TURBO Continuous Feed Mobile Fiber Dispenser System

Transcription

1 Installation, Operation, and Maintenance Instructions version1.2 17JUL12 Page 1

2 The TURBO C Mobile Fiber Dispenser is a self-contained, continuous feed, loss-in-weight fiber dispensing system. It is primarily designed for use with mobile asphalt production plants. The entire system is housed within an easily transportable trailer. The TURBO C Mobile has one operational mode: Local Mode. As a Local Mode only machine, the TURBO C Mobile operates as a stand-alone system with no control connections with the asphalt plant. This requires that an operator start and stop the machine in coordination with the asphalt plant. The operator must enter the desired fiber feed rate in lb/min (i.e. 5 lb/min). The operator then presses the Start (F1) button on the TURBO C control panel display to start feeding fiber. The TURBO C system will then control the fiber feed rate independently. When the run is complete the operator presses the Stop (F2) button to stop the flow of fiber. Please refer to the OPERATION section. The TURBO C Mobile C is equipped to alert the operator if it is low in fiber or if there is a system Process Fault. If a Process Fault occurs, the machine will not run. The operator is alerted to a Low Fiber condition or a Process Fault The TURBO C Mobile C is equipped with a Data Logging System. The Data Logging System records key fiber dispensing parameters that can be used for documentation and reports. The TURBO C Mobile C comes fully equipped with almost everything that is required to setup and operate the system. These items include: Self-contained, stand-alone control system Integrated delivery blower, negating the need for a compressed air supply Various lengths of delivery system tubing An assortment of tubing bends and couplers Dispenser, custom-designed with shorter legs, to allow filling dispenser from within the trailer Extra space within the trailer to store boxes of fiber (1 pallet or more) The only things that must be supplied by the customer include the following: Electrical Power Supply Clear and level space to park the trailer version1.2 17JUL12 Page 2

3 INSTALLATION Location of the Trailer AREA TO LOCATE THE FIBER TRAILER A clear and level space is required to locate (park) the trailer. The dimensions of this space are 20 x 12, with a minimum overhead clearance of 12. The space must be as close as possible to point on the drum plant where the fiber is dispensed. The trailer should be oriented in a manner to minimize the overall length and the number of bends in the delivery system tubing FIBER ACCESS POINT A provision must be made on the drum plant to allow the fiber to be discharged. This provision must consist of a round opening that will allow the 4 O.D. fiber delivery tubing to pass through the bulkhead to the desired point of discharge. Setup of Trailer Once the trailer position is established, the trailer support jacks must be deployed. These jacks are scissor type and must be screwed down so that the weight of the trailer is supported by the jacks, not by the trailer s tires and suspension (Fig 1). When the jacks are properly deployed, the trailer should be level and feel firmly supported. Fig1 version1.2 17JUL12 Page 3

4 Setup of Dispenser The fiber dispenser Drum Base comes secured with Transport Straps. This keeps the Drum Base from bouncing on the Load Cell Adjusters during Transport. This prevents damage to the load cells during transport. To setup the dispenser for operation, the Transport Straps must be removed. The load cells will, then, need to be adjusted to balance the load evenly between them and to ensure there is an Air Gap (Fig 2) between the Drum Base Discharge Tube and the Funnel. The load cells are adjusted using the threaded adjusters as shown in Fig 3. Final adjustment of load cells should be done when the scale is calibrated. A professional scale technician should perform the calibration (please refer to the CALIBRATION section). Fig 2 Fig 3 version1.2 17JUL12 Page 4

5 Electrical Connections A dedicated 40 Amp 240 VAC (60Hz) circuit with center-tapped neutral is required for the fiber dispenser. This circuit MUST be on a dedicated 40A circuit breaker. An electrical disconnect box is installed on the front of the trailer (Fig 4). The electrical supply must be connected in that disconnect box only. No connections should be made in the any of the trailer s interior electrical enclosures. All electrical connections should be made by a licensed electrician. Fig 4 Electrical Requirements: 240 VAC 60 Hz Single-Phase 40 Amps 4-Wire Connection (L1, L2, N, PE (Ground)) version1.2 17JUL12 Page 5

6 Delivery System The delivery system consists of 4 OD Busada Anti-Static clear tubing and an integral material handling blower (Fig 5). The tubing, manufactured by Busada Manufacturing Corporation, is specially designed for pneumatic material delivery systems. The trailer comes equipped with straight lengths and tubing sweeps sufficient to assemble a delivery system. Some means of support, such as wooden braces, should be made to bear the weight of the tubing. If there is insufficient tubing to reach the asphalt plant, the trailer should be moved closer. An example of how the Busada tubing is coupled together is shown in Fig 6. The trailer is also equipped with tubing couplers and a length of aluminum tubing. The aluminum tubing should be used for the final piece of the delivery system. Aluminum is used because the heat of an asphalt plant mixing drum would melt the Busada tubing. For that reason, the last length of tubing of the delivery system must be aluminum. Fig 5 version1.2 17JUL12 Page 6

7 Fig 6 version1.2 17JUL12 Page 7

8 Stacklight Pole The trailer is equipped with a stack lights on the end of an extendable pole (Fig 7). These lights are used to indicate that the trailer needs attention from the operator. There is also a two tone siren that works while the lights. The pole should be raised when the machine is setup on a new location. To raise the pole, loosen the black hold down knob. Raise the pole to its extended position, then tighten knob. The pole must be returned to is lowered position before transport. The red light indicates a Process Fault condition. This means that the dispenser is not running. The specific fault condition that halted the machine is displayed on the Control Panel Touchscreen Display (refer to OPERTION section). The amber light means that the machine needs to be refilled with fiber (refer to OPERTION section). Fig 7 version1.2 17JUL12 Page 8

9 CONTROLLER SETUP AND CALIBRATION Setup Menu The Setup Menu is accessed by pressing the Setup Menu button on the Home screen of the Control Panel touch screen display. It contains access to various set up and testing functions of the dispenser s control system. These include: Scale Weights Scale Calibration Analog Output Testing Digital I/O Testing Air System Delays Scale Zeroing Fiber Flow Monitoring System Auto-Fill System Enable Set Up Scale Weights The Scale Weights Set up Screen can be accessed from the Set up Menu. These are weight values that perform certain defined functions within the Fiber Dispenser program. These are set at the factory for this particular fiber scale and changed only after thoroughly understanding their function. Scale Full Weight This is the Full Scale value of the fiber scale. It is factory set at its current value of 400 Lbs. DO NOT CHANGE THIS VALUE. Any change in this value will affect the accuracy of the fiber scale. Scale Over-Filled Weight This is the over-filled value of the scale. The dispenser will not run at a fill value above this. It is factory set at its current value of 420 Lbs. DO NOT CHANGE THIS VALUE. Any change in this value will result in permanent damage to the fiber scale. Scale Low Warning Weight This is the weight at which the Low Drum Weight banner is displayed on the Control Panel Display. This can be set to any value that suits customer s needs. Scale Under-Filled Weight -This is the minimum weight below which the fiber dispenser will not feed properly. This is typically set at 20-30% of Full Scale ( lb.) The dispenser will not run at a weight below this value. This can be set to any value that suits customer s needs Analog Output Testing The Analog Output Test Menu is used as a diagnostic tool for service technicians only. It is used to forcing the Analog outputs to their minimum (0%) and maximum (100%) values. This function should not be used by the operator. Digital I/O Testing This screen allows the operator to individually toggle the memory bits associated with each Input and Output. For example, an operator can press the Output button for Air System to turn on the Blower. This is helpful to clear the Delivery System tubing of any fiber. These test buttons can only be pressed one at a time. version1.2 17JUL12 Page 9

10 Zero the Scale The dispenser is delivered and should be transported without any fiber in the drum. The dispenser scale must be zeroed before loading fiber. The dispenser has a net fiber capacity of 400 Lb. (181 Kg). Before zeroing the scale, make sure there is no fiber in the dispenser and that there are no foreign object on the dispenser. To perform zeroing, press the Setup Menu button on the Touchscreen Display. This will bring up the Setup Menu Screen. Press the Zero Scale button on the lower righthand side of the screen. This will zero out any drift that might have occurred during transport, setup, or temperature variations. The Zero Scale button will not work if the scale reads greater than 2% of full scale (Scale Full value). Therefore, with a scale that has a full scale of 400 lb., the machine will not zero if there is a scale reading of more than 8 lb. This is done to prevent the operator from inadvertently zeroing the scale while it has fiber in it. If during setup an empty dispenser reads greater than 8 lb. and preventing zeroing, please contact VM Fiber Feeders for instructions. Auto-Fill System Enable This button must remain disabled (OFF) on the TURBO C Mobile (Forta-Fi) units. The Auto-Fill System Enable is a feature for TURBO C Fiber Dispenser systems equipped with the optional Secondary Fill Device (Auto-Fill System). The TURBO C Mobile units are not equipped with Auto-Fill Systems. Air System Delays There are 2 Air System Time Delays, the On-Delay and the Off-Delay. The On-Delay is the time in seconds between when the Blower is started and when the Drum and Rake start. This time delay allows the Delivery System to develop sufficient airflow before the fiber starts feeding. It also allows the fiber scale to stabilize due to suction from the blower before it starts sending pulses. This is factory set at 5 seconds. Setting the On-Delay to a value less than 5 seconds can affect the accuracy of the fiber pulses. The Off-Delay is the amount of time in seconds that the Blower remains on after the Drum and Rake stop. The Off-Delay allows the delivery System to be purged of all fiber dispensed during a batch run. It is factory set at 7 seconds. Fiber Flow Monitoring System The Fiber Flow Monitoring System uses an optical sensor mounted in the Blower Inlet Funnel. The sensor detects if a fiber clog is occurring. There are two timers in the Fiber Flow Monitoring System, one that temporarily stops the fiber Drum (Temp Drum Stop Timer) and another that initiates a Process Fault (Fault Tolerance Timer). If the sensor detects a clog for the amount of time of the Temp Drum Stop Timer, the drum will be temporarily halted allowing the delivery System to run without feeding fiber until the clog clears. If the clog remains for the amount of time of the Fault Tolerance Timer, a Process Fault is initiated halting the feeding program and shutting off all motors. The Temp Drum Stop Timer is set at the factory to 0.50 seconds. The Fault Tolerance Timer is set at the factory to 2 seconds. To disable the Fiber Flow Monitoring System, press the Enable button. When disabled, the button will be red-colored and read OFF. The system automatically enables the Fiber Flow Monitoring System on power up of the Control Panel. version1.2 17JUL12 Page 10

11 Calibration of Scale The weight load cell outputs are summed together with a summing junction inside a J box attached to the dispenser frame. The scale is calibrated at the factory. The fiber scale should be re-calibrated on-site by a professional scales technician. The load cell swivel mounts should be adjusted so that each has equal load. Please refer to the scale calibration procedure below. If you have any questions, please call VM Fiber Feeders, Inc. Calibration Procedure 1. Ensure that the Load Cell swivel mounts are adjusted for equal load. 2. Press the Set Up Menu button on the Control Panel touch screen. 3. Tap the box under text Calibration Setup Screen 4. Enter the password , and then press the return button. This leads to the Calibration Setup Screen. 5. Press the Clear Calibration button; press the Yes button to clear old calibration values. 6. Tap the box for Step 1. This will allow you to enter the amount of the test reference weights you plan to use. The closer the Test Weight is to the scale s Full Scale weight (900lb.), the more accurate the scale will be. 7. Ensure that the Fiber Scale is empty and that no tools or other foreign objects are on it. 8. Press the Press to Calibrate Scale Zero button (Step 2). 9. Place the Test Weights on the scale. Try to distribute the weights as evenly as possible. Try to keep the test weights within a circle formed by the four load cells. This may require placing the test weights inside the Fiber Drum. 10. Press the Press to Calibrate Test Weight button (Step 3). 11. The calibration is complete. Return to the Set up Menu, and then the Home display. 12. Check the calibration by placing a known weight on the fiber scale and noting the weight display. version1.2 17JUL12 Page 11

12 OPERATION OF DISPENSER Control Panel The Control panel is shown below (Fig 8). The control panel has the following operators: Emergency Stop Pushbutton Used to halt the machine in an emergency situation and to lockout the machine to clear jams. Safety Interlock Fault Indicator - This lamp is lit to indicate that the Safety Interlock System has detected a fault condition caused by actuating the Emergency Stop Pushbutton. This will remain lit even after the fault condition is removed, until it is reset. Safety Interlock Reset Button This button is used to reset the Safety Interlock System after actuating the Emergency Stop Pushbutton. This button must be pressed every time the machine is powered up. Failure to do so will prevent operation of the dispenser. Electrical Disconnect Handle This is used to shut off power to the dispenser. This must be on the off (0) position in order to open the control panel door. Electrical power must be shut off using this disconnect handle prior to any service of the dispenser that involves opening any of the machines electrical junction boxes or disconnecting any of the machines cables electrical cables. Fig 8 version1.2 17JUL12 Page 12

13 Safety Interlock System The fiber dispenser contains a control reliable Safety Interlock Emergency Stop system in compliance with OSHA safety regulations. Actuation of the Emergency Stop plunger on the controller will result in a fault condition. The system will not operate unless it is properly reset. The following is the reset procedure: 1. Ensure that the dispenser system is safe to operate. No one should be touching the dispenser and belt guard must be in place. 2. Rotate and pull out the Emergency Stop plunger. 3. Press the blue Safety Interlock Reset button. 4. Press the Fault Reset on the Touchscreen Display. Pre-Fill the Dispenser Once the TURBO C Mobile system is setup on a new location, it must be pre-filled with fiber prior to operation. Before initial filling, the scale must be Zeroed (as described in CONTROLLER SETUP and CALIBRATION section above). Add fiber by directly dumping boxes of fiber into the Drum. Do not exceed the Full Scale amount of 400 lb. After the initial fill, the rake must be turned by hand at the Rake Motor Drive Coupler (Fig 3). This is done to prevent the Rake from becoming jammed when it is first started after an initial fill. During this process fiber will become dislodged from the rake and fall into the funnel. Clear the Funnel by pressing the Air System Enable button located on the Digital I/O Testing Screen described above. Great care and caution must be observed if the Air System is run while hand turning the Rake. Keep hands away from any moving parts. Setting Feedrate The Target Feedrate is set by pressing the Press to Change Target Feed Rate button on the Home screen. Tap the box to enter a new Fiber Feedrate value, then press the enter button. You can the press the Return to Home button to view the Home screen. The Target Feedrate can be changed before or during a fiber run. Run the Dispenser START Press the F1 softkey to start the dispensing process. First the Blower will start, then after a predetermined delay (On Delay in Set Up Menu) the Drum and Rake motors start. The machine begins to dispense fiber at this time. STOP Press the F2 softkey to stop the dispensing process. First the Drum motor stops and Rake motor begins to slow down to a stop (9 seconds). Then, after a pre-determined delay (Off Delay in Set Up Menu), the Blower will begin to slow down to a stop (20 seconds). The machine stops to dispensing fiber at this time. version1.2 17JUL12 Page 13

14 Filling The Fiber Drum can be filled while the dispenser is running. Before doing so the controller MUST be placed in FILL mode by pressing the green FILL Mode button located on the lower left portion of the main display. In FILL Mode, the Drum Drive Signal is locked in to the value it had when the FILL Mode button was pressed. While in FILL Mode the dispenser is operating in a volumetric, fixed speed mode and is not compensating for loss-in-weight. As soon as the filling of the Fiber Drum is complete, the yellow Loss-in-Weight Mode button MUST be pressed. When this button is pressed, the dispenser returns to Loss-in-Weight Mode. For maximum accuracy, filling must be done as quickly as is possible and practical. While in FILL Mode the dispenser will tend to feed faster than the Target Feedrate. Do not exceed the Full Scale Value of 400 Lb. If the Dispenser Scale reads more than 420 Lb., an Over-Filled Fault will be triggered and the dispenser will not run version1.2 17JUL12 Page 14

15 Process Faults: All faults will require the operator to press the Fault Reset button on the Control Panel display to enable the feeding program to restart. Safety Fault This fault indicates that Emergency Stop plunger has been pushed. This fault would halt the feeding program. This fault will halt the feeding program. This fault will show on the main display and would set the Process Fault output on. Drum Motor Drive Fault This fault indicates that the Drive (VFD) for the Drum Motor has experienced a fault condition. This fault would halt the feeding program. This fault would show on the main display and would set the Process Fault on. If a Drive Fault occurs, please refer to Appendix A. Fiber Discharge Clogged Fault This fault indicates that the Blower Inlet Funnel is clogged with fiber. This fault will halt the feeding program. This fault will show on the main display and would set the Process Fault output on. Rake Motor Fault This fault indicates that the Drive (VFD) for the Rake Motor has experienced a fault condition. A fault condition can occur when too much current is drawn by the Rake Motor. This can result from the Rake being jammed by a foreign object. This fault will halt the feeding program. This fault will show on the main display and would set the Process Fault output on. If a Drive Fault occurs, please refer to Appendix A. Blower Motor Fault This fault indicates that a current overload condition or other fault condition has occurred on the Blower Motor Drive (VFD). A fault condition can occur when too much current is drawn by the Blower motor. This can result from the Blower being jammed by a foreign object or jammed with fiber due to too high a feed rate. This fault will halt the feeding program. This fault will show on the main display and would set the Process Fault output on. If a Drive Fault occurs, please refer to Appendix A. Fiber Drum Over-Filled Fault This fault indicates that the weigh bin has been over-filled, exceeding the Scale Over-Filled Weight set in the Scale Weights Setup screen. This fault will halt the feeding program. This fault will show on the main display and would set the Process Fault output on. Fiber Drum Under-Filled Fault This fault indicates that the weigh bin has been under-filled, falling below the Scale Under-Filled Weight set in the Scale Weights Setup screen. This fault will halt the feeding program. This fault will show on the main display and would set the Process Fault output on. Loadcell Out-of-Range Fault This fault indicates that the controller has sensed a loadcell signal with a value outside the expected range of values. This would indicate a damaged loadcell, loadcell cable, or loadcell summing junction box. version1.2 17JUL12 Page 15

16 Data Logging The TURBO C Control System is equipped with an integrated Data Logging system. This system tracks date, time, Scale Net Weight, and instantaneous Fiber Feedrate. These data are written into a row of.csv (Comma Separated Value) file. Every 30 seconds a new entry (row) is written. The.CSV files can be easily read into Microsoft Excel. Each time a fiber run is initiated, a new.csv file is created. Each data file has a distinct file name (based on date) to distinguish it from previous files. The data files are written to a Micro SD card located on the back side of the Touchscreen Display unit in the area marked Micro SD. You must first shut off the Control Panel Electrical Disconnect to open the Control Panel. Open the Control Panel to allow access to the backside of the Touchscreen Display. version1.2 17JUL12 Page 16

17 TRANSPORT The Fiber Dispenser MUST be properly prepared for transport. This preparation involves the following: Disconnecting the Electrical Supply Wiring Retracting the Trailer Support Jacks (Fig 1) Removal and stowage of the Delivery System Components Removal of Funnel from Blower, then packed in a box for safe transport Preparing the Dispenser for Transport (described below) Closing and securing all panel covers and trailer doors Preparing the Dispenser for Transport The Dispenser MUST be properly prepared for transport to prevent damage to the Drum, Base, and Loadcells. Two (2) Wooden Base Supports, five (5) ratchet straps, and 4 locknuts are to be used (see Appendix B). 1. The Wooden Base Supports must be placed on the stand as shown in Figure 9. Care must be taken so that no wire or cables are pinched when the Base Supports are loaded. Also, make sure that the Base Supports do not touch the Loadcells or Loadcell cables. 2. Lower the Base on to the Base Supports by turning the Loadcell Adjusters until they are fully seated on to the Loadcells (as shown in Figure 10). Lightly tighten the Loadcell Adjusters on to the Loadcells. Do NOT over tighten as this can damage the Loadcells. Tighten Locknuts on to the threaded portion of the Loadcell Adjusters (as shown in Figure 10). At this point all the weight of the Base and Drum should be borne by the Supports and the Loadcell Swivels should be loose. There must be no contact between the Loadcell Adjusters (sockets) and the Loadcell Swivels (balls). 3. Attach the Base to Stand Straps (2 ratchet straps) as shown in Figure 9. Before tightening, make sure that tightening the straps will not pinch and wires or electrical or Loadcell cables. Also apply Foam Padding as shown. Check to make sure that none of the Loadcell swivels is bound up. They must all be loose. If any are bound up, loosen straps and adjust the position of the Base to free them up. Retighten straps and check again. 4. Attach the Drum to Base Transport Support Strap as shown in Figure 11. This strap is positioned crosswise relative to the trailer and must be centered across the Drum. Use Foam Padding to prevent any marring of the paint. 5. Attach the 2 Centering straps as shown in Figure 12. These straps are required to prevent the Drum to Base Transport Support Strap from sliding off the Drum during transport. Use Foam Padding as shown. version1.2 17JUL12 Page 17

18 Figure 9 Figure 10 version1.2 17JUL12 Page 18

19 Figure 11 Figure 12 version1.2 17JUL12 Page 19

20 MAINTENANCE Dispenser Lockout Procedure: Before any maintenance or repairs are performed on the fiber dispenser, it must be locked out as shown in Figure 13. Figure 13 Control Panel Lockout Procedure: Before any repairs are performed on the Control Panel, the power mains supplying the dispenser must be shut off and locked-out at the circuit breaker panel. Bearing and Roller Inspection The dispenser is equipped with 2 mounted-unit shaft bearings that support the Rake assembly. These bearings are equipped with grease fittings. They should be inspected and lubricated on a regular basis. Also look for loss of grease. This would indicate a failed seal, requiring replacement of the bearing. The dispenser is also equipped with support rollers. There are 3 Vertical Support Rollers (larger rollers) and 6 Lateral Support Rollers (smaller rollers). These should be inspected periodically. If the bearings or rollers make any squealing or scraping noises while operating, they should be replaced. Lock-out Dispenser before servicing. version1.2 17JUL12 Page 20

21 Drive Belt and Tensioner The dispenser is equipped with cogged drive belt (see Fig 14). Drive Belt H Pitch (0.500 ), 1.5 wide. The belt should be inspected periodically for wear. Lock-out Control Panel before servicing. Figure 14 Lovejoy Couplers The Rake motor employs a Lovejoy brand shaft coupler (size L095). This should be inspected periodically. The metal jaws should be inspected for damage and the spiders (tan plastic inserts) for excessive wear. These should be replaced as necessary. They are available at Granger (part #1A925). Lock-out Control Panel disconnect electrical power and before servicing. Cleaning The dispenser should be kept free of accumulated dust and dirt. That accumulation can affect the reading of the scale. Do not wash down the Dispenser or Control Panel. All maintenance and repair work should be done by qualified technicians. For any questions involving the proper installation, set-up, operation, maintenance, or service of your Elite Fiber Dispenser system please call or contact VM Fiber Feeders. version1.2 17JUL12 Page 21

22 For assistance or technical support, please contact: VM Fiber Feeders, Inc Fruitville Road Sarasota, FL USA office FAX or Contact via version1.2 17JUL12 Page 22

23 APPENDIX A AC Drive Fault Condition - Trip Event Error Codes version1.2 17JUL12 Page 23

24 APPENDIX B Materials Required for Transport Ratchet Straps Base to Stand Straps Drum to Base Strap Centering Straps 10 Long, 2 required 16 Long, 1 required 10 Long, 2 required Locknuts Threaded Hex Nut, 1/2-20 thread, Stainless Steel. 4 required Wooden Base Supports Made from standard 2x4 s, screwed together as shown below: Not to Scale version1.2 17JUL12 Page 24

25 Addendum 1 New Design Funnel A newer design Funnel was included in the Mobile Continuous Fiber Dispenser after Unit 512 was released. It includes a backboard to help prevent fiber from escaping between the Air Gap. This new funnel must be positioned properly to allow it to operate properly. Please note proper position in photo below: version1.2 17JUL12 Page 25