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OPERATION & INSTALLATION MANUAL

1. CLEARANCE HOLE 5 8 24 2 F i 60 15 75 TYPICAL SHAFT EXTENSIO 7 WITH SPRING COUPLING 42 1100 840 110 0 840 10 FIXED PULLEY WITH FLANGE UNIT EXAMPLE 1 N E we Ie ADJUSTABLE PULLEY SCREW TAKE UP ENCLOSURE ENCLOSURE USING TAKE UP BEARING UNIT EXAMPLE 5 HOLES 012 0 y ey 3 7 A F SCREW Dp 24 222 50 980 77 7 LTORQUE ARM MOUNTED TO EQUIPMENT END ELEVATION TO TO MASTERWEIGH MASTERWEIGH ENCLOSURE ENCLOSURE al
2. ern gee as in Menu 2 during which calibration weights or weigh chains are placed on the or 10 Seen only if span invalid weighframe A mass total is accumulated in the course of test This total is then ke is invalid compared with an expected or target weight and the span adjusted accordingly The display shows the currently stored load cell span value 1 Press Enter when at Menu Entry 4 to proceed 2 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 Menu entry 4 Fixed weight calibrate span 222 1 Manual entry of Span Factor 0 000 or press Enter to continue 3 Masterweigh 5 has been provided with two methods of span calibration Fixed Weight or Empirical Menu 5 3 After initial calibration user by Span Cal Mode Fixed Weight w asa es cee F Press Clear to Change Enter to accept toggling Fixed Weight to R Cal perform a calibration verification An explanation of this procedure follows this text 4 Current weight 120 8 tonnes Enter target weight 0 000 tonnes For initial calibration toggle this menu step to Fixed Weight by pressing the Clear C button if R Cal has been selected Press E to continue Mass rate 0 000 To Start span cali
3. ROTARY SHAFT ENCODER ASSEMBLY MOUNTED DIRECTLY TO PULLEY FIXED PULLEY WITH PLUMMER BLOCK MOUNTING EXAMPLE 4 EXAMPLE 2 NOTES 1 THIS DRAWING SHOWS TYPICAL EXAMPLES ONLY 2 IS RECOMMENDED THAT THE ROTARY SHAFT ENCODER TACHO AND SPRING COUPLING BE SHROUDED TO PROTECT AGAINST MECHANICAL DAMAGE 3 EXAMPLE 3 BRACKET COUPLING BOLTS TO BE LOOSENED BEFORE ADJUSTING PULLEY TAKE UP TO ALLOW FOR THE REALIGNMENT OF THE SHAFT ENCODER RETIGHTENED FOLLOWING ADJUSTMENT 3 1 TORQUE ARM WEB TECH SUPPLY 2 1 ROTARY SHAFT ENCODER TACHO WEB TECH SUPPLY 1 1 5 8 S S SPRING COUPLING 5 5 SUPPLY ITEM QTY PART NUMBER DRAWING No SIZE DESCRIPTION LENGTH MAT SPEC WEIGHT REMARKS lt STATED BRAWN WEB TECH AUSTRALIA PTY LTD SIZE DRAWING No 9 a UNTOLERANCED DIMENSIONS re i i A NUMBER SHT REV a ae TO WITHIN THE LIMITS SHOWN CHECKED 11 ELECTRONICS STREET EIGHT MILE PLAINS QUEENSLAND 4113 AUSTRALIA N z 8 2 5 RG S Ae 1 ats PO pe 81 7 3841 0005 wr5013 oo 5 wa E TYPICAL INSTALLATIONS OF ROTARY s Bu ATE JEC Sloxlox 8 83 Shae SHAFT ENCODER IN CONJUNCTION PRSS 9282 lt MACHINING 01 02 203 205 1 0 SCALE NTS I CAD FILE S AT SAA WITH CONVEYOR BELT SCALES 53301 ziS S u 2 FABRICATION 05 05 05 10 20 24 DO
4. SCALE WI0230 eal ars IF IN DOUBT ALL DIMENSIONS IN MILLIMETRES ehe ane ASK UNLESS OTHERWISE SEECIED K er a 1 2 5 4 5 6 7 8 9 10 11 12 CONTAINED WITHIN MASTERWEIGH ENCLOSURE gt x 2 2 gt O Yn 5 06 Zin lt 5 ME Ver S D lt u 4 IO NN Z gt de o a z Wb Pe FE GR a 0 DP 22 aa D KOM ce ee 1 1 1 I lt 2 gt SS Ja u i u ie ar Br x lt lt lt lt an m m m a 1 J
5. 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 5V supply is regulated to 5V It is not isolated from ground External load resistance should not be lower than 50 ohms The internal 28V is unregulated and may vary over the range 25 35V It is isolated from ground to allow configuration of fully isolated pulse output This 28V supply is shared with the 4 20mA analogue loop output and is rated at 400mA continuous maximum current The contact closure is completely isolated and is rated at 32V maximum and 500mA maximum It must not be used for 110V or 240V operation All pulse outputs are protected by 2 of 500 fast blow fuses F2 and F3 Analog Output The Masterweigh provides one analog output channel The output operates over a 4 20 range and provides a resolution of better than 0 5 It operates as loop powered configuration and 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
6. EXISTING CONVEYOR STRINGER SURFACE REVISIONS OF EXISTING CONVEYOR STRINGER DETAL D UNLESS OTHERWISE STATED DRAWN T BERNARDI WEB TECH AUSTRALIA PTY LTD Size DRAWING No UNTOLERANCED_ DIMENSIONS RER NUMBER REV 11 ELECTRONICS STREET EIGHT MILE PLAINS QUEENSLAND 4113 AUSTRALIA WITHIN THE LIMITS SHOWN CHECKED 0 BOX 4006 EIGHT MILE PLAINS QUEENSLAND 4113 AUSTRALIA m FR 5 APPROVED Phone 61 7 3841 2844 61 7 3841 0005 WT 1 1 1 NOMINAL size 5 159 0200 1000 TITLE D FL WTE11 CUSTOMER 150 300 1000 DATE APP D PROJECT co ta CONVEYOR BELTSCALE as WACHINNG 01 02 03 05 10 SCALE 1 20 5 SE INSTALLATION GENERAL ARRANGEMENT en FABRICATION 505 505 05 10 20 2 IF IN DOUBT This drawing and any information or descriptive matter set out hereon are the confidential 5 ALL DIMENSIONS MILLIMETRES and copyright property of WEB TECH AUSTRALIA PTY 170 6 ASSEMBLIES 505 05 05 10 20 ASK UNLESS OTHERWISE SPECIFIED nok oanad copied for _mmanufacturing Sentra
7. 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 3 FACILITIES AVAILABLE 28 Masterweigh 5 Operation USER CONFIGURATION 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 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 cel input is disconnected from the terminal block 6 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 se
8. DDMMYY needs to be entered Where DD is the desired days ie 27 04 etc MM is Elapsed Time Press clear to reset the desired months ie 11 05 etc and YY 0 days 00 19 58 hours is the desired years ie 94 01 etc E g to enter 12 Feb 2000 press 1 2 0 2 0 0 E Here a free running elapsed time count is Pressing Enter advances to displayed Pressing Clear will reset the 7 elapsed time counter Pressing Enter advances to Day of the week Wednesday Press to change Enter to accept Clock is currently in 12 hour mode Here the current day of the week is displayed Press to change Enter to accept and may be changed by the user Pressing the or key toggles through the days of The Masterweigh 5 real time clock can be the week configured to display the current time in either Pressing Enter advances to 12 or 24 hour mode the selection is made in 8 this menu Power on hours 1 Pressing Enter advances to Press Enter to continue 4 Time 09 13 56am Here a count of power on hours since the last Enter new time HHMM unit re configuration is displayed This display is provided for information only it is Here the current time is displayed and may not user adjustable Pressing Enter returns be modified A 4 digit time string of the form to step 1 above HHMM needs to be entered Where HH is the desired hours ie 12 03 etc and MM is the desired minutes ie 45 07 etc E g to enter 9
9. Load Cell junction box Refer to drawing WTMW5 01 1 in the drawing section of the manual Speed sensor junction box Refer to drawing WTMW5 01 1 in the drawing section of the manual START UP Prior to turning on the equipment or operating the belt scale ensure the following has been done 1 Double check all electrical connections are correct 2 All mechanical installation has been completed and no tools have been left on the belt Start Up Steps When starting up the system for the first time use the following steps 1 Turn on the electronics and ensure it displays the Mass Rate Mass Total MRMT MODEL WTE11 ELECTRICAL INSTALLATION 2 Start the conveyor If using variable speed drive set it in local and ramp the frequency up to 50Hz 3 The load cell output can be directly read from the electronics Refer to the electronics manual for the appropriate menu for reading the load cell voltage Refer to the calibration sheets at the rear of the manual and compare the factory programmed voltage mV to the existing value It should be within 0 5mV 4 The belt speed sensor output can be read directly from the electronics Refer to the electronics manual for the appropriate menu for reading the belt speed sensor frequency output Run the conveyor and ensure that there is a stable output from the speed sensor 3 Hz If all readings appear correct proceed to the Calibration section
10. Press E Pulse counted Time 5 To stop belt pulse count Press E Pulses counted Time 6 Enter number of belt revolutions Pulses counted Time 7 Pulses per 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 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 MENU 2 6 Masterweigh 5 Operation MENU ZERO CALIBRATION This menu entry enables the operating zero to be calibrated A specified number of belt revolutions are run as determined by Menu 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
11. engraved onto the right hand side of the main pcb under the label Cal Zero then press E 9 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 10 Press then E to return to normal running mode Remember If MW5 is reconfigured all calibration data is lost Keep Notes RECONFIGURING MASTERWEIGH 24 Masterweigh 5 Operation FACILITIES AVAILABLE Introduction The Masterweigh is a precision microprocessor based instrument for accurate integration of mass totals in belt scale applications The core highly successful Masterweigh 1 design has been 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 the following pages 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 mi
12. i Weighframe and Weigh Idlers The function of the weighframe is to support the weigh idler s and conveyor belt and to convert the weight of the material within the weigh span to an electrical signal which can be processed by the electronics Weighframes are varied in design however the majority of the designs incorporate one or more transducers most typically strain gauge loadcells The weighframe is usually self contained low profile and designed to be installed within the limits of the conveyor structure The number of idlers used is dependant upon the accuracy required and the conveyor parameters Various weighframe designs exist each with their own perceived advantages Most Belt Scale manufacturers use either a pivoted design a fully floating design With a pivoted design one or more idlers are mounted frame which is pivoted at one end by some form of fulcrum point The fulcrum point is designed to be both maintenance free and as close to frictionless as possible Early pivot designs included knife edges and bearings or ball bearings however due to the perceived maintenance problems and the advent of transducers with very small amounts of movement these were replaced with components such as torque tubes flexures or rubber trunnions BELT SCALE SELECTION AND INSTALLATION GUIDE CONT D The fully floating design comprises one or more idlers mounted on a frame which is in turn supported at each corner b
13. J 1 1 98 J7 45 J5 J6 c J1 112131415 6 7186 9 10 112 13 14 1121314 5 1 92012 P Po SHD DG Tin A A AG L L E E SHD GND TxD RxD Rx Rx SYSTEM STATUS AUTOZEFO LIMIT N ARN dge al RS232 RS485 L LIN L2 YO 2 5 786 y GH 2 BZ Se wo 9 S L a 5 x l x gt on m 2 2 D 6 INTERCONNECTION CABLE TO BE REMOTE TOTALISER OR PLC INPUT z FOUR 4 CORE SCREENED 6 SUPPLIED BY OTHERS 110 240 VAC 50 60 Hz 12345678 0 1 Amp 240V 0 2 Amp 120V NOTES 1 RATE OUTPUT IS ISOLATED 4 20mA 2 PULSE OUTPUT BE 5VDC 24 VDC OR LOADCELL JUNCTION BOX REMOTE RATE METER VOLTAGE FREE CONTACTS LINK SELECTABLE OR PLC INPUT LOADCELL J BOX TERMINATION BOARD F GREEN SIGNAL SIGNAL L 7 SIGNAL UNCION BER WHITE SIGNAL O SIGNAL O SIGNAL SCREEN SCREEN O SCREEN SCREEN SCREEN 0 100 ENCODER RED EXCITE TIO EXCITE 1 O EXCITE SENSE O SENSE O SENSE BLACK Ol EXCITE O EXCITE Be Ol EXCITE O SENSE Oy SENSE Ol SENSE OADCELL OADCELL 2 INDICATOR 5 G L L L L SHIELD D 4 4 D OR BLUE U OV GND 5 3 O wire 51 SUPPLY D 2 240 GREEN SIGNAL 1 1 F SHIELD LOAD CELL CONTAINED CABLE INTEGRAL ri i WIT
14. be relatively simple the tasks required of the electronics are more complex Not only must the electronics be capable of receiving and processing the signals from the weighing mechanism and belt speed travel device it must also be capable of the following Display Rate and Total readings BELT SCALE SELECTION AND INSTALLATION GUIDE CONT D Provide stable power supplies to the weighing and belt speed travel elements Provide analogue and digital outputs for remote equipment Provide Automatic Zero and Span calibration facilities Provide serial communications for remote computers Carry out AutoZero routines when the belt is empty Provide alarm functions Provide control functions Interface with the operator lt I lt lt I lt I lt lt IS I lt The measurement of the weight on the conveyor belt and the belt speed travel also present some physical problems which must be overcome The accuracy of the weight measurement is dependant on a number of factors such as belt tension belt construction weighframe location troughing angle and material loading The degree of accuracy and ways of improving the accuracy are discussed in further detail in the following sections 3 SCALE COMPONENTS Basically Belt Scales consist of four main components The main components are i Weighframe and associated weigh idlers Belt speed travel sensor iii Electronic Integrator iv Calibration device
15. d 1 Menu Entry 7 press Enter to proceed 2 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 3 Enter the period required 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 4 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 5 Step five allows the user to enter the value in mV below which it may be considered that an invalid Autozero is taking place 6 Step six allows the user to enter the value in mV above which it may be considered that an invalid Autozero is taking place 7 Increase this factor if the letter is being encountered in the main display 8 The function of displaying the letter E can be switched on or off here by pressing the C button Page 15 MENU 7 16 Masterweigh 5 Operation MENU 8 LOADCE
16. enter to save the value or abort to ignore the calculation Note that if you entered a belt length in step 3 and nota belt speed in step 4 this value will be meaningless Press E to continue Masterweigh 5 Operation Page 19 MENU Y 13 CLEARING MASS TOTAL Menu entry 13 Press C to clear Mass Total 1 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 MENU 13 20 Masterweigh 5 Operation MENU 14 REAL TIME CLOCK Pressing Enter advances to This menu controls the operation of the 5 Masterweigh 5 real time clock The real time Time ave clock is a separate module with its own a t t battery power source that will continue to ERSAN ey ae keep accurate time even in the case of power loss to the Masterweigh 5 unit This Here the current 12 hour time format postfix menu is only accessible if the real time clock is displayed and may be modified The user module has been installed Step 1 displays can select either am or pm the following current time date and day of week information Pressing Enter advances to 1 6 Menu entry 14 Wed Date 29 6 94 Time 09 12 43am Date 9 6 94 Enter new date DDMMYY Pressing Enter advances to Here the current date is displayed and may be modified A 6 digit time string of the form 2
17. 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 N 1 Menu entry 3 Zero cal 2 563mV 2 563mV 2 2 Manual entry of Zero Error or press Enter to continue 0 000mV 3 Press E to continue Mass rate 0 000 4 Zero reset To Start zero cal Press E Mass rate 0 000 Revs 0 0 5 To Abort zero calibration Press A Mass rate 0 000 Revs 0 0 6 To calculate new calibration Press E Mass total 1 150 Revs 10 7 Zero error 2 756 millivolts Press E to save otherwise press A MENU 3 1 At Menu Entry 3 press Enter to proceed 2 Optional Using 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 th
18. roll face 9 Position the idler so that it is e Inline with the stringline e layed out as shown on the installation drawing When the idler is positioned correctly the idler base is to be welded to the mounting plates on the weighframe MODEL WTE11 MECHANICAL INSTALLATION NOTE THE LOADCELL IS PRE INSTALLED IN THE WEIGHFRAME AND COULD BE DAMAGED BY IMPROPER WELDING PRACTICES ENSURE THAT WELDING EARTH STRAP IS CONNECTED AT THE POINT OF WELDING 10 Locate the remaining In Line Weigh Quality idlers and sit frames across the conveyor stringers with two sets upstream and two sets downstream of the weighframe Install centre rolls in these frames Measure and mark the centre of the centre roll face on these idlers 11 Position the idlers so that they are e Inline with the stringline e Are dimensionally layed out as shown on the installation drawing 12 Mark out mounting holes on stringers and drill holes to suit the idler mounting feet Install bolts washers and nuts and tighten down Ensure spring washers are used 13 Re check idler spacing and centres Adjust if necessary 14 Run a further two stringlines 30 Ib fishing line from the same existing idlers as the centre line was tied off to The stringlines should be approximately 12 mm in from each edge of the roll 15 Go to the first in line shown as C2 Place a spirit level across the top of the centre roll Adjust
19. splices Metal clip fasteners should not be used Belt Tracking Belt tracking should be central to the idlers regardless of belt loading Training idlers should not be used any closer than 5 idler spacings from the weighframe Conveyor Idlers It is more desirable to use idlers with shallow troughing angles Idlers with 20 angle are better than 30 angle and 30 is better than 35 Idlers with 45 troughing angle can be used however errors due to belt tension changes are more significant The steepness of the troughing angle determines the planar moment of inertia of the belt which determines how susceptible the Belt Scale is to belt tension variations and misalignment Idlers on the weighframe two approach and two retreat idlers should be In Line Weigh Quality Rolls should be machined concentric to provide 0 13 mm Total Indicated Runout Rolls to be balanced within 0 011 Nm Rolls to be fitted with some form of height adjustment On some low accuracy applications some of the above requirements may not be required Idler Alignment The mechanical alignment of the weigh approach and retreat idlers is critical The height misalignment in this area should be no greater than 0 4 mm Mechanical misalignment of these idlers will cause the accuracy of the system to vary depending on belt tension variations It is advisable to have the Belt Scale supplier assist in the mechanical installation Conveyor Stringers The
20. the coupling is not correctly aligned it will eventually break Provision must be made so that if the pulley position is changed the encoder bracket can also be moved to maintain accurate alignment See drawing WT 5013 in the drawing section of the manual to see typical installation arrangements ELECTRICAL INSTALLATION The encoder is provided with a three 3 core cable approximately 1 metre long Therefore the belt speed sensor junction box must be installed within its reach The cable should be mechanically protected Refer to drawing Tach 1 for termination details PART NUMBERS The part number s for the encoder include the PPR output of the encoder The typical P No is WXT XXX where XXX is the PPR Therefore a 100 ppr encoder would have the P No WXT 100 Page 1 Masterweigh 5 Operation Page 1 KEYBOARD LAYOUT AND KEY FUNCTIONS MASTERWEIGH 5 KEYBOARD LAYOUT TOTAL RESET CAL A ABORT E ENTER gt 15 m 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 all
21. the display filter time constant 2 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 3 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 4 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 MENU 10 Page 18 Masterweigh 5 Operation MENU 11 MODIFICATION OF DISPLAYED UNITS The displayed units for mass may be selected from tonnes lbs tons and kgs The displayed units for mass rate will be the same as those selected for mass ie tonnes hour lbs hour tons hour or kgs hour 1 Menu entry 11 To modify display units Press 2 16 4 tonnes 1 Pressing the Enter key will advance to select mass units 2 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
22. the idler roll using the grub screws so that it is level If the amount of adjustment required is more than approximately 5 mm it is better to use a packer under the idler mounting foot 16 Go to the last in line idler shown as C2 and level centre roll 17 The in line idlers should be higher than the existing offset idlers due to their design The levelled centre rolls should already be in contact with the two stringlines at the edge of the rolls The in line idlers should never be lower than the standard existing idlers If they are they will require packers to be installed under all mounting feet 18 The two reference stringlines should be clear of the centre rolls in the other idler frames 1 W1 amp 1 If not adjust the grub screws on 2 2 idlers by equal amounts until both stringlines are clear of all centre rolls When this has been completed ensure locknuts are tightened Permissible tolerance is 0 4 0 0 mm 19 Proceed to adjust the remaining centre rolls until they just touch the stringlines Ensure all locknuts have been tightened after adjustment After all rolls have been adjusted recheck all rolls are still in contact with the stringlines 20 Locate the remaining idler rolls and install all wing rolls Ensure that grub screws in roll shafts are not protruding from the bottom of the shaft 21 Run a further two string lines on both sides of wing rolls similar to the centre rolls 2
23. these will be packed on a separate pallet or skid STORAGE If the equipment is to be stored for a long period prior to installation we would suggest that the equipment be covered if in an outdoors situation EQUIPMENT DAMAGE If any equipment has been damaged in transit or some item s appears to be missing please contact Web Tech immediately Page 1 Web Tech Australia Pty Ltd BELT SCALE SELECTION AND INSTALLATION GUIDE BRISBANE SYDNEY WEB TECH BRISBANE Head Office SYDNEY OFFICE 11 Electronics Street Tel 61 2 9757 2296 Web page Eight Mile Plains QLD 4113 Australia Fax 61 2 9899 6585 Tel 61 7 3841 2844 Email webtech onaustralia com au Email webtech onaustralia com au MELBOURNE OFFICE Tel 61 3 9653 9260 Fax 61 3 9653 9699 Web Tech are manufacturers and designers Email webtech onaustralia com au Weigh belt feeders Conveyor belt scales Loss in Weight screw feeders Volumetric screw feeders Loss in Weight vibratory feeders Gain in Weight vibratory feeders Company Profile Web Tech is awholly owned Australian company which specialise in the design and manufacture of continuous and static weighing systems for all facets of industry Web Tech have 15 years experience in the field of continuous weighing Web Tech s Head office and manufacturing works are located in Brisbane with a sales and service office in Sydney and Melbourne We have a standard range of designs for equipm
24. use chains 1 standard idlers already exist remove five sets from the conveyor 2 Mark out the centre of the space created and this will be the centre of the weighframe 3 Remove the weighframe from the packing crate Note the proper orientation of the weighframe The torque tube should be at the discharge end of the conveyor unless declined 4 Lift the weighframe into the conveyor so that the weighframe mounting feet are sitting on the stringers Position the weighframe so that the centre of the weighframe is in line with the previously marked out centre of the space 5 Measure and mark the centre of the centre horizontal roll on the first of the existing idlers in each direction Tie a stringline between these centre points 6 Measure and mark the centre of the weighframe crossbeams Square the weighframe up so that the centre of the crossbeams are in line with the stringline 7 Mark out the position of the weighframe mounting holes on the conveyor stringers Drill 14 mm holes for M12 bolts Install bolts washers and nuts and tighten down Ensure that spring washers are used 8 Locate one of the In Line Weigh Quality idlers Sit the idler frames across the weighframe on the idler mounting plates Install centre roll into the idler frame wing rolls not required at this stage Ensure that grub screws in roll shafts are not protruding from the bottom of the shaft Measure and mark the centre of the centre
25. with a mass total of zero The test can be aborted at any time by pressing the Abort key 8 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 9 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 10 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 4 Calibration Methods 1 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 load cell via the weighframe carriage at representative speeds 2 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 3 Static calibration weights are often used where a chain is impractical to use Bars of a known weight are loaded direct
26. 2 Starting on one side of wing rolls the same procedure is required to be carried out as the centre rolls Adjust the wing rolls on 2 and 2 idlers evenly so that they are clear of all remaining wing rolls 23 Go through and adjust all rolls so that they are just touching the stringlines When this has been completed ensure that all locknuts are tightened Permissible tolerance is 0 4 0 0 mm 24 Review all adjustments and if satisfied remove all stringlines 25 Carefully lower the conveyor belt Do not drop the belt onto the weighframe MODEL WTE11 ELECTRICAL INSTALLATION Electrical connection diagrams for the belt scale electronics load cell and belt speed sensor junction boxes are located in the drawing section of this manual The required drawing is are WTMW5 01 1 Electrical installation comprises the following work 1 Install and connect Masterweigh 5 electronics to mains supply 2 Install and connect load cell wiring between weighframe and electronics 3 Install and connect cable between load cell junction box and electronics 4 Install and connect cable between belt speed sensor junction box and electronics 5 Install cable between electronics and PLC if required for output signals BELT SCALE ELECTRONICS The belt scale is supplied with the following model electronics e Masterweigh 5 The appropriate electrical connection drawing or the electronics supplied is locate
27. 30 press 0 9 3 0 E MENU 14 Masterweigh 5 Operation Page 21 MENU 15 ACCESS CODE Masterweigh 5 provides for 2 levels of user the Configuration access code Pressing configurable access code If no access Enter returns to step 1 above codes are activated 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 Here a new Configuration access code may be enter
28. ED AT RIGHT ANGLES TO THE DIRECTION OF BEL CENTRELINE DIMENSIONS SHOWN BETWEEN IDLERS MUS BE MAINTAINED TO A TOLERANCE OF 0 5mm IDLER MOUNTING FRAME foe BARS 3 GENERALLY IDLER HEIGHTS FOR OFFSET IDLERS IS LESS T HAN THOSE FOR INLINE IDLERS PACKERS MAY BE USED TO RAISE OFFSET IDLERS TO THE HEIGHT OF INLINE IDLERS REFER DETAIL AS A RULE A 3 0mm GRADIENT PER METRE IS AN ALLOWABLE OLERANCE HEIGHT BETWEEN ROLL HEIGHTS IGNORE THIS NOTE F IN LINE IDLERS ARE SOLELY USED EXISTING CONVEYOR STRINGER SURFACE TYPICAL WELD IDLER FRAME TO SUPPORT BRACKETS STRINGLINE REFERENCE LOADCELL JUNCTION BOX 4 ROLLS C2 THRU TO C2 INCLUDING W2 THRU TO W1 ARE BE 0 OPTIONAL SUPPLY RILLED AND TAPPED M8 10 ROLLS IN TOTAL REFER DETAIL A 5 ALL ROLLS MUST ADJUSTED STRINGLINE REFERENCE DETAIL A OLERANCE OF 0 4mm 0 0 LEVEL CENTRE ROLLS ON C2 D C2 IDLERS PRIOR ANY ADJUSTMENTS ENSURE ALL LOCKING UTS ARE TIGHTENED AFTER ADJUSTMENTS ARE COMPLETED EIGHFRAME ORIENTATION AS SHOWN IS CORRECT FOR INCLINED ND HORIZONTAL CONVEYORS FOR DECLINED CONVEYORS REVERSE RECTION OF WEIGHFRAME s 7 THE LOAD CELL OR A LOAD CELL DUMMY OF EXACTLY THE SAME HEIGHT AS THE LOAD CELL MUST BE INSTALLED PRIOR TO ALIGNING IDLERS REPRESENTATIONAL CROSS TE i SECTION
29. H PTY LTD 24 2 89 H CHECKED 24 2 89 MODEL 400 0 BELT SCALE s G A CLIENT TYPICAL REPRESENTATION OF INLINE CONVEYOR IDLERS IDLERS 2 THROUGH 2 TYPICAL REPRESENTATION OF OFFSET CONVEYOR IDLERS AS NOMINATED AS NOMINATED 5 NOMINATED ARE WEIGH QUALITY IDLERS AS NOMINATED STRINGLINE REFERENCE T TORQUE TUBE EXISTING CONVEYOR STRINGER THIS IS A NO STEP ZONE PLAN VIEW DIRECTION OF CONVEYOR BELT TRAVEL TYPICAL WELD 5 TYPICAL CALIBRATION BARS IN PLACE IDLER FRAME TO BRACKETS 5 EQUAL AMOUNTS IN EACH POSITION fi 1 _ AWARE VIEW FROM SIDE RETURN TRAVEL OF THE BELT IS NOT TO FOUL THE INTERNAL FRAME OF THE BELT SCALE DEFLECTION 20 IDLERS BE INSTALLED IF oe OFFSET CONVEYOR IDLER INLINE CONVEYOR IDLER THIS IS THE CASE STRINGLINE REFERENCE 2 D ED BSED gt gt SQ I CONVEYOR IDLER gt EN LOCKNUT NOTES PACKING PLATE USED RAISE IDLER vwo SOCKET SCREW HEIGHT OF INLINE IDLER EXISTING CONVEYOR 1 CONVEYOR IDLERS FROM C2 THRU TO 2 WEIGH QUALITY 5 OFF REFER NOTE 3 STRINGER SURFACE MUST BE INLINE IDLERS NOT OFFSET IDLERS DRILL THRU 96 9 2 CONVEYOR IDLERS FROM C3 THRU TO C3 MUST TAP M8 BOTH ENDS MOUNT
30. HIN WEICHERAME INTERCONNECTION CABLE TO BE THREE 3 CORE SCREENED H SUPPLIED BY OTHERS SEANN 7 WEB TECH AUSTRALIA PTY LTD size DRAWING No ACN 010 764 431 CHECKED 008 ULE PLANS 4113 ASTRA Phone 61 7 3841 2844 Fox 61 7 3841 0005 5 01 1 APPROVED TITLE CUSTOMER 5 rn ELECTRICAL CONNECTION DIAGRAM FOR ane TE SINGLE LOAD CELL BELT SCALES INCORP 8 T CAD FILE DO nor Scale MASTERWEIGH 5 amp CODER SPEED SENSOR WIWWS 0124 5 IF IN DOUBT ALL DIMENSIONS IN MILLIMETRES and formation descriptive it hereon are the z2 ASK UNLESS OTHERWISE SPECIFIED ane must Ro be disclosed loaned copied or used for manufacturing tendering Addendum ADDENDUM The following addenda are applicable to the equipment supplied for this contract Page 1 DESIGN DATA E SERIES Conveyor Date CAL BARS 1 Nominated Conveyor Capacity t hr No Wt kg 2 Max Capacity in kg s 1 x 1900090 kg min 1 3 Measured Belt Speed m min 2 4 Max Load on Belt 2 3 kg m 3 5 Weigh Span metres 4 6 Loading across Weigh Span 4 x 5 kg 5 6 7 Effective Load Load cell See Fig 1 7 8 Length of Weigh Moment 0 305 yin table below 8 c c Torque tu
31. LL INPUT Millivolts This entry displays the load cell input in millivolts The displayed value is unaffected by the load zero load calibration and zero tracking functions The entry also displays the excitation voltage as currently sensed 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 This display enables a user to confirm that the Masterweigh is correctly sensing the excitation voltage and thus that all links etc are correctly installed Incorrect excitation sensing will result in inaccurate and unstable mass rate measurements Access is also available to the output of the voltage to frequency converters Menu Entry 8 Loadcell 16mV Extin 10V 2 V to count Press Enter to continue This facility is for technician s use only 1 Menu Entry 8 displays the load cell millivolt output and excitation voltage 2 Press E to access the current V to F output 3 Press E again to return to Menu Entry 8 MENU ENTRY 9 TACHO FREQUENCY This entry displays the current tacho frequency in hertz the input range is 5Hz to 1000Hz and switches between software or hardware inputs Menu Entry 9 Tacho Frequency 50 005 Hertz Tacho Source Hardware Press Clear to change Enter to accept Tacho Source Simulated Press Clear to change Enter to accept Tacho Source Ext Con Press Clear to change Enter
32. OPERATION 8 INSTALLATION MANUAL WTE11 E400 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 wr Section 1 Web Tech Australia Pty Ltd TABLE OF CONTENTS Description Unpacking the Equipment Belt Scale Installation Guide Weighframe amp Electronics Installation Belt Speed Sensor Installation Masterweigh 5 Operation Drawings Addendum Calibration Sheets Model WTE11 Scale Unpacking MODEL WTE11 UNPACKING EQUIPMENT PACKING 1 WEIGHFRAME The weighframe is shipped in a timber crate and is retained by bolts in the floor of the crate Remove these bolts before attempting to lift out the weighframe 2 ELECTRONICS The Masterweigh or Optimus electronics and enclosure are shipped in a separate cardboard box When removing the packing be sure to check for any documentation that may be supplied within the box 3 BELT SPEED SENSOR The belt speed sensor is normally shipped in the same box as the Masterweigh or Optimus electronics 4 CALIBRATION WEIGHTS The calibration weights if supplied are shipped in the same crate as the weighframe They are also bolted to the floor 5 WEIGH IDLERS If weigh idlers have been supplied by Web Tech
33. actual belt speed or belt travel The weight of material on the conveyor belt is obtained by measuring the load on one or more idlers This load can then be expressed in terms of kg metre W of belt The belt speed or belt travel is measured by using a device which gives an output proportional to the belt speed S or belt travel T The flow rate of material passing over the Belt Scale can be expressed as Rate WxS WEIGHT BELT SPEED FLOW RATE Weighframe Belt Speed Sensor The total weight of material that has passed over the Belt Scale can be expressed as Total W x T WEIGHT BELT TRAVEL Weighframe Belt Travel TOTAL WEIGHT Sensor Belt Scale manufacturers use either the belt speed or belt travel methods depending on their design philosophy Those that use the belt travel method generally use a low frequency device which delivers a number of pulses per unit of belt length The integration primarily calculates the total weight from which the flow rate is then derived The second method is to use a high frequency device up to 1 KHz the output of which is proportional to the belt speed The integration primarily calculates the rate passing over the Belt Scale from which the total is then derived Due to the availability of high speed processors most modern Belt Scales use the rate method as the basis for their electronic design Whilst the mathematics used by the Belt Scale electronics may appear to
34. aining for the site personnel in the event of an emergency breakdown situation These site visits are normally scheduled at three monthly intervals The following work should be carried out on a regular basis Clean down of build up on weighframe and removal of spillage Inspection and cleaning of idler rolls Zero calibrations Inspect belt tracking Inspect belt wear q iS S The following work can be carried out less frequently Span calibrations Check mechanical alignment Balance transducers where necessary Check cabling and junction boxes Apart from the general housekeeping of the installation the other important aspect that should be addressed is the record keeping for each installation Most modern Belt Scale electronics store all data in battery backed or non volatile memory however in the case of catastrophic failure this data will probably be lost or not accessible At these times it is essential that accurate records be available for reprogramming purposes Accurate records also allow review of the Belt Scale performance and possible problems that may require attention Belt Scale suppliers will usually be able to provide proper data record sheets that can be used in conjunction with the maintenance program MODEL WTE11 MECHANICAL INSTALLATION The model WTE11 weighframe is a single idler single load cell design The mechanical installation comprises the following work e Lifting of convey
35. be and Load cell 9 9 Force on Load cell s Full Scale 7 x 8 kg 10 10 Calibration Bars Total kg 11 11 Length of Moment 0 457 in table below 12 c c Torque Tube and Weights 13 12 Force on Load cell s with Cal Bars 10 x 11 kg 14 13 Cal Bars as a of Max Capacity 12 9 x 100 15 14 Mass Rate with Cal Bars 1 13 100 t hr 16 15 Tonnes per min with Cal Bars 14 60 t min 17 16 Time per Belt Revs secs 18 17 Time expressed in minutes 16 60 min 19 18 Target Weight for time period 15 17 tonnes 20 Load on cells x z Item Total y 2 1 451 x y 2 400 0 305 0 305 0 457 800 0 305 0 305 0 457 2400 0 219 0 991 1 219 1 374 2800 0 219 0 991 1 219 1 374 Fig 1 2 All dims from ofpivot T T Distance to centre of first idler dual idler only y Distance to load cell s centre z Distance tocentreof second idler a Distance Tocentreof Cal Wt WEB TECH AUSTRALIA PTY LTD Conveyor Designation Model Tacho Data Software Version Contract No MENU FUNCTION MASTERWEIGH 5 SETTINGS 1 Parameter Setup Capacity Increments Size Pulse Time On Zero Reference Precision Reference 2 Pulses per Belt Programmed Pulses per Belt Revolution Revolution No of Belt Revs Zero Calibration Zero Calibration mV AutoZero Tracking mV 5 Emperical Span Emp
36. bration Press E Mass Rate 0 000 Revs 0 0 To abort span calibration Press A Mass rate 1543 000 Revs 1 507 To calculate new calibration Press Mass total 120 000 Revs 10 MENU 4 9 Masterweigh 5 Operation MENU 4 FIXED WEIGHT CALIBRATION Cont d 4 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 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 5 The current mass rate is shown the number of belt revolutions is zeroed Press the Enter key to start the test 6 Once started the test will run until the currently specified number of belt revolutions has been counted Refer to Menu 2 7 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
37. conveyor stringers should be rigid free from vibration and capable of supporting the load without deflection Weighframes and approach retreat idlers should not be installed where joins in the stringers exist If this is not possible stringers should be welded together using fish plates The stringers should be suitably supported in the area of the weighframe approach retreat idlers so that the total deflection within the weigh area does not exceed 0 25 mm BELT SCALE SELECTION AND INSTALLATION GUIDE CONT D Environmental Protection Where the conveyor is exposed to the elements errors may be induced by external influences such as wind Errors equivalent to 30 tonnes per hour have been measured on large conveyors subject to high wind velocities These errors can be minimised by installing guards which protect the weighframe and 5 metres of conveyor in each direction Where possible supply the Belt Scale manufacturer with a detailed arrangement drawing of the proposed installation with as many parameters as known WEIGHFRAME LOADING POINT DISTANCE The weighframe should be located far enough from the loading point to ensure that the material has achieved the same velocity as the conveyor belt Typically most materials will settle within 5 idler spacings of the loading point MAXIMUM CONVEYOR INCLINATION ANGLE Product Roll Back The conveyor incline angle should not so steep as to allow the material to be able to r
38. crovolts 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 and automatically compensates for any voltage change that may occur The 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 plus minus bipolar voltage by configuration FACILITIES AVAILABLE of links The positive 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 allowa 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
39. d in the drawings section of the manual Enclosure Mounting The electronics enclosure is an IP66 RFP or stainless steel enclosure The enclosure should be located so that 1 Is not in direct sunlight install sunshield if located outdoors 2 Is not subject to direct washdown Is not installed in close proximity to high power cables variable speed drives or vibratory feeder controllers 4 Not more than 5 metres from the weighframe The closer the electronics can be located to the weighframe reduces the chances of electrical interference on the cables It also makes it easier when carrying out calibrations and fault finding The weighframe has been supplied with an integral 5 metre cable for connection to the electronics Cables All cables between the load cell belt speed sensor junction boxes and the electronics should be proper screened instrumentation quality As the signal levels from these devices are very low any cable runs between the weighframe speed sensor and electronics should be carried out so that these cables are not installed close to power cables Suggested cable type for each application is as follows Load Cell 4 core overall screened Belden type 8723 or equivalent Belt Speed Sensor core overall screened Belden type 8723 or equivalent Ensure that all cable entries into the electronics enclosure and junction boxes use the correct size waterproof glands Cable Terminations
40. d weigher this figure should be approximately 1 to 2 of capacity MENU 6 14 Masterweigh 5 Operation MENU 7 AUTO ZERO TRACKING 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 2 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 5 2 It may be required that the user wishes to know if the Autozero 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 be
41. e 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 normally includes contributions from both 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 Masterweigh 5 Operation MENU ZERO CALIBRATION Cont d 6 This display will come up automatically when the belt has completed 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 Page 7 MENU 3 8 Masterweigh 5 Operation MENU 4 FIXED WEIGHT CALIBRATION 9 This menu entry allows the automatic calibration of the load cell span The test is factor 2 run over a preset number of belt revolutions
42. ed this can be a number in the range 1 to 32766 Note that entering a Configuration access code of 0 zero clears MENU 15 22 Masterweigh 5 Operation MENU 16 REPORT PRINTING Optional 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 RS232 serial port on either a 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 Off Pressing Enter advances to Press Clear to print report NOW Press E to continue Pressing Clear will cause report to be immediately printed via the RS232 serial port Pressing Enter advances to 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 MENU 16 Pressing Enter when report mode is Time based advances to 4 Report every 1 hour Enter new value 0 hours Here the time based reporting period is displayed and may be modified The time period ent
43. ence to it If the value recorded in subsequent tests exceeds 0 5 of the original value perform a full calibration using weights etc Note Zero system prior to R Cal test MENU 4 Masterweigh 5 Operation MENU 5 EMPERICAL SPAN CALIBRATION This menu entry enables the entry of manual belt totalisations and the resultant recalculation of the load cell span To use this calibration facility it is necessary to weigh a quantity of material with the belt scales and then to accurately determine the actual mass of that material by independent means i e via a weighbridge The two totals are then entered and the Masterweigh computes the new span factor 1 5 Empirical calibration soan 211 7 Enter weigh bridge total 0 000 2 3 Enter belt scale total 0 000 4 New span 205 6 previous 211 7 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 Page 11 MENU 5 12 Masterweigh 5 Operation THIS PAGE INTENTIONALLY LEFT BLANK Masterweigh 5 Operation Page 13 MENU 6 NULL LEVEL This entry displays the level at which the load is considered to be zero Below t
44. ent Where a customer has a special requirement we will where possible modify our design or design a new device to meet the application requirements Our feeders are currently in use with most ofthe major companies in Australia and our electronic systems are widely used in the U S A South America and Europe Web Tech is proud to include companies such as BHP Steel BHP Minerals BHP Temco BHP Australia Coal CSR Sugar amp Plaster Board Monier Queensland Cement amp Lime Tomago Aluminium Company Boyne Smelters Limited Blue Circle Southern Cement Swan Cement Boral Comalco Aluminium Incitec Mt Isa Mines Limited Port Waratah Coal Services Simplot Uncle Bens Kellogg Australia amp Malaysia and SPC amongst our users Whe WEB TECH AUSTRALIA PTY LTD TABLE OF CONTENTS 1 BELT SCALE FUNCTIONS 2 THEORY OF OPERATION 3 BELT SCALE COMPONENTS 4 CONVEYOR DESIGN 5 WHICH MODEL BELT SCALE 6 ONGOING MAINTENANCE The information contained in this document remains the property of Web Tech Australia Pty Ltd and should not be reproduced or disclosed without their permission BELT SCALE SELECTION AND INSTALLATION GUIDE The following guide has been produced as an aid in the correct selection and installation of Conveyor Belt Scales This publication does not cover the operation of Nuclear Belt Scales 1 BELT SCALE FUNCTIONS The requirement of a Belt Scale may be for a variety of reasons Most applications r
45. ep 3 above 4 Masterweigh 5 Operation MENU 1 PARAMETER SET UP Cont d 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 100 5 then at it s fastest rate the output will on for 100ms then off for 100ms This will give a maximum output of 5 complete pulses per second 100mS 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 for increment value of 0 01tonnes the limit will be 180tph To modify factory calibration data 5 Menu Entry 1 press the 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 6 The 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 7 Enter new data and or press the E k
46. equire a Belt Scale to accurately weigh the total amount of material that has been conveyed from one location to another However some applications only require the Belt Scale to accurately measure the rate that the material is being conveyed at and the total figure is only of a secondary interest Other applications place great emphasis on both the total and rate results An example of a total application could be a shiploading operation where it is critical to know the actual total tonnes that have been loaded into each section of the ship The ship holds can be relatively easily topped up to the required weight however it is difficult to take excess tonnes back off the ship A Belt Scale can be installed on the ship loading conveyor to continually record the total tonnes that have been transferred onto the ship and thereby not have to wait for draft surveys to be carried out An example of a rate application could be a long drift conveyor transporting coal from underground to the surface It is important not to overload the conveyor as this may cause the conveyor to trip due to the excessive load This will then require the conveyor to be shovelled off so that the conveyor can restart A Belt Scale can be installed on the drift conveyor to measure the rate passing over it which can then be used to control the rate of feed onto the conveyor An example of an application where both the total and rate are equally i
47. ered 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 5 100 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 serial 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 Stop bit 2 bits Parity None Masterweigh 5 Operation Page 23 RECONFIGURING MASTERWEIGH 5 Under some circumstances Masterweigh s 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 on 240 110V 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 o
48. eset 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 voltage where the tachometer ceases to work owing to significant voltage drop from long cable runs IS barriers or the like CAUTION Application of 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 tachometer is normally selected for the user by the factory FACILITIES AVAILABLE Masterweigh 5 Operation Page 26 FACILITIES AVAILABLE Cont d 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 in Masterweigh s total has occurred 1 An Internally Generated 5VDC Pulse 2 An Internally Generated 28VDC Pulse 3 Contact closure from an internal relay providing voltage free contacts
49. ey to proceed Now access to the precision reference has been gained Enter new data and or press the E key gt again 8 Either exit at this step by pressing the A key or press E to access the menu which exercises the 4 20mA output 9 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 790mA 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 MENU 1 Masterweigh 5 Operation Page 5 MENU 2 PULSES PER BELT REVOLUTION This calibration is carried out with the belt moving 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 1 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 2 3 4 To start belt pulse count
50. his level the mass rate display will show zero no increment of the mass total will occur no pulse outputs to the pulse counter and the mass rate analog output will be set to 4 1 Menu entry 6 Null level 20 000 tonnes hour 2 Enter a new null level 2 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 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 aligne
51. his will cause a variation in frequency output and therefore the measured belt speed wheel is usually mounted on the return belt adjacent to the weighframe This can be along distance away from the weighframe by belt travel and therefore the belt speed measured may not be the same belt speed at the weighframe BELT SCALE SELECTION AND INSTALLATION GUIDE CONT D Belt Travel Sensor A belt travel sensor usually consists of one or more flags welded to a pulley usually the tail pulley and a proximity probe As the flags pass by the proximity probe they are counted and this relates to the amount of conveyor belt that has passed around the pulley The advantage of this type of system is that it is relatively simple and robust however the disadvantage is that it is low frequency in output and therefore the resolution can be coarse iii Electronic Integrator The electronic integrator is designed to carry out the following basic functions Provide supply voltages to weighframe transducers and speed travel sensors Measure and integrate the instantaneous weight weighframe and instantaneous belt speed travel which calculates the Mass Rate and Mass Total passing over the conveyor Provide analogue and pulse outputs for remote equipment Provide facilities for calibration The electronic integrator may also provide the following options Provide P I D control output Provide serial commu
52. in Train Static Calibration Weights e Electronic Simulation Material Test A material test is the best form of test that can be done The test involves collecting an amount of material that has passed over the Belt Scale and weighing it on an accurate static weighing system such as a weighbridge or bin weighing system Other methods of testing simulate material loading however only a material test duplicates the actual operating conditions of the conveyor With regard to the amount of material required for a test a general rule of thumb is a test of 10 minutes duration When considering the installation of a Belt Scale system a method of diverting material from the process should be investigated It is essential when carrying out a material test that it can be guaranteed that all of the material that has passed over the Belt Scale has been collected BELT SCALE SELECTION AND INSTALLATION GUIDE CONT D Calibration Chain Train Test A calibration chain train is a device that sits on the conveyor belt above the weighframe and approach and retreat idlers is restrained in position whilst the conveyor is run and simulates material loading A calibration chain consists of a series of interconnected steel rolls which is manufactured to represent approximately 80 of the maximum belt loading A calibration train is similar to a chain except that it consists of a series of interconnected carriages which can be loaded with weights
53. ing 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 at the right hand side of the display where the Z is normally shown MENU 7 Step 7 allows the user to increase the tolerance before displaying the E At step 8 the user can toggle the above function on or off depending on preferences Note Under normal running conditions negative loadcell excursions should not be occurring Check the weigh area for abnormalities Menu Entry 7 Zero Track if greater than 20 0 for 5 revs Auto Zero Level 20 00 tonnes hour Auto zeroing period 5 revs Enter new period 0 4 Delay before auto zeroing 60secs Enter new Delay 0 Auto Zero Low Limit 0 000mV Enter new level Auto Zero High Limit 0 000mV Enter new level 0 000mV 7 Auto Zero Error Level 2 times Auto Zero Autozero Error Display is On Press Clear to Change Enter to accept Masterweigh 5 Operation MENU 7 AUTO ZERO TRACKING Cont
54. ircal Span Null Level Null Level 7 Auto Zero Auto Zero Level Auto Zero Period Tracking Delay Time secs Fixed Weight Span Target Weight Calibration LoadcellInput Dynamic No Load Dynamic with weights Tacho Frequency Tacho Frequency Hz Hz on VF Drive if appl Filter Constants Display Time Constant Rate O P Time Constant Tacho I P Time Constant Displayed Units tonnes hr kg hr kg min tons hr Ibs hr 0 1 2 Belt Speed Indicated Belt Speed m sec Hz on VF Drive if appl Indication Current Belt Length metres 5 1 Access Codes Operator Code Configuration Code 1 1 1
55. lect 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 USER CONFIGURATION Externally generated LK4 LK5 2 3 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 LK8 LKQ 1 2 1 2 1 2 1 2 Internally generated 28 VDC Isolated LK6 LK8 12 1 2 2 3 2 3 Relay provided voltage free contacts LK6 LK8 23 23 2 3 2 3 CPU PCB Top Board LK1 When installed to the bottom Masterweigh s digital communication is based on the RS232 protocol When installed to the top the digital communication is based on the RS485 protocol RS485 communications are only available if the main board has the relevant optional components installed LK2 Not user configurable Link 1 4 amp 3 6 or leave un linked Masterweigh 5 Operation Page 29 POTENTIOMETER ADJUSTMENTS Power Supply Bottom Board RV1 Used to adjust the load cell excitation used in conjunction with a digital meter or the Masterweigh when menu 8 been selected RV2 Used to boost the tachometer supply voltage when the voltage drops are evident at the tachome
56. ly onto the weighframe and hence simulated load This method does not take into consideration belt tension or weight transfer through the belt It does however exercise the weighframes mechanics 4 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 the 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 10 Masterweigh 5 Operation MENU 4 FIXED WEIGHT CALIBRATION Cont d 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 note the number but do not accept it by pressing enter Press the Abort key The total achieved should be logged and future R Cal tests refer
57. mportant could be a feed conveyor into a coal preparation plant The rate is important as the coal feed into the plant must be maintained at a predetermined setpoint The total input into the plant is important as this determines the yield or quality of the coal when compared to the amount of saleable coal that comes out of the plant A Belt Scale can be installed on the feed conveyor to accomplish both functions All modern Belt Scales calculate both total and rate figures which can be used for whatever purpose Some also have additional features and options such as in built controllers batching facilities and rate alarms which can be used as an adjunct to the primary function It is important when discussing the requirements of a new installation with the Belt Scale supplier to advise him of the intended function of the system to ensure that all the necessary facilities and hardware are available It is also important to discuss what the technical requirements may be for the interface of the Belt Scale with other equipment such as aPLC or controller BELT SCALE SELECTION AND INSTALLATION GUIDE CONT D 2 THEORY OF OPERATION Belt Scales enable material to be weighed on a conveyor whilst in motion A Belt Scale differs from a static weighing system such as a bin weighing system in that the Belt Scale is required to measure two variables The first variable is the actual weight on the conveyor belt and the second variable is the
58. nications for remote computers Provide Rate alarm outputs Provide batching facilities Most modern integrators are microprocessor based with computing power similar to a personal computer Each manufacturer engineers their own software which incorporates their own design philosophies Whilst all integrators may look similar at first glance the methods used by the various manufacturers to achieve the end result can vary significantly The current state of the art integrators are designed to make operation calibration easier for site personnel and great emphasis should be placed on the ease of use Many sites will prefer the Belt Scale supplier to carry out routine maintenance and calibration however in an emergency situation there is nothing worse than having to wade through a manual attempting to understand what a displayed code means Integrator Location The electronic integrator does not have to be located adjacent to the weighframe Some customers may wish to mount the integrator in a nearby motor control centre or in a control room Whilst this is possible the following points should be considered when selecting the location e The weighframe transducers produce very low voltage levels and therefore if long cables are used voltage drops may occur e The longer the cable run the greater the chance of picking up electrical noise on the cables BELT SCALE SELECTION AND INSTALLATION GUIDE CONT D e Long distances be
59. nnected to the drive pulley as any slippage between the drive pulley and conveyor belt will not be measured A second type of belt speed sensor involves mounting a sprocket at the end of a conveyor roll and sensing it s rotational speed with the use of a Magnetic Pick up The Magnetic Pick up counts the number of sprocket teeth that pass by a sensing element and therefore produces a frequency proportional to the speed This system is not normally used on applications where the conveyor rolls are subject to material build up as this will change the diameter of the roll and therefore the indicated belt soeed However on some applications where the idler rolls appear to be carrying build up closer inspection will show that the area of idler roll in contact with the belt remains clean The advantages of using the idler roll sprocket type of sensor is that they are relatively simple and robust and can be situated close to the weighframe When installed close to the weighframe the belt speed being measured is the actual belt speed at the weighframe A third type of system still popular with some manufacturers customers is the use of a pivoted trailing arm with a wheel in contact with the return belt The wheel is attached to a rotary sensor similar to that used with the tail pulley method The disadvantages of this method are The wheel is prone to bounce when disturbance in the surface such a splice passes under it T
60. 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 and LK5 on the board appropriately and connect the external supply in series with the analog loop Span calibration of the output is readily performed by accessing the analog calibration in the Menu 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 and analog grounds to power earth FACILITIES AVAILABLE Masterweigh 5 Operation Page 27 FACILITIES AVAILABLE Cont d 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
61. of the manual Belt Speed Sensor Encoder BELT SPEED SENSOR ENCODER DESCRIPTION The belt speed sensor supplied with the belt scale is a digital incremental encoder It produces a square wave output the frequency of which is proportional to the belt speed The encoder should be connected to a non driven pulley ie not a drive pulley This is because there could be some slippage between the drive pulley and the belt The encoder is typically connected to the tail pulley or a snub pulley The encoder is available in the following models 100 PPR 200 PPR 500 PPR The model supplied for your application has been based on the belt speed and pulley diameter information that was provided For slower belts an additional pulse multiplier board may be supplied This board is located in the belt speed sensor junction box It allows the pulses from the encoder to be multiplied X1 X2 or X4 The frequency range is typically 80 to 500 Hz MECHANICAL INSTALLATION The installation of the encoder can be either by direct connection to the pulley shaft using a solid coupling or on a separate bracket and spring coupling If using a solid coupling the encoder must use a restraining arm which is in contact with a fixed part of the conveyor This will prevent the encoder from rotating with the pulley shaft If using the spring coupling method most common the spring coupling alignment must be within 1 mm in all axes If
62. oll back on itself CONCAVE CURVES Tangent Point The minimum distance between the last weigh idler on weighframe and the tangent point of the curve should be no less than 20 metres and preferably 30 metres if possible CONVEX CURVES Tangent Point The minimum distance between the last weigh idler on weighirame and the tangent point of the curve should be no less than 6 metres WEIGHFRAME LOCATION CONCAVE AND CONVEX CURVES WEIGHSPAN Weighspan The amount of belt that the weighframe weighs Is called the welghspan The welgh idler s share half of the load with the adjacent fixed Idlers BELT LOADING When sizing conveyors the belt should be 75 80 volumetrically full CONVEYOR STIFFENING Weigh Idlers Fish Plates Install weighframe and at least one approach and one retreat idler on the same section of conveyor stringer Where this is not possible weld fish plate s between conveyor joints to prevant movement CONVEYOR SUPPORTS Weigh Area Ensure that conveyor structure is adequately supported within the Weigh Area Total deflection under full load should not exceed 0 25 TRAINING IDLERS 5 Idlers min 5 Idlers min Training Idlers H is preferable not to locate tracking idlers within the weighframe area Tracking idlers should be no closer than 5 Idler spacings from the weighframe WIND GUARDS 5 Idlers min 5 Idlers min External Influences s
63. or belt in proposed weighframe location e Installation of weighframe and support beams e Installation of Weigh idler on weighframe e Installation of approach and retreat idlers e Aligning the height of the weigh approach and retreat idlers Refer to drawings WTE11 amp WT400 1 for installation general layout Weighframe Location weighframe location may have been previously nominated after discussions with Web Tech If not refer to the Belt Scale Installation Guide section of this manual for guidance or contact Web Tech to confirm the position BEFORE CARRYING OUT ANY WORK ON THE CONVEYOR ISOLATE THE CONVEYOR DRIVE AS REQUIRED Lifting of Belt The conveyor belt if fitted will be required to be lifted off the idlers in the area of the installation The belt should be lifted so that access is available for approximately 5 metres either side of the weighframe centre The belt should be lifted approximately 600 mm above the idlers and the belt should be lifted by means of placing pipe or timber under the belt which will keep the belt flat If the conveyor is fitted with a gravity take up it will be necessary to lift the take up weight first Ensure that the belt is supported securely before commencing any work Weighframe Installation weighframe is robust in design however care should be exercised when lifting and installing it into position The weighframe should be lifted with web slings do not
64. ows 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 If security codes have been activated on pressing 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 If 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 This key switches between the main display mode showing Mass Rate Mass Total MRMT and the Menu mode AND When Menu mode pressing the 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 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 Similar to Abort except that the current screen data only is cancelled and the existing entrie
65. r 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 Note that units can be changed to tons Ibs or kg if preferred within Menu Entry 11 3 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 4 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 st
66. r 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 on the main PCB under Calibration zero and Precision ref LOG ALL CALIBRATION DATA AS YOU MAY NEED TO MANUALLY RE ENTER IT A LATER DATE TO RE INITIALISE MASTERWEIGH 5 PROCEED AS FOLLOWS 1 Switch off Masterweigh 2 Simultaneously press the Blank and Abort keys 3 With both the above keys pressed switch Masterweigh on 4 The display will now show the message Press C to Configure Any other key to continue 5 Now press the C key and Masterweigh will return to normal running mode 6 Masterweigh is now configured to factory defaults 7 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 8 The display will request a new Calibration Zero to be entered Enter the value that is
67. rface 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 30 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 Tacho Input and Supply a Electrical Characteristics The tacho input is designed to accept a voltage input of 2 5 to 50 volts peak and so will accept either a 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 r
68. roach and two retreat idlers to the weighframe Idler roll height is adjustable to allow for accurate alignment of the idlers within the weigh area Weigh Quality idlers are available from most idler manufacturers The following design aspects should be confirmed when considering a proposed weighframe Self contained and preassembled for easy installation Rigidity with great emphasis placed on eliminating deflection Provide minimal surface area for material build up Provide equal loading all transducers BELT SCALE SELECTION AND INSTALLATION GUIDE CONT D Provide maintenance free and frictionless pivot points Be provided with mechanical tare facility for lightly loaded conveyors Reduce the effects of material off centre loading ii Belt Speed Travel Sensor As previously discussed a sensor is supplied to provide a signal to the electronic integrator as to the actual belt speed or belt travel Belt Speed Sensor Belt speed sensors can be supplied in several arrangements The most common method is for a rotary type sensor to mounted in an enclosure to be connected to a shaft pulley usually the tail pulley As the pulley rotates the speed sensor shaft is also rotated which in turn produces a pulse output The frequency of the pulse output is proportional to the rotational speed of the pulley Typical frequencies fall within the range of 100 1000 Hz Belt speed sensors should not be co
69. roximately 5 idler spacings or 6 metres Conveyor Inclination Ideally the conveyor would be horizontal to provide for more consistent belt tensions however this is not generally practical The conveyor inclination angle should not be so great as to allow the product to roll back This will cause a positive error from the Belt Scale Concave and Convex Curves Concave curves should be avoided where possible The weighframe should be located as far away as possible from the tangent point of the curve and no closer than 20 metres Convex curves are less of a problem however the weighframe should be located no closer than 6 metres from the tangent point of the curve Conveyor Take up The conveyor should preferably be fitted with gravity take up on the return belt Gravity take ups located on the tail pulley are acceptable however less desirable Screw take ups on short conveyors less than 15 metres may be acceptable however not preferred Belt Loading Belt loading should be uniform and consistent Belts should be sized so that they are volumetrically 75 80 full BELT SCALE SELECTION AND INSTALLATION GUIDE CONT D Belt Type The selected belt type should use the minimum number of plies possible Additional plies add to the stiffness of the belt and therefore reduce the achievable accuracy Steel cored belts are the least desirable due to the stiffness of these belts Conveyor belts should be uniform in weight with a minimum of
70. s are carried out without the use of weights material or chains When the test is initiated a shunt resistor is applied across the transducer input which creates an offset The value of the resistor is usually calculated to represent approximately 75 80 of maximum belt loading A test value is initially established at the time of commissioning which can then be used to check the repeatability of the system SCALE SELECTION AND INSTALLATION GUIDE CONT D This method of testing does not obviously take into account the belt effects or conveyor running conditions Web Tech provides this method of testing as a standard feature however we do not place great emphasis on it s use 4 CONVEYOR DESIGN Conveyors are designed to transport material from one location to another and not specifically for the benefit of a Belt Scale A Belt Scale is often an after thought and therefore the conveyor design may be less than ideal for accurate and repeatable results The following is asummary of recommended conveyor design Weighframe Location The weighframe should be located in a position where the belt tension and belt tension variations are minimal Generally speaking this location is at the tail end of the conveyor at the loading point However sufficient distance from the loading point should be provided to allow the material to be settled and be travelling at the same velocity as the belt Typically for most products this is app
71. s restored The display remains at the current screen ENTER In menu mode 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 central processor unit status is displayed and also the number of times the CPU has been restarted KEYBOARD LAYOUT AND KEY FUNCTIONS 2 Masterweigh 5 Operation KEYBOARD LAYOUT AND KEY FUNCTIONS Cont d If the display is flashing the CPU fault status may be viewed by pressing the enter key in the MRMT display mode SPEED KEYS TOTAL RESET When this key is pressed MW5 clears the accumulated mass total Pressing this key takes the operator directly to the belt zero function without having to scroll through the menu structure When this key is pressed operating display jumps to the fixed weight calibration function ready to span the system The blank key has been deliberately left this condition as it is a key that will be assigned to user s 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 la
72. st keypad operation NUMERIC KEYS These keys are used to enter calibration data KEYBOARD LAYOUT AND KEY FUNCTIONS Masterweigh 5 Operation Page 3 MENU 1 PARAMETER SET UP Menu 1 is used firstly to enter the maximum capacity of the weigher and the precision of the remote counter pulse 1 Menu Entry 1 Parameter Set Up 2 Current capacity 1000 000 tonnes hour Enter new capacity 0 000 3 Mass total increment 1 000 tonnes Enter new inc 10 0 001 0 000 4 Remote totaliser pulse width 100ms Enter new value 20 1000 0 Menu 1 can also be used to access and modify the precision zero reference and reference voltage by pressing the C key It is advisable however not to adjust this data unless the unit has been reconfigured 5 1 Parameter setup 6 WARNING Calibration data Do not modify Press A to continue 7 Calibration zero x xxx milli volts Enter new zero ref 0 000 8 Precision ref x xxx millivolts Enter new precision ref 0 000 9 Press for Rate O P span calibration else press A MENU 1 10 Rate O P x xxmA C for next E to reset unit 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 feede
73. ter due to a large separation between Masterweigh and the tachometer or due to Intrinsic Safety Barriers on the tachometer cables CPU PCB 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 C 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 POTENTIOMETER ADJUSTMENTS 30 FIELD TERMINATIONS J1 Power supply input 1 L L1 240VAC 110VAC 2 N L2240VAC 110VAC 240VAC 110VAC Earth 3 G J8 Auto Zero Limit Alarm 1 COM Common contact 2 NO 3 NC Normally open contact Normally closed contact J7 System Status Relay 1 COM Common contract 2 3 J3 Load cell tachometer inputs pulse counter and analog outptuts P N Shd DG Tin TE 00 NI 10 L 11 L 12 E 13 E 14 Shd Normally open contract Normally closed contact Pulse Counter Output Pulse Counter Output Shield Tacho Digital Ground Tacho Signal In Tacho Excitation 5V Analog output ve Analog output ve Analog ground Loadcell output ve Loadcell output ve Loadcell excitation ve Loadcell e
74. to accept 1 Press to enter the menu to select the source of the tachometer signal MENUS 8 amp 9 2 Press C to change or toggle between the available pulse sources which are e Hardware input signal to the system as generated by the speed sensor Magnetic pick up or optical tachometer Simulated an internally generated 100 2 signal that is always on Ext Con an internally generated signal that is only on when an external contact is closed between terminals and on terminal strip J3 usually auxillary motor contacts 3 Press E to accept and return to the Menu Entry 9 Masterweigh 5 Operation Page 17 MENU 10 FILTER CONSTANTS 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 Menu Entry 10 To modify Filter factors press Enter Display Time constant is 2 secs Enter new Time constant 0 3 Rate O P Time constant is 4secs Enter new Time constant Tacho Time constant is 1 secs Enter new time constant 1 Press Enter to modify
75. to simulate various belt loadings The disadvantages of calibration chains trains are as follows Xx They are generally expensive sometimes more expensive than the Belt Scale they are testing x They require additional personnel to set up x They have to be stored above the conveyor and therefore a storage structure has to be built X They require maintenance Static Weight Test Static weight tests are the most common form of testing carried out on Belt Scales All Belt Scale manufacturers offer calibration weights as an option with the system the weight and quantity sized to approximate 75 80 of maximum belt loading The calibration weights are applied directly to the weighframe the belt is run and material loading is simulated The advantages of this method are as follows They generally the cheapest method They be applied by one person and for high belt loadings permanent weights that can be jacked on off the weighframe can be installed material test be initially carried out they can be referenced to the material test results Repeatability tests are easy to carry out The disadvantages of static calibration weights are as follows Xx They cannot exactly duplicate the running conditions of the conveyor Xx They sit directly on the weighframe and therefore do not duplicate the belt effects Xx They tend to be lost Electronic Simulation Test Electronic Simulation test
76. tween weighframe and integrator increases the time required when carrying out calibrations 15 the proposed area classified as Dust Ignition Proof or Hazardous It is Web Tech s belief that the best location for the integrator is adjacent to the weighframe where possible The output signals can be used to provide information to remote equipment The integrator should be mounted so that it is free from vibration not subject to direct sunlight and rain If installed outdoors it is suggested that rain sun hoods are used When selecting a Belt Scale system the following integrator features should be investigated Are the operation calibration functions displayed entered in plain English or in code form Is the circuit design truly digital or does it require potentiometer adjustments in it s setup Are service and fault finding functions available Does the integrator maintain it s accuracy over a wide temperature range typically 0 to 40 C Are the analogue and pulse outputs isolated Is the integrator enclosure suitable for the environment Does the system provide Automatic zero and calibration facilities Are the integrator outputs compatible with remote equipment Is the integrator supplied with filters on the mains input Can the integrator be easily serviced 44 KA K iv Calibration Device There are basically four methods that can be used to calibrate a Belt Scale system e Material Test Calibration Cha
77. uch as wind can effect the accuracy of the Belt Scale Wind guards should be installed for at least 5 idlers either side of the weighframe where necessary SINGLE IDLER PIVOTED WEIGHFRAME TRANSDUCER LOADCELL DUAL IDLER PIVOTED WEIGHFRAME TRANSDUCER LOADCELL SINGLE IDLER FULLY FLOATING WEIGHFRAME RR MULTI IDLER FULLY FLOATING WEIGHFRAME VARIOUS WEIGHFRAME CONFIGURATIONS BELT SCALE SELECTION AND INSTALLATION GUIDE CONT D 5 WHICH MODEL BELT SCALE Most Belt Scale manufacturers can supply a number of different model weighframes and electronics Some models may appear to duplicate each other in regard to accuracy specifications and general features For example two different model weighframes may be specified at an accuracy of 0 5 However one model may be designed for medium duties with relatively light belt loadings and the other for heavy duty applications with high belt loadings When you examine the construction of the weighframe will it stand up to the duty The accuracy of the system will be determined by the weighframe type as the same model electronics will normally be used regardless of the accuracy requirements More than one model electronics may be available however this is generally because they offer various options When specifying a desired accuracy for the Belt Scale system the application should be investigated thoroughly Like most equipment the higher the acc
78. unit number or pressing Abort will not change the currently displayed units 3 Press Menu and Enter to save MENU ENTRY 12 BELT SPEED INDICATION 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 1 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 4 5 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 MENUS 11 amp 12 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 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 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
79. uracy specified the more expensive the system will be Belt Scale accuracy depends on a number of factors such as belt tension belt type location and belt loadings However they are usually categorised into one of three groups SINGLE IDLER General purpose process scales with typical accuracies in the order of 1 to 3 DUAL IDLER Inventory purpose scales with typical accuracy of 0 5 MULTI IDLER High precision systems such as shiploaders and scales for payment purposes Accuracy typically 0 25 However in some applications it may be necessary to use a four idler weighframe to achieve 1 accuracy On other applications a single idler weighframe may achieve 0 5 accuracies The Belt Scale supplier will require certain information regarding the application which should be detailed on their Application Data sheets It may be preferable to allow the supplier to review the data and advise what options are available in regard to the possible accuracy versus the costs rather than specifying the accuracy BELT SCALE SELECTION AND INSTALLATION GUIDE CONT D 6 ONGOING MAINTENANCE Many Belt Scale installations are ignored until a problem exists Like all equipment a minimum of maintenance will assist in providing long term reliability For multiple installations at the one site it may be worth contracting the Belt Scale supplier to carry out the maintenance and regular calibrations These visits can also be used to provide basic tr
80. will cause erratic mass rate readings The millivolt input accepts either a 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 and depends the duration of the overload Masterweigh 5 Operation Page 25 FACILITIES AVAILABLE Cont d 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 With the exception of short periods allocated to self calibration 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 and short circuit protected however short circuiting of the excitation output will interfere with normal operation of analog input circuitry and the RS232 inte
81. xcitation ve Loadcell Shield FIELD TERMINATIONS Active Neutral Masterweigh 5 Operation J5 RS232 Communications Port Ground 2 TXD Transmit 3 RXDReceive J6 RS485 Communications Port Transmit Transmit Ground Receive Receive 10 N TUBE gt 3 L Ea i i 3 T O 1 I 4 55 N A x RUCTU TINC CO NG UV VEYOR U R x gt 200 mm 600 mm 24 904mm 692mm 754mm 804mm mm PEN 5 50 30 843mm 29 SAS 800 mm 32 1104mm 895mm mm 1204mm Zn 304mm NOR DIRECTION 435 354mm 1148mm OF CONVEYOR BELT TRAVEL CONVEYOR IDLER CALIBRATION BAR POSITION DLER FRAME TO NGLE BRACKETS SUPPLIED DRAWING DESIGN AND DETAIL 1 PTY LTD AND MUS NOT BE REPRODUCED S THE CONFIDENTIAL PROPERTY OF OR DISC OSED TO D BY ION OF WEB TECH PTY 2 L H EXTRA BELT WIDTHS AD 1 L H JIM JIMS ADDED REV NAME DESCRIPTION DATI NAME 7 B TEC
82. y a transducer Horizontal and transverse restrainers limit the movement of the weighframe in any direction except that perpendicular to the belt line The advantages of both types of design are as follows PIVOTED TYPE FULLY FLOATING TYPE Less Expensive Same design as used in high accuracy static weighing systems Require less transducers Do not use pivots which could influence measurements Can be counterweighted which allows Forces acting on weigh idlers act deadweight of belt and idlers to be directly on tranducers removed Better sensitivity from the Calibration weights represent the transducers same weight regardless of where Less calibration weights required placed on weighframe Generally speaking fully floating multi idler weighframes are normally used for high accuracy weighing applications and pivoted single or multi idler weighframes are used for general purpose weighing applications However similar performance can be achieved by installing two pivoted weighframes in series Weigh Idlers The weighframe supports the belt by means of Weigh Quality idlers The differences between these idlers and standard conveyor idlers are The idler rolls are in line rather than offset The idler rolls are machined concentric to provide 0 13 mm Total Indicated Runout The idler rolls are balanced within 0 011 Nm The idler roll height can be adjusted Weigh Quality idlers are also supplied for the two app

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OPERATION & INSTALLATION MANUAL