Belt-Way Scales Conveyor Belt Scale Product Manual Download

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Phone: (815) 625-5573

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Conveyor Belt Scale

Product Manual

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Summary of Contents for Conveyor Belt Scale

Page 1: ...815 625 5573 beltwayscales com sales beltwayscales com Belt Way Scales Inc Conveyor Belt Scale Product Manual Belt Way Scales Inc 1 Beltway Rd Rock Falls IL 61071 USA Phone 815 625 5573 www beltwayscales com ...

Page 2: ...Phone 815 625 5573 beltwayscales com sales beltwayscales com Page 2 of 44 Conveyor Belt Scale Product Manual This page intentionally left blank ...

Page 3: ... MUST be used as described in this manual Please note the labels on the integrator and in the manual denote dangerous voltage Failure to take safety precautions may result in serious injury or death The protective conductor terminal Earth Ground is signified by the following label It must be properly connected to earth ground per local electrical codes ...

Page 4: ...and Power Wiring 19 Sensor Board 20 Terminal Board with AC Power Supply 21 Terminal Board with DC Power Supply 22 Integrator Configuration 23 36 Setup Wizard 24 25 Scale Setup 26 Scale Calibration 27 Zero Calibration 27 Test Weight Calibration 28 29 Material Test Calibration 30 Totals and Diagnostics 31 33 Scale Totals 31 Scale Diagnostics 31 Device Setup 34 35 Plant Connect 35 Administration 36 R...

Page 5: ...tegrator AKA controller display indicator load cell assemblies and speed sensor The scale system processes speed and load signals to accumulate weight and calculate flow rate This manual covers the following belt scale models Model 45 Model 50 Low capacity Model 100 Model 150 Model 200 Medium capacity Model 350 Model 500 Model 1000 High Capacity This manual pertains to scales operating on firmware...

Page 6: ...nstalled on the conveyor to place the scale integrator up to 1000 ft from the scale IO Board The IO board allows the scale to interface with a PLC system automate loadout of trucks and rail cars or control a VFD to blend multiple products Outdoor Protection Enclosure Heavy duty enclosure offers extra protection for the scale integrator Includes power switch Wireless Multi Scale Remote Display The ...

Page 7: ...art Number BWIOKIT Field Installed Display 4 3 Color LCD Enclosure Cast Aluminum Operating Temperature 20 C to 45 C Required Power 12 24 VDC 55 Watts optional 110 240 AC power adapter Inputs 8 Load Cells millivolts 1 Speed Sensor 0 5 VDC Pulse 1 Angle Sensor 0 4 VDC Outputs 1 RS232 Printer Port 1 RS232 Display Port 1 Ethernet Port Modbus TCP 1 USB 2 0 Client Optional IO Outputs 4 20 mA outputs Ton...

Page 8: ...isconnect point such as a breaker or switch box is recommended Conformance to local electrical codes is required Digital Inputs IO option installed 12 24VDC 50mA sink Digital Outputs IO option installed 12 24VDC 100mA sink Analog Outputs IO option installed 4 20mA 24VDC powered loop Relay Outputs UL contact ratings IO option installed 220VDC 0 24A 60W 125VDC 0 24A 30W 250VAC 0 25A 62 5VA 125VAC 0 ...

Page 9: ...are Kit 1 Speed Sensor with mounting arm The dual idler scale consists of the following components 1 Integrator 4 Load Cell Assemblies 4 Mounting pipes 2 Hardware Kits 1 Speed Sensor with mounting arm Unpacking the Scale Each scale is comprised of at least three boxes 26 x 10 x 8 Integrator and Speed Sensor 26 x 10 x 8 Load Cells and Hardware kit 48 60 or 72 long boxes for mounting pipe and variou...

Page 10: ...im kit to adjust idler height 4 way screwdriver integrator mounting integrator door hose clamps Small Belt way screwdriver integrator wiring B Conveyor Design Recommendations The following design suggestions are essential for best scale accuracy and repeatability Reduce speed whenever possible to maximize belt load Slow moving heavily loaded belts work better than fast moving lightly loaded belts ...

Page 11: ...st not impact the belt near the scale D Define the Weighbridge The weighbridge idlers must be in good mechanical condition The weighbridge idlers must be the same trough angle and diameter The weighbridge idlers should be an equal distance apart Skirting should not make contact with the belt in the weighing area A single idler weighbridge consists of 5 idlers Scale must be installed on the center ...

Page 12: ...clearance between the load cell assembly and conveyor frame Do not overtighten the V Block bolts The bolts should be tightened turn after compressing the lock washer Position the load cell assemblies an equal distance from the conveyor frame This balances the load of the belt evenly between the load cells NOTE Stainless Steel Load Cells Do not use a full thread bolt or over tighten the existing V ...

Page 13: ...ill side must create an oval opening Center the pipe in the oval hole The load cell assembly must be free to move up and down slightly on the pipes This eliminates torque on the conveyor frame which allows automatic alignment of the weighing elements Install the four hose clamps onto the pipe with the screw fitting directly over the top of the pipe but do not tighten the clamps at this time Uphill...

Page 14: ... The centers of the leveling plates and pipes should measure 15 apart The holes should be at least 7 16 to clear the 3 8 16 U bolts H Remove and Modify Idler Unbolt idler from frame Remove the idler mounting feet to create clearance above the conveyor frame If the idler feet are not removed all other weighbridge idlers must be shimmed up 3 8 Ensure the idler is centered on the conveyor 15 ...

Page 15: ...pty belt must rest uniformly on all idlers within the weighbridge Use a minimum of three strings to align all 5 or 6 weighbridge idlers Shim idlers if necessary to bring them into alignment Use the 3 8 16 leveling bolts to adjust the scale idler height Tighten U bolts evenly so pipes remain parallel and oval clearance around bottom pipe is maintained Tighten the jam nuts against the leveling plate...

Page 16: ...the belt Avoid installing it near return idlers that may cause the wheel to bounce A small amount of weight may be added to the speed wheel arm to hold the wheel firmly on the belt Use two hose clamps to retain the mounting arm Secure the cable to the arm with cable ties Route the cables carefully along the conveyor frame so they are protected from falling debris and pinch points L Optional Angle ...

Page 17: ...ludes four mounting feet and four M6 x 1mm x 60mm screws with nuts to attach mounting feet to the Integrator Customer must supply fasteners from mounting feet to mounting location The integrator is weatherproof but should be installed in a protective enclosure whenever possible Physical damage to the integrator is not covered under warranty Do not install the integrator where it is subject to vibr...

Page 18: ... integrator board MAKE SURE THE USB IS INSTALLED BEFORE PROCEEDING WITH SCALE SETUP The scale will function without the USB but it records Important calibration and operating data USB Flash Drive 1 25 Amp Fuse The door pouch includes a test report and power over ethernet fuse for the terminal board The fuse should be installed only when the integrator is connected to a wireless transmitter ...

Page 19: ...a small screwdriver to carefully remove each connector Shield Wire Grounding Load Cell Speed Sensor and Angle Sensor wires MUST be connected as shown below Properly terminating the shield wire is required to reduce electrical interference Route the cable through the rubber grommet and loop the shield wire back out so it touches the aluminum connector ...

Page 20: ...rd Load cells the speed sensor and angle sensor connect to the sensor board 1 25 A Fuse Speed Sensor Wiring SIGA GREEN 5V RED GND BLACK WHITE Angle Sensor Wiring SIG GREEN GND WHITE 5V RED GND BLACK Load Cell Wiring SUP BLACK SUP RED SIG WHITE SIG GREEN USE LC1 LC2 FOR SINGLE IDLER SCALES USE LC1 LC4 FOR DUAL IDLER SCALES ...

Page 21: ...CK NEUTRAL WHITE EARTH GROUND GREEN The user must supply a minimum 16 gauge 3 wire power cord Connect to a properly grounded receptacle that is rated for at least 15 Amps at 110 VAC 24 VDC From Power Supply GND BLACK 24V RED 6 A Fuse NOTE FOR GENERATOR POWER A generator may produce unstable power during the startup or shutdown sequence The integrator is sensitive to power fluctuations and should b...

Page 22: ... DC Power supply is installed below the Sensor Board It boosts 9 24 VDC up to 24 VDC and regulates the voltage during engine cranking User should supply a toggle switch to isolate the integrator from the battery 9 24 VDC Landing Board 9 24 VDC VDC 15 A Fuse VDC BLACK 24 VDC RED Input from Battery Output from to Power Supply Power Supply To Integrator ...

Page 23: ... TWICE to reset the accumulated weight to 0 ENTER KEY Middle Arrow Press to select menu options or accept value changes ARROW KEYS Use to navigate menus Editing Numeric Values Various integrator functions require the user to edit numeric values Idler distance test weight calibration IP address etc When prompted use the arrow keys and follow the on screen instructions Editing Alphanumeric Values Va...

Page 24: ...1 for single idler scale and 2 for dual idler scale Load cell capacity found on Load cell assembly label 45 kg 100 kg 200kg etc one box will be punched out Idler spacing distance Measure as shown below Single Idler Scale Distance A Distance B Dual Idler Scale Distance A Distance B Distance C Conveyor Angle if an automatic angle sensor is not used Note If the conveyor angle is not known leave the a...

Page 25: ...Stacker Mobile track mounted Conveyor Make Conveyor Model Scale Setup Parameters Run Mode Number of Idlers Load Cell Size Units Distance Weight Rate Time Conveyor Angle Angle Sensor Installed YES Idler Distance Dist A Dist B Dist C Speed Sensor Decimal Places I O Option Board Installed Calibration Parameters Trim Factor Zero Value Belt Length Test Weight Calibration Test Weight Amount Belt Speed T...

Page 26: ...ing Number of Idlers 1 2 3 4 Load Cell 45 50 100 150 200 350 500 1000 kg 1000 lb Custom Distance Units English Metric Weight Units Tons Long Tons Pounds Tonnes Kilograms Rate Time Units Hour Minute Conveyor Angle 12 factory default or install Angle Sensor Idler Distance 48 factory default Speed Sensor Wheel Diameter 7 97 Pulses per Revolution 100 Decimal Places 0 0 0 0 00 0 000 applies to only to ...

Page 27: ...g a longer Belt length value in the scale This will improve the stability of the Zero Calibration Simply allow the belt to run 2 or 3 revolutions during the Length and Zero procedure ii Perform Zero Calibration from Keypad The Zero Calibration weighs one revolution of the empty belt and calculates a new zero weight Start the belt running empty and press the Zero Calibration button on the keypad Fo...

Page 28: ...rdware used to hang the weights from the load cells If the bar weight is unknown place the bar on the scale first and perform the zero calibration Then enter the exact weight value for the calibration At the end remove the bar and do a second zero calibration Test Weight Calibration Notes A test weight calibration is quick and easy but a repeatable material test is typically better than a test wei...

Page 29: ...he calibration Test Weight Amount Idler Distance Belt Speed 60 2000 Tons Per Hour Example 100 lbs 4 ft 400 feet per minute 60 2000 300 Tons Per Hour If the Trim Factor is not in that range navigate to Main Menu Totals Diag Live Weight The Live Weight shows the actual force on the load cells and Trimmed Live Weight adjusts the value by the Trim Factor If the Live Weight isn t close to the actual te...

Page 30: ...load 5 Compare the results to prove the scale is repeatable See the example below 6 Discard any tests that are unreasonably different from the rest Test 1 is excluded in the example 7 Navigate to Calibration Material Test 8 Enter the Belt Scale Weight Add tests 2 4 to calculate Belt Scale Total of 35 75 9 Choose the Certified Units Units in example are Tons 10 Enter the Certified Weight Add tests ...

Page 31: ...ther scale information i Scale Totals Navigate to Totals Diagnostics Totals Job Total Accumulates until it is manually reset Press Clear Weight twice to reset the Job Total to 0 Daily Total Automatically resets each day Weekly Total Automatically resets each week Monthly Total Automatically resets each month Yearly Total Automatically resets each year Master Total Does NOT reset ii Firmware Naviga...

Page 32: ...on Navigate to Totals Diagnostics Diagnostics Calibration Trim Factor Calibration Multiplier Should be close to 1 000 Zero Value Empty Belt Weight Typically 75 150 pounds This varies based on belt width idler spacing idler weight etc Belt length Voltages Navigate to Totals Diagnostics Diagnostics Voltages Load Cell Supply Typically 9 9 10VDC 5v Typically is between 4 95 5 10VDC ...

Page 33: ...ell is wired wrong or could be damaged Check weighbridge for anything pushing up on the idler Testing the Load Cells If mV readings are out of range use a volt meter to manually check the load cells Measure Actual Excitation Voltage at the Sensor Board Sup and Sup should should be 9 9 10VDC Measure Actual Load Cell mV Signal Set your meter to DC mV or DC Volts on auto ranging meter Place the Black...

Page 34: ... per hour The data can be manually synced to the USB drive by holding the down arrow for 5 seconds Insert the USB into a PC to view the files Files are stored at BeltwayScales Belt Scale Periodic Logs Backup Restore Function Navigate to Device Setup USB Report Data This feature saves the scale s current settings the USB It is ideal to create a backup file after the initial scale setup and calibrat...

Page 35: ...ales com Page 35 of 44 Conveyor Belt Scale Product Manual Contact Belt Way for more information about how to sign up Realtime Dashboard Historical Data iPhone Android App Production Reports Unlimited Scales Unlimited Users web based production monitoring ...

Page 36: ...e to Administration Security Create a password to restrict access to any desired scale function Any locked item requires the password Set the Time and Date Navigate to Administration Settings Time must be in 24 hour format The Date can be MM DD YYYY or DD MM YYYY format Scale Restart Navigate to Administration Restart This feature allows a user to restart the integrator firmware ...

Page 37: ...r mounting pipes X String Line Re string line when replacing idlers The idlers need to be the same type angle They also need to be square and equally spaced 1 16th Inch X Return Rollers Make sure they are in good condition and in position They must also be clean free from any material build up X Speed Sensor Check for wear flat spots on the and ensure that the wheel spins freely Make sure wheel re...

Page 38: ...ecks for an open circuit or broken wire If the cable is not damaged then the encoder board may be damaged Contact tech support for further assistance Angle Sensor Problems Compare the angle reading to an external angle finder Manually move the angle sensor up and down to see if the angle changes Check Angle Sensor Signal on Diagnostics Screen If angle sensor is connected make sure it is Installed ...

Page 39: ...avoid damage to the integrator Low power will cause the integrator screen to blink or go white A toggle switch should be installed so integator can be turned off prior to startup and shut down Error Messages No Comms with sensor Board Check supply voltage Sensor board drops out below 12 VDC Unplug small ribbon cables if using a junction box Check the cable running from integrator to the junction b...

Page 40: ...y parts or accessories which have been furnished repaired or altered by others so as in the opinion of Belt Way to have affected the same adversely Belt Way cannot and does not warrant or represent that machinery or parts furnished by it will handle specific materials or will produce specific results from such materials This warranty does not include damage to the product resulting from accident m...

Page 41: ...Y OTHER WARRANTY EXCEPT AS STATED HEREIN Exclusion of Consequential Damages BELT WAY SCALES INC SHALL IN NO EVENT BE RESPONSIBLE FOR SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES CAUSED BY ANY PRODUCT SOLD HEREUNDER WHETHER ON THEORIES OF BREACH OF EXPRESS OR IMPLIED WARRANTIES UNDER THE UNIFORM COMMERCIAL CODE STRICT LIABILITY NEGLIGENCE OR ANY OTHER LEGAL THEORY REGARDLESS OF WHETHER THE LOSS RESU...

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Page 44: ...573 beltwayscales com sales beltwayscales com Page 44 of 44 Conveyor Belt Scale Product Manual Belt Way Scales Inc 1 Beltway Rd Rock Falls IL 61071 USA Phone 815 625 5573 sales beltwayscales com www beltwayscales com ...

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