Service Instructions Syntron Control Model: RSMC-2B
INSTRUCTION MANUAL MODEL: RSMC-2B Solid State Regulating Control Installation Operation Maintenance IMPORTANT The instructions and data herein are VITAL to the proper installation and operation of this equipment. In order to avoid delays due to faulty installation or operation, PLEASE SEE THAT THESE INSTRUCTIONS ARE READ BY THE PERSONS WHO WILL INSTALL, OPERATE AND MAINTAIN THIS EQUIPMENT!! 1
GENERAL DESCRIPTION The Syntron Material Handling Model RSMC2B Solid-State Control System is an electrically-powered circuit, incorporating silicon-controlled rectifiers (SCRs) and printed circuit components. The circuit is designed for manually controlling Syntron Material Handling Electromagnetic Vibratory Feeders, with unique features to provide improved linearity of feed rate versus control dial setting (see Illustration Curve, Figure 1). The control circuit will also automatically hold the amplitude (vibration or stroke) of an Syntron Material Handling Vibratory Feeder constant at a desired setting, regardless of change or fluctuation (-5%, +10%) in the line voltage power supply. THEORY OF OPERATION FIGURE 1 TYPICAL RSMC CONTROL CHARACTERISTICS A change or fluctuation in line voltage will affect the voltage and current of a vibratory feeder, which, in turn, will affect and alter feeder amplitude. However, by using the Syntron Material Handling Model RS-2B control circuit, the feeder amplitude can be held constant at the desired control setting, regardless of line voltage fluctuation (-5%, +10%). A fixed reference voltage from the Control Potentiometer (RH) on the lid of the controller is compared with the line voltage in the gate control package (PCB). The gate control package converts these two inputs into an output signal suitable to control the firing of a power Silicon-Controlled Rectifier (SCR). In turn, the firing of the SCR controls the feed rate of the vibratory feeder. As long as these two input signals (line voltage and RH) are matched in the printed circuit gate control package, the power SCR will control the feeder in accordance with the setting of the Control Potentiometer (RH). Any variation in line voltage (-5%, +10%) is immediately sensed in the printed circuit gate control package. The line voltage input and the RH input are now mismatched, and this difference is noted in the output signal to the SCR. The printed circuit gate control package will now signal the SCR to fire either earlier or later in the cycle to increase or decrease the feeder amplitude by the amount necessary to hold it constant with the setting of the Control Potentiometer (RH). This described procedure is continually and automatically being made within the control circuitry with each fluctuation in line voltage. The control is designed to hold the feeder amplitude constant at control setting regardless of a line voltage change within 5% or +10% of the nominal voltage (as designated on the nameplate). 2
WARNING: Use of this control involves electrical current. There is potential hazard of electrical shock to the operator. These instructions and safety precautions must be followed to assure a reasonable degree of safety. It is important that caution be used when installing, operating and maintaining this controller. Voltage to the controller must be rated as designated by the equipment nameplate and the wiring diagram. INSTALLATION CAUTION: For multiple feeder applications, each feeder is factory tested with a corresponding controller, and numerical identification is provided; i.e. Feeder No. 1, Controller No. 1, etc. EXTREME CARE MUST BE TAKEN TO MATCH A FEEDER WITH ITS CONTROL PARTNER WHEN FIELD INSTALLATION IS BEING MADE. This equipment must be properly matched in the field for desired feed rate results. The controller assembly should be installed as close to the feeder as possible, preferably on a wall in a clean, dry location, free from excessive vibration. The controller should be located where it is easily seen and accessible to the operator. If at all possible, the controller should be installed at a location where it will receive proper ventilation. Most electrical components experience a shortage of life when operating in an atmosphere of extreme heat. Good ventilation of the control enclosure will permit internal heat to be dissipated through the sides of the cabinet and into the outside atmosphere, thus prolonging component life. THE CONTROLLER CABINET SHOULD NOT BE LOCATED IN DIRECT SUNLIGHT OR NEAR HEAT FURNACES, ETC. Syntron Material Handling does not recommend installation where the atmosphere surrounding the control enclosure will exceed 40 C (104 F) ambient temperature, at any time. WIRING THE CONTROLLER (Reference: Wiring Diagram which is included in each control box) This controller is designed for a specific line voltage and frequency. These values are noted on both the equipment nameplate and on the wiring diagram furnished with each unit. External connections between the feeder, controller and power supply must be securely made and in strict accordance with the wiring diagram. The power supply voltage and frequency must match the information stamped on the equipment nameplate. WARNING: A ground connection to the controller and feeder is required to ensure maximum safety to the operator! Controllers involving heavy feeders usually specify the line disconnect switch and/or the fuses to be SUPPLIED BY THE CUSTOMER. The line switch must be rated equal to or above the full load current rating. The line fuses should be rated at approximately 1-1/2 times the full load current as indicated on the controller nameplate data. THIS IS VERY IMPORTANT FOR SAFE OPERATION OF THE EQUIPMENT. The line conductor and the conductor between the feeder and controller must be of a size sufficient to carry the current and voltage as stamped on the equipment nameplate. The distance between the controller and feeder is an important factor that must be taken into consideration when determining the size of the conductor. The voltage 3
drop through a conductor of insufficient size, for the distance involved, will result in a definite lack of feeder amplitude during operation. The further the distance, the larger the required size of the conductor. SPECIAL CIRCUITRY (Reference: Wiring Diagram included in each control box) This instruction manual is supplied as a general guide for the Model "CRSAC-2B" Control in its basic design. We cannot attempt to cover the wide variety of special circuitry as specified by particular customers for their exact requirements. The purpose of these components (such as auxiliary relays, interlocks, indicating lamps, etc.) can be traced on the special wiring schematics prepared for these specific applications. TROUBLESHOOTING CAUTION: The STOP push button on the lid of the controller DOES NOT DISCONNECT THE LINE VOLTAGE TO THE CONTROL BOX. De-energize the line switch before any work is to be performed on the feeder or controller. The stop push button on the lid of the controller does not disconnect the line voltage to the control box. 1. Before attempting any troubleshooting procedures on this control, it is essential that the feeder is in correct adjustment and operating condition. Syntron Material Handling Service Instructions SM0504 contain detailed information concerning the feeder. Review this information thoroughly before checking out the controller. 2. Compare the controller circuitry with the wiring diagram furnished with the unit. Make sure all connections are correct and secure. 3. The following checkpoints should be measured using a quality multi-meter. Syntron Material Handling recommends a multi-meter with a sensitivity rating of 20,000 ohms per volt DC (min.) and 1,000 ohms per volt AC (min.). a. Check the line source for proper voltage, making sure line voltage and frequency are same as values specified on the equipment nameplate. b. Check for blown line or load fuses. Check for open line switchgear. c. Check for loose connections on the PCB Gate Control Terminal Block. d. The output of the current sensing transformer, where it enters the Motor Current Sensing Panel, should read 30 volts AC at maximum current on the crusher motor. 4. Checking the Printed Circuit Board (PCB): NOTE: All values are approximate for a typical feeder; actual values could vary ±20%. The Printed Circuit Board (PCB) can be easily checked by reading its DC output value to the Silicon-Controlled Rectifier (SCR). To read this value, proceed as follows: (Refer to Figure 2) 4
FIGURE 2 PRINTED CIRCUIT BOARD CHECK a. Disconnect main power source to de-energize equipment. b. Disconnect SCR gate lead from gate control terminal block point 19. c. Place meter leads across gate control package terminals 19 and 20. d. Energize equipment power supply, and close all switchgear. e. By adjusting the manual control potentiometer (RH), the meter reading should range between approximately 1.0 volts DC at zero dial setting and approximately 2.0 volts DC at 100% dial setting. The only other field check for the printed circuit board is a visual inspection of the relay operation. The small relay, soldered to the printed circuit board, should be making and breaking contact when the switchgear is opened and closed. If values do not agree, or printed circuit components appear defective, the printed circuit board must be replaced as a component assembly. SYNTRON MATERIAL HANDLING DOES NOT RECOMMEND ANY FIELD REPAIRS ON THE PRINTED CIRCUIT BOARD. If values do agree and components appear operating satisfactorily, the printed circuit gate control package can be eliminated as a possible trouble spot. 5. Checking the Manual Control Potentiometer (RH) 5
The only true check of the control potentiometer (RH) is a resistance reading across its terminals. This can be performed by the following procedure: (Refer to Figure 3) FIGURE 3 CONTROL POTENTIOMETER CHECK 6
a. De-energize main power supply. b. Place transfer switch in MANUAL position. c. Disconnect terminal block leads 7, 8 and 9. d. A resistance check across the two outside terminals of RH should read 50 ohms. e. The resistance value across the center terminal and either outside terminal of RH should vary from 0 to 50 ohms when RH is adjusted from minimum to maximum. If values do agree, the potentiometer can be eliminated as a possible trouble spot. If the values do not agree, the potentiometer must be replaced. 6. Checking the DC Reference Voltage: NOTE: All values are approximate for a typical feeder; actual values could vary ±20%. FIGURE 4 D-C REFERENCE VOLTAGE CHECK Using the gate control terminal block points 8 and 9 (refer to Figure 4), the DC value of the reference voltage can be checked as follows: a. With the control potentiometer (RH) set at zero, values across terminals 8 and 9 should read 1 volt DC. b. With control potentiometer (RH) set at 100%, values across terminals 8 and 9 should read approximately 0 volts DC. If values do not agree, the trouble is in the printed circuit board, as RH has already been eliminated by troubleshooting in step 5. The printed circuit board must be replaced as a complete assembly. Syntron Material Handling does not recommend any field repairs to the printed circuit board. If values do agree, the reference circuit portion of the printed circuit board can be eliminated as a possible trouble spot. 7. Checking the Silicon-Controlled Rectifier (SCR): (Outlined below is a simple and effective cold-state check of an SCR.) a. Disconnect the controller from its power supply. b. Remove the SCR from the circuit. c. Referring to Figure 5, construct a simple DC circuit using two flashlight batteries and a flashlight bulb. 7
FIGURE 5 SCR CHECK d. Connect the positive (+) lead to the SCR anode and the negative (-) lead to the SCR cathode. e. IF THE BULB LIGHTS AT THIS POINT, THE SCR IS SHORTED AND SHOULD BE REPLACED! f. If the bulb does not light, connect one end of a jumper on the anode side of the SCR. g. Momentarily touch the gate on the SCR with the other end of the jumper lead. The bulb should stay lit. IF THE BULB DOES NOT STAY LIT, THE SCR IS OPEN AND SHOULD BE REPLACED! As mentioned before, this test is effective only if the rectifier is completely open or shorted. Any partial breakdown of the SCR under load conditions can be determined and remedied only by replacement of the defective SCR. 8. Checking the Printed Circuit Gate Control Package: NOTE: All values are approximate for a typical feeder; actual values could vary ±20%. a. Check incoming voltage at terminals 2 and 4. Value should read 115 volts AC when started. Actual values may vary ±20%. b. Observe the plug-in relay. Contacts should close when start button is pressed. c. Disconnect gate lead terminal No. 19 and connect a DC milliamp meter in series. Values should read 110 to 120 Ma. with control potentiometer turned to 100%. Turn the control potentiometer back to zero; the range at the low setting should be 35 or 40 Ma. The only other field check for the printed circuit board is a visual inspection of the relay operation. The small relay, soldered to the printed circuit board, should be making and breaking contact when the switchgear is opened and closed. If values do not agree, or printed circuit board components appear defective, the printed circuit board must be replaced as a component assembly. Syntron Material Handling does not recommend any field repair procedures on the printed circuit board. If values do agree and components appear operating satisfactorily, the printed circuit gage control package can be eliminated as a possible trouble spot. THIS CONTROLLER HAS BEEN FACTORY TESTED AND ADJUSTED WITH ITS FEEDER PARTNER TO GIVE OUPUT CAPACITY AS ORDERED; THEREFORE, IT SHOULD NOT REQUIRE ANY ADJUSTMENT ON YOUR PART. BUT IF YOU FEEL THAT ADJUSTMENT IS REQUIRED, CONTACT SYNTRON MATERIAL HANDLING SERVICE DEPARTMENT FOR ASSISTANCE. ANY UNAUTHORIZED ADJUSTMENT MAY VOID THE WARRANTY ON BOTH THE FEEDER AND CONTROLLER!! 8
SENSITIVITY ADJUSTMENTS ON THE PRINTED CIRCUIT BOARD Each printed circuit board is equipped with three small, round, adjustable potentiometers. These potentiometers are labeled "AUTO-MAX", "MAN-MAX" and "MIN". (Refer to Figure 6) SENSITIVITY ADJUSTMENT PROCEDURE: FIGURE 6 SENSITIVITY ADJUSTMENT NOTE: Only the MAN-MAX and MIN sensitivity potentiometers are used in the basic RSC-B Control System. The AUTO-MAX Potentiometer is wired into the circuit, when using RSMC circuit. MANUAL MODE: 1. De-energize line switch and depress STOP push button. 2. Set control potentiometer (RH) to zero dial setting. 3. Adjust MAN-MAX sensitivity potentiometer to its mid-range. 4. Adjust the MIN sensitivity potentiometer to its extreme counterclockwise position. 5. Connect a suitable A-C voltmeter across the feeder load terminal in the control enclosure. 6. Energize the line switch and push START push button. 7. Slowly adjust the MIN Sensitivity Potentiometer clockwise until the feeder produces a bare minimum feed rate (dribble feed). 8. Increase control potentiometer (RH) to 100%. 9. Slowly adjust the MAN-MAX Sensitivity Potentiometer clockwise to a setting where.060" feeder amplitude is obtained, as viewed on the amplitude sticker (stroke gauge) located on the side of the feeder trough. (See Instruction Manual No. SM0504 for proper use of stroke gauge). CAUTION: Feeder amplitude must not exceed.060". (Voltmeter should read approximately 440 volts A-C on a 460-volt rated feeder; or 215 volts A-C on a 230-volt rated feeder. If a multimeter is used, the approximate readings should be 410 volts or 200 volts respectively.) 10. Re-check MIN Sensitivity Potentiometer by repeating Steps 2 and 7. Readjust MIN potentiometer, if required. This completes the Sensitivity Adjustment Procedure for the manual mode. AUTOMATIC MODE: 9
1. Set up manual mode, as above, first. 2. Crusher empty, set MAX AUTO Potentiometer for approximately 440 volts AC on a 460-volt rated feeder, or 215 volts AC on a 230-volt rated feeder. If multimeter is used, the approximate readings should be 410 volts or 220 volts respectively. Motor Sensing Panel This panel is set at the factory for maximum sensitivity. The control potentiometer can be set for a slower feeder action by turning counterclockwise. The ten-turn potentiometers function is to limit the crusher motor current so as not to exceed its maximum current. The ten-turn potentiometer has been set for your motor current, but it may have to be reset after installation. Clockwise increases the max motor current, and counterclockwise decreases the max motor current. PARTS LIST MODEL RSMC-2B CONTROL 10
Item Description Part No. 1 Box Assembly D.T. C-140963 Box Lid Assembly B-140964 2 Pushbutton 0051X569 3 Transfer Switch 0051X169 4 Knob 0118X009 5 AC Ammeter ------------- 6 Indicating Light 0146X011 7 Pushbutton (Meter Short Switch) 0051X422 8 Control Nameplate A-61713 9 PCB Assembly C-156447 10 Relay 0051X514 Socket 0038X345 11 Transformer 0042X098 12 Contactor ------------- 13 SCR Assembly ------------- 14 Fuse ------------- Fuse Block ------------- 15 Terminal Block ------------- Terminal Block End Plate ------------- 16 Ground Strap A-139645 11
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Important Syntron Material Handling reserves the right to alter at any time, without notice and without liability or other obligations on its part, materials, equipment specifications, and models. Syntron Material Handling also reserves the right to discontinue the manufacture of models, parts, and components thereof. Your satisfaction is very important to us. Please direct any comments, questions, or concerns to our Marketing Communications Department. 15
Corporate Office P.O. Box 1370 Tupelo, Mississippi 38802 Phone: 662.869.5711 Fax: 662.869.7449 Tupelo 2730 Hwy 145 South Saltillo, Mississippi 38866 Phone: 662.869.5711 Fax: 662.869.7493 Toll Free: 800.356.4898 info@syntronmh.com Changshu #2 Road No. 1 Changshu Export Processing Zone Changshu, Jiangsu, China 215513 Phone: +86 0512.52299002 Fax: +86 0512.52297228 info@syntronmh.com Form No. SM0146_120514 Printed in U.S.A