34-27-13 AutoBall Charger 301W Operations Maintenance [PDF]

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AutoCharge 301-W AutoCharge Operations & Maintenance Manual Weight-based Automatic Ball Feeder Version 3.0W

Process Engineering Resources, Inc. Salt Lake City, Utah, USA

JUNE 2012

Contents AutoCharge Operations & Maintenance Manual ......................................................................................... 1 1.0

List of Drawings ................................................................................................................................. 3

2.0

Component Data Sheets ................................................................................................................... 4

3.0

System Description ........................................................................................................................... 5

4.0

AUTOCHARGE™ Hopper Door Adjustment ....................................................................................... 7

5.0

Maintenance Schedule ..................................................................................................................... 9

6.0

Recommended Spare Parts............................................................................................................. 11

7.0

Operator Local Control ................................................................................................................... 12

8.0

Remote Operation .......................................................................................................................... 19

9.0

Version History ................................................................................................................................ 27

AUTOCHARGE™ Operations & Maintenance Manual

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1.0

List of Drawings

Drawing Number PER- 1115-R2 PER- 1121-R1 PER- 1122-R1 PER- 1210-R1 PER- 1211-R1

Date 11 JUNE 2012 29 FEB. 2012 29 FEB. 2012 01 MAR. 2012 01 MAR. 2012

AC-CBPAC-D10-PPC

AUTOCHARGE™ Operations & Maintenance Manual

Title General Assembly Feeder Mounting Detail Safety Guards Ball Counter General Arrangement Ball Counter Detail AutoCharge Control Box

Page 3

2.0

Component Data Sheets

Component data sheets for the following items are included with this documentation AutoCharge™ Control Box •

Control Box Wiring Diagram

•

Norgren Control Valves

AutoCharge™ Feeder / Counter Equipment: •

Norgren Air Cylinder

•

Mettler-Toledo Load Cells

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3.0

System Description

3.1 AUTOCHARGE™ Components The Process Engineering Resources Inc. AUTOCHARGE™ air-powered automatic grinding ball charging system consists of the following equipment: •

Ball Feeder

•

Discharge Chute Actuator

•

Control Box

The Ball Feeder equipment should be assembled and mounted to the storage bin as shown in the sitespecific fabrication drawings. The Discharge Chute Actuator must be mounted below the discharge chute and allow full travel of the chute without binding according to the site-specific fabrication drawings. The Control Box should be mounted in a position close enough to the ball feeder so that an operator can observe the action of the feeder while adjusting the controls (feedrate, ball count, etc.). Connections to be completed before proceeding include the following: 1. Electrical connections from the bottom of the control box to the load cell junction box (see Control Box wiring diagram). 2. Control box air lines from compressed air supply to the box and from the box to the ports on the Ball Feeder and Discharge Chute Actuator air cylinders (see Control Box wiring diagram). 3.

Main electrical connection into the bottom of the control box to the disconnect switch terminal

4. Optionally, an Ethernet 100BaseT (Cat 5/5e/6) connection to the plant control system or network

3.2 Drawing List Refer to the drawing list on Page 2 for a complete list of the drawings related to the feeder and discharge chute general assembly and maintenance.

3.3 Functional Description The grinding balls gravity feed from the storage bin into the AUTOCHARGE™, where they accumulate on the feeder table. An air cylinder (5”-bore, 4.75”-stroke) powers primary and secondary rotating feed wheels. Each extension of the cylinder indexes the primary feed wheel 1/8 turn, controlled by a oneway clutch and brake arrangement. As the feed wheel turns, it picks up a number of balls in the flight of AUTOCHARGE™ Operations & Maintenance Manual

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the wheel. As the balls pass top center of the wheel, they roll off the wheel into the discharge chute. The balls are held momentarily in the discharge chute while the chute assembly is weighed by the load cells integrated into the discharge chute actuator. The discharge chute then lowers, releasing the balls onto the mill feed conveyor belt or feed stream.

3.4 Stop/Start The feeder stop/start, feed rate and operating parameters may be controlled locally at the AUTOCHARGE™ control box or from the plant distributed control system.

3.5 Weighing Balls drop into the discharge chute where they are weighed by the integrated load cells. The weights are accumulated by the AUTOCHARGE™ controller generating both total weight and feed rate of balls to the mill.

3.6 Power & Air Requirements The AUTOCHARGE™ ball feeder and counting system accommodates all electrical power and requires 90 psi compressed air with an approximate flow rate of 1 cfm.

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4.0 4.1

AUTOCHARGE™ Hopper Door Adjustment Safety Precautions All plant SAFETY rules must be strictly followed. The minimum personal protection equipment required for this operation: Hardhat, Safety glasses, Steel-toed safety boots, and Work gloves.

The EXTEND / RETRACT motion of the air cylinder must be stopped while adjusting the hopper door. Note: Stop the feeder by following the stop procedure described in the Local Control section of this manual. Never dump grinding balls into the storage bin while adjusting the door.

4.2 Door Adjustment The hopper door adjustment feature of the AUTOCHARGE™ is provided for two reasons: 1. To close the opening from the storage hopper to the feeder while filling an empty hopper with grinding balls. Failure to close the hopper gate may result in damage to the feeding and counting equipment. 2. To provide the optimum opening for the smooth flow of balls out of the hopper into the ball feeder.

4.3 Proper Door Height The optimum flow of balls through the opening can be regulated by the height the door is raised. Typically, this is approximately 80% of two ball diameters. Out-of-round grinding balls, debris accumulating in the hopper, and other obstacles should be removed that may impede ball flow out of the hopper into the feeder. There should be a single layer of balls on the feeder table when the hopper door opening is properly set.

4.4 Torque Limiter The door is held in position by a torque limiter keyed to the door adjustment shaft. The torque limiter will be adjusted at the initial installation to hold the door in any opening height from 0" to 16", while allowing the operator to turn the shaft with a wrench.

4.5 Positioning Hopper Door To position the door, use a 1-1/4" box end wrench at least 18" long. Turning the shaft clockwise raises the door; turning counter clockwise lowers the door.

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4.6 Positioning Procedure Initially set the door to position the bottom of the door approximately 1.6 ball diameters distance from the feeder bottom plate. Start the feeder system (see the Local Control section of this manual) from the control panel; observe the operation of the feeder and the flow of balls out of the hopper for approximately five minutes. If further adjustment is required, stop the feeder, adjust the opening up or down about 1-1/2'', then restart the feeder and observe until a smooth operation is achieved. There should be a single layer of balls on the feeder table when the hopper door opening is properly set.

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5.0

Maintenance Schedule

5.1 Safety Precautions All maintenance must be conducted while following all plant SAFETY rules. Never perform maintenance while dumping balls into the storage hopper or while the ball feeder is operating; always shut down the feeder, disconnect electrical power, and shut off compressed air before attempting any maintenance or adjustments. The minimum personal protection equipment required: Hardhat, Safety glasses, Steeltoed work boots, and Work gloves.

5.2 Daily Maintenance Every 24 hours of operation. Observe the operation of each piece of equipment in the grinding ball transfer/count system from storage hopper to mill entry. Watch for loose or broken parts, erratic or unusual operating conditions, compressed air leaks, loose electrical connections, and damaged electrical insulation. Shut down the equipment to make any required repairs.

5.3 Storage Bin Maintenance If the storage bin contains 24 hours supply of grinding balls, once each 24 hours run the storage bin empty and sweep out or remove all dust, accumulated debris, and ball chips or halves. If the storage bin has a larger capacity, schedule this maintenance operation to coincide with the bin capacity.

5.4 Weekly Maintenance Every 168 hours of operating time, check the adjustment of the AUTOCHARGE hopper door torque limiter. Check the torque of the 44 cap screws holding the chain to the hopper door. Check the operation of the discharge chute and load cell inputs. The load cell inputs can be read directly from the “Manual” operation screen, check that the signal responds according to no-load and loaded conditions (maximum 100 lbs load). Check the cylinder clevis rod to make sure it has not loosened.

5.5 Yearly Maintenance Every 8760 hours of operating time. Replace the Feed Wheel Torque Limiter Friction Disc and check the Hopper Door Torque Limiter Friction Disc for wear. Check all mating parts for scoring or wear. Check the hopper door for damage. Check the door guides for wear or damage. Check the torque on all mounting bolts, cap screws and setscrews. Replace the rod and piston seals in the air cylinder and check the rod and clevis pins for wear. Disassemble the feeder one-way clutch following the manufacturer’s instructions; replace any worn parts and reassemble. Check all electrical wiring for loose or damaged connections. Check all air piping and hoses for damage or leaks. AUTOCHARGE™ Operations & Maintenance Manual

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5.6

Safety Guards

Always replace safety guards that have been removed for maintenance, before restoring electrical power or air pressure.

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6.0

Recommended Spare Parts

6.1 Recommended Parts per Installation Recommended AUTOCHARGE™ wear parts and capital spare parts per installed unit are listed in the tables below. Items designated with an asterisk (*) are capital spare parts with only one item required per two installed units.

6.2

Wear Part (One Year)

Part Name/Number

Manufacturer

Drawing

Torque Limiter Friction Disk (700A) Cylinder Repair Kit (rod & piston)

Morse Norgren

PER-1115-R2 PER-1115-R2

Part Name/Number

Manufacturer

Drawing

*A-1233C1-P(3/8B)-5X4.75 Air Cylinder Seal Kit (SWK-35) Air Cylinder Piston Seal Kit (AJK-503) Torque Limiter Friction Disk (700A) *P-16A-LH Cam Clutch Unisphere Bearing (048034) *ASA#8012-Tooth Sprocket *ASA#8014-Tooth Sprocket

Norgren Norgren Norgren Morse Morse Dodge Utah Fabrication Utah Fabrication

PER-1115-R2 PER-1115-R2 PER-1115-R2 PER-1115-R2 PER-1115-R2 PER-1115-R2 PER-1115-R2 PER-1115-R2

6.3

Quantity 1 1

Capital Spare Parts

AUTOCHARGE™ Operations & Maintenance Manual

Quantity 0.5 1 1 2 0.5 4 0.5 0.5

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7.0

Operator Local Control

7.1 Local Operator Interface The AUTOCHARGE™ control box incorporates a panel mounted touchscreen PC for local control and configuration of the feeder system. The computer is configured to boot and automatically launch the controller interface when power is applied from the disconnect switch located on the right side of the control box. When the computer boots and the operator interface starts the screen in Figure 1 is shown for 60 seconds or until the Continue button is clicked after about 5 seconds.

Figure 1 AUTOCHARGE™ startup screen

7.2

Local Data Entry

Since the AUTOCHARGE™ control box does not have a keyboard, all information is entered through the touchscreen using and on-screen keyboard or on-screen numeric keypad. To edit a value, click on an editable value and the computer will show the appropriate keypad (numeric or alpha-numeric) as shown in Figure 2. To enter a new value, type the value using the on-screen buttons and click OK. For numeric values, the minimum and maximum allowable values are shown. The keypad will not accept values outside this range.

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Figure 2 On-screen numeric keypad

7.3 Local and Remote Modes The AUTOCHARGE™ may be operated from the local display or from a remote network connection. Initially, when the AUTOCHARGE™ starts, it enters LOCAL mode. The mode is indicated in the upper right corner of the screen as shown in Figure 3 and Figure 4. The mode can be toggled by clicking either the “REMOTE” or “LOCAL” button.

Figure 3 Main screen, local operation

For safety reasons, the local/remote operating mode can only be set from the local display.

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Figure 4 Main screen, remote operation

7.4 Initial Configuration When the AUTOCHARGE™ is shipped, it does not contain any configuration information and must be configured prior to first use. Attempting to start the AUTOCHARGE™ with missing configuration parameters will generate a configuration error. To enter the configuration settings, use the “Setup” button located on the main LOCAL screen. This will open the setup screen shown in Figure 5. Each of the configuration parameters is described below.

Figure 5 AUTOCHARGE™ Setup screen

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Ball Weight Units – defines the units used for the nominal ball weight (typically lb or kg). Weight Scale Factor – applies a scaling factor to the load cell input signal. By default, the load cell input is in kilograms. Enter the conversion factor here for other ball weight units of measure. Cylinder Extend Time – is the amount of time (in seconds) required for the air cylinder to fully extend. This value depends on supplied air pressure, but is typically 1 – 3 seconds. Cylinder Retract Time – is the amount of time (in seconds) required for the air cylinder to fully retract. This value depends on supplied air pressure, but is typically 1 – 3 seconds. Settling Time – is the time (in milliseconds) the AUTOCHARGE™ will delay after the cylinder retracts and before it attempts to measure the weight of the discharge chute. Feed Zero Count Limit – the AUTOCHARGE™ counts the number of feed attempts for which there are no balls counted across all channels. If the value exceeds this limit, the controller will indicate a “ball jam or bin empty” condition. This condition must be reset by an operator before the AUTOCHARGE™ will continue. Chute Discharge Time – is the time (in seconds) for the discharge chute to lower. This value depends on supplied air pressure, but is typically 1-3 seconds. Auto-Tare – when this box is checked, the AUTOCHARGE™ will weigh the empty discharge chute between each discharge. If this box is unchecked, the AUTOCHARGE™ will weigh the empty discharge chute only once when the mode is set to RUN. Español – click this button to display the user screen in Spanish. In addition to the configuration parameters, the feed rate must be set for the AUTOCHARGE™ to start feeding balls. The feed rate is set in the ball weight units per hour and is adjustable from the main local display (or remotely).

7.5 Remote Operation Network Setup For remote operation, the AUTOCHARGE™ controller must be connected to the local network and have its IP address set accordingly. The AUTOCHARGE™ controller has two network ports, Ethernet 1 and Ethernet 2, located on the top of the controller inside the control box. Ethernet 1 is used internally to connect the controller to the panel PC. Ethernet 2 is available for connection to the plant control network and its address can be set using the “NETWORK” button from the AUTOCHARGE™ setup screen. The network setup screen is shown in Figure 6. The controller does not support dynamic address assignment through DHCP. It must be configured for a static IP address that is compatible with the plant control network.

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Figure 6 Network setup screen

To enter an address, subnet mask, gateway and DNS, click on each number of the address field and enter the appropriate values using the on-screen numeric keypad. When the address settings are correct, click the “Update” button to apply the changes. Updating the network address takes several seconds and will reset the controller. A message is displayed on the screen while the address is being updated. After the update is complete, click “Close” to return to the AUTOCHARGE™ setup screen.

The internal IP address (Ethernet 1) is set to 192.168.96.55/255.255.255.0 and the panel PC address is 192.168.96.2/255.255.255.0. If these addresses conflict with the plant network, please contact PERI for assistance on modifying the internal addresses. For more information on remote operation, see the Remote Operation section of this manual.

7.6 Local Automatic Operation When the AUTOCHARGE™ is configured, local operation is possible by setting the feed rate and clicking the “START” button. The feeder will discharge balls according to the desired feed rate and the number of balls counted at each discharge. The delay between discharges is automatically adjusted based on the weight per discharge and the desired feed rate. The delay time is displayed on the main screen (in both local and remote modes), as well as the average weight per discharge, measured charge rate and feeder status. The feed rate is only adjustable locally when LOCAL mode is selected. When in remote mode, the feed rate is displayed but cannot be modified.

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To stop the feeder in local mode, click the STOP button (STOP is only visible when the AUTOCHARGE™ is running). To stop the feeder locally when it is being operated remotely, first click “LOCAL” then click “STOP”.

7.7 Local Manual Operation In local mode, the feeder can be operated manually by clicking the “MANUAL” button on the main screen. If the feeder was running in automatic, it will be stopped for manual operation. The manual operation screen is shown in Figure 7. There are four controls on the manual operation screen described below.

Figure 7 Manual operation screen

Advance – causes the feeder to advance one half of one full discharge cycle, which is to extend and retract the air cylinder once. Using the Advance button does not perform any weighing. Extend – extends the air cylinder (feeder or discharge chute), no balls are weighed using this action. Retract – retracts the air cylinder (feeder or discharge chute), no balls are weighed using this action. The raw and filtered input signals from the load cells are displayed for testing/troubleshooting. To exit manual operation, click either the REMOTE or AUTO button to return to automatic remote or automatic local operation, respectively.

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7.8 Feed Simulator The AUTOCHARGE™ controller has a simple feed simulator used for testing of the controller and screens. The simulator is accessed through the Setup page (described in section 7.4 Initial Configuration above). Click the “Simulator” button to open the AUTOCHARGE™ Simulator screen shown in Figure 9. Click the selector switch to start or stop the simulator. When the AUTOCHARGE™ runs with the simulator, all actual inputs and outputs from the controller box are disabled and replaced with simulated inputs and outputs.

Figure 8 AUTOCHARGE™ Feed Simulator

When “RUN SIMULATOR” is selected, the controller generates a random weight for the discharge chute and actual outputs to the air cylinders are disabled. When the selector switch is set to “RUN SIMULATOR” the AUTOCHARGE™ controller will not actuate the feeder mechanism. When finished using the simulator, ensure the selector is returned to “NORMAL OPERATION.” If the controller is reset or powered off, the controller automatically returns to “NORMAL OPERATION.” When the simulator is running a message is displayed in both local and remote modes indicating the simulator is running and I/O is disabled as shown in Figure 7.

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8.0

Remote Operation

This section contains information related to both the counter-based and weight based AUTOCHARGE™ systems. Reading parameters for the wrong type of system may result in undefined values. Writing version-specific parameters for the wrong type of system will be ignored by the AUTOCHARGE™ controller.

8.1 Functional Description Remote operation of the AUTOCHARGE™ is provided via the secondary Ethernet port on the controller located inside the control box. By reading/writing values to controller memory addresses, a remote system can start and stop the AUTOCHARGE™, set configuration parameters, and adjust the feed rate set point. All individual channel counts plus overall counters are accessible over the remote connection. The AUTOCHARGE™ controller simultaneously supports three separate communication protocols. Obviously, there must be only one remote source writing values to the AUTOCHARGE™ controller. The three protocols are EtherNet/IP, Modbus/TCP and IEEE 1394 memory mapped protocol. 8.2 EtherNet/IP To use the AUTOCHARGE™ with EtherNet/IP, two assemblies exist in the controller. The EtherNet/IP compatible device must be configured to read/write values from these assemblies. In ControlLogix, the AUTOCHARGE™ controller is configured as a “Generic EtherNet/IP” device. See the relevant Rockwell Automation or other vendor documentation for exact configuration options. The first assembly (100) consists of 80 DINT values in the order specified in the Integer Variables table below. All locations support both read and write operations, however values written to read-only variables will be ignored. The second assembly (101) consists of 32 REAL values in the order specified in the Float Variables table below. All locations support both read and write operations, however values written to read-only variables will be ignored. 8.3 Modbus/TCP The AUTOCHARGE™ controller supports Modbus/TCP acting as a Modbus slave device (i.e. it can be read/written by a Modbus master, but cannot initiate Modbus communication itself). Since the AUTOCHARGE™ controller has more accessible data than is possible in a single Modbus device, its memory locations are divided into multiple Modbus units. The unit ID for AUTOCHARGE™ variables is 110. Each variable is accessed through a register address given in the Integer and Real Variable tables below. If the Modbus master device uses register number rather than register address, it is necessary to add 1 to the address value to determine the register number.

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8.4 OptoMMP/IEEE 1934 Memory Mapped Protocol The AUTOCHARGE™ controller supports the IEEE 1394 memory mapped protocol standard. The memory mapped address is shown for each AUTOCHARGE™ variable in the tables below.

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8.5

Variable Conventions

The variable definitions use the following conventions VariableName (DataType, Access, Persistence) – Description. Where DataType is one of the following Int32 – 32-bit integer value. Either taken as an integer value or using individual bits to indicate a particular state Real – 4-byte floating point value String*Len – a string with maximum Len characters Int32*n – an array of 32-bit integer values Access is given by RO for read-only or RW for read-write access. Persistence is P for a persistent variable, that is the value will be maintained even if the controller is powered off. T is for a transitory variable that does not maintain its value during controller power-off

8.6 Variable Definitions bInputError (Int32, RO, T) – each bit corresponds to a ball counter channel when set indicates the number of flights of balls with zero counts through the channel has exceeded the limit set by nChannelZeroCountThreshold. bRemoteMode (Int32, RO, T) – flag controlling the remote/local mode of the AutoCharge controller. Non-zero indicates remote operation (parameter values changed by remote DCS or other network connection). When this value is zero, the controller will only accept parameters from the local operator display. This value is only changeable from the operator display. bState (Int32, RO, T) – each bit corresponds to one or more states set in the AutoCharge controller Bit 0 – Configuration error (one or more parameters has not been set) Bit 1 – Ball jam or bin empty indicator Bits 2-31 – not defined/future use fAvgWeightPerDischarge (Real, RO, T) – calculated average weight of balls charged per flight, in userdefined units (see szUnits) fBallWeight (Real, RW,P) – user-entered nominal ball weight, in user-defined units (see szUnits) fDischargePerHour (Real, RO, T) – calculated feed rate, in user-defined units (see szUnits) per hour. fDischargeTime (Real, RW, T) – the time (in seconds) required for the discharge chute to move to the fully lowered position. fFeedDelayCalc (Real, RO, T) – calculated delay between flights of balls in seconds. AUTOCHARGE™ Operations & Maintenance Manual

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fFeedRate (Real, RW ,P) – user-entered feed rate, in user-defined units (see szUnits) per hour. fTimeDetect (Real, RW, P) – time allowed, in seconds, for detection of balls through the counter chutes after a discharge. fTimeDischarge (Real, RO, T) – calculated total time, in seconds, for a single discharge. fTimeExtend (Real, RW, P) - user-entered time required to extend the air cylinder, in seconds. fTimeRetract (Real, RW, P) – user-entered time required to retract the air cylinder, in seconds. fWeight (Real, RO, T) – calculated weight in the current discharge of balls in user-entered units (see szUnits) fWeightFilter (Real, RO, T) – calculated weight value given to the current discharge used to determine the average weight per discharge according to (fWeightFilter * fWeight) + (fAvgWeightPerDischarge * (1-fWeightFilter)). fScaleFactor (Real, RW, P) – user-entered weight conversion factor for load-cells. This factor should convert 1 kg to 1 unit of the user-defined ball weight units. fSettlingTime (Real, RW, P) – the delay time between feeder discharge into the discharge chute and reading of the load cell inputs. MAX_CHANNEL (Int32, RW, P) – defines the maximum number of channels to scan, must be from 0 to 15 (the first channel is 0). nChannelCountZeroThreshold (Int32, RW, P) – defines the maximum number of discharges with zero counts through a chute before an error is indicated for a chute in bInputError. nCountDelay (Int32, RW, P) – defines the time, in milliseconds, allowed between successive counts in the same chute. This value provides some signal debounce for the limit switch return to center position, typically between 5 and 20 ms. nDischargeCount (Int32, RO, T) – number of balls counted in the current discharge. nFeedStep (Int32, RO, T) – the current step of the discharge according to the following values 0 – Idle/Waiting for next discharge 1 – First extension of the air cylinder 2 – First retraction of the air cylinder 3 – Second extension of the air cylinder 4 – Second retraction of the air cylinder 5 – Detecting balls passing through the chutes nManualCommand (Int32, RW, T) – when in manual mode, it will execute a command according to the following values 1 – One complete discharge cycle AUTOCHARGE™ Operations & Maintenance Manual

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2 – Advance feeder one-half discharge (extend and retract the air cylinder) 3 – Extend the air cylinder 4 – Retract the air cylinder nRunMode (Int32, RW, T) – determines the AutoCharge run mode according to the following values 0 – Stop, the AutoCharge will not actuate the air cylinder or count balls through the feeder 1 – Auto, the AutoCharge will automatically feed balls according the user-entered feed rate 2 – Manual, the AutoCharge will process manual commands (see nManaualCommand above) nZeroDischargeCount (Int32, RO, T) – is the number of successive discharges where no balls have been counted. When this value exceeds the limit set by nZeroDischargeCountThreshold, the AutoCharge will indicate a ball jam or bin empty condition in bState. nZeroDischargeCountThreshold (Int32, RW, P) – sets the limit for the number of successive discharges with no balls counted before indicating a ball jam/bin empty condition. szUnits (String*10, RW, P) – user-defined weight unit of measure for grinding balls (not currently accessible remotely) tbl_counts (Int32*16, RO, P) – counts in each channel since installation or table reset. tbl_curcounts (Int32*16, RO, T) – counts for each channel in the current discharge tbl_zero_counts (Int32*16, RO, T) – number of successive zero-ball discharges for each channel

8.7

AUTOCHARGE™ Integer Variables Memory Addresses INTEGER VARIABLES

Scratch Pad

IEEE 1394

Index 0 1 2 3 4 5 6 7 8 9 10 11

Address F0D81000 F0D81004 F0D81008 F0D8100C F0D81010 F0D81014 F0D81018 F0D8101C F0D81020 F0D81024 F0D81028 F0D8102C

Modbus Register Unit ID Address Variable 110 2049 bRemoteMode 110 2051 bState 110 2053 bInputError 110 2055 nFeedStep 110 2057 nDischargeCount 110 2059 nZeroDischargeCount 110 2061 Not Used 110 2063 Not Used 110 2065 Not Used 110 2067 Not Used 110 2069 Not Used 110 2071 Not Used

AUTOCHARGE™ Operations & Maintenance Manual

Access RO RO RO RO RO RO

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12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52

F0D81030 F0D81034 F0D81038 F0D8103C F0D81040 F0D81044 F0D81048 F0D8104C F0D81050 F0D81054 F0D81058 F0D8105C F0D81060 F0D81064 F0D81068 F0D8106C F0D81070 F0D81074 F0D81078 F0D8107C F0D81080 F0D81084 F0D81088 F0D8108C F0D81090 F0D81094 F0D81098 F0D8109C F0D810A0 F0D810A4 F0D810A8 F0D810AC F0D810B0 F0D810B4 F0D810B8 F0D810BC F0D810C0 F0D810C4 F0D810C8 F0D810CC F0D810D0

110 110 110 110 110 110 110 110 110 110 110 110 110 110 110 110 110 110 110 110 110 110 110 110 110 110 110 110 110 110 110 110 110 110 110 110 110 110 110 110 110

2073 2075 2077 2079 2081 2083 2085 2087 2089 2091 2093 2095 2097 2099 2101 2103 2105 2107 2109 2111 2113 2115 2117 2119 2121 2123 2125 2127 2129 2131 2133 2135 2137 2139 2141 2143 2145 2147 2149 2151 2153

AUTOCHARGE™ Operations & Maintenance Manual

Not Used Not Used Not Used Not Used nRunMode nManualCommand nChannelCountZeroThreshold nZeroDischargeCountThreshold MAX_CHANNEL nCountDelay Not Used Not Used Not Used Not Used Not Used Not Used Not Used Not Used Not Used Not Used Total counts channel 0 Total counts channel 1 Total counts channel 2 Total counts channel 3 Total counts channel 4 Total counts channel 5 Total counts channel 6 Total counts channel 7 Total counts channel 8 Total counts channel 9 Total counts channel 10 Total counts channel 11 Total counts channel 12 Total counts channel 13 Total counts channel 14 Total counts channel 15 Current counts channel 0 Current counts channel 1 Current counts channel 2 Current counts channel 3 Current counts channel 4

RW RW RW RW RW RW

RO RO RO RO RO RO RO RO RO RO RO RO RO RO RO RO RO RO RO RO RO Page 24

53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79

F0D810D4 F0D810D8 F0D810DC F0D810E0 F0D810E4 F0D810E8 F0D810EC F0D810F0 F0D810F4 F0D810F8 F0D810FC F0D81100 F0D81104 F0D81108 F0D8110C F0D81110 F0D81114 F0D81118 F0D8111C F0D81120 F0D81124 F0D81128 F0D8112C F0D81130 F0D81134 F0D81138 F0D8113C

110 110 110 110 110 110 110 110 110 110 110 110 110 110 110 110 110 110 110 110 110 110 110 110 110 110 110

2155 2157 2159 2161 2163 2165 2167 2169 2171 2173 2175 2177 2179 2181 2183 2185 2187 2189 2191 2193 2195 2197 2199 2201 2203 2205 2207

AUTOCHARGE™ Operations & Maintenance Manual

Current counts channel 5 Current counts channel 6 Current counts channel 7 Current counts channel 8 Current counts channel 9 Current counts channel 10 Current counts channel 11 Current counts channel 12 Current counts channel 13 Current counts channel 14 Current counts channel 15 Zero counts channel 0 Zero counts channel 1 Zero counts channel 2 Zero counts channel 3 Zero counts channel 4 Zero counts channel 5 Zero counts channel 6 Zero counts channel 7 Zero counts channel 8 Zero counts channel 9 Zero counts channel 10 Zero counts channel 11 Zero counts channel 12 Zero counts channel 13 Zero counts channel 14 Zero counts channel 15

RO RO RO RO RO RO RO RO RO RO RO RO RO RO RO RO RO RO RO RO RO RO RO RO RO RO RO

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8.8

AUTOCHARGE™ Real Variable Memory Addresses REAL VARIABLES

Scratch Pad

IEEE 1394

Index 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

Address F0D82000 F0D82004 F0D82008 F0D8200C F0D82010 F0D82014 F0D82018 F0D8201C F0D82020 F0D82024 F0D82028 F0D8202C F0D82030 F0D82034 F0D82038 F0D8203C F0D82040 F0D82044 F0D82048 F0D8204C F0D82050 F0D82054 F0D82058 F0D8205C F0D82060 F0D82064 F0D82068 F0D8206C F0D82070 F0D82074 F0D82078 F0D8207C

Modbus Register Unit ID Address Variable 110 4097 fDischargePerHour 110 4099 fFeedDelayCalc 110 4101 fTimeDischarge 110 4103 fWeight 110 4105 fWeightFilter 110 4107 fAvgWeightPerDischarge 110 4109 Not Used 110 4111 Not Used 110 4113 Not Used 110 4115 Not Used 110 4117 Not Used 110 4119 Not Used 110 4121 Not Used 110 4123 Not Used 110 4125 Not Used 110 4127 Not Used 110 4129 fFeedRate 110 4131 fBallWeight 110 4133 fTimeDetect 110 4135 fTimeExtend 110 4137 fTimeRetract 110 4139 fScaleFactor 110 4141 fDischargeTime 110 4143 fSettlingTime 110 4145 Not Used 110 4147 Not Used 110 4149 Not Used 110 4151 Not Used 110 4153 Not Used 110 4155 Not Used 110 4157 Not Used 110 4159 Not Used

AUTOCHARGE™ Operations & Maintenance Manual

Access RO RO RO RO RO RO

RW RW RW RW RW RW RW RW

Page 26

9.0

Version History

9.1 Version 3.0W This document applies to version 3.0W of the AutoCharge PAC-based controller with feeder and weightbased discharge chute. This version includes an embedded PC with touchscreen control mounted on the AutoCharge controller enclosure. The AutoCharge star feeder empties balls into a discharge chute where they are weighed from load cell inputs and then discharged onto the mill feed conveyor. 9.2 Version 3.0 Applies to version 3.0 of the AutoCharge PAC-based controller with limit switch counters. This version includes an embedded PC with touchscreen control mounted on the AutoCharge controller enclosure. Version 3.0 includes two AutoCharge models, the 301 and 301W. Model 301 uses limit-switches to count individual balls charged to the mill through ball discharge chutes. Model 301W is the weightometer-based unit that measures actual weight of balls charge through separate instrumented discharge hopper (See Version 3.0W above). 9.3 Version 2.0 Version 2.0 added a local touchscreen display from a dedicated G70 terminal, replacing the output counter, indicator lamps and pushbuttons. Operation and configuration are performed locally on the touchscreen. 9.4 Version 1.0 Version 1.0 is the first programmable automation controller (PAC) based AutoCharge unit. Previous systems used programmable logic controllers (PLC) . Version 1.0 included only an output counter, panel indicator lamps and push-button controls for start, stop and reset. Configuration was provided through a Windows client software program.

AUTOCHARGE™ Operations & Maintenance Manual

Page 27

100BaseT Connection to Plant Network +V +V

MW

MEAN WELL

-V

-V

DR-120-24

230VAC INPUT 100-120VAC 3.3A 200-240VAC 2.0A OUTPUT: 24VDC 5A 115VAC

L

N

-V

+V

LED ADJ

INPUT: 100 – 240Vac 1.5A 50-60Hz

MW

MODEL No: DR-4505

MEAN WELL UL UL

N

L

LOAD CELL CONNECTION (USE 4-WIRE CONNECTION FOR AUTOCHARGE, 24VDC POWER NOT SHOWN ON DIAGRAM)

32

30 31

28 29

6

26 27

5

4

3

1

-

+

2

CAT5

GND

+24V

*24VDC power supply must be switched to match incoming AC voltage

L1

L2

L3

T1

T2

T3

-

+

PPC-L61T TOUCHSCREEN PANEL PC

G

G

AC MAIN SUPPLY 100-240VAC 50/60Hz NEUT LIVE GND

AutoCharge Control Box AutoCharge PAC-based Control Box with load cell input and PPC-L61T FSCM NO

DAVID TAYLOR FEEDER CYLINDER

DISCHARGE CHUTE CYLINDER

6/15/2012

DWG NO

REV

AC-CBPAC-LC SCALE

1:1

SHEET

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