CS2024MANUAL

1. APPLICATION AND BASIC SPECIFICATIONS

Model CS2024 coal Feeder is a microprocessor control belt feeder featuring electronic

weighing and automatic speed regulation. It is used to feed precision calibrated coal to the

pulverizer with functions of automatic regulation and control.

The feeder is applied in a heat power plant of high degree of automatic control. It is an

essential associate equipment to a coal-fired boiler of pressure or suction operation.

BASIC SPECIFICATIONS

ITEM DESCRIPTION BASIC SPECIFICATION UNIT

1 Feedrate 10-100 T/h

2 Feeder Inlet Diameter 629 mm

3 Center Distance Between Inlet And

Discharge

2135 mm

4 Belt Drive 3 KW

5 Cleanout Conveyor Motor Power 0.25 KW

6 Feeder Over Dimensions (L×W×H) 3360×1700×1620 mm

7 Weight Of Feeder 4 TON

2. CONSTRUCTION

The feeder is comprised of feeder frame, feeder belt assembly, cleanout conveyor, weighing

system, coal plug-gage and coal void signaling devices. lubrication piping and electric wiring,

microprocessor control cabinet.

2.1 The feeder frame is comprised of casing, inlet and discharge end doors, side doors and

internal feeder light. The casing is an enclosed weldment that can resist explosive pressure

up to 0.34 MPa to meet requirements specified in NFPA Code 85F by National Fire

Protection Association of the U.S.A. Guide plate and skirt are provided in the inlet to form

fixed section of coal flow on the belt after coal is dropped into the feeder. All parts

contacting coal are made of OCr18Ni9 stainless steel. Inlet and discharge end doors are

firmly bolted to the casing to ensure perfect seal. All doors are optional to open leftward or

rightward. sight glasses are provided on all doors and nozzles are equipped interior of sight

glasses to clear off accumulated coal dust by pressurized air or water.

Internal feeder light of sealed construction enables observation of internal feeder operation.

2.2 The feeder belt assembly is comprised of motor, reducer, drive pulley, take-up pulley,

tension roll, belt supporting plate and the belt. The belt is rimmed and provided with a v-

guide at the inner belt center to engage with grooves on rollers to keep good belt tracking. At

the end of drive pulley scraper is equipped to clear off coal adhered on the outer surface of

belt. The tension roll is located at the midpoint of bell travel, it keeps the belt under a fixed

tension to obtain optimum weighing effect. The belt tension varies with different

temperature and with temperature variation. Intensive observations should be frequently

done and make tension adjustment by means of the take-up screws. Scaled indicator is

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equipped interior of side door to the feeder, the tension roll should be regulated to locate its

center at the midpoint of the indicator. Totally enclosed, variable frequency motor is used to

drive the belt. Which is comprised of a 3-phase ac motor, a tacho-generator. A variable

frequency driver and variable frequency motor provide an ac stepless speed regulation .It

can provide a smooth and stepless speed regulation within a rather broad range.

The feeder belt reducer is a two-stage reducer, comprised of cylindrical gears and worm

wheel. The worm wheel is oil bath lubricated while a cycloidal pump in the reducer pumps

oil via a hole in the worm shaft to lubricate the gears. The drive pulley is driven through a

pin type coupling which is mounted on the worm wheel shaft.

2.3 The coal void signaling device is located above the belt. When there is no coal on the belt,

the paddle of signaling device deflects and causes cam on the axle of device to turn and

actuate the limit switch, either to control the belt drive motor, or to initiate the coal bunker

vibrator, or to output a signal back to control room to signify no coal on the belt. The

customer may determine, according to operating system requirements, which of these

functions shall be performed. The coal void signal can also deactivate integrated weight and

can prevent feeder calibration with coal on the belt.

The coal plug-gage signaling device locates at the feeder discharge and is of identical

construction to the coal void signaling device. The limit switch outputs signal signifying

coal flow plug-gage at discharge and stops the feeder operation.

2.4 The weighing system is located between feeder inlet and drive pulley. All of the three

roller surfaces are finely finished, of which two rollers are fixed on the feeder casing to form

a weigh span and the third roller hangs on a pair of load cells. Coal weight on the belt acts

on load cells to output a signal. Output signal from the calibrated load cells signifies unit

length coal weight and frequency signal from the tacho-generator signifies belt speed. The

microprocessor controls integrates both signals to obtain the feedrate.

Test weights are located below the load cells and the weigh roller. During feeder operation,

test weights are supported by the weigh arm and the eccentric disc to part from the weigh

roller. On calibration, turn the ratchet handle so that the eccentric disc is turned to make test

weights hang on the load cells to check if the weight signal is correct.

2.5 Cleanout conveyor is used to clean off coal accumulated on inner floor of the feeder.

During feeder operation, coal adhered on the belt is cleaned off by a scraper and dirt

accumulated on inner belt is dropped off from both ends of the self-cleansing type tension

roll. As seat air also generates dirt, dirt will deposit on the inner floor to cause self-ignition if

it is not timely cleaned off. Cleanout chain is driven by a motor via a reducer, wing type

chain scrapes off the dirt to the feeder discharge. It is recommended that the cleanout

conveyor is synchronously operated with the feed belt operation so that coal accumulation

interior of the feeder is minimized. Furthermore, continue clean off is also of advantage both

to reduce feedrate error and to prevent chain pin from adhesion and rustiness. The cleanout

conveyor reducer is comprised of cylindrical gears and worm wheel. Electric overload

protection is provided for the cleanout conveyor drive motor, when overload the cleanout

conveyor motor’s power is automatically turn off by electronic overload relay to stop

reducer.

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2.6 Seal air inlet is located below the feeder inlet with a flange-type connection for the

customer to supply seal air into the feeder.

Under pressure operation status, the feeder needs sear air to prevent pulverizer heat air from

reversing into the feeder through the inlet. The seal air pressure is 60～245 Pa higher than the pulverizer inlet pressure. The required seal air delivery is the sum of air leakage from

hopper of downspout and the amount required to form a pressure difference between inlets

of the feeder and of the pulverizer. The feeder itself is construed as of reliable sealed with no

leak.

A threaded hole is provided near the feeder inlet for adapting a pressure gauge to test the

feeder internal pressure. The hole must be plugged if a pressure gauge is not equipped.

If the seal air pressure is too low, it will cause the pulverizer heat air reverse back to the

feeder so that coal dusts will stagnate at the door frames and at protrusion parts to induce

self-ignition. If either the seal air pressure or its flow rate is too high, it will blow coal

particles off the belt to degrade weighing accuracy and to increase the load on clean out

scrapers.

Furthermore, if the seal air flow rate is too large, dustiness is prone to be formed interior of

the sight glass to hamper observation. Therefore, suitable seal air pressure has to be

adjusted.

2.7 Except that the reducer is oil bath lubricated, grease lubrication is used for al l other parts.

All lubricating points within the feeder are connected with hoses that extend outside the

feeder so that, lubrication can be performed without opening doors to the feeder. Flexible

tubes are used for electric wiring, cables are led into the feeder through the tubes so that

casing seal is kept.

2.8 Control cabinet is installed on the body of the feeder. Power supply switch is located in

cabinet. It can turn on or turn off the power.

2.9 Microprocessor control board, power supply board signal converting board, variable

frequency driver disconnect switch, transformers, fuses and relays are installed within the

microprocessor control cabinet which is mounted on the feeder casing. On the panel of

cabinet microprocessor display keyboard and switches SSC and FLS are equipped. For their

functions. Please see CHAPTER 4-SYSTEM COMPONENT DESCRIPTION.

3. ACCEPTANCE AND INSTALLATION

3.1 Completion and perfect packing should be examined on receiving the feeder. If necessary,

open packing box is permissible but packing bags shall not be damaged. Having checked,

repack as it was and inquire timely for any doubt.

3.2 If the feeder is not to be installed right after arriving on jobsite then proper maintenance

should be carried out.

3.2.1 Properly maintain the original packing boxes to avoid being damaged. Storage area

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should be kept clean and carry out frequent inspections.

3.2.2 Inspect the protective film and drying-agent bags which are packed in the box before ex-

work delivery and keep them in good order.

3,2.3 Equipments are to be stored indoors, ventilated and waterproof hoods are to be provided

if equipments have to be stored outdoors. Pillows should be placed under the packing box

and drying-agent bags should be put within the hoods and carry out monthly inspection for

assurance.

3.2.4 In order to facilitate inspection and maintenance packing box shall not be stacked one

over the other.

3.2.5 Packing boxes of feeder accessory and of small hard wares are to be stored in a dry

place.

3.2.6 Packing boxes of electric parts (electronics), such as power supply cabinet and

microprocessor control cabinet etc. shall be stored indoors with heatproof and ventilation

means.

3.2.7 Regular inspection of drying-agent in boxes of electric parts (electronics) is of necessity.

Replace if failure is found.

3.3 Regular inspection and maintenance is of necessity during period of storage.

3.3.1 Note that in each routine maintenance only open those packing in which the parts that

need to be maintained are packed. Having accomplished maintain, repack them as they were.

3.3.2 Turn the belt drive motor and the cleanout conveyor drive motor by hand respectively

200 revolutions every month to make each part in motion and be lubricated. Place the belt

after every turn in a different location to the previous one so that belt deformation caused by

resting resting at the same location for a longs time is avoided.

3.3.3 Turn the tension roll by hand monthly.

3.3.4 Inspect monthly for the perfection of plastic packing film and for the validity of drying-

agent.

3.3.5 Lubricate all bearings tri-monthly.

3.3.6 Replace lubricating oil in the reducer annually.

3.3.7 Throughly cleanse and lubricate cleanout conveyor chain links with rust-proof oil or gear

lubrication oil annually.

3.4 For a storage period of more than one year:

3.4.1 Fill the reducer full of lubrication oil and seal all breathers. Keep the lubrication oil until

installation is to be carried out and then replace and refill the oil to specified level.

3.4.2 Remove the feeder belt and place it laterally in a dry cool place. Re-fold the belt tri-

monthly in order to change bend locations and to avoid bend marks.

3.4.3 Having removed the belt, turn monthly by hand the weigh rollers, the tension roll, the

take-up pulley and the driven sprocket shaft of cleanout conveyor to make each part in

motion and be lubricated.

3.5 Installation of equipments

3.5.1 As tension roll and weigh rollers are fixed by woodblocks when they are packed, do not

dismantle for assembly until the feeder has been installed onto the foundation.

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3.5.2 Beside applying the feeder accessory, a leveling ruler about 600 mm long and pillowing

blocks of 100×100 mm with different thickness should also be provided for installation.

3.5.3 Open the packing box and remove all packing material. However, do not take packing

film off the motor and off the reducer temporarily.

3.5.4 Place the feeder onto the foundation, make alignment for anchor bolt holes, put on bolts

and nuts but do not turn the nuts firmly.

3.5.5 Place both checking bars from the feeder accessory onto either side of two weigh span

rollers surface, then confirm the level of feeder with the leveling ruler. Adjust the level by

means of adjusting blocks under the feeder. Adjusting blocks must be placed as near to

anchor bolts as possible so that the feeder casing will not buckle as anchor bolts are firmly

screwed.

3.5.6 The transverse level of feeder is checked by the weigh span roller which is adjacent to

the feeder inlet.

3.5.7 Make final leveling after the second grouting and then firmly screw the four anchor

bolts.

3.5.8 Associated equipments such as downspout, coupling and discharge bunker etc are to be

assembled only after the feeder is firmly fixed.

3.5.9 The coal valve upstream of feeder upper downspout should be closed. When the feeder is

installed and the upper downspout is not yet assembled, the feeder inlet should be

temporarily covered with a robust cover which should be waterproof and dustproof.

3.5.10 Connect seal air duct to the feeder seal air inlet.

3.5.11 Assemble the coal void signaling device and the coal plug-gage signaling device.

3.5.12 Replace the lubrication oil in reducers of belt drive and of cleanout conveyor drive.

3.5.13 Inspect all mechanic jointed parts.

3.5.14 Assemble the microprocessor control cabinet onto the feeder.

3.5.15 Inspect all electric parts and contactors. Rub off rust and make fixation for loosened

parts.

3.5.16 Inspect and confirm that all wirings for feeder control system are correct without error

avoid that circuit board for control be seriously damaged when they are energized.

3.5.17 Assemble separately packed PC boards onto the microprocessor control cabinet.

3.5.18 Connect load cells to PC boards by receptacle plugs.

3.5.19 All electric cabinets should be reliably grounded.

3.5.20 Clean out dirt and foreign material interior of the feeder. Inspect carefully the

appearance of feeder and make timely repair for any damage. Replace sight-glass for any

scratch mark damage.

3.5.21 After installation keep on inspection and maintenance as required for period of storage

until the feeder is to be operated.

3.5.22 Do not energize until the operated is familiar with the construction of the feeder and

knows how to operate it. Please inform the manufacturer one month prior to operating the

feeder for detail information.

4. SYSTEM COMPONENT DESCRIPTION

4.1 FEEDER MICROPROCESSOR CONTROLS

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The microprocessor feeder electronics control system is designed to operate in industrial and

power plant environments where harsh conditions and frequent power disturbance exist. It

uses special circuits, software subroutines, and nonvolatile memories to store data,

programming and operating parameter. This allows the system to recover and keep the

feeder running under control after a momentary power loss. The microprocessor is package

in the feeder NEMA 4 control enclosure with a glass door for keyboard access. The

keyboard is part of an environmentally sealed display panel that is gasket against the

enclosure door. The feeder control consists of three hardware packages: a power supply, a

CPU board, and a motor speed control. Additional input and output device are available and

can be formatted to a variedly of requirements, both digital and analog.

4.1.1 Power Supply

The power supply board converts the customer’s ac power into the regulated low voltages

required to operate the control electronics. Input to the power supply is 110 V ac @ 50-60

hertz. This is converted by transformers into a series of low voltages which are rectified,

filtered, and regulated. The voltages and the electronics they supply listed below

Voltage Device

+5 V dc Microprocessor and Transistor-Transistor Logic

(TTL) Display, and Converter Cards

+10 V dc Load Cells and Amplifiers

-10 V dc Amplifiers +15 V dc Calibration Probes

-15 V dc Opto-coupled Inputs and Calibration Probes

The ± 15 volt supplies are isolated from the logic and amplifier Supplies. In addition, there

is an unregulated voltage which is used to energize relay coils, provided from the filter side

of the 20 Volt supply. There are also two 20 V ac supplies for the isolated feedrate converter

cards (A3) and speed demand converter cards (A2). Each converter card has on-board filters

and regulators. The applied voltage from the power supply to the controller board (CPU

board) is provided through a connector with six conductors.

4.1.l.1 Input/Output Circuit Description

Located on the power supply board, the input/output circuits isolate the microprocessor and

its associated circuitry from the electrical and control systems of the plant to eliminate

malfunction from transients or noise.

All inputs to the CPU board are optically isolated at the power supply board. The system is

designed to accept a maximum of twelve digital inputs or contact closures, a belt speed

signal and an analog demand signal. All output signals are similarly isolated and include:

seven power relays (each with two Form contacts), one read relay with two Form A contacts

and two analog signals. Logic signals are transmitted to and from the power supply board to

the microprocessor through a 50-pin ribbon cable. A typical isolated input operates as

follows: incoming signals are used to bias a light emitting diode whose light output is

directly proportional to input current. The light output of the diode is optically coupled to the

base of a phototransistor. The collector lead of the transistor sinks current from the

microprocessor to ground. Thus, inputs and outputs are electrically isolated.

A typical isolated output operates as follows. CPU signals are used to bias a light emitting

diode and an optically coupled transistor, as with inputs. However, the transistor emitter

sinks current to energize a relay coil and the relay contacts provide the output signal.

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4.1.1.2 Input Current to Frequency Converter Card (Al)

The function of the input signal converter is to convert the customer fuel demand signal to

normalized 0 to 10 kHz signal for interfacing with the microprocessor system. The fuel

demand signal is a current signal of 4～20 mA.4.1.1.3 Output Frequency to Current converter Card (A3)

The frequency to current converter card is used as a feedback module for customers who

require a feedrate feedback. This circuit allows the digital electronics of the microprocessor

to output a digital signal, while the customer receives a current feedback signal of 4～20 mA .

4.1.1.4 Frequency to Current Converter Card (A2)

The frequency convert card is used to convert a digital motor speed demand signal into an

analog speed demand signal for variable frequency driver.

4.1.2 CPU Board

The CPU board assembly is mounted against the interior of the door to the microprocessor

control cabinet and is electromagnetic ally shielded from the rest of the feeder electrical

controls. It contains the microprocessor, memories, digital interface circuits, and a

keyboard/display. The analog circuits used to amplify and convert the load cell signals to a

digital form are located on this board.

The CPU board is the principal mechanism through which control of the system is achieved.

Digital inputs and keyboard commands are processed by software algorithms which then

route signals either to digital outputs or to the display as required. All digital I/O interfaces

are isolated by circuits on the power supply board which prevent damage due to transients

and prevent operational malfunction due to noise.

Interfacing between the microprocessor and the analog parts of the system is accomplished

by conversion circuits. Signals which pass from an external analog device to the

microprocessor first must pass through an analog to digital converter (voltage to binary

number). If the microprocessor must operate an external analog device, its output is sent in

the form of a frequency to a frequency to voltage or current Converter card. This device is a

digital to analog converter since its converts a binary number to either a voltage or a current.

The A/D and D/A conversions are made with a resolution of one part in 4000 or 0.025

percent.

The software is contained in a permanent memory to the microprocessor control system. The

software is written so that the most important system activities (such as the motor speed

loop, and demand signal input) are processed fast enough to allow good control to be

achieved, while less important signals (such as relay outputs) are processed at a slower

speed. This time multiplexing concept in the software program allows for better control of

the process when a great number of tasks must be performed. The only inputs directly

accessing the CPU board are the keyboard and the load cells. All other I/0 signals pass

through optical isolation circuits located on the power supply, which gives the system

excellent noise immunity.

4.1.2.1 Microprocessor Memory

Programming of the microprocessor is done in assembly language, which provides the

operating speed required for maximum performance and reduces the memory space required

to store the operating program. The system utilizes either 8K or 16K bytes of available

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memory for program storage, depending on application requirements and memory circuits

used. There are also 2K bytes of random-access memory (RAM) for temporary storage of

data during operation, and two nonvolatile memories for permanent and noise-immune

storage of operating parameters and system totalizes.

The microprocessor accesses a type of permanent read only memory (ROM) called a UV

erasable EPROM for all operating instructions which form the system software program.

This ensures that the control program instructions are not lest during a power interruption.

All operations involving the microprocessor utilize the transfer of information to and from

memory. As the CPU executes its program by reading instructions from EPROM, data may

be needed from one of the I/0 interface chips, EEPROM, or NVRAM. This data may be

stored in RAM for later processing of stored directly in the CPU in a storage location called

a register. After the data is acted upon by the CPU, it may be stored in either its original

memory location or in another. In all cases, the use of memory for storage of programs, data,

and even memory addresses is an essential part of the microprocessor system.

4.1.2.2 Power Interrupt Protection Circuit

During operation, a temporary power interrupt may occur. This type of power failure may be

frequent and if the feeder memory data is erased during the interrupt, can shut down feeder

operations even after power has been restored. To prevent this, a power interrupt protection

circuit has been designed into the microprocessor controls which stores all incoming and

outgoing data, and all operating parameters, as soon as the start of a power failure is

detected. This allows the feeder to recover and keeps the system operating in an orderly

manner when power is restored after a failure.

4.1.2.3 Display Keyboard

Commands are entered to the controls via the keyboard on the front panel of the

microprocessor cabinet. To operate the keyboard, it is necessary to open the small outer door

by loosening its two thumbscrews. This door must remain tightly closed when the keyboard

is not being used to maintain the NEMA rating of the control enclosure. The clear window

allows the operation of the feeder to be checked without opening the door.

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The keyboard contains keys of three colors: white, blue, and yellow. The white keys are the

standard REMOTE-OFF-LOCAL selection of feeder operating mode and will be the keys

most frequently used. The blue keys are functions and numbers that are activated simply by

pressing them in the proper order. The yellow keys are additional functions and are accessed

by first pressing the solid yellow SHIFT key at the lower right corner of the keyboard.

REMOTE (white) allows the feeder to be controlled from the customer run permissive

contacts and demand signal. OFF (white) deactivates the feeder. (Belt JOG (blue) and

feeder calibration are possible only after deactivating the feeder.) LOCAL (white) operates

the feeder at a selectable speed. There cannot be material on the belt during LOCAL

operation or else the feeder trips after a two-second delay.

The JOG (blue) key may be pressed and held to operate the belt drive motor for as long as

the key is pressed. This command is used to check motor operation or to slowly move the

belt for service. The feeder must first be in the OFF mode to jog the belt. The belt drive

motor can be reversibly operated by pressing OFF- SHIFT-F2 for service.

Display Selection Keys

The upper eight-digit display (TCI-1) normally shows the totalized weight of material

delivered in kilograms. It is also used for number entry and display of special functions.

Whenever the display is not otherwise in use it reverts to show the totalized weight. There

are three totalized weight display selection: gravimetric only, volumetric only, or a total of

both. Gravimetric is defined as material delivered with a functioning weighing system.

Volumetric is defined as material delivered when the weigh system is at fault and the amount

of material is delivered using an assumed weight on the weigh span. The assumed weight is

an average of what the material was known to weigh before the weighing system faulted.

This weight is used to determine a nominal material density. Volumetric totalization has no

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guarantee of accuracy and may be at considerable error if material density is not uniform.

Therefore, a separate total is kept.

Total is the sum of both the gravimetric and volumetric weights.

Pressing TOTAL (blue) selects the totalizer mode on the eight- digit display. Repeated

pressings will cycle through each of the three modes. One of the three red indicators

immediately below the display is energized to show which mode is active, GRAV, TOTAL,

& or VOL. The mode being displayed in no way affects how all three of the totalizers are

updated internally. Whenever one of the totalizers becomes filled to capacity, it will roll over

and begin again at zero but Will have no effect on the other two totalizers.

From time to time it may be desirable to reset the three totalizers back to zero. To do this,

press:

SHIFT (yellow) TOTAL RESET (yellow)

The lower four-digit display (FRI-1) shows the feed RATE in tons per hour, the motor speed,

or the DENSITY (kg/m3) of material on the belt. Simply pressing the correct blue selector

key calls up the appropriate display. One of the three red indicators immediately below the

display is energized to show which display is active.

DENSITY (blue) shows the density of material on the belt in the gravimetric mode in actual

kilograms per cubic meter. In the volumetric mode, the density shown is based on an

average density determined before the weight system faulted.

RPM (blue) shows the feeder belt drive motor speed.

RATE (blue) shows the operating feedrate of the feeder when in the gravimetric mode or the

equivalent feedrate using the average density of the material when in the volumetric mode.

Display Indicators

The ten indicators on the keyboard panel give information as to the current operational status

of the feeder:

a. RUNNING (green) is energized whenever the belt drive motor is energized.

b. READY (green) is energized whenever the microprocessor is powered and the operation

of its core components has been verified.

c. FEEDING (green) is energized when the motor is energized and there is material on the

belt, as sensed by paddle switch (LSFB)

d. REMOTE (green) is energized when the feeder is operating in the REMOTE mode

under control of the customer's process control system.

e. CALIBRATIOON (amber) is energized throughout the feeder calibration procedure.

f. ADD WEIGHT (amber) prompts the operator to mount the calibrating test weights at the

appropriate point in the calibrating procedure.

g. ALARM (red) indicates that a problem exists which requires attention but which is not

serious enough to immediately stop feeder operation.

h. TRIP (red) indicates that a problem-exists which is serious enough that feeder operation

has been stopped.

i. VOLUMETRIC (red) indicates that a fault exists in the weighing system or its

electronics which prevents the feeder from operating in the gravimetric mode.

j. MAINTENANCE (red) indicates that routine lubrication and service of the feeder is

now due. For a lubrication schedule and maintenance procedure, refer to Chapter 6 of this

manual.

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Diagnostic Error Codes

Whenever an ALARM or TRIP condition occurs, an error code number is stored internally

to identify the source of the problem. To access the error code, press:

SHIFT (Yellow) ERROR RECALL (yellow)

A number will appear in the totalizer display. To decode the number, refer to Section 7.3.

4.1.2.4 Functional Specifications of Microprocessor Controls

INPUT POWER: 110 V ac ±10%,5O-60 Hz @ 100 VA.

DIGIAL INPUTS: Contact closures from system -15 V dc to opto-coupler input @ 20 mA,

optically isolated from low level logic signals.

Functions: Material on Belt (LSFB)

Discharge Plug-gage (LSFD)

Feeder Motor Starter (FFR)

Feeder Start (FS)

One Spare Channel

DIGITAL OUTPUTS: Relays controlled by optically isolated low

Level signals.

Relays: KI-K7 each With 2 form C contacts rated at 117 V ac @ 5 A or 125 V dc @ 5 A

resistive loading.

Functions: Trip (K1)

Reverse Motor (K2)

Remote (K3)

Feeding Volumetric (K4)

Feeding Material (K5)

Feeder Run (K6)

Alarm (K7)

Relay: K8 dry reed relay, with 2 Form A contacts, rated at 100 V dc max, 500

ma max, 10 VA max, make or break.

Function: Remote data logging pulse for TCI

(Total Material Integrator)

Pulse duration 200 msec on.

ANALOG INPUTS: Low level dc signals of 4-20mA with input internal resistance 250 Ω

representing customer demand.

Weight signals: Two Wheatstone bridge, inputs (J1 and J2) on CPU board scaled for 30 mV

full scale with 10 V dc excitation to bridge.

ANALOG OUTPUTS: Current feedback signals of 4-20mA with max, load of 600 Ω

representing material feedrate.

TACHOMETER INPUT: 0 to 2000 Hz sinusoid or square-wave, 3 to 50 V ac.

ACCURACY: Feedarte: ±0.5%

Integrated Totalized Weight: ±0.5%

4.1.2.5 FEEDRATE MEASUREMENT AND CONTROL CIRCUIT

The feeder weighing signal is generated by two load cells which support a weigh roller.

Located on each side of the weigh roller is a weigh span roller which together accurately

define a given length of belt on which the material is weighed. Each load cell supports 25

percent of the weight of material on the weigh span. The output of the load cells is scaled

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into a signal which represents tons of material per meter of belt. This weigh data contributes

to the feedrate formula from which the feeder is operated.

Weight (T/M) × belt speed (M/sec) =feedrate (T/sec)

The feeder controls can accept either an internal feedrate set point or a customer feedrate

demand signal. This signal is compare with a computed feedrate derived from measured

weight on the belt, belt speed, and other parameters to generate the system error signal

which operates the motor speed control. Compensation for system stability is provided in the

software. Furthermore, since the microprocessor has stored all system parameters and limits,

the error signal includes all these setting so that no adjustments are require on the speed

controls.

The microprocessor (software) computes the feeder delivery rate as follows: a measurement

sample is taken of the output of one load cell. This signal is converted into a digital signal

(binary number) by an analog to digital converter in the microprocessor having a resolution

of one part in 4000 (12 bit), or 0.025 percent. This number is compared against parameters

stored in permanent memory (ROM). If the signal is within acceptable limits, it is stored in

temporary memory (RAM). The same operation is then performed on the other load cell.

The signals are compared to each other to further test their validity. If the signals are

determined to be invalid, the feeder is switched to volumetric operation and the controls use

a simulated load cell output generated from a historical overage value stored in memory. If

the signals are determined to be valid, the two load cell signals are summed and the tare is

subtracted. The result is multiplied by a calibration factor (determined during feeder

calibration) to arrive at weight of material per unit of belt length. The result obtained is

stored in RAM. The belt speed is determined by measuring the period of the output

frequency of an ac tachometer attached to the motor shaft. The accuracy of this measurement

using the microprocessor, with a crystal as a reference oscillator, is 0.025 percent. This

analog signal is converted into a digital signal (binary number) and multiplied by another

calibration factor (determined during feeder calibration) to arrive at a number that represents

belt travel per second. Finally, the belt speed and weights are multiplied together to arrive at

the feedrate. This result is then compared to the demanded feedrate to determine the error

and to operate the speed control.

The feedrate is displayed in tons per hour. The federate is integrated to obtain totalized

delivery in kilograms. The feeder is designed to maintain uniform material volume on the

weigh span, therefore, the density is determined from the load cell output. This density

measurement is also available to the operator on the display panel.

4.1.2.6 SERVICE TOOL KIT

Special tools are listed below to facilitate accomplishment of test-run, calibration of the

feeder and maintenance. It is recommended that these tools be kept in their tool kits when

not in use.

a. Two checking bars for aligning the level of weigh roller with both weigh span rollers.

b.A calibration tool kit containing 2 calibration probes (Y8406-1), 2 probe connecting wires

(X9633-3) and 1 pack of retroreflective tape (W20393-1). They are used to calibrate the

feeder after it starts up and after it has been operating for a period of 6 months. How to

apply this tool kit is detailed in CHAPTER 5-ADJUSTMENT.

4.1.2.7 FEEDER DISCHARGE PLUCGAGE ALARM

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A paddle limit switch is located at the feeder discharge to sense the discharge plug-gage.

When material compacts and touch the contactor which limits the paddle motion, the paddle

actuates limit switch LSFD to contact closure and trip the belt drive motor. The alarm device

consists of a stainless steel paddle and a limit switch mounted separately on either side of a

horizontal shaft, of which the switch is located outside the feeder. The closure of unit pole

contact interior of the limit switch capsule can be adjusted through a cam which is mounted

on the shaft end.

4.2 PRELIMINARY START-UP

4.2.1 PRELIMINARY START-UP MEASURES

a. If the bunker is empty, open and close the valve above the feeder to deposit any foreign

material in the bunker or downspout on the feeder belt.

CAUTION

BEFORE ATTEMPTING ANY WORK INSIDE THE FEEDER, DEENERGIZE THE

ELECTRICAL CONTROL CENTER BY LOCKING THE MAIN CIRCUIT BREAKER

IN THE OFF POSITION.

b. Open all feeder doors and remove all debris from on the belt and inside the feeder.

c. Check oil level of reducer.

d. Remove fibrous tape and load cells packing support. Mount load cells onto the feeder to

support weigh and weigh span rollers.

e. Align the weigh roller according to the procedures in SECTION 5.3.3. Check the weigh

span and weigh rollers for freedom of rotation.

f. Inspect the electronics controls for proper installation and that all P.C. cards and cable

connectors are firmly in their sockets.

g. Measure the input voltage at the main feeder disconnect. If the voltage is correct, apply

power. Verify that green READY indicator is energized.

4.2.2 MICROPROCESSOR CONTROL SET-UP

There are a number of job-specific physical measurements that must be entered into the

microprocessor controls in order to operate a given feeder. The values are stored in

permanent memory and only have to be entered once.

The set-up command for each such value consists or calling upon a specific memory address

Location and storing at this memory location either a value or an instruction. Each memory

address consists of a two-digit number, therefore, the single-digit addresses (0-9) must be

prefixed with a zero for proper recognition. An instruction is usually a single-digit number

which sets the controls or display to operate in a predetermined way. A value is a feeder

parameter which is used by the microprocessor in its control sequence. When appropriate the

key for a particular instruction exists itself on the keyboard and can be used instead of

entering the memory address location. For example, the feedrate set point address location is

00, but the RATE (blue) key can be used instead to access that memory location.

All set-up commands require use of the SET-UP (yellow) key to access memory locations.

Then the desired address and parameter value are selected. To enter a value, or to alter one

previously entered, type it in and press ENTER (blue) according to the following sequence:

SHIFT (yellow) SET-UP (yellow) Key Or Address Location (blue) New Value (blue)

ENTER (blue)

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When recall for reference a value previously stored by pressing: SHIFT (yellow) SET-UP

(yellow) Key Or Address Location (blue) SHIFT (yellow) ? (yellow)

Note that the address location is shown on the left side of the display while being operated.

Each memory address location and its set point can be checked and altered by following

these sequences. When the feeder is powered but in the OFF mode, the blue arrow keys may

be used to proceed from one address location to another. Use the down arrow key to reach a

lower-numbered address or the up arrow key to reach a higher-numbered address by

pressing:

↓or ↑(blue) NEW VALUE (blue) ENTER (blue)

The arrow keys will respond only when the feeder is powered but in the OFF mode. When

the feeder is in the REMOTE or LOCAL mode, then SHIFT (yellow) SET-UP (yellow)

and ADDRESS LOCATION (blue) followed directly by specified commands or set-up

values must be operated when a value is to enter a certain address or to read out a certain

address.

Use the following general instructions when entering set-up values:

1. Before entering a set-up a value if is necessary to select an address for the value and the

display will become blank. If it is necessary to read out the address then press:

SHIFT (yellow) ? (Yellow). When the address is read and intend to alter if, then it is

necessary to press the key according to the sequence which is require for entering a new

value and revert to blank display status.

2. Enter numbers as if using a pocket calculator.

3. Do not use decimal point value (blue) unless it is indispensable.

4. No more than three numbers can be entered after the decimal point.

5. If a mistake is made press CLEAR (blue) to erase the entry and start again.

6. Press SHIFT (yellow) EXIT (yellow) to release the set-Up function without affecting

the already stored Value.

7. Press ENTER (blue) to enter the value into memory.

8. "88888888" will flash if an inappropriate entry is made. Simply start over and try again.

9. The keyboard may have a lockout feature which prevents any change from being made

to the Set-up parameters. The lockout feature is either a switch or a jumper wire

between terminals 107 and 117 in the microprocessor cabinet. To remove the lockout

feature so that set-up parameters may be entered, either open the switch or remove the

jumper wire.

10. It is recommended that the Set-up parameters be reviewed for correctness after all initial

entrees have been made.

11. To exit the set-up mode after entering or verifying set-up parameters, press the OFF

(white) key. If a value of 2 has been entered in Address 26, exit the set-up mode by

pressing SHIFT (yellow) EXIT (yellow)

4.2.3 FEEDER PARAMETER TABLE

The following table summarizes all the operating parameters of the microprocessor control

system. The values entered in the preliminary value column are to be used for guidance

during equipment start-up. They should be checked and changed as required in accordance

with actual jobsite conditions and, when verified, recorded, in the final value column for

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permanent reference.

Address Function Preliminary

Value

00 Feedrate (Tons per Hour) --

0l Speed Set Point (rpm) --

02 Initial Density Estimate (kg/m3) --

03 Run Mode Select --

04 Feed Display Select --

05 Maximum Feedrate (Tons per Hour) --

06 Minimum Feedrate (Tons per Hour) --

07 Totalizer Increment (Kilograms per Pulse) --

08 Demand Mode --

09 Tachometer Type --

10 Weigh Span --

11 Volume --

12 Calibration Probe Span --

13 Calibration Weight (Kgs) --

14 MSC Servo Loop Gain --

15 MSC Servo Loop Rate Feedback Gain --

16 Discharge Plug-gage Delay (Tenths of a Second) --

17 Belt Motion Monitor Delay (Seconds) --

18 Nuclear Monitor Trip Delay --

19 Weight Signal Filtering --

20 Feedback Signal filtering --

21 Feedback Filter Override Threshold --

22 (Not Used in This Application) --

23 (Not Used in This Application) --

24 Paddle Feedback Permissive --

25 Communications Unit Number --

26 Mode Select Enable/Disable --

27 FRI Output Frequency @ 1 tph

28 Raise/Lower Contact input Response Time --

4.2.4 INITIAL TESTS

This procedure verifies that the feeder and its controls are operating properly, simulates

feeder trip conditions, and checks the principal input/output connections.

4.2.4.1 With power applied, verify that only the displays and the green READY indicator are

energized. The red VOLUMETRIC indicator must not be energized. I it is, there is a

problem with the weighing system, which could be in a load cell, cable, or amplifier.

4.2.4.2 Unbalance the load cell by applying the calibration weight on one side of the weigh

roller. After a two-second delay the VOLUMETRIC indicator should be energized. This

closes a contact which changes the DENSITY display from approximately zero to the initial

density estimate entered in Address 02. Unbalance each load cell in order to check both

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sides, then remove the calibration weights.

4.2.4.3 Test that all keyboard indicators and displays are operational. When this test is

performed, all components will be energized for five seconds and then return off

automatically.

press:

OFF (white) SHIFT (yellow) SELF TEST (yellow) 4 (blue)

4.2.4.4 Press and maintain the JOG (blue) key to verify belt travel in the direction of the

feeder outlet.

4.2.4.5 Energize the feeder for operation at 500 rpm. Press:

SHIFT (yellow) SET-UP (yellow) RPM (blue) 500 (blue) ENTER (blue) LOCAL (white)

Verify that the green RUNNING indicator is energized and check the motor speed for

stability within ±5 rpm. If it is unstable, check the motor speed control servo loop gain

(Address 14) and the motor speed control servo loop rate feedback gain ( Address l5) to see

that those two parameters match the recommended initial settings. If they match, contact

SPERI for assistance in selecting values more suitable to the particular application.

4.2.4.6 Check for proper belt tracking. Verify that the V-guide of the belt within the grooves on

the pulleys and rollers, and that no humping is noticeable at any of these points. Adjust the

belt for proper tracking as per SECTION 5.3.2, if necessary.

4.2.4.7 Check belt tension and adjust as per SECTION 5.3.1 if necessary.

4.2.4.8 Connect a digital tachometer to the speed pick-up signal located at wires 145 and 146

on the terminal blocks inside the microprocessor cabinet. Set the tachometer to the

appropriate range for the type of feedback signal present. Select the RPM mode on the

lower keyboard display and verify that the display and the tachometer readings are equal. If

they are not, either the tachometer type (Address 09) is incorrectly entered, or the speed

feedback jumper on the CPU board is not adjusted correctly.

4.2.4.9 De-energize the feeder and deflect the material on belt limit switch (LSFB) paddle to

simulate a loaded belt. Energize the feeder in the LOCAL (white) mode to verify that the

feeder operates for only two seconds in the LOCAL mode with material on the belt.

After the feeder has stopped, verify that the red TRIP indicator is energized. If the feeder

does not trip or if the indicator is not energized, check the adjustment of the paddle switch

cams as per SECTION 5.3.4

4.2.4.10 Check the error recall function of the microprocessor controls. Press:

SHIFT (yellow) ERROR RECALL (yellow).

The display should now show 08, the error code indicating material on the belt in the

LOCAL mode. Return limit switch (LSFB) paddle to its in-service position.

4.2.4.11 Press the OFF (white) key and align the analog inputs and outputs according to the

procedure in Section 5.2.

4.2.4.12 Calibrate the feeder according to the procedure in Section 5.1

4.2.4.13 Apply the calibration weights. Produce or simulate a feeder start permissive and apply

a 100 percent demand signal. Check the motor current draw on each phase to verify that it

does not exceed the nameplate rating.

4.2.4.14 Check feedrate and feedback linearity by applying demand signals of 100,75,50 and

25 percent. Compare each demand signal applied to the displayed feedrate and to the

feedback signal output to verify linearity within ±0.5 percent.

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If simulation of maximum feedrate cannot be achieved during this test, proceed as follows:

1. Calculate the density by the test weight(s) supplied:

2 × test weight

———————————— = density (kg/m2)

volume on weigh span

2. Press the DENSITY (blue) key on the keyboard.

3. If the density displayed matches the calculated density but falls below 560kg /m2, the test

weight mat be insufficient to simulate 100 percent federate. When this occurs, the feeder

should be forced into volumetric operation by removing the test weight from one side of

the weigh roller. In the volumetric mode, the density value used by the microprocessor is

approximately 800kg/m3, so that a 100 percent simulated federate should be obtainable.

4. If the density displayed differs greatly from the calculated density, then it may be that the

feeder has not been correctly calibrated or that there is problem on the CPU board.

4.2.4.15 while the feeder is operating in the REMOTE (white) mode, deflect plug-gage alarm

limit switch (LSFD) paddle, the feeder should be tripped as delay time set in Address 16

expires. Check if the red TRIP indicator is energized when the feeder is deactivated. If the

feeder is not stopped or TRIP (red) is de-energized, adjust paddle or limit switch cams

according to procedures in Section 5.3.5.

4.2.4.16 check error recall function of microprocessor controls. Press SHIFT (yellow)

ERROR RECALL (yellow), the display should show 07 signifying feeder discharge plug-

gage occurs. Revert limit switch (LSFD) paddle to normal operation status and revert the

feeder to operate in the REMOTE mode.

4.2.4.17 White the feeder is operating in the RMOTE mode, deflect the material on bell limit

switch (LSFB) paddle and apply or simulate a demand signal from the combustion control

system. Verify that the two displays respond to feeder operation and that the four green

indicators, RUNNING, READY, FEEDING, and REMOTE are all energized.

4.2.4.18 Press: SHIFT (yellow) SELF TEST (yellow) 6 (blue).

Verify that the lower display shows the demand signal currently being applied to the feeder.

This signal will be displayed in the same unit of measure, tons per hour, as the feedrate

display, and should change as the demand signal changes. In this mode, all three LEDs

beneath the display will be de-energized. The controls will continue to display the demand

signal until the RPM, DENSITY or RATE (blue) key is pressed.

4.2.4.19 Press: SHIFT (yellow) SELF TEST (yellow) 5 (blue) and note the number shown in

the upper display. De-energize the control cabinet at the main disconnect switch and then

reapply power. Press: SHIFT (yellow) SELF TEST (yellow) 5 (blue) again to verify that

the number in the upper display is increased by one.

4.2.4.20 When initial feeder test has been completed successfully, press the OFF (white) key

to deactivate the feeder. Note that if the feeder is put into use right after the initial test is

completed, please go on test running according to procedures in section. 4.2.8. If the feeder

is to be inactive for a certain period, please proceed according either to section 4.2.5 or 4.2.6

depending on the duration of being inactive.

4.2.5 Maintenance for feeder to be inactive for a short period (less than 1 year) after the initial

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test.

1. Clean out all foreign material in the feeder.

2. Thoroughly flush interior of the feeder, apply rust-protective coating onto interior of

feeder after the flushing is dried.

3. The feeder inlet should be firmly and lastingly covered to keep off moisture and foreign

material.

4. Clean out dust, dirt and accumulated water within the control cabinets, put in bags of

drying-agent and keep the door tightly closed. Drying-agent bags should be put near to

limit switches installed interior of the feeder to keep off rust corrosion.

5. Mount on calibration weight and operate the feeder in the LOCAL mode for at least one

hour every month.

6. Proceed storage maintenance as detailed in section 3.2.

4.2.6 Maintenance for feeder to be inactive over one year after the initial test.

1. Proceed maintenance according to Section 4.2.5.

2. Loosen the belt take-up screws to release the belt tension.

3. If the feeder is to be inactive over 36 months, dismantle and store the belt according to

Section 5.3.6 in order to obtain the longest possible belt life. The belt should be stored

laterally and sunshade in a dry, cool place without ozone. Refold the belt every three

months to change the positions of bend, the radius of bend should be as large as possible.

4. Lubricate all bearings quarterly as detailed in SECTION 6.2.

5. Fill the reducer with lubrication oil up to its top if the feeder is to be inactive over one year

so as to prevent the forming of moisture. Seal the oil inlet with a dead plug after filling.

Note that lubrication oil should be reduced to normal level before the feeder starts up.

4.2.7 INITIAL SYSTEM OPERATION

Follow these special operating instructions the first time the feeder is energized to operate

according to typical operating procedures.

1. Be sure that the calibration weights are removed from the load cells.

2. Carefully load the feeder belt slowly opening the inlet valve to load the belt at a controlled

rate. This procedure minimizes compaction of the material and thereby reduces the force

necessary to start the belt moving which prolongs its life.

3. Clear the totalizers. Press: SHIFT (yellow) TOTAL RESET (yellow).

4. Clear the error stack. Press: SHIFT (yellow) ERROR RECALL (yellow) CLEAR

(blue).

5. Reset the feeder maintenance time. Press: SHIFT (yellow) F1 (yellow).

6. When the feeder is operating for the first time, check and adjust the belt tension every 15

minutes until the belt no longer extends.

4.3 TYPICAL OPERATING PROCEDURES

1. When filling the bunker, first close the inlet valve to minimize the filling pressure on the

feeder and to avoid compaction of the material at the feeder inlet. This precaution is

unnecessary if the bunker is refilled while at least 2.4-3M of material remain in it.

2. When starting the feeder, open the inlet valve slowly to load the belt at a controlled rate

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and to minimize compaction at the feeder inlet.

3. Energize the feeder controls at the circuit breaker (CB1) in the control cabinet. Observe

that the green READY indicator is energized, signifying that the microprocessor is

powered.

4. Press the REMOTE (white) key. Upon receipt of a customer generated feeder start

command and a demand signal from the combustion control system, the feeder begins to

operate and the green RUNNING and REMOTE indicators are also energized.

5. As material fills the feeder belt, the green FEEDING indicator is energized.

6. When the microprocessor has verified the operation of the weighing system electronics,

the feedrate is displayed above the energized RATE indicator and the totalized weight is

displayed above the energized GRAV indicator.

7. The feeder will operate as outlined above and will respond automatically to the changing

demands of the combustion control system until it is de-energized.

During normal operation, only the four green status indicators are energized. If any of the

amber or red status indicators are energized, then a problem has been detected and the

feeder requires attention.

8. For a brief feeder stop with a loaded belt, press the OFF (white) key.

9. For a clean shutdown with an empty belt, close the inlet valve while the feeder is still

running. When the belt is emptied, the feeder is automatically deactivated by paddle type

limit switch on the Void Alarm device, then press the OFF (white) key. This procedure is

recommended whenever the feeder will be inactive for more than a brief interval, since it

eliminates the possibility of material compaction at the feeder inlet due to consolidation

caused by its own weight.

10. To jog the feeder belt, press the OFF (white) key followed by the JOG (blue) key on the

microprocessor keyboard for as long as motion is required.

11. Cleanout conveyor selector switch SSC is located on the panel of the microprocessor

control cabinet to activate or deactivate the cleanout conveyor.

12. Illuminator switch FLS is located on the panel of the microprocessor control cabinet to

turn the illuminating light on and off.

5. ADJUSTMENT

5.1 FEEDER CALLBRATION

The feeder should be calibrated at start-up, after one month of initial operation, after every

six months thereafter, and after any of the following occurrences: belt replacement, weigh

roller adjustment, or replacement of a load cell module, the CPU board, or the

microprocessor program chip.

Calibration consists of the elimination of system tare, which includes the weight of the

weigh roller, load cell support assembly, and the feeder belt. It also involves measuring belt

speed and its relationship to motor speed, and calibrating the load cell output with a known

weight.

Cancellation of feeder tare is performed by measuring the average weighing system output

over exactly one belt revolution and then subtracting this amount from the total weight

measurement. When the belt is running empty, it produces a zero average contribution to the

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totalized weight. In normal operation, the average tare is automatically subtracted from the

gross weight of the belt. Therefore, only the weight on the belt is reflected as totalized

weight.

During the same time the empty belt is being weighed, the belt speed is accurately

measured. This is done by measuring the time it takes a retro-reflective tape marker on the

belt to travel between two fixed points. This parameter is measured a number of times to

determine repeatability and to compensate for variations in belt thickness. From this data,

the belt speed is calculated and the relationship between belt speed and motor speed is

established. The feeder operates with zero belt slippage. Therefore, the ratio of belt speed to

average motor speed is constant. This ratio is stored in memory and is used to determine the

belt speed for any motor speed.

The span of the weighing system is set after the tare has been measured. A known weight is

applied to the weigh roller and the average output over exactly one belt revolution is

measured. This calibrated span factor is stored in memory and used to accurately determine

the value of the weight of the material on the belt.

In principle, the calibration procedure involves placing a test weight on the weigh roller and

precisely measuring one revolution of belt and the weight on a fixed length of belt. This date

is processed using an algorithm developed from the results of material tests and guarantees

the specified feeder accuracy without the need of test chains of other material tests.

5.1.1 CALIBRATION PROCEDRE

NOTE

BEFORE CALIBRATING THE FEEDER. ALLOW IT TO OPERATE FOR 15 TO 30 MINUTES

TO LIMBER THE BELT.

5.1.1.1 Close the inlet valve above the feeder and empty the belt.

5.1.1.2 Press the OFF (white) key.

5.1.1.3 Close the feeder discharge valve below the feeder discharge.

5.1.1.4 Open all feeder side and end access doors, as well as the door to the microprocessor

control cabinet.

5.1.1.5 Adjust the belt to proper tension and tracking according to section 5.3.

5.1.1.6 Apply four strips of retro-reflective adhesive tape from the calibration kit to the belt

curb on the same side as the control enclosure. Each strip should be positioned

vertically on the belt curb and located entirely between two flexing slits in the belt,

rather than spanning over a slit. Place one strip each outboard of the drive and take-up

pulleys, a third adjacent to the weigh roller, and the fourth on the return belt beneath

the third.

5.1.1.7 Verify that all four tapes are spaced at a distance greater than one calibration probe

span length from each other.

NOTE

THE TAPES MAY STAY ATTACHED TO THE BELT FROM ONE CALIBRATION TO THE

NEXT. BEFORE SUBSEOUENT CALIBRATIONS, INSPECT AND CLEAN OFF THE TAPES

AT THIS POINT IN THE PROCEDURE.

5.1.1.8 Align the weigh roller according to section 5.3.3. Clean off any dirt accumulation at

each drag link pivot point.

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5.1.1.9 Separately insert both probes into relevant threaded holes on the weigh plate.

NOTE

ALTHOUGH THE TWO PROBES ARE NOT DEDICATED TO PARTICULAR LOCATIONS,

NOTE THAT THE PROBE LOCATION NEAREST TO THE FEEDER INLET IS

DESIGNATED LOCATION AND THE PROBE LOCATION A NEAREST TO THE

DISCHARGE IS DESIGNATED LOCATION B.

5.1.1.10 Connect the probe cables to the probes and to the receptacles in the microprocessor

control cabinet. Connect probe A to receptacle CAL A and probe B to receptacle CAL

B.

5.1.1.11 Compare the total weight of the two calibration weights against the value that is

stored in the microprocessor memory. To display the value stored in memory, Press:

SHIFT (yellow) SET-UP (yellow) 13 (blue) SHIFT (yellow) ? (yellow)

5.1.1.12 If the calibration weight displayed from memory above is incorrect, enter the correct

calibration weight as follows. Press:

SHIFT SET-UP 13 ** ** ENTER

* Enter in place of the asterisks the actual value stamped on each calibration weight,

accurate to two decimal places.

NOTE

IF A MISTAKE IS MADE DURING ENTRY OF THE CORRECT CALIBRATION WEIGHT

VALUE, PRESS CLEAR (BLUE) AND RE-ENTER ONLY THE VALUE. DO NOT RE-ENTER

ANY SET-UP COMMANDS.

5.1.1.13 Verify that the calibration weight is OFF the weigh roller on each side of the feeder.

5.1.1.14 Initiate tare and belt travel calibration. Press:

SHIFT (yellow) CAL 1 (yellow)

The feeder will now begin to operate under control of the microprocessor. Observe the

TOTALIZED WEIGHT display to verify that the calibration is proceeding in the

following manner:

1. The display will clear and a zero will be shown at the extreme right of the display.

2. The amber CALIBRATION indicator is energized.

3. A 25-second delay is initiated while the belt drive motor is brought up to 1000 rpm

and stabilized there.

4. When the delay expires, the first tape passing probe A causes the display to read

“.1”.The decimal point is turned off when the tape passes probe B. Each following

tape turns on the decimal point when it passes probe A and turns it off when it passes

probe B. In addition, as each tape passes probe A, the number on the display is

increased by one.

5. As the ninth tape crosses probe A, the belt will have traveled exactly two revolutions

(or four revolutions if two tapes were applied). The drive motor is de-energized and

the display shows the percentage repeatability error of the eight belt speed

measurements just performed.

6. If this error is greater than a programmed limit, the display returns to zero and the

calibration is automatically repeated until a measurement accuracy within the

programmed limits is obtained.

7. If after numerous attempts the calibration still fails, press SHIFT (yellow) EXIT

-21-

(yellow) to end the calibration and proceed to troubleshoot for problems in the motor

speed control or with belt travel.

5.1.1.15 If tare and belt travel calibration are successful, the amber ADD WEIGHT indicator is

energized and the expected value of the calibration weight appears on the display. If

the value shown is incorrect, press SHIFT (yellow) EXIT (yellow) to stop the

calibration. Refer to Section 5.1.1.12 for entry of the correct calibration weight value.

5.1.1.16 when the correct calibration weight is displayed, mount one calibration weight

beneath each load cell.

5.1.1.17 initiate span calibration. Press:

SHIFT (yellow) CAL 2 (yellow)

1. The belt drive motor is energized and after approximately 25 seconds, the display

shows zero and begins to count the passage of eight tapes as in Section 5.1.1.14.

2. After the passage of the ninth tape (not displayed), the feeder is de-energized and its

displays return to their normal functions.

5.1.2 CALIBRATION CHECK

By comparing the current calibration to the one done previous to it, the operator can

determine how repeatable the calibration is and how it may have changed over the last six

months. The microprocessor controls calculate the percentage change between the two

calibrations when the commands are entered as follows:

5.1.2.1 To compare tare percent change, press:

SHIFT (yellow) SELF TEST (yellow) 1 (blue)

5.1.2.2 To compare belt travel percent change, press:

SHFT (yellow) SELF TEST (yellow) 2 (blue)

5.1.2.3 To compare span percent change, press:


The results of all three calibration checks should be 0 ±0.20 maximum. If they fall outside

this limit, check the suspension of the calibration weight from the load cell for sticking or

other unusual characteristics; then repeat the complete calibration procedure.

NOTE

THE NUMBERS 99 AT THE EXTREME LEFT OF THE DISPLAY REPRESENT A NEGATIVE

SIGN, MEANING THAT THE INOICATION IS LESS THAN 0. THE SIGN OF THE CHANGE

(PLUS OR MINUS) IS SHOWN IN SUCH A WAY THAT A POSITIVE ERROR INDICATES

THAT THERE WAS TOO MUCH MATERIAL BEING DELIVERED BEEORE THE

CALIBRATION AND A NEGATIVE ERROR INDICATES THAT THERE WAS NOT ENOUGH

MATERIAL BEING DELIVERED.

5.2 INPUT AND OUTPUT ALIGNMENT PROCEDURE

The feeder controls can respond to a federate demand signal and return isolated analog

feedback signals. When the input and output modules associated with these signals are used

with the plant's control system, they must be adjusted prior to operating the feeder under

remote control.

There is one customer input channel used in the microprocessor control system, designated

A1. There are three output channels used in the control system which may require

-22-

alignment, designated A2, A3,and A4. Output channels used by the customer are determined

by the type of belt drive motor used in the feeder. The following are the standard output

channel configurations for the three available types of motors:

a. For eddy current clutch applications, A2 is an optional analog feedback, and A3 is the

standard customer analog feedback. A4 is used internally by the microprocessor and does

not require trimming.

b. For dc drive motor applications, A2 is used internally by the microprocessor for the

motor speed demand output and does not require trimming, A3 is used for customer

feedback, and A4 is the optional tachometer driver.

c. For ac variable frequency drive applications: A2 is used internally by the

microprocessor for the motor speed demand output and does not require trimming, A3 is

the customer analog feedback, and A4 is the optional tachometer driver.

Any analog input or feedback signal used by the customer must be matched or adjusted to

the microprocessor controls. Two signal levels must be adjusted for each channel used. The

first signal level, offset, corresponds to the lower value. The second, span, corresponds to the

higher value.

The internal tachometer and motor drive outputs do not require customer adjustment. Motor

speed signals are processed by the microprocessor controls in a closed-loop configuration.

Motor speed is monitored by the tachometer and processed by an algorithm which

determines if changes in motor speed are required to match the feedrate to the demand, and

then automatically makes those changes.

NOTE

IF THE FEEDER IS NOT EQUIPPED WITH A REMOTE ANALOG DEMAND INPUT, THE

INPUT ALIGNMENT SECTION CAN BE OMITTED. IF AN ANALOG OUTPUT SIGNAL IS

NOT PRESENT, THE OUTPUT ALIGNMENT SECTION CAN BE OMITTED.

When adjusting the signals to the microprocessor control, memory locations are accessed

which correspond to the particular channel being adjusted. For reference, the trim address

numbers and the channels they control are listed in the following table:

Output Channel Trim Address Wire Numbers

A3 Offset (low level) 0 139,140,141

A3 Span (high level) 1 139,140,141





A1 Offset (low level) 8 SIG+,SIG-,COM,S1

Al Span (high level) 9 SIG+,SIG-,COM,S1

Equipment required:

(1) A ammeter.

(2) An analog input demand Signal.

NOTE

THE PLANT COMBUSTION CONTROL SYSTEM IS THE PREFERRED SOURCE OF THE

DEMAND SIGNAL. THIS WILL PRECISELY ALIGN THE FEEDER TO THE CONTROL

-23-

SYSTEM.

5.2.1 OUTPUT ADJUSTMENT

NOTE

THE SPECIFIC TRIM ADDRESS NUMBERS PRESENTED IN THIS SECTION REFER TO

OUTPUT CHANNEL A3 AS AN EXAMPLE. ADJUSTMENT FOR OTHER OUTPUT

CHANNELS FOLLOWS IDENTICAL STEPS; HOWEVER, THE ADDRESS NUMBERS WILL

CHANGE. THESE ADJUSTMENTS MUST BE PREFORMED ONLY WITH THE FEEDER

OFF.

5.2.1.1 Verify that the proper current converter card is plugged into power supply board socket

A3 the customer feedback output module.

5.2.1.2 Connect an appropriate meter to the customer output feedback signal. This analog

signal is generated by a precision frequency source. By setting the low and high end

frequencies, the offset and span analog signals, respectively, are set.

5.2.1.3 To set the offset of channel A3, press:

SHIFT (yellow) TRIM (yellow) 0 (blue)

The display shows the frequency being sent to the analog conversion card. While observing

the meter connected to the output, press the blue up or down arrow keys to adjust the output

to 4 mA.

NOTE

PRESSING AND RELEASING AN ARROW KEY WTLL ADJUST THE FREQUENCY IN

SMALL INCREMENTS. PRESSING AND HOLDING THE KEY WILL CAUSE MORE RAPID

ADJUSTMENTS.

5.2.1.4 When the analog output offset is correct, press:

ENTER (blue) OFF (white)

This will store the adjustment in the microprocessor control memory.

5.2.1.5 To set the span of channel A3, press:


Adjust the frequency with the arrow keys until the proper span adjustment 20 mA is

obtained at the analog output. To store the adjustment in memory, press:

ENTER (blue) OFF (white)

5.2.l.6 To save time by avoiding starting at zero to set an offset or span value, press:

CLEAR (blue)

This key resets the frequency to approximate offset and span Values, 200 hertz and l000

hertz, respectively.

5.2.1.7 To exit an adjustment mode without changing a previously stored value, press:

SHIFT (yellow) EXIT (yellow).

5.2.2 INPUT ADJUSTMEMT

CAUTION

IMPROPER USE CAN CAUSE OPERATIONAL PROBLEMS. THESE TRIM ADJUSTMENTS

ARE COMMANDS TO ACCEPT WHATEVER SIGNAL IS AT THE INPUT. DO NOT USE IT

TO CHECK PREVIOUSLY STORED VALUES. (TO CHECK THE INPUT SIGNAL, USE

SELF TEST 6.) THESE ADJUSTMENTS MUST BE PERFORMED ONLY WITH THE

FEEDER OFF.

-24-

5.2.2.1 Verify that the proper input card is plugged into the input module socket Al. When

aligning the input, minimum and maximum demand signals are given to the microprocessor.

The analog demand is converted to a frequency, which is stored in the memory.

5.2.2.2 Apply a 4mA demand signal to the feeder. Use either a precision source or, preferably,

a 4mA analog demand signal directly from the combustion control system. Then press:


The feeder display will show the demand signal as an equivalent frequency that corresponds

to 4mA demand.

IMPORTANT

IF THE DISPLAY IS ZERO, FIRST CHECK THE FOLARITY OF THE DEMAND

SIGNAL.IF THE POLARITY IS CORRECT, THE INPUT CARD MAY BE DEFECTIVE.

5.2.2.3 Apply a 20mA analog demand signal to the feeder. The press:


The display, will show the demand signal as an equivalent frequency a few thousand counts

higher than the minimum reading; however, the absolute maximum frequency of 10 kHz

should not be exceeded.

5.2.2.4 To test the linearity on the demand signal with the feeder running, press:


The display will now show the demand signal converted into an equivalent feedrate in tons

per hour. All three LEDs which indicate RATE, RPM and DENSITY should be de-

energized. Apply the analog signal equivalent to zero feedrate; the display should indicate

the minimum feedrate as entered into the set-up parameter at Address 06. Increase the

analog signal in steps of 25, 50 and l00 percent and the display should show the

corresponding feedrate in tons per hour as soon as the demand signal exceeds the minimum

feedrate in Address 06.

To return the display to its normal operating mode, press the RATE (blue) key.

5.2.2.5 To test the linearity of the feedback signal, the feeder should be run in the REMOTE

mode with the calibrating weights engaged and the material on belt paddle switch (LSFB)

closed. If the switch is not closed, linearity will be affected. Until the FEEDING LED is

illuminated, the rate control circuit operates the belt speed based on the density entered into

the set-up parameter at Address 02. This feature prevents the feeder from running at its

maximum speed while the belt is being loaded.

5.3 MECHANICAL ADJUSTMENT OF FEEDER

Following basic requirements must be ensured to keep the weighing accuracy of the feeder;

proper belt tension; proper belt tracking; correct alignment of the weigh roller with weigh

span rollers; the six-month feeder calibration frequency and adjustment of minimum seal air

pressure for normal operation.

5.3.1 BELT TENSION

It is preferable to adjust the belt tension while the feeder is operating. Observe through the

sight glass on the side door of the feeder to see if the center of tension roll is located at the

middle of the scaled indicator. It is required that the tension roll fluctuates around the middle

of the scaled indicator. Belt tension can be adjusted by take-up screws which are mounted on

the feeder inlet end door. Both screws should be equally and alternatively adjusted to avoid

-25-

damaging the screw thread.

Newly mounted belt should be operating under tension no less than one hour to release belt

internal stress before normal operation. If a new belt is required to operate with load

immediately after it is mounted then attentively observe within the first hour and make

adjustment every 15 minutes. Note that both take-up screws must be equally adjusted.

Normal operation according to tension indicator can be performed after such adjustments.

5.3.2 BELT TRACKING

Belt tracking is to keep the belt travel along centers of drive pulley and take-up pulley to

avoid off track while maintaining a smooth and stable travel through the weigh span to

ensure weighing accuracy.

At the middle of inner belt a v-guide is provided to engage with grooves on pulleys, roll and

rollers to keep the belt travel centrally. The belt surface must be flat as it travels, tracking

adjustment should be made if belt humping occurs as it passes through pulleys or rollers.

Belt tracking can be accomplished by adjusting take-up screws. Screw or unscrew the left-of

right-side screw can cause the belt to travel leftward or rightward and thus tracking the belt.

Practical amount of adjustment is determined during test run.

PULLEYS AND ROLLERS

BELT V-GAIDE

BELT TRACKING ADJUSTMENT

5.3.2.1 BELT TRACKING PROCEDURES WHILE THE FEEDER IS NOT

OPERATING

It is most convenient to track the belt while the feeder is not operating, because all end and

side doors may be opened and belt humping can be clearly observed.

1. Open the feeder end door and turn on the internal feeder light.

2. When the belt is changed, verify its perpendicularity to the take-up pulley.

3. Properly adjust the belt tension.

4. Draw a cross chalk mark on the belt surface for determining the number of belt

revolutions. Initiate the feeder and operate it at low speed, attentively observe belt travel

for at least 5 revolutions to check if there is any belt humping. Then operate at high speed

for at least 20 revolutions. Belt tracking can be construed as perfect if no belt humping

occurs.

5. If belt humping occurs, then first make it correctly tracked on the drive pulley by adjusting

-26-

take-up screws to move and center the belt. Then operate the belt successively at low and

high speed for 5 and 20 revolutions respectively to check for belt humping until the belt

travels to perfection.

Some belt will reciprocately offset along the axis of drive pulley as it travels, adjustment

should then be made to cause the offset align with the midpoint of drive pulley.

6. In general, correct tracking is obtained after above adjustment as a crown is machined on

the surface of take-up pulley. Whenever belt humping is found at the take-up pulley, turn

the eccentric bushing on any side of the tension roll for an angle of 90° clockwise or anti-

clockwise depending on which side the belt off tracks. If belt humping still exists after

operation of 20 revolutions, then turn the eccentric bushing on the other side of the tension

roll 90° in a reverse direction and further observe belt operation for at least 20 revolutions.

Thereafter, in-between holes on the eccentric bushing can be used for adjustment until belt

humping is totally eliminated.

Whenever belt tracking has been adjusted on the take-up pulley then, check again the

tracking on the drive pulley and make re-adjustment if necessary.

7. After the belt tracking is accomplished, re-adjust belt tension to locate the center of tension

roll at the middle of the scaled indicator and verify that both take-up screws have been

equally adjusted lest that another belt off-track is induced.

Belt Tension Proper Belt too LooseBelt too Tight

Indicator (The Centre of Tension Roller)

Tension Roller Arm

Scale

Side Door Fram Side Door Fram Side Door Fram

Tension Roller Arm

Scale


Tension Roller Arm

Scale


5.3.2.2 It is hard to find out belt humping by observing while the feeder is operating with

material on the belt. The only possibility of evaluating belt off-track is to observe carefully

to see if the distance between either side of belt and roller is equal.

Observe the belt travel attentively while adjusting to be ready for a prompt reverse of

adjustment, because the belt is traveling at high speed and any maladjustment will instantly

off-track the belt to damage it.

-27-

Adjust both take-up screws equally for proper belt tension after the belt tracking is

accomplished.

5.3.3 INLET SKIRT

The inlet skirt should be mounted upright and parallel to the material flow. It should not

contact the belt and there should be a clearance between both parts.

Si de Ski rt

Spac

e Be

twee

n Ba

ck S

kirt

and

Bel

t

Coal Secti onal Vi ew 165-180mm

Spac

e Be

twee

n Si

de

Ski

rt a

nd B

elt

10-1

3mm 000

111

6-10

mm

Space Between Ski rt and Bel t

5.3.4 WEIGH ROLLERS

The weigh roller is to be horizontally lineal with both weigh span rollers. The linearity

should fall within 0.05 mm to ensure weighing accuracy.

Put on standard calibration weights to load the cells.

1. Add weights. Let the load cells loaded.

2. Place both checking bars from the feeder accessory beside either side of the belt and on

weigh span rollers, machined surface of checking bar between the surfaces of weigh span

rollers.

-28-

3. Apply feeler gauge and adjust the adjusting units on load cells so the checking bars contact

all three rollers at once. Make orderly adjustment on either side of weigh span rollers.

4. Raise standard calibration weights.

5. The feeder shall be recalibrated after weigh rollers have been adjusted.

ADJUSTMENT OF WEIGH ROLLER

5.3.5 CLEANOUT CONVEYOR

5.3.5.1 ABNORMAL OPERATION

The wing type cleanout conveyor only scrapes off a small amount of material while the

feeder is operating. If material is excessively accumulated to overload drive system then

abnormal operation is to happen. Excessive accumulation may be caused by an excessive

clearance the inlet skirt; a cleanout scraper failure or an excessive flow rate of seal air to

blow material from on the belt.

5.3.5.2 TAKE-UP OF CONVEYOR CHAIN

Take-up screws which are mounted against interior of inlet end door can be used for the take-

up of conveyor chain. Proper chain take-up is performed if droop of approximate 50 mm

exists between drive sprocket top circle and the lower chain. As the chain elongates so

indiscernibly that take-up re-adjustment is only necessary after a normal operation of three to

four years.

5.3.6 MATERIAL ON BELT SIGNALLING DEVICE (LSFB)

SPACER

PADDLE(No Coal on Belt)

BELT

PADDLE(Coal on belt)

ADJUSTMENT OF COAL SIGNAL DEVICE

(MATERIAL ON THE BELT)

1. Place a spacer of 38 mm thick between paddle of signaling device and the belt so that the

paddle is raised toward the direction of material flow.

2. Adjust the location of cam interior of the signaling device to make a just closure of limit

switch.

3. Apply set screw to fix the cam at its adjusted location.

4. Remove all adjusting blocks from the bell.

-29-

5.3.7 MATERIAL PLUGGAGE SIGNALING DEVICE (LSFD)

CLEANOUT CONVEYOR CHAIN

PADDLE PADDLE(Coal Plugged)

FEEDER BODY

PLUGGAGE SIGNALING DEVICE (LSFD)

1. Move the paddle of plug signaling device 38 mm toward the feeder inlet.

2. Adjust the location of cam interior of the signaling device to make a just closure of limit

switch.

3. Apply set screw to fix the cam to its adjusted location.

5.3.8 BELT CHANGING

5.3.8.1 CHANGING PROCEDURES

1. Close the valve above feeder and clear off material on the belt.

2. Before attempting and word inside of the feeder, be sure both the feeder operating switch

and the main circuit breaker are de-energized.

3. Open all end doors and side doors of the feeder.

4. Place woodblock under the tension roll to make the roll rest on the block and part from the

belt.

5. Remove the tension indicator.

6. Remove lubrication tube connected to the tension roll.

7. Remove weigh roller connecting plates from under the load cells.

8. Remove the linking rods.

9. Dismount and remove weight rollers from under the load cells through the side door of

the feeder and then take away calibration weights

10. Unscrew take-up screws to release the belt to its utmost relaxation. Take-up screws must

be alternatively unscrewed to avoid damaging the threads and never impact the wrench.

11. Push the roll dismantle prop into under the tension roll and bolt the prop onto the door

frame. Threaded holes may be provided on the door frame for fixing the prop.

-30-

DISMANTLE OF TENSION ROLL

12. Remove tension roll from the tension roll arm.

13. Pull out tension roll with the roll dismantle prop.

14. Dismantle and remove weigh span rollers.

15. Prop up belt cleanout scrapers to part them from the belt.

16.Mount the roll raiser into from the feeder discharge end door and adjust

the turn buckle to make the non-drive end of drive pulley rest on the

raiser.

-31-

DISMANTLE OF DRIVE PULLEY

17. Dismantle bearing cap from the pillow block on the non-drive end of drive pulley with

pillow block remains on the pulley shaft.

18. Push the roll dismantle prop into between the belt and the drive pulley with until the prop

is laid on the feeder casing and bolt the prop onto the feeder casing

19. Dismantle the roll raiser, the drive pulley and the roll dismantle prop in order.

20. Remove the inlet skirt.

21. Remove bolts from the belt supporting plate.

22. Remove bolts which are used for fixing of the upper and the lower guide rail and of the

take-up screw frame.

23. Remove take-up screw frame and take-up screws. Mount on the extended rail.

24. Remove lubrication tube from the take-up pulley.

25. Pull out take-up pulley and belt from the feeder inlet end door. Dismantle drive pulley, belt

supporting plate and then the belt.

26. Put on a new belt in reverse order as that mentioned above.

-32-

DISMANTLE OF TAKE-UP PULLEY5.3.8.2 NOTICES ON CHANGING

1. When remount the drive pulley after changing the belt, note that the half coupling on drive

pulley shaft shall be kept 3 mm away from the other half on the output shaft of the

reducer.

2. Make sure that the center of belt is aligned before being take-up so that the V-guide on

inner bell is sure to engage with grooves on pulleys and rolls.

3. Make sure that either take-up screw frame is kept equally apart from the slide so that the

perpendicularity of take-up pulley is ensured.

4. Adjust the belt tension properly.

5. Perform correct belt tracking.

6. Recalibrate the feeder after belt changing.

5.3.9 SEAL AIR.

Adjust the seal air flow rate so that pressure difference between the feeder and the pulverizer

falls within 60～245 Pa. Pressure gauge may be equipped on the feeder casing for checking internal pressure.

After the pressure is suitably adjusted. Confirm the opening of seal air inlet valve on the air

duct so that relocation is possible once the valve is open up or close down.

6. MAINTENANCE

6.1 INSPECTION AND REGULATION SCHEDULE

To inspect regulate and calibrate the feeder at regular interval is the basis for its safe, reliable

and functional operation and is also the guaranty of the feeder to operate according to the

-33-

engineering design standard.

(1) Before attempting any work inside the feeder, be sure that the selector switch is de-

energized and that the main circuit breaker is set at the OFF position.

(2) Daily inspection: belt tension, belt tearing.

(3) Weekly inspection: belt tension, belt tearing or laminating, reducer oil level.

(4) Monthly inspection: accomplishment of routine lubrication.

(5) Tri-monthly inspection: replacement of oil in reducer.

(6) Biannual inspection: de-energize the feeder and inspect.

a. All anti-friction and pivot bearings for any damage and all gears for wear.

b. The feeder for any excessive wear and erosive parts.

c. Free movement of weighing system (tie-rod, load cell, weigh roller etc.)

d. The belt for excessive abrasion.

e. The belt cleanout scraper.

f. The load cell and keep it clean.

g. All electric contacts to rub off any rust; all wire terminals for firm connection.

h. The interior of feeder to cleanout all accumulated material.

i. The inlet skirt for correct location and status of wear.

j. The accomplishment of routine lubrication.

k. The tension of cleanout conveyor chain and the agility of chain link pivot.

l. The accomplishment of feeder calibration.

(7) Additional regular inspection that should be considered:

a. Newly mounted belt should be inspected for proper tension, and check belt tracking 2 to 3

times each operating shift until the belt travels stably and its internal stress is fully

released. Thereafter check belt tracking every week.

b. Re-check the status of belt supporting rolls whenever one of the following changes are

made: replacement of a load cell module, belt changing or adjustment of weigh roller.

c. Take every opportunity to inspect the cleanout conveyor when end doors to the feeder are

opened.

(8) In addition to the six-month feeder calibration frequency, the feeder must be recalibrated

whenever one of the following changes are made: belt changing or adjusting, adjustment

of weigh roller or replacement of a load cell module.

6.2 LUBRICATION OF THE FEEDER

-34-

LUBE POINTS ON FEEDERLube points are marked on the attached drawing. Carry out routine lubrication according to

following schedule and notice reference remarks.

(1) Lubrication ScheduleLUBE

PT.

LOCATION NO.OF LUBE

PT.

PERIOD REF.PEMARKS

1 Belt Take-up Mechanism 4 Monthly 1.3

2 Cleanout Scraper Take-up device 2 Places on the

shaft

Monthly 3

3 Weigh Span Roller Shaft 2 Places on the

shaft

Biannually 3

4 Tension Roll Arm 2 Places on the

shaft

Biannually 3

5 Tension Roll 2 Places on the

shaft

Biannually 3

6 Weigh Roller 2 Places on the

shaft

Biannually 3

7 Belt Drive Reducer 1 Places on

Reducer

Monthly 3

8 Belt Drive Shaft 1 Places on the

shaft

Monthly 3

9 Cleanout conveyor Reducer 2 Places on Top Tri- Monthly 3

10 Cleanout conveyor Reducer 1 Places on

Reducer

Monthly 3

11 Cleanout Scraper Shaft 1 Places on the

shaft

Monthly 3

12 Material on The Belt signaling 1 Places on the Monthly 3

-35-

Device shaft

13 Material Plug-gage Signal Device 1 Places on the

shaft

Monthly 3

14 Shaft of Weight Checking Bar 2 Places on the

shaft

Biannually 3

15 Belt Drive Motor Depends on Motor Biannually 2.3.4

16 Cleanout conveyor Drive Motor 2 Places on the

shaft

Biannually 2.3.5

17 Belt Drive Reducer 4.5～6 liter See Remarks 6

18 Cleanout conveyor Reducer 3.5～6 liter See Remarks 6

(2) Remarks for Lubrication

a. Grease take-up mechanism and shaft monthly.

b. Remove the plug, press in grease until fully filled, reset the plug.

c. If grade of grease is to be changed, be sure of the possibility of mixing both grades in

order not to deteriorate the grease and cause lubrication failure. It is preferable to

thoroughly cleanse the old grease before filling in the new grade of grease.

d. Since the plug and the nipple parts from each other, power supply must be de-energized

before filling in the grease. Turn the motor by hand when it is de-energized until the nipple

is seen and located at the center of the hole and then fill in greases.

e. After the filling of grease, operate the motor for about 10 minutes so that grease is

completely and depressurizely delivered, then put on the plug.

f. After the first month operation of the feeder, thoroughly cleanse the filled grease and refill

in new grease. Then refill grease after every six months of operation or after operation of

2500 hours.

g. When another grade of grease is intended, whether the latter grade matches with the

previous one should be carefully studied. It is preferable to thoroughly cleanse the

previous grade before filling in the other grade.

h. The applied lubricant should be stored according to its specified requirements to avoid

from filling of decomposed and deteriorated lubricant.

(3) LUBRICATION GREASE

According to jobsite ambient temperature, calcium grease or compound calcium grease or

compound aluminum grease of water repelling property is optional.

Notice how the operating temperature changes with seasonal variation so that suitable grade

of grease can be selected.

(4) LUBRICATION OIL

Usually engine oil HQ-15 is used for the reducer lubrication, however, other grades of oil

may be used to suit seasonal variation and jobsite ambient temperature. Condensation Point

of the oil is to be 5～6℃ lower than the lowest ambient temperature.

6.3 CALIBRATION OF THE FEEDER

The feeder must be recalibrated after its first month of operation. Thereafter, in addition to

the six-month feeder calibration frequency, the feeder must be recalibrated whenever one of

-36-

the following changes are made: adjustment of weigh roller, belt changing, or replacement

of a load cell module, the CPU board or the microprocessor program chip.

7. TROUBLESHOOTING GUIDE

7.1 DIANGOSTIC LED INDICATORS

The four red LED indicators on the door of the microprocessor cabinet are energized to

signal that the feeder or its controls requires attention. These indicators, and the appropriate

response to each of them, are listed below.

7.1.1 Alarm

This indicates that a problem exists which requires attention, but which is not serious

enough to immediately stop feeder operation. To learn the code number of the problem,

press:

SHIFT (yellow) ERROR RECALL (yellow)

The error code number will be displayed above the LED panel. Refer to Section 7.3 for a

translation of the error code and for suggested corrective action. To reset the alarm and de-

energize the indicator when the problem has been corrected, press any of the while keys. If

the feeder is in operation, press the white key corresponding to its current operating mode

once again to reset the alarm.

7.1.2 Trip

This indicates that a problem exists which is serious enough that feeder operation has been

stopped. This occurs, for example, when the feedback signal is lost: when a motor starter

fault, gross speed error or feeder discharge plug-gage is detected, or when material is present

on the belt in the LOCAL mode or during the calibration procedure. To learn the code

number of the problem, press:

SHLFT (yellow) ERROR RECALL (yellow)

The error code number will be displayed above the LED panel. Refer to Section 7.3 for a

translation of the error code and for suggested corrective action. To reset the trip and de-

energize the indicator when problem has been corrected, press any of the white keys.

7.1.3 Volumetric

This indicates that a fault exists in the weighing system or its electronics which prevents the

feeder from operating in the gravimetric mode. Check for a defective load cell or for a

defective analog-to-digital converter. The indicator will be de-energized when the

microprocessor determines that the feeder can again operate in the gravimetric mode.

7.1.4 Maintenance

This indicates that routine lubrication and service of the feeder is now due. To reset the 720

hour running timer and de-energize the indicator when servicing is completed, press:

SHIFT (yellow) F1 (yellow)

NOTE

RESETTING THE FEEDER RUNNING TIMER ALSO RESETS THE RESTART

-37-

COUNTER. REFER TO SECTION 7.4

7.2 ERROR RECALL

An alarm or trip is always associated with an error code number which can be examined in

the TOTALIZED WEIGHT display by pressing in sequence the SHLFT (yellow) and

ERROR RECALL (yellow) keys. The displayed response to this command activity

depends upon the mode the feeder is currently operating in:

Remote Mode

The error code for the most recent alarm or trip will be displayed for five seconds while the

feeder continues to run.

Off Mode

In this mode, the codes of the eight previous alarms and trips can be examined. The error

code is displayed with an index number to its left indicating the specific error being

displayed. The most recent error has a zero index.

The following is an example of error conditions that might have occurred.

Index Error Code

0 13

1 09

2 04

3 01

4 03

5 00

6 00

7 00

When the ERROR RECALL keys is invoked, the latest error code, 13 in this example,

follows the zero in the display, indicative of the most recent alarm of trip. To examine what

specific error occurred before this, press the down arrow key ↓ (blue) causing the display to

show the index number 1 and error code 09. This means that the error having the code

number 09 happened prior to the error having code number 13. To proceed back into the

history of feeder alarms and trips, press the down arrow ↓ (blue) key. To go forward to ward

the most recent error, press the up arrow key ↑ (blue)

When in ERROR RECALL mode, all error code numbers can be cleared by pressing

CLEAR. For units equipped with the keyboard lock feature, the error list can be cleared only

when the keyboard is enabled.

In this example, only five error occurred since the index 5, 6, and 7 was last cleared. The

error recall mode must be terminated by pressing the OFF (blue) key before the feeder can

be operated in the REMOTE or LOCAL mode. If the microprocessor keyboard mode select

switches have been disabled by entering a value of 2 into set-up parameter 26, the error

recall mode is terminated by pressing SHFT (yellow) EXIT (yellow).

7.3 ERROR CODES

The following are translations of the error codes with suggested areas of corrective action.

-38-

Error

Number

Description Alarm

/ Trip

Possible Cause

01 A/D converter over range Alarm Defective load cell and/or cable.

Defective A /D converter (analog front

end components).

02 A/D not converting Alarm Defective A/D converter

03 Loss of tachometer feedback Trip The electronics does not sense the belt

drive motor turning. The motor can still

be jogged, but cannot be run in LOCAL

or REMOTE.

Stalled or defective motor.

Defective tachometer.

05 EEPROM write error Alarm Defective U43, device or socket.

06 NVRAM defective Alarm Defective U44 device, power down sense

circuits, or too low of a power loss

threshold.

07 Feeder discharge plugged Trip Feeder discharge valve closed or plug-

gage in feeder outlet hopper or

downspout.

Maladjusted feeder discharge Switch

paddle or limit switch LSFD cams.

08 Material on belt in LOCAL

or CALIBRATE

Trip Close the inlet valve above the feeder

any empty the belt.

Check for defective valve operator or

valve position indicator, if one is

supplied.

09 Remote TCI error

(TOTALIZED WEIGHT

display)

Alarm The total material integrator pulses

cannot keep up with the delivery rate and

some pulses are being lost. Operating

parameter #07 is set too small for too

large a federate. A maximum of five

pulses per second can be generated.

Increase parameter #07 setting Per

Section 4.2.2.

10 Feedrate error Alarm The demand federate has not been met,

usually because of an empty belt. Verify

that the green FEEDING indicator is De-

energized.

Check that the federate demand may be

too high for the density of the material

even with the belt operating at maximum

speed.

11 Motor starter fault Trip The belt drive motor starter does not

-39-

open or close upon command.

12 Motor speed control error Trip The belt drive motor or motor speed

control is producing a serious motor

speed deviation from the desired speed.

The system will trip if the motor speed

discrepancy is greater than±100 rpm for

more than 30 seconds.

7.4 SELF TEST SUMMARY

1. To compare tare percent change from the previous feeder calibration, press:


2. To compare belt travel percent change from the previous feeder calibration, press:


3. To compare span percent change from the previous feeder calibration, press:


4. To test all indicator lamps and displays, press:


All displays and indicators will be energized for five seconds and then return off

automatically. This test can be performed only with the feeder in the OFF mode.

5. The restart counter monitors the power supply to the controls by incrementing one count

for each time power is reapplied. To check the number in the counter, press:


To reset the total in the counter to zero, press:

SHIFT (yellow) F1 (yellow)

NOTE

RESETTING THE RESTART COUNTER ALSO RESETS THE FEEDER RUNNING TIMER

WHICH IS USED TO INDICATE WHEN ROUTINE SERVICE OF THE FEEDER IS DUE.

6. If run mode 0, 1 or 2 is programmed as the set-up parameter in Address 03, the input

demand signal will be displayed in tons per hour. If run mode 3, 4 or 5 is programmed in

Address 03, the motor running speed will be displayed in rpm. To check the input demand

signal or motor speed, press:


7. To identify the program chip currently installed in the microprocessor board, press:

SHIFT (yellow) SELT TEST (yellow) 8 (blue)

The upper display on the microprocessor keyboard will read, for example, “2712812”;

and the lower display will read, for example, “20”. The displays can be understood as

follows:

27128 = IC manufacturer’s number

12 = program family number

2 = program revision number

0 = manufacturing number irrelevant to field use.

8. To view the raw A/D reading from the load cells, press:


The upper display on the microprocessor keyboard will show the signal from load cell J1;

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the lower display will show the signal from cell J2.

NOTE

SELF TEST 9 CAN BE PERFORMED ONLY WHEN THE FEEDER IS OPERATING IN

THE LOCAL OR OFF MODE.

8. SPECIAL ACCESSORY

Special accessory supplied with the feeder is for adjustment and calibration. The accessory is

to be properly stored so that damage or deform does not occur. Electrical instrument is to be

humid-proof stored.

(1) CHECKING BAR

In checking the linearity of weigh and weigh span roller, both checking bars are respectively

placed on roller surface at either side of the belt and then check and regulate with a gauge

ruler.

On installation of the feeder, checking bar is also used to level the feeder.

(2) ROLL DISMANTLE PROP

Roll dismantle prop is used to replace the belt and to mount or dismantle the roller by sliding

the roller in or out of the feeder sideways.

(3) ROLL RAISER

When dismantling the drive pulley, open the discharge end door and hang the roll raiser on

corresponding holes on the inner wall of the feeder. Turn the adjusting nut of the raiser to

make one end of the pulley lie on the raiser so that the roll dismantle prop can be pushed

into between the pulley and the belt to slide out the pulley.

(4) EXTENDED RALL

The take-up pulley can be moved out of the feeder from the inlet end door by means of the

extended rail and then to dismantle the pulley assembly.

(5) CALIBRATION INSTRUMENT

It consists of two calibration probe assemblies, two probe interconnecting cables, and one

package of retro-reflective tape. Calibration is done according to feeder calibration

procedures. Usually, a six-month feeder calibration frequency is to be carried out.

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CS2024MANUAL

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