6 minute read
Starter enclosure............................................................5
Control system operating parameters
The following parameters affect the operation of the machine as indicated:
Breaker underspeed
If the pick break sensor does not pick up within ten seconds of the breaker motor starting, the control system will shutdown the breaker motor and a “BREAKER UNDERSPEED ALARM” will be displayed.
Breaker motor overload
If the breaker motor current exceeds a preset value, the control system will shutdown the machine and the “BREAKER MOTOR OVERLOAD ALARM” will be displayed.
Pump motor overload
If the pump motor current exceeds a preset value, the control system will shutdown the machine and the “PUMP MOTOR OVERLOAD ALARM” will be displayed.
High oil temperature
If the hydraulic oil temperature exceeds a preset value, the control system will shutdown the machine and the “HIGH OIL TEMPERATURE ALARM” will be displayed.
Low oil level
If the hydraulic oil level falls below a preset level for more than three seconds, the control system will shutdown the machine and the “LOW OIL LEVEL ALARM” will be displayed.
Emergency stop
If the master control relay is opened by activating a panic strip, the pull cord, or the emergency stop on the starter enclosure, the machine will shutdown and the “EMERGENCY STOP ALARM” will be displayed.
Big jam shutdown
If the machine fails to clear a jam after three attempts (see Conveyor operation in this section), the control system will shutdown the machine and the “BIG JAM SHUTDOWN ALARM” will be displayed.
Breaker motor contactor
If the auxiliary switch on the breaker motor contactor fails to close within one second of the contactor closing, the control system will shutdown the machine and the “BREAKER MOTOR CONTACTOR ALARM” will display.
Pump motor contactor
If the auxiliary switch on the pump motor contactor fails to close within one second of the contactor closing, the control system will shutdown the machine and the “PUMP MOTOR CONTACTOR ALARM” will display.
Pressure line dirty filter
If the pressure line hydraulic oil filter pressure, as monitored by the dirt indicator on the end of the filter, closes for more than five seconds, the “PRESSURE LINE DIRTY FILTER ALARM” will be displayed.
Return line dirty filter
If the return line hydraulic oil filter pressure, as monitored by the dirt indicator on the end of the filter, closes for more than five seconds, the “RETURN LINE DIRTY FILTER ALARM” will be displayed.
hydraulic oil water removal filter
There is a filter in the case drain lines of the open loop load sense pump and the conveyor motor that removes water from the hydraulic oil. If the filter pressure, as monitored by the dirt indicator on the end of the filter, closes for more than five seconds, the “HYDRAULIC OIL WATER REMOVAL FILTER ALARM” will be displayed.
High oil pressure
If the hydraulic oil pressure exceeds 4,800 psi for more than three second, the control system will shutdown the machine and the “HIGH OIL PRESSURE ALARM” will be displayed.
Low pump suction
If the vacuum in the main suction line in the hydraulic oil tank is less than a preset value for five seconds, the control system will shutdown the machine and the “LOW PUMP SUCTION ALARM” will be displayed. The vacuum transducer is located in the suction line fitting of the pump suction port.
Tram control magnet switch
If the neutral start switch (see Controls and Indicators section of this chapter) is not in place when the pump motor is started, the control system will not allow the motor to start and the “TRAM CONTROL MAGNET SWITCH ALARM” will be displayed.
Pressure transducer
If the hydraulic system pressure transducer reads greater than 1,000 psi, the water solenoid is turned on and the water sprays are activated. This transducer also activates the high oil pressure alarm and is located in the gauge manifold at the main operator’s station.
Breaker idle shutdown timer
If the conveyor is running and no cars dump on the conveyor within a two and one half (2-1/2) minute time period, the control system will shutdown the conveyor motor.
If no conveyor function is engaged on a running machine within a fifteen minute time period, the control system will shutdown the breaker motor.
Electrical system
The following pages contain a brief description of the major electrical components and assemblies that are on the feeder breaker.
The machine receives electrical power through a heavy-duty trailing cable. Be sure that the box connector is correctly identified and is securely connected; also check that the cable entrance is in good mechanical condition. Walk along the trailing cable from the power center to the feeder breaker and check the condition of the trailing cable. Give special attention to points most apt to cause damage, such as corners, intersections, and where cable may be run over by moving equipment. Never use trailing cable with exposed wires or splices which heat up or spark under load.
WARNING! This section is intended only to familiarize the user with the major electrical components of the feeder breaker. All electrical maintenance should be performed only by a qualified electrician with the knowledge of the function of the components involved.
WARNING! Before removing the cover from the starter enclosure and attempting any maintenance or troubleshooting on the machine, the main power must be disconnected and locked and tagged out at the main power center.
Fig. 25: Major electrical component locator
Head shaft tachometer
Belt pulley underspeed sensor
Panic strip
Breaker power unit
Photo eye board enclosure
Trailing cable junction box
Starter enclosure Oil temperature probe
Suction transducer
High temperature
Conveyor power unit
Oil level float and switch
Panic strip
Breaker shaft underspeed sensor and tachometer
Shuttle car power distribution enclosure
Panic strip
Pressure transducer
Photo eye sensor Emergency pull cord
Photo eye sensor
belt pulley underspeed sensor
breaker shaft underspeed sensor
panic strips
emergency pull cord
photo eye sensors
high temperature switch
low oil switch
breaker power unit
conveyor power unit
The belt pulley underspeed sensor in mounted on tailpiece on the right hand side of the machine, near the pulley. The sensor will shut down the conveyor electric motor if the conveyor stops running.
The breaker shaft underspeed sensor is mounted on the breaker shaft assembly and monitors the speed of the breaker shaft. If the breaker shaft speed falls below a preset value, the electric motors will shut off.
There are three panic strips located on the machine. Activating any one of the panic strips will open the master control relay, “MCR”, thereby shutting down the machine.
Activating the emergency pull cord, located over the hopper, will open the master control relay, “MCR”, thereby shutting down the machine.
The photo eye sensors are used to remotely start the conveyor/pump motor and are mounted on top of the machine on both sides of the hopper. The pump motor will start when a light shines on the sensor for approximately four seconds.
The high temperature switch is mounted on the wall behind the conveyor power unit on the right hand side of the machine and will shut down the machine if the hydraulic oil temperature exceeds a preset value. The temperature probe is located in the oil tank.
The low oil switch is mounted inside the oil tank. The electric motors will shut off if the oil level in the tank falls below a preset value.
The breaker power unit is a 200 HP, 950 VAC, 3 phase, 60 Hz, 1750 rpm, totally enclosed, fan cooled non-explosion proof electric motor.
The conveyor power unit is a 125 HP, 950 VAC, 3 phase, 60 Hz, 1750 rpm, totally enclosed, fan cooled non-explosion proof electric motor.
Fig. 26: Trailing cable junction box Trailing cable junction box
The trailing cable junction box (Fig. 26) is located on the right side of the machine. From the trailing cable junction box, power is sent to a junction box on the shuttle car distribution enclosure. There is an “EMERGENCY STOP” button located on the trailing cable junction box. When activated, the “EMERGENCY STOP” but will shut the machine down by disconnection the pilot in the incoming trailing cable. If the “EMERGENCY STOP” button is activated, the power must be reset at the main power center.
Connection to shuttle car distribution box (not shown)
“EMERGENCY STOP”
Trailing cable connection
