5 minute read
Conveyor .......................................................................5
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Conveyor
1. Start the machine in either “AUTO”or “MAN”mode (see Starting procedures in this chapter).
2. Turn the “OFF/TRAM/CONVEYOR”selector switch located on the cover of the starter enclosure to the “CONVEYOR”position.
3. Push the “START CONV/PUMP”button to start the conveyor motor.
4. Turn the “OFF/FWD/REV”selector switch located on the cover of the starter enclosure to the “FWD”position.
It is important to note the following concerning the operation of the conveyor in the forward direction:
– The current of the breaker shaft motor is constantly monitored by the PLC. If the current remains below 100% of the full load current (FLA), the conveyor will continue to run at the set speed.
– If the current increases above 125% FLA and stays at that level for three seconds, the PLC will assume there is a conveyor jam. The
PLC will try to clear the jam by stopping the conveyor, running it in reverse for three seconds at 10% speed, and then running it forward for ten seconds at 25% speed.
– If the current at this point is still above 125% FLA, the conveyor will repeat the above reverse/forward sequence for a second time.
– If the current at this point is still above 125% FLA, the conveyor will repeat the above reverse/forward sequence for a third time.
– If the current at this point is still above 125% FLA, the machine will shutdown and the display will read “BIG JAM”. The conveyor will need to be cleared before operation resumes.
– If the current drops below 125% FLA at any time during the three reverse/forward sequences, the speed of the conveyor will ramp back up to the set speed.
IMPORTANT! If it is necessary to reverse the conveyor, it should be jogged only. Running the conveyor in the reverse direction for a period of time with material in the hopper, will jam the conveyor and it will be necessary to empty the machine hopper before the conveyor will restart.
Operating the conveyor in reverse
1. Turn the “OFF/FWD/REV”selector switch located on the cover of the starter enclosure to the “REV”position. The conveyor chain will now run in reverse at 25% full speed as long as the switch is in the “REV”position. Note: the conveyor should not be run in reverse for extended periods; only jog the conveyor when in reverse. ______________________________________________________________
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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.
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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.
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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.
Conveyor speed
There is a mag pulse sensor located on the head shaft that counts how many revolutions per minute the head shaft turns. This information is sent to the PLC where it is converted to feet per minute (fpm) and displayed as conveyor speed.
