Dodge CST Instruction Manual

CST Controlled Start Transmission Controls System
These instructions must be read thoroughly before installation or operation. This instruction manual was accurate at the
time of printing. Please see dodgeindustrial.com for updated instruction manuals.
WARNING: To ensure the drive is not unexpectedly started, turn off and
lock-out or tag power source before proceeding. Failure to observe these
precautions could result in bodily injury.
To avoid startup delays, this checklist should be completed
before scheduling the onsite engineering comissioning trip.
CST DRIVE SYSTEM
PRE-COMMISSIONING CHECKLIST
1. The input and output coupling alignments have been
completed.
2. All bolts in the base, CST and motor have been tightened to
specified torque values.
3. The CST reducers have been filled to the proper oil level.
4. The power source is connected to the primary motors and the
direction of motor rotation is the same as the directional arrow
on the CST input shaft.
5. The power source is connected to the CST electrical control
panel.
6. All input and output connections from the CST electric control
panel are properly terminated at the electrical junction boxes
on each CST and other field devices.
7. The emergency stop push buttons on the CST junction boxes
and the one on the electrical control panel have been tested.
8. Cooling pumps are rotating in the correct direction and have
been run for at least one hour with no significant leaks.
9. The pressure gauge on CST oil inlet manifold reads 20 psi or
higher.
10. Cooling fans are rotating in the correct direction with air
moving over the motor and then through the radiator.
11. Oil sump heaters, if installed, have been energized.
12. The motors and all electrical equipment are ready to be tested
in local control mode.
13. Spare 10 and 25 micron filters are on site.
14. The output coupling between the reducer and pulley shafts
has been left uncoupled.
WARNING: Because of the possible danger to person(s) or property
from accidents which may result from the improper use of products,
it is important that correct procedures be followed. Products must be
used in accordance with the engineering information specified in the
catalog. Proper installation, maintenance and operation procedures
must be observed. The instructions in the instruction manuals must
be followed. Inspections should be made as necessary to assure
safe operation under prevailing conditions. Proper guards and other
suitable safety devices or procedures as may be desirable or as may
be specified in safety codes should be provided, and are neither
provided by Dodge nor are the responsibility of Dodge. This unit and
®
its associated equipment must be installed, adjusted and maintained
by qualified personnel who are familiar with the construction and
operation of all equipment in the system and the potential hazards
involved. When risk to persons or property may be involved, a holding
device must be an integral part of the driven equipment beyond the
speed reducer output shaft.
Instruction Manual
WARNING: All products over 25 kg (55 lbs) are noted on the shipping
package. Proper lifting practices are required for these products.
CONTROLS OVERVIEW
Controls
A CST can be used for control of conveyor belt acceleration
during starts to minimize dynamic belt tension. The acceleration
ramp can be controlled to minimize peak tension and
compression transients during an empty or fully-loaded belt start.
On long conveyors, the results can be further improved by adding
an additional dwell period in the acceleration ramp (see Figure
1). The dwell period allows the initial belt slack to be removed,
and all the conveyor elements to attain a running condition at a
very low torque and speed before the acceleration is ramped up
with higher torque values. This eliminates overstressing of the
belt. The CST control system provides a communication port to
establish remote data acquisition with plant central computer
system.
Sensors
The sensors and transducers for monitoring the CST are part
of the control. On a typical CST, the following parameters are
monitored: sump oil temperature, coolant pressures, hydraulic
(disc pack) pressure, and output speed. The main drive motor
kW signal is fed to the PLC control system from the motor
control center. The kW transducer is calibrated for 0-150% of
the maximum kW rating of the motor. Other parameters, as
an OPTION such as belt speed (slip), belt tension, and motor
winding temperature, as well as motor and CST vibrations, can
also be monitored by the PLC control system. The PLC gives
a controlled output signal (4-20mA) to a specially designed
1
Figure 1 - CST S-Ramp Velocity Curve
with Linear Braking
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