
MENU OPERATIONS Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.4-R1 • • • •
Deviation Time Reset time I2 Amplification P2 Dead Band
• • • • • • •
W1,Un-interlocked setpoint Wm,Manual setpoint Capacity limitation,% Q1,Quantity setpoint1 q1,Dribble setpoint1 Q2,Quantity setpiont2 q2,Dribble setpoint2
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¾ SET2
¾ SET3 • Belt Loading Limit,BB_Limit • Belt Loading delay,BB_Delay • Initial PF setpoint,BB_Setpnt • BB Load control,BB_Control • Belt Load Band,BB_Band • Max. PF setpoint,PF_Limit • Regulation Type • Regulator Tracking ¾ SET4 (Entry with ) • Dead Load count, Count_DL • Span count, Span_Cnt • Anaput, Tare • Anaput, Span • Belt Revolution time • Drive constant,Drv_Const • tControl count value,tCTRL_Cnt ¾ SET5 -Display E,A,M,T variables status See "Commissioning Instructions" for descriptions of each parameter. 2.5
Keys inside the Menu -Entry into a Menu/Sub-menu or -Selection of various options available for that parameter
Software_version: 4.1 (onwards) 2010-11-29
MENU OPERATIONS Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.4-R1
.....
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-Saving an entry and/or -Move further in the menu list -Numerical data input from the keypad -Exit from menu
+
-Call Online parameters from Main_Program menu
SET 2.6
Calling and operating the menus
1.
Power On TRANSWEIGH Version_1.0
a]
Possibility 1 X = 00,00 t/h BB = 100,0 %
The system enters Main_Program menu after 5 Secs., if no key is pressed during this delay period. If 'VER' is pressed during the 5 sec. delay, the delay is byed. a.1] Press 'Esc' and 'CL' to exit the online menu and enter the offline menus. Exit to Offline menus is possible in Weigh Feeder 'Stop' condition. a.2] Enter
Software_version: 4.1 (onwards) 2010-11-29
MENU OPERATIONS Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.4-R1
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Press key to enter the menu. All Offline menus are protected. Entry into the menu is allowed only if the right is pressed. a.3] Enter
…..
5 Digit entry using 1 TO 9 keys. a.4] Enter :Y If is right, the configuration menus can be accessed a.5] Measuring Param The Offline menus can be accessed by pressing '↓↑' key. Press 'Esc' and '↓↑' key to scroll the menu backwards. a.6]
M. Range 1,0 mV Press
key to enter the menu. The first menu parameter is displayed in the 2nd
display line. a.7] M. Range Press a.8]
3,0 mV
to change this value.
Software_version: 4.1 (onwards) 2010-11-29
Configuration
MENU OPERATIONS Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.4-R1
Page 10 of 11
Press 'Esc' and 'CL' to exit the sub-menu and enter the main menu list. b]
Possibility 2
b.1] The system enters the Offline menu directly, if 'CL' key is pressed during the 5 sec. delay. 2. Calling Online parameters from Main_Program menu STEP 1
Main_Program menu X = 00,00 t/h BB = 100,0 %
STEP 2 Press 2.7
SET
IT_Time =000,0s P1_Gain =000,0%
to return back to Main_Program
Menu operation Example
Example : Change the digit step from 1 to 2 in the Measuring parameters menu. STEP 1
Enter Offline menu as per 2.6 above.
STEP 2 Enter
Software_version: 4.1 (onwards) 2010-11-29
MENU OPERATIONS Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.4-R1
Page 11 of 11
STEP 3 ……
Enter
5–digit , using numerical keys STEP 4
Enter :Y
Only on right entry. STEP 5 Measuring Param STEP 6 M. Range 1,0 mV STEP 7 M. Range 1,0 mV UNITS,X kg/h STEP 8 M. Range 1,0 mV UNITS,X t/h STEP 9 UNITS,X D.Pt. X
t/h 0000,00
Step 9 saves the change made in the Units, X in Step 9.
Software_version: 4.1 (onwards) 2010-11-29
PARAMETER LISTING Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.5-R0
Sr. No.
Parameter
1.0
Measuring parameters
1.1
M. Range
1.2
Units, X
1.3
D. Pt, X
1.4
Nom. Cap.
1.5
D. Pt, S1
1.6
Units, S1
1.7
D. Pt, S2
1.8
Units, S2
1.9
Freq. I/P
1.10
Tacho Freq.
1.11
Belt Speed
1.12
Max. load
1.13
Min. Load
2.0
Configuration Parameters
2.1
Block Mode
2.2
Reg. Mode
2.3
Batch mode
2.4
Rev. Time
2.5
No. of Rev.
2.6
Zero Limit
2.7
Belt track
2.8
Run Time
2.9
Impulse 1
2.10
On_Time
Software_version: 2.0 2008-11-15
Page 1 of 6
Value 1
Value 2
PARAMETER LISTING Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.5-R0
Sr. No.
Parameter
2.11
Impulse 2
2.12
I1 value
2.13
Limit 1
2.14
Limit 2
2.15
L_ Delay
2.16
Clear, S2
2.17
Meas_Filt
2.18
Disp_step
2.19
Mode_sel
2.20
Setpoint %
2.21
Ctrl_mode
3.0
Interface
3.1
No_Of_Inv
3.2
Inv_Type
3.3
No_Of_DIO
3.4
No_Of_AIO
3.5
Ext_SP
3.6
SP_Filter
3.7
AIO1_Output
3.8
AIO2_Output
3.9
AIO3_Output
3.10
SIO_Interface
3.11
SIO_Baud
3.12
SIO_Setup
3.13
SIO_Addr
3.14
SIO_Monitor
Software_version: 2.0 2008-11-15
Page 2 of 6
Value 1
Value 2
PARAMETER LISTING Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.5-R0 Sr. No.
Parameter
3.15
CAN_Int
4.0
AIO AnalgInp Cal
4.1
Channel 1 Min_value
4.2
Channel 1 Max_value
4.3
Channel 2 Min_value
4.4
Channel 2 Max_value
5.0
TUC AnalgOut Cal
5.1
Min_Value
5.2
Max_Value
6.0
AIO AnalgOut Cal
6.1
Channel 1 Min_value
6.2
Channel 1 Max_value
6.3
Channel 2 Min_value
6.4
Channel 2 Max_value
6.3
Channel 3 Min_value
6.4
Channel 3 Max_value
7.0
Calibratn - Scale
7.1
Count_DL
7.2
Count_BL
8.0
PLC Program
8.1
SPSS_00
8.2
SPSS_01
8.3
SPSS_02
8.4
SPSS_03
8.5
SPSS_04
9.0
Calibration correction
9.1
Displayed Value
Software_version: 2.0 2008-11-15
Page 3 of 6 Value 1
Value 2
PARAMETER LISTING Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.5-R0 Measured Value 9.2
Displayed Value Measured Value
9.3
Displayed Value Measured Value
9.4
Displayed Value Measured Value
9.5
Displayed Value Measured Value
9.6
Displayed Value Measured Value
9.7
Displayed Value Measured Value
9.8
Displayed Value Measured Value
9.9
Displayed Value Measured Value
9.10
Displayed Value Measured Value
10.0
CAN Configuration
10.1
CAN_Baud
10.2
X5_Int
10.3
X5_Baud
10.4
X5_Setup
10.5
X5_Addr
10.6
X5_Monitor
10.5
AO1output
10.6
AO2 output
Software_version: 2.0 2008-11-15
Page 4 of 6
PARAMETER LISTING Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.5-R0
Page 5 of 6
Sr. No.
Parameter
11.0
CAN HopperParam
11.1
M. Range
11.2
Units, L
11.3
D. Pt, L
11.4
Nom. Cap
11.5
L_Min
11.6
L_Nom
11.7
L_Max
11.8
Meas_Damp, L
12.0
Calibration – Hopper
12.1
Count_DL
12.2
Count_BL
13.0
CAN AnalgInp Cal
13.1
Channel 1 Min value
13.2
Channel 1 Max value
13.3
Channel 2 Min value
13.4
Channel 2 Max value
14.0
CAN AnalgOut Cal
14.1
Channel 1 Min value
14.2
Channel 1 Max value
14.3
Channel 2 Min value
14.4
Channel 2 Max value
15.0
System Data
15.1
U Crystal
16 MHz
16 MHz
15.2
S/W Version
Ver_2.0
Ver_2.0
16.0
Main Program-SET1
16.1
I1_Time
Software_version: 2.0 2008-11-15
Value 1
Value 2
PARAMETER LISTING Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.5-R0 Sr. No.
Parameter
16.2
P1_Gain
16.3
Dev_Limit
16.4
Dev_Time
16.5
I2_ Time
16.6
P2_Gain
16.7
Dead_Band
17.0
Main Program-SET 3
17.1
BB_Limit
17.2
BB_Delay
17.3
BB_Setpoint
17.4
BB_control
17.5
BB_Band
17.6
PF-Limit
17.7
Reg_Type
17.8
Reg_Track
Software_version: 2.0 2008-11-15
Page 6 of 6 Value 1
Value 2
OPERATING INSTRUCTIONS - PLC Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.6-R0
Page 1 of 16
TABLE OF CONTENTS 1.0
Programmable Logic Controller.............................………………………... 2 1.1 Description..........................................……………………………………. 2 1.2 PLC Operation........................................…………………………………. 2 1.3 Instructions.........................................……………………………………. 3 1.4 Inputs,Outputs and Markers...........................…….…………………….. 4 1.5 Timers...............................................…………………………………….. 4
2.0
Programming Functions.....................................…….…………………….. 5 2.1 General..............................................…………………………………….. 5 2.2 Functions............................................……………………………………. 5 2.2.1 Assemble...................................…………………………………6 2.2.2 Delete.....................................…………………………………... 6 2.2.3 Editor.....................................…………….……………………... 6 2.2.4 Insert.....................................……………………………………. 7 2.2.5 List.......................................…………………………………….. 7 2.3 Error Messages.......................................………….……………………... 8
3.0
Allocation of Variable....................................……………………………….. 8 3.1 Inputs...............................................……………………………………… 8 3.2 Outputs..............................................…………………………………….. 9 3.3 Markers..............................................…………………………………….. 9 3.3.1 Input Markers..............................……………………………….. 9 3.3.2 Output Markers.............................……….……………………... 10 3.4 Timers...............................................……………………………………... 12
4.0
Standard Programs and I/O Assignments...............………………………. 12 4.1 Standard Program 1...................................………………………………12 4.1.1 Program List - SPSS_00.........................……………………….12 4.1.2 I/O Assignment.................................…….…………………….. 14 4.2 Standard Program 2...................................………………………………. 15 4.2.1 Program List - SPSS_01.........................……………………….15 4.2.2 I/O Assignment.................................…….……………………...16
Software_version: 2.0 (onwards) 2008-11-15
OPERATING INSTRUCTIONS - PLC Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.6-R0 1.0
Programmable Logic Controller
1.1
Description
Page 2 of 16
TUC-6 has an inbuilt PLC, that is used to control the Digital Inputs, Digital Outputs and Internal Memory Flags (Markers). The Programmable control system processes the instructions from the control program, SPSS. The Input data and Output data for the control program are physically in the TUC RAM, logically in the so called "process images". The instructions in the control program with the variables "A E M T" always refer to the process image in RAM. The programmable control system continuously operates on the control program in the following sequence, -Transfer hardware inputs to the TUC RAM -Execute instructions in the control program (SPSS) -Transfer output process image to the Hardware Outputs Several variable types are used in the PLC program. "A" stands for outputs, "E" for inputs, "M" for marker and "T" for timers. Addition of "N" (UN or ON) means that the associated variable is scanned for signal status "0" ; otherwise the scanning of variables is for signal status "1". 1.2
PLC Operation
The programmable control system consists of a 1_bit_wide BIT accumulator. Instructions in the PLC can be classified into two types; one type operating on the result of previous instruction (Result Instruction) and second changing the accumulator value (Command instruction). The control program is always started with accumulator = "1". ' Command ' instructions change the accumulator value till a ' Result ' instruction is encountered. After execution of all ' Result ' instructions, accumulator is again made ' 1 ' and the sequence is continued. Software_version: 2.0 (onwards) 2008-11-15
OPERATING INSTRUCTIONS - PLC Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.6-R0 Example: 000 001 002
*SPSS01 UM 045 UM 068
003
UNE 050
004 005
=A 008 UE 000
1.3
Page 3 of 16
;Comment Line ;Command Instruction - Accumulator = '1' ;Command Instruction - 'AND' result of above instruction with M068 value ;Command Instruction - 'AND' result of above instr. with 'NOT'of E050 input. ;Result Instruction ;Command Instruction - Accumulator = '1'
Instructions Instruction
Meaning
UE xxx UA xxx UM xxx UT xxx
AND operation with INPUT AND operation with OUTPUT AND operation with MARKER AND operation with TIMER
Y Y Y Y
N N N N
UNExxx UNAxxx UNMxxx UNTxxx
AND + NOT operation with Input AND + NOT operation with Output AND + NOT operation with Marker AND + NOT operation with Timer
Y Y Y Y
N N N N
OE xxx OA xxx OM xxx OT xxx
OR operation with INPUT OR operation with OUTPUT OR operation with MARKER OR operation with TIMER
Y Y Y Y
N N N N
ONExxx ONAxxx
OR + NOT operation with Input OR + NOT operation with Output
Y Y
N N
ONMxxx ONTxxx
OR + NOT operation with Marker OR + NOT operation with Timer
Y Y
N N
SA xxx SM xxx
SET Output SET Marker
N N
Y Y
RA xxx
RESET Output
N
Y
Software_version: 2.0 (onwards) 2008-11-15
Command
Result
OPERATING INSTRUCTIONS - PLC Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.6-R0 RM xxx RT xxx
RESET Marker RESET Timer
N N
Y Y
=A xxx =M xxx
Equate Output to result Equate Marker to result
N N
Y Y
LT xxx
Load Timer xxx with value in next Instruction Start Timer with xxx sec. in ON-delay mode
N
Y
N
Y
SITxxx 1.4
Page 4 of 16
Inputs, Outputs and Markers
These are one bit variables that can have status "LOW" (Logical 0) or "HIGH" (Logical 1). The differentiation between inputs and outputs is done by the "signal direction" on which these variables are based. Inputs are signals from "outside" to the control program, and outputs are signals from the control program to the external system. Thus inputs can only be read, while outputs can be allocated. Inputs and Outputs are available outside the TUC-6 system with the help of digital I/O card. Markers are internal variables and serve as memory within the control system. They are available outside the control system when they have been copied onto outputs. Markers are classified into Input Markers and Output Markers. Input markers are used to control the software execution while Output markers are derived as a result of the software execution. 1.5
Timers
Ten ON-delay timers are available in the system for timing functions. Instruction "LT xxx" loads timer "xxx" if the result of previous instruction is "1". Instruction "SIT yyy" starts the previously loaded timer with time "yyy". Timers continue to run till the input condition is "1" or till the set time is over, which ever is earlier. After completion of set time, the respective Timer "Txxx" bit status is made "1". Timers are reset (Txxx is made "0") with "RT xxx" instruction. Instruction "RT xxx", if executed while timer is running, stops the timer.
Software_version: 2.0 (onwards) 2008-11-15
OPERATING INSTRUCTIONS - PLC Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.6-R0 2.0
Programming Functions
2.1
General
Page 5 of 16
The Programmable Logic Controller in TUC-6 serve to adjust the scale to the plant control logic. The control program can be edited via the TUC keypad and display. Designation of files in the PLC menu is as follows, SPSS - Source file containing lit of instructions SPSA - Assembler file after translation from SPSS 2.2
Functions
The following functions are available in the "PLC Program" menu, PLC EDITOR A, D, E, I, L Key.
Meaning
Function
A D E I
Assemble Delete Editor Insert
L
List
Assembles SPSS file to generate SPSA file Delete SPSS file from memory Open editor for reading/altering SPSS file Append a std. SPSS file from EPROM to current SPSS file. List SPSS, SPSA file lengths
2.2.1 Assemble This function is invoked by pressing 'A' in the PLC Editor menu. PLC EDITOR Assemble → Press '→' key to assemble the SPSS file in memory or 'VER' to exit without assembling.
Software_version: 2.0 (onwards) 2008-11-15
OPERATING INSTRUCTIONS - PLC Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.6-R0
Page 6 of 16
2.2.2 Delete This function is invoked by pressing 'D' in the PLC Editor menu. PLC EDITOR Delete? → Yes Press ‘→ ‘ key to delete the SPSS file from memory or 'VER' to exit without deleting. 2.2.3 Editor Press 'E' in the PLC Editor menu, to edit the SPSS file in memory. The following functions are available within the Edit option, Key
Function
ESC + CL
Save and exit
ESC + I
Insert blank line
ESC + D
Delete line - The line indicated by cursor is deleted.
ESC + ANY OTHER KEY
Cancel "ESC" status
Keys used in this menu, Key
Function
0 to 9
Numeric entry
A,D,E,I,L,M,N,O,P,R,S,T,U,=,*
SPSS command characters
UP
Previous line
DOWN
Next line
HOR
Scroll to next/prev character position
Software_version: 2.0 (onwards) 2008-11-15
OPERATING INSTRUCTIONS - PLC Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.6-R0
Page 7 of 16
based on ESC key status ESC
Used in combination with other keys.
2.2.4 Insert This function is invoked by pressing 'I' in the PLC Editor menu. PLC EDITOR Insert SPSS=00 Standard SPSS files are resident in the EPROM memory, which can be used directly. These files are called into memory with the help of this function. Enter the SPSS file number to be inserted into memory and Press '→' key. Press 'VER' key to exit command without inserting the file. 2.2.5 List This function is invoked by pressing 'L' in the PLC Editor menu. SPSS = 120 LINES SPSA = 050 BYTES Press any key to return back to the Editor menu. 2.3
Error Messages Text In-correct Inst.
3.0
Meaning Assembling: non-existent address or instruction at the cursor line indicated.
Allocation of Variable
The variables are sub-divided into inputs, outputs, markers and timers. Free variables (read Markers) can be used by the control program as general purpose variables.
Software_version: 2.0 (onwards) 2008-11-15
OPERATING INSTRUCTIONS - PLC Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.6-R0 3.1
Inputs E000 to E007 E008 to E015 E016 to E019 E020 E021 E022 E023 E024 E025 E026 E027 E028 E029 E030 E031 E032 E033 E034 E035 E036 to E037 E038 to E049
3.2
Page 8 of 16
- DIO #1 Inputs - DIO #2 Inputs - Free ;Inverter #1 Inputs - LI1 input - LI2 - LI3 - LI4 - RL1 - RL2 - LI5 (J7, ATV31 & ACS550 Inverters only) - LI6 (ATV31 & ACS550 Inverters only) - Inverter Running (PF4 Inverter only) - RL3 (ACS550 Inverter only) ;Inverter #2 Inputs - LI1 input - LI2 - LI3 - LI4 - RL1 - RL2 - Free - Feild Interface Module - Digital Inputs
Outputs A000 to A007 A008 to A015 A016 A017 A018 A019 A020 A021 to A029
- DIO #1 Outputs - DIO #2 Outputs ;TUC-6 Outputs - RL1 (Totaliser 1 Pulse output, if selected) - RL2 (Totaliser 2 Pulse output, if selected) - RL3 - RL4 ;Inverter #1 Outputs - Start/Stop - Free ;Inverter #2 Outputs
Software_version: 2.0 (onwards) 2008-11-15
OPERATING INSTRUCTIONS - PLC Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.6-R0 A030 A031 to A037 A038 to A045 A046 to A049 3.3
Page 9 of 16
- Start/Stop - Free - Field Interface module - Digital Outputs - Free
Markers
Marker are classified into Input markers (M000 - M031) and Output markers (M032 M071). Input markers are read by the control program while Output markers are written by the control program. Reading access is allowed to both these types of markers. 3.3.1 Input Markers Marker
Meaning "1"
M000 M001 M002 M003 M004 M005 M006 M007
Start via SIO Stop via SIO Free Free Accept Count_DL, Span_Count (Only with Profibus) Reset Totaliser1 Remote ON (Control through SIO) Zeroing Start
M008 M009 M010 M011 M012 M013 M014 M015
Remote Mode Belt Track status-Healthy Emergency status-Healthy Local Start-WF Local Stop-WF Local Start-PF Local Stop-PF De-Interlock Mode
Local Mode Fault Fault
M016 M017 M018 M019 M020 M021 M022
Remote Start Downstream Interlock-Healthy Error Reset WF Drive Interlock-Healthy PF Drive Interlock-Healthy Material Low (Fault) Local Start-Vibrator Motor
Stop Fault
Software_version: 2.0 (onwards) 2008-11-15
Meaning "0"
Interlock Mode
Fault Fault High Stop
OPERATING INSTRUCTIONS - PLC Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.6-R0
Page 10 of 16
M023
Gravimetric mode select
Volumetric mode
M024 M025 M026 M027 M028 M029 M030 M031
Select Q1,q1 Select Q2,q2 Bin Pre-feeder Start/Stop Start Control Measurement Stop Control Measurement Accept Control Measurement Error Free Free Free
3.3.2 Output Markers Marker
Meaning "1"
Meaning "0"
M032 M033 M034 M035 M036 M037 M038 M039
Load Disturbance Fault Belt Tracking Fault Drive Disturbance Deviation Disturbance General Fault Belt Slip Zeroing: Correction>Limit Zeroing: Aborted
Healthy Healthy Healthy Healthy Healthy
M040 M041 M042 M043 M044 M045 M046 M047
Free Feeder Selected Free Local Mode Gravimetric mode Interlock Mode Free Vibrator Start
M048 M049 M050 M051 M052 M053 M054
Limit Value 1 Limit Value 2 Overload Error Underload Error Free Bin Pre-feeder Start Control Measurement ON
Software_version: 2.0 (onwards) 2008-11-15
Remote Mode Volumetric mode De-Interlock Mode Stop
Healthy Healthy Stop
OPERATING INSTRUCTIONS - PLC Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.6-R0 M055
Control Measurement Aborted
M056 M057 M058 M059 M060 M061 M062 M063
Zeroing: In Progress Zeroing: OK Correction max exceeded Quantity Reached Free BLMS Level < L_min BLMS Level < L_nom BLMS Level < L_max
M064 M065 M066 M067 M068 M069 M070 M071
WF-Start PF-Start WF-Start PF-Start System Healthy Loadcell Fault AI Card Communication fault PF Tacho Fault
M072 M073 M074 M075 M076 M077 M078 M079
Free Free Free Free Free Free Free Free
M080 M081
Free Free
M082 M083 M084 M085 M086 M087 M088 M089
Input from Profibus Input from Profibus Input from Profibus Input from Profibus Input from Profibus Input from Profibus Input from Profibus Input from Profibus
Software_version: 2.0 (onwards) 2008-11-15
Page 11 of 16
Stop Stop Stop Stop Fault Healthy Healthy
(Blinking-Fault) (Blinking-Fault)
OPERATING INSTRUCTIONS - PLC Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.6-R0 3.4
Page 12 of 16
Timers T000 to T009 are timers available for use in the SPSS program.
4.0
Standard Programs and I/O Assignments
4.1
Standard Program 1 Standard Program for 8 Digital I/O card.
4.1.1 Program List - SPSS_00 / / / / / / / / / / / / / / / / / / / / / / / / / / / / /
*SPSS00/ UE 001/ =M 009/ UE 004/ =M 023/ UE 005/ =M 015/ UE 006/ =M 017/ UE 007/ UM 045/ SM 016/ UNE007/ UM 045/ RM 016/ UE 021/ SM 011/ RM 012/ UNE020/ SM 012/ RM 011/ UNE022/ =M 008/ UE 023/ =M 010/ UE 024/ =M 019/ =M 020/ UM 064/
;BELT TRACK SWITCH ;GRAV/VOL. SELECT ;INT./DE-INT. SELECT ;DOWNSTREAM INTERLOCK ;START/STOP - INTERLOCK MODE ;SET START MARKER ;RESET START MARKER ;LOCAL START - PB ;SET "START" ;RESET "STOP" ;LOCAL STOP - PB ;SET "STOP" ;RESET "START" ;LOCAL/REMOTE SELECTION ;EMERGENCY S/W ;DRIVE INTERLOCK ;DRIVE INTERLOCK - WF ;DRIVE INTERLOCK - PF ;WF START/STOP/FAULT - LCS INDICATION
Software_version: 2.0 (onwards) 2008-11-15
OPERATING INSTRUCTIONS - PLC Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.6-R0 / / / / / / / / / / / / / / / / / /
=A 000/ UM 066/ =A 001/ UM 066/ =A 002/ UM 033/ =A 003/ UM 036/ =A 004/ UM 045/ UM 068/ =A 005/ UM 035/ =A 006/ UM 034/ =A 007/ UM 066/ =A 020/
Page 13 of 16
;WF DRIVE START/STOP - NO ;WF DRIVE START/STOP - NO ;BELT TRACKING FAULT O/P ;GENERAL FAULT O/P ;INT. MODE ;SYSTEM HEALTHY ;READY TO START O/P - INT. MODE ;DEVIATION FAULT ;DRIVE FAULT ;WF DRIVE START/STOP - NO
4.1.2 I/O Assignment Digital Inputs - DIO #1 Input
High
Low
E000 E001 E002 E003
Free Belt Track S/W-Healthy Fault Free Free
E004 E005 E006 E007
Volumetric Interlock D. Interlock-Healthy Start
Gravimetric De-Interlock Fault Stop
Signal Type Steady
Steady Steady Steady Steady
Digital Outputs - DIO #1 Output High
Low
A000
Stop
Start
Software_version: 2.0 (onwards) 2008-11-15
(Blinking-Fault)
OPERATING INSTRUCTIONS - PLC Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.6-R0
Page 14 of 16
A001 A002 A003
Drive Start Drive Start Belt Track. Fault
Stop Stop Healthy
A004 A005 A006 A007
General Fault Ready to Start Deviation Fault Drive Fault
Healthy Fault/Not-Healthy Healthy Healthy
Inverter 1 Inputs Input
High
Low
Signal Type
E020 E021 E022 E023
Start-Local Local Emg. Switch-Healthy
Stop-local
Impulse Impulse Steady Steady
E024
Drive Interlock_Healthy Fault
Remote Fault
Inverter 1 Outputs
4.2
Output
High
Low
A020
Drive Start
Stop
Standard Program 2 Standard Program for Pre-Feeder
4.2.1 Program List - SPSS_01 / *SPSS01/ / UNE030/ / SM 014/ / RM 013/ / UE 031/ / SM 013/ / RM 014/ / UE 034/ / =M 020/
;PF STOP FROM LCS ; ;PF START FROM LCS ; ;PF DRIVE INTERLOCK
Software_version: 2.0 (onwards) 2008-11-15
Steady
OPERATING INSTRUCTIONS - PLC Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.6-R0 / / / /
UM 067/ =A 030/ UM 065/ =A 001/
Page 15 of 16
;PF DRIVE START/STOP ;PF START/STOP/FAULT - LCS INDICATION
NOTE:SPSS_01 when used with SPSS_00, the following changes should be made to the standard SPSS_00 program i) SPSS_00: . . / UE 024/ / =M 019/ / =M 020/
;DRIVE INTERLOCK ;DRIVE INTERLOCK - WF ;DRIVE INTERLOCK - PF *****Delete******
Pre-Feeder 'Drive Interlock' Marker is assigned in SPSS_01. Duplicate assignment in SPSS_00 should be deleted. ii) SPSS_00: . . / UM 066/ / =A 001/
;WF DRIVE START/STOP *****Delete***** *****Delete*****
Output A001 is used in SPSS_01 for 'Pre-Feeder Start/Stop/Fault' indication. Above lines in SPSS_00 should be deleted. 4.2.2 I/O Assignment Digital Outputs - DIO #1 Output High
Low
A001
PF Stop
(Blinking-Fault)
Low
Signal Type
Stop-local
Impulse
PF Start
Inverter 1 Inputs Input
High
E030 Software_version: 2.0 (onwards) 2008-11-15
OPERATING INSTRUCTIONS - PLC Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.6-R0 E031 E034
Start-Local Drive Interlock_Healthy Fault
Inverter 1 Outputs Output High
Low
A030
Stop
Drive Start
Software_version: 2.0 (onwards) 2008-11-15
Page 16 of 16 Impulse Steady
APPLIANCE DESCRIPTION
Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.10-R0
Page 1 of 12
TABLE OF CONTENTS 1.0
General...................................................……………………………………… 2
2.0
System Representation....................................……………………………... 2
3.0
Configuration of Jumpers..................................…………………………….3 3.1 Main Board...........................................…………………………………3 3.2 Measuring Card.......................................………………………………3 3.3 Field Interface Module……………………………………………………3
4.0
Rear View of TUC6CAN.................................……………………………….. 4
5.0
Main Board External Connectors............................……………………….. 5
6.0
Layout of Main Board......................................……………………………… 6
7.0
AIO Card Connector Details................................…………………………... 7 7.1 F868………………………………………………………………………..7 7.2 F875………………………………………………………………………..8 DIO Card Connector Details...............................…………………………… 9 8.1 F866………………………………………………………………………..9 8.2 F889………………………………………………………………………..10 8.2 F890………………………………………………………………………..11
8.0
9.0
Field Interface Module Connector Details…………………………………..12 9.1 F892………………………………………………………………………..12
Software_version: 2.0 (onwards) 2008-11-15
APPLIANCE DESCRIPTION
Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.10-R0 1.0
Page 2 of 12
General
Each member of the TUC-6 family comprises a Basic unit & several I/O modules connected to the Basic unit on the RS-485 serial Interface. The I/O modules are suited for external mounting on an assembly plate. 2.0
System Representation
TUC-6 X1
F1
0.5A
Mains Connections 24Vdc
+Main Board Measuring card X6 X1
Software_version: 2.0 (onwards) 2008-11-15
X3
Loadcell connection 12V/0.11A for max. 3 loadcells 350 Ohm
X1
4 Digital outputs 4-20mA Isolated Output Tacho Pulse Input
X2
Serial interface RS485
X4
Profibus Interface TUC-6 Display & Keypad Interface Card
X5
X1
X7
CANbus connection to FIM card (F892)
APPLIANCE DESCRIPTION
Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.10-R0
Page 3 of 12
3.0
Configuration of Jumpers & Dip Switches
3.1
Main Board
Jumper J1 : 1-2 → Terminating resistor for X2 Interface – RS485 (Connects 120E resistor) Jumper J2 : 1-2 → Terminating resistor for X7 Interface – CAN Interface (Connects 120E resistor) Jumper J4 : 1-2 → Modbus interface with X4 connector(BUS+ line) 3-4 → Modbus interface with X4 connector(BUS- line) 3.2
Measuring Card
Jumper J1 : 1-2 / 9-10 1-2 / 7-8 3-4 / 9-10 3-4 / 7-8 5-6 / 9-10 5-6 / 7-8
measurement period
Software_version: 2.0 (onwards) 2008-11-15
4ms 8ms 8ms 16ms 16ms 32ms
ASSEMBLY & START UP INSTRUCTION MANUAL FOR WEIGH FEEDER The Assembly At Site Is Done According To The Corresponding Implantation Drawing. Furthermore the following has to be observed ( maintenance instructions and instructions ). 1)
lubrification
The fixation of the weigh feeder has to be done in a way, that the belt frame may not be distorted. It also has to be horizontal in both directions.
2) Detach Transport Saftenings. 2.1) Protection Of Weigh Lever. Unscrew protection plate 1 of the load cell. Unscrew protection plate 3 which is lacquered in red at the upper screw and pull it out. Do not change the overload buffer 5 see also point 4 of the maintenance instructions.
3)
Discharge hood normally the discharge hood is mounted at the belt frame for transport. In case the discharge hood is fixed at site at a chute, The screws between hood and arm straps have to be screwed out.
4)
Check oil filling of drive gear. Quantity and quality can be seen from the type plate and lubrification plan.
5)
Connect the scale and start it in manual mode. See electrical start-up instructions.
6)
Adjustment of belt tracking see maintenance instructions point.
7)
Check function of scrapers and belt tracking sensors.
8)
Fix all protection facilities. For the assembly the regulations for preventation of acciedents have to be observed.
FLSmidth Pfister India Ltd.
MAINTENANCE INSTRUCTION MANUAL FOR WEIGH FEEDER
Interrupt the power supply before starting any work on rotating parts or parts being under voltage.
Drive motor All motors are supplied in completely assembled condition ready for operation. The bearings are filled with the requisite amount of grease at the time of assembly of the motors. While regreasing the bearings, a lithium based grease should be used. Do not force in the grease. The bearing shall be cleaned thoroughly and be refilled with grease upto 2/3 of their empty internal space. More grease would cause overheating of the bearings. Drive gear
Gear units are supplied in completely assembled condition ready for operation after first filling of oil. Care should be taken to fill the oil to the correct oil mark. It should be emphasized that excess oil must not be put in to the unit,because this may result in excessive temperature rise due to running. Cleanliness of oil is of prime importance and it is imperative to flush the gear unit with flushing oil before refilling. Flushing fluid is to be drained off completely before filling the fresh oil. If the gear has to be replaced or repaired, the supply tubes to the motor and tacho have to be disconnected. Unscrew the motor at its flange, and remove the tacho in the drive casing. Unscrew at the gear flange. Pull gear off the drive shaft with the help of the puller. Suspend the gear unit with the pull lift device and lower at the platform with the lever. Hoist has to be used for removal or replacement of the gear unit.
Digital tachometer The digital tachometer is installed in the drive casing. Accessible by dismounting the motor. The distance between counting wheel and inductive transducer is 1.5 mm. The impulse pause ratio is about 1:1.
FLSmidth Pfister India Ltd.
MAINTENANCE INSTRUCTION MANUAL FOR WEIGH FEEDER
All the works at the weighing system have to be carried out with special care. The load Cell 1 is maintenance - free. It can only be destroyed by inissibl, external machanical Or electrical influences. The exchange of the load cell must be followed by a new Adjustment of the overload stop 5. Check of the adjustment by electrical measurement. The overload stop must becomeeffective at 125% of the rated load of the load cell. Check the adjustment of the height of the measuring idler 2. This idler is about 2mm Higher than the neighbouring idlers 3 when the belt is not loaded. An adjustment can be Made at the screws 4 under the measuring idler shaft. By means of the excenter 6 the Lever movement is limited to the opposed direction. It is adjusted in a way, so that the Tension rod at the load cell has a stroke of about 4 mm when relieved.
FLSmidth Pfister India Ltd.
MAINTENANCE INSTRUCTION MANUAL FOR WEIGH FEEDER - weigh lever Check the v-ring seal to correct function. For the dismounting of the bearing or the V-ring the tension rod to the load cell is unscrewed (adjustment of lever see above Point). The bearings are maintained according to lubrification instructions.
Conveyor belt Belt change In case of excessive wear or destruction of the when changing the belt the rubber blades of the inner belt scrapers and the pulley Scraper be readjusted,replaced at the same time. If necessary, also clean the idlers and Pulleys and check if they are rotating easily. The belt change is made at the side opposite to the belt drive as described below. 1) unscrew the side covers 1 and their s 2 at the side on which the belt is taken off as well as the protection covers 3 of the tail pulley. Screws 4.
FLSmidth Pfister India Ltd.
MAINTENANCE INSTRUCTION MANUAL FOR WEIGH FEEDER
2) unscrew discharge hood cover 4. 3) dismount outer belt scrapers (see point 11). 4) in case of weighers having a distance of pulley centers of more than 3500 mm unhinge The return idlers. 5) put in the isolating gate at the hopper and if needed, lower the gate for bed depth of material.
6) displace the tail pulley by turning the nuts 1 on the spindles 2. 7) suspend the supplied for belt change on the frame structure, put on the new belt and lift the slightly on its end. Weighers with a distance of pulley centers of up to 3500 have one and weighers of more than 3800 mm have two belt change s.
FLSmidth Pfister India Ltd.
MAINTENANCE INSTRUCTION MANUAL FOR WEIGH FEEDER 8) dismount the resp. Suspension of the weigher on the side of belt changing. A) weighers with Slightly undo the screwings between and conveyor frame. Lift the belt change till the s are free. Dismount the s. B) weighers with suspension Undo the screwings between suspensions and conveyor frame. Lift the belt change till the screwings are relieved of the load and can be removed. Dismount the Suspensions by lowering themdown a little from the girder. 9) cut up the old belt or take it off and put on the new belt. Now the maintenance works Mentioned at the beginning can be carried out. Mount new belt. 10) mount the s resp. Suspensions and the return idlers if there are any. 11) shift the tail pulley uniformly (1) towards outside till the belt has the correct tension according to the belt tension indication (see point 7). 12) mount outer belt scrapers, discharge hood, protection covers of tail pulley and s for the side covers. 13) adjustment of belt tracking ( in manual operation). A) without material If the belt deviates to one side, the distance of the pulley centers has to be increased on This side by the pressure spindles at the return pulley resp.to be decreased on the Opposite side, depending on the belt tension.
FLSmidth Pfister India Ltd.
MAINTENANCE INSTRUCTION MANUAL FOR WEIGH FEEDER
The belt tension is indicated by indications on the side covers, see 8. Indication belt Tension. The belt tension can be changed by turning the nuts 1 (evenly on both sides). During the first operating hours the belt has to be adjusted more often. B) with material When the belt is standing still lift gate for bed depth, if it has changed, and pull out the Isolating gate. If the form of the belt is not quite cylindric, the belt may be displaced Laterally under load. This deviation can be avoided by a horizontal displacement of the Idlers. The conical form is determined by measuring the pulley centers on both sides. Spacings ant the idlers, ie. The idler s are shifted in a corresponding way.The first 3 idlers seen from the drive, must not be shifted. The axes of the remaining idlers And pulleys intersect in a common point
FLSmidth Pfister India Ltd.
MAINTENANCE INSTRUCTION MANUAL FOR WEIGH FEEDER Belt tension holding rod The belt tension must be checked regularly & readjusted if necessary. It is indicated, When the return roller is not in with belt, so to do the tensioning raise
The upper nut of tensioning rod till the return roller touches the belt & the belt is Tightend. After tensioning raise the spacer of the indicating rod & raise the lower nut This act as a lock for the tensioning rod.
Belt tracking controls Check function of the limit switches and switching point position of the lever.
FLSmidth Pfister India Ltd.
MAINTENANCE INSTRUCTION MANUAL FOR WEIGH FEEDER Pulley bearings For maintenance please see lubrification plan. Idlers Dirty idlers are to be cleaned and checked for easy running. The 3 carrying idlers of the Measuring section have a higher true running accuracy as the other carrying idlers and May be exchanged against one another. The idlers have life- time greasing. Principal position of idlers and pulleys.
Outer belt scraper The correct pressure of the scraper 1 has to be adapted to the operating conditions. The pressure can be modified by the nuts 2 at the end of the pull 3. For replacement or Readjustment of the rubber blade it is useful to take out the scraper 1 . After having Removed the nuts 2 and the springs 4 it can be taken out of its . See lubrification plan
.
FLSmidth Pfister India Ltd.
MAINTENANCE INSTRUCTION MANUAL FOR WEIGH FEEDER Inner belt scraper Check function of the scraper.for readjustment or replacement of the rubber blade the Whole scraper is taken out from the conveyor structure. Extract guide bolt 2,remove Scraper 1 from its guidance,hang out chain 3 at belt frame.eventually the return pulley Has to be shifted some what towards inside for an easier dismounting.
Pulley scraper (not for cage pulleys or rubber-lagged pulleys) . The scrapers on head and tail pulleys function free of .the distance between Blade and pulley is about 1 mm. It can be checked and adjusted during belt change. Cover/skirt boards Weighers for granular material. Check the wear of the skirtboards. A gap of at least 1 mm must exist between belt and rubber blade. Weighers for powdery material. Check the wear of the skirtboards. The thin rubber Blades are bent by 90 deg. And lie on the belt with the wide side. Weighers with flexowell board for powdery material do not have any skirtboards or Else skirtboards as described above.
FLSmidth Pfister India Ltd.
MAINTENANCE INSTRUCTION MANUAL FOR WEIGH FEEDER
Check the electrical connections and replace damaged cables. Observe lubrification plan . Check the screw connections of parts under load or mobile parts. Clean the weigher, especially in the zone of the measuring sections,drive and flexible parts.all dust protections have to be remounted after the end of the maintenance work..
FLSmidth Pfister India Ltd.
LUBRICATION INSTRUCTION MANUAL FOR WEIGH FEEDER
FLSmidth Pfister India Ltd.
LUBRICATION INSTRUCTION MANUAL FOR WEIGH FEEDER
FLSmidth Pfister India Ltd.
LUBRICATION INSTRUCTION MANUAL FOR WEIGH FEEDER Legend to lubrication list Column-1 No.of the lubrication point in accordance with the numbering in the drawing. Column-2 Number of lubication points (per machine unit). Column-3 Designation of the machine part to be lubicated Column-4 Type of lubrication The lubrication methods listed below are identified in column 4 by a figure. Lubrication nipple
–
1
Splash lubrication
–
2
Grease filling
–
3
Central grease Lubrication system
–
4
Circulating oil Lubrication
–
5
Spray lubrication
–
6
Application of the Lubrication by means Of a brush,spray can,etc
–
7
Hydraulic or Power transmission Oil filling
–
8
Lifetime lubrication
–
9
FLSmidth Pfister India Ltd.
LUBRICATION INSTRUCTION MANUAL FOR WEIGH FEEDER Column-5 Lubricant designation
k=servogem no.2-i.o.c 2k= bharat mp grease 2-bp Clp=benzene or kerosene
Column-6 First filling (oil in liters, grease in cub cm) Column-7 Relubrication volume (oil in liters,grease in cub cm) Column-8 Lubrication intervals in operating hours of the entire plant. Basis:24 hours operation. 640-1000 operating hours (4 weeks or 6 weeks) 2200 operating hours (a quarter of a year) 4400 operating hours (half a year) 6600 operating hours (three quarters of a year) 8800 operating hours (1 year) Column-9 Lubricant replacement (in operating hours as above). Column-10 Observations to the above columns.
FLSmidth Pfister India Ltd.
TESTING / ADJUSTING MANUAL FOR WEIGH FEEDER The tests described below shall be called the acceptance tests. The acceptance tests shall comprise of the following: 1) GENERAL ECHANICAL & ELECTRICAL TESTS: CONTINUOUS RUN During the tests , the equipment shall be operated for a period of 48 hours continuously At the maximum rated capacity/speed. During the last 4 to 6 hours of this time a check Shall be carried out to observe that the operation of all the elementsof the machinery, Such as bearings,grease,scrapers,etc. Are free from abnormal defects such as noise, Vibration and over heating. During this period the shift in the variable speed shall also be noted. CAPACITY TEST After the completion of the continuous run test, the feeders shall be tested for Establishing their maximum carrying capacity.this shall be done under simulated loading With calibrated load.the capacity of the equipment shall be calculated as follows: Q = 3600 a x s x d , tonnes/hour where: A = cross sectional gate opening in sq.meters. S = velocity in meters/sec. D = bulk density in tonnes/cubic meter. 2) THE WEIGHING AND INDICATING SYSTEM TEST (SEE BELOW) 3) THE FEED BACK CONTROL SYSTEM TEST The test for both above systems should be carried out simultaneously for a period of 48 hours,after the general mechanical and electrical tests are conducted. the tests Should be either continuous,or aggregate of 48 hours,depending on the availability of material,operating staff,power etc. The tests are designed to check the dependability, accuracy, repeatability and the degree of drift in calibration of the system and shall comprise the following procedure:
FLSmidth Pfister India Ltd.
TESTING / ADJUSTING MANUAL FOR WEIGH FEEDER The accuracy of the weighing & indicating system to be ascertained by means of the calibration weight laid on the empty, running belt,and the indicating checked against The oretical through put at a particular belt speed. The epeatability to be ascertained By repeating the above checks three times at the same setting and noting the difference in the indication at each check. This test to be carried out at 0 hours,24 hours and 48 hours of the test period. As soon as the above test at zero hours is satisfactory, it shall be assumed that the weighing and indicating system is functioning correctly.and the indications shall Thereafter be used to check the control system as follows: Material shall be feed as in normal operation through the feeder and the steadiness of The feed maintained by the control as indicated by the indication system shall be noted periodically manually. This test shall be continued till is necessary to interrupt the flow of material for carrying out test 2 (a) at 12 hours,and recommenced immediately thereafter. Should it not be possible to conduct the tests specified herein for any reason not attributable to the supplier, within 30 days from the supplier having given their readiness To carry out such tests to the purchaser,in writing,the tests shall be deemed to have been carried out and accepted. Apart from the preliminary acceptance Test for the individual equipment, the performance guarantee test shall be completed by the supplier with all weighfeeders at a time for 72 hours in continuous operation of the plant. During this test, the supplier shall show the performance guarantee figures as offered By them and should they fail to do so, on of faulty design or defects in manufacturing of the equipment, the necessary changes / modifications shall be carried Out by them to comply with the offered quarantee figures, free of cost,without which the system shall not be accepted by the purchaser.
FLSmidth Pfister India Ltd.
ERECTION INSTRUCTION MANUAL FOR WEIGH FEEDER ERECTION QUALITY CONTROL PLAN FOR WEIGH FEEDER Sr.no.
Desciption
Responsibility
1
Supervisory staff should be well trained in enforcing Erection safety regulation & be able to distinguish safe unsafe Contractor workmanship.
2
While engaging men for the job the supervisor should check up & make sure that they are skilled in the particular job they have to perfor
3
Package & equipment should be check for damage during transit.
4
Quantity should be checked as per packing list to ensure completeness of supply.
5
Special care should be taken so as to avoid the damage to the load sensing mechanism of supplied equipment.
6
All the points mentioned in the erection manual for weigh feeder & belt weighers should be complied with Wire rope,clams, lifting tackles should be inspected for their condition before used.
7
8
The safe working load of the ropes, tackles needed to lift the weighfeeder & belt weigher should never be exceeded.
9
When moving the weigh feeder, belt weigher in to place the area should be cordoned off to prevent persons from hitting against structural component etc.
FLSmidth Pfister India Ltd.
ERECTION INSTRUCTION MANUAL FOR WEIGH FEEDER During transit the storage of equipment after it has reached at site considerable dust & foreign material may have lodged on the various parts of the weigh feeder. All parts / assembled unit must be cleaned & checked with grat care before commencing erection. It is necessary to remove the anti-rust coat given on the machined surfaces. Check all the bolts & nuts for their tightness as there is possibility of nuts getting loose during transit & handling. Though all parts are inspected & duly packed while dispatching from works. There is possibility of damage to the machined portions during transit. Hence following checks should be made before commencing the installation: 1) All the mating surfaces fit properly. 2) While assembling do not apply undue force. 3) Avoid use of hammer. 4) Ensure perfect matching of surfaces. 5) Take care that no part is left out through over sight. Every single item, however small has an importance in the proper functioning of the equipment. 6) Take care that no foreign substance is dropped or left inside. They will get stuck up & cause jamming. 7) all tools are kept ready on h & before starting the erection. General arrangement drawing should be referred to during erection. 8) Erection should be done by experienced personnel.
FLSmidth Pfister India Ltd.
ERECTION INSTRUCTION MANUAL FOR WEIGH FEEDER ERECTION SHOULD BE CARRIED OUT CONSIDERING THE FOLLOWING: 1) The floor on which weigh feeder is to be installed should be properly leveled & foundation should be correctly marked. all levels should tally with general arrangement drawing of the equipment. 2) Check that weigh feeder assembly frame assembly is perfectly aligned & correctly leveled, before clamping to the foundation plate at four places. 3) Ensure that all carring idlers at the top & return idlers at bottom, these set are correctly mounted & that all the rollers are rotating freely. 4) Ensure that the self aligning idler set provided on the return side when fitted is pivoting freely. 5) Ensure that the screw take-up arrangement at the tail end is adjusted initially to remove under slack from the belt. 6) Ensure that rubber strips of skirt board, scrappers are correctly filled & adjusted, so that they touch the feeder belt. 7) Eheck that all components like motors, gearbox, couplings of drive unit are installed on the drive pulley shaft & torque arm is fixed to the main frame. 8) Ensure that electric wiring for electric motor, belt sway switch & loadcell are correctly carried out & that no loose electric connection is left out. 9) Ensure that all parts of the weigh feeder are greased or oiled as per lubrication chart given in this manual. 10) Eee that belt is not creased, folded or strained any where along the weigh feeder. 11) Check drives machinery for correct alignment. 12) Before starting the weigh feeder check motor insulation resistance. 13) Check along the length of the weigh feeder & ensure that there are no items left, lying about which could obstruct & cause damage to moving equipment. 14) check that matching flange of the infeed hopper assembly is as per the drawing requirment. 15) install the infeed hopper below material silo & above weigh feeder frame, holding on to top flange. 16) adjust the height of the gate as required through the height adjustment screws provided. 17) install discharge hood at the discharge end side of weigh feeder. FLSmidth Pfister India Ltd.
ERECTION INSTRUCTION MANUAL FOR WEIGH FEEDER LOADCELLMOUNTING PROCEDURE Load cell is mounted an angle bracket with a machined pad at its bottom as base. Weight of material on the belt is transferred to a swinging cradle and finally through a hook bolt no.-2to the load cell. The hook bolt and lode cell 1 are connected to each other through a wire rope and collect rope gripe at bolt ends. For the replacement of lode cell slacken the wire rope by loosening the nuts provided on collet gripe remove not no. 3 . Remove the collet rope gripe from the hole of lode cell. Now remove the base bolts of the lode cell and remove the same from its place. Install new lode at the same place.connect the other end of the lode cell to the hook through wire rope and firm collect wire grips. Adjust and stopper 4 so that grip face and stopper face is 0.2 mm.
FLSmidth Pfister India Ltd.
SAFETY & STORAGE MANUAL SAFETY & STORAGE MANUAL FOR WEIGH FEEDER
Sefety Note General information All work related to transport, putting in to storage, setting up/mounting Connection, start up, trained personnel observing should only perform Maintenance and repair • The corresponding detailed operating instructions and wiring diagrams, • The warning and safety sign • The specific regulations and requirements for the system and • Normal / regional regulations governing safety and prevention of accidents. Severe injuries and damage to property may result from • Incorrect use • Incorrect installation or operation • Remove of required protective covers or the housing when this is not permitted. Designated use
These equipments are intended for industrial systems. They correspond to the applicable Standards and regulations. The technical data and the information about permitted condition are to be found on the nameplate and in the documentation. It is essential that you observe all specified information!
Transportation
Inspect the delivery for any damage in transit as soon as you receive The Delivery. Inform the shipping company immediately. It maybe Necessary To preclude startup. Use suitable, sufficiently rated handling equipment if necessary. Remove any transportation fixture prior startup.
FLSmidth Pfister India Ltd.
SAFETY & STORAGE MANUAL STORAGE Comply with the storage conditions specified in the following table for Storage: Climate zone Packing 1 Storage location Storage time Temperature (Europe, USA, Canada, China and Russia, excluding tropical zones)
With roof, protected against rain and Max .3 year with regular Packed in snow, no shock loads. checks on the packaging containers, with and moisture indictor desiccant and (rel. atmospheric humidly moisture and < 50%) moisture indicator sealed in the plastic film.
Open
Tropical (Asia, Africa, central and south America, Australia , new Zealand excluding temperate zone)
With roof, enclosed, at constant temperature and atmospheric humidity (5c
60C, 50% relative atmospheric humidity) No sudden temperature fluctuation with filter (free from dirt and dust.) no aggressive vapors and shock loads.
2 years or more given regular inspections. And mechanical damage as part of the inspection. Check the corrosion protection as intact.
With roof, protected against, no Max. 3 yeasr with regular Packed in shock loads. checks on the packaging containers, with and moisture desiccant and indicator(rel. atmospheric moisture indicator humidity <50%) sealed in the plastic film. Protected against insect damage and mildew by chemical treatment. Open
With roof, enclosed, at constant temperature and atmospheric humidity (5c
60C, 50% relative atmospheric humidity) No sudden temperature fluctuation and controlled ventilation with filter (free From dirt and dust). No aggressive vapors and no shock loads. Protection against insect damage.
2 year or more gave regular inspections. Check for cleanliness and mechanical damage as part of the inspection. Check the corrosion protection is intact.
1) Packing must be performed by an experienced company using the packing materials, Which have been expressly qualified for the particular application. FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR AC MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR AC MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR AC MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR AC MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR AC MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR AC MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR AC MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR AC MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR AC MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR AC MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR AC MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR AC MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR AC MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR AC MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR AC MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR AC MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR AC MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR AC MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR AC MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR AC MOTOR
FLSmidth Pfister India Ltd.
INSTALLATION & MAINTENANCE MANUAL FOR GEAR BOX
FLSmidth Pfister India Ltd.
INSTALLATION & MAINTENANCE MANUAL FOR GEAR BOX
FLSmidth Pfister India Ltd.
INSTALLATION & MAINTENANCE MANUAL FOR GEAR BOX
FLSmidth Pfister India Ltd.
INSTALLATION & MAINTENANCE MANUAL FOR GEAR BOX
FLSmidth Pfister India Ltd.
INSTALLATION & MAINTENANCE MANUAL FOR GEAR BOX
FLSmidth Pfister India Ltd.
INSTALLATION & MAINTENANCE MANUAL FOR GEAR BOX
FLSmidth Pfister India Ltd.
INSTALLATION & MAINTENANCE MANUAL FOR GEAR BOX
FLSmidth Pfister India Ltd.
INSTALLATION & MAINTENANCE MANUAL FOR GEAR BOX
FLSmidth Pfister India Ltd.
INSTALLATION & MAINTENANCE MANUAL FOR GEAR BOX
FLSmidth Pfister India Ltd.
INSTALLATION & MAINTENANCE MANUAL FOR GEAR BOX
FLSmidth Pfister India Ltd.
INSTALLATION & MAINTENANCE MANUAL FOR GEAR BOX
FLSmidth Pfister India Ltd.
INSTALLATION & MAINTENANCE MANUAL FOR GEAR BOX
FLSmidth Pfister India Ltd.
INSTALLATION & MAINTENANCE MANUAL FOR GEAR BOX
FLSmidth Pfister India Ltd.
INSTALLATION & MAINTENANCE MANUAL FOR GEAR BOX
FLSmidth Pfister India Ltd.
INSTALLATION & MAINTENANCE MANUAL FOR GEAR BOX
FLSmidth Pfister India Ltd.
INSTALLATION & MAINTENANCE MANUAL FOR GEAR BOX
FLSmidth Pfister India Ltd.
INSTALLATION & MAINTENANCE MANUAL FOR GEAR BOX
FLSmidth Pfister India Ltd.
INSTALLATION & MAINTENANCE MANUAL FOR GEAR BOX
FLSmidth Pfister India Ltd.
INSTALLATION & MAINTENANCE MANUAL FOR GEAR BOX
FLSmidth Pfister India Ltd.
INSTALLATION & MAINTENANCE MANUAL FOR GEAR BOX
FLSmidth Pfister India Ltd.
INSTALLATION & MAINTENANCE MANUAL FOR GEAR BOX
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
TACHOMETER TECHNICAL LITERATURE TACHOMETER PROBE Tachometer probe may be regarded as having three parts. 1) an oscillator 2) a trigger circuit 3) an output stage Immediately an exitation voltage is applied, oscillation begins which causes the emmission, Of a radio frequency electromagnetic sensing particular current to be drawn. The coil is wound on a ferrite core which concentrates the sensing field in the axial direction through the active face of the tachometer probe. When a metel object enters the radiated field, it absorbs energy from the field.a load is placed upon the oscillator and the output amplitude is reduced. This alters the amount of current being drawn. The trigger circuit recognises this and changes the state of the switching device in the output stage. If the metal object is removed, the oscillation will begin again, and the device will return to its orginal state. Sensor type
:-
inductive
Switching distance
:-
1.5 mm
Housing dia.
:-
6.5 mm
Voltage range
:-
5-25v dc
Switching range
:-
5 khz
Conduction type
:-
cable
Housing material
:-
metal
Length
:-
22 mm
Make
:-
pepperl + fuchs
FLSmidth Pfister India Ltd.
LOADCELL SPECIFICATION
FLSmidth Pfister India Ltd.
LOADCELL SPECIFICATION
FLSmidth Pfister India Ltd.
LOADCELL SPECIFICATION
FLSmidth Pfister India Ltd.
DATA SHEET
FLSmidth Pfister India Ltd.
ELECTRICAL DRAWING
ELECTRICAL DRAWING
FLSmidth Pfister India Ltd.
ELECTRICAL DOCUMENTATION FOR WEIGH FEEDER
ELECTRICAL DRAWINGS -R0 DETAIL ELECTRICAL DRAWINGS R0 TERMINATION DETAILS -R0 AND SPSS PROGRAM JOB NO
: 90.1291
CUSTOMER
: SAIL-ROURKELA STEEL PLANT
PROJECT
:
P.O. NO.
: 003/315/1202001030/1300300060 DTD. 01-06-2013
CATEGORY OF DRG.
REFERENCE
APPROVAL
AS BUILT
FLSMIDTH PFISTER INDIA Ltd. Mumbai - 400067, India Tel.: +91 22 67726000/2868 2311. Fax +91 2267726100
90A1291
124, ABCD, Govt.Indl. Estate, kandivli (West),
1
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14
TABLE OF CONTENTS PAGE NO.
PAGE DESIGNATION
=A1_FC/1
FC
DRAWING NO.
=A1_TOC/1
TABLE OF CONTENTS
----
=A1_TOC/2
TABLE OF CONTENTS
----
=A1_BAS/1
SYSTEM BLOCK DIAGRAM
011-EE01-R0
=A1_BAS/2
SINGLE LINE DIAGRAM
011-EE02-R0
=A1_BAS/3
CABLE SCHEDULE FOR
POWER CABLES
011-EE04-1-R0
=A1_BAS/4
CABLE SCHEDULE FOR
CONTROL CABLES
011-EE04-2-R0
=A1_BAS/5
CABLE SCHEDULE FOR
SCREENED CABLES
011-EE04-3-R0
=A1_BAS/6
ELECTRICS ENCLOSURE GA
011-EE05-R0
=A1_BAS/7
ELECTRICS ENCLOSURE LAYOUT
011-EE06-R0
=A1_BAS/8
ELECTRICS ENCLOSURE MOUNTING DETAILS
011-EE07-R0
=A1_BAS/9
LOCAL CONTROL STATION
011-EE09-1-R0
=A1_BAS/10
OP (OPERATORS )
011-EE09-2-R0
=A1_BAS/11
JUNCTION BOX DETAIL (BIG)
011-EE10-R0
=A1_BAS/12
TUC-6 WEIGH FEEDER
011-EE25-R0
=A1/1
ELECTRICAL WIRING DIAGRAM
011-EE16-R0
=A1/2
ELECTRICAL WIRING DIAGRAM
011-EE16-R0
=A1/3
VOLTAGE SUPPLY
011-EE16-R0
=A1/4
MCC SUPPLY
011-EE16-R0
=A1/5
UPS SUPPLY
011-EE16-R0
=A1/6
LOADCELL & TACHO
011-EE16-R0
=A1/7
ANATERFACE
011-EE16-R0
=A1/8
INPUTS E000-E003
011-EE16-R0
=A1/9
INPUTS E004-E007
011-EE16-R0
=A1/10
OUTPUTS A000-A003
011-EE16-R0
=A1/11
OUTPUTS A004-A007
011-EE16-R0
=A1/12
INPUTS E008-E011
011-EE16-R0
=A1/13
INPUTS E012-E015
011-EE16-R0
=A1/14
OUTPUTS A008-A011
011-EE16-R0
=A1/15
OUTPUTS A012-A015
011-EE16-R0
DATE
CHANGE
DATE/NAME
CHKD
NAME
18.Jun.2013
HS
ENGG
18.Jun.2013
HS
CHKD
18.Jun.2013
HS
DRN
18.Jun.2013
HS
WEIGH FEEDER CUSTOMER: PROJECT: CONSULTANT:
SAIL-ROURKELA STEEL PLANT
TITLE:
TABLE OF CONTENTS
= A1_TOC
DRG.NO.: 90.1291
+
- ----
90A1291
APPROVED BY
SHEET 1 2
1
2
3
5
4
6
7
8
9
10
11
12
13
14
TABLE OF CONTENTS PAGE NO.
PAGE DESIGNATION
DRAWING NO.
=A1/16
OUTPUTS A016-A019
011-EE16-R0
=A1/17
INVERTER
011-EE16-R0
=A1/18
AC INVERTOR
011-EE16-R0
=A1/19
VIB MOTOR
011-EE16-R0
=A1_TER/1
=A1-X9
011-EE17-R0
=A1_TER/2
=A1-X10
011-EE17-R0
=A1_TER/3
=A1-X11
011-EE17-R0
=A1_TER/4
=A1-X12
011-EE17-R0
=A1_TER/5
=A1-X13
011-EE17-R0
=A1_TER/6
=A1-LCS-X14
011-EE17-R0
=A1_TER/7
=A1-JB1-X15
011-EE17-R0
=A1_TER/8
=A1-X21
011-EE17-R0
=A1_TER/9
=A1-X22
011-EE17-R0
=A1_TER/10
=A1-X23
011-EE17-R0
=A1_TER/11
=A1-LCS-X41
011-EE17-R0
=A1_TER/12
=A1-OP-X42
011-EE17-R0
=A1_TER/13
=A1-OP-X43
011-EE17-R0
=A1_BOM/1
BILL OF MATERIALS
011-EE03-R0
=A1_BOM/2
BILL OF MATERIALS
011-EE03-R0
=A1_BOM/3
BILL OF MATERIALS
011-EE03-R0
DATE
CHANGE
DATE/NAME
CHKD
NAME
18.Jun.2013
HS
ENGG
18.Jun.2013
HS
CHKD
18.Jun.2013
HS
DRN
18.Jun.2013
HS
WEIGH FEEDER CUSTOMER: PROJECT: CONSULTANT:
SAIL-ROURKELA STEEL PLANT
TITLE:
TABLE OF CONTENTS
= A1_TOC
DRG.NO.: 90.1291
+
- ----
90A1291
APPROVED BY
SHEET 2 2
1
2
3
5
4
6
8
7
9
10
11
12
1. INPUTS /OUTPUTS OF WF. OUTPUTS : RELAY S MAX. 220V./5A LOAD INPUTS
14
13
EPT. NO.
MATERIAL
CAPACITY
WF-01
LIMESTONE &
60 TPH
DOLOMITE
: 220VAC
1. CONTROL CABLES TO & FROM CUSTOMER'S CAN BE COMBINED TOGETHER HOWEVER 4-20mA SIGNALS CABLES ARE SEPERATE. 3. * FLSMIDTH PFISTER (FPIL) SCOPE VM
HOPPER OPERATOR
LCS ZSS T
WF
/
/
BELT TRACKING S2
S1 *WC 01
LOADCELL
*WCS 02
*WC 02
*WC 06
*WC 08
*WCS 01
T
/
M
/
TACHO
JUNCTION BOX (JB1)
WC 12
WC 10
WC 11
WCS 10
WC 05
WCS 08
WC 07 WCS 09
*WCS 04
*WCS 03
WP 02
WP 03
AT FIELD
ELECTRICS ENCLOSURE WITH
DATE
CHANGE
DATE/NAME
CHKD
NAME
18.Jun.2013
HS
ENGG
18.Jun.2013
HS
CHKD
18.Jun.2013
HS
DRN
18.Jun.2013
HS
WEIGH FEEDER CUSTOMER: PROJECT: CONSULTANT:
SAIL-ROURKELA STEEL PLANT
4-20mA ISO O/P à MOTOR CURRENT
WCS 07 = A1_BAS
SYSTEM BLOCK DIAGRAM
DRG.NO.: 90.1291
PLC/DCS CUSTOMER
+
- 011-EE01-R0
90A1291
WCS 06
WCS 05 TITLE:
4-20mA ISO I/P à SET POINT
WF ON
(CUSTOMER)
4-20mA ISO O/P à FEEDRATE
MCC
START/STOP
3í SUPPLY
(CUSTOMERS)
VIB ON
50 Hz ñ3%
UPS
WC 04
WC 03
415 V ñ10%
50 Hz
REMOTE SEL
220 V ñ5%
GENERAL FAULT
WP 01
WP 04
TUC-6 ELECTRONICS
SHEET 1 12
2
3
5
4
MCC/UPS (CUSTOMER)
6
8
7
9
10
11
12
13
14
415 V ñ10% 50 Hz ñ3%
UPS SUPPLY
1
3í SUPPLY 4 KW.
220 V ñ10% 50 Hz ñ3%
3
Q1
TX1
ELECTRIC ENCLOSURE
2
I >
F1
2
Fb I
> >
I
> >
Fa
2
K1 U1
Fc
I >
F2
2
~ ~
I
~ ~
CONTROL SUPPLY
K4
2
220V AC
L2
K2
ILLUMINATION
U3
220V AC
U2
FIELD
K3
~ ~
> >
-
TUC-6
2
M ~
M ~
WF MOTOR - M1
VIB MOTOR - M2
PW-2.2 KW
PW-0.27 KW
4POLE
2POLE
1500RPM
3000RPM
IL-4.4 AMPS
IL-0.52 AMPS
90A1291
NOTE: ACTUAL DISTANCE BETWEEN AND MOTOR IS MAX. 250 MTRS.
DATE
CHANGE
DATE/NAME
CHKD
NAME
18.Jun.2013
HS
ENGG
18.Jun.2013
HS
CHKD
18.Jun.2013
HS
DRN
18.Jun.2013
HS
WEIGH FEEDER CUSTOMER: PROJECT: CONSULTANT:
SAIL-ROURKELA STEEL PLANT
TITLE:
= A1_BAS
SINGLE LINE DIAGRAM
DRG.NO.: 90.1291
+
- 011-EE02-R0
SHEET 2 12
6
8
7
01
WP 01
ELECT. ENCL
MCC
13
YWY
14
3x50
3x35
3x25
4x10
4x6
4x4
3x16
3x4
3x2.5
3x1.5
3x6
YWY
YWY
REMARKS
1
INCOMER
415VAC
1
WF MOTOR
1
VIB MOTOR
1
INCOMER
CUSTOMER
03
WP 03
ELECT. ENCL FIELD
CUSTOMER
04
WP 04
MCC
CUSTOMER
415VAC
220VAC
90A1291
ELECT. ENCL
12
415VAC
ELECT. ENCL FIELD
WF-01
11
CUSTOMER
WP 02
02
YWY
2x50
SCOPE
2x35
TO
2x6
FROM
2x4
NO.
2x2.5
CABLE.
NO.
2x1.5
EQUIP.
OPERATING VOLTAGE
NO.
10
2 CABLE TYPE NO. OF LEADS x AREA IN mm
CABLE SR.
9
NO.OF RUNS
5
4
2x25
3
2x16
2
2x10
1
DATE
CHANGE
DATE/NAME
CHKD
NAME
18.Jun.2013
HS
ENGG
18.Jun.2013
HS
CHKD
18.Jun.2013
HS
DRN
18.Jun.2013
HS
WEIGH FEEDER CUSTOMER: PROJECT: CONSULTANT:
SAIL-ROURKELA STEEL PLANT
TITLE:
CABLE SCHEDULE FOR POWER CABLES
= A1_BAS
DRG.NO.: 90.1291
+
- 011-EE04-1-R0
SHEET 3 12
5
6
8
7
11
12
14
13
NO.OF RUNS
YWY
-----
-----
-----
-----
-----
-----
-----
2x1.5
-----
22x1.5
16x1.5
18x1.5
YY 14x1.5
SCOPE
5x1.5
TO
FROM
4x1.5
NO.
3x1.5
CABLE.
NO.
2x1.5
EQUIP.
OPERATING VOLTAGE
NO.
10
2 CABLE TYPE NO. OF LEADS x AREA IN mm
CABLE SR.
9
12x1.5
4
10x1.5
3
8x1.5
2
6x1.5
1
REMARKS
JB1
FPIL
220 VAC
1
BELT SWAY (L)
JB1
FPIL
220 VAC
1
BELT SWAY (R)
*
1
DIGITAL O/P
220VAC
1
DIGITAL I/P
----
1
CONTROLS
WC 01
FIELD
WC 02
FIELD
03
WC 03
EE
04
WC 04
PLC/DCS
EE
CUSTOMER
05
WC 05
LCS
EE
CUSTOMER
06
WC 06
FIELD
JB1
07
WC 07
JB1
LCS
CUSTOMER
220 VAC
1
BSS,ZSS, FLAP TYPE. SW
08
WC 08
FIELD
JB1
FPIL
220 VAC
1
FLAP TYPE SW.
09
WC 10
OPERATOR
EE
CUSTOMER
220 VAC
1
DIGITAL I/P
1
SUPPLY 220VAC
1
BC117 ILK(CUS)
01 02
WF-01
10 11
CUSTOMER
PLC/DCS
1
220 VAC
FPIL
WC 11
OPERATOR
EE
CUSTOMER
220 VAC
WC 12
OPERATOR
EE
CUSTOMER
220 VAC
ZSS
YWY - ARMOURED CABLE YY - UNARMOURED CABLE * - POTENTIAL FREE
90A1291
JB-JUNCTION BOX EE-ELEC.ENGG DATE
CHANGE
DATE/NAME
CHKD
NAME
18.Jun.2013
HS
ENGG
18.Jun.2013
HS
CHKD
18.Jun.2013
HS
DRN
18.Jun.2013
HS
WEIGH FEEDER CUSTOMER: PROJECT: CONSULTANT:
SAIL-ROURKELA STEEL PLANT
TITLE:
CABLE SCHEDULE FOR CONTROL CABLES
= A1_BAS
DRG.NO.: 90.1291
+
- 011-EE04-2-R0
SHEET 4 12
5
6
8
7
WCS 01
FIELD
WCS 02
FIELD
WCS 03
JB1
04
WCS 04
JB1
05
WCS 05
EE
06
WCS 06
PLC/DCS
07
WCS 07
EE
01 02 03
WF-01
08
WCS 08
EE
09
WCS 09
EE
10
11
12
14
13
NO.OF RUNS
-----
-----
-----
-----
-----
-----
4x0.35++
2x0.35++
24x0.75
YY 19x0.75
14x0.75
16x0.75
YWY 12x0.75
SCOPE
REMARKS
JB1
FPIL
8.2V
1
TACHO
JB1
FPIL
12V
1
LOADCELL
EE
FPIL
8.2V
1
TACHO
EE
FPIL
12V
1
LOADCELL
CUSTOMER
----
1
4-20mA ISO O/P à FEEDRATE
CUSTOMER
----
1
4-20mA ISO I/P à SET POINT
CUSTOMER
----
1
CUSTOMER
----
1
FEEDRATE DISPLAY
CUSTOMER
----
1
FEEDRATE SET
CUSTOMER
----
1
FEEDRATE SET
PLC/DCS
EE PLC/DCS OPERATOR
LCS OPERATOR
EE
WCS 10
TO
4x0.35++
FROM
3x0.75
NO.
2x0.75
CABLE.
NO.
2x0.35++
EQUIP.
OPERATING VOLTAGE
NO.
10
2 CABLE TYPE NO. OF LEADS x AREA IN mm
CABLE SR.
9
10x0.75
4
7x0.75
3
6x0.75
2
4x0.75
1
4-20mA ISO O/P à MOTOR CURRENT
YY - UNARMOURED CABLE YWY - ARMOURED CABLE EE - ELECTRIC ENCLOSURE
90A1291
JB-JUNCTION BOX ++ INTEGRAL CABLE SUPPLIED WITH LOADCELL & TACHO DATE
CHANGE
DATE/NAME
CHKD
NAME
18.Jun.2013
HS
ENGG
18.Jun.2013
HS
CHKD
18.Jun.2013
HS
DRN
18.Jun.2013
HS
WEIGH FEEDER CUSTOMER: PROJECT: CONSULTANT:
SAIL-ROURKELA STEEL PLANT
TITLE:
CABLE SCHEDULE FOR SCREENED CABLES
= A1_BAS
DRG.NO.: 90.1291
+
- 011-EE04-3-R0
SHEET 5 12
1
2
3
5
4
6
8
7
9
10
11
12
13
14
NOTE
1) MAX. FLOOR OPENING FOR CABLE : - 630 mm x 350 mm NAME PLATE
2) DESIGN FEATURES : - FRONT SIDE WITH SWIVEL DOOR.
TUC-6
- REAR SIDE FIXED ON BOLTS.
INVERTER DISPLAY
- PROTECTION SYSTEM IP54 WITH DOORS CLOSED. - INLINE INSTALLATION. - GLAND PLATES:- DRILLED GLAND HOLES WITH 1800
WF ON
BC 117 RUN
DOOR LOCK
2 WAY SEL. SW. 4 WAY SEL. SW.
BLANKING PLUGS.
2000
LABEL
3) SHEET THICKNESS :
POWER ON
- FRONT DOOR
- 2.0 mm THK.
- SIDE COVERS
- 1.6 mm THK
DOOR ISOLATOR
4) WEIGHT :-
200
- APPROX. 200 KGS.
100
1000 (MIN)
600
25
100
MAINTENANCE SPACE REQD.
800
5) SURFACE PROTECTION : INSIDE & OUTSIDE
2 N0S EARTHING BOLT (M10)
POWDER COAT 460
(STRUCTURE FINISH)
500
AS PER SHADE NO. RAL 7035
SPACE FOR CABLES RUNNING ACROSS
BASE - AS PER IS:5 - DARK BLACK 6) PACKED SIZE: - 880 mm x 590 mm x 2110 mm.
DATE/NAME
CHKD
8) TOTAL NO OF SIDE COVER 2 NOS./ PROVIDED 9) EARTHING BOLT - 2 NOS./ PROVIDED.
SPACE REQD.
QTY.: 1 NO.
90A1291
DATE
CHANGE
1000 (MIN) MAINTENANCE
30
MAX. FRONT 70 PROJECTION 70 mm.
14í HOLE 4 NOS
500
420
7) ALL DIMENSIONS ARE IN `MM'.
NAME
18.Jun.2013
HS
ENGG
18.Jun.2013
HS
CHKD
18.Jun.2013
HS
DRN
18.Jun.2013
HS
WEIGH FEEDER CUSTOMER: PROJECT: CONSULTANT:
SAIL-ROURKELA STEEL PLANT
TITLE:
ELECTRICS ENCLOSURE GA
= A1_BAS
DRG.NO.: 90.1291
+
- 011-EE05-R0
SHEET 6 12
1
2
3
5
4
6
8
7
9
10
11
12
13
14
SIDE
(MIN)
(MIN)
(MIN)
2.5 Mtr
1 Mtr.
EE01
500
1 Mtr.
(MIN)
1 Mtr.
COVER (1 NO)
FRONT 1 Mtr
SIDE COVER (1 NO)
0.8 Mtr
2.8 Mtr.(MIN.)
NOTE:
2) ACTUAL LAYOUT TO BE DECIDE BY CUSTOMER DATE
CHANGE
DATE/NAME
CHKD
NAME
18.Jun.2013
HS
ENGG
18.Jun.2013
HS
CHKD
18.Jun.2013
HS
DRN
18.Jun.2013
HS
WEIGH FEEDER CUSTOMER: PROJECT: CONSULTANT:
SAIL-ROURKELA STEEL PLANT
TITLE:
= A1_BAS
ELECTRICS ENCLOSURE LAYOUT
DRG.NO.: 90.1291
+
- 011-EE06-R0
SHEET 7 12
90A1291
1) TYPICAL LAYOUT DRAWING FOR REFERENCE
1
2
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12
14
13
A 400
- ALL DIMENSIONS ARE IN MM.
400 OF C L
50 x 50 x 6 THK. 100
MOUNTING DETAILS
100
(BY CUSTOMER)
FIELD WELD (TYP.) (NO WELDING ON
- ELECT.ENCLOSURE 1 NO.
470
420 (CRS)
25
600 (TYP)
- TYPICAL ELECT.ENCLOSURE
ELECTRICS ENCL.
8, SLOT HOLES í14 x 50 LG.
300
300
TYP
TYP
25
TOP FACE)
800 A
FLOOR CUT-OUT(TYP.)
ANGLE FRAME
630 x 350
80
470
5
420 CRS
45 ANGLE FRAME
630 (TYP)
85
400
5 THK.PLATE
350
470
M-10 EARTHING BOLTS 2 NOS.@500 CRS.ON EACH
75
BASE.FR
350 TYP.
ELECTRICS ENCLOSURE
FRONT
200
75
ANGLE FRAME DETAIL
(FLR.CUT-OUT)
85
400
FLOOR CUT-OUT DETAIL 90A1291
SEC.- AA
DATE
CHANGE
DATE/NAME
CHKD
NAME
18.Jun.2013
HS
ENGG
18.Jun.2013
HS
CHKD
18.Jun.2013
HS
DRN
18.Jun.2013
HS
WEIGH FEEDER CUSTOMER: PROJECT: CONSULTANT:
SAIL-ROURKELA STEEL PLANT
TITLE:
= A1_BAS
ELECTRICS ENCLOSURE MOUNTING DETAILS
DRG.NO.: 90.1291
+
- 011-EE07-R0
SHEET 8 12
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12
13
14
EMERGENCY STOP
4 NOS. í10 HOLES FOR
NOTE:1) ALL DIMENSION ARE IN MM.
MTG. WITH M8 BOLT
2) DOUBLE DOOR ENCLOSURE WITH ALL SWITCHES AND INDICATIONS MOUNTED ON INNER DOOR, ACRYLIC WINDOW AND DOOR LOCK ON OUTER DOOR,
75
EMERGENCY OFF MOUNTED ON RIGHT SIDE. 3) GLAND PLATE :- DRILLED GLAND HOLES WITH
S3
BLANKING PLUGS. 4) SHEET THICKNESS : - 1.5 mm DOOR
120
- 1.38mm REST
L1
LOCK
320(CTC)
5) WEIGHT :
295
300
L2 VIB ON VIB OFF
- APPROX. 10 KGS. 6) SURFACE PROTECTION : - OUTSIDE & INSIDE EPOXY POWDER COAT-
65 S1
S2
S4
(STRUCTURE FINISH) AS PER SHADE NO. RAL 7035
P1 7)
PROTECTION/CLASS : IP55
55
8) PACKED SIZE: - 250mm x 340 mm x 440 mm.
9) MAINTENANCE SPACE REQUIRED:
LCS IDENTIFICATION LABEL
- 1.5 m. IN FRONT - 1.0 m. AT SIDES
175 (CTC)
360 (CTC)
QTY.- 1 NO.
220 .
400
EARTHING
CONTROLS/INDICATIONS
C L OF CABLE ENTRY
BOLTS M6 2 NOS.
S1
START - TEKNIC MAKE.
S2
STOP - TEKNIC MAKE.
S3
EMG OFF. TEKNIC MAKE
S4
VIB ON/OFF SWITCH- TEKNIC MAKE
L1
BELT RUN LAMP - TEKNIC MAKE.
L2
VIB ON LAMP - TEKNIC MAKE. FEEDRATE POT(10 TURNS) - BOURNS MAKE 90A1291
P1
DATE
CHANGE
DATE/NAME
CHKD
NAME
18.Jun.2013
HS
ENGG
18.Jun.2013
HS
CHKD
18.Jun.2013
HS
DRN
18.Jun.2013
HS
WEIGH FEEDER CUSTOMER: PROJECT: CONSULTANT:
SAIL-ROURKELA STEEL PLANT
TITLE:
= A1_BAS
LOCAL CONTROL STATION
DRG.NO.: 90.1291
+
- 011-EE09-1-R0
SHEET 9 12
1
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10
11
12
4 NOS. í10 HOLES FOR
13
14
NOTE:1) ALL DIMENSION ARE IN MM.
MTG. WITH M8 BOLT
2) DOUBLE DOOR ENCLOSURE WITH ALL SWITCHES AND INDICATIONS MOUNTED ON INNER DOOR, ACRYLIC WINDOW AND DOOR LOCK ON OUTER DOOR,
3) GLAND PLATE :- DRILLED GLAND HOLES WITH BLANKING PLUGS. 4) SHEET THICKNESS : DPM
- 1.5 mm DOOR - 1.38mm REST
D1
LOCK
320(CTC)
5) WEIGHT :
295
300
- APPROX. 10 KGS. 6) SURFACE PROTECTION : - OUTSIDE & INSIDE EPOXY POWDER COAT-
65 S1-1
S2-1
(STRUCTURE FINISH) AS PER SHADE NO. RAL 7035
P1 7)
PROTECTION/CLASS : IP55
55
8) PACKED SIZE: - 250mm x 340 mm x 440 mm.
9) MAINTENANCE SPACE REQUIRED:
LCS IDENTIFICATION LABEL
- 1.5 m. IN FRONT - 1.0 m. AT SIDES
175 (CTC)
360 (CTC)
QTY.- 1 NO.
220 .
400
EARTHING
CONTROLS/INDICATIONS
C L OF CABLE ENTRY
BOLTS M6 2 NOS.
S1-1
START/STOP SWITCH- TEKNIC MAKE
S2-1
FAULT RESET PB- TEKNIC MAKE
P1-1
FEEDRATE POT(10 TURNS) - BOURNS MAKE
FEEDRATE INDICATOR (DPM) - TRANSWEIGH MAKE 90A1291
D1
DATE
CHANGE
DATE/NAME
CHKD
NAME
18.Jun.2013
HS
ENGG
18.Jun.2013
HS
CHKD
18.Jun.2013
HS
DRN
18.Jun.2013
HS
WEIGH FEEDER CUSTOMER: PROJECT: CONSULTANT:
SAIL-ROURKELA STEEL PLANT
TITLE:
= A1_BAS
OP (OPERATORS )
DRG.NO.: 90.1291
+
- 011-EE09-2-R0
SHEET 10 12
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13
14
247 225 200
BACKGROUND / OUTER SURF. COLOUR - RAL 7035
30
45
160
200 45
45
45
45
45 45
30
45
35
í6.5 EARTHING BOLT (2 nos)
í22.5 HOLE FOR
83.14
83.14
120
CABLE GLAND (3 Nos.)
120 M5, SCREW (4 nos) FOR COVER FITTING
í22.5 HOLE FOR CONDUIT GLAND (6 Nos.)
LABEL DETAIL
M6 SCREW (4 nos)
(ON COVER)
FOR JB MTG.
QTY : 1 NO. NOTE: 1. OVERALL DIMENSIONS : 120
200.0 W x 200.0 HT. x 120.0 D 2. WEIGHT :
2.05 KGS.
3. MATERIAL SPECIFICATION : CRCA SHEET 1.5 mm THK. 4. SURFACE : POWDER COAT RAL 7035 5. PROTECTION CLASS :
IP 65
6. ALL UNUSED HOLES WILL BE PLUGGED.
90A1291
7. ALL DIMENSION ARE IN `MM'
DATE
CHANGE
DATE/NAME
CHKD
NAME
18.Jun.2013
HS
ENGG
18.Jun.2013
HS
CHKD
18.Jun.2013
HS
DRN
18.Jun.2013
HS
WEIGH FEEDER CUSTOMER: PROJECT: CONSULTANT:
SAIL-ROURKELA STEEL PLANT
TITLE:
= A1_BAS
JUNCTION BOX DETAIL (BIG)
DRG.NO.: 90.1291
+
- 011-EE10-R0
SHEET 11 12
1
2
3
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8
9
10
11
12
14
13
245
62
144 5
1
TRANSWEIGH
TUC-6
2 D
4
X I
T
5
L
N
6
2 M
8
7
VFD DISPLAY
3
1 E
O
P
O --
9
72
W A
0
CL *
SET R
S
T
U
ESC
=
WEIGHT 2.0 Kgs (approx.)
ELEVATION
SIDE VIEW
QTY : 1 NO.
CUTOUT 138.0 mm x 68.0 mm
NOTE:
- ALL DIMENSIONS ARE IN MM.
90A1291
MOUNTING
DATE
CHANGE
DATE/NAME
CHKD
NAME
18.Jun.2013
HS
ENGG
18.Jun.2013
HS
CHKD
18.Jun.2013
HS
DRN
18.Jun.2013
HS
WEIGH FEEDER CUSTOMER: PROJECT: CONSULTANT:
SAIL-ROURKELA STEEL PLANT
TITLE:
TUC-6 WEIGH FEEDER
= A1_BAS
DRG.NO.: 90.1291
+
- 011-EE25-R0
SHEET 12 12
2
3
5
4
6
7
8
9
10
11
12
13
CUSTOMER
:
SAIL - ROUREKLA STEEL PLANT
TITLE
:
WEIGH FEEDER
DRG. NO
:
90.1291-011-EE16-R0
QTY.
:
1 NO.
EQPT. NO. :
WF-01
14
90A1291
1
DATE
CHANGE
DATE/NAME
CHKD
NAME
18.Jun.2013
HS
ENGG
18.Jun.2013
HS
CHKD
18.Jun.2013
HS
DRN
18.Jun.2013
HS
WEIGH FEEDER CUSTOMER: PROJECT: CONSULTANT:
SAIL-ROURKELA STEEL PLANT
TITLE:
= A1
ELECTRICAL WIRING DIAGRAM
DRG.NO.: 90.1291
+
- 011-EE16-R0
SHEET 1 19
1
2
3
5
4
6
7
8
9
10
11
EQPT. NO.
MATERIAL
WF-01
LIMESTONE & 60 TPH
12
13
14
REVISED REV
SHEET NAME
DATE
KIND OF REVISION
NAME
CAPACITY QTY. 1 NO.
DOLOMITE
WIRING COLOR CODE COLOR
415V -
BLACK
(L1, L2, L3)
220/110VAC
RED
(PHASE/NEUTRAL)
24VDC
GREY BLACK
(+VE) (-VE)
EARTHING
YELLOW / GREEN
POT. FREE.
BLUE
90A1291
VOLTAGE
DATE
CHANGE
DATE/NAME
CHKD
NAME
18.Jun.2013
HS
ENGG
18.Jun.2013
HS
CHKD
18.Jun.2013
HS
DRN
18.Jun.2013
HS
WEIGH FEEDER CUSTOMER: PROJECT: CONSULTANT:
SAIL-ROURKELA STEEL PLANT
TITLE:
= A1
ELECTRICAL WIRING DIAGRAM
DRG.NO.: 90.1291
+
- 011-EE16-R0
SHEET 2 19
1
2
3
5
4
6
8
7
9
10
11
12
14
13
MCC POWER SUPPLY 415 V ñ10% 50 Hz ñ3% 3í SUPPLY R
Y
B
E
WP01 3x4
L3 X13
1
2
3
E
LAMP
L N
S1
1 2
1
3
5
2
4
6
S2 DOORLIMIT SWITCH
Q1 32Amps
E/4.12
L2
L1 P S
0V
4
2
3
1
Fb
TX1
1 Amp.
415V I/P 220V O/P @ 1 Amp.
1L
P/4.2 220vac
1
LP1 2
N/4.2
L3.1/19.3 L2.1/19.3 L1.1/19.3 L3/18.5 L2/18.5
DATE
CHANGE
DATE/NAME
CHKD
NAME
18.Jun.2013
HS
ENGG
18.Jun.2013
HS
CHKD
18.Jun.2013
HS
DRN
18.Jun.2013
HS
WEIGH FEEDER CUSTOMER: PROJECT: CONSULTANT:
SAIL-ROURKELA STEEL PLANT
TITLE:
VOLTAGE SUPPLY
= A1
DRG.NO.: 90.1291
+
- 011-EE16-R0
90A1291
L1/18.5
SHEET 3 19
2
3
5
4
6
220VAC
3.13
3.13
P
N
X6
E
X6
X6
X6 1
3
2
4
Fc 1 Amp.
X6
X6
X6
X6
X6
X6
N
X6
N
X6
N
X6
N
X6
N
7
8
9
10
11
12
14
13
220N1.10/12.9 220N1.9/12.2
P
220P1.9/12.2 220N1.8/9.8
P
220P1.8/9.8 220N1.7/7.11
P
220P1.7/7.11 220N1.6/10.12
P
220P1.6/10.12 X6
N
X6
N
X6
N
220N1.5/17.3
220N1.4/16.11
P
220P1.4/16.11 220N1.3/12.13
P
220P1.3/12.13 X6
N
X6
N
X6
N
220N1.2/12.10
P
220P1.2/12.10 220N1.1/9.4
P
220P1.1/10.5 220N/8.3 POWER SUPPLY 220 VAC
P
220P/8.3
90A1291
1
E/3.4 DATE
CHANGE
DATE/NAME
CHKD
NAME
18.Jun.2013
HS
ENGG
18.Jun.2013
HS
CHKD
18.Jun.2013
HS
DRN
18.Jun.2013
HS
WEIGH FEEDER CUSTOMER: PROJECT: CONSULTANT:
SAIL-ROURKELA STEEL PLANT
TITLE:
MCC SUPPLY
= A1
DRG.NO.: 90.1291
+
- 011-EE16-R0
SHEET 4 19
1
2
3
5
4
6
8
7
9
10
11
12
14
13
UPS SUPPLY 220 VAC ñ3% 50 Hz
L
N
WP04 2x2.5
X13
10
U3
11
220VAC N
V-
1
3
Fa 1 Amp.
2
4
X4
N
X4
P
L
24VDC @2.2Amps.
X5
P
X5
N
X5
P
X5
N
X5
P
X5
N
X5
P
X5
N
24P.4/12.2 24N.4 24P.3/12.4 24N.3/12.4 24P.2/8.6 24N.2/8.6 24P.1/7.2 24N.1/7.2
V+
24P/6.3
POWER SUPPLY +24V DC
24N/6.3
WCSX-1 2X0.75
N
X4
P
X4
N
X4
P
N1.1/18.9
POWER SUPPLY 220 VAC
P1.1/18.9
N1/7.3 P1/7.3 90A1291
X4
DATE
CHANGE
DATE/NAME
CHKD
NAME
18.Jun.2013
HS
ENGG
18.Jun.2013
HS
CHKD
18.Jun.2013
HS
DRN
18.Jun.2013
HS
WEIGH FEEDER CUSTOMER: PROJECT: CONSULTANT:
SAIL-ROURKELA STEEL PLANT
TITLE:
UPS SUPPLY
= A1
DRG.NO.: 90.1291
+
- 011-EE16-R0
SHEET 5 19
1
2
3
5
4
6
8
7
9
10
11
12
13
14
UPS SUPLLY
5.12/24N 5.12/24P
24V DC
X11
5
7
3
4
6
X1:12
SIGNAL X1:11
X1:10
+12V
SUPPLY X3:9
X3:8
SENSE -
SIGNAL X3:6
SENSE + X3:4 2
X3:2
X1:3
SUPPLY +
X1:2
X3:1
X1:1
X3:5
TUC-6
SIGNAL +
U2 7.1 16.2 17.10
WCSB
WCSC
6x0.35
2x0.35
1
8
9
10
WCS04
WCS03
6x0.75
2x0.75
JB1
X15
5
2
7
3
4
A
D
B
C
6
1
8
9
10
WCS02
WCS01
4x0.35
2x0.35
-LC1
DATE
CHANGE
DATE/NAME
CHKD
NAME HS
ENGG
18.Jun.2013
HS
CHKD
18.Jun.2013
HS
DRN
18.Jun.2013
HS
WEIGH FEEDER CUSTOMER: PROJECT: CONSULTANT:
SAIL-ROURKELA STEEL PLANT
90A1291
FIELD
FIELD
18.Jun.2013
TACHO WF
TITLE:
LOADCELL & TACHO
= A1
DRG.NO.: 90.1291
+
- 011-EE16-R0
SHEET 6 19
1
2
3
5
4
PLC/DCS
6
OP
(CUSTOMER)
3
à SET POINT
WCS06
X9
1
2
SUPLLY
5.12/N1
N
E
I/P+
5
6
7
14
13
FEEDRATE INDICATOR
OP
9
4-20mA ISO O/P
10
D1
à ACTUAL FEEDRATE 2
1 WCSD
OPERATOR
2x0.35
I/P-
WCS10
WCS05
3x0.75
2x0.75
I/V O/P+
4
3
U8 L
12
3x0.35
X43
5.12/P1
11
OPERATOR
WCSK-1
2x0.75
10
(CUSTOMER)
1 VOLUME SETPOINT
2
9
PLC/DCS P1.1
4-20mA ISO I/P
UPS
8
7
X9
O/P-
4
5
6
X9
X42 7
8
1
X43
2
1
2
3
1
2
3
9 WC11
220VAC
2x1.5 WCS08 2x0.75 500ê
5.12
K5
500ê
12.9
SUPLLY
24
23
K6
UPS
WCSE2-1 2x0.35
12.12
5.12
24P.1 24N.1 PE
23
X23
1
2
WCSL1
4.12/220P1.7
X4:3
1
2 J3
1
2 J4
AIC
3
4 J4
(F-875)
1
2 J1
0-10V
3
4 J1
4-20mA
1
2 J2
0-10V
3
4 J2
X3:4
X2:6
X3:1
4-20mA
X3:5
X3:2
WCSA
WCSA1
3x0.35
3x0.35
X2:4
X2:7
PE
X2:+5
X3:3
X1B:4
X1B:-3
X1B:+2
PE
X1A:4
X1A:-3
0-5VDC
X1A:+2
2x0.35
4.12/220N1.7
X2:1
X4:2
X2:3
X2:2
U4 X4:1
X22
24
U4:X1B:4:U5:X2A:4 /8.4 U4:X1B:3:U5:X2A:3 /8.4
DATE
CHANGE
DATE/NAME
CHKD
90A1291
TUC-6
PE
X2:5
X2:-3
6.1
X2:+2
U4:X1B:2:U5:X2A:2 /8.4 U2
X1:+13 X1:-14
NAME
18.Jun.2013
HS
ENGG
18.Jun.2013
HS
CHKD
18.Jun.2013
HS
DRN
18.Jun.2013
HS
WEIGH FEEDER CUSTOMER: PROJECT: CONSULTANT:
SAIL-ROURKELA STEEL PLANT
TITLE:
ANATERFACE
= A1
DRG.NO.: 90.1291
+
- 011-EE16-R0
SHEET 7 19
1
2
3
5
4
6
8
7
9
10
11
12
13
14
7.4/U4:X1B:4:U5:X2A:4 7.4/U4:X1B:3:U5:X2A:3 7.4/U4:X1B:2:U5:X2A:2
24N.2/5.12
24P.2/5.12
24VDC
UPS SUPLLY
E0
J1
X1:2
X1:1
DIO ( F-889)
PE
9.1 10.2 11.2
X2A:4
X2A:2+
3x0.35
U5
X2A:3-
WCSA1
E2
E1
E3 X3:E3
X3:24N
X3:24P
X3:E2
X3:24N
X3:24P
X3:E1
X3:24N
X3:24P
X3:E0
X3:24P
X3:24N
2
1
220V AC RELAY BOARD
RL1
COM
RL2
1
RL3:P
RL3:O
4 CH, 1C/O
RL2:O
RL1:P
RL1:O
9.2
RL2:P
U7:RL3:O"RL4:O U7
RL3
2
F1 18.8
220V AC
INTERLOCK
14
3
NON UPS SUPLLY
WF DRIVE
13
F2 19.8
4.12/220N
VIB DRIVE
13
INTERLOCK
14
4.12/220P
X10
1
X14
1
2
3
4
5
3
4
5
6
WC05 14x1.5
LCS 2
9.2/220PA.4 10.7/220NA.4
WC07 4x1.5
JB1
FIELD
WC06
15
16
11
12
13
WC01
1
WC02
2x1.5
2x1.5
X15
14
18 1
2x1.5
LEFT
17 WC08 2x1.5
RIGHT
2
90A1291
X15
2
BELT SWAY ZERO SPEED SW. DATE
CHANGE
DATE/NAME
CHKD
NAME
18.Jun.2013
HS
ENGG
18.Jun.2013
HS
CHKD
18.Jun.2013
HS
DRN
18.Jun.2013
HS
CUSTOMER: PROJECT: CONSULTANT:
S/W
WEIGH FEEDER
SAIL-ROURKELA STEEL PLANT
MATERIAL DETECTION . TITLE:
INPUTS E000-E003
= A1
DRG.NO.: 90.1291
+
- 011-EE16-R0
SHEET 8 19
1
2
3
5
4
6
8
7
9
10
11
12
13
14
U5:X2B:+2:U1:29 /18.5 U5:X2B:-3:U1:30 /18.5 U5:X2B:4:U1:31 /18.5
WCSG
PE
X2B:4
DIO ( F-889)
E6
X3:E7 RL1:P
RL1:O
U11 1CH, 1C/O
14
1 CH, 1C/O
220V AC
220VAC RELAY CARD
RL4
13
K6 12.9
14
RL1:P
RL1:O
RL4:P
U12 4CH, 1C/O
X3:24N
X3:24P
X3:E6
X3:24N
X3:24P
X3:E5
X3:24P
X3:E4
12.12
RL4:O
U7
13
K5
U7:RL3:O:RL4:O
8.3
E7
E5
X3:24N
X3:24P
E4
X3:24N
8.2
X2B:3-
X2B:2+
3x0.35
U5
RL1
COM
220V AC RELAY BOARD
RELAY BOARD
1
RL1
COM
1
4
4.12/220N1.8 4.12/220P1.8
X12
K4
3
220N1.1/4.12
10
1
VIB START/STOP S4
2
220PA.4/8.3
1 3 5 13 13A
2 4 6 14 14A
WC10
WC04
3x1.5
2x1.5
OP
X42
19.7 19.7 19.7 10.6 13.4
5
3
3
5
6
4
1
S2.1
4
220PA.3/17.2 VIB. ON /OFF
S1.1
START/STOP
2
FAULT RESET
START/STOP
220VAC
220VAC
DATE/NAME
CHKD
NAME
18.Jun.2013
HS
ENGG
18.Jun.2013
HS
CHKD
18.Jun.2013
HS
DRN
18.Jun.2013
HS
WEIGH FEEDER CUSTOMER: PROJECT: CONSULTANT:
SAIL-ROURKELA STEEL PLANT
BC-117 ILK
220VAC
PLC/DCS (CUSTOMER)
OPERATOR DATE
CHANGE
4
A1 A2
14x1.5
LCS
2
9
WC05
X14
1
90A1291
X10
7
TITLE:
INPUTS E004-E007
= A1
DRG.NO.: 90.1291
+
- 011-EE16-R0
SHEET 9 19
1
2
3
5
4
6
7
8
9
10
11
12
14
13
U5 DIO F-889
X5:2
X5:1
X4:3NO
X5:2
X4:2C
X5:1
A3 X4:2NO
X5:2
X5:1
X5:2
X5:1
X4:0C
A3
A2 X4:1NO
A1
X4:0NO
A0
A2
X4:3C
A1
A0
X4:1C
8.2
220N1.6/4.12 220P1.6/4.12
220VAC
NON UPS SUPLLY
4.12/220P1.1
K4 9.4
X10
13 14
10
11
11
12
1
1
WC05 14x1.5
X14
1
L1
2
LP2
L2
2
2
WF ON 220NA.4/8.3 VIB ON F/B
LCS
EE DOOR
DATE
CHANGE
DATE/NAME
CHKD
90A1291
BELT RUN F/B
LAMP
NAME
18.Jun.2013
HS
ENGG
18.Jun.2013
HS
CHKD
18.Jun.2013
HS
DRN
18.Jun.2013
HS
WEIGH FEEDER CUSTOMER: PROJECT: CONSULTANT:
SAIL-ROURKELA STEEL PLANT
TITLE:
OUTPUTS A000-A003
= A1
DRG.NO.: 90.1291
+
- 011-EE16-R0
SHEET 10 19
1
2
3
5
4
6
8
7
9
10
11
12
13
14
/12.4/ U5
X6-M
9PINDB
DIO F-889
1
2
3
4
6
7
X5:2
X5:1
X5:2
X5:1
5
X4:7C
A7
X4:6C
X5:2
X5:1
X5:2
X5:1
X4:4C
X21
A7
A6 X4:5NO
A5 X4:4NO
A4
A6
X4:7NO
A5
X4:6NO
A4
X4:5C
8.2
8
WC03 8x1.5
WF ON
PLC SEL
220VAC
220VAC
GENERAL
MATERIAL OVERLOAD
FAULT
ON BELT
PLC/DCS
90A1291
(CUSTOMER)
DATE
CHANGE
DATE/NAME
CHKD
NAME
18.Jun.2013
HS
ENGG
18.Jun.2013
HS
CHKD
18.Jun.2013
HS
DRN
18.Jun.2013
HS
WEIGH FEEDER CUSTOMER: PROJECT: CONSULTANT:
SAIL-ROURKELA STEEL PLANT
TITLE:
OUTPUTS A004-A007
= A1
DRG.NO.: 90.1291
+
- 011-EE16-R0
SHEET 11 19
1
2
3
5
4
6
8
7
9
10
11
12
13
14
/11.5/ U6
X6-F
13.1 14.1 15.2 17.9
EE
9PINDB
DIO ( F-890)
X3:E11
X3:24P
X3:E10
X3:24N
X3:24P
X3:E9
X3:24N
X3:24P
X3:E8
X3:24N
X3:24P
E11
E10
X3:24N
E9
E8
5.12/24N.3
UPS
5.12/24P.3
SUPLLY
COM
RL1
1
RL1
COM
1
COM
RL1
1
RL1:O
U16
RL1:P
RL1:O
U15
RL1:P
RL1:O
U14
RL1:P
RL1:O
U13
RL1:P
5.12/24P.4
COM
RL1
1 CH 1 C/O 220V AC 1
4.12/220N1.9 4.12/220P1.9 4.12/220N1.10
A4
1
1
1
1
SW2
U18
1
COM
1
RL1:O
RL1:P
RL1:O
RL1 RL1:P
COM
RL1
4 PLC MODE
A3
3. - TUC MODE
A2
2 OPERATING VOLUMETRIC
A1
1 LCS VOLUMETRIC
U17
NON UPS A1
K6
SUPLLY
220P1.3/4.12 NON UPS 220N1.3/4.12 SUPLLY OPERATOR MODE A2
PLC MODE 13 23
14 24
9.12 7.3
A1
K5
220P1.2/4.12 220N1.2/4.12
A2
13 23
14 24
9.9 7.6
EE DOOR
90A1291
SW1
DATE
CHANGE
DATE/NAME
CHKD
NAME
18.Jun.2013
HS
ENGG
18.Jun.2013
HS
CHKD
18.Jun.2013
HS
DRN
18.Jun.2013
HS
WEIGH FEEDER CUSTOMER: PROJECT: CONSULTANT:
SAIL-ROURKELA STEEL PLANT
TITLE:
INPUTS E008-E011
= A1
DRG.NO.: 90.1291
+
- 011-EE16-R0
SHEET 12 19
1
2
3
5
4
6
7
8
9
10
11
12
U6
EE DIO ( F-890)
K4 9.4
X3:E15
X3:24N
X3:24P
E15 X3:E14
X3:24N
X3:24P
E14 X3:E13
X3:24P
X3:E12
E13 X3:24N
X3:24P
E12
X3:24N
12.1
14
13
13A 14A
VIB ON/OFF
3
SW1
4 GRAV/VOL ON DOOR
ONLY APPLICABLE FOR PLC AND MODE
90A1291
EE DOOR
DATE
CHANGE
DATE/NAME
CHKD
NAME
18.Jun.2013
HS
ENGG
18.Jun.2013
HS
CHKD
18.Jun.2013
HS
DRN
18.Jun.2013
HS
WEIGH FEEDER CUSTOMER: PROJECT: CONSULTANT:
SAIL-ROURKELA STEEL PLANT
TITLE:
INPUTS E012-E015
= A1
DRG.NO.: 90.1291
+
- 011-EE16-R0
SHEET 13 19
1
2
3
5
4
6
7
8
9
10
11
12
U6
14
EE DIO (F-890)
A10 A8
A11
A9 A10
A11
X8:11NO
X8:10C
X8:10NO
X8:9C
X8:8C
X8:9NO
A9
X8:8NO
A8
X8:11C
12.1
13
LOC SEL
90A1291
/17.9/
DATE
CHANGE
DATE/NAME
CHKD
NAME
18.Jun.2013
HS
ENGG
18.Jun.2013
HS
CHKD
18.Jun.2013
HS
DRN
18.Jun.2013
HS
WEIGH FEEDER CUSTOMER: PROJECT: CONSULTANT:
SAIL-ROURKELA STEEL PLANT
TITLE:
OUTPUTS A008-A011
= A1
DRG.NO.: 90.1291
+
- 011-EE16-R0
SHEET 14 19
1
2
3
5
4
6
8
7
9
10
11
12
U6 12.1
13
14
EE DIO (F-890) A13
A14
A15
A12 A13
A14
A15
90A1291
X8:15C
X8:15NO
X8:14C
X8:14NO
X8:13C
X8:13NO
X8:12C
X8:12NO
A12
DATE
CHANGE
DATE/NAME
CHKD
NAME
18.Jun.2013
HS
ENGG
18.Jun.2013
HS
CHKD
18.Jun.2013
HS
DRN
18.Jun.2013
HS
WEIGH FEEDER CUSTOMER: PROJECT: CONSULTANT:
SAIL-ROURKELA STEEL PLANT
TITLE:
OUTPUTS A012-A015
= A1
DRG.NO.: 90.1291
+
- 011-EE16-R0
SHEET 15 19
1
2
3
5
4
6
8
7
9
10
11
12
14
13
NON UPS SUPPLY U2
220P1.4/4.12 220 VAC
6.1
TUC-6 A016 A017 A018 A019 1
3
2
4
NORMAL/BY SW.
X4:8-
X1:9
COMMUNICATION X4:3+
RL4
COMMUNICATION X4:7-
RL3
PROFIBUS
X4:2+
RL2
X1:8
X1:6
X1:5
X1:4
RL1
X1:7
SW3 MODBUS
X21
9
4x1.5
LOC SEL /17.13/
REM SEL /17.12/
WC12
1
SW4
33
STOP BY
2
BC117 34
CUSTOMER SCOPE A1
K3
A1
K1
A2
3
K2
A2
.11
13 4
WC12
SW5
4x1.5
START BY
X21
14
10
A1
K2
A2
1
LP3
2
K2 .11
21
K3 .9
22
21 22
220N1.4/4.12 2 4 6 22
18.7 18.7 18.7 .11
1 3 5
2 4 6
18.7 18.7 18.7
1 3 5 13 21
2 4 6 14 22
18.2 18.3 18.3 .11 .10
90A1291
1 3 5 21
220 VAC
DATE
CHANGE
DATE/NAME
CHKD
NAME
18.Jun.2013
HS
ENGG
18.Jun.2013
HS
CHKD
18.Jun.2013
HS
DRN
18.Jun.2013
HS
WEIGH FEEDER CUSTOMER: PROJECT: CONSULTANT:
SAIL-ROURKELA STEEL PLANT
TITLE:
OUTPUTS A016-A019
= A1
DRG.NO.: 90.1291
+
- 011-EE16-R0
SHEET 16 19
5
4
6
8
7
9
10
U1
11
REMOTE SEL
U2 AC INVERTER
6.1
(ACS550) 16
17
13
10
14
15
X1:7
18
RL2 A17
12
RL3 A18
13
14
LOCAL SEL
3
X1:8
2
X1:6
1
NOTE: FAULT I/P USED
RL3 COM
3
FAULT RESET
12.1
U1
LOCA/ SEL.
.1 RL2:25
X8:10C
AS STOP FOR
U6
RL1:P
RL1:O
RL2:P
RL2:O
RL3:O
U10
RL3:P
X8:10NO
A10
RL2:27
A10
RL2
RL1
2
4 CH, 1C/O
1
NON UPS
220V AC RELAY BOARD
SUPPLY 4.12/220N1.5
X10
8
7
X21
6
WC05
WC12
14X1.5
4X1.5
X14
LCS
9
8
1
3
S3
12
7
1
S1 2
11
S2
4
2
BC-117 CONVEYOR RUNNING
EMG.OFF DATE
CHANGE
DATE/NAME
CHKD
NAME
18.Jun.2013
HS
ENGG
18.Jun.2013
HS
CHKD
18.Jun.2013
HS
DRN
18.Jun.2013
HS
START
STOP
WEIGH FEEDER CUSTOMER: PROJECT: CONSULTANT:
SAIL-ROURKELA STEEL PLANT
90A1291
9.2/220PA.3
PLC / DCS TITLE:
INVERTER
= A1
DRG.NO.: 90.1291
+
- 011-EE16-R0
SHEET 17 19
1
2
3
5
4
6
8
7
9
10
11
12
14
13
E1 3.13/L3
415 V/50Hz
3.13/L2 3.13/L1
1
3
5
13
F1
14 8.13
4-6 AMPS 2
4
NOTE:
6
DESIGN SCHEME IS SUITABLE FOR MAX.250 MTRS. BETWEEN INVERTER & INDIVIDUAL MOTOR
NORMAL
K1 16.10
1
3
5
2
4
6 WCS09
U1 V1
W1
E
X22
4
X41
1
2
X22
5
X41
2
3
X22
6
X41
3
3x0.35 X22 7
X41
4
4 9.5/U5:X2B:+2:U1:29
X1:29
MODBUS
9.5/U5:X2B:-3:U1:30
X1:30
9.5/U5:X2B:4:U1:31
X1:31
K2 16.11
3
5
25
2
4
6
26
WCSM
2.2 KW
11
U2
V2
W2
L2
NORMAL
K3
16.9
3
A1
B1
C1
A2
B2
C2
1
3
5
9
WCSR
UPS
2
4
VOLUME 1 SET POINT
2
8
PE
12
NOCH-0016/15 AMPS
3x0.35
P1 AC INVERTER (ACS 550)
1
WCSK-2
LCS
3x0.75 U1
2x0.35
SUPPLY
U9
5.12/P1.1
L I/P+ I/P-
5.12/N1.1
N
6
I/I
O/P1+ O/P1-
WCSQ 2x0.35 WP02X13
4
5
6
E
X9
4x4
TERMINAL BOX
10
11
12
WCS07 1
2
3
E
2x0.75
M1
4-20mA ISO O/P
4POLE,1500RPM IL-4.4AMPS DATE
CHANGE
DATE/NAME
CHKD
NAME
18.Jun.2013
HS
ENGG
18.Jun.2013
HS
CHKD
18.Jun.2013
HS
DRN
18.Jun.2013
HS
WEIGH FEEDER CUSTOMER: PROJECT: CONSULTANT:
SAIL-ROURKELA STEEL PLANT
à CURRENT
M 3
~
PLC/DCS 90A1291
PW-2.2KW
(CUSTOMER)
WF MOTOR TITLE:
AC INVERTOR
= A1
DRG.NO.: 90.1291
+
- 011-EE16-R0
SHEET 18 19
1
2
3
5
4
6
8
7
9
10
11
12
13
14
E
3.13/L3.1
415V/50Hz
3.13/L2.1 3.13/L1.1
1
3
5
13
F2
14 8.13
0.4-0.6 Amps. 2
4
6
1
3
5
2
4
6
X13
7
8
9
X17
4
5
6
K4 9.4
E
WP03 3x2.5
M2
M 3
2POLE,1500RPM IL-0.52AMPS DATE
CHANGE
DATE/NAME
CHKD
NAME
18.Jun.2013
HS
ENGG
18.Jun.2013
HS
CHKD
18.Jun.2013
HS
DRN
18.Jun.2013
HS
VIB MOTOR
WEIGH FEEDER CUSTOMER: PROJECT: CONSULTANT:
~
90A1291
PW-0.27KW
E
SAIL-ROURKELA STEEL PLANT
TITLE:
VIB MOTOR
= A1
DRG.NO.: 90.1291
+
- 011-EE16-R0
SHEET 19 19
1
2
3
5
4
6
8
7
9
10
11
12
13
Terminal diagram
14
=A1-WCSQ
=A1-WCSE2-1
=A1-W2
Type
Cable name Target design.
Connection
Connection
Target design.
Terminal number
Function text
Jumpers
=A1-X9 Connection
=A1-WCS06
Cable name
Strip designation
Type
=A1-WCS10
=A1-WCS05
=A1-WCS07
ESSK034E
Page/ path
4-20mA ISO I/P à SET POINT
1
-PLC/DCS
1
-U8
I/P+
1
=A1/7.4
=
2
-PLC/DCS
2
-U8
I/P-
2
=A1/7.4
SH
3
SH
SHIELD
=A1/7.4
VOLUME SETPOINT
1
-OP-X43
4
4
-U4
X2:1
=A1/7.5
=
2
-OP-X43
5
5
-K5
23
=A1/7.6
=
3
-OP-X43
6
6
-U4
X2:3
=A1/7.6
4-20mA ISO O/P à ACTUAL FEEDRATE
1
-PLC/DCS
7
-U4
X3:1
1
=A1/7.8
=
2
-PLC/DCS
8
-U4
X3:2
2
=A1/7.8
SH
9
SH
SHIELD
=A1/7.9
4-20mA ISO O/P à CURRENT
1
-PLC/DCS
10
-U9
O/P1+
1
=A1/18.10
=
2
-PLC/DCS
11
-U9
O/P1-
2
=A1/18.10
SH
12
SH
=A1/18.11
90A1291
SHIELD
DATE
CHANGE
DATE/NAME
CHKD
NAME
18.Jun.2013
HS
ENGG
18.Jun.2013
HS
CHKD
18.Jun.2013
HS
DRN
18.Jun.2013
HS
WEIGH FEEDER CUSTOMER: PROJECT: CONSULTANT:
SAIL-ROURKELA STEEL PLANT
TITLE:
=A1-X9
= A1_TER
DRG.NO.: 90.1291
+
- 011-EE17-R0
SHEET 1 13
1
2
3
5
4
6
8
7
9
10
11
12
13
Terminal diagram
14
Target design.
Type
Connection
Connection
Terminal number
Target design.
Jumpers
=A1-X10 Connection
Function text
Cable name
Strip designation
Type
=A1-WC05
Cable name
ESSK034E
Page/ path
1
-LCS-X14
1
1
-X6
P
=A1/8.4
220N
2
-LCS-X14
3
2
-U7
COM
=A1/8.4
ZERO SPEED SW.
3
-LCS-X14
4
3
-U7
1
=A1/8.5
BELT SWAY S/W
4
-LCS-X14
5
4
-U7
2
=A1/8.7
MATERIAL DETECTION .
5
-LCS-X14
6
5
-U7
3
=A1/8.9
STOP
6
-LCS-X14
7
6
-X21
11
=A1/17.7
START
7
-LCS-X14
8
7
-U10
2
=A1/17.6
EMG.OFF
8
-LCS-X14
9
8
-U10
3
=A1/17.4
VIB. ON /OFF
9
-LCS-X14
10
9
-K4
A1
=A1/9.2
BELT RUN F/B
10
-LCS-X14
11
10
-U5
X4:0C
=A1/10.3
VIB ON F/B
11
-LCS-X14
12
11
-K4
14
=A1/10.6
90A1291
220P
DATE
CHANGE
DATE/NAME
CHKD
NAME
18.Jun.2013
HS
ENGG
18.Jun.2013
HS
CHKD
18.Jun.2013
HS
DRN
18.Jun.2013
HS
WEIGH FEEDER CUSTOMER: PROJECT: CONSULTANT:
SAIL-ROURKELA STEEL PLANT
TITLE:
=A1-X10
= A1_TER
DRG.NO.: 90.1291
+
- 011-EE17-R0
SHEET 2 13
1
2
3
5
4
6
8
7
9
10
11
12
13
Terminal diagram
14
=A1-WCSC
=A1-WCSB
Type
Cable name Target design.
Connection
Connection
Target design.
Terminal number
Function text
Jumpers
=A1-X11 Connection
=A1-WCS04
Cable name
Strip designation
Type
=A1-WCS03
ESSK034E
Page/ path
SUPPLY -
1
-JB1-X15
1
1
-U2
X3:9
1
=A1/6.7
SUPPLY +
2
-JB1-X15
2
2
-U2
X3:5
2
=A1/6.5
SIGNAL +
3
-JB1-X15
3
3
-U2
X3:2
3
=A1/6.6
SIGNAL -
4
-JB1-X15
4
4
-U2
X3:6
4
=A1/6.6
5
SH
SHIELD
SH
=A1/6.5
SENSE -
5
-JB1-X15
6
6
-U2
X3:8
5
SENSE +
6
-JB1-X15
7
7
-U2
X3:4
6
=A1/6.7 =A1/6.5
+12V
1
-JB1-X15
8
8
-U2
X1:10
1
=A1/6.8
SIGNAL
2
-JB1-X15
9
9
-U2
X1:11
2
=A1/6.9
SH
10
SH
=A1/6.9
90A1291
SHIELD
DATE
CHANGE
DATE/NAME
CHKD
NAME
18.Jun.2013
HS
ENGG
18.Jun.2013
HS
CHKD
18.Jun.2013
HS
DRN
18.Jun.2013
HS
WEIGH FEEDER CUSTOMER: PROJECT: CONSULTANT:
SAIL-ROURKELA STEEL PLANT
TITLE:
=A1-X11
= A1_TER
DRG.NO.: 90.1291
+
- 011-EE17-R0
SHEET 3 13
1
2
3
5
4
6
8
7
9
10
11
12
13
Terminal diagram
14
Cable name Target design.
Type
Connection
Connection
Target design.
Terminal number
Function text
Jumpers
=A1-X12 Connection
=A1-WC10
Cable name
Strip designation
Type
=A1-WC04
=A1-WC04.2
ESSK034E
path
220P
1
-OP-X42
3
1
-X6
P
START/STOP 220VAC
2
-OP-X42
4
2
-U12
1
220P START/STOP 220VAC
Page/ =A1/9.8 =A1/9.9
1
-PLC/DCS
3
=A1/9.11
2
=A1/9.12
-PLC/DCS
4
=
1
-PLC/DCS
5
BC-117 ILK
2
-PLC/DCS
6
-U11
1
=A1/9.13
7
-U7
4
=A1/9.7
3
-OP-X42
5
90A1291
FAULT RESET 220VAC
=A1/9.12
DATE
CHANGE
DATE/NAME
CHKD
NAME
18.Jun.2013
HS
ENGG
18.Jun.2013
HS
CHKD
18.Jun.2013
HS
DRN
18.Jun.2013
HS
WEIGH FEEDER CUSTOMER: PROJECT: CONSULTANT:
SAIL-ROURKELA STEEL PLANT
TITLE:
=A1-X12
= A1_TER
DRG.NO.: 90.1291
+
- 011-EE17-R0
SHEET 4 13
1
2
3
5
4
6
8
7
9
10
11
12
13
Terminal diagram
14
Cable name Target design.
Type
Connection
Connection
Target design.
Terminal number
Function text
Jumpers
=A1-X13 Connection
=A1-WP01
Cable name
Strip designation
Type
=A1-WP02
=A1-WP03
=A1-WP04
ESSK034E
Page/ path
415 V ñ10% 50 Hz ñ3% 3í SUPPLY
1
-MCC
R
1
-Q1
1
=A1/3.2
=
2
-MCC
Y
2
-Q1
3
=A1/3.2
=
3
-MCC
B
3
-Q1
5
=A1/3.2
1
-TERMINALBOX
1
4
-K3
2
=A1/18.7
2
-TERMINALBOX
2
5
-K3
4
=A1/18.7
3
-TERMINALBOX
3
6
-K3
6
1
-X17
4
7
-K4
2
X
=A1/19.7
2
-X17
5
8
-K4
4
X
=A1/19.7
3
-X17
6
9
-K4
6
X
=A1/19.7
-TERMINALBOX
E
E
-U1
PE
-MCC
E
E
-E
=A1/3.3
E
-E
=A1/19.8
VIB MOTOR
4
EARTH = =
=A1/18.7
=A1/18.8
1
-UPSSUPPLY
L
10
-Fa
1
X
=A1/5.2
=
2
-UPSSUPPLY
N
11
-Fa
3
X
=A1/5.2
90A1291
220 VAC ñ3% 50 Hz
DATE
CHANGE
DATE/NAME
CHKD
NAME
18.Jun.2013
HS
ENGG
18.Jun.2013
HS
CHKD
18.Jun.2013
HS
DRN
18.Jun.2013
HS
WEIGH FEEDER CUSTOMER: PROJECT: CONSULTANT:
SAIL-ROURKELA STEEL PLANT
TITLE:
=A1-X13
= A1_TER
DRG.NO.: 90.1291
+
- 011-EE17-R0
SHEET 5 13
1
2
3
5
4
6
8
7
9
10
11
12
13
Terminal diagram
14
X
ZERO SPEED SW.
2
220N
2
1
15
2
-LCS-L2
2
-X10
-JB1-X15 X
ZERO SPEED SW.
-LCS-S4
3
Target design.
=A1-WC07
=A1-WC05
Type
Connection
Connection
Jumpers
Terminal number
Target design.
Connection
=A1-LCS-X14
Function text 220P
Cable name
Cable name
Strip designation
Type
=A1-WC07
=A1-WC05
ESSK034E
Page/ path
-X10
1
1
3
-X10
2
2
3
4
-JB1-X15
=A1/8.4 =A1/8.4
16
=A1/8.4 3
=A1/8.5
BELT SWAY S/W
1
-JB1-X15
14
5
-X10
4
4
MATERIAL DETECTION .
4
-JB1-X15
17
6
-X10
5
5
=A1/8.7 =A1/8.9
X
-LCS-S2
1
7
-X10
6
6
=A1/17.7
START
X
-LCS-S1
3
8
-X10
7
7
=A1/17.6
EMG.OFF
X
-LCS-S3
1
9
-X10
8
8
=A1/17.4
VIB. ON /OFF
X
-LCS-S4
1
10
-X10
9
9
=A1/9.2
BELT RUN F/B
-LCS-L1
1
11
-X10
10
10
=A1/10.3
VIB ON F/B
-LCS-L2
1
12
-X10
11
11
=A1/10.6
90A1291
STOP
DATE
CHANGE
DATE/NAME
CHKD
NAME
18.Jun.2013
HS
ENGG
18.Jun.2013
HS
CHKD
18.Jun.2013
HS
DRN
18.Jun.2013
HS
WEIGH FEEDER CUSTOMER: PROJECT: CONSULTANT:
SAIL-ROURKELA STEEL PLANT
TITLE:
=A1-LCS-X14
= A1_TER
DRG.NO.: 90.1291
+
- 011-EE17-R0
SHEET 6 13
1
2
3
5
4
6
8
7
9
10
11
12
13
=A1-WC07
=A1-WCS03
Type
=A1-WCS04
Cable name Target design.
Connection
Connection
Target design.
Terminal number
Function text
Jumpers
=A1-JB1-X15 Connection
=A1-WCS02
Cable name
Strip designation
Type
=A1-WC01
=A1-WCS01
=A1-WC02
ESSK034E =A1-WC06
=A1-WC08
Terminal diagram
14
Page/ path
SUPPLY -
1
-FIELD-LC1
C
1
-X11
1
1
=A1/6.7
SUPPLY +
2
-FIELD-LC1
B
2
-X11
2
2
=A1/6.5
SIGNAL +
3
-FIELD-LC1
A
3
-X11
3
3
=A1/6.6
SIGNAL -
4
-FIELD-LC1
D
4
-X11
4
4
=A1/6.6
5
SH
SENSE -
6
-X11
6
5
SENSE +
7
-X11
7
6
SHIELD
SH
=A1/6.5 =A1/6.7 =A1/6.5
+12V
1
-FIELD
8
-X11
8
1
=A1/6.8
SIGNAL
2
-FIELD
9
-X11
9
2
=A1/6.9
SHIELD
SH
10
SH
=A1/6.9
BELT SWAY S/W
1
-FIELD
11
=A1/8.6
=
2
-FIELD
12
=A1/8.6
=
1
-FIELD
13
=
2
-FIELD
14
-LCS-X14
5
1
=A1/8.7
=A1/8.7
ZERO SPEED SW.
1
-FIELD
1
15
-LCS-X14
2
2
=A1/8.4
=
2
-FIELD
2
16
-LCS-X14
4
3
=A1/8.5
-LCS-X14
6
4
=A1/8.9
1
-FIELD
2
17
=
2
-FIELD
1
18
=A1/8.8
90A1291
MATERIAL DETECTION .
DATE
CHANGE
DATE/NAME
CHKD
NAME
18.Jun.2013
HS
ENGG
18.Jun.2013
HS
CHKD
18.Jun.2013
HS
DRN
18.Jun.2013
HS
WEIGH FEEDER CUSTOMER: PROJECT: CONSULTANT:
SAIL-ROURKELA STEEL PLANT
TITLE:
=A1-JB1-X15
= A1_TER
DRG.NO.: 90.1291
+
- 011-EE17-R0
SHEET 7 13
1
2
3
5
4
6
8
7
9
10
11
12
13
Terminal diagram
14
Type
=A1-WC12
Cable name Target design.
Connection
Connection
Target design.
Terminal number
Function text
Jumpers
=A1-X21 Connection
=A1-WC03
Cable name
Strip designation
Type
=A1-WC12
ESSK034E
Page/ path
WF ON 220VAC
1
-PLC/DCS
1
-U5
X4:4NO
=A1/11.3
=
2
-PLC/DCS
2
-U5
X4:4C
=A1/11.4
PLC SEL 220VAC
3
-PLC/DCS
3
-U5
X4:5NO
=A1/11.6
=
4
-PLC/DCS
4
-U5
X4:5C
=A1/11.7
GENERAL FAULT
5
-PLC/DCS
5
-U5
X4:6NO
=A1/11.9
=
6
-PLC/DCS
6
-U5
X4:6C
=A1/11.10
7
-PLC/DCS
7
-U5
X4:7NO
=A1/11.12
8
-PLC/DCS
8
-U5
X4:7C
33
9
-SW3
1
10
-CUSTOMERSCOPE-BC117
MATERIAL OVERLOAD
ON BELT
= 1
-CUSTOMERSCOPE-BC117 -SW4
4
=A1/11.12 X
34
=A1/16.14 2
=A1/16.14
3
-PLC/DCS
11
-X10
6
=A1/17.9
=
3
-PLC/DCS
12
-U10
1
=A1/17.10
90A1291
BC-117 CONVEYOR RUNNING
DATE
CHANGE
DATE/NAME
CHKD
NAME
18.Jun.2013
HS
ENGG
18.Jun.2013
HS
CHKD
18.Jun.2013
HS
DRN
18.Jun.2013
HS
WEIGH FEEDER CUSTOMER: PROJECT: CONSULTANT:
SAIL-ROURKELA STEEL PLANT
TITLE:
=A1-X21
= A1_TER
DRG.NO.: 90.1291
+
- 011-EE17-R0
SHEET 8 13
1
2
3
5
4
6
8
7
9
10
11
12
13
Terminal diagram
14
=A1-WCSM
Type
=A1-WCSL1
Cable name Target design.
Connection
Connection
Target design.
Terminal number
Function text
Jumpers
=A1-X22 Connection
=A1-WCS08
Cable name
Strip designation
Type
=A1-WCS09
ESSK034E
Page/ path
FEEDRATE INDICATOR
1
-OP-X43
1
1
-U2
X1:+13
1
=A1/7.13
=
2
-OP-X43
2
2
-U2
X1:-14
2
=A1/7.13
3
SH
SHIELD
SH
=A1/7.14
FEEDRATE SET
1
-LCS-X41
1
4
-U1
4
1
=A1/18.9
=
2
-LCS-X41
2
5
-U1
2
2
=A1/18.9
=
3
-LCS-X41
3
6
-U1
3
3
=A1/18.9
SH
7
=A1/18.9
90A1291
SHIELD
DATE
CHANGE
DATE/NAME
CHKD
NAME
18.Jun.2013
HS
ENGG
18.Jun.2013
HS
CHKD
18.Jun.2013
HS
DRN
18.Jun.2013
HS
WEIGH FEEDER CUSTOMER: PROJECT: CONSULTANT:
SAIL-ROURKELA STEEL PLANT
TITLE:
=A1-X22
= A1_TER
DRG.NO.: 90.1291
+
- 011-EE17-R0
SHEET 9 13
1
2
3
5
4
6
8
7
9
10
11
12
13
Terminal diagram
14
Target design.
Type
Connection
Connection
Terminal number
Target design.
Jumpers
=A1-X23 Connection
Function text
Cable name
Strip designation
Type
=A1-WC11
Cable name
ESSK034E
Page/ path
1
-OP-X42
1
1
-X6
P
=A1/7.11
220PN
2
-OP-X42
2
2
-X6
N
=A1/7.12
90A1291
220P
DATE
CHANGE
DATE/NAME
CHKD
NAME
18.Jun.2013
HS
ENGG
18.Jun.2013
HS
CHKD
18.Jun.2013
HS
DRN
18.Jun.2013
HS
WEIGH FEEDER CUSTOMER: PROJECT: CONSULTANT:
SAIL-ROURKELA STEEL PLANT
TITLE:
=A1-X23
= A1_TER
DRG.NO.: 90.1291
+
- 011-EE17-R0
SHEET 10 13
1
2
3
5
4
6
8
7
9
10
11
12
13
Terminal diagram
14
Target design.
Type
Connection
Connection
Jumpers
Target design.
Terminal number
Function text
Connection
=A1-LCS-X41
=A1-WCS09
Cable name
Strip designation
Type
=A1-WCSK-2
Cable name
ESSK034E
Page/ path
FEEDRATE SET
1
-LCS-P1
3
1
-X22
4
1
=A1/18.11
=
2
-LCS-P1
2
2
-X22
5
2
=A1/18.11
=
3
-LCS-P1
1
3
-X22
6
3
=A1/18.11
4
SH
SH
=A1/18.11
90A1291
SHIELD
DATE
CHANGE
DATE/NAME
CHKD
NAME
18.Jun.2013
HS
ENGG
18.Jun.2013
HS
CHKD
18.Jun.2013
HS
DRN
18.Jun.2013
HS
WEIGH FEEDER CUSTOMER: PROJECT: CONSULTANT:
SAIL-ROURKELA STEEL PLANT
TITLE:
=A1-LCS-X41
= A1_TER
DRG.NO.: 90.1291
+
- 011-EE17-R0
SHEET 11 13
1
2
3
5
4
6
8
7
9
10
11
12
13
Terminal diagram
14
Target design.
=A1-WC10
=A1-WC11
Type
Connection
Connection
Terminal number
Target design.
Jumpers
=A1-OP-X42 Connection
Function text
Cable name
Strip designation
Type
=A1-W4
Cable name
ESSK034E
Page/ path
220P
1
-OP-D1
9
1
-X23
1
1
220PN
2
-OP-D1
10
2
-X23
2
2
=A1/7.11 =A1/7.12
-OP-S2.1
4
3
-X12
1
1
=A1/9.8
START/STOP 220VAC
-OP-S1.1
1
4
-X12
2
2
=A1/9.9
FAULT RESET 220VAC
-OP-S2.1
3
5
-X12
7
3
=A1/9.7
90A1291
220P
DATE
CHANGE
DATE/NAME
CHKD
NAME
18.Jun.2013
HS
ENGG
18.Jun.2013
HS
CHKD
18.Jun.2013
HS
DRN
18.Jun.2013
HS
WEIGH FEEDER CUSTOMER: PROJECT: CONSULTANT:
SAIL-ROURKELA STEEL PLANT
TITLE:
=A1-OP-X42
= A1_TER
DRG.NO.: 90.1291
+
- 011-EE17-R0
SHEET 12 13
1
2
3
5
4
6
8
7
9
10
11
12
13
Terminal diagram
14
=A1-WCS10
Type
=A1-WCS08
Cable name Target design.
Connection
Connection
Target design.
Terminal number
Function text
Jumpers
=A1-OP-X43 Connection
=A1-WCSD
Cable name
Strip designation
Type
=A1-WCSK-1
ESSK034E
Page/ path
FEEDRATE INDICATOR
1
-OP-D1
1
1
-X22
1
1
=A1/7.13
=
2
-OP-D1
2
2
-X22
2
2
=A1/7.13
3
SH
SHIELD
SH
=A1/7.14
VOLUME SETPOINT
1
-OP-P1.1
3
4
-X9
4
1
=A1/7.5
=
2
-OP-P1.1
2
5
-X9
5
2
=A1/7.6
=
3
-OP-P1.1
1
6
-X9
6
3
=A1/7.6
7
SH
SH
=A1/7.6
90A1291
=
DATE
CHANGE
DATE/NAME
CHKD
NAME
18.Jun.2013
HS
ENGG
18.Jun.2013
HS
CHKD
18.Jun.2013
HS
DRN
18.Jun.2013
HS
WEIGH FEEDER CUSTOMER: PROJECT: CONSULTANT:
SAIL-ROURKELA STEEL PLANT
TITLE:
=A1-OP-X43
= A1_TER
DRG.NO.: 90.1291
+
- 011-EE17-R0
SHEET 13 13
1
2
3
5
4
6
7
8
9
10
11
12
14
13
BILL OF MATERIAL COMPONENT LEGEND
QTY.
TIL-FLS BOM
TYPE NUMBER
DEVICE
GENERAL SPECIFICATION
PAGE/PATH
MAKE
=A1-F1
1
MPCB
3VU 1340-1MKOO
4-6 Amp
SIEMENS
=A1/18.
7
=A1-F2
1
MPCB
3VU1340 1MEOO
0.4-0.6 Amp
SIEMENS
=A1/19.
7
=A1-Fa
1
MCB
DP
1 Amp(2P)
MDS/SIEMENS
=A1/5.
2
=A1-Fb
1
MCB
DP
1 Amp(2P)
MDS/SIEMENS
=A1/3.
11
=A1-Fc
1
MCB
DP
1 Amp(2P)
MDS/SIEMENS
=A1/4.
2
=A1-K1
1
OR
3TF30 10-0A PO
9 Amp
SIEMENS
=A1/16.
10
=A1-K1
1
SURGE SUPRSSOR
3TX7402-3TY2
220VAC (RC)
SIEMENS
=A1/16.
10
=A1-K2
1
OR
3TF30 10-0A PO
9 Amp
SIEMENS
=A1/16.
11
=A1-K2
1
AUXILLIARY BLOCK
3TX4 001-2A
1 NC
SIEMENS
=A1/16.
11
=A1-K2
1
SURGE SUPRSSOR
3TX7402-3TY2
220VAC (RC)
SIEMENS
=A1/16.
11
=A1-K3
1
OR
3TF3O 01-0A-PO
9 Amp
SIEMENS
=A1/16.
9
=A1-K3
1
SURGE SUPRSSOR
3TX7402-3TY2
220VAC (RC)
SIEMENS
=A1/16.
9
=A1-K4
1
OR
3TF3O 10-0A-PO
9 Amp
SIEMENS
=A1/9.
4
=A1-K4
1
SURGE SUPRSSOR
3TX7402-3TY2
220VAC (RC)
SIEMENS
=A1/9.
4
=A1-K5
1
OR
3TH30 40-0A PO (4NO)
10A
SIEMENS
=A1/12.
12
=A1-K5
1
SURGE SUPRSSOR
3TX7402-3TY2
220VAC (RC)
SIEMENS
=A1/12.
12
=A1-K6
1
OR
3TH30 40-0A PO (4NO)
10A
SIEMENS
=A1/12.
9
=A1-K6
1
SURGE SUPRSSOR
3TX7402-3TY2
220VAC (RC)
SIEMENS
=A1/12.
9
=A1-L2
1
OUTPUT CHOKE
NOCH-0016
15 Amp
ABB
=A1/18.
7
=A1-L3
1
CFL LAMP
8020070V0200
8 WATT
PHILIPS
=A1/3.
=A1-LCS-L1
1
LAMP
P2PL BR4L-RED
220VAC
TEKNIC
=A1/10.
3
=A1-LCS-L2
1
LAMP
P2PL BR4L-RED
220VAC
TEKNIC
=A1/10.
6
=A1-LCS-P1
1
POTENTIOMETER
808006000100
1K,10 TURNS
BOURNS
=A1/18.
13
=A1-LCS-S1
1
START PUSH BUTTON
P2AF3-GREEN(1NO)
------
TEKNIC
=A1/17.
6
=A1-LCS-S2
1
STOP PUSH BUTTON
P2AF4-RED (1NC)
------
TEKNIC
=A1/17.
7 90A1291
11
DATE
CHANGE
DATE/NAME
CHKD
NAME
18.Jun.2013
HS
ENGG
18.Jun.2013
HS
CHKD
18.Jun.2013
HS
DRN
18.Jun.2013
HS
WEIGH FEEDER CUSTOMER: PROJECT: CONSULTANT:
SAIL-ROURKELA STEEL PLANT
TITLE:
BILL OF MATERIALS
= A1_BOM
DRG.NO.: 90.1291
+
- 011-EE03-R0
SHEET 1 3
1
2
3
5
4
6
7
8
9
10
11
12
14
13
BILL OF MATERIAL COMPONENT LEGEND
QTY.
TIL-FLS BOM
TYPE NUMBER
DEVICE
GENERAL SPECIFICATION
PAGE/PATH
MAKE
=A1-LCS-S3
1
EMG STOP SW
P2AML4-RED (1NC)
MUSHROOM HEAD
TEKNIC
=A1/17.
=A1-LCS-S4
1
VIB ON/OFF SW.
P2AS2-2P (1NO+1NC)
------
TEKNIC
=A1/9.
2
=A1-LP1
1
LAMP
P2PL BR4L-RED
220VAC
TEKNIC
=A1/3.
8
=A1-LP2
1
LAMP
P2PL BR5L-AMBER
220 VAC
TEKNIC
=A1/10.
9
=A1-LP3
1
LAMP
P2PL BR5L-AMBER
220 VAC
TEKNIC
=A1/16.
14
=A1-OP-D1
1
DISPLAY(TPH)
3 1/2 DIGIT
220VAC
FPIL
=A1/7.
12
=A1-OP-P1.1
1
POTENTIOMETER
808006000100
1K,10 TURNS
BOURNS
=A1/7.
6
=A1-OP-S1.1
1
START / STOP SW.
P2AS2-2P (1NO)
------
TEKNIC
=A1/9.
8
=A1-OP-S2.1
1
FAULT / RESET SW.
P2AS2-2P (1NO)
------
TEKNIC
=A1/9.
7
=A1-Q1
1
DOOR ISOLATOR
FFO
32 Amp
L & T
=A1/3.
2
=A1-S1
1
SURFACE MOUNLED ON/OFF SW
50G0090C0200
5 Amp
ANCHOR
=A1/3.
10
=A1-S2
1
DOOR LIMIT SWITCH
3SE3-020-0A
500V AC, 600 VDC, 10A
SIEMENS
=A1/3.
11
=A1-SW1
1
GRAV / VOLL SWITCH
P2AS2-2P (1NO+1NC)
------
TEKNIC
=A1/13.
10
=A1-SW2
1
4 WAY SELECTOR SW.
-----
1 POLE - 4 WAY
KAYCEE
=A1/12.
3
=A1-SW3
1
NORMAL BY SW.
P2AS2-2P (1NO+1NC)
------
TEKNIC
=A1/16.
12
=A1-SW4
1
STOP BY PB
P2AF4-RED (1NC)
------
TEKNIC
=A1/16.
11
=A1-SW5
1
START BY PB.
P2AF3-GREEN(1NO)
------
TEKNIC
=A1/16.
11
=A1-TX1
1
TRANSFORMER
------
415 VAC/ [email protected],200VA
FPIL
=A1/3.
6
=A1-U1
1
INVERTER
ACS 550-01-5A4-4
2.2 KW
ABB
=A1/18.
=A1-U2
1
CONTROLLER
TUC 6
WEIGHING CONTROLLER
FPIL
=A1/6.
1
=A1-U3
1
POWER PACK
NES-50-24
[email protected]
MEANWELL
=A1/5.
7
=A1-U4
1
ANALOG I/O CARD
F875
2CH AIO INTERFACE
FPIL
=A1/7.
1
=A1-U5
1
DIGITAL I/O CARD
F889
DI-8 CH, DO-8 CH
FPIL
=A1/8.
2
=A1-U6
1
DIGITAL I/O CARD
F890
DI-8 CH, DO-8 CH
FPIL
=A1/12.
=A1-U7
1
RELAY BOARD
1CHANGE OVER
4 CHANNEL/220 VAC
FPIL
=A1/8.
4
6
1
90A1291
3
DATE
CHANGE
DATE/NAME
CHKD
NAME
18.Jun.2013
HS
ENGG
18.Jun.2013
HS
CHKD
18.Jun.2013
HS
DRN
18.Jun.2013
HS
WEIGH FEEDER CUSTOMER: PROJECT: CONSULTANT:
SAIL-ROURKELA STEEL PLANT
TITLE:
BILL OF MATERIALS
= A1_BOM
DRG.NO.: 90.1291
+
- 011-EE03-R0
SHEET 2 3
1
2
3
5
4
6
7
8
9
10
11
12
14
13
BILL OF MATERIAL COMPONENT LEGEND
QTY.
TIL-FLS BOM
TYPE NUMBER
DEVICE
GENERAL SPECIFICATION
PAGE/PATH
MAKE
1
SINGLE ISOLATOR
I TO V
220 VAC
MESIBUS
=A1/7.
3
=A1-U9
1
SINGLE ISOLATOR
I TO I (SIGNAL ISOLATOR)
220 VAC
MESIBUS
=A1/18.
10
=A1-U10
1
RELAY BOARD
1CHANGE OVER
4 CHANNEL/220 VAC
FPIL
=A1/17.
3
=A1-U11
1
RELAY BOARD
1CHANGE OVER
1 CHANNEL/220 VAC
FPIL
=A1/9.
10
=A1-U12
1
RELAY BOARD
1CHANGE OVER
1 CHANNEL/220 VAC
FPIL
=A1/9.
7
=A1-U13
1
RELAY BOARD
1CHANGE OVER
1 CHANNEL/220 VAC
FPIL
=A1/12.
2
=A1-U14
1
RELAY BOARD
1CHANGE OVER
1 CHANNEL/220 VAC
FPIL
=A1/12.
3
=A1-U15
1
RELAY BOARD
1CHANGE OVER
1 CHANNEL/220 VAC
FPIL
=A1/12.
5
=A1-U16
1
RELAY BOARD
1CHANGE OVER
1 CHANNEL/220 VAC
FPIL
=A1/12.
6
=A1-U17
1
RELAY BOARD
1CHANGE OVER
1 CHANNEL/220 VAC
FPIL
=A1/12.
9
=A1-U18
1
RELAY BOARD
1CHANGE OVER
1 CHANNEL/220 VAC
FPIL
=A1/12.
12
90A1291
=A1-U8
DATE
CHANGE
DATE/NAME
CHKD
NAME
18.Jun.2013
HS
ENGG
18.Jun.2013
HS
CHKD
18.Jun.2013
HS
DRN
18.Jun.2013
HS
WEIGH FEEDER CUSTOMER: PROJECT: CONSULTANT:
SAIL-ROURKELA STEEL PLANT
TITLE:
BILL OF MATERIALS
= A1_BOM
DRG.NO.: 90.1291
+
- 011-EE03-R0
SHEET 3 3
SPSS I/O LISTING FOR TUC - 6 WF
JOB NO:90.1291-R1 INVERTER:- ABB ACS 550 SR NO.
CODE
DT. 25.07.2013
IO INPUTS TO DIO CARD
1
SM 017
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27
UE 000 UM 066 =M 060 UM 060 LT 000 SIT020 UT 000 =M 063 UNE000 UM 066 =M 061 UM 061 LT 001 SIT020 UT 001 =M 040 UM 063 OM 040 =M 062 UNM 062 =M 020 UNM 066 RT 001 RT 000 UM 062 =M 037
E000
28 29
UE 001 =M 009
E001
30 31 32
UE 003 UE 024 =M 019
E003 E024
33 34
UE004 =M 018
E004
35 36
UE 002 =M 021
E002
37 38
UNE 012 =M 022
E012
39 40
UM 047 =A 001
A001
ZERO SPEED SWITCH
BELT SWAY SWITCH
WF INTERLOCK
FAULT RESET
MAT. DET. SW
VIB ON/OFF SW.
VIB IN LAMP
SPSS I/O LISTING FOR TUC - 6 WF 41 42 43 44 45 46 47 48
UE 006 OE 007 UM 045 SM 016 UNE 006 UNE 007 UM 045 RM 016
E006 E007
49 50 51 52 53 54 55
UE 008 RM 015 RM 023 RM 008 RA 010 UNE 014 =M 023
E008
56 57 58 59 60 61 62 63
UE 010 SM 015 SM 008 SA 010 UE 011 RM 015 SM 008 SA 010
E010
64 65 66 67 68 69 70
UE 009 RM 015 RM 023 SM 008 SA 010 UE 022 =M 008
E009
71 72
UE 023 =M 010
E023
73 74 75 76 77 78 79 80
UE 025 UNM 008 SM 011 RM 012 UNE 025 UNM 008 SM 012 RM 011
E025
81 82
UM 064 = A000
A000
BELT RUN
83 84
UM 066 = A004
A004
WF ON
85 86
UM 036 = A006
A006
GENERAL FAULT
87 88
UNM 043 = A005
A005
REMOTE SELECTION
89 90
UM 064 =A 002
A002
91 92
UM 050 .=A 007
A007
MAT.O/L
93 94 95
UNM 043 UE 022 = A017
A017
REMOTE SELECTION
96 97 98
UM 043 UNE022 = A018
A018
LOCAL SELECTION
99 100
UM 066 = A020
A020
LOCAL START
START / STOP
LCS-VOLUMETRIC
E014
GRAV/VOL.(On door -
- TUC MODE
E011
PLC MODE
OPERATING VOL.
E022
LOCAL / REMOTE
EMG
DRIVE RUNNING
WF ON LAMP
SPSS I/O LISTING FOR TUC - 6 WF
JOB NO:- 90.1291 INVERTER:- ABB ACS 550 INPUTS E000 E001 E002 E003 E004 E005 E006 E007
ZERO SPEED SWITCH BELT SWAY SWITCH MATERIAL DET.SW. WF INTERLOCK FAULT RESET FREE START / STOP - OPERATOR PL. START/STOP - PLC/DCS
E008 E009 E010 E011 E012 E013 E014 E015
LCS-VOLUMETRIC OPERATING VOL. - TUC MODE PLC MODE VIB ON / OFF FREE GRAV/VOL.(On door - only applicable for mode ) FREE
E020 E021 E022 E023 E024 E025
LOCAL START LOCAL STOP LOCAL / REMOTE EMG STOP DRIVE INTERLOCK DRIVE RUNNING
OUTPUTS A000 A001 A002 A003 A004 A005 A006 A007
BELT RUN LAMP VIB.ON LAMP WF ON LAMP FREE WF ON PLC SELECTION GENERAL FAULT MAT.O/L
A008 A009 A010 A011 A012 A013 A014 A015
FREE
A017 A018 A019 A020
REMOTE SELECTION LOCAL SELECTION FREE DRIVE START STOP
FREE LOCAL SEL FREE FREE FREE FREE FREE
MECHANICAL GAD
MECHANICAL GAD
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR WEIGH FEEDER
FLSmidth Pfister India Ltd.
FPIL JOB NO : 90.1291 CUSTOMER : SAIL-ROURKELA STEEL PLANT EQPT : WEIGH FEEDER (WF) TABLE OF CONTENTS DESCRIPTION
SR. NO. 1.0 2.0 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9
PAGE NO.
OPERATION & MAINTENANCE MANUAL FOR TUC-6 CONTROLLER MECHANICAL DATA. ASSEMBLY & STARTUP INSTRUCTION. MAINTENANCE INSTRUCTION. LUBRICATION CHART. TESTING / ADJUSTING MANUAL. ERECTION INSTRUCTION MANUAL. SAFETY & STORAGE MANUAL. OPERATION & MAINTENACE MANUAL FOR AC MOTOR. INSTALLATION & MAINTENANCE MANUAL FOR GEAR BOX. OPERATION & MAINTENACE MANUAL FOR VIBRATORY MOTOR
100
01 10 04 02 04 02 20 21 62
3.0 3.1 3.2 3.3
TECHNICAL DATA. TACHOMETER TECHNICAL LITERATURE. LOADCELL SPECIFICATION WF. DATA SHEET
01 03 01
4.0
ELECTRICAL DRAWING
53
5.0
MECHANICAL GAD
01
6.0
INVERTER MANUAL FOR ACS 550
322
FLSmidth Pfister India Ltd.
TUC 6 OPERATION & MAINTENANCE MANUAL
TUC 6 OPERATION & MAINTENANCE MANUAL
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL - INDEX Weigh Feeder with TUC-6CAN Electronics Page 1 of 1
1.0
Technical data............................................……………………………………10 TUC6CAN-010-EE23.0-R0
2.0
Functional Description....................................……………………………… 06 TUC6CAN-010-EE23.1-R0
3.0
Operator's Manual.........................................…………………………………12 TUC6CAN-010-EE23.2-R0
4.0
Commissioning Instructions................................………………………….. 26 TUC6CAN-010-EE23.3-R1
5.0
Menu Operations...........................................…………………………………11 TUC6CAN-010-EE23.4-R1
6.0
Parameter Listing.........................................………………………………….06 TUC6CAN-010-EE23.5-R1
7.0
PLC Program...............................................…………………………………..16 TUC6CAN-010-EE23.6-R0
8.0
Appliance Description.....................................……………………………… 12 TUC6CAN-010-EE23.10-R0
9.0
Front Facia Layout........................................…………………………………01 TUC6CAN-010-EE25-R0
Software_version: 4.1 (onwards) 2010-11-29
TECHNICAL DATA Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.0-R0 1.0
System
1.1 1.2
Microprocessor Memory
2.0
Construction
2.1
Housing
2.2 2.3 2.4 2.5 2.6
Page 1 of 10
: :
8xC51FA 64K EPROM 16K Data EEPROM 32K RAM with integral Battery Backup.
Colour Dimensions (W*H*D) Control cutout Control thickness Mounting space
: : : : : : :
2.7
Wall clearance
:
2.8 2.9 2.10
Weight Mounting Protection type
: : :
Aluminum enclosure in DIN format Silver anodized 144 * 72 * 245 mm 138 * 68 mm Min. 1 mm, max. 15 mm Approx. 300 mm deep with connectors Min. 100 mm upwards. Min. 60 mm on each side with natural convection Approx. 1.0 Kg 2 Grub screws at the sides IP 54 (Front)
3.0
Display
3.1
Display
:
3.2 3.3 3.4 3.5 3.6
Colour Type Digit height Reading angle Dimension sign
: : : : :
4.0
Control
4.1
Type
Software_version: 2.0 (onwards) 2008-05-17
:
2 lines * 16 Characters Vacuum Fluorescent Display Blue VFD, alphanumeric 5.5 mm legible to approx. 2 m Approx. 40 °. kg, t ( selectable)
Membrane foil with pressure sensitive keyboard.
TECHNICAL DATA Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.0-R0 5.0
Environment
5.1 5.2 5.3
Operating temperature Storage temperature Humidity
6.0
Measurement Input - Loadcell
6.1 6.2 6.3
Page 2 of 10
: : :
0 ° C to +55 ° C -20 ° C to +85 ° C Max 85 % relative, without condensation
Terminal Measurement input range Supply voltage
: : :
6.4
Measuring cable
:
9 pole, DB connector 0 to 28 mV Internal 12 V ± 5 %, Max. 110mA (e.g. 3 loadcells of 350 ohms in parallel) 6 core, shielded (min. 80% optical cover) Isolation resistance min.120 Mohm/Km Core cross-section min. 0.34 mm² to 0.5 mm² solderable directly to connector. Cable diameter up to 8mm mountable in connector. Connect greater cross-sections with solderable connectors.
6.5
Cable length
:
l = 5.1 * R * A / n R = Loadcell resistance in ohm A = Cable cross-section in mm² n = no. of loadcells in parallel l = Cable length , max. 1000 m
7.0
Measurement Input - Tacho
7.1
Terminal
:
7.2 7.3 7.4 7.5
Input signal Measurement input range Supply voltage Measuring cable
: : : :
Software_version: 2.0 (onwards) 2008-05-17
Screw clamped terminals. Conductor size 0.14 to 1.5 mm2. Max. 15 V 10 - 2500 Hz, 12 V Internal 12 V ± 5 %; max. 10 mA 3 core, shielded (min. 80%
TECHNICAL DATA Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.0-R0
Page 3 of 10
7.6
Cable length
8.0
Digital Outputs
8.1
Output type
:
8.2
Terminal
:
8.3
Functions
:
9.0
Power supply
9.1
Terminal
:
9.2 9.3
Voltage Power consumption
: :
10.0
Analog output
10.1
Function
Software_version: 2.0 (onwards) 2008-05-17
:
:
optical cover) Isolation resistance min.120 Mohm/Km Core cross-section min. 0.34 mm² to 1.5 mm2. Max. 1000 m
4 Nos. Relay s, 220Vac, 2 Amp rating Screw clamped terminals Conductor size from 0.5 to 1.5 mm2 2 Nos. outputs can be assigned as totaliser outputs. Non-assigned outputs can be used in SPSS program for any desired function.
Screw clamped terminals Conductor size 0.14 to 1.5 mm2. 18-36 Vdc 12 VA max.
0 -20 mA / 4-20 mA isolated o/p corresponding to any of the following functions, -Actual feedrate -Belt Load -Belt Speed -Weigh Feeder drive setpoint -Pre-feeder drive setpoint -Current setpoint -Pre-Hopper Level -Control measurement error
TECHNICAL DATA Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.0-R0
Page 4 of 10
10.2 10.3 10.4
Isolation type Load Terminal
: : :
10.5
Cable type
:
11.0
Impulse outputs
11.1
Function
:
11.2
Terminal
:
12.0
RS-485 Interface (X2)
12.1 12.2
Terminal Transmission
: :
12.3 12.4 12.5
Baud rate Format Cable type
: :
12.6
Function
:
13.0
RS-485 Interface (X4)
13.1 13.2
Terminal Transmission
: :
13.3 13.4
Baud rate Format
:
13.5
Cable type
:
Software_version: 2.0 (onwards) 2008-05-17
Galvanic 500 Ohm Screw clamped terminals Conductor size 0.14 to 1.5 mm2. 2 core ,shielded. Individual core connectable directly to connector.
2 relay outputs corresponding to either Totaliser1 or Totaliser2. 50mSec to 500mSec programmable ON time pulses Screw clamped terminals Conductor size 0.14 to 1.5 mm2.
5 pole DIN socket Half duplex, serial bit, asynchronous mode 19200 baud 8 bite, 1 stop, No Parity 2 core ,shielded ,max 0.5 mm2 individual core connectable directly to connector. Used to interface I/O cards to TUC-6 unit.
9 pole, DB connector Half duplex, serial bit, asynchronous mode 4800,9600,19200 baud 8 bits, 1 stop bit, None, Even or Odd Parity 2 core ,shielded ,max 0.5 mm2 individual core connectable
TECHNICAL DATA Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.0-R0
13.5
Function
14.0
Profibus-DP Interface (X4)
14.1 14.2 14.3 14.4
Terminal Transmission mode Baud rate Station Address
15.0
CANBUS Interface (X7)
15.1 15.2 15.3
Terminal Baud rate Cable Type
Page 5 of 10
:
directly to connector. Modbus-RTU
: : : :
9 pole, DB connector RS 485 9600 bps to 12 Mbps max 01 to 99
: : :
5 pole, DIN socket 10 kbps to 1 Mbps max Circular cable, 2x2 core, twisted pair, plus total shield, max 0.56mm2 connectable directly. to connector.
8 Nos, opto-coupled, 24 Vdc positive logic, max. 5 mA. 8 Nos. Relay s, 220Vac, 2 Amp rating Screw less Terminals. Conductor size from 0.5 to 1.5 mm2. Inputs/Outputs can be assigned any desired function through SPSS program. 2 Nos maximum
Optional Interface Modules 16.0
Digital I/O Interface Card (F-866)
16.1
Input type
:
16.2
Output type
:
16.3
Terminal
:
16.4
Functions
:
16.5
Max. cards ed
:
17.0
Digital I/O Interface Card (F-889/F-890)
17.1
Input type
:
17.2
Output type
:
Software_version: 2.0 (onwards) 2008-05-17
8 Nos, opto-coupled, 24 Vdc positive logic, max. 5 mA. 8 Nos. Relay s, 220Vac,
TECHNICAL DATA Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.0-R0
Page 6 of 10
17.3
Terminal
:
17.4
Functions
:
17.5
Max. cards ed
:
18.0
Analog I/O Interface Card (F- 868 card)
18.1
Input Type
:
18.2
Output Type
:
18.3 18.4
Isolation type Load - Input
: :
18.5 18.6
Load - Output Terminal
: :
18.7
Cable type
:
18.8
Max. cards ed
:
Software_version: 2.0 (onwards) 2008-05-17
2 Amp rating Screw less Terminals. Conductor size from 0.5 to 1.5 mm2. Inputs/Outputs can be assigned any desired function through SPSS program. 1 No. F889 card along with 1 No. F890 card
2 Channels. 0/4-20 mA/0-10 V isolated Inputs corresponding to, -Feeder Setpoint. -Gate Position for Flow Control Gates 1 Channel 0/4-20 mA isolated output corresponding to any of the following functions, -Actual feedrate -Belt Load -Belt Speed -Weigh Feeder drive setpoint -Pre-feeder drive setpoint -Current setpoint -Pre-Hopper Level -Control measurement error Optical. 4 - 20 mA - 100 Ohm 0 -10 V < 1 mA 4 - 20 mA - 500 Ohm (max.) Screw less terminations Conductor size 0.14 to 1.5 mm2. 2 core ,shielded. Individual core connectable directly to connector. Max. 3 cards can be interfaced
TECHNICAL DATA Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.0-R0
Page 7 of 10 to TUC-6 unit.
19.0
Analog I/O Interface Card (F- 875 card)
19.1
Input Type
:
19.2
Output Type
:
19.3 19.4
Isolation type Load - Input
: :
19.5 19.6
Load - Output Terminal
: :
19.7
Cable type
:
19.8
Max. cards ed
:
2 Channels. 0/4-20 mA/0-10 V isolated Inputs corresponding to, -Feeder Setpoint. -Gate Position for Flow Control Gates 2 Channels 0/4-20 mA isolated output corresponding to any of the following functions, -Actual feedrate -Belt Load -Belt Speed -Weigh Feeder drive setpoint -Pre-feeder drive setpoint -Current setpoint -Pre-Hopper Level -Control measurement error Optical. 4 - 20 mA - 100 Ohm 0 -10 V < 1 mA 4 - 20 mA - 500 Ohm (max.) Screw less terminations Conductor size 0.14 to 1.5 mm2. 2 core ,shielded. Individual core connectable directly to connector. Max. 2 cards can be interfaced to TUC-6 unit.
20.0 Field Interface Module (F- 892) 20.1
Power supply (X1) 20.1.1
Terminal
Software_version: 2.0 (onwards) 2008-05-17
:
Screw clamped terminals
TECHNICAL DATA Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.0-R0
20.1.2 20.1.3 20.2
20.3
20.4
Voltage Power consumption
Page 8 of 10
: :
Conductor size 0.14 to 1.5 mm2. 18-36 Vdc 12 VA max.
Measurement Inputs – Loadcell (X10, X11) 20.2.1 Terminal 20.2.2 Measurement input range 20.2.3 Supply voltage
: : :
20.2.4 Measuring cable
:
9 pole, DB connector 0 to 28 mV Internal 12 V ± 5 %, Max. 110mA (e.g. 3 loadcells of 350 ohms in parallel) 6 core, shielded (min. 80% optical cover) Isolation resistance min.120 Mohm/Km Core cross-section min. 0.34 mm² to 0.5 mm² solderable directly to connector. Cable diameter upto 8mm mountable in connector. Connect greater cross-sections with solderable connectors.
Measurement Inputs – Tacho (X9) - 2 Nos 20.3.1 Terminal
:
20.3.2 20.3.3 20.3.4 20.3.5
Input signal Measurement input range Supply voltage Measuring cable
: : : :
20.3.6
Cable length
:
Screw clamped terminals. Conductor size 0.14 to 1.5 mm2. Max. 15 V 10 - 2500 Hz, 12 V Internal 12 V ± 5 %; max. 10 mA 3 core, shielded (min. 80% optical cover) Isolation resistance min.120 Mohm/Km Core cross-section min. 0.34 mm² to 1.5 mm2. Max. 1000 m
:
0-20mA/ 4-20mA/ 0-10V input
Anaputs (X9) -2 Nos 20.4.1
Input Type
Software_version: 2.0 (onwards) 2008-05-17
TECHNICAL DATA Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.0-R0
20.5
20.4.2
Terminal
:
20.4.3
Cable Type
:
20.7
corresponding to setpoint Screw clamped terminals Conductor size 0.14 to 1.5mm2. 2 core shielded. Individual core connectable directly to connector.
Analog outputs (X8) -2 Nos 20.5.1
20.6
Page 9 of 10
Function
:
20.5.2 Isolation type 20.5.3 Load 20.5.4 Terminal
: : :
20.5.5 Cable type
:
0/4-20 mA isolated o/p corresponding to any of the following functions, -Actual feedrate -Belt Load -Belt Speed -Weigh Feeder drive setpoint -Pre-feeder drive setpoint -Current setpoint -Pre-Hopper Level -Control measurement error Optical 500 Ohm Screw clamped terminals Conductor size 0.14 to 1.5 mm2. 2 core ,shielded. Individual core connectable directly to connector.
Digital Inputs (X3) -12 Nos 20.6.1 Input Type 20.6.2 Terminal
: :
20.6.3 Function
:
12 Nos, opto-coupled 24Vdc Screw clamped terminal Conductor size 0.5 to 1.5mm2. Inputs can be assigned any desired function through SPSS program.
Digital Outputs (X2) -8 Nos 20.7.1
Output Type
Software_version: 2.0 (onwards) 2008-05-17
:
8 Nos, opto-coupled, 24Vdc, 250 mA max load
TECHNICAL DATA Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.0-R0
20.8
20.9
Page 10 of 10
20.7.2 Terminal
:
20.7.3 Function
:
Screw clamped terminal Conductor size 0.5 to 1.5mm2. Outputs can be assigned any desired function through SPSS program.
RS-485 Interface (X4) 20.8.1 Terminal 20.8.2 Transmission
: :
20.8.3 Baud rate 20.8.4 Format 20.8.5 Cable type
: :
20.8.6 Function
:
9 pole, DB connector Half duplex, serial bit, asynchronous mode 19200 baud 8 byte, 1 stop, No Parity 2 core ,shielded ,max 0.5 mm2 individual core connectable directly to connector. Modbus-RTU, can be used to Interface to local display
RS-485 Interface (X5) 20.9.1 Terminal 20.9.2 Transmission
: :
20.9.3 Baud rate 20.9.4 Format
:
20.9.5 Cable type
:
20.9.6 Function
:
9 pole, DB connector Half duplex, serial bit, asynchronous mode 9600 to 19200 baud 8 bits, 1 stop bit, None, Even or Odd Parity options 2 core, shielded, max 0.5 mm2 individual core connectable directly to connector. Modbus-RTU
20.10 CANBUS Interface (X6) 20.10.1 Terminal 20.10.2 Baud rate 20.10.3 Cable Type
Software_version: 2.0 (onwards) 2008-05-17
: : :
9 pole, DB connector 10 kbps to 1Mbps max. Circular cable, 2x2 core, twisted pair, plus total shield, max 0.56mm2 connectable directly to connector.
FUNCTIONAL DESCRIPTION Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.1-R0
Page 1 of 6
TABLE OF CONTENTS 1.0
Principle.................................................………………………………………... 2 1.1 TUC-6 Weigh Feeder system, Overview..................……………………. 2 1.2 System Features......................................………………………………... .. 2
2.0
Functions.................................................………………………………………. 3 2.1 Modes of operation...................................…………………………………. 3 -Interlock - Gravimetric Mode.......................………………………………. 3 -Interlock - Volumetric Mode.........................……………………………….3 -De-Interlock - Gravimetric Mode.....................……………………………. 3 -De-Interlock - Volumetric Mode......................……………………………. 3 -Local Mode..........................................……………………………………..3 2.2 Belt off-track monitoring............................…………………………………. 4 2.3 Zero Setting.........................................……………………………………... 4 2.4 Linearization of belt load...........................…………………………………. 4 2.5 Programmable Scale Control...........................……………………………. 4 2.6 Error Messages.......................................…………………………………... 4 2.7 Scale types..........................................……………………………………... 4 2.7.1 Directly extracting Weigh Feeder................………………………… 4 2.7.2 Weigh Feeder with pre-feed regulation...........……………………… 4 2.7.3 Flow metering device............................………………………………5 2.7.4 Batch operation.................................………………………………… 5 2.7.5 Control Measuring…............................……………………………… 5 2.7.6 Measuring Mode…............................…………………………………5
3.0
Interfaces................................................……………………………………….. 6 3.1 Computer Interface...............................…………………………………….. 6 3.2 Modbus Interface...............................………………………………………. 6 3.3 Canbus Interface...............................………………………………………. 6 3.4 Pulse outputs........................................……………………………………. 6 3.5 Analog outputs.......................................…………………………………… 6 3.6 Digital I/O..........................................……………………………………….. 6
Software_version: 2.0 (onwards) 2008-11-15
FUNCTIONAL DESCRIPTION Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.1-R0
1.0
Page 2 of 6
Principle
The Weigh Feeder consists of a conveyor belt whose material load is continuously weighed with a measuring device. The mass flow is calculated from the product of Belt Load (Loadcell value) and belt speed (Tacho frequency). The amount of material being conveyed is controlled by controlling the belt speed. This is done by generating the setpoint and control signals to control a suitable drive controller. Belt speed is monitored to ensure that the required speed is being achieved by the drive controller. In addition to controlling the material flowrate, the system can also control a Pre-feeder to control the material bed-height 1.1
TUC-6 Weigh Feeder System, Overview:
The unit is operated using the TUC-6 keypad and the 2 line * 16 digit VFD display. The display values are called using fixed keys or displayed through pull-down selection. The Configuration of the system is determined by the parameter values. To do this, a selection is made from the fixed values in the configuration menus or a parameter is entered using the front keypad. 1.2
System Features
- Fail safe EEPROM memory for configuration parameters - Battery buffered RAM for working data - Date/Time in battery buffered Real Time Clock - Integrated keyboard and display - Data memory even with replacement of interface cards - Up to 36 inputs / 28 outputs - 2 Impulse outputs - Analog to Digital and Digital to Analog signal interfaces - Auto-Calibration - Curve correction - Zero correction - Inbuilt PLC for easy adaptation to different control schemes - Alphanumeric Text displays for Fault diagnosis
Software_version: 2.0 (onwards) 2008-11-15
FUNCTIONAL DESCRIPTION Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.1-R0
2.0
Functions
2.1
Modes of operation
Page 3 of 6
The system can operate in any one of the following 5 modes, i)
Interlock - Gravimetric Mode
In this mode, the system operates through External setpoint in the form of analog 4-20 mA signal or setpoint through the serial interface. Start/Stop to the system is either through external digital Inputs or through the serial Interface. ii)
Interlock - Volumetric Mode
In this mode, the system operation is un-regulated (Volumetric). Setpoint in this mode is from an external 4-20 mA signal and Start/Stop to the system is through external digital Inputs. iii)
De-Interlock - Gravimetric mode.
In this mode, the system operates through setpoint entered through the TUC keypad. System Start/Stop is through the keys provided on the keypad. iv)
De- Interlock - Volumetric mode.
In this mode, the system operation is un-regulated (Volumetric). Setpoint and Start/Stop is from the TUC keypad. v)
Local Mode.
In this mode, Setpoint & Start/Stop commands to the system are from the Local Control station. In this mode, system operation is un-regulated (Volumetric) i.e. the setpoint from the Local control station directly varies the belt speed.
Software_version: 2.0 (onwards) 2008-11-15
FUNCTIONAL DESCRIPTION Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.1-R0 2.2
Page 4 of 6
Belt off-track monitoring
Off-track running of the belt can be monitored via an external signal from the Belt tracking sensors to the control unit. 2.3
Zero setting
Belt related influences on the belt load can be compensated by means of zero correction. To do this, the correction process is started with the belt running idle. The zero correction value, with which the belt load is set off, is calculated automatically after the zero correction process. The zero correction is initiated from the front keypad. 2.4
Linearization of belt load
If the load on the measuring cell is not linear in the whole range, the load can be laniaries by entering up to ten correction points. 2.5
Programmable Scale Control
To achieve optimum adjustment of the dosing control as per the customer's requirements, a PLC is built into the Controller. This enables digital signals within the control unit and to the process to be freely defined. Standard PLC programs are implemented internally for standard configurations. These may be called directly and used or modified to suit diverse application needs. 2.6
Error Messages
Faults/Errors caused by incorrect operations are displayed in clear text in the control display. Faults are also made available at the output in the form of potential free s. 2.7
Scale types
2.7.1 Directly extracting weigh feeder Material is extracted directly from a hopper, without a pre-feeding device. 2.7.2 Weigh Feeder with pre-feed regulation
Software_version: 2.0 (onwards) 2008-11-15
FUNCTIONAL DESCRIPTION Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.1-R0
Page 5 of 6
As a result of variation of belt speed, required for output regulation, a varying bed-height of material may occur on the conveyor belt. If a constant bed-height of material is required or in the event of unfavorable material properties which do not permit direct extraction, pre-feed regulation is necessary. For this purpose, an output setpoint can be generated to control a pre-feed device. This output value is coupled to the flow regulator i.e. changes in flow setpoint automatically adjusts the pre-feed device. 2.7.3 Flow metering device With flow metering devices no speed tachometer is available. Regulation of mass flow is realized by regulation of material load. In this mode, system operation is with fixed internal tachometer. 2.7.4 Batch operation By specifying a target quantity, it is possible to proportion individual batches. In this mode, proportioning is done as per the prescribed setpoint. After the target quantity of material has been conveyed, an alarm or automatic belt stop command can be generated. 2.7.5 Control measuring If a hopper with a measuring device is present on the weigh feeder, it is possible to perform control measuring. In this case, the material volume removed from the hopper within a defined period of time is compared with the volume of material which the weigh feeder has recorded for the corresponding period. In the event of a difference, a correction value is calculated, which is taken into when measuring the belt loading. Thus, it is possible to compensate zero point fluctuations, which may have occurred during operation. 2.7.6 Measuring Mode It is possible to by feed regulation and operate the unit only in measuring mode, for equipments like Belt Weighers.
Software_version: 2.0 (onwards) 2008-11-15
FUNCTIONAL DESCRIPTION Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.1-R0 3.0 3.1
Page 6 of 6
Interfaces Computer Interface
It is possible to enable remote monitoring and control of the system, by connecting the unit to a master controller through the serial interface. Modbus RTU and Profibus protocol options are ed through use of optional modules. 3.2
Modbus Interface
The controller can be directly connected to PLC through this MODBUS interface. It is possible to enable remote monitoring and control through this interface.
3.3
CAN bus Interface
The controller can communicate to the Field Interface Module (FIM) through CAN protocol. Data collected locally at the field can be communicated to the controller through a single cable. 3.4
Pulse Output
Two pulse outputs are available from the system corresponding to the quantity being conveyed. The resolution & pulse width of the Totaliser pulses are configurable. 3.5
Analog outputs
Analog outputs are available for display and/or measurement tasks. Up to 4 analog current outputs can be generated from the system. Each individual output can be selected to various measurement/control variables, such as Feeder setpoint, Pre-feeder setpoint, Material Feedrate, Belt loading, Belt Speed. 3.6
Digital I/O
A maximum of 36 inputs and 28 outputs are available for controlling the weigh feeder and other plant interlocks. Outputs are available corresponding to various status and fault conditions in the system.
Software_version: 2.0 (onwards) 2008-11-15
OPERATOR’S MANUAL Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.2-R0
Page 1 of 12
TABLE OF CONTENTS 1.0
Keypad and display..........................................……………………………... 2 1.1 Keypad...............................................…………………………………….. 2 1.2 Display..............................................……………………………………... 4
2.0
Functions.................................................…………………………………….. 5 2.1 Start................................................……………………………………….. 5 2.2 Stop.................................................………………………………………. 5 2.3 Zero setting.........................................……………………………………. 6 2.4 Interlock/De-Interlock...............................………………………………... 6 2.5 Batch Operation......................................………………………………… 7 2.6 Control Measurement................................……………………………. 7 2.7 Error Acknowledgement................................……………………………. 8 Modes.....................................................….........................................…….. 9 3.1 Local mode...........................................….........................................…..9 3.2 Remote mode.....................................................................................…9 3.2.1 Interlock - Gravimetric Mode.....................................................… 9 3.2.2 De-Interlock - Gravimetric Mode................………………………... 9 3.2.3 Interlock - Volumetric Mode....................………………………….. 9 3.2.4 De-Interlock - Volumetric Mode.................………………………... 10
3.0
4.0
Parameter input...........................................…………………………………. 10 4.1 Control Parameters (SET1)............................…………………………… 10 4.2 Setpoint (SET2)................................................................................….. 10 4.3 PF parameters (SET3).................................…………………………….. 10
5.0
Error Messages............................................………………………………… 10
6.0
Abbreviations.............................................………………………………….. 12
Software_version: 2.0 (onwards) 2008-11-15
OPERATOR’S MANUAL Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.2-R0 1.0
Keypad and display
1.1
Keypad
Page 2 of 12
TUC-6 has a multi-function keypad; the definition of keys change as per the menu operations. Some keys have alphabets in the lower left hand corner. These are used in editing the PLC programs. The numbers 0 to 9 in the upper right hand corner of some keys are used for numeric entries. Characters/Symbols used in the keys have following meaning,
Display current setpoint
BB - Display Belt Load in %
Switch between Gravimetric / Volumetric selections
Display Actual Flowrate
Display Totaliser 1
Switch between Interlock/De-interlock modes Display Tacho Frequency Software_version: 2.0 (onwards) 2008-11-15
OPERATOR’S MANUAL Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.2-R0
Page 3 of 12
Display Totaliser 2 Start Zeroing in Manual/Local modes
Call online menus within Main_Program Cancel (CL) -In Main_Program, S1 value displayed in Line 2 is cleared -Used to Clear Fault displays -When used with 'Esc' key, is used to exit from menu. -Used to accept values modified in the SET menu. HOR -Selection of options from list. -'ENTER' key to accept value Start/Stop ESC -Used in combination with 'CL' key to exit from menu. -Used to discard values modified in the SET menu. -Display mV value in Calibration menu UP/DOWN - Scroll Menu/parameter list being displayed.
Software_version: 2.0 (onwards) 2008-11-15
OPERATOR’S MANUAL Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.2-R0 1.2
Page 4 of 12
Display
When the TUC-6 is powered on from the mains, the display "Transweigh" is shown for 5 secs. The system then displays either the Online Menu or the Offline menus, depending on the status of keypressed during the 5 secs. delay. -Press 'VER' to by 5 sec. delay & jump to Main_Program menu. -Press 'CL'to by 5 sec. delay & jump to Offline menus. If no key is pressed, the system enters Main_Program menu at the end of 5 sec. delay. a)
In the Online menu - Main_Program, the following parameters can be displayed by selecting keys from the keypad, 'W','BB','X', 'S1','S2','T': Wc BB X S1 S2 Ta
Current setpoint in units selected Belt load value in % Actual flowrate value in units selected Totaliser1 value Totaliser2 value Weigh Feeder Tacho frequency in Hz.
Other Values are selectable with the '↑↓' key. These values are shown below with their designated names. W1 W2 W3 Wm Xd L L F W D Sk
De-Interlocked setpoint Interlocked setpoint Interlocked setpoint through X4 Manual mode setpoint Deviation in % Weight of pre-hopper in units selected Weight of pre-hopper in % Weighed quantity during control measuring Quantity extracted during control measuring Difference between F and W Control measuring error
BS Date
Belt Speed in m/sec In format yy-mm-dd
Software_version: 2.0 (onwards) 2008-11-15
OPERATOR’S MANUAL Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.2-R0 Time Q q GATE b)
Page 5 of 12
In format Hour:Minute Quantity Setpoint Dribble setpoint Gate position in % (For Flow Control Gates)
Error messages The error messages have the highest priority, i.e. they are not overwritten by any other display and remain in display until they are acknowledged. The error messages are listed in section 5.0 "Errors Messages" of this manual.
2.0
Functions
2.1
Start
Conditions - Interlock input high Mode
Start trigger
De-Interlock-Gravimetric De-Interlock-Volumetric Interlock-Gravimetric Interlock-Gravimetric
'Start' from TUC 'Start' from TUC 'Start' from external digital input ‘Start' from superior computer (For configuration with Computer) 'Start' from external digital input Local pushbutton
Interlock-Volumetric Local Display - LED 'START' on. 2.2
Stop
Stop trigger for all modes -An Error condition leading to stop -Interlock input removed Mode Stop trigger De-Interlock-Gravimetric De-Interlock-Volumetric Interlock-Gravimetric
'Stop' from TUC 'Stop' from TUC 'Stop' from external digital input
Software_version: 2.0 (onwards) 2008-11-15
OPERATOR’S MANUAL Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.2-R0 Interlock-Gravimetric Interlock-Volumetric Local Display - LED 'START' off. 2.3
Page 6 of 12
'Stop' from superior computer (For configuration with Computer) 'Stop' from external digital input Local pushbutton
Zero setting With this key, Zero correction process is initiated.
Conditions - System in Local/De-Interlock-Volumetric mode - Belt started Display - LED over '>0<' flashing. Note: Zero setting operation can be canceled by pressing '>0<' key during zeroing process. With canceling, the old zero setting value is not lost. Operation: The zero setting runs for one belt revolution determined by the belt revolution time set in configuration. After zero setting operation, the mean value over the zero curve is calculated and the belt load is re-calculated with the zero correction value. An error message occurs when the correction limit is exceeded. 2.4
Interlock/De-Interlock With this key, it is possible to switch between the two modes.
Display: Interlock : LED over 'Int./De-Int.' ON De-Interlock: LED over 'Int./De-Int.' OFF Note: Switching between the modes is only possible in Weigh Feeder Stop mode. Software_version: 2.0 (onwards) 2008-11-15
OPERATOR’S MANUAL Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.2-R0 2.5
Page 7 of 12
Batch Operation
The Feeder can be selected for Batch mode operation. In this mode, a fixed quantity of material can be delivered by the Feeder and an alarm generated or the system stopped, if required. The quantity setpoint values are entered in SET2 menu. Two Setpoint parameters, 'Q1' & 'Q2', are provided in the system. Selection between 'Q1' and 'Q2' is through marker 'M024'. Each Quantity setpoint (Qx) is associated with a corresponding Dribble value (qx). When operating in the Batch mode, an alarm is generated after delivering 'Q-q' quantity of material. 'q' is usually the amount of material overfed by the feeder after it is stopped. Conditions: - Weigh feeder configured for Batch mode operation Operation : When the feeder is started in Batch mode, Totaliser, S1 is cleared if greater than 'Q'. Totaliser, S1 increments up to 'Q-q' and "Quantity Over!" is displayed. Marker 'M059' is set. This marker can be used in SPSS to stop the feeder if requried. Pressing 'CL' key clears the alarm display and resets 'M059' marker if set. 2.6
Control measurement With this key, it is possible to initiate a control measurement cycle.
Conditions : - Feeder configured with pre-hopper scale - Started in automatic mode. Display : LED over >O< flashing Note: During the control measurement, no level regulation will take place. The control measurement is aborted if, ™ the hopper weight falls below the pre-hopper Limit1. Software_version: 2.0 (onwards) 2008-11-15
OPERATOR’S MANUAL Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.2-R0
Page 8 of 12
™ the hopper is being filled. ™ an abort request is received from the keypad or super-ordinate system. ™ System is switched to manual operation. Operation: ™ Initiate control measurement via front keyboard, Master computer or external input. ™ Automatic filling of pre-hopper to pre-hopper Limit3 if the hopper weight is lower than Limit2 at the time of starting the control measurement. ™ Wait for the damping period. ™ Control measurement is started for time defined by Parameters "Belt_Revolution_Time" * "No_of_Belt_Rev". ™ Values, "F"-Material conveyed by feeder and "W"-Material extracted from Hopper, are calculated. ™ On completion of control measurement, the following values are calculated, D =F-W Sk = D x 100 x Current Setpoint , % error F System capacity ™ The error value can be corrected via front keyboard (' 'key), Master computer or external input. ™ The correction can be applied to either Feeder ‘Tare’ or ‘Span’ value. ™ The correction for control measurement error is limited by the maximum correction limit parameter entered in TUC-6. 2.7
Error Acknowledgment key is used to acknowledge errors.
Display The Error text message is displayed in line 2. All Error texts are characterized with "!" in the last column Note: If an error is already in the display, further errors will not be displayed until this error has been acknowledged. 3.0
Modes
Software_version: 2.0 (onwards) 2008-11-15
OPERATOR’S MANUAL Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.2-R0 3.1
Page 9 of 12
Local mode
This mode is invoked by a "Low" signal on the 'Local/Remote' digital input. In this mode, Setpoint & Start/Stop commands to the system are from the Local Control Station. System operation in this mode is unregulated. Zero setting operation is possible in this mode. 3.2
Remote mode
This mode is invoked by a "High" signal on the 'Local/Remote' digital input. This mode is further sub-divided into the following four modes. 3.2.1 Interlock - Gravimetric mode This mode is invoked by a "Low" signal on the 'Int/De-Int' digital input & "High" signal on 'Vol/Grav. Select' digital input or selected through TUC-6 keypad. Selection either from External Inputs or from Keypad is defined in the Configuration Menu. In this mode, Start/Stop & Setpoint are through external I/Os 3.2.2 De-Interlock - Gravimetric mode This mode is invoked by a "High" signal on the 'Int/De-Int' digital input & "High" signal on 'Vol/Grav. Select' digital input or selected through TUC-6 keypad. Selection either from External Input or from Keypad is defined in the Configuration Menu. In this mode, Start/Stop & Setpoint are through the keypad. 3.2.3 Interlock - Volumetric mode This mode is invoked by a "Low" signal on the 'Int/De-Int' digital input & "Low" signal on 'Vol/Grav. Select' digital input or selected through TUC-6 keypad. Selection either from External Input or from Keypad is defined in the Configuration Menu. System operation in this mode is unregulated. In this mode, Start/Stop & Setpoint are through external I/Os. 3.2.4 De-Interlock - Volumetric (Manual) mode This mode is invoked by a "High" signal on the 'Int/De-Int' digital input & "Low" signal on 'Vol/Grav. Select' digital input or selected through TUC-6 keypad. Selection either from External Input or from Keypad is defined in the Configuration Menu. System operation in this mode is un-regulated. Software_version: 2.0 (onwards) 2008-11-15
OPERATOR’S MANUAL Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.2-R0
Page 10 of 12
In this mode, Start/Stop & Setpoint are through the keypad. Zero setting operation is possible in this mode. 4.0
Parameter input
Operating the menus via the TUC keys is described in the Operating Instructions section of this manual (see Menu Operations, section 2.0) 4.1
Control Parameters (SET1)
In this menu, control parameters related to the PI regulator are set. 4.2
Setpoint (SET2)
In this menu, it is possible to input the setpoints for system operation. The setpoints are entered with the units and decimal points as selected in configuration. Operating mode De-Interlock - Volumetric De-Interlock - Gravimetric 4.3
Valid setpoint Wm W1
Pre-feeder parameters (SET3)
Parameters for Pre-feeder control are set in this menu. 5.0
Error Messages
Errors are characterised by "!" display in the last position of the messages occurring during operation are shown below. " Message
!"
" Tacho Fault
!"
"Drive Int. Err.
!"
Software_version: 2.0 (onwards) 2008-11-15
= > = > = >
Meaning Help Tacho freq. input missing Check tacho, tacho cable external drive disturbance check drive interlocks
display. Error
OPERATOR’S MANUAL Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.2-R0 "Belt Tracking "Corr.>set-limit
!"
=
!”
> = >
"Corr. Aborted
!”
=
"Deviation
!"
> =
" AIO1 Commun.
!"
"EEProm read
!"
"EEProm write
!"
"Integration Off
!"
" Overload
!"
> = > = > =
!"
> =
" Underload "Emergency Stop
!"
"Anal. i/p Error
!"
" No PLC File
!"
"In-correct Inst
!"
Software_version: 2.0 (onwards) 2008-11-15
> = > =
> = > =
> = > = >
Page 11 of 12 Belt off track message at input for time greater than permissible time Set belt Zero correction or control measurement error, greater than permitted Check load, repeat zero correction or control measuring Zero correction or Control Measurement cycle aborted Check Tacho input, Drive Interlock input. Actual capacity outside the tolerance band longer than =deviation time= check load, setup Communication error AIO card Check AIO connection, interface, setup Data and checksum in EEProm do not match Enter parameters anew. Not possible to write to EEProm Hardware fault. Replace unit. Downstream Interlock input not present Check input. BB > MAX. LOAD value set in Measuring param. Check material on belt BB < MIN. LOAD value set in Measuring Param. Check material on belt Emergency stop switch pressed Check Switch status, cable. This error occurs during AIO scaling if Max_Value selected is lower than Min_Value or Communication error with Anaput module Check anaput value, Interface No assembled PLC file in memory. Enter PLC program, Assemble Error found in PLC file during assembly. Check line indicated.
OPERATOR’S MANUAL Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.2-R0 "Quantity Over
!"
"Inverter1 Comm.
!"
"Inverter2 Comm.
!"
" DIO 1 Commun.
!"
" DIO 2 Commun.
!"
" SIO Communicat.
!”
" Master Commun.
!"
= > = > = > = > = > = > =
" Belt Slip
!"
> =
" CAN Communicatn
!"
> =
" Loadcell Fault
!"
“ Zero Correction
!"
" Bin LC Fault
!"
" Error Scaling
!"
> = > = > = > = >
6.0 '....' =....= LED VFD SPSS
Page 12 of 12 Totaliser S1 greater than Q-q value set. Check set values Communication error with Inverter1 Check connection, interface, setup Communication error with Inverter2 Check connection, interface, setup Communication error with DIO card 1 Check connection, interface, setup Communication error with DIO card 2 Check connection, interface, setup Communication error with SIO module Check connection, interface, setup Communication error between TUC & master (Modbus/Profibus) Check connection, interface, setup Tail Pulley tacho input missing for time greater than permissible time Set belt Communication error between FIM & CAN master (TUC) Check connection, power, baudrate Hopper Loadcell not connected Check Loadcell connection. BB > limit value set in config. Check material on belt Bin Loadcell not connected Check Loadcell connection. Dimensions of weigh feeder and hopper do not match. Check parameters
Abbreviations key... Parameter in configuration Light emitting diode Vacuum Fluorescent display (16 characters X 2 line) PLC program
Software_version: 2.0 (onwards) 2008-11-15
COMMISSIONING INSTRUCTIONS Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.3-R1
Page 1 of 26
TABLE OF CONTENTS 1.0
First start...............................................………………………………………. 2
2.0
Parameters................................................…………….…….……………….. 2
3.0
OFFline parameters........................................………………………………. 2 3.1 .............................................…………….……………………..2 3.2 Measuring Parameters................................…………………………….. 3 3.3 Configuration Parameters............................……………………………. 4 3.4 Interface...........................................…………………….……………….. 7 3.5 Anaput........................................…………….…………………….. 9 3.6 TUC Analog Output............................…………….…………………….. 10 3.7 AIO Analog Output………………………………………………………… 11 3.8 Calibration - Feeder...........................……………………………………. 11 3.8.1 Calibration using weights.......................……………………….. 12 3.8.2 Calibration without weights.....................………………………. 13 3.9 Calibration correction ….………………………………………….………..13 3.10 CAN Configuration…..............................……………….……………….. 14 3.11 Hopper Parameters…………………………………………………………15 3.12 Calibration - Hopper……………………………………………………….. 16 3.13 Anaputs – FIM……………………………………………………….. 16 3.14 Analog Outputs – FIM………………………………………………………17 3.15 System data.........................................………………………………….. 18
4.0
ONline parameters.........................................……………………………….. 18 4.1 Main program........................................…………………………………. 18 4.1.1 SET1...........................................………………………………….. 19 4.1.2 SET2...........................................………………………………….. 21 4.1.3 SET3...........................................………………………………….. 22 4.1.4 SET4...........................................………………………………….. 23 4.1.5 SET5...........................................………………………………….. 24 4.1.6 Zero Correction................................………………………………. 25 4.1.7 Control Measuring............................……………………………… 25
Software_version: 4.1 (onwards) 2010-29-11
COMMISSIONING INSTRUCTIONS Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.3-R1
1.0
Page 2 of 26
First start
When starting for the first time the following procedure must be followed: Steps 1.1 1.2 1.3 1.4 1.5 1.6 1.7 2.0
Check jumpers Connect peripheral appliances Enter parameters Enter PLC Program Calibrate system Zero setting Calibration correction Parameters
See "Menu Operations" (section 2.0) for description about menu parameters and operations. 3.0
OFFline parameters
3.1
== When power is turned ON and 'CL' key is pressed during the 5 sec. delay, the system comes to this option Press '↑/↓' keys to scroll through the different menus. To select any menu,Press '→' key with that menu being displayed in the 2nd display line. =Enter = Enter the 5 digit and press '→' key. The OFFline parameter access is disabled if the wrong is entered. The same can be accessed only on right entry. Once enabled, the parameters can be accessed till the ONline menu is accessed or power to the system is turned 'Off'. Display: "Y" - On right entry "N" - On wrong entry Software_version: 4.1 (onwards) 2010-29-11
COMMISSIONING INSTRUCTIONS Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.3-R1 3.2
Page 3 of 26
Measuring parameters
=M. RANGE= Measuring Range The voltage rise is defined as the voltage difference which the measuring cell delivers between a belt loaded with 100% load and an empty belt.The value to be set is the next lowest setting value to this value. Select : 1.0 / 3.0 / 6.0 / 12 mV =Units,X= Units,Capacity Designation of all capacity displays. If "t/h" is selected as designation,all other values are automatically defined with "t". Select : kg/h, t/h =D. Pt,X= Decimal point,capacity Definition of the position of the decimal point within the 4 digit capacity display. Select : 000000 / 00000,0 / 0000,00 / 000,000 =Nom. Cap.= Nominal capacity Flow rate with 100% belt load and nominal tacho frequency = 100% capacity. Input : Numerical value of capacity =D. Pt,S1=Decimal point, Totaliser 1 Definition of the position of the decimal point within the 6 digits display of Totaliser 1 Select : 000000 / 00000,0 / 0000,00 / 000,000 =Units,S1= Units ,Totaliser 1 Definition of designation for resettable Totaliser 1 Select : kg / t =D. Pt,S2= Decimal point, Totaliser 2 Definition of the position of the decimal point within the 6 digits display of Totaliser 2 Select : 000000 / 00000,0 / 0000,00 / 000,000 =Units,S2 = Units ,Totaliser 2 Software_version: 4.1 (onwards) 2010-29-11
COMMISSIONING INSTRUCTIONS Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.3-R1
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Definition of designation for non-resettable Totaliser 2 Select : kg / t =Freq. I/P= Frequency input source Select : Fixed - Tacho frequency is simulated internally (1000 Hz) Tacho - Tacho frequency is read from tacho input Inv. – Tacho frequency is read from the inverter (Requires inverter to be connected to TUC-6 on the RS-485 serial bus) =Tacho Freq= Nominal tacho frequency Input : 0-9999 Hz (Only used for fixed frequency = "No") =Belt Speed= Nominal Belt speed in m/sec at nominal tacho frequency Input : 0-0,000 m/s (Only used for fixed frequency = "No") =Max. Load= Limit maximum load Maximum limiting value causing error message "Overload!". Input : Numerical value in % =Min. Load= Limit minimum load Minimum limiting value causing error message "Underload!". Input : Numerical value in % 3.3
Configuration Parameters
=Block mode= Block mode Definition of the weigh feeder as a Block system i.e with or without Control Measuring. Selection: Yes = Weigh feeder with pre-hopper and control measuring No = Weigh feeder without pre-hopper =Reg. mode= Regulation mode Definition of 2nd regulator Selection : Direct Removing = no 2nd regulator Feed regulation = With supplementary regulation of load =Batch mode= Batch mode Software_version: 4.1 (onwards) 2010-29-11
COMMISSIONING INSTRUCTIONS Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.3-R1
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In Batch mode operation feeder can be made to generate an alarm or stop, after delivering a set quantity of material. Quantity setpoints for this operation are entered in SET2 menu in Main_Program. Selection :Yes = Weigh feeder selected for Batch operation No = Weigh feeder not selected. =Rev. Time= Belt revolution time Time for one revolution of the belt with nominal tacho frequency. Input : Numerical value in 0,1 s steps =No. of Rev.= No. of belt revolutions Number of revolutions for control measurement. Input : numerical value with 2 digits =Zero Limit= Zero correction limit This parameter determines the number of percentage points by which the zero correction value may differ from the zero value. If the difference is greater, the error message "CORR.>SET-LIMIT!" is displayed and the zero value calculated is discarded. Input : numerical value in % =Belt track= Belt tracking monitoring time Time for monitoring the belt tracking input. Input : numerical value in 0,1 sec. steps =Run Time= Tacho supervision time Time for monitoring the tacho input pulses. Input : 0-999.9 s in 0.1s steps (No monitoring with input "0") =Impulse1= The impulse output can be assigned to Totaliser 1, Totaliser 2 or kept Off. Select : ϊ1 / ϊ2 / Off =On_Time= The impulse ON time can be set using this parameter. Select : 50mS / 100mS / 250mS / 500mS =Impulse2= Software_version: 4.1 (onwards) 2010-29-11
COMMISSIONING INSTRUCTIONS Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.3-R1
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A 2nd Inpulse output can be enabled/disabled with this parameter. Select : NO / YES =I1 value= I1 value Definition of analog output type at I1 Select : TPH/BB/Ta/Wc/WFsp/PFsp/Sk/LEVEL NOTE : TPH - Actual Material Flowrate BB - Instantaneous Belt Load Ta - Weigh feeder Tacho frequency (Belt speed) Wc - Current setpoint WFsp - Weigh feeder drive setpoint PFsp - Prefeeder drive setpoint Sk - Control measurement error LEVEL- Hopper level =Limit 1= Limit value 1 The potential free output for Belt load value above this value. Select : Numerical value in % =Limit 2= Limit value 2 The potential free output for Belt load value above this value. Select : Numerical value in % =L_Delay= Hysteresis time Time after which the output goes high when Belt load remains above limit values 1 or 2 Input : Numerical value in 0,1 sec steps. =Clear,S2= Clear Totaliser2 value Input : No / YES =Meas_Filt= Meas_Filt provides Loadcell input signal filtering. Select ‘0’ to de-select filtering. Select: 0/ 1 / 2 / 3 / 4 / 5 steps
Software_version: 4.1 (onwards) 2010-29-11
COMMISSIONING INSTRUCTIONS Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.3-R1
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=Display_Step= Digit step provides damping of display and analog output values. Select : 1 / 2 / 3 / 4 / 5 / 6 steps =Mode_Sel= This parameter defines the selection for switching between Interlock/Un-Interlock & Gravimetric/Volumetric modes. Selecting "External" defines mode selections from external digital inputs. Selecting "Internal" defines mode selections through TUC-6 keypad. Select : External/Internal =Setpoint %= Multiplying factor for setpoint to Drive in Volumetric modes. Select : Numerical value in % =CTRL_Mode= Selects the control mode for WF drive. Selecting "PI" selects PI control action. Selecting "tCTRL" selects "TRANScontrol" action for WF drive control. In this mode, the drive setpoint is automatically adjusted by the controller based on an internal algorithm. Selecting “Off” for this parameter, TUC-6 works in measuring mode, bying corrective action on drive setpoint. With “Off”, SET1, SET2, SET3 menus are disabled. Select : PI / tCTRL / Off 3.4
Interface
=No_Of_Inv= Inverter selection Inverters can be connected to TUC-6 serial interface. When connected to serial interface, drive setpoint, start/stop, signals are exchanged between TUC & Inverters via the serial interface only. The number of inverters connected to TUC-6 is selected with this parameter. Select : 0 / 1 / 2 NOTE : i) The address for each Inverter interfaced with TUC-6 should be separate. Address for Inverters are selected with the help of =Address= parameter in Inverter.
Software_version: 4.1 (onwards) 2010-29-11
COMMISSIONING INSTRUCTIONS Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.3-R1
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ii) The =Address= parameter in Inverter should be set to '01' for the 1st Inverter and '02' for the 2nd Inverter. iii) TUC-6 communicates with Inverters at 19200 baud, 8 bits, 1 stop, NO parity. =Inv_Type= Select Inverter type Select the Inverter type with this parameter. Select : ATV28 / MM4 / J7/V7 / ATV31 / PF4/40 / ACS550 =No_Of_DIO= Digital I/O card interface The number of DIO cards interfaced TUC-6 is selected with this parameter. Select : 0 / 1 / 2 NOTE: i) The address for each DIO card interfaced with TUC-6 should be separate. ii) Address for DIO cards are selected with the help of jumper plugs on the DIO card. (Refer "Appliance Description" for jumper selection details) =No_Of_AIO= Analog I/O card interface The number of AIO cards interfaced TUC-6 is selected with this parameter. Select : 0 / 1 / 2 / 3 NOTE: i) The address for each AIO card interfaced with TUC-6 should be separate. ii) Address for AIO cards are selected with the help of jumper plugs on the AIO card. (Refer "Appliance Description" for jumper selection details) =AIO_Type= Select AIO type Select the type of AIO interfaced in the system. Select : F868 / F875 =Ext_SP= External setpoint Selects source of external analog setpoint Select : OFF / AIO1 / Inverter =SP_Filter= Filter step provides damping for anaput setpoint value. Select : 0 / 1 / 2 in seconds =AIO1_OP= Definition of analog output (4-20mA) type from the 1st AIO card Select : TPH/BB/Ta/Wc/WFsp/PFsp/Sk/LEVEL Software_version: 4.1 (onwards) 2010-29-11
COMMISSIONING INSTRUCTIONS Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.3-R1
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=AIO2_OP= Definition of analog output (4-20mA) type from the 2nd AIO card Select : TPH/BB/Ta/Wc/WFsp/PFsp/Sk/LEVEL =AIO3_OP= Definition of analog output (4-20mA) type from the 3rd AIO card Select : TPH/BB/Ta/Wc/WFsp/PFsp/Sk/LEVEL =SIO_INT= SIO Interface Selection of the peripheral device at the serial interface Select: Off / Modbus / Profibus =SIO_BAUD= SIO baud rate Setting the baud rate at serial interface Select: 4800 / 9600 / 19200 baud =SIO_SETUP= SIO data format Definition of data format at serial interface Select: Data Stop Parity 8 1 None 8 1 Even 8 1 Odd =SIO_ADDR= SIO address Address of controller when connected to a multi-drop bus on the Serial network Input: Numerical value from 00-99. =SIO_MONITOR= SIO monitoring time Monitoring time for communication. Input: Numerical value in 1 sec. steps Note: IF "00" selected, SIO communication monitoring is disabled. In systems, where "Remote Interlock" mode of operation is used, i.e. Setpoint & Start/Stop through SIO, this parameter should not be set to "00". =CAN_Int= Selection of Field Interface Module via CAN is selected through this parameter. Select: Off / On
Software_version: 4.1 (onwards) 2010-29-11
COMMISSIONING INSTRUCTIONS Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.3-R1 3.5
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AIO AnalgInp Cal
=Re-Calibrate?= AIO1 anaput re-calibration The calibration menu is released on selecting '→' for this parameter.Pressing '↓' key will not affect the existing values stored in memory. Selection : → / ↓ =CHANNEL1= Recalibration of anaput for AIO1 channels =CHANNEL2= The Channel for calibration is selected by '→' key. Press '↓' key for scrolling to next channel Selection : → / ↓ =Min_Value= AIO Min. value With the anaput at the minimum value, Press '→' key to accept the value as 0% value for the channel selected. =Max_Value= AIO Max. value With the anaput at 100%, press '→' key to accept the value as 100% for the channel selected. 3.6
TUC AnalgOut Cal
=Re-Calibrate?= Analog output re-calibration The analog output calibration menu is released on selecting '→' for this parameter.Pressing '↓' key will not affect the existing values stored in memory. Selection : → / ↓ =Min_Value= I1 Output Min. value This is used to adjust the minimum output value at the Analog output I1. The present analog output count value is displayed. Press '→' key to increase/decrease the analog output value. ‘Esc’ key is used to toggle assignment of '→' key as increase or decrease key. Press ‘↓’ to save value and proceed further. =Max_Value= I1 Output Max. value
Software_version: 4.1 (onwards) 2010-29-11
COMMISSIONING INSTRUCTIONS Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.3-R1
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This is used to adjust the maximum output value at the Analog output I1. The present analog output count value is displayed. Press '→' key to increase/decrease the analog output value. ‘Esc’ key is used to toggle assignment of '→' key as increase or decrease key. Press ‘↓’ to save value and proceed further. 3.7
AIO AnalgOut Cal
=Re-Calibrate?= AIO card Analog outputs re-calibration The analog output calibration menu is released on selecting '→' for this parameter.Pressing '↓' key will not affect the existing values stored in memory. Selection : → / ↓ =OUTPUT1= AIO card output1 recalibration =OUTPUT2= =OUTPUT3= The enter key will proceed for recalibration of selected Output. The down key will give options for other channel outputs. Selection : → / ↓ =Min_Value= AIO Output Min. value This is used to adjust the minimum output value at the Analog output. The present analog output count value is displayed. Press '→' key to increase/decrease the analog output value. ‘Esc’ key is used to toggle assignment of '→' key as increase or decrease key. Press ‘↓’ to save value and proceed further. =Max_Value= AIO Output1 Max. value This is used to adjust the maximum output value at the Analog output1. The present analog output count value is displayed. Press '→' key to increase/decrease the analog output value. ‘Esc’ key is used to toggle assignment of '→' key as increase or decrease key. Press ‘↓’ to save value and proceed further. 3.8
Calibration - Scale Calibration of the scale can be carried out in 2 ways, i) Using Calibration weights
Software_version: 4.1 (onwards) 2010-29-11
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ii) Using previous calibration values. In this mode, previous calibration values , viz 'COUNT_DL' and 'COUNT_BL', are used to calibrate the scale. =Re-calibrate? ->= Recalibrate? The 2 modes in calibration menu are initiated by the following procedure, i)
Mode 1 - Calibration using Weights Press '→'. Pressing '↑↓' key will exit the menu without recalibration.
ii)
Mode 2 - Calibration without weights Press keys '1','2','3' and '→' in sequence. Pressing '↑↓' key will exit the menu without recalibration. Input : As above 3.8.1 Mode 1 - Calibration using Weights =Dead load= The actual value is displayed in of "d" in the lower display line.With a completely empty belt , delete the dead load with the '→' key.The actual value displayed then shows 0000 d; the dead load is compensated.Press '↑↓' key to switch further. Input : None TIP : Press 'ESC' key to display the actual value in mV. =Calibration load= Calibration load The actual value is displayed in of "d" in the lower display line. Load a known weight and wait for a steady display. The display then shows the actual value on the left and is ready to accept the new value. CALIBRATION LOAD 1230 => 0000 Enter the calibration load value on the right hand side. A value of 2000 corresponds to 100% Belt load. Scale the input value according to the calibration load. Conclude the calibration procedure with '↓' key.The value entered is saved on exit.
Software_version: 4.1 (onwards) 2010-29-11
COMMISSIONING INSTRUCTIONS Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.3-R1
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Input : Numerical value of calibration load in of "d". TIP : Press 'ESC' key to display the actual value in mV. 3.8.2 Mode 2 - Calibration without Weights =Count_DL= Dead Load Count The Dead Load is displayed in of internal calibration counts. The numerical keys can be used to change this value. Press '↑↓' key to switch further. Input : Numerical value =Count_BL= Belt Load Count The Belt Load corresponding to 100% load is displayed in of internal calibration counts. The numerical keys can be used to change this value. Press '↑↓' key to switch further. Input : Numerical value 3.9
Calibration correction
If measurement of the momentary load shows non-linear characteristics, correction in order to increase the linearity is possible. For this upto 10 measuring points can be taken and stored from 0....100% capacity. Between these measuring points, the curve is then linearized. To start the calibration correction process, calibrate the system. Take a measuring point e.g at 20% capacity and operate the system at 20% of nominal capacity. Switch on the capacity display on the unit and note the average indicated capacity. By a determined quantity (at completed belt revolutions) and reweigh it using a static weigher. Take the measurement time by a stop watch. From the actual conveyed capacity and the time taken, calculate the true conveying capacity. Conveying capacity (t/h) = Reweighed quantity (t) Time (sec)
x 3600
Input the displayed value (S1)and the measured value in the unit. Repeat the procedure for other calibration points,if necessary. Software_version: 4.1 (onwards) 2010-29-11
COMMISSIONING INSTRUCTIONS Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.3-R1
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=Curve_Correction= =Edit ->= Press '→' key to enter the curve correction menu. Press '↑↓' key to exit the menu. Pressing '→' key will display the correction points as shown, N DISP →MEASURED 0 0123,0→0000,0 "N"
- The correction point number,from 0 to 9
"DISP." - Input for quantity of conveyed material as displayed Input : Numerical value in units & resolution of S1. "MEASURED" - Input for measured quantity of material using a static scale. Input : Numerical value in units & resolution of S1. Press '↑↓" key to increment to the next correction point. After 10 correction points are displayed, next '↑↓" press will display the following in the lower line, "Exit ->" Press '→' to exit the menu and '↑↓' to move to correction point number 0 3.10
CAN Configuration
This menu is displayed only if =CAN_Int= is selected as ‘Yes’ in “Interface menu” =CAN_Baud= The Baud rate for communication between TUC6 and FIM can be selected through this parameter. Select: 10K / 20K / 50K / 100K / 125K / 250K / 500K / 1000K. =X5_Int= Modbus Interface Selection of MODBUS interface Select: Off / Modbus =X5_Baud= Modbus Baudrate Setting the baud rate for Modbus Software_version: 4.1 (onwards) 2010-29-11
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Select: 4800 / 9600 / 19200 baud =X5_Setup= Modbus data format Definition of data format at modbus interface Select: Data Stop Parity 8 1 None 8 1 Even 8 1 Odd =X5_Addr= Modbus Address Address of FIM when connected to a multi-drop bus through MODBUS Input: Numerical value from 00-99. =X5_Monitor= Modbus monitoring time Monitoring time for modbus communication. Input: Numerical value in 1 sec. steps Note: IF "00" selected, communication monitoring is disabled. =AO1_output= Definition of analog output type from channel 1 (X8) of FIM. Select: TPH/BB/Ta/Wc/WFsp/PFsp/Sk/LEVEL =AO2_output= Definition of analog output type from channel2 (X8) of FIM. Select: TPH/BB/Ta/Wc/WFsp/PFsp/Sk/LEVEL 3.11 CAN HopperParam This menu is displayed only if =CAN_Int= is selected as ‘Yes’ in “Interface menu” =M. RANGE= Measuring Range The voltage rise is defined as the voltage difference which the measuring cell delivers between a belt loaded with 100% load and an empty belt. The value to be set is the next lowest setting value to this value. Select1.0 / 3.0 / 6.0 / 12 mV =Units, L= Units, Hopper Software_version: 4.1 (onwards) 2010-29-11
COMMISSIONING INSTRUCTIONS Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.3-R1
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Designation of capacity display. Select: kg, t =D. Pt, L= Decimal point, Hopper Definition of the position of the decimal point within the 5 digit capacity display. Select: 000000 / 00000,0 / 0000,00 / 000,000 =Nom. Cap, L= Nominal capacity, Hopper Input: Numerical value of capacity =L_MIN= Limit Value Minimum Marker M061 set high, if Hopper level below this limit Input: Numerical value in % =L_NOM= Limit Value Nominal Marker M062 set high, if Hopper level below this limit Input: Numerical value in % =L_MAX= Limit Value Maximum Marker M063 set high, if Hopper level below this limit Input: Numerical value in % =Meas_Damp, L= Meas_Filt provides Loadcell input signal filtering. Select: 1 / 2 / 3 steps 3.12 Calibration – Hopper This menu is displayed only if =CAN_Int= is selected as ‘Yes’ in “Interface menu” The calibration procedure for hopper is similar to that explained in section 3.7 for Feeder. 3.13
CAN AnalgInp Cal
This menu is displayed only if =CAN_Int= is selected as ‘Yes’ in “Interface menu”
Software_version: 4.1 (onwards) 2010-29-11
COMMISSIONING INSTRUCTIONS Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.3-R1
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=Re-Calibrate?= AIO re-calibration The calibration menu is released on selecting '→' for this parameter. Pressing '↓' key will not affect the existing values stored in memory. Selection: → / ↓ =Channel1= Channel Selection =Channel2= The Channel for calibration is selected by '→' key. Press '↓' key for scrolling to next channel Selection: → / ↓ =Min_Value= AI Min. value With the anaput at the minimum value, Press '→' key to accept the value as 0% value for the Channel selected. =Max_Value= AI max. value With the anaput at 100%, press '→' key to accept the value as 100% for the Channel selected 3.14
CAN AnalgOut Cal
This menu is displayed only if =CAN_Int= is selected as ‘Yes’ in “Interface menu” =Re-Calibrate?= Analog output re-calibration The analog output calibration menu is released on selecting '→' for this parameter. Pressing '↓' key will not affect the existing values stored in memory. Selection: → / ↓ =Channel1= Channel Selection =Channel2= The Channel for calibration is selected by '→' key. Press '↓' key for scrolling to next channel Selection: → / ↓ =Min_Value= Output Min. value This is used to adjust the minimum output value at the Analog output. The present analog output count value is displayed. Software_version: 4.1 (onwards) 2010-29-11
COMMISSIONING INSTRUCTIONS Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.3-R1
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Press '→' key to increase/decrease the analog output value. ‘Esc’ key is used to toggle assignment of '→' key as increase or decrease key. Press ‘↓’ to save value and proceed further. =Max_Value= Output Max. Value This is used to adjust the maximum output value at the Analog output. The present analog output count value is displayed. Press '→' key to increase/decrease the analog output value. ‘Esc’ key is used to toggle assignment of '→' key as increase or decrease key. Press ‘↓’ to save value and proceed further. 3.15
System data
=U crystal= U crystal frequency is displayed Input : None =S/W Ver.= Software version Display of software version Input : None =Date= The date can be changed through this parameter. Input : Numerical value in format YY:MM:DD =Time= The system time can be changed through this parameter. Input : Numerical value in format HH:MM:SS 4.0
ONline parameters
If 'CL' key is not pressed during the 5 sec. power on delay, system goes to the ONline mode when power is switched ON. 4.1
Main Program
Software_version: 4.1 (onwards) 2010-29-11
COMMISSIONING INSTRUCTIONS Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.3-R1
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The display in the ONline mode can be switched directly by using keys 'W','BB','Ta','X', 'S1' and 'S2'. Other parameters are called by pressing '↑↓' key. The following parameters can be displayed in this mode, X S1 S2 BB Ta BS W1 W2 W3 Wm Wc Xd Y0 Y1 L L F W D SK Date Time Q q GATE
Actual flowrate value in units selected Totaliser1 value Totaliser2 value Belt load value in % Weigh Feeder Tacho frequency in Hz. Belt Speed in m/sec Un-Interlocked setpoint Interlocked setpoint Remote, Interlocked setpoint Manual mode setpoint Current setpoint Deviation in % WF drive setpoint in % PF drive setpoint in % Weight of pre-hopper in units selected Weight of pre-hopper in % Weighed quantity during control measuring quantity deducted during control measuring difference between F and W Control measurement error in % In format yy-mm-dd In format Hour:Minute Quantity setpoint. Dribble setpoint. Gate Position in % (for Flow Control gates)
4.1.1 SET1 This menu allows access to the PI regulator of the system. The P-share of the regulator is represented by =Amplification P1= and the I-share by =Reset Time I1=.
Software_version: 4.1 (onwards) 2010-29-11
COMMISSIONING INSTRUCTIONS Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.3-R1
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For Weigh Feeders with Feeding regulation or level regulation, a second regulator is implemented in the system to regulate the material on the belt or the pre-hopper content to a defined level. The parameters for second regulator are represented by =Reset Time I2= and =Amplification P2=. Since regulator1 and regulator2 mutually influence each other,an evaluation factor =Regulator Tracking= must be entered. This establishes a coupling between the output value for the drive speed setpoint and the output value for the feeding device. A setpoint change can thus be followed quickly. Note: SET1 menu is disabled if =CTRL_Mode= parameter in Configuration menu is selected “Off”.
=Reset Time I1= "I" time of the PI regulator for belt speed setpoint.If this value is zero, the "I" part is ignored in the regulator action. Input : Numerical value in 0,1 sec steps =Amplification P1= "P" part of the PI regulator for belt speed setpoint. Input : Numerical value in 0,1 steps =Deviation Limit= Tolerance range around the actual flow rate. Input : Numerical value in percent =Deviation Time= Maximum time that the actual flow rate is allowed to remain outside the tolerance range. At the end of this time, the scale trips due to "Deviation" error. Input : Numerical value 0,1 sec steps =Reset Time I2= Similar to =Reset Time I1= =Amplification P2= Similar to =Amplification P1= =Dead Band= % Error band for which no control action takes place on the drive setpoint. Software_version: 4.1 (onwards) 2010-29-11
COMMISSIONING INSTRUCTIONS Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.3-R1
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Input : Numerical value 0,1 % steps 4.1.2 SET2 This menu allows access to setpoints effective in different modes. The actual setpoint for system operation is dependent on the operational mode. Note: SET1 menu is disabled if =CTRL_Mode= parameter in Configuration menu is selected “Off”. =W1= De-Interlock - Gravimetric setpoint Setpoint W1, can be entered in the units and resolution selected in config. Input : Numerical value,4 digit number =Wm= De-Interlock-Volumetric (Manual) setpoint Setpoint Wm, can be entered in the units and resolution selected in config. Input : Numerical value, 4 digit number =Capacity Limitation= The setpoint input can be scaled from 0 to 100% using this parameter. Input : Numerical value in % =Q1= Quantity setpoint1 Setpoint Q1, can be entered in the units and resolution selected of S1. Input : Numerical value, 6 digit number =q1= Dribble setpoint1 Setpoint q1, can be entered in the units and resolution selected of S1. Input : Numerical value,6 digit number =Q2= Quantity setpoint2 Setpoint Q2, can be entered in the units and resolution selected of S1. Input : Numerical value, 6 digit number =q2= Dribble setpoint2 Setpoint q2, can be entered in the units and resolution selected of S1. Input : Numerical value, 6 digit number
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COMMISSIONING INSTRUCTIONS Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.3-R1
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4.1.3 SET3 This menu allows access to pre-feeder control parameters. Note: SET1 menu is disabled if =CTRL_Mode= parameter in Configuration menu is selected “Off”. =BB_Limit= Used for Weigh Feeder with "Feed regulation" mode selected. When Belt Load value is less than this value, the pre-feeder is started with a fixed setpoint, for time defined by parameter =BB_Delay=. After this time period, the setpoint value changes as per the 2nd PI regulator settings. The initial setpoint for Pre-feeder is defined by parameter =BB_Setpnt=. Input : Numerical value in % =BB_Delay= Description as above. Input : Numerical value in seconds. =BB_Setpnt= Description as above. Input : Numerical value in % =BB_Control= This parameter determines the level about which Belt Load regulation takes place. Input : Numerical value in % =BB_Band= Percentage Belt loading band within which no correction of the 2nd PI regulator takes place. Input : Numerical value in 0,1 % steps
=PF_Limit= Multiplying factor for limiting maximum setpoint to prefeeder drive. Set value equal to 100,0 % for maximum PF setpoint equal to 10 Vdc; set correspondingly lower values for clamping maximum PF setpoint value. Input : Numerical value in % Software_version: 4.1 (onwards) 2010-29-11
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=Reg_Type= PI / WSP / DSP This parameter selects the control action of 2nd regulator. Select, PI - Pre-feeder drive control as per PI control action WSP - pre-feeder drive setpoint tracks the current WF setpoint,Wc DSP - pre-feeder drive setpoint tracks the WF drive setpoint Select : Use '→' key to select =Regulator Tracking= When WSP or DSP is selected for parameter =Reg_Type=, pre-feeder drive setpoint tracks the selected variable by a multiplying factor defined by this parameter. Input : Numerical value in 0,1 % steps 4.1.4 SET4 This menu allows access to certain offline parameters. These paramters may be viewed/edited in this menu. Entry to this menu is allowed only after entry of the 5 digit system . =Count_DL= The Dead Load count value is displayed in of internal calibration counts. Input : Numerical value =Span_Cnt= The Belt Load corresponding to 100% load is displayed in of internal calibration counts. Input : Numerical value in count =AI_Tare= The Tare value is displayed in of internal calibration counts for the Anaput. Input: Numerical value =AI_Span= The Anaput corresponding to 100% value is displayed in of internal calibration counts. Software_version: 4.1 (onwards) 2010-29-11
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Input : Numerical value in count =Rev. Time= Belt revolution time Time for one revolution of the belt with nominal tacho frequency. Input : Numerical value in 0,1 s steps =Drv_Const= Used with "tCTRL" control mode for WF drive. Select the initial drive setpoint value with this parameter. Input : Numerical value in %. =tCTRL_Cnt= Used with "tCTRL" control mode for WF drive. Select the speed of control action with this parameter. Input : Numerical value in 01 step 4.1.5 SET5 This menu displays the status of Digital Inputs, Digital Outputs, Markers and Timer bits.
E00_ 9 ■ ■ ■ ■ ■ ■ 2 ■ ■ A00_ ■ ■ ■ ■ 5 ■ ■ ■ ■ 0
Bit status ‘0’ is indicated by ‘■’ and Bit status’1’ is indicated by the corresponding bit number. Example: In the above display, E002, E009, A000 & A005 are with status ‘1’ while all remaining bits are with status ‘0’ Press ‘→’ key to switch the 2nd line display to next block Press ‘↓’ or ‘↑’ to scroll the display lines Press either ‘Esc’ or ‘CL’ to exit and return to Main_Program
Software_version: 4.1 (onwards) 2010-29-11
COMMISSIONING INSTRUCTIONS Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.3-R1
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4.1.6 Zero correction Since the belt conveyor scale shows system related oscillation around the zero position, the zero point is corrected during one belt revolution in order to improve the measuring precision. The deviation of the zero point is measured and stored with a plus or minus prefix. This value is used to correct the momentary load during each measuring cycle. Zeroing can be started with the system in "Local" or "Manual" mode and in "Start" condition. Press key to initiate the zero correction cycle. When zero correction is in progress, deviation of zero point is displayed continuously. At the end of the zero correction cycle, the average deviation is displayed in percent. If the deviation is greater than the =Zero_limit= parameter, an error message is displayed and the value calculated is discarded. Zero correction has to be repeated. Press
key to stop zeroing in progress.
4.1.7 Control Measurement Feeders with pre-hopper scale can be selected to operate as a "Block" system. In this mode, material conveyed by the feeder for a fixed time can be compared with the amount of material extracted from the hopper for the same time period. The difference between can be measured and used to correct the feeder calibration automatically. Control Measuring (CM) can be started with the system in "Gravimetric" mode and in "Start" condition. Press key to initiate the zero correction cycle. When CM is in progress, "F"-Material conveyed by feeder and "W"-Material extracted from Hopper are displayed continuously. At the end of the CM cycle the following results are calculated and displayed, “D” – Difference between “F” and “W” “Sk” – Control Measurement error in %. The feeder calibration can be corrected on the basis of the error value calculated by pressing the key. The correction can be applied to either Feeder ‘Tare’ or ‘Span’ value.
Software_version: 4.1 (onwards) 2010-29-11
COMMISSIONING INSTRUCTIONS Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.3-R1
Page 26 of 26
If deviation is greater than the =Zero_limit= parameter, an error message is displayed and the value calculated is discarded. Press
key to stop Control Measuring in progress.
Control Measurement can also be initiated and controlled through Serial I/O or Digital I/O.
Software_version: 4.1 (onwards) 2010-29-11
MENU OPERATIONS Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.4-R1
Page 1 of 11
TABLE OF CONTENTS 1.0
General...............................................………………………………………… 2 1.1 Parameter save...................................………………….……………….. 2
2.0
Parameter menus.......................................………………………………….. 2 2.1 OFFline parameters...............................………………………………… 2 2.2 ONline parameters................................…………………………………. 2 2.3 Parameter label..................................…………………………………… 2 2.4 Menu structure...................................…………………………………… 3 2.5 Keys inside the menu.............................………………………………… 8 2.6 Calling and operating the menus..................…………………………… 8 2.7 Menu operation example...........................……………………………… 11
Software_version: 4.1 (onwards) 2010-11-29
MENU OPERATIONS Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.4-R1 1.0
Page 2 of 11
General
The Parameters are entered using the keypad and a 16 digit x 2 line display. The arrangement of parameters within the menus, options available for each parameters and writing the parameters are explained in the commissioning instructions. 1.1
Parameter save
The parameters of the system are stored in an EEPROM. On each power ON, the data in the EEPORM is checked with the contents of the Battery Buffered RAM. If a mismatch occurs, error message is displayed. Acknowledging the error, reloads the RAM from EEPROM. Instantaneous values during system operation are stored in the Battery buffered RAM. The parameters in a menu are automatically saved when the display is scrolled to display the next parameter. When the Online menu "Main_Program" is called,the parameters set in various menus are checked for logical settings.In case of mismatch, error message is generated.The corresponding parameter should then be correctly set. 2.0
Parameter Menus
The menu structure is divided into 2 categories, 2.1
OFFline parameters
These parameters can be changed only when the measuring mode is "OFF". 2.2
ONline parameters
These parameters can be changed even when the system is in operation. 2.3
Parameter Label
A differentiation is made between 2 types of parameters: Parameter label 1. Parameter whose value is entered numerically 2. Parameter whose value is selected from a list Software_version: 4.1 (onwards) 2010-11-29
Display xxxxxxx Selection →
MENU OPERATIONS Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.4-R1 2.4
Page 3 of 11
Menu structure
The parameters are arranged in different menus. The menus and the parameter listing is as shown below. Power ON ¾ • Enter ¾ Measuring Parameters • Measuring range • Units, Capacity • Decimal point, Capacity • Nominal capacity • Decimal point, S1 • Units, S1 • Decimal point, S2 • Units, S2 • Frequency Input • Nominal Tacho frequency • Belt Speed • Limit max. load • Limit min. load ¾ Configuration • Block mode • Regulation mode • Batch mode • Belt revolution time • No. of Belt Revolutions • Zero correction limit • Belt track monitoring time • Tacho supervision time • Impulse1 (S1,S2,OFF) • On_Time for Impulse output • Impulse2 • I1-Output Value • Limit value1 • Limit value2 • Limit delay time • Clear Totaliser2 Software_version: 4.1 (onwards) 2010-11-29
MENU OPERATIONS Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.4-R1 • • • • •
Measurement Filter Display Filter Step Mode selection (Internal/External) Setpoint %, Wm Ctrl_Mode
¾ Interface • No of Inverter • Inverter Type • No of DIO • No of AIO • AIO Type • Ext. Setpoint source • Ext. SP filter • AIO1 output • AIO2 output • AIO3 output • SIO Interface • SIO Baud • SIO Setup • SIO address • SIO monitor • CAN Interface ¾ AIO Anaput • Re-Calibrate? ¾ Channel1 ¾ Channel2 ƒ Min_Value ƒ Max_Value ¾ TUC Analog Output • Re-Calibrate? • Min_Value • Max_Value ¾ AIO Analog output • Re-Calibrate? ¾ Channel1 ¾ Channel2 ¾ Channel3 ƒ Min_Value ƒ Max_Value Software_version: 4.1 (onwards) 2010-11-29
Page 4 of 11
MENU OPERATIONS Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.4-R1 ¾ Calibration - Scale • Recalibrate? • Dead load set • Calibration load set ¾ PLC Program ¾ Calibration correction • Edit? • N Displayed_value Measured_value ¾ CAN Configuration • CAN Baudrate • X5 Interface • X5 Baudrate • X5 setup • X5 Addr • X5 Monitor • AO1 output • AO2 output ¾ CAN Hopper Parameters • Measuring Range • Units, L • Decimal Point, L • Nominal Capacity • Limit Min • Limit Nom • Limit Max • Measurement Damp, L ¾ Calibration - Hopper • Recalibrate? • Dead load set • Calibration load set ¾ Anaputs - FIM • Recalibrate? o Channel1 o Channel2 ƒ Min_Value ƒ Max_Value ¾ Analog Outputs - FIM • Recalibrate? o Channel1 Software_version: 4.1 (onwards) 2010-11-29
Page 5 of 11
MENU OPERATIONS Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.4-R1
Page 6 of 11
o Channel2 ƒ Min_Value ƒ Max_Value ¾ System data • • • • ¾ Main Program • • • • • • • • • • • • • • • • •
U crystal frequency Software version Date Time
• • • • • • •
Display Actual Flowrate Display S1 Display S2 Display belt load, BB Display WF Tacho frequency, Ta Display belt speed in m/sec, BS Display Internal setpoint, W1 Display External setpoint, W2 Display setpoint through X4, W3 Display Manual setpoint, Wm Display current setpoint, Wc Display Deviation, X0 Display WF drive setpoint, Y0 Display PF drive setpoint, Y1 Display Pre-hopper level, L Display material weighed during control measuring, F Display material extracted from hopper during control measuring, W Display D, difference between F & W Display Sk, control measurement error Display Date Display Time Display Quantity setpoint, Q Display dribble setpoint, q Display Gate Position
• • •
Reset Time I1 Amplification P1 Deviation Limit
¾ SET1
Software_version: 4.1 (onwards) 2010-11-29
MENU OPERATIONS Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.4-R1 • • • •
Deviation Time Reset time I2 Amplification P2 Dead Band
• • • • • • •
W1,Un-interlocked setpoint Wm,Manual setpoint Capacity limitation,% Q1,Quantity setpoint1 q1,Dribble setpoint1 Q2,Quantity setpiont2 q2,Dribble setpoint2
Page 7 of 11
¾ SET2
¾ SET3 • Belt Loading Limit,BB_Limit • Belt Loading delay,BB_Delay • Initial PF setpoint,BB_Setpnt • BB Load control,BB_Control • Belt Load Band,BB_Band • Max. PF setpoint,PF_Limit • Regulation Type • Regulator Tracking ¾ SET4 (Entry with ) • Dead Load count, Count_DL • Span count, Span_Cnt • Anaput, Tare • Anaput, Span • Belt Revolution time • Drive constant,Drv_Const • tControl count value,tCTRL_Cnt ¾ SET5 -Display E,A,M,T variables status See "Commissioning Instructions" for descriptions of each parameter. 2.5
Keys inside the Menu -Entry into a Menu/Sub-menu or -Selection of various options available for that parameter
Software_version: 4.1 (onwards) 2010-11-29
MENU OPERATIONS Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.4-R1
.....
Page 8 of 11
-Saving an entry and/or -Move further in the menu list -Numerical data input from the keypad -Exit from menu
+
-Call Online parameters from Main_Program menu
SET 2.6
Calling and operating the menus
1.
Power On TRANSWEIGH Version_1.0
a]
Possibility 1 X = 00,00 t/h BB = 100,0 %
The system enters Main_Program menu after 5 Secs., if no key is pressed during this delay period. If 'VER' is pressed during the 5 sec. delay, the delay is byed. a.1] Press 'Esc' and 'CL' to exit the online menu and enter the offline menus. Exit to Offline menus is possible in Weigh Feeder 'Stop' condition. a.2] Enter
Software_version: 4.1 (onwards) 2010-11-29
MENU OPERATIONS Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.4-R1
Page 9 of 11
Press key to enter the menu. All Offline menus are protected. Entry into the menu is allowed only if the right is pressed. a.3] Enter
…..
5 Digit entry using 1 TO 9 keys. a.4] Enter :Y If is right, the configuration menus can be accessed a.5] Measuring Param The Offline menus can be accessed by pressing '↓↑' key. Press 'Esc' and '↓↑' key to scroll the menu backwards. a.6]
M. Range 1,0 mV Press
key to enter the menu. The first menu parameter is displayed in the 2nd
display line. a.7] M. Range Press a.8]
3,0 mV
to change this value.
Software_version: 4.1 (onwards) 2010-11-29
Configuration
MENU OPERATIONS Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.4-R1
Page 10 of 11
Press 'Esc' and 'CL' to exit the sub-menu and enter the main menu list. b]
Possibility 2
b.1] The system enters the Offline menu directly, if 'CL' key is pressed during the 5 sec. delay. 2. Calling Online parameters from Main_Program menu STEP 1
Main_Program menu X = 00,00 t/h BB = 100,0 %
STEP 2 Press 2.7
SET
IT_Time =000,0s P1_Gain =000,0%
to return back to Main_Program
Menu operation Example
Example : Change the digit step from 1 to 2 in the Measuring parameters menu. STEP 1
Enter Offline menu as per 2.6 above.
STEP 2 Enter
Software_version: 4.1 (onwards) 2010-11-29
MENU OPERATIONS Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.4-R1
Page 11 of 11
STEP 3 ……
Enter
5–digit , using numerical keys STEP 4
Enter :Y
Only on right entry. STEP 5 Measuring Param STEP 6 M. Range 1,0 mV STEP 7 M. Range 1,0 mV UNITS,X kg/h STEP 8 M. Range 1,0 mV UNITS,X t/h STEP 9 UNITS,X D.Pt. X
t/h 0000,00
Step 9 saves the change made in the Units, X in Step 9.
Software_version: 4.1 (onwards) 2010-11-29
PARAMETER LISTING Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.5-R0
Sr. No.
Parameter
1.0
Measuring parameters
1.1
M. Range
1.2
Units, X
1.3
D. Pt, X
1.4
Nom. Cap.
1.5
D. Pt, S1
1.6
Units, S1
1.7
D. Pt, S2
1.8
Units, S2
1.9
Freq. I/P
1.10
Tacho Freq.
1.11
Belt Speed
1.12
Max. load
1.13
Min. Load
2.0
Configuration Parameters
2.1
Block Mode
2.2
Reg. Mode
2.3
Batch mode
2.4
Rev. Time
2.5
No. of Rev.
2.6
Zero Limit
2.7
Belt track
2.8
Run Time
2.9
Impulse 1
2.10
On_Time
Software_version: 2.0 2008-11-15
Page 1 of 6
Value 1
Value 2
PARAMETER LISTING Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.5-R0
Sr. No.
Parameter
2.11
Impulse 2
2.12
I1 value
2.13
Limit 1
2.14
Limit 2
2.15
L_ Delay
2.16
Clear, S2
2.17
Meas_Filt
2.18
Disp_step
2.19
Mode_sel
2.20
Setpoint %
2.21
Ctrl_mode
3.0
Interface
3.1
No_Of_Inv
3.2
Inv_Type
3.3
No_Of_DIO
3.4
No_Of_AIO
3.5
Ext_SP
3.6
SP_Filter
3.7
AIO1_Output
3.8
AIO2_Output
3.9
AIO3_Output
3.10
SIO_Interface
3.11
SIO_Baud
3.12
SIO_Setup
3.13
SIO_Addr
3.14
SIO_Monitor
Software_version: 2.0 2008-11-15
Page 2 of 6
Value 1
Value 2
PARAMETER LISTING Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.5-R0 Sr. No.
Parameter
3.15
CAN_Int
4.0
AIO AnalgInp Cal
4.1
Channel 1 Min_value
4.2
Channel 1 Max_value
4.3
Channel 2 Min_value
4.4
Channel 2 Max_value
5.0
TUC AnalgOut Cal
5.1
Min_Value
5.2
Max_Value
6.0
AIO AnalgOut Cal
6.1
Channel 1 Min_value
6.2
Channel 1 Max_value
6.3
Channel 2 Min_value
6.4
Channel 2 Max_value
6.3
Channel 3 Min_value
6.4
Channel 3 Max_value
7.0
Calibratn - Scale
7.1
Count_DL
7.2
Count_BL
8.0
PLC Program
8.1
SPSS_00
8.2
SPSS_01
8.3
SPSS_02
8.4
SPSS_03
8.5
SPSS_04
9.0
Calibration correction
9.1
Displayed Value
Software_version: 2.0 2008-11-15
Page 3 of 6 Value 1
Value 2
PARAMETER LISTING Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.5-R0 Measured Value 9.2
Displayed Value Measured Value
9.3
Displayed Value Measured Value
9.4
Displayed Value Measured Value
9.5
Displayed Value Measured Value
9.6
Displayed Value Measured Value
9.7
Displayed Value Measured Value
9.8
Displayed Value Measured Value
9.9
Displayed Value Measured Value
9.10
Displayed Value Measured Value
10.0
CAN Configuration
10.1
CAN_Baud
10.2
X5_Int
10.3
X5_Baud
10.4
X5_Setup
10.5
X5_Addr
10.6
X5_Monitor
10.5
AO1output
10.6
AO2 output
Software_version: 2.0 2008-11-15
Page 4 of 6
PARAMETER LISTING Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.5-R0
Page 5 of 6
Sr. No.
Parameter
11.0
CAN HopperParam
11.1
M. Range
11.2
Units, L
11.3
D. Pt, L
11.4
Nom. Cap
11.5
L_Min
11.6
L_Nom
11.7
L_Max
11.8
Meas_Damp, L
12.0
Calibration – Hopper
12.1
Count_DL
12.2
Count_BL
13.0
CAN AnalgInp Cal
13.1
Channel 1 Min value
13.2
Channel 1 Max value
13.3
Channel 2 Min value
13.4
Channel 2 Max value
14.0
CAN AnalgOut Cal
14.1
Channel 1 Min value
14.2
Channel 1 Max value
14.3
Channel 2 Min value
14.4
Channel 2 Max value
15.0
System Data
15.1
U Crystal
16 MHz
16 MHz
15.2
S/W Version
Ver_2.0
Ver_2.0
16.0
Main Program-SET1
16.1
I1_Time
Software_version: 2.0 2008-11-15
Value 1
Value 2
PARAMETER LISTING Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.5-R0 Sr. No.
Parameter
16.2
P1_Gain
16.3
Dev_Limit
16.4
Dev_Time
16.5
I2_ Time
16.6
P2_Gain
16.7
Dead_Band
17.0
Main Program-SET 3
17.1
BB_Limit
17.2
BB_Delay
17.3
BB_Setpoint
17.4
BB_control
17.5
BB_Band
17.6
PF-Limit
17.7
Reg_Type
17.8
Reg_Track
Software_version: 2.0 2008-11-15
Page 6 of 6 Value 1
Value 2
OPERATING INSTRUCTIONS - PLC Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.6-R0
Page 1 of 16
TABLE OF CONTENTS 1.0
Programmable Logic Controller.............................………………………... 2 1.1 Description..........................................……………………………………. 2 1.2 PLC Operation........................................…………………………………. 2 1.3 Instructions.........................................……………………………………. 3 1.4 Inputs,Outputs and Markers...........................…….…………………….. 4 1.5 Timers...............................................…………………………………….. 4
2.0
Programming Functions.....................................…….…………………….. 5 2.1 General..............................................…………………………………….. 5 2.2 Functions............................................……………………………………. 5 2.2.1 Assemble...................................…………………………………6 2.2.2 Delete.....................................…………………………………... 6 2.2.3 Editor.....................................…………….……………………... 6 2.2.4 Insert.....................................……………………………………. 7 2.2.5 List.......................................…………………………………….. 7 2.3 Error Messages.......................................………….……………………... 8
3.0
Allocation of Variable....................................……………………………….. 8 3.1 Inputs...............................................……………………………………… 8 3.2 Outputs..............................................…………………………………….. 9 3.3 Markers..............................................…………………………………….. 9 3.3.1 Input Markers..............................……………………………….. 9 3.3.2 Output Markers.............................……….……………………... 10 3.4 Timers...............................................……………………………………... 12
4.0
Standard Programs and I/O Assignments...............………………………. 12 4.1 Standard Program 1...................................………………………………12 4.1.1 Program List - SPSS_00.........................……………………….12 4.1.2 I/O Assignment.................................…….…………………….. 14 4.2 Standard Program 2...................................………………………………. 15 4.2.1 Program List - SPSS_01.........................……………………….15 4.2.2 I/O Assignment.................................…….……………………...16
Software_version: 2.0 (onwards) 2008-11-15
OPERATING INSTRUCTIONS - PLC Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.6-R0 1.0
Programmable Logic Controller
1.1
Description
Page 2 of 16
TUC-6 has an inbuilt PLC, that is used to control the Digital Inputs, Digital Outputs and Internal Memory Flags (Markers). The Programmable control system processes the instructions from the control program, SPSS. The Input data and Output data for the control program are physically in the TUC RAM, logically in the so called "process images". The instructions in the control program with the variables "A E M T" always refer to the process image in RAM. The programmable control system continuously operates on the control program in the following sequence, -Transfer hardware inputs to the TUC RAM -Execute instructions in the control program (SPSS) -Transfer output process image to the Hardware Outputs Several variable types are used in the PLC program. "A" stands for outputs, "E" for inputs, "M" for marker and "T" for timers. Addition of "N" (UN or ON) means that the associated variable is scanned for signal status "0" ; otherwise the scanning of variables is for signal status "1". 1.2
PLC Operation
The programmable control system consists of a 1_bit_wide BIT accumulator. Instructions in the PLC can be classified into two types; one type operating on the result of previous instruction (Result Instruction) and second changing the accumulator value (Command instruction). The control program is always started with accumulator = "1". ' Command ' instructions change the accumulator value till a ' Result ' instruction is encountered. After execution of all ' Result ' instructions, accumulator is again made ' 1 ' and the sequence is continued. Software_version: 2.0 (onwards) 2008-11-15
OPERATING INSTRUCTIONS - PLC Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.6-R0 Example: 000 001 002
*SPSS01 UM 045 UM 068
003
UNE 050
004 005
=A 008 UE 000
1.3
Page 3 of 16
;Comment Line ;Command Instruction - Accumulator = '1' ;Command Instruction - 'AND' result of above instruction with M068 value ;Command Instruction - 'AND' result of above instr. with 'NOT'of E050 input. ;Result Instruction ;Command Instruction - Accumulator = '1'
Instructions Instruction
Meaning
UE xxx UA xxx UM xxx UT xxx
AND operation with INPUT AND operation with OUTPUT AND operation with MARKER AND operation with TIMER
Y Y Y Y
N N N N
UNExxx UNAxxx UNMxxx UNTxxx
AND + NOT operation with Input AND + NOT operation with Output AND + NOT operation with Marker AND + NOT operation with Timer
Y Y Y Y
N N N N
OE xxx OA xxx OM xxx OT xxx
OR operation with INPUT OR operation with OUTPUT OR operation with MARKER OR operation with TIMER
Y Y Y Y
N N N N
ONExxx ONAxxx
OR + NOT operation with Input OR + NOT operation with Output
Y Y
N N
ONMxxx ONTxxx
OR + NOT operation with Marker OR + NOT operation with Timer
Y Y
N N
SA xxx SM xxx
SET Output SET Marker
N N
Y Y
RA xxx
RESET Output
N
Y
Software_version: 2.0 (onwards) 2008-11-15
Command
Result
OPERATING INSTRUCTIONS - PLC Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.6-R0 RM xxx RT xxx
RESET Marker RESET Timer
N N
Y Y
=A xxx =M xxx
Equate Output to result Equate Marker to result
N N
Y Y
LT xxx
Load Timer xxx with value in next Instruction Start Timer with xxx sec. in ON-delay mode
N
Y
N
Y
SITxxx 1.4
Page 4 of 16
Inputs, Outputs and Markers
These are one bit variables that can have status "LOW" (Logical 0) or "HIGH" (Logical 1). The differentiation between inputs and outputs is done by the "signal direction" on which these variables are based. Inputs are signals from "outside" to the control program, and outputs are signals from the control program to the external system. Thus inputs can only be read, while outputs can be allocated. Inputs and Outputs are available outside the TUC-6 system with the help of digital I/O card. Markers are internal variables and serve as memory within the control system. They are available outside the control system when they have been copied onto outputs. Markers are classified into Input Markers and Output Markers. Input markers are used to control the software execution while Output markers are derived as a result of the software execution. 1.5
Timers
Ten ON-delay timers are available in the system for timing functions. Instruction "LT xxx" loads timer "xxx" if the result of previous instruction is "1". Instruction "SIT yyy" starts the previously loaded timer with time "yyy". Timers continue to run till the input condition is "1" or till the set time is over, which ever is earlier. After completion of set time, the respective Timer "Txxx" bit status is made "1". Timers are reset (Txxx is made "0") with "RT xxx" instruction. Instruction "RT xxx", if executed while timer is running, stops the timer.
Software_version: 2.0 (onwards) 2008-11-15
OPERATING INSTRUCTIONS - PLC Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.6-R0 2.0
Programming Functions
2.1
General
Page 5 of 16
The Programmable Logic Controller in TUC-6 serve to adjust the scale to the plant control logic. The control program can be edited via the TUC keypad and display. Designation of files in the PLC menu is as follows, SPSS - Source file containing lit of instructions SPSA - Assembler file after translation from SPSS 2.2
Functions
The following functions are available in the "PLC Program" menu, PLC EDITOR A, D, E, I, L Key.
Meaning
Function
A D E I
Assemble Delete Editor Insert
L
List
Assembles SPSS file to generate SPSA file Delete SPSS file from memory Open editor for reading/altering SPSS file Append a std. SPSS file from EPROM to current SPSS file. List SPSS, SPSA file lengths
2.2.1 Assemble This function is invoked by pressing 'A' in the PLC Editor menu. PLC EDITOR Assemble → Press '→' key to assemble the SPSS file in memory or 'VER' to exit without assembling.
Software_version: 2.0 (onwards) 2008-11-15
OPERATING INSTRUCTIONS - PLC Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.6-R0
Page 6 of 16
2.2.2 Delete This function is invoked by pressing 'D' in the PLC Editor menu. PLC EDITOR Delete? → Yes Press ‘→ ‘ key to delete the SPSS file from memory or 'VER' to exit without deleting. 2.2.3 Editor Press 'E' in the PLC Editor menu, to edit the SPSS file in memory. The following functions are available within the Edit option, Key
Function
ESC + CL
Save and exit
ESC + I
Insert blank line
ESC + D
Delete line - The line indicated by cursor is deleted.
ESC + ANY OTHER KEY
Cancel "ESC" status
Keys used in this menu, Key
Function
0 to 9
Numeric entry
A,D,E,I,L,M,N,O,P,R,S,T,U,=,*
SPSS command characters
UP
Previous line
DOWN
Next line
HOR
Scroll to next/prev character position
Software_version: 2.0 (onwards) 2008-11-15
OPERATING INSTRUCTIONS - PLC Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.6-R0
Page 7 of 16
based on ESC key status ESC
Used in combination with other keys.
2.2.4 Insert This function is invoked by pressing 'I' in the PLC Editor menu. PLC EDITOR Insert SPSS=00 Standard SPSS files are resident in the EPROM memory, which can be used directly. These files are called into memory with the help of this function. Enter the SPSS file number to be inserted into memory and Press '→' key. Press 'VER' key to exit command without inserting the file. 2.2.5 List This function is invoked by pressing 'L' in the PLC Editor menu. SPSS = 120 LINES SPSA = 050 BYTES Press any key to return back to the Editor menu. 2.3
Error Messages Text In-correct Inst.
3.0
Meaning Assembling: non-existent address or instruction at the cursor line indicated.
Allocation of Variable
The variables are sub-divided into inputs, outputs, markers and timers. Free variables (read Markers) can be used by the control program as general purpose variables.
Software_version: 2.0 (onwards) 2008-11-15
OPERATING INSTRUCTIONS - PLC Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.6-R0 3.1
Inputs E000 to E007 E008 to E015 E016 to E019 E020 E021 E022 E023 E024 E025 E026 E027 E028 E029 E030 E031 E032 E033 E034 E035 E036 to E037 E038 to E049
3.2
Page 8 of 16
- DIO #1 Inputs - DIO #2 Inputs - Free ;Inverter #1 Inputs - LI1 input - LI2 - LI3 - LI4 - RL1 - RL2 - LI5 (J7, ATV31 & ACS550 Inverters only) - LI6 (ATV31 & ACS550 Inverters only) - Inverter Running (PF4 Inverter only) - RL3 (ACS550 Inverter only) ;Inverter #2 Inputs - LI1 input - LI2 - LI3 - LI4 - RL1 - RL2 - Free - Feild Interface Module - Digital Inputs
Outputs A000 to A007 A008 to A015 A016 A017 A018 A019 A020 A021 to A029
- DIO #1 Outputs - DIO #2 Outputs ;TUC-6 Outputs - RL1 (Totaliser 1 Pulse output, if selected) - RL2 (Totaliser 2 Pulse output, if selected) - RL3 - RL4 ;Inverter #1 Outputs - Start/Stop - Free ;Inverter #2 Outputs
Software_version: 2.0 (onwards) 2008-11-15
OPERATING INSTRUCTIONS - PLC Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.6-R0 A030 A031 to A037 A038 to A045 A046 to A049 3.3
Page 9 of 16
- Start/Stop - Free - Field Interface module - Digital Outputs - Free
Markers
Marker are classified into Input markers (M000 - M031) and Output markers (M032 M071). Input markers are read by the control program while Output markers are written by the control program. Reading access is allowed to both these types of markers. 3.3.1 Input Markers Marker
Meaning "1"
M000 M001 M002 M003 M004 M005 M006 M007
Start via SIO Stop via SIO Free Free Accept Count_DL, Span_Count (Only with Profibus) Reset Totaliser1 Remote ON (Control through SIO) Zeroing Start
M008 M009 M010 M011 M012 M013 M014 M015
Remote Mode Belt Track status-Healthy Emergency status-Healthy Local Start-WF Local Stop-WF Local Start-PF Local Stop-PF De-Interlock Mode
Local Mode Fault Fault
M016 M017 M018 M019 M020 M021 M022
Remote Start Downstream Interlock-Healthy Error Reset WF Drive Interlock-Healthy PF Drive Interlock-Healthy Material Low (Fault) Local Start-Vibrator Motor
Stop Fault
Software_version: 2.0 (onwards) 2008-11-15
Meaning "0"
Interlock Mode
Fault Fault High Stop
OPERATING INSTRUCTIONS - PLC Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.6-R0
Page 10 of 16
M023
Gravimetric mode select
Volumetric mode
M024 M025 M026 M027 M028 M029 M030 M031
Select Q1,q1 Select Q2,q2 Bin Pre-feeder Start/Stop Start Control Measurement Stop Control Measurement Accept Control Measurement Error Free Free Free
3.3.2 Output Markers Marker
Meaning "1"
Meaning "0"
M032 M033 M034 M035 M036 M037 M038 M039
Load Disturbance Fault Belt Tracking Fault Drive Disturbance Deviation Disturbance General Fault Belt Slip Zeroing: Correction>Limit Zeroing: Aborted
Healthy Healthy Healthy Healthy Healthy
M040 M041 M042 M043 M044 M045 M046 M047
Free Feeder Selected Free Local Mode Gravimetric mode Interlock Mode Free Vibrator Start
M048 M049 M050 M051 M052 M053 M054
Limit Value 1 Limit Value 2 Overload Error Underload Error Free Bin Pre-feeder Start Control Measurement ON
Software_version: 2.0 (onwards) 2008-11-15
Remote Mode Volumetric mode De-Interlock Mode Stop
Healthy Healthy Stop
OPERATING INSTRUCTIONS - PLC Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.6-R0 M055
Control Measurement Aborted
M056 M057 M058 M059 M060 M061 M062 M063
Zeroing: In Progress Zeroing: OK Correction max exceeded Quantity Reached Free BLMS Level < L_min BLMS Level < L_nom BLMS Level < L_max
M064 M065 M066 M067 M068 M069 M070 M071
WF-Start PF-Start WF-Start PF-Start System Healthy Loadcell Fault AI Card Communication fault PF Tacho Fault
M072 M073 M074 M075 M076 M077 M078 M079
Free Free Free Free Free Free Free Free
M080 M081
Free Free
M082 M083 M084 M085 M086 M087 M088 M089
Input from Profibus Input from Profibus Input from Profibus Input from Profibus Input from Profibus Input from Profibus Input from Profibus Input from Profibus
Software_version: 2.0 (onwards) 2008-11-15
Page 11 of 16
Stop Stop Stop Stop Fault Healthy Healthy
(Blinking-Fault) (Blinking-Fault)
OPERATING INSTRUCTIONS - PLC Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.6-R0 3.4
Page 12 of 16
Timers T000 to T009 are timers available for use in the SPSS program.
4.0
Standard Programs and I/O Assignments
4.1
Standard Program 1 Standard Program for 8 Digital I/O card.
4.1.1 Program List - SPSS_00 / / / / / / / / / / / / / / / / / / / / / / / / / / / / /
*SPSS00/ UE 001/ =M 009/ UE 004/ =M 023/ UE 005/ =M 015/ UE 006/ =M 017/ UE 007/ UM 045/ SM 016/ UNE007/ UM 045/ RM 016/ UE 021/ SM 011/ RM 012/ UNE020/ SM 012/ RM 011/ UNE022/ =M 008/ UE 023/ =M 010/ UE 024/ =M 019/ =M 020/ UM 064/
;BELT TRACK SWITCH ;GRAV/VOL. SELECT ;INT./DE-INT. SELECT ;DOWNSTREAM INTERLOCK ;START/STOP - INTERLOCK MODE ;SET START MARKER ;RESET START MARKER ;LOCAL START - PB ;SET "START" ;RESET "STOP" ;LOCAL STOP - PB ;SET "STOP" ;RESET "START" ;LOCAL/REMOTE SELECTION ;EMERGENCY S/W ;DRIVE INTERLOCK ;DRIVE INTERLOCK - WF ;DRIVE INTERLOCK - PF ;WF START/STOP/FAULT - LCS INDICATION
Software_version: 2.0 (onwards) 2008-11-15
OPERATING INSTRUCTIONS - PLC Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.6-R0 / / / / / / / / / / / / / / / / / /
=A 000/ UM 066/ =A 001/ UM 066/ =A 002/ UM 033/ =A 003/ UM 036/ =A 004/ UM 045/ UM 068/ =A 005/ UM 035/ =A 006/ UM 034/ =A 007/ UM 066/ =A 020/
Page 13 of 16
;WF DRIVE START/STOP - NO ;WF DRIVE START/STOP - NO ;BELT TRACKING FAULT O/P ;GENERAL FAULT O/P ;INT. MODE ;SYSTEM HEALTHY ;READY TO START O/P - INT. MODE ;DEVIATION FAULT ;DRIVE FAULT ;WF DRIVE START/STOP - NO
4.1.2 I/O Assignment Digital Inputs - DIO #1 Input
High
Low
E000 E001 E002 E003
Free Belt Track S/W-Healthy Fault Free Free
E004 E005 E006 E007
Volumetric Interlock D. Interlock-Healthy Start
Gravimetric De-Interlock Fault Stop
Signal Type Steady
Steady Steady Steady Steady
Digital Outputs - DIO #1 Output High
Low
A000
Stop
Start
Software_version: 2.0 (onwards) 2008-11-15
(Blinking-Fault)
OPERATING INSTRUCTIONS - PLC Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.6-R0
Page 14 of 16
A001 A002 A003
Drive Start Drive Start Belt Track. Fault
Stop Stop Healthy
A004 A005 A006 A007
General Fault Ready to Start Deviation Fault Drive Fault
Healthy Fault/Not-Healthy Healthy Healthy
Inverter 1 Inputs Input
High
Low
Signal Type
E020 E021 E022 E023
Start-Local Local Emg. Switch-Healthy
Stop-local
Impulse Impulse Steady Steady
E024
Drive Interlock_Healthy Fault
Remote Fault
Inverter 1 Outputs
4.2
Output
High
Low
A020
Drive Start
Stop
Standard Program 2 Standard Program for Pre-Feeder
4.2.1 Program List - SPSS_01 / *SPSS01/ / UNE030/ / SM 014/ / RM 013/ / UE 031/ / SM 013/ / RM 014/ / UE 034/ / =M 020/
;PF STOP FROM LCS ; ;PF START FROM LCS ; ;PF DRIVE INTERLOCK
Software_version: 2.0 (onwards) 2008-11-15
Steady
OPERATING INSTRUCTIONS - PLC Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.6-R0 / / / /
UM 067/ =A 030/ UM 065/ =A 001/
Page 15 of 16
;PF DRIVE START/STOP ;PF START/STOP/FAULT - LCS INDICATION
NOTE:SPSS_01 when used with SPSS_00, the following changes should be made to the standard SPSS_00 program i) SPSS_00: . . / UE 024/ / =M 019/ / =M 020/
;DRIVE INTERLOCK ;DRIVE INTERLOCK - WF ;DRIVE INTERLOCK - PF *****Delete******
Pre-Feeder 'Drive Interlock' Marker is assigned in SPSS_01. Duplicate assignment in SPSS_00 should be deleted. ii) SPSS_00: . . / UM 066/ / =A 001/
;WF DRIVE START/STOP *****Delete***** *****Delete*****
Output A001 is used in SPSS_01 for 'Pre-Feeder Start/Stop/Fault' indication. Above lines in SPSS_00 should be deleted. 4.2.2 I/O Assignment Digital Outputs - DIO #1 Output High
Low
A001
PF Stop
(Blinking-Fault)
Low
Signal Type
Stop-local
Impulse
PF Start
Inverter 1 Inputs Input
High
E030 Software_version: 2.0 (onwards) 2008-11-15
OPERATING INSTRUCTIONS - PLC Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.6-R0 E031 E034
Start-Local Drive Interlock_Healthy Fault
Inverter 1 Outputs Output High
Low
A030
Stop
Drive Start
Software_version: 2.0 (onwards) 2008-11-15
Page 16 of 16 Impulse Steady
APPLIANCE DESCRIPTION
Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.10-R0
Page 1 of 12
TABLE OF CONTENTS 1.0
General...................................................……………………………………… 2
2.0
System Representation....................................……………………………... 2
3.0
Configuration of Jumpers..................................…………………………….3 3.1 Main Board...........................................…………………………………3 3.2 Measuring Card.......................................………………………………3 3.3 Field Interface Module……………………………………………………3
4.0
Rear View of TUC6CAN.................................……………………………….. 4
5.0
Main Board External Connectors............................……………………….. 5
6.0
Layout of Main Board......................................……………………………… 6
7.0
AIO Card Connector Details................................…………………………... 7 7.1 F868………………………………………………………………………..7 7.2 F875………………………………………………………………………..8 DIO Card Connector Details...............................…………………………… 9 8.1 F866………………………………………………………………………..9 8.2 F889………………………………………………………………………..10 8.2 F890………………………………………………………………………..11
8.0
9.0
Field Interface Module Connector Details…………………………………..12 9.1 F892………………………………………………………………………..12
Software_version: 2.0 (onwards) 2008-11-15
APPLIANCE DESCRIPTION
Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.10-R0 1.0
Page 2 of 12
General
Each member of the TUC-6 family comprises a Basic unit & several I/O modules connected to the Basic unit on the RS-485 serial Interface. The I/O modules are suited for external mounting on an assembly plate. 2.0
System Representation
TUC-6 X1
F1
0.5A
Mains Connections 24Vdc
+Main Board Measuring card X6 X1
Software_version: 2.0 (onwards) 2008-11-15
X3
Loadcell connection 12V/0.11A for max. 3 loadcells 350 Ohm
X1
4 Digital outputs 4-20mA Isolated Output Tacho Pulse Input
X2
Serial interface RS485
X4
Profibus Interface TUC-6 Display & Keypad Interface Card
X5
X1
X7
CANbus connection to FIM card (F892)
APPLIANCE DESCRIPTION
Weigh Feeder with TUC-6CAN Electronics TUC6CAN-010-EE23.10-R0
Page 3 of 12
3.0
Configuration of Jumpers & Dip Switches
3.1
Main Board
Jumper J1 : 1-2 → Terminating resistor for X2 Interface – RS485 (Connects 120E resistor) Jumper J2 : 1-2 → Terminating resistor for X7 Interface – CAN Interface (Connects 120E resistor) Jumper J4 : 1-2 → Modbus interface with X4 connector(BUS+ line) 3-4 → Modbus interface with X4 connector(BUS- line) 3.2
Measuring Card
Jumper J1 : 1-2 / 9-10 1-2 / 7-8 3-4 / 9-10 3-4 / 7-8 5-6 / 9-10 5-6 / 7-8
measurement period
Software_version: 2.0 (onwards) 2008-11-15
4ms 8ms 8ms 16ms 16ms 32ms
ASSEMBLY & START UP INSTRUCTION MANUAL FOR WEIGH FEEDER The Assembly At Site Is Done According To The Corresponding Implantation Drawing. Furthermore the following has to be observed ( maintenance instructions and instructions ). 1)
lubrification
The fixation of the weigh feeder has to be done in a way, that the belt frame may not be distorted. It also has to be horizontal in both directions.
2) Detach Transport Saftenings. 2.1) Protection Of Weigh Lever. Unscrew protection plate 1 of the load cell. Unscrew protection plate 3 which is lacquered in red at the upper screw and pull it out. Do not change the overload buffer 5 see also point 4 of the maintenance instructions.
3)
Discharge hood normally the discharge hood is mounted at the belt frame for transport. In case the discharge hood is fixed at site at a chute, The screws between hood and arm straps have to be screwed out.
4)
Check oil filling of drive gear. Quantity and quality can be seen from the type plate and lubrification plan.
5)
Connect the scale and start it in manual mode. See electrical start-up instructions.
6)
Adjustment of belt tracking see maintenance instructions point.
7)
Check function of scrapers and belt tracking sensors.
8)
Fix all protection facilities. For the assembly the regulations for preventation of acciedents have to be observed.
FLSmidth Pfister India Ltd.
MAINTENANCE INSTRUCTION MANUAL FOR WEIGH FEEDER
Interrupt the power supply before starting any work on rotating parts or parts being under voltage.
Drive motor All motors are supplied in completely assembled condition ready for operation. The bearings are filled with the requisite amount of grease at the time of assembly of the motors. While regreasing the bearings, a lithium based grease should be used. Do not force in the grease. The bearing shall be cleaned thoroughly and be refilled with grease upto 2/3 of their empty internal space. More grease would cause overheating of the bearings. Drive gear
Gear units are supplied in completely assembled condition ready for operation after first filling of oil. Care should be taken to fill the oil to the correct oil mark. It should be emphasized that excess oil must not be put in to the unit,because this may result in excessive temperature rise due to running. Cleanliness of oil is of prime importance and it is imperative to flush the gear unit with flushing oil before refilling. Flushing fluid is to be drained off completely before filling the fresh oil. If the gear has to be replaced or repaired, the supply tubes to the motor and tacho have to be disconnected. Unscrew the motor at its flange, and remove the tacho in the drive casing. Unscrew at the gear flange. Pull gear off the drive shaft with the help of the puller. Suspend the gear unit with the pull lift device and lower at the platform with the lever. Hoist has to be used for removal or replacement of the gear unit.
Digital tachometer The digital tachometer is installed in the drive casing. Accessible by dismounting the motor. The distance between counting wheel and inductive transducer is 1.5 mm. The impulse pause ratio is about 1:1.
FLSmidth Pfister India Ltd.
MAINTENANCE INSTRUCTION MANUAL FOR WEIGH FEEDER
All the works at the weighing system have to be carried out with special care. The load Cell 1 is maintenance - free. It can only be destroyed by inissibl, external machanical Or electrical influences. The exchange of the load cell must be followed by a new Adjustment of the overload stop 5. Check of the adjustment by electrical measurement. The overload stop must becomeeffective at 125% of the rated load of the load cell. Check the adjustment of the height of the measuring idler 2. This idler is about 2mm Higher than the neighbouring idlers 3 when the belt is not loaded. An adjustment can be Made at the screws 4 under the measuring idler shaft. By means of the excenter 6 the Lever movement is limited to the opposed direction. It is adjusted in a way, so that the Tension rod at the load cell has a stroke of about 4 mm when relieved.
FLSmidth Pfister India Ltd.
MAINTENANCE INSTRUCTION MANUAL FOR WEIGH FEEDER - weigh lever Check the v-ring seal to correct function. For the dismounting of the bearing or the V-ring the tension rod to the load cell is unscrewed (adjustment of lever see above Point). The bearings are maintained according to lubrification instructions.
Conveyor belt Belt change In case of excessive wear or destruction of the when changing the belt the rubber blades of the inner belt scrapers and the pulley Scraper be readjusted,replaced at the same time. If necessary, also clean the idlers and Pulleys and check if they are rotating easily. The belt change is made at the side opposite to the belt drive as described below. 1) unscrew the side covers 1 and their s 2 at the side on which the belt is taken off as well as the protection covers 3 of the tail pulley. Screws 4.
FLSmidth Pfister India Ltd.
MAINTENANCE INSTRUCTION MANUAL FOR WEIGH FEEDER
2) unscrew discharge hood cover 4. 3) dismount outer belt scrapers (see point 11). 4) in case of weighers having a distance of pulley centers of more than 3500 mm unhinge The return idlers. 5) put in the isolating gate at the hopper and if needed, lower the gate for bed depth of material.
6) displace the tail pulley by turning the nuts 1 on the spindles 2. 7) suspend the supplied for belt change on the frame structure, put on the new belt and lift the slightly on its end. Weighers with a distance of pulley centers of up to 3500 have one and weighers of more than 3800 mm have two belt change s.
FLSmidth Pfister India Ltd.
MAINTENANCE INSTRUCTION MANUAL FOR WEIGH FEEDER 8) dismount the resp. Suspension of the weigher on the side of belt changing. A) weighers with Slightly undo the screwings between and conveyor frame. Lift the belt change till the s are free. Dismount the s. B) weighers with suspension Undo the screwings between suspensions and conveyor frame. Lift the belt change till the screwings are relieved of the load and can be removed. Dismount the Suspensions by lowering themdown a little from the girder. 9) cut up the old belt or take it off and put on the new belt. Now the maintenance works Mentioned at the beginning can be carried out. Mount new belt. 10) mount the s resp. Suspensions and the return idlers if there are any. 11) shift the tail pulley uniformly (1) towards outside till the belt has the correct tension according to the belt tension indication (see point 7). 12) mount outer belt scrapers, discharge hood, protection covers of tail pulley and s for the side covers. 13) adjustment of belt tracking ( in manual operation). A) without material If the belt deviates to one side, the distance of the pulley centers has to be increased on This side by the pressure spindles at the return pulley resp.to be decreased on the Opposite side, depending on the belt tension.
FLSmidth Pfister India Ltd.
MAINTENANCE INSTRUCTION MANUAL FOR WEIGH FEEDER
The belt tension is indicated by indications on the side covers, see 8. Indication belt Tension. The belt tension can be changed by turning the nuts 1 (evenly on both sides). During the first operating hours the belt has to be adjusted more often. B) with material When the belt is standing still lift gate for bed depth, if it has changed, and pull out the Isolating gate. If the form of the belt is not quite cylindric, the belt may be displaced Laterally under load. This deviation can be avoided by a horizontal displacement of the Idlers. The conical form is determined by measuring the pulley centers on both sides. Spacings ant the idlers, ie. The idler s are shifted in a corresponding way.The first 3 idlers seen from the drive, must not be shifted. The axes of the remaining idlers And pulleys intersect in a common point
FLSmidth Pfister India Ltd.
MAINTENANCE INSTRUCTION MANUAL FOR WEIGH FEEDER Belt tension holding rod The belt tension must be checked regularly & readjusted if necessary. It is indicated, When the return roller is not in with belt, so to do the tensioning raise
The upper nut of tensioning rod till the return roller touches the belt & the belt is Tightend. After tensioning raise the spacer of the indicating rod & raise the lower nut This act as a lock for the tensioning rod.
Belt tracking controls Check function of the limit switches and switching point position of the lever.
FLSmidth Pfister India Ltd.
MAINTENANCE INSTRUCTION MANUAL FOR WEIGH FEEDER Pulley bearings For maintenance please see lubrification plan. Idlers Dirty idlers are to be cleaned and checked for easy running. The 3 carrying idlers of the Measuring section have a higher true running accuracy as the other carrying idlers and May be exchanged against one another. The idlers have life- time greasing. Principal position of idlers and pulleys.
Outer belt scraper The correct pressure of the scraper 1 has to be adapted to the operating conditions. The pressure can be modified by the nuts 2 at the end of the pull 3. For replacement or Readjustment of the rubber blade it is useful to take out the scraper 1 . After having Removed the nuts 2 and the springs 4 it can be taken out of its . See lubrification plan
.
FLSmidth Pfister India Ltd.
MAINTENANCE INSTRUCTION MANUAL FOR WEIGH FEEDER Inner belt scraper Check function of the scraper.for readjustment or replacement of the rubber blade the Whole scraper is taken out from the conveyor structure. Extract guide bolt 2,remove Scraper 1 from its guidance,hang out chain 3 at belt frame.eventually the return pulley Has to be shifted some what towards inside for an easier dismounting.
Pulley scraper (not for cage pulleys or rubber-lagged pulleys) . The scrapers on head and tail pulleys function free of .the distance between Blade and pulley is about 1 mm. It can be checked and adjusted during belt change. Cover/skirt boards Weighers for granular material. Check the wear of the skirtboards. A gap of at least 1 mm must exist between belt and rubber blade. Weighers for powdery material. Check the wear of the skirtboards. The thin rubber Blades are bent by 90 deg. And lie on the belt with the wide side. Weighers with flexowell board for powdery material do not have any skirtboards or Else skirtboards as described above.
FLSmidth Pfister India Ltd.
MAINTENANCE INSTRUCTION MANUAL FOR WEIGH FEEDER
Check the electrical connections and replace damaged cables. Observe lubrification plan . Check the screw connections of parts under load or mobile parts. Clean the weigher, especially in the zone of the measuring sections,drive and flexible parts.all dust protections have to be remounted after the end of the maintenance work..
FLSmidth Pfister India Ltd.
LUBRICATION INSTRUCTION MANUAL FOR WEIGH FEEDER
FLSmidth Pfister India Ltd.
LUBRICATION INSTRUCTION MANUAL FOR WEIGH FEEDER
FLSmidth Pfister India Ltd.
LUBRICATION INSTRUCTION MANUAL FOR WEIGH FEEDER Legend to lubrication list Column-1 No.of the lubrication point in accordance with the numbering in the drawing. Column-2 Number of lubication points (per machine unit). Column-3 Designation of the machine part to be lubicated Column-4 Type of lubrication The lubrication methods listed below are identified in column 4 by a figure. Lubrication nipple
–
1
Splash lubrication
–
2
Grease filling
–
3
Central grease Lubrication system
–
4
Circulating oil Lubrication
–
5
Spray lubrication
–
6
Application of the Lubrication by means Of a brush,spray can,etc
–
7
Hydraulic or Power transmission Oil filling
–
8
Lifetime lubrication
–
9
FLSmidth Pfister India Ltd.
LUBRICATION INSTRUCTION MANUAL FOR WEIGH FEEDER Column-5 Lubricant designation
k=servogem no.2-i.o.c 2k= bharat mp grease 2-bp Clp=benzene or kerosene
Column-6 First filling (oil in liters, grease in cub cm) Column-7 Relubrication volume (oil in liters,grease in cub cm) Column-8 Lubrication intervals in operating hours of the entire plant. Basis:24 hours operation. 640-1000 operating hours (4 weeks or 6 weeks) 2200 operating hours (a quarter of a year) 4400 operating hours (half a year) 6600 operating hours (three quarters of a year) 8800 operating hours (1 year) Column-9 Lubricant replacement (in operating hours as above). Column-10 Observations to the above columns.
FLSmidth Pfister India Ltd.
TESTING / ADJUSTING MANUAL FOR WEIGH FEEDER The tests described below shall be called the acceptance tests. The acceptance tests shall comprise of the following: 1) GENERAL ECHANICAL & ELECTRICAL TESTS: CONTINUOUS RUN During the tests , the equipment shall be operated for a period of 48 hours continuously At the maximum rated capacity/speed. During the last 4 to 6 hours of this time a check Shall be carried out to observe that the operation of all the elementsof the machinery, Such as bearings,grease,scrapers,etc. Are free from abnormal defects such as noise, Vibration and over heating. During this period the shift in the variable speed shall also be noted. CAPACITY TEST After the completion of the continuous run test, the feeders shall be tested for Establishing their maximum carrying capacity.this shall be done under simulated loading With calibrated load.the capacity of the equipment shall be calculated as follows: Q = 3600 a x s x d , tonnes/hour where: A = cross sectional gate opening in sq.meters. S = velocity in meters/sec. D = bulk density in tonnes/cubic meter. 2) THE WEIGHING AND INDICATING SYSTEM TEST (SEE BELOW) 3) THE FEED BACK CONTROL SYSTEM TEST The test for both above systems should be carried out simultaneously for a period of 48 hours,after the general mechanical and electrical tests are conducted. the tests Should be either continuous,or aggregate of 48 hours,depending on the availability of material,operating staff,power etc. The tests are designed to check the dependability, accuracy, repeatability and the degree of drift in calibration of the system and shall comprise the following procedure:
FLSmidth Pfister India Ltd.
TESTING / ADJUSTING MANUAL FOR WEIGH FEEDER The accuracy of the weighing & indicating system to be ascertained by means of the calibration weight laid on the empty, running belt,and the indicating checked against The oretical through put at a particular belt speed. The epeatability to be ascertained By repeating the above checks three times at the same setting and noting the difference in the indication at each check. This test to be carried out at 0 hours,24 hours and 48 hours of the test period. As soon as the above test at zero hours is satisfactory, it shall be assumed that the weighing and indicating system is functioning correctly.and the indications shall Thereafter be used to check the control system as follows: Material shall be feed as in normal operation through the feeder and the steadiness of The feed maintained by the control as indicated by the indication system shall be noted periodically manually. This test shall be continued till is necessary to interrupt the flow of material for carrying out test 2 (a) at 12 hours,and recommenced immediately thereafter. Should it not be possible to conduct the tests specified herein for any reason not attributable to the supplier, within 30 days from the supplier having given their readiness To carry out such tests to the purchaser,in writing,the tests shall be deemed to have been carried out and accepted. Apart from the preliminary acceptance Test for the individual equipment, the performance guarantee test shall be completed by the supplier with all weighfeeders at a time for 72 hours in continuous operation of the plant. During this test, the supplier shall show the performance guarantee figures as offered By them and should they fail to do so, on of faulty design or defects in manufacturing of the equipment, the necessary changes / modifications shall be carried Out by them to comply with the offered quarantee figures, free of cost,without which the system shall not be accepted by the purchaser.
FLSmidth Pfister India Ltd.
ERECTION INSTRUCTION MANUAL FOR WEIGH FEEDER ERECTION QUALITY CONTROL PLAN FOR WEIGH FEEDER Sr.no.
Desciption
Responsibility
1
Supervisory staff should be well trained in enforcing Erection safety regulation & be able to distinguish safe unsafe Contractor workmanship.
2
While engaging men for the job the supervisor should check up & make sure that they are skilled in the particular job they have to perfor
3
Package & equipment should be check for damage during transit.
4
Quantity should be checked as per packing list to ensure completeness of supply.
5
Special care should be taken so as to avoid the damage to the load sensing mechanism of supplied equipment.
6
All the points mentioned in the erection manual for weigh feeder & belt weighers should be complied with Wire rope,clams, lifting tackles should be inspected for their condition before used.
7
8
The safe working load of the ropes, tackles needed to lift the weighfeeder & belt weigher should never be exceeded.
9
When moving the weigh feeder, belt weigher in to place the area should be cordoned off to prevent persons from hitting against structural component etc.
FLSmidth Pfister India Ltd.
ERECTION INSTRUCTION MANUAL FOR WEIGH FEEDER During transit the storage of equipment after it has reached at site considerable dust & foreign material may have lodged on the various parts of the weigh feeder. All parts / assembled unit must be cleaned & checked with grat care before commencing erection. It is necessary to remove the anti-rust coat given on the machined surfaces. Check all the bolts & nuts for their tightness as there is possibility of nuts getting loose during transit & handling. Though all parts are inspected & duly packed while dispatching from works. There is possibility of damage to the machined portions during transit. Hence following checks should be made before commencing the installation: 1) All the mating surfaces fit properly. 2) While assembling do not apply undue force. 3) Avoid use of hammer. 4) Ensure perfect matching of surfaces. 5) Take care that no part is left out through over sight. Every single item, however small has an importance in the proper functioning of the equipment. 6) Take care that no foreign substance is dropped or left inside. They will get stuck up & cause jamming. 7) all tools are kept ready on h & before starting the erection. General arrangement drawing should be referred to during erection. 8) Erection should be done by experienced personnel.
FLSmidth Pfister India Ltd.
ERECTION INSTRUCTION MANUAL FOR WEIGH FEEDER ERECTION SHOULD BE CARRIED OUT CONSIDERING THE FOLLOWING: 1) The floor on which weigh feeder is to be installed should be properly leveled & foundation should be correctly marked. all levels should tally with general arrangement drawing of the equipment. 2) Check that weigh feeder assembly frame assembly is perfectly aligned & correctly leveled, before clamping to the foundation plate at four places. 3) Ensure that all carring idlers at the top & return idlers at bottom, these set are correctly mounted & that all the rollers are rotating freely. 4) Ensure that the self aligning idler set provided on the return side when fitted is pivoting freely. 5) Ensure that the screw take-up arrangement at the tail end is adjusted initially to remove under slack from the belt. 6) Ensure that rubber strips of skirt board, scrappers are correctly filled & adjusted, so that they touch the feeder belt. 7) Eheck that all components like motors, gearbox, couplings of drive unit are installed on the drive pulley shaft & torque arm is fixed to the main frame. 8) Ensure that electric wiring for electric motor, belt sway switch & loadcell are correctly carried out & that no loose electric connection is left out. 9) Ensure that all parts of the weigh feeder are greased or oiled as per lubrication chart given in this manual. 10) Eee that belt is not creased, folded or strained any where along the weigh feeder. 11) Check drives machinery for correct alignment. 12) Before starting the weigh feeder check motor insulation resistance. 13) Check along the length of the weigh feeder & ensure that there are no items left, lying about which could obstruct & cause damage to moving equipment. 14) check that matching flange of the infeed hopper assembly is as per the drawing requirment. 15) install the infeed hopper below material silo & above weigh feeder frame, holding on to top flange. 16) adjust the height of the gate as required through the height adjustment screws provided. 17) install discharge hood at the discharge end side of weigh feeder. FLSmidth Pfister India Ltd.
ERECTION INSTRUCTION MANUAL FOR WEIGH FEEDER LOADCELLMOUNTING PROCEDURE Load cell is mounted an angle bracket with a machined pad at its bottom as base. Weight of material on the belt is transferred to a swinging cradle and finally through a hook bolt no.-2to the load cell. The hook bolt and lode cell 1 are connected to each other through a wire rope and collect rope gripe at bolt ends. For the replacement of lode cell slacken the wire rope by loosening the nuts provided on collet gripe remove not no. 3 . Remove the collet rope gripe from the hole of lode cell. Now remove the base bolts of the lode cell and remove the same from its place. Install new lode at the same place.connect the other end of the lode cell to the hook through wire rope and firm collect wire grips. Adjust and stopper 4 so that grip face and stopper face is 0.2 mm.
FLSmidth Pfister India Ltd.
SAFETY & STORAGE MANUAL SAFETY & STORAGE MANUAL FOR WEIGH FEEDER
Sefety Note General information All work related to transport, putting in to storage, setting up/mounting Connection, start up, trained personnel observing should only perform Maintenance and repair • The corresponding detailed operating instructions and wiring diagrams, • The warning and safety sign • The specific regulations and requirements for the system and • Normal / regional regulations governing safety and prevention of accidents. Severe injuries and damage to property may result from • Incorrect use • Incorrect installation or operation • Remove of required protective covers or the housing when this is not permitted. Designated use
These equipments are intended for industrial systems. They correspond to the applicable Standards and regulations. The technical data and the information about permitted condition are to be found on the nameplate and in the documentation. It is essential that you observe all specified information!
Transportation
Inspect the delivery for any damage in transit as soon as you receive The Delivery. Inform the shipping company immediately. It maybe Necessary To preclude startup. Use suitable, sufficiently rated handling equipment if necessary. Remove any transportation fixture prior startup.
FLSmidth Pfister India Ltd.
SAFETY & STORAGE MANUAL STORAGE Comply with the storage conditions specified in the following table for Storage: Climate zone Packing 1 Storage location Storage time Temperature (Europe, USA, Canada, China and Russia, excluding tropical zones)
With roof, protected against rain and Max .3 year with regular Packed in snow, no shock loads. checks on the packaging containers, with and moisture indictor desiccant and (rel. atmospheric humidly moisture and < 50%) moisture indicator sealed in the plastic film.
Open
Tropical (Asia, Africa, central and south America, Australia , new Zealand excluding temperate zone)
With roof, enclosed, at constant temperature and atmospheric humidity (5c
2 years or more given regular inspections. And mechanical damage as part of the inspection. Check the corrosion protection as intact.
With roof, protected against, no Max. 3 yeasr with regular Packed in shock loads. checks on the packaging containers, with and moisture desiccant and indicator(rel. atmospheric moisture indicator humidity <50%) sealed in the plastic film. Protected against insect damage and mildew by chemical treatment. Open
With roof, enclosed, at constant temperature and atmospheric humidity (5c
2 year or more gave regular inspections. Check for cleanliness and mechanical damage as part of the inspection. Check the corrosion protection is intact.
1) Packing must be performed by an experienced company using the packing materials, Which have been expressly qualified for the particular application. FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR AC MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR AC MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR AC MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR AC MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR AC MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR AC MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR AC MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR AC MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR AC MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR AC MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR AC MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR AC MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR AC MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR AC MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR AC MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR AC MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR AC MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR AC MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR AC MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR AC MOTOR
FLSmidth Pfister India Ltd.
INSTALLATION & MAINTENANCE MANUAL FOR GEAR BOX
FLSmidth Pfister India Ltd.
INSTALLATION & MAINTENANCE MANUAL FOR GEAR BOX
FLSmidth Pfister India Ltd.
INSTALLATION & MAINTENANCE MANUAL FOR GEAR BOX
FLSmidth Pfister India Ltd.
INSTALLATION & MAINTENANCE MANUAL FOR GEAR BOX
FLSmidth Pfister India Ltd.
INSTALLATION & MAINTENANCE MANUAL FOR GEAR BOX
FLSmidth Pfister India Ltd.
INSTALLATION & MAINTENANCE MANUAL FOR GEAR BOX
FLSmidth Pfister India Ltd.
INSTALLATION & MAINTENANCE MANUAL FOR GEAR BOX
FLSmidth Pfister India Ltd.
INSTALLATION & MAINTENANCE MANUAL FOR GEAR BOX
FLSmidth Pfister India Ltd.
INSTALLATION & MAINTENANCE MANUAL FOR GEAR BOX
FLSmidth Pfister India Ltd.
INSTALLATION & MAINTENANCE MANUAL FOR GEAR BOX
FLSmidth Pfister India Ltd.
INSTALLATION & MAINTENANCE MANUAL FOR GEAR BOX
FLSmidth Pfister India Ltd.
INSTALLATION & MAINTENANCE MANUAL FOR GEAR BOX
FLSmidth Pfister India Ltd.
INSTALLATION & MAINTENANCE MANUAL FOR GEAR BOX
FLSmidth Pfister India Ltd.
INSTALLATION & MAINTENANCE MANUAL FOR GEAR BOX
FLSmidth Pfister India Ltd.
INSTALLATION & MAINTENANCE MANUAL FOR GEAR BOX
FLSmidth Pfister India Ltd.
INSTALLATION & MAINTENANCE MANUAL FOR GEAR BOX
FLSmidth Pfister India Ltd.
INSTALLATION & MAINTENANCE MANUAL FOR GEAR BOX
FLSmidth Pfister India Ltd.
INSTALLATION & MAINTENANCE MANUAL FOR GEAR BOX
FLSmidth Pfister India Ltd.
INSTALLATION & MAINTENANCE MANUAL FOR GEAR BOX
FLSmidth Pfister India Ltd.
INSTALLATION & MAINTENANCE MANUAL FOR GEAR BOX
FLSmidth Pfister India Ltd.
INSTALLATION & MAINTENANCE MANUAL FOR GEAR BOX
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
OPERATION & MAINTENANCE MANUAL FOR VIBRATORY MOTOR
FLSmidth Pfister India Ltd.
TACHOMETER TECHNICAL LITERATURE TACHOMETER PROBE Tachometer probe may be regarded as having three parts. 1) an oscillator 2) a trigger circuit 3) an output stage Immediately an exitation voltage is applied, oscillation begins which causes the emmission, Of a radio frequency electromagnetic sensing particular current to be drawn. The coil is wound on a ferrite core which concentrates the sensing field in the axial direction through the active face of the tachometer probe. When a metel object enters the radiated field, it absorbs energy from the field.a load is placed upon the oscillator and the output amplitude is reduced. This alters the amount of current being drawn. The trigger circuit recognises this and changes the state of the switching device in the output stage. If the metal object is removed, the oscillation will begin again, and the device will return to its orginal state. Sensor type
:-
inductive
Switching distance
:-
1.5 mm
Housing dia.
:-
6.5 mm
Voltage range
:-
5-25v dc
Switching range
:-
5 khz
Conduction type
:-
cable
Housing material
:-
metal
Length
:-
22 mm
Make
:-
pepperl + fuchs
FLSmidth Pfister India Ltd.
LOADCELL SPECIFICATION
FLSmidth Pfister India Ltd.
LOADCELL SPECIFICATION
FLSmidth Pfister India Ltd.
LOADCELL SPECIFICATION
FLSmidth Pfister India Ltd.
DATA SHEET
FLSmidth Pfister India Ltd.
ELECTRICAL DRAWING
ELECTRICAL DRAWING
FLSmidth Pfister India Ltd.
ELECTRICAL DOCUMENTATION FOR WEIGH FEEDER
ELECTRICAL DRAWINGS -R0 DETAIL ELECTRICAL DRAWINGS R0 TERMINATION DETAILS -R0 AND SPSS PROGRAM JOB NO
: 90.1291
CUSTOMER
: SAIL-ROURKELA STEEL PLANT
PROJECT
:
P.O. NO.
: 003/315/1202001030/1300300060 DTD. 01-06-2013
CATEGORY OF DRG.
REFERENCE
APPROVAL
AS BUILT
FLSMIDTH PFISTER INDIA Ltd. Mumbai - 400067, India Tel.: +91 22 67726000/2868 2311. Fax +91 2267726100
90A1291
124, ABCD, Govt.Indl. Estate, kandivli (West),
1
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TABLE OF CONTENTS PAGE NO.
PAGE DESIGNATION
=A1_FC/1
FC
DRAWING NO.
=A1_TOC/1
TABLE OF CONTENTS
----
=A1_TOC/2
TABLE OF CONTENTS
----
=A1_BAS/1
SYSTEM BLOCK DIAGRAM
011-EE01-R0
=A1_BAS/2
SINGLE LINE DIAGRAM
011-EE02-R0
=A1_BAS/3
CABLE SCHEDULE FOR
POWER CABLES
011-EE04-1-R0
=A1_BAS/4
CABLE SCHEDULE FOR
CONTROL CABLES
011-EE04-2-R0
=A1_BAS/5
CABLE SCHEDULE FOR
SCREENED CABLES
011-EE04-3-R0
=A1_BAS/6
ELECTRICS ENCLOSURE GA
011-EE05-R0
=A1_BAS/7
ELECTRICS ENCLOSURE LAYOUT
011-EE06-R0
=A1_BAS/8
ELECTRICS ENCLOSURE MOUNTING DETAILS
011-EE07-R0
=A1_BAS/9
LOCAL CONTROL STATION
011-EE09-1-R0
=A1_BAS/10
OP (OPERATORS )
011-EE09-2-R0
=A1_BAS/11
JUNCTION BOX DETAIL (BIG)
011-EE10-R0
=A1_BAS/12
TUC-6 WEIGH FEEDER
011-EE25-R0
=A1/1
ELECTRICAL WIRING DIAGRAM
011-EE16-R0
=A1/2
ELECTRICAL WIRING DIAGRAM
011-EE16-R0
=A1/3
VOLTAGE SUPPLY
011-EE16-R0
=A1/4
MCC SUPPLY
011-EE16-R0
=A1/5
UPS SUPPLY
011-EE16-R0
=A1/6
LOADCELL & TACHO
011-EE16-R0
=A1/7
ANATERFACE
011-EE16-R0
=A1/8
INPUTS E000-E003
011-EE16-R0
=A1/9
INPUTS E004-E007
011-EE16-R0
=A1/10
OUTPUTS A000-A003
011-EE16-R0
=A1/11
OUTPUTS A004-A007
011-EE16-R0
=A1/12
INPUTS E008-E011
011-EE16-R0
=A1/13
INPUTS E012-E015
011-EE16-R0
=A1/14
OUTPUTS A008-A011
011-EE16-R0
=A1/15
OUTPUTS A012-A015
011-EE16-R0
DATE
CHANGE
DATE/NAME
CHKD
NAME
18.Jun.2013
HS
ENGG
18.Jun.2013
HS
CHKD
18.Jun.2013
HS
DRN
18.Jun.2013
HS
WEIGH FEEDER CUSTOMER: PROJECT: CONSULTANT:
SAIL-ROURKELA STEEL PLANT
TITLE:
TABLE OF CONTENTS
= A1_TOC
DRG.NO.: 90.1291
+
- ----
90A1291
APPROVED BY
SHEET 1 2
1
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14
TABLE OF CONTENTS PAGE NO.
PAGE DESIGNATION
DRAWING NO.
=A1/16
OUTPUTS A016-A019
011-EE16-R0
=A1/17
INVERTER
011-EE16-R0
=A1/18
AC INVERTOR
011-EE16-R0
=A1/19
VIB MOTOR
011-EE16-R0
=A1_TER/1
=A1-X9
011-EE17-R0
=A1_TER/2
=A1-X10
011-EE17-R0
=A1_TER/3
=A1-X11
011-EE17-R0
=A1_TER/4
=A1-X12
011-EE17-R0
=A1_TER/5
=A1-X13
011-EE17-R0
=A1_TER/6
=A1-LCS-X14
011-EE17-R0
=A1_TER/7
=A1-JB1-X15
011-EE17-R0
=A1_TER/8
=A1-X21
011-EE17-R0
=A1_TER/9
=A1-X22
011-EE17-R0
=A1_TER/10
=A1-X23
011-EE17-R0
=A1_TER/11
=A1-LCS-X41
011-EE17-R0
=A1_TER/12
=A1-OP-X42
011-EE17-R0
=A1_TER/13
=A1-OP-X43
011-EE17-R0
=A1_BOM/1
BILL OF MATERIALS
011-EE03-R0
=A1_BOM/2
BILL OF MATERIALS
011-EE03-R0
=A1_BOM/3
BILL OF MATERIALS
011-EE03-R0
DATE
CHANGE
DATE/NAME
CHKD
NAME
18.Jun.2013
HS
ENGG
18.Jun.2013
HS
CHKD
18.Jun.2013
HS
DRN
18.Jun.2013
HS
WEIGH FEEDER CUSTOMER: PROJECT: CONSULTANT:
SAIL-ROURKELA STEEL PLANT
TITLE:
TABLE OF CONTENTS
= A1_TOC
DRG.NO.: 90.1291
+
- ----
90A1291
APPROVED BY
SHEET 2 2
1
2
3
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1. INPUTS /OUTPUTS OF WF. OUTPUTS : RELAY S MAX. 220V./5A LOAD INPUTS
14
13
EPT. NO.
MATERIAL
CAPACITY
WF-01
LIMESTONE &
60 TPH
DOLOMITE
: 220VAC
1. CONTROL CABLES TO & FROM CUSTOMER'S CAN BE COMBINED TOGETHER HOWEVER 4-20mA SIGNALS CABLES ARE SEPERATE. 3. * FLSMIDTH PFISTER (FPIL) SCOPE VM
HOPPER OPERATOR
LCS ZSS T
WF
/
/
BELT TRACKING S2
S1 *WC 01
LOADCELL
*WCS 02
*WC 02
*WC 06
*WC 08
*WCS 01
T
/
M
/
TACHO
JUNCTION BOX (JB1)
WC 12
WC 10
WC 11
WCS 10
WC 05
WCS 08
WC 07 WCS 09
*WCS 04
*WCS 03
WP 02
WP 03
AT FIELD
ELECTRICS ENCLOSURE WITH
DATE
CHANGE
DATE/NAME
CHKD
NAME
18.Jun.2013
HS
ENGG
18.Jun.2013
HS
CHKD
18.Jun.2013
HS
DRN
18.Jun.2013
HS
WEIGH FEEDER CUSTOMER: PROJECT: CONSULTANT:
SAIL-ROURKELA STEEL PLANT
4-20mA ISO O/P à MOTOR CURRENT
WCS 07 = A1_BAS
SYSTEM BLOCK DIAGRAM
DRG.NO.: 90.1291
PLC/DCS CUSTOMER
+
- 011-EE01-R0
90A1291
WCS 06
WCS 05 TITLE:
4-20mA ISO I/P à SET POINT
WF ON
(CUSTOMER)
4-20mA ISO O/P à FEEDRATE
MCC
START/STOP
3í SUPPLY
(CUSTOMERS)
VIB ON
50 Hz ñ3%
UPS
WC 04
WC 03
415 V ñ10%
50 Hz
REMOTE SEL
220 V ñ5%
GENERAL FAULT
WP 01
WP 04
TUC-6 ELECTRONICS
SHEET 1 12
2
3
5
4
MCC/UPS (CUSTOMER)
6
8
7
9
10
11
12
13
14
415 V ñ10% 50 Hz ñ3%
UPS SUPPLY
1
3í SUPPLY 4 KW.
220 V ñ10% 50 Hz ñ3%
3
Q1
TX1
ELECTRIC ENCLOSURE
2
I >
F1
2
Fb I
> >
I
> >
Fa
2
K1 U1
Fc
I >
F2
2
~ ~
I
~ ~
CONTROL SUPPLY
K4
2
220V AC
L2
K2
ILLUMINATION
U3
220V AC
U2
FIELD
K3
~ ~
> >
-
TUC-6
2
M ~
M ~
WF MOTOR - M1
VIB MOTOR - M2
PW-2.2 KW
PW-0.27 KW
4POLE
2POLE
1500RPM
3000RPM
IL-4.4 AMPS
IL-0.52 AMPS
90A1291
NOTE: ACTUAL DISTANCE BETWEEN AND MOTOR IS MAX. 250 MTRS.
DATE
CHANGE
DATE/NAME
CHKD
NAME
18.Jun.2013
HS
ENGG
18.Jun.2013
HS
CHKD
18.Jun.2013
HS
DRN
18.Jun.2013
HS
WEIGH FEEDER CUSTOMER: PROJECT: CONSULTANT:
SAIL-ROURKELA STEEL PLANT
TITLE:
= A1_BAS
SINGLE LINE DIAGRAM
DRG.NO.: 90.1291
+
- 011-EE02-R0
SHEET 2 12
6
8
7
01
WP 01
ELECT. ENCL
MCC
13
YWY
14
3x50
3x35
3x25
4x10
4x6
4x4
3x16
3x4
3x2.5
3x1.5
3x6
YWY
YWY
REMARKS
1
INCOMER
415VAC
1
WF MOTOR
1
VIB MOTOR
1
INCOMER
CUSTOMER
03
WP 03
ELECT. ENCL FIELD
CUSTOMER
04
WP 04
MCC
CUSTOMER
415VAC
220VAC
90A1291
ELECT. ENCL
12
415VAC
ELECT. ENCL FIELD
WF-01
11
CUSTOMER
WP 02
02
YWY
2x50
SCOPE
2x35
TO
2x6
FROM
2x4
NO.
2x2.5
CABLE.
NO.
2x1.5
EQUIP.
OPERATING VOLTAGE
NO.
10
2 CABLE TYPE NO. OF LEADS x AREA IN mm
CABLE SR.
9
NO.OF RUNS
5
4
2x25
3
2x16
2
2x10
1
DATE
CHANGE
DATE/NAME
CHKD
NAME
18.Jun.2013
HS
ENGG
18.Jun.2013
HS
CHKD
18.Jun.2013
HS
DRN
18.Jun.2013
HS
WEIGH FEEDER CUSTOMER: PROJECT: CONSULTANT:
SAIL-ROURKELA STEEL PLANT
TITLE:
CABLE SCHEDULE FOR POWER CABLES
= A1_BAS
DRG.NO.: 90.1291
+
- 011-EE04-1-R0
SHEET 3 12
5
6
8
7
11
12
14
13
NO.OF RUNS
YWY
-----
-----
-----
-----
-----
-----
-----
2x1.5
-----
22x1.5
16x1.5
18x1.5
YY 14x1.5
SCOPE
5x1.5
TO
FROM
4x1.5
NO.
3x1.5
CABLE.
NO.
2x1.5
EQUIP.
OPERATING VOLTAGE
NO.
10
2 CABLE TYPE NO. OF LEADS x AREA IN mm
CABLE SR.
9
12x1.5
4
10x1.5
3
8x1.5
2
6x1.5
1
REMARKS
JB1
FPIL
220 VAC
1
BELT SWAY (L)
JB1
FPIL
220 VAC
1
BELT SWAY (R)
*
1
DIGITAL O/P
220VAC
1
DIGITAL I/P
----
1
CONTROLS
WC 01
FIELD
WC 02
FIELD
03
WC 03
EE
04
WC 04
PLC/DCS
EE
CUSTOMER
05
WC 05
LCS
EE
CUSTOMER
06
WC 06
FIELD
JB1
07
WC 07
JB1
LCS
CUSTOMER
220 VAC
1
BSS,ZSS, FLAP TYPE. SW
08
WC 08
FIELD
JB1
FPIL
220 VAC
1
FLAP TYPE SW.
09
WC 10
OPERATOR
EE
CUSTOMER
220 VAC
1
DIGITAL I/P
1
SUPPLY 220VAC
1
BC117 ILK(CUS)
01 02
WF-01
10 11
CUSTOMER
PLC/DCS
1
220 VAC
FPIL
WC 11
OPERATOR
EE
CUSTOMER
220 VAC
WC 12
OPERATOR
EE
CUSTOMER
220 VAC
ZSS
YWY - ARMOURED CABLE YY - UNARMOURED CABLE * - POTENTIAL FREE
90A1291
JB-JUNCTION BOX EE-ELEC.ENGG DATE
CHANGE
DATE/NAME
CHKD
NAME
18.Jun.2013
HS
ENGG
18.Jun.2013
HS
CHKD
18.Jun.2013
HS
DRN
18.Jun.2013
HS
WEIGH FEEDER CUSTOMER: PROJECT: CONSULTANT:
SAIL-ROURKELA STEEL PLANT
TITLE:
CABLE SCHEDULE FOR CONTROL CABLES
= A1_BAS
DRG.NO.: 90.1291
+
- 011-EE04-2-R0
SHEET 4 12
5
6
8
7
WCS 01
FIELD
WCS 02
FIELD
WCS 03
JB1
04
WCS 04
JB1
05
WCS 05
EE
06
WCS 06
PLC/DCS
07
WCS 07
EE
01 02 03
WF-01
08
WCS 08
EE
09
WCS 09
EE
10
11
12
14
13
NO.OF RUNS
-----
-----
-----
-----
-----
-----
4x0.35++
2x0.35++
24x0.75
YY 19x0.75
14x0.75
16x0.75
YWY 12x0.75
SCOPE
REMARKS
JB1
FPIL
8.2V
1
TACHO
JB1
FPIL
12V
1
LOADCELL
EE
FPIL
8.2V
1
TACHO
EE
FPIL
12V
1
LOADCELL
CUSTOMER
----
1
4-20mA ISO O/P à FEEDRATE
CUSTOMER
----
1
4-20mA ISO I/P à SET POINT
CUSTOMER
----
1
CUSTOMER
----
1
FEEDRATE DISPLAY
CUSTOMER
----
1
FEEDRATE SET
CUSTOMER
----
1
FEEDRATE SET
PLC/DCS
EE PLC/DCS OPERATOR
LCS OPERATOR
EE
WCS 10
TO
4x0.35++
FROM
3x0.75
NO.
2x0.75
CABLE.
NO.
2x0.35++
EQUIP.
OPERATING VOLTAGE
NO.
10
2 CABLE TYPE NO. OF LEADS x AREA IN mm
CABLE SR.
9
10x0.75
4
7x0.75
3
6x0.75
2
4x0.75
1
4-20mA ISO O/P à MOTOR CURRENT
YY - UNARMOURED CABLE YWY - ARMOURED CABLE EE - ELECTRIC ENCLOSURE
90A1291
JB-JUNCTION BOX ++ INTEGRAL CABLE SUPPLIED WITH LOADCELL & TACHO DATE
CHANGE
DATE/NAME
CHKD
NAME
18.Jun.2013
HS
ENGG
18.Jun.2013
HS
CHKD
18.Jun.2013
HS
DRN
18.Jun.2013
HS
WEIGH FEEDER CUSTOMER: PROJECT: CONSULTANT:
SAIL-ROURKELA STEEL PLANT
TITLE:
CABLE SCHEDULE FOR SCREENED CABLES
= A1_BAS
DRG.NO.: 90.1291
+
- 011-EE04-3-R0
SHEET 5 12
1
2
3
5
4
6
8
7
9
10
11
12
13
14
NOTE
1) MAX. FLOOR OPENING FOR CABLE : - 630 mm x 350 mm NAME PLATE
2) DESIGN FEATURES : - FRONT SIDE WITH SWIVEL DOOR.
TUC-6
- REAR SIDE FIXED ON BOLTS.
INVERTER DISPLAY
- PROTECTION SYSTEM IP54 WITH DOORS CLOSED. - INLINE INSTALLATION. - GLAND PLATES:- DRILLED GLAND HOLES WITH 1800
WF ON
BC 117 RUN
DOOR LOCK
2 WAY SEL. SW. 4 WAY SEL. SW.
BLANKING PLUGS.
2000
LABEL
3) SHEET THICKNESS :
POWER ON
- FRONT DOOR
- 2.0 mm THK.
- SIDE COVERS
- 1.6 mm THK
DOOR ISOLATOR
4) WEIGHT :-
200
- APPROX. 200 KGS.
100
1000 (MIN)
600
25
100
MAINTENANCE SPACE REQD.
800
5) SURFACE PROTECTION : INSIDE & OUTSIDE
2 N0S EARTHING BOLT (M10)
POWDER COAT 460
(STRUCTURE FINISH)
500
AS PER SHADE NO. RAL 7035
SPACE FOR CABLES RUNNING ACROSS
BASE - AS PER IS:5 - DARK BLACK 6) PACKED SIZE: - 880 mm x 590 mm x 2110 mm.
DATE/NAME
CHKD
8) TOTAL NO OF SIDE COVER 2 NOS./ PROVIDED 9) EARTHING BOLT - 2 NOS./ PROVIDED.
SPACE REQD.
QTY.: 1 NO.
90A1291
DATE
CHANGE
1000 (MIN) MAINTENANCE
30
MAX. FRONT 70 PROJECTION 70 mm.
14í HOLE 4 NOS
500
420
7) ALL DIMENSIONS ARE IN `MM'.
NAME
18.Jun.2013
HS
ENGG
18.Jun.2013
HS
CHKD
18.Jun.2013
HS
DRN
18.Jun.2013
HS
WEIGH FEEDER CUSTOMER: PROJECT: CONSULTANT:
SAIL-ROURKELA STEEL PLANT
TITLE:
ELECTRICS ENCLOSURE GA
= A1_BAS
DRG.NO.: 90.1291
+
- 011-EE05-R0
SHEET 6 12
1
2
3
5
4
6
8
7
9
10
11
12
13
14
SIDE
(MIN)
(MIN)
(MIN)
2.5 Mtr
1 Mtr.
EE01
500
1 Mtr.
(MIN)
1 Mtr.
COVER (1 NO)
FRONT 1 Mtr
SIDE COVER (1 NO)
0.8 Mtr
2.8 Mtr.(MIN.)
NOTE:
2) ACTUAL LAYOUT TO BE DECIDE BY CUSTOMER DATE
CHANGE
DATE/NAME
CHKD
NAME
18.Jun.2013
HS
ENGG
18.Jun.2013
HS
CHKD
18.Jun.2013
HS
DRN
18.Jun.2013
HS
WEIGH FEEDER CUSTOMER: PROJECT: CONSULTANT:
SAIL-ROURKELA STEEL PLANT
TITLE:
= A1_BAS
ELECTRICS ENCLOSURE LAYOUT
DRG.NO.: 90.1291
+
- 011-EE06-R0
SHEET 7 12
90A1291
1) TYPICAL LAYOUT DRAWING FOR REFERENCE
1
2
3
5
4
6
8
7
9
10
11
12
14
13
A 400
- ALL DIMENSIONS ARE IN MM.
400 OF C L
50 x 50 x 6 THK. 100
MOUNTING DETAILS
100
(BY CUSTOMER)
FIELD WELD (TYP.) (NO WELDING ON
- ELECT.ENCLOSURE 1 NO.
470
420 (CRS)
25
600 (TYP)
- TYPICAL ELECT.ENCLOSURE
ELECTRICS ENCL.
8, SLOT HOLES í14 x 50 LG.
300
300
TYP
TYP
25
TOP FACE)
800 A
FLOOR CUT-OUT(TYP.)
ANGLE FRAME
630 x 350
80
470
5
420 CRS
45 ANGLE FRAME
630 (TYP)
85
400
5 THK.PLATE
350
470
M-10 EARTHING BOLTS 2 NOS.@500 CRS.ON EACH
75
BASE.FR
350 TYP.
ELECTRICS ENCLOSURE
FRONT
200
75
ANGLE FRAME DETAIL
(FLR.CUT-OUT)
85
400
FLOOR CUT-OUT DETAIL 90A1291
SEC.- AA
DATE
CHANGE
DATE/NAME
CHKD
NAME
18.Jun.2013
HS
ENGG
18.Jun.2013
HS
CHKD
18.Jun.2013
HS
DRN
18.Jun.2013
HS
WEIGH FEEDER CUSTOMER: PROJECT: CONSULTANT:
SAIL-ROURKELA STEEL PLANT
TITLE:
= A1_BAS
ELECTRICS ENCLOSURE MOUNTING DETAILS
DRG.NO.: 90.1291
+
- 011-EE07-R0
SHEET 8 12
1
2
3
5
4
6
8
7
9
10
11
12
13
14
EMERGENCY STOP
4 NOS. í10 HOLES FOR
NOTE:1) ALL DIMENSION ARE IN MM.
MTG. WITH M8 BOLT
2) DOUBLE DOOR ENCLOSURE WITH ALL SWITCHES AND INDICATIONS MOUNTED ON INNER DOOR, ACRYLIC WINDOW AND DOOR LOCK ON OUTER DOOR,
75
EMERGENCY OFF MOUNTED ON RIGHT SIDE. 3) GLAND PLATE :- DRILLED GLAND HOLES WITH
S3
BLANKING PLUGS. 4) SHEET THICKNESS : - 1.5 mm DOOR
120
- 1.38mm REST
L1
LOCK
320(CTC)
5) WEIGHT :
295
300
L2 VIB ON VIB OFF
- APPROX. 10 KGS. 6) SURFACE PROTECTION : - OUTSIDE & INSIDE EPOXY POWDER COAT-
65 S1
S2
S4
(STRUCTURE FINISH) AS PER SHADE NO. RAL 7035
P1 7)
PROTECTION/CLASS : IP55
55
8) PACKED SIZE: - 250mm x 340 mm x 440 mm.
9) MAINTENANCE SPACE REQUIRED:
LCS IDENTIFICATION LABEL
- 1.5 m. IN FRONT - 1.0 m. AT SIDES
175 (CTC)
360 (CTC)
QTY.- 1 NO.
220 .
400
EARTHING
CONTROLS/INDICATIONS
C L OF CABLE ENTRY
BOLTS M6 2 NOS.
S1
START - TEKNIC MAKE.
S2
STOP - TEKNIC MAKE.
S3
EMG OFF. TEKNIC MAKE
S4
VIB ON/OFF SWITCH- TEKNIC MAKE
L1
BELT RUN LAMP - TEKNIC MAKE.
L2
VIB ON LAMP - TEKNIC MAKE. FEEDRATE POT(10 TURNS) - BOURNS MAKE 90A1291
P1
DATE
CHANGE
DATE/NAME
CHKD
NAME
18.Jun.2013
HS
ENGG
18.Jun.2013
HS
CHKD
18.Jun.2013
HS
DRN
18.Jun.2013
HS
WEIGH FEEDER CUSTOMER: PROJECT: CONSULTANT:
SAIL-ROURKELA STEEL PLANT
TITLE:
= A1_BAS
LOCAL CONTROL STATION
DRG.NO.: 90.1291
+
- 011-EE09-1-R0
SHEET 9 12
1
2
3
5
4
6
8
7
9
10
11
12
4 NOS. í10 HOLES FOR
13
14
NOTE:1) ALL DIMENSION ARE IN MM.
MTG. WITH M8 BOLT
2) DOUBLE DOOR ENCLOSURE WITH ALL SWITCHES AND INDICATIONS MOUNTED ON INNER DOOR, ACRYLIC WINDOW AND DOOR LOCK ON OUTER DOOR,
3) GLAND PLATE :- DRILLED GLAND HOLES WITH BLANKING PLUGS. 4) SHEET THICKNESS : DPM
- 1.5 mm DOOR - 1.38mm REST
D1
LOCK
320(CTC)
5) WEIGHT :
295
300
- APPROX. 10 KGS. 6) SURFACE PROTECTION : - OUTSIDE & INSIDE EPOXY POWDER COAT-
65 S1-1
S2-1
(STRUCTURE FINISH) AS PER SHADE NO. RAL 7035
P1 7)
PROTECTION/CLASS : IP55
55
8) PACKED SIZE: - 250mm x 340 mm x 440 mm.
9) MAINTENANCE SPACE REQUIRED:
LCS IDENTIFICATION LABEL
- 1.5 m. IN FRONT - 1.0 m. AT SIDES
175 (CTC)
360 (CTC)
QTY.- 1 NO.
220 .
400
EARTHING
CONTROLS/INDICATIONS
C L OF CABLE ENTRY
BOLTS M6 2 NOS.
S1-1
START/STOP SWITCH- TEKNIC MAKE
S2-1
FAULT RESET PB- TEKNIC MAKE
P1-1
FEEDRATE POT(10 TURNS) - BOURNS MAKE
FEEDRATE INDICATOR (DPM) - TRANSWEIGH MAKE 90A1291
D1
DATE
CHANGE
DATE/NAME
CHKD
NAME
18.Jun.2013
HS
ENGG
18.Jun.2013
HS
CHKD
18.Jun.2013
HS
DRN
18.Jun.2013
HS
WEIGH FEEDER CUSTOMER: PROJECT: CONSULTANT:
SAIL-ROURKELA STEEL PLANT
TITLE:
= A1_BAS
OP (OPERATORS )
DRG.NO.: 90.1291
+
- 011-EE09-2-R0
SHEET 10 12
1
2
3
5
4
6
8
7
9
10
11
12
13
14
247 225 200
BACKGROUND / OUTER SURF. COLOUR - RAL 7035
30
45
160
200 45
45
45
45
45 45
30
45
35
í6.5 EARTHING BOLT (2 nos)
í22.5 HOLE FOR
83.14
83.14
120
CABLE GLAND (3 Nos.)
120 M5, SCREW (4 nos) FOR COVER FITTING
í22.5 HOLE FOR CONDUIT GLAND (6 Nos.)
LABEL DETAIL
M6 SCREW (4 nos)
(ON COVER)
FOR JB MTG.
QTY : 1 NO. NOTE: 1. OVERALL DIMENSIONS : 120
200.0 W x 200.0 HT. x 120.0 D 2. WEIGHT :
2.05 KGS.
3. MATERIAL SPECIFICATION : CRCA SHEET 1.5 mm THK. 4. SURFACE : POWDER COAT RAL 7035 5. PROTECTION CLASS :
IP 65
6. ALL UNUSED HOLES WILL BE PLUGGED.
90A1291
7. ALL DIMENSION ARE IN `MM'
DATE
CHANGE
DATE/NAME
CHKD
NAME
18.Jun.2013
HS
ENGG
18.Jun.2013
HS
CHKD
18.Jun.2013
HS
DRN
18.Jun.2013
HS
WEIGH FEEDER CUSTOMER: PROJECT: CONSULTANT:
SAIL-ROURKELA STEEL PLANT
TITLE:
= A1_BAS
JUNCTION BOX DETAIL (BIG)
DRG.NO.: 90.1291
+
- 011-EE10-R0
SHEET 11 12
1
2
3
5
4
6
7
8
9
10
11
12
14
13
245
62
144 5
1
TRANSWEIGH
TUC-6
2 D
4
X I
T
5
L
N
6
2 M
8
7
VFD DISPLAY
3
1 E
O
P
O --
9
72
W A
0
CL *
SET R
S
T
U
ESC
=
WEIGHT 2.0 Kgs (approx.)
ELEVATION
SIDE VIEW
QTY : 1 NO.
CUTOUT 138.0 mm x 68.0 mm
NOTE:
- ALL DIMENSIONS ARE IN MM.
90A1291
MOUNTING
DATE
CHANGE
DATE/NAME
CHKD
NAME
18.Jun.2013
HS
ENGG
18.Jun.2013
HS
CHKD
18.Jun.2013
HS
DRN
18.Jun.2013
HS
WEIGH FEEDER CUSTOMER: PROJECT: CONSULTANT:
SAIL-ROURKELA STEEL PLANT
TITLE:
TUC-6 WEIGH FEEDER
= A1_BAS
DRG.NO.: 90.1291
+
- 011-EE25-R0
SHEET 12 12
2
3
5
4
6
7
8
9
10
11
12
13
CUSTOMER
:
SAIL - ROUREKLA STEEL PLANT
TITLE
:
WEIGH FEEDER
DRG. NO
:
90.1291-011-EE16-R0
QTY.
:
1 NO.
EQPT. NO. :
WF-01
14
90A1291
1
DATE
CHANGE
DATE/NAME
CHKD
NAME
18.Jun.2013
HS
ENGG
18.Jun.2013
HS
CHKD
18.Jun.2013
HS
DRN
18.Jun.2013
HS
WEIGH FEEDER CUSTOMER: PROJECT: CONSULTANT:
SAIL-ROURKELA STEEL PLANT
TITLE:
= A1
ELECTRICAL WIRING DIAGRAM
DRG.NO.: 90.1291
+
- 011-EE16-R0
SHEET 1 19
1
2
3
5
4
6
7
8
9
10
11
EQPT. NO.
MATERIAL
WF-01
LIMESTONE & 60 TPH
12
13
14
REVISED REV
SHEET NAME
DATE
KIND OF REVISION
NAME
CAPACITY QTY. 1 NO.
DOLOMITE
WIRING COLOR CODE COLOR
415V -
BLACK
(L1, L2, L3)
220/110VAC
RED
(PHASE/NEUTRAL)
24VDC
GREY BLACK
(+VE) (-VE)
EARTHING
YELLOW / GREEN
POT. FREE.
BLUE
90A1291
VOLTAGE
DATE
CHANGE
DATE/NAME
CHKD
NAME
18.Jun.2013
HS
ENGG
18.Jun.2013
HS
CHKD
18.Jun.2013
HS
DRN
18.Jun.2013
HS
WEIGH FEEDER CUSTOMER: PROJECT: CONSULTANT:
SAIL-ROURKELA STEEL PLANT
TITLE:
= A1
ELECTRICAL WIRING DIAGRAM
DRG.NO.: 90.1291
+
- 011-EE16-R0
SHEET 2 19
1
2
3
5
4
6
8
7
9
10
11
12
14
13
MCC POWER SUPPLY 415 V ñ10% 50 Hz ñ3% 3í SUPPLY R
Y
B
E
WP01 3x4
L3 X13
1
2
3
E
LAMP
L N
S1
1 2
1
3
5
2
4
6
S2 DOORLIMIT SWITCH
Q1 32Amps
E/4.12
L2
L1 P S
0V
4
2
3
1
Fb
TX1
1 Amp.
415V I/P 220V O/P @ 1 Amp.
1L
P/4.2 220vac
1
LP1 2
N/4.2
L3.1/19.3 L2.1/19.3 L1.1/19.3 L3/18.5 L2/18.5
DATE
CHANGE
DATE/NAME
CHKD
NAME
18.Jun.2013
HS
ENGG
18.Jun.2013
HS
CHKD
18.Jun.2013
HS
DRN
18.Jun.2013
HS
WEIGH FEEDER CUSTOMER: PROJECT: CONSULTANT:
SAIL-ROURKELA STEEL PLANT
TITLE:
VOLTAGE SUPPLY
= A1
DRG.NO.: 90.1291
+
- 011-EE16-R0
90A1291
L1/18.5
SHEET 3 19
2
3
5
4
6
220VAC
3.13
3.13
P
N
X6
E
X6
X6
X6 1
3
2
4
Fc 1 Amp.
X6
X6
X6
X6
X6
X6
N
X6
N
X6
N
X6
N
X6
N
7
8
9
10
11
12
14
13
220N1.10/12.9 220N1.9/12.2
P
220P1.9/12.2 220N1.8/9.8
P
220P1.8/9.8 220N1.7/7.11
P
220P1.7/7.11 220N1.6/10.12
P
220P1.6/10.12 X6
N
X6
N
X6
N
220N1.5/17.3
220N1.4/16.11
P
220P1.4/16.11 220N1.3/12.13
P
220P1.3/12.13 X6
N
X6
N
X6
N
220N1.2/12.10
P
220P1.2/12.10 220N1.1/9.4
P
220P1.1/10.5 220N/8.3 POWER SUPPLY 220 VAC
P
220P/8.3
90A1291
1
E/3.4 DATE
CHANGE
DATE/NAME
CHKD
NAME
18.Jun.2013
HS
ENGG
18.Jun.2013
HS
CHKD
18.Jun.2013
HS
DRN
18.Jun.2013
HS
WEIGH FEEDER CUSTOMER: PROJECT: CONSULTANT:
SAIL-ROURKELA STEEL PLANT
TITLE:
MCC SUPPLY
= A1
DRG.NO.: 90.1291
+
- 011-EE16-R0
SHEET 4 19
1
2
3
5
4
6
8
7
9
10
11
12
14
13
UPS SUPPLY 220 VAC ñ3% 50 Hz
L
N
WP04 2x2.5
X13
10
U3
11
220VAC N
V-
1
3
Fa 1 Amp.
2
4
X4
N
X4
P
L
24VDC @2.2Amps.
X5
P
X5
N
X5
P
X5
N
X5
P
X5
N
X5
P
X5
N
24P.4/12.2 24N.4 24P.3/12.4 24N.3/12.4 24P.2/8.6 24N.2/8.6 24P.1/7.2 24N.1/7.2
V+
24P/6.3
POWER SUPPLY +24V DC
24N/6.3
WCSX-1 2X0.75
N
X4
P
X4
N
X4
P
N1.1/18.9
POWER SUPPLY 220 VAC
P1.1/18.9
N1/7.3 P1/7.3 90A1291
X4
DATE
CHANGE
DATE/NAME
CHKD
NAME
18.Jun.2013
HS
ENGG
18.Jun.2013
HS
CHKD
18.Jun.2013
HS
DRN
18.Jun.2013
HS
WEIGH FEEDER CUSTOMER: PROJECT: CONSULTANT:
SAIL-ROURKELA STEEL PLANT
TITLE:
UPS SUPPLY
= A1
DRG.NO.: 90.1291
+
- 011-EE16-R0
SHEET 5 19
1
2
3
5
4
6
8
7
9
10
11
12
13
14
UPS SUPLLY
5.12/24N 5.12/24P
24V DC
X11
5
7
3
4
6
X1:12
SIGNAL X1:11
X1:10
+12V
SUPPLY X3:9
X3:8
SENSE -
SIGNAL X3:6
SENSE + X3:4 2
X3:2
X1:3
SUPPLY +
X1:2
X3:1
X1:1
X3:5
TUC-6
SIGNAL +
U2 7.1 16.2 17.10
WCSB
WCSC
6x0.35
2x0.35
1
8
9
10
WCS04
WCS03
6x0.75
2x0.75
JB1
X15
5
2
7
3
4
A
D
B
C
6
1
8
9
10
WCS02
WCS01
4x0.35
2x0.35
-LC1
DATE
CHANGE
DATE/NAME
CHKD
NAME HS
ENGG
18.Jun.2013
HS
CHKD
18.Jun.2013
HS
DRN
18.Jun.2013
HS
WEIGH FEEDER CUSTOMER: PROJECT: CONSULTANT:
SAIL-ROURKELA STEEL PLANT
90A1291
FIELD
FIELD
18.Jun.2013
TACHO WF
TITLE:
LOADCELL & TACHO
= A1
DRG.NO.: 90.1291
+
- 011-EE16-R0
SHEET 6 19
1
2
3
5
4
PLC/DCS
6
OP
(CUSTOMER)
3
à SET POINT
WCS06
X9
1
2
SUPLLY
5.12/N1
N
E
I/P+
5
6
7
14
13
FEEDRATE INDICATOR
OP
9
4-20mA ISO O/P
10
D1
à ACTUAL FEEDRATE 2
1 WCSD
OPERATOR
2x0.35
I/P-
WCS10
WCS05
3x0.75
2x0.75
I/V O/P+
4
3
U8 L
12
3x0.35
X43
5.12/P1
11
OPERATOR
WCSK-1
2x0.75
10
(CUSTOMER)
1 VOLUME SETPOINT
2
9
PLC/DCS P1.1
4-20mA ISO I/P
UPS
8
7
X9
O/P-
4
5
6
X9
X42 7
8
1
X43
2
1
2
3
1
2
3
9 WC11
220VAC
2x1.5 WCS08 2x0.75 500ê
5.12
K5
500ê
12.9
SUPLLY
24
23
K6
UPS
WCSE2-1 2x0.35
12.12
5.12
24P.1 24N.1 PE
23
X23
1
2
WCSL1
4.12/220P1.7
X4:3
1
2 J3
1
2 J4
AIC
3
4 J4
(F-875)
1
2 J1
0-10V
3
4 J1
4-20mA
1
2 J2
0-10V
3
4 J2
X3:4
X2:6
X3:1
4-20mA
X3:5
X3:2
WCSA
WCSA1
3x0.35
3x0.35
X2:4
X2:7
PE
X2:+5
X3:3
X1B:4
X1B:-3
X1B:+2
PE
X1A:4
X1A:-3
0-5VDC
X1A:+2
2x0.35
4.12/220N1.7
X2:1
X4:2
X2:3
X2:2
U4 X4:1
X22
24
U4:X1B:4:U5:X2A:4 /8.4 U4:X1B:3:U5:X2A:3 /8.4
DATE
CHANGE
DATE/NAME
CHKD
90A1291
TUC-6
PE
X2:5
X2:-3
6.1
X2:+2
U4:X1B:2:U5:X2A:2 /8.4 U2
X1:+13 X1:-14
NAME
18.Jun.2013
HS
ENGG
18.Jun.2013
HS
CHKD
18.Jun.2013
HS
DRN
18.Jun.2013
HS
WEIGH FEEDER CUSTOMER: PROJECT: CONSULTANT:
SAIL-ROURKELA STEEL PLANT
TITLE:
ANATERFACE
= A1
DRG.NO.: 90.1291
+
- 011-EE16-R0
SHEET 7 19
1
2
3
5
4
6
8
7
9
10
11
12
13
14
7.4/U4:X1B:4:U5:X2A:4 7.4/U4:X1B:3:U5:X2A:3 7.4/U4:X1B:2:U5:X2A:2
24N.2/5.12
24P.2/5.12
24VDC
UPS SUPLLY
E0
J1
X1:2
X1:1
DIO ( F-889)
PE
9.1 10.2 11.2
X2A:4
X2A:2+
3x0.35
U5
X2A:3-
WCSA1
E2
E1
E3 X3:E3
X3:24N
X3:24P
X3:E2
X3:24N
X3:24P
X3:E1
X3:24N
X3:24P
X3:E0
X3:24P
X3:24N
2
1
220V AC RELAY BOARD
RL1
COM
RL2
1
RL3:P
RL3:O
4 CH, 1C/O
RL2:O
RL1:P
RL1:O
9.2
RL2:P
U7:RL3:O"RL4:O U7
RL3
2
F1 18.8
220V AC
INTERLOCK
14
3
NON UPS SUPLLY
WF DRIVE
13
F2 19.8
4.12/220N
VIB DRIVE
13
INTERLOCK
14
4.12/220P
X10
1
X14
1
2
3
4
5
3
4
5
6
WC05 14x1.5
LCS 2
9.2/220PA.4 10.7/220NA.4
WC07 4x1.5
JB1
FIELD
WC06
15
16
11
12
13
WC01
1
WC02
2x1.5
2x1.5
X15
14
18 1
2x1.5
LEFT
17 WC08 2x1.5
RIGHT
2
90A1291
X15
2
BELT SWAY ZERO SPEED SW. DATE
CHANGE
DATE/NAME
CHKD
NAME
18.Jun.2013
HS
ENGG
18.Jun.2013
HS
CHKD
18.Jun.2013
HS
DRN
18.Jun.2013
HS
CUSTOMER: PROJECT: CONSULTANT:
S/W
WEIGH FEEDER
SAIL-ROURKELA STEEL PLANT
MATERIAL DETECTION . TITLE:
INPUTS E000-E003
= A1
DRG.NO.: 90.1291
+
- 011-EE16-R0
SHEET 8 19
1
2
3
5
4
6
8
7
9
10
11
12
13
14
U5:X2B:+2:U1:29 /18.5 U5:X2B:-3:U1:30 /18.5 U5:X2B:4:U1:31 /18.5
WCSG
PE
X2B:4
DIO ( F-889)
E6
X3:E7 RL1:P
RL1:O
U11 1CH, 1C/O
14
1 CH, 1C/O
220V AC
220VAC RELAY CARD
RL4
13
K6 12.9
14
RL1:P
RL1:O
RL4:P
U12 4CH, 1C/O
X3:24N
X3:24P
X3:E6
X3:24N
X3:24P
X3:E5
X3:24P
X3:E4
12.12
RL4:O
U7
13
K5
U7:RL3:O:RL4:O
8.3
E7
E5
X3:24N
X3:24P
E4
X3:24N
8.2
X2B:3-
X2B:2+
3x0.35
U5
RL1
COM
220V AC RELAY BOARD
RELAY BOARD
1
RL1
COM
1
4
4.12/220N1.8 4.12/220P1.8
X12
K4
3
220N1.1/4.12
10
1
VIB START/STOP S4
2
220PA.4/8.3
1 3 5 13 13A
2 4 6 14 14A
WC10
WC04
3x1.5
2x1.5
OP
X42
19.7 19.7 19.7 10.6 13.4
5
3
3
5
6
4
1
S2.1
4
220PA.3/17.2 VIB. ON /OFF
S1.1
START/STOP
2
FAULT RESET
START/STOP
220VAC
220VAC
DATE/NAME
CHKD
NAME
18.Jun.2013
HS
ENGG
18.Jun.2013
HS
CHKD
18.Jun.2013
HS
DRN
18.Jun.2013
HS
WEIGH FEEDER CUSTOMER: PROJECT: CONSULTANT:
SAIL-ROURKELA STEEL PLANT
BC-117 ILK
220VAC
PLC/DCS (CUSTOMER)
OPERATOR DATE
CHANGE
4
A1 A2
14x1.5
LCS
2
9
WC05
X14
1
90A1291
X10
7
TITLE:
INPUTS E004-E007
= A1
DRG.NO.: 90.1291
+
- 011-EE16-R0
SHEET 9 19
1
2
3
5
4
6
7
8
9
10
11
12
14
13
U5 DIO F-889
X5:2
X5:1
X4:3NO
X5:2
X4:2C
X5:1
A3 X4:2NO
X5:2
X5:1
X5:2
X5:1
X4:0C
A3
A2 X4:1NO
A1
X4:0NO
A0
A2
X4:3C
A1
A0
X4:1C
8.2
220N1.6/4.12 220P1.6/4.12
220VAC
NON UPS SUPLLY
4.12/220P1.1
K4 9.4
X10
13 14
10
11
11
12
1
1
WC05 14x1.5
X14
1
L1
2
LP2
L2
2
2
WF ON 220NA.4/8.3 VIB ON F/B
LCS
EE DOOR
DATE
CHANGE
DATE/NAME
CHKD
90A1291
BELT RUN F/B
LAMP
NAME
18.Jun.2013
HS
ENGG
18.Jun.2013
HS
CHKD
18.Jun.2013
HS
DRN
18.Jun.2013
HS
WEIGH FEEDER CUSTOMER: PROJECT: CONSULTANT:
SAIL-ROURKELA STEEL PLANT
TITLE:
OUTPUTS A000-A003
= A1
DRG.NO.: 90.1291
+
- 011-EE16-R0
SHEET 10 19
1
2
3
5
4
6
8
7
9
10
11
12
13
14
/12.4/ U5
X6-M
9PINDB
DIO F-889
1
2
3
4
6
7
X5:2
X5:1
X5:2
X5:1
5
X4:7C
A7
X4:6C
X5:2
X5:1
X5:2
X5:1
X4:4C
X21
A7
A6 X4:5NO
A5 X4:4NO
A4
A6
X4:7NO
A5
X4:6NO
A4
X4:5C
8.2
8
WC03 8x1.5
WF ON
PLC SEL
220VAC
220VAC
GENERAL
MATERIAL OVERLOAD
FAULT
ON BELT
PLC/DCS
90A1291
(CUSTOMER)
DATE
CHANGE
DATE/NAME
CHKD
NAME
18.Jun.2013
HS
ENGG
18.Jun.2013
HS
CHKD
18.Jun.2013
HS
DRN
18.Jun.2013
HS
WEIGH FEEDER CUSTOMER: PROJECT: CONSULTANT:
SAIL-ROURKELA STEEL PLANT
TITLE:
OUTPUTS A004-A007
= A1
DRG.NO.: 90.1291
+
- 011-EE16-R0
SHEET 11 19
1
2
3
5
4
6
8
7
9
10
11
12
13
14
/11.5/ U6
X6-F
13.1 14.1 15.2 17.9
EE
9PINDB
DIO ( F-890)
X3:E11
X3:24P
X3:E10
X3:24N
X3:24P
X3:E9
X3:24N
X3:24P
X3:E8
X3:24N
X3:24P
E11
E10
X3:24N
E9
E8
5.12/24N.3
UPS
5.12/24P.3
SUPLLY
COM
RL1
1
RL1
COM
1
COM
RL1
1
RL1:O
U16
RL1:P
RL1:O
U15
RL1:P
RL1:O
U14
RL1:P
RL1:O
U13
RL1:P
5.12/24P.4
COM
RL1
1 CH 1 C/O 220V AC 1
4.12/220N1.9 4.12/220P1.9 4.12/220N1.10
A4
1
1
1
1
SW2
U18
1
COM
1
RL1:O
RL1:P
RL1:O
RL1 RL1:P
COM
RL1
4 PLC MODE
A3
3. - TUC MODE
A2
2 OPERATING VOLUMETRIC
A1
1 LCS VOLUMETRIC
U17
NON UPS A1
K6
SUPLLY
220P1.3/4.12 NON UPS 220N1.3/4.12 SUPLLY OPERATOR MODE A2
PLC MODE 13 23
14 24
9.12 7.3
A1
K5
220P1.2/4.12 220N1.2/4.12
A2
13 23
14 24
9.9 7.6
EE DOOR
90A1291
SW1
DATE
CHANGE
DATE/NAME
CHKD
NAME
18.Jun.2013
HS
ENGG
18.Jun.2013
HS
CHKD
18.Jun.2013
HS
DRN
18.Jun.2013
HS
WEIGH FEEDER CUSTOMER: PROJECT: CONSULTANT:
SAIL-ROURKELA STEEL PLANT
TITLE:
INPUTS E008-E011
= A1
DRG.NO.: 90.1291
+
- 011-EE16-R0
SHEET 12 19
1
2
3
5
4
6
7
8
9
10
11
12
U6
EE DIO ( F-890)
K4 9.4
X3:E15
X3:24N
X3:24P
E15 X3:E14
X3:24N
X3:24P
E14 X3:E13
X3:24P
X3:E12
E13 X3:24N
X3:24P
E12
X3:24N
12.1
14
13
13A 14A
VIB ON/OFF
3
SW1
4 GRAV/VOL ON DOOR
ONLY APPLICABLE FOR PLC AND MODE
90A1291
EE DOOR
DATE
CHANGE
DATE/NAME
CHKD
NAME
18.Jun.2013
HS
ENGG
18.Jun.2013
HS
CHKD
18.Jun.2013
HS
DRN
18.Jun.2013
HS
WEIGH FEEDER CUSTOMER: PROJECT: CONSULTANT:
SAIL-ROURKELA STEEL PLANT
TITLE:
INPUTS E012-E015
= A1
DRG.NO.: 90.1291
+
- 011-EE16-R0
SHEET 13 19
1
2
3
5
4
6
7
8
9
10
11
12
U6
14
EE DIO (F-890)
A10 A8
A11
A9 A10
A11
X8:11NO
X8:10C
X8:10NO
X8:9C
X8:8C
X8:9NO
A9
X8:8NO
A8
X8:11C
12.1
13
LOC SEL
90A1291
/17.9/
DATE
CHANGE
DATE/NAME
CHKD
NAME
18.Jun.2013
HS
ENGG
18.Jun.2013
HS
CHKD
18.Jun.2013
HS
DRN
18.Jun.2013
HS
WEIGH FEEDER CUSTOMER: PROJECT: CONSULTANT:
SAIL-ROURKELA STEEL PLANT
TITLE:
OUTPUTS A008-A011
= A1
DRG.NO.: 90.1291
+
- 011-EE16-R0
SHEET 14 19
1
2
3
5
4
6
8
7
9
10
11
12
U6 12.1
13
14
EE DIO (F-890) A13
A14
A15
A12 A13
A14
A15
90A1291
X8:15C
X8:15NO
X8:14C
X8:14NO
X8:13C
X8:13NO
X8:12C
X8:12NO
A12
DATE
CHANGE
DATE/NAME
CHKD
NAME
18.Jun.2013
HS
ENGG
18.Jun.2013
HS
CHKD
18.Jun.2013
HS
DRN
18.Jun.2013
HS
WEIGH FEEDER CUSTOMER: PROJECT: CONSULTANT:
SAIL-ROURKELA STEEL PLANT
TITLE:
OUTPUTS A012-A015
= A1
DRG.NO.: 90.1291
+
- 011-EE16-R0
SHEET 15 19
1
2
3
5
4
6
8
7
9
10
11
12
14
13
NON UPS SUPPLY U2
220P1.4/4.12 220 VAC
6.1
TUC-6 A016 A017 A018 A019 1
3
2
4
NORMAL/BY SW.
X4:8-
X1:9
COMMUNICATION X4:3+
RL4
COMMUNICATION X4:7-
RL3
PROFIBUS
X4:2+
RL2
X1:8
X1:6
X1:5
X1:4
RL1
X1:7
SW3 MODBUS
X21
9
4x1.5
LOC SEL /17.13/
REM SEL /17.12/
WC12
1
SW4
33
STOP BY
2
BC117 34
CUSTOMER SCOPE A1
K3
A1
K1
A2
3
K2
A2
.11
13 4
WC12
SW5
4x1.5
START BY
X21
14
10
A1
K2
A2
1
LP3
2
K2 .11
21
K3 .9
22
21 22
220N1.4/4.12 2 4 6 22
18.7 18.7 18.7 .11
1 3 5
2 4 6
18.7 18.7 18.7
1 3 5 13 21
2 4 6 14 22
18.2 18.3 18.3 .11 .10
90A1291
1 3 5 21
220 VAC
DATE
CHANGE
DATE/NAME
CHKD
NAME
18.Jun.2013
HS
ENGG
18.Jun.2013
HS
CHKD
18.Jun.2013
HS
DRN
18.Jun.2013
HS
WEIGH FEEDER CUSTOMER: PROJECT: CONSULTANT:
SAIL-ROURKELA STEEL PLANT
TITLE:
OUTPUTS A016-A019
= A1
DRG.NO.: 90.1291
+
- 011-EE16-R0
SHEET 16 19
5
4
6
8
7
9
10
U1
11
REMOTE SEL
U2 AC INVERTER
6.1
(ACS550) 16
17
13
10
14
15
X1:7
18
RL2 A17
12
RL3 A18
13
14
LOCAL SEL
3
X1:8
2
X1:6
1
NOTE: FAULT I/P USED
RL3 COM
3
FAULT RESET
12.1
U1
LOCA/ SEL.
.1 RL2:25
X8:10C
AS STOP FOR
U6
RL1:P
RL1:O
RL2:P
RL2:O
RL3:O
U10
RL3:P
X8:10NO
A10
RL2:27
A10
RL2
RL1
2
4 CH, 1C/O
1
NON UPS
220V AC RELAY BOARD
SUPPLY 4.12/220N1.5
X10
8
7
X21
6
WC05
WC12
14X1.5
4X1.5
X14
LCS
9
8
1
3
S3
12
7
1
S1 2
11
S2
4
2
BC-117 CONVEYOR RUNNING
EMG.OFF DATE
CHANGE
DATE/NAME
CHKD
NAME
18.Jun.2013
HS
ENGG
18.Jun.2013
HS
CHKD
18.Jun.2013
HS
DRN
18.Jun.2013
HS
START
STOP
WEIGH FEEDER CUSTOMER: PROJECT: CONSULTANT:
SAIL-ROURKELA STEEL PLANT
90A1291
9.2/220PA.3
PLC / DCS TITLE:
INVERTER
= A1
DRG.NO.: 90.1291
+
- 011-EE16-R0
SHEET 17 19
1
2
3
5
4
6
8
7
9
10
11
12
14
13
E1 3.13/L3
415 V/50Hz
3.13/L2 3.13/L1
1
3
5
13
F1
14 8.13
4-6 AMPS 2
4
NOTE:
6
DESIGN SCHEME IS SUITABLE FOR MAX.250 MTRS. BETWEEN INVERTER & INDIVIDUAL MOTOR
NORMAL
K1 16.10
1
3
5
2
4
6 WCS09
U1 V1
W1
E
X22
4
X41
1
2
X22
5
X41
2
3
X22
6
X41
3
3x0.35 X22 7
X41
4
4 9.5/U5:X2B:+2:U1:29
X1:29
MODBUS
9.5/U5:X2B:-3:U1:30
X1:30
9.5/U5:X2B:4:U1:31
X1:31
K2 16.11
3
5
25
2
4
6
26
WCSM
2.2 KW
11
U2
V2
W2
L2
NORMAL
K3
16.9
3
A1
B1
C1
A2
B2
C2
1
3
5
9
WCSR
UPS
2
4
VOLUME 1 SET POINT
2
8
PE
12
NOCH-0016/15 AMPS
3x0.35
P1 AC INVERTER (ACS 550)
1
WCSK-2
LCS
3x0.75 U1
2x0.35
SUPPLY
U9
5.12/P1.1
L I/P+ I/P-
5.12/N1.1
N
6
I/I
O/P1+ O/P1-
WCSQ 2x0.35 WP02X13
4
5
6
E
X9
4x4
TERMINAL BOX
10
11
12
WCS07 1
2
3
E
2x0.75
M1
4-20mA ISO O/P
4POLE,1500RPM IL-4.4AMPS DATE
CHANGE
DATE/NAME
CHKD
NAME
18.Jun.2013
HS
ENGG
18.Jun.2013
HS
CHKD
18.Jun.2013
HS
DRN
18.Jun.2013
HS
WEIGH FEEDER CUSTOMER: PROJECT: CONSULTANT:
SAIL-ROURKELA STEEL PLANT
à CURRENT
M 3
~
PLC/DCS 90A1291
PW-2.2KW
(CUSTOMER)
WF MOTOR TITLE:
AC INVERTOR
= A1
DRG.NO.: 90.1291
+
- 011-EE16-R0
SHEET 18 19
1
2
3
5
4
6
8
7
9
10
11
12
13
14
E
3.13/L3.1
415V/50Hz
3.13/L2.1 3.13/L1.1
1
3
5
13
F2
14 8.13
0.4-0.6 Amps. 2
4
6
1
3
5
2
4
6
X13
7
8
9
X17
4
5
6
K4 9.4
E
WP03 3x2.5
M2
M 3
2POLE,1500RPM IL-0.52AMPS DATE
CHANGE
DATE/NAME
CHKD
NAME
18.Jun.2013
HS
ENGG
18.Jun.2013
HS
CHKD
18.Jun.2013
HS
DRN
18.Jun.2013
HS
VIB MOTOR
WEIGH FEEDER CUSTOMER: PROJECT: CONSULTANT:
~
90A1291
PW-0.27KW
E
SAIL-ROURKELA STEEL PLANT
TITLE:
VIB MOTOR
= A1
DRG.NO.: 90.1291
+
- 011-EE16-R0
SHEET 19 19
1
2
3
5
4
6
8
7
9
10
11
12
13
Terminal diagram
14
=A1-WCSQ
=A1-WCSE2-1
=A1-W2
Type
Cable name Target design.
Connection
Connection
Target design.
Terminal number
Function text
Jumpers
=A1-X9 Connection
=A1-WCS06
Cable name
Strip designation
Type
=A1-WCS10
=A1-WCS05
=A1-WCS07
ESSK034E
Page/ path
4-20mA ISO I/P à SET POINT
1
-PLC/DCS
1
-U8
I/P+
1
=A1/7.4
=
2
-PLC/DCS
2
-U8
I/P-
2
=A1/7.4
SH
3
SH
SHIELD
=A1/7.4
VOLUME SETPOINT
1
-OP-X43
4
4
-U4
X2:1
=A1/7.5
=
2
-OP-X43
5
5
-K5
23
=A1/7.6
=
3
-OP-X43
6
6
-U4
X2:3
=A1/7.6
4-20mA ISO O/P à ACTUAL FEEDRATE
1
-PLC/DCS
7
-U4
X3:1
1
=A1/7.8
=
2
-PLC/DCS
8
-U4
X3:2
2
=A1/7.8
SH
9
SH
SHIELD
=A1/7.9
4-20mA ISO O/P à CURRENT
1
-PLC/DCS
10
-U9
O/P1+
1
=A1/18.10
=
2
-PLC/DCS
11
-U9
O/P1-
2
=A1/18.10
SH
12
SH
=A1/18.11
90A1291
SHIELD
DATE
CHANGE
DATE/NAME
CHKD
NAME
18.Jun.2013
HS
ENGG
18.Jun.2013
HS
CHKD
18.Jun.2013
HS
DRN
18.Jun.2013
HS
WEIGH FEEDER CUSTOMER: PROJECT: CONSULTANT:
SAIL-ROURKELA STEEL PLANT
TITLE:
=A1-X9
= A1_TER
DRG.NO.: 90.1291
+
- 011-EE17-R0
SHEET 1 13
1
2
3
5
4
6
8
7
9
10
11
12
13
Terminal diagram
14
Target design.
Type
Connection
Connection
Terminal number
Target design.
Jumpers
=A1-X10 Connection
Function text
Cable name
Strip designation
Type
=A1-WC05
Cable name
ESSK034E
Page/ path
1
-LCS-X14
1
1
-X6
P
=A1/8.4
220N
2
-LCS-X14
3
2
-U7
COM
=A1/8.4
ZERO SPEED SW.
3
-LCS-X14
4
3
-U7
1
=A1/8.5
BELT SWAY S/W
4
-LCS-X14
5
4
-U7
2
=A1/8.7
MATERIAL DETECTION .
5
-LCS-X14
6
5
-U7
3
=A1/8.9
STOP
6
-LCS-X14
7
6
-X21
11
=A1/17.7
START
7
-LCS-X14
8
7
-U10
2
=A1/17.6
EMG.OFF
8
-LCS-X14
9
8
-U10
3
=A1/17.4
VIB. ON /OFF
9
-LCS-X14
10
9
-K4
A1
=A1/9.2
BELT RUN F/B
10
-LCS-X14
11
10
-U5
X4:0C
=A1/10.3
VIB ON F/B
11
-LCS-X14
12
11
-K4
14
=A1/10.6
90A1291
220P
DATE
CHANGE
DATE/NAME
CHKD
NAME
18.Jun.2013
HS
ENGG
18.Jun.2013
HS
CHKD
18.Jun.2013
HS
DRN
18.Jun.2013
HS
WEIGH FEEDER CUSTOMER: PROJECT: CONSULTANT:
SAIL-ROURKELA STEEL PLANT
TITLE:
=A1-X10
= A1_TER
DRG.NO.: 90.1291
+
- 011-EE17-R0
SHEET 2 13
1
2
3
5
4
6
8
7
9
10
11
12
13
Terminal diagram
14
=A1-WCSC
=A1-WCSB
Type
Cable name Target design.
Connection
Connection
Target design.
Terminal number
Function text
Jumpers
=A1-X11 Connection
=A1-WCS04
Cable name
Strip designation
Type
=A1-WCS03
ESSK034E
Page/ path
SUPPLY -
1
-JB1-X15
1
1
-U2
X3:9
1
=A1/6.7
SUPPLY +
2
-JB1-X15
2
2
-U2
X3:5
2
=A1/6.5
SIGNAL +
3
-JB1-X15
3
3
-U2
X3:2
3
=A1/6.6
SIGNAL -
4
-JB1-X15
4
4
-U2
X3:6
4
=A1/6.6
5
SH
SHIELD
SH
=A1/6.5
SENSE -
5
-JB1-X15
6
6
-U2
X3:8
5
SENSE +
6
-JB1-X15
7
7
-U2
X3:4
6
=A1/6.7 =A1/6.5
+12V
1
-JB1-X15
8
8
-U2
X1:10
1
=A1/6.8
SIGNAL
2
-JB1-X15
9
9
-U2
X1:11
2
=A1/6.9
SH
10
SH
=A1/6.9
90A1291
SHIELD
DATE
CHANGE
DATE/NAME
CHKD
NAME
18.Jun.2013
HS
ENGG
18.Jun.2013
HS
CHKD
18.Jun.2013
HS
DRN
18.Jun.2013
HS
WEIGH FEEDER CUSTOMER: PROJECT: CONSULTANT:
SAIL-ROURKELA STEEL PLANT
TITLE:
=A1-X11
= A1_TER
DRG.NO.: 90.1291
+
- 011-EE17-R0
SHEET 3 13
1
2
3
5
4
6
8
7
9
10
11
12
13
Terminal diagram
14
Cable name Target design.
Type
Connection
Connection
Target design.
Terminal number
Function text
Jumpers
=A1-X12 Connection
=A1-WC10
Cable name
Strip designation
Type
=A1-WC04
=A1-WC04.2
ESSK034E
path
220P
1
-OP-X42
3
1
-X6
P
START/STOP 220VAC
2
-OP-X42
4
2
-U12
1
220P START/STOP 220VAC
Page/ =A1/9.8 =A1/9.9
1
-PLC/DCS
3
=A1/9.11
2
=A1/9.12
-PLC/DCS
4
=
1
-PLC/DCS
5
BC-117 ILK
2
-PLC/DCS
6
-U11
1
=A1/9.13
7
-U7
4
=A1/9.7
3
-OP-X42
5
90A1291
FAULT RESET 220VAC
=A1/9.12
DATE
CHANGE
DATE/NAME
CHKD
NAME
18.Jun.2013
HS
ENGG
18.Jun.2013
HS
CHKD
18.Jun.2013
HS
DRN
18.Jun.2013
HS
WEIGH FEEDER CUSTOMER: PROJECT: CONSULTANT:
SAIL-ROURKELA STEEL PLANT
TITLE:
=A1-X12
= A1_TER
DRG.NO.: 90.1291
+
- 011-EE17-R0
SHEET 4 13
1
2
3
5
4
6
8
7
9
10
11
12
13
Terminal diagram
14
Cable name Target design.
Type
Connection
Connection
Target design.
Terminal number
Function text
Jumpers
=A1-X13 Connection
=A1-WP01
Cable name
Strip designation
Type
=A1-WP02
=A1-WP03
=A1-WP04
ESSK034E
Page/ path
415 V ñ10% 50 Hz ñ3% 3í SUPPLY
1
-MCC
R
1
-Q1
1
=A1/3.2
=
2
-MCC
Y
2
-Q1
3
=A1/3.2
=
3
-MCC
B
3
-Q1
5
=A1/3.2
1
-TERMINALBOX
1
4
-K3
2
=A1/18.7
2
-TERMINALBOX
2
5
-K3
4
=A1/18.7
3
-TERMINALBOX
3
6
-K3
6
1
-X17
4
7
-K4
2
X
=A1/19.7
2
-X17
5
8
-K4
4
X
=A1/19.7
3
-X17
6
9
-K4
6
X
=A1/19.7
-TERMINALBOX
E
E
-U1
PE
-MCC
E
E
-E
=A1/3.3
E
-E
=A1/19.8
VIB MOTOR
4
EARTH = =
=A1/18.7
=A1/18.8
1
-UPSSUPPLY
L
10
-Fa
1
X
=A1/5.2
=
2
-UPSSUPPLY
N
11
-Fa
3
X
=A1/5.2
90A1291
220 VAC ñ3% 50 Hz
DATE
CHANGE
DATE/NAME
CHKD
NAME
18.Jun.2013
HS
ENGG
18.Jun.2013
HS
CHKD
18.Jun.2013
HS
DRN
18.Jun.2013
HS
WEIGH FEEDER CUSTOMER: PROJECT: CONSULTANT:
SAIL-ROURKELA STEEL PLANT
TITLE:
=A1-X13
= A1_TER
DRG.NO.: 90.1291
+
- 011-EE17-R0
SHEET 5 13
1
2
3
5
4
6
8
7
9
10
11
12
13
Terminal diagram
14
X
ZERO SPEED SW.
2
220N
2
1
15
2
-LCS-L2
2
-X10
-JB1-X15 X
ZERO SPEED SW.
-LCS-S4
3
Target design.
=A1-WC07
=A1-WC05
Type
Connection
Connection
Jumpers
Terminal number
Target design.
Connection
=A1-LCS-X14
Function text 220P
Cable name
Cable name
Strip designation
Type
=A1-WC07
=A1-WC05
ESSK034E
Page/ path
-X10
1
1
3
-X10
2
2
3
4
-JB1-X15
=A1/8.4 =A1/8.4
16
=A1/8.4 3
=A1/8.5
BELT SWAY S/W
1
-JB1-X15
14
5
-X10
4
4
MATERIAL DETECTION .
4
-JB1-X15
17
6
-X10
5
5
=A1/8.7 =A1/8.9
X
-LCS-S2
1
7
-X10
6
6
=A1/17.7
START
X
-LCS-S1
3
8
-X10
7
7
=A1/17.6
EMG.OFF
X
-LCS-S3
1
9
-X10
8
8
=A1/17.4
VIB. ON /OFF
X
-LCS-S4
1
10
-X10
9
9
=A1/9.2
BELT RUN F/B
-LCS-L1
1
11
-X10
10
10
=A1/10.3
VIB ON F/B
-LCS-L2
1
12
-X10
11
11
=A1/10.6
90A1291
STOP
DATE
CHANGE
DATE/NAME
CHKD
NAME
18.Jun.2013
HS
ENGG
18.Jun.2013
HS
CHKD
18.Jun.2013
HS
DRN
18.Jun.2013
HS
WEIGH FEEDER CUSTOMER: PROJECT: CONSULTANT:
SAIL-ROURKELA STEEL PLANT
TITLE:
=A1-LCS-X14
= A1_TER
DRG.NO.: 90.1291
+
- 011-EE17-R0
SHEET 6 13
1
2
3
5
4
6
8
7
9
10
11
12
13
=A1-WC07
=A1-WCS03
Type
=A1-WCS04
Cable name Target design.
Connection
Connection
Target design.
Terminal number
Function text
Jumpers
=A1-JB1-X15 Connection
=A1-WCS02
Cable name
Strip designation
Type
=A1-WC01
=A1-WCS01
=A1-WC02
ESSK034E =A1-WC06
=A1-WC08
Terminal diagram
14
Page/ path
SUPPLY -
1
-FIELD-LC1
C
1
-X11
1
1
=A1/6.7
SUPPLY +
2
-FIELD-LC1
B
2
-X11
2
2
=A1/6.5
SIGNAL +
3
-FIELD-LC1
A
3
-X11
3
3
=A1/6.6
SIGNAL -
4
-FIELD-LC1
D
4
-X11
4
4
=A1/6.6
5
SH
SENSE -
6
-X11
6
5
SENSE +
7
-X11
7
6
SHIELD
SH
=A1/6.5 =A1/6.7 =A1/6.5
+12V
1
-FIELD
8
-X11
8
1
=A1/6.8
SIGNAL
2
-FIELD
9
-X11
9
2
=A1/6.9
SHIELD
SH
10
SH
=A1/6.9
BELT SWAY S/W
1
-FIELD
11
=A1/8.6
=
2
-FIELD
12
=A1/8.6
=
1
-FIELD
13
=
2
-FIELD
14
-LCS-X14
5
1
=A1/8.7
=A1/8.7
ZERO SPEED SW.
1
-FIELD
1
15
-LCS-X14
2
2
=A1/8.4
=
2
-FIELD
2
16
-LCS-X14
4
3
=A1/8.5
-LCS-X14
6
4
=A1/8.9
1
-FIELD
2
17
=
2
-FIELD
1
18
=A1/8.8
90A1291
MATERIAL DETECTION .
DATE
CHANGE
DATE/NAME
CHKD
NAME
18.Jun.2013
HS
ENGG
18.Jun.2013
HS
CHKD
18.Jun.2013
HS
DRN
18.Jun.2013
HS
WEIGH FEEDER CUSTOMER: PROJECT: CONSULTANT:
SAIL-ROURKELA STEEL PLANT
TITLE:
=A1-JB1-X15
= A1_TER
DRG.NO.: 90.1291
+
- 011-EE17-R0
SHEET 7 13
1
2
3
5
4
6
8
7
9
10
11
12
13
Terminal diagram
14
Type
=A1-WC12
Cable name Target design.
Connection
Connection
Target design.
Terminal number
Function text
Jumpers
=A1-X21 Connection
=A1-WC03
Cable name
Strip designation
Type
=A1-WC12
ESSK034E
Page/ path
WF ON 220VAC
1
-PLC/DCS
1
-U5
X4:4NO
=A1/11.3
=
2
-PLC/DCS
2
-U5
X4:4C
=A1/11.4
PLC SEL 220VAC
3
-PLC/DCS
3
-U5
X4:5NO
=A1/11.6
=
4
-PLC/DCS
4
-U5
X4:5C
=A1/11.7
GENERAL FAULT
5
-PLC/DCS
5
-U5
X4:6NO
=A1/11.9
=
6
-PLC/DCS
6
-U5
X4:6C
=A1/11.10
7
-PLC/DCS
7
-U5
X4:7NO
=A1/11.12
8
-PLC/DCS
8
-U5
X4:7C
33
9
-SW3
1
10
-CUSTOMERSCOPE-BC117
MATERIAL OVERLOAD
ON BELT
= 1
-CUSTOMERSCOPE-BC117 -SW4
4
=A1/11.12 X
34
=A1/16.14 2
=A1/16.14
3
-PLC/DCS
11
-X10
6
=A1/17.9
=
3
-PLC/DCS
12
-U10
1
=A1/17.10
90A1291
BC-117 CONVEYOR RUNNING
DATE
CHANGE
DATE/NAME
CHKD
NAME
18.Jun.2013
HS
ENGG
18.Jun.2013
HS
CHKD
18.Jun.2013
HS
DRN
18.Jun.2013
HS
WEIGH FEEDER CUSTOMER: PROJECT: CONSULTANT:
SAIL-ROURKELA STEEL PLANT
TITLE:
=A1-X21
= A1_TER
DRG.NO.: 90.1291
+
- 011-EE17-R0
SHEET 8 13
1
2
3
5
4
6
8
7
9
10
11
12
13
Terminal diagram
14
=A1-WCSM
Type
=A1-WCSL1
Cable name Target design.
Connection
Connection
Target design.
Terminal number
Function text
Jumpers
=A1-X22 Connection
=A1-WCS08
Cable name
Strip designation
Type
=A1-WCS09
ESSK034E
Page/ path
FEEDRATE INDICATOR
1
-OP-X43
1
1
-U2
X1:+13
1
=A1/7.13
=
2
-OP-X43
2
2
-U2
X1:-14
2
=A1/7.13
3
SH
SHIELD
SH
=A1/7.14
FEEDRATE SET
1
-LCS-X41
1
4
-U1
4
1
=A1/18.9
=
2
-LCS-X41
2
5
-U1
2
2
=A1/18.9
=
3
-LCS-X41
3
6
-U1
3
3
=A1/18.9
SH
7
=A1/18.9
90A1291
SHIELD
DATE
CHANGE
DATE/NAME
CHKD
NAME
18.Jun.2013
HS
ENGG
18.Jun.2013
HS
CHKD
18.Jun.2013
HS
DRN
18.Jun.2013
HS
WEIGH FEEDER CUSTOMER: PROJECT: CONSULTANT:
SAIL-ROURKELA STEEL PLANT
TITLE:
=A1-X22
= A1_TER
DRG.NO.: 90.1291
+
- 011-EE17-R0
SHEET 9 13
1
2
3
5
4
6
8
7
9
10
11
12
13
Terminal diagram
14
Target design.
Type
Connection
Connection
Terminal number
Target design.
Jumpers
=A1-X23 Connection
Function text
Cable name
Strip designation
Type
=A1-WC11
Cable name
ESSK034E
Page/ path
1
-OP-X42
1
1
-X6
P
=A1/7.11
220PN
2
-OP-X42
2
2
-X6
N
=A1/7.12
90A1291
220P
DATE
CHANGE
DATE/NAME
CHKD
NAME
18.Jun.2013
HS
ENGG
18.Jun.2013
HS
CHKD
18.Jun.2013
HS
DRN
18.Jun.2013
HS
WEIGH FEEDER CUSTOMER: PROJECT: CONSULTANT:
SAIL-ROURKELA STEEL PLANT
TITLE:
=A1-X23
= A1_TER
DRG.NO.: 90.1291
+
- 011-EE17-R0
SHEET 10 13
1
2
3
5
4
6
8
7
9
10
11
12
13
Terminal diagram
14
Target design.
Type
Connection
Connection
Jumpers
Target design.
Terminal number
Function text
Connection
=A1-LCS-X41
=A1-WCS09
Cable name
Strip designation
Type
=A1-WCSK-2
Cable name
ESSK034E
Page/ path
FEEDRATE SET
1
-LCS-P1
3
1
-X22
4
1
=A1/18.11
=
2
-LCS-P1
2
2
-X22
5
2
=A1/18.11
=
3
-LCS-P1
1
3
-X22
6
3
=A1/18.11
4
SH
SH
=A1/18.11
90A1291
SHIELD
DATE
CHANGE
DATE/NAME
CHKD
NAME
18.Jun.2013
HS
ENGG
18.Jun.2013
HS
CHKD
18.Jun.2013
HS
DRN
18.Jun.2013
HS
WEIGH FEEDER CUSTOMER: PROJECT: CONSULTANT:
SAIL-ROURKELA STEEL PLANT
TITLE:
=A1-LCS-X41
= A1_TER
DRG.NO.: 90.1291
+
- 011-EE17-R0
SHEET 11 13
1
2
3
5
4
6
8
7
9
10
11
12
13
Terminal diagram
14
Target design.
=A1-WC10
=A1-WC11
Type
Connection
Connection
Terminal number
Target design.
Jumpers
=A1-OP-X42 Connection
Function text
Cable name
Strip designation
Type
=A1-W4
Cable name
ESSK034E
Page/ path
220P
1
-OP-D1
9
1
-X23
1
1
220PN
2
-OP-D1
10
2
-X23
2
2
=A1/7.11 =A1/7.12
-OP-S2.1
4
3
-X12
1
1
=A1/9.8
START/STOP 220VAC
-OP-S1.1
1
4
-X12
2
2
=A1/9.9
FAULT RESET 220VAC
-OP-S2.1
3
5
-X12
7
3
=A1/9.7
90A1291
220P
DATE
CHANGE
DATE/NAME
CHKD
NAME
18.Jun.2013
HS
ENGG
18.Jun.2013
HS
CHKD
18.Jun.2013
HS
DRN
18.Jun.2013
HS
WEIGH FEEDER CUSTOMER: PROJECT: CONSULTANT:
SAIL-ROURKELA STEEL PLANT
TITLE:
=A1-OP-X42
= A1_TER
DRG.NO.: 90.1291
+
- 011-EE17-R0
SHEET 12 13
1
2
3
5
4
6
8
7
9
10
11
12
13
Terminal diagram
14
=A1-WCS10
Type
=A1-WCS08
Cable name Target design.
Connection
Connection
Target design.
Terminal number
Function text
Jumpers
=A1-OP-X43 Connection
=A1-WCSD
Cable name
Strip designation
Type
=A1-WCSK-1
ESSK034E
Page/ path
FEEDRATE INDICATOR
1
-OP-D1
1
1
-X22
1
1
=A1/7.13
=
2
-OP-D1
2
2
-X22
2
2
=A1/7.13
3
SH
SHIELD
SH
=A1/7.14
VOLUME SETPOINT
1
-OP-P1.1
3
4
-X9
4
1
=A1/7.5
=
2
-OP-P1.1
2
5
-X9
5
2
=A1/7.6
=
3
-OP-P1.1
1
6
-X9
6
3
=A1/7.6
7
SH
SH
=A1/7.6
90A1291
=
DATE
CHANGE
DATE/NAME
CHKD
NAME
18.Jun.2013
HS
ENGG
18.Jun.2013
HS
CHKD
18.Jun.2013
HS
DRN
18.Jun.2013
HS
WEIGH FEEDER CUSTOMER: PROJECT: CONSULTANT:
SAIL-ROURKELA STEEL PLANT
TITLE:
=A1-OP-X43
= A1_TER
DRG.NO.: 90.1291
+
- 011-EE17-R0
SHEET 13 13
1
2
3
5
4
6
7
8
9
10
11
12
14
13
BILL OF MATERIAL COMPONENT LEGEND
QTY.
TIL-FLS BOM
TYPE NUMBER
DEVICE
GENERAL SPECIFICATION
PAGE/PATH
MAKE
=A1-F1
1
MPCB
3VU 1340-1MKOO
4-6 Amp
SIEMENS
=A1/18.
7
=A1-F2
1
MPCB
3VU1340 1MEOO
0.4-0.6 Amp
SIEMENS
=A1/19.
7
=A1-Fa
1
MCB
DP
1 Amp(2P)
MDS/SIEMENS
=A1/5.
2
=A1-Fb
1
MCB
DP
1 Amp(2P)
MDS/SIEMENS
=A1/3.
11
=A1-Fc
1
MCB
DP
1 Amp(2P)
MDS/SIEMENS
=A1/4.
2
=A1-K1
1
OR
3TF30 10-0A PO
9 Amp
SIEMENS
=A1/16.
10
=A1-K1
1
SURGE SUPRSSOR
3TX7402-3TY2
220VAC (RC)
SIEMENS
=A1/16.
10
=A1-K2
1
OR
3TF30 10-0A PO
9 Amp
SIEMENS
=A1/16.
11
=A1-K2
1
AUXILLIARY BLOCK
3TX4 001-2A
1 NC
SIEMENS
=A1/16.
11
=A1-K2
1
SURGE SUPRSSOR
3TX7402-3TY2
220VAC (RC)
SIEMENS
=A1/16.
11
=A1-K3
1
OR
3TF3O 01-0A-PO
9 Amp
SIEMENS
=A1/16.
9
=A1-K3
1
SURGE SUPRSSOR
3TX7402-3TY2
220VAC (RC)
SIEMENS
=A1/16.
9
=A1-K4
1
OR
3TF3O 10-0A-PO
9 Amp
SIEMENS
=A1/9.
4
=A1-K4
1
SURGE SUPRSSOR
3TX7402-3TY2
220VAC (RC)
SIEMENS
=A1/9.
4
=A1-K5
1
OR
3TH30 40-0A PO (4NO)
10A
SIEMENS
=A1/12.
12
=A1-K5
1
SURGE SUPRSSOR
3TX7402-3TY2
220VAC (RC)
SIEMENS
=A1/12.
12
=A1-K6
1
OR
3TH30 40-0A PO (4NO)
10A
SIEMENS
=A1/12.
9
=A1-K6
1
SURGE SUPRSSOR
3TX7402-3TY2
220VAC (RC)
SIEMENS
=A1/12.
9
=A1-L2
1
OUTPUT CHOKE
NOCH-0016
15 Amp
ABB
=A1/18.
7
=A1-L3
1
CFL LAMP
8020070V0200
8 WATT
PHILIPS
=A1/3.
=A1-LCS-L1
1
LAMP
P2PL BR4L-RED
220VAC
TEKNIC
=A1/10.
3
=A1-LCS-L2
1
LAMP
P2PL BR4L-RED
220VAC
TEKNIC
=A1/10.
6
=A1-LCS-P1
1
POTENTIOMETER
808006000100
1K,10 TURNS
BOURNS
=A1/18.
13
=A1-LCS-S1
1
START PUSH BUTTON
P2AF3-GREEN(1NO)
------
TEKNIC
=A1/17.
6
=A1-LCS-S2
1
STOP PUSH BUTTON
P2AF4-RED (1NC)
------
TEKNIC
=A1/17.
7 90A1291
11
DATE
CHANGE
DATE/NAME
CHKD
NAME
18.Jun.2013
HS
ENGG
18.Jun.2013
HS
CHKD
18.Jun.2013
HS
DRN
18.Jun.2013
HS
WEIGH FEEDER CUSTOMER: PROJECT: CONSULTANT:
SAIL-ROURKELA STEEL PLANT
TITLE:
BILL OF MATERIALS
= A1_BOM
DRG.NO.: 90.1291
+
- 011-EE03-R0
SHEET 1 3
1
2
3
5
4
6
7
8
9
10
11
12
14
13
BILL OF MATERIAL COMPONENT LEGEND
QTY.
TIL-FLS BOM
TYPE NUMBER
DEVICE
GENERAL SPECIFICATION
PAGE/PATH
MAKE
=A1-LCS-S3
1
EMG STOP SW
P2AML4-RED (1NC)
MUSHROOM HEAD
TEKNIC
=A1/17.
=A1-LCS-S4
1
VIB ON/OFF SW.
P2AS2-2P (1NO+1NC)
------
TEKNIC
=A1/9.
2
=A1-LP1
1
LAMP
P2PL BR4L-RED
220VAC
TEKNIC
=A1/3.
8
=A1-LP2
1
LAMP
P2PL BR5L-AMBER
220 VAC
TEKNIC
=A1/10.
9
=A1-LP3
1
LAMP
P2PL BR5L-AMBER
220 VAC
TEKNIC
=A1/16.
14
=A1-OP-D1
1
DISPLAY(TPH)
3 1/2 DIGIT
220VAC
FPIL
=A1/7.
12
=A1-OP-P1.1
1
POTENTIOMETER
808006000100
1K,10 TURNS
BOURNS
=A1/7.
6
=A1-OP-S1.1
1
START / STOP SW.
P2AS2-2P (1NO)
------
TEKNIC
=A1/9.
8
=A1-OP-S2.1
1
FAULT / RESET SW.
P2AS2-2P (1NO)
------
TEKNIC
=A1/9.
7
=A1-Q1
1
DOOR ISOLATOR
FFO
32 Amp
L & T
=A1/3.
2
=A1-S1
1
SURFACE MOUNLED ON/OFF SW
50G0090C0200
5 Amp
ANCHOR
=A1/3.
10
=A1-S2
1
DOOR LIMIT SWITCH
3SE3-020-0A
500V AC, 600 VDC, 10A
SIEMENS
=A1/3.
11
=A1-SW1
1
GRAV / VOLL SWITCH
P2AS2-2P (1NO+1NC)
------
TEKNIC
=A1/13.
10
=A1-SW2
1
4 WAY SELECTOR SW.
-----
1 POLE - 4 WAY
KAYCEE
=A1/12.
3
=A1-SW3
1
NORMAL BY SW.
P2AS2-2P (1NO+1NC)
------
TEKNIC
=A1/16.
12
=A1-SW4
1
STOP BY PB
P2AF4-RED (1NC)
------
TEKNIC
=A1/16.
11
=A1-SW5
1
START BY PB.
P2AF3-GREEN(1NO)
------
TEKNIC
=A1/16.
11
=A1-TX1
1
TRANSFORMER
------
415 VAC/ [email protected],200VA
FPIL
=A1/3.
6
=A1-U1
1
INVERTER
ACS 550-01-5A4-4
2.2 KW
ABB
=A1/18.
=A1-U2
1
CONTROLLER
TUC 6
WEIGHING CONTROLLER
FPIL
=A1/6.
1
=A1-U3
1
POWER PACK
NES-50-24
[email protected]
MEANWELL
=A1/5.
7
=A1-U4
1
ANALOG I/O CARD
F875
2CH AIO INTERFACE
FPIL
=A1/7.
1
=A1-U5
1
DIGITAL I/O CARD
F889
DI-8 CH, DO-8 CH
FPIL
=A1/8.
2
=A1-U6
1
DIGITAL I/O CARD
F890
DI-8 CH, DO-8 CH
FPIL
=A1/12.
=A1-U7
1
RELAY BOARD
1CHANGE OVER
4 CHANNEL/220 VAC
FPIL
=A1/8.
4
6
1
90A1291
3
DATE
CHANGE
DATE/NAME
CHKD
NAME
18.Jun.2013
HS
ENGG
18.Jun.2013
HS
CHKD
18.Jun.2013
HS
DRN
18.Jun.2013
HS
WEIGH FEEDER CUSTOMER: PROJECT: CONSULTANT:
SAIL-ROURKELA STEEL PLANT
TITLE:
BILL OF MATERIALS
= A1_BOM
DRG.NO.: 90.1291
+
- 011-EE03-R0
SHEET 2 3
1
2
3
5
4
6
7
8
9
10
11
12
14
13
BILL OF MATERIAL COMPONENT LEGEND
QTY.
TIL-FLS BOM
TYPE NUMBER
DEVICE
GENERAL SPECIFICATION
PAGE/PATH
MAKE
1
SINGLE ISOLATOR
I TO V
220 VAC
MESIBUS
=A1/7.
3
=A1-U9
1
SINGLE ISOLATOR
I TO I (SIGNAL ISOLATOR)
220 VAC
MESIBUS
=A1/18.
10
=A1-U10
1
RELAY BOARD
1CHANGE OVER
4 CHANNEL/220 VAC
FPIL
=A1/17.
3
=A1-U11
1
RELAY BOARD
1CHANGE OVER
1 CHANNEL/220 VAC
FPIL
=A1/9.
10
=A1-U12
1
RELAY BOARD
1CHANGE OVER
1 CHANNEL/220 VAC
FPIL
=A1/9.
7
=A1-U13
1
RELAY BOARD
1CHANGE OVER
1 CHANNEL/220 VAC
FPIL
=A1/12.
2
=A1-U14
1
RELAY BOARD
1CHANGE OVER
1 CHANNEL/220 VAC
FPIL
=A1/12.
3
=A1-U15
1
RELAY BOARD
1CHANGE OVER
1 CHANNEL/220 VAC
FPIL
=A1/12.
5
=A1-U16
1
RELAY BOARD
1CHANGE OVER
1 CHANNEL/220 VAC
FPIL
=A1/12.
6
=A1-U17
1
RELAY BOARD
1CHANGE OVER
1 CHANNEL/220 VAC
FPIL
=A1/12.
9
=A1-U18
1
RELAY BOARD
1CHANGE OVER
1 CHANNEL/220 VAC
FPIL
=A1/12.
12
90A1291
=A1-U8
DATE
CHANGE
DATE/NAME
CHKD
NAME
18.Jun.2013
HS
ENGG
18.Jun.2013
HS
CHKD
18.Jun.2013
HS
DRN
18.Jun.2013
HS
WEIGH FEEDER CUSTOMER: PROJECT: CONSULTANT:
SAIL-ROURKELA STEEL PLANT
TITLE:
BILL OF MATERIALS
= A1_BOM
DRG.NO.: 90.1291
+
- 011-EE03-R0
SHEET 3 3
SPSS I/O LISTING FOR TUC - 6 WF
JOB NO:90.1291-R1 INVERTER:- ABB ACS 550 SR NO.
CODE
DT. 25.07.2013
IO INPUTS TO DIO CARD
1
SM 017
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27
UE 000 UM 066 =M 060 UM 060 LT 000 SIT020 UT 000 =M 063 UNE000 UM 066 =M 061 UM 061 LT 001 SIT020 UT 001 =M 040 UM 063 OM 040 =M 062 UNM 062 =M 020 UNM 066 RT 001 RT 000 UM 062 =M 037
E000
28 29
UE 001 =M 009
E001
30 31 32
UE 003 UE 024 =M 019
E003 E024
33 34
UE004 =M 018
E004
35 36
UE 002 =M 021
E002
37 38
UNE 012 =M 022
E012
39 40
UM 047 =A 001
A001
ZERO SPEED SWITCH
BELT SWAY SWITCH
WF INTERLOCK
FAULT RESET
MAT. DET. SW
VIB ON/OFF SW.
VIB IN LAMP
SPSS I/O LISTING FOR TUC - 6 WF 41 42 43 44 45 46 47 48
UE 006 OE 007 UM 045 SM 016 UNE 006 UNE 007 UM 045 RM 016
E006 E007
49 50 51 52 53 54 55
UE 008 RM 015 RM 023 RM 008 RA 010 UNE 014 =M 023
E008
56 57 58 59 60 61 62 63
UE 010 SM 015 SM 008 SA 010 UE 011 RM 015 SM 008 SA 010
E010
64 65 66 67 68 69 70
UE 009 RM 015 RM 023 SM 008 SA 010 UE 022 =M 008
E009
71 72
UE 023 =M 010
E023
73 74 75 76 77 78 79 80
UE 025 UNM 008 SM 011 RM 012 UNE 025 UNM 008 SM 012 RM 011
E025
81 82
UM 064 = A000
A000
BELT RUN
83 84
UM 066 = A004
A004
WF ON
85 86
UM 036 = A006
A006
GENERAL FAULT
87 88
UNM 043 = A005
A005
REMOTE SELECTION
89 90
UM 064 =A 002
A002
91 92
UM 050 .=A 007
A007
MAT.O/L
93 94 95
UNM 043 UE 022 = A017
A017
REMOTE SELECTION
96 97 98
UM 043 UNE022 = A018
A018
LOCAL SELECTION
99 100
UM 066 = A020
A020
LOCAL START
START / STOP
LCS-VOLUMETRIC
E014
GRAV/VOL.(On door -
- TUC MODE
E011
PLC MODE
OPERATING VOL.
E022
LOCAL / REMOTE
EMG
DRIVE RUNNING
WF ON LAMP
SPSS I/O LISTING FOR TUC - 6 WF
JOB NO:- 90.1291 INVERTER:- ABB ACS 550 INPUTS E000 E001 E002 E003 E004 E005 E006 E007
ZERO SPEED SWITCH BELT SWAY SWITCH MATERIAL DET.SW. WF INTERLOCK FAULT RESET FREE START / STOP - OPERATOR PL. START/STOP - PLC/DCS
E008 E009 E010 E011 E012 E013 E014 E015
LCS-VOLUMETRIC OPERATING VOL. - TUC MODE PLC MODE VIB ON / OFF FREE GRAV/VOL.(On door - only applicable for mode ) FREE
E020 E021 E022 E023 E024 E025
LOCAL START LOCAL STOP LOCAL / REMOTE EMG STOP DRIVE INTERLOCK DRIVE RUNNING
OUTPUTS A000 A001 A002 A003 A004 A005 A006 A007
BELT RUN LAMP VIB.ON LAMP WF ON LAMP FREE WF ON PLC SELECTION GENERAL FAULT MAT.O/L
A008 A009 A010 A011 A012 A013 A014 A015
FREE
A017 A018 A019 A020
REMOTE SELECTION LOCAL SELECTION FREE DRIVE START STOP
FREE LOCAL SEL FREE FREE FREE FREE FREE
MECHANICAL GAD
MECHANICAL GAD
FLSmidth Pfister India Ltd.
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