Belt Weigher BCW51L0 Manual

ISO 9001: 2000 COMPANY
INSTRUCTION MANUAL
Belt Weigher
JOB ORDER: 843/09

CUSTOMER : M/s. LARSEN AND TOUBRO LTD.
IPA PVT LTD

472/B2, 12th Cross, IV Phase,
Peenya Industrial Area,
Bangalore – 560 058.
Phone: (080) 28362851
Fax: (080) 28360520
E-mail:ipa@ipaindia.com
Instruction manual for Belt scale
TABLE OF CONTENTS
Section 1 …. 2 Cable routing

Supply Verification & Visual Inspection
Caution Section 6 – System Description …. 30
Warning Belt scale panel
Section 2 – Introduction …. 4 Remote indicator panel
Basic Operation
Signal Diagram Section 7 – User Interface …. 34
Display
Section 3 – System Modules …. 7 Operation
Weigh Frame key functions
Load Sensor
Speed Sensor Section 8– Symptoms & faults …. 55
Electronic Unit
Calibration Rod/Chain Section 9 – Replaceble spares ….56
Section 4 – System Specification…. 16 Section 10 – Annexure …. 57

Conveyor specification
Belt scale panel specification
Remote indicator panel Section 11 -Maintenance schedule …. 59
Loadcell specification
Section 12 – Warranty ….61
Section 5 – System Installation …. 20
Weigh Frame & loadcell installation Drawings
Speed sensor installation Test report
Belt scale panel installation
Log sheet
Page 1
Section 1
SUPPLY VERIFICATION AND VISUAL INSPECTION
The following verification checks are to be carried out on receipt of the equipment
before they are moved to the installation site.
• Check all the items as per the packing list supplied by the manufacturer. IPA Private
Limited, Bangalore. In case of short supply, please inform the company
immediately.
• Carry out a visual inspection of each item. If any damages are noticed inform the
Company giving the details of the damages, quoting the item numbers and box
numbers in which they are packed. If applicable, inform the insurance company
immediately and request them to arrange for a survey of the damages. If requested,
one of our representatives can be sent to assist in assessment of the extent of
damages. After physical verification and inspection, please repack the items like the
original packing and store them in a cool and dry place. Take care that they are not
exposed to sun and rain. While repacking, please ensure that no moisture is
entrapped in any of the packing.
Equipment packing consists of the following in the order as shown below ( Fig 1.1)
• Polythene sheet for sealing against moisture and air bubble sheet for absorbing
shocks.
• Thermocole as second layer for absorbing shock.
• Cardboard box.
• ‘Kurlon’ as third layer for absorbing shock.
• Wooden box.
Fig 1.1 Packing details
Page 2
Cautions
 Read manual carefully before installing, wiring, operating, servicing or inspecting

the system
 Keep this manual within reach for quick reference
 Improper handling blocks, incorrect operations are cause a short life or failure
 Deliver this manual to end user of the product or operator
Warning
 Operate the switches with dry hands

 Do not use the cable when its insulating tube is damaged
 Do not subject the cables to scratches, excessive stress, heavy loads or pinching
 Always follow instructions to prevent the short life or failure of the system
 Do not allow lint, paper, wood chips, dust, metallic clips or other foreign matter into
the panel
 Do not place heavy items on the panel or weigh frame assembly.
 Protect the system from corrosive gas, combustible gas, oil mist or dust.
 Incorrect terminal wiring could result in the equipment damage.
 Do not install or operate the system that is damaged or lacking parts
 Never attempt to modify the system without proper instruction from manufacturer
Page 3
Section 2 Introduction
Basic Operation
In most of plant situations require the transport of materials like coal, sand,
salt aggregate gravel, lime etc., with the advent of fast mode of transportation,
accounting the quantity of material transferred assumes great importance. Belt scales
are most common type continuous weighing devices and consists of one or more
conveyor idlers mounting on a weigh frame as shown in fig (2.1). Since weight remains
as the most reliable index of material accounting and can be measured directly and
precisely, designers can offer accurate weighing systems to maintain higher accuracy
and better accountability in the process.
The belt load is transmitted from weigh frame either direct or via a lever
system to a loadcell. The combined output from loadcell and speed sensor provides the
flow rate of the material passing over the scale
Main features are

High reliability and accuracy
Trouble free operation under severe environmental conditions
Practically no effect of belt tension on weighing
Remote data transmission
Simple installation and easy maintenance.
Approved by Weights & Measures Model Approval No: BCW:IND/09/06/478
PRINCIPLE OF OPERATION
fig. 2.1
Page 4
Belt scales are integrating weighing devices that use a simple integral
calculus summation process to measure a conveyed quantity of material. Two variables
are involved in this :weight and speed. The weight function measure small section of
conveyor. The speed function is the second variable to be measured .Most modern
speed sensors rotary digital pulse generators. This can be optical, magnetic or other
on/off sensing units. They are mounted on pulley or wheel that rotates as belt moves.
The material passing over a Belt Conveyor exerts a downward force proportional
to its weight. The product of this force and the speed of the belt is the rate of flow, the
unit being kg/minute or Tonnes/hour.
Taking a section of unit length between ‘aa’ and ‘bb’ on the belt (fig. 1), the
reaction ‘R’ at the center of that section equals the weight of the material including the
belt weight, on that section. The tension of the belt ‘T’ has got no influence on reaction
‘R’ if ‘T’ and ‘R’ are mutually perpendicular.
Let the weight between ‘aa’ and ‘bb’ (unit length) = w kg./m
Let the speed of belt = s m/s
Therefore, material flow/min. = wxs
The rate of flow w x s integrated over a period of time gives the total quantity of
material transferred over that time.
Signal Diagram
The belt scale electronics consists of Power supply section, ADC section, Relay section
display and keypad section.
The power supply section consists of On/Off switch, fuse, step down transformer and
SMPS card it can provide supply voltages need for the system operation.
ADC section card consists of Micro controller, Instrumentation Amplifier, ADC, DAC
(for 4-20 mA /0-20mA /0-5V output),
Relay section is used to provide potential free contacts (250V, 5A) – 4Nos. For
Overload, Under load, Totaliser pulse and Totaliser set achieved.
Page 5
The display section Which displays load in kg/m, speed in m/s, rate in t/hr and
totaliser in tonnes, various system alarms and annunciations.
Keypad (4 X 4 matrix keypad) is interfaced with the microcontroller which is used to

enter the programmable parameters.
Load cell input is given to the instrumentation amplifier circuitry, which amplify the
input signal and is given to ADC. The digital output from ADC is given to the micro
controller. The DAC will produce a analog 4-20 mA out put corresponding to flow rate.
The tacho input is given to the ADC card via frequency divider circuit as pulse input.
Page 6
Section 3 System Modules

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

The arrangement is to have a platform on to which the idlers are mounted and the
platform is supported on four loadcells. Fig 3.1.
This arrangement is used for applications like weighing in conveyors having minimum
material load of 20 Kg/m. This arrangement will get accuracy of 0.5% better under ideal
conditions.
Fig. 3.1 FOUR LOADCELL SYSTEM
Weighing arrangement with counter balancing weight
This consists of a framework pivoted or supported by bearings at both ends of a shaft

with an adjustable balancing weight at one end and the frame resting on loadcell at the
other end. (Fig. 3.2).
This type of arrangement using where material load is less then 20 kg/m and accuracy is
in the range of 1-3% depending upon site conditions.
Page 8
Fig. 3.2 COUNTER BALANCING WEIGHT SYSTEM
Weighing arrangement for garland conveyor
This arrangement is using when garland type idler are using for Weighment. Here DS
type load cells are directly connecting to the idlers for the Weighment (Fig. 3.3).
Page 9
Fig. 3.3 GARLAND CONVEYOR WEIGHING SYSTEM

Weighing arrangement with two loadcells
The arrangement is to have a platform on to which the idlers are mounted and the
platform is supported on two loadcells. Fig 3.4.
Fig. 3.4 TWO LOADCELL SYSTEM

LOAD SENSOR
To measure the load, the gravimetric, force must be countered by an opposing force
measurement. This opposing or counter balancing force becomes the measurement of
weight.
The load sensor is a high accuracy strain gauge based loadcell, which gives excellent
linearity and repeatability. The zero and span of loadcells are fully temperature
compensated. These loadcells are hermetically sealed to withstand the hostile industrial
environment. The loadcells are provided with S.S. bellows to resist industrial corrosion.
BR type Loadcell (Fig.3.4) & DS type loadcell (Fig 3.5)
Page 10
Fig. 3.5 BR TYPE LOADCELL EXPLODED VIEW
Fig. 3.6 DS TYPE LOADCELL
SPEED SENSOR:
The accurate measurement of belt displacement is important for computation of total
mass passed over a conveyor.
The speed of the belt is measured by means of speed sensor that is driven by the return
belt/tail pulley. Generally four types of speed sensors are used
AC tachogenerator
DC tachogenerator
DC pulse encoder
Proximity switch.
Page 11
Selection of speed sensor is purely depends upon the conveyor speed and conveyor
construction.
AC Tachogenerator
AC Tachogenerator consists of a rotor having permanent magnetic poles that rotate
inside a stator having suitable winding. It generates 0-20V AC proportional to 0-1000
rpm.
DC Tachogenerator
DC Tachogenerator generates 0-160V DC proportional to 0-1000 rpm.
DC Pulse encoder
DC pulse encoder to be excited by the voltage specified on it. It produces rated pulses
per revolution with amplitude equal to excitation voltage.
Proximity switch
Proximity switch is also to be excited by the voltage specified on it. It provides pulse
whenever metal part comes closer to its surface (for inductive type)
A proximity switch is used to measure the speed of the conveyor. The switch is
inductive type. A pick up wheel (reference drawing enclosed) is fixed to the shaft of tail
pulley or special wheel assembly and the proximity switch is placed such that
proximity switch senses the rotation of pick up wheel, hence speed of the conveyor.
The proximity switch is excited by belt scale panel and proportional to the speed of
conveyor, it provides pulses to the belt scale panel.
SPEED SENSOR MOUNTING ARRANGEMENTS
TELESCOPIC ARM:
An aluminium wheel is fixed to the axle of the speed sensor. The aluminium disc is
allowed to be on the belt by a hinged telescopic arrangement.
As the belt runs, the speed sensor is rotated due to the friction between the aluminium
wheel and the belt. The speed sensor produces AC/DC voltage or pulses while it rotates
and the frequency is truly proportional to the speed of rotation. (fig.3.6)
Page 12
Fig.3.7 TELESCOPIC ARM ASSEMBLY WITH DC PULSE ENCODER
IDLER MOUNTIG:
WEIGHING IDLER:
Machined idlers matching with the existing conveyor idlers dimensions. This will
improve the weighing accuracy, worn out idlers will cause errors in weighing. Usually
one pre and post carrying idlers are also machined idlers for better performance.
Fig.3.8 IDLER MOUNTING WITH AC TACHOGENERATOR
Page 13
PICK UP WHEEL & SENSOR:
3.9 PICK UP WHEEL & SENSOR
Page 14
ELECTRONIC UNIT
BELT SCALE PANEL

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

Conveyor Specification
Conveyor No. : 2B
Material handled : ROM COAL
Bulk density (kg/m3) :
Conveyor capacity (tph) : 1600tph (Rated)/1760tph (Design)
Belt speed (m/s) : 3.5
Material load (kg/m) : 126.98
Belt width (mm) : 1400
Belt weight (kg/m.) : 22.6
Idler spacing (mm) : 1200
Idler weight (one set) (kg) : 73
Conveyor inclination (Deg.) : 8.602
Conveyor length (m) :
Load cell capacity (kg) : 500
No. of load cells : 4
Cal. Rod wt (kg) :
Tot. Cal. Rod wt (kg/m) :
Page 16
Cal. Chain (kg/m) :
Tacho (Make/Model) : KUBLER/8.5000.8351.0100

Belt Scale panel Specification
Model No. : BCW51L0
Power supply : 230V, 50Hz AC
Operating temperature : 5°C to 50°C
Input : mV from transducer corresponding to load
Pulses from Speed Sensor.
Output :
♦ Excitation to transducer (4-wire system)
♦ 4-20mA corresponding to load,
rate and speed
♦ Potential-free contacts (4 Nos.)
Over load
Under load
Totalizer Pulse
Totalizer set achieve
Display : 7Digit Seven Segment LED Display
Features :
♦ Tare and Calibration through
keypad
♦ System reset through keypad
♦ Programmable parameters
Filter value (corresponds to load and speed)
Decimal point (corresponds to load speed, rate and totalizer)
Resolution corresponds to load
Under load
Over load
Set Speed
Span speed
Span rate
Totaliser Set
Span load
Page 17
Speed type
Sleeve Address
Speed measuring time
REMOTE INDICATOR PANEL
Model No. : RD177A0
Power supply : 230V, 50Hz AC
Operating temperature : 5°C to 50°C
Input : RS485(modbus) input from belt scale
Output : 4 – 20 mA output to customer
Display : 8Digit Seven Segment Red LED Display for

Totalizer and 7Digit Seven Segment Red LED
for Rate.
Features :
♦ Address through keypad.
Page 18
Load cell Specification
Model No.: BR052H9 Capacity: 500kg
Parameters Specified Value

(% Of Rated Output)
RATED OUTPUT 1.5 ± 0.01 mV/V
COMBINED ERROR ± 0.1%
REPEATABILITY ± 0.05%
CREEP ON LOAD (30 mins.) ± 0.1%
ZERO BALANCE VOLTAGE ± 0.2 mV
INPUT RESISTANCE 390 ± 10 OHMS
OUTPUT RESISTANCE 350 ± 2 OHMS
COMPENSATED TEMP.RANGE 5 - 55° C
OPERATING TEMP.RANGE 5 - 70° C
TEMP. EFFECT ON SPAN 0.006% /° C
TEMP. EFFECT ON TARE 0.008% /° C
EXCITATION VOLTAGE 10V DC/AC (MAX.12V)
SAFE OVERLOAD 200%
ULTIMATE OVERLOAD 300%
INSULATION RESISTANCE, BRIDGE TO > 1000 M OHMS
CASE AT 30V DC AT 30° C
PROTECTION IP- 68
CABLE 5 m . 4 CORE SHIELDED PU
SHEATHED
LOADCELL CONNECTION DETAIL:
SIGNAL COLOUR OF WIRE

+ EXCITATION BLACK
+ IN HIGH RED
- EXCITATION GREEN
- IN LOW WHITE
SHIELD
Page 19
Section 5 System Installation

System Installation Requirements
Your conveyor may not meet all of these requirements and still give good accuracy
readings. Use these as guidelines for good design and realize that violating good
design will probably reduce accuracy
Avoid high speed, lightly loaded belts for scale application. Lowering the belt speed
which increases belt load will cure most scale problems.
The idler used at the scale as well as preceding and following the scale should turn
true(concentric) and the scale idler should be reasonably balanced(especially with
high speed belts) so as not to generate an out of balance vibration
Idlers should be on equal centers a minimum of two before and two after the scale
and must be string lined to be level for this span. Skirt boards must be avoided in
the scale area.
The conveyor should be rigid in design and reasonably free from vibration. The
conveyor must not be subjected to stress that will cause structural deflection
The conveyor should have an automatic belt tighter. A gravity take up system is
preferred.
The belt must be in contact with the scale idler at all times and should track in the
center both empty and full
The idler troughing angle should be 35° or less.
Conveyor inclination must not exceed the material angle of slide.
Conveyor loading should be reasonably uniform and loading cannot take place on
the area of belt being used as the weighing platform.
Sufficient impact location idlers should be provided under each feeding location so
as not to cause any deflection of the belt at the feed point.
The conveyor should be designed with a straight run without a vertical curve. The
conveyor may be horizontal, inclining or declining in scope.
Conveyor feeding to be uniform for better performance.
Page 20
A few typical locations of mounting weighing frames are shown in Fig 4.0.
Fig. 4.0 LOCATION OF WEIGHING FRAME IN CONVEYOR BELT INSTALLATION
Avoid the following!

• Badly worn belts and splices.
• Joined belts with different thickness.
• Poor belt training or alignment.
• Wind, temperature or vibration extremes.
• Mud or material build up on belt or idlers.
• Loosely mounted unstable conveyor.
• Steep troughing angles.
• High belt tension.
• Steep conveyors allowing material to roll back.
• Belt skirting or other interference near scale.
Page 21
Weigh Frame & Loadcell Installation
Locate the suitable place to install weigh frame

Remove the existing idlers from the located place.
Weld the load cell fixing frame to stringer as per GA
Fix the load cells in correct orientation
Fix the weighing frame above the load cell
Fix the weighing idlers on weighing frame
All the idlers should be in the same level, if the weighing idler is lower give
padding plates where the weighing idler is fixed to the weighing frame.
Adjust the load cell button height suitably
Align at least two pre and post carrying idlers with weighing idlers
Care should be taken to ensure that the load pin touches only the sensing stud of
the loadcell and not the loadcell casing.
Tacho fixing frame should be near to weighing frame
Note: While keeping active loadcells the welding should not be carried out
Fig.4.1 WEIGHING FRAME
Page 22
Speed Sensor Installation

For standard speed sensors:
Mount the speed sensor assembly so that it is aligned exactly with the belt. If it is not
straight, it may bounce and wear down the wheel or belt. Position the wheel so that it is
at least 200 to 300mm from a return idler.
a) Telescopic arrangement
It contains two aluminium wheels and one wheel is coupled to the tacho shaft. The
telescopic arrangement is mounted with a frame that is fixed in the stringer and a
telescopic arrangement to adjust the tacho with respect to the belt.
1) Weld the supplied channel to the conveyor stringers.(Make sure that load cells
removed from structure before any kind of welding)
2) Fix the speed sensor assembly onto the pivot arm on the welded channel.
Fig.4.2 TACHO-GENERATOR
b) Idler mounting arrangement

In this arrangement separate idler is used which is made to rotate by the returning belt.
Tacho coupled to this idler with required mounting accessories.(fig 3.7)
Page 23
ANGLE SENSOR
Angle sensor is an instrument to measure the angle of inclination of a particular plane.
It is also called Inclino Meter. There are some situations in weighing where the angle of
inclination having relevance.
Principle
The basic principle behind angle sensor is law of gravity. A freely suspended mass
which can move according to the tilt of the plane to which it is attached. This rotation is
connected to a sensor.
There are two ways to sense the inclination:

1. Pulse Encoding
2. Potentiometric
Installation
Take the base plate of the Angle sensor and weld it on the stringer, so that the sticker
coming portion is on top of the stringer. Mount the angle sensor on the base plate using
bolts. In this also the sticker portion should come on top. Detach the top lid and
removing the thermocol given for packing, ensure that the horizontal position of the
stringer, pendulum is in vertical position (zero level). Attach the lid to the sensor and
give the connections
Application
When same conveyor is being used for stacking and reclaiming of the material the
inclination of the conveyor changes accordingly. This change induces a cosine error in
the measured load. To avoid this angle, Angle sensor is used.
Angle sensor is mounted to the conveyor stringer. Keeping the conveyor in horizontal
position system is calibrated. This is the 0° (zero) inclination, after that if there is any
change in inclination, positive or negative sensor gives corresponding pulse. This is
processed and corresponding cosine correction is made.
Page 24
Measuring Range
-40 Degrees to +40 Degrees.
The following thing should be taken care while installation
Errors in the accurate measurement of belt travel for conveyor scale weighing can occur
from variety of sources
a) The tacho should be coupled with the idler.
b) The tacho mounting idler should rotate freely to ensure that the pillow blocks
can be periodically lubricated.
c) The tacho mounting idler should be in-line with the belt so that it can rotate
freely without slip.
d) The cable from the tachogenerator should be brought out through a flexible
conduit and be terminated in the junction box, where the loadcell cable is
terminated.
e) Slip between belt travel pickup and conveyor belt.
f) Belt speed varies with in the conveyor as a function of tension.
Note: -
In case where single junction box provided for both loadcell & speed sensor
connection, do not connect speed sensor terminal to 5th pin (shield) of MKDSN
connectors in junction box.
Page 25
Belt Scale Panel Installation
CAUTION
 Do not hold the panel by front cover, It may fall off
 Install in a location where temperature with in the permissible limit.
The dimensional detail of the common panel which houses all the four remote
indicators is shown in the enclosed dimensional drawings.
Page 26
The dimensional details of the independent belt scale panel (wall mounting) is shown
in the enclosed dimensional drawings. Belt weigher or belt scale panel is micro
controller based electronic panel with protection class of IP-55, having glass window to
view display.
Cable termination is from bottom hence panel bears detachable cable gland plate .
Page 27
While selecting the mounting place for the panel following points should be kept in
mind:
Mount the panel in a reasonably clean area away from severe heat and isolated
from vibration.
Avoid areas of bright sunlight since the lighted displays may become difficult to
read. Also avoid dripping water areas.
The unit should be firmly fitted into the panel. Clamps for mounting are
provided in the unit.
Where outdoor installation is necessary, the panel should be mounted under a
“roof” or “dog house” to provide rain and snow protection as well as shade.
There should be sufficient space around the panel to do the periodic maintenance
or servicing or replacement of components.
There should be an instrumentation earth available and that is to be connected to
the panel.
Cables to the panel should be routed through conduit and terminated through
glands.
The power supply should be steady.
The panel can be located up to 25m from the weighing zone. Take note, however,
that calibration will require one person at the weighing zone and one person at
the panel.
Page 28
CABLE ROUTING:
Cable routing is an important factor, which governs the trouble free performance of the
equipment, especially, on a long-term basis. The following points are to be borne in
mind.
1. Never run any of the signal cables alongside a power line. The distance of the signal
from a power line should be at least one meter.
2. Do not use the power cables as a supporting point for signal cables especially when
supported by metallic wires.
3. It is always better to run the signal cables through metallic conduits.
4. Cables should not be routed beside relays, or electrical equipment.
5. Cables should not be exposed to sun or rain as this may cause deterioration of
insulation resistance. High insulation resistance is necessary for accurate operation.
6. When cables are terminated to an equipment or device, at least a small length of
flexible conduit is used at the point of termination or the cable connected to the
terminals should be allowed a little free length to avoid straining.
7. Joining of cables are to be done either by proper soldering or by cable connectors
and not by twisting them together. At the joining point they are to be properly
insulated by insulation tape of high quality. Joining the cables with connectors and
screws are not preferred. It is better to have soldered tags on the wire when
screwing connections are adopted.
8. For trouble free operation of the equipment proper earthing is essential which
improves signal to noise ratio, as well as minimizes transmitting of spikes. It also
helps to keep 50 Hz noise at a minimum level.
9. In many cases the power line earth (not neutral) may prove to be satisfactory. But
sometimes, this may also carry a voltage due to some return current from different
equipment connected to it.
10. Make a separate earth connection for the equipment. A long pipeline running under
the earth may be a good choice.
11. A good earth connection can be made by digging a pit of 0.6 X 0.6 X 2 m and
burying a copper bar of about 6 mm X 12 cm X 2 m , the pit being filled with
charcoal and common salt. From this point electrical connection can be made by 12
gauge copper wire. The main display unit casing should be connected to earth.
12. All the interconnecting resistance should not be more than 0.5 ohms.
Page 29
Section 6 System Description

Belt weigher or scale panel is independent wall mounting panel, operates on mains.
It comprises of main control unit and necessary components. The mains supply is fed
the main control unit through control switch. Protective fuse, spike suppressor card,
line filter and step down transformer.
For more details of main control unit refer section main control unit description.
Apart from these, there is a relay card which receives necessary voltage and data from
the main control unit and provides potential free contacts for status like under load,
over load, totaliser set achieved & totaliser pulse.
All the remote indicators pertaining to this project are housed in a wall mounting panel
with a glass window on the door. This panel receives data from respective belt scale
panel on RS485 to display rate of flow as well as cumulative totalized quantity. Apart
from this, it also provides 4-20mA signal proportional to rate of flow and RS485 for
customer interface.
Caution
 Only apply input power after assuring all wiring is correct.
 Connect shield wires to the panel only, not to other devices.
 Insulate shield wires to prevent shorts.
 Use only water tight compression fittings.
MAIN CONTROL UNIT DESCRIPTION (BELT SCALE PANEL)

Refer below diagram for easy identification of various modules (cards)
Page 30
SMPS CARD (PS30PX) :

This card is common power supply card designed to operate on mains
voltage 90 – 240V AC, 50Hz . It provides various DC supplies required for all the
modules.
CONTROLLER CARD (MB080509) :

This is the mother card which contains micro controller, memory chip
(EEPROM) and RTC.
This card controls all the various functions of the entire module.
DISPLAY CARD (DISP 250207) :

This is display, keyboard cum annunciation card. It contains 13mm
height 7 segment, 7 digit display and 4 keypad along with 8 annunciation LED’s.
It receives digital data to be displayed from the controller card and
power from power supply card.
ADC CARD (AIIP 140207) :

This card received all necessary voltage from SMPS card and provides
excitation voltage (7.5V) to loadcells.
It accept loadcell output (max 20mV) and converts in to digital form
for further processing.
DAC CARD (AOIP 12509) :
Page 31
This card receives power from SMPS card and digital data from
controller card. It provides 2 channels of analog output in the form of 4-20mA or
2-10V DC.
DIGITAL OUTPUT CARD (DIOP 120509)

controller card. It provides 8 digital output of 18V DC logic level. External
relays are to be used to convert digital outputs to potential free contacts.
DIGITAL INPUT CARD CUM COMMUNICATION CARD (DIIP 120509)

This card received power from SMPS card and capable to accept 4 nos.
of digital inputs. Common ground point provided to be shorted to respective
input point as these inputs are logic low sensitive
This card also provides RS232 or RS485 serial output. For user
interface.
INTERFACE CARD (230207):

This card interfaces all the above mentioned cards together to form modular
construction
The miscellaneous card are as under
RELAY CARD (9830C (M))

This card comprises of four-sugar cube relays rated for 5A, 250V AC. It
receives power supply and control signals from digital o/p card of belt scale panel for
activation of relays. The potential free contacts are for under load, over load, totaliser
set achieved and totaliser pulse.
LINE DRIVER CARD

The line driver used in this job is having non standard software. It is
loaded with software for modbus protocol.
On one port it acts as modbus master (on the indicator side) and on the other
port it acts as modbus slave (on the PC side).
On the indicator side : It polls the different belt scale indicators and requests for
the data one by one. This data is then written to the four remote indicators. The
Page 32
address of the belt scale and remote indicators are different and unique due to
which they can be on the same bus.
On the PC side : The PC requests for the belt scale data by polling the address
one by one. The earlier read data (On the other port) is stored in the line driver. This
data is then made available to the PC on request.
SMPS CARD (PS30PX) :

This card is common power supply card designed to operate on mains
voltage 90 – 240V AC, 50Hz . It provides various DC supplies required for all the
modules.
CONTROLLER CARD (MB080509) :

This is the mother card which contains micro controller, memory chip
(EEPROM) and RTC.
This card controls all the various functions of the entire module.
DISPLAY CARD (IPA_RD_8&7 R1)

This is display, keyboard cum annunciation card. It contains 13mm
height 7 segment, 8 digit display in first row and 13mm height 7 segment, 7 digit
display in second row and 2 micro switch along with 8 annunciation LED’s.
It receives digital data to be displayed from the controller card and
power from power supply card.
DAC CARD (AOIP 12509) :

controller card. It provides 2 channels of analog output in the form of 4-20mA or 2-
10V DC.
DIGITAL INPUT CARD CUM COMMUNICATION CARD (DIIP 120509)

This card received power from SMPS card and capable to accept 4 nos. of
digital inputs. Common ground point provided to be shorted to respective input point
as these inputs are logic low sensitive
This card also provides RS232 or RS485 serial output. For user interface.
Page 33
Section 7 User Interface

Display
The diagram below shows the Belt scale front panel.
There is a 7-Digit 7-Segment red LED display indicates following data selected by the
keypad.
♦ Belt load in kg/m.
♦ Belt speed in m/s
♦ Rate of flow in tph.
♦ Total quantity conveyed in t
Power ON belt on, under load, over load, and totaliser set achieved (SA) totaliser pulse
output and faults are also indicated on the LED. Password protection for all
programmable parameters, totaliser clear and tare run has been provided to prevent
unauthorized setting changes.
Page 34
Remote Indicator: Remote indicator is a slave unit which receives data from Belt scale
on RS485 bus and indicates instantaneous rate of flow and cumulative quantity.
The diagram below shows the Remote indicator front panel.
While switching on the remote indicator keep pressing the F1 key. Use F1 key
for setting of modbus parameters ie, Address (from 0 – 247) and mode selection (slave
& master). After setting the parameters press F2 to save the changes and switch OFF
indicator and again switch ON the indicator for operation.
Page 35
OPERATION
Setting up the system

♦ Refer back panel details for making the necessary connections.
♦ Connect the transducer to the indicator.
♦ Connect the PF contacts to the respective terminals.
♦ Connect the AC supply with proper earthing to the indicator (within 2 meters
of the panel) through the connector provided.
♦ Before put into operation set all the programmable parameters.
KEY FUNCTIONS
• To change the display to the next parameter.

• To increase the value of the digit.
▲ 1 • To Select the Display Item.
• To change the display to the previous parameter.

• To decrease the value of the digit.
▼ 2
• To enter into Different Mode (Password protected).

FUNC
• To store the value of the parameter.
↵ 3
ESC • To escape from any function.

• To shift the position of the blinking digit.
► 4
Page 36
NOTE: - To unlock the key Pad Hold the Enter Key for Some time before System is
powered till display shows unlock (Un_ling)
If Keypad is locked Only Display Selection (SPEED, LOAD, RATE and TOTALIZER)
and Totalizer reset is possible through keypad.
USING THE SYSTEM
When the system is switched ON, the display shows the following message
momentarily,
--Ipa Put--
The display then changes to
The display shows
If ENTER key is not pressed for unlocking the keypad

Then display shows
XXXXXXX
After wait display if ENTER key is pressed (Hold for few seconds) for unlocking
the keypad
Then display shows
Page 37
After releasing the ENTER key

The display changes to
Then display changes to
XXXXXXX
SET PARAMETERS
The set parameters are:
a) Under load
b) Over load
c) Set speed
d) Span speed
e) Span rate
f) Totaliser set
g) Span load
h) Speed type
i) Slave address
j) Speed measuring time
Under load:
This is the minimum load above which totaliser updating will takes place and below
which fault indication will be given.
Over load:
This is the maximum load that the system can withstand and above which fault
indication will be given.
Set Speed :
This is the speed of feeder in internal speed type.
Span speed
Page 38
This is the maximum speed of the system for which current output is maximum (i.e., 4-
20mA).
Span rate :
This is the maximum tph of the system i.e., normally rated capacity of the system and
also this is the rate for which current output is maximum (i.e., 4-20mA).
Totaliser set :
This is the set value of the totaliser to get set achieved P.F contact
Span load
This is the maximum load of the system for which current output is maximum (i.e., 4-
20mA).
Speed type:
This parameter selects the speed type of the system
For internal speed type select 1
For external speed type select 0
During calibration speed type is set to 0
Speed Measuring time: Measurement of speed is based on no of pulses/speed

measuring time in second i.e. frequency. For the given sensor and mounting
arrangement, frequency can be worked out. If the frequency is 500 Hz, speed
measuring time can be set as 2. This is the time interval in second at which the speed is
sampled periodically. For slower speed the value is set as high i.e >2.
Setting of SET parameters

Press the key marked FUNC key.
The display will show
Then Enter password 1122334

U_LoA
Page 39
Press ↵ key then the display changes to
XXXX.X
Use ▲key,▼key & ▶ key to change the value.

Press ↵ key to store the value
Press ▲key
Then the display will
LoA
XXXX.X

Press ▲key
SP
XXXX.X

Press ▲key
XXXX.X
Page 40

Press ▲key
XXXX.X

Press ▲key
XXXX.X

Press ▲key
XXXX.X

Press ▲key
Page 41
Use ▲key,▼key & ▶ key to change the value(1 to 5).
Press ▲key

Press ▲key
XX

Use ESC key is to come back to measurement mode.
Setting CON parameters:

Enter into CON mode (as mentioned previously)
Press the key marked FUNC.
The display will show
Page 42

Loa
Use ▲key &▼key to change the value.

Press ▲key
XX

Press ▲key
Page 43

Press ESC key & press ▲key
Then the display changes to
CON SPEED
XX

Press ▲key

Then the display changes to
Page 44
CON RATE

CON TOTALISER
Use ▲key & ▼key to change the value.

Use ESC key is to come back to measurement mode.
Calibrating the system

The indicator has been calibrated with loadcell at factory. However the system can be
fine adjusted at site if required as explained in the following section.
After completion of platform and loadcell assembly route all the loadcell cables of
each platform through junction boxes to the indicator.
Page 45
Switch ON the indicator and allow initial warm up time of 10 minutes then tare the
initial value.
Load each corner of the platform with 10% of the rated capacity one after the other
and note down the readings at the corresponding corner.
Now load a known weight of 60% of rated capacity at the center of the platform and
check the readout and calibrate the indicator using keypad calibration.
SYSTEM CALIBRATION
Assuming all parameters are correct and the unit is installed properly, you can now
calibrate the system. Without calibration, the system will not show correct rate value.
Turn ON the conveyor, make sure the belt is empty, and let the whole conveyor
system warm up for approximately one hour.
The Belt Weighing System is calibrated at site with a calibration chain or rod of
known weight per unit length or weight respectively. The calibration process is
generally carried out at 25 –75% of the rated capacity of the system.
The process of calibration involves two steps
a) Tare run operation
b) Calibration
a) Tare run operation

This is carried out when there is no load on the belt. Make sure the belt is empty and
clean. Run the empty belt for at least 15 minutes.
Make sure that all weighing pre/post idlers are in line and in contact with the belt.
b) Load calibration
After performing tare run operation load calibration is done. Load calibration may be
carried out using Calibration chain or Calibration rods or both. All of these are
explained in the following sections.
Chain calibration
Page 46
In case of CALIBRATION CHAIN

• Note down kg/m punched on the chain.
• Carry out tare run operation.
• Put the chain on the belt & suspend one end.
• Ensure the chain covering the total weighing zone.
• Enter kg/m value. (Load calibration)
• If the kg/m is not found weigh the total chain & measure the total length.
• Total weight /total length gives kg/m value.
The speed of the belt is monitored using a stopwatch. The length of the belt and time
taken are noted down.
The speed of the belt in m/s is calculated as
Speed = (distance) (Time taken in s).
The test chain is put on the belt and the rate reading is noted.
CALCULATION OF ACTUAL RATE:

Let
Belt speed = S m/s
Weight of the chain = W kg/m
Actual Rate in TPH = W x S x 60 x 60

1000
Reset the totaliser and start the stopwatch simultaneously. Take the reading of the
quantity for a known time. The quantity should agree with the rate reading. The tests
are repeated three times and the average value is calculated on the basis of these tests.
Rod calibration
IN CASE OF CALIBRATION ROD
• Ensure quantity of rods.
• Note down the weight punched on each rod and sum it up.
• Total weight/idler spacing x 2 gives kg/m value.
• Carry out tare run operation.
• Put the calibration rods on the bracket provided on weighing frame.
• Enter kg/m value.
Page 47
Note :
Always refer calibration chain/calibration rod data given at Page No.16 (Section 04.
SPECIFICATION) the value given in GA is only approximate value only.
Calibrating the system with both chain and rod.

After chain calibration perform drop test and make the necessary adjustments in the
indicator settings. Now conduct rod calibration. Observe the displayed load (kg/m)
value and note down the same.
The displayed value is __________ (To be entered by our service engineer).
There will be some variation in this value with respect to the value displayed when
chain calibration was done. Do not change any indicator settings.
During subsequent rod calibrations the above noted down load value is to be
considered for ascertaining the correctness of calibration.
Note: If drop test cannot be conducted then rod calibration is done after the chain
calibration.
TARE
Make sure there is no material on the Belt. Start the conveyor
Press FUNC key then the Display shows..

After 2 or 3 revolution press ↵ key, then TARE RUN will be completed

If we are pressing ESC key the Display will show AbOrt
The display changes to measurement mode
Page 48
CALIBRATION
Press FUNC key
then the Display shows..

XXXXX

Press ▲key
XXXXX

Press ▲key
Then the display will changes to
Page 49
XXXXX

Press ESC key to come out of programming loop.
For finding out the Totaliser calibration factor, reset the calibration factor to 1.0000.
Store and Exit back to Display mode by pressing the ESC key. Now run the conveyor at
a constant speed with the calibration chain/rod on it and clear the Totaliser.
Let the system run for 10 minutes. After ten minutes note down the indicated Totaliser
(ti ).
Now calculate the actual Totaliser value as
ta = rate ( in tph ) x time ( in s )

60 x 60
Calculate the Totaliser calibration factor ta / ti

Enter this value as the calibration factor.
Note:
1) The default calibration value is 1.0000 and normally no change will be required.
Page 50
CALIBRATION DETAILS
LOAD CALIBRATION
Capacity of the system : 2080tph (130% OF FULL LOAD)

Belt speed : 3.5 m/s
Rate in tph X 1000
Material load on the belt in Kg/m (Wm) : -----------------------------
Speed in m/s X60 X 60
: 165 kg/m
Total material load on loadcells : Wm X Idler spacing X No. of Idlers

: 165 X1.2 X 4
: 792 kg
The system has been calibrated such that 792 kg on loadcell (100%) to read as 165
kg/m
SPEED CALIBRATION
In case of AC OR Pulse tacho

Belt speed in m/s
Tacho speed (RPS) = -------------------------
ΠxD
= 1.76 rps
Where D is the diameter of the tacho wheel or tacho mounting idler 106 rpm
corresponds to 3.5 m/s
In case of Speed sensor & Pick up wheel (Not Applicable)
Belt speed in m/s
RPS of pick up wheel = ------------------------
ΠxD
= ---- rps
Where D is the diameter of the peck up wheel
Frequency = RPS x No. of pulses/revolution
= ---- X --
= ----Hz
--- Hz corresponds belt speed of ----m/sec
Page 51
CURRENT SELECTION

If you want current output (4-20mA) corresponding to Load

Press ↵ key otherwise press ▲key
If you want current output (4-20mA) corresponding to Speed

Press ↵ key otherwise press ▲key
If you want current output (4-20mA) corresponding to Rate

Press ↵ key
TEST MODE
SF_
Press ↵ key
Page 52
Press ↵ key
If the system pass EEPROM test it will show
Otherwise it will show FAIL

And screen changes to
SF_
Press ↵ key
Press ▲key
Press ↵ key
If the system pass NV RAM test it will show
Otherwise it will show FAIL

And screen changes to
Page 53
SF_
TOTALISER RESET

Totaliser will be reseted
SYSTEM RESET

System will be reseted

Once the system is reset all the parameter will be reset to default values and the system
calibration will be disturbed. In order to use the system after reset, it should be
recalibrated.
The table below shows the different parameters and their factory set values.
Page 54
Sl . No. Parameter Factory set value

1 Under load 0000.0
2 Over load 0180.0
3 Set speed 003.50
4 Span speed 003.50
5 Span rate 02080
6 Totaliser set 00010
7 Span load 0180.0
8 Speed type 0
9 Decimal point (load) 1
10 Filter value (load) 25
11 Resolution (load) 1
12 Speed decimal point 2
13 Speed filter 25
14 Rate decimal point 0
15 Totaliser decimal point 0
16 Slave address
17 Speed measuring time 0.2
Section 8 SYMPTOMS AND FAULTS
Page 55
SYMPTOMS POSSIBLE FAULTS
1. Unsteady reading a) Low power supply.

b) Bad earthing.
c) Transducer cables are not connected
properly.
d) Interruption in supply.
2. Display shows ‘Hor’ a) Loadcell is over loaded.
3. Display shows ‘FAIL’ a) Password entered is wrong.
Section 9 REPLACEBLE SPARES
Page 56
BELT SCALE PANEL

(To be ordered separately)
SMPS CARD - PS30PX

CONTROLLER CARD - MB080509
DISPLAY CARD - DISP 250207
ADC CARD - AIIP 140207
DAC CARD - AOIP 120509
DIGITAL O/P CARD - DIOP 120509
DIGITAL I/P CARD - DIIP 120509
INTERFACE CARD - 230207
RELAY CARD - 9830C(M)
TRANSFORMER - TR-314
LINE FILTER - EP-42-1
SPIKE ELIMINATOR CARD- 1053

SMPS CARD - PS30PX
CONTROLLER CARD - MB080509
DISPLAY CARD - IPA_RD_8&7 R1
DAC CARD - AOIP 120509
DIGITAL I/P CARD - DIIP 120509
LINE DRIVER - 9842(M)
TRANSFORMER - TR-314
LINE FILTER - EP-42-1
LOADCELL
MODEL - BR052H0
TACHO
MAKE - KUBLER
MODEL - 8.5000.8351.0100
Section 10 ANNEXURE-I
Page 57
CONNECTOR DETAILS
LOAD CELL CONNECTOR -7 PIN (ADC CARD)

1. BLACK +VE EXT.
2. SENSE +
3. SENSE-
4. GREEN -VE EXT.
5. RED +VE I/P
6 WHITE -VE I/P.
7 SHIELD
DIGITAL OUTPUTS (10 PIN CONNECTOR)

1 V18
2 NC
3 NC
4 TOT PULSE
5 NC
6 GND
7 NC
8 Under Load
9 Over Load
10 TOT SET Achieved
CURRENT OUTPUT (6 PIN CONNECTOR)

1 O/p 1
2 NO CONNECTION
3 NO CONNECTION
4 O/p 2
5 NO CONNECTION
6 GND
RS485 O/P and Digital I/P (9 PIN MKDSN CONNECTOR)
Page 58
RS485 o/p can be taken directly from the digital I/P connector (9 pin MKDSN)
provided at the back panel of the beltscale panel.
1. + Vcc
2. I/P
3. NO CONNECTION
4. NO CONNECTION
5. NO CONNECTION
6 GND
7 A
8 B
9 SHIELD
Page 59
Section 15 Maintenance Schedule

Item/ Period of Type of problem Cause Remedy
Component Verification
Idler Once in six i) Excess run out a) Bearing and / or Replace idler
months Bearing seal wear out
Belt Everyday i) Excess belt a) Belt loose Adjust takeup
sway a) Skirt plate Touching Lift skirt plate
ii) Undue wear the belt
out b) Lump getting stuck Remove lump
between feed chute manually and
& belt and /or skirt clean
& belt
Load cell Everyday i) No load or a) Check for foreign Remove foreign
Excess load body causing load body and set
shunting right
a) Load cell wire open Reconnect
b) Insulation failure Change loadcell

Tacho Everyday i) Speed a) Tacho wheel or Set right
fluctuates coupling not making
proper contact
b) Loose connection
a) Tacho coupling Align coupling
ii) Sudden jump loose/missing
in signal pulse
Speed Everyday i) Speed a) Pick wheel
Sensor fluctuates alignment not ok
ii) Sudden jump b) Loose connection
in signal c) Speed sensor
iii) No speed coupling loose Align coupling
feedback d)Sensor is not in
proximity with pick up
wheel
Page 60
Item/ Period of Type of problem Cause Remedy

Component Verification
Coupling Everyday i) Undue noise a) coupling loose Tighten bolt
b) Axial or angular Align coupling
misalignment
Weighing Weekly Material a)Material may fall Clean it at
Frame accumulation from belt regular interval
Idler/Pulley Once in six i)Wobbling a) Bearing and /or Clean bearing
months ii)Excess heat in Bearing seal wear Apply grease/
bearing block out Replace bearing
Page 61
Section 16 Warranty
The items are covered by our warranty /guarantee for a period of 18 months from the
date of dispatch or 12 months from the date of commissioning whichever is earlier,
provided the terms and conditions in our offer are complied with.
Our guarantee does not extend to damages caused due to negligence or improper
handling or erection by the buyer or any alteration carried out without our
knowledge /approval. During this period, the items are to be returned to us at your
cost.
How ever our guarantee does not cover
Normal wear and tear of the items during operations.

Damages or losses caused during transit
Consumable items such lubrication oil, grease etc.
Deterioration or rusting due to atmospheric conditions.
Damages resulting from accidents, mishandling or negligence on the part of
customer.
Breakage or damage of back light, proclaim, glass part, indicator lamp, power
card, plating, chipping or peeling of enamel and denting of the equipment.
After Sales Service

We can also service/ maintain the system supplied by entering into an ANNUAL
SERVICE CONTRACT at nominal charges available on request after the guarantee
period.
Page 62

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ISO 9001: 2000 COMPANY

JOB ORDER: 843/09

IPA PVT LTD

Section 1 …. 2 Cable routing

Section 4 – System Specification…. 16 Section 10 – Annexure …. 57

Fig 1.1 Packing details

 Read manual carefully before installing, wiring, operating, servicing or inspecting

 Operate the switches with dry hands

Main features are

Keypad (4 X 4 matrix keypad) is interfaced with the microcontroller which is used to

Section 3 System Modules

* Suitable arrangement selecting according to application.

Weighing arrangement with four loadcells

Fig. 3.1 FOUR LOADCELL SYSTEM

Weighing arrangement with counter balancing weight

This consists of a framework pivoted or supported by bearings at both ends of a shaft

Fig. 3.2 COUNTER BALANCING WEIGHT SYSTEM

Weighing arrangement for garland conveyor

Fig. 3.3 GARLAND CONVEYOR WEIGHING SYSTEM

Fig. 3.4 TWO LOADCELL SYSTEM

Fig. 3.5 BR TYPE LOADCELL EXPLODED VIEW

Fig. 3.6 DS TYPE LOADCELL

SPEED SENSOR MOUNTING ARRANGEMENTS

Fig.3.7 TELESCOPIC ARM ASSEMBLY WITH DC PULSE ENCODER

Fig.3.8 IDLER MOUNTING WITH AC TACHOGENERATOR

PICK UP WHEEL & SENSOR:

3.9 PICK UP WHEEL & SENSOR

BELT SCALE PANEL

Section 4 System Specification

Material handled : ROM COAL

Bulk density (kg/m3) :

Conveyor capacity (tph) : 1600tph (Rated)/1760tph (Design)

Belt speed (m/s) : 3.5

Material load (kg/m) : 126.98

Belt width (mm) : 1400

Belt weight (kg/m.) : 22.6

Idler spacing (mm) : 1200

Idler weight (one set) (kg) : 73

Conveyor inclination (Deg.) : 8.602

Conveyor length (m) :

Load cell capacity (kg) : 500

No. of load cells : 4

Cal. Rod wt (kg) :

Tot. Cal. Rod wt (kg/m) :

Cal. Chain (kg/m) :

Tacho (Make/Model) : KUBLER/8.5000.8351.0100

Display : 8Digit Seven Segment Red LED Display for

Load cell Specification

Model No.: BR052H9 Capacity: 500kg

Parameters Specified Value

LOADCELL CONNECTION DETAIL:

SIGNAL COLOUR OF WIRE

Section 5 System Installation

Fig. 4.0 LOCATION OF WEIGHING FRAME IN CONVEYOR BELT INSTALLATION

Avoid the following!

Weigh Frame & Loadcell Installation

Locate the suitable place to install weigh frame

Fig.4.1 WEIGHING FRAME

Speed Sensor Installation

b) Idler mounting arrangement

There are two ways to sense the inclination:

a) The tacho should be coupled with the idler.

can be periodically lubricated.