NEW BELTWEIGHER STD MANUALmodified]

INDEX

Section 1. Introduction 2. System Overview 3. Technical Specification 4. Installation 5. Operating Instructions 6. Preventive Maintenance 7. Symptoms and Faults 8. Factory Settings 9. Bill of material 10. Drawings and Documents 11. Your contact at Sartorius

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Project Manual for Belt Weigher

SECTION 1 INTRODUCTION


Sartorius Mechatronics India Pvt. Ltd., headquartered at Bangalore, is 100% owned subsidiary of Sartorius AG, a 135-year-old company, with its headquarters at Gottingen, Germany. Its manufacturing activities include Mechatronics, Biotechnology, Hydro Dynamic Bearings and Environmental Technology. The Mechatronics division deals with almost all type of weighing system like ULTRA AND HIGH PRECISION LAB BALANCES. GOLD AND CARAT BALANCES. PLATFORM SCALES. ELECTRO CHEMISTRY PRODUCTS. HIGHLY ACCURATE AND RELIABLE LOAD CELLS. WEIGHT INDICATORS ADVANCED BATCHING CONTROLLERS. WEIGHING ACCESSORIES LIKE MOUNTING KIT, JUNCTION BOX ETC. SOFTWARE (CUSTOM & STANDARD) TANK WEIGHING SYSTEM WEIGHBRIDGES BELT WEIGHERS BATCHING SYSTEMS HOPPER WEIGHING SYSTEMS WEIGH FEEDERS LOSS IN WEIGHT FEEDERS Weighing System For Special Application. Owing to its sustained accuracy and reliability, Sartorius have installation of various types of weighing system in almost all types of industries like, Steel, Power, Petrochemicals, Ports, RTO Check Posts, Fertilizers, Refinery, Petrochemical, Glass, Food & Beverage, Pharmaceuticals, Chemicals etc.


SECTION 2 SYSTEM OVERVIEW

2.1 System Description Belt conveyors are the fastest mode of material transportation in mining and Project Manual for Belt Weigher

process industries where bulk material transportation is the important criterion. It is required to measure material transported over these conveyors, In order to achieve consistent quality in the process and accountability. Sartorius Belt weigher are designed to achieve this by delivering consistent accuracy and reliability. Belt weigher is basically a load measurement system installed in a conveyor belt. Which is designed to indicate and record the flow rate of the material conveyed from one location to another location? It will also record the total weight conveyed per unit time. High precisions Sartorius Load Cells are used for measuring the load. Reliable Speed measuring device is used to measure the belt speed. Using these two Parameters (Load & Speed) the material flow rate can be expressed in terms of tonne/hour. This flow rate output is integrated with respect to time for giving the continuous totalised value of the material conveyed Main features of Sartorius Belt Weighers are Simple installation and easy maintenance. Trouble free operation under severe environmental conditions Practically no effect of belt tension on weighing Remote data transmission High reliability and accuracy Easy integration with supervisory systems Note: The performance of Belt weigher is purely depends on the belt conveyor system, location of installation and the alignment of Adjacent Idlers. Hence it is recommended to read the Installation Guidelines prior to the installation. Belt weigher consists of the following components: Load cells with Belt weighing frame to measure the load Weigh Idlers Speed measuring device (encoder) with mounting arrangement to measure the speed Encoder mounting arrangement. Controller to process load and speed data and display the Flow Project Manual for Belt Weigher

Rate/totaliser The Formula to Calculate the Flow rate is

Q = P x V x 3600Q= Flow Rate in TPH P= Load in kg/m V= Speed in m/s Belt weigher Platform with Sartorius Load cell is mounted on the conveyor system to measure the load. Reliable speed-measuring device like proximity sensor / encoder / Analog DC Encoder is used according to the application / selection to measure the speed. By using the above formula the flow rate is calculated by Intelligent X4 Controller (PR 5510). 2.2 Basic Blocks of Belt Weigher The belt weigher consists of the followings 1.0 Belt weigher mechanicals Weigh Frame Loadcell mounting frame Weighing Idlers Pre/post carrying idlers Encoder mounting arrangement. Calibration rod 2.0 Load cell 3.0 Encoder 4.0 X4 Process Controller (PR5510/00) with following option cards Control I/O 6/12 Opto (PR5510/12) Analog out put (PR5510/06) 5.0 Encoder Interface Module (ST 5010/00) 6.0 Panel 1.0 Belt weigher Mechanicals: The Sartorius Belt weigher platform is a compact, rugged fabricated structural frame. This frame supports the weighing idlers and is isolated from conveyer stringer. Load cell is mounted


on load cell mounting frame. The weigh frame with weigh idlers is supported on load cell withloading pins/load buttons. The weighing idler /pre & post idlers are machined to limit the radial run out.

Weighing Idlers

EB Series Weigh Frame The encoder mounting idler is supported on a pivot frame with pillow blocks. The encoder is coupled to the wheel shaft. This assembly is mounted on or top of the return belt on the conveyor stringer. Calibration Rod: These are machined out of MS rod, whose weight is proportional to belt load. Individual weight of rod is punched. This can be used to periodic verification of calibration status. 2.0 Load cell (MP 47): Load cells are heart of the system. They are strain gauge based transducers, which converts mechanical force (strain) into electrical signal (mV) when given an excitation voltage. Strain gauges are arranged in a wheat stone bridge network by bonding to the specially designed/machined steel membrane. This is housed in an SS enclosure with inert gas filled and comes with a protection of IP68.When load is applied the resistivity in strain gauges changes proportional to applied load. The change in resistance is converted to electrical signal by giving an excitation voltage. Load cell will have an integral 4 core cable of standard length. Two cores are connected for supply voltage to the load cell & other two for the measuring voltage from the load cell


3.0 Encoder The encoder coupled to idler senses the speed of the conveyor. The encoder is a digital pulse encoder type whose output frequency is proportional to the speed of the belt. The encoder is excited with 5V DC supply from the controller. The pulse output is fed to the controller.

4.0 Weighing Controller The PR5510 X4controller is microprocessor based multitasking operator system. This controller is equipped with a high precision weighing point and analog to digital Converter. The controller has a VFD display and a multi foil keypad at front side and the process interface at rear side. The controller can be loaded with Belt Weigher application programs.

Basic Features One internal weighing point, approved for OIML 6000d 13mm Vacuum Fluorescent display for weight Additional 2-line 5mm dot matrix, each for 20-digit alphanumeric.


text Programmable for messages, operator guidance, values... Front panel controls, multi-function keys and soft keys. Closed aluminum-steel housing, front panel protection type IP 65, IP 30 for the rest of the instrument. Suitable for panel mounting (inserted through the panel cutout and easy to by clamped from rear) Plugable rear panel connectors for load cell, in-output, communication and supply Compact wide-range supply 115230V for electronic and load cell supply An optional normal PC keyboard (PS2) instead of the front panel keypad can be connected. A simple serial RS 232 interface is built in (Built-in) and available on the DSUB-9 socket. Configurable for e.g. printer, remote display, terminal, communication and Flash It (not for Modem) based on application program. Control I/O 6/12 Opto (PR5510/12) This module converts the external binary process signals into the internal signal levels of the weighing controller or vice versa (DIGITAL INPUTS or DIGITAL OUTPUTS in short DIO)This module has 12 digital outputs for process control, galvanically isolated with passive optocoupler outputs (max. 25mA) each with two pole potential free outputs and 6 digital inputs for process control, galvanically isolated by means of opto-couplers. The input signal is logic0 with open input each with two pole potential free input. Analog out (PR5510/06) The module is used for analog value of the displayed weight This is a single output 20mA (10V output only with external 500Ohm resistor. The range is 0/420mA configurable via software SETUP. This current output corresponds to error output & this is fed to drive for controlling the motor. Built-in RS 232 : The controller communicates with LFD(optional) via built-in RS 232 after conversion to Current Loop by converter module as the distance is more. Project Manual for Belt Weigher

5.0 Encoder Interface Module (ST5010/00) Encoder interface is a module for dividing the frequency of the encoder output to required frequency .The input frequency is 0 to 10 kHz and output frequency is 0 to 55 HZ. The divider setting can be selected with the dipswitch selection depending on the requirement. This is also annunciation for power on, pulse out, Error and pulse IN and pulse OUT. If the frequency exceeds 55 Hz there is an error output. 6.0 Panel (ST5010/21) The floor mounted panel, with dimension (HXWXD) houses the following X4 Process Controller (PR5510/00) with option cards And Encoder Interface module (ST 5010/00) The remote panel also houses the switchgears like MCB, Relays, X4 controller, Terminal blocks, Annunciation Lamps, 24V DC power supply Unit & Service socket. The various input/outputs configured in the panel are as follows Annunciations: 24V DC Cluster LED lamps for BELT ON, FAULT & TOT. PULSE for each controller. Analog Input/Outputs 1. Load cell Input : mV input from load cell corresponding to load on load cell. 2. Analog Outputs : 4-20mA corresponding to rate to customers PLC Digital input/output 1. Inputs : Speed input Belt ON Totaliser Pulse : encoder (field) : This output is given by the controller when the controller receives the speed Input signal from field. : This is the totaliser pulse output. This interval can be set from the controller I.e. pulse for every 1, 2, 5 or 10 increment. Cumulative fault: This is output from the controller for ADC fault, belt overload, Belt under load. Belt Overload : This is output from controller if actual belt load is more than 2. Outputs:


the set value In the controller.


SECTION 3 TECHNICAL SPECIFICATIONS

3.1 Conveyor: Equip No Conveyer No Material Belt Width in mm

: : : :


Bulk density T/m3 Capacity in TPH Speed in M/s Conveyer belt weight Load cell Type Tacho Type Make

: : : : : : :

Calibration Rod/ Equivalent Kg/Mt 3.2 Load Cell: Make Type Of Load cell Type No. Housing Construction

: : : :

Sartorius Bending beam type MP 47 Full stain less steel construction, hermetically sealed (IP 67), filled with inert gas

3.3 Junction Box: Type No. MOC Protection Painting Glands 3.4 X4 Controller: Type No. Material : PR 5510/00 : Aluminum. : ST 2620/13 : Die Cast Aluminum : IP 65 : Powder Quoted : 5 Nos, Double Compression


Protection Class Front Panel Power Supply Accuracy Display Load cell Input Load cell Supply Minimum Load cell Impedance Conformity Vibration Electrical Safety Linearity Resolution Input Signal Range Temperature Effect On Zero Temperature Effect On Span Measuring time Filter Operating Temperature

: IP 30 : IP65 : 115-230VAC 50-60 Hz+10%/-15% max. 19VA : 6000e OIML R76 min. verification interval 0.5V : 7 Digit plus status symbols text:2 line, 20 characters. : 6 Wire or 4 Wire : 12 VDC : 75 . : EN61000-6-2 and EN61000-6-4 : According to IEC 60068-2-6 : According to IEC 61010-1 : < 0.002% : 2.5 Mio.counts for 1 mV/V : 0...36 mV : < 0.05 V / K RTI : < +/-4 ppm/K : 10...160ms, adjustable : 4-pole digital filter 0.1 to 5 z.. : -10C To +40C


Interface

:

Built-in bidirectional serial interface RS 232, User selectable protocols: remote display, printer Keyboard interface PS2 Integrated Freely, as per customers requirement Totally through software. ST 5010/00 HT Push pull / RS422. Low 0 to 3V High 7 to 24V (X4/1713) 1 to 1024(in step of 1) 0 to 10 kHz. 0 to 55 Hz. If the freq exceeds 55 Hz. Power ON. Pulse In Pulse OUT Error Serial Interface(RS 232/485) 6 dig. In/12 dig Outputs(Opto) 1 analog Output 4 Analog Input /1 Output BCD open emitter BCD open collector Ethernet Profibus DP Interbus S DeviceNet CC-Link

Other Interface

:

Keyboard Programmability Calibration & Configuration 3.5 Encoder Interface Module: Model Input Signal. Output Signal Division Factor Input Frequency Output Frequency Error Output : : : : : : : : LED Indication for

: : :


3.6 Analog output Interface card: Model No of outputs Output Range Resolution Temp Linearity Zero error Potential Isolation Cable length(screened) 3.7 Control I/O 6/12 Opto card: Model No of inputs/outputs used Input signal : : : PR 5510/12 Input6 , output 12 Low: 05V or open High:1031V Passive external power supply required < 7 mA @ 24V < 3 mA @ 12V protected against wrong polarity passive external power supply required : : : : : : : : : : PR 5510/06 1 current output 20mA(10V output only with external 5000 resistor Gross ,net weight or application dependent 0/420mA,configurable through software setup 16 bits binary,20.000 internal divisions