Tuc 6 WF Manual

WEIGH FEEDER
TUC -6 OPERATION & MAINTENANCE MANUAL
OPERATION & MAINTENANCE MANUAL - INDEX

Weigh Feeder with TUC-6 Electronics Page 1 of 1
1.0
Technical data............................................06 TUC6-010-EE23.0-R1 Functional Description.................................... 06 TUC6-010-EE23.1-R0 Operator's Manual.........................................11 TUC6-010-EE23.2-R1 Commissioning Instructions.................................. 20 TUC6-010-EE23.3-R2 Menu Operations...........................................11 TUC6-010-EE23.4-R1 Parameter Listing..........................................05 TUC6-010-EE23.5-R1 PLC Program.................................................16 TUC6-010-EE23.6-R2 Appliance Description..................................... 10 TUC6-010-EE23.10-R1 Front Facia Layout........................................01 TUC6-010-EE25-R0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
9.0
Software_version: 3.0 (onwards) 2008-01-03
TECHNICAL DATA
Weigh Feeder with TUC-6 Electronics TUC6-010-EE23.0-R1 1.0 1.1 1.2 System Microprocessor Memory : : 8xC51FA 64K EPROM 8K RAM with integral Battery Backup. Page 1 of 6
2.0 2.1 2.2 2.3 2.4 2.5 2.6 2.7
Construction Housing Colour Dimensions (W*H*D) Control Panel cutout Control Panel thickness Mounting space Wall clearance : : : : : : : : Aluminium enclosure in DIN format Silver anodized 144 * 72 * 245 mm 138 * 68 mm Min. 1 mm, max. 15 mm Approx. 300 mm deep with connectors Min. 100 mm upwards. Min. 60 mm on each side with natural convection Approx. 1.0 Kg 2 Grub screws at the sides IP 54 (Front)
2.8 2.9 2.10 3.0 3.1 3.2 3.3 3.4 3.5 3.6 4.0 4.1
Weight Mounting Protection type Display Display Colour Type Digit height Reading angle Dimension sign Control panel Type
: : :
: : : : : :
2 lines * 16 Characters Vacuum Fluorescent Display Blue VFD, alphanumeric 5.5 mm legible to approx. 2 m Approx. 40 . kg, t (User selectable)
Membrane foil with pressure sensitive keyboard.
TECHNICAL DATA
Weigh Feeder with TUC-6 Electronics TUC6-010-EE23.0-R1 Page 2 of 6
5.0 5.1 5.2 5.3
Environment Operating temperature Storage temperature Humidity : : : 0 C to +55 C -20 C to +85 C Max 85 % relative, without condensation
6.0 6.1 6.2 6.3
Measurement Input - Loadcell Terminal Measurement input range Supply voltage : : : 9 pole, DB connector 0 to 28 mV Internal 12 V 5 %, Max. 110mA (e.g. 3 loadcells of 350 ohms in parallel) 6 core, shielded (min. 80% optical cover) Isolation resistance min.120 Mohm/Km Core cross-section min. 0.34 mm to 0.5 mm solderable directly to connector. Cable diameter upto 8mm mountable in connector. Connect greater cross-sections with solderable connectors. l = 5.1 * R * A / n R = Loadcell resistance in ohm A = Cable cross-section in mm n = no. of loadcells in parallel l = Cable length , max. 1000 m
6.4
Measuring cable
6.5
Cable length
7.0 7.1 7.2
Measurement Input - Tacho Terminal Input signal : : Screw clamped terminals. Conductor size 0.14 to 1.5 mm2. Max. 15 V
TECHNICAL DATA
Weigh Feeder with TUC-6 Electronics TUC6-010-EE23.0-R1 7.3 7.4 7.5 Measurement input range Supply voltage Measuring cable : : : Page 3 of 6 10 - 2500 Hz, 12 V Internal 12 V 5 %; max. 10 mA 3 core, shielded (min. 80% optical cover) Isolation resistance min.120 Mohm/Km Core cross-section min. 0.34 mm to 1.5 mm2. Max. 1000 m
7.6 8.0 8.1 8.2
Cable length Digital Outputs Output type Terminal
: :
8.3
Functions
4 Nos. Relay contacts, 220Vac, 2 Amp contact rating Screw clamped terminals Conductor size from 0.5 to 1.5 mm2 2 Nos. outputs can be assigned as totaliser outputs. Non-assigned outputs can be used in SPSS program for any desired function.
9.0 9.1 9.2 9.3 10.0 10.1
Power supply Terminal Voltage Power consumption Analog output Function : 0 -20 mA / 4-20 mA isolated o/p corresponding to any of the following functions, -Actual feedrate -Belt Load -Belt Speed : : : Screw clamped terminals Conductor size 0.14 to 1.5 mm2. 18-36 Vdc 12 VA max.
TECHNICAL DATA
Weigh Feeder with TUC-6 Electronics TUC6-010-EE23.0-R1 Page 4 of 6 -Weigh Feeder drive setpoint -Pre-feeder drive setpoint -Current setpoint Galvanic 500 Ohm Screw clamped terminals Conductor size 0.14 to 1.5 mm2. 2 core ,shielded. Individual core connectable directly to connector.
10.2 10.3 10.4 10.5
Isolation type Load Terminal Cable type
: : : :
11.0 11.1
Impulse outputs Function : 2 relay outputs corresponding to either Totaliser1 or Totaliser2. 50 mSec to 500 mSec programmable ON time pulses Screw clamped terminals Conductor size 0.14 to 1.5 mm2.
11.2
Terminal
12.0 12.1 12.2 12.3 12.4 12.5
RS-485 Interface Terminal Transmission Baud rate Format Cable type : : : : 5 pole DIN socket Half duplex, serial bit, asynchronous mode 19200 baud 8 bite, 1 stop, No Parity 2 core ,shielded ,max 0.5 mm2 individual core connectable directly to connector. Used to interface I/O cards to TUC-6 unit.
12.6
Function
13.0 13.1 13.2 13.3
Profibus-DP Interface Terminal Transmission mode Baud rate : : : 9 pole, DB connector RS 485 9600 bps to 12 Mbps max
TECHNICAL DATA
Weigh Feeder with TUC-6 Electronics TUC6-010-EE23.0-R1 13.4 Station Address : 01 to 99 Page 5 of 6
Optional Interface Modules 14.0 14.1 14.2 14.3 Digital I/O Interface Card Input type Output type Terminal : : : 8 Nos, opto-coupled, 24 Vdc positive logic, max. 5 mA. 8 Nos. Relay contacts, 220Vac, 2 Amp contact rating Screw less Terminals. Conductor size from 0.5 to 1.5 mm2. Inputs/Outputs can be assigned any desired function through SPSS program. Max. 2 cards of F866 or 1 F889 card along with 1 F890 card can be interfaced to TUC-6 unit.
14.4
Functions
14.5
Max. cards supported
15.0 15.1 15.2
Analog I/O Interface Card (F-868 card) Input Type Output Type : : 0-20 mA/ 4-20 mA/0-10 V isolated input corresponding to setpoint 0-20 mA/ 4-20 mA isolated output corresponding to any of the following functions, -Actual feedrate -Belt Load -Belt Speed -Weigh Feeder drive setpoint -Pre-feeder drive setpoint -Current setpoint Optical. 4 - 20 mA - 100 Ohm 0 -10 V < 1 mA 4 - 20 mA - 500 Ohm (max.) Screw less terminations
15.3 15.4 15.5 15.6
Isolation type Load - Input Load - Output Terminal
: : : :
TECHNICAL DATA
Weigh Feeder with TUC-6 Electronics TUC6-010-EE23.0-R1 Page 6 of 6 Conductor size 0.14 to 1.5 mm2. 2 core ,shielded. Individual core connectable directly to connector. Max. 3 cards can be interfaced to TUC-6 unit.
15.7
Cable type
15.8
Max. cards supported
16.0 16.1 16.2 16.3 16.4 16.5 16.6 16.7
Serial I/O Module Interface Protocol Terminal Transmission Baud rate Format Cable type : : : : : : : RS-485 Modbus RTU 14-pin screwed terminals Half duplex, serial bit, synchronous, adjustable bit mode. 4800, 9600, 19200 baud. 3 options, user selectable. 2 core, shielded, max 0.5 mm individual core connectable directly to connector. Max. 1000 m at 19200 baud.
16.8
Cable length
FUNCTIONAL DESCRIPTION
TABLE OF CONTENTS
1.0 Principle.................................................... 2 1.1 TUC-6 Weigh Feeder system, Overview................... 2 1.2 System Features......................................... .. 2 Functions.................................................. 3 2.1 Modes of operation.................................... 3 -Interlock - Gravimetric Mode........................ 3 -Interlock - Volumetric Mode..........................3 -De-Interlock - Gravimetric Mode...................... 3 -De-Interlock - Volumetric Mode....................... 3 -Local Mode............................................3 2.2 Belt off-track monitoring............................. 3 2.3 Zero Setting............................................ 4 2.4 Linearisation of belt load............................ 4 2.5 Programmable Scale Control............................ 4 2.6 Error Messages.......................................... 4 2.7 Scale types............................................. 4 2.7.1 Directly extracting Weigh Feeder................ 4 2.7.2 Weigh Feeder with pre-feed regulation........... 4 2.7.3 Flow metering device............................5 2.7.4 Batch operation................................. 5 Interfaces.................................................. 5 3.1 Computer Interface................................. 5 3.2 Pulse outputs.......................................... 5 3.3 Analog outputs........................................5 3.4 Digital I/O............................................ 6
2.0
3.0
1.0
Principle
The Weigh Feeder consists of a conveyor belt whose material load is continuously weighed with a measuring device. The mass flow is calculated from the product of Belt Load (Loadcell value) and belt speed (Tacho frequency). The amount of material being conveyed is controlled by controlling the belt speed. This is done by generating the setpoint and control signals to control a suitable drive controller. Belt speed is monitored to ensure that the required speed is being achieved by the drive controller. In addition to controlling the material flowrate, the system can also control a Pre-feeder to control the material bed-height 1.1 TUC-6 Weigh Feeder System, Overview:
The unit is operated using the TUC-6 keypad and the 2 line * 16 digit VFD display. The display values are called using fixed keys or displayed through pull-down selection. The Configuration of the system is determined by the parameter values. To do this, a selection is made from the fixed values in the configuration menus or a parameter is entered using the front keypad. 1.2 System Features
- Fail safe EEPROM memory for configuration parameters - Battery buffered RAM for working data - Date/Time in battery buffered Real Time Clock - Integrated keyboard and display - Data memory even with replacement of interface cards - Upto 24 inputs / 20 outputs - 2 Impulse outputs - Analog to Digital and Digital to Analog signal interfaces - Curve correction - Zero correction - Inbuilt PLC for easy adaptation to different control schemes - Alphanumeric Text displays for Fault diagnosis
Weigh Feeder with TUC-6 Electronics TUC6-010-EE23.1-R0 2.0 2.1 Functions Modes of operation Page 3 of 6
The system can operate in any one of the following 5 modes, i) Interlock - Gravimetric Mode
In this mode, the system operates through External setpoint in the form of analog 4-20 mA signal or setpoint through the serial interface. Start/Stop to the system is either through external digital Inputs or through the serial Interface. ii) Interlock - Volumetric Mode
In this mode, the system operation is un-regulated (Volumetric). Setpoint in this mode is from an external 4-20 mA signal and Start/Stop to the system is through external digital Inputs. iii) De-Interlock - Gravimetric mode.
In this mode, the system operates through setpoint entered through the TUC keypad. System Start/Stop is through the keys provided on the keypad. iv) De-Interlock - Volumetric mode.
In this mode, the system operation is un-regulated (Volumetric). Setpoint and Start/Stop is from the TUC keypad. v) Local Mode.
In this mode, Setpoint & Start/Stop commands to the system are from the Local Control station. In this mode, system operation is un-regulated (Volumetric) i.e. the setpoint from the Local control station directly varies the belt speed. 2.2 Belt off-track monitoring
Off-track running of the belt can be monitored via an external signal from the Belt tracking sensors to the control unit. 2.3 Zero setting
Belt related influences on the belt load can be compensated by means of zero correction. To do this, the correction process is started with the belt running idle. The zero correction value, with which the belt load is set off, is calculated automatically after the zero correction process. The zero correction is initiated from the front keypad. 2.4 Linearisation of belt load
If the load on the measuring cell is not linear in the whole range, the load can be laniaries by entering upto ten correction points. 2.5 Programmable Scale Control
To achieve optimum adjustment of the dosing control as per the customer's requirements, a PLC is built into the Controller. This enables digital signals within the control unit and to the process to be freely defined. Standard PLC programs are implemented internally for standard configurations. These may be called directly and used or modified to suit diverse application needs. 2.6 Error Messages
Faults/Errors caused by incorrect operations are displayed in clear text in the control display. Faults are also made available at the output in the form of potential free contacts. 2.7 Scale types
2.7.1 Directly extracting weigh feeder Material is extracted directly from a hopper, without a pre-feeding device. 2.7.2 Weigh Feeder with pre-feed regulation As a result of variation of belt speed, required for output regulation, a varying bed-height of material may occur on the conveyor belt. If a constant bed-height of material is
required or in the event of unfavorable material properties which do not permit direct extraction, pre-feed regulation is necessary. For this purpose, an output setpoint can be generated to control a pre-feed device. This output value is coupled to the flow regulator i.e changes in flow setpoint automatically adjusts the pre-feed device. 2.7.3 Flow metering device With flow metering devices no speed tachometer is available. Regulation of mass flow is realized by regulation of material load. In this mode, system operation is with fixed internal tachometer. 2.7.4 Batch operation By specifying a target quantity, it is possible to proportion individual batches. In this mode, proportioning is done as per the prescribed setpoint. After the target quantity of material has been conveyed, an alarm or automatic belt stop command can be generated. 2.7.5 Measuring Mode It is possible to bypass feed regulation and operate the unit only in measuring mode, for equipments like Belt Weighers. 3.0 3.1 Interfaces Computer Interface
It is possible to enable remote monitoring and control of the system, by connecting the unit to a master controller through the serial interface. Modbus RTU and Profibus protocol options are supported through use of optional modules. 3.2 Pulse Output
Two pulse outputs are available from the system corresponding to the quantity being conveyed. The resolution & pulse width of the Totaliser pulses are configurable. 3.3 Analog outputs
Analog outputs are available for display and/or measurement tasks. Upto 4 analog current outputs can be generated from the system. Each individual output can be selected to various measurement/control variables, such as Feeder setpoint, Pre-feeder setpoint, Material Feedrate, Belt loading, Belt Speed. 3.4 Digital I/O
A maximum of 24 inputs and 20 outputs are available for controlling the weigh feeder and other plant interlocks. Outputs are available corresponding to various status and fault conditions in the system.
OPERATORS MANUAL
TABLE OF CONTENTS
1.0 Keypad and display............................................. 2 1.1 Keypad................................................. 2 1.2 Display................................................. 4 Functions................................................... 5 2.1 Start.................................................. 5 2.2 Stop.................................................. 5 2.3 Zero setting.......................................... 6 2.4 Interlock/De-Interlock.................................. 6 2.5 Batch Operation...................................... 7 2.6 Error Acknowledgement................................. 7 Modes................................................................................................ 8 3.1 Local mode......................................................................................8 3.2 Remote mode..................................................................................... 8 3.2.1 Interlock - Gravimetric Mode..................................................... 8 3.2.2 De-Interlock - Gravimetric Mode................... 8 3.2.3 Interlock - Volumetric Mode...................... 8 3.2.4 De-Interlock - Volumetric Mode.................... 8 Parameter input............................................ 9 4.1 Control Parameters (SET1)............................ 9 4.2 Setpoint (SET2).................................................................................. 9 4.3 PF parameters (SET3)................................... 9 Error Messages............................................ 9 Abbreviations............................................... 11
2.0
3.0
4.0
5.0 6.0
OPERATORS MANUAL
Weigh Feeder with TUC-6 Electronics TUC6-010-EE23.2-R1 1.0 1.1 Page 2 of 11
Keypad and display Keypad
TUC-6 has a multi-function keypad; the definition of keys change as per the menu operations. Some keys have alphabets in the lower left hand corner. These are used in editing the PLC programs. The numbers 0 to 9 in the upper right hand corner of some keys are used for numeric entries. Characters/Symbols used in the keys have following meaning,
Display current setpoint
BB - Display Belt Load in %
Switch between Gravimetric / Volumetric selections
Display Actual Flowrate
Display Totaliser 1
Switch between Interlock/De-interlock modes Display Tacho Frequency Software_version: 2.0 (onwards) 2006-11-13
OPERATORS MANUAL
Display Totaliser 2 Start Zeroing in Manual/Local modes
Call online menus within Main_Program Cancel (CL) -In Main_Program, S1 value displayed in Line 2 is cleared -Used to Clear Fault displays -When used with 'Esc' key, is used to exit from menu. -Used to accept values modified in the SET menu. HOR -Selection of options from list. -'ENTER' key to accept Password value Start/Stop ESC -Used in combination with 'CL' key to exit from menu. -Used to discard values modified in the SET menu. -Display mV value in Calibration menu UP/DOWN - Scroll Menu/parameter list being displayed.
OPERATORS MANUAL
Weigh Feeder with TUC-6 Electronics TUC6-010-EE23.2-R1 1.2 Display Page 4 of 11
When the TUC-6 is powered on from the mains, the display "Transweigh" is shown for 5 secs. The system then displays either the Online Menu or the Offline menus, depending on the status of keypressed during the 5 secs. delay. -Press 'VER' to bypass 5 sec. delay & jump to Main_Program menu. -Press 'CL'to bypass 5 sec. delay & jump to Offline menus. If no key is pressed, the system enters Main_Program menu at the end of 5 sec. delay. a) In the Online menu - Main_Program, the following parameters can be displayed by selecting keys from the keypad, 'W','BB','X', 'S1','S2','T': Wc BB X S1 S2 Ta Current setpoint in units selected Belt load value in % Actual flowrate value in units selected Totaliser1 value Totaliser2 value Weigh Feeder Tacho frequency in Hz.
Other Values are selectable with the '' key. These values are shown below with their designated names. W1 W2 W3 Wm Xd Y0 Y1 BS Date Time Q q De-Interlocked setpoint Interlocked setpoint Interlocked setpoint through SIO Manual mode setpoint Deviation in % Weigh Feeder drive setpoint in % Pre-feeder drive setpoint in % Belt Speed in m/sec In format yy-mm-dd In format Hour:Minute Quantity Setpoint Dribble setpoint
OPERATORS MANUAL
Weigh Feeder with TUC-6 Electronics TUC6-010-EE23.2-R1 b) Page 5 of 11
Error messages The error messages have the highest priority, i.e they are not overwritten by any other display and remain in display until they are acknowledged. The error messages are listed in section 5.0 "Errors Messages" of this manual.
2.0 2.1
Functions Start
Conditions - Interlock input high Mode De-Interlock-Gravimetric De-Interlock-Volumetric Interlock-Gravimetric Interlock-Gravimetric Interlock-Volumetric Local Display - LED 'START' on. 2.2 Stop Start trigger 'Start' from TUC 'Start' from TUC 'Start' from external digital input Start' from superior computer (For configuration with Computer) 'Start' from external digital input Local pushbutton
Stop trigger for all modes -An Error condition leading to stop -Interlock input removed Stop trigger Mode De-Interlock-Gravimetric De-Interlock-Volumetric Interlock-Gravimetric Interlock-Gravimetric Interlock-Volumetric Local Display - LED 'START' off. 'Stop' from TUC 'Stop' from TUC 'Stop' from external digital input 'Stop' from superior computer (For configuration with Computer) 'Stop' from external digital input Local pushbutton
OPERATORS MANUAL
Weigh Feeder with TUC-6 Electronics TUC6-010-EE23.2-R1 2.3 Page 6 of 11
Zero setting With this key, Zero correction process is initiated.
Conditions - System in Local/De-Interlock-Volumetric mode - Belt started Display - LED over '>0<' flashing. Note: Zero setting operation can be canceled by pressing '>0<' key during zeroing process. With canceling, the old zero setting value is not lost. Operation: The zero setting runs for one belt revolution determined by the belt revolution time set in configuration. After zero setting operation, the mean value over the zero curve is calculated and the belt load is re-calculated with the zero correction value. An error message occurs when the correction limit is exceeded. 2.4 Interlock/De-Interlock With this key, it is possible to switch between the two modes. Display: Interlock : LED over 'Int./De-Int.' ON De-Interlock : LED over 'Int./De-Int.' OFF Note: Switching between the modes is only possible in Weigh Feeder Stop mode.
OPERATORS MANUAL
Weigh Feeder with TUC-6 Electronics TUC6-010-EE23.2-R1 2.5 Batch Operation Page 7 of 11
The Feeder can be selected for Batch mode operation. In this mode, a fixed quantity of material can be delivered by the Feeder and an alarm generated or the system stopped, if required. The quantity setpoint values are entered in SET2 menu. Two Setpoint parameters, 'Q1' & 'Q2', are provided in the system. Selection between 'Q1' and 'Q2' is through marker 'M024'. Each Quantity setpoint (Qx) is associated with a corresponding Dribble value (qx). When operating in the Batch mode, an alarm is generated after delivering 'Q-q' quantity of material. 'q' is usually the amount of material overfed by the feeder after it is stopped. Conditions: - Weigh feeder configured for Batch mode operation Operation : When the feeder is started in Batch mode, Totaliser, S1 is cleared if greater than 'Q'. Totaliser, S1 increments upto 'Q-q' and "Quantity Over!" is displayed. Marker 'M059' is set. This marker can be used in SPSS to stop the feeder if requried. Pressing 'CL' key clears the alarm display and resets 'M059' marker if set. 2.6 Error Acknowledgment
'CL' key is used to acknowledge errors. Display The Error text message is displayed in line 2. All Error texts are characterised with "!" in the last column Note: If an error is already in the display, further errors will not be displayed until this error has been acknowledged.
OPERATORS MANUAL
Weigh Feeder with TUC-6 Electronics TUC6-010-EE23.2-R1 3.0 3.1 Modes Local mode Page 8 of 11
This mode is invoked by a "Low" signal on the 'Local/Remote' digital input. In this mode, Setpoint & Start/Stop commands to the system are from the Local Control Station. System operation in this mode is unregulated. Zero setting operation is possible in this mode. 3.2 Remote mode
This mode is invoked by a "High" signal on the 'Local/Remote' digital input. This mode is further sub-divided into the following four modes. 3.2.1 Interlock - Gravimetric mode This mode is invoked by a "Low" signal on the 'Int/De-Int' digital input & "High" signal on 'Vol/Grav. Select' digital input or selected through TUC-6 keypad. Selection either from External Inputs or from Keypad is defined in the Configuration Menu. In this mode, Start/Stop & Setpoint are through external I/Os 3.2.2 De-Interlock - Gravimetric mode This mode is invoked by a "High" signal on the 'Int/De-Int' digital input & "High" signal on 'Vol/Grav. Select' digital input or selected through TUC-6 keypad. Selection either from External Input or from Keypad is defined in the Configuration Menu. In this mode, Start/Stop & Setpoint are through the keypad. 3.2.3 Interlock - Volumetric mode This mode is invoked by a "Low" signal on the 'Int/De-Int' digital input & "Low" signal on 'Vol/Grav. Select' digital input or selected through TUC-6 keypad. Selection either from External Input or from Keypad is defined in the Configuration Menu. System operation in this mode is unregulated. In this mode, Start/Stop & Setpoint are through external I/Os. 3.2.4 De-Interlock - Volumetric (Manual) mode This mode is invoked by a "High" signal on the 'Int/De-Int' digital input & "Low" signal on 'Vol/Grav. Select' digital input or selected through TUC-6 keypad. Selection either from Software_version: 2.0 (onwards) 2006-11-13
OPERATORS MANUAL
External Input or from Keypad is defined in the Configuration Menu. System operation in this mode is un-regulated. In this mode, Start/Stop & Setpoint are through the keypad. Zero setting operation is possible in this mode. 4.0 Parameter input
Operating the menus via the TUC keys is described in the Operating Instructions section of this manual (see Menu Operations, section 2.0) 4.1 Control Parameters (SET1)
In this menu, control parameters related to the PI regulator are set. 4.2 Setpoint (SET2)
In this menu, it is possible to input the setpoints for system operation. The setpoints are entered with the units and decimal points as selected in configuration. Operating mode De-Interlock - Volumetric De-Interlock - Gravimetric 4.3 Valid setpoint Wm W1
Pre-feeder parameters (SET3)
Parameters for Pre-feeder control are set in this menu. 5.0
Error Messages display. Error
Errors are characterised by "!" display in the last position of the messages occurring during operation are shown below. "Message "Tacho Fault !" !" = > = Meaning Help Tacho freq. input missing
OPERATORS MANUAL
Weigh Feeder with TUC-6 Electronics TUC6-010-EE23.2-R1 "Drive Int. Err. "Belt Tracking !" !" > = > = > "Corr.>set-limit "Corr. aborted "Deviation " AIO1 Commun. "EEProm read "EEProm write "Integration Off " Overload " Underload !" !" !" !" !" !" !" !" !" = > = > = > = > = > = > = > = > = > "Emergency Stop "Anal. i/p Error !" !" = > = Page 10 of 11 Check tacho, tacho cable external drive disturbance check drive interlocks Belt off track message at input for time greater than permissible time Set belt Zero correction error greater than permitted Check belt load, repeat zero correction Zero correction cycle aborted. Check Tacho input, Drive Interlock input. Actual capacity outside the tolerance band longer than =deviation time= check load, setup Communication error AIO card Check AIO connection, interface, setup Data and checksum in EEProm do not match Enter parameters anew. Not possible to write to EEProm Hardware fault. Replace unit. Downstream Interlock input not present Check input. BB > MAX. LOAD value set in Measuring param. Check material on belt BB < MIN. LOAD value set in Measuring Param. Check material on belt Emergency stop switch pressed Check Switch status, cable. This error occurs during AIO scaling if Max_Value selected is lower than Min_Value or Communication error with Analog input module Check analog input value, Interface
> Software_version: 2.0 (onwards) 2006-11-13
OPERATORS MANUAL
Weigh Feeder with TUC-6 Electronics TUC6-010-EE23.2-R1 " No PLC File "In-correct Inst "Quantity Over "Inverter1 Comm. "Inverter2 Comm. " DIO 1 Commun. " DIO 2 Commun. " SIO Communicat. " Master Commun. " Belt Slip !" !" !" !" !" !" !" ! !" !" = > = > = > = > = > = > = > = > = > = > 6.0 '....' =....= LED VFD SPSS Page 11 of 11 No assembled PLC file in memory. Enter PLC program, Assemble Error found in PLC file during assembly. Check line indicated. Totaliser S1 greater than Q-q value set. Check set values Communication error with Inverter1 Check connection, interface, setup Communication error with Inverter2 Check connection, interface, setup Communication error with DIO card 1 Check connection, interface, setup Communication error with DIO card 2 Check connection, interface, setup Communication error with SIO module Check connection, interface, setup Communication error between SIO & Modbus master Check connection, interface, setup Tail Pulley tacho input missing for time greater than permissible time Set belt
Abbreviations key... Parameter in configuration Light emitting diode Vacuum Fluorescent display (16 characters X 2 line) PLC program
COMMISSIONING INSTRUCTIONS
TABLE OF CONTENTS
1.0 2.0 3.0 First start................................................ 2 Parameters.................................................... 2 OFFline parameters......................................... 2 3.1 Password................................................2 3.2 Measuring Parameters................................... 3 3.3 Configuration Parameters.............................. 4 3.4 Interface............................................... 7 3.5 Analog input............................................ 10 3.6 Analog Output......................................... 10 3.7 Calibration........................................... 11 3.7.1 Calibration using weights......................... 11 3.7.2 Calibration without weights...................... 12 3.8 Calibration correction.................................. 12 3.9 System data............................................ 13 ONline parameters........................................... 14 4.1 Main program.......................................... 14 4.1.1 SET1............................................. 15 4.1.2 SET2............................................. 16 4.1.3 SET3............................................. 17 4.1.4 SET4............................................. 18 4.1.5 SET5............................................. 19 4.1.5 Zero Correction................................. 19
4.0
1.0
First start
When starting for the first time the following procedure must be followed: Steps 1.1 Check jumpers 1.2 Connect peripheral appliances 1.3 Enter parameters 1.4 Enter PLC Program 1.5 Calibrate system 1.6 Zero setting 1.7 Calibration correction 2.0 Parameters
See "Menu Operations" (section 2.0) for description about menu parameters and operations. 3.0 3.1 OFFline parameters Password
=Password= When power is turned ON and 'CL' key is pressed during the 5 sec. delay, the system comes to this option Press '/' keys to scroll through the different menus. To select any menu,Press '' key with that menu being displayed in the 2nd display line. =Enter Password= Enter the 5 digit Password and press '' key. The OFFline parameter access is disabled if the wrong password is entered. The same can be accessed only on right password entry. Once enabled, the parameters can be accessed till the ONline menu is accessed or power to the system is turned 'Off'. Display: "Y" - On right password entry "N" - On wrong password entry
3.2
Measuring parameters
=M. RANGE= Measuring Range The voltage rise is defined as the voltage difference which the measuring cell delivers between a belt loaded with 100% load and an empty belt.The value to be set is the next lowest setting value to this value. Select : 1.0 / 3.0 / 6.0 / 12 mV =Units,X= Units,Capacity Designation of all capacity displays. If "t/h" is selected as designation,all other values are automatically defined with "t". Select : kg/h, t/h =D. Pt,X= Decimal point,capacity Definition of the position of the decimal point within the 4 digit capacity display. Select : 000000 / 00000,0 / 0000,00 / 000,000 =Nom. Cap.= Nominal capacity Flow rate with 100% belt load and nominal tacho frequency = 100% capacity. Input : Numerical value of capacity =D. Pt,S1=Decimal point, Totaliser 1 Definition of the position of the decimal point within the 6 digits display of Totaliser 1 Select : 000000 / 00000,0 / 0000,00 / 000,000 =Units,S1= Units ,Totaliser 1 Definition of designation for resettable Totaliser 1 Select : kg / t =D. Pt,S2= Decimal point, Totaliser 2 Definition of the position of the decimal point within the 6 digits display of Totaliser 2 Select : 000000 / 00000,0 / 0000,00 / 000,000
Weigh Feeder with TUC-6 Electronics TUC6-010-EE23.3-R2 =Units,S2 = Units ,Totaliser 2 Definition of designation for non-resettable Totaliser 2 Select : kg / t =Freq. I/P= Frequency input source Select : Fixed - Tacho frequency is simulated internally (1000 Hz) Tacho - Tacho frequency is read from tacho input Inv. Tacho frequency is read from the inverter (Requires inverter to be connected to TUC-6 on the RS-485 serial bus) =Tacho Freq= Nominal tacho frequency Input : 0-9999 Hz (Only used for fixed frequency = "No") =Belt Speed= Nominal Belt speed in m/sec at nominal tacho frequency Input : 0-0,000 m/s (Only used for fixed frequency = "No") =Max. Load= Limit maximum load Maximum limiting value causing error message "Overload!". Input : Numerical value in % =Min. Load= Limit minimum load Minimum limiting value causing error message "Underload!". Input : Numerical value in % 3.3 Page 4 of 20
Configuration Parameters
=Reg. mode= Regulation mode Definition of 2nd regulator Selection : Direct Removing = no 2nd regulator Feed regulation = With supplementary regulation of load
=Batch mode= Batch mode In Batch mode operation feeder can be made to generate an alarm or stop, after delivering a set quantity of material. Quantity setpoints for this operation are entered in SET2 menu in Main_Program. Selection :Yes = Weigh feeder selected for Batch operation No = Weigh feeder not selected. =Rev. Time= Belt revolution time Time for one revolution of the belt with nominal tacho frequency. Input : Numerical value in 0,1 s steps =No. of Rev.= No. of belt revolutions Number of revolutions for control measurement. Input : numerical value with 2 digits =Zero Limit= Zero correction limit This parameter determines the number of percentage points by which the zero correction value may differ from the zero value. If the difference is greater, the error message "CORR.>SET-LIMIT!" is displayed and the zero value calculated is discarded. Input : numerical value in % =Belt track= Belt tracking monitoring time Time for monitoring the belt tracking input. Input : numerical value in 0,1 sec. steps =Run Time= Tacho supervision time Time for monitoring the tacho input pulses. Input : 0-999.9 s in 0.1s steps (No monitoring with input "0") =Impulse1= The impulse output can be assigned to Totaliser 1, Totaliser 2 or kept Off. Select : 1 / 2 / Off =On_Time= The impulse ON time can be set using this parameter. Select : 50mS / 100mS / 250mS / 500mS
=Impulse2= A 2nd Inpulse output can be enabled/disabled with this parameter. Select : NO / YES =I1 mode= Selection of analog output from the TUC-6 unit (I1) Select : 0-20 / 4-20 mA =I1 value= I1 value Definition of analog output type at I1 Select : TPH/BB/Ta/Wc/WFsp/PFsp NOTE : TPH - Actual Material Flowrate BB - Instantaneous Belt Load Ta - Weigh feeder Tacho frequency (Belt speed) Wc - Current setpoint WFsp - Weigh feeder drive setpoint PFsp - Prefeeder drive setpoint =Limit 1= Limit value 1 The potential free output for Belt load value above this value. Select : Numerical value in % =Limit 2= Limit value 2 The potential free output for Belt load value above this value. Select : Numerical value in % =L_Delay= Hysteresis time Time after which the output goes high when Belt load remains above limit values 1 or 2 Input : Numerical value in 0,1 sec steps. =Clear,S2= Clear Totaliser2 value Input : No / YES
=Meas_Filt= Meas_Filt provides Loadcell input signal filtering. Select 0 to de-select filtering. Select: 0/ 1 / 2 / 3 / 4 / 5 steps =Display_Step= Digit step provides damping of display and analog output values. Select : 1 / 2 / 3 / 4 / 5 / 6 steps =Mode_Sel= This parameter defines the selection for switching between Interlock/Un-Interlock & Gravimetric/Volumetric modes. Selecting "External" defines mode selections from external digital inputs. Selecting "Internal" defines mode selections through TUC-6 keypad. Select : External/Internal =Setpoint %= Multiplying factor for setpoint to Drive in Volumetric modes. Select : Numerical value in % =CTRL_Mode= Selects the control mode for WF drive. Selecting "PI" selects PI control action. Selecting "tCTRL" selects "TRANScontrol" action for WF drive control. In this mode, the drive setpoint is automatically adjusted by the controller based on an internal algorithm. Selecting Off for this parameter, TUC-6 works in measuring mode, bypassing corrective action on drive setpoint. With Off, SET1, SET2, SET3 menus are disabled. Select : PI / tCTRL / Off 3.4 Interface
=No_Of_Inv= Inverter selection Inverters can be connected to TUC-6 serial interface. When connected to serial interface, drive setpoint, start/stop, feedback signals are exchanged between TUC & Inverters via the serial interface only. The number of inverters connected to TUC-6 is selected with this parameter. Select : 0 / 1 / 2 NOTE : Software_version: 3.0 (onwards) 2008-01-03
i) The address for each Inverter interfaced with TUC-6 should be separate. Address for Inverters are selected with the help of =Address= parameter in Inverter. ii) The =Address= parameter in Inverter should be set to '01' for the 1st Inverter and '02' for the 2nd Inverter. iii) TUC-6 communicates with Inverters at 19200 baud, 8 bits, 1 stop, NO parity. =Inv_Type= Select Inverter type Select the Inverter type with this parameter. Select : ATV28 / MM4 / J7/V7 / ATV31 / PF4/40 / ACS550 =No_Of_DIO= Digital I/O card interface The number of DIO cards interfaced TUC-6 is selected with this parameter. Select : 0 / 1 / 2 NOTE: i) The address for each DIO card interfaced with TUC-6 should be separate. ii) Address for DIO cards are selected with the help of jumper plugs on the DIO card. (Refer "Appliance Description" for jumper selection details) =No_Of_AIO= Analog I/O card interface The number of AIO cards interfaced TUC-6 is selected with this parameter. Select : 0 / 1 / 2 / 3 NOTE: i) The address for each AIO card interfaced with TUC-6 should be separate. ii) Address for AIO cards are selected with the help of jumper plugs on the AIO card. (Refer "Appliance Description" for jumper selection details) =Ext_SP= External setpoint Selects source of external analog setpoint Select : OFF / AIO1 / Inverter =SP_Filter= Filter step provides damping for analog input setpoint value. Select : 0 / 1 / 2 in seconds =AIO1 output= Definition of analog output type from the 1st AIO card Select : TPH/BB/Ta/Wc/WFsp/PFsp
=AIO1 mode= Selection of analog output from the 1st AIO card Select : 0-20 / 4-20 mA =AIO2 output= Definition of analog output type from the 2nd AIO card Select : TPH/BB/Ta/Wc/WFsp/PFsp =AIO2 mode= Selection of analog output from the 2nd AIO card Select : 0-20 / 4-20 mA =AIO3 output= Definition of analog output type from the 3rd AIO card Select : TPH/BB/Ta/Wc/WFsp/PFsp =AIO3 mode= Selection of analog output from the 3rd AIO card Select : 0-20 / 4-20 mA =SIO_INT= SIO Interface Selection of the peripheral device at SIO module Select: Off / Modbus / Profibus =SIO_BAUD= SIO baud rate Setting the baud rate at serial interface Select: 4800 / 9600 / 19200 baud =SIO_SETUP= SIO data format Definition of data format at serial interface Select: Data Stop Parity 8 1 None 8 1 Even 8 1 Odd =SIO_ADDR= SIO address Address of controller when connected to a multi-drop bus on the SIO module Input: Numerical value from 00-99. =SIO_MONITOR= SIO monitoring time Software_version: 3.0 (onwards) 2008-01-03
Weigh Feeder with TUC-6 Electronics TUC6-010-EE23.3-R2 Monitoring time for communication. Input: Numerical value in 1 sec. steps Note: IF "00" selected, SIO communication monitoring is disabled. In systems, where "Remote Interlock" mode of operation is used, i.e Setpoint & Start/Stop through SIO, this parameter should not be set to "00". 3.5 Analog input Page 10 of 20
=Re-Calibrate?= AIO1 re-calibration The calibration menu is released on selecting '' for this parameter.Pressing '' key will not affect the existing values stored in memory. Selection : / =Min_Value= AIO1 Min. value With the analog input at the minimum value, Press '' key to accept the value as 0% value. =Max_Value= AIO1 Max. value With the analog input at 100%, press '' key to accept the value as 100%. 3.6 Analog Output
=Re-Calibrate?= Analog output re-calibration The analog output calibration menu is released on selecting '' for this parameter.Pressing '' key will not affect the existing values stored in memory. Selection : / =Min_Value= I1 Output Min. value This is used to adjust the minimum output value at the Analog output I1. The present analog output count value is displayed in the display 2nd line. Press '' key to increase/decrease the analog output value. Esc key is used to toggle assignment of '' key as increase or decrease key. Press to save value and proceed further. =Max_Value= I1 Output Max. value This is used to adjust the maximum output value at the Analog output I1. The present analog output count value is displayed in the display 2nd line. Press '' key to increase/decrease the analog output value. Software_version: 3.0 (onwards) 2008-01-03
Esc key is used to toggle assignment of '' key as increase or decrease key. Press to save value and proceed further. 3.7
Calibration
Calibration of the scale can be carried out in 2 ways, i) Using Calibration weights ii) Using previous calibration values. In this mode, previous calibration values , viz 'COUNT_DL' and 'COUNT_BL', are used to calibrate the scale. =Re-calibrate? ->= Recalibrate? The 2 modes in calibration menu are initiated by the following procedure, i) ii) Mode 1 - Calibration using Weights Press ''. Pressing '' key will exit the menu without recalibration.
Mode 2 - Calibration without weights Press keys '1','2','3' and '' in sequence. Pressing '' key will exit the menu without recalibration. Input : As above 3.7.1 Mode 1 - Calibration using Weights =Dead load= The actual value is displayed in terms of "d" in the lower display line.With a completely empty belt , delete the dead load with the '' key.The actual value displayed then shows 0000 d; the dead load is compensated.Press '' key to switch further. Input : None TIP : Press 'ESC' key to display the actual value in mV. =Calibration load= Calibration load The actual value is displayed in terms of "d" in the lower display line.Load a known weight and wait for a steady display. The display then shows the actual value on the left and is ready to accept the new value.
Weigh Feeder with TUC-6 Electronics TUC6-010-EE23.3-R2 CALIBRATION LOAD 1230 => 0000 Enter the calibration load value on the right hand side. A value of 2000 corresponds to 100% Belt load.Scale the input value according to the calibration load.Conclude the calibration procedure with '' key.The value entered is saved on exit. Input : Numerical value of calibration load in terms of "d". TIP : Press 'ESC' key to display the actual value in mV. 3.7.2 Mode 2 - Calibration without Weights =Count_DL= Dead Load Count The Dead Load is displayed in terms of internal calibration counts. The numerical keys can be used to change this value. Press '' key to switch further. Input : Numerical value =Count_BL= Belt Load Count The Belt Load corresponding to 100% load is displayed in terms of internal calibration counts. The numerical keys can be used to change this value. Press '' key to switch further. Input : Numerical value 3.8 Calibration correction Page 12 of 20
If measurement of the momentary load shows non-linear characteristics, correction in order to increase the linearity is possible. For this upto 10 measuring points can be taken and stored from 0....100% capacity. Between these measuring points, the curve is then linearized. To start the calibration correction process, calibrate the system. Take a measuring point e.g at 20% capacity and operate the system at 20% of nominal capacity. Switch on the capacity display on the unit and note the average indicated capacity. Bypass a determined quantity (at completed belt revolutions) and reweigh it using a
static weigher. Take the measurement time by a stop watch. From the actual conveyed capacity and the time taken, calculate the true conveying capacity. Conveying capacity (t/h) = Reweighed quantity (t) Time (sec) x 3600
Input the displayed value (S1)and the measured value in the unit. Repeat the procedure for other calibration points,if necessary. =Curve_Correction= =Edit ->= Press '' key to enter the curve correction menu. Press '' key to exit the menu. Pressing '' key will display the correction points as shown, N DISP MEASURED 0 0123,00000,0 "N" - The correction point number,from 0 to 9
"DISP." - Input for quantity of conveyed material as displayed Input : Numerical value in units & resolution of S1. "MEASURED" - Input for measured quantity of material using a static scale. Input : Numerical value in units & resolution of S1. Press '" key to increment to the next correction point. After 10 correction points are displayed, next '" press will display the following in the lower line, "Exit ->" Press '' to exit the menu and '' to move to correction point number 0 3.9 System data
=CPU crystal= CPU crystal frequency is displayed Input : None =S/W Ver.= Software version Software_version: 3.0 (onwards) 2008-01-03
Weigh Feeder with TUC-6 Electronics TUC6-010-EE23.3-R2 Display of software version Input : None =Date= The date can be changed through this parameter. Input : Numerical value in format YY:MM:DD =Time= The system time can be changed through this parameter. Input : Numerical value in format HH:MM:SS 4.0 ONline parameters Page 14 of 20
If 'CL' key is not pressed during the 5 sec. power on delay, system goes to the ONline mode when power is switched ON. 4.1 Main Program
The display in the ONline mode can be switched directly by using keys 'W','BB','Ta','X', 'S1' and 'S2'. Other parameters are called by pressing '' key. The following parameters can be displayed in this mode, X Actual flowrate value in units selected Totaliser1 value Totaliser 2 Belt load value in % Weigh Feeder Tacho frequency in Hz. Belt Speed in m/sec Un-Interlocked setpoint Interlocked setpoint Remote, Interlocked setpoint Manual mode setpoint Current setpoint Deviation in % WF drive setpoint in % PF drive setpoint in %
S1 S2
BB Ta BS W1 W2 W3 Wm Wc Xd Y0 Y1
Date Time Q q 4.1.1 SET1
In format yy-mm-dd In format Hour:Minute Quantity setpoint. Dribble setpoint.
This menu allows access to the PI regulator of the system. The P-share of the regulator is represented by =Amplification P1= and the I-share by =Reset Time I1=. For Weigh Feeders with Feeding regulation or level regulation, a second regulator is implemented in the system to regulate the material on the belt or the pre-hopper content to a defined level. The parameters for second regulator are represented by =Reset Time I2= and =Amplification P2=. Since regulator1 and regulator2 mutually influence each other,an evaluation factor =Regulator Tracking= must be entered. This establishes a coupling between the output value for the drive speed setpoint and the output value for the feeding device. A setpoint change can thus be followed quickly. Note: SET1 menu is disabled if =CTRL_Mode= parameter in Configuration menu is selected Off. =Reset Time I1= "I" time of the PI regulator for belt speed setpoint.If this value is zero, the "I" part is ignored in the regulator action. Input : Numerical value in 0,1 sec steps =Amplification P1= "P" part of the PI regulator for belt speed setpoint. Input : Numerical value in 0,1 steps =Deviation Limit= Tolerance range around the actual flow rate. Input : Numerical value in percent =Deviation Time= Maximum time that the actual flow rate is allowed to remain outside the tolerance range. At the end of this time, the scale trips due to "Deviation" error. Input : Numerical value 0,1 sec steps Software_version: 3.0 (onwards) 2008-01-03
=Reset Time I2= Similar to =Reset Time I1= =Amplification P2= Similar to =Amplification P1= =Dead Band= % Error band for which no control action takes place on the drive setpoint. Input : Numerical value 0,1 % steps 4.1.2 SET2 This menu allows access to setpoints effective in different modes. The actual setpoint for system operation is dependent on the operational mode. Note: SET1 menu is disabled if =CTRL_Mode= parameter in Configuration menu is selected Off. =W1= De-Interlock - Gravimetric setpoint Setpoint W1, can be entered in the units and resolution selected in config. Input : Numerical value,4 digit number =Wm= De-Interlock-Volumetric (Manual) setpoint Setpoint Wm, can be entered in the units and resolution selected in config. Input : Numerical value, 4 digit number =Capacity Limitation= The setpoint input can be scaled from 0 to 100% using this parameter. Input : Numerical value in % =Q1= Quantity setpoint1 Setpoint Q1, can be entered in the units and resolution selected of S1. Input : Numerical value, 6 digit number =q1= Dribble setpoint1 Setpoint q1, can be entered in the units and resolution selected of S1. Input : Numerical value,6 digit number =Q2= Quantity setpoint2 Setpoint Q2, can be entered in the units and resolution selected of S1. Software_version: 3.0 (onwards) 2008-01-03
Weigh Feeder with TUC-6 Electronics TUC6-010-EE23.3-R2 Input : Numerical value, 6 digit number =q2= Dribble setpoint2 Setpoint q2, can be entered in the units and resolution selected of S1. Input : Numerical value, 6 digit number 4.1.3 SET3 This menu allows access to pre-feeder control parameters. Note: SET1 menu is disabled if =CTRL_Mode= parameter in Configuration menu is selected Off. =BB_Limit= Used for Weigh Feeder with "Feed regulation" mode selected. When Belt Load value is less than this value, the pre-feeder is started with a fixed setpoint, for time defined by parameter =BB_Delay=. After this time period, the setpoint value changes as per the 2nd PI regulator settings. The initial setpoint for Pre-feeder is defined by parameter =BB_Setpnt=. Input : Numerical value in % =BB_Delay= Description as above. Input : Numerical value in seconds. =BB_Setpnt= Description as above. Input : Numerical value in % =BB_Control= This parameter determines the level about which Belt Load regulation takes place. Input : Numerical value in % =BB_Band= Percentage Belt loading band within which no correction of the 2nd PI regulator takes place. Input : Numerical value in 0,1 % steps Page 17 of 20
=PF_Limit= Multiplying factor for limiting maximum setpoint to prefeeder drive. Set value equal to 100,0 % for maximum PF setpoint equal to 10 Vdc; set correspondingly lower values for clamping maximum PF setpoint value. Input : Numerical value in % =Reg_Type= PI / WSP / DSP This parameter selects the control action of 2nd regulator. Select, PI - Pre-feeder drive control as per PI control action WSP - pre-feeder drive setpoint tracks the current WF setpoint,Wc DSP - pre-feeder drive setpoint tracks the WF drive setpoint Select : Use '' key to select =Regulator Tracking= When WSP or DSP is selected for parameter =Reg_Type=, pre-feeder drive setpoint tracks the selected variable by a multiplying factor defined by this parameter. Input : Numerical value in 0,1 % steps 4.1.4 SET4 This menu allows access to certain offline parameters. These paramters may be viewed/edited in this menu. Entry to this menu is allowed only after entry of the 5 digit system password. =Count_DL= The Dead Load count value is displayed in terms of internal calibration counts. Input : Numerical value =Span_Cnt= The Belt Load corresponding to 100% load is dispayed in terms of internal calibration counts. Input : Numerical value in count =Rev. Time= Belt revolution time Time for one revolution of the belt with nominal tacho frequency. Input : Numerical value in 0,1 s steps Software_version: 3.0 (onwards) 2008-01-03
=Drv_Const= Used with "tCTRL" control mode for WF drive. Select the initial drive setpoint value with this parameter. Input : Numerical value in %. =tCTRL_Cnt= Used with "tCTRL" control mode for WF drive. Select the speed of control action with this parameter. Input : Numerical value in 01 step 4.1.5 SET5 This menu displays the status of Digital Inputs, Digital Outputs, Markers and Timer bits. E00_ 9 2 A00_ 5 0
Bit status 0 is indicated by and Bit status1 is indicated by the corresponding bit number. Example: In the above display, E002, E009, A000 & A005 are with status 1 while all remaining bits are with status 0 Press key to switch the 2nd line display to next block Press or to scroll the display lines Press either Esc or CL to exit and return to Main_Program 4.1.6 Zero correction Since the belt conveyor scale shows system related oscillation around the zero position, the zero point is corrected during one belt revolution in order to improve the measuring precision. The deviation of the zero point is measured and stored with a plus or minus prefix. This value is used to correct the momentary load during each measuring cycle. Zeroing can be started with the system in "Local" or "Manual" mode and in "Start" condition. Press key to initiate the zero correction cycle. Software_version: 3.0 (onwards) 2008-01-03
When zero correction is in progress, deviation of zero point is displayed continuously. At the end of the zero correction cycle, the average deviation is displayed in percent. If the deviation is greater than the =Zero_limit= parameter, an error message is displayed and the value calculated is discarded. Zero correction has to be repeated. Press key to stop zeroing in progress.
MENU OPERATIONS
TABLE OF CONTENTS
1.0 2.0 General............................................... 2 1.1 Parameter save...................................... 2 Parameter menus......................................... 2 2.1 OFFline parameters................................2 2.2 ONline parameters................................. 2 2.3 Parameter label...................................2 2.4 Menu structure.................................... 3 2.5 Keys inside the menu............................. 6 2.6 Calling and operating the menus................... 7 2.7 Menu operation example........................... 9
MENU OPERATIONS
Weigh Feeder with TUC-6 Electronics TUC6-010-EE23.4-R1 1.0 General Page 2 of 11
The Parameters are entered using the keypad and a 16 digit x 2 line display. The arrangement of parameters within the menus, options available for each parameters and writing the parameters are explained in the commissioning instructions. 1.1 Parameter save
The parameters of the system are stored in an EEPROM. On each power ON, the data in the EEPORM is checked with the contents of the Battery Buffered RAM. If a mismatch occurs, error message is displayed. Acknowledging the error, reloads the RAM from EEPROM. Instantaneous values during system operation are stored in the Battery buffered RAM. The parameters in a menu are automatically saved when the display is scrolled to display the next parameter. When the Online menu "Main_Program" is called,the parameters set in various menus are checked for logical settings.In case of mismatch, error message is generated.The corresponding parameter should then be correctly set. 2.0 Parameter Menus
The menu structure is divided into 2 categories, 2.1 OFFline parameters
These parameters can be changed only when the measuring mode is "OFF". 2.2 ONline parameters
These parameters can be changed even when the system is in operation. 2.3 Parameter Label
A differentiation is made between 2 types of parameters:
MENU OPERATIONS
Weigh Feeder with TUC-6 Electronics TUC6-010-EE23.4-R1 Parameter label 1. 2. 2.4 Parameter whose value is entered numerically Parameter whose value is selected from a list Menu structure Page 3 of 11 Display xxxxxxx Selection
The parameters are arranged in different menus. The menus and the parameter listing is as shown below. Power ON Password Enter Password Measuring Parameters Measuring range Units, Capacity Decimal point, Capacity Nominal capacity Decimal point, S1 Units, S1 Decimal point, S2 Units, S2 Frequency Input Nominal Tacho frequency Belt Speed Limit max. load Limit min. load Configuration Regulation mode Batch mode Belt revolution time No. of Belt Revolutions Zero correction limit Belt track monitoring time Tacho supervision time Impulse1 (S1,S2,OFF) On_Time for Impulse output Software_version: 2.0 (onwards) 2006-11-13
MENU OPERATIONS
Weigh Feeder with TUC-6 Electronics TUC6-010-EE23.4-R1 Interface Analog input Analog Output Re-Calibrate? Min_Value Max_Value Re-Calibrate? Min_Value No of Inverter Inverter Type No of DIO No of AIO Ext. Setpoint source Ext. SP filter AIO1 output AIO1 mode AIO2 output AIO2 mode AIO3 output AIO3 mode SIO Interface SIO Baud SIO Setup SIO address SIO monitor Impulse2 I1-Mode I1-Output Value Limit value1 Limit value2 Limit delay time Clear Totaliser2 Measurement FIlter Display Filter Step Mode selection (Internal/External) Setpoint %, Wm Ctrl_Mode Page 4 of 11
MENU OPERATIONS
Weigh Feeder with TUC-6 Electronics TUC6-010-EE23.4-R1 Calibration Recalibrate? Dead load set Calibration load set PLC Program Calibration correction Edit? N Displayed_value Measured_value System data CPU crystal frequency Software version Date Time Main Program Display Actual Flowrate,X Display S1 Display S2 Display Belt Load,BB Display WF Tacho Frequency,Ta Display Belt speed in m/sec,BS Display Internal setpoint,W1 Display External Setpoint,W2 Display Setpoint thr. X4, W3 Display Manual setpoint,Wm Display Current setpoint,Wc Display Deviation,X0 Display WF drive setpoint,Y0 Display PF drive setpoint,Y1 Display Date Display Time Display Quantity setpoint,Q Display Dribble setpoint,q SET1 Reset Time I1 Amplification P1 Deviation Limit Deviation Time Max_Value Page 5 of 11
MENU OPERATIONS
Weigh Feeder with TUC-6 Electronics TUC6-010-EE23.4-R1 SET2 SET3 Belt Loading Limit,BB_Limit Belt Loading delay,BB_Delay Initial PF setpoint,BB_Setpnt BB Load control,BB_Control Belt Load Band,BB_Band Max. PF setpoint,PF_Limit Regulation Type Regulator Tracking SET4 (Entry with Password) Dead Load count, Count_DL Span count, Span_Cnt Belt Revolution time Drive constant,Drv_Const tControl count value,tCTRL_Cnt SET5 -Display E,A,M,T variables status See "Commissioning Instructions" for descriptions of each parameter. 2.5 Keys inside the Menu -Entry into a Menu/Sub-menu or -Selection of various options available for that parameter -Saving an entry and/or -Move further in the menu list Software_version: 2.0 (onwards) 2006-11-13 W1,Un-interlocked setpoint Wm,Manual setpoint Capacity limitation,% Q1,Quantity setpoint1 q1,Dribble setpoint1 Q2,Quantity setpiont2 q2,Dribble setpoint2 Reset time I2 Amplification P2 Dead Band Page 6 of 11
MENU OPERATIONS
Weigh Feeder with TUC-6 Electronics TUC6-010-EE23.4-R1 ..... Page 7 of 11
-Numerical data input from the keypad -Exit from menu
SET 2.6 1.
-Call Online parameters from Main_Program menu
Calling and operating the menus Power On TRANSWEIGH Version_1.0
a]
Possibility 1 X = 00,00 t/h BB = 100,0 %
The system enters Main_Program menu after 5 Secs., if no key is pressed during this delay period. If 'VER' is pressed during the 5 sec. delay, the delay is bypassed. a.1] Password Press 'Esc' and 'CL' to exit the online menu and enter the offline menus. Exit to Offline menus is possible in Weigh Feeder 'Stop' condition. a.2] Password Enter Password Press key to enter the menu.
MENU OPERATIONS
All Offline menus are Password protected. Entry into the menu is allowed only if the right password is pressed. a.3] .. Password Enter Password
5 Digit PASSWORD entry using 1 TO 9 keys. a.4] Password Enter Password:Y If PASSWORD is right, the configuration menus can be accessed a.5] Password Measuring Param The Offline menus can be accessed by pressing '' key. Press 'Esc' and '' key to scroll the menu backwards. a.6]
M. Range 1,0 mV Press display line. a.7] M. Range Press to change this value. 3,0 mV key to enter the menu. The first menu parameter is displayed in the 2nd
MENU OPERATIONS
Weigh Feeder with TUC-6 Electronics TUC6-010-EE23.4-R1 a.8] Configuration Press 'Esc' and 'CL' to exit the sub-menu and enter the main menu list. b] b.1] Password The system enters the Offline menu directly, if 'CL' key is pressed during the 5 sec. delay. 2. Calling Online parameters from Main_Program menu STEP 1 Main_Program menu X = 00,00 t/h BB = 100,0 % STEP 2 SET Press IT_Time =000,0s P1_Gain =000,0% to return back to Main_Program Possibility 2 Page 9 of 11
2.7
Menu operation Example
Example : Change the digit step from 1 to 2 in the Measuring parameters menu. STEP 1 Enter Offline menu as per 2.6 above. Password
MENU OPERATIONS
STEP 2 Password Enter Password STEP 3 5digit password, using numerical keys STEP 4 Password Enter Password:Y Password Enter Password
Only on right password entry. STEP 5 Password Measuring Param STEP 6 M. Range 1,0 mV
STEP 7 M. Range 1,0 mV UNITS,X kg/h STEP 8 M. Range 1,0 mV UNITS,X t/h Software_version: 2.0 (onwards) 2006-11-13
MENU OPERATIONS
Weigh Feeder with TUC-6 Electronics TUC6-010-EE23.4-R1 STEP 9 UNITS,X D.Pt. X Step 9 saves the change made in the Units,X in Step 9. t/h 0000,00 Page 11 of 11
PARAMETER LISTING
Sr. No. 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 1.11 1.12 1.13 2.0 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10
Parameter Measuring parameters M. Range Units, X D. Pt, X Nom. Cap. D. Pt, S1 Units, S1 D. Pt, S2 Units, S2 Freq. I/P Tacho Freq. Belt Speed Max. load Min. Load Configuration Parameters Reg. Mode Batch mode Rev. Time No. of Rev. Zero Limit Belt track Run Time Impulse 1 On_Time Impulse 2
Value 1
Value 2
Software_version: 2.0 2006-11-13
PARAMETER LISTING
Sr. No. 2.11 2.12 2.13 2.14 2.15 2.16 2.17 2.18 2.19 2.20 2.21 3.0 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 3.12 3.13 3.14
Parameter I1 mode I1 value Limit 1 Limit 2 L_ Delay Clear, S2 Meas_Filt Disp_step Mode_sel Setpoint % Ctrl_mode Interface No_Of_Inv Inv_Type No_Of_DIO No_Of_AIO Ext_SP SP_Filter AIO1_Output AIO1_Mode AIO2_Output AIO2_Mode AIO3_Output AIO3_Mode SIO_Interface SIO_Baud
Value 1
Value 2
PARAMETER LISTING
Weigh Feeder with TUC-6 Electronics TUC6-010-EE23.5-R1 Sr. No. 3.15 3.16 3.17 4.0 4.1 4.2 5.0 5.1 5.2 6.0 6.1 Parameter SIO_Setup SIO_Addr SIO_Monitor Analog Output Min_Value Max_Value Calibration Count_DL Count_BL Calibration correction Displayed Value Measured Value 6.2 Displayed Value Measured Value 6.3 Displayed Value Measured Value 6.4 Displayed Value Measured Value 6.5 Displayed Value Measured Value 6.6 Displayed Value Measured Value 6.7 Displayed Value Measured Value 6.8 6.9 Displayed Value Measured Value Displayed Value Value 1 Page 3 of 5 Value 2
PARAMETER LISTING
Weigh Feeder with TUC-6 Electronics TUC6-010-EE23.5-R1 Sr. No. Parameter Measured Value 6.10 7.0 7.1 7.2 8.0 8.1 8.2 8.3 8.4 8.5 9.0 9.1 9.2 9.3 9.4 9.5 9.6 9.7 10.0 10.1 10.2 10.3 10.4 10.5 10.6 Displayed Value Measured Value System Data CPU Crystal S/W Version PLC Program SPSS_00 SPSS_01 SPSS_02 SPSS_03 SPSS_04 Main Program-SET1 I1_Time P1_Gain Dev_Limit Dev_Time I2_ Time P2_Gain Dead_Band Main Program-SET 3 BB_Limit BB_Delay BB_Setpoint BB_control BB_Band PF-Limit 11 MHz Ver_2.0 11 MHz Ver_2.0 Value 1 Page 4 of 5 Value 2
PARAMETER LISTING
Weigh Feeder with TUC-6 Electronics TUC6-010-EE23.5-R1 Sr. No. 10.7 10.8 Parameter Reg_Type Reg_Track Value 1 Page 5 of 5 Value 2
OPERATING INSTRUCTIONS - PLC

TABLE OF CONTENTS
1.0 Programmable Logic Controller................................ 2 1.1 Description........................................... 2 1.2 PLC Operation......................................... 2 1.3 Instructions.......................................... 3 1.4 Inputs,Outputs and Markers.............................. 4 1.5 Timers................................................. 4 Programming Functions........................................ 5 2.1 General................................................ 5 2.2 Functions............................................. 5 2.2.1 Assemble...................................6 2.2.2 Delete........................................ 6 2.2.3 Editor......................................... 6 2.2.4 Insert...................................... 7 2.2.5 List......................................... 7 2.3 Error Messages........................................... 8 Allocation of Variable...................................... 8 3.1 Inputs............................................... 8 3.2 Outputs................................................ 9 3.3 Markers................................................ 9 3.3.1 Input Markers................................ 9 3.3.2 Output Markers................................. 10 3.4 Timers.................................................. 11 Standard Programs and I/O Assignments................ 12 4.1 Standard Program 1...................................12 4.1.1 Program List - SPSS_00..........................12 4.1.2 I/O Assignment.................................... 13 4.2 Standard Program 1.................................... 14 4.2.1 Program List - SPSS_01..........................14 4.2.2 I/O Assignment.....................................15
2.0
3.0
4.0

Programmable Logic Controller Description
TUC-6 has an inbuilt PLC, that is used to control the Digital Inputs, Digital Outputs and Internal Memory Flags (Markers). The Programmable control system processes the instructions from the control program, SPSS. The Input data and Output data for the control program are physically in the TUC RAM, logically in the so called "process images". The instructions in the control program with the variables "A E M T" always refer to the process image in RAM. The programmable control system continuously operates on the control program in the following sequence, -Transfer hardware inputs to the TUC RAM -Execute instructions in the control program (SPSS) -Transfer output process image to the Hardware Outputs Several variable types are used in the PLC program. "A" stands for outputs, "E" for inputs, "M" for marker and "T" for timers. Addition of "N" (UN or ON) means that the associated variable is scanned for signal status "0" ; otherwise the scanning of variables is for signal status "1". 1.2
PLC Operation
The programmable control system consists of a 1_bit_wide BIT accumulator. Instructions in the PLC can be classified into two types; one type operating on the result of previous instruction (Result Instruction) and second changing the accumulator value (Command instruction).

The control program is always started with accumulator = "1". ' Command ' instructions change the accumulator value till a ' Result ' instruction is encountered. After execution of all ' Result ' instructions, accumulator is again made ' 1 ' and the sequence is continued Example: 000 001 002 003 004 005 : : 1.3 *SPSS01 UM 045 UM 068 UNE 050 =A 008 UE 000 ;Comment Line ;Command Instruction - Accumulator = '1' ;Command Instruction - 'AND' result of above instruction with M068 value ;Command Instruction - 'AND' result of above instr. with 'NOT'of E050 input. ;Result Instruction ;Command Instruction - Accumulator = '1'
Instructions Instruction UE xxx UA xxx UM xxx UT xxx UNExxx UNAxxx UNMxxx UNTxxx OE xxx OA xxx OM xxx OT xxx ONExxx ONAxxx Meaning AND operation with INPUT AND operation with OUTPUT AND operation with MARKER AND operation with TIMER AND + NOT operation with Input AND + NOT operation with Output AND + NOT operation with Marker AND + NOT operation with Timer OR operation with INPUT OR operation with OUTPUT OR operation with MARKER OR operation with TIMER OR + NOT operation with Input OR + NOT operation with Output Command Y Y Y Y Y Y Y Y Y Y Y Y Y Y Result N N N N N N N N N N N N N N

Weigh Feeder with TUC-6 Electronics TUC6-010-EE23.6-R2 ONMxxx ONTxxx SA xxx SM xxx RA xxx RM xxx RT xxx =A xxx =M xxx LT xxx SITxxx 1.4 OR + NOT operation with Marker OR + NOT operation with Timer SET Output SET Marker RESET Output RESET Marker RESET Timer Equate Output to result Equate Marker to result Load Timer xxx with value in next Instruction Start Timer with xxx sec. in ON-delay mode Y Y N N N N N N N N N Page 4 of 16 N N Y Y Y Y Y Y Y Y Y
Inputs, Outputs and Markers
These are one bit variables that can have status "LOW" (Logical 0) or "HIGH" (Logical 1). The differentiation between inputs and outputs is done by the "signal direction" on which these variables are based. Inputs are signals from "outside" to the control program, and outputs are signals from the control program to the external system. Thus inputs can only be read, while outputs can be allocated. Inputs and Outputs are available outside the TUC-6 system with the help of digital I/O card. Markers are internal variables and serve as memory within the control system. They are available outside the control system when they have been copied onto outputs. Markers are classified into Input Markers and Output Markers. Input markers are used to control the software execution while Output markers are derived as a result of the software execution. 1.5 Timers
Ten ON-delay timers are available in the system for timing functions.

Instruction "LT xxx" loads timer "xxx" if the result of previous instruction is "1". Instruction "SIT yyy" starts the previously loaded timer with time "yyy". Timers continue to run till the input condition is "1" or till the set time is over, which ever is earlier. After completion of set time, the respective Timer "Txxx" bit status is made "1". Timers are reset (Txxx is made "0") with "RT xxx" instruction. Instruction "RT xxx", if executed while timer is running, stops the timer. 2.0 2.1 Programming Functions General
The Programmable Logic Controller in TUC-6 serve to adjust the scale to the plant control logic. The control program can be edited via the TUC keypad and display. Designation of files in the PLC menu is as follows, SPSS - Source file containing lit of instructions SPSA - Assembler file after translation from SPSS 2.2 Functions
The following functions are available in the "PLC Program" menu, PLC EDITOR A, D, E, I, L Key. A D E I L Meaning Assemble Delete Editor Insert List Function Assembles SPSS file to generate SPSA file Delete SPSS file from memory Open editor for reading/altering SPSS file Append a std. SPSS file from EPROM to current SPSS file. List SPSS, SPSA file lengths

Weigh Feeder with TUC-6 Electronics TUC6-010-EE23.6-R2 2.2.1 Assemble This function is invoked by pressing 'A' in the PLC Editor menu. PLC EDITOR Assemble Press '' key to assemble the SPSS file in memory or 'VER' to exit without assembling. 2.2.2 Delete This function is invoked by pressing 'D' in the PLC Editor menu. PLC EDITOR Delete? Yes Press key to delete the SPSS file from memory or 'VER' to exit without deleting. 2.2.3 Editor Press 'E' in the PLC Editor menu, to edit the SPSS file in memory. The following functions are available within the Edit option, Key ESC + CL ESC + I ESC + D ESC + ANY OTHER KEY Keys used in this menu, Function Save and exit Insert blank line Delete line - The line indicated by cursor is deleted. Cancel "ESC" status Page 6 of 16

Weigh Feeder with TUC-6 Electronics TUC6-010-EE23.6-R2 Key 0 to 9 A,D,E,I,L,M,N,O,P,R,S,T,U,=,* UP DOWN HOR ESC 2.2.4 Insert This function is invoked by pressing 'I' in the PLC Editor menu. PLC EDITOR Insert SPSS=00 Standard SPSS files are resident in the EPROM memory, which can be used directly. These files are called into memory with the help of this function. Enter the SPSS file number to be inserted into memory and Press '' key. Press 'VER' key to exit command without inserting the file. 2.2.5 List This function is invoked by pressing 'L' in the PLC Editor menu. SPSS = 120 LINES SPSA = 050 BYTES Press any key to return back to the Editor menu. Function Numeric entry SPSS command characters Previous line Next line Scroll to next/prev character position based on ESC key status Used in combination with other keys. Page 7 of 16

Weigh Feeder with TUC-6 Electronics TUC6-010-EE23.6-R2 2.3 Error Messages Text In-correct Inst. 3.0 Meaning Assembling: non-existent address or instruction at the cursor line indicated. Page 8 of 16
Allocation of Variable
The variables are sub-divided into inputs, outputs, markers and timers. Free variables (read Markers) can be used by the control program as general purpose variables. 3.1 Inputs E000 to E007 E008 to E015 E016 to E019 E020 E021 E022 E023 E024 E025 E026 E027 E028 E029 E030 E031 E032 E033 E034 E035 E036 to E039 - DIO #1 Inputs - DIO #2 Inputs - Free ;Inverter #1 Inputs - LI1 input - LI2 - LI3 - LI4 - RL1 - RL2 - LI5 (J7, ATV31 & ACS550 Inverters only) - LI6 (ATV31 & ACS550 Inverters only) - Inverter Running (PF4 Inverter only) - RL3 (ACS550 Inverter only) ;Inverter #2 Inputs - LI1 input - LI2 - LI3 - LI4 - RL1 - RL2 - Free

Weigh Feeder with TUC-6 Electronics TUC6-010-EE23.6-R2 3.2 Outputs A000 to A007 A008 to A015 A016 A017 A018 A019 A020 A021 to A029 A030 A031 to A039 3.3 - DIO #1 Outputs - DIO #2 Outputs ;TUC-6 Outputs - RL1 (Totaliser 1 Pulse output, if selected) - RL2 (Totaliser 2 Pulse output, if selected) - RL3 - RL4 ;Inverter #1 Outputs - Start/Stop - Free ;Inverter #2 Outputs - Start/Stop - Free Page 9 of 16
Markers
Marker are classified into Input markers (M000 - M031) and Output markers (M032 M071). Input markers are read by the control program while Output markers are written by the control program. Reading access is allowed to both these types of markers. 3.3.1 Input Markers Marker M000 M001 M002 M003 M004 M005 M006 M007 M008 Meaning "1" Meaning "0"
Start via SIO Stop via SIO Free Free Accept Count_DL, Span_Count (Only with Profibus) Reset Totaliser1 Remote ON (Control through SIO) Zeroing Start Remote Mode Local Mode

Weigh Feeder with TUC-6 Electronics TUC6-010-EE23.6-R2 M009 M010 M011 M012 M013 M014 M015 M016 M017 M018 M019 M020 M021 M022 M023 M024 M025 M026 M027 M028 M029 M030 M031 3.3.2 Output Markers Marker M032 M033 M034 M035 M036 M037 M038 M039 Meaning "1" Load Disturbance Fault Belt Tracking Fault Drive Disturbance Deviation Disturbance General Fault Belt Slip Zeroing: Correction>Limit Zeroing: Aborted Meaning "0" Healthy Healthy Healthy Healthy Healthy Belt Track status-Healthy Emergency status-Healthy Local Start-WF Local Stop-WF Local Start-PF Local Stop-PF De-Interlock Mode Remote Start Downstream Interlock-Healthy Error Reset WF Drive Interlock-Healthy PF Drive Interlock-Healthy Material Low (Fault) Local Start-Vibrator Motor Gravimetric mode select Select Q1,q1 Free Free Free Free Free Free Free Fault Fault Page 10 of 16
Interlock Mode Stop Fault Fault Fault High Stop Volumetric mode Select Q2,q2

Weigh Feeder with TUC-6 Electronics TUC6-010-EE23.6-R2 M040 M041 M042 M043 M044 M045 M046 M047 M048 M049 M050 M051 M052 M053 M054 M055 M056 M057 M058 M059 M060 M061 M062 M063 M064 M065 M066 M067 M068 M069 M070 M071 3.4 Timers T000 to T009 are timers available for use in the SPSS program. Software_version: 3.0 (onwards) 2008-01-03 Free Feeder Selected Free Local Mode Gravimetric mode Interlock Mode Free Vibrator Start Limit Value 1 Limit Value 2 Overload Error Underload Error Free Free Free Free Zeroing: In Progress Zeroing: OK Free Quantity Reached Free Free Free Free WF-Start PF-Start WF-Start PF-Start System Healthy Free AI Card Communication fault PF Tacho Fault Stop Stop Stop Stop Fault Healthy Healthy (Blinking-Fault) (Blinking-Fault) Page 11 of 16
Remote Mode Volumetric mode De-Interlock Mode Stop
Healthy Healthy

Standard Programs and I/O Assignments Standard Program 1 Standard Program for 8 Digital I/O card.
4.1.1 Program List - SPSS_00 / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / *SPSS00/ UE 001/ =M 009/ UE 004/ =M 023/ UE 005/ =M 015/ UE 006/ =M 017/ UE 007/ UM 045/ SM 016/ UNE007/ UM 045/ RM 016/ UE 021/ SM 011/ RM 012/ UNE020/ SM 012/ RM 011/ UNE022/ =M 008/ UE 023/ =M 010/ UE 024/ =M 019/ =M 020/ UM 064/ =A 000/ UM 066/ ;BELT TRACK SWITCH ;GRAV/VOL. SELECT ;INT./DE-INT. SELECT ;DOWNSTREAM INTERLOCK ;START/STOP - INTERLOCK MODE ;SET START MARKER ;RESET START MARKER ;LOCAL START - PB ;SET "START" ;RESET "STOP" ;LOCAL STOP - PB ;SET "STOP" ;RESET "START" ;LOCAL/REMOTE SELECTION ;EMERGENCY S/W ;DRIVE INTERLOCK ;DRIVE INTERLOCK - WF ;DRIVE INTERLOCK - PF ;WF START/STOP/FAULT - LCS INDICATION ;WF DRIVE START/STOP - NO

Weigh Feeder with TUC-6 Electronics TUC6-010-EE23.6-R2 / / / / / / / / / / / / / / / / =A 001/ UM 066/ =A 002/ UM 033/ =A 003/ UM 036/ =A 004/ UM 045/ UM 068/ =A 005/ UM 035/ =A 006/ UM 034/ =A 007/ UM 066/ =A 020/ ;WF DRIVE START/STOP - NO ;BELT TRACKING FAULT O/P ;GENERAL FAULT O/P ;INT. MODE ;SYSTEM HEALTHY ;READY TO START O/P - INT. MODE ;DEVIATION FAULT ;DRIVE FAULT ;WF DRIVE START/STOP - NO Page 13 of 16
4.1.2 I/O Assignment Digital Inputs - DIO #1 Input E000 E001 E002 E003 E004 E005 E006 E007 High Low Signal Type Steady
Free Belt Track S/W-Healthy Fault Free Free Volumetric Interlock D. Interlock-Healthy Start Gravimetric De-Interlock Fault Stop
Steady Steady Steady Steady
Digital Outputs - DIO #1 Output High A000 Start Low Stop (Blinking-Fault)

Weigh Feeder with TUC-6 Electronics TUC6-010-EE23.6-R2 A001 A002 A003 A004 A005 A006 A007 Drive Start Drive Start Belt Track. Fault General Fault Ready to Start Deviation Fault Drive Fault Stop Stop Healthy Healthy Fault/Not-Healthy Healthy Healthy Page 14 of 16
Inverter 1 Inputs Input E020 E021 E022 E023 E024 High Start-Local Local Emg. Switch-Healthy Remote Fault Low Stop-local Signal Type Impulse Impulse Steady Steady Steady
Drive Interlock_Healthy Fault
Inverter 1 Outputs Output A020 4.2 High Drive Start Low Stop
Standard Program 2 Standard Program for Pre-Feeder
4.2.1 Program List - SPSS_01 / *SPSS01/ / UNE030/ / SM 014/ / RM 013/ / UE 031/ / SM 013/ / RM 014/ ;PF STOP FROM LCS ; ;PF START FROM LCS ;

Weigh Feeder with TUC-6 Electronics TUC6-010-EE23.6-R2 / / / / / / UE 034/ =M 020/ UM 067/ =A 030/ UM 065/ =A 001/ ;PF DRIVE INTERLOCK ;PF DRIVE START/STOP ;PF START/STOP/FAULT - LCS INDICATION Page 15 of 16
NOTE:SPSS_01 when used with SPSS_00, the following changes should be made to the standard SPSS_00 program i) SPSS_00: . . / UE 024/ / =M 019/ / =M 020/
;DRIVE INTERLOCK ;DRIVE INTERLOCK - WF ;DRIVE INTERLOCK - PF *****Delete******
Pre-Feeder 'Drive Interlock' Marker is assigned in SPSS_01. Duplicate assignment in SPSS_00 should be deleted. ii) SPSS_00: . . / UM 066/ / =A 001/
;WF DRIVE START/STOP *****Delete***** *****Delete*****
Output A001 is used in SPSS_01 for 'Pre-Feeder Start/Stop/Fault' indication. Above lines in SPSS_00 should be deleted. 4.2.2 I/O Assignment Digital Outputs - DIO #1 Output High A001 PF Start Low PF Stop (Blinking-Fault)

Weigh Feeder with TUC-6 Electronics TUC6-010-EE23.6-R2 Inverter 1 Inputs Input E030 E031 E034 High Low Stop-local Start-Local Drive Interlock_Healthy Fault Signal Type Impulse Impulse Steady Page 16 of 16
Inverter 1 Outputs Output High A030 Drive Start Low Stop
APPLIANCE DESCRIPTION
TABLE OF CONTENTS
1.0 2.0 3.0 General................................................... 2 System Representation....................................... 2 Configuration of Jumpers...................................3 3.1 Main Board.............................................. 3 3.2 Measuring Card....................................... 3 Rear View of TUC6......................................... 4 Main Board External Connectors.............................. 5 Layout of Main Board...................................... 6 AIO Card Connector Details................................... 7 DIO Card Connector Details............................... .8
5.0 6.0 7.0 8.0 9.0
Weigh Feeder with TUC-6 Electronics TUC6-010-EE23.10-R1 1.0 Page 2 of 10
General
Each member of the TUC-6 family comprises a Basic unit & several I/O modules connected to the Basic unit on the RS-485 serial Interface. The I/O modules are suited for external mounting on an assembly plate. 2.0 TUC-6 X1 F1 0.5A Mains Connections 24Vdc System Representation
+Main Board Measuring card X6 X1 X3 X1 Loadcell connection 12V/0.11A for max. 3 loadcells 350 Ohm 4 Digital outputs 4-20mA Isolated Output Tacho Pulse Input
X2 X4
Serial interface RS485 Profibus Interface TUC-6 Display & Keypad Interface Card
X5
X1
Configuration of Jumpers & Dip Switches Main Board
Jumper J1 : 1-2 Terminating resistor for X2 Interface (Connects 120E resistor) 3.2 Measuring Card measurement period 4ms 8ms 8ms 16ms 16ms 32ms
Jumper J1 : 1-2 / 9-10 1-2 / 7-8 3-4 / 9-10 3-4 / 7-8 5-6 / 9-10 5-6 / 7-8

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WEIGH FEEDER

TUC -6 OPERATION & MAINTENANCE MANUAL

OPERATION & MAINTENANCE MANUAL - INDEX

Software_version: 3.0 (onwards) 2008-01-03

2.0 2.1 2.2 2.3 2.4 2.5 2.6 2.7

Membrane foil with pressure sensitive keyboard.

Software_version: 1.0 (onwards) 2007-10-30

5.0 5.1 5.2 5.3

6.0 6.1 6.2 6.3

7.0 7.1 7.2

Software_version: 1.0 (onwards) 2007-10-30

7.6 8.0 8.1 8.2

Cable length Digital Outputs Output type Terminal

9.0 9.1 9.2 9.3 10.0 10.1

Software_version: 1.0 (onwards) 2007-10-30

10.2 10.3 10.4 10.5

Isolation type Load Terminal Cable type

12.0 12.1 12.2 12.3 12.4 12.5

13.0 13.1 13.2 13.3

Software_version: 1.0 (onwards) 2007-10-30

Max. cards supported

15.0 15.1 15.2

15.3 15.4 15.5 15.6

Isolation type Load - Input Load - Output Terminal

Software_version: 1.0 (onwards) 2007-10-30

Max. cards supported

16.0 16.1 16.2 16.3 16.4 16.5 16.6 16.7

Software_version: 1.0 (onwards) 2007-10-30

Software_version: 1.0 (onwards) 2006-05-25

Software_version: 1.0 (onwards) 2006-05-25

Software_version: 1.0 (onwards) 2006-05-25

Software_version: 1.0 (onwards) 2006-05-25

Software_version: 1.0 (onwards) 2006-05-25

Software_version: 1.0 (onwards) 2006-05-25

Software_version: 2.0 (onwards) 2006-11-13

Keypad and display Keypad

Display current setpoint

BB - Display Belt Load in %

Switch between Gravimetric / Volumetric selections

Display Actual Flowrate

Display Totaliser 2 Start Zeroing in Manual/Local modes

Software_version: 2.0 (onwards) 2006-11-13

Software_version: 2.0 (onwards) 2006-11-13

Software_version: 2.0 (onwards) 2006-11-13

Zero setting With this key, Zero correction process is initiated.

Software_version: 2.0 (onwards) 2006-11-13

Software_version: 2.0 (onwards) 2006-11-13

Pre-feeder parameters (SET3)

Parameters for Pre-feeder control are set in this menu. 5.0

Error Messages display. Error

Software_version: 2.0 (onwards) 2006-11-13

> Software_version: 2.0 (onwards) 2006-11-13

Software_version: 2.0 (onwards) 2006-11-13

Software_version: 3.0 (onwards) 2008-01-03

Software_version: 3.0 (onwards) 2008-01-03

Software_version: 3.0 (onwards) 2008-01-03

Software_version: 3.0 (onwards) 2008-01-03

Software_version: 3.0 (onwards) 2008-01-03

Software_version: 3.0 (onwards) 2008-01-03

Software_version: 3.0 (onwards) 2008-01-03

Software_version: 3.0 (onwards) 2008-01-03

Software_version: 3.0 (onwards) 2008-01-03

;DRIVE INTERLOCK ;DRIVE INTERLOCK - WF ;DRIVE INTERLOCK - PF *Delete**

;WF DRIVE START/STOP ***Delete* *Delete***