maple leaf cement storage area machinery

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SUBMITTED BY: SAEED ANWAR KHAN

SUBMITTED TO: TARIQ AHMED MIR

SUPERVISED BY: M.ASIF HABIB

26-SEP-2014 to 24-DEC-2014

Chapter Page

number

MAGNET REED SWITCHES (BN20-2rz)

(BN20-11rz)

1

EMERGENCY CIRCUIT (PILZ RELAY PNOZ-X3)

12

ENCODER (2R)

20

DISPLACEMENT TRANSDUCER (LDI260FLS18)

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ULTRASONIC SENSOR (3RG6115-3BE00)

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PT-100 34

INTERNSHIP REPORT ON THE INSTRUMENTATION OF LIMESTONE STACKER (131-ST-200)

1

MAGNET REED SWITCHES

(BN20-2rz)

(BN20-11rz)

2

REED SWITCH:

It is proximity Switch.

Its contacts alter their state when it encounters “magnetic field”.

CONTACT TYPES IN REED SWITCHES:

There are three types of contacts in different reed Switches:

S= normally open

O= normally closed

R= bi-stable

The reed Switches on lime stone stacker line-II are all R (bi-stable)

type.

HOW REED SWITCHES WORK?

Let we take a reed switch BN20-2rz

It is a bi-stable double contact reed switch

If the contacts of reed switch are opened initially and we pass it in front of north pole in

right direction, contacts will close as shown below:

If we further pass it in front of north pole magnet its contacts will remain close in right

direction

Now if we pass it in front of South Pole, contacts will open,

If we further pass it in front of South Pole contacts will remain open

Figure 1

3

In the same fashion , if we reverse the motion of direction of reed switch on left side,

opposite thing will happen as shown below

ACTUATOR MAGNET IDENTIFICATION:

The type of magnet used are BP21N & BP21S

North Pole magnet color is green

South Pole magnet color is red

Here 2xBP21N & 2xBP21S are used

The purpose to use double magnets is to make the magnetic field strong

SENSING RANGE:

The sensing range of the Magnet is 35mm

If two Magnets are used together i.e. SS or NN, the range extends to 50 mm

4

BN20-2RZ:

BN20-2rz is a reed Switch with 2 bi-stable contacts.

Its contact alters their state by either facing North Pole or South Pole of magnet in

specific direction.

BN20-2RZ WITH NORTH POLE MAGNET:

If BN20-2rz is passed in front of North Pole magnet in right direction, its both contacts

closes if they are opened before otherwise no effect. As shown in figure 2.

If BN20-2rz is passed in front of North Pole magnet in left direction, its both contacts

opens if they are closed before otherwise no effect. As shown in figure 2

Reed switch change their present state when they have fully crosses the magnet

BN20-2RZ WITH SOUTH POLE MAGNET:

The distance between magnet and reed Switch is 35mm

South Pole magnet color is red

If BN20-2rz is passed in front of South Pole magnet in right direction, its both contact

opens if they are close before otherwise no effect. As shown in figure 3.

If BN20-2rz is passed in front of South Pole magnet in left direction, its both contact

closes if they are opened before otherwise no effect. As shown in figure 3


Figure 2

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BASIC DIFFERENCE BETWEEN NORTH & SOUTH MAGNET EFFECT (figure 4)

ON MOVING THE REED SWITCH IN RIGHT DIRECTION:

North Pole magnet closes the contact, while South Pole magnet opens the close contacts

ON MOVING THE REED SWITCH IN LEFT DIRECTION:

South Pole magnet closes the contact, while North Pole magnet opens the close contacts

BN20-11RZ:

BN20-11rz is a reed Switch with 2 bi-stable contacts one NO & one NC.

Its contact alters their state by either facing North Pole or South Pole of magnet in

specific direction.

Figure 3

Figure 4

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BN20-11RZ WITH NORTH POLE MAGNET:

If BN20-11rz is passed in front of North Pole magnet in right direction, its opened contact

closes and closed contact opens as shown in figure 5

If BN20-11rz is passed in front of North Pole magnet in left direction, its closed contact

opens and opened contact closes as shown in figure 5


BN20-11RZ WITH SOUTH POLE MAGNET:

If BN20-11rz is passed in front of North Pole magnet in right direction, its closed contact

opens and opened contact closes as shown in figure 6

If BN20-11rz is passed in front of North Pole magnet in left direction, its opened contact

closes and closed contact opens as shown in figure 6


ORDER GUIDE REED SWITCH:

1. Reed Switch =BN

2. Switch type = 20-

3. Contact type = 2 r (Detailed description in table below)

4. Enclosure sealing IP67 = z

=BN 20- 2 r z

Figure 5

Figure 6

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ORDER GUIDE MAGNET ACTUATOR:

1. Magnet actuator (permanent magnet) =BP

2. Magnet type = 21

3. Polarity = S

=BP 21 S

For further detailed catalogue of Magnet Actuator & Reed Switch by SCHMERSAL visit:

http://www.schmersal.net/cat?lang=en&produkt=cxn733134btnohq2jfm597593ybstn

CONTACT TYPES:

NO NC R

(Bi-stable) Description Figures

1 0 - One NO contact

2 0 - Two NO contact

0 1 - One NC contact

0 2 - Two NC contact

1 1 - One NO & One NC

contact

- - R One bi-stable contact

- - 2r Two bi-stable contacts

1 1 R One NO, One NC bi-stable

contact

THE MAGNET REED SWITCH AT STACKER

(Drawing reference sheet # 2.9, 131-ST-200 Limestone stacker)

The permanent magnets used are

BP 2x21S

BP 2x21N

The reed Switches are

http://www.schmersal.net/cat?lang=en&produkt=cxn733134btnohq2jfm597593ybstn

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BN20-2rz

BN20-11rz

Note:

Before mounting, the required contact function - NC or NO - has to be

established by actuation with a magnet

Magnets are fixed on ground on poles according to the height of reed Switches

The drawing is

REED SWITCH S31.00 (BN20-11RZ): BN20-11RZ=1NO, 1NC

S31.00 is used with its NO contact. Reed Switch S31.00 when crosses the South Pole magnet

in right direction its NO contact closes. Further when it will cross the North Pole magnet going

right, its contact will open. Going back to left, North Pole magnet closes the contact and South

Pole magnet opens the contact. Here we have used 11-12 contact.

(Reed switches are shown inverse, as these are attached in the same fashion)

REED SWITCH S31.01 (BN20-2RZ): BN20-2RZ=2NO

Reed Switch S31.01 when crosses the South Pole magnet in right direction its contact closes.

Further when it will cross the North Pole magnet going right, its contact will open. Going back to

left, North Pole magnet closes the contact and South Pole magnet opens the contact.

Here we have used 11-12 contact.

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REED SWITCH S31.05: BN20-2RZ=2NO

Reed Switch S31.05 goes to the right side it opens & when go back to left side it again closes.

Here we have used 11-12 contacts.

REED SWITCH S31.06: BN20-11RZ=1NO, 1NC

Reed Switch S31.06 goes to the right side it opens & when it goes back to left side it again

closes. It is used with its NO contact

OVER TRAVEL SWITCH S31.02:

It is a NC mechanical Switch. It remains NC until unless it crosses the limits at both ends.

Whenever over travel Switch crosses limits it gets open & machine stops.

10

ALL OF THE DISCUSSION ABOVE IS SUMMARIZED

O1=Over travel limit Pile 1

O2=Over travel limit Pile 1

R1=Reverse end Pile 1

R2= Reverse end Pile 1

W1= Work area Pile 1

W2= Work area Pile 2

F1= Forward end Pile 1

F2= Forward end Pile 2

MAGNET REED SWITCH STATUS AT PLC CARD A05.07

PLC inputs

Read Switches

Pile 1 Pile2

W1 F1 R1 W2 F2 R1

12.3 S31.00 0 1 0 1 0 1

12.4 S31.01 1 1 0 0 0 1

12.5 S31.02 1 1 1 1 1 1

12.6 S31.02 1 1 1 1 1 1

13.2 S31.05 0 1 1 0 0 0

13.3 S31.06 1 0 0 1 1 1

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REED SWITCH CONNECTION TO PLC:

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EMERGENCY CIRCUIT

(PILZ RELAY PNOZ-X3)

13

INTRODUCTION TO PILZ

Table#01 Terminal Configuration Sr.# Terminal Function Description

1 A1,A2 Supply AC 230VAC

2 B1(+ve), B2(-ve)

Supply DC 24VDC

3 Y31,Y32 Semiconductor o/p

4 S11,S12 Input Emergency loop



7 S13,S14 Reset/Start

8 S33,S34 Reset/Start

9 13-14, 23-24, 33-34

NO contacts

Output contacts

10 41-42 NC contact Normally closed Auxiliary contact

TIMING DIAGRAM

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WORKING OF PILZ RELAY:

ALL EMERGENCY CHANNELS CLOSED:

If all the input channels are closed and the momentarily 24VDC pulse signal is applied at

start/reset terminal (-S13-S14), the output contacts K1 & K2 will be closed and auxiliary contact

(41-42) will be open. As shown in figure 7.

BREAKING OF EMERGENCY CHANNEL:

If ever any one input channel is opened or broken the output contacts K1 & K2 will be opened.

As shown in figure 8 the input channel S31& S32 is opened, the Output contacts K1 & K2 are

opened.

Figure 8

Figure 7

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CONDITIONS TO RESET THE PILZ:

To reset or close the output contacts again there are two conditions to full fill.

(1) Close all the input channels as shown in figure , contact K1 is closed & the channel 1

LED glows up

(2) Apply the 24VDC pulsed signal to the reset/start terminals S13,S14 i.e close the loop

S13,S14 momentarily, contact K2 is closed as in figure and LED of channel 2 glows up

(3) Input channels loop should always be in closed condition for running of machine, if it

opens ever, machine stops.

(4) The start/reset loop is just pulse operated

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Priority setting in Pilz :

If there are two Pilz

Pilz 1

Pilz 2

Let the Pilz 1 has the 1st priority and Pilz 2 has the 2nd priority.

Close all the input channels of Pilz 1

Apply the start pulse 24VDC at S13,14 at Pilz 1

Pilz 1 output energizes the relays Q1,Q2 (figure below ), which will close the input

(emergency) channel (by means of Q1,Q2 contacts) of Pilz 2

Note: Here until Pilz 1 output contact K1,K2 are not activated, the Pilz 2 is not going to operate.

Most important emergencies are at the first priority Pilz 1.

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Emergency circuit of Stacker LIMESTONE L-II

Loop S13, S14 (start/reset) of Pilz K03.00

As NC (auxiliary) contacts of any contactor are closed, the power contacts

are open, this is define as ready condition of a contactor

NC (21-22 auxiliary) contacts of the following contactors are used to the

reset/start loop to check the ready condition &

Only one NO contact of PLC auxiliary relay is used in loop, it will be closed

by PLC momentarily just to give a start/reset pulse

Note: Each contactor should be in ready condition at start or reset given below.

Sr.# Contactors Description Condition

1 Q03.00 Main power contactor Should not be in energized condition

2 Q03.00 Power contactor power cable reel

3 Q11.00 Belt conveyor Contactor

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4 Q11.01 Bypass belt conveyor Contactor

5 Q17.00 Hydraulic pump contactor

6 Q17.01 Contactor heating

7 Q31.00 Travel motors power Contactor

8 K03.01 Auxiliary relay of Pilz

9 K03.02 Auxiliary relay of Pilz

10 K03.12 Auxiliary relay of PLC card

If all auxiliary contact of contactors are NC, it means all contactor are in

ready position

A PLC command at K03.12 will close the loop

.

Loop S13, S14 (start/reset) of Pilz K03.03

The reset/start loop of this Pilz consist of the following Auxiliary relays’ NC

contact and

One NO contact of PLC auxiliary relay is used, it will be closed by PLC

momentarily just to give a start/reset pulse

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Sr.# Contacts Description

1 K3.04 Auxiliary relay of Pilz K0.03

2 K3.05 Auxiliary relay of Pilz K0.03

3 K3.12 PLC auxiliary relay

If all auxiliary contact are NC, it means auxiliary relay are in ready position

A PLC command at K03.12 will close the loop

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ENCODER

(2R)

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What is shaft encoder?

Encoder is an electromechanical device

Measure motion, position & direction

Most encoders use optical sensors to provide electrical signals in the form of pulse

These pulses, in turn, be translated into motion, direction or position

Types of encoder:

Basically there are two types of encoder

Incremental encoder:

It is also called quadrature encoder

Incremental encoder is designed for the direction of motion.

It gives incremental train of pulses by two channels A, B.

Incremental encoder’s disc is shown figure 1.

Absolute encoder:

Absolute encoder is specially design for the detection

of absolute position.

Absolute encoder uses a disk with concentric circle patterns.

Absolute encoder’s disc shown in figure 2.

NOTE: In lime stone stacker L-II Incremental Encoder (Type 2R) is being used.

Characteristics

Encoder Type: Shaft encoder

SMD-Technology: Strong compact electronic

IP: Standard IP=65, optional 67

Thermal protection: Shutdown at temperature 1550 & above

Wide supply Range: 4V to 30V

Strong construction: Base on 2 ball bearings, for harsh environment

Construction of encoder:

Shaft encoder consists of:

Housing assembly

A rotating disc attached to shaft

Light source

Photo detector (usually photo transistor)

Electronic circuit

Figure 1

Figure 2

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Working of encoder (Type 2R):

In figure 4 the white cells are transparent, light is transmitted through them & is sensed

by the sensor

There are 3 channels in the Type 2R encoder A, B, Z

The duty cycle of the channel A & B is 180 electrical degrees.

The duty cycle of channel Z is 90 electrical degrees

The phase difference between channels A & B is 90 electrical degrees.

Channel A & B have 10 pulses in one full rotation Channel Z has one pulse in one

rotation as shown in figure there are 10 transparent segments/channel

In clock wise rotation the channel B leads A by 900 as shown in figure 5

Figure 9

Clock

wise

900

Channel A

Channel B

Channel Z

Opaque

Transparent

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In counter clock wise rotation channel A leads B by 900 as shown in figure

Why channel A & B?

An encoder with one set of pulses would not be useful because it could not indicate the

direction of rotation.

Using two code tracks with sectors positioned 90° out of phase the two output channels

of the encoder indicate both position and direction of rotation.

If A leads B, for example, the disk is rotating in a clockwise direction.

If B leads A, then the disk is rotating in a counter-clockwise direction.

By monitoring the number of pulses & the relative phase of signal A & B we can track

both position and direction of rotation.

By the frequency of pulses we can also track the speed of motor because as disc speed

varies, the frequency of pulses also varies.

Ordering guide:

Type Pulses output signal Shaft IP-rating Length of cable cable connection

On Limestone stacker L-II the encoder is:

2R-0010-N-06-65-03-S

2R: Type

0010: 10 pulses per revolution

N: N is for normal connection

06: Shaft dimension which is in mili meters

65: Index of protection which is 65

03: Length of cable attached with the encoder

S: S stand for side connection of output terminals

Counter

Clock wise

900

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For furhther detailed parameter check:

http://www.storkdrives.se/pdf/Scancon/Inkrementella/standard/axel/2R.pdf

Encoder Connection to PLC

25

DISPLACEMENT TRANSDUCER

(LDI260FLS18)

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DESCRIPTION:

The displacement transducer, in its most elementary form, consists of a fixed part and a

mobile part.

The mobile part is attached to the external mobile contact, while the fixed part acts as a

reference.

TYPES:

Several types of transducers are available in the market. Their differences reside in the method

used to identify the relative value against the reference value. Some examples of transducers

are:

Differential Reluctance Transducer

Magnetic transducer

Optical transducer

Resistive transducer

Here we are concerned with differential variable reluctance transducer.

DIFFERENTIAL VARIABLE RELUCTANCE TRANSDUCER (LDI 260 FLS18)

This transducer works on the principle of differential variable reluctance

It is a linear transducer

It is made by HF JENSEN

Its type is LDI 260 FLS18 and the amplifier used with it is ICA FLS18

What is reluctance?

Reluctance is the analogous of resistance.

Reluctance is the measure of opposition of two opposite magnetic fields.

Electric field creates current & current faces resistance.

Magnetic field creates flux & flux faces reluctance

WORKING OF SENSOR

Sensor consists of two parts, stationary and

mobile.

Stationary part is clamped with stationary part of

the stacker and mobile part is attached to the jib of

stacker.

There are two coils in series with each other inside

the stationary tube.

There are three (3) terminals at sensor

1(Green) is connected to Vin+, 2(Blue) is connected to Vb- & 3(Red) is

connected to Vb+

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.When the core is at center position of the coils, self-induction of two coils

is same.

When the core goes in either direction by the movement of stacker jib, the

self-induction of the coils goes in opposite direction.

Amplifier (ICA FLS18)

Amplifier is fed on 24 Vdc

Jumper setting of the amplifier is shown below.

We are using the jumper setting A.

This jumper setting is to get 4-20mA, 5VDc output and gain of 1.

We have used the ½ bridge configuration in the sensor

connection, in which two coils are used in series with

each other.

There are three terminal of sensor with following

colors.

The following diagram illustrate amplifier & its connections with sensor &

output

Terminal (sensor)

1 Green

2 Blue

3 Red

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Output current versus position of transducer (mm) & Jib position (%):

Position [mm]

Jib Position [%]

Output [mA]

0 0 20.1

20 10 18.39

40 20 16.79

60 30 15.18

80 40 13.58

100 50 11.99

120 60 10.37

140 70 8.77

160 80 7.20

180 90 5.59

200 100 4.00

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Connection to PLC:

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ULTRASONIC SENSOR

(3RG6115-3BE00)

31

What is ultrasonic?

The sonic (audible) range of sound for human is 20 to 20 kHz.

If the sound has the frequency greater than 20 kHz, it is called ultrasonic.

Working principle

Ultrasonic sensors generate high frequency sound waves and evaluate the echo which is

received back by the sensor, measuring the time interval between sending the signal and

receiving the echo to determine the distance to an object.

SONAR BERO (3RG6115-3BE00) AT LIMESTONE STACKER L-II

Specifications:

Input voltage: 24VDc

Output: 4-20mA analogue, switching (NC)

Sensing range: 0.4 m to 3 m

Working resistance: 0 to 300 Ω

Object size: At least (50x50) mm

Rated frequency: 120 KHz

Built in short circuit protection

Built in overload withstand capability

Connector: M12

M12

connector

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Input/output TERMINALS:

The normal connection to SONAR-BERO are as follow

Pin 1 is for 24VDc & maximum up-to 30VDc

Pin 2 is for ground

Pin 4 is used to communicate two SONAR-BEROS mutually

Pin 5 is for analogue output 4-20mA

WORKING

The SONAR-BERO under discussion gives two types of outputs , analogue and digital

We have two screw type potentiometer , through which we can set our operating area

In operating area SONAR-BERO give 4-to-20 mA analogue output

When material it is detecting crosses the initial adjustment or final adjustment it gives the

digital signal by making NC to NO through switching output

We are using just 1, 3 & 5 pins i.e. only analogue output as shown below

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The initial adjustment must be beyond the blind zone

If the initial or final adjustment is not calibrated correctly , indication LED will blink

CONNECTION TO PLC:

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PT-100

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PT-100:

This is basically a RTD(resistance temperature detector)

It follows a positive slope which means resistance increases when temperature

increases

A platinum resistance temperature detector Pt100

At 00C its resistance is 100 Ω

At 1000C its resistance is 138.5 Ω

The measuring range of PT-100 is -500C to 2300C

Standard connection is two wire but there are PT-100 available with three & four wire

connection

RESISTANCE VERSUS TEMPERATURE TABLE

TEMPERAURE RESISITANCE

0 100

10 103.9

20 107.8

30 111.7

40 115.5

50 119.4

60 123.2

70 127.1

80 130.9

90 137.7

100 138.5

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CONNECTION TO PLC: