EG2490 Equipment Manual

Shenyang Stock Electric Power Equipment Co.,Ltd.
No.6,Zhaogong North Street,Shenyang,China

(+86)-024-25823903
INSTRUCTION MANUAL
FOR THE
INSTALLATION,
OPERATION AND MAINTERNANCE
OF THE
MODEL EG2490 GRAVIMETRIC FEEDER
Shenyang Stock Electric Power Equipment Co.,Ltd. No.6,Zhaogong North Street,Shenyang,China

Tel: (+86)-024-2582 3903
Fax: (+86)-024-2582 0538
MANUAL CONTENT
Section 1.0 Installation

Section 2.0 Operation
Section 3.0 Maintenance
1.0 Installation
Section Index
Topic Page
1.1 RECEIVING INSPECTION 1–1
1.2 STORAGE PROCEDURES 1–1
1.3 STORAGE MAINTENANCE PROCEDURES 1–2
1.4 EXTENDED STORAGE PROCEDURES 1–3
1.5 INSTALLATION PROCEDURES 1–3

1.0 INSTALLATION
1.1 RECEIVING INSPECTION

Upon delivery, inspect the equipment for shortages or evidence of physical damage and make a report to
the independent carrier. Also notify the Contracts Department of Stock Equipment Company to arrange
for the shipment of replacement parts.
1.2 STORAGE PROCEDURES

Prior to shipment from the factory, provisions have been made to protect the equipment in the event that
prolonged storage is required at the job site. These storage procedures are provided as recommendations
to aid in maintaining the equipment in a warrantable and ready condition.
1.2.1 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 its removal, the packaging and protective covers should be visually
inspected to ensure that all 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.
1.2.2 Equipment is to be stored in such a manner as to provide ready access for inspection and
maintenance with a minimum of handling. Items should be positioned so that any markings or
labelings can be easily identified without excessive handling. Shipping documents are attached
to the outside of each crate to identify the equipment contained inside.
1.2.3 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, Storage Maintenance Procedures, should be kept
on record here.
1.2.4 Feeders are shipped with pliofilm coverings over the motors, gear reducers, feeder inlet, seal air
inlet, feeder–mounted electrical controls, and the control cabinet access door. Inspect and
replace any damaged covering when the feeders are received and while they are in storage.
1.2.5 All feeders with electronic enclosures mounted to them must be stored in a heated, ventilated
building where ambient temperatures may be controlled between 5°C (40°F) minimum and
50°C (120°F) maximum. Control enclosure access doors must be tightly closed to engage the
sealing gaskets.
1.2.6 Store feeders without electronic enclosures in a heated warehouse or 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 be placed over 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 each cover, 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.
1–1
1.0 INSTALLATION Shenyang Stock Electric Power Equipment Co.,Ltd.
1.2.7 Do not store other equipment on or near the feeders. Each feeder should be fully accessible for
periodic servicing and inspection while in storage.
1.2.8 Feeder accessories and crates containing miscellaneous hardware must be stored in a dry area
until installation takes place.
1.2.9 Electrical and electronics control enclosures for installation remote from the feeders are
shipped wrapped in pliofilm and crated. They must be stored in a heated, ventilated building
where ambient temperature may be controlled between 5°C (40°F) minimum and 50°C (120°F)
maximum. Control enclosure access doors must be tightly closed to engage the sealing gaskets.
1.2.10 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.
Saturated desiccant can be cured for 16 hours at approximately 120°C (250°F) and returned to
service, or discarded and replaced.
1.2.11 Inspect and service the feeders according to the following storage maintenance procedures until
equipment startup occurs.
1.3 STORAGE MAINTENANCE PROCEDURES
1.3.1 At each service interval, special care should be taken to remove only the crating and pliofilm
covers necessary to perform the maintenance and to replace them when servicing is complete.
1.3.2 MONTHLY, inspect feeders and control enclosures for damage to pliofilm covers, damage due
to corrosion or contamination, and for desiccant saturation.
1.3.3 QUARTERLY, to avoid “shaping” the belt around the drive and take–up pulleys, remove
tension from the belt by loosening the belt take–up screws and pull the belt to a different
position.
1.3.4 QUARTERLY, lubricate all bearings according to the instructions in Section 3.2, Lubrication.
1.3.5 ANNUALLY, change the oil in the gear reducers according to the lubrication instructions
in Section 3.2, Lubrication.
1.3.6 ANNUALLY, lubricate the cleanout conveyor chain pins thoroughly with a rust preventive
lubricant or gear reducer oil.
1.3.7 Refer to Section 7.0, Vendor Information for the manufacturer’s short– and long–term
storage recommendations on motors.
1.4 EXTENDED STORAGE PROCEDURES
1–2
1.0 INSTALLATION
1.4.1 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.
Note
The oil must be reduced to the normal operating level prior to operation of the feeder.
1.4.2 For maximum belt life when storage will exceed 36 months, remove and store the feeder belt
per the procedure in Section 3.5.7, Belt Changing – Spliced Belt. 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

The following items of equipment are required for feeder installation: a machinist’s level, several pieces
of four inch square shim stock in various thicknesses, and the feeder mounting hardware.
Note
System installation, schematic, and connection drawings are provided in Section 4.0, Certified
Drawings. Assembly drawings and parts lists are provided in Section 5.0, Mechanical Drawings
and Parts Lists and Section 6.0, Electrical/Electronic Drawings and Parts Lists.
Note
The weigh roller is held in place by blocking supported in the weigh compartment access door
frames. This blocking must remain in position until after the feeder is permanently installed.
Note
Before installation of the feeder, check the support steel for proper location of mounting holes.
1.5.1 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.
1–3
1.5.2 Place the feeder in position and insert the mounting bolts into the holes provided but do not
tighten the nuts.
1.5.3 Using the level, check the lengthwise level on both sides of the feeder using the two checking
bars (A2451–1) from the service tool kit placed across the weigh span rollers. Shim the feeder if
necessary by inserting shims adjacent to the mounting bolts.
1.5.4 Level the feeder widthwise from the bottom of the weigh span roller nearest the inlet.
1.5.5 Should the feeder side plates 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.
Note
Add shims as required to solidly support the feeder at all four corners to avoid twisting the
feeder body when tightening the mounting bolts.
1.5.6 Tighten the four mounting bolts in place.
1.5.7 Erect the connecting equipment above and below the feeder. Flexible connections are required
to minimize the loading on the feeder.
1.5.8 Ensure 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.
1.5.9 Install the feeder discharge pluggage sensor.
1.5.10 Drain and refill the belt drive and cleanout conveyor drive motor gear reducers with
fresh lubricant.
1.5.11 Check all mechanical components. Clean off any corrosion and tighten any loose connections.
1.5.12 Refer to Section 4.0, Certified Drawings and Section 6.0, Electrical/Electronic Drawings
and Parts Lists. Interconnect the feeder microprocessor/power control cabinet with the
combustion control system.
Note
Keep three phase power leads and motor supply leads at least 3” (76 mm) away from all 240 volt
wiring and at least 6” (153 mm) away from load cell instrumentation wiring (shielded cables).
1–4
1.0 INSTALLATION
1.5.13 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.
1.5.14 Refer to Section 6.0, Electrical/Electronic Drawings and Parts Lists. If new A1, A2, and A3
electronics cards:
• are provided, remove them from their individual packages and plug them into the
power supply P.C. board assembly (D21232 series).
• are not provided, continue using the existing A1, A2, and A3 electronics cards that are
plugged into the power supply P.C. board assembly. Do not remove the electronics
cards.
1.5.15 Verify that the ground lugs provided in each control enclosure are connected to ground
potential and structure of the plant.
Important
Safety considerations require that electrical apparatus and enclosures be solidly connected to
building ground.
1.5.16 Connect three phase electrical service to the main disconnect device in the feeder
microprocessor/power control cabinet.
1.5.17 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 cabinets. Scratched or cracked glass should be
replaced to maintain explosion protection. Arrange for the replacement of any damaged
mechanical or electrical components from Stock Equipment Company prior to startup.
1.5.18 Continue to follow the storage maintenance procedures described in Section 1.3, Storage
Maintenance Procedures regularly until startup.
1.5.19 Notify Stock Equipment Company one month in advance of the startup date to permit
scheduling of a startup engineer to the site.
1–5
Warning!
Do not energize the feeder or the power to the control cabinets until a Stock service engineer is
present. If a service engineer is not present when the feeder or the power to the control cabinets
are energized, damage to the equipment, injury or loss of life may occur.
1–6
2.0 Operation
Section Index
Topic Page
2.1 SYSTEM COMPONENT DESCRIPTION 2–1
2.1.1 Feeder Body 2–1

2.1.2 Belt and Drive System 2–1
2.1.3 Cleanout Conveyor 2–2
2.1.4 Feeder Electrical Controls 2–3
2.1.5 Feeder Microprocessor Controls 2–3
2.1.6 Feed Rate Measurement and Control Circuit 2–13
2.1.7 Service Tool Kit 2–14
2.2 STARTUP 2–15
2.2.1 Preliminary Startup Measures 2–15

2.2.2 Microprocessor Controls Setup 2–16
2.2.3 Initial Tests 2–37
2.2.4 Storage Maintenance After Startup 2–41
2.2.5 Extended Storage After Startup 2–42
2.2.6 Initial System Operation 2–42
2.3 TYPICAL OPERATING PROCEDURES 2–43
2.4 SITE SPECIFIC DATA 2–46
2.4.1 Feeder Operation Specifications 2–46

2.4.2 Feeder Parameter Table 2–47
2.0 OPERATION
2.1 SYSTEM COMPONENT DESCRIPTION

The Stock Equipment Company Model EG2490 gravimetric feeder has electronic weighing and STOCK
196NTR microprocessor controls. Feeder capacity and specifications are listed on the feeder dimension and
specification drawing in Section 4.0, Certified Drawings.
2.1.1 Feeder Body
Feeder design meets or exceeds NFPA Code 8503 requirements and will withstand an explosion
pressure of 50 psi. All structural members of the feeder in contact with active material flow are
fabricated of type 304 stainless steel. Skirting is installed across the end of the belt upstream of the
inlet and along both sides of the inlet above the belt to contain the material on the belt. The inlet end
skirt is removable for debris clearing and lump removal. A leveling bar, mounted downstream from
the inlet, shears the material column to form a profile conducive to maximum weighing accuracy.
Dust–tight doors are provided at both ends and on each side of the feeder for access to critical
components. Bull’s–eye 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.
2.1.2 Belt and Drive System
The feeder is equipped with a STOCKR ACCUFLEX™ spliced belt. The belt is supported by a
machined drive pulley near the outlet; a slotted, self–cleaning take–up pulley at the inlet end; and a
support pan beneath the inlet itself. A counterweighted scraper with replaceable rubber blade
continuously cleans the carrying surface of the belt after the material is delivered to the outlet.
Constant uniform belt tension is applied by two take–up screws which project through the inlet end
door of the feeder and act through a spring to draw the take–up pulley toward it. The tensioning
screws can be turned to make adjustments while the feeder is operating or at rest. Since changes in
temperature and humidity can cause belt length to vary, the belt should be checked regularly for
proper tension.
Proper belt tracking is primarily accomplished by crowning the take–up pulley. A belt turning on a
crowned pulley will tend to center itself on the highest point, the pulley center. In addition, all
pulleys and rollers are grooved to accept the molded V–guide in the belt. The belt tension
adjustment screws can be used to “steer” the belt in either direction if tracking adjustment is
necessary. All pulleys and rollers are easily removable for belt changing and bearing maintenance.
A variable frequency drive speed control provides motor speed control to an AC motor. A speed
feedback for the feeder control system is provided by a 60–tooth gear reluctance pickup attached to
the belt drive motor. This pickup generates 60 pulses per motor revolution; therefore, at a nominal
1800 RPM, the output frequency from the pickup is 1800 Hertz. This frequency is used to maintain
motor speed.
2–1
2.0 OPERATION Shenyang Stock Electric Power Equipment Co.,Ltd.
A level control switch assembly is mounted above the center of the belt to detect the presence or
absence of material on the belt. The assembly consists of a sensor with electronic control and a
stainless steel ball attached to the level control assembly. The stainless steel sensing element forms
with the material one plate of a variable capacitor with the feeder body acting as the second plate.
As the material reaches and comes in contact with the sensor a change in capacitance at the sensor
causes a change in signal in the electronic unit to indicate the presence of material.
Specially–designed circuitry enables the instrument to ignore the effects of material buildup on the
sensing elements, variations in moisture content, and changes in density and operating temperature.
Loss of material on the belt results in a contact closure of switch LSFB, input to the 196NT MPC.
This contact closure prevents operation of the total material integrator when the belt is empty and
prevents calibration when there is material on the belt.
2.1.3 Cleanout Conveyor
A single strand of cast iron drag chain with carbon steel pins and with alternately spaced wing links
are used to automatically clean the bottom pan of the feeder. This prevents interference with the
belt and removes stagnant material which may otherwise ignite spontaneously. Material buildup in
the cleanout conveyor area may be due to the following:
1. Material falling from the belt scraper.
2. Dust settling out of the air.
3. Material falling from the self–cleaning take–up pulley.
4. Material blown off the belt by an improperly adjusted seal air flow.
The cleanout conveyor is driven by a totally enclosed, nonventilated motor through a reducer to an
operating speed of slightly greater than two feet per minute. A two–position Cleanout Conveyor
OFF/RUN selector switch (SSC) is provided on the exterior of the control cabinet for manual
control. It is recommended that the cleanout conveyor be operated continuously with feeder
operation to keep the bottom pan of the feeder clean. Continuous operation also prevents a
corrosive buildup on the links which may, after long idle periods, cause binding of the links and
subsequent drive overload.
2.1.4 Feeder Electrical Controls
Electrical controls for the gravimetric feeder are housed in a microprocessor/power control cabinet
mounted remotely. The principal components in the cabinet are described in the following text.
2–2
Shenyang Stock Electric Power Equipment Co.,Ltd. 2.0 OPERATION
2.1.4.1 Microprocessor/Power Control Cabinet
The microprocessor/power control cabinet contains the variable frequency drive motor
speed control (see Section 7.0, Vendor Information), 196NT microprocessor control
electronics (see Section 2.1.5), transformers, relays and additional components for the
feeder control system. Refer to the installation, schematic, and connection drawings for
additional details.
2.1.5 Feeder Microprocessor Controls
The microprocessor feeder electronics control system is designed to operate in industrial and power
plant environments where harsh conditions and frequent power disturbances exist. It uses special
circuits, software subroutines, and nonvolatile memories to store data, programming and operating
parameters. This allows the system to recover and keep the feeder running under control after a
momentary power loss. The microprocessor electronics are contained in a NEMA rated electrical
control cabinet. The keyboard/display assembly is part of an environmentally sealed panel that is
gasketed against the enclosure door. The feeder control consists of four hardware packages: a
power supply, a CPU board, a keyboard/display assembly and a motor speed control. Additional
input and output devices are available and can be formatted to a variety of requirements, both
digital and analog.
The program chip used in the electronic system is part number D32400–140. The last digit is the
least significant digit of the program chip part numbers, and is variable and reserved for
manufacturing use. It does not denote a change in programming or in equipment operation.
2.1.5.1 Power Supply (Ref. Dwg. D21232 series)
The power supply board converts the customer’s AC power into the regulated low
voltages required to operate the control electronics. Input to the power supply is 117 V
AC @ 50–60 hertz. This is converted by transformers into a series of low voltages which
are rectified, filtered, and regulated. The voltages and the electronics they supply are
listed below (refer also to Figure 2–1).
2–3
Transformer Power Supply
Rectifier +5 V DC
and Regulator Filter
Filter
Logic
Common
120 V AC
50/60 Hertz
Rectifier
Regulator Filter ?0 V DC
and
Filter
Rectifier
Filter ?5 V DC
and Regulator
Filter
15 V DC for Relays O.C. GND
Isolated 20 V AC Supply
Figure 2–1 Power Supply
Voltage Device
+ 5 V DC Microprocessor, CMOS Display and Converter Cards
+10 V DC Load Cells and Amplifiers
–10 V DC Amplifiers
+15 V DC Calibration Probes
–15 V DC Optocoupled Inputs and Calibration Probes
The ±15 volt supplies are isolated from the logic and amplifier supplies. In addition,
there is an unregulated voltage which is used to energize relay coils, provided from the
filter side of the +15 volt supply. There are also two 20 V AC supplies for the isolated
feedrate converter cards (A2) and/or (A3). Each converter card has on–board filters
and regulators.
2–4
The applied voltage from the power supply to the controller board is provided through a
six–conductor cable. To troubleshoot the power supply board, refer to Section 3.6,
Troubleshooting Guide.
2.1.5.1.1 Input/Output Circuit Description
Located on the power supply board, the input/output circuits isolate the
microprocessor and its associated circuitry from the electrical and control
systems of the plant to eliminate malfunction from transients or noise.
All inputs to the CPU board are optically isolated at the power supply board.
The system is designed to accept a maximum of twelve digital inputs or
contact closures, a belt speed signal, an analog demand signal and a 20 mA
serial communication input. All output signals are similarly isolated and
include: seven power relays (each with two Form C contacts), one reed
relay with two Form A contacts, two analog signals (one for the customer
and one to operate the speed control), one 20 mA serial communication
output, and two spare outputs that can be formatted to meet special
requirements of the control system. Logic signals are transmitted to and
from the power supply board to the microprocessor through a 50–pin
ribbon cable.
A typical isolated input operates as follows. Incoming signals are used to

bias a light emitting diode whose light output is directly proportional to
input current. The light output of the diode is optically coupled to the base
of a phototransistor. The collector lead of the transistor sinks current from
the microprocessor to ground. Thus, inputs and outputs are
electrically isolated.
A typical isolated output operates as follows. CPU signals are used to bias a
light emitting diode and an optically coupled transistor, as with inputs.
However, the transistor emitter sinks current to energize a relay coil and the
relay contacts provide the output signal.
2–5
2.1.5.1.2 Input Signal Converter Card (A1)
The function of the input signal converter is to convert the customer fuel
demand signal to a normalized 0 to 10 kHz signal for interfacing with the
microprocessor system. The fuel demand signal can be any standard
control signal: current, voltage or potentiometer. The voltage and current
mode cards are essentially the same except for a terminating resistor on the
current mode card. The potentiometer input card supplies 5 volts across the
customer’s potentiometer and the proportionate signal is generated at the
slider. If supplied, refer to the schematic(s) in Section 4.0, Certified
Drawings for the input and feedback signal types supplied. Refer to the
cardgroup drawing in Section 6.0, Electrical/Electronic Drawings and
Parts Lists for card part numbers.
2.1.5.1.3 Frequency to Current Converter Card (A2) (A3)
The frequency to current converter card is used as a feedback module for

customers who require an analog feedback. The output signal is unipolar
and within a range of 20 mA. This circuit allows the digital electronics of
the microprocessor to output a digital signal, while the customer receives a
current feedback signal. In special applications, this circuit may be used to
convert a digital motor speed demand signal into an analog demand signal.
If supplied, refer to the schematic(s) in Section 4.0, Certified Drawings
for the input and feedback signal types supplied. Refer to the cardgroup
drawing in Section 6.0, Electrical/Electronic Drawings and Parts Lists
for card part numbers.
2.1.5.2 196NT CPU Board (Ref. Dwg. D31771 series)
The 196NT CPU board assembly is mounted on the hinged panel between the panel and
the interior of the door to the microprocessor control cabinet, and is electromagnetically
shielded from the rest of the feeder electrical controls. It contains a 16 MHz, 16 bit
embedded controller, memories, and digital interface circuits. The analog circuits used
to amplify and convert the load cell signals to a digital form are located on this board.
The keyboard assembly with vacuum fluorescent (VF) display is directly cabled to the
CPU board assembly.
The CPU board is the principal mechanism through which control of the system is
achieved. Digital inputs and keyboard commands are processed by software algorithms
which then route signals either to digital outputs or to the display as required. All digital
I/O interfaces are isolated by circuits on the power supply board which prevent damage
due to transients and prevent operational malfunction due to noise.
2–6
Interfacing between the microprocessor and the analog parts of the system is
accomplished by conversion circuits. Signals which pass from an external analog device
to the microprocessor first must pass through an analog to digital converter (voltage to
binary number). When the microprocessor must operate an external analog device, its
output is sent in the form of a frequency to a frequency to voltage or current converter
card. This device is a digital to analog converter since its converts a binary number to
either a voltage or a current. The A/D conversions for the load cell signals are made with
a resolution of one part in 65,000 or 0.00153%. Other A/D conversions are made with a
resolution of better than one part in 3200 or 0.03%.
The microprocessor control configuration is shown in Figure 2–2. A transparent portion

of the configuration is the software contained in a permanent memory. The software is
written so that the most important system activities (such as the motor speed loop and
demand signal input) are processed fast enough to allow good control to be achieved,
while less important signals (such as relay outputs) are processed at a slower speed. This
time multiplexing concept in the software program allows for better control of the
process when a great number of tasks must be performed. As can be seen from the
illustration, the only inputs directly accessing the CPU board are the keyboard and the
load cells. All other I/O signals pass through optical isolation circuits located on the
power supply which gives the system excellent noise immunity.
From User
Input Card A1
Input 20 mA
Demand
Keyboard Contacts Serial Link
Display Output Cards
A2/A3
20 mA
Serial Link
Power Power Supply

Relay To
196 MPC and
Outputs User
Board Logic Insulation I/O
Isolated
Feedback
Load Load
Cal Motor Speed
Cal
2 Control
1
Microprocessor Control
AC Configuration
Motor
Tach
2–7
Figure 2–2 Microprocessor Control Configuration
2.1.5.2.1 Microprocessor Memory
Programming of the microprocessor is done in the C programming

language, which fully utilizes the 16 mHz operating speed of the
microprocessor and expands the program memory space required to store
the operating program. The system utilizes 128K bytes of available
memory for program storage. There are also 32K bytes of random–access
memory (RAM) for temporary storage of data during operation, and two
nonvolatile memories for permanent and noise–immune storage of
operating parameters and system totalizers.
The microprocessor accesses a type of permanent read–only memory

(ROM) called a UV erasable EPROM for all operating instructions which
form the system software program. This ensures that the control program
instructions are not lost during a power interruption.
All operations involving the microprocessor utilize the transfer of

information to and from memory. As the CPU executes its program by
reading instructions from EPROM, data may be needed from one of the I/O
interface chips, EEPROM or BatRAM (battery backed up RAM). This data
may be stored in RAM for later processing or stored directly in the CPU in
a storage location called a register. After the data is acted upon by the CPU,
it may be stored in either its original memory location or in another. In all
cases, the use of memory for storage of programs, data, and even memory
addresses is an essential part of the microprocessor system.
2.1.5.2.2 Power Interrupt Protection Circuit
During operation, a temporary power interrupt may occur. This type of

power failure may be frequent, and if the feeder memory data is erased
during the interrupt, can shut down feeder operations even after power has
been restored. To prevent this, a power interrupt protection circuit has been
designed into the microprocessor controls which stores all incoming and
outgoing data, and all operating parameters, as soon as the start of a power
failure is detected. This allows the feeder to recover and keeps the system
operating in an orderly manner when power is restored after a failure.
2.1.5.3 Alphanumeric Display/Keyboard
Commands are entered to the controls via the keyboard on the front panel of the
microprocessor cabinet as shown in Figure 2–3.
2–8
CALIBRATION MODE PROGRAMMING
SETUP TRIM
CAL1 CAL2
REMOTE OFF LOCAL
7 8 9
OPERATION STATUS
INFO
4 5 6
TOTAL RUNNING
SELECT SELECT
SELF ERROR
FEEDING 1 2 3
TEST RECALL
TOTAL
VOLUMETRIC
0 EXIT
JOG
RESET
ALARM
ENTER CLEAR
F1 F2
TRIP
Stock Equipment Company

A Unit of General Signal
Figure 2–3 Keyboard and Front Panel of the Microprocessor Cabinet
The keyboard consists of small switches which input data digitally by creating a low
signal level (GND or binary number 0) when they are pressed. This signal is first stored
in a specific memory location which is different for each key of the keyboard. The signal
is then debounced to eliminate false signals. A true keypress is then decoded into data
which determines the function which is to be implemented and then the decoded data is
placed in a queue for processing.
When the microprocessor is checking to see if the keyboard has been operated, it reads
through the queue and implements any function allowed in the keyboard function table.
That function may require further data (numbers) which are also read from the queue.
At the same time that pressed key signals are being stored in a decoded form in the queue,
a demultiplexer (decoder) reads the queue for any data which is numerical and drives the
keyboard display with alphanumeric data. Thus, as numbers and function keys are
entered, they are displayed.
2–9
The keyboard contains keys of two colors: white and blue. The white keys are the
standard REMOTE/OFF/LOCAL selection of feeder operating mode and will be the
keys most frequently used. To activate a mode selection, press the bottom center of the
key below the LED light. The blue keys are functions and numbers that are activated by
pressing the key in the exact center in the proper order.
When a key is pressed, the VF display will change to acknowledge that the membrane
switch beneath the key has been activated successfully.
Keyboard Commands
The three white keys with LED indicators at the upper center of the keyboard select the
feeder operating mode, REMOTE, OFF or LOCAL. REMOTE allows the feeder to be
controlled from the customer run permissive contacts and demand signal. OFF
deactivates the feeder. LOCAL operates the feeder at a selectable speed. If there is
material on the belt during LOCAL operation, the feeder will trip after a
two–second delay.
Note
Pressing any of the white keys allows the feeder to operate in the selected mode. It also resets any
ALARM or TRIP indication, turning off the red panel indicators and opening the appropriate relay
contacts.
The JOG key may be pressed and held to operate the belt drive motor for as long as the
key is maintained. This command is used to check motor operation or to slowly move
the belt for service. The feeder must be in the OFF mode to jog the belt.
Reversing Belt Feature (Optional)
To operate the feeder belt in reverse (belt travel from discharge to inlet), press the OFF
key and then the F2 key. The display now indicates REVERSE and the belt is ready to
travel in the direction indicated when either the LOCAL or JOG key is pressed. To exit
the reverse mode, press the OFF key.
Display Selection Keys
There are three totalized weight display selections: gravimetric total, volumetric total,
and material total (combined totals of gravimetric and volumetric). The upper
forty–character line of the VF display shows the totalized weight of material delivered. It
may also be used to display function keys, number entry values and special functions.
Whenever the display is not otherwise in use, it will show the totalized weight of
material delivered.
2–10
Gravimetric is defined as material delivered with a functioning weighing system.
Volumetric is defined as material delivered when the weigh system is at fault and the
amount of material is delivered using an assumed weight on the weigh span. The
assumed weight is an average of what the material was known to weigh before the
weighing system faulted. This weight is used to determine a nominal material density.
Volumetric totalization has no guarantee of accuracy and may be at considerable error if
material density is not uniform. Therefore, a separate total is kept.
Pressing TOTAL SELECT key selects the totalizer mode on the display. Repeated
pressings will cycle through each of the three totalizer modes (Gravimetric Total,
Volumetric Total or Material Total). The upper line of the display will show which
mode is active. All totalizers are continually updated regardless of mode displayed.
Whenever one of the totalizers reaches full capacity, it will roll over and begin again
at zero.
From time to time it may be desirable to reset the three totalizers back to zero. To do this,
press and maintain: TOTAL RESET.
Important
There is no way to recall totalizer amounts once they have been reset.
The lower forty–character line of the VF display shows RATE, DENSITY or SPEED
by pressing the INFO SELECT key. The display will cycle and can be stopped by
releasing the key on the selected mode which appears at the left of the display.
RATE shows the operating feed rate of the feeder when in the gravimetric mode, or the
equivalent feed rate using the average density of the material when in the volumetric
mode.
DENSITY shows the density of material on the belt in the gravimetric mode in pounds
per cubic foot or kilograms per cubic meter. In the volumetric mode, the density shown
is based on an average density determined before the weight system faulted..
SPEED shows the feeder belt drive motor rpm.
Keyboard Disable Feature
2–11
The feeder programming includes a feature which will disable selected keys on the
keyboard and thereby prevent accidental or unauthorized alterations to the operating
parameters. To activate this feature, the customer may either install a jumper or close a
key–operated selector switch between wires 107 and 117 in the control cabinet. The
lower display line will indicate KEYS LOCKED on the right and all data entry is
locked out. This closure disables the CAL 1, CAL 2 and TOTAL RESET keys, and
only allows data verification in the TRIM and SETUP modes. To alter the feeder
operating parameters, reset the totalizers, or calibrate the feeder, the jumper must first be
removed or the key switch must be opened.
Status LEDs
The five LEDs on the keyboard panel indicate current operational status of the feeder.
a. RUNNING (green) is illuminated whenever the belt drive motor is energized.
b. FEEDING (green) is illuminated when the motor is energized and material on
the belt is sensed by the level control switch assembly (LSFB).
c. ALARM (red) indicates that a problem exists which requires attention, but is
not serious enough to immediately stop feeder operation.
d. TRIP (red) indicates that a serious problem exists and feeder operation has been
stopped.
e. VOLUMETRIC (red) indicates that a fault exists in the weighing system or its
electronics which prevents the feeder from operating the gravimetric mode.
Diagnostic Error Codes
Whenever an ALARM or TRIP condition occurs, an error code number is stored

internally to identify the source of the problem. To access the error code, press: ERROR
RECALL
A diagnostic message will appear in the display. For a description of the error code, refer
to Section 3.6.3, Error Codes.
2.1.5.4 Motor Speed Control
Information on the variable frequency drive motor speed control is located in

Section 7.0, Vendor Information.
2.1.6 Feed Rate Measurement and Control Circuit
The feeder weighing signal is generated by two load cells which support a weigh roller. Located on
each side of the weigh roller is a weigh span roller which together accurately define a given length
of belt on which the material is weighed. Each load cell supports 25% of the weight of material on
the weigh span. The output of the load cells is scaled into a signal which represents kilograms of
material per centimeter of belt. This weight data contributes to the feed rate formula from which the
feeder is operated:
2–12
weight (lbs/in x belt speed (in/sec) = feed rate (lbs/sec)

The feeder controls can accept either an internal feed rate set point or a customer feed rate demand
signal. This signal is compared with a computed feed rate derived from measured weight on the belt,
belt speed, and other parameters to generate the system error signal which operates the motor speed
control. Compensation for system stability is provided in the software. Furthermore, since the
microprocessor has stored all system parameters and limits, the error signal includes all these
settings so that no adjustments are required on the speed controls.
The microprocessor (software) computes the feeder delivery rate as follows. A measurement
sample is taken of the output of one load cell. This signal is converted into a digital signal (binary
number) by an analog to digital converter in the microprocessor having a resolution of one part in
65,000 (16 bit), or 0.00153%. This number is compared against parameters stored in permanent
memory (ROM). If the signal is within acceptable limits, it is stored in temporary memory (RAM).
The same operation is then performed on the other load cell. The signals are compared to each other
to further test their validity. If the signals are determined to be invalid, the feeder is switched to
volumetric operation and the controls use a simulated load cell output generated from a historical
average value stored in memory. If the signals are determined to be valid, the two load cell signals
are summed and the tare is subtracted. The result is multiplied by a calibration factor (determined
during feeder calibration) to arrive at weight of material per unit of belt length. The result obtained
is stored in RAM. The belt speed is determined by measuring the period of the output frequency of
an ac tachometer attached to the motor shaft. The accuracy of this measurement using the
microprocessor, with a crystal as a reference oscillator, is 0.025%. This measurement of the period
of the frequency signal is multiplied by another calibration factor (determined during feeder
calibration) to arrive at a number that represents belt travel speed per second. Finally, the belt speed
and weights are multiplied together to arrive at the feed rate. This result is then compared to the
demanded feed rate to determine the error and to operate the speed control.
The feed rate is displayed in selected units of weight per hour. The feed rate is integrated to obtain
totalized delivery in selected units of weight. The feeder inlet is designed to maintain uniform
material volume on the weigh span; therefore, the density is determined from the load cell output
and setup parameter entered for the volume on the weigh span.
2.1.7 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.
2.1.7.1 A checking bar is used in the weigh roller adjustment procedure to maintain alignment
between the weigh roller and the two weigh span rollers.
2.1.7.2 Test calibration weights are supplied for mounting beneath the load cells during
feeder calibration.
2–13
2.2 STARTUP
2.2.1 Preliminary Startup Measures
2.2.1.1 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 performing any work inside the feeder, deenergize the electrical control center by locking
the main disconnect switch or circuit breaker in the OFF position.
2.2.1.2 Open all feeder doors and remove all debris from on the belt and inside the feeder.
2.2.1.3 Carefully remove the fiberglass tape and load cell shipping brackets and install the load
cells in place of the brackets to support all the weight of the weigh roller.
2.2.1.4 Inspect the gear reducers for proper oil level.
2.2.1.5 Align the weigh roller according to the procedure in Section 3.5.4, Weigh Roller
Adjustment and check the weigh span and weigh rollers for freedom of rotation.
2.2.1.6 Check that the cleanout conveyor chain tension is adjusted to provide two inches of sag
per the procedure in Section 3.5.5, Cleanout Conveyor.
2.2.1.7 Inspect the electronics controls for proper installation and that all P.C. cards and cable
connectors are firmly in their sockets.
2.2.1.8 Measure the input voltage at the main feeder disconnect. If the voltage is correct, apply
power. Verify that the green OFF indicator is energized.
2.2.1.9 A blank alphanumeric display or a flashing red STATUS TRIP indicator signals a
potential problem with cabling or the CPU board, or may indicate a missing
programming chip.
Note
2–14
The CPU board is shipped from the factory with the real time clock disabled. To set the real time
clock to the time and date, refer to SELF TEST 11 in Maintenance, Section 3.6.4.
2.2.2 Microprocessor Controls Setup
The microprocessor controller is tailored to specific feeders and customer needs by approximately
36 setup variables. Feeder–specific physical dimensions must be entered into the microprocessor
controller in addition to user–selectable display modes and set points. These values are stored in
permanent memory and only have to be entered once.
The setup procedure for changing these parameters consist of referencing a specific parameter by a
two–digit address and associating either a value or an instruction with this address. An instruction
is usually a single–digit number which sets the controls or display to operate in a predetermined
way. A value is a feeder set point or dimension which is used by the microprocessor in its control
sequence.
To access the parameter changing mode, the SETUP key is pressed. The microprocessor display
prompts the operator to enter the address (00–36) for the parameter that needs to be viewed or
changed. The display reads:
< SETUP > Enter Parameter 00–36
The microprocessor will select a default address if one is not selected by the operator in 4 seconds.
Other addresses can then be accessed by pressing the UP or DOWN arrow keys. For each address,
the display shows the address number, the current parameter’s value, units of measure, and a brief
description. For example, the display may appear as follows for Address 05.
< SETUP 05 > 5.000 Tons/hr

Maximum Feed Rate
The microprocessor controls are capable of displaying units of weight in pounds, kilograms, U.S.
tons, and metric tons. To choose alternate units for setup parameters that are values, press the
SETUP key until the desired units are displayed. The microprocessor recalculates the displayed
value to accommodate the new units. Each of the setup parameters that are values have independent
units. Changing units for one parameter does not affect the other parameters.
To alter a parameter value, key in the new value on the numeric keyboard and press the ENTER
key. As the new value is entered, it is displayed next to the old value. If a typographical error is
made on entry, the CLEAR key blanks the current new entry without affecting the original value.
The value of any setup parameter can be viewed in any of the modes (REMOTE, OFF, LOCAL).
Any of the setup parameters can be altered in the OFF mode. Motion–dependent setup parameters
cannot be changed when the feeder is running (REMOTE or LOCAL). The display will then warn
the operator with the message: ”Feeder must be OFF to change.”
2–15
Note
Pressing the OFF key de–energizes the feeder motor.
Pressing the EXIT key or OFF key immediately ends the setup operation. The setup operation will
also end after 5 minutes of keyboard inactivity.
Use the following general instructions when entering setup values:
1. Select the units of measure (pounds, kilograms, etc.) by pressing the SETUP key until the
desired units are displayed.
2. Enter numbers as if using a pocket calculator.
3. When entering a decimal value which is less than 1.0, a zero must be entered before the
decimal point, as in 0.15.
4. The microprocessor displays three decimal places for most values, but internally keeps six
digits of accuracy (ANSI/IEEE single precision). If more than six digits are entered at the
keyboard, the microprocessor will round or truncate the value entered.
5. If a decimal point is used at a setup address which requires a coded entry, the
microprocessor will ignore the decimal point.
6. If a mistake is made, press CLEAR to erase the entry and start again.
7. Press ENTER to store the value in memory.
8. If a value for a setup parameter is entered which exceeds the usable range of the specific
setup parameter, the microprocessor displays the message OUT OF RANGE, and the
original value for that specific setup parameter is used. Changing the units (e.g., pounds to
kilograms) automatically changes the usable range.
9. The keyboard may have a lockout feature which prevents any change from being made to
the setup parameters. The lockout feature is either a switch or a jumper wire between
terminals 107 and 117 in the microprocessor cabinet. To remove the lockout feature so that
setup parameters may be entered, either open the switch or deenergize the controls and
remove the jumper wire.
10. It is recommended that the setup parameters be reviewed for accuracy after all initial
entries have been made.
SETUP FUNCTIONS
2–16
2.2.2.1 Initiate the Setup Mode
Initiate the setup mode by pressing the OFF key on the microprocessor keyboard. Then
press:
< SETUP > 00.
Note
If a delay of five seconds or more occurs after setup is pressed, the MPC will default to the last
setup address accessed. Use the up or down arrow to return to 00.
2.2.2.2 Feed Rate Set Point (Address 00)
This is the feed rate set point used when the feeder is operating in the REMOTE mode
controlled by feed rate set point (see Address 03, option 2). The available units for this
parameter are pounds/hour, tons/hour, kilograms/second, kilograms/hour, and
metric tons/hour.
Example: If the feeder will operate in the REMOTE mode controlled by

the feed rate set point, press:
18.25 tons/hr ENTER
If the feeder will operate in the REMOTE mode controlled by the analog customer feed
rate demand signal, this address is not recognized.
2.2.2.3 Speed Set Point RPM (Address 01)
This is the operating speed of the belt drive motor in the LOCAL and CALIBRATION
modes, and also in the REMOTE mode when the feeder is controlled by speed set point
(see Address 03, option 5). The value must be less than the value entered for the motor
maximum speed (see Address 29) and greater than the value entered for the motor
minimum speed (see Address 30).
Example: If the feeder is to operate at 1000 rpm, press:
° until < SETUP 01 > appears, then 1000 ENTER
2–17
2.2.2.4 Initial Density Estimate (Address 02)
This is an initial density estimate of the material which will be fed and is used to
initialize the average running density whenever a new value is entered. The average
running density calculated by the microprocessor can be viewed in <SELF TEST 12>.
Available units for the parameter are pounds/cubic foot or kilograms/cubic meter.
Example: If the feeder will be feeding material with an expected density of

47.5 pounds per cubic foot, press:
° until < SETUP 02 > appears.
Then press SETUP until the units appear as lbs/cu ft.
Press 47.5 ENTER
2.2.2.5 Run Mode (Address 03)

The feeder can be run in REMOTE operation in any of eight run modes, according to the
following table:
Run Mode Operating Characteristics

0 Analog Customer Feed Rate Demand. The feeder will seek to match a
feed rate demand from the analog customer demand input. This demand
may be 4–20 mA, 0–10 volts, etc. Note: It is necessary to align the input
converter card according to the procedure in Section 3.4.1, I/O Channel
Adjustment before operating the feeder. The limits on the feed rate
demand signal are set by the minimum (Address 06) and maximum
(Address 05) feed rates of the feeder.
1 Raise/Lower Customer Feed Rate Demand. This mode increases or
decreases an internal feed rate set point depending upon the raise or lower
contact closures. The limits on the raise/lower control are set by the
minimum (Address 06) and maximum (Address 05) feed rates of
the feeder.
2 Feed Rate Set Point. The feeder will deliver material at the rate
contained in the feed rate set point (Address 00).
3 Analog Customer RPM Demand. The feeder will seek to match a speed
demand from the analog customer demand input. The value entered in
Address 29 determines the maximum speed that can be attained and the
value in Address 30 determines the minimum speed. This mode permits
net material weighing within a volumetric rate feed system. NOTE: It is
necessary to align the input converter card according to the procedure in
Section 3.4.1, I/O Channel Adjustment before operating the feeder.
4 Raise/Lower Customer Speed Demand. This mode increases or
decreases an internal motor speed set point depending upon the raise or
lower contact closures. The value entered in Address 29 determines the
maximum speed that can be attained and the value in Address 30
2–18
determines the minimum speed.

5 Speed Set Point. The feeder will operate at the constant speed contained
in the motor speed set point (Address 01). This permits a constant volume
per second delivery but with electronic weighing, like a belt scale.
6 Feed Rate Serial. The feeder will deliver material at a constant feed rate.
This is set by a command sent through the serial port.
7 RPM Serial. The feeder will deliver material at a constant motor speed.
This is set by a command sent through the serial port.
Example: If the feeder will be controlled by the analog customer demand input, press:
2.2.2.6 Display Select (Address 04)
This parameter specifies which units of measure the microprocessor will use to display
feed rates, densities, belt travel and totals.
Units of Measure Selection Chart
Unit Option Description Units of Measure

0 Feed Rate U.S. tons/hour
Density pounds/cubic foot
Belt Travel inches
Totals U.S. tons
1 Feed Rate pounds/hour
Density pounds/cubic foot
Belt Travel inches
Totals pounds
2 Feed Rate metric tons/hour
Density kilograms/cubic meter
Belt Travel meters
Totals metric tons
3 Feed Rate kilograms/hour
Belt Travel meters
Totals kilograms
4 Feed Rate kilograms/second
Belt Travel meters
Totals kilograms
2–19
Example: If the desired feed rate unit of measure is U. S. tons per hour,
density is pounds per cubic foot, belt travel is inches and totals are
U. S. tons, press:
2.2.2.7 Maximum Feed Rate (Address 05)
This is the maximum feed rate that the feeder can achieve in the REMOTE mode
following a demand signal or a RAISE command. The available units for this parameter
are pounds/hour, tons/hour, kilograms/second, kilograms/hour and metric tons/hour.
Example: If the maximum permissible feed rate is 15 tons per hour, press:
Then press SETUP until the units appear as U.S. tons/hr
Press 15 ENTER
2.2.2.8 Minimum Feed Rate (Address 06)
This is the minimum feed rate that the feeder can achieve in the REMOTE mode
following a demand signal or a LOWER command. The available units for this
parameter are pounds/hour, tons/hour, kilograms/second, kilograms/hour and
metric tons/hour.
Note
This address along with address 30 should be set at 0 when the feeder supplies coal to a Williams
mill. When the minimum feed rate causes the belt drive motor speed to drop to 50 rpm, both
feeding and running relays will de–energize, stopping the feeder. When the demand increases and
exceeds the 50 rpm cutoff, the feeder restarts.
Example: If the minimum permissible feed rate is 2.5 U.S. tons per
hour, press:
° until < SETUP 06 > appears, then 2.5 ENTER
2–20
2.2.2.9 Remote Data Logging Totalizer Increment (Address 07)
This sets the amount of material registered on a remote totalizer for every pulse of the
data logging output. A typical value is 100 units (pounds, U.S. tons, kilograms, or metric
tons). Press:
2.2.2.10 Demand Mode (Address 08)
This is a switch denoting where the speed control demand signal and secondary
feedback are present. There are two cases:
Demand Mode Secondary Feedback Source

0 The feeder has an eddy current clutch connected to lines 131 and
132, and a secondary feedback from output socket A2, or the
feeder has a DC or variable frequency drive motor speed control
with a signal converter connected to lines 131 and 132.
1 The feeder has a DC or variable frequency motor speed control
with a drive card in slot A2, and secondary analog feedback
available via lines 131 and 132 using an optional signal
transmitter.
Example: If the feeder motor is equipped with an ac variable frequency drive,

press:
2.2.2.11 Tachometer Type (Address 09)
This parameter specifies the type of tachometer used, according to the following table:
Value Tachometer
0 60–Tooth Gear
1 40–Tooth Gear
2 Ac Tachometer – 18 cycles (36–pole)
3 Ac Tachometer – 12 cycles (24–pole)
Example: If a 60–tooth gear is in use, press:
2–21
2.2.2.12 Weigh Span (Address 10)
The weigh span is the distance between the centers of the weigh span rollers expressed in
one of the following units: inches, centimeters, millimeters or meters. Enter up to two
decimal places if necessary.
Example: If the distance between weigh span rollers is 36.00 inches, press:
Then press SETUP until the units appear as “in”.
Press 36.00 ENTER
2.2.2.13 Volume (Address 11)
This represents the volume of material on the weigh span. It is calculated from the
following dimensions: leveling bar height, material stream width, corner cut–off
dimensions, and weigh span length. Round the entry to three decimal places. The
available units for this setup parameter are cubic inches, cubic feet, cubic centimeters, or
cubic meters.
The following dimensions are required for this calculation:
Leveling bar height: 7–1/8 in
Material stream width: 24 in
Weigh span length: 36 in
Cut–off dimensions: 2–7/8 in x 5 in
(Note that the two cut–off corners together form a rectangle.)
Example using the sample dimensions listed:
1. Cross Sectional Area = Total Area - Cut Off Area
= (Bar Height x Mtl. Stream) - (Height x Width)
= (7–1/8 in x 24 in) - (2–7/8 in x 5 in)
= 156.625 sq. in
2. Convert square inches to square feet.
144 sq. in = 1 sq. ft.
2–22
156.625 sq in
144 sq in/sq ft=1.09 sq ft
3. Volume on weigh span = Cross sectional area x weigh span length
=1.09 sq. ft. x 36 in.
= 3.26 cu ft.
To enter this sample value, press:
Then press SETUP until the units appear as “cu ft”.
Press 3.26 ENTER
2.2.2.14 Calibration Probe Span (Address 12)
This is the linear length of belt being sensed by the calibration probes and is expressed in
inches, centimeters, millimeters or meters.
Example: If the center distance between calibration probes is 36.00

inches, press:
Then press SETUP until the units appear as “in”.
Press 36.00 ENTER
2.2.2.15 Calibration Weight (Address 13)
This value represents the total weight of the calibration weight(s). The value of each
calibration weight is stamped on the end of the weight weldment. Possible units for this
parameter are pounds or kilograms.
Example: A feeder has two 40–pound calibration weights. Enter the total,
rounded to three decimal places. Press:
Then press SETUP until the units appear as “lbs”.
Press 80 ENTER
2–23
2.2.2.16 Motor Speed Control Servo Loop Gain (Address 14)
This parameter is predetermined for each particular motor/control combination and

should not be altered without consulting Stock Equipment Company. Typical values are
listed in the following table:
Value Motor/Control Combination

4800 Eddy Current Clutch Speed Control
2000 DC Motor Speed Control
4000 AC Variable Frequency Drive
Example: If the feeder motor is equipped with an AC variable frequency

drive, press:
Note
Incorrect values may cause wild instability in motor speed.
2.2.2.17 Motor Speed Control Servo Loop Rate Feedback Gain (Address 15)
This parameter, like the servo loop gain, is predetermined for each particular
motor/control combination and also can cause uncontrolled motor behavior
if improperly set. Its value is highly dependent upon the amount of
acceleration/deceleration control used in the speed control. Typical values
are listed in the following table:
Value Motor/Control Combination

14000 Eddy Current Clutch Speed Control
14000 DC Motor Speed Control
8000 AC Variable Frequency Drive
Example: If the feeder motor is equipped with an AC variable frequency

drive, press:
2–24
2.2.2.18 Discharge Pluggage Delay (Address 16)
If the feeder is equipped with a discharge pluggage sensor, this parameter sets the delay
after closure of the discharge pluggage switch contacts until the feeder is tripped. To
disable this function if a discharge pluggage sensor is not provided, enter “0”; otherwise,
the delay must be entered in seconds as:
1/2 second = 0.5
2 seconds = 2.0
5 seconds = 5.0 (this is the maximum allowable delay)
Example: If the feeder is to be stopped after a 2–second delay, press:
2.2.2.19 Belt Motion Monitor Delay Time (Address 17)
If the feeder is equipped with a belt motion monitor, this parameter specifies the
maximum time interval in seconds, between pulses received from the motion monitor
magnetic pick–up before the belt can be identified as not moving. The interval is
determined when the feeder is operating at its minimum design feed rate and is equal to
the time necessary for the pulley or roller which inputs the sensor to make one complete
revolution, divided by two, plus ten percent. Therefore, time intervals for motion
monitors mounted to the tension roll or belt take–up pulley will be considerably longer
than those for sensors mounted to the weigh span roller. To disable this function if a belt
motion monitor is not provided, enter “0”.
Example: If the motion monitor is mounted to the weigh span roller which makes one
revolution every 20 seconds at minimum feed rate, the time interval between
pulses before the belt is certain not to be moving is: 20 ÷ 2 = 10 + 10% = 11
seconds. Press:
° until “17” appears, then 11 ENTER
2.2.2.20 Level/Temperature Sensor Trip Delay (Address 18)
If the bunker to pulverizer system includes a level monitor, this parameter specifies the
delay after a material void is detected in the downspout before the feeder is tripped. The
delay is expressed as the volume of material delivered from the downspout after the void
is sensed. The available units for this setup parameter are cubic inches, cubic feet, cubic
centimeters or cubic meters.
To disable this function, enter 0. For an immediate trip, enter 0.1.

2–25
As an example, the following data are required for this calculation: downspout radius,
downspout height (from level monitor elevation to coupling) and maximum feeder
operating pressure differential.
Downspout radius: 1 ft.

Downspout height: 12 ft. (from nuclear monitor elevation to coupling)
Max. feeder operating pressure differential: 25 inches of water
Example using the sample dimensions listed:
1. Volume in downspout = π × radius of downspout squared × height
= 3.14 × (1)2 × 12
= 37.68 cu ft
2. The volume of material which must remain in the downspout to safely maintain
a head seal is based upon 2 inches of material per inch of feeder operating
pressure differential.
25 in H2O×2 in per in H2O = 50 in of material required
3. If the downspout height from level monitor elevation to the downspout coupling
at the feeder is 144 inches, and if 50 inches of material must remain in the
downspout to preserve the head seal, then the amount of material which may
safely be fed before deactivation of the feeder is:
144 in - 50 in = 94 in
4. To determine what volume of material may be fed, set up a proportion as

follows. Inches of material which may be fed is to total inches of downspout
height as volume of material which may be fed is to total downspout volume.
94 in X cu ft
144 in=37.68 cu ft
X=24.6 cu ft
To set up using these sample dimensions, press:
Then press SETUP until the units appear as “cu ft”.
Press 24.6 ENTER
2–26
2.2.2.21 Weight Signal Filtering (Address 19)
This sets the amount of filtering between load cell measurement. It is used where there is
considerable mechanical vibration at the feeder or when the belt has an inconsistent
weight.
The recommended initial setting is 4. Increasing the value by one, doubles the degree of
filtering; decreasing it by one, halves the degree of filtering. A value of zero provides no
filtering, and 8 provides the maximum degree of filtering available.
Example: Using the recommended initial setting, press:
2.2.2.22 Feedback Signal Filtering (Address 20)
This sets the amount of filtering directly on the feedback signal. More filtering smooths
out the feedback signal but also makes it slower to respond. Less filtering increases the
response but with more variation. This parameter should be adjusted according to
individual plant requirements.
The recommended initial setting is 2 or 3. Increasing the value by one, doubles the
degree of filtering; decreasing it by one, halves the degree of filtering. A value of 8
provides maximum filtering. For smooth response in noisy environments, enter 4 or 5.
For fastest response (with greatest variation), enter 0 (this is suggested for PID
control loops).
Example: Using the recommended initial setting, press:
2.2.2.23 Feedback Filter Override Threshold (Address 21)
When the feedback is filtered and a large scale step change is made in demand, the filter
on the feedback can be bypassed to allow quick reaction to this large change. This
parameter specifies how large the change must be before the filter is overridden. The
typical value is 15% (entered as “0.15”), so that if the feed rate demand changes more
than 15%, the filter is bypassed. In general, a smaller percentage more accurately
reproduces the output but may result in more feedback variation due to small, random
changes in the weight of the belt.
Example: Using the typical value. Press:
2–27
2.2.2.24 Belt Travel Revolutions (Address 22)
This sets the total belt travel (in belt revolutions) used for simulated material tests (see
Self Test 13). Best test results will be obtained if multiples of one complete belt
revolution are entered, although partial belt revolutions will be accepted.
Example: To set the material test duration to five belt revolutions, press:
2.2.2.25 (Address 23)
This setup function address is not used in this application.
2.2.2.26 Paddle Feedback Permissive (Address 24)
This parameter specifies how the feeder’s analog feedback signal reacts to the absence
of the material on belt paddle as determined by the material–on–belt limit switch input:
Value Feedback
0 The analog feedback signal is proportional to the RATE regardless of
the position of the material–on–belt paddle switch.
1 If the material–on–belt paddle switch indicates an empty belt, the
analog feedback shows zero output (i.e., 4 mA in a 4–20 mA
configuration, 0 volts in a 0–10 volt configuration, etc.)
Example: “0” is the preferred value. Press:
2.2.2.27 Communications Unit Number (Address 25)
This number must be assigned to differentiate individual feeder units when a number of
units are connected to a centralized computer control system for data logging purposes.
Numbers 1 to 255 may be entered here as necessary. When a value of 0 is entered, serial
communications are disabled.
Example: A particular feeder is to be designated No. 5. Press:
2–28
2.2.2.28 Mode Select Enable/Disable (Address 26)
This parameter specifies the source of control for the feeder REMOTE, OFF, or LOCAL
operating modes according to the following table:
Value Mode Input(s) Enabled

0 Feeder operating mode can be established only by pressing one of the
three white keys on the microprocessor keyboard.
1 The operating mode and white keys on the microprocessor keyboard
are governed by a remotely located mode selector switch when the
microprocessor control cabinet is feeder mounted, or a feeder mounted
mode selector switch when the microprocessor control cabinet is
remotely installed. When the selector switch is placed in the REMOTE
position, the feeder will go immediately into remote mode and respond
to the feeder start permissive. When the selector switch is placed in the
LOCAL position, the feeder will immediately begin to operate in the
local mode. The feeder OFF key can always be used to deactivate the
feeder regardless of the position of the selector switch.
To restart the feeder after the feeder OFF key is pressed, proceed as
follows. For operation in the remote mode, simply press the
REMOTE key; for operation in the local mode, the selector switch
must be turned first to OFF, then turned to LOCAL. The feeder JOG
key will respond only when the selector switch is in the OFF position.
2 Feeder operating mode can be established only by means of
a feeder–mounted mode selector switch when the microprocessor
control cabinet is also feeder mounted, or when a remote feeder
control cabinet has installed within it both a microprocessor and a
feeder mode selector switch. The three white keys on the
microprocessor keyboard are disabled.
Example: Feeder mode selection is through the microprocessor

keyboard. Press:
2.2.2.29 FRI Output Frequency (Address 27)
This parameter specifies the frequency of the feedrate indicator output which
corresponds to hertz per ton per hour, hertz per kilogram per second, hertz per metric ton
per hour feed rate.
Example: Using the standard feed rate indicator with output of 10 hertz per
metric ton per hour. Press:

2–29
Then press SETUP until the units appear as “Hz/mtph”
Press 10 ENTER
2.2.2.30 Raise/Lower Contact Input Response Time (Address 28)
When the feeder is operating in the REMOTE mode controlled by either RUN mode 1 or
4 (see Address 03, option 1 or 4), this parameter will allow you to vary the time to go
from 0% to 100% feed rate. It has a range of 5–300 and a response time of 60% of the
number entered based on a step input of 0% to 100% feed rate. A starting value of 100 is
recommended to get a response time of 60 seconds.
Example: If 100 is the value required, press:
2.2.2.31 Maximum Motor Speed Clamp (Address 29)
This address determines the maximum rpm at which the motor will run. Address 01
(speed set point rpm) will be changed automatically to be with in this limit.
When the feeder is running in rpm demand mode (Address 03, option 3) or in the
RAISE/LOWER rpm mode (Address 03, option 4), this maximum rpm value will
correspond to the maximum demand signal.
Example: The motor is rated at 1750 rpm maximum, press:
2.2.2.32 Minimum Motor Speed Clamp (Address 30)
This address determines the minimum rpm at which the motor will run. Address 01
(speed set point rpm) will be changed automatically to be within this limit.
When the feeder is running in rpm demand mode (Address 03, option 3) or the
RAISE/LOWER rpm mode (Address 03, option 4), this minimum rpm value will
correspond to the minimum demand signal.
Note
When the feeder supplies coal to a Williams mill, the minimum motor rpm must be set to 0.
Example: The minimum motor rpm is 175, press:
2–30
Warning!
For variable frequency drive applications, operating the motor at speeds less than the values
shown in Table 2–1 shortens motor life and voids the warranty.
FOR VARIABLE FREQUENCY DRIVE APPLICATIONS
Motor Nameplate RPM Rating Minimum Motor Speed (RPM)

1725 - 1800 180
1150 - 1200 120
Table 2–1 Minimum Motor Speed Settings for

Variable Frequency Drive Applications
2.2.2.33 (Address 31)
2.2.2.34 (Address 32)
2.2.2.35 Weight Signal Gain Factor (Address 33)
This address specifies the gain set on the load cell A/D converter according to the
following table:
Value Gain Factor

0 This is the normal setting. It should always be used when normal
Stock load cells (3mV/V) are connected directly to the 196NT
controller.
1 This is a high gain setting used when low output (less then 3mV/V)
load cells are connected directly to the 196NT controller. It should not
be used with Stock load cells.
2–31
2 This is the normal setting when the load cells are connected through a
remote load cell amplifier.
3 This is the high gain setting when the load cells are connected through
a remote load cell amplifier.
Note
The feeder must be recalibrated after setup address 33 has been changed.
Example: To use the normal gain factor, press:
2.2.2.36 (Address 34)
2.2.2.37 Remote Totalizer Pulse Width (Address 35)
This address specifies the duration of the remote totalizer (K8 relay) output pulse. This
value is rounded to the nearest 50 ms by the microprocessor. It has a range of 0.005 to
2.0 seconds.
The relay OFF TIME must be at least as long as the ON TIME. If this register is set up
incorrectly, the remote TOTALIZER INDICATOR (TCI) will not display the actual
totalized amount. The value of this register multiplied by the value of address 07,
specifies the MAXIMUM feed rate that the feeder can deliver.
Example: Maximum Feed Rate = 200,000 lbs per hour.

Address 07 = 100 lbs
2–32
Maximum Feed Rate

Pulses Per Hour = Address 07
200000 lbs/hr
= 100 lbs
= 2000
Pulses Per Hour

Pulses Per Second = 3600
2000
= 3600
= 0.55
This is equal to 1.8 seconds per pulse. Address 35 must be programmed to 0.9 or lower.
Press:
2.2.2.38 Test Chain Weight (Address 36)
The value entered into this register represents the total weight of the optional test chains
in units of weight per unit length, and is used at the end of SELF TEST 13 to calculate
the feeder weighing error. When test weights are not used (a zero load test), this address
should be set to a value of zero. Units available for this parameter are: pounds/inch,
kilograms/meter, kilograms/centimeter, kilograms/millimeter. The weight of each
test chain is stamped on the end of the chain assembly.
Example: A set of six test chains has the following weights marked in lbs./in.:
0.7212, 0.7214, 0.7213, 0.7215, 0.7214, and 0.7212. Enter the
TOTAL SUM of each chain rounded to four decimal places.
° until < SETUP 36 > appears, then press:
SETUP until the units appear as “lbs/in”.
Then press 4.3280 ENTER.
2–33
2.2.2.39 Go to Section 2.4, Site Specific Data and Section 3.7, Site Specific Data, and enter all
the operating parameters. When complete, return here and continue with the following
step.
2.2.2.40 Terminate the setup mode after entering and verifying all setup parameters by pressing
the OFF or EXIT key.
2.2.3 Initial Tests
This procedure verifies that the feeder and its controls are operating properly, simulates feeder trip
conditions, and checks the principal input/output connections.
2.2.3.1 With power applied, verify that only the displays and the green OFF LED is illuminated.
The red VOLUMETRIC LED is extinguished. If it is not, there is a problem with the
weighing system, which could be in a load cell, cable, or amplifier.
2.2.3.2 Energize the feeder work lights.
2.2.3.3 Unbalance the load cells by engaging the calibration weight on one side of the weigh
roller. After a two–second delay, the VOLUMETRIC LED should be illuminated. This
changes the DENSITY display from approximately zero to the initial density estimate
entered in Address 02. Unbalance each load cell in order to check both sides, then
disengage the calibration weight(s).
2.2.3.4 Test that all keyboard LEDs and displays are operational. When this test is performed,
all components will be illuminated for three seconds and then return off automatically.
Press: OFF SELF TEST 04.
2.2.3.5 Refer to Section 3.7, Site Specific Data and adjust the motor speed control.
2.2.3.6 Press and maintain the JOG key to verify belt travel in the direction of the feeder outlet.
Disconnect power and rewire the motor starter if it is improperly phased.
2.2.3.7 Turn the CLEANOUT CONVEYOR selector switch (SSC) to the RUN position.
Verify conveyor operation and travel in the direction of the feeder outlet. Disconnect
power and rewire the motor starter if it is improperly phased. Allow the cleanout
conveyor to operate until the feeder initial tests are completed to verify performance of
the motor starter thermal overloads.
2.2.3.8 Energize the feeder for operation in the LOCAL mode. Press: LOCAL.
The feeder will operate at the speed programmed in Address 01.
2–34
Verify that the green RUNNING LED is illuminated and check the motor speed for
stability within ”5 rpm. If it is unstable, check the motor speed control servo loop gain
(Address 14) and the motor speed control servo loop rate feedback gain (Address 15) to
see that those two parameters match the recommended initial settings. If they match,
contact Stock Equipment Company for assistance in selecting values more suitable to
the particular application.
2.2.3.9 Check for proper belt tracking. Verify that the V–guide of the belt is within the grooves
on the pulleys and rollers, and that no humping is noticeable at any of these points.
Adjust the belt for proper tracking, if necessary, according to the procedure in
Section 3.5.2, Belt Tracking.
2.2.3.10 Check belt tension and adjust, if necessary, according to the procedure in Section 3.5.1,
Belt Tension.
2.2.3.11 Connect a digital tachometer to the speed pick–up signal located at wires 145 and 146 on
the terminal blocks inside the microprocessor cabinet. Set the tachometer to
the appropriate range for the type of feedback signal present. Press INFO SELECT
until the SPEED is on the lower display line and verify that the display and the
tachometer readings are equal. If they are not, the tachometer type (Address 09)
is incorrectly entered.
2.2.3.12 De–energize the feeder and deflect the material–on–belt level control switch to simulate
a loaded belt. Energize the feeder in the LOCAL mode to verify that the feeder operates
for only two seconds in the LOCAL mode with material on the belt.
After the feeder has stopped, verify that the red TRIP LED is illuminated. If the feeder
does not trip or if the LED is not illuminated, check the adjustment of the level control
switch according to the procedure in Section 3.5.6, Feeder Discharge Pluggage Sensor
(LSFD) and Material On Belt Level Switch (LSFB).
2.2.3.13 Check the error recall function of the microprocessor controls. Press:
ERROR RECALL.
The display should now show <Error Code 08>, a reference time, and a message
indicating material on the belt in the LOCAL mode. Return the material–on–belt level
control switch to its in–service position.
2–35
2.2.3.14 Press the OFF key and align the analog inputs and outputs according to the procedure in
Section 3.4, Input and Output Alignment Procedure.
2.2.3.15 Calibrate the feeder according to the procedure in Section 3.3, Feeder Calibration.
2.2.3.16 Apply the calibration weight(s). Produce or simulate a feeder start permissive and apply
a 100% demand signal. Check the motor current draw on each phase to verify that it does
not exceed the nameplate rating.
2.2.3.17 Check feed rate and feedback linearity by applying demand signals of 100, 75, 50 and
25%. Compare each demand signal applied to the displayed feed rate and to the feedback
signal output to verify linearity within ”0.5%.
If simulation of maximum feed rate cannot be achieved during this test, proceed
as follows:
a. Calculate the density implied by the test weight(s) supplied:
2 x test weight
volume on weigh span=lbs per cu ft –or kgs per cu. m
b. Press the INFO SELECT key on the keyboard until DENSITY is displayed.
c. If the density displayed matches the calculated density but falls below 45
pounds per cubic foot (lowest operating density), the test weight may be
insufficient to simulate 100% feed rate. When this occurs, the feeder should be
forced into volumetric operation by removing the test weight from one end of
the weigh roller. In the volumetric mode, the density value used by the
microprocessor is approximately 47.5 pounds per cubic foot (average operating
density), so that a 100% simulated feed rate should be obtainable.
d. If the density displayed is not close to the calculated value, the feeder calibration
is suspect or a problem may exist in the CPU board.
2.2.3.18 With the lowest density of material being fed, verify that the belt drive motor rpm is
below the full load speed.
a. Place the feeder into volumetric operation by engaging the calibration weight on
one side of the weigh roller. After a two–second delay, the VOLUMETRIC
LED should illuminate.
b. Deflect the material–on–belt level control switch to simulate material on belt.
c. In Address 02 enter the lowest density rating of the material being fed. Press:
SETUP 02 45 ENTER.
d. Produce or simulate a feeder start permissive and apply a 100% demand signal.
Observe the rpm display and verify that the rpm is below the full load speed as
shown on the motor nameplate.
2–36
e. In Address 02, enter the average density of the material being fed, press:
SETUP 02 47.5 ENTER.
2.2.3.19 Energize the feeder in the REMOTE mode and touch the discharge pluggage alarm
sensor with a metal rod. After the preset delay entered at Address 16, the feeder should
be de–energized.
After the feeder has stopped, verify that the red TRIP LED is illuminated. If the feeder
does not trip or if the LED is not illuminated, check the adjustment of the level control
switch according to the procedure in Section 3.5.6, Feeder Discharge Pluggage Sensor
(LSFD) and Material On Belt Level Switch (LSFB).
2.2.3.20 Check the error recall function of the microprocessor controls. Press:
ERROR RECALL.
The display should show < Error Code 07 >, the error code indicating a pluggage at the
feeder discharge. Remove the metal rod from the discharge pluggage alarm sensor.
Return the feeder to REMOTE operation.
2.2.3.21 While the feeder is operating in the REMOTE mode, deflect the material–on–belt level
control switch and apply or simulate a demand signal from the combustion control
system. Verify that the two displays respond to feeder operation and that the three green
LEDs RUNNING, FEEDING and REMOTE are all illuminated.
2.2.3.22 Press: SELF TEST 06.
Verify that the upper line shows the demand signal currently being applied to the feeder.
This signal will be displayed in the same unit of measure as the feed rate display, and
should change as the demand signal changes.
2.2.3.23 Press: SELF TEST 05 and note the restart count shown on the lower line. De–energize
the control cabinet at the main disconnect switch and then reapply power. Press: SELF
TEST 05 again to verify that the restart count has increased by one.
2.2.3.24 When initial feeder testing has been completed successfully, press the OFF key to
deactivate the feeder. Also turn the CLEANOUT CONVEYOR selector switch (SSC)
to the OFF position.
Note
2–37
If the feeder will be placed on line immediately after its startup testing is complete, proceed to
Section 2.2.6. If the feeder will be stored in place following its startup testing, refer to Sections 2.2.4
or 2.2.5, depending upon the anticipated storage interval.
2.2.4 Storage Maintenance After Startup
Follow the procedures below for feeders that have been operational and must be stored in place for
a period of a year or less.
2.2.4.1 Remove all material from the equipment, bunker to pulverizer.
2.2.4.2 Clean the inside of the feeder thoroughly and, when it has dried, paint the feeder interior
with rust–preventive paint.
2.2.4.3 Cover the top of the bunkers to prevent any moisture or foreign objects from
contaminating the equipment.
2.2.4.4 Clean all dust, dirt and moisture from the control cabinet. Place desiccant bags in the
cabinet and tightly close the access door. Also place desiccant in the feeder near the limit
switches to prevent corrosion.
2.2.4.5 MONTHLY, operate the feeder in the LOCAL mode, with the calibrating weight
engaged, for at least an hour. Also operate the cleanout conveyor at this time.
2.2.4.6 Follow the storage maintenance procedures detailed in steps 1.3.1 through 1.3.6 in
Section 1.3, Storage Maintenance Procedures.
2.2.5 Extended Storage After Startup
Follow the procedures below for feeders that have been operational and must be stored in place for
a period of more than a year.
2.2.5.1 Follow the storage maintenance after startup procedures detailed in steps 2.2.4.1
through 2.2.4.4 in Section 2.2.4, Storage Maintenance After Startup.
2.2.5.2 Block up the tension roller and fully loosen the belt take–up screws to remove tension
from the feeder belt.
2–38
2.2.5.3 For maximum belt life when storage will exceed 36 months, remove and store the feeder
belts per the maintenance procedure in Section 3.5.7, Belt Changing – Spliced Belt.
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.
2.2.5.4 QUARTERLY, lubricate all bearings according to the instructions in

Section 3.2, Lubrication.
2.2.5.5 An alternative to annually changing oil in the gear reducers when storage will exceed 12
months is to fill them to the top with oil, which prevents the formation of moisture. After
filling, seal the fill port with a non–vented plug.
Note
The oil must be reduced to normal operating level prior to operation of the feeder.
2.2.6 Initial System Operation
Follow these special operating instructions the first time the feeder is energized to operate
according to typical operating procedures.
2.2.6.1 Be sure that the calibration weight(s) is disengaged from both load cells.
2.2.6.2 Carefully load the feeder belt slowly opening the inlet 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.
2.2.6.3 Clear the totalizers. Press and maintain: TOTAL RESET.
2.2.6.4 Reset the restart counter. Press: SELF TEST 05 CLEAR.
2.2.6.5 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.
2.2.6.6 With the feeder in operation, and when the bunker has been filled and the pulverizer is
operating, pressurize the feeder and adjust the seal air flow.
2–39
2.3 TYPICAL OPERATING PROCEDURES
2.3.1 When filling the bunker, first close the inlet valve to minimize the filling pressure on the feeder and
to avoid compaction of the material at the feeder inlet. This precaution is unnecessary if the bunker
is refilled while at least 8 to 10 feet of material remains in it.
2.3.2 When starting the feeder, open the inlet valve slowly to load the belt at a controlled rate and to
minimize compaction at the feeder inlet.
2.3.3 Energize the feeder controls at the disconnect switch in the control cabinet. Observe that the display
and one of the two LEDs (REMOTE or OFF) is illuminated.
2.3.4 If the OFF LED is illuminated, press the REMOTE key. Upon receipt of a customer–generated
feeder start command and a demand signal from the combustion control system, the feeder begins
to operate and the green RUNNING LED is also illuminated.
2.3.5 Turn the CLEANOUT CONVEYOR selector switch to the RUN position for continuous
operation whenever the feeder is activated
2.3.6 As material fills the feeder belt, the green FEEDING LED is illuminated.
2.3.7 When the microprocessor has verified the operation of the weighing system electronics, the feed
rate and the totalized weight are displayed.
2.3.8 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.
During normal operation, only the three green status LEDs are illuminated. If any of the amber or
red status LEDs are illuminated, then a problem has been detected and the feeder requires attention.
2.3.9 For a brief feeder stop with a loaded belt, press the OFF key.
2.3.10 For a clean shutdown with an empty belt, close the inlet valve while the feeder is still running.
When the belt is emptied, then press the OFF key. This procedure is recommended whenever the
feeder will be inactive for a long period of time, since it eliminates the possibility of material
compaction at the feeder inlet due to consolidation caused by its own weight.
2.3.11 To jog the feeder belt, press the OFF key followed by the JOG key on the microprocessor
keyboard for as long as motion is required.
2–40
2.3.12 To operate the feeder in the LOCAL mode for inspection or servicing, press the LOCAL key. The
feeder will run at the speed programmed into the setup parameter at Address 01.
2.3.13 Determine if the optional belt reversing circuit is provided by performing the following steps.
a. Refer to Section 4.0, Certified Drawings and determine if the belt reversing circuit is
shown. Confirm that the K2 relay contact is wired to the motor speed control.
b. Press the OFF key, the F2 key, and then either the:
• LOCAL key for continuous operation,
or the
• JOG key for operation as long as the key remains pressed.

c. Press the OFF key to release the controls for normal belt operation.
Note
If the feeder belt does not reverse when pressing either the LOCAL or JOG keys, then the belt
reversing circuit is not provided.
2.3.14 If necessary, clear material from the feeder and the downspout or bunker above it by performing the
following steps:
a. Open the inlet end door.
b. Remove the inlet end skirt.
c. Bolt the emergency discharge chute to the feeder floor.
d. Operate the feeder belt drive motor in reverse. This bypasses the feeder discharge and
pulverizer inlet.
THIS PAGE INTENTIONALLY LEFT BLANK
2–41
2.4 SITE SPECIFIC DATA
2.4.1 Feeder Operation Specifications
The following are for use in determining the feeder operating parameters:
1. Gear Reduction _______________
2. Leveling Bar Height _______________
3. Weigh Span Length _______________
4. Calibration Probe Span Length _______________
5. Area of Cross Section under Leveling Bar _______________
6. Specified Density of Material Handled _______________
7. Maximum Capacity Feed Rate _______________
8. Minimum Capacity Feed Rate _______________
9. Maximum Capacity Motor Speed _______________

(Based on __________ density)
10. Tachometer Type _______________
11. Input Signal _______________
12. Feedback Signal _______________
2–43
2.0 OPERATION
Shenyang Stock Electric Power Equipment Co,.Ltd.
2.4.2 Feeder Parameter Table
The following table summarizes all the operating parameters of the microprocessor control
system. The values entered in the preliminary value column are to be used for guidance during
equipment startup. They should be checked and changed as required in accordance with actual
job site conditions and, when verified, recorded in the final value column for
permanent reference.
Address Function Preliminary Value Final Value

00 Feed Rate Min. Rate
01 Speed Set Point (RPM)
02 Initial Density Estimate
03 Run Mode Select
04 Display Select
05 Maximum Feed Rate
06 Minimum Feed Rate
07 Totalizer Increment
08 Demand Mode
09 Tachometer Type
10 Weigh Span Length
11 Volume
12 Calibration Probe Span
13 Calibration Weight Stamped on Weight(s)
14 MSC Servo Loop Gain
15 MSC Servo Loop Rate Feedback
16 Discharge Pluggage Delay
17 Belt Motion Monitor Delay (seconds)
18 Level/Temperature Trip Delay
19 Weight Signal Filtering
20 Feedback Signal Filtering
21 Feedback Filter Override Threshold
22 Belt Travel Revolutions
23 (Not used in this application)
24 Paddle Feedback Permissive
25 Communications Unit Number
26 Mode Select Enable/Disable
27 Remote FRI Frequency @ 1 MTPH
28 Raise/Lower Response Time
29 Maximum Allowable Motor RPM
30 Minimum Allowable Motor RPM
2–44

33 Weight Signal Gain Factor
35 Remote Totalizer Pulse Width
36 Test Chain Weight Stamped on Weight(s)
2–43
3.0 Maintenance
Section Index
Topic Page
3.1 INSPECTION AND ADJUSTMENT SCHEDULE 3–1
3.2 LUBRICATION 3–1
3.2.1 Lubrication Schedule 3–2

3.2.2 Grease Specifications 3–2
3.2.3 Worm Gear Oil Specifications 3–3
3.3 FEEDER CALIBRATION 3–4
3.3.1 Calibration Procedure 3–5

3.3.2 Calibration Check 3–9
3.4 INPUT AND OUTPUT ALIGNMENT PROCEDURE 3–11
3.4.1 I/O Channel Adjustment 3–12
3.5 FEEDER ADJUSTMENTS 3–14
3.5.1 Belt Tension 3–14

3.5.2 Belt Tracking 3–15
3.5.3 Inlet Side Skirts and Belt Support Pan 3–17
3.5.4 Weigh Roller Adjustment 3–17
3.5.5 Cleanout Conveyor 3–18
3.5.6 Feeder Discharge Pluggage Sensor (LSFD) and
Material On Belt Level Switch (LSFB) 3–18
3.5.7 Belt Changing – Spliced Belt (ACCUFLEXR) 3–21
3.5.8 Drive Pulley Centering 3–23
3.5.9 Seal Air 3–24
3.0 MAINTENANCE Shenyang Stock Electric Power Equipment Co.,Ltd.
Topic Page
3.6 TROUBLESHOOTING GUIDE 3–24
3.6.1 Diagnostic LED Indicators 3–24

3.6.2 Error Recall 3–25
3.6.3 Error Codes 3–26
3.6.4 Self Test Summary 3–27
3.6.5 Electronics P.C. Boards 3–32
3.7 SITE SPECIFIC DATA 3–37
3.7.1 Motor Speed Control Adjustments 3–37

Shenyang Stock Electric Power Equipment Co.,Ltd. 3.0 MAINTENANCE
3.1 INSPECTION AND ADJUSTMENT SCHEDULE

Periodic inspection, adjustment and calibration of the feeder are essential to its safe, reliable and
efficient operation, and to ensure that it operates according to the engineering design criteria.
To maintain maximum weighing accuracy, the following factors are essential: proper belt tension,
proper belt tracking, proper alignment of the weigh 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.
Important
Before performing any work inside the feeder, press the OFF key and de–energize the feeder by
locking the main circuit breaker or disconnect switch in the OFF position.
Inspection Schedule
Daily Inspection: • Check belt tracking.
Weekly Inspection: • Check belt tension.
• Check belt for tears.
• Check oil level in gear reducers.
Monthly Inspection: • Perform monthly lubrication service.
Quarterly Inspection: • Change gear reducer oil.
• Check seal air adjustment.
Semiannual Inspection at • Check rotating parts for evidence of bearing failure or gear wear.
Shutdown for Servicing: • Check the feeder for excessively worn or corroded parts.
• Check for freedom of movement of the weigh system (drag links, load cells, rollers).
• Check the belt for signs of excessive wear.
• Check the belt scraper for wear and proper operation.
• Clean the load cell modules.
• Clean corroded electrical contacts and tighten loose wire terminals.
• Remove material buildup on the inside of the feeder body and clean the interior surface of all
viewing ports.
• Check the inlet skirts for positioning and wear.
• Perform semiannual lubrication service.
• Check cleanout conveyor chain tension and free any binding links.
• Calibrate the feeder.
Periodic Inspection: • Inspect newly installed belts for proper tension and tracking two to three times per shift until
the belt is stabilized and has lost its initial stretch; thereafter, inspect weekly.
• Adjust the weigh roller whenever the load cell modules, belt, or weigh span rollers are
changed or serviced.
• Anytime the feeder end doors are removed, inspect the cleanout conveyor.
Note
Feeder calibration should also be performed following a weigh roller adjustment or replacement
of the belt, the CPU board, a load cell module, or the microprocessor program chip.
3.2 LUBRICATION
The gravimetric feeder should be lubricated according to the following schedule.
3–1
3.2.1 Lubrication Schedule
Refer to Figure 3–1, Lubrication Diagram for point code locations.
Point Code Description Number of Points Frequency

2 Belt Drive Gear Reducer 1 Grease Fitting Monthly
3 Belt Drive Motor See Note 1
4 Head Pulley Bearing 1 Grease Fitting Monthly
5 Cleanout Conveyor Motor 1 Grease Fitting See Note 1
7 Cleanout Conveyor Gear Reducer 1 Oil Level Plug
8 Cleanout Conveyor Gear Reducer 1 Grease Fitting Monthly
9 Cleanout Conveyor Take Up Assembly 1 Per Side Monthly
10 Belt Drive Gear Reducer 1 Oil Level Plug
11 Belt Take–Up Pulley Bearing 1 Per Side Monthly
Point Code Description Quantity Frequency

1 Belt Drive Reducer As Required See Notes 2, 3,
6 Cleanout Conveyor Reducer As Required See Note 2, 3
Lubrication Notes
1. Refer to Section 7.0, Vendor Information for the manufacturer’s lubrication requirements.
2. Drain oil from reducer and refill after the first month of operation; thereafter, at six–month intervals or every 2500
hours of operation, whichever occurs first.
3. The gear reducer is equipped with a dipstick for checking oil level and is located on the top of the reducer. Unscrew
the dipstick and pull out of the reducer. The dipstick has an oil level mark near the end of the dipstick.
The belt drive gear reducer is equipped with a plug located in the center of the gear box. This plug must be
removed to check oil level.
Figure 3–1 Lubrication Diagram
3.2.2 Grease Specifications
3–2
The feeder has been factory–lubricated with NLGI No. 2 lithium base grease with the
following specifications:
Dropping Point 191°C (375°F)

Penetration Unworked 275
Penetration Worked 272
Temperature Range 15°F to 250°F
The grease selected should be designed for long bearing life and formulated to provide
protection against rust, corrosion, oxidation and water washout.
While no bearings are loaded heavily enough to require using grease with extreme pressure
additives, most premium quality multipurpose greases contain additives and may provide extra
wear protection in cases where grease is not applied often enough or in sufficient quantity.
If changing to a new grease, consult the lubricant supplier to verify its compatibility with the
former grease. Some greases are incompatible with others, resulting in possible bearing failure.
If there is any doubt about compatibility, the former grease must first be flushed or cleaned
out completely.
The following is a partial listing of lubricant manufacturers’ recommended greases. They are
intended only as examples. Other manufacturers may be consulted for their recommendations.
Chevron Chevron SRI–2

Gulf Oil Gulfgem Grease
Mobil Oil Mobilux EP 2
Shell Oil Dolium Grease R
BP Energrease LS–EP2
Texaco Texaco RB No. 2
3.2.3 Worm Gear Oil Specifications
Ambient Temperature Ranges *
16°F to 60°F 50°F to125°F

AGMA Lubricant Number 7C 8C
Viscosity Range (MM/S@104_F) 414–506 612–748
ISO Grade 460 680
Lubricant Temperature Range 15°F to 175°F 50°F to 175°F
*For ambient temperatures below –9_C (16_F), consult Stock Equipment Company. The pour point of all
gear lubricants should be at least 10_C (50_F) lower than the lowest ambient temperature expected.
In all cases, the lubricant manufacturer’s storage instructions should be followed to avoid
separation of compounds. If changing to a new oil, consult the lubricant supplier to verify its
compatibility with the former oil. AGMA compounded, rust– and oxidation–resisting gear oils
are generally compatible with each other. If any doubt exists about their compatibility, the
reducer must first be drained and flushed with a commercially available flushing agent, or with
the new oil, to remove all traces of the previously used oil.
3–3
Worm Gear Oil Examples
Amoco Oil Co. Amoco Worm Gear Oil Amoco Cyl. Oil 680
Chevron Oil Co. Cylinder Oil 460X Cylinder OIl 680X
Exxon Oil Co. Cylesstic TK460 Cylesstic TK680
Fiske Brothers SPO 277 SPO 288
Gulf Oil Co. Senate 460 Senate 680
Mobil Oil Corp. 600W Cyl. Oil 600W Super Cyl. Oil
Pennzoil Cyl. Oil #8 Cyl. Oil #6
Phillips Petroleum Co. Hector 460S Hector 630S
Shell Oil Co. Valvata J460 Valvata J680
BP Energol DC–C460 Energol DC–C460
Texaco, Inc. Vanguard 460 Honor 680
Union Oil Co. (Calif.) Steaval B110 Steaval B165
3.3 FEEDER CALIBRATION

The feeder should be calibrated at start–up, after one month of initial operation and every six months
thereafter. Calibration should also be performed following a weigh roller adjustment or replacement of
the belt, the CPU board, a load cell module, or the microprocessor program chip. Calibration is
accomplished in two separate steps.
Step one of calibration consists of the elimination of system tare, which includes the weight of the
weigh roller, load cell support assembly, and the feeder belt. It also involves measuring belt speed and
its relationship to motor speed. Step two calibrates the load cell output with a known weight.
Cancellation of feeder tare is performed by measuring the average weigh system output over exactly
two belt revolutions and then subtracting this amount from the total weight measurement. When the belt
is running empty, it produces a zero average contribution to the totalized weight. In normal operation,
the average tare is automatically subtracted from the gross weight of the belt. Therefore, only the
material weight on the belt is reflected as totalized weight.
During the same time the empty belt is being weighed, the belt speed is accurately measured. This is
done by measuring the time it takes a retro–reflective tape marker on the belt to travel between two
fixed points. This parameter is measured a number of times to determine repeatability and to
compensate for variations in belt thickness. From this data, the belt speed is calculated and the
relationship between belt speed and motor speed is established. The feeder operates with zero belt
slippage. Therefore, the ratio of belt speed to average motor speed is constant. This ratio is stored in
memory and is used to determine the belt speed for any motor speed.
The span of the weighing system is set after the tare has been measured. A known weight is applied to
the weigh roller and the average output over exactly two belt revolutions is measured. This calibrated
span factor is stored in memory and used to accurately determine the value of the weight of the material
on the belt.
To calibrate the feeder, the Stock Equipment Company supplied calibration kit is required. In principle,
the calibration procedure involves placing a test weight on the weigh roller and precisely measuring one
revolution of belt and the weight on a fixed length of belt. This data is processed using an algorithm
developed from the results of material tests and guarantees the specified feeder accuracy without the
need of test chains or other material tests.
3–4
3.3.1 Calibration Procedure
Note
Before calibrating the feeder, allow it to operate for 15 to 30 minutes to limber the belt.
3.3.1.1 Close the inlet valve above the feeder and empty the belt.
3.3.1.2 Press the OFF key.
3.3.1.3 Close the seal air supply.
3.3.1.4 Close the feeder discharge valve if one is provided.
3.3.1.5 Open all feeder side and end access doors, as well as the door to the microprocessor
control cabinet.
3.3.1.6 Adjust the belt to proper tension and tracking according to the procedures in
Section 3.5, Feeder Adjustments.
3.3.1.7 Apply four strips of retro–reflective adhesive tape from the calibration kit to the belt
curb on the same side as the control enclosure. Each strip should be positioned
vertically on the belt curb and located entirely between two flexing slits in the belt,
rather than spanning over a slit. Place one strip each outboard of the drive and
take–up pulleys, a third adjacent to the weigh roller, and the fourth on the return belt
beneath the third.
3.3.1.8 Verify that all four tapes are spaced at a distance greater than one calibration probe
span length from each other. (If four tapes cannot fit on the belt at a separation of
greater than one calibration probe span length from each other, two tapes spaced
equidistantly from each other are to be used.)
Note
The tapes may stay attached to the belt from one calibration to the next. Inspect and clean the
tapes at this point in the procedure.
3.3.1.9 Align the weigh roller according to the procedure in Section 3.5.4, Weigh Roller
Adjustment. Clean off any dirt accumulation at each drag link pivot point.
3.3.1.10 Remove the two plugs adjacent to the weigh span roller grease fittings for insertion
of the calibration probes.
3–5
3.3.1.11 Remove the protective caps from the calibration probes and insert one probe into
each access port in the feeder body, taking care to align the detent pins on the probe
with the machined holes in the feeder. Although the two probes are not dedicated to
particular locations, note that the probe location nearest to the feeder inlet is
designated LOCATION A and the probe location nearest to the discharge is
designated LOCATION B.
Caution
Disconnect power to the feeder by opening the main circuit breaker or disconnect switch before
connecting the probe cables to receptacles CAL A and CAL B. Reapply power after probe
cables are connected.
3.3.1.12 Connect the probe cables to the probes and to the receptacles in the microprocessor
control cabinet. Connect probe A to receptacle CAL A and probe B to receptacle
CAL B.
3.3.1.13 Compare the calibration weight against the value that is stored in the microprocessor
memory. The correct value is stamped on the calibration weight. To display the
value stored in memory, press: SETUP 13.
3.3.1.14 If the calibration weight displayed from memory above is incorrect, enter the correct
calibration weight as follows. Press: **.*** ENTER.
*Enter in place of the asterisks the actual value rounded to three decimal places.
3.3.1.15 Compare the desired calibration speed against the value stored in the microprocessor
memory. To display the value stored in the memory, press: SETUP 01, and the
set–up address and value will be displayed.
If the calibration speed is incorrect, enter the desired value as follows,

press: **** ENTER, and the set–up address and new value will be displayed.
*Enter in place of the asterisks the actual numeric value.
Note
If a mistake is made during entry of the correct calibration weight value, press CLEAR and
re–enter only the value. Do not re–enter any set–up commands.
3.3.1.16 Verify that the calibration weight is disengaged from both load cells.
3–6
3.3.1.17 Initiate step one of calibration which is the tare and belt travel measurement.
Press: CAL 1.
The feeder will now begin to operate under control of the microprocessor. Observe
the LOCAL mode LED illuminates to verify that the calibration is proceeding in the
following manner:
3.3.1.17.1 The display will clear and <CAL 1> initialization will be shown for
two seconds on the upper line of the display.
3.3.1.17.2 A 25–second delay is initiated while the belt drive motor is brought up
to the calibration rpm and stabilized. The display changes to show:
< CAL 1 > Tare and Belt Speed Factor

HH:MM:SS Stabilizing @ XXXX RPM
where HH:MM:SS represents the estimated calibration time and

XXXX represents the calibration speed programmed into setup 01.
Note
The calibration time is only a reference value based on the last complete CAL 1 and does not
affect calibration. The time may be wrong if the belt, CPU board or EEPROM have been
changed.
3.3.1.17.3 When the delay expires, the first tape passing probe A causes the
display to read:

HH:MM:SS Pass #1 Timing
and the HH:MM:SS timer starts counting down to zero. When the tape
passes probe B, the display changes to:

HH:MM:SS Pass #1 Done
Each following tape displays “TIMING” and the pass number is

incremented by one when the tape passes probe A and displays
“DONE” when the tape passes probe B. When the eighth tape passes
probe B, the display changes to:
< CAL 1 > Finishing Belt Revolution–

HH:MM:SS Pass #8 Done
3–7
3.3.1.17.4 As the ninth tape crosses probe A, the belt will have traveled exactly
two revolutions (or four revolutions if two tapes were applied). The
drive motor is de–energized and the display shows the percentage
repeatability error of the eight belt speed measurements just performed
for 4.5 seconds.
< CAL 1 > Dev: 0.20%

Good Values = 8
The display shows the calibration values for CAL1:
< CAL 1 > Tare factor NNNNNNN

Speed factor 0.XXX < ENTER > saves
where NNNNNNN is the tare number and XXX is the speed factor
stored by the controls. Press ENTER to save the new measurements
and proceed to step 3.3.1.18.
3.3.1.17.5 If this error is greater than a programmed limit, the display shows:
< CAL 1 > Dev: 0.70% Bad!

< ENTER > to reCAL < EXIT > to QUIT
Press ENTER to make another attempt.
3.3.1.17.6 If after numerous attempts the calibration still fails, press EXIT to end
the calibration and proceed to troubleshoot for problems in the motor
speed control or with belt travel. The following conditions will cause
calibration to exit automatically with a diagnostic message showing on
the display:
1. Feeder Tripped During CAL 1

2. Calibration Tapes Too Close
3. Weighing System Volumetric During CAL 1
3.3.1.18 If CAL 1, the tare and travel measurement, is successful, either proceed to
step 3.3.1.19 or repeat step 3.3.1.17 as many times as desired.
3.3.1.19 Initiate step 2 of calibration by pressing CAL 2. The display will show:
Add Calibration Weight of XXX.XXX Lbs.

< ENTER > to start CAL 2
Refer to step 3.3.1.13 for entry of the correct calibration weight value. When
the correct calibration weight is displayed, engage the calibration weight on both
load cells.
3.3.1.20 Initiate the load cell span calibration. Press: ENTER.

3–8
3.3.1.20.1 The display will clear and <CAL 2> initialization will be shown on the
upper line of the display for two seconds. The belt drive motor is
energized, a 25–second delay is initiated while the belt drive motor is
stabilized at the calibration rpm, and the display shows:
< CAL 2 > Span Factor

HH:MM:SS Stabilizing @ XXXX RPM
where HH:MM:SS represents the estimated calibration time and

XXXX represents the calibration speed programmed into Address 01.
Note that the time is a reference value as discussed in step 3.3.1.17.4.
When the delay expires, the display begins to count the passage of the
eight tapes as described in step 3.3.1.17.4.
3.3.1.20.2 After the passage of the ninth tape (not displayed), the feeder is
de–energized and the display shows:
< CAL 2 > Dev: 0.20%

Good Values = 8
Then the display shows the calibration values for CAL 2:
< CAL 2 > Span factor NNNNNNN

Speed factor 0.XXX < ENTER > saves
where NNNNNNN is the span number stored by the controls. Note that
XXX is a reference number only and is not stored in CAL 2. Press
ENTER to save the new measurements.
3.3.2 Calibration Check
By comparing the current calibration to the previous one, the operator can determine how
repeatable the calibration is and how it may have changed over the last six months. The
microprocessor controls calculate the percentage change between the two calibrations when the
commands are entered as follows:
3.3.2.1 To compare tare percent change, press:
SELF TEST 01
3.3.2.2 To compare belt travel percent change, press:
SELF TEST 02
3.3.2.3 To compare span percent change, press:
SELF TEST 03
3–9
The results of all three calibration checks should be 0 ”0.25 maximum. If they fall
outside this limit, check the suspension of the calibration weight from the load cell
for sticking or other unusual mechanical conditions; then repeat the complete
calibration procedure. Refer to SELF TEST 01, 02 or 03 for more information.
Caution
When calibrating the feeder with probes, disconnect power to the feeder by opening the main
circuit breaker or disconnect switch before disconnecting the probe cables from receptacles
CAL A and CAL B.
3–10
3.4 INPUT AND OUTPUT ALIGNMENT PROCEDURE

The feeder controls can respond to a feed rate demand signal and return isolated analog feedback signals.
When the input and output modules associated with these signals are used with the plant’s control
system, they must be adjusted prior to operating the feeder under remote control. To perform this
procedure, Stock Equipment Company recommends the Fluke Model 87 Digital Multimeter or
equivalent. The DC accuracy of the meter for milliamps should be ”0.2% plus 2 digits and the DC
accuracy for voltage should be ”0.1% plus 1 digit. It also must have a 4–1/2 digit high resolution mode.
Note
The plant combustion control system is the preferred source of the demand signal. This will
precisely align the feeder to the control system.
There is one customer input channel used in the microprocessor control system, designated A1. There
are three output channels used in the control system which may require alignment, designated A2, A3,
and A4. Output channels used by the customer are determined by the type of belt drive motor used in the
feeder. The following are the standard output channel configurations for the three available types
of motors:
a. For eddy current clutch applications, A2 is an optional analog feedback, and A3 is the
standard customer analog feedback. For eddy current clutch applications, A4 is used internally
by the microprocessor and does not require trimming.
b. For DC drive motor applications, A2 is used internally by the microprocessor for the motor
speed demand output and does not require trimming, A3 is used for customer feedback, and A4
is the optional stock equipment company tachometer driver.
c. For AC variable frequency drive applications, A2 is used internally by the microprocessor
for the motor speed demand output and does not require trimming, A3 is the customer analog
feedback, and A4 is the optional stock equipment company tachometer driver.
Any analog input or feedback signal used by the customer (including Stock Equipment Company
tachometers) must be matched or adjusted to the microprocessor controls. Two signal levels must be
adjusted for each channel used. The first signal level, OFFSET, corresponds to the lower value being
adjusted and is transmitted when the feed rate is at 0%. The second level, SPAN, corresponds to the
higher value being adjusted and is transmitted when the feed rate is a 100%. (The internal tachometer
and motor drive outputs do not require customer adjustment. Motor speed signals are processed by the
microprocessor controls in a closed–loop configuration. Motor speed is monitored by the tachometer
and processed by an algorithm which determines if changes in motor speed are required to match the
feed rate to the demand, and then automatically makes those changes.)
Note
If the feeder is not equipped with a remote analog demand input, the input alignment section
can be omitted. If an analog output signal is not present, the output alignment section can be
omitted.
3–11
When adjusting the signals to the microprocessor controls, memory locations are accessed which
correspond to the particular channel being adjusted. For reference, the trim channels and the channel
wire numbers are listed in the following tables:
Input Channel Wire Numbers

A1 Card 0% (offset) SIG+, SIG-, COM, S1
A1 Card 100% (span) SIG+, SIG-, COM, S1
Output Channel Wire Numbers

A3 Card 0% (offset) 139, 140, 141
A3 Card 100% (span) 139, 140, 141
3.4.1 I/O CHANNEL ADJUSTMENT
Note
The specific output channel trim instructions presented in this section refer to output Channel
A3 as an example. Adjustment for other output channels follows identical steps. These
adjustments can only be performed with the feeder OFF and the key lock off. Input and output
adjustment values can be verified in OFF with the key lock on.
3.4.1.1 Verify that the proper input card is plugged into the input module socket A1. Verify
that the proper voltage or current converter card is plugged into power supply board
sockets A2 and A3, the customer feedback output modules. All I/O channel
adjustments are made by entering the TRIM function. This accesses a circular list of
I/O channel descriptions which can be viewed on the display by pressing the up ° or
± down arrows. Previous adjustment values can be displayed and verified without
accidently making changes because each change is a two–step procedure. First you
must start the input measurement or output adjustment mode and then actually
ENTER or accept the new value.
3.4.1.2 Press TRIM to initiate TRIM function and view the I/O channel descriptions. The
display shows:
< TRIM > A1 Card: 0% Stored = XXXX Hz

Up/Down–Next/Prev SETUP–Measure
where XXXX is the frequency stored in memory from the previous time that the
measurement was made. Note that pressing EXIT will return to the normal display.
3–12
3.4.1.3 When aligning the input card A1, the minimum and maximum analog demand
signals are applied to the input signal wires of the microprocessor. The analog
demand is converted to a frequency by the A1 card, which is measured by the CPU
and then stored in memory.
Press SETUP to enter the measurement mode for the A1 card offset measurement
and the display changes to:

EXIT – Cancel ENTER – Store
where XXXX is the actual frequency being measured by the microprocessor.

Apply the minimum analog demand signal to the feeder. Use either a precision
source or, preferably, a minimum demand signal directly from the combustion
control system. The feeder display will show the demand signal as an equivalent
frequency that corresponds to minimum demand.
Important
If the display is zero, first check the polarity of the demand signal. If the polarity is correct, the
input card may be defective.
Press EXIT to leave the adjustment mode without saving the value, or press
ENTER to store the signal in memory. The display will then show:

Record this value for future reference and then press ° to change to the A1 Card
100% signal display:

Apply a maximum analog demand signal to the feeder. Press SETUP to enter the
measurement mode. Press ENTER to store the signal in memory. The display
will show:

where XXXX is the new 100% analog demand signal. Record this value.
Note
3–13
Pressing and releasing an arrow key will adjust the frequency in small increments. Pressing
and holding the key will cause more rapid adjustment.
3.4.1.4 Press the ° and the display changes to:
< TRIM > A3 Card: 0% Output = XXXX Hz

Up/Down–Next/Prev SETUP–Adjust Freq
where XXXX is the previously stored offset frequency. Connect an appropriate

meter to the customer output feedback signal. This analog signal is generated by a
precision frequency source. By setting the low and high end frequencies, the offset
and span analog signals are set, respectively. To set the offset of channel A3, press
SETUP and the display changes to:

Up/Down–Adjust Freq ENTER–Store
The display shows the actual frequency being sent to the analog conversion card.
While observing the meter connected to the output, press the up or down arrow keys
to adjust the output to represent the specific offset analog signal in use. (This may be
1 mA, 4 mA, or 0 volts, 1 volt, etc.)
When the analog output offset is correct, press: ENTER.
This will store the adjustment in the microprocessor control memory and return the
display to the A3 card 0% description with the new value displayed.
3.4.1.5 To set the span of channel A3, press the up arrow key until the display shows:

Up/Down–Next/Prev SETUP–Adjust Freq
3.4.1.6 Press SETUP to enter the adjustment mode and adjust the frequency with the arrow
keys until the proper A3 span adjustment is obtained at the analog output. To store
the adjustment in memory, press: ENTER.
3.5 FEEDER ADJUSTMENTS

To maintain maximum weighing accuracy, the following factors are essential: proper belt tension,
proper belt tracking, proper alignment of the weigh 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.
3.5.1 Belt Tension
3–14
Belt tensioning is accomplished by means of compression springs in the belt take–up

assemblies. When the spring is compressed by the take–up screw to the 3/16 inch dimension,
both grooves on the spring guides are inside the take–up housing. The belt is now fully
tensioned. When the red groove on the spring guide becomes fully visible, retensioning is
required. To maintain belt tracking, re–tension the belt by tightening the take–up screws a
maximum of four complete turns on one side and four complete turns on the other side until the
green groove on the spring guide is just inside the take–up housing.
Belt tension adjustments, when necessary, can be made most efficiently while the feeder
is operating.
Note
A new belt should be run 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.
3.5.2 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.
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 properly,
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.
3.5.2.1 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.
3.5.2.1.1 Open the feeder end doors. Turn on the work lights.
3–15
3.5.2.1.2 If the belt has just been replaced, verify that the take–up pulley is
square with the feeder body. See Figure 3–2, Squaring the Take-Up
Pulley.
Figure 3–2 Squaring the Take–Up Pulley
3.5.2.1.3 Adjust belt tension per Section 3.5.1, Belt Tension.
3.5.2.1.4 Make a chalk mark across the width of the belt surface to indicate a
complete revolution of the belt. Start and operate the feeder at
slow speed.
Observe the belt closely for at least five 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.
3.5.2.1.5 In the event that humping occurs at the pulleys, the belt is first tracked
on the drive pulley. Tighten the appropriate belt tensioning screw one
turn to steer the belt in the desired direction. Observe the effect of this
adjustment for at least five 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.
Note
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.
3–16
3.5.2.1.6 After tracking adjustments are complete, recheck the belt

tension adjustments.
3.5.2.2 Tracking Procedure – Feeder Online
Humping of the belt is not visible through the viewing ports when the feeder is in
normal operation. 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 tracking adjustment is necessary, observe the belt closely. Since the belt may be
traveling at 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.
3.5.3 Inlet Side Skirts and Belt Support Pan
Inlet side skirts should be mounted plumb, parallel to the belt, with no interference to the belt.
Clearance between the side skirts and top of the belt must increase in the direction of material
flow to prevent material from being trapped between the skirts and the belt. Clearance at the
inlet end should be 1/4” to 3/8” and increase to 3/8” to 1/2” at the discharge end.
The belt support pan has several mounting holes in its sides to allow for adaptation to feeders
with varying dimensions. Correct pan location is necessary to ensure smooth, uninterrupted belt
travel for maximum weighing accuracy.
3.5.4 Weigh Roller Adjustment
The alignment between the weigh roller and the two weigh span rollers should be within ”0.002
inches (”0.0051 cm) on each side for an accurate weight reading. Refer to Figure 3–3, Weigh
Roller Adjustment.
3–17
Figure 3–3 Weigh Roller Adjustment
3.5.4.1 Engage the calibration weight on both load cells.
3.5.4.2 Insert the checking bars (A2451–1) through the inlet end access door of the feeder,
adjacent to the sides of the belt, and with their machined surfaces resting on the
weigh span and weigh rollers.
3.5.4.3 Beginning on either side, insert a .005 inch (0.013 cm) shim between each of the
three rollers and the machined surface of the checking bar (three places).
3.5.4.4 Loosen the jam nut, then turn the adjustment block to lower the weigh roller.
3.5.4.5 Slowly turn the adjustment block to raise the weigh roller until the shim is touching
both checking bar and weigh roller (slip fit). Then tighten the jam nut.
3.5.4.6 Similarly adjust the weigh roller on the opposite side of the feeder.
3.5.4.7 Remove the checking bars and disengage the calibration weight.
3.5.4.8 The feeder must be recalibrated after weigh roller adjustment. Refer to the procedure
in Section 3.3, Feeder Calibration.
3.5.5 Cleanout Conveyor
3.5.5.1 Improper Operation
Under normal operating conditions, the bottom pan of the feeder should be visible
with only a small accumulation of material in front of the wing links. Improper
operation occurs when an excessive material buildup overloads the drive system.
Possible causes to be checked are: improper inlet skirt clearances, a worn or
malfunctioning belt scraper, and an improperly adjusted seal air flow.
3.5.5.2 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 door. Proper tension is indicated by a
two–inch sag in the chain from the drive sprocket to the first chain support pan. On
long–centered feeders, the two–inch sag should be observed between each support
pan. Retensioning the chain can be accomplished during feeder belt
replacement. Under normal operating conditions, this procedure would be required
about once every three to four years.
3.5.6 Feeder Discharge Pluggage Sensor (LSFD) and Material On Belt Level Switch (LSFB)
3.5.6.1 Control Adjustments
3–18
A single operating adjustment is used to control the level at which the relay operates.
Turning the adjustment clockwise raises the level at which the relay operates.
Turning the adjustment counterclockwise lowers the level at which the relay
operates. When the LED is on, the relay is energized.
The fail–safe may be changed in the field by moving the position of the jumper
located on the instrument circuit board. Fail–safe describes the level condition which
causes the output relay to de–energize. High–level fail–safe means that the relay is
de–energized either under high level conditions or upon loss of power. Low–level
fail–safe means that the relay is de–energized either under low level conditions or
upon loss of power.
3.5.6.2 Calibration for Feeder Discharge Pluggage Sensor (LSFD)
Caution
This procedure requires the use of an insulated tool. Do not attempt to turn any adjustment past
its mechanical stops or damage to the unit may occur.
Note
Energization of the LED indicates that the relay is either energized or is in normal (not alarm)
condition. Refer to Figure 3–4, Calibrating the Sensor and verify that the failsafe selector jumper
is set for HIGH level.
Figure 3–4 Calibrating the Sensor
3.5.6.2.1 Verify that no coal is in contact with the feeder discharge level sensor.
3–19
3.5.6.2.2 Using the insulated tool, turn the operating point adjustment to the full
counterclockwise position (the LED extinguishes).
3.5.6.2.3 Turn the adjustment slowly clockwise until the relay just operates (the
LED illuminates).
3.5.6.2.4 Turn the adjustment slowly clockwise an additional one turn. The
calibration is now complete.
Note
If false alarms occur, turn the adjustment clockwise an additional one to two turns.
3.5.6.3 Calibration for Material On Belt Level Sensor (LSFB)
Note
Energization of the LED indicates that the relay is either energized or is in normal (not alarm)
condition. Refer to Figure 3–4, Calibrating the Sensor and verify that the failsafe selector jumper
is set for LOW level.
3.5.6.3.1 Place 3 inches (76 mm) of coal on the feeder belt.
3.5.6.3.2 Verify that the material on belt level sensor is in contact with the coal.
3.5.6.3.3 Using the insulated tool, turn the operating point adjustment to the full
counterclockwise position (the LED extinguishes).
3.5.6.3.4 Turn the adjustment slowly clockwise until the relay just operates (the
LED illuminates).
3.5.6.3.5 Turn the adjustment slowly clockwise an additional one–half turn. The
calibration is now complete.
Note
If false alarms occur, turn the adjustment clockwise an additional one to two turns.
3–20
3.5.6.3.6 Remove the coal from the belt.
3.5.7 Belt Changing – Spliced Belt (ACCUFLEXR)
3.5.7.1 Close the valve above the feeder inlet and empty the belt.
3.5.7.2 When removing a spliced 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 side access doors.
3.5.7.3 Before performing any work inside the feeder, power to the feeder must be shut off at
the main disconnect switch.
Note
Review the complete installation procedure and belt installation notes before work is started.
3.5.7.4 Open all feeder body access doors.
3.5.7.5 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.
3.5.7.6 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.
3.5.7.7 Remove the flex cable from the belt. This task is made easier if a second man lifts
the belt up and down from the opposite side access door as the cable is being pulled
and rotated.
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.
3.5.7.8 Attach the new belt to the optional BELT PULL TOOL assembly by using the
supplied (0.187“) diameter rod. Refer to Figure 3–5, Accuflex Belt.
3–21
3.5.7.9 Feed a rope or strap through the feeder, and tie it to the BELT PULL TOOL
assembly. Refer to Figure 3–5, Accuflex Belt.
Note
Make sure that the rope or strap is installed either above the top of the span rollers, head pulley,
support pan and any support rollers, or under the take–up, head pullies.
3.5.7.10 Pull the belt through and then remove the solid rod and BELT PULL TOOL. The
splice portion of the belt should be located in the center of the side access doors.
Figure 3–5 Accuflex Belt
3.5.7.11 Align the leading edge of the splice and insert the ZIP TUBE into the splice portion
of the belt. Push the tube as far as possible and than tap on the driving plug until the
ZIP TUBE is fully inserted. Refer to Figure 3–5, Accuflex Belt. To facilitate the
insertion of the zip tube into the splice part of the belt, occasional lifting and aligning
of the two belt edges is required. Spray the spliced area with a penetrating oil to
assist the insertion of the ZIP TUBE.
3.5.7.12 Slide the furnished retaining washer over the free flex cable. Refer to Figure 3–6,
Installing Lead Wire. Crimp the washer tightly into place.
3–22
3.5.7.13 Insert the guide wire of the flex cable fully into the ZIP TUBE. Lock the guide wire
in place by tightening the screw on ZIP TUBE nut. While rotating the ZIP TUBE
and lifting the belt up and down, pull the ZIP TUBE and flex cable through the belt
until the crimped washer stops at the belt.
3.5.7.14 Cut off the excess flex cable, then install and crimp the second washer on the flex
cable. Refer to Figure 3–6, Installing Lead Wire.
Figure 3–6 Installing Lead Wire
3.5.7.15 With reference to Belt Installation Notes 1 through 3, properly adjust the belt.
3.5.7.16 With reference to Belt Installation Note 4, properly calibrate the feeder.
Belt Installation Notes
1. Center the belt before it is tensioned so that the bottom V–guide is seated
within the groove on all pulleys and rollers.
2. Perform belt tracking adjustments per Section 3.5.2.
3. Perform belt tensioning adjustments per Section 3.5.1.
4. Calibrate the feeder per the procedure in Section 3.3.
3.5.8 Drive Pulley Centering
3–23
When replacing the drive pulley, the centerline of pulley V–guides must be aligned to each
other within ±1/16 inch and to the center of machined surfaces on both sides of feeder within
±1/8 inch. Refer to Drawing D34519.
3.5.9 Seal Air
Adjust the seal air while the feeder and equipment below are in normal operation and after the
bunker has been filled. Install a temporary feeder manometer at the tap indicated on drawing in
Section 4.0, Certified Drawings and a manometer at the equipment below. Adjust the seal air
butterfly valve until a feeder pressure differential, as indicated on the feeder manometer, is 6
millimeters of water ABOVE the manometer reading on the equipment installed below.
Observe the feeder interior through the viewing ports in the discharge end access door. If 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 millimeters of water.
Remove the manometers and adjust the stop on the butterfly valve, if so equipped, so that when
the valve is closed, it can be reopened to the same position without recalibration.
3.6 TROUBLESHOOTING GUIDE
3.6.1 Diagnostic LED Indicators
The three red LED indicators on the keyboard panel are illuminated to signal that the feeder or
its controls requires attention. These indicators, and the appropriate response to each of them,
are listed below.
3.6.1.1 Alarm
This indicates that a problem exists which requires attention, but is not serious
enough to immediately stop feeder operation. To identify the problem, press:
ERROR RECALL.
The error code number and a diagnostic message will be displayed. Refer to
Section 3.6.3, Error Codes for an explanation of the error code and for suggested
corrective action. To reset the alarm and extinguish the indicator when the problem
has been corrected, press any of the white keys. If the feeder is in operation, press the
white key corresponding to its current operating mode once again to reset the alarm.
Note that some alarms will automatically reset once the problems causing the alarm
are cleared.
3.6.1.2 Trip
This indicates that a problem exists which is serious enough that feeder operation has
been stopped. This occurs, for example, when the feedback signal is lost; when a
motor starter fault, gross speed error or feeder discharge pluggage is detected; when
no belt motion is detected; or when material is present on the belt in the LOCAL
mode or during the calibration procedure. To identify the problem, press: ERROR
RECALL.
3–24
The error code number and a diagnostic message will be displayed. Refer to
Section 3.6.3, Error Codes for an explanation of the error code and for suggested
corrective action. To reset the trip and extinguish the indicator when the problem has
been corrected, press the OFF (white) key.
3.6.1.3 Volumetric
This indicates that a fault exists in the weighing system or its electronics which
prevents the feeder from operating in the gravimetric mode. The origin of the fault
may be from a temporary condition, such as an A/D overrange or A/D read error, or
may be from a permanent defect such as open wires to the load cells or bad A/D chip.
To troubleshoot a volumetric fault, first note that alarm error codes 01, 02 and 15
will force volumetric operation. Also note that there are two conditions which do not
cause an alarm error code to register. The first condition is if the output of the two
load cells are not tracking determined by a difference between the two load cell A/D
converter outputs being greater than 1/8 of the sum of the two outputs. The second
condition is if the output of the A/D converter is zero or negative. Use SELF TEST
09 to isolate these two conditions if no alarms are present when in the volumetric
mode.
Once the symptoms of the volumetric fault is isolated, troubleshoot the appropriate
area by checking for a defective load cell. The indicator will be extinguished when
the microprocessor determines that the feeder can again operate in the gravimetric
mode.
3.6.2 Error Recall
An alarm or trip is always associated with an error code number, diagnostic message and the
actual time and date, which can be examined by pressing the ERROR RECALL key. The
displayed response to this command is:
< ERROR CODE XX > YY Date: MM/DD/YY

Diagnostic Message... Time: HH:MM:SS
When the ERROR RECALL procedure is entered, data on eight previous errors can be
examined. The value of YY represents an index number of the eight previous errors from 00 to
07. The most recent error has a 00 index and will always be the first error displayed when
ERROR RECALL is pressed. The actual error code XX is a reference number which allows
the operator to find suggested corrective actions in Section 3.6.3, Error Codes.
The following is an example of error conditions that might have occurred.
Index Error Code Diagnostic Message Date Time

00 13 Level/Temp Sensor TRIP Date: 1/2/97 Time: 04:23:00
01 09 Remote TCI ALARM Date: 1/2/97 Time: 03:23:00
02 04 Motion Monitor TRIP Date: 1/2/97 Time: 23:04:00
03 01 A/D Overrange ALARM Date: 1/2/97 Time: 02:45:02
3–25
04 03 Tach Feedback TRIP Date: 1/2/97 Time: 17:33:44

05 00 Time: 00:00:00
06 00 Time: 00:00:00
07 00 Time: 00:00:00
When the ERROR RECALL key is pressed, the latest error code (13 in this example) follows
the index number 00 in the display, indicative of the most recent alarm or trip. To examine
which specific error occurred before this, press the up arrow key ° or the ERROR RECALL
key causing the display to show the index number 01 and error code 09. This means that error
code 09 occurred prior to error code 13. To review the history of feeder alarms and trips, press
the up arrow ° key. To move toward the most recent error, press the down ± arrow key.
In this example, only five errors occurred since the feeder was initially started, which explains
the double zero error code entries along side of indications 05, 06 and 07.
The actual date and time of each error is displayed.
3.6.3 Error Codes
The following chart provides a description of the error codes with suggested corrective action.
The actual descriptions found on the display are shown in bold, italicized text.
Error Description Alarm/ Possible

Number Trip Cause
01 A/D converter Alarm Defective load cell and/or load cell cable.
overrange Excessive weight on weigh span.
Incorrect load cell sense line voltages to pins 14 and 15 of the A/D
converter. This alarm automatically resets when the overrange condition is
cleared.
Defective A/D converter (analog front end components).
02 A/D read error Alarm The CPU detected a not READY signal from the A/D converter (pin 22 is a
logic high signal). This alarm will automatically reset when the CPU can
read the A/D converter again.
Possible loss of +10 V DC supply.
Defective A/D converter.
03 Loss of tachometer Trip The electronics sense no rotation of the belt drive motor.
feedback The motor will operate in the JOG mode only. It will not operate in LOCAL or
REMOTE.
Stalled or defective motor/defective tachometer.
Verify frequency and voltage on tachometer wires 145 and 146.
04 Belt motion monitor Trip The time between pulses from the belt motion monitor exceeds the value
timed out programmed into setup Address 17.
Check feeder for belt slippage due to low belt tension.
Verify that the time interval in seconds is large enough to permit feeder
operation at the minimum feed rate allowed. If it is not, alter Address 17 per
Section 2.2.2, Microprocessor Controls Setup. (If there is no belt motion
monitor supplied, set Address 17 to 0 to disable this trip.)
05 EEPROM write error Alarm The CPU could not write data to the EEPROM and then read the
same data.
Defective U15 chip or socket. (Note: Replacement requires that Section
2.2.2, Microprocessor Controls Setup be repeated completely.)
3–26
06 Battery low Alarm Alarm The checksum of the data read from the battery backed–up RAM is
incorrect indicating a problem with the data stored in BatRAM.
Defective U14 chip, power down sense circuits, or too low of a power
loss threshold.
07 Feeder discharge Trip The discharge pluggage sensor detected a pluggage for a time longer than
plugged the delay programmed into setup Address 16.
Feeder discharge valve closed or pluggage in feeder outlet hopper
or downspout.
Maladjusted feeder discharge level sensor.
08 Material on belt in Trip The material–on–belt level switch is detecting material for more than two
LOCAL or CALIBRATE seconds while operating in the LOCAL or CALIBRATE mode.
Close the inlet valve above the feeder and empty the belt prior to running in
the LOCAL or CALIBRATE mode.
Check for defective valve operator or valve position indicator if one
is supplied.
09 Remote TCI Alarm The total material integrator pulses cannot keep up with the delivery rate
increment too small and some pulses are being lost. Review settings of Address 07 and 35 per
Section 2.2.2, Microprocessor Controls Setup.
10 Feedrate Error Alarm The demand feed rate has not been met, usually because of an empty belt
or partial inlet blockage. The actual feed rate differs from the demand feed
rate by more than 5% for 2000 %–seconds. The belt should be visually
inspected to verify how much material is present and where the blockage
may be. This error will reset if the difference falls below the 5% threshold.
11 Motor starter fault Trip The belt drive motor starter does not energize or de–energize upon
command within two seconds. The motor starter or its auxiliary contacts
may be defective.
12 RPM deviation Trip The belt drive motor or motor speed control is producing a serious motor
speed deviation from the desired speed. The system will trip if the motor
speed discrepancy is greater than ±100 rpm for 10,000 rpm–seconds. This
may be caused by a stalled or runaway motor, an unstable speed control or
an incorrect address entry.
13 Level detector fault Trip The volume of material specified in set–up Address 18 has been delivered
and the level detector continues to indicate that a void remains in the
or valve/downspout
Feeder high or
temperature sensor An overtemperature condition has been sensed inside the feeder.
14 Event processor array Alarm Possible failure of frequency outputs to feedback cards or speed control
EPA watchdog loop. Contact Stock Equipment Company immediately.
15 A/D calibration error Alarm Inconsistent results during automatic electronic self–calibration of A/D
converter; defective A/D converter.
The reference voltage on pins 14 and 15 of the A/D converter is unstable.
Possible loss of +10 V DC supply.
3.6.4 Self Test Summary
The eighteen SELF TEST functions can be entered in OFF, REMOTE or LOCAL mode by
pressing the SELF TEST key from the normal display mode. The function will initially return
to whatever SELF TEST was last accessed. Once the SELF TEST mode is entered, one of two
methods can be used to access other SELF TESTS. Either the up° or down ± arrow keys can be
used to scroll to different tests, or a two–digit number from 01–18 can be entered. The EXIT
key must be pressed to get out of the SELF TEST mode.
3–27
1. SELF TEST 01 displays the system tare factor (determined during CAL 1) as well as
the difference between the last two calibrations. The tare value is the sum of the two
load cell signals, usually averaged over two complete belt revolutions (nine counts of
the probe tapes). The changes are calculated as [(new value – old value)/new] so that a
positive percentage indicates that the value has increased. To see the current value of
the tare and to compare the tare percent change from the previous feeder calibration,
press: SELF TEST 01.
< SELF TEST 01 > Current: XXXXXXX

Cal Factor–Tare Change: 0.10%
2. SELF TEST 02 displays the system speed factor (determined during CAL1) as well as
the difference between the last two calibrations. The speed factor is the relationship
between the motor speed (in rpm) and the belt speed, and is in units of inches per motor
revolution. The changes are calculated as [(new value – old value)/new] so that a
positive percentage indicates that the value has increased. To see the current value of
the speed factor and compare the speed factor percent change from the previous feeder
calibration, press: SELF TEST 02.

Cal Factor–Speed Change: 0.10%
3. SELF TEST 03 displays the system span factor (determined during CAL 2) as well as
the difference between the last two calibrations. The span factor is the relationship
between the digital signal received from the A/D converter and the actual weight on the
belt. It is in units of pounds per A/D count. The changes are calculated as [(new value –
old value)/new] so that a positive percentage indicates that the value has increased. To
see the current value of the span factor and compare the span percent change from the
previous feeder calibration, press: SELF TEST 03.

Cal Factor–Span Change: 0.10%
4. To test all indicator lamps and displays, press: SELF TEST 04.
All displays and 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 be
energized for five seconds.
5. The restart counter monitors the power supply to the controls by incrementing one
count for each time power is reapplied. To check the number in the counter, press:
SELF TEST 05.
< SELF TEST 05 > Date: MM/DD/YY

Restart Count 1 Time: HH:MM:SS
3–28
The display shows both the restart counts and the date and time that the last restart
happened. To reset the total in the counter to zero, press: CLEAR while in SELF TEST
05. Resetting the counter does not affect the date and time. To determine when the last
restart occurred, compare the date and time clock in SELF TEST 11 to the restart date
and time in SELF TEST 05.
6. If run mode 0, 1 or 2 is programmed as the setup parameter in Address 03, the input
demand signal will be displayed in the feed rate units of the main display as follows:
< SELF TEST 06 > Demand: 12345.3 lbs/hr

Feedrate Actual: 12345.3 lbs/hr
If run mode 3, 4 or 5 is programmed in Address 03, the motor running speed will be
displayed in rpm as follows:
< SELF TEST 06 > Demand: 1234 rpm

Motor Speed Actual: 1234 rpm
If SELF TEST 06 is accessed in the LOCAL mode, the motor running speed is always
displayed as follows, regardless of the run mode programmed into setup Address 03:
< SELF TEST 06 > Set Pt: 1234 rpm

Motor Speed Actual: 1234 rpm
7. SELF TEST 07 is the Communications Test. Commands that are received over the
serial port are displayed on the top line of the display. The MPC’s response to these
commands are displayed on the bottom line. Both lines are displayed in hexadecimal
and any line that exceeds the width of the display is truncated.
To review the communication commands received and the MPC response,

< SELF TEST 07 >

Communications Test
8. To identify the program chip currently installed in the microprocessor board,

< SELF TEST 08 > Chip No. D32400–140

Copyright (c) 1998 Stock Equipment Co.
9. To view the raw A/D reading from the load cells, press: SELF TEST 09.
< SELF TEST 09 > J1: 3456

Raw Load Cell SIgnals J2: 3457
3–29
The number shown for each load cell will range from 0 to 16777. The approximate
scaling is 240 counts per millivolt input. If the millivolt input signal is negative, the
number displayed will be a zero.
10. This SELF TEST is unused at this time.
11. To view the time of the real time clock (RTC), press SELF TEST 11 and the display
changes to:
< SELF TEST 11 > Date: MM/DD/YY

Clock (F1 To Set) HH:MM:SS
The clock is set by pressing F1 key. The message ”Setting Clock” will be displayed and
the cursor will move to the month part of the date. Each value (month, day, year etc.) is
accepted as a two digit number. The RTC chip is set immediately after the second digit
is entered and the cursor moves to the next value. The arrow keys can be used to go
forward or backward without changing the current value and the ENTER, EXIT or
OFF keys can be used to exit the clock–set mode when the time is correct. Please note
that the feeder will be stopped when the OFF key is used.
During extended storage the clock oscillator on the RTC chip can be stopped to
conserve battery power. The clock is stopped by pressing the TOTAL RESET key
while in the clock–set mode. The time and date will be displayed as usual, except that
when the oscillator has been stopped, the time will not be updated. The oscillator is
restarted by pressing the JOG key while in the clock–set mode. There is a three second
delay between the time that the JOG key is pressed and the time that the clock begins to
operate. The feeder totals are stored in the battery backed up RAM portion of the RTC
chip and are not affected by the state of the oscillator.
12. To display the average material density calculated internally by the microprocessor,
press SELF TEST 12 and the display shows:
< SELF TEST 12 > Avg: 45 Lbs/CuFt

Density Initial: 42 Lbs/CuFt
This displays the average material density over the last 3 hours, as well as the initial
density estimate from setup Address 02. The average density value is used to calculate
the correct motor speed when the feeder is in volumetric mode.
13. To run simulated material tests from the OFF mode, press SELF TEST 13 and the
display changes to:
< SELF TEST 13 >

Material Simulation LOCAL–Start
3–30
This SELF TEST is used to run simulated material tests. It can be used to test the feeder
tare value (by running with an empty belt) or to test for changes in the weighing system
(by running with a simulated load). The duration of the test is set by the number of belt
revolutions entered into setup Address 22. If the LOCAL pushbutton is now pressed,
or SELF TEST 13 is accessed while in local mode, the display changes to:
< SELF TEST 13 > Total: XXXX Lbs

HH:MM:SS Travel: YYYY in
While initiating SELF TEST 13 from the OFF mode, the feeder will run for 20 seconds
to stabilize the motor speed, then the simulated material totalizer and the travel counter
will begin to operate and the feeder will run for the designated number of belt
revolutions. The estimated time remaining is based on factors calculated during the last
calibration procedure and will count down to zero during the simulated test.
Note
The feeder is actually running in LOCAL while the test is taking place and will continue to run in
local if SELF TEST 13 is exited before the test has finished. SELF TEST 13 does not run in
REMOTE and will not affect remote mode operation. Note that the mode keys are active, and
pressing the OFF key while in SELF TEST 13 will end remote operation.
At the end of the test the display will show the totalized weight, total travel and
percentage of error.
< SELF TEST 13 > Total: 2595 Lbs

Error: 3.9% Travel: 1353 In
The percentage of error is calculated as follows:
Measured weight-Actual weight Address 36

100× Actual weight Address 36
14. To display the length of the belt, press SELF TEST 14 and the display shows:
< SELF TEST 14 > Current: 1570 in

Belt Length Change: 0.07%
SELF TEST 14 displays a calculated belt length (determined during the last CAL 1) as
well as the difference in calculated belt lengths from the previous two calculations. The
change is calculated as [(new – old)/new] so that a positive percentage indicates that
the value has increased.
15. The tare factor in SELF TEST 01 is calculated from the sum of the two load cells.
SELF TEST 15 shows the tare factor for the individual load cells.
3–31
< SELF TEST 15 > J1: XXXXXX

Cal Factor–Tare J2: XXXXXX
These values are shown for reference only. The actual weight of the material on the belt
is calculated using the value in SELF TEST 01. They are updated every time that a
CAL 1 is performed, regardless of whether or not the calibration is saved.
16. The frequency output used to control the motor speed, and the frequency input used to
read the motor speed, are displayed by SELF TEST 16.
< SELF TEST 16 > MSC Demand: XX.X Hz

Motor Frequencies Tach: XX.X Hz
If Setup 08 (Demand Mode) is set to 0 (Eddy Current Clutch/DC Drive/ Variable

Frequency Drive) the motor speed control uses the A4 channel. If Setup 08 is set to 1
(DC Drive/Variable Frequency Drive) the A2 channel is used. The MSC Demand
signal is controlled by a closed loop system. The tach signal is converted to rpm using
Setup 09 (Tachometer Type).
17. The demand signal received from the customer control system (A1 channel) along with
the primary feedback signal (A3 channel) returned to the customer control system, is
displayed by SELF TEST 17.
< SELF TEST 17 > Demand: XX.X Hz

I/O Frequencies Feedback: XX.X Hz
When Setup 03 is set to 0, 1 or 2 (Feed rate Demand, Raise/Lower or Set Point) these
signals are converted to feed rate values using trim data (to generate percent of full
scale) and Setup 05 (to generate feed rate). When Setup 03 is set to 3, 4 or 5 (RPM
Demand, Raise/Lower or Set Point) Setup 29 is used in place of Setup 05, and the result
is in rpm.
18. The signal to the external feedrate indicator and the unused frequency output channel
(A2 or A4) are displayed by SELF TEST 18.
< SELF TEST 18 > A2: XX.X Hz

Aux Output Frequencies FRI: XX.X Hz
If Setup 08 (Demand Mode) is set to 0 (Eddy Current Clutch/DC Drive/ Variable

Frequency Drive) the A2 channel is displayed. If Setup 08 is set to 1 (DC
Drive/Variable Frequency Drive) the A4 channel is displayed. the feed rate (or rpm) is
calculated using the method described in SELF TEST 17. The FRI frequency is
calculated using Setup 27.
3.6.5 Electronics P.C. Boards
3.6.5.1 196NT CPU and Power Supply Boards (Ref. Figure 3–7 and Dwg. D21232)
3.6.5.1.1 Incoming Power Verification
3–32
Measure the voltage between wires 102 and 103 inside the control
cabinet. The allowable range of the incoming power supply is 100–130
V AC, 50/60 hertz.
There is one 3–amp fuse (F1) on the power supply board. To check the
fuse, remove it from the board for test with an ohmmeter.
Figure 3–7 Power Supply Board Indicator Lights and Test Points
3.6.5.1.2 DC Voltage Measurements
Unregulated Voltage: Measure the unregulated voltage at test point

TP10 with reference to digital ground, TP13. Since this voltage is
unregulated, it will vary from board to board but must be high enough
to allow the +5 volt supply (U1) to operate correctly. The best check for
test point TP10 is to verify that the +5 volt supply at test point TP7 is
within its allowable range. For reference, the voltage at test point TP10
will usually be in the range of +10.0 to +14.0 V DC.
Regulator U1: Measure the +5 volt supply at test point TP7 with
reference to digital ground, TP13. The voltage should be +5.1 to
+5.3 V DC.
reference to analog ground, TP9. The voltage should be +10.0 to
+10.25 V DC.
3–33
Regulator U3: Measure the –10 volt supply at test point TP8 with
reference to analog ground, TP9. The voltage should be –10.0 to
–10.25 V DC.
reference to opto ground, TP6. The voltage should be +14.25 to
+15.75 V DC.
Regulator U5: Measure the –15 volt supply at test point TP4 with
reference to opto ground, TP6. The voltage should be –14.25 to
–15.75 V DC.
3.6.5.1.3 Signal Converter Cards
Input Signal Converter (A1): This card accepts the various customer
demand signals and converts them into a frequency for use by the
microprocessor. Test point TP3 is used to measure the frequency output,
using a frequency counter or oscilloscope, with reference to digital
ground, TP13. While trimming this card according to the procedure in
Section 3.4.1, I/O Channel Adjustment, a frequency will be
displayed on the keyboard. This frequency should be the same as that
measured at test point TP3.
Feedback Card (A2): This card converts the feedback frequency

generated by the microprocessor into analog signals for customer use.
Test point TP2 is used to measure the frequency input to this card from
the microprocessor, with reference to digital ground, TP13. While
trimming this card according to the procedure in Section 3.4.1, I/O
Channel Adjustment, a frequency will be displayed on the keyboard.
This frequency should be the same as that measured at test point TP2.
Feedback Card (A3): This card converts the feedback frequency

generated by the microprocessor into analog signals for customer use.
Test point TP1 is used to measure the frequency input to this card from
the microprocessor, with reference to digital ground, TP13. While
trimming this card according to the procedure in Section 3.4.1, I/O
Channel Adjustment, a frequency will be displayed on the keyboard.
This frequency should be the same as that measured at test point TP1.
3.6.5.1.4 Input Contact and LED Verification
The LED corresponding to each input contact may be energized by

closing the circuit between its wire and wire 107 (–15 volts). If a given
circuit is open, the LED should not be energized.
3–34
Input Contact LED Opto–Isolator Wire Number

FS DS9 U15 112
MSF DS10 U16 110
LSFB DS11 U17 108
LSFD DS12 U18 109
*Reverse or (Memory Hold Reset) DS13 U19 111
Raise DS14 U20 113
Lower DS15 U21 114
Belt Motion DS16 U22 115
Nuclear Monitor DS17 U23 116
Keyboard Lockout DS18 U24 117
Remote DS19 U25 118
Local DS20 U26 119
Depends upon the program chip
3.6.5.1.5 Tachometer Verification
Measure test point TP12 with reference to digital ground, TP13. This
test point is the frequency from the feedback device, which may be
either a tachometer generator or a reluctance pick–up. The frequency
measured at test point TP12 should be the same as the frequency
measured at wires 145 and 146.
3.6.5.1.6 Test Point Summary
Test Point Function Voltage Specifications

TP4 - TP6 - 15 V DC -14.25 V DC to -15.75 V DC
TP5 - TP6 +15 V DC +14.25 V DC to +15.75 V DC
TP8 - TP9 -10 V DC -10.0 V DC to -10.25 V DC
TP10 - TP13 unregulated +10.0 V DC to +14.0 V DC
3.6.5.2 Input Signal Converter (A1)
Perform the TRIM input adjustment at 100% of input per Section 3.4.1, I/O
Adjustment. If the frequency displayed differs from 9600 ”200 hertz, return the A1
card to Stock Equipment Company for repair.
3.6.5.3 Frequency to Current Converter (A2) (A3)
If the A2 and A3 cards are both 4–20 mA, and A2 card is used to drive the VFD or
DC motor speed control, determine if A2 is functioning properly as follows:
1. Insert the A2 card in the A3 card slot on the power supply board.
3–35
2. Insert the A3 card in the A2 card slot on the power supply board.
3. Perform TRIM output adjustment per Section 3.4.1, I/O Adjustment. The
current output should equal 4–20 mA ±0.4 mA when the frequency
displayed equals 1000 Hz. If 4–20 mA ±0.4 mA is unachievable, return the
A3 card to Stock Equipment Company for repair.
3–36
3.7 SITE SPECIFIC DATA
3.7.1 Motor Speed Control Adjustments
The motor speed control is an AC Tech Model MC1000 Variable Frequency Drive (VFD) control.
This microprocessor–controlled device requires adjustment and programming prior to startup.

Typically, the programming of the speed control is performed at the factory and only verification is
required before feeder startup. New programming is required only if the speed control is replaced. All
entries in the programming are stored in a nonvolatile RAM and retained when the speed control power
is off.
Note
Before making any programming changes, refer to the variable frequency drive manual in
Section 7.0, Vendor Information.
Programming Parameters
Item Parameter Name Value Limit or Menu Choice Default Initial

Number Setting STOCK Setting
0 LINE VOLTS HIGH, LOW, AUTO AUTO
1 SPEED #1 MIN FRQ - MAX FRQ 20.00 Hz
5 SKIP #1 .00 Hz - MAX FRQ .00 Hz
6 SKIP #2 .00 Hz - MAX FRQ .00 Hz
7 BAND WID .00 - 10.00 Hz 1.00 Hz
8 ACCEL 0.1 - 3600 SEC (NOTE 1) 30.0 SEC
9 DECEL (NOTE 2) 30.0 SEC
10 MIN FRQ .00 - 120.0 Hz .50 Hz
(NOTE: MAX LIMIT IS 400 Hz ON UNITS
WITH HIGH FREQ SOFTWARE)
11 MAX FRQ MAXREQ - 120.0 Hz 60.00 Hz
(NOTE: MAX LIMIT IS 400 Hz ON UNITS
12 DC BRAKE (NOTE 2) .0 VDC
13 DC TIME .0 - 999.9 SEC. .0 SEC
14 DYN BRAKE OFF, ON OFF
16 CURRENT 25 - 180% 180%
(NOTE: IF LINE VOLTS IS SET TO “LOW”
(OR SET TO “AUTO” AND THE INPUT VOLTAGE
IS LOW), THE RANGE IS 25 - 150%)
17 MOTOR OL 25 - 100% 100%
3–37
18 BASE 20.00 - 360.0 Hz 60.00 Hz

(NOTE: MAX LIMIT IS 650 HZ ON UNITS
19 FX BOOST .0 - 30.0% (NOTE 2)
20 AC BOOST .0 - 20.0% .0%
21 SLIP CMP .0 - 5.0% .0%
22 TORQUE CONSTANT, VARIABLE, CT/NO CMP CONSTANT
23 CARRIER 2.5, 6, 8, 10, 12, 14 kHz 2.5 kHz
25 START NORMAL, POWER-UP, AUTO RE-, RE-BRAKE NORMAL
26 STOP RAMP, COAST COAST
27 ROTATION FORWARD, REVERSE, FWD&REV, FWD@LOC FORWARD
28 AUTO/MAN AUTO, MANUAL, BOTH BOTH
29 MANUAL KEYPAD, 0 - 10 VDC KEYPAD
30 CONTROL LOCAL, REMOTE, BOTH LOCAL
31 HZ UNITS HERTZ, RPM, %HZ, /SEC, /MIN., /HR., NONE HERTZ
32 HZ MULT .10 - 650.0 1.00
33 SPEED DP XXXXX, XXX.X, XX.XX, X.XXX, .XXXX XXXXX
34 LOAD MLT 90 - 139% 100%
35 CONTRAST LOW, MED, HIGH HIGH
39 TB5 MIN .00 - 360.0 Hz .00 Hz
(NOTE: MIN LIMIT IS 650 HZ ON UNITS
40 TB5 MAX .00 - 360.0 Hz 60.00 Hz
42 TB10A OUT NONE, 0-10 V, 2-10 V NONE
43 @TB10A 3.00 - 360.0 Hz 60.00 Hz
44 TB10B OUT NONE, 0-10 V, 2-10 V NONE
45 TB10B 10 - 200% 125%
47 TB13A NONE, 0-10 V DC, 4-20 mA, SPEED #1, NONE
LOC SEL, DEC FREQ
48 TB13B NONE, 0-10 V DC, 4-20 mA, SPEED #2, NONE
INC FREQ, JOG FWD, JOG REV
49 TB13C NONE, 0-10 V DC, 4-20 mA, SPEED #3, NONE
LOC SET, RUN REV, STRT REV
50 TB13D EXT FAULT, EXT/FAULT, EXT CLEAR EXT FAULT
52 TB14 OUT NONE, RUN, FAULT, /FAULT, LOCK, @ SPEED, NONE
ABOVE #3, I LIMIT, AUT/MAN
53 TB15 OUT NONE, RUN, FAULT, /FAULT, LOCK, @ SPEED, NONE
54 RELAY NONE, RUN, FAULT, /FAULT, LOCK, @ SPEED, NONE
57 SERIAL DISABLE, ENABLE DISABLE
58 ADDRESS 1 - 247 30
61 PASSWORD 0000 - 9999 0019
63 SOFTWARE VIEW - ONLY N/A
64 MONITOR OFF, ON ON
65 PROGRAM MAINTAIN, RESET 60, RESET 50 RESET 60
(NOTE: “RST HIGH” OPTION WILL APPEAR
3–38
ON UNITS WITH HIGH FREQ SOFTWARE.)

66 HISTORY MAINTAIN, CLEAR MAINTAIN
69 LANGUAGE NOTE 2 ENGLISH
70 FAULT HISTORY VIEW - ONLY N/A
NOTE 1 = Range for 25, 30, and 40 HP Units is 0.3 - 3600 Sec.
NOTE 2 = Refer to Section 7.0, Vendor Information for a description of parameters.
- = Default Settings.
This completes the variable frequency control adjustment procedure as it relates to the gravimetric
feeder. All other parameters and functions remain the same.
3–37

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Shenyang Stock Electric Power Equipment Co.,Ltd.

No.6,Zhaogong North Street,Shenyang,China

Shenyang Stock Electric Power Equipment Co.,Ltd. No.6,Zhaogong North Street,Shenyang,China

Section 1.0 Installation

1.1 RECEIVING INSPECTION 1–1

1.2 STORAGE PROCEDURES 1–1

1.3 STORAGE MAINTENANCE PROCEDURES 1–2

1.4 EXTENDED STORAGE PROCEDURES 1–3

1.5 INSTALLATION PROCEDURES 1–3

1.1 RECEIVING INSPECTION

1.2 STORAGE PROCEDURES

1.3 STORAGE MAINTENANCE PROCEDURES

1.4 EXTENDED STORAGE PROCEDURES

1.5 INSTALLATION PROCEDURES

1.5.6 Tighten the four mounting bolts in place.

1.5.9 Install the feeder discharge pluggage sensor.

2.1 SYSTEM COMPONENT DESCRIPTION 2–1

2.1.1 Feeder Body 2–1

2.2 STARTUP 2–15

2.2.1 Preliminary Startup Measures 2–15

2.3 TYPICAL OPERATING PROCEDURES 2–43

2.4 SITE SPECIFIC DATA 2–46

2.4.1 Feeder Operation Specifications 2–46

2.1 SYSTEM COMPONENT DESCRIPTION

2.1.1 Feeder Body

2.1.2 Belt and Drive System

2.1.3 Cleanout Conveyor

1. Material falling from the belt scraper.

2. Dust settling out of the air.

3. Material falling from the self–cleaning take–up pulley.

2.1.4 Feeder Electrical Controls

2.1.4.1 Microprocessor/Power Control Cabinet

2.1.5 Feeder Microprocessor Controls

2.1.5.1 Power Supply (Ref. Dwg. D21232 series)

Transformer Power Supply

15 V DC for Relays O.C. GND

Figure 2–1 Power Supply

2.1.5.1.1 Input/Output Circuit Description

A typical isolated input operates as follows. Incoming signals are used to

2.1.5.1.2 Input Signal Converter Card (A1)

2.1.5.1.3 Frequency to Current Converter Card (A2) (A3)

The frequency to current converter card is used as a feedback module for

2.1.5.2 196NT CPU Board (Ref. Dwg. D31771 series)

The microprocessor control configuration is shown in Figure 2–2. A transparent portion

Power Power Supply

Figure 2–2 Microprocessor Control Configuration

2.1.5.2.1 Microprocessor Memory

Programming of the microprocessor is done in the C programming

The microprocessor accesses a type of permanent read–only memory

All operations involving the microprocessor utilize the transfer of

2.1.5.2.2 Power Interrupt Protection Circuit

During operation, a temporary power interrupt may occur. This type of

2.1.5.3 Alphanumeric Display/Keyboard

CALIBRATION MODE PROGRAMMING

Stock Equipment Company

Figure 2–3 Keyboard and Front Panel of the Microprocessor Cabinet

Reversing Belt Feature (Optional)

Display Selection Keys

Gravimetric is defined as material delivered with a functioning weighing system.