schenck process india ltd

JOB LIST FOR WEIGHFEEDER

1. Visual
1.1 Customer to check, identify and confirm receipt of all material as per dispatch
document / packing list. Any damage to be made good before arrival of
commissioning engineer.
1.2 Customer is requested to go through this Job List, Electrical and
Mechanical drg. We request customer to confirm that this Job List is understood
and have acted as per this.
2. MECHANICAL:2.1 Installation preparation:
Note:
BEFORE STARTING THE ERECTION, IDENTIFY AND SEGREGATE SETS
OF RESPECTIVE W/Fs, FEED
HOPPER & DRIVE UNIT (TAKE REF.
EQUIPMENT TAG & W/Fs SL.NO ). THIS IS TO AVOID WRONG ITEM
PLACEMENT WHICH WILL LEAD TO
REWORK ......valid for multiple
equipment supply under one Project Head.
2.1.1. Ensure the storage bin is in final position vis-a-vis upstream and down
stream equipment.
2.1.2.
Check head room for the Weigh feeder installation as per
arrangement drg. This is vertical space between bin outlet flange / lower flange
for bin bottom gate to WF installation platform. Extra head room can be filled
by stool below WF mounting base but less head room cannot be
accommodated.
2.1.3. Check distance between C-L feed to C-L discharge. It must match as
per arrangement drg. Max permissible deviation = 50 mm for a 2 meter long
machine.

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2.1.4. Check space for belt change as given in the arrangement drg. This is
essential maintenance space.
2.1.5. Check bin bottom flange to match with the feed hopper for WF. Ref feed
hopper flange detail given in the arrangement drg.
2.1.6. Check WF foundation detail
installation base platform / structural.

as per arrangement drg and prepare

2.1.7. Arrange lifting tools and hooks for Feed Hopper and WF mechanics
installation.
2.1.8. Check availability of all the required fasteners to fix the feed hopper,
WF, drive group, vibrator motor, discharge chute etc.

2.2. Installation of the Weigh feeder.

CAUTION: USE EYE BOLTS FOR LIFTING. TIGHTEN THE EYE BOLTS
BEFORE LIFTING. DO NOT USE MOTOR SHAFT OR INPUT OR
OUTPUT COUPLINGS OF DRIVE GROUP FOR CONNECTING
LIFTING HOOKS.
2.2.1. Position the WF under the storage bin.
2.2.2. Fix the feed hopper with bin bottom flange. Use gasket / rope between
the flanges. In case of V-Hopper, following are the parts:
1) Suspension frame to be fastened with bin bottom flange,
2) S-bracket to be fastened with suspension frame,
3) Vibration pads to be fastened within S-brackets,
4) Feed Hopper to be placed over vibration pads within S-Bracket and
fastened.,
5) Sealing Band Rubber to fill gap between S-Frame and feed hopper,
6) Material sensor with limit switch to be fitted on mtl bed height setter
gate,
7) Vibrator motor at the back wall of the feed hopper and
8) Sling rope and D-Shackle in case of large hoppers, to be connected
between bin and feed hopper..

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2.2.3. Ensure recommended gap between feed hopper rear edge and belt
top. This is important for insertion of maintenance gate. Keep aprox 5-8 mm
extra gap to accommodate vibration pads possible compression under load.
2.2.4. Erect the WF in final position over foundation and fasten. Take care of
following points:Check level of the WF (REF. PUNCH MARK OF ALL FOUR CORNER ON
FRAME).
Use shims below the struts to align the WF horizontal.
2.2.5.

Axis of the WF must match with the axis of Feed Hopper. Max
permissible offset is 20 mm. Larger mismatch will result into belt sway with
material load and material may touch the side skirt

2.2.6. Install drive group as give below ( This step is

mounted drive unit ).

not valid for shaft

Drive-Bracket ( hanger ) to be fixed with the WF frame.

Erect drive group on anti-vibration pads. .

Check alignment of coupling between motor and gear box and

between gear box and pulley. Complete drive units alignment in X,
Y and Z direction is possible through slotted holes on drive
bracket, flange plate on weigh feeder frame and drive group base
plate.

Note:- Alignment of coupling between motor to gear box is done at

factory during assembly.

Alignment of coupling to be checked by steel rule and filler gauge. Gap

between coupling to be maintained to aporx 1/2 mm to 1-1/2 mm for
motor to Gear Box coupling and aprox 2-3 mm for GB to pulley
coupling.

- Check tightness of all fasteners for the Drive-Bracket ( hangers).

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2.2.7. Lubrication of gear box. Use 320 grade oil of any make. Check and
set oil level with the help of dip-stick indicator or glass tube indicator or glass
eye or by draining excess oil through over-fill port ( kept plugged ). Ref GB
manual.
Note:- Most of the shaft mounted geared motors are pre-filled with
lubricant. Some of the worm-wheel GB also comes pre-filled.
2.2.8. Lubricate pulley bearings.
NOTE:- Although these bearings are sealed, original lubrication may
become dry during long storage.
It is better to pack the bearing covers with grease to avoid ingress of dust
into the bearings. This is to assure long trouble free performance of the
bearings under dusty environment.
2.2.9. Check thoroughly for any damage occurred during handling /
erection. Repair the damaged parts.
2.2.10. Tighten all fasteners of WF.
2.2.11. Adjust belt tension following tension indicator.
2.2.12. Adjust belt scrapers, side skirts and tail pulley scraper.
2.2.13. Remove transit locks from 1) steering unit, 2) steering rollers and 3)
weighing idler.
2.2.14. Adjust overload protection gap below load cell to 0.5 mm. Use filler
gauge for precise setting of this gap.
2.2.15. Check and adjust steering cum tensioning unit, its sensor roller
arm.
2.2.16. Check alignment of weigh zone idlers.
2.2.17.

Check alignment of tacho encoder unit with tail pulley extension shaft.
Check tightness of all fasteners.

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2.2.18.

Incase of Proximity switch version tacho model JGA-24, adjust

proximity switch for 2.2 to 2.3 mm gap with respect to the mark
position of the toothed wheel.

2.2.19. Provide additional support to the discharge chute from external

structure or platform.
2.2.20. Vent connection to be given from discharge area as need be.
2.2.21. PRE-FEEDER INSTALLATION:
Essential Components with a speed controlled pre-feeder are:a)
b)
c)
d)
e)

Manual Gate below the storage bin.

The Screw feeder or RVF.
A flexible connection below RVF or screw discharge.
Settling chamber with mounting struts.
Vent connection from the settling chamber.

Check arrangement drg and install all the components.

Drive alignment for the pre-feeder, lubrication of bearings, stuffing boxes and
gear box, as the case may be, will be added steps for installation.

3.Electrical:3.1. Panel installation and cabling .

3.1.1. Panel to be installed in dust free room.
3.1.2. Arrange cable as per cable schedule. Specs for special screened cable
for load cell signal given in the Elect drg. This specs must be adhered
strictly.
3.1.3. Load cell and tacho signal cable to be laid separate or through ferrous
conduit. Recommended separation is 300 mm or more.
3.1.4. Earth connection ( PE) to be given in the earth bus provided inside the
panel.
3.1.5. As a standard, we provide TE for connection to electronic earth, TE can
be shorted to PE where assured good TE is not available.

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3.1.6. Motor cable i.e., Inverter output cable can cause EMI to other
electronics signal cables. We recommend armored cable for this and
armor to be perfectly earthed below the panel entry gland.
Note:- For fractional HP motors ( = Low power motor ), this armor for the motor
cable may have to be completely insulated at both end. This will be detected
during testing.
3.1.7. Shield for screen cable to be insulated in the panel entry gland and
this is to be connected only at designated terminals at the panel end and
junction boxes.
3.2 Local Control Box ( LCB) to be installed near the WF mechanics at a safe
place but must be visible for anyone working in the WF mechanics. Better
to install in the motor side.
Note-1:- Ensure the Junction Box is sealed / tightened perfectly. Otherwise,
conductive dust or moisture entry can cause problem to load cell signal.

4) Test and Calibration.

4.1 Power supply connection to the panel as per voltage level recommended in
the elect. Drg.
4.2 Electronic unit to be set by feeding data ( parameters ).
Note: Ensure correct entry of Impulse / meter parameter as per pulley diameter,
gear ratio and tacho constant. Effective pully dia will be dia plus thickness of belt,
e.g. for DABX model with 190 mm pulley ( bare ) dia and 8 mm thick belt, this will
be 0.198 m. Similarly, for coated pulley, this will be 210 mm + 8 mm = 0.218 m.
4.3. Parameterize the inverter drive unit as per input and output connectivity
given in the elect drg. Decide and feed max freq data as per motor related data
available in the Technical data Sheet. However, for a 1000 RPM motor, this will
be 75 Hz.
4.4. Deactivate all unused digital inputs to the drive. This is essential to
avoid inadvertent false / wrong operation under influence of strong EMI.

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4.5. First Run of the WF belt must be from local stn:- Check correct direction,
- Monitor motor current,
- Observe any running noise,
- Observe temperature rise of bearings of moving parts and couplings,
- Adjust belt tension and monitor belt runs centrally.
- Check speed pulse frequency in the electronic unit and cross check with
calculated value. Important information given below.
For tail pulley mounted encoder, tacho frequency = (RPS of the pulley,
calculate from nominal belt speed and effective pulley dia ) x (encoder
constant , pulse / rev ).
For Proximity switch version tacho, calculate from Pulley RPS, gear ratio
and tacho constant ( pulse / rev ).
Note: Ref data from Technical Data Sheet.
Necessary corrective actions to be taken as per observations.
4.6 Perform Belt Circuit program ( LB ) and Tare program (TW).
4.7 Check repeatability of tare result for stability of conveyor and weighing
mechanism.
4.8 Cross check belt speed measured by instrument with physical speed of
the running belt.
Note: It is not essential to use test weight for calibration. The weigher is
calibrated by correct entry of data ( parameters ) and upon performance of LB
and TW program.
4.9. Operation from PLC or DCS to be established.
4.10. All peripherals signals / units to be set and cross checked.

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Caution: Before connection of any Analog signal to the PLC / DCS system,
ensure that PLC is fully tested and connection is not going into any wrong
terminal. Some of the PLC ports can carry potential.
Note-2:- Correction need more than 2 % upon cross check with material
must be doubted as something is wrong.
Note-3:- Inconsistency of tare result indicate problem in the mechanics, or
load cell assembly or load cell connection.

5. Test data documentation:Test data and parameter to be recorded for future use.

6. Important information for user:6.1. Type SPP or SPTT Load Cells has 4 wire plus shield connection. Color
code:Red = +ve excitation.
Black = -ve excitation.
Green = +ve output.
White = -ve output.
6.2. Type SPP / SPTT Load cell input and output resistance.
Input resistance = 380 ohms +/- 50 ohms,.
Output resistance = 350 ohms +/- 0.5 ohms.
6.3 Load cell connections in parallel.
6.3.1. Series-X WF, i.e. models DABX, DAMX etc, uses 2 nos SPP or SPTT load
cells. Load cells will be connected in parallel.
6.3.2. Combined input and output resistance must be cross checked before
connection to electrical panel.

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6.4. Protecting circuit for Intrinsic safety elements.
6.4.1. When Zener Barrier is used for intrinsic safety, series resistance of zener
barrier will be added to the combined resistance of load cells..
Note:- In above cases, actual excitation supply to the load cells will be less than
excitation voltage by instrument because part of the excitation voltage will be
dropped in the series resistance elements.