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Operating procedures.........................................................5
The feeder breaker is normally operated in “AUTO”mode. While in “AUTO”mode, the belt sequence switch is active: the outby belt must be running for the feeder breaker’s conveyor chain to operate.
After reading the previous descriptions and locating each control, the operator is ready to operate the feeder breaker. An experienced operator should monitor a new operator’s indoctrination to the starting procedure.
WARNING! The machine should not be started if it’s core temperature is below 30° F. If the machine is started at extremely low temperatures pump and pump motor failure could occur.
IMPORTANT! Before start-up, check that daily maintenance has been performed on the machine.
1. Operate all valve bank control levers to ensure that they are free and in neutral position.
2. Position the valve bank handle neutral start lock guard over the valve handles so that they cannot be operated. Make sure the magnetic contactors are fully seated and are in direct contact.
IMPORTANT! The machine will not start unless all valve control levers on the primary valve bank are in neutral position and the guard is fully closed, engaging the magnetic switch.
3. Check conveyor for any foreign material or objects.
4. Check that all other personnel are within a safe distance of the machine.
WARNING! Before start-up, check the conveyor for any foreign material or objects and that all other personnel are within a safe distance of the machine.
5. Set main circuit breaker located on the door of the starter enclosure by first moving the circuit breaker lever to the “RESET”position and then to the “ON”position.
6. Turn the “OFF/MANUAL/AUTO”selector switch located on the cover of starter enclosure to the “AUTO”position.
7. Engage the “START”pushbutton located on the cover of the starter enclosure to start the conveyor/breaker motor.
If the machine needs to be operated while the outby belt is off (belt sequence switch by-passed), start the machine in “MANUAL”mode.
After reading the previous descriptions and locating each control, the operator is ready to operate the feeder breaker. An experienced operator should monitor a new operator’s indoctrination to the starting procedure.
WARNING! The machine should not be started if it’s core temperature is below 30° F. If the machine is started at extremely low temperatures pump and pump motor failure could occur.
IMPORTANT! Before start-up, check that daily maintenance has been performed on the machine.
1. Operate all valve bank control levers to ensure that they are free and in neutral position.
2. Position the valve bank handle neutral start lock guard over the valve handles so that they cannot be operated. Make sure the magnetic contactors are fully seated and are in direct contact.
IMPORTANT! The machine will not start unless all valve control levers on the primary valve bank are in neutral position and the guard is fully closed, engaging the magnetic switch.
3. Check conveyor for any foreign material or objects.
4. Check that all other personnel are within a safe distance of the machine.
WARNING! Before start-up, check the conveyor for any foreign material or objects and that all other personnel are within a safe distance of the machine.
5. Set main circuit breaker located on the door of the starter enclosure by first moving the circuit breaker lever to the “RESET”position and then to the “ON”position.
6. Turn the “OFF/MANUAL/AUTO”selector switch located on the cover of starter enclosure to the “MANUAL”position.
7. Engage the “START”pushbutton located on the cover of the starter enclosure to start the conveyor/breaker motor.
Shutdown procedures
There are several methods of shutting down the feeder breaker.
1. Allow the machine to run until the hopper is empty. Continue to run the machine until all material that has been carried back into the return line has been cleaned out.
IMPORTANT! If material is very wet or sticky, it is recommended that the return line be flushed with water and the conveyor be allowed to run and clean out the return line before shutting the machine down.
To shutdown the feeder breaker in “AUTO”OR “MANUAL”mode:
2. Engage the “STOP”pushbutton located on the starter enclosure.
This will stop the conveyor/breaker motor.
3. Turn the circuit breaker reset switch to the “OFF”position .
The machine can also be shutdown in emergency situations using either panic strip or the “E-STOP CONTROLLER”button on the starter enclosure. Activating any of these shutdown devices will open the master control relay, “MCR”. Power will still be on the machine and the machine can be restarted using normal starting procedures.
To shutdown the feeder breaker using a panic strip:
There is two (2) panic strips located on feeder breaker: on at the control station and one beside the hydraulic oil tank. Striking either panic strip with a small amount of force will shutdown the machine.
To shutdown the feeder breaker using the “E-STOP”button:
There is an emergency stop, “E-STOP CONTROLLER”, button located on the cover of the starter enclosure. Push the “E-STOP CONTROLLER”button to shutdown the machine.
Start up and tramming with hydraulic control levers
1. Turn the “CONV FWD/OFF/CONV REV”selector switch located on the cover of the starter enclosure to the “OFF”position.
2. Turn the “TRAM/OFF/CONVEYOR”selector switch located on the cover of the starter enclosure to the “TRAM”position.
3. Turn the “MANUAL/OFF/AUTO”selector switch located on the cover of starter enclosure to the “MANUAL”position.
4. Set main circuit breaker located on the door of the starter enclosure by first moving the circuit breaker lever to the “RESET”position and then to the “ON”position.
5. Engage the “START”switch on the remote to start the motor.
Once the motor is started, relase the deadman switch on the front of the remote.
or
5. Engage the “START”switch on the front of the starter enclosure.
6. If the valve handles are installed, lift the neutral start valve handle guard. Make sure to lift the guard all the way back so that the guard will not fall on the operator’s hands.
7. Hydraulic functions can not be engaged from the remote or the valve bank.
The machine can now be trammed.
Conveyor operation - forward
1. Start the machine in either “AUTO”or “MAN”mode (see Starting procedures in this chapter).
2. Turn the “TRAM/OFF/CONVEYOR”selector switch located on the cover of the starter enclosure to the “CONVEYOR”position.
3. Push the “START”button to start the convyeor/breaker motor.
4. Turn the “CONV FWD/OFF/CONV REV”selector switch located on the cover of the starter enclosure to the “FWD”position.
5. Adjust the speed of the conveyor using the “CONV SPEED POT” dial located on the front of the starter enclosure. Speed is adjustable from slow (0% full speed) to fast (100% full speed).
Conveyor operation - reverse
1. Turn the “CONV OFF/FWD/CONV REV”selector switch located on the cover of the starter enclosure to the “CONV REV”position. The conveyor chain will now run in reverse as long as the switch is in the “CONV REV”position, however, to avoid jamming the conveyor, the coveyor should only be jogged in reverse.
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.
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.
Breaker motor overload
If the breaker motor current exceeds a preset value, the control system will shutdown the machine.
High oil temperature
If the hydraulic oil temperature exceeds a preset value, the control system will shutdown the machine and lights L3 and L4 will be on and L2 will be off.
Low oil level
If the hydraulic oil level falls below 165° F for more than three seconds, the control system will shutdown the machine and lights L2, L3, and L4 will be off.
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.
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 lights L2 and L3 will be on and L4 will be off.
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.
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 electric motor. To restart, see Startup procedure in this chapter.
Radio remote (optional)
If equipped with a radio remote, there will be an antennae and a control box mounted on the feeder breaker. The radio remote (Fig. 17) can be used to operate the feeder breaker’s tram and machine lift and tilt hydraulic functions. The “MAN/OFF/AUTO”switch must be in the “OFF” position for the radio remote to be active.
Fig. 17: Radio remote
1 2
3 1. Push to operate bar (deadman switch) 2. Battery good indicator 3. Battery low indicator 4. Left tram 5. Right tram 6. Left lift cylinder 7. Right lift cylinder 8. Tilt cylinder 9. Pump (breaker motor) start/stop 10. Radio remote power on/off 11. Emergency stop 12. Reset
4
6
8
11 5
7
9
10
12
push to operate bar (deadman switch)
left and right “TRAM”
left and right “LIFT”
“TILT”
“PUMP”
“POWER”
“STOP”
“RESET”
The remote is equipped with the following performance and safety features:
Power on self diagnostics: When the radio remote is powered on (“POWER”toggle switch is in the “ON”position), a self-test is initiated. when the self-test is complete, the radio remote will beep two times.
Transmit/battery charge indicator: When the battery is good, the green LED will flash with each transmission. When the battery level drops below a preset level, the radio remote will beep every ten seconds and the red LED will flash during data transmission. At this point, there is approximately one hour of battery life remaining. The radio remote will shut itself off before the battery drops low enough to result in erratic operation.
Battery saver: The radio remote will enter sleep mode if there is no input for fifteen minutes. To reset the remote, toggle the “POWER” switch to the “OFF”position and then to “ON”.
The operational controls on the remote are:
The push to operate bar (deadman switch) is a spring-return switch located on top of the radio remote that is used as a safety device that electrically disconnects all functions when released. This bar must be held in while operating any function on the radio remote.
The left and right “TRAM”switches are used to tram the machine. Each crawler can be trammed independently in either the forward or reverse direction.
The left and right “LIFT”switches are used to operate the lift cylinders. The left and right cylinders can be raised and lowered independently.
The “TILT”switch is used to operate the left and right tilt cylinders. These cylinders are not independent and operate on a common hydraulic circuit.
The “PUMP”start/stop switch is used to start the breaker electric motor.
The “POWER”on/off switch is used to power on and off the radio remote.
The “STOP”pushbutton is an emergency stop button used to shutdown the radio remote.
The “RESET”button is used to reset the system and must be pressed after turning the “POWER”switch to the “ON”position. Each time the radio remote is powered “OFF”and then back to “ON”the “RESET” pushbutton must be pressed initially before any command will work.
Tramming using the radio remote
1. Turn the “CONV FWD/OFF/CONV REV”selector switch located on the cover of the starter enclosure to the “OFF”position. 2. Turn the “TRAM/OFF/CONV”selector switch located on the cover of the starter enclosure to the “TRAM”position. 3. Turn the “MAN/OFF/AUTO”selector switch located on the cover of starter enclosure to the “OFF”position. 4. Set main circuit breaker located on the door of the starter enclosure by first moving the circuit breaker lever to the “RESET”position and then to the “ON”position. 5. Remove the tram valve handles from the primary valve bank. 6. Position the neutral start guard over the primary valve bank. 7. Move the radio remote “POWER”button to the “ON”position. 8. Press the “RESET”button on the radio remote.
9. Press and hold the push to operate (deadman) switch on the top of the radio remote.
10. Move the “PUMP START”button on the radio remote to the
“START”position. 11. While holding the push to operate switch in, tram the machine using the left and right “TRAM”switches.
