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INDEX Section Page No. 1. Introduction 2. System Overview 3. Technical Specification 4. Installation 5. Operating Instructions 6. Preventive Maintenance 7. Symptoms and Faults 8. Factory Settings 9. Bill of material 10. Drawings and Documents 11. Your contact at Sartorius Project Manual for Belt Weigher SECTION 1 INTRODUCTION Project Manual for Belt Weigher Sartorius Mechatronics India Pvt. Ltd., headquartered at Bangalore, is 100% owned subsidiary of Sartorius AG, a 135-year-old company, with its headquarters at Gottingen, Germany. Its manufacturing activities include Mechatronics, Biotechnology, Hydro Dynamic Bearings and Environmental Technology. The Mechatronics division deals with almost all type of weighing system like … ULTRA AND HIGH PRECISION LAB BALANCES. GOLD AND CARAT BALANCES. PLATFORM SCALES. ELECTRO CHEMISTRY PRODUCTS. HIGHLY ACCURATE AND RELIABLE LOAD CELLS. WEIGHT INDICATORS ADVANCED BATCHING CONTROLLERS. WEIGHING ACCESSORIES LIKE MOUNTING KIT, JUNCTION BOX ETC. SOFTWARE (CUSTOM & STANDARD) TANK WEIGHING SYSTEM WEIGHBRIDGES BELT WEIGHERS BATCHING SYSTEMS HOPPER WEIGHING SYSTEMS WEIGH FEEDERS LOSS IN WEIGHT FEEDERS Weighing System For Special Application. Owing to its sustained accuracy and reliability, Sartorius have installation of various types of weighing system in almost all types of industries like, Steel, Power, Petrochemicals, Ports, RTO Check Posts, Fertilizers, Refinery, Petrochemical, Glass, Food & Beverage, Pharmaceuticals, Chemicals etc. Project Manual for Belt Weigher SECTION 2 SYSTEM OVERVIEW 2.1 System Description Belt conveyors are the fastest mode of material transportation in mining and Project Manual for Belt Weigher process industries where bulk material transportation is the important criterion. It is required to measure material transported over these conveyors, In order to achieve consistent quality in the process and accountability. Sartorius Belt weigher are designed to achieve this by delivering consistent accuracy and reliability. Belt weigher is basically a load measurement system installed in a conveyor belt. Which is designed to indicate and record the flow rate of the material conveyed from one location to another location? It will also record the total weight conveyed per unit time. High precisions Sartorius Load Cells are used for measuring the load. Reliable Speed measuring device is used to measure the belt speed. Using these two Parameters (Load & Speed) the material flow rate can be expressed in terms of tonne/hour. This flow rate output is integrated with respect to time for giving the continuous totalised value of the material conveyed Main features of Sartorius Belt Weighers are ™ Simple installation and easy maintenance. ™ Trouble free operation under severe environmental conditions ™ Practically no effect of belt tension on weighing ™ Remote data transmission ™ High reliability and accuracy ™ Easy integration with supervisory systems Note: The performance of Belt weigher is purely depends on the belt conveyor system, location of installation and the alignment of Adjacent Idlers. Hence it is recommended to read the Installation Guidelines prior to the installation. Belt weigher consists of the following components: ™ Load cells with Belt weighing frame to measure the load ™ Weigh Idlers ™ Speed measuring device (encoder) with mounting arrangement to measure the speed ™ Encoder mounting arrangement. ™ Controller to process load and speed data and display the Flow Project Manual for Belt Weigher Rate/totaliser The Formula to Calculate the Flow rate is Q = P x V x 3600 Q= Flow Rate in TPH P= Load in kg/m V= Speed in m/s Belt weigher Platform with Sartorius Load cell is mounted on the conveyor system to measure the load. Reliable speed-measuring device like proximity sensor / encoder / Analog DC Encoder is used according to the application / selection to measure the speed. By using the above formula the flow rate is calculated by Intelligent X4 Controller (PR 5510). 2.2 Basic Blocks of Belt Weigher The belt weigher consists of the followings 1.0 Belt weigher mechanicals ™ Weigh Frame ™ Loadcell mounting frame ™ Weighing Idlers ™ Pre/post carrying idlers ™ Encoder mounting arrangement. ™ Calibration rod 2.0 Load cell 3.0 Encoder 4.0 X4 Process Controller (PR5510/00) with following option cards ™ Control I/O 6/12 Opto (PR5510/12) ™ Analog out put (PR5510/06) 5.0 Encoder Interface Module (ST 5010/00) 6.0 Panel 1.0 Belt weigher Mechanicals: The Sartorius Belt weigher platform is a compact, rugged fabricated structural frame. This frame supports the weighing idlers and is isolated from conveyer stringer. Load cell is mounted Project Manual for Belt Weigher on load cell mounting frame. The weigh frame with weigh idlers is supported on load cell with loading pins/load buttons. The weighing idler /pre & post idlers are machined to limit the radial run out. Weighing Idlers EB Series Weigh Frame The encoder mounting idler is supported on a pivot frame with pillow blocks. The encoder is coupled to the wheel shaft. This assembly is mounted on or top of the return belt on the conveyor stringer. ™ Calibration Rod: These are machined out of MS rod, whose weight is proportional to belt load. Individual weight of rod is punched. This can be used to periodic verification of calibration status. 2.0 Load cell (MP 47): Load cells are heart of the system. They are strain gauge based transducers, which converts mechanical force (strain) into electrical signal (mV) when given an excitation voltage. Strain gauges are arranged in a wheat stone bridge network by bonding to the specially designed/machined steel membrane. This is housed in an SS enclosure with inert gas filled and comes with a protection of IP68.When load is applied the resistivity in strain gauges changes proportional to applied load. The change in resistance is converted to electrical signal by giving an excitation voltage. Load cell will have an integral 4 core cable of standard length. Two cores are connected for supply voltage to the load cell & other two for the measuring voltage from the load cell Project Manual for Belt Weigher 3.0 Encoder The encoder coupled to idler senses the speed of the conveyor. The encoder is a digital pulse encoder type whose output frequency is proportional to the speed of the belt. The encoder is excited with 5V DC supply from the controller. The pulse output is fed to the controller. 4.0 Weighing Controller The PR5510 X4controller is microprocessor based multitasking operator system. This controller is equipped with a high precision weighing point and analog to digital Converter. The controller has a VFD display and a multi foil keypad at front side and the process interface at rear side. The controller can be loaded with Belt Weigher application programs. Basic Features ¾ One internal weighing point, approved for OIML 6000d ¾ 13mm Vacuum Fluorescent display for weight ¾ Additional 2-line 5mm dot matrix, each for 20-digit alphanumeric. Project Manual for Belt Weigher text ¾ Programmable for messages, operator guidance, values... ¾ Front panel controls, multi-function keys and soft keys. ¾ Closed aluminum-steel housing, front panel protection type IP 65, IP 30 for the rest of the instrument. ¾ Suitable for panel mounting (inserted through the panel cutout and easy to by clamped from rear) ¾ Plugable rear panel connectors for load cell, in-output, communication and supply ¾ Compact wide-range supply 115…230V for electronic and load cell supply ¾ An optional “normal” PC keyboard (PS2) instead of the front panel keypad can be connected. ¾ A simple serial RS 232 interface is built in (Built-in) and available on the DSUB-9 socket. ¾ Configurable for e.g. printer, remote display, terminal, communication and Flash It (not for Modem) based on application program. ™ Control I/O 6/12 Opto (PR5510/12) This module converts the external binary process signals into the internal signal levels of the weighing controller or vice versa (DIGITAL INPUTS or DIGITAL OUTPUTS in short DIO)This module has 12 digital outputs for process control, galvanically isolated with passive opto- coupler outputs (max. 25mA) each with two pole potential free outputs and 6 digital inputs for process control, galvanically isolated by means of opto-couplers. The input signal is logic”0” with open input each with two pole potential free input. ™ Analog out (PR5510/06) The module is used for analog value of the displayed weight This is a single output 20mA (10V output only with external 500Ohm resistor. The range is 0/4…20mA configurable via software SETUP. This current output corresponds to error output & this is fed to drive for controlling the motor. ™ Built-in RS 232 : The controller communicates with LFD(optional) via built-in RS 232 after conversion to Current Loop by converter module as the distance is more. Project Manual for Belt Weigher 5.0 Encoder Interface Module (ST5010/00) Encoder interface is a module for dividing the frequency of the encoder output to required frequency .The input frequency is 0 to 10 kHz and output frequency is 0 to 55 HZ. The divider setting can be selected with the dipswitch selection depending on the requirement. This is also annunciation for power on, pulse out, Error and pulse IN and pulse OUT. If the frequency exceeds 55 Hz there is an error output. 6.0 Panel (ST5010/21) The floor mounted panel, with dimension (HXWXD) houses the following X4 Process Controller (PR5510/00) with option cards And Encoder Interface module (ST 5010/00) The remote panel also houses the switchgears like MCB, Relays, X4 controller, Terminal blocks, Annunciation Lamps, 24V DC power supply Unit & Service socket. The various input/outputs configured in the panel are as follows ™ Annunciations: • 24V DC Cluster LED lamps for BELT ON, FAULT & TOT. PULSE for each controller. ™ Analog Input/Outputs 1. Load cell Input : mV input from load cell corresponding to load on load cell. 2. Analog Outputs : 4-20mA corresponding to rate to customers PLC ™ Digital input/output 1. Inputs : Speed input : encoder (field) 2. Outputs: Belt ON : This output is given by the controller when the controller receives the speed Input signal from field. Totaliser Pulse : This is the totaliser pulse output. This interval can be set from the controller I.e. pulse for every 1, 2, 5 or 10 increment. Cumulative fault: This is output from the controller for ADC fault, belt overload, Belt under load. Belt Overload : This is output from controller if actual belt load is more than Project Manual for Belt Weigher the set value In the controller. Project Manual for Belt Weigher SECTION 3 TECHNICAL SPECIFICATIONS 3.1 Conveyor: Equip No : Conveyer No : Material : Belt Width in mm : Project Manual for Belt Weigher Bulk density T/m3 : Capacity in TPH : Speed in M/s : Conveyer belt weight : Load cell Type : Tacho Type : Make Calibration Rod/ : Equivalent Kg/Mt 3.2 Load Cell: Make : Sartorius Type Of Load cell : Bending beam type Type No. : MP 47 Housing Construction : Full stain less steel construction, hermetically sealed (IP 67), filled with inert gas 3.3 Junction Box: Type No. : ST 2620/13 MOC : Die Cast Aluminum Protection : IP 65 Painting : Powder Quoted Glands : 5 Nos, Double Compression 3.4 X4 Controller: Type No. : PR 5510/00 Material : Aluminum. Project Manual for Belt Weigher Protection Class : IP 30 Front Panel : IP65 Power Supply : 115-230VAC 50-60 Hz+10%/-15% max. 19VA Accuracy : 6000e OIML R76 min. verification interval 0.5µV Display : 7 Digit plus status symbols text:2 line, 20 characters. Load cell Input : 6 Wire or 4 Wire Load cell Supply : 12 VDC Minimum Load cell Impedance : 75 Ω. Conformity : EN61000-6-2 and EN61000-6-4 Vibration : According to IEC 60068-2-6 Electrical Safety : According to IEC 61010-1 Linearity : < 0.002% Resolution : 2.5 Mio.counts for 1 mV/V Input Signal Range : 0...36 mV Temperature Effect On Zero : < 0.05 µV / K RTI Temperature Effect On Span : < +/-4 ppm/K Measuring time : 10...160ms, adjustable Filter : 4-pole digital filter 0.1 to 5 z.. Operating Temperature : -10°C To +40°C Project Manual for Belt Weigher Interface : Built-in bidirectional serial interface RS 232, User selectable protocols: remote display, printer Keyboard interface PS2 Other Interface : - Serial Interface(RS 232/485) - 6 dig. In/12 dig Outputs(Opto) - 1 analog Output - 4 Analog Input /1 Output - BCD open emitter - BCD open collector - Ethernet - Profibus DP - Interbus S - DeviceNet - CC-Link Keyboard : Integrated Programmability : Freely, as per customers requirement Calibration & Configuration : Totally through software. 3.5 Encoder Interface Module: Model : ST 5010/00 Input Signal. : HT Push pull / RS422. : Low – 0 to 3V Output Signal High – 7 to 24V (X4/1713) Division Factor : 1 to 1024(in step of 1) Input Frequency : 0 to 10 kHz. Output Frequency : 0 to 55 Hz. Error Output : If the freq exceeds 55 Hz. : Power ON. Pulse In LED Indication for Pulse OUT Error Project Manual for Belt Weigher 3.6 Analog output Interface card: Model : PR 5510/06 : 1 current output 20mA(10V output only with No of outputs external 5000¥ resistor Output : Gross ,net weight or application dependent : 0/4—20mA,configurable through software Range setup Resolution : 16 bits binary,20.000 internal divisions Temp : <100ppm/k : @ 0-20mA; 0.04% Linearity @ 4-20mA ;0.02% Zero error : 0.04% Potential Isolation : Yes Cable length(screened) : 150m current output 3.7 Control I/O 6/12 Opto card: Model : PR 5510/12 No of inputs/outputs used : Input6 , output 12 : Low: 0—5V or open Input signal High:10—31V Passive external power supply required : < 7 mA @ 24V < 3 mA @ 12V protected against wrong Input Current polarity passive external power supply required Project Manual for Belt Weigher : Max.switching voltage:32V Output Max.switching current:25mA Voltage drop @25mA :3V 3.8 Encoder: Model No. : Make : Supply voltage : Output type : 3.9 Panel: Model : Mounting : Dimension : Paint shade : Display : : 7 Digit plus status symbols text:2 line, 20 characters, multiline VCF-display Inputs Power supply : 230V, 50Hz,1φ, AC to controller Load signal : corresponding to material load on the belt from load cell Speed signal : Corresponding to speed from encoder. Outputs Excitation : 12V to load cells. 5V to encoder Project Manual for Belt Weigher Potential free contacts : Belt ON. Fault. Totaliser pulse. Belt Overload. Analog output (4..20mA) : To customer’s PCS 3.10 Connection Details of Load cell: Red. : + supply White : - supply Green : + signal Blue : - signal Cable screen 3.11 Connection Details of Encoder: Pin No. Connection 12 : Vcc(+5V) 10 : Gnd 6 : 5 : A Project Manual for Belt Weigher SECTION 4 INSTALLATION Project Manual for Belt Weigher 4.1 Installation Precautions Shipment Verification: The EB Series weighbridge components are shipped from the factory as a single unit. Each item should be inspected as it is removed from the packing box. To avoid scale installation problems, please compare the site conditions with the EB Series installation drawings available. If you have any questions, please contact your Sartorius representative. Follow the installation procedure carefully and read the related documents. NOTE: Before installation, be sure to determine the ideal location of your EB Series Belt Weigher in relation to your conveyor system and refer the installation Guidelines Keep the following things in mind for achieving bets result out of the belt weigher. 1. The conveyor should have only splice joints and not metallic clamps. 2. Only one belt joint should be there in case of belt length up to 100 meters. 3. In addition to weighing idlers, two nos. of pre carrying & post carrying idlers should be machined in order to limit the radial run out. 4. Ensure conveyor inclination is limited according to material handled. This is to prevent material rolling back on the conveyor Project Manual for Belt Weigher 4.2 Installation Guide lines Installation Location The ideal placement of the Sartorius Belt Weigher depends on the conveyor system. This section provides guidelines to determine this placement. Fig-1 Project Manual for Belt Weigher NOTE: 1. Select a location such that external vibrations do not influence weighing zone. 2. Location of belt weigher should be minimum 5meters away from the skirt board, which allows the material to stabilize before entering the weighing zone. 3. Location should be 5 meters away from the tangent point (not on curvature zone). Belt could be lifted from the weighing idler at the concave curvature zone and at convex zone there could be an extra pressure on the weighing idler. 4. For different types of inclined conveyors, the distance of Belt weigher location from discharge pulley is given below. 20°troughing idler should have minimum 4m distance from discharge pulley. 30-35° troughing idler should have minimum 5m distance from discharge pulley. 45° troughing idler should have minimum 7m distance from discharge pulley. The above distances are required in order to provide sufficient transition distance before the belt enters the pulley. The troughing belt has to gradually flair out as it approaches the pulley. Pre Requisites For Accuracy 1. Belt Should have one Vulcanized joint upto 100 mt 2. Location of Belt Weigher is to be away from a) Feed Zone (Skirt Zone) b) Curvature c) Very close to discharge pulley d) Vibration Zone 3. Weighing Idler/ Pre & Post carrying Idlers to be machined to limit radial run out 4. Accuracy Criteria a) Min flow rate should be 20% of max/DSN flow rate. b) Minimum totalized load should be ≽ of the following 1. 20% of load totalized in 1 Hr at max flow rate 2. Load obtained at max flow rate for one revolution of belt 5. Customer to make provision for taking drop test. 5. Weighing Section Project Manual for Belt Weigher Fig-2 The effective bridge length extends across a total of six idler stations, i.e., incl. two each preceding and succeeding of the two-idler weighbridge (cf. FIG. 2). It is important that all six idler stations be situated within a single section of the conveyor flight (stringer). Otherwise, the sections involved would have to be welded together. After the six idlers are to be properly leveled ,minimum 4 nos of idlers (2 Weigh Idlers,1 No pre and 1no post carrying idlers) to be machined to limit radial run out. 4.3 Installation Procedure After identifying proper location, remove four idlers in case of existing conveyor (not applicable in case of new installation). ™ Weighing Frame, weighing Idler and Load cell: Assemble the weigh frame with 2 nos ‘T’ Section Across. Position the ‘T’ Section Across on the conveyer stringer. Mount the load cell below ‘T’ section and mount load force measurement bolt through load cell on weigh frame .Ensure direction of load cell in Fig4.Mount the weighing idlers on the weighing frame. Align the weigh idler with a suitable string, with respect to pre, post idler in vertical side ensuring all idler top level in same by adjusting load measurement system. While aligning ensure these four idlers 3-5mm above normal idlers. Load force measure bolt can be further adjusted (later after the completion of wiring) in case of alignment. Project Manual for Belt Weigher Fig-3 With due attention to the direction of belt travel (FIG. 3, pos. 1), slide the weighbridge into the belt structure from the side. If necessary, relax the belt or raise it by inserting blocks. The support ‘T’ section (2) lies across the stringer (3). The section must be in parallel with each other and at right angles to the stringer ensuring the direction of belt as shown in fig.5 .In the above figure position (4) is weighing idler. Fig-4 ™ Mounting of Encoder: The Encoder is used for determining the belt speed. It produces pulses proportional to the speed of the conveyor. Encoder is mounted on a separate wheel on the Project Manual for Belt Weigher conveyor belt. The mounting arrangement is given IN Fig- 5. Couple the Encoder to the wheel and make sure that the Encoder rotates smoothly. 1. Assemble the Tacho wheel with pillow block and encoder on the pivoted frame with a proper coupling. 2. Assemble the pivoted frame to the tacho mounting channel. 3. Assemble the Encoder mounting channel to the conveyer stringer. Fig-5 ™ Weighing Controller Install the weighing electronics unit in a clean, closed room, where it will not be exposed to direct sunlight or the effects of weather. Do not install the weighing electronics unit in the near vicinity of contact controls, thyristor convertors, etc. When installing the weighing electronics unit, ensure good accessibility and easy reading of its digital display. 4.4 Cable Routing For long-term trouble free operation of belt weigher, cable routing should be done keeping the following points in mind. 1. Never run any of the signal cables along with a power line. The distance of the signal from a power line should be at least one meter. 2. Do not route signal cables beside relays, or electrical equipment. 3. Do not expose the cables to sun or rain as this may cause deterioration of insulation resistance. High insulation resistance is necessary for accurate operation. 4. Use a small piece of flexible conduit at the cable termination point, in order Project Manual for Belt Weigher to avoid straining. 5. Joining of cables is to be done either by proper soldering or by cable connectors and not by twisting them together. At the joining point they are to be properly insulated by insulation tape of high quality. 6. For trouble free operation of the equipment proper earthing is essential which improves signals to noise ratio, as well as minimizes transmitting of spikes. 7. In many cases the power line earth (not neutral) may prove to be satisfactory. But sometimes, this may also carry a voltage due to some return current from different equipment connected to it. 8. If one is not sure about the earth, make a separate earth connection for the equipment. 9. Connect the earth wire to the earthing bar provided inside the panel. 4.5 Alignment: 1. Align pre carrying idler and post carrying idler along with the weighing idler using string. In case of difference in level shims to be used to ensure all the rollers are making contact with the belt. 2. Fasten all the nuts and bolts properly. 4.6 Commissioning: 1. Before commissioning the system allow the belt to run without material for at least Two hours. 2. Make sure that the belt runs smoothly over the weighing frame. It does not slide, Shift or have any jerky motions. 3. The load cell cable has to be laid till junction box. To protect the cable conducting Has to be done. Care should be taken not to cut the load cell cable. If the cable is Long then it has to be folded and kept( If the cables were made short by cutting, Then this would induce an error in weighing results). 4. Connect the cables in the junction box as per terminal connection details given Inside the junction box. 5. Lay all the cables till the panel. 6. Connect the cables to the panel as per terminal connection details. 7. Check if all the option cards are inserted in their respective slots. Project Manual for Belt Weigher 8. After reading the instruction and operating manual turn on the indicator. 9. Do all the settings as per requirement (ref PR 5510/00 manual). 10. Configure various parameters like decimal point, resolution, range, current setting, in the controller. 11. Make sure that there are no error messages. 12. Now check up the mV signal of each load cell and output pulses of encoder. 13. Now the system is ready for calibration. 14. Become familiar with the calibration procedure by reading the instruction and operational manual of the indicator. 15. Calibrate the system and note down the readings and document it. 16. Configure the indicator for all the inputs/outputs. 17. Take minimum 3 drop test and find out the deviation in totalizer with respect to actual weight of collected material. Considering average deviation enter totaliser factor. 18. The system is now commissioned. SECTION 5 Project Manual for Belt Weigher OPERATING INSTRUCTIONS Operation Procedures Before proceeding with operation ensure the following: ¾ Ensure that the load cells are not subjected to any corrosive material and are safe against any type of physical damage. ¾ Keep the area where the load cell is installed clean. ¾ Ensure that the load cell cable is well protected. ¾ The earthing connection is secure. ¾ Check the earth-pit resistance regularly and document it. The resistance should be less than 1Ω. ¾ The junction box should be protected, by covering it suitably. ¾ Terminations in the junction box and at panel should be checked for any loose contact. ¾ The operator should be well trained on the operation of the system. Project Manual for Belt Weigher ¾ The controllers have to be configured for all parameters and configuration data of the controller has to be noted for future reference. ¾ Do not tamper with the system in case of any problem. Call authorized person to attend the problem. ¾ The controller has to be calibrated before put to operation. 5.1 Calibration After the proper installation of weigh frame, the encoder and the controller, calibrate the weighing system. Internal weigh point should be enabled for doing the calibration. Refer to the Pro-X4 instruction manual for programming and calibration. The Belt Weighing System is calibrated at site with a calibration rod of known weight. The weight is punched on the calibration rod. The process of calibration involves two steps a) Static Zero Calibration b) Static Span calibration a) Static Zero Calibration This is carried out when there is no load on the belt at “Conveyor off” condition. Select ‘Weighing Point’ from ‘Config’ Menu. Controller Displays “Calibration” menu. For performing a new calibration select “New” from the list and perform ‘Zero Calibration’ when there is no load on the conveyor. Pro-X4 operations manual can be referred for performing the Calibration. b) Static Span Calibration Span calibration should be done, after performing ‘Zero Calibration’. Span calibration could be carried out using Calibration rods. All of these are explained in the following sections. Rod calibration Measure the weight of the Calibration rod using a weighing scale. The calibration rods are placed at specified position on the weighing frame. Set the Span Value according to the weight of Calibration Rod. After the Span Calibration press “Exit” button, Controller provides an Project Manual for Belt Weigher option for saving the calibration. Now the system is ready for use. 5.2 Rate Calculation Let Belt speed = S m/sec. Weight of the rod = W kg/m Actual Rate in TPH = W x S x 3600 1000 Reset the totaliser and start the stopwatch simultaneously. Take the reading of the quantity for a known time. The quantity should agree with the rate reading. The tests are repeated three times and the average value is calculated on the basis of these tests. 5.3 Speed calculation Let Belt speed = S m/sec. Tacho roller dia =D m Roller rps(R) = S ᅲX D Pulses per sec (Freq) = R X No of pulses of encoder Note: Here the encoder used gives 1024 pulses per rotation. Calculate the output frequency and select the divider switch on the encoder interface module accordingly so that the input frequency to the controller is between (20 –35) Hz. Refer the table below for the settings. Project Manual for Belt Weigher Tag No Speed in m/s Tacho roller dia in mm Roller RPS Pulse per Second ( frequency) Division required 5.4 Key pad Functions For the entry, front panel is provided with alpha numeric keypad with 16 keys. Following are the keypad functions. Key Functions : Open the indicated menu item. Store the edited parameters : Displace cursor left during value selection. To select between options (Applicable where Is present) : Displace cursor right during value selection. To select between options (Applicable where Is present : Scroll up in menu tree. : Scroll down in menu tree. : Leave the menu item : This is a function key. Program text on the display indicates the function, which can be called up. Project Manual for Belt Weigher : To clear the Totaliser : To select production menu display with units or percentage. 5.5 Parameter Settings When Pro- X4 controller is turned on, the display shows Setup Config Basic Parameters Process Parameters Calibration Parameters Prod Speed : x.xx m/s B Load : x.xx kg/m B Load : x.xx kg/m Rate : x.xx t/hr Rate : x.xx t/hr Totlzr :x t Project Manual for Belt Weigher Totlzr :x t Speed : x.xx m/s Basic parameters Unit of Rate Rated Capacity. Rated Speed (m/s) Weigh Span Belt Length (mtr) Main Display Disch Pnt Dist. (m) Speed Input Speed Input Analog (DC Encoder) Encoder o/p - Min Encoder o/p – Max. Encoder Speed – Project Manual for Belt Weigher Idler Dia. (mtr) Proximity Sensor Wheel Dia. (mtr) No. of Holes Encoder Idler Dia. (mtr) Encoder PPR EIM Factor Fixed Speed Analog Other Analog i/p -Min Analog i/p - Max Rated Speed (m/s) Process Parameters Cal Parameters Min Under load (%) D_Value Belt Empty (%) T.Factor Auto Zero Project Manual for Belt Weigher Belt Overload Dec P1 - Rate Dec.P1 - Tot Analog Out 1 Analog Out1 Range Analog Out2 Analog Out2 Range Pulse every (t) Pulse Dur (m Sec) Remote Disp Out 5.6 Parameter Description: All the parameters related to operation of the belt weigher are programmed under “Config Menu”. : Used for configuration of Basic Parameters, Process Parameters, and Cal. Parameters Project Manual for Belt Weigher : This Menu contains all the Design parameters of Belt weigher. : To select different units for Rate display.i.e g/hr, kg/hr, t/hr. : The designed capacity of the belt weigher. : The designed speed of belt weigher in m/sec. : Effective Weigh length : The total length of belt in meters : To Enable / Disable internal weighment display : Distance from weigh point to discharge point in meters. : To select Analog DC Encoder input. : Minimum output of Analog DC Encoder. Project Manual for Belt Weigher : Maximum output of Analog DC Encoder : Maximum rated RPM of Analog DC Encoder : Encoder Mounting Idler Dia. : To select Proximity Sensor Input. : Wheel Dia of Proximity Sensor mounting assembly. : No. of holes on the wheel of Proximity Sensor mounting assembly : To select encoder input. : Encoder mounting Idler Dia in meters : Rated PPR of Encoder. : Encoder Interface Module Factor is a pulse divider for Encoder Pulses Project Manual for Belt Weigher : To select constant speed option in case of encoder failure. : Actual Speed of the conveyor in m/Sec. : To select Analog Encoder input. : The minimum value of analog input : The maximum value of analog input : The designed speed of conveyor : The menu contains all the parameters related to operation of the Belt Weigher : The minimum belt load as a percentage of rated belt load, recommended by the weigher. : Empty-belt recognition as a percentage of rated belt load. : To Enable / Disable auto zero function. Project Manual for Belt Weigher : Maximum practical belt load, above which the weigher should not be operated. : Decimal places for the rate display : Decimal places for the totaliser display : Configuration of Analog Output-1 corresponding to Speed / Rate : To select the range for Analog output -1 : Configuration of Analog Output-2 corresponding to Speed / Rate : To select the range for Analog output -2 : Totaliser pulse output : Totaliser pulse duration. : Output for remote display. Project Manual for Belt Weigher : The menu contains parameters related to Calibration. : Displays the dynamic Zero value (can not be edited) : To Perform dynamic zero calibration. : Totaliser correction factor for fine-tuning of totaliser value Production Menu: To view different combinations of process parameters. The combinations are given below. More key is used for scrolling among display of units and percentage. Press ‘OK’ key or key Press ‘OK’ key or key Press ‘OK’ key or key Project Manual for Belt Weigher Clearing the Toaliser For clearing the totaliser value –press “stop” key, the display shown is as follows Select “yes”, for clearing the totaliser NOTE FOR OTHER PROGRAMMING PARAMETERS REFER X4 CONTROLLER MANUAL. Project Manual for Belt Weigher MANUAL FOR PR 5510/00 Project Manual for Belt Weigher SECTION 6 PREVENTIVE MAINTENANCE 6.1Maintenance The Belt weigher is virtually a maintenance-free device. How ever the following points to be checked periodically. 1. Check for proper alignment of weighing, pre and post idlers. 2. Check for free running of rollers 3. Cleaning of accumulated dust on load cells Project Manual for Belt Weigher 4. Free running of Encoder idlers 5. Greasing of Encoder idlers bearing 6. Allignment of Encoder idler, coupling Note: Re-install the overload protection during maintenance or any other time for protection of Load cell. 6.2 Calibration Check and its Periodicity To calibrate the system refer calibration procedure explained in the earlier section. After calibration, record kg/m value against cal, rod as well as actual speed value. These parameters values should be crosschecked at least three months once and also tare run should be performed against empty belt condition. Precautions to be followed strictly. ™ Load cells and Encoder: Checks Frequency 1. Load cell and Encoder cable is intact, free from damage : 6 Months 2. Verticality of load cell : 6 Months 3. Checking tightness of mounting kit bolts. : 6 Month 4. mV output and resistance of the load cells : 6 Months ™ Junction Box: Checks Frequency 1. Cable terminations are secure : 6 Months 2. Junction box is clean from inside and free of moisture and : 6 Months dust. Project Manual for Belt Weigher 3. Checking the conditions of cable, to and from the junction : 6 Months box ™ Process Controller: Checks Frequency 1. The indicator is clean & connections are secure : 6 Months 2. Check conditions of cables to / from the indicator : 6 Months 3 Calibration : 1 Year 4. Configuration : 1 Year ™ Earthing Connections: Checks Frequency 1. Check earth resistance : 1Year 2. Earth connections to load cell base plate : 1 Year 3. Earth connection to belt weigher : 1 Year Project Manual for Belt Weigher SECTION 7 SYMPTOMS AND FAULTS 7.1 Error Messages For Troubleshooting, the main Display (Weighing point A) should be enabled using the parameter ‘Main Display’ which is programmed under Basic parameters. Error 1 Internal arithmetic over flow Error 2 Input voltage is above FSD + Over load Project Manual for Belt Weigher Error 3 Input voltage is above permissible range of 36 mV. However , an error in the analog section , a defective load cell, or a cable break are also possibl Error 4 Weight value exceeds display digits. Error 5 Weight is not available, e.g. weighing point is busy Error 6 No voltage, or polarity error at sense line Error 7 Input Voltage is negative or incorrect load cell connection Error 8 ADC error, e.g. internal ADC defective or overload Error 9 No communication with weighing point Error 11 Weight is not available Speed Error: Check the Encoder connection; Make sure that Encoder wires are not open. Tighten the connection wires if required. Make sure that Encoder is giving output, the switch selection in the encoder interface module is correct. Controller Display less than actual reading but steady: Calibration disturbed and the controller needs to be recalibrated Project Manual for Belt Weigher SECTION 8 FACTORY SETTINGS FACTORY SETTINGS 8.1 Basic Parameters Parameter Name Description Set Range Unit Factory Your Setting Settings Project Manual for Belt Weigher Unit of Rate Unit for Flow rate NA NA T/hr T/hr, kg/hr, Rated Capacity Designed Capacity 0 - 1500 300 g/hr Rated Speed Designed Speed 0-5 mtr/sec 2.5 Weigh Span Weighing span 0-3 mtrs 1.6 Belt Length Total Length of belt 0 - 5000 mtrs 5 Main Display Weigh point A NA NA Enable Distance of Discharge Disch pnt Dist. point to weighing 0 - 5000 Mtrs 200 point. Encoder O/P Min Minimum O/p of 0-4 mA 4 mA Encoder Encoder O/P Maximum O/p of 0-20 mA 20 mA Max Encoder Encoder Speed Rated RPM of Encoder 0-1500 RPM 1500 Range Idler Dia Dia of Encoder 0-1 mtr 0.076 Mounting idler Wheel Dia Dia of proximity 0-1 mtr 1 mounting wheel No. of Holes No. of hoes on the 0-100 NA 2 proximity mounting wheel Idler Dia Dia of Encoder 0-1 mtr 0.076 Mounting idler Encoder PPR Maximum O/P PPR of 0-1024 PPR 100 Encoder EIM Factor Encoder interface 0-256 NA 1 module factor Fixed Speed Designed Speed 0-4 m/sec 2.5 Analog i/p Min Minimum analog i/p 0-4 mA 4 Analog i/p Max Maximum analog i/p 0-20 mA 20 Rated Speed Designed speed 0-4 m/Sec 2.5 8.2 Process Parameters Parameter Name Description Set Range Unit Factory Your Setting Settings Project Manual for Belt Weigher Min. Under Load Under load value in 0 - 50 % of F.S 10 (%) % Belt Empty (%) Belt empty % 0 - 50 % of F.S 10 Auto Zero Auto Zero function NA NA Disable Belt overload (%) Overload value in % 0-50 % of F.S 10 Dec P1 - Rate Decimal point for 0,1,2,3 NA 2 rate Dec P1 - Tot Decimal point. For 0,1,2,3 NA 2 totaliser. Analog out1 Analog output-1 NA NA Rate Analog out1- Range of analog 0-20 or mA 4-20 Range output1 4-20 Analog out2 Analog output-2 NA NA Rate Analog out2- Range of analog 0-20 or mA 4-20 Range output2 4-20 Pulse every t Tot pulse output 0 - 500 NA 1 Selection Pulse dur (msec) Duration of tot pulse 0 - 5000 mSec 500 Remote Disp Out O/p for remote LFD NA NA Tph 8.3 Cal. Parameters Parameter Name Description Set Range Unit Factory Your Setting Settings D_Value Dynamic Zero Value NA NA NA T_Factor Fine tuning Factor for 0.99999 to NA 1.00000 Totaliser 1.11111 Project Manual for Belt Weigher SECTION 9 BILL OF MATERIAL Project Manual for Belt Weigher Project Manual for Belt Weigher SECTION 10 DRAWINGS AND DOCUMENTS Following drawings and documents enclosed for reference: 1. Data Sheet of MP 47 Load cell. 2. Catalog of PR 5510/00, Weighing Terminal. 3. Data sheet for Junction box 4. Data sheet for encoder 5. Drawings ¾ GA Drawing of belt weigher Project Manual for Belt Weigher ¾ GA Drawing of panel ¾ Drawing OF ST 2620/13, Junction Box. ¾ Dimensional cut out details of Digital Controller PR 5510/00. ¾ Technical Specification for Encoder –ST5013/13. ¾ Interconnection Details for Encoder Interface Module-ST 5010/00. ¾ System block, Electrical Wiring & connection Diagrams. 6. Test Reports Project Manual for Belt Weigher SECTION 11 YOUR CONTACT AT SARTORIUS For New Requirement: For Service: Your Contact : Mr. Sethumadhavan.V.S Tel: (080) 41272741/41272742/41272743 Fax: (080) 41171423 Address M/s. Sartorius Mechatronics India Pvt.Ltd., #17/A, 5th Main, IIIrd Phase, Peenya, KIADB Indl Area, Bangalore – 560 058 Email: Project Manual for Belt Weigher Email: Your Contact : Mr. Pramesh Shah Tel: (080) 41272741/41272742/41272743 Fax: (080) 41171423 Mobile: (0)9342509285 Address M/s. Sartorius Mechatronics India Pvt.Ltd., #17, 5th Main, 3rd Phase, Peenya, KIADB Indl Area, Bangalore – 560 058 Corporate Office: Your Contact : Mr. Mohan Bhat Tel: (080) 28375381-85 Fax: (080) 28378716 Address M/s. Sartorius Mechatronics India Pvt.Ltd., #10, 6th Main, 3rd Phase, Peenya, KIADB Indl Area, Bangalore – 560 058 Email: Project Manual for Belt Weigher Project Manual for Belt Weigher