SAFETY STOP CONTROL WITH CABLE BREAK DETECTION

SAFETY STOP CONTROL WITH CABLE BREAK DETECTION

The Model RSB is a heavy-duty safety control that provides a positive shut off of dangerous equipment in an emergency. A cable pulled by endangered personnel actuates it. The output contacts of the Model RS can control up to two separate circuits, one for machinery shutdown and one for an alarm The Model RSB has the built-in- advantage of cable break detection.

 

WHAT IT IS, AND WHAT IT DOES

The Model RSB is designed to act as an emergency stop pull cord control on conveyors and other moving machinery that incorporates built-in broken cable detection. The Model RSB has extension springs, attached to opposite ends of the pull cable, which maintain the cable under constant tension. The RSB is mounted so that it is centered between the end springs. In this way, temperature changes, which cause cable length changes, are canceled out. The operating handle is held in the center vertical position with the internal switch in a normally closed condition. If the cable is pulled or the cable breaks, the handle rotates to release the switch lever. In this way, the alarm signal is generated for either condition. The operating handle must be manually reset back to the center position after the cause has been corrected.

 

RSB TECHNICAL INFORMATION

 

 

 

 

 

 

 

 

Note: Dual-Rated enclosures also available. Contact Sales for details

TECHNICAL SPECIFICATIONS

  • The housing is cast aluminum, with optional epoxy or polyester powder coatings available.
  • The unit can be actuated via a cable pull from either or both directions on every unit; in other words, the unit is “double ended”. Cable must extend from both sides of the RSB unit.
  • The unit is mounted on the conveyor by drilling (3) 13/32” diameter holes. • All units have (3) 3/4” NPT conduit openings.
  • The standard units have dry, unpowered SP/DT microswitch(es) rated for 20A @ 120 VAC, 240VAC, and 480 VAC; 1/2 amp at 125 VDC and 1/4 amp at 250 VDC.
  • Special spring tensioning kits included with each RSB unit provide stability due to temperature fluctuations, and ease of cable adjustment.
  • The functional ambient temperature is -50° to 85° C [-58° to 185° F].
  • The general purpose units are rated NEMA type 4/4X weatherproof and corrosion-resistant. Explosion proof units are rated NEMA type 7/9 for dust ignition proof and vapor explosion proof. Specifically, they are listed for Class I, Div. 1, Groups C and D; and Class II, Div. 1, Groups E, F and G. The dual-rated “D” units are rated NEMA type 4X weatherproof and NEMA type 9 dust ignition proof. Specifically, they are listed for Class II, Groups E, F and G.
  • The general purpose controls meet or exceed IP65.
  • UL listed and CSA listed.

DAMAGED BELT DETECTOR FOR CONVEYOR BELTS

AN EARLY WARNING SYSTEM FOR DAMAGED BELTS

Get an extra measure of protection for valuable conveyor belts with these new Damaged Belt Detectors. Economical and easy to install, they warn supervisory personnel of impending belt failures due to rips, punctures, splice failures, or sharp objects protruding through the belt fabric. Damaged Belt Detectors mount in pairs positioned on either side of the belt. The units are connected by two spans of vinyl coated aircraft cable. One end of the cable mounts permanently to a support bracket and the other connects to a spring-loaded ball located in the unit. The cables loop underneath the belt from each side crossing at the midpoint. A belt problem is detected when an object or a piece of damaged belt hangs below the belt’s surface and sweeps away one or both cables. As the cable is detached, it pulls a spring-loaded ball out of a socket, causing two microswitches to sound an alarm or to shut down the conveyor. One end of each cable is permanently affixed to the bracket preventing the loss of the cable. It’s simple, effective, and it gives that extra warning of possible belt failure. But, even though the idea is simple, these detectors are not lightweights. They’re rugged, heavy duty units that are designed to work in any industrial environment including hazardous locations. So check out the cost/benefit ratio on this valuable detection system. Like a good insurance policy, it’s protection you can’t afford to be without.

 

EASY TO MAINTAIN

 

Damaged Belt Detectors are virtually maintenance free — thanks to their simple, yet tough construction. The units can be wired normally open or normally closed. Everything you need to install your system is included, and accessory or replacement items are always available for immediate shipment.

 

COST EFFECTIVE

When you consider the cost of the average replacement belt, or the cost of repairing the mechanical damage from a torn belt, a damage detection system is very inexpensive by comparison. Other than internally wired belts (tears are electronically indicated), there’s nothing like this system available in the U.S. It’s a lot of protection for very little cost.

 

HOW IT OPERATES

The Damaged Belt Detector operates using a spring-loaded ball and socket connected to two plunger type microswitches. As an object hanging below the belt sweeps away the cable, it pulls the ball connector from its socket (only 4 lbs. of force required). When this happens, a spring-loaded shaft is released causing the plungers of the two microswitches to ride down cam surfaces machined on the shaft. This deactuates the switches causing them to sound an alarm, turn on a warning light, or shut down the system. To reactivate the detectors, all that’s required is to snap the ball connector and cable back into its socket.

SPECIFICATIONS

Note: Dual-Rated enclosures also available. Contact Sales for details.

Housing: Aluminum (Standard). Epoxy coating available.

Conduit Opening: Two 1” NPT. Standard units and explosion proof models have two conduit openings.

External Hardware: Stainless Steel.

Switches: SP/DT microswitch. Rated 20 amp at 125, 250 or 480V AC, 1/2 Amp 125 VDC; 1/4 Amp 250 VDC. Controls may be wired for single throw operation, either normally open or normally closed as required. DP/DT microswitches also available.

 

INSTALLATION NOTES

When installing a Damaged Belt Detection system on your conveyor, the following points should be considered: • The force required to extract the ball end of the pull cable from a detector unit increases proportionally with the distance from the detector. Therefore, the Cable extending beyond the midpoint of the opposite side, is considered inactive for damaged detection purposes. Thus, a second unit is mounted opposite the first to effectively cover this inactive section. (See accompanying drawing.) • A damaged portion of a belt may in certain instances be confined to the top surface of the belt. This renders it undetectable by a system mounted between belt surfaces. However, this damaged section will fall below the surface on the belt’s return run. In order to detect this type of damage to a belt, a second detection system can be installed below the return belt’s surface. This will provide even more reliable protection for your belt systems. • Detection units must be mounted high enough for the cables to cover the entire active area under the belt. In other words, the cables must follow the contour of the belt closely enough to detect damaged sections of the belt both at the center or near the edge.

Arroz Diana automates its largest plant in Colombia

“One of the biggest rice companies in the country, with nearly 50 years in the market, automates its process, providing agility to the operation and opening the most technified plant in the country”.

One of the most critical and essential activities that take part in the rice mill is the drying process, it is imperative to have control of the temperature and humidity of the paddy, to obtain better results and rice quality in the threshing zone. The tradition al drying process have basics temperature controls for the oven and manual control of heat to batteries and towers (Drying systems).

The plant is located in Yopal, Casanare, it is the biggest of the Diana Corporation Group, which has a robust drying system, adaptable to ambient temperature and humidity conditions.

Ingetes S.A.S, Siemens Partner Solution, modernized and automated the entire drying system, with a solution that included the technology PLCs S7-1500, S7-1200, TP Comfort, KTP Basics, decentralized peripheries with profinet and profibus, Scada supervision system, WebUX and information server. The technologies used and the possibility of expansion of the system were important to carry out the project.

The system was divided into two topologies, the first implemented in 2015 and the second in 2016. The first topology architecture consisted of a PLC S7-1516 3PN/DP and a periphery IM 155-5 DP ST (56 digital inputs, 56 digital outputs, 64 analog inputs and 32 analog outputs), a TP900 Comfort and a TP1200 Comfort. A pre-installed system with 2 PLCs (each one with 8 digital inputs, 6 digital outputs, 5 analog inputs, thermocouple module, switch CSM 1277 and a USS communication module) and 2 displays KTP600 Basic, was integrated. All the devices were connected to a switch Scalance XB005.

The second topology architecture consisted of a PLC S7-1511 PN and a periphery IM 155-5 PN ST (40 digital inputs, 16 digital outputs, 32 analog inputs and 24 analog outputs) and two TP900 Comfort. A pre-installed system with 3 PLCs (each one with 8 digital inputs, 6 digital outputs, 5 analog inputs, thermocouple module, switch CSM 1277 and a USS communication module) and 3 displays KTP600 Basic, were integrated.

Control panels, programming and commissioning were carried out. The programming has manual and automatic operation, PLCs integration, process assurances, breaks, emergency stops, engineering values, alarms, management reports with the information server software for digitally support and align the process. With the WebUX is possible to visualize the SCADA from any point of the plant in cell phones, tablets and computers, which are in the network.

Some of the benefits obtained after automation are:

  • Decrease in operating times.
  • Improvement in the quality of the operator’s work and in the development of the process.
  • Reduction of costs, drying times, information processing times and the consumption of husk as fuel for the kilns.
  • Increase security and protection for workers.
  • Autonomous operation of the process.
  • Supervision and diagnosis of equipment, facilitating its maintenance.
  • Opening information to management levels.
  • Registration of process values in SCADA, storage in SQL databases.
  • Reports of the values in certain time ranges, graphs and tables, using information server. Generated by event or every certain period programmed.
  • Real-time visualization of the drying variables from any network point of the plant using the WebUX tool.

 

UNACEM Ecuador S.A

Planta Cementera, Otavalo

Review

UNACEM Ecuador (before “Lafarge Cementos”), is a company dedicated to manufacture cement. Their industrial plant is located in Otavalo, Imbaura province, Ecuador.  The plant provide two clinker kilns for their productive process. The line No. 1 has a pre-heater tower of four stages with a gases flow stream from the kiln; This process work with liquid residual combustible oil, pet coke and biomass. The Line 2 has a tower pre-heater of five stages, besides of pre-heater and tertiary air works with liquid residual combustible, solids (pet coke) and biomass.

In 2015, the Company received the Environment license of co-process waste dangerous products for cement kilns (Governmental agreement 048. Official register N° 439 of 3td of May   2011, from environment minister of Ecuador), turn into the first industrial plant of the country that could do this treatment  controlled For that,, UNACEM Ecuador supervised their emission gases continuously, mainly the concentrations of CO, SO2, NOx, VOC oxygen reference at 7%.

Design

For this CEMS in UNACEM Ecuador, was installed a complete system with field instrumentation. Through an analytics enclosure, which has gas analyzers units correspond to variables required, the control system doing the correction on line.

The stack emission gases of the line 2, was  selected a ring´s measurement where were installed the following instruments: a extractive sample heated probe BÜHLER, with a dust filter of 2 micros heated to 180°C to reduce condensates , an absolute pressure transmitter SIEMENS, SITRANS DSIII model; a RTD with a temperature transmitter in head.

The sample gas is transported approx., 30 meters length through a heated hose to the analytic enclosure. The analytic enclosure provided of 19 inches rack, double door with safety glass door each, auto-supportable and laterals removable.

In this enclosures was installed a ULTRAMAT 23 (U23) to measure CO, SO2 and O2; a HCT gas analyzer FIDAMAT 6; and NOx gas analyzer with chemioluminicence technology, it was required with Ecuatorian norms.

The sample conditioning systems (SCS) is composed of a dust filter 2 micras PTFE made, with moisture detector. In addition, a simple gas compressor cooler, with two gas stream, 320 kJ/h capacity, two peristaltic pumps to remove the condensation and drain it to a condensate tank of 6.5 lt capacity, with a high level switch installed; a sample gas pump diaphragm type with a needle valve to regulated the gas flow rate. Finally, a rotameter installed downstream to the inlet port of the U23 with a parallel connection with the outlet port.

Secondly, the analog outputs of U23 of the gas concentration conditioned through a PLC SIEMENS S7-1200, at 7%  O2 and communicated (PROFIBUS DP) to a DCS SIEMENS, PCS7 based, called CEMAT.

The control system is also in charge of validating the starting conditions of the gas outlet; for example, check the temperature of the probe and heated hose is maintained at 180 ° C, the cooler temperature reaches 5 ° C, there is no humidity in the sample line and the high level sensor with condensate tank not be activated. Those validations connected in series to enable the operation of the suction pump sample gas.

The display of process variables showed on a touch screen display, SIEMENS, KTP-700 model, second generation of 64K color. It allows you to see the starting up sequence changing the color of each instrument according to their status. In addition, let see trends in real-time gas concentrations of both raw variables as the corrected, logging alarms gas concentration levels as the levels allowed by the Ecuadorian Standard. Finally show an explanatory menu helps each deployment, with the ability to view excerpts from text documents such as standards and technical articles on the continuous measurement of gases.

 Advantages.

 The proposed design was very versatile and flexible in the assembly system in Colombia, reducing transportation costs and implementation. Likewise, the control equipment used in Siemens SIMATIC (S7-1200 PLC) line and its monitoring screen “touch screen” KTP-700, become strong, the control system and improve undoubtedly the presentation of the process variables discrete and analog system signals.

Additionally, the control system has wide potential offered by communications integration with existing systems, or by RS-485 networks via PROFIBUS-DP, Ethernet or PROFINET networks.

Conclusions

The solution offered, integrates the best SIEMENS product solutions in different segments, under the concept of TIA (“totally integrated automation”). The pressure transmitter SITRANS DSIII, gas analyzers ULTRAMAT 23 and FIDAMAT 6, the S7-1200 control system, KTP 700 display 7 “high resolution color and all its accessories electrical connection of the SIRIUS family, allow a solution CEMS integral and open as it is robust and differentiating CGA’s market.

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