Sonic Ear

Service Manual

BV-H2535 GB
PASS - A service you can count on. Fast, comprehensive and anywhere in the world.
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cludes the entire range of services from simple inspections all the way down to a complete service program. Further information can
be found at www.schenckprocess.com.

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by Schenck Process GmbH, Pallaswiesenstrae 100, 64293 Darmstadt, Germany

Phone: +49 6151 1531-0 ; www.schenckprocess.com

All rights reserved. This documentation or excerpts thereof may not be reproduced in any form without prior written permission by
Schenck Process GmbH. Subject to change without prior notice.

Note: The original manual is in German. This is a translation.

(origin: 27021598813374859 V4)

 Contents

Contents

1 Safety ..........................................................................................................................................................1
1.1 Signal Words for Safety Warnings..........................................................................................................1
1.2 Signal Words for Application Notes ........................................................................................................2
1.3 Damaged/Defective Electrical Components ...........................................................................................3
1.4 Five Safety Rules of Electrical Engineering ...........................................................................................3
1.5 Hazard from Operation of the Ball Mill ...................................................................................................4
1.6 Noise Hazard ..........................................................................................................................................4

2 Function .....................................................................................................................................................5

3 Mounting the Sonic Ear ............................................................................................................................7

4 Connecting the Sonic Ear ...................................................................................................................... 11

5 Adjusting the Sonic Ear ......................................................................................................................... 13

6 Technical Data ........................................................................................................................................ 15

7 Rectifying Malfunctions ......................................................................................................................... 17

Index ........................................................................................................................................................ 18

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 Safety

1 Safety
Intended Use
The supplied system is to be used exclusively for the specified task. Any other use which exceeds this shall
not be considered part of the intended use.
The supplied system may be part of a more complex system. The system operator bears overall responsibil-
ity for the operating safety of the system.

Personnel
Preparation, assembly, commissioning, operation, maintenance and servicing may only be carried out by
qualified personnel.
All persons working on the system are required to observe the safety hints and know the parts of the tech-
nical documentation relevant to their work.
The operating company is responsible for instructing his operators to observe all regulations and instructions
given.

Moisture and Humidity

All of the scale components (particularly electrical components) should be protected from moisture and hu-
midity when the housing is open such as during service work. Beyond this, the housing's protection classes
should be complied with.

1.1 Signal Words for Safety Warnings

Potential dangers will always exist when working with technical devices. Dangers will arise if the machine is
incorrectly installed,
started up incorrectly,
operated by untrained personnel, or
serviced by unqualified personnel.
The following signal words in this manual indicate dangers that may arise when handling this machine:

Danger
The signal word DANGER identifies a danger with a high degree of risk that, if not prevented, will cause
grievous injury or death. Follow all instructions to prevent this danger from arising.

Warning
The signal word WARNING identifies a danger with a moderate degree of risk that, if not prevented, may
cause grievous injury or death. Follow all instructions to prevent this danger from arising.

Caution
The signal word CAUTION identifies a danger with a low degree of risk that, if not prevented, may cause a
minor or moderate injury. Follow all instructions to prevent this danger from arising.

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Safety

Representation of safety instructions

Fig. 1: Components Safety Instruction

1 Symbol 2 Signal word

3 Type and source of danger 4 Possible consequences if the danger is not pre-
vented.

5 Possible measures for preventing the danger.

1.2 Signal Words for Application Notes

Always Observe
The signal words ALWAYS OBSERVE identify situations in which material or environmental damage could
occur.
Example:

STRICTLY OBSERVE
Welding on load-bearing parts

TIP
The signal word TIP highlights information that can be utilized to treat the product economically and at an
optimal level of efficiency.
Example:

HINT
Take note of the measures listed below to rectify malfunctions.

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 Safety

1.3 Damaged/Defective Electrical Components

DANGER
Live damaged or defective components
Danger of life from electric shocks.
1. Have trained personnel ensure that all live components are undamaged
and in proper working order.
2. Have trained personnel replace damaged or defective electrical compo-
nents.

1.4 Five Safety Rules of Electrical Engineering

These fives safety rules must be followed in the order shown before work is begun on electrical systems.
Once the work is finished, they are to be applied in reverse order.

DANGER
Electric shock from live components
There is a danger of life from an electric shock.
Take all possible precautions to ensure safety before work is begun on
live components. Observe, among other things, the following:
1. Disconnect the components.
2. Secure against restart.
3. Ensure that the components have been de-energized.
4. For voltages above 1 kV: Ground and short-circuit cables.
5. Cover or shield adjacent, live components.

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Safety

1.5 Hazard from Operation of the Ball Mill

DANGER
Moving and driven parts
Danger to life from rotating or driven machine elements
Before performing any work on the machine:
1. Shut down the machine.
2. Allow the machine to come to a stop.
3. Secure the machine against restart.
4. Disconnect completely the machine from the power supply.
5. Remove pressure from any pressure reservoirs.
6. Comply with information in any further applicable documents.
Check the operation of re-mounted safety guards before restarting the
machine.

1.6 Noise Hazard

WARNING
Noise source
Possible damage to hearing as a result of loud operation.
1. Wear suitable protective equipment, such as ear protectors.
2. Provide suitable noise protection.

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 Function

2 Function
General Description

Fig. 2: Operating Principle of the Sonic Ear

The sonic ear consists of the microphone FOR 0052 and the converter FOR 0051 and analyzes the milling
sounds that emanate from ball mills. The sonic ear is suitable for ball mills in which the operational noise
level depends on the fill level of the mill.
Empty mill: loud, clear sound
Full mill: quiet, dull sound

Function
The operational noise level of the ball mill is recorded by the FOR 0052 microphone. The FOR 0051 con-
verter transforms the operational noise level into a direct current signal that is independent of the sound
pressure and frequency spectrum. A signal inversion makes the relation between signal level and mill fill-
level more intuitive:
Empty mill: low output signal
Full mill: high output signal

Application
The signal can be analyzed and used to control the ball mill in a process control system (PCS) or a host
system, a DISOCONT Master for example. The following can be implemented:
1. Fill level recording
2. Fill-level threshold signaling
3. Emergency intervention in the control
4. Material discharge control, principally as an underlay for a return material or mill output control (control of
the bucket elevator output).

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Function

Take the example of the noise pressure level of a twin-chamber sifter mill
The apparently linear course arose from the arbitrary intervals between EMPTY-NORMAL-FULL.

Fig. 3: Fundamental relationship between mill fill level and mill noise level

Level Mill fill level Noise Mill noise level

Fig. 4: Fundamental relationship between mill fill level and output current

Level Mill fill level C Output current

Off Mill stopped

The output signal of the mill when off is 20 mA.

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 Mounting the Sonic Ear

3 Mounting the Sonic Ear

Dimensions Converter FOR 0051

Fig. 5: FOR 0051 Converter Dimensions

1 75 mm 2 90 mm

3 62 mm 4 75 mm, assembly boreholes 8.5 mm

5 Cable opening M16

Dimensions Microphone FOR 0052

Fig. 6: FOR 0052 Dimensioning

1 300 mm 2 300 mm

3 62 mm 4 75 mm

5 190 mm

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Mounting the Sonic Ear

Components Converter FOR 0051

Fig. 7: Converter FOR 0051 Components

1 Housing/cover, circuit board inside 2 Cable opening for higher-order process

3 Cable opening for microphone FOR 0052

Components Microphone FOR 0052

Fig. 8: FOR 0052 Microphone Components

1 Opening Microphone FOR 0052 2 Shielding plate

3 Screws for removing the microphone cover 4 Boreholes 8.5 mm (M10)

5 Slot holes 8.5 mm (M10) 6 Cable opening

7 Microphone FOR 0052

The shielding plate (2) serves to screen the microphone from the noise of neighboring ball mills.

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 Mounting the Sonic Ear

Mounting the FOR 0051 Converter

Fig. 9: FOR 0051 Converter Mounting Boreholes

1 Mounting boreholes

1. Unscrew the cover. The converter circuit board is located beneath it.
2. Install the FOR 0051 converter. Use the mounting boreholes provided.

Installing the FOR 0052 Microphone

STRICTLY OBSERVE
Choose an installation location where the microphone, cable runs and con-
verter cannot be damaged by passing industrial trucks.

Fig. 10: Drawing for mounting the FOR 0051 microphone

R Rotational direction A Clearance 50 mm ... 100 mm

1 Material infeed 2 Ball mill

3 Microphone 4 Microphone frame

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Mounting the Sonic Ear

1. Construct a rigid frame for the microphone.

2. Switch off the ball mill before attaching the microphone. Secure the ball mill against inadvertent re-
start.
3. Before installing the microphone ensure that any protruding parts of the ball mill cannot damage the mi-
crophone during operation, such as the hinges on maintenance openings or the frames of other open-
ings.
4. Place the microphone at the position at which the grinding balls (most likely) will knock against the inner
surface of the mill AND ensure that this position is relatively close to the material infeed of the mill (refer
to the drawing).
5. Align the microphone so that a clearance of between 50 mm and 100 mm is maintained between it and
the wall of the ball mill.
6. Secure the frame.
7. Mount the cable conduits.
8. Feed the microphone cable through to the converter.

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 Connecting the Sonic Ear

4 Connecting the Sonic Ear

Electrical Connection
The sonic ear consists of the microphone FOR 0052 and the converter FOR 0051.

Fig. 11: Interconnection of FOR 0051 - FOR 0052, block diagram and connections

BP Bandpass filter Gain Adjusting the gain

S2 Bandpass filter frequency selector S3 Coarse adjustment via switch

PS Power supply R10 Gain fine adjustment

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Connecting the Sonic Ear

Fig. 12: Circuit board layout

BP Bandpass filter Gain Adjusting the gain

S2 Bandpass filter frequency selector S3 Coarse adjustment via switch

R10 Gain fine adjustment H1 LED

H2 LED

Component Setting options and displays

S2 Factory setting: 3 kHz

S3 Gain ranges
13 ... 150
100 ... 1200
30 .... 340

R10 Use a potentiometer for fine adjustment within the range previously set by switch S3.

H1 Display indicates sound pressure high (loud, clear sound), mill empty

H2 Display indicates sound pressure low (quiet, dull sound), mill full

Performing a Function Test after Installation

1. Turn on the power supply.
2. Perform the test while the housing is open.
3. Check the following items:
Without the influence of sound LED H1 should light up and the output current should be approx. 20 mA.
With the influence of sound LED H2 should light up and the output current should drop. Speak loudly into
the microphone to perform the test.

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 Adjusting the Sonic Ear

5 Adjusting the Sonic Ear

Adjusting the Sonic Ear
The adjustment is performed at the FOR 0051 converter. LEDs H1 and H2 indicate whether the mill signal
must be reduced or amplified.

Aim of the adjustment

The sonic ear should be adjusted to the loudness level that the ball mill emits when optimally filled (100 % fill
level). An output current of 10 mA or an output voltage of 2.5 V should correspond to a mill fill level of 100 %.
At this point both LED H1 and H2 should light up. By assigning an output current of 10 mA (2.5 V) to a level
of 100 % mill fill level there remains sufficient modulation reserve for overfilling.

Fig. 13: Suggested setting for linearization

LIN Linearizer in the external controller M % Percentage ball-mill fill-level in the external controller display

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Adjusting the Sonic Ear

Adjusting the Sonic Ear

Microphone FOR 0052 and converter FOR 0051 have been connected. Both microphone and converter
function normally.
The microphone housing has been closed. This is important as the closing the cover can alter the output
signal.
Supply voltage is present.

1. Check that the conditions listed above have been met.

2. Start the ball mill.
3. Fill the ball mill with as much material as required to ensure that the mill runs optimally (100 % fill level,
no overfilling!).
4. Operate the ball mill for a long period of time at 100 % fill level. Adjust the sonic ear during this period.
5. Open the converter housing to perform an adjustment.
6. Set gain switch S3 and potentiometer R10 such that the output current is approx. 10 mA or that the out-
put voltage is 2.5 V. The output filter of 10 s means that once the gain has been adjusted a period of at
least 20 s must pass before the next adjustment may be tried to allow the output sufficient time to reach
its final value.
The adjustment is complete once both LEDs (H2, H1) light up.
Increase the gain via S3 or R10 if LED H2 lights up only.
Decrease the gain via S3 or R10 if LED H1 lights up only.
7. Close the converter housing.
8. Then set the spread and the linearization of the signal in the host system.

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 Technical Data

6 Technical Data
Technical Data

Power supply 22 V ... 26 VDC max. 50 mA

or max. 50 mA
25 V ... 40 VDC

Output 0 V ... 5 V max. 4 mA

0 mA ... 20 mA max. 500

Input voltage Adjustable between 2.5 mV ... 250 mV For

Sound pressure level Adjustable between 85 dB ... 125 dB Ia = 10 mA

Bandpass Can be set to 1 kHz or 3 kHz

Output filter time constant 10 s

Display 2 LEDs; both light up when output current is within the range 9.6 ... 10.5 mA
Outside of this range one LED only will light up.

Protection class IP65

Temperature range -20 C 50 C

Housing Fiber-glass reinforced polyester

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 Rectifying Malfunctions

7 Rectifying Malfunctions
Potential problems resulting from external noise
External noises (e.g. neighboring mills) seldom influence measurement.
Corrective measures for the FOR 0052:
Place a felt mat with a hole for the microphone (10 mm) beneath the circuit board.
Fit the inside of the housing cover with an iron or lead plate (5 ... 10 mm).
Fill up the housing with an acoustic wadding.
Set up a second sonic ear in the mill hall and compensate in the host system for the negative influence.

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 Index

Index
Adjusting the Sonic Ear ..................................................................................................................................................... 13
Always Observe .................................................................................................................................................................. 2
Application........................................................................................................................................................................... 5
Caution ................................................................................................................................................................................ 1
Components Converter FOR 0051...................................................................................................................................... 8
Components Microphone FOR 0052................................................................................................................................... 8
Connecting the Sonic Ear.................................................................................................................................................. 11
Damaged/Defective Electrical Components ........................................................................................................................ 3
Danger ................................................................................................................................................................................ 1
Dimensions Converter FOR 0051 ....................................................................................................................................... 7
Dimensions Microphone FOR 0052 .................................................................................................................................... 7
Electrical Connection ........................................................................................................................................................ 11
Fig. 1: Components Safety Instruction ................................................................................................................................ 2
Fig. 10: Drawing for mounting the FOR 0051 microphone .................................................................................................. 9
Fig. 11: Interconnection of FOR 0051 - FOR 0052, block diagram and connections ........................................................ 11
Fig. 12: Circuit board layout .............................................................................................................................................. 12
Fig. 13: Suggested setting for linearization ....................................................................................................................... 13
Fig. 2: Operating Principle of the Sonic Ear ........................................................................................................................ 5
Fig. 3: Fundamental relationship between mill fill level and mill noise level ........................................................................ 6
Fig. 4: Fundamental relationship between mill fill level and output current.......................................................................... 6
Fig. 5: FOR 0051 Converter Dimensions ............................................................................................................................ 7
Fig. 6: FOR 0052 Dimensioning ......................................................................................................................................... 7
Fig. 7: Converter FOR 0051 Components ........................................................................................................................... 8
Fig. 8: FOR 0052 Microphone Components ........................................................................................................................ 8
Fig. 9: FOR 0051 Converter Mounting Boreholes ............................................................................................................... 9
Five Safety Rules of Electrical Engineering......................................................................................................................... 3
Function .............................................................................................................................................................................. 5
General Description ............................................................................................................................................................ 5
Hazard from Operation of the Ball Mill................................................................................................................................. 4
Installing the FOR 0052 Microphone ................................................................................................................................... 9
Intended Use ....................................................................................................................................................................... 1
Moisture and Humidity......................................................................................................................................................... 1
Mounting the FOR 0051 Converter ..................................................................................................................................... 9
Mounting the Sonic Ear ....................................................................................................................................................... 7
Noise Hazard ...................................................................................................................................................................... 4
Performing a Function Test after Installation ..................................................................................................................... 12
Personnel ............................................................................................................................................................................ 1
Potential problems resulting from external noise............................................................................................................... 17
Rectifying Malfunctions ..................................................................................................................................................... 17
Representation of safety instructions .................................................................................................................................. 2
Safety .................................................................................................................................................................................. 1
Signal Words for Application Notes ..................................................................................................................................... 2
Signal Words for Safety Warnings ...................................................................................................................................... 1
Technical Data .................................................................................................................................................................. 15
TIP ...................................................................................................................................................................................... 2
Warning ............................................................................................................................................................................... 1

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