MULTIBELT Belt Weighers: Installation and Operating Instructions

MULTIBELT Belt Weighers
Installation and Operating Instructions
we make processes work
BV-H2190 GB
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© Copyright 2005
SCHENCK PROCESS GmbH
Measuring and Process Technologies
Landwehrstraße 55, D-64293 Darmstadt
http://www.schenck-process.com
All rights reserved. Any reproduction of manual, regardless of method, without prior permission by
SCHENCK PROCESS GmbH in writing, even by excerpt, is prohibited.
Subject to change without prior notice.
BV-H2190 GB 0536 MULTIBELT Belt Weighers Installation and Operating Instructions

© SCHENCK PROCESS GmbH, Darmstadt
Contents
1 General Information ......................................................................... 1

1.1 Hints for Delivery...................................................................................................... 1
1.2 Information on Documentation................................................................................. 1
2 Belt Weighers Overview................................................................... 3
2.1 Single-idler Belt Weighers ....................................................................................... 4
2.1.1 BEM type........................................................................................................... 4
2.1.2 BEP type ........................................................................................................... 5
2.1.3 BED type ........................................................................................................... 6
2.2 Multi-idler Belt Weighers.......................................................................................... 6
2.2.1 BMP type........................................................................................................... 7
2.2.1.1 BMP2 type .................................................................................................. 8
2.2.1.2 2BMP type .................................................................................................. 8
3 Planning-in Hints (The 10 Rules)..................................................... 9
3.1 General Information ................................................................................................. 9
3.1.1 Hints for Movable Conveyors .......................................................................... 10
3.2 The 10 Rules.......................................................................................................... 10
3.2.1 Overview ......................................................................................................... 10
3.2.2 The Rules in Detail .......................................................................................... 11
4 Single-idler Belt Weigher BEM ...................................................... 22
4.1 Installation Instructions .......................................................................................... 22
4.1.1 Items Supplied................................................................................................. 22
4.1.2 Installation Prerequisites ................................................................................. 22
4.1.3 Displacing Measuring Modules ....................................................................... 23
4.1.4 Installation ....................................................................................................... 24
4.1.4.1 Prerequisites............................................................................................. 24
4.1.4.2 Mounting Measuring Modules .................................................................. 25
4.1.4.3 Mounting Carrying Idler Sets.................................................................... 27
4.1.4.4 Cabling ..................................................................................................... 28
4.1.5 Aligning............................................................................................................ 28
4.1.6 Acquiring Effective Platform Length ................................................................ 30
4.2 Operating Instructions............................................................................................ 31
4.2.1 Maintaining Belt Weigher ................................................................................ 31
4.2.1.1 Maintaining ............................................................................................... 32
4.2.1.2 Inspecting ................................................................................................. 32
4.2.1.2.1 Ensuring Proper Alignment of Carrying Idler Sets............................. 32
4.2.1.2.2 Checking Leaf Spring Parallel Guidance ........................................... 33
4.2.1.2.3 Checking Load Cell Signal................................................................. 34
4.2.1.2.4 Checking Load Cell............................................................................ 34
4.2.1.3 Repairing Belt Weigher............................................................................. 35
5 Single-idler Belt Weigher BEP....................................................... 37
5.1 Installation Instructions .......................................................................................... 37
5.1.1 Items Supplied................................................................................................. 37
5.1.2 Installation Prerequisites ................................................................................. 38
5.1.3 Installation ....................................................................................................... 38
5.1.3.1 Prerequisites:............................................................................................ 39
5.1.3.2 Mounting Weighed Idler Set ..................................................................... 41
5.1.3.3 Mounting Carrying Idler Sets.................................................................... 43
5.1.3.4 Aligning..................................................................................................... 44
5.1.3.5 Acquiring Effective Platform Length ......................................................... 46
5.1.4 Cabling ............................................................................................................ 46
5.2 Operating Instructions............................................................................................ 47
5.2.1 Maintaining ...................................................................................................... 47
5.2.2 Inspecting and Repairing ................................................................................ 47
5.2.2.1 Replacing Load Cell ................................................................................. 48
5.2.2.2 Replacing Leaf Springs ............................................................................ 49
MULTIBELT Belt Weighers Installation and Operating Instructions 0536 BV-H2190 GB

©SCHENCK PROCESS GmbH , Darmstadt -I-
Contents
6 Single-idler Belt Weigher BED....................................................... 50

6.1 Installation Instructions ...........................................................................................50
6.1.1 Items Supplied .................................................................................................50
6.1.2 Installation Prerequisites..................................................................................50
6.1.3 Installation........................................................................................................51
6.1.3.1 Prerequisites .............................................................................................51
6.1.3.2 Mounting Belt Weigher on Belt Stringers ..................................................54
6.1.3.2.1 Mounting Load Cells...........................................................................55
6.1.3.3 Mounting Carrying Idler Sets.....................................................................56
6.1.3.4 Aligning Carrying Idler Sets.......................................................................57
6.1.3.5 Aligning Weighed Idler Set........................................................................58
6.1.3.6 Acquiring Effective Platform Length..........................................................60
6.1.4 Cabling .............................................................................................................60
6.2 Operating Instructions ............................................................................................61
6.2.1 Maintaining.......................................................................................................61
6.2.2 Inspecting and Repairing .................................................................................62
6.2.2.1 Replacing Load Cell ..................................................................................62
6.2.2.2 Replacing Leaf Springs .............................................................................63
7 Multi-idler Belt Weigher BMP......................................................... 64
7.1 Installation Instructions ...........................................................................................64
7.1.1 Items Supplied .................................................................................................64
7.1.2 Installation Prerequisites..................................................................................64
7.1.3 Installation........................................................................................................65
7.1.3.1 Prerequisites: ............................................................................................65
7.1.3.2 Mounting Weighed Idler Set(s)..................................................................67
7.1.3.3 Mounting Carrying Idler Sets.....................................................................71
7.1.3.4 Aligning......................................................................................................71
7.1.3.5 Acquiring Effective Platform Length..........................................................73
7.1.4 Cabling .............................................................................................................74
7.2 Operating Instructions ............................................................................................75
7.2.1 Maintaining.......................................................................................................75
7.2.2 Inspecting and Repairing .................................................................................76
7.2.2.1 Replacing Load Cell ..................................................................................76
7.2.2.2 Replacing Leaf Springs .............................................................................77
8 Speed Transducer (Option) ........................................................... 78
8.1 FGA20-RSLE Type.................................................................................................78
8.1.1 Installation Instructions ....................................................................................78
8.1.1.1 Installing Speed Transducer .....................................................................78
8.1.1.1.1 Further Installation Instructions ..........................................................79
8.1.1.2 Cabling ......................................................................................................79
8.1.2 Operating Instructions......................................................................................80
8.1.2.1 FGA 20-RSlE for Legal-for-trade Belt Weighers .......................................80
8.1.2.2 Maintenance..............................................................................................80
8.1.2.3 Inspection and Repair ...............................................................................81
8.2 FGA24A Type.........................................................................................................81
8.2.1 Installation Suggestions ...................................................................................81
8.2.1.1 Suitability ...................................................................................................82
8.2.1.2 Mounting Pole Wheel ................................................................................83
8.2.1.3 Mounting Proximity Switch ........................................................................83
9 Test Weight Suspension (Option) ................................................. 84
9.1 BEP, BMP Types....................................................................................................85
9.1.2 Installation and Setting Instructions .................................................................85
9.2 BED Type ...............................................................................................................86
9.2.2 Operating and Setting Instructions ..................................................................87

- II - © SCHENCK PROCESS GmbH, Darmstadt
General Information
1 General Information
1.1 Hints for Delivery

Inspection of incoming goods
• Carefully inspect packaging for any damage during transit.
• If damage is discovered, contact your carrier immediately and file a claim

for damages.
• Check items supplied for completeness. For information on items supplied,

please refer to the individual 'Items Supplied" items of Chapters 4 to 7.
Storage hints
Check to see whether the admissible limit temperatures of - 25 oC or + 55 oC can
possibly be exceeded:
• If no, store the items supplied in their genuine packaging in dry and clean
rooms whose relative humidity does not exceed 75%.
• If yes, remove load cell, (optional) speed transducer and terminal box, and
store the electronic components in rooms meeting the above requirements.
Additionally observe the

'Guideline for Storage and Handling of Components and Machines
Supplied'
(BV-R2000 AA).
1.2 Information on Documentation

This manual includes any information required for installation and operation of our
belt weighers:
Single-idler belt weighers: BEM, BEP and BED types
Multi-idler belt weighers BMP, 2BMP and BMP2 types
For general information on the belt weighers described in the present manual,
please refer to the 'Belt Weighers Overview' chapter.
• Application
• Construction
• Operating Principle
• Accuracy

©SCHENCK PROCESS GmbH , Darmstadt -1-
General Information
The information is complete with significant technical data on every belt weigher type:
• Operating principle
• Dimensions
• Load cell type
• Possible belt widths
• Feed rates
• Accuracies
Optimal planning-in is essential for obtaining the specified data and ensuring proper
functioning of your belt weigher.
Before mounting, please read the

'Planning-in Hints (The 10 Rules)' item.
To every belt weigher type, a main chapter is dedicated comprising the following
information:
• Installation Instructions
• Operating and Setting Instructions

Identify your belt weigher type and refer to the relevant chapter.
If your belt weigher is equipped with optional devices, the variants of the particular
type as well as the relevant Installation and Operating Instructions are referenced
accordingly:
Speed measurement system: See chapter

'Speed Transducer (Option)'
Test weight system:: See chapter

'Test Weight Receptors (Option)'

-2- © SCHENCK PROCESS GmbH, Darmstadt
Belt Weighers Overview
2 Belt Weighers Overview

Belt weighers are components designed for installation in user's belt conveyor
systems. The systems are designed and documented so that the user can perform
installation and commissioning single-handedly. However, advanced mechanical skills
and utmost care are required to provide the proper environment for the belt weighers.
Proper mounting is an important consideration for system accuracy.

Therefore, we recommend to have commissioning and inspections
performed by a SCHENCK engineer.
Application
Used for continuous acquisition of feed rates and totalized amounts, the belt weighers
are designed for installation in continuously operating belt conveyor systems. There is
a broad range of applications:
• Throughput and consumption measurement in production plants
• Balancing of amounts fed in and out
• Reporting of load limits
• Batching in load-out stations
• Legal-for-trade weighing
• Prefeeder control
The rugged design of the system ensures a high degree of operating safety and
availability.
Construction
A standard belt weigher comprises:
• Weighing modules or weighing platform for accommodation of user's idler sets
• Overload protected load cell(s) with a high degree of protection
• Cable junction box for connection of sensors
• Fixing elements for the installation

For speed measurement, various speed transducers (e.g. frequency generators with
friction wheel) are available as options.
Operating Principle
Belt weighers are designed to acquire continuous material flows of varying strengths.
Load cells acquire the weight of the load on a certain belt section, and a speed
transducer measures the belt speed (up to approx. 6 m/s). The product of the two
measured variables results in the current feed rate. Totalization of feed rate results in
the material amount fed.
If belt speed acquisition is omitted (belt load measuring system), a constant speed
value must be transferred to the weighing electronics in form of a parameter.
However, this procedure has the potential to adversely affect weighing accuracy.

Accuracy
The stated accuracies assume that the belt weigher is mounted in suitable belt
conveyor systems and that the weighed idler set is installed and calibrated in
accordance with our installation and calibration instructions.
For accuracy data, please refer to the following documention:

BV-D2105 AA 'Definition of Belt Weigher System Accuracy'
2.1 Single-idler Belt Weighers

• Easy integration into user's belt stringers with no need to interrupt the
construction
• Belt tension forces absorbed by leaf spring parallel guidances
• Suitable for handling feed rates up to 15,000 t/hr
• Accuracies of up to ± 0.5 %
2.1.1 BEM type

Type: Fixation by welding
• Belt weigher of modular design, suitable for DIN

belt widths from 400 to 1400 mm
(exceptionally, up to 2000 mm)
• Easy installation
• 2 lateral weighed idler sets
• Components independent of belt width
• Load cell: PWS type (platform load cell)
• Feed rates up to approx. 4,000 t/hr
• Accuracy ± 1 % of nominal feed rate

2.1.2 BEP type
• Belt weigher with weighing platform, suitable for

DIN belt widths from 400 to 1400 mm
• Weighed idler set inside belt stringers
• Insensitive to crosswise belt stringers
instabilities caused by centrally displaced cross-
member
• Load cell:
o PWS type (platform load cell)
o RT.. types (ring-torsion load cells)
• Accuracy ± 0.5 % of nominal feed rate
• Acuracy ± 1 % of actual feed rate
• Legal-for-trade variants also available

2.1.3 BED type

The BED type comprises two weighing sections.

• 2 weighed idler sets inside belt stringers
instabilities caused by centrally displaced cross-
member
• Load cell:
o VBB type (shear beam)
• Accuracy ± 0.5 % of nominal feed rate
• Accuracy ± 1 % of actual feed rate
2.2 Multi-idler Belt Weighers

• Easy integration into user's belt stringers with no need to interrupt the
construction
• Belt tension forces absorbed by leaf spring parallel guidances
• Suitable for handling feed rates up to 15,000 t/hr
• Accuracies of up to ± 0.25 %
• Legal-for-trade variants also available

2.2.1 BMP type

The design of the BMP series is similar to that of the BEP series. The weighing
platform is designed to accommodate two carrying idler sets.
• Belt weigher with weighing platform suitable for

• Weighed idler set inside belt stringers
instabilities: extended weigh span
• Load cell:
o VBB type (shear beam)
• Acuracy ± 0.25 % of nominal feed rate
• Accuracy ± 0.5 % of actual feed rate

2.2.1.1 BMP2 type

• For higher belt widths (to increase the feed
rate), two BMP weighed idler sets are
arranged side by side.
• Dimensions of weighed idler sets identical with
those of the BMP type
• For feed rate, see BMP.
• For accuracy, see BMP.
2.2.1.2 2BMP type
• Belt weigher with weighing platform, suitable for DIN belt widths from 500 to
1400 mm
• To extend the weigh span (and increase accuracy), two BMP weighed idler
sets are arranged in a row.
• Dimensions of weighed idler sets identical with those of the BMP type
• Accuracy ± 0.25 % of actual feed rate

Planning-in Hints (The 10 Rules)
3 Planning-in Hints (The 10 Rules)

3.1 General Information
The specified accuracies assume that your belt weigher is regularly and carefully
maintained and calibrated in accordance with the instructions and planning-in hints
supplied.
Carefully plan the integration of the weighed idler set into your belt
conveyor system using the 10 rules. This is an important consideration
for obtaining the specified measuring accuracy.
General Information
The stricter these rules are followed, the lower is the risk of adversely affecting
functioning and measuring accuracy of your belt weigher.
To achieve highest accuracies (related to actual value), rules 4, 5, and 9 are of

special import. The weighed idler sets themselves are designed stable and rigid.
The installation, calibration and commissioning instructions for the individual weigher
types detail installation and alignment.
To be observed
• With legal-for-trade belt weighers, additionally observe the applicable

regulations of the Verification Ordinance.
• Never change belt stringers when using belt conveyors to DIN 22107.
• The accuracy of belt weighers without speed transducer (v-measurement)

varies as a function of belt speed.
• Verify accuracy by check measurements under load. Ensure that the check
amount is at least 10% of the hourly amount fed at nominal feed rate (Inom)
over at least one belt circuit.
• Ensure that the location of your belt weigher is fully accessible to installation
work.
• Particularly observe the relation

'Feed rate measuring accuracy' ↔ 'number of carrying idlers in the
weigher influential zone'
o Accuracies related to nominal value require the presence of 2

carrying idlers approach and retreat of weighed idler set.
o Accuracies related to actual value require the presence of 3

carrying idlers approach and retreat of weighed idler set.
Depending on type of weigher, the weighed idler set is equipped with one or multiple
carrying idler sets.

3.1.1 Hints for Movable Conveyors

Movable conveyors (mobile systems, crushers1) are normally of light-weight design.
The lacking stiffness has the potential to cause additional issues (vibrations).
Here, the constancy of the slope is an important consideration for accuracy. With
stationary conveyors, the influence resulting from the slope is considered upon
calibration.
If the belt slope is changed with mobile conveyors (e.g. on vehicles) or in adjustable
conveyors (e.g. booms), there are two possibilities:
• Angle measurement and correction of measured value via cosine pendulum

(option)
• Calibration at mean slope and specification of accuracy at maximum

adjustment angle.
1
Ensure constant power supply.
3.2 The 10 Rules
3.2.1 Overview
No. Meaning
1 Install belt weigher in a straight belt section (horizontal or rising).

Ensure that the ascending or descending slope of the belt conveyor (angle of
2 inclination) is selected so that relative movements of the material are excluded.
Install belt weigher with sufficient distance from prefeeder, so that the material
3 flow is settled and no relative material movements can occur.
Ensure that the minimum distance of belt weigher from the belt pulley in a
4 troughed belt is given.
5 Depth and shape of troughing are important considerations for accuracy.
6 Ensure that the belt is fully troughed in the weigher influential zone.
Accurately align idler sets in the weigher influential zone.
7 Sets with offset idlers (viewed from above) have the potential to adversely
affect measuring accuracy.
8 Ensure that the belt stringers are mounted on a solid and level base.
9 Provide gravity take-up.
Safeguard your system against wind, weather, extreme temperature variations
10 and vibrations.

- 10 - © SCHENCK PROCESS GmbH, Darmstadt
3.2.2 The Rules in Detail
Please note:
For simplicity reasons, the measuring station in the following sketches
consists of one idler station only ("single-idler belt weigher"). All statements
anologously apply to multi-idler belt weighers that feature a measuring
station composed of multiple idler stations.
Rule 1: Install belt weigher in a straight belt section

(horizontal or rising).
• Ensure that the unloaded conveyor belt also fully rests on all carrying idlers,
i.e.
o in weigher influential zone
o and, if possible, in two further sets approach and retreat of weigher

influential zone.
• Garlands are not suitable.
The figures below show belt conveyor systems with typical belt weigher locations. The
circled numbers refer to a valuation scale (1= preferred to 7=unfavourable) used to
judge the influence of location on accuracy.

©SCHENCK PROCESS GmbH , Darmstadt - 11 -
Horizontal belt conveyor
Rising belt conveyor
Belt conveyor with curved belt

Rule 2: Ensure that the ascending or descending slope of the belt conveyor
(angle of inclination) is selected so that relative movements of the
material are excluded.
• If conveyors are designed for adjustable slope, any change fully enters into
measurement as error (see 'Hints for Movable Conveyors' item).
Caution! Relative movements may occur:
o with fines and uniformly shaped materials
('grain size' max. 100 mm)
o with high belt speeds
o right downstream of feed units
o upon loading gaps.

Rule 3: Install belt weigher with sufficient distance from prefeeder, so that
the material flow is settled and no relative material movements can
occur.
• Ensure that the complete weigher influential zone is outside the prefeeder
area.
• The required distance is influenced by
o belt speed
o belt inclination
o type of material infeed, and
o material properties.
(*) Make sure the minimum distance corresponds to the belt travel per
second, however, to minimum 2 m.
• Arrange skirt boards in weigh span so that the weighing accuracy is not
affected.

Ensure that the minimum distance of belt weigher from the belt
Rule 4: pulley in a troughed belt is given.
Rule 5: Depth and shape of troughing are important considerations for

accuracy.
A flat belt (small belt troughing angle α) increases the measuring accuracy.
A V-shaped belt (*) is unfavourable.
(*) Deep or V-shaped belts are suitable only if more approximate measurement will
suffice.

• Ensure that the belt always rests on the carrying idlers of the sets. This is best
achieved by
o small troughing
o flexible belt.
• Provide for high belt load.
• Ensure correct belt tracking and avoid off-centre load that could lead to belt
slip and inaccurate weighing results.

Rule 6: Ensure that the belt is fully troughed in the weigher influential zone.
• Avoid the use of belt conveyors whose pulleys are arranged higher than the
carrying idlers. If need be, increase distance between pulley and weigher
influential zone.

Rule 7: Accurately align idler sets in the weigher influential zone.

Sets with offset idlers (viewed from above) have the potential to
adversely affect measuring accuracy.
• Arrange carrying idlers in the weigher influential zone elevated by 3 to 5 mm.
• Secure aligned carrying idler sets against displacement and lowering.
• Mean the carrying idlers' out-of-round tolerance during alignment.
• Maximum admissible out-of-round tolerance = 0.2 mm; identify location of

mean out-of-round tolerance on idler shell on either side.

• Ensure that the spindles of the weighed and limiting idlers are perfectly level
viewed from above.
(also applies to V-shaped belts)
• Weighed and limiting idler sets with offset spindles do not produce any exact
weigh span.

Rule 8: Ensure that the belt stringers are mounted on a solid and level base.
• Ensure that the belt stringers impact points in the weigher influential zone are
welded.
• Select belt stringers and support so that the carrying idler alignment is
secured (see Rule 6). If need be, reinforce or shim belt stringers accordingly.
• Wire-rope-suspended belt conveyors are unsuitable for the installation of belt

weighers.
• Avoid vibrations in the weigher influential zone.
• Always install belt tracking idlers for correction of belt run outside the weigher
influential zone.

Rule 9: Provide gravity take-up.
• The potential measuring error increases along with varying belt tension.
Rule 10: Safeguard your system against wind, weather, extreme temperature
variations and vibrations.
• Wind falsifies the measurement.
• Direct insolation can excessively raise load cell temperature.
• Moisture, ice and snow give rise to material build-ups and cause misalignment
in the weigher influential zone.
• One-sided insolation of belt weigher has the potential to cause twisting and
temperature drifts.
• Protect foundation from strong vibrations.

Single-idler Belt Weigher BEM
4 Single-idler Belt Weigher BEM

Type: Fixation by welding
4.1 Installation Instructions

4.1.1 Items Supplied
Documentation
Manual BV-H2190
Dimensioned BEM drawing no. F008 401
drawing
Guideline 'Guideline for Storage and Handling of Components and
Machines Supplied' (BV-R2000 AA)
Mechanical Equipment
Qty Type Name Comments
1 pc. Measuring module with clamping plate R.H. type
1 pc. Measuring module with clamping plate L.H. type
1 pc. Speed transducer (*) Optional
with friction wheel and rocker
1 pc. Terminal box
for summation of load cell, transducer and weighing
electronics cables
1 set Compression screws Short
1 set Compression screws Long
1 set Shims Limiting blocks
for alignment of carrying idler sets in weigher influential Thick shims
zone Shims
(*) See 'Speed Transducer (Option)' item.
4.1.2 Installation Prerequisites
SAFETY HINT:
Ensure work protection at this device by using it as originally intended only, in
accordance with supply specification, and having it installed by skilled
technicians.
• Plan arrangement of weighed idler set in belt conveyor in accordance with

the 10 RULES. The latter ensure that the measuring accuracy will be
obtained. See 'Planning-in Hints (The 10 Rules)' item.
• The belt weigher is suitable for integration into belt conveyors in accordance
with DIN 22107 with 400-1400 mm belt widths, without any modification of belt
stringers.
• After adjustment of belt stringers, the belt weigher can also be integrated into
other types of conveyor.

4.1.3 Displacing Measuring Modules

4.1.4 Installation
4.1.4.1 Prerequisites
• Determine belt weigher location using the 10 RULES.

Make sure all checklist criteria have been kept:
Catchword Rules
Location in conveyor 1 2 3 4 5 10
Stability 78
Belt tension 9
Requirements of carrying idler sets 4 5 6
(profile, out-of-round tolerance)
• If the belt has already been applied, release tension, if need be, and lift off
from carrying idlers in the weigher influential zone using appropriate lifting
tackle. Raise belt so far that you can plug the measuring modules onto the
belt stringers at the proper time.
• Further prerequisites:
o If necessary, ready additional supports for use on belt stringers and in

measuring module area (see "Displacing Belt Weigher Measuring
Modules' item).
o Optional: use hole pattern if the speed transducer is to be bolted in

place (instead of being welded on).
o Debur ties of carrying idler sets in support points.
• For alignment of carrying idler sets in the weigher influential zone as well as
for later alignment and fixing of sets, use the parts of the shim set supplied.
• Mount hoist used to be able to raise belt in mounting area.
• Remove the carrying idler seat to be used for weighed idler set.

4.1.4.2 Mounting Measuring Modules
• Lift both measuring modules with proper sides onto belt stringers in the
provided displacement point. (Transit weight per measuring module = approx.
20 kg).
• Align both measuring modules square to belt stringers.
To perform welding work, and in order to protect the load cell,

connect the minus pole direct to the point of welding.
• Attach measuring modules to belt stringers using the clamping plates, and
align vertically using the compression bolts.
• Use the short or the long compression bolt sets, as the steel channel of the
belt conveyor may be situated.
• Shift carrying idler set on measuring module brackets.

Make sure they are mounted square to belt stringers.
• Evenly set measures H to 3 to 5 mm. This is the space between carrying idler
set bottom edge and belt stringers top edge.
Measure H serves as reference for the alignment of the two carrying

idler sets approach and retreat of weighed idler set.

• Use the compression bolts to carefully adjust the brackets for two-sided
support on the tie of the carrying idler set over the entire surface.
• When adjusting brackets for measure H, carefully tighten the

compression/tension bolts.
Secure all nuts using counter nuts.
• Mount transit restraints in depicted location to save them for later use.
To secure clamping, weld measuring modules in place in the area of the

non-painted surfaces of the module base plates.

4.1.4.3 Mounting Carrying Idler Sets
• Arrange carrying idlers in the weigher influential zone elevated by 3 to 5 mm.
• Place prepared carrying idler sets (troughing profile, out-of-round tolerance)

on belt stringers using the shims supplied.
• Align all idler sets in the weigher influential zone (also consider the adjacent
non-elevated carrying idler sets):
o Ensure squareness to belt stringers.
o Align sets relative to one another.
o Observe preset double idler spacing between the carrying idler sets
adjacent to the weighed idler set.
o VERY IMPORTANT: Make sure the two carrying idler sets adjacent to
the weighed idler set are parallel.
• Provisionally bolt carrying idler sets onto belt stringers.

4.1.4.4 Cabling
• Mount cable junction box on clamping plate of relevant measuring module on

the selected side. Use the provided mounting holes.
• For cable junction, please refer to the instructions given in Weighing

Electronics manual.
Also observe the following:
o Lead cables of load cells and (optional) speed transducer to cable
junction box (terminal box) in the protected areas of the belt stringers.
ATTENTION: Observe cable end lengths:
Load cell = 5 m
Transducer = 6 m
o Never shorten ready-to-connect cable ends; if need be, arrange in
loops.
o Pay heed to the local regulations.
o Check to see that the cable connector of the (optional) speed

transducer does not affect the positive contact of the friction wheel
with the return belt.
4.1.5 Aligning
• Align the carrying idler sets arranged in the weigher influential zone elevated
by 3 to 5 mm for max. 0.2 mm tolerance.
o Remove all idlers from carrying idler sets 1 and 2 and from the
weighed idler set.
o Tension six (*) 5-mm steel wires.
o Insert first idler in one of carrying idler sets 2, and align as described
below.
o Align one idler after the other terminating with the idlers of the
weighed idler set.
• Align every idler side with meaned out-of-round tolerance (mark on idler shell
turned towards the steel wires) by adjusting the spindle seat of the idler in the
carrying idler set on the particular idler side.
o To lower, refile idler side,
o To raise, shim idler side, e.g. by deposit welding with subsequent

refiling.

(*) Flat belt conveyors can be aligned with 2 steel wires only.
• Upon alignment, ensure that
o carrying idler sets adjacent to the weighed idler set are parallel
o all carrying idler sets are square to belt stringers in the weigher
influential zone
o idler spacing = 2 x L ± 5 mm.
• Affix carrying idler sets to belt stringers by welding shims and limiting blocks
in place.

• Before removing the steel wires, check bolted connections for tight fit, and re-
check idler alignment.
• Ensure that belt stringers and measuring module areas affected by welding
and other work are well protected from corrosion.
4.1.6 Acquiring Effective Platform Length

When installation is complete, acquire the effective platform length.
Measure spindle spacings a1 and a2 on

either side of your belt conveyor and
calculate effective platform length 'Ing' as
mean value:
Enter acquired value with proper unit into

the weighing electronics as shown in the
Electrical Equipment manual.

4.2 Operating Instructions

The measuring modules are designed on the principle of leaf spring parallel guidance.
Attached to the belt stringers, the modules support the base profile with load cell and
the leaf spring parallel guidance.
The leaf spring parallel guidance, in turn, supports the weighing profile transmitting the
measured load from the bracket of the carrying idler set onto the load cell without lever
ratio.
An overload protection with deflection for measurement S protects the load cell from
overload peaks (S = deflection for measurement from load cell to overload protection).
4.2.1 Maintaining Belt Weigher
SAFETY HINT:
Before performing maintenance, inspection and/or repair work, remove and
lock out power to the belt weigher.

4.2.1.1 Maintaining
• Regularly remove material build-ups in the earmarked area between

(1) tie of weighed idler set and hood of measuring modules
(2) tie of weighed idler set and belt stringers.
Material build-ups in the earmarked areas can cause shunt forces to

occur which adversely affects belt weigher accuracy.
• Do not remove build-ups recurring in other areas of the weighed idler set
because of the associated change in tare.
Measuring modules need not be maintained.
4.2.1.2 Inspecting
Inspect belt weigher each time your conveyor system is inspected.
4.2.1.2.1 Ensuring Proper Alignment of Carrying Idler Sets
(See also the "Alignment" paragraph of the 'Installation" item.)
• Raise conveyor belt in weigher influential zone.
• Align carrying idler sets arranged in weigher influential zone elevated by 3 to 5

mm to max. 0.2 mm tolerance.
o Remove all idlers from carrying idler sets 1 and 2 and from weighed
idler set.
o Exchange all idlers featuring an out-of-round tolerance over 0.2 mm.
o Remove materials build-ups from all idlers.
below.
weighed idler set.

o To lower, refile idler side,

refiling.
• Keep the carrying idlers in the weigher influential zone free from build-ups.
4.2.1.2.2 Checking Leaf Spring Parallel Guidance
The leaf spring thickness is adjusted to

the rated capacities of the load cells
used:
Rated capacity Leaf spring thickness
60 kg
100 kg 1 mm
150 kg
300 kg 2 mm
In perfect condition, both leaf springs must be totally plane. The upper leaf spring is
loaded by tensile forces; the lower, by compressive forces.
Damage to leaf springs with buckling of the lower leaf springs can occur only upon
measuring modules overload. In this case, the weighed idler set is no longer square to
conveyor belt.

4.2.1.2.3 Checking Load Cell Signal

• Ensure that check is performed by a skilled measuring and control
engineer !
• Ensure that the weighing electronics is ready to operate and the
conveyor cut off.
• Check load cell measured load

signal (totals output signal of both
load cells) in the load range
between preload and preload +
belt load using commercial
weights.
(For load cell rated capacity [kg]
and characteristic value [mV/V],
see load cell type plate.)
• Display load cell signal of preload.
• Stagger commercial weights on
weighed idler set, at best with
conveyor belt removed.
• Record load diagram as shown on
the left.
The measuring points connecting
line should result in a straight line.
If you note bigger deviations from straight line, follow these steps.
4.2.1.2.4 Checking Load Cell
• To begin with, stagger commercial weights on one side of the belt weigher.
• Record load diagram.
• Repeat on other side of belt weigher.
• Result: the measuring module featuring a big deviation from the straight line
requires further checking.
• Repeat the above steps with load cell connecting lines disconnected.
• Any damaged measuring module should now be clearly identified.
NOTE:
Errors in measurement can also be caused by torsional forces in belt stringers
transferred to the measuring modules via the weighed idler set. For reliable diagnosis,
remove the weighed idler set.
• Remove counter nuts and nuts of tension bolt.

ATTENTION: Mark side position to ensure proper reassembly.
• Check individual measuring modules by suspension of test weights, and a

damaged measuring module, if any, can be clearly identified.
Normally, a damaged measuring module cannot be repaired at site since devices and
gauges are required for reassembly. Therefore, mount new measuring module as
described below.

4.2.1.3 Repairing Belt Weigher
Replace damaged measuring

module.
Remove load cell cable.
Unscrew the 3 fixing bolts of

the base profile and remove
measuring module from
module base plate.
Mount new measuring

module as supplied.
Any new measuring module comes with a transit restraint protecting the load cell.
Carefully lift weighing profile and remove load cell transit restraint from the side.
Carefully lower weighing profile to prevent it from hitting the contact plate of the
measured load application.
Make sure the weighed idler set easily centers in bores when being plugged into the
weighing profiles on both sides.

Carefully run load cell cable and ensure protection to IP 65 of cable junction box.
Align idler sets as described at the 'Ensuring Proper Alignment of Carrying Idler Sets'
item.

Single-idler Belt Weigher BEP
5 Single-idler Belt Weigher BEP

Documentation
Manual BV-H2190
Dimensioned BEP drawing no. D607 522
drawing
Machines Supplied'
(BV-R2000 AA)
1 pc. Weighed idler set
2 pcs. Cross-member
1 pc. Terminal box
for summation of load cell, transducer and
weighing electronics cables
1 pc. Load cell
PWS type (platform load cell) or
VBB type (shear beam) or
RT.. type (ring-torsion load cell)
1 set Test weight receptors (**), comprising Optional
2 telescopic tubes
1 tubular cross-member For suspension of test weights
2 test weights
for alignment of carrying idler sets in Thick shims
weigher influential zone Shims
(*) see 'Speed Transducer (Option)' item
(**) see 'Test Weight Receptors (Option)' item

SAFETY HINT:
technicians.

with DIN 22107 with 400-1400 mm belt widths, without any modification of belt
stringers.
5.1.3 Installation
• Modify belt stringers as shown in the relevant dimensioned drawing.
• Displace weighed idler set using two cross-beams to DIN 1026.

5.1.3.1 Prerequisites:

Catchword Rules
Stability 78
Belt tension 9
• If the belt has already been applied, raise by at least 500 mm in the weigher
influential zone using appropriate lifting tackle, so that you can insert the belt
weigher from the side and align it at the proper time.
• Make sure the profiles of the carrying idler sets are identically shaped, so as
to provide the prerequisites specified at the 'Aligning' item.
Place carrying idler sets on a levelling plate and align using a ruler in place of
tensioned steel wires as described at the 'Aligning' item.
ATTENTION! Identify the locations so as to protect carrying idler sets and

idlers from being confused when being mounted as described at the 'Mounting
Carrying Idler Sets' item.
• Debur ties of carrying idler sets in support points.
• Shim carrying idler sets using the elements of the shim set supplied. Arrange
the carrying idler sets in the weigher influential zones elevated by 3 to 5 mm
as described at the 'Mounting Carrying Idler Sets' item .

• Recess the ends of the tie of the weighed idler set.
• To secure carrying idler alignment:
o Secure foundation against settlement.
o Anchor stringer supports in foundation.
o Provide reinforced belt stringers or additional supports, if required.
o Weld belt stringers impact points all around.
• Remove return belt cover plates in the weigher influential zone, or
• remove return belt cover plates in weighed idler set area, and disengage them
in carrying idler set support points.

5.1.3.2 Mounting Weighed Idler Set
To insert load cell (PWS, VBB or RT..) in weighed idler set:
• Remove transit restraint from weighed idler set.
• Carefully raise weighing yoke by approx. 5 mm and shim.
• Remove dummy plate.
• Insert load cell (PWS, VBB or RT..) complete with pre-mounted mount.
NOTE: The design of load transducers PWS and VBB differs from that of the
load cell RT. The operational overall height and the load transmission
elements are identical to the load cell RT. Fastening is done in the same spot
with a bolt M8 and a spring washer.

• PWS and VBB types only:
Ensure that no shunt forces occur between weighing yoke

and load cell; this would falsify the weighing result.
To do so, turn load cell so (angle W) that the screw heads cannot
come into contact with the weighing yoke. Angle W is of no import
for the weighing result.
• Carefully center load cell (PWS, VBB or RT..) relative to the load button, and
bolt in place.
Never grease load buttons of weighing yoke and load cell but clean
using a soft cloth.
• Carefully lower weighing yoke.
To perform welding work, and in order to protect the load cell,

connect the minus pole direct to the point of welding.
• To install weighed idler set, loosely bolt set to cross-members and place onto
belt stringers with correct side in direction of travel.

• Align weighed idler set square to belt stringers as specified in dimensioned

drawing and bolt:
• Weighed idler set to cross-members, and
• Cross-members to belt stringers.
• Arrange carrying idler sets in weigher influential zone elevated by 3 to 5 mm.

onto the premade shims on belt stringers.
• Place weighed idler set on its height-adjustable receptors and protect from
overbalancing.
• Align all idler sets in the weigher influential zone (also consider the adjacent
non-elevated carrying idler sets):
o VERY IMPORTANT: Make sure the two limiting idler sets adjacent to

5.1.3.4 Aligning
• Align the carrying idler sets arranged in the weigher influential zone elevated
by 3 to 5 mm for max. 0.2 mm tolerance.
o Remove all idlers from carrying idler sets 1 and 2 and from the
weighed idler set.
o Tension six (*) 0.5 mm steel wires.
below.
weighed idler set.
o To lower, refile idler side.

refiling.

influential zone
• Affix carrying idler sets to belt stringers by welding shims and limiting blocks
in place.
• Affix weighed idler set by welding it to its receptors.

5.1.3.5 Acquiring Effective Platform Length

When installation is complete, acquire the effective platform length.
Measure spindle spacings a1 and a2 on

either side of your belt conveyor and
calculate effective platform length 'Ing' as
mean value:

5.1.4 Cabling
• For details, please refer to the instructions given in Weighing Electronics
manual, and observe the following additional hints:
• Lead cables of load cells and (optional) speed transducer to cable junction
box mounted in a safe location.
o Load cell = 5 m
o Transducer = 6 m
• Never shorten ready-to-connect cable ends; if need be, arrange in loops.
• Connect (optional) speed transducer as shown the in circuit diagrams

supplied.
• Attach cables to stationary parts of construction directly approach and retreat

of connectors using sleeves. In-between, run cables in ducts or use sleeves.
• Check to see that the cable connector of the (optional) speed transducer does
not affect the positive contact of the friction wheel with the return belt.


The weighed idler set is designed on the principle of leaf spring parallel guidance.
Bolted to the two cross-members in three points, a rigid support frame serves for
accommodation of the load cell and the leaf spring parallel guidance used to restrain
the weighing yoke. Mounted on the load cell, the weighing yoke supports the weighed
idler set.
The SCHENCK load cell is hermetically sealed and service-free.
For type, please see load cell type plate and Belt Weigher Spec Sheet.
Explosion Protection
If the belt weigher operates in hazardous areas, Zones 1, 2 or 11 as
specified by DIN 57165, or VDE 0165, the load cell is protected to EEx
ibIIC T6.
5.2.1 Maintaining
If the weighing accuracy gives rise to doubt, first check the carrying idler sets for
proper alignment:
• Tension six 0.5-mm steel wires over the cleaned carrying idlers.
• Align individual carrying idlers as described at the 'Aligning' item.
• Replace idlers featuring an out-of-round tolerance > 0.2 mm.
• Keep carrying idlers in the weighing influential zone free from build-ups.
5.2.2 Inspecting and Repairing

• Proceed as described at the 'Maintaining' item.

5.2.2.1 Replacing Load Cell
(if required)
• Disconnect load cell cable in terminal box and remove from fixing points.
• Raise weighing yoke by approx. 5 mm and shim.
• Unscrew fixing bolt from load cell mount and remove from weighed idler set
from the side.
• Handle new load cell as described in the attached brochure.
• If need be, also replace load button before installing the new load cell.
• Introduce load cell complete with pre-installed mount.

(With PWS types: observe the 'Mounting Weighed Idler Set' item.)
• Carefully center load cell relative to load button, and bolt in place.
• If need be, align weighed idler set relative to the carrying idler sets in the
weigher influential zone as described at the 'Aligning' item.
• Run and affix load cell cable.

5.2.2.2 Replacing Leaf Springs
(if required)
• Always replace all 4 leaf springs.
• Ensure that the connecting surfaces of the parts to be bolted are metallically
clean and deburred.
• Before tightening bolts in steps, align weighing yoke
o centrically to the load cell load button
o vertically to the load cell load button
o axis-parallel to the weighed idler set support frame.
• Align weighed idler set relative to the carrying idler sets in the weigher
influential zone as described at the 'Aligning' item.
ATTENTION!
• Check effective platform length.
• If necessary, correct value in weighing electronics.

Single-idler Belt Weigher BED
6 Single-idler Belt Weigher BED

Documentation
Manual BV-H2190
Dimensioned BED drawing no. D608 600
drawing
Machines Supplied'
(BV-R2000 AA)
2 pcs. Weighing section
2 pcs. Cross-member
1 pc. Terminal box
2 pcs. Load cell
RT.. type (ring torsion load cell) or
VBB type (shear beam)
2 pcs. Test weight receptor (**) Optional
For suspension of test weights
(*) see 'Speed Transducer (Option)' item
(**) see 'Test Weight Receptors (Option)' item
SAFETY HINT:
technicians.


with DIN 22107 with 1600-2000 mm belt widths, without any modification of
belt stringers.
6.1.3 Installation
• Modify belt stringers as shown in the relevant dimensioned drawing.
• Displace weighed idler set using two cross-beams to DIN 1026.
6.1.3.1 Prerequisites

Catchword Rules
Stability 78
Belt tension 9
weigher from the side and align it at the proper time.
to provide the prerequisites given at the 'Aligning Carrying Idler Sets' item.
Place carrying idler set on a levelling plate and align using a ruler in place of
tensioned steel wires as described at the 'Aligning Carrying Idler Sets' item.



in weighed idler set support points.

6.1.3.2 Mounting Belt Weigher on Belt Stringers
• Install the two identical cross-members with distance 'A' = approx. 1080 mm in
the provided location on belt weigher and protect from overbalancing.
• Lift weighing sections and place between cross-members with correct sides in
direction of travel.
o Bolt loosely to cross-members, and
o adjust in height using the set screws so that the four holes are flush
with the cross-member bottom edge.
• Remove cross-member fixations to be able to bolt cross-members to the

weighing modules. (Unscrew again upon belt weigher alignment as described
at the "Aligning Carrying Idler Sets' item).

6.1.3.2.1 Mounting Load Cells
Insert load cells in weighing sections.
• Cut transit restraint straps and remove the dummy plates replacing the load
cells in the weighing sections.
• Lift compression bolts using a hex socket head spanner s = 6 mm so far that
you can insert the load cells from below complete with pre-assembled mounts.
Never grease load cell load buttons and compression bolt. Clean
using a soft cloth.
• Carefully bolt load cells in place using the central fixing bolts secured with
spring washers.
• Place a ruler along the leaf spring and set surfaces A and B to ≤ 0.5 mm
difference in height (compression bolt resting in place) using the compression
bolts on both weighing sections.
• Immediately secure each compression bolt using a counter nut (SW 24).
NOTE: The design of force transducers PWS and VBB differs from that of the

To perform welding work, and in order to protect the load cell, connect
the minus pole direct to the point of welding.
• Align belt weigher accurate and square to belt stringers, and bolt cross-
members to belt stringers.
• Arrange carrying idler sets in weigher influential zone elevated by 3 to 5 mm.

on the premade shims on belt stringers.
overbalancing.

• Align all idler sets in the influential zone (also consider the adjacent non-
elevated carrying idler sets):
6.1.3.4 Aligning Carrying Idler Sets
• Align the carrying idler sets arranged in the influential zone elevated by 3 to 5
mm to max. 0.2 mm tolerance.
o Remove all idlers from carrying idler sets 1 and 2, however, not from
the weighed idler set.
below.
o Align one idler after the other, terminating the procedure without the
idlers of the weighed idler set.

refiling.

6.1.3.5 Aligning Weighed Idler Set
• Lightly unscrew bolted connections between cross-member and weighing

sections and cross-member and belt stringers and remove the fixation
between weighed idler set and receptors. Now you can level weighing
sections and thus the weighed idler set relative to the tensioned steel wires
with finger-tip control so as to be free from tension.

• To do so, use the set screws on weighing sections.
ATTENTION!
o Ensure that the transversal and longitudinal axes of the weighing

sections have the same level. Check to see that the 4 alignment holes
are in the same position relative to the cross-members.
o Also ensure that the tie of the weighed idler set rests on the two
weighed idler receptors over their entire width.
Provide a 'spy' ( = 0.2 mm thick).
• To ensure proper alignment, re-check all bolted connections for tight fit, and
set screws for the rpesence of counter nuts.
• Align weighed idler set as described at the 'Aligning Carrying Idler Sets' item.
Ensure that
influential zone
• Affix carrying idler sets to belt stringers by welding limiting blocks and shims
in place.
• Attach the weighed idler set by four approx. 30 mm welds at the corners of
both weighed idler sets.


When installation is complete, acquire the effective platform length 'lng'.
Measure spindle spacings on either side of

your belt conveyor and calculate as mean
value:

6.1.4 Cabling
o Load cell = 5 m
o Transducer = 6 m
• Connect (optional) speed transducer as shown the in the circuit diagrams

supplied.



The belt weigher is designed on the principle of leaf spring parallel guidance.
Two weighing sections each equipped with a load cell measure the load exerted from
the weighed idler set direct.
The support frame of every weighing section accommodates the load cell and the leaf
spring parallel guidance used to restrain the weighed idler receptors.
The SCHENCK load cells of the RT.. type are hermetically sealed and service-free.
For exact type, see load cell type plate or Belt Weigher Spec Sheet.
6.2.1 Maintaining
proper alignment:
• Raise conveyor belt in weigher influential zone by approx. 500 mm.
• Align individual carrying idlers as described at the 'Aligning Carrying Idler

Sets' item.

• Keep carrying idlers in the weigher influential zone free from build-ups.

(if required)
• Unscrew fixing bolt from load cell mount.
• Raise weighed idler receptors by approx. 5 mm, secure in this position, and
remove load cell from weighing section from below.

• In case of doubt, also replace the compression bolt before mounting the new
load cell.
ATTENTION! Before replacing the compression bolt, always
o adjust weighed idler set in height as described at the 'Mounting Load

Cells' item
o align weighed idler set as described at the 'Aligning Carrying Idler

Sets' item.
• Introduce load cell complete with pre-installed mount and bolt in place using
fixing bolt and spring washer.
• Carefully lower weighed idler set.
influential zone as described at the 'Aligning Carrying Idler Sets' item.
(if required)
• Always replace all 4 leaf springs.
clean and deburred.
• Before tightening bolts in steps, align the weighed idler receptors of both
weighing sections relative to the weighed idler set:
o centrically
o vertically to the load cell load button.
influential zone as described at the 'Aligning Carrying Idler Sets' item.

Multi-idler Belt Weigher BMP
7 Multi-idler Belt Weigher BMP

Documentation
Manual BV-H2190
Dimensioned Type BMP drawing no. 676 300
drawing Type 2BMP drawing no. 677 954
Type BMP2 drawing no. 677 700
Machines Supplied' (BV-R2000 AA)
1 pc. Weighed idler set (*)
2 pcs. Side part (*)
2 pcs. Weighed idler receptor (*)
2 pcs. Cross-member (*)
1 set Screws
1 pc. Terminal box
1 pc. Load cell
RT.. type (ring-torsion load cell) or
VBB type (shear beam)
2 pcs. Test weight receptors (***) Optional
(telescopic tubes) For suspension of test weights
(*) pre-assembled in double number when two weighed idler sets are installed
(**) see 'Speed Transducer (Option)' item
(***) see 'Test Weight Receptors (Option)' item
SAFETY HINT:
technicians.


with DIN 22107.
7.1.3 Installation
Install one or two weighed idler set(s), as the belt width may be.
• Check against dimensioned drawing to see if belt stringers must be modified.
• Thoroughly follow the given installation instructions in order to ensure the belt
weigher's measuring accuracy. This is of special importance if your belt
weigher is going to be stamped.
7.1.3.1 Prerequisites:

Catchword Rules
Stability 78
Belt tension 9
weigher from the side and align at the proper time.
to provide the prerequisites given at the 'Aligning' item.
Place carrying idler set on a levelling plate and align using a ruler in place of
tensioned steel wires as described at the 'Aligning' item.



in weighed idler set support points.
7.1.3.2 Mounting Weighed Idler Set(s)
First mount load cell(s).
• Remove transit restraint angle (painted red), twist and bolt in place.
• Turn in compression bolt (SW 17) with counter nut (SW 24) until the fitting
dimension of load cell with mount is approximately reached.

• Carefully raise weighing yoke against leaf spring force by max. 5 mm to be

able to insert the load cell with pre-assembled mount. Center fixing bolts and
spring washer relative to compression bolt and bolt in place. Carefully lower
weighing yoke.
• Place a ruler along one of the leaf springs and set surfaces A and B to ≤ 0.5
mm difference in height (compression bolt resting in place) using the
compression bolt.
• Secure compression bolt using a counter nut.

NOTE: The design of force transducers PWS and VBB differs from that of the
To perform welding work, and in order to protect the load cell, connect
the minus pole direct to the point of welding.

Assemble weighed idler set; first bolt loosely outside the belt stringers.
• Belt weigher with one weighed idler set
• Belt weighers with two weighed idler sets normally come pre-assembled and
aligned.

Detail of 'A':
Mount weighed idler set(s) on belt stringers with correct side in direction of travel.
• Belt weighers with one weighed idler set, first loosely bolted.
• Align weighed idler set(s) as shown in dimensioned drawing and bolt the 4
screw heads in place on belt stringers.
• Place rulers in measuring positions [1] and [2].
• Level surfaces C-D, and E-F relative to each other using set screws (4) and
(5), however, without twisting the weighed idler set(s), i.e. ensure that
distance 'H' is almost the same in the 4 corner points.
• If only one weighed idler set is installed, additionally tighted bolts (1), (2) and
(3). If necessary, mean the difference in height between surfaces C-D, or E-F,
within the hole pattern of bolts (1) and (2) and set distance 'H' anew.

• Arrange carrying idler sets in weighing influential zone elevated by 3 to 5 mm.

on the premade shims on belt stringers.
overbalancing.
• Align all idler sets in the influential zone (also consider the adjacent non-
elevated carrying idler sets):
o Observe preset triple idler spacing between the carrying idler sets
7.1.3.4 Aligning
• Align the weighed and carrying idler sets arranged in the weigher influential
zone elevated by 3 to 5 mm to max. 0.2 mm tolerance.
o Remove all idlers from carrying idler sets 1 and 2.
o Set weighed idler set with nuts (4) and (5) to distance H + X, roughly
aligning the weighed idler set relative to carrying idler sets 3.

o Remove idlers from weighed idler sets.
below.
o Align idlers one after the other, terminating with the idlers of the
weighed idler set.
refiling.

o all carrying idler sets in the weigher influential zone are square to belt
stringers
• Affix carrying idler sets to belt stringers by welding limiting blocks and shims in
place.
• Attach the weighed idler set by welding it to the weighed idler receptors.

When installation is complete, acquire the effective platform length 'lng'.
Measure spindle spacings on either side of your belt conveyor and compute as mean
values:
a = (spindle spacing side a1 + side a2) / 2 =
__________
b = (spindle spacing side b1 + side b2) / 2 =

__________
c = (spindle spacing side c1 + side c2) / 2 =

__________

Effective platform length:
Enter acquired value with proper

unit into the weighing electronics
as shown in the Electrical
Equipment manual.
7.1.4 Cabling
o Load cell = 5 m
o Transducer = 6 m
• Connect (optional) speed transducer as shown the in the circuit diagrams

supplied.



Depending on belt width, one or two weighed idler set(s) are available. The weighed
idler set(s) are designed on the principle of leaf spring parallel guidance.
Bolted to the two cross-members in three points, a rigid support frame serves for
accommodation of load cell and leaf spring parallel guidance used to restrain the
weighing yoke. Mounted on the load cell, the weighing yoke supports the weighed
idler set.
The SCHENCK load cells of the RT.. type are hermetically sealed and service-free.
For exact type designation, see load cell type plate or Belt Weigher Spec Sheet.
Explosion Protection
If the belt weigher operates in hazardous areas, Zones 1, 2 or 11 as
specified by DIN 57165, or VDE 0165, the load cell is protected to EEx
ibIIC T6.
7.2.1 Maintaining
proper alignment:
• Align individual carrying idlers as described at the 'Aligning' item.
• Keep carrying idlers in the weighing influential zone free from build-ups.


(if required)
• Unscrew fixing bolt of load cell mount.
• Raise weighing yoke by approx. 5 mm, secure in this position, and remove
load cell from weighed idler set from below.
• In case of doubt, also replace the compression bolt before mounting the new
load cell.
ATTENTION! Before replacing the compression bolt:
o Adjust weighing yoke in height as described at the 'Mounting Weighed

Idler Set' item.
o Align weighed idler sets as described at the 'Aligning' item.
• Introduce load cell complete with pre-installed mount, carefully center load cell
relative to compression bolt, and bolt in place.
• If need be, align weighed idler set relative to the carrying idler sets in the
weigher influential zone as described at the 'Aligning' item.

(if required)
• Always replace all 4, or 8, leaf springs.
clean and deburred.
• Before tightening bolts in steps, align weighing yoke
o centrically to the load cell load button
o vertically to the load cell load button
o axis parallel to the weighed idler set support frame.
influential zone as described at the 'Aligning' item.
ATTENTION!
• Check effective platform length.
• If necessary, correct value in weighing electronics.

Speed Transducer (Option)
8 Speed Transducer (Option)
8.1 FGA20-RSLE Type

8.1.1 Installation Instructions
SAFETY HINTS:
• Ensure work protection at this device by having it installed by skilled
technicians and using it as originally intended only, in accordance with
supply specification, and by operating it in accordance with the
suggestions to follow.
• Ensure that the rocker joint cannot detach from belt stringers and
damage your belt weigher.
8.1.1.1 Installing Speed Transducer
The speed transducer of the FGA 20-RSLE type equipped with friction wheel and
rocker is designed to acquire the belt speed at the inside of the return belt.

• Mount speed transducer on weighed idler set direct or max. 5 m away.
• Avoid vibration of the return belt in speed transducer area. Arrange return idler
towards transducer in return belt direction of travel as shown in sketch.
• Ensure ≤1 mm maximum out-of-round tolerance of return idler.
• Remove build-ups from return idler and/or avoid build-ups, e.g. by using
rubber-coated idlers.
• To avoid slip between friction wheel and belt, keep belt interior clean using
appropriate devices, so as to avoid errors in measurement.
8.1.1.1.1 Further Installation Instructions
• Carefully align speed transducer with friction wheel relative to belt run. Slip
causes wear of the running ring.
• Securely bolt speed transducer with joint to the provided location on weighed
idler set or belt stringers or weld in place; ensure that rocker joint does not
detach from belt stringers and damage your belt conveyor.
• To ensure positive contact of friction wheel on return belt, check to see that
o loops of sensor cable in rocker spindle area are sufficiently long
o rocker joint freely moves
o friction wheel is perfectly level with return belt.
8.1.1.2 Cabling
• Connect cables as described in the Weighing Electronics manual and observe

the following additional hints:
• Run load cell and speed transducer cables to terminal box supplied using
cable ducts. Mount terminal box in a safe location.
ATTENTION!
Observe cable end lengths:
Load cell = 5 m
Transducer = 6 m
o Never shorten ready-to-connect cable ends; if need be, arrange in
loops.
o Pay heed to the local regulations.
Check to see that the speed transducer cable does not affect
the positive contact of friction wheel and return belt and
does not interfere with the rocker spindle.

8.1.2 Operating Instructions

Rolling on the interior of the return belt, the webs of the friction wheel dampen an
inductive proximity switch, thus causing the latter to output a pulse frequency
proportional to belt speed.
The number of pulses per belt meter is the speed characteristic vs-K used to
acquire the belt weigher's feed rate.
Enter this value into the weighing electronics in form of a parameter; for details, see
Weighing Electronics manual.
8.1.2.1 FGA 20-RSlE for Legal-for-trade Belt Weighers
The counter pulses of the second switch are

offset with respect to those of the first switch
by measure 'O'. The weighing electronics
continuously compares counter results and
reports error when a deviation is detected. T
is the pulse interval.
8.1.2.2 Maintenance
• Ensure free movement of the rocker joint; if necessary, dismount and clean.
• Check friction wheel rubber ring for wear, and replace if necessary.
• Ensure positive contact with return belt.

8.1.2.3 Inspection and Repair
Measure 'X': Mild steel variant (galvanized) = 2 ... 3 mm
Stainless steel variant = 1 ... 1.5 mm
• The friction wheel is mounted in sealed grooved ball bearings lubricated for
life. If you note bearing damage, replace speed transducer.
• When replacing proximity switch, ensure proper switching distance.
• When running sensor cable, observe the instructions given at the 'Installation
Instructions' item.
8.2 FGA24A Type

8.2.1 Installation Suggestions
SAFETY HINT:
Ensure work protection at this device by having it installed by skilled

technicians and using it as originally intended only, in accordance with supply
specification, and by operating it in accordance with the suggestions to follow.
The speed transducer of the FGA 24 A type is designed for measuring the belt speed
on the belt conveyor tail pulley.

8.2.1.1 Suitability
Make sure the

following prerequisite
is given:
DTr = Pulley diameter in [m]
tbelt = Belt thickness in [m]
Smallest frequency the weighing electronics can measure ( ≥

fmin = 0.04 Hz with INTECONT and DISOCONT,
10% safety allowance for running message, etc. included)
24 = Number of pulses per pole wheel / belt pulley revolution
Related to the pulley diameters below and assuming 10 mm belt thickness, the
following minimum belt speeds Vbelt result:
Belt conveyor Comments
as per DIN
DTr [m] 0.200 0.250 0.315 0.400 0.500 0.630
22101
Vbelt [m/s] 0.15 0.19 0.23 0.30 0.37 0.46
determines
calibration
vs-characteristic [I/m] 36.38 29.38 23.51 18.63 14.98 11.94
accuracy
(*)
(*) Having been computed with 10 mm assumed belt thickness, the vs-characteristics
in table can only serve as mean values .

Decisive for feed rate determination

is the vs-characteristic (number of
pulses per belt meter) to be
computed using the formula on the
right, to be then entered into the
weighing electronics.
8.2.1.2 Mounting Pole Wheel
Best mount pole wheel on webs in the belt pulley protected area. Weld or bolt in place.
The pole wheel is equipped with a centre hole d=8mm serving for adjustment to the
required diameter. Ensure min. 20 mm distance from pulley bottom in order to prevent
the pulse quality from being affected.
8.2.1.3 Mounting Proximity Switch
Mount proximity switch on belt stringers using the mounting angle. The provided hole
pattern allows for universal arrangement; two possibilities are depicted in the figure.
Arrange switch centrally to pole wheel windows. Protect the switch cables from
mechanical damage by using cable ducts.

Test Weight Suspension (Option)
9 Test Weight Suspension (Option)

The weighed idler sets of the BEP, BED and BMP types are prepared for manual
suspension of test weights.
The test weight suspension lets you simulate the belt weigher's operating points with
the use of test weights in place of a material load.
ATTENTION
• Ensure that test weights are accurate to 1‰.
• Check to see that the weight value display of every single weight is easy-to-
read.
• Ensure that number and assignment of single weights are clearly identified.
• Remove test weights after test weighing.
• Select test weights in the range of 50 % to 80 % of belt load.
Check to see that no material is present in weighed idler set area.
Maintenance
• The test weight suspension is free from maintenance and requires no special
inspection.
• Before every test operation, remove lumpy material possibly jammed between
weighing sections. Do not remove overaged build-ups from belt weigher
components; this would only cause taring errors.

9.1 BEP, BMP Types

• Turn out threaded pins on either side of weigher, so that the telecopic tubes
can be pushed in.
• Twist telecopic tubes, turn threaded pins into guide grooves and counter.
In pushed-in state, the telecopic tubes rest inside the belt stringers; in pulled-
out state, the test weights can be suspended.
9.1.2 Installation and Setting Instructions
G= total of suspended test weights

Operating Principle
The test weight suspension lets you simulate the belt weigher's operating points
without material load on belt.
• Pull out telescopic tubes from both sides of the weighed idler set and suspend
the test weights supplied (or commercial units) in equal shares.
• Remove test weights when test weighing is complete.
• Push in telecopic tubes.
9.2 BED Type

The test weight equipment consists of two weld-on pieces and a number of test
weights.
To assemble, expertly weld the weld-on pieces to the faces of the weighed idler set tie
on either side as depicted above.
Consider the following:
• Weld the weld-on pieces in place best before aligning the weighed idler set.
The welding heat can cause deformation and deteriorate the accuracy of
alignment so that realignment is required.

9.2.2 Operating and Setting Instructions

The test weight equipment consists of
• two weld-on pieces welded to the weighed idler set as described above, and
• a number of test weights supplied upon request or readied by the user.

The test weights suspended on either side in equal shares = G/2 let you simulate the
belt weigher's measuring points without belt load.
Concerning the testing accuracy, please always heed the instructions given in the
Weighing Electronics manual and
• never remove overaged build-ups from belt weighers components because of

the change in tare.

Appendix
2BMP type 8
Acquiring Effective Platform Length 30, 46, 60, 73
Aligning 28, 44, 71
Aligning Carrying Idler Sets 57
Aligning Weighed Idler Set 58
BED type 6
BED Type 86
Belt Weighers Overview 3
BEM type 4
BEP type 5
BEP, BMP Types 85
BMP type 7
BMP2 type 8
Cabling 28, 46, 60, 74, 79
Checking Leaf Spring Parallel Guidance 33
Checking Load Cell 34
Checking Load Cell Signal 34
Displacing Measuring Modules 23
Ensuring Proper Alignment of Carrying Idler Sets 32
FGA 20-RSlE for Legal-for-trade Belt Weighers 80
FGA20-RSLE Type 78
FGA24A Type 81
Further Installation Instructions 79
General Information 1, 9
Hints for Delivery 1
Hints for Movable Conveyors 10
Information on Documentation 1
Inspecting 32
Inspecting and Repairing 47, 62, 76
Inspection and Repair 81
Inspection of incoming goods 1
Installation 24, 38, 51, 65
Installation and Setting Instructions 85
Installation Instructions 22, 37, 50, 64, 78, 85, 86
Installation Prerequisites 22, 38, 50, 64
Installation Suggestions 81
Installing Speed Transducer 78
Items Supplied 22, 37, 50, 64
Maintaining 32, 47, 61, 75
Maintaining Belt Weigher 31
Maintenance 80
Mounting Belt Weigher on Belt Stringers 54
Mounting Carrying Idler Sets 27, 43, 56, 71
Mounting Load Cells 55
Mounting Measuring Modules 25
Mounting Pole Wheel 83
Mounting Proximity Switch 83
Mounting Weighed Idler Set 41
Mounting Weighed Idler Set(s) 67
Multi-idler Belt Weigher BMP 64
Multi-idler Belt Weighers 6
Operating and Setting Instructions 87
Operating Instructions 31, 47, 61, 75, 80
Overview 10
Planning-in Hints (The 10 Rules) 9
Prerequisites 24, 51
Prerequisites: 39, 65
Repairing Belt Weigher 35
Replacing Leaf Springs 49, 63, 77
Replacing Load Cell 48, 62, 76
Single-idler Belt Weigher BED 50
Single-idler Belt Weigher BEM 22
Single-idler Belt Weigher BEP 37
Single-idler Belt Weighers 4
Speed Transducer (Option) 78
Storage hints 1

Appendix
Suitability 82
Test Weight Suspension (Option) 84
The 10 Rules 10
The Rules in Detail 11

Measuring and Process Technologies
SCHENCK PROCESS GmbH

D-64273 Darmstadt
Phone: +49 (0) 6151-32 10 28
Fax: +49 (0) 6151-32 11 72
E-Mail: sales.process@schenck.net
www.schenck-process.net
The Group

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MULTIBELT Belt Weighers

Installation and Operating Instructions

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Sales: Tel.: +49 (0) 61 51 32 - 10 28

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BV-H2190 GB 0536 MULTIBELT Belt Weighers Installation and Operating Instructions

1 General Information ......................................................................... 1