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Instruction manual for Belt scale

TABLE OF CONTENTS
Section 1
…. 2
Supply Verification & Visual Inspection
Caution
Warning
Section 2 – Introduction
…. 4
Basic Operation
Signal Diagram
Section 3 – System Modules
Weigh Frame
Load Sensor
Speed Sensor
Electronic Unit
Calibration Rod/Chain

…. 7

Key functions
Section 8– Parameter Table
Factory settings
Parameter definitions

…. 35

Section 9 – Commissioning

….46

Section 10 – Calibration

…. 47

Calibration details
Acceptance test
Running the system

Section 4 – System Specification…. 15
Conveyor specification
Belt scale panel specification
Loadcell specification
Section 5 – System Installation …. 18
Weigh Frame & loadcell installation
Speed sensor installation
Belt scale panel installation
Cable routing

Section 11– Trouble shooting
Status message
Operation trouble shooting
Section 12- Parameter entry table

….59

Section 13- Replaceable spares

….60

Section 14 –Dip switch position

…. 61

Section 15 -Maintenance schedule …. 62

Section 6 – System Description …. 27
Belt scale panel
Remote indicator

Section 16 – Warranty

Section 7 – User Interface
Display

Test report

Page 1

…. 29

…. 56

Drawings

Log sheet

….64

Instruction manual for Belt scale

Section 1
SUPPLY VERIFICATION AND VISUAL INSPECTION
The following verification checks are to be carried out on receipt of the equipment
before they are moved to the installation site.

Check all the items as per the packing list supplied by the manufacturer. IPA Private
Limited, Bangalore.
In case of short supply, please inform the company
immediately.

Carry out a visual inspection of each item. If any damages are noticed inform the
Company giving the details of the damages, quoting the item numbers and box
numbers in which they are packed. If applicable, inform the insurance company
immediately and request them to arrange for a survey of the damages. If requested,
one of our representatives can be sent to assist in assessment of the extent of
damages. After physical verification and inspection, please repack the items like the
original packing and store them in a cool and dry place. Take care that they are not
exposed to sun and rain. While repacking, please ensure that no moisture is
entrapped in any of the packing.
Equipment packing consists of the following in the order as shown below ( Fig 1.1)
• Polythene sheet for sealing against moisture and air bubble sheet for absorbing
shocks.
• Thermocole as second layer for absorbing shock.
• Cardboard box.
• ‘Kurlon’ as third layer for absorbing shock.
• Wooden box.

Fig 1.1 Packing details

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Instruction manual for Belt scale

Cautions
Read manual carefully before installing, wiring, operating, servicing or inspecting
the system
Keep this manual within reach for quick reference
Improper handling blocks, incorrect operations are cause a short life or failure
Deliver this manual to end user of the product or operator

Warning
Operate the switches with dry hands
Do not use the cable when its insulating tube is damaged
Do not subject the cables to scratches, excessive stress, heavy loads or pinching
Always follow instructions to prevent the short life or failure of the system
Do not allow lint, paper, wood chips, dust, metallic clips or other foreign matter into
the panel
Do not place heavy items on the panel or weigh frame assembly.
Protect the system from corrosive gas, combustible gas, oil mist or dust.
Incorrect terminal wiring could result in the equipment damage.
Do not install or operate the system that is damaged or lacking parts
Never attempt to modify the system without proper instruction from manufacturer

Page 3

1). Since weight remains as the most reliable index of material accounting and can be measured directly and precisely. salt aggregate gravel. with the advent of fast mode of transportation. Approved by Weights & Measures Model Approval No: BCW:IND/09/06/478 PRINCIPLE OF OPERATION fig.. The belt load is transmitted from weigh frame either direct or via a lever system to a loadcell. accounting the quantity of material transferred assumes great importance. lime etc. sand. designers can offer accurate weighing systems to maintain higher accuracy and better accountability in the process.1 Belt scales are integrating weighing devices that use a simple integral calculus summation process to measure a conveyed quantity of material. Two variables Page 4 .Instruction manual for Belt scale Section 2 Introduction Basic Operation In most of plant situations require the transport of materials like coal. The combined output from loadcell and speed sensor provides the flow rate of the material passing over the scale Main features are High reliability and accuracy Trouble free operation under severe environmental conditions Practically no effect of belt tension on weighing Remote data transmission Simple installation and easy maintenance. 2. Belt scales are most common type continuous weighing devices and consists of one or more conveyor idlers mounting on a weigh frame as shown in fig (2.

the unit being kg/minute or Tonnes/hour. on that section. magnetic or other on/off sensing units.Most modern speed sensors rotary digital pulse generators. Relay section display and keypad section. The power supply section consists of On/Off switch. Keypad (4 X 4 matrix keypad) is interfaced with the microcontroller which is used to enter the programmable parameters. material flow/min. various system alarms and annunciations. = wxs The rate of flow w x s integrated over a period of time gives the total quantity of material transferred over that time. The weight function measure small section of conveyor.Instruction manual for Belt scale are involved in this :weight and speed. DAC (for 4-20 mA /0-20mA /0-5V output). ADC section. fuse. Let the weight between ‘aa’ and ‘bb’ (unit length) = w kg. step down transformer and SMPS card it can provide supply voltages need for the system operation. speed in m/s. Overload. Load cell input is given to the instrumentation amplifier circuitry. Totaliser pulse and Totaliser set achieved. rate in t/hr and totaliser in tonnes. Relay section is used to provide potential free contacts (250V. the reaction ‘R’ at the center of that section equals the weight of the material including the belt weight. Signal Diagram The belt scale electronics consists of Power supply section. The product of this force and the speed of the belt is the rate of flow. For The display section Which displays load in kg/m. The speed function is the second variable to be measured . Under load. The material passing over a Belt Conveyor exerts a downward force proportional to its weight. The digital output from ADC is given to the micro Page 5 . which amplify the input signal and is given to ADC. 5A) – 4Nos. ADC. Taking a section of unit length between ‘aa’ and ‘bb’ on the belt (fig. Instrumentation Amplifier./m Let the speed of belt = s m/s Therefore. ADC section card consists of Micro controller. This can be optical. The tension of the belt ‘T’ has got no influence on reaction ‘R’ if ‘T’ and ‘R’ are mutually perpendicular. They are mounted on pulley or wheel that rotates as belt moves. 1).

Section 3 The belt weigher consists of Page 6 System Modules . The DAC will produce a analog 4-20 mA out put corresponding to flow rate. The tacho input is given to the ADC card via frequency divider circuit as pulse input.Instruction manual for Belt scale controller.

WEIGHING FRAME: Weighing arrangement with four loadcells Page 7 . 6. Loadcell/s * BR type DS type Speed sensor * AC Tachogenerator DC Tachogenerator DC Pulse encoder Proximity switch Speed sensor mounting frame * Telescopic arrangement Idler Pickup wheel Electronic unit * Local panel Remote panel Calibration weight * Chain Rod 3. Weighing frame * Weighing arrangement with four loadcells Weighing arrangement with single load cell and counter balancing weight Weighing arrangement for garland conveyor 2. * Suitable arrangement selecting according to application.Instruction manual for Belt scale 1. 5. 4.

1. (Fig.Instruction manual for Belt scale The arrangement is to have a platform on to which the idlers are mounted and the platform is supported on four loadcells. This arrangement will get accuracy of 0. 3. This type of arrangement using where material load is less then 20 kg/m and accuracy is in the range of 1-3% depending upon site conditions.1 FOUR LOADCELL SYSTEM Weighing arrangement with counter balancing weight This consists of a framework pivoted or supported by bearings at both ends of a shaft with an adjustable balancing weight at one end and the frame resting on loadcell at the other end. Fig 3. Page 8 . 3. Fig.2). This arrangement is used for applications like weighing in conveyors having minimum material load of 20 Kg/m.5% better under ideal conditions.

Instruction manual for Belt scale Fig.3).3 GARLAND CONVEYOR WEIGHING SYSTEM Page 9 . 3. 3. Here DS type load cells are directly connecting to the idlers for the Weighment (Fig.2 COUNTER BALANCING WEIGHT SYSTEM Weighing arrangement for garland conveyor This arrangement is using when garland type idler are using for Weighment. 3. Fig.

BR type Loadcell (Fig. These loadcells are hermetically sealed to withstand the hostile industrial environment. The load sensor is a high accuracy strain gauge based loadcell. Fig 3. 3.S. the gravimetric. bellows to resist industrial corrosion.5) Page 10 . The loadcells are provided with S. This opposing or counter balancing force becomes the measurement of weight. The zero and span of loadcells are fully temperature compensated.3.4) & DS type loadcell (Fig 3.Instruction manual for Belt scale Weighing arrangement with two loadcells The arrangement is to have a platform on to which the idlers are mounted and the platform is supported on two loadcells.4. Fig. force must be countered by an opposing force measurement. which gives excellent linearity and repeatability.4 TWO LOADCELL SYSTEM LOAD SENSOR To measure the load.

5 BR TYPE LOADCELL EXPLODED VIEW Fig. The speed of the belt is measured by means of speed sensor that is driven by the return belt/tail pulley. Generally four types of speed sensors are used AC tachogenerator DC tachogenerator DC pulse encoder Proximity switch. 3. Page 11 . 3.6 DS TYPE LOADCELL SPEED SENSOR: The accurate measurement of belt displacement is important for computation of total mass passed over a conveyor.Instruction manual for Belt scale Fig.

6) Page 12 . It provides pulse whenever metal part comes closer to its surface (for inductive type) A proximity switch is used to measure the speed of the conveyor. The aluminium disc is allowed to be on the belt by a hinged telescopic arrangement. (fig. the speed sensor is rotated due to the friction between the aluminium wheel and the belt. DC Tachogenerator DC Tachogenerator generates 0-160V DC proportional to 0-1000 rpm. As the belt runs. It produces rated pulses per revolution with amplitude equal to excitation voltage.3. A pick up wheel (reference drawing enclosed) is fixed to the shaft of tail pulley or special wheel assembly and the proximity switch is placed such that proximity switch senses the rotation of pick up wheel.Instruction manual for Belt scale Selection of speed sensor is purely depends upon the conveyor speed and conveyor construction. The speed sensor produces AC/DC voltage or pulses while it rotates and the frequency is truly proportional to the speed of rotation. DC Pulse encoder DC pulse encoder to be excited by the voltage specified on it. hence speed of the conveyor. The proximity switch is excited by belt scale panel and proportional to the speed of conveyor. It generates 0-20V AC proportional to 0-1000 rpm. Proximity switch Proximity switch is also to be excited by the voltage specified on it. AC Tachogenerator AC Tachogenerator consists of a rotor having permanent magnetic poles that rotate inside a stator having suitable winding. The switch is inductive type. SPEED SENSOR MOUNTING ARRANGEMENTS TELESCOPIC ARM: An aluminium wheel is fixed to the axle of the speed sensor. it provides pulses to the belt scale panel.

Instruction manual for Belt scale Fig.3.7 TELESCOPIC ARM ASSEMBLY WITH DC PULSE ENCODER Page 13 .

Usually one pre and post carrying idlers are also machined idlers for better performance.Instruction manual for Belt scale IDLER MOUNTIG: WEIGHING IDLER: Machined idlers matching with the existing conveyor idlers dimensions.9 PICK UP WHEEL & SENSOR Page 14 . Fig. worn out idlers will cause errors in weighing.8 IDLER MOUNTING WITH AC TACHOGENERATOR PICK UP WHEEL & SENSOR: 3. This will improve the weighing accuracy.3.

fast and does not need any complicated calculation. The rate signal is integrated to get the cumulative quantity. The advantage of this method of calibration is that it is simple. OPTIONAL FEATURES These units supplying according to the customer requirements.Instruction manual for Belt scale ELECTRONIC UNIT BELT SCALE PANEL Belt scale is a micro controller based electronics. CALIBRATION ROD Rods used for calibration are made of mild steel. Calibration rods are advantageous in handling calibration weights as the total weight is split into number of rods which can easily be placed on the weighing frame. accurate. Provision is made to place these rods on the weighing frame. which operates on mains. mounting etc. The weight per unit length of the chain is known. Page 15 . Refer specifications for voltage. It accepts the signals from loadcell and speed sensor to compute rate of flow. The standard length of chain is 3 times the idler spacing in case of single idler weighing and 4 times the idler spacing in case of double idler weighing. These are to be placed on the weighing frame during calibration. CALIBRATION CHAIN A flexible roller chain made of mild steel is used for calibration.

Instruction manual for Belt scale Section 4 System Specification Conveyor Specification Conveyor No. Chain (kg/m) : Speed sensor (Make/Model) : Page 16 INFRA/IS41 . : BS-2A Material handled : COAL Bulk density (kg/m3) : 800 Conveyor capacity (tph) : 600tph (Rated)/660tph (Design) Belt speed (m/s) : 1. Rod wt (kg/m) : Cal. Cal.8 Material load (kg/m) : 92.) : 10. of load cells : 4 Cal.4 Idler spacing (mm) : 1000 Idler weight (one set) (kg) : 55 Conveyor inclination (Deg.59 Belt width (mm) : 1200 Belt weight (kg/m.7 Conveyor length (m) : Load cell capacity (kg) : 200 No. Rod wt (kg) : Tot.) : 21.

120 mA 0-15mV from Loadcell Pulses from Speed Sensor Outputs ♦ ♦ Display Annunciation Features Page 17 : 4-20mA corresponding to rate (Loop resistance: Maximum – 1 kΩ Minimum – 100 Ω) Potential free contacts (230V. System reset . speed. Power supply Mounting Operating temperature Excitation to loadcell : : : : : Inputs : BCW55L0 230V ±10%. and totaliser through keypads Current span setting Selectable speed mode Self – test. : LED Power ON Belt ON Under load Over load Totaliser pulse out Set achieved Fault : Set value for under load and overload Calibration of load. 5A rating) Under load Overload Totaliser pulses Totaliser set achieved RS-485 output to Remote indicator : 7-Digit 7-Segment red LED Display.50Hz ±3% Wall 5°C to 50°C ± 5V DC.Instruction manual for Belt scale Belt Scale panel Specification Model No.

RANGE TEMP.IN LOW WHITE Page 18 .Instruction manual for Belt scale Password protection for all programmable parameters and functions Load cell Specification Model No.1% ± 0.006% /° C 0.55° C 5 .1% ± 0. EFFECT ON SPAN TEMP.EXCITATION GREEN .) ZERO BALANCE VOLTAGE INPUT RESISTANCE OUTPUT RESISTANCE COMPENSATED TEMP.12V) 200% 300% > 1000 M OHMS IP. BRIDGE TO CASE AT 30V DC AT 30° C PROTECTION CABLE Specified Value (% Of Rated Output) 1.008% /° C 10V DC/AC (MAX.01 mV/V ± 0.05% ± 0.68 4 m . EFFECT ON TARE EXCITATION VOLTAGE SAFE OVERLOAD ULTIMATE OVERLOAD INSULATION RESISTANCE.2 mV 390 ± 10 OHMS 350 ± 2 OHMS 5 .70° C 0. 4 CORE SHIELDED PU SHEATHED LOADCELL CONNECTION DETAIL: SIGNAL COLOUR OF WIRE + EXCITATION BLACK + IN HIGH RED .: BR022H0 Capacity: 200kg Parameters RATED OUTPUT COMBINED ERROR REPEATABILITY CREEP ON LOAD (30 mins.5 ± 0.RANGE OPERATING TEMP.

Instruction manual for Belt scale SHIELD Section 5 System Installation System Installation Requirements Your conveyor may not meet all of these requirements and still give good accuracy readings. lightly loaded belts for scale application. The belt must be in contact with the scale idler at all times and should track in the center both empty and full The idler troughing angle should be 35° or less. Conveyor inclination must not exceed the material angle of slide. Page 19 . The idler used at the scale as well as preceding and following the scale should turn true(concentric) and the scale idler should be reasonably balanced(especially with high speed belts) so as not to generate an out of balance vibration Idlers should be on equal centers a minimum of two before and two after the scale and must be string lined to be level for this span. The conveyor should be rigid in design and reasonably free from vibration. Conveyor feeding to be uniform for better performance. inclining or declining in scope. A gravity take up system is preferred. The conveyor must not be subjected to stress that will cause structural deflection The conveyor should have an automatic belt tighter. Use these as guidelines for good design and realize that violating good design will probably reduce accuracy Avoid high speed. Lowering the belt speed which increases belt load will cure most scale problems. Sufficient impact location idlers should be provided under each feeding location so as not to cause any deflection of the belt at the feed point. The conveyor may be horizontal. Conveyor loading should be reasonably uniform and loading cannot take place on the area of belt being used as the weighing platform. The conveyor should be designed with a straight run without a vertical curve. Skirt boards must be avoided in the scale area.

• High belt tension. Fig. • Loosely mounted unstable conveyor. • Wind.Instruction manual for Belt scale A few typical locations of mounting weighing frames are shown in Fig 4.0. • Mud or material build up on belt or idlers. • Steep conveyors allowing material to roll back. temperature or vibration extremes. • Poor belt training or alignment. • Belt skirting or other interference near scale.0 LOCATION OF WEIGHING FRAME IN CONVEYOR BELT INSTALLATION Avoid the following! • Badly worn belts and splices. • Joined belts with different thickness. Page 20 . • Steep troughing angles. 4.

Tacho fixing frame should be near to weighing frame Note: While keeping active loadcells the welding should not be carried out Fig. Weld the load cell fixing frame to stringer as per GA Fix the load cells in correct orientation Fix the weighing frame above the load cell Fix the weighing idlers on weighing frame All the idlers should be in the same level. Adjust the load cell button height suitably Align at least two pre and post carrying idlers with weighing idlers Care should be taken to ensure that the load pin touches only the sensing stud of the loadcell and not the loadcell casing.4.Instruction manual for Belt scale Weigh Frame & Loadcell Installation Locate the suitable place to install weigh frame Remove the existing idlers from the located place. if the weighing idler is lower give padding plates where the weighing idler is fixed to the weighing frame.1 WEIGHING FRAME Speed Sensor Installation Page 21 .

7) ANGLE SENSOR Page 22 . The telescopic arrangement is mounted with a frame that is fixed in the stringer and a telescopic arrangement to adjust the tacho with respect to the belt. Tacho coupled to this idler with required mounting accessories. If it is not straight. 1) Weld the supplied channel to the conveyor stringers. it may bounce and wear down the wheel or belt.(fig 3.2 TACHO-GENERATOR b) Idler mounting arrangement In this arrangement separate idler is used which is made to rotate by the returning belt. Position the wheel so that it is at least 200 to 300mm from a return idler. a) Telescopic arrangement It contains two aluminium wheels and one wheel is coupled to the tacho shaft.(Make sure that load cells removed from structure before any kind of welding) 2) Fix the speed sensor assembly onto the pivot arm on the welded channel.4.Instruction manual for Belt scale For standard speed sensors: Mount the speed sensor assembly so that it is aligned exactly with the belt. Fig.

after that if there is any change in inclination. This change induces a cosine error in the measured load. positive or negative sensor gives corresponding pulse. Angle sensor is mounted to the conveyor stringer. Attach the lid to the sensor and give the connections Application When same conveyor is being used for stacking and reclaiming of the material the inclination of the conveyor changes accordingly. Keeping the conveyor in horizontal position system is calibrated. The following thing should be taken care while installation Page 23 . This rotation is connected to a sensor. There are some situations in weighing where the angle of inclination having relevance. Pulse Encoding 2. ensure that the horizontal position of the stringer. Principle The basic principle behind angle sensor is law of gravity. Potentiometric Installation Take the base plate of the Angle sensor and weld it on the stringer. Angle sensor is used.Instruction manual for Belt scale Angle sensor is an instrument to measure the angle of inclination of a particular plane. It is also called Inclino Meter. pendulum is in vertical position (zero level). To avoid this angle. This is the 0° (zero) inclination. Measuring Range -40 Degrees to +40 Degrees. A freely suspended mass which can move according to the tilt of the plane to which it is attached. so that the sticker coming portion is on top of the stringer. This is processed and corresponding cosine correction is made. Mount the angle sensor on the base plate using bolts. Detach the top lid and removing the thermocol given for packing. There are two ways to sense the inclination: 1. In this also the sticker portion should come on top.

d) The cable from the tachogenerator should be brought out through a flexible conduit and be terminated in the junction box.Instruction manual for Belt scale Errors in the accurate measurement of belt travel for conveyor scale weighing can occur from variety of sources a) The tacho should be coupled with the idler. do not connect speed sensor terminal to 5th pin (shield) of MKDSN connectors in junction box. Belt Scale Panel Installation Page 24 . f) Belt speed varies with in the conveyor as a function of tension. e) Slip between belt travel pickup and conveyor belt. b) The tacho mounting idler should rotate freely to ensure that the pillow blocks can be periodically lubricated. c) The tacho mounting idler should be in-line with the belt so that it can rotate freely without slip. Note: In case where single junction box provided for both loadcell & speed sensor connection. where the loadcell cable is terminated.

It may fall off Install in a location where temperature with in the permissible limit. For connections. signal processing unit which may be fixed inside panel enclosures by two fixing clamps provided at the side of the unit. To prevent possible shorts to the terminals or to the printed circuit boards keep the wiring neat and insulate all shields. Page 25 . Electronic panel of the belt weigher is micro controller based panel mounting. Wiring connections should only be made through the bottom of the enclosure using waterproof fittings. The dimensional details of the electronic unit (panel mounting) are shown in the enclosed dimensional drawings. use the connectors provided at the rear side of the unit. For easy serviceability all the cards are interconnected by connectors.Instruction manual for Belt scale CAUTION Do not hold the panel by front cover.

There should be an instrumentation earth available and that is to be connected to the panel. CABLE ROUTING: Page 26 . Also avoid dripping water areas. The panel can be located up to 25m from the weighing zone. that calibration will require one person at the weighing zone and one person at the panel. however. Where outdoor installation is necessary. the panel should be mounted under a “roof” or “dog house” to provide rain and snow protection as well as shade. There should be sufficient space around the panel to do the periodic maintenance or servicing or replacement of components. The power supply should be steady. Take note.Instruction manual for Belt scale While selecting the mounting place for the panel following points should be kept in mind: Mount the panel in a reasonably clean area away from severe heat and isolated from vibration. Clamps for mounting are provided in the unit. The unit should be firmly fitted into the panel. Avoid areas of bright sunlight since the lighted displays may become difficult to read. Cables to the panel should be routed through conduit and terminated through glands.

5 ohms. But sometimes. It also helps to keep 50 Hz noise at a minimum level. 10. 8. High insulation resistance is necessary for accurate operation.6 X 2 m and burying a copper bar of about 6 mm X 12 cm X 2 m . Joining of cables are to be done either by proper soldering or by cable connectors and not by twisting them together. Cables should not be exposed to sun or rain as this may cause deterioration of insulation resistance. Cables should not be routed beside relays. Make a separate earth connection for the equipment.6 X 0. 1. Joining the cables with connectors and screws are not preferred. Never run any of the signal cables alongside a power line. 7. A good earth connection can be made by digging a pit of 0. All the interconnecting resistance should not be more than 0. The distance of the signal from a power line should be at least one meter. on a long-term basis. as well as minimizes transmitting of spikes. It is always better to run the signal cables through metallic conduits.Instruction manual for Belt scale Cable routing is an important factor. The following points are to be borne in mind. In many cases the power line earth (not neutral) may prove to be satisfactory. 4. The main display unit casing should be connected to earth. Do not use the power cables as a supporting point for signal cables especially when supported by metallic wires. At the joining point they are to be properly insulated by insulation tape of high quality. 12. When cables are terminated to an equipment or device. the pit being filled with charcoal and common salt. 5. 11. 3. 6. 2. especially. this may also carry a voltage due to some return current from different equipment connected to it. 9. or electrical equipment. From this point electrical connection can be made by 12 gauge copper wire. For trouble free operation of the equipment proper earthing is essential which improves signal to noise ratio. which governs the trouble free performance of the equipment. at least a small length of flexible conduit is used at the point of termination or the cable connected to the terminals should be allowed a little free length to avoid straining. Section 6 Page 27 System Description . A long pipeline running under the earth may be a good choice. It is better to have soldered tags on the wire when screwing connections are adopted.

Relay Card (9830C) This card housed four-sugar cube relays rated for 5A. loadcell excitation circuit. -5V. SMPS Card (9823D) This card generates different voltages. digital input circuit. data acquisition circuit. which are used in ADC and processor card. overload. overload. not to other devices. It receives control signals from processor card for activation of relays. belt ON. current output section. and driving an LED. tacho pulse shaping circuit. Display card (7060) This module is a 7-digit 7-segment LED display with various separate LED annunciation for power ON. The potential free contacts are for underload. ADC and Processor Card (9830 FR02) This card consists AT89C51RC controller. memory. Use only water tight compression fittings. Insulate shield wires to prevent shorts. Supply is provided from power supply card (9823D).Instruction manual for Belt scale Belt scale & Remote description is covered in this section. This card provides 4-20 mA current corresponding to flow rate. underload. The different voltage levels obtained from this card are +5V. interfacing circuit for port expansion and key board/display interfacing circuit. 250V AC and opto-couplers for isolation. totaliser pulse. REMOTE INDICATOR Page 28 . +12V. and 24V. Caution Only apply input power after assuring all wiring is correct. Connect shield wires to the panel only. It has got a capability of accessing a 4X4 keypad. totaliser set achieved and totaliser pulse. set achieved and fault.

Page 29 .Instruction manual for Belt scale Remote indicator. The card also has two keys F1 for clearing the totaliser and F2 to recall the cleared value. This card also provides isolation for RS 485 signals. Model RD165A0 shows “rate” on a 5 digit display and totalised quantity on a 6 digit display. The rate and totaliser signals are transmitted from main panel to remote by RS485 standard signals. Controller card 9825C The controller card (9825C) used in remote indicator is with RS 485 serial input and two serial outputs for display. Two soft touch keys F1 and F2 are provided on the front to clear the totaliser and to recall the totaliser value. The controller receives the string from belt scale panel and converts back to BCD format to display totaliser and rate Display card 9825B This is a display card with a 6 digit totaliser and a 5 digit rate display.

Since the unit has not been set up yet. Page 30 . The display windows should light up with information. The diagram below shows the Belt scale front panel. and totaliser set achieved (SA) totaliser pulse output and faults are also indicated on the LED. Power up the unit. There is a 7-Digit 7-Segment red LED display indicates following data selected by the keypad.Instruction manual for Belt scale Section 7 User Interface Display At this point. ♦ Belt load in kg/m. the panel should be installed and the Weight Processor mounted and wired. totaliser clear and tare run has been provided to prevent unauthorized setting changes. disregard any error messages or incorrect values on the display. over load. ♦ Belt speed in m/s ♦ Rate of flow in tph. ♦ Total quantity conveyed in t Power ON belt on. under load. Password protection for all programmable parameters.

Page 31 . The diagram below shows the Remote indicator front panel.Instruction manual for Belt scale Remote Indicator: Remote indicator is a slave unit which receives data from Belt scale on RS485 bus and indicates instantaneous rate of flow and cumulative quantity.

5 SYS. 4 TOT. From which all the SET parameters can be programmed. 1 CAL This key is used to enter into Calibration mode and the system calibration can be performed. SET This key is used to enter into Set mode. From which all the configuration parameters can be programmed. 6 F1 This key is used to perform Self-test 7 F2 Used as a Numeric key.RST This key is used to Reset the totaliser. 3 TARE RUN This key is used to perform Tare. 1 CON 2 2 E T This key is used to enter into Con mode. RST This key is used to Reset the system.Instruction manual for Belt scale KEY FUNCTIONS: Numeric keys 0 to 9 are used to enter/modify the value of the Parameter. 8 F3 Page 32 9 .

Page 33 . This key is used to Shift the blink digit right. Used as a Numeric key. ESC This key is used to Exit from the present level or mode. 0 This key is used to View /Modify the parameters and store the parameters. This key is used to move forward to the Next parameter/level.Instruction manual for Belt scale Used as a Numeric key. This key is used to move back to the Previous Parameter/level. This key is used to Shift the blink digit left.

Then display shows PASS Then the display changes to Oa Then the display shows XXXXXX -Totaliser Press key then the display shows S XXXX S -Speed Press key then the display shows xxxx Page 34 . the Display shows the following message momentarily Ipa The display then changes to The display shows SS If the system passes the self-test .Instruction manual for Belt scale POWER ON SCREENS: When the system is Switched ON.

If belt is On – If belt is Off Section 8 Page 35 Parameter Table .Load Press key then the display shows * - .Rate Press key then the display shows XXXX .Instruction manual for Belt scale .

e. Setting CON LOAD parameters: Press the key marked CON. RESOLUTION This parameter is used to select the least count. then the display shows XX. Set to ‘2 ’ for a least count of 2 Set to ‘5’ for a least count of 5. then the display shows XXXX 1. Set to ‘1 ’ for a least count of 1. 2 and 3. If the parameter is set to 0.XX 3. then the display shows XXX.. CON LOAD (LOAD CONFIGURATION PARAMETERS): DECIMAL POINT This parameter can be set as 0. The display will show u Page 36 . This parameter can be set from 000 to 199. reading update will be slower) and vice versa when time constant is set at 000.XXX FILTER VALUE This system incorporates an averaging method of displaying. The damping would be maximum at 199 and hence the rate at which load value is updated will be minimum (i.X 2. it is recommended that you properly calibrate the scale before enabling the optional outputs. then the display shows X. 1. It is set ‘0’ to for a least count of 10. In addition. which are the minimum and maximum values respectively.Instruction manual for Belt scale Parameter Definitions Read each parameter description and enter the appropriate value.

Press ↵ key to record the value. Press ESC key to exit from CON mode. Resolution S Then enter the desired values using the numeric keys. Filter Value L Then enter the desired value using the numeric keys and press ↵ key to record the value. CON SPEED (SPEED CONFIGURATION PARAMETERS): DECIMAL POINT (Speed decimal Point) This is the decimal point setting for speed displayed. The values from 0 to 3 can be entered. Then the display will show next parameter. Then the display changes to Decimal Point Then use the numeric keys to set the decimal point value. 1 to one decimal point and so on. Press ↵ key to record the value. 0 corresponds to no decimal point.Instruction manual for Belt scale Then Enter password 14673 The display changes to o L Press ↵ key. Then the display will show next parameter. Page 37 .

Setting CON SPEED parameters: Enter into CON mode (as mentioned previously) Press the key marked CON. reading update will be slower) and vice versa when time constant is set at 00. display will show o S Press ↵ key. which are the minimum and maximum values respectively.Instruction manual for Belt scale FILTER VALUE` This system incorporates an averaging method of displaying.e. The damping would be maximum at 99 and hence the rate at which speed value is updated will be minimum (i. Then the display changes to Decimal Point Page 38 .. This parameter can be set from 00 to 99. The display will show u Then Enter password 14673 The display changes to o Press the L key.

display will show o Page 39 L . CON RATE (RATE CONFIGURATION PARAMETERS): DECIMAL POINT (Rate decimal Places) This parameter is used to get the required resolution of rate. The values that can be entered are 0.1 tph 2 corresponds to 0. 0 corresponds to 1 tph 1 corresponds to 0. Then the display will show next parameter. The display will show u Then Enter password 14673 The display changes to o Press the twice. Filter Value L Then enter the desired value using the numeric keys and press ↵ key to record the value.01 tph 3 corresponds to 0. Press ↵ key to record the value. 2 or 3.001 tph Setting CON RATE parameters: Press the key marked CON. Press ESC key to exit from CON (Speed) mode. 1.Instruction manual for Belt scale Then use the numeric keys to set the decimal point value.

The values that can be entered are 0.001 ton Setting CON TOTALISER Parameter: Press the key marked CON. Press ESC key to exit from CON (Rate) mode. CON TOTALISER (TOTALISER CONFIGURATION PARAMETERS): DECIMAL POINT (Totaliser Decimal Places): This parameter is used to set the resolution of the Totaliser. Then the display changes to Decimal Point Then enter the desired value using the numeric keys and press ↵ key to record the changes. The display will show u Page 40 . which correspond to 1 ton.1 ton 2 corresponds to 0.001 ton respectively.Instruction manual for Belt scale Press ↵ key.01 and 0. 1 2 or 3.1 ton.01 ton 3 corresponds to 0. 0. 0 corresponds to 1 ton 1 corresponds to 0. 0.

SET PARAMETERS The set parameters are: • Under load • Over load • Set speed • Speed type • Span rate • Load factor Page 41 . display will show o L Press ↵ key. Press ESC key to exit from CON (Rate) mode. Then the display changes to Decimal Point Then enter the desired value using the numeric keys and press ↵ key to record the changes.Instruction manual for Belt scale Then Enter password 14673 The display changes to o Press the L thrice.

Speed type: This parameter selects the speed type of the system For internal speed type select 1 In this case the parameter set in “set speed” is assumed to be the speed of the conveyor. Page 42 .Instruction manual for Belt scale • • • Address Speed measuring time Totaliser set Under load: This is the minimum load above. design capacity is set in this parameter. If the frequency is 500 Hz. For the given tacho and mounting arrangement. Proximity sensor. When belt scale is used with remote indictor (master unit) address of the belt scale shall be entered as 001. This is applicable when the parameter “speed type” is set as 1 (internal speed type). Address: This is an address of the beltscale (slave unit) for MODBUS communication. Range of entry 001 to 247. For external speed type select 0 In this case actual speed of the conveyor is measured through pulses from external device. For slower speed the value is set as high i. Generally. and gives fault indication. Load factor: This is the correction (multiplication) factor for fine corrections to the calibrated load.e >2. When belt scale is interfaced with client’s PLC /DCS the address can take any value other than 01 up to 247 Speed Measuring time: Measurement of speed is based on no of pulses/speed measuring time in second i. Ex: Tacho.e. Set Speed: This is the assumed speed of the conveyor instead of the actual measured value. frequency. Over load: This is the maximum load that the system can withstand and above which fault indication will be given. frequency can be worked out. This is the time interval in second at which the speed is sampled periodically. which totaliser updating will take place and below which totaliser updating will not take place. speed measuring time can be set as 2. During calibration speed type is set to 0 Span rate: This is the value of rate of flow at which system provides 20mA current output.

Over load OU L Press ↵ key then the display changes to XXXXX Use numeric key to change the value. the “set achieved” P. Press ↵ key to record the change. Then the display will show next parameter. Page 43 . Setting of SET parameters Press the key marked SET key. Press ↵ key to record the change. The display will show u Then Enter password 14673 The display changes to Under load U L Press ↵ key then the display changes to XXXXX Use numeric key to change the value.Instruction manual for Belt scale Totaliser set : This is the set value. Then the display will show next parameter. On achieving which (by the totaliser).F contact operates to give pulse output.

Press ↵ key to record the change. Speed type S Press ↵ key then the display changes to X Use numeric key to change the value. Then the display will show next parameter. Load Factor L Page 44 . Then the display will show next parameter. Press ↵ key to record the change. Then the display will show next parameter. Press ↵ key to record the change.Instruction manual for Belt scale Set speed S S Press ↵ key then the display changes to XXXX Use numeric key to change the value. Span rate S Press ↵ key then the display changes to XXXX Use numeric key to change the value.

Press ↵ key to record the change.Instruction manual for Belt scale Press ↵ key then the display changes to XXXXX Use numeric key to change the value. Then the display will show next parameter. Totaliser Set O S Press ↵ key then the display changes to XXXXXX Use numeric key to change the value Page 45 . Address SS Press ↵ key then the display changes to XXX Use numeric key to change the value. Speed measuring time S.SPress ↵ key then the display changes to XX Use numeric key to change the value. Press ↵ key to record the change. Then the display will show next parameter. Press ↵ key to record the change.

shift or have any jerky motions. Make sure that the belt runs smoothly over the weighing frame. It does not slide. Press ESC key to come out of programming loop. SYSTEM RESET Press SYS RESET key and the system displays u Enter the password ‘42391’ Then the display shows momentarily ESE Then it will comeback to the normal mode. Page 46 . Note: From any of the levels if ↵ key is pressed the parameter value is automatically stored in the system memory and display changes to the next parameter. Section 9 Commissioning Before commissioning the system allow the belt to run for at least one hour.Instruction manual for Belt scale Press ↵ key to record the change. Press ESC key to come out of programming loop. make sure that they are functioning correctly. Before connecting the loadcells and tachogenerator to the electronic panel.

Allow the belt to run continuously for half an hour and see whether the reading remains zero. Now perform tare using the keypad. Without calibration. you can now calibrate the system. The indicator reading should be zero. Page 47 . connect the loadcells and the tachogenerator to the electronic unit. switch on the unit and check up the functions of the unit by shorting the tachogenerator and the Red & White wires of each loadcell at the terminal block connector in the control panel. The Belt Weighing System is calibrated at site with a calibration chain or rod of known weight per unit length or weight respectively. Now the system is ready for calibration. and let the whole conveyor system warm up for approximately one hour. Allow the belt to run and adjust the weighing frame. Section 10 Calibration Assuming all parameters are correct and the unit is installed properly.Instruction manual for Belt scale Before connecting loadcells and tachogenerator to the electronic panel. check whether the idlers is running freely and also check the loadcell connection. Turn ON the conveyor. If it does not. the system will not show correct rate value. The calibration process is generally carried out at 25 –75% of the rated capacity of the system. make sure the belt is empty. Keeps the belt running for half-an-hour to see the stability of the reading. Now.

The speed of the belt in m/s is calculated as Speed = (distance) (Time taken in s). The speed of the belt is monitored using a stopwatch. The quantity should agree with the rate reading. All of these are explained in the following sections. Make sure that all weighing pre/post idlers are in line and in contact with the belt. The length of the belt and time taken are noted down. • Ensure the chain covering the total weighing zone. Page 48 . • Put the chain on the belt & suspend one end. The tests are repeated three times and the average value is calculated on the basis of these tests. • Total weight /total length gives kg/m value. • Enter kg/m value. Carry out tare operation as explained under the “CALIBRATION” section in the user manual for BCW55L0 b) Load calibration After performing tare run operation load calibration is done. (Load calibration) • If the kg/m is not found weigh the total chain & measure the total length. Chain calibration In case of CALIBRATION CHAIN • Note down kg/m punched on the chain.Instruction manual for Belt scale The process of calibration involves two steps a) Tare run operation b) Calibration a) Tare run operation This is carried out when there is no load on the belt. • Carry out tare run operation. CALCULATION OF ACTUAL RATE: Let Belt speed = S m/s Weight of the chain = W kg/m Actual Rate in TPH = W x S x 60 x 60 1000 Reset the totaliser and start the stopwatch simultaneously. Run the empty belt for at least 15 minutes. Take the reading of the quantity for a known time. Make sure the belt is empty and clean. Load calibration may be carried out using Calibration chain or Calibration rods or both. The test chain is put on the belt and the rate reading is noted.

During subsequent rod calibrations the above noted down load value is to be considered for ascertaining the correctness of calibration. The Display will show u Page 49 . The displayed value is __________ (To be entered by our service engineer). • Enter kg/m value. • Carry out tare run operation. Observe the displayed load (kg/m) value and note down the same. Note: If drop test cannot be conducted then rod calibration is done after the chain calibration. • Total weight/idler spacing x No. SPECIFICATION) the value given in GA is only approximate value only. of Idlers gives kg/m value.16 (Section 04. Note : Always refer calibration chain/calibration rod data given at Page No. From belt scale panel TARE RUN: Make sure there is no material on the Belt. Now conduct rod calibration. Start the conveyor Press the TARE RUN key. Calibrating the system with both chain and rod After chain calibration perform drop test and make the necessary adjustments in the indicator settings. • Note down the weight punched on each rod and sum it up. There will be some variation in this value with respect to the value displayed when chain calibration was done.Instruction manual for Belt scale Rod calibration IN CASE OF CALIBRATION ROD • Ensure quantity of rods. • Put the calibration rods on the bracket provided on weighing frame. Do not change any indicator settings.

Instruction manual for Belt scale

Then Enter password 14673

O
After 2 or 3 revolution press ↵ key, then TARE RUN will be completed
If we are pressing ESC key the Display will show AbOrt
Note:
If TARE RUN is attempted in Belt OFF condition the Display shows
‘bELtOFF’. TARE RUN can be carried out in Belt OFF condition by putting the
system in internal speed mode.
TARE RUN should be carried out for at least 2 BELT revolutions.
To escape from the TARE RUN Press ESC key
LOAD CALIBRATION:
Place the Calibration chain on the Belt and start the Conveyor
Press CAL key then the Display shows..

u

Then Enter password 14673
The display changes to

Press ↵ key then the display changes to

XXXX
Enter the actual load value in kg/m and press ↵ key.
Display then shows..

Page 50

Instruction manual for Belt scale

O
To complete the calibration press ↵ key once again.
SPEED CALIBRATION:
Put the system in External Speed Mode (See SPEED TYPE in Set Parameters).
Run the conveyor at maximum Rated Speed. Wait for the Speed Display to stabilize.
Press CAL key then the Display shows..

u

Then Enter password 14673
The display then enters into calibration mode.
Press / key till the display shows

S
Press ↵ key then the display changes to

XXXX
Enter the actual Belt Speed in m/s and press ENTER key once again.
TOTALISER CALIBRATION:
Press CAL key then the Display shows..

u

Then Enter password 14673
The display then enters into calibration mode.

Page 51

Instruction manual for Belt scale
Press

/

key till the display shows

Reset the calibration factor to 1.0000. Store and Exit back to Display mode by pressing
the ESC key. Now run the conveyor at a constant speed with the calibration chain/rod
on it and clear the Totaliser.
Let the system run for 10 minutes. After ten minutes note down the indicated Totaliser
(ti ).
Now calculate the actual Totaliser value as
ta =

rate ( in tph ) x time ( in s )
60 x 60

Calculate the Totaliser calibration factor ti / ta
Enter this value as the calibration factor.
Note:
1) The default calibration value is 1.0000 and normally no change will be required.

DIP SWITCH SELECTION FOR SPEED MEASUREMENT
Set the required resolution for speed readout by selecting decimal point through
key pad.
If the speed of the conveyor is 1m/s, select decimal point as ‘2’ so that the read
out shall be 1.00m/s
Set cal speed to 0000 in calibration speed parameter and the dip switch position
to 1
Ensure the conveyor is running & speed sensor pick up wheel/tacho is also
running.
Observe the speed readout on the display. The readout shall be ten times more
than the actual speed.

Page 52

Make sure that at least two sets of the idler rollers of the conveyor on either side of the weighing idler are free to rotate. Make sure that the chain runs steadily on the belt at the center without any sliding and that all the chain rollers are rotating. of Idlers . Place the calibration rod at the specified position on the weighing frame.* 7.59 kg/m : Wm X Idler spacing X No. During calibration ensure that the belt is not whipping when calibration is being carried out. 4. 6.* Note down the correct weight and length of the chain (weight/length gives kg/m) or the correct weight and quantity of calibration rods provided. If necessary. Tie the chain at central point across the width and above the belt so that the chain occupies the centre of the belt when the belt is running. Once the read out gets stable.* 3. CALIBRATION DETAILS LOAD CALIBRATION Capacity of the system Belt speed Material load on the belt in Kg/m (Wm) Total material load on loadcells Page 53 : 600tph : 1. *Applies only when calibration is done using chain.Instruction manual for Belt scale If the readout is more than ten times then adjust the dipswitch such that the readout shall be closer to ten times the actual speed. PRECAUTIONS FOR CALIBRATION: 1. Make sure that the rollers of the chain are free to rotate and also the link points are free. lubricate the rollers and the link points. 2. calibrate the speed to actual speed.8m/s Rate in tph X 1000 : ----------------------------Speed in m/s X60 X 60 : 92. Position the chain in such a way that it covers equal lengths on either side of the weighing roller.* 5.

8 m/sec ACCEPTANCE TEST EXAMPLE Accuracy specified ± 0.96 Hz corresponds belt speed of 1. of pulses/revolution = 3.5 X Cap (rated) in terms of 100 tph is allowed in the operating range specified [generally 25 to 100% of rated capacity in comparison between the totalised quantity and the actual material weight (collected for minimum 15 minutes duration) This acceptance test subjected to the following ♦ Page 54 Fulfillment of pre-requisite conditions .m/s In case of Speed sensor & Pick up wheel Belt speed in m/s RPS of pick up wheel = -----------------------ΠxD = 3.Instruction manual for Belt scale : 92.58rps Where D is the diameter of the peck up wheel Frequency = RPS x No.96Hz 42.59 X 1 X 2 : 185.58 X 12 = 42.59 kg/m SPEED CALIBRATION In case of AC OR Pulse tacho Belt speed in m/s Tacho speed (RPS) = ------------------------ΠxD = ------rps Where D is the diameter of the tacho wheel or tacho mounting idler -----rps corresponds to ---.18kg on loadcell (100%) to read as 92.5% of full scale that is error of 0.18kg The system has been calibrated such that 185.

5 tonne or 500 Kg 100 An error of ± 500 Kg is acceptable with respect to totaliser reading to actual material weight collected CALIBRATION CHECK AND ITS PERIODICITY To calibrate the system refer calibration procedure explained in the earlier section.Instruction manual for Belt scale ♦ condition. The Display then shows. u Page 55 . CLEARING THE TOTALISER Press the TOT RST key. After calibration.5 X 100 = 0. System in under healthy and calibrated Specimen calculation Capacity (rated) 100 tph Accuracy specified ± 0. record kg/m value against cal. Reset the total as explained below. stability of structure. the rate should be zero. Chain/rod as wel as actual speed value. These parameters values should be cross checked at least twice in a month and also tare run should be performed against empty belt condition. Precautions/prerequisites to be followed strictly. physical changes of conveyor belt or conveyor system and rate of built-up of dust or spill on the scale. Running the System Now the system should be ready to run. With the calibration weights up.5 % Full scale Error allowed 0. The calibration interval is affected by things such as sensitivity of the system to ambient condition..

Instruction manual for Belt scale Then Enter password 14673 S Press ↵ key to clear the Totaliser. The Display automatically comes back to normal Display mode. Section 11 Trouble Shooting CAUTION When a fault occurs. the cause must be corrected before the fault can be cleared. If protective function keeps active it could lead to reduction in product life and damage equipment. Status Messages Page 56 . Make sure to remove the input power while maintenance Do not change any inner parts and connectors.

Many of the messages were discussed as needed throughout the manual already. The following list expands on a few of those previous messages and also includes messages that were not yet discussed. If it fails this test the system will Display Page 57 . When this is complete SELF TEST PASS message will appear in the panel display SELF TEST: This system incorporates an internal self-test feature. This is carried out whenever the system is POWER ON. RAM Check This test is performed to check the presence and proper functioning of the memory chip the RAM IC.Instruction manual for Belt scale There are many messages that may appear in the panel display that either indicate a potential problem or give status information. On power up the system performs a check on the memory chip and the chip that stores the “flash” parameters to assure no information has been corrupted. The Display will show u Then Enter password 14673 The display shows SS If the system passes the self-test. The user can also initiate the self-test by pressing F1 key. Press the F1 key. Then display shows PASS Then the display changes to XXXXXX The following tests are performed during SELF-TEST.

but steady. NOTE: If any of the above tests fail. Loadcell & speed sensor are not connected properly.Instruction manual for Belt scale and halts. Speed indication fluctuates Page 58 . Blinking display or unsteady readings Low power supply Bad earthing Loadcell cable not connected in the same sequence as in the drg The indicator display other than the actual reading. even if the ADC passes the test it does not imply that the ADC is fully functional. Therefore. this test will fail. On failure. Serial EEPROM Check This test is performed for the serial EEPROM IC. ADC Check This test is performed to check the digital section of the ADC. None of these problems are user rectifiable. there is a fault annunciation and the display will show Note that if the serial EEPROM is write protected. Calibration disturbed (requires re-calibration) Fluctuations in readings Input voltage is below 180 V. Please contact IPA if any of these failures occur. the system will halt and no further operation can be carried out. there is an fault annunciation and the display shows Note that this test does not check the analog section of the ADC. On failure.

High winds cause fluctuations in weighing.00 0 500. Panel is subject to high vibration near a crusher or screen. High temperature fluctuations cause scale.Instruction manual for Belt scale Speed sensor wires are open. Electrical interference causes false speed or load signal Parameters are incorrect Section 12 Page 59 Parameter Entry Table Parameter Default settings Factory settings Under load Over load Set speed Speed type Span rate Load factor Address 0010.0 1.0 01. Conveyor belt has many splices. Incorrect or invalid parameter settings Material on belt during calibration. Material test was never performed Belt speed not calibrated properly. repairs and irregularities.0 0800.0 0800.80 0 720. Speed sensor does not spin freely. No proper feedback from speed sensor System is inaccurate… Here are several potential problems that can lead to System inaccuracy: Weigh idler are not aligned properly Weigh idler rollers do not spin freely.0 01.0 1. conveyor and belt deformation.0000 000 0000. Rain increases weight of material after the scale weighs it and before truck is weighed.0000 001 . System is mounted on an incline causing material to roll back and be weighed twice.

The following part may deteriorate with age because of their structures or physical characteristic.Instruction manual for Belt scale Speed measurement time Totaliser set Decimal point Filter value (load) Resolution Decimal point (speed) Filter value (speed) Decimal point (rate) Decimal point (totaliser) Section 13 01 099999 1 000 1 2 10 1 0 01 000002 1 000 1 2 01 1 0 Replaceable Spares The belt scale consists of many electronic parts such as semiconductor devices. It is better to maintain the following spares to be used in emergency: Belt Scale Panel Page 60 . For quick maintenance keep a set of spare cards. leading to reduced performance or failure of belt scale. Component level servicing of card at site is not recommended. Send the defective card to IPA for rectification. Repairing the belt weigher by replacing the defective card is very easy.

Instruction manual for Belt scale Line filter : EP-42-1 Transformer : TR-314 SMPS card : 9823D ADC card : 9830 FR02 Display card : 7060 Relay card : 9830C Keypad : 4X4 type : TR-305 Controller card : 9825C Display card : 9825B Model : BR071H0 Speed sensor Make : INFRA : IS41 Remote Indicator Transformer Loadcell Model Section 14 Dip Switch Positions ADC Card 9830FR02 SWITCH 1 (Speed sensor Selection Switch) PIN POSITION ON OFF 1 √ 2 √ 3 √ 4 √ SWITCH 2 (Frequency Selection Switch) Page 61 SPEED SENSOR .

Instruction manual for Belt scale PIN 1 2 3 4 5 6 7 8 POSITION ON OFF √ √ √ √ √ √ √ √ SPEED SENSOR SWITCH 3 (Current Selection Switch) PIN 1 2 3 4 Section 15 Item/ Component Idler Belt Load cell Page 62 POSITION ON OFF √ √ √ √ Maintenance Schedule Period of Type of problem Verification Once in six i) Excess run out months Everyday i) Excess belt sway ii) Undue wear out Everyday 4-20mA i) No load or Excess load Cause a) Bearing and / or Bearing seal wear out a) Belt loose a) Skirt plate Touching the belt b) Lump getting stuck between feed chute & belt and /or skirt & belt a) Check for foreign body causing load shunting Remedy Replace idler Adjust takeup Lift skirt plate Remove lump manually and clean Remove foreign body and set right .

Instruction manual for Belt scale Tacho Speed Sensor Item/ Component Coupling Everyday Everyday Period of Verification Everyday Weighing Weekly Frame Idler/Pulley Once in six months Page 63 i) Speed fluctuates ii) Sudden jump in signal i) Speed fluctuates ii) Sudden jump in signal iii) No speed feedback Type of problem i) Undue noise Material accumulation i)Wobbling ii)Excess heat in bearing block a) Load cell wire open Reconnect b) Insulation failure a) Tacho wheel or coupling not making proper contact b) Loose connection a) Tacho coupling loose/missing pulse a) Pick wheel alignment not ok b) Loose connection c) Speed sensor coupling loose d)Sensor is not in proximity with pick up wheel Change loadcell Set right Align coupling Align coupling Cause Remedy a) coupling loose b) Axial or angular misalignment a)Material may fall from belt a) Bearing and /or Bearing seal wear out Tighten bolt Align coupling Clean it at regular interval Clean bearing Apply grease/ Replace bearing .

grease etc. provided the terms and conditions in our offer are complied with. the items are to be returned to us at your cost. During this period. Our guarantee does not extend to damages caused due to negligence or improper handling or erection by the buyer or any alteration carried out without our knowledge /approval. Damages or losses caused during transit Consumable items such lubrication oil. Page 64 .Instruction manual for Belt scale Section 16 Warranty The items are covered by our warranty /guarantee for a period of 18 months from the date of dispatch or 12 months from the date of commissioning whichever is earlier. How ever our guarantee does not cover Normal wear and tear of the items during operations. Deterioration or rusting due to atmospheric conditions.

glass part. indicator lamp. After Sales Service We can also service/ maintain the system supplied by entering into an ANNUAL SERVICE CONTRACT at nominal charges available on request after the guarantee period.Instruction manual for Belt scale Damages resulting from accidents. plating. mishandling or negligence on the part of customer. Page 65 . power card. proclaim. Breakage or damage of back light. chipping or peeling of enamel and denting of the equipment.