90.18737 WF GDC O&m Manual

OPERATION & MAINTENANCE MANUAL FOR
WEIGH FEEDER
OPERATION & MAINTENANCE MANUAL
FOR
WEIGH FEEDER
FLSmidth Private Ltd.

FPL JOB NO : 90.18737
CUSTOMER : NIRMA LTD.
EQPT : WEIGH FEEDER (WF)
TABLE OF CONTENTS
SR. NO. DESCRIPTION NO OF PAGES
OPERATION & MAINTENANCE MANUAL FOR GDC

01 108
CONTROLLER WITH PROFIBUS COMMUNICATION
02 OPERATION & MAINTENANCE MANUAL FOR WEIGH FEEDER 67
03 OPERATION & MAINTENANCE MANUAL FOR AC MOTOR 20
04 MOTOR SPECIFICATION 01
05 INSTALLATION & MAINTENANCE MANUAL FOR GEAR BOX. 68
INSTALLATION & OPERATION MANUAL FOR VIBRATORY

06 16
MOTOR
07 OPERATION & MAINTENANCE MANUAL FOR SKF BEARING 36
08 TECHOMETER TECHNICAL LITERATURE 01
09 LOADCELL SPECIFICATION 03
10 DATA SHEET 02
11 ELECTRICAL DRAWING 81
12 MECHANICAL GAD 02
FLSmidth Pfister India Ltd.

GRAVIMETRIC DOSING CONTROLLER (GDC) FOR
WEIGH FEEDER
GRAVIMETRIC DOSING CONTROLLER (GDC)
FOR
WEIGH FEEDER

USER MANUAL Ver 1.3
Feeding controller GDC – WF
ppol-in / 08.Aug.2017 / File: GDC.WF.User.Manual.doc RNDE1009201403
User Manual
Feeding controller GDC
This documentation is valid for: WF

Software : WF
Version : V2.440 onwards
FLSmidth Private Limited page 1/17

USER MANUAL Ver 1.3
Table of content page

1 Safety instructions ........................................................................... 3
2 General ............................................................................................. 4
2 .1 Conventions ....................................................................................... 4
3 HMI Panel ......................................................................................... 5

3 .1 Online Menu....................................................................................... 5
3 .1.1 Status Line...................................................................................................... 5
3 .1.2 Online Parameters ........................................................................................... 5
3 .1.3 Base Line ........................................................................................................ 6
3 .2 Error screen ....................................................................................... 6
3 .3 Command screen ............................................................................... 6
3 .4 GDC mode operation (Remote-Local-Field) ........................................ 8
3 .4.1 Remote-Local operations .................................................................................. 8
3 .4.2 Field operations ............................................................................................... 8
3 .4.3 Inverter View .................................................................................................. 9
3 .5 Menus ................................................................................................ 9
3 .5.1 User Menu ...................................................................................................... 10
3 .5.1.1 Parameter Section ........................................................................................... 10
3 .5.1.2 Sub-Menu Section ............................................................................................ 11
3 .5.1.3 Base Line ....................................................................................................... 11
3 .5.2 Maintenance .................................................................................................... 12
3 .5.2.1 Base Line ....................................................................................................... 12
3 .5.2.2 Sub-Menu Section ............................................................................................ 12
3 .5.2.2.1 Sub-Menu Diagnostics ...................................................................................... 13
3 .5.2.2.2 Sub-Menu Totalizer 2 ..................................................................................... 14
3 .5.3 Commissioning ................................................................................................ 15
3 .5.3.1 Sub-Menu Section ............................................................................................ 15
3 .5.3.2 Base Line ........................................................................................................ 16
4 Index history .................................................................................... 17

USER MANUAL Ver 1.3
1 SAFETY INSTRUCTIONS
For Safety instructions, please refer Section 1.2 of Appliance Description document.

USER MANUAL Ver 1.3
2 GENERAL
This manual is dedicated to "Users". User is defined as a person using the feeder for
production including:
• Monitoring values
• Correcting errors
• Trouble shooting
2 .1 CONVENTIONS
>ButName< means a button with name ButName
"ScrName" means a screen with name ScrName
[PrmName] means a parameter with Name PrmName
xx.yy means parameter number
xx.yy [PrmName] means indication of parameter name with its corresponding
parameter number

USER MANUAL Ver 1.3
3 HMI PANEL
The HMI panel is serially connected to GDC. The HMI panel offers a touch-sensitive colored
display. HMI content is structured like:
Access to
"Online "Command" "Menu"
Menu" "User
"Maintenance" "Commissioning"
Menu"
User X X X
level
Service X X X X
Admin X X X X X
3 .1 ONLINE MENU
Picture 1 : Online menu
The "Online Menu" is the basic display at the HMI and serves as a data display and as a
branch to the "Command Screen" and "Menus"
Tapping on Belt Load and Motor Speed parameter changes their unit. Belt Load is available
in % and Kg/m and Belt Speed is available in rpm and cm/s
3 .1.1 Status Line

The status line in the header of "Online Menu" the mode status and system status is
displayed.
Regarding the mode status refer to the Table 1 & 2 .
System status is displayed as under and valid in any mode:

o Run = feeder is operating
o Halt = feeder is stopped
3 .1.2 Online Parameters

The online parameters present values of the feeder. For each value a help is accessible via the
question mark in the value field.

USER MANUAL Ver 1.3
3 .1.3 Base Line

In the base line of "Online Menu" access to "Error Screen", "Command Screen" and "Menu" is
available. On the right corner, date and time are shown.
3 .2 ERROR SCREEN
In case of error or warning, this is displayed in the >error< of the "Online Menu".
Pressing >Error< the "Error Screen" is displayed.
Picture 2 : Error screen
In the "Error Screen" errors are displayed in red and warnings in yellow
In the base line of the "Error Screen" two buttons are offered:
• >Back< to "Online Menu"
• >Reset< to acknowledge errors and warnings. If error/warning still exists, it is redisplayed after
acknowledging.

USER MANUAL Ver 1.3
3 .3 COMMAND SCREEN
Access to "Command Screen" is available via >Command< in the "Online Menu".
Picture 3 : Command screen
In "Command Screen", on top of the header the present operating mode (refer to Table 1 & 2)
and present system status .
Depending on the source of Run/Halt Command, there are three operating modes.
Table 1
Operating Mode Source of Run/Halt Command Condition

Local GDC HMI or Web Interface
Plant PLC via Hardwired or
Remote
Fieldbus Interface
LOCAL PERMISSION
Field LCS
should be active
Depending on the feeder operation, Local and Remote modes are further divided into four
operating modes
Table 2
Operating Mode Feeder Operation Condition

Local Gravimetric In this mode, GDC sets Feed
Mode setpoint as the feed output in
t/h
Local Volumetric In this mode, GDC sets Speed
Mode setpoint as the drive speed in
rpm
Remote Gravimetric In this mode, PLC sets Feed
t/h
Remote Volumetric In this mode, PLC sets Speed
t/h

USER MANUAL Ver 1.3
3 .4 GDC MODE OPERATION (REMOTE-LOCAL-FIELD)
• Modes can be changed through commands and these commands can come from HMI or
Digital Input or Fieldbus.
• If command source is “Internal”, then HMI commands can be used to change the modes and
if command source is “External”, then Digital Input or Fieldbus Command can be used to
change the modes.
• For more details see Section 2.7 of Parameter Manual or System Control Settings in
Commissioning Manual.
3 .4.1 Remote-Local operations
• If 38.01 [Remote-Local Selection] is set to “External” then Digital Input “Remote/Local” or

fieldbus command ”Remote/Local” controls the Remote-Local Selection.
If 38.02 [Control Source in Remote] is set to “Hardwire” then System is controlled through
Digital Input in Remote Mode.
If 38.02 [Control Source in Remote] is “Hostlink” then System is controlled through fieldbus
connected to GDC.
• If 38.01 [Remote-Local Selection] is set to “Internal” then Remote-Local Command on HMI
can only be used for Remote-Local Selection.
3 .4.2 Field operations
• If 38.07 Field Switch Operation is “Yes” then Digital Input “Field Selector Switch” controls the
Field Mode Selection.
If 38.07 Field Switch Operation is “No” then Digital Input “Field Selector Switch” doesn’t affect
the Field Mode Selection and Field Active/Field Release Command on HMI can be used for Field
Mode Selection.
• If 38.05 Field Permission control is “External” then Digital Input “Field Permission” controls the
Field Permission.
If 38.05 Field Permission control is “Internal” then Digital Input “Field Permission” doesn’t
affect the Field Permission. Field Permission Command on HMI can be used to Enable/Disable
Field Permission.
Important points:
• Change in Operating mode in WF Running condition, stops the feeder.
• Field mode cannot be activated in WF Running condition.
• Gravimetric-Volumetric mode cannot be changed in WF Running condition.

USER MANUAL Ver 1.3
Command Button on Action Active in

HMI/Web Interface
>Run/Halt< starts/stops the feeder local mode
>Local/Remote< switches mode between only active if [38.01 Remote-
remote mode and local Local Selection] is set to
mode Internal
>Gravimetric/Volumetric< switches operation only active if [38.03
between gravimetric and Gravimetric-Volumetric
volumetric mode Selection] is set to Internal
>Field Active/Field Release< switches mode between non remote mode
local mode and field
mode
>Field Enable/Disable< gives control permission only active if [38.05 Fieldbus
to field Permission] is set to Internal
>Reset Totalizer 1< resetting totalizer 1 All modes
>Inverter View< branch to "Inverter refer to "Inverter View"
View" Active in all modes
>Batch Mode< This can be used to set All modes
Batch operation.
>Aeration On/Off< This can be used to Local mode

on/off the aeration
3 .4.3 Inverter View

Value Action Dimension
Speed Calculated speed of motor Rpm
Current Motor current measured by inverter Amps
Torque Torque on motor shaft % of nominal motor torque
AI Value Input value at analog input % of input range
3 .5 MENUS
Parameters can be accessed through menus. There are 3 different types of menus and it can
be accessed using different levels.
Access to
"User Menu" "Maintenance" "Commissioning"
User level X
Service X X
Admin X X X
Login Success and Login Failure events are logged in Event Log.

USER MANUAL Ver 1.3
Picture 4 : Login menu
Procedure
Select User type and enter the Password.
Press >Login< button. On Login Success, >Menu< button gets enabled and Menu access will be
given as per User Type.
Software versions, GDC name and GDC IP Address are displayed on Login screen as seen in the
Picture.
3 .5.1 User Menu
Picture 5 : User menu
3 .5.1.1 Parameter Section

The parameters shown in the parameter section can be modified if background is highlighted
by typing in a new value after tapping the present value field. Abort of editing is available by
tapping the cross button in the edit window

USER MANUAL Ver 1.3
3 .5.1.2 Sub-Menu Section

Access to sub menus is available by tapping the corresponding button.
SubMenu Action Remark

Local Local setpoints can be changed using this menu
Setpoints
LAN Settings of integrated Ethernet (LAN) port.
Settings Device name should be 8 characters long. This name will be
appeared in all the files that are copied to USB.
Parameter Display of parameter values explanation to
View single
parameters can
be displayed by
tapping >?<
Picture 6 : Parameter view
>Arrow< offers access to "Parameter View shortcut"

>Back< offers return to Sub-Menu-Section
>Prev< switches to previous page of parameters
>Next< switches to next page of parameters
>?< gives explanations to single parameters
Parameter as above but access via parameter number xx.yy
View If you know the parameter by its number then this feature
Shortcut will help you to jump directly to view the parameter instead
of searching in function-wise parameter group
Copy Event and Data log files can be copied to Connected USB Refer
Datalog drive. USB Connected Indication is available in the menu. Troubleshooting
Select Date of which data log is to be copied and guide for more
press >Copy Datalog< details
Backup Parameters backup can be taken to USB through this menu
Parameter
3 .5.1.3 Base Line

In the base line of "User Menu" access to "Online Menu", "Maintenance" and
"Commissioning" are available

USER MANUAL Ver 1.3
3 .5.2 Maintenance
Picture 7 : Maintenance screen
In "Maintenance" all data and actions are available which are performed for service purposes
like diagnostics, adjustments and calibration
3 .5.2.1 Base Line

In the base line of "Maintenance" access to "Online Menu", "Commissioning" and "User
Menu" is available

Group Group Content Remark
Name
2.1 Diagnostics Digital IOs, Communications, Refer
Loadcells, Peripherals can be troubleshooting
Diagnosed using this menu guide for more
information
2.2 Totalizer 2 To reset the totalizer 2
2.3 Speed PI Settings PI parameters for Speed deviation
Regulations Used in combination
with iDD and should be disabled in
Standalone GDC Configuration
2.4 & 2.5 AIO Calibration Calibration of analog inputs Refer
2.5 & 2.7 Loadcell Calibration Calibration of load cell commissioning
2.8 Dynamic Zero Dynamic zeroing can be performed guide
2.9 Feeder PI Settings PI parameters for Feedrate

regulations
2.10 Filter Settings This menu provides filtering options
for Loadcell and feedrate
2.11 Load Correction Zero-Span correction, Control Refer
measurement, Curve Correction commissioning
can be done using this menu guide
2.12 Aeration Aeration Settings
If not all parameters of a group can be displayed on one screen, this is indicated on base line
by the present page number and with >Next< next page can be accessed.
In the base line of sub-menu, this menu can be left by >Back<and returned to "Maintenance"

USER MANUAL Ver 1.3
3 .5.2.2.1 Sub-Menu Diagnostics

Menu Screen Content
Digital IO Status • Status of Digital
Inputs and Outputs
can be monitored
• Black LED indicates
input/output is low
and Green LED
indicates
input/output is high.
• Help for Input and
Output assignments
is available
Picture 8 : Digital IO status screen
Communication • Status of all

Diagnostics communication lines
can be monitored
• Error counts
increments wherein
case of
communication
failure
• Please read System
Errors and Warnings
table for
Rectification of
communication fault
Picture 9 : Communication diagnostics screen
Loadcell Refer troubleshooting

Diagnostics guide for more
information
Picture 10 : Loadcell diagnostics screen

USER MANUAL Ver 1.3
Menu Screen Content

Master-Slave • Status of
Diagnostics Master/Slave
communication
lines can be
monitored
• Error counts
increments wherein
case of
communication
failure
3 .5.2.2.2 Sub-Menu Totalizer 2
Picture 11 : Totalizer 2 screen
The totalizer 2 is a long time running totalizer representing the mass fed over the feeding
system. This totalizer can be cleared in this menu by >Reset<. To leave this menu >Cancel<
or any other key in the base line can be used

USER MANUAL Ver 1.3
3 .5.3 Commissioning
Picture 12 : Commissioning screen
In "Commissioning" all parameters and actions are available which need to be adjusted
before commissioning the feeder

In the sub-menu section all the accessible parameters are categorized according to functional
groups like >Weigh feeder<, >Prehopper<, >configuration<, …. Additionally access to a
certain parameter groups is available via >shortcuts<.
Some parameter groups are not accessible because they are not configured,
e.g. >1.4 Prehopper<, if not configured in >1.2 configuration<
Picture 13: weigh feeder parameters
In the specific parameter screen parameters are shown with:

xx.yy [PrmName] >?< Value
parameter number parameter name help present value and edit window
The single parameters are explained in document GDC.Parameter.Manual

On left and right margin access to previous and next parameter group is available (here group
1.11 and group 1.2).

USER MANUAL Ver 1.3
If not all parameters of a group can be displayed on one screen, this is indicated on base line
by the present page number and with >Next< next page can be accessed.
In the base line of parameters, menu can be left by >Back<and returned to "Commissioning"
Group Group Content Remark

Name
1.1 Weigh feeder parameters related to weigh feeder machinery
1.2 Configuration selection of feeder type and feeding system
1.3 Measuring function Setting of measuring channels (Loadcells)
1.4 Prehopper Setting for prehopper above feeder
1.5 Prefeed Setting for prefeeder feeding onto weigh feeder
1.6 Interface Comm. setting to inverters and IO devices
1.7 System Control Setting for interface to host (plant control)
1.8 System Type Selection ‘Standalone’ or ‘iDD’
1.9 USB Operations Action to USB: save, restore, copy ..
1.10 Date & Time Adjust clock and calendar
1.11 IO Configurations Configuration of IOs and monitoring
3 .5.3.2 Base Line

In the base line of "Commissioning" access to "Online Menu", "Maintenance" and "User
Menu" are available

USER MANUAL Ver 1.3
4 INDEX HISTORY
Index Author Edition Modifications
1.0 ppol-in First issue
1.1 ppol-in Second issue Maintenance menu changed
1.2 ppol-in Third issue Minor changes
1.3 ppol-in Fourth issue Batch Mode, Aeration, Master-slave
Subject to change without notice.

The technical data and specifications are valid at the time of publication of this documentation.
The information provided in this publication is, however, checked on a regular basis and any
necessary corrections made in subsequent editions.
FLSmidth Private Limited reserves the right to alter these versions at any time.
We are always grateful for suggestions for improvement.

PARAMETER MANUAL Ver 1.3
Feeding Controller GDC – WF
ppol‐in / 08.Aug.2017 / File: GDC.WF.Parameter.Manual.docx RNDE1009201402
Parameter Manual

Software : WF
Version : V2.440

Table of content page
1 Parameters ............................................................................................................................. 3
1 .1 Parameter groups ................................................................................................................... 3
1 .2 Parameter group 1.1 Weigh feeder ......................................................................................... 4
1 .3 Parameter group 1.2 configuration.......................................................................................... 7
1 .4 Parameter group 1.3 Measuring function ................................................................................ 9
1 .5 Parameter group 1.4 Prehopper .............................................................................................. 11
1 .6 Parameter group 1.5 PreFEED.................................................................................................. 12
1 .7 Parameter group 1.6 Interface ................................................................................................ 14
1 .8 Parameter group 1.7 System Control ....................................................................................... 15
1 .9 Parameter group 1.8 System Type ........................................................................................... 16
1 .10 Parameter group 1.9 USB Operations ...................................................................................... 16
1 .11 Parameter group 1.10 Date & Time ......................................................................................... 17
1 .12 Parameter group 1.11 IO CONFIGURATIONS ............................................................................ 18
1 .13 Parameter group 2.9 FEEDEr PI settings ................................................................................... 20
1 .14 Parameter group 2.10 Filter settings ....................................................................................... 21
1 .15 Parameter group 2.11 Correction paramters ........................................................................... 22
1 .16 Parameter group 2.12 Aeration ............................................................................................... 23
1 .17 Parameter group 3.1 Local setpoints ....................................................................................... 25
1 .18 BATCH MODE .......................................................................................................................... 26
1 .19 Parameter list ......................................................................................................................... 27
2 Index history ...........................................................................................................................36

1 PARAMETERS
1 .1 PARAMETER GROUPS
All parameters are arranged in groups relating to main themes like configuration, System Control, …
Group Group Name Content
1.1 Weigh feeder Parameters related to weigh feeder machinery
1.3 Configuration Selection of feeder type and feeding system
1.3 Measuring Setting of measuring channels

function
1.2 Interface Communication setting to inverters and IO devices
1.8 System Type Selection Standalone or iDD
1.9 USB Operations Action to USB: save, restore, copy, .. firmware and
configuration
1.11 IO Configuration Configuration of analog and digital IOs inclusive monitoring

1 .2 PARAMETER GROUP 1.1 WEIGH FEEDER

These parameters are related to the weigh feeder machinery
ID & Meaning Remark

parameter
name
For feeding systems with the option speed source (40.14)
41.31
tachometer or incremental sensor (right) / incremental
Revolution
sensor (left) the speed of the feeder drive is calculated
pulses [/r] from this information. (Alternative designation: number of
teeth)
When encoder is mounted on Motor Shaft Division Factor
41.34 Division
should be 1.
Factor []
When encoder is mounted on Drive Pulley, Division factor is
generally a value of Gear Box Ratio.
In order to be able to calculate the material speed, the
41.32 Speed
ratio of feeder drive speed to the conveying speed and
constant []
the conveyor section must be known. This ratio reflects the
speed constant (Gk). The value can be seen in or
calculated from the datasheet of the weigh feeders.
41.33 Drive This is the delay time of the powertrain against the change
inertia [] of the speed setpoint. This dwell time must be taken into
account for precise control of the speed of the feeder drive
at the material drop point (prosCon). This value is
determined by testing and is a constant for each individual
feeder scale type.
The rotation constant represents the number of increments
41.36 Rotation
of the feeder drive for a complete rotation of the conveyor
constant []
belt. It serves as the basis for segmenting the conveyor
belt. A rotation constant can only be logged if the
synchronization option in synchronization (40.13) is not
time based.
The slip constant is logged as part of logging the rotation
41.37 Slip
constant. It contains the number of increments of the
constant []
feeder drive between two synchronization pulses. If, under
synchronization (40.13),the synchron sensor option is
selected, the rotation constant and the slip constant are
identical. However, if the 2 synchron sensors option is
selected, rotation constant is a multiple of the slip
constant.
Slip means that the drive "is skidding". As a result, the
41.38 Max. slip
speed measured is no longer proportional to the material
[%]
speed. Using max. slip the tolerated deviance of the
current number of increments (per rotation of the conveyor
belt) from the slip constant is established. If this value is
exceeded, the warning message slip monitoring is given.
ID & Meaning Remark
parameter

name
The max. feed rate limits the defining of setpoints.
41.11
(Alternative designation: max. flowrate)
Maximum
feedrate [t/h]
41.21 The distance between the measuring point and weigh feeder
outlet (material drop point) is given as charging distance with
Discharge
band scales. This parameter is required for feeding at the
distance [m]
drop point.
41.23 Length of the area where material mass is measured Only
applicable for belt weigh feeders. See section LM below
Measuring
under characteristics. (Alternative designation: effective
section [m]
weigh length)
41.12 This load value serves as a reference for the relative display
of load‐relevant data such as load WIa1[%], (), etc
Nominal load
[Kg/m]
41.13 When measuring the load, the material weight is moved

using a lever on the load cell(s).The total ratio of this leverage
Scale Leverage
is to be stated here.
41.14 The check weight is applied to the load cell via a lever. The
total ratio of the lever for hanging the check weight is stated
Checkweight
here.
Leverage
41.35 Time that the conveyor needs for one rotation at max. speed
(31.33) of the feeder drive.
Nom. rotation
time [Sec]
31.19 A newly logged dynamic zero point is limited by this

parameter. This stops erroneously logged dynamic zero
Max. dynamic
points (for example unintentional logging with material in the
zero [%]
conveyor belt) causing false readings at the weighfeeder
measurement area. The dynamic zero point is to be taken
again after the weigh feeder has been checked.
31.21 Weight value of the check weight that is used for the
theoretical calibration of the weigh feeder.
Checkweight
[Kg]
ID & Meaning Remark

parameter
name
31.33 Maximum Tacho speed. It serves as a speed reference for

various proportioning functions.
Max. Speed
[rpm]
31.34 Maximum Tacho speed Limit. It serves as a limit for

frequency set point to Inverters.
Max. Speed
Limit [rpm]
31.51 If a correction value greater than increment zero correction is

given by the interface, the correction is only undertaken up
Increment zero
to increment zero correction. Erratic changes of the feeder
correction Zero
outputs are therefore avoided.
correction [%]
31.52 This value limits the amount of correction values of the zero
point that can be transferred via the interface.
Max. zero
correction [%]
31.54 This value consists of the sum of individual corrections.

Sum of zero
correction [%]

1 .3 PARAMETER GROUP 1.2 CONFIGURATION

These parameters are related to the configuration of the feeding system
ID & parameter Meaning Remark

name
The measurement principle of a weigh feeder is
40.11 Feeding
established here.
system
a) DRW rotor feeder
Feeding rotors are feeding systems with rotating
conveyors and pneumatic material transport. The
measuring section is defined by the rotary axis of the
rotor mounting.
b) XRW rotor feeder
Feeding rotors are feeding systems with rotating
conveyors and pneumatic material transport. The
measuring section is defined by the rotary axis of the
rotor mounting.
c) DBW/FBW belt feeder
Band scales are feeding systems with transport belts
as conveyors and a controllable belt speed. The
measuring section is defined by two limit rollers.
d) Belt Weigher
The Conveyor Belt Weigher system consists of a
conveyor belt whose load is constantly weighed with a
measuring device.
The type of synchronization determines how a circulation
40.13
of the conveyor belt is detected for a weigh feeder with a
Synchronization
defined measuring section. The dynamic zero always goes
for one rotation.
a) Time based
Means that one rotation of the conveyor at max. speed
(31.33) of the feeder drive needs the time specified in
the parameter nom. rotation time (41.35).The actual
time needed for a rotation is calculated permanently in
dependence on the current speed of the feeder drive.
b) Synchron sensor
With each rotation of the conveyor, a pulse is sent to a
feeding computer. For this, the mechanics of the weigh
feeder must be equipped with a synchron sensor. The
conveyor can be divided into segments using a
synchron pulse and the position generated by the
feeder drive. As a result of this, a more precise logging
and processing of the dynamic zero point as well as
precise control of the speed of the feeder drive on the
material drop point ProsCon) is possible. Furthermore,
any slippage that may occur can be detected by the
synchron sensor.
c) 2 synchron sensors

If this option is selected, the mechanics of the weigh

feeder are equipped with a second synchron sensor.
This second synchron sensor is used for monitoring
slippage for very slow-running conveyors.
d) Disable
Static Zero will be considered for Load Calculations
The source of the feeder drive's speed constant is thus
40.14 Speed
established.
source
a) Fix frequency
The feeder device does not record speed in terms of
revolutions; the conveyor belt is operated at a constant
speed.
b) Tachometer
At the feeder drive shaft there is a feeder drive
sprocket that creates a defined number of revolution
pulses (41.31). The speed of the feeder drive is
calculated in the feeder computer using the pulse
recorded over time.
c) Incremental sensor (right)
An incremental sensor is fitted at the feeder drive
shaft, which creates a defined amount of revolution
pulses (41.31), like the option Tacho. With the
incremental sensor, it is possible, in addition to speed,
to also detect the rotational direction of the drive.
Incremental sensor (right) means that the motor for
the feeder drive turns in a clockwise direction when
looking at the drive side.
d) Incremental sensor (left) or Inverter
However, as with incremental sensor (right), the motor
turns counter-clockwise when looked at from the drive
side.
Inverter - Tacho frequency is read from the inverter
Types of fieldbus supported:
40.51 SIO
a) Off
Interface
b) Modbus
c) Profibus
d) DeviceNet
e) Ethernet/IP
f) Modbus TCP/IP
40.52 SIO
Address of controller when connected to a multi-drop bus
Address
on the Serial network
40.53 SIO Baud Setting the baud rate at serial interface 9600-
Rate 115200 bps
40.21 This parameter defines the specification of the feeder

Prehopper system with or without a prehopper or silo.

40.19 Prefeed This parameter defines the specification of the feeder

system with or without prefeeder.
a) Off
b) On-Auto Control – Start/Stop as per WF
Start/Stop
c) On – IO Control – Start/Stop via Digital Inputs
a) None
40.25 Feeder
b) Screw Feeder
Variant
c) Weigh Belt Feeder
d) Reserve
Select as per the target application
40.26 Prefeed This parameter is used to set Master or Slave Master-

Master/Slave Slave
40.27 Slave ID If 40.26 is set to Slave, unique slave ID need to be

selected
40.28 Number Number of slaves connected to master. Max 5 Slaves can

of Slaves be connected
1 .4 PARAMETER GROUP 1.3 MEASURING FUNCTION

These parameters are related to load measuring function on base of load cells

name
Loadcell 1 function selection
46.15 Loadcell
1 (MF1)
46.16 Loadcell Loadcell 2 function selection

2 (MF2)
In order to optimally adapt the processing of measurement values
46.22 MF1
Input Voltage
to the signal voltages,the measurement range of the
[mV] measurement function is selected using this parameter.
The selected input area is the maximum signal voltage that is
digitalised by the amplifier.This input area may not be exceeded at
any time; any feeding that may be ongoing may be stopped.
Feeding systems often have high tare load that can result in high
46.23
Compensation
pre‐tension at the measurement system. This pre‐tension can be
of dead load suppressed by the compensation of dead load MF1 field. The
MF1 [%] compensation is given in percent of the selected inputrange MF1.
46.24 MF1 If the weighfeeder is empty, this measuring point is set as

Dead load point dead load point MF1 during calibration.

[d]
The calibration factor MF1 represents the increase of the
46.25 MF1
weigh characteristic after calibration.
Calibration
factor
46.26 MF1 Corrections to the calibration from dynamic calibrations.

Correction
calibration [%]
In order to optimally adapt the processing of measurement
46.32 MF2
values to the signal voltages,the measurement range of
Input voltage
the measurement function is selected using this
[mV] parameter.The selected input area is the maximum signal
voltage that is digitalised by the amplifier.This input area
may not be exceeded at any time; any feeding that may
be ongoing may be stopped.
Feeding systems often have high tare load that can result in high
46.33
Compensation
pre‐tension at the measurement system. This pre‐tension can be
of dead load suppressed by the compensation of dead load MF2 field. The
MF2 [%] compensation is given in percent of the selected inputrange MF2.
46.34 MF2 If the weighfeeder is empty, this measuring point is set as

Dead load point dead load point MF2 during calibration.
[d]
46.35 MF2 The calibration factor MF2 represents the increase of the
Calibration weigh characteristic after calibration.
factor

1 .5 PARAMETER GROUP 1.4 PREHOPPER

These parameters are related to the configuration of the prehopper

name
Material Level in Hopper, below which control measuring
46.21 Limit1
cycle should stop
[%]
Material Level in Hopper below which control measuring
46.22 Limit2
cycle should not start
[%]
Material fill level in Hopper up to which material is to be
46.23 Limit3
filled for control measuring cycle to re-start
[%]
Is the bin weight capacity in tons, to which it is calibrated
46.24 Nominal
Capacity [t]
Underload fault is generated if bin loadcell value
46.25
drops below this limit
Underload Limit
[%]
Overload fault is generated if bin loadcell value
46.26 Overload
goes above this limit
Limit [%]

1 .6 PARAMETER GROUP 1.5 PREFEED

These parameters are related to the configuration of the prehopper

name
32.01 Range 0.1 to

PID Parameters
Proportional 2
Gain Kp []
32.02 Integral Range 1 to

PID Parameters
Gain Tn [Sec] 10
32.03 Range 1 to
PID Parameters
Derivative Gain 10
Tv [Sec]
32.04 Range 1 to
PID Parameters
10
Derivative
Damping Time
Td [Sec]
32.05
Set point value for Prefeed System
Load Setpoint
[%]
32.06 Applicable
Prefeeder set point is relative value of main Drive Set
When 32.18
Proportionate point.
Proportion of this much percentage of main drive set point set to “WF
Value [%]
is sent to Prefeeder Drive as set point. Drive SP”
32.18 Prefeed This is to set Type of Prefeeder

Type
a) WF Drive SP – Percentage of main drive setpoint is
sent to PF Setpoint
b) Belt Load PI – PF Drive set point is controlled through
PI to maintain Bed height
c) Prefeed Load PI – PF Drive set point is controlled
thorough PI to maintain hopper level
32.19 Percentage Belt loading band within which no PI correction
Permissible takes place.
Deviation [%]
32.20 Minimum When Load value is less than Min Initial Load then
Initial Load Prefeeder runs at Initial Load Setpoint for time defined by
[%] Initial Load Delay. After this time period, the setpoint

value is generated by PI
32.21 Initial Description as above

Load Delay [s]
32.22 Initial Description as above

Load Setpoint
[%]
32.23 Max PF Max speed of Prefeeder Motor

Motor speed
[rpm]
32.24 Max If prefeed load is greater than Max Prefeed load then It doesn’t
Prefeed Load Prefeeder motor stops affect the
[%] Prefeeder
On Output

1 .7 PARAMETER GROUP 1.6 INTERFACE

These parameters are related to configuration of communication nodes like Analog/Digital IOs,
inverters, ..

name
36.01 Number This enables to select number to inverters interfaced with

of Inverters the controller. Example 0,1,2
36.02 Inverter This enables to select type of inverter interfaced with the
Type 1 controller. Example ACS550
Also select the Inverter Address
36.03 Inverter This enables to select type of inverter interfaced with the
Type 2 controller. Example ACS550
Also select the Inverter Address
36.04 Number Select type and select number of AIO cards interfaced with Select Old
of AIO the controller. Example 0,1,2 875 or New
type of card
Please read note Below
36.05 Number Select type and select number of DIO cards interfaced with Select Old
of DIO the controller. Example 0,1,2,3 889 or New
type of card
Please read note Below
36.06 Number This enables to select number of field AIO modules

of AIO (Field) interfaced with the controller.
36.07 Number This enables to select number to field DIO modules

of DIO (Field) interfaced with the controller.
This Enables Word and Byte Swapping to handle Endian-
36.08 Fieldbus
ness of connected system.
Swap
Fieldbus monitoring : It enables fieldbus monitoring
36.09 Fieldbus
feature of the System. Communication Counter data must
Monitoring
contain a different value for each write cycle, the data is
discarded otherwise. System generate "Fieldbus
Communication Error!" if Communication Counter value
doesnt change over period of time.
Frequency drives ACS550, VACON20, ACS850, PF40, SK520 are currently supported.
Note for Old AIO/DIO Cards
 OLD DIO will not work when Master Slave Configuration is enabled
 Inverter port baud rate should be set to 19200.
 Inverter port Parity should be None.

 OLD AIO should be used along with OLD DIO. New n OLD combination is not possible
in case of AIO. For DIO its possible.
 Only one OLD AIO card is supported i.e. Max 2 Inputs & 2 Outputs.
 Only two DIO with two daughter board are supported i.e. max 32 inputs & 32 outputs.
 Transmit will not be same as Receive counts but double.
1 .8 PARAMETER GROUP 1.7 SYSTEM CONTROL

These parameters are related to the way how dosing is controlled

name
is used to set a control of Remote-Local mode selection.
38.01 Remote-
a) Internal means It can be changed from HMI
Local Selection
b) External means via PLC.
is used to set a control of System Operations in Remote
38.02 Control
mode.
Source in
a) Hardwire means Control through Digital Inputs
Remote b) Hostlink means control through Fieldbus.
is used to set a control of Gravimetric-Volumetric
38.03
selection.
Gravimetric-
a) Internal means it can be changed from HMI
Volumetric b) External means via PLC
Selection c) Auto means as per mode that is, in Remote mode,
it can be changed via PLC and in Local mode, it can
be changed from HMI.
is used to set Type of Start-Stop input in Remote Mode.
38.04 Start-
a) Level Type means Start input is high then feeder
Stop type in
will start
Remote b) Rising Edge Type means when Start input goes low
to high then only feeder will start.
is used to set a control of Fieldbus Permission.
38.05 Fieldbus
Internal means It can be given from HMI and External
Permission
means via PLC.
is used to set seperate inputs for Start-Stop in Remote
38.06 Separate
mode.
Start-Stop in
Remote
is used to set Field permission with or without Switch in
38.07 Field
LCB. In field permission without switch can be given
Switch
through HMI.
Selection
is used to set a control of System Operations in Field
38.08 Control
mode.
Source in Field
a) Hardwire means control through Digital Inputs
b) PHT means through Handheld Terminal
c) Drive means through Inverter Digital Inputs

1 .9 PARAMETER GROUP 1.8 SYSTEM TYPE

These parameters are related to system configuration

name
40.40 System This option enables to configure the system to work with
Type iDD or as a standalone unit.
Standalone GDC : This option enables user to operate
GDC controller as a standalone unit. Here the loadcell
signal is directly given to the GDC controller.
GDC with iDD : This option enables user to operate the

GDC controller with iDD controller. Here the loadcell signal
is given to the iDD controller.
1 .10 PARAMETER GROUP 1.9 USB OPERATIONS

These parameters are related to system operations on base of USB

name
It copies the firmware file from USB to internal memory.

Copy Firmware
On next power on, controller loads with new firmware.
Copy Resources This menu enables user to copy resources from USB to
from USB Internal memory.
Restore This menu enables user to restore backup files from the
Configuration USB.
from USB

1 .11 PARAMETER GROUP 1.10 DATE & TIME

These parameters handle the calendar and clock

name
Enter Correct Date, Month & Year and Press Set Date to
Set date
change the Controller Date.
Valid Range of Values
a. Date : 1 – 31
b. Month : 1 – 12
c. Year : 2000 – 2100
Enter Correct Hour, Minute & Second and Press Set Time
Set time
to change the Controller Time.
Valid Range of Values (24 Hour Format)
a. Hour : 0 – 23
b. Minute : 0 – 59
c. Second : 0 – 59

1 .12 PARAMETER GROUP 1.11 IO CONFIGURATIONS

These parameters are related to hardwired interface
ID & Meaning Remark

parameter
name
Analog Inputs and outputs can be defined here.
Analog IO
Definitions
Inversion can be used to invert IOs individually.
IO Inversion
 Inversion can be enabled/disabled by pressing ON-
OFF Switch.
 Green LED indicates inversion is disabled and Red
LED indicates inversion is enabled.
 Number indicates IO number.
 These Timers can be used to set a monitoring time

IO Monitoring
for IOs.
Timers
 Set value to 0, bypasses respective error.
37.26 Pulse Pulse Output can be enabled/disabled

Output
37.27 Pulse Width of Pulse Output

Width
37.28 Pulse Resolution of pulse output. When Totalizer Value changes

Resolution by this value, pulse output is generated.
37.29 If difference between set point and actual feedrate greater

Deviation Limit than this value then output will be generated
37.30 Limit for Loading underload condition

Underload
Limit
37.31 Limit for Loading overload condition

Overload Limit
37.32 Change the type between Warning and Error for SF Belt
Slip fault
SF ZSS Type
E.g.
37.14 Output can be scaled to 0.10 to 2.00
AIO1 Output 1 If set to 1 then
Output is
scaled to 0‐

100 % and If
37.14 Output can be scaled to 0.10 to 2.00
set to 2 then
AIO1 Output 2 Output is
scaled to 0‐
200 %.
37.15 Output can be scaled to 0.10 to 2.00 Note:
AIO2 Output 1
Analog output
scale can’t be
set to 0. If set
37.16 Output can be scaled to 0.10 to 2.00 it to 0 then it
is changed to
AIO2 Output 2
1.

1 .13 PARAMETER GROUP 2.9 FEEDER PI SETTINGS

name
PI Settings
32.10
Proportional
Gain Kp []
PI Settings
32.11 Integral
Gain Tn [s]
PI Settings
32.12
Derivative Gain
[s]
PI Settings
32.13
Derivative
Dumping Time
Td [s]

1 .14 PARAMETER GROUP 2.10 FILTER SETTINGS

name
This filter will be applied to Feedrate calculation
32.14 Feedrate Filter values
calculation set to 1 if 0
Filter []
This filter will be applied to Belt Load Display

32.15 Belt Load
Display Filter []
This filter will be applied to Feederate display filter

32.16 Feedrate
display Filter []
Feedrate calculation filter can be set from 1 - 20.

1 .15 PARAMETER GROUP 2.11 CORRECTION PARAMTERS
ID & parameter name Meaning Remark

39.02 This is the time for which control
measurement is to be carried out
Correction time [sec]
39.03 This parameter is timeout in case the user

does not accept or reject the control
CM Timeout [min] measurement

1 .16 PARAMETER GROUP 2.12 AERATION

These parameters are related to the configuration of aeration system

name
This parameter selects number of aeration outputs that is
35.01 Number
to be used.
of Aeration []
Maximum 6 numbers of aeration outputs are available
Two types of aeration schemes are available
35.02 Aeration
Concurrent – All aeration outputs are on/off concurrently
Scheme []
Sequential – Aeration outputs are on/off sequentially one
at a time
Aeration timings for outputs can be same or different
35.03 Aeration
Same – On/Off Timings that are set for Aeration 1 will be
Timer Setting
copied to all remaining aeration outputs
[] Different – On/Off timing for each aeration outputs need to
be set separately
When Aeration scheme is concurrent then Common ON
35.04
time is used for all selected Aeration outputs
Common ON
Time [s]
When Aeration scheme is concurrent then Common OFF
35.05
time is used for all selected Aeration outputs
Common OFF
Time [s]
35.09 Time for which Aeration 1 output remains High

Aeration 1 ON
Time [s]
35.09 Time for which Aeration 1 output remains Low

Aeration 1 OFF
Time [s]

Aeration 2 ON
Time [s]

Aeration 2 OFF
Time [s]

Aeration 3 ON

Time [s]

Aeration 3 OFF
Time [s]

Aeration 4 ON
Time [s]

Aeration 4 OFF
Time [s]

Aeration 5 ON
Time [s]

Aeration 5 OFF
Time [s]

Aeration 6 ON
Time [s]

Aeration 6 OFF
Time [s]

1 .17 PARAMETER GROUP 3.1 LOCAL SETPOINTS

name
It is maximum feedrate that can be achieved by the
41.11
feeder.
Maximum
Feedrate [t/h]
It is used to limit the maximum feedrate of the feeder.

36.10
Proportionate
Feedrate [%]
In Local gravimetric mode, this is feedrate setpoint.

36.11
Gravimetric
Setpoint [t/h]
In Local unregulated mode, this is feedrate setpoint.

36.12
Volumetric
Setpoint [t/h]

1 .18 BATCH MODE

Batch mode settings can be accessed in command menu.
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.

name
To enable/disable the Batch mode operation
47.01 Batch
mode selection
To set the reference value for the Batch. After the target
47.02 Target
quantity of the material has been conveyed, a warning or
Quantity [t]
automatic halt command can be generated
To enter the error value of the batch due to inflight weight

47.03 Inflight
that can be quantity overfed by the feeder
Compensation
[t]
To set the action on completion of the batch
47.04 Batch
Complete Warning or Halt
action
Current target quantity is displayed that set by any
47.05 Current
selected source
Target Quantity

1 .19 PARAMETER LIST
Parameter Nr Description Range

41.31 Revolution pulses -999 to 9999
41.34 Division Factor 0.1 to 999.9999
41.32 speed constant 0.0 to 9999.99
41.33 Drive inertia 0.0 to 99.99
41.36 Rotation constant 99999999
41.37 slip constant 99999999
41.38 max. slip 0.0 to 100
41.11 max. feed rate 0.0 to 9999.99
41.21 discharge distance 0.0 to 999.999
41.23 Measuring section 0.0 to 999.999
41.12 nominal load 0.0 to 9999.99
41.13 scale leverage 0.0 to 99.999
41.14 Checkweight leverage 0.0 to 99.999
41.35 nom. Rotation time 0.0 to 9999.99
31.19 max. dynamic zero 0.0 to 50.00
31.21 checkweight 0.0 to 999.99
31.33 Max Speed [rpm] 0.0 to 9999.99
31.34 Max Speed Limit [rpm] 0.0 to 9999.99
31.51 increment zero correction 0.0 to 99.99
31.52 max. zero correction 0.0 to 99.99
31.54 Sum of zero correction 0.0 to 9999.99
40.11 Bit arrange- System Function
ment
B0..B1 B0 B1 feeding system
0 0 DRW rotor
feeder
1 0 XRW rotor
feeder
0 1 DBW/FBW
belt feeder
B2..B7 Not used
B8..B9 B8 B9 synchronization
0 0 time based
1 0 Synchron
sensor
0 1 2 synchron
Sensors
1 1 Disable
B10..B11 Not used
B12..B13 B12 B13 speed source
0 0 fix frequency
Limited 1 0 tachometer
0 1 Incremental
sensor
(right)
1 1 incremental
FLSmidth Private page 27/36

sensor
(left)/Inverter
B14..B31 Not used
example:
3101h=
XRW + synchron sensor +
incremental sensor (left)
40.51 SIO Interface 0 to 5
Value Selection
0 Off
1 Modbus
2 Profibus
3 DeviceNet
4 Ethernet IP
5 Modbus TCP/IP
40.52 SIO Address 1 to 127
40.53 SIO Baud Rate 9600 to 115200
40.19 Prefeed 0 to 2
0 = Off 1 = On – Auto Control 2 = On – IO Control
40.21 prehopper 0 to 1
0 = no 1 = yes
40.25 Feeder Variant 0 to 3
0 = None 1 = Screw Feeder 2 = Weigh Belt Feeder
3 = Reserve
40.26 Prefeed Master/Slave 0 to 2

0 = Slave 1 = Master 2 = Disable
40.27 Slave ID 0 to 5
40.28 Number of Slaves 0 to 5
46.15 Loadcell Selection 0 to 2
Value Loadcell 1 Loadcell 2
0 Disabled Disabled
1 Enabled Disabled
2 Enabled Enabled
46.22 Loadcell1 input range [mV] 0 to 7
Value Selection
0 41.48
1 20.74
2 10.37
3 5.19
4 +/- 5.19
5 +/- 10.37
6 +/- 20.74
7 +/- 41.48
46.23 Loadcell1 compensation of dead load [%] 0 to 6
(not supported with FDMVa)
Value Selection
0 0
1 -25
2 -50

3 -75
4 -100
5 -150
6 -175
46.24 Loadcell1 dead load point [Digit]
46.25 Loadcell1 calibration factor
46.26 Loadcell1 correction calibration [%]
46.32 Loadcell2 input range [mV] 0 to 7
Value Selection
0 41.48
1 20.74
2 10.37
3 5.19
4 +/- 5.19
5 +/- 10.37
6 +/- 20.74
7 +/- 41.48
46.33 Loadcell2 compensation of dead load [%] 0 to 6
Value Selection
0 0
1 -25
2 -50
3 -75
4 -100
5 -150
6 -175
46.34 Loadcell2 dead load point [Digit]
46.35 Loadcell2 calibration factor
46.21 Limit1 [%] 0.0 to 100.0
46.22 Limit2 [%] 0.0 to 100.0
46.23 Limit3 [%] 0.0 to 100.0
46.24 Nominal Capacity [t] 0 to 9999
46.25 Underload Limit [%] 0 to 200
46.26 Overload Limit [%] 0 to 200
32.01 Proportional Gain Kp 0.0 to 25.99
32.02 Integral Gain Tn [s] 0.0 to 99.99
32.03 Derivative Gain Tv [s] 0.0 to 99.99
32.04 Derivative Damping Time Td [s] 0.0 to 99.99
32.05 Set point Value [%] 0.0 to 199.99
32.17 Proportionate Value [%] 0.0 to 200.00
32.18 Prefeed Type 0 to 2
32.19 Permissible Deviation 0 to 99.99
32.20 Minimum Initial Load [%] 0 to 999.99
32.21 Initial Load Delay [s] 0 to 999
32.22 Initial Load Setpoint [%] 0 to 999.99
32.23 Max PF Motor Speed [rpm] 0 to 9999.99
32.24 Max Prefeed Load [%] 0 to 999.99
36.01 Number of Inverters 0 to 2
36.02 Inverter 1 Type 0 to 5
Value Selection

0 SK520
1 VACON20
2 ACS550
3 NA
4 PF40
5 ACS550
36.03 Inverter 2 Type 0 to 5
Value Selection
0 SK520
1 VACON20
2 ACS550
3 NA
4 PF40
5 ACS550
36.04 Number of AIO (Max 2) 0 to 2
36.05 Number of DIO (Max 3) 0 to 3
36.06 Number of Field AIO 0 to 3
36.07 Number of Field DIO 0 to 3
36.08 Fieldbus Swap 0 to 3
0 = Disable 1 = Word Swap
2 = Byte Swap 3 = Word_Byte Swap
36.09 Fieldbus Monitoring 0 to 1
0 = Disabled 1 = Enabled
38.01 Remote Local Selection 0 to 1
0 = Internal 1 = External
38.02 Control Source in Remote 0 to 1
0 = Hardwire 1 = Hostlink
38.03 Gravimetric Volumetric Selection 0 to 2
0 = Internal 1 = External 2 = Auto
38.04 Start Stop Type in Remote 0 to 1
0 = Level 1 = Rising Edge
38.05 Fieldbus Permission 0 to 1
0 = Internal 1 = External
38.06 Separate Start Stop in Remote 0 to 1
0 = No 1 = Yes
38.07 Field Switch Selection 0 to 1
0 = No 1 = Yes
38.08 Control Source in Field 0 to 2
0 = Hardwire 1 = PHT 2 = Drive
System Type 11 or 12
11 – Standalone GDC 12 – GDC with iDD
MAC Address
Date and Time(24 Hr Format)
37.01 AIO1 Input 1 Definition 0 to 3
Value Input
0 Off
1 PLC Setpoint
2 Proportionate Capacity
3 Field Set point

37.05 CAN Input Definition 0 to 1
Value Input
0 Off
1 Field Set point
37.06 CAN Input Type 0 to 1
37.07 AIO1 Output 1 Definition 0 to 8
Value Output
0 Feedrate
1 Belt Load
2 Motor Speed
3 Current Set point
4 Drive Set point
5 Prefeed Set point
6 Bin Weight
7 Sk Value
8 12 mA
37.11 CAN Output Definition 0 to 5
Value Output
0 Feedrate
1 Belt Load
2 Motor Speed
3 Current Set point
4 Drive Set point
5 Prefeed Set point
37.12 CAN Output Type
DIO1 Input Inversion in Hex format E11.....E00
DIO2 Input Inversion in Hex Format E23.....E12
DIO3 Input Inversion in Hex Format E31.....E24
CAN Input Inversion in Hex Format E56.....E36
DIO1 Input Inversion in Hex Format A11.....A00
CAN Input Inversion in Hex Format A59.....A36
37.13 Tacho Monitoring Time [s] 0 to 999.9
37.14 Belt Track Monitoring Time [s] 0 to 999.9
37.15 Deviation Monitoring Time [s] 0 to 999.9
37.16 ZSS Time [s] 0 to 999.9
37.26 Pulse Output 0 to 1
0 = Disable 1 = Enable
37.27 Pulse Width 0 to 5
Value Meaning
0 50 ms
1 100 ms
2 150 ms
3 200 ms
4 500 ms

5 1 Sec
37.28 Pulse Resolution 100Kg/250Kg/500Kg 0 to 2
37.29 Deviation Limit [%] 0 to 100.00
37.30 Underload Limit [%] 0 to 100.00
37.31 Overload Limit [%] 0 to 100.00
37.32 SF ZSS Type 0 to 1
32.08 PI Selection 0 to 1
0 = Disable 1 = Enable
32.12 Derivative Gain Tv [s] 0.0 to 99.99
32.13 Derivative Damping Time Td [s] 0.0 to 99.99
32.14 Feedrate calculation Filter 0 to 20
32.15 Belt Load Display Filter 0 to 20
35.01 Number of Aeration 0 to 6
35.02 Aeration Scheme 0 to 2
0 = Off 1 = Concurrent 2 = Sequential
35.03 Aeration Timer Settings 0 to 1
0 = Same 1 = Different
35.04 Common On Time 0 to 999
35.05 Common Off Time 0 to 999
35.09 Aeration 0 On Time 0 to 999
35.09 Aeration 0 Off Time 0 to 999
32.16 Feedrate Display Filter 0 to 20
36.10 Proportionate Feedrate [%] 0.0 to 100.0
36.11 Gravimetric Set point [tph] 0.0 to 9999.99
36.12 Volumetric Set point [tph] 0.0 to 9999.99
Free Bytes in Internal Storage Memory [Bytes]
37.50 AIO1 Output1 Scaling 0.1 to 2.0
39.02 Correction Time [s] 0 to 999
39.03 CM Timeout 0 to 20
IO Mapping for Inputs and Outputs 0 to 49
Mapping for E00 – E49 and A00 – A49
Input and Output lists are given below
GDC CPU Software version BWFX.X
Parameter List Version vX.X

Inputs Codes
0 Belt Slip
1 Belt Track
2 Material Detection
3 Synchronous Sensor
4 Remote Start [Stop]
5 Fault Reset
6 Drive Interlock
7 Field Selector Switch
8 Emergency LCB
9 Start Feeder LCB
10 Stop Feeder LCB
11 Start Release
12 Field Permission
13 Volumetric [Gravimetric]
14 Control Supply On
15 Isolation Switch On
16 Field Supply On
17 [Emergency]
18 Vibration Interlock
19 Remote [Local]
20 Prefeed Start
21 Prefeed Stop
22 Aeration
26 Spil Conveyor Off
27 Maintenance Switch
28 Motor Thermal Switch
29 Vibrator Switch
30 Prefeed Slip
31 Prefeed Belt Track
32 Set point Increase
33 Set point Decrease
34 Start Prefeeder LCB
35 Stop Prefeeder LCB
36 Prefeeder Set point Increase
37 Prefeeder Setpoint Decrease
38 Remote Stop

39 Vibrator Stop
40 Pull Chord Switch
41 PF Motor Interlock
42 CM Abort
43 CM Start
44 CM Accept
45 BIN PF On
46 BIN PF Loc/Rem
47 Shutoff Gate
48 SF Belt Slip
Output Codes
Code Meaning 1 [0]
0 Feeder On
1 General Fault
2 Remote [Local]
3 Pulse
4 Panel Healthy
5 Feeder On Lamp
6 Feeder On Lamp LCB
7 Field mode [Local]
8 Volumetric [ Gravimetric]
9 Drive Fault
10 Vibrator On Signal
11 Vibrator On Status
12 Belt Track Fault
13 Prefeeder On
14 Prefeeder Fault
15 Deviation Fault
16 Loadcell Fault
17 Tacho fault
18 Belt Slip Fault
19 Emergency Off
21 CM Aborted
22 Bin Gate Open/Close
23 Vibrator On Lamp LCB
24 Prefeeder On Lamp LCB
25 Feeder Trip
26 Vibrator Motor Fault
27 Material Low
28 Zeroing On
29 Pull Chord Healthy
30 Maintenance Off
31 PF Motor Fault
32 Bin High

33 Bin Low
34 CM On
35 Sk Exceeded
36 BIN PF Start/Stop
37 LC1 Underload
38 SF Belt Slip Fault
39 LC1 Overload
41 Aeration 1
42 Aeration 2
43 Aeration 3
44 Aeration 4
45 Aeration 5
46 Aeration 6
47 Aeration Header
48 High
49 Low

2 INDEX HISTORY
1.0 PPOL-IN 01-09-2014 First issue.
1.1 PPOL-IN 06-01-2015 Curve Correction Help
1.2 PPOL-IN 13-01-2015 Parameter List information added, Prefeed Parameter

Updated
1.3 PPOL-IN 02-03-2016 Master-Slave, Aeration, Parameter list

The technical data and specifications are valid at the time of publication of this documentation. The
information provided in this publication is, however, checked on a regular basis and any necessary
corrections made in subsequent editions.

COMMISSIONING GUIDE Ver 1.4
ppol-in / 03.May.2017 / File: GDC.WF.Commissioning.Guide .docx RNDE1009201404
Commissioning Guide
Software : WF
Version : V2.440 onwards

Table of Content Page

1 General ........................................................................................................................................... 4
Conventions ...................................................................................................................................... 4
2 GDC Modular System Overview ............................................................................................ 5
3 Connectors on GDC ................................................................................................................... 6
4 Controller LED Indications ...................................................................................................... 9
5 Parameter Settings .................................................................................................................. 10
6 System Control Setting .......................................................................................................... 12
7 Weigh Feeder Calculations .................................................................................................... 13
7.1 Nominal Belt Speed Calculation .................................................................................. 13
7.2 e-Distance Calculation .................................................................................................... 13
7.3 Speed Constant Calculation (Gk) ................................................................................ 14
8 Digital IO List ............................................................................................................................. 15
8.1 Inputs .................................................................................................................................... 15
8.2 Outputs ................................................................................................................................. 16
8.3 Inverter Inputs .................................................................................................................. 17
9 Analog IO List ............................................................................................................................ 18
9.1 Inputs .................................................................................................................................... 18
9.2 Outputs ................................................................................................................................. 18
10 Fieldbus Mapping .................................................................................................................. 19
10.1 General ............................................................................................................................. 19
10.2 Modbus RTU Interface (16 bit protocol) .............................................................. 19
10.3 Profibus DP Interface (32 bit protocol) ................................................................ 19
10.4 Ethernet-IP/Modbus TCP Interface (32 bit protocol)...................................... 19
10.5 Fieldbus Memory Map (16 Bit Protocol-Modbus) ............................................. 20
Input Registers .............................................................................................................................. 20
Command Register Bit Definition ........................................................................................... 21
Output Register ................................................................................................................................. 23

Status Register Bit Definition .................................................................................................. 24

10.6 Fieldbus Memory Map (32 Bit Protocol-Profibus, Ethernet/IP, Modbus
TCP/IP) 25
Input Registers .............................................................................................................................. 25
Command Register Bit Definition ........................................................................................... 26
Output Register ................................................................................................................................. 28
Status Register Bit Definition .................................................................................................. 29
Optional read values scheme .................................................................................................. 30
11 Analog Input Calibration .................................................................................................... 31
12 Analog Output Calibration ................................................................................................. 31
13 Loadcell Calibration ............................................................................................................. 32
13.1 Loadcell Calibration ..................................................................................................... 32
13.2 Dynamic Zero................................................................................................................. 33
14 Loadcell Calibration Correction ....................................................................................... 34
14.1 Zero Correction ............................................................................................................. 34
14.2 Span Correction ............................................................................................................ 35
14.3 Control Measurement ................................................................................................. 36
14.4 Remote Correction ....................................................................................................... 37
15 Master Slave Communication .......................................................................................... 37
16 Backup & Restore Configuration, Firmware Upgrade ............................................. 38
16.1 Configuration Backup.................................................................................................. 38
16.2 Configuration Restore and Firmware Upgrade from USB ............................. 39
17 Index history .......................................................................................................................... 40

1 General
This document describes the installation and commissioning of GDC for Weigh Feeder.
The followings sections contain information on:
Operations
Connection Details
Parameter and IO Settings as per Specific Job
System Calibration
Data Backup Restore and Firmware Upgrade
Conventions
>ButName< means a button with name ButName

[PrmName] means a parameter with Name PrmName
xx.yy means parameter number
xx.yy [PrmName] means indication of parameter name with its corresponding
parameter number
"PrmOptn" means a parameter option with name PrmOptn

2 GDC Modular System Overview

3 Connectors on GDC
No Connector Connector Name and Connector Connector Type Connector
Location Function Details Colour
1 Power Supply Card X1 – 24 V DC Power X1.1 ( 24P) 3 Way screw Black
Supply Terminal
X1.2 (24N)
X1.3 (E)
2 Power Supply Card X2 – Modbus X2.1 (T+) 3 Way Screw Green

Communication Terminal
(Inverter/VFD)
X2.2 (T-)
X2.3 (SH)
3 CPU Card X3 – USB Device Standard USB B

Type
4 CPU Card X4 – Ethernet 1 RJ45

(Service Port)
5 CPU Card X5 – USB Host Standard USB A

Type
6 CPU Card X6 – Modbus X6.1 (T+) 3 Way Screw Green

Communication (HMI) Terminal
X6.2 (T-)
X6.3 (SH)
7 DIO Card X7 – Digital Outputs D Type 15 Pin

Male
8 DIO Card X8 – Digital Inputs D Type 15 Pin

Female
9 AIO Card X9 – Analog Output 2 X9.1 (+) 2 Way Screw Green

(4-20 mA) Terminal
X9.2 (-)


10 AIO Card X10 – Analog Output 1 X10.1 (+) 2 Way Screw Green
(4-20 mA) Terminal
X10.2 (-)
11 AIO Card X11 – Analog Input 2 X11.1 (10V) 3 Way Screw Green
Terminal
X11.2 (I/P+)
X11.3 (I/P-)
12 AIO Card X12 – Analog Input 1 X12.1 (10V) 3 Way Screw Green
Terminal
X12.2 (I/P+)
X12.3 (I/P-)
13 Fieldbus 1 Card X13 – Ethernet 2 RJ45

(Modbus TCP/IP,
PROFINET, Ethernet/IP)
14 Fieldbus 2 Card X14 – Profibus D Type 9 Pin

Female
15 Loadcell Card X15 - Loadcell 1 D Type 9 Pin

Female
16 Loadcell Card X16 – Tacho 1/Encoder X16.1 (+12 V) 6 Way Screw Green
Terminal
X16.2 (A+)
X16.3 (A-)
X16.4 (B+)
X16.5 (B-)
X16.6 (GND)


18 CAN Card X18 – CAN 1 X18.1 (CAN1 L) 3 Way Screw Green
X18.2 (CAN1 H)
X18.3 (GND)
19 CAN Card X19 – CAN 2 X19.1 (CAN2 L) 3 Way Screw Green

X19.2 (CAN2 H)
X19.3 (GND)
20 RS485 Card X20 – Modbus X20.1 (T+) 3 Way Screw Green

Communication (SIO) Terminal
X20.2 (T-)
X20.3 (SH)
Note:
Electrical Connection information in above table may change subject to change in hardware.
Always refer engineering wiring diagram or Appliance Description for wiring assistance.

4 Controller LED Indications
LED Name LED Color LED Meaning

Power Orange In power on, this LED glows steadily
RUN Green In feeder run condition, this LED glows steadily
In feeder stop condition, this LED is off
In feeder trip condition, this LED blinks with 0.5 sec interval
ERROR Red In case of healthy condition, this LED is off
In case of general fault, this LED glows steadily
In case of CPU card failure, this LED blinks with 0.5 sec interval
INVERTER Green In case of Inverter communication failure, this LED blinks with 0.5
sec interval
If Inverter communication is healthy then this LED glows steadily
CAN Green In case of CAN communication failure, this LED blinks with 0.5 sec
interval
If CAN communication is healthy then this LED glows steadily
FIELDBUS Green In case of Fieldbus communication failure, this LED blinks with 0.5
sec interval
If Fieldbus communication is healthy then this LED glows steadily
LOADCELL Green In case of Loadcell fault, this LED blinks with 0.5 sec interval
If Loadcell fault is healthy then this LED glows steadily

5 Parameter Settings
Parameters need to be set as per specific job. For more information on Parameters,
check Parameter manual. Parameters editing in Commissioning menu is possible with
Admin Login only.
Group Group Content

Name
1.1 Weigh feeder Parameters related to weigh feeder machinery
1.2 configuration selection of feeder type and feeding system
1.3 Measuring function Setting of measuring channels
1.6 Interface Comm. setting to inverters and IO devices
1.8 System Type Selection Standalone GDC or with iDD
1.9 USB Operations Action to USB: Restore, Copy Firmware, ..
1.11 IO Configurations Configuration of IOs and monitoring
Follow these steps to bring up your new GDC controller to perform as per job
1. Go to 1.8 [System Type] menu and select the appropriate option as per Job
requirement
2. Go to 1.2 [Configuration menu].
Select 40.11 [Feeding System Type] in Configuration menu. For e.g. Belt Feeder or
Belt Weigher
Select 40.14 [Speed source] for e.g. Tachometer, Encoder
Select 40.51 [Fieldbus Type] as per job requirement and set other parameters
appropriately
3. Calculate and Set parameters in 1.1 [Weigh Feeder] menu. Parameter Calculations
are explained in Weigh Feeder Calculation section.
4. Go to 1.3 [Measuring Function] and Select Loadcell parameters as per requirement.
5. If prefeed is included then Go to 1.5 [Prefeed] and set Prefeed parameters For e.g.
PI Settings, Proportionate Setpoint Value.
6. Go to 1.6 [Interface] and select No of Inverters, Type of Inverters, No of Analog and
Digital cards
7. Go to 1.7 [System Control] and set the parameters as per requirement. These
parameters are explained in System Control Settings section.
8. Go to 1.10 [Date & Time] and check and set correct system date and time.
9. Go to 1.11 [IO Configurations] and select Analog IOs as per job requirement.
IO Logic can be inverted in [IO Inversion] menu.

IO monitoring timers and other IOs (ZSS, Pulse) can be set in this menu.
10. Go to 2.8 [Feeder PI Settings] in Maintenance menu and set PI Parameters and
Feedrate Filters.
11. Go to 3.2 [LAN Settings] and set the device name. Device name should be 8
characters long. This name will be appeared in all the log files that copied from GDC.
12. Calibrate the Analog IOs, Loadcell, and perform Dynamic Zeroing
13. Check Digital IOs status in Diagnostics as per job requirement. Now system should
be in healthy condition and so it’s ready to Run.

6 System Control Setting
• If 38.01 [Remote-Local Selection] is “External” then Digital Input “Remote/Local” controls

the Remote-Local Selection.
If 38.01 [Remote-Local Selection] is “Internal” then Digital Input “Remote/Local” doesn’t
affect the Remote-Local Selection and >Remote-Local< Command on HMI can be used
for Remote-Local Selection.
• If 38.02 [Control Source in Remote] is “Hardwire” then System is controlled through

Digital Input in Remote Mode.
If 38.02 [Control Source in Remote] is “Hostlink” then System is controlled through
fieldbus connected to GDC.
• 38.03 [Gravimetric-Volumetric Selection] is used to set a control of Gravimetric-

Volumetric selection.
Internal means it can be changed from HMI,
External means via PLC and
Auto means in Remote mode, it can be changed via PLC and in Local mode; it can be
changed from HMI.
• 38.04 [Start-Stop Type in Remote] is used to set Type of Start-Stop input in Remote
Mode.
Level Type means Start input is high then feeder will start and
Rising Edge Type means when Start input goes low to high then only feeder will start.
• If 38.05 [Field Permission] is “External” then Digital Input “Field Permission” control the
Field Permission.
If 38.05 [Field Permission] is “Internal” then Digital Input “Field Permission” doesn’t
affect the Field Permission. >Field Permission< Command can be used to Enable/Disable
Field Permission.
• 38.06 [Separate Start-Stop in Remote] is used to set separate inputs for Start-Stop in
Remote mode.
• If 38.07 [Field Switch Operation] is “Yes” then Digital Input “Field Selector Switch”
controls the Field Mode Selection.
If 38.07 [Field Switch Operation] is “No” then Digital Input “Field Selector Switch” doesn’t
affect the Field Mode Selection and >Field Active/Release< Command on HMI can be
used for Field Mode Selection.
• 38.08 [Control Source in Field] is used to set control of Field Operations in Field mode.
“Hardwire” means via Digital Inputs,
“PHT” means via Handheld Terminal and
“Drive” means via Inverter

7 Weigh Feeder Calculations
7.1 Nominal Belt Speed Calculation
Revolution Impulses = No of Teeth = 512 (Parameter 41.31)
Belt Length = 5.500 m
Nominal RPM = 1000 (Parameter 31.33 Max Speed)
Nominal Rotation Time @ 1000 RPM (Nominal RPM) = 30.5 Sec (Parameter 41.35)
Nominal Belt Speed = Belt Length/Nominal Rotation Time = 0.1799 m/s
7.2 e-Distance Calculation
Maximum Feedrate = Nominal Load * Nominal Belt Speed * 3.6
Nominal Load = Maximum Feedrate/(Nominal Belt Speed * 3.6)
Maximum Feedrate = 90 tph (Parameter 41.11)
Nominal Belt Speed = 0.1799 m/s
Nominal Load = 90 / (0.1799 * 3.6) = 138.97 Kg/m (Parameter 41.12)
Gm (Load on Measuring Zone) = Nominal Load * Measuring Section
Measuring Section = 0.35 m (Parameter 41.23)
Gm = 138.97 * 0.35 = 48.64 Kg
Fm = Gm * Scale Lever Ratio
Scale Lever Ratio = c Distance/d Distance = 80/200 = 0.4 (Parameter 41.13)
Fm = 48.64 * 0.4 = 19.46 Kg
e Distance = (Fm * 200) / Check Weight
Check Weight = 23.6 (Parameter 31.21)
e Distance = (19.46 * 200) / 23.6 = 164.9 mm

Actual e Distance adjusted on Feeder Mechanical = ?? mm,
Check weight Lever Ratio = Actual e Distance/Calculated e Distance = ??/200 = ??

(Parameter 41.14).
7.3 Speed Constant Calculation (Gk)
GK = Gear Box Ratio/ ((dTr + dBand) * Pi)
Gear Box Ratio = nMotor / nTr
nMotor = Feeder Nominal RPM = 1410 (Parameter 31.33 Max Speed)
nTr = Pully RPM @ Nominal RPM = 12.73
dTr = Pully Diameter = 0.27 m
dBand = Belt Thickness = 0.0075 m
Gear Box Ratio = 1410/12.73 = 110.77
(*note = the above numerical values are used for example purpose)
Gk = 110.77/(0.2775 * Pi) = 127.06 (Parameter 41.32)

8 Digital IO List
8.1 Inputs
Code Meaning 1 [0] Source Destination
0 Belt Slip Feeder GDC
1 Belt Track Feeder GDC
2 Material Detection Feeder GDC
3 Synchronous Sensor Feeder GDC
4 Remote Start [Stop] PCS GDC
5 Fault Reset PCS GDC
6 Drive Interlock Panel GDC
7 Field Selector Switch LCB GDC
8 Emergency LCB LCB GDC
9 Start Feeder LCB LCB GDC
10 Stop Feeder LCB LCB GDC
11 Start Release PCS GDC
12 Field Permission PCS GDC
13 Volumetric PCS GDC
[Gravimetric]
14 Control Supply On Panel GDC
15 Isolation Switch On Panel GDC
16 Field Supply On Panel GDC
17 [Emergency] Panel GDC
18 Vibration Interlock Panel GDC
19 Remote [Local] PCS GDC
20 Prefeed Start PCS GDC
21 Prefeed Stop PCS GDC
22 Aeration LCB GDC
26 Spil Conveyor Off PCS GDC
27 Maintenance Switch Feeder GDC
28 Motor Thermal Switch Feeder GDC
29 Vibrator Switch LCB GDC
30 Prefeed Slip Feeder GDC
31 Prefeed Belt Track Feeder GDC
32 Set point Increase LCB GDC
33 Set point Decrease LCB GDC
34 Start Prefeeder LCB LCB GDC
35 Stop Prefeeder LCB LCB GDC
36 Prefeeder Set point LCB GDC
Increase
37 Prefeeder Setpoint LCB GDC
Decrease
38 Remote Stop PCS GDC
39 Vibrator Stop LCB GDC
40 Pull Chord Switch Feeder GDC

41 PF Motor Interlock Panel GDC

42 CM Abort PCS GDC
43 CM Start PCS GDC
44 CM Accept PCS GDC
45 BIN PF On PCS GDC
46 BIN PF Loc/Rem PCS GDC
47 Shutoff Gate PCS GDC
48 SF Belt Slip Panel GDC
8.2 Outputs
Code Meaning 1 [0] Source Destination
0 Feeder On GDC PCS
1 General Fault GDC PCS
2 Remote [Local] GDC PCS
3 Pulse GDC PCS
4 Panel Healthy GDC PCS
5 Feeder On Lamp GDC Panel
6 Feeder On Lamp LCB GDC LCB
7 Field mode [Local] GDC PCS
8 Volumetric [ GDC PCS
Gravimetric]
9 Drive Fault GDC PCS
10 Vibrator On Signal GDC Panel
11 Vibrator On Status GDC PCS
12 Belt Track Fault GDC PCS
13 Prefeeder On GDC PCS
14 Prefeeder Fault GDC PCS
15 Deviation Fault GDC PCS
16 Loadcell Fault GDC PCS
17 Tacho fault GDC PCS
18 Belt Slip Fault GDC PCS
19 Emergency Off GDC PCS
21 CM Aborted GDC PCS
22 Bin Gate Open/Close GDC PCS
23 Vibrator On Lamp LCB GDC LCB
24 Prefeeder On Lamp GDC LCB
LCB
25 Feeder Trip GDC PCS
26 Vibrator Motor Fault GDC PCS
27 Material Low GDC PCS
28 Zeroing On GDC PCS
29 Pull Chord Healthy GDC PCS
30 Maintenance Off GDC PCS
31 PF Motor Fault GDC PCS

32 Bin High GDC PCS

33 Bin Low GDC PCS
34 CM On GDC PCS
35 Sk Exceeded GDC PCS
36 BIN PF Start/Stop GDC PCS/Panel
37 LC1 Underload GDC PCS
38 SF Belt Slip Fault GDC PCS
39 LC1 Overload GDC PCS
41 Aeration 1 GDC Field
47 Aeration Header GDC Field
48 High GDC -
49 Low GDC -
Digital IOs will be mapped according to Electrical Drawing.
Refer Digital IO Diagnostics to check Digital IO Status
8.3 Inverter Inputs
GDC Inverter Input name Remark

Input Input
E57 DI1 Local Start Pulse Input – NO contact
E58 DI2 Local Stop Pulse Input – NC contact
E59 DI3 Field-Non Field Level Input – (Field- High)
E60 DI4 Emergency NC contact
E61 DI5 - -
E62 DI6 - -
E63 RO1 Drive Disturbance Drive Fault
E64 RO2 Drive Running Drive is running
E65 RO3 Overload Supervision Fault For ACS550, Supervised parameter 3201
exceeds the Limit 3203

9 Analog IO List
9.1 Inputs
Input Name Source Destination

Off
Set point PCS GDC
Proportionate Capacity PCS GDC
Field Set point LCB GDC
9.2 Outputs
Output Name Source Destination

Feedrate GDC PCS/LCB
Belt Load GDC PCS/LCB
Motor Speed GDC PCS/LCB
Current Set point GDC PCS/LCB
Drive Set point GDC PCS/LCB
Prefeed Set point GDC PCS/LCB
Bin Weight GDC PCS/LCB
Sk Value GDC PCS/LCB
Belt Speed GDC PCS/LCB
12 mA GDC PCS/LCB
Analog Inputs are available in 4-20 mA and 0-10 V through selection using Jumper
settings on AIO Cards.
Analog Outputs are available in 4-20 mA.

10 Fieldbus Mapping
10.1 General
Fieldbus card can be used to interface many fieldbus options to GDC controller. GDC
supports Modbus RTU, Profibus DP, Modbus TCP, and Ethernet IP.
10.2 Modbus RTU Interface (16 bit protocol)
Transmission Mode - RS485
Transmission Rate – 9600, 19200, 38400, 57600, 115200
Data Format – 8, E, 1
10.3 Profibus DP Interface (32 bit protocol)
Transmission Mode - RS485
Transmission Rate – 9.6 K baud to 12 M baud (Auto baud rate detection)
Station address setting – 01 to 99 (from GDC)
10.4 Ethernet-IP/Modbus TCP Interface (32 bit protocol)
Transmission Mode - Ethernet
Transmission Rate – 10/100 Mbps
IP Address – Static(User Configurable), DHCP Support

10.5 Fieldbus Memory Map (16 Bit Protocol-Modbus)
Input Registers
Register Type Name Unit
No
0-1 32 Bit Unsigned Integer Input Header NA
4-5 32 Bit Unsigned Integer Command Register NA
8-9 Float Gravimetric Set point t/h
10-11 Float Remote Zero Correction Value %
14-15 Float Volumetric Set point %
16-17 Float Prefeeder Set point %
28-29 32 Bit Unsigned Integer Selection of Optional Read Values
Byte 0 Optional Read value 1
Byte 1 Optional Read value 2 Lower word

contains
30-30 32 Bit Unsigned Integer Selection of Optional Read Values Parameter code
that is to be
Byte 0 Optional Read value 3 read
Byte 1 Optional Read value 4 Upper word is

not used
Refer Optional
read values
Byte 1 Optional Read value 6 scheme

Command Register Bit Definition

Register Byte Bit Function Logic Remark
No No No
4 0 0 Acknowledge Failure rising edge (L-->H) Acknowledge Error
2 Remote Mode On H active Access from PCS
4 Clear Totalizer rising edge (L-->H) Reset totalizer 1
6 Start rising edge (L-->H) Start feeder in remote

mode
7 Stop rising edge (L-->H) Stop feeder in remote

mode
1 8 Toggle Operating H active Operation with constant

Mode speed
10 Accept Remote Zero rising edge (L-->H) Remote Correction

Correction
11 Accept CM H active
12
13
14
15 Start CM H active
5 0 0 Abort CM H active
2 Bin Prefeeder On H active Bin Prefeeder Status

1 8
10
11
12
13
14
15

Output Register
No
0-1 32 Bit Unsigned Integer Output Header
8-9 32 Bit Unsigned Integer Status Register
12-13 Float Feedrate t/h
14-15 Float Motor Speed Rpm
16-17 Float Current Set point %
18-19 Float Totalizer 1 t
20-21 Float Pre-hopper Content Level t
22-23 Float CM Correction Value %
24-25 32 Bit Unsigned Integer optional read value 1
38-39 Float Actual Load %
40-41 Float Totalizer 2 t
44-45 Float Speed Setpoint for Prefeeder %
54-55 Float Bin Weight %
56-57 32 Bit Unsigned Integer Optional read value 5

Status Register Bit Definition

Register Byte No Bit No Function Logic Remark
No
8 0 0
1 No Emergency H-Signal Emergency stop is not

activated
3 Remote Mode H-Signal Control through PCS
4 Field Mode H-Signal Control through LCS
5 Local Mode H-Signal Control through cabinet
6 Volumetric Mode H-Signal Constant Speed

Operation
1 8 Fault Status Feeder H-Signal Fault of feeder
9 Feeding Started H-Signal Feeder is in operation
10
11 CM On H-Signal Control Measurement

On
12 CM Aborted H-Signal CM operation Aborted
13
14 Pre-feeder Fault H-Signal Pre-feeder Fault
15 Pre-feeder On H-Signal Pre-feeder Running
9 0 0-14 Device Address - 0-127
1 15 Swap Flag - 0 – Swap Disabled
1 – Word Swapped

10.6 Fieldbus Memory Map (32 Bit Protocol-Profibus, Ethernet/IP, Modbus

TCP/IP)
Input Registers
No
0 32 Bit Unsigned Integer Input Header NA
2 32 Bit Unsigned Integer Command Register NA
4 Float Gravimetric Set point t/h
5 Float Remote Zero Correction Value %
7 Float Volumetric Set point %
8 Float Prefeeder Set Point %
14 32 Bit Unsigned Integer Selection of Optional Read Values
Byte 1 Optional Read value 2 Byte 0 and 1

contains
15 32 Bit Unsigned Integer Selection of Optional Read Values Parameter code
that is to be
Byte 0 Optional Read value 3 read
Byte 1 Optional Read value 4 Byte 2 and 3

are not used
Refer Optional
read values
Byte 1 Optional Read value 6 scheme

Command Register Bit Definition

Byte Bit Function Logic Remark
No No
0 0 Acknowledge Failure rising edge (L-->H) Acknowledge Error
2 Remote Mode On H active Access from PCS
4 Clear Totalizer rising edge (L-->H) reset totalizer 1 (FQ1)
6 Start rising edge (L-->H) start feeder in remote mode
7 Stop rising edge (L-->H) stop feeder in remote mode
1 8 Toggle Operating Mode H active operation with constant speed
10 Accept Remote Zero rising edge (L-->H) Remote Correction

Correction
11 Accept CM H active
12
13
14
15 Start CM H active
2 16 Abort CM H active
17
18 Bin Prefeeder On H active Bin Prefeeder Status
19
20
21

22
23
3 24
25
26
27
28
29
30
31

Output Register
No
0 32 Bit Unsigned Integer Output Header
4 32 Bit Unsigned Integer Status Register
6 Float Feedrate t/h
7 Float Motor Speed Rpm
8 Float Current Set point %
9 Float Totalizer 1 t
10 Float Pre-hopper Content Level t
11 Float CM Correction value %
12 32 Bit Unsigned Integer optional read value 1
19 Float Actual Load %
20 Float Totalizer 2 t
22 Float Speed Setpoint for Prefeeder %
27 Float Bin Weight %
28 32 Bit Unsigned Integer Optional read value 5

Status Register Bit Definition

Byte No Bit No Function Logic Remark
0 0 Feeder Trip H-Signal Feeder is tripped
1 No Emergency H-Signal Emergency stop is not

activated
3 Remote Mode H-Signal Control through PCS
4 Field Mode H-Signal Control through LCS
5 Local Mode H-Signal Control through cabinet
6 Volumetric Mode H-Signal Constant Speed

Operation
7 Warning Status Feeder H-Signal Warning of Feeder
1 8 Fault Status Feeder H-Signal Fault of feeder
9 Feeding Started H-Signal Feeder is in operation
10
11 CM On H-Signal Control Measurement On
12 CM Aborted H-Signal CM operation Aborted
13 Pre-feeder Fault H-Signal Pre-feeder Fault
14 Pre-feeder On H-Signal Pre-feeder Running
15
2 16-23 Device Address - 0-127
3 31 Swap Flag - 0 – Swap Disabled
1 – Word Swapped

Optional read values scheme

• Using Optional Read Values, we can map and read desired Parameters values from GDC.
• Parameters that are to be read can be selected by writing Parameter codes in Input Registers
14, 15, 16, 17. These input register holds the codes for Parameters that are to be read. Refer
Input Register table for more details.
• In return Parameter values of selected Parameters will be written to respective Output
Registers.
Parameter Code Parameter Name Remarks

0 None
1 Digital Input 0-11 Status DIO 1 Inputs
2 Digital Output 0-11 Status DIO 1 Outputs
7 System Error 0-15 Status
10 Totalizer 1 in Integer format Decimal at 3rd Place
11 Totalizer 2 in Integer format Decimal at 3rd Place
12 CM Status CM Status Codes (given below)
13 SUM of Zero Correction
14 Inverter Speed
15 Inverter Current
16 Inverter Torque Read from Inverters
17 Inverter Set point
18 Inverter AI Value
Example:
• If Digital Input 0-11 Status (Parameter Code 1) and Digital Output 12-23 Status (Parameter
Code 2) needs to be read,
then Byte 0 of Input Register 14 should be set to code 1 and Byte 1 of Input Register 14
should be should be set to code 2. Input Register 14 holds Parameter Codes for Optional Read
Value 1 and 2.
• Hence Digital Input 0-11 Status can be read at Optional read value 1 i.e. Output Register 12
and Digital Output 0-11 Status can be read at Optional Read Value 2 i.e. Output register 13.
CM Status Codes
0 – Abort Reset,
1 – Hopper below Limit 1, 2 – User Aborted, 3 – Prefeeder On, 4 – Feeder Stopped, 5 – CM Started,
6 – Hopper below Limit 2, 7 – CM Completed, 8 – CM Correction Saved, 9 – Correction exceeded,
10 – CM Timeout

11 Analog Input Calibration
• This menu can be accessed in Maintenance menu>AIO Calibration

• Use certified and calibrated 4-20 mA source, connected at input and adjust 4 mA
current and press >Save as Zero<.
• Adjust 20 mA current at input and press >Save as Span<.
• Internal ADC counts will be displayed
• Press >Input 2< to access calibration menu for Analog Input 2.
12 Analog Output Calibration

• This menu can be accessed in Maintenance menu>AIO Calibration

• Connect multi-meter to analog output channel on AIO card and adjust counts to set 4
mA on Multi-meter by pressing +/-. Increase the step size by using 1X, 2X, 5X,
100X, 500X. Then press >Save as Zero<.
• Adjust counts to set 20 mA on multi-meter by pressing +/-. Increase the step size by
using 1X, 2X, 5X, 100X, 500X. Then press >Save as Span<.
13 Loadcell Calibration
This menu can be accessed in Maintenance menu>2.6/2.7Loadcell Calibration
Conditions
1. All feeder parameters should be entered.

2. Feeder Should not be in Running Condition
Procedure
1. To fully calibrate the Weigh Feeder, Perform Loadcell Calibration and Record Dynamic
Zero.
13.1 Loadcell Calibration
Conditions
1. The feeder is Empty

2. The feeder is stopped

3. Parameter Checkweight 31.21 is entered
Procedure
1. Go to Loadcell 1 Calibration in Maintenance Mode

2. Click on >Save as Zero< to set the zero point of the feeder.
3. Place the check weight on Knife Edge.
4. Click on >Save as Span< to set the span of the feeder.
5. The load should now correspond to the check weight.
13.2 Dynamic Zero

This menu can be accessed in Maintenance menu>2.8 Dynamic Zero
Conditions
1. The feeder is empty

2. The loadcell has been calibrated
3. The Weigh Feeder has been started
Procedure
1. Enter Nominal RPM as Drive Setpoint and Run the feeder.

2. To start the recording dynamic zero, click on >Record new< (>Accpet< button will
be disabled).
3. A message “Recording Zero..” appears.
4. If recording is over, the >Accept< button becomes active.
5. To accept the recorded Dynamic Zero, click on >Accept<.

14 Loadcell Calibration Correction

This menu can be accessed in Maintenance menu>2.11 Load Correction
14.1 Zero Correction
Zero Correction can be used to correct calibration error due to zero drifting. Zero
drifting is result od mechanical error and losses.
Procedure
1. Enter Totalizer quantity
2. Enter weighed quantity
3. Press >Calculate< to calculate correction factor
4. Press >Accept< to apply correction
5. Zero correction value can be entered directly
6. 31.54 Sum of Zero correction indicated total correction
7. 31.52 Max. Zero Correction limits the amount of correction.

14.2 Span Correction
Span Correction can be used to correct calibration error.
Procedure
1. Enter Totalizer quantity

2. Enter weighed quantity
3. Press >Calculate< to calculate correction factor
4. Press >Accept< to apply correction
5. Span correction value can be entered directly
To reset the value of span correction factor, enter 0 manually and accept it.

14.3 Control Measurement
The curve correction menu is used to store F and W values in tph for respective
setpoints.These values are used to linearize the beltload.
Procedure
1. Start the feeder in Gravimetric operation.
2. Enter the gravimetric setpoint and press >Enter SP<.
3. Wait until the feedrate matches the current SP.
4. When feedrate matches current SP press >Start CM<.
5. Control measurement will be performed for time entered in 36.02 Correction Time.
Wait until the process status is updated to "CM completed".
6. Press >Accept Correction< to store F and W values for the current SP.
Press >Clear Zero Correction< to clear correction.
If Correction is not accepted within 36.03 CM Timeout, then correction is aborted
7. To stop CM, press >Abort CM<.
Note:
Check and set parameter 31.51, 31.52 and Correction Parameters
appropriately before performing control measurement. Refer parameter
manual for Parameters help.

14.4 Remote Correction
Zero correction can be done remotely through fieldbus communication.
Zero correction value is sent over fieldbus and Accept remote correction
command bit is set to apply zero correction.
Sum of Zero Correction is available on fieldbus and can be observed to zero

correction.
Zero correction value is limited by Parameter 31.51 Increment Zero Correction

and Max Zero Correction.
15 Master Slave Communication
GDC supports Master- Slave communication. Master interface is shared with

Inverter port and for Slave interface, RS485 card is required.
Switch Settings on RS485 card
Switch Setting Remarks

Name
S1, S2 S1 - All ON & For Master-Slave Communication
S2 – All OFF
S1, S2 S1 - All OFF & For Modbus RTU Slave Communication
S2 – All ON
Upto 5 slaves are supported. Master sends bin level data to all the slaves.
Master Slave parameters can be accessed in Commissioning menu > 1.2

Configuration

16 Backup & Restore Configuration, Firmware Upgrade
16.1 Configuration Backup
• This menu can be accessed in User Menu>3.6 Backup Parameter

• When USB is connected, LED colour changes to green and buttons get enabled.
• Backup Configuration: Copies the current parameters backup to the connected USB
drive.
• Parameter List: Copies the current parameter settings to the connected USB drive. This
Parameter List is in MS-Excel compatible readable format.
To get Parameter list on USB, Resource file “Paralist_wf.txt” should be copied to GDC.
• Status of Copy operation appears on screen
Success - If file is copied successfully.
File not found - If data is not available for selected date.
Failure - If system is failed to copy data of selected date.

16.2 Configuration Restore and Firmware Upgrade from USB
Connect this pen drive to GDC Controller at Connector X5.

When USB is connected, LED color changes to green and buttons get enabled.
• Copy Firmware from USB:

Provided firmware file binary.bin should be copied to root directory of Pen Drive.
Press >Copy Firmware from USB< to copy firmware into internal memory.
On next power on, controller upgrades system with new firmware.
Current Firmware Version will be displayed above button to check the successful
upgrade.
• Copy Resources from USB:

This menu enables user to copy resource files from the USB.
Resource file should be copied to RESOURCES folder inside USB.
• Restore Configuration from USB:

This menu enables user to restore backup files from the USB.
Configuration file should be copied to CONFIG folder inside USB.
Parameters will be restored to values as per Configuration file.
• Status of Copy operation appears on screen

Success - If file is copied successfully.
File not found - If data is not available for selected date.
Failure - If system is failed to copy data of selected date.

17 Index history

1.0 PPOL-IN First issue
1.1 PPOL-IN Second issue Curve Correction, Control Measurement
Digital I/O Map, Fieldbus Mapping,
Analog IOs
1.2 PPOL-IN Third Issue Fieldbus Mapping for 16 Bit Protocols
1.3 PPOL-IN Fourth Issue Optional Read Value codes are corrected
1.4 PPOL-IN Fifth issue Linearization Removed, IO List, Master-Slave

The technical data and specifications are valid at the time of publication of this
documentation. The information provided in this publication is, however, checked on a
regular basis and any necessary corrections made in subsequent editions.

Troubleshooting Manual Ver 1.3
ppol-in / 03.Aug.2017 / File: GDC.WF.Troubleshooting.Guide .doc RNDE1009201405
Troubleshooting Manual

Software : WF
Version : V2.440

1.0 System Errors and Warnings
Code Message Causes Rectification Type

0 Communication failure between Loadcell • Check if the card is properly inserted. Error
LC1 COM ERROR! card - 1 and CPU card • Check DIP Switch located on LCT card
is set to 1
1 Communication failure between Loadcell • Check if the card is properly inserted Error
LC2 COM ERROR! card - 2 and CPU card • Check DIP Switch located on LCT card
is set to 2
2 Communication failure between analog • Check if the card is properly inserted Warning
AIO1 COM ERROR! card - 1 and CPU card • Check DIP Switch located on AIO card
is set to 1
3 Communication failure between analog • Check if the card is properly inserted Warning
AIO2 COM ERROR! card - 2 and CPU card • Check DIP Switch located on AIO card
is set to 2
4 ADAM DIO Module is not connected Check connections Warning
FIELD DIO1 FAULT!
properly
5 ADAM DIO Module is not connected Check Connections Warning
FIELD DIO2 FAULT
properly
6 ADAM DIO Module is not connected Check Connections Warning
FIELD DIO3 FAULT!
properly
7 INTERNAL MEMORY ERR! Internal memory is not working properly Send CPU card for repairs Warning
8 Communication failure between fieldbus • Check if the card is properly inserted. Warning
FIELDBUS COM ERROR! card and CPU card • Check Fieldbus configuration
parameters 40.51, 40.52, 40.53
10 INVERTER1 COM ERROR! Inverter wiring, parameters may be • Check if the PSU card is properly Error
wrong. inserted
• Check Inverter communication cable
wiring

• Check Inverter Parameters like

Station ID, Baud Rate
11 INVERTER2 COM ERROR! Inverter wiring, parameters may be • Check if the PSU card is properly Error
wrong. inserted
• Check Inverter communication cable
wiring
• Check Inverter Parameters like
Station ID, Baud Rate
12 SD card is not installed or detected • Check if Micro SD memory card is Warning
MEMORY NOT FOUND! present on CPU Card
• Send CPU Card for repair
13 BELT SLIP FAULT! Drive drum slips because belt tension is • Check the 37.16 [ZSS Timer Value], Error
too low or load on the belt is too large Possibly this time needs to be
Faulty Belt Switch increased
• Check the conveyor belt position
• Check Digital Input “Feeder Slip”
Status in Diagnostics
• Check installation of slip sensor and
signal disk
• Check slip sensor for function, replace
if necessary
14 Loadcell counts below minimum load • Check Loadcell Calibration Warning
value • Check Loadcell connections
• Check Loadcell supply voltage
• Check feeder mechanics whether
UNDERLOAD ERROR! sufficient load is being applied on
Loadcell or not
• Check position of Weighing idler, Tie
Rod tension, Lever Functionality
• Check if Loadcell is defective
15 Loadcell counts above maximum load • Check Loadcell Calibration Warning
OVERLOAD ERROR! value • Check Loadcell connections


excess load is being applied on
Loadcell or not
• Check actual mV vs mV reported on
HMI in Loadcell Diagnostics.
• Check 46.22 Input Range
16 Tacho is not installed properly • Check Tacho Wiring Error
• Check Tacho wheel and Tacho sensor
TACHO FAULT! alignment
• Replace Tacho
• Get Tacho Card repaired
17 Vibrator is not powered on • Check Vibrator Connections Error
• Check Digital Input “Vibrator
VIBRATOR INTERLOCK!
Interlock” Status in Diagnostics
18 USB drive is not inserted • Check if Insert USB Pen drive Warning
USB MOUNT FAILED! • Check whether inserted Pen Drive is
not faulty
19 Start Release input is absent • Check Digital Input “Start Release” Error
INTEGRATION OFF!
20 Belt tracking Switch defective • Readjust belt tracking Error
• Check function of the switch, possibly
BELT TRACK FAULT! replace
• Check Digital Input “Belt Track”
21 FIELDBUS H/W ERROR! Send Fieldbus card for repairs Error
22 Emergency signal is present • Check Digital Input “Emergency” Error
EMERGENCY STOP!
• Check and rectify Emergency
Condition

23 Drive is not powered on or • Check Digital Input “Drive Interlock” Error

Drive MPCB is tripped Status in Diagnostics
DRIVE INTERLOCK!
• Check Drive MPCB and Drive
Overcurrent conditions
24 DATA MEMORY FULL! SD card Memory is full Replace SD card Warning
25 More than one input has assigned for the Set parameters properly Error
INPUT DUPLICATION!
same value
26 CAN baud rate mismatch or wiring Check CAN parameters and its wiring Error
CAN COMM FAULT!
problem
27 MEMORY UNFORMATTED! Memory card corrupted Change memory card Warning
28 CONFIG FILE ERROR! Configuration File is corrupted Use correct configuration file Warning
29 HMI TIMEOUT! HMI wiring problem Check HMI Connections Warning
30 Material in bin below limit1 • Check Status of associated digital Warning
BIN LOW! input
• Fill the bin
31 Material in bin above limit3 • Check Status of associated digital Warning
BIN HIGH! input
• Empty the bin
32 To carry out control measurement, Pre- Stop Pre-feed while control Warning
BIN PF ON! feed should be off measurement is in progress
33 ADAM AIO Module is not connected Check Connections Warning

FIELD AINP FAULT!
properly
34 ADAM AIO Module is not connected Check Connections Warning
FIELD AOUT FAULT!
properly
35 Drive is not ready Drive is not initialized (Not ready to take Warning
DRIVE DISTURBANCE! start command n needs power cycle)
Restart the drive
36 DRIVE LIMIT FAULT Inverter Supervisory parameter related • Check Supervisory Parameter Warning
fault definition and its limit in Inverter
• Check Supervisory parameter over
limit condition
37 DEVIATION FAULT! Loading is too low for the required Check material feeding Error

feedrate
Minimum speed of drive is too high
38 LOADCELL 1 FAULT Any type of Loadcell fault occurs Check Loadcell Diagnostics for more Error
details
39 LOADCELL 2 FAULT Any type of Loadcell fault occurs Check Loadcell Diagnostics for more Error
details
40 INVALID DYNAMIC ZERO • Difference between Static zero and • Perform Loadcell Calibration Warning
dynamic zero is not in acceptable • Record dynamic zero
limits
Possible Causes:
• Zero calibration is shifted
• Dynamic zero is not performed
after Loadcell Zero calibration
41 BATCH COMPLETED • Batch operation completed • Warning
42 FILE OPEN ERROR GDC is not able to open new file in • Check SD Card Warning
memory
43 THERMAL FAULT Motor thermal switch input is absent • Check Digital Input “Motor Thermal Error
Switch” Status in Diagnostics
44 PULL CHORD HEALTHY Pull chord input is absent • Check Digital Input “Pull Chord Error
Status” Status in Diagnostics
45 PF MOTOR FAULT Motor is not powered or • Check Digital Input “PF Motor Error
Motor MPCB is tripped Interlock” Status in Diagnostics
• Check Drive MPCB and Motor
Overcurrent conditions
46 BIN UNDERLOAD Loadcell counts below minimum load • Check Loadcell Calibration Warning
sufficient load is being applied on
Loadcell or not

47 BIN OVERLOAD Loadcell counts above maximum load • Check Loadcell Calibration Warning
excess load is being applied on
Loadcell or not
• Check actual mV vs mV reported on
HMI in Loadcell Diagnostics.
• Check 46.32 Input Range
48 SHUTOFF GATE ERROR! If Shutoff gate is not opened • Check Digital Input “Shutoff Gate” Warning
status in Diagnostics
• Check Shutoff gate mechanical
49 SF BELT SLIP FAULT! Drive drum slips because belt tension is • Check the 37.17 [ZSS Timer Value], As per
too low or load on the belt is too large Possibly this time needs to be setting
Faulty Belt Switch increased 37.32
• Check the conveyor belt position
• Check Digital Input “SF Belt Slip”
• Check installation of slip sensor and
signal disk
• Check slip sensor for function, replace
if necessary
50 MASTER COM ERROR Master communication is not working • Check if the RS485 card is properly Warning
properly inserted
• Check communication cable wiring
51 SLAVE COM ERROR Slave communication is not working • Check if the PSU card is properly Warning
inserted
• Check communication cable wiring

2.0 Diagnostics features
This feature is available on HMI and web server in Maintenance Menu.
2.1 Digital IO Status
Menu Screen Content

Digital IO Status • Status of Digital Inputs and Outputs
can be monitored
• Black LED indicates input/output is low
and Green LED indicates input/output
is high.
• Help for Input and Output assignments
is available

2.2 Communication Diagnostics
Menu Screen Content

Communication • Status of all communication lines can
Diagnostics be monitored
• Error counts increments wherein case
of communication failure
• Please read System Errors and
Warnings table for Rectification of
communication fault

2.3 Loadcell Diagnostics
Menu Screen Content

Loadcell • This feature can be used to diagnose
Diagnostics the Loadcell behavior
Sense Voltage: This is the
excitation voltage given to the
Loadcell
Loadcell Input [mV]: This is the
output voltage from the Loadcell in
millivolts
Loadcell counts: These are the
digital counts equivalent to the
Loadcell input voltage.
Loadcell Status: Error/Healthy
• This shows whether the Loadcell is

healthy or not.
• The Loadcell could have the following

possible errors
S+ Open
S- Open
IN+ Open
IN-Open
EXC Low
EXC High

2.4 Peripheral Diagnostics
Menu Screen Content

Peripheral • This feature can be used to diagnose
Diagnostics the Internal Memory and USB Host
status
• Free space in Memory card has
shown.
• Memory Card content can be seen.
Press >Show Dirs< and then Press
>Dir Up< or Press >Dir Down< to
scroll the content.

2.5 Master Slave Diagnostics
Menu Screen Content

Master Slave • Status of Master/Slave communication
Diagnostics lines can be monitored
• Error counts increments wherein case
of communication failure

3.0 Data Logging features
• In Order to analyze the feeding and for long-term monitoring of the feeding system, data is stored in memory inside the
feeding controller. GDC Stores two years of data.
• The event log contains different events such as start, stop, and error message for the various units. An entry is only
made in the event of a status change, e.g. start.
• Data will be logged with the interval of 2 seconds in MS Excel Compatible format.
• These logs can be copied to USB Pen Drive using Copy Datalog User Menu. GDC creates different folders inside pen
drives before copying data.
Folder Name Folder Content

DATALOG Data logs
EVENTLOG System Events and Error Events Logs
CONFIG Backup Configuration files

4.0 Index history

1.0 ppol-in First issue 25th Aug, 2014
1.1 ppol-in Second Issue System errors and warnings are updated
1.2 ppol-in Third Issue System errors and warnings are updated, Peripheral Diagnostics added
1.3 Ppol-in Fourth Issue System errors and warnings are updated, Master-Slave Diagnostics added

The technical data and specifications are valid at the time of publication of this documentation. The information provided
in this publication is, however, checked on a regular basis and any necessary corrections made in subsequent editions.
FLSmidth Pfister GmbH reserves the right to alter these versions at any time.

PASSWORD CALCULATIONS
ppol-in / 10.Sep.2014 / File: GDC.Password.Calculation.docx RNDE1009201402
User Password
00000
Service Password
MMDDX
Where MM - Month, DD - Date, X - Need to be calculated as given below
• Calculation for X
1. SUM (Sum of Digits of Month and Day) = M + M + D + D
2. If SUM <= 10 then X = 10 - SUM
If 10 <= SUM <= 20 then X = 20 - SUM
Admin Password
Password = 99999 – MMDDX
Password Calculation Example
Password Calculation for 12th Nov, 2013 – MM = 11, DD = 12
Calculation of X
1. SUM = 1 + 1 + 1 + 2 = 5 (<=10)
2. SUM < 10 hence X = 10 - 5 = 5
Service Password = 11125
Admin Password = 99999 - 11125 = 88874

WEIGH FEEDER
Weigh Feeder
Operations and Maintenance manual
Version 1.0

WEIGH FEEDER
Copyright
© All copyright and other property in this document and its contents are confidential and proprietary to FLSmidth Pfister. No
part of these materials should be reproduced, published, transmitted or distributed in any form or by any means, electronic,
mechanical, photocopying, recording or otherwise, or stored in any information storage or retrieval system of any nature nor
should the materials be disclosed to third parties without the prior express written authorization of FLSmidth Pfister.

WEIGH FEEDER
Content
About this Guide ................................................................................................................................... 7

Purpose of this Guide ..................................................................................................................... 7
Who should read this Guide? ......................................................................................................... 7
Occupational safety instructions ........................................................................................................ 8

1 About Weigh Feeder ................................................................................................................... 11
1.1 Introduction .......................................................................................................................... 11
1.2 Operating Principle .............................................................................................................. 11
2 Technical Details......................................................................................................................... 12
2.1 Technical Description .......................................................................................................... 13
2.1.1 Main Frame ............................................................................................................. 14
2.1.2 Drive Unit ................................................................................................................ 14
2.1.3 Pulley ...................................................................................................................... 14
2.1.4 Idlers ....................................................................................................................... 15
2.1.5 Conveyor Belts ....................................................................................................... 15
2.1.6 Measuring and Testing Device ............................................................................... 15
2.1.7 Tensioning and Guiding Device .............................................................................. 15
3 Packing and Transport ............................................................................................................... 17

3.1 Packing ................................................................................................................................ 18
3.2 Preparation for Transport..................................................................................................... 18
3.2.1 Securing the weighing device for transport ............................................................ 18
3.2.2 Securing the Testing Device ................................................................................... 19
3.3 Delivery from the Factory..................................................................................................... 19
3.4 Weight of the Belt Weigh Feeder ......................................................................................... 19
3.5 Weigh Feeder Handling ....................................................................................................... 20
3.6 Transport Damage ............................................................................................................... 20
3.7 Temporary Storage .............................................................................................................. 20
4 Mounting Instructions ................................................................................................................ 21

4.1 Assembling the Weigh Feeder............................................................................................. 22

WEIGH FEEDER
4.1.1 Check for Drive and Tail pulleys ............................................................................. 22
4.2 Electrical connections .......................................................................................................... 23
4.3 Disassembly......................................................................................................................... 23
5 Weigh Feeder Commissioning .................................................................................................. 25

5.1 Safety Instructions ............................................................................................................... 26
5.2 Installing the Weigh Feeder ................................................................................................. 27
5.2.1 Measuring Device ................................................................................................... 27
5.2.2 Measuring Section .................................................................................................. 28
5.2.3 Testing Device ........................................................................................................ 29
5.3 Check List ............................................................................................................................ 30
5.4 Test Run of Weigh Feeder................................................................................................... 30
5.4.1 Test Run without Material ....................................................................................... 30
5.4.2 Test Run with Material ............................................................................................ 34
5.4.3 Dosing Accuracy ..................................................................................................... 35
5.4.4 Shutdown ................................................................................................................ 35
6 Inspection and Maintenance Routine ....................................................................................... 37

6.1 Safety Instruction ................................................................................................................. 38
6.2 Lubrication ........................................................................................................................... 38
6.2.1 Lubrication Points ................................................................................................... 38
6.2.2 Lubrication intervals and lubricants ........................................................................ 40
6.2.3 Lubricating Instruction ............................................................................................. 42
6.3 Maintenance ........................................................................................................................ 44
6.3.1 Maintenance Points ................................................................................................ 44
6.3.2 Maintenance Interval .............................................................................................. 46
6.3.3 Maintenance Activity ............................................................................................... 47
6.3.4 Possible sources of faults ....................................................................................... 48
7 Repair Instructions ..................................................................................................................... 53

7.1 Repair Instruction ................................................................................................................. 54
7.2 Conveyor belt ....................................................................................................................... 55
7.2.1 Remove covers and secure measuring devices ..................................................... 56

WEIGH FEEDER
7.2.2 Inlet hopper ............................................................................................................. 57
7.2.3 Release the belt tension ......................................................................................... 58
7.3 Measuring and testing device .............................................................................................. 59
7.3.1 Replacing the load cell............................................................................................ 60
7.3.2 Testing Device ........................................................................................................ 61
7.3.3 Weighing rocker and weighing rocker bearing ....................................................... 61
7.4 Drive ..................................................................................................................................... 63
7.4.1 Removing the gear motor ....................................................................................... 64
7.4.2 Mounting the gear motor......................................................................................... 65
7.5 Outer Belt Stripper ............................................................................................................... 65
A Index of Figures .......................................................................................................................... 68

WEIGH FEEDER
About this Guide
Purpose of this Guide
The Weigh Feeder Operations and Maintenance manual provides

instructions for performing day-to-day operational tasks and maintenance
activities associated with Weigh Feeder. This is a prerequisite for fault free
operation and serves to prevent damage and hazards.
Who should read this Guide?
This guide helps Operator and Servicing / Maintenance personnel,

authorized to use Weigh Feeder, to efficiently use and carry out
maintenance activity on Weigh Feeder. The persons responsible for
transport, assembly, commissioning, operation, maintenance and repairs
must read and apply the operating instructions.

WEIGH FEEDER
Occupational safety instructions
This belt weigh feeder is constructed in accordance with the state of the art
and the recognized technical safety regulations. However, a precondition is
that it is essential to follow the safety instructions.
The instructions relating to correct and intended use must be followed.
During transportation, lift the belt weigh feeder using the marked points
on the belt frame.
The relevant sections of the operating instructions must be read through

carefully before any work is carried out. Pay special attention to the
instructions relating to personal safety. If you feel uncertain about
anything, please contact the FLSmidth Pfister Service Department.
External electrical installation must be carried out in accordance with the

relevant local regulations.
In order to ensure safe operation of the belt weigh feeder, all the drives
must be fitted with repair switches that can be locked in position.
Before commissioning work begins, the belt weigh feeder must be

inspected to ensure that the safety regulations are maintained.
The belt weigh feeder and its surroundings must be cleaned once a day.
Leaking points in the system must be sealed off immediately.
In order to avoid overheating, the bearings must be checked daily for

unusual noises during operation.
Burst, torn, brittle, melted, leaking or otherwise recognisably damaged

parts must be repaired or replaced immediately. If there is a risk
involved for people, the system must be put out of operation until the
damage has been rectified.
Parts may only be replaced by parts that are at least equal in quality,
i.e. with the same or higher strength, temperature resistance, resistance
to chemicals, nominal pressure and test pressure.
In order to ensure operational safety of the belt weigh feeder, use

original spare parts having same or higher strength, temperature
resistance, resistance to chemicals, nominal pressure and test pressure.
Disconnect all the electrical connections before initiating the

repair/servicing.

WEIGH FEEDER
Repairs, particularly the reworking of parts should be done in accordance

with the outlined repair instructions. The necessary tolerances must be
observed.
After the repair work has been completed, the belt weigh feeder may
only be put into operation as outlined in the commissioning instructions.
Fitted parts may only by repaired in accordance with the manufacturer’s

instructions.
Safety regulations must be complied with when handling the bulk

material (protective clothing, protective goggles, and mask).
When changing the belt, steady the belt weigh feeder with the belt
replacement brackets to ensure that it does not tilt.
The local accident prevention regulations must also be observed.

Particular care must be taken when working with electrical systems and
equipment.
Use of the Weigh feeder for purposes other than the intended purpose is
prohibited.
The manufacturer cannot be held liable for damage resulting from

improper use. The risk in cases of this kind must be carried entirely by
the operating company

WEIGH FEEDER
1 About Weigh Feeder
This chapter introduces Weigh Feeder and explains the operating

principle.
1.1 Introduction
The TLD XXXX/3.1X Belt Weigh Feeder is used for continuous gravimetric
feeding of bulk material in powder or grain form at a specified rate. The
Weigh Feeder output ranges from approx. 0.5 - 500 t/hr. Control ranges are
possible to 1:10.
1.2 Operating Principle
The belt weigh feeder consists of a circulating driven conveyor belt, on

which the load is weighed constantly by a measuring device.
Simultaneously, a speed recorder monitors the current speed of the
conveyor belt. In the weighing electronics, the required belt speed is
calculated at the discharge point according to the specified feed rate set
point and the weighed belt load and adjusted by the drive. On this principle
of prospective control, the belt weigh feeder achieves a disturbance variable
compensation that results in an extremely high short-term accuracy.

WEIGH FEEDER
2 Technical Details
In this chapter, users will about:
Technical Details of Weigh Feeder
Brief technical description of major components

WEIGH FEEDER
2.1 Technical Description
The Weigh Feeder system comprises of the following major components:
Mounting Frame
Rotating Components like Belts, Pulleys and Idlers
Weighing Electronics
Speed Monitoring Devices
Figure 1: Structure of Belt Weigh Feeder-Layout

WEIGH FEEDER
1 – Main Frame 2 –Storage Hopper
5 - Dive Pulley 6- Tail Pulley
8 - Idler 9 – Measuring Roller
11 - Self Alignment & Tensioning 17 – Measuring Device

Arrangement
27 – Gear Box 28 – Conveyor Belt
The belt weigh feeder consists of a belt frame (1) in which the idlers (8) are
inserted. The conveyor belt (29) is pulled by the spherically turned drive
pulley (5). Together with its continuous shaft, it is mounted in flanged
bearings that are fastened to the belt frame. The conveyor belt is tensioned
and guided by the spherically turned tail pulley (6) so that it runs centrally
over the idlers and pulleys. The Self Alignment & Tensioning Arrangement
(11) compensates fluctuations in the belt pull caused by changing material
loading conditions. In the measuring section, which is formed by the three
measuring rollers (9), the belt load is taken up by the central roller and
guided over the weighing section to the measuring device (17). At the
weigher, there are material strippers fitted at the drive, tail pulley and inner
and outer conveyor belt sides.
2.1.1 Main Frame
The Mainframe is fabricated steel structure that acts as a supporting

structure for the Weigh Feeder.
2.1.2 Drive Unit
The drive unit comprises of motor and reduction gear box both mounted on
a Main frame
2.1.3 Pulley
The pulley used is the standard steel drum pulley, which consists of a
continuous rim and two end discs fitted with compression hubs. The pulley
is covered with rubber to increase the co-efficient of friction between the
belt and the pulley.

WEIGH FEEDER
2.1.4 Idlers
Idler configuration used is to support the belts. Idler rolls consist of ERW
tube enclosed at each end and fitted with stationary shaft, anti-friction
bearings and seals.
2.1.5 Conveyor Belts
Conveyor belts are used to carry the feed material.
2.1.6 Measuring and Testing Device
Measuring and Testing device weighs the material in measuring section.
2.1.7 Tensioning and Guiding Device
A Tensioning and Guiding device is used to guide the conveyor belt and to
maintain the requisite tension.

WEIGH FEEDER
3 Packing and Transport
In this chapter, users will learn how to:
Pack and Transport the Weigh Feeder

WEIGH FEEDER
3.1 Packing
The type of packing depends on the transportation route and type and
storage possibilities on the customer's premises. The belt weigh feeder is
usually supplied without packing.
The symbols applied to the belt weigh feeder and the packing must be
observed.
3.2 Preparation for Transport
On delivery, the belt weigh feeder is secured for transportation. If it is then

transported again at a later date, it must first be secured and prepared as
described below.
3.2.1 Securing the weighing device for transport
For transportation, the Weighing Rocker must be locked with the Locking
Screw (17). To protect the Load Cell (18), push it down by tightening the
Nut (14). In this way, all pressure is removed from the load cell and the
tension rod (4) has a play of approx. 2 mm at the load cell.
Do not alter the length of the tension rod at the screw (8).

WEIGH FEEDER
3.2.2 Securing the Testing Device
Figure 2: Securing Testing Device
The Testing Device is secured with the screw and nut (15) to prevent the
lever (5) moving out of place. For transportation, the locking screw (15)
must be screwed in with the lever positioned upwards (as on delivery). The
testing device is ready for operation when the locking screw has been
removed. It is not necessary to secure the motorised testing device
(optional extra) before transportation.
3.3 Delivery from the Factory
When delivered from the factory, the belt weigh feeder is already prepared
for transport. If the belt weigh feeder is transported later, it must first be
secured and prepared as outlined under section 3.2.
3.4 Weight of the Belt Weigh Feeder
The weight of the belt weigh feeder can be read off the name plate.

WEIGH FEEDER
3.5 Weigh Feeder Handling
TRANSPORT SUPPORT ASSY.
Figure 3: Lifting Points
To facilitate the lifting of Weigh feeder during transport and commissioning,

a set of dedicated lifting points are provided on the Main Frame structure.
To ensure safety, the Weigh feeder should be lifted at these points only.
The Lifting Points are marked with symbols.
Lifting with fork-lift forks is not permitted!

The weighing device and the load cells can be easily damaged by
impacts.
3.6 Transport Damage
Check the contents of the consignment upon receipt. Missing parts or

possible transport damage must be reported in writing immediately.
3.7 Temporary Storage
If temporary storage is necessary, the weigh feeder must be stored in a

closed room. The belt weigher must be covered so that it is protected from
dust and moisture.

WEIGH FEEDER
4 Mounting Instructions
In this chapter, users will learn to:
Mount the Weigh Feeder

WEIGH FEEDER
4.1 Assembling the Weigh Feeder
Assembly of the Weigh Feeder is carried out on site using the corresponding
installation drawing. Ensure that all relevant accident prevention regulations
are observed throughout the assembly work.
While assembling the Weigh Feeder follow the below mentioned

instructions:
1. The belt Weigh Feeder must be installed and secured in such a

way that the Main Frame is not distorted. The feeder must also be
horizontal in both directions.
2. The standard requirement with respect to the foundation should
be followed as mentioned on the GAD. Secure the foundation
fasteners as per the applicable tightening torque.
3. Ensure the proper leveling of the equipment using the Spirit
leveling indicator. The Drive and Tail pulleys must be aligned
horizontally so that the conveyor belt does not run off towards one
side.
4. If welding work is required close to the belt Weigh Feeder, in order
to install the system, the belt weigh feeder and in particular the
conveyor belt must be protected from welding splashes. 0.
The belt weigh feeder must be set up centrally over the width of the belt
and underneath the material infeed chute.
The belt weigh feeder can be leveled with the support plates supplied on
delivery.
4.1.1 Check for Drive and Tail pulleys
Figure 4: Check for Drive and Tail pulleys

WEIGH FEEDER
After assembling the weigh feeder check horizontal position of the

Drive and Tail Pulley by following the below mentioned instructions:
1. Place shims of the same thickness under the spirit level at the left
and right at the same distance from the pulley end because the
pulleys are convex in shape.
2. Align the pulleys horizontally if necessary. To this end, adjust the
shims under the belt weigh feeder support. 0.
Remove the transport lugs and keep them in a safe place in case the belt
weigh feeder needs to be transported subsequently.
4.2 Electrical connections
The belt weigh feeder is fully wired internally. The leads run to the control
box inside protective cable conduits.
Exception: The motor is connected directly to the motor terminal box.
While making the electrical connections of the Weigh Feeder it is

essential to adhere to below mentioned instructions:
1. The local accident prevention regulations must also be observed.

Particular care must be taken when working with electrical
systems and equipment.
2. In order to ensure that the belt weigh feeder operates safely, all
drives must be fitted with repair switches that can be shut off.
3. Ensure that the motor turns in the right direction. 0.
4.3 Disassembly
Before the belt Weigh Feeder is disassembled, it must be shut down in

accordance with the commissioning instructions. Disassemble the Weigh
Feeder in the reverse order of assembly.

WEIGH FEEDER
5 Weigh Feeder Commissioning
In this chapter, users will learn:
Commissioning of Weigh Feeder

WEIGH FEEDER
5.1 Safety Instructions
The initial start-up must only be conducted by FLSmidth Pfister personnel.

Reoperation may only be carried out by those staff members who have
been trained by FLSmidth Pfister.
During commissioning of the Weigh Feeder, the standard directives for

machines should be followed. In addition, the local accident prevention
regulations always apply. Though the above-mentioned regulations were
taken into account in the manufacture of this machine it is essential to
maintain the consistency of the installation with respect to the design
worksheets like assembly drawing, electrical circuit diagram and position
plans of the cables. To ensure safe and smooth installation of the weigh
feeder it is important to adhere to the instructions related to the mounting
and commissioning.
The operating authority of the installation is obliged to provide a

lockable repair switch for driving the belt Weigh feeder.

WEIGH FEEDER
5.2 Installing the Weigh Feeder
5.2.1 Measuring Device
Figure 5: Measuring Device ready for operation
During transportation the weighing device is secured with a locking device.

When all the assembly work on and around the belt weigh feeder is
complete, the weighing device can be set up ready for operation.
To install the measuring device follow the below mentioned

instructions:
1. Remove the cover (2) by releasing the screw (16).

2. Turn the nut (8) to the bottom until there is a play of about 2 mm
at the screw head (17). The tension rod (4) is now free of play.

WEIGH FEEDER
3. The screw (12) acts as an overload limit and is pre-set in the

factory so that the force on the load cell (18) is limited to 125% of
the nominal load. Check the settings. 0.
5.2.2 Measuring Section
Figure 6: Measuring Section
Check the height adjustment of the measuring roller (9.1) and the
measuring section limiting rollers (9.2). With an unloaded belt, the
measuring roller (9.1) is 0.3 mm higher than the two adjacent limiting
rollers (9.2). These again are 2 mm higher than all other idlers/rollers
(factory setting). The height of each measuring roller may be adjusted with
a self-locking set screw positioned in the roller carrier. To adjust height,
release the belt tension and lift the concerning roller.

WEIGH FEEDER
5.2.3 Testing Device
Figure 7: Testing Device
During transportation the testing device is secured with the locking screw.
To activate the Testing device remove the locking screw (15). Sometimes
the belt weigh feeders are additionally secured by using the transport lug
which is to be removed during installation.
The test weight (20) is not applied to the weighing rocker (16) when the
lever (5) is swiveled up and the locking screw (8) is engaged in the hole in
the retainer plate.
Ensure that the test weight and application prism are clean and
the weighing rocker is not blocked by foreign particle deposits.

WEIGH FEEDER
5.3 Check List
To insure proper installation of the Weigh Feeder, perform the

below mentioned checks:
1. Ensure that the Weigh feeder assembly is stabilized on the

platform using the specified support brackets.
2. All bolt connections to the fastening plate are fastened properly.
3. Ensure that the material infeed chute only touch the conveyor belt
with the sealing strips.
4. Ensure that the belt weigh feeder, in particular the suspension
(mechanism) of the weighing device is free from any visible
mechanical damage.
5. Ensure that the Motor and Gear Box is fitted with the Ventilation
screw (breather plug).
6. Ensure that the electrical installation (damaged tubing, cables,
switches) is free from detectable mechanical damage.
7. Ensure that the Weigh Feeder is fitted with the repair switch.
8. Ensure that the cabling between belt weigh feeder, control box is
in accordance with the electrical and cable hook-up schematic.
9. Ensure that the Terminal boxes (CSC-box, local control box, motor
terminal box) are fitted with proper cable glands.0.
5.4 Test Run of Weigh Feeder
It is essential to carry out the test run of the weigh feeder for calibration
and to ensure the proper installation of equipment.
5.4.1 Test Run without Material
In this process the Weigh Feeder is operated without loading any material
for the purpose of calibration and to measure the Zero curve. During this
run the Rod gate at the material infeed chute is closed and the silo is
empty.
To test run the weigh feeder without material follow the below
mentioned instructions:

WEIGH FEEDER
1. Commission the belt weigh feeder drive as described in the

manufacturer’s repair instructions.
2. In the overriding control system, switch over the operating mode
from Automatic mode to Local mode.
3. On the Local Control Box switch over the belt weigh feeder to
Manual operation. Set the potentiometer to approx. 20% of
output value, confirm the start button.
4. Check that the belt is runs in the right direction without slipping
considerably on one side. 0.
Follow the instructions mentioned in the below sections to ensure proper

running of the Conveyor Belt.
5.4.1.1 Belt Run Setting
Figure 8: Belt Run Setting
To ensure smooth and safe motion of the belt, follow the below
1. If the belt slips to one side during running, increase the pulley axle
base on this side by means of the forcing spindles at the tail
pulley, or reduce it on the other side, depending on the height of
the belt tension.
2. The belt must be regulated often during the first operating hours.
0.

WEIGH FEEDER
5.4.1.2 Belt Tension
Figure 9: Belt Tension Setting
5 – Pivot Bracket 6 – Pivot Pin
7 - Guide Roller Assembly. 9 - Roller Cage Holding Chain
10 - Tensioning Arrangement
Indicator Plate
The Tensioning / Guiding Device runs along the return side of the conveyor
belt and compensates for the changes in length caused by temperature
fluctuations or changing material extraction forces. During running the belt
tension should be checked and adjusted as necessary.
To adjust the belt tension, follow the below mentioned instructions:
1. Adjust the axle distance to the forcing spindles on the tail pulley.
2. Ensure that the mounting distance of both the spindle is same.
3. When the belt tension is correct, the indicator marking on the
tensioning / guiding device in correct position. 0.

WEIGH FEEDER
5.4.1.3 Automatic Belt Guide
Figure 10: Tensioning / Guiding Device
Due to various pulling forces across the width of the belt, the belt can move
gradually to the side. Carry out basic adjustment as described in section
5.4.1.1. The Tensioning / Guiding Device compensate for the belt
movements during operation caused by changing conditions in the material
infeed chute or silo.
If the belt has drifted to the side, the Tensioning Roller (8) will be set askew
by the Guiding Rollers (5) on both sides and will counteract the drift.
The distance between the guiding rollers and the belt edge should
be approx. 3 mm on both sides.

WEIGH FEEDER
5.4.1.4 Zero Setting
The zero curve compensates for fluctuations due to the tare effect.
To perform the Zero Setting, follow the below mentioned

instructions:
1. Run the conveyor belt until it is completely empty.

2. Perform zero value calculation according to Adjustment
Instructions (electrical documentation), chapter "Zero value (zero
curve)". 0.
5.4.1.5 Calibration
To calibrate the Weigh Feeder, follow the below mentioned

instructions:
1. Apply the test weight on the weighing rocker by swiveling the

lever of the testing device downwards. Refer 5.2.1.
2. Call up the calibration menu on the controller.
3. Calibrate according to Adjustment Instructions (electrical
documentation).
4. In the calibration menu compare the variation in input voltage of
the test weight with the value cited in the data sheet.
5. After calibration, apply the test weight again several times and
check the display, including the zero value. If the display deviates
by > 0.2%, check again that the weighing rocker runs freely. 0.
5.4.2 Test Run with Material
To test run the weigh feeder with material follow the below
1. Set the material height limiter at the outlet of the infeed chute to
the material height H specified in the data sheet. Fill the silo with
the material and then open the (Rod) gate over the infeed chute.
2. Set the control to automatic operating mode.
3. Ensure that further transportation of the material after the belt
Weigh Feeder is guaranteed.

WEIGH FEEDER
4. Set a low hourly speed.

5. Start the Belt Weigh Feeder drive. The belt load should now be
between 95 and 105% of the value specified in the data sheet. If
the deviation is greater, adjust the material height limiter
accordingly.
6. A few hours after starting up the machine, check the conveyor
progress. If the belt is moving off to one side and the automatic
guiding device is not able to compensate this automatically, you
must correct the course of the belt manually. Refer 5.4.1.1. 0.
5.4.3 Dosing Accuracy
The accuracy information stated in the confirmation of order, which can be

checked by comparative weighing between the belt weigh feeder and silo
and by subsequent weighing, is subject to the following conditions:
1. The zero point of the belt weigh feeder is set when the machine is
warm.
2. The maximum material temperature is not exceeded.
3. There is no interruption to the material supply from the silo. 0.
An overall error is calculated from errors of the belt weigh feeder and errors
in the comparative weighing process, including the increments of both
displays.
5.4.4 Shutdown
To stop the machine, it is essential that the following steps be followed in

order to prevent damage to the machine:-
1. Stop feeding material into the Feeder.

2. Wait for all material to fully discharge from Feeder, Hopper and all
Conveyors.
3. Shut down the systems in the order to feeding of material
sequence.
4. Wait for each system to come to a complete stop.
5. Push the stop button or by turning key to 'off' position.

WEIGH FEEDER
6 Inspection and Maintenance Routine
In this chapter, users will learn about:
Periodic Maintenance of Weigh Feeder

WEIGH FEEDER
6.1 Safety Instruction
Before initiating the maintenance activity follow the below

6. The relevant sections of the operating instructions must be read

through carefully before any work is carried out. Pay special
attention to the instructions relating to personal safety.
7. Before maintenance work commences, the conveyor belt must be
run until it is empty. The safety regulations for handling bulk
material must be complied with (protective clothing, protective
goggles, mask).
8. Before starting maintenance work on the belt weigh feeder,
disconnect the electrical connections and take precautions to
ensure that the connections are not made again unintentionally
9. Always comply with national Accident Prevention Regulations.
Special care must be taken when working on electrical installations
and facilities.
10. All spare and wearing parts are available. 0.
6.2 Lubrication
6.2.1 Lubrication Points
During maintenance of the Weigh Feeder following components should be

lubricated with the lubrication oil and grease.
Lubrication Points:
1. Helical-Bevel Gear Unit 2. Helical Gear Unit
3. Motor 4. Pulley bearing
5. Weighing rocker bearing 6. Idler bearing
7. Self alignment & tensioning arrangement.
The lubrication points of the Weigh Feeder are as marked in the

WEIGH FEEDER
Figure 11.
Figure 11: Lubrication Points

WEIGH FEEDER
6.2.2 Lubrication intervals and lubricants
The lubrication intervals and the lubricants to be used are as mentioned in

the below table.

WEIGH FEEDER
No Designation Lubricant Lubricant Lubricant Quantity Change Remark

change for
Lubrication
component
1st Fill Recharge (Hrs)
1 Heli Bevel Roller VG 220 Initiall 2.2 10,000 At

gear unit- IC bearing - (Shell y Ltrs. latest
BAUER- Gear oil Omala filled- after 2
BK50Z (WF- /Indian Oil) 6.3 years
01) Sealing ltrs
rings -
grease
2 Drive motor Lifetime

lubrication
3 Bearings: Grease KL 2K/ EP2 10gm 10gm 20,000 -

Drive pulley/ Filling
Tail pulley
4 Weighing Grease KL 2K/EP2 5 gm 5 gm 20,000 -

rocker Filling
bearing
5 Idler bearing Lifetime KL 2K/EP2 - - - -

lubrication
6 Self- Grease KL 2K/EP2 5 gm 5 gm On visual -

alignment & filling inspectio
tensioning n
arrangement
NOTE:- Grease filling is also change when the oil or shaft sealing ring are replaced.
(Qty - Oil in Litres & Grease ig.

WEIGH FEEDER
6.2.3 Lubricating Instruction
6.2.3.1 Helical Bevel Gear Unit
Replace the Roller Bearing grease and Sealing Rings whenever the Helical
Bevel Gear Unit is changed. The lubrication interval and the lubricant
quantity and specification are as mentioned in the above table.
Recommended lubricant for gear unit:
Gear oil CLP 220 DIN 51517 / ISO VG 220.
Bearing grease SERVOGEM NO - 2 (I O C) /

BHARAT MP GREASE 2 - BP
When changing the lubricants, please observe the gear

manufacturer's instructions.
6.2.3.2 Helical Gear Unit
Replace the Roller Bearing grease and Sealing Rings whenever the Helical
Gear Unit is changed. The lubrication interval and the lubricant quantity and
specification are as mentioned in the above table. Recommended lubricant
for gear unit:
Gear oil CLP 220 DIN 51517 / ISO VG 220.
Bearing grease SERVOGEM NO - 2 (I O C) /

BHARAT MP GREASE 2 - BP
When changing the lubricants, please observe the gear

manufacturer's instructions.
6.2.3.3 Drive Motor
The ball bearings and shaft sealing rings have lifetime lubrication. The ball
bearings and shaft sealing rings must be replaced every 10,000 operating
hours. The grease filling must be renewed when they are replaced.

WEIGH FEEDER
During periodic maintenance, the bearings should be thoroughly cleaned

and Lithium based grease should be filled up to 2/3rd of the capacity.
To avoid overheating of the bearings, avoid excess filling of

grease.
6.2.3.4 Bearing of Drive Pulley / Tail pulley
The bearings of the drive and tail pulleys must be re-lubricated every
10,000 operating hours.
All drive motors are supplied in assembled and ready to use condition. All
bearings of the drive motors are filled with pre-requisite amount of grease.
During periodic maintenance, the bearings should be thoroughly cleaned
and Lithium based grease should be filled up to 2/3rd of the capacity.
Re-grease until a fresh rim of grease appears around the edge.

The bearings of the tail pulley can only be lubricated when the
conveyor belt is at a standstill.
6.2.3.5 Weighing rocker bearing
The bearings of weighing rocker bearing are maintenance-free. However if

the bearings are heavily soiled or a V-ring or sealing cap is damaged they
should be washed out and 2/3 of the space filled with grease.
6.2.3.6 Idler Bearing
The Idler bearings are maintenance free.
6.2.3.7 Self alignment & tensioning arrangement
The bearings used in self alignment & tension arrangement are

maintenance-free. If the bearings are not free to move they should be
cleaned and the filled with new grease.

WEIGH FEEDER
6.3 Maintenance
6.3.1 Maintenance Points
During periodic maintenance activity on the weigh feeder following

components should be checked for the instruction listed in the maintenance
table.
Maintenance Points:
1. Drive Unit 2. Gear Unit
3. Drive pulley 4. Tail pulley
5. Tensioning/guiding device 6. Outer belt stripper
7. Inner belt stripper 8. Measuring device
9. Tail Tacho Assembly (zero speed switch).
The maintenance points of the Weigh Feeder are as marked in the

WEIGH FEEDER
Figure 12.
Figure 12: Maintenance Points

WEIGH FEEDER
6.3.2 Maintenance Interval
The maintenance intervals and the activities to be carried out are as

mentioned in the below table.
Ref - Maintenance Activity 1T 1W 1M 3M 12M 36M

Section
6.3.3.1 Check the belt Weigh Feeder for settled X

dust and leaks.
If necessary, clean off the dust and seal
the leaks
6.3.3.2 Check the bearing for unusual noises X
6.3.3.3 Measuring device: X

cleaning X
checking and adjusting
6.3.3.3 Load measuring device: check to ensure it X

moves
easily (smoothness of operation)
6.3.4.1 Conveyor belt: check for wear X X X
6.3.4.2 Drive Pulley - Belt Stripper: check function X
6.3.4.3 Tail Pulley - Belt Stripper: check function X
6.3.4.2 Drive / tail pulley stripper: check function X

&
6.3.4.3
6.3.4.4 Gear unit: X

Visual inspection of the seals X
Change the shaft sealing ring X
6.3.4.5 Three-phase motor and encoder: X

Change the shaft sealing rings and ball X
bearing,
Inspect the digital tachometer /
incremental encoder

WEIGH FEEDER
6.3.3 Maintenance Activity
6.3.3.1 Check the Belt Weigh Feeder for settled dust
The belt weigh feeder is a measuring instrument. Soiling and dust deposits
can cause incorrect dosing results. For this reason, dirt of this kind must be
removed daily, or, even better, prevented from collecting.
Very high temperatures can build up in the motor and gear. The heat is
dissipated from their surface. Dust deposits reduce the amount of heat
given off, and can lead to overheating. Please observe the manufacturer's
operating instructions.
6.3.3.2 Check the bearing for unusual noises
The bearings in the motor gear and drive / tail pulleys can get very hot if
they are overloaded, the lubrication fails or they are soiled. For this reason,
check them daily for unusual and loud noises during operation and lubricate
the bearings if necessary. If the area of the bearings gets hot, switch the
unit off immediately.
6.3.3.3 Measuring Device
Dust deposits and foreign particles on the weighing device go into the
dosing as measuring errors. To maintain the proportioning accuracy, the
weighing device must be inspected and adjusted once a month and
recalibrated if necessary.
Perform the below mentioned checks on the Measuring Device:
6.3.3.3.1 Cleaning and checking the Measuring Device
Dust deposits on the weighing device affect measurements. For this reason,
it is important to brush or vacuum off dust carefully, in particular from the
weighing rocker, holder and load cell. To clean the measuring device, open
Cover (2). (Refer Figure 5 )
Protect the weighing device from dirt. Replace the lid and tank
after maintenance work.
6.3.3.3.2 Checking the smoothness of operation

WEIGH FEEDER
Check that the weighing device runs smoothly at the screw (17) and the
overload limit screw (12).
Check that the weighing rocker with holder (3) runs smoothly in relation to
the belt frame (1). (Refer Figure 5 )
During dosage operation, the test weight (20) and the lever (7)
must not touch the weighing rocker.
6.3.3.3.3 Checking and adjusting the zero point
To check the zero point, stop the supply of material to the belt weigh feeder
and empty the weigher and infeed chute completely.
6.3.3.3.4 Checking the calibration
After checking the zero setting, check the calibration.
To calibrate the measuring device follow the below mentioned

instructions:
1. Apply the test weight to the weighing rocker. To do so, swivel the
lever (5) down by pulling out the locking screw (8).
2. Select the calibration menu.
3. Compare the displayed calibration weight with the value stated on
the test weight or data sheet. Both values must agree.
4. Compare calibration value in kg/m with the displayed loading. In
the case of a deviation of the two values >0.2% recalibrate
according to adjusting instructions (electrical documentation).
5. In the calibration menu compare the change of the input voltage
on applying the test weight with the value in the data sheet. 0.
6.3.4 Possible sources of faults
1. Power Shunt
− If there are foreign particles between belt frame and
weighing rocker, etc Power shunts are caused by

WEIGH FEEDER
unauthorised connection between weighing rocker and Main

frame or Testing device, e.g. at transport locking device.
− Clean the equipment to avoid foreign particle deposite.
2. The gap between the overload limit and housing of the measuring
device is soiled. Clean the gap.
3. Load cell up against its overload protection: readjust the overload
protection of the load cell.
4. Load cell is defective: Replace/Repair Load cell. 0.
6.3.4.1 Conveyor belt
Check the conveyor belt for wear. If it is heavily worn (rubber belt is
damaged; belt carrier is visible), the belt must be replaced as described in
the repair instructions.
6.3.4.2 Drive Pulley - Belt Stripper
Figure 13: Drive Pulley Belt Stripper
Check the Drive Pulley Belt stripper for correct functioning.
If necessary, adjust the application pressure by releasing or tensioning the

pressure spring (8) with the nut (17) or replace the stripper blade (7).

WEIGH FEEDER
6.3.4.3 Tail Pulley - Belt Stripper
Figure 14: Tail Pulley Stripper
Check that the drive pulley stripper and the tail pulley stripper function
correctly. The strippers operate without contact. If necessary, correct the
distance between the stripper and pulley. This distance should be about 1
mm.
Rubber-coated pulleys (optional extra) and rod pulleys (optional

extra) do not need a pulley stripper.
6.3.4.4 Gear Unit
Perform a visual inspection of the seals for leaks every 3,000 operating
hours, and at least every 6 months.
Change the shaft sealing rings every 10,000 operating hours, depending on
the oil temperature, at least every 3 years.

WEIGH FEEDER
Please follow the gear manufacturer's maintenance instructions.
6.3.4.5 Three-phase motor and encoder
Change the shaft sealing rings every 10,000 operating hours. Inspect and,
if necessary, replace the ball bearings.
Inspect and service tacho-generator every 10,000 operating hours in

accordance with the supplied operating and maintenance instructions. The
surface of the motor must always be kept free of dust deposits.
Burn injury hazard: The surface temperature can exceed over

100°C.
Please follow the motor manufacturer's maintenance instructions.

WEIGH FEEDER
7 Repair Instructions
In this chapter, users will learn how to:
Repair the Weigh Feeder

WEIGH FEEDER
7.1 Repair Instruction
Before initiating the repair activity follow the below mentioned

instructions:
1. Repairs may only be performed as outlined in these repair

instructions. The necessary tolerances must be observed.
2. After the repair work has been completed, the belt weigh feeder
may only be put into operation as outlined in the commissioning
instructions.
3. Fitted parts should be repaired in accordance with the
manufacturer’s instructions.
4. Disconnecting product and de-dusting lines is prohibited when the
system is running.
5. The relevant sections of these manual must be read through
carefully before any work is carried out. Pay special attention to
the instructions relating to personal safety.
6. Before starting repair work, empty the conveyor belt. Safety
regulations for work with bulk goods must be followed. (Protective
clothing, goggles, respirator).
7. Before starting repair work on the belt weigh feeder, disconnect
the electrical connections and take precautions to ensure that the
connections are not made again unintentionally (assembly switch).
8. For repair work, please also observe the maintenance and
commissioning instructions and safety sheet.
9. The local accident prevention regulations must also be observed.
Particular care must be taken when working with electrical
systems and equipment. 0.

WEIGH FEEDER
7.2 Conveyor belt
Figure 15: Preparations for changing the belt
5 Drive pulley 6 Tail pulley
8 Idlers 7 Return idler
9 Measuring rollers (3x) 11 Tensioning / guiding device
14 Outer belt stripper 15 Inner belt stripper
16 Cover plate 17 Support
18 Protection hood 19 Discharge hood
If the conveyor belt is excessively worn or damaged, it must be replaced.

When the conveyor belt is replaced, the rubber strips on the inner and
outer belt stripper and the pulley stripper plates should also be readjusted
or replaced. Also check, and replace when necessary, the rubber edges of
the side covers and of the inlet hoppers.
The idlers and pulleys should also be cleaned and checked to ensure they
run smoothly whenever necessary. The belt is changed on the side opposite
the drive or terminal box.
To replace the conveyor belt perform the below mentioned actions

sequentially:

WEIGH FEEDER
1. Remove covers and secure measuring devices.

2. Remove Inlet hopper
3. Release the belt tension
4. Supporting the main frame structure
5. Remove Belt. 0.
7.2.1 Remove covers and secure measuring devices
To replace the belt follow below mentioned instructions:
1. Secure the weighing device as per the instructions in 3.2.1

2. Unscrew the protection hood (18) and discharge point hood (19).
3. On the belt changing side, unscrew the cover (16) and its supports
(17).
4. Dismount the Outer belt stripper (14).
5. Lift and disengage any return idlers (7) that are fitted. Unscrew
their holders on the belt change side.
6. Raise the tensioning/guiding device (11) and inner belt stripper
(15) and secure to the belt frame with the chain. 0.

WEIGH FEEDER
7.2.2 Inlet hopper
Figure 16: Inlet Hopper
To remove the Inlet hopper follow below mentioned instructions:
1. Loosen the clamping strap (1).

2. Remove the rubber edges (2) of the inlet.
3. Remove the mounting bolts (3) of hopper (4) and hang using
chain block. 0.

WEIGH FEEDER
7.2.3 Release the belt tension
Figure 17: Releasing Belt Tension
To release the belt tension follow below mentioned instructions:
1. Release the Nuts (3) on the pulling head and turn back. (Refer
Figure 17)
2. Pull in the Tail pulley (5) with Hexagonal Nut; if necessary, hold
spindle still with the lock nuts. (Refer Figure 17)
3. Push the tail pulley in equally on both sides. (Refer Figure 17)
4. Pull back the threaded rod (4) hold the threaded rod with locked
nuts. (Refer Figure 17)
5. Unscrew the threaded rod (4) from the belt frame part (2) and pull
the threaded rod back until it no longer protrudes over the tail
pulley. (Refer Figure 17)

WEIGH FEEDER
6. Dismount the belt frame part (2) on the belt change side (1).
(Refer Figure 17)
7. Engage the supplied belt replacement bracket(s) in the belt frame
in the locking plate (15). (Refer Figure 17)
8. Push on the new belt onto the bracket(s) and raise them slightly
at the end. (Refer Figure 17)
9. Cut through the old conveyor belt.
10. Remove the support or suspension device of the conveyor
weigher on the belt changing side. 0.
Figure 18: Belt Replacement Bracket
Please follow the gear manufacturer's maintenance instructions.

Support/hold the belt replacement brackets at the end so that the
weigher does not tilt over
7.3 Measuring and testing device
To repair the measuring and testing device perform the below mentioned
actions sequentially:
1. Replace the Load Cell.

WEIGH FEEDER
2. Replace Testing Device.

3. Replace the Weighing Rocker and Rocker Bearing
4. Height adjustment of the idlers and measuring rollers
5. Remove Belt0.
7.3.1 Replacing the load cell
To replace the load cell follow below mentioned instructions:
1. Remove the cover (17.2).

2. Release pressure from the load cell (18): screw the nut (17.14) in
the transport locking device upwards until the tension rod (17.4)
is loose.
3. Release the tension rod at one end: hold the screw fitting (17.8b)
tight and screw down the swivel nut (17.8a).
4. Turn the bush (17.5) down from the tension rod.
5. Replace the load cell (18). Maintain the original position of the
name plate. Mount the tension rod.
6. Push the cable through the protective sheath to the outside, into
the terminal box, and connect.
7. Apply pressure to the load cell: screw the nut (17.14) downwards
until there is a play of approx. 2 mm.
8. Set the overload screw (17.12) and then lock it so that the
maximum load that can be applied at the load cell is 125% of the
load cell nominal weight. This value is as per the rating of load
cell. An overload can be achieved by raising the weighing rocker
(16.1).
9. During this process, ensure that the screw head and nut (17.14)
of the transport locking device do come into contact with the
housing.
10. After the load cell has been replaced, the zero point setting and
calibration must be carried out again. (Refer 5.4.1) 0.

WEIGH FEEDER
Work on the weighing system must be carried out with special

care. The load cell (18) is maintenance-free. It can, however, be
damaged by unauthorised external influences of a mechanical or
electrical nature.
7.3.2 Testing Device
7.3.3 Weighing rocker and weighing rocker bearing
7.3.3.1 Cleaning Weighing Rocker
Free the weighing rocker (16.1) so that it moves easily. Blocked or stiff
weighing rocker can result in dosing errors.
7.3.3.2 Weighing Rocker Bearing
Figure 19: Weighing Rocker Bearing

WEIGH FEEDER
To replace the Weighing Rocker Bearing follow below mentioned

instructions:
1. Replace damaged truarc inverter ring (16.13) /cover (16.10).

Clean/replace bearing (16.11). Refer 3.2 to secure the weighing
device.
2. Remove the side cover panel (31.01) in the area of the weighing
rocker bearing.
3. Remove the cover (16.10).
4. Remove the screw (16.21).
5. Remove the washer (16.12) (only fitted with fixed bearing on the
load cell side).
6. Pull out the ball bearing (16.11), if necessary remove the second
washer and remove the bearing pin with truarc inverted ring
(16.13).
7. Replace damaged truarc inverted ring and cover.
8. Clean the ball bearing and re-grease. Refer 6.2.3.5. If the ball
bearing runs roughly and/or stiffly it must be replaced with a new
one.
9. Assemble the weigheing bearing again by following the
instructions above in reverse order.
10. Mount the side cover again.
11. Carry out zero setting and calibration of the belt weigh feeder
again. (Refer 5.4.1). 0.
7.3.3.3 Height adjustment of the idlers and measuring rollers
The rollers on the measuring section have higher rotational accuracy than
the other idlers/rollers and must not be replaced with the others. The
measuring rollers are a different color from the other idlers/rollers so that
they are easy to distinguish.
Height adjustment of the measuring rollers and limiting rollers can be

carried out with a self-locking set screw in the roller seating

WEIGH FEEDER
Figure 20: Height adjustment of the rollers
To adjust the height of the idlers and measuring rollers, follow

below mentioned instructions:
1. Release tension on the conveyor belt and raise the relevant roller.
2. Adjust the set screw as required. Insert the roller. Check height
adjustment.
3. Tension the belt, check the belt course adjustment and automatic
belt guidance. Refer 5.4.1. 0.
7.4 Drive
The belt weigh feeder is driven by a frequency-controlled three-phase

motor and a helical bevel gear unit or a straight bevel gear unit.

WEIGH FEEDER
7.4.1 Removing the gear motor
Figure 21: Height adjustment of the rollers
To remove the Gear Motor follow below mentioned instructions:
1. Remove the protective cap (1).

2. Release the hexagon head screw (2).
3. Remove the washer (3).
4. Pull the gear off the drive shaft. 0.
Please observe the assembly/removal instructions provided by the

gear manufacturer.

WEIGH FEEDER
7.4.2 Mounting the gear motor
To mount the Gear Motor follow reverse the procedure of 7.4.1 :
Please follow the Gear Motor manufacturer's maintenance

instruction.
7.5 Outer Belt Stripper
Figure 22: Inlet Hopper

WEIGH FEEDER
To replace the rubber stripper blade follow below mentioned

instructions:
1. Screw out Nut (2) to release the pressure of the pressure springs
(3).
2. Remove the holder with rubber stripper blade (4) from the U-bolts
(1).
3. Pull out the rubber stripper blade (4) with its holder.
4. Replace the rubber stripper blade.
5. Fit the new rubber stripper blade by following the instructions in
reverse order.
6. Adjust the pressure of the stripper for the operating conditions by
tensioning the pressure springs.

WEIGH FEEDER
Index of Figures
FIGURE 1: STRUCTURE OF BELT WEIGH FEEDER-LAYOUT ........................................................................................................................................... 13
FIGURE 2: SECURING TESTING DEVICE ................................................................................................................................................................... 19
FIGURE 3: LIFTING POINTS .................................................................................................................................................................................. 20
FIGURE 4: CHECK FOR DRIVE AND TAIL PULLEYS ....................................................................................................................................................... 22
FIGURE 5: MEASURING DEVICE READY FOR OPERATION ............................................................................................................................................. 27
FIGURE 6: MEASURING SECTION .......................................................................................................................................................................... 28
FIGURE 7: TESTING DEVICE ................................................................................................................................................................................. 29
FIGURE 8: BELT RUN SETTING.............................................................................................................................................................................. 31
FIGURE 9: BELT TENSION SETTING ........................................................................................................................................................................ 32
FIGURE 10: TENSIONING / GUIDING DEVICE ........................................................................................................................................................... 33
FIGURE 11: LUBRICATION POINTS......................................................................................................................................................................... 39
FIGURE 12: MAINTENANCE POINTS ...................................................................................................................................................................... 45
FIGURE 13: DRIVE PULLEY BELT STRIPPER .............................................................................................................................................................. 49
FIGURE 14: TAIL PULLEY STRIPPER........................................................................................................................................................................ 50
FIGURE 15: PREPARATIONS FOR CHANGING THE BELT ................................................................................................................................................ 55
FIGURE 16: INLET HOPPER .................................................................................................................................................................................. 57
FIGURE 17: RELEASING BELT TENSION ................................................................................................................................................................... 58
FIGURE 18: BELT REPLACEMENT BRACKET .............................................................................................................................................................. 59
FIGURE 19: WEIGHING ROCKER BEARING .............................................................................................................................................................. 61
FIGURE 20: HEIGHT ADJUSTMENT OF THE ROLLERS ................................................................................................................................................... 63
FIGURE 21: HEIGHT ADJUSTMENT OF THE ROLLERS ................................................................................................................................................... 64
FIGURE 22: INLET HOPPER .................................................................................................................................................................................. 65

AC MOTOR

AC MOTOR

AC MOTOR

AC MOTOR

AC MOTOR

AC MOTOR

AC MOTOR

AC MOTOR

AC MOTOR

AC MOTOR

AC MOTOR

AC MOTOR

AC MOTOR

AC MOTOR

AC MOTOR

AC MOTOR

AC MOTOR

AC MOTOR

AC MOTOR

AC MOTOR

MOTOR SPECIFICATION

INSTALLATION & MAINTENANCE MANUAL
FOR GEAR BOX

FOR GEAR BOX

FOR GEAR BOX

FOR GEAR BOX

FOR GEAR BOX

FOR GEAR BOX

FOR GEAR BOX

FOR GEAR BOX

FOR GEAR BOX

FOR GEAR BOX

FOR GEAR BOX

FOR GEAR BOX

FOR GEAR BOX

FOR GEAR BOX

FOR GEAR BOX

FOR GEAR BOX

FOR GEAR BOX

FOR GEAR BOX

FOR GEAR BOX

FOR GEAR BOX

FOR GEAR BOX

FOR GEAR BOX

FOR GEAR BOX

FOR GEAR BOX

FOR GEAR BOX

FOR GEAR BOX

FOR GEAR BOX

FOR GEAR BOX

FOR GEAR BOX

FOR GEAR BOX

FOR GEAR BOX

FOR GEAR BOX

FOR GEAR BOX

FOR GEAR BOX

FOR GEAR BOX

FOR GEAR BOX

FOR GEAR BOX

FOR GEAR BOX

FOR GEAR BOX

FOR GEAR BOX

FOR GEAR BOX

FOR GEAR BOX

FOR GEAR BOX

FOR GEAR BOX

FOR GEAR BOX

FOR GEAR BOX

FOR GEAR BOX

FOR GEAR BOX

FOR GEAR BOX

FOR GEAR BOX

FOR GEAR BOX

FOR GEAR BOX

FOR GEAR BOX

FOR GEAR BOX

FOR GEAR BOX

FOR GEAR BOX

FOR GEAR BOX

FOR GEAR BOX

FOR GEAR BOX

FOR GEAR BOX

FOR GEAR BOX

FOR GEAR BOX

FOR GEAR BOX

FOR GEAR BOX

FOR GEAR BOX

FOR GEAR BOX

FOR GEAR BOX

FOR GEAR BOX

INSTALLATION & OPERATION MANUAL FOR
VIBRATORY MOTOR

VIBRATORY MOTOR

VIBRATORY MOTOR

VIBRATORY MOTOR

VIBRATORY MOTOR

VIBRATORY MOTOR

VIBRATORY MOTOR

VIBRATORY MOTOR

VIBRATORY MOTOR

VIBRATORY MOTOR

VIBRATORY MOTOR

VIBRATORY MOTOR

VIBRATORY MOTOR

VIBRATORY MOTOR

VIBRATORY MOTOR

VIBRATORY MOTOR

SKF BEARINGS

SKF BEARINGS

SKF BEARINGS

SKF BEARINGS

SKF BEARINGS

SKF BEARINGS

SKF BEARINGS

SKF BEARINGS

SKF BEARINGS

SKF BEARINGS

SKF BEARINGS

SKF BEARINGS

SKF BEARINGS

SKF BEARINGS

SKF BEARINGS

SKF BEARINGS

SKF BEARINGS

SKF BEARINGS

SKF BEARINGS

SKF BEARINGS

SKF BEARINGS

SKF BEARINGS

SKF BEARINGS

SKF BEARINGS

SKF BEARINGS

SKF BEARINGS

SKF BEARINGS

SKF BEARINGS

SKF BEARINGS

SKF BEARINGS

SKF BEARINGS

SKF BEARINGS

SKF BEARINGS

SKF BEARINGS

SKF BEARINGS

SKF BEARINGS

TACHOMETER TECHNICAL LITERATURE
TACHOMETER PROBE
Tachometer probe may be regarded as having three parts.
1) an oscillator
2) a trigger circuit
3) an output stage
Immediately an exitation voltage is applied, oscillation begins which causes the emmission, Of a radio
frequency electromagnetic sensing particular current to be drawn.
The coil is wound on a ferrite core which concentrates the sensing field in the axial direction through the
active face of the tachometer probe.
When a metel object enters the radiated field, it absorbs energy from the field.a load is placed upon the
oscillator and the output amplitude is reduced.
This alters the amount of current being drawn. The trigger circuit recognises this and changes the state of
the switching device in the output stage. If the metal object is removed, the oscillation will begin again, and
the device will return to its orginal state.
Sensor type :- inductive
Switching distance :- 1.5 mm
Housing dia. :- 6.5 mm
Voltage range :- 5-25v dc
Switching range :- 5 khz
Conduction type :- cable
Housing material :- metal
Length :- 22 mm
Make :- pepperl + fuchs

LOADCELL SPECIFICATION



DATA SHEET FOR WEIGH FEEDER
Weigh feeder :- TLD100/ 1.1 VHLIC Job No. 90.18737

Customer : - NIRMA LIMITED-NIMBOL
Order no. Eqpt. No. Drg.No.-(Mech)
K/8001062PO180700145 WF-01 P90.18737-1-000-A1 R01
PO DATE: 19/07/2018 PRPD. BY LAD
General
Feed rate (Q) 60 t/h Moisture 6.00 %
Material CHINA CLAY Matl. Temp. AMBIENT ° C
Bulk density 1.3 t/m3 Matl. Characteristics SLIGHTLY SLUGGISH
95 % < 75,
Grain size mm Ambient Temp. 40 ° C
MAX 90
Weigh feeder
Mes. Section 3.5 dm Matl. X sextion (A) 0.12 m2
Pulley dia 235 mm Height of layer (h) 230 mm
Pulley crs. 3000 mm Nom.load (GM) 52.07 kg
Belt width 1000 mm Belt Speed (VB) 0.1120 m/sec
Bed LG. Top (X) 210.82 mm Output rpm (nTR) 9.11 rpm
Drive - Motor
Drive Side R.H. SIDE Rated Speed (RPM) 1450 Rated Freq. (Hz) 50
Motor Make SIEMENS IE2 Max. Speed (RPM) 1556 Max. Freq.(Hz) 53.6
3 PHASE AC TEFC SQUIRREL
Motor Type Min. Speed (RPM) 127 Min. Freq.(Hz) 4.4
CAGE INDUCTION MOTOR
Insulation Class F Base Speed (RPM) 1400 Base Frequency (Hz.) 48.3
Protection IP 55 Rated Torque (kgf m) 1.03
Rated Current (A) 3 Rated Power ( kW) 1.50
Connection Scheme Star Limiting Req. Torque Value (VVFD) NA
Drive - Gear box

G/B Make IC BAUER Ratio (i) 153.70 :1
G/B Model BK60Z Oil / Grease VG-220
G/B Type BEVEL HELICAL Qty. 6.9 Ltrs
Encoder
Make :- NA Range :- NA Model:- NA
Coupling
Make NA Type N/A
Nr. Of teeth on Ratio (I) N/A
G/B sprocket N/A Pulley sprocket N/A
Belting
Make FPIL STD Endless length 6848 mm
Rating 315/3, EP, 3/1.5, M24 Grade M24
Belt width 1000 mm Total thickness 7.5 mm
Loadcell
Make SCAIME
Type AVX75XC3CH 75 Kg x 2 150 kg
Rated load(FN) 150 kg ≅ 100 %
Tare load (FT) 15 kg ≅ 10 %
Mes. Load(FM) 52.07 kg ≅ 34.72 %
FM max =
1.25 x FM 65.09 kg ≅ 43.39 %
Condition FT + FM max. ≤ FN
Lever
Lever ratio (I) = 2.5 Dim. c = mm
Test load(actual load)(GP) 23.60 kg Dim. d = mm
Selected Test Weight 23.60 kg
Test Weight Calibration Percentage 100.00 % Dim. e = mm
Speed Sensor (Tacho)

Type:- NJ 1.5
No of Teeth:- 30 TEETH
Motor Frame Size:- 100L
DATA SHEET FOR WEIGH FEEDER
Weigh feeder :- TLD100/ 1.1 VLIC Job No. 90.18737

Customer : - NIRMA LIMITED
Order no. Eqpt. No. Drg.No.-(Mech)
K/8001062PO180700145 WF-02 P90.18737-2-000-A1 R02
PO DATE: 19/07/2018 PRPD. BY LAD
General
Feed rate (Q) 60 t/h Moisture 1.00 %
Material RED OCHRE Matl. Temp. AMBIENT ° C
Bulk density 2.0 t/m3 Matl. Characteristics SLIGHTLY SLUGGISH
Grain size 95 % < 75, MAX 90 mm Ambient Temp. 35 ° C
Weigh feeder
Mes. Section 3.5 dm Matl. X sextion (A) 0.12 m2
Pulley dia 215 mm Height of layer (h) 230 mm
Pulley crs. 3400 mm Nom.load (GM) 80.88 kg
Belt width 1000 mm Belt Speed (VB) 0.0721 m/sec
Bed LG. Top (X) 210.82 mm Output rpm (nTR) 6.41 rpm
Drive - Motor
Drive Side R.H. SIDE Rated Speed (RPM) 1450 Rated Freq. (Hz) 50
Motor Make SIEMENS Max. Speed (RPM) 1611 Max. Freq.(Hz) 55.6
3 PHASE AC TEFC SQUIRREL
Motor Type Min. Speed (RPM) 132 Min. Freq.(Hz) 4.5
CAGE INDUCTION MOTOR
Insulation Class F Base Speed (RPM) 1450 Base Frequency (Hz.) 50.0
Protection IP 55 Rated Torque (kgf m) 1.5
Rated Current (A) 4.4 Rated Power ( kW) 2.20
Connection Scheme Delta Limiting Req. Torque Value (VVFD) NA
Drive - Gear box

G/B Make IC BAUER Ratio (i) 226.20 :1
G/B Model BK70Z-K70 Oil / Grease VG-220
G/B Type BEVEL HELICAL Qty. 11.4 Ltrs
Encoder
Make :- NA Range :- NA Model:- NA
Coupling
Make NA Type N/A
Nr. Of teeth on Ratio (I) N/A
G/B sprocket N/A Pulley sprocket N/A
Belting
Make FPIL STD Endless length 7575 mm
Rating 400/3, EP, 3/1.5, M24 Grade M24
Belt width 1000 mm Total thickness 7.5 mm
Loadcell
Make SCAIME
Type AVX75XC3CH 75 Kg x 2 150 kg
Rated load(FN) 150 kg ≅ 100 %
Tare load (FT) 15 kg ≅ 10 %
Mes. Load(FM) 80.88 kg ≅ 53.92 %
FM max =
1.25 x FM 101.10 kg ≅ 67.40 %
Condition FT + FM max. ≤ FN
Lever
Lever ratio (I) = 1.0 Dim. c = mm
Test load(actual load)(GP) 23.60 kg Dim. d = mm
Selected Test Weight 23.60 kg
Test Weight Calibration Percentage 100.00 % Dim. e = mm
Speed Sensor (Tacho)

Type:- NJ 1.5
No of Teeth:- 30 TEETH
Motor Frame Size:- 132S
Job No. : 90.17253
Equipment No. : WF-01
Customer : Tata Metaliks Limited.
Recommended Electrical Spare Parts List for Weigh Feeder
Type No. Qty. PER

Sr. No. Description General Specification
(Order Code) EQPT.
1 GDC CONTROLLER -WF 8 RACK SYSTEM - 24V DC 5000I00D0L00 1
2 POWER PACK(SMPS) 24VDC 2.5A C030K1500100 1
3 INVERTER 1.1 KW,415V AC, 3 PHASE C000N00V0400 1
4 GDC AIO CARD 2AI/ /2AO 81T090020200 1
5 GDC DIO CARD 12DI / 12DO 81T0A0040200 1
6 GDC POWER SUPPLY CARD 24V DC 81T000000000 1
7 GDC LCT CARD LOADCELL 81T0D0020200 1
8 GDC TACHO TACHO 81T020020200 1
9 GDC CPU CARD PROCESSOR UNIT 81T050020200 1
10 HMI 7" TOUCH SCREEN DISPLAY 24V DC 80Z003002200 1
11 DPM FOR LCS 24V DC - 4 (DIGIT) (TPH) C050A6040700 1
12 SMALL RELAY BOARD (RLIO MODULE) 12 I/O & 12 O/P 5000P00H0P00 1
13 PROFIBUS CONNECTOR LED TYPE - EASYCONN - PB 0° E0J050060400 1

ELECTRICAL DRAWING
ELECTRICAL DRAWING

FLSMIDTH PVT. LTD.
(PFISTER INDIA BUSSINESS UNIT)
i-THINK TECHNO CAMPUS, 'A' WING,1ST FLOOR,
OFFICE NO. 2, OFF POKHRAN ROAD 2, BEHIND TCS,
THANE, MAHARASHTRA
CITY : MUMBAI ZIP CODE : 400 601 COUNTRY : INDIA
PHONE : 022 6117 2555 FAX : 022 6117 2917 E-MAIL : transweigh.sales@flsmidthpfister.com
ELECTRICAL DOCUMENTATION FOR

WEIGH FEEDER
JOB NO. : 90.18737

EQPT. : WEIGH FEEDER
PROJECT :
CONSULTANT :
P.O NO. : K/8001062PO180700145 DTD.17-07-2018
ELECTRICAL DRAWING - R0
DETAIL ELECTRICAL DRAWINGS - R0
TERMINATION DETAILS - R0
CATEGORY OF DRG. : REFERENCE APPROVAL AS BUILT

1 2 3 4 5 6 7 8 9 10 11 12 13 14
TABLE OF CONTENTS
SR. NO. PAGE DESCRIPTION DRAWING NO. PAGE. NO.
1 TITLE PAGE ---- =A1_FC/1
2 TABLE OF CONTENTS ---- =A1_TOC/1
5 SYSTEM BLOCK DIAGRAM 011-EE01-R0 =A1_BAS/1
6 SINGLE LINE DIAGRAM 011-EE02-R0 =A1_BAS/2
7 ELECTRICS ENCLOSURE GA 011-EE05-R0 =A1_BAS/3
8 LOCAL CONTROL STATION 011-EE09-R0 =A1_BAS/4
9 JUNCTION BOX DETAIL (JB1) 011-EE10-R0 =A1_BAS/5
10 GDC GA 011-EE26-R0 =A1_BAS/6
11 DETAIL ELECTRICAL DRAWING 011-EE16-R0 =A1/1
12 VOLTAGE SUPPLY 011-EE16-R0 =A1/2
13 UPS 011-EE16-R0 =A1/3
14 GDC - 8 RACK ARCHITECTURE 011-EE16-R0 =A1/5
15 ANALOG INTERFACE 1 011-EE16-R0 =A1/6
16 INPUTS E0-E5 011-EE16-R0 =A1/7
17 INPUTS E6-E11 011-EE16-R0 =A1/8
18 OUTPUTS A0-A5 011-EE16-R0 =A1/9
19 OUTPUTS A6-A11 011-EE16-R0 =A1/10
REV REVISION REVISED CHECKED

NO. DATE BY BY
WEIGH FEEDER TITLE: = A1_TOC + LANGUAGE :
CUSTOMER : NIRMA LTD. TABLE OF CONTENTS en_US

DRG.NO.:
90.18737-WF-011
PROJECT : SHEET : 1
90.18737 - ----
CONSULTANT : START DATE DRAWN BY OF : 3
P.O. NO. : K/8001062PO180700145 DTD.17-07-2018 8/17/2018 HAP-IN TOTAL : 41
1 2 3 4 5 6 7 8 9 10 11 12 13 14
TABLE OF CONTENTS
20 INPUTS E12-E17 011-EE16-R0 =A1/11
21 INPUTS E18-E23 011-EE16-R0 =A1/12
22 OUTPUTS A12-A17 011-EE16-R0 =A1/13
23 OUTPUTS A18-A23 011-EE16-R0 =A1/14
24 WF LOADCELL & TACHO 011-EE16-R0 =A1/15
25 AC INVERTER 011-EE16-R0 =A1/16
26 VIB MOTOR 011-EE16-R0 =A1/17
27 CABLE SCHEDULE 011-EE04-R0 =A1_CAB/1
29 Terminal diagram =A1+-X4-X4 011-EE17-R0 =A1_TER/1
30 Terminal diagram =A1+-X9 011-EE17-R0 =A1_TER/2
35 Terminal diagram =A1+-LCS-X14 011-EE17-R0 =A1_TER/7
36 Terminal diagram =A1+-JB1-X15 011-EE17-R0 =A1_TER/8

NO. DATE BY BY

DRG.NO.:
90.18737-WF-011
PROJECT : SHEET : 2
90.18737 - ----
1 2 3 4 5 6 7 8 9 10 11 12 13 14
TABLE OF CONTENTS
40 BILL OF MATERIALS 011-EE03-R0 =A1_BOM/1

NO. DATE BY BY

DRG.NO.:
90.18737-WF-011
PROJECT : SHEET : 3
90.18737 - ----
1 2 3 4 5 6 7 8 9 10 11 12 13 14
EQPT. NO. MATERIAL CAPACITY EE QTY.
WF-01 CHINA CLAY 60 TPH 1 NO

1. INPUTS /OUTPUTS OF WF.
OUTPUTS : RELAY CONTACTS MAX. 220V./5A LOAD
INPUTS : 220 VAC
1. CONTROL CABLES TO & FROM CUSTOMER'S

PANEL CAN BE COMBINED TOGETHER
HOWEVER 4-20mA SIGNALS
CABLES ARE SEPERATE.
3. * FLSMIDTHPFISTER SCOPE
VM HOPPER
LCS
TACHO
M T WF ZSS
BELT TRACKING LOADCELL
*WCS 02
*WC 08
*WC 06
S1 S2 *WCS 01.2
*WCS 01.1
*WC 01 *WC 02
JUNCTION BOX (JB1)

AT FIELD
WP 03
WC 07
WCS 11
WCS 04
WCS 03
WP 02
WC 05
WCS 07
ELECTRICS ENCLOSURE WITH
GDC ELECTRONICS
WC 03
WP 04
WP 01
WC 04
WCS 05
WCS 06
WCS 08
DOWNSTREAM INTERLOCK
MATERIAL STARVATION
INT/DEINT MODE SEL.

TOTALISER PULSE O/P
EMG STOP FEEDBACK
415 V ±10% 110 VAC
α ACTUAL FEEDRATE
REMOTE MODE SEL
50 Hz ±5% 50 Hz
LOCAL MODE SEL.
FEEDER HEALTHY
GRAV. MODE SEL.

READY TO START
COMMUNICATION
VOL. MODE SEL.
TPH DEVIATION
GENERAL FAULT
4-20mA ISO O/P

3ø SUPPLY 1ø SUPPLY
4-20mA ISO I/P

VIB ON
α SET POINT
FAULT RESET
START/STOP
PROFIBUS
(MCC SUPPLY (UPS
BSS O/P
ZSS O/P
WF TRIP
WF ON
CUSTOMER) CUSTOMER)
PLC/DCS PANEL
(CUSTOMER)

NO. DATE BY BY
WEIGH FEEDER TITLE: = A1_BAS + LANGUAGE :
CUSTOMER : NIRMA LTD. SYSTEM BLOCK DIAGRAM en_US

DRG.NO.:
90.18737-WF-011
PROJECT : SHEET : 1
90.18737 - 011-EE01-R0
1 2 3 4 5 6 7 8 9 10 11 12 13 14
MCC (CUSTOMER) UPS

MCC POWER SUPPLY
110 VAC
415 V ±10%
50 Hz
50HZ ±5%
1ø SUPPLY
3ø SUPPLY
150 VA
3 KW
1;3;5
Q1
3
32 Amps
2;4;6
1;3;5
F1
3 1;3;5
1;3
F2 TX1 Fa
ELECTRIC ENCLOSURE
I>> 3 L2;L1 415I/P

2 Amps. 2
2;4;6
220V O/P@1 Amps
2;4
I>> 110V O/P@1 Amps
2;4;6 0V;1L
U4 X1
L1 L2 L3 2
INVERTER
U V W
X2 1;3 U3
1;3 Fc 110V AC
Fb
2
1 Amp. 2 24VDC @2 Amps.
2 1 Amp.
U V W
K1
2;4 2;4
L2 1 1 1
110V AC
U1
U1 V1 W1 GDC
LAMP & GDC
ILLUMINATION
24V DC
3+PE
3+PE
M
M
FIELD
3~
3~
M1 M2
WF MOTOR VIB MOTOR
1.5 KW 0.27 KW
4 POLE 4 POLE MAX DISTANCE BETWEEN PANEL & MOTOR IS 150 MTRS
1500 RPM 1500 RPM
3.3A 0.52 A

NO. DATE BY BY
CUSTOMER : NIRMA LTD. SINGLE LINE DIAGRAM en_US

DRG.NO.:
90.18737-WF-011
PROJECT : SHEET : 2
90.18737 - 011-EE02-R0
1 2 3 4 5 6 7 8 9 10 11 12 13 14
NOTE:-
LOUVERS + 1) MAX. FLOOR OPENING FOR CABLE :- 430 mm x 350 mm
FILTERS
2) DESIGN FEATURES :
NAME PLATE - FRONT SIDE WITH SWIVEL DOOR.
HMI
- REAR SIDE FIXED ON BOLTS.
DISPLAY
- PROTECTION SYSTEM IP54 WITH DOORS CLOSED.
INVERTER DISPLAY - INLINE INSTALLATION.
- UNDRILLED GLAND PLATE TO BE PROVIDED
PANEL LABEL
1800
DOOR LOCK POWER WF UPS
3) SHEET THICKNESS :
2000
ON ON ON
- FRONT DOOR - 2.0 mm THK.

DOOR ISOLATOR
- SIDE COVERS - 1.6 mm THK.
- GLAND PLATE - 3.0 mm THK.
DRAWING
POCKET
INDSIDE
4) WEIGHT :- APPROX. 200 KGS.
LOUVERS + 5) SURFACE PROTECTION :
FILTERS
INSIDE & OUTSIDE POWDER COAT
200
(STRUCTURE FINISH) AS PER SHADE NO. RAL 7035
2 N0S BASE - AS PER IS:5 - DARK BLACK
EARTHING
600 BOLT 460 6) PANEL DIMENSION : 600 mm X 500 mm X 2000 mm.
(M10)
500 PACKED SIZE:- 680 mm x 590 mm x 2110 mm.
MAINTENANCE
7) ALL DIMENSIONS ARE IN `MM'.

SPACE REQD.
1000 (MIN)
100 400 100 SPACE FOR CABLES

RUNNING ACROSS 8) TOTAL NO OF SIDE COVER 2 NOS./PANEL PROVIDED.
25
9) EARTHING BOLT - 2 NOS./PANEL PROVIDED.
10) MAKE: PYROTECH

14ø HOLE
420
500
4 NOS QTY.: 1 NO.
WARNING LABELS FOR PANEL

PROJECTION 70 mm.
30
MAINTENANCE
SPACE REQD.
MAX. FRONT70
1000 (MIN)
EARTHING
DO NOT DRILL
CAUTION

NO. DATE BY BY
CUSTOMER : NIRMA LTD. ELECTRICS ENCLOSURE GA en_US

DRG.NO.:
90.18737-WF-011
PROJECT : SHEET : 3
90.18737 - 011-EE05-R0
1 2 3 4 5 6 7 8 9 10 11 12 13 14
4 NOS. ø10 HOLES FOR NOTE:-

MTG. WITH M8 BOLT EMERGENCY STOP
1) ALL DIMENSION ARE IN MM.
2) DOUBLE DOOR ENCLOSURE WITH ALL SWITCHES
AND INDICATIONS MOUNTED ON INNER DOOR,
ACRYLIC WINDOW AND DOOR LOCK
ON OUTER DOOR,
EMERGENCY OFF MOUNTED ON RIGHT SIDE.
85
3) GLAND PLATE :- DRILLED GLAND HOLES WITH
BLANKING PLUGS.
S4 90 4) SHEET THICKNESS :
TPH
- 1.5 mm DOOR
D1 L2
VIB VIB - 1.38mm REST
DOOR ON OFF
LOCK 5) WEIGHT :
- APPROX. 10 KGS.
295
300
S5
330(CTC)
L2
6) SURFACE PROTECTION :
FIELD NON-FIELD
- OUTSIDE & INSIDE
EPOXY POWDER COAT-
65 (STRUCTURE FINISH)
S3 S2 S1 P1
AS PER SHADE NO. RAL 7035
7) PROTECTION/CLASS : IP55
8) PACKED SIZE:
55
- 260mm x 340 mm x 440 mm.
9) MAINTENANCE SPACE REQUIRED:

LCS IDENTIFICATION
LABEL - 1.5 m. IN FRONT
- 1.0 m. AT SIDES
360 (CTC) 175 (CTC) 10) LCS MAKE : PYROTECH
400 210
.
CL OF CABLE
EARTHING
ENTRY QTY.- 1 NO.
BOLTS M6
2 NOS.
CONTROLS/INDICATIONS
S1 FIELD/NON-FIELD WARNING LABELS FOR LCS

S2 START
S3 STOP
EARTHING
S4 EMG.OFF (STAY-PUT TYPE)
S5 VIB ON/OFF SEL
D1 FEEDRATE INDICATOR (DPM) DO NOT DRILL
L1 WF RUN LAMP
L2 VIB ON/OFF LAMP
P1 FEEDRATE POT(10 TURNS) CAUTION

NO. DATE BY BY
CUSTOMER : NIRMA LTD. LOCAL CONTROL STATION en_US

DRG.NO.:
90.18737-WF-011
PROJECT : SHEET : 4
90.18737 - 011-EE09-R0
1 2 3 4 5 6 7 8 9 10 11 12 13 14
247
225
200
ø22.5 HOLE FOR BACKGROUND / OUTER SURF.
Ø22.5 HOLE FOR COLOUR - RAL 7035
CABLE GLAND (3 Nos.)
30 35 30
CONDUIT GLAND (6 Nos.)
21.25
43.75
55
168.00
45
45
TERMINALS
45
168
45
200
160
45
45
45
ø6.5 EARTHING BOLT
45
(2 nos)
15
55
44
21.25
15
FRONT VIEW
83.14 INNER VIEW 83.14
M5, SCREW (4 nos)
LABEL DETAIL
120 120
M6 SCREW (4 nos) (ON COVER)
FOR COVER FITTING
FOR JB MTG.
VIEW-(LEFT SIDE) VIEW-(RIGHT SIDE)
QTY : 1 NO.
NOTE:
1. OVERALL DIMENSIONS :
200.0 W x 200.0 HT. x 120.0 D
2. WEIGHT : 2.05 KGS.
3. MATERIAL SPECIFICATION :
130
- CRCA SHEET 1.5 mm THK.
4. SURFACE:- POWDER COAT RAL 7035
5. PROTECTION CLASS : IP 65
20
6. ALL UNUSED HOLES WILL BE PLUGGED.

7. ALL DIMENSION ARE IN `MM'
8. JB MAKE : PYROTECH
WARNING LABELS FOR JB
EARTHING
DO NOT DRILL
CAUTION

NO. DATE BY BY
CUSTOMER : NIRMA LTD. JUNCTION BOX DETAIL en_US

DRG.NO.:
90.18737-WF-011
(JB1)
PROJECT : SHEET : 5
90.18737 - 011-EE10-R0
1 2 3 4 5 6 7 8 9 10 11 12 13 14
268.96
240.56
U1
U1.1 U1.2 U1.3 U1.4 U1.5 U1.6 U1.7 U1.8
CPU PSU AIO DIO LTC FIELD BUS DIO
T+ T+ X14
10V1 +V
T- X6 T- X2
(OPTIONAL)
I/P+ A+
PROFIBUS
SH SH
I/P-
X12 X8 A- X8
AI1 X16
RS-485 (HMI) INVERTER B+ DI
DI
RS-485 B-
GND
10V2
X5 I/P+X11 ENCODER
128.4
132.5
RUN
I/P- AI2 LOADCELL
USB HOST
83
HEALTHY COMM
ERROR HEALTHY
+ X10
(OPTIONAL) X4 - AO1
POWER
Ethernet X7 X7
DO X15 DO
24 P
X3
24 N X1 + X9
E
– AO2
USB Device 24 V DC
LOADCELL

NO. DATE BY BY
CUSTOMER : NIRMA LTD. GDC GA en_US

DRG.NO.:
90.18737-WF-011
PROJECT : SHEET : 6
90.18737 - 011-EE26-R0
1 2 3 4 5 6 7 8 9 10 11 12 13 14
DETAIL ELECTRICAL DRAWING:-

GENERAL NOTES:-
1. PANEL WIRING COLOR CODE:-
VOLTAGE COLOR
415 VAC BLACK
110V AC RED - PHASE /

NEUTRAL
GREY (+VE)
24V DC
BLACK (-VE)
EARTHING YELLOW / GREEN
POT. FREE BLUE
2. EQPT DETAILS
WF-01 CHINA CLAY 60 TPH 1 NO

NO. DATE BY BY
WEIGH FEEDER TITLE: = A1 + LANGUAGE :
CUSTOMER : NIRMA LTD. DETAIL ELECTRICAL DRAWING en_US

DRG.NO.:
90.18737-WF-011
PROJECT : SHEET : 1
90.18737 - 011-EE16-R0
1 2 3 4 5 6 7 8 9 10 11 12 13 14
MCC
(CUSTOMER)
POWER SUPPLY
415 V AC ±10%
50HZ ±5%
3ø SUPPLY
S1 L3
R Y B E X6 P L N
P1.4 / LAMP
X6 N
N1.4 / 11.2
X6 P
TX1 P1.3 / 10.1 1
WP01 S2
415I/P X6 N
3x4 mm² N1.3 / 10.1 DOORLIMIT
220V O/P@1 Amps 2 SWITCH
X6 P
L2 L1 P1.2 / 10.13
110V O/P@1 Amps
P X6 N POWER SUPPLY
X13 1 2 3 E N1.2 / 10.13
S 2N 2L 110V AC
0V 1L X6 P
P1.1 / 7.1
110VAC
X6 N
N1.1 / 7.1
LP1
4 2
1
Fc 4 2
1 Amps. 3 1
2 Fb
1 Amp. 3 1
1 3 5
Q1
32Amps
2 4 6
L3.1 / 17.5
L2.1 / 17.5
L1.1 / 17.5
L3 / 16.2
L2 / 16.2
415V/50Hz
L1 / 16.2
E / 3.11

NO. DATE BY BY
CUSTOMER : NIRMA LTD. VOLTAGE SUPPLY en_US

DRG.NO.:
90.18737-WF-011
PROJECT : SHEET : 2
90.18737 - 011-EE16-R0
1 2 3 4 5 6 7 8 9 10 11 12 13 14
UPS
(CUSTOMER)
UPS
110V AC
50HZ
1ø SUPPLY
L N E
WP04
2x2.5 mm²
X13 10 11 E
1 3
Fa
2 4
2 Amp.
LP3
UPS ON
2
X5 P
24P1.4 / 11.12
1
X5 N
24N1.4 / 11.12
X5 P
24P1.3 / 7.13
X5 N
24N1.3 / 7.13
N L
U3 X5 P
110V AC 24P1.2 / 5.8
24VDC @2.5Amps. E X5 N
POWER SUPPLY
24N1.2 / 5.8
V- V+
24V DC
24P1.1 / 5.5
24N1.1 / 5.5
WCSA-1
2x0.50 mm²
E / 2.13

NO. DATE BY BY
CUSTOMER : NIRMA LTD. UPS en_US

DRG.NO.:
90.18737-WF-011
PROJECT : SHEET : 3
90.18737 - 011-EE16-R0
1 2 3 4 5 6 7 8 9 10 11 12 13 14
U1
GDC
/6 HMI
/7
U1.1
/8
CPU (T+) X6.1 6
(T+) HMI:E E / 17.5
/9
SUPPLY
/10
HMI:24N 24N1.2 / 3.11
COM2
/11 X6.2 8
(T-) (T-)
/12
/13
HMI:24P 24P1.2 / 3.11
/14 X6.3 9
(SH) (SH)
/15
/16.12
U1.2
FREE
U1.3
POWER SUPPLY (24P)
X1.1 24P1.1 / 3.11
(24N) X1.2 24N1.1 / 3.11
X1.3
(E)
INVERTER MODBUS
COMMUNICATION
U1.4 ANALOG IO CARD 1
U1.5
DIGITAL IO CARD 1
U1.6
LOADCELL & TACHO CARD
CONNECTOR MOUNTED
ON CONTROLLER WCS 08
U1.7 2x0.75
X14:3+ X4
X4 3
PROFIBUS
FIELD BUS CARD
PROFIBUS DP INTERFACE
X14:8- X4 8
X14:5 PLC/DCS
(CUSTOMER)
U1.8
DIGITAL IO CARD 2

NO. DATE BY BY
CUSTOMER : NIRMA LTD. GDC - 8 RACK en_US

DRG.NO.:
90.18737-WF-011
ARCHITECTURE
PROJECT : SHEET : 5
90.18737 - 011-EE16-R0
1 2 3 4 5 6 7 8 9 10 11 12 13 14
U1
GDC
/5
U1.5
SETPOINT
ANALOG CARD
AI1 AI2 AO1
AO2
FREE
4-20mA 4-20mA O/P
4-20mA O/P
ANALOG INPUT
+10V
+10V
AI1+ AI1- AI2+ AI2- AO1+ AO1-
PE AO2+ AO2-
X12 1 2 3 X11 1 2 3 X10 1+ 2-+
PE X9 1+ 2-
-X22 4 5 6 7
WCS11
3x0.75
GREEN
BLACK
GRAY
X9 1 2 3
X22 1 2 3
X41 4 5 6 7
X9 4 5 6
WCSF
1
3x0.35 mm²
BLACK
RED
2
P1
3
LOCAL SETPOINT LCS
WCS07
2x0.75
WCS06 WCS05 LCS

2x0.75 2x0.75
X41 1 2 3
WCSD
2x0.35
+7 -8
20
11.1 / 110P2
4-20mA I/P 19
4-20mA O/P 11.1 / 110N2
α SET POINT D1
α ACTUAL FEEDRATE
10.4 / 110N2.1
PLC/DCS
(CUSTOMER) FEEDRATE INDICATOR

NO. DATE BY BY
CUSTOMER : NIRMA LTD. ANALOG INTERFACE 1 en_US

DRG.NO.:
90.18737-WF-011
PROJECT : SHEET : 6
90.18737 - 011-EE16-R0
1 2 3 4 5 6 7 8 9 10 11 12 13 14
U1
GDC
/5 DIGITAL INPUT CARD 1
=A1-U3-U2.7-X8:15
U1.5
10
3
DB-15(F)
24P1.3 / 3.11
24VDC
24N1.3 / 3.11
E1.1 / 11.13
U2
E0 E1 E2 E3 E4 E5
P1:1
/8.1
3
E0 E1 E2 E3 E4 E5
/9.1
/10.1
E0 E1
E2 E3 E4
BELT TRACK E5
BELT SLIP FLAP TPYE SW. REMOTE START/STOP
24P
E2
E5
24P
24P
24P
24P
24P
E0
E1
E3
E4
U7
RL1 P C O RL2 P C O RL3 P C O
U5
RELAY BOARD RL1 P C O RL2 P C O RL3 P C O
110V AC
RL1 4CH/1CO RL2 RL3
RELAY BOARD
110V AC
RL1 4CH/1CO RL2 RL3
RL1 COM 1 RL2 COM 2 RL3 COM 3
110V AC
RL1 COM 1 2 3
2.8 / N1.1
2.8 / P1.1
X10 1 2 3 4 5
WC05
12x1.5
LCS
X14 1 2 3 4 5 6 7
X12 1 2 3 4 5 6
110P 110N
11.1 11.1
WC07
6x1.5
JB1 WC04
6x1.5
X15 16 17 18 19 20 21 22 23 24
WC06 WC01 WC02 WC08

2x1.5 2x1.5 2x1.5 2x1.5
START/STOP DOWNSTREAM INTERLOCK FAULT RESET
1 2
(110V AC) (110V AC) (110V AC)
LEFT RIGHT
2 3
PLC/DCS
(CUSTOMER)
ZERO SPEED SWITCH BELT SWAY SWITCH FLAP TYPE SW.
FIELD

NO. DATE BY BY
CUSTOMER : NIRMA LTD. INPUTS E0-E5 en_US

DRG.NO.:
90.18737-WF-011
PROJECT : SHEET : 7
90.18737 - 011-EE16-R0
1 2 3 4 5 6 7 8 9 10 11 12 13 14
U1 U1.5
GDC
DIGITAL INPUT CARD 1
=A1-U3-U2.7-X8:8
/5
11
2
6
DB-15(F)
U2
E6 E7 E8 E9 E10 E11
/7.2
E6 E7 E8 E9 E10 E11
E6 E7 E8 E9 E10 E11
E10
E11
24P
24P
24P
24P
24P
24P
E6
E7
E8
E9
13 13
F1 F2
/16.3 14 /17.8 14
WF INTERLOCK VIB INTERLOCK

NO. DATE BY BY

DRG.NO.:
90.18737-WF-011
PROJECT : SHEET : 8
90.18737 - 011-EE16-R0
1 2 3 4 5 6 7 8 9 10 11 12 13 14
U1
GDC
DIGITAL OUTPUT CARD 1
=A1-U3-U2.7-X7:3
/5
U1.5
6
DB-15(M)
U2
A0 A1 A2 A3 A4 A5
/7.2
A0 A1 A2 A3 A4 A5
A000 A002
A001 A003 A004 A005
WF ON TRIP
GENERAL FAULT UNDERLOAD REMOTE (LOCAL) EMG STOP
NO:0
NO:1
NO:2
NO:3
NO:4
NO:5
NC:0
NC:1
NC:2
NC:3
NC:4
NC:5
C:0
C:1
C:2
C:3
C:4
C:5
21 13
F1 K1
/10.12 14
22/16.3
X21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
WC03
34x1.5
WF VIB ON
WF ON GENERAL FAULT TPH DEVIATION MATERIAL STARVATION REMOTE MODE SEL EMG STOP FEEDBACK
TRIP
PLC/DCS
(CUSTOMER)

NO. DATE BY BY
CUSTOMER : NIRMA LTD. OUTPUTS A0-A5 en_US

DRG.NO.:
90.18737-WF-011
PROJECT : SHEET : 9
90.18737 - 011-EE16-R0
1 2 3 4 5 6 7 8 9 10 11 12 13 14
U1
GDC
=A1-U3-U2.7-X7:11
/5
U1.5
15
10
9
DB-15(M)
U2
A6 A7 A8 A9 A10 A11
/7.2
A6 A7 A8 A9 A10 A11
A006 A007 A008 A009 A010 A011

FEEDER ON LAMP INT/DEINT MODE SEL. TOTALISER PULSE O/P VOL./GRAV MODE SEL. VIB ON
NO:10
NO:11
NC:10
NC:11
NO:6
NO:7
NO:8
NO:9
NC:6
NC:7
NC:8
NC:9
C:10
C:11
C:6
C:7
C:8
C:9
2.8 / P1.3
A1
110V AC K1
A2 P1.2 / 2.8 110V AC
N1.2 / 2.8
13A
2.8 / N1.3
K1
/10.12 14A
VIB START/STOP
X21 17 18 19 20 21 22 23 24
X10 6 7
WC03
34x1.5
WC 05
12x1.5
LP2 LCS
X14 8 9 INT/DEINT MODE SEL. TOTALISER PULSE O/P VOL. MODE SEL. GRAV MODE SEL.
1
2 1 1
L1 L2
2 2
1 2 /17.7
WF ON 110N2.1 / 6.12 3 4 /17.7
PLC/DCS 5 6 /17.7
(CUSTOMER) 13 14 /9.14
EE DOOR WF ON/FAULT VIB ON/OFF
13A 14A /10.4

NO. DATE BY BY

DRG.NO.:
90.18737-WF-011
PROJECT : SHEET : 10
90.18737 - 011-EE16-R0
1 2 3 4 5 6 7 8 9 10 11 12 13 14
U1
GDC
=A1-U3-U2.7-X8:15
U1.8
10
3
DB-15(F)
24P1.4 / 3.11 24VDC

24N1.4 / 3.11
E1.1 / 7.13
U8
E0 E1 E2 E3 E4 E5
P1:1
/12.1
3
E0 E1 E2 E3 E4 E5
/13.2
/14.2
E1
E0 E2
E3 E4 E5
24P
24P
24P
24P
24P
24P
E0
E1
E2
E3
E4
E5
U6 P C O P C O P C O P C O P C O P C O
RL1 RL2 RL3 RL4 RL5 RL6
RELAY BOARD
110VAC
RL1 RL2 RL3 8CH/1CO RL4 RL5 RL6
RL1 COM 1 RL2 2 RL3 3 RL4 4 RL5 5 RL6 6
110V AC 2.8 / N1.4

X10 8 9 10 11 12
WC05
12x1.5
LCS 7.2 7.2

110P 110N
X14 10 11 12 13 14 15 16
3 3 1 1 3
110N2 / 6.12 S1 S2 S3 S4 S5
LOC/REM START STOP EMG OFF VIB ON/OFF
110P2 / 6.12 4 4 2 2 4
FIELD/NON-FIELD START STOP EMG OFF VIB ON/OFF

NO. DATE BY BY

DRG.NO.:
90.18737-WF-011
90.18737 - 011-EE16-R0
1 2 3 4 5 6 7 8 9 10 11 12 13 14
U1 U1.8
GDC
=A1-U3-U2.7-X8:8
/5
11
2
6
DB-15(F)
U8
E6 E7 E8 E9 E10 E11
/11.1
E6 E7 E8 E9 E10 E11
E6 E7 E8 E9 E10 E11
E10
E11
24P
24P
24P
24P
24P
24P
E6
E7
E8
E9

NO. DATE BY BY

DRG.NO.:
90.18737-WF-011
90.18737 - 011-EE16-R0
1 2 3 4 5 6 7 8 9 10 11 12 13 14
U1
GDC
=A1-U3-U2.7-X7:3
/5
U1.8
6
DB-15(M)
U8
A0 A1 A2 A3 A4 A5
/11.1
A0 A1 A2 A3 A4 A5
A000
A001 A002 A003 A004 A005
NO:0
NO:1
NO:2
NO:3
NO:4
NO:5
NC:0
NC:1
NC:2
NC:3
NC:4
NC:5
C:0
C:1
C:2
C:3
C:4
C:5
X21 25 26 27 28 29 30 31 32 33 34
WC03
34x1.5
FEEDER HEALTHY READY TO START BSS O/P LOCAL MODE SEL ZSS O/P
PLC/DCS
(CUSTOMER)

NO. DATE BY BY

DRG.NO.:
90.18737-WF-011
90.18737 - 011-EE16-R0
1 2 3 4 5 6 7 8 9 10 11 12 13 14
U1
GDC
=A1-U3-U2.7-X7:11
/5
U1.8
15
10
9
DB-15(M)
U8
A6 A7 A8 A9 A10 A11
/11.1
A6 A7 A8 A9 A10 A11
A006 A007 A008 A009 A010 A011
NO:10
NO:11
NC:10
NC:11
NO:6
NO:7
NO:8
NO:9
NC:6
NC:7
NC:8
NC:9
C:10
C:11
C:6
C:7
C:8
C:9

NO. DATE BY BY

DRG.NO.:
90.18737-WF-011
90.18737 - 011-EE16-R0
1 2 3 4 5 6 7 8 9 10 11 12 13 14
U1 LOADCELL AND ENCODER CARD 1

GDC
/5 U1.6 LOADCELL TACHO
TACHO I/P
SUPPLY +
SUPPLY +
SIGNAL +
SUPPLY -
SIGNAL -
GROUND
SENSE +
SENSE -
FREE
FREE
X15 1 5 4 2 6 8 9 3 7 X16 1 2
X11 5 2 7 3 4 6 1 X11 8 9 10
WCS03
6x0.75 mm²
WCS04
2x0.75
JB1
X15 5 2 11 1 3 12 4 8 7 10 9 6 13 14 15
SH
WCS02
/15.3
2x0.35
WCS01-1 WCS01-2
4x0.35 4x0.35
A C
A C TH
LC1
LC2
LOADCELL
B D
TACHO
B D
FIELD

NO. DATE BY BY
CUSTOMER : NIRMA LTD. WF LOADCELL & TACHO en_US

DRG.NO.:
90.18737-WF-011
90.18737 - 011-EE16-R0
1 2 3 4 5 6 7 8 9 10 11 12 13 14
415 V/50Hz
2.13 2.13 2.13

L1 L2 L3 E1 U1
/5
U1.2
1 3 5
13 21 INVERTER MODBUS
COMMUNICATION
F1 14 22
2.4-4 Amps (T-)
/8.3 /9.13 (T+)
X2.1 X2.2 SH
I>> I>> I>>
2 4 6
+24V GND DCOM DI1 DI2 DI3 DI4 DI5 DI6 SRC B A AGND SCR
-U4
1.5KW U1 V1 W1 PE X1.10 X1.11 X1.12 X1.13 X1.14 X1.15 X1.16 X1.17 X1.18 X3.28 X3.29 X3.30 X3.31 X3.32
ON
S1
ON
ACS550-01-04A1-4
ON
U2 V2 W2 PE X1.4 X1.5 X1.6 X1.7 X1.9 X1.8 X1.9 X1.19 X1.20 X1.21 X1.22 X1.23 X1.24 X1.25 X1.26 X1.27
+10V AI2 AGND AO1 AGND AO2 AGND RO1C RO1A RO1B RO2C RO2A RO2B RO3C RO3A RO3B
/11.10/
L2 U V W
150uH / 15 AMPS
U1 V1 W1
X13 4 5 6 E
WP02
4x4 mm² NOTE:
TERMINAL
MAX CABLE DISTANCE BETWEEN VFD PANEL & RESPECTIVE
1 2 3 E
BOX MOTOR CAN BE 150 MTRS
M1 M
3~
M1
WF MOTOR
1.5 KW,4 POLE
1500 RPM,3.3A

NO. DATE BY BY
CUSTOMER : NIRMA LTD. AC INVERTER en_US

DRG.NO.:
90.18737-WF-011
90.18737 - 011-EE16-R0
1 2 3 4 5 6 7 8 9 10 11 12 13 14
5.8 / E
2.13 / L3.1
415V/50Hz 2.13 / L2.1
2.13 / L1.1
1 3 5 13
F2
14
0.4-0.6 Amps
/8.5
I>> I>> I>>

2 4 6
1 3 5
K1
/10.12
2 4 6
X13 7 8 9 E
WP03
3x1.5
M2
X17 1 2 3 E
M2
M2 M
VIB MOTOR
0.27 KW 3~
4 POLE
1500 RPM
0.52 A
VIB MOTOR

NO. DATE BY BY
CUSTOMER : NIRMA LTD. VIB MOTOR en_US

DRG.NO.:
90.18737-WF-011
90.18737 - 011-EE16-R0
1 2 3 4 5 6 7 8 9 10 11 12 13 14
CABLE OVERVIEW
TOTAL USED CROSS-SECTION NO OF
CABLE NAME SOURCE (FROM) TARGET (TO) CABLE TYPE VOLTAGE CONDUCTORS CONDUCTORS (SQ MM) RUNS REMARKS SCOPE OF CABLE PAGE NO.
=A1-WC01 =A1-JB1-X15 =A1-FIELD (YY) UNARMOURED 110V AC 2 2 1.5 1 BELTSWAY SW (LEFT) FPIL =A1/7.3
=A1-WC02 =A1-JB1-X15 =A1-FIELD (YY) UNARMOURED 110V AC 2 2 1.5 1 BELT SWAY SW (RIGHT) FPIL =A1/7.4
=A1-WC03 =A1-X21 =A1-PLC/DCS (YWY) ARMOURED 220 VAC 34 34 1.5 1 DIGITAL INPUT TO PLC CUSTOMER =A1/9.2
=A1-WC04 =A1-X12 =A1-PLC/DCS (YWY) ARMOURED 110V AC 6 6 1.5 1 DIGITAL INPUT TO WF GDC CUSTOMER =A1/7.8
=A1-WC05 =A1-LCS-X14 =A1-X10 (YWY) ARMOURED 110V AC 12 12 1.5 1 CONTROLS CUSTOMER =A1/7.1
=A1-WC06 =A1-JB1-X15 =A1-FIELD (YY) UNARMOURED 110V AC 2 2 1.5 1 ZERO SPEED SW FPIL =A1/7.1
=A1-WC07 =A1-JB1-X15 =A1-LCS-X14 (YWY) ARMOURED 110V AC 6 5 1.5 1 ZSS, BSS,FLAP TYPE FPIL =A1/7.1
=A1-WC08 =A1-JB1-X15 =A1-FIELD (YY) UNARMOURED 110V AC 2 2 1.5 1 FLAP TYPE SW. FPIL =A1/7.6
=A1-WCS01-1 =A1-JB1-X15 =A1-FIELD-LC1 (YY) UNARMOURED 12V 4 4 0.35 1 LOADCELL-1 FPIL =A1/15.3
=A1-WCS02 =A1-JB1-X15 =A1-FIELD-TH (YY) UNARMOURED 12V DC 2 2 0.35 1 TACHO FPIL =A1/15.10
=A1-WCS03 =A1-JB1-X15 =A1-X11 (YWY) ARMOURED 12V DC 6 6 0.75 1 LOADCELL CUSTOMER =A1/15.3
=A1-WCS04 =A1-JB1-X15 =A1-X11 (YWY) ARMOURED 12V DC 2 2 0.75 1 TACHO CUSTOMER =A1/15.10
=A1-WCS05 =A1-X9 =A1-PLC/DCS (YWY) ARMOURED 4-20mA 2 2 0.75 1 4-20mA O/P α ACTUAL FEEDRATE CUSTOMER =A1/6.8
=A1-WCS06 =A1-X9 =A1-PLC/DCS (YWY) ARMOURED 4-20mA 2 2 0.75 1 4-20mA I/P α SET POINT CUSTOMER =A1/6.2
=A1-WCS07 =A1-LCS-X41 =A1-X22 (YWY) ARMOURED 4-20mA 2 2 0.75 1 FEEDRATE INDICATOR CUSTOMER =A1/6.13
=A1-WCS08 =A1-X4-X4 =A1-PLC/DCS (YWY) ARMOURED ----- 2 2 0.75 1 PROFIBUS COMMUNICATION CUSTOMER =A1/5.7
=A1-WCS11 =A1-LCS-X41 =A1-X22 (YWY) ARMOURED 0-10V 3 3 0.75 1 LOCAL SETPOINT CUSTOMER =A1/6.5
=A1-WP01 =A1-X13 =A1-MCC (YWY) ARMOURED 415V AC 3 3 4 1 MCC SUPPLY CUSTOMER =A1/2.1
(YWY) - ARMOURED COPPER CABLE (YY) - UNARMOURED COPPER CABLE (*) - POTENTIAL FREE (AYWY) - ARMOURED ALUMINIUM CABLE (AYY) - UNARMOURED ALUMINIUM CABLE

NO. DATE BY BY
WEIGH FEEDER TITLE: = A1_CAB + LANGUAGE :
CUSTOMER : NIRMA LTD. CABLE SCHEDULE en_US

DRG.NO.:
90.18737-WF-011
PROJECT : SHEET : 1
90.18737 - 011-EE04-R0
1 2 3 4 5 6 7 8 9 10 11 12 13 14
CABLE OVERVIEW
=A1-WP02 =A1-TERMINALBOX =A1-X13 (YWY) ARMOURED 415V AC 4 4 4 1 WF MOTOR CUSTOMER =A1/16.2
=A1-WP03 =A1-M2-X17 =A1-X13 (YWY) ARMOURED 415V AC 3 3 1.5 1 VIB MOTOR CUSTOMER =A1/17.7
=A1-WP04 =A1-X13 =A1-UPS (YWY) ARMOURED 110V AC 2 2 2.5 1 UPS CUSTOMER =A1/3.1

NO. DATE BY BY

DRG.NO.:
90.18737-WF-011
PROJECT : SHEET : 2
90.18737 - 011-EE04-R0
1 2 3 4 5 6 7 8 9 10 11 12 13 14
TERMINAL DIAGRAM
-WCS08
Strip
Cable name
Cable name
=A1+-X4-X4
(YWY) ARMOURED
Connection
Connection
Cable type
Cable type
Terminal
Jumper
point
point
Function text Target designation Target designation Page / column
PROFIBUS INTERFACE -PLC/DCS 3 -U1-U1.7-X14 3+ /5.6
= -PLC/DCS 8 -U1-U1.7-X14 8- /5.6

NO. DATE BY BY
WEIGH FEEDER TITLE: = A1_TER + LANGUAGE :
CUSTOMER : NIRMA LTD. Terminal diagram =A1+-X4-X4 en_US

DRG.NO.:
90.18737-WF-011
PROJECT : SHEET : 1
90.18737 - 011-EE17-R0
1 2 3 4 5 6 7 8 9 10 11 12 13 14
TERMINAL DIAGRAM
-WCS05
-WCS06
Strip
Cable name
Cable name
=A1+-X9
(YWY) ARMOURED
(YWY) ARMOURED
Connection
Connection
Cable type
Cable type
Terminal
Jumper
point
point
1 /6.2
4-20mA I/P α SET POINT -PLC/DCS 2 -U1-U1.5-X12 2 /6.2
= -PLC/DCS 3 -U1-U1.5-X12 3 /6.2
4-20mA O/P α ACTUAL FEEDRATE -PLC/DCS 4 -U1-U1.5-X10 1+ /6.8
= -PLC/DCS 5 -U1-U1.5-X10 2-+ /6.8
= 6 /6.9

NO. DATE BY BY
CUSTOMER : NIRMA LTD. Terminal diagram =A1+-X9 en_US

DRG.NO.:
90.18737-WF-011
PROJECT : SHEET : 2
90.18737 - 011-EE17-R0
1 2 3 4 5 6 7 8 9 10 11 12 13 14
TERMINAL DIAGRAM
-WC05
Strip
Cable name
Cable name
=A1+-X10
(YWY) ARMOURED
Connection
Connection
Cable type
Cable type
Terminal
Jumper
point
point
ZERO SPEED SWITCH -LCS-X14 1 1 -X6 P /7.2
110N -LCS-X14 3 2 -X6 N /7.2
-U7-RL1 COM
ZERO SPEED SWITCH -LCS-X14 5 3 -U7-RL1 1 /7.3
BELT SWAY SWITCH -LCS-X14 6 4 -U7-RL2 2 /7.5
FLAP TYPE SW. -LCS-X14 7 5 -U7-RL3 3 /7.7
WF ON/FAULT -LCS-X14 8 6 -U2-NO 6 /10.3
-LP2 1
VIB ON/OFF -LCS-X14 9 7 -K1 14A /10.4
FIELD/NON-FIELD -LCS-X14 12 8 -U6-RL1 1 /11.2
START -LCS-X14 13 9 -U6-RL2 2 /11.4
STOP -LCS-X14 14 10 -U6-RL3 3 /11.7
EMG OFF -LCS-X14 15 11 -U6-RL4 4 /11.9
VIB ON/OFF -LCS-X14 16 12 -U6-RL5 5 /11.11

NO. DATE BY BY

DRG.NO.:
90.18737-WF-011
PROJECT : SHEET : 3
90.18737 - 011-EE17-R0
1 2 3 4 5 6 7 8 9 10 11 12 13 14
TERMINAL DIAGRAM
-WCS04
-WCS03
Strip
Cable name
Cable name
=A1+-X11
(YWY) ARMOURED
(YWY) ARMOURED
Connection
Connection
Cable type
Cable type
Terminal
Jumper
point
point
SUPPLY - 4 -JB1-X15 4 1 -U1-U1.6-X15 9 /15.6
SUPPLY + 1 -JB1-X15 2 2 -U1-U1.6-X15 5 /15.3
SIGNAL + 5 -JB1-X15 1 3 -U1-U1.6-X15 2 /15.4
SIGNAL - 6 -JB1-X15 3 4 -U1-U1.6-X15 6 /15.5
GROUND -WCSA 5 -WCSA /15.3
SENSE - 3 -JB1-X15 12 6 -U1-U1.6-X15 8 /15.5
SENSE + 2 -JB1-X15 11 7 -U1-U1.6-X15 4 /15.4
SUPPLY + -JB1-X15 13 8 -U1-U1.6-X16 1 /15.10
TACHO I/P -JB1-X15 14 9 -U1-U1.6-X16 2 /15.11
= 10 /15.11

NO. DATE BY BY

DRG.NO.:
90.18737-WF-011
PROJECT : SHEET : 4
90.18737 - 011-EE17-R0
1 2 3 4 5 6 7 8 9 10 11 12 13 14
TERMINAL DIAGRAM
-WC04
Strip
Cable name
Cable name
=A1+-X12
(YWY) ARMOURED
Connection
Connection
Cable type
Cable type
Terminal
Jumper
point
point
START/STOP (110V AC) -PLC/DCS 1 -U5-RL1 COM /7.8
= -PLC/DCS 2 -U5-RL1 1 /7.9
DOWNSTREAM INTERLOCK (110V AC) -PLC/DCS 3 /7.10
= -PLC/DCS 4 -U5-RL1 2 /7.11
FAULT RESET (110V AC) -PLC/DCS 5 /7.13
= -PLC/DCS 6 -U5-RL1 3 /7.13

NO. DATE BY BY

DRG.NO.:
90.18737-WF-011
PROJECT : SHEET : 5
90.18737 - 011-EE17-R0
1 2 3 4 5 6 7 8 9 10 11 12 13 14
TERMINAL DIAGRAM
-WP04
-WP03
-WP02
-WP01
Strip
Cable name
Cable name
=A1+-X13
(YWY) ARMOURED
(YWY) ARMOURED
(YWY) ARMOURED
(YWY) ARMOURED
Connection
Connection
Cable type
Cable type
Terminal
Jumper
point
point
POWER SUPPLY 415 V AC ±10% 50HZ ±5% 3ø SUPPLY 1 -MCC R 1 -Q1 1 /2.1
= 2 -MCC Y 2 -Q1 3 /2.2
= 3 -MCC B 3 -Q1 5 /2.2
-TERMINALBOX 1 4 -L2 U1 /16.2
M1 WF MOTOR 1.5 KW,4 POLE 1500 RPM,3.3A -TERMINALBOX 2 5 -L2 V1 /16.2
= -TERMINALBOX 3 6 -L2 W1 /16.2
VIB MOTOR -M2-X17 1 7 -K1 2 /17.7
= -M2-X17 2 8 -K1 4 /17.7
= -M2-X17 3 9 -K1 6 /17.7
UPS 110V AC 50HZ 1ø SUPPLY 1 -UPS L 10 -Fa 1 /3.2
= 2 -UPS N 11 -Fa 3 /3.2
POWER SUPPLY 415 V AC ±10% 50HZ ±5% 3ø SUPPLY -MCC E E /2.2
UPS 110V AC 50HZ 1ø SUPPLY -UPS E E /3.3
M1 WF MOTOR 1.5 KW,4 POLE 1500 RPM,3.3A -TERMINALBOX E E -U4 PE /16.3
VIB MOTOR E -HMI-HMI E /17.8

NO. DATE BY BY

DRG.NO.:
90.18737-WF-011
PROJECT : SHEET : 6
90.18737 - 011-EE17-R0
1 2 3 4 5 6 7 8 9 10 11 12 13 14
TERMINAL DIAGRAM
-WC07
-WC05
Strip
Cable name
Cable name
=A1+-LCS-X14
(YWY) ARMOURED
(YWY) ARMOURED
Connection
Connection
Cable type
Cable type
Terminal
Jumper
point
point
ZERO SPEED SWITCH -JB1-X15 16 1 -X10 1 /7.2
220P 2 /7.2
220N -JB1-X15 17 3 -X10 2 /7.2
= 4 /7.2
BELT SWAY SWITCH -JB1-X15 22 6 -X10 4 /7.5
FLAP TYPE SW. -JB1-X15 24 7 -X10 5 /7.7
WF ON/FAULT -LCS-L1 1 8 -X10 6 /10.3
VIB ON/OFF -LCS-L2 1 9 -X10 7 /10.4
-LCS-S1 4 10 /11.1
-LCS-D1 20
-LCS-D1 19 11 /11.1
FIELD/NON-FIELD -LCS-S1 3 12 -X10 8 /11.2
START -LCS-S2 3 13 -X10 9 /11.4
STOP -LCS-S3 1 14 -X10 10 /11.7
EMG OFF -LCS-S4 1 15 -X10 11 /11.9
VIB ON/OFF -LCS-S5 3 16 -X10 12 /11.11

NO. DATE BY BY
CUSTOMER : NIRMA LTD. Terminal diagram =A1+-LCS-X14 en_US

DRG.NO.:
90.18737-WF-011
PROJECT : SHEET : 7
90.18737 - 011-EE17-R0
1 2 3 4 5 6 7 8 9 10 11 12 13 14
TERMINAL DIAGRAM
-WC08
-WC02
-WC01
-WC06
-WCS02
-WCS01-2
-WCS01-1
-WCS03
-WCS02
-WCS04
-WC07
Strip
Cable name
Cable name
=A1+-JB1-X15
(YY) UNARMOURED
(YY) UNARMOURED
(YY) UNARMOURED
(YY) UNARMOURED
(YY) UNARMOURED
(YY) UNARMOURED
(YY) UNARMOURED
(YWY) ARMOURED
(YY) UNARMOURED
(YWY) ARMOURED
(YWY) ARMOURED
Connection
Connection
Cable type
Cable type
Terminal
Jumper
point
point
SIGNAL + 1 -FIELD-LC1 A 1 -X11 3 5 /15.4
SUPPLY + 2 -FIELD-LC1 B 2 -X11 2 1 /15.3
SIGNAL - 3 -FIELD-LC1 C 3 -X11 4 6 /15.5
SUPPLY - 4 -FIELD-LC1 D 4 -X11 1 4 /15.6
-JB1-WCS01-1 SH 5 -WCS02 SH /15.3
FREE -JB1-WCS01-2 SH 6 /15.9
= 1 -FIELD-LC2 A 7 /15.7
= 4 -FIELD-LC2 B 8 /15.7
= 2 -FIELD-LC2 C 9 /15.9
= 3 -FIELD-LC2 D 10 /15.8
SENSE + 11 -X11 7 2 /15.4
SENSE - 12 -X11 6 3 /15.5
SUPPLY + -FIELD-TH 13 -X11 8 /15.10
TACHO I/P -FIELD-TH 14 -X11 9 /15.11
= 15 /15.11
ZERO SPEED SWITCH -FIELD 1 16 -LCS-X14 1 /7.2
= 17 -LCS-X14 3 /7.2
= -FIELD 2 18 -LCS-X14 5 /7.3
BELT SWAY SWITCH -FIELD 19 /7.4
= -FIELD 20 /7.4
= -FIELD 21 /7.4
= -FIELD 22 -LCS-X14 6 /7.5
= -FIELD 2 23 /7.6
FLAP TYPE SW. -FIELD 3 24 -LCS-X14 7 /7.7

NO. DATE BY BY
CUSTOMER : NIRMA LTD. Terminal diagram =A1+-JB1-X15 en_US

DRG.NO.:
90.18737-WF-011
PROJECT : SHEET : 8
90.18737 - 011-EE17-R0
1 2 3 4 5 6 7 8 9 10 11 12 13 14
TERMINAL DIAGRAM
-WC03
Strip
Cable name
Cable name
=A1+-X21
(YWY) ARMOURED
Connection
Connection
Cable type
Cable type
Terminal
Jumper
point
point
WF ON -PLC/DCS 1 -U2-NO 0 /9.2
= -PLC/DCS 2 -U2-C 0 /9.2
GENERAL FAULT -PLC/DCS 3 -U2-NO 1 /9.4
= -PLC/DCS 4 -U2-C 1 /9.4
TPH DEVIATION -PLC/DCS 5 -U2-NO 2 /9.6
= -PLC/DCS 6 -U2-C 2 /9.6
MATERIAL STARVATION -PLC/DCS 7 -U2-NO 3 /9.8
= -PLC/DCS 8 -U2-C 3 /9.8
REMOTE MODE SEL -PLC/DCS 9 -U2-NO 4 /9.10
= -PLC/DCS 10 -U2-C 4 /9.10
EMG STOP FEEDBACK -PLC/DCS 11 -U2-NO 5 /9.11
= -PLC/DCS 12 -U2-C 5 /9.12
= -PLC/DCS 13 -F1 21 /9.13
WF TRIP -PLC/DCS 14 -F1 22 /9.13
= -PLC/DCS 15 -K1 13 /9.13
VIB ON -PLC/DCS 16 -K1 14 /9.14
INT/DEINT MODE SEL. -PLC/DCS 17 -U2-NO 7 /10.5
= -PLC/DCS 18 -U2-C 7 /10.5
TOTALISER PULSE O/P -PLC/DCS 19 -U2-NO 8 /10.7
= -PLC/DCS 20 -U2-C 8 /10.7
VOL. MODE SEL. -PLC/DCS 21 -U2-NO 9 /10.9
= -PLC/DCS 22 -U2-C 9 /10.9
GRAV MODE SEL. -PLC/DCS 23 -U2-NO 10 /10.11
= -PLC/DCS 24 -U2-C 10 /10.11
FEEDER HEALTHY -PLC/DCS 25 -U8-NO 0 /13.2
= -PLC/DCS 26 -U8-C 0 /13.2
READY TO START -PLC/DCS 27 -U8-NO 1 /13.4
= -PLC/DCS 28 -U8-C 1 /13.4
BSS O/P -PLC/DCS 29 -U8-NO 2 /13.6
= -PLC/DCS 30 -U8-C 2 /13.6
LOCAL MODE SEL -PLC/DCS 31 -U8-NO 3 /13.8
= -PLC/DCS 32 -U8-C 3 /13.8
ZSS O/P -PLC/DCS 33 -U8-NO 4 /13.10
= -PLC/DCS 34 -U8-C 4 /13.10

NO. DATE BY BY

DRG.NO.:
90.18737-WF-011
PROJECT : SHEET : 9
90.18737 - 011-EE17-R0
1 2 3 4 5 6 7 8 9 10 11 12 13 14
TERMINAL DIAGRAM
-WCS11
-WCS07
Strip
Cable name
Cable name
=A1+-X22
(YWY) ARMOURED
(YWY) ARMOURED
Connection
Connection
Cable type
Cable type
Terminal
Jumper
point
point
FEEDRATE INDICATOR -LCS-X41 1 1 -U1-U1.5-X9 1+ /6.13
= -LCS-X41 2 2 -U1-U1.5-X9 2- /6.13
= 3 /6.14
LOCAL SETPOINT -LCS-X41 4 4 -U1-U1.5-X11 1 /6.5
= -LCS-X41 5 5 -U1-U1.5-X11 2 /6.5
= -LCS-X41 6 6 -U1-U1.5-X11 3 /6.5
= 7 /6.6

NO. DATE BY BY

DRG.NO.:
90.18737-WF-011
90.18737 - 011-EE17-R0
1 2 3 4 5 6 7 8 9 10 11 12 13 14
TERMINAL DIAGRAM
-LCS-WCSF
-WCS07
-LCS-WCSD
-WCS11
Strip
Cable name
Cable name
=A1+-LCS-X41
(YWY) ARMOURED
(YWY) ARMOURED
Connection
Connection
Cable type
Cable type
Terminal
Jumper
point
point
FEEDRATE INDICATOR -X22 1 1 -LCS-D1 +7 2 /6.13
= -X22 2 2 -LCS-D1 -8 1 /6.13
= 3 /6.14
LOCAL SETPOINT 3 -LCS-P1 3 4 -X22 4 /6.5
= 2 -LCS-P1 2 5 -X22 5 /6.5
= 1 -LCS-P1 1 6 -X22 6 /6.5
= 7 /6.6

NO. DATE BY BY

DRG.NO.:
90.18737-WF-011
90.18737 - 011-EE17-R0
1 2 3 4 5 6 7 8 9 10 11 12 13 14
BILL OF MATERIALS
LEGEND QTY. DESIGNATION GENERAL SPECIFICATIONS PART NO. ERP PART NO. MANUFACTURER PAGE NO.
=A1-F1 1 MOTOR PROTECTION CIRCUIT BREAKER 2.4-4 AMPS 3VU13 40-1MJ00 805001010000 SIEMENS =A1/16.2
=A1-F2 1 MOTOR PROTECTION CIRCUIT BREAKER 0.4-0.6 AMPS 3VU13 40-1ME00 80500F0E0000 SIEMENS =A1/17.7
=A1-Fa 1 MINIATURE CIRCUIT BREAKER 2 AMPS 5SL42020RC 8030020G0100 SIEMENS =A1/3.2
=A1-Fb 1 MINIATURE CIRCUIT BREAKER 1.0 AMP-2P 5SL62017RC 8030010E0100 SIEMENS =A1/2.12
=A1-Fc 1 MINIATURE CIRCUIT BREAKER 1.0 AMP-2P 5SL62017RC 8030010E0100 SIEMENS =A1/2.7
=A1-HMI 1 7" TOUCH SCREEN DISPLAY 24V DC HMI WITH CABLE 80Z003002200 FPIL =A1/5.6
=A1-K1 1 POWER CONTACTOR 9 AMPS - 1 NO 3TF30 10-0AF0 800002080000 SIEMENS =A1/10.12
=A1-K1 1 SURGE SUPPRESSOR 48-127V AC 3TX7 402-3SY2 80S001010000 SIEMENS =A1/10.12
=A1-L2 1 OUTPUT REACTOR 150uH / 15 AMPS ------- C02010100000 OM INDUSTRIES =A1/16.2
=A1-L3 1 CFL LAMP 8 WATT ------- 80200T0V0200 PHILIPS =A1/2.13
=A1-LCS-D1 1 DIGITAL PANEL METER 85 TO 270V AC - 4 (DIGIT) (TPH) PIC101N C05096040700 SELECTRON =A1/6.12
=A1-LCS-L1 1 LED LAMP 110V AC - RED 3SB52 85-6HC02 80200G130000 SIEMENS =A1/10.3
=A1-LCS-P1 1 POTENTIOMETER 1K, 10 TURNS ------- 808006000100 BOURNS =A1/6.5
=A1-LCS-S1 1 MODULAR SELECTOR ACTUATORS 2 POSITION SELECTOR SW. (BLACK) 3SB50 00-2AB01 50G0060A0100 SIEMENS =A1/11.2
=A1-LCS-S2 1 MODULAR PUSH BUTTON ACTUATORS PUSH BUTTON (GREEN) WITH NO CONTACT BLOCK 3SB50 00-0AE01+3SB54 00-0B 50G005070100 SIEMENS =A1/11.4
=A1-LCS-S3 1 MODULAR PUSH BUTTON ACTUATORS PUSH BUTTON (RED)WITH NO CONTACT BLOCK 3SB50 00-0AC01+3SB54 00-0B 50G005080100 SIEMENS =A1/11.7
=A1-LCS-S4 1 MUSHROOM ACTUATORS EMERGENCY STOP (RED) 3SB52 03-0UC01 50G002090100 SIEMENS =A1/11.9

NO. DATE BY BY
WEIGH FEEDER TITLE: = A1_BOM + LANGUAGE :
CUSTOMER : NIRMA LTD. BILL OF MATERIALS en_US

DRG.NO.:
90.18737-WF-011
PROJECT : SHEET : 1
90.18737 - 011-EE03-R0
1 2 3 4 5 6 7 8 9 10 11 12 13 14
BILL OF MATERIALS
=A1-LP1 1 LED LAMP 110V AC - RED 3SB52 85-6HC02 80200G130000 SIEMENS =A1/2.5
=A1-LP2 1 LED LAMP 110V AC - AMBER 3SB52 85-6HL02 80200I140000 SIEMENS =A1/10.2
=A1-Q1 1 DOOR ISOLATOR 32 AMPS 3KL8121-3TA00 80A00B420000 SIEMENS =A1/2.1
=A1-S1 1 SURFACE MOULED ON / OFF SW. 5 AMPS ------- 50G0090C0200 ANCHOR =A1/2.11
=A1-S2 1 DOOR LIMIT SWITCH 400V AC, 6A 3SE5250-0BC05 80A026460000 SIEMENS =A1/2.13
=A1-TX1 1 TRANSFORMER I/P 415V AC, O/P 220V AC @ 1 AMP, 110V AC @ 1 AMP------- 80F00K0D0200 OM INDUSTRIES =A1/2.4
=A1-U1 1 GRAVIMETRIC DOSING CONTROLLER 24V DC GDC (LCT-BASIC) 5000I00D0L00 FPIL =A1/5
=A1-U2 1 SMALL RELAY BOARD 12 I/O & 12 O/P RL I/O 5000P00H0P00 FPIL =A1/7.2
=A1-U3 1 POWER SUPPLY Input: AC 100-240V, Output 24VDC 2.5A S8VK - C06024 C030K1500100 OMRON =A1/3.7
=A1-U4 2 INVERTER 1.5 KW ACS550-01-04A1-4 C00000000000 ABB =A1/16.2
=A1-U5 1 RELAY BOARD 4 CHANNEL - 1 CHANGE OVER 110V AC - 4CH/1CO 80900D0E0B00 FPIL =A1/7.8
=A1-U6 1 RELAY BOARD 8 CHANNEL - 1 CHANGE OVER 110V AC - 8CH/1CO 809005070100 FPIL =A1/11.2
=A1-X4 1 PROFIBUS CONNECTOR LED TYPE - EASYCONN - PB 0° 972-0DP30 E0J050060400 VIPA =A1/5.6

NO. DATE BY BY

DRG.NO.:
90.18737-WF-011
PROJECT : SHEET : 2
90.18737 - 011-EE03-R0
P.O. NO. : K/8001062PO180700145 DTD.17-07-2018 1/11/2019 VIM-IN TOTAL : 41
FLSMIDTH PVT. LTD.
(PFISTER INDIA BUSSINESS UNIT)
i-THINK TECHNO CAMPUS, 'A' WING,1ST FLOOR,
OFFICE NO. 2, OFF POKHRAN ROAD 2, BEHIND TCS,
THANE, MAHARASHTRA
CITY : MUMBAI ZIP CODE : 400 601 COUNTRY : INDIA
PHONE : 022 6117 2555 FAX : 022 6117 2917 E-MAIL : transweigh.sales@flsmidthpfister.com
ELECTRICAL DOCUMENTATION FOR

WEIGH FEEDER
JOB NO. : 90.18737

EQPT. : WEIGH FEEDER
PROJECT :
CONSULTANT :
P.O NO. : K/8001062PO180700145 DTD.17-07-2018
ELECTRICAL DRAWING - R0
DETAIL ELECTRICAL DRAWINGS - R0
TERMINATION DETAILS - R0
CATEGORY OF DRG. : REFERENCE APPROVAL AS BUILT

1 2 3 4 5 6 7 8 9 10 11 12 13 14
TABLE OF CONTENTS
1 TITLE PAGE ---- =A2_FC/1
5 SYSTEM BLOCK DIAGRAM 012-EE01-R0 =A2_BAS/1
6 SINGLE LINE DIAGRAM 012-EE02-R0 =A2_BAS/2
7 ELECTRICS ENCLOSURE GA 012-EE05-R0 =A2_BAS/3
8 LOCAL CONTROL STATION 012-EE09-R0 =A2_BAS/4
9 JUNCTION BOX DETAIL (JB1) 012-EE10-R0 =A2_BAS/5
10 GDC GA 012-EE26-R0 =A2_BAS/6
11 DETAIL ELECTRICAL DRAWING 012-EE16-R0 =A2/1
12 VOLTAGE SUPPLY 012-EE16-R0 =A2/2
13 UPS 012-EE16-R0 =A2/3
14 GDC - 8 RACK ARCHITECTURE 012-EE16-R0 =A2/5
15 ANALOG INTERFACE 1 012-EE16-R0 =A2/6
16 INPUTS E0-E5 012-EE16-R0 =A2/7
17 INPUTS E6-E11 012-EE16-R0 =A2/8
18 OUTPUTS A0-A5 012-EE16-R0 =A2/9
19 OUTPUTS A6-A11 012-EE16-R0 =A2/10

NO. DATE BY BY

DRG.NO.:
90.18737-WF-012
PROJECT : SHEET : 1
90.18737 - ----
1 2 3 4 5 6 7 8 9 10 11 12 13 14
TABLE OF CONTENTS
20 INPUTS E12-E17 012-EE16-R0 =A2/11
21 INPUTS E18-E23 012-EE16-R0 =A2/12
22 OUTPUTS A12-A17 012-EE16-R0 =A2/13
23 OUTPUTS A18-A23 012-EE16-R0 =A2/14
24 WF LOADCELL & TACHO 012-EE16-R0 =A2/15
25 AC INVERTER 012-EE16-R0 =A2/16
28 Terminal diagram =A2+-X4-X4 012-EE17-R0 =A2_TER/1
35 Terminal diagram =A2+-JB1-X15 012-EE17-R0 =A2_TER/8

NO. DATE BY BY

DRG.NO.:
90.18737-WF-012
PROJECT : SHEET : 2
90.18737 - ----
1 2 3 4 5 6 7 8 9 10 11 12 13 14
TABLE OF CONTENTS

NO. DATE BY BY

DRG.NO.:
90.18737-WF-012
PROJECT : SHEET : 3
90.18737 - ----
1 2 3 4 5 6 7 8 9 10 11 12 13 14
WF-02 RED OCHRE 60 TPH 1 NO

1. INPUTS /OUTPUTS OF WF.
OUTPUTS : RELAY CONTACTS MAX. 220V./5A LOAD
INPUTS : 220 VAC
1. CONTROL CABLES TO & FROM CUSTOMER'S

PANEL CAN BE COMBINED TOGETHER
HOWEVER 4-20mA SIGNALS
CABLES ARE SEPERATE.
3. * FLSMIDTHPFISTER SCOPE
HOPPER
LCS
TACHO
M T WF ZSS
BELT TRACKING LOADCELL
*WCS 02
*WC 06
S1 S2 *WCS 01.2
*WCS 01.1
*WC 01 *WC 02
JUNCTION BOX (JB1)

AT FIELD
WC 07
WCS 11
WCS 04
WCS 03
WP 02
WC 05
WCS 07
ELECTRICS ENCLOSURE WITH
GDC ELECTRONICS
WC 03
WP 04
WP 01
WC 04
WCS 05
WCS 06
WCS 08
DOWNSTREAM INTERLOCK
MATERIAL STARVATION
INT/DEINT MODE SEL.

TOTALISER PULSE O/P
EMG STOP FEEDBACK
415 V ±10% 110 VAC
α ACTUAL FEEDRATE
REMOTE MODE SEL
50 Hz ±5% 50 Hz
LOCAL MODE SEL.
FEEDER HEALTHY
GRAV. MODE SEL.

READY TO START
COMMUNICATION
VOL. MODE SEL.
TPH DEVIATION
GENERAL FAULT
4-20mA ISO O/P

3ø SUPPLY 1ø SUPPLY
4-20mA ISO I/P

α SET POINT
FAULT RESET
START/STOP
PROFIBUS
(MCC SUPPLY (UPS
BSS O/P
ZSS O/P
WF TRIP
WF ON
CUSTOMER) CUSTOMER)
PLC/DCS PANEL
(CUSTOMER)

NO. DATE BY BY
CUSTOMER : NIRMA LTD. SYSTEM BLOCK DIAGRAM en_US

DRG.NO.:
90.18737-WF-012
PROJECT : SHEET : 1
90.18737 - 012-EE01-R0
1 2 3 4 5 6 7 8 9 10 11 12 13 14
MCC (CUSTOMER) UPS

MCC POWER SUPPLY
110 VAC
415 V ±10%
50 Hz
50HZ ±5%
1ø SUPPLY
3ø SUPPLY
100 VA
1;3;5
Q1
3
32 Amps
2;4;6
1;3;5
F1
3
1;3
TX1 Fa
ELECTRIC ENCLOSURE
I>> L2;L1 415I/P

2 Amps. 2
2;4;6
220V O/P@1 Amps
2;4
110V O/P@1 Amps
0V;1L
U4 X1
L1 L2 L3 2
INVERTER
U V W
X2 1;3 U3
1;3 Fc 110V AC
Fb
2
1 Amp. 2 24VDC @2 Amps.
2 1 Amp.
U V W
2;4 2;4
L2 1 1 1
110V AC
U1
U1 V1 W1 GDC
LAMP & GDC
ILLUMINATION
24V DC
3+PE
M
FIELD
3~
M1
WF MOTOR
2.2 KW
4 POLE MAX DISTANCE BETWEEN PANEL & MOTOR IS 150 MTRS
1500 RPM
4.4 A

NO. DATE BY BY
CUSTOMER : NIRMA LTD. SINGLE LINE DIAGRAM en_US

DRG.NO.:
90.18737-WF-012
PROJECT : SHEET : 2
90.18737 - 012-EE02-R0
1 2 3 4 5 6 7 8 9 10 11 12 13 14
NOTE:-
LOUVERS +
FILTERS 1) MAX. FLOOR OPENING FOR CABLE :- 430 mm x 350 mm
2) DESIGN FEATURES :
NAME PLATE
- FRONT SIDE WITH SWIVEL DOOR.
HMI - REAR SIDE FIXED ON BOLTS.
DISPLAY
- PROTECTION SYSTEM IP54 WITH DOORS CLOSED.
INVERTER DISPLAY
- INLINE INSTALLATION.
- UNDRILLED GLAND PLATE TO BE PROVIDED
PANEL LABEL
1800
DOOR LOCK POWER WF UPS
3) SHEET THICKNESS :
2000
ON ON ON
DOOR ISOLATOR - FRONT DOOR - 2.0 mm THK.

- SIDE COVERS - 1.6 mm THK.
DRAWING
POCKET
INDSIDE
4) WEIGHT :- APPROX. 200 KGS.
LOUVERS +
FILTERS 5) SURFACE PROTECTION :
INSIDE & OUTSIDE POWDER COAT
200
(STRUCTURE FINISH) AS PER SHADE NO. RAL 7035

2 N0S BASE - AS PER IS:5 - DARK BLACK
EARTHING
600 BOLT 460 6) PANEL DIMENSION : 600 mm X 500 mm X 2000 mm.
(M10)
500 PACKED SIZE:- 680 mm x 590 mm x 2110 mm.
MAINTENANCE
SPACE REQD.
7) ALL DIMENSIONS ARE IN `MM'.

1000 (MIN)
100 400 100 SPACE FOR CABLES

RUNNING ACROSS
8) TOTAL NO OF SIDE COVER 2 NOS./PANEL PROVIDED.
25
9) EARTHING BOLT - 2 NOS./PANEL PROVIDED.
10) MAKE: PYROTECH

14ø HOLE
420
500
4 NOS QTY.: 1 NO.
WARNING LABELS FOR PANEL

PROJECTION 70 mm.
30
MAINTENANCE
SPACE REQD.
MAX. FRONT70
1000 (MIN)
EARTHING
DO NOT DRILL
CAUTION

NO. DATE BY BY
CUSTOMER : NIRMA LTD. ELECTRICS ENCLOSURE GA en_US

DRG.NO.:
90.18737-WF-012
PROJECT : SHEET : 3
90.18737 - 012-EE05-R0
1 2 3 4 5 6 7 8 9 10 11 12 13 14
4 NOS. ø10 HOLES FOR NOTE:-

MTG. WITH M8 BOLT EMERGENCY STOP
1) ALL DIMENSION ARE IN MM.
2) DOUBLE DOOR ENCLOSURE WITH ALL SWITCHES
AND INDICATIONS MOUNTED ON INNER DOOR,
ACRYLIC WINDOW AND DOOR LOCK
ON OUTER DOOR,
EMERGENCY OFF MOUNTED ON RIGHT SIDE.
85
3) GLAND PLATE :- DRILLED GLAND HOLES WITH
BLANKING PLUGS.
S4 90 4) SHEET THICKNESS :
TPH
- 1.5 mm DOOR
D1 L1
- 1.38mm REST
DOOR - GLAND PLATE - 3.0 mm THK.
LOCK 5) WEIGHT :
- APPROX. 10 KGS.
295
300
330(CTC)
6) SURFACE PROTECTION :
FIELD NON-FIELD
- OUTSIDE & INSIDE
EPOXY POWDER COAT-
65 (STRUCTURE FINISH)
S3 S2 S1 P1
AS PER SHADE NO. RAL 7035
7) PROTECTION/CLASS : IP55
8) PACKED SIZE:
55
- 260mm x 340 mm x 440 mm.
9) MAINTENANCE SPACE REQUIRED:

LCS IDENTIFICATION
LABEL - 1.5 m. IN FRONT
- 1.0 m. AT SIDES
360 (CTC) 175 (CTC)
400 210
.
CL OF CABLE
EARTHING
ENTRY QTY.- 1 NO.
BOLTS M6
2 NOS.
CONTROLS/INDICATIONS
S1 FIELD/NON-FIELD WARNING LABELS FOR LCS

S2 START
S3 STOP
EARTHING
S4 EMG.OFF (STAY-PUT TYPE)
D1 FEEDRATE INDICATOR (DPM)
L1 WF RUN LAMP DO NOT DRILL
P1 FEEDRATE POT(10 TURNS)
CAUTION

NO. DATE BY BY
CUSTOMER : NIRMA LTD. LOCAL CONTROL STATION en_US

DRG.NO.:
90.18737-WF-012
PROJECT : SHEET : 4
90.18737 - 012-EE09-R0
1 2 3 4 5 6 7 8 9 10 11 12 13 14
247
225
200
ø22.5 HOLE FOR BACKGROUND / OUTER SURF.
Ø22.5 HOLE FOR COLOUR - RAL 7035
CABLE GLAND (3 Nos.)
30 35 30
CONDUIT GLAND (5 Nos.)
21.25
43.75
55
168.00
45
45
TERMINALS
45
168
45
200
160
45
45
45
ø6.5 EARTHING BOLT
45
(2 nos)
15
55
44
21.25
15
FRONT VIEW
83.14 INNER VIEW 83.14
M5, SCREW (4 nos)
LABEL DETAIL
120 120
M6 SCREW (4 nos) (ON COVER)
FOR COVER FITTING
FOR JB MTG.
VIEW-(LEFT SIDE) VIEW-(RIGHT SIDE)
QTY : 1 NO.
NOTE:
1. OVERALL DIMENSIONS :
200.0 W x 200.0 HT. x 120.0 D
2. WEIGHT : 2.05 KGS.
3. MATERIAL SPECIFICATION :
130
- CRCA SHEET 1.5 mm THK.
4. SURFACE:- POWDER COAT RAL 7035
5. PROTECTION CLASS : IP 65
20
6. ALL UNUSED HOLES WILL BE PLUGGED.

7. ALL DIMENSION ARE IN `MM'
WARNING LABELS FOR JB
EARTHING
DO NOT DRILL
CAUTION

NO. DATE BY BY
CUSTOMER : NIRMA LTD. JUNCTION BOX DETAIL en_US

DRG.NO.:
90.18737-WF-012
(JB1)
PROJECT : SHEET : 5
90.18737 - 012-EE10-R0
1 2 3 4 5 6 7 8 9 10 11 12 13 14
268.96
240.56
U1
U1.1 U1.2 U1.3 U1.4 U1.5 U1.6 U1.7 U1.8
CPU PSU AIO DIO LTC FIELD BUS DIO
T+ T+ X14
10V1 +V
T- X6 T- X2
(OPTIONAL)
I/P+ A+
PROFIBUS
SH SH
I/P-
X12 X8 A- X8
AI1 X16
RS-485 (HMI) INVERTER B+ DI
DI
RS-485 B-
GND
10V2
X5 I/P+X11 TACHO
128.4
132.5
RUN
I/P- AI2 LOADCELL
USB HOST
83
HEALTHY COMM
ERROR HEALTHY
+ X10
(OPTIONAL) X4 - AO1
POWER
Ethernet X7 X7
DO X15 DO
24 P
X3
24 N X1 + X9
E
– AO2
USB Device 24 V DC
LOADCELL

NO. DATE BY BY
CUSTOMER : NIRMA LTD. GDC GA en_US

DRG.NO.:
90.18737-WF-012
PROJECT : SHEET : 6
90.18737 - 012-EE26-R0
1 2 3 4 5 6 7 8 9 10 11 12 13 14
DETAIL ELECTRICAL DRAWING:-

GENERAL NOTES:-
1. PANEL WIRING COLOR CODE:-
VOLTAGE COLOR
415 VAC BLACK
110V AC RED - PHASE /

NEUTRAL
GREY (+VE)
24V DC
BLACK (-VE)
EARTHING YELLOW / GREEN
POT. FREE BLUE
2. EQPT DETAILS
WF-02 RED OCHRE 60 TPH 1 NO

NO. DATE BY BY
CUSTOMER : NIRMA LTD. DETAIL ELECTRICAL DRAWING en_US

DRG.NO.:
90.18737-WF-012
PROJECT : SHEET : 1
90.18737 - 012-EE16-R0
1 2 3 4 5 6 7 8 9 10 11 12 13 14
MCC
(CUSTOMER)
POWER SUPPLY
415 V AC ±10%
50HZ ±5%
3ø SUPPLY
S1 L3
R Y B E X6 P L N
P1.4 / LAMP
X6 N
N1.4 / 11.2
X6 P
TX1 P1.3 / 10.1 1
WP01 S2
415I/P X6 N
3x4 mm² N1.3 / 10.1 DOORLIMIT
220V O/P@1 Amps 2 SWITCH
X6 P
L2 L1 P1.2 /
110V O/P@1 Amps
P X6 N POWER SUPPLY
X13 1 2 3 E N1.2 /
S 2N 2L 110V AC
0V 1L X6 P
P1.1 / 7.1
110VAC
X6 N
N1.1 / 7.1
LP1
4 2
1
Fc 4 2
1 Amps. 3 1
2 Fb
1 Amp. 3 1
1 3 5
Q1
32Amps
2 4 6
L3 / 16.2
L2 / 16.2
415V/50Hz
L1 / 16.2
E / 3.11

NO. DATE BY BY
CUSTOMER : NIRMA LTD. VOLTAGE SUPPLY en_US

DRG.NO.:
90.18737-WF-012
PROJECT : SHEET : 2
90.18737 - 012-EE16-R0
1 2 3 4 5 6 7 8 9 10 11 12 13 14
UPS
(CUSTOMER)
UPS
110V AC
50HZ
1ø SUPPLY
L N E
WP04
2x2.5 mm²
X13 7 8 E
1 3
Fa
2 4
2 Amp.
LP3
UPS ON
2
X5 P
24P1.4 / 11.12
1
X5 N
24N1.4 / 11.12
X5 P
24P1.3 / 7.13
X5 N
24N1.3 / 7.13
N L
U3 X5 P
110V AC 24P1.2 / 5.8
24VDC @2.5Amps. E X5 N
POWER SUPPLY
24N1.2 / 5.8
V- V+
24V DC
24P1.1 / 5.5
24N1.1 / 5.5
WCSA-1
2x0.50 mm²
E / 2.13

NO. DATE BY BY
CUSTOMER : NIRMA LTD. UPS en_US

DRG.NO.:
90.18737-WF-012
PROJECT : SHEET : 3
90.18737 - 012-EE16-R0
1 2 3 4 5 6 7 8 9 10 11 12 13 14
U1
GDC
/6 HMI
/7
U1.1
/8
CPU (T+) X6.1 6
(T+) HMI:E E/
/9
SUPPLY
/10
HMI:24N 24N1.2 / 3.11
COM2
/11 X6.2 8
(T-) (T-)
/12
/13
HMI:24P 24P1.2 / 3.11
/14 X6.3 9
(SH) (SH)
/15
/16.12
U1.2
FREE
U1.3
POWER SUPPLY (24P)
X1.1 24P1.1 / 3.11
(24N) X1.2 24N1.1 / 3.11
X1.3
(E)
INVERTER MODBUS
COMMUNICATION
U1.4 ANALOG IO CARD 1
U1.5
DIGITAL IO CARD 1
U1.6
LOADCELL & TACHO CARD
CONNECTOR MOUNTED
ON CONTROLLER WCS 08
U1.7 2x0.75
X14:3+ X4
X4 3
PROFIBUS
FIELD BUS CARD
PROFIBUS DP INTERFACE
X14:8- X4 8
X14:5 PLC/DCS
(CUSTOMER)
U1.8
DIGITAL IO CARD 2

NO. DATE BY BY
CUSTOMER : NIRMA LTD. GDC - 8 RACK en_US

DRG.NO.:
90.18737-WF-012
ARCHITECTURE
PROJECT : SHEET : 5
90.18737 - 012-EE16-R0
1 2 3 4 5 6 7 8 9 10 11 12 13 14
U1
GDC
/5
U1.5
SETPOINT
ANALOG CARD
AI1 AI2 AO1
AO2
FREE
4-20mA 4-20mA O/P
4-20mA O/P
ANALOG INPUT
+10V
+10V
AI1+ AI1- AI2+ AI2- AO1+ AO1-
PE AO2+ AO2-
X12 1 2 3 X11 1 2 3 X10 1+ 2-+
PE X9 1+ 2-
-X22 4 5 6 7
WCS11
3x0.75
GREEN
BLACK
GRAY
X9 1 2 3
X22 1 2 3
X41 4 5 6 7
X9 4 5 6
WCSF
1
3x0.35 mm²
BLACK
RED
2
P1
3
LOCAL SETPOINT LCS
WCS07
2x0.75
WCS06 WCS05 LCS

2x0.75 2x0.75
X41 1 2 3
WCSD
2x0.35
+7 -8
20
11.1 / 110P2
4-20mA I/P 19
4-20mA O/P 11.1 / 110N2
α SET POINT D1
α ACTUAL FEEDRATE
10.4 / 110N2.1
PLC/DCS
(CUSTOMER) FEEDRATE INDICATOR

NO. DATE BY BY
CUSTOMER : NIRMA LTD. ANALOG INTERFACE 1 en_US

DRG.NO.:
90.18737-WF-012
PROJECT : SHEET : 6
90.18737 - 012-EE16-R0
1 2 3 4 5 6 7 8 9 10 11 12 13 14
U1
GDC
=A2-U3-U2.7-X8:15
U1.5
10
3
DB-15(F)
24P1.3 / 3.11
24VDC
24N1.3 / 3.11
E1.1 / 11.13
U2
E0 E1 E2 E3 E4 E5
P1:1
/8.1
3
E0 E1 E2 E3 E4 E5
/9.1
/10.1
E0 E1
E2 E3 E4
BELT TRACK E5
BELT SLIP FLAP TPYE SW. REMOTE START/STOP
24P
E2
E5
24P
24P
24P
24P
24P
E0
E1
E3
E4
U7
RL1 P C O RL2 P C O RL3 P C O
U5
RELAY BOARD RL1 P C O RL2 P C O RL3 P C O
110V AC
RL1 4CH/1CO RL2 RL3
RELAY BOARD
110V AC
RL1 4CH/1CO RL2 RL3
RL1 COM 1 RL2 COM 2 RL3 COM 3
110V AC
RL1 COM 1 2 3
2.8 / N1.1
2.8 / P1.1
X10 1 2 3 4
WC05
12x1.5
LCS
X14 1 2 3 4 5 6
X12 1 2 3 4 5 6
110P 110N
11.1 11.1
WC07
6x1.5
JB1 WC04
6x1.5
X15 16 17 18 19 20 21 22
WC06 WC01 WC02

2x1.5 2x1.5 2x1.5
START/STOP DOWNSTREAM INTERLOCK FAULT RESET
1
(110V AC) (110V AC) (110V AC)
LEFT RIGHT
2
PLC/DCS
(CUSTOMER)
ZERO SPEED SWITCH BELT SWAY SWITCH
FIELD

NO. DATE BY BY

DRG.NO.:
90.18737-WF-012
PROJECT : SHEET : 7
90.18737 - 012-EE16-R0
1 2 3 4 5 6 7 8 9 10 11 12 13 14
U1 U1.5
GDC
=A2-U3-U2.7-X8:8
/5
11
2
6
DB-15(F)
U2
E6 E7 E8 E9 E10 E11
/7.2
E6 E7 E8 E9 E10 E11
E6 E7 E8 E9 E10 E11
E10
E11
24P
24P
24P
24P
24P
24P
E6
E7
E8
E9
13
F1
/16.3 14
WF INTERLOCK

NO. DATE BY BY

DRG.NO.:
90.18737-WF-012
PROJECT : SHEET : 8
90.18737 - 012-EE16-R0
1 2 3 4 5 6 7 8 9 10 11 12 13 14
U1
GDC
=A2-U3-U2.7-X7:3
/5
U1.5
6
DB-15(M)
U2
A0 A1 A2 A3 A4 A5
/7.2
A0 A1 A2 A3 A4 A5
A000 A002
A001 A003 A004 A005
WF ON TRIP
GENERAL FAULT UNDERLOAD REMOTE (LOCAL) EMG STOP
NO:0
NO:1
NO:2
NO:3
NO:4
NO:5
NC:0
NC:1
NC:2
NC:3
NC:4
NC:5
C:0
C:1
C:2
C:3
C:4
C:5
21
F1
22/16.3
X21 1 2 3 4 5 6 7 8 9 10 11 12 13 14
WC03
34x1.5
WF
WF ON GENERAL FAULT TPH DEVIATION MATERIAL STARVATION REMOTE MODE SEL EMG STOP FEEDBACK
TRIP
PLC/DCS
(CUSTOMER)

NO. DATE BY BY

DRG.NO.:
90.18737-WF-012
PROJECT : SHEET : 9
90.18737 - 012-EE16-R0
1 2 3 4 5 6 7 8 9 10 11 12 13 14
U1
GDC
=A2-U3-U2.7-X7:11
/5
U1.5
15
10
9
DB-15(M)
U2
A6 A7 A8 A9 A10 A11
/7.2
A6 A7 A8 A9 A10 A11
A006 A007 A008 A009 A010 A011

FEEDER ON LAMP INT/DEINT MODE SEL. TOTALISER PULSE O/P VOL./GRAV MODE SEL. VIB ON
NO:10
NO:11
NC:10
NC:11
NO:6
NO:7
NO:8
NO:9
NC:6
NC:7
NC:8
NC:9
C:10
C:11
C:6
C:7
C:8
C:9
2.8 / P1.3
110V AC
2.8 / N1.3
X21 15 16 17 18 19 20 21 22
X10 5
WC03
34x1.5
WC 05
12x1.5
LP2 LCS
X14 7 INT/DEINT MODE SEL. TOTALISER PULSE O/P VOL. MODE SEL. GRAV MODE SEL.
1
2 1
L1
2
WF ON 110N2.1 / 6.12 PLC/DCS

(CUSTOMER)
EE DOOR WF ON/FAULT

NO. DATE BY BY

DRG.NO.:
90.18737-WF-012
90.18737 - 012-EE16-R0
1 2 3 4 5 6 7 8 9 10 11 12 13 14
U1
GDC
=A2-U3-U2.7-X8:15
U1.8
10
3
DB-15(F)
24P1.4 / 3.11 24VDC

24N1.4 / 3.11
E1.1 / 7.13
U8
E0 E1 E2 E3 E4 E5
P1:1
/12.1
3
E0 E1 E2 E3 E4 E5
/13.2
/14.2
E1
E0 E2
E3 E4 E5
24P
24P
24P
24P
24P
24P
E0
E1
E2
E3
E4
E5
U6 P C O P C O P C O P C O P C O P C O
RL1 RL2 RL3 RL4 RL5 RL6
RELAY BOARD
110VAC
RL1 RL2 RL3 8CH/1CO RL4 RL5 RL6
RL1 COM 1 RL2 2 RL3 3 RL4 4 RL5 5 RL6 6
110V AC 2.8 / N1.4

X10 6 7 8 9
WC05
12x1.5
LCS 7.2 7.2

110P 110N
X14 8 9 10 11 12 13
3 3 1 1
110N2 / 6.12 S1 S2 S3 S4
LOC/REM START STOP EMG OFF
110P2 / 6.12 4 4 2 2
FIELD/NON-FIELD START STOP EMG OFF

NO. DATE BY BY

DRG.NO.:
90.18737-WF-012
90.18737 - 012-EE16-R0
1 2 3 4 5 6 7 8 9 10 11 12 13 14
U1 U1.8
GDC
=A2-U3-U2.7-X8:8
/5
11
2
6
DB-15(F)
U8
E6 E7 E8 E9 E10 E11
/11.1
E6 E7 E8 E9 E10 E11
E6 E7 E8 E9 E10 E11
E10
E11
24P
24P
24P
24P
24P
24P
E6
E7
E8
E9

NO. DATE BY BY

DRG.NO.:
90.18737-WF-012
90.18737 - 012-EE16-R0
1 2 3 4 5 6 7 8 9 10 11 12 13 14
U1
GDC
=A2-U3-U2.7-X7:3
/5
U1.8
6
DB-15(M)
U8
A0 A1 A2 A3 A4 A5
/11.1
A0 A1 A2 A3 A4 A5
A000
A001 A002 A003 A004 A005
NO:0
NO:1
NO:2
NO:3
NO:4
NO:5
NC:0
NC:1
NC:2
NC:3
NC:4
NC:5
C:0
C:1
C:2
C:3
C:4
C:5
X21 23 24 25 26 27 28 29 30 31 32
WC03
34x1.5
FEEDER HEALTHY READY TO START BSS O/P LOCAL MODE SEL ZSS O/P
PLC/DCS
(CUSTOMER)

NO. DATE BY BY

DRG.NO.:
90.18737-WF-012
90.18737 - 012-EE16-R0
1 2 3 4 5 6 7 8 9 10 11 12 13 14
U1
GDC
=A2-U3-U2.7-X7:11
/5
U1.8
15
10
9
DB-15(M)
U8
A6 A7 A8 A9 A10 A11
/11.1
A6 A7 A8 A9 A10 A11
A006 A007 A008 A009 A010 A011
NO:10
NO:11
NC:10
NC:11
NO:6
NO:7
NO:8
NO:9
NC:6
NC:7
NC:8
NC:9
C:10
C:11
C:6
C:7
C:8
C:9

NO. DATE BY BY

DRG.NO.:
90.18737-WF-012
90.18737 - 012-EE16-R0
1 2 3 4 5 6 7 8 9 10 11 12 13 14
U1 LOADCELL AND ENCODER CARD 1

GDC
/5 U1.6 LOADCELL TACHO
TACHO I/P
SUPPLY +
SUPPLY +
SIGNAL +
SUPPLY -
SIGNAL -
GROUND
SENSE +
SENSE -
FREE
FREE
X15 1 5 4 2 6 8 9 3 7 X16 1 2
X11 5 2 7 3 4 6 1 X11 8 9 10
WCS03
6x0.75 mm²
WCS04
2x0.75
JB1
X15 5 2 11 1 3 12 4 8 7 10 9 6 13 14 15
SH
WCS02
/15.3
2x0.35
WCS01-1 WCS01-2
4x0.35 4x0.35
A C
A C TH
LC1
LC2
LOADCELL
B D
TACHO
B D
FIELD

NO. DATE BY BY
CUSTOMER : NIRMA LTD. WF LOADCELL & TACHO en_US

DRG.NO.:
90.18737-WF-012
90.18737 - 012-EE16-R0
1 2 3 4 5 6 7 8 9 10 11 12 13 14
415 V/50Hz
2.13 2.13 2.13

L1 L2 L3 E1 U1
/5
U1.2
1 3 5
13 21 INVERTER MODBUS
COMMUNICATION
F1 14 22
4-6 Amps (T-)
/8.3 /9.13 (T+)
X2.1 X2.2 SH
I>> I>> I>>
2 4 6
+24V GND DCOM DI1 DI2 DI3 DI4 DI5 DI6 SRC B A AGND SCR
-U4
2.2 KW U1 V1 W1 PE X1.10 X1.11 X1.12 X1.13 X1.14 X1.15 X1.16 X1.17 X1.18 X3.28 X3.29 X3.30 X3.31 X3.32
ON
S1
ON
ACS550-01-05A4-4
ON
U2 V2 W2 PE X1.4 X1.5 X1.6 X1.7 X1.9 X1.8 X1.9 X1.19 X1.20 X1.21 X1.22 X1.23 X1.24 X1.25 X1.26 X1.27
+10V AI2 AGND AO1 AGND AO2 AGND RO1C RO1A RO1B RO2C RO2A RO2B RO3C RO3A RO3B
/11.10/
L2 U V W
150uH / 15 AMPS
U1 V1 W1
X13 4 5 6 E
WP02
4x4 mm² NOTE:
TERMINAL
MAX CABLE DISTANCE BETWEEN VFD PANEL & RESPECTIVE
1 2 3 E
BOX MOTOR CAN BE 150 MTRS
M1 M
3~
M1
WF MOTOR
2.2 KW,4 POLE
1500 RPM,4.4 A

NO. DATE BY BY
CUSTOMER : NIRMA LTD. AC INVERTER en_US

DRG.NO.:
90.18737-WF-012
90.18737 - 012-EE16-R0
1 2 3 4 5 6 7 8 9 10 11 12 13 14
CABLE OVERVIEW
=A2-WC01 =A2-JB1-X15 =A2-FIELD (YY) UNARMOURED 110V AC 2 2 1.5 1 BELTSWAY SW (LEFT) FPIL =A2/7.3
=A2-WC02 =A2-JB1-X15 =A2-FIELD (YY) UNARMOURED 110V AC 2 2 1.5 1 BELT SWAY SW (RIGHT) FPIL =A2/7.4
=A2-WC03 =A2-X21 =A2-PLC/DCS (YWY) ARMOURED 220 VAC 34 32 1.5 1 DIGITAL INPUT TO PLC CUSTOMER =A2/9.2
=A2-WC04 =A2-X12 =A2-PLC/DCS (YWY) ARMOURED 110V AC 6 6 1.5 1 DIGITAL INPUT TO WF GDC CUSTOMER =A2/7.8
=A2-WC05 =A2-LCS-X14 =A2-X10 (YWY) ARMOURED 110V AC 12 9 1.5 1 CONTROLS CUSTOMER =A2/7.1
=A2-WC06 =A2-JB1-X15 =A2-FIELD (YY) UNARMOURED 110V AC 2 2 1.5 1 ZERO SPEED SW FPIL =A2/7.1
=A2-WC07 =A2-JB1-X15 =A2-LCS-X14 (YWY) ARMOURED 110V AC 6 4 1.5 1 ZSS, BSS,FLAP TYPE FPIL =A2/7.1
=A2-WCS02 =A2-JB1-X15 =A2-FIELD-TH (YY) UNARMOURED 12V DC 2 2 0.35 1 TACHO FPIL =A2/15.10
=A2-WCS03 =A2-JB1-X15 =A2-X11 (YWY) ARMOURED 12V DC 6 6 0.75 1 LOADCELL CUSTOMER =A2/15.3
=A2-WCS04 =A2-JB1-X15 =A2-X11 (YWY) ARMOURED 12V DC 2 2 0.75 1 TACHO CUSTOMER =A2/15.10
=A2-WCS05 =A2-X9 =A2-PLC/DCS (YWY) ARMOURED 4-20mA 2 2 0.75 1 4-20mA O/P α ACTUAL FEEDRATE CUSTOMER =A2/6.8
=A2-WCS06 =A2-X9 =A2-PLC/DCS (YWY) ARMOURED 4-20mA 2 2 0.75 1 4-20mA I/P α SET POINT CUSTOMER =A2/6.2
=A2-WCS07 =A2-LCS-X41 =A2-X22 (YWY) ARMOURED 4-20mA 2 2 0.75 1 FEEDRATE INDICATOR CUSTOMER =A2/6.13
=A2-WCS08 =A2-X4-X4 =A2-PLC/DCS (YWY) ARMOURED ----- 2 2 0.75 1 PROFIBUS COMMUNICATION CUSTOMER =A2/5.7
=A2-WCS11 =A2-LCS-X41 =A2-X22 (YWY) ARMOURED 0-10V 3 3 0.75 1 LOCAL SETPOINT CUSTOMER =A2/6.5
=A2-WP01 =A2-X13 =A2-MCC (YWY) ARMOURED 415V AC 3 3 4 1 MCC SUPPLY CUSTOMER =A2/2.1
=A2-WP02 =A2-TERMINALBOX =A2-X13 (YWY) ARMOURED 415V AC 4 4 4 1 WF MOTOR CUSTOMER =A2/16.2

NO. DATE BY BY

DRG.NO.:
90.18737-WF-012
PROJECT : SHEET : 1
90.18737 - 012-EE04-R0
1 2 3 4 5 6 7 8 9 10 11 12 13 14
CABLE OVERVIEW
=A2-WP04 =A2-X13 =A2-UPS (YWY) ARMOURED 110V AC 2 2 2.5 1 UPS CUSTOMER =A2/3.1

NO. DATE BY BY

DRG.NO.:
90.18737-WF-012
PROJECT : SHEET : 2
90.18737 - 012-EE04-R0
1 2 3 4 5 6 7 8 9 10 11 12 13 14
TERMINAL DIAGRAM
-WCS08
Strip
Cable name
Cable name
=A2+-X4-X4
(YWY) ARMOURED
Connection
Connection
Cable type
Cable type
Terminal
Jumper
point
point
PROFIBUS INTERFACE -PLC/DCS 3 -U1-U1.7-X14 3+ /5.6
= -PLC/DCS 8 -U1-U1.7-X14 8- /5.6

NO. DATE BY BY
CUSTOMER : NIRMA LTD. Terminal diagram =A2+-X4-X4 en_US

DRG.NO.:
90.18737-WF-012
PROJECT : SHEET : 1
90.18737 - 012-EE17-R0
1 2 3 4 5 6 7 8 9 10 11 12 13 14
TERMINAL DIAGRAM
-WCS05
-WCS06
Strip
Cable name
Cable name
=A2+-X9
(YWY) ARMOURED
(YWY) ARMOURED
Connection
Connection
Cable type
Cable type
Terminal
Jumper
point
point
1 /6.2
4-20mA I/P α SET POINT -PLC/DCS 2 -U1-U1.5-X12 2 /6.2
= -PLC/DCS 3 -U1-U1.5-X12 3 /6.2
4-20mA O/P α ACTUAL FEEDRATE -PLC/DCS 4 -U1-U1.5-X10 1+ /6.8
= -PLC/DCS 5 -U1-U1.5-X10 2-+ /6.8
= 6 /6.9

NO. DATE BY BY

DRG.NO.:
90.18737-WF-012
PROJECT : SHEET : 2
90.18737 - 012-EE17-R0
1 2 3 4 5 6 7 8 9 10 11 12 13 14
TERMINAL DIAGRAM
-WC05
Strip
Cable name
Cable name
=A2+-X10
(YWY) ARMOURED
Connection
Connection
Cable type
Cable type
Terminal
Jumper
point
point
ZERO SPEED SWITCH -LCS-X14 1 1 -X6 P /7.2
110N -LCS-X14 3 2 -X6 N /7.2
-U7-RL1 COM
ZERO SPEED SWITCH -LCS-X14 5 3 -U7-RL1 1 /7.3
BELT SWAY SWITCH -LCS-X14 6 4 -U7-RL2 2 /7.5
WF ON/FAULT -LCS-X14 7 5 -U2-NO 6 /10.3
-LP2 1
FIELD/NON-FIELD -LCS-X14 10 6 -U6-RL1 1 /11.2
START -LCS-X14 11 7 -U6-RL2 2 /11.4
STOP -LCS-X14 12 8 -U6-RL3 3 /11.7
EMG OFF -LCS-X14 13 9 -U6-RL4 4 /11.9

NO. DATE BY BY

DRG.NO.:
90.18737-WF-012
PROJECT : SHEET : 3
90.18737 - 012-EE17-R0
1 2 3 4 5 6 7 8 9 10 11 12 13 14
TERMINAL DIAGRAM
-WCS04
-WCS03
Strip
Cable name
Cable name
=A2+-X11
(YWY) ARMOURED
(YWY) ARMOURED
Connection
Connection
Cable type
Cable type
Terminal
Jumper
point
point
SUPPLY - 4 -JB1-X15 4 1 -U1-U1.6-X15 9 /15.6
SUPPLY + 1 -JB1-X15 2 2 -U1-U1.6-X15 5 /15.3
SIGNAL + 5 -JB1-X15 1 3 -U1-U1.6-X15 2 /15.4
SIGNAL - 6 -JB1-X15 3 4 -U1-U1.6-X15 6 /15.5
GROUND -WCSA 5 -WCSA /15.3
SENSE - 3 -JB1-X15 12 6 -U1-U1.6-X15 8 /15.5
SENSE + 2 -JB1-X15 11 7 -U1-U1.6-X15 4 /15.4
SUPPLY + -JB1-X15 13 8 -U1-U1.6-X16 1 /15.10
TACHO I/P -JB1-X15 14 9 -U1-U1.6-X16 2 /15.11
= 10 /15.11

NO. DATE BY BY

DRG.NO.:
90.18737-WF-012
PROJECT : SHEET : 4
90.18737 - 012-EE17-R0
1 2 3 4 5 6 7 8 9 10 11 12 13 14
TERMINAL DIAGRAM
-WC04
Strip
Cable name
Cable name
=A2+-X12
(YWY) ARMOURED
Connection
Connection
Cable type
Cable type
Terminal
Jumper
point
point
START/STOP (110V AC) -PLC/DCS 1 -U5-RL1 COM /7.8
= -PLC/DCS 2 -U5-RL1 1 /7.9
DOWNSTREAM INTERLOCK (110V AC) -PLC/DCS 3 /7.10
= -PLC/DCS 4 -U5-RL1 2 /7.11
FAULT RESET (110V AC) -PLC/DCS 5 /7.13
= -PLC/DCS 6 -U5-RL1 3 /7.13

NO. DATE BY BY

DRG.NO.:
90.18737-WF-012
PROJECT : SHEET : 5
90.18737 - 012-EE17-R0
1 2 3 4 5 6 7 8 9 10 11 12 13 14
TERMINAL DIAGRAM
-WP04
-WP02
-WP01
Strip
Cable name
Cable name
=A2+-X13
(YWY) ARMOURED
(YWY) ARMOURED
(YWY) ARMOURED
Connection
Connection
Cable type
Cable type
Terminal
Jumper
point
point
POWER SUPPLY 415 V AC ±10% 50HZ ±5% 3ø SUPPLY 1 -MCC R 1 -Q1 1 /2.1
= 2 -MCC Y 2 -Q1 3 /2.2
= 3 -MCC B 3 -Q1 5 /2.2
-TERMINALBOX 1 4 -L2 U1 /16.2
M1 WF MOTOR 2.2 KW,4 POLE 1500 RPM,4.4 A -TERMINALBOX 2 5 -L2 V1 /16.2
= -TERMINALBOX 3 6 -L2 W1 /16.2
UPS 110V AC 50HZ 1ø SUPPLY 1 -UPS L 7 -Fa 1 /3.2
= 2 -UPS N 8 -Fa 3 /3.2
POWER SUPPLY 415 V AC ±10% 50HZ ±5% 3ø SUPPLY -MCC E E /2.2
UPS 110V AC 50HZ 1ø SUPPLY -UPS E E /3.3
M1 WF MOTOR 2.2 KW,4 POLE 1500 RPM,4.4 A -TERMINALBOX E E -U4 PE /16.3

NO. DATE BY BY

DRG.NO.:
90.18737-WF-012
PROJECT : SHEET : 6
90.18737 - 012-EE17-R0
1 2 3 4 5 6 7 8 9 10 11 12 13 14
TERMINAL DIAGRAM
-WC07
-WC05
Strip
Cable name
Cable name
=A2+-LCS-X14
(YWY) ARMOURED
(YWY) ARMOURED
Connection
Connection
Cable type
Cable type
Terminal
Jumper
point
point
220P 2 /7.2
220N -JB1-X15 17 3 -X10 2 /7.2
= 4 /7.2
BELT SWAY SWITCH -JB1-X15 22 6 -X10 4 /7.5
WF ON/FAULT -LCS-L1 1 7 -X10 5 /10.3
-LCS-S1 4 8 /11.1
-LCS-D1 20
-LCS-D1 19 9 /11.1
FIELD/NON-FIELD -LCS-S1 3 10 -X10 6 /11.2
START -LCS-S2 3 11 -X10 7 /11.4
STOP -LCS-S3 1 12 -X10 8 /11.7
EMG OFF -LCS-S4 1 13 -X10 9 /11.9

NO. DATE BY BY

DRG.NO.:
90.18737-WF-012
PROJECT : SHEET : 7
90.18737 - 012-EE17-R0
1 2 3 4 5 6 7 8 9 10 11 12 13 14
TERMINAL DIAGRAM
-WC02
-WC01
-WC06
-WCS02
-WCS01-2
-WCS01-1
-WCS03
-WCS02
-WCS04
-WC07
Strip
Cable name
Cable name
=A2+-JB1-X15
(YY) UNARMOURED
(YY) UNARMOURED
(YY) UNARMOURED
(YY) UNARMOURED
(YY) UNARMOURED
(YY) UNARMOURED
(YWY) ARMOURED
(YY) UNARMOURED
(YWY) ARMOURED
(YWY) ARMOURED
Connection
Connection
Cable type
Cable type
Terminal
Jumper
point
point
SIGNAL + 1 -FIELD-LC1 A 1 -X11 3 5 /15.4
SUPPLY + 2 -FIELD-LC1 B 2 -X11 2 1 /15.3
SIGNAL - 3 -FIELD-LC1 C 3 -X11 4 6 /15.5
SUPPLY - 4 -FIELD-LC1 D 4 -X11 1 4 /15.6
-JB1-WCS01-1 SH 5 -WCS02 SH /15.3
FREE -JB1-WCS01-2 SH 6 /15.9
= 1 -FIELD-LC2 A 7 /15.7
= 4 -FIELD-LC2 B 8 /15.7
= 2 -FIELD-LC2 C 9 /15.9
= 3 -FIELD-LC2 D 10 /15.8
SENSE + 11 -X11 7 2 /15.4
SENSE - 12 -X11 6 3 /15.5
SUPPLY + -FIELD-TH 13 -X11 8 /15.10
TACHO I/P -FIELD-TH 14 -X11 9 /15.11
= 15 /15.11
ZERO SPEED SWITCH -FIELD 1 16 -LCS-X14 1 /7.2
= 17 -LCS-X14 3 /7.2
= -FIELD 2 18 -LCS-X14 5 /7.3
BELT SWAY SWITCH -FIELD 19 /7.4
= -FIELD 20 /7.4
= -FIELD 21 /7.4
= -FIELD 22 -LCS-X14 6 /7.5

NO. DATE BY BY
CUSTOMER : NIRMA LTD. Terminal diagram =A2+-JB1-X15 en_US

DRG.NO.:
90.18737-WF-012
PROJECT : SHEET : 8
90.18737 - 012-EE17-R0
1 2 3 4 5 6 7 8 9 10 11 12 13 14
TERMINAL DIAGRAM
-WC03
Strip
Cable name
Cable name
=A2+-X21
(YWY) ARMOURED
Connection
Connection
Cable type
Cable type
Terminal
Jumper
point
point
WF ON -PLC/DCS 1 -U2-NO 0 /9.2
= -PLC/DCS 2 -U2-C 0 /9.2
GENERAL FAULT -PLC/DCS 3 -U2-NO 1 /9.4
= -PLC/DCS 4 -U2-C 1 /9.4
TPH DEVIATION -PLC/DCS 5 -U2-NO 2 /9.6
= -PLC/DCS 6 -U2-C 2 /9.6
MATERIAL STARVATION -PLC/DCS 7 -U2-NO 3 /9.8
= -PLC/DCS 8 -U2-C 3 /9.8
REMOTE MODE SEL -PLC/DCS 9 -U2-NO 4 /9.10
= -PLC/DCS 10 -U2-C 4 /9.10
EMG STOP FEEDBACK -PLC/DCS 11 -U2-NO 5 /9.11
= -PLC/DCS 12 -U2-C 5 /9.12
= -PLC/DCS 13 -F1 21 /9.13
WF TRIP -PLC/DCS 14 -F1 22 /9.13
INT/DEINT MODE SEL. -PLC/DCS 15 -U2-NO 7 /10.5
= -PLC/DCS 16 -U2-C 7 /10.5
TOTALISER PULSE O/P -PLC/DCS 17 -U2-NO 8 /10.7
= -PLC/DCS 18 -U2-C 8 /10.7
VOL. MODE SEL. -PLC/DCS 19 -U2-NO 9 /10.9
= -PLC/DCS 20 -U2-C 9 /10.9
GRAV MODE SEL. -PLC/DCS 21 -U2-NO 10 /10.11
= -PLC/DCS 22 -U2-C 10 /10.11
FEEDER HEALTHY -PLC/DCS 23 -U8-NO 0 /13.2
= -PLC/DCS 24 -U8-C 0 /13.2
READY TO START -PLC/DCS 25 -U8-NO 1 /13.4
= -PLC/DCS 26 -U8-C 1 /13.4
BSS O/P -PLC/DCS 27 -U8-NO 2 /13.6
= -PLC/DCS 28 -U8-C 2 /13.6
LOCAL MODE SEL -PLC/DCS 29 -U8-NO 3 /13.8
= -PLC/DCS 30 -U8-C 3 /13.8
ZSS O/P -PLC/DCS 31 -U8-NO 4 /13.10
= -PLC/DCS 32 -U8-C 4 /13.10

NO. DATE BY BY

DRG.NO.:
90.18737-WF-012
PROJECT : SHEET : 9
90.18737 - 012-EE17-R0
1 2 3 4 5 6 7 8 9 10 11 12 13 14
TERMINAL DIAGRAM
-WCS11
-WCS07
Strip
Cable name
Cable name
=A2+-X22
(YWY) ARMOURED
(YWY) ARMOURED
Connection
Connection
Cable type
Cable type
Terminal
Jumper
point
point
FEEDRATE INDICATOR -LCS-X41 1 1 -U1-U1.5-X9 1+ /6.13
= -LCS-X41 2 2 -U1-U1.5-X9 2- /6.13
= 3 /6.14
LOCAL SETPOINT -LCS-X41 4 4 -U1-U1.5-X11 1 /6.5
= -LCS-X41 5 5 -U1-U1.5-X11 2 /6.5
= -LCS-X41 6 6 -U1-U1.5-X11 3 /6.5
= 7 /6.6

NO. DATE BY BY

DRG.NO.:
90.18737-WF-012
90.18737 - 012-EE17-R0
1 2 3 4 5 6 7 8 9 10 11 12 13 14
TERMINAL DIAGRAM
-LCS-WCSF
-WCS07
-LCS-WCSD
-WCS11
Strip
Cable name
Cable name
=A2+-LCS-X41
(YWY) ARMOURED
(YWY) ARMOURED
Connection
Connection
Cable type
Cable type
Terminal
Jumper
point
point
FEEDRATE INDICATOR -X22 1 1 -LCS-D1 +7 2 /6.13
= -X22 2 2 -LCS-D1 -8 1 /6.13
= 3 /6.14
LOCAL SETPOINT 3 -LCS-P1 3 4 -X22 4 /6.5
= 2 -LCS-P1 2 5 -X22 5 /6.5
= 1 -LCS-P1 1 6 -X22 6 /6.5
= 7 /6.6

NO. DATE BY BY

DRG.NO.:
90.18737-WF-012
90.18737 - 012-EE17-R0
1 2 3 4 5 6 7 8 9 10 11 12 13 14
BILL OF MATERIALS
=A2-F1 1 MOTOR PROTECTION CIRCUIT BREAKER 4-6 AMPS 3VU13 40-1MK00 805005050000 SIEMENS =A2/16.2
=A2-Fa 1 MINIATURE CIRCUIT BREAKER 2 AMPS 5SL42020RC 8030020G0100 SIEMENS =A2/3.2
=A2-Fb 1 MINIATURE CIRCUIT BREAKER 1.0 AMP-2P 5SL62017RC 8030010E0100 SIEMENS =A2/2.12
=A2-Fc 1 MINIATURE CIRCUIT BREAKER 1.0 AMP-2P 5SL62017RC 8030010E0100 SIEMENS =A2/2.7
=A2-HMI 1 7" TOUCH SCREEN DISPLAY 24V DC HMI WITH CABLE 80Z003002200 FPIL =A2/5.6
=A2-L2 1 OUTPUT REACTOR 150uH / 15 AMPS ------- C02010100000 OM INDUSTRIES =A2/16.2
=A2-L3 1 CFL LAMP 8 WATT ------- 80200T0V0200 PHILIPS =A2/2.13
=A2-LCS-D1 1 DIGITAL PANEL METER 85 TO 270V AC - 4 (DIGIT) (TPH) PIC101N C05096040700 SELECTRON =A2/6.12
=A2-LCS-P1 1 POTENTIOMETER 1K, 10 TURNS ------- 808006000100 BOURNS =A2/6.5
=A2-LCS-S2 1 MODULAR PUSH BUTTON ACTUATORS PUSH BUTTON (GREEN) WITH NO CONTACT BLOCK 3SB50 00-0AE01+3SB54 00-0B 50G005070100 SIEMENS =A2/11.4
=A2-LCS-S3 1 MODULAR PUSH BUTTON ACTUATORS PUSH BUTTON (RED)WITH NO CONTACT BLOCK 3SB50 00-0AC01+3SB54 00-0B 50G005080100 SIEMENS =A2/11.7
=A2-LCS-S4 1 MUSHROOM ACTUATORS EMERGENCY STOP (RED) 3SB52 03-0UC01 50G002090100 SIEMENS =A2/11.9
=A2-LP2 1 LED LAMP 110V AC - AMBER 3SB52 85-6HL02 80200I140000 SIEMENS =A2/10.2
=A2-Q1 1 DOOR ISOLATOR 32 AMPS 3KL8121-3TA00 80A00B420000 SIEMENS =A2/2.1
=A2-S1 1 SURFACE MOULED ON / OFF SW. 5 AMPS ------- 50G0090C0200 ANCHOR =A2/2.11

NO. DATE BY BY

DRG.NO.:
90.18737-WF-012
PROJECT : SHEET : 1
90.18737 - 012-EE03-R0
1 2 3 4 5 6 7 8 9 10 11 12 13 14
BILL OF MATERIALS
=A2-S2 1 DOOR LIMIT SWITCH 400V AC, 6A 3SE5250-0BC05 80A026460000 SIEMENS =A2/2.13
=A2-TX1 1 TRANSFORMER I/P 415V AC, O/P 220V AC @ 1 AMP, 110V AC @ 1 AMP------- 80F00K0D0200 OM INDUSTRIES =A2/2.4
=A2-U1 1 GRAVIMETRIC DOSING CONTROLLER 24V DC GDC (LCT-BASIC) 5000I00D0L00 FPIL =A2/5
=A2-U3 1 POWER SUPPLY Input: AC 100-240V, Output 24VDC 2.5A S8VK - C06024 C030K1500100 OMRON =A2/3.7
=A2-U4 1 INVERTER 2.2 KW ACS550-01-05A4-4 C00040050000 ABB =A2/16.2
=A2-U6 1 RELAY BOARD 8 CHANNEL - 1 CHANGE OVER 110V AC - 8CH/1CO 809005070100 FPIL =A2/11.2
=A2-X4 1 PROFIBUS CONNECTOR LED TYPE - EASYCONN - PB 0° 972-0DP30 E0J050060400 VIPA =A2/5.6

NO. DATE BY BY

DRG.NO.:
90.18737-WF-012
PROJECT : SHEET : 2
90.18737 - 012-EE03-R0
MECHANICAL GAD
MECHANICAL GAD

90.18737 WF GDC O&m Manual

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OPERATION & MAINTENANCE MANUAL FOR

OPERATION & MAINTENANCE MANUAL

FLSmidth Private Ltd.

OPERATION & MAINTENANCE MANUAL FOR GDC

02 OPERATION & MAINTENANCE MANUAL FOR WEIGH FEEDER 67

03 OPERATION & MAINTENANCE MANUAL FOR AC MOTOR 20

05 INSTALLATION & MAINTENANCE MANUAL FOR GEAR BOX. 68

INSTALLATION & OPERATION MANUAL FOR VIBRATORY

07 OPERATION & MAINTENANCE MANUAL FOR SKF BEARING 36

08 TECHOMETER TECHNICAL LITERATURE 01

FLSmidth Pfister India Ltd.

GRAVIMETRIC DOSING CONTROLLER (GDC)

FLSmidth Private Ltd.

Feeding controller GDC – WF

ppol-in / 08.Aug.2017 / File: GDC.WF.User.Manual.doc RNDE1009201403

Feeding controller GDC

This documentation is valid for: WF

FLSmidth Private Limited page 1/17

Feeding controller GDC – WF

ppol-in / 08.Aug.2017 / File: GDC.WF.User.Manual.doc RNDE1009201403

Table of content page

3 HMI Panel ......................................................................................... 5

4 Index history .................................................................................... 17

FLSmidth Private Limited page 2/17

Feeding controller GDC – WF

ppol-in / 08.Aug.2017 / File: GDC.WF.User.Manual.doc RNDE1009201403

FLSmidth Private Limited page 3/17

Feeding controller GDC – WF

ppol-in / 08.Aug.2017 / File: GDC.WF.User.Manual.doc RNDE1009201403

FLSmidth Private Limited page 4/17

Feeding controller GDC – WF

ppol-in / 08.Aug.2017 / File: GDC.WF.User.Manual.doc RNDE1009201403

Picture 1 : Online menu

3 .1.1 Status Line

System status is displayed as under and valid in any mode:

3 .1.2 Online Parameters

FLSmidth Private Limited page 5/17

Feeding controller GDC – WF

ppol-in / 08.Aug.2017 / File: GDC.WF.User.Manual.doc RNDE1009201403

3 .1.3 Base Line

Picture 2 : Error screen

FLSmidth Private Limited page 6/17

Feeding controller GDC – WF

ppol-in / 08.Aug.2017 / File: GDC.WF.User.Manual.doc RNDE1009201403

Picture 3 : Command screen

Operating Mode Source of Run/Halt Command Condition

Operating Mode Feeder Operation Condition

FLSmidth Private Limited page 7/17

Feeding controller GDC – WF

ppol-in / 08.Aug.2017 / File: GDC.WF.User.Manual.doc RNDE1009201403

3 .4 GDC MODE OPERATION (REMOTE-LOCAL-FIELD)

3 .4.1 Remote-Local operations

• If 38.01 [Remote-Local Selection] is set to “External” then Digital Input “Remote/Local” or

3 .4.2 Field operations

FLSmidth Private Limited page 8/17

Feeding controller GDC – WF

ppol-in / 08.Aug.2017 / File: GDC.WF.User.Manual.doc RNDE1009201403

Command Button on Action Active in

>Aeration On/Off< This can be used to Local mode

3 .4.3 Inverter View

FLSmidth Private Limited page 9/17

Feeding controller GDC – WF

ppol-in / 08.Aug.2017 / File: GDC.WF.User.Manual.doc RNDE1009201403