oe 425- SlA-0185° OPERATING AND SERVICE MANUAL FOR RAMSEY SERIES 10-20B OR 10-22B BELT SCALE SYSTEM REC 3694 REV D 6/93 TECHNOLOGY INC. PART NO. 039585 ‘An EnviroTech companyRevision History Revision A duly 1991 Revision B October 1991 Revision C June 1992 Revision D June 1993 COPYRIGHT 1990, BY RAMSEY TECHNOLOGY INC. THIS DOCUMENT IS CONFIDENTIAL AND IS THE PROPERTY OF RAMSEY TECHNOLOGY INC. (*RAMSEY"). IT MAY NOT BE COPIED OR REPRODUCED IN ANY WAY WITHOUT THE EXPRESS WRITTEN CONSENT OF RANSEY. THIS DOCUMENT ALSO IS AN UNPUBLISHED WORK OF RAMSEY. RAMSEY INTENDS TO AND IS MAINTAINING THE WORK AS CONFIDENTIAL INFORMATION. RAMSEY ALSO MAY SEEK TO PROTECT THIS WORK AS AN UNPUBLISHED COPYRIGHT. IN THE EVENT OF EITHER INADVERTENT OR DELIBERATE PU3LICATION, RAMSEY INTENDS TO ENFORCE ITS RIGHTS TO THIS WORK UNDER THE COPYRIGHT LAWS AS A PUBLISHED WORK. THOSE HAVING ACCESS TO THIS WORK MAY NOT COPY, USE OR DISCLOSE THE INFORMATION IN THIS WORK UNLESS EXPRESSLY AUTHORIZED BY RAMSEY. PLEASE READ AND OBSERVE THE FOLLOWING SAFETY PRECAUTIONS FOUND THROUGHOUT THIS MANUAL DANGER Failure to observe will cause very serious personal injury or death. WARNING Failure to observe could cause serious personal injury CAUTION Failure to observe may cause minor or moderate personal injury or damage to the equipment. REC 3694 uaa Ve fat Ob Lys NEW 4p}SYSTEM DATA SHEET RAMSEY TECHNOLOGY, INC. SERIES 10-; 208 OR 10-228 BELT SCALE SYSTEM CUSTOMER: END USER: P.O. NO.: FILE NO.: CONVEYOR DATA Conveyor No. Equip. Tag fal eee Product: Capacity: a Belt Speed? FPN Speed Pulley Dia IN Belt Width ts Idler Spacin Idler Trough AngTe: nt: INSTRUMENT DATA Integrator Model: Speed Sensor Model: Pulse Output TONS Current Output: ma Integrator S/N: Digitizer S/H: Load Cell S/W: REC 3694 SCALE DATA Weigh Spar Tare Load: Net Load: Gross Loa Load Cell Size: “Ibs Belt Loading: Ts/ft CALIBRATION DATA Load Cell Resistance: okms R-CAL Resistor Value ‘obs R-CAL Equiv. Lbs: Style: ILChapter 1.0 2.0 REC 3694 RAMSEY PRODUCTS 10-208 OR 10-228 BELT SCALE SYSTEM TABLE OF CONTENTS Title INTRODUCTION. 1.1 GENERAL 1.2 DESCRIPTION... 1.2.1 1.3. UNPACKING AND INSPECTION. . 1.4 STORAGE 1.5. WARRANTY... INSTALLATION. ... 2.1 GENERAL... 2.2 SCALE LOCATION AND CRITERIA, “13 214 215 216 17 +18 Model 10-20 or 10-22 Carriage/ Weighbridge. Model 60-12 Digital Speed Sensor. Model 61-12 Digital Speed Sensor. Model 10-301 Micro-Tech™ Integrator. Optional Accessories. Wind and Weather Effects Vibration and Deflections. Conveyor Support. Tension.....+ Uniform Belt Loading Material Slippage Convex Curves Concave Curves. Trippers..... Single Load Point. Conveyor Belt Take-Ups Belt Tracking... Scale Service Idlers Belt Scale Area Idlers Idler Troughing Angles. Training Idlers Idler Alignment Cable Conveyors. WwChapter 3.0 REC 3694 Pe 2. 2. 2. OPERATION 3 4 5 6 al -10 TABLE_OF CONTENTS (Continued) Title WEIGHBRIDGE/CARRIAGE INSTALLATION........+++0++ 2.3.1 Terms.. 2.3.2 Location. 2.3.3. Site Preparation 2.3.4 Carriage/Weighbridge Installation MICRO-TECH™ I] INTEGRATOR INSTALLATION... MODEL 60-12 SPEED SENSOR. INITIAL SETUP PROCEDURE 2.6.1 Determining Installation Parameters 2.6.2 Programming Micro-Tech™ II Integrator. GENERAL. ACCURACY MODEL 60-12 SPEED SENSOR... MODEL 10-20 OR 10-22 WEIGHBRIDGE. SCALE JUNCTION BOX. MODEL 10-301 MICRO-TECH™ II INTEGRATOR... MENU DISPLAYS... MAIN MENU T 3.8.1 Zero Calibrate. 3.8.2 Span Calibrate. 3.8.3 Material Calibration MAIN MENU 2 3.9.1 Display Options. 3.9.2 Scale Data.. 3.9.3. Calibration Data Scroll. MAIN MENU 3 3.10.1 Options. 3.10.2 Communications 3.1 36 38 3-9 311 311 313 3-18 3-26 3-26 3-29 331Chapter 4.0 5.0 REC 3694 TABLE_OF CONTENTS (Continued) Title 3.11 RUN MENU. 3.11.1 Total Weight 3.11.2 Reset Total 3.12 PERMANENT FIELD RECORD 3.13 CALIBRATION - BELT SCALE 3.13.1 Initial Calibration Procedure. 3.13.2 Routine Calibration Procedure. 3.14 MATERIAL CALIBRATION MAINTENANCE 4.1 GENERAL 4.2 SERVICE AND REPAIR. 4.3. FREQUENT CHECKPOINTS 4.4 TROUBLESHOOTING... 4.4.1 Calibration Shifts. 4.4.2 Zero Calibration Shifts. 4.4.3. Span Calibration Shifts. 4.4.4 Field Wiring... 4.4.5 Integrator Nodel 10-301, General 4.4.6 Error Conditions and Alarm Messages 4.4.7 Clearing Alarm Messages....... 4.4.8 Micro-Tech™ Integrator Cold Start. 4.4.9 Internal Test Procedure. 4.4.10 Speed Sensor Check... 4.4.11 Load Cell Excitation and Signa 4.4.12 Resetting Master Total Procedure 4.4.13 System Defaults - English/Metric REPLACEMENT 5.1 GENERAL... 5.2 ORDER INFORMATION §.2.1 Returned Material Authorization 5.2.2 Parts List. VIIS LUSTRATIONS DESCRIPTION 1 Carriage Weighbridge (Model 10-20) 1-2 Speed Sensor (Model 60-12) 1-3 Micro-Tech™ IT Integrator. 1 10-208 Typical Installation. 2 Conveyor Support Illustration. 3 Recommended Installation Area. 4 Depth Limiting Gate I1lustration 5 Conveyor Speed and Slope Illustration 6 Convex Curve Illustration. 7 Concave Curve Illustration 8 Tripper Location Illustration. 3 Feed Point Illustration. 1 Take-Ups Illustration. . 1 Belt Tracking [Tustration 1 Scale Service Idler Illustration. 1 Idler Type Illustration. : 1 1 1 1 1 1 0 1 2 3 4 Troughing Angle Illustration 5 Cable or Rope Conveyor Illustration 6 Shipping Lock Illustration 7 Weigh Idler Modification. . 8 Load Cell Hardware Arrangement 9 Micro-Tech™ II and Scale Junct. Mounting Dimensions. 2-20 Field Wiring Diagram. 2-21 Outline and Installation Model 60- pee and ensor. 2-23 2-22 ‘Typical Shaft Coupling Model 60-12 Speed Sensor... 2-24 2-23 Measuring Angle of Incline. 2-24 Model 10-301 CPU Board. 1 10-208 Belt Scale System Simplified 2 Mode? 10-301 Integrator. 3 Scale Area Idlers. 4 Calibration Report - Permanent Record APPENDIX IST_OF DRAWINGS litle Menu Selections Micro-Tech™ II, Integrator Model 10-301 Menu Selections Micro-Tech” II, Integrator Model 10-301 Optional Equipment System Drawings REC 3694 Vit Drawing No c07164C-Vo03 (Sheet 1 of 2) ¢07164C-V003 (Sheet 2 of 2)CHAPTER 1.0 INTRODUCTION 1.1 GENERAL This instruction manual contains information on the installation, operation, calibration, and maintenance of the Series 10-20B Belt Scale System. The Series 10-20B or 10-228 Belt Scale System is available with a wide rarge of useful analog and digital outputs for applications in a variety of process operations. 1,2 DESCRIPTION The Series 10-208 or 10-228 Belt Conveyor Scale System consists of three mejor components: the carriage/weighbridge assembly, the belt speed sensor and the integrator. Each serves a distinct function in the process of accurately weighing material moving on the conveyor belt. 1.2.1 Ramsey Node] 10-20 or 10-22 Carriage/Weighbridge The Carriage/Weighbridge (Figure 1-1) is a complete, factory pre-assembled unit available with a single weigh idler (Model 10-20) or with a dual weigh idler (Model 10-22). CARRIAGE WEIGHBRIDGE (MODEL 10-20) FIGURE 1-1 REC 3694 11.2.2 Model 60-12 Digital Speed Sensor The Speed Sensor (Figure 1-2) is directly connected to the conveyor tail pulley, snubbing rol], or large diameter return roll. The Speed Sensor employs a brushless pulse generator producing an electrical output signal whose output frequency is proportional to true belt speed. 1.2.3, Model 61-12 Digital Speed Sensor The Model 61-12 is identical to the Model 60-12 in all respects, with the exception of the enclosure, which is Factory Mutual (FM) approved for Class 1, Division II, Group D, and Class II, Division I and II, Groups E, F and G. SPEED SENSOR (MODEL 60-12) FIGURE 1-2 REC 3694 1-21.2.4 Model 10-301 Micro-Tech™ II Integrator REC 3694 The Micro-Tech™ II Integrator (Figure 1-3) is a micro- computer driven instrument used for deriving rate and quantity of flowing material from signals representing the weight of a segment (pounds/foot) of moving material and its velocity (feet/minute). By suitable processing of these two input signals, the Integrator delivers visible and electrical output Yepresenting the rate of material movement and visible and electrical output representing total amount of material which has passed the weighbridge. For remote indicating, three options are available: Remote totalization. Remote flow rate - current or frequency. + Communications. Many automatic and check functions are available to the operator for calibration and maintenance. MICRO-TECH™ II INTEGRATOR MODEL 10-301 MICRO-TECH™ I] INTEGRATOR FRONT PANEL FIGURE 1-3 1-31.2.5 Optional Accessories In addition to the standard Series 10-20B or 10-22B Belt Scale System components delineated above, a wide variety of optional accessories are available. These include recorders, controllers, printers, load-out and batch controllers. Also available are a wide variety of calibration standards and calibration standard hand] ing equipment. 1.3. UNPACKING AND INSPECTION The Model 10-20 or 10-22 Carriage/Weighbridge has been aligned at the factory for installation in your conveyor and has been properly packaged for shipment. Refer to the appropriate manual in the Appendix for unpacking procedures for optional equipment. Inspect all packages for damage before opening as oftentimes the carrier may be responsible for shipping damage. Refer to the appropriate manual in the Appendix for inspection procedure for optional equipment. 1.4 STORAGE The Series 10-208 or 10-228 belt scale and associated equipment can be safely stored, with cover latches secured and hole plugs installed, between -50° and +85° C. (-58° to +158° F.). The unizs should be protected against moisture. REC 3694 141.5 WARRANTY RAMSEY TECHNOLOGY, INC. WARRANTY The seller agrees, represents, and warrants that the equipment delivered hereunder shall be free from defects in material and workmanship. Such warranty shall not apply to accessories, parts, or material purchased by the seller unless they are manufactured pursuant to seller's design, but shall apply to the workmanship incorporated in the installation of such items in the complete equipment. To the extent purchased parts or accessories are covered by the manufacturer’s warranty, seller shall extend such warranty to buyer. Seller’s obligation under said warranty is conditioned upon the return of the defective equipment, transportation charges prepaid, to the seller’s factory in Minneapolis, Minnesota, and the submission of reasonable proof to seller prior to return of the equipment that the defect is due to a matter embraced within seller’s warranty hereunder. Any such defect in material and workmanship shal] be presented to seller as soon as such alleged errors or defects are discovered by purchaser and seller is given opportunity to investigate and correct alleged errors or defects and in all cases, buyer must have notified seller thereof within one (1) year after delivery, or one (1) year after installation if the installation was accomplished by the seller. Said warranty shall not apply if the equipment shai1 not have been operated and maintained in accordance with seller's written instructions applicable to such equipment, or if such equipment shall have been repaired or altered or modified without seller’s approval; provided, however, that the foregoing limitation of warranty insofar es it relates to repairs, alterations, or modifications, shall not be applicable so routine preventive and corrective maintenance which normally occur in the operation of the equipment. "EXCEPT FOR THOSE WARRANTIES SPECIFICALLY CONTAINED HEREIN, SELLER DISCLAIMS ANY AND ALL WARRANTIES WITH RESPECT TO THE EQUIPMENT DELIVERED HEREUNDER, INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR USE. THE SOLE LIABILITY OF SELLER ARISING OUT OF THE WARRANTY CONTAINED HEREIN SHALL BE EXCLUSIVELY LIMITED TO BREACH OF THOSE WARRANTIES. THE SOLE AND EXCLUSIVE REMEDY FOR BREACH OF THE WARRANTIES SET OUT ABOVE SHALL BE LIMITED TO THE REPAIR OR REPLACEMENT OF ANY DEFECTIVE ACCESSORY, PART OR MATERIAL WITH A SIMILAR ITEM FREE FROM DEFECT, AND THE CORRECTION OF ANY DEFECT IN WORKMANSHIP. IN NO EVENT SHALL SELLER BE LIAGLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES." FIELD SERVICE Purchaser agrees to underwrite the cost of any labor required for replacement; including time, travel, and living expenses of Ramsey Field Service Engineer at closest factory base RAMSEY TECHNOLOGY, INC. 501 90th Avenue N.W. Minneapolis, MN 55433 (612) 783-2700 (612) 780-1537 REC 3694 1-5is Ce REC 3694 10-208 TYPICAL It FIGURE 2-1 2-1 INSTALLATIONCHAPTER 2.0 INSTALLATION 2.1 GENERAL 7 : Al] Ramsey Belt Conveyor Scale Systems, regardless of their applications, are manufactured to the same high degree of accuracy and reliability. However, it is the application and installation of these systems that determine the overall system operating capabilities and accuracy that can be realized. 2.2 SCALE LOCATION CRITERIA In applying belt conveyor scales, one must always consider external influences originating from the material handling system and belt conveyor. Regardiess of stated accuracies, these two factors will determire the overall long-term and short-term accuracy expected. 2.2.1 Wind and Weather Effects The scale and conveyor at the scale should be protected from wind and weather effects. The magnitude of weighing errors caused by wind is dependent on wind velocity. 2.2.2 Vibration and Deflections The entire conveyor frame should be isolated from bins, feeders, crushers, and other mechanical equipment. This is to prevent bin loading from causing conveyor defections ard to protect the weighing equipment from vibrations and shocks “mposed by mechanical equipment. 2.2.3 Conveyor Support In the design of the scale system, several deflections are taken into consideration. These are the deflection of the load cells, the deflection of the scale carriage and bridge assembly, and the deflection of the supporting conveyor structure. It is of utmost importance that these deflections not be excessive. In the manufacture of the scale, the amount of deflection in the load cells and the carriage and bridge assembly is controlled. The only variable is the deflection of the conveyor itself. Therefore, the conveyor stringers supporting the scale and two idlers to either side of the scale should be of ample size and be adequately supported to limit the relative deflection between +2 and -2 idlers to not more than +0.025 inches. No conveyor expansion joints or stringer splices should be located in this region >f the conveyor. Refer to field installation drawing for required mechanical supports. REC 3694 2-2Rigid weld stringers Expansion, ea na ae Stinger ST Suing dete eee eet Provide ample support CONVEYOR SUPPORT ILLUSTRATION FIGURE 2-2 2.2.4 Tension In all installations, the belt scale should be installed in an area where belt tension and tension variations are minimal. For this reason, the belt scale should be installed near the tail section of the conveyor, but far enough forward so as not to be influenced by infeed skirt boards. RECOMMENDED INSTALLATION AREA FIGURE 2-3 REC 3694 2-32.2.5 Uniform Belt Loading Pithough in most applications the scale system is capable of cperating accurately over a 4 to 1 range, it is desirable that the belt loading be as uniform as possible. To minimize surges or feed variations, hoppers, if possible, should be equipped with depth limiting gate. DEPTH LIMITING GATE ILLUSTRATION FIGURE 2-4 2.2.6 Material Slippage The belt scale system processes belt loading and belt travel to arrive at an accurate weight. Product speed must equal belt speed at the scale. For this reason, the conveyor speed and slope should not exceed that at which material slippage occurs. CONVEYOR SPEED AND SLOPE ILLUSTRATION FIGURE 2-5 REC 3694 242.2.7 Convex Curves Convex curves are permissible at a distance of 20 feet or a minimum of five idler spaces beyond the scale area idlers. CONVEX CURVE ILLUSTRATION FIGURE 2-6 2.2.8 Concave Curves The point of tangency on a concave (upward going) curve must be at least 40 feet beyond the scale. The belt scale should always be between the infeed and curve. DOVVVIUD| HOTS? CONCAVE CURVE ILLUSTRATION FIGURE 2-7 REC 3694 2-52.2.9 Trippers In any installation where weighing accuracy is important, the scale system should not be applied to a conveyor that has a novable tripper. If the scale must be installed on a conveyor with a tripper, then the same rules apply as for an installation in a concave conveyor. The minimum distances outlined in the above paragraph must be adhered to with the tripper in its fully retracted position. | 1 — 9 Geen TRIPPER LOCATION ILLUSTRATION FIGURE 2-8 2.2.10 Single Load Point On high accuracy installations, the conveyor should be loaded at one and the same point. This assures constant belt tension at the scale during all loading conditions. ate FEED POINT ILLUSTRATION FIGURE 2-9 REC 3694 2-62.2.11 Conveyor Belt Take-Ups For best weighing system accuracies, al] conveyors more than 40 feet in length should be equipped with a constant tension or gravity type take-up. If the conveyor is shorter than 40 Feet and exposed to changing ambient temperature conditions, or if the loading on such conveyors is not constant, then chey also should be equipped with constant tension take-ups Jo enhance the weighing system accuracy. il “Sem G&A ey Sl ser i if i Best i I ‘TAKE-UPS ILLUSTRATION FIGURE 2-10 2.2.12 Belt Tracking One problem in obtaining optimum belt scale accuracy is the effect of belt tracking from an empty to a fully loaded condition. To enhance belt tracking, the construction of the belting should have the necessary flexibility to assure contact with all scale area idler rolls when the belt is running empty. In addition, this also assures that the conveyed material is being supported by the weighing idlers rather than by the carcass of the conveyor belting. In no case should the belt extend beyond the edge of the idler roller in the weighing area. BELT TRACKING ILLUSTRATION FIGURE 2-11 REC 3694 272.2.13 Scale Service Idlers 2.2.14 REC 3694 Idlers in the weighing area should be round, uniform and of same make, troughing angle and rating. The top grade idler, manufactured by most of the major idler suppliers, under normal conditions, is an adequate idler for scale service use. It may be required, however, to select a series of idlers that have similar dimensions and troughing angles for scale service. Recommend TIR should not exceed 0.015". SCALE SERVICE IDLER ILLUSTRATION FIGURE 2-12 Belt Scale Area Idlers The selection of the idlers used within the scale area is extremely inportant. This pertains not only to the idler type, but the idler construction itself. Since idler alignment plays an extremely important role in the operation cf a belt conveyor scale, it is extremely important that alt jdlers be manufactured a nearly alike as possible. It is zlso important that certain types be avoided, such as "V" types and rope or cable types. NOTE: Offset idlers should not be used on single or dual pivoted carriage/weighbridge type scales (please check with Ramsey). IDLER TYPE ILLUSTRATION FIGURE 2-13 2-82.2.15 2.2.16 2.2.17 REC 3694 Idler Troughing Angles The use of idlers with steep troughing angles causes many problems. Not only does the beam or catenary effect of the elt become more pronounced as the troughing increases, but the effect of idler misalignment is amplified as well. ne very important function to perform at the time of installation of the scale system is to check out the alignment of all idlers within the weighing area. This is done to help minimize the extraneous forces introduced into the weighing system caused by changes in belt tension or other external forces as the belt travels across the idlers. Troughing angles of 35° or less are preferred for all hign accuracy installations, Troughing angles of 45° are acceptable under certain conditions (please check with Ramsey). A < Sas a A. 70° «35° Preferred. &. 745° Acceptable under certain conditions. TROUGHING ANGLE ILLUSTRATION FIGURE 2-14 Training Idlers It is extremely important that the belt tracks centrally from no load to full load conditions. Training idlers are normally acceptable if located beyond 40 feet from the nearest scale weigh idler. Idler Alignment The weigh idler(s) and two idlers either side of the weigh idler(s) are very closely aligned to make as true a weighing platform or section as possible. It is the installation of these idlers that is the most critical. Good idler al ignnent throughout the entire conveyor is important to assure adequate and true belt tracking under all load conditions. Scale area idlers must be shinned higher than the exist ng elt Tine.2.2.18 Cable Conveyors Conveyors commonly known as "cable" or "rope" conveyors are rot suitable for electro-mechanical belt conveyor scale weighing unless a rigid conveyor section Tong enough to support the scale and scale service idlers is added. CABLE OR ROPE CONVEYOR ILLUSTRATION FIGURE 2-15 2.3 WEIGHBRIDGE/CARRIAGE INSTALLATION This section is to be used as a guide in the installation of the Model 10-20-1 Single Idler Weighbridge or Model 10-22-2 Dual Idler Weighbr-dge. The two models are installed in the same manner with reference made where installation procedures differ. 2.3.1 REC 3694 Terms The following terms are referred to in the installation procedure: 1. Carriage/Weighbridge The carriage/weighbridge is a factory aligned assembly consisting of one carriage, one Toad cell support. bean, and one precision strain gauge load cell applied in tension. The carriage/ weighbridge will be referred to as weighbridge only for the remainder of this chapter. 2. Weigh Idler(s) The weigh idler(s) refer to those idler(s) mounted directly on the weighbridge. 3. Scale Area Idlers The scale area idlers refer to the weigh idler(s) and the group of idlers located adjacent to and on either side of the weigh idler(s). The idlers are identified as plus (+) or minus (-) on the installation drawing. At least, two and as many as four plus and minus idlers are closely aligned with the weigh idler(s). The quantity of scale area idlers will ultimately be determined by conveyor profile, existing belt line and idler profile as well as other conveyor parameters. They are considered part of 2-102.3.2 2.3.3 REC 3694 the belt scale system and play an important role in the overall belt scale accuracy and operation. Location Select the scale location by following the outline in Section 2.2, Scale Location Criteria. A partial listing of the required guidelines follows: 1. Install the scale system on a rigid conveyor. If not rigid, additional bracing is required. 2. The existing conveyor belt Tine must be determined before proceeding. 3. The scale should not be located closer than 15 feet or three idler spaces from feeders, hoppers, and skirt boards. 4. The scale must not be placed in concave or convex curves. 5. The scale should not be installed where conveyor speed and slope causes material slippage to occur. 6. Locate the scale where it has maximum protection from the elements. 7. The scale conveyor should not be attached to or have vibrating devices installed on it. Site Preparation After determining scale location on the conveyor, proceed with site preparation as follows: 1. Strengthen the conveyor framework. Refer to the field installation drawing for placement of reconmended bracing and support legs. 2. Fishplate and weld together all conveyor sections in the region of the scale. 3. Level the conveyor in the transverse plane between the minus 2 and plus 2 idlers. 4. All scale area idlers must be the same make, style, and model, and should be in free-rolling and otherwise good mechanical condition. Troughing profiles should match each other within 0.015 inch. Roller concentricity must not vary more than +0.015 inch T.1.R. (This is operating T.1.R. and not a roll machine specification.) 2-12.3.4 REC 3694 5. Locate the exact center of the carry rol] on all idlers from minus 2 to plus 2. Permanently scribe or punch this center position on each carry roll. In addition, perform tiene procedure on the minus and plus 2 troughing rolls. 6. Depending on the model of scale (10-20-1 or 10-22-2) one or two idler(s) must have their fect modified to be used as weigh idler(s). Refer to weigh idler modification drawing. 7. For ease in equipment installation and alignment, elevate or remove the conveyor belting from the belt scale area. Belt clearance will be needed from at least the minus 3 to plus 3 idler. 8. Remove all idler(s) between minus 2 and plus 2 from the conveyor section where the weighbridge will be installed. Carriage /Wei ghbridge Installation After scale location selection and site preparation, proceed with installation as follows: 1, Dimensionally locate the minus 2 and plus 2 idler using a known reference point or the diagonal method. At the same time, shim these idlers 1/4 inch above the belt line. Place level on carry rolls and shim as necessary. Refer to installation drawing. Note: Make al] dimension measurements from the center of the grease fittings on the idlers. 2. Insert the unitized weighbridge assembly into the conveyor gallery. If modification is necessary, refer to the appropriate drawing in Figure 2-17. Note: Trunnions on the weighbridge are shown on the installation drawing toward the tail section of the conveyor. On some applications, it may be advantageous to install the weighbridge trunnions toward the conveyor head section. This procedure is acceptable and weighing accuracy will not be affected. In all installations, the load cell cable and static weight lifting lever (when supplied) must be on the side of the canveyor which is accessible for calibration and maintenance. 2-12REC 3694 . Remove the two shipping locks and install weigh idler(s) and static calibration lower mounting brackets on the weighbridge. Refer to Static Calibration System ‘installation drawing when supplied. Dimensionally align the weigh idler(s) using the load cell bridge support for the reference point. Shipping Lod SHIPPING LOCK ILLUSTRATION FIGURE 2-16 . Locate the weighbridge assembly exactly between the minus 2 and plus 2 idlers. Use grease fittings on the idlers for proper dimensions. . Locate and drill holes for fastening all four corners of the weighbridge to the conveyor gallery. . Slide weighbridge assembly back into place. Check for being level and shim if necessary. Fasten weighbridge to ‘the conveyor gallery. . Verify installation of lower load cell clevis rod (Figure 2-18). When properly adjusted, the carriage side member will be parallel with the top of the conveyor stringer. CAUTION INSTALL SHIPPING BRACKETS WHENEVER CONVEYOR IS BEING TRANSPORTED. LOAD CELL CLEVIS ROD MUST BE FREE DURING ‘TRANSPORT. 2-13LER MOUNTING @RACKET Pra goassl 2 PLACES. (eUpecikD ar eawsew 3.00 2.90 fee bed Lousser 2 practs oar ‘WEIGH IDLER MODIFICATION 42" THROUGH 72" BELT WIDTH JOUER MOUNTING BRACKET Ja gees BES [oGpscigd Be Ralser) 750 REF a.s0 ae cause é Z | —a —.30 curour zoo p) ae { cur-our WEIGH IDLER MODIFICATION 18" THROUGH 36" BELT WIDTH WEIGH IDLER MODIFICATION FIGURE 2-17 REC 3694 2-14STYLE "s" 12-20 NUT 1/2" 1.0. SPHERICAL WASHER \/2-20 NUTS CLEVIS ROD -B¢C : FSR no. t i 4 { (eee bees 7 3/8-24 NUT REF + ' Ne 72" 1.0. SPHERICAL WASHER LG. 1/2-20 NUTS LOAD CELL HARDWARE ARRANGEMENT FIGURE 2-18 STYLE "BSP" 4 REC 3694 2-15REC 3694 10. M. i. B. Tie a high quality 30 pound test monofilament line, or equivalent, to the base of the plus 3 idler. Run this alignment line across the center mark on the plus 2 carry roll through the scale area and across the center mark on the minus 2 carry roll. Attach a 30 pound weight to the end of the line to maintain constant tension. Check for clearance between the line and the carry rolls of weigh idler(s). If the line is touching, additional shimming in 1/16" increments should be inserted under the minus 2 and plus 2 idlers. Prior to proceeding, a check of the foregoing steps should be reviewed. a. Minus 2 and plus 2 are dimensionally aligned. b. Weigh idler(s) is dimensionally aligned to the load cell support. c. Weighbridge and weigh idler(s) are dimensionally aligned to the minus 2 and plus 2 idler. Install additional alignment lines across the minus 2 and plus 2 troughing or wing rolls. Reference points for alignment lines were established in Step 5 of paragraph 2.3.3. Note: On conveyors 42 inches and wider, additional alignment lines are necessary to insure accurate shinming. Shim and dimensionally align the minus 1 and plus 1 idlers one at a time. The measurement between each icler and the reference weigh idler must be accurate to within 4 1/32 inch. All idlers must be shinmed to within 4 1/32 Ynch of the alignment Tines. Shim the weigh idler(s) to within + 1/32 inch of the alignment Tines. Note: A combination of shimming and movement of the idler may be necessary to bring the troughing end wing rolls up to the stretched lines. EXAMPLE: Center roll elevation - OK Left wing rol] elevation - too high Right wing roll elevation - too low This indicates one of two conditions: a. The idler is tipped down to the right. (Remedy - add shims to the right end of the idler and remove shims from the left end.) 2-16b. The idler is located too far to the right of the conveyor center. (Remedy - shift idler to the left.) 14. This completes the weighbridge and scale service idler installation. Prior to removing the alignment Tines, complete the following checks: a. Insure measurement between al] idlers and reference weigh idler are accurate to within + 1/32 inch at the grease fittings. b. All carry and troughing rolls are shinmed to within + 1/32 inch of the reference height of the minus 2 and plus 2 idlers. 15, Install remaining portion of the static calibration system. Refer to assembly drawing. 26. Remove al] alignment lines. 17. Place conveyor belt back in place. 2.4 MICRO-TECH™ IT INTEGRATOR INSTALLATION Integrazor installation is accomplished in the following manner: REC 3694 Mounting Site Selection Installation Wiring Site Selection The Micro-Tech™ II Integrator mounting site should be selected with care. The Integrator should be mounted within 0 to 200 fest of the load cell. It should not be exposed to excessive vioration, heat, or moisture. The ideal mounting location would be on a separate wall or beam in view of the scale (Figure 2-1). Where distance exceeds 200 feet, a special six wire shielded cable is recommended for wiring the load cell and renote excitation sense lines. Installation Mount the Micro-Tech™ II Integrator to a rigid fixture in an area of minimum vibration. Mounting dimensions are shown in Figure 2-19, Outline and Mounting Dimensions. The integrator is mounted with the door hinge on the left and at a height which allows confortable viewing of the displays and access to the keypad, power switch, and field wiring terminals. 217REC 3694 425 Outline and Mounting Micro-Tech™ IT ‘onduit entrance through jottom only. Remove chassis prior to drilling or punching. ~ 8.3) MOUNTING HOLES ca pURces) Outline and Mounting Seale Junction Box NEHA 4 MICRO-TECH™ TX & SCALE JUNCTION BOX ‘OUTLINE & MOUNTING DIMENSIONS FIGURE 2-19 2-18REC 3694 Wiring Use the Typical Field Wiring Diagram (Figure 2-20) as a guide if there is not _a specific wiring diagram for your system in the Appendix. Follow your local electrical codes and regulations for minimum wire size and routing. NOTE: Nove Some 1. 2. 3 4. 5. 6 1 It 1s recommended that the chassis be removed from the enclosure to prevent any damage during the hole punching process. See Figure 2-19 for recommended hole location. : Stranded, rather than solid, wire should be used. critical wiring considerations are: Insure power is off. Do not shorten the load cell cable supplied with the scale. The wire length is critical for load cell temperature compensation. Do not route load cell or signal cables in the same conduit with power wires or any large source of electrical noise. Connect the shields ONLY where shown. Check that all wires are tight in their connectors. This is particularly important for the load cell connectiors. Earth ground all enclosures and conduit. Never use a "megger" to check the wiring. 2-19FIGURE 2-20 EEE FIELD WIRING DIAGRAN 193735 BND. 193735 “yNo| 140 ee 2-20 REC 36942.5 MODEL 60-12 SPEED SENSOR The Speed Sensor is coupled to a rotating shaft which drives a generator inside the housing. The Model 60-12C Speed Sensor senses speeds ranging between 20 and 200 RPN. The 60-12F is used for speed Jess than 20 RPM. The frequency of the Speed Sensor output signal is exactly proportional to shaft speed and is an input to a Ramsey Integrator/Controller. lL. REC 3694 Site Selection The Speed Sensor must be attached to an idler shaft which turns at true conveyor belt speed. Normally, the tail pulley shaft satisfies this requirement. In installations where the tail pulley is not accessible, an additional idler must be installed spacifically for the Speed Sensor. See Figure 2-21, Speed Sensor Outline and Installation. NOTE: NEVER MOUNT SPEED SENSOR ON A DRIVEN PULLEY. When using an additional idler for the Speed Sensor, the following requirements are essential: a. Select the proper diameter to provide a shaft RPM within the range of the Speed Sensor. b. Locate the idler on the clean side of the return belt to minimize material build up on the idler. c. Install the unit in such a manner as to provide at least 15 degrees contact wrap on the idler. Any slippage between belt and idler will decrease the belt scale accuracy. Mount ing Two methods of coupling the Speed Sensor to the idler shaft are shown in Figure 2-22. Other methods may work as well. The only requirement is that the Speed Sensor remains free floating and not rigidly coupled to the conveyor frame. Proceed as Follows: a. Fit the supplied coupling onto the 5/8 inch diameter by 1 inch unthreaded shaft or insert the 5/8 diameter speed sensor shaft into the fabricated coupling. Tighten the set screws. b. Attach the restraint arm to the Speed Sensor with two 5/16 inch by 1-1/4 inch bolts. c. Weld, or otherwise secure, an appropriate mechanical stop such’as a piece of scrap iron (or bolt) to the conveyor frame. (See Figure 2-21.) 2-21d. Fit one end of the supplied retaining spring through the hole in the end of the restraint arm. Attach the other end to the conveyor frame. Location should provide a 1/2 inch spring stretch, e. Although not required, it is highly reconmended that a rock or step shield be fabricated and installed around the Speed Sensor. NOTE: The purpose of this mounting arrangement is to allow the speed sensor to "float" and accommodate any slight misalignment of the coupling. No resultant bearing stress is applied due to the misalignment, nor will a slight "wobble" of the device result in electrical errors. CAUTION UNLESS THE INSTALLATION IS CONSISTENT WITH THESE INSTRUCTIONS AND OUR INSTALLATION DRAWINGS, THE WARRANTY 1S VOID! 3, Wiring a. Remove the terminal strip cover and the dust plug from the threaded conduit aperture in the speed sensor housing. b. Instat] 1/2 inch flexible conduit to the speed sensor housing. Do not route cable in the same conduit with power wires. d. Only use shielded cable e. Connect cable shields only where shown. Refer to field wiring in Figure 2-20 or the supplied field wiring drawing in the Appendix. REC 3694 2-222.6 INITIAL SETUP PROCEDURE Following mechanical and electrical installation, it is necessary that you program field data that is specific to your application into the Micro-Tech™ II Integrator memory. The following setup procedure should be completed before calibration of your belt scale system is attempted. Refer to Chapter 3 if more details or assistance is necessary. 2.6.1 Determining Installation Parameters Before turning on the conveyor belt or applying power to the belt scale system, it is necessary to complete the following statements. Refer to your System Data Sheet in the front of this manual. 1. Scale Capacity Determine the scale’s capacity in tons per hour and record the capacity below. (Example: 400.0) 500.0 _ (Tons Per Hour) 2. Belt Scale Model Number Determine the belt scale’s model number and record the number below. (Example: 10-20-1) 10-20-| (Model Number) 3. Belt Scale Carriage Dimensions a. Pivot to Load Cell ‘As indicated on the following drawing, measure the distance from the pivot center line to the load cell center line to the nearest 0.032 (1/32)". Record the distance below. (Example: 32.00) 32.0 __" (Pivot to Load Cell Distance) Pivotto | Weigh 9 Load—}-- idler cell REC 3694 2-25REC 3694 b. Pivot to Weigh Idler As indicated on the following drawing, measure the distance from the pivot center Tine to the weigh idler’s grease Fitting center line to the nearest 9,032 (1/32)". Record the distance below. (Example: -00) 24.00 " (Pivot to Weigh Idler Distance) Pivot—tO | Weigh: © Load—+-- Idler cell Idler Spacing Scale Area Measure the idler spacing in the belt scale area to the nearest 0.032 (1/32)". Record the distance below. (Example: 36.00) ZBl.00_" (Idler Spacing) Conveyor’s Angle of Incline Measure the conveyor’s angle of incline to the nearest 0.1 degrees. Record the degree of angle below. (Example: 16.0) Refer to Figure 2-23 for more information on how to measure angle of incline. _I°_G__ degrees (Angle of Conveyor Incline) Load Cell Size From the belt scale data sheet located in the front of this manual, determine the load cell size in pounds. Record the weight below. (Example: 250.0) 505.0 pounds (Load Cell Weight) 2-26Horizontal Angie = Angle of Incline cosp = Distance AC Distance AB Choose a convenient distance ‘AB’ and measure it in inches. Hang a plumb line from ‘B’. Measure the horizontal distance from ‘A’ to plumb line in inches (‘AC’). Divide ‘AC’ by ‘AB’ to get COS 9. If angle of incline in degrees is known, use the following table:- [Angie Z| Cos | [Angie d| CosH| [Angie A Cos g 0 | 1.0000 6 9945 12 | .9781 1 9998] 7 9925 13 9744 2 gga 8 9903 14_| 9703 3_| 3986 9 | .9877 1s | .9659 4 | 9976 1o_| 9848 16 | 9613 [ees 9962 4 9816 7 9563 MEASURING ANGLE OF INCLINE FIGURE 2-23 REC 3694 2-277. Conveyor Belt Length Using a long tape measure, measure the length of one complete belt revolution. Measure to the nearest 0.1 foot. Record the Tength below. (Example: 1000.0) feet (Conveyor Belt Length) 2.6.2 Programming the Hicro-Tech™ II Integrator When power is first applied to the Integrator, the system steps the operator through menus and options that bring the system to a weighing state. Soft keys, numeric keys and the scroll control keys are used to select choices. The RUN and HENU control keys are inactive during this procedure. 1. Turn the belt scale conveyor belt on. Run the conveyor empty during setup and calibration. 2. Inside the Integrator’s front panel are two slide switches. Ensure the red, line voltage switch is in the correct position -- either 115 or 230 volt. Power up the Integrator by moving the black, power slide switch to the ON position. Voltage Switch Power Switch MODEL 10-301 CPU BOARD FIGURE 2-24 REC 3694 2-28REC 3694 3. The programming mode begins with the following instructional screens: - MEMORY ERASED - Pres down SCROLL key to continue to next menu. Press the down scroll key. Initial scale setup and calibration. Press down SCROLL. Press the down scroll key. Press key under HELP for more information HELP "HELP" is Flashing Press the HELP soft key. Key with dot (soft key) performs action of word above it. WORE RETURN When RETURN is pressed, the user is returned to the previous screen. Pressing MORE advances the system to the next screen Use down SCROLL key to advance through the menus. WORE — RETURN Pressing HORE or RETURN will revert the screen back to previous screens in this series. By pressing the down scroll key, you will enable the system to proceed through the menus needed for system setup. NOTE: Menus appearing during initial setup may operate differently in normal operation. 2-29REC 3694 4. This setup screen gives the operator the choice of displaying English or Metric weights and measures. The defaulted (selected) value is English. DISPLAY SCROLL 1 - Units: English Selected CHOICES ENTER HELP Press the ENTER soft key for measurements expressed in English, or CHOICES soft key to select the Metric standard of measurement. Scroll down. Dependent upon the type of measurement progranmed in Display Scroll 1, units of weight can now be entered: Tons, Long Tons, Pounds or Tonnes, Kilograms. The English default value is tons; the Metric value is tonnes. = DISPLAY SCROLL 2 - Weight units: Tons Selected CHOICES ENTER HELP Press the ENTER soft key to accept the selected value, or CHOICES soft key to select other units. Scroll down. . The next value to be entered is the scale capacity usirg a decimal in units of tenths. Refer to the System Data Sheet under "Conveyor Data - Capacity" in front of this manual for your scale capacity. Pressing the numerical keys will enter or change values. The defaulted value is 500.0 T/h (tons, or tonnes, per hour). Large values will Vimit the decimal entry. - SC DATA SCROLL 2 - Scale capacity with decimal: 500.0 Tph ENTER HELP Scrol1 down. By entering the model number of your Ramsey scale on the next screen, the Integrator will automatically calculate parameters of the system such as number of load cells and nunber of weigh idlers. This entry will also be used for internal calibration calculations. Refer to the model nunber of your scale recorded in Section 2.6.1. The default is Model 10-20-1. - SC DATA SCROLL 3 - Beit scale model # —— \n.7,).| 10-20-1 Selected CHOICES ENTER HELP 2-30REC 3694 If the scale model number did not appear under CHOICES and you selected OTHER for your choice, refer to paragraph 3.9.2, number 3, SC Data Scroll 3. 8. Scroll down to SC Data Scroll 3A. This menu, plus Scale Data Scrolls 38 and 3C, is used to calculate lever ratio. These menus are activated when certain scale models are entered in Scale Data Scroll 3. (See Section 4.4.13, System Defaults.) The distance from pivot to load cell should be measured to within 0.032 (1/32)" (1 mm). Using the numeric keys, enter the distance recorded in Section 2.6.1 and press "ENTER. = SC DATA SCROLL 3A- Pivot to load cell distance: 000.00 In ENTER HELP Scroll down. 9. Calculate the distance between the pivot and idler. (Refer to Section 4.4.13, System Defaults.) Enter the distance (within 0.032 inch or 1 mm) recorded in Section 2.6.1 using the numeric keys. Press ENTER. = SC DATA SCROLL 38- Pivot to Ist idler distance: 000.00 In ENTER HELP Scroll down to SC Data Scroll 3C, if applicable, or SC Data Scroll 4. 20. Calculate the distance between the pivot and second idler within 0.032 (1/32)" or 1 mm. Using the numeric keys, enter the distance. Press ENTER. = SC DATA SCROLL 3C- Pivot to 2nd id?er distance: 000.00 In NA ENTER HELP Seroll down. 11. Using the numeric keys, enter the spacing recorded in Section 2.6.1 and press ENTER. Only a single value my be entered from a minimum of 1" (20mm) to 72" (2000nm). The default value is 36" (100mm). 2-31Rec 3694 1. 14, = SC DATA SCROLL 4 - Idler spacing: 36.00 In BL oo ENTER HELP Scroll down. Enter the angle of incline recorded in Section 2.6.1 using the numeric keys. Press ENTER. Degree field is 0 to 25 with 16 being the default value. ~ SC DATA SCROLL 5 - Conveyor?s angle: Goes 16.0 Degrees 14 ENTER HELP Serol] down. . The units of measure for this entry were determined in Section 2.6.1 and entered on Display Scroll 1. Under some conditions, the operator may need to convert units to accommodate new load cell specifics. The range of input permitted is 10 to 6,000 pounds or 10 to 3,000 kilograms. Default value is 250 pounds (113,4Kg). See the System Data Sheet for the size of load cell. ~ SC DATA SCROLL 6 - Load celi size: pe 250.0 Lbs $80.0 ENTER HELP Seroll down. This menu is used to set the degree of load cell sensitivity (nl//V) that will be used in any future R-Cal calibrations which calculate a span number. The useable range is 1.5 to 3.5 mV/V. Default value is 3.0 nV/V. Ramsey load cells are normally 3.000 mV/V. Verify by the Jabel on the end of the Toad cell cable or on the System Data Sheet. Press the numerical keys to enter or change the value. Press the soft key under ENTER when the entry is complete. = SC DATA SCROLL 7 ~ Load cell sens.: aeaee 3.000 avy 3.0 m/y ENTER HELP ! Serol] down. 2-32REC 3694 15. 16. 7. Load cel] resistance is entered on this screen. The resistance for the load cell has been recorded on the System Data Sheet. (It is also stamped on the load cell cable.) Enter the ohms for the load cell. The systen default is 350.00 ohms. =~ SC DATA SCROLL 8A- load cell J Res.: 350.000 Ohms ENTER HELP The speed input screen allows the operator to select either the actual speed sensor input (default value) or @ simulated value using an internal timer. Simulation allows operation without a speed sensor. When simulated speed is selected, a conveyor running input is required. Refer to the field wiring diagram. ~ SC DATA SCROLL 9 - ‘Speed input: Actual Selected CHOICES ENTER HELP Select "Actual". Scroll down after entering the speed input. The “Acquire” test function calibrates the belt to the system. Zeroing and spanning are the most accurate when done over complete passes of the belt. The system also calculates a new speed prescale value. ~CAL DATA SCROLL 4 - Establish test duration ACQUIRE MANUAL HELP Select "ACQUIRE". ACQUIRE is the recommended selection. a. Acquire Test Duration i. When selecting FULL, use a 100 foot tape to measure belt length to the nearest .1 foot. Reference a fixed point (an idler) on the conveyor when counting belt revolutions. See Section 2.6.1 for the recorded conveyor belt length. 2-33REC 3694 Is, ii. ACQUIRE TEST DUR Choose belt Jength measurement method. FULL PARTIAL HELP FULL is the recommended selection. Select "FULL". The following screen appears. Enter length of one belt revolution. Tength: 1000.0 Ft ABORT ENTER HELP Press "ENTER". Enter the length recorded in Section 2.6.1 using the numeric keys. Press ENTER. The default value is 1,000 feet. Pressing ABORT returns the screen to CAL DATA SCROLL 4. When measuring the total conveyor belt length, mark the belt so it is at speed when it passes the fixed point. ‘The PARTIAL (belt length measurement) selection enables the operator to acquire test duration without the entire belt length measurement. Refer to paragraph 3.9.3, number 4.,a.,ii- CAUTION THIS OPTION SHOULD ONLY BE USED WHEN BELT LENGTHS EXCEED 1000 FEET. b. Manual Test Duration a This procedure allows direct entry of parameters that would otherwise be generated by the Acquire Test Duration modes. This menu is generally used when the operator cannot see the belt while standing at the front panel. Refer to paragraph 3.9.3, number 4., b. After the Tength of one revolution of belt has been entered in the Step 17a menu, the system automatically moves to the following screen which prompts the operazor to press START when the mark passes the reference point. The belt must be running at its maximum speed before executing this function. If not, the speed prescale will be improperly calculated. 2-34Start belt. Press START when Ist mark passes reference. ABORT START HELP 19. When START is pressed above, the system automatically moves to the next instructional screen. The operator presses COUNT each time the mark passes the reference point until both of the following conditions are met: 3 revolutions of the belt or more than 6 minutes. When the Jast revolution passes the mark, the operator must press COUNT followed by pressing DONE Press COUNT each time a mark passes. 0000 secs 000 revs ABORT COUNT DONE 20. The Micro-Tech™ II Integrator responds with the following informational displays. TEST DURATION Checking Toad cell ‘The system checks that a load cell is connected using the R-CAL resistor. TEST DURATION Length = 0000.0 Ft Time = 000 seconds CONTINUE New values for test duration and speed prescale have been installed. Press CONTINUE, 21. The initial calibration procedure is now complete anc the Wicro-Tech™ II Integrator responds with the following: SCALE CALIBRATED Press RUN to start, or MENU for scrolls. The field data entered during this procedure enabled the Micro-Tech™ [I to perform an unassisted zero balance and REC 3694 2-35NOTE: REC 3694 span calibration. Assuming no mistakes were made, the scale is calibrated and is ready for use at this time NOTE: If you were unable to power up the Micro-Tech™ II, check SW3 #3 (under the current board). It should be in the OFF (down) position. ‘The operator should now proceed to Chapter 3, Operation, and become familiar with all the Maintenance Calibration menus and Test menus. 22. In addition to the above setup entries, the operator must select the available options from the OPTION menu prior ‘to using the scale. “he span number was calculated from the data that was entered during this Initial Calibration Setup Procedure, and entered this Calculated Span number into the unit. This Calculated Span number is based on a perfect mechanical alignment of the scale and its adjacent idlers. Therefore, verify this by performing a Material Calibration (paragraph 3.8.3) or by performing a Span Calibration procedure (Main Menu 1 paragraph 3.8.2, and Main Menu 2 paragraph 3.9.3 Calibration Data Scroll). 2-363.1 3.2 CHAPTER 3.0 OPERATION GENERAL Your Ramsey Series 10-20B Belt Scale System is capable of accurate weighing, provided it is installed, calibrated, operated, and iaintaired in complete accordance with the instructions contained in this marual. ‘The accepted methods of belt scale calibration are: 1. Material test in which material is pre-weighed or post-weighed on an acceptable weighing standard. 2. Electronic calibration. 3. Roller calibration chain test. 4. Static weight test. No single method of calibration is necessarily optimum for all belt scale iistallations. Each method has its own advantages and disadvantages. Presumably your Ramsey belt conveyor scale systen has been supplied with the calibration equipment best suited for your specific application. ACCURACY Ramsey Series 10-20B or 10-22B Belt Scale System, Model 10-20 or 10- 22 Weighbridge with 10-301 Integrator, and 60-12 Speed Sensor: On factory approved installations, Ramsey warrants that the total Series 10-208 or 10-228 Belt Scale System will weigh and total ize with an error not to exceed 1/2 of 1 percent of TEST LOAD at flow rates tetween 25 and 100 percent of scale system capacity. TEST LOAD is defined as: 1, At least three (3) circuits or revolutions of the belt, and 2. At least 500 counts on the Model 10-301 Integrator, and 3. At Teast six (6) minutes running time. ‘These ZEST LOAD conditions prevail regardless of the method of testing: i.e., use of material test, electronic calibration, roller calibration chain, or static test weight. This performance warranty is conditioned upon: 1. Power being applied to the entire system for at least one hour prior to initiation of the test. REC 3694 341MODEL 10-301 INTEGRATOR FIGURE 2 REC 3694 343.3 3.4 3.5 3.6 MODEL 60-12 SPEED SENSOR Node! 60-12 Speed Sensor provides a digital output proportional to conveyor belt travel for accumulative total computation. MODEL 10-20 WEIGHBRIDGE Model 10.20 (single idler) Weighbridge or Model 10-22 (dual Idler) Weighbridge consists of a pivoted carriage and strain gauge load cell, Load cell output is proportional to weight applied in the weigh span for rate and accumulative total computations. SCALE JUNCTION BOX Scale Junction Box is supplied to reduce conduit runs and for ease of electrical terminations. MODEL 10-301 MICRO-TECH™ II INTEGRATOR Model 10-301 Integrator is a micro-computer based instrument that accepts and conditions speed and weight signals and provides visual and electrical outputs for total weight and rate of flow. A stable 10 volt DC excitation voltage capable of exciting up to four strain gauge load cells is produced by the Integrator. Sense lead ferminations are also provided for six wire load cell cable. ‘Auto Zero Track enables the belt scale system to automatically zero itself during extended periods when the conveyor belt is running empty. Auto Zero Track is menu selectable because some installations may not desire this option. A "Z" will appear on the second line of the display to indicate the selection of this option. Life expectancy of the RAN support battery is approximately five years, if power is not applied. Under normal operation where power Ys on continuously, life expectancy will be much longer. Errors may occur during initial calibration and their reason must be corrected during initial calibration. During normal operation, an error would most likely indicate a failure in the system or improper operation. Error messages are: 1. Span out of range. Invalid calibration. (Does not control relay output.) 2. A/D overrange. 3. A/D underrange. 4. Remote total output pulses too fast. 5. Load cell does not respond. 6. Printer off line. Refer to the troubleshooting section of this manual for more information. REC 3694 3-53.8.2 Span Calibrate REC 3694 This function is implemented as a machine directed procedure. 1. Auto Span The text displayed in the following screen depends on which type of calibrate is active. = AUTO SPAN Ral ~ Run belt enpty, then press START. START = EXIT Pressing EXIT soft key or MENU control key returns the screen to Main Menu 1. When START is pressed, a seconds counter begins counting down to zero. Seconds are calculated from current belt speed. If the belt stops, the value of 99999 will be displayed. Pressing EXIT soft key or MENU control key returns the screen to Main Menu 1. AUTO SPANNING Time remaining 0000 Rate: 900.0 Iph When time remaining reaches zero, the system automatically displays the following screen. ‘AUTO SPAN COMPLETE —"CONPLETE" is flashing. Error +/-00.00 % Change span ? YES NO Pressing NO returns the screen to Nain Menu 1 without changing the span nunber. When YES is pressed, the span number is changed. The screen displays the new and old span numbers. SPAN # CHANGED New span # 900000 01d span # 900000 RUN MENU 3-82. Manual Span ~ AUTO SPAN R Cal - Run belt empty, then press START. START EXIT Press the down scroll key. This menu allows direct entry of a span value. Minimum entry is 1000, maximum is 3500000 - MANUAL SPAN - Rate 000.0 Toh Span # 0000000 MENU ENTER Your Entry 3.8.3. Naterial Calibration REC 3694 This function is implemented as a machine directed procedure. Calibration is done by weight. 1. Test By Accumulated Weight The first screen instructs the operator on how to begin. WAT? L CALIBRATION Run belt empty, then press START. START WENU By pressing START, the next message screen appears. When MENU is selected, the Hain Menu 1 screen is displayed. Run quantity of material over scale. CONTINUE Press CONTINUE.REC 3694 90000.0 Tons 0000.0 Tph Press DONE to end DONE ABORT Pressing DUNE signals the end of the material passing over the belt scale, and brings the operator to the next screen. Selecting ABORT returns to start of Material Calibration procedures. 000.00 Tons Ref. weight known? Yes WO Selecting YES indicates to the system that the reference (actual) weight of the material is known. If YES is pressed, skip to section l.a. when NO is selected, the system is notified that the reference (actual) weight of the material is not known. Tf NO is selected, the system moves to the run display where MAT’L is flashing to remind the operator that the material test is incomplete. 000.0 Tons 9.0 Tph MATL HELP "NAT*L" is flashing. Press WAT’L if actual material weight is known. a. If YES or MAT’L was pressed in previous steps, the system responds wit! 0000.00 Tons Enter reference weight: 00.9 Tons ABORT ENTER Your Entry Selecting ABORT returns the system to the start of the Material Calibration procedures. Enter the actual material weight using the numerical keys. When finished, press ENTER to install the value in the system. 3-10WAT?L CAL. COMPLETE “COMPLETE” is flashing Error 000.00 * Change span? YES NO . Selecting NO returns you tu the start of the Material Calibration procedures without changing span. If YES is selected, the system responds with the following screen which asks if the reference weight should be added to the totals. MAT? L CALIBRATION Add reference weight to totals YES NO ‘The span number is changed and a new value displayed when YES is selected. SPAN # CHANGED New span # 000000 Old span # 000000 RUN MENU 3.9 MAIN MENU 2 Main Menu 2 contains display message options for the Micro-Tech™ II, scale data selections relating to the physical characteristics of the scale carriage, and calibration data choices of parameters for the calibration of the scale system. Menu 2 may be selected by pressing the MENU soft key until Main Menu 2 appears. Desired menus are selected by pressing the appropriate soft key and using the scroll keys to view selections. 3.9.1 Display Options These menus set various modes relating to the run display messages. = START OF SCROLL - Use SCROLL keys to View Selections. 1. Display Scroll 1 - English or Metric Units This setup screen gives the operator the choice of displaying English or Metric weights and measures. REC 3694 ail- SC DATA SCROLL 3 - Belt scale model #: 10-20-1 Selected CHOICES ENTER HELP ~~ Your Entry Press the soft key under CHOICES to view options. Press the soft key under ENTER to select options. ‘The next series of screens to appear depend upon the choice made in this step. If you have selected belt scale models: 10-11, 10-12, 10-20-1, or 10-20-2, proceed to step 3.a. 10-17-2, 10-17-4, or 10-22-2, proceed to step 3.b. OTHER, proceed to step 3.c. a. Belt Scale Models 10-11, 10-20-1, 10-20-2 SC Data Scrol] 3A - Pivot to Load Cell This menu, plus Scale Data Scrol] 3B, is used to calculate lever ratio. These menus are activated when certain scale models are entered in Scale Data Scroll 3. (See Section 4.4.13, System Defaults.) The distance from pivot to oad cell should be measured to within 0.032" (1 im). = SC DATA SCROLL 3A- Pivot to Toad cell distance: 000.00 In ENTER HELP ——Your Entry ii, SC Data Scroll 3B - Pivot to Idler Calculations of the distance between the pivot and idler are entered on Data Scroll 3B. (Refer to Section 4.4.13, System Defaults.) The distance (within 0.032 inch or 1 mm) is entered using the numeric keys. ~ SC DATA SCROLL 3B- Pivot to Ist idler distance: 000.00 In ENTER HELP Your Entry REC 3694 314REC 3694 b. Belt Scale Models 10-17-2, 10-17-4, 10-22-2 i iis iii. SC Data Scroll 3A - Pivot to Load Cell This menu, plus Scale Data Scrolls 3B and 3C, ‘is used to calculate lever ratio. These merus are activated when certain scale models are entered in Scale Data Scroll 3. (See Section 4.4.13, System Defaults.) The distance from pivot to load cell should be measured to within 0.032" (1 mm) SC DATA SCROLL 34- Pivot to load cell distance: 000.90 In ENTER HELP ~~ Your Entry SC Data Scrol] 38 - Pivot to Idler Calculations of the distance between the pivot and idler are entered on Data Scroll 3B. (Refer to Section 4.4.13, System Defaults.) The distance (within 0.032 inch or 1 mm) is entered using the numeric keys. - SC DATA SCROLL 3B- Pivot to Ist idler distance: 000.00 In eae ENTER HELP ~~ Your Entry SC Data Scroll 3C ~ Pivot to 2nd Idler For Data Scroll 3C, the distance between the pivot and second idler are calculated within 0.032" or 1 am. = SC DATA SCROLL 3C- Pivot to 2nd idler distance: 000.00 In ENTER HELP ~~ Your Entry c. Unlisted Belt Scale Models (OTHER) i SC Data Scroll 3D - Lever Ratio If the model number of the scale is not listed under CHOICES, selecting OTHER will allow the operator to determine the lever ratio of the scale. Refer to Figure 3-3, Scale Area Idlers. The lever ratio is entered (minimum .01, maximum 9.99). (See Section 4.4.13, System Defaults.) 3-159. SC Data Scroll 9 - Speed Input This screen permits the selection of the type of speed sensor system. Select ACTUAL when speed sensor is present or SIMULATED when a speed sensor is not present. When simulated speed is selected, a conveyor running ‘input is required. - SC DATA SCROLL 9 - Speed input Actual Selected CHOICES ENTER HELP ~ Your Entry Press the soft key under CHOICES to view options. Press the soft key under ENTER to select options. 3.9.3. Calibration Data Scrol1 REC 3694 These scrolls allow the setting of parameters related to calibration of the machine ~ START OF SCROLL - Use SCROLL keys to View Selections. 4 1. Calibration Data Scroll 1 - Calibration Mode This screen is used to set which form of calibration (R-CAL, CAL CHAIN, or WEIGHTS) will be used in any future calibration (Span Calibrate), and sets which menus wil] be visible to the operator. The default is R-CAL. -CAL DATA SCROLL 1 ~ Calibration mode: ReCAL Selected CHOICES ENTER HELP ~—Your Entry a. Calibration Data Scroll 1A - R-CAL Selected When R-CAL is the selected mode, the following screen appears. The default is 165,000 ohms. Allowable range to enter is 10,000 to 999,999 ohms. CAL DATA SCROLL 1A~ R-CAL selected Res: 000000 ohms ENTER HELP. Your Entry 3-18REC 3694 Calibration Data Scroll 1B - Chain Selected This display appears if CAL CHAIN is selected above. The value entered here insures later chain calibration is performed correctly. The default value is 0 Lb/Ft. Allowable range is a minimum of 0, maximum of 900,00. CAL DATA SCROLL 1B~ Chain selected weight: 00.00 LbjFt ENTER HELP ~~ Your Entry Calibration Data Scroll IC - Weights Selected If WEIGHTS is selected in Calibration Data Scroll] 1, this display appears and is used to set the correct value of future test weights. The default value is 20 Lbs. Weight range is a minimum of 1.00, maximum of 9999.00. -CAL DATA SCROLL IC- Total test weight on scale: 20.00 Lbs ENTER Your Entry i. When ENTER is pressed, the following sub-menu screen appears. The value entered is the test weight lever ratio created by the mounting position of the test weights. The default value is 1. Test weight lever ratio range is a minimum of .01 to a maximum of 9.99. Test weight Jever ratio: 1.0000 AUTONATIC ENTER HELP ~~Your Entry A. Two methods of determining the test weight Tever ratio can be used: 1, Test weight lever ratio can be calculated using the following formula: Test weight lever ratio = 4 x cos 8 7 d, = Distance trunnion to static weight d, = Distance trunnion to load cell cos 8 = Cosine of the angle of incine Press the numerical keys to enter your calculated value. Press ENTER. 3-19REC 3694 2. If AUTOMATIC is pressed, the following informational screen appears. The system measures the effective lever ratio (after weights are applied and CONTINUE is pressed) by comparing the entered value of the test weights with the measured value. Stop belt. Apply weights to scale, then press CONTINUE. ABORT CONTINUE NOTE: Test weights must not be hanging on the scale when this test begins. Pressing ABORT returns the screen to "CAL DATA SCROLL 1¢". Selecting CONTINUE signals the system to measure the test weights ard compute a lever ratio. MEASURING Actual test weights lever ratio. ABORT The following message appears when the measurement is complete. Test weight lever ratio: (+/-)1.0000 RUN MENU To repeat the function, press scroll keys to return to the start of the procedure. Calibration Data Scroll 2 - Calibration Constant This menu displays the amount of weight that should be accumulated during the test duration. Each calibration has an independent constant; the one displayed depends on which calibration mode is currently active (R-CAL, CHAIN, or WEIGHT). ~CAL DATA SCROLL 2 - R-CAL :Cal. constant 900.00 Tons Calibration Data Scroll 3 - Material Factor The calibration constant, based on an actual material test, is fine tuned when data is entered in this menu. Once a Material Calibration has been performed, any following calibrations (R-CAL, CHAIN, or WEIGHTS) will be automatically adjusted by the displayed material factor. 3-20RFC 3698 The operator may enter a material factor, but if a Material Calibration is performed later, the value entered by the operator will be overwritten by the value calculated by the system. CAL DATA SCROLL 3 ~ Haterial factor RACAL: 4/- 00.00% +7 ENTER “HELP ~~Your Entry Ihe plus/minus (+/-) can be changed either befure or after the digits have been entered. Calibration Data Scroll 4 - Test Duration This procedure determines how long to perform the zeroing and spanning of the system; it does so by determining the Jength of the belt in speed pulses. ACQUIRE is the recommended length. The “Acquire” test function calibrates the belt to the system. Zeroing and spanning are the most accurate when done over complete passes of the belt. The system also calculates a new speed prescale value ~CAL DATA SCROLL 4 - Establish test duration ACQUIRE MANUAL HELP ~~ Your Entry a. Acquire Test Duration The following screens appear when ACQUIRE is selected as the type of test duration. The operator must choose the belt length measurement method. PARTIAL is selected when the belt is hard to measure, but may be less accurate than selecting FULL. When selecting FULL, a 100 foot tape should be used to measure belt length to the nearest .1 foot. A fixed point (an jdler) on the conveyor should be used when counting belt revolutions. See Section 2.6.1 for the recorded conveyor belt length. ACQUIRE TEST DUR Choose belt length measurement method. FULL PARTIAL HELP ~ Your Entry FULL is the recommended selection. i. Selecting FULL If FULL is selected, the following screen appears, Enter length of one belt revolution. Tength: 1000.0 Ft eee ABORT ENTER HELP Your Entry 3-21REC 3694 When the last belt revolution passes the reference mark, press COUNT followed by DONE. This action signals the end of this procedure and the Micro-Tech™ II display responds with: TEST DURATION Checking Toad cell TEST DURATION Length = 900.0 Ft Time = 000 seconds CONTINUE After reading the above screen, press the soft key under CONTINUE and the Micro-Tech™ II display responds with: - END OF SCROLL - RUN = MENU ot Manual Test Duration This procedure allows direct entry of parameters that would otherwise be generated by the Acquire Test Duration modes. This menu is generally used when the operator cannot see the belt while standing at the front panel Start belt. Press CONTINUE when belt is at maxinum speed. ABORT CONTINUE After pressing CONTINUE, the operator enters the length of one belt revolution. ENTER length of one belt revolution. Tength: 000.0 Ft ABORT ENTER HELP ~~Your Entry After the length is entered, the system automatically progresses to the next screen. 3-24The operator decides how many revolutions of the belt to use in the test. ENTER the number of belt revolutions to : 000 revs ENTER HELP ~~ Your Entry The number chosen should be sufficient enough to allow for at least 6 minutes for performing the test. ENTER the time for revolutions to pass reference: 000 sec ABORT ENTER HELP ~— Your Entry — After the time is entered for the belt revolutions to pass the reference point, the system automatically displays the seconds of timing belt travel and progresses to the last screens of the Test Duration procedure. Timing belt travel 900 secs ABORT TEST DURATION Checking load cel] TEST DURATION Length = 900.9 Ft Time = 000 seconds CONTINUE After reading the above screen, press the soft key under CONTINUE and the Micro-Tech™ II display responds with: - END OF SCROLL ~ RUN MENU REC 3694 3-253.10 MAIN MENU 3 Main Menu 3 contains additional option selections required for some scale applications and a test selection for diagnostics. It also can contain a separate purchasable option called Communications where the operator can select such items as printed reports, baud rates of a digital serial output, and time/date settings. Menu 3 may be selected by pressing the MENU soft key until Main Menu 3 appears. Desired menus are selected by pressing the appropriate soft key and using the scroll] keys to view selections. 3.10.1 Options “he Micro-Tech* II Integrator needs additional information for some scale applications. This information is programmed into the Options Scrolls. With the exception of Option Scrolls 8 and 9, the word "Option" does not refer to the purchasable options described in Ramsey’s sales literature. ~ START OF SCROLL - Use SCROLL keys to View Selections. + L. Options Scrol 1 - High Rate Alarm This entry sets the percentage of scale capacity at which the high rate alarm output becomes active. The minimum allowable entry 0; the maximum is 105 percent. The default is 0 percent. An entry of 0 turns off the high rate alarm option. - OPTIONS SCROLL I - Hi rate alarm set point: 105.00 % EWTER HELP ——Your Entry — Press the numerical keys to enter or change the value. Press soft key under ENTER when the entry is complete. 2. Options Scroll 2 - Low Rate Alarm This entry sets the percentage of scale capacity at which the low rate alarm output becomes deactivated. The minimum allowable entry is 0; the maximum is the 103 percent. The default value is 0 percent. An entry of 0 turns off the lo rate alarm option. ~ OPTIONS SCROLL 2 - Lo rate alarm set point: 00.00 % ENTER HELP —~Your Entry REC 3694 3-26