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DISOCONT® Tersus (DT-9) 196NT to DT-9 Conversion Manual VCU 20104 STOCK EQUIPMENT COMPANY 16490 Chillicothe Rd.

DISOCONT® Tersus (DT-9)

196NT to DT-9 Conversion Manual VCU 20104

STOCK EQUIPMENT COMPANY

16490 Chillicothe Rd. Chagrin Falls, OH 44023 (440) 543-6000 FAX (440) 543-6839 24 Hrs. (800) 628-3347

e-mail address: sales@stockequipment.com

BVH2409GB; February, 2010 Revision A

DISOCONT® Tersus (DT-9) 196NT to DT-9 Conversion Manual VCU 20104 STOCK EQUIPMENT COMPANY 16490 Chillicothe Rd.
  • 1 ABOUT THIS MANUAL

5

  • 2 SAFETY INSTRUCTIONS

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

7

  • 3 OVERVIEW

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

9

  • 3.1 What is the DISOCONT Tersus/DT-9?

9

  • 3.2 Definitions

10

  • 3.3 Measuring Principle

10

  • 3.4 Operating Modes - Remote

12

Gravimetric

  • 3.4.1 ...............................................................................................................................

12

Volumetric

  • 3.4.2 ................................................................................................................................

12

  • 3.4.3 Volumetric Control

12

  • 3.5 Operating Modes – OFF/Maintenance

12

  • 4 HARDWARE AND INSTALLATION

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

13

  • 4.1 DT-9 Installation

13

  • 4.1.1 Installation Notes

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

13

  • 4.1.2 Removing 196NT controller

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

14

  • 4.1.3 Installing the DT-9 Controller

14

  • 4.2 Installing the (optional) Touch Screen HMI

15

  • 4.2.1 Installing the Touch Screen HMI

15

  • 4.2.2 Touch Screen HMI Parameter Changes

16

  • 4.3 Startup and Functional Check

16

  • 4.4 Setup Parameters

18

  • 4.4.1 Converting 196NT Parameters to DT-9 Parameters

18

  • 4.5 Calibration

22

  • 4.5.1 Performing Calibrations

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

23

  • 4.5.2 Weigh Roller Adjustment

24

Basic (CAL 1)

  • 4.5.3 ...........................................................................................................................

25

Span (CAL 2)

  • 4.5.4 ...........................................................................................................................

27

  • 4.5.5 TC: Span Calibration

29

  • 4.5.6 LB: Pulses per Belt

30

TA: Tare

  • 4.5.7 ...................................................................................................................................

30

  • 4.6 Analog

Trim

32

  • 5 OPERATION USING THE (OPTIONAL) TOUCH SCREEN HMI

33

  • 5.1 Initial Configuration

33

  • 5.1.1 The

“Network” Screen

34

  • 5.1.2 The “Display Settings” Screen

34

5.1.3

The “Feeder” Screen

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

34

5.1.4

The “Configuration” Screen

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

34

5.1.5

The “Communication” Screen

34

5.1.6

The “Calibration” Screen

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

35

5.1.7

Exiting HMI Configuration

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

35

5.2

Display Functions

35

5.2.1

The “Home” Screen

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

35

5.2.1.1

Operating the HMI in “Off/Maintenance” Mode

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

35

5.2.1.2

Operating the HMI in “Remote” Mode

35

5.2.2

The “Trend” Screen

36

5.2.3

The “Values” Screen

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

36

5.2.4

The “Setup” Screen

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

36

5.2.4.1

Data Log Values

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

37

5.2.4.2

Event Log Values

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

37

5.2.4.3

Parameter Log Values ......................................................................................................

37

5.2.4.4

Parameter Setup

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

37

5.2.4.5

Trimming the Analog Inputs and Outputs

37

5.2.4.6

Restoring the Factory Default Settings

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

39

5.2.4.7

Simulation Mode

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

39

5.2.4.8

Calibrating the Feeder

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

39

5.2.4.9

Setting the Current Time and Date

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

39

5.3

Typical Operating Procedures

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

39

6

OPERATION USING THE 196NT DISPLAY

41

6.1

Startup Operation-

41

6.2

Display FunctionsDisplay Functions

41

6.2.1

Total Select

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

41

6.2.2

Info Select

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

42

6.2.3

Self Test

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

42

6.2.4

Error Recall

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

43

6.2.5

Reset Totalizing Counters

44

6.3

Operating Functions

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

44

6.3.1

OFF Mode

44

6.3.2

LOCAL Mode

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

44

6.3.3

REMOTE Mode

44

6.3.4

Jog Key

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

44

6.3.5

F1 Key

44

6.3.6

F2 Key

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

45

6.3.7

Acknowledge Event Messages

45

6.4

Setup Functions

45

6.4.1

Read Parameters

45

6.4.2

Enter Parameters

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

46

6.4.3

Load Default Parameters

46

6.4.4

Set Time

47

6.5

Analog Trim Function

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

48

6.5.1

I/O Channel Adjustment

48

6.6

Typical Operating Procedures

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

49

7

OPERATION USING EASYSERVE

51

7.1

Program EasyServe VPC 20150

51

7.2

Minimum System Requirements

51

7.3

Installation

51

7.4

Start Program and Connect to Feeder

52

7.4.1

Connecting to Feeder

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

52

7.4.2

Access to Feeder Commands and Parameters

53

7.5

Parameter Set

54

7.5.1

.PAR Files

54

7.5.2

Read/change Parameters

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

54

7.5.3

Loading

Custom Default Parameters

54

7.5.4

Loading Factory Default Parameters

55

7.5.5

Expert Mode

55

7.5.6

Print Parameters

55

7.6

Operating the Feeder

56

7.6.1

Scale Operation Screens

56

7.6.2

Events

56

7.6.3

Calibration

56

7.6.4

Service Values

57

7.6.5

Trends

57

7.6.6

Setting

Time

58

7.6.7

Options

58

8

TESTING

59

8.1

Calibration Weight Test

59

8.2

Chain Test

59

8.3

Material Test

59

9

PARAMETERS

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

61

9.1

General Information-

61

9.2

DT-9 Parameter List

65

9.2.1

Parameter Group 01 - Hardware Modules

65

9.2.2

Parameter Group 02 - Feeder Definitions ................................................................................

68

9.2.3

Parameter Group 03 - Control Sources

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

74

9.2.4

Parameter Group 04 - Feeder Rated Data

79

9.2.5

Parameter Group 05 – Feeder Control

82

9.2.6

Parameter Group 06 - Feeder Monitoring

84

9.2.7

Parameter Group 07 – Belt Monitoring

90

9.2.8

Parameter Group 08 - Display Filters

91

9.2.9

Parameter Group 09 - Limit Values

93

  • 9.2.10 Parameter Group 10 - Calibration Data

97

  • 9.2.11 Parameter Group 11 – Rate Controller

100

  • 9.2.12 Parameter Group 12 - Moisture

103

  • 9.2.13 Parameter Group 13 – Cleanout Control

106

  • 9.2.14 Parameter Group 14 - Analog Outputs

108

  • 9.2.15 Parameter Group 15 - Digital Inputs

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

113

  • 9.2.16 Parameter Group 16 - Digital Outputs

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

121

  • 9.2.17 Parameter Group 17 – Analog Calibration

128

  • 9.2.18 Parameter Group 18 - 2-Sensor Slip

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

130

  • 9.2.19 Parameter Group 19 – Maintenance Interval

133

  • 9.2.20 Parameter Group 20 - Reports

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

134

  • 9.2.21 Parameter Group 21 - Comm. EasyServe

135

  • 9.2.22 Parameter Group 22 - Comm. Fieldbus

136

  • 9.2.23 Parameter Group 23 - Ethernet

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

137

  • 9.2.24 Parameter Group 24 - PLS Outputs

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

138

  • 9.2.25 Parameter Group 25 – Fixed Mode

138

  • 9.2.26 Parameter Group 26 – FCB Analog Output

138

  • 9.2.27 Parameter Group 27 – FCB Digital Output

138

  • 9.2.28 Setup Parameters 196NT

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

139

  • 10 EVENT (ERROR) MESSAGES

145

  • 11 APPENDIX A

153

  • 11.1 Parameter Overview

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

153

  • 12 APPENDIX B

163

  • 12.1 Default Digital Inputs

163

  • 12.2 Default Digital Outputs

164

  • 12.3 Default Analog

164

  • 13 APPENDIX C

165

  • 13.1 Trending Data

165

iv

DISOCONT® Tersus (DT-9) Conversion Manual ©Schenck Process Group

1 About this Manual

These instructions are intended as an addendum to the manual originally supplied with the equipment. The original manual continues to be valid. It is recommended that these instructions be filed with the instruction manual.

Additional copies of these instructions may be ordered from the Parts Department, Stock Equipment Company, Chagrin Falls, Ohio. Refer to Part No. ATPDISOCONTUPGRADE.

Proprietary Note

The information in this manual, including technical data and copies of drawings, contains information that is proprietary to Stock Equipment Company. This manual is provided to the user of equipment purchased from Stock Equipment Company for use only in operation or maintenance of such equipment. Information in this manual is not to be used, disclosed, copied, reproduced in whole or part for any use other than that indicated above, or for any other purpose detrimental to the interests of Stock Equipment Company. Patents owned by Stock Equipment Company have been issued or are pending on some of the information in this manual. Any unauthorized use of this subject matter of such patents is a violation of such patents and is prohibited by law.

Electrostatic Sensitive Devices

Caution: The electronic controls contain ESD (Electrostatic Discharge) sensitive parts and assemblies that can be damaged by static electricity. The following static control precautions are required when testing, servicing, or repairing the electronic assemblies.

  • 1. Disconnect power at the main disconnect switch or circuit breaker.

  • 2. Only qualified personnel are permitted to perform and install the electronic controls.

  • 3. Wear a wrist type grounding strap that is grounded to the control cabinet chassis.

  • 4. When replacing the electronic circuit board. Do not remove the board from the static shielding bag it came in until you are ready to install the board.

  • 5. When removing any electronic circuit board, immediately place it in static shielding bag.

  • 6. Stock Equipment Company advises that all printed circuit boards should be returned to the factory for repair since our technicians are trained to work with electrostatic sensitive components.

  • 7. Contact Stock Equipment Company’s Parts Department for a returns good authorization number to facilitate the return of an electronic circuit board. Boards should be shipped in static shielding type bags. If packing materials are used, they should be static dissipative material.

Note: If you are not familiar with static control procedures, before replacing electronic components, refer to US Department of Defense DOD – HDBK-263, Electrostatic Discharge Control Handbook for protection of electronic parts, assemblies, and equipment.

2 Safety Instructions

To avoid personal injury and equipment damage, follow the safety regulations stated below.

Additionally, you should observe:

Safety hints given in order-specific documentation

Safety hints relating to mechanical components

Instructions given in sub-suppliers documentation.

When performing installation, commissioning and service work, observe all applicable local regulations.

Use As Originally Intended

The measuring system and its connected mechanical components are exclusively designed for weighing and controlling tasks. Any use other than originally intended is considered inappropriate.

Risks

Upon use of the measuring system, danger may result during transit of material to be weighed (e.g. from auxiliaries used to handle or feed material) or if system assumes control tasks.

Residual risks may originate from the measuring system if unskilled operators improperly handle the system. The measuring system can be part of a more complex plant. The user is fully responsible for the overall plant safety.

Identification of Residual Risks

The presence of this symbol indicates that the machine or component used has the
potential to cause severe injury or death.

The presence of this symbol indicates that the machine or component used has the

potential to cause damage to the measuring system or other plant sections.

Personnel

Preparation, installation, commissioning, operation, maintenance, and servicing may be performed by trained personal only. All personal working on the measuring system are required to observe the safety hints and know the parts of the technical documentation relevant to their work. The supervisor is responsible for instructing his operators to observe all regulations and instructions.

Parameter Changes

The measuring system's functionality is determined by parameters, which may only be changed by persons familiar with the measuring system operating principles (e.g. after training by Stock). Incorrect parameter settings may cause injuries or damage to the machine and can adversely affect weighing operation.

Password

Passwords are used to protect system settings from inadvertent changes. It is the users responsibility to insure that passwords are handled safely. The default DISOCONT® Tersus (DT-9) password is 7353.

Error Message Acknowledgement

Error messages may be acknowledged only after cause of fault has been corrected. Before acknowledging an error message, check to see that connected peripherals operate properly. Check to see that connected control systems, if any, are in fail-safe state.

Maintenance and Repair

During maintenance and repair, observe any warning symbols on the scale.

Before performing work on the mechanical system or peripherals (particularly the control

system), disconnect the measuring system and protect the system from inadvertent restart. Before performing work on the electrical equipment, disconnect the power supply.

The devices may be operated only in the housings provided. There is danger of contacting live parts.

Moisture Protection

Protect all system parts, electrical items in particular, from moisture (e.g. during maintenance and servicing) when housings are open. Observe housing protection standards.

Modification & Replacement

Unauthorized modifications to the system and/or use of replacement parts not supplied by Stock voids Stock's liability for any resulting damages. This particularly applies to modifications, which have the potential to affect the operating safety of the measuring system.

Component Replacement

Spare parts must meet the technical specifications indicated by Stock. To ensure this requirement is met, only genuine Stock spare parts should be used. When using other spare parts, the warranty will be void.

3 Overview

This chapter explains the principle functions of the DISOCONT Tersus system used in conjunction with a Stock coal feeder.

3.1 What is the DISOCONT Tersus/DT-9?

The DISOCONT Tersus is a versatile family of modular weighing electronics for use with weighing and feeding systems.

The DISOCONT Tersus performs all weighing and processing functions required for the measuring and feeding of bulk solids. It is designed for continuous measuring and control tasks as well as discontinuous batching.

Used in conjunction with the specific application software for weighing and feeding tasks, the DISOCONT Tersus can be used in the following industries:

Power

Steel

Basic Materials

Cement

Food

Chemical

In connection with the corresponding mechanical equipment, the following systems are supported:

Belt Scales

Weigh Feeders

Solids flow meters (chutes)

Solids flow feeders

Loss-in-weight, gain-in-weight feeders

Mass flow meters (Coriolis meters)

Mass flow feeders (Coriolis feeders)

Filling systems

The Stock DT-9 configuration of the DISOCONT TERSUS is a modified version, optimized for feeding coal in power plant environment. There are two different versions of the DT-9. One is a completely redesigned and updated version that is used in new installations. The second is designed to upgrade existing Stock 8085, 196 and 196NT installations, and maintains the 196NT connectors and mounting footprint.

VCU 20103 – Designed for new installations where backwards compatibility is not required. This version can be identified by the steel mounting frame and the screw type electrical connectors. A Touch Screen HMI is always used when a VCU 20103 is installed.

VCU 20104 – Designed as a drop in replacement for the 196NT in existing installations. This version

can be identified by the brown, Amp style electrical connectors. either a Touch Screen HMI or with an existing 196NT display.

The VCU 20104 can be used with

3.2

Definitions

The table below explains some basic terms used in this manual.

Abbreviation

Meaning

Explanation

Unit

   

The actual amount of

 

I

Actual feed rate

material delivered per unit time

Lbs/hr, Lbs/min, USTons/hr, Kg/hr, Kg/min or Metric Tons/hr

P

Feedrate setpoint

The desired amount of material delivered per unit time

Lbs/hr, Lbs/min, USTons/hr, Kg/hr, Kg/min or Metric Tons/hr

Z

Totalized amount

Weight of material delivered since last counter reset

Lbs, US Tons, Kg or Metric tons

V

Belt speed

Feeder belt speed

Inches/sec, m/sec

Q

Belt load

Weight of material per unit of belt length.

Lbs/inch, Kg/m

QB

Platform load

 

Lbs, Kg

Y

Controller magnitude

Output signal

mA

magnitude

Xd

Deviation

Difference between the actual feedrate and the feedrate setpoint.

%

  • 3.3 Measuring Principle

The belt weighing system is designed to continuously weigh the amount of material transported on the feeder belt. The actual weight of material transported is calculated by multiplying the feeder belt load, in lbs/inch, times the feeder belt speed. The systems used to measure these two values are described below.

Belt Load

The feeder weight signal is generated by two load cells that support a single weigh roller. Two weigh span rollers are located on each side of the weigh roller to accurately define the length of belt (and amount of coal) being supported by the weigh roller.

Since the load cells only support half of the weight on the weigh span (each load cell supports 25 percent of the total weight) the effective platform length (Leff) is calculated as:

Leff = Lg / 2

Leff = Effective platform length Lg = Total platform length

The microprocessor computes the feeder belt load by repeatedly reading the voltage signal from each load cell and converting the signal into a digital value (binary number) using an analog to digital (A/D) converter. Each value is then compared to parameters stored in permanent memory to determine if the signal is within acceptable limits, and if it is, it is stored for use. The same operation is then performed on the other load cell, and the signals are compared to each other to test their validity. If the signals are determined to be invalid, the feeder is switched to volumetric operation and the controller uses a simulated belt load calculated from an historical average stored in memory. If the signals are determined to be valid, the two load cell signals are summed, the tare is subtracted and the result is multiplied by a scaling factor based on the load cell data specified in P04.01 LC Characteristic Value and P04.02 LC Rated Capacity to determine the nominal weight of material on the belt. This nominal value is then multiplied by the three range correction factors (P10.03, P10.04 and P10.05) to determine the actual weight (QB).

The belt load (Q) is computed from the total weight (QB) as follows:

Q = QB / Leff

Q = Belt load in kg/m QB = Weight of load on platform in kg

NOTE: The 196NT parameter 10 Weigh Span Length is the full distance between the two weigh span rollers. The DT-9 parameter P04.03 Effective Platform Length is half the distance between the two weigh span rollers. For any given feeder, the value used by the DT-9 should be one half of the value used by the 196NT.

Belt Speed

During normal feeder operation, the belt speed is calculated from the motor RPM rather then being measured directly. The relation ship between motor speed and belt speed is determined during calibration and is displayed as P10.02 Pulses per Length.

Feedrate Control and Totals

The weigh and speed information is used to calculate the actual feedrate as shown.

Feedrate (I) = Belt load (Q) x Belt Speed (V)

The feeder control accepts a feedrate set point from the source selected using parameter P03.02 Absolute Setpoint. This signal is compared with a computed feedrate derived from measured weight and speed signals to generate the system error signal which is used to adjust the speed of the motor. Compensation for system stability is provided in the software using parameters P11.01 P-Component KP and P11.02 I-Component TN. These calculations are repeated periodically and at each iteration, the actual feedrate is multiplied by the time interval to calculate the totalizer increment. Separate totals are kept for gravimetric and volumetric operation.

3.4

Operating Modes - Remote

The Remote Operating Mode is provided for normal operation, with the feeder feeding coal under control of the plant control system. The source for the Start/Stop signal is designated by P03.01 Feeder Start and the source for the feedrate set-point is designated by P03.02 Absolute Setpoint. Analog feedback signals are generated based on the entries to parameter block 14 Analog Outputs. Digital feedback signals (relay outputs) are generated based on the entries to parameter block 16 Digital Outputs.

While in the Remote Operating Mode the feeder can use one of three systems to generate the required belt speed set point.

  • 3.4.1 Gravimetric

Gravimetric Mode is the normal mode of operation. The feed rate is calculated using the belt speed and the actual belt load, and is controlled by the feed rate demand signal supplied by the plant control system. Parameter P03.05 Maximum Feedrate, corresponds to the maximum demand signal and the minimum federate is set by parameter P03.06 Minimum Feedrate. Parameters P02.05 Nominal Flow Rate should always match parameter P03.05 Maximum Feedrate. The system can be set to produce an error if the demand signal is outside to normal range.

  • 3.4.2 Volumetric

Volumetric Mode is used when an error is detected in the weighing system. The actual feed rate is calculated using the belt speed and an assumed belt load based on the average value over the last several hours, and is controlled by the feed rate demand signal supplied by the plant control system. Parameter P03.05 Maximum Feedrate, corresponds to the maximum demand signal and the minimum federate is set by parameter P03.06 Minimum Feedrate. Parameters P02.05 Nominal Flow Rate should always match parameter P03.05 Maximum Feedrate. The system can be set to produce an error if the demand signal is outside to normal range.

  • 3.4.3 Volumetric Control

Volumetric Control Mode is a variation of the gravimetric mode that is used when the feeder weigh system is working correctly but the material on belt switch indicates that the belt is empty. The displayed feedrate and the customer feedback signal is still based on the actual material being fed and the gravimetric total is still being incremented but the belt speed is determined as if the feeder were in volumetric mode. This mode is used to prevent the feeder from running to maximum belt speed when material flow is lost.

  • 3.5 Operating Modes – OFF/Maintenance

The OFF/Maintenance mode is similar to the 196NT LOCAL mode and is provided so that the feeder can be isolated from the plant control system during startup, calibration and other maintenance operations. In this operating mode, the plant start/stop and demand signals are ignored and feedback signals are not generated. The feeder must be in OFF/Maint. mode before a system calibration can be performed. When the feeder is operated in the OFF/Maint. mode, the belt speed is set based on the value of parameter P02.14 Maintenance Speed. This is an open loop signal calculated as a percentage of the full scale signal to the motor speed control (see parameters P11.04 Lower Limit, P11.05 Upper Limit and P11.06 Contr. Magn.Offset.)

4 Hardware and Installation

4.1 DT-9 Installation

The DT-9 replaces both the 196NT CPU board and the Power Supply Board. It is mounted in the same location as the Power Supply Board.

4 Hardware and Installation 4.1 DT-9 Installation The DT-9 replaces both the 196NT CPU board and

Warning: Although the VCU 20104 version of the DT-9 was designed to fit in the same location, and perform the same function, as the 196NT there are significant differences. Read the items below carefully to avoid damage to the controller or attached components.

The polarity of the digital inputs is reversed and the interrogation voltage is +24VDC rather than -15VDC.

If a belt motion monitor switch is used and connected directly to the microprocessor (wires 107 & 115), the wires must be reversed. The current limiting resistor is no longer necessary and may be removed.

Installing the DT-9 in a feeder that uses the Stock load cell amplifier will damage the DT-9. The old style load cell amplifier must be replaced with the new version before the DT-9 is used.

DO NOT connect a normal Ethernet cable to X96 (red RJ45 connector). This connector uses normally unused wires in the CAT 5 cable to provide power to the touch screen display. Failure to follow this warning may result in damage to the DT-9 or to the attached network device.

The weigh span is specified using parameter P 04.03 Effective Platform Length. This parameter is the distance between the weigh roller and either one of the weigh span rollers. This is one half the value used by the 196NT which is the distance between the weigh span rollers.

4.1.1 Installation Notes

This section is a general description of the feeder setup process. This process can be performed using either the touch screen HMI or a PC loaded with the EasyServe software. Section 5 describes the use of the Touch Screen HMI and Section 6 describes the use of EasyServe.

Error conditions (Events) are usually defined using three parameters. The first, which is usually hidden by default, defines the input signal that initiates the event, the second specifies the delay between the time when the error is detected and the time when the event is generated, and the third, specifies the type of event that is generated (A, W1, W2 or IG). In most cases, the error (event) can be disabled by setting the type of event to IG.

The DT-9 has 15 digital inputs (DI 1 through DI 15) and 13 digital outputs (DO 1 through DO 13). Each is assigned to a specific function, and wired to the appropriate external device. These assignments are hidden and should not be changed. See Appendix B for a list of the default assignments.

The DT-9 has one analog input (AI 3) and two analog outputs (AO 1 and AO 2).

AI 3 is

normally used as the customer demand signal, AO 1 is normally used to control the motor

speed control and AO 2 is normally used as the customer feedback signal. These assignments are hidden and should not be changed.

If a frequency to current converter (FCI) is installed on the Digital Mode output (A4 channel, wires 131-133), it must be reprogrammed when the DT-9 is installed.

If the motor speed control (MSC) is installed on the Digital Mode output (A4 channel, wires 131-133), parameter P11.03 Motor Speed Control Output must be set to FRQ, parameter 11.04 Lower Limit must be set to 0.00 mA, parameter 11.05 Upper Limit must be set to 20.00 mA and parameter 11.06 Controller Magnitude Offset must be set to 0.00 mA.

4.1.2

Removing 196NT controller

1)

De-energize the MPC cabinet and open the cabinet door to gain access to 196NT CPU and Power Supply Board

2)

Disconnect all Cables from the 196NT CPU Board. Label the connectors as they are disconnected.

 

o

Load Cell cables J1 and J2

o

Display/Keyboard ribbon cables

o

50 pin ribbon cable to Power Supply Board

o

W6 cable (Red connector)

3)

Disconnect all Cables from Power Supply Board. Label the connectors as they are disconnected.

 

o

Cal A and Cal B Cables (if permanently installed)

o

50 pin ribbon cable from 196NT Board

o

W1, W2, W3, W4, W5 & W6 cables (Red Connectors)

The W6 cable and the 50 pin ribbon cable are not use with the DT-9.

4)

Remove the 196NT CPU and Power Supply Board

4.1.3

Installing the DT-9 Controller

1)

Mount DT-9 board in the old Power Supply Board Location using the existing hardware.

2)

Connect all cables that were removed in steps 2 and 3 above (except W6 and the 50 pin ribbon cable), the DT-9 connectors are labeled to the connectors to show the correct location.

o

Display/keyboard ribbon cables (if the 196NT display is being reused)

Note: Route the cables through the hinge on the mounting panel. The clips provided must be used to keep the cables away from areas where they can be pinched and damaged.

o

Load Cell cables J1 and J2

o

W1, W2, W3, W4 & W5 cables (Red connectors)

o

Optional – Connect Ethernet cable to X93, X94, or X95 if EasyServe will be used from a remote location.

3)

If the 196NT keyboard and display are being reused, apply DT-9 sticker provided with the new controller over the Stock 196NT logo.

4)

If the (optional) Touch Screen HMI is being installed, see section 4.2 below.

5)

The controller is now ready for start up

4.2 Installing the (optional) Touch Screen HMI

This section describes the removal of the existing 196NT display and the installation of the (optional) Touch Screen HMI.

2) Connect all cables that were removed in steps 2 and 3 above (except W6 and

Warning: When a Touch Screen HMI is used, it is essential that the Belt Drive Motor Enable switch be installed between wires 107 and 111, and that parameter P03.10 DI: Run Enable is set to DI 8 – High. The Touch Screen HMI is a stand-alone device that communicates with the DT-9 using an Ethernet connection. In the event that the connection is lost or the HMI is disabled, the Motor Enable switch allows the feeder to be stopped at the keyboard.

4.2.1 Installing the Touch Screen HMI

1)

Disconnect the ribbon cables installed between the 196NT display and the existing controller.

2)

Remove the 12 nuts that hold the 196NT display in place

3)

Remove the support brackets, spacer rings and 196NT display.

4)

Install the Touch Screen HMI and mounting plate using the new gasket and mounting hardware supplied with the kit.

5)

Install the special CAT 5 cable between the RJ 45 connector on the Touch Screen HMI and connector X96 on the DT-9. X96 may only be used for the Touch Screen HMI and has a special cover to prevent normal RJ 45 connectors from being inserted. One end of the special cable has been modified to fit into this connector.

6)

The Belt Drive Motor Enable switch is installed on the Touch Screen HMI mounting panel. Use the wire and terminals supplied with the kit to connect the normally open contact on the switch to wires 107 and 111 on the cabinet terminal block.

Note: The Belt Drive Enable switch is an essential part of the Touch Screen HMI. If wire 111 is already in use, or if the switch cannot be installed for any reason, contact Stock engineering for an alternate configuration.

7)

Carefully close the hinge panel and check for clearance between the panel and the Touch Screen HMI. The existing standoffs are no longer needed and may be removed if necessary. If the hinge panel itself contacts the HMI, remove the panel and place one or more flat washer over each mounting stud, between the panel and the door.

4.2.2 Touch Screen HMI Parameter Changes

When a Touch Screen HMI is installed, the following DT-9 parameters must be changed to allow the Belt Drive Motor Enable switch to stop the feeder.

P03.10 DI: Run Enable – Set the run enable input to DI 8 – High. This is wire 111.

P03.11 Event: Run Disable – Set the run disable event to W2 to generate a warning when the Run Enable switch has disabled the belt drive motor.

4.3 Startup and Functional Check

This procedure verifies that the feeder and its controls are operating properly, simulates feeder trip conditions, and checks the principal input/output connections.

1)

Apply power to the feeder.

2)

Insure that the feeder is in OFF/Maint. mode and that the 196NT display (or the optional touch screen HMI) is set to the home screen.

3)

Set the feeder parameters as described in section 4.4

4)

Interpret event messages, if any, and remedy fault.

5)

Unbalance the load cells by engaging the calibration weight on one side of the weigh roller. The display should indicate volumetric mode. Unbalance each load cell in order to check both sides, then remove the calibration weight(s).

6)

Press and maintain the JOG key (or Jog>> button) to verify belt travel is in the correct direction.

7)

Run the feeder in LOCAL mode by pressing the LOCAL key (or the Run>> button). The feeder will operate at the maintenance speed programmed in P02.16. Check the motor speed for stability.

8)

If the (optional) Touch Screen HMI is installed, run the feeder in LOCAL by pressing the Run>> button. Set the Belt Drive Motor (Run Enable) switch to the STOP position. The feeder should stop and the display should show a IL01 Event: Run Disabled error message. Acknowledge the event and return the Belt Drive Motor switch to its normal position.

9)

Stop the feeder and deflect the material-on-belt limit switch paddle to simulate a loaded belt. Run the feeder in the LOCAL mode to verify that the feeder trips. If this does not happen, check the adjustment of the paddle switch cams.

10) Check the event display (Error Recall on the 196NT display) or the event line on EasyServe. They should both show a WM12 Material-on-Belt alarm message with a time stamp. Acknowledge the event and return the coal-on-belt paddle to its normal position.

11) Calibrate the feeder as described in section 4.5.

12) Align the analog inputs and outputs as describe in section 4.6.

13) Hang the calibration weights. Produce or simulate a feeder start permissive. Check feedrate and feedback linearity by applying demand signals of 100, 75, 50, and 25 percent. Compare each demand signal applied to the feedback signal output. Compare the demand feedrate setpoint (service value 4) with the measured feed rate of the feeder (service value 5) for each signal.

14) Energize the feeder in the REMOTE mode and deflect the discharge pluggage alarm (or touch the discharge pluggage sensor with a metal rod). After the preset delay in P15.10, the feeder should be de-energized. If the feeder does not trip, check the adjustment of the cams for the paddle switch or the sensitivity setting of the sensor according to the procedure in the original equipment manual.

15) Check the event display or the event line on EasyServe. They should both show a WM07 Discharge Pluggage alarm with a time stamp. Acknowledge the event and return the discharge switch to its original state.

16) Return the feeder to REMOTE operation.

17) If the 196NT display is being used, apply a start and demand signal, then deflect the material- on-belt level control switch. Verify that the red REMOTE LED along with the green RUNNING and FEEDING LED’s are illuminated.

18) If the 196NT display is being used, view service value 14. Verify that the rate shown matches the demand signal currently being applied to the feeder. The value should change as the demand signal changes.

4.4 Setup Parameters

The microprocessor controller is tailored to specific feeders and customers needs by the setup parameters. Feeder-specific physical dimensions must be entered as well as user-selectable display modes and set points. These values are stored in permanent memory and are only entered once. See section 8 for a complete list and description of the parameters.

Note: In any given application, the majority of the DT-9 parameters are either not used, or fixed by the design of the feeder and cabinet. These parameters can be viewed using EasyServe in expert mode (default password 7353) but should not be changed.

The controllers will come preprogrammed from Stock Equipment Company but if changes are needed, there are three ways to do this:

Using the existing 196NT display (See section 6.4)

Using EasyServe Software (See section 5.2.4)

Using the Touch Screen HMI (See Section 7.5)

4.4.1 Converting 196NT Parameters to DT-9 Parameters

When replacing an older generation 196NT with an updated DT-9 controller it is necessary to transfer the installation specific parameters from the older unit to the newer one. Although the two systems have different parameter sets they both perform the same function, and require the same information.

Before transferring parameters, load the DT-9 Custom Default Parameters using EasyServe (see section 6.5.3) or the Setup screen on the 196NT display (see section 5.5.3). DT-9 parameters can then be entered directly, or using Parameter Group 50 Setup Parameter 196NT, which is an automatic translation system built into the DT-9.

To transfer parameters using group 50 a record of the original 196NT setup values must be available. This can be obtained from the controller being replaced, other feeders on the some boiler, or plant records. Enter the complete set of 196NT values normally. Once all of the values have been entered, change the value of parameter P50.50 Convert Now from OFF to ON, to initiate the conversion process and updates the DT-9 parameters. Changing parameter P50.50 from ON to OFF has no effect, so initiating the conversion may be a two step process.

Setup Notes:

Unlike other DT-9 parameters, group 50 parameters do not control the feeder directly and do not take effect as they are entered. They are translated, and transferred to the DT-9 when parameter P50.50 is changed from NO to YES. For this reason, the values shown may not be the ones currently being used by the controller.

All group 50 parameters are transferred when P50.50 is changed, so all parameters must be set correctly prior to initiating the conversion process.

The Parameter Group 50 translation mechanism will correctly translate the setup parameters

from most 196NT installations.

However, in some cases it may be necessary to change

parameters in Parameter Groups 1 through 27 directly. See the translation table, and

comments, below.

When programming the 196NT certain functions can be disabled by setting their time delay to zero (e.g., setting parameter 17 BMM Trip Delay to 0.0 disables the belt motion monitor). This is still the case when Parameter group 50 is used to translate 196NT parameters but it is not the case with other DT-9 parameters (Parameter groups 1 through 27). In most cases, one parameter is used to set the time delay and another is used to determine the event that is generated at the end of the delay. The function can usually be disabled by setting the event to IG (Ignore).

Over the years, Stock has supplied many special 196NT programs to meet special customer requirements. The DT-9 can duplicate most of the features added to these programs but special configuration is usually required. Appendix B contains a list of special programs and features, and the DT-9 configuration changes required to implement them.

Parameter Conversion Table:

The table below compares the DT-9 and 196NT parameter sets. It can be used as a guide for transferring 196NT parameters to the DT-9 directly, or for making modification to the values selected by the automatic translation mechanism in parameter group 50.

 

196NT Parameters

DT-9 Parameters

Comments:

00

Feedrate Setpoint

N/A

See parameter P03.02 for feedrate

01

Speed Setpoint RPM

P02.14 Maint. Speed

setpoint options. The 196NT uses RPM. The DT-9 uses percent of speed control full

Not a direct translation.

scale. Normally set to 50%

02

Initial Density Estimate

N/A

 

03

Run Mode

P03.02 Absolute

No DT-9 equivalent. Not all 196NT run modes are

Setpoint.

supported. Set P03.02 to AI 3 for

Not a direct translation.

analog demand signal on Sig+, Sig-.

04

Display Select

P02.01, P02.02 & P02.05 thru P02.09

Parameter group 2 provides a variety of customer selectable display

Not a direct translation.

options.

05

Maximum Feedrate

P02.05 Nominal Flow Rate & P03.05 Maximum Feedrate

Transfer directly

06

Minimum Feedrate

P03.06-Minimum

Both DT-9 parameters must be set. Transfer directly

Feedrate

07

Totalizer Increment

P02.13 Totalizer

Transfer directly

Increment

08

Demand Mode

P11.03 Motor Speed Control Output

Set P11.03 to AO 1 for analog output (VFD or DC drive) and FRQ for Eddy Current Clutch.

When P11.03 is set to FRQ, P11.05 must be set to 20.0 mA, and both P11.04 and P11.06 must be set to 0.0 mA.

09

Tachometer Type

P04.09 Tachometer Pulses per Rev.

Directly input the number of pulses per motor revolution.

10

Weigh Span

2 X P04.03 Effective Platform Length

DT-9 Parameter P04.03 is half the

11

Volume

P04.10 Load Cross Section.

196NT weigh span length The 196NT uses the volume on the weigh span. The DT-9 used the

Not a direct translation.

area under the leveling bar. Calculate the correct value for P04.10 by dividing 196NT Setup 11

12

Calibration Probe Span

P10.01 Calibration Probe Span

by Setup 10 (weigh span). Transfer directly

13

Calibration Weight

P10.08 Calibration Weight

Transfer directly

14

Servo Loop Gain

P11.01 and P11.02.

Use values specified in parameter

Not a direct translation.

section below.

15

Rate Feedback Gain

P11.01 and P11.02.

Use values specified in parameter

Not a direct translation.

section below.

16

Discharge Pluggage

P15.10 Discharge

If Setup 16 was set to zero, set

Trip Delay

Pluggage Delay

P15.11 Discharge Pluggage to IG to

17

BMM Trip Delay

P07.02 Belt Motion Monitor Delay

disable discharge trip. If Setup 17 was set to zero, set P07.03 Event: Belt Motion Monitor to IG to disable discharge trip.

If Setup 17 is non-zero set P07.03 to A to trip the feeder on a belt motion error.

If a BMM sensor is connected directly to the 196NT the polarity of the sensor leads must be reversed and the current limiting resistor must be removed.

18

Level/Temp Trip Delay

P15.20

If Setup 18 was set to zero, set

disable discharge trip.

Level/Temperature Sensor Delay

P15.21 Event: Coal Flow to IG to

19

Weigh Signal Filtering

P08.01 LC Filter

 

20

Feedback Signal Filtering

P08.02 I-Display and P08.03 I-Analog Out.

See description below See parameter description below.

21

Feedback Filter Override Threshold

P08.04 I Feedback Filter Override Threshold

Both DT-9 parameters must be set. Transfer directly.

22

Belt Travel Rev.

P10.07 Simulation Travel (Belt Rev.)

Transfer directly

23

Low Density Alarm Threshold

P09.05 Value for Q-Min P09.06 Event Class for Q-min.

If Setup 23 is present and is set to a non-zero value, set P09.05 to Setup 23 as a percentage of the nominal material density (100 X Setup 23 / Setup 02), and set P09.06 to W2.

If Setup 23 is not present or is set to zero, set P09.06 to IG.

24

Paddle Feedback

P15.16 Belt Paddle

If Setup 24 was set to 0 (Paddle

Permissive

Feedback Permissive

Ignored), set P15.16 to prop to Rate.

     

If Setup 24 was set to 1 (Paddle Enables), set P15.16 to Low. Lim. if

25

Communications Unit Number

N/A

empty. No DT-9 equivalent

26

Mode Select

N/A

No DT-9 equivalent

Enable/Disable

If Setup 26 is set to 0 (Keyboard Only), 3 (Keyboard and Local) or 4 (Keyboard and Jog), DT-9 parameter P15.23 DI: Remote CTRL must be set to n/a.

27

FRI Output Frequency

P02.18 Remote FRI Frequency.

Transfer directly

28

Raise/Lower Response Time.

P03.09 Raise/Lower Response Time

Transfer directly

29

Maximum Motor Speed

N/A

No DT-9 equivalent.

30

Minimum Motor Speed

N/A

No DT-9 equivalent.

31

Not used

N/A

No DT-9 equivalent

32

Not used

N/A

No DT-9 equivalent

33

Weigh Signal Gain

N/A

No DT-9 equivalent.

34

Not used

N/A

 

35

TCI Pulse Width

P 02.14 Remote Totalizer Pulse Width

No DT-9 equivalent Transfer directly

36

Test Chain Weight

P10.09 Test Chain Weigh

Transfer directly

37

Hourly Total Time

P20.01 Hourly Total Time

Transfer directly

38

Daily Total Time

P20.02 Daily Total Time

Transfer directly

39

Loss of Flow Trip Delay

P15.13 Loss of Flow Delay

Transfer directly

40

Auxiliary Output Type

N/A

No DT-9 equivalent

Other DT-9 parameters that must be updated include:

P02.06 Nominal Speed - See parameter description below for calculation required.

P03.10 Run Enable - must be set to DI 8 - High if the (optional) touch screen display is installed and to n/a if it is not.

P04.02 LC Rated Cap. - must be set to match the actual load cell. The default value of 100 Lbs is correct for most feeders but some Modular, Compact Gravimetric and 18 inch gravimetric feeders use 50 lbs load cells, and some 36 inch and larger feeders use 150 lbs load cells.

P11.03 Motor Speed Control Output - If the motor speed control (MSC) is installed on the Digital Mode output (A4 channel, wires 131-133), parameter P11.03 must be set to FRQ

If P11.03 is set to FRQ, parameter 11.04 Lower Limit must be set to 0.00 mA, parameter 11.05 Upper Limit must be set to 20.00 mA and parameter 11.06 Controller Magnitude Offset must be set to 0.00 mA.

P15.12 DI: Coal on Belt Switch - If a coal on belt switch (LSFB) is not installed this parameter must be set to n/a (not used).

P15.14 Event: Loss of Material - If it is necessary for the feeder to trip when a loss of material on the belt is detected, parameter P15.14 must be set to A.

P15.23 DI: Remote CTRL - If Setup 26 is set to 0 (Keyboard Only), 3 (Keyboard and Local) or 4 (Keyboard and Jog), DT-9 parameter P15.23 must be set to n/a.

4.5 Calibration

The feeder should be calibrated at startup, after one month of initial operation and every six months there after. Calibration should also be performed following a weigh roller adjustment or replacement of the belt, the CPU board, or a load cell module. The controller should also be calibrated after the controller firmware is updated or a Load Default Values operation is performed. Calibration is accomplished in two separate steps.

Step one of calibration consists of the elimination of system tare, which includes the weight of the weigh roller, load cell support assembly, and the feeder belt. It also involves measuring belt speed and its relationship to motor speed. Step two calibrates the load cell output with a known weight.

Cancellation of feeder tare is performed by measuring the average weigh system output over exactly two belt revolutions (eight tape passes) and then subtracting this amount from the total weight measurement. When the belt is running empty, it produces a zero average contribution to the totalized weight. In normal operation, the average tare is automatically subtracted from the gross weight of the belt. Therefore, only the material weight on the belt is reflected as totalized weight.

While the empty belt is being weighed, the belt speed is also being accurately measured. This is done by measuring the time it takes a retro-reflective marker, attached to the belt, to travel between two fixed points on the feeder body. This parameter is measured eight times to determine repeatability and to compensate for variations in belt thickness. From this data, the belt speed is calculated and the relationship between belt speed and motor speed is established. The feeder operates with zero belt slippage. Therefore, the ratio of belt speed to average motor speed is constant. This ratio is stored in memory and is used to determine the belt speed for any motor speed.

The span of the weighing system is set after the tare has been measured. A known weight is applied to the weigh roller and the average output over exactly two belt revolutions (eight tape passes) is measured. This calibrated span factor is stored in memory and used to accurately determine the value of the weight of the material on the belt.

NOTE: The DT-9 parameter P04.03 Effective Platform Length is the distance from either weigh span roller to the central weigh roller, which is supported by the load cell. This is half the distance between the two weigh span rollers. For any given feeder, the value used by the DT-9 should be one half of the value used by the 196NT.

4.5.1 Performing Calibrations

The calibration process consists of the following three steps.

1)

Weigh Roller Adjustment.

2)

Basic (Cal 1) – Belt speed and tare calibration.

3)

Span (Cal 2) – Belt Speed and span calibration.

Note: At least one Basic (Cal 1) must be performed prior to performing a Span (Cal 2).

The following special calibration processes can be preformed for testing or special maintenance operations, but are not normally required.

1)

TC: Span calibration - Chain test calibration.

2)

LB: Pulses / Belt - Belt speed calibration.

3)

TA: Tare - Tare calibration.

Note: Calibration is considered a local operation. No totalization takes place and analog feedback signals are set to minimum.

4.5.2 Weigh Roller Adjustment

For the feeder to weigh accurately, the central weigh roller must be aligned with the weigh span rollers within 0.002 inch (0.05mm). Refer to Figure 4-1.

NOTE: The parts shown may differ from those that actually shipped. This figure is to be used as a general guideline.

Weigh Roller Adjustment Procedure

1)

Mount the calibration weight on both load cells.

2)

Insert the checking bars (A2451-1) through the discharge end access door of the feeder, adjacent to the sides of the belt, and with their machined surfaces resting on the weigh span and weigh rollers.

3)

Beginning on either side, insert a 0.005 in. shim between each of the three rollers and the machined surface of the checking bar (three places).

4.5.2 Weigh Roller Adjustment For the feeder to weigh accurately, the central weigh roller must be

Figure 4-1

Weigh Roller Adjustment

4)

Loosen the jam nut, and then turn the adjustment block to lower the weigh roller.

5)

Slowly turn the adjustment block to raise the weigh roller until the shim is touching both checking bar and weigh roller (slip fit). Tighten the jam nut.

6)

Similarly, adjust the weigh roller on the opposite side of the feeder.

7)

Remove the checking bars.

8)

Remove the calibration weights.

9)

The feeder must be recalibrated after weigh roller adjustment. (See procedure on next page.)

4.5.3 Basic (CAL 1)

This operation measures the tare factor and the belt speed factor and updates the following parameters.

P10.02 Pulses per Length

P10.10 Basic Tare

P10.11 Belt Circuit No.

Note:

The calibration results are not saved to the parameter table until the operator accepts them

buy pressing <Apply> in EasyServe, <SAVE> on the (optional) Touch Screen HMI or <ENTER> on the 196NT display.

Requirements:

The weigh span must be level prior calibration. If the weigh roller height has been adjusted, a complete calibration (Basic (Cal 1) and Span (Cal 2)) must be performed.

The calibration probes must be installed and in the correct location.

o

Cal probe A is located closer to the feeder inlet.

o

De-energize the DT-9 before installing the probes.

Four retro-reflective tape clips must be installed on the belt.

o

The tape clips must be farther apart than the distance between the cal probes or a Probe Error will be generated and the calibration will not complete.

o

Four tape clips are normally used but two can be used if the feeder is very shot or eight can be used if the feeder is very long or slow. If two tape clips are used, the feeder will be calibrated over four belt revolutions, instead of two, and P10.11 Belt Circuit No. will be twice the correct value. If eight tape clips are used, the feeder will be calibrated over one belt revolution and P10.11 Belt Circuit No. will be half the correct value.

The feeder must NOT be in volumetric mode.

The feeder must be in OFF/Maint mode.

The feeder belt must be empty.

The calibration weights must NOT be installed.

Calibration Procedure:

1)

Before starting the calibration, record the values of parameters P10.02 Pulses per Length and P10.10 Basic Tare. These will be used later to verify that the calibration results are consistent.

2)

If the calibration is being performed using EasyServe, navigate to the calibration window using the Tools | Calibration Programs menu items. If the (optional) touch screen HMI is being used, first log in, then go to the calibration display by pressing the <Setup> and <Calibration> buttons.

3)

Select Basic (Cal 1)

 

4)

Initiate the Basic (Cal 1) calibration process by pressing the <Start> button in EasyServe or the (optional) Touch Screen HMI, or the <CAL 1> button on the 196NT display.

5)

The feeder will begin to run and go through a stabilization process.

o

The motor will first run at a one-half the value specified in P02.16 Maintenance Speed, then at the full value of P02.16.

6)

After Stabilizing, the feeder will go through eight tape passes. The DT-9 will display the pass number and tachometer pulses on the screen.

7)

Upon completion of the calibration four values will be displayed on the screen:

o

Deviation

(Variation between belt speed measurements)

o

Belt Circuit No

(P 10.11)

o

Basic Tare

(P 10.10)

o

Pulses per Length Value

(P 10.02).

8)

After successful completion, the screen will prompt you to either save or cancel the calibration values.

Note:

If the calibration results in bad values, correct any mechanical issues and run the

calibration program again.

 

9)

Press the <SAVE>, < ENTER> or <Apply> button to store the new calibration values, or the <EXIT> or <Cancel> button to abort the calibration leaving the parameters unchanged.

10) After the calibration has been performed, verify that the results are consistent by comparing the latest values of P10.02 and P10.10 to the previous values (Recorded in step 1). Calculate the percent change using the formula [100 x (new value - old value) / (new value)]. If the result is greater then 0.25 %, check for mechanical errors in the weigh system and repeat the calibration.

4.5.4 Span (CAL 2)

This operation measures the load cell span factor and the belt speed factor, and updates the following parameters.

P10.03 Range Correction TW

P10.10 Basic Tare

P10.11 Belt Circuit No.

Note:

The calibration results are not saved to the parameter table until the operator accepts them

buy pressing <Apply> in EasyServe, <SAVE> on the (optional) Touch Screen HMI or <ENTER> on the 196NT display.

Requirements:

The weigh span must be level prior calibration. If the weigh roller height has been adjusted, a complete calibration (Basic (Cal 1) and Span (Cal 2)) must be performed.

The calibration probes must be installed and in the correct location.

o

Cal probe A is located closer to the feeder inlet.

o

De-energize the DT-9 before installing the probes.

Four retro-reflective tape clips must be installed on the belt

o

The tape clips must be farther apart than the distance between the cal probes or a Probe Error will be generated and the calibration will not complete.

o

Four tape clips are normally used but two can be used if the feeder is very shot or eight can be used if the feeder is very long or slow. If two tape clips are used, the feeder will be calibrated over four belt revolutions, instead of two, and P10.11 Belt Circuit No. will be twice the correct value. If eight tape clips are used, the feeder will be calibrated over one belt revolution and P10.11 Belt Circuit No. will be half the correct value.

The feeder must NOT be in volumetric mode.

The feeder must be in OFF/Maint mode.

The feeder belt must be empty.

A Basic (Cal 1) had been performed.

Enter Parameter P 10.08 Calibration Weight. Ensure that the value entered matches the total value stamped on the calibration weight(s).

Mount the calibration weight(s) on the load cells.

Calibration Procedure:

1)

Before starting the calibration, record the value of parameters P10.02 Pulses per Length and P10.03 Range Correction TW. These will be used later to verify that the calibration results are consistent.

2)

If the calibration is being performed using EasyServe, navigate to the calibration window using the Tools | Calibration Programs menu items. If the (optional) touch screen HMI is being used, first log in, then go to the calibration display by pressing the <Setup> and <Calibration> buttons.

3)

Select Span (Cal 2)

 

4)

Initiate the Span (Cal 2) calibration process by pressing the <Start> button in EasyServe or the (optional) Touch Screen HMI, or the <CAL 2> button on the 196NT display.

5)

The screen will prompt to add the calibration weight. The top line of the display will show the value entered in P 10.08 and the bottom line show what the load cells are measuring based on the current calibration parameters. Press the <ENTER> or <Start> button to proceed with calibration.

6)

The feeder will begin to run and go through a stabilization process

o

The motor will run at the value specified in P02.16 Maintenance Speed.

7)

After Stabilizing the feeder will go through eight tape passes

o

The pass number and tachometer pulses will be displayed on the screen

8)

Upon completion of the calibration, four values will be displayed on the screen.

o

Deviation

(Variation between belt speed measurements)

o

Belt Circuit No

(P 10.11)

o

Range Correction TW

(P 10.03)

o

Pulses per length. Value

(P 10.02)

9)

After successful completion, the screen will prompt you to either save or cancel the calibration values.

Note:

If the calibration results in bad values, correct any mechanical issues and run the

calibration program again.

10) Press the <SAVE>, < ENTER> or <Apply> button to store the new calibration values, or the <EXIT> or <Cancel> button to abort the calibration leaving the parameters unchanged.

11) After the calibration has been performed, verify that the results are consistent by comparing the latest values of P10.02 and P10.03 to the previous values (Recorded in step 1). Calculate the percent change using the formula [100 x (new value - old value) / (new value)]. If the result is greater then 0.25 %, check for mechanical errors in the weigh system and repeat the calibration.

4.5.5 TC: Span Calibration

This operation performs a chain calibration using the values in P10.07 Simulation Travel (Belt Rev.) and P10.09 Test Chain weight. The results are used to update the following parameter.

P10.04 Range Correction TC.

Note:

The calibration results are not saved to the parameter table until the operator accepts them

buy pressing <Apply> in EasyServe, <SAVE> on the (optional) Touch Screen HMI or <ENTER> on the 196NT display.

Note:

The calibration probes are not used during this operation and do not need to be installed.

Requirements:

The weigh span must be level prior calibration. If the weigh roller height has been adjusted, a complete calibration (Basic (Cal 1) and Span (Cal 2)) must be performed.

The feeder must NOT be in volumetric mode.

The feeder must be in OFF/Maint mode.

The feeder belt must be empty.

The calibrated test chains must be installed.

Calibration Procedure:

1)

Before starting the calibration, record the value of parameter P10.04 Range Correction TC. This will be used later to verify that the calibration results are consistent.

2)

If the calibration is being performed using EasyServe, navigate to the calibration window using the Tools | Calibration Programs menu items. If the (optional) touch screen HMI is being used, first log in, then go to the calibration display by pressing the <Setup> and <Calibration> buttons.

3)

Select TC: Span Calibration.

4)

Initiate the TC: Span Calibration process by pressing the <Start> button in EasyServe or the (optional) Touch Screen HMI. This process cannot be performed using the 196NT display.

5)

The screen will prompt to add the calibration weight (test chain). The top line of the display will show the value entered in P 10.09 and the bottom line show what the load cells are measuring based on the current calibration parameters. Press the <Start> button to proceed with calibration.

6)

The feeder will begin to run and go through a stabilization process

o

The motor will run at the value specified in P02.16 Maintenance Speed.

7)

After Stabilizing the feeder will run for the number of belt revolutions specified in P10.07.

o

The percentage complete will be displayed on the screen

8)

Upon completion of the calibration, four values will be displayed on the screen.

o

TC: Ready

(Simulated weight delivered)

o

Range Correction TC

(P 10.04)

9)

After successful completion, the screen will prompt you to either save or cancel the calibration values.

10) Press the <SAVE>, < ENTER> or <Apply> button to store the new calibration values, or the <EXIT> or <Cancel> button to abort the calibration leaving the parameters unchanged.

Note:

If the calibration results in bad values, correct any mechanical issues and run the

calibration program again.

11) After the calibration has been performed, verify that the results are consistent by comparing the latest value of P10.04 to the previous value (Recorded in step 1). Calculate the percent change using the formula [100 x (new value - old value) / (new value)]. If the result is greater then 0.25 %, check for mechanical errors in the weigh system and repeat the calibration.

  • 4.5.6 LB: Pulses per Belt

The LB: Pulses per Belt calibration process is not intended for use in coal feeder applications and should not normally be preformed.

  • 4.5.7 TA: Tare

This operation measures the weight of the empty belt (tare factor) for a period of time based on the value of P10.11 Belt Circuit No. times P10.07 Simulation Travel, and updates the following parameter.

P10.10 Basic Tare

Note:

The calibration results are not saved to the parameter table until the operator accepts them

buy pressing <Apply> in EasyServe, <SAVE> on the (optional) Touch Screen HMI or <ENTER> on the 196NT display.

Note:

The calibration probes are not used during this operation and do not need to be installed.

Requirements:

The weigh span must be level prior calibration. If the weigh roller height has been adjusted, a complete calibration (Basic (Cal 1) and Span (Cal 2)) must be performed.

The feeder must NOT be in volumetric mode.

The feeder must be in OFF/Maint mode.

The feeder belt must be empty.

The calibration weights must NOT be installed.

Calibration Procedure:

1)

Before starting the calibration, record the value of parameter P10.10 Basic Tare. This will be used later to verify that the calibration results are consistent.

2)

If the calibration is being performed using EasyServe, navigate to the calibration window using the Tools | Calibration Programs menu items. If the (optional) touch screen HMI is being used, first log in, then go to the calibration display by pressing the <Setup> and <Calibration> buttons.

3)

Select TA: Tare calibration.

4)

Initiate the TA: Tare calibration process by pressing the <Start> button in EasyServe or the (optional) Touch Screen HMI. This process cannot be performed using the 196NT display.

5)

The feeder will begin to run and go through a stabilization process

o

Run the motor at the value specified in P02.16 Maintenance Speed.

6)

After Stabilizing, the feeder will run for the specified time (P10.07 times P10.11). The DT-9 will display the percent completion and the current tare value as a percentage of the rated belt load. The nominal belt load is defined as the nominal flow rate divided by the nominal belt speed.

7)

Upon completion of the calibration two values will be displayed on the screen:

o

Deviation – Percent deviation between the new tare value and the previous value.

o

Tare – Tare value as a percentage of the nominal belt load.

8)

After successful completion, the screen will prompt you to either save or cancel the calibration values.

9)

Press the <SAVE>, < ENTER> or <Apply> button to store the new calibration values, or the <EXIT> or <Cancel> button to abort the calibration leaving the parameters unchanged.

Note:

If the calibration results in bad values, correct any mechanical issues and run the

calibration program again.

10) After the calibration has been performed, verify that the results are consistent by comparing the latest value of P10.10 to the previous value (Recorded in step 1). Calculate the percent change using the formula [100 x (new value - old value) / (new value)]. If the result is greater then 0.25 %, check for mechanical errors in the weigh system and repeat the calibration.

4.6 Analog Trim

The feeder controls respond to a feed rate demand signal and return isolated analog feedback signals. When the input and output modules associated with these signals are used with the plant’s control system, they must be adjusted prior to operating the feeder under remote control. To perform this procedure, Stock Equipment Company recommends the Fluke Model 87 Digital Multimeter or equivalent. The DC accuracy for milliamps should be ± 0.2% and the DC accuracy for voltage should be ± 0.1% plus 1 digit. It also must have a 4-1/2 digit high resolution mode.

Setting analog trim values using the 196NT display (See section 6.5)

Setting analog trim values using EasyServe (See section 7.5)

Setting analog trim values using the Touch Screen HMI (See section 5.2.4)

Note:

The plant combustion control system is the preferred source of the demand signal. This will precisely align the feeder to the control system.

The DT-9 has three slots for analog input and output cards which are pre-installed at Stock Equipment Company. The slots are located next to the power supply and below the calibration probe sockets.

1)

A10: Connected to wires 142, 143 & 144 and equivalent to the A2 card on the 196NT. It is controlled by P 01.03 Analog Channel A10 which should be set to AO 1. This card is used to control the motor speed control and the values in P 11.03 Controller Magnit. Y and P 01.03 must match (both AO 1).

2)

A11: Connected to wires 139, 140, & 141 and equivalent to the A3 card on the 196NT. It is controlled by P 01.04 Analog Channel A11 which should be set to AO 2. This card is used to provide the customer feedback signal and the values in P 14.04 Actual Flow Rate and P 01.04 must match (both AO 2).

3)

A12: Connected to wires SIG+ & SIG- and equivalent to the A1 card on the 196NT. It is controlled by P 01.05 Analog Channel A12 which should be set to AI 3. This card is used to provide the customer demand signal and the values in P 03.02 Absolute Setpoint and P 01.05 must match (both AI 3).

5 Operation Using the (Optional) Touch Screen HMI

This chapter describes control of the DT-9 using the Touch Screen HMI (Human-Machine Interface).

Notes:

1)

The following values and settings remain stored after power failure:

 

o

Counter readings

o

Parameter settings

o

Setpoints

o

Service values

o

Counter pulses pending.

2)

This manual uses the abbreviations "[Button

button", e.g. [HOME] button, to

describe the buttons displayed on the touch screen HMI.

3)

Text entry fields on the HMI are indicated by a white box surrounded by a gray rectangle. To enter text, tap the desired text entry field to select it. A keyboard will appear on the screen. When you have finished entering text, press the [OK] button to save your changes and exit the keyboard. To exit the keyboard without saving changes, press the [EXIT] button.

4)

In the event of a power failure while the feeder was running in remote mode, the system will restart in remote mode and, if the running contact is active, continue to feed coal.

5.1 Initial Configuration

When the DT-9 is first powered up, the HMI will automatically log in to the connected DT-9 controller. In order to change the settings of the HMI itself, it is necessary to log out of the DT-9 and log into the HMI via the following steps:

1)

From the “Home” screen, press the [Login] button and enter the DT-9 password (the default is ‘”7353”). The “Home” screen will reappear and the [Login] button will change to [Logout] to indicate that you have successfully logged in to the DT-9.

2)

Press the [Sel. Scale] button. A prompt will appear asking if you really want to exit the scale. Press [YES].

3)

The main HMI configuration screen will now appear. A list of available DT-9 controllers on the local subnet will be displayed on the upper left portion of the screen, and the main function buttons will be displayed along the right edge. The display function buttons are described in the following subsections. Most of the function buttons will be grayed out and unavailable. To gain full access, press the [Login] button and enter the HMI password (the default is ‘”7353”). Press the [Start] button to return to the main HMI configuration screen, or press the [Change Password] button to change the display password. All of the function buttons will now be available, indicating that you have successfully logged in to the HMI.

  • 5.1.1 The “Network” Screen

Press the [VHM Addr.] button to change the network settings of the HMI. This screen allows you to set the IP Address, Subnet, and Gateway of the HMI. These settings should be obtained from your network administrator. Press the [Save] button to save any changes you have made to these settings before exiting.

  • 5.1.2 The “Display Settings” Screen

Press the [Display] button to adjust the HMI display settings. The “Inactivity Timeout” parameter defines the length of time that the HMI will remain at full brightness after being touched before entering “Sleep Mode” and dimming the display. The “Working Brightness” parameter adjusts the brightness of the display during normal operation, and the “Sleeping Brightness” parameter adjusts the brightness of the display during “Sleep Mode”. Press the [Save] button to save any changes you have made to these settings before exiting.

  • 5.1.3 The “Feeder” Screen

Press the [Feeder] button to select the DT-9 controller that the HMI will connect to. A list of all available DT-9 controllers on the local subnet will be displayed, and the selected controller will be indicated with a check mark. To connect to a different DT-9, press the check box next to the desired controller and then press the [Select] button. The HMI will then connect to the new DT-9 the next time it is power cycled or when the [Con. Scale] button is pressed. To rescan the local subnet, press the [Scan] button.

  • 5.1.4 The “Configuration” Screen

Press the [Config] button to adjust the networking options of the HMI. The “URL of start page” parameter defines the start page of the DT-9’s embedded web server. The “Start timeout in seconds” parameter defines the amount of time that the HMI will attempt to connect to the attached DT-9 before defaulting to the HMI configuration screen.

  • 5.1.5 The “Communication” Screen

Press the [Com] button to change the method by which the HMI will communicate with an attached DT-9 controller. The available options are “Ethernet”, “Bluetooth”, and “RS485”. The factory default is “Ethernet”, and this should not be changed.

5.1.6

The “Calibration” Screen

Press the [Calibration] button and follow the on-screen prompts to calibrate the touch screen.

  • 5.1.7 Exiting HMI Configuration

Press the [Con. Scale] button to exit the HMI calibration screen and return to the DT-9 “Home” screen.

5.2 Display Functions

  • 5.2.1 The “Home” Screen

The Home screen is the first screen displayed after the HMI has finished booting. It displays the current status of the feeder, and contains the main operating controls.

The Mode Select buttons are located on the bottom left of the Home screen, and are used to select the operating mode of the feeder (See sections 3.4 and 3.5 for more information on operating modes).

  • 5.2.1.1 Operating the HMI in “Off/Maintenance” Mode

Press the [Off/Maint] button to place the feeder in “Off/Maintenance” mode. The background color of the Home screen will turn yellow to indicate that “Off/Maintenance” mode has been selected. In this mode, the plant start/stop signals and demand signals are ignored. The feeder can be run in the forward or reverse directions by pressing the [Run >>] or [Run <<] buttons on the Home screen, as long as there is no material on the feeder belt. The feeder will run in the desired direction at the speed defined in P 02.14 Maintenance Speed. The [Stop] button will stop the feeder. Pressing and holding the [<< Jog] or [Jog >>] buttons will cause the feeder to jog backwards or forwards for as long as the button is pressed. The jog speed is the same as the Maintenance Speed defined in P 02.14. The feeder can be jogged with or without material on the belt.

  • 5.2.1.2 Operating the HMI in “Remote” Mode

Press the [Remote] button to place the feeder in “Remote” mode. The background color of the Home screen will turn white to indicate that “Remote” mode has been selected. At this point, the feeder is ready to receive commands from the plant’s control system. Upon receipt of a feeder start command and a demand signal from the control system, the feeder will begin to operate and the feeder graphic on the Home screen will indicate that the feeder is running in the forward direction. As material fills the belt, the Belt Load and Material Total values displayed on the Home screen will begin to update. The feeder will respond automatically to the changing demands of the plant’s control system until it receives a feeder stop command or until the [Off/Maint] button is pressed. If an alarm occurs, it will be displayed in a banner across the top of the Home screen and can be cleared by pressing the [Ack Event] button. If a trip occurs, the feeder will be stopped and the display will automatically switch to “Off/Maintenance” mode. The trip can be cleared by resolving the problem that caused the trip and pressing the [Ack Event] button. “Remote” mode can then be resumed by pressing the [Remote] button.

5.2.2

The “Trend” Screen

The “Trend” screen is a customizable line graph that can be used to plot various data items that are logged by the DT-9 over time. See Appendix C for a list of available data items.

5.2.3

The “Values” Screen

The “Values” screen displays information about the feeder on two sub screens, which can be accessed by pressing the [Values] or [Totals] buttons.

The [Totals] button displays the following data:

Material Total is the total amount of material delivered by the feeder, and is the sum of the Gravimetric and Volumetric Totals.

Gravimetric Total is the total amount of material delivered by the feeder while operating in Gravimetric Mode.

Volumetric Total is the total amount of material delivered by the feeder while operating in Volumetric Mode.

The [Reset] button will reset all three totalizers. The total values cannot be recovered after the [Reset] button is pressed.

The [Values] button displays the following data:

Belt Speed shows the current speed of the belt in feet or meters per second.

Belt Load shows the weight of the material on the belt per unit of belt length in pounds per foot or kilograms per meter.

Speed shows the shaft speed of the belt drive motor in revolutions per minute.

Density shows the currently calculated density of the material on the belt in pounds per cubic foot or kilograms per cubic meter.

5.2.4

The “Setup” Screen

The “Setup” Screen is used to configure the DT-9 and to access the various log files that are stored by the controller.

The following buttons are initially shown on the “Setup” screen: [Data Log], [Event Log], [Param Log], [Parameter], and [ ] (Right Arrow).

Pressing the Right Arrow button causes the display to scroll to the following additional buttons: [Trim], [Defaults], [Simulation], [Calibration], and [Set Time]. Pressing the Right Arrow button again will cause the display to scroll back to the initial list of buttons.

The [Trim], [Defaults], and [Calibration] buttons will be grayed out and unavailable unless the user is logged in to the DT-9. The user must also log in before changing any of the parameters that are accessed via the [Parameter] button.

To log in to the DT-9, press the [Login] button, enter the DT-9 password (the default is ‘”7353”), and press [Login]. The previously selected screen will reappear and the [Login] button will change to [Logout] to indicate that you have successfully logged in to the DT-9.

The following subsections describe the various screens that are accessed via the buttons on the “Setup” screen.

  • 5.2.4.1 Data Log Values

The “Data Log Values” screen displays the hourly and daily material totals in pounds or kilograms. The Up and Down Arrow buttons can be used to scroll from hour to hour or day to day to view the previously saved totals.

  • 5.2.4.2 Event Log Values

The “Event Log Values” screen displays the Event Log and Command Log. The Up and Down Arrow buttons can be used to scroll through the various events and user commands that were recorded by the DT-9.

  • 5.2.4.3 Parameter Log Values

The “Parameter Log Values” screen displays a log of all the DT-9 parameters that have been modified by the user. The Up and Down Arrow buttons can be used to scroll through the various parameter changes that were recorded by the DT-9.

  • 5.2.4.4 Parameter Setup

The “Parameter” screen is used to display and edit the various parameters available on the DT-9. Refer to Section 8 of this manual for a detailed description of the available parameters and settings.

The top half of the “Parameter” screen displays the current Parameter Block. The bottom half of the screen displays the various parameters that are available in the selected Parameter Block. Press the Up and Down Arrow buttons to scroll through the various blocks and parameters.

To change the value of a parameter, press the [Edit] button (Note: the user must be logged in to change parameter values). If the parameter contains a list of possible settings, a set of Up and Down Arrow buttons will appear and can be used to scroll through the available options. If the parameter contains a discrete value, a text box will appear. Press the [Save] button to save any changes that were made to the parameter value, or press the [Exit] button to exit without saving any changes.

  • 5.2.4.5 Trimming the Analog Inputs and Outputs

The “Trim” screen is used to trim the analog inputs and outputs.

Any active analog input or feedback must be matched or adjusted to the DT-9 controls. Two signals levels must be adjusted for each channel used. The first signal level, MIN, corresponds to the lower value being adjusted and is transmitted when the feed rate is at 0%. The second level, MAX, corresponds to the higher value being adjusted and is transmitted when the feed rate is at 100%.

Note: If the feeder is not equipped with a remote analog demand input, the input alignment can be omitted. If an analog output signal is not present, the output alignment section can be omitted.

Note: Unlike the 196NT, it is necessary to trim the analog output channel (normally AO 1) that is used to control the motor speed control.

I/O Channel Adjustment

When setting the output channels use a meter to measure the signal on:

 

o

AO 1: Connected to wires 142, 143 & 144.

o

AO 2: Connected to wires 139, 140 & 141.

When setting the input channel source the signal to:

o

AI 1: Connected to wires SIG+ & SIG-.

Follow These Steps:

1)

Press [Trim] to initiate the Trim function. Analog Output Channel 1 is always the first one displayed. To access other channels use the arrow up or down buttons. Press [Exit] to get back to the main screen.

2)

When aligning the output channels, the minimum and maximum analog signals are sent by the DT-9. The user measures and enters the actual values. The AO 1 values are stored in P17.11 and P17.12, and the AO 2 values are stored in P17.13 and P17.14.

  • a. Press the Down arrow button to scroll to the measure mode for output channel AO 1 Min. The DT-9 will output the minimum signal value. The display will ask for the measured value. Enter the value measured on your meter in the “Analog value measured” text box then press [Save] to store.

  • b. Press the Down arrow button to scroll to the measure mode for output channel AO 1 Max. The DT-9 will output the maximum signal value. The display will ask for the measured value. Enter the value measured on your meter in the “Analog value measured” text box then press [Save] to store.

  • c. Repeat steps a. and b. for output channel AO 2.

  • d. Press the [Exit] button to exit the Trim function.

3)

When aligning the input channel AI 1, the minimum and maximum analog demand signals are applied to the input signal wires of the DT-9. The analog demand is measured then stored in P 17.01 Analog Input 1 Min and P 17.02 Analog Input 2 Max.

  • a. Press [Trim] then use the arrow keys to select Analog Input 1 Min. Press [Start] to enter the measure mode. The first value measured is the minimum analog demand signal AI 1. Use either a precision source or, preferably, a minimum demand signal directly from the combustion control system. The display will show the value being measured from the source. Press [Save] to store the value.

  • b. Press the Down arrow button to scroll to the maximum analog demand signal AI 1 and press [Start] to enter the measure mode. Use either a precision source or, preferably, a maximum demand signal directly from the combustion control system. The display will show the value being measured from the source. Press [Save] to store the value.

5.2.4.6

Restoring the Factory Default Settings

The “Defaults” screen allows the user to overwrite all parameter settings with the factory default values. The [Custom] button will overwrite all parameters with the original values as set by Stock Equipment at the time that the feeders were shipped. The [Factory] button will overwrite all parameters with the factory default values. In general, the [Custom] button should always be used when resetting the parameters.

  • 5.2.4.7 Simulation Mode

The “Simulation” is not currently operational and should not be used.

  • 5.2.4.8 Calibrating the Feeder

The “Calibration” screen allows the user to access the various calibration functions. Refer to Section 4 of this manual for a complete description of the available calibration functions. Press the Up and Down Arrow buttons to select the desired calibration function, then press the [Start] button and follow the on-screen instructions. When the calibration function has completed, press the [Save] button to save the new calibration values or press the [Exit] button to exit without saving.

  • 5.2.4.9 Setting the Current Time and Date

The [Set Time] button allows the user to edit the current Date and Time. The current values are displayed, and can be edited via a text box.

5.3 Typical Operating Procedures

1)

When filling the bunker, first close the inlet valve to minimize the filling pressure on the feeder and to avoid compaction of the material at the feeder inlet. This precaution is unnecessary if the bunker is refilled while at least 8 to 10 feet (2.43 to 3.05 meters) of material remain in it.

2)

When starting the feeder, open the inlet valve slowly to load the belt at a controlled rate and to minimize compaction at the feeder inlet.

3)

Energize the feeder controls at the disconnect switch in the control cabinet. Observe that the HMI is illuminated.

4)

From the [HOME] screen, press the [Remote] button. Upon receipt of a customer- generated feeder start command and a demand signal from the combustion control system, the feeder begins to operate and the display indicates that the feeder is running forward.

5)

As material fills the feeder belt, the display indicates that the feeder is feeding material.

6)

The DT-9 will begin totalizing the weight and updating the current feeder information.

7)

The feeder will respond automatically to the changing demands of the combustion control system until it is de-energized.

8)

For a brief stop with a loaded belt, press the [OFF/Maint.] button.

9)

For a clean shutdown with an empty belt, close the inlet valve while the feeder is still running. When the belt is emptied, press the [OFF/Maint] button. This procedure is recommended whenever the feeder will be inactive for a long period of time, since it eliminates the possibility of material compaction at the feeder inlet due to consolidation caused by its own weight.

10) To jog the feeder belt forward, press the [OFF/Maint] button followed by the [Jog >>] button on the microprocessor keyboard for as long as motion is required. Pressing the [<< Jog] button will jog the feeder belt backwards.

11) To operate the feeder in the MAINTENANCE mode for inspection or servicing, press the [OFF/Maint] button followed by the [Run >>] button. The feeder will run forward at the speed programmed in P02.14 Maintenance Speed. Pressing the [<< Run] button will cause the feeder to run backwards at the same speed.

6 Operation using the 196NT Display

This chapter describes control of the DT-9 using the existing 196NT display.

6.1

Startup Operation-

 

After start of the DT-9 control unit, display is automatically tested. If test is complete, the device version number is displayed for some seconds, to be then replaced by the normal display.

NOTES:

 

2)

The following values and settings remain stored after power failure:

o

Counter readings

o

Parameter settings

o

Setpoints

o

Service values

o

Counter pulses not yet output

3)

This manual uses the abbreviations "<Key Name keys are called "cursor <UP> or <DOWN>".

...>

key", e.g. <ENTER> key. Cursor

4)

In the event of a power failure while the feeder was running in remote, the system will restart remote mode and, if the running contact is active, continue to feed coal.

5)

See section 4.3 for instructions on running a functional check of the feeder and controller.

6)

See section 6.6 for typical operating procedures.

 

6.2

Display FunctionsDisplay Functions

Controller display functions are selected using the following keys.

6.2.1 Total Select

Pressing <Total Select> key selects the totalizer mode on the display. Repeated pressings will cycle through each of the three totalizer modes (Gravimetric Total, Volumetric Total, or Material Total). The upper line of the display will show which mode is active. All totalizers are updated continuously regardless of mode displayed.

6.2.2

Info Select

Pressing <Info Select> key selects the information displayed on the lower line of the display. Repeated pressings will cycle through the different information (Rate, Belt Load, Belt Speed, or Speed). Pressing the <UP> or <DOWN> cursors will also cycle through the values.

RATE shows the operating feedrate of the feeder when in gravimetric mode, or the equivalent feedrate using the average density of the material when in the volumetric mode. (units: lb/h, lb/min, US t/h or kg/h, kg/min or METRIC t/h)

BELT LOAD shows the weight of material per unit of belt length. (units: lb/inch or kg/m)

BELT SPEED shows the speed of the belt. (units: inch/s or m/s)

SPEED shows the feeder belt drive motor rpm.

  • 6.2.3 Self Test

Pressing <SELF TEST> will enter the list of Service Values and will initially return to whatever Service Value last accessed. Once the Service Value mode is entered, the <UP> and <DOWN> cursors are used to scroll to different tests. Press <EXIT> key to get out of the Service Value Mode.

The service values provide detailed information on the weighing system, its active units and their digital and analog inputs/outputs.

 

Service Value

Explanation

Unit

0

Disocont Tersus VCF20171-003 3069

Device Family, software number, ID number and VSM module

 

1

Current Time

Current Date and time

day-month-year

hr-min-sec

2

Speed Setpoint

Speed based on feeder demand signal for remote mode and current belt load

RPM

3

Tachometer

Speed sensor measured frequency

Hz

4

Actual Setpoint

Current feedrate based on demand signal

lb/hr, lb/min, USTons/hr, kg/hr, kg/min, Metric Tons/hr

5

Rate

Measured feedrate that the feeder is currently running at

lb/hr, lb/min, USTons/hr, kg/hr, kg/min, Metric Tons/hr

6

FRI Output

Feedrate indicator output frequency (See P 02.18)

Hz

7

Dig.Out. (LSB MSB) ..

Digital Outputs on Disocont

 

8

Dig. Inp. (LSB MSB) ..

Digital Inputs on Disocont

 

9

Analog Out. 1 (A10)

Analog output signal to motor speed control (Analog channel A10 on disocont controller)

mA

10

Analog Out. 2 (A11)

Analog output signal for customer feedback (Analog channel A11 on disocont controller)

mA

14

Analog Inp. 3 (A12)

Analog input demand signal from customer (analog channel A12 on disocont controller)

mA

15

Time Voltage ON

Length of time controller has been energized

h

 

Service Value

Explanation

Unit

16

Time Feeder ON

Length of time feeder has been continuously running

h

17

Nominal Belt Load

Weight on belt per unit measure

lb/inch, kg/m

18

Utilize LC 1

Load cell 1 Load

%

19

Utilize LC 2

Load cell 2 Load

%

20

Loadcell

Combined raw measured load cell value

mV/V

21

Loadcell 1

Raw measured load cell 1 value

mV/V

22

Loadcell 2

Raw measured load cell 2 value

mV/V

25

Controller Magnitude

Motor speed controller signal magnitude

mA

26

Digital Mode Output

Frequncy output on wires 131, 132

Hz

27

Pulses Output

Number of totalizer output pulses (See P 02.13)

 

28

Echo: Pulses output

Number of totalizer output pulses (See P 02.13)

 
   

Indicates the weight of the empty belt. Calculated

 

29

Actual Tare

by the DT-9 during the tare portion of the calibration process. (P 10.10)

Lb/inch, kg/m

30

Belt Load Average

Average measured belt load, the value used if feeder goes into volumetric mode

Lb/inch, kg/m

31

Nominal Density

Feeder design density

lb/ft3, kg/m3

32

Density

Average density measured by the feeder

lb/ft3, kg/m3

33

Belt Motion Counter

Time since last belt motion monitor pulse

s

34

Calibr. Probe: A B

Shows if cal probes are reading tape passes and shows tach pulses counted per pass.

 

35

FCB Variant

Function block values.

 

6.2.4 Error Recall

All significant feeder functions are monitored. If an error occurs, an event message is stored by the processor and may be displayed by pressing the <ERROR RECALL> key. If several messages occur at the same time, the most significant event is displayed first.

Priority sequence: Alarm, Warning 1, Warning 2.

Pressing <ERROR RECALL> takes you to the Error Stack screen. The most recent alarm or warning will be displayed here. If several events are available, these can be viewed by pressing the <UP> or <DOWN> cursors. The top line of the display will show the time and date it occurred and the bottom line shows the error number and a description of the alarm/warning. The arrows between the number and the description indicate the then entry is for the time that the event was detected (-->) or cleared (<--).

Note: Dates shown in Error Recall are in European format (DD.MM.YY) rather then American format (MM/DD/YY).

Alarms require acknowledgement once the cause of fault has been removed. To do this press <EXIT> to get back to the main screen, the alarm can be cleared by pressing <OFF> or <REMOTE>.

6.2.5

Reset Totalizing Counters

The totalizers can be reset to zero by pressing the <TOTAL RESET> key. The display will prompt <EXIT> to cancel and <ENTER> to reset. Both gravimetric and volumetric totals will be reset. They can not be reset individually.

6.3 Operating Functions

The basic feeder operation functions are described below.

Use the white keys, REMOTE/OFF/LOCAL to select one of the three operation modes. (See section 3.4 for more information on operating modes)

  • 6.3.1 OFF Mode

Off mode deactivates the feeder. Plant start/stop signals and demand signals are ignored.

  • 6.3.2 LOCAL Mode

LOCAL operates the feeder at a selectable speed set in P 02.14 Maintenance Speed. This is set as a percentage of the full scale signal to the motor speed control. If material is on the belt during LOCAL operation, the feeder will trip.

  • 6.3.3 REMOTE Mode

REMOTE mode allows the feeder to be controlled from the customer run permissive contacts and demand signal.

  • 6.3.4 Jog Key

Pressing and holding <JOG> will operate the belt drive motor at a THE SAME SPEED AS LOCAL OPERATION. The feeder belt drive motor will run as long as the button is maintained. The feeder will run in JOG mode with or without material on the belt.

  • 6.3.5 F1 Key

Main Screen:

Pressing <F1> at the main screen takes you to the special features screen. The hourly and daily total logs can be accessed from here. The hourly total log is displayed first, press the <up> or <down> cursor to get to the daily log. To view the selected log press <ENTER>. To view past hours/days use the <UP> and <DOWN> cursors.

Entering Parameters:

When in the entering setup parameters screen pressing <F1> lets you enter a mode to change the selected parameter. (See section 6.4)

6.3.6

F2 Key

Pressing <F2> puts the feeder into reverse mode and REV will appear in the top right corner of the display. To get out of reverse mode press <F2> again and REV should disappear from the display. The feeder can only be jogged or operated in local mode in reverse.

  • 6.3.7 Acknowledge Event Messages

All significant feeder functions are monitored. If an error occurs, an event message is stored by the processor and may be displayed by pressing the ERROR RECALL key. Errors that are designated as A (Alarm/Trip) or W1 (warning) must be acknowledged by the operator.

6.3.6 F2 Key Pressing <F2> puts the feeder into reverse mode and REV will appear in

Before acknowledge the DT-9 event message, be sure that the source of the error has been corrected.

To acknowledge:

Remove cause of fault. Press the OFF or REMOTE key to acknowledge the failure.

For list of Event (Error) messages, see Section 10.

6.4 Setup Functions

Feeder parameters are entered using the Setup functions. Press the <SETUP> key to access the following functions.

Read Parameters Load Custom Defaults Load Factory Defaults Enter Parameters Set Time

The Setup functions are organized in a menu structure. The currently active value is designated by a flashing display and is changed using the arrow keys. Parameters are organized by function blocks and consecutively numbered within a block.

  • 6.4.1 Read Parameters

The Read Parameters function is used to view parameters, editing is not possible. Press <ENTER> on READ PARAMETERS to get to parameter block selection then use <UP> or <DOWN> to scroll through the parameter blocks. Press <ENTER> to access the parameters.

NOTE: Parameters deviating from default values are identified by *.

To read:

1)

Press <SETUP> from the main screen.

2)

Use <UP> or <DOWN> until READ PARAMETERS is flashing on the bottom line of the display.

3)

Press <ENTER>, the display shows title of first parameter block.

4)

Select parameter block with <UP> or <DOWN> and then press <ENTER>

5)

View parameters within a block using <UP>or <DOWN>, when you reach the beginning or end of a parameter block pressing <UP> or <DOWN> again will access the previous/next block.

6)

Return to the parameter block selection screen using <EXIT>.

7)

Return to the main screen using <EXIT>.

6.4.2

Enter Parameters

The Enter Parameters function is used to view and edit parameters. Press <ENTER> on ENTER PARAMETERS to get to parameter block selection then use the <UP> and <DOWN> cursors to scroll through the parameter blocks. Press <ENTER> to access the parameters.

NOTE: Parameters deviating from default values are identified by *.

To enter:

1)

Press <SETUP> from the main screen.

2)

Use <UP> or <DOWN> until ENTER PARAMETERS is flashing on the bottom line of the display.

3)

Press <ENTER>, the display shows title of first parameter block.

4)

Select parameter block with <UP> or <DOWN> and then press <ENTER>

5)

View parameters within a block using <UP>or <DOWN>, when you reach the beginning or end of a parameter block pressing <UP> or <DOWN> again will access the previous/next block.

6)

Press <F1> to edit a parameter, the parameter value should begin flashing.

7)

Use <UP>, <DOWN> or the number keypad to change the parameter. Press <CLEAR> to delete an entered value. Press <EXIT> to get out of editing mode and leave the parameter unchanged. Press <ENTER> to store the entered value.

8)

Return to the parameter block selection screen using <EXIT>.

9)

Return to the main screen using <EXIT>.

6.4.3

Load Default Parameters

A set of Factory Default Parameters and a set of Custom Default Parameters can be loaded to the DT-9 controller. The Factory Default Parameters are a basic set of values that are used as a starting point for all applications. When they are loaded all values (including values that are not used with Stock coal feeders) are visible and some values may not be appropriate for coal feeder applications. The Custom Default Parameters are specifically tailored for Stock applications and parameters that are not user, are hidden.

The Load Default Parameters operation will reset all calibration values and any parameters that have been

The Load Default Parameters operation will reset all calibration values and any parameters that have been edited, and will also reset the Custom Default Parameters. Stock recommends that parameters be printed or saved to disk before loading default values. Stock does not recommend loading factory defaults except after a firmware update or when a memory error is detected.

To load:

1)

Press <ENTER> on LOAD CUSTOMER DEFAULTS.

2)

The display will prompt you OK ? YES=1, NO=0.

3)

To select press <1> or <0> then <ENTER>.

4)

If NO is selected the display shows refused and goes back to the main screen.

5)

If YES is selected the display shows factory set loaded then goes back to the main screen.

6.4.4 Set Time

To enter:

1)

To set the time press <SETUP> then use the <UP> or <DOWN> cursor until set time is flashing on the bottom line of the display.

2)

Press < ENTER> to begin.

3)

Enter year via number keypad

4)

Acknowledge with <ENTER>.

5)

Enter month via number keypad.

6)

Acknowledge with <ENTER>.

7)

Enter day via number keypad.

8)

Acknowledge with <ENTER>.

9)

Enter hour via number keypad.

10) Acknowledge with <ENTER>.

11) Enter minute via number keypad.

12) Acknowledge with <ENTER>.

13) Enter second via number keypad.

14) NOTE: No entry means 00 seconds.

15) Acknowledge with <ENTER>.

16) Once you have set the year, month, day, hour, minute and second the date and time entered will be displayed for a few seconds then take you back to the main screen.

Note:

To clear an entry press <CLEAR>, to exit without setting the time press <EXIT>.

6.5 Analog Trim Function

Any analog input or feedback used by the customer (including Stock Equipment Company tachometers) must be matched or adjusted to the DT-9 controls. Two signals levels must be adjusted for each channel used. The first signal level, OFFSET, corresponds to the lower value being adjusted and is transmitted when the feed rate is at 0%. The second level, SPAN, corresponds to the higher value being adjusted and is transmitted when the feed rate is at 100%.

Note: If the feeder is not equipped with a remote analog demand input, the input alignment can be omitted. If an analog output signal is not present, the output alignment section can be omitted.

Note: Unlike the 196NT, it is necessary to trim the analog output channel (normally AO 1) that is used to control the motor speed control.

6.5.1 I/O Channel Adjustment

When setting the output channels use a meter to measure the signal on:

 

o

A10: Wires 142 & 143

o

A11: Wires 139 & 140

When setting the input channel source the signal to:

o

A12: Wires SIG+ & SIG-

Follow These Steps

1)

Verify that the proper input card is plugged into the DT-9 slot A12. Verify that the proper voltage or current converter card is plugged into the DT-9 slot A10 or A11. All I/O channel adjustments are made by entering the TRIM function.

2)

Press <TRIM> to initiate the TRIM function. Channel 3 is always the first one displayed. To access channel 1 and 2 use the <UP> cursor. Press <EXIT> or <UP> three times to get back to the main screen.

3)

When aligning the input card A12, the minimum and maximum analog demand signals are applied to the input signal wires of the DT-9. The analog demand is measured then stored in P 17.05 Analog Input 3 Low and P 17.06 Analog Input 3 Up.

  • a. Press <TRIM> then press <SETUP> to enter the measure mode. The first value measured is the minimum analog demand signal. Use either a precision source or, preferably, a minimum demand signal directly from the combustion control system. The display will show the value being measured from the source. Press <ENTER> to store the value.

  • b. Next the maximum analog demand signal is measured. Once the maximum value is being supplied and shown on the display press <ENTER> to save this value.

  • c. This will take you out of the measure mode and back to the TRIM function with Output Channel 1 selected.

4)

When aligning the output cards A10 & A11, the minimum and maximum analog signals are sent by the DT-9. The measured signal values are then to be entered by the user to the DT-9 then stored in P 17.11 / P 17.13 Analog Output 1 / 2 Low and P 17.12 / P 17.14 Analog Input 1 / 2 Up.

  • a. Again press <SETUP> to enter the measure mode for output channel 1. The DT-9 will output the minimum signal value. The display will ask for the measured value. Enter, using the number keypad, the value measured on your meter then press <ENTER> to store.

  • b. Next the DT-9 outputs the maximum signal value. The display will ask for the measured value. Enter, using the number keypad, the value measured on your meter then press <ENTER> to store.

  • c. This will take you out of the measure mode and back to the TRIM function with output channel 2 selected.

  • d. Press <SETUP> and follow steps 4) a, b, & c to set output channel 2 (A11). Make sure to measure the signal on the correct wires.

6.6 Typical Operating Procedures

1)

When filling the bunker, first close the inlet valve to minimize the filling pressure on the feeder and to avoid compaction of the material at the feeder inlet. This precaution is unnecessary if the bunker is refilled while at least 8 to 10 feet (2.43 to 3.05 meters) of material remain in it.

2)

When starting the feeder, open the inlet valve slowly to load the belt at a controlled rate and to minimize compaction at the feeder inlet.

3)

Energize the feeder controls at the disconnect switch in the control cabinet. Observe that the display and one of the two LEDs (REMOTE or OFF) is illuminated.

4)

If the OFF LED is illuminated press the <REMOTE> key. Upon receipt of a customer-generated feeder start command and a demand signal from the combustion control system, the feeder begins to operate and the green RUNNING LED is also illuminated.

5)

Turn the CLEANOUT CONVEYOR selector switch (if one exists) to the RUN position for operation whenever the feeder is activated.

6)

As material fills the feeder belt, the green FEEDING LED is illuminated

7)

The DT-9 will begin totalizing the weight and updating the current feeder information.

8)

The feeder will respond automatically to the changing demands of the combustion control system until it is de-energized.

9)

For a brief stop with a loaded belt, press the <OFF> key.

10) For a clean shutdown with an empty belt, close the inlet valve while the feeder is still running. When the belt is emptied, press the <OFF> key. This procedure is recommended whenever the feeder will be inactive for a long period of time, since it eliminates the possibility of material compaction at the feeder inlet due to consolidation caused by its own weight.

11) To jog the feeder belt, press the <OFF> key followed by the <JOG> key on the microprocessor keyboard for as long as motion is required.

12) To operate the feeder in the LOCAL mode for inspection or servicing, press the <LOCAL> key. The feeder will run at the speed percentage programmed into P 02.14 Maintenance Speed.

7 Operation Using EasyServe

This chapter describes control of the DT-9 using EasyServe.

7.1

Program EasyServe VPC 20150

Designed as PC program for DISOCONT commissioning and servicing, EasyServe lets you perform any operating and calibrating operation. The program is operable under Microsoft 2000/XP/Vista operating systems. The control unit lets you perform all controlling and calibrating operations without restrictions. The menu control permits flexible and easy adjustment, lets you access service data, operate the scale for servicing, and customize the menu texts on PC screen and all operator units.

7.2

Minimum System Requirements

Pentium or CPU-compatible

900MB free hard disk space

VGA display, 32768 color monitor recommended

Operating systems Microsoft Windows 2000/XP/Vista with latest service packs

Mouse or other type of pointer

CD-ROM drive

7.3

Installation

EasyServe Insert CD VPC20150 into CD-ROM drive. Normally, installation starts automatically. If not, open Windows explorer select your CD-ROM drive. To open, double click on file. The automatic installation program prompts you through a number of dialogs, for you to confirm.

Upgrade If an old EasyServe version is available on your PC it must be removed (using Control Panel | Add or Remove Programs) before the installation can be performed.

Attention To be able to install the EasyServe program, your name must be registered as user in the group of administrators under Windows 2000/XP/Vista. Top execute program, main user rights are required.

7.4 Start Program and Connect to Feeder

Before EasyServe can be used the laptop or PC, an Ethernet cable must be installed between the DT-9 and the PC and the PC must be configured for direct Ethernet communications. This is process is described below.

7.4 Start Program and Connect to Feeder Before EasyServe can be used the laptop or PC,

DO NOT use the RJ45 connector marked X96 to connect the DT-9 to a laptop or PC. This

connector is designed to supply power for the Touch Screen HMI through normally unused

connections. Connecting a PC to X96 could cause damage to the DT-9, the PC or both. A red cover is normally installed over this connector to prevent it from being used with a PC.

7.4.1 Connecting to Feeder

The EasyServe program and an Ethernet connection are used for most DT-9 Programming operations. The DT-9 cannot generate an IP address for the computer running EasyServe so the PC must be set to a static IP address. The DT-9 default IP address is 192.168.240.1 and the PC must be on the same subnet. Set the PC address to 192.168.240.254 as starting point. One of several ways to do this is listed below. (Instructions are for windows XP)

Windows® XP

1)

Select Network Connections in Control Panel

2)

Double click on the Local Area Connection line to bring up Local Area Connection Status dialog box. If you have more then one Local Area Connection you probably want to select the one that is not connected.

3)

Click on the Properties button (under th