FOR

36” GRAVIMETRIC FEEDER-

VFD DRIVE & BHELFEED R
MICROPROCESSOR BASED
CONTROL SYSTEM
The copyright on all documents, drawings and other instruments are the sole property
of Bharat Heavy Electricals Limited. These shall not be used without their express
written permission in any form or part thereof for any other purpose on for which these
are sent, to the receiver.

Issued by

Engineering Support Services / PE (FB)

Bharat Heavy Electricals Limited
High Pressure Boiler Plant
Tiruchirappalli - 620 014

2
 HOW TO USE THIS MANUAL

This equipment manual is divided into sections, which separate the material according to its
principal use at the site.

Section 1 For use by the equipment installers, covers receiving inspection, storage
procedure, storage maintenance procedure required and equipment
installation procedures.

Section 2. Oriented to the operations personnel, contains a system component description

of the major items of equipment supplied, an initial start-up sequence, and
procedure for typical operation.

Section 3,. Shows the service tool kit recommended for maintenance.

Section 4. Shows the feeder option provided.

Section 5. Shows the start-up procedure.

Section 6. For use by the maintenance staff, contains an inspection schedule, lubrication
information, adjustment and calibration procedures, and any necessary
troubleshooting guides.

Section 7. Contains mechanical drawings.

Section 8. Contains recommended spares.

Note: Certified Electrical and Mechanical drawings applicable to each contract are issued
separately.

3
 7. LIST OF FIGURES
LIST OF SECTIONS/VIEWS - FIG.01
FINAL ASSEMBLY VIEW - AA - FIG.02
FINAL ASSEMBLY VIEW - BB - FIG.03
FINAL ASSEMBLY SECTION - EE - FIG.04
FINAL ASSEMBLY SECTION- FF - FIG.05
(BELT TAKE-UP ASSEMBLY)
FINAL ASSEMBLY VIEW –D1D1 - FIG.06
FINAL ASSEMBLY VIEW- GG - FIG.07
FINAL ASSEMBLY SECTION- JJ - FIG.08
(CLEAN-OUT CONVEYOR TAKE-UP)
FINAL ASSEMBLY WEIGH SENSING SYSTEM - FIG.09
(SECTION-KK)
FINAL ASSEMBLY SECTION- LL
(WEIGH SPAN ROLLER) - FIG.10
FINAL SECTION - RR(TENSION ROLL ASSY) - FIG.11
FINAL ASSEMBLY SECTION-TT
(BELT DRIVE ASSEMBLY) - FIG.12
FINAL ASSEMBLY SECTION -XX - FIG.13
FINAL ASSEMBLY SECTION -YY - FIG.14
FINAL ASSEMBLY SECTION -HH & SECTION -ZZ - FIG.15
FINAL ASSEMBLY SECTION –H1H1 - FIG.16A
FINAL ASSEMBLY SECTION –H1H1 - FIG.16B
FINAL ASSEMBLY SECTION L1L1
(WEIGH SPAN ROLLER) - FIG.17
INLET SPAN ROLLER SECTION -MM - FIG.18
FINAL ASSEMBLY SECTION -UU - FIG.19
FINAL ASSEMBLY SECTION - WW - FIG.20
CHECKING BAR - FIG.21
BAR-PULLEY LIFT ASSEMBLY - FIG.22
WEIGH SENSING SYSTEM - FIG.23
BELT SCRAPER ASSEMBLY - FIG.24
CHUTE ASSEMBLY - FIG.25

4
 INLET ROLLER ASSEMBLY - FIG.26
WEIGHING MODULE ASSEMBLY - FIG.27
DRAG LINK ASSEMBLY - FIG.28
LIGHT ASSEMBLY - FIG.29
WEIGH SPAN ROLLER ASSEMBLY - FIG.30
FINAL ASSEMBLY GREASE HOSE INSTALLATION - FIG.33
ALARM PADDLE ASSEMBLY-OUTLET - FIG.34
DRIVE PULLEY ASSEMBLY - FIG.35
TOOL-PULLEY REMOVAL - FIG.36
ALARM PADDLE ASSEMBLY - INLET - FIG.37

7. LIST OF ILLUSTRATIONS - (CONTD).

1 BELT HUMPING

2. TAKE-UP SQUARING & SKIRT CLEARANCE

3. CONVEYOR CHAIN TENSION ADJUSTMENT

4. WEIGHING ROLLER ALIGNMENT

5. SHEAR PIN REPLACEMENT

6. PADDLE ALARM ADJUSTMENT

7. TENSION ROLL REMOVAL

8. ROLLER REMOVAL

9. HEAD PULLEY REMOVAL

10. TAKE-UP PULLEY REMOVAL

I1. HEAD PULLEY - COUPLING GAP

12. BELT CHANGING - SPLICED BELT

13. BELT CHANGING - SPLICED BELT

14. BELT CHANGING - SPLICED BELT

15. SCHEME FOR BULLS EYE CLEANING

16. BLOCK DIAGRAM ELECTRONIC WEIGHING FEEDER

5
 1. INSTALLATION
1.1 RECEIVING INSPECTION
Upon delivery, inspect the equipment for shortages or evidence of physical damage and report
them to the independent carrier. Also notify the Commercial Department of BHEL to arrange
for the shipment of replacement parts.

1.2 STORAGE PROCEDURES

Provisions have been made to protect the equipment prior to shipment from the factory in the
event that prolonged storage at the jobsite is required. These storage procedures are provided
as recommendations to aid in maintaining the equipment in a warrantable and ready condition.

i. Storage areas shall be periodically inspected to ensure cleanliness. Discarded packaging

and trash shall be removed. Access shall be limited to authorized personnel. Upon
placing an item in storage and prior to it ensure closures are intact. Any defects in the
packaging may be repaired, after insuring that the packaged material is intact and
undamaged, using the original method of packaging. Surface preservatives may be
reapplied or touched up as required.

ii. Materials are to be stored in such a manner as to provide ready access for inspection and
maintenance with a minimum of handling. Items should be placed to allow any
markings or labeling to be easily identified without excessive handling.

iii. Shipping documents are attached to the outside of each crate to identify the equipment
contained inside. A file record shall be kept on the location of all items in storage.
Special periodic maintenance requirements, such as those in Section 1.3 should be kept
on record here.

iv. Feeders are shipped with Pliofilm coverings over the motors, gear reducers, feeder inlet,
seal air inlet, work light fixtures and the electrical compartment access doors. Inspect
and replace any damaged covering when the feeders are received and while they are in
storage.

v. Store feeders in an enclosed building. If it is necessary to store the feeders outside or in

a structure with open sides, a weatherproof, moisture and mildew – resistant covering
should cover the entire feeder. This cover should be vented, but drip proof, and arranged
to permit access to the drive motors. When stored in this manner, condensation may
form under this cover and under the Pliofilm. Desiccant should be placed under both
covers, inspected monthly, and replaced when necessary. Be certain that the feeders are
stored above any conceivable high water level and placed on timbers if the floor
condition is damp.

vi. Do not store other equipment on or about the feeders. Each feeder should be fully
accessible for service and inspection.

6
vii. Feeder accessories and crates containing miscellaneous hardware must be stored in a dry
area where installation take place.

viii. Electrical and electronics control enclosures are shipped wrapped in pliofilm and crated.
They must be stored in a heated, ventilated building where ambient temperature may be
controlled between 4o C minimum and 49o C maximum. Control enclosure access doors
shall be tightly closed to engage the sealing gaskets.

ix. Desiccants are provided to protect electrical control enclosures and all moisture
sensitive components from humidity. Desiccant indicator labels shall be checked at
monthly intervals and all desiccants whose labels have changed color from blue to light
red shall be replaced. Desiccant location tags are utilized to indicate the presence of
desiccants within the shipping/packaging materials used to protect the components
during shipment and storage. The location tags will be firmly attached to the exterior of
the component packaging material.

x. Inspect and service the feeders according to the following storage maintenance
procedures until equipment start-up.

1.3 STORAGE MAINTENANCE PROCEDURES

i. At each service interval, special care should be taken to remove only the crating and
pliofihn covers necessary to perform the maintenance and to replace them when
servicing is complete.

ii. MONTHLY, inspect feeders and control enclosures for damage to pliofilm covers,
damage due to corrosion or contamination, and for desiccant saturation.

iii. QUARTERLY, to avoid "shaping" the belt around the drive and take-up screws by a
maximum of four complete turns followed by a maximum of eight complete turns on the
opposite screw to prevent thread damage; and pull the belt to a different position. If the
feeder can be operated, operate it to reposition the belt.

iv. QUARTERLY, lubricate all bearings according to the instruction in Section 3.0 of this
manual.

v. ANNUALLY, change the oil in the gear reducers according to the lubrication
instruction in Section 3.0.

vi. ANNUALLY, lubricate the cleanout conveyor chain pins thoroughly with a rust
preventive lubricant or gear reducer oil.

7
1.4 EXTENDED STORAGE INSTRUCTION
i. An alternative method to changing oil in gear reducers when storage will exceed 12
months is to fill the reducers to the top with oil, which prevents the formation of
moisture. Since the vented oil fill port is lower than the top with of the reducer, remove
the dipstick and threaded pipe nipple projecting above the top of the reducer in its place.
After filling, seal the fill port extension with a non-vented plug.

Note: The oil must be reduced to normal operation level, and the extension removed
and replaced with the threaded tube assembly and dipstick prior to operation of the
feeder.

ii. For maximum belt life when storage will exceed 36 months, remove and store the feeder
belts per the maintenance procedure in Section 3.0 of this manual. Belts should be
stored on edge, protected from sunlight, in a cool, dry, ozone-free location. Belts should
be refolded every three months so that bends are in different places. Bends should be
made as large as possible.

1.5 INSTALLATION PROCEDURES ( Ref. GR. FEEDER ARRGT.

DRG)
Note: The tension roller and weigh roller are held by wooden blocking supported in
the tension roller access doorframe. This blocking must remain in position until after
the feeder has been bolted in its installed location.

Before installing the feeder, check the support steel for proper location of mounting
holes.

The following items of equipment are required for feeder installation: A 600 mm
carpenter's level, several pieces of 200 mm. square shim stock in various thickness, and
the feeder mounting hardware.

i. To install the feeder, it is necessary to remove the protective crating and some of the
pliofilm covers. Do not remove the covers from the motors and gear reducers.

ii. Place the feeder in position and insert the mounting bolts into the holes provided but do
not tighten nuts.

iii. Using the carpenter's level, check the lengthwise level on both sides of the feeder using
the two checking bars (Fig.21) placed across the weigh span rollers. Shim the feeder if
necessary by inserting shims adjacent to the mounting bolts.

iv. Level the feeder widthwise from the bottom of the weigh span roller nearest the inlet.

v. Should the feeder side plate rest on a solid support, add equal shims at all four corners to
raise the feeder sufficiently for the side plates to clear any bearing surface.

8
 Note: Add shims as required to solidly support the feeder at all four corners to avoid
twisting the feeder body when tighten the mounting bolts.

vi. Tighten the four mounting bolts in place.

vii. Erect the connecting equipment above and below the feeder. Flexible connections are
required to minimize the loading on the feeder.

viii Be sure that the valve above the feeder is closed. if the feeder is installed but the valve
or downspout above it is not, the feeder inlet must be covered. The covering should be
of a substantial material capable of excluding water, dirt, weld spatter and construction
debris.

ix. Install the seal air butterfly valve and air supply piping between the feeder seal air
connection and the clean air supply.

x. Install water supply piping between the two feeder spray valves and the clean water
supply.

xi. Install the alarm paddles for the coal on belt and feeder discharge alarms.

xii. Drain and refill the belt drive and cleanout conveyor drive motor gear reducers with
fresh lubricant.

xiii. Check all mechanical components. Clean off any corrosion and tighten any loose
connections found.

xiv. Install the free-standing feeder power cabinet assembly total weight integrator and
digital feedrate indicator in remote locations determined by the customer.

xv. Interconnect the feeder control cabinet with the power cabinet assembly.

xvi. Check all electrical components and contacts. Clean off any corrosion and tighten any
loose connections found.

Note: Before installing electronics cards, all field wiring for the feeder control system
must be checked and verified improper wiring may result in severe damage to the
electronics cards when power is applied.

xvii. Remove the electronics cards packaged separately, and install them into the cages.

xviii. Connect the belt travel sensor and load cells to the electronics card cage with the plug-in
connectors provided. Arrange the interconnecting cables away from the Cage mounting
area. Install the cable connectors into their mating receptacles located at the right side of
the cage. Verify proper connector alignment before tightening the two jackscrews on
each connector. Tighten the screws on each side evenly to avoid chocking of the plug,
and do not over tighten.

9
xix Clean out all debris from the feeder and from the equipment mounted above it. Make a
visual inspection of the feeder body and its control cabinet. Scratched or cracked glass
should be replaced to maintain explosion protection. Arrange for the replacement of any
damaged mechanical or electrical components from BHEL prior to start-up.

xx. Verify that ground lugs provided in each control enclosure are connected to ground
potential and structure of the plant.

Important: Personnel safety considerations require that electrical apparatus and

enclosures be connected to building ground.

xxi. Install 415 volt, 3-phase, 50 hertz 3 wire electrical service to the fused disconnect switch
(DS 1) and 240 volt, single phase service to the fused disconnect switch (CS 1). Both
components are located in the feeder power cabinet. If aluminum wire is used, all
exposed ends must be coated to prevent oxidation before the wire is connected to
terminals

xxii. Continue to follow the storage maintenance procedures described in Section 1.3
regularly until start-up.

xxiii. Notify BHEL one month in advance of the start-up date to permit scheduling of a
start-up engineer to the site.

Note: Do Not Energize The Feeder or Its Power Or Control Cabinets Until A BHEL
Service Engineer is Present.

10
 2. OPERATION
2.1 SYSTEM COMPONENT DESCRIPTION
The gravimetric feeder with electronic weighing is designed to supply required amount
of coal to the pulverizer while operating on a 415-volt 3-Phase, 50Hertz power supply.
Minimum and maximum capacities can be varied to suit the requirement of individual
contract. Operation of the principal feeder components is described below.

i) Feeder Body

Feeder design exceeds NFPA 8503 Code requirements and will withstand an explosion
pressure of 7 kg/cm2 (100 psi), All parts in contact with active coal flow are fabricated
of type 304 stainless steel. Side skirting is provided to contain the coal on the belt and a
leveling bar near the feeder inlet shears the coal column to form a profile conducive to
maximum weighing accuracy.

Dust-tight doors are provided at both ends and each side of the feeder for access to
critical components. Bullseye viewing ports in the doors permit observation of the
feeder interior during operation. A work light mounted above each end door is designed
to allow bulb changing from outside the feeder.

ii) Belt and Drive System

The feeder belt is supported by a machined drive pulley near the outlet, a slotted take-up
pulley and six belt support rollers at the inlet end, a weighted idler in the middle of the
feeder. A counterweighted scraper with replaceable rubber blade continuously cleans the
carrying surface of the belt after the coal is delivered to the outlet. Proper belt tracking is
accomplished by crowning the take-up pulley; in addition, all three pulley faces and the
inlet span roller are grooved to accept the molded V - guide in the belt. The pulleys are
easily removable for belt changing and bearing maintenance.

Belt tension is applied through downward pressure exerted by the tensioning idler on the
return strand of the belt. Proper tension is obtained when the round protrusion at the
center of the tension roll is in line with the center indicator mark on the tension indicator
plate. The tension roll indicator is found on the drive motor side of the feeder and is
visible through the viewing port in each tension roll access door. Tension adjustments
can be made with the feeder operating or at rest by turning the two belts take-up screws
which protrude through the inlet end access door.

Note: Changes in humidity or temperature may cause variations in belt length. Belt tension
should always be maintained within the two extreme marks on the tension indicator
plate.

The drive system for the belt consists of a 4-pole, 3-phase variable frequency drive
induction motor, coupled to a speed reducing gearbox. The motor is 7.5KW, 415V, 3ph,
50 Hz, totally enclosed, fan cooled motor. The feeder load appears to the system as a
low inertia, constant torque load.

11
 A 24-pole AC tachogenerator attached to the output shaft of the clutch provides a speed
feedback for the feeder system. This tachogenerator provides an output rated nominally
at 45V/1000 rpm and generates 12 pulses per revolution. Therefore, at a nominal 1500
rpm, the output frequency from the AC tachogenerator is 300 Hz

A paddle - type alarm (Fig-37) is mounted above the center of the belt to detect the
presence or absence of coal on the belt. The assembly consists of a stainless steel paddle
mounted on one end of a horizontal shaft and a dusttight switch housing on the other
end, accessible on the outside of the feeder. Multiple single- pole switches, depending
upon the number of functions requiring control, are mounted in the switch housing. The
switches are actuated by cam mounted on the end of the shaft inside the switch housing.
Loss of coal on the belt results in a contact changeover of limit switch LSFB. This
switch can be used to stop the belt drive motor, start bunker vibrator, or simply to
indicate a loss of coal to the control room, as directed by the customer. This contact
changeover also prevents weight correction and operation of the total coal integrator
when there is no coal on the total coal integrator when there is no coal on the belt and
prevents calibration when there is coal on the belt.

iii) Weight Sensing Components

The feeder weighing signal is generated by two load cells which support a weighing
roller. Located on each side of the weighing roller are two weigh span rollers, which
accurately define a given length of belt on which the coal is weighed. Each load cell is
scaled into a signal, which represents grains of coal per centimeters of belt. This weight
data contributes to the feedrate formula from which the feeder is operated

Weight (gms./cm) x belt speed (cm./sec.)= feedrate (gms./sec.)

iv) Cleanout Conveyor

Two strands of malleable iron drag chain with alternately- spaced wing links are used to
automatically clean coal from the bottom pan of the feeder. This prevents interference
with the belt and removes stagnant coal, which may otherwise ignite spontaneously. The
sources of coal in the cleanout area may be: coal falling from the belt scraper, coal dust
settling out of the air, coal removed from the self cleaning take-up pulley, or coal blown
off the belt by an improperly-adjusted seal air flow.

The cleanout conveyor is driven by 0.25 KW totally enclosed non- ventilated drive
motor through a 5-to- 1 ratio gearhead and a reduction gearbox to an operating speed of
approximately 60 cms per minute. It is recommended that the cleanout conveyor be
operated continuously with feeder operation to keep the coal in the bottom pan of the
feeder at a minimum since this coal is not weighed and will introduce an error into the
coal feedrate. Continuous operation also prevents a corrosive buildup on the links,
which may, after a long idle periods cause binding of the links and subsequent drive
overload.

In addition to electrical overload protection, a shear pin in the gearbox limits the output
torque to prevent mechanical overload and damage. Shear pin breakage results in
contact closure of limit switch LSCC, actuating a remote alarm annunciator supplied by
others.
12
v. Electrical controls for the gravimetric feeder are housed in a free standing remote control
panel assembly and in a feeder mounted local control panel assembly mounted to the
feeder adjacent to the drive motors. The principal components in each assembly are
described in the following text.
a) Remote control panel
The remote control panel houses the fused feeder disconnect switches for the 415 Volt ,
3-phase supply and for the 240 volt , single phase supply, the variable frequency drive
controller with overload protection for the belt drive and motor starter with thermal
overload protection for cleanout conveyor motors, the power transformer with fused
primaries and secondary for the feeder control circuit, the power transformer with fused
primaries and secondary for the MPGFC electronics, 240 volt convenience outlet ,
cabinet work light with switch, cabinet ventilation fan on/off selection switch, and
control relays for various functions. Schematic diagram to be referred for the details of
functions.
The disconnect switch operator is installed on the front face of the cabinet. The left-
front door contains a ventilation fan and a filter at the bottom for air inlet. This door also
contains key board display unit and a filter at the top for air exhaust. The right door
contains indication lamps, selector switch etc. Indication lamps are provided for various
fault conditions of the system. Feeder delivery rate, drive speed, feed rate demand etc are
indicated in the vacuum flourescent display of the MPGFC key board display unit.
Please refer to C&I portion of the manual for further details.
b) Local control panel
The feeder mounted local control panel contains the signal conditioning module,
selector switch for feeder worklights, feeder Forward / Reverse operation. Indication
lamps for Feeder OFF, Feeder RUN etc.
The 3-position selector is locked in the FORWARD position to effect forward feeder
belt travel. A key must be inserted to unlock the FORWARD position whenever the
OFF or REVERSE mode is being selected . Selector switch-MSL can cause the feeder
belt to travel in either direction by selecting the mode select through the GFC key board
on the remote control panel.
This 2-position selector switch energizes the feeder work lights. Within the feeder body
when placed in the ON position and de-energizes the work lights when positioned in the
OFF position.
Indication lamps for Remote, Local, Calibration, Feeder Run Forward, Feeder Run
Reverse, Feeder OFF, Cleanout conveyor RUN, Cleanout conveyor OFF, Bunker No
Coal Flow (as applicable) are provided in the local control panel.

2.2. WEIGHING SYSTEM ELECTRONICS

i. Microprocessor based gravimetric feeder controls (MPGFC) makes use of load cell
weighing, belt speed measurement by tachogenerator and dedicated feeder logic to
obtain reliable and accurate feed rate control.

Feed rate = Weight (kg/m) x Belt speed (M/s)

The weight signal is measured by the Load Cell and drive speed is measured by
tachogenerator mounted on eddy current clutch output shaft or VFD motor as applicable.
For further details C&I portion of this manual shall be referred.

13
ii. Modes of Operation Of Feeder

The feeder control logic has capability to operate the feeder in either of two modes as
below
a) Gravimetric mode:- In this mode (REMOTE selection of feeder mode thro key
board) the feeder is under combustion control which decides the feedrate required
and compares it with actual feedrate: the error being used to correct the belt speed
to achieve the required feedrate.
b) Volumetric mode:- This feature allows the feeder to operate if there is a fault in
weighing electronic components or when feeder is selected for local operation.

3. SERVICE TOOL KIT

The special tools listed below are supplied to assist the maintenance staff during
adjustment, calibration and service of the feeder. It is recommended that the tools be
stored in the container of their original shipment when not in use.

a. Two checking bars (Fig.21) are used in the weighing roller adjustment procedure to
maintain alignment between the weighing roller and the two-weigh span rollers.

b. A pulley removal tool allows the service technician to slide the drive pulley and
tensioning idler into and out of the feeder when belt changing is necessary. (Ref. Fig.36)

c. The pulley lift bar raises and supports one end of the drive pulley so that the pulley
removal tool may be inserted between it and the belt. (Ref. Fig.22)

4. FEEDER OPTIONS PROVIDED

i) Seal Air Connection (Ref. Gr. Feeder Arrgt Drg)

Feeder operating under positive pressures require seal air to prevent hot air from flowing
back up to the discharge and into the feeder. The quantity of seal air flow required is an
amount equal to the air flow loss into the bunker, plus the amount to create a 6 mm
minimum, 25 mm maximum of water pressure differential between the feeder and
pulverizer inlet.

Insufficient airflow and loss of pressure differential will allow hot air and coal dust to
back up into the feeder from the pulveriser. The coal dust will settle on doorsills and
other edges and may ignite spontaneously. Excess seal air flow, on the other hand, may
result in blowing coal off the belt, creating loss of accuracy and, in servere cases,
overloading the cleanout conveyor. Excess air can also cause a "frosting" of the interior
of the viewing ports and abrasion and failure of grease hoses in the interior of the feeder.

Seal air is supplied to a orifice located beneath the feeder inlet on the side opposite the
drive motors. A butterfly valve is required for flow control and shutoff. The valve may
include an adjustable stop, which is set during start-up. If the valve must subsequently

14
 be closed, it can then be reopened to the same position without recalibration.
Manometer connections are provided on the feeder body for calibration.

ii) Feeder Discharge Paddle Alarm (Fig.34)

An alarm paddle is mounted in the feeder outlet to detect the presence of coal plugging
the discharge. As the coal backs up to the level of the paddle, it pushes the paddle
toward the feeder end plate and closes the contacts of limit switch LSFD, stopping the
belt drive motor. The alarm consists of a stainless steel paddle mounted on one end of a
horizontal shaft and a dusttight switch housing on the other end, accessible on the
outside of the feeder. Adjustable cams on the end of the shaft actuate single-pole
switches mounted in the housing.

iii) Reversing Belt Drive Motor

A reversing motor starter enables the feeder belt to be driven forward, for normal
operation, or in reverse. Reverse operation is a safety feature to quickly discharge
burning coal from the feeder or to clear the belt in the event of a pulverizer failure.
Reverse can also be used to conveniently remove coal from a bunker through a
temporary discharge chute (FIG. 25) attached to the inlet end of the feeder, or to
facilitate removal of an interior pluggage or obstruction. A REVERSE/
OFF/FORWARD selector switch (FRSL) on the exterior door of the remote control
panel is used to control the direction of belt travel.

Note: When bunker emptying by reverse rotation of the feeder belt is resorted to, it must be
ensured that the belt is tracking properly during reverse rotation. If not, the take up
screws are to be suitably adjusted and proper belt tracking ensured before bunker
emptying by reverse rotation is commenced This is necessary to avoid damage to the
belt due to sliding of belt to one side because of improper tracking. After completion
of bunker emptying by reverse rotation, the take up screws are to be readjusted for
proper tracking of the belt in forward direction.

iv) Water Spray Nozzles

Spray nozzles are provided above the belt at both the inlet and discharge ends of the
feeder for application of water onto the belt in case of a fire inside the feeder. Two
Connections are provided on the exterior of the feeder body for water piping.

15
 5. START-UP
i) Preliminary Start-up Measures

a. If the bunker is empty, open and close the valve above the feeder to deposit any foreign
material in the bunker or downspout on the feeder belt.

Caution: Before attempting any work inside the feeder, de- energize the electrical
control center at the feeder selector switch and at the main disconnect.

b. Open all feeder doors and remove all debris from on the belt and inside the, feeder.

c. Remove the blocking and tape, which was used to secure the load cells tension roller
during shipment.

d. Check to make sure there is a 75 mm. to 100 mm. sag in the cleanout conveyor chain.
Adjust accordance with the instructions in Section 6.4 if necessary.

ii) Storage Maintenance After Start-up

Follow the procedures below for feeders that have been started up and must be stored in
place for an anticipated duration of a year or less.

a. Remove all coal from the equipment between the bunker and the pulverizer.

b. Clean inside of the feeder thoroughly and, when it has dried, paint inside feeder with
rust preventive paint.

c. Cover the top of the bunkers to prevent any moisture or foreign objects from
contaminating the equipment. This cover should be permanent and substantial.

d. Clean all dust, dirt and moisture from the power and control cabinets. Place desiccant
bags in the cabinets and tightly close the access doors. Also place desiccant in the feeder
near limit switches and electrical control components to prevent corrosion.

e. MONTHLY, operate the feeder in the LOCAL mode, with the calibrating weight
engaged, for at least an hour. Also during this time operate the cleanout conveyor.

f Follow the storage maintenance procedures detailed in Sections 1.3. (iv) through
1.3.(vi).

iii) Extended Storage After Start-up

Follow the procedures below for feeders that have been started up and must be stored in
place for an anticipated interval of more than a year.

a. Follow the storage maintenance after start-up procedures detailed in Section 5

16
b. Block up the tension roller to remove tension from the feeder belt.

c. MONTHLY inspect feeders and control enclosures for damage due to corrosion or
contamination, and for desiccant saturation.

d. To avoid "shaping" the belt around the drive and take up pulleys, remove additional
tension from the belt by loosening the belt take-up screws by a maximum of four
complete turns followed by a maximum of eight complete turns on the opposite screw
to prevent thread damage; and pull the belt to a different Position following each
inspection.

For maximum belt life when storage will exceed 36 months, remove and store the feeder
belts as per the maintenance procedure in Section 6.0 of this manual. Belts should be
stored on edge, protected from sunlight, in a cool, dry, ozone-free location; Belts should
be refolded every three months so that bends are in different places. Bends should be
made as large as possible.

e. QUARTERLY, lubricate all bearings according to the instructions in Section 6.0 of this
manual.

f. An alternate method to annually changing oil in gear reducers when storage will exceed
12 months is to fill the reducers to the top with oil, which prevents the formation of
moisture. Since the vented oil fill port is lower than the top of the reducer, remove the
dipstick and threaded tube assembly from the fill port and install a threaded pipe nipple
projecting above the top of the reducer in its place. After filling, seal the fill port
extension with a non- vented plug.

Note:The oil must be reduced to normal operating level and the extension removed and
replaced with the threaded tube assembly and dipstick, prior to operation of the
feeder.

g. ANNUALLY, lubricate the cleanout conveyor chain pins thoroughly with

rust-preventive lubricant or gear reducer oil.

iv) Initial System Operation

Follow these special operating instructions the first time the feeder is energized to
operate according to typical operating procedures.

a. Be sure that the calibration weights are dis-engaged from the load cells.

b. Carefully load coal onto the feeder belt: slowly open the coal valve to load the belt at a
controlled rate. This procedure minimizes compaction of the material and thereby
reduces the force necessary to start the belt moving, which prolongs its life.

c. When first placed on line, the feeder should be operated with full tension on the belt for
an hour to remove its initial stretch. During this time, belt operation must be closely
observed and tension corrected after each 15 minutes. After the first hour, return the belt
to proper operating, tension by observing the tension indicator (Ref, Section 6.3 (i)).

17
d. With the feeder in operation and when the bunker has been filled with coal and the
pulverizer is operating, adjust the seal air flow to pressurize the feeder. Install a
monometer temporarily at the tap indicated on Fig 31/32. Open the seal air connection
butterfly valve until a pressure of 6 mm water is achieved. Observe the feeder interior
through the viewing ports in the outlet end access door. If coal dust is moving slowly
toward the outlet, the pressure differential is satisfactory. If the dust is stationary or is
rising from the outlet open the butterfly valve further until the dust shows positive
movement toward the outlet, but do not exceed a pressure differential of 25 mm water.
Remove the manometer and adjust the stop on the, butterfly valve (VBU 3) so that when
the valve is closed it can be reopened to the same position without a recalibration
procedure.

v) Typical Operating Procedures

a. When filling the bunker with coal, first close the inlet coal valve to minimize the
filling pressure on the feeder and to avoid compaction of the coal at the feeder inlet.
This precaution is unnecessary if the bunker is refilled while at least 2.4 to 3 meters of
coal remain in it.

b. When starting the feeder, open the inlet coal valve slowly to load coal on to the belt at a
controlled rate and to minimize its compaction at the feeder inlet.

c. Energize the feeder control panel and observe FEEDER OFF indication in the MPC
keyboard at the remote control panel.

d. Turn the FEEDER MODE selector switch (MSL) to the REMOTE position, the belt
travel selector switch (FRSL) to the FORWARD position. Upon receipt of a demand
input from the combustion control system, feeder operation begins and the FEEDER
RUN indication in the MPC keyboard energized.

e. As coal fills the feeder belt, the FEEDING COAL indicator is energized.

f. Manually turn the CLEANOUT CONVEYOR selector switch (CSS) to the

CONTINUOUS position.

g. The feeder will operate as outlined above and will respond automatically to the
changing demands of the combustion control system until it is de-energized.

h. For a brief feeder stop with coal on the belt, turn the feeder mode selector switch (MSL)
to the OFF position.

i. For a clean shutdown with no coal on the belt. Close the inlet coal valve while the
feeder is still running. When the belt is emptied of coal, the feeder will be de-energized
by the coal on the belt paddle alarm. Then turn the feeder mode selector switch (MSL)
to the OFF position. This procedure is recommended
Whenever the feeder will be inactive for more than a brief interval, since it eliminates
the possibility of coal compaction at the feeder inlet due to consolidation caused by its
own weight.

18
j. To operate the feeder in the LOCAL mode, turn the feeder mode selector switch
(MSL) to the local position: then turn the local mode selector switch (FRSL) to the
FORWARD position for as long as operation is desired.

k. The feeder is equipped with a reversing motor starter, which enables the belt to be
driven forward, for normal operation, or in reverse. Reverse operation is a safety feature
to quickly discharge burning coal from the feeder or to clear the belt in the event of a
pulverizer failure. Reverse can also be used to conveniently facilitate removal of an
interior pluggage or obstruction.

To access the reverse, turn the feeder mode selector switch (MSL) to the OFF position.
Turn the belt travel selector switch (FRSL) to the REVERSE position. Then turn the
feeder mode selector switch (MSL) to the LOCAL position and the local Mode switch
(FRSL) to the REVERSE for as long as operation is desired.

Note: when the feeder is scheduled for a period of inactivity, do not disconnect the 240- volt
power supply at switch DS. This power service must remain available to energize the
electrical cabinet.

19
 6. MAINTENANCE
6.1 Inspection And Adjustment Schedule

Periodic inspection, adjustment and calibration of the feeder is essential to its safe,
reliable and efficient operation, and to ensure that it operates according to the
engineering design criteria.

Warning: Before attempting any work inside the feeder, it must be de- energized at the
selector switch, and the main circuit breaker must be locked in the off position.

Daily Inspection Check belt tracking.

Weekly Inspection Check belt tension

Check belt for tears or gouges
Check oil level in gear reducers.

Monthly Inspection Perform monthly lubrication service.

Quarterly Inspection Change gear reducer oil.

Perform quarterly lubrication service.

Semiannual Inspection At Shutdown For Servicing:

1 Check all rotating parts for evidence of bearing failure or gear wear.

2. Check feeder for excessively worn or corroded parts.

3. Check freedom of weigh system (drag links, load cells, rollers).

4. Check belt for signs of excessive wear.

5. Check belt scraper for wear and proper operation.

6. Clean load cell modules.

7. Clean any corroded electrical contacts and check wire terminals for tightness.

8. Remove any coal build-up on the inside of the feeder body.

9. Check inlet side skirts for positioning and wear.

10. Perform semiannual lubrication service.

11. Check cleanout conveyor chain tension and free any binding links.

12. Calibrate the feeder.

20
Additional Periodic Inspection Considerations:

1. Inspect newly-installed belts for proper tension and tracking two to three per shift until
the belt is stabilised and has lost its initial stretch; thereafter, inspect weekly.

2. Inspect the weighing roller whenever the load cell modules, belt, or weigh span rollers
are changed or serviced.

3. Any time the feeder end doors are removed, take the opportunity to inspect the cleanout
conveyor.

Note: In addition to the six-month feeder calibration frequency, the feeder must be
recalibrated whenever one of the following changes are made: adjustments of weigh
roller, belt changing, or load cell module replacement.

6.2 Lubrication Guide (refer Drgs)

The gravimetric feeder lubrication guide includes Lubrication Diagram (3 sheets) which
pictorially locates the points requiring lubrication requirement schedule, which
correlates the point code locations with their descriptions, lubrication interval and
advisory notes. The guide also includes recommended specifications of lubricants and a
partial listing of lubricant suppliers with the trade names of their appropriate products.

LUBRICATION NOTES

1. All old grease must be flushed.

2. If changing to new grease, consult the lubricant supplier to verify its compatibility with
the former grease. Some grease are incompatible with others, resulting in possible
bearing failure. If any doubt exists about their compatibility, the former grease must first
be flushed or cleaned out completely. The feeder has been factory-lubricated with
SERVOGEM EP2. Lithium-Lead base grease.

3. The motor is factory-lubricated for life and does not require periodic re-lubrication
while in service. At maintenance disassembly, refer to the vendor literature for
lubrication requirements.

4. Grease fittings and plugs for the input and pilot bearings are internal. Re-lubrication
must be performed with power off and rotation stopped. For access to grease fitting,
remove the screen and rotate the shaft until the fittings appear.

5. Drain and refill after the first month of operation; thereafter, at 6 months intervals or
every 2500 hours of operation, whichever occurs first.

6. If changing to new oil, consult the lubricant supplier to verify its compatibility with the
former oil. A.G.M.A. compounded and rust - and oxidation – resisting gear oils are
generally compatible with each other. If any doubt exists about their compatibility, the
gearbox must first be drained and flushed with the new oil to remove all traces of the
previously used oil.

21
7. Lubricant manufacturer's storage instructions must be followed to avoid separation of
compounds.

Grease Specifications

A premium quality, multipurpose, EP2 grade grease designed for long bearing life and
formulated to provide protection against rust, corrosion, oxidation, and water washout
shall be used. It should provide good lubrication protection without excessive thinning
or thickening in an operating temperature range of -260 C (-150 F) to 1210 C (2500 F).
While no bearings are loaded heavily enough to require extreme pressure additives,
most premium quality multipurpose greases contain them and they may provide extra
wear protection in cases where grease is not applied often enough or in sufficient
quantity.

6.3 FEEDER ADJUSTMENTS

To maintain maximum weighing accuracy, the following factors are essential: proper
belt tension, proper belt tracking, proper alignment of weighing and weigh span rollers,
feeder recalibration after every six months of operation, and adjustment of seal air to a
minimum positive air pressure in the feeder body.

i) Belt Tension

Belt tension can be adjusted most efficiently while the feeder is operating. Check for
proper belt tension by observing the belt tension indicator through the viewing port in
the tension roll access door on the drive motor side of the feeder. The projection in the
center of the tension roll bearing cap should oscillate with equal travel above and below
the midpoint of the tension indicator. Adjust tension, if necessary, by turning the belt
take-up screws protruding through the inlet end access door. They may be adjusted with
the door open or closed.

Adjustment should be accomplished by turning both adjustment screws equally in the

same direction. When tension adjustments are made, each screw must be tightened or
loosened by a maximum of four complete turns, followed by a maximum of eight
complete turns on the opposite screw, to prevent thread damage. This procedure may be
repeated or reversed until the desired tension has been achieved.

Note: A new belt should be run in under full tension for at least an hour to remove its
initial stretch. If the feeder must be returned to operation immediately, belt operation
must be closely observed for at least an hour. Belt tension should be corrected after
each 15 minutes of running time, then return the belt to proper operating tension
using the tension indicator.

ii) Belt Tracking

The purpose of belt tracking is to center the belt on the drive and take-up pulleys. This
prevents possible damage from the belt running off the pulley sides. It also allows
smooth, uninterrupted movement of the belt through the weigh span area, so that
weighing accuracy is not compromised.
22
The underside of the belt has a "V" guide molded in its center, which rides in grooves in
the center of each pulley and roller to aid in keeping the belt centered. If the belt is not
tracked property, the "V" guide will begin to ride on one edge of the groove, causing a
hump to become evident on the top of the belt. A properly-tracked belt will have no sign
of humping on the weigh roller or weigh span rollers, and no more than a slight hump
occurring intermittently at the drive or take-up pulley. If regular humping is present at
one of the pulleys, or intermittent humping at one of the rollers, the belt requires
tracking adjustment.

Belt tracking is primarily accomplished by crowning the take-up pulley. A belt turning
on a crowned pulley will seek the highest point, the pulley center, unless the belt slips
sidewise. Tightening the take-up adjustment screw on the right side will shift the
centerline of the pulley to the left, causing the belt to move to the left on the take-up
pulley until it again centers on the crown. Similarly, tightening the take-up adjustment
screw on the left will cause the belt to move to the right.

Tracking of the belt on the drive pulley is also accomplished by adjusting the take-up
pulley screws. This causes the belt to move to its new centerline, which in turn, causes it
to move sidewise on the drive pulley. The distance the belt will move on the drive
pulley as a result of adjusting the take-up screws will vary and must be determined in
each application by trial and error.

a. Tracking Procedure: Feeder Not in Operation

It is preferable to perform tracking adjustments when the feeder is not in operation. This
way, the belt can be run empty with the doors open so that the top surface is readily
visible for evidence of humping.

* Open the feeder end doors-and turn on the work lights.

* If the belt has just been replaced, verify that the take-up pulley is square. (See
Illustration 10.)

* Adjust belt tension per Section 6.3. (i).

* Make a chalk mark across the width of the belt surface to indicate a complete
revolution of the belt. Start up the feeder and operate it at slow speed. Observe the
belt closely for at least 5 revolutions for signs of humping. Operate the feeder at
maximum speed for at least 20 belt revolutions. If no humping appears, the belt
can be considered properly tracked.

* In the event that humping occurs at the pulleys, the belt is first tracked on the
drive pulley. Tighten one turn on the appropriate take-up pulley tensioning screw
to steer the belt in the desired direction. The effect of this adjustment should be
observed for at least 5 belt revolutions at slow speed. If no humping appears,
operate the feeder at maximum speed for at least 20 belt revolutions. Continue this
procedure until the belt is properly tracked on the drive pulley.

23
 Notes: Certain belts will show a back-and-forth travel pattern on the drive pulley.
Adjustments should be made to average this movement in the center of the pulley. If
tracking adjustment have been made to the take-up pulley, recheck the tracking of the
drive pulley and readjust it if necessary.

* After tracking adjustments are complete, readjust belt tension to the midpoint of
the tension indicator

b. Tracking Procedure: Feeder On Line

Humping of the belt is not visible through the viewing ports when the feeder is in
operation and feeding coal. Close observation of the distance between the belt and
pulley on each side must be made. The distance between these two points must remain
equal on both sides of the pulley.

If a tensioning adjustment is necessary, observe the belt closely throughout: Since the
belt may be traveling at a high speed, an adjustment in the wrong direction may quickly
cause the belt to run off to the point where it can be damaged. If the wrong adjustment is
made, an opposite adjustment to compensate must be made immediately.

After tracking adjustments are complete, readjust belt tension to the midpoint of the
tension indicator.

iii) Inlet Side Skirts

Inlet side skirts should be mounted plumb, parallel to the belt, with no interference to
the belt curbs. Clearance between the side skirts and the top surface of the belt must
increase in the direction of coal flow in order to prevent coal from being trapped
between the skirt and belt. Clearance at the inlet end should be 6 mm to 10 mm and
increase to 10 mm and 12 mm at the discharge end.

iv). Weighing Roller (See Illustration 04)

The alignment between the weighing roller and the two weigh span rollers should be
within ±0.05 mm on each side for weighing accuracy.

a. Lower the calibration weight into position.

b. Insert the checking bars through the inlet end access door of the feeder, adjacent to
the sides of the belt, and with their machined surfaces at the weigh span and
weighing rollers.

c. Beginning on either side, insert a 0.12 mm shim between each roller and the
machined surface of the checking bar (3 places).

d. Loosen the jam nut, then turn the adjustment block to lower the weighing roller.

e. Slowly turn the adjustment block to raise the weighing roller until the shim
tension at all 3 points is equal. Then tighten the jam nut.

24
 f. Similarly adjust the weighing roller on the opposite side of the feeder.

g. Remove the checking bars and raises the calibration weight.

h. The feeder must be recalibrated after weighing roller adjustment. Refer to the
procedure in electrical portion.

v) Cleanout Conveyor

a. Improper Operation

Under normal operating conditions, the bottom pan of the feeder should be visible with
only a small accumulation of coal in front of the wing links. Improper operation occurs
when an excessive coal build-up overloads the drive system. Possible causes to be
checked are: improper inlet skirt clearances, worn or malfunctioning belt scraper, and
excessive seal air flow blowing coal off the belt.

b. Chain Tension Adjustment

Chain tension is adjusted by tightening the screw attached to each end of the take-up
sprocket, accessible through the feeder inlet end door. A 75 to 100 mm sag in the chain
from the drive end to the first chain support pan indicates proper tension. Since chain
stretch is very slow, re-tensioning is only necessary every 3-4 year under normal
operating conditions.

c. Shear- Pin Replacement

In addition to electrical overload protection, a shear pin is installed in the worm

reduction gearbox to limit the output torque and prevent mechanical overload and
damage. Shear pin breakage results in a contact closure, stopping the drive. For
replacement, refer to illustration 05

Caution: Electrical voltage may be present at shear pin switch connections. Use
extreme care when working in this area.

* To replace the shear pin, remove the worm gearbox outer cover.

* Remove the hex head bolt in the center of the cone-shaped torque hub.

* Remove the torque hub and the broken shear pin hex head.

* Remove the sheared pin half from the bushing on the worm gear shaft, using a
magnet.

* Inspect the cleanout conveyor system for the cause of the overload and correct as
required.

25
 * Check for proper drive operation by removing the retaining ring and spring
retainer washer from the torque hub and installing the torque hub backwards. It
should be possible to rotate the torque hub slightly by hand. This movement will
allow for alignment of the torque hub and worm gear shaft during shear pin
installation.

* Remove the torque hub and install it in the proper direction, aligning the shear pin
holes at this time.

* Install the new shear pin, rotating the torque hub to align it with the shear pin hole.

* Install the spring and spring retaining washer using the hex bolt to compress the
spring.

* Install the retaining ring and back the hex bolt out 9.5 mm to allow the torque hub
to move out and trip the alarm switch when the shear pin breaks.

* Replace the gearbox outer cover.

* Return the cleanout conveyor to operation.

vi) Paddle Alarms

a. Coal On Belt Paddle Alarm (LSFB) (See illustration 6 Figure No. 1)

* Raise the paddle in the direction of coal flow and insert a 38 mm thick measuring
block between the paddle and belt.

* Ensure switch contacts have just closed.

* Remove the measuring block.

b. Feeder Discharge Paddle Alarm (LSFD) (See illustration 06, Figure No.2)

There are two possible mounting locations for this alarm, depending upon design
considerations:

For alarms mounted close to the feeder discharge end plate (as shown in location 1)
move the paddle toward the end plate, insert a 38 mm thick measuring block between
the paddle and end plate, and fasten it there.

For alarms mounted away from the end plate (as shown in location 2), move the paddle
toward the inlet end until it is 38 mm from its normal vertical position, and fasten it
there.

* Ensure switch contacts have just closed.

* Remove the measuring block.

26
vii) Belt Changing: Endless Belt

Warning: Before attempting any work inside feeder, power to the feeder must be shut off
at the selector switch and main circuit breaker.

a. Close the valve above the feeder inlet and remove all coal from the belt.

b. Open all feeder body access doors.

c. Insert blocking beneath the tension roller arms to raise the roller from the belt and
to support its weight.

d. Remove the belt tension indicator from the drive motor side access doorsill.

e. Disconnect the grease hoses to the tension roller.

f. Disconnect the weighing roller drag links on both sides of the feeder by removing
the support rods pins fastened to the tension roller doorframe.

g. Remove the hardware connecting the support rods and calibration weight to the
bearing housing.

h. Remove the weighing roller and drag links through the tension roller access door;
then remove the calibration weight.

i. Loosen the take-up pulley adjusting screws to provide maximum belt slack. This
is accomplished by first turning the take-up screw on one side four turns
maximum turn turning the opposite screw eight turns. Continue alternating at
eight turns per side to the stop points. Do not use an impact wrench. Insert the
pulley removal tool beneath the tension roller and bolt it to the access doorframe.
(See Illustration 07)

k. Disconnect the tension roller bearing housing from its support arms, allowing the
roller to rest on the pulley removal tool.
l. Remove the tension roller from the feeder by sliding it out on the pulley removal
tools.

m. Disconnect both weigh span roller from the bearing housings from one side of the
feeder and remove the rollers with bearing assemblies still attached.

n. Remove the inlet span roller bearing retainer plate from one side of feeder and
remove rollers with opposite bearing assemblies attached.

o. Properly tie back the belt scraper.

p. With reference to illustration 09, install the pulley lift bar at the feeder discharge
access door and adjust it to support the weight of the drive pulley on the end
opposite the drive motor.

27
 q. Remove the drive pulley dead end bearing cover. The bearing catridge remains
attached to the pulley shaft.

r. Insert the unflanged end of the pulley removal tool into the bearing cover port.
Push the tool between the belt and pulley until the unflanged end is supported by
the counter bored hole at the pulley drive end. Bolt the flanged end to the feeder
body using bolts from the pulley bearing cover.

s. Remove, in order, the pulley lift bar assembly, the drive pulley, and the pulley
removal tool.

t. Remove the inlet end skirt.

u. Remove the bolts holding the take-up pulley adjusting screw housings to the upper
and lower bearing slide rails.

v. Disconnect the take-up bearing grease hoses from the feeder body.

w. Remove the, take-up pulley, with its adjusting screw assemblies, from the feeder
body; then remove the remainder of the belt.

x. Install the new belt by reversing this procedure and by following the installation
notes below.

Belt Installation Notes

1 Install the belt to operate in the direction of travel indicated by arrows on the belt.

2. Maintain 3.2 mm between drive pulley coupling halves when the drive pulley is
replaced. The coupling half with drive studs remains on the reducer when it is removed.
(See Illustration 11)

3. Center the belt before it is tensioned so that the bottom "V" guide is seated within the
groove on all pulleys and rollers.

4. Square the take-up pulley with feeder by maintaining equal distances from the end of the
bearing side rails to the bearing housings. (See Illustration 10)

5. Perform belt tensioning adjustments per section 6.3. (i)

6. Perform belt tracking adjustments per section 6.3. (ii)

7. Calibrate the feeder per the procedure in Electrical Section

viii) Belt Changing: Spliced Belt

Note: This procedure is provided in the event that the endless belt supplied with the feeder
must be temporarily replace at a later with a mechanically spliced belt

28
a) Close the valve above the feeder inlet and remove all coal from the belt.

Warning: Before attempting any work inside the feeder, power to the feeder must be
shut off at the selector switch and at the main circuit breaker.

b) When removing an endless belt that is no longer usable, cut the belt and remove it
through one of the feeder end doors. When removing a spliced belt that may be used
again, operate the belt drive motor to position the splice in the belt in the middle of the
tension roll access doors.

c) Open all feeder body access doors.

d) Loosen the take-up pulley adjusting screws to provide maximum belt slack. This is
accomplished by first turning the take-up screw on one side four turns maximum, then
turning the opposite screw eight turns. Continue alternating at eight turns per side to the
stop points. Do not use an impact wrench.

e) Before attempting to remove the flex cable in the belt splice, spray the spliced area with
a penetrating oil to loosen the cable inside the belt. This will prevent the cable from
breaking as it is being removed.

f) Remove the flex cable from the belt. Ibis task is made easier if a second man works the
belt up and down from the opposite side access door as the cable is being pulled.

Note: Before installing the new spliced belt, make sure that the flex cable will pass through
both ends of the belt easily and that a washer is placed at the end of the flex cable
opposite the lead wire.

g) Attach the new belt to the old belt and pull the old belt out of the feeder as the new one
is being installed. Position the new belt so that the splice is outboard of the take-up
pulley.

h) As shown in illustration 12, insert a temporary wooden or metal support through the
side access door and beneath the belt. Resting on the door frame, this will support the
belt and eliminate sag.

i) Using strips of wood as a buffer between the belt and clamps, clamp the belt to the
take-up pulley above and below the splice. (See Illustration 13) Position the clamps far
enough apart so that some slack exists for alignment of the splice.

j) Manually mesh the belt splices together and insert the lead wire through the splice.

k) Pull the flex cable itself through the connecting belt splices, and cut the lead wire so that
approximately 5 cm protrudes from the area of the splice

l) Slide the furnished retaining washer over the cable and into the notch of the belt. Refer
to Illustration 10. Crimp the washer tightly into place.

29
m) Remove the clamps and buffer strips from the take-up pulley, and the belt support from
the side access door.

n) Refer to Belt Installation 6.3 to properly adjust the belt and calibrate the feeder to it.

Important: Replace the temporary mechanically-spliced belt with an endless belt

as soon as possible. The mechanical belt splice seriously compromises the accuracy
of the electronic weighing system.

ix. Seal air

Adjust the amount of seal air applied so that the feeder to pulverizer pressure differential
6 mm water column minimum, and 25 mm water column maximum. A manometer can
be used to check this differential. (For location of the manometer tap in the feeder body,
refer to Fig 31 & 32)

When the pressure differential has been adjusted, make similar adjustments to the stop
on the butterfly valve so that the calibrated setting is retained when the valve is closed
and reopened.

6.4 Troubleshooting Guide

i) Load Cells

a. Verify that the load cell live end and are properly oriented.

b. Verify that there is one, and only one, load path. This load path must be through
the load axis of the load cell.

c. Verify that the excitation (input) voltage is at the specified value. Load cells are
rated for 3 mV/V with a supply typically of 10 V. Therefore, with a full (45 kg.)
load, the load cell output should be 30 mV ±10%.

d. Check the bridge circuitry and zero balance with an ohmmeter having 0.1ohm
resolution in the range of 200 to 400 ohms. (See Drgs. 4-95-485-05143 &
4-95-485-05144)

First test the bridge circuit by measuring the resistance across opposite corners of
the bridge. RAD and R BC in Fig 1 in drg no. 4-95-485-05143 should both be 350
±3.5 ohms.

Next, measure and record the resistance across each leg of the bridge at points
RAB, RAC, RBD and RCD in Figure 2 in drg no. 4-95-485-05143.

Use these resistance values to compute the unbalance of the bridge, which is
indicative of the general condition of the load cell. The computed unbalance is
determined as follows:

Unbalance = 1.4 (R AC – R AB + R BD - R CD)

30
 % Zero Offset = (m V/V Unbalance) x 100
(m V/V @ Rated Output)

It ohmmeter resolution is 0.1 ohm, then a computed zero balance of greater than
20% is a clear indication of overload. A computed zero balance of 10 to 20% is an
indication of probable overload. Overloading may result in permanent deformation
of the load cell flexural element. Specification performance and cyclic life of the
load cell would be altered as a result.

e. For a zero balance of less than 20%, the readings should be verified using a
transducer indicator. A zero reference point must first be established for the
instrument by shorting the signal leads to provide a zero reference signal. Once
instrument zero has been established, plug in the load cell and read zero with no
load applied to the cell. The difference between instrument zero reading, and load
cell zero reading divided by the difference between instrument reading at rated
load for the load cell, load cell zero, should be within a range of ±1%. If the load
cell zero falls outside this range, the cell has probably been overloaded and should
be replaced.

f. Test load cell insulation resistance with reference to Figure 3. in drg no.
4-95-485-05143. If a standard ohmmeter is used and the resistance is beyond its
range (10 megohms), the load cell may be considered satisfactory.

g. Megohmmeter, limited to 50 V, may be used to give more certain results of

insulation resistance. In this test, all corners of the bridge must be tied together or
a good load cell bridge may be damaged. Low ground resistance (below 5000
megohms) is often caused by moisture or pinched wires.

31
 8. Recommended Spares For 2 To 3 Years Operation

- For 36" Inlet, 7' C.D.

MPGFC gravimetric feeder

SI. Description BHEL Ref. No. Quantity/

No. Boiler

Head Pulley And Drive Assembly

I Head Pulley 1-65-736-00165 1

2. Head pulley bushing GF - 061 28
3. Head pulley GF-059 2
4. Head pulley grease seal GF-066 2
5. Head pulley wear sleeve 4-65-736-00568 2
6. Half coupling 1-65-736-00167 1
7. Drive study 4-65-736-00343 14
8. Key for half coupling 4-65-736-00517 2
9. Head pulley 'O' -Ring GF-031 3
10. Main drive motor 1
11. Main drive gear box - 1
12. First stage helical gears
of main drive gear box - 1 set
13. Worm wheel and worm shaft - 1 set
14. Lubrication pump of
main drive gear box - 1 set

Belt Take-up Pulley Assembly:

15. Belt take-up pulley 1-65-736-00256 1

16. Belt take-up pulley shaft 2-65-736-00245 1
17. Block-Belt take-up 2-65-736-00198 2
18. Screw - Belt take-up 3-65-736-00491 2
19. Wear sleeve-Belt take-up 4-65-736-00569 2
20. Belt take-up pulley bearing GF-060 2
21. Retainer-ring for belt
take-up pulley bearing GF-062 2
22. Gease seal for Belt
take-up pulley GF-038 2
23. Gasket for belt take-up screw
housing GF-074 2
24. Bolt for belt take-up rail support 4-65-736-00477 8

Weigh Span Roller Assembly:

25. Weigh span roller 2-65-736-00252 3

26. Weigh span roller bearing GF-036 6
27. Weigh span roller grease seal GF-057 6

32
28. Weigh span roller Retainer-ring GF-055 16
29. Weigh span roller pre loading
washer GF-043 3
30. Weigh span roller 'O' -Ring GF-029 3
31. Weigh span roller housing 'O' -Ring GF-030 4

Weigh Sensing System Assembly:

32. Drag link assembly 2-65-736-00242 2

33. Pin for drag link 4-65-736-00732 4
34. Bolt for drag link 4-65-736-00596 2
35. Bolt for weigh module 4-65-736-00595 2
36. 'O' -Ring for weigh roller cover GF-028 2
37. Grease seal for calibrating GF-058 1
38. Retainer-ring for calib. shaft GF-056 1

Inlet Span Roller Assembly:

39. Inlet span roller 1-65-736-00100 3

40. Inlet span roller bearing GF-034 6
41. Inlet span roller Retainer-ring. GF-056
42. Inlet span roller 'O' -Ring GF-030 12

Tension Roll Assembly:

43. Tension roll pivot bolt 4-65-736-00478 2

44. Tension roll bearing GF-047 2
45. Tension roll grease seal GF-039 2
46. Tension roll wear sleeve 4-65-736-00570 2
47. Tension roll Retainer-ring GF-054 2

Clean Out Drive Assembly

48. Clean out drive shaft with sprocket 2-65-736-00258 1

49. Clean out coupling GF-073 1
50. Clean out coupling key 4-65-736-00518 2
51. Clean out 'Y' bearing GF-068 1
52. Clean out drive with gearbox 1
53. Clean out shear pin 12

Clean Out Take-up Assembly:

54. Chain take-up shaft with sprocket 2-65-736-00249 1

55. Chain take-up block 2-65-736-00197 2
56. Chain take-up screw 3-65-736-00396 2
57. Chain take-up bearing GF-060 2
58 Chain take-up grease seal GF - 038 2
59. Chain take-up wear sleeve 4-65-736-00569 2
60. Chain take-up Retainer-ring GF-062 2

33
Clean Out Chain Assembly:

61. Chain link 3-65-736-00371 30

62. Chain link (wing type) 2-65-736-00188 18
63. Chain pin 4-65-736-00342 60

Coal On Belt Alarm Assembly:

64. Coal on belt paddle 4-65-736-00495 6

65. Coal on belt bearing GF-035 2
66. Coal on belt grease seal GF-065 2

Miscellaneous (Mechanical)

67. Belt 3
68. Belt scraper GF-041 6
69. Inlet skirt (RH) 3-65-736-00349 6
70. Inlet skirt(LH) 3-65-736-00256 6
71. End skirt 3-65-736-00249 6
72. Levelling bar 3-65-736-00252 6
73. Bulls eye glass GF-052 12
74. Bulls eye gasket GF-051 12
75. End door gasket GF-0 10 4
76 Weigh compartment door gasket GF-008 4
77. Retainer-ring for end door screw GF-064 8
78. Grease hose for Belt take-up and
-drag link (L 525 mm) GF-069 4
79. Grease hose for chain take-up
and tension roll (L 770 mm) GF- 069 4
80. Gasket for slip-on pipe coupling GF 001 4

Controls & Instrumentation items:

81. 32bit embedded CPU 3

(loaded with application software)
82 Digital input Module 2
83 Digital output Module 2
84 Analog input Module 2
85 Analog output Module 2
86 Pulse input Module 2
87 Bus Terminator Module 2
88 Key board display unit with communication cable 2
89 24pole AC Tacho-generator 4
90 Single interface module 2
91 Signal conditioning module 2
92 VFD Controller unit for VFD drive only 2
93 24 V DC Power supply unit for I/O Rack 2
94 12 V DC Power supply unit for CPU 2

34
95 I/O Rack with mother board & cable assy. 2
96 Calibration Probe 2
97 Cable for calibration probe 2
98 Coal Motion Sensor 2
99 Cable Assy. For CMM Sensor 2
100 Retro-reflective tape 100
101 150lbs weighing module – load cell assembly 4

35
FIG -1 GRAVIMETRIC FEEDER

69
FIG -2 FINAL ASSEMBLY VIEW-AA

70
FIG -3 FINAL ASSEMBLY VIEW-BB

71
FIG -4 FINAL ASSEMBLY SECTION-EE

72
FIG -5 FINAL ASSEMBLY SECTION-FF

73
FIG -6 FINAL ASSEMBLY VIEW-D 1D1

FIG -7 FINAL ASSEMBLY VIEW-GG

74
FIG -8 FINAL ASSEMBLY SECTION-JJ

75
FIG -9 FINAL ASSEMBLY WEIGH SENSING SYSTEM

76
FIG -10 FINAL ASSEMBLY SECTION L-L

77
FIG -11 FINAL ASSEMBLY SECTION-R-R

78
FIG -12 FINAL ASSEMBLY SECTION-TT

79
FIG -13 FINAL ASSEMBLY SECTION-XX

80
FIG -14 FINAL ASSEMBLY SECTION-YY

81
FIG -15 FINAL ASSEMBLY SECTION HH & SECTION-ZZ

82
FIG -16A FINAL ASSEMBLY SECTION-H1H1

83
FIG -16B FINAL ASSEMBLY SECTION-H1H1

84
FIG -17 FINAL ASSEMBLY SUPPORT ROLLER WITH MOTION
MONITOR SECTION -L1L1

85
FIG -18 INLET SPAN ROLLER SECTION -MM

86
FIG-19 FINAL ASSEMBLY SECTION-UU

87
FIG -20 FINAL ASSEMBLY SECTION -WW

88
FIG -21 CHECKING BAR

89
FIG -22 BAR - PULLEY LIFT ASSEMBLY

90
FIG -23 WEIGH SENSING SYSTEM

91
FIG -24 BELT SCRAPER ASSEMBLY

92
FIG -25 CHUTE ASSEMBLY

93
FIG -26 INLET ROLLER ASSEMBLY

94
FIG -27 WEIGHING MODULE ASSEMBLY

95
FIG -28 DRAG LINK ASSEMBLY

96
FIG -29 LIGHT ASSEMBLY

97
FIG -30 WEIGH SPAN ROLLER ASSEMBLY

98
FIG -33 FINAL ASSEMBLY GREASE HOSE INSTALLATION

99
FIG -35 DRIVE PULLEY ASSEMBLY

100
FIG -36 TOOL - PULLEY REMOVAL

101
FIG -37 ALARM PADDLE ASSEMBLY-INLET

102
BELT HUMPING

103
TAKE-UP SQUARING AND SKIRT CLEARANCE

104
CONVEYOR CHAIN TENSION ADJUSTMENT

105
WEIGHING ROLLER ADJUSTMENT

106
SHEAR PIN REPLACEMENT

107
PADDLE ALARM ADJUSTMENT

108
TENSION ROLL REMOVAL

109
ROLLER REMOVAL

110
HEAD PULLEY REMOVAL

111
TAKE-UP PULLEY REMOVAL

112
HEAD PULLEY-COUPLING GAP

113
ILLUSTRATION NO.12 BELT CHANGING - SPLICED BELT

114
ILLUSTRATION NO.13 BELT CHANGING - SPLICED BELT

115
ILLUSTRATION NO.14 BELT CHANGING - SPLICED BELT

116
SCHEME FOR BULLS EYE CLEANING

117
ELECTRONIC WEIGHING FEEDER

118
FEEDER REMOTE OPERATING LOGIC

129
FEEDER LOCAL OPERATING LOGIC

130
LOAD CELL TROUBLESHOOTING

131
LOAD CELL TEST FLOW CHART

132
LOAD CELL EQUIPMENT CIRCUIT AND SIGNAL AMPLIFIER

133
 INSTALLATION, OPERATION

MAINTENANCE MANUAL

FOR

BHELFEED ®
Microprocessor Based
Gravimetric Feeder
Control System
(MPGFC)

Bharat Heavy Electricals Limited

DANGEROUS VOLTAGES ARE PRESENT IN
THIS EQUIPMENT. GREAT CARE SHOULD
BE EXERCISED WHEN SERVICING THE
EQUIPMENT AND ANY WARNING NOTICES
OR PROCEDURES CONTAINED IN THIS
MANUAL OR ON THE EQUIPMENT SHOULD
BE STRICTLY OBSERVED.
 Guide to use this Manual
The BHELFEED – MPGFC System Manual is divided into various sections based on its
usage.

For use by the Erection, Operation, Maintenance / service Group,

Section –1.0 which covers,

General information on Gravimetric Feeder

Principle of Operation

For use by the Erection Group, which covers,

Section –2.0
. Inspection of Equipments on Receipt
Storage Instructions & Maintenance Procedures
Equipment Installation Procedures.

For use by the Operations Group, which covers,

Section – 3.0
BHELFEED System Description
BHELFEED Startup & Operating Procedures
Project Specific Data

For use by the Maintenance Group, which covers,

Section – 4.0
Inspection Schedule of Major Sub-systems
Tuning and Calibration Procedures
Troubleshooting Guidelines

For use by the Operation & Maintenance group, which covers,

Section – 5.0 Electrical / Electronics Schemes and Schematics
Assembly Drawings, and Parts Lists.

Note:
Keep the manual current, by updating the revision packages will be supplied if necessary.
Revision History Record form is provided to record these revisions as they are received and
processed.

Bharat Heavy Electricals Limited

 NOTE

The drawings and other details included in this manual are

valid for the equipment supplied against this contract only.

IPR Notice

The information contained in this manual, including

Technical Data and Drawings are the property of M/s. Bharat
Heavy Electricals Limited and Intellectual Property Rights
(IPR) are with them only. The information contained in this
manual should not be used by the purchaser for any other
purpose other than the operation and maintenance of the
equipment.

Bharat Heavy Electricals Limited

 Table of Contents

Section Description

Section – 1.0 Introduction

Section – 2.0 Installation

Section – 3.0 Operation

Section – 4.0 Maintenance

Section – 5.0 Drawings

Bharat Heavy Electricals Limited

 Record of Revision History

Revision Revision
Description of Revision Remarks
Number Date

00 17/03/07 First release

01 12/09/07 Block Diagrams added

02 15/10/08 Module details added

Bharat Heavy Electricals Limited

Section – 1.0

Introduction

Bharat Heavy Electricals Limited

 Section – 1.0

Introduction
Title

1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2 Principle of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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1.1 GENERAL:

The thermal efficiency of fossil boiler depends on the specific coal consumption and is usually
expressed as MTons of coal burnt per million units of energy produced. The micro processor
based gravimetric feeder control system (BHELFEED – MPGFC) continuously weighs the weight
of coal fed to pulveriser proportional to the changing demand. The rate of coal fed signal is used
to maintain the excess air quantity at the optimum level to make the combustion process efficient.
Therefore, the feeder must deliver mass at a rate proportional to a demand. This must be done,
regardless of environmental variations in coal physical parameters. The secondary purpose of a
gravimetric feeder is to give the total coal weight of coal fed during an interval of time.

The BHELFEED - MPGFC System with electronic weighing, 36” feeder is designed for coal
delivery up to 250 ton per hour of coal to the pulveriser, with suitable gear ratio selection for the
main drive gear box. The drive system for the feeder belt consist of a 415 V, 3 phase 50 Hz,
7.5KW AC induction motor suitable for operation with variable frequency drive controller, coupled
to a speed reducing gearbox. The drive system includes dual tacho generators for speed
measurement.

1.2 PRINCIPLE OF OPERATION:

The BHELFEED system uses two precision strain gauge type load cells to measure the weight of
coal acting over the weighing span of the conveying belt. The actual gravimetric feed rate is
computed as:

Mass Flow Rate = Belt Speed x Mass / Unit Length.

The above mass flow equation allows the use of several approaches in designing a gravimetric
feeder. The most commonly used are,
Keep the mass / unit length constant and vary belt speed with demand signal.
Allow both the mass/ unit length and belt speed to vary, multiply the two factors together,
compare the product with the demand signal and vary the belt speed to remove the error.

Bharat Heavy Electricals Limited

Section – 2.0

Installation

Bharat Heavy Electricals Limited

 Section – 2.0

Installation

Title

2.1 Inspection of Equipments on Receipt . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2 Storage Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3 Equipment Installation Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bharat Heavy Electricals Limited

2.1 Inspection of Equipments on Receipt

On receipt of the BHELFEED - MPGFC System equipments, inspect for any

• Shortages against shipping list / Packing list
• Physical damage etc.
In case of any physical damage, report to the transport carrier and also notify the Commercial
Department of BHEL, Tiruchy, for necessary action.

2.2 Storage Instructions

Prior to dispatch from the works, provisions have been made to protect the equipment in the
event of prolonged storage is required at the erection site. Following are the recommendations for
long storage.

2.2.1 Equipment shall be stored in covered dry area until installation takes place to protect
against environment, where ambient temperatures may be controlled between 5°C
minimum and 50°C maximum and shall be periodically inspected to ensure for
cleanliness.
2.2.2 Equipment shall be stored in such a manner as to provide ready access for inspection
and maintenance with a minimum of handling.
2.2.3 Do not store other equipment on or near the Control panels. Each Control panel shall be
fully accessible for periodic servicing / inspection while in storage.
2.2.4 Desiccants are provided to protect electrical / electronics devices and all moisture -
sensitive components from humidity. Desiccant shall be checked at monthly intervals and
all desiccants whose color changed from blue to light red shall be replaced.

2.3 Equipment Installation Procedures

Equipment / System installation, Interconnection drawings are provided in Section 5.0

2.3.1 Install the Remote Control Panel at the Unit Control Equipment Room as required by the
customer and interconnect with Local Control Panel as per inter connection diagram and
cable schedule.

Note:
Keep all 415 volt field wiring at least 75 mm away from all 240 volt wiring and at least
150 mm away from instrumentation wiring (shielded cables).

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2.3.2 Make a visual inspection for any damage of electrical / electronic components mounted
inside the Remote / Local Control Panels and if any replace the same.

2.3.3 Check and ensure all electrical components and terminations / contacts are intact.

Caution:
All field wiring / interconnection shall be checked and verified. Ensure proper wiring to avoid
damage to the electronic modules when power is applied.

Statutory Requirement:
Safety considerations require that electrical equipment and panels shall be earthed.

2.3.4 Connect 415V, AC, 3Phase electrical supply to the main power Terminal Blocks provided
in the Remote Control Panel (RCP) and extend the same to Local Control Panel (LCP)
as per schematic / interconnection diagram. A separate 240 V, AC, 1Phase electrical
supply shall be provided at utility Terminal Blocks.

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Section – 3.0

Operation

Bharat Heavy Electricals Limited

 Section – 3.0

Operation

Title

3.1 BHELFEED - MPGFC System description .. . . . . . . . . . . . . . . . . . . . . ..

3.1.1 BHELFEED - MPGFC Remote Control Panel . . . . . . . . . . . . . .

3.1.2 BHELFEED - MPGFC Local Control Panel . . . . . . . . . . . . . . . .

3.1.3 BHELFEED – MPGFC Rate Measurement . . . . . . . . . . . . . . . .

3.1.4 System Architect. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1.5 Electronic module details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2 BHELFEED – MPGFC System Startup & Operation Procedure. . . . . .

3.2.1 Preliminary Startup Checks / Sequence . . . . . . . . . . . . . . . . . .

3.2.2 Program Parameter Summary. . . . . . . . . . . . . . . . . . . . . . . . . .

3.2.3 Program Parameter Data - Typical . . . . . . . . . . . . . . . . . . . . . .

Bharat Heavy Electricals Limited

3.1 BHELFEED - MPGFC System description
BHELFEED - MPGFC system consists of a Remote Control Panel (RCP) located at the Unit
Control Equipment Room and a Local Control Panel (LCP) mounted on the feeder body located
at feeder floor. The major components / sub-systems are briefed in the following pages.

3.1.1 BHELFEED – MPGFC Remote control panel

The following are the major components housed inside the Remote Control Panel viz.
• Disconnecting Switch (DS) is 3 Phase power isolator with HRC fuse links and status
monitoring contacts, in the incoming power circuit.
• Phase Failure Monitor (PFM) is a protection device in the 3phase power circuit to
monitor Over voltage, Under voltage, Reverse Phase sequence, Single phasing etc.
• Miniature Circuit Breakers (MCB1 & MCB2) are protection devices, in the power
circuit, feeding the primaries of control transformer (T1).
• Variable Frequency Drive controller with input output filter and in-built overload
protection in the power circuit for the forward / reverse operation of Feeder belt drive
motor.
• Cleanout conveyor (COC) motor starter (CMS) with HRC fuses(F4-F6) and thermal
overload relay (CMOL) in the power circuit of COC drive motor.
• Control transformer(T1) is step down transformer with primary terminals (P1 - P2)
and a dual secondary terminals (S1 - S2 & S3 - S4). The first secondary terminals
S1- S2 is to source the feeder hardwired control logic through isolator (MCB3) and
the other secondary terminals S3-S4 is to source the Power supply units (PS1 &
PS2) through EMI Filter (EMI -1) pertaining to I/O rack and CPU respectively.
• Set of electro-pneumatic timers, Time delay feeder start(TFS) which inputs the
controller when the customer start circuit is energized and Time delay – Control
(TPM) which monitors the presence of control power supply.
• Set of electromagnetic control relays viz. Remote relay (RM), Local relay (LM),
Calibration relay (CR), Feeder run relay (FR), Feeder Remote Auxiliary relay (R3A),
Feeder run Auxiliary relay (R6A), Master Reset relay (MRS), Phase Failure Monitor
Auxiliary relay (PFMA), Coal on Belt relay (COB), Feeder Discharge Pluggage relay
(FDP), and Bunker Coal Flow Monitor relay (BCFM) to support the control logics.
• Rotary Selector switch (CSS) to ON / OFF the Cleanout conveyor.
• Indication lamps viz. Cleanout conveyor motor overload (LR1), Feeder motor
overload (LR2), No Coal Flow (LR3), Feeder Discharge Plugged (LR4), Phase
Failure (LR5), Cleanout Conveyor Run (LR6), Cleanout Conveyor Off (LR7), Bunker
No Coal Flow (LR8) to indicate the status of various logic / control operation.
• Key Board with Display (KBD) is Human Machine Interfacing Input / Output device for
easy operation and status information.

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 • MPGFC - CPU is an industrial PC, which is the master controller of BHELFEED –
MPGFC System.
• I/O modules viz. Analog Input Module (AIM), Digital Input Module (DIM), Pulse Input
Module (PIM), Analog Output Module (AOM), Digital Output Module (DOM), Bus
Terminator Module (BTM) housed in a double euro rack with back plane wiring.
• Interface board (IFB), Signal Interface Modules (SIM), Relay Board (RB), Pulse
Relay (PR) are mounted in side the panel.

3.1.2 BHELFEED – MPGFC Local control panel

The following are the major components housed inside the Local Control Panel viz.
• Signal conditioning module (SCM) to condition the load cell signals and the Belt
Motion sensor signal and transmit to the Remote Control Panel.
• Door mounted Rotary Selector switches for Forward - Off - Reverse operation of
feeder belt (FRSL), Remote - Off - Local - Calibrate mode of operation selector
(MSL) pertaining to feeder control logic.
• Indication lamps viz. Feeder Local (LL1), Feeder Remote (LL2), Feeder Run Forward
(LL3), Feeder Run Reverse (LL4), Feeder Off (LL5), Cleanout Conveyor Run (LL6),
Cleanout Conveyor Off (LL7), Calibrating (LL8) to indicate the status of various logic /
control operation.
• Feeder Work light switch (WLS) for On / Off control of feeder internal illumination
lights.

Bharat Heavy Electricals Limited

 3.1.3 BHELFEED – MPGFC Rate Measurement

Raw coal

Gear VFD Motor

Box

Load cell Tacho

Signal Signal

Signal VFD Controller

Conditioner

Demand Signal from GFC

Combustion Control Controller
Output Signal
to Customer

KBD & Display

The BHELFEED – MPGFC System employs,

• Two load cells to measure the weight of coal acting over the weighing span of
the coal conveying belt.
• Dual Tacho generator to measure the drive speed

The gravimetric feedrate is calculated as:

Wt. of coal per unit length of belt (Kg / m) X Speed of belt ( m / sec) = Feedrate (Kg / sec)

Since the bulk density of the coal being fed can vary during the operation of the boiler,
the feedrate can be maintained constant by continuously measuring the weight of the
coal and adjusting the belt speed in a closed loop. This feedback control maintains the
coal feeding rate proportional to fuel demand signal by continuously adjusting the belt
speed in relation to varying bulk density of the coal.

Bharat Heavy Electricals Limited

3.1.4 System Architecture

110V AC

12V DC PS-2 24V DC PS-1

12V DC 24V DC

INTER SIM
PROCESSOR FACE I / O RACK SCM
MODULE

KEYBOARD AND RELAY VFD

DISPLAY BOARD CONTROLLER

Brief Description on MPGFC Electronic Hardware:

MPGFC Electronic hardware consists of the following major components.

• Processor Unit
• Interface Madule
• I / O Rack
• Relay Board
• Power Supplies
• Keyboard and Display

Bharat Heavy Electricals Limited

Processor Unit - 32bit, DIN mounted Pentium III, Embedded processor.
Interface module - DIN mounted unit which interfaces Processor and I/O rack.
I/O rack - 6U, 42T Euro rack housing 6 I/O modules with mother board.
Bus Terminator Module - A signal terminator unit.
Analog Input Module - To accept 16 channels of analog input of 4 -20mA.
Analog Output Module- To output 16 channels of current output 4-20mA.
Digital Input Module - To accept 32 channels of digital input of 24V DC nominal.
Digital Output Module - To drive 32 channels of digital output at 24v DC, 100mA(max).
Pulse Input Module - To accept 9+9 channels of pulse input to measure the Pulse
Width / Ffrequency. The maximum frequency is 15kHz.
Relay Board - To drive 12 interposing relays with two change over contacts @
230V AC, 6Amps, DIN mounted
Power Supply 1 - DIN mounted unit, sources 24V DC to all I/O modules, Signal
Interface Module, Keyboard Display etc.
Power Supply 2 - DIN mounted unit, sources 12V DC to Processor Unit.
Keyboard and Display (KBD):
§ It is meant for operator’s interaction and monitoring purposes.
§ The keyboard is a membrane type with 32 keys. The legend printed on each key
identify its function. It also contains 9 LEDs to show the system status.
§ The display is of dot-matrix alphanumeric. It is a two line vacuum fluorescent
display of 40 characters on each line.
§ Key pad layout is made based on different functional groups.

Keyboard and Display Functional Groups:

Numeric group:
• The keys 0 to 9 are defined in this. Apart from 0 to 9 an additional key ‘00’ is
provided to enter dual zeros.

Programming group:
• ‘NEXT / PREV’ keys are for incrementing or decrementing the parameter
numbers while monitoring on the display.
• PROG key is meant for programming the parameters to be set for the feeder
operation.
• CLS key is used for clearing the entered data in different modes.
• ENTER key is used to confirm the data entered. The data gets updated on
pressing this key.
• ESC key allows to exit from a particular mode or operation.

Status group:
• The status group indicates the operating status of the feeder through the LED,
viz. FEEDER RUN, GRAVIMETRIC, VOLUMETRIC, ALARM and TRIP.

Bharat Heavy Electricals Limited

Tune group:
• This group consists of cal functions viz. TARE CAL and SPAN CAL.

Operation group:
• These keys are meant for monitoring the dynamic operating parameters on line.
• TOTAL DISPLAY key selects the display of Material Total, Gravimetric Total or
Volumetric Total.
• TOTAL RESET key reset all the 3 integrator viz. Material Total, Gravimetric Total
and Volumetric Total through a pass word.
• SELECT DATA is equivalent to NEXT switch in default screen.
• SELF CHECK selects a list of feeder operating parameters that can be
monitored. ERROR LIST displays the Alarms / Trips occurred in chronological
sequence with Date & Time stamp, with an index number to identify the
sequence of occurrence.
• SPL FUN to reset an Alarm LED indication.

Select mode group:

These keys, on selection will define the operating mode of the gravimetric feeder.
REMOTE key selects the feeder to operate corresponds to customer Feed rate
Demand signal and this will be indicated by red LED embedded in the switch.
OFF key switches OFF the feeder operation in both LOCAL & REMOTE mode
and this will be indicated by the green LED embedded in the switch.
LOCAL key selects the feeder to run at RPM value set in < PROG. 01 > and is
indicated by the red LED embedded in the switch.
BELT REV key on selection energizes the relay (R10) which facilitate the reverse
operation of the feeder belt in LOCAL mode.
INCH is a momentary key. Feeder runs at RPM value set in < PROG. 01 > as
long as the key is held in pressed condition and is indicated by the red LED
embedded in the switch.
CLOCK SET key allows the RTC clock to set to a desired time and date.

Bharat Heavy Electricals Limited

Module Descriptions:
A) ANALOG INPUT MODULE (4-20 mA) AIM 2000 :

AIM 2000 is an Intelligent Analog Input Module with processing capabilities. They are
used for 16 analog current signals from the field. The Modules send Values to the CPU
Module through parallel I/O Bus. The Module performs self-diagnostics and LED is
provided to indicate errors in interface with CPU in both single and redundant modes.
Features
• Online validation of Signal Range
• Built-in Auto Calibration
• Optical Isolation between field Signal and Logic Electronics
• Channel to Channel and field to Electronics Isolation
• Successive approximation A to D conversion
• Module address selection through Thumb Wheel Switches (hexadecimal) on the
Module

B) ANALOG OUTPUT MODULE (4-20mA) AOM 2000

AOM 2000 is an Intelligent Analog output Module with processing
capabilities. It is meant for controlling 8 Analog Devices. This module sends Analog
Values processed by the CPU to Output Devices. The communication between CPU and
this Module is through parallel Input /Output Bus. It performs self-diagnostics and
LED is provided to indicate errors in the interface with CPU. The Module has
capabilities of maintaining the Output Values at a pre-determined level in the event of
CPU failure. These Values to Output Devices are online configurable.

Features
• Auto Calibration
• Optical isolation of Logic Electronics and Field Signals
• Output update rate 50 milliseconds
• Insertion / Removal with power on.
• Double-Euro format with two part connectors for high reliability
• Module address selection through two Thumb Wheel Switches (hexadecimal) on
the Module
C) DIGITAL INPUT MODULE FOR VOLTAGE INPUTS 32 Channel Voltage
Inputs - (24V DC) DIM 2001
DIM 2001 is an Intelligent Module with processing capabilities. It
is meant for monitoring the status of Voltage Inputs. DIM 2001 sends the status
of Input Voltage to the CPU Module through parallel Input/ Output Bus. The module
 performs self-diagnostics and LED is provided to indicate errors in interface with
CPU both in single and redundant modes of operation.

Features

• Monitors 32 Voltage Inputs

• Optical Isolation for each Channel from electronics as well as other Channels
• Insertion/ Removal with power-on ( Hot plug-in )
• Protection against reverse polarity
• Software Programmable de-bounce time
• Scan-time of one millisecond
• Module address selection through two Thumb Wheel Switches (hexadecimal) on
the Module
Indications
D) DIGITAL OUTPUT MODULE SOLID STATE 32 CHANNEL 24VDC
@100ma
DOM 2000 is an Intelligent Digital Output Module with processing
capabilities. It is meant for controlling the on/off type devices such as Solenoid,
Motorized Valves and Contactors. DOM 2000 sends logic status processed by the
CPU Module to the Output Device. The communication between CPU and this
Module is through Parallel Input/ Output Bus. It performs self-diagnostics and
LED is provided to indicate errors in the Interface with CPU both in single and
redundant modes. Thi s fail-safe status of Output Devices is online configurable.
There is an onboard 24V supply that drives the Field Devices.

Features
• Controls 32 Output Devices
• Optical Isolation for each Channel from electronics as well as other Channels
• Built-in Free Wheeling Diode for Inductive Loads
• Insertion/ Removal with power-on ( Hot plug-in )
• Onboard 24V power supply for Field Devices
• Module address selection through two Thumb Wheel Switches (hexadecimal) on
the Module

E) Pulse Input Module (9 Channel PCNT & 9 Channel PWDT) PIM 2000
 PIM 2000 is an intelligent Pulse Input Module with processing capabilities. It is
used for counting / frequency of pulses and measuring pulse width. It sends the
pulse information to the CPU. The communication between CPU and this Module
is through parallel input/ouput Bus. It performs self-diagnostics and LED is
provided to indicate errors in the interface with CPU both in single and
redundant modes.This Module can take 5v and 24v pulses or open collector
outputs. This Module can perform 9 pulse count / frequency and 9 pulse width
measurements.

Features

• 9 Pulse count / frequency and 9 pulse width measurements

• Insertion/Removal with power-on (Hot plug-in)
• Module address selection through two Thumb Wheel switches (hexadecimal) on
the Module

F) MOTOR CONTROL MODULE

The motor control module accepts input demand from controller and feeder drive
speed feedback from the tachogenerator. These signals are processed in this card and
output is provided to eddy current clutch for varying the output speed of the drive.

G) SIGNAL INTERFACE MODULE:

The signal interface module received input from belt motion sensor and calibration
probes, provide isolation and provide output for further processing in the
microprocessor. This module also process the tachogenerator input signal and provide
input to the microprocessor for further processing.

H) SIGNAL CONDITIONING MODULE:

The signal conditioning module received input from load cell sensor, tachogenerator and
process the signal which is taken to remote control panel for further processing in the
microprocessor.

I) 12 V POWER SUPPLY MODULE SMPS-1

The 12 V power supply module shall be used to power the CPU (supplied by others) in
the GFC panel.

J) 24 V POWER SUPPLY MODULE SMPS-2

The 24V power supply module shall be used to power the I/O rack module (supplied by
others) in the GFC panel.

K) KEY PANEL COMMUNICATION MODULE

The Key panel communication module is the communication bridge between the CPU and
the key-panel, display module. The required communication is established by means of
RS232 serial link. The module is to be designed for 24V DC input power supply.
L) CPU - PACKED INDUSTRIAL PC WITH INTEL PENTIUM III PROCESSOR
The PIP8-11 is a highly integrated robust industrial PC with a specially designed high
quality aluminum housing. This allows the system to operate without fan or ventilation
holes. The PIP8 can be used in a standard or in a rugged operating environment, is
100% PC/AT compatible and can easily be mounted on a 35mm DIN rail. Fully bootable
FLASH disks are supported for projects where hard disks or floppy disks cannot be
used. Particular precautions have been taken that the EMC for the entire system be
within the CE and FCC limits.
All these features make the PIP8 the ideal solution for the industry wher ever a
flexible, rugged, and durable
complete Industrial PC is needed.

Features of CPU
? Low power Pentium® III processor
? Processor speed 1000 MHz
? Up to 256 Mbytes SDRAM
? CRT and panel support
? Integrated 10/100 Mbit/s Ethernet controller
? Integrated 2.5 inch HDD and FDD
? Four RS232 ports
? 2 isolated half duplex RS485 ports (optional)
? 1 isolated full duplex RS422 port (optional)
? Integrated temperature sensor
? Wide supply voltage range
3.1.5.1 ANALOG INPUT MODULE (AIM):

AIM 2000 is an Intelligent Analog Input Module with processing

capabilities. They are used for 16 analog current signals from the field.
The Modules send Values to the CPU Module through parallel I/O Bus.
This Module can be connected to both the CPU Modules for hot stand-by
operation using two CPU Modules. The Module performs self-diagnostics
and LED is provided to indicate errors in interface with CPU in both single
and redundant modes.

Features

♦ Monitors 16 Analog Current Signals

♦ Online validation of Signal Range
♦ 16 bit resolution
♦ Built-in Auto Calibration
♦ Optical Isolation between field Signal and Logic Electronics
♦ Channel to Channel and field to Electronics Isolation
♦ 10 millisecond scan-time for all 16 Channels
♦ Successive approximation A to D conversion
♦ Insertion/ Removal with power-on (Hot plug-in)
♦ Double-Euro format with two part connectors for high reliability
♦ Rear I/O terminators for easy replacement
♦ Module address selection through Thumb Wheel Switches (hexadecimal)
on the Module
 Block Diagram

24V
5V 5V F + 12 VF - 12 VF
module supply

A1

C1

B
u M
I
s A u
s
I m l
o
/ I p t
l
O n A l i Signal
a
t D i p Condition-
t
B e C f l ing
i
u r i e
o
s f e x
n
a r e
c r
e
A 32

C 32

GND GND
Front Panel

+ 5V

ERROR
COMMN

ADDRESS

AIM
2000
Specifications
Specifications AIM 2000
Supply Voltage for Operation 17 – 28V DC
Absolute maximum Supply Voltage 40 V DC
Module Supply Current 200mA at 24V DC
Number of Inputs 16 Channels
Type of Input Current
Input Span 4-20 mA
Input Resistance 50 Ohms
Type of A/D Conversion successive
approximation

15 bits +sign
Resolution
Scan rate for all Channels 10 millisecond
Accuracy 0.3% FSR
CMRR 90dB

Indications
♦ Communication Status LED (Blinks when Card is communicating with
processor)
♦ Power Status LED (Glows when Module Power is present)
♦ Error Status LED (Glows in case of Module error)

Environment
♦ Operating Temperature : 0-60 Degree Centigrade
♦ Humidity : 95% RH non-condensing
♦ Transient Withstand Capability : IEC-61000 - 4 - 4
♦ Surge Withstand Capability : IEC - 255 - 4

Dimensions
♦ Size : 233.4 X 160 mm
♦ Width : 5T (25 mm)
♦ Mounting : 6 U Rack
Field Wiring AIM J 2 PINOUT
A1 B1 C1
DEMAND O O O
NC O O O
LOADCELL1 O O O
NC O O O
LOADCELL2 O O O
NC O O O
NC O O O
NC O O O
NC O O O
NC O O O
NC O O O
O O O
NC
NC O O O
NC O O O
NC O O O
NC O O O
A16 B16 C16
 Field Wiring

AIM J 2 PINOUT
A17 B17 C17
NC O O O
NC O O O
NC O O O
NC O O O
NC O O O
NC O O O
NC O O O
NC O O O
NC O O O
NC O O O
NC O O O
NC O O O
NC O O O
NC O O O
NC O O O
NC O O O
A32 B32 C32

3.1.5.2 ANALOG OUTPUT MODULE (AOM):

AOM 2000 is an Intelligent Analog output Module with processing

capabilities. It is meant for controlling 16 Analog Devices. AOM 2000
sends Analog Values processed by the CPU to Output Devices. The
communication between CPU and this Module is through parallel Input
/Output Bus. When two CPUs are used in the redundant mode this
Module can be connected to both CPUs. AOM 2000 performs self-
diagnostics and LED is provided to indicate errors in the interface with
CPU both in single and redundant modes. The Module has capabilities of
maintaining the Output Values at a pre-determined level in the event of
CPU failure. These Values to Output Devices are online configurable.
Features

♦ Capacity to control 16 Analog Current operated devices

♦ 16 bit resolution
♦ Optical isolation of Logic Electronics and Field Signals
♦ Output update rate 50 milliseconds
♦ Span 4-20mA
♦ Load Impedance 0-1 k ohms
♦ Insertion / Removal with power on.
♦ Double-Euro format with two part connectors for high reliability
♦ Rear I/O terminators for easy replacement
♦ Module address selection through two Thumb Wheel Switches
(hexadecimal) on the Module

Block Diagram

+ 24 VF
5V

A1

C1
DAC#1

B
u
s
I
/ I
O n Optical
t Isolation
B e
u r
s f
a
c
e
A32
DAC#16
C32

5V GND
Front panel:

+ 5V

ERROR
COMMN

ADDRESS

AOM
2000
Specifications

♦ Rated Power Supply - 17-28V DC

♦ Absolute maximum Power Supply - 40V DC
♦ Power Supply Current - 200 mA max. at 24V DC

Indications

♦ Communication Status LED (Blinks when Card communicated with

processor)
♦ Power Status LED (Glows when Module Supply is present)
♦ Error Status LED (Glows in case of Module error)

Environment

♦ Operating Temperature : 0-60 Degree Centigrade,

♦ Humidity : 95% RH non-condensing
♦ Transient Withstand Capability : IEC-61000 -4-4
♦ Surge Withstand Capability : IEC-255 - 4

Dimensions

♦ Size : 233.4 X 160 mm

♦ Width : 5T (25 mm)
♦ Mounting : 6 U Rack
Field Wiring

AOM J 2 PINOUT
A1 B1 C1
CUMB. CONT. O O O
NC O O O
CUMB.CONT R O O O
NC O O O
MILL AIR CON. O O O
NC O O O
MILL AIR CON. R O O O
NC O O O
NC O O O
NC O O O
NC O O O
O O O
NC
NC O O O
NC O O O
NC O O O
NC O O O
A16 B16 C16
 AOM J 2 PINOUT
A17 B17 C17
SAD CONT. O O O
NC O O O
FA SYSTEM O O O
NC O O O
MS CONTROL O O O
NC O O O
NC O O O
NC O O O
NC O O O
NC O O O
NC O O O
O O O
NC
NC O O O
NC O O O
NC O O O
NC O O O
A32 B32 C32

3.1.5.3 DIGITAL INPUT MODULE (DIM):

DIM 2001 is an Intelligent Module with processing capabilities. It is meant

for monitoring the status of Voltage Inputs. DIM 2001 sends the status of
Input Voltage to the CPU Module through parallel Input/ Output Bus. For
hot stand-by mode of operation using two CPU Modules, One DIM 2001
Module can be connected to both the CPUs. The module performs self-
diagnostics and LED is provided to indicate errors in interface with CPU
both in single and redundant modes of operation.
 Features

♦ Monitors 32 Voltage Inputs

♦ Optical Isolation for each Channel from electronics as well as other
Channels
♦ 32 Front Panel LEDs for Voltage status indication
♦ Insertion/ Removal with power-on (Hot plug-in)
♦ Protection against reverse polarity
♦ Software Programmable de-bounce time
♦ Scan-time of one millisecond
♦ Double-Euro format with two part connectors for high reliability
♦ Rear I/O Terminators for easy replacement
♦ Module address selection through two Thumb Wheel Switches
(hexadecimal) on the Module

Block Diagram

24V
Module Power

5V

+ A1
Ch1
DC Voltage Ch1
Source in
Field
I
C1 /
O
-
Signal Interface
Conditioning to Bus B
Circuit u
s
A 32
+
Ch32

C 32
- Ch 32

0V
Front Panel

+ 5V

ERROR
COMMN

ADDRESS

DIM
2001
2
4
6
8
10

12
14
16
18
20
22
24
26
28
30
32
Specifications

Specification DIM 2001

Rated Supply Voltage for operation 17 – 28V DC
Absolute maximum Voltage 40 V DC
Module Supply Current 200mA at
24V DC

Number of Voltage Inputs 32

Logic one Input Voltage:
Minimum 15 V DC
Absolute Maximum 30 V DC
Logic zero Input Voltage:
Maximum 5 V DC
Minimum 0 V DC

Indications

♦ Input Voltage Status LED (Glows when Logic 1 Voltage is present)

♦ Communication Status LED (Blinks when Card is communicating with
processor)
♦ Power Status LED (Glows when Module Power is present)
♦ Error status LED ( Glows in case of Module error)

Environment
♦ Operating Temperature : 0– 60 Degree Centigrade
♦ Humidity : 95% RH non-condensing
♦ Transient Withstand Capability : IEC - 61000 -4- 4
♦ Surge Withstand Capability : IEC-255 - 4
Dimensions
♦ Size : 233.4 X 160 mm
♦ Width : 5T (25 mm)
♦ Mounting : 6 U Rack
Field Wiring

DIM J 2 PIN OUT

A1 B1 C1
O O O
O O O
O O O
O O O
O O O
O O O
O O O
O O O
O O O
O O O
O O O
O O O
O O O
O O O
O O O
O O O
A16 B16 C16
 DIM J 2 PIN OUT
A17 B17 C17
START O O O
MOT. START O O O
COAL ON BELT O O O
FDR. DIS.PLGD. O O O
MOT.SPEED O O O
RAISE O O O
LOWER O O O
BELT MOTN. O O O
NO COAL FLOW O O O
KBD LOCKED O O O
REMOTE O O O
LOCAL O O O
NC O O O
NC O O O
PROBE A O O O
PROBE B O O O
A32 B32 C32
3.1.5.4 DIGITAL OUTPUT MODULE (DOM)

DOM 2000 is an Intelligent Digital Output Module with processing

capabilities. It is meant for controlling the on/off type devices such as
Solenoid, Motorized Valves and Contactors. DOM 2000 sends logic
status processed by the CPU Module to the Output Device. The
communication between CPU and this Module is through Parallel Input/
Output Bus. When two CPUs are used in the redundant mode these
Modules can be connected to both the CPU Modules. DOM 2000
performs self-diagnostics and LED is provided to indicate errors in the
Interface with CPU both in single and redundant modes. The Module has
capacity for maintaining the Outputs in any desired state in the event of
CPU failure. This fail-safe status of Output Devices is online configurable.
There is an onboard 24V supply that drives the Field Devices.

Features

♦ Controls 32 Output Devices

♦ Optical Isolation for each Channel from electronics as well as other
Channels
♦ 24V DC Output @ 100ma
♦ Built-in Free Wheeling Diode for Inductive Loads
♦ Thermal cut-out with auto reset for each output
♦ Insertion/ Removal with power-on ( Hot plug-in )
♦ LED status indication for each output
♦ Double-Euro format with two part connectors for high reliability
♦ Rear I/O termination for easy replacement
♦ Onboard 24V power supply for Field Devices
♦ Module address selection through two Thumb Wheel Switches
(hexadecimal) on the Module
 24V
Module Supply SC
24V DC
5V DC

C1

Load 1
A1

I
/
O Interface Optical
to Isolated
B Bus Output
u
s

C 32

Load 32
A 32

5V GND 24V GND

SC: Short Circuit Protection

Front Panel
+ 5V

ERROR
COMMN

ADDRESS

DOM
2000
2
4
6
8
10
12
14
16
18
20
22
24
26
28
30
32
Specifications

♦ Rated Supply Voltage for operation - 17-28V DC

♦ Absolute maximum Supply Voltage - 40V DC
♦ Module Supply Current - 200 mA. max. at 24V DC
♦ Number of Outputs - 32
♦ Type of Output Contact - Solid State
♦ Output Contact on State Resistance - 6 Ohms max.
♦ Output Contact off State Resistance - 100 K Ohms min.
♦ Voltage across Open Output Contacts - 250 V max.
♦ Load Current to Contact - 100mA. max.
♦ Maximum Contact Power - 600 m W
♦ Isolation from Logic Electronics to Output- 1.5 kV max.

Indications
♦ Output Status LED (Glows when Output is on)
♦ Communication Status LED (Blinks when Card is communicating with
processor)
♦ Power status LED (Glows when Module Power is present)
♦ Error status LED (Glows in case of Module error)

Environment
♦ Operating Temperature : 0– 60 Degree Centigrade
♦ Humidity : 95% RH non-condensing
♦ Transient Withstand Capability : IEC - 61000 - 4- 4
♦ Surge Withstand Capability : IEC – 255 - 4

Dimensions
♦ Size : 233.4 X 160 mm
♦ Width : 5T (25 mm)
♦ Mounting : 6 U Rack
Field Wiring
DOM J 2 PINOUT
A1 B1 C1
NC O O O
NC O O O
NC O O O
NC O O O
NC O O O
NC O O O
NC O O O
NC O O O
TRIP K1 O O O
FR>50% K2 O O O
REMOTE K3 O O O
VOL.MET.K4 O O O
FEED.COAL K5 O O O
FEED.RUN K6 O O O
ALARM K7 O O O
BELT.MM K8 O O O
A16 B16 C16
 DOM J 2 PIN OUT
A17 B17 C17
NC O O O
NC O O O
NC O O O
NC O O O
NC O O O
NC O O O
NC O O O
NC O O O
NC O O O
BELT <8Hz K9 O O O
BELT REV. K10 O O O
TACHO 2 K11 O O O
BELT TMD K12 O O O
DATA LOG.COTO O O O
NC O O O
NC O O O
A32 B32 C32
3.1.5.5 PULSE INPUT MODULE (PIM)

PIM 2000 is an intelligent Pulse Input Module with processing capabilities.

It is used for counting / frequency of pulses and measuring pulse width.
PIM 2000 sends the pulse information to the CPU. The communication
between CPU and this Module is through parallel input/ouput Bus. When
two CPUs are used in the redundant mode this Module can be connected
to both the CPU Modules. PIM 2000 performs self-diagnostics and LED is
provided to indicate errors in the interface with CPU both in single and
redundant modes.This Module can take 5v and 24v pulses or open
collector outputs. This Module can perform 9 pulse count / frequency and
9 pulse width measurements.

Features

♦ 9 Pulse count / frequency and 9 pulse width measurements

♦ Insertion/Removal with power-on (Hot plug-in)
♦ Double-Euro format with two part connectors for high reliability
♦ Rear I/O termination for easy replacement
♦ Module address selection through two Thumb Wheel switches
(hexadecimal) on the Module
Front Panel

+ 5V

ERROR
COMMN

ADDRESS

PIM
2000
Block Diagram

+5v +5v(F) +5v(F) +24v(F)

+5v

P
B C Signal
U N
S
Condition
T
I - ing
I S
N O
I
T L
/
E A
O
R T +24v(F) GND
I +5v(F) GND
B F
A O
U
C N +5v(F)
S +24v(F)
E

P
W Signal
D Condition
T -ing

+ 5V GND + 5V GND + 5V(F) GND + 5V(F) GND +24v(F) GND

+ 5V(F) GND + 24V(F) GND

Specifications

Specification PIM 2000

Rated Supply Voltage for operation 17 – 28V DC
Absolute maximum Voltage 40 V DC
Module Supply Current 200mA at
24V DC

Number of Pulse Inputs : 9CNT+ 9 PW

Type of Input : Open
Collector
Maximum Frequency : 15 KHz.
PW Resolution : 0.1 m.Sec.

Indications

♦ Communication Status LED (Blinks when Card is communicating with

processor)
♦ Power Status LED (Glows when Module Power is present)
♦ Error status LED ( Glows in case of Module error)

Environment
♦ Operating Temperature : 0– 60 Degree Centigrade
♦ Humidity : 95% RH non-condensing
♦ Transient Withstand Capability : IEC - 61000 -4- 4
♦ Surge Withstand Capability : IEC-255 - 4
Dimensions
♦ Size : 233.4 X 160 mm
♦ Width : 5T (25 mm)
♦ Mounting : 6 U Rack
Field Wiring

PIM J 2 PINOUT
A1 B1 C1
TACHO 1 O O O
TACHO 2 O O O
BELT MOTION O O O
NC O O O
NC O O O
NC O O O
NC O O O
NC O O O
NC O O O
NC O O O
NC O O O
NC O O O
NC O O O
NC O O O
NC O O O
NC O O O
A16 B16 C16
PIM J 2 PIN OUT
A17 B17 C17
NC O O O
NC O O O
NC O O O
NC O O O
NC O O O
NC O O O
NC O O O
TACHO 1 O O O
TACHO 2 O O O
NC O O O
NC O O O
NC O O O
NC O O O
NC O O O
NC O O O
NC O O O
A32 B32 C32
3.2 BHELFEED- MPGFC System Startup & Operation Procedure

The I/O module are selected for the following ADDRESS in hexadecimal.

Module description Model Address

Digital Input Module DIM 2001 05
Digital Output Module DOM 2000 15
Analog Input Module AIM 2000 25
Analog Output Module AOM 2000 1F
Pulse Input Module PIM 2000 9F

3.2.1 Preliminary Startup Checks / Sequence

When the BHELFEED system is powered up, the following display will appear on the
display screen once the PC boot sequence is completed.

BHEL GRAVIMETRIC FEEDER CONTROLLER

After few seconds it displays the following,

Material Total : XXXXXX.XX MTons

PREV Speed : XXXX RPM

SELECT Material Total : XXXXXX.XX MTons

DATA Feed Rate : XX.XX MTons / hr.

Material Total : XXXXXX.XX Mtons

NEXT Density : XXXX.XX Kgs/Cum

PROG Mode Initiation

To access the PROG mode, first press the OFF then press the PROG key on the
keyboard and observe the following on display screen (Vacuum Fluorescent display)

< PROG. > Enter Parameter 00 - 49

Bharat Heavy Electricals Limited

A total of 49 PROG parameters are listed in this mode, which can be verified by the
Operation / Maintenance personnel for BHELFEED - MPGFC System setup.

The keys that can be operated are:

NUMERIC PAD
PROG NEXT PREV ENTER ESC
0 . . . . . 9 , 00

Note:
If a delay of 5 seconds or more occurs after PROG is pressed, the controller
will return to the last PROG address accessed.

Fig .3.1 Illustration on PROG Operational Keys

The PROG parameter number can be incremented by pressing PROG or NEXT keys. By
pressing PREV key parameter number can be decremented. At the first instance any
parameter number can be entered, to reach a selected parameter. This mode can be
terminated by pressing ESC key.

All the PROG parameters values are verified for their limits, if any deviation noted will be
displayed as Invalid.

Bharat Heavy Electricals Limited

 Note:
The PROGRAM parameter values can be modified only by authorized
personnel using password.

3.2.2 Program Parameter Summary:

The < PROG. XX > parameters that can be programmed in this mode are,

Program 00:
This is the constant feed rate set point used by the controller while operating in REMOTE
mode (useful when feeder is required to be operated independently). The unit of
measurement is MTons / Hour. Currently not used.

< PROG. 00 > XX.XXXX MTons/Hr

SET FEED RATE XX.XX

Program 01:
This is the speed set point for the belt drive motor in the LOCAL, CALIBRATION and
INCH modes. The value must be in between the maximum and minimum set values
(Program parameters 29 & 30).

< PROG. 01 > XXXX RPM

SET LOCAL SPEED XXXX

Program 02:
This is an initial density estimate of the material and it is used to initialize running
average density. Also used for feed rate calculation when the feeder is started in
volumetric mode. The unit for this parameter is Kg / Cu.m.

< PROG. 02 > XXXX.XXXX Kg/Cu.m

SET DENSITY XXXX.XX

Program 03:
The feeder can be set to run in any one of the 3 run modes. Viz.
Mode-0: Analog Feed rate Demand in mA,
Mode-1: Raise / Lower Feed rate demand,
Mode-2: Meant for Future Use

< PROG. 03 > X

SET RUN MODE (0-2) X

Bharat Heavy Electricals Limited

 Program 04:
This parameter specifies the unit of measure the processor will use for display the Feed
rates, Densities, Belt travel, Gravimetric / Volumetric Totals etc.
This is currently preset for Metric units as ‘0’ and the same should not be changed.
1 - Meant for Future Use

< PROG. 04 > X

UNIT SELECT (0-1) X

.
Program 05:
This is to set the Maximum Feed rate achievable by the feeder in REMOTE mode for a
Maximum Customer Feedrate Demand signal of 20mA (100%). The unit is MTons/Hour.

< PROG. 05 > XX.XXXX MTons/Hr

MAX FEED RATE XX.XX

Program 06:
This is to set the Minimum Feed rate achievable by the feeder in REMOTE mode for a
Customer Feedrate Demand signal between 4.0 and 7.2mA(20%). The unit is
MTons/Hour.

< PROG. 06 > XX.XX MTons/Hr

MIN FEED RATE XX.XX

Program 07:
This parameter is set to indicate the weight of coal delivered in Kg for every pulse output
for data logging purpose.
This is currently preset as 100 Kg and the same should not be changed.

< PROG. 07 > XXX Kg

SET TOTALIZER INCR XXX

Program 08:
This is to set the type of variable speed drive (ECC/VFD).
This is currently preset for VFD as ‘1’ and the same should not be changed.
1 - Meant for Variable Frequency Drive

< PROG. 08 > X

SELECT DRIVE (0-1) X

Bharat Heavy Electricals Limited

Program 09:
This is to set the type of tachometer used
‘0’ for 24 pole Tachometer and ‘1’ for 48 pole Tachometer
This is currently preset for VFD as ‘0’ and the same should not be changed.

< PROG. 09 > X

TACHO TYPE (0-1) X

Program 10:
This is to set the weigh span length, distance between the centers of the weigh span
rollers in metre.
This is currently preset for VFD as ‘0’ and the same should not be changed.

< PROG. 10 > X.XXXX M

WEIGHING LENGTH X.XXXX

Program 11:
This is to set the volume of material on the weigh span in cubic metre. It is calculated
from leveling bar contour height, material stream width, corner cut off dimensions and
weighing length. The unit of this parameter is Cubic meters
Volume for 24” Feeder : 0.0926 Cu.m
Volume for 36” Feeder : 0.1726 Cu.m

< PROG. 11 > X.XXXX Cu.m

ENTER VOLUME X.XXXX

Program 12:

This is to set the center distance between the (two) calibration probes, in metre.
This is currently preset as 0.914M and the same should not be changed.

< PROG. 12 > X.XXXX M

STANDARD PROBE SPAN X.XXXX

Program 13:
This is to set the Standard Test weight in kg. The value of Standard weight is stamped on
the weight assembly. The unit of measure is Kgs
Standard weight for 24” Feeder : 34.70 Kg
Standard weight for 36” Feeder : 86.80 Kg

< PROG. 13 > XX.XXXX Kg

STANDARD WEIGHT XX.XX

Bharat Heavy Electricals Limited

Note:
Incorrect value set in < PROG. 14 > and < PROG. 15 > may cause instability in
speed control.

Program 14:
This is to set the speed control gain of the control loop. This is predetermined for each
particular drive motor and control system combination.
This is currently preset for VFD as ‘30’ and the same should not be changed.

< PROG. 14 > XXX

SPEED CONTROL GAIN XXX

Program 15:
This parameter sets the feed back gain and it may cause uncontrolled motor behavior if
set improperly. This can affect the acceleration or deceleration of the drive speed.
This is currently preset for VFD as ‘14000’ and the same should not be changed.

< PROG. 15 > XXXXX

FEEDBACK GAIN XXXXX

Program 16:
This parameter sets the delay between the closure of Coal on Belt (LSCOB) or Feeder
Discharge Plugged (LSFDP) switch and feeder trip. The unit of measure is seconds.

< PROG. 16 > XXX sec

NO COB OR FDP DELAY XXX

Program 17:
This parameter sets the time delay in seconds to annunciate no detection of belt motion.
This is determined based on the time required for the pulley or roller to make one
complete revolution (when the feeder is operating at its minimum design feed rate). The
delay can be equal to the time as calculated above divided by 2 ± 10%.

< PROG. 17 > XXX sec

MOTN.MONI. DELAY XXX

Bharat Heavy Electricals Limited

Program 18:
This parameter sets the delay after a material void is detected in the down spout before
the feeder is tripped. The delay is computed based on the feeder feed rate and is
expressed as the volume of material delivered from the down spout after the void is
sensed.

< PROG. 18 > XX.XX Cu.m

COAL FLOW VOLUME XX.XX

Program 19:
This parameter sets the level of filtering on load cell signal measurement. It smooths out
the load cell signal where there is considerable mechanical vibration in the feeder. The
recommended initial setting shall be 4. Increasing the value by one, doubles the degree
of filtering and halves when the value is decreased by one.

< PROG. 19 > X

LC FILTER (1-8) X

Program 20 - 23:
These program parameters are reserved for future use.

< PROG. 20 >

FOR FUTURE USE

< PROG. 21 >

FOR FUTURE USE

< PROG. 22 >

FOR FUTURE USE

< PROG. 23 >

FOR FUTURE USE

Program 24:
This sets how the feeder’s actual feed rate signal to the customer behaves in the
absence of material on belt. A value of ‘0’ set for this parameter, ignores “No coal on belt”
signal and provides continuous feed rate signal. A value of 1 set for this parameter
makes the feed rate signal to zero incase of “No coal on belt” is detected.

< PROG. 24 > X

NO COAL ON BELT FB X

Bharat Heavy Electricals Limited

Program 25:
When a number of feeder controllers are connected to a centralized computer for data
logging purpose, each controller is identified by a unique number. This parameter is used
to set this number.
This is currently preset as ‘0’ and the same should not be changed.

< PROG. 25 > XXX

FEEDER ID NUMBER XXX

Program 26:
This parameter sets the source of feeder run for ‘REMOTE / OFF / LOCAL’ operations,
available as soft membrane keys on the Key Board Display (KBD) unit at Remote Control
Panel(RCP) front door and as door mounted rotary switch(MSL) at Local Control
Panel(LCP) front door.
‘0’ - Enables only the membrane keys at RCP,
‘1’ - Enables both membrane keys and rotary switch at RCP and LCP respectively.

For regular feeder operation this will be set as ‘0’ and the same may be set as ‘1’
for testing and calibration during maintenance.

< PROG. 26 > X

RUNMODE SELECT (0-1) X

Program 27 - 28:
These program parameters are reserved for future use.

< PROG. 27 >

FOR FUTURE USE

< PROG. 28 >

FOR FUTURE USE

Program 29 - 30:
Theses parameters is used only to compute and display the feeder main drive speed as
percentage to the maximum rated RPM

< PROG. 29 > XXXX RPM

MIN. SPEED LIMIT XXXX

< PROG. 30 > XXXX RPM

MAX. SPEED LIMIT XXXX

Bharat Heavy Electricals Limited

Program 31 - 32:
These program parameters are reserved for future use.

< PROG. 31 >

FOR FUTURE USE

< PROG. 32 >

FOR FUTURE USE

Program 33:
This parameter sets the ‘ON’ time of the Pulse Relay(PR) which is used for Remote Total
Coal Integrator (TCI) logging. The unit measured is seconds.
If this is set incorrectly, the Remote Total Coal Integrator may show erratic value of
material total.

< PROG. 33 > X.XXXX sec

TOTLZ.PULSE ON TIME X.XXX

Program 34:
This program parameter is reserved for future use.

< PROG. 34 >

FOR FUTURE USE

Program 35:
This parameter sets the allowed difference between the two load cell outputs with respect
to the average value of the output of load cells in terms of percentage.

< PROG. 35 > XX.XXXX %

LOADCELL TRACKING XX.XX

Program 36:
This parameter sets the gear ratio of the feeder main drive used for the specific project.

< PROG. 36 > XXX.X

GEAR RATIO (100-300) XXX.X

Program 37:
This parameter sets the diameter of the head pulley of the feeder main drive used for the
specific project. The unit for this parameter is in metre.

< PROG. 37 > X.XXXX M

HEAD PULLY DIA X.XXXX

Bharat Heavy Electricals Limited

Program 38:
This parameter is set to take care of the availability of belt motion sensor and its signal.
‘0’ - Enables the Belt Motion Sensor signal for monitoring and initiate a Trip if the
signal frequency is < the threshold.
‘1’ - Disables the above.

< PROG. 38 > X

B.M. BYPASS X

Program 39:
When feeder is started, depending on the system dynamics the system needs some time
for stabilization. This parameter sets the time delay before considering the RPM deviation
to generate feeder trip. The unit for this parameter is in seconds.

< PROG. 39 > XX sec

START- UP DELAY XX

Program 40:
This parameter sets the difference in RPM between computed reference value and actual
value for generating feeder trip on RPM deviation.

< PROG. 40 > XXX

RPM DIFFERENCE XXX

Caution:
Program 41 - 49 will be updated by the system after every calibration.

Program 41:
This parameter is to set the ‘TARE CAL FACTOR’ obtained during calibration process.

< PROG. 41 > XXXXX.XX

TARE CAL FACTOR XXXXX.XX

Program 42:
This parameter is to set the ‘SPEED CAL FACTOR’ obtained during calibration process.

< PROG. 42 > X.XXXXXX

SPEED CAL FACTOR X.XXXXXX

Bharat Heavy Electricals Limited

Program 43:
This parameter is to set the ‘SPAN CAL FACTOR’ obtained during calibration process.

< PROG. 43 > X.XXXXXX

SPAN CAL FACTOR X.XXXXXX

Program 44:
This parameter is to set the ‘BELT LENGTH’ obtained during calibration process.

< PROG. 44 > X.XXXXXX

BELT LENGTH X.XXXXXX

Program 45:
This parameter is to set the ‘BELT CAL FACTOR’ obtained during calibration process.

< PROG. 45 > X.XXXXXXXX

BELT CAL FACTOR X.XXXXXXXX

Program 46:
This parameter is to set the ‘LOADCELL 1 .TARE’ obtained during calibration process.

< PROG. 46 > XXXXX.XX

LOADCELL 1 .TARE XXXXX.XX

Program 47:
This parameter is to set the ‘LOADCELL 2 .TARE’ obtained during calibration process.

< PROG. 47 > XXXXX.XX

LOADCELL 2 .TARE XXXXX.XX

Program 48:
This parameter is to set the ‘LOADCELL 1 .SPAN’ obtained during calibration process.

< PROG. 48 > XXXXX.XX

LOADCELL 1 .SPAN XXXXX.XX

Program 49:
This parameter is to set the ‘LOADCELL 1 .SPAN’ obtained during calibration process.

< PROG. 49 > XXXXX.XX

LOADCELL 2 .SPAN XXXXX.XX

Bharat Heavy Electricals Limited

3.2.3 Program Parameter Data – Typical (Refer Note-1):

PROG. Value as
Description Unit Reference
No. Tested
00 SET FEED RATE 14.0 MTon/ Hr
01 SET LOCAL SPEED 1000 RPM
Project Specific
02 SET DENSITY 1000 kg/cu.m
0 - FR Dem.(mA),
03 SET RUN MODE 0 1 – Raise / Lower
2 – Future use
0 – Metric
04 UNIT SELECT 0
1 – Future use
05 MAX FEED RATE 70.0 MTon/ Hr Project Specific
06 MIN FEED RATE 14.0 MTon/ Hr
07 SET TOTALIZER INCR. 100 kg
0 – ECC / VFD
08 SELECT DRIVE 0
1 – Future use
09 TACHO TYPE 0 0 – 24 Pole, 1 – 48 Pole
10 WEIGHING LENGTH 0.914 M
11 ENTER VOLUME 0.1726 Cu.m Project Specific
12 STANDARD PROBE SPAN 0.914 M
13 STANDARD WEIGHT 86.8 Kg
14 SPEED CONTROL GAIN 20
15 FEED BACK GAIN 14000
16 NO COB OR FDP DELAY 2.0 sec
17 MOTN. MONI. DELAY 0.0 sec
18 COAL FLOW VOLUME 0.5 Cu.m Project Specific
19 LC FILTER 4
20 - 23 FOR FUTURE USE
24 NO COAL ON BELT FB 0
25 FEEDER ID NUMBER 0
0 - RCP only.
26 RUN MODE SELECT 0
1 - Both RCP & LCP.
27&28 FOR FUTURE USE
29 MIN. SPEED LIMIT 5 RPM
30 MAX. SPEED LIMIT 1500 RPM
31& 32 FOR FUTURE USE
33 TOTALIZER PULSE ON TIME 0.10 sec
34 FOR FUTURE USE
35 LOAD CELL TRACKING 12.5 %
36 GEAR RATIO 138.9 Project Specific
37 HEAD PULLEY DIA 0.325 m
38 B.M BY PASS 0 0 – Disabled, 1 - Enabled
39 START-UP DELAY 15 sec
40 RPM DIFFERENCE 100 RPM
41 TARE CAL FACTOR
42 SPEED CAL FACTOR
43 SPAN CAL FACTOR
44 BELT LENGTH Parameter 41 to 49 will be
45 BELT CAL FACTOR updated by the system after
46 LOADCELL1 TARE every calibration.
47 LOADCELL2 TARE
48 LOADCELL1 SPAN
49 LOADCELL2 SPAN

Note 1:
Refer Project specific Program Parameters detail.

Bharat Heavy Electricals Limited

 PACKED INDUSTRIAL PC WITH INTEL PENTIUM III PROCESSOR
The PIP8 is a highly integrated robust industrial PC with a specially designed hi g h qu a l it y aluminum
housing. This allows the system to operate without fan or ventilation holes. The design integrates standard
connectors for easy connection. It can be used for any PC application where a complete solution is needed.
The PIP8 can be used in a standard or in a rugged operating environment, is 100% PC/AT compatible, and can
easily be mounted on a 35 mm DIN rail.
The PIP8 housing offers space for a 2.5 inch hard disk and a slim-line floppy disk drive. With the integrated
PC/104 interface flexible expansion possibilities are available. Fully bootable FLASH disks are supported for
projects where hard disks or floppy disks cannot be used. Particular precautions have been taken that the EMC
for the entire system is within the CE and FCC limits.
All these features make the PIP8 the ideal solution for the industry wherever a flexible, rugged and d ur a b le
complete Industrial PC is needed.

Features:
● Low power Pentium® III processor ● M-Systems DiskOnChip® 2000 Support
● Processor speed 700 MHz ● Multipurpose Socket
● Up to 256 Mbytes SDRAM ● Isolated CAN bus interface
● Integrated SXGA graphics controller ● 2 USB Ports
● CRT and panel support ● Integrated 2.5 inch HDD and FDD
● Integrated 10/100 Mbit/s Ethernet controller ● Four RS232 ports
● Integrated SCSI-2 Host Controller ● 2 Isolated half duplex RS485 ports (optional)
● 2 PC/104 and PC/104+interface ● 1 Isolated full duplex RS422 ports (optional)
● 48 Digital I/O’s via PIPDIO48-1 (optional) ● Integrated temperature sensor
● BIOS source code owned by MPL ● Wide supply voltage range

1
 TABLE OF CONTENTS

1 INTRODUCTION........................................................................................................ 4
1.1 ABOUT THIS MANUAL.................................................................................................... 4
1.2 SAFETY PRECAUTIONS AND HANDLING.................................................................... 4
1.3 ELECTROSTATIC DISCHARGE (ESD) PROTECTION.................................................. 4
1.4 EQUIPMENT SAFETY...................................................................................................... 4

2 GENERAL INFORMATION.........................................................................................5
2.1 ELECTRICAL................................................................................................................... 5
2.2 EXTERNAL INTERFACES.............................................................................................. 5
2.3 INDICATORS……………….............................................................................................. 5
2.3.1 Reset Button, Power Button…………………………………………………………...…….. 5
2.4 PHYSICAL....................................................................................................................... 6
2.4.1 Housing...................................................................................................................... 6
2.4.2 Form factor................................................................................................................. 6
2.4.3 Weight........................................................................................................................ 6
2.5 POWER........................................................................................................................... 6
2.5.1 Power supply.............................................................................................................. 6
2.5.2 Fuse........................................................................................................................... 6
2.5.3 RTC Battery................................................................................................................ 6
2.5.4 Input Power Range..................................................................................................... 6
2.6 ENVIRONMENT.............................................................................................................. 6
2.6.1 Temperature Range................................................................................................... 6
2.6.2 Relative Humidity........................................................................................................ 6

3 DIMENSIONS.............................................................................................................. 7
3.1 TOP VIEW........................................................................................................................ 7
3.2 BOTTOM VIEW............................................................................................................... 8
3.3 SIDE VIEW 1.................................................................................................................. 9
3.4 SIDE VIEW 2.................................................................................................................. 10
3.5 SIDE VIEW 3.................................................................................................................. 11
3.6 SIDE VIEW 4.................................................................................................................. 11

4 CONNECTORS.......................................................................................................... 12
4.1 PARALLEL PORT CONNECTOR................................................................................... 12
4.2 DIGITAL I/O PORT 1 & 2 CONNECTORS………............................................................ 13
4.3 SERIAL PORT1 AND SERIAL PORT 2 CONNECTOR.................................................... 14
4.4 SERIAL PORT 3 AND SERIAL PORT 4 CONNECTOR.................................................... 14
4.5 EXTERNAL POWER CONNECTOR............................................................................... 15
4.5.1 External Power Connector Pin Out............................................................................. 15
4.5.2 Mounting An External Reset And Power Button......................................................... 15
4.6 PS/2 KEYBOARD AND MOUSE CONNECTORS.......................................................... 16
4.7 USB CONNECTOR........................................................................................................ 16
4.8 VGA CONNECTOR.......................................................................................................... 17
4.9 LAN Connector 10/100 Base TX……….......................................................................... 17

2
5 OPERATION.............................................................................................................. 18
5.1 PC/AT FUNCTIONALITY................................................................................................ 18
5.2 STATUS INDICATORS……………………………............................................................ 18
5.2.1 Power Indicator LED................................................................................................... 18
5.2.2 Reset Indicator LED................................................................................................... 18
5.2.3 HDD Access r LED.................................................................................................... 18
5.2.4 SCSI Access Indicator LED…………………………………………………………..…….. 18
5.2.5 LAN Activity Indicator LED......................................................................................... 18
5.2.6 LAN 100 Indicator…………........................................................................................ 18
5.2.7 USER1, USER2 Indicator LEDs................................................................................ 18
5.2.8 Power Button............................................................................................................. 18

6 COPYRIGHT.............................................................................................................. 19

7 DISCLAIMER............................................................................................................. 19

8 TRADEMARKS.......................................................................................................... 19

9 SUPPORT.................................................................................................................. 19
9.1 FAQ................................................................................................................................. 19
9.2 SERIAL NUMBER AND REVISION................................................................................ 19
9.3 CONTACT MPL AG......................................................................................................... 19

3
1 INTRODUCTION

1.1 ABOUT THIS MANUAL

This manual provides all the information necessary to handle and configure the PIP8.

This manual is written for technical personnel responsible for integrating the PIP8 into their systems.

It is strongly recommended to read this manual before the PIP8 is switched on.

1.2 SAFETY PRECAUTIONS AND HANDLING

For personal safety and safe operation of the PIP8, follow all safety procedures described here and in other
sections of the manual.

● Remove power from the system before installing (or removing) the PIP8, to prevent the possibility of personal
injury (electrical shock) and / or damage to the product.
● Handle the product carefully; i.e. dropping or mishandling the PIP8 can cause damage to assemblies and
components.
● Do not expose the equipment to moisture.

NOTE

There are no user-serviceable components on the PIP8.

1.3 ELECTROSTATIC DISCHARGE (ESD) PROTECTION

Various electrical components within the product are sensitive to static and electrostatic discharge (ESD). Even
a small static discharge can be sufficient to destroy or degrade a component's operation!
With an open housing, do not touch any electronic components. Handle or touch only the unit chassis.

1.4 EQUIPMENT SAFETY

Great care is taken by MPL AG that all its products are thoroughly and rigorously tested before leaving the
factory to ensure that they are fully operational and conform to specification. However, no matter how reliable a
product, there is always the remote possibility that a defect may occur. The occurrence of a defect on this
device may, under certain conditions, cause a defect to occur in adjoining and/or connected equipment. It is
your responsibility to protect such equipment when installing this device. MPL accepts no
responsibility whatsoever for such defects, however caused.

4
2 GENERAL INFORMATION
This chapter provides an overview of the PIP8 and its features. It outlines the electrical and physical
specifications of the product and its power requirements.

2.1 ELECTRICAL
• Processor: Intel Low power Embedded Pentium® III CPU, 700MHz
• Chipset: Intel 440BX with 100MHz bus speed
• Graphics: Chips & Technology 69000 Graphics Accelerator
• BIOS: 256Kbyte Flash EEPROM, easy updateable.
• SDRAM: 144 pin SO-DIMM memory module up to 256MB
• E-IDE: Ultra DMA/33, PIO mode 4, bus master IDE

2.2 EXTERNAL INTERFACES

• 1x Input Power (8-28VDC) connector.
• 2 × PS/2 Interfaces for Keyboard & Mouse.
• 1 × VGA Interface
• 1 × SCSI Interface
• 1 × CAN Bus Interface
• 2 × USB 1.1 ports
• 2 × Serial Ports (COM1, COM2 as RS232)
• 2 x Serial ports (COM3 & COM4) can be equipped either with RS232/485/422 interface modules (optional)
• 1 × Parallel Port
• 2 x Digital I/O Ports (optional)
• 1 × Fast Ethernet Interface

2.3 INDICATORS
• Power (yellow)
• Reset (red) and power fail (red blinking) LED
• HDD activity (green) LED
• LAN link (green) and activity (green blinking) LED
• LAN Speed LED (100MBit/s green)
• 2 user-programmable LED’s (green)

2.3.1 Reset Button, Power Button

• Reset button, protected against unintended actuation
• Connection for an external remote reset switch
• Connection for an external remote power button switch (ATX functionality)

5
2.4 PHYSICAL
2.4.1 Housing
• Aluminum
• No ventilation holes
• Easily mountable on 35 mm DIN rail

2.4.2 Form factor

• Length: 270 mm (10.63 inch)
• Width: 162 mm (6.38 inch)
• Height: 62 mm (2.44 inch) standard version
78 mm (3.07 inch) high version

2.4.3 Weight
• Typically approximately 2.2 kg (4.85 lb.)
(Standard housing versions, equipped with internal 2.5 inch HDD and FDD)

2.5 POWER
2.5.1 Power supply
• High-efficiency 4 channel switching regulator module
• ATX behavior (Soft off)
• ESD protected

2.5.2 Fuse
• 5 x 20 mm, 3.15 AT

2.5.3 RTC Battery

• Lithium coin cell CR2032 (20.0 x 3.2 mm)
• 3 V / 235 mAh
Field changeable

2.5.4 Input Power Range

+8V to +28VDC

2.5.5 Power Consumption

Typical 17W

2.6 ENVIRONMENT
2.6.1 Temperature Range
• 0°C to +60°C (+32°F to +140°C) without internal HDD or FDD’
• Extended temperature range available

2.6.2 Relative Humidity

• 10% to 90% non-condensing

6
3 DIMENSIONS

3.1 TOP VIEW

7
3.2 BOTTOM VIEW

8
3.3 SIDE VIEW 1

9
3.4 SIDE VIEW 2

10
3.5 SIDE VIEW 3

3.6 SIDE VIEW 4

11
4 CONNECTORS

4.1 PARALLEL PORT CONNECTOR

The parallel port can also operate as an external floppy disk port. (see BIOS Setup “Customer configuration).

Parallel Port Mode Pinout

Pin Signal Description
1 STROBE Strobe
2 DATA0 Data bit 0
3 DATA1 Data bit 1
4 DATA2 Data bit 2
5 DATA3 Data bit 3
6 DATA4 Data bit 4
7 DATA5 Data bit 5
8 DATA6 Data bit 6
9 DATA7 Data bit 7
10 ACK Acknowledge
11 BUSY Busy
12 PE Paper empty
13 SELIN Select in
14 AUTOFD Autofeed
15 ERROR Error
16 /INIT Initialize
17 /SEL Select
18 GND Ground
19 GND Ground
20 GND Ground
21 GND Ground
22 GND Ground
23 GND Ground
24 GND Ground 13 1
25 GND Ground
Floppy Disk Mode
Pin Signal Description
1 DS0 Drive Select 0 25 14
2 IDX Index
D-SUB 25 pin female
3 TR00 Track 0
4 WP Write Protected
5 RDATA Read Data
6 DSKCHG Disk Change
7 MID0 Media ID 0
8 MTR0 Motor On 0
9 MID1 Media ID 1
10 DS1 Drive Select 1
11 MTR1 Motor On 1
12 WDATA Write Data
13 WGATE Write Gate
14 DRVDEN0 Drive Density 0
15 HDSEL Head Select
16 DIR Direction
17 STEP Step
18 GND Ground
19 GND Ground
20 GND Ground
21 GND Ground
22 GND Ground
23 GND Ground
24 GND Ground
25 VCC 5 V Power, enable in BIOS

12
4.2 DIGITAL I/O PORT 1 & 2 CONNECTORS

DIGITAL I/O Port (1 & 2) Pinout

Pin Signal Description
1 DIOA7 Digital I/O A7
2 GND Ground
3 DIOA6 Digital I/O A6
4 GND Ground
5 DIOA5 Digital I/O A5
6 GND Ground
7 DIOA4 Digital I/O A4
8 GND Ground
9 DIOA3 Digital I/O A3
10 GND Ground
11 DIOA2 Digital I/O A2
12 GND Ground
13 DIOA1 Digital I/O A1
14 GND Ground
15 DIOA0 Digital I/O A0
16 GND Ground
17 DIOC7 Digital I/O C7
18 GND Ground
19 DIOC6 Digital I/O C6
20 GND Ground
21 DIOC5 Digital I/O C5
22 GND Ground
23 DIOC4 Digital I/O C4
24 GND Ground
25 DIOC3 Digital I/O C3
26 GND Ground
27 DIOC2 Digital I/O C2
28 GND Ground
29 DIOC1 Digital I/O C1 Figure 8: Digital I/O Connector
30 GND Ground (50Pin female HD Connector)
31 DIOC0 Digital I/O C0
32 GND Ground
33 DIOB7 Digital I/O B7
34 GND Ground
35 DIOB6 Digital I/O B6
36 GND Ground
37 DIOB5 Digital I/O B5
38 GND Ground
39 DIOB4 Digital I/O B4
40 GND Ground
41 DIOB3 Digital I/O B3
42 GND Ground
43 DIOB2 Digital I/O B2
44 GND Ground
45 DIOB1 Digital I/O B1
46 GND Ground
47 DIOB0 Digital I/O B0
48 GND Ground
49 +5V +5V
50 GND Ground

13
4.3 SERIAL PORT 1 AND SERIAL PORT 2 CONNECTOR
Pin Signal Description Pinout
1 DCD Carrier detect
2 RXD Receive data 1 5
3 TXD Transmit data
4 DTR Data terminal ready
5 GND Ground
6 DSR Data set ready 6 9
7 RTS Request to send
8 CTS Clear to send D-SUB
D-SUB 9 pin 9 Pin
eUB 9 male) male
9 RI Ring indicator

4.4 SERIAL PORT 3 AND SERIAL PORT 4 CONNECTOR

Pin Number Signal Description

1 GND Ground
2 TXD3 Transmit data (SERIAL 3)
3 RXD3 Receive data (SERIAL 3)
4 RTS3 Request to send (SERIAL 3)
5 CTS3 Clear to send (SERIAL 3)
6 DSR3 Data set ready (SERIAL 3)
7 GND Ground
8 DCD3 Carrier detect (SERIAL 3)
9 IRRX3 Control pin for fast IrDA (TTL level, controlled by COM2)
10 CTS4 Clear to send (SERIAL 4)
11 485B4 RS485 balanced RTX4-line (SERIAL 4)
12 485B3 RS485 balanced RTX3-line (SERIAL 3)
13 485SHLD3 RS485 isolated shield (SERIAL 3)
14 TXD4 Transmit data (SERIAL 4)
15 IRRX Infrared receive signal (TTL level, controlled by COM2)
16 RXD4 Receive data (SERIAL 4)
17 VCC5 5 V power supply
18 IRTX Infrared transmit signal (TTL level, controlled by COM2)
19 RTS4 Request to send (SERIAL 4)
20 DTR3 Data terminal ready (SERIAL 3)
21 GND Ground
22 RI3 Ring indicator (SERIAL 3)
23 485SHLD4 RS485 isolated shield (SERIAL 4)
24 485A4 RS485 balanced RTX+ line (SERIAL 4)
25 485A3 RS485 balanced RTX+ line (SERIAL 3)

14
4.5 POWER CONNECTOR
4.5.1 External Power Connector Pin Out

Pin Signal Description Pinout

1 VIN Input voltage (+8 to +28 VDC)
2 GND Ground
3 RST Reset Input
4 PWRBTN Power Button Input 1 2 3 4

Figure 11: Power Connector (Connector: Phoenix

Contact AG, MC1,5/4GF-3,81)

WARNING

Wrong polarization of the input voltage can cause serious damage to your PIP8!

4.5.2 Mounting An External Reset And Power Button Switch

1 2 3 4

Reset Power
Button Button

VINCON GNDCON

Figure 12: External Reset and Power Button Switch

15
4.6 PS/2 KEYBOARD AND MOUSE CONNECTORS
Standard PS/2 pin out (6 pin mini-DIN, female). A PC/AT keyboard can also be connected with an adapter.
Pin Signal Description Pinout
1 DAT Data
2 NC Not connected 6 5
3 GND Ground
4 3
4 VCC +5 V
5 CLK Clock
6 NC Not connected 2 1

Figure 13: PS/2 Keyboard & Mouse Connector

(Connector: Compona, 129108-7)

4.7 USB CONNECTOR

Pin Number Signal Description Pin out

1 VCC Cable Power +5 V
2 -Data Balanced Data Line
3 +Data Balanced Data Line +
4 GND Cable Ground

16
4.8 VGA CRT CONNECTOR
Standard DB 15-HD pin out.

Pin Number Signal Description Pin out

1 Red
2 Green
3 Blue
4 Not connected
5 Ground
6 Analog Ground
7 Analog Ground
8 Analog Ground
9 +5 V
10 Ground
11 Not connected
12 DDC data
13 Horizontal synchronization HD-SUB 15 pin female 15 610 1115
14 Vertical synchronization
15 DDC clock

4.9 LAN CONNECTOR 10/100 BASETX

Standard RJ45 connector for a 100 ohm cable.

Pin Signal Description Pin

1 TX+ Transmit data+ out
2 TX- Transmit data -
3 Rx+ Receive data +
4 NC Not connected
5 NC Not connected
8 1
6 Rx- Receive data -
7 NC Not connected RJ45 Connector
8 NC Not connected

17
5 OPERATION

5.1 PC/AT FUNCTIONALITY

The PIP8 operates as a standard PC/AT with all dedicated registers for
● Timers
● Interrupt controller
● DMA controller
● Real-time clock
● Keyboard controller
● Parallel, serial ports
● IDE controller
● FDD controller
● VGA controller

5.2 STATUS INDICATORS

The PIP8 provides eight status indicator LEDs, giving you visual information about the actual operating status.

5.2.1 Power Indicator LED

The yellow power LED indicator is lit when the system is powered.

5.2.2 Reset Indicator LED

The red reset LED is lit if the system is powered and reset is activate.
If the RED reset LED is blinking the system is in power-fail state. This means the power supply was overloaded
or a short circuit has occurred for a longer time. In this case the power supply switches off to protect itself. You
can restart the power supply by pressing the reset button (future option) or by cycling the power itself.

5.2.3 HDD Access Indicator LED

The green HDD access indicator is lit whenever a IDE device is accessed.

5.2.4 SCSI Access Indicator LED

The green SCSI access indicator is lit whenever a SCSI device is accessed.

5.2.5 LAN Activity Indicator LED

The green LAN access indicator is lit whenever a link is detected. It blinks on network activity.

5.2.6 LAN 100 Indicator LED

The green LAN100 link indicator is lit whenever a 100MBit/s link is detected.

5.2.7 USER1, USER2 Indicator LEDs

The green USER1 and USER2 LEDs are programmable.

Programming USER LEDs

The green USER1 and USER2 LEDs are programmable

5.2.8 Power Button

You control the LEDs by programming the registers ULEDCTRL at I/O address 809H.

18
6 COPYRIGHT AND REVISION HISTORY
Copyright © 2005 by MPL AG Elektronikunternehmen. All rights are reserved. Reproduction of this document in
part or whole, by any means, is prohibited, without written permission from MPL AG Elektronikunternehmen.
This manual reflects revision D of the PIP8-1.

7 DISCLAIMER
The information contained herein is believed to be accurate as of the data of this publication, however, MPL
AG will not be liable for any damages including indirect or consequential, arising out of the application or use of
any product, circuit or software description herein.

MPL AG reserves the right to make changes to any product herein to improve reliability, function or design.

8 TRADEMARKS
Brand or product names are trademarks and registered trademarks of their respective holders.

9 SUPPORT

9.1 FAQ
Please have a look at our homepage www.mpl.ch/t2400.html. In the menu at the left hand side you will find
FAQ's for each PIP.

9.2 SERIAL NUMBER AND REVISION

For support it is necessary that you know the product name, the product variant, the serial number and revision
and the BIOS number of your PIP8. Please have a look at the label on the bottom of the PIP8 housing for this.

Product Product Serial Number

Name Variant and Revision

PIP8-1
SN: 10265 [E]
BIOS: MEV-10100-071
Rating: 8-28VDC, 3.15A

Figure 17: PIP8 Label

9.3 CONTACT MPL AG
In case of general information questions please feel free to contact us at our homepage (www.mpl.ch) or per
email ([email protected]).
In case of sales information questions please send an email to [email protected].
If you have a technical problem with a PIP8, first please read the BIOS User Manual, the Technical Reference
Manual and also this manual carefully. If you can’t solve the Problem on your own you can contact us for
technical support per email at [email protected].

Our local Distributor:

19
 Section – 4.0

Maintenance

Bharat Heavy Electricals Limited

 Section – 4.0

Maintenance

Title

4.1 BHELFEED – MPGFC Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1.1 Feeder Calibration Procedure . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1.2 Error List Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1.2 Self Check Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2 BHELFEED - MPGFC Trouble Shooting on I/O Modules. . . . . . . . . . . .

4.3 DO’s and DON’Ts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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4.1 BHELFEED – MPGFC Maintenance

Inspection, Maintenance and Calibration schedule:

Periodic inspection, Maintenance and Calibration are essential for the safe and efficient operation
of the BHELFEED – MPGFC System.

To obtain maximum weighing accuracy, the following checks are essential:

• Check & ensure proper belt tension & tracking,
• Check & ensure proper alignment / leveling / freeness of weigh span rollers,
• Check & ensure freeness / alignment of test weight and drag link assembly
• Check & ensure Calibration after every 6 months of feeder run or as and when required
• Check & ensure seal air mechanism for proper pressure levels.

4.1.1 Feeder Calibration Procedure

The feeder should be calibrated with Standard Test Weight supplied along with the
feeder,
• At startup,
• After one month of initial operation,
• Once in six months thereafter.

Calibration should also be performed when,

§ Weigh roller leveling / readjusted,
§ Replacement of the belt,
§ Replacement of load cell units,
§ Replacement of Processor Unit.

Calibration process consists of 3 major steps viz.

• Elimination of system tare, which includes the weight of the weigh span rollers,
feeder belt, load cell support mechanism etc.
• Belt speed measurement and its relationship to motor speed.
• Calibrate of the load cell output with a known test weight.

which are covered in two steps viz. TARE CAL & SPAN CAL

Note:
Before calibration let the feeder be run for 20 to 30 minutes to make the belt flexible.

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 The following are the steps to be adopted during feeder calibration,
§ Close the feeder inlet gate provided in the coal pipe.
§ Run the feeder in local and empty the belt if any material on it.
§ Switch off the feeder
§ Close the seal air supply.
§ Close the feeder discharge gate
§ Open all the feeder access doors at ends and sides.
§ Ensure foe adequate tension and tracking of belt by adjusting the belt tensioning
screws.
§ Count the number of curbs and put reflective tapes (4 nos.) at equal intervals on
the curb vertically.
§ Ensure the distance between any to tapes must be greater than the standard
calibration probe distance.
§ Align / level the weigh rollers (leading, trailing and center loadcell rollers all in
same level) using level bar (supplied as calibration tool along with the feeders),
by adjusting the adjuster nut provided in the load cell assembly units at both
sides of the feeder. Once the leveling of these weigh rollers is finished, lock the
position with the help of lock nuts available on the load cell assemblies.
§ Ensure freeness of draglink mechanism at the fulcrums and at load cell
suspension roller ends.
§ Remove the two plugs adjacent to the weigh span roller end fittings for insertion
of the calibration probes. Remove the protective caps from the calibration probes
and insert one probe into each access port in the feeder body.
§ Align the detent pins on the probe with the machined pin holes adjacent to the
probe access hole. Both probes are identical, the probe inserted nearest to the
feeder inlet is designated as Probe - A and the probe inserted nearest to the
discharge is designated as Probe - B.

Caution:
Ensure the power (toggle) switch in the Signal Conditioning Module is OFF before
connecting the probe cables to circular receptacles CP - A & CP - B.

§ Verify the Standard Test weight against the value that is stored in the < PROG.
13 >. If there is any mismatch, enter the correct value as stamped on the
Standard test weight.
§ Verify the calibration speed against the value stored in the < PROG. 01 > If there
is any mismatch, enter the required value of calibration speed.

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 Calibration is an off line activity and performed while the feeder is in OFF mode. It is
performed in two steps.

1. TARE CAL and 2. SPAN CAL.

§ Before performing SPAN CAL, TARE CAL must be completed successfully.

§ Now the feeder is ready for calibrations viz. TARE & SPAN sequentially.
§ Ensure that the Standard Test Weight is disengaged from the load cells by
positioning the test weight operating lever at 9 o’clock position

TARE CAL
Initiate the TARE CAL sequence to process the tare and belt travel measurement by
pressing the TARE CAL on the Key Board
The feeder begins to operate in LOCAL with constant speed as set in < PROG. 01 >

Observe the following LEDs status,

FEEDER RUN & LOCAL LEDs (Red) are ON

OFF LED (Green) is OFF
VF Display indicates :

< TARE CAL > Initializing . . . .

for two seconds on the upper line of the display.

A 25 second time delay is initiated to permit the system to stabilize at the desired
calibration speed as set in < PROG. 01 >
The display changes to show:

< TARE CAL > Tare and Belt Speed Factor

HH:MM:SS Stabilizing . . . . @ XXXX RPM,

where HH:MM:SS shows the estimated calibration time and XXXX shows the drive speed
during calibration.

Note:
The calibration time shown is only for reference based on the last TARE CAL and it no
way hampers the present TARE CAL. The time displayed may be different if the CPU,
Memory chip, feeder belt etc. under gone a change.

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After the expiry of preset delay time (25sec.) the display shows

< TARE CAL > Tare and Belt Speed Factor

HH:MM:SS Stabilized . . . . @ XXXX RPM,

st
and when the 1 reflector tape passes Cal. Probe - A, initiates the display to show

< TARE CAL > Tare and Belt Speed Factor

HH:MM:SS Pass # 1 Timing

and the HH:MM:SS count down timer starts counting.

When the tape passes Cal. Probe - B, the display changes to

< TARE CAL > Tare and Belt Speed Factor

HH:MM:SS Pass # 1 Done

When the next tape passes Cal Probe – A / B the Pass number is incremented by 1 and
It continues till the completion of 8 events.
i.e When the eighth tape passes Cal. Probe B, the display changes to:

< TARE CAL > Finishing Belt Revolution

Pass # 8 Done

th
As the 9 reflector tape passes Cal. Probe - A, the belt would have completed exactly
two revolutions (or four revolutions if 2 reflector tapes were used).
The drive motor is de-energized and the display shows the farthest Tare Cal Factor
deviation of the eight belt speed measurements made during TARE CAL, for 3 seconds
as shown below

< TARE CAL > Dev:X.XX %

Good Values = X

The display also shows the calibration values for TARE CAL as

< TARE CAL > Tare Factor: XXXXXXX.XX

Speed factor X.XXXXXX < ENTER > Saves

Press ENTER to save the new measurements and the system is ready for SPAN CAL
sequence.
If the cal results are greater than a programmed threshold limits, the display shows:

< TARE
Press CALto >make another TARE
ENTER Dev:X.XX % Bad!
CAL sequence.
< ENTER > to re CAL < ESC > to Quit

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Even after many attempts the TARE CAL still fails, press EXIT to end the calibration.
Troubleshoot for possible problems in the motor speed control / belt travel.

If TARE CAL, is successful, either proceed to SPAN CAL or repeat TARE CAL as many
times as desired.

SPAN CAL
Initiate the SPAN CAL sequence by pressing the SPAN CAL on the Key Board
The feeder begins to operate in LOCAL with constant speed as set in < PROG. 01 >
Observe the following LEDs status,
FEEDER RUN & LOCAL LEDs (Red) are ON
OFF LED (Green) is OFF
The display shows,

Add Calibration Weight of xx.xx Kg

< ENTER > to start SPAN CAL

Ensure that the Standard Test Weight is engaged on the load cells by positioning the test
weight operating lever at 3 o’clock position.

Press ENTER to start the SPAN CAL sequence

VF Display indicates :

< SPAN CAL > Initialization . . . .

for two seconds on the upper line of the display.

A 25 second time delay is initiated to permit the system to stabilize at the desired
calibration speed as set in < PROG. 01 >
The display changes to show:

< SPAN CAL > Span Factor

HH:MM:SS Stabilizing . . . . @ XXXX RPM,

where HH:MM:SS shows the estimated calibration time and XXXX shows the drive speed
during calibration.

Note:
The calibration time shown is only for reference based on the last SPAN CAL
and it no way hampers the present SPAN CAL. The time displayed may be
different if the CPU, Memory chip, feeder belt etc. under gone a change.

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After the expiry of preset delay time (25sec.) the display shows

< SPAN CAL > Span Factor

HH:MM:SS Stabilized . . . . @ XXXX RPM,

st
and when the 1 reflector tape passes Cal. Probe - A, initiates the display to show

< SPAN CAL > Span Factor

HH:MM:SS Pass # 1 Timing

and the HH:MM:SS count down timer starts counting.

When the tape passes Cal. Probe - B, the display changes to

< SPAN CAL > Span Factor

HH:MM:SS Pass # 1 Done

When the next tape passes Cal Probe – A / B the Pass number is incremented by 1 and
It continues till the completion of 8 events.
i.e When the eighth tape passes Cal. Probe B, the display changes to:

< SPAN CAL > Finishing Belt Revolution

Pass # 8 Done

th
As the 9 reflector tape passes Cal. Probe - A, the belt would have completed exactly
two revolutions (or four revolutions if 2 reflector tapes were used).
The display shows the farthest Span Cal Factor deviation of the eight belt measurements
made during SPAN CAL, for 3 seconds as

< SPAN CAL > Dev:X.XX %

Good Values = X

The display also shows the calibration values for SPAN CAL as

< SPAN CAL > Span factor X.XXXXXX

Speed Factor: X.XXXX < ENTER > Saves

Press ENTER to save the new measurements.

If the cal results are greater than a programmed threshold limit, the display shows:

< SPAN CAL > Dev:X.XX % Bad!

< ENTER > to re CAL < ESC > to Quit

If calibration has failed the display shows:

Bad values = x
Press ENTER to repeat the calibration
ESC to return to the default Screen.

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4.1.2 ERROR LIST Summary:

Operate ERROR LIST key on the membrane key board and observe the following on
vacuum fluorescent (VFD) display sceen.

< ERROR CODE XX > Date:DD/MM/YY

Description Time: HH:MM:SS

A total of 21 ERROR LIST parameters are listed in this mode, which can be verified by
the Operation / Maintenance personnel for BHELFEED system diagnostic.

The keys that can be operated are:

ERROR NUMERIC PAD

NEXT PREV ENTER ESC
LIST 0 . . . . . 9 , 00

Fig .4.1 Illustration on ERROR LIST Operational Keys

XX denotes the error code, YY denotes an index number ranging from 00 to 08. Index
number 00 indicates the latest occurrence of the error. Each error on occurrence is time
stamped with date. A maximum of 8 errors can be monitored in this mode.

By operating ERROR LIST or NEXT / PREV key, parameter number can be incremented
/ decremented. This mode can be terminated by pressing ESC key .

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The Error List parameters that can be monitored are,

Error Error Alarm/

Code Description Trip
01 LC 1 SIGNAL OUT OF RANGE Alarm
02 LC 2 SIGNAL OUT OF RANGE Alarm
03 DEMAND SIGNAL OUT OF RANGE Alarm
04 LOSS OF BOTH TACHOS Trip
05 LOSS OF TACHO - 1 Alarm
06 LOSS OF TACHO - 2 Alarm
07 BELT MOTN. MONI. TIMED OUT Trip
08 FEEDER DISCHARGE PLUGGED Trip
09 MATL. ON BELT LOCAL / CALIB Trip
10 REMOTE TCI INCREMENTS TOO SMALL Alarm
11 FEED RATE ERROR Alarm
12 MOTOR STARTER FAULT Trip
13 RPM DEVIATION Trip
14 CF MONITOR FAULT Trip
15 LOSS OF FLOW Trip
16 AIM MODULE BAD Trip
17 DIM MODULE BAD Trip
18 PIM MODULE BAD Trip
19 AOM MODULE BAD Trip
20 DOM MODULE BAD Trip
21 NO MATL. ON BELT IN REMOTE Trip

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4.1.3 SELF CHECK Summary:

Operate SELF CHECK key on the membrane key board and observe the following on
vacuum fluorescent (VFD) display sceen.

< SELF CHECK > Enter Parameter 01 - 27

XX

A total of 27 SELF CHECK parameters are listed in this mode, which can be verified by
the Operation / Maintenance personnel for BHELFEED system diagnostic.

The keys that can be operated are:

SELF NUMERIC PAD

NEXT PREV ENTER ESC
CHECK 0 . . . . . 9 , 00

Fig . 4.2 Illustration on SELF CHECK Operational Keys

By operating SELF CHECK or NEXT / PREV key, parameter number can be

incremented / Decremented. This mode can be terminated by pressing ESC key .

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The parameters that can be monitored are,

01. TARE CAL FACTOR 15. MOTOR RPM

02. SPEED CAL FACTOR 16. I/O SIGNAL
03. SPAN CAL FACTOR 17. TACHO SIGNAL
04. KEY BOARD DISPLAY TEST 18. BELT MOTION. REF
05. POWER-UP COUNT 19. DAY’S TOTAL
06. FEED RATE 20. G. TOTAL
07. COMMUNICATION TEST 21. V.TOTAL
08. VERSION 22. M.TOTAL
09. RAW LOAD CELL SIGNAL 23. BELT CAL FACTOR
10. CLOCK SET 24. LOADCELL !. TARE
11. DENSITY 25. LOADCELL 2. TARE
12. FOR FUTURE USE 26. LOADCELL !. SPAN
13. BELT LENGTH 27. LOADCELL 2. SPAN
14. LOAD CELL TARE FACTOR

SELF CHECK Description:

Self Check 01:

This shows the system TARE CAL FACTOR, computed during ‘TARE CAL’ event and
the difference between the last two calibrations. It is the sum of the two load cell signal
counts, averaged over 2 complete belt revolutions i.e 8 counts of the probe span. The
change is calculated as [(New value – Old value) / New value] so that a positive /
negative percentage indicates that the value has increased / decreased.

< SELF CHECK 01 > Current: XXXXX.XX

TARE CAL FACTOR Change: ± XX.XX %

Self Check 02:

This shows the system SPEED CAL FACTOR, computed during ‘TARE CAL’ event and
the difference between the last two calibrations. It is the relationship between variable
speed drive output shaft speed (RPM) and the belt speed or velocity(M/sec) and is
expressed in units of metre per drive unit revolution. The change is calculated as [(New
value – Old value) / New value] so that a positive / negative percentage indicates that the
value has increased / decreased.

< SELF CHECK 02 > Current: X.XXXXXX

SPEED CAL FACTOR Change: ± XX.XXXXXX %

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Self Check 03:
This shows the system SPAN CAL FACTOR, computed during ‘SPAN CAL’ event and
the difference between the last two calibrations. The SPAN CAL FACTOR is the
relationship between the digitised signal received from the A/D converter and the actual
weight acting on the belt. The change is calculated as [(New value – Old value) / New
value] so that a positive / negative percentage indicates that the value has increased /
decreased.

< SELF CHECK 03 > Current: X.XXXXXX

SPAN CAL FACTOR Change: ± XXXXX.XX %

Self Check 04:

All displays & indicators will be illuminated for five seconds and then turn off
automatically. This test can be performed only with the feeder in the OFF mode. If this
test is performed in the REMOTE or LOCAL mode, only the VF display will scroll all
characters. Each operation of key is echoed on the VFD screen.

< SELF CHECK 04 > XXXX

KEY BOARD DISPLAY TEST

Self Check 05:

This shows the number of power-ups the system encountered by incrementing one count
on each time power is applied and the date / time stamp that the last restart happened.

< SELF CHECK 05 > DATE: DD/MM/YYYY

POWER_UP COUNT XXX Time: HH:MM:SS

Self Check 06:

This shows the Customer Feedrate Demand and the Feedrate Actual in Mtons / Hr, when
the system operates in REMOTE mode.

< SELF CHECK 06 > Demand: XXX.XX MTons/Hr

FEED RATE Actual: XXX.XX MTons/Hr

Self Check 07:

This is to test the healthiness of communication received over serial port.

< SELF CHECK 07 >

COMMUNICATION TEST Done

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Self Check 08:
This shows the program chip currently installed in the controller

< SELF CHECK 08 > Chip No: FL1- 013

VERSION 2.0 – COPYRIGHT © 2005 B H E L

Self Check 09:

This shows the raw A/D counts of load cells. The count shown for each load cell will
correspond to the range from 0000 H to FFFF H (00000D to 65535 D).

< SELF CHECK 09 > LC 1: XXXXX

RAW LOAD CELL SIGNAL LC2: XXXXX

Self Check 10:

This shows the Date & Time of the real time clock inbuilt.

< SELF CHECK 10 > Date:DD/MM/YYYY

CLOCKSET <TO SET RTC> Time:HH:MM:SS

To Set the real time clock, press CLOCK SET key, the cursor on the display moves to DD
/ MM / YYYY to set the date and HH : MM : SS to set the time. On entry of SS, the
seconds information set values are updated in the clock, and the clock continues.

Self Check 11:

This shows the average material density, as well the initial density estimate from
Program parameter 02. The average density value is used to calculate the required
speed of the motor when the feeder is in volumetric mode. The unit is in Kg/Cu.m,

< SELF CHECK 11 > Avg : XXX.XX Kg/Cu.m

DENSITY Initial : XXXX Kg/Cu.m

Self Check 12:

This program parameter is reserved for future use.

< SELF CHECK 12 >

FOR FUTURE USE

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Self Check 13:
To displays the length of the belt calculated in TARE CAL. It displays a calculated belt
length (determined during the last TARE CAL) as well as the difference in calculated belt
lengths from the previous two calculations. The change is calculated as [(New value –
Old value) / New value] so that a positive / negative percentage indicates that the value
has increased / decreased.

< SELF CHECK 13 > Current: X.XXXXXX M

BELT LENGTH Change: ± X.XXXXXX %

Self Check 14:

The TARE CAL FACTOR shown in SELF CHECK 01 is calculated from the sum of two
load cell counts. SELF CHECK 14 shows the TARE CAL FACTOR for the individual load
cells. These values are shown for reference only. The actual weight of the material acting
on the belt is calculated using the value in SELF CHECK 01. They are updated every
time TARE CAL is performed and saved.

< SELF CHECK 14 > LC 1: XXXXX

LOAD CELL TARE FACTOR LC2: XXXXX

Self Check 15:

This shows the Demand set point used to control the motor speed and the tacho output
in speed, as percentage. The tacho signal is converted to RPM using < PROG. 09 >
parameter value fed.

< SELF CHECK 15 > MSC Demand: XX.XX %

MOTOR RPM Tach : XX.XX %

Self Check 16:

This shows the customer feed rate demand signal received from the combustion control
system and the computed set point demand signal from processor to Motor control
Module (MCM) in mA.

< SELF CHECK 16 > Demand: XX.XXXX mA

I/O SIGNAL Output : XX.XXXX mA

Self Check 17:

This shows the actual RPM of eddy current drive output shaft, by the speed signal
generated from Tacho 1(P1) & Taco 2 (P2) and computed using < PROG. 09 >
parameter value.

< SELF CHECK 17 > P1: XXXX RPM

TACHO SIGNAL P2: XXXX RPM

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Self Check 18:
This shows the processed Belt Motion sensor signal pulse frequency (P3) and the
reference RPM for RPM deviation computation made based on the customer federate
demand, material density etc.

< SELF CHECK 18 > P3 : XXXX

BELT MOTION, REF RPM : XXXX

Self Check 19:

This shows the Every day Total Material handled by the feeder and is reset / registered
every day at 00.00 Hr. with date stamping. This Material Total is the summed total of
Gravimetric & Volumetric Totals handled during the 24 hours operation of that feeder.

< SELF CHECK 19 > Date: DD:MM:YY

DAY’s TOTAL : XXXXXXX.XX MTons

Self Check 20:

This shows the value of Gravimetric Total accumulated / integrated / handled by that
feeder in since its earlier TOTAL RESET to the last TOTAL RESET with Date & Time
stamp and is expressed in MTons.

< SELF CHECK 20 > Date: DD/MM/YYYY

G. TOTAL : HH:MM:SS XXXXXXX.XX MTons

Self Check 21:

This shows the value of Volumetric Total accumulated / integrated / handled by that
feeder since its earlier TOTAL RESET of display to the last TOTAL RESET with Date &
Time stamp. The unit is MTons.

< SELF CHECK 21 > Date: DD/MM/YYYY

V. TOTAL : HH:MM:SS XXXXXXX.XX MTons

Self Check 22:

This shows Material Total and is the summed value of both Gravimetric (Self Check 20)
and Volumetric (Self Check 21) Total accumulated / integrated / handled by that feeder
since its earlier TOTAL RESET of display to the last TOTAL RESET with Date & Time
stamp. The unit is MTons.

< SELF CHECK 22 > Date:DD/MM/YYYY

M. TOTAL : HH:MM:SS XXXXXXX.XX MTons

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Self Check 23:
This shows the system BELT CAL FACTOR, computed during ‘TARE CAL’ event. It is
the relationship between the variable speed drive output shaft speed (RPM) and the belt
speed or velocity (M/sec) and is expressed in units of Metre per drive unit revolution.

< SELF CHECK 23 > : X.XXXXXX

BELT CAL FACTOR

Self Check 24:

This shows the system LOADCELL 1 value, computed during ‘TARE CAL’. It is the signal
counts, averaged over 2 complete belt revolutions i.e 8 counts of the probe span with
Standard weight not acting on the load cell.

< SELF CHECK 24 > : XXXXX.XX

LOADCELL 1.TARE

Self Check 25:

This shows the system LOADCELL 2 value, computed during ‘TARE CAL’. It is the signal
counts, averaged over 2 complete belt revolutions i.e 8 counts of the probe span with
Standard weight not acting on the load cell.

< SELF CHECK 25 > : XXXXX.XX

LOADCELL 2.TARE

Self Check 26:

This shows the system LOADCELL 1 value, computed during ‘SPAN CAL’. It is the signal
counts, averaged over 2 complete belt revolutions (8 counts of the probe span) with
Standard weight acting on the load cell.

< SELF CHECK 26 > : XXXXX.XX

LOADCELL 1.SPAN

Self Check 27:

This shows the system LOADCELL 2 value, computed during ‘SPAN CAL’. It is the signal
counts, averaged over 2 complete belt revolutions (8 counts of the probe span) with
Standard weight acting on the load cell.

< SELF CHECK 27 > : XXXXX.XX

LOADCELL 2.SPAN

Bharat Heavy Electricals Limited

4.2 BHELFEED – MPGFC System Trouble Shooting on I/O Modules

The GFC system has five I/O modules and have self diagnostic features to identify the
healthiness of a particular module.

Module Diagnostic indications Possible reason / Description

Power supply • DC power indication lamp • Input AC power missing

normally ON • Power supply trip due to over
load
Processor Unit • DC power indication normally • DC power input missing.
ON. • Booting problem.
• Hard disk access indication • Problem with the device where
blinks. application is loaded.
• Reset indication normally OFF.
AIM2000 • DC power indication normally • Power supply input is missing.
ON. • DC to DC converter on module is
• Error indication normally OFF. bad or over loaded.
• Communication indication • Watch dog pulse to module from
normally blinks. CPU is missing or not able to
• Module address indication receive the signal
static. • No communication from CPU.

AOM2000 • DC power indication normally • Power supply input is missing.

ON. • DC to DC converter on module is
• Error indication normally OFF. bad or over loaded.
• Communication indication • Watch dog pulse to module from
normally blinks. CPU is missing OR not able to
• Module address indication receive the signal
static. • No communication from CPU.

DIM2001 • DC power indication normally • Power supply input is missing.

ON. • DC to DC converter on module is
• Error indication normally OFF. bad or over loaded.
• Communication indication • Watch dog pulse to module from
normally blinks. CPU is missing or not able to
• Module address indication receive the signal
static. • No communication from CPU.
• Chanel status indication for • Channel indication off even after
each chanel. LED is on when the input is closed, particular
input chanel is closed. chanel is bad.
DOM2000 • DC power indication normally • Power supply input is missing.
ON. • DC to DC converter on module is
• Error indication normally OFF. bad or over loaded.
• Communication indication • Watch dog pulse to module from
normally blinks. CPU is missing or not able to
• Module address indication receive the signal
static. • No communication from CPU.
• Channel status indication for
each channel. LED ON when
output channel is energized.
PIM2000 • DC power indication normally • Power supply input is missing.
ON. DC to DC converter on module is
• Error indication normally OFF. bad or over loaded.
• Communication indication • Watch dog pulse to module from
normally blinks. CPU is missing or not able to
• Module address indication receive the signal.
static. • No communication from CPU.

Bharat Heavy Electricals Limited

4.3 DO’s and DON’Ts

DO

• Switch off Control power supply (MCB-1) before replacing any Electronic Modules /
CPU.
• Visually check / ensure for the healthiness of euro connector pins on all I/O modules
before installation / insertion on the card rack
• Ensure the correct location of the I/O modules in the card rack as identified by the name
tag.
• Follow jumper details before inserting / fixing of any module.
• Ensure selection of customer end analog input circuits as potential free, as the analog
output current sourced from BHELFEED AOM, (representing the feeder federate in TPH)
doesn’t require any external sourcing of drive power.
• Ensure proper safety earth to panels / drive motors
• Ensure the extension of circuit grounding as applicable / as per document
• Return faulty electronic module to BHEL - Trichy or Bangalore (EDN) after consulting
C&I / FES / BHEL(T) for servicing

Don’t

• Remove / Plug-in communication cables between CPU, Interface card, Bus terminator
Module (BTM) and Key Board Display unit in powered up condition
• Interchange any power supply wires in powered up condition
• Keep the Panel doors open
• Use a hot blower for cleaning the panel.
• Attempt field servicing.

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Section – 5.0

Drawings

Bharat Heavy Electricals Limited

 Section – 5.0

Drawings

Title

5.1 BHELFEED – MPGFC Drawings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1.1 MP based Gravimetric Feeder – Schematic Diagrams . . . . . . . .

5.1.2 MP based Gravimetric Feeder Control – Remote Control Panel .

5.1.3 MP based Gravimetric Feeder – Local Control Panel GA . . . . . .

5.1.4 Gravimetric Feeder – Interconnection Diagram . . . . . . . . . . . . . .

5.2 BHELFEED – MPGFC Calibration / Datasheets. . . . . . . . . . . . . . . . . . . .

5.2.1 System / Feeder Calibration - Log / Data Sheet Formats. . . . . . .

5.2.2 BHELFEED – MPGFC Project Specific Data . . . . . . . . .. . . . . . . .

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 5.2.1 System / Feeder Calibration - Log / Data Sheet Format:

Section 1: General data

Project. : Date of Test / Calibration: Test Team:

Feeder Size / No.: RCP No.: LCP No.:

W.O. No. : Shop/Vendor: Prepared By :

Section 2: Feeder Data

Cleanout
*T.P.No. Details Main Drive Others / Specify
Conveyor
2.1.1 Make: Motor / Gear unit -

2.1.2 KW / FL Amp -

2.1.3 Voltage -

2.1.4 Gear Ratio -

2.1.5 Sl. No. Motor / Gear unit -

2.1.6 Variable Speed Unit ECC / VFD NA -

2.2.1 Main Drive – Gear box oil level – Checked & OK OK

2.2.2 Cleanout Conveyor – Gear box oil level – Checked & OK OK

Visual check on feeder wiring for completeness, correct and secure connection and wire /
2.2.3 OK
ferrule numbers
2.2.4 Adjust cam to properly actuate ‘Coal on Belt’ (COB) limit switch OK

2.2.5 Adjust cam to properly actuate ‘Discharge plugged’ (FDP) limit switch OK

2.2.6 OLR for Main & Cleanout conveyor drive motors Check & Set OK

Leading span roller to Weigh roller to Trailing span roller (Drive side) OK
2.2.7
Leading span roller to Weigh roller to Trailing span roller (Opposite side) OK

Weigh roller to span roller clearance (Drive side) OK

2.2.8
Weigh roller to span roller clearance (Opposite side) OK

Drag link / Loadcell adjustment locked in (Drive side) OK

2.2.9
Drag link / Loadcell adjustment locked in (Opposite side) OK

2.2.10 Loadcell Sl. Nos. Drive side: / Opposite side: OK

Bharat Heavy Electricals Limited

Section 3: Feeder Program Parameter Table - Typical ( Refer Note 1):
PROG. Project Value as
Description Unit Reference
No. Value Tested
00 SET FEED RATE 17 17 Mton/ Hr
01 SET LOCAL SPEED 1000 1000 RPM
Project Specific
02 SET DENSITY 1000 1000 kg/cu.m
0 0 0 – FR Dem.(mA),
03 SET RUN MODE 1 – Raise / Lower
2 – Future use
0 0 0 – Metric
04 UNIT SELECT
1 – Future use
05 MAX FEED RATE 85 85 Mton/ Hr Project Specific
06 MIN FEED RATE 17 17 Mton/ Hr
07 SET TOTALIZER INCR. 100 100 kg
0 0 0 – ECC / VFD
08 SELECT DRIVE
1 – Future use
09 TACHO TYPE 0 0 0 – 24 Pole, 1 – 48 Pole
10 WEIGHING LENGTH 0.914 0.914 M
11 ENTER VOLUME 0.1726 0.1726 Cu. Met Project Specific
12 STANDARD PROBE SPAN 0.914 0.914 M
13 STANDARD WEIGHT 86.8 86.8 Kg
14 SPEED CONTROL GAIN 20 20
15 FEED BACK GAIN 14000 14000
16 NO COB OR FDP DELAY 2.0 2.0 sec
17 MOTN. MONI. DELAY 0.0 0.0 sec
18 COAL FLOW VOLUME 1.0 1.0 Cu. M Project Specific
19 LC FILTER 4 4
20 – 23 FOR FUTURE USE
24 NO COAL ON BELT FB 0 0
25 FEEDER ID NUMBER 0 0
0 0 0 – RCP only.
26 RUN MODE SELECT
1 – Both RCP & LCP.
27&28 FOR FUTURE USE
29 MIN. SPEED LIMIT 5 5 RPM
30 MAX. SPEED LIMIT 1500 1500 RPM
31& 32 FOR FUTURE USE
33 TOTALIZER PULSE ON TIME 0.10 0.10 sec
34 FOR FUTURE USE
35 LOAD CELL TRACKING 12.5 12.5 %
36 GEAR RATIO 138.9 : 1 138.9 : 1 Project Specific
37 HEAD PULLEY DIA 0.325 0.325 m
38 B.M BY PASS 0 0 0 – Disabbled, 1 – Enabled
39 START-UP DELAY 15 15 sec
40 RPM DIFFERENCE 100 100 RPM
41 TARE CAL FACTOR _ _ _
42 SPEED CAL FACTOR _ _ _
43 SPAN CAL FACTOR _ _ _
44 BELT LENGTH _ _ _ Parameter 41 to 49 will be
45 BELT CAL FACTOR _ _ _ updated by the system after
46 LOADCELL1 TARE _ _ _ every calibration.
47 LOADCELL2 TARE _ _ _
48 LOADCELL1 SPAN _ _ _
49 LOADCELL2 SPAN _ _ _

Note 1:
Refer Project specific Prog. Parameters details.

Bharat Heavy Electricals Limited

 Section 4: Feeder Logic / Calibration Checks:
*T.P.No. Transformer Primary (Volts) Secondary 1 (Volts) Secondary 2 (Volts)
4.1.1 T1:
4.1.2 T2: NA
4.1.3 Voltages are within ±10% and secondaries are wired as per dwg.

4.2.1 Vacuum Fluorescent Display (VFD) illuminates

Verify Cleanout Conveyor doesn’t snag
4.2.2
Shear pin and switch OK

4.3.1 ‘VOLUMETRIC’ LED (R4-A&B) and DENSITY Display respond correctly

4.3.2 Customer R4-1 contact is CLOSED (261 – 262) NO
4.3.3 Customer R4-1 contacts is OPENED (259 – 260) NC

4.4.1 ‘INCH’ Control & ‘FEEDER RUN’ LED are Functional and motor direction is correct
Tach Voltage is at least 25V per 1000 RPM
4.4.2
Speed shown by VFD matches speed shown by Digital Tacho Meter ±2%
‘LOCAL’ Control is functional and SPEED stability is within ±5 RPM
4.4.3 Customer R6A contacts are CLOSED 210 – 211), (212 – 213) NO
Customer R6A contacts are OPENED 214 – 215), (216 – 217), (218 – 219) NC
4.4.4 Belt tracks properly after running for 10 minutes

4.5.1 Feeder Trips in ‘LOCAL’ mode when ‘LSCOB’ is activated ( R1 Energises)

4.5.2 Customer R1 contact is CLOSED (236 – 237) NO
4.5.3 ‘TRIP’ LED glows
4.5.4 Customer COB contacts are CLOSED (226 – 227), (228 – 229) NO
4.5.5 Other customer contacts

4.6.1 SELF CHECK-09 without Test weight Drive side : Opposite side :
4.6.2 SELF CHECK-09 with Test weight Drive side : Opposite side :

Feeder Calibration Results:

*T.P.No. Tare Cal Run 1 Run 2 Run 3
Good Values
Tare Cal. Factor (41)
Belt Speed Factor(42)
Belt Length (44)
4.7.1
Belt Cal Factor (45)
Loadcell 1. Tare (46)
Loadcell 2. Tare (47)
Cal. RPM (Prog.01)

*T.P.No. Span Cal Run 1 Run 2 Run 3

Good Values
Span Cal. Factor (43)
4.8.1
Loadcell 1. Span (48)
Loadcell 2. Span (49)

Bharat Heavy Electricals Limited

 ‘REMOTE’ LED and R3 energise – Customer ‘START’ signal starts feeder & GRAVIMETRIC
4.9.1
TOTALISER begins to count
4.9.2 Customer R3A Contacts – Closed (222 – 223 ) NO

4.9.3 Customer R3A Contacts – Open

4.10.1 GRAVIMETRIC LED ON

4.10.2 Customer R5, R7 & R4B Contacts – Closed (232 – 235) NO

4.10.3 Customer R5 Contacts

4.10.4 Customer PR contacts Pulses (243 – 244)

*T.P.No. % Demand Main Drive Motor Cleanout Conv. Motor Others / Specify

4.11.1 100% Site Site -

4.11.2 Verify motor current is < name plate rating and overload settings for all listed motors OK

Feedrate (FR) Demand FR Actual Customer Feedback - mA Disp. Speed

4.12.0
% mA TPH TPH Ch1 Ch2 Ch3 Ch4 Ch5 Ch6 RPM (Appx.)
100 20.0

75 16.0

4.12.1 50 12.0

25 8.0

<20 <7.2

4.12.2 Customer Feedback / Current Linearity (Channel-1 to 6)

4.13.1 Feeder trips in REMOTE mode when FDP is actuated (R1 energises)

4.13.2 Customer FDP contacts change state

4.13.3 Key Board Display Test (Self Check – 04) is OK

4.13.4 Power-up count (Self Check – 05) is OK

4.13.5 Customer Start is latched correctly

4.13.6 Verify Date & Time

Section 5: Check on other feeder peripherals / Accessories:

Sl.No. Description Tested Comments

5.1 Belt Motion Monitor

5.2 Remotely mounted REMOTE / LOCAL switch

5.3 Work Lights & Power outlets

5.4 Reverse Feeder operation

5.5 Middle Conveyor belt operation / interlock lock

(NA)
Tested / Calibrated Witness by Customer
Date :

Form : BF10 - IT-2436/01

Bharat Heavy Electricals Limited

 BHELFEED - MPGFC
Demand Signal Keyboard & Analog Output (FR) DIGITAL INPUTS:
Block Diagram
from Combustion Display to Customer
Control START TFS TBR2-
FEEDER 43/44 1 A1
4- 4-20mA 7
FEEDER FR 83/84 TBR2-
L AIM RUN 3 A1
AOM 8
COAL ON COB TBR2-
BELT 13/14 5 A1
SCM 9
ANALOG INPUTS:
32 Bit
B B B CPU
PIM DOM CUST. DCS TBR3-
SIM DEMAND 1/2 AC

T T DIGITAL OUTPUTS:

TRIP R1 2/3 AC9

FEEDRATE > R2 2/3 AC10
50%
REMOTE R3 2/3 AC11
C C C FEEDING R4A 1/2 & AC12
VOLUMETRIC 5/6
DIM ROB
R4B 1/2
FEEDING R5 2/3 AC13
MATERIAL
ANALOG OUTPUTS:

COMBUSTION TBR3- AC1

CONTL. 11/12
COMBUSTION TBR3- AC3
CONTL - 14/15
REDUNDANT
Digital Inputs Relay Outputs
MEMBRANE KEY BOARD & DISPLAY
VFD controller
VF DISPLAY : 2LINES - 40 CHAR. / LINE

NUMERIC PAD : 0 T0 9, DECIMAL

L LEGEND: PROGRAMMING : PROG, NEXT,
B T M - BELT DRIVE VFD MOTOR SIM - SIGNAL INTERFACE MODULE
VFD - VARIABLE FREQUENCY DRIVE GB - GEAR BOX PREV, CLS, ESC &
M C AIM - ANALOG INPUT MODULE BM - BELT MOTION MONITOR ENTER
AOM - ANALOG OUTPUT MODULE LC - LOAD CELL (WEIGHT) SIGNALS TUNE : TARE & SPAN
G VFD DIM - DIGITAL INPUT MODULE CP - CAL PROBE SIGNALS OPERATION : TOTAL DISPLAY,
B MOTOR DOM - DIGITAL OUTPUT MODULE TG - TACHO (SPEED) SIGNALS SELECT DATA,
PIM - PULSE INPUT MODULE ROB - RELAY OUTPUT BOARD
SCM - SIGNAL CONDITIONING MODULE SELF CHECK,
Jumpers & Connectors detail for Signal Interface Module:
X6 X4 X5
Legend:

JP1 - Jumper on Power Circuit 3 1 9 1 9 1

X1 - Combi Connector for 110V AC Power

X2 - Combi Connector for Belt Motion &
Cal. Probe Signals (I/P)
X3 - Combi Connector for Tach. Signals (I/P)
SIM - COMPONENT SIDE
X4 - Combi Connector for Belt Motion &
Cal. Probe Signals (O/P)
X5 - Combi Connector for Tach. Signals (O/P)
X6 - Combi Connector for 24V DC Power

L01 - LED for 110V AC Power indicator

L01

JP1
1 3 1 9 1 9

X1 X2 X3

Jumpers & Connectors detail for Motor Control Module:

Legend:

JP1 - Jumper on Power Circuit

X1 - Combi Connector for 110V AC Power

X2 - Combi Connector for Ref. Demand, MCM - COMPONENT SIDE
ECC excitation & Tach FB Signals

L01 - LED for 110V AC Power indicator

L01

1 2
JP1
1 3 1 8

X1 X2