CHAPTER -7

SYSTEM DOCUMENTATION
PE/206

MANUAL
`D1 BELT WEIGHER INDICATOR

NRE

HIGH WT

ACK VB CAL NW

ENT

NRE

kg
TOTAL FLOW
RESET

page 2 of 14 CONTENTS

G.A. DRAWING OF BELT WEIGHER INDICATOR .................................................................................................... 3 INSIDE VIEW OF BELT WEIGHER INDICATOR ....................................................................................................... 3 TERMINAL CONNECTIONS...................................................................................................................................... 4 BOARD INTERCONNECTION DETAILS ................................................................................................................... 5 INSTRUMENT SETTINGS ......................................................................................................................................... 8 INSTRUMENT OPERATION.................................................................................................................................... 11 FAULT FINDING & TROUBLE SHOOTING ............................................................................................................. 12 NOTES .................................................................................................................................................................... 13

Page 3 of 14

NRE

NRE

HIGH WT

ACK VB CAL NW

ENT

NRE

kg
TOTAL FLOW
RESET

G.A. DRAWING OF BELT WEIGHER INDICATOR

INSIDE VIEW OF BELT WEIGHER INDICATOR

`D1 Belt Weigher Indicator - Users Manual

page 4 of 14 TERMINAL CONNECTIONS 1) 2) 3) 4) 5) 6) 7) 8) 9) Terminal 1 Terminal 2 Terminal 3 Terminal 4 Terminal 5 Terminal 6 Terminal 7 Terminal 8 Terminal 9 230 VAC Phase 230 VAC Neutral Earth Load Cell 1 Supply Load Cell 1 Supply Load Cell 1 Signal Load Cell 1 Signal Load Cell 1 Shield Load Cell 2 Supply Load Cell 2 Supply Load Cell 2 Signal Load Cell 2 Signal Load Cell 2 Shield Encoder Encoder Encoder Encoder Supply Signal Supply Shield or 0-5 / 10 VDC Output +ve or 0-5 / 10 VDC Output ve (*) (*) (*) (*) ve +ve +ve ve +ve ve +ve ve +ve ve

10) Terminal 10 11) Terminal 11 12) Terminal 12 13) Terminal 13 14) Terminal 14 15) Terminal 15 16) Terminal 16 17) Terminal 17 18) Terminal 18 19) Terminal 19 20) Terminal 20 21) Terminal 21 -

0 / 4-20 mA Output +ve 0 / 4-20 mA Output ve Alarm Relay Contact Pole Alarm Relay Contact NO

Note: If no Junction Box is used, the two load cells may be connected directly to the Belt Weigher Indicator. If Junction Box is used, connect the load cell output cable to either the Load Cell 1 block or Load Cell 2 block.

Page 5 of 14 BOARD INTERCONNECTION DETAILS A) MAIN BOARD -

1) Connector J1 a) Pin 21 b) Pin 22 -

Totaliser Output (Use 2 pin Bergstrip female connector with wires) (*) Count (To Totaliser Terminal 2)

Ground (To Totaliser Terminal 3) To Display Board Connector J1 (Use 16 pin FRC Box type female to 16 pin FRC Box type Unused Load cell (Use 6 Pin Relimate female white connector with wires)

2) Connector J2 3) Connector J3 4) Connector J4 a) Pin 1 b) Pin 2 c) Pin 3 d) Pin 4 e) Pin 5 f) Pin 6 -

female cable assembly. Max. cable length 5 m)

Supply +ve Sense +ve Sense ve Supply ve Signal +ve Signal ve Unused Power Supply (Use 3 pin CPU female connector). If operation is on 230 VAC only, connect (To be shorted with Pin No. 1) (To be shorted with Pin No. 4)

5) Connector J5 6) Connector J6 -

13.5-0-13.5 V/400 mA Mains Transformer here. If operation is on 230 VAC as well as 12 VDC, connect to Battery Charger Board Connector JP6. a) Pin 1 b) Pin 2 c) Pin 3 13.5 VAC 0 13.5 VAC (or 12 VDC from Battery Charger Board - JP6, Pin 1) (or 0 V from Battery Charger Board - JP6, Pin 2) (or 12 VDC from Battery Charger Board - JP6, Pin 3) Open collector outputs for relay coil supply, corresponding to set points (Use 3 Pin Relimate

7) Connector J7 a) Pin 1 -

female connector) (*) Open Collector Output 1

`D1 Belt Weigher Indicator - Users Manual

page 6 of 14 b) Pin 2 c) Pin 3 a) Pin 1 b) Pin 2 c) Pin 3 9) Connector J9 10) Connector J10 11) Connector J11 12) Connector J12 13) Connector J13 +12V (Max. current 100 mA) Open Collector Output 2 Encoder (Use 3 Pin Relimate female connector) Supply +ve Channel A Supply ve Unused To Current Output Board Connector J1 or RS232 Board Connector J1. (Use 6 Pin Unused Shorted Unused

8) Connector J8 -

Relimate female white connector to 6 Pin Relimate female white connector assembly) (*)

Note: If 3 or more load cells are to be connected to the belt weigher indicator, then transistors Q1 & Q2 and ICs U2 & U4 (TO220 package) are de-soldered from the main board and fixed on a separate heat sink plate (with proper insulation pads and washers).
B) DISPLAY BOARD -

1) Connector J1 2) Connector J2 a) Pin 1 b) Pin 2 c) Pin 3 d) Pin 4 e) Pin 5 -

To Main Board Connector J2 (For cable details, see Main Board Conn. J2) External Keyboard (Or for remote operation of keys) (*)

Ground Key No.4 (Function Key) Key No.3 (Tare Key) Key No.2 (Zero Key) Key No.1 (Net/Gross Key) To Additional Display Board Connector J3 (Use 20 pin FRC Box type female to 20 pin FRC

3) Connector J3 -

Box type female cable assembly) (*)

Page 7 of 14 4) Connector J4 Unused For fixing decimal point, at any one location with shorting link.

5) Connector JP1 to JP5 -

C) CURRENT OUTPUT BOARD -

(*)

1) Connector J1 -

To Main Board Connector J10 (Use 6 pin Relimate female white connector with wires to 6

pin Relimate female white connector assembly) 2) Connector J2 3) Connector J3 a) Pin 1 b) Pin 2 Mains Transformer, 0-24 V/100 mA (Use 2 pin CPU female connector) Current/Voltage Output (Use 2 pin CPU female connector with wires) -ve +ve Current output at connector J3 5 VDC output 10 VDC output

I-out or V-out I-out or V-out

4) Connector J4 -

Output selection jumpers

a) No shorting link

b) Shorting link between pins 1 & 2 c) Shorting link between pins 2 & 3 D) TOTALISER (Selectron XC410) 1) Terminal 1 2) Terminal 2 3) Terminal 3 4) Terminal 4 5) Terminal 5 Unused

To Main Board Connector J1 Pin 21 To Main Board Connector J1 Pin 22 Short with Terminal 5 for enabling Front Reset key Short with Terminal 4 for enabling Front Reset key Unused 230 VAC Neutral Unused 230 VAC Phase (To Main CMT4 Terminal 1) (To Main CMT4 Terminal 2)

6) Terminals 6 to 9 7) Terminal 10 8) Terminal 11 9) Terminal 12 -

`D1 Belt Weigher Indicator - Users Manual

page 8 of 14 INSTRUMENT SETTINGS A) POWER-ON SEQUENCE After making the connections, when the power is switched on, the flow rate display shows `88888 then `123d0 and then `0. Operation is to be started only after `0 is displayed. The totaliser display shows `0 or the last totalized value in memory. B) INSTRUMENT SET-UP Various settings required for the instrument are done as follows 1) Decimal point selection 2) Initial settings as given below a) Full scale & resolution selection Display shows the default range-resolution of `00101, or the last selected range. Here the first 3 digits denote net weight full scale display counts, as 001x100=100. The last two digits denote the net weight resolution. Pressing <VB> (up arrow key) repeatedly will scroll through all the available ranges. On getting the desired range, press <ENT> to store the selection and to go to the next step. b) Flow Rate Full Scale On pressing <ENT> to store the full-scale range, the display will show some Activate the decimal point at the desired location by putting the shorting link in one of the jumpers, JP1- JP5, on the rear of the display board. Press <NW> key and then switch power on. The instrument goes into initial settings mode,

value with the leftmost digit flashing. Enter the required value of Flow Rate Full Scale, using <VB>, <NW> and <CAL> (up, down and right shift keys). Press <ENT> to store the value and to go to the next step. c) Current output direction On pressing <ENT> to store the flow rate full-scale value, the display will show `Co-UP or last selected value. Pressing <VB> (up arrow key) will toggle display between `Co-UP and `Co-dn. If `Co-UP is selected, the current output, 4-20 mA, will be proportional to flow rate zero to flow rate full scale. If `Co-dn is selected, the current output, 4-20 mA, will be proportional to flow rate full scale to flow rate zero. Press <ENT> to store the selection and to go to next step. d) Decimal Point Selection On pressing <ENT> to store the current output direction, the display will
st

show `dp-1 or last selected value. Pressing <VB> (up arrow key) repeatedly will scroll through 1 to 3. The selection is made as per the decimal point location - 1 for decimal point after 1 digit from right, (format xxxx.x), 2 for decimal point after 2nd digit from right, (format xxx.xx), and 3 for decimal point after 3 digit from right, (format xx.xxx). Press <ENT> to store the selection and to go to next step. e) Flow Rate Unit Selection On pressing <ENT> to store the decimal point selection, display shows Frks or last selected unit. On pressing <VB> display toggles between `Fr-ks and `Fr-tH. `Fr-ks denotes flow rate unit as kg/s and `Fr-tH as tph. Press <ENT> to store the selection and to go to next step. f) Totaliser Pulse Unit Selection On pressing <ENT> to store the flow rate unit, display shows `tP-kg or last selected value. On pressing <VB> display toggles between `tP-kg and `tP-tn. If `tP-kg is selected, totaliser increment is per kg, and with `tP-tn selection, totaliser increment is per ton of flow. Press <ENT> to store the selection. The instrument will then go into power-on sequence and then show `0 or the current flow rate. 3) Calibration Ensure that there is no material on the belt. Press <NW> so that <NW> LED lights up. The
rd

press <CAL> for more than 5 seconds, till the display shows `Pwrd? Release the keys. The display will show `00000' with the leftmost digit flashing. Using the arrow keys, enter the password `07968' and press <ENT> to enter calibration mode.

Page 9 of 14 If a wrong password is entered, the instrument will revert back to measurement mode. If the correct password is entered, the dead weight is zeroed automatically, and the display shows `Putwt'. At this point, pressing <VB> and <NW> together will show the ADC count on the display. Disregard the decimal point when reading

the ADC counts. Note down the ADC count for zero (dead) weight. Put any known weight on the load cells
and once again check the ADC count for that weight. The ADC count at full-scale load should NOT exceed 40,000. Extrapolate the ADC counts at dead weight & known weight to calculate the ADC count at full scale. If the ADC counts are either higher or lower, adjust the same by turning preset R36.

If the display shows 40,000 counts, then it signifies that the load cell is not connected. If the display shows 65,535 counts, then it signifies that the load cell outputs are reverse connected. In both these cases, turning R36 will NOT have any effect on the display counts!
After putting a known weight on the load cells, press <ENT>. Display will show `00000' with the leftmost digit flashing. Enter the value of known weight using the arrow keys. Press <ENT> to store the calibration weight. The instrument comes out of calibration mode and returns back to net weight mode (NW LED On). The display shows the actual weight, which will be the calibration weight that is still on the load cells. Remove the weight from the load cells and check that the display shows `0 at zero load. If not, press <CAL> once to zero the display. Press <NW> to go to flow rate mode.

Calibrate the system once again for fine-tuning, if there is a big difference the actual weight and display readings. Use a calibration weight of minimum 10% of full scale and maximum 90% of full scale. Using a calibration weight between 50% and 75% of full scale will give the best results.
4) Settings Correction Factor, Digital Filter and Current Output Constants (Optional) (*) - Press <NW> &

<ENT> together. The display shows `SEt. Release the keys. The instrument goes into alarm settings mode. The following settings are done one after the other, as given below a) High Net Weight Alarm - On releasing <NW> & <ENT> keys, the LED `High Wt will be flashing and the display will show some value with the leftmost digit flashing. This alarm gets activated when the net weight increases beyond this value. Enter the required value of High Net Weight Alarm using the arrow keys. Press <ENT> to store the entered value. b) Low Flow Rate Alarm On pressing <ENT> to store the value of High Net Weight Alarm, the LED `Low Flo will be flashing and the display will show some value with the leftmost digit flashing. This alarm gets activated when the flow rate decreases below this value. Enter the required value of Low Flow Rate Alarm using the arrow keys. Press <ENT> to store the entered value. c) Correction Factor On pressing <ENT> to store the value of Low Flow Rate Alarm, the LED `High Wt will be on and LED `Low Flo will be flashing, and the display will show some value with the leftmost digit flashing. This is the correction factor for totaliser reading. The default constant is `001.00 and needs to be changed if the totaliser reading does not match the total conveyor output. The procedure for checking the same is as follows Zero the net weight and totaliser. Start the conveyor and pass a known quantity of material through the conveyor over the load cells. Use such a minimum quantity of material so that the conveyor runs for at least 2 hours, for accurate calibration. The flow rate during this should be near or equal to the capacity of
`D1 Belt Weigher Indicator - Users Manual

page 10 of 14 the conveyor, with the heap height as high as possible, but ensuring that the actual weight on weigh rollers does not increase full scale value, or that the material does not spill out of the belt width. When the entire material is conveyed, stop the belt immediately and check the totaliser value. If the totaliser value and the actual material conveyed values do not match, find the correction factor using following formula

New Correction Factor

= Present Correction Factor x

ActualMaterialQuantity TotaliserValue

Change the correction factor to the new value and cross check the results once again. Enter the new correction factor using the arrow keys. Press <ENT> to store the value of the Correction Factor. d) Digital Filter (*) On pressing <ENT> to store the value of Correction factor, the display shows `Ftr

1' or last selected value, where the rightmost digit, i.e. `1' is flashing. 1 is the level of digital filter. Pressing <VB> repeatedly will scroll this value between 1, 2, 4, 8 and again 1. Thus, four levels of filter can be applied. The values 1, 2, 4 & 8 denote the no. of counts that will be averaged (filtered). Press <ENT> to store the displayed digital filter value. e) 0/4 mA Constant (*) On pressing <ENT> to store the value of Digital Filter, the `VB LED will be on

and LED `Low Flo will be flashing, and the display will show some value with the leftmost digit flashing. This is the constant for 0 / 4 mA output at dead load. Check the current output at dead load. If the output required is 0-20 mA, keep this constant `00000. If the output required is 4-20 mA, keep this constant approximately `00700. If the output is not exactly 4 mA, change this constant correspondingly. Press <ENT> to store the value of the 0 / 4 mA constant. f) 20 mA Constant (*) On pressing <ENT> to store the value of 4 mA constant, the `NW LED will be on

and LED `Low Flo will be flashing, and the display will show some value with the leftmost digit flashing. This is the constant for 20 mA output at full load. Keep this constant approximately `02700. Check the current output at full load, and if the output is not exactly 20 mA, change this constant correspondingly. Press <ENT> to store the value of the 20 mA constant. The instrument reverts back to measurement mode.

For 0-20 mA or 4-20 mA, the output load allowed is < 500 ..

For 0-5/10 VDC output, set current output settings at 0-20 mA. The min. output load allowed is > 5 k.
Now, according to the flow rate of the belt conveyor, a current output of 0 / 4 mA (at dead load) to 20 mA (at flow rate full scale) is available, which will be following the display value.

Page 11 of 14 INSTRUMENT OPERATION A) KEY OPERATIONS 1) Flow Display The various key operations are as follows

This display normally shows the flow rate in kg/s. The various keys and their effect on this

display are as follows Flow Display Key Press <NW> & then put power on <VB> <CAL> <NW> <NW> & then <CAL> for long duration <NW> & <ENT> together 2) Totaliser Display Action / Effect Goes into Initial Settings mode `VB LED gets On, Display shows Encoder pulses per second No effect `NW LED gets On, Display shows Net Weight Goes into Net Weight Calibration mode Goes into Settings mode This display shows the totalised flow in kg or t, since last reset. Pressing <RESET> on

the totaliser resets the totalised flow count. However, this reset key is enabled ONLY if the terminals 4 & 5 on the rear of the totaliser are shorted.

B) OPERATION -

After the instrument is calibrated and set up, when the belt conveyor is started and material

starts flowing on the belt conveyor, the flow display starts showing the instantaneous flow rate. The totaliser display starts showing the totalised flow.

IMPORTANT: In a belt weighing system, the instrument itself plays a minor role in the system accuracy! For proper operation and best results, it is very important that the following actions are carried out regularly by the operator 1) Zero Setting - Being a dynamic weighing system, the zero of the net weight shifts due to changes in the belt tension and the inherent variations in the belt self weight. Therefore it is very important to regularly set the net weight zero; generally once a day or at the start of every shift. 2) Maintenance - Being a process instrument, maintaining the system clean and lubricated is very important for proper operation of the system. 3) Always keep the heap height as high as possible for best accuracy, so that the effects of belt tension and belt self weight variations are reduced as much as possible.

`D1 Belt Weigher Indicator - Users Manual

page 12 of 14 FAULT FINDING & TROUBLE SHOOTING

Fault 1. After power on, display stops at `1 2. Display shows `EPErr 3. On pressing <NW>, display shows `65535

Description / Possible Reasons ADC 7135 and / or OP07 are not working or is faulty EEPROM is not working a) Load cell is not connected b) Instrument is not calibrated c) Load cell is overloaded d) Load cell is connected with reverse output polarity

Corrective action Replace ADC and / or OP07

Replace EEPROM a) Connect load cell b) Calibrate instrument with load cell c) Reduce load on load cell d) Correct the polarity of load cell output signals a) Short Supply & Sense wires b) Check connections of all the wires of load cell properly

4. During calibration, display shows 40000 ADC counts

a) Supply & Sense wires are not shorted b) Load cell connections are not proper

5. During calibration, display shows 65500 ADC counts 6. During calibration, available ADC counts are very less 7. During calibration, ADC counts at dead load are very high

a) Load cell is connected with reverse output polarity

a) Correct the polarity of load cell output signals

a) Load cell capacity is very high than selected full scale

a) Use load cell of lesser capacity

a) Dead load is very large as a part of the full scale

a) Reduce dead load as much as possible. Best results are obtained when dead load is less than 20% of full scale

8. Display shows zero flow rate although there is material flowing on the belt

a) Net Weight is zeroed by pressing <NW> and <CAL> b) Encoder pulse output is zero

a) Remove all material from belt, zero the dead load of belt and start conveyor again b) Either encoder is not rotating or is not connected properly

[W2DOC050.DOC[]18/11/2003]

Page 13 of 14 NOTES

`D1 Belt Weigher Indicator - Users Manual

page 14 of 14