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TABLE OF CONTENTS
Section 1
. 2
Supply Verification & Visual Inspection
Caution
Warning
Section 2 Introduction
. 4
Basic Operation
Signal Diagram
Section 3 System Modules
Weigh Frame
Load Sensor
Speed Sensor
Electronic Unit
Calibration Rod/Chain
. 7
Key functions
Section 8 Parameter Table
Factory settings
Parameter definitions
. 35
Section 9 Commissioning
.46
Section 10 Calibration
. 47
Calibration details
Acceptance test
Running the system
.59
.60
. 61
Section 16 Warranty
Test report
Page 1
. 29
. 56
Drawings
Log sheet
.64
Section 1
SUPPLY VERIFICATION AND VISUAL INSPECTION
The following verification checks are to be carried out on receipt of the equipment
before they are moved to the installation site.
Check all the items as per the packing list supplied by the manufacturer. IPA Private
Limited, Bangalore.
In case of short supply, please inform the company
immediately.
Carry out a visual inspection of each item. If any damages are noticed inform the
Company giving the details of the damages, quoting the item numbers and box
numbers in which they are packed. If applicable, inform the insurance company
immediately and request them to arrange for a survey of the damages. If requested,
one of our representatives can be sent to assist in assessment of the extent of
damages. After physical verification and inspection, please repack the items like the
original packing and store them in a cool and dry place. Take care that they are not
exposed to sun and rain. While repacking, please ensure that no moisture is
entrapped in any of the packing.
Equipment packing consists of the following in the order as shown below ( Fig 1.1)
Polythene sheet for sealing against moisture and air bubble sheet for absorbing
shocks.
Thermocole as second layer for absorbing shock.
Cardboard box.
Kurlon as third layer for absorbing shock.
Wooden box.
Page 2
Cautions
Read manual carefully before installing, wiring, operating, servicing or inspecting
the system
Keep this manual within reach for quick reference
Improper handling blocks, incorrect operations are cause a short life or failure
Deliver this manual to end user of the product or operator
Warning
Operate the switches with dry hands
Do not use the cable when its insulating tube is damaged
Do not subject the cables to scratches, excessive stress, heavy loads or pinching
Always follow instructions to prevent the short life or failure of the system
Do not allow lint, paper, wood chips, dust, metallic clips or other foreign matter into
the panel
Do not place heavy items on the panel or weigh frame assembly.
Protect the system from corrosive gas, combustible gas, oil mist or dust.
Incorrect terminal wiring could result in the equipment damage.
Do not install or operate the system that is damaged or lacking parts
Never attempt to modify the system without proper instruction from manufacturer
Page 3
Section 2
Introduction
Basic Operation
In most of plant situations require the transport of materials like coal, sand,
salt aggregate gravel, lime etc., with the advent of fast mode of transportation,
accounting the quantity of material transferred assumes great importance. Belt scales
are most common type continuous weighing devices and consists of one or more
conveyor idlers mounting on a weigh frame as shown in fig (2.1). Since weight remains
as the most reliable index of material accounting and can be measured directly and
precisely, designers can offer accurate weighing systems to maintain higher accuracy
and better accountability in the process.
The belt load is transmitted from weigh frame either direct or via a lever
system to a loadcell. The combined output from loadcell and speed sensor provides the
flow rate of the material passing over the scale
Main features are
fig. 2.1
Belt scales are integrating weighing devices that use a simple integral
calculus summation process to measure a conveyed quantity of material. Two variables
Page 4
Signal Diagram
The belt scale electronics consists of Power supply section, ADC section, Relay section
display and keypad section.
The power supply section consists of On/Off switch, fuse, step down transformer and
SMPS card it can provide supply voltages need for the system operation.
ADC section card consists of Micro controller, Instrumentation Amplifier, ADC, DAC
(for 4-20 mA /0-20mA /0-5V output),
Relay section is used to provide potential free contacts (250V, 5A) 4Nos.
Overload, Under load, Totaliser pulse and Totaliser set achieved.
For
The display section Which displays load in kg/m, speed in m/s, rate in t/hr and
totaliser in tonnes, various system alarms and annunciations.
Keypad (4 X 4 matrix keypad) is interfaced with the microcontroller which is used to
enter the programmable parameters.
Load cell input is given to the instrumentation amplifier circuitry, which amplify the
input signal and is given to ADC. The digital output from ADC is given to the micro
Page 5
Section 3
The belt weigher consists of
Page 6
System Modules
Weighing frame *
Weighing arrangement with four loadcells
Weighing arrangement with single load cell and counter balancing
weight
Weighing arrangement for garland conveyor
2.
Loadcell/s *
BR type
DS type
Speed sensor *
AC Tachogenerator
DC Tachogenerator
DC Pulse encoder
Proximity switch
Speed sensor mounting frame *
Telescopic arrangement
Idler
Pickup wheel
Electronic unit *
Local panel
Remote panel
Calibration weight *
Chain
Rod
3.
4.
5.
6.
WEIGHING FRAME:
Weighing arrangement with four loadcells
Page 7
Page 8
This arrangement is using when garland type idler are using for Weighment. Here DS
type load cells are directly connecting to the idlers for the Weighment (Fig. 3.3).
Page 9
Page 10
Page 11
Page 12
Page 13
Page 14
Page 15
Section 4
System Specification
Conveyor Specification
Conveyor No.
BS-2A
Material handled
COAL
800
1.8
92.59
1200
21.4
1000
55
10.7
200
Page 16
INFRA/IS41
:
:
:
:
:
Inputs
BCW55L0
230V 10%,50Hz 3%
Wall
5C to 50C
5V DC, 120 mA
Display
Annunciation
Features
Page 17
:
4-20mA corresponding to rate
(Loop resistance: Maximum 1 k
Minimum 100 )
Potential free contacts (230V, 5A rating)
Under load
Overload
Totaliser pulses
Totaliser set achieved
RS-485 output to Remote indicator
:
7-Digit 7-Segment red LED Display.
:
LED
Power ON
Belt ON
Under load
Over load
Totaliser pulse out
Set achieved
Fault
:
Set value for under load and
overload
Calibration of load, speed, and
totaliser through keypads
Current span setting
Selectable speed mode
Self test, System reset
Capacity: 200kg
Parameters
RATED OUTPUT
COMBINED ERROR
REPEATABILITY
CREEP ON LOAD (30 mins.)
ZERO BALANCE VOLTAGE
INPUT RESISTANCE
OUTPUT RESISTANCE
COMPENSATED TEMP.RANGE
OPERATING TEMP.RANGE
TEMP. EFFECT ON SPAN
TEMP. EFFECT ON TARE
EXCITATION VOLTAGE
SAFE OVERLOAD
ULTIMATE OVERLOAD
INSULATION RESISTANCE, BRIDGE TO
CASE AT 30V DC AT 30 C
PROTECTION
CABLE
Specified Value
(% Of Rated Output)
1.5 0.01 mV/V
0.1%
0.05%
0.1%
0.2 mV
390 10 OHMS
350 2 OHMS
5 - 55 C
5 - 70 C
0.006% / C
0.008% / C
10V DC/AC (MAX.12V)
200%
300%
> 1000 M OHMS
IP- 68
4 m . 4 CORE SHIELDED PU
SHEATHED
COLOUR OF WIRE
+ EXCITATION
BLACK
+ IN HIGH
RED
- EXCITATION
GREEN
- IN LOW
WHITE
Page 18
Section 5
System Installation
Page 19
Page 20
Fig.4.2 TACHO-GENERATOR
b) Idler mounting arrangement
In this arrangement separate idler is used which is made to rotate by the returning belt.
Tacho coupled to this idler with required mounting accessories.(fig 3.7)
ANGLE SENSOR
Page 22
Application
When same conveyor is being used for stacking and reclaiming of the material the
inclination of the conveyor changes accordingly. This change induces a cosine error in
the measured load. To avoid this angle, Angle sensor is used.
Angle sensor is mounted to the conveyor stringer. Keeping the conveyor in horizontal
position system is calibrated. This is the 0 (zero) inclination, after that if there is any
change in inclination, positive or negative sensor gives corresponding pulse. This is
processed and corresponding cosine correction is made.
Measuring Range
-40 Degrees to +40 Degrees.
The following thing should be taken care while installation
Page 23
b)
The tacho mounting idler should rotate freely to ensure that the pillow blocks
can be periodically lubricated.
c)
The tacho mounting idler should be in-line with the belt so that it can rotate
freely without slip.
d)
The cable from the tachogenerator should be brought out through a flexible
conduit and be terminated in the junction box, where the loadcell cable is
terminated.
e)
f)
Note: In case where single junction box provided for both loadcell & speed sensor
connection, do not connect speed sensor terminal to 5th pin (shield) of MKDSN
connectors in junction box.
Page 24
CAUTION
Do not hold the panel by front cover, It may fall off
Install in a location where temperature with in the permissible limit.
The dimensional details of the electronic unit (panel mounting) are shown in the
enclosed dimensional drawings. Electronic panel of the belt weigher is micro controller
based panel mounting, signal processing unit which may be fixed inside panel
enclosures by two fixing clamps provided at the side of the unit. For connections, use
the connectors provided at the rear side of the unit. For easy serviceability all the cards
are interconnected by connectors.
Wiring connections should only be made through the bottom of the enclosure using
waterproof fittings. To prevent possible shorts to the terminals or to the printed circuit
boards keep the wiring neat and insulate all shields.
Page 25
CABLE ROUTING:
Page 26
Cable routing is an important factor, which governs the trouble free performance of the
equipment, especially, on a long-term basis. The following points are to be borne in
mind.
1. Never run any of the signal cables alongside a power line. The distance of the signal
from a power line should be at least one meter.
2. Do not use the power cables as a supporting point for signal cables especially when
supported by metallic wires.
3. It is always better to run the signal cables through metallic conduits.
4. Cables should not be routed beside relays, or electrical equipment.
5. Cables should not be exposed to sun or rain as this may cause deterioration of
insulation resistance. High insulation resistance is necessary for accurate operation.
6. When cables are terminated to an equipment or device, at least a small length of
flexible conduit is used at the point of termination or the cable connected to the
terminals should be allowed a little free length to avoid straining.
7. Joining of cables are to be done either by proper soldering or by cable connectors
and not by twisting them together. At the joining point they are to be properly
insulated by insulation tape of high quality. Joining the cables with connectors and
screws are not preferred. It is better to have soldered tags on the wire when
screwing connections are adopted.
8. For trouble free operation of the equipment proper earthing is essential which
improves signal to noise ratio, as well as minimizes transmitting of spikes. It also
helps to keep 50 Hz noise at a minimum level.
9. In many cases the power line earth (not neutral) may prove to be satisfactory. But
sometimes, this may also carry a voltage due to some return current from different
equipment connected to it.
10. Make a separate earth connection for the equipment. A long pipeline running under
the earth may be a good choice.
11. A good earth connection can be made by digging a pit of 0.6 X 0.6 X 2 m and
burying a copper bar of about 6 mm X 12 cm X 2 m , the pit being filled with
charcoal and common salt. From this point electrical connection can be made by 12
gauge copper wire. The main display unit casing should be connected to earth.
12. All the interconnecting resistance should not be more than 0.5 ohms.
Section 6
Page 27
System Description
REMOTE INDICATOR
Page 28
Page 29
Section 7
User Interface
Display
At this point, the panel should be installed and the Weight Processor mounted and
wired. Power up the unit. The display windows should light up with information.
Since the unit has not been set up yet, disregard any error messages or incorrect values
on the display.
The diagram below shows the Belt scale front panel.
There is a 7-Digit 7-Segment red LED display indicates following data selected by the
keypad.
Belt load in kg/m.
Belt speed in m/s
Rate of flow in tph.
Total quantity conveyed in t
Power ON belt on, under load, over load, and totaliser set achieved (SA) totaliser pulse
output and faults are also indicated on the LED. Password protection for all
programmable parameters, totaliser clear and tare run has been provided to prevent
unauthorized setting changes.
Page 30
Page 31
SET
This key is used to enter into Set mode. From which all the
SET parameters can be programmed.
1
CON
2
E
T
This key is used to enter into Con mode. From which all the
configuration parameters can be programmed.
1
CAL
TARE
RUN
TOT.RST
5
SYS. RST
6
F1
7
F2
ESC
Page 33
When the system is Switched ON, the Display shows the following message
momentarily
Ipa
The display then changes to
SS
If the system passes the self-test ,
Then display shows
PASS
Then the display changes to
Oa
Then the display shows
XXXXXX
-Totaliser
Press key then the display shows
S XXXX
S -Speed
Press key then the display shows
xxxx
Page 34
- Rate
Press key then the display shows
XXXX
- Load
Press key then the display shows
* -
- If belt is On
If belt is Off
Section 8
Page 35
Parameter Table
Parameter Definitions
Read each parameter description and enter the appropriate value. In addition, it is
recommended that you properly calibrate the scale before enabling the optional
outputs.
CON LOAD (LOAD CONFIGURATION PARAMETERS):
DECIMAL POINT
This parameter can be set as 0, 1, 2 and 3.
If the parameter is set to
0, then the display shows XXXX
1, then the display shows XXX.X
2, then the display shows XX.XX
3, then the display shows X.XXX
FILTER VALUE
This system incorporates an averaging method of displaying. This parameter can be set
from 000 to 199, which are the minimum and maximum values respectively. The
damping would be maximum at 199 and hence the rate at which load value is updated
will be minimum (i.e., reading update will be slower) and vice versa when time
constant is set at 000.
RESOLUTION
This parameter is used to select the least count.
It is set 0 to for a least count of 10.
Set to 1 for a least count of 1.
Set to 2 for a least count of 2
Set to 5 for a least count of 5.
u
Page 36
Press key.
Then the display changes to
Decimal Point
Then use the numeric keys to set the decimal point value. Press key to record the
value. Then the display will show next parameter.
Filter Value
L
Then enter the desired value using the numeric keys and press key to record the
value. Then the display will show next parameter.
Resolution
S
Then enter the desired values using the numeric keys. Press key to record the value.
Press ESC key to exit from CON mode.
CON SPEED (SPEED CONFIGURATION PARAMETERS):
DECIMAL POINT (Speed decimal Point)
This is the decimal point setting for speed displayed. The values from 0 to 3 can be
entered. 0 corresponds to no decimal point, 1 to one decimal point and so on.
Page 37
o
Press the
Press key.
Then the display changes to
Decimal Point
Page 38
L
Then enter the desired value using the numeric keys and press key to record the
value. Press ESC key to exit from CON (Speed) mode.
CON RATE (RATE CONFIGURATION PARAMETERS):
DECIMAL POINT (Rate decimal Places)
This parameter is used to get the required resolution of rate. The values that can be
entered are 0, 1, 2 or 3.
0 corresponds to 1 tph
1 corresponds to 0.1 tph
2 corresponds to 0.01 tph
3 corresponds to 0.001 tph
Setting CON RATE parameters:
Press the key marked CON. The display will show
o
Press the
o
Page 39
Press key.
Then the display changes to
Decimal Point
Then enter the desired value using the numeric keys and press key to record the
changes. Press ESC key to exit from CON (Rate) mode.
CON TOTALISER (TOTALISER CONFIGURATION PARAMETERS):
DECIMAL POINT (Totaliser Decimal Places):
This parameter is used to set the resolution of the Totaliser. The values that can be
entered are 0, 1 2 or 3, which correspond to 1 ton, 0.1 ton, 0.01 and 0.001 ton respectively.
0 corresponds to 1 ton
1 corresponds to 0.1 ton
2 corresponds to 0.01 ton
3 corresponds to 0.001 ton
Page 40
o
Press the
Press key.
Then the display changes to
Decimal Point
Then enter the desired value using the numeric keys and press key to record the
changes. Press ESC key to exit from CON (Rate) mode.
SET PARAMETERS
The set parameters are:
Under load
Over load
Set speed
Speed type
Span rate
Load factor
Page 41
Address
Speed measuring time
Totaliser set
Under load: This is the minimum load above, which totaliser updating will take place
and below which totaliser updating will not take place, and gives fault
indication.
Over load: This is the maximum load that the system can withstand and above which
fault indication will be given.
Set Speed: This is the assumed speed of the conveyor instead of the actual measured
value. This is applicable when the parameter speed type is set as 1 (internal speed
type).
Speed type: This parameter selects the speed type of the system
For internal speed type select 1
In this case the parameter set in set speed is assumed to be the speed of the conveyor.
For external speed type select 0
In this case actual speed of the conveyor is measured through pulses from external
device. Ex: Tacho, Proximity sensor.
During calibration speed type is set to 0
Span rate: This is the value of rate of flow at which system provides 20mA current
output. Generally, design capacity is set in this parameter.
Load factor: This is the correction (multiplication) factor for fine corrections to the
calibrated load.
Address: This is an address of the beltscale (slave unit) for MODBUS communication.
Range of entry 001 to 247. When belt scale is used with remote indictor (master unit)
address of the belt scale shall be entered as 001. When belt scale is interfaced with
clients PLC /DCS the address can take any value other than 01 up to 247
Speed Measuring time: Measurement of speed is based on no of pulses/speed
measuring time in second i.e. frequency. For the given tacho and mounting
arrangement, frequency can be worked out. If the frequency is 500 Hz, speed
measuring time can be set as 2. This is the time interval in second at which the speed is
sampled periodically. For slower speed the value is set as high i.e >2.
Page 42
XXXXX
Use numeric key to change the value.
Press key to record the change.
Then the display will show next parameter.
Over load
OU
XXXXX
Use numeric key to change the value.
Press key to record the change.
Then the display will show next parameter.
Page 43
XXXX
Use numeric key to change the value.
Press key to record the change.
Then the display will show next parameter.
Speed type
S
Press key then the display changes to
X
Use numeric key to change the value.
Press key to record the change.
Then the display will show next parameter.
Span rate
S
Press key then the display changes to
XXXX
Use numeric key to change the value.
Press key to record the change.
Then the display will show next parameter.
Load Factor
Page 44
XXXXX
Use numeric key to change the value.
Press key to record the change.
Then the display will show next parameter.
Address
SS
Press key then the display changes to
XXX
Use numeric key to change the value.
Press key to record the change.
Then the display will show next parameter.
Speed measuring time
XX
Use numeric key to change the value.
Press key to record the change.
Totaliser Set
O S
Press key then the display changes to
XXXXXX
Use numeric key to change the value
Page 45
ESE
Then it will comeback to the normal mode.
Section 9
Commissioning
Before commissioning the system allow the belt to run for at least one hour.
Make sure that the belt runs smoothly over the weighing frame. It does not
slide, shift or have any jerky motions.
Before connecting the loadcells and tachogenerator to the electronic panel,
make sure that they are functioning correctly.
Page 46
Section 10
Calibration
Assuming all parameters are correct and the unit is installed properly, you can
now calibrate the system. Without calibration, the system will not show correct rate
value.
Turn ON the conveyor, make sure the belt is empty, and let the whole conveyor
system warm up for approximately one hour.
The Belt Weighing System is calibrated at site with a calibration chain or rod of
known weight per unit length or weight respectively. The calibration process is
generally carried out at 25 75% of the rated capacity of the system.
Page 47
Chain calibration
In case of CALIBRATION CHAIN
Note down kg/m punched on the chain.
Carry out tare run operation.
Put the chain on the belt & suspend one end.
Ensure the chain covering the total weighing zone.
Enter kg/m value. (Load calibration)
If the kg/m is not found weigh the total chain & measure the total length.
Total weight /total length gives kg/m value.
The speed of the belt is monitored using a stopwatch. The length of the belt and time
taken are noted down.
The speed of the belt in m/s is calculated as
Speed = (distance) (Time taken in s).
The test chain is put on the belt and the rate reading is noted.
CALCULATION OF ACTUAL RATE:
Let
Belt speed
= S m/s
Weight of the chain
= W kg/m
Actual Rate in TPH
= W x S x 60 x 60
1000
Reset the totaliser and start the stopwatch simultaneously. Take the reading of the
quantity for a known time. The quantity should agree with the rate reading. The tests
are repeated three times and the average value is calculated on the basis of these tests.
Page 48
Rod calibration
IN CASE OF CALIBRATION ROD
Ensure quantity of rods.
Note down the weight punched on each rod and sum it up.
Total weight/idler spacing x No. of Idlers gives kg/m value.
Carry out tare run operation.
Put the calibration rods on the bracket provided on weighing frame.
Enter kg/m value.
Note :
Always refer calibration chain/calibration rod data given at Page No.16 (Section 04.
SPECIFICATION) the value given in GA is only approximate value only.
Calibrating the system with both chain and rod
After chain calibration perform drop test and make the necessary adjustments in the
indicator settings. Now conduct rod calibration. Observe the displayed load (kg/m)
value and note down the same.
The displayed value is __________ (To be entered by our service engineer).
There will be some variation in this value with respect to the value displayed when
chain calibration was done. Do not change any indicator settings.
During subsequent rod calibrations the above noted down load value is to be
considered for ascertaining the correctness of calibration.
Note: If drop test cannot be conducted then rod calibration is done after the chain
calibration.
Page 49
O
After 2 or 3 revolution press key, then TARE RUN will be completed
If we are pressing ESC key the Display will show AbOrt
Note:
If TARE RUN is attempted in Belt OFF condition the Display shows
bELtOFF. TARE RUN can be carried out in Belt OFF condition by putting the
system in internal speed mode.
TARE RUN should be carried out for at least 2 BELT revolutions.
To escape from the TARE RUN Press ESC key
LOAD CALIBRATION:
Place the Calibration chain on the Belt and start the Conveyor
Press CAL key then the Display shows..
XXXX
Enter the actual load value in kg/m and press key.
Display then shows..
Page 50
O
To complete the calibration press key once again.
SPEED CALIBRATION:
Put the system in External Speed Mode (See SPEED TYPE in Set Parameters).
Run the conveyor at maximum Rated Speed. Wait for the Speed Display to stabilize.
Press CAL key then the Display shows..
S
Press key then the display changes to
XXXX
Enter the actual Belt Speed in m/s and press ENTER key once again.
TOTALISER CALIBRATION:
Press CAL key then the Display shows..
Page 51
Reset the calibration factor to 1.0000. Store and Exit back to Display mode by pressing
the ESC key. Now run the conveyor at a constant speed with the calibration chain/rod
on it and clear the Totaliser.
Let the system run for 10 minutes. After ten minutes note down the indicated Totaliser
(ti ).
Now calculate the actual Totaliser value as
ta =
Page 52
Note down the correct weight and length of the chain (weight/length gives
kg/m) or the correct weight and quantity of calibration rods provided.
Make sure that the rollers of the chain are free to rotate and also the link points
are free. If necessary, lubricate the rollers and the link points.
Make sure that at least two sets of the idler rollers of the conveyor on either side
of the weighing idler are free to rotate.
Tie the chain at central point across the width and above the belt so that the chain
occupies the centre of the belt when the belt is running.
Place the calibration rod at the specified position on the weighing frame.
Make sure that the chain runs steadily on the belt at the center without any
sliding and that all the chain rollers are rotating.
Position the chain in such a way that it covers equal lengths on either side of the
weighing roller.
During calibration ensure that the belt is not whipping when calibration is being
carried out.
CALIBRATION DETAILS
LOAD CALIBRATION
Capacity of the system
Belt speed
Material load on the belt in Kg/m (Wm)
Page 53
: 600tph
: 1.8m/s
Rate in tph X 1000
: ----------------------------Speed in m/s X60 X 60
: 92.59 kg/m
: Wm X Idler spacing X No. of Idlers
: 92.59 X 1 X 2
: 185.18kg
The system has been calibrated such that 185.18kg on loadcell (100%) to read as 92.59
kg/m
SPEED CALIBRATION
In case of AC OR Pulse tacho
Belt speed in m/s
Tacho speed (RPS)
= ------------------------xD
=
------rps
Where D is the diameter of the tacho wheel or tacho mounting idler -----rps
corresponds to ---- m/s
In case of Speed sensor & Pick up wheel
Belt speed in m/s
RPS of pick up wheel
= -----------------------xD
= 3.58rps
Where D is the diameter of the peck up wheel
Frequency = RPS x No. of pulses/revolution
= 3.58 X 12
= 42.96Hz
42.96 Hz corresponds belt speed of 1.8 m/sec
ACCEPTANCE TEST
EXAMPLE
Accuracy specified 0.5% of full scale that is error of
0.5
Page 54
condition.
Specimen calculation
Capacity (rated) 100 tph
Accuracy specified 0.5 % Full scale
Error allowed 0.5 X 100 = 0. 5 tonne or 500 Kg
100
An error of 500 Kg is acceptable with respect to totaliser reading to actual material
weight collected
CALIBRATION CHECK AND ITS PERIODICITY
To calibrate the system refer calibration procedure explained in the earlier
section. After calibration, record kg/m value against cal. Chain/rod as wel as actual
speed value. These parameters values should be cross checked at least twice in a month
and also tare run should be performed against empty belt condition.
Precautions/prerequisites to be followed strictly.
The calibration interval is affected by things such as sensitivity of the system to
ambient condition, stability of structure, physical changes of conveyor belt or conveyor
system and rate of built-up of dust or spill on the scale.
Page 55
S
Press key to clear the Totaliser. The Display automatically comes back to normal
Display mode.
Section 11
Trouble Shooting
CAUTION
When a fault occurs, the cause must be corrected before the fault can be
cleared. If protective function keeps active it could lead to reduction in
product life and damage equipment.
Make sure to remove the input power while maintenance
Do not change any inner parts and connectors.
Status Messages
Page 56
SS
If the system passes the self-test,
Then display shows
PASS
Then the display changes to
XXXXXX
The following tests are performed during SELF-TEST.
RAM Check
This test is performed to check the presence and proper functioning of the memory chip
the RAM IC. If it fails this test the system will Display
Page 57
and halts.
Serial EEPROM Check
This test is performed for the serial EEPROM IC. On failure, there is a fault
annunciation and the display will show
Note that if the serial EEPROM is write protected, this test will fail.
ADC Check
This test is performed to check the digital section of the ADC. On failure, there is an
fault annunciation and the display shows
Note that this test does not check the analog section of
the ADC. Therefore, even if the ADC passes the test it does not imply that the ADC is
fully functional.
NOTE: If any of the above tests fail, the system will halt and no further operation can be
carried out.
None of these problems are user rectifiable.
Please contact IPA if any of these failures occur.
Section 12
Page 59
Parameter
Default settings
Factory settings
Under load
Over load
Set speed
Speed type
Span rate
Load factor
Address
0010.0
0800.0
01.00
0
500.0
1.0000
000
0000.0
0800.0
01.80
0
720.0
1.0000
001
Section 13
01
099999
1
000
1
2
10
1
0
01
000002
1
000
1
2
01
1
0
Replaceable Spares
The belt scale consists of many electronic parts such as semiconductor devices. The
following part may deteriorate
with age because of their structures or physical
characteristic, leading to reduced performance or failure of belt scale.
Component level servicing of card at site is not recommended. For quick maintenance
keep a set of spare cards. Repairing the belt weigher by replacing the defective card is very
easy. Send the defective card to IPA for rectification.
It is better to maintain the following spares to be used in emergency:
Belt Scale Panel
Page 60
EP-42-1
Transformer
TR-314
SMPS card
9823D
ADC card
9830 FR02
Display card
7060
Relay card
9830C
Keypad
4X4 type
TR-305
Controller card
9825C
Display card
9825B
Model
BR071H0
Speed sensor
Make
INFRA
IS41
Remote Indicator
Transformer
Loadcell
Model
Section 14
POSITION
ON
OFF
1
Page 61
SPEED SENSOR
POSITION
ON
OFF
SPEED SENSOR
Section 15
Item/
Component
Idler
Belt
Load cell
Page 62
POSITION
ON
OFF
Maintenance Schedule
Period of
Type of problem
Verification
Once in six i) Excess run out
months
Everyday
i) Excess belt
sway
ii) Undue wear
out
Everyday
4-20mA
i) No load or
Excess load
Cause
a) Bearing and / or
Bearing seal wear out
a) Belt loose
a) Skirt plate Touching
the belt
b) Lump getting stuck
between feed chute
& belt and /or skirt
& belt
a) Check for foreign
body causing load
shunting
Remedy
Replace idler
Adjust takeup
Lift skirt plate
Remove lump
manually and
clean
Remove foreign
body and set
right
Tacho
Speed
Sensor
Item/
Component
Coupling
Everyday
Everyday
Period of
Verification
Everyday
Weighing
Weekly
Frame
Idler/Pulley Once in six
months
Page 63
i) Speed
fluctuates
Type of problem
i) Undue noise
Material
accumulation
i)Wobbling
ii)Excess heat in
bearing block
Reconnect
b) Insulation failure
a) Tacho wheel or
coupling not making
proper contact
b) Loose connection
a) Tacho coupling
loose/missing
pulse
a) Pick wheel
alignment not ok
b) Loose connection
c) Speed sensor
coupling loose
d)Sensor is not in
proximity with pick up
wheel
Change loadcell
Set right
Align coupling
Align coupling
Cause
Remedy
a) coupling loose
b) Axial or angular
misalignment
a)Material may fall
from belt
a) Bearing and /or
Bearing seal wear
out
Tighten bolt
Align coupling
Clean it at
regular interval
Clean bearing
Apply grease/
Replace bearing
Section 16
Warranty
The items are covered by our warranty /guarantee for a period of 18 months from the
date of dispatch or 12 months from the date of commissioning whichever is earlier,
provided the terms and conditions in our offer are complied with.
Our guarantee does not extend to damages caused due to negligence or improper
handling or erection by the buyer or any alteration carried out without our
knowledge /approval. During this period, the items are to be returned to us at your
cost.
How ever our guarantee does not cover
Normal wear and tear of the items during operations.
Damages or losses caused during transit
Consumable items such lubrication oil, grease etc.
Deterioration or rusting due to atmospheric conditions.
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