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 2135 mm
Discharge
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
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
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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.
2.6 Seal air inlet is located below the feeder inlet with a flange-type connection for the
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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 all 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
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-
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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.
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.
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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

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
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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.
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
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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
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
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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
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.
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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.
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 /m 2, the test
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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
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
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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
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.
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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
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,
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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.
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
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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
(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
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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
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
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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
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
-23-
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.
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
-24-
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
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
-25-
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.
BELT V-GAIDE
PULLEYSAND ROLLERS
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
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
-26-
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.
Side Door Fram Side Door Fram Side Door Fram
Tension Roller Arm Tension Roller Arm

Tension Roller Arm
Sc ale Sc ale
Sc ale
　Indicator 　Indicator
(The C entre of 　Indic ator
(The C entre of
Tension Roller) (The C entre of
Tension Roller)
Tension Roller)
Belt too Tight Belt Tension Proper Belt too Loose
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.
Space Bet ween Si de

Coal Sect i onal
Space Bet ween Back
Ski rt and Bel t

Si de Ski rt Vi ew 165- 180mm
Ski r t and Bel t
6-10mm
10-13mm
111
000
Space Bet ween 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.
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-
-28-
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)
PADDLE PADDLE(Coal on belt)

(No Coal on Belt)
SPACER
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.
5.3.7 MATERIAL PLUGGAGE SIGNALING DEVICE (LSFD)
-29-
CLEANOUT CONVEYOR CHAIN
FEEDER BODY
PADDLE PADDLE
(Coal Plugged)
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 PULLEY
5.3.8.2 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 FEEDER
Lube points are marked on the attached drawing. Carry out routine lubrication according to
following schedule and notice reference remarks.
(1) Lubrication Schedule

LUBE LOCATION NO.OF LUBE PERIOD REF.PEMARKS
PT. PT.
1 Belt Take-up Mechanism 4 Monthly 1.3
2 Cleanout Scraper Take-up device 2 Places on the Monthly 3
shaft
3 Weigh Span Roller Shaft 2 Places on the Biannually 3
shaft
4 Tension Roll Arm 2 Places on the Biannually 3
shaft
5 Tension Roll 2 Places on the Biannually 3
shaft
6 Weigh Roller 2 Places on the Biannually 3
shaft
7 Belt Drive Reducer 1 Places on Monthly 3
Reducer
8 Belt Drive Shaft 1 Places on the Monthly 3
shaft
9 Cleanout conveyor Reducer 2 Places on Top Tri- Monthly 3
10 Cleanout conveyor Reducer 1 Places on Monthly 3
Reducer
11 Cleanout Scraper Shaft 1 Places on the Monthly 3
shaft
12 Material on The Belt signaling 1 Places on the Monthly 3
Device shaft
13 Material Plug-gage Signal Device 1 Places on the Monthly 3
shaft
14 Shaft of Weight Checking Bar 2 Places on the Biannually 3
shaft
15 Belt Drive Motor Depends on Motor Biannually 2.3.4
16 Cleanout conveyor Drive Motor 2 Places on the Biannually 2.3.5
shaft
17 Belt Drive Reducer 4.5～6 liter See Remarks 6
18 Cleanout conveyor Reducer 3.5～6 liter See Remarks 6
-35-
(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
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
-36-
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
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
-37-
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.
Error Description Alarm/ Possible Cause
Number Trip
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.
-38-
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 Trip Close the inlet valve above the feeder
or CALIBRATE any empty the belt.
Check for defective valve operator or
valve position indicator, if one is
supplied.
09 Remote TCI error Alarm The total material integrator pulses
(TOTALIZED WEIGHT cannot keep up with the delivery rate and
some pulses are being lost. Operating
display)
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
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:
-39-
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;
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
-40-
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.
-41-

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1.

APPLICATION AND BASIC SPECIFICATIONS

3. ACCEPTANCE AND INSTALLATION

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

3.4 For a storage period of more than one year:

3.5 Installation of equipments

4. SYSTEM COMPONENT DESCRIPTION

4.1 FEEDER MICROPROCESSOR CONTROLS

4.2 PRELIMINARY START-UP

4.2.3 FEEDER PARAMETER TABLE

4.2.4 INITIAL TESTS

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

4.2.7 INITIAL SYSTEM OPERATION

4.3 TYPICAL OPERATING PROCEDURES

5.1 FEEDER CALLBRATION

5.1.1 CALIBRATION PROCEDRE

5.1.2 CALIBRATION CHECK

5.2 INPUT AND OUTPUT ALIGNMENT PROCEDURE

5.2.2 INPUT ADJUSTMEMT

5.3 MECHANICAL ADJUSTMENT OF FEEDER

5.3.2 BELT TRACKING

BELT TRACKING ADJUSTMENT

5.3.2.1 BELT TRACKING PROCEDURES WHILE THE FEEDER IS NOT

Side Door Fram Side Door Fram Side Door Fram

Tension Roller Arm Tension Roller Arm

Belt too Tight Belt Tension Proper Belt too Loose

5.3.3 INLET SKIRT

Space Bet ween Si de

Ski rt and Bel t

5.3.4 WEIGH ROLLERS

ADJUSTMENT OF WEIGH ROLLER

5.3.6 MATERIAL ON BELT SIGNALLING DEVICE (LSFB)

PADDLE PADDLE(Coal on belt)

ADJUSTMENT OF COAL SIGNAL DEVICE

5.3.7 MATERIAL PLUGGAGE SIGNALING DEVICE (LSFD)

PLUGGAGE SIGNALING DEVICE (LSFD)

5.3.8 BELT CHANGING

5.3.9 SEAL AIR.

6.1 INSPECTION AND REGULATION SCHEDULE

6.2 LUBRICATION OF THE FEEDER

(1) Lubrication Schedule

6.3 CALIBRATION OF THE FEEDER

7.1 DIANGOSTIC LED INDICATORS

7.2 ERROR RECALL

7.3 ERROR CODES

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