Hempathane Topcoat 55210

TECHNICAL MANUAL
CONVEYOR CONTROL PANEL
NIAGARA FALLS WPEP

DEWATERING FACILITY
PROJECT :RN 04-03
SUPPLIED BY INC.
DESIGNED AND BUILT BY
Belcatec Design Inc.
INSTALLATION DATE
SPRING 2005
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MASTER CABINET (Electric room)
REMOTE CABINET (Truck Level)
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Content of manual:
Section1 How manual is written
Section2 Short description of operations controlled
Section3 Detailed description of operations controlled
Section4 How to use the Vision Operator Terminal Interface
Section5 Troubleshooting problems
Section6 Wiring diagram of control
Section7 Listing of PLC program
Section8 Technical data of parts and suppliers
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Section1 How manual is written
This manual is written by sections
This manual shall be read by any people involved in the operation of the out loading
conveyors of the Waste Water Plant. Not reading this manual may result in personal
injury, equipment breakage and even loss of life.
This manual has been written with all possible attention but may include errors.
The author shall not be considered responsible for omissions or wrongly written
information. If more details are required please contact: René Bellefleur from
Belcatec Design Inc. (514) 645-6353
This manual may be copied but it contents stay the property of BELCATEC DESIGN
INC. No part of this manual may be used by any entity to reproduce or/and specify a
similar construction/design without the written consent of Belcatec Design Inc (the
author).
Section 2 is a short explanation of the control panel and how it relates to the remote
control panel
Section 3 is detailed information of the control panel and how it relates to the remote
control panel and also included detailed logistic of controlled equipments and details
about PLC programs.
Section 4 is detailed information about small Vision Operator Terminal and it purpose
in system
Section 5 is detailed information about possible troubles with some guidelines how to
locate troubles and solutions
Section 6 is wiring diagram of control and remote control panel
Section 7 is list of the program loaded in the PLC
Section 8 is group of technical data about all devices used to build control panel
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Section2 Short description of operations controlled
This section explains the purpose of the control panel and what it controls
Control panel has been designed to control conveyors of out loading system in Waste
Water Plant. All eight conveyors are controlled. Control panel is interfaced to one
centrifuge (3 futures) centrifuges which dewater sludge at an acceptable level so it
can be loaded to bin trucks and disposed.
Conveyor group are all controlled by the conveyor control panel only, interface
signals are to and from centrifuges. When settings of all conveyors are ready to be
operated or in operation a signal is fed to centrifuges which can start operating. In
event of a fault, the signal is removed forcing centrifuges to stop input of sludge and
eventually stop completely.
First three conveyors are used to transfer sludge outputted by centrifuges to transfer
conveyor 4 or to drain. At start-up sludge is too liquid to be loaded to truck so transfer
conveyors 1-3 rotate to drain. Water valves controlled by the centrifuge help to
dissolve partially dewatered sludge when conveyors 1-3 are running to drain. When
the sludge is dewatered enough; direction of conveyor is changed to transfer sludge
to conveyor 4 and water valve is stopped. Activation and direction are controlled by
centrifuges control panel.
When any of conveyors 1-3 is running, conveyor 4 is started to transfer to conveyor

5. Conveyor 5 transfers sludge and elevate it to bi-directional conveyor 6. Depending
on selected truck conveyor will rotate to conveyor 7 or conveyor 8. Conveyors 7 and
conveyor 8 are equipped with pneumatic gates and ultrasonic level detectors.
Using level detector combined with timing of gate sequences truck in place is loaded
evenly.
When truck is almost full centrifuge is stopped. Remaining sludge in conveyor system
is cleared and conveyors are stopped.
If an empty truck is present conveyor 6 direction is changed and sludge is directed to

empty truck.
To verify the rotation of conveyors sensocontrollers are monitoring rotation. In the

event that conveyor rotation is not detected, conveyor is stopped and stops all
preceding conveyors and signals the centrifuges to shut down.
Remote control panel located in truck bay allow control of conveyor 6 to 8 and
manual operation of gates.
System is intended to run in auto mode but operations may be executed in manual
mode.
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Two locations in the truck bay are with emergency stop push-buttons. One other
emergency P.B. is present near conveyor 4. One other is part of the remote panel.
One other is part of the front panel of main cabinet. One is located in centrifuges bay.
Pressing one emergency push-button will stop all conveyors and stops the
centrifuges. When an emergency push-button is pushed it’s illuminated to indicate
that it is in the stopped position.
Following figure shows nomination of conveyors and gates.
Drawing is not to scale

Gates 6 don’t exist. They are open end holes
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Section 3 Detailed description of operations controlled
This section will explain in full detail the operation of the control panel and remote
panel. Please refer to electrical diagram for details of cabling. Some pictures are
included to help comprehension/location of elements.
This section is subdivided in sub-section.
3.1 Front panel of main cabinet
Left side of panel controls conveyors 1 to 5
Operator interface VISION is located on left

side.
One emergency push-button is located on

left side.
Right side is to verify and control ultrasonic

(PROSONIC) controller. See adjustment and
control of ultrasonic controller for more
details.
Selectors on right side allow enabling or

disabling loading of truck.
Master disconnect and door handle are present on right side
Door may not be open when disconnect is ON but this feature can be overridden.
(See how in section 9 on data sheet of this part)
3.2 Front panel of remote panel
Left side of panel controls conveyors 6 to 8
One emergency push-button is located on left

side.
Right side controls gates.

All push-buttons are illuminated and show
position of gates. Selector allows operation in manual mode. When in manual mode,
pushing of gate buttons will initiate movements of gates close or open. Push-button
illumination indicates that gate has reached desired position. When in auto mode
movement of gates are initiated by the main control PLC. Other light on right side
informs about status of bin such as: truck is present, truck is loading and truck is
loaded.
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3.3 Operation of conveyors
At the left side of main and remote front panel selectors allow choosing mode of
operation for each conveyor such as: AUTO OFF MANUAL.
When place at AUTO operation of conveyor is primary controls by centrifuges
operation and a logical sequence programmed in PLC.
When place at OFF conveyors are stop and will also stops preceding operational
conveyors including centrifuges.
When place at MANUAL conveyor operation are controlled by a second selector
which allow to run or stop (off) conveyor.
Beware that if next conveyor selectors are at auto they will start in sequence if
preceding conveyor is started in manual mode.
Conveyor 1-3 and 6 can be run in both directions.
Conveyor 5 is equipped with a speed knob if conveyor is run in manual for more than
two minutes manual speed is registered by PLC and auto mode speed is reset to that
manual speed value. In fact it is the easiest way to adjust auto speed.
Auto speed can also be adjusted using VISON operator interface. (See that section
for more details)
Switching between auto and manual mode will not stop preceding conveyors if
selection change is made is less than 1.5 second and operation selector is at run.
At start-up or after a release of an emergency P.B. if a selection is at manual and
selection of operation is at run in single or any direction, this operation will generate a
fault and stops that conveyor and preceding elements.
To reset fault operator must place conveyor selector in off position (Either mode or
operation selector).
In the case the conveyor is stopped by overload the fault will remains active until the
overload reset. (Overloads are auto reset)
When it’s a direction change a delay of 1 sec is implemented allowing motor to slow
down before it reverse. That delay is also in effect in manual operation.
If conveyor 5 is stop VFD drive stay in operation for 120 seconds but a 30 seconds
delay is implemented if drive has shut off before it can be reenergized.
During start-up the LED’s indicating conveyor operation are blinking for 12 seconds
During general fault (produce by faulty gate operation) the LED’s will blink at a rate of
1.5 per second. Emergency button must be pressed to release the general fault.
3.4 Loading sequence and control of conveyor gates
For conveyor 7 and 8: Sequence of bin loading is control by PLC.

Interval between changes of gate is adjustable using VISION operator interface.
Automatic sequence will start by opening gate 1 for programmed time and then close
and open gate 2.
Sequence is cascaded up to gate 6.
Gate 6 is not present (it’s and open hole in conveyor.)
When timed period is completed for gate 6 (hole), sequence is restarted at gate 1.
When ultrasonic detector of gate 6 reaches predetermined level of half full, the
sequence of loading position 6 is stop until other gates are all at full level.
Interval may be shortened if preset ultrasonic level of full is reached.
Operations of gates are intended to be run in auto mode.
If a gate becomes defective it’s possible to partially load a truck using following
procedure.
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If for any reason gate must stay closed, placing it selector to manual and insure that
gate indicator shows it closed will by-pass control and verification of level by
ultrasonic sensor for that gate.
Truck will be filled using all other gates and ultrasonic sensor as explained.
This preceding trick shall be used if ultrasonic sensor is defective.
In other hand if a gate is place in manual and left open.
Loading sequence will repeat up to that gate only.
When ultrasonic sensor of opened gate reached full level truck will be considered full
and operation of conveyor will stop.
Preceding trick may allow shorter truck to be loaded. (But with less accuracy)
3.5 Loading control and information’s pilot lights
One selector for each truck bay located on right side of main control panel allow
loading of truck.
If selector is place to NO a truck located at that bay will not be loaded.
Selector may be changed to NO during a loading sequence.
If so loading of truck will be interrupted.
Pilot lights are present on main panel and remote panel to indicate status of loading.
Truck Present pilot light when illuminated indicates that truck is present in loading
bay.
Detection of presence of truck is known using ultrasonic detector of gate 2 and
gate 4.
Both detectors must have reached preset level to validate truck present signal.
Truck loading (truck loaded on Main Panel) pilot light when illuminated indicates
which truck is selected for loading sequence.
Truck half full pilot light when illuminated indicates that ultrasonic sensor of gate 6
has reached predetermined level half full.
Pilot lamp will not light if truck is fully loaded.
Truck loaded (on remote panel) pilot light when illuminated indicates that loading
sequence is completed truck is full.
3.6 Operator Interface VISION
VISION interface allows setting variable parameters of conveyors system.

Interface also shows using multiple screens elements status of system and may help
to find defective elements without probing inside control panel.
Following picture shows the first screen.
See section 4 for details of operations and others screen.
3.6.1 First Screen
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First screen displayed when the power is turn on shows the Scada vision 10 version
and program.
Pressing to NEXT (F1) will change display to screen 1
Pressing to PREV (F2) will change display to last screen.
A slight delay is implemented before the screen changes
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3.7 Inside control panel
Following picture show inside of the main panel. The left section hold PLC with all
I/O’s. Middle section hold circuit disconnect fuses and conveyor relays. Right section
holds PROSONIC ultrasonic controllers
3.7.1 Location of control elements
Left section of main panel hold PLC. From up to down left to right:
Power supply 24VDC 12 Amps
PLC Input 1 (a DC converter is installed on cover of

input 1 block to supply output 1-5 and
input 2-6 with 5VDC)
Output 1 Input 2
Output 2 Input 3
Output 3 Input 4
Output 4 Input 5
Output 5 Input 6
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Middle left section of main panel holds. From up to down:
Control Power transformer
3 phases filter choke of VFD
VFD drive conveyor 5
Centrifuges Signal relays
Middle section of main panel holds the power relays. From up to down left to right:
Master Disconnect Disconnect Fuse Block

Conv4, Conv3, Conv2, Conv1
Disconnect Fuse Block

PS, 120 sec of transformer, 600 primary of transformer, Conv8,
Conv7, Conv6, Conv5
Relays
MRV6, MFW6, MRV3, MFW3, MRV2, MFW2, MRV1,
MFW1
Thermal Breakers, By-pass relays, Relays

Conv8, TBP8, Conv7, TBP7, MR4, MR5, MR7, MR8
Thermal Breakers, By-pass relays

Conv6, TBP6, Conv4, TBP4, Conv3 rev, Bypass rev
conv3FW Bypass FW
Thermal Breakers, By-pass relays
Conv2RV Bypass RV conv2FW Bypass FW conv1RV
Bypass RV conv1FW Bypass FW
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Right section of main panel holds. From up to down:
Prosonic controller unit 1-6
Prosonic controllers are mounted in two levels. Wiring is easily

accessible. Remote controller are mounted on the right door and
are plug to each controller
3.7.2 Details description of DC power supply
Power supply 24VDC 12 Amps is a commonly linear DC power supply

Unit installed is a Concord model: F24-12-A
An added angle piece support terminal block and fuse for 24VDC
110 VAC supply come from the 5 Amps fuse block
24VDC is place over three fused terminal blocks
Earth body ground is also the return point for the 24VDC.
Three fuses are present for

the 24VDC supply to
elements. 5 Amps fuse for
the output of PLC. 5 Amps
fuse for the input elements.
10Amps fuse for outputs and
supply to others elements.
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3.7.3 Details of Interconnections terminal block
Terminal block are connecting point to all external devices. Four different strips are
present.
High left part is for future connection of centrifuge 2 & 3. Lower left strip is to connect
centrifuge 1. Right portion of strip is used to connect gate control including the gate
solenoid valves and cylinder position Reid sensors.
High right part is for power connection for conveyor motors right side connections of
Sensocontroller rotation sensors. Conveyor motor terminal blocks are spec’s for 45
Amps with associated earth ground terminal
Lower right part is for interconnection to remote control panel and emergency push-
buttons. Wiring from remote control panel is wire to wire using the same order to/from
remote control panel
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3.7.4 Details of isolating relays
RTIPR8, 7 Truck in Place Ready to load
RTP8, 7 Truck in Place
RTHF8, 7 Truck Half Full
RTF8, 7 Truck Full
RA1 Conv1 in Auto RF1 Conv1 fault
Emergency General fault
All small relays are equipped with led and diodes. Emergency and General Fault are
with position windows only.
To help differentiate between centrifuges wiring three colors are used red, yellow and
pink
3.8 Details of interconnections
All conveyor motors of conv1-3 are two speeds motor YY-DELTA wiring. Both three
phases connections are using 600VAC. Connections are not phase changed in the
control. All the connection respects the scheme L1, L2, L3. Six wires are used for
each motor. (3 for low speed, 3 for high speed) All other motors are standard delta
wiring connected.
Interconnections to/from centrifuges are with one common line for input and one
common line for outputs all contacts are isolated from the control panel supply. Most
contacts are using small relays interfaces but some uses power relay extension
contacts.
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3.8.1 Conveyor motor supply
Following scheme is supplying the motor: Master disconnect to disconnect fuse block
to control relays (direction change if so) to thermal relay which is by pass at start-up
by a control relay. At start-up the by pass relay is activated 5 seconds only. Timing in
PLC program (one second) allows the motor to slow down before it can be restarted
when direction is changed. The VFD still energized for 2 minutes after the conv5 is
stopped and a timing of 30 second off state is implemented before it can be
reenergized.
Following figure is extract from electrical diagram Conveyor 1.
Master disconnect
Disconnect fuse block
Reversing contactor with mechanical

interlock
No phase changed
Forward (to conv4) Thermal By-Pass

Thermal relay
Reverse (to Drain) Thermal By-Pass
Thermal Relay
Field disconnect switch
Motor connections
3.8.2 Conveyor Sensocontroller
Model WA-5 Sensocontrollers are used to sense the rotation of conveyors.
Sensocontroller is a micro controlled device which

can sense the movement of ferromagnetic near it.
Sensocontroller may be compare to a zero speed
device except for following particularities:
Sensocontroller have ability to sense the
movement with a distance up to 4 inches or more,
learn the movement frequency and adapt to it, stop
the operation if the frequency is lower than 1 ½ the
learned frequency. 45 seconds delay is
implemented is case of no detection. Pilot lights of operation are present on front of
main panel and remote panel in group of control for each conveyor. When conveyor
is started pilot light will flash for a period of 5 seconds indicating energizing of
Sensocontroller. Pilot light will then follow movement of conveyor, will flash after 6
passages indicating learning curve is complete and will flash every 20 passages
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indicating relearn of frequency. In the event that a conveyor is stopped by it
Sensocontroller a fault signal will be generated and shall be reset by placing the
conveyor selector to OFF.
WA-5 Sensocontroller wiring is 8 wired with a PVC jackets. For Niagara Falls
installation only 4 wires are used: RED is 24VDC, BLACK is return, BLUE is rotation
OK, White is LED signal. Rotation OK and LED signal are 24VDC feed back.
3.8.3 Remote panel interconnections
Wiring from remote control panel is wire to wire using the same order to/from remote
control panel. The emergency push-buttons located in truck bay are wired to the
terminal block. Except for the emergency push-buttons connections which are at
110VAC other connections carry only small signal of 40 to 100 mA. Following picture
shows terminal strip (extract from electrical diagram)
3.8.4 Centrifuges interconnections
Three centrifuge controls may be connected to the main control panel.

Centrifuges interfaces signal to control the conv1-3.
Centrifuge 1-3 is controlling conv1-3
When centrifuge request the operation of conveyors the information will enable the
main control to start the conveyor train up to the last out loading.
Feed back of main control enable or disable operation of centrifuges.
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The following picture shows wiring terminal block.
Output signals to centrifuge 1
Status of conveyor control &

others pertinent information
Input from centrifuges
Control of conv1
Left numbers are number in the cabinet of centrifuge control

No connected cables are number of cable (w-xx)
3.9 Details of ultrasonic controller
Ultrasonic controllers are located inside the control panel. Six units are installed. Six
remote controllers allow to programmed and adjust the parameters of ultrasonic
devices. Twelve probes (two per controller) are connected to controllers. Ultrasonic
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controller informs the PLC of the presence of truck in bay, level of sludge in truck and
limit of loaded bin.
3.9.1 Operation principle
Ultrasonic controller with ultrasonic probe is emitting (using the probe) ultrasonic
sound which by reflecting a surface send signal to probe. Distance is evaluated with
compensation of air density to accurately measure the distance from probe to
reflective elements. Preset levels are programmed in controller to energize output
relays: 1 for maximum level of sludge, 1 for presence of truck. Using six probes per
truck it is possible to achieve with good accuracy the loading of cake. Limitation is
implemented to reduce interference from emitting probe and receiving with the same
probe. The system is interlock so only one probe is sending sound at time.
Furthermore the signal is read more than once before controller apply the value to
output. 4-20ma output is used from probe place at open gate. Analog signal is read
by PLC to complete the loading.
Prosonic controller is able to read and compute Parshall flows or level difference
none of those function is used in the conveyor system. Only level is measured. That
configuration permits to connect two independent level sensors per unit.
Three relays only are installed in the controller and used as such: One relay is
programmed to be energized when level of cake reach maximum for channel 1
sensor. One relay is programmed to be energized when level of cake reach
maximum for channel 2 sensor. One relay is programmed to be energized when truck
is present using sensor channel 2.
Two analogue outputs (sensor channel 2) of unit 3 and unit 6 which sense level at
gate 6 of conveyor 7 and 8 is connected to PLC to be read for accurately finish
loading the bin. In counter part third relays of unit 3 and 6 are programmed to give
the HALF FULL information to PLC.
Tough the programming of PLC may not be all time accurate the only loading point
affected is at gate 6. It is also possible that the operating conveyor 7 or 8 might be
stopped prematurely if detected level at gate 6 reached the maximum setting. During
normal operation an evaluation of load from conv1-3 to end chain of loading
conveyor is programmed in PLC in event that the flow of cake is smaller than
expected the truck will not be completely full. In other hand if the flow is larger end
chain conveyor may be stopped with cake in it. Consideration of how many
centrifuges are running simultaneously is programmed with other truck bin present,
empty and o.k. to load. In normal operation conveyor 5 which elevate the sludge to
conveyor 6 should stay partially filled when stopped.
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3.9.2 Location
Following picture shows the location of controller
Unit 1 with under Unit 2
Following picture shows ultrasonic remote control

Locate on right side of main control panel door are six units to adjust
and program ultrasonic sensors. Prosonic ultrasonic controllers are
sophisticated equipments which are used only in part in conveyor
control installation. Two sensors FU81 located over truck bin are
connected per controller. See adjustment chart in next section to
program units
Following pictures shows sensor connections to controller.
Connections are with junction box. (one

per conveyor) Sensors are connected
directly to controller inside main control
panel right side of controller.
Unit sensing conveyor 7 gates 1-2 are

connected to controller unit 1. Unit sensing
conveyor 7 gates 3-4 are connected to unit 2, Unit sensing
conveyor 7 gates 5-6 are connected to unit 3. Unit sensing
conveyor 8 gates 5-6 are connected to unit 6.
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3.9.3 Programming a unit
Programming of unit is achieved with remote control installed on right door of main
control panel. Pressing active keys to select V setting and H setting and entering
corresponding value it is possible to set parameters. Following table shows values
entered at start-up of system.
V/H H0 H1 H2 H3 H4 H5 H6 H7 H8 H9
V0 % 14.91 12 0 81 0 100 5 MEASURED MEASURED

DISTANCE LEVEL
PROBE1 VALUE
READ
V1 SEE CHART BELLOW FOR RELAY SETTING
V2 0 N/A NA N/A N/A N/A N/A N/A N/A N/A
V3 0 ECHO SIGNAL/ 0 0 N/A 20 0 N/A N/A

ATTENUATION NOISE
RATIO
V4 % 14.91 12 0 81 0 100 5 MEASURED MEASURED
DISTANCE LEVEL
PROBE2 VALUE
READ
V5 0 N/A N/A N/A N/A N/A N/A N/A N/A N/A
V6 0 ECHO SIGNAL/ 0 0 N/A 20 0 N/A N/A

ATTENUATION NOISE
RATIO
V7 SERVICE SERVICE SERVICE SERVICE SERVICE SERVICE SERVICE SERVICE SERVICE SERVICE
V8 1 0 0 1 N/A N/A 0 0 N/A N/A
V9 DIAG LAST LAST BUT ID & N/A 333 LOCK SIMUL SIMUL SIMUL
CODE CODE ONE VERSION
RESET CODE LEVEL VOLUME mA
CODE
Relay setting for unit 1,2,4,5
V1 H0 V1 H1 V1 H2 V1 H3 V1 H4
1 0 92 91.5 0
2 1 92 91.5 0
5 1 40 39.5 0
Relay 1 setting is use to set the full limit of probe 1

Relay 2 setting is use to set the full limit of probe 2
Relay 5 setting is use to set detection of presence of truck
Relay 5 of unit 3 and 6 are set for detecting half full level of truck
5 1 64 70 0
Please refer to FMU manual for more details on controller unit
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Preceding table is for the following distance:
Height of truck bed 5 feet
Full height limit 11 feet 4 inches
The 100% of the shown value is 12 feet from the floor where the floor is at 15 feet
from the sensors
The adjustment of 92 % is then 76 inches of material loaded in truck
3.9.4 Removing a unit
In event that a controller become defective and have to be replace:

It is possible to remove bottom controller without removing the wires of top controller.
The controllers are hold in the cabinet by four ¼ inches screws.
Removing the four screws of top unit allows putting away the controller and reach the
bottom unit, all wired are identified with shrink tubing and bundled with nylon straps
the wire bundle shall be easily put away when all screws are loosed.
3.10 Details of Gates
Gates are built to slide out and open the orifice in the conveyor so the cake will fall
down.
Opening and closing is changed by pneumatic actuators.
Two actuators connected in twin allow moving the plastic gates.
Actuators are connected to dual maintained positions pneumatic valves.
3.10.1 Electrically control valves
Valves are controlled with two electric solenoids.

It is also possible to activate valve manually. (See details of valves)
In auto mode electric signal is controlled by PLC.
In event of leaking valve (actuator move) PLC will send signal to move cylinder back
to place.
If actuator request to move don’t reached requested position in time a general fault
will be generated by PLC.
In manual electric signal is applied when corresponding push-buttons is pressed.

In manual operation pushing a non illuminated button will shift valve position,
actuator will move to required position, push-button of actual position will go off,
push-button of required position will go on indicating requested position reached.
In auto mode pushing buttons will have no effect.
Following picture show electric valve

Quarter turn valve allow to close air supply
line for service
Solenoids are working with 24 VDC and are

equipped with LED pilot and transient
suppressor elements
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3.10.2 Gate position sensors
The push-buttons are illuminated when corresponding position sensing elements

located on cylinder actuator reached full extend or full extract limit.
Only one of two actuator cylinders is equipped with position sensors.
Following picture shows Reid switch (closed position)
To adjust loose the detector using a small flat screwdriver

and move until the lamp on the remote control panel light
up. Just tight the detector
Note: The air elbows are adjustable and shall be open with
two turns minimum.
The speed shall be adjusted with the yellow adjustments
on the electric valve
3.11 Electrical diagram explanation
This section is intended to give more explanation about electric diagram pages.
Please refer to electric diagrams section 6. (52 pages)
Page 1, 2 shows design position of elements on the front doors of control panel and
remote panel.
Page 3 shows power circuitry for the three conveyors receiving cakes from
centrifuges.
Page 4 shows power circuitry for the conveyor 4, 5, 6.
Page 5 shows power circuitry for conveyor 7, 8 and control transformer.
Page 6 shows power supply distribution and fuse for the 24VDC power supply and
the 110VAC for Prosonic FMU controllers.
Page 7 shows end of Prosonic supply. The normally open contact of emergency EM-
1-1 may open the return line of all contactors. Output contacts of output block 3 to
motor contactors and reversing interlocks
Page 8 shows end of contactor supply from output block 3 and thermal by pass
contactors from output block 6.
Page 9 shows end of thermal by pass, command relays of the VDF drive for
conveyor 5 and the general fault relay. The supply of 24VDC used for the Scadapack
PLC is fused by two different fuses so output relays are fused separately.
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Page 10 & 11 shows command and contacts for centrifuges 1. The interface wires
are orange for the centrifuge 1. Some wires are using relays strip others use auxiliary
contacts on contactors relays. The interconnections are grouped on terminal block.
are yellow for the centrifuge 2. Some wires are using relays strip others use auxiliary
are pink for the centrifuge 3. Some wires are using relays strip others use auxiliary
Page 16 shows interface command to centrifuge respective conveyor 1-3 and use
part of input of the PLC base block
Page 17 shows conveyor control input for conveyor 1. Note that interface relay RA-1
is hard wired to the selector Auto off manual. Inputs used are to the PLC block.
is hard wired to the selector Auto off manual. Inputs used are to the PLC block.
is hard wired to the selector Auto off manual. Inputs used are to the input 1 block.
is hard wired to the selector Auto off manual. Inputs used are to the input 1&2 blocks.
Page 25&26 shows Prosonic control input for conveyor 7&8. Note that interface
relays RTHF-7&8 (truck half full relays) are hard wired to the Prosonic control 3&6.
Inputs used are to the input 3&4 blocks. Last part of page 26 shows input from gates
position sensors (Reid) Note that they are hard wired to the pilot lamps located in the
illuminated push-buttons open or closed on remote panel. Interconnections are
grouped on the terminal blocks of the remote panel.
Page 27, 28&29 shows input from gates position sensors (Reid) and note that they
are hard wired to the pilot lamps located in the illuminated push-buttons open or
closed on remote panel. Interconnections are grouped on the terminal blocks of the
remote panel. Inputs used are to the input 4&5 blocks.
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Page 30 to 34 shows the input of selectors for gates operation and output for gates
activation solenoid valves. The normally open push buttons are the contacts of the
illuminated push buttons open and close gate. Diodes are blocking the reading when
selector is in auto and push button is pressed to the input block. The diodes are
integrated in the wiring at the input connection points. Outputs are used from blocks
2&3. Input used are to the input 5&6 blocks.
Page 35 to 38 shows the output for control of conveyors 1 to 8 such as:

Sensocontroller supply and it related feed-back LED, conveyor direction & fault LED
pilot lights. Note that the RF 1 to 8 (fault relays) are hard wired with the fault LED’s.
Outputs are used from PLC & block 4.
Page 39 shows the output for status of truck loading. Note that the RTP 7&8 (truck
present relays) and RTF 7&8 (Truck full relays) are hard wired to respective LED’s
pilot lights. Outputs are used from block 5.
Page 40 shows the output for the status of truck; RTIPR 7&8 (truck in place ready to
load relays), the input of selector truck OK to load 7&8. The DC to DC converter
supply +5VDC for extension I/O’s (located on the cover of input block 1).
Page 41 shows spare input points and spare output points. Note those points are not
wired to any terminal block in the control panel.
Page 42 shows: details of connections to the VFD drive for conveyor 5, Details of
synchronization lines of Prosonic controller (so only one sensor is activated at a
time), Details of analog connections of mA drive from Prosonic controller 3 & 6.
Page 43 shows the Emergency push-buttons chain. Note that the two relays EM-1
and EM-1-1 are energized when all push-buttons are in released position. Lamp
inside each push-button is illuminated when button is pressed. The push-buttons are
maintained position type and must be pulled to be at (not in emergency) position.
Page 44 shows wiring diagram of the remote control panel
Page 45 shows interconnection barrier of the remote panel. The same numbering
order is maintained on the terminal block barrier inside the main panel.
Page 46 shows interconnection barrier of the three centrifuges terminal strip.

Note at the start-up in spring 2005 only one centrifuge was connected. Double
numbering at left of it interconnection represents the wiring number inside the
centrifuge panel. Few wires are not connected and are identified as NC with a W-x.
This nomination is present on the wires inside the centrifuge control panel.
Page 47&48 shows interconnections for conveyor 1 to 8 (motors & Sensocontroller)

In a case of a Sensocontroller becoming defective a shorting jumper may be place
from (Sensocontroller +24VDC) to (Sensocontroller relay signal) disabling is function.
Note that the motors 1-3 are two speed poly-phase motors so only three power lines
must be energized at a time
26
Page 49 shows interconnections of gates position Reid switches sensors & electric
valve actuators.
Page 50 shows wiring schematic between master panel, remote panel and controlled
elements.
Page 51 shows instructions to contractor for field wiring
Page 51 shows last revision modification. (rev3)
3.11.1 Inputs
All digital inputs to Scadapack PLC and extended digital Inputs are wired from
24VDC
All analog input on the Scadapack 32 PLC module are reading from 0 to 20Ma
3.11.2 Outputs
Some outputs are wired from 110VAC to motor contactor devices and interfaces
Each centrifuge outputs bank are isolated to one common line and are using isolated
contacts.
Other outputs are wired from 24VDC to devices
Because the low power of outputs in PLC modules they are used for low current
devices only.
All output except for analog signal are with isolated relays contact.
PLC digital outputs are in the rage of 1 amp.
Extended output modules are in the range of 2.5amps.
27
Section4 How to use the Vision Operator Terminal Interface
Section shows all screens and explains operator possible interventions for variable
parameters and status information’s of the Interface displays two lines of 20
characters.
At start-up the display shows model and version of Scada vison 10
Pressing on (NEXT or PREV) F1 or F2 button will change the display to display 1 or

21
4.1 First Screen
F1 will move to next screen, F2 will move to screen 30.
4.2 Second screen
This screen allows modification of timing for gates operation. The values presented
are in 1/10 of seconds
To change or enter a new value F4 is used to increased the value from 0 to 9
F3 is used to shift the value to left
F5 is used to clear the value to zero.
F6 is used to validate the value which will be transferred to left indicating the setting
F1 will move to next screen, F2 will move to previous screen.
Maximum value of 9999.9 seconds may be enter (2 hours, 46 minutes, 39.9 seconds)
28
4.3 Third screen
This screen allows changing speed (in auto mode) of the VFD drive conveyor 5
Pressing F4 will increase the value by one. Pressing F3 will decrease the value by
one. The value may be adjusted from 00000 up to 32767. The maximum value will
set the speed to 60 cycles on the VFD drive.
4.4 Fourth screen
This screen shows actual speed of the VFD drive

4.5 Fifth screen
This screen shows the actual value in analog of the percentage of loading of the
Prosonic ultrasonic level detector. The value may vary from 0 to 32767 where 32767
is 100% of the loading. The analog value represents the read value in the FM862
sensor 2 of Prosonic 3 (The sensor of open gate on truck under conveyor 7)
29
4.6 Sixth screen
This screen shows the actual value in analog of the percentage of loading of the
Prosonic ultrasonic level detector. The value may vary from 0 to 32767 where 32767
is 100% of the loading. The analog value represents the read value in the FM862
sensor 2 of Prosonic 6 (The sensor of open gate on truck under conveyor 8)
4.7 Seventh screen
This screen shows the gates which generated the fault. The left position of the
number will indicate the gate 5 and the right position of the number indicate the gate
1. Left string of number shows gates fault of conveyor 7 and right string position for
conveyor 8. A gate fault is generated when the time delay of 20 seconds is
exhausted and the fault is activated. The fault is latched. To clear the fault it is
necessary to push the emergency push-button and release it. If the faulty gate is not
positioned in open or close position the fault is not cleared. When a general fault is
activated the system is stopped and the direction pilot lights of the conveyor on the
front panel are blinking at a rate of 1.5 times per second.
30
4.8 Eighth screen
This screen shows the status of the conveyor 1

From left to right a 1 is shows if:
Pos.1: Sensocontroller is active

Pos.2: Overload protection is not activated
Pos.3: Fault is activated
Pos.4: Conveyor is running reverse (to Drain)
Pos.5: Conveyor is running forward (to conveyor 4)
Pos.6: Manual selector is at to drain or to conveyor 4
Pos.7: Selector auto off manual is at manual
Pos.8: Selector auto off manual is at auto
4.9 Ninth screen


31
4.10 Tenth screen


4.11 Eleventh screen


Pos.4: Conveyor is running
Pos.5: Manual selector is at on
32
4.12 Twelfth screen


Pos.4: Conveyor VFD is energized
4.13 Thirteenth screen


Pos.4: Conveyor is running reverse (to conv 7)
Pos.5: Conveyor is running forward (to conv 8)
Pos.6: Manual selector is at to 7 or to 8
33
4.14 Fourteenth screen


4.15 Fifteenth screen


34
4.16 Sixteenth screen
This screen shows the status of the PLC input first 16 bits
Pos.1: Sensocontroller conveyor 2 is active

Pos.2: Not used always zero
Pos.3: Overload conveyor 2 not active
Pos.4: Manual selector conveyor 2 is at to conveyor 4
Pos.5: Manual selector conveyor 2 is at to drain
Pos.6: Selector auto off manual conveyor 2 is at auto
Pos.7: Selector auto off manual conveyor 2 is at manual
Pos.15: Command from centrifuge 3 to run conveyor 3 to conveyor 4
Pos.16: Command from centrifuge 3 to run conveyor 3 to drain
4.17 Seventeenth screen
This screen shows the status of the PLC input last 4 bits

35
4.18 Eighteenth screen
This screen shows the status of the input block 1 16 bits

Pos.1: Manual selector conveyor 5 is at on

4.19 Nineteenth screen


36
Pos.10: Manual selector conveyor 6 is at fwd (to conveyor 8)
Pos.11: Manual selector conveyor 6 is at rev (to conveyor 7)
4.20 Twentieth screen

Pos.1: Prosonic gate 6 conveyor 7 truck half full

Pos.2: Prosonic gate 6 conveyor 7 at limit
Pos.4: Prosonic gate 4 conveyor 7 truck present
Pos.10: Emergency push-button not pressed
37
4.21 Twenty-first screen

Pos.1: Gate 4 conveyor 7 open

Pos.2: Gate 3 conveyor 7 close
Pos.8: Prosonic gate 6 conveyor 8 truck half full
4.22 Twenty-second screen

Pos.1: Selector Gate 3 conveyor 7 at auto

38
4.23 Twenty-third screen


Pos.8: Selector load conveyor 8 at yes
Pos.9: Selector load conveyor 7 at yes
39
4.24 Twenty-fourth screen
This screen shows the status of the PLC output 12 bits

Pos.1: Conveyor 1 Sensocontroller active

Pos.2: Conveyor 1 running to drain (pilot lamp)
Pos.3: Conveyor 1 running to conveyor 4 (pilot lamp)
Pos.4: Conveyor 1 in fault (pilot lamp)
4.25 Twenty-fifth screen

Pos.1: Signal permission to run centrifuge 3

Pos.4: General fault activate
Pos.5: Command conveyor 5 run 2 on
Pos.6: Command conveyor 5 run 1 on
Pos.7: Contactor thermal by-pass 8 on
Pos.8: Contactor thermal by-pass 7on
40
Pos.11: Contactor thermal by-pass 3 rev on
Pos.12: Contactor thermal by-pass 3 fwd on
4.26 Twenty-sixth screen
This screen shows the status of the output block 2 16 bits

Pos.1: Close gate 3 conveyor 8 signal

Pos.2: Open gate 3 conveyor 8 signal
41
4.27 Twentieth screen

Pos.1: Contactor conveyor 8 (MR-8) on

Pos.3: Contactor conveyor 6 to conveyor 7 (MRV-6) on
Pos.4: Contactor conveyor 6 to conveyor 8 (MFW-6) on
Pos.5: Contactor VFD conveyor 5 (MR-5) on
Pos.7: Contactor conveyor 3 to drain (MRV-3) on
4.28 Twenty-seventh screen


Pos.2: Conveyor 8 running (pilot lamp)
Pos.3: Supply to Sensocontroller conveyor 8 on
42
4.29 Twenty-ninth screen

Pos.1: Not assigned

Pos.2: Not assigned
Pos.3: Not assigned
Pos.4: Not assigned
Pos.5: Not assigned
Pos.6: Not assigned
Pos.7: Not assigned
Pos.8: Not assigned
Pos.9: Conveyor 7 truck in place ready to load signal
Pos.10: Conveyor 7 truck in place ready to load signal
Pos.11: Conveyor 8 loaded (pilot lamp)
Pos.12: Conveyor 8 truck present (pilot lamp)
Pos.13: Conveyor 8 loading (pilot lamp)
Pos.14: Conveyor 7 loaded (pilot lamp)
Pos.15: Conveyor 7 truck present (pilot lamp)
Pos.16: Conveyor 7 loading (pilot lamp)
F1 will move to next screen, F2 will move to previous screen
43
4.30 Thirtieth screen
This screen shows the activated gate

Left indicate conveyor 7 gate
Right indicate conveyor 8 gate
F1 will move to screen 1, F2 will move to previous screen
44
Section 5 trouble shooting the control panel
This section is subdivide is sub section
5.1 What can happen to stop the system and its operation?
5.1.1 Stopped by fault:
5.1.1.1 A fault is generated when the overload sensing device sense a too large
amount of current passing trough it.
The contactor for the motor is then release and the preceding conveyor are stopped.
The overload detector are built with auto reset meaning that fault will not stay and will
be cleared itself, tough the fault is latched by the PLC program and must be cleared
by the operator. To clear the fault it is required to place the selector of the conveyor
in fault at OFF. The fault lamp shall go off. If the lamp stay on it means that the
overload is not reset yet, wait a moment it shall reset and cleared the fault.
One word about the overload:

They are adjustable if a drive goes in fault often it current in operation shall be
verified and the overload shall be place with a factor of 1.5 the current measured. If
the current is exceeding the value normally required verification of the drive, gear box
and conveyor shall be performed.
The thermal breakers (overload) are by-pass at start-up for a 5 seconds period. This
option allows starting the conveyors when they are heavy loaded allowing a longer
delay at start-up.
The VFD for the conveyor 5 is using an electronic current measurement and may be
adjusted on the drive itself see manual for the Altivar in section 9.
5.1.1.2 A fault will also occurs if the system is power up or come back from an
emergency stop and the selector auto off manual is at manual and the selector of on
off or fwd off rev is in a position where the conveyor was operating before the stop. In
that case the fault is logic; the conveyor can not be restarted after an emergency
when it was running in manual. Placing one of the selector at OFF will reset the fault.
5.1.2 Stopped by a general fault:
The general fault is a fault generated by the movements of the gates and occurs
when the movement of a gate is not completed in the delay of 20 seconds. The
movements of the gates are not timed when they are in manual. A general fault may
occur if there is accumulation of cakes at the closing of the gates and the position
sensor can not be reached by the actuator. This may eventually happen if the
dryness of the cake is to low. The gates are not designed to run with wet material. If a
general fault happen the indicator of running of both panel will flashes at a rate of 1.5
times per second. It is possible to verify using the vision 10 which gate has caused
the fault. (See section 4 for more details) The only way to reset a general fault is to
push emergency push-button and release it. The system shall restart normally. Note
that a fault (emergency or general fault) place the centrifuge in pause, it is required
by the operator to resume the centrifuge operation after clearing the fault.
45
5.2 Localizing a problem with I/O’s
All the inputs and outputs are represented by digital value with the vision 10. It is a
good practice to look at them and familiarize what they look like. As for inputs the
value is active (1) when the input is present. As for output when the value is active (1)
the output shall be activated.
Each relay on the relays strip, except for emergency and general fault, is equipped
with LED and transient suppressor. The normal current passing trough the contact is
low (only few Ma).
5.3 Prevention
It is a good practice to verify and retighten all power lines on all contactors up to the
terminal barrier once per six months. The wired are carrying medium current and may
heat, become loose after a long period.
Cleaning the gates slot and verify their good operation will minimize the general fault
occurrence.
The compressed air shall be maintained dry, if the air is not dry the valves may
clogged and actuator may stop working well. If condensed water is present
disconnecting the end on line and purging the line may extend the life of the
pneumatic systems. If system is contaminated with water adding pneumatic oil will
help reduce failures.
It is a good practice to verify the temperature of the motors and reducers (after one or
two hours of operation). None should exceed 40 degrees C. (warm at touch).
The interior of the master control panel temperature may reach 50 degrees C during
summer season; Excessive heat may reduce the life of the VFD drive or cause the
PLC to crash.
46
Section6 Wiring diagram of control
The following page shows wiring diagram of the control panel

INTERCONNECTIONS TO CENTRIFUGE 1

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TECHNICAL MANUAL

CONVEYOR CONTROL PANEL

NIAGARA FALLS WPEP

REMOTE CABINET (Truck Level)

Section1 How manual is written

Section2 Short description of operations controlled

Section3 Detailed description of operations controlled

Section4 How to use the Vision Operator Terminal Interface

Section5 Troubleshooting problems

Section6 Wiring diagram of control

Section7 Listing of PLC program

Section8 Technical data of parts and suppliers

This manual is written by sections

Section 6 is wiring diagram of control and remote control panel

Section 7 is list of the program loaded in the PLC

When any of conveyors 1-3 is running, conveyor 4 is started to transfer to conveyor

If an empty truck is present conveyor 6 direction is changed and sludge is directed to

To verify the rotation of conveyors sensocontrollers are monitoring rotation. In the

Following figure shows nomination of conveyors and gates.

Drawing is not to scale

This section is subdivided in sub-section.

3.1 Front panel of main cabinet

Left side of panel controls conveyors 1 to 5

Operator interface VISION is located on left

One emergency push-button is located on

Right side is to verify and control ultrasonic

Selectors on right side allow enabling or

Master disconnect and door handle are present on right side

3.2 Front panel of remote panel

Left side of panel controls conveyors 6 to 8

One emergency push-button is located on left

Right side controls gates.

3.4 Loading sequence and control of conveyor gates

For conveyor 7 and 8: Sequence of bin loading is control by PLC.

3.5 Loading control and information’s pilot lights

3.6 Operator Interface VISION

VISION interface allows setting variable parameters of conveyors system.

3.6.1 First Screen

3.7.1 Location of control elements

Power supply 24VDC 12 Amps

PLC Input 1 (a DC converter is installed on cover of

Control Power transformer

3 phases filter choke of VFD

VFD drive conveyor 5

Centrifuges Signal relays

Master Disconnect Disconnect Fuse Block

Disconnect Fuse Block

Thermal Breakers, By-pass relays, Relays

Thermal Breakers, By-pass relays

Prosonic controller unit 1-6

Prosonic controllers are mounted in two levels. Wiring is easily

3.7.2 Details description of DC power supply

Power supply 24VDC 12 Amps is a commonly linear DC power supply

Three fuses are present for

RTIPR8, 7 Truck in Place Ready to load

RTP8, 7 Truck in Place

RTHF8, 7 Truck Half Full

RTF8, 7 Truck Full

RA1 Conv1 in Auto RF1 Conv1 fault

RA2 Conv2 in Auto RF2 Conv2 fault

RA3 Conv3 in Auto RF3 Conv3 fault

RA4 Conv4 in Auto RF4 Conv4 fault

RA5 Conv5 in Auto RF5 Conv5 fault

RA6 Conv6 in Auto RF6 Conv6 fault