Belt-Way Scales 45 Manuel utilisateur

Phone: (815) 625-5573 beltwayscales.com [email protected]

Belt-Way Scales, Inc.

Conveyor Belt Scale

Product Manual

Belt-Way Scales, Inc.

1 Beltway Rd.

Rock Falls, IL 61071 USA

Phone: (815) 625-5573

beltwayscales.com

Revision 2.4 Date: 7/2020

Phone: (815) 625-5573 beltwayscales.com [email protected]

Page 2 of 40

Conveyor Belt Scale

Product Manual

Safety and Warnings

All Belt-Way components MUST be used as described in this manual!

Please note the labels on the integrator and in the manual denote

dangerous voltage. Failure to take safety precautions may result in

serious injury or death.

The protective conductor terminal (Earth Ground) is signified by the

following label. It must be properly connected to earth ground per

local electrical codes.

Phone: (815) 625-5573 beltwayscales.com [email protected]

Page 3 of 40

Conveyor Belt Scale

Product Manual

Table of Contents

Scale Accessories ...............................................................................5

Integrator Specs & Scale Components .............................................6-8

Mechanical Installation....................................................................9-15

Wiring the Sensors / Integrator Installation...................................................16-21

A. Sensor Board ...................................................................................................................................18

B. Terminal Board with AC Power Supply..............................................................................................19

C. Terminal Board with DC Power Supply..............................................................................................20

D. Integrator Board ..............................................................................................................................21

E. IO Board ..........................................................................................................................................21

Integrator Configuration................................................................ 22-36

A. Integrator Navigation.......................................................................................................................22

B. Setup Wizard ..................................................................................................................................23

C. C. Scale Setup .............................................................................................................................23-24

D. Scale Calibration .........................................................................................................................25-28

Zero Calibration....................................................................................................................................25

Test Weight Calibration ...................................................................................................................26-27

Material Test Calibration ......................................................................................................................28

E. Scale Totals .....................................................................................................................................29

F. Device Setup...............................................................................................................................29-30

Plant Connect.......................................................................................................................................31

G. Administration.................................................................................................................................32

Routine Maintenance .........................................................................33

Diagnostics / Troubleshooting ..................................................... 34-36

Message Icons / Error Messages ...........................................................................................................36

Calibration Logs ........................................................................... 37-38

Product Warranty ..............................................................................39

Phone: (815) 625-5573 beltwayscales.com [email protected]

Page 4 of 40

Conveyor Belt Scale

Product Manual

Introduction

The Belt-Way conveyor belt scale is a highly accurate and cost effective in-

motion weighing system. It is designed to measure material flow over a

conveyor belt in real-time. The primary components are the integrator (AKA,

controller, display, indicator), load cell assemblies, and speed sensor. The

scale system processes speed and load signals to accumulate weight and

calculate flow rate.

This manual covers the following belt scale models:

•Model 45 (Low capacity)

•Model 100, Model 200 (Medium capacity)

•Model 350, Model 500, Model 1000 (High Capacity)

This manual pertains to scales operating on firmware 6.43 and above.

A manual for previous versions may be found at beltwayscales.com

BELT

LOAD

BELT

SPEED

ACCUMULATED

WEIGHT

FLOW RATE

Phone: (815) 625-5573 beltwayscales.com [email protected]

Page 5 of 40

Conveyor Belt Scale

Product Manual

Scale Accessories

Call or visit beltwayscales.com for a complete list of all the accessories

that Belt-Way has to offer.

▪Angle Sensor

The angle sensor eliminates the need for constant recalibration

when the scale is installed on a variable angle conveyor or portable

machine.

▪RS485 Junction Box

A Smart junction box can be installed on the conveyor to place

the scale integrator up to 1000 ft. from the scale.

▪IO Board

The IO board allows the scale to interface with a PLC system, automate

loadout of trucks or rail cars, control a VFD, and blend multiple products.

▪Self-Storing Test Weight Kit

The test weight kit remains installed on the conveyor.

It is activated from one side for easy, safe calibration.

▪Outdoor Protection Enclosure

Heavy duty enclosure offers extra protection for the scale integrator.

Includes power switch.

▪Wireless Multi-Scale Remote Display

The remote display allows multiple scales to be viewed from one

location. Monitor production, clear weight, and perform zero calibrations.

Wireless communication makes installation simple and cost effective.

▪Plant Connect - Online Scale Production Reporting

Our Plant-Connect website allows users to monitor belt

scale production on a PC, tablet or smart phone.

Phone: (815) 625-5573 beltwayscales.com [email protected]

Page 6 of 40

Conveyor Belt Scale

Product Manual

Integrator Specifications

Replacement Part Number: BWINT

100-240 AC Power Supply Factory Installed Part Number: BWPS-AC

100-240 AC Power Supply Field Installation Kit Part Number: BWPSKIT-AC

9-30 DC Power Supply Factory Installed Part Number: BWPS-DC

9-30 DC Power Supply Field Installation Kit Part Number: BWPSKIT-DC

IO Option Board Part Number: BWIO (Factory Installed)

IO Option Board Kit Part Number: BWIOKIT (Field Installed)

Display: 4.3" Color LCD

Enclosure: Cast Aluminum

Operating Temperature: -20C to 45C

Required Power: 12-24 VDC, 55 Watts

optional 110/240 AC power adapter

Inputs: 8 Load Cells (millivolts)

1 Speed Sensor (0-5 VDC Pulse)

1 Angle Sensor (0- 4 VDC)

Outputs: 1 RS232 (Printer Port)

1 RS232 (Display Port)

1 Ethernet Port (Modbus TCP)

1 USB 2.0 Client

Optional IO Outputs:

4-20 mA outputs (Tons Per Hour)

Digital Pulsed Output (Total Weight)

Min / Max Speed

Min / Max Tons Per Hour

Zero Calibration

Loadout

Optional IO Inputs:

Clear Weight

Print Ticket

Zero Calibration

Phone: (815) 625-5573 beltwayscales.com [email protected]

Page 7 of 40

Conveyor Belt Scale

Product Manual

Electrical Ratings

Input Power to

Belt-Way Integrator:

12-30 VDC, 24 VDC 2.25A Max

AC Power option:

Input:100-240VAC 50/60Hz, 1A Max

Output: 24VDC, 2.25A Max

Use of the factory supplied AC Power option is recommended.

AC control power over-current protection with isolated circuit, and

disconnect point such as a breaker or switch box, is recommended.

Conformance to local electrical codes is required.

Digital Inputs:

(IO option installed)

12-24VDC, 50mA sink

Digital Outputs:

(IO option installed)

12 - 24VDC, 100mA sink

Analog Outputs:

(IO option installed)

4-20mA, 24VDC powered loop

Relay Outputs, UL

contact ratings:

(IO option installed)

220VDC, 0.24A, 60W

125VDC, 0.24A, 30W

250VAC, 0.25A, 62.5VA

125VAC, 0.5A, 62.5VA

30VDC, 2A, 60W

Environmental

▪Temperature: Normal operating range -20⁰C to +45⁰C.

▪Humidity: The unit is suitable for outdoor use.

▪Altitude: The unit is suitable for use to elevation of 2000m.

Phone: (815) 625-5573 beltwayscales.com [email protected]

Page 8 of 40

Conveyor Belt Scale

Product Manual

Scale Components

The single idler scale consists of the following components

1 - Integrator

2 - Load Cell

Assemblies

2 - Mounting pipes

1- Hardware Kit

1 - Speed Sensor with

mounting arm

The dual idler scale consists of the following components

1 - Integrator

4 - Load Cell

Assemblies

4 - Mounting pipes

2 –Hardware Kits

1 - Speed Sensor with

mounting arm

Unpacking the Scale

Each scale is comprised of at least three boxes

26” x 10” x 8” - Integrator and Speed Sensor

26” x 10” x 8” - Load Cells and Hardware kit

48”, 60” or 72” long boxes for mounting pipe

and various sizes for angle sensors and other accessories

Phone: (815) 625-5573 beltwayscales.com [email protected]

Page 9 of 40

Conveyor Belt Scale

Product Manual

Mechanical Installation

2D component and installation drawings are available at beltwayscales.com

3D drawings are available by request.

A. Recommended Tools

▪Cutting torch and grinder (remove idler mounting feet)

▪Heavy duty drill or magnetic drill press (drill u-bolt holes)

▪Tape Measure (measure idler distance)

▪Angle finder or phone app (measure conveyor angle)

▪1/2”socket and wrench (load cell and speed sensor brackets)

▪9/16” deep socket and wrench (V-block, u-bolts, leveling bolts)

▪String (to level weighbridge idlers)

▪Shim kit (to adjust idler height)

▪4 way screwdriver (integrator mounting, integrator door, hose clamps)

▪Small Belt-way screwdriver (integrator wiring)

B. Conveyor Design Recommendations

The following design suggestions are essential for best scale accuracy and repeatability.

▪Reduce speed whenever possible to maximize belt load. Slow moving, heavily loaded belts

work better than fast moving, lightly loaded belts.

▪Proper belt tension must result in 1%-2% deflection between idlers.

For example, 2% deflection is 1 inch sag in the belt over a 4 ft. idler spacing.

▪Lower trough angles, 0-35, are preferred. Avoid 45troughed idlers.

▪Install a belt scraper to keep the belt clean.

▪Cover the conveyor to shelter it from wind, rain and snow.

MOUNTING PIPE

AND

LEVELING

PLATES

MODIFIED

CEMA IDLER

LOAD CELL

ASSEMBLIES

SPEED

SENSOR

V-Block

CONVEYOR

FRAME

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Page 10 of 40

Conveyor Belt Scale

Product Manual

C. Scale Placement

▪Install the scale where it is easily accessible for maintenance purposes.

▪Choose a very rigid section of conveyor such as an idler over a brace.

▪The scale must be at least 40 ft. away from curves in the conveyor.

▪Stay at least three idlers away from the head pulley, tail pulley, and loading points.

Material must not impact the belt near the scale!

D. Define the Weighbridge

The Weighbridge is the section of belt actively being weighed by the scale.

▪The weighbridge idlers must be in good mechanical condition.

▪The weighbridge idlers must be the same trough angle, and diameter.

▪The weighbridge idlers should be an equal distance apart.

▪Skirting should not make contact with the belt in the weighing area.

▪A single idler weighbridge consists of 5 idlers.

Scale must be installed on the center idler

▪The dual idler weighbridge consists of 6 idlers.

The scale must be installed on the 2 center idlers.

GOOD

AVOID

5 Idler Weighbridge

Single Idler Scale

6 Idler Weighbridge

Dual Idler Scale

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