Telebelt Receiver Fuses

The e-stop circuit of Telebelts includes the HBC 735 radio receiver.  Actually, the e-stop circuit supplies power to the radio receiver. 

The images below, A370160 Pg 4 and Pg 5 show the circuit. To view at a larger size, click on each photo individually and they will open in a new window.

The 12V supply (red) goes through the e-stop stations to X81 pin 13.  X-81 is located on the right-hand (hinge side) of the control cabinet.  The power then goes through a fuse in the radio receiver and returns to X81 pin 5, and then through the e-stop stations to 4A17, the e-stop relay. 

 

 

 

This image shows the pin locations on X81.

 

 

 

 

 

 

The image shows the inside of the 735 radio receiver.  There are 4 fuses called out in the image, and their reference numbers correspond to the reference numbers in the image that follows.

 

They are:

42 = Power supply primary – 6.3A

43 = Power supply secondary – 1.0A

44 = Proportional output card – 12.5A

45 = E-Stop card – 4A

 

 

All of these fuses remove by pushing the end cap in slightly and rotating it to the left.  When the cap releases, a spring pushes it out a little.  The fuse will be attached to the cap.  You might need a coin or flat blade screwdriver to remove the cap.

 

RULE #1 – The problem is NOT in the radio system

 

Symptoms of a problem:  

 

E-stop will not reset and there are no LED’s lit on the receiver.

 

FUSE FAILURES IN THE RECEIVER ARE RARE.  Make sure you check all the way through the e-stop circuit (SEE RULE #1).  A blown 4F17 or a bad e-stop button causes the same symptoms.

 

If you have no power at pin X81-13, the problem is NOT in the receiver.  If you have 12V at X81-13 and zero volts at X81-5, check fuses 42 and 43 in the receiver.  Either one of these fuses, when blown, cause these symptoms.

 

Before replacing any fuses and turning power back on, find the short.  Likely places are faulty e-stop buttons or their boxes, or cable shorts between X81 and the radio receiver.  The 90’ cable can be substituted for troubleshooting purposes.

 

E-stop will not reset and there are LED’s lit on the receiver.

 

SEE RULE #1.  There are many possibilities, including:

  • Remote switch problem.  Verify with cable remote
  • See control box schematic:
    • Blown 3F64
    • 4K69 or 3K275 bad or unseated – confirm by flashing 4A17-T33 to 4A17-T-34
    • 4A17 connections bad
    • 4A17 defective
  • Problem with receiver cable from X81 – use 90’ cable to confirm

 

If all else doesn’t correct the problem, check 4A fuse #45 on the e-stop card.  If the receiver cover is off, you will see the “light show,” but attempts to reset will just cause relays on the card to click.

 

E-stop will reset and there are LED’s lit on the receiver.  Only non-proportional functions (toggle switches) work, but moving joysticks only cause the WBV (Boom/Outrigger) selector valve to move.  The actual function levers do not move.

 

RULE #1 might not apply.  This is opposite from when the pilot valve relay is bad, or when you turn on the transmitter but don’t reset.  In that case, the function levers move but the WBV valve does not.   Just to be sure, use the cable remote to confirm the radio problem, then check the 12.5A fuse #44 on the proportional output card.

 

Before replacing any fuses and turning power back on, find the short.  Likely places are faulty cables or plug connectors on MBC valve, or cable shorts between X81 and the radio receiver.  The 90’ cable can be substituted for troubleshooting purposes.

Tele-Teaching Telebelt Radio Remotes

There are some differences between Putzmeister boom pump remotes and Telebelt remotes.  Let’s look at them.

The early Telebelt radio functions were programmed via Tele-Teach battery, using buttons on the side of the receiver.  The newer “Ergonic” (single joystick) Telebelt remote controls are set up a little differently.

The Ergonic radio transmitters have no Tele-Teach buttons.  They are programmed with a Tele-Teach battery.  They are also different in that you Tele-Teach rabbit ONLY.  Do not Tele-teach snail, with the battery.  The minimums you set, in “rabbit,” will be the minimums used by “snail.”

NOTE:  Any Tele-Teach battery will work.  The older (yellow) Tele-Teach batteries have a lower amp/hour rating than the new (red) ones, and don’t last as long.  If you are using a yellow battery, make sure it is fully charged.  Use your standard battery for set-up, and then switch to the Tele-Teach battery for programming.

The procedure:

  • Properly set the Telebelt on outriggers.  Raise the feeder and transfer and set the feeder on the ground.  Raise the boom out of the transport rest, high enough to clear mufflers and inlets.  Allow room for boom movement in all directions.
  • Turn the radio off and insert the Tele-Teach battery.
  • Hold the “+” AND “-” buttons in while turning the radio on.  The green transmit light will be blinking twice as fast.

Each function, e.g. slew right, has to be set for minimum and maximum.  Only one function can be set at a time.  It is necessary to be able to see the Modular Boom Control (MBC) valve while programming.  So, let’s set “slew right” on the rabbit side.

  • Reset the e-stop with the horn-reset/outrigger switch.
  • Set throttle up to max
  • Set boom speed switch to “rabbit.”
  • While watching the WBV (selector) valve, move the joystick to the right
  • When the WBV moves to the boom position, stop moving the joystick farther and hold that position.
  • After a slight delay, the boom should start creeping to the right.  If it moves too quickly, use slight taps on the minus (“-“) button to slow it down.  If there is no movement, use slight taps on the plus (+) button.
  • Release the stick, then move it back to the start position to check the setting.  Very often the slight taps will take you too far.
  • When you are satisfied with the start point, slowly move the stick to full right, while watching the slewing valve.  The slewing valve must contact its mechanical stop AT THE SAME TIME you reach full right on the stick.
    • If it hits too soon, you have a narrow adjustment window in the stick, and the boom will be jerky.
    • If it doesn’t hit at all, you will not get full speed
  • While holding the stick full right, adjust valve handle travel with the plus and minus buttons.  PAY ATTENTION TO BOOM POSITION.  If you are getting close to something, like the feeder, slew left and start again.
  • After setting the maximum, recheck the minimum setting.
  • Repeat for the remaining 5 functions.
  • Turn the radio off.  The settings will be retained by the transmitter memory.
  • Remove the Tele-Teach battery and replace it with the regular battery.

NOTE:  Telebelts manufactured after early 2011 have “teachable” feeders.  Set the horn-reset/outrigger switch to outrigger and use the battery to Tele-Teach feeder slewing and elevate in “rabbit” mode, ONLY.  User-defined mode and “snail” mode have no effect on those speeds.

Now, before you stow the outriggers, let’s set slew right in the “snail” position:

  • Turn the radio on and reset the e-stop.
  • Switch the boom speed control to “snail.”
  • Move the stick to the right until the WBV valve engages.  The “creep” speed will be the same as it was in “rabbit.”  DO NOT attempt to Tele-Teach this minimum.  That will change the rabbit setting as well.  Center the stick.
  • To set the maximum speed for snail slew right
    • Move the boom speed switch up to the user-defined position and hold it there.  It’s spring-loaded.
    • Move the joystick right until the desired maximum speed is reached and hold the stick at that position.
    • Release the boom speed switch
    • Center the joystick.  Now, even if you move the joystick all the way right, the boom will only slew to the maximum you set with user-defined.
    • If you want to change the maximum, just repeat the procedure.
    • Repeat for the other functions.

Telebelt Ergonic Radio

Tele-Teach Battery

Telebelt Belt Card Adjustments

Putzmeister Telebelts give the operator the means to adjust the speeds of the main and feeder conveyors.  When adjustments are made to the belt speed knobs (potentiometers), a variable signal (4 to 10 mA) is sent to the 14A20 amplifiers. Depending on the input signal, these amplifiers supply 0 to 10 volts to the belt on/off relays, then to the 14A24 proportional amplifiers, known as belt cards.

The belt cards supply voltage to the motor control valves 14B36.  Feedback sensors on the motor control valves report valve position back to the belt cards.

Note: Older Telebelts have the belt circuits on schematic page 10. The components are 10Axx, instead of 14Axx.

All of the components in the belt card circuits operate on 24 volts.  The 12/24 converter is on the inside of the cabinet door.  The belt cards are protected by 24v fuses. All 24v conductors are purple.

There are two completely separate circuits (refer to A370160K, pages 6 and 14 shown here):

A370160KUNIFIEDCRTLBOX 06

A370160KUNIFIEDCRTLBOX14

Main belt:  A43.1,  14A20.1, 6K360, 14A24.1, 14B36.1

Feeder belt: A43.2, 14A20.2, 6K361, 14A24.2, 14B36.2

Older TB-105’s using schematic A383009 have the same components on pages 6 and 10. The component numbers are 10A20.1,2, 10A24.1,2 and 10B36.1,2

The belt cards have indicator LED’s and adjustment screws as shown.

TelebeltBeltCard

Telebeltbox

TelebeltBoxCloseUp

Belt card adjustment may be required for component wear or replacement.  If the belt cards were swapped for troubleshooting, and not put back where they came from, adjustments could be off.

ADJUSTING CARD SETTINGS

The following outlines the adjustment of the four adjustable values of the belt cards.  All values INCREASE by turning CLOCKWISE.

Ramp Adjustments

“Ramp Up” controls the time it takes the belt to accelerate to its set speed, and “Ramp Down” controls the time it takes the belt to decelerate to a stop. Adjustment is from 0 –5 seconds.  Care must be taken if adjustment is made, since it is possible to have the feeder in a ramp cycle while the main is not running.

Factory setting:

1. Decrease all ramp screws (counterclockwise) to zero

2. Set ramp down on both cards to two full turns open (clockwise)

3. Set main ramp up to four full turns open (clockwise)

4.Set feeder ramp up to six full turns open (clockwise)

To be sure which way to turn the screws, remove a card and look at the adjustable resistor connected to the screws.  Turn the screws counterclockwise so the sliding “slugs” in the resistors move to the end away from the black face plate of the card. There are no stops, so there is no way to turn too far.  This is the zero point in step 1.

Max

The gain “MAX” screw adjusts the gain of the belt speed knobs.  To check these adjustments, time the belts while running them at full speed with the manual by-pass.  Next, run the belts with the remote to see if the same speed is reached.  If the belt is slower, increasing the gain will speed the belt up.

STOP increasing the setting when the belt doesn’t go any faster.  You can determine this by timing the belt, or just go by the sound of the belt.  Turning the gain screw up too far narrows the adjustment “window” on the belt speed knobs.  Therefore, if you have a belt that doesn’t run until “3” or “4,” and full speed is reached at “6” or “7,” set the knob at “10” and decrease the gain setting until the belt starts to slow down.  This will open the “window” back up.

Zero

The zero screw calibrates the position of the feedback sensor.  Whenever the e-stop circuit is reset, the LED’s on the belt motor controllers will be on.  The ZERO setting positions the valves so that the belts are not running.

If the ZERO is too high, the belts can “creep” or run slowly when the belt switches are off.  Pushing an e-stop will stop the belts.  With the e-stop reset, adjust by turning the ZERO screw counterclockwise toward “-“, 1/8 turn at a time, until the belt stops.

If the ZERO is too low, a speed setting of “2” or “3” might be required to get the belt to move.  Increase the ZERO setting until the belt just starts, then back off until it stops again.  Subsequent adjustments might be necessary, due to change in resistance from the rollers, scrapers or skirts.

TelebeltRemoteControl