SCANDIBELT 2010 BF6042 SKÖTSELINSTRUKTION INNEHÅLLSFÖRTECKNING 1) Introduktion.............................................................................................................3 2) Beskrivning av reglage............................................................................................4 3) Användning av startpanel.......................................................................................5 · Start av motor.................. .................................................................................5 · Start sekvens........................ ............................................................................6 · Inställning av motorhastighet.............................................................................6 · Avstängning av motor............. ..........................................................................7 · Grafisk.... display.................... ..........................................................................7 · Visning av instrument........................................................................................7 4) Kontroll av tippgaller.................. ............................................................................9 5) Fjärrkontroll tippgaller...........................................................................................10 6) Drift av larvband....................................................................................................11 7) Fjärrkontroll handhavande...................................................................................12 8) Drift av transportör.................................................................................................13 · Manuell transportördrift....................................................................................13 · Automatisk transportördrift..........................................................................14-15 9) Sirén och ljussignal.............................................................................................16 10) Skydd · Avstängning och varningar..............................................................................17 11)Startpanel, felmeddelanden och symboler...........................................................18 12) Startpanel konfiguration · Öppna konfigurationsfunktion........................................................................19 · Ändring av Parameter....................................................................................19 13)Felsökning....................................................................................................20-21 14) Underhåll och reservdelar · Säkringar........................................................................................................22 · Avfallshantering..............................................................................................22 15) Anteckningar.........................................................................................................23 16) Front Panel Parameters & Diagrams..............................................................24-25 2|P a g e Introduktion Detta dokument innehåller instruktioner för drift av Elect automation 3500 start panel. 3000 seriens modul har konstruerats för start och stop av motor. Användaren kan även få överblick över systemets driftparametrar via LCD skärmen 3000 modulen övervakar motorn, indikerar driftstatus och visar felmeddelanden samt utför automatisk stopp av motor med omedelbar indikering av felets art och visning på LCD skärmen. Den kraftfulla mikroprocessorn i modulen ger möjlighet för en rad extra funktioner: · Ikon och textbaserad LCD display · Övervakning av motorparametrar · Två inställbara input för användning av alarm eller en rad olika funktioner · Magnetisk avläsning av motorhastighet i varv/minut Med hjälp av en PC och mjukvara för 3000 serien kan utvalda sekvenser, tidsfunktioner och alarmgränsvärden ändras. Man kan även ändra dessa funktioner direkt på skärmen via displayens konfigurationsfunktion. Modulen har en robust plastinkapsling för montering i frontpanel. Inkopplingar till modulen sker via låskopplingar. 3|P a g e Beskrivning av kontroller Denna sektion beskriver kontroll-lådans alla funktioner Navigations knapp Stop/Reset Mode Huvudstatus display Auto Start/Stop(Option) Alarmindikator Manuell motorstart Nyckelvredet på kontroll-lådan stänger av strömmen när den inte används efter att korrekt nedstängningssekvens har utförts. Nyckeln kan tas ur för att säkerställa att endast behörig personal använder maskinen. ! OBSERVERA: Använd inte denna nyckel som isolering/startspärr vid underhåll. Använd istället det avstängningsvred som sitter monterat bredvid hydraulblockets ventilvred. Avstängningsvredet isolerar batteriet. 4|P a g e 3) Drift av motorns startpanel Start av motorn Tryck först på STOP/RESET knappen Tryck sedan på startknappen en gång En blinkande hand symbol lyses upp för att möjliggöra mauell start Tryck två gånger Motorn förvärms Siren & ljussignal aktiveras i tio sekunder innan motorn startas 5|P a g e Sekvensstart I händelse av "falska" startförsök finns en fördröjning på 1 sekund. Om alla startförsök tas bort under fördröjningstiden, återgår enheten till stand-by läge Om ett startförsök fortfarande ligger kvar efter fördröjningstiden, aktiveras motorns förvärmningsrelä och sirén och ljudsignal aktiveras i 10 sekunder. Sedan aktiveras bränsle- och oljekylar-reläer och motorn startas. Om motorn inte tänder/startar under detta försök, stängs startmotorn av under en period på 10 sekunder och sedan görs ett nytt startförsök. Efter 3 misslyckade startförsök stoppas sekvensen och displayen visar fail to start ikonen (se felkoder och ikoner) När motorn startar stängs startmotorn av. Hastighetsmätning är inställd från fabrik som en magnetisk mätare monterad vid svänghjulet. After att startmotorn stoppats aktiveras Safety On timern, som tillåter värden på Oljetryck, Hög motortemperatur, Laddningsfel och andra invärden att stabilisera sig utan att utlösa ett fel. Om ett felvärde fortfarande ligger kvar efter att Sefety On timern stoppar, stannas motorn och ett felmeddelande visas (se felmeddelanden och ikoner) När alla timerfunktioner har stoppats och systemet fungerar normalt visas Engine running (motor igång) ikonen. Inställning av motorhastighet/varvtal På 3500 BFA seriens panel regleras och kontrolleras varvtalet via motorhastighetskontrollen. Användaren reglerar varvtalet via en potentiometer på framsidan av motorns startpanel. Minimum inställt varvtal är 1000 rpm (varv/min) Maximum inställt varvtal är 2500 rpm (varv/min) När bandtransportörer startas körs motorn på ett förinställt värde av 1400 rpm för att sedan återgå till det av operatören förinställda värdet efter en kort tids fördröjning. Notera! Under sekvensstart av bandtransportörerna är motorvarvtalet fast och potentiometern urkopplad! 6|P a g e Stänga av motorm För att stänga av motorn, tryck på knappen en gång och motorn stängs av omedelbart I nödlägen kan de två nödstoppsknapparna på framsidan av inkapslingen och på 3000 seriens startpanel användas för att stänga av motorn. Ytterliggare en nödstopp är placerad vid larvaggregatet och kan användas efter inkoppling i kopplingslådan på bandtransportörens högra sida. !OBSERVERA! Vidanvändning aktiveras ett allmännt alarm och sirén och ljussignal (se Sirén och ljussignal). Nödstopp(ar) måste återställas och sedan även kontrollådan för att ta bort alarmet och stänga av sirénen. När motorn ligger under driftskontroll av modulen (start och stopp) visas en ikon iform av en äggklocka på displayen för att indikera att timerfunktionen är aktiverad. Exempelvis vevtid, vevstopp etc. Grafisk Display En 32x132 pixel LCD (35mm / 1.4”) är monterad för instrumentering och alarmlista. Displyen är indelad i områden för instrumentering, enhet, alarmikoner och för Front Panel Editering (FPE) läge. Instrumentering FPE Ikon Enhet När enheten inte körs i FPE läge visar FPE området den aktuella konfigurationen. Bokstaven "M" står för huvud(Main) konfiguration aktiv och bokstaven "A" står för Alternativ konfiguration Visning av instrumenteringen Man skrollar genom de olika sidorna av information med hjälp av pilknappen nedan. När man valt en sida ligger den kvar i displayen tills dess att en annan sida väljs eller efter en lång tids inaktivitet. Då återgår modulen till varvtalsvisning (RPM Status). Vid manuell skrollning kommer displayen automatiskt gå tillbaka till Satus sidan om ingen knapp trycks under konfigurationstiden under LCD Sidans timerfunktion. 7|P a g e OM ett alarm aktiveras under tiden man är inne på status sidan, visas sidan med alarm för att uppmärksamma operatören på alarmet. Page Order Motor varvtal 2200rpm Motor drifttid 16.2 Batterispänning 13.8v 8|P a g e 4) Tipping Grid Controls By Using the selector switch on the front of the engine starting panel you can select auto mode or manual mode. Manual Mode When the selector switch is in the manual position the tipping grid can be raised and lowered via up down push buttons on the engine starting panel Grid Raise Grid Lower The Tipping grid remote control Up/Down buttons will also operate in this way when the selector switch is in manual position Automatic Mode When the tipping grid selector switch is placed in automatic mode, the tipping grid up/down cyle will be automatic, This reduces the operator time involved in clearing the tipping grid of debris. In order to start the automatic sequence the grid raise up push button must be pushed on either the engine starting panel or via the up push button on the tipping grid remote control. The Grid Raise and lower sequence is controlled by a timer, the time Up/Down time setting of each automatic cycle can be set and adjusted using the potentiometer on the front of the engine starting panel. NOTE: The downward stroke of the tipping grid is controlled by a hydraulic pressure sensor located at the grid valve block in the canopy, this de-energises power at rising oil pressure towards the end of the stroke. Setting The Grid Raise/Lower Time Start the Engine (as described earlier in this manual) and set the desired engine speed To adjust the grid Raise/Lower time turn the potentiometer fully clockwise then press the up button once, The tipping grid will start to rise. As the tipping grid reaches its fully raised limit start to turn the potentiometer anticlockwise until the grid lower led light on the front of the panel illuminates and the grid starts to lower. The grid raise and lower time is now adjusted for the set engine speed. The Time may need to be adjusted again if a lower or higher engine speed is desired. 9|P a g e 5) Manövrering av tippgaller Av/På Fjärrkontrollen har en Av/På knapp på backsidan till vänster om bältesfästet. Denna måste vara påslagen för att fjärrkontrollen skall fungera. Manuellt körläge-Manual mode När väljarvredet på panelen är i manuell position används upp och ned knapparna för att reglera tippgallret Automatisk körning -Auto Mode Med väljarvredet i position Auto, kan automatisk reglering av tippgaller aktiveras genom att knappen trycks ned en gång. Detta aktiverar automatisk sekvens beskrivet ovan. Ned knappen är deaktiverad i detta läge Auto-körläge kan deaktiveras när som helst om manuellt körläge önskas. Detta görs genom att trycka ned knappen M/O (Manual override). När denna knapps trycks ned lyser den röda led lampan på motors startpanel för att indikera att manuellt körläge är activerat. Tillbakagång till Auto-körläget kan göras genom This can be deactivated at any time by Pushing the M/O button a second time The remote manual override light will go out and auto mode will be reinstated if the selector switch on the front panel is in Auto. 070-9114695, 072-3684733 042-197900 tryck 1 för att acceptera sedan Batterier Fjärrkontroller använder 2 st AAA batterier Fjärrkontroll för tippgaller 10 | P a g e 6) Operation of Track Control !Note: Machine will only track when the engine is running !Note: Hydraulics for raising, lowering, folding & jack legs will be disabled when tracks are enabled Manual Lead Operation Insert plug of track lead into socket housing located on underside of 3300series starting panel and on the Right side of conveyor, Sockets and plugs should be clipped together to maintain a waterproof seal. !Note: Emergency Stop on Track box will shutdown the engine and sound an alarm but only if it is plugged in. Switch on track controls Via the Off/On toggle switch on the track box. The siren and beacons will activate when switched on and will continue to operate until switched off. 0 1 OFF ON A 5-10 second delay will activate when switched on, before the machine will track Move the machines tracks via the up – down toggle switches. Independent operation of each track can be achieved with the forward and reverse positions F Forward F R Reverse R Left Track Right Track When Tracking is not required, Track Box and lead should be stored and the sockets cover mounted on the machine closed to prevent ingress of dust and water 11 | P a g e 7) Remote Control Operation Insert 16 pin plug of track/belt remote receiver into socket housing located on underside of 3500series starting panel. Switch on remote control transmitter Ensure that the on/off switch at the back of the transmiter is in the 1 position. Reset or twist out the red pushbutton located at the bottom of the transmitter. The leds located beside Buttons 7 & 8 will flash simultaneously. Press buttons 7 & 8 simultaneously for 1 second. The led located above buttons 1 & 2 will now flash green. The transmitter is now ready to transmit. Tracking Ensure that the jacklegs are slightly raised off the ground and that the area is clear before attempting track Note: Hydraulic levers controlling the conveyor height, Head section & Jack Legs will not operate if tracking has been enable by the remote control or track lead! Press button 2 on the transmitter to enable the tracks. The siren and beacons will activate. A 5-10 second delay will activate when switched on, before the machine will track Engine ‘fast’ Stop Left track Forward Tracking ON/OFF Right track Forward Left track Reverse Right track Reverse Transmitter STARTUP Belts start in auto Transmitter STARTUP Belts stop Transmitter off / reset The Transmitter will ‘sleep’ if not used for three minutes, this will also disengage tracking. Store Remote control in a cool dry environment. Remote Control Charging A vehicle charging socket is located at the right hand side of the panel, the supplied vehicle charger can either be plugged into the back of the transmitter or into the holder mounted to the right hand side of the starting panel. LED Indicators indicate battery status, Flashing red – charging, Solid Green –Fully charged. 12 | P a g e 8) Belt Operation !Note: Belts will only run when the engine is running !Note: Hydraulics for raising, lowering, folding & jack legs will be disabled when the main discharge conveyor is running Before attempting to start the belts ensure that the belts are clear and that the stockpile area is free from obstruction and all personnel The System has been designed to automatically start the belts at a preset engine speed of 1400 rpm, this is achieved via the use of an electronic throttle actuator system. Starting the belts at this lower speed reduces excessive wear and premature failure of the machines components. Starting of the belts can be conducted manually at the control panel or automatically via the Track/Belt remote control, Manual Belt Operation Selector switch for manual and automatic belt operation 1. In the bordered BELT CONTROLS section set selector switch at the manual position. 2. Set desired engine run speed using the potentiometer marked ‘engine speed’ 3. Press the green start button on the belt to be started. 4. The engine speed will lower to 1400 rpm, the belt will then start after a 10 second delay 5. Press the green start button on the next belt to be started 6. The engine speed will then lower (or remain low) for a further 10 seconds before the second belt is started. 7. The engine speed will then return (ramp up/ramp down) to the variable speed requested at step 2. 13 | P a g e Manually Stopping the belts The belts can be stopped at any time individually by using the red pushbuttons in the bordered belt controls section on the engine starting panel. It is recommended that both belts are cleared of material before they are stopped. They can also be stopped simultaneously using the remote control as detailed in the next section Automatic Belt operation Starting the belts For ease of operator use, the system has been designed, by using a plc, to control automatic startup and stopping sequence of the belts. This can be controlled by remote control. 1. In the bordered BELT CONTROLS section set selector switch at the AUTO SEQUENCE position. 2. Set desired engine run speed using the potentiometer marked ‘engine speed’ Switch on remote control transmitter Ensure that the on/off switch at the back of the transmiter is in the 1 position. Reset or twist out the red pushbutton located at the bottom of the transmitter. The leds located beside Buttons 7 & 8 will flash simultaneously. Press buttons 7 & 8 simultaneously for 1 second. The led located above buttons 1 & 2 will now flash green. The transmitter is now ready to transmit. 3. Once the remote control transmitter has been started press button 7 once 4. 5. 6. 7. 8. 9. The Prestart siren will cycle on and off to warn that a belt startup is imminent The engine speed will then lower to 1400 rpm The main discharge conveyor will then start After a 10 second time delay the feeder belt will then start The engine will continue to run at a low speed for 20 seconds The engine will then return to the speed set at step 2. Please note, variable engine speed is disabled during automatic belt startup! 14 | P a g e Stopping the belts in auto The belts can also be stopped remotely by use of the remote control or control panel stop buttons. If the remote transmitter is in sleep mode, startup the transmitter as described in the previous section. After the remote has been started and the green led between buttons 1&2 is flashing press button 8 fully (Note: If pressed when the engine is at low fixed speed both belts will stop instantly without delay) The feeder conveyor will immediately stop and the main discharge conveyor will stop 25 seconds later to allow any material on the belt to clear If required, pressing button 8 again will bypass the run on time delay on the main discharge conveyor and will stop the belt. If the remote transmitter is switched on this button will stop both belts simultaneously in manual belt operation The Belts can also be stopped individually at the engine starting panel by using the stop buttons, the selector switch does not need to be switched to manual in order to stop the belts. 15 | P a g e 9) Siren & Beacon Operation Siren and Beacons will operate for 10 seconds after start button is pressed twice , after the engine has started these will deactivate, unless Track lead is switched on or there is an alarm present. The siren and beacon will be activated if the track lead is switched on. If an alarm shutdown or warning becomes active when the machine is in operation or an emergency stop has been pressed the siren and beacon will activate to get an operators attention 16 | P a g e 10) Protections Shutdowns And Warnings When an alarm is present, the Common alarm LED if configured will illuminate. The LCD display will show an icon to indicate the failure. Warnings Warnings are non-critical alarm conditions and do not affect the operation of the engine, they serve to draw the operators attention to an undesirable condition. Warning alarms are self-resetting when the fault condition is removed. The icon will appear steady in the display. Shutdowns Shutdowns are critical alarm conditions that stop the engine and draw the operator’s attention to an undesirable condition. Shutdown alarms are latching. The fault must be removed and the button pressed module. The icon will appear flashing in the display to reset the The siren and beacon will activate on shutdowns to draw an operator’s attention. 17 | P a g e 11) Starting Panel Fault Codes & Icons negative 18 | P a g e 12) Front Panel Configuration Note! Changes to module parameters may cause damage to equipment, competent and qualified persons only should access parameter configuration. This configuration mode allows the operator limited customising of the way the module operates. Use the module’s navigation buttons to traverse the menu and make value changes to the parameters: Accept ICON DESCRIPTIO Next Page Decrease value/ next item Increase value/next item N ACCESSING THE FRONT PANEL EDITOR (FPE) Press and buttons simultaneously. The display shows the configuration icon The first parameter is also displayed. Parameter number Current Value Configuration icon Changing a Parameter Enter the editor as described above. Press to select the required ‘page’ as detailed below). Press page. (+) to select the next parameter or (-) to select the previous parameter within the current When viewing the parameter to be changed, press the button Press ( Press the +) or ( . The value begins to flash. -) to adjust the value to the required setting. to save the current value, the value ceases flashing. Press and hold the button to exit the editor, the configuration icon is removed from the display. Check data sheet to see parameter value data tables. 19 | P a g e 13) Fault Finding Fault Remedy Main Panel Inoperative Check Main Panel fuse f8 beside battery isolation switch Check F4 inside 3500 series starting panel Oil Cooler Inoperative Check oil cooler midi fuse F9 beside battery isolation switch Check F1 inside 3500 series starting panel Unit locks out on emergency stop Ensure that a negative signal is connected to the Emergency Stop input (wire no. 11 & terminal no. 12 on controller). Check emergency stop switch block is functioning correctly. Check Wiring is not open circuit. Intermittent Magnetic pickup Fault Check pick up is correct distance from gear teeth Check that pick up sensor is clean ! Care must be taken when reinstalling pickup to achieve correct air gap! !when reinstalling pick up centre gear tooth to hole, screw in pick up fully to it touches flywheel. then screw out ¾ of a full turn, tighten locknut ensuring that pick up does not move to achieve correct air gap from flywheel Check oil pressure switch is not faulty Check oil pressure switch wiring Low oil Pressure fault after eng. has fired High engine temp shutdown Check water temp switch wiring Check coolant radiator is getting sufficient air flow Check switch is not faulty Warning fault operates Check relevant switch and wiring of fault indicated on LCD display. Check configuration of input Shutdown Fault operates Check relevant switch and wiring of fault indicated on LCD display. Check configuration of input Fail to Start is activated after preset number of attempts to start Check wiring of fuel solenoid. Check fuel. Check battery supply. Check battery supply is present on the Fuel output of the module. Check Fuel relay in 3000 series enclosure, Check Fuse F3, Check Magnetic pick up signal is present and reading rpm as the engine turns Refer to engine manual. Pre-heat inoperative Check F2 Midi fuse beside starter, Check preheat relay in 3000 series starting panel, Check wiring and correct voltages at relay Siren & Beacons not activating Check F6 Fuse, Check siren & beacon relay, Check terminal diodes Track control inoperative Check F5 Fuse, Check track enabled relay is switching on when track box is switched on, check wiring Starter motor inoperative Check Fuse F3, Check crank relay provides voltage to crank wire at starter or crank slave relay at starter, Check wiring to starter solenoid. Check battery supply. Check battery supply is Present on the Starter output of controller. Ensure that the Emergency Stop input is at Positive. Ensure oil pressure switch is indicating the low oil pressure” state to the 3000 series controller. Fail to stop alarm when engine is at rest Check wiring to oil pressure switch, Ensure oil pressure switch is connected Water In Fuel Alarm Drain water / fuel separator filter of water, Clean Sensor Troubleshooting continued 20 | P a g e Fault Remedy Tipping not operational Engine must be running Check Fuse F12 Inside Engine starting panel Put selector switch on engine starting panel door in Manual and operate manually via front door push buttons Check relays inside control panel are secure Tipping grid remote control not operational Check Remote control is switched on via off/on switch located beside the belt clip Replace batteries if transmitter led does not light Check that receiver is plugged in via 10 pin plug on the 3400series starting panel base Check internal tipping grid relays (Manual override, Up relay, Auto Up Latch relay) Check Fuse F5 Check plug on bottom of 3500 panel is plugged in for track lead Track Lead not operational Remote control not operational Check fuse F5 Check plug on bottom of 3500 is plugged in for remote receiver. Ensure that internal remote transmitter batteries are charged Charger not operational Check fuse F7 Check vehicle charger on known supply Ensure contacts are clean on back of transmitter, Check cabling on charger and panel Belts not operational Ensure engine is running Check fuse f10 Switch to manual and start Check belt control plc is set to run on display inside panel 21 | P a g e 14) Maintenance and Spares All Electrical connections must to be checked regularly as vibration may loosen contacts. Enclosure must be kept clean using a suitable cleaning agent. All Spares are available for 3000Series Engine Starting Panel and associated machine electrics. Contact McGrath Engineering/ Ezystak Fuses On Engine Loom midi fuses F2- Preheat 40A Midi Fuse located under engine starter F8- Main Panel- 40A Midi Fuse located beside battery isolator F9- Oil Cooler- 40A Midi fuse located beside battery isolator 3000 Series Engine Starting Enclosure Blade Fuses F3- 30 Amp fuse Crank F3A- 20 Amp Fuel F4- 10 Amp fuse 3110 controller and relays F5- 10 Amp fuse Track controls and track enable relay F6- 10 Amp fuse Siren & Beacon F7- 10 Amp work Light/ Charger supply F9- 10 Amp Speed Controller. F10- 5 Amp Fuse Main Ignition relay control circuit (Dual Power only) F11- Belt Controls F12- 10 amp Tipping Grid controls (tipping grid only) DISPOSAL WEEE (WASTE ELECTRICAL AND ELECTRONIC EQUIPMENT) Directive 2002/96/EC If you use electrical and electronic equipment you must store, collect, treat, recycle and dispose of WEEE separately from your other waste. 22 | P a g e Anteckningar 23 | P a g e 24 | P a g e 25 | P a g e
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