doc1010 model n-64-2 io manual

7/23/2019 Doc1010 Model N-64-2 IO Manual

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DOC1010

Bulk Pro Systems, LLC 13361 Aberdeen Street NE Ham Lake MN 55304

Ph: 7637670003 Fax: 7637673282 Web: www.bulkprosystems.com

Confidential Page 1

MODELN642,3&4

Two(2)IdlerBeltScaleSystem

Version1.0


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Confidential Page 2

TableofContents

ChapterOne IntroductionandOverview1.0

SystemComponents............... 1.1

ScaleCarriage.1.1.1

LoadCells..1.1.3

SpeedSensor.1.1.4

Integrator.1.1.5

MountingLocation..1.2

Tension1.2.1

UniformBeltLoading1.2.2

SingleLoadBelt1.2.3

MaterialSlippage.1.2.4

ConvexCurves1.2.5

ConcaveCurves.1.2.6

Trippers..1.2.7

Speed

Sensor.

1.2.8

Wiring.1.2.9

OtherMitigatingFactors.1.2.10

ChapterTwo HardwareInstallation.. 2.0

Storage.2.1

Unpacking&Assembly.2.2

WeighbridgeInstallation.2.3

Terminology2.3.1

CarriageLocation.2.3.2

WorksitePreparation2.3.3

WeighbridgeInstallation2.3.5

ScaleIdler

Installation.

2.3.6

ChapterThree Maintenance.. 3.0

CheckPoints.3.1

FrequentCheckPoints..3.2

ChapterFour Troubleshooting..4.0

CalShifts.4.1

ZeroCalShifts..4.1.2

SpanCalShifts..4.1.3

FieldWiring..4.2

LoadCellResistanceCheck4.3

LoadCellmVCheck.4.4

ChapterFive

Warranty..

5.0


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1.0 IntroductionandOverview

Abeltconveyorscaleisadevicethatcontinuouslymeasuresbulkmaterialasitmovesalongaconveyor.

Thesystemrequirestwogeneralparameterstooperate,onebeingitneedstoknowtheweightofthe

materialbeingmovedalongtheconveyorbeltandsecond,itneedstoknowthespeedatwhichits

movingalongtheconveyorbelt. Theweightofthematerialonthebeltisdeterminedbyweighinga

sectionofconveyorbeltloadedwithmaterialandthensubtractingtheaverageweightoftheunloaded

belt. Thespeedatwhichthematerialismovingisdeterminedbymeasuringthespeedofanidleror

wheelincontactwiththeconveyorbelt. Theweightandspeediscombinedtogivearunningtotalanda

rateofflowofthematerial.Thecorrectoperationofthescalesystemrequiresthecomponentstobe

installedcorrectly,periodicallycalibrated,andproperlymaintained.

Typicalapplicationswhereabeltconveyorscalecanbeusedare:

Mining

Quarries

BulkMaterialBlending

Truck/Barge/RailLoading

ProcessControlApplications

Abeltconveyorscaleisalsoabletocomputethetotalmassofthematerialthatisconveyedoveragiven

periodoftimeandwhileitisinmotion.

1.1 BeltConveyorScaleSystemComponents

Themain

components

of

abelt

conveyor

scale

are:

Scalecarriage

Loadcells

Belttravelpickupspeedsenor

ElectronicIntegrator

1.1.1 ScaleCarriage

Thescalecarriageismountedtoaconveyorstructureandtransmitstheforcesresultingfromthebelt

loadanddirectsthoseforcestotheloadsensor(s).

1.1.2 LoadCells

Therearefourstraingaugeloadcellslocatedtwopereachweighbridge. Thesesensorssupportthe

weightoftheconveyorbeltandthematerialmovingalongonthebelt.Theweightsignalsfromtheload

cellsarecombinedandprocessedbytheintegrator.


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1.1.3 BeltTravelSpeedSensor

Thebelttravelspeedsensorismounteddirectlytoanondrivenpulley. Inmostcasesthisisthetail

pulleyoftheconveyorbelt. Thesignalgeneratedbythespeedsensorisconvertedbytheintegrator

intoavaluethatrepresentsbelttraveldistance. VariousdevicesusedforsensingbelttravelincludeAC

andDC

generators,

mechanical

belt

or

chain

drives,

photo

optical

segmented

disks,

and

electromagnetic

pulsegenerators.

1.2 SelectingaMountingLocation

Itisveryimportanttoselecttherightmountinglocationforthescalecarriagealongtheconveyor

structureandthelocationofthespeedsensor. Thereareseveralfactorsthatmustbetakeninto

considerationwhenselectingamountinglocation. Thosefactorswilldetermine theoveralllongterm

andshorttermaccuracyyoumightexpect.Thosefactorsincludethefollowing:

Tension

UniformBelt

Loading

SingleLoadBelt(Contactfactoryifmultipleloadpoints)

MaterialSlippage

ConvexCurves

ConcaveCurves

Trippers

SpeedSensorMountingLocation

ElectronicWiringLocation

SpeedSensor

OtherMitigatingFactors

1.2.1 Tension

Thetransferofweightalongtheconveyorbeltcanbegreatlyaffectedbybelttension. Bylocatingthe

scalecarriageinanareaoftheconveyorwiththeleastamountoftension,thescalewillbemore

accurateandachievebetterperformance. Anideallocationtomountthescalecarriageisnearatail

sectionoftheconveyor,butfarenoughforwardsoasnottobeinfluencedbyinfeedskirtsboards,etc.

1.2.2 UniformBeltLoading

Itisdesirablethatthebeltloadingbeasuniformaspossibletopreventunequalshiftsinmaterial. To

minimizesurges

or

feed

variations,

hoppers

should

be

equipped

with

depth

limiting

gates

or

other

flow

controldevicessuchasafeeder.


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1.2.3 SingleLoadBelt

Onhighaccuracyinstallations,theconveyorshouldbeloadedatoneandthesamepoint. Thisassures

constantbelttensionatthescaleduringallloadingconditions.(Contactfactoryaboutmultiple feed

points.)

1.2.4 MaterialSlippage

Thebeltscalesystemprocessesbeltloadingandbelttraveltoarriveatanaccurateweight. Product

speedmustbeequaltothebeltspeedatthescale.Sotheconveyorspeedandslopeshouldnotexceed

thatatwhichmaterialslippageoccurs,whichisapproximatelyat18angle.

1.2.5 ConvexCurves

Conveyorsthathaveconvexcurvesshouldbeavoidedorthescaleshouldbelocatedinasectionofthe

conveyorthatisnotaffectedbythecurve.

Convexcurves

are

permissible

at

adistance

of

20

feet

or

aminimum

of

five

idler

spaces

beyond

the

scaleareaidlers.

Figure 1-5. Convex Curved Conveyor


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1.2.6 ConcaveCurves

Conveyorsthathaveconcavecurvesshouldbeavoidedorthescaleshouldbelocatedinasectionofthe

conveyorthatisnotaffectedbythecurve. Ifthereisacurve,thebeltmustremainincontactwiththe

idler

rollers

at

all

times

for

at

least

20

feet

(6m).

Figure16.ConveyorConvexandConcaveCurves

1.2.7 Trippers

Inanyinstallation,whereweighingaccuracyisimportant,thescaleshouldnotbeappliedtoaconveyor

thathasamovabletripper. Ifthescalemustbeinstalledonaconveyorwithatripper,thenthesame

rulesapplyasforaninstallationinaconcaveconveyor. Theminimumdistancesoutlinedintheabove

paragraphmustbeadheredtowiththetripperinitsfullyretractedposition. Itisalsoofextreme

importancethatthebelttrackscentrallyatthescaleareaforalltripperlocations.

Figure17.TripperLocationIllustration


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1.2.8 SpeedSensorMountingLocation

Thespeedsensorlocationisjustascriticalasscalecarriagelocation. Improperinstallationofthespeed

sensorwillsignificantlyaffecttheperformanceofthescalesystem. Thespeedsensormustgivean

accuraterepresentationofthespeedofthematerialandtravelofthebelt.

Ifthetailrollisnotaccessiblethenthespeedsensorcanbemountedonatailingwheelthatridesonthe

returnsideofthebelt,oronaliveshaftroller. Ifatrailingwheelisused,thewheelshouldbelocated

onasectionofthebeltinwhichbeltvibrationwillnotaddmovementtothewheel. Thepreferable

locationwouldbedirectlyoppositeaconveyorreturnroll.

Ifaliveshaftrollerisinstalledtosensethebeltspeed,therollershouldhavepositivecontactwiththe

belt. Thepreferredlocationwouldbebetweentworeturnidlerswiththespeedrollerbeinginstalled

onthetopsideofthereturningbeltandthereturnidlersinstalledonthebottomside.

Figure17.SpeedSensorPulley

1.2.9 ElectronicWiringLocation

Thelocationfortheelectronicstobemountedisdeterminedbyaccessibility,wirerouting,and

environment. Thescaleelectronicsrequireacleanandstable120VACsupply. Theenclosureforthe

electronicsis

rated

NEMA

4X.

The

electronics

can

be

mounted

up

to

3000

away

from

the

scale

carriage

providedtheoptionalloadcellsensewiringisinstalled. Iftheelectronicsaretobeinstalledwithin200

ofthescalecarriage,theoptionalsensewiringisnotrequired. Toreducetheeffectsofsignal

interference,thescalesignalsshouldnotberuninconduitorcabletraysinconjunctionwithhigh

voltagecables.


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ThedigitalinputandoutputsignalsarecompatiblewithOPTO22relaymodulesandcanbecontrolled

withAC,DCordrycontactsignals. Theanalogoutputsignalforrateofflowcanbewiredfor010VDC,

210VDC,020mAcurrentor4 20mAcurrent.TheprintersignalcanbeRS232,RS485,or20mA

currentloop.

1.2.10Other

Mitigating

Factors

Windandweathereffects

Vibrationanddeflection

ConveyorSupport

Thescaleandconveyoratthescalewillbeprotectedfromwindandweathereffects. Themagnitudeof

weighingerrorscausedbywindisdependentonwindvelocity.

Theentireconveyorframeshouldbeisolatedfrombins,feeders,crushers,andothermechanical

equipment. Thisistopreventbinloadingfromcausingconveyordeflectionsandtoprotectthe

weighingequipment

from

vibrations

and

shocks

imposed

by

mechanical

equipment.

Inthedesignofthescale,severaldeflectionsaretakenintoconsideration. Thesearethedeflectionof

theloadcells,thedeflectionofthescalecarriageandbridgeassembly,andthedeflectionofthe

supportingconveyorstructure. Itisofutmostimportancethatthesedeflectionsnotbeexcessive. In

themanufactureofthescale,theamountofdeflectionintheloadcellsandthecarriageandbridge

assemblyiscontrolled. Theonlyvariableisthedeflectionoftheconveyoritself. Therefore,the

conveyorstringerssupportingthescaleandfiveidlerstoeithersideofthescaleshouldbeofamplesize

andbeadequatelysupportedtolimittherelativedeflectionbetweentwoadjacentidlerstonomore

than0.025inches(0.6mm). Noconveyorexpansionjointsorstringersplicesshouldbelocatedinthis

region

of

the

conveyor.

Refer

to

field

installation

drawing

for

required

mechanical

supports.

2.0 HardwareInstallation

Thissectiondescribesproceduresforconnectingthescalecarriage,speedsensor,andanyassociated

wiring. Installationinstructionsareexplainedinfurtherdetailinthefollowingsections.

Installationinstructionsfortheintegratorareexplainedintheseparateintegratormanual.

TakeallnecessarysafetyprecautionswhensettinguptheBulkProSystems,LLC In

motion

belt

scale

system,

including

wearing

safety

shoes,

protective

eyewear

and

using

the

proper

tools.


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2.1 Storage

ThePrecisionBeltScaleandassociatedequipmentcanbesafelystored,withcoverlatchessecuredand

holeplugsinstalled,between58to+185F(50and+85C).Theunitsshouldbeprotectedagainst

moisture.

2.2 UnpackingandAssembly

Uponreceiptoftheshippingpallet,visuallyinspectallcomponentstomakesurethattheyareincluded

andundamaged. Theshippingcartonshouldcontainthescalecarriage,theindicator,thismanual,anda

partskit. Ifanypartsweredamagedinshipment,notifyBulkPro Systemsandtheshipperimmediately.

NOTE:Toensurethatallproductsreceivedfromthemanufacturerareingoodshapeuponarrival,itis

recommendedtofullyinspectallcontentsandproperlycompletethebilloflading.

2.3 WeighCarriageInstallation

Thissection

is

to

be

used

as

aguide

in

the

installation

of

the

Bulk

Pro

Systems

Model

N

64

Weighbridge

andassociatedscaleareaidlers. Allmodelsareinstalledinthesamemanner,asthemodelsdifferonly

innumberofweighidlersandthescaleareaidlerspacing. Overallstructuredeflectionmustbe

maintainedwithin0.025inches(0.6mm)betweenadjacentidlers.

2.3.1 Terminology

Weighbridge: TheWeighbridgeisafactoryalignedassemblyconsistingofafullfloatingweigh

platform,twosupportbeamsandfourprecisionstraingaugeloadcellsappliedintension.

WeighIdlers: TheWeighIdlersrefertothoseidlersmounteddirectlyontheWeighbridge.

Scale

Area

Idlers:

The

Scale

Area

Idlers

refer

to

the

weigh

idlers

and

the

group

of

idlers

located

adjacenttoandoneithersideoftheweighidlers. Theidlersareidentifiedasplus(+)orminus(

)ontheinstallationdrawing. Atleastfourandasmanyassevenplusandminusidlersare

closelyalignedwiththeweighidlers. Theyareconsideredpartofthebeltscale,andplayan

importantroleinoverallbeltscaleaccuracyandoperation.

2.3.2 CarriageLocation

SelectthescalelocationbyfollowingtheoutlineinChapter1,MountingLocaitonCriteria. Apartial

listingoftherequiredguidelinesfollows:

Thescale

conveyor

should

not

be

attached

to,

or

have

vibrating

devices

installed

on

it.

Installthescaleonarigidconveyor.

Theapproachweighidlershouldnotbelocatedcloserthan20feetorfiveidlerspaces;

whicheverisgreater,fromloadingpointorskirting.

Thescalemustnotbeplacedinconcaveorconvexcurves.


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Thescalemustnotbeinstalledwhereconveyorspeedandslopecausesmaterialslippageto

occur.

Locatethescalewhereithasmaximumprotectionfromtheelements.

Thescaleconveyorshouldnotbeattachedto,orhavevibratingdevicesinstalledonit.

2.3.3

WorksitePreparation

Afterdeterminationofscalelocationintheconveyor,proceedwithsitepreparationasfollows:

Strengthentheconveyorframework.

Fishplateandweldtogetherallconveyorsectionsintheregionofthescale.

Leveltheconveyorinthetransverseplanebetweentheminus4andplus4idlers.

Allscaleareaidlersmustbethesamemake,style,andmodel,andshouldbeinfreerollingand

otherwisegoodmechanicalcondition.

Locatetheexactcenterofthecarryrollonallidlersfromminus4toplus4.Permanentlyscribe

orpunchthiscenterpositiononeachcarryroll. Inaddition,performthesameprocedureonthe

troughingand

wing

rolls.

Dependingonthemodelofscale(N642,N643orN644)two,threeorfouridlersmusthave

theremountingbracketsmodifiedtobeusedasweighidlers. Refertoweighidlermodification

drawing(Figure21).

Onscalesforbeltwidthsover36inches,thescaleareaidlers(plus4tominus4)shouldhavea

strengtheningbracefromthewingrollbracetothebottomframe. Thisbracingstrengthensthe

idlersoitwillnotwarpunderload. Refertoweighidlermodificationdrawing(Figure22).

Foreaseinequipmentinstallationandalignment,elevateorremovetheconveyorbeltingfrom

thebeltscalearea. Beltclearancewillbeneededfromatleasttheminus6toplus6idler.

Removetheidlersfromthesectionoftheconveyorwheretheweighbridgewillbeinstalled.

Althoughnotrequired,inmostinstallationsitiseasiertoremoveallidlersbetweentheplusand

minus

4

idlers.


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Figure

2

1.

Weigh

Idler

Modification

Notes:

1. Troughingidler(s)suppliedbycustomer.

2. Removeexistingmountingfeetorchannelfromidlerbytorchcuttingorsawing. Makecutouts

asshown. Weldidlermountingbracketsinpositionasshown.

3. Mountingbracketsmustbeequallyspacedfromidlercenterline.

TwoplacessuppliedbyBulkPro


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Figure22. WeighIdlerModification42"through96"BeltWidth

Notes:

1. Troughingidler(s)suppliedbycustomer.

2. Fabricatesteelchannelgussettosuitidler. Gussettobeinstalledbeforeremovingfeet(see

note3)topreventtroughinganglefrombeingdisturbed.

3.

Removeexistingmountingfeetorchannelfromidlerbytorchcuttingorsawing. Makecutouts

asshown. Weldidlermountingbrackets,inpositionasshown.

4. Mountingbracketsmustbeequallyspacedfromidlercenterline.

Two laces su lied b Bulk Pro


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2.3.4 WeighbridgeInstallation

Afterselectionofthescalelocationandpreparationofthesite,proceedwithinstallationasfollows:

1. Dimensionallylocateandmounttheminus4andplus4idlers. Atthesametime,shimthese

idlersto1/4inchabovethebeltline.

2. Ononesideoftheconveyor,scribeamarkequidistantfromtheminus4andplus4idlers.

3. Determinewhichendoftheweighbridgeistowardtheheadpulleyinahorizontalor

inclinedconveyor.

4. Inserttheweighbridgeintotheconveyorgallery. Determinethelongitudinalcenterofthe

weighbridgeandaligntheweighbridgecenteronthescribemarklocatedinStep2.

5. Establishaconveyorcenterline. Extremecareshouldbegiventothisprocedure,asall

measurementswillbereferencedfromthiscenterline.

6. Tieahighquality30poundtestmonofilamentline,orequivalent,tothebaseoftheplus5

idler. Runthislineacrossthecentermarkontheplus4carryrollthroughthescaleareaand

acrossthecentermarkontheminus4carryroll. Attacha30poundweighttotheendof

thelinetomaintainconstanttension.

7.

Ifnecessary,movetheminus4andplus4idlerstopositionthecenterofthecarryrollson

theconveyorcenterline.

8. Checkforclearance(ifany)betweenthelineandtheminus4andplus4idlercarryrolls.

Theproperheightatthistimefortheserollsis1/4inchbelowtheminusandplus4idlers. If

necessary,addadditionalshimmingunderminusandplus4idlers.

9.

Positionthecentermarkonthetwoweighbridgesupportsdirectlybelowtheconveyor

centerlinewithreferencetothelongitudinalcenterestablishedinStep4ofabove.

10. Drillholesfortheweighbridgesupports. Ifadditionalshimmingisrequiredtolevelthe

weighbridge

supports,

it

should

be

added

at

this

time.

Insert

bolts

and

fasten

weighbridge

totheconveyor.

11. Removeweighbridgeshippingboltsandblocks(Figure23). Insureweighbridgeisrestingon

all4loadcells. Ifitwobbles,theweighbridgeisnotlevel.

NOTE:DonotadjustStayorCheckRods.


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Figure23. WeighBridgeShippingBoltandBlock

2.3.5 ScaleIdlerInstallation

Beforeproceedingwiththescaleareaidlerinstallation,makesuretheInstallationfollowingprocedures

have

been

completed:

1. Conveyorcenterlinehasbeenestablished.

2. Minus4andplus4idlersarelevelandinfact,1/4inchabovethenormalbeltline.

3.

Theweighbridgeisontheconveyorcenterline,levelandequidistantfromtheminusand

plus4idlers.

NOTE: Thefullfloatingweighplatformisattachedtotheweighbridgesupportsbyfour

straingaugeloadcells. Iftheweighbridgesupportsarenotlevel,weighing

errorsmayresult. Duringinitialcalibration,loadcellbalanceischeckedto

insureweightisappliedequallytoallfourloadcells. See"LoadcellCheckBy

Millivolt"forthisprocedure.

4. Weighbridgeshippingboltsandblockshavebeenremoved. Proceedwithscaleareaidler

installation.

5. PlacemodifiedweighidlerontheWeighbridgemountingpadadjacenttotheplus1idler.

6. Dimensionallyaligntheweighidlertotheadjacentweighbridgesupportandcenterthe

carryrollontheconveyorcenterline. Anaccuratemeasurementisnecessary,asthisweigh


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idlerbecomesthereferencepointforallremainingidlers. Atthistime,theweighidlermust

bebelowthecenterstringline. Donotshimtheidleratthistime.

NOTE: Makealldimensionmeasurementsfromthecenterofthegreasefittingsonthe

idlers.

7. Whenlocatingthesecondandsubsequentidlers,alwaysmakemeasurementsfromthe

weighidler

located

in

Step

2(reference

weigh

idler)

to

avoid

cumulative

measuring

errors.

8. Dimensionallylocatetheminus4andplus4idlersfromthereferenceweighidler. Placea

levelonthecarryrollandshimasnecessarytoleveltheminus4andplus4idler. Thisisthe

finallocationofthesetwoidlers.

9. Installadditionalstringlinesacrosstheminus4andplus4troughingorwingrolls.Thestring

linereferencepointswereestablished.

NOTE: Onconveyorswiderthan42inches,additionalstringlinesmaybenecessaryto

ensureaccurateshimming. Installtheremainingminusandplusidlersoneata

time,workingfromtheminusandplusfivetowardstheweighidlers,priorto

installingtheremainingweighidlers. Themeasurementbetweeneachidlerand

thereference

weigh

idler

must

be

accurate

to

within

1/32

inch.

All

idlers

must

beshimmedtowithin1/32inchofthestringlines.

NOTE: Acombinationofshimmingandmovementoftheidlermaybenecessaryto

bringthetroughingandwingrollsuptothestringlines.

EXAMPLE: Centerrollelevation OK

Leftwingrollelevation TooHigh

Rightwingrollelevation TooLow

Thisindicatesoneoftwoconditions.

1. Theidleristippeddowntotheright(Remedy Addshimstothe

rightendoftheidlerandremoveshimsfromtheleftend).

2.

Theidlerislocatedtoofartotherightoftheconveyororcenter.

(Remedy shiftidlertotheleft).

10.

InstalltheremainingweighidlersfollowingtheprocedureinStep9.

11. Shimthereferenceweighidleruptothestringline.

12. Thiscompletestheweighbridgeandscaleareaidlerinstallation. Priortoremovingthe

stringlines,completethefollowingchecks:

a.

Insuremeasurementbetweenallidlersandreferenceweighidlerare

accuratetowithin1/32inch.

b. Allcarryandtroughrollsareshimmedtowithin1/32inchofthereference

heightoftheminus4andplus4idlers.

13. Removeallstringlines.

14. Placeconveyorbeltbackinplace.


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3.0 Maintenance

3.1 CheckPoints

Calibrationshouldonlybeperformedafterthebelthasbeenrunningforatleast30minutes. Optimum

timeis

immediately

after

it

has

been

used.

1.

Inspectformaterialwedgedinweighbridgeorexcessivebuilduponweighbridgeindicating

conveyorbeltoverloads.

2. Bealertandwatchforevidenceofconveyormaintenancethathasoccurredinthescalearea

sincelastcalibration. Scaleareaisdefinedasdimensionalareabetweenminusfourapproach

scaleserviceidlerandplusfourretreatscaleserviceidler. Ifmaintenancehasbeenperformed

inthisareathenscalealignmentshouldbecheckedandcorrectedifnecessary.

3. Measureweighspanonbothsidesofconveyorduringcalibration. Weighspandimension

shouldneverchange.

4. Donotattemptcalibrationduringadverseweatherconditionssuchasduringhighwinds,rain,

andsnow. Calibrationsshouldcorrelatewithaverageweatherandoperatingconditions.

5. Mostcalibrationerrorscanbetracedtomechanicalalignment,housekeeping,andbelt

overloads. Theseproblemstendtobeoverlookedinanelectromechanicalbeltscale. Expected

accuracyisproportionaltomaintenance.

3.2 FrequentCheckPoints

Eachinstallationshouldbecheckedfrequentlytodeterminewhencalibrationisrequired. Itis

recommendedthatzerobecheckedeveryotherdayandthatcalibrationbecheckedeveryweekfor

severalmonthsafterinstallation. Observetheresultsandlengthentheperiodbetweencalibration

checks,depending

upon

the

accuracy

desired.

1. Cleaning: Keepscaleareacleanofrocks,dust,andmaterialbuildup.

2. Lubrication: Theweighidlersshouldbegreasedonceortwiceyearly. Overloadingtheweigh

idlerswithgreasemaychangethetareweightandplacethescaleoutofcalibration. Zero

calibrationisnecessaryaftergreasing.

3. BeltTraining: Thebeltmustbetrainedtoruntruetothecenterlineoftheidlersintheareaof

thescalewhilerunningempty,aswellasunderloadedconditions. Wherethiscannotbe

accomplishedduetooffcenterloading,theloadingshouldbemodified. Whereabeltdoesnot

trainwhileemptybutdoestrainwhileloaded,itwillbenecessarytotrainthebeltoverthescale

area

at

least

during

the

calibration

checks.

4. BeltTension: Itisimportantthatconveyorconditionsremainconstantatalltimes. Therefore,

gravitytypetakeupsarerecommendedonallconveyorswherebeltscalesareinstalled.

Conveyors,whichdonothaveaconstanttensiondevice,willrequirecalibrationwheneverthe

belttensionchangesandthetakeuparereadjusted.


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5. BeltLoading: Extremeloadingconditions,whichcauseflowrateofmaterialabovetherangeof

theinstrument,mustbeavoided. Beltloadingshouldbeadjustedtostaywithintheinstrument

range. Beltloadingequalto80percentofrangeisrecommended.

6. Conversely,verylowflowrates,withrespecttofullscalerange,mayproducelowaccuracy.

Whereextremehighorlowflowrates,asdescribedabove,persist,thescalerangeshouldbe

changed.

7. Materialstickingtothebelt: Materialmayformafilmonthebelt,whichiscarriedcontinually

aroundthebeltandisneverdischarged. Thisconditionisoftentruewhenhandlingwet,fine

material. Beltscrapersmaycorrectthiscondition.

8. Ifthefilmcannotberemoved,theTarewillhavetobeadjusted. Anychangeinthebuildupof

thefilmadheringtothebeltwillrequirefurtheradjustment

6. SkirtBoardsandCovers: Skirtboardsshouldneverbeplacedclosertotheweighidlersthanare

necessaryintheweighingarea,theymustnotplaceanythoughtheskirtsareclearofthebelt

under"noload"conditions,theboardsandthebeltwhentheconveyorisoperating.Errorsof

wheresuchconditionsexist. Noteloadcelldamagemayoccur.

4.0 Troubleshooting

Ifyourbeltscalefailstooperatecorrectlyduringorafterperformingsetupandcalibration,itis

suggestedtoperformtheprocedureagainandiftheproblempersistsfollowthetroubleshooting

proceduresbelow.

4.1 CalibrationShifts

Frequentcalibrationshiftsshouldbeisolatedtozeroshiftsorspanshifts.

4.1.1 ZeroCalibrationShifts

Zeroshiftsarenormallyassociatedwiththeconveyingsystem. WhenaShiftszeroshiftoccurs,thespan

willshiftbyalikenumberofTPH,thisthenappearsasaspanshift.

Commoncausesofzeroshifts:

Materialbuilduponthecarriage/weighbridge.

Rockslodgedinthecarriage/weighbridge.

Conveyorbelttracking.

Nonuniform

conveyor

training.

Conveyorbeltbeltingstretchduetomaterialtemperaturevariations.

Troubleintheelectronicmeasuringcomponents.

Severelyoverloadedloadcell.


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4.1.2 SpanCalibrationShifts

Spanshiftsarenormallyassociatedwiththeelectronicmeasuringofcomponentsofthesystem,with

oneexception,

which

is

conveyor

belt

tension.

A

span

shift

is

present

if

both

points

change

by

the

same

percentageTPH.

4.3 FieldWiring

Checkforproperinterconnectionbetweencomponentsofthesystem. Allwiringmustbeasspecified

ontheFieldWiringdrawing.

Checkallwiringandconnectionsforcontinuity,shorts,andgroundsusinganohmmeter.

Looseconnections,poorsolderjoints,shortedorbrokenwiresandunspecifiedgroundsin

wiring

will

cause

erratic

readings

and

shifts

in

weight

readings.

CheckthatgroundingofallcableshieldsismadeatonlythelocationsasspecifiedontheField

Wiringdrawing.

4.4 LoadCellResistanceCheck

BulkProSystemsusesprecisionstraingaugeloadcellswith3mV/voltsensitivity.Toverifyitsoperation,

usethefollowingprocedure.

Disconnectloadcellwiresfromfieldterminalsinexciterdigitizer.

Usingohmmeter,checkresistancebetweensignalwires. Shouldbe350ohms5ohms.

Usingohmmeter,checkresistancebetweenexcitationwires. Shouldbe400ohms10%.

Checkcontinuitybetweenshieldandallwires. Allleadsshouldbeopen(infinite)fromshield.

4.5 LoadMillivoltCheck

VerifyloadcelloperationbyusingaDCvoltmetercapableofreading millivolts.

Completeresistancecheck.

Reconnectallfourexcitationwires. DONOTreconnectredandwhitesignalwires.

Measureexcitationvoltageacrossexcitationwires. Voltageshouldbe10VDC5%.

Measuresignalvoltageacrosssignalpositiveandsignalnegativeoneachloadcell. Reading

mustbewithin030mVDC.

Themillivoltoutputisadirectrelationshiptoweightapplied. Asweightisincreased,output

shouldincrease.


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DOC1010




Whentheweighbridgeisproperlybalancedtheoutputfromeachloadcellshouldbethesame

within1.0 mVDC.

Ifazeroshiftissuspectedreinstalltheshippinglocksandmeasureallloadcelloutputs. Normal

readingis0mVDC. Aslightpositiveshiftof0.1or0.2mVDCisokaybutanegativeshiftwould

indicateafailure.


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DOC1010




5.0 Warranty

BulkProSystems,LLC(BPS)warrantsthatallBPSequipmentandsystemsproperlyinstalledbya

DistributororOriginalEquipmentManufacturer(OEM)willoperateperwrittenspecificationsas

confirmedbytheDistributor/OEMandacceptedbyBPS. Allsystemsandcomponentsarewarranted

againstdefectsinmaterialsandworkmanshipforone(1)year.

BPSwarrantsthattheequipmentsoldhereunderwillconformtothecurrentwrittenspecifications

authorizedbyBPS. BPSwarrantstheequipmentagainstfaultyworkmanshipanddefectivematerials. If

anyequipmentfailstoconformtothesewarranties,BPSwill,atitsoption,repairorreplacesuchgoods

returnedwithinthewarrantyperiodsubjecttothefollowingconditions:

UpondiscoverybyBuyerofsuchnonconformity,BPSwillbegivenpromptwrittennoticewitha

detailedexplanationoftheallegeddeficiencies.

IndividualelectroniccomponentsreturnedtoBPSforwarrantypurposesmustbepackagedto

preventelectrostatic

discharge

(ESD)

damage

in

shipment.

ExaminationofsuchequipmentbyBPSconfirmsthatthenonconformityactuallyexists,andwas

notcausedbyaccident,misuse,neglect,alteration,improperinstallation,improperrepairor

impropertesting;BPSshallbethesolejudgeofallallegednonconformities.

Suchequipmenthasnotbeenmodified,altered,orchangedbyanypersonotherthanBPSorits

dulyauthorizedrepairagents.

BPSwillhaveareasonabletimetorepairorreplacethedefectiveequipment. Buyeris

responsibleforshippingchargesbothways.

InnoeventwillBPSberesponsiblefortraveltimeoronlocationrepairs,includingassemblyor

disassemblyofequipment,norwillBPSbeliableforthecostofanyrepairsmadebyothers.

THESEWARRANTIESEXCLUDEALLOTHERWARRANTIES,EXPRESSEDORIMPLIED,INCLUDINGWITHOUT

LIMITATIONWARRANTIESOFMERCHANTABILITYORFITNESSFORAPARTICULARPURPOSE. NEITHER

BPSNORDISTRIBUTORWILL,INANYEVENT,BELIABLEFORINCIDENTALORCONSEQUENTIALDAMAGES.

BPSANDBUYERAGREETHATBPSSSOLEANDEXCLUSIVELIABILITYHEREUNDERISLIMITEDTOREPAIR

ORREPLACEMENTOFSUCHGOODS.INACCEPTINGTHISWARRANTY,THEBUYERWAIVESANYANDALL

OTHERCLAIMSTOWARRANTY.

SHOULDTHESELLERBEOTHERTHANBPS,THEBUYERAGREESTOLOOKONLYTOTHESELLERFOR

WARRANTYCLAIMS.

NOTERMS,CONDITIONS,UNDERSTANDING,ORAGREEMENTSPURPORTINGTOMODIFYTHETERMSOF

THISWARRANTYSHALLHAVEANYLEGALEFFECTUNLESSMADEINWRITINGANDSIGNEDBYA

CORPORATEOFFICEROFBPSANDTHEBUYER.

doc1010 model n-64-2 io manual

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