Service Manual Schenck

Sonic Soni c Ear Ear Service Manual

BV-H2535 GB

PASS PASS - A A ser vi ce yo u c an c ou nt on . Fast, c om pr ehen siv e and anyw here i n t he wo rld . Quality and reliability are the cornerstones of our company’s philosophy. That is why we consider a comprehensive service concept simply par for t he course, from strict quality control, installation and commissioning commissioning through to seamless support across the entire life cycle of our products. With over 30 service stations and over 180 service specialists, you can count on us to be there whenever and wherever you need us. During business hours, our service specialists from all business areas are ready to analyze problems and find the reasons for failures. You can find the Schenck Process location nearest to you on our website www.schenckprocess.com . Are you looking for individual individual and tailor-made tailor-made service solutions? solutions? Then our our modular PASS service service system is just just right for you. It includes the entire range of services from simple inspections all the way down to a complete service program. Further information can be found at www.schenckprocess.com. www.schenckprocess.com. Heavy Cement, Gypsum, Sand & Gravel, Steel and NF-Metals Coal-Fired Power Plants and related Industry T: +49 6151 1531-3138 F: +49 6151-1531-1423

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Individual phone consulting - fee required (Mo. - Fr., 8.00 – 17.00 CET) © by Schenck Process GmbH, Pallaswiesenstraße 100, 64293 Darmstadt, Germany Phone: +49 6151 1531-0 ; www.schenckprocess.com www.schenckprocess.com All rights reserved. This documentation documentation or excerpts thereof may not be reproduced in any any form without prior prior written permission by Schenck Process GmbH. Subject to change without prior notice. Note: The Note: The original manual is in German. This is a translation.

(origin: 27021598813374859 V4)

Contents

Contents

1 Safet y ..........................................................................................................................................................1 1.1 Signal Words for Safety Warnings..........................................................................................................1 1.2 Signal Words for Application Notes ........................................................................................................2 1.3 Damaged/Defective Electrical Components ...........................................................................................3 1.4 Five Safety Rules of Electrical Engineering ...........................................................................................3 1.5 Hazard from Operation of the Ball Mill ...................................................................................................4 1.6 Noise Hazard ..........................................................................................................................................4 2

Fun ct io n .....................................................................................................................................................5

3

Mou nt in g th e Son ic Ear ............................................................................................................................7

4

Con necti ng th e Son ic Ear ...................................................................................................................... 11

5

Ad ju st in g th e Son ic Ear ......................................................................................................................... 13

6

Tech ni cal Data ........................................................................................................................................ 15

7

Rect if ying Malfu nc ti on s ......................................................................................................................... 17 Ind ex ........................................................................................................................................................ 18

Sonic Ear , Service Manual Schenck Process Group

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Safety

Intended Use The supplied system is to be used exclusively for the specified task. Any other use which exceeds this sh all not be considered part of the intended use. The supplied system may be part of a more complex system. The system operator bears overa ll responsibility for the operating safety of the system.

Personnel Preparation, assembly, commissioning, operation, maintenance and servicing may onl y be carried out by qualified personnel. All persons working on the system are required to observe the safety hints and know the parts of the technical documentation relevant to their work. The operating company is responsible for instructing his operators to observe all regulations and instructions given.

Moisture and Humidit y All of the scale components (particularly electrical components) should be protected from moisture and humidity when the housing is open such as during service work. Beyond this, the housing's protection classes should be complied with.

Potential dangers will always exist when working with technical devices. Dangers will arise if the machine is ▪

incorrectly installed,

▪

started up incorrectly,

▪

operated by untrained personnel, or

▪

serviced by unqualified personnel.

The following signal words in this manual indicate dangers that may arise when handling this machine:

Danger The signal word DANGER identifies a danger with a high degree of risk that, if not prevented, will cause grievous injury or death. Follow all instructions to prevent this danger from arising.

Warning The signal word WARNING identifies a danger with a moderate degree of risk that, if not prevented, may cause grievous injury or death. Follow all instructions to prevent this danger from arising.

Caution The signal word CAUTION identifies a danger with a low degree of risk that, if not prevented, may cause a minor or moderate injury. Follow all instructions to prevent this danger from arising.


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Safety

Representation of safety instructions

Fig. 1: Components Safety Instruction 1 Symbol

2 Signal word

3 Type and source of danger

4 Possible consequences if the danger is not prevented.

5 Possible measures for preventing the danger.

Always Obs erv e The signal words ALWAYS OBSERVE identify situations in which material or environmental damage could occur. Example:

STRICTLY OBSERVE Welding on load-bearing parts

TIP The signal word TIP highlights information that can be utilized to treat the product economically and at an optimal level of efficiency. Example:

HINT Take note of the measures listed below to rectify malfunctions.

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Safety

DANGER Live damaged or defective compon ents Danger of lif e from electric shocks.

1. Have trained personnel ensure that all live components are undamaged and in proper working order. 2. Have trained personnel replace damaged or defective electrical components.

These fives safety rules must be followed in the order shown before work is begun on electrical systems. Once the work is finished, they are to be applied in reverse order.

DANGER Electric shock from live compo nents

There is a danger of life from an electric shock. – Take all possible precautions to ensure safety before work is begun on live components. Observe, among other things, the following: 1. Disconnect the components. 2. Secure against restart. 3. Ensure that the components have been de-energized. 4. For voltages above 1 kV: Ground and short-circuit cables. 5. Cover or shield adjacent, live components.


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Safety

DANGER Moving and driven parts

Danger to life from rotating or driven machine elements – Before performing any work on the machine: 1. Shut down the machine. 2. Allow the machine to come to a stop. 3. Secure the machine against restart. 4. Disconnect completely the machine from the power supply. 5. Remove pressure from any pressure reservoirs. 6. Comply with information in any further applicable documents. ⇨ Check the operation of re-mounted safety guards before restarting the machine.

WARNING Noise source

Possible damage to hearing as a result of loud operation. 1. Wear suitable protective equipment, such as ear protectors. 2. Provide suitable noise protection.

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Function

General Descripti on

Fig. 2: Operating Principle of the Sonic Ear

The sonic ear consists of the microphone FOR 0052 and the converter FOR 00 51 and analyzes the milling sounds that emanate from ball mills. The sonic ear is suitable for ball mills in which the operational noise level depends on the fill level of the mill. ▪

Empty mill: loud, clear sound

▪

Full mill: quiet, dull sound

Function The operational noise level of the ball mill is recorded by the FOR 0052 microphone. The FOR 0051 converter transforms the operational noise level into a direct current signal that is independent of the sound pressure and frequency spectrum. A signal inversion makes the relation between signal level and mill filllevel more intuitive: ▪

Empty mill: low output signal

▪

Full mill: high output signal

Appl ic ati on The signal can be analyzed and used to control the ball mill in a process control system (PCS) or a host system, a DISOCONT Master for example. The following can be implemented: 1. Fill level recording 2. Fill-level threshold signaling 3. Emergency intervention in the control 4. Material discharge control, principally as an underlay for a return material or mill output control (control of the bucket elevator output).


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Function

Take the example of th e noise pressure level of a twin-chamber sift er mill

The apparently linear course arose f rom the arbitrary intervals between EMPTY-NORMAL-FULL.

Fig. 3: Fundamental relationship between mill fill level and mill noise level Level Mill fill level

Noise Mill noise level

Fig. 4: Fundamental relationship between mill fill level and output current Level Mill fill level

C Output current

Off Mill stopped

The output signal of the mill when off is 20 mA.

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Mounting the Sonic Ear

Dimensi ons Converter FOR 0051

Fig. 5: FOR 0051 Converter Dimensions 1 75 mm

2 90 mm

3 62 mm

4 75 mm, assembly boreholes ∅ 8.5 mm

5 Cable opening M16

Dimensi ons Mic rop hone FOR 0052

Fig. 6: FOR 0052 Dimensioning 1 300 mm

2 300 mm

3 62 mm

4 75 mm

5 190 mm


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Compon ents Convert er FOR 0051

Fig. 7: Converter FOR 0051 Components 1 Housing/cover, circuit board inside

2 Cable opening for higher-order process

3 Cable opening for microphone FOR 0052

Compon ents Micr oph one FOR 0052

Fig. 8: FOR 0052 Microphone Components 1 Opening Microphone FOR 0052

2 Shielding plate

3 Screws for removing the microphone cover

4 Boreholes ∅ 8.5 mm (M10)

5 Slot holes ∅ 8.5 mm (M10)

6 Cable opening

7 Microphone FOR 0052

The shielding plate (2) serves to screen the microphone from the noise of neighboring ball mills.

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Mount ing the FOR 0051 Converter

Fig. 9: FOR 0051 Converter Mounting Boreholes 1 Mounting boreholes

1. Unscrew the cover. The converter circuit board is located beneath it. 2. Install the FOR 0051 converter. Use the mounting boreholes provided.

Installing the FOR 0052 Microphone

STRICTLY OBSERVE Choose an installation location where the microphone, cable runs and converter cannot be damaged by passing industrial trucks.

Fig. 10: Drawing for mounting th e FOR 0051 microphone R Rotational direction

A Clearance 50 mm ... 100 mm

1 Material infeed

2 Ball mill

3 Microphone

4 Microphone frame


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1. Construct a rigid frame for the microphone. 2. Switch off the ball mill before attaching the microphone. Secure the ball mill agains t inadvertent restart. 3. Before installing the microphone ensure that any protruding parts of the ball mill cannot damage the microphone during operation, such as the hinges on maintenance openings or the frames of other openings. 4. Place the microphone at the position at which the grinding balls (most likely) will knock against the inner surface of the mill AND ensure tha t this position is relatively close to t he material infeed of the mill (ref er to the drawing). 5. Align the microphone so that a clearance of between 50 mm and 100 mm is maintained between it and the wall of the ball mill. 6.

Secure the frame.

7. Mount the cable conduits. 8. Feed the microphone cable through to the converter.

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Connecting the Sonic Ear

Electri cal Connection The sonic ear consists of the microphone FOR 0052 and the converter FOR 00 51.

Fig. 11: Interconnection of FOR 0051 - FOR 0052, block diagram and connections BP Bandpass filter S2 Bandpass filter frequency selector PS Power supply


Gain Adjusting the gain S3 Coarse adjustment via switch R10 Gain fine adjustment

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Connecting the Sonic Ear

Fig. 12: Circuit board layout BP Bandpass filter S2 Bandpass filter frequency selector R10 Gain fine adjustment

Gain Adjusting the gain S3 Coarse adjustment via switch H1 LED

H2 LED Component

Setting options and displays

S2

Factory setting: 3 kHz

S3

Gain ranges 13 ... 150 100 ... 1200 30 .... 340

R10

Use a potentiometer for fine adjustment within the range previously set by switch S3.

H1

Display indicates sound pressure high (loud, clear sound), mill empty

H2

Display indicates sound pressure low (quiet, dull sound), mill full

Perfor ming a Functi on Test aft er Installation 1. Turn on the power supply. 2. Perform the test while the housing is open. 3. Check the following items: ▪

Without the influence of sound LED H1 should light up and the output current should be approx. 20 mA.

▪

With the influence of sound LED H2 should light up and the output current should drop. Speak loudly into the microphone to perform the test.

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Adjusting the Sonic Ear

Adju st in g t he Soni c Ear The adjustment is performed at the FOR 0051 c onverter. LEDs H1 and H2 indicate whether the mill signal must be reduced or amplified.

Ai m o f t he ad ju st men t

The sonic ear should be adjusted to the loudness level that the ball mill emits when optimally filled (100 % fill level). An output current of 10 mA or an output voltage of 2.5 V should correspond to a mill fill level of 100 %. At this point bot h LED H1 and H2 should light up. By assigning an output current of 10 mA (2.5 V) to a level of 100 % mill fill level there remains sufficient modulation reserve for overf illing.

Fig. 13: Suggested setting for linearization LIN Linearizer in the external controller


M % Percentage ball-mill fill-level in the external controller display

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Adjusting the Sonic Ear

Ad ju st in g t he So ni c Ear ▪

Microphone FOR 0052 and converter FOR 0051 have been connected. Both microphone and converter function normally.

▪

The microphone housing has been closed. This is important as the closing the cover can alter the output signal.

▪

Supply voltage is present.

1. Check that the conditions listed above have been met. 2. Start the ball mill. 3. Fill the ball mill with as much material as required to ensure that the mill runs optimally (100 % fill level, no overfilling!). 4. Operate the ball mill for a long period of time at 100 % fill level. Adjust the sonic ear during this period. 5. Open the converter housing to perform an adjustment. 6. Set gain switch S3 and potentiometer R10 such that the output current is approx. 10 mA or that the output voltage is 2.5 V. The output filter of 10 s means that once the gain has been adjusted a period of at least 20 s must pass before the next adjustment may be tried to allow the output sufficient time to reach its final value. The adjustment is complete once both LEDs (H2, H1) light up. Increase the gain via S3 or R10 if LED H2 lights up only. Decrease the gain via S3 or R10 if LED H1 lights up only. 7. Close the converter housing. 8. Then set the spread and the linearization of the signal in the host system.

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Technical Data

Techn ical Data Power supply

22 V ... 26 VDC

max. 50 mA

or

max. 50 mA

25 V ... 40 VDC Output

0 V ... 5 V

max. 4 mA

0 mA ... 20 mA

max. 500 Ω

Input voltage

Adjustable between 2.5 mV ... 250 mV

For

Sound pressure level

Adjustable between 85 dB ... 125 dB

Ia = 10 mA

Bandpass

Can be set to 1 kHz or 3 kHz

Output filter time constant

10 s

Display

2 LEDs; both light up when output current is within the range 9.6 ... 10.5 mA Outside of this range one LED only will light up.

Protection class

IP65

Temperature range

-20 °C … 50 °C

Housing

Fiber-glass reinforced polyester


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Rectifying Malfunctions

Potential problems resulting f rom external noise External noises (e.g. neighboring mills) seldom influence measurement. Corrective measures for the FOR 0052: ▪

Place a felt mat with a hole for the microphone (10 mm) beneath the circuit board.

▪

Fit the inside of the housing cover with an iron or lead plate (5 ... 10 mm).

▪

Fill up the housing with an acoustic wadding.

▪

Set up a second sonic ear in the mill hall and compensate in the host system for the negative influence.


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Index

Index Adjusting the Sonic Ear ............................................................. .................................................................. ...................... 13 Always Observe ............................................................ ................................................................... ................................... 2 Application.......................................................... ................................................................... .............................................. 5 Caution ............................................................... ................................................................... .............................................. 1 Components Converter FOR 0051 ................................................................. .................................................................. ... 8 Components Microphone FOR 0052 ............................................................. .................................................................. .... 8 Connecting the Sonic Ear.................................................................................................................................................. 11 Damaged/Defective Electrical Components ............................................................ ............................................................ 3 Danger ................................................................................................................................................................................ 1 Dimensions Converter FOR 0051 ....................................................................................................................................... 7 Dimensions Microphone FOR 0052 ................................................................................. ................................................... 7 Electrical Connection ........................................................................................................................................................ 11 Fig. 1: Components Safety Instruction ............................................................................ .................................................... 2 Fig. 10: Drawing for mounting the FOR 0051 microphone ......................................................... ......................................... 9 Fig. 11: Interconnection of FOR 0051 - FOR 0052, block diagram and connections ................................................. ....... 11 Fig. 12: Circuit board layout .............................................................................................................................................. 12 Fig. 13: Suggested setting for linearization ....................................................................................................................... 13 Fig. 2: Operating Principle of the Sonic Ear ............................................................................................................. ........... 5 Fig. 3: Fundamental relationship between mill fill level and mill noise level ........................................................................ 6 Fig. 4: Fundamental relationship between mill fill level and output current.......................................................................... 6 Fig. 5: FOR 0051 Converter Dimensions ........................................................ .................................................................. .. 7 Fig. 6: FOR 0052 Dimensioning ......................................................... .................................................................. .............. 7 Fig. 7: Converter FOR 0051 Components ................................................................. .......................................................... 8 Fig. 8: FOR 0052 Microphone Components ............................................................. ........................................................... 8 Fig. 9: FOR 0051 Converter Mounting Boreholes .................................................................................... ........................... 9 Five Safety Rules of Electrical Engineering............................................................. ............................................................ 3 Function .............................................................................................................................................................................. 5 General Description ............................................................................................................................................................ 5 Hazard from Operation of the Ball Mill................................................................................................................................. 4 Installing the FOR 0052 Microphone .......................................................... .................................................................. ....... 9 Intended Use ............................................................ .................................................................. ......................................... 1 Moisture and Humidity......................................................................................................................................................... 1 Mounting the FOR 0051 Converter ..................................................................................................................................... 9 Mounting the Sonic Ear ................................................................. .................................................................. .................... 7 Noise Hazard ...................................................................................................................................................................... 4 Performing a Function Test after Installation .............................................................. ....................................................... 12 Personnel ........................................................... ................................................................... .............................................. 1 Potential problems resulting from external noise .................................................................. ............................................. 17 Rectifying Malfunctions ..................................................................................................................................................... 17 Representation of safety instructions .................................................................................................................................. 2 Safety ............................................................... .................................................................. ................................................. 1 Signal Words for Application Notes .............................................................. .................................................................. ..... 2 Signal Words for Safety Warnings ...................................................................................................................................... 1 Technical Data .................................................................................................................................................................. 15 TIP ...................................................................................................................................................................................... 2 Warning .......................................................... .................................................................. ................................................... 1

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Service Manual Schenck

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