34-27-13 AutoBall Charger 301W Operations Maintenance

AutoCharge 301-W
AutoCharge Operations & Maintenance Manual

Weight-based Automatic Ball Feeder
Version 3.0W
Process Engineering Resources, Inc.
Salt Lake City, Utah, USA

JUNE 2012
Contents
AutoCharge Operations & Maintenance Manual ......................................................................................... 1
1.0 List of Drawings ................................................................................................................................. 3
2.0 Component Data Sheets ................................................................................................................... 4
3.0 System Description ........................................................................................................................... 5
4.0 AUTOCHARGE™ Hopper Door Adjustment ....................................................................................... 7
5.0 Maintenance Schedule ..................................................................................................................... 9
6.0 Recommended Spare Parts............................................................................................................. 11
7.0 Operator Local Control ................................................................................................................... 12
8.0 Remote Operation .......................................................................................................................... 19
9.0 Version History ................................................................................................................................ 27
AUTOCHARGE™ Operations & Maintenance Manual Page 2

1.0 List of Drawings
Drawing Number Date Title

PER- 1115-R2 11 JUNE 2012 General Assembly
PER- 1121-R1 29 FEB. 2012 Feeder Mounting Detail
PER- 1122-R1 29 FEB. 2012 Safety Guards
PER- 1210-R1 01 MAR. 2012 Ball Counter General Arrangement
PER- 1211-R1 01 MAR. 2012 Ball Counter Detail
AC-CBPAC-D10-PPC AutoCharge Control Box

2.0 Component Data Sheets
Component data sheets for the following items are included with this documentation
AutoCharge™ Control Box
• Control Box Wiring Diagram
• Norgren Control Valves
AutoCharge™ Feeder / Counter Equipment:
• Norgren Air Cylinder
• Mettler-Toledo Load Cells

3.0 System Description
3.1 AUTOCHARGE™ Components

The Process Engineering Resources Inc. AUTOCHARGE™ air-powered automatic grinding ball charging
system consists of the following equipment:
• Ball Feeder
• Discharge Chute Actuator
• Control Box
The Ball Feeder equipment should be assembled and mounted to the storage bin as shown in the site-
specific fabrication drawings. The Discharge Chute Actuator must be mounted below the discharge
chute and allow full travel of the chute without binding according to the site-specific fabrication
drawings.
The Control Box should be mounted in a position close enough to the ball feeder so that an operator can
observe the action of the feeder while adjusting the controls (feedrate, ball count, etc.). Connections to
be completed before proceeding include the following:
1. Electrical connections from the bottom of the control box to the load cell junction box (see
Control Box wiring diagram).
2. Control box air lines from compressed air supply to the box and from the box to the ports on the
Ball Feeder and Discharge Chute Actuator air cylinders (see Control Box wiring diagram).
3. Main electrical connection into the bottom of the control box to the disconnect switch terminal
4. Optionally, an Ethernet 100BaseT (Cat 5/5e/6) connection to the plant control system or
network
3.2 Drawing List

Refer to the drawing list on Page 2 for a complete list of the drawings related to the feeder and
discharge chute general assembly and maintenance.
3.3 Functional Description

The grinding balls gravity feed from the storage bin into the AUTOCHARGE™, where they accumulate on
the feeder table. An air cylinder (5”-bore, 4.75”-stroke) powers primary and secondary rotating feed
wheels. Each extension of the cylinder indexes the primary feed wheel 1/8 turn, controlled by a one-
way clutch and brake arrangement. As the feed wheel turns, it picks up a number of balls in the flight of

the wheel. As the balls pass top center of the wheel, they roll off the wheel into the discharge chute.
The balls are held momentarily in the discharge chute while the chute assembly is weighed by the load
cells integrated into the discharge chute actuator. The discharge chute then lowers, releasing the balls
onto the mill feed conveyor belt or feed stream.
3.4 Stop/Start
The feeder stop/start, feed rate and operating parameters may be controlled locally at the
AUTOCHARGE™ control box or from the plant distributed control system.
3.5 Weighing
Balls drop into the discharge chute where they are weighed by the integrated load cells. The weights
are accumulated by the AUTOCHARGE™ controller generating both total weight and feed rate of balls to
the mill.
3.6 Power & Air Requirements

The AUTOCHARGE™ ball feeder and counting system accommodates all electrical power and requires 90
psi compressed air with an approximate flow rate of 1 cfm.

4.0 AUTOCHARGE™ Hopper Door Adjustment
4.1 Safety Precautions

All plant SAFETY rules must be strictly followed. The minimum personal protection equipment
required for this operation: Hardhat, Safety glasses, Steel-toed safety boots, and Work gloves.
The EXTEND / RETRACT motion of the air cylinder must be stopped while adjusting the hopper door.
Note: Stop the feeder by following the stop procedure described in the Local Control section of this
manual. Never dump grinding balls into the storage bin while adjusting the door.
4.2 Door Adjustment

The hopper door adjustment feature of the AUTOCHARGE™ is provided for two reasons:
1. To close the opening from the storage hopper to the feeder while filling an empty hopper with
grinding balls. Failure to close the hopper gate may result in damage to the feeding and counting
equipment.
2. To provide the optimum opening for the smooth flow of balls out of the hopper into the ball
feeder.
4.3 Proper Door Height

The optimum flow of balls through the opening can be regulated by the height the door is raised.
Typically, this is approximately 80% of two ball diameters. Out-of-round grinding balls, debris
accumulating in the hopper, and other obstacles should be removed that may impede ball flow out of
the hopper into the feeder. There should be a single layer of balls on the feeder table when the hopper
door opening is properly set.
4.4 Torque Limiter

The door is held in position by a torque limiter keyed to the door adjustment shaft. The torque limiter
will be adjusted at the initial installation to hold the door in any opening height from 0" to 16", while
allowing the operator to turn the shaft with a wrench.
4.5 Positioning Hopper Door

To position the door, use a 1-1/4" box end wrench at least 18" long. Turning the shaft clockwise raises
the door; turning counter clockwise lowers the door.

4.6 Positioning Procedure
Initially set the door to position the bottom of the door approximately 1.6 ball diameters distance from
the feeder bottom plate. Start the feeder system (see the Local Control section of this manual) from the
control panel; observe the operation of the feeder and the flow of balls out of the hopper for
approximately five minutes. If further adjustment is required, stop the feeder, adjust the opening up or
down about 1-1/2'', then restart the feeder and observe until a smooth operation is achieved. There
should be a single layer of balls on the feeder table when the hopper door opening is properly set.

5.0 Maintenance Schedule
5.1 Safety Precautions

All maintenance must be conducted while following all plant SAFETY rules. Never perform maintenance
while dumping balls into the storage hopper or while the ball feeder is operating; always shut down the
feeder, disconnect electrical power, and shut off compressed air before attempting any maintenance or
adjustments. The minimum personal protection equipment required: Hardhat, Safety glasses, Steel-
toed work boots, and Work gloves.
5.2 Daily Maintenance

Every 24 hours of operation. Observe the operation of each piece of equipment in the grinding ball
transfer/count system from storage hopper to mill entry. Watch for loose or broken parts, erratic or
unusual operating conditions, compressed air leaks, loose electrical connections, and damaged electrical
insulation. Shut down the equipment to make any required repairs.
5.3 Storage Bin Maintenance

If the storage bin contains 24 hours supply of grinding balls, once each 24 hours run the storage bin
empty and sweep out or remove all dust, accumulated debris, and ball chips or halves. If the storage bin
has a larger capacity, schedule this maintenance operation to coincide with the bin capacity.
5.4 Weekly Maintenance

Every 168 hours of operating time, check the adjustment of the AUTOCHARGE hopper door torque
limiter. Check the torque of the 44 cap screws holding the chain to the hopper door. Check the
operation of the discharge chute and load cell inputs. The load cell inputs can be read directly from the
“Manual” operation screen, check that the signal responds according to no-load and loaded conditions
(maximum 100 lbs load). Check the cylinder clevis rod to make sure it has not loosened.
5.5 Yearly Maintenance

Every 8760 hours of operating time. Replace the Feed Wheel Torque Limiter Friction Disc and check the
Hopper Door Torque Limiter Friction Disc for wear. Check all mating parts for scoring or wear. Check the
hopper door for damage. Check the door guides for wear or damage. Check the torque on all mounting
bolts, cap screws and setscrews. Replace the rod and piston seals in the air cylinder and check the rod
and clevis pins for wear. Disassemble the feeder one-way clutch following the manufacturer’s
instructions; replace any worn parts and reassemble. Check all electrical wiring for loose or damaged
connections. Check all air piping and hoses for damage or leaks.

5.6 Safety Guards
Always replace safety guards that have been removed for maintenance, before restoring electrical
power or air pressure.

6.0 Recommended Spare Parts
6.1 Recommended Parts per Installation

Recommended AUTOCHARGE™ wear parts and capital spare parts per installed unit are listed in the
tables below. Items designated with an asterisk (*) are capital spare parts with only one item required
per two installed units.
6.2 Wear Part (One Year)

Part Name/Number Manufacturer Drawing Quantity
Torque Limiter Friction Disk (700A) Morse PER-1115-R2 1
Cylinder Repair Kit (rod & piston) Norgren PER-1115-R2 1
6.3 Capital Spare Parts

Part Name/Number Manufacturer Drawing Quantity
*A-1233C1-P(3/8B)-5X4.75 Norgren PER-1115-R2 0.5
Air Cylinder Seal Kit (SWK-35) Norgren PER-1115-R2 1
Air Cylinder Piston Seal Kit (AJK-503) Norgren PER-1115-R2 1
Torque Limiter Friction Disk (700A) Morse PER-1115-R2 2
*P-16A-LH Cam Clutch Morse PER-1115-R2 0.5
Unisphere Bearing (048034) Dodge PER-1115-R2 4
*ASA#8012-Tooth Sprocket Utah Fabrication PER-1115-R2 0.5
*ASA#8014-Tooth Sprocket Utah Fabrication PER-1115-R2 0.5

7.0 Operator Local Control
7.1 Local Operator Interface

The AUTOCHARGE™ control box incorporates a panel mounted touchscreen PC for local control and
configuration of the feeder system. The computer is configured to boot and automatically launch the
controller interface when power is applied from the disconnect switch located on the right side of the
control box.
When the computer boots and the operator interface starts the screen in Figure 1 is shown for 60
seconds or until the Continue button is clicked after about 5 seconds.
Figure 1 AUTOCHARGE™ startup screen
7.2 Local Data Entry
Since the AUTOCHARGE™ control box does not have a keyboard, all information is entered through the
touchscreen using and on-screen keyboard or on-screen numeric keypad. To edit a value, click on an
editable value and the computer will show the appropriate keypad (numeric or alpha-numeric) as shown
in Figure 2. To enter a new value, type the value using the on-screen buttons and click OK. For numeric
values, the minimum and maximum allowable values are shown. The keypad will not accept values
outside this range.

Figure 2 On-screen numeric keypad
7.3 Local and Remote Modes

The AUTOCHARGE™ may be operated from the local display or from a remote network connection.
Initially, when the AUTOCHARGE™ starts, it enters LOCAL mode. The mode is indicated in the upper
right corner of the screen as shown in Figure 3 and Figure 4. The mode can be toggled by clicking either
the “REMOTE” or “LOCAL” button.
Figure 3 Main screen, local operation
For safety reasons, the local/remote operating mode can only be set from the local display.

Figure 4 Main screen, remote operation
7.4 Initial Configuration

When the AUTOCHARGE™ is shipped, it does not contain any configuration information and must be
configured prior to first use. Attempting to start the AUTOCHARGE™ with missing configuration
parameters will generate a configuration error.
To enter the configuration settings, use the “Setup” button located on the main LOCAL screen. This will
open the setup screen shown in Figure 5. Each of the configuration parameters is described below.
Figure 5 AUTOCHARGE™ Setup screen

Ball Weight Units – defines the units used for the nominal ball weight (typically lb or kg).
Weight Scale Factor – applies a scaling factor to the load cell input signal. By default, the load cell input
is in kilograms. Enter the conversion factor here for other ball weight units of measure.
Cylinder Extend Time – is the amount of time (in seconds) required for the air cylinder to fully extend.
This value depends on supplied air pressure, but is typically 1 – 3 seconds.
Cylinder Retract Time – is the amount of time (in seconds) required for the air cylinder to fully retract.
This value depends on supplied air pressure, but is typically 1 – 3 seconds.
Settling Time – is the time (in milliseconds) the AUTOCHARGE™ will delay after the cylinder retracts and
before it attempts to measure the weight of the discharge chute.
Feed Zero Count Limit – the AUTOCHARGE™ counts the number of feed attempts for which there are no
balls counted across all channels. If the value exceeds this limit, the controller will indicate a “ball jam or
bin empty” condition. This condition must be reset by an operator before the AUTOCHARGE™ will
continue.
Chute Discharge Time – is the time (in seconds) for the discharge chute to lower. This value depends on
supplied air pressure, but is typically 1-3 seconds.
Auto-Tare – when this box is checked, the AUTOCHARGE™ will weigh the empty discharge chute
between each discharge. If this box is unchecked, the AUTOCHARGE™ will weigh the empty discharge
chute only once when the mode is set to RUN.
Español – click this button to display the user screen in Spanish.
In addition to the configuration parameters, the feed rate must be set for the AUTOCHARGE™ to start
feeding balls. The feed rate is set in the ball weight units per hour and is adjustable from the main local
display (or remotely).
7.5 Remote Operation Network Setup

For remote operation, the AUTOCHARGE™ controller must be connected to the local network and have
its IP address set accordingly. The AUTOCHARGE™ controller has two network ports, Ethernet 1 and
Ethernet 2, located on the top of the controller inside the control box. Ethernet 1 is used internally to
connect the controller to the panel PC. Ethernet 2 is available for connection to the plant control
network and its address can be set using the “NETWORK” button from the AUTOCHARGE™ setup screen.
The network setup screen is shown in Figure 6. The controller does not support dynamic address
assignment through DHCP. It must be configured for a static IP address that is compatible with the plant
control network.

Figure 6 Network setup screen
To enter an address, subnet mask, gateway and DNS, click on each number of the address field and
enter the appropriate values using the on-screen numeric keypad. When the address settings are
correct, click the “Update” button to apply the changes. Updating the network address takes several
seconds and will reset the controller. A message is displayed on the screen while the address is being
updated. After the update is complete, click “Close” to return to the AUTOCHARGE™ setup screen.
The internal IP address (Ethernet 1) is set to 192.168.96.55/255.255.255.0 and the panel PC

address is 192.168.96.2/255.255.255.0. If these addresses conflict with the plant network,
please contact PERI for assistance on modifying the internal addresses.
For more information on remote operation, see the Remote Operation section of this manual.
7.6 Local Automatic Operation

When the AUTOCHARGE™ is configured, local operation is possible by setting the feed rate and clicking
the “START” button. The feeder will discharge balls according to the desired feed rate and the number
of balls counted at each discharge. The delay between discharges is automatically adjusted based on
the weight per discharge and the desired feed rate. The delay time is displayed on the main screen (in
both local and remote modes), as well as the average weight per discharge, measured charge rate and
feeder status. The feed rate is only adjustable locally when LOCAL mode is selected. When in remote
mode, the feed rate is displayed but cannot be modified.

To stop the feeder in local mode, click the STOP button (STOP is only visible when the AUTOCHARGE™ is
running). To stop the feeder locally when it is being operated remotely, first click “LOCAL” then click
“STOP”.
7.7 Local Manual Operation

In local mode, the feeder can be operated manually by clicking the “MANUAL” button on the main
screen. If the feeder was running in automatic, it will be stopped for manual operation. The manual
operation screen is shown in Figure 7. There are four controls on the manual operation screen
described below.
Figure 7 Manual operation screen
Advance – causes the feeder to advance one half of one full discharge cycle, which is to extend and
retract the air cylinder once. Using the Advance button does not perform any weighing.
Extend – extends the air cylinder (feeder or discharge chute), no balls are weighed using this action.
Retract – retracts the air cylinder (feeder or discharge chute), no balls are weighed using this action.
The raw and filtered input signals from the load cells are displayed for testing/troubleshooting.
To exit manual operation, click either the REMOTE or AUTO button to return to automatic remote or
automatic local operation, respectively.

7.8 Feed Simulator
The AUTOCHARGE™ controller has a simple feed simulator used for testing of the controller and screens.
The simulator is accessed through the Setup page (described in section 7.4 Initial Configuration above).
Click the “Simulator” button to open the AUTOCHARGE™ Simulator screen shown in Figure 9. Click the
selector switch to start or stop the simulator.
When the AUTOCHARGE™ runs with the simulator, all actual inputs and outputs from the controller box
are disabled and replaced with simulated inputs and outputs.
Figure 8 AUTOCHARGE™ Feed Simulator
When “RUN SIMULATOR” is selected, the controller generates a random weight for the discharge chute
and actual outputs to the air cylinders are disabled.
When the selector switch is set to “RUN SIMULATOR” the AUTOCHARGE™ controller will not
actuate the feeder mechanism. When finished using the simulator, ensure the selector is
returned to “NORMAL OPERATION.”
If the controller is reset or powered off, the controller automatically returns to “NORMAL OPERATION.”
When the simulator is running a message is displayed in both local and remote modes indicating the
simulator is running and I/O is disabled as shown in Figure 7.

8.0 Remote Operation
This section contains information related to both the counter-based and weight based
AUTOCHARGE™ systems. Reading parameters for the wrong type of system may result in
undefined values. Writing version-specific parameters for the wrong type of system will be
ignored by the AUTOCHARGE™ controller.
8.1 Functional Description

Remote operation of the AUTOCHARGE™ is provided via the secondary Ethernet port on the controller
located inside the control box. By reading/writing values to controller memory addresses, a remote
system can start and stop the AUTOCHARGE™, set configuration parameters, and adjust the feed rate
set point. All individual channel counts plus overall counters are accessible over the remote connection.
The AUTOCHARGE™ controller simultaneously supports three separate communication protocols.

Obviously, there must be only one remote source writing values to the AUTOCHARGE™ controller. The
three protocols are EtherNet/IP, Modbus/TCP and IEEE 1394 memory mapped protocol.
8.2 EtherNet/IP
To use the AUTOCHARGE™ with EtherNet/IP, two assemblies exist in the controller. The EtherNet/IP
compatible device must be configured to read/write values from these assemblies. In ControlLogix, the
AUTOCHARGE™ controller is configured as a “Generic EtherNet/IP” device. See the relevant Rockwell
Automation or other vendor documentation for exact configuration options.
The first assembly (100) consists of 80 DINT values in the order specified in the Integer Variables table
below. All locations support both read and write operations, however values written to read-only
variables will be ignored.
The second assembly (101) consists of 32 REAL values in the order specified in the Float Variables table
below. All locations support both read and write operations, however values written to read-only
variables will be ignored.
8.3 Modbus/TCP
The AUTOCHARGE™ controller supports Modbus/TCP acting as a Modbus slave device (i.e. it can be
read/written by a Modbus master, but cannot initiate Modbus communication itself). Since the
AUTOCHARGE™ controller has more accessible data than is possible in a single Modbus device, its
memory locations are divided into multiple Modbus units. The unit ID for AUTOCHARGE™ variables is
110. Each variable is accessed through a register address given in the Integer and Real Variable tables
below. If the Modbus master device uses register number rather than register address, it is necessary to
add 1 to the address value to determine the register number.

8.4 OptoMMP/IEEE 1934 Memory Mapped Protocol
The AUTOCHARGE™ controller supports the IEEE 1394 memory mapped protocol standard. The memory
mapped address is shown for each AUTOCHARGE™ variable in the tables below.

8.5 Variable Conventions
The variable definitions use the following conventions

VariableName (DataType, Access, Persistence) – Description.
Where DataType is one of the following
Int32 – 32-bit integer value. Either taken as an integer value or using individual bits to indicate a
particular state
Real – 4-byte floating point value
String*Len – a string with maximum Len characters
Int32*n – an array of 32-bit integer values
Access is given by RO for read-only or RW for read-write access.
Persistence is P for a persistent variable, that is the value will be maintained even if the controller is
powered off. T is for a transitory variable that does not maintain its value during controller
power-off
8.6 Variable Definitions

bInputError (Int32, RO, T) – each bit corresponds to a ball counter channel when set indicates the
number of flights of balls with zero counts through the channel has exceeded the limit set by
nChannelZeroCountThreshold.
bRemoteMode (Int32, RO, T) – flag controlling the remote/local mode of the AutoCharge controller.
Non-zero indicates remote operation (parameter values changed by remote DCS or other
network connection). When this value is zero, the controller will only accept parameters from
the local operator display. This value is only changeable from the operator display.
bState (Int32, RO, T) – each bit corresponds to one or more states set in the AutoCharge controller
Bit 0 – Configuration error (one or more parameters has not been set)
Bit 1 – Ball jam or bin empty indicator
Bits 2-31 – not defined/future use
fAvgWeightPerDischarge (Real, RO, T) – calculated average weight of balls charged per flight, in user-
defined units (see szUnits)
fBallWeight (Real, RW,P) – user-entered nominal ball weight, in user-defined units (see szUnits)
fDischargePerHour (Real, RO, T) – calculated feed rate, in user-defined units (see szUnits) per hour.
fDischargeTime (Real, RW, T) – the time (in seconds) required for the discharge chute to move to the
fully lowered position.
fFeedDelayCalc (Real, RO, T) – calculated delay between flights of balls in seconds.

fFeedRate (Real, RW ,P) – user-entered feed rate, in user-defined units (see szUnits) per hour.
fTimeDetect (Real, RW, P) – time allowed, in seconds, for detection of balls through the counter chutes
after a discharge.
fTimeDischarge (Real, RO, T) – calculated total time, in seconds, for a single discharge.
fTimeExtend (Real, RW, P) - user-entered time required to extend the air cylinder, in seconds.
fTimeRetract (Real, RW, P) – user-entered time required to retract the air cylinder, in seconds.
fWeight (Real, RO, T) – calculated weight in the current discharge of balls in user-entered units (see
szUnits)
fWeightFilter (Real, RO, T) – calculated weight value given to the current discharge used to determine
the average weight per discharge according to (fWeightFilter * fWeight) +
(fAvgWeightPerDischarge * (1-fWeightFilter)).
fScaleFactor (Real, RW, P) – user-entered weight conversion factor for load-cells. This factor should
convert 1 kg to 1 unit of the user-defined ball weight units.
fSettlingTime (Real, RW, P) – the delay time between feeder discharge into the discharge chute and
reading of the load cell inputs.
MAX_CHANNEL (Int32, RW, P) – defines the maximum number of channels to scan, must be from 0 to 15
(the first channel is 0).
nChannelCountZeroThreshold (Int32, RW, P) – defines the maximum number of discharges with zero
counts through a chute before an error is indicated for a chute in bInputError.
nCountDelay (Int32, RW, P) – defines the time, in milliseconds, allowed between successive counts in
the same chute. This value provides some signal debounce for the limit switch return to center
position, typically between 5 and 20 ms.
nDischargeCount (Int32, RO, T) – number of balls counted in the current discharge.
nFeedStep (Int32, RO, T) – the current step of the discharge according to the following values
0 – Idle/Waiting for next discharge
1 – First extension of the air cylinder
2 – First retraction of the air cylinder
3 – Second extension of the air cylinder
4 – Second retraction of the air cylinder
5 – Detecting balls passing through the chutes
nManualCommand (Int32, RW, T) – when in manual mode, it will execute a command according to the
following values
1 – One complete discharge cycle

2 – Advance feeder one-half discharge (extend and retract the air cylinder)
3 – Extend the air cylinder
4 – Retract the air cylinder
nRunMode (Int32, RW, T) – determines the AutoCharge run mode according to the following values
0 – Stop, the AutoCharge will not actuate the air cylinder or count balls through the feeder
1 – Auto, the AutoCharge will automatically feed balls according the user-entered feed rate
2 – Manual, the AutoCharge will process manual commands (see nManaualCommand above)
nZeroDischargeCount (Int32, RO, T) – is the number of successive discharges where no balls have been
counted. When this value exceeds the limit set by nZeroDischargeCountThreshold, the
AutoCharge will indicate a ball jam or bin empty condition in bState.
nZeroDischargeCountThreshold (Int32, RW, P) – sets the limit for the number of successive discharges
with no balls counted before indicating a ball jam/bin empty condition.
szUnits (String*10, RW, P) – user-defined weight unit of measure for grinding balls (not currently
accessible remotely)
tbl_counts (Int32*16, RO, P) – counts in each channel since installation or table reset.
tbl_curcounts (Int32*16, RO, T) – counts for each channel in the current discharge
tbl_zero_counts (Int32*16, RO, T) – number of successive zero-ball discharges for each channel
8.7 AUTOCHARGE™ Integer Variables Memory Addresses

INTEGER VARIABLES
Scratch
Pad IEEE 1394 Modbus
Register
Index Address Unit ID Address Variable Access
0 F0D81000 110 2049 bRemoteMode RO
1 F0D81004 110 2051 bState RO
2 F0D81008 110 2053 bInputError RO
3 F0D8100C 110 2055 nFeedStep RO
4 F0D81010 110 2057 nDischargeCount RO
5 F0D81014 110 2059 nZeroDischargeCount RO
6 F0D81018 110 2061 Not Used
7 F0D8101C 110 2063 Not Used
8 F0D81020 110 2065 Not Used
9 F0D81024 110 2067 Not Used
10 F0D81028 110 2069 Not Used
11 F0D8102C 110 2071 Not Used

12 F0D81030 110 2073 Not Used
13 F0D81034 110 2075 Not Used
14 F0D81038 110 2077 Not Used
15 F0D8103C 110 2079 Not Used
16 F0D81040 110 2081 nRunMode RW
17 F0D81044 110 2083 nManualCommand RW
18 F0D81048 110 2085 nChannelCountZeroThreshold RW
19 F0D8104C 110 2087 nZeroDischargeCountThreshold RW
20 F0D81050 110 2089 MAX_CHANNEL RW
21 F0D81054 110 2091 nCountDelay RW
22 F0D81058 110 2093 Not Used
23 F0D8105C 110 2095 Not Used
24 F0D81060 110 2097 Not Used
25 F0D81064 110 2099 Not Used
26 F0D81068 110 2101 Not Used
27 F0D8106C 110 2103 Not Used
28 F0D81070 110 2105 Not Used
29 F0D81074 110 2107 Not Used
30 F0D81078 110 2109 Not Used
31 F0D8107C 110 2111 Not Used
32 F0D81080 110 2113 Total counts channel 0 RO
35 F0D8108C 110 2119 Total counts channel 3 RO
39 F0D8109C 110 2127 Total counts channel 7 RO
40 F0D810A0 110 2129 Total counts channel 8 RO
43 F0D810AC 110 2135 Total counts channel 11 RO
44 F0D810B0 110 2137 Total counts channel 12 RO
47 F0D810BC 110 2143 Total counts channel 15 RO
48 F0D810C0 110 2145 Current counts channel 0 RO
51 F0D810CC 110 2151 Current counts channel 3 RO
52 F0D810D0 110 2153 Current counts channel 4 RO

55 F0D810DC 110 2159 Current counts channel 7 RO
56 F0D810E0 110 2161 Current counts channel 8 RO
59 F0D810EC 110 2167 Current counts channel 11 RO
60 F0D810F0 110 2169 Current counts channel 12 RO
63 F0D810FC 110 2175 Current counts channel 15 RO
64 F0D81100 110 2177 Zero counts channel 0 RO
67 F0D8110C 110 2183 Zero counts channel 3 RO

8.8 AUTOCHARGE™ Real Variable Memory Addresses
REAL VARIABLES
Scratch
Pad IEEE 1394 Modbus
Register
Index Address Unit ID Address Variable Access
0 F0D82000 110 4097 fDischargePerHour RO
1 F0D82004 110 4099 fFeedDelayCalc RO
2 F0D82008 110 4101 fTimeDischarge RO
3 F0D8200C 110 4103 fWeight RO
4 F0D82010 110 4105 fWeightFilter RO
5 F0D82014 110 4107 fAvgWeightPerDischarge RO
6 F0D82018 110 4109 Not Used
7 F0D8201C 110 4111 Not Used
8 F0D82020 110 4113 Not Used
9 F0D82024 110 4115 Not Used
10 F0D82028 110 4117 Not Used
11 F0D8202C 110 4119 Not Used
12 F0D82030 110 4121 Not Used
13 F0D82034 110 4123 Not Used
14 F0D82038 110 4125 Not Used
15 F0D8203C 110 4127 Not Used
16 F0D82040 110 4129 fFeedRate RW
17 F0D82044 110 4131 fBallWeight RW
18 F0D82048 110 4133 fTimeDetect RW
19 F0D8204C 110 4135 fTimeExtend RW
20 F0D82050 110 4137 fTimeRetract RW
21 F0D82054 110 4139 fScaleFactor RW
22 F0D82058 110 4141 fDischargeTime RW
23 F0D8205C 110 4143 fSettlingTime RW
24 F0D82060 110 4145 Not Used
25 F0D82064 110 4147 Not Used
26 F0D82068 110 4149 Not Used
27 F0D8206C 110 4151 Not Used
28 F0D82070 110 4153 Not Used
29 F0D82074 110 4155 Not Used
30 F0D82078 110 4157 Not Used
31 F0D8207C 110 4159 Not Used

9.0 Version History
9.1 Version 3.0W

This document applies to version 3.0W of the AutoCharge PAC-based controller with feeder and weight-
based discharge chute. This version includes an embedded PC with touchscreen control mounted on the
AutoCharge controller enclosure. The AutoCharge star feeder empties balls into a discharge chute where
they are weighed from load cell inputs and then discharged onto the mill feed conveyor.
9.2 Version 3.0

Applies to version 3.0 of the AutoCharge PAC-based controller with limit switch counters. This version
includes an embedded PC with touchscreen control mounted on the AutoCharge controller enclosure.
Version 3.0 includes two AutoCharge models, the 301 and 301W. Model 301 uses limit-switches to
count individual balls charged to the mill through ball discharge chutes. Model 301W is the
weightometer-based unit that measures actual weight of balls charge through separate instrumented
discharge hopper (See Version 3.0W above).
9.3 Version 2.0

Version 2.0 added a local touchscreen display from a dedicated G70 terminal, replacing the output
counter, indicator lamps and pushbuttons. Operation and configuration are performed locally on the
touchscreen.
9.4 Version 1.0

Version 1.0 is the first programmable automation controller (PAC) based AutoCharge unit. Previous
systems used programmable logic controllers (PLC) . Version 1.0 included only an output counter, panel
indicator lamps and push-button controls for start, stop and reset. Configuration was provided through
a Windows client software program.

100BaseT Connection
to Plant Network
+V +V -V -V
MW
MEAN WELL DR-120-24 L N -V +V LED ADJ
230VAC
INPUT:
INPUT 100-120VAC 3.3A
100 – 240Vac
200-240VAC 2.0A
1.5A 50-60Hz
OUTPUT: 24VDC 5A
115VAC MW MODEL No:

MEAN WELL
DR-4505
UL
UL
N L
*24VDC power
supply must be
switched to match
incoming AC
voltage
+24V
GND
CAT5
LOAD CELL CONNECTION (USE 4-WIRE

CONNECTION FOR AUTOCHARGE, 24VDC
26
27
28
29
30
31
32
1
2
3
4
5
6
POWER NOT SHOWN ON DIAGRAM)
L1 L2 L3
+ - + -
PPC-L61T TOUCHSCREEN PANEL PC
G G
T1 T2 T3
AC MAIN SUPPLY
100-240VAC 50/60Hz
NEUT
LIVE
GND
AutoCharge Control Box
AutoCharge PAC-based Control Box with load cell input

and PPC-L61T
FSCM NO DWG NO REV
DAVID TAYLOR
AC-CBPAC-LC A
FEEDER CYLINDER DISCHARGE CHUTE CYLINDER 6/15/2012 SCALE 1:1 SHEET 1 OF 5

34-27-13 AutoBall Charger 301W Operations Maintenance

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34-27-13 AutoBall Charger 301W Operations Maintenance

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AutoCharge 301-W

AutoCharge Operations & Maintenance Manual

Process Engineering Resources, Inc.

Salt Lake City, Utah, USA

AUTOCHARGE™ Operations & Maintenance Manual Page 2

Drawing Number Date Title

AC-CBPAC-D10-PPC AutoCharge Control Box

AUTOCHARGE™ Operations & Maintenance Manual Page 3

AutoCharge™ Control Box

• Control Box Wiring Diagram

• Norgren Control Valves

AutoCharge™ Feeder / Counter Equipment:

• Norgren Air Cylinder

• Mettler-Toledo Load Cells

AUTOCHARGE™ Operations & Maintenance Manual Page 4

3.1 AUTOCHARGE™ Components

• Discharge Chute Actuator

3.2 Drawing List

3.3 Functional Description

AUTOCHARGE™ Operations & Maintenance Manual Page 5

3.6 Power & Air Requirements

AUTOCHARGE™ Operations & Maintenance Manual Page 6

4.1 Safety Precautions

4.2 Door Adjustment

4.3 Proper Door Height

4.4 Torque Limiter

4.5 Positioning Hopper Door

AUTOCHARGE™ Operations & Maintenance Manual Page 7

AUTOCHARGE™ Operations & Maintenance Manual Page 8

5.1 Safety Precautions

5.2 Daily Maintenance

5.3 Storage Bin Maintenance

5.4 Weekly Maintenance

5.5 Yearly Maintenance

AUTOCHARGE™ Operations & Maintenance Manual Page 9

AUTOCHARGE™ Operations & Maintenance Manual Page 10

6.1 Recommended Parts per Installation

6.2 Wear Part (One Year)

6.3 Capital Spare Parts

AUTOCHARGE™ Operations & Maintenance Manual Page 11

7.1 Local Operator Interface

Figure 1 AUTOCHARGE™ startup screen

7.2 Local Data Entry

AUTOCHARGE™ Operations & Maintenance Manual Page 12

7.3 Local and Remote Modes

Figure 3 Main screen, local operation

AUTOCHARGE™ Operations & Maintenance Manual Page 13

7.4 Initial Configuration

Figure 5 AUTOCHARGE™ Setup screen

AUTOCHARGE™ Operations & Maintenance Manual Page 14

Español – click this button to display the user screen in Spanish.

7.5 Remote Operation Network Setup

AUTOCHARGE™ Operations & Maintenance Manual Page 15

The internal IP address (Ethernet 1) is set to 192.168.96.55/255.255.255.0 and the panel PC

7.6 Local Automatic Operation

AUTOCHARGE™ Operations & Maintenance Manual Page 16

7.7 Local Manual Operation

Figure 7 Manual operation screen

AUTOCHARGE™ Operations & Maintenance Manual Page 17

Figure 8 AUTOCHARGE™ Feed Simulator

AUTOCHARGE™ Operations & Maintenance Manual Page 18

8.1 Functional Description

The AUTOCHARGE™ controller simultaneously supports three separate communication protocols.