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Belt Scale
Installation & Operating Manual
REC-4031 Rev D P/N 057133
© 2012 Thermo Fisher Scientific Inc. All rights reserved. All trademarks are the property of Thermo Fisher Scientific
Inc. and its subsidiaries. Specifications, terms and pricing are subject to change. Not all products are available in all
countries. Please consult your local sales representative for details.
Revision History
General This instruction manual contains information on the installation and maintenance of
your Model 10-101R Belt Scale.
The Model 10-101R Belt Scale is available with a wide range of useful analog and
digital outputs for applications in a variety of process operations.
Description The Model 10-101R Belt Conveyor Scale consists of one or two completely
assembled scale modules.
Both scales require two approach and two retreat idlers to be aligned along with the
weight idler to provide the necessary "weighing platform" in order to achieve accurate
weighing results.
Specifications
Scale Module Minimum Net Load @ Rated Capacity: 15 of load cell capacity
Load Cell:
Output 2.0 MvN
Excitation: 10 VDC
Temperature Range: Safe: -22 º to +194º F
(-30 º to +90º C)
Compensated: +14 º to +104º F
(-10 º to +40º C)
Environmental Protection: Hermetically Sealed, IP67
Load Cell Construction: Stainless Steel
Cable: 6-Conductor shielded, 10 Ft.
DO NOT ALTER LENGTH of cable
Unpacking The Model 10-101R scale module(s) and installed load cells have been aligned at the
factory for installation in your conveyor and has been properly packaged for shipment.
and Inspection
Inspect all packages for damage before opening, as oftentimes the carrier may be
responsible for shipping damage.
Storage The Model 10-101R scale module(s) and associated equipment can be safely stored,
with cover latches secured and hole plugs installed, between -58º to +185º F (-50º to
+85º C). The units should be protected against moisture.
General All Thermo Scientific Belt Conveyor Scale Systems, regardless of their applications,
are manufactured to the same high degree of accuracy and reliability. However, it is
the application and installation of these systems that determine the overall system
operating capabilities and accuracy that can be realized.
Scale Location In applying belt conveyor scales one must always consider external influences
originating from the material handling system and belt conveyor. Regardless of stated
Criteria accuracies, these two factors will determine the overall long-term and short-term
accuracy you may expect. The following guidelines should be adhered to in order to
optimize belt scale performance and weighing accuracy.
Tension In all installations, the belt scale should be installed in an area where belt tension
and tension variations are minimal. For this reason, the belt scale should be
installed near the tail section of the conveyor, but far enough forward so as not to
be influenced by infeed skirt boards.
Uniform Belt Although in most applications the scale system is capable of operating accurately
over a 4 to 1 range, it is desirable that the belt loading be as uniform as possible.
Loading
To minimize surges or feed variations, hoppers, if possible, should be equipped
with depth limiting gate.
Material Slippage The belt scale system processes belt loading and belt travel to arrive at an
accurate weight. Product speed must equal belt speed at the scale. For this
reason, the conveyor speed and slope should not exceed that at which material
slippage occurs.
Convex Curves Convex curves are permissible at a distance of 20 feet or a minimum of five idler
spaces beyond the scale area idlers.
Concave Curves If there is a concave curve in the conveyor before or after scale, the scale should
be installed so that the belt is in contact with all the idler rollers at all times for at
least 20 ft (6 m) or 5 idler spaces, whichever is greater, before and after the scale.
A concave curve should start no closer than 40 ft (12 m) from the scale to the
tangent point of the curve.
Trippers In any installation where weighing accuracy is important, the scale system should
not be applied to a conveyor that has a movable tripper. If the scale must be
installed on a conveyor with a tripper, then the same rules apply as for an
installation in a concave conveyor. The minimum distances outlined in the above
paragraph must be adhered to with the tripper in its fully retracted position.
Conveyor In the design of the scale system, several deflections are taken into consideration.
These are the deflection of the load cell, scale module 10-101 R, and the supporting
Design conveyor structure. It is of utmost importance that these deflections not be excessive.
No conveyor expansion joints should be located in the scale area.
Vibration and The entire conveyor frame should be isolated from bins, feeders, crushers, and
other mechanical equipment. This is to prevent bin loading from causing conveyor
Deflections
deflections and to protect the weighing equipment from vibrations and shocks
imposed by mechanical equipment.
Cable Conveyors Conveyors commonly known as "cable" or "rope" conveyors are not suitable for
electro-mechanical belt conveyor scale weighing unless a rigid conveyor section
long enough to support the scale and scale service idlers is added.
Belt Tracking One problem in attaining optimum belt scale accuracy is the effect of belt tracking
from an empty to a fully loaded condition. To enhance belt tracking, the
construction of the belting should have the necessary flexibility to assure contact
with all scale area idler rolls when the belt is running empty. In addition, this also
assures that the conveyed material is being supported by the weigh idler rather
than by the carcass of the conveyor belting.
Belt Scale Idlers in the weighing area (minimum +2 to -2 idlers and on scale) should be round,
uniform and of same make, troughing angle and rating.
Area Idlers
Idler Type The selection of the idlers used within the scale area is important. This pertains
not only to the idler type, but the idler construction itself. Since idler alignment
plays an important role in the accuracy of a belt conveyor scale, it is important that
all idlers be manufactured as nearly alike as possible. It is also important that
certain types be avoided, such as "V" types and rope or cable types.
Training Idlers It is important that the belt tracks centrally from no load to full load conditions.
Training idlers are normally accepted if located at least eight idler spaces either
side of the scale-mounted idlers.
Idler Alignment The scale mounted idlers and a minimum of two idlers to either side should be
dimensionally aligned. Good idler alignment throughout the entire conveyor is
important to assure adequate and true belt tracking under all load conditions.
Single or Dual This section is to be used as a guide in the installation of the 10-101 R Scale Modules.
Scale Module
Installation
Location Select the scale location by following Scale Location Criteria. A partial listing of the
required guidelines follows:
2. The scale should not be located closer than 20 feet from feeders, hoppers, and
skirt boards.
4. The scale should not be installed where conveyor speed and slope causes
material slippage to occur.
5. Locate the scale where it has maximum protection from the elements.
6. The scale conveyor should not be attached to or have vibrating devices installed
on it.
Site Preparation After determination of scale location in the conveyor, proceed with site preparation
as follows:
1. All scale area idlers must be the same make, style, and model, and should be
in free-rolling and otherwise good mechanical condition.
2. Locate the exact center of the carry roll on all idlers from minus 2 to plus 2.
Permanently scribe or punch this center position on each carry roll. In
addition, perform the same procedure on the minus and plus 2 troughing rolls.
3. Select one idler for the weigh idler and modify if necessary. Refer to weigh
idler modification drawing, Figure 2-10.
Mechanical After scale location selection and site preparation, proceed with installation as
follows. Refer to the installation diagram and system data sheet for idler spacing.
Installation –
Single Scale 1. Dimensionally locate the minus 2 and plus 2 idler using a known reference
Module point or the diagonal method. At the same time, shim these idlers 1/4 (0.25)
inch above the belt line. Place a level on the carry rolls and shim as
necessary.
NOTE: Make all dimension measurements from the center of the grease
fittings on the idlers.
2. Mount the scale module to the supporting cross beam. Do not tighten the
scale module mounting bolts (1, 2, and 5) (see Figure 2-11).
4. Remove the weigh idler mounting clamps from the mounting plate and scribe
a line in the center of the weigh idler mounting plate (3) (see Figures 2-11
and 2-12).
5. Locate and install the scale module supporting beam (2) on the conveyor
matching the reference marks in steps 3 and 4 above (see Figure 2-11).
6. Level the weigh idler mounting plate by rotating the scale module and/or
shimming under the supporting beam mounting feet. Tighten the scale
module mounting bolts (5) (see Figure 2-11).
7. Modify weigh idler if not already modified by removing the mounting feet and
making a 3/8 (.375) inch cutout for stringer clearance (see Figure 2-10).
8. Attach modified weigh idler to mounting plate with supplied clamps and
hardware (see Figure 2-12).
9. Remove the load cell shipping bolt (6) (see Figure 2-11).
10. Dimensionally align weigh idler between plus and minus 2 idlers. Proceed to
Scale Area Idler Alignment.
Mechanical After scale location selection and site preparation, proceed with installation as
follows. Refer to the installation diagram and system data sheet for idler spacing.
Installation – Two
Scale Modules 1. Dimensionally locate the minus 2 and plus 2 idler using a known reference
point or the diagonal method. At the same time, shim these idlers 1/4 (0.25)
inch above the belt line. Place a level on the carry rolls and shim as
necessary.
NOTE: Make all dimension measurements from the center of the grease
fittings on the idlers.
3. Remove the weigh idler mounting clamps from both mounting plates and
scribe a line in the center of the weigh idler mounting plates (3) (see Figures
2-12 and 2-13).
4. Locate and install the right and left scale modules (2) on the conveyor
stringers matching the reference marks in steps 2 and 3 above (see Figure 2-
13). Scale module supports go on the inside of the stringers.
5. Loosen the scale module mounting bolts (5) (see Figure 2-12).
6. Level the weigh idler mounting plate of one module by rotating the scale
module. Tighten the scale module mounting bolts (5) (see Figure 2-12). Leave
the other side loose.
7. Modify weigh idler if not already modified by removing the mounting feet and
making a 3/8 (.375) inch cutout for stringer clearance (see Figure 2-10).
8. Attach modified weigh idler to mounting plate of both scale modules with
supplied clamps and hardware (see Figure 2-12).
9. Tighten the scale module mounting bolts on the second scale module.
10. Remove the load cell shipping bolts (6) from both scale modules (see Figure
2-13).
11. Dimensionally align weigh idler between plus and minus 2 idlers. Proceed to
Scale Area Idler Alignment.
Scale Area Idler The scale area idlers are composed of the weigh idler and the idlers located adjacent
to and on either side of the weigh idler. The idlers are identified as plus (+) or minus (-)
Alignment
on the installation drawings. The weigh idler and fixed idlers have to be considered a
part of the scale.
1. Tie a high quality 30 round test monofilament line or equivalent to the base of
the plus 3 idler. Run this alignment wire across the center mark on the plus 2
carry roll through the scale area and across the center mark on the minus 2
carry roll. Attach a 30 pound weight to the end of the wire to maintain constant
tension.
2. Check for clearance between the line and the carry roll of the weigh idler. If
the wire is touching, additional shimming in 1/16 (.0625) inch increments
should be inserted under the plus 2 and minus idlers.
4. Install additional alignment lines across the plus 2 and minus 2 troughing or
wing rolls. Reference points for alignment wires were established in Step 2 of
5. Shim and dimensionally align the plus 1 and minus 1 idlers one at a time. The
measurement between each idler and the weigh idler must be accurate to
within 1/32 (.031) inch. All idlers must be shimmed to within ±1/32 (.031) inch
of the alignment lines.
6. Shim the weigh idler to within 1/32 (.031) inch of the alignment lines.
a. The idler is tipped down to the right. (Remedy: Add shims to the right end of
the idler and remove shims from the left end.)
b. The idler is located too far to the right of the conveyor center. (Remedy: Shift
idler to the left.)
Load Cell The load cell cable is encased in a sealtight flex conduit for protection of the load cell
cable. The load cell cable length should not be altered. Refer to Figure 2-14 below for
Wiring load cell connections.
General The 10-101 R Belt Scale may normally be expected to operate satisfactorily and hold
its calibration for weeks with a minimum of maintenance. However, on a new
installation, some calibration shifts may be expected due to changes in measuring
components, conveyor belt, or idlers.
Service and The maintenance information in this manual is adequate to meet your service needs.
However, if you run into problems requiring technical assistance, please call 800-
Repair 445-3503.
Thermo Scientific has a repair center located at our plant in Minneapolis, Minnesota.
Please contact our Repair Representative at 800-445-3503 for assistance.
Please have available your machine model and serial number as this will expedite
your service request.
When returning parts for repair, please use a Return Material Authorization form which
can be requested at 800-445-3503.
1. Cleaning
Keep scale area clean of rocks, dust, and material build-up.
2. Greasing
The weigh idlers should be greased once or twice yearly. Overloading the
weigh idlers with grease may change the tare weight and place the scale out
of calibration.
Zero calibration is necessary after greasing.
3. Belt Training
The belt must be trained to run true to the centerline of the idlers in the area
of the scale while running empty, as well as underloaded conditions. Where
this cannot be accomplished due to off-center loading, the loading should be
modified. Where a belt does not train while empty but does train while loaded,
it will be necessary to train the belt over the scale area at least during the
calibration checks.
4. Belt Tension
It is important that conveyor conditions remain constant at all times.
Conveyors which do not have a constant tension device will require
calibration whenever the belt tension changes and the take-up is readjusted.
5. Belt Loading
Extreme loading conditions which cause flow rate of material to be above 125
percent of the instrument range must be avoided. Any load capacity above his
amount cannot be measured. Belt loading should be adjusted to stay within
the instrument range.
Conversely, very low flow rates, with respect to full scale range, may produce
low accuracy. Where extreme high or low flow rates, as described above,
persist, the scale range should be changed.
If the film cannot be removed, the zero will have to be adjusted. Any change
in the build-up of the film adhering to the belt will require further adjustment.
Trouble- If your belt scale fails to operate correctly during or after performing set up and
calibration it is suggested to perform the procedure again and if the problem persists
shooting follow the troubleshooting procedures below.
Calibration Shifts Frequent calibration shifts should be isolated to zero shifts or span shifts.
Zero Calibration Zero shifts are normally associated with the conveying system. When a zero shift
occurs, the span will shift by a like number of TPH, this then appears as a span
Shifts shift. Common causes of zero shifts:
Span Calibration Span shifts are normally associated with the electronic measuring of components of
the system, with one exception, which is conveyor belt tension. A span shift is present
Shifts
if both points change by the same percentage of TPH. Common causes of span shifts:
Field Wiring 1. Check for proper interconnection between components of the system. All
wiring must be as specified on the Field Wiring drawing.
2. Check all wiring and connections for continuity, shorts, and grounds using an
ohmmeter.
Load Cell 1. Measure excitation voltage across the load cell blue and black leads.
Excitation and
2. Measure DC millivolt signal voltage across the load cell red and white leads.
Signal Voltage
3. The millivolt output is in direct relation to weight applied. As weight is
increased, output should increase.
General This section gives information on how to order replaceable parts for your 10-101 R
belt Scale.
Ordering For faster service when ordering parts, write or telephone Thermo Fisher Scientific
Parts Department.
Information
The recommended procedure for ordering parts is as follows:
3. Find the part number(s) for the item(s) needed and determine the quantity
you require.
4. Write or telephone:
Spare Parts
4.2.2 Parts List
EQUIPMENT PART NUMBER
LOAD CELL
Load Cell, Bending Beam, 50kg 056768
Chile
+56 (2) 2378 5080
+56 (2) 2370 1082 fax
ventas.Bulk.LA@thermofisher.com
China
+86 10-8419-3588
+86 10-8419-3580 fax
Germany
+49 (0) 208-824930
+49 (0) 208-852310 fax
service.oberhausen@thermofisher.com
sales.oberhausen@thermofisher.com
India
+91-22-4157-8800
+91-22-4157-8801 fax
sales.process.in@thermofisher.com
Italy
+39 02-950590.1 main
+39 02-950590.55 sales
+39 02-953200.15 fax
sales.mi.ramsey.it@thermofisher.com
Mexico
+52 53 125 556
+52 53 125 557 fax
email.mxnau.sales@thermofisher.com
South Africa
+27 (0) 11-822-4120
+27 (0) 11-822-3982 fax
sales@thermo.co.za
REC-4031 Rev D