PART 677-3

‘SPD15’ COAL VALVE

PART 677-3

MAINTENANCE SECTION
 PART 677-3 — MAINTENANCE MANUAL

TABLE OF CONTENTS
SECTION 1. .................................................................................................................................. 29
1.1 TECHNICAL DATA — COAL VALVE ASSEMBLY ............................................................................ 29
SECTION 2. ................................................................................................................................. 31
2.1 IDENTIFICATION ......................................................................................................................... 31
2.2 WEIGHTS .................................................................................................................................... 31
SECTION 3. .................................................................................................................................. 32
3.1 GENERAL INSPECTION ................................................................................................................ 32
3.2 GENERAL MAINTENANCE ........................................................................................................... 33
3.3 MAINTENANCE PROCEDURES .................................................................................................... 33
3.4 ACTUATOR MOTOR REMOVAL (Refer Drg 70648-B1-2) ............................................................ 34
3.5 POINTS TO NOTE ........................................................................................................................ 34
SECTION 4. .................................................................................................................................. 35
4.1 CARE OF LUBRICANTS ................................................................................................................ 35
4.2 CLEANING ................................................................................................................................... 35
4.3 LUBRICATION SCHEDULE ........................................................................................................... 35
SECTION 5. .................................................................................................................................. 37
5.1 PROPRIETARY EQUIPMENT INDEX ............................................................................................. 37

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SECTION 1.
1.1 TECHNICAL DATA — COAL VALVE ASSEMBLY

TYPE CLAM SHELL (Twin Gate)

MODEL SPD 15
INLET SIZE 1174mm x 1174mm (outlet ref.)
OUTLET SIZE 1175mm x 1274mm (maximum)
HEIGHT 2400mm O/A INCL. OUTLET
CONSTRUCTION MATERIAL 10mm MILD STEEL
LINER MATERIAL 3mm ST.ST. GRD 3CR12
PIVOT BEARING 45mm SPHERICAL PLAIN
ACTUATOR QUANTITY TWO PER VALVE
ACTUATOR TYPE ‘COSMIC’
ACTUATOR CAPACITY 6000kg
ACTUATOR POWER 4.0kW
MASS Control Gate 890kg
Cut-Off Gate 490kg
(Outlet 650kg)
(Valve Support Beam 740kg)
(Actuator Support Beam 370kg)
(Control Gate Actuator 219kg)
(Cut-Off Gate Actuator 265kg)

(a) Actuator Type –

‘COSMIC’ motor cylinder, ‘DG’ series, 4.0kW manual release brake
motor, 6000kg thrust, supplied with fire resistant bellows and trunnion
columns. Model No. DGODP6T with thrust limiter.

One Cylinder of 1300mm stroke (Cut-Off Gate)

One Cylinder of 800mm stroke (Control Gate)

(b) Pivot Bearing –

‘ELGES’ spherical plain bearing to suit 45mm dia. shaft,
No. GE45 DO-2RS.

(c) Electrics – (Proximity Limit PCE.1)

‘Pepperl + Fuchs’ inductive proximity switch, 30mm DIA. brass housing,
10mm sensing range, class IP67 model No. NBB10–30GM60-20.

(d) Electrics – (Material Flow)

‘Delavan – Microwave / 320’ remote switch set comprising amplifier
(microwave 320), transmitter (MT8515) and receiver (MR0515) all
suitable for 24 VDC.

(e) Electrics – (Position Transducer)

‘ASM’ type ‘WS12’ position sensor with analog output to suit
measurement range of 250mm, output of 420 A and linearity of +10%.
Model No. WS12-250-420A-L10.
Supplied with female connector No. WS-CONN-D8.
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SECTION 1. (CONT’D)
1.1 TECHNICAL DATA — COAL VALVE ASSEMBLY (cont’d)
(f) Electrics - (Proximity Limits –PCE.23)
‘PEPPERL+FUCHS’ inductive proximity switch, 40 sq. Housing,
40mm sensing range, class IP68, suitable for 24 VDC.
Model No. NCN40+UI+Z2

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SECTION 2.
2.1 IDENTIFICATION
Coal Valve (1) Model No. SPD 15 CV-1
Serial No. 70648

(2) Model No. SPD 15 CV-2

Serial No. 70648

(3) Model No. SPD 15 CV-3

Serial No. 70648

2.2 WEIGHTS
The following are typical nominal weights for fully assembled units.

a) COAL VALVE c/w Actuators & 3920 kg

Beams

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SECTION 3.
This Coal Valve Assembly has been designed to provide many years of dependable,
trouble-free service and a regular schedule of inspection, maintenance and lubrication
will assure peak performance at all times.

This section contains maintenance instructions applicable to personnel having

operating and maintenance responsibilities for the unit. The services projected herein
are to be performed at regular scheduled intervals to maintain the unit in good
operating condition at all times and to minimise the chances of mechanical failure.

3.1 GENERAL INSPECTION

Inspection should be made before operation, during operation, at halt, and after
operation. Inspection of assemblies, sub-assemblies or parts must include supporting
members or connections and must determine whether or not the unit is in good
condition, correctly assembled, secure or excessively worn. Any mechanical
condition which may result in further damage to the unit should be corrected
immediately before the equipment is operated further.

(a) Inspection for 'good condition' is usually an external visual inspection

to determine whether the unit is damaged beyond safe or serviceable
limits, or to determine if it is in such a condition that damage would
result from further operation.

(b) Inspection of a unit to see that it is 'correctly assembled' is usually an

external visual inspection to determine whether it is in its normal
assembled position in the equipment.

(c) Inspection of a unit to determine if it is 'secure' is usually an external

inspection, a hand feel, or pry bar or wrench check for looseness.
Such an inspection should include brackets, lockwashers and
locknuts used in the assembly.

(d) 'Excessively worn' may be construed as meaning worn close to or

beyond serviceable limits, a condition which, if not corrected, is likely
to result in failure of the equipment.

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SECTION 3. (CONT’D)
3.2 GENERAL MAINTENANCE
The operator is responsible for detecting and correcting unusual sounds or odours,
deficiencies in performance, or other signs of abnormal operation. To properly
maintain the equipment the following procedures should be performed at regularly
scheduled intervals. No special tools are required.

(a) Inspect entire unit for missing or damaged lubrication fittings and for
indications of insufficient lubrication. Replace missing or damaged
fittings and lubricate as required.

(b) Inspect all exposed wiring for soiled, cracked or frayed insulation.
Look for broken wires and loose or corroded connections. Check
mounting and operation of switches. Clean and tighten wiring
connections. Replace defective wiring and switches.

(c) Investigate any unusual noise. A properly operated Stockpile

Discharger will make little noise. Any unusual sound can usually be
traced to some difficulty such as physical contact being made with the
inner sock or drive components loose.

3.3 MAINTENANCE PROCEDURES

Most maintenance involved with the unit will be a matter of logical disassembly, repair
and reassembly of components and consultation with the manufacturer's data
included in the component literature in this manual.

A daily visual inspection of the installation and its components and accessories is
recommended as undetected or unattended deficiency or malfunction could result in
costly down-time.

A weekly inspection of motors, bearings, etc. will ensure satisfactory operation and
prolonged life of the equipment and its components and accessories.

1. Motors (weekly)
Regular inspection checks should be made of bearing looseness, running
temperature, vibration and noise levels.

2. Bearings (weekly)
Regular inspection checks should be made of mounting firmness, running
temperature and seal condition.

3. Coal Valve Actuator Cylinders (weekly)

Regular inspection checks should be made of mounting firmness and
general condition.

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SECTION 3. (CONT’D)
3.3 MAINTENANCE PROCEDURES (cont’d)
4. Electrical Switches (weekly)
Regular inspection checks should be made of mounting firmness, target
plate fixture and general functionality.

3.4 ACTUATOR MOTOR REMOVAL (Refer Drg 70648-B1-2)

The following can be used as a guide:

1. Isolate power to Coal Valve and associated equipment.

2. Clamp Gates in position, both to each other and surrounding
structure. (Mounting points are provided)
3. Disconnect electrical cabling at motor terminal box.
4. Remove flange bolts and carefully lower motor to platform.
5. Repair work to motor must be performed by authorised repairer.
6. Installation is a reversal of the before mentioned procedure.

**Warning: GATES WILL ‘GRAVITATE’ TO NEUTRAL POSITION WHEN BRAKE

MOTOR REMOVED FROM ACTUATORS IF NOT CLAMPED IN
POSITION.

3.5 POINTS TO NOTE

The following general maintenance comments should prove helpful in
maintaining the unit.

(a) Do not weld anything to the Coal Valve assembly for any reason without
first consulting your local Ludowici Australia representative.

(b) Allow at least 50mm lateral and 100mm vertical clearance between any
nearby "fixed" member or machine.

(c) Do not trim any structural members on the Coal Valve assembly for any
reason without consulting your local Ludowici Australia representative.
Reducing the structural members could cause high stress concentrations
which could result in fatigue failures.

(d) Recommended bolt tension values for site assembly:

(1) Coal Valve: (High Strength Structural Bolts)

M20 – 565 Nm
M24 – 970 Nm

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SECTION 4.
LUBRICATION
The procedures projected herein are to be performed at regular
scheduled intervals to maintain the unit in good operating condition at all
times and to minimise the chances of mechanical failure.

4.1 CARE OF LUBRICANTS

When lubricating the unit, care must be exercised in handling and
applying the various lubricants. The containers which house these
lubricants must be free of dust, dirt and water. Clean the lubrication
equipment before and after it is used. Close the containers tightly after
use and keep them in a protected place.

4.2 CLEANING
Clean the lubrication fittings and other points of application with a clean
cloth dampened with a cleaning solvent before applying lubricant. Wipe
excess lubricant from fittings and parts after lubrication.

4.3 LUBRICATION SCHEDULE

Reference should be made to the Proprietary Components' Detailed
Lubrication requirements found further on in this manual.

The following page is to be used as a guide only (For 1 unit assembly):

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SECTION 4. (CONT’D)
Coal Valve:

(a) Valve pivot bearings

- 2 places, 2 points @ 2g every 1250 hrs.

(b) Cylinder shaft (900mm stroke)

- 1 place, 1 point @ 90g every 1250 hrs.

(c) Cylinder shaft (1300mm stroke)

- 1 place, 1 point @ 130g every 1250 hrs.

(d) Cylinder gear drive

- 2 places, 1 point @ 130g every 5000 hrs.

(e) Cylinder ball bearings

- 2 places, 2 points @ 50g every 5000 hrs.

(f) Cylinder slide bearings

- 2 places, 2 points @ 50g every 5000 hrs.

(g) Cylinder rod clevis pin

- 2 places, 1 point @ 2g every 1250 hrs.

(h) Cylinder motor bearings

- “Greased for Life”

NOTE: ALL POINTS ARE TO BE SERVICED BY GREASE GUN.

The recommended lubricant for this application is:

‘Shell’ ‘Alvania EP2’

Equivalent products may be used as follows:

‘BP’ ’Energrease LS EP2’

‘Castrol’ ’EP L2’

‘Valvoline’ ’L2 EP’

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 PART 677-3

SECTION 5.
5.1 PROPRIETARY EQUIPMENT INDEX

COAL VALVE:

PART 5.1 Cylinders — ‘COSMIC’

PART 5.2 Cylinder Motors — ‘CMG’

PART 5.3 Valve Pivot Bearings — ‘ELGES’

ELECTRICS:

PART 5.4 Flow Sensor — ‘DELAVAN’

PART 5.5 Position Transducer — ‘ASM’

PART 5.6 Proximity Switches — ‘PEPPERL + FUCHS’

PART 5.7 Proximity Switches — ‘PEPPERL + FUCHS’

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 PART 677-3

PROPRIETARY EQUIPMENT DATA: 5.1

COAL VALVE: ACTUATORS

BRAND: “COSMIC”

DRAWING REFERENCE: 70648-B1-2 PCE. No.1

DESCRIPTION: MOTOR CYLINDER

6000kgf, FITTED WITH
BELLOWS

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SPECIFICATIONS:
1. CONTROL GATE ACTUATOR

TYPE : BALL SCREW

CAPACITY : 6000kg

STROKE : 800mm

MOUNTING : TRUNNION COLUMNS

MODEL NUMBER : DGODP6T-8J

FEATURES : FEMALE CLEVIS ROD FITTING

: BELLOWS BOOT
: BRAKE MOTOR (4.0kW)
: MANUAL RELEASE BRAKE

SPEED : 45mm/sec

2. CUT-OFF GATE ACTUATOR

TYPE : BALL SCREW

CAPACITY : 6000kg

STROKE : 800mm

MOUNTING : TRUNNION COLUMNS

MODEL NUMBER : DGODP6T-13J

FEATURES : MALE CLEVIS ROD FITTING

: BELLOWS BOOT
: BRAKE MOTOR (4.0kW)
: MANUAL RELEASE BRAKE

SPEED : 45mm/sec

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MAINTENANCE:
In order to insure the actuators provide good service over a period of years the
following notes should be followed:

1. PRECAUTIONS
Ensure careful alignment at all times between actuator mount and Gate
clevis point.

Clamp Gates in position, both to each other and surrounding structure,

due to Gates ‘gravitating’ to neutral position when power isolated from
actuators.

CAUTION:
DO NOT ALLOW ACTUATOR TRAVEL TO GO BEYOND CLOSED
LENGTH OR SERIOUS INTERNAL DAMAGE MAY OCCUR.

DO NOT ALLOW ACUTATOR TRAVEL TO GO BEYOND EXTENDED

LENGTH OR SERIOUS INTERNAL DAMAGE MAY OCCUR.

REPLACE TORN BELLOWS IMMEDIATELY TO PREVENT DUST AND

GRIT BUILDING UP ON THREAD.

2. LUBRICATION
Shall be relubricated at two (2) monthly intervals or 1500 hours using an
extreme pressure grease.

CAUTION
BALL SCREW SHOULD NEVER DRY OUT. (COATING OF OIL
REQUIRED)

3. STROKE ADJUSTMENT
THE STANDARD TYPE OF ACTUATOR IS NOT EQUIPPED WITH AN
INTERNAL TURN STOP. IF IT IS SWITCHED ON WITHOUT BEING
CONNECTED TO THE GATE TO PREVENT A TURNING TORQUE,
THE ROD WILL TURN, CAUSING DAMAGE TO THE BELLOWS.

(a) Manual stroke adjustments can be made by turning the manual

shaft. For the type with no turn stop, the rod freely moves in and
out by turning. Stroke setting at the time of installation is also
available by turning the rod by hand. For the type having bellows,
loosen the band to fix the bellows before the rod is turned.

(b) Never fail to switch OFF before operating the cylinder by hand.

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MAINTENANCE:
4. BELLOWS ATTACHING
THE BELLOWS ARE FIXED ONLY ON THE ROD END SIDE WHEN
SHIPPING. FIX THE BELLOWS ACCORDING TO THE FOLLOWING
PROCEDURES AFTER CONNECTING THE ROD WITH THE MATE
MACHINE. BELLOWS REPLACEMENTS ARE ALSO PERFORMED AS
FOLLOWS:

(a) Tighten the bellows with the rod completely locked after
connecting it with the mate machine.

(b) Draw in the piston rod by inching manually or electrically to the

stroke end. Then with the bellows shrinked, clamp the band on the
rod side. Fitting the bellows shrinked too much may cause its
breaking.
Make sure the air breather holes on the bellows boot face
downward, to prevent rain water intrusion.

5. CAUTIONS
Note the following points:

(a) The switch box of the thrust limiter and the connectors of the pass
through section of the cable have been completely tightened
before shipment. If they are loosened or disassembled at site,
please completely tighten them. If incomplete, water may come
into them, causing an accident to be brought about.

(b) In manual operation be sure to turn off the power source and
rotate the manual shaft with exclusive handle or spanner with the
body unloader after releasing the brake. After operation the brake
release unit should be put back. Excessive power should be
avoided in manipulating. Never fail to tighten the cap for manual
shaft after operation.

6. WIRING METHOD
IN WIRING THE MOTOR CYLINDER, GIVE SPECIAL CARE TO THE
FOLLOWING POINTS:

(a) Since the cylinder itself swings around the trunnion shaft during
operation, it is preferable to use flexible cabtyre cables for wiring.

(b) For the outdoor type, it should be installed so that the outlets of the
motor and the brake terminal boxes may be downward without
failure. The terminal box is attached with four screws and the
direction of it is changeable every 90 degrees, except that the box
of the thrust limiter is fixed.

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MAINTENANCE:
6. WIRING METHOD (cont’d)
End treatment should be perfect so that water may never enter.
Do not use flexible tubes because of incomplete waterproof;
packing-type cabtyre cables are good for use. If flexible tubes are
unavoidably used, use the waterproof type and seal the contact
surface with liquid packing (Three Bond No.2).
For this particular application the Basic Operation Circuit is used.
ALWAYS INCORPORATE THE EXTERNAL LIMIT SWITCHES
INTO THE THRUST LIMITER SWITCH CIRCUIT. (Refer to
Drawing 20-386-010 at end of this section).

7. MAINTENANCE
Since our motor cylinder is coated with good quality grease before
shipping, it can be used without additional lubrication. For grease
lubrication refer to the following table and the construction.

Lubrication Each Grease

Points Supply Method
(g)
Screw Shaft 5 ~ 10 Lubricating through the
per 100mm stroke lubrication point in the middle of
the cylinder with a grease gun.
Gears, 100 ~ 150 Application to the gears each two
Bearings years or after 100 thousand
times.
Sliding 50 ~ 100 Application to the surface each
Bearings two years or at every routine
inspection.

Overhaul
Overhaul should be made every two years or after 100 thousand times.

Lubrication Cycle to Screw Shaft

Operational Cycle Lub. condition varies depending on
Frequency ambient temperature, operating
500 ~ 100 times / day One month conditions, etc.
100 ~ 50 times / day One to Six months Determine appropriate lub. cycle
according to actual lub. condition.
50 ~ 10 times / day Six months to One
year

Recommendable Greases
Shell Alvania No. EP2.

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MAINTENANCE:
7. MAINTENANCE (cont'd)

Lubrication to Screw Shaft

As shown in Fig. A With the piston rod

extended to the far most end, apply a Fig. A
small quantity of grease to the screw
shaft through the lubrication point in the
middle of the cylinder with a grease gun
or a spatula. Then reciprocate the
cylinder several times. Repeat this
cycle three or four times.

8. BRAKE DESCRIPTION
Through pressure springs, the axial force acts on the axially moving
armature plate which subsequently generates the brake friction torque.

The rotor with its friction material is connected to the shaft to be braked,
but is axially movable either directly or via the hub. The spring force
working against the armature plate acts on the rotor between the
armature plate and the counter friction face. The brake torque is
generated at both friction faces.

When applying a dc voltage to the coil windings, the magnetic force acts
on the armature plate. This plate is subsequently pulled towards the
stator across the air gap against the force of the springs. The rotor is
released and the brake is then free.

The hand release serves to release the brake manually, automatically

returning to its base position after operating.

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MAINTENANCE:
9. BRAKE MAINTENANCE
The brakes are practically maintenance free. The air gap should be
checked periodically. If the maximum air gap of 0.6mm is reached, it
must be readjusted to a nominal value of 0.2mm.

For this, loosen the fixing screws and then tighten the adjustment tubes
until you can measure the same value (0.2mm) at three points on the
circumference, between the stator and the armature. The fixing screws
must then be retightened.

10. FAULT FINDING (MOTOR)

Refer following section.

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PROPRIETARY EQUIPMENT DATA: 5.2

COAL VALVE: ACTUATOR MOTOR

BRAND: ‘CMG’

DRAWING REFERENCE: 70648-B1-2 PCE. 1 & 2

DESCRIPTION: 4.0kW 4 POLE TEFC

ELECTRIC MOTOR.
FITTED WITH MODEL M60
BRAKE.

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GENERAL PERFORMANCE:
BRAND ‘CMG’

FRAME NUMBER : HGABD 112M-4

OUTPUT (kW) : 4.0

FULL LOAD SPEED (rpm) : 1500 (4 pole)

CURRENT (FULL LOAD) : 7.9A

(LOCKET ROTOR) : 60.0A

EFFICIENCY (AT 100% FL) : 85.0%

(AT 75% FL) : 84.8%
(AT 50% FL) 82.7%
:

POWER FACTOR (AT 100% FL) : 0.83

(AT 75% FL) : 0.76
(AT 50% FL) 0.64
:

FULL LOAD TORQUE (Nm) : 26.5

NETT WEIGHT (kg) : 49

MOUNTING ARRANGEMENT : FLANGE MOUNT, SHAFT INCLINED

NO. IM 3001

DEGREE OF PROTECTION : IP66

BEARING SIZE (DRIVE END) : 6306-2RS

(NON DRIVE END) 6306-2RS

BRAKE MODEL : M60

BRAKE WEIGHT (kg) : 7.4kg

BRAKE TORQUE : 220% (% of full load)

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INSTALLATION & MAINTENANCE:

These motors have been manufactured in accordance with strict quality controls and to
obtain optimum performance please not the following instructions:

1. INSPECTION
Check for damage due to transport and loading.

2. PRE-COMMISSIONING
(a) VENTILATION – Ensure that there is a free area in front of the air
intake.
(b) DRAINAGE – Ensure at all times condensation drain holes are
clear.

3. COMMISSIONING
(a) Motors are fitted with lifting eye-bolt. This is intended for lifting
motor only when required.
DO NOT USE AS LIFT POINT FOR ANY OTHER PURPOSE.
(b) Electrical connection to be in reference to ‘Ludowici’ drawing
NS119-A3-41 and 415V delta connection diagram.

CAUTION
(c) PRIOR TO STARTING ENSURE THAT THERE ARE NO LOOSE
ITEMS IN THE CLOSE VICINITY, PREVENTING “FLY OFF”
WHEN THE MOTOR IS SWITCHED ON.

4. BEARINGS
Each bearing (drive and non-drive end) is lubricated via easily accessible
grease points at the top of the motor.

Lithium based grease is recommended, re-greasing at 3 monthly intervals

(or 2200 hours). Grease quantity in bearing chamber is 13 grams.

5. MAINTENANCE
It is recommended that the motor be removed for inspection and
dismantling every five (5) years.

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PROPRIETARY EQUIPMENT DATA: 5.3

COAL VALVE: PIVOT BEARINGS

BRAND: “ELGES”

DRAWING REFERENCE: 70648-B1-2 PCE. 3

DESCRIPTION: SPHERICAL PLAIN

BEARING TYPE 45mm
SHAFT.

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SPECIFICATIONS:
TYPE : SPHERICAL PLAIN BEARING

DESIGNATION : GE 45 DO - 2RS

BORE SIZE : 45mm

FEATURES : FITTED WITH SEALS

INSTALLATION & MAINTENANCE:

(Taken from “Elges” Catalogue # K234 GB)

The following information is given as a guide only to the mounting, dismounting,

lubrication and maintenance of the bearings.

1. DESCRIPTION
These bearings have a hardened inner ring of bearing steel with the
spherical surface honed and hard-chromium plated.

The outer ring is made from a steel sleeve with an inserted ptfe fabric
bearing BUSH AND HAVE A SINGLE SPLIT IN THE AXIAL DIRECTION.

2. HANDLING
THESE BEARINGS ARE PRECISION COMPONENTS AND MUST BE
HANDLED WITH CARE BEFORE AND DURING FITMENT.

THEY MUST NOT BE TAKEN OUT OF THEIR PACKAGING UNTIL

IMMEDIATELY REQUIRED.

DO NOT CLEAN WITH ANY SOLVENTS.

3. MOUNTING
To assist in the fitment of these bearings, the housing bore may be lightly
oiled, but the shaft should always remain dry. When fitting it is
recommended a sleeve or piece of tube be used on the outer ring to
ensure proper seating.

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INSTALLATION & MAINTENANCE:

3. MOUNTING (cont’d)
DIRECT BLOWS WITH A HAMMER OR DRIFT ON THE SIDE FACES
OF THE BEARING RINGS MUST ALWAYS BE AVOIDED.

4. DISMOUNTING
REMOVAL OF THE BEARINGS WILL USUALLY RESULT IN DAMAGE
AND REPLACMENT WILL BE REQUIRED, DUE TO SPACE
LIMITATIONS.

5. LUBRICATION
Re-greasing at two (2) monthly intervals is recommended.

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PROPRIETARY EQUIPMENT DATA: 5.4

COAL VALVE: FLOW SENSOR

BRAND: “DELAVAN/MICROWAVE 320”

DRAWING REFERENCE: 70648-B1-4 PCE. 2

DESCRIPTION: TYPE M AMPLIFIER /

TRANSMITTER / RECEIVER
SUITABLE FOR 12/24 VDC
OR 115/230 VAC

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SPECIFICATION:

MODEL NO. (TRANSMITTER) : MT 851

MODEL NO. (RECEIVER) : MR 851

MODEL NO. (AMPLIFIER) : MICROWAVE / 320

VOLTAGE : 230 VAC ANALOG (Client Request)

FREQUENCY : 50 - 60 Hz

HOUSING SIZE : 2½” PIPE

MATERIAL (WINDOW) : VHMW POLYETHYLENE 1” THICK

TEMPERATURE RANGE : -20°F TO + 140°F

MOUNTING : PIPE SOCKET

NOTE: CARE MUST BE TAKEN WHILE HANDLING THESE UNITS.

INSTALLATION & MAINTENANCE:

(Taken from “Delavan” Operation Manual)

1. DESCRIPTION
THIS DEVICE IS A SINGLE POINT ELECTRONIC SWITCH FOR ON-
OFF ACTION.

THE SENSING PRINCIPLE PERMITS THE APPLICATION OF THE

MICROWAVE/320 TO DIFFICULT MEASUREMENTS. THE ENERGY
CAN “SEE” THROUGH WINDOWS THAT ARE TRANSPARENT TO
MICROWAVE ENERGY.

THE DEGREE OF REFLECTION AND TRANSMISSION OF

MICROWAVE ENERGY AT A MATERIAL BOUNDARY DEPENDS ON
MANY FACTORS.

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INSTALLATION & MAINTENANCE:

2. PRINCIPLE OF OPERATION
THESE CONTROLS ARE NON-CONTACT SENSING MICROWAVE
BASED CONTROLS. THE TRANSMITTER (SOURCE) CONSISTS
BASICALLY OF A PULSE MODULATOR, GUNN OSCILLATOR, AND
DIRECTIONAL ANTENNA. THE RECEIVER CONSISTS OF A
DIRECTIONAL ANTENNA, A MICROWAVE MIXER CAVITY WITH A
SCHOTTKY BARRIER DIODE DETECTOR, A HIGH GAIN, LOW NOISE
AMPLIFIER. THE CONTROL CIRCUITRY CONSISTS OF A POWER
SUPPLY, A PULSE CODING NETWORK, A VOLTAGE COMPARATOR
CIRUCIT, AND A RELAY DRIVER CIRCUIT.

IN THE TRANSMITTER, THE 12 VDC SUPPLY IS FILTERED THEN

PULSED AT ABOUT 1kHz BY THE PULSE MODULATOR CIRCUIT.
THIS CIRUCIT IS INCLUDED TO PERMIT PULSE DISCRIMINATION
CIRCUITRY TO BE USED. THE PULSED DC IS FED TO A GUNN
OSCILLATOR IN THE ANTENNA ASSEMBLY, WHERE THE 12 VDC
1kHz SQUARE WAVE IS CONVERTED TO A PULSED X BAND (10.525
GHz) MICROWAVE SIGNAL. THIS SIGNAL IS RADIATED BY THE
DIRECTIONAL ANTENNA, WHICH IS TYPICALLY A 10 dB GAIN HORN
WITH A BEAM SPREAD OF APPROXIMATELY 40°.

IN THE RECEIVER, THE SIGNAL IS RECEIVED BY A DIRECTIONAL

ANTENNA AND COUPLED TO A MIXER CAVITY CONTAINING A
SCHOTTKY DETECTOR DIODE. THIS DIODE CONVERTS THE LOW
LEVEL MICROWAVE SIGNAL TO A LOW LEVEL PULSED DC WHICH
IS SENT TO THE CONTROL BOARD. IN THESE SYSTEMS THE
RECEIVER IS ON ONLY WHEN THE TRANSMITTER IS ON, THUS IS
VIRTUALLY IMMUNE TO FALSE TRIGGERING FROM STRAY
MICROWAVE SIGNALS FROM ADJACENT TRANSMITTERS OR
OTHER RANDOM SOURCES OF INTERFERENCE. IN THE
CONTROLLER, THE PULSED DC IS RECEIVED THEN AMPLIFIED BY
AN ADJUSTABLE GAIN - LOW NOISE IC AMPLIFIER TO A 0-10 VDC
CONTROL SIGNAL. THE LEVEL OF THE AMPLIFIED RECEIVED
SIGNAL IS COMPARED WITH A PRESET VALUE IN A VOLTAGE
COMPARATOR CIRCUIT. WHEN THE SIGNAL RECEIVED EXCEEDS
THE COMPARATOR SETPOINT, AN OUTPUT SIGNAL IS INITIATED
WHICH IS PROCESSED THROUGH TIME DELAY CIRCUITS TO
DRIVE THE OUTPUT RELAY.

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3. SPECIFICATIONS
SUPPLY VOLTAGE : 230 VAC

FREQUENCY, AC POWER : 50-60Hz 45Hz minimum

TIME DELAY : DUAL, INDEPENDENT DELAYS

ON MAKE, OR BREAK 100
MILLISECOND, MINIMUM

DELAY TIME RANGE : 100 MILLISECOND, MINIMUM 30

SECOND MAXIMUM

FAILSAFE : SWITCH SELECTABLE, HIGH OR

LOW LEVEL

ENVIRONMENTAL : NEMA 4X, IP55

RATING CONTROL UNIT

DISTANCE - SENSOR TO : UP TO 1000 FEET OF DELAVAN

CONTROL UNIT, SUPPLIED SPECIAL CABLE.
MAXIMUM

INDICATORS : TWO, LIGHT EMITTING DIODES

(LED)
RED - ILLUMINATED WHEN
PATH IS MADE (NO OBJECT
BETWEEN TRANSMITTER &
RECEIVER)
YELLOW - ILLUMINATED WHEN
RELAY IS ENERGIZED.

OUTPUT : RELAY, DPDT 2 FORM C

CONTACTS 5 A AT 120 VAC
NON-INDUCTIVE

NOTE: Receiver and transmitter housings should be packed internally as

required, to make units suitable for vibration duty.

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4. MECHANICAL INSTALLATION (contd)

(b) SENSORS & GENERAL:
SENSORS ARE SUPPLIED AS TRANSMITTERS AND
RECEIVERS.

THE MT851 / MR851 SYSTEM REQUIRES THE USE OF

MOUNTING SOCKETS.

MODEL 851’s, WILL HAVE ARROWS ON BOTH TRANSMITTER

AND RECEIVER. WHEN MOUNTING THESE MODELS
ALIGNMENT OF THE ARROWS IS IMPORTANT. LINE
ARROWS SO THEY BOTH POINT IN SAME DIRECTION.

5. ELECTRICAL INSTALLATION
GENERAL
ALL ELECTRICAL CONNECTIONS ARE MADE TO THE TERMINAL
STRIPS IN THE ENCLOSURE. REMOVE THE ENCLOSURE COVER,
AND THE PLUG-IN CIRCUIT CARD AND WIRE THE UNIT TO POWER
AND CONTROL CIRCUITS IN ACCORDANCE WITH APPLICABLE
ELECTRICAL CODES.

SENSORS
IF PERMITTED BY APPLICABLE ELECTRICAL CODES, THE
TRANSMITTING SENSOR LEAD MAY BE RUN IN THE SAME
CONDUIT AS THE POWER WIRING, NEVER LOCATE THE
RECEIVING SENSOR LEADS IN CONDUIT WITH OTHER LEADS,
(EXCEPT IN MULTIPLE UNIT INSTALLATIONS, LEADS OF OTHER
RECEIVING SENSORS CAN BE RUN TOGETHER). IF IT IS
NECESSARY TO INSTALL THE CONTROL UNIT MORE THAN
EXISTING CABLE PERMITS, APPROVED CABLE AND SPLICING
CONNECTORS SHOULD BE USED.

6. OPERATION
(a) GENERAL
THIS SECTION CONTAINS THE CALIBRATION AND
OPERATIONAL INFORMATION FOR THE MICROWAVE/320
SWITCH.

(b) CONTROLS AND INDICATORS

b.1 RELAY FUNCTION (FAILSAFE) SWITCH
THE RELAY FUNCTION SWITCH DETERMINES IF THE
RELAY IS ENERGIZED WHEN THE OBJECT TO BE
DETECTED IS PRESENT (PATH BROKEN) OR ABSENT
(PATH MADE). FAILSAFE HIGH OR FAILSAFE LOW
DOES NOT INDICATE THE PHYSICAL LOCATION OF
THE SENSOR INSTALLED IN THE VESSEL.

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6. OPERATION
(b) CONTROLS AND INDICATORS (contd)
b.1 RELAY FUNCTION (FAILSAFE) SWITCH

Switch Position Relay De-Energized

Relay Function:
Facing Switch: When Path is:

Normal Toggle toward Blocked, broken

High Level delay
Failsafe adjustment
potentiometers

Reverse Toggle toward Open, complete

Low Level status lights
Failsafe

b.2 TIME DELAY

THE MICROWAVE/320 CONTROL UNIT HAS TWO

INDEPENDENTLY ADJUSTABLE TIME DELAYS. DELAY
“ON MAKE” OR “ON BREAK”. TWO 20 TURN
POTENTIOMETERS ARE SUPPLIED.

b.3 GAIN CONTROL

A 20 TURN POTENTIOMETER IS FURNISHED TO

MATCH THE AMPLIFIER GAIN TO THE APPLICATION
CONDITIONS. CLOCKWISE ROTATION (CW) FACING
THE ADJUSTING SCREW INCREASES THE GAIN.

b.4 GAIN RANGE SWITCH

A SLIDE SWITCH WHEN PLACED TOWARD THE EDGE

CONNECTOR IS THE (HIGH GAIN RANGE).

b.5 BEAM STATUS INDICATOR

A RED LED IS ILLUMINATED WHEN THE PATH IS MADE

(BEAM NOT BLOCKED CONDITION).

b.6 RELAY STATUS INDICATOR

A YELLOW LED IS ILLUMINATED WHEN THE RELAY IS

ENERGIZED.

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65
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66
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 PART 677-3
7. TROUBLESHOOTING

1.
Problem:

Unit not functioning as described.

Probable Cause:

No power to unit, or power exceeds absolute limits:

95-135 VAC
180-270 VAC
20-28 VDC
Remedy:

Make sure power is reaching main terminal block; that wires are connected properly;
power is within absolute limits.

2.
Problem:

Power to unit, but signal is not received (RED LED stays ON).

Probable Cause:

(a) Gain potentiometer setting is too low.

(b) Receiver malfunctioning.

(c) Transmitter placement is relation to side of vessel wrong, causing out of phase
reflections.

Remedy:

(a) Adjust gain potentiometer.

(b) If the receiver diode fails, no signal is received. (Consult Factory).

(c) Move transmitter either in our out slightly (± ½ inch). Connect a voltmeter to
analog test point and ground and adjust transmitter placement for maximum
voltmeter reading (0-10 VDC).

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 PART 677-3

3.
Problem:

Relay remains unchanged when beam is broken.

Probable Cause:

(a) Reflections. Beam reflects from unrelated surfaces; provides as path around
object in the beam.

(b) Microwave passes through objects because of microwave transparency.

(c) Electrical signals may be passing from one cable to another creating an auxiliary
path.

(d) Defective 320 board.

Remedy:

(a) Place an object directly in front of the transmitting sensor. If relay changes, then
reflections may be a problem.
Relocate sensors.

(b) Check as in 2a. Readjust gain potentiometer.

(c) Examine cables. Make sure that the receiving sensor cables are not run with
power, transmitting, or control wires. Repair unshielded poor cable splices. Run
transmitting and receiving cables in separate conduit and check for insufficient
cable shielding at terminal connections. (See Figure 5).

(d) Plug in spare amplifier to check this.

4.
Problem:

Intermittent operation.

Probable Cause:

Usually results from two or more causes in step 3. While one alone might not affect
operation, adding a 2nd or 3rd might decrease path so total loss between sensors is less
than amplifier gain.

Remedy:
Follow all the procedures in (step 3) to isolate and correct potential cause of
intermittent operation.

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 PART 677-3
5.
Problem:

External device, that is wired to relay terminal, does not function. Status LED’s indicate
operation.

Probable Cause:

System components other than the Microwave 320 may be defective; relay contacts
burned or external device defective. No power at relay contacts.

Remedy:

Check microwave relay contacts and external device. Wire power to relay contacts.

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 PART 677-3

PROPRIETARY EQUIPMENT DATA: 5.5

COAL VALVE: POSITION TRANSDUCER

BRAND: “ASM”

DRAWING REFERENCE: 70648-B1-4 PCE 3 & 4

DESCRIPTION: TYPE ‘WS12’ POSITION

SENSOR WITH ANALOG
OUTPUT.
SUITABLE FOR 12-27 VDC

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 PART 677-3

SPECIFICATION:
MODEL NO. : WS12-250-420-L10

RANGE : 250mm

OUTPUT : 4-20 Ma

MATERIAL : CORROSION RESISTANT ALUMINIUM

MATERIAL (CABLE) : STAINLESS STEEL

CONNECTOR : FEMALE NO. WS-CONN-D8

PROTECTION : IP67

INSTALLATION & MAINTENANCE:

(Taken from “ASM” Catalogue # KAT-WS-E-96)

1. SAFETY INSTRUCTIONS

DO NOT OPEN SENSOR RELEASE OF SPRING UNDER

TENSION CAN RESULT IN INJURY

DO NOT SNAP CABLE UNCONTROLLED CABLE

RETRACTION CAN BREAK OFF
CABLE CLIP. BROKEN CLIP AND
CABLE CAN RESULT IN INJURY.
ALSO SENSOR WILL BE
DAMAGED

DO NOT TRAVEL OVER UNCONTROLLED CABLE

RANGE RETRACTION CAN RESULT IN
INJURY. ALSO SENSOR WILL BE
DAMAGED

DO NOT TOUCH HIGH VOLTAGE (DC) IS

CONNECTOR PINS IN PRODUCED FROM THE VELOCITY
OPERATION OUTPUT AT HIGH CABLE
VELOCITY

DO NOT EXCEED MAXIMUM RISK OF INJURY

OPERATING VOLTAGE SENSOR WILL BE DAMAGED

AVOID SHOCKS TO CASE SENSOR MAY BE DAMAGED

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 PART 677-3
2. PRODUCT DESCRIPTION
The purpose of position and velocity sensors is to transform position of a
linear and guided movement into an electrical signal. Specifications of
measuring range, environment, handling and connections as specified,
must be followed.

(a) MEASURING - CABLE PRINCIPLE

Linear motion of the measuring cable (flexible stainless steel) is
converted into rotation by means of a precision cable drum. A
spring motor provides torque for the cable retraction. Special
design assures precise and reproducible winding of the measuring
cable.

Cable extraction or retraction is transformed into an electrical

signal. Depending on application different sensing elements are
used.

(b) MEASURING SIGNAL AND RANGE

ANALOG ADJUSTED Measuring range corresponds
Integrated signal conditioner to electrical measuring range
Sensitivity adjusted by (e.g. 4-20 mA)
manufacturer

3. INSTALLATION
DO NOT DAMAGE CABLE!
CABLE MUST NOT BE OILED OR LUBRICATED!
DO NOT SNAP CABLE!
DO NOT TRAVEL OVER RANGE!
DO NOT CRACK CABLE!
CABLE TRAVEL SHOULD ONLY BE AXIAL TO THE CABLE OUTLET
- NO MISALIGNMENT ALLOWED!
DO NOT DRAG CABLE ALONG OBJECTS!

(a) PRECAUTIONS
DO NOT SNAP CABLE
UNCONTROLLED RETRACTION OF CABLE MAY DAMAGE
SENSOR

No warranty will be granted for snapped cables.

MOUNTING HINTS
If possible fasten cable clip with cable in retracted position.

Cable clip may be opened for easy attachment

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 PART 677-3
(b) MOUNTING
To ensure proper operation, install the sensor only as supplied.
CABLE TRAVEL MUST ONLY BE AXIAL TO CABLE OUTLET.
- NO MISALIGNMENT IS ALLOWED.
Cable misalignment shortens service life of sensor and causes
error in measurement.
When fastening cable clip take notice of precautions.

(c) CONNECTOR WS-CONN-D8

PART NUMBER: OPERATION:
1 to 2 Assemble O – Rings (LUBRICATE!) on
Shielding Ring and Rotating Hull.
3 to 7 Stringing parts and cut off Projecting Braiding.
Note detail drawing of Shielding.
8 Thread wires through Housing, then assemble
Shielding Ring, Sealing Ring and Pinch Ring.
Turn on Pressing Screw to fix the Cable.
Solder wires.
9 to 13 Assemble remaining parts according to
diagram. Fasten Pressing Screw.
14 Insert Profile Seal and unfix Female
Connector at Male Socket.

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 PART 677-3
THE SENSOR PROTECTION CLASS IS ONLY VALID WHEN
CORRECTLY CONNECTED.
TO ENSURE SENSOR PROTECTION CLASS, ASSEMBLE ALL
CONNECTOR SEALS CAREFULLY.
SEALING RING HAS TO ENCLOSE CABLE TIGHTLY. IF NECESSARY,
USE HEAT SHRINK TUBE.

4. CONNECTION
Electrical Specifications & Circuits See Connection Diagram

Operating Voltage Do not exceed maximum

operating Voltage

Connecting 420 A
To convert the 4-20mA signal into a Voltage signal, it needs an
Impedance RM (Measuring Impedance) as shown in the diagram.
Additionally, there is a cable Impedance RL dependent on the equation:

RMmax – (UB-12V)/0.02A-RL

With and excitation e.g. 24VDC and a cable impedance R L =500Ω, a

maximum value of RM =100 Ω , can be used.

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 PART 677-3

5. ELECTROMAGNETIC COMPATIBILITY
Electromagnetic compatibility of ws-position sensors depends on wiring
practice.

RECOMMENDED WIRING:
 Use shielded twisted pair sensor cable.
 Ground shield single ended at switch cabinet. Connect shield
directly before or at cable inlet of switch cabinet by low impedance
ground cable bond.
 Keep sensor signal and power wiring well separated. Use separate
conduit or ducts for each.

If application includes highly electromagnetic disturbance emitting

equipment like switch converter drives, additional measures are
recommended.

 Use double shielded sensor cable with outer shield and separate
shield for each element of twisted pair wires.

 Use shielded conduit or ducts connected to ground potential.

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 PART 677-3

6. CONNECTION DIAGRAM FOR ASM POSITION AND VELOCITY

TRANSDUCERS

PINOUT AND CABLE ASSIGNMENT OUTPUT SIGNALS FOR

POSITION
Male Socket Cable Output Male Socket DIN 420A
WS-CONN-026P according to 8-Pin Current Output
DIN 47100 Two wire
Pin Colour Pin
A white 1 Excitation +
B brown 2 Excitation -
C green 3
D yellow 4
E grey 5
F rose 6
- blue 7
- red 8

For not listed output configurations refer to data sheets or special connection
diagrams.

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PART 677-3

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 PART 677-3

PROPRIETARY EQUIPMENT DATA: 5.6

COAL VALVE: PROXIMITY SWITCH

BRAND: ”PEPPERL & FUCHS”

DRAWING REFERENCE: 70648-B1-4 PCE. 23

DESCRIPTION: INDUCTIVE PROXIMITY

SWITCH
TYPE NCN40
SUITABLE FOR 5-60 VDC

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 PART 677-3

SPECIFICATION:
TYPE : INDUCTIVE PROXIMITY SWITCH

ELECTRICAL DESIGN : DC

NOMINAL SENSING RANGE : 40mm

ORDER NO: :

DESIGNATION : NCN40+UI+Z2

OPERATING VOLTAGE : 48 VDC (Client Request)

HOUSING : 40 SQUARE PBT HOUSING

CONNECTION : TERMINAL COMPARTMENT

INSTALLATION & MAINTENANCE:

The following information is given as a reference only to ensure trouble-free operation:

1. OPERATION
The operation of these proximity switches is maintenance free.

To ensure trouble-free running, the sensing face and the clearances

should be free of deposits and foreign bodies.

2. MOUNTING
Always ensure the proximity switches are rigidly fixed to their respective
brackets and that these same brackets are rigidly secure.

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PROPRIETARY EQUIPMENT DATA: 5.7

COAL VALVE: PROXIMITY SWITCH

BRAND: ”PEPPERL & FUCHS”

DRAWING REFERENCE: 70648-B1-4 PCE. 1

DESCRIPTION: INDUCTIVE PROXIMITY

SWITCH
TYPE NBB10
SUITABLE FOR 5-60 VDC

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 PART 677-3

SPECIFICATION:
TYPE : INDUCTIVE PROXIMITY SWITCH

ELECTRICAL DESIGN : DC

NOMINAL SENSING RANGE : 10mm

ORDER NO: :

DESIGNATION : NBB10-30GM60-Z0

OPERATING VOLTAGE : 48 VDC (Client Request)

HOUSING : 30mm DIA. BRASS HOUSING

CONNECTION : 2m PVC CABLE

INSTALLATION & MAINTENANCE:

The following information is given as a reference only to ensure trouble-free operation:

1. OPERATION
The operation of these proximity switches is maintenance free.

To ensure trouble-free running, the sensing face and the clearances

should be free of deposits and foreign bodies.

2. MOUNTING
Always ensure the proximity switches are rigidly fixed to their respective
brackets and that these same brackets are rigidly secure.

83