SiloWeigh User Manual
Contents
1. P Perfecting the Art of Concrete Production SiloWeigh Silex Sensor Installation User s Manual Ver 4 8 April 2015 COPYRIGHT Neither the whole or any part of the information contained in nor the product described in this document may be adapted or reproduced in any material form except with the prior written consent of Scale tron Inc 2011 Scale Tron Inc 6428 Trans Canada Highway Ville St Laurent Quebec Canada H4T 1X4 All rights reserved Customer Responsibility The customer in applying the product described in this document accepts that the product is a programmable electronic system which is inherently complex and which may not be completely free of errors In doing so the customer therefore undertakes the responsibility to ensure that the product is properly installed commissioned operated and maintained by competent and qualified personnel trained in accordance with any instructions or safety precautions made available or though proper engineering practices and to thoroughly verify the use of the product in each particular application Errors in documentation The product described in this documentation is subject to continuous development and improvement All information of a technical nature and particulars of the product and its use including the information and particulars contained in this documentation are given in good faith by Scale Tron Inc Scale Tron welcomes comments and suggestions relatin2. SILEX SENSOR INSTALLATION FEED SILO LEG OMEGA 45 April 2015 page 5 of 45 Silo Weigh User s Manual Ver 4 8 1MA 1580 4 7ST INTRODUCTION 10 Introduction amp Installation Overview SiloWeigh tells you the quantity of contents in your silo or vessel not as an empty or full signal or even a percentage full signal based on a level measurement SiloWeigh measures the actual weight of the silo and contents to give a true picture of the amount on hand and it costs little more than a level sensor SiloWeigh can display the weight of contents in practically any vessel Examples are cement sand aggregates flour grains such as corn rice wheat oats barley mineral ores coal coke chemicals plastics even liquids and liquefied gases The easiest application is on H beam legs but round section square L and S sections have been gauged successfully as well as skirted silos The only limitations are the ability to bolt the sensor and the 4 100mm square waterproof junction box onto the leg and the available stress in the leg The stress can be calculated by measuring the cross sectional area of the leg and dividing the maximum live load in the leg by the area The calculated stress should be at least 1500 Ib sq inch 105 kg sq cm Visit www scaletron com for a handy online Cross Sectional Area calculator For example a vessel holds 100 tons 200 000 Ib
3. 39vid NI 38093S 9371 3Hl 3O SIXV TVWOILYSA JHL HUM ANY SMNVI A 30V AISnOIA3Md JHL M3AO Q3NM31N39 3HY SBVL QT34 3Hl 3M SN3 S8Vl JHL 1SVd JGNYLOYd LON 1SnW 51109 JHL 931 JHL NO S8Vl GSM l GAIGNASSVY JHL 3Ovld 217 3ividWil 3HL 3SN LYVd S3HONI 9 SIXV JHL 931 JHL NO SLNIOd MYYN 9371 HOY3 GATIVLSNI 38 OL Q33N SYL QT3A S39V4 5 T3TIvMVd 1v1J S931 ANNOY NO YOSN3S X31S IHL TIVISNI ATInJSS3990nS OL N3QHO NI SALON TIIM 30v4 ONILNNOW 29 SIP Silo Weigh User s Manual page 43 of 45 April 2015 1MA 1580 4 7ST Ver 4 8 APPENDIX 3HL NI 31130 Sv YOSNAS 3H1 NOLLOS NO 533135 1 JHL 3H SN3 SA332S ONIddvl AIS ONITIIMQ 4J13S JHL NOILVOO1 LN3IN3ANOOS V NI XOA lt IHL LNNON OL N31H9lL HON3MA 3Hl HLIM NOSN3S JHL ISNIVOY LON 3HL N31H9lL HON33A QV3H 1108 JHL ONIGIOH NMOHS SV ONINdS ASIA LAN 1108 OLW HIIA NAOHS SV YOSNAS XJS JHL INNOW YSHLO HOV3 OL T3TIvsvd 79 1 14 38v SEVL TIM 3HI SYNSNA d3TIVISNI 38 OL Q33N S3Ovd ONILNNOW T3Tlvsvd P 1 14 S93 ANNOY NO YOSNAS XJS JHL TIVISNI ATInJSS399nS OL YIYO NI S310N MOSN3S ISNIVOv INN N31H9IL M3MOS S9NIddVL 413S 413s Buuds ysig nu Hog OLN NOILONnIP MOSN3S X3lIS vd ONI
4. The system can then be set up and calibrated Refer to section 4 2 of this manual for set up amp calibration procedures Silo Weigh User s Manual page 24 of 45 January 2011 1MA 1580 4 7ST Ver 4 7 INSTALLATION AND SET UP 40 INSTALLATION AND SET UP 4 1 Indicator Connections The supplied Indicator cabinet is intended for an indoor location typically the user s office If your intended location is outdoors or the location is in an area prone to temperature fluctuations wash down of equipment etc call us We have optional cabinets designed for outdoor and hazardous locations Affix the metal mounting clips to the back of the cabinet with the supplied hardware Mount the indicator cabinet on a convenient wall with the supplied wood screws User supplies mounting hardware for alternate installations Ensure the cabinet is close to a power source If not done or if another power cord is required pass the power cord up through a strain relief in the bottom of the cabinet Connect the power cord to the power terminal inside the cabinet Connect the Hot wire to the LI terminal Neutral to L2 and the ground wire to the GND terminal stud Thread the cables from each silo through separate strain reliefs to the cabinet interior Allowing plenty of slack in the cable to prevent it tightening when the door is opened Cut the cable and strip about 4 inches of insulation from it Remove the shield and insulate the s
5. punch two marks through the two holes in the template Strike the with a hammer Remove the template and set aside for the next leg Ensure the punched center marks are on the line and enough to hold the drill bit in place At the punched marks drill a 3mm pilot hole and step 8 5mm diameter hole Finally enlarge the hole to 13mm Use a cutting lubricant to ease the work and prolong the life of the drill bits Spray the holes and any exposed steel with the rubberized spray coating provided Spray the bolts washers and toothed contact areas of the sensors assembly to seal them from possible rust buildup Affix the sensor to the leg with the M10 bolts nuts Schnorr disk spring washers provided Put spring washer convex side out on the bolt and insert the washer into the sensor first then through the leg punch deep up toa before and bolt amp Verify that when the bolts are assembled as above there is freedom of movement on the sensor up amp down This freedom ensures the holes have been drilled correctly and will not bind the sensor as they are tightened If the drilled holes do not line up with the holes in the sensor and the bolt jams the sensor it will be damaged Take care Do not tighten yet Place a disk spring washer convex side out on the side of the leg on the exposed bolt and add the nut Tighten finger tight Repeat for the other hole in the sensor then tighten each nut an addition
6. 7 CHOOSING A POSITION 2 1 To Find the Cross Sectional Area Before starting it is important to verify that the stress in the legs is sufficient for accurate amp reliable readings to be obtained Download the stress calculator from the SiloWeigh page of our website www scaletron com B LA to 7 J r we O Leg Dim mm Dim inches A B C D E F For H legs H beams I beams etc Fill above table with missing dimensions Multiply AxB square mm inches Multiply CxD Total CSA 2 AxB CxD mm in Cross Sectional Area Or for round legs 3 14 x Ex F mm CSA for round legs Divide the total silo capacity by the number of legs per Silo tons Multiply this number by 2000 to convert from tons to pounds Divide the total weight per leg Pounds by the CSA computed earlier This is the stress per leg We require a minimum leg loading of 1500psi Need some input For example a vessel holds 100 tons 200 000 Ib of cement and has 4 legs with a cross section of 12 square inches Each leg will carry a maximum live load of 200 000 4 50 000 Ib Dividing this by 12 gives 4166 Ib sq in which is safely above the limit of 1500 Note that legs that are designed for greater safety margins will have less stress and will have a lower electrical output as a result The lower output will increase the drift in readings due to t
7. Drill a pilot hole for the self tapping screw Use the 5mm hole to tap the 6mm hole for the bolts 5mm Silo Weigh User s Manual page 18 of 45 January 2011 1MA 1580 4 7ST Ver 4 7 INSTALLING SILEX BOLT ON SENSORS 17 Spray the welded pads and any exposed steel with the rubberized spray coating provided Spray the bolts washers and toothed contact areas of the sensors before assembly to seal them from possible rust buildup 10 Affix the sensors to the legs at the weld tabs with the supplied M10 bolts and nuts Thread a nut onto the bolt to about 5mm from the bolt head Place a disk spring washer convex side out on the bolt and insert the bolt amp washer into the weld tab until the bolt bottoms Back it out one full turn and then run the nut onto the washer and sensor until finger tight Verify that there is freedom of movement on the sensor up amp down This freedom ensures the weld tabs have been welded in place correctly and will not bind the sensor as they are tightened If the holes do not line up with the holes in the sensor and the bolt jams the sensor it will be damaged Take care 11 Repeat for the other hole in the sensor 12 Tighten each nut an additional 1 6 of a turn 13 At this point it is best to complete the wiring to the indicator leaving the green and white wires from the sensor free but connecting the black red and shield as detailed in section 3 6 When wiring is complete apply power and return
8. bolts and re measure Re tighten sensors that have returned to within the voltage range above or replace any damaged sensors Re test the combined millivilt output on pins amp 3 again If the reading is negative some resistors need to be added Refer to section 4 4 Dead Load Adjustment on how to install the resistors Calibration consists of two operations Dead load Adjustment and Span Adjustment Ideally the silo should be close to empty before you start If the weight of the silo contents are known can be closely estimated or are available from a previous calibration the calibration can be made equally well Inspect the interior visually if necessary Span adjustment is done with trucks which have been weighed before delivery The printed delivery ticket is the calibration weight If possible have a delivery of material waiting so that the two steps can be done with as little delay as possible This maximizes the accuracy of the calibration 4 6 Dead Load Adjustment Before the indicator is calibrated the sensor output must be brought within range This is accomplished with the supplied shunt resistors First measure the voltage between the SIG pin 1 and SIG pin 3 terminals red lead on Pin 1 black lead on pin 3 on the indicator using a digital voltmeter on the 200mV DC range Estimate the fullness of the silo the signal voltage should lie within the following limits Empty to half full 2 to 8 mV Half full t
9. calibration is complete check the display as the contents are used and if possible return the silo to the empty condition to ensure that the reading returns to zero Because the sensors and structure are not perfect do not expect it to return exactly to zero The average error for this type of system is in the 2 of full scale region when all legs are gauged and 4 when half the legs are gauged the zero reading could be in error by this amount depending on loading conditions and temperature For example 2 error for a 100 ton silo is 2 ton if the reading returns to within 2 0 ton this is acceptable Note however that the accuracy is not guaranteed it depends on the structure on which the sensors are mounted as well as the workmanship during installation Whether or not the display is returned to zero further deliveries can be used to check the accuracy This check should be done from time to time as a verification of correct operation The calibration can be corrected at any time by repeating the previous steps Use the table appendix 6 2 to record the deliveries and readings This table also allows you to calculate the error on each delivery You will notice a drift in the reading during the day this is normal and is due to a slight warping of the beams caused by sunlight The amount of drift depends on the geometry of the legs and the heat rise it can be reduced by insulating the legs from the sun with the supplied sunshield kit S
10. loading must be greater than 0 1 mV for calibration to be possible If it is less than this amount transfer a second load and check again before continuing Press and hold the or Y button to adjust the display to the weight in the silo obtained from the delivery ticket or sum of all tickets if more than one delivery plus the initial amount in the silo used for zero setting if not empty Press the P button repeatedly to complete calibration and exit Before doing anything else RECORD THE MILLIVOLT READING it can be used for fault diagnosis if necessary Keep the recorded readings in a safe place such as Inside the display cabinet ERROR indicates an unsuccessful calibration The new calibration values just entered will not take effect and the previously stored values will remain The four most likely causes of this error are Low and high signals too similar Use a larger weight change for the calibration Difference in signal voltage must be 0 1 mV or more The input signal exceeds the requirements of the bar graph Check the Dead Load setting above change in input signal due to incorrect installation of sensors Call Scale Tron for guidance ncorrect values for Zero and Span Span must be higher than Zero If you have a Shunt Calibration Option Now or later when the level in the vessel has lowered to allow it close each switch in turn then both switches together and note the readings Open both switches an
11. with a digital meter to the junction box for each sensor First check that the excitation voltage is present by monitoring the red and black wires with the meter Voltage should be approx 12 volts DC Connect the meter to the white and green wires from the sensor and set it to the lowest range usually 200 mV DC Reading should be within 5 to 5 mV 14 Using the torque wrench and a long socket fit it bM over both bolt head and nut Tighten each of the bolt nut combinations against the washers amp sensor in 2 3 stages to 41Nm 301b ft about a 1 2 turn of the wrench while monitoring the voltage This voltage should remain within 5 to 5 mV If it increases much above these limits do not tighten further but check the alignment of the bolts and weld tabs When fully tightened the voltage should remain within these limits If the voltage is allowed to exceed 20 mV the sensor can be damaged Take care 15 Repeat for all legs then connect the green and white wires as detailed in section 3 6 April 2015 page 19 of 45 Silo Weigh User s Manual Ver 4 8 1MA 1580 4 7ST INSTALLING SILEX BOLT ON SENSORS 3 4 Installation Animal Feed Silo Leg Omega shaped leg Many farm feed amp grain silos have a shaped steel leg that resembles an Omega symbol The Silex sensor can be attached to legs of this shape or any other similar shape The sensor is to be mounted around the minor neutral axis of the leg 1 2 1
12. 0 11 12 13 14 First identify the legs on the silo to be fitted Pick a location for the sensors Refer to section 2 1 for proper placement Ideally the sensor should be in the middle of the leg away from any cross bracing catwalks or any other structure The locations should also be away from direct sunlight preferably on a north or west facing surface The sensors are mounted vertically centered on the flat of the leg Ensure the desired mounting location is free from bumps burrs and weld seams The sensors need to mount on a flat face In the case of excessive paint the paint under the sensor must be removed The little teeth on the back of the sensor must bite into the metal of the leg Ensure there is no interference from paint under the length of the sensor body The sensor can be painted over once installed Measure the width of the intended mounting face From the front edge measure back about 45 50 of the overall width refer to the appendix Mark a line parallel to the axis of the leg at this point for installing the sensors These will be the mounting centers Place the drill template on the leg so that the line amp holes in the template align with the line previously drawn on the leg Tape in place With the supplied center punch punch two marks through the two holes in the template Strike the punch with a hammer Remove the template and set aside for the next leg Ensure the punched cente
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14. LNNOW January 2011 page 44 of 45 Silo Weigh User s Manual 1MA 1580 4 7ST Ver 4 7 APPENDIX 6 8 Silex Sensor Installation Feed Silo Leg shaped q31vOIdNI SY MOSN3S JHL LOANNOO SA3H2S ONiddvl 313S SNITH3G 5135 JHL HLIM NOILYOOT INGINIANOO Y NI XO8 NOILONNP 3HL 3uno3S 1 3015 XJANOO SONINdS ASIC AHL AYNSNA 39v4 INOY4 3HL HION31 TVlOl 3Hl 30 505 6 IV NOSN3S 3Hl LNNOW 509 5 1X3N SHL OL GQ3NIVHO ASIVQ SI 931 H VA 13NI8V9 HOIMO1S s3ovld 2 31OH Ti Buds LAN OLW sqi 3 a S s e O Wul y OL 3nOMOL d3di OMd ANVMGYVH OLN JHL HLM JOYA 3GISNI IHL OL NOSN3S AHL ANN 1vOLIN3A SIHL ONO lIMVdV 9 S31OH Wwe OML TING 29 3ov4 LNOMS 3Hl WOMJ HIGIM SIHL dO 26 06 Sr 1Y V Q31NGON 38 Ol 51 YOSNAS AHL 3H3HM 39 5 3Hl dO AHL SYNSVAN S310N 93 3 S OL 3NDYOL l108 wwogxoLnN Buds ysi MIYOS ONIdd VL ON NAS ZL xoa Silo Weigh User s Manual page 45 of 45 April 2015 1MA 1580 4 7ST Ver 4 8
15. S A T NOlLdO ON tdS 1409138 AVT3H pores 1 oI on tas zT U WOO Weds eM na N3S 9 6 4 SiloWeigh Electrical Schematic APPENDIX d N3S davod NOLLdO 1N HS NO HO OLWOIONI NO 193NNOO vit Aldd SHIMO d O1801S ve 4 LO1IS HOSN3S OVAOCCIOLL January 2011 page 40 of 45 Silo Weigh User s Manual 1MA 1580 4 7ST Ver 4 7 APPENDIX 6 5 Silex Sensor Installation H Beam Leg To display Ground April 2015 page 41 of 45 Silo Weigh User s Manual Ver 4 8 1MA 1580 4 7ST APPENDIX 6 6 Silex Sensor Sunshield Installation LEG WRAPPED SILEX SILOWEIGH SENSOR L Tie Wrap SUN SHIELD ALUMINIUM SHEET Silo Weigh User s Manual page 42 of 45 January 2011 1MA 1580 4 7ST Ver 4 7 APPENDIX 6 7 Silex Sensor Installation Beam Leg NOLLVTIVISNI MOSN3S S1108 OLW AHL NIVL3H O31 1X3N 3HL YO4 3AVS ANY 917 1 3AOW3M O30 134 JONO M3HlO HOv3 OL l3TiVMVd ANY 1515 38 1SnW SJOV 9NILNDOW OML JHL GALSIML Q314IHS LON 3 vH SYNSNA OL ATIvOIQOlM3d MOSHO 931 JHL OL Sayl 1 ANINA ITAM 59Vl
16. V If it increases much above these limits do not tighten further but check the alignment of the bolts in the holes When fully tightened the voltage should remain within these limits If the voltage is allowed to exceed 20 mV the sensor can be damaged Take care 16 Repeat for all legs then connect the green and white wires as detailed in section 3 6 April 2015 page 15 of 45 Silo Weigh User s Manual Ver 4 8 1MA 1580 4 7ST INSTALLING SILEX BOLT ON SENSORS 3 2 Installation Tapped Hole installation kit For round legs or hollow structural steel provisions must be made in order to properly affix the sensors to the legs In most cases the sensor s mounting points need to be tapped into the leg In soft steel thin steel or round legs less than 150mm 6 in diameter mounting faces must be added to the leg These can be supplied by us Refer to the drawings in the appendix Ideally the leg should be 200mm 8 in diameter or greater and have a wall thickness of at least 6mm 74 1 First identify the legs on the silo to be fitted 2 Pick a location for the sensors Refer to section 2 1 for proper placement Ideally the sensor should be in the middle of the leg away from any cross bracing catwalks or any other structure The locations should also be away from direct sunlight preferably on a north or west facing surface The sensors are mounted vertically centered on the leg Ensure the desired mounting location i
17. ading you should always enter a capacity value at least 1096 higher than the design capacity Example silo rated at 100 ton capacity set capacity to 110 or 120 ton and keep your Overfill limit to 100 ton or less During this set up phase the bar graph will revert back to normal operations after 15 seconds of no activity Enter the calibration sub menu by pressing the P and A buttons at the same time The display toggles between CAL and oFF Press the P button The display toggles between bHi and the previous setting This sets the bar graph HI level Typically it is a percent of silo capacity Press and hold the A or Y button to adjust the display to the capacity of the silo Press the P button The display toggles between bLo and the previous setting This sets the bar graph Low level Press and hold the A or Y button to adjust the display to zero if not already at this value Press the P button The display changes from oFF to dP This sets the decimal point position Press and hold the A or Y button to adjust the decimal point to the desired position Press the P button The display toggles between br and the previous brightness setting Press and hold the A or Y button to adjust the display to the desired bar graph brightness setting 4 is the brightest setting At this point the display setup is complete and if no analog output option is installed pressing the P button will exit from the setup menu Chec
18. al 1 6 of a Mount the junction box in a convenient location close installed sensor Mount the junction box so that the cables exit through the bottom of the box Use either supplied self drilling self tapping screws or the M6 hardware provided Drill a 5mm pilot hole for the tapping screw Use the 5mm hole to tap the 6mm hole the bolts Repeat the mounting for the remaining legs in the position and orientation as the first sensor Silo Weigh User s Manual page 14 of 45 1MA 1580 4 7ST Ver 4 7 January 2011 same INSTALLING SILEX BOLT ON SENSORS 14 At this point it is best to complete the wiring to the indicator leaving the green and white wires from the sensor free but connecting the black red and shield as detailed in section 3 6 When wiring is complete apply power and return with a digital meter to the junction box for each sensor First check that the excitation voltage is present by monitoring the red and black wires with the meter Voltage should be approx 12 volts DC Connect the meter to the white and green wires from the sensor and set it to the lowest range usually 200 mV DC Reading should be within 5 to 5 mV 15 Using the torque wrench tighten each of the bolt nut combinations against the washers amp sensor from the rear of the leg holding the bolt head steady in 2 3 stages to 41Nm 301b ft about a turn of the wrench while monitoring the voltage This voltage should remain within 5 to 5 m
19. an or does not change when incorrectly must be greater than low weight weight added Wires crossed at bar graph or in sensor boxes e Check wiring of sensors No power at sensors e Check for 12 volts between blk red recheck connections at bar graph Shorted signal wires e Disconnect sensor connector at bar graph Resistance between blk red and between wht grn should be 350Q Ohms divided by number of legs i e 87Q to 88Q for 4 legs Weldable sensors installed wrongly e Check orientation of sensors according to diagrams Bar graph shows overfull even though silo is empty flashing bar graph Lost connection or incorrect sensor output e Check wiring and mV signal between wht grn wires e Remove covers and check for water May need to replace sensor if this is cause April 2015 page 35 of 45 Ver 4 8 Silo Weigh User s Manual 1MA 1580 4 7ST TROUBLE SHOOTING Readings erratic and drifting with time One or more sensors installed incorrectly Disconnect sensors one leg at a time until readings stabilize Water in sensor or connection box Remove sensor wires from indicator connector Check insulation resistance between any sensor wire and ground or silo leg Must exceed 20 Megaohms Remove covers and check for water May need to replace sensor if this is cause Readings still erratic and drifting with time after checking and eliminating causes ab
20. d note the reading again Subtract this last reading from each of the others in turn to give the INCREASE in each case as shown below These readings are used later to check accuracy adjust the calibration by a small amount diagnose sensor and cable faults and allow replacement of the indicator without need of a full calibration Switch designation Switch open Switch closed Increase in reading W 25 4 47 3 21 9 G 25 4 47 4 22 0 W G 25 2 69 0 43 8 Silo Weigh User s Manual page 30 of 45 January 2011 1MA 1580 4 7ST Ver 4 7 INSTALLATION AND SET UP 4 10 Relay Set Points Option Four relay set points are available on each bar graph display Option R14 Set points 1 amp 2 have form C SPDT contacts and set points 3 amp 4 have form A SPST All include MOV suppressors max switching is 10A for SP1 2 and 5A for SP3 4 Commons for SP1 and 3 are connected together as are SP2 and 4 Connections are marked on the meter case Enter the Set point mode by pressing the P and Y buttons at the same time The display toggles between SP1 and the previous SP1 setting Press and hold the A or Y button to adjust the display to the desired SP1 value Press the P button The display toggles between doM and the previous doM setting Press and hold the A or Y button to adjust the display to the desired Delay On Make value 0 to 9999 seconds The reading must continuously remain in an alarm condition un
21. e cable to the SiloWeigh Cabinet as directed If any unused strain reliefs remain plug the holes with plastic plugs provided or use a short piece of sensor cable Tighten to ensure water tightness Should the need arise to cut the cable please note you will be faced with 7 wires in total once cut The SiloWeigh only requires the Red Green Black White and Shield wires The yellow blue and Brown wires are not required for the installation Simply clip these wires as short as possible Although these wires have a purpose they are not required for your SiloWeigh system and in no way affect the results of the SiloWeigh April 2015 page 23 of 45 Ver 4 8 Silo Weigh User s Manual 1MA 1580 4 7ST INSTALLING SILEX BOLT ON SENSORS 3 7 Silo Grounding To avoid damage due to lightning or static build up on the silo both the silo amp the display cabinet should be at the same potential Run a 10 or thicker wire from a convenient location on the silo to the GND stud inside the display cabinet If this is not done the silo being grounded and the display cabinet being grounded separately they may not be at the same potential during lighting storms and can be damaged This damage is not covered by the warranty 3 8 Calibrate amp Set up Once the sensors are installed refer to section 4 1 to wire the sensors to the indicator When all is working coat the sensors with a generous coating of the supplied rubberized spray sealant
22. e green and white wires as detailed in section 3 6 April 2015 page 21 of 45 Silo Weigh User s Manual Ver 4 8 1MA 1580 4 7ST INSTALLING SILEX BOLT ON SENSORS 3 5 Installation Skirted silo Sensors installed on skirted silos are done in the same manner as Through Hole legs but with a few minor differences Locate the sensors in 4 or more places on the inside walls of the skirt away from seams in the wall doorways windows etc The sensors should be evenly distributed around the skirt except in the area facing southeast where the rising sun is strongest this will minimize the resulting disturbance The sensors do not need to be at equal distances apart but as close to this as possible If the doorway extends less than halfway to the attachment ring for the discharge cone install the sensors on a line above the level of the top of the door but at least 3 feet below the cone attachment ring If wall strengtheners have been used install directly above these if they do not extend all the way to the cone attachment ring see picture at right If the strengtheners do extend to the cone ring it needs to be determined whether the strengtheners bear most of the load or whether they are only designed to be braces Consult our engineering office and supply pictures or drawings where possible Mount the sensors and junction boxes on the inside of the skirt as per the instructions for Through Hole section 3 1 Silo Weig
23. emperature changes and side loads April 2015 page 11 of 45 Silo Weigh User s Manual Ver 4 8 1MA 1580 4 7ST INSTALLING SILEX BOLT ON SENSORS 2 2 Drills and drilling machine The drills supplied are adequate for installation on a few silos If installation is to be done on many silos we recommend the use of a drilling machine with magnetic base fitted with a cutter that drills the correct sized hole in a single pass The C5000 from Grainger Inc is shown at right This cutter has a hollow center through which a spring loaded pilot pin extends This locates the cutter onto the center punch mark As the cutter proceeds it leaves a plug of metal in this hole that locates the cutter as it cuts The second picture shows the magnetic based drill and cutter in operation An assistant is spraying lubricant onto the cutter This installation was done on a group of 12 silos 25 ft in diameter in southern California The eight sensors per silo required a total of 192 holes and the rental of the magnetic based drill shaved several days off the job Silo Weigh User s Manual page 12 of 45 1MA 1580 4 7ST Ver 4 7 January 2011 INSTALLING SILEX BOLT ON SENSORS 3 0 Installing SILEX Bolt on Sensors The Silex Sensor is a bolt on strain gauge sensor designed to measure the expansion amp compression of the vessel leg Refer to the drawing in the appendix 3 1 Installation using Through Hole installation kit The
24. esssesssesssesscessesssesseeeaes 28 4 6 DEAD LOAD ADJ STMENT iere tt a tren ee Uie tree Ete Rc Ee 28 4 7 CALIBRATION WHEN NO ANALOG OUTPUT OPTION PRESENT LOW WEIGHT ADJUSTMENT 29 4 8 CALIBRATION WHEN ANALOG OUTPUT OPTION IS PRESENT LOW WEIGHT ADJUSTMENT 29 4 9 SPAN ADJUSTMENT iecit ul ipto 30 4 10 RELAY SET POINTS een en teni nene 31 zZAPARM OPTION mite tedio toa im sa t mu teni ee 32 4 12 ANALOG OUTPUT OPTION ecce tinto a nisa eee oett ertet retro eleven 32 SUNSHIELDINSTAL ATION ih rte ect et c de ee ei eee un gas 33 4 14 CHECKING ACCURACY 5 0 TROUBLE SHOOTING 6 0 APPENDIX 6 1 TO CALCULATE SILO 37 6 2 FILL CALIBRATION TABLE cc cccccccccssscescceseceeecssecesecesesssesssesssessceescsssceesceueceseceuecssscsseeeseesseesaes 38 6 3 SILEX SENSOR INSTALLATION ccccccccsscesecssecssecesecssecesesssesssesssessceescessceasceaeceuecsueceeecssseeseessesaes 39 6 4 SILOWEIGH ELECTRICAL SCHEMATIC eene nennen enne enne nitent tenete nnn 40 6 5 SILEX SENSOR INSTALLATION H BEAM LEG eene ennemi 41 6 6 SILEX SENSOR SUNSHIELD INSTALLATION tnee nnne 42 6 7 SILEX SENSOR INSTALLATION BEAM LEG csseseeeeene enn enne enne nnne nnen 43 6 8
25. g decimal point Silo Weigh User s Manual page 32 of 45 January 2011 1MA 1580 4 7ST Ver 4 7 INSTALLATION AND SET UP 4 13Sun shield installation Supplied with your SiloWeigh kit are some aluminum sheets This is used as a sun shield You will notice a drift in the reading during the day this is normal and is due to a slight warping of the legs caused by sunlight The amount of drift depends on the geometry of the legs and the heat rise it can be reduced by insulating the legs from the sun With the system working correctly and to your satisfaction the legs can be wrapped with the sun shield The supplied aluminum sheet should fit around a 10 beam leg with a little overlap If your legs are smaller trim to size or make multiple wraps around the leg Wrap and position the sun shield so that the sensor is centered in the wrap Secure in place with cable tie provided A little tape is useful to hold the sunshield once wrapped and also in place while you strap the sunshield Repeat for the second cable tie so that each sunshield is held in place with 2 cable ties one at the top one at the bottom Additional securing methods may be used Repeat for each leg It is not recommended to paint the sunshield once applied If the need does arise use a light colored paint April 2015 page 33 of 45 Silo Weigh User s Manual Ver 4 8 1MA 1580 4 7ST INSTALLATION AND SET UP 4 14 Checking Accuracy Once
26. g see Dead Load above Go no further at this point see Span Adjustment below The display can be left indefinitely in this state but do not remove power the sequence will have to be restarted if you do 4 8 Calibration when Analog Output option is present Low Weight Adjustment Enter calibration mode by pressing the P and A buttons at the same time The display toggles between CAL and oFF Press and hold the A or Y button Release the button when the display changes from oFF to on Press the P button The display toggles between CAL and out Press the A button until the display changes to iP Then press the P button The display toggles between ZEro and the previous low setting Press and hold the A or Y button to adjust the display to the weight in the silo zero if empty Press the P button The display toggles between Span and the previous span setting If you have not already done so make a note of the millivolt reading see Dead Load above Go no further at this point see Span Adjustment below The display can be left indefinitely in this state but do not remove power the sequence will have to be restarted if you do April 2015 page 29 of 45 Silo Weigh User s Manual Ver 4 8 1MA 1580 4 7ST INSTALLATION AND SET UP 4 9 Span Adjustment Start the transfer of material from the truck into the silo When loading is complete check the millivolt reading again The increase in the reading caused by
27. g the product and supplied documentation This manual is intended only to assist the user in the installation use and operation of the product and therefore Scale Tron Inc shall not be liable for any loss or damage whatsoever from the use of the information in or any error in or omission from this manual INFORMATION HOT LINE 1 800 632 7083 Please read follow and understand the steps in this manual Failure to do so can result in a faulty installation and erroneous readings Should you have any difficulty in installation operation or maintenance of your SiloWeigh system our staff are available to help you during normal business hours and at any other time by special arrangement CALL 514 940 0337 FAX 514 940 0342 Web site www scaletron com E mail scaletron scaletron com Use of this manual for any purpose other than as an aid to operation and service of the equipment described herein is strictly prohibited No part of this document may be reproduced transcribed or transmitted to other parties without the express written permission of Scale Tron Inc 6428 Trans Canada Highway St Laurent Quebec Canada H4T 1X4 TABLE OF CONTENTS Table of Contents 1 0 INTRODUCTION amp INSTALLATION OVERVIEW 2 0 CHOOSING A POSITION AA 2 1 TO FIND THE CROSS SECTIONAL AREA ccccccccesscesecssecssecesecssesssesssesssesssesscssceusceaecsecuecseesseees 1
28. h User s Manual page 22 of 45 January 2011 1MA 1580 4 7ST Ver 4 7 INSTALLING SILEX BOLT ON SENSORS 3 6 Wiring 1 Refer to the connection diagram in the appendix Pass sensor cable and connecting cable up though the strain reliefs in the junction box and connect the 4 wires to connector strip This will give four colored wire connections and one more for the shield wire Insulate shield wire with some heat shrink tubing or use some the jacket stripped from the cable to insulate it The sensor cable may be longer than required Cutting shorter will not interfere with the normal operation of SiloWeigh but it is not recommended Neatly coil the length and secure with a cable tie Run the connecting cable between the junction boxes daisy chaining them together in parallel adding ties as needed After passing cable into the junction leave about one foot 30cm loose cut and strip cables Connect all wires of the same color together at the terminal strip including shields Start at the last sensor junction box and work towards the first Refer to the diagram in the appendix Repeat for each leg and when complete tighten cable strain reliefs to make them watertight the the the of it the extra cable box Once the first box is connected run the cable from the first box to the SiloWeigh cabinet This may require going though a wall or two Run amp secure this cable as required Connect th
29. hield wire with either heat shrink tubing the previously removed outer jacket or some other suitable insulation Connect all shields for incoming cables to the GROUND terminal green wire at the indicator or the stud on the power entry terminal strip together with the green ground conductor from the power cable and blue wire from the 12 volt power supply negative already connected in units after Nov 2013 Attach these cables to the existing wiring harness with tie wraps as shown Twist and run the inner conductors of each cable being careful not to mix them to the upper green connector on each bar graph indicator Connect the cable conductors as follows Pin 1 is the uppermost position Connect the Green wire to pin 1 on the green connector Connect the White wire to pin 3 on the green connector Connect the Red wire to the Red wire on the 2 pole terminal block pig tail hanging from the Green connector Connect the Black wire to the Blue wire on the 2 pole terminal block pig tail hanging from the Green connector Secure the cables to the existing wires with tie wraps Wire Function Pin GREEN SIG 1 WHITE SIG 3 RED SEN 5 Red wire from pigtail BLACK SEN 6 Blue wire from pigtail SHIELD GND power cable entry green wire plus 12V DC negative blue Note Internal power is already connected to pins 5 amp 6 If any existing wires fall out of the connector replace them
30. hite and green wires from the sensor and set it to the lowest range usually 200 mV DC Reading should be within 5 to 5 mV 15 Using the torque wrench tighten each of the bolts against the washers amp sensor in 2 3 stages to 41Nm 301b ft about a turn of the wrench while monitoring the voltage This voltage should remain within 5 to 5 mV If it increases much above these limits do not tighten further but check the alignment of the bolts and holes When fully tightened the voltage should remain within these limits If the voltage is allowed to exceed 20 mV the sensor can be damaged Take care 16 Repeat for all legs then connect the green and white wires as detailed in section 3 6 April 2015 page 17 of 45 Silo Weigh User s Manual Ver 4 8 1MA 1580 4 7ST INSTALLING SILEX BOLT ON SENSORS 3 3 Installation Weld Tabs installation kit For legs with thin walls or a diameter of 150mm 6 in diameter or less mounting faces weld tabs must be installed These weld tabs can be purchased from us Refer to the drawings in the appendix 1 First identify the legs on the silo to be fitted 2 1 bein 2 Pick a location for the sensors Refer to section for proper placement Ideally the sensor should the middle of the leg away from any cross bracing catwalks or any other structure The locations should also be away from direct sun preferably on a north or west facing surface The sensors are mounted vertically cen
31. ilo Weigh User s Manual page 34 of 45 January 2011 1MA 1580 4 7ST Ver 4 7 5 0 Trouble shooting TROUBLE SHOOTING Should you have any problems with your set up installation and or calibration refer to the table below If your particular issue is not listed please call us for immediate assistance Issue problem Probable Cause Solution Bar graph not reading Sensors not connected correctly e Check wire connections to bar graph and sensors Check voltages at bar graph connector Volts between blk red should be 12V V blk grn and blk wht should be 6 V V wht grn should be 3 to 15 millivolts No power e Check power voltage power fuse power at bar graph power connector Calibration not completed correctly e Practice calibration procedure and re calibrate During dead load adjustment section 4 4 voltage between wht grn is too high and cannot be brought within range Disconnected or damaged sensor e If mV signal is greater than 50mV disconnect sensor connector at bar graph and check resistance between blk red and between wht Each should be equal and should be 350Q Ohms divided by number of legs i e 87 to 88O for 4 legs If not disconnect and check each sensor Incorrect resistors used for dead load e Resistors for compensation should be between 50 and 200 compensation Weight reading decreases e Calibration done e Check low weight and span settings Sp
32. in the same way as other bar graphs in the cabinet or consult the schematic provided in the appendix April 2015 page 25 of 45 Silo Weigh User s Manual Ver 4 8 1MA 1580 4 7ST INSTALLATION AND SET UP 4 2 Connections with Shunt Calibration board The Shunt Calibration option makes connection easier due to only one wire being connected to each terminal Its main function is to serve as a means of quick calibration any time after the main calibration is complete This allows you to replace the indicator without doing a full calibration as well as adjust the calibration by a small amount diagnosing sensor and cable problems training users in calibration and checking accuracy once or twice per year The operation and features of the Shunt Calibration option are covered in a separate manual supplied with the unit when purchased or any time on request The picture at right shows how the sensor cable is connected when this option is used The unit plugs directly into the indicator s sensor socket and the existing connector if already wired to the sensor circuit can be plugged into the Shunt Cal input socket This allows one Shunt Cal board to be used in many places by adding it when necessary However the best way to use this useful option is to install one on every indicator and wire as shown here making the job easier 4 3 Adding extra Bar Graph indicators If you order the cabinet plus bar graph indicators from the factory the
33. k the appearance of the display and repeat if necessary If the analog output option is installed the display toggles between Cto and oFF and the previous setting Press and hold the A or Y button to adjust the display to the capacity of the silo or the weight value at which the analog output will be at its full scale output Remember that the decimal point is not shown so that your setting must be 10 times the desired value Press the P button The display toggles between anLo and the previous setting Press and hold the A or Y button to adjust the display to zero or the desired weight value at which the analog output will be at its minimum value if not already at this value Press the P button The display exits the setup menu April 2015 page 27 of 45 Silo Weigh User s Manual Ver 4 8 1MA 1580 4 7ST INSTALLATION AND SET UP 4 5 Preparation for Calibration With the voltmeter check the millivolt output on pins 1 amp 3 red lead on Pin 1 black lead on pin 3 The reading should be positive and if using Silex sensors within the range of 0 10mV If the readings exceed 2mV to 10mV this indicates that one or more Silex sensors are overstressed To identify the overstressed sensor disconnect the green amp white wires from each sensor in the junction box and measure the voltage between these sensor wires It should be within 5mV to 5mV if installed correctly If these values are exceeded loosen the sensor mounting
34. measure all of the load Likewise if there are load bearing struts from the silo or anything else to the legs the sensors must be installed under these struts Load bearing struts can be identified by their shape and cross section If they are similar in cross section thickness to the legs they are load bearing If they are thin flat bars or light angle they are cross braces and not load bearing The sensors can be installed above the bottom ends of these type of struts See examples on the next page and chose the one that suits your setup the best In the example at right they have been installed in the center of the leg section shown you can see the box on the left leg about 12 inches above level with the top of the ladder If you are unsure CALL US this simple step can prevent big problems later CHOOSING A POSITION It is more important to be able to see and work comfortably than it is to place the sensors in the exact centre of a run Before starting it is important to verify that the stress in the legs is sufficient for accurate amp reliable readings to be obtained Download the stress calculator from the SiloWeigh page of our website www scaletron com code silow htm April 2015 page 9 of 45 Ver 4 8 Silo Weigh User s Manual 1MA 1580 4 7ST CHOOSING A POSITION I 4 x m m us RECOMMENDED SENSOR LOCATIONS Silo Weigh User s Manual page 10 of 45 January 2011 1MA 1580 4 7ST Ver 4
35. mps when sun rises Local heating of sensors Some variation is normal and is minimized by sun shield Oversized legs make problem worse Use larger shield for sunlight Mount Silex sensors on north or west facing sides of legs Voltage at blk red sensor wires is less than 12 volts and varies Power supply cannot supply enough power or is faulty Too many sensors capacity is 40 legs or AC power is low in voltage Power voltage must be in the range 100 260 volts Silo Weigh User s Manual 1MA 1580 4 7ST page 36 of 45 Ver 4 7 January 2011 APPENDIX 6 0 Appendix 6 1 To Calculate Silo Volume Ca i To calculate the volume of a silo Calculate the cylinder volume 3 1416 Calculate volume v 1 0472r h Add the two volumes together to get the overall volume of the silo Y Example Silo measures 50 high 12 diameter Cylinder 40 high cone 10 high Upper cylinder volume 3 1416 x 6x6 x 40 4523 8 cubic feet E 4 Y Lower cone volume i 1 0472 x 6x6 x 10 376 9 cubic feet NA n Silo 376 9 4523 8 4900 7 cubic feet The radius of a circle is 1 2 its diameter A 12 diameter circle has a radius of 6 Tonnage can be calculated by multiplying the silo volume by the material density In most cases the typical material in the silo will be Cement Portland Portland cement 94 Ib cu ft density when compacted 70 Ib cu ft as it is bl
36. nstaller understands how to use the tools and that they are used in a safe manner This list is not definitive but outlines the basic tools required for the basic installation task Tools required Silex Sensors Grinder amp various grits of emery cloth To remove paint and to remove any pits holes scratches etc Drill amp bits capable of 3mm 5mm 8 5mm amp 13mm dia holes Bits supplied by Scale Tron Inc Drilling template supplied by Scale Tron Inc Center punch supplied by Scale Tron Inc M6 amp M10 tap set supplied by Scale Tron Inc Digital multi meter able to read millivolts ohms amp megohms 10mm amp 17mm wrenches for M6 amp M10 bolts amp nuts Torque Wrench to fit the above mentioned nuts amp bolts Small slot blade screwdriver for wire connections Wire cutter amp stripper for 22AWG wire Knife Appropriate tools amp hardware to mount the cabinet Silo Weigh User s Manual page 8 of 45 January 2011 1MA 1580 4 7ST Ver 4 7 2 0 Choosing a Position In general sensors are best positioned in the centre of an unobstructed run of the support beam Since the sensors will measure the load in the beam at the point of mounting it is important to first ensure that the point you choose is bearing all the load of the silo and attachments If the silo empties into a screw conveyor and the screw conveyor is supported by beams attached to the legs the sensors must be installed under these beams to
37. o full 4 to 12 mV If the voltage lies within the limits no further action is necessary If not add a resistor between SIG and EXC to increase the voltage or SIG to EXC to decrease the voltage Typically affixed to the front of the bar graph cabinet are a SOK ohm and 100Kohm resistor for this purpose Two or more resistors can be used in parallel if necessary When you are finished RECORD THE MILLIVOLT READING for each silo it can be used for fault diagnosis later if necessary Wire Function Pin GREEN SIG 1 WHITE SIG 3 RED EXC 5 BLACK EXC 6 SHIELD GND Ground terminal on power supply Silo Weigh User s Manual page 28 of 45 January 2011 1MA 1580 4 7ST Ver 4 7 INSTALLATION AND SET UP 4 7 Calibration when no Analog Output option present Low Weight Adjustment Enter calibration mode by pressing the P and buttons at the same time The display toggles between CAL and oFF Press and hold the A or Y button Release the button when the display changes from oFF to on Press the P button The display toggles between ZEro and the previous low setting If the display toggles between CAL and out the analog output option is present Go to 5 6 below Press and hold the A or Y button to adjust the display to the weight in the silo zero if empty Press the P button The display toggles between Span and the previous span setting If you have not already done so make a note of the millivolt readin
38. of cement and has 4 legs with a cross section of 12 square inches Each leg will carry a maximum live load of 200 000 4 2 50 000 Ib Dividing this by 12 gives 4166 Ib sq in which is safely above the limit of 1500 Note that legs that are designed for greater safety margins will have less stress and will have a lower electrical output as a result The lower output will increase the drift in readings due to temperature changes and side loads Install and calibrate the system yourself We deliver a kit with complete instructions You bolt the Silex sensors to the leg with two bolts each along with the associated junction box and install the bar graph cabinet in an indoor location All required cables are provided and are color coded Calibration is straightforward using the weighed deliveries as reference April 2015 page 7 of 45 Silo Weigh User s Manual Ver 4 8 1MA 1580 4 7ST INTRODUCTION Please read follow and understand the steps in this manual Failure to do so can result in a faulty installation and erroneous readings Installation overview Installation is simple amp straightforward Anyone with a certain amount of mechanical aptitude amp dexterity can perform the installation Choose a suitable sensor location Prepare legs amp install sensors Route cable to display cabinet location Install display cabinet Set up system amp calibrate Tools required A few basic tools are required for the install Ensure the i
39. oles and any exposed steel with the rubberized spray coating provided Spray the bolts washers and toothed contact areas of the sensors before assembly to seal them from possible rust buildup 12 Affix the sensor to the leg with the M10 bolts and Schnorr disk spring washers provided Put a disk spring washer convex side out on the bolt and insert the bolt amp washer into the sensor first then into the tapped hole in the leg Verify that there is freedom of movement on the sensor up amp down This freedom ensures the holes have been drilled correctly and will not bind the sensor as they are tightened If the drilled amp tapped holes do not line up with the holes in the sensor and the bolt jams the sensor it will be damaged Take care 13 Tighten bolt finger tight Repeat for the other hole in the sensor then tighten each nut an additional 1 6 of a turn Silo Weigh User s Manual page 16 of 45 January 2011 1MA 1580 4 7ST Ver 4 7 INSTALLING SILEX BOLT ON SENSORS 14 At this point it is best to complete the wiring to the indicator leaving the green and white wires from the sensor free but connecting the black red and shield as detailed in section 3 6 When wiring is complete apply power and return with a digital meter to the junction box for each sensor First check that the excitation voltage is present by monitoring the red and black wires with the meter Voltage should be approx 12 volts DC Connect the meter to the w
40. or 4 20 mA It can also be set to 0 10 V by snapping off the rear cover pulling out the main board locating the analog output piggyback board and change the jumper position as marked The output is isolated The analog output range settings appear as the first step in the Calibration Menu Enter calibration mode by pressing the P and A buttons at the same time The display toggles between CAL and oFF Press and hold the A or Y button Release the button when display changes from oFF to on Press the P button The display toggles between CAL and out Press the P button while out is displayed The display toggles between cLo and an internal scale factor Set a multimeter to the 20 mA range or 20 V range for voltage output and connect it between pins 17 and 18 as shown on bar graph cover Press and hold the A or Y button to adjust the display to the desired low value normally 4 00 mA The range is from 0 3 mA to 18 mA or 0 6 V to 8 V Press the P button and repeat for the high value normally 20 mA or 10 V Range is 18 to 24 mA or 8 to 10 3 V Press P button to exit The weights that represents the analog low and high outputs are set from Calibration Mode See section 5 2 Initial Set Up Following the decimal point and display brightness set up enter the weights for the low and high output extremes normally zero and the silo capacity not forgetting to multiply by 10 because of the missin
41. ove Sensors installed in wrong part of structure Must be on main load bearing members send sketch or picture and get advice Structure too sturdy for application When calculated loading is 1500 psi per leg or less these errors increase proportionally No cure Structures interconnected Check possible impediments and ask for advice Try to separate structures free welded catwalks at one end Reads correctly after calibration but jumps suddenly to an incorrect value Faulty installation of sensor Silex sensor remove check and eliminate paint or rust layers ensure mounting surface is bare and flat reinstall with correct torque Strong local RF field may cause temporary jumps Check for walkie talkie or mobile radios local radio station etc May need steel cabinet to shield electronics Reading follows true weight over some but not Incorrect initial setting of sensor output in Estimate filling of silo and repeat section 4 4 then recalibrate all of the empty to full millivolts range When not every leg of silo e Load not shared by all e Gauge different or more of the available legs is gauged readings are legs equally Ideally all legs should be gauged erratic foundations not equal Bar graph or power supply destroyed Electrical storm damage Ensure indicator cabinet is grounded to silo structure with thick direct copper ground cable Reading ju
42. own into a silo Fly Ash 40 Ib cu ft From the example above 4900 cu ft x 70 2 343 000 Ib of cement To get tons divide Ib by 2000 1 ton 2000 Ib 343 000 Ib 2000 171 5 ton of cement conservatively April 2015 page 37 of 45 Silo Weigh User s Manual Ver 4 8 1MA 1580 4 7ST uns oN ung w einjejedujo OOLXI O 3 J0413 1 ul eseoJou n Buunp p sn junouy gv o ul Jeuv V e0jeg 3NWI L 6 2 Fill Calibration Table APPENDIX January 2011 page 38 of 45 Ver 4 7 Silo Weigh User s Manual 1MA 1580 4 7ST APPENDIX 6 3 Silex Sensor Installation Silex sensor typical installation April 2015 page 39 of 45 Silo Weigh User s Manual Ver 4 8 IMA 1580 4 7ST 018 92 SHOLVOIGNI Hdvidouva OL 4 HHHH SAV nejed 15 s juodjes dmes ydesg Jeg ul I TJ3A31H9IH 84 dS I Wav TV 1J3A31 MOT19U SI LdS jeg A 103 NOl1dO WHv1v 9qAZL Wavy NOLING Wai og 1 NYOH IsHdVuouvg 1 e WIG O1 38019 NONNOO lt 3901 01 38019 MJE ay Andino DOWNY WOO civtd
43. r marks are on the line and deep enough to hold the drill bit in place At the punched marks drill a 3mm pilot hole and step up to a 8 5mm diameter hole Finally enlarge the hole to 13mm Use a cutting lubricant to ease the work and prolong the life of the drill bits Spray the holes and any exposed steel with the rubberized spray coating provided Spray the bolts washers and toothed contact areas of the sensors before assembly to seal them from possible rust buildup Affix the sensor to the leg with the M10 bolts nuts and Schnorr disk spring washers provided Put spring washer convex side out on the bolt and insert the bolt amp washer into the sensor first then through the leg Verify that when the bolts are assembled as above there is freedom of movement on the sensor up amp down This freedom ensures the holes have been drilled correctly and will not bind the sensor as they are tightened If the drilled holes do not line up with the holes in the sensor and the bolt jams the sensor it will be damaged Take care Place a disk spring washer convex side out on the back side of the leg on the exposed bolt and add the nut Tighten finger tight Repeat for the other hole in the sensor then tighten each nut an additional 1 6 of a turn Mount the junction box in a convenient location close to the installed sensor Mount the junction box so that the cables exit through the bottom of the box Use either the supplied self drilling
44. s free from bumps burrs and weld seams 3 Remove as much paint as required so that each end of the sensor when mounted is against bare metal Use a sanding disc or scraping tool Do not use a grinder Ensure there is no interference from paint under the length of the sensor body 4 Mark a line parallel to the axis of the leg at the chosen point for installing the sensors Place the drill template on the leg so that the line amp holes in the template align with the line previously drawn on the leg Tape in place 6 With the supplied center punch punch two marks through the two holes in the template Strike the punch with a hammer 7 Remove the template and set aside for the next leg Ensure the punched center marks are on the line and deep enough to hold the drill bit in place 8 At the punched marks drill a 3mm pilot hole and step up to a 8 5mm diameter hole Use cutting lubricant to ease the work and prolong the life of the drill bits 9 Tap each hole with the M10 tap amp handle provided Ensure the tapping is straight amp perpendicular to the leg 10 Mount the junction box in a convenient location close to the installed sensor Mount the junction box so that the cables exit through the bottom of the box Use either the supplied self drilling self tapping screws or the M6 hardware provided Drill a 5mm pilot hole for the self tapping screw Use the 5mm hole to tap the 6mm hole for the bolts 11 Spray the h
45. se indicators are normally pre installed If ordered from a distributor they are supplied as separate kits and must be assembled prior to or after installation Cutouts are provided for this purpose Use a sharp knife to cut around the grooves in the panel taking care not to damage the front panel in the process Slide the indicator into the hole and secure with the plastic clamps provided Jumper the AC power and DC power wires as shown at right not forgetting the small jumpers between terminals 4 and 6 using the wires supplied in the kits Add the shunt calibration boards if supplied and wire them to the incoming sensor cables as shown in the previous picture Twist all shield wires together and terminate at the ground connector green wire Silo Weigh User s Manual page 26 of 45 January 2011 1MA 1580 4 7ST Ver 4 7 INSTALLATION AND SET UP 4 4 Initial Set Up Determine the capacity of the silo in tons or tonnes for metric measurement One ton equals 2000 Ib and one tonne equals 1000 kg Silos up to 1000 tons tonnes can be displayed with one decimal place i e 200 0 tons Capacities above 1000 tons must be displayed without a decimal place NOTE The vessel capacity is normally calculated to conservatively hold the stated amount when density is at its lowest volume is highest Under normal conditions it is usually possible to add more material than this calculated amount To prevent your display going over scale and not re
46. se procedures apply typically apply to legs of H L and S section plus others where both sides of the surface are accessible 1 First identify the legs on the silo to be fitted 2 Pick a location for the sensors Refer to section 2 1 for proper placement Ideally the sensor should be in the middle of the leg away from any cross bracing catwalks or any other structure The locations should also be away from direct sunlight preferably on a north or west facing surface The sensors are mounted vertically centered on the flat of the beam web Ensure the desired mounting location is free from bumps burrs and weld seams The sensors need to mount on a flat face 3 Inthe case of excessive paint the paint under the sensor must be removed The little teeth on the back of the sensor must bite into the metal of the leg Use a sanding disc or scraping tool Do not use a grinder Ensure there no interference from paint under the length of the sensor body The sensor can be painted over once installed 4 Draw a vertical line in the center of the leg at the chosen sensor location 5 Place the drill template on the leg so that the line amp holes in the template align with the line previously drawn on the leg Tape in place April 2015 page 13 of 45 Silo Weigh User s Manual Ver 4 8 1MA 1580 4 7ST INSTALLING SILEX BOLT ON SENSORS 6 10 11 12 13 With the supplied center punch
47. self tapping screws or the M6 hardware provided Repeat the mounting for the remaining legs in the same position and orientation as the first sensor Silo Weigh User s Manual page 20 of 45 January 2011 1MA 1580 4 7ST Ver 4 7 INSTALLING SILEX BOLT ON SENSORS 15 At this point it is best to complete the wiring to the indicator leaving the green and white wires from the sensor free but connecting the black red and shield as detailed in section 3 6 When wiring is complete apply power and return with a digital meter to the junction box for each sensor First check that the excitation voltage is present by monitoring the red and black wires with the meter Voltage should be approx 12 volts DC Connect the meter to the white and green wires from the sensor and set it to the lowest range usually 200 mV DC Reading should be within 5 to 5 mV 16 Using the torque wrench tighten each of the bolt nut combinations against the washers amp sensor from the rear of the leg holding the bolt head steady in 2 3 stages to 41Nm 301b ft about a turn of the wrench while monitoring the voltage This voltage should remain within 5 to 5 mV If it increases much above these limits do not tighten further but check the alignment of the bolts in the holes When fully tightened the voltage should remain within these limits If the voltage is allowed to exceed 20 mV the sensor can be damaged Take care 17 Repeat for all legs then connect th
48. tered on the Ensure the desired mounting location is free from bumps burrs and weld seams light leg 3 Remove as much paint as required so that welding take place can 4 Marka line parallel to the axis of the leg at the chosen point for installing the sensors 5 If not already done so assemble two weld tabs onto one weld tabs alignment jig with the short M10x22mm bolts Using the longer mounting when welding can degrade the quality of the bolt Thread one of the attachment bolts through the alignment jig into a weld tab and tighten the weld finger tight only Ensure that the bolt does not protrude out of the opposite side of the jig Repeat for other weld tab bolts tab 6 Place and secure in position the assembled weld tabs amp alignment jig The weld tabs should be centered on the previously drawn marks The faces may be mitered to better fit the curvature of leg if necessary for welding weld the weld faces 7 Firsttack weld in three or four places then fully the weld tabs to the leg Ensure the mounting of the pair remain flat flush and parallel to each other 8 Once welded remove the placement jig DO NOT discard the M10 bolts close that Use 9 Mount the junction box in a convenient location to the installed sensor Mount the junction box so the cables exit through the bottom of the box either the supplied self drilling self tapping screws or the M6 hardware provided
49. til this delay has elapsed before the relay will close It is normally set to 0 Press the P button The display toggles between dob and the previous dob setting Enter the Delay On Break value in the same way as the Delay On Make value as above Press the P button The display toggles between hYSt and the previous hYSt setting Use the and Y buttons to select Hysteresis Off Note Hysteresis is used for specialized filling operations and does not normally apply For full details see the bar graph manual FL B101 D40 Press the P button and continue setting SP2 SP3 and SP4 as above Press the P button The display toggles between rLYS and the previous relay setting Use the and V buttons to select whether relays close on rising or falling weight values The display LLLL represents SP1 to 4 reading left to right and h represents rising while L represents falling Press the P button to exit April 2015 page 31 of 45 Silo Weigh User s Manual Ver 4 8 1MA 1580 4 7ST INSTALLATION AND SET UP 4 11 Alarm Option Adjust SP1 and SP3 as in section 4 8 SP1 is the low alarm and SP3 is the high alarm SP2 and SP4 can be used for other purposes Connect terminal B for all silos together toa 12VDC horn Connect terminal A to an external 12V lamp if required Pushing the ALARM CANCEL button will silence the audible alarm but the light remains on 4 12 Analog Output option The Analog Output module is normally set f
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