Transweigh Weigh Feeder Maintanence

Weigh Feeder with TUC Electronics
WEIGH FEEDER
Transweigh India Ltd

124, ABCD, Govt. Indl. Estate,
Kandivli(w)
Mumbai 400 067.
India
Tel : +91-22-6772 6000 / 6772 6002

DID : +91-22-2868 9680 www.transweigh-india.com
FAX : +91-22-6772 6100 Service@transweigh-india.com
Copyright © 2010 Transwigh India Ltd
NOTICE
All Rights Reserved
No part of this manual may be reproduced or transmitted in any form or by any means
without prior written consent of Transweigh India Ltd
The information in this manual is subject to change without notice. Every effort has been
made in the preparation of this manual to ensure accuracy of the contents, but all
statements, information, and recommendations in this manual do not constitute the
warranty of any kind, expressed or implied.
The examples and diagrams in this manual are included solely for illustrative purposes.
Because of the many variables and requirements associated with any particular
installation, Transweigh India Ltd cannot assume responsibility or liability for actual use
based on the examples and diagrams.
No patent liability is assumed by Transwigh India Ltd with respect to use of information,
circuits, equipment, or software described in this manual.
In no event will Transweigh India Ltd be responsible or liable for indirect or

consequential damages resulting from the use or application of this equipment.
WARNINGS & CAUTIONS
Warnings, Cautions
The following Warnings and Cautions are provided for your safety and as a means of
preventing damage to the product or components in the machines connected. Specific
Warnings, Cautions and Notes that apply to particular activities are listed at the
WARNING
beginning of the relevant chapters and are repeated or supplemented at critical points
throughout these sections. Please read the information carefully, since it is provided for
your personal safety and will also help prolong the service life of your WEIGHFEEDER
and inter related equipments.
WARNING
This equipment contains dangerous voltages and controls potentially dangerous rotating
mechanical parts. Non-compliance with Warnings or failure to follow the instructions
contained in this manual can result in loss of life, severe personal injury or serious
damage to property.
Only suitable qualified personnel should work on this equipment, and only after
becoming familiar with all safety notices, installation, operation and maintenance
procedures contained in this manual. The successful and safe operation of this equipment
is dependent upon its proper handling, installation, operation and maintenance.
While using the inter related equipments like AC/DC motor, AC/DC drives, Gear box
etc., ensure the precautions & safety points from the respective manual.
Note
Before installing and commissioning, please read these safety instructions and warnings
carefully and all the warning labels attached to the equipment.
ATTITION This manual is intended for qualified personnel. You must be able to understand the
Weigh feeder GAD, Electrical diagram, TUC parameter settings and operate Adjustable
Frequency AC Drive /DC drive devices. In addition, you must have an understanding of
the dynamic weighing fundamentals. .
Throughout this manual, when necessary we use notes to make you aware of safety
considerations.
WARNING: Identifies information about practices or circumstances that can cause an

explosion in a hazardous environment, which may lead to personal injury or death,
property damage, or economic loss.
Shock Hazard labels identifies the may be located on or inside the equipment (e.g., drive
or motor) to alert people that dangerous voltage may be present.
Rotating Hazard labels identifies rotating moment parts the may be located on or inside
the equipment (e.g., drive or motor) to alert people that dangerous voltage may be
present.
PREFACE
Chapter -1
Descriptions of Mechanicals
1.1 Weigh Feeder structure . 05
1.2 In-feed Hopper . 07
1.3 Discharge hoot ......................... . 08
1.4 08
1.5 Scrappers . . 09
1.6 Auto Tensioning Assembly . 10
1.7 Gear box and drive unit . 11
1.8 Weighing assembly
Chapter -2
Descriptions of Electricals
2.1 TUC . 12
2.2 Analog Cards .. 14
14
15
2.2. 16
2.3 Digital Cards . 17
.17
18
2.3.3 F890 & (F889 + F890) .. ..19
2.4 Motor . .20
2.5 Load cell .. 20
2.5.2 C
2.5.3 Color code for SCAI
2.6 Tacho 23
23
2.7 Zero Speed Sw 24
24
Chapter -3
Descriptions of TUC Operation ...............................25
3.1 Mode of operation 6
3.1.1 Gravimetric mode .. .26
26
.27
..27
3.2.2 Remot .27
3.2.3 De- .27
3.2.4 De- .28
.28
..29
Chapter -4
4. Commissioning
4.1 TUC password calculations ...............................................................................30
4.2 Calibration 31
31
..31
4.3 Calibration .32
4.4 Calibration calculation 33
4.5 ..34
4.6 Error calculations ...36
37
4.8 42
4.9 .42
Chapter - 5
5. Course of action for Calibration & Zero correction
5.1 Calibration course of action for TUC 6 ....................................................................44
5.2 Calibration course of action for TUC 4 ..46
48
.50
51
Chapter - 6
6. Fault & Trouble shooting
53
6.2 Belt Tracking !............................................................................................................54
.55
6.4 Integration off !.........................................................................................................56
6.5 Emergency Stop !......................................................................................................57
6.6 Corr.> Set .58
.58
58
6.9 AIO Communication !...............................................................................................59
6.10 Under load !.............................................................................................................59
6.11 Over load !...............................................................................................................60
6.12 Anal. i/p Error !........................................................................................................60
.60
.61
61
62
6.17 SIO communication !...............................................................................................62
6.18 Master communication !...........................................................................................62
CHAPTER 1
1.1 WEIGH FEEDER STRUCTURE
This feeder / conveyor arrangement is constructed with drive and tail pulley unit along with idler
arrangements.
The weighing mechanism fabricated along with the feeder.
1.2 INFEED HOPPER
In-feed chute arrangement is installed at bottom of the storage bin / silo. The chute type is
selected based on the material specification and capacity.
TYPES OF IN-FEED CHUTE
1. V-Hopper
2. U-Hopper
3. VLC Hopper
CHAPTER 1
1.3 DISCHARGE HOOD
(These details will be provided in the next updates)
1.4 SKIRT BOARD
This arrangements is guide the material, such a way that the material should not come out from
running belt. The skirt board should not touch the belt.
If the skirt board arrangement touches on the running belt at measuring zone area, it causes the
wrong indication TPH, due to wrong excess load.
If the gap between the skirt board & running belt is more gap it causes the material is possible to
stuck the inside the gap and damage the belt and it gives wrong readings.
The recommended gap is 2mm between belt and scatter board, it is possible to changes depends
up on the site condition.
Figure shows the material is struck between the belt & the skirt board.
CHAPTER 1
1.5 SCRAPPER
1.5.1 INSIDE SCRAPPER:
Scrapper locker
Scrapper
1.5.1 OUTSIDE SCRAPPER:
Scrapper adjustments
Scrapper
CHAPTER 1
1.6 AUTO TENSIONING ASSEMBLY

CHAPTER 1
1.7 Gearbox and Drive unit
1.7.1 Drive unit for threaded type tacho
1.7.2 Drive unit for Flange type tacho

CHAPTER -2
2.1 TUC (Transweigh Universal Controller)
Obsolete
Cut out size :

Power supply :
Outputs :
Interface cards :
External interface:
Cut out size :

Power supply :
Outputs :
Interface cards :
External interface:
Cut out size :

Power supply :
Outputs :
Interface cards :
External interface:
Cut out size :

Power supply :
Outputs :
Interface cards :
External interface:
CHAPTER -2
Cut out size :

Power supply :
Outputs :
Interface cards :
External interface:
Cut out size :

Power supply :
Outputs :
Interface cards :
External interface:
TUC Types & Applications
TYPE APPLICATION
TUC-2 (+) WF, LIW, Kiln feed systems

TUC-3 BLMS, Belt weigher, SFM
TUC-4 Weigh feeder
TUC-5 Bagging and batching
TUC-6 WF, BW, BLMS.
CHAPTER -2
2.2 ANALOG CARDS
2.2.1 F875 Analog card
Model : F875
Supply input : 24 V DC
No of analog input :2
No of analog output :2
Analog input : (0-10)V / (4-10)mA (selection based on Jumper settings J1)
Analog output : (4-20)mA
Interface : Modbus.
Analog input tuning : Software (Analog input menu)
Analog output tuning : Software (Analog output menu)
Jumper J1 for Input selection
X4: Power supply X1-A: Comm. X1-B: Comm. X2 : Analog Input X3 : Analog Output
X1-B: Comm. X2 -1: +5 V DC
X4 -1 : 24V DC+ X1 A-2: + X1 B-2: + X3 -1: AO 1 +
X4-2 : 24 V DC - X1 A-3: - X1 B-3: - X2-2 : AI 1 + X3-2 : AO 1 -
X4-3 : GND X1- A-4 : GND X1- B-4 : GND X2-3 : AI 1 - X3-3 : GND
X2-4 : GND X3-4 : AO 2+
X2-5 : AI 2 +
X2-6 : AI 2 -
X3-5 : AO 2 -
TUC support X2-7 : GND
F875- Ver : 1.0
TUC 6 CAN : Ver 1.0 onwards

TUC 2+ : Ver 7.2 onwards
GFC : Ver 1.0 onwards
CHAPTER -2
Model : F868
Supply input : 230 V AC
Interface : Modbus.
Analog output tuning : By Pot
Analog input tuning : By Software (Analog input menu)
X5: Power supply X2 : Analog Input X3 : Analog Output X1-A: Comm. X1-B: Comm.
X5 -1 : 220 AC L X2 -1: AI + X3 -1: AO + X1 A-2: + X1 B-2: +
X5-2 : 220 AC N X2-2 : AI - X3-2 : AO - X1 A-3: - X1 B-3: -
X5-3 : GND X2-3 : GND X3-3 : GND X1- A-4: GND X1- B-4 : GND
X2-4 : + 5V DC
TUC support
F868- Ver : 1.0 F868- Ver :4.0
TUC 4 : Ver 1.0 to 7.0 TUC 4 : Ver 9.0 onwards

TUC 2+: Ver 1.0 to 3.2 TUC 2+: Ver 4.0 onwards
TUC 6 : Ver 1.0 TUC 6 : Ver 2.0 onwards
TUC 6 CAN : Ver 1.0 onwards
CHAPTER -2
Model : F840
Interface : Modbus.
Analog input tuning : Software (Analog input menu)
Output tuning : By Pot
X5: Power supply X2 : Analog Input CH1 X3 : Analog Output X2 : Analog Input CH2 X1 : Comm.
X5 -1 : 220 AC L X2 -1: AI + X3 -1: AO + X2 -1: AI + X1-1 : ?
X5-2 : 220 AC N X2-2 : AI - X3-2 : AO - X2-2 : AI - X1 -2: ?
X5-3 : GND X2-3 : GND X3-3 : GND X2-3 : GND X1- 3: ?
X2-4 : + 5V DC X2-4 : + 5V DC
X1- 4: ?
TUC support
F840 - Ver : 1.0
TUC 2: Ver 1.0 onwards

CHAPTER
CHAPTER-2-2
2.3 DIGITAL CARDS
2.3.1. F866 Digital card
Model : F866
No of Digital input :8
No of Digital output :8
Digital input type : 24V DC input (24 V Dc available in DIO card)
Digital output type : Potential free.
Interface : Modbus.
Controller support : TUC-4 (S.V: / TUC -5 (S.V..) TUC-6 (S.V:
Cascade : F866 & F866
F866
CHAPTER -2
Model : F889
Supply input : 24V DC
Interface : Modbus.
Cascade : F889 & F890
F889
CHAPTER -2
Model : F890
Supply input : 24V DC
Interface : Modbus.
Connection : Only along with F889
F890
F889 & F890

CHAPTER -2
2.4 MOTOR
If motor is less than 2.2 Kw configure as a star.

If motor is more than 3.7Kw configure as a delta.
Note: Before cable termination ensure the connection as per motor name plate.
Star connection Delta connection
2.5 LOAD CELL
Most of the cases the following load cell has been used for Weigh feeder application.
CHAPTER -2
2.5.1. Load cell mounting details
Knife edge
Load transfer Idler
Fulcrum
Load cell base bolt
Tie rod
Load cell Lock bolt
(Photo for load cell mounting arrangements)
2.5.2. Color code for HBM Load cell:
COLOR DETAILS
BLACK EXC (-)
BLUE EXC (+)
GRAY SENSE (-)
GREEN SENSE (+)
WHITE OUTPUT (+)
RED OUTPUT (-)

CHAPTER -2
2.5.3. Color code for SCAME Load cell:
COLOR DETAILS
WHITE EXC (-)
RED EXC (+)
BLACK OUTPUT (+)
BLUE OUTPUT (-)
2.6 TACHO
CHAPTER -2
2.6.1 Tacho details
Inner shell
Outer shell
Tacho Lock nut
Sensing Gap 0.2 0.5 mmm
Color code for 2wire tacho

COLOR DETAILS
Brown EXC (+)
Blue Output
CHAPTER -2
2.7 ZERO SPEED SWITCH (ZSS)
Sensing device
2.8 MATERIAL DETECTOR SWTICH (MDS)

CHAPTER -3
3.0 DESCRIPTION OF TUC OPERATION
Load cell Yo
TUC
Tacho
Wc
W1 Wm W3
Power cable
Screen Cable
WF discharge the material from the storage Bin with respect to the set point TPH (Wc).
TUC first
to Wc.
-10)volt / (4-20)mA / through modbus
communication to run the motor.
Again the TUC is taken the feedback from Tacho to determine the speed reference (m/s)
with respect to PI settings in SET1

CHAPTER -3
The load reference is given to controller through Load cell calibration by using test
weight.
The speed reference is given to controller through setting of Nominal tacho frequency in
measuring parameter.
3.1 MODES OF OPERATION
TUC Operation
Gravimetric Volumetric
mode mode
CCR TUC (Panel) CCR TUC (Panel)
(Interlock mode) (De-Interlock (Interlock mode) (De-Interlock
Local
(LCS)
3.1.1 Gravimetric = Automatic = Closed loop
Material flow is controlled as per set point TPH

The running TPH (X) is always matched with the set point TPH (Wc)
3.1.2 Volumetric = Manual = Open loop
Material flow is controlled by controlling of motor speed.

The set point TPH (Wc) is not matched with running TPH (X)
CHAPTER -3
3.2 LOCATION OF OPERATION
Local mode (LCS)

TUC / panel mode
Remote mode (CCR)
3.2.1 LocalMode
The set point & Start/stop commands from Local LCS.

The operation is unregulated due to volumetric operation.
3.2.2 Remote Mode
put. This mode is sub-divided

into four modes.
De-Interlock Gravimetric mode
De-Interlock Volumetric mode
Interlock Gravimetric mode
Interlock Volumetric mode
3.2.3 De-Int. Gravimetric mode
or selected through TUC keypad.

Start/Stop & Set point are through TUC keypad.
Set point given from SET-2, in W1
CHAPTER -3
3.2.4 De-Int. Volumetric mode
De-

Start/Stop & Set point are through TUC keypad.
Zero correction possible in this menu.
Set point given from SET-2, in Wm
3.2.5 Interlock Gravimetric mode
This -

CHAPTER -3
3.2.6 Interlock Volumetric mode
Thi -

CHAPTER -4
4.1 TUC PASSWORD CALCULATIONS
The password is a 5-digit number dependent on current date.
digit digit digit digit digit

1 2 3 4 5
m1 m2 d1 d2 X
Current month in two-digit format
Current date in two-digit format
X = (20) ( m1 + m2 + d1+ d2)
The year digits are not considered for calculation
Example-1
Current Date: 01-06-2007
digit 1 digit 2 digit 3 digit 4 digit 5
M1 m2 d1 d2 X
0 6 0 1 X
Now calculate X from date and month digits:
( m1 + m2 + d1+ d2) = 0 + 6 + 0 + 1 = 7
therefore X = 20 7=13
Password: 06013
Example-2
Current Date: 11-12-2006
digit 1 digit 2 digit 3 digit 4 digit 5
M1 m2 d1 d2 X
1 2 1 1 X
Now calculate X from date and month digits:
( m1 + m2 + d1+ d2) = 1+ 2+ 1 + 1 = 5
therefore X = 20 5=15
Password: 12115
CHAPTER -4
4.2 CALIBRATION
4.2.1 Load Calibration

The field load reference (100%) and speed reference (100%) is informed / fed to the TUC
by the method of calibration.
The load reference is given to the controller by simulation of mV by using the test
weight.
TUC consider the Tare mV is equal to zero load by the action of dead load calibration in
calibration menu.
TUC consider the Simulated span mV is equal to percentage of load with respect to the
Based on these two references TUC recognize the instantaneous load on the load cell.
4.2.2 Speed Calibration

The 100% speed reference is directly declared to the controller by feeding of tacho
frequency (TF) in Measuring parameter.
TUC gathers the pulse input from the tacho and it is converted in the form of Hz.(Ta)
TUC recognize the instantaneous m/s by comparison of instantaneous running Tacho
(Ta) with reference frequency (TF).
Calculation
TPH
X = BB (%) x Ta (Hz) x 3
100 % concept
For achieve 100% TPH the BB should 100 % at 100 % speed.
ve same set TPH value.
Error
If there is any error in the speed reference or load reference, the indicated value is not in line
with the actual. It can be encounter by the drop test. The drop test error is compensated by
adjusting any one reference with respect to the error.
The error can be eliminated by the exact calculation of calibration percentage & proper speed
reference.
CHAPTER -4
4.3 CALIBRATION CALCULATIONS
TPH = Kg/M x M/s x 3.6 (General Standard) (factor 3.6 to convert m/s to Tph)
X = BB (%) x Ta ( Hz) ( TIL Standard)
Revolution Per Seconds (RPS) : 1000

60 x GB Ratio
(1000 is reference speed for calculation of m/s)
Speed M/s : RPS x (3.14) x d
Kg Per Meter : TPH

M/S x 3.6
Kg per measuring zone (GM): Kg/M x 0.35

(0.35 is measuring zone distance)
Load on the Load cell (FM) : Gm /2.5

(2.5 is Lever ratio)
in mm : FM x 200
Test Weight
Eg: 250 mm for 100% calibration if it is not possible, calibr

distance.
Tacho calculations
Tacho Frequency : Reference RPM x No. of Teeth in wheel

60
CHAPTER -4
4.4 CALIBRATION CALCULATIONS AS PER MV CALCULATION
Example for Weigh feeder
Capacity : 100 TPH

Speed : 0.182 m/s
Load cell : 50 Kg
EXC : 11.81 Volt
Tare mV : 2.4 mV
Span mV : 11.4 mV (keeping the test weight on the knife edge for calibration)
Test weight : 16.4 Kg.
mV for Lever ratio : 5.38 mV (Keeping the test weight on the center of the center measuring idler )
Step by step of calibration calculation:
TPH : Kg/m x m/s x 3.6
Kg /m : TPH / (M/s.x3.6) : 152.672 Kg (100 / (0.182*3.6)
Kg @ Measuring Zone 0.35m) : Kg/m x 0.35 : 53.435 Kg (152.672 x 0.35)
(Load on Load cell) : GM / Lever ratio : 20.552 Kg
Lever Ratio:
As per the design the Lever ratio is 2,5, but due to the mechanical clearness the Lever ratio is
It means how much Kg applied on one side and how much Kg is getting on the another side,
This ratio is called as lever ratio.
Lever ratio point:

Remove the skirt board and keep the test weight in line with the Center of the center measuring idler.
CHAPTER -4
50 Kg = 23.62 mV (11.81 x2)
Net mV : (Lever ratio mV Tare mV)

: (5.38 mV 2.4 mV)
: 2,98 mV
As per mV cross calculation getting Kg :
Applied weight is 16.4 Kg but getting 6.308 Kg.
Therefore Lever Ratio : 16.4 / 6.308

: 2.6 (use this value for FM calculation)
Calibration Percentage:
two methods,
Method 1:
The calibratio
Formula:
Note:
In this method, the error is possible in the calibration due to following reason:
1.1 Mechanical clearness error.
1.2
2. The accuracy of the weigh feeder is got disturbed due to this above error.
3. To over come this error, cross check the calibration percentage w.r.t load cell mV.
Method 2:
It is derived based on the comparison of net weight on the load cell (by cross calculation weight w.r.t to
Note:
1. In this method the all the errors are possible to over come.
Method: 1
: (FM x 200) / Test weight.

: ( 20.552 x 200) / 16.4
: 250.6 mm
Note:
1.
calibration percentage by the method-2
CHAPTER -4
Method: 2
The span mV: 10.8 mV.
EXC : 11.81 V
Load cell Sensitivity : (2mV/V)
50 Kg = 23.62 mV (11.81 x2)
As per test weight mV : Span mV Tare mV
(11.4 2.4) 9 mV = 19.051 kg ((50 / 23.62) x 8.4)
100 % weight is
19.051 Kg is
2000 d = 100 % )
Therefore as per the cross check the calibration percentage is not a 100% it is 92.69% .
The error in the calculation is around 8%.
There is no needed for drop test if the calibration has been done by method: 2.
Note:
1. The site r
2. The calculated values are marked as a under line.
3.
calibration.
CHAPTER -4
4.5 SPEED CALIBRATION
1. Measure the total belt length, operate the weigh feeder inching by inch and put a measurement
mark on the belt and find out the total belt length.
2. Run the weigh feeder at calibration speed (33Hz / 1000RPM).
3. Measure the time for 5 revolution, & average the revolution time, at the same time note down the
4. Calculate the M/s.

5.
Example:
Belt length : 7 Meter

Time for 5 Rev : 146 Sec
Average time : 146 / 5 = 29.2 Sec
Speed : Meter /sec = 7/29,2 = 0.24 m/s. (At the time Ta is 557 Hz).
Cross check:
1. Run the weigh feeder at 20Hz, calculate the Practical m/s and compare with the TUC displayed
M/s.
2. The same way ensure 4 to 5 point of drive frequency and conformed the indicated M/s. is in line
with the displayed M/s.
Note:
4.6 ERROR CALCULATIONS
Mismatches in measuring distance area.

Mismatches in Lever ratio.
Mismatches in speed (m/s).
Percentage of Error Calculation
% of Error : Indication value Actual material x Set point x 100.

Actual material Rated Capacity
CHAPTER -4
4.7 ERROR TROUBLE SHOOTING
IF any error in the weigh feeder indication, it might due to the following reason:
1. Field tacho reference to TUC is not proper.

2. Field Load (cell) reference to TUC is getting disturbed.
3. The 100% reference feed to the TUC is getting disturbed.
Tacho Details:
Outer shell
Mounting caller
Inner shell
Sensing tip
Washer
Tacho termination Details:
Tacho wire Field JB Panel TUC
Brown (+) 8 8 10
Blue 0 or O/P 9 9 11
Ground / Shield 10 10 12
Tacho Installation:
Gear Wheel
Sensing gap
CHAPTER -4
Ensure the sensing gap between 0.5 to 1mm.

If the gap is more sensor could not sense the striker point.
If the gap is very less tacho sensor possible to damage due to mechanical contact.
Note:
Once tacho has been installed, rotate the motor shaft by hand to ensure the gap settings.
Tacho Voltage Check Points:
Tacho status X11 Panel (8 & 9) X15 JB (8 & 9)
Sensing time 11.82 V 11.72 V
Non sensing time 5.92 V 5.92 V
Note:
Small voltage variation is possible due to the variation in the sensing gap.
Tacho cross checking:
ation, wiring continuity, termination,

sensing distance & voltage variation.
ing gap
is not proper or the tacho signal is got disturbed due to noise.
Tacho Vs M/s
Run the weigh feeder in volumetric mode at rated calibration RPM. (Generally the calibration
RPM consider as 1000 RPM).
Calculate the practical belt speed (m/s) at this calibration reference (1000RPM) & enter the m/s in
measuring parameter.
TUC Considered the entered Nominal Tacho fre
Example:
w.r.t practical
m/s.
CHAPTER -4
Cross check table:
Sl.No Drive RPM Tacho frequency Indication m/s Prac. m/s
1 1000 600 2.0 2.0
2 750 450 1.5 1.5
3 500 300 0.1 0.1
4 250 150 0.5 0.5
If all the indication value matches with the practical value, then there is no variation in the m/s
LOAD (CELL) REFERENCE:
The load reference is got disturbed due to the following reasons:

1. Improper weighing mechanism repeatability by observation of load cell mV.
2. Arresting the free moment of weighing mechanism.
3. Constant load is added for weighing due to skirt board sitting on the measuring idler.
4. Ageing of bearing in the weighing idler causes wobbling of idler rotation, affects the weighing
impact.
5. Improper belt tensioning & metal joints in the belt.
6. Disturbing of (load refer
To ensure the weighing mechanism repeatability:
.
Knife edge
Load transfer Idler
Fulcrum
Load cell base bolt
2 Tie rod
1
3 3
Load cell Lock bolt
The yellow rings are showing suspected problematic area in case of poor repeatability.
CHAPTER -4
Yellow ring 1:
ad cell locking bolt due to in sufficient gap.
Cause:
If the both the bolts are touching to gather, the actual weighing impact got disturbed causes the minimum
mV variation.
Solution:
Lose the load cell lock bolt & ensure the sufficient gap between the both the bolts and check the mV
Note:
Ensure that, the load cell mV should not increase 24mV, accordingly tight adjusted the lock bolt.
Yellow ring 2:
The problem is suspected the con
arrangements is not proper.
Cause:
Due to this bolt lose causes the improper load transfer, hence the load cell mV is not increased w.r.t test
weight.
Solution:
weighing cradle.
Yellow ring 3:
The problem is suspected the connection in Tie-rod connection.
Cause:
Due to this bolt lose causes the improper load transfer, hence the load cell mV is not increased w.r.t test
weight.
Solution:
ight on the weighing cradle.
2. Arrest the free moment of the weighing mechanism:
Weighing cradle is hanged between the two fulcrum points. Hence weighing is done by transferring of
material impact from the running belt. If any material will struck / disturb the free moment of cradle it
causes the error in the reading due to transfer loss of weighing impact.
CHAPTER -4
3. Elimination skirt board weight added for weighing:
Fig:1 Proper skirt board Picture :2 Improper skirt board
Symptom:
If the gap is less the skirt board sited on the weighing zone, hence the error in the measurement.
If the gap is more, material might struck between the belt and skirt board it reflects the error in the
measurement. Picture: 2
Solution:
Recommended to maintaining the 2mm gap between skirt board and the belt.
4. Ageing of weighing idlers:

Symptom:
The weighing idler bearings are might be damaged due to ageing. Due to this the idler might run like
wobbling, Hence it is disturb the actual weighing impact. It reflects error in the weighing measurement.
Solution:
Suggested to replace the weighing idlers.
5. Improper belt tensioning:

Ensure the belt is in proper tensioning, unless the belt will swag in between the idlers. It disturb the
weighing impact, hence the error in the weighing measurement.
Suggested to tighten the belt and adjusted the auto tensioning assembly to avoid the same.
6. Disturbances of Calibration counts:
counts it is reflects error in the weighing measurement.
Please ensure the above mentioned points while regular maintenances to sustained better performance of
weigh feeders.
CHAPTER -4
4.8 ERROR CORRECTION
T
by the below formula.
Error correction in Speed reference:
New Tacho frequency: (Indicated value / Actual value) x old tacho frequency.
The existing tacho frequency in the measuring parameter has to be adjusted according to the above
formula to compensate the error.
Note:
Error correction in Load reference:

(Indicated value / Actual value) x old Span count .
The existing Span count in SET- 4 has to be adjusted according to the above formula to compensate the
error.
Note:
keep the same test weight in
Refer this indicated percentage for future
calibrat
4.9 DROP TEST PROCEDURE
minimum of 6 minutes OR more to be collected in each drop test for completed revolutions . e.g. For
weigh feeder capacity of 60.00 TPH, minimum 6.00 ton of material needs to be collected.
Drop test to be preceded by successful Zero Correction with empty belt running which is the pre-
condition to drop test. Pls refer Zero Correction procedure.
Drop test to be conducted on same set point. No changes in set point to be carried out.
The drop test to be conducted for operating range of 75% to 100% of Weigh Feeder Designed Capacity.
The drop test to be collected for completed revolutions of belt. Drop test with part revolution of belt is not
considered. The start command to be from any location; however the feeder to be stopped only from field
at completed revolution.
Weigh Feeder with TUC Electronics CHAPTER -4
The drop test to be conducted only and only for establishing the accuracy of weighing. The cumulative
value of totalizer for drop test cycle is compared with the actual reading measured of the collected
material during drop test, on the pre-calibrated static weighing scale.
The least count of weigh feeder controller' cumulative totalizer should have 1 kg OR 0.001 ton.
For cumulative drop test totalized value of 5000 kg OR less, the acceptable least count of pre-calibrated
static weighing scale should be 1 kg OR 0.001 ton with maximum allowable error of static weighing scale
of +/- 0.1% or lesser.
For cumulative drop test totalized value of above 5000 kg to 20,000 kg, the acceptable least count of pre-
calibrated static weighing scale should be 5 kg OR 0.005 ton with maximum allowable error of static
weighing scale of +/- 0.1% or lesser.
For cumulative drop test totalized value of above 20,000 kg, the acceptable least count of pre-calibrated
static weighing scale should be 10 kg OR 0.010 ton with maximum allowable error of static weighing
scale of +/- 0.1% or lesser.
The Static Weighing Scales are rated for certain capacities. The drop test collected material should be
within the range of 50% to 100% of capacity of pre-calibrated static weighing scale.
Minimum 3 no. drop test readings with consistent error band within 0.5% range is required for affecting
error compensation. e.g. 3 no. error readings of drop of 1.5 %, 1.6 %, 1.7% will mean the error of
minimum 1.5% to 1.7%. However the band is 1.5% - 1.7% which is 0.2% error band.
Post error compensation, further minimum 2 no. drop test are required to establish weigh feeder error.
Error can be calculated with the following formula.
Error = {(S1 Reading) (Static Weigh Scale Reading)} X100X(Set Point)/{(S1 Reading) X (WF capacity)}
The committed accuracy is +/- 0.5 % of rated capacity.
Typical table for drop test readings:
DURATION TOTALIZER ACTUAL

SET
MATERIAL
SR. NO. POINT (IN MNTS./ 1 (IN ERROR REMARK
COLLECTED
(IN TPH) SEC.) (In %)
KGS.) (In Kgs.)
CHAPTER -5
5.1 CALIBRATION PROCEDURE FOR TUC-6 (WF)
CHAPTER -5
CHAPTER -5
5.2 CALIBRATION PROCEDURE FOR TUC-4 (WF)
CHAPTER -5
CHAPTER -5
5.3 CALIBRATION PROCEDURE FOR TUC 2+ (WF)
CHAPTER -5
CHAPTER -5
5.4 RAM INITIALIZATION PROCEDURE FOR TUC-6 & /TUC-4
Note: After the above procedure, check the SET 1 parameters values, if the values are become zero it
means that RAM initialization has been done successfully.
If the values are not become zero it means RAM initialization execution is not proper.
CHAPTER -5
5.5 ANALOG INPUT CALIBRATION PROCEDURE
CHAPTER -5
CHAPTER -6
6.FAULT & TROUBLE SHOOTING
6.1 TACHO FAULT !
Tacho Fault ! Tacho input missing
Cause:
What to do: Ensure the tacho wiring & termination as per elec.
diagram.
Ensure the distance between tacho sensing point & wheel should be
0.5 to 1mm.
Ensure the voltage variation in tacho terminals w.r.t to sensing.
Ensure the physical running of weigh feeder.
Voltage Check points :

1. X11 (panel) -- 8 &9 is 12 V when tacho not connected.
2. X11 (panel) -- 8 & 9 is around 11.82 when tacho connected.
3. X15 (field JB) -- 8 & 9 is around 11.72 V when tacho sensing.
4. X15 (field JB) -- 8 & 9 is around 5.92V when tacho non-sensing.
Note: 1.The Tacho cable must be screened cable.

2. If the field tacho failed, use drive tacho through modbus communication. By selection of Tacho type as
asuring parameter.
3. Do not apply direct 12V source voltage to tacho for checking purpose.
4. For more details pls refer tacho cross checking note.
CHAPTER -6
6.2 BELT TRACKING !
Belt Tacking! Belt track input missing
Cause: TUC not detected the belt swat input from the field sensor
What to do:
Ensure the hard ware wiring as per electrical diagram.
Ensure the study glowing status on the defied green LED in the
DIO card w.r.t to SPSS.
Ensure the SPSS logics inline with the panel hard ware.
Check the input & marker healthy status in SET 5
SPSS Program:
*SPSS
UE 001 (Input no. depends on the hard logics )
=M 009
On line status in SET 5 Press & to view the reporting status of Inputs & Markers.
As per the display E001 & M009 is healthy. If M009 unhealthy

CHAPTER -6
6.3 DRIVE INTERLOCK ERROR !
Drive Int. Err. ! Drive interlock input missing
Cause: TUC not detected the Drive interlock input from the MPB /
Drive.
What to do: Ensure the drive communication healthy if the drive

configured through modbus communication.
Ensure the SPSS logics inline with panel hard ware.
Check the input & marker healthy status in SET 5.
SPSS Program:
Drive & TUC with out Drive & TUC in Modbus

Modbus communication communication
SPSS SPSS
UE 000 UE 000
UE 003 UE 024
UE 001 UE 001
=M 019 =M 019
INPUTS INPUTS
E0 :Drive MCB. E0 :Drive MCB.
E1: Vibrator MCB E1: Vibrator MCB
E3: Drive healthy E24: Drive healthy (comm)
Press & to view the reporting status of Inputs & Markers.

On line status in SET 5
As per the display E000, E001, E003 & M019 is healthy. If M019
unhealthy TUC displays
CHAPTER -6
6.4 INTEGRATION OFF !
Integration off ! Down stream input missing.
Cause:
TUC not detected the Down stream interlock input while
What to do:
Ensure the hard ware wiring as per Diagram,
Ensure the SPSS logic inline with panel hard ware logic.
Check the input & Marker healthy status in SET 5
SPSS:
UE 001
=M 017
Note:
If there is no input specified for down stream interlock,
permanently set the marker (SM 017) in the beginning of SPSS.
As per the display E001 & M017 is healthy. If M017 unhealthy

CHAPTER -6
6.5 EMERGENCY STOP !
Emg. stop ! Emergency input is missing.
Cause: TUC not detected the emergency input from the LCS /
Panel.
What to do:
Ensure the SPSS logic inline with hard ware logic.
Check the input & Marker healthy status in SET 5
Ensure the Hardware configuration is proper.
through drive.
Case:1 Case:2
EMG input through hard EMG input through Drive
ware configuration. communication.
SPSS SPSS
UE 001 UE 023
=M 010 =M 010
INPUTS INPUTS
E1 : EMG input. E 23 : EMG input.
AS per the display E001 & M010 is healthy. If M010 unhealthy

CHAPTER -6
6.6 CORR.>SET LIMIT !
Corr.> set-limit ! Cause: Zero correction error greater than permitted check (zero limit) belt
load which is declared in configuration menu), TUC starts showing
-
What to do:
Ensure the running belt must be in empty while zero correction.
6.7 CORR.>ABORTED !
Corr.> Aborted ! Cause:

Failure of Tacho input while zero correction. Or force to stop the zero
correction.
What to do:
Ensure the running of weigh feeder while zero correction.
unning.
Avoid the failure of start commend while zero correction.
6.8 DEVIATION !
Deviation ! Cause:
-1) longer than
-1)
What to do:
Ensure the TUC parameter settings as per the commissioning report.
Note:
To de-activate the deviation, keep the deviation set limit :00 & deviation
time :00 in SET1, This is only for emergency purpose .
This is not advisable as per safety point of view.
CHAPTER -6
6.9 AIO COMMUNICATION !
AIO commun. ! Cause:

TUC not detected the AIO 1 Card through modbus communication.
What to do:
Ensure the Interface settings in TUC
Ensure the communication cable termination between TUC to AIO.
Ensure the AIO jumper settings.
Ensure the AIO power supply is healthy.
J4 Jumper settings for 1&2 3&4

card selection
AIO -1 OPEN OPEN
AIO -2 SHOT SHOT
AIO -3 OPEN SHOT
J1 Jumper settings 1&2 3&4

for AI selection
Voltage (0-10)V OPEN SHOT
mA (0-20) / (4-10) mA SHOT OPEN
AIO -3 OPEN SHOT
6.10 UNDER LOAD !
Under load ! Cause:
What to do:
Ensure the physical material flow on the weigh feeder.

CHAPTER -6
6.11 OVER LOAD !
Over load ! Cause:
What to do:
Ensure the physical material flow on the weigh feeder.
6.12 ANALOG INPUT ERROR !
Anal. i/p Error! Cause:

This error occurs during AI scaling when the communication error between
the TUC & AI module. (or)
Max_Value selected is lower than Min_value.
What to do:
Ensure the AI module communication is healthy.
Ensure the AI calibration in line with the standard and proper input
increment.
6.13 INVERTOR -1 COMMUNICATION !
Inv. 1 comm. ! Cause:

TUC not detected the Inverter 1 input.
What to do:
Ensure the Interface settings in the TUC.
Ensure the Inverter communication settings,
Ensure the hardware configuration for communication
CHAPTER -6
6.14 INVERTOR -2 COMMUNICATION !
Inv. 2 comm. ! Cause:

TUC not detected the Inverter 2 input.
What to do:
Ensure the Inverter communication settings,
Ensure the hardware configuration for communication
6.15 DIO -1 COMMUNICATION !
DIO1 Commun.! Cause:

DIO 1 is not detected by the TUC.
What to do:
Ensure the Interface settings in TUC.
Ensure the DIO Jumper settings.
Ensure the hardware configuration for communication.
JI JUMPER SETTINGS FOR JUMPER J1

CARD SELECTION
DIO 1 OPEN
DIO 2 SHOT
CHAPTER -6
6.16 DIO -2 COMMUNICATION !
DIO2 Commun.! Cause:

DIO 2 is not detected by the TUC.
What to do:
Ensure the Interface settings in TUC.
Ensure the DIO Jumper settings.
Ensure the hardware configuration for communication.
6.17 SIO COMMUNICATION !
SIO Communicar.! Cause:

SIO module is not detected by the TUC.
What to do:
Ensure the SIO Interface module is healthy.
Ensure the hardware configuration.
6.18 MASTER COMMUNICATION !
Master com. ! Cause:

The PLC master is not communicated with TUC.
What to do:
Ensure the Master PLC communication settings must be in line with TUC.
Ensure the hardware configuration.

Transweigh Weigh Feeder Maintanence

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Weigh Feeder with TUC Electronics

Transweigh India Ltd

Tel : +91-22-6772 6000 / 6772 6002

All Rights Reserved

In no event will Transweigh India Ltd be responsible or liable for indirect or

WARNING: Identifies information about practices or circumstances that can cause an

1.1 WEIGH FEEDER STRUCTURE

1.2 INFEED HOPPER

TYPES OF IN-FEED CHUTE

1.3 DISCHARGE HOOD

(These details will be provided in the next updates)

1.4 SKIRT BOARD

1.5.1 INSIDE SCRAPPER:

1.5.1 OUTSIDE SCRAPPER:

1.6 AUTO TENSIONING ASSEMBLY

1.7 Gearbox and Drive unit

1.7.1 Drive unit for threaded type tacho

1.7.2 Drive unit for Flange type tacho

2.1 TUC (Transweigh Universal Controller)

Cut out size :

Cut out size :

Cut out size :

Cut out size :

Cut out size :

Cut out size :

TUC Types & Applications

TUC-2 (+) WF, LIW, Kiln feed systems

2.2 ANALOG CARDS

2.2.1 F875 Analog card

TUC 6 CAN : Ver 1.0 onwards

2.2.2 F868 Analog card

TUC 4 : Ver 1.0 to 7.0 TUC 4 : Ver 9.0 onwards

2.2.3 F840 Analog card

TUC 2: Ver 1.0 onwards

2.3 DIGITAL CARDS

2.3.1. F866 Digital card

2.3.2. F889 Digital card

2.3.3. F890 Digital card

F889 & F890

If motor is less than 2.2 Kw configure as a star.

Star connection Delta connection

2.5 LOAD CELL

2.5.1. Load cell mounting details

Load transfer Idler

Load cell base bolt

Load cell Lock bolt

(Photo for load cell mounting arrangements)

2.5.2. Color code for HBM Load cell:

BLACK EXC (-)

BLUE EXC (+)

GRAY SENSE (-)

GREEN SENSE (+)

WHITE OUTPUT (+)

RED OUTPUT (-)

2.5.3. Color code for SCAME Load cell:

WHITE EXC (-)

RED EXC (+)

BLACK OUTPUT (+)

BLUE OUTPUT (-)

2.6.1 Tacho details

Tacho Lock nut

Sensing Gap 0.2 0.5 mmm

Color code for 2wire tacho