ASHSCAN

On-Belt Ash Analyser

and
ASHSCAN DUO
On-Belt Ash/Moisture Analyser

Operation Manual

Version 3.2
Revised October 2010

Contact Details

Real Time Instruments Pty Ltd Phone +61 7 4955 5944

PO Box 6920 Fax +61 7 4955 7338
Mackay Mail Centre QLD 4741 [email protected]
Australia www.realtimeinstruments.com.au

Contents
ASHSCAN/ASHSCAN DUO OPERATION MANUAL
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1 INTRODUCTION 5
1.1 Ash/Moisture Measurement 5
1.2 Features and Benefits 5
1.3 Dual Energy Ash Measurement Technique 5
1.4 Microwave Measurement Technique 5
1.5 Health and Safety 6

2 SYSTEM DESCRIPTION 6
2.1 C-Frame 6
2.2 Control Cabinet 7

3 INSTALLATION 9
3.1 Electrical 9

4 INSTALLATION DIAGRAMS 10
4.1 Mechanical Installation Diagram 10
4.2 Electrical Installation Diagram 10

5 HUMAN MACHINE INTERFACE (HMI) 11

5.1 Operation 11
5.2 Pages 14
5.2.1 Ash Trends 14
5.2.2 SCA Data 15
5.2.3 IP Address 16
5.2.4 Analog Outputs 17
5.2.5 Digital Outputs 18
5.2.6 Digital Inputs 19
5.2.7 Parameters 19
5.2.7.1 Ash Alarms 20
5.2.7.2 Limits 20
5.2.7.3 Calibration 21
5.2.7.4 Smoothing 21
5.2.7.5 Radiation 22
5.2.7.6 Misc 22
5.2.8 Standardise 23
5.2.9 Sampling 25
5.2.10 Calibrate 27
5.2.11 Ash Results 28
5.2.12 Moisture Menus (ASHSCAN DUO) 28

6 COMMISSIONING AND CALIBRATION 34

6.1 Power-Up Checks 34
6.2 Empty Belt Standardisation 34
6.3 Online Calibration 34
6.4 Static Calibration 35

7 MAINTENANCE 35
7.1 Recalibration 35

8 APPENDIX 36
8.1 Typical Results 36

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 1 INTRODUCTION
1.1 Ash/Moisture Measurement
Ash and Moisture have always been important process parameters that are usually
determined using laboratory techniques on infrequently obtained samples. This method of
analysis is expensive and consumes valuable time and labour. Most of all, the results from
the laboratory analysis are too old to confidently act upon.

The ASHSCAN On-Belt Ash Analyser provides accurate measurement of ash in real time,
the ASHSCAN DUO On-Belt Ash/Moisture Analyser also provides measurement of moisture
in real time.

Instantly available ash and moisture data for confident and proactive control:

• Metallurgical/process accounting
• Net weight monitoring for quality control purposes
• Product specification compliance

1.2 Features and Benefits

Features: Benefits:
On-belt Frame construction No segregation effects, low cost, simple installation
Non-contact measurement No wearing, no intrusion, low maintenance
Rapid real time results Relevant data, proactive process control
Automatic operation Low cost, simpler logistics, no operator intervention
Factory set up Uncomplicated commissioning, simple calibration
Australian design and manufacture High quality instrument, excellent technical support

1.3 Dual Energy Ash Measurement Technique

The dual energy ASHSCAN uses two radioactive sources directed through the coal on the
belt to determine the ash content of the coal. The two sources used are a high energy
gamma source (Caesium 137) and a low energy gamma source (Americium 241). The
absorption of the low energy gamma rays is related to both the ash content and the depth of
coal on the belt and the absorption of the high energy gamma rays is related only to the
depth of coal on the belt. It is therefore possible to use the high energy count rate to
compensate for material depth and derive a value that correlates to ash.

1.4 Microwave Measurement Technique

The ASHSCAN DUO’s result for moisture content is determined by measuring the effect that
process material has on a microwave signal being passed through it. This signal is emitted
from a transmitting antenna and is passed through the process material and then detected by
a receiving antenna. The microwave signal interacts with any moisture in the process
material between the two antennas. The degree of interaction is measured and used to
derive a value for the amount of moisture present.

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 1.5 Health and Safety
Due to the fact that the ASHSCAN contains radioisotopes, the system has been designed to
maintain the highest levels of safety. The gamma rays during operation are tightly collimated
in a beam from the source (under the belt) upward to the detector (above the belt). Outside of
this beam the radiation levels drop to background inside of 1m. The measurement beam can
be turned on and off using the shutter control lever below the electronics cabinet on the C-
Frame. The shutter control lever can be locked on the beam off position. The current state of
the source shutter is clearly marked on the main page of the HMI and indicated via lamps on
the electronics cabinet door.

The ASHSCAN DUO is designed to use low level microwave radiation. The microwave
power emitted from the lower antenna is less than 10 mW (10 dBm). This radiation level is
restricted to the region directly between the two antennas, which is typically inaccessible.
Microwave emissions are virtually undetectable further than 1m from the ASHSCAN DUO.

2 SYSTEM DESCRIPTION
The ASHSCAN is comprised of two major components; the C-Frame and the Control
Cabinet. The functions and operations of these units are described in this chapter.

2.1 C-Frame
The On-Belt C-Frame houses the measuring system – the gamma sources and detector.
When operating as the ASHSCAN DUO the C-Frame also houses the moisture
measurement system comprising the microwave transmit and receive antennas. The
measuring system is accurately aligned during the manufacturing process, which means that
there is no need for lengthy set up on site. The C-Frame is designed to fit directly to the
conveyor stringers and is normally arranged so the measuring system is aligned with the
centre of the conveyor belt. The lower arm of the C-Frame contains the gamma ray sources.
The upper arm of the C-Frame contains the scintillation detector and count rate detection
electronics.

The C-Frame is designed to meet IP65 standard for dust and moisture intrusion.

In a retro fit application the C-Frame or equivalent may be supplied from the original
instrument.

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 2.2 Control Cabinet
The Control Cabinet is attached directly to the C-Frame in the standard ASHSCAN
configuration. The interior of the cabinet comprises the following:

Figure 2.1 ASHSCAN Control Cabinet

1) Digital IO Module
2) Analog IO Module
3) Detector Temperature Controller
4) 24V Power Supply Unit
5) 24V Terminal Strip
6) Relays
R1 - Heater Relay
R2 - High Ash Alarm
R3 - Low Ash Alarm
7) Line Filter
8) Circuit Breaker/ RCD
9) Terminal Strip

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 In the ASHSCAN DUO the upper two rows of the Control Cabinet is comprised of the
following:

Figure 2.2 ASHSCAN DUO Electronics Cabinet

1) Digital IO Module
2) Analog IO Module
3) Programmable Logic Controller
4) Microwave Enclosure
5) 24V Power Supply Unit
6) 15V Power Supply Unit
7) Relays
R1 - Heater Relay
R2 - High Ash Alarm
R3 - Low Ash Alarm
R4 - Moisture System Healthy
8) 24V Terminal Strip
9) Microwave Terminal Strip
10) Detector Temperature Controller

On both the ASHSCAN and ASHSCAN DUO the Human Machine Interface (HMI) is mounted
on the door of the Control Cabinet for easy instrument setup and instant access to a range of
data.

In a retro fit application extra components may be required to interface with the original
instrument hardware, most commonly this relates to the source drive mechanism, and
consists of two extra relays controlling the source drive motor and source drive clutch.

The Control Cabinet is designed to meet IP65 standard for dust and moisture intrusion.

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 3 INSTALLATION

3.1 Electrical
The ASHSCAN supports 110 to 240V AC (60 to 50Hz) input voltage, and requires a supply
current of 2A. Please refer to Section 5.2 Electrical Installation Diagram on page 4 for a
schematic diagram.

The inputs and outputs provided by the ASHSCAN in its standard configuration are as
follows.

2x 4-20mA outputs designated AO1 and AO2.

In the standard setup AO1 provides an output of instantaneous ash which is an average of
the measured ash over a configurable number of seconds.

In the standard setup AO2 provides an output of the tonnage weighted ash measurement
since the last tons weighted reset; this is normally used for shift results.

The ASHSCAN DUO has a further 2x 4-20mA outputs designated MAO1 and MAO2 that
duplicated the behaviour of AO1 and AO2 but provide moisture results.

The scaling parameters for each output are configurable on the HMI.

2x Digital inputs designated Conveyor Run and Tons Weighted Rest

Conveyor Run is an input signal from plant that is used to tell the instrument when the
conveyor belt it is installed on is actually running. This is used internally to control analysis.

Tons Weighted Reset is an input that is used to initiate a reset of the current tons weighted
ash result.

Warning: The ASHSCAN Control Cabinet contains 110/240V AC terminals. Site-specific

procedures for isolating 110/240V equipment should be performed before working
on the analyser power circuit. Only qualified personnel should perform work inside
the Control Cabinet.

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 4 INSTALLATION DIAGRAMS
Please refer to the supplied A3 format diagrams.

4.1 Mechanical Installation Diagram

Figure 4.1 Mechanical Installation Diagram

4.2 Electrical Installation Diagram

Figure 4.2 Electrical Installation Diagram

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 5 HUMAN MACHINE INTERFACE (HMI)
5.1 Operation
The HMI is designed to present relevant and up to date data as well as allow quick setup and
adjustment of system and calibration parameters. Parameters are entered via the touch
screen on the front panel, allowing the Control Cabinet to be kept closed.

Figure 5.1 HMI

All operation of the HMI is via its touch screen interface. To edit any parameter just double
touch the parameter’s value and a numeric keypad will popup allowing numeric data entry.
Editable fields can be identified by the black box surrounding the parameter.

For example to change the Network Mask variable on the IP Address page. First touch the
I/O button once, followed by the Ethernet button. Now double touch the value to the right of
the parameter name text. Now enter the desired value using the number pad and press
ENTER.

On pages utilising toggle switches to control parameters, touch the right side of the switch to
move the parameters state to the right and the left side of the switch to move the state to the
left.

To return to the default page at any time press the Menu button.

When operating as an ASHSCAN DUO the top button on the left side displays the Ash
Analyser menu structure and the second button displays the Moisture Analyser menu
structure.

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 The menu structure uses 4 buttons that are always available at the bottom of every window.
Each button displays a popup menu when pressed. Each popup menu is briefly described
below.

Figure 5.2 I/O Menu

The I/O popup menu is used to access various pages related to the various inputs and
outputs of the analyser.

Figure 5.3 Setup Menu

The Setup popup menu is used to access various pages that setup the operation parameters
and calibration of the analyser.

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 Figure 5.4 Tests Menu

The Tests popup menu is used to access diagnostic test routines.

Figure 5.5 Information Menu

The Information popup menu is used to display informational data such as current results.

The Menus have been laid out such that working from left to right on the menu buttons and
from bottom to top within each popup menu should step through the initial setup process in a
logical manner.

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 5.2 Pages
5.2.1 Ash Trends

Figure 5.6 Ash Trends

The Ash Trends page displays a historical graphical trend plot of the Time Smoothed Ash
and the Tons Weighted Ash. The buttons at the bottom of the trend have the following
functions.

<< and < move the current display window backwards in time to review historical data from
the last 48 hours.

>> and > move the current display window forwards in time, only functioning when the
current display is not showing current data.

Live moves the current display window to show the current live data.

In and Out change the time width of the display window.

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 5.2.2 SCA Data

Figure 5.7 SCA Data

The SCA Data page displays the data transmitted from the SCA radiation detection system to
the HMI for ash calculation. The data is transmitted via RS-232 as a comma separated string.
The meanings of the values on this page are as follows:

Data String: This is the actual comma separated string as received by the HMI before any
processing has occurred, it should consist of 12 parameters separated by commas.

Channel 1-6: The count rate measured for each channel, the count rates should always
decrease in magnitude as channel number increases.

Ratio: This value is used internally in the SCA to control the HV control algorithm.

HV Drive: This value is the control set point for HV generation.

HV: This is the actual measured HV that is being generated.

HV Adjust Float and HV Adjust Int: These parameters show the amount by which the HV
Drive parameter is being adjusted. The Int value is the actual adjustment as applied to the
HV Drive and is the Float value rounded to an integer. This value should be close to zero and
both positive and negative.

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 5.2.3 IP Address

Figure 5.8 IP Address

The IP Address page is used for setting up the IP settings for the HMI. The IP address,
Network Mask and Gateway IP can be set via the appropriate input fields. For these settings
to be applied the Apply button must be pressed. This will display the following popup:

Figure 5.9 IP Address Apply Popup

If you select Continue on this popup the settings will be applied and the HMI will restart, if
you select Cancel the values will not be applied and the popup will be dismissed.

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 5.2.4 Analog Outputs

Figure 5.10 Analog Outputs

The Analog Outputs page is used to setup and control the analog outputs of the ash
analyser. The Time Smoothed Ash is output on Analog Output 1 and the Tons Weighted
Ash is output on Analog Output 2.

The ash value represented by 4mA and the ash value represented by 20mA for each output
can be set using the appropriate field.

The behaviour of the Time Smoothed Ash output when the amount of material on the belt is
too high or too low can be set by the appropriate field. The output can be set to hold the last
ash or report zero for each condition independently.

The Cesium output is only shown on the HMI when the analyser is setup as an Ashscan
Duo.

The toggle buttons allow for manual control of the outputs, when in the AUTO position the
current value being output is displayed, when in the MAN position the output value can be
edited.

Figure 5.11 Analog Outputs in MAN mode

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 5.2.5 Digital Outputs

Figure 5.12 Digital Outputs

The Digital Outputs page is used to control the digital outputs of the ash analyser. Each of
the outputs can be set to one of three states AUTO, ON or OFF. In AUTO mode the state of
the digital output is controlled by the software logic, this should be the state for normal
operation. In ON mode the digital output will be on, in OFF mode the digital output will be off.
The modes are used for testing the digital output functionality during commissioning or
diagnostic procedures. In any of the modes the green lamp in the bottom right of each switch
shows the current output status, the lamp will be illuminated when the output is on.

On retro fit gauges configured with motor driven source drive mechanisms this page will
display a button marked Source Drive Control, this button will take the user to the following
page:

Figure 5.13 Digital Outputs

This page allows for direct control of the source drive and source clutch using the three-way
switches. To protect the drive from accidental overload it will only stay on for a short period
before turning itself off. The two buttons Turn On and Turn Off can be used to turn the
source on and off using the correct sequence of clutch and drive, and following the correct
logic for error detection. Under normal operation this process is controlled via the conveyor
running input.

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 5.2.6 Digital Inputs

Figure 5.14 Digital Inputs

The Digital Inputs page is used to control the digital inputs of the ash analyser. The
Conveyor Run and Tons Weighted Reset inputs can be set to one of three states AUTO,
ON or OFF. In AUTO mode the state of the digital input is controlled by the hardware status,
this should be the state for normal operation. In ON mode the digital input will be on, in OFF
mode the digital input will be off. The modes are used for forcing the digital input status
during commissioning or diagnostic procedures. In any of the modes the green lamp in the
bottom right of each switch shows the current input status, the lamp will be illuminated when
the input is on.

The Source Off, Source On and Heater inputs cannot be manually controlled but the status
is indicated with a lamp that is illuminated when the input in on.

5.2.7 Parameters

Figure 5.15 Parameters

The Parameters page has six buttons for accessing six popup windows, each dedicated to
various setup parameters.

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 5.2.7.1 Ash Alarms

Figure 5.16 Ash Alarms

The Ash Alarms popup is used to set the ash levels for which the High Ash Alarm and Low
Ash Alarm are triggered. These are digital outputs that are normally off when the ash value is
below the high level and above the low level. When the ash level leaves these bound the
appropriate alarm is set on and the digital output is set on. It is also possible to set a delay so
that the alarm is not set for a certain amount of time after the condition becomes true.

5.2.7.2 Limits

Figure 5.17 Limits

The Limits popup is used to set limits on the value of the inputs for which the material on the
belt will be analysed. If an input is below its minimum or greater than its maximum the
analyser will not calculate an ash result.

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 5.2.7.3 Calibration

Figure 5.18 Calibration

The Calibration popup is used to modify the ash calibration constants for 16 possible
calibrations and also to change which of the 16 calibration sets is currently in use.

5.2.7.4 Smoothing

Figure 5.19 Smoothing

The Smoothing popup is used to set the time smoothing period for the time smoothed ash
output. During normal operation the time smoothed ash is calculated every second but is
smoothed over a variable period of time that is set on this popup.

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 5.2.7.5 Radiation

Figure 5.20 Radiation

The Radiation popup is used to setup parameters related to the correct measurement of the
radiation count rates and the correction for miscounting of some radiation due to physical
effects. These parameters are setup during QA in the factory and should not be adjusted
without a full understanding of the way these values control analysis.

5.2.7.6 Misc

Figure 5.21 Misc

The Misc popup allows for the enabling or disabling of the DUO functionality in the software.
The ASHSCAN DUO is a modified ASHSCAN with microwave moisture measurement
technology built in. It also allows for the enabling or disabling of the source drive control
functionality used on some retro fit gauges.

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 5.2.8 Standardise

Figure 5.22 Standardisation Setup

For the ASHSCAN Ash Analyser to work the values of the radiation measurement must be
known for the empty belt condition, in a similar way to the tare weight of a scale. The
ASHSCAN has a built in procedure called Standardisation that must be performed on a
running empty belt.

The Standardise Setup page is used to setup this procedure. On this page the current
stored empty belt values for Cesium and Americium are displayed along with the value for
each currently being measured by the ASHSCAN. Finally the difference between those two
values is displayed. When first setting up the ASHSCAN the difference may well be high as
the correct values have not been measured, but once correctly setup the difference should
be quite small if Standardisation is performed regularly.

The Standardisation Period should be set such that it is a multiple of the belt revolution
time. The longer the standardisation period, the better the outcome of the standardisation
process.

To perform a standardisation make sure the belt is running and free of any material and
press the Start button.

Figure 5.23 Standardisation Running

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 When a standardisation is being run the above figure will be displayed. As the
standardisation proceeds the New Cesium and New Americium empty belt values will show
for the average of the standardisation so far. If either of the new values is more than 5%
different from the current value the text below the new values will be in red and say "New
standardisation is out of bounds" otherwise it will be green and say "New standardisation
within bounds". If at any time the process needs to be stopped, for instance if there is
material on the belt, the Stop/Start button can be pushed to pause the standardisation
process.

Figure 5.24 Standardisation Paused

Whilst the standardisation process is paused it can be restarted using the Stop/Start button,
the new empty belt values saved using the Save button or completely aborted using the
Cancel button.

Figure 5.25 Standardisation Finished

If the standardisation runs through to 100% the above figure is displayed. From this page the
new empty belt values can be saved using the Save button or the process can be completely
aborted using the Cancel button. If the new values are out of bounds when saving the popup
menu displayed below will be shown, allowing you to accept the new value despite being out
of bounds. If the new values are within bounds they are saved without prompting.

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 Figure 5.26 Standardisation Out of Bounds Save

5.2.9 Sampling

Figure 5.27 Sampling

The Sampling page allows for the collection of the analyser response during sample
collection for up to 20 samples. The Prev Sample and Next Sample buttons allow cycling
through the collected data for each of the 20 samples. When first setup only sample number
one is accessible. As samples are collected the next sample will be accessible. To collect the
analyser response during sampling simply press the Start Sampling button. At this point a
sample start time will be recorded and a mass weighted analyser response will start to be
calculated.

Figure 5.28 Sampling Running

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 During this time the Start Sampling button will not be shown and the Stop Sampling button
will be displayed. When the sampling process is complete press the Stop Sampling button
and a sample stop time will be recorded and the mass weighted analyser response will stop
being calculated.

Figure 5.29 Sampling Finished

The final result for each sample will appear like the figure above. If for any reason you wish
to clear all sample data and start from scratch the Clear Sample Data button can be
pressed. You will be asked for confirmation via the following popup menu.

Figure 5.30 Clear Sample Data

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 5.2.10 Calibrate

Figure 5.31 Calculate Calibration

The Calibrate page allows a lab result for each of the samples collected to be added to the
system and calculate a calibration to map the analyser response to the lab results. The Prev
Sample and Next Sample buttons are used to move through the available samples. For
each sample a Lab Result can be entered. It is also possible to remove a sample from the
calibration calculation using Enabled in calibration? button. This button is green when the
sample is being used and red when it is not. Pressing the button will toggle its state.

On the right of the page is an XY plot with analyser response on the X axis and Lab result on
the Y Axis. The set of green points are the samples currently in use for calibration calculation
and the red points are those samples not in use.

Below the plot are the results of the calibration calculation, a lope and offset, as well as two
measures of the quality of the calibration, the standard error and R squared.

To set the results of the current calibration calculation to one of the 16 calibrations, first
select the calibration you wish to change in the Current Calibration edit field, then press the
Set Calibration button.

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 5.2.11 Ash Results

Figure 5.32 Ash Results

The Ash Results page displays the current Time Smoothed and Tons Weighted Ash values
as well as the current Cesium and Americium values.

5.2.12 Moisture Menus (ASHSCAN DUO)

Figure 5.33 Moisture Results

Moisture 1 (read only)

Displays the percentage moisture as a rolling average over the “Smoothing 1” time period (set
on this page). This value is output to Analog 3.

Smoothing 1
Sets the analysis time for “Moisture 1” in seconds.

Moisture 2 (read only)

Displays the percentage moisture as a rolling average over the “Smoothing 2” time period (set
on this page). This value may be output to Analog 2.

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 Smoothing 2
Sets the analysis time for “Moisture 2” in minutes.

Figure 5.34 Input Setup

IN1 (read only)

Displays the measured value for the first microwave parameter.

IN2 (read only)

Displays the measured value for the second microwave parameter.

IN3 (read only)

Displays the measured value for the third input to the processor (this input is usually the mass
loading as measured from the cesium count rate).

IN4 (read only)

Displays the measured value for the fourth input to the processor. This may be any optional
input such as a belt scale or temperature measurement.

IN1 (2,3,4) Connected

Nominates that an input is connected to the corresponding analog input position on the
processor and that the user wishes for this input to be used.

IN1 (2,3,4) Type

Nominates whether the input is 0 to 20mA (0 to 5 Volt) or 4 to 20mA (1 to 5 Volt).

IN1 (2,3,4) @4mA

Sets the 4mA scaling factor for the corresponding input to the processor.

IN1 (2,3,4) @20mA

Sets the 20mA scaling factor for the corresponding input to the processor.

Conveyor Input
Used to tell the ASHSCAN DUO if there is a conveyor running digital input to the PLC, if the
input is present the ASHSCAN DUO will stop analysing when the conveyor is stopped. If there
is no input the ASHSCAN DUO will always analyse.

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 Figure 5.35 Input Setup

AO1 @4mA
Sets value of percentage moisture to be output over analog output 1 at 4mA

AO1 @20mA
Sets value of percentage moisture to be output over analog output 1 at 20mA

Action if Low
Nominates if the value for Moisture 1 should reset to zero or continue holding after a lower limit
has been exceeded for more than 10 seconds

Action if High
Nominates if the value for Moisture 1 should reset to zero or continue holding after an upper
limit has been exceeded for more than 10 seconds

AO2 Output
Selects which parameter to output on Analog Output 2.

Weighting
If the “Wtd” option is selected for AO2 Output, analog output 2 will be the weighted moisture
value. The weighting can be calculated on any of the inputs, usually Input 3 (mass loading of
material) or tonnage if a belt scale is connected to Input 4. A belt scale can also be connected
as a pulse input in which case TPulse is selected and a tonnage value for each pulse needs to
be input.
To reset the weighted average an input from the plant is required.

Pulse Value
Select the number of tons each pulse represents.

AO2 @4mA
Sets value of percentage moisture to be output over analog output 2 at 4mA

AO2 @20mA
Sets value of percentage moisture to be output over analog output 2 at 20mA

Action if Low
Nominates if the value for Moisture 2 should reset to zero or continue holding after a lower
limit has been exceeded for more than 10 seconds

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 Action if High
Nominates if the value for Moisture 2 should reset to zero or continue holding after an upper
limit has been exceeded for more than 10 seconds

Figure 5.36 Calibration

Offset
Sets the offset or ‘y-intercept’ for the calibration.

ASlope
Sets the slope for the first factor of the calibration, by default microwave 1-on-depth.

BSlope
Sets the slope for the second factor of the calibration, by default microwave 2-on-depth.

EB IN1
Sets the baseline response, or Empty Belt value for Input 1 for the selected calibration.

EB IN2
Sets the baseline response, or Empty Belt value for Input 2 for the selected calibration.

Moisture Equation Configuration

This page sets up the factors to be used in the calibration. It refers to this equation:

Var 1 Var 3
Moisture% = Offset n + ASlope n + BSlope n
Var 2 Var 4
Where Var1, Var2, Var3 and Var4 can be any of the four inputs to the processor or values 1, 10
or 100. By default Var1 is Input1 (MW1), Var2 is Input2 (MW2) and Var3 is Input3 (Mass
Loading). It is only in rare situations that this needs to be changed.

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 Figure 5.37 Configuration

Threshold
Sets the fraction of a second that all inputs must be within min and max limits for the 1 second
moisture calculation to proceed.

SH Tolerance
Sets tolerance in mA on the analog inputs. This is to allow for slight variation in analog signal
inputs. Out of range inputs will turn off the System Healthy relay.

System Timeout
Sets time delay for the System Healthy relay to turn off after a faulty analog or PLC battery
signal has been received.

Feed Timeout
Sets time delay before ASHSCAN DUO results hold or go to zero after an input goes outside
the min or max limits.

Figure 5.38 PLC Info

PLC Version (read only)
Displays the program version that is implanted in the processor

Date (read only)

Displays the creation date of the processor program

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 Figure 5.39 Limits

IN1 Min
Sets the minimum limit for IN1, the first microwave parameter

IN1 Max
Sets the maximum limit for the IN1, first microwave parameter

IN2 Min
Sets the minimum limit for the IN2, second microwave parameter

In2 Max
Sets the maximum limit for the IN2, second microwave parameter

IN3 Min
Sets the minimum limit for the third input to the processor

IN3 Max
Sets the maximum limit for the third input to the processor

IN4 Min
Sets the minimum limit for the fourth input to the processor

IN4 Max
Sets the maximum limit for the fourth input to the processor

DAN JASIECKI

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 COMMISSIONING AND CALIBRATION
The ASHSCAN is tuned and tested as part of the manufacturing process; however all
applications require specific calibration settings. Once the analyser has been installed by the
client, arrangements should be made for a Commissioning Engineer to carry out
commissioning and calibration procedures. Alternatively, this procedure may be followed:

5.3 Power-Up Checks

After powering up the ASHSCAN:

• Check for a green light on both the 24V and power supply, indicating that 110/240V
AC supply is present.
• Check the 24V rails on the terminal strip. (See Section 4.2).
• Check that values appear on the HMI display when viewing the SCA Data page.

5.4 Empty Belt Standardisation

So that the influence of the conveyor belt upon the analysis of the material is eliminated, it is
necessary to standardise the system against an empty belt. Performing this step correctly is
crucial to the analyser’s performance.

The following steps are required:

• After initial power up and before commencing any standardisation, the analyser
needs to get to its normal operating temperature range of around 40 degrees Celsius.
You should allow between 30 to 50 minutes before commencing standardisation. The
operating temperature can be observing the display on the temperature controller in
the cabinet.

• Turn the source on using the shutter control lever. Verify that the High Voltage locks
on and is stable by viewing the HV value on the SCA Data page.

• On the Standardise page set the Standardisation Period to 300s or a multiple of

the belt revolution time and make sure the Americium and Cesium values are stable
on a running empty belt. Press the start button.

• The standardisation will proceed. Follow the description of the standardisation

procedure in 5.2.8.

5.5 Online Calibration

Before commencing the online calibration procedure, it is important to arrange for a

laboratory to analyse the samples in a consistent, accurate and timely manner. Similarly, it is
also important to arrange for plant conditions to be altered in order to create a range of ash in
the material.

At least 20 samples should be collected in order to form an adequate basis for the
calibration. The amount of necessary samples will depend upon the availability of samples
with a range of ash content. Ideally the samples should reflect the total range of ash content
that will be present during normal operation.

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 The objective of sampling is to collect representative samples. The location of the ASHSCAN
and the design of the process will greatly affect the sampling options. In fact, it may not be
possible to sample in a representative manner. Whatever the scenario, every effort must be
made to eliminate as many errors as possible.

Each sample should be collected over a 15-minute period and consist of a minimum of 15
primary increments. Secondary sampling may be required if the sample mass is too large.
Refer to the appropriate ISO sampling standard.

The procedure in 5.2.9 and 5.2.10 should be followed for the full set of 20 samples.

5.6 Static Calibration

While a static calibration is not as ideal as an on-line calibration, it can be very useful to
provide a relatively quick calibration for a wide range of ash. In many processes it is very
difficult to obtain a large variation in ash during the commissioning phase.

• Approx 20 samples should be prepared. The sample size will depend upon the typical bed
depth to be measured, but as a general rule should be large enough to fill a 20 litre bucket.

• Ensure the conveyor belt is stationary, clean, and appropriately isolated so that there is no
possibility of the conveyor accidentally starting and endangering personnel.

• The first sample should be presented under the analyser. Ensure the profile of the material
is even and typical of what will be presented to the analyser when operating on-line.

Proceed with the process described in 5.2.9 and 5.2.10, presenting each sample for >5
minutes each.

6 MAINTENANCE
The ASHSCAN electronics are a robust and reliable system that will provide precise ash
measurements of the material for which it has been calibrated. However, like any precision
instrument, it requires occasional maintenance and recalibration.

6.1 Recalibration
It is recommended that the system be recalibrated on a monthly basis or when a process
variable is significantly altered. Typically the effect of belt wear and electronics drift results in
an error of approx 0.1 to 0.2% total ash over the course of a month. The recalibration
process is identical to the procedure described in Chapter 0 on page 23. This work should
take approximately 1 hour.

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 7 APPENDIX
7.1 Typical Results
The following data is from a typical coal wash plant. The first plot, Figure 7.1 ASHSCAN
result against laboratory result, is a plot of the calibrated ASHSCAN ash result against the
ash value determined by laboratory analysis. The second plot, Tracking plot of ASHSCAN
result against laboratory result by sample, is a tracking plot of the same data, plotted against
sample number.

Figure 7.1 ASHSCAN result against laboratory result

Figure 7.2 Tracking plot of ASHSCAN result against laboratory result by sample

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