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OPERATION & INSTALLATION MANUAL

1. 64 65 Calculating the target weight 12 Lee eere esee rere eene nns 66 N Pp WELDING OF IDLER TRANSOM TO WEIGH ARM THE LOAD CELLS WILL HAVE BEEN FACTORY FITTED TO THE E40 WEIGHER LOAD CELLS MUST NOT BE SUBJECTED TO THE FLOW OF STRAY ELECTRIC CURRENTS IF THE WEIGH IDLER IS TO BE WELDED IN PLACE MAKE SURE THE WELDER MACHINES EARTH CLAMP IS ATTACHED TO THE IDLER MOUNTING BRACKET AND THERE IS A GOOD CONNECTION FAILURE TO COMPLY WITH THIS NOTE WILL RESULT IN LOAD CELL FAILURE LOAD CELL OVER LOADING DURING INSTALLATION THE LOAD CELLS HAVE BEEN FACTORY FITTED TO THE E40 WEIGHER TO PREVENT OVERLOADING THE OVER LOAD STOPS HAVE BEEN FACTORY SET HOWEVER THE E40 WEIGH WEIGHER SHOULD NOT BE SUBJECTED TO LOADS HIGHER THAN THE MAXIMUM LOADING DESIGNATED FOR THE CONVEYOR Generally the following requirements must be adhered to if the stated performance figures are to be met Web Tech may vary from this subject to a conveyor analysis We urge you to commission your local Web Tech agent to either install the scales or supervise the installation of them 1 The conveyor incline should not exceed 20 degrees from horizontal 2 The conveyor should be quipped with a gravity take up system 3 The conveyor should not exceed 3000 metres 4 The conveyor should be rigid in design free from vibrations and not subject to stress that will cause structural deflection 5 The co
2. e vi cf m 110 240 VAC 50 60 Hz 0 1 Amp 240V 0 2 Amp 120V Ti SCREEN SIGNAL ui WEB TECH AUSTRALIA PTY LTD DRAWING ACH 784 431 11 ELECTRDIES STREET MILE PLAS CUEERSLAVD 4113 E40 08 ES BOW 4006 EIGHT PLAH QUEENSLAHD 4113 AUSTRAL Phen L6 2 341 4617 3841 01 E40 06 ELECTRICAL CONNECTION DIAGRAM FOR E WEB TECH BELT E40 SCALE SYSTEMS BEEN EN INCORP MASTERWEIGH 5 INTEGRATOR ee 03 05 08 CRIGNAL ESUE ALL DIMENSIONS N MILLIMETRES Eun dro ae pense of WEB TECH MEM mime hermnn erm the UNLESS OTHERWISE SPECIFIED and pauwi mol ba loaned cr uad f r memctacturing ur far ony other purpose withnut thelr edtten perrimninn DC Power Supply DC Power Supply Power Supply Modules DC Power Connector Check Voltage Against that shown on Power Supply Modules This section includes a minimum of basic press the Enter key The display will now information that needs to be input into change to the following Masterweigh 5 to get you started Detailed Manual entry of Pulses Rev calibration procedures are to be found in or Press Enter to Continue Masterweigh Operation The set up sequence is as follows Manual entry of Pulses Rev Enter pulses revolution Zero Span This entry is used when
3. MASTERWEIGH 5MENU Menu 1 Note that units can be changed to tons lbs or kg if preferred within Menu Entry 11 This step displays and allows alteration to the mass total increment This increment is used for both the mass rate and the mass total displays Enter the new value required and press the Enter key No change is made if Enter is pressed without data entry Note that the increment set is the increment required to cause one pulse output from the electronic counter Also do not change the increment in normal operation as the change insetting will invalidate any existing accumulated mass total This step displays and allows alteration to remote counter pulse width this value is limited to between 20ms and 1000ms Note the value entry should be in multiple of 10ms ie 20 30 990 1000 No change is made if Enter is press without data entry One pulse is output each time the mass total increases by one increment as set in step 3 above Enter a pulse width that will match with the remote counter response time but keep the following in consideration when selecting this value The pulse output can go no faster than the value you just selected but the accumulation of the mass total may and so the remote totaliser will fall behind the actual mass total E g if the pulse width is set to 100mS then at it s fastest rate the output will on for 100ms then off for 100ms This will give a maximum output of
4. X oec Over Load Stop Screw Weigh Arms Drawing E40 001 100mm WOE CALIBRATION WEIGHTS OPTIONAL SUPPLIED BY WEIGHT TO SUIT APPLICATION BELT SCALE LOADCELL CAPACITY SUIT mo S WEICH MODULE BOLTIMG POINTS MINIMUM MID BOLTS MUST PARALLEL FROM SIDE TO SIDE M PICK UP BRACKET WELD TO TRANSOU CALBRATION SUPPORTS TO IDLER TRANSOW BOTH SIDES BELT SCALE ASSEMBLY LOADCELL INSTALLED BY CUSTOMER WEIGH IDLER TRANSOM WELDED TO ADJUSTABLE BELT SCALE BRACKET WEIGH IDLER TO BE DIRECTLY EXISTING IDLER TRANSOM MOUNT FOOT REMOVED MAGNETIC PICK UP CABLE 10 BE SUPPORTED PROTECTED FROM DAMAGE RIDGED CONDUIT TO BE AVOIDED MAGNETIC PICK UP JUNCTION BOX UNLESS OTHERWISE STATED TONY BERNARDI WEB TECH AUSTRALIA PTY LTD UNTOLERANCED DIMENSIONS 1 ELECTRONCS STREET EAT PLAN QUEDELANI 4113 AUSTRALIA BE WITHIN THE LIMITS SHOWN T BERNARDI T BERNARDI MAG PICKUP SPROCKET T BERNARDI T BERNARDI P O 4008 EIGHT PLAINS QUEENSLAND 4113 AUSTRALIA Phone 61 7 341 284 61 73841 0005 E40 PLUS BELT SCALE 21 06 02 ORIGINAL ISSUE DO NOT SCALE INSTALLATION DETAILS IF IN DOUBT ALL DIMENSIONS IN MILLIMETRES ASK UNLESS OTHERWISE SPECIFIED MODIFIED TO SHOW NEW MAG PICKUP MOUNT ECN 0000 CALIBRATION SUPPORT BARS MODIFIED B 12 08 02 MOVED TO INNER IDLER ECN 0000 24
5. 1 BUOANMHENDERSBOSNERENM Field Wiring Power Input Connector Standard Switch selectable 240 110VAC Special must be pre ordered Either 12VDC or 24VDC Web Tech advise that Masterweigh should not be mounted in direct sunlight or close to a device that can generated heat Generally semiconductor devices specifications state that a semiconductor device will not operate reliably in temperatures in excess of 55 C Direct sunlight can quickley raise the temperature in the electronic enclosure to well above 55 C therefore consideration must be given to the enclosure location and protection from direct sunlight If the enclosure is to be fitted in an exposed area Web Tech can supply a suitable sunshade as shown below Manufacutured from 304 grade stainless steel and engineered to allow for easy access of conduites and wiring it will provide the protection required Contact the factory for pricing and availability ELECTRONIC ENCLOSURE It is advisable to mount the enclosure as close to the weigh frames as possible The maximum cable length from weighframe load cells junction box to the enclosure is approximately 150m Fix the enclosure to a suitable post or wall It is advisable to select a position which is not subject to excessive vibration and is out of direct sunlight Use a sunshade if the electronics are to be mounted in direct sunlight contact Web Tech for the price if required The enclosure must no
6. REVISIONS 22 3 04 ORIGINAL ISSUE an dnd must not be disclosed loaned copied or used fer manufneturimg z tendering or for fission Drawing E40 04 SPEED SENSOR TACHO JUNCTION BOX MWS ENCLOSURE J3 CABLE SUPPLIED BY CUSTOMER CABLE TO BE BELDEN 3 CORE PART No 8770 OR EQUIVALENT UNLESS OTHERWISE STATED UNTOLERANCED DIMENSIONS ACH 010 784 431 WEB TECH AUSTRALIA PTY LTD 3 eS 5 71 5 s er E T S 1j 10 2 2 T A f SIZE DRAWING Mo BE WITHIN THE LIMITS SHOWN checken PS IPD BU 4068 EET MLE PLANS QUEDISUND 411 Phone 81 7 3841 2044 61 7 38041 0005 ABOVE ABOVE ABOVE ABOVE APPROVED LH sae BEBE e onov EXE ee HM E40 CONVEYOR BELTSCALE MAGNETIC PICKUP WITH AMPLIFIER JUNCTION BOX CONNECTION DETAILS ALL DIMENSIONS MILLIMETRES ASK UNLESS OTHERWISE SPECIFIED su ar _ vas 05 ns ns a 21 PR Pu sams es pe en vio en ST REVISIONS k 1 3 96 ORIGINAL ISSUE Drawing E40 05 a eae RESONS k Fiks ESUE WEBSTER CC lt Q ENCLOSURE 13 REV D PCB Ep 1 SHD E SPEED SENSOR CABLE SUPPLIED BY CUSTOMER CABLE BELDEN 5 CORE PART No 8770 OR EQUIVALENT TACHO JUNCTION BOX APPROX 2
7. 2 CORE OVERALL SCREENED INSTRUMENT CABLE ELECTRONIC MAGNETIC REMOTE TOTALISER PICK UP JUNCTION BOX OR PLC WEIGH IDLER OPTIONALLY SUPPLIED 12445678 UNLESS OTHERWISE STATED DRAWN K WEBSTER WEB TECH AUSTRALIA PTY LTD SIZE DRAWING No UNTOLERANCED DIMENSIONS AGH O10 764 431 NUMBER RET TO BE WITHIN THE LIMITS SHOWN CHECKED 11 ELECTRONICS STREET EIGHT MILE PLANS QUEENSLAND 4113 AUSTRALIA JAN E40 01 up To ABOVE ABOVE ABOVE APPROVED CUSTOMER sef ES e 9m E 40 CONVEYOR FIELD WIRING _ 7550605 DATE APP D D BLOCK DIAGRAM CAD FILE C1 Engineering Drowings Eleetricol Drawings FABRICATION T i i SCALE IF IN DOUBT ALL DIMENSIONS IN MILLIMETRES Tis information er ma hereon ara the confidential ASSEMBLIES x E i j ASK UNLESS OTHERWISE SPECIFIED ahd must not be disclosed loaned copied or use ufoeturing tendering for any ether purpese without their written pemiasian REVISIONS Dd 20 02 2008 ORIGINAL ISSUE 0000 Drawing E40 02 CONTAINED WITHIN MASTERWEIGH ENCLOSURE EXTERNAL SUPPLY AND PULSE GND BELT SPEED SENSOR GND BELT SPEED SENSOR SIGNAL BELT SPEED SENSOR SUPPLY RATE OUTPUT 4 20 RATE OUTPUT 4 20 POS RATE OUTPUT SCREEN LOAD CELL SIGNAL POS LOAD CELL SIGNAL NEG LOAD CELL SUPPLY 10 V LOAD CELL SUPPLY GND LOAD C
8. 000mV Enter new level 0 000mV MASTERWEIGH 5MENU Menu 7 Increase this factor if the letter E is being 7 encountered in the main display Auto Zero Error Level 2 times Auto The function of displaying the letter E can Zero be switched on or off here by pressing the C button Autozero Error Display is On Press Clear to Change Enter to accept At Menu Entry 7 press Enter to proceed Enter the new autozero level in mass rate units and press the Enter key If the Enter key is pressed with no data entry then the stored value remains unchanged Enter the period required in belt revolutions over which autozeroing occurs Note that the number of belt revolutions should be chosen such that the total zeroing period is of the order of 5 minutes or more This will ensure that accurate zero levels are produced Note that the actual zero level used by the Masterweigh will not be updated until a zeroing period has been completed If a new value is entered and the Enter key is pressed then that value is saved otherwise no update occurs This step enables the qualifying delay time to be set Choose a time that will ensure that all material is off the belt The delay time commences when the mass rate falls below the minimum level set above Step five allows the user to enter the value in mV below which it may be considered that an invalid Autozero is taking place step six allows the user to enter t
9. 03 03 D 02 07 03 ECN 0000 p l 1 9 8 Weigh Arm Drawing E40 002 2 SIRMGLMES USE 50 100kg BREAKING STRAIN FISHING LINE TIE OFF SECURELY AND PULL TIGHT VIEW FROM SIDE THE IS THE CASE TYPICAL WELD IDLER FRAME TO SUPPORT BRACKETS 2 ROLE C2 THRU 70 22 ARE TO DRILLED AND TAPPED 6 15 ROLLS IN TOTAL REFER DETAL A SCALE INTERNAL FRAME 5 3 AL ROLLS MUST BE ADJUSTED TO STRINGUNE REFERENCE TO TOLERANCE OF 0 4mm Omm LEVEL CENTRE ROLLS OW 402 AND 2 IDLERS PRIOR ANY ADJUSTMENTS ENSURE ALL LOCKING EE LO 4 F RALERMACES STATED CAM BE ACHIEVED WITHOUT THE USE OF E AMUSTING SCREWS IGNORE REQUIREMENTS FOR FITTING OF SCREW LIFTING DETAIL D d UNLESS OTHERWISE STATED UNTOLERANCED DIMENSIONS TS BE WITHIN THE LIMITS SHOWN 2 E40 PLUS CONVEYOR BELTSCALE mem cn 2 wm ani en 120 oo INSTALLATION GENERAL ARRANGEMENT on sns ans sas sin 220 IF IN DOUBT Th ung ripe or ai eun aru EIE adi ee ESPEN ERA Weigh Arm Drawing E40 008 o m 7 REVISIONS 26 03 2007 WELD TO TRANSOM WELD TO TRANSOM DRAWN K WEBSTER CHECKED LANCE HARTLEY UNLESS OTHERWISE STATED UNTOLERANCED DIMENSIONS TO
10. 25 volts LK3 On Board Half Bridge This link allows use of input devices that have a half bridge configuration When linked for half bridge input micro the negative side of the load cell input is disconnected from the terminal block J6 and instead connected to an on board half bridge circuit This half bridge is energised from the excitation as supplied to the external device The zero point is adjustable via RV1 Refer to Section Potentiometer Adjustments RV1 LK4 LK5 Current loop supply These links select the power supply for the analog output current loop The supply can be an internally generated isolated 28VDC supply or an external supply of 20 to 50VDC set the links to select the appropriate power source as follows Internally generated LK4 1 2 LK5 1 2 Externally generated LK4 2 3 LK5 2 3 LK6 LK7 LK8 LK9 Control Pulse Output Type These links select the power source for the totaliser counter pulse output Set the links to suit the external counter device Internally generated 5VDC not isolated LK6 LK7 LK8 LKQ 1 2 1 2 1 2 1 2 Internally generated 28 VDC Isolated LK6 LK7 LK8 LK9 12 1 2 2 3 2 3 Relay provided voltage free contacts LK6 8 LK9 2 3 2 3 2 3 23 CPU PCB Top Board LK1 When installed to the bottom Masterweighs digital communication is based on the RS232 protocol When installed to the top the digital communication is based on the RS
11. 5 complete pulses per second 100mS on and 100mS off 200mS per total pulse Therefore if the feeder is running faster than 5 increments per second 18000 increments per hour then the remote total will be wrong E g for an increment value of 0 01tonnes the limit will be 180tph To modify factory calibration data At Menu Entry 1 press the C key to gain access to the factory calibration data The correct values for these calibration constants have been engraved onto the main board of the Master Weigh 5 stack the top board Check that the values in the computer are the same as the engraved values and modify the values in the computer as required Ihe display will warn the operator not to modify data and to press A to exit and continue Press the E key at this point for access to the Zero Reference Enter new data and or press the E key to proceed Now access to the precision reference has been gained Enter new data and or press the E key again Either exit at this step by pressing the A key or press E to access the menu which exercises the 4 20mA circult Press C to step through the Rate O P s to the desired value namely 20 0 10 04 5 02 7 53 6 27 5 645 5 335 5 178 5 099 1 90mA Press E to reset unit A current meter needs to be connected across pins 6 amp 7 of J3 and in series with the load if connected MASTERWEIGH 5MENU Menu 2 This calibration is carried out wi
12. E40 SCALE SYSTEMS p INCORP MASTERWEIGH 5 INTEGRATOR ww moter pei hereon erm thm oonfidertal Tm dro and ony Information nr doer ALL DIMENSIONS MILLIMETRES and propert af WEB TECH pre LID n and raubi red locnad ied cr nad f r menutacturi Eareharini UNLESS OTHERWISE SPECIFIED ur fur ony other purpose without their writan perrimnin ORIGNAL SUE LOGG MAG PICK UP ADDED Drawing E40 03 3 a 5 10 EI LOADCELL JUNCTION BOX LOADCELL J BOX TERMINATION BOARD GREEN OJ SIGNAL GREEN JO SIGNAL SCREEN JO SCREEN RED EXCITE SENSE LOADCELL 1 LOADCELL 2 INDICATOR SIGNAL SIGNAL r EXCITATION TO OPTIMUS EXCITATION SCREEN SUPPLIED WIRING BY OTHERS WITH LOAD CELLS BELDEN 8723 OR EQUIVALENT CONTAINED WITHIN WEIGHARM WEB TECH AUSTRALIA PTY LTD sze DRAWING No K T WEBSTER KT WEBSTER 11 ELECTRONICS STREET af WILE 4113 AUSTRALIA NUMBER REV 222 1 40 0 A T aaa LOAD CELL JUNCTION BOX ae us WIRING DIAGRAM ear CONNECTIONS TO OPTIMUS INTEGRATOR COTE IF IN DOUBT ALL DIMENSIONS IN MILLIMETRES Tis ah bt decariptive rater eat hereon ara the confidential ASK UNLESS OTHERWISE SPECIFIED any ather purpose without their written pernissia
13. Press E Mass Hate 0 000 Revs 0 0 1 MASTERWEIGH 5MENU Menu 4 Press Enter when at Menu Entry 4 to proceed At this stage the belt span factor can be set manually by entering the desired span factor and pressing the Enter key If no value has been entered then no change is made to the stored value and the next level is entered Masterweigh 5 has been provided with two methods of spanning calibrating Fixed Weight or Empirical Menu 5 After initial calibration the user can by toggling Fixed Weight to R Cal perform a Calibration verification An explanation of this procedure follows this text For initial calibration toggle this menu step to Fixed Weight by pressing the Clear C button if R Cal has been selected The target weight is the mass total that is expected over the number of belt revolutions as currently set Menu 2 This target weight may at this point be changed to suit the calibration weights being used Note that this value will generally be determined by running this procedure and recording the result immediately after performing an empirical calibration Menu 5 A load zero calibration should generally be performed Menu 3 before running this procedure If a new value is entered then pressing the Enter key will save this as the new target weight If the Enter key is pressed without entering a target weight then no change to the stored value occurs The current mass rate
14. With the exception of short periods allocated to self calibration the Masterweigh is continuously monitoring the load cell input rather than periodically sampling as is the case for systems which use dual slope integrating converters This results in a more accurate measurement of the rapidly fluctuating input signal from the load cell Careful design of the input circuitry ensures excellent rejection of common mode signals both AC and DC Note The excitation voltage regulators are overload short circuit protected however short circuiting of the excitation output will interfere with normal operation of analog input circuitry and the RS232 interface Caution Application of an external voltage source to the excitation terminals may cause serious damage to the Masterweigh No calibration or adjustment of the Masterweigh analog inputs is required Gain and zero are automatically adjusted by the reference This automatic calibration is repeated once every 30 seconds whenever the Masterweigh is energised After energising the Masterweigh always allow a minimum of thirty 80 seconds for this automatic calibration to be performed before initiating a span or zero calibration sequence Note If Masterweigh has not been energised for some time allow 3 minutes before initiating the above MASTERWEIGH 5 DETAILED DESCRIPTION Tacho Input and Supply a Electrical Characteristics The tacho input is desig
15. belt scale total 0 000 New span 205 6 previous 211 7 MASTERWEIGH 5MENU Menu 6 This entry displays the level at which the load is considered to be zero Below this level the mass rate display will show zero no increment of the mass total will occur no pulses will be output to the e m pulse counter and the mass rate analog output will be set to 4 0mA 1 Menu entry 6 Null level 20 000 tonnes hour Enter a new null level 25 Mass rate 22 657 tonnes hour 3 Enter belt scale total 0 000 4 New span 205 6 Previous 211 7 Press E to save otherwise press A 1 At Menu Entry 6 press Enter to proceed 2 Enter the exact mass total as measured by the weighbridge or other accurate method Press Enter when the data Is correct 3 Enter the mass total as measured by this Masterweigh unit Press Enter 4 Press Enter to store the new span value as the loadcell span calibration factor Press Abort if no update is required 5 At Menu Entry 6 press Enter to proceed 6 Key in the new null level of zero Press Enter when the data is correct Note on selecting the null level This entry is used to mask variations in mass rate caused by variations in the belt weight caused by the belt splice etc To select the null level observe the mass rate shown over several belt revolutions with the belt running completely empty ie no product or calibration weights Take note of
16. can be derived Mass rate m mmmm Revs empirically or calculated In the Getting At the end of the test routine the display will change to that shown below Current target weight 50 000 tones at this point pressing the Enter key will Enter target weight 0 000 tones indicate to Masterweigh that it should calculate the new target weight Started section of this manual only the calculated method will be used To calculate new calibration press E When the system is purchased from Mass total w wwww revs r r Web Tech a set of data referring to the Belt Scale parameters accompany the r r belt revolutions delivery see back of manual for a w wwww current belt revolutions sample One of the data set is Target m mmmm mass rate Weight The target weight is the On pressing the Enter key Masterweigh uses the target weight and the found mass total to calculate it s new span factor NOTE The above calibration data will not be stored in the Masterweigh working memory until the following key sequence has been carried out 1 Press Menu 2 Press E Enter key If A Abort is pressed instead of E Enter then the new calibration information is lost and Masterweigh uses previous data The same loss occurs if power is lost during calibration Fine Tuning Now that the system is running it can be fine tuned a Null Level Most conveyor belts have sections which are much hea
17. conveyor belt The rolls are machined and balanced which eliminates vibration around the weigh area Why use these weigh quality idler assemblies By using and accurately installing weigh quality idler assemblies over the prescribed weighing zone A stable and uniform path is provided for the conveyor belt This is an attempt to eliminate false load indication being transmitted to the load cells and distorting the weigher performance In some instances acceptable results can be obtained even if the mentioned idler assemblies are not used The mechanical installation and alignment is critical for accuracy and long term repeatability of any belt scale system Failure to carry out the installation correctly will seriously degrade the performance of the system The following belt scale installation notes assume that the user wishes to gain the maximum accuracy from the scale After the location for the scales weighframe has been decided using the guidelines specified in the previous chapter carry out the mechanical installation as follows referring to drawings E40 001 E40 002 amp E40 002 2 The E40 002 2 shows all idlers as off set type Not the preferred type 1 Electrically isolate the conveyor Tag out equipment where necessary 2 With reference to drawing E40 002 or E40 002 2 depending on idler sets lift the conveyor belt so that access Is gained to idlers numbered C3 to 3 Using string line
18. not impart any force to the load cells A large loop in the cable at the point where the cable is tied to the stringers is advisable See Drawings WIMW5 E40 for wiring details Note If a tachometer is not being used it is important that Masterweigh 5 be field programmed to use the internal tachometer Menu 9 It should be noted that if the conveyor stops with load over the weigh area Masterweigh 5 will indicate mass rate Masterweigh 5 can be wired to gate the internally generated tachometer signal through an external switch Voltage free contacts if available on motor contactor Masterweigh 5 low voltage connector strip J3 is not to be exposed to any external Belt Stop Switch Supplied by Others J3 Tg Gnd J3 Tg Inn Masterweigh 5 voltages other than those specified in this manual In Menu 9 set Masterweigh 5 to Ext Con When set to Ext Con External Connection Masterweigh 5 will use the internally generated 100Hz as a pseudo tachometer frequency Any voltage free switch connected in series with Tg Gnd and Tin will indicate to Masterweigh 5 that the belt has stopped No consideration is given to variation of belt speed Magnetic Electonic Pick Up wi gt e LLL 10 11 SPROCKET PRE MACHINED TO MATCH CUSTOMERS BED ROLL M6 x 25 LONG CSK BOLT 4 OFF DRILL amp TAP BI D ROLL M6 SPROCKET ALIGNING TOOL SUPPLIED USE AS TEMPLATE FOR M6 TAPPED
19. piano wire or nylon fishing line 100 150 kg breaking strain Line out the idler assemblies as shown in the drawing It is useful if the tie off point is slightly raised with respect to the weigh zone idlers This allows the installer to bring up the rolls to a common datum If weigh quality idlers have not been purchased with jacking screws installed on the rolls shim blocks may need to be installed under the idler mounting feet 4 Itis important that the two weigh arms be installed inline and parallel to the conveyor stingers It is also important that the weigh arm idler mounting plate be centrally located between idlers C1 amp C1 It is recommended that a large set square or other device be used to assist in this operation When the arms are aligned bolt them down through the holes provided Weigh Arms Weld Here Both sides of idler 5 At this point the weigh idler transom should be readied for mounting to the adjustable idler mounting brackets See DWG E40 001 amp 008 1 idler mounting feet are not required and should be removed This can be accomplished by gas axing etc The calibration bar carry brackets should now be welded securely to the base of the transom angle iron as shown above All welding of components to the weighing idler must be performed before mounting on the weigh arms 2 Place the idler assembly gently on to the idler mounting brackets Using t
20. sources which are Menu Entry 9 Hardware input signal to the system as Tacho Frequency 50 005 Hertz generated by the speed sensor magnetic pick up or optical tachometer Simulated an internally generated 100Hz signal that is always on Tacho Source Hardware Press Clear to change Enter to accept Ext Con an internally generated signal that is only on when an external contact is closed between terminals and T In Tacho Source Simulated Press Clear to change Enter accept 9 P 3 Press E to accept and return to the Menu Entry 9 Tacho Source Ext Con Press Clear to change Enter to accept MASTERWEIGH 5MENU Menu 10 Filtering can be applied to the following functions Displayed mass rate 4 20mA mass rate output Tacho input The level of filtering is specified by a constant that may be in the range 1 second to 120 seconds Time constants greater than 120 seconds have the same effect as a 120 second constant A time constant of 1 second is equivalent to no filtering Time constants greater than 1 second introduce a delay in the rate of change of the filtered function 1 Menu Entry 10 To modify Filter factors press Enter Display Time constant is 2 secs Enter new Time constant 0 Hate O P Time constant is 4secs Enter new Time constant Tacho Time constant is 1 secs Enter new time constant Press Enter to modify the display filter
21. the highest equivalent mass rate reached then enter a value slightly higher than this level Eg if the mass rate was swinging from 20 to 0 to 20 select 22 as the null level On a correctly installed and aligned weigher this figure should be approximately 196 of capacity MASTERWEIGH 5MENU Menu 7 This entry specifies the mass rate level below which automatic zero tracking occurs and the number of belt revolutions required before a new zero level is established in the Masterweigh Control of the Autozero Alarm relay is achieved from this menu The auto zero mode will not be entered or continue unless the mass rate remains below the specified level The value is normally set at approximately 1 5 of capacity A qualifying time delay period is also provided to ensure that the belt is completely free of material Should it be necessary to clear the present auto zero value then this can be done by entering Menu 3 load zero calibration then aborting after starting the test 7 will be displayed at the right hand side bottom line of the main mass rate mass total display when the auto zero conditions are met and the Masterweigh is collecting data for a possible new zero level Note The auto zero tracking procedure is inhibited under the following conditions Masterweigh not in the mass rate mass total display mode Input tacho frequency less than 5Hz It may be required that the user wishes to know if the Auto
22. the number of Fine tune pulses per revolution is known and is not applicable to a new installation Press the Enter key to advance and the display will change to the following Most Belt Scales require to be zeroed and spanned The time required to zero and span a system is determined by the belt speed and length It is recommended that a minimum time of about 5 minutes or 1 belt revolution be used which ever is the greater be used Only full belt revolutions must be used The longer the time and hence more belt revolutions used the better Once again this entry is not normally used in a new installation Press the Enter key to advance and the display will change to the following At this point Masterweigh is ready to Entering Pulses per Revolution start counting the pulses Masterwiegh uses the number of pulses per revolution to provide a time base for zeroing and spanning To input this variable into Masterweigh mark the conveyor belt with chalk or paint a particular point on the belt If there is already a distinguishing mark on the belt use that Select a static point that can be easily used as a reference point to start and stop counting belt revolutions Set the Belt Scale running Manual entry of No of Revs or Press Enter to continue You should now wait until the mark on the belt coincides with the selected reference point and as they coincide press the Enter key The display will now change to t
23. the required number of revolutions The measuring phase of the test has finished and the resulting mass total is displayed This mass total should be approximately zero however if non zero then a new loadcell zero may be required Press the Enter key to display the millivolt offset resulting from this test 7 The new loadcell zero or offset is displayed in millivolts Press the Enter key to save this value as the new loadcell zero or press Abort to exit without saving MASTERWEIGH 5MENU Menu 4 This menu entry allows th automatic calibration of the load cell span To abort span calibration Press A revolutions as in Menu 2 during which Mass rate 1543 000 Revs 1 507 calibration weights or weigh chains are test This total is then compared with an calculate new calibration Press E expected or target weight and the span 55 total 120 000 Revs 10 the currently stored load cell span value 1 New span factor 223 580 Menu entry 4 Press E to save otherwise press A Fixed weight calibrate span 222 1 Manual entry of Span Factor 0 000 opan of 345678 123 is invalid or press Enter to continue Press A to continue opan Cal Mode Fixed Weight Press Clear to Change Enter to accept 10 Only displayed if the calculated span is out of range Current weight 120 8 tonnes Enter target weight 0 000 tonnes Press E to continue Mass rate 0 000 To Start span calibration
24. time constant The display mass rate filter time constant is shown When a time constant of greater than 1 is selected the main mass rate display is damped A new value for the display filter constant may be entered The 4 20mA mass rate output filter time constant is now displayed A new value for the mass rate output filter constant may be entered The tachometer input filter is displayed here and a new constant applied if necessary Note At each step pressing the Enter key Will save the new value If a new value has not been entered then the current value is unchanged MASTERWEIGH 5MENU Menu 11 The displayed units for mass rate will be the same as those selected for mass ie tonnes hour Ibs hour tons hour or kgs hour Menu entry 11 To modify display units Press E 2 lbs 4 tonnes 1 tons kgs Pressing the Enter key will advance to select mass units At this stage the mass units which can be displayed are shown To select the mass unit required press the number key associated with it then press the Enter key The units number selected will be shown in the lower right hand corner of the display Numbers greater than 4 will not change the currently displayed mass total and mass rate units Pressing the Enter key without entering a new unit number or pressing Abort will not change the currently displayed units Press Menu and Enter to save menu entry 12 belt speed indi
25. to be entered Where HH is the desired hours ie 12 03 etc and MM is the desired minutes ie 45 to enter 0 9 3 0 E E g 9 30 press Pressing Enter advances to Time is currently am Press to change Enter to accept Here the current 12 hour time format postfix is displayed and may be modified The user can select either am or pm Pressing Enter advances to 6 Date 29 6 94 Enter new date DDMMY Y Here the current date is displayed and may be modified 6 digit time string of the form DDMMYY needs to be entered Where DD is the desired days ie 27 04 etc MM is the desired months ie 11 05 etc and YY is the desired years 94 01 etc E g to enter 12 Feb 2000 press 1 2 0 2 0 0 E Pressing Enter advances to Day of the week Wednesday Press to change Enter to accept Here the current day of the week is displayed and may be changed by the user Pressing the or key toggles through the days of the week Pressing Enter advances to 8 Power on hours 1 Press Enter to continue MASTERWEIGH 5MENU Here a count of power on hours since the last unit re configuration is displayed This display is provided for information only it is not user adjustable Pressing Enter returns to step 1 above MASTERWEIGH 5MENU Menu 15 Masterweigh 5 provides for 2 levels of user configurable access code If no access codes are activate
26. 0 001 0 000 3 Remote totaliser pulse width 100ms Enter new value 20 1000 0 4 Menu 1 can also be used to access and modify the precision zero reference and reference voltage by pressing the C key Menu Entry 1 Parameter setup It is advisable however not to adjust this data unless the unit has been reconfigured 5 At the Menu press the Entry 1 position Clear key C WARNING Calibration data Do not modify Press A to continue 6 Calibration zero x xxx milli volts Enter new zero ref 0 000 Precision ref x xxx millivolts Enter new precision ref 0 000 9 Press E for Rate O P span calibration else press A Hate O P x xxmA C for next E to reset unit 10 1 At Menu Entry 1 press Enter to examine or modify the maximum capacity of the weigher the precision of the remote counter pulse or the remote counter pulse width 2 At this step the current feeder capacity is displayed A new value may be keyed in then press Enter to continue Otherwise press Enter with no data entry to retain existing values and continue This value sets the 100 point for the 4 20mA mass rate output signal Note that the system can measure mass rates above this value assuming the instruments remain within their normal operating range and higher values will be shown on the screen and totalised However the 4 20mA mass rate output signal will show 20mA for all mass rates above this value
27. 485 protocol RS485 communications are only available if the main board has the relevent optional components installed LK2 MASTERWEIGH 5 DETAILED DESCRIPTION Power Supply PCB Bottom Board RV1 Used to adjust the load cell excitation used in conjunction with a digital meter or the Masterweigh when menu 8 has been selected RV2 Used to boost the tachometer supply voltage when the voltage drops are evident at the tachometer due to a large separation between Masterweigh and the tachometer or due to Intrinsic Safety Barriers on the tachometer cables CPU Top Board VR1 Adjusts the LCD display viewing angle so that the display can be easily read VR2 Used to span the analog output channel Use this potentiometer with a digital current meter in series with the output Use this potentiometer in conjunction with Menu 1 Sub Menu final step to calibrate the analog output by setting the output to 20 000mA in the menu then adjusting the potentiometer until the current meter shows 20 000mA MASTERWEIGH 5 DETAILED DESCRIPTION J1 Power supply input 1 L L1 240VAC 110VAC Active J5 RS232 Communications Port 2 N L2 240VAC 110VAC Neutral 1 GND Ground 3 G 240VAC 110VAC Earth 2 TXD Transmit 3 RXD Heceive J8 Auto Zero Limit Alarm J6 RS485 Communications Port 1 COM Common contact 1 TX Transmit 2 NO Normally open contact 2 TX Transmit 3 Normally closed contact 3 COM Gro
28. BE WITHIN THE LIMITS SHOWN ACH 010 764 431 11 ELECTRONICS STREET EIGHT MILE PLAINS QUEENSLAND 4113 AUSTRALLA P O 4008 EIGHT WILE PLAINS QUEENSLAND 4173 AUSTRALIA Phone 1 7 3 841 244 Fox 51 7 3641 0065 WEB TECH AUSTRALIA PTY LTD 10 2 22 T ey Al REV weaned ias ener jon se EIE mar aeoo Lance werner E40 PLUS CONVEYOR BELTSCALE 99 E oro saa CALIBRATION BAR SUPPORTS vows perpe o ma s u fse lso ea T o ES a IF IN DOUBT ALL DIMENSIONS IN MILLIMETRES T PTY LTD 05 05 05 210 20 UNLESS OTHERWISE SPECIFIED be dide oanad ar usad for tendering Magnetic Electonic Pick Up Tachometer Magnetic Pick Up Installation NOTE The E40 may have been specified without the use of a tachometer Therefore the following section will not apply Refer to Figures 2 3 4 5 amp 6 amp drawing E40 008 on following pages The tachometer magnetic pick up electronic magnetic up provides the Masterweigh integrator with a means of calculating the belt speed Any inaccuracies in this signal will result in a weigher inaccuracy The magnetic pick up or the electronic pick up Web Tech selects the style after reviewing the conveyor technical data is activated by sprocket teeth passing the detector s sensing area The sprocket is attached to t
29. ELL SCREEN PULSE OUTPUT TACHO SCREEN 12181121485 GND TxD RxD Tx Tx Com Rxt Rx RS232 RS485 COM NO NC COM NO NC SYSTEM STATUS AUTOZERO LIMIT L LIN L2 G ALARM ALARM a e NTERCONNECTION CABLE TO BE OUR 4 CORE SCREENED SUPPLIED BY OTHERS LOAD CELLS CONTAINED WITHIN 110 240 VAC 50 60 Hz v WEIGHFRAME 0 1 Amp 240V 0 2 120V REMOTE TOTALISER E OPTIONALLY SUPPLIED 123456 0 5 m REFER TO DRAWING 2 REMOTE RATE METER E40 03 ux OPTIONALLY SUPPLIED LOADCELL JUNCTION BOX CONNECTION DETAILS SPROCKET MOUNTED TO END IDLER ROLL S Oe eS SS a RELAY ACTMATED GN MOTOR STARTUP CLEAN CONTACTS REQUIRED SUPPLY BY OTHERS 1 E LOGIC MAGNETIC PICKUP SEE DRAWING 40 05 JUNCTION BOX B ve SIGNAL 5 E SPROCKET MOUNTED END OF IDLER ROLL SEE DRAWING 40 06 _______________ TYPICAL ELECTRICAL CONNECTION WHEN APPROX 2m GF CABLE SPEED SENSOR MOT USED SUPPLIED EITHER SENSOR MAGNETIC PICKUP DETAIL TYPICAL SEE DRAWING E40 04 WEB TECH AUSTRALIA PTY LTD DRAWING Na 11 ELECTRONES STREET ERI ME PLANS APAIN 2113 AUTUA E40 02 teak art ram M E40 02 B ELECTRICAL CONNECTION DIAGRAM FOR E WEB TECH BELT
30. HOLES IN BED ROLL SED ROLL T BERNARDI A 0703 ORIGINAL ISSUE NOMINAL SIZE UNLESS OTHERWISE STATED UNTOLERANCED DIMENSIONS TO BE WITHIN THE LIMITS SHOWN WEB TECH AUSTRALIA PTY LTD DRAWN TONY BERNARDI CHECKED E40 CONVEYOR BELTSCALE Ww DRAWING No 1 E40 006 A CUSTOMER PROJECT APPROVED DATE APP D MACHINING MAGNETIC ELECTRONIC PICKUP SPROCKET SCALE CAD FILE FABRICATION INSTALLATION DETAILS DO NOT SCALE F40 nns IF IN DOUBT ASSEMBLIES ALL DIMENSIONS IN MILLIMETRES UNLESS OTHERWISE SPECIFIED ASK Magnetic Electonic Pick Up SPROCKET ALIGNMENT TOOL SIZED TO SUIT IDLER ROLL SHAFT DIAMETER Fig 2 SPROCKET WITH ALIGNMENT TOOL IN PLACE Fig 3 ROLL SPROCKET amp ALIGNMENT TOOL IN PLACE PRIOR TO DRILLING FIXING HOLES Fig 4 Magnetic Electonic Pick Up ELECTRONIC PICK UP ASSEMBLED ON SUPPORT BRACKET Fig 5 WELD HERE DO NOT WELD WITH THE PICK UP IN PLACE MAGNETIC PICK UP ASSEMBLED ON SUPPORT BRACKET Fig 6 WELD HERE DO NOT WELD WITH THE PICK UP IN PLACE Voltage Select Switch Only used when MW5 is powered using AC IP 65X Rated Enclosure On Off Switch b bitte o M 4 Ban gt 11 moyUnmmuctEmmt
31. OPERATION amp INSTALLATION MANUAL WTE40 Belt Scale with Masterweigh 5 Integrator Web Tech Australia Pty Ltd Head Office Sydney Office 11 Electronic Street PO Box 4006 Phone 02 9757 2296 EIGHT MILE PLAINS QLD 4113 EIGHT MILE PLAINS BRISBANE QLD 4113 Phone 07 3841 2844 AUSTRALIA Fax 07 3841 0005 WY AUIS 2 E40 Basic Site Requirements 3 Weigher Description E40 Components 4 9 Installation Mechanical amp Electrical Details 9 18 Weigh AFMS e 9 14 Magnetic Electronic Pick Up 15 18 Masterweigh 5 19 28 C legii e 29 34 Masterweigh 5 Detailed Description 35 41 Masterweigh 5 Menu Functions eeu 42 65 Keyboard Layout 42 43 MEDU qmec n 44 45 MONU p p ee ee 46 IVIOCTIU GS E X 47 48 49 51 MONU 52 MONU O 53 E a TE 54 55 MONU 9 56 MENU TO 57 MeDU ATG 12 iau Ex 58 59 Menu 13 X RAR RR 60 MENU De 61 62 MENU 19 E NOS 63
32. alculate the number of pulses per revolution and the display will change to the following By pressing the Enter E key the calculated data is stored in Masterweigh memory and will be used as a time base for zeroing and spanning calibrating Pulses per Revolution Press E to save otherwise press A The display will now return to Menu 2 entry display showing the new data If the A key was pressed no calculations would be done and the display would show oreviously stored data Zeroing Masterweigh Advance to Menu No 3 by pressing the key The display will now look like the following Press the Enter key to gain access to the menu The display will now look like the following Menu entry 3 Zero cal 20 010mV Ztrk 0 010 To proceed with the zero calibration press the Enter key to continue The display will change to that shown below Manual entry of zero error 0 000mV or press Enter to continue A zero as displayed in Menu 8 can be entered here Note that the entry of data at this point only assists Masterweigh in finding an average zero and does NOT negate the requirement to run the zero test Press enter again the display will change to the following Press E to continue Mass rate a aaaa Where a aaa shows the current zero if the belt is running This data is raw that is not adjusted by the computer and will be changing frequently This information is mostly used by tec
33. b where the humidity is high Coil the excess load cell wire and fit it into the box prior to sealing the junction box Avoid the use sealants the mechanical seals on the junction box will keep water and dust out if the box is screwed down properly DO NOT USE SEALANT THAT RELIES ON ACETIC ACID TO CURE THE COMPOUND Tachometer Magnetic Pick Up Speed Sensor Masterweigh 5 can utilise a wide variety of devices to provide belt speed indication Masterweigh can also function without belt speed indication However the accuracy of the system will be degraded Determine the type of speed sensor to be used and connect as shown in the drawing E40 04 It should be noted that magnetic pick up assemblies require that they be correctly installed mechanically See the accompanying manufacturers manual Wrongly set air gap between the toothed sprocket and sensor or low sprocket rotational speed will cause MW5 to operate incorrectly Masterweigh Connections Using drawing E40 01 proceeded with the terminating of the field wiring Power PCB Power is connected to MW5 at terminal J1 located on the lower PCB Masterweigh 5 can be powered using 240 or 110V AC 50 60 2 The slide switch on the power pcb selects the voltage Incorrect selection will blow the mains fuse or damage the PCB Masterweigh 5 is protected against most industrial electrical noise however excessive noise can in certain circumstances cause problems If the
34. cation This entry displays the current belt speed in metres second or feet minute if the mass rate unit is in tons or lbs based on the total belt length in metres Menu entry 12 Belt speed 3 10 metre second Belt load 75 015 kg metre Press E to continue Current belt total length 200 000m Enter new belt total length Enter measured belt speed in metres min 0 000 Press E for belt length Calculated belt length 0 000 metres Press E to save otherwise Press A 1 This entry shows the current calculated belt speed Press Enter once view the current belt loading 2 The current calculated belt loading will be displayed in the appropriate units Kg m or Lb ft depending on the mass units selected This belt loading is calculated from the current Mass Rate and belt speed 3 The current value for the belt length is shown If the belt length is known enter it here 4 If the belt length is not known and an accurate belt speed has been physically measured from the belt itself the Masterweigh can calculate the belt length Enter the measured belt speed in the units MASTERWEIGH S5MENU shown then press E to calculate the new belt length 5 If you entered a belt speed this value will be the calculated belt length If it seems correct Press enter to save the value or abort to ignore the calculation Note that if you entered a belt length in step 3 and not a belt speed in step 4 this valu
35. ction Box E 1 For the sake of clarity The Tachometer Encoder has been shown attached to the Weigh Idler 7 gt any idler within 2m of the weighing area could be used If the tachometer encoder is to be fitted to the Weigh Idler The installer must make sure the cable does not affect the weighing performance NOTE WELDING PROCEDURES FOR WELDING IN THE VACINITY OF LOAD CELLS 5 2 Ifthe idler has been supplied with feet They should be removed as shown above 5 3 Itis important that the distance between the weigh idler and the upstream and downstream pitch be equal on both sides All Web Tech s product calculations will have been based on a pitch of 1m E Consult the factory if you are changing gt 3 4 If sprocket has not been fitted by factory use the supplied jig to accurately align the sprocket with 2 the roll It is important that the sprocket is concentric with the roll NOV AVAVAVAVAVAVAVAVAVAVAVAVAVAVAVAVAVAVAVAVAVAVAVAVAVAVAVAVAVAVAVAVAVAVAVAVAVAVAVAVAVAVAVAVAVAVAVAVAVAVAVAVAVAVAVAVAVAVAVAVAVAVAVAVAVAVAVAVAVAVAVAVAVAVAVAVAVAVAVAVAVAVAVAVAVAVAYAVAVAVATAVAVAVAVAVAVAVAVAVAVAVAVAVAVAVAVAVAVAVAVAVAVAYAVAVA Us 40 Components LHS Weighing Arm RHS Weighing Arm showing Load Cell Fitted showing Load Cell Fitted Tachometer Sprocket Target Electronic Magnetic Pick Up Web Tech to select either this device or standard magnetic pick up style Magnetic Pick Up Web Tech to select either thi
36. d 2 Optional Using a digital voltmeter measure the belt zero error value in millivolts at the loadcell or read the mV level displayed in menu 8 Manually key in the value to the Masterweigh and press the Enter key to accept Otherwise press Enter with no data entered to continue with no change Note that entering this value does not negate the need to perform a zero calibration 3 The live zero error is now displayed as a mass rate Press Enter for the loadcell calibration procedure 4 The mass total will now display zero Check that the belt is empty then press the Enter key to begin the zero calibration test 5 The difference between the current loadcell zero and the actual load reading is accumulated over the test duration which is the total number of belt revolutions specified in menu 2 The test can be aborted at any time by pressing the Abort key If the test is aborted the working copy of the load zero is reinitialised from the stored load zero calibration value This working copy normally includes contributions from both MASTERWEIGH 5MENU Menu 3 the load zero calibration as carried out in this menu entry and the auto zero tracking function It is thus possible by entering the menu to this level and then aborting to reinitialise the working copy of the load zero and remove any auto zero tracking contribution 6 This display will come up automatically when the belt has completed
37. d all Masterweigh 5 menus are accessible all the time An Operator and a Configuration access code may be entered As soon as an access code is activated the user cannot leave the main mass rate total menu and gain entry to the menu system without entering a valid correct access code Entering the correct Configuration access code allows full access to all Masterweigh 5 menus and parameters Entering the correct Operator access code allows limited access to the Masterweigh 5 menu system Step 1 of this menu displays 1 Menu Entry 15 Press Enter to modify access codes Unless the special security key has been installed in link 3 of the CPU PCB the following menus cannot be accessed If the security key is installed then pressing Enter advances to 2 Operator Access Code Enter access code 0 Here a new Operator access code may be entered this can be a number in the range 1 to 32766 Note that entering and Operator access code of 0 zero clears the Operator access code If the security key is installed then pressing Enter advances to 3 Configuration access code Enter access code 0 MASTERWEIGH 5MENU Menu 16 This menu controls the automatic report printing function of the Masterweigh 5 This menu is only accessible if the real time clock module has been installed It is possible to configure the Masterweigh 5 to automatically produce a report via the 5232 serial port on either a
38. e hardware required for the use is an optional extra and therefore only supplied to order Assuming that your system is rigged for R Cal proceed as follows Initially calibration Menu 4 should be accessed and the enter key pushed until the sub menu Span Cal Mode is reached Menu 4 Span Cal Mode R Cal Press Clear to change Enter to accept Toggle the clear key until R Cal has been selected Now proceed as for normal calibration which is performed as described under Menu Entry No 4 When Masterweigh 5 completes the test MASTERWEIGH S5MENU Menu 5 This menu entry enables the entry of manual belt totalizations and the resultant 1 At menu Entry 5 press Enter to proceed recalculation of the load cell soan To use this calibration facility it is necessary to 2 Enter the exact mass total as measured weigh a quantity of material with the belt by the weighbridge Press Enter when the scales and then to accurately determine the data is correct actual mass of that material by independent means i e via a weighbridge The two 3 Enter the mass total as measured by the totals are then entered and the weigher Press Enter Masterweigh computes the new span factor 1 4 Press Enter to store the new span value as the load cell span calibration factor Press Abort if no update is required Press Menu entry 5 Menu and Enter to save Empirical calibration soan 211 7 Enter weigh bridge total 0 000 Enter
39. e will be meaningless Press E to continue MASTERWEIGH 5MENU Menu 13 Menu entry 13 Press C to clear Mass Total When the mass total on the mass rate mass total display MRMT is to be zeroed press C at Menu Entry 13 All totalised figures are then cancelled by the integrator Press Menu then Enter to return to the MRMT display MASTERWEIGH 5MENU Menu 14 This menu controls the operation of the Masterweigh 5 real time clock The real time clock is a separate module with its own battery power source that will continue to keep accurate time even in the case of power loss to the Masterweigh 5 unit This menu is only accessible if the real time clock module has been installed Step 1 displays the following current time date and day of week information 1 Wed Date Menu entry 14 Time 09 12 43am Elapsed Time Press clear to reset 0 days 00 19 58 hours Clock is currently in 12 hour mode Press to change Enter to accept Above is a free running elapsed time clock Pressing Clear will reset the elapsed time counter Pressing Enter advances to 24 Hour clock The Masterweigh 5 real time clock can be configured to display the current time in either 12 or 24 hour mode the selection is made in this menu Pressing Enter here advances to Time 09 13 56am Enter new time HHMM Here the current time is displayed and may be modified A 4 digit time string of the form HHMM needs
40. een in operation for many years and has been proven in the field and tested by the National Standards Authority of Australia The tests on the core proved that the instrument is accurate to 0 1 over its operating range The operating environment is based on a series of discrete Menus Each menu allows the user to set up a working environment or calibrate the system For a detailed description of each menu refer to Section OP 3 OPxx of the manual Note that detailed information relating to the keyboard operating command procedures is to be found earlier in this manual Load Cell Input and Excitation The Masterweigh is designed to accept a load cell millivolt signal in the range 0 to 32 millivolts with a resolution of approximately 4 microvolts An on card voltage source provides excitation for the load cell This source can provide excitation for up to four 350 ohm load cells in parallel The excitation is not precisely controlled but is maintained within approximately 1 percent of the set value The Masterweigh monitors the excitation voltage automatically compensates for any voltage change that may occur he excitation is adjustable over a wide range to enable optimum performance to be obtained from a wide variety of load cells The Masterweigh may be configured to provide either a positive excitation voltage referenced to ground unipolar or a plus minus bipolar voltage by configuration of links The pos
41. enu 1 set up There is no provision for zero adjustment on the analog output Earthing This is achieved by installing the shunt on LK1 link located on the lower pcb above the capacitors Installing this link will connect the Masterweigh s digital analog grounds to power earth Display Backlighting The liquid crystal display used in the Masterweigh provides LED backlighting for improved readability under adverse light conditions If the unmarked key has not been activated then the display will switch off if any key has not been used within 5 minutes system Output Status A voltage free contact has been provided for remote monitoring of the Masterweigh autozero function If the autozero function returns a value that is outside the high and low limits that were set in Menu 7 the relay will energise It will remain energised until an operator initiated zero is performed in Menu MASTERWEIGH 5 DETAILED DESCRIPTION Power Supply PCB Lower Board LK1 Grounding When the shunt is in position Masterweigh is referenced to ground When open Masterweigh is floating LK2 Excitation Selection This link allows the user to select either a unipolar or bipolar excitation voltage Refer also to Section Load cell Input and Excitation Unipolar OV is used for excitation voltages in the range 4 to 13 volts Selecting bipolar VE allows a plus minus excitation with a total voltage within the range 16 to
42. erial port every time the increment is added to the mass total ie a total increment of 2500 tonnes will cause a report to be automatically printed at 20000 tonnes 22500 tonnes 25000 tonnes 27500 tonnes etc Pressing Enter here returns to step 1 above The RS232 Parameter are Baud 19200 bps Data bit 8 bits otop bit 2 bits Parity None MASTERWEIGH S5MENU Under some circumstances Masterweighs memory can be corrupted so that correct operation of the unit is not possible This condition can occur if Masterweigh has been subjected to severe electrical noise or spikes These phenomena usually occur 240 110V AC power lines however they can also appear on the load cell input cables as well as the tachometer cables Masterweigh has been protected as far as possible however severe noise or spikes can get through Once any part of memory has been corrupted Masterweigh will detect it and automatically flag an error If the corruption has only changed data an error may not be detected and some erroneous results may occur The only way to clear the memory of this data is by re initialising Switching off and on will not clear the memory The act of re initialising causes all the calibration data to be lost and replaced by factory data The calibration data specific to your application can easily be re entered if you have kept a note of what was in the menus Menu 1 however does have specific data that is logged o
43. esentative amount of material over the conveyor and weigher The load is then taken over a recently calibrated static weigh bridge weighed and the weight logged The results from the static weighbridge can then be entered into the Masterweigh 5 integrator Masterweigh 5 will then calculate a calibration constant that will cause the E40 belt scale to accurately calculated the weight passing over the weigh section in the conveyor
44. eter is normally selected for the user by the factory Selection depends on rotational speed of the pick up pulley which in turn is supplied by the user Note that the tacho frequency has no affect on the rate at which the load cell signal is sampled Pulse Output The Masterweigh provides a pulse output for external accumulation of the mass total Masterweigh provides for three methods of indicating when an increment Masterweighs total has occurred An Internally Generated 5VDC Pulse An Internally Generated 28VDC Pulse Contact closure from an internal relay providing voltage free contacts Which of these options is used can be selected from links LK6 LK7 Lk8 and LK9 as shown in the USER CONFIGURATION section The pulse duration is adjustable in Menu 1 One pulse is output each time the least significant mass total digit displayed is incremented by 1 count A minimum of 20 milliseconds is guaranteed between pulses thereby providing a maximum pulse rate of 25 pulses per second 20 milliseconds on plus 20 milliseconds off The internal 45V supply is regulated to 5V It is not isolated from ground External load resistance should not be lower than 50 ohms MASTERWEIGH 5 DETAILED DESCRIPTION The internal 28V is unregulated and may vary over the range 25 35V It is isolated from ground to allow configuration of a fully isolated pulse output This 28V supply is shared with the 4 20mA analogue lo
45. he bed roll as shown in figures 5 amp 6 The detector is held in place by means of a bracket see figures 5 amp 6 which is welded to the angle forming the base of the idler transom Two bracket designs are shown The bracket shown in Fig 5 positions an electronic pick up An electronic pick up is used when the belt speed is low The factory selects the pick up to be used The sprocket s teeth passing close to the pick up when the roll is rotating results in an electrical pulse being generated If the sprocket is not accurately fixed to the idler roll the signal amplitude will be affected resulting in inaccurate integration Therefore it is important that the sprocket is accurately fixed to the bed roll of an idler adjacent to the weighing idler The sprocket and pickup must not be fitted to the weighing idler If it is fitted to the weighing idler assembly the wiring to the pick up can adversely affect the load cell out put and there is a high probability of destroying the load cells when welding the pick up support bracket to the idler angle base Web Tech offer an in house idler modification service using customer supplied idler assemblies or Web Tech can supply the assembly If the assembly has been modified by Web Tech the following works will have been done Feet removed from weighing idler Sprocket accurately fixed to a roll Pick up support bracket fixed to adjacent idler angle base For those customers who are
46. he following Where xxxx Pulses accumulated since pressing the Enter key Where yyyy Time in seconds elapsed since pressing the Enter key Masterweigh should now be switched on Press Menu key and then to advance to Menu Entry No 2 If the instrument is new it may show the following To stop belt pulse count Press E Menu Entry 2 Pulses counted yyyy Time xxxx Pulses per rev 21000 Revs 5 On pressing the E Enter key Masterweigh will start counting pulses and showing elapsed time When the minimum time 5 minutes or the minimum 1 belt or the desired time belt revolutions revolution has occurred press the Enter key again The entry shown above is a factory setting The variable entered her will be application specific To gain access to change these values to the application specific values Note Web Tech advises using 5 belt revolutions or more assuming that 5 belt revolutions take longer than 5 minutes and that full belt revolutions only are used The display will now change to the following Where number of pulses counted number of pulses counted Enter number of belt revolutions 0 Pulses counted yyyy time You should now enter the number of complete belt revolutions that have occurred since the start and stop of the test When the correct number of revolutions have been entered press the Enter key and now Masterweigh will c
47. he idler fixing brackets bolt down the idler transom as shown below The idler must be accurately mounted on both weigh arms Use the string lines to achieve the required alignment 3 Electric MIG TIG Stick welding can damage the load cells if stray electrical currents are allowed to flow through the load cells The earth clamp of the welder must attached to either the idler mounting bracket or the idler assembly The earth connection must be good and secure during the welding procedure omn 4 Following the fixing of the idler assembly to the E40 weigh arms the wiring needs to be installed See drawings E40 01 E40 02 E40 03 amp E40 04 Install conduit or other means of protecting the load cell cables on their passage to the load cell junction box T Remove the string lines and lower the belt Load Cell The load cells supplied are an 5 type cell hermetically sealed and sized to suit the application They are used in tension and are fixed to the weighing mechanism by means of two swivel joints To protect the load cells from the possibility of being over loaded an overload stop has been provided The over load stop will only protect the load cells from overloads not exceeding 150976 of the rated capacity The over load stops are usually set at the factory Generally a gap between the screw and swivel joint knuckle should be 2 5mm Set over load gap at 2 5mm using the overload stop bolt
48. he value in mV above which it may be considered that an invalid Autozero is taking place MASTERWEIGH 5MENU Menu 8 amp 9 This entry displays the load cell input in millivolts The displayed value is unaffected 1 by the load zero load calibration and zero tracking functions The entry also displays Menu Entry 8 the excitation voltage as currently sensed Loadcell 16mV Extin 10V by the Masterweigh It is displayed to the nearest volt only ie 10V is in the range 9 501 to 10 5V It is updated once every 3 minutes V to F count xxxxx This display enables a user to confirm that Press Enter to continue the Masterweigh is correctly sensing the excitation voltage and thus that all links etc This facility is for technician s use only are correctly installed Incorrect excitation sensing will result in inaccurate and 1 Menu Entry 8 displays the load cell unstable mass rate measurements Access millivolt output and excitation voltage is also available to the output of the voltage to frequency converters 2 Press E to access the current V to F output 3 Press E again to return to Menu Entry 8 menu entry 9 tachometer frequency This entry displays the current tacho Press E to enter the menu to select the frequency in hertz the input range is 5Hz source of the tachometer signal to 1000Hz and switches between software or hardware inputs Press C to change or toggle between the available pulse
49. hnicians Press the Enter key again and the display will change to the following Zero reset To start zero cal Press E Mass rate 0 000 Revs 0 0 Masterweigh is now ready to zero and will as soon as the Enter key is pressed again Masterweigh did not start executing its Zeroing immediately because it gives time to make sure that the belt is empty most important After confirming that the belt is empty press the Enter key to start the zeroing The display will now change to the following Where a aaa the zero error the number of belt revolutions completed To abort zero calibration Press A Mass rate a aaa Revs Once Masterweigh has completed the test the display will change to the following Where Z ZZZ the totalised value of the mass rate found during the routine r r the number of belt revolutions To calculate new calibration Press E Mass total z zzzz Revs x x By pressing the Enter key at this point Masterweigh will calculate a new zero If something went wrong during the test e g material did accidentally get onto the belt pressing the Abort A key will cancel the test Following the pressing of the Enter key Masterweigh will display the zero as a voltage output from the load cell and once again give you the ability to cancel out the result Masterweigh will also cancel the tests if the results from that test fall outside preset limits See the
50. is shown the number of belt revolutions is zeroed Press the Enter key to start the test Once started the test will run until the currently specified number of belt revolutions has been counted Refer to Menu 2 During this step the weight Is totalised over the specified number of belt revolutions after which time the totalisation is automatically stopped If the Enter key is pressed during the test then the totalisation will be terminated with a mass total of zero The test can be aborted at any time by pressing the Abort key The resulting mass total is displayed along with the number of belt revolutions counted Press the Enter key to calculate the new span calibration factor The new derived loadcell span is displayed Press the Enter key to save this value as the new loadcell span Press the Abort key if this value is not to be stored Should the span value calculated be outside the range 0 1 to 3000 then the Masterweigh will display a warning message Under these circumstances the new span will not be saved and the unit will revert to the value previously stored Calibration Methods Ideally conveyor belt scales should initially be calibrated using empirical data obtained from accurate static scales However in most situations this task is impossible to achieve but the fact remains that there is no substitution for data being input to Masterweigh 5 that has been derived from real material bearing down on the
51. itive voltage is continuously adjustable from 4 to 12 volts The negative voltage is set at 12 volts The Masterweigh is factory set for a unipolar excitation of 10 volts Following adjustment of the excitation allow a minimum of 30 seconds for the Masterweigh to update its internal excitation reading before proceeding with calibration functions The approximate value of the excitation voltage sensed by the Masterweigh is displayed in Menu 8 This should match the voltage sensed at terminals J3 pin 12 and 13 if link LK3 is correctly installed and should be checked when configuring the Masterweigh Allow 30 seconds for update of display after adjusting the excitation Incorrect configuration of excitation sensing will cause erratic mass rate readings The millivolt input accepts either differential millivolt signal or a half bridge input and will operate accurately over a common mode range of minus 8 to plus 8 volts The input is overload protected to plus or minus 35 volts on either terminal with the Masterweigh energised and plus or minus 20 volts on either terminal when not energised Transient overload capacity is much higher than this continuous rating MASTERWEIGH 5 DETAILED DESCRIPTION Load cell Input and Excitation Contd The analog digital conversion is performed using voltage to frequency conversion techniques thereby providing excellent rejection of signal noise over a wide frequency range
52. load cell via the weighframe carriage at representative speeds A calibration chain a device that rolls on top of the belt provides the next best method of calibration and check calibration It imparts load to the cells through the belt but can not simulate belt tensions as a fully loaded belt does MASTERWEIGH 5MENU Menu 4 note the number but do not accept it by Static calibration weights are often used pressing enter Press the Abort key where a chain is impractical to use Bars of a known weight are loaded directly onto the total achieved should be logged and weighframe and hence simulated a load future R Cal tests reference to it If the This method does not take into value recorded in subsequent tests consideration belt tension or weight transfer exceeds 0 5 of the original value through the belt It does however exercise perform a full calibration using weights etc the weighframes mechanics Note Zero system prior to R Cal test R Cal is an electronic method of checking the calibration A simulated loadcell signal is created by running the belt empty and electronically unbalancing the loadcell by switching in a reference signal across one arm of the loadcell bridge This method provides a reasonable method of quickly checking a weightometer but is no substitution for the aforementioned calibration methods The software required to implement this function is supplied in all Masterweigh 5 units but th
53. m OF CABLE SUPPLIED PICK UP SUPPORT SOLID STATE LOGIC PICK UP SPROCKET WELD TO IDLER ANGLE REMOVE LOGIC PROBE FIRST ADJUST TO APPROX mm og oe AUSTRALIA WIN THE Ls PSO t APPROVED LH Pheng 61 7 3041 204 Rm 61 7 2841 E40 CONVEYOR BELTSCALE EE SOLID STATE PICKUP JUNCTION BOX CONNECTION DETAILS sos sos 10 20 The orang od nana eerie mattar met aut hi tht ALL DIMENSIONS IM MILLIMETRES She papery ab WE BUAPT LO ean ASSEMBLES tos evo UNLESS OTHERWISE SPECIFIED and uel ah M oF rud far tanearing ici for ong ether purpoen without thelr writin permiminn Drawing E40 06 a ee a a Ss eS er CONTAINED WITHIN MASTERWEIGH ENCLOSURE a 5 e uu 3 286 8 L a amp gt om gt zm 2 wow ux a 2 on 6 LL TA ee FR Ree r gt a o6 0 0 15652 x gg p ER oz du dc ww o 55 o S 3 3 dc gt 5 iun A in T e O I ada d 3 z AA G HEE HH HH Bo HB Hc EES 28685 COM NO NC COM NO NC GND TxD RxD Tx Com Rx4 Rx SYSTEM STATUS AUTOZERO LIMIT Lor 2 4 LATNA2 ALARM ALARM 2 RS232 RS485 xog
54. mains supply is Suspected as being noisy an external mains filter should be used The relays on the power pcb are rated at 0 5A 240VAC and therefore should not be used to switch large loads or high voltages Masterweigh 5 can also be ordered using either 12 24 or 48VDC as a power source When DC power is used the connector is still referred to as J1 The pcb is marked with to indicate polarity The same wiring precautions as described in the connecting of AC power above must be observed Field Wiring Main PCB Top PCB Only the low voltage field wiring is to be terminated on this PCB See dwg E40 01 The load cell wiring is terminated across J3 10 11 12 13 It is important to tie the screen down and make sure all connections are secure On power up the out put from the load cell can be viewed in menu 8 or on a digital volt meter placed across pins 10 amp 11 lead on 10 amp lead on 11 with the scale set to millivolts If connected correctly the output from the load cell should be approximately 0 1 to 15mV Check the wiring if these approximate voltages are not observed The speed sensor wiring is applied across J3 3 4 amp 5 On power up and with the conveyor running The signal from the sensor can be observed in Menu 9 Masterweigh accurately measures and displays the output from the speed sensor to a high precision The frequency signal should be reasonably steady assuming the conveyor speed is
55. n increment of the main totaliser s least significant digit This pulse has been designed to drive plc input or an electronic counter Use 28 volt for electromagnetic counter The type of pulse is determined by the settings of the links LK6 LK7 LK8 LK9 on the lower pcb Link set up as shipped Voltage free contacts selected In this situation the setting of LK8 amp 9 is irrelevant KG LK7 LK8 LK9 INT 1 6 1 t m 1 g 5V 28208 282 EXT M 3 3 9 3 9 28v Masterweigh sourcing 5 Volt pulse Fig10 An 18 METOEDE M Masterweigh sourcing 28 Volt pulse Fig 11 n m 050 4080 Load Cell Voltage Select Use only the following set up for all conveyor belt scales OV 2LK 2 VE B Cell Type Selection Use only the following set up for all conveyor belt scales Fig 12 Fig 13 123 LK LOAD MICRO Load Cell Excitation Voltage Adjustment This potentiometer is used to boost the load cell supply voltage Generally this is only required if the load cell voltage at the load cell is less than 10 Volts S 2 Fig 14 RV2 Tacho Boost Adjustment This potentiometer allows the user to increase the voltage as measured at the electronic speed sensing device The E40 series may have been supplied with an electronic magnetic pick up If this is the case the factory will have adjusted RV2 to 10V which is the required Fig 15 RV 2 v
56. n the main under Calibration zero and Precision ref LOG ALL CALIBRATION DATA AS YOU MAY NEED TO MANUALLY RE ENTER IT AT A LATER DATE TO RE INITIALISE MASTERWEIGH 5 PROCEED AS FOLLOWS Switch off Masterweigh oimultaneously press the Blank and Abort keys With both the above keys pressed switch Masterweigh on The display will now show the message Press C to Configure Any other key to continue Now press the C key and Masterweigh will return to normal running mode Masterweigh is now configured to factory defaults Press Menu to enter menu entry 1 then press C to enter the calibration data section The display will warn you not to continue Press E to continue The display will request a new Calibration Zero to be entered Enter the value that is engraved onto the right hand side of the main pcb under the label Cal Zero then press E The display will request a new Precision Reference Enter the value that is engraved onto the right hand side of the main pcb under the label Prec Ref then press E Press M then E to return to normal running mode Remember If MW5 is reconfigured all calibration data is lost Keep Notes CALCULATING THE TARGET WEIGHT CALIBRATION USING CALIBRATION BARS If a static weigh bridge is not available The following procedure can be used to calibrate the E40 belt scale The method requires the application of a known weight to the weigher If a fact
57. ned to accept a voltage input of 2 5 to 50 volts peak and so will accept either TTL or sinusoidal voltage input The input threshold voltage is 1 2 volts at the positive input with respect to the negative input The negative input is directly connected to the Masterweigh grounds Avoid earthing this input in the field as it will create ground loops The tacho input will not accept frequencies in excess of 800 Hz approx A regulated 5 volt supply is provided for energising a digital pulse generator This supply is rated at 200mA maximum and is overload and short circuit proof with fold back current limiting It may be necessary to briefly remove all load after removing a short circuit in order to reset the protection circuit Short circuiting of the tacho 5 volt supply will not affect the Masterweigh CPU operation Masterweigh is fitted with a potentiometer RV2 to adjust the tachometer s 5V rail if required Normally only used when the tacho supply drops to a voltage where the tachometer ceases to work owing to significant voltage drop from long cable runs IS barriers or the like CAUTION Application of an external voltage source to the tacho supply terminals may cause damage to the Masterweigh b Frequency Selection The tacho generator should be selected and fitted to provide a frequency input to the Masterweigh within the range 5 to 1000 Hz to ensure compatibility amp accurate measurement The tachom
58. ng the Enter key again the AS POSSIBLE display will change to the following At this point the required number of belt A MORE DETAILED EXPLANATION OF revolutions over which the auto zero will THE AVAILABLE FUNCTIONS ARE be accomplished can be set DETAILED IN THE FOLLOWING SECTION Enter number of belt revolutions 0 Pulses counted time Note by entering into this entry the Autozero mode is switched off When the desired variables have been set into this menu press Menu followed by Enter to save and exit Note When the autozero is running a lower case z appears on the MRMT display when load is detected it will be switched off Should an E appear where the z normally appears it means that the signal from the load cell has gone negative with respect to the normal load cell output The lower the autozero tracking level selected the more sensitive Masterweigh is to detecting a relatively negative signal the appearance of the E during normal operation signifies to the operator that the weighframe should be inspected for mechanical damage or positional change MASTERWEIGH 5 DETAILED DESCRIPTION Introduction Masterweigh 5 is a precision microprocessor based instrument designed for the accurate weighing of material being transported by a conveyor belt The core of Masterweigh 5 is derived from the highly successful Masterweigh 1 core The Masterweigh 1 design has b
59. nveyor should be free from interference from all other operations 6 The system should be designed so that the complete contents of each load passes over the scale 7 Sufficient impact idlers should be provided under each infeed so as not to cause a deflection of the belt at the feed point 8 The feed rate should be between 30 and 95 of full scale It must be adequate and constant 9 A Windscreen should be erected around the entire weighing element unless it is not exposed to wind forces 10 Adequate access to the scale must be provided All gates and feeders associated with the weighing conveyor must be designed so that the material will flow freely when operated and not leak material when stopped 11 The troughing angle of the idlers must not exceed 45 degrees 12 The conveyor should be equipped with gravity type belt wipers if material build up on the belt is a problem 13 Belts with edges moulded or vulcanised onto the carrying surface should not be used 14 Belt soeed should not exceed 1 6 metre per second on a belt of 8 metres or less E40 Components Inline Weigh Idler Belt Travel Direction The E40 MUST be square with respect to the conveyor stringers on both sides Magnet Pick Up Electronic Flexures LHS Flexures RHS Magnetic Pick Up Electronic Pick Up Calibration Bar Carry Bracket RHS Weigh Arm LHS Weigh Arm Load Cell Junction Box Tacho Encoder Jun
60. oltage for an electronic magnetic pick up Note if a regular magnetic pick up is X employed the voltage should be 5 Volts less than 4 7 Volts will make the output signal unreliable S Auto Zero Alarm Masterweigh 5 if configured to do so will perform an automatic zero Under certain circumstances the zero can accumulate an unacceptable value This can be due to a number of operational factors e g product build up on the belt or rolls Masterweigh can track this build up and flag the user if the build up exceeds a programmed value The output provided is a clean set of contacts Connector J8 COM NO NC System Status A relay and contacts have been provided to provide the user with a means of monitoring the operational status of Masterweigh 5 If the electrical supply is unavailable or an internal error is detected then the relay contacts will change over Connector J7 COM NO NC General Arrangement Drawing E40 01 3 r a 5 8 10 Fn POWER 240VAC 110VAV MASTERWEIGH 5 50 60 Hz POWER 12 24 48VDC MUST BE PRE ORDERED 12 24 48 VDC 954 6 2 CONTAINED WITHIN WEIGHARM REMOTE RATE METER FR 7 OR PLC LOAD CELL OPTIONALLY SUPPLIED JUNCTION BOX d CONI ANED 100 2 CORE OVERALL SCREENED P 4 CORE OVERALL SCREENED INSTRUMENT CABLE L INSTRUMENT CABLE 3 CORE OVERALL SCREENED INSTRUMENT CABLE
61. op output and is rated at 400mA continuous maximum current The contact closure is completely isolated and is rated at 32V maximum and 500mA maximum t must not be used for 110V or 240V operation All pulse outputs are protected by 2 of 500mA fast blow fuses F2 and Analog Output The Masterweigh provides one analog output channel The output operates over a 4 20mA range and provides a resolution of better than 0 5 It operates as a loop powered configuration therefore derives its operating power from the 4mA residual loop current A minimum of 20 volts is required to operate with zero ohms load rising by 1 volt for every 50 ohms of load ie 30 volt supply required for 500 ohm load The output can operate with supply voltage of up to 50 volts and provides excellent rejection of power supply ripple and noise The loop power supply thus need not be heavily filtered or regulated An unregulated DC supply is provided on the Masterweigh board which can be used for energisation of the analog loop This supply provides a nominal 28V DC and is isolated from the Masterweigh ground Links are provided on the board to enable this supply to energise the analog output To use an external loop supply configure links LK4 LK5 on the board appropriately and connect the external supply in series with the analog loop opan calibration of the output is readily performed by accessing the analog calibration in the M
62. ory produced calibration system has been purchased The weights will be in the form of zinc plated galvanized flat bar The length and total weight of the bar bars will have been selected by Web Tech following inspection of the conveyor data supplied by the purchaser Data Required To Calculate the Target Weight 1 Total Weight of the calibration bars We Pitch Distance between idlers Pi Belt length The number of belt revolutions used in menu 2 Rv P509 Iw Masterweigh 5 performs both the zero and calibration function over known belt lengths The computer uses the data in Menu 2 to obtain the belt length Masterweigh 5 calibrates it s self against a user generated number called the target weight Which is entered into Menu 5 The target weight is a theoretical weight that is the result of the following calculation Target Weight BI x Rv x Pi x We Eg 250 Rv 5 PI 1 We 15kg Target Weight 250x5x1x15 18 750kg The above example would be entered into Menu 4 as the Target Weight The above number is an example only and will not satisfy the requirements of your weigher unless the numbers used in the example are good for your conveyor The belt should be stopped and the calibration bars placed on the weigher With the bars on the weigher and the belt running run the calibration test in Menu 4 EMPIRICAL CALIBRATION The E40 belt weigher can be calibrated by passing a repr
63. pulses and start counting revolutions Note that the display panel will show the counting 5 After at least 5 minutes press E again to stop the count as the mark passes the fixed point 6 Key in the number of revolutions counted and press E to confirm 7 Press E to save the number of pulses rev just calibrated otherwise press A to abort and return to the original values if any MASTERWEIGH 5MENU Menu 3 This menu entry enables the operating zero to be calibrated A specified number of belt revolutions are run as determined by Menu 2 with no material or calibration weights on the belt If the zero is correct then the mass total accumulated over the period will be zero The display shows the currently stored value in millivolts as read at the load cell input including any contribution made by the autozero function Note that the zero value is automatically adjusted if the excitation voltage changes 1 Menu entry 3 Zero cal 2 563mV 2 563mV 7 Manual entry of Zero Error 0 000mV or press Enter to continue 3 Press E to continue Mass rate 0 000 Zero reset To Start zero cal Press E Mass rate 0 000 0 0 To Abort zero calibration Press A 0 0 Mass rate 0 000 Revs To calculate new calibration Press E Mass total 1 150 Revs 10 2 56 millivolts Press E to save otherwise press A Zero error 1 At Menu Entry 3 press Enter to procee
64. ral processor unit status is displayed and also the number of times the CPU has been restarted If the ma IS the CPU fault e status may viewed by pressing the Enter key in the MRMT display mode SPEED KEYS TOTAL RESET Total reset Key When this key is pressed MW5 clears the accumulated mass total Zero Key Activation of this key takes the operator directly to the belt zero function without having to scroll through the menu structure CAL Calibration Key When this key is pressed the operating display jumps to the fixed weight calibration function ready to span the system Blank Key The blank key has been deliberately left in this condition as it is a key that will be assigned to users requiring special functions ordered as option However if no options are required this key provides the user with a method of switching on and off the displays back lighting The action of this key overrides the normal timed function of the backlighting That is under normal operating conditions the back lighting will automatically switch off 5 minutes after the last keypad operation MASTERWEIGH 5MENU Menu 1 Menu 1 is used firstly to enter the maximum capacity of the weigher the precision of the remote counter pulse and the pulse width Menu Entry 1 Parameter Set Up Current capacity 1000 000 tonnes hour Enter new capacity 0 000 Mass total increment 1 000 tonnes Enter new inc 10
65. rt to flow Autozero level 20 000 tonnes hour Enter new level 0 000 Masterweigh immediately cancels the Auto zeroing and works with previously set values set these values press the enter key The display will change as shown above The level at which the flow rate must drop to prior to an auto zero being performed As some conveyors experience surges of material then run empty as part of the plant s normal operating conditions Masterweigh can if instructed delay any Auto zeroing process for a predetermined time Press Enter and the display will change that shown on the next page Enter the delay in seconds if one is lt lt _ _ TY required Setting the delay to zero will The E can also appear if the conveyor cause the auto zeroing routine to start as belt is damaged with pieces missing etc so as the selected mass rate is achieved As previously discussed the zeroing and Spanning of Masterweigh using menu 3 amp 4 is performed over fixed belt revolutions The auto zero tracking should also be performed of the same number of belt Delay before auto zeroing 60 sec Enter new delay THE PREVIOUS SECTION WAS WRITTEN TO ASSIST CUSTOMERS revolutions This is desirable but not WHO WANTED TO GET THE WEIGHING necessary SYSTEM UP AND RUNNING AS QUICK On pressi
66. s device or electronic style 40 Components Magnetic Pick Electronic Magnetic Pick Up Up Mounting Bracket Calibration Weight Bar Mounting Bracket x 2 40 Components Load Cell Metric Load Cell Imperial Load Cell Junction Box Tachometer Junction Box 40 Components Attach the Calibration Weight Bar mounting brackets here Both Sides E40 Assembly with calibration bracket and two calibration bars in place Weigh Arms The E40 Plus is an economy multi belt width single idler conveyor belt scale It has been designed for applications where a high order of accuracy is not required By virtue of it s design the E40 Plus can be used on a variety of conveyors of varying belt widths Generally conveyor belt scale designs incorporate a ridged weigh frame which provides the weighing element with a stable platform This is essential for high accuracy weighing applications However the weigh frame can be eliminated in applications where high accuracy is not required or the application is not conducive to high accuracy weighing Mobile conveyors etc In our mechanical drawings we refer to weigh quality idler assemblies These assemblies are manufactured by most idler manufacturers They are manufactured to exacting tolerances They are generally inline roll types and the transoms are manufactured true to template assuring an accurate profile is presented to the
67. section Load Zero Calibration in Masterweigh Operation Spanning Calibration There are three ways of calibrating spanning Masterweigh By passing material over the belt weighing that material and then entering that value into Masterweigh via Menu 5 Using a weigh chain Using supplied calibration bars This part of the manual will deal only with method 3 Refer to the calibration data sheet supplied with your system and the sample sheet at the rear of this manual The calibration bars supplied have been manufactured to weigh approximately 70 of the load that the weighframe will carry when the maximum flow rate as detailed in the client s data sheet is achieved With the belt stopped load all the calibration bars supplied onto the calibration bar carry brackets An even number of calibration bars will have been supplied An even number of bars should be loaded on either side of the weighing idler See figure 16 The weight of each bar has been stamped on it Now set the weighfeeder running and advance Masterweigh to Menu 4 and enter that Menu by pressing the Enter key The display will change to the following Menu entry 4 50 00 Fixed weight calibrate span The span value shown will be a factory default Following a successful calibration the value shown in Menu 4 will change to reflect the application Masterweigh will calculate the span value theoretical weight that the in
68. should be fairly stable if the conveyor is not surging or slipping Wild fluctuations generally indicate a mechanical problem With the tacho installation or conveyor drive Loadcell Installation Only fit the load cells after all mechanical works have been completed and the conveyor is ready to be run The E40 uses two tension load cells that are wired in parallel The weigh arms are shipped with the load cells factory installed and set up All wiring is to done in the field Load Cells The two load cell cables should not be shortened Shortening these cables voids the load cell manufacturers warranty Connect the load cells to the load cell junction box see drawing E40 03 Make sure the cables are protected from falling debris and other means of cable damage over the entire cable runs Connect the two cables to the pcb located in the junction box Connect the Masterweigh 5 field wiring to the same pcb It is important that all wiring is correctly terminated The load cell load cells are connected in the field using a specially designed printed circuit board located in a junction box The pcb is capable of marshalling up to 2 load cells It is important that the two load cells are correctly terminated The circuit boards unique design requires that the wiring be separated into supply and load cell output The separation of these two supplies and the use of a voltage leak shield prevents current leakage across the pc
69. steady Small variations in this signal are to be expected If the frequency varies greatly check the wiring and mechanical installation of the sensor The scale is now ready for use in it s basic form Remote Rate Signal Masterweigh 5 provides the user with a remote analogue rate signal as well as digital one on the local display The signal is a 4 20mA type capable of driving into 7500 The 20mA point coinciding with the maximum rate as set in Menu 1 and the 4mA point being zero mass rate This signal is usually used by a plc or a remote 4 20mA meter Masterweigh 5 can be the source of the current or sink 4 20mA signal supplied by other equipment This option is set by setting a jumpers link 4 amp 5 The following diagram Fig 7 shows this link set so that Masterweigh is the source of the current Fig 8 shows Masterweigh sinking an external 4 20ma supply Masterweigh Sourcing 4 20mA Masterweigh Sinking 4 20mA Fig 7 Fig 8 LK4 LK5 LK4 LK5 INT 1 1 2 2 2182 31 3 EX 3 M 3 M EX LK Remote Totaliser Signal Masterweigh 5 has a battery backed 10 year plus life local resettable totaliser Provision has also made for the use of a remote counter by means of a 28 5 volt or voltage free relay contact pulse that coincides with the incrementation of the local counter The 28V 5V and voltage free contact pulse is available across pins J3 1 amp 2 Each pulse coincides with a
70. supplying their own idler assemblies and will be modifying the idlers Web Tech will have supplied a sprocket and aligning tool see figure 2 and 3 x M6 counter sunk fixing screws The tool must be used if the magnetic pick up is to function correctly The sprocket must be accurately aligned to the roll and shaft The sprocket is fixed to the roll by means of three 6 mm counter sunk bolts The jig and sprocket are assembled onto the roll shaft and the position for the bolts marked out Three 5 5mm holes should be drilled and tapped The sprocket should then be fixed using the screws that have had Loctite or other similar product applied to prevent them coming loose The magnetic pick up positioning bracket should be now welded to the transom angle Note Load cells can be damaged if stray welding currents flow through the cell For complete safety do not install the load cells until all welding work is complete When all the tachometer magnetic pick up installation work is complete adjust the magnetic pick up until there is a 0 125mm Magnetic Electonic Pick Up gap between the sprocket teeth and the pick up If an electronic magnetic pick up has been installed make sure that the pick up probe is no further than 4mm from the sprocket teeth Note there should be no run out between sprocket and magnetic pick up The wiring from the magnetic pick up should be securely fixed to the transom However the cable should
71. t be positioned where it may subjected to running water during periods of rain or hosing Field Wiring Refer to Drawings E40 01 E40 02 E40 03 amp E40 04 All field wiring should be run away from the influence of high voltage and current carrying cables Note If the field wiring is run in conduit make sure that the conduit termination is sealed so as to prevent the ingress of water into the Masterweigh enclosure If sealants are to be used on junction box s make sure that Neutral Cure Based Sealants are used Note Keep the enclosure door closed to prevent ingress of water and dirt Tachometer Magnetic Pick Up Wiring Refer to Dwg No s E40 004 If using the Web Tech junction box Connect the tacho up as shown using Beldon 8771 or equivalent It is important to seal the junction box against water and to run the cable away from high voltage power cables Loosen the four screws on the junction box cover plate noting that they have retaining washers for the screws and gasket The enclosed PCB can be removed by squeezing the nylon locks on the PCB stand offs in turn and pulling the board forward This will facilitate easier termination of the cables Note When Masterweigh 5 has been fully connected and ready for commissioning it is advisable to observe the frequency of the tacho pulses arriving at Masterweigh which are displayed in Menu 9 The minimum frequency is 10Hz and the maximum 1000Hz The reading
72. tegrator will display after the system has been run with calibration weights fitted over the number of belt revolutions set in Menu 2 On occasions Web Tech may not have been supplied with the data required to calculate the target weight The target weight may then have to be calculated during commissioning Assuming that the target weight is available and has been entered precede as follows Where w www is the un calibrated instantaneous mass rate There should be a mass rate shown here using data entered into this Menu Press the Enter key and the display will change to the following This Menu entry point is used when the span is known Perhaps the Masterweigh Press E to continue Mass rate w WWWW Press Enter key to continue Manual entry of Span Factor The above Menu provides the user with a 0 000 pause point should it be required unit has been changed over To start span calibration Press E Press the Enter key again and the Mass rate 0 0000 Revs 0 0 display will change to the following Only Fixed Weight will be discussed in getting started Press the Entry key to Press the Enter key to proceed At this point the display will show the current mass rate and the number of belt revolutions that have elapsed since Span Cal Mode Fixed Weight initiating the test Press Clear to change Enter to accept proceed To abort span calibration press A The target weight
73. th the belt moving The number of complete belt revolutions over a time period are counted by the operator and the Masterweigh counts the pulses returned from the speed sensor device The revolutions are then entered using the keypad and the pulses rev calculated by the Masterweigh and then saved To enable the revolutions to be counted a point on the belt should be marked with paint and a suitable point on the framework chosen close to the belt The count is then started as the belt mark passes this point and stopped as the mark again passes this point after the greater of 5 minutes or 5 belt revolutions Menu entry 2 Pulse per rev 1000 Revs 5 Manual entry of Pulses Rev or press Enter to continue Manual entry of N of Revs or press enter to continue To start belt pulse count Press E Pulse counted Time To stop belt pulse count Press E Pulses counted Time Enter number of belt revolutions Pulses counted Time Pulses per belt revolution Press E to save otherwise press A 1 At Menu Entry 2 press Enter to proceed with calibration 2 If the pulses per rev are known then manually key in the number of pulses and press E Otherwise simply press E to continue 3 Manually key in the number of revs for the above number of pulses and press E Otherwise press E to continue 4 At the moment the belt mark passes the fixed point chosen press E to start the Masterweigh counting
74. the Menu key the computer waits for the four digit code If no attempt is made to enter a code then the display returns to MRMT format after 30 seconds lf an invalid code is detected the display returns to MRMT format immediately If a security code is detected then limited or complete access is gained to the menus as appropriate Once the menu format is exited the code will have to be re entered for further access KEY FUNCTIONS MENU This key switches between the main display mode showing Mass Rate Mass Total MRMT and the Menu mode H When in Menu mode pressing the or key once will go forward or backward one menu entry If either key is held down the menu changes will repeat at a rate of approx 5 per second When entering the data the key is the decimal point A ABORT Abort When in the Menu mode and entering changes or new data this key enables the user to abort the changes and restore the existing entries The top level menu screen is then displayed C Cancel Similar to Abort except that the current screen data only is cancelled and the existing entries restored The display remains at the current screen MASTERWEIGH 5MENU E ENTER Enter Key In menu mode the key accepts the default setting or confirms any data entered and moves to the next level in the operating sequence In MRMT display mode if the Enter key is pressed the current CPU cent
75. time or mass total basis It is also possible to manually command a report at any time The format of the report is Masterweigh Report Date 29 06 00 Time 12 01 41 Mass total 2474450 tonnes Mass rate 5380 tonnes hour Menu step 1 displays the following 1 Menu entry 16 Automatic report printing Pressing Enter advances to 2 Press Clear to print report NOW Press E to continue Report Mode Off Press Clear to change Enter to accept Pressing Clear toggles the report mode between off time based or total based Pressing Enter when report mode is Off returns to Step 1 above Pressing Enter when report mode is Time based advances to 1 hour O hours Report every Enter new value Here the time based reporting period is displayed and may be modified The time period entered here will cause the Masterweigh 5 to automatically print a report via the serial port every time the period expires ie a report period of 4 hours will cause a report to be automatically printed at midnight 4 am 8 am noon 4 pm 8 pm etc Pressing enter here returns to step 1 above Pressing Enter when report mode is Total based advances to 100 tonnes 0 tonnes Report every Enter new value Here the total based reporting increment is displayed and may be modified The mass total increment entered here will cause the Masterweigh 5 to automatically print a report via the s
76. und 4 RX Receive J7 System Status Relay 5 RX Receive 1 COM Common contract 2 Normally open contract 3 NC Normally closed contact J3 Load cell and tachometer inputs pulse counter and analogue outputs 1 P Pulse Counter Output 2 P Pulse Counter Output 3 Shd Shield 4 DG Tacho Digital Ground 5 Tin Tacho Signal In 6 TE Tacho Excitation 5V 7 A Analogue output ve 8 A Analogue output ve 9 AG Analogue ground 10 L Loadcell output ve 11 L Loadcell output ve 12 E Loadcell excitation ve 13 E Loadcell excitation ve 14 Shd Loadcell Shield MASTERWEIGH 5MENU MASTERWEIGH 5 KEYBOARD LAYOUT TOTAL nm o m IN GS Masterweigh 5 can operate in a protected security or open mode depending how the user has configured it see Security for set up details The following text assumes that the operator has gained access to the system SECURITY CODES If a user has entered security codes into the Masterweigh 5 entry to the menus will be restricted Two four digit codes will have been entered see Menu 15 for details One code low level allows for the code holder limited access to any data in the menus for inspection only The other code high level is needed for access to menus and to make modifications to constant start calibration sequences etc Note that no access is given if no code is entered lf security codes have been activated on pressing
77. vier or lighter than the average weight of the belt To stop Masterweigh adding small amounts of weight to its total during those periods when the belt is running empty Masterweigh has a menu entry which is called Null The joint in the belt is a major cause of small amounts of weight being added to the totaliser and the effects of the joint can be seen by entering Menu 6 The display will change to the following Enter new null level 0 000 Mass rate 0 165 tonnes hour By running the belt empty in this menu the raw empty belt mass rate can be observed As the joint or any other belt abnormality passes the weighing element observe the highest mass rate value achieved over one belt revolution and enter a null value just higher than the mass rate noted b Autozero Tracking Material sometimes builds up on the conveyor belt and the weigh area even though belt scrapers are used and Masterweigh s weigh area is narrow Masterweigh can automatically compensate for these build ups if Menu 7 is activated Advance Masterweigh to Menu 7 At the Menu entry 7 Zero track if 20 0 for 5 revs point of entry Masterweigh displays the following if no entry has been previously entered This display tells us that Masterweigh will automatically force itself to read zero when the recorded mass rate is less than 20 tonnes per hour and stays below that value for the duration of five belt revolutions Should material sta
78. zero function is being forced to zero out belt zero errors which could be considered as abnormal This is achieved by setting a window around the signal being returned during any period that the belt is considered to be running empty by the computer The window Is set in this menu at step 5 amp 6 If the signal from the load cell falls outside these user preset levels then the Autozero limit alarm relay will energise Under some circumstances it may be necessary to increase the tolerance at which Masterweigh flags in the display that a negative loadcell excursions has taken place which is greater than the level set in the null x 2 The error is only flagged in the local display in the form of an E at the right hand side of the display where the Z is normally shown 1 At menu Entry 5 press Enter to proceed 2 Enter the exact mass total as measured by the weighbridge Press Enter when the data is correct 3 Enter the mass total as measured by the weigher Press Enter 4 Press Enter to store the new span value as the load cell span calibration factor Press Abort if no update is required Press Menu and Enter to save 1 Menu Entry 7 Zero Track if greater than 20 0 for 5 revs Auto Zero Level 20 0000 tonnes hour 3 Auto zeroing period 5 revs Enter new period 0 4 Delay before auto zeroing 60secs Enter new Delay 0 5 Auto Zero Low Limit 0 000mV Enter new level Auto Zero High Limit 0

OPERATION & INSTALLATION MANUAL

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OPERATION &amp; INSTALLATION MANUAL

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OPERATION & INSTALLATION MANUAL