Hefei Jinshan

CONTENTS 1 2 3 3.1 3.1.1 3.1.2 3.2 3.2.1 3.2.2 3.2.3 3.3 4 4.1 4.2 4.3 4.4 4.5 5 5.1 5.2 5.3 5.4 5.4.1 5.4.2 5.5 5.6 6 6.1 6.2 6.3 BELT-SCALE STRUCTURE..................................................................... BELT-SCALE MACHINERY INSTALLATION........................................................ BELT-SCALE ELECTRICAL INSTALLATION....................................................... THE
CONTROLLER INSTALLATION

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Open the controller packaging ..................................................... Putting the Controller into control cabinet ....................................... THE
SENSOR INSTALLATION

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The Z6 sensor installation ........................................................ The general sensor installation ................................................... The Measure Speed Sensor installation ............................................. THE
CABLING CONNECT THE CONTROL CABINET WITH THE BELT SCALE AND ITS REQUIREMENTS.

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THE BELT SCALE POWER UP AND DEBUG...................................................... SET THE

UP THE FREQUENCY CONVERTER PARAMETER OPERATION OF THE CONTROLLER

...................................................

GENERAL

....................................................... ....................................................... ...........................................

BELT SCALE MECHANICAL PARAMETER

CORRECTS THE SLANTING OF

THE

BELT RUNNING CORRECTS

CHECK

SIGNALS OF THE CONTROLLER

.......................................................

THE BELT SCALE CALIBRATION.............................................................

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

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ENTER CALIBRATION INTERFACE ............................................................. TARE

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

Zero calibration ................................................................ Full calibration ................................................................ DYNAMIC REAL

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

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

COMMUNICATIONS CORRECTION.............................................................. COMMUNICATIONS I/O ANALOG

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

INPUT TEST ....................................................................... OUTPUT TEST

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APPENDIX 1REPLACEMENT BELT ................................................................ APPENDIX 2THE USE OF LUBRICANTS MODEL ..................................................... APPENDIX 3THE CONTROLLER BACK PANEL TERMINAL DRAWING ...................................... APPENDIX 4PARAMETER TABLE 1 ............................................................... APPENDIX 5PARAMETER TABLE 2 ...............................................................

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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.

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

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

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

Passive DrumBy 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 BlockIt can adjust Belt-scale deviation and take-up

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(5) (6) Measurement Framework.It is Transmission Structures of Belt ScaleIt spread material weight on belt to sensors. Automatic Tension DeniceIt can make Belt to maintain a certain degree of tensionand 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 Motorthe 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

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 - -

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from the underside the discharging hopper underside to the belt upper surface is 1015mm,and the distance from the

Flange center of the discharging hopper to the center line of the Passive Drum is 250300mm.
Check whether the belt weighing components intact.

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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3.1.2 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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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 slowlythen repet step until just do not fight Gearand revolve the copper piper backward one loop,and fix the fix screw nut.Insert the sensor into its installation foundation againfix the screw. 2.if not, adjust the fixed copper pipe backward slowlythen repet step until just fight Gearthen 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 carefulThere are triangles to connect France and star and connect two kinds of laws quantitatively for the electromechanics machine wiring of materialGenerally speaking the single-phase frequency converter which enters the line adopts the triangle to connect the lawAnd the frequency converter that three phases enter the line adopts the star to connect

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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

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 signal 2 Electric current signal electric current signal 3 Voltage and 1 Voltage 2 Generally establish

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F02 F03 F04 F07 F08 F11 Start set the highest frequency Basic frequency First acceleration time First moderation time Hot protection electric current of the motor 0 Panel launched 1external signal 50400Hz 50400Hz 6 6 1 50 50 10 10 Establish according to the 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 manageyou 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 statusDisplay picture of acquiescence when being electric each time of the controller. Operation 1: Method to enter main menuPush The key can enter the main menuIf you want to withdraw the

main menu and return the normal display status, press 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 areathe 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 exampleIn 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 carefulWhen 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 input digit and press the

key deletes the single figure, press the

key confirms inputting, 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 simplification C00 C01 Roller dia. Speed Reducer Cylinder diameter motor speed ratio 0.22 m 51 Explanation Default value Position in the figure 21 proving correspondingly 1 3 Mark in the plate of reduce machine. C02 Eff.Platf.Length The length C03 Gear Number The number of pulses when motor rotates a circle C04 Nominal Load Nominal Load of the sensor C05 Belt Length Belt girth 3.95 m 4 100 kg 5 Mark in the plate of sensor. 30 effective Weigh 0.45 m Half of shown length position 2. in the and

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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 " statuspress the Starting button of the locate boxand adjust the potentiometer,to the belt scale a suitable speed. Monitor the running and leaning towards the direction of the belt scaleIn 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 statusand 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 sensors 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.Unitrpm Load.AD Load signal AD conversion value key,observe the controller Following the two state: Numerical range01500rpm

The value should be relative the speed on frequency converter. Numerical range1004000

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 sensors line connection are damage, and ensure that there are no short and circuit Opening situation.

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 polemark as PKg.

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

3,press the

key and start the belt scale.

Select Tare calibrationon 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 arent 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 statusImmediately following the above steps,selectzero calibrationon 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 arent satisfied with the reslute ,press the 5.4.2 Full calibration

key to cancel the operation.

Maintain the belt weighing stop,put the weight and the calibration pope on the scale.Then selectfull calibrationon 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 arent satisfied with the

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reslute ,press the

key to cancel the operation.

5.5 Dynamic hunging weight calibration

Dont move the weight on the belt scalestop volum mode and enter gravity mode. Interrelated step

figure 31 Continuously press the key and return to the nomally display status,set the motor flow (t/h) by operation 3,record

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

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=3.6Pthe belt loop length/S1/ The effective Weigh length then calculate Errors value Error

T1T2 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 materialthe 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 2.

keyclear cumulation Strat the belt scale

Press the

keyset 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 keyobserve the display value of Z1 or Z2.

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

key stop material to fall.

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

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4. Calculated correction

when the belt scale stop,the status is as shown in the dawing 1 of figure 32Weigh 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 demandno need to modify any parameter. If the Absolute value of K2-1 isnt less than 1%do follow steps 1. again. 2. have done the Real material calibration until the absolute value of K2-1 is less than 1% . The original values of the parameter D06 multiplied by K2 and input the result to the parameter D06

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

___111___

Display DO TEST DA1-DA7 OFF

I/O output test

I/O output dont 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 disappearEtc. Return Higher-level menu.

6.3 Analog output test

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when set DAC0-DAC1 4 mAthe 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 mAthe 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 1Replacement belt

figure 33 1. 2. 3. 4. Remove corresponding components on no motor side of belt scale,let the side hang in the air Screw off the screw of the tension sliding block on the side,and put the end of passive drum into inside. Screw off the fixed screw of the tension sliding block on the side,and remove it. Remove the long screw of the tension sliding block rest part. - -

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5. move belt along the arrow of the drawing display. Replace new belt and setup the rest part by inverse order of steps.

6.

Appendix 2The 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 1/31/2 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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Appendix 3The controller back panel terminal drawing

figure 34

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Appendix 4Parameter table 1
Code function Initiali-zation data A00 A01 A02 A03 A04 A05 A06 A07 A08 B00 B01 B02 B03 B04 B05 C00 C01 C02 C03 Setpoint mode Control mode Speed mode Load_Max Load_Min Speed_Max Speed_Min Par.ini BAK Nominal Feed Rate Ex.Setpoint Min Ex.setpoint Max Ex.sp min Flow_Out Min Flow_Out Max Roller dia. Speed Reducer Eff.Platf.Length Gear Number Configure mode Control mode Measure speed mode Load max limit set Load min limit set Speed max limit set Speed min limit set Initialization parameters backup Rated flow External min signal value External max signal value External signal threshold value flow output min value Flow output max value Drum diameter speed ratio The effective Weigh length The number of measure speed gear teeth C04 C05 C06 D00 D01 Nominal Load Belt Length Nominal Speed Calibrate load Zero The load sensor standard range Belt length Motor standard rotate speed Weigh weight Zero parameter 100 3.95 1500 10 0 kg m rpm Kg Sampling word D02 Full Full parameter 2000 Sampling word D03 Tare Belt weight parameter 0 Sampling word D04 D05 D06 D07 D08 Test load Flow_K Modify_K N Circle Belt Load mode Test load Flow parameter Modify parameter Calibration laps Simulation load mode 10 1 1 1 0 integer integer Kg 51 0.45 30 m integer 0 0 0 90 10 1200 300 1 0 100 4 20 4 4 20 T/h mA mA mA mA mA rpm rpm Unit User settings

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Hefei Jinshan Appendix 5Parameter table 2

Code function Initialization data E00 E01 E02 E03 E04 E05 E06 F00 F01 F02 G00 G01 H00 H01 H02 H03 Ctronl_Out Min Ctronl_Out Max Filter constant DEAD PID_K YUZHI_PIANCHA MIN_PROTECT ADDress Baud Rate Mode PROFIBUS_ADDr PROFIBUS_mode Ctronl_2 Min Ctronl_2 Max Pre_control_mode Pre_Feed Rate The min value of control output The max value of control output Filtering constant Dead area Pid parameter Preferences deviation Preferences protection Communications address Baudrate Communications mode PROFIBUS address PROFIBUS mode Pre-feeding control min output Pre-feeding control max output Pre-feeding control mode Pre-feeding machine capability 30 5 1 1 1 1 0 4 20 0 100 T/h mA mA Kg 4 20 10 0.1 mA mA integer Unit User settings

H04 H05 H06 H07 H08 H09 H10 H11 H12 H13 H14 H15 H16 H17 H18

Pre_control time PIANCHA limit Pre_ctrl limit P.C_limit_k DEAD2 PP1 PI1 PD1 PP2 PI2 PD2 PP3 PI3 PD3 time-lapse start

Preferences adjustment time Deviation limit Preferences adjustment limit Limit parameter adjustment dead area P1 parameter I1 parameter D1 parameter P2 parameter I2 parameter D2 parameter P3 parameter I3 parameter D3 parameter Delay time

8 40 40 1 1 10 4 0 8 3 0 5 4 0 1

technical support 05513439417

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