ASSEMBLY AND OPERATING

INSTRUCTIONS
for conveyer belt scale
ESW 2 (Easy Weighing)

Note:
The pictured idler is not part of the equipment.

Date: 01/2015

Manual ESW 2 www.mts-waagen.de

 Table of contents

1.0 General information about the ESW 2 built-in belt scale

1.1 Safety instruction
1.2 Functional principle

2.0 Assembly of the ESW 2 built-in belt scale with measuring wheel MR 10
2.1 Operating instructions

3.0 Adjustment

4.0 Current maintenance

5.0 Technical data and connector alignment

5.1 Connection with weight control unit
5.2 CE- technical connection conditions

6.0 Detail view of the ESW 2

7.0 Spare parts list

ATTENTION:
To ensure the faultless operation of this measuring equipment it is important
that all the operating instructions listed in this manual are followed.

Manual ESW 2 page 2 of 11

1.0 General information about the ESW 2 built-in belt scale
The ESW 2 is a robust and simply designed single-idler belt scale, which can be used in
nearly all current conveyers. It is characterized by a very good cost / performance ratio.
The ESW 2 can be built in very fast and easily due to its simple mechanical construction.
The support spar of the belt scale is simply screwed upon the conveyer. By exchanging
the spar, the scale can quickly be adjusted to another belt width. The low installation
height allows for applications in conveyers with a very small interspace between the
upper and lower belt.
The support spar and the weighing platform are made of powder-coated angle steel
profile. The support spar serves as bracket for the weighing platform as well as for the
speed measurement wheel. Two strain gauge load cells are installed on both sides of the
weighing platform and are reliably protected from stone-chipping.

1.1 Safety instructions

Please read the instruction and assembly manual carefully before commencing installation
and operation.
The positioning site for the belt scale must be sufficiently accessible for servicing and
maintenance as well as operational work to be carried out.
Any applicable local safety regulations as well as those relating to mechanical and
electrical installations must be adhered to.
The conveyer system must be switched off before you attempt to install the belt
scale or carry out maintenance work!
Work on the scale should only be carried out by trained and authorised personnel.

1.2 Functional principle of the ESW 2 built-in belt scale

The flow of materials that is continually being conveyed results in a pressure load on the
idlers and transport rollers on the belt.
The weight load on the idler (measuring station) of the belt scale is measured as a weight
value by the DMS load cell and evaluated and normalised by the in-line weighing
controller.
At the same time the measuring wheel running simultaneously on the lower belt records
the current belt speed.
The weight of material on the measuring station and the speed of the conveyer belt
combine to give the overall flow rate in tonnes per hour.
The measurement accuracy of the belt scale is determined by the construction of the
conveyer and the properties of the conveying belt.

Important:
The conveyer belt must always bear on the weighing rollers of the belt scale. This
also applies for conveyers running in idle mode.
The material being conveyed must not slide on the conveyer belt.
Belt tension should be as even as possible. Changes in belt tension significantly
influence the weighing result!

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2.0 Assembly of the ESW 2 built-in belt scale with MR 10 measuring
wheel
The MTS belt scale is integrated into the conveyer belt. To do this one of the existing
idlers is removed and secured to the weighing platform on the scale.

Important:
The idler or roller that is converted into the measuring station should be shortened
at both ends so that it is no longer in contact with the belt frame and lies
completely on the weighing platform.
The belt scale should be so mounted that the load cell points in the direction of
travel of the conveyer belt. The MR 10 measuring wheel (optional) is then
automatically pulled in the direction of travel by the belt underneath.

The measurement of the support bar of the belt scale is adjusted to the belt or frame width
of the conveyer and the flowrate in the factory. The load bearing spar is secured with four
securing brackets which are part of the delivery.

The connecting cables from the load cell and the measuring wheel transmitter are both
protected by a heavy duty protective shield that provides maximum protection from
damage.

Manual ESW 2 page 4 of 11

 Important:
On the underside of the support bar there are large access holes. The cables can be
fed through these holes either on the left or the right side of the belt scale as
required.

Connection to the customer’s cable network is made with a terminal box which is included
in the delivery and mounted directly near the belt scale.
The MR 10 speed measuring wheel (optional) runs on the inside of the returning belt d
is fixed as standard to the belt scale frame by an articulated joint.
Speed measurements are taken using an induction proximity switch with plug connector
mounted on the wheel’s punched disk. The controller translates the number of pulses
measured as the wheel turns into the current belt speed.

Important:
The gap between the proximity switch and the punched disk is 2 mm. Gaps greater
than this can lead to inaccurate measurements. The light diode/function indicator
integrated into the switch can be used to check whether it is functioning.

Manual ESW 2 page 5 of 11

2.1 Operating instructions for the ESW 2 built-in belt scale
When operating built-in conveyer belt scales the following instructions should be followed
to ensure accurate and consistent weighing of the material being conveyed:

⇒ The base frame of the conveyer must be solidly built.

⇒ The distance between the scale and the material feed should correspond to at least
three to five times the maximum belt speed.

⇒ Two, or better three, permanently mounted idlers with the same trough angle should be
allowed for both before and after the belt scale.

⇒ Always ensure that the conveyer belt lies on both the weighing rollers and the
neighbouring idler rollers in such a way as to ensure a correct weighing result.

⇒ The transport rollers on the belt scale should be aligned so that they exactly match the
neighbouring transport rollers (idlers) both in height and width.

⇒ The material being conveyed must not slide on the conveyer belt during operation.

⇒ A gravimetric (weighted) belt tensioning station is envisaged to assure optimal

precision.

⇒ The conveyer belt should be of consistent quality and show no signs of repair.

⇒ The speed measuring wheel should be mounted so that there is continuous contact
with the returning belt. The guides for the lower belt should ensure an even and stable
feed.

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3.0 Adjustment
Once assembly is complete and operation with the weighing controller connected has
begun, the belt scale should be calibrated using comparative weighing of known material
weights. This process should be repeated as often as possible to achieve optimal
precision.
An optional calibration check using static weights can also be carried out. Further
information on calibrating the belt scale can be found in the instruction manual for the
weighing controller.

4.0 Current maintenance

The MTS belt scale is nearly maintenance free. For current maintenance it is important to
control the mechanical parts and in the case of depositions to clean the weighing frame,
rollers and the measuring wheel.
Furthermore it is important to control dependent on the mounting and working situation:

⇒ For a constant accuracy please check rotation of weighing rollers and clean if
necessary. Changes by the weighing frame and rollers have significantly influence of
the weighing result!

⇒ The speed measurement wheel must have a continuous contact to the lower belt and it
must run without interruption on the belt surface.

Manual ESW 2 page 7 of 11

5.0 Technical data and connector alignment

Built-in belt scale MTS ESW 2

Comprising frame and integrated DMS load cell with mechanical overload protection
Power supply: nominal 10 VDC
via the weighing controller
Load cell: Single-Point
Output signal: 2 mV/V
Finish: Aluminium
Load cell capacity: 30, 50, 75 or 100 kg
depending on conveying capacity
Output resistance: 350 Ohm
Maximum electronic
overload: 2,5 times standard capacity based on standard
conveying capacity

Connection: 6-wire cable

Cable length: 3m
- with colour code: green excitation +
blue sense +
red output +
white output –
brown sense –
black excitation -
Combined error
belt scale: depending on the installation conditions nominal +/-
1% max. 2% based on the nominal conveying capacity
in the area between 50% and 100 of max. capacity
Operating temperature range: -30°C to + 80°C
Sealing: IP 66
Frame finish: powder coated RAL 3020
Basic dimensions: see diagram in the appendix

Speed measuring wheel MTS MR 10

comprising a ball bearing wheel with polyurethane surface and induction proximity
switch
Power supply: nominal 24 VDC
via the weighing controller
Output signal: tension pulses, 22 per revolution
Switch function: NPN
Connection: 3-wire cable with plug connector
Cable length: 5m
- with colour code: brown excitation +
black signal +
blue excitation -
Operating temperature range: -30°C to + 80°C
Sealing: IP 67
Wheel diameter: 200 mm
Finish on fixings: fully galvanised
Basic dimensions: see diagram in the appendix

Option MR10-DG, with Encoder:

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 Junction box for the ESW 2
Finish: normal steel, painted
Dimensions (WxHxD): 150x150x120 mm
Cable glands: 2 x M20
Sealing: IP 65
Connection: via junction box
DMS load cell
Terminal 1 green excitation +
Terminal 2 blue sense +
Terminal 3 red output +
Terminal 4 white output –
Terminal 5 brown sense –
Terminal 6 black excitation -
Terminal 7 shield

Measuring wheel
Terminal 8 brown excitation +
Terminal 9 black signal +
Terminal 10 blue excitation -
Terminal 11 shield

5.1 Connection with weight indicator

The connection between weight indicator and built-in belt scale as well as between weight
indicator and measuring wheel should be made by separate and shielded cables. We
recommend a wire cross-section of 1 mm². With regard to the connection of the load cell a
6-wire cable is necessary, regarding the measuring wheel a 3-wire cable is necessary. We
recommend LIYCY or any corresponding shielded oil flex connection.
The distance between built-in belt scale and weight indicator should not exceed 100 m.
Please also note the following CE connection conditions.

5.2 CE- technical connection conditions

• Lay separate cables for the load cell of the belt scale and the speed
monitor/measuring wheel
• Use shielded connecting cables between the weight indicator and the belt scale
• Do not exceed cable lengths of 100 m
• Where there is an increased requirement for breakdown protection for the scale, the
cables for the load cell and the speed monitor/measuring wheel should be laid inside
steel pipes
• The guidelines applicable to electrical engineering must be adhered to!

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6.0 Detail view of the ESW 2

Manual ESW 2 page 10 of 11

7.0 Spare parts list for ESW 2 belt scale and MR 10 measuring wheel

Article No. : Description:

5370800 02 Induction proximity switch IF 5544 for measuring wheel
5370800 03 Connecting cable with plug for measuring wheel
5270701 50 Punched disk for measuring wheel
5270701 51 Ball bearing wheel for measuring wheel
5270701 52 Flexa protective shield for connecting cable for measuring wheel or load
cell, 2 m
5270701 53 Flexa screw connection M 16
5270701 56 Junction box including terminals and cable glands
5270701 58 Support bars for belt scale cut to size and galvanised
3172300 105 DMS load cell type 1042, capacity 30/50/75/100 kg

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