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Schenck Process India Limited

FH 5180 SPI

CONTENTS
Chapters

Page

1. Check of Shipment upon Receipt

2. Suggestions for Storage

3. Installation of Mechanical Equipment

3.1 Installation Hints

3.1.1 Mounting of Measuring Station

15

3.1.2 Mounting of Speed Transducer

17

3.2 Installation

18

3.2.1 Completeness of Items

18

3.2.2 Preparation of Installation

19

3.2.3 Installation of Measuring Station

21

3.2.4 Installation of Speed Transducer

24

3.2.5 Cabling

25

3.2.6 Installation of Carrying Idler Sets

26

3.3 Alignment and Ascertainment of Effective Platform Length


4. Operating Hints
4.1 Measuring Station

27
30
30

4.1.1 Construction and Principle of Operation

30

4.1.2 Maintenance

31

4.1.3 Inspection and Repair

33

4.2 Speed Transducer

34

4.2.1 Construction and Principle of Operation

34

4.2.2 Maintenance

35

4.2.3 Inspection and Repair

35

FH 5180 E

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Check of Shipment upon Receipt

Check packing for possible transport damages.

Claim damages immediately and in written form to forwarding agent.

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.

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Suggestions for Storage

Check to see whether the permissible limit temperatures of -25 C and +55 C may be
exceeded.
- If not,
store the shipment in original packing in dry and clean room where the
relative humidity will not exceed 75 %.
- If so,
remove
Load cell,
Speed transducer and
Terminal box
(see also Section 3.2.1, Completeness of Items)
from packages.
These electronic components require storage in a room where limit
temperatures and humidity mentioned above will not be exceeded.

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Installation of Mechanical Equipment

General comments:
The following instructions for installation, summarized into 10 rules, are essential if the belt weigher
is to achieve the required weighing accuracy. Strict adherence to these rules will minimize the
influence of external factors affecting the functioning and measuring accuracy of the unit.
Observe the special relation :
weigher accuracy and feed rate - number of idlers in weigher's influential zone

requires two idlers in front of and two behind of


measuring station
Feed rate -

requires three idlers in front of and three


behind of measuring station

According of the weigher type one or more idlers are installed on the measuring station

1.

Integrate the belt weigher into the conveyor belt in accordance with the 10 rules
given below.

Install Belt Weigher in a Straight Belt Section

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Unloaded belt must rest on all idlers of carrying idler sets, i.e.:
In the weigher influential zone and On two further idler sets upstream and
downstream of influential zone.

Catenary rollers are unsuitable.

Here below typical locations of belt weigher are indicated, ranked:

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2
Rise or slope of belt conveyor must only be such that the material handled does not
exert relative movements to the conveyor belt

Maximum possible angle of rise: 20


Note:
o
Relative movements may occur also below 20 :
- If material is fine and of uniform grain size
- If belt speed is very high
- Immediately after belt feeder(s)
- If there are gaps in feeding

In the case of conveyors with adjustable inclination, any changes therein will enter
measurements as an error.
Talk to SCHENCK PROCESS for possibility of correction.

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3.
Install belt weigher so far removed from point(s) of feed that material stream can
settle and will exert no relative movement

The entire influential zone must be away from the point(s) of feed,

The required distance depends on:


- Belt speed
- Belt inclination
- Type of material feed
- Material properties

(*)

The minimum distance must correspond to the distance the belt covers in one
second but must not be less than 2 m.
Skirt boards must not extend into weigh length or should be attached such that
weighing accuracy is not affected.

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4.

Observe minimum distance between belt weigher and belt pulley


Measuring station

5.

Idler troughing influences accuracy


Upto 20 GOOD
Upto 30 ADEQUATE
Upto 45 Deep troughing has an adverse
effect on accuracy. Use only for low
accuracy requirements

Ensure that the belt is in contact with the idlers at all times.
This is assisted by
- light troughing
- Flexible belt.

Ensure high belt loads.

V-shaped troughing has an adverse effect on accuracy . Use only for low accuracy requirements.

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6.

In the influential zone of the weigher full and constant belt troughing must exist

Belt conveyors with pulleys arranged at a higher level than the carrying idlers are not suitable.
If necessary, select a larger distance of pulley from influential zone.

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7.

Align idlers in influential zone of weigher accurately


Idler sets with offset idlers (as viewed from above) may have an adverse effect on accuracy

Arrange carrying idlers in influential zone elevated by 10 mm.

Secure aligned idler sets against displacement and settling.

Average idler out-of-round when aligning.

Maximum permissible out-of-round is 0.2 mm. Mark position of average out-of-round on roller

shell on both sides.

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Ensure that the axes of weighed and limiting idler are perfectly level and aligned
(as viewed from above).

Weighed and limiting idler sets with offset spindles will result in an incorrect weigh length.

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Ensure that in the weigher influential zone belt stringers are rigid and that the foundation is
solid and safe from settling

In the influential zone, belt stringer joints must be welded.

Belt stringers and substructure must ensure permanent alignment of idlers (see Rule 6). If
necessary, reinforce belt stringers, or support additionally.
measuring station

Wire-rope-suspended belt conveyors are not suitable for installation of belt weighers,

Keep vibrations from influential zone.

Belt tracking idlers for correcting belt tracking should not be installed in the influential zone of
the belt weigher.

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Provide gravity take-up unit

10

The larger the variations in belt tension the larger the possible error in measurement.

Take precautionary measures to protect belt from the effects of wind, weather, and extreme
temperature changes

Wind falsifies measurements.

Direct sun radiation can cause an impermissibly high temperature to occur at load cell.

Moisture, ice, and snow support material build-up and thus produce misalignment in influential

zone.

Solar radiation on one side of the belt weigher may cause twisting and possible temperature

drifts.

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3.1.1

Mounting of Measuring Station

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Measuring station is suitable


for installation in belt conveyors
to DIN 22 107 with belt widths
500 1400mm, without
modification to belt stringers.

Travel

Installation into other types of


conveyor is possible by adapting
belt stringers accordingly.
Mounting of measuring station is
via two supplied cross-members
Weight of measuring station is
Determined according to belt
width :
500mm
650mm
800mm
1000mm
1200mm
1400mm

=
=
=
=
=
=

approx. 160 Kg
approx. 170 Kg
approx. 185 Kg
approx. 200 Kg
approx. 210 Kg
approx. 265 Kg

Example of adaptation to other types of conveyor

Add additional longitudinal beams


in influential zone and cut out
existing support frame in measuring
station area.

Tubular framework should be stiffened by two (2) longitudinal channels of minimum section IMC 125 to
accommodate the two cross-members.

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3.1.2

Mounting of Speed Transducer


MEASURING STATION

MOUNTING YOKE

FRICTION WHEEL
ROCKER

65

14

200

MIN. 17
200-300

MAX. 100

113

55

ARTICULATION

490
DIRECTION OF TRAVEL RETURN BELT

Pick-up of belt speed takes place at the inside of lower belt strand.
If at all possible, locate transducer directly at weighed idler set. If not, do not exceed a 5-m
distance. Holes are provided in mounting yoke of measuring station for attachment of transducer.
Keep vibrations from return belt in transducer area. Therefore, install transducer next to a return
roller in direction of travel of lower belt strand (as shown).
Maximum out-of-round tolerance of return roller 1 mm.
Remove material build-ups from roller, or avoid them by using a rubber-coated roller.
Slippage between friction wheel and belt causes errors in measurement. Therefore, keep belt
inside clean by installing a suitable device.

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3.2

3.2.1

Installation

Completeness of items
Mechanical scope of supply:
Measuring station
Two side parts
Two receptors for user's weighed idler sets
Two cross-members
One set of bolts
Load cell
Speed transducer with friction wheel
Rocker for mounting speed transducer
Terminal box for connection of load cell and transducer cables to evaluation system.

.
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3.2.2

Preparation or Installation
Mark envisaged location of belt weigher in accordance with criteria given in Section 31.1, and ensure that criteria are observed with the aid of the check list below:
Keyword

Rules according to 3.1.1

Placement in conveyor

Stability

Belt Tension

Idler set requirements


(profile, out-of-round)

10

If conveyor belt is already placed, tension may have to be released and for the belt to be
lifted from carrying idlers in the influential zone by means of suitable lifting tackle such
that later the measuring station with its cross-members can be inserted from the side.
Further Preparations
- Provide, if required, the items described in Section 3.1.2: additional supports
and/or longitudinal beams.
- Note Section 3.1.3 for installation of speed transducer.
- Debur idler set ties at points of support.

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Recess measuring stations at both ends.

min 15

min 15

To shim idler sets in the influential zone as well as for subsequent alignment and fixing
of sets are required:

35

24 limiting blocks
12 shims
6 packing plates 1.0mm
6 packing plates 0.5mm
12 packing plates 0.2mm

Fit hoist (100 kg) above weigher location.

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3.2.3

Installation of Measuring Station


First install load cell:

Loosen the red painted transit


restraint angle, but bolt it back in place
upside down (as shown in drawing) so
that it cannot be lost.

Insert compression screw (SW 17) with counter nut (SW 24) such that the
installation dimension of the load cell complete with boot is approximately
reached.
Straight edge
Leaf Springs

Weighing yoke

Load cell with boot

Compression screw
with counter nut

Air duct for


pressure compensation

Fixing screw
With spring washer

Raise weighing yoke carefully by approx 5 mm against the force of the plate
springs to insert the load cell complete with boot and screw it in place with
fixing screw complete with spring washer centered to compression screw.
Clean carefully contact surfaces of compression screw and load button of
load cell with a soft cloth (do not grease), before letting weighing yoke
carefully down.
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Place a straightedge alongside one of the plate springs and adjust the
difference in height of surface areas A to B 0.5 mm by means of the
compression screw resting on the load button.
Then secure compression screw by its counter nut.
NOTE: From now on, for protection of the load cell, the minus pole must be applied
directly to the welding point during welding work on measuring station.
Now install measuring station, at first bolted loosely outside of belt stringers.
Cross - members
Side parts

Weighed idler set receptors

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Lift measuring station onto belt stringers with correct side in direction of belt travel

Travel
5
4
3
1

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Align measuring station at its place of installation in a rectangular way to belt


stringers and weld the 4 bolt heads in place on belt stringers.
Set straightedges on measuring positions 1 and 2.
Level areas C to D using set nuts 4 and 5, however, without twisting the measuring
station, i.e. distance H has to be about equal at all 4 corner points.
Then tighten bolts 1, 2, and 3 have to be screwed in place, compensating for a
possibly resulting displacement in height of areas C to D within the hole play of bolts
1 and 2. Then set distance H once more.
3.2.4

Installation of Speed Transducer

Screw transducer to rocker. The four (4) screws can be turned one after the other
into the transducer tap holes via the enlarged recess in the friction wheel if you set
recess to an angle of 45 by turning the friction wheel accordingly.
MEASURING STATION

BELT STRINGERS

ROCKER ARM ARTICULATION

DIRECTION OF TRAVEL RETURN BELT

SUPPORT ROLLER

Note : Cable connection of transducer must not show up.


Bolt speed transducer with its articulation at envisaged location to belt stringers or
measuring station.
See to it that transducer with its friction wheel is in positive contact with lower belt.

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3.2.5

Cabling

For detailed description, see INTECONT Manual FHa 116, Section "Connections",
but also note the following suggestions:
#

Run load cell and speed transducer cables to cable junction box
supplied and installed at a protected place.
NOTE:
Watch cable lengths:
Load cell
5m
Transducer 6 m

Do not shorten cables. If necessary, arrange in a loop.

Connect white wire of speed transducer cable for 1270 pulses per
revolution in terminal box.

+ Supply

1270 Pulses/Rev

RD

WH

BL

OV

BK

Interconnecting Cable 6M Long

Core Colours

RD RED

WH WHITE

BL BLUE

BK - BLACK

Attach cables by means of clamps to stationary structural parts immediately ahead of


and after connections. In between, attach cables with clamps, or place in a conduit if
required.
Ensure that cable connection of speed transducer will not affect positive contact
between friction wheel and lower belt.
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3.2.6

Installation of Carrying Idler Sets


Arrange carrying idlers in influential weigher zone at a level higher by 3 to
5 mm above remaining idlers.

Carrying idlers

Carrying idlers

Weigher idlers

3 - 5mm

Weigher influential zone

For this purpose, place prepared carrying idler sets (troughing profile, outof-round tolerance) via prefabricated shims on belt stringers.
Place weighed idler set on height-adjustable receptor plates of measuring
station, and protect from tilting.
Align all idler sets in influential zone in accordance with criteria mentioned
below and include in alignment the carrying idlers next to the influential
zone but not elevated.
- Correct angle to belt stringers.
- Alignment of idler sets relative to one another
- Maintenance of twice the idler spacing between the carrying idler
sets next to the measuring station.
- PARTICULARLY IMPORTANT: Parallelity of the two carrying idler
3 x L 5mm
3 - 5mm

sets next to the measuring idler set.

Bolt idler sets temporarily to belt stringers.

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3.3

Alignment and Ascertainment of Effective Platform Length


Align the weighed and carrying idler sets arranged in the influential zone
raised by 3 to 5 mm to a tolerance of max. 0.2 mm.
- For this purpose, remove all idlers from the carrying idler sets 1 & 2 and from
the weighed idler set.
- String six (6) (*) steel wires, 0.5mm thick. (See figure on the next page.)
- Set the measuring station with nuts 4 and 5 to distance measure = H + X with
the aid of which the weighed idler sets are coarsely aligned to the carrying idler
sets no. 3.
3 x L 5 mm

1
H

- Remove all idlers from weighed idler sets.


- Place first idler into one of the carrying idler sets 2, and align this idler as
described below. Align each single idler this way, completing the sequence of
work with the weighed idler set.
Align each idler side with averaged out-of-round tolerance (marked point on
idler shell turned towards steel wires) :
-

Refile the idler spindle seat at the respective end of the idler to lower the
idler on the particular side.

- Raise the idler end, for instance, by deposit welding followed by filing to raise
the idler on the particular side.

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Out-of-round tolerance
max. 0.2 mm

influential zone comprising three (3)


approach and three (3) retreat idler sets.

Fix wire here

0.2

3/5

3 x L 5 mm
2xL

Alignment tolerance
max 0.2 mm

Steel wire 0.5


Fix wire here

40 kg

Positions of six (6)strung steel wires


Mark position of averaged out-of
-round tolerance on idler shell

(*) Note:

Flat belt conveyors can be aligned with two (2) steel wires only.
In parallel to alignment, ensure that:
- The two carrying idler sets next to the weighed idler are parallel.
- All carrying idler sets in the influential zone fit square to belt stringers.
- Idler spacing = 3 x L 5mm.
Fix carrying idler sets on belt stringers by welding on the limiting blocks and
shims.

Weld on limiting blocks


and shims.

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Fix measuring idler set by welding to the receptor plates of the measuring
station (weighed idler set).
Check idler alignment once more ensuring fixed seat of all bolted
connections, and then remove steel wires.
To complete installation, determine effective platform length (Ing):
- Measure idler spindle spacing on both sides of the conveyor and
calculate as average value
a=

Spindle spacing Side a1+ Side a 2


=
2

b=

Spindle spacing Side b1+ Side b 2


=
2

c=

Spindle spacing Side c1+ Side c 2


=
2

Effective platform lng :


lng =

a+b
+ c = LLLL Enter this value into the measuring system with the
2
units stated in the electrical manual.

.
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Operating Hints

4.1

Measuring Station

Travel
Weighed Idler Sets

Belt Stringers
Carrying Frame
Weighed Idler Receptors

Cross Members
Weighing Yoke
Load Cell

NOTE: During welding work on the measuring station, apply the minus pole direct to
the point of welding for protection of the load cell.
4.1.1

Construction and Principle of Operation


The measuring station is constructed on the principle of leaf spring parallel guides.
At three points, a rigid carrying frame is bolted to the two cross-members provided by
user. The carrying frame is designed to receive load cell and leaf spring parallel
guides staying the weighing yoke. Mounted on the load cell, the weighing yoke
carries the two weighed idler sets.
The Load cell, Series RT / Series S make SPIL is hermetically sealed and
maintenance free.
For the exact type designation, see load cell type plate. For essential data, see
below :
Rated capacity
: In accordance with type plate.
Maximum load
: Max. load at rated capacity of
1.5 t
=
0.15 - 0.22 t
2.0 t
=
0.33 t
2.5 t
=
0.47 - 0.68 t
Protection mode
: IP 67
Nominal temperature
: - 10 to + 40C
Service temperature
: - 30 to + 80C
Cable:
Length
:5 m
Service temperature : - 30 to + 150C

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4.1.2 Maintenance
If there are any doubts as to the accuracy of the weighing results, by all means first
check the alignment of the idler sets :
Lift conveyor belt in weigher influential zone.
String six (6) steel wires (0.5 mm thick) over the clean idlers.
Align each idler in accordance with Section 3.3 "Alignment", and
Replace idlers with an out-of-round tolerance exceeding 0.2 mm.
influential zone comprising three (3)
approach and three (3) retreat idler sets.

Fix wire here

Alignment tolerance
max 0.2 mm

0.2

3 x L 5 mm
2xL

3/5

Out-of-round tolerance
max. 0.2 mm

Steel wire 0.5


Fix wire here

40 kg

Positions of six (6)strung steel wires


Mark position of averaged out-of
-round tolerance on idler shell

Keep air duct for pressure compensation of load cell open. Suck off dust deposits.
(Compressed air could damage load cell by its pressure burden.)

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Load button

Load cell

Air duct for pressure


compensation

In the weigher influential zone, keep weigher free of material build-ups.


Carrying idlers

Weigher idlers

Carrying idlers
3 - 5mm

Weigher influential zone

Ensure full troughing of unloaded conveyor belt on carrying idlers:


- In the weigher influential zone and
- at another two idler sets upstream and downstream of the influential zone.

Ensure correct tracking of the belt, and avoid off-middle loading, leading to belt drift
and incorrect weighing results.

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4-1-3 Inspection and Repair

First, proceed in accordance with Section 4.1.2 "Maintenance".


However, if you have to replace the load cell
Straight edge

Leaf Springs

Load cell with boot

Compression screw
with counter nut

Air duct for pressure compensation

Fixing screw

NOTE!

Pinch off load cell cable and disconnect from fixing points.
Lift weighing yoke by approx. 5 mm and prop up.
Unscrew fixing screw from load cell boot, and remove load cell from
measuring station from below.
Handle new load cell in accordance with instructions packed with
load cell.
If in doubt, also replace compression screw before installing new load
cell.
For exchange of compression screw, the following is required in any
case:
Set the height of the weighing yoke in accordance with
Section 3.2.3 "Installation of Measuring Station"
and
-

Align the weighed idler sets in accordance with Section


3.3 "Alignment".

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Do not grease load button, as greasing as indicated in brochure


concerning load cell applies exclusively for sealed load application
devices, but clean compression surfaces using a soft cloth.

Push load cell, complete with boot attached, fully in place such that
the air duct for pressure compensation is turned by 90 as compared
to representation, and screw in place after careful centring to load
button.

Carefully let weighing yoke down.

If necessary, align weighed idler set with carrying idler sets in


influential zone as described in Section 3.3 "Alignment".

Lay and connect load cell cable.

If you have to replace leaf springs :

Always replace all four (4) leaf springs.

Take care for metallically clean and burfree connecting surfaces on


parts to be bolted together.

Align weighing yoke before tightening all screws in steps:


- centrically to load cell load button,
- vertically to load cell load button, and
- with axis parallel to measuring station carrying frame or cross
members.

4.2

Align weighed idler with remaining idler sets in influential zone as


described in Section 3.3 "Alignment".

Speed Transducer

BELT STRINGER

FRICTION WHEEL

ROCKER ARM
ARTICULATION

ROCKER ARM

PROXIMITY SWITCH

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4.2.1

Construction and principle of operation


The speed transducer is fixed to the weighed idler set or a neighbouring structure by
means of a retainer.
A friction wheel, rolling off the inside of the lower belt, drives the speed transducer.
The speed transducer outputs pulses proportional to belt speed which, as speed
signal multiplied by the load cell signal, result in the belt weigher flow rate.
Technical data of speed transducer:
Type
:
Supply
:
Output
:
Diagram of Friction Wheel
:
Protection Class
:
Service temperature
:

JGA 20
S.P.I.L.
20 Pulse / Rev. of Friction Wheel
200 mm
IP 65 (for Proximity Switch)
- 25 to +100C

4.2.2

Maintenance

The speed transducer itself is maintenance-free, its bearings are


lubricated for life.

Ensure good mobility of rocker arm articulation.

Replace rubber running ring of friction wheel as soon as wear is


recognized.

Ensure good friction connection to lower belt.

4.2.3

Inspection and Repair


Repair of the speed transducer is not possible. Replace the device if defective:

Unscrew the four (4) screws fixing the transducer to the rocker arm by
turning the friction wheel until the respective screw can be accessed
through the enlarged recess within a 45 angle.

Screws

Circlips
Washer
Split Pin
Bearing Cover
Extractor

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Pull friction wheel from spindle by means of an extractor

Place friction wheel on spindle of new transducer, also by means of a


device.

If necessary, first check spindle fitting.

NOTE:

It must be possible to pushing friction wheel almost by hand.


- Never clamp transducer in a vise, and
- Never force on friction wheel by means of a hammer.

Carefully secure friction wheel


with end plate and countersunk screw.

Screws

Circlips

Washer
Split Pin
Bearing Cover

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FH 5180 E/36

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