B ACKGROUND

The initial installed weighing controller for Bagging & Shipping in Fatimafert, Sheikhupura
site was obsolete Premier Tech SpeecAC 5. The project of Replacement of the Weighing
Controller Panel for BF 301 train B of Bagging & Shipping FFT was required because of
continuous troubles in installed HMI. The scope of the project included:
1. Replacement of the electrical cables conduits:
a. Motor cable replacement
b. Load cell cable from weigher
c. Control cable from sensors and to SOVs
2. Installation of Load cell junction box with grounding cable
3. Replacement of all Proximity sensors on Catch gate, Discharge door & Bag Clamp
4. Replacement of all 4 solenoid valves (SOVs) from 110V to 24V
5. Installation of silencers/dead plugs in SOVs
6. Installation of the power cable
7. Calibration after complete connections for Panel
8. Configuration of the input parameters or I/Os
9. Testing of the Weighing Controller Panel
10. Training of the operating staff

I NTRODUCTION
The “Premier Tech Chronos SpeedAC iQ Panel” for BF 301B Bagging and Shipping
was installed successfully on 19th January, 2020 at Fatimafert Sheikhupura site to fulfill the
demanding needs of the system with advanced technology. The SpeedAC iQ uses the latest
generation and most powerful state-of-the-art microprocessor controlled technology to provide
extremely precise bag weights for various bulk materials.
This new universal controller is designed for demanding industrial applications in:

 Chemical
 Pharmaceutical
 Food and feed mill industries
 All weighing applications across numerous industry sectors, offering the ultimate user
experience
The SpeedAC iQ is designed for new installation or easy retrofit from an older version of weight
controller. Used with all our bagging systems requiring weight measurement, this user-friendly
controller allows complete control of the filling process with unprecedented efficiency and ease

Prepared by: Aatrah Rauf Shaikh | E&I Engineer Date: 04/02/2020

with the newest “Smart Feed” algorithm. Operation is carried out via a large touchscreen
graphic display, which provides live performance feedback, fine-tuning functions, statistical
data, information on system status, and much more.

Figure 1. New Replaced Premier Tech Chronos SpeedAC iQ Weighing Controller

Its key features and benefits include:

 Improved user experience – intuitive navigation menus;
 7” Bright TFT Color Touch Screen (180mm);
 Auto tune - user simply enters weight set point;
 Smart Feed - two-stage, controlled loop, powerful algorithm;
 Preload programming, hassle free to install - backup & restore files using a USB stick;
 Top performance - speed, accuracy and standard deviation;
 Remote access and support capabilities, across the Internet;
 Communication with major PLC brands: Modbus TCP, Profibus DP, Profinet &
Ethernet/IP – simplify integration with PLCs;
 Easy to configure and integrate with a flexible/customizable I/Os page for custom
needs;
 Easy to upgrade/retrofit from previous generations of controllers;
 W&M approvals;
 Renowned Premier Tech customer service and support
“The SpeedAC iQ is W&M approved and guarantees weight accuracy in dynamic operation”

Prepared by: Aatrah Rauf Shaikh | E&I Engineer Date: 04/02/2020

T ECHNICAL D ETAILS
The field instrumentation required in the project comprised of:

1. Inductive Proximity Sensor NJ15 Series

This sensor was required for Catch gate & Hopper (discharge door).
SPECIFICATIONS:
Product Attribute Attribute Value
Part Number 106672
Connection Type Screw 2-Wire
Housing Material Plastic, PBT
Mounting Type Flush
Output NAMUR
Primary Type Inductive Proximity Sensors
Series NJ15 Series
Shielding Shielded
Termination 2-wire
Voltage Regulation DC

Figure 2. Proximity Sensor for Catch Gate & Discharge Door

Prepared by: Aatrah Rauf Shaikh | E&I Engineer Date: 04/02/2020

 2. Inductive NAMUR Proximity Sensor
This sensor was required for the Bag Clamp.

Figure 3. Proximity Sensor for Bag Clamp

PRODUCT CHARACTERISTICS:
Product Attribute Attribute Value
Part Number 106672
Connection Type Screw 2-Wire
Housing Material Plastic, PBT
Mounting Type Flush
Output NAMUR

Prepared by: Aatrah Rauf Shaikh | E&I Engineer Date: 04/02/2020

 3. FESTO Solenoid coils and SOVs

Figure 4. New FESTO SOVs

Electrical Data
3-pin
Electrical Connection Plug pins with connection pattern to Festo
standard for MSSD-F
Max. tightening torque of plug socket [Nm] 0.4
Min. pickup time [ms] 10
Permissible voltage fluctuations [%] –10 / +10
Duty cycle [%] 100
Degree of protection to EN 60529 IP65 with plug socket

Prepared by: Aatrah Rauf Shaikh | E&I Engineer Date: 04/02/2020

P ROJECT G ALLERY

Prepared by: Aatrah Rauf Shaikh | E&I Engineer Date: 04/02/2020

Prepared by: Aatrah Rauf Shaikh | E&I Engineer Date: 04/02/2020
C HALLENGES
The project was executed successfully but there were a few challenges that the team had to
overcome including:

 The required proximity sensors were:

o PEPPERL+FUCHS 106672 (Qty:1)
o NM500A (Qty:2)
Whereas, the delivery package included:
o PEPPERL+FUCHS 106672 (Qty:2)
o NM500A (Qty:1)
 The NM500A NAMUR inductive sensor (to be installed on bag clamp) was giving output
between 0 and 10 V and not the required 24V for which it had to be replaced by
Autonics Inductive Proximity Sensor
 The management between different departments including operators, mechanical (for
alignment of belt and feed gate) and the instrumentation team was also a critical job
 Due to unavailability of air compressor on time as well as the malfunctioning of the
proximity sensors added delay in the project
 The misalignment of the belt after cleaning
 The delay in calibration of the panel due to welding required for mounting of sensors
 The speed adjustment of the feed gate & catch gate

C ONCLUSION
It was a great learning opportunity for me in managing such a project independently for
which I am extremely thankful to Fatimafert Site management & instrument team. All the
challenges definitely helped me grow and think critically to get the project completed on time.
It was my first experience doing a project in Bagging & Shipping area as well which helped me
understand the process technically as well.
The PT Controller SpeedAC iQ installed is a state of the art panel which is robust and
more user friendly and will definitely help the site as its “SMART FEED” algorithm also
calculates the weight of the in-flight material.

Prepared by: Aatrah Rauf Shaikh | E&I Engineer Date: 04/02/2020

WAY FORWARD:
I suggest that following should be considered to make this integral part of the plant systems:

 Update the relevant as-built drawings

 Place the new manuals of the PTC weighing controller in the library
 Formal training of the staff
 Make it part of the Preventive maintenance regime
 Develop SOPs and Checklists for its periodic maintenance
 Order spares for field instrumentation
 Budget & plan to replace the existing panels for trains A, C & D with Premier Tech
Chronos SPeedAC iQ to have all the Bagging Trains automated properly.

Prepared by: Aatrah Rauf Shaikh | E&I Engineer Date: 04/02/2020