Fco-461 Operation English)

Hefei Jinshan CONTENTS 1

BELT-SCALE STRUCTURE..................................................................... ２

2

BELT-SCALE MACHINERY INSTALLATION........................................................ ３

3

BELT-SCALE ELECTRICAL INSTALLATION....................................................... ４ 3.1

THE

CONTROLLER INSTALLATION

............................................................... ４

3.1.1

Open the controller packaging ..................................................... ４

3.1.2

Putting the Controller into control cabinet ....................................... ５

3.2

THE

SENSOR INSTALLATION

.................................................................. ６

3.2.1

The Z6 sensor installation ........................................................ ６

3.2.2

The general sensor installation ................................................... ８

3.2.3

The Measure Speed Sensor installation ............................................. ９

3.3 4

THE

CABLING CONNECT THE CONTROL CABINET WITH THE BELT SCALE AND ITS REQUIREMENTS.

..................... ９

THE BELT SCALE POWER UP AND DEBUG...................................................... １０ 4.1

SET

4.2

GENERAL

4.3

THE

4.4

CORRECTS THE SLANTING OF

4.5

CHECK

5

UP THE FREQUENCY CONVERTER PARAMETER

................................................... １０

OPERATION OF THE CONTROLLER

....................................................... １１

BELT SCALE MECHANICAL PARAMETER

....................................................... １３

THE

BELT RUNNING CORRECTS

SIGNALS OF THE CONTROLLER

........................................... １４

： ....................................................... １５

THE BELT SCALE CALIBRATION............................................................. １５ 5.1

DETERMINED THE TOTAL WEIGHT OF THE WEIGHT AND THE CALIBRATION POLE.

.............................. １５

5.2

ENTER CALIBRATION INTERFACE ............................................................. １６

5.3

TARE

CALIBRATION ......................................................................

１６

5.4

STATIC HUNGING WEIGHT CALIBRATION .........................................................

１７

5.4.1

Zero calibration ................................................................ １７

5.4.2

Full calibration ................................................................ １７

5.5

DYNAMIC

5.6

REAL

6

HUNGING WEIGHT CALIBRATION ........................................................

１８

MATERIAL CALIBRATION ...............................................................

１８

COMMUNICATIONS CORRECTION.............................................................. ２０ 6.1

COMMUNICATIONS

CORRECTION FUNCTION ........................................................

２０

6.2

I/O

INPUT TEST .......................................................................

２０

6.3

ANALOG

OUTPUT TEST

.................................................................... ２０

APPENDIX 1：REPLACEMENT BELT ................................................................ ２１ APPENDIX 2：THE USE OF LUBRICANTS MODEL ..................................................... ２２ APPENDIX 3：THE CONTROLLER BACK PANEL TERMINAL DRAWING ...................................... ２３ APPENDIX 4：PARAMETER TABLE 1 ............................................................... ２４ APPENDIX 5：PARAMETER TABLE 2 ............................................................... ２５

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FCO-461 controller is a new generation of controllers introduced by Hefei Cement Research & Design Institute Jinshan factory Electrical & Automation Equipment Plant in recent years.FCO-461 as a multi-function controller, can be used for a single measurement equipment or the measurement equipment with pre-feeding equipment.

1

Belt-scale structure The significance of uderstanding the belt scale’s setup,debugging,calibration and safeguardi is very important

Figure 1 Figure 1 shows major part of the belt scale.

(1) Initiative Drum：Initiative Drum is driven by reduce motor ,and drag the belt. (2)

Passive Drum：By adjusting the screws of the Tension Slip Block (4), change the location of Passive Drum, you can adjust the belt tension and deviation

(3) Cross Reed： Cross Reed used to link Scale body and Measurement Framework. (4)

Tension Slip Block：It can adjust Belt-scale deviation and take-up - ２ -

Hefei Jinshan (5)

Measurement Framework.：It is Transmission Structures of Belt Scale，It spread material weight on belt to sensors.

(6)

Automatic Tension Denice：It can make Belt to maintain a certain degree of tension，and make the belt weight to change in a very small range。

(7)

Discharging hopper：passing by the discharging hopper ,stuff come from the Silo to the belt,and it can adjust thickness of the material layer by adjusting the opening of the hopper strobe. Geared Motor：the Driving Device of belt scale,it have the speed sensor which convert the angular velocity controller to

the identify electronic signals. (8)

Sensor:it convert weight to electronic signal which can be transmited to the contoller. Otherwise， On the surface of the scale, there are a the small drum roller which is parallel by Initiative Drum & Passive

Drum. According to their different functions, can be divided into Measurement Drum and Support Drum.

Figure 2

2

Belt-scale machinery installation The gradient of surface of the belt scale should be Less than 3/1000.

Figure 3 According to figure 3 , adjust installation location of discharging hopper,and when it is over ,the distance - ３ -

Hefei Jinshan from the underside the discharging hopper underside to the belt upper surface is 10～15mm,and the distance from the

Flange center of the discharging hopper to the center line of the Passive Drum is 250～300mm. Check whether the belt weighing components intact.

3

Belt-scale electrical installation Used a four-way Control panel as an example.

figure 4

3.1 The controller installation The Control panel ought to installed in the indoor with less dust and the Control panel shell should be connected to a good grounding. 3.1.1

Open the controller packaging

figure 5

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Putting the Controller into control cabinet

figure 6 Let us see the backup of the controller.

figure 7 there are some connection terminal rows and some computer plugs.the terminal row is pluggable,their have connected before it outed the factory,you only need to insert correct plugs to the right faucet. Each connection terminal number is not the same.According to its number and direction,you can finish right connection. And nearby connection terminal row,it marked "1" is No. 1 terminal Notice: Do not inserted connection terminal rows wrong,it will make the controller to go wrong or damage.

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figure 8

3.2 The sensor installation 3.2.1

The Z6 sensor installation

A set of components for the installation of sensor devices include a Pressure head screw and a fixed nut, a Z6 sensor, a steel Ball, a steel ball installed Block,two Fixed screw. The first step

figure 9 The second step

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Figure 10 The third step

Figure 11 The fourth step

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Figure 12 3.2.2

The general sensor installation

General sensor installation steps are Almost the same with Z6 sensor,but their installation foundations are different. Please refer to the Figure 13,put the sensor into its installation foundation,and Tighten the screws to Fix sensors(there are some corresponding position screw hole.)

Figure 13

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Hefei Jinshan 3.2.3

The Measure Speed Sensor installation

Figure 14

Figure 15 ▲ Please refer to the Figure 15,put the measure speed sensor into its installation foundation,and fix the sensor,then turn motor fan by your hand,check weather the sensor fight the gear) 1.If Yes, adjust the fixed copper pipe forward slowly，then repet ▲ step until just do not fight Gear，and revolve the copper piper backward one loop,and fix the fix screw nut.Insert the sensor into its installation foundation again，fix the screw. 2.if not, adjust the fixed copper pipe backward slowly，then repet ▲ step until just fight Gear，then do 1 step.

3.3 The cabling connect the control cabinet with the belt scale and its requirements. There are three type line between the control cabinet and the belt scale ,their is the signal line and the electrical line, the Control line three types.

The Signal line must be Shielded cable,and how to place different lines please to the drawings with the scale. The signal line demands to wear in charge of laying or the thread goes along the special-purpose bridge shelfing while connecting up， The line of signal should carry on earthing the single-end of shielding layer in the switch board to enter the switch board. All shielding layer all unsettled while wiring, no earthing, In scene, all shielding layer all unsettled while wiring, no earthing, please. Be careful：There are triangles to connect France and star and connect two kinds of laws quantitatively for the electromechanics machine wiring of material，Generally speaking the single-phase frequency converter which enters the line adopts the triangle to connect the law，And the frequency converter that three phases enter the line adopts the star to connect

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Hefei Jinshan the law. The detailed conditions please consult the frequency converter selected for use to prove. Please measure every wiring carefully after all wiring finish. Strong electricity and weak electricity have errorless to connect especially, so as not to lead to the fact unnecessary loss pay cable. The following is a wiring design of the line of signal between a belt balance and switch board, concrete wiring consults the paper of figure.

Figure 16

4

The belt scale power up and debug

4.1 Set up the frequency converter parameter Turn on the back door of the switch board, close the air switch from left to right, give electricity of the switch board, the controller and frequency converter are with electricity at this moment. Turn on the forward door the control cabinet, establish the frequency converter parameter. Take frequency converter F11S of Fuji as an example below, provide the parameter form that the frequency converter needs to revise, other parameters are subject to that dispatched from the factory and established。 Frequency

Parameter meaning

Number value 0 The panel is operated

F01

Signal mode

Generally establish 1 Voltage

signal 2 Electric current signal electric current signal

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3 Voltage and

2

Hefei Jinshan 0 Panel launched

F02

Start set

F03

the highest frequency

50～400Hz

50

F04

Basic frequency

50～400Hz

50

F07

First acceleration time

6

10

F08

First moderation time

6

10

F11

，1external signal

1

Hot protection electric current

Establish according to the

of the motor

motor

4.2 General operation of the controller First of all, make us familiar with the operation interface of the controller：

Figure 17 FCO-461 controller adopts systematic menu type way to carry on the function to manage，you can consult the chart of making and combine the manual to familiar with it to generally operate.

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Figure 18 The normal display status：Display picture of acquiescence when being electric each time of the controller. Operation 1: Method to enter main menu，Push The

main menu and return the normal display status, press the

key can enter the main menu，If you want to withdraw the

key.

Operation 2: Select the necessary function and method to enter the next grade of menu in each menu. At first ,Use the key moves the necessary function to and reveals the down area of the area（the up area of the area reveal the name of this menu），press the

key to enter the next grade of menu or sub function. If you want to get back to the menu at a

higher level and only need to press the

key.

Figure 19 For example：In Figure 19, We pass in the picture of having Move” Programing” to the down area of the area by pressing

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the

key. Push the

key and enter the next grade of menu.

Figure 20 Be careful：When you select the sub menu with black arrow point in the list and enter the next grade of menu, it will spring a menu Password _ _ _ _ _ _ _ _ and require you to input the password. It will enter the next grade of menu or sub function after only inputting the correct password Operation 3: Method to revise number value. Describe in the list as the parameter of revising, in fact this operation mode not only merely revise the parameter, but also revise the flow of establishing or establish the rotational speed under revealing the state normally. Number value is changed and generally gone on by this method. The concrete step:when you enter concrete parameter unit of the parameter form(As the upper list shows the procedure), If need to revise the parameter to push The

key is entered and press the

key confirms inputting, press the

Key input digit and press the

key deletes the single figure, press the

key cancel inputting.

4.3 The belt scale mechanical parameter When at being the initial electricity debug ,you only need input some parameters of the C mechanicals parameters mechanicals. The following is relevant number value of input of the necessary parameter. address

English

Explanation

Default value

simplification

Position in the figure 21

and

proving correspondingly

C00

Roller dia.

Cylinder diameter

0.22 m

1

C01

Speed Reducer

motor speed ratio

51

3 Mark in the plate of reduce machine.

C02

Eff.Platf.Length

The

effective

Weigh

0.45 m

length C03

Gear Number

Half of shown length

in the

position 2.

The number of pulses

30

when motor rotates a circle C04

Nominal Load

Nominal Load of the

100 kg

5 Mark in the plate of sensor.

3.95 m

4

sensor C05

Belt Length

Belt girth

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figure 21

4.4 corrects the slanting of The belt running corrects the figure 22 show me installation sites and panels of the locate box.

figure 22 turn the change-over switch of the locate box to the " manual " status，press the Starting button of the locate box，and adjust the potentiometer,to the belt scale a suitable speed. Monitor the running and leaning towards the direction of the belt scale，In general belt driven to the location as the passive drum. If the belt deviation to the left side, tighten the nut on the back of tension sliding block on the belt scale left side .If the belt deviate to the right side, tighten the nut on the back of tension sliding block on the belt scale right side. every time twist a nut one, two laps , After finish the work , should allowed the belt to run continutely, observe the effects.

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figure 23 Be careful：The new scale should run for several days and Observe status of its machinery, You need to carry out regular checks of belt running deviation status，and revise it。

4.5 Check signals of the controller ： When the belt scale runing,you can check whether the load signaal and the measure speed signal are normal.If the singals are irregular,please shut off the power of th controller at once and check whether sensor and sensor’s line connection are damage, and ensure that there are no short and circuit Opening situation. When the belt scale runing,press the Speed ＝ Motor speed value.Unit：rpm。

key,observe the controller Following the two state: Numerical range：0～1500rpm

The value should be relative the speed on frequency converter. Load.AD ＝ Load signal AD conversion value

Numerical range：100～4000

If these data are not in the numerical range or inconsistent with the requirements,please shut off the power of the controller, check whether sensor and sensor’s line connection are damage, and ensure that there are no short and circuit Opening situation.

5

The belt scale calibration

5.1 determined the total weight of the weight and the calibration pole. Record the total weight the weight and the calibration pole，mark as P（Kg）.

figure 24 Now assume that P = 20.7 (Kg), input this value as a weight weight into the D00 unit of the parameters list D00 unit

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figure 26

5.2 Enter Calibration Interface

figure 27 According to the process the figure provided by the figure 27 the calibration process enter the calibration sub-menu. At this time the manul/automatic switch of the locate box should be turned to "automatic" status.

5.3 Tare calibration After finish the second step，do the belt weight calibration.

figure 28 Then turn the controller status to the Volume mode. Interrelated step：

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figure 29 If system have a pre-feeding equipment ,you must stop the pre-feeding equipment. Continuously press the

3,press the

key and return to the nomally display status,set the motor speed as 600rpm by operation

key and start the belt scale.

Select “Tare calibration”on the calibration submenu and enter. The display will shows the percentage of the belt running 1 lap or N lap and the AD average value of belt weight.when the percentage change into 100%,the belt scale will stop automatically and display a ultimate value,press the

key and the

ultimate value will be written into the controller corresponding Parameter, the belt weight calibration process is over.If you aren’t satisfied with the reslute ,press the

key to cancel the operation.

5.4 static hunging weight calibration 5.4.1

Zero calibration

Let belt scales in the empty status and static status。Immediately following the above steps,select“zero calibration”on the calibration submenu and enter.The controller will sample A / D numers,system automatically stop after 10 seconds and show average AD sampling value, press the

key and the ultimate value will be written into the controller corresponding

Parameter,the zero calibration is over. If you aren’t satisfied with the reslute ,press the 5.4.2

key to cancel the operation.

Full calibration

Maintain the belt weighing stop,put the weight and the calibration pope on the scale.Then select“full calibration”on the calibration submenu and enter.

figure 30 system automatically stop after 10 seconds and show average AD sampling value, press the

key and the ultimate

value will be written into the controller corresponding Parameter,the zero calibration is over. If you aren’t satisfied with the

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reslute ,press the

key to cancel the operation.

5.5 Dynamic hunging weight calibration Don’t move the weight on the belt scale，stop volum mode and enter gravity mode. Interrelated step：

figure 31 Continuously press the

the flow as S1(t/h),press the

key and return to the nomally display status,set the motor flow (t/h) by operation 3,record

key and start the belt scale.

Using a stopwatch to record the time T1 (seconds)how long the belt circle one loop,and calculate the theoretical time T2 how long the belt circle one loop. computing formula T2=3.6×P×the belt loop length/S1/ The effective Weigh length then calculate Errors value Error＝

T1－T2 × 100% ，the value ought to be less than 1%。 T2

If the result Is greater than or equal 1%，enter the parameter D05. The original values of the parameter D05 multiplied byT2/T1 and input the result to the parameter D05 again. Restart the belt scale and repeat the test with a stopwatch,and calculate Errors value,until the result is satisfied with requirement. 。

5.6 Real material calibration whether do real material calibration should be dependent on the scene condition . if the belt scale is used for the dosage of raw material，the process should be finished.

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figure 32 change the controller mode to Volume mode.According to the figure 32, divide the process of the real material calibration in four steps. 1.

Preparation step

Open the strobe of the discharging hopper, let materials fall

Start the belt scale by pressing the

key.When the material overspead the upper belt,press the

key and

stop the belt scale,the material status is as shown in the dawing 1 of figure 32, materials just spread to materials fall position of the initiative drum. Clean the Surplus material fallen from the initiative drum during the belt runing.

Press the

key，clear cumulation。 2.

Press the

Strat the belt scale

key，set the motor speed (for example 600rpm)according to operation 3,then press the

key and

strat the belt scale,let material fall. 3. Press the

monitoring the cumulation value key，observe the display value of Z1 or Z2.

When the value reach the amount of material calibration,press the

key ，stop material to fall.

Be careful：the material calibration must be not less than 1/20 of the belt scale maximum production per hour.

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Hefei Jinshan 4.

Calculated correction

when the belt scale stop,the status is as shown in the dawing 1 of figure 32。Weigh total weight wich is fallen from belt start to belt stop this time,record total weight as W1. record the controller display cumulation as W2. The correction factor K2=W1/W2 If the absolute value of K2-1 is less than 1%,the calibration pass demand，no need to modify any parameter. If the Absolute value of K2-1 isn’t less than 1%，do follow steps： 1.

The original values of the parameter D06 multiplied by K2 and input the result to the parameter D06

again. 2.

6

have done the Real material calibration until the absolute value of K2-1 is less than 1% .

communications correction the primary fuction of communication correction is used for correcting analog output signal in system which have a host

computer. Interrelated step： Calling function list

6.1 Communications correction function Select OUTPUT Test

Please input Password. Password

Display “DO TEST

___111___

I/O output test

” DA1-DA7

OFF

I/O output don’t take out

DA1-DA7

ON

I/O output take out

Return Higher-level menu.

6.2 I/O input test Select DI TEST

Display “ RUN STOP SPEED P S “ When RUN have signal,the display of RUN will disappear，Etc. Return Higher-level menu.

6.3 Analog output test Select AO TEST - ２０ -

Hefei Jinshan

when set DAC0-DAC1 4 mA，the current of DAC0 and DAC1 will be up to 4mA When DAC0 out put minimum current,check by multimeter whether the A0 analog terminal is equal to 4mA,if not,modify the E00 parameter and make it to be 4mA. When DAC1 out put minimum current,check by multimeter whether the A0 analog terminal is equal to 4mA,if not,modify the B04 parameter and make it to be 4mA. when set DAC0-DAC1 20 mA，the current of DAC0 and DAC1 will be up to20mA When DAC0 output maximum current,check by multimeter whether the A0 analog terminal is equal to 4mA,if not,modify the E01 parameter and make it to be 20mA. When DAC1 output maximum current,check by multimeter whether the A0 analog terminal is equal to 4mA,if not,modify the B05 parameter and make it to be 20mA. Return Higher-level menu.

Appendix 1：Replacement belt

figure 33 1.

Remove corresponding components on no motor side of belt scale,let the side hang in the air

2.

Screw off the screw of the tension sliding block on the side,and put the end of passive drum into inside.

3.

Screw off the fixed screw of the tension sliding block on the side,and remove it.

4.

Remove the long screw of the tension sliding block rest part. - ２１ -

Hefei Jinshan 5.

move belt along the arrow of the drawing display.

6.

Replace new belt and setup the rest part by inverse order of steps.

Appendix 2：The use of lubricants model 1.

Recommend to use the special lubricant of 2*supramoly or 2L-2 Li radical , 90# Industrial gear oil in

reduction machine.before the belt scan run,you must check the smooth condition , maintain adequate lubrication and the filling volume of lubricant is the 1/3～1/2 empty volume of reduction machine. 2.

There are two filler well on the top of the reduction machine,and there are one screw plug on the bottom of

the reduction machine. 3.

The reduction machine lubricant should be replace once every 2,500 hours, appropriatily shorten the time of

replacing lubricant in the bad condition 4.

When the belt scale go out of factory,the reduction machine have be fillen with 2*supramoly,you need

appropriatily supply the lubricant after three month. 5.

The rest mechanical bearings of the belt scale only need be supplied with general lubricant.

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Hefei Jinshan Appendix 3：The controller back panel terminal drawing

figure 34

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Hefei Jinshan Appendix 4：Parameter table 1 Code

function

Initiali-zation

Unit

data A00

Setpoint mode

Configure mode

0

A01

Control mode

Control mode

0

A02

Speed mode

Measure speed mode

0

A03

Load_Max

Load max limit set

90

％

A04

Load_Min

Load min limit set

10

％

A05

Speed_Max

Speed max limit set

1200

rpm

A06

Speed_Min

Speed min limit set

300

rpm

A07

Par.ini

Initialization parameters

1

A08

BAK

backup

0

B00

Nominal Feed Rate

Rated flow

100

T/h

B01

Ex.Setpoint Min

External min signal value

4

mA

B02

Ex.setpoint Max

External max signal value

20

mA

B03

Ex.sp min

External signal threshold value

4

mA

B04

Flow_Out Min

flow output min value

4

mA

B05

Flow_Out Max

Flow output max value

20

mA

C00

Roller dia.

Drum diameter

C01

Speed Reducer

speed ratio

51

C02

Eff.Platf.Length

The effective Weigh length

0.45

m

C03

Gear Number

The number of measure speed gear

30

integer

teeth C04

Nominal Load

The load sensor standard range

100

kg

C05

Belt Length

Belt length

3.95

m

C06

Nominal Speed

Motor standard rotate speed

1500

rpm

D00

Calibrate load

Weigh weight

10

Kg

D01

Zero

Zero parameter

0

Sampling word

D02

Full

Full parameter

2000

Sampling word

D03

Tare

Belt weight parameter

0

Sampling word

D04

Test load

Test load

10

D05

Flow_K

Flow parameter

1

D06

Modify_K

Modify parameter

1

D07

N Circle Belt

Calibration laps

1

integer

D08

Load mode

Simulation load mode

0

integer

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Kg

User settings

Hefei Jinshan Appendix 5：Parameter table 2 Code

function

Initialization

Unit

data E00

Ctronl_Out Min

The min value of control output

4

mA

E01

Ctronl_Out Max

The max value of control output

20

mA

E02

Filter constant

Filtering constant

10

integer

E03

DEAD

Dead area

0.1

％

E04

PID_K

Pid parameter

E05

YUZHI_PIANCHA

Preferences deviation

30

％

E06

MIN_PROTECT

Preferences protection

5

Kg

F00

ADDress

Communications address

1

F01

Baud Rate

Baudrate

1

F02

Mode

Communications mode

1

G00

PROFIBUS_ADDr

PROFIBUS address

1

G01

PROFIBUS_mode

PROFIBUS mode

0

H00

Ctronl_2 Min

Pre-feeding control min output

4

mA

H01

Ctronl_2 Max

Pre-feeding control max output

20

mA

H02

Pre_control_mode

Pre-feeding control mode

0

H03

Pre_Feed Rate

Pre-feeding machine capability

100

T/h

H04

Pre_control time

Preferences adjustment time

8

s

H05

PIANCHA limit

Deviation limit

40

％

H06

Pre_ctrl limit

Preferences adjustment limit

40

％

H07

P.C_limit_k

Limit parameter

1

H08

DEAD2

adjustment dead area

1

H09

PP1

P1 parameter

10

H10

PI1

I1 parameter

4

H11

PD1

D1 parameter

0

H12

PP2

P2 parameter

8

H13

PI2

I2 parameter

3

H14

PD2

D2 parameter

0

H15

PP3

P3 parameter

5

H16

PI3

I3 parameter

4

H17

PD3

D3 parameter

0

H18

time-lapse start

Delay time

1

technical support ： 0551－3439417

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％

s

User settings