Know what’s wrong, anywhere on your conveyor line(s): 24hrs a day 7 days a week 365 days a year. - PowerPoint PPT Presentation

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Know what’s wrong, anywhere on your conveyor line(s): 24hrs a day 7 days a week 365 days a year.

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  1. Know Where, When, Why, How & What went wrong… Before Costly Damage Occurs! via Exact Location Fault Diagnostics Know what’s wrong, anywhere on your conveyor line(s): 24hrs a day 7 days a week 365 days a year. • A Simple Switch or Alarm will: • Save Lives • Prevent Costly Damage • Keep Production Rates @ Highest

  2. Conveyor Management System (CMS) Eliminates downtime and improves safety with a unique network of monitoring and protection devices -- without conduit or extra wiring. Continuous monitoring from conveyor startup to shutdown identifies problems before they cause stoppage, damage, or personnel injury. Modular design allows functions and devices to be added or removed to meet your specific needs. No need for conduit or extra wiring. CTS Pull Cable supplies all the communications for the system, while also functioning as the pull cable. Other systems require individual switches to be hardwired through conduit. Pinpoints faults by type and location so maintenance crews spend less time searching for the problem, and get vital equipment back online sooner. Emergency stop, pre-start warning, and speech communications along the entire length of the conveyor enhance employee safety and equipment protection. Interlocking and sequencing can control material flow. If a safety device stops a downstream conveyor, either upstream conveyors are stopped or flow is diverted to another conveyor. Once the problem is corrected, all conveyors are restarted sequentially, and the conveyor system is once again charged with material. Central control room provides an overview of your entire operation, combining information from all controllers and field components, using Supervisory Control and Data Acquisition (SCADA) software. Hardwire or RF radio communications. Controllers can use any industrial protocol or serial communications (RS-32, RS-422, or RS-485). Or, RF radio transmitters can be used to remove the need for hardwire communications. Pull Cable Pull Cord Switches Dynamic Speed Monitoring Multiple Conveyor Sequencing/Interlocking Fault Location & Identification PLC/PC Interface Troughing and Return Belt Misalignment Audible/Visible Prestart Warning Voice Communication Control Room Interface Blocked Chute CO Monitoring Belt Tear and Rip Belt Underspeed and Slip Choose an Option or Next to Continue Exit Show NEXT

  3. Conveyor Pull Cord Switches Main Page NEXT BACK Emergency stop switches stop the conveyor electrically at any point along the conveyor. Heavy duty pulling mechanism compensates for temperature drifts, preventing false trips. Electrical rotary switch allows the switch to be tripped manually. The electrical switch is a self-wiping rotary switch (not a microswitch), and consists of two normally open and two normally closed contacts. Switch knob is padlockable in the "Off" position. Once the switch has been tripped, the knob latches in the "Off" position and must be manually reset in order to restart the conveyor. High impact U.V. stabilized polycarbonate enclosure is rated IP 66 and D.I.P. (Dust Ignition Proof) degree of protection. Recommended distance between switches is 330 feet (100.6 m). Approved for use in non-hazardous locations by the Pennsylvania Dept. of Environmental Resources Mine Safety and Health Administration (MSHA). Standard Pull Cord Switch • All the standard features listed above. • Self-wiping rotary switch (not a microswitch). • Isolated mechanical and electrical sections. • Heavy duty pulling mechanism eliminates false trips. • Mounted on 330' (100.6 m) intervals. • Corrosion-proof construction. • For non-hazardous locations. • For hazardous locations, must be installed in an intrinsically safe circuit. Part Number: CTS 100

  4. Conveyor Pre-Start Alarms Main Page BACK Enhance conveyor safety with audible and visible pre-start alarms. High impact, UV stabilized polycarbonate enclosure rated at an IP 65 degree of protection. Two audible alarms rated at 105dB each. Can be used as a signaling device when equipped with a push button. • Intrinsically Safe AudioVisual Pre-Start Alarm • Standard Audio VisualPre-Start Alarm Part Number: CTS 900 AVA Part Number: CTS 800 IS AVA Flashing Strobe Light Operating Voltage:110-220 VAC Current Consumption: 100 mA Flashing LED Operating Voltage: 12-15 VDC(Intrinsically Safe Power Supply) Current Consumption: 100 mA

  5. Conveyor Pull Cord Switches Main Page NEXT BACK Emergency stop switches stop the conveyor electrically at any point along the conveyor. • Heavy duty pulling mechanism compensates for temperature drifts, preventing false trips. • Electrical rotary switch allows the switch to be tripped manually. The electrical switch is a self-wiping rotary switch (not a microswitch), and consists of two normally open and two normally closed contacts. • Switch knob is padlockable in the "Off" position. Once the switch has been tripped, the knob latches in the "Off" position and must be manually reset in order to restart the conveyor. • High impact U.V. stabilized polycarbonate enclosure is rated IP 66 and D.I.P. (Dust Ignition Proof) degree of protection. • Recommended distance between switches is 330 feet (100.6 m). • Approved for use in non-hazardous locations by the Pennsylvania Dept. of Environmental Resources Mine Safety and Health Administration (MSHA). Pull Cord Switch with Trip Light • Standard switch features. • Trip indicator light rated at 15W for locating the tripped switch. • For use in a non-hazardous locations only. Part Number: CTS 200L

  6. Conveyor Pull Cord Switches Main Page NEXT BACK Emergency stop switches stop the conveyor electrically at any point along the conveyor. • Heavy duty pulling mechanism compensates for temperature drifts, preventing false trips. • Electrical rotary switch allows the switch to be tripped manually. The electrical switch is a self-wiping rotary switch (not a microswitch), and consists of two normally open and two normally closed contacts. • Switch knob is padlockable in the "Off" position. Once the switch has been tripped, the knob latches in the "Off" position and must be manually reset in order to restart the conveyor. • High impact U.V. stabilized polycarbonate enclosure is rated IP 66 and D.I.P. (Dust Ignition Proof) degree of protection. • Recommended distance between switches is 330 feet (100.6 m). • Approved for use in non-hazardous locations by the Pennsylvania Dept. of Environmental Resources Mine Safety and Health Administration (MSHA). Intrinsically Safe Pull Cord Switch • Standard switch features. • Trip indication LEDs. • Hazardous and non-hazardous locations. Part Number: CTS 300

  7. Conveyor Pull Cord Switches Main Page NEXT BACK Emergency stop switches stop the conveyor electrically at any point along the conveyor. • Heavy duty pulling mechanism compensates for temperature drifts, preventing false trips. • Electrical rotary switch allows the switch to be tripped manually. The electrical switch is a self-wiping rotary switch (not a microswitch), and consists of two normally open and two normally closed contacts. • Switch knob is padlockable in the "Off" position. Once the switch has been tripped, the knob latches in the "Off" position and must be manually reset in order to restart the conveyor. • High impact U.V. stabilized polycarbonate enclosure is rated IP 66 and D.I.P. (Dust Ignition Proof) degree of protection. • Recommended distance between switches is 330 feet (100.6 m). • Approved for use in non-hazardous locations by the Pennsylvania Dept. of Environmental Resources Mine Safety and Health Administration (MSHA). Intrinsically Safe Switch with Pre-Start Alarm • Standard switch features. • Audible and visible pre-start alarms. • Trip indication LEDs. Hazardous and non-hazardous locations. Part Number: CTS 300 PSW

  8. Main Page Conveyor Pull Cord Switches: Specifications NEXT BACK Dimensions: • . 7 13/16" (198 mm) • . 6 1/8" (156 mm) • . 7" (178 mm) • D. 5 1/2" (140 mm) • E. 5 1/2" (140 mm) Enclosure: I.P. 66 and DIP Housing: High Impact Polycarbonate Switch: Rated 16A at 500V standard10A at 500V-CSA2 normally open and 2 normally closed contacts Hardware: 316 Stainless Steel Approved by the Commonwealth of Pennsylvania - Department of Environmental Resources, Mine Safety and Health Administration (MSHA) for use in non-hazardous locations. For use in hazardous locations, the CTS 100 must be installed in an intrinsically safe circuit. Typical Connection Diagram

  9. Main Page Conveyor Management System Controllers NEXT BACK The Conveyor Management System's intelligent controllers monitor and supervise the entire operation. The Safeline Circuit™ provides an extra level of safety. The Safeline Circuit in every CMS controller ensures that every safety device is operating at all times. • 1. Field PCB • 2. End Unit • 3. Supply • 4. Control • 5. Safeline • 6. Communication A voltage inverting device used as the last unit in line transmits a negative voltage through a normally closed contact within each switch, back to the controller. The controller monitors for the presence of the negative voltage, ensuring that the circuit is complete. CMS Controllers Selection Chart Engineering Capabilities Our Electrical Controls Division can design, build, integrate and test a system customized for your needs, planned for the best cost efficiency and ease of operation. As a company with many years of experience in the material handling industry, we understand the entire process rather than only the individual controls. • From 10 feet to 10 miles, we can provide the complete solution for your conveyor control needs. • Any level of service and components, literally from the pull cord switch to the SCADA screen. • Complete system pre-testing eliminates start-up delays. Because we provide both the field components and control units, we can completely test the entire system prior to shipment, eliminating delays due to incompatible components.

  10. System Capabilities CTS-ISP CTS-1000 CTS-3000 • Pull Cable Y Y Y • Pre-Start Warning Y Y • Dynamic Speed Monitoring Y • Multi-Conveyor Sequencing Y Y • Fault Location and Identification Y • PLC/PC Interface Y Y • Belt Protection Devices CTS-ISP CTS-1000 CTS-3000 • Belt Underspeed/Slip Y Y Y • Belt Tear Y Y Y • Belt Rip Y Y Y • Belt Misalignment Y Y Y • Blocked Chute Y Y Y • Pre-Start Warning Y Y • Conveyor Pull Cord Switches CTS-ISP CTS-1000 CTS-3000 • Padlockable Safety Switch Y Y Y • Carbon Monoxide Monitoring Y Y • Audible/Visible Pre-Start Alarm Y Y • Voice CommunicationY Main Page NEXT BACK CTS 3000: Head End Control Unit CTS 1000: Conveyor Control Unit Provides prestart warning alarm capability, either as stand-alone units or within CTS 300 PSW Pull Cord Switches. CTS ISP: Power Supply and Line Check Unit Provides emergency stop pull cord switch capability, using CTS Pull CordSwitches.

  11. CTS 3000: Head End Control Unit Main Page NEXT BACK Programmable control unit with internal fault diagnostics controls, monitors, and supervises all safety and belt protection devices. LCD display shows fault type and location, giving maintenance personnel the information they need to solve the problem quickly, minimizing downtime. Transmits fault information to the control room with a fail safe interlock. Safeline Circuit for uncompromising safety. Intrinsically safe power supply allows our CTS Pull Cable to be used, eliminating the need for conduit. CTS 1000: Conveyor Control Unit Provides prestart warning alarm capability, either as stand-alone units or within CTS 300 PSW Pull Cord Switches. Includes push buttons and a serial interface port for PC control. Safeline Circuit for uncompromising safety. Intrinsically safe power supply allows our CTS Pull Cable to be used, eliminating the need for conduit. CTS ISP: Power Supply and Line Check Unit Provides emergency stop pull cord switch capability, using CTS Pull CordSwitches. Safeline Circuit for uncompromising safety. Intrinsically safe power supply allows our CTS Pull Cable to be used, eliminating the need for conduit. 1. Motor Control Circuit 2. CTS IPS 3. Pull Cord Switches 4. End Unit

  12. Conveyor Management System Components Main Page NEXT BACK The CMS system's modular design allows components to be added or removed to meet the needs of your specific application. In addition to the pre-start alarms and monitors on this page, we provide a wide selection of Belt Protection Units,Pull Cord Switches,Pre-Start Alarms, and other devices. Pre-Start Alarm with Termination Enclosure Two enclosures mounted on a chassis plate that forms a canopy above the unit. Pre-Start Alarm: Our CTS 300 PSW Pull Cord Switch. Emergency stop pull cord switch. Padlockable electrical rotary switch rated to 500V 16 amp. 2 audible prestart warning alarms. Trip indication LEDs. Replaceable resin-coated PC board. Part Number: CTS 300 PSW/DC Termination Enclosure: A resin coated PC board populated with spring-loaded type terminals for the cable connections and compression entry glands. Pre-Start Alarm with Speech Communication A "push to talk" speech communication unit enables operators and maintenance personnel to communicate from any point along the conveyor. Pre-Start Alarm: A CTS 300 PSW Pull Cord Switch. Emergency stop pull cord switch. Padlockable electrical rotary switch rated to 500V 16 amp. 2 audible prestart warning alarms. Trip indication LEDs. Replaceable resin-coated PC board. Speech Communication Unit: A PC board populated with terminals for pull cable connections equipped with 2 gland entries and a "push to talk" speech communication unit. Part Number: CTS 300 PSW/DC/SC

  13. Pre-Start Alarm with Carbon Monoxide Monitor Main Page NEXT BACK Pre-Start Alarm: A CTS 300 PSW Pull Cord Switch. Emergency stop pull cord switch. Padlockable electrical rotary switch rated to 500V 16 amp. 2 audible prestart warning alarms. Trip indication LEDs. Replaceable resin-coated PC board. Part Number: CTS 300 PSW/DC/CO CO Gas Monitor: Sounds an alarm at 100 PPM, and stops the conveyor at 400 PPM. The bottom enclosure consists of a PC board populated with terminals for pull cable connections equipped with 2 gland entries. Primary Device Incorporates auxiliary equipment such as an emergency stop push button, take-up limit switches, fluid coupling temperature devices, blocked chute detectors, etc. into the Conveyor Management System's network. The normally closed contact of the auxiliary equipment is connected to terminals in the unit's termination box. If the auxiliary equipment is activated and the normally closed contact opens, the unit will stop the conveyor and latch in the "Off" position. Part Number: CTS 400 PD

  14. Temperature Monitor Main Page NEXT BACK Monitors the temperature of bearings, electrical motors, oil tanks, etc. The unit has two settings: one for alarm and one for stopping the conveyor. Alarm settings range from 120° to 300° F, in 10° increments. The unit is incorporated into the safety system of the conveyor by the pull cable. Part Number: CTS 500 TM Vibration Monitor Monitors the vibration of bearings, electrical motors, crushers, etc. The unit's "accept" push button that is used to set the normal working vibration as the reference for alarm or trip. The unit has two settings, one for alarm and one for stopping the conveyor. The alarm settings are set in increments of 5% from the normal vibration. The trip settings are set in increments of 5% above the alarm settings. The unit is incorporated into the safety system of the conveyor by the pull cable. Part Number: CTS 500 VM

  15. Main Page Conveyor Management System (CMS): Hardware NEXT BACK • CMS Pull Cable • High-tensile braided steel cable with six internal conductors. The dual purpose cable serves as both the electrical and control cable for the entire system, as well as the emergency stop pull cable, eliminating the need for conduit and extra wiring. For added protection, the steel braiding is covered with U.V. stabilized flame retardant PVC. Part Number: CTS PC Termination Kit Cable clamp and steel hook terminates the pull cable between the pull-keys. The cable clamp grips the pull cord and the steel J-bolt is fastened to the pull cord switch pulling mechanism. Part Number: CTS TK Pull Cable Carrier Carries the pull cable between the pull cord switches (and to other various belt protection units). Pull cable carrier is mounted on the conveyor structure at 10 ft (254 mm) centers. Part Number: CTS PCC Conventional Hardware Galvanized TurnbucklePart Number: CTS TRB Galvanized ThimblePart Number: CTS THB Galvanized Pull Cord FastenerPart Number: CTS PCF Vinyl Coated Pull CordPart Number: CTS CRD

  16. Conveyor Belt Protection:Troughing Belt Misalignment Detector Main Page NEXT BACK Troughing belt misalignment is detected by two upright arms, which are connected to an electrical switch by a glass reinforced polycarbonate coupling. If the belt misaligns on either side to the extent that it could cause damage to the belt or conveyor structure, it contacts one of the upright arms. The arm tilts in the direction of the moving belt and activates the switch. Adjustable mechanical trip delay on the switch coupling mechanism prevents false trips. Switch structure is designed to minimize material build-up which could render the switch inoperable. Belt protection units can be combined to meet your specific needs. Part Number: CTS 700 BL • Enclosure: I.P. 66 • Housing: High Impact Polycarbonate • Switch: Rated 16A/500V (2 normally open and 2 normally closed contacts) Conveyor Belt Protection:Return Belt Misalignment Detector Return belt misalignment is detected by two downcast arms, which are connected to an electrical switch by a glass reinforced polycarbonate coupling. If the belt misaligns on either side to the extent that it could cause damage to the belt or conveyor structure, it contacts one of the downcast arms. The arm tilts in the direction of the moving belt and activates the switch. Adjustable mechanical trip delay on the switch coupling mechanism prevents false trips. Switch structure is designed to minimize material build-up which could render the switch inoperable. Belt protection units can be combined to meet your specific needs. Part Number: CTS 700 RBL Enclosure: I.P. 66 Housing: High Impact Polycarbonate Switch: Rated 16A/500V(2 normally open and 2 normally closed contacts)

  17. Conveyor Belt Protection:Conveyor Belt Tear Detector Main Page NEXT BACK A tear to the wing section of the belt is detected by a profiled arm mounted below the belt, which is connected to an electrical switch by a glass reinforced polycarbonate coupling. A torn piece of belt hanging at least 2 3/8" (60 mm) beneath the belt will strike the profiled arm, and activate the switch. Part Number: CTS 700 BT Enclosure: I.P. 66 Housing: High Impact Polycarbonate Switch: Rated 16A/500V (2 normally open and 2 normally closed contacts) Conveyor Belt Protection:Conveyor Belt Tear and Rip Detector Combines two types of protection on a single frame. A tear in the belt's wing section or a rip in the belt's center section is detected by a profiled arm mounted below the belt, which is connected to an electrical switch by a glass reinforced polycarbonate coupling. A torn piece of the belt's center or wing section that hangs at least 2 3/8" (60 mm) under the belt will strike the profiled arm mounted under the belt, activating the switch. Part Number: CTS 700 BTR Adjustable mechanical trip delay on the switch coupling mechanism prevents false trips. Switch structure is designed to minimize material build-up which could render the switch inoperable. Belt protection units can be combined to meet your specific needs. Enclosure: I.P. 66 Housing: High Impact Polycarbonate Switch: Rated 16A/500V (2 normally open and 2 normally closed contacts)

  18. Conveyor Belt Protection:Conveyor Belt Speed Unit Main Page NEXT BACK Belt speed is monitored by a spring-loaded revolving roller mounted underneath the troughing belt. A sensor monitors pulses from the revolving roller. The enclosure contains a programmable electronic motion detector that displays the speed of the belt in feet per minute. The unit receives a signal from the speed roller, which can be monitored in two modes: Part Number: CTS 700 BSD Static mode monitors for off-speed condition Dynamic mode monitors for movement, acceleration, and operating speed Enclosure: I.P. 66 Housing: High Impact Polycarbonate Power Requirements: 120 VAC Switch: One normally closed and one normally open contact Adjustable mechanical trip delay on the switch coupling mechanism prevents false trips. Switch structure is designed to minimize material build-up which could render the switch inoperable. Belt protection units can be combined to meet your specific needs. Conveyor Belt Protection:Belt Misalignment and Tear Detector • Troughing belt misalignment is detected by two upright arms, which are connected to an electrical switch by a glass reinforced polycarbonate coupling. • If the belt misaligns on either side to the extent that it could cause damage to the belt or conveyor structure, it contacts one of the upright arms. The arm tilts in the direction of the moving belt and activates the switch. • A tear to the wing section of the belt is detected by a profiled arm mounted below the belt, which is connected to an electrical switch by a glass reinforced polycarbonate coupling. • A torn piece of belt hanging at least 2 3/8" (60 mm) beneath the belt will strike the profiled arm, and activate the switch. Part Number: CTS 700 BLT Enclosure: I.P. 66 Housing: High Impact Polycarbonate Switch: Rated 16A/500V(2 normally open and 2 normally closed contacts)

  19. Main Page Conveyor Belt Protection:Belt Misalignment, Tear, and Speed Detector NEXT BACK • Troughing Belt Misalignment Detection • Troughing belt misalignment is detected by two upright arms, which are connected to an electrical switch by a glass reinforced polycarbonate coupling. • If the belt misaligns on either side to the extent that it could cause damage to the belt or conveyor structure, it contacts one of the upright arms. The arm tilts in the direction of the moving belt and activates the switch. • Troughing Belt Tear Detection • A tear to the wing section of the belt is detected by a profiled arm mounted below the belt, which is connected to an electrical switch by a glass reinforced polycarbonate coupling. • A torn piece of belt hanging at least 2 3/8" (60 mm) beneath the belt will strike the profiled arm, and activate the switch. • Belt Underspeed/Slip Detection • Belt speed is monitored by a spring-loaded revolving roller mounted underneath the troughing belt. A sensor on the structure receives pulses from the revolving roller. Part Number: CTS 700 BLTS Conveyor Belt Protection:Doppler Conveyor Belt Speed Unit • Non-contact, high accuracy speed unit has no moving parts so it is maintenance free. • The Doppler Speed Unit uses the latest technology to provide a revolutionary method of monitoring conveyor speed. The unit is equipped with a 2-line LCD display with 4 push buttons. The push buttons are used to configure the unit, and belt speed is displayed on the LCD with the belt is in motion. Part Number: CTS 7000 DSU

  20. Conveyor Belt Protection:Infrared Conveyor Belt Rip Detector Main Page NEXT BACK Network of infrared sensors detects material spilled through a rip in the conveyor belt. The Infrared Rip Detector is an electronic device consisting of a network of infrared sensors mounted beneath the troughing belt. If a foreign object penetrates the belt, material will fall through the cut in the belt onto the detector's tray. As material builds up on the tray, the infrared beams are blocked and the conveyor is stopped. A "wash" cycle allows the unit to be cleaned without stopping the conveyor belt. Part Number: CTS 9000 IRRD Conveyor Belt Protection:Ultrasonic Conveyor Belt Misalignment Detector Ultrasonic beams detect misalignment with no moving parts. The Ultrasonic Misalignment Detector has a profiled arm shaped in the same configuration as the troughed section of the belt. Two alignment sensors near its edge each emit a narrow ultrasonic beam towards the belt surface at predetermined angles. The beams are reflected back to the sensors. Belt misalignment in either direction causes the reflected signal to be outside the acceptable limit, and the detector will provide a visual indication that misalignment is occurring. If misalignment continues beyond a predefined time limit, the detector will trip and must be manually reset. Part Number: CTS 7000 RF/BL

  21. Conveyor Belt Protection:Motion Detector Main Page NEXT BACK Programmable electronic motion detector displays the speed of any rotating or moving object in meters per second, feet per second, or revolutions per minute (RPM). An object's movement is detected by a proximity switch connected to the unit, in two different modes: • Static mode monitors for off-speed condition • Dynamic mode monitors for movement, acceleration, and operating speed • A two line LCD and four push buttons are used to set system mode, run speed, trip speed, movement time, acceleration time, and other settings. Part Number: CTS 700 MD Conveyor Belt Protection:Blocked Chute Detector The blocked chute detector is a tilt switch mounted inside the chute to detect any restriction of material flow within a transfer point. Blockage which causes the switch to tilt more than 15° will activate the switch. The switch consists of 3 normally closed mercury switches connected in series, mounted 120° from each other. A steel enclosure provides optimum protection. Part Number: CTS 600 BCD

  22. Engineering Capabilities Main Page NEXT BACK Our Electrical Controls Division can design, build, integrate and test a system customized for your needs, planned for the best cost efficiency and ease of operation. As a company with many years of experience in the material handling industry, we understand the entire process rather than only the individual controls. • From 10 feet to 10 miles, we can provide the complete solution for your conveyor control needs. • Any level of service and components, literally from the pull cord switch to the SCADA screen. • Complete system pre-testing eliminates start-up delays. Because we provide both the field components and control units, we can completely test the entire system prior to shipment, eliminating delays due to incompatible components. Head End Control Unit (HECU) Conveyor Trip Switches with Pre-Start Warning Alarm Conveyor Underspeed/Slip Detector(Connected direct to controller) Sequence Roller(Connected to controller of upstream conveyors) Pull Cable Pull Cable Carrier (Pigtail) Blocked Chute Detector Fusable Plug Bearing Temperature Tension Limit Switches Troughing Belt Misalignment Detector Return Belt Misalignment Detector Troughing Belt Tear Detector Return Belt Rip Detector

  23. Factory Direct Let us automate you! Questions? Comments? Call us or visit us online. Phone: 800-940-4044 Fax: 800-845-6787 Click below for more information: www.directline-supply.com