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Shutdown procedure ..................................................... 5
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Shutdown procedures
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 from the starter enclosure:
2. Engage the “PICK BKR STOP” pushbutton located on the starter enclosure to stop the breaker motor.
3. Move the circuit breaker reset switch to the “OFF” position .
4. Move the “TRAM/OFF/CONV” switch to the “OFF” position.
5. Move the “MAN/OFF/AUTO” switch to the “OFF” position.
To shutdown the feeder breaker from the radio remote:
2. Move the “PUMP” start/stop toggle switch to the “STOP” position to stop the breaker motor.
3. Move the radio remote “ON/OFF” toggle switch to “OFF”.
4. Move the circuit breaker reset switch, located on the starter enclosure, to the “OFF” position.
5. Move the “TRAM/OFF/CONV” switch located on the starter enclosure to the “OFF” position.
6. Move the “MAN/OFF/AUTO” switch located on the starter enclosure to the “OFF” position.
Emergency stop procedures:
The machine can also be shutdown in emergency situations using:
1. Either panic strip
2. The “EMERGENCY STOP” button on the starter enclosure
3. The “EMERGENCY STOP” button on the radio remote, or
Activating any one of the emergency stop 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.
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remote control batteries Battery Options
The remote control is battery powered. There are two different battery pack options:
Disposable Alkaline Battery Pack (standard—machine ships with this battery pack) - provides approximately 75 hours of life (based on continuous transmission).
Rechargeable Ni-Cad Battery Pack (optional) - provides approximately 23 hours of life (based on continuous transmission).
Battery Replacement
When the “TRANSMIT/LOW BATTERY” LED begins to flash red, there is approximately one hour of continuous operation remaining.
To replace the battery pack:
1. Set the remote control power switch to “OFF”.
2. Unlatch and open the battery door and remove the battery pack from the tray.
3. Insert a fully charged battery pack into the remote control. Ensure that the contacts on the underside of the battery pack align with the corresponding contacts on the battery tray.
4. closs and latch the battery door.
5. Move the remote control power switch to the “ON” position. The
“TRANSMIT/LOW BATTERY” LED should flash yellow and two quick beeps will be heard.
6. Operate a non-motion function such as the lights. The
“TRANSMIT LOW/BATTERY” LED should flash green, indicating the remote control is fully operational.
Battery Charging (optional)
The Ni-Cad battery pack is rechargeable using the appropriate charging station. Contact your Cat Service Representative for battery and battery charging options.
To recharge:
1. Remove the Ni-Cad battery pack from the radio remote.
2. Connect the charger to a standard 120VAC outlet.
3. Insert the battery pack into the charger. The battery charger red
“CHARGING” LED will be lit until the end of the charging process.
When fully charged, the green “FULLY CHARGED” LED will illuminate.
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Tramming using the hydraulic control levers
1. Turn the “FWD/OFF/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 “MAN” 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. Push the “ACKNOWLEDGE ALARMS” button once to engage the
MCR. Press the button a second time to clear any faults. 6. Engage the “START BREAKER” pushbutton located on the cover of the starter enclosure to start the pump motor. 7. Lift up the neutral start valve handle guard all the way back so that the guard will not fall on the operator’s hands.
The machine can now be trammed.
Tramming using the radio remote
1. Turn the “FWD/OFF/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. Push the “ACKNOWLEDGE ALARMS” button once to engage the
MCR. Press the button a second time to clear any faults. 8. Move the radio remote “POWER” button to the “ON” position. Listen for 2 beeps. 9. Press the “RESET” button on the radio remote. Listen for 2 beeps. 10. Press and hold the push to operate (deadman) switch on the top of the radio remote. 11. Move the “PUMP START” button on the radio remote to the
“START” position. 12. While holding the push to operate switch in, tram the machine using the left and right “TRAM” switches.
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Conveyor forward
1. Start the machine in either “AUTO” or “MAN” mode (see Starting procedures in this chapter).
2. Turn the “TRAM/OFF/CONV” selector switch located on the cover of the starter enclosure to the “CONV” position.
3. Push the “START BREAKER” button to start the breaker motor.
4. Turn the “FWD/OFF/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.
5. Press the “START CONVEYOR” button on the front of the starter enclosure or the “START” button on either one of the remote pushbutton stations. A siren will sound warning that the conveyor is starting. The siren will sound any time the conveyor has timed out and is restarted.
Notes:
1. The PLC controls the speed of the conveyor based upon the amperage monitoring of the breaker motor. There are three preset forward conveyor speeds that are, by default, 20%, 50%, and 100%. These speeds are adjustable and can be reset to suit the operating conditions. ______________________________________________________________
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2. The conveyor operating time is controlled by a timer that is reset by pushing a start button on the starter enclosure or either remote pushbutton station or shining a light on the photo eye sensor mounted above the hopper. If the timer is not reset within the allotted time, the conveyor will stop.
3. There is a second adjustable timer that will shut down the electric motor if, within a preset amount of time, there is no conveyor activity. If, within this amount of time, the conveyor is idle and a conveyor start button is pushed, the PLC will allow the pump to ramp back up to full flow.
Conveyor reverse
IMPORTANT! If it is necessary to reverse the conveyor, it should be jogged only. Running the conveyor in the reverse direction for even a short period of time with material in the hopper may cause the conveyor to jam. It will then be necessary to empty the machine hopper before the conveyor can be restarted.
Operating the conveyor in reverse
1. Turn the “FWD/OFF/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 under-speed
If the breaker under-speed sensor does not pick up within five 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.
Breaker idle shutdown timer
If the conveyor is running and no cars dump on the conveyor within a 21/2 minute time period (adjustable within the PLC), the control system will shutdown the conveyor motor.
If no conveyor function is engaged on a running machine within a 15 minute time period (adjustable within the PLC), the control system will shutdown the breaker motor.
High oil temperature
If the hydraulic oil temperature exceeds a preset value of 165° F, 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.
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 two psi for three 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.
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Pressure transducer
If the hydraulic system pressure transducer reads greater than 1,200 psi (adjustable within the PLC), 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.
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.
Emergency stop
If the master control relay is opened by activating an emergency stop device, 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.
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.
