fco-461 operation english)

Hefei Jinshan

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CONTENTS

1 BELT-SCALE STRUCTURE.....................................................................２

2 BELT-SCALE MACHINERY INSTALLATION........................................................３

3 BELT-SCALE ELECTRICAL INSTALLATION.......................................................４

3.1 THE CONTROLLER INSTALLATION ............................................................... ４ 3.1.1 Open the controller packaging ..................................................... ４ 3.1.2 Putting the Controller into control cabinet ....................................... ５

3.2 THE SENSOR INSTALLATION .................................................................. ６ 3.2.1 The Z6 sensor installation ........................................................ ６ 3.2.2 The general sensor installation ................................................... ８ 3.2.3 The Measure Speed Sensor installation ............................................. ９

3.3 THE CABLING CONNECT THE CONTROL CABINET WITH THE BELT SCALE AND ITS REQUIREMENTS. ..................... ９

4 THE BELT SCALE POWER UP AND DEBUG......................................................１０

4.1 SET UP THE FREQUENCY CONVERTER PARAMETER ................................................... １０ 4.2 GENERAL OPERATION OF THE CONTROLLER ....................................................... １１ 4.3 THE BELT SCALE MECHANICAL PARAMETER ....................................................... １３ 4.4 CORRECTS THE SLANTING OF THE BELT RUNNING CORRECTS ........................................... １４ 4.5 CHECK SIGNALS OF THE CONTROLLER ： ....................................................... １５

5 THE BELT SCALE CALIBRATION.............................................................１５

5.1 DETERMINED THE TOTAL WEIGHT OF THE WEIGHT AND THE CALIBRATION POLE. .............................. １５ 5.2 ENTER CALIBRATION INTERFACE ............................................................. １６ 5.3 TARE CALIBRATION ...................................................................... １６ 5.4 STATIC HUNGING WEIGHT CALIBRATION ......................................................... １７

5.4.1 Zero calibration ................................................................ １７ 5.4.2 Full calibration ................................................................ １７

5.5 DYNAMIC HUNGING WEIGHT CALIBRATION ........................................................ １８ 5.6 REAL MATERIAL CALIBRATION ............................................................... １８

6 COMMUNICATIONS CORRECTION..............................................................２０

6.1 COMMUNICATIONS CORRECTION FUNCTION ........................................................ ２０ 6.2 I/O INPUT TEST....................................................................... ２０ 6.3 ANALOG OUTPUT TEST .................................................................... ２０

APPENDIX 1：REPLACEMENT BELT ................................................................２１

APPENDIX 2：THE USE OF LUBRICANTS MODEL .....................................................２２

APPENDIX 3：THE CONTROLLER BACK PANEL TERMINAL DRAWING ......................................２３

APPENDIX 4：PARAMETER TABLE 1 ...............................................................２４

APPENDIX 5：PARAMETER TABLE 2 ...............................................................２５

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FCO-461 controller is a new generation of controllers introduced by Hefei Cement Research & Design Institute Jinshan

factory Electrical & Automation Equipment Plant in recent years.FCO-461 as a multi-function controller, can be used for a

single measurement equipment or the measurement equipment with pre-feeding equipment.

1 Belt-scale structure The significance of uderstanding the belt scale’s setup,debugging,calibration and safeguardi is very important

Figure 1

Figure 1 shows major part of the belt scale.

(1) Initiative Drum：Initiative Drum is driven by reduce motor ,and drag the belt. (2) Passive Drum：By adjusting the screws of the Tension Slip Block (4), change the location of Passive Drum,

you can adjust the belt tension and deviation

(3) Cross Reed： Cross Reed used to link Scale body and Measurement Framework. (4) Tension Slip Block：It can adjust Belt-scale deviation and take-up

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(5) Measurement Framework.：It is Transmission Structures of Belt Scale，It spread material weight on belt to sensors.

(6) Automatic Tension Denice：It can make Belt to maintain a certain degree of tension，and make the belt weight to change

in a very small range。

(7) Discharging hopper：passing by the discharging hopper ,stuff come from the Silo to the belt,and it can adjust thickness of

the material layer by adjusting the opening of the hopper strobe.

Geared Motor：the Driving Device of belt scale,it have the speed sensor which convert the angular velocity controller to

the identify electronic signals.

(8) Sensor:it convert weight to electronic signal which can be transmited to the contoller.

Otherwise， On the surface of the scale, there are a the small drum roller which is parallel by Initiative Drum & Passive

Drum. According to their different functions, can be divided into Measurement Drum and Support Drum.

Figure 2

2 Belt-scale machinery installation The gradient of surface of the belt scale should be Less than 3/1000.

Figure 3

According to figure 3 , adjust installation location of discharging hopper,and when it is over ,the distance

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from the underside the discharging hopper underside to the belt upper surface is 10～15mm,and the distance from the

Flange center of the discharging hopper to the center line of the Passive Drum is 250～300mm.

Check whether the belt weighing components intact.

3 Belt-scale electrical installation Used a four-way Control panel as an example.

figure 4

3.1 The controller installation The Control panel ought to installed in the indoor with less dust and the Control panel shell should be connected to a good

grounding.

3.1.1 Open the controller packaging

figure 5

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3.1.2 Putting the Controller into control cabinet

figure 6

Let us see the backup of the controller.

figure 7

there are some connection terminal rows and some computer plugs.the terminal row is pluggable,their have connected

before it outed the factory,you only need to insert correct plugs to the right faucet. Each connection terminal number is not the

same.According to its number and direction,you can finish right connection. And nearby connection terminal row,it marked "1"

is No. 1 terminal

Notice: Do not inserted connection terminal rows wrong,it will make the controller to go wrong or damage.

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figure 8

3.2 The sensor installation

3.2.1 The Z6 sensor installation

A set of components for the installation of sensor devices include a Pressure head screw and a fixed nut, a Z6 sensor, a

steel Ball, a steel ball installed Block,two Fixed screw.

The first step

figure 9

The second step

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Figure 10

The third step

Figure 11

The fourth step

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Figure 12

3.2.2 The general sensor installation

General sensor installation steps are Almost the same with Z6 sensor,but their installation foundations are different. Please

refer to the Figure 13,put the sensor into its installation foundation,and Tighten the screws to Fix sensors(there are some

corresponding position screw hole.)

Figure 13

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3.2.3 The Measure Speed Sensor installation

Figure 14

Figure 15

▲ Please refer to the Figure 15,put the measure speed sensor into its installation foundation,and fix the sensor,then turn

motor fan by your hand,check weather the sensor fight the gear)

1.If Yes, adjust the fixed copper pipe forward slowly，then repet ▲ step until just do not fight Gear，and revolve the

copper piper backward one loop,and fix the fix screw nut.Insert the sensor into its installation foundation again，fix the screw.

2.if not, adjust the fixed copper pipe backward slowly，then repet ▲ step until just fight Gear，then do 1 step.

3.3 The cabling connect the control cabinet with the belt scale and its requirements. There are three type line between the control cabinet and the belt scale ,their is the signal line and the electrical line, the

Control line three types.

The Signal line must be Shielded cable,and how to place different lines please to the drawings with the scale. The signal line demands to wear in charge of laying or the thread goes along the special-purpose bridge shelfing while

connecting up， The line of signal should carry on earthing the single-end of shielding layer in the switch board to enter the

switch board. All shielding layer all unsettled while wiring, no earthing, In scene, all shielding layer all unsettled while wiring,

no earthing, please.

Be careful：There are triangles to connect France and star and connect two kinds of laws quantitatively for the

electromechanics machine wiring of material，Generally speaking the single-phase frequency converter which enters the line

adopts the triangle to connect the law，And the frequency converter that three phases enter the line adopts the star to connect

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the law. The detailed conditions please consult the frequency converter selected for use to prove.

Please measure every wiring carefully after all wiring finish. Strong electricity and weak electricity have errorless to

connect especially, so as not to lead to the fact unnecessary loss pay cable.

The following is a wiring design of the line of signal between a belt balance and switch board, concrete wiring consults

the paper of figure.

Figure 16

4 The belt scale power up and debug

4.1 Set up the frequency converter parameter Turn on the back door of the switch board, close the air switch from left to right, give electricity of the switch board, the

controller and frequency converter are with electricity at this moment.

Turn on the forward door the control cabinet, establish the frequency converter parameter. Take frequency converter F11S

of Fuji as an example below, provide the parameter form that the frequency converter needs to revise, other parameters are

subject to that dispatched from the factory and established。

Frequency Parameter meaning Number value Generally establish

F01 Signal mode

0 The panel is operated 1 Voltage

signal

2 Electric current signal 3 Voltage and

electric current signal

2

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F02 Start set 0 Panel launched

，1external signal 1

F03 the highest frequency 50～400Hz 50

F04 Basic frequency 50～400Hz 50

F07 First acceleration time 6 10

F08 First moderation time 6 10

F11 Hot protection electric current

of the motor

Establish according to the

motor

4.2 General operation of the controller First of all, make us familiar with the operation interface of the controller：

Figure 17

FCO-461 controller adopts systematic menu type way to carry on the function to manage，you can consult the chart of

making and combine the manual to familiar with it to generally operate.

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Figure 18

The normal display status：Display picture of acquiescence when being electric each time of the controller.

Operation 1: Method to enter main menu，Push The key can enter the main menu，If you want to withdraw the

main menu and return the normal display status, press the key.

Operation 2: Select the necessary function and method to enter the next grade of menu in each menu. At first ,Use the

key moves the necessary function to and reveals the down area of the area（the up area of the area reveal the name

of this menu），press the key to enter the next grade of menu or sub function. If you want to get back to the menu at a

higher level and only need to press the key.

Figure 19

For example：In Figure 19, We pass in the picture of having Move” Programing” to the down area of the area by pressing

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the key. Push the key and enter the next grade of menu.

Figure 20

Be careful：When you select the sub menu with black arrow point in the list and enter the next grade of menu, it will

spring a menu Password _ _ _ _ _ _ _ _ and require you to input the password. It will enter the next grade of menu or sub

function after only inputting the correct password

Operation 3: Method to revise number value. Describe in the list as the parameter of revising, in fact this operation mode

not only merely revise the parameter, but also revise the flow of establishing or establish the rotational speed under revealing

the state normally. Number value is changed and generally gone on by this method. The concrete step:when you enter concrete

parameter unit of the parameter form(As the upper list shows the procedure), If need to revise the parameter to push The

key is entered and press the Key input digit and press the key deletes the single figure, press the

key confirms inputting, press the key cancel inputting.

4.3 The belt scale mechanical parameter When at being the initial electricity debug ,you only need input some parameters of the C mechanicals parameters

mechanicals.

The following is relevant number value of input of the necessary parameter.

address English

simplification

Explanation Default value Position in the figure 21 and

proving correspondingly

C00 Roller dia. Cylinder diameter 0.22 m 1

C01 Speed Reducer motor speed ratio 51 3 Mark in the plate of reduce

machine.

C02 Eff.Platf.Length The effective Weigh

length

0.45 m Half of shown length in the

position 2.

C03 Gear Number The number of pulses

when motor rotates a

circle

30

C04 Nominal Load Nominal Load of the

sensor

100 kg 5 Mark in the plate of sensor.

C05 Belt Length Belt girth 3.95 m 4

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figure 21

4.4 corrects the slanting of The belt running corrects the figure 22 show me installation sites and panels of the locate box.

figure 22

turn the change-over switch of the locate box to the " manual " status，press the Starting button of the locate box，and

adjust the potentiometer,to the belt scale a suitable speed.

Monitor the running and leaning towards the direction of the belt scale，In general belt driven to the location as the

passive drum.

If the belt deviation to the left side, tighten the nut on the back of tension sliding block on the belt scale left side .If the

belt deviate to the right side, tighten the nut on the back of tension sliding block on the belt scale right side. every time twist a

nut one, two laps , After finish the work , should allowed the belt to run continutely, observe the effects.

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figure 23

Be careful：The new scale should run for several days and Observe status of its machinery, You need to carry out regular

checks of belt running deviation status，and revise it。

4.5 Check signals of the controller ： When the belt scale runing,you can check whether the load signaal and the measure speed signal are normal.If the singals

are irregular,please shut off the power of th controller at once and check whether sensor and sensor’s line connection are

damage, and ensure that there are no short and circuit Opening situation.

When the belt scale runing,press the key,observe the controller Following the two state:

Speed ＝ Motor speed value.Unit：rpm。 Numerical range：0～1500rpm

The value should be relative the speed on frequency converter.

Load.AD ＝ Load signal AD conversion value Numerical range：100～4000

If these data are not in the numerical range or inconsistent with the requirements,please shut off the power of the

controller, check whether sensor and sensor’s line connection are damage, and ensure that there are no short and circuit

Opening situation.

5 The belt scale calibration

5.1 determined the total weight of the weight and the calibration pole. Record the total weight the weight and the calibration pole，mark as P（Kg）.

figure 24

Now assume that P = 20.7 (Kg), input this value as a weight weight into the D00 unit of the parameters list D00 unit

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figure 26

5.2 Enter Calibration Interface

figure 27

According to the process the figure provided by the figure 27 the calibration process enter the calibration sub-menu.

At this time the manul/automatic switch of the locate box should be turned to "automatic" status.

5.3 Tare calibration After finish the second step，do the belt weight calibration.

figure 28

Then turn the controller status to the Volume mode.

Interrelated step：

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figure 29

If system have a pre-feeding equipment ,you must stop the pre-feeding equipment.

Continuously press the key and return to the nomally display status,set the motor speed as 600rpm by operation

3,press the key and start the belt scale.

Select “Tare calibration”on the calibration submenu and enter.

The display will shows the percentage of the belt running 1 lap or N lap and the AD average value of belt weight.when the

percentage change into 100%,the belt scale will stop automatically and display a ultimate value,press the key and the

ultimate value will be written into the controller corresponding Parameter, the belt weight calibration process is over.If you

aren’t satisfied with the reslute ,press the key to cancel the operation.

5.4 static hunging weight calibration

5.4.1 Zero calibration

Let belt scales in the empty status and static status。Immediately following the above steps,select“zero calibration”on

the calibration submenu and enter.The controller will sample A / D numers,system automatically stop after 10 seconds and

show average AD sampling value, press the key and the ultimate value will be written into the controller corresponding

Parameter,the zero calibration is over. If you aren’t satisfied with the reslute ,press the key to cancel the operation.

5.4.2 Full calibration

Maintain the belt weighing stop,put the weight and the calibration pope on the scale.Then select“full calibration”on the

calibration submenu and enter.

figure 30

system automatically stop after 10 seconds and show average AD sampling value, press the key and the ultimate

value will be written into the controller corresponding Parameter,the zero calibration is over. If you aren’t satisfied with the

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reslute ,press the key to cancel the operation.

5.5 Dynamic hunging weight calibration Don’t move the weight on the belt scale，stop volum mode and enter gravity mode.


figure 31

Continuously press the key and return to the nomally display status,set the motor flow (t/h) by operation 3,record

the flow as S1(t/h),press the key and start the belt scale.

Using a stopwatch to record the time T1 (seconds)how long the belt circle one loop,and calculate the theoretical time T2

how long the belt circle one loop.

computing formula T2=3.6×P×the belt loop length/S1/ The effective Weigh length

then calculate Errors value 100%T2

T2T1Error ×－

＝，the value ought to be less than 1%。

If the result Is greater than or equal 1%，enter the parameter D05.

The original values of the parameter D05 multiplied byT2/T1 and input the result to the parameter D05 again.

Restart the belt scale and repeat the test with a stopwatch,and calculate Errors value,until the result is satisfied with

requirement. 。

5.6 Real material calibration whether do real material calibration should be dependent on the scene condition . if the belt scale is used for the dosage

of raw material，the process should be finished.

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figure 32

change the controller mode to Volume mode.According to the figure 32, divide the process of the real material calibration

in four steps.

1. Preparation step

Open the strobe of the discharging hopper, let materials fall

Start the belt scale by pressing the key.When the material overspead the upper belt,press the key and stop the belt scale,the material status is as shown in the dawing 1 of figure 32, materials just spread to materials fall position of

the initiative drum. Clean the Surplus material fallen from the initiative drum during the belt runing.

Press the key，clear cumulation。

2. Strat the belt scale

Press the key，set the motor speed (for example 600rpm)according to operation 3,then press the key and

strat the belt scale,let material fall.

3. monitoring the cumulation value

Press the key，observe the display value of Z1 or Z2.

When the value reach the amount of material calibration,press the key ，stop material to fall. Be careful：the material calibration must be not less than 1/20 of the belt scale maximum production per hour.

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4. Calculated correction

when the belt scale stop,the status is as shown in the dawing 1 of figure 32。Weigh total weight wich is fallen from belt

start to belt stop this time,record total weight as W1. record the controller display cumulation as W2.

The correction factor K2=W1/W2

If the absolute value of K2-1 is less than 1%,the calibration pass demand，no need to modify any parameter.

If the Absolute value of K2-1 isn’t less than 1%，do follow steps：

1. The original values of the parameter D06 multiplied by K2 and input the result to the parameter D06

again.

2. have done the Real material calibration until the absolute value of K2-1 is less than 1% .

6 communications correction the primary fuction of communication correction is used for correcting analog output signal in system which have a host

computer.


Calling function list

6.1 Communications correction function

Select OUTPUT Test

Please input Password. Password ___111___

Display “DO TEST I/O output test

”

DA1-DA7 OFF I/O output don’t take out

DA1-DA7 ON I/O output take out

Return Higher-level menu.

6.2 I/O input test

Select DI TEST

Display “ RUN STOP SPEED P S “

When RUN have signal,the display of RUN will disappear，Etc.


6.3 Analog output test

Select AO TEST

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when set DAC0-DAC1 4 mA，the current of DAC0 and DAC1 will be up to 4mA

When DAC0 out put minimum current,check by multimeter whether the A0 analog terminal is equal to 4mA,if not,modify

the E00 parameter and make it to be 4mA.

When DAC1 out put minimum current,check by multimeter whether the A0 analog terminal is equal to 4mA,if not,modify

the B04 parameter and make it to be 4mA.

when set DAC0-DAC1 20 mA，the current of DAC0 and DAC1 will be up to20mA

When DAC0 output maximum current,check by multimeter whether the A0 analog terminal is equal to 4mA,if not,modify

the E01 parameter and make it to be 20mA.

When DAC1 output maximum current,check by multimeter whether the A0 analog terminal is equal to 4mA,if not,modify

the B05 parameter and make it to be 20mA.


Appendix 1：Replacement belt

figure 33

1. Remove corresponding components on no motor side of belt scale,let the side hang in the air

2. Screw off the screw of the tension sliding block on the side,and put the end of passive drum into inside.

3. Screw off the fixed screw of the tension sliding block on the side,and remove it.

4. Remove the long screw of the tension sliding block rest part.

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5. move belt along the arrow of the drawing display.

6. Replace new belt and setup the rest part by inverse order of steps.

Appendix 2：The use of lubricants model 1. Recommend to use the special lubricant of 2*supramoly or 2L-2 Li radical , 90# Industrial gear oil in

reduction machine.before the belt scan run,you must check the smooth condition , maintain adequate lubrication and the

filling volume of lubricant is the 1/3～1/2 empty volume of reduction machine.

2. There are two filler well on the top of the reduction machine,and there are one screw plug on the bottom of

the reduction machine.

3. The reduction machine lubricant should be replace once every 2,500 hours, appropriatily shorten the time of

replacing lubricant in the bad condition

4. When the belt scale go out of factory,the reduction machine have be fillen with 2*supramoly,you need

appropriatily supply the lubricant after three month.

5. The rest mechanical bearings of the belt scale only need be supplied with general lubricant.

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Appendix 3：The controller back panel terminal drawing

figure 34

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Appendix 4：Parameter table 1 Code function Initiali-zation

data

Unit User settings

A00 Setpoint mode Configure mode 0

A01 Control mode Control mode 0

A02 Speed mode Measure speed mode 0

A03 Load_Max Load max limit set 90 ％

A04 Load_Min Load min limit set 10 ％

A05 Speed_Max Speed max limit set 1200 rpm

A06 Speed_Min Speed min limit set 300 rpm

A07 Par.ini Initialization parameters 1

A08 BAK backup 0

B00 Nominal Feed Rate Rated flow 100 T/h

B01 Ex.Setpoint Min External min signal value 4 mA

B02 Ex.setpoint Max External max signal value 20 mA

B03 Ex.sp min External signal threshold value 4 mA

B04 Flow_Out Min flow output min value 4 mA

B05 Flow_Out Max Flow output max value 20 mA

C00 Roller dia. Drum diameter

C01 Speed Reducer speed ratio 51

C02 Eff.Platf.Length The effective Weigh length 0.45 m

C03 Gear Number The number of measure speed gear

teeth

30 integer

C04 Nominal Load The load sensor standard range 100 kg

C05 Belt Length Belt length 3.95 m

C06 Nominal Speed Motor standard rotate speed 1500 rpm

D00 Calibrate load Weigh weight 10 Kg

D01 Zero Zero parameter 0 Sampling

word

D02 Full Full parameter 2000 Sampling

word

D03 Tare Belt weight parameter 0 Sampling

word

D04 Test load Test load 10 Kg

D05 Flow_K Flow parameter 1

D06 Modify_K Modify parameter 1

D07 N Circle Belt Calibration laps 1 integer

D08 Load mode Simulation load mode 0 integer

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Appendix 5：Parameter table 2 Code function Initialization

data

Unit User settings

E00 Ctronl_Out Min The min value of control output 4 mA

E01 Ctronl_Out Max The max value of control output 20 mA

E02 Filter constant Filtering constant 10 integer

E03 DEAD Dead area 0.1 ％

E04 PID_K Pid parameter

E05 YUZHI_PIANCHA Preferences deviation 30 ％

E06 MIN_PROTECT Preferences protection 5 Kg

F00 ADDress Communications address 1

F01 Baud Rate Baudrate 1

F02 Mode Communications mode 1

G00 PROFIBUS_ADDr PROFIBUS address 1

G01 PROFIBUS_mode PROFIBUS mode 0

H00 Ctronl_2 Min Pre-feeding control min output 4 mA

H01 Ctronl_2 Max Pre-feeding control max output 20 mA

H02 Pre_control_mode Pre-feeding control mode 0

H03 Pre_Feed Rate Pre-feeding machine capability

100 T/h

H04 Pre_control time Preferences adjustment time 8 s

H05 PIANCHA limit Deviation limit 40 ％

H06 Pre_ctrl limit Preferences adjustment limit 40 ％

H07 P.C_limit_k Limit parameter 1

H08 DEAD2 adjustment dead area 1 ％

H09 PP1 P1 parameter 10

H10 PI1 I1 parameter 4

H11 PD1 D1 parameter 0







H18 time-lapse start Delay time 1 s

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