Download PDF: Sandvik Crusher Electrical Presentation Manual 260712

Electrical Presentation 260712 issue 0

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Safety first

Protective Equipment

Safety is our top priority

Emergency Exit

Emergency Number

Assembly Point Alarm

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QH/QJ/QI Electrical Overview.

Training Seminar

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QH440 Contents Introduction to CAN Bus systems Machine Overview Components & Sensors Tracking and Remote Options Wiring Diagrams Questions & Answers 4

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Section 1: Introduction to CANbus

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What is CAN? CAN stands for: Controller Area Network It is a communication network between devices. Each device (or Node) on the network can broadcast a message which any other device connected to the network has the ability to receive.

This network is commonly referred to as a Bus. 6

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Introduction to CANBus – a Machine Communication Network

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CAN Bus Cable The recommended cable used on the CAN Network is called Twisted Pair.

This is physically made up of 2 wires running through a plastic coating, as the wires run down the cable they spiral around each other.

This helps eliminate any noise or electrical interference.

A variant of this is shielded twisted pair. This cable is the same as the standard twisted pair but also has a shield cable which surrounds the twisted pair giving even more protection from interference.

Below are some examples of how twisted pair cable may be represented in electrical drawings

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CANbus cable

CAN High 120Ω Ω

120Ω Ω CAN Low

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Bus resistance Another requirement of the CAN bus is that there needs to be a resistive load applied to the bus of 60Ω. If this is not applied there is the chance of messages being missed or the nodes not able to communicate with each other.

This is achieved by installing two 120Ω resistors, one on each end of the bus.

CAN High

CAN Low

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CANbus Resistance 120 ohm resistor

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CANbus Resistance 120 ohm resistor

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CANbus Resistance QH only 120 ohm resistor

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Bus resistance It is not acceptable to place one 60Ω resistor on the bus. This may cause problems.

CAN High

CAN Low

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What are controllers?

OUPUT INPUTS

Feeder Valve

The controller will receive signals from ALL of the sensors around the machine (INPUTS).

The programme in the controller will determine how the system will react to these inputs e.g. switch on the feeder.

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J1939

J1939 Contains information broadcast by the engine such as: Current Engine Speed Engine Operating Hours Air Intake Temperature Boost Pressure This is utilised in the M Pro S Panels to display engine operating information and to display engine warning information.

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Safety Considerations Warning !!!

Control Unit

Do not attempt to supply output circuits independently of the controller with the controller still connected to the outputs.

This will result in serious damage to the controller and could lead to a potentially dangerous operating condition.

Electrical Solenoid

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Section 2: Machine Overview

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Panel overview QH & QJ MC88 – Main Controller

E-Stop relay (K2)

GW3000 GATEWAY/DATA LOGGER

Main Power Relay 1 & 2 (K1 & K11)

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MC88 Main Controller QH440

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MC88 Main Controller QJ341

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E-STOPS Reset button S33 & S39

Power indicatorA1=24v A2=0v Channel 1 = S11 & S12 Channel 2 = S21 & S22

All 3 lights MUST be illuminated before the safety relay will be in a “HEALTHY” state. !!

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Main power Relay

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A1 = 24v+ A2 = Negative

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Main Power Relay

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Panel overview QH & QJ

DOWNSTREAM E-STOP

FRONT DRIVE LAMPS

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UPSTREAM E-STOP

WORK LAMPS

TIMER RELAY

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Drive/worklamp relay Relay N/O contacts are pins 7/11 8/12 9/5 10/6.

When power is applied to the coil pins 13&14 then the contacts will close.

LED will illuminate when power is applied between pins 13&14 26

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Pin 13 = Negative Pin 14 = 24v

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Timer Relay A1- 24v

15- common contact B1-trigger Current setting shown = 8 seconds Divide set time in multiples of ten Set time in seconds, minutes, hours, days

Timing modes set to R

This timer is installed on ALL models but is only fully used on the QJ machines.

16- N/C contact 18- N/O contact A2- negative 28

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Timer Relay

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Timer Relay

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Timer ensures that clamp 4 remains energized after the ignition key has been switched off

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On the QH machines, the timer function is set to zero so that there is no delay when switching off.

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Upstream/downstream e-stop relays

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Upstream/downstream e-stop relays

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Panel overview UPSTREAM RELAY DOWNSTREAM RELAY SLAVE POWER RELAY TRACK RELAY 1 TRACK RELAY 2

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Relays

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Chassis panel overview QH only

UNIT A104

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Chassis panel overview QH only

REAR DRIVE LAMPS AIR BLOWER RELAY

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E-STOPS

E-stop RESET button is pushed on “power up” and when any e-stop has been pushed and then released.

RESET button is wired across S33 & S39

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E-Stops E-Stop activated

White flags in windows

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Power at relay but both channels “off”

No power at relays

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E-Stops E-Stop Healthy

No white flags in windows

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Power at relay and both channels healthy (lights on)

Relays activated ( these relays only need to be active when using e-stop upstream/downstream)

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To reset switch, Terminals 33 & 39 Make to reset after fault + 24v to e-stops

- 0v to e-stops

0v

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To manual track control handset, Upstream, downstream dummy plugs e-stops circuit

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E-STOPS

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24v from e-stops

24v return to e-stops

0v from e-stops

0v return to e-stops

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E-STOPS 24v from e-stop relay contacts

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FUSEBOX Engine ECM 40 amp

Alternator 105 amp

Starter Motor 40 amp

From battery positive

Control Panel 40 amp

DC Motor 200 amp (QI Machines only) All of these fuses are “push to reset” apart from the DC Motor 200 amp fuse which is located inside the fuse box and must be replaced when blown !

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Starter Relay

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Positive 24v -White/red

Red from fuse box

Negative - Black

White/red to starter motor

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Engine Crank

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Engine Crank

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Section 3: Components & Sensors

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Hopper level sensor

Detects the level of material in the hopper and slows/speeds the feeder in accordance.

This sensor has a default setting of 200-1300 mm.

200mm = 0v 1300mm = 10v.

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Tail Conveyor level sensor

Detects the level of material in the hopper of next machine in train and slows/speeds the feeder in accordance.

This sensor has a default setting of 200-1300 mm. 200mm = 0v 1300mm = 10v.

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Tail Conveyor level sensor “Red square” = Manual restart of feeder

Sensor “By-pass”. This sensor is NOT fitted as standard . If the sensor is not fitted then it MUST be switched off or the feeder will not start !!

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“Green square” = auto restart of feeder

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Hopper level sensor

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Hopper level sensor Power supply to sensor is 24v dc. (Red wire)

UNIT A104 Return signal from sensor is between 0 – 10 v dc. (Green wire) 54

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Hopper level sensor position

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30mm proximity sensor Monitors the speed of the crusher flywheel.

Green light when metal is detected.

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Will output 24v when the face of the sensor comes within 5 to 8mm of a metal surface.

Crusher speed display.

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30mm proximity sensor

Feeder will stop 8% slippage.

Machine shutdown 12% slippage.

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30mm proximity sensor

Belt slippage is the ratio between the engine speed and the crusher flywheel speed. E.g. If the engine speed is 1800rpm and the crusher speed is 600rpm then this is a 3:1 ratio.

If the crusher speed varies from this ratio over a set % then the feeder will stop or the machine will shutdown.

If a non standard pulley is installed then the new ratio will need to be calculated and entered into the machine parameters.

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30mm proximity sensor Cr usher speed sensor

Slippage w ar ning 8%

feed c onveyor shut off

Slippage c r itic al 12%

Plant auto shutdow n sequenc e

ENGINE IDLE

By-pass available

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30mm proximity sensor

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30mm proximity sensor test Return signal from sensor is 24v when green light is on. (No2 wire)

Power supply to sensor is 24v dc. (No 1 wire)

UNIT A104

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YG = 0v

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30mm proximity sensor test

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30mm proximity sensor

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Temperature Sensor Monitors the temperature of the lubrication oil, hydraulic oil and clutch oil.

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Temperature Sensor

Main Hydraulic oil

Lubrication oil temperature

temperature

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Temperature Sensor

Clutch oil temperature

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LUBRICATION OIL TEMPERATURE SENSOR

Temperature Sensor – lube oil temp. greater than 4C -ARCTIC 12 C -NORMAL 19 C -HOT

Healthy for crusher YES

start-up

NO

lube oil heater " ON" (below 20 C)

temp. greater than 37C -ARCTIC 45C -NORMAL 51C -HOT

temp. less than 34C -ARCTIC 40C -NORMAL 47C -HOT

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wait for temp to increase

lube oil cooler on

lube oil cooler off

temp. achieved

temp. greater than 53C -ARCTIC 61C -NORMAL 66C -HOT

temp equal to or above 20 C

WARNING! lube oil temp high

lube oil heater "OFF"

temp. greater than 55C -ARCTIC 63C -NORMAL 68C -HOT

plant shutdown sequence

ENGINE IDLE

feed conveyor off

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Temperature Sensor

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Temperature Sensor – Hydraulic oil HYDRAULIC OIL LEVEL SENSOR

level critical

plant stopped

engine crank disabled

plant operating

5 Second buffer

plant tracking

30 Second buffer

WARNING! low hyd oil level plant auto shutdown sequence

ENGINE STOP

By-pass available

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Temperature Sensor – clutch oil CLUTCH OIL TEMPERATURE SENSOR

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Clutch oil high temp. warning above 85C

feed conveyor shut off

Clutch oil high temp. critical above 90C

Plant auto shutdown sequence

ENGINE SHUTDOWN

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Temperature Sensor

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Temperature Sensor Set meters to ohms. Unplug the sensor before testing.

This sensor will give a resistance reading according to the temperature of the oil e.g. if the oil is at 40 degrees then the resistance will be approx 1000 ohms .

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Temperature Sensor

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Temperature Sensor

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CSS Position sensor This sensor is used to determine the position of the mantle.

It will return a voltage reading dependant on the position of the mantle.

This voltage will vary between 0v – 10v

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CSS Position sensor Current CSS position

Desired CSS position

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CSS Position sensor CSS POSITION SENSOR

sesor unavailable

5 sec ond buffer

auto shutd ow n sequenc e

ENGINE STOP

input value high

input value low

A dimension MAX - QH331= 175 CSS less than 10mm

A dimension MAX - QH440= 185 A dimension lesss than 25= No auto c alibr ation

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CSS Position sensor expected voltages

0-10v

24v

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Oil level sensor This sensor is used to monitor the level of the following; MAIN HYDRAULIC OIL LUBRICATION OIL CLUTCH OIL This is a normally closed sensor so that if the connector is removed then a fault will register.

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Hydraulic oil level sensor HYDRAULIC OIL LEVEL SENSOR

level critical

plant stopped

engine crank disabled

plant operating

5 Second buffer

plant tracking

30 Second buffer

WARNING! low hyd oil level plant auto shutdown sequence

ENGINE STOP

By-pass available

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Clutch oil level sensor CLUTCH OIL LEVEL SENSOR

level critical

WARNING! low clutch oil level

plant operating

5 Second buffer

plant auto shutdown sequence

ENGINE STOP

By-pass available

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Lubrication oil level sensor LUBE OIL LEVEL SENSOR

level critical

WARNING! low lube oil level

5 Second buffer

plant auto shutdown sequence

ENGINE STOP

only when lube pump operating

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Oil level sensor

Set meters to ohms.

This sensor will give a resistance reading according to the state of the level.

When oil level sensor is in fault state the resistance will read very high or “OL”.

When the oil level sensor is in healthy state then the resistance will read 0 ohms.

This reading should be taken across pins 1&2

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Oil level sensor A red square beside the oil level indicates a fault state.

A green square beside the oil level indicates a healthy state.

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Oil level sensor 24v when oil level healthy

24v

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Oil level sensor 24v

24v 24v when oil level healthy

24v

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Oil level sensor

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9 bar pressure transducer (Pinion (countershaft)) This transducer measures the pressure of the pinion

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9 bar pressure transducer (pinion (counter shaft))

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9 bar pressure transducer (pinion (countershaft)) COUNTERSHAFT PRESSURE SENSOR QH440 ONLY

PRESSURE BELOW 7 PSI

Cr usher star t not available

c ounter shaft pessur e w ar ning

4 sec ond buffer

feed c onveyor stop

4 sec ond buffer

plant auto shutdown sequenc e

less than 40 psi

c ounter shaft pr essur e c r itic al

ENGINE IDLE

less than 7 psi

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9 bar pressure transducer (pinion (countershaft))

This transducer has a supply voltage of 24v and a return signal of 0-10v.

This can be measured across No 1 = 24v No2 = 0-10v YG = 0v

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9 bar pressure transducer (pinion (countershaft))

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9 bar pressure transducer (pinion (countershaft))

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160 bar pressure transducer (hydroset) Dependant on the pressure then the Hydroset rises, lowers or remains steady.

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This transducer measures the pressure of the hydroset.

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160 bar pressure transducer (hydroset)

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160 bar pressure transducer (hydroset) HYDROSET PRESSURE SENSOR

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sesor unavailable

ENGINE STOP

pressure above setpoint

cone will open CSS to relieve pressure

pressure relieved

return to desired CSS

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160 bar pressure transducer (hydroset) 5v Supply

This transducer has a supply voltage of 5v and a return signal of 0-5v.

This can be measured across White/Orange = 5v Green wire = 0-5v White/Black wire = 0v

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160 bar pressure transducer (hydroset)

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Section 3c: Components & Sensors Other Components

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Flow meter This transducer is used to measure the rate of oil flow in the lubrication system.

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Flow meter FLOW METER

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Crusher cannot start "low lubrication flow"

NO

flow rate greater than 50 LPM

YES

Flow rate OK for crusher start

Feeder cannot start "low lubrication flow"

NO

flow rate greater than 70 LPM

YES

Flow rate OK for feeder start

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Flow rate falls below 70 LPM

FEEDER STOP

Flow rate falls below 65 LPM

PLANT SHUTDOWN ENGINE IDLE

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Flow meter

5v

0v

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5v

0v

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5v

0v

0v

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Flow meter

This transducer has a supply voltage of 5v and a return signal of 0-5v pulsed.

This can be measured across Red wire = supply 5v Black wire = 0v supply Green wire = 0-5v pulsed To measure the signal wire effectively you will require a meter with a frequency setting (Hz DCv).

5v

5v

5v

This will measure in hertz.

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0v

0v

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Flow meter

Flow meter reading.

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Speed Wheel

This sensor is used to measure the conveyor speed.

The wheel rests on the conveyor and rotates as the belt moves.

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Speed Wheel MAIN CONVEYOR SPEED SENSOR

speed war ning

feed con off

below 120 M/M QH440 below 100 M/M QH330

speed c r itical below 10 M/M QH440 below 10 M/M QH330

Plant auto shutdown sequence

ENGINE IDLE

By-pass available

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Speed Wheel RECIRC CONVEYOR SPEED SENSOR

speed war ning

feed c on off

below 75 M/M QH440 below 75 M/M QH330

speed cr itical below 10 M/M QH440 below 10 M/M QH330

Plant auto shutdow n sequenc e

ENGINE IDLE

By-pass available

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Speed Wheel FINES CONVEYOR SPEED SENSOR

speed war ning

feed con off

below 93 M/M QH440 below 93 M/M QH330

speed cr itical below 10 M/M QH440 below 10 M/M QH330

Plant auto shutdown sequence

ENGINE IDLE

By-pass available

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Speed Wheel

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Speed Wheel

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Speed Wheel This transducer has a supply voltage of 24v and a return signal of 24v pulsed.

This can be measured across Pin 1 = supply 24v Pin 2 wire = 24v signal Pin 3 = 0v

This transducer has a pulsed return signal.

When measuring pin 2 voltage the wheel can be turned slowly by hand, every time the pick ups on the wheel pass the internal sensor the 24v will be present.

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Speed Wheel

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Over pressure fan switch over pressure fan by-pass available

switch open on plant start-up

YES

plant operating

switch closed

30 second buffer

plant auto sequence shutdown

ENGINE SHUTDOWN

NO

clutch disabled

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Fuel Gauge This sensor measures in Resistance (ohms). 120 ohms = 75% full.

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Fuel Gauge Fuel Gauge by-pass available

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fuel level low warning

12 second buffer

feed conveyor off

push "OK" to restart feeder

fuel level crirical

12 second buffer

auto shutdown sequence

ENGINE SHUTDOWN

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Fuel gauge

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Section 3d: Components & Sensors Outputs

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Outputs Expected Voltages

24v

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24v

24v

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Outputs

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Expected Voltages

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Outputs

Expected Voltages

Left track/right track 1 = 18v reverse/6v forward

24v

24v

24v

24v

24v

24v

2= 24v 3= Earth

Feeder 1 = 16v min- 18v max 2= 24v 3= Earth 120

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Outputs

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Expected Voltages

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Outputs

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Expected Voltages

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Outputs

24v

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24v

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Expected Voltages

24v

24v

24v

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Outputs

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Expected Voltages

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Outputs

24v 24v 24v,

24v

??? miniamps

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Outputs

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Expected Voltages

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Outputs Power on/off

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Input speed detected

Output speed detected

Pressure transducer detected

CANBUS detected

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Outputs Oil pressure

Oil Temp.

Filter clogged

Safety switch

Clutch engaged Coil fault

Timed lockout

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Clutch overload

RPM too high

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Outputs

PWM coil should measure 0-1000ma 129

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Expected Voltages

ON/OFF coil should measure 24v Electrical Training 260712 Issue 0

Clutch CLUTCH

Disengage

auto shutdown sequence

ENGINE STOP

Engage with no response

Pr essure unavailable

Clutch pressur e less than 208 208 psi - QH440 less than 200 psi - QH330

Select Clutch engage (auto)

Select Clutch engage (manual)

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Clutch low pr essur e warning

feed conveyor off

engine auto ramp to 1000 rpm

clutch engage auto

engine manual ramp to 1000 rpm

clutch engage manual

Clutch pressur e less than 208 145 psi - QH440 less than 145 psi - QH330

engine auto r amp to 1800 r pm operating speed

engine manual r amp to 1800 r pm operating speed

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Outputs (clutch)

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Outputs (clutch)

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Outputs (clutch)

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Outputs (clutch)

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Outputs (clutch)

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Outputs (clutch)

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Outputs (clutch)

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24v

0v

24v

24v

24v

24v

Hertz reading

0v

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0v

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Section 4: Tracking & Remote Options

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Engine logic ENGINE

BELOW 1500 rpm

air fiter warning will only show once

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feed conveyor stop

4 second buffer

feed conveyor stop

push "OK" button to restart feeder

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Tracking

Manual Handset

Remote Handset

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Track Diagnostics

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Tracking

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Tracking 24v from F14 24v to both tracks forward/reverse when track on/off switch closed

0v

5v

4.5 V reverse 2.5 v = Neutra 0.5 v = Forward

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Fault codes

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Fault codes Example of DM1 Codes displayed on machine control screen, QI, SPN cross reference SPN/FMI Number (Cat/PT Tech Ref) E.G. SPN 1074 FMI 05

Fault Description

Machine Fault Number (JMG Ref)

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Extra Information /FMI Descriptor (Where Applicable)

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Fault codes QI

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Fault codes

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Fault codes

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Fault codes CAT T3a C9/C13

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Fault codes CAT T3a C9/C13

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Fault codes CAT T3a C9/C13

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QI Red Faults

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QH PT Tech fault codes

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QH PT Tech fault codes

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QH PT Tech fault codes

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CAT T3a C9/C13

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CAT T3a C9/C13

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QH Red faults

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QH Red faults

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QH Red faults

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QH Blue faults

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QH Blue faults

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QH Blue faults

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QH Blue faults

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QJ Red Faults

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QJ Blue faults

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Remote Control Transmitter After switching ON the transmitter, the signal ON LED on the transmitter’s control panel starts to flash, you will hear two short acoustic signals, which indicates the self test routine of the transmitter.

Radio Transmitter

Signal on LED

An acoustic interval signal for 30 seconds indicates that the battery is nearly discharged and should be exchanged with a fully charged battery.

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Remote control receiver Pulses with main board communication light.

Can connection light

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Remote control receiver

E-stop relay. Red light MUST be on for machine to operate

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Remote control receiver Fault in system Communication good Power on

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System I.D Radio Receiver Radio Transmitter

System Number

Transmitter Module

Address Module (Admo)

Receiver Module

Frequency jumper switches

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Section 5: Wiring Diagrams

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Temperature Sensor QJ Monitors the temperature of the hydraulic oil and clutch oil.

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Temperature Sensor QJ

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HYDRAULIC OIL TEMPERATURE SENSOR

Temperature Sensor – Hydraulic oil temp. greater than 49 C

5 sec ond buffer

oil cooler on

temp. less than 40 C

5 sec ond buffer

oil cooler off

Main c onveyor r aise Main c onveyor lower Main c onveyor head section raise Main c onveyor head section lower

temp. greater than 79 C

5 sec ond buffer

temp. sensor unavailable

WARNING! sensor unavailable

temp. greater than 84 C

5 sec ond buffer

WARNING! hyd oil temp high

Feed c onveyor off

Plant operating

plant tr acking

plant shutdown sequenc e

20 second buffer

plant idling

WARNING! hyd oil temp high

ENGINE SHUTDOWN

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Temperature Sensor – clutch oil CLUTCH OIL TEMPERATURE SENSOR

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Clutc h oil high temp. w ar ning above 85C

feed c onveyor shut off

Clutc h oil high temp. c r itic al above 90C

Plant auto shutdow n sequenc e

ENGINE SHUTDOWN

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Temperature Sensor QJ

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Hydraulic oil temp

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Temperature Sensor QJ

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Oil level sensor

This sensor is used to monitor the level of the following; MAIN HYDRAULIC OIL CLUTCH OIL (optional) This is a normally closed sensor so that if the connector is removed then a fault will register.

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Oil level sensor

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Hydraulic oil level sensor HYDRAULIC OIL LEVEL SENSOR

level critical

plant stopped

engine crank disabled

plant operating

5 Second buffer

plant tracking

30 Second buffer

WARNING! low hyd oil level plant auto shutdown sequence

ENGINE STOP

By-pass available

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Clutch oil level sensor CLUTCH OIL LEVEL SENSOR

level critical

WARNING! low clutch oil level

plant operating

5 Second buffer

plant auto shutdown sequence

ENGINE STOP

By-pass available

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Oil level Sensor QJ

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500Bar pressure transducer Is used to monitor the pressure of the main pump.

230 bar

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500Bar pressure transducer

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500Bar pressure transducer 500 bar pressur e transducer

dr ive pressur e warning above 420 bar

dr ive pressur e critical above 450 bar

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feed conveyor off

auto shutdown sequence

ENGINE SHUTDOWN

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500Bar pressure transducer

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500Bar pressure transducer

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30mm proximity sensor Monitors the speed of the crusher flywheel.

Will output 24v when the face of the sensor comes within 5mm of a metal surface.

Green light when metal is detected.

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30mm proximity sensor Crusher speed display.

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As the speed falls below a setpoint then the feeder will stop, as the speed then increases above a setpoint then the feeder will restart.

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30mm proximity sensor

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30mm Sensor QJ

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250 bar Sensor

Is used to monitor the toggle pressure

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250 bar Sensor 250 bar pr essur e tr ansducer

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above 155 bar

c har ge pr essur e off

below 135 bar

c har ge pr essur e on

below 115 bar

autoshutdown sequence

ENGINE SHUTDOWN

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250 bar Sensor

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250 Bar pressure transducer

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Hopper level sensor QJ Detects the level of material in the hopper and slows/speeds the feeder in accordance.

This sensor has a default setting of 200-1300 mm. 200mm = 0v 1300mm = 10v.

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Hopper level

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Hopper level

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Speed Wheel This transducer has a supply voltage of 24v and a return signal of 24v pulsed.

This can be measured across Pin 1 = supply 24v Pin 2 wire = 24v signal Pin 3 = 0v

This transducer has a pulsed return signal. When measuring pin 2 voltage the wheel can be turned slowly by hand, every time the pick ups on the wheel pass the internal sensor the 24v will be present.

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Speed Wheel

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Speed wheel

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Speed Wheel

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24v

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24v

24v

24v

24v

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24v

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24v

24v

24v

24v

24v

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Outputs The EDC (Electric Displacement Control) operates at a current of approx. 100mA The greater the mA reading then the more oil is allowed to flow by the EDC 24v

As the mA reading increases then the crusher will ramp up.

This mA reading will tell us if the EDC is operating properly electrically.

0v

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Outputs

Current at EDC Forward and Reverse

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Outputs

24v

24v

Left track/right track

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1 = 18v reverse/6v forward

Feeder

2 = 24v

2= 24v

3 = Earth

3= Earth

4 = Fault Signal

4 = Fault Signal

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1 = 12v min- 18v max

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0utputs

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Outputs

24v

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24v

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