conveyor installation manual

Doc. No. : V-2155-2001-A-502 Revision : 1A Date : 11- Jan- 2011 Prep’d. by : Atmo

JCF DEMO PROJECT PT. JGC INDONESIA

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INSTALLATION MANUAL FOR CONVEYOR SYSTEM

Appr’d by : Unehara

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List of Contents 1. General 3

1.1.General 3 1.2.Precaution in use 3

2. Preparation 3 2.1. Foundation inspection procedure 3 2.2. Measurement result and the correction of the foundation 5 2.3. Final confirmation of foundation work 5

3. Belt Conveyor 5 3.1.Structure of belt conveyor 5

3.1.1. Outline of Belt Conveyor 5 3.1.2. Outline flow for installation of Belt Conveyor 9

3.2.Pre-assembling of support on the ground 14 3.2.1. Assembling tolerance 14

3.3.Pre-assembling of divided truss frame on the ground 15 3.3.1. Preparation of the pre-assembling 15 3.3.2. Pre-assembling procedure 16

3.4.Setting of camber for truss frame 17 3.5.Setting of idler 19

3.6. Centering of rotating parts 21 3.6.1. Pulley centering 21 3.6.2. Centering of rotating parts 22

3.7.Dragging tension of belt (Lead-in and splicing of belt) 23 3.7.1. Preparation 23 3.7.2. Belt dragging flow 24 3.7.3. Belt dragging procedure 25

3.8.Installation of various belt cleaners 27 3.8.1. Kind of belt cleaner 27



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List of Contents (Cont’d)

3.8.2. General items for the installation of cleaner 28 3.8.3. Tip type head cleaner 29 3.8.4. Installation of return belt cleaner 30

3.9.Installation of rain cover 31 4. Installation procedure for Belt conveyor 32

4.1.Installation procedure of conveyor frame 32 4.1.1. Lift up the girder 32 4.1.2. Installation of one side plane frame 33 4.1.3. Installation standard of the conveyor frame 34

4.2.Installation procedure of the drive part for Belt conveyor 38 4.2.1. Installation of head frame and drive unit 38

4.3.Installation of take-up unit 40 5. Inspection procedure / General 42

5.1.Inspection standard and manual 42 5.1.1. For ironworks 42 5.1.2. For belt conveyor 42 5.1.3. For driving part 43

5.2.Performance test 45 5.3.Welding inspection 45 5.4.Visual check 45

6. Conveyor belt scale installation 46 6.1.Theory of operation 46 6.2.Installation procedure 47

6.3.Operation 57 6.4.Calibration 68



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1. General 1.1. This instruction shall be applied to erection and installation work for Conveyor System RAW COAL

FEED CONVEYOR K-101, RAW COAL WEIGHING CONVEYOR K-102, UG CAKE FEED CONVEYOR #2 K-303 for JCF Demo PROJECT PT. JGC Indonesia.

1.2.Precautions In Use

Before erection and installation of the conveyor system, be sure to read thoroughly this installation manual and apply it correctly.

! IMPORTANT

Please be notice the sequence of erection, especially in Pit Area. The improper sequence of installation may be cause the difficulty of installation.

2. Preparation 2.1.Foundation and inspection procedure (Fig. 2.1)



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2.2. Measurement result and correction of the foundation 1) To record tolerance of the position and height of embedded anchor bolt or the box type

anchor bolt hole which was measured from the Marked line through the foundation

investigation, in the foundation drawing. 2) Synthetically examine and decide whether any defect or conformity they have hindrance

for the installation, by the installation personal concerned. 3) When any defect or nonconformity is found for the installation of equipment, investigate

and conclude the countermeasure between concerned members, if necessary.

2.3. Final confirmation of the foundation work After foundation correction work finished by foundation worker, to be reconfirmed dimensions before installation by concerned members.

3. Belt Conveyor

3.1. Structure of Belt Conveyor 1. Outline of belt conveyor

a. Raw Coal Weighing Conveyor K-102 (Fig.3.1-1a) b. Raw Coal Feed Conveyor K-101 (Fig.3.1-1b) c. UG Cake Feed Conveyor #2 K-303 (Fig.3.1-1c)



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2. Outline flow for installation of Belt Conveyor

a. Raw Coal Weighing Conveyor K-102 (Fig. 3.1-2a).

Fig. 3.1-2a



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Fig. 3.1-2a (Cont’d)



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b. Raw Coal Feed Conveyor K-101 (Fig. 3.1-2b).



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c. UG Cake Feed Conveyor #2 K-303 (Fig. 3.1-2c).



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Fig. 3.1-2c (cont’d)



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3.2. Pre- assembling of support on the ground 3.2.1 Assembling Tolerance

1) Measure and check the following boundary dimensions (Fig.3.2-1)



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2) After the confirmation of construction accuracy, tighten up bolts and nuts. 3) After tightening up, check construction accuracy once again.

(reference drawing)

4) Tighten up anchor bolt which is temporary tightened after centering base and

set up wire rope for tumble prevention. 5) After that, remove wire rope for the handling & lifting.

3.3. Pre-assembling of divided truss frame on the ground.

3.3.1. Preparation of the pre-assembling



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1) Place of the pre-assembling a Place for the pre-assembling shall be located close to the installation place. b Space for the pre-assembling shall be large enough and suitable for the size of the

equipment. c Robust flat surface suits with equipment shall be set temporarily.

2) Preparation of the part a Pre-assembling parts shall be sorted out and in order beforehand.

3.3.2. Pre-assembling procedure 1) Divided of truss frame: general example of the divided parts are shown below.



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3.4. Setting of camber for truss frame 1) Set jack under the vertical number in the side frame. 2) Set camber while it makes frame lift up and down by jack, confirming the value shown in

a drawing with leveler and adjusting it by liner.



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3.5. Setting of idler 1) Set idlers as indicated in the drawing. 2) Set each idler onto frame. 3) In case of idlers, unify the standard line to the direction of belt forward for either. 4) Set roller. Adjust of the sway belt while testing. Treat politely not to hurt roller.



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5) Centering

a Stretch piano wire on the center line of roller and check with a marked center (Fig.3.5-3)

Fig. 3.5-3



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3.6. Centering of the rotating parts

3.6.1. Pulley centering

Fig. 3.6-1



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3.6.2. Centering of rotating parts

1) Chain wheel a Adjust the each side of chain wheels to meet same surface level on the side of the

machine and motor.

In this case, adjust each points of (A,B,C,D) (A’,B’,C’,D’) to became straight using strings.

Tolerance(e) Less than 1mm

Fig. 3.6-2

b When monitoring roller chain, engage with both edges on chain wheel and connect

them with connecting link.

Fig. 3.6-3



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c Adjust the sagging of roller chain using take up bolt which is set on the side of motor.

d When the sagging range can not be adjusted by adjustment bolt, use off-set link.

Sagging range(S. S’) Within 2% of (L)

Fig. 3.6-4

3.7. Dragging tension of belt (Belt Pulling and splicing of belt) 3.7.1. Preparation

1) Belt will be rolled in drum and/or only merely tied up. But prepare the temporary implement ( support stand) for unrolling belt by the procedure of Fig. 3.7-1.

Fig. 3.7.1-1



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2) Prepare winch, wire rope, belt cramp and belt dragging metal fittings.

Fig. 3.7.1-2 Fig. 3.7.1-3

IMPORTANT! :

a Take care handling of belt because there is a front and back in belt surface. b Be careful to handle belt without damage, curvature and a burr and so on in belt

during belt dragging. c Splicing procedure for belt is shown other manual.

3.7.2. Belt dragging flow

Selection of the belt dragging place

Installation of the support stand for belt drum

Joint of belt and wire rope

Belt dragging

Belt tension



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3.7.3. Belt dragging tension procedure 1) Selection of the belt dragging place

Select belt dragging place, in general, tail side is recommeded. 2) Installation of the support stand for belt drum

a Install a support stand for belt drum, winch and wire rope and sheave.

When dragging belt from above carrier side : Example 1 : Fig. 3.7.3-1 (Note : Drag in front surface up).

Take-up pulley of gravity shall be fixed upper side temporary without weight.

Fig. 3.7.3-1

When dragging belt from under on return roller : Example 2 : Fig. 3.7.3-2

(Note : Drag in back surface up).

Fig. 3.7.3-2



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3) Drag wire rope into the direction contrary to the direction of the arrow of the figure of example 1, 2. IMPORTANT! When stringing wire rope around pulley, protect on the pulley surface by

timber etc.

Fig. 3.7.3-3

4) Joint of belt and wire rope Lift belt drum on the support stand, and mount belt dragging metal fittings on belt and set wire rope onto the dragging metal fittings.

Fig. 3.7.3-3 5) Belt dragging

Drag belt by winch. Note 1:Moving of belt end, super-intendent shall move and always contact with the winch operator.



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Note 2 :Vulcanize or splice long belt conveyor on the way while dragging. 6) Belt tension

After the completion of belt dragging, over lap and fix the both edges of belt by belt clamp (for the last belt connection zone).

3.9. Installation of various belt cleaners 3.8.1. Kinds of belt cleaner

1) Kinds of belt cleaner

General kinds of belt cleaner are as follows.

Head cleaner ( For the front surface)

Return belt cleaner (For the back surface)

2) Position of belt cleaner General position are as follows.

Fig. 3.8.3-5



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3.8.2. General items for the installation of the cleaner Installed position for cleaner of the outline is shown in the construction drawing, but some parts maybe modified to adjust during construction and test run. At this time pay attention to the following items. 1) Check the installed position of cleaner with the drawing and confirm it. 2) Confirm whether the direction and the angel of tip and rubber are proper. 3) Confirm whether the end of tip and rubber touches belt surface uniformly. 4) Confirm whether the pressure that tip and rubber contact on belt is proper. 5) Confirm whether lock nut of adjusment bolt or all fixations bolt are sufficiently

fastened up. 6) Confirm whether it is functionally installed in the position not to be in the problem

even if tip and rubber consume. 7) When the spills falls onto direct cleaner during load testing, change the other

position. 8) Correct installation angle or adjustment bolt plainly in case of flapping (moving) tip

or the rubber tip during test run.

Fig. 3.9.1



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3.8.3. Tip type head cleaner 1) Installed position

As for head cleaner attached to the head pulley part, the optimum installation angle is decided. Generally, install tip within the optimum installation angle and also the direction of

tip to turn to the pulley axis center or rather up.

2) Pressure adjustment Adjus a pressure adjusting screw to be optimum pressure which the tip presses belt surface.

Fig. 3.9.3-1

Fig. 3.9.3-2



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3) Installation adjustment (for reference)

Manufacturer Type Optimum installation angle Remarks

H 0 ~ 150 The optimum installation angle to be almost 150 as

much as possible. MARTIN ENG.

P Specified in drawing

3.8.4. Installation of return belt cleaner

1) Install return belt cleaner in the illustrated place of the belt back, arrange V-shaped vertex on the centerline of conveyor frame, place as fully attached on the belt and rubber and adjust setting angle by bolt on the frame.

Fig. 3.9.4



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2) Then set sway stoppers to both sides of the frame.

3.9. Installation of Rain Cover

1) Install rain cover onto Z-plate on the conveyor frame as arrangement in the figure

below. Bracket of rain cover should be welded at Z-plate. 2) First, install the rain cover near Belt Cover as lower cover. Give space max 10

mm. 3) Continue with upper cover and next installation should be overlapped alternately

between upper and lower cover

Fig. 3.9.5



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IMPORTANT! Check arngement upper and lower cover shall be overlapped

alternately. Ensure the opening side will be in the walkway side.

4) If necessary to open the lower cover, must open the both of upper cover on the

two side. 4. Installation procedure for Belt conveyor

4.1. Installation procedure of conveyor frame 4.1.1. Lift up the girder

1) Lifting of girder shall be carried out according to the procedure of 4.1 figure 4.1 (refer to construction procedure of conveyor frame).

2) After lifting the girder reaches on the support leg, in accordance with conveyor frame

installation standard, check the level, center of the frame, and correct them when exceeds each tolerance.

Fig. 4.1



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Conveyor frame : check of conveyor center (when use transit).

4.1.2. Installation of one side plane frame 1) Confirm a center line by measuring diagonal distance of grid below (figure 4.3 a, b size)

every 30 m and correct according to the necessity. Tolerance of “a” and “b” is within 6 mm.

2) Provide a temporary support leg at every 30 m and measure dimensions based on this line. (for reference).



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4.1.3. Installation standard of the conveyor frame 1) Level of the frame (level of the orthogonal direction for the longitudinal center line)

L To the standard level line …...∆ h ≤

500

2) Center of conveyor frame Measure the center of conveyor frame with the piano wire or the transit and correct the displacement which exceeds allowable value. Checking and correction work shall be done elaborately an hardly for reversible conveyor.

Allowable value of the conveyor center line

L(m) MAX S (mm)

Within 100 20

101~300 30

301~500 50

501~1000 80

1001~2000 150



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2001~ 200

Partial displacement : within 5 mm for every 20 m L

3) Dimensional tolerance of the general steel structure part Connecting parts,

mechanical mounting part and the independent part of the general steel structure, check then based on the following dimensional tolerance.

Dimensional check These dimensional tolerance shall be applied otherwise specified in drawing

Inspection item Inspection part Tolerance

1. Overall size

1 Connecting part Shown in table 1

2 Mounted machine part

3 Independent part



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Table 1 Tolerance for steel structure part

Unit mm Dimensional range Connecting part Mounted machine

part Independent part

Equal to or less than 50 0.5 0.5 1.5

50~250 1.5 1.0 3.0

250~500 2.0 1.2 3.0

500~1,000 2.0 1.5 3.0

1,000~2,000 2.5 2.0 4.0

2,000~5,000 3.0 2.0 5.0

5,000~10,000 4.0 6.0

10,000~20,000 6.0 12.0

20,000~30,000 8.0 16.0

30,000~50,000 12.0 20.0

50,000~70,000 16.0 22.0

Connecting part ………… Mutual machine parts by the steel structure products.

Mounted machine part….. Part installs mechanics in the steel structure product.

Independent part………… Part which has not a mutual interface with the steel structure product



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4) Installation accuracy for steel structure.

Fig. 4.8

Fig. 4.7



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4.2. Installation procedure of the drive part for Belt conveyor 4.2.1. Installation of Head frame and drive unit

1. Installation work procedure 1) Install a drive bed frame 2) Install and level geared motor

3) Centering of the sprocket wheel 4) Tighten up bolts for geared motor and adjusting bolts 5) Install roller chain 6) Install a cover 7) Filling of lubrication



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2. Erection procedure

1) Confirmation of the drive unit structure

2) Confirm the condition of the drive unit structure installed by direct welding or bolt fixation to the conveyor girder or the head frame structure.

3) Install drive bed frame. Place geared motor temporarily using, the lifting or point

specified by the crane or chain block onto the drive bed. Then use liner or shim and adjust the level As the position of geared motor installation hole as shown in Fig.4.10, always make the position which is the head pulley side of the drive bed slot hole beforehand.

4) Sprocket wheel centering For setting the sprocket wheel on the side of the geared motor, the jig tools and Lead wire or the straight measure shall be used and adjust to the installed head pulley side. Carry out this work more simultaneously with the clause 3).

Fig. 4.10



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5) Tighten up geared motor installation bolt and the adjusting bolt of the above after completion of the work clause 3), 4)

6) Install roller chain Hang roller chain on the sprocket wheels on the side of the head pulley and the side of the geared motor and connect it.

To shorten length of the chain shall be and set-off link when necessary. Incidentally, remove once beforehand and the roller chain shall be re-installed at the time of test run beginning because the conveyor is possibly operated dangerous.

7) Chain cover installation and the lubrication Supply lube oil from the mouth and install cover on roller chain.

4.3. Installation of take-up unit 1) General item

There are three kinds of forms to take-up belt in the following procedure. a. Notes

1) During dragging of wire rope and belt, laying or wrapping with sheet avoiding clay and sand so on not to adhere.

2) Move the tail pulley of the screw type beforehand on the side of the head until the tension time of belt.



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b. Installation procedure 1) Screw type 2) Gravity type

1) Cart type

Frame installation

Size measurementand adjusment

Tightening

Tail pulley installation

Measurementand record

Weight guide and weight box

Safety fence installation

pre assembly on the ground

Weight guide installation

Weight box installation

Foundation centering

Chipping of gravitytower foundation

Placing of pads

Gravity towertemporary installation

Mortar filling in theanchor bolt hole

(in case of anchor box)

Tightening boltand centering

Connecting of wire rope

Lifting and fixing ofgravity weight

Safety fence installation

Adjustment of line

Pre-assembling andcentering of the frame

Anchor bolt set

Mortar filling in theanchor bolt hole

(in case of anchor box)

Tightening boltand centering

Rail laying and centering

Measurementand record

Cart installation

Installation of pulley andwire rope sheave centering

to the cartMortar filling under the rail



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5. Inspection Procedure / General 5.1 Inspection standard and manual

5.1.1. For ironworks Steel measuring tape for dimension is JIS class 1. or equivalent.

1) General standard

a. Length of conveyor frame Length (m)

2 2~5 5~10 10~15 15~20 20~30 30~50 50~100 Equal to or more than 100m

Tolerance (mm)

Equal to or less than

± 4 ± 5 ± 6 ± 10 ± 12 ± 15 ± 20 ± 30 every 100m

b. Levelness of the full length

Length (m) Within 10m 10~20 20~30 Equal to or more than 30m

Tolerance (mm) ± 3 ± 5 ± 7 ± 10

c. Levelness (Either side frame) Within 2-m width, irrespective of the length : ± 3mm

d. Structure and support

Heigth (m) ~ 10 ~ 20 ~ 30

Tolerance (mm) ± 5 ± 8 ± 10 Leg width (m) Within 10

Tolerance (mm) ± 5

e. Straightness (center line)

Whole length : ± 3 mm

5.1.2. Inspection procedure for belt conveyor

a. Length inspection



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Measures between the centers of the head pulley and the tail pulley with the measuring tape on the horizontal belt conveyor. Inclined and / or short belt conveyors are applied with the above method. Measure with the tape the center distance at every span of middle support between the tail pulley and the head pulley, about the frame length more than 50 m in the above.

b. Levelness of the full length As for horizontal belt conveyor ,marking Y level in the optional part on the middle frame, measure level with standing stretch scale. As for inclined conveyor, measure lift level from GL of FL with transit and scale.

c. Levelness (Either side frame) Measure the level of the either side frame with standing stretch scale by the leveler which is mounted on the optional on the middle frame.

d. Structure and the support Check dimensions of the full length (H), leg width with the tape measure at the time of the pre-assembly on the ground. Inspect structure for levelness, plumpness with Y level, the transit, and the tape measure after assembly finishing.

e. The straightness (center line) For the short frame, measure a difference from center of the frame edge to the real center between head frame and tail frame center, using piano wire or transit. For the long frame, divide into suitable length, measure a difference from the center middle of the frame to the real center line transferred onto the foundation center by

transit.

5.1.3. Drive part a. Inspection of pulley Unit : mm

Levelness ± 0.5

Right angle degree ± 0.5

Centering ± 3 from the frame center



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Levelness : Place leveler on the top of the pulley outside diameter surface and measure it. Or measure level by Y level standing stretch

on the either side bearing Right angle degree : Piano wire set up piano wire to the frame

center, plumb bobs in front and back of the pulley and adjust same value (A,A’) with the pulley center marked around the pulley.

b. Chain drive

Sag For the roller chain transmission, suitable sag shall be set. In general, suitable sag will be (S,S’) about 4% of the span length. In the following case, set it about 2%.

1) In case of arrangement perpendicular transmission 2) When the distances among axes is equal to or more than 1m 3) When starting often in the heavy load 4) When operating suddenly

Fig. 5.1



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Parallelism and the levelness

In case of installation, install sprocket wheel after confirming the parallel and level of both axes. Put the stretch of stretched string on the side of both sprocket wheel, adjust a both sprocket wheel to be in being same plane.

5.2 Performance test 1) Measurement of the belt speed

Measure the speed by the installed circumstances measurement onto the handy clock type rotating speed indicator by JISB7521.

2) Power check 3) Measure the electric current and the voltage with the meters in the Electrical room or handy

ammeter. 4) Noise measurement

If necessary, measure noise by the ordinary noise meter type NA-09.

5.3 Welding inspection Inspect about excess metal, the throat thickness leg, the undercut, the overlap, the leg length. The crater, the blowhole and so on and repair the defect part.

5.4 Visual check

Inspect the surface strain part in each join part, hammer mark, the other flaw of temporary weld point, top coat and repair the defect part.

Fig. 5.2



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6. Conveyor belt Scale Installation 6.1 Theory of operation

A conveyor belt scale has two components: the weigh-frame that transmits the mass of the product being conveyed to the load cells and the speed sensor that measures the speed at which the conveyor is moving. These two components are then computed by the scale electronics to give the total bulk material that has moved over the scale.

It is necessary for the weigh-frame to transfer the mass being carried by the conveyor belt to the load cells in a totally linear fashion. For obvious reasons if the mass is held up by the conveyor belt in any way during the weighing cycle then the scale weigh-frame cannot transfer the mass to the load cells in a linear and accurate way. This will mean that the scale will not measure the mass of the product being conveyed accurately.

In order to allow accurate weight transfer to the load cells, the scale weigh-frame must be accurately installed in relation to the conveyor itself. This installation process is of paramount importance to the accuracy, reliability and longevity of the scale. The installation process is covered in detail in Section 4 of this manual.

The speed input device is often overlooked when it comes to accurately setting up a scale or checking the calibration of a scale. The speed input device, although far less imposing than the weigh-frame, is as important as the weigh-frame when it comes to achieving accuracy on a conveyor belt scale. As can be seen in the calculation below, it is imperative that both speed and weight are accurately measured as they are both used in calculating the quantity of bulk material that passes over the belt.

The scale electronics computes the quantity of bulk material passing over the scale as follows:

M = Mass in Kilograms per meter / Pounds per feet S = Speed in Meters per second / Feet per second CT = Calculation time in milliseconds Tt = Totalizer adder

Every time the calculation is run the result (Tt) is added to an accumulator on the scale electronics display. This is commonly known as the totalizer function of the scale. The totalizer may also be



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transmitted by the scale electronics to a peripheral device such as a remote pulse counter, PLC, SCADA or DCS using a potential free contact pulse or any number of industrial communication protocols.

Note: The totalizer calculation shown above runs in both forward and reverse mode depending on whether or not M is negative or positive at the time. In addition to a totalizer tonnage, the scale is often required to indicate and transmit the instantaneous flow-rate over the scale. This calculation is much the same as the totalizer.

M = Mass in Kilograms per meter / Pounds per feet S = Speed in Meters per second / Feet per second Cs = Constant in order to convert seconds to hours Ct = Constant in order to convert Kilograms to hours Tph = Material rate of flow in tons per hour

For example: A belt is loaded at 100 Kilograms per running meter of length and is moving at 2.0 meters per second.

Once the instantaneous flow-rate has been computed it is written to the scale electronics on the board display and may be transmitted by means of an analogue 4-20mA signal or even using one of the many industrial protocols to a peripheral device such as a SCADA, PLC or DCS.

As can be seen in the above calculations, the speed and weight measurements are equally important and must be accurate in order for the scale to give accurate weighing results. In order to “pass” accurately accounted for speeds and masses onto the scale electronics for computation purposes, the integrity of the weigh-frame and speed input device must be beyond question.

6.2.1 Correct application of the technology

The rollers are the only components of the weigh-frame that come into contact with the conveyor belt itself. It goes without saying that the rollers must be aligned accurately with the belt in order to transfer the weight of the material conveyed accurately to the weigh-frame without exerting any



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other dynamic forces in the process.

The weigh-frame is the structure that supports the rollers and the weight of the belt and the product conveyed and ultimately transfers this mass to the load cells. Because of this, it is imperative that none of the aforementioned mass is “lost” due to the frame absorbing the load through deflection. Thus the scale frame is over-engineered to be rigid to a degree where deflection will be less than 1/1000. As it is the idler frame that holds the rollers in position, it is imperative that the frame allows the rollers to maintain an exact alignment with the belt. For this reason the scale frame and weigh class-idler sets must be precision made.

The load cells ultimately transfer the mass of the belt and product conveyed to the electronic controller. The calculations shown on the previous pages will enable you to envisage how important it is to have this done repeatedly and accurately. Once again the load cell mounting arrangement must be rigid and not absorb weight transfer through deflection of the scale frame or the stringer structure. The load cells themselves must have high resolution and must be capable of returning to the exact same position once they have been stressed and de-stressed. In order to this the load cells must only operate within their specified range, even during gross overloading of the conveyor.

The speed input device, as can be seen in the calculations on previous pages, is as crucial in determining accurate weights as the aforementioned components. The contact made with the belt must be consistent and without excessive wear and the device should deliver a high resolution accurate output to the scale electronics. The speed sensor must also be designed not to slip when the belt is wet.

The electronics, as can be seen in the calculations on previous pages, must have sufficient computing power in order to do the relevant computing in the shortest possible time. The more times per second that this calculation is performed the better the cut (sample) of actual product on the belt. This in turn will mean that at the higher the sampling rate of the scale the less the chance of “missing” a peak or trough of the product conveyed, hence higher accuracy. The electronics are not only responsible for computing, it must also display all relevant information to the operator and scale technician as well as transmit data to control devices such as a PLC, DCS or SCADA.

6.2 Installation Procedure

Installation of conveyor belt scale are bellow item: 1. Position Scale Frame And Idler Sets On Conveyor Stringers

1.1 Check for obstruction over proposed installation area 1.2 Check securing points of scale and idler sets for obstructions

2. Obtain The Mean Centre Line

3. Install Scale Frame To Mean Centre Line

3.1 Check Scale Frame Assembly



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3.2 Check On Scale Weigh Class Idler Set Installation 3.3 Install And Level Frame 3.4 Shim Frame To Correct Height 3.5 Check Scale Frame Installation

4. Install The +3 And -3 Idler Sets

4.1 Align +3 And -3 Idler Sets 4.2 Level +3 And -3 Idler Sets 4.3 Shim +3 And -3 Idler Sets 4.4 Check +3 And -3 Idler Sets

5. Run Installation Reference Lines 6. Install +1 , +2, -1 And -2 Weigh Class Idler Sets

6.1 Align +1 And +2 And -1 And -2 Weigh Class Idler Sets 6.2 Level +1 And +2 And -1 And -2 Weigh Class Idler Sets 6.3 Shim +1 And +2 And -1 And -2 Weigh Class Idler Sets 6.4 Check All Weigh Class Idler Sets Installation

7. Check Installation Integrity 8. Check Belt Tracking And Alignment 9. Commissioning Of The Scale



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6.2.1. Position Scale Frame And Idler Sets On Conveyor Stringers

1.1 Check For Obstructions Place frame and idler sets in conveyor stringers where proposed installation is to take place. Check if there are any stringer components in the way of the scale frame, any components hindering the accurate installation and free movement of the scale frame must be removed. Obtain the permission of the resident engineer and remove the obstruction. Care must be taken not to affect the integrity of the conveyor structure in any way. If the integrity of the structure will be affected then the conveyor must be supported in another way before the obstruction is removed. Care must be taken to abide by corrosion protection and engineering standards when removing any obstructions linked to the conveyor structure. If any obstruction is found to be immovable then the scale installation must be shifted to the closest and next best location on the conveyor.

1.2 Check Securing Points

Once the scale and idler sets are placed in position, check the points that require welding or drilling on the stringers. They must be free of obstruction and stringers must not be joined over scale area. Any joints within or in close proximity to the scale installation must be welded up to prevent movement. If drilled hole centers fall on the beam centres or other obstructions, the installation must be moved slightly if possible. If not possible, the mounting method or the scale itself must be modified to work around the obstruction.

6.2.2 Obtain The Mean Centre Line

Obtain a mean centre line as shown in Diagram 01. This is done by lightly pock marking the centre of the centre roll on each idler set at least six idler sets before either scale installation and six idler sets after the scale installation (excluding weigh class approach and retreat idler sets). A fish line is then run taking the mean average of all the pock marks as dead centre for the installation.



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6.2.3. Install Scale Frame To Mean Centre Line

6.2.3.1 Check Scale Frame Assembly Check that the scale frame has been correctly assembled and that the torsion rods and load cell assemblies are correctly installed and tensioned.

6.2.3.2 Check On Scale Weigh Class Idler Sets For Correct Installation

In most cases the scale itself will arrive on site with the on scale idler sets already installed, leveled, and aligned. The scale is set up in the factory to be exactly square. If the scale is not fully assembled for transportation or access reasons this must be done at the point of installation before the scale is placed in the conveyor.

On factory set up scales check the scale assembly before placing the scale in the conveyor. Look out for the following: Idler sets installed exactly 1000mm apart, center roll level to scale frame in cross sectional direction. All securing bolts are tight and washers and nylock nuts are in place, the centre rolls are marked dead centre. The scale can now be positioned in the conveyor between the stringers and the alignment can take place. Make sure that the scale frame is level across the conveyor and dead centre to the mean centre line. The entire scale frame will then be square and level to the mean centre of the conveyor. NB: DO NOT USE THE STRINGERS TO ALIGN THE SCALE THEY ARE NOT A RELIABLE REFERENCE POINT.

6.2.3.3 Install And Level Frame The scale frame which is already in position on the stringer can now be aligned and installed exactly according to the installation reference line (mean centre line). Make sure that the scale frame is level and dead centre to the mean centre line. Refer to Diagram 02.



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6.2.3.4. Shim Frame To Correct Height The scale frame can now be shimmed to the correct height using the mean centre installation reference line to obtain the exact height within 0.25 mm. The correct height is between 4 and 8 mm higher that the existing conveyor idler sets taken over at least eight idler sets before and after the scale weigh platform.

6.2.3.5 Check Scale Installation Make sure that the scale is installed exactly centre to the mean centre line, level across the stringers, level along the stringers, and 4-8mm higher than the existing conveyor idlers according to the mean centre installation reference line. Check that the on scale torsion rods and load cell mounting arrangements are correctly installed and tensioned. If these are loose or if they work loose, the scale installation is affected and inaccuracies will occur. Check the scale frame for cross square in order to make sure that nothing has shifted

6.2.4. Install The +3 And -3 Idler Sets

4.1 Allign +3 And -3 Idler Sets The first approach and last retreat weigh class idler set must now be installed and aligned according to the mean centre line. Refer to Diagram 03. These idler sets must be exactly the same distance from the centre of the scale frame to within 0,25 mm. Leave the correct spacing for the +2, +1 and -2, -1 off scale weigh class idler sets. Spacing is 1000 mm +/-0,25 mm. The idler sets must be installed square to the mean centre line with the centre of their centre rolls being exactly on the mean centre line.



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4.2 Level +3 And -3 Idler Sets

Once the idler sets have been installed as above, they must be checked for being level across the conveyor. Place a spirit level on the centre roll and shim the idler set until it is level. Be careful on installations that are on an incline or decline. If the level is held slightly skew on the centre roll, the idler set will appear to be out of level. Make sure the level is held straight along the top of the centre roll. A line can be drawn on the centre roller using a square to assist with this.

4.3 Shim +3 And -3 Idler Sets

Once the +3 and -3 weigh class approach and retreat idler sets have been leveled, they must be shimmed to be 4 to 8 mm higher than the existing conveyor idler sets using the already installed scale frame as a reference for height. Again, we work off a mean average as any of the existing conveyor idler sets may not be exactly the same height. The rule is however, that no existing roll within fifteen idler sets on either side of the scale installation may sit higher on the conveyor than any scale roll.

4.4 Check +3 And -3 Idler Sets The +3 and -3 weigh class approach and retreat idler sets are now installed and can be used to run the installation reference lines. Do a final check on the +3 and -3 idler sets verifying that they are:

a) Square to the centre line b) The correct distance from the centre of the scale c) Equidistant from each other on both sides of the conveyor d) Level across the conveyor using a good spirit level e) Between 4 to 8 mm higher than any existing conveyor roll (using the scale height

as a reference) within 15 idler sets on either side of the scale installation (or mean level).



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6.2.5. Run Installation Reference Lines Once point 3 above has been completed the +3 and – 3 idler sets can be used to run the scale installation reference lines. Using fish line at least 1mm thick, run six installation reference lines as per Diagram 02. Make sure that the lines are tensioned to almost breaking point so as to limit sagging between idler sets. Make sure that each line is placed the same distance from the sides of the rollers on both idler sets.

6.2.6. Install +1, +2 And -1, -2 Off Scale Weigh Class Idler Sets

6.1 Align +1,+2 And -1, -2 Off Scale Weigh Class Idler Sets The second and third approach and first and second retreat weight class idler set must now be installed and aligned according to the mean centre line. See Diagram 04. These idler sets must be exactly 1000mm (±0.25 mm) from each other and the +3 approach and retreat idler set as well as the No. 1 and No. 4 (or 2 or 6 scale dependent) on scale weigh class idler sets. The idler sets must be installed square to the mean centre line with the centre of their centre rolls being exactly on the centre line.

6.2 Level +1,+2 And -1, -2 Off Scale Weigh Class Idler Sets

Once the idler sets have been installed as above, they must be checked for level across the conveyor. Place a spirit level on the centre roll and shim the idler set until it is level. Be careful on installations that are on an incline or decline. If the level is held slightly skew on the centre roll the idler set will appear to be out of level. Make sure the level is held straight along the top of the centre roll.

6.3 Shim +1,+2 And -1, -2 Off Scale Weigh Class Idler Sets

Once the off scale idler sets have been leveled, they must be shimmed to be the same height as the scale itself. Again, work off the installation reference lines.



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6.4 Check All Weigh Class Idler Sets

The weigh class idler sets both off scale and on scale are now installed. The installation must be verified. Do a final check on the idler sets verifying that they are square to the mean centre line, 1000mm apart from each other, level across the stringers and 4 to 8 mm higher than any existing conveyor roller for at least 15 idler sets on either side of the scale installation.

6.2.7. CHECK INSTALLATION INTEGRITY

Once the installation has been completed the entire installation must be re-checked as one loose bolt can cause the scale to perform badly or even get damaged. Leaving the installation reference lines in place check the installation from start to finish. Fill in the installation check sheet provided in order to start a history of the scale. Before checking the installation, check that the installation reference lines have not shifted and are still tensioned correctly. Check that all of the torsion rods are correctly tensioned. (You should be able to turn these with your hand. There should be some lateral movement in the cross sectional torsion rods above the scale frame.)

6.2.8. CHECK BELT TRACKING AND ALIGNMENT

Once the belt has been lowered, the belt must be run for at least 20 minutes before belt tracking can be accessed. The belt must be tracked as the correct installation of a scale can influence the belt tracking. If the tracking is out it must be adjusted without interfering with the scale installation area.

6.2.9. COMMISSIONING OF THE SCALE

The conveyor must be run for several days under normal loading in order for the scale installation to settle in before the scale is commissioned. Once the conveyor has been run under load any shift in the stringer structure (conveyor structure) will be able to be detected and corrected. In order to commission the scale the belt will have to be lifted over the scale installation area to a height of at least 1000mm. The scale installation is then checked using the same reference lines as used during the installation. If the scale installation has not shifted commissioning and calibration can proceed. If the installation has shifted the conveyor structure must be reinforced and the scale re-aligned before commissioning and calibration. Leave the conveyor in its lifted position. The load cells are then connected to the electronics and the speed sensor fitted to the # 2 idler set on the scale itself. The scale is then calibrated using static test weights on the scale frame itself. NOTE: this is not final calibration as final calibration can only be done once the belt has been lowered and run for 20 min. The scale is then checked for balance using a single 20kg test weight placed on each of the four corners of the scale as close to the load cells as possible. When the weight is moved from one corner to the other the SM (scale mass) reading should be 20kg +/- 0.3kg. If this is not the case a minor adjustment of the load cell mounting rod underneath the scale frame can be made. Tighter will increase the SM indicated mass, looser will reduce it. Care must be taken not to adjust the scale out of alignment when



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making these adjustments.

Once the scale has been balanced the belt can be lowered and run empty for at least 20 min before final calibration can be done. See Section 4 - Calibration.

6.2.10 Initial Installation

6.2.10.1 920i Hardware

Installation of the hardware (option cards) required for the intelli-weigh conveyor belt scale is carried out at the factory by trained technicians. These cards can be replaced if found to be faulty by switching off the supply to the electronics and removing the fastening screws located on the one end of the card. The card is then unplugged from the option slot connector and the replacement card fitted in its place. Care must be taken not to expose the option card to an electrostatic charge when handling the cards. The cards are shipped in antistatic packets and should be stored and transported inside these packets. Once the card has been replaced, the fastening screws are re-inserted and tightened and the scale is switched back on. The scale does not require re-calibration.

6.2.10.2. 920i Software

The software version of the intelli-weigh model that you have purchased is shown on the home screen. This software is compiled and loaded at the factory and cannot be accessed by the user. Custom software can be written on request for special applications.



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6.3. OPERATION

1. Home Screen 2. Various Screen Views

2.1 Views Diagnostics

2.2 Scale Setpoints

2.3 Calibration Screens

2.3A Perform Dynamic Zero Calibration 2.3B A-Manual Span Adjustment 2.3C Material Bulk Test



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2.1 Views Diagnostics

The diagnostics screen allows the user to view all the values relating to each of the four load cells and the speed input device associated with either A or B scales. This screen further allows the user to override any one of the load cells or a speed input device that s/he may feel is faulty.



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2.2 Scale Setpoints NOTE: A technician level password is required to access the Scale setpoints



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6.4. Calibration

Calibration of your conveyor belt scale consists of two types of calibration namely, initial calibration and routine or maintenance calibration. Initial calibration is only performed after installation or major repairs or overhauling of the scale. Routine or maintenance calibration is performed after minor repairs or as part of a routine inspection in order to confirm the scales accuracy.

4.1 Initial Calibration

Initial calibration is done after the scale installation has been correctly performed and only after the conveyor belt has been run and checked for proper alignment to the carry rollers on the conveyor.

Initial calibration consist of a mass and a speed calibration. The mass calibration is done on a static (stationary) belt, while the speed calibration is done on a moving belt.

4.2 Speed Calibration

Run the conveyor empty as this will give the highest speed output as the conveyor drive unit will not be under load. Measure the conveyor’s speed using a distance wheel and stop watch or a digital tachometer. Either method is acceptable provided the accuracy of the equipment used can be verified. Leaving the conveyor running adjust the conveyor belt scale integrator to show the same speed as the speed which you have just measured. Different scale integrators have different methods of adjusting this, so you will have to utelize the Operation & Maintenance Manual for the type of scale integrator you have installed. Turn to section 3. on page 21 of this manual if you have an Intelli-weigh scale.

4.3 Static Zero Calibration

Stop the conveyor belt and make sure that it is completely empty over the scale weigh-platform*. Perform a static (belt stopped) zero calibration on the scale integrator using the scales Operation & Maintenance Manual. For Intelli-weigh scales go to section 3 on page 52 of this manual.

4.4 Static Span Calibration

Leaving the conveyor in exactly the same position as it was in when the static zero calibration was performed calculate the test-weight (Tw) mass required to do the static span calibration. The test-weight mass should be a least 70% of the scales maximum operational loading although the closer to 100% the better the confirmed accuracy will be. The test-weight can be in the form of material (product) or static mass pieces which will be placed over the scale weigh-area* (Wa) during calibration. The test-weight mass must be able to be traced to an accurate and reliable source i.e. certified mass pieces or a certified check scale. The test-weight (Tw) value is calculated as such.



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DESIGN THROUGHPUT t/hr = t/hr/60/60/m/sec

BELT SPEED m/sec = Max kg/M = TW Value

The test-weight value above is 100% of the scale’s maximum operation loading (Lm) if it is not practical for logistical purposes or if the scale is to be checked by means of a material bulk test after the initial calibration, then we can allow a test-weight (Tw) value of as low as 70% of the scales maximum operational loading (Lm). Before commencing the static span calibration, check that the scale integrator is reading exactly zero loading, if not, you may have to perform the steps in point 3 above again. If the scale is reading exactly zero, continue with the steps below.

The test-weight is taken and placed evenly over the scales weigh-area (Wa), in the case of static mass pieces it is preferable to place these between the idler sets and not directly above the carry rollers as this forms a more realistic loading of the belt, thus allowing belt tension to play a more realistic part in the calibration. Once the test-weight (Tw) has been evenly spaced over the weigh-area (Wa), adjust the scale integrator (indicated value “Ind”) using the Operation & Maintenance Manual to read the same as the actual (“Act”) or test-weight (Tw) mass.

Your scale has now been initially calibrated. A routine calibration or maintenance calibration shown in Section 4. of this manual must now be performed in order to confirm the scale’ operational accuracy.

4.5 Routine / Maintenance Calibration

The routine/maintenance calibration is performed after an initial calibration or minor repairs to the scale or for the purposes of verifying the scale’s accuracy. A routine calibration consists of using the scales on board calibration functions to verify/check the scale’s existing calibration and, if necessary, to make adjustments to the existing calibration. The routine calibration, like the initial calibration, covers both the speed and mass components of the scale on both the zero and span calibration points. Unlike the initial calibration, we do not adjust the scale without first evaluating the scale’s existing calibration several times.

4.6 Speed Calibration Checks

Stop the conveyor and make sure that the speed indication is reading zero. Once the speed indication has been verified to read zero on a stationary belt, start the conveyor and run it empty. Once the conveyor has reached optimal speed and is reading a stable speed reading, begin to measure the actual conveyor speed using a distance wheel and a stopwatch or a digital tachometer. Measure the actual speed while observing the scale integrator speed in order to make sure that it does not drift or is not erratic. If the integrator speed is drifting or is erratic consult with the factory technician and correct the problem before commencing with the



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routine calibration.

Compare the actual measured speed with the indicated speed displayed on the scale integrator and work out the indicated error. Complete this process until you have three separate test results all showing an indicated error. If the error is over 0.125% and is consistent over all three readings within 0.25%, use the average of the three readings and make a correction to the Tacho Resol value as shown on screen # 1 on page 61 of this manual.

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