NTPC_UNIT-1_RSTPS_CALLBRATION_Report.doc

COMMISSIONING AND CALIBRATION

TEST REPORT

OF

MODEL EG3690 GRAVIMETRIC COAL FEEDERS UPGRADATION WITH 196 NT CONTROLLER AND

VFD.

FOR NTPC RAMAGUNDAM STAGE-1 UNIT-1Job No.- 1221/NTPC-STAGE-1

Date: 25/01/2014

1

1 Pre-Start-up Inspection and Results

MANUAL REFERENCE: Operation Section: Page .

DescriptionFeeder No.

1A 1B 1C 1D 1E 1F

1.1 Visual inspectiona. Check for any damage of all parts mounted on the

feeder.√ √ √ √ √ √

b. Check for any damage of all electric parts. √ √ √ √ √ √c. Check for any objects which may interfere with

belt or cleanout chain operation of the feeder.√ √ √ √ √ √

d. Check the all gear reducers for proper oil level. √ √ √ √ √ √

e. Check the grease at grease discharge points. √ √ √ √ √ √

f. Check the cleanout conveyor chain tension. √ √ √ √ √ √g. Check for proper belt tension by observing the

belt tension indicator.√ √ √ √ √ √

1.2 Check of the skirts and leveling bara. Check for clearance between top of the belt and

inlet end of the side skirts. (Fixed)√ √ √ √ √ √

b. Check for clearance between top of the belt and discharge end of the side skirts. (Fixed)

√ √ √ √ √ √

c. Check for clearance between top of the belt and end skirt. ¼ to 3/8 gap

√ √ √ √ √ √

d. Check for clearance between top of the belt and leveling bar which should be 17.46 Centimeters

√ √ √ √ √ √

1.3 Adjustment of the weigh roller levela. Check for freedom of movement of the weight

system (drag links, load cells, rollers).√ √ √ √ √ √

b. Clean the load cell modules, weighing and weight span rollers, drag link assembly and support bolts.

√ √ √ √ √ √

c. Inspect the drag link bushings and set screws. √ √ √ √ √ √d. Carefully install the load cells in place of the

temporary shipping brackets (if necessary).√ √ √ √ √ √

e. Adjust the weigh roller level with the calibration weights on both load cells.

√ √ √ √ √ √

2

AC & DC voltage measurement checks.

MANUAL REFERENCE: Operation Section: Page .Test point Summary page .


1A 1B 1C 1D 1E 1F

FEEDER MICROPROCESSOR CABINET

a. Measure the input power supply voltages.

1) Wires between L1 and L2 456 VAC 504 (±5% Tolerance)

432 424 439 425 431 424


428 423 433 425 433 427


430 426 433 423 429 422

b. Measure the secondary voltage of transformers.

1) Wires between X1 and X3 (T1) 98 VAC 132 127.8 127.7 127.2 127.1 126.8 126.5

2) Wires between 2 and 3 (Customer UPS Power) 98 VAC 132

121.7 121.6 121.4 121.1 120.8 120.9

3) External 120Vac Work Lights & Heater between wire 90 and 91. 98 VAC 132

116.2 115.5 115.1 114.8 114.6 114.5

c. Measure and record the 24 Vdc from ICMS

1) Wire 131 & 132 NA NA NA NA NA NA

2) Wire 139 & 140 NA NA NA NA NA NA

d. Measure and record the 24 Vdc from PS1

1) Wire 400 & 401 23.96 23.97 23.97 24.03 24.01 23.96

FEEDER DISCHARGE VALVE LIMITORQUE OPERATOR L120

NA NA NA NA NA NA


NA NA NA NA NA NA


NA NA NA NA NA NA


NA NA NA NA NA NA

b. Measure the secondary voltage of transformers.

1) Wires between 20 and 21 (CPT) 109.25 VAC 120.75 (±5% tolerance)

NA NA NA NA NA NA

3

DC Voltage Measurements

1A 1B 1C 1D 1E 1F

Unregulated Voltage

Measure the unregulated voltage at test point TP10 with reference to digital ground, TP13. Since the voltage is unregulated, it will vary from board to board but must be high enough to allow the +5 volt supply (U1) to operated correctly. The best check for the test point TP10 is to verify that the +5 volt supply at test point TP7 is within its allowable range. For reference, the voltage at test point TP10 will usually be in the range of Ground +10 to +14 V dc

9.88 9.88 9.82 9.76 9.80 9.75

Regulator U1Measure the +5 volt supply at test point TP7 with reference to digital ground, TP13. The voltage should be +5.1 to +5.3V dc.

5.12 5.18 5.10 5.19 5.16 5.16

Regulator U2Measure the +10 volt supply at test point TP11 with reference to digital ground, TP9. The voltage should be 10.0 to +10.25 V dc.

10.22 10.25 10.01 10.10 10.24 10.26

4

Regulator U3

Measure the -10 volt supply at test point TP8 with reference to digital ground, TP9. The voltage should be –10.00 to 10.25 V dc.

-10.20 -10.16 -10.12 -10.16 -10.13 -10.14

Regulator U4

Measure the +15 volt supply at test point TP5 with reference to digital ground, TP6. The voltage should be +14.25 to +15.75V dc.

14.83 14.86 14.89 14.90 14.87 15.07

Regulator U5

Measure the -15 volt supply at test point TP4 with reference to digital ground, TP6. The voltage should be –14.25 to -15.75 V dc.

-15.12 -15.06 -15.12 -15.07 -15.05 -14.97

2.2 Test all Indicator lamps and displays

a. With power applied, verify that only the display and the OFF LED is illuminated. √ √ √ √ √ √

b. Press SELF TEST 04 keys. Verify that all displays and LEDs are illuminated for five seconds.

√ √ √ √ √ √

2.3 Feeder Parameter Check

a. Check the set-up parameters by referring to the MICROPROCESSOR CONTROLLER FEEDER DATA SHEET. To exit the set-up mode, press the OFF or EXIT key.

√ √ √ √ √ √

b. Press SELF TEST 11 keys. Set the clock by pressing F1 key. √ √ √ √ √ √

c. Check the Inverter setting value by referring to the VFD PROGRAMMING PARAMETERS, refer motor speed control adjustments.

√ √ √ √ √ √

2.4 Check of the alarm switches

a. Check the operation to properly actuate coal on belt level sensor. (LSFB) √ √ √ √ √ √

b. Check the operation to properly actuate discharge plugged sensor. (LSFD) √ √ √ √ √ √

c. Check the operation to properly actuate temperature switch (TS-3) √ √ √ √ √ √

2.5 Install I/O Cards.a. Turn the power off.b. Insert Card part number Z10874-1 into socket A1c. Insert Card part number Z10867-1 into socket A2d. Insert Card part number Z10867-1 into socket A3

√ √ √ √ √ √

5

MICROPROCESSOR SETUP PARAMETERS

EPROM NO- D32400-1810Address Function Preliminary Value Final Value

00 Feed Rate MTPH 4.00 mt/h 4.00 t/h01 Speed Set Point (RPM) 1000.00 1000.0002 Initial Density Estimate (kgs m‾³) 881 kg/cum 881 kg/cum03 Run Mode Select 0.00 0.0004 Display Select 2.00 2.0005 Maximum Feed Rate (Metric Tons Hr‾¹) 40 Mt/h 28 mt/h06 Minimum Feed Rate (Metric Tons Hr‾¹) 4 mt/h 10 mt/h07 Totalizer Increment (Kilograms per

pulse) 100 kg 100 kg08 Demand Mode 1.00 1.0009 Tachometer Type 3 010 Weight Span Length (cm) 0.9144 m 112.700 cm11 Volume (m³) 0.1720 cum 0.1730 cum12 Calibration Probe Span (cm) 0.9144 m 112.713 cm13 Calibration Weight(s) (kgs) 34 kg 31.100 kg14 MSC Servo Loop Gain 4000.00 4000.0015 MSC Servo Loop Rate Feedback 8000.00 8000.0016 Discharge Plug gage Delay (seconds) 2.00 2.0017 Belt Motion Monitor (seconds) 0.00 0.0018 Level / Temperature Sensor Trip Delay 0.00 0.0019 Weight Signal Filtering 4.00 8.0020 Feedback Signal Filtering 2.00 4.0021 Feedback Filter Override Threshold 0.150 0.15022 Belt Travel Revolutions 5.00 6.0023 Loss of Flow Trip Delay 0.00 2.0024 Paddle Feedback Permissive 0.00 0.0025 Communications Unit Number 0.00 0.0026 Mode Select Enable /Disable 1 127 Remote FRI Frequency @ 1 mtph 10 hz/mtph 10 hz/mtph28 Raise / Lower Response Time (s) 5.00 5.0029 Maximum Allowable Motor RPM 1430.00 1445.0030 Minimum Allowable Motor RPM 100.00 10031 (Not Used In This Application) 0.00 0.0032 (Not Used In This Application) 0.00 0.0033 Weight Signal Gain Factor 0.00 2.0034 (Not Used In This Application) 0.00 0.0035 Remote Totalizer Pulse Width 0.10 sec 0.10 sec36 Test Chain Weight 4.300 LBS/IN 4.300 LBS/IN

Power Flex 70 Parameters ParameterNumber Parameter Name Default Setting

6

FOR ANALOG INPUT 2(DEFAULT) FOR ANALOG INPUT 1

E 196 PARAM ACCESS Lvl 0 BASIC 1 ADVANCEDB 040 MOTOR TYPE 0 INDUCTION 0 INDUCTIONB 041 MOTOR NP VOLTS 415 400

B 042 MOTOR NP FLADRIVE RATING

BASED 7.8

B 043 MOTOR NP HertzDRIVE RATING

BASED 50

B 044 MOTOR NP RPMDRIVE RATING

BASED 1445

B 045 MOTOR NP POWERDRIVE RATING

BASED 5HP

B 046MOTOR NP POWER UNITS

DRIVE RATING BASED 0 HORSEPOWER

B 047 MOTOR OL Hertz 0.0Hz 55.0HzB 048 MOTOR OL Factor 1 1B 049 MOTOR POLES 4 4B053 TORQUE PERF MODE 0 SENSRLS VECT 0 SENSRLS VECT

C 080

SPEED MODE/FEEDBACK SELECT 0 OPEN LOOP 0 OPEN LOOP

C 081 MINIMUM SPEED 0.0Hz 2.5HzC 082 MAXIMUM SPEED 50Hz 50HzC 083 OVERSPEED LIMIT 10.0Hz 0.0HzC 090 SPEED REF A SEL 2 ANALOG IN 2 1 ANALOG IN 1C 091 SPEED REF A Hi MAX SPEED 50HzC 092 SPEED REF A LO 0.0Hz 0.0HzC 096 TB MAN Ref Sel 1 ANALOG IN 1 2 ANALOG IN 2D 140 ACCEL TIME-1 10.0SEC 3.0 SECD 141 ACCEL TIME-2 10.0SEC 10.0 SECD 142 DECEL TIME-1 10.0SEC 3.0 SECD 143 DECEL TIME-1 10.0SEC 10.0 SECD 151 PWM FREQUENCY 4 KHZ 4 KHZD 155 STOP MODE A 1 RAMP 0 COASTD 156 STOP MODE B 0 COAST 0 COASTD 190 DIRECTION MODE 0 UNIPOLAR 0 UNIPOLARJ 320 ANLG IN CONFIG XXXX XX00 XXXX XX11J 321 ANLG IN SQR ROOT XXXX XX00 XXXX XX00J 322 ANALOG IN 1 HI 10 VOLT 20.000mAJ 323 ANALOG IN 1 LO 0 VOLT 4.000mAJ 324 ANALOG IN 1 LOSS 0 DISABLED 0 SET INPUT LOJ 325 ANALOG IN 2 HI 10 VOLT 10J 326 ANALOG IN 2 LO 0 VOLT 0J 327 ANALOG IN 2 LOSS 0 DISABLED 0 SET INPUT LO

J 340ANALOG OUT CONFIG XXXX XX00 XXXX XX01

J 341ANALOG OUT CONFIG XXXX XX00 XXXX XX01

J 342 ANALOG OUT1 SEL 0 OUTPUT FREQ 2 OUTPUT FREQJ 343 ANALOG OUT1 HI 10.00VOLT 20.000mAJ 344 ANALOG OUT1 LO 0.00VOLTS 4.000mA

J 354ANALOG OUT1 SCALE 0 15.6

J 361 DIGITAL IN1 SeL 8 8 RUN FORWARDJ 362 DIGITAL In2 SeL 5 START 9 RUN REVERSEJ 363 DIGITAL In3 Sel 18 AUTO/MANUAL 0 NOT USEDJ 380 DIGITAL OUT1 1 FAULT 4 RUNJ 384 DIGITAL OUT2 SEL 4 RUN 1 FAULT

MANUAL REFERENCE: Operation Section: Page .

7


1A 1B 1C 1D 1E 1F

2.5 Local Operationa. Press the JOG key to verify belt travel in the

direction of the feeder outlet.√ √ √ √ √ √

b. Switch to LOCAL. Verify that LOCAL LED and RUNNING LED are illuminated and K6 relay is energized.

√ √ √ √ √ √

c. Verify that feeder is operated at the speed program in Setup Address 01 = 1000 RPM. (Motor AMP test Only)

√ √ √ √ √ √

d. Measure the FEEDER DRIVE MOTOR current. Refer to Motor Name Plate: 5 HP 7.8A

@ 400 VAC FLA1) Phase 1T1 Amps OK OK OK OK OK OK2) Phase 1T2 Amps OK OK OK OK OK OK3) Phase 1T3 Amps OK OK OK OK OK OK

e. Turn the CLEANOUT CONVEYOR selector switch (COC) to the ON position. Verify conveyor operation and travel in the direction of the feeder outlet.

√ √ √ √ √ √

f. Measure the CLEANOUT CONVEYOR MOTOR current.

Refer To Motor name Plate 0.25 HP, 415VAC, 0.5 A FLA.

1) Phase 2T1 Amps 0.5 0.5 0.5 0.5 0.5 0.52) Phase 2T2 Amps 0.49 0.49 0.49 0.49 0.49 0.493) Phase 2T3 Amps 0.5 0.5 0.5 0.5 0.5 0.5

m. Continue to run in LOCAL and check for proper belt tracking. Verify that the V-guide of the belt is within the grooves on the pulleys and rollers, and that no humping is noticeable at any of these points.

√ √ √ √ √ √

n. While running in LOCAL, simulate the coal on belt level sensor (LSFB) and verify that the feeder trips after two seconds.

√ √ √ √ √ √

o. Verify that TRIP LED is illuminated and K1 relay is energized.

√ √ √ √ √ √

p. Press ERROR RECALL keys and verify that Error Code 08 is displayed.

√ √ √ √ √ √

q. Switch to OFF and verify that TRIP LED is extinguished and K1 relay is de-energized.

√ √ √ √ √ √

AL REFERENCE: Maintenance Section: Page 3-11 to 3-12.


1A 1B 1C 1D 1E 1F

8

2.7 I/O Channel Adjustment Signal Converter CardsInput Signal Converter (A1): This card accepts he various customer demand signals and converts them into a frequency for use by the microprocessor. Test point TP3 is used to measure the frequency output, using a frequency counter or oscilloscope, with reference to digital ground, TP13 (see figure 5).

a. A1 Card 0% Input. Specification: 1800 Hz 2000

Apply the appropriate ZERO demand signal (4.00 mA) at

wire +SIG & -SIG. Press key, and the display changes to A1 CARD 0%.

Press to enter the measurement mode. Press key to store the signal in memory.

Records the value shown in the display

1265 1322 1218 1320 1227 1268

b. A1 Card 100% Specification: 9400 Hz 9800

10088 9855 10132 10062 10050 10207

Apply the appropriate maximum demand signal (20.0 mA).

Press key, and the display changes to A1 CARD 100%.

Press to enter the measurement mode. Press key to store the signal in memory. Records the value shown in the display.

Frequency to Current Converter Card (A2) (A3)The frequency to current converter card is used as a feedback

module for customers who require an analog feedback. The output

signal is unipolar and within a range of 20 mA. This circuit allows

the digital electronics of the microprocessor to output a digital

signal, while the customer receives a current feedback signal. In

special applications, this circuit may be used to convert a digital

motor speed demand signal into an analog demand signal

c. A2 Card 0% Specification: 196 Hz 204

9

Measure current at wire #142. Press key, and the

display changes to A2 CARD 0%. Press key to

enter the adjustment mode, and press the or

keys to adjust the output to 4mA. Press key to store the signal in memory. Records the value shown in the display.

203.3 202.5 201.6 200.8 203.0 200.2

d. A2 Card 100% Specification: 980 Hz 1020

Press keys, and the display changes to A2 CARD

100%. Press to enter the adjustment mode, press the

or keys to adjust the output to 20mA. Press

key to store the signal in memory. Records the value shown in the display.

1022.6 1017.4 1008.9 1007.2 1019.0 1003.8

e. A3 Card 0% Specification: 196 Hz 204

Measure current at wire #139 &140. Press key, and

the display changes to A3 CARD 0%. Press key to enter the adjustment mode.

press the or keys to adjust the output to 4.0 mA.

Press key to store the signal in memory. Records the value shown in the display.

197.4 199.2 199.5 196.7 199.2 199.5

f. A3 Card 100% Specification: 980 Hz 1020

Press keys, and the display changes to A3 CARD

100%. Press to enter the adjustment mode,

Press the or keys to adjust the output to 20.0

mA. Press key to store the signal in memory. Records the value shown in the display.

990.9 997.0 994.1 986.3 997.1 993.8

10

Section 2.0 Remote simulation Test. MANUAL REFERENCE: Operation Section: Page . Error Codes page


1A 1B 1C 1D 1E 1F

2.9 Remote Operation

a. With the calibration weights still hung under the

lugs on bottom of weigh roller, switch to

REMOTE key. Verify that REMOTE LED is

illuminated and K3 relay is energized.

√ √ √ √ √ √

b. Start the feeder by the customer's contact start

signal or Jumper (J).√ √ √ √ √ √

c. Simulate coal on belt by blocking the LSFB

contacts. Verify that FEEDING LED is illuminated

and K5 relay is energized. The feeder should start

and the gravimetric Totalizer should begin to

accumulate.

√ √ √ √ √ √

d. Press the INFO SELECT key on the keyboard

until DENSITY is displayed. Verify that the density

displayed matches the calculated density.

Calculated = 734.34Kgm‾³

√ √ √ √ √ √

e. Measure and record the displayed feed rate, revolution and

feedback signal by applying,1= demand signals by

customer's control system.

√ √ √ √ √ √

f. Remove one of the calibration weight from lug on

bottom of weigh roller. Verify that

VOLUMETRIC LED is illuminated and K4 relay

is energized.

√ √ √ √ √ √

g. Remove both calibration weights. Verify that

ALARM LED is illuminated and K7 relay is

energized.

√ √ √ √ √ √

h. Press ERROR RECALL key and verify that <

Error Code 10 > appears on the display.√ √ √ √ √ √

i. Hang both calibration weights. Verify that

ALARM LED is extinguished and K7 relay is de-

energized.

√ √ √ √ √ √

j. Simulate discharge plugged sensor (LSFD) and

verify the feeder trips at the time at SETUP

ADDRESS 16 as listed in the data sheet.

√ √ √ √ √ √

k. Verify TRIP LED is illuminated and K1 relay is

energized.√ √ √ √ √ √

l. Press ERROR RECALL key and verify that <

Error Code 07 > appears on the display.√ √ √ √ √ √

11

m. Switch OFF key and verify that TRIP LED is

extinguished and K1 relay is de-energized.√ √ √ √ √ √

12

Section 3.0 Load cell and Density AnalysisThe calculated density implied by the test weight(s) supplied: = [(2 • test weight) / (volume on weight span)] = (2 • 31.10) / 0.173 mˉ³ = 358 Kg mˉ³

MANUAL REFERENCE:

Feeder Numb

er

LOAD CELL READING WITH CALIBRATION WEIGHT ON

LOAD CELL READING WITH CALIBRATION WEIGHT OFF

CALCULATED DENSITY =

UNBALANCE LOAD CELLS 16-Bit A/D CONVERTER│J1-J2│≥ 1/8 •│J1+ J2│

J1 J2 J1 J2 ACTUAL VOLUMETRIC K41A 4886 4920 1951 1986 354.2 √1B 4510 4610 2015 2060 362.8 √1C 4930 4835 1992 2045 348.2 √

1D 4388 4499 2085 2133 356.8 √1E 4978 4812 1961 2091 351.4 √1F 4866 4919 1890 1884 359.9 √

√

13

1A MANUAL REFERENCE: Maintenance Section: Page 3-2 to 3-8.FEEDER CALIBRATION DATA SHEET– 4 PIECES OF TAPE USED

░░░░░░░░░░░░ TEST #1 TEST #2 TEST #3 SPECIFICATIONSELF TEST NUMBER DESCRIPTION ░░░░░░░░░░░░ ░░░░░░░░░░░░ ░░░░░░░░░░░░ ░░░░░░░░░░░░

Number Of Good Readings / Deviation 7 0.24% 7 0.119% 7 0.213% 8

Self Test #1 Tare Factor 3938922 3960622 3968950 ░░░░░░░░░░░░% Error Change From Last Reading 0.03% -0.24% 0.21% ±0.25%

Self Test #2 Belt Travel 0.12305 0.12329 0.12319 ░░░░░░░░░░░░% Error Change From Last Reading -0.11% 0.04% -0.08% ±0.25%


Self Test #3 Span Factor 1.3861 e-05 1.3929e-05 1.4102 e-05 ░░░░░░░░░░░░% Error Change From Last Reading -0.06% 0.22 % 0.04% ±0.25%

Self Test #14 Belt Length Reading [Meters] 6.543 M 6.555 M 6.550 M ░░░░░░░░░░░░% Error Change From Last Reading -0.19% 0.04% -0.08% ±0.25%

1B MANUAL REFERENCE: Maintenance Section: Page 3-2 to 3-8.FEEDER CALIBRATION DATA SHEET– 4 PIECES OF TAPE USED



Self Test #1 Tare Factor 4276620 4034566 3888119 ░░░░░░░░░░░░% Error Change From Last Reading -0.02% 0.12% 0.01% ±0.25%

Self Test #2 Belt Travel 0.09747 0.12030 0.12028 ░░░░░░░░░░░░% Error Change From Last Reading -0.03% 0.15% 0.05% ±0.25%


Self Test #3 Span Factor 1.4245e-05 1.4794e-05 1.4045e-05 ░░░░░░░░░░░░% Error Change From Last Reading -0.21% -0.10% -0.00% ±0.25%

Self Test #14 Belt Length Reading [Meters] 5.298M 6.544 M 6.543 M ░░░░░░░░░░░░% Error Change From Last Reading -0.03 % 0.23% 0.05% ±0.25%

14

1C MANUAL REFERENCE: Maintenance Section: Page 3-2 to 3-8.FEEDER CALIBRATION DATA SHEET– 4 PIECES OF TAPE USED



Self Test #1 Tare Factor 2886179 3734748 3824656 ░░░░░░░░░░░░% Error Change From Last Reading 0.04% -0.25% -0.10% ±0.25%

Self Test #2 Belt Travel 0.12328 0.12329 0.12335 ░░░░░░░░░░░░% Error Change From Last Reading 0.00% -0.00% 0.00% ±0.25%

Number of Good Readings / Deviation 8 0.209% 8 0.114% 7 0.244% 8


Self Test #14 Belt Length Reading [Meters] 6.524 M 6.529M 6.533M ░░░░░░░░░░░░% Error Change From Last Reading 0.00% -0.00% 0.15% ±0.25%

1D MANUAL REFERENCE: Maintenance Section: Page 3-2 to 3-8.FEEDER CALIBRATION DATA SHEET– 4 PIECES OF TAPE USED



Self Test #1 Tare Factor 3439631 4369921 4362967 ░░░░░░░░░░░░% Error Change From Last Reading -0.14% 0.14% -0.16% ±0.25%

Self Test #2 Belt Travel 0.12230 0.12230 0.1223 ░░░░░░░░░░░░% Error Change From Last Reading -0.17% -0.13% 0.00% ±0.25%



Self Test #14 Belt Length Reading [Meters] 6.560M 6.560M 6.565 M ░░░░░░░░░░░░% Error Change From Last Reading -0.17 % -0.13% -0.08% ±0.25%

MANUAL REFERENCE: Maintenance Section: Page 3-2 to 3-8.

15

1E FEEDER CALIBRATION DATA SHEET– 4 PIECES OF TAPE USED░░░░░░░░░░░░ TEST #2 TEST #3 TEST #4 SPECIFICATION

SELF TEST NUMBER DESCRIPTION ░░░░░░░░░░░░ ░░░░░░░░░░░░ ░░░░░░░░░░░░ ░░░░░░░░░░░░


Self Test #1 Tare Factor 2627160 3647833 3672980 ░░░░░░░░░░░░% Error Change From Last Reading 0.19 % 0.04% -0.11% ±0.25%

Self Test #2 Belt Travel 0.12397 0.12396 0.12391 ░░░░░░░░░░░░% Error Change From Last Reading 0.03 % 0.00% -0.05% ±0.25%


Self Test #3 Span Factor 1.1069e-05 1.3139e-05 1.2853e-05 ░░░░░░░░░░░░% Error Change From Last Reading 0.03% 0.02% -0.13% ±0.25%

Self Test #14 Belt Length Reading [Meters] 6.513 M 6.512 M 6.510 M ░░░░░░░░░░░░% Error Change From Last Reading 0.11% 0.00% -0.05% ±0.25%

1F MANUAL REFERENCE: Maintenance Section: Page 3-2 to 3-8.FEEDER CALIBRATION DATA SHEET– 4 PIECES OF TAPE USED



Self Test #1 Tare Factor 4481226 4298198 4343221 ░░░░░░░░░░░░% Error Change From Last Reading 0.12% 0.00% -0.06% ±0.25%

Self Test #2 Belt Travel 0.12177 0.12169 0.12186 ░░░░░░░░░░░░% Error Change From Last Reading -0.04% -0.09% 0.08% ±0.25%



Self Test #14 Belt Length Reading [Meters] 6.475 M 6.470 M 6.479 M ░░░░░░░░░░░░% Error Change From Last Reading -0.04% -0.01% 0.00% ±0.25%

16

Feeder Simulation Test in REMOTE Mode of Operation from DCS Demand Signal:

1A MANUAL REFERENCE: Operation Section: Page. Self Test Summary page

DemandSignal SELF TEST 06

Feed rateActual

SELF TEST 06Feed rateDemand

MotorSpeed (RPM)From Display

A3 Feed Rate O/P

to DCS mA

Power Flex 70

T/Hr mA Freq(Hz)

Volts(AC)

Load(%)

0% 4.01 10.00 10.00 443 4 14.9 38 3.6625% 8.02 10.00 10.00 443 8 14.9 95 3.6650% 11.98 14.00 14.00 616 12 20.7 180 3.3675% 16.03 21.00 21.00 927 16 31.5 267 3.40

100% 19.99 28.00 28.00 1239 20 41.3 350 3.41

1B MANUAL REFERENCE: Operation Section: Page. Self Test Summary page


Feed rateActual



A3 Feed Rate O/P

to DCS mA

Power Flex 70

T/Hr mA Freq(Hz)

Volts(AC)

Load(%)

0% 4.00 10.00 10.00 465 4 15.7 40 3.3625% 8.05 10.00 10.00 443 8 15.7 100 3.3650% 12.03 14.00 14.00 651 12 21.7 185 3.3575% 16.09 21.00 21.00 972 16 32.6 280 3.40

100% 20.84 28.00 28.00 1300 20 43.6 355 3.42

17

1C MANUAL REFERENCE: Operation Section: Page. Self Test Summary page


Feed rateActual



A3 Feed Rate O/P

to DCS mA

Power Flex 70

T/Hr mA Freq(Hz)

Volts(AC)

Load(%)

0% 4.02 10.00 10.00 440 4 14.8 35 3.6625% 8.04 10.00 10.00 440 8 14.8 93 3.6650% 12.00 14.00 14.00 616 12 20.7 179 3.3675% 16.09 21.00 21.00 925 16 31.5 267 3.40

100% 20.01 28.00 28.00 1234 20 41.4 349 3.41

1D MANUAL REFERENCE: Operation Section: Page. Self Test Summary page


Feed rateActual



A3 Feed Rate O/P

to DCS mA

Power Flex 70

T/Hr mA Freq(Hz)

Volts(AC)

Load(%)

0% 4.02 10.00 10.00 439 4 14.8 37 3.3325% 8.04 10.00 10.00 439 8 14.8 93 3.3350% 12.00 14.00 14.00 626 12 21.7 180 3.3575% 16.09 21.00 21.00 931 16 31.0 276 3.36

100% 20.01 28.00 28.00 1236 20 41.4 355 3.36

18

1E MANUAL REFERENCE: Operation Section: Page. Self Test Summary page


Feed rateActual



A3 Feed Rate O/P

to DCS mA

Power Flex 70

T/Hr mA Freq(Hz)

Volts(AC)

Load(%)

0% 4.00 10.00 10.00 450 4 15.1 37 3.2625% 8.02 10.00 10.00 450 8 15.1 96 3.2650% 12.01 14.00 14.00 629 12 21.1 185 3.3375% 16.02 21.00 21.00 945 16 31.7 278 3.34

100% 20.00 28.00 28.00 1264 20 42.3 360 3.45

1F MANUAL REFERENCE: Operation Section: Page. Self Test Summary page


Feed rateActual



A3 Feed Rate O/P

to DCS mA

Power Flex 70

T/Hr mA Freq(Hz)

Volts(AC)

Load(%)

0% 4.10 10.00 10.00 448 4 15.0 37 3.2425% 8.00 10.00 10.00 448 8 15.0 97 3.2450% 11.98 14.00 14.00 631 12 21.0 184 3.2975% 16.02 21.00 21.00 944 16 31.0 277 3.30

100% 20.03 28.00 28.00 1255 20 42.0 359 3.31

19

NTPC_UNIT-1_RSTPS_CALLBRATION_Report.doc

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