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Tecnetics Industries Tecweigh 20, Operation Manual

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Tecnetics Industries Tecweigh 20 Operation Manual Download Page 60

 

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9.02

 

Electrical troubleshooting  

This section provides methods of diagnosing lower level electrical problems. If this is a first time 
installation, verify that it is correctly wired and that all wires are secure in their terminals. For 
reference for the following paragraphs, the following three figures show the layout of the MP400 
PCB and the SC300 and SC400 signal conditioner PCB’s. 
 
 
 
 
 
 

 

 
 
  

  

 

 

 
 
 
 
 

 

MP400 Main 

Processor PCB 

Summary of Contents for Tecweigh 20

Page 1: ...re Version 8 XX MP400 main PCB Signal Conditioner Model SC300 WY15 WY25 HY15 HY25 SC400 WY10 WY10HD WY20 Tecnetics Industries Inc Manufacturer of Tecweigh Products 1201 N Birch Lake Boulevard Saint Paul MN 55110 Ph 651 777 4780 Fax 651 777 5582 www tecweigh com Tecweigh 20 WP20 WY15 P N 20984330 Last Update February 16 2012 WY10 HY15 ...

Page 2: ... 1 ...

Page 3: ...ls 12 3 04 Speed sensor installation WY models 13 3 05 Modular Scale Description HY models 14 3 06 Idler Preparation HY models 14 3 07 Scale Mounting HY models 15 3 08 Speed Sensor Installation HY models 17 3 09 Tecweigh 20 WP20 installation 18 CHAPTER 4 WP20 System Wiring 20 4 00 Wiring precautions 20 4 01 Tecweigh 20 WP20 wiring 20 4 02 Load cell wiring WY15 and WY25 22 4 02 1 Load cell wiring H...

Page 4: ...0 CHAPTER 8 Serial Communication 52 8 01 Overview 52 8 02 Automatic transmission 52 8 03 Manual transmission 53 8 04 Tecweigh Protocol 54 8 05 Remote calibration 54 CHAPTER 9 Troubleshooting 55 9 01 Status messages 55 9 02 Electrical troubleshooting 59 9 03 Operation troubleshooting 63 9 04 Auxiliary outputs troubleshooting 64 9 05 Load cell testing replacement 66 9 06 LVDT testing replacement 67 ...

Page 5: ...ations Use caution at all times when transporting rigging or hoisting scale carriages Mishandling can cause damage and or injury to personnel Remove the calibration weights during transport to prevent damage to the scale and also to prevent the weights from falling 1 04 Electrical Codes WARNING DANGER Follow all local electrical and safety codes as well as the National Electrical Code NEC and the ...

Page 6: ...ironments within a temperature range of 32 104 degrees Fahrenheit 0 40 degrees Celsius and a relative humidity less than 80 Although the equipment will operate outside this temperature range the accuracy of the equipment might be affected If the equipment is to be stored for an extended period of time keep it in a cool dry area and do not expose the shipping crate or pallet to the weather unless c...

Page 7: ...al hardware version 00 and initial firmware version 00 SC300 02 01 A 300 series SC Signal Conditioner on its second hardware version 02 and first firmware version 01 Tecnetics Tecweigh Service Department contact information Phone 651 777 4780 General number 651 233 1946 Service Department 651 233 1976 Parts FAX 651 777 5582 Email svobodac tecweigh com Service Department Tecweigh web site www tecwe...

Page 8: ...gh scale model was purchased Models WY10 and WY15 replaces one idler while the WY20 and WY25 replaces two idlers The speed sensor wheel rides on the return side of the belt to indicate the speed the belt is moving Load cells or LVDT sensors on the scale carriage measure the weight of material on the belt The weight and speed signals are sent to the signal conditioner mounted on the scale carriage ...

Page 9: ...t it collects and electronically conditions the material weight and belt speed signals and secondly it detects problems at the scale such as faulty weight or speed sensors The weight speed and scale status information is continuously sent to the WP20 via the standard RS485 serial communications protocol 2 08 Tecweigh 20 WP20 The WP20 is the microprocessor of the scale system All settings are store...

Page 10: ... 9 2 09 I O Quick Reference Guide ...

Page 11: ...e temperature wind and vibration The shimming and aligning of the idlers surrounding the scale is extremely critical because the weigh area must be slightly raised above the other idlers as indicated below Avoid the following Badly worn belts and splices Joined belts with different thickness Poor belt training or alignment Wind temperature or vibration extremes Material build up on belt idlers or ...

Page 12: ...rvice department for advice Section 2 01 DO NOT WELD ON OR NEAR THE SCALE 1 Mark the center of each roller on the scale idler three idlers before the scale and three after see below 2 Remove the idler where the scale will be located this will be used as the weigh idler 3 Remove the weigh idler s factory mounting pads 4 Center the weigh idler on the unpainted scale mounting pads and mark the locati...

Page 13: ...s across the idlers centered on the 3 roller center marks 4 Use elastic cords to hold the fish line in place at each end 5 Lower the calibration weight on the scale so the idler is at its normal running height 6 Shim the scale feet leaving a 1 16 inch gap between weigh idler and fish line 7 Use thin shims under the scale if necessary so it does not rock or pivot while laying flat 8 Tighten the sca...

Page 14: ...he wheel so that it is at least 6 to 12 inches from a return idler 1 Weld two of the supplied pieces of pipe to the conveyor stringers 2 Slide the spacers other pieces of pipe and speed sensor assembly onto the pivot arm 3 Tack weld the spacers so the speed sensor is loosely constrained but can still swing freely The heavy duty SS11 speed sensor Since most brands and styles of conveyors are constr...

Page 15: ...nd HY25 3 06 Idler Preparation HY Models After finding a suitable location for the scale reduce the conveyor belt tension Raise the belt so it is supported at least one foot above the idler where the scale will be located and also one foot above the two idlers before and after the scale Note if you are installing a dual idler scale model HY25 follow the same instructions as for the single idler sc...

Page 16: ...uld be used The spherical bearing mount may be detrimental in these application Applications with over 150lbs per foot of belt load 500Kg per meter Non top mounted CEMA idlers Flat carrier idlers or rollers Belt speeds over 600 FPM Belt widths over 48 1200mm Consult our factory for unique applications The HY15 modular scale is very adaptable If the application requires a symmetrical rigid mount si...

Page 17: ...th the inverted angle of the CEMA idler For HY25 dual idler installations repeat this process for the second idler Note that if the structure is truly flat and square the idler s that have now been mounted on the modular scale assemblies is approximately 1 8 higher than the adjacent idlers This is not always the case but the following instructions are based on this assumption Adjustments and shim ...

Page 18: ... idlers and tighten them down Re tension and align the belt so that it tracks in the center of the idlers Make sure all of the rollers are turning freely and are securely bolted down 3 08 Speed Sensor Installation HY Models The HY15 and HY25 standard RL200 speed sensor Since most brands and styles of conveyors are shaped differently it is difficult to give specific installation instructions for th...

Page 19: ... reasonably clean area away from severe heat and isolated from vibration Avoid areas of bright sunlight since the lighted displays may become difficult to read Where outdoor installation is necessary the WP20 should be mounted under a roof or dog house to provide rain and snow protection as well as shade Be sure to allow room for the enclosure door to swing out The WP20 can be located up to 4000 f...

Page 20: ... 19 ...

Page 21: ...iring diagrams provided with those specific devices for further information Section 6 02 defines the Parameter settings required to enable the features of the outputs used Scale to WP20 wiring Communications between the signal conditioner SC on the scale carriage and the WP20 is accomplished using the industry standard RS485 communications protocol At both ends terminal 10 is signal common termina...

Page 22: ...TPUT IS ACTIVE THAT MEANS A DC VOLTAGE IS PRESENT AT THE TERMINALS ENSURE THAT THE LOOP IS CONNECTED TO A PASSIVE LOAD resistive only OR DAMAGE WILL RESULT In most systems applications current loop isolation is essential to eliminate induced noise interference and also to eliminate ground loops when more than one load is in the loop The current loop outputs at the PCB are non isolated Consequently...

Page 23: ...ystem Jumper J23 shorts DI1 T3 to CM 10 which effectively deactivates the interlock when not in use remove the jumper to use the interlock feature 4 02 Load Cell Wiring WY15 WY25 The Tecweigh standard color code for wiring strain gauge load cells has changed from time to time because of load cell availability The following is a cross reference for the different load cell manufacturers that have be...

Page 24: ... 23 4 03 WY15 and WY25 Scale Wiring load cells ...

Page 25: ... 24 4 04 HY15 and HY25 Field Wiring ...

Page 26: ... 25 4 05 WY10 WY10HD and WY20 Scale Wiring LVDTs ...

Page 27: ... 26 4 06 Chart Recorder Data Logger using the 4 20 ma output ...

Page 28: ... 27 4 07 Chart Recorder Data Logger using the HFR output ...

Page 29: ... 28 4 08 Remote Rate Total Display 4 09 Remote Tons Counter ...

Page 30: ... 29 4 10 Radio Transceivers Local Scale Remote Processor ...

Page 31: ... 30 4 11 Radio Transceivers Local Processor Remote PLC PC or Remote Display ...

Page 32: ... 31 4 12 Radio Transceivers Local DC Generator Remote Processor ...

Page 33: ... 32 4 13 Radio Transceivers Local DC Generator and Processor ...

Page 34: ... 33 4 14 Multiple Processors to Tecweigh Multi Scale Display MSD ...

Page 35: ... 34 4 15 Interposing Relay External 120 vac Power 4 16 Interposing Relay Internal 30 vdc Power ...

Page 36: ...ow displays the material flow RATE over the belt scale MODE window there are four different modes in which the WP20 can run In each mode only certain information is displayed and only certain functions are available 1 Run mode displays the RATE units of measure the BELT SPEED and SCALE STATUS 2 Program mode displays the list of settings such as BELT SPEED RELAY OPTIONS etc 3 Simulations mode displ...

Page 37: ... permits access to the Parameter Table The Parameter Table contains all the values that define a particular installation such as Units of Measure Parameter 3 Belt Length Parameter 8 etc Once in Program Mode press the FUNCTION key momentarily to move through the Parameter Table one Parameter at a time Hold the down ARROW and press the FUNCTION key to move backward through the Parameter Table Hold t...

Page 38: ...an artificial RATE SPEED and TOTAL These values can be very useful when calibrating auxiliary equipment such as a chart recorder or a remote display Note that the scales do not need to be connected for the Simulation mode to work The selections are Simulation OFF or ON When ON the Simulated values are SPEED 376 feet per minute RATE the value entered in the Sim Rate Parameter Parameter 2 following ...

Page 39: ...he factory supplied calibration weight To determine this value weigh the chain in pounds or kilograms and measure its length in feet or meters Be sure to use only English or Metric units Then divide the weight by the length weight length and enter the resultant value 7 Wgh Span The Weigh Span is the length of the belt directly over the scale The weigh span equals the distance from the idler before...

Page 40: ... will be forced to zero when the actual RATE falls below AZT option one If Track Revs is not zero the FC20 will show a RATE of zero and do an Auto Zero calibration if the RATE falls below AZT for longer than the number of belt revolutions in Track Revs option two Refer to the following graph Assume the normal running rate is 200 tons per hour AZT is set to 10 tons per hour and Track Revs is set to...

Page 41: ...at will fit in the display a series of dashes will appear in the RATE window and looks like 15 Rate Damp Enter the damping factor for the RATE display Damping makes the RATE display more stable so the numbers do not change faster than they can be read The higher the Damping Factor the more stable the reading RATE damping does not affect the TOTAL or the accuracy of the system Note that the higher ...

Page 42: ... output terminals for this adjustment Increase the number to increase the current and decrease the number to decrease the current 23 Rate HTrm This Parameter allows fine tuning of the Rate 20mA Parameter A milliamp range ammeter will need to be connected to the output terminals for this adjustment Increase the number to increase the current and decrease the number to decrease the current 24 HFR Da...

Page 43: ...inuous on Start with 0 10 seconds and increase the value if the remote totalizer does not respond to the shorter pulse 30 RLY 1 TS When TPR is selected enter the frequency of the relay pulse or the total scaling For example set RLY 1 TS to 1 00 to close the relay every 1 ton Set to 01 to close the relay every 01 tons If RLY 1 TS is set too small and the RATE is too high there will not be enough ti...

Page 44: ...TS Parameter the relay cannot be closed longer than the time between pulses because that would be the equivalent of a continuous on Start with 0 10 seconds and increase the value if the remote totalizer does not respond to the shorter pulse 37 RLY 2 TS When TPR is being used enter the frequency of the relay pulse or the total scaling For example set RLY 2 TS to 1 00 to close the relay every 1 ton ...

Page 45: ...re Tec Std and Tec Old Tec Std provides more secure communications and Tec Old provides historical commands for older processors New users should use Tec Std and older existing installations should use Tec Old The request for data formats are the same for either protocol Refer to Section 8 04 for further details Field bus Protocol Cards The following four commands will only appear in the Parameter...

Page 46: ...e shooting Section 9 04 Scale is inaccurate section 56 Span Detect During an AUTO SPAN the processor waits for a change in the load cell signal before initiating the procedure This Parameter represents that change in load cell signal that is a requirement to start the AUTO SPAN procedure The factory setting should be adequate unless a calibration weight change is made in the field As a reference t...

Page 47: ...alibration Upon exiting the Program Mode the MODE window will display PARAMETERS SAVED Defaults before proceeding refer to Section 9 09 for a detailed discussion of the defaulting procedure Get Users when selected all the user s Parameter values that were previously entered will be retrieved Upon exiting Program Mode the MODE window will display MEMORY RESTORED It is highly recommended that once t...

Page 48: ... problem must be corrected before continuing Consult Section 9 08 scale data error for troubleshooting tips 7 02 LVDT Alignment for Scales with a SC400 Signal Conditioner WY10 WY10HD WY20 scales Only The WY10 and WY10HD have two LVDTs while the WY20 has four LVDTs Alignment of the LVDTs is critical for scale accuracy The LVDTs were aligned at the factory but it must be verified that they are still...

Page 49: ... all entered Parameters are correct the scale is installed properly and scales with LVDTs are in alignment the scale can now be calibrated Without calibration the scale will only approximate the RATE Note that an AUTO ZERO must always be done before an AUTO SPAN 7 03 1 Auto Zero AUTO ZERO is the first calibration step to perform This is defined as the WP20 displaying zero RATE when the belt is emp...

Page 50: ...N so as to re zero the belt due to zero drift Zero drift can be caused by material build up variation of belt tension or changes in the environment surrounding the scale Note 2 If the AUTO SPAN had to be started manually the Span Detect Parameter Section 6 02 56 needs to be changed so the next AUTO SPAN request proceeds to completion Change this Parameter after the calibration has been completed T...

Page 51: ...Mode go to the P P Wt Parameter Section 6 02 9 and enter the test material weight When Program Mode is exited the WP20 will automatically compare the material test total to the total that it calculated and then modify the ASC Parameter Section 6 02 55 accordingly P P Wt is automatically set to zero after the test is done The calculation is Post Actual Weight Pre WP20 Scale Weight x ASC New ASC If ...

Page 52: ...ny messages that appear in the MODE window If the system is determined to be running properly auxiliary equipment such as a recorder can now be added Consult Section 4 for wiring information Refer to Section 6 02 for configuration information to enable the WP20 to interface with auxiliary equipment Consult Section 8 for complete instructions on using the Serial Communication features ...

Page 53: ...cations related Parameters are correct for the system Station ID Parity Baud Rate Command Menu and Protocol See Sections 6 02 41 45 Important The plant remote equipment must also be operating with the exact same serial communications settings mutually compatible for the system to operate properly 8 02 Automatic Transmission When a Command Menu Parameter selected from the following table other than...

Page 54: ...75 four characters M one character Example 3 Station A has a RATE of 103 8 the TOTAL is 399 75 and the Command Menu parameter is 14 RATE Status TOTAL Station ID RATE Status TOTAL A one character 1038 four characters P one character 00039975 eight characters Carriage Return M one character 8 03 Manual Transmission If the Command Menu Parameter is set to 00 in the WP20 it will only send data after a...

Page 55: ...ng format to send the WP20 Remote Calibration commands Station ID Command Carriage Return TEC STD Command Action R Resets the TOTAL display Z Starts an AUTO ZERO Cycle S Starts an AUTO SPAN Cycle C Cancels an AUTO ZERO or AUTO SPAN Cycle Example To start an AUTO SPAN cycle at Station G send the following command Station ID Command Carriage Return G one character S two characters M one character TE...

Page 56: ...ermined Parameters will need to be re entered Refer to Sections 6 and 11 The MODE window can display many different messages that either indicate a potential problem or convey status information Some of them have already been discussed as needed throughout this manual The following discussion expands on some of those messages and also includes messages that have not yet been discussed The followin...

Page 57: ... 45 Important The plant remote equipment must also be operating with the exact same serial communications settings mutually compatible for the system to operate properly INTERLOCK OPEN Terminals T3 DI1 and 10 COM is an interlock that must be electrically connected closed for normal WP20 operation This is easily accomplished by installing a jumper on the pins at J23 which is located at the bottom c...

Page 58: ...C power version DC power to the WP20 is less than 9 VDC on the DC power version The WP20 AC power version is not producing 30 VDC across terminals 10 and 29 The WP20 DC power version is not producing 28 VDC across terminals 10 and 29 The cable between the WP20 and the signal conditioner is longer than 4000 feet Attached devices such as a chart recorder are drawing more than 1 amp total There is a ...

Page 59: ...f it is blinking rapidly If it is not blinking possible causes are a defective speed sensor or circuit the signal conditioner has failed or there is no DC power If the message appears even when the belt is moving check for the following adverse conditions The speed sensor wheel is not turning freely replace it if that condition exists A broken or shorted cable from the speed sensor to the signal c...

Page 60: ...roblems If this is a first time installation verify that it is correctly wired and that all wires are secure in their terminals For reference for the following paragraphs the following three figures show the layout of the MP400 PCB and the SC300 and SC400 signal conditioner PCB s MP400 Main Processor PCB ...

Page 61: ... 60 SC300 PCB WY15 and WY25 SC400 PCB WY10 and WY20 ...

Page 62: ...B This is also the DC power for the SC at the scale If 30 VDC does not exist across those terminals disconnect the incoming power and check for continuity across self resetting fuse F1 on the PCB F1 is a tiny white rectangle located at the very bottom of the PCB and just right of center If continuity does not exist contact the Tecweigh Service Department Section 2 01 for assisstance If 30 VDC is p...

Page 63: ...hen ON a portion of the voltage produced by standard and heavy duty speed sensors is grounded out which prevents damage caused by high speed belts This switch must be ON unless a magnetic pickup open collector or TTL type speed sensor is used Pos2 O C turn ON to add a pull up resistor when using an open collector type speed sensor Pos3 Noise when ON lower level electrical noise is grounded out but...

Page 64: ...gh Span in Since the Cal Factor and Weigh Span do not change the only possible problems with RATE will originate from the scale load and belt SPEED By using the calibration weight to load the scale and by simulating the belt speed the RATE should be steady If the rate is still unsteady it is most likely caused by vibration or excessive electrical noise See Section 9 03 paragraph other electrical p...

Page 65: ...g it 9 04 Auxiliary Outputs Troubleshooting Bench Test Mode All of the WP20 auxiliary outputs can be tested for proper operation using the Bench Test Mode While in Run Mode press and hold both the UP and DOWN arrows for five seconds to enter the Bench Test Mode Press both the UP and DOWN arrows momentarily to exit the Bench Test Mode In Bench Test Mode the following items are held constant 1 The R...

Page 66: ...displayed on the milli ammeter Now fine tune this value by adjusting the Rate LTrim Parameter Section 6 02 22 until the milli ammeter reads exactly 4 0 ma Next change the Simulated RATE to the value usually xxx tons hr that corresponds to a 20 ma output Now adjust the Rate at 20mA Parameter until approximately 20 ma is displayed on the milli ammeter Next adjust the Rate HTrim Parameter Section 6 0...

Page 67: ...not consult the supplier of that device otherwise contact the Tecweigh Service Department Section 2 01 for assistance 9 05 Load Cell Testing Replacement The following explains how to test a load cell s First stop the conveyor and disconnect power from the WP20 Then disconnect the green connector from the SC300 signal conditioner SC that the load cell wires are connected to If more than one load ce...

Page 68: ...stance values If even one resistance value varies by more than 20 replace that LVDT ORG YEL 70 Ω GRN BLK 100 Ω BLU RED 100 Ω If replacement of a defective LVDT is necessary use the following instructions Refer to the following figure First remove the LVDT wiring from the green connector Then remove the two bolts from the LVDT clamp Next remove the LVDT assembly from the carriage Now loosen the cla...

Page 69: ...xt step is to check several DC voltages at terminals on the PCBs First disconnect from the WP20 PCB the four wires or the plug in connector that connect the WP20 to the SC Next measure the voltages between the following terminals on the WP20 PCB The indicated voltages are what should be present at the terminals Terminal 10 CM is common 10 to 20 2 4 0 2 vdc 10 to 22 2 4 0 2 vdc 10 to 29 MP400 ac ve...

Page 70: ...nds When the Simulation OFF message appears that is verification that the Parameter Table has been accessed Now hold in the DOWN ARROW key and simultaneously press the FUNCTION key once The message Params NO CHANGE will appear Now press the SELECT key once The message NO CHANGE will flash Press the UP ARROW key twice and the flashing DEFAULTS message appears Press the SELECT key and it will stop f...

Page 71: ... 70 10 01 WY10 Dimensions CHAPTER 10 DIMENSIONS ...

Page 72: ... 71 10 02 WY10 HD Heavy Duty Dimensions ...

Page 73: ... 72 10 03 WY15 Dimensions ...

Page 74: ... 73 10 04 WY20 Dimensions ...

Page 75: ... 74 10 05 WY25 Dimensions ...

Page 76: ... 75 10 06 HY15 and 25 Dimensions ...

Page 77: ...peed Sensor Model Style WP20 supply voltage WP20 milliamp output set at SPECIAL ______________________________________________________ ________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ __________________________________...

Page 78: ...state N O or N C N O 29 RLY 1 Pls Relay 1 pulse duration seconds 1 00 30 RLY 1 TS Relay 1 totalizer state 000000 31 RLY 1 Low Relay 1 low rate alarm setpoint 00010 32 RLY 1 High Relay 1 high rate alarm setpoint 01000 33 RLY 1 Delay Relay 1 delay before alarm output seconds 10 34 RLY 2 Func Relay 2 output function TPR 35 RLY 2 Lgc Relay 2 logic state N O or N C N O 36 RLY 2 Pls Relay 2 pulse durati...

Page 79: ...nal user and no other express or implied warranties shall apply Excluded from the warranty are normal wear and tear removal or installation of warranty parts freight physical abuse or buyer caused damage including but not limited to such things as overloading of the system change in belt speed or damage resulting from over voltage lightning or water entry WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL O...

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