Instruction manual for Belt scale

TABLE OF CONTENTS
Section 1 …. 2 Key functions
Supply Verification & Visual Inspection
Caution Section 8– Parameter Table …. 35
Warning Factory settings
Section 2 – Introduction …. 4 Parameter definitions
Basic Operation
Signal Diagram Section 9 – Commissioning ….46

Section 3 – System Modules …. 7 Section 10 – Calibration …. 47

Weigh Frame
Calibration details
Load Sensor
Speed Sensor Acceptance test
Electronic Unit
Running the system
Calibration Rod/Chain

Section 4 – System Specification…. 15 Section 11– Trouble shooting …. 56

Conveyor specification Status message
Belt scale panel specification Operation trouble shooting
Loadcell specification
Section 12- Parameter entry table ….59
Section 5 – System Installation …. 18
Weigh Frame & loadcell installation Section 13- Replaceable spares ….60
Speed sensor installation
Belt scale panel installation Section 14 –Dip switch position …. 61
Cable routing
Section 15 -Maintenance schedule …. 62
Section 6 – System Description …. 27
Belt scale panel Section 16 – Warranty ….64
Remote indicator
Drawings
Section 7 – User Interface …. 29 Test report
Display
Log sheet

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Instruction manual for Belt scale

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.

Fig 1.1 Packing details

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Instruction manual for Belt scale

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

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Instruction manual for Belt scale

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

High reliability and accuracy
Trouble free operation under severe environmental conditions
Practically no effect of belt tension on weighing
Remote data transmission
Simple installation and easy maintenance.
Approved by Weights & Measures Model Approval No: BCW:IND/09/06/478

PRINCIPLE OF OPERATION

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

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Instruction manual for Belt scale

are involved in this :weight and speed. The weight function measure small section of
conveyor. The speed function is the second variable to be measured .Most modern
speed sensors rotary digital pulse generators. This can be optical, magnetic or other
on/off sensing units. They are mounted on pulley or wheel that rotates as belt moves.

The material passing over a Belt Conveyor exerts a downward force proportional
to its weight. The product of this force and the speed of the belt is the rate of flow, the
unit being kg/minute or Tonnes/hour.

Taking a section of unit length between ‘aa’ and ‘bb’ on the belt (fig. 1), the
reaction ‘R’ at the center of that section equals the weight of the material including the
belt weight, on that section. The tension of the belt ‘T’ has got no influence on reaction
‘R’ if ‘T’ and ‘R’ are mutually perpendicular.
Let the weight between ‘aa’ and ‘bb’ (unit length) = w kg./m
Let the speed of belt = s m/s
Therefore, material flow/min. = wxs
The rate of flow w x s integrated over a period of time gives the total quantity of
material transferred over that time.

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. For
Overload, Under load, Totaliser pulse and Totaliser set achieved.

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

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Instruction manual for Belt scale

controller. The DAC will produce a analog 4-20 mA out put corresponding to flow rate.
The tacho input is given to the ADC card via frequency divider circuit as pulse input.

Section 3 System Modules

The belt weigher consists of

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1. 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
3. Speed sensor *
AC Tachogenerator
DC Tachogenerator
DC Pulse encoder
Proximity switch
4. Speed sensor mounting frame *
Telescopic arrangement
Idler
Pickup wheel
5. Electronic unit *
Local panel
Remote panel
6. Calibration weight *
Chain
Rod

* Suitable arrangement selecting according to application.

WEIGHING FRAME:

Weighing arrangement with four loadcells

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The arrangement is to have a platform on to which the idlers are mounted and the
platform is supported on four loadcells. Fig 3.1.

This arrangement is used for applications like weighing in conveyors having minimum
material load of 20 Kg/m. This arrangement will get accuracy of 0.5% better under
ideal conditions.

Fig. 3.1 FOUR LOADCELL SYSTEM

Weighing arrangement with counter balancing weight

This consists of a framework pivoted or supported by bearings at both ends of a shaft

with an adjustable balancing weight at one end and the frame resting on loadcell at the
other end. (Fig. 3.2).
This type of arrangement using where material load is less then 20 kg/m and accuracy
is in the range of 1-3% depending upon site conditions.

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Fig. 3.2 COUNTER BALANCING WEIGHT SYSTEM

Weighing arrangement for garland conveyor

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).

Fig. 3.3 GARLAND CONVEYOR WEIGHING SYSTEM

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Weighing arrangement with two loadcells

The arrangement is to have a platform on to which the idlers are mounted and the
platform is supported on two loadcells. Fig 3.4.

Fig. 3.4 TWO LOADCELL SYSTEM

LOAD SENSOR
To measure the load, the gravimetric, force must be countered by an opposing force
measurement. This opposing or counter balancing force becomes the measurement of
weight.
The load sensor is a high accuracy strain gauge based loadcell, which gives excellent
linearity and repeatability. The zero and span of loadcells are fully temperature
compensated. These loadcells are hermetically sealed to withstand the hostile industrial
environment. The loadcells are provided with S.S. bellows to resist industrial corrosion.
BR type Loadcell (Fig.3.4) & DS type loadcell (Fig 3.5)

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Fig. 3.5 BR TYPE LOADCELL EXPLODED VIEW

Fig. 3.6 DS TYPE LOADCELL

SPEED SENSOR:
The accurate measurement of belt displacement is important for computation of total
mass passed over a conveyor.
The speed of the belt is measured by means of speed sensor that is driven by the return
belt/tail pulley. Generally four types of speed sensors are used
AC tachogenerator
DC tachogenerator
DC pulse encoder
Proximity switch.

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Selection of speed sensor is purely depends upon the conveyor speed and conveyor
construction.

AC Tachogenerator
AC Tachogenerator consists of a rotor having permanent magnetic poles that rotate
inside a stator having suitable winding. It generates 0-20V AC proportional to 0-1000
rpm.

DC Tachogenerator
DC Tachogenerator generates 0-160V DC proportional to 0-1000 rpm.

DC Pulse encoder
DC pulse encoder to be excited by the voltage specified on it. It produces rated pulses
per revolution with amplitude equal to excitation voltage.

Proximity switch
Proximity switch is also to be excited by the voltage specified on it. It provides pulse
whenever metal part comes closer to its surface (for inductive type)
A proximity switch is used to measure the speed of the conveyor. The switch is
inductive type. A pick up wheel (reference drawing enclosed) is fixed to the shaft of tail
pulley or special wheel assembly and the proximity switch is placed such that
proximity switch senses the rotation of pick up wheel, hence speed of the conveyor.
The proximity switch is excited by belt scale panel and proportional to the speed of
conveyor, it provides pulses to the belt scale panel.

SPEED SENSOR MOUNTING ARRANGEMENTS

TELESCOPIC ARM:
An aluminium wheel is fixed to the axle of the speed sensor. The aluminium disc is
allowed to be on the belt by a hinged telescopic arrangement.
As the belt runs, the speed sensor is rotated due to the friction between the aluminium
wheel and the belt. The speed sensor produces AC/DC voltage or pulses while it
rotates and the frequency is truly proportional to the speed of rotation. (fig.3.6)

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Fig.3.7 TELESCOPIC ARM ASSEMBLY WITH DC PULSE ENCODER

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IDLER MOUNTIG:
WEIGHING IDLER:
Machined idlers matching with the existing conveyor idlers dimensions. This will
improve the weighing accuracy, worn out idlers will cause errors in weighing. Usually
one pre and post carrying idlers are also machined idlers for better performance.

Fig.3.8 IDLER MOUNTING WITH AC TACHOGENERATOR

PICK UP WHEEL & SENSOR:

3.9 PICK UP WHEEL & SENSOR

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Instruction manual for Belt scale

ELECTRONIC UNIT

BELT SCALE PANEL

Belt scale is a micro controller based electronics, which operates on mains. It accepts the
signals from loadcell and speed sensor to compute rate of flow. The rate signal is
integrated to get the cumulative quantity. Refer specifications for voltage, mounting etc.

CALIBRATION CHAIN
A flexible roller chain made of mild steel is used for calibration. The standard length of
chain is 3 times the idler spacing in case of single idler weighing and 4 times the idler
spacing in case of double idler weighing. The weight per unit length of the chain is
known. The advantage of this method of calibration is that it is simple, accurate, fast
and does not need any complicated calculation.

CALIBRATION ROD
Rods used for calibration are made of mild steel. These are to be placed on the weighing
frame during calibration. Provision is made to place these rods on the weighing frame.
Calibration rods are advantageous in handling calibration weights as the total weight is
split into number of rods which can easily be placed on the weighing frame.

OPTIONAL FEATURES
These units supplying according to the customer requirements.

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Instruction manual for Belt scale

Section 4 System Specification

Conveyor Specification
Conveyor No. : BS-2A

Material handled : COAL

Bulk density (kg/m3) : 800

Conveyor capacity (tph) : 600tph (Rated)/660tph (Design)

Belt speed (m/s) : 1.8

Material load (kg/m) : 92.59

Belt width (mm) : 1200

Belt weight (kg/m.) : 21.4

Idler spacing (mm) : 1000

Idler weight (one set) (kg) : 55

Conveyor inclination (Deg.) : 10.7

Conveyor length (m) :

Load cell capacity (kg) : 200

No. of load cells : 4

Cal. Rod wt (kg) :

Tot. Cal. Rod wt (kg/m) :

Cal. Chain (kg/m) :

Speed sensor (Make/Model) : INFRA/IS41

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Instruction manual for Belt scale

Belt Scale panel Specification

Model No. : BCW55L0
Power supply : 230V ±10%,50Hz ±3%
Mounting : Wall
Operating temperature : 5°C to 50°C
Excitation to loadcell : ± 5V DC, 120 mA

Inputs :
0-15mV from Loadcell
Pulses from Speed Sensor

Outputs :
♦ 4-20mA corresponding to rate
(Loop resistance: Maximum – 1 kΩ
Minimum – 100 Ω)
♦ Potential free contacts (230V, 5A rating)
Under load
Overload
Totaliser pulses
Totaliser set achieved
RS-485 output to Remote indicator
Display : 7-Digit 7-Segment red LED Display.
Annunciation : LED
Power ON
Belt ON
Under load
Over load
Totaliser pulse out
Set achieved
Fault
Features :
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

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Instruction manual for Belt scale

Password protection for all

programmable parameters and functions
Load cell Specification
Model No.: BR022H0 Capacity: 200kg

Parameters Specified Value

(% Of Rated Output)
RATED OUTPUT 1.5 ± 0.01 mV/V
COMBINED ERROR ± 0.1%
REPEATABILITY ± 0.05%
CREEP ON LOAD (30 mins.) ± 0.1%
ZERO BALANCE VOLTAGE ± 0.2 mV
INPUT RESISTANCE 390 ± 10 OHMS
OUTPUT RESISTANCE 350 ± 2 OHMS
COMPENSATED TEMP.RANGE 5 - 55° C
OPERATING TEMP.RANGE 5 - 70° C
TEMP. EFFECT ON SPAN 0.006% /° C
TEMP. EFFECT ON TARE 0.008% /° C
EXCITATION VOLTAGE 10V DC/AC (MAX.12V)
SAFE OVERLOAD 200%
ULTIMATE OVERLOAD 300%
INSULATION RESISTANCE, BRIDGE TO > 1000 M OHMS
CASE AT 30V DC AT 30° C
PROTECTION IP- 68
CABLE 4 m . 4 CORE SHIELDED PU
SHEATHED

LOADCELL CONNECTION DETAIL:

SIGNAL COLOUR OF WIRE

+ EXCITATION BLACK

+ IN HIGH RED

- EXCITATION GREEN

- IN LOW WHITE

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Instruction manual for Belt scale

SHIELD

Section 5 System Installation

System Installation Requirements
Your conveyor may not meet all of these requirements and still give good accuracy
readings. Use these as guidelines for good design and realize that violating good
design will probably reduce accuracy

Avoid high speed, lightly loaded belts for scale application. Lowering the belt speed
which increases belt load will cure most scale problems.
The idler used at the scale as well as preceding and following the scale should turn
true(concentric) and the scale idler should be reasonably balanced(especially with
high speed belts) so as not to generate an out of balance vibration
Idlers should be on equal centers a minimum of two before and two after the scale
and must be string lined to be level for this span. Skirt boards must be avoided in
the scale area.
The conveyor should be rigid in design and reasonably free from vibration. The
conveyor must not be subjected to stress that will cause structural deflection
The conveyor should have an automatic belt tighter. A gravity take up system is
preferred.
The belt must be in contact with the scale idler at all times and should track in the
center both empty and full
The idler troughing angle should be 35° or less.
Conveyor inclination must not exceed the material angle of slide.
Conveyor loading should be reasonably uniform and loading cannot take place on
the area of belt being used as the weighing platform.
Sufficient impact location idlers should be provided under each feeding location so
as not to cause any deflection of the belt at the feed point.
The conveyor should be designed with a straight run without a vertical curve. The
conveyor may be horizontal, inclining or declining in scope.
Conveyor feeding to be uniform for better performance.

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A few typical locations of mounting weighing frames are shown in Fig 4.0.

Fig. 4.0 LOCATION OF WEIGHING FRAME IN CONVEYOR BELT INSTALLATION

Avoid the following!

• Badly worn belts and splices.
• Joined belts with different thickness.
• Poor belt training or alignment.
• Wind, temperature or vibration extremes.
• Mud or material build up on belt or idlers.
• Loosely mounted unstable conveyor.
• Steep troughing angles.
• High belt tension.
• Steep conveyors allowing material to roll back.
• Belt skirting or other interference near scale.

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Weigh Frame & Loadcell Installation

Locate the suitable place to install weigh frame

Remove the existing idlers from the located place.
Weld the load cell fixing frame to stringer as per GA
Fix the load cells in correct orientation
Fix the weighing frame above the load cell
Fix the weighing idlers on weighing frame
All the idlers should be in the same level, if the weighing idler is lower give
padding plates where the weighing idler is fixed to the weighing frame.
Adjust the load cell button height suitably
Align at least two pre and post carrying idlers with weighing idlers
Care should be taken to ensure that the load pin touches only the sensing stud of
the loadcell and not the loadcell casing.
Tacho fixing frame should be near to weighing frame

Note: While keeping active loadcells the welding should not be carried out

Fig.4.1 WEIGHING FRAME

Speed Sensor Installation

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For standard speed sensors:

Mount the speed sensor assembly so that it is aligned exactly with the belt. If it is not
straight, it may bounce and wear down the wheel or belt. Position the wheel so that it is
at least 200 to 300mm from a return idler.

a) Telescopic arrangement
It contains two aluminium wheels and one wheel is coupled to the tacho shaft. The
telescopic arrangement is mounted with a frame that is fixed in the stringer and a
telescopic arrangement to adjust the tacho with respect to the belt.
1) Weld the supplied channel to the conveyor stringers.(Make sure that load cells
removed from structure before any kind of welding)
2) Fix the speed sensor assembly onto the pivot arm on the welded channel.

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

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Angle sensor is an instrument to measure the angle of inclination of a particular plane.

It is also called Inclino Meter. There are some situations in weighing where the angle of
inclination having relevance.

Principle
The basic principle behind angle sensor is law of gravity. A freely suspended mass
which can move according to the tilt of the plane to which it is attached. This rotation is
connected to a sensor.

There are two ways to sense the inclination:

1. Pulse Encoding
2. Potentiometric

Installation
Take the base plate of the Angle sensor and weld it on the stringer, so that the sticker
coming portion is on top of the stringer. Mount the angle sensor on the base plate using
bolts. In this also the sticker portion should come on top. Detach the top lid and
removing the thermocol given for packing, ensure that the horizontal position of the
stringer, pendulum is in vertical position (zero level). Attach the lid to the sensor and
give the connections

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

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Errors in the accurate measurement of belt travel for conveyor scale weighing can occur
from variety of sources

a) The tacho should be coupled with the idler.

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) Slip between belt travel pickup and conveyor belt.
f) Belt speed varies with in the conveyor as a function of tension.

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.

Belt Scale Panel Installation

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Instruction manual for Belt scale

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.

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While selecting the mounting place for the panel following points should be kept in
mind:
Mount the panel in a reasonably clean area away from severe heat and isolated
from vibration.
Avoid areas of bright sunlight since the lighted displays may become difficult to
read. Also avoid dripping water areas.
The unit should be firmly fitted into the panel. Clamps for mounting are
provided in the unit.
Where outdoor installation is necessary, the panel should be mounted under a
“roof” or “dog house” to provide rain and snow protection as well as shade.
There should be sufficient space around the panel to do the periodic maintenance
or servicing or replacement of components.
There should be an instrumentation earth available and that is to be connected to
the panel.
Cables to the panel should be routed through conduit and terminated through
glands.
The power supply should be steady.
The panel can be located up to 25m from the weighing zone. Take note, however,
that calibration will require one person at the weighing zone and one person at
the panel.

CABLE ROUTING:

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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 System Description

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Instruction manual for Belt scale

Belt scale & Remote description is covered in this section.

Caution
Only apply input power after assuring all wiring is correct.
Connect shield wires to the panel only, not to other devices.
Insulate shield wires to prevent shorts.
Use only water tight compression fittings.

SMPS Card (9823D)

This card generates different voltages, which are used in ADC and processor card. The
different voltage levels obtained from this card are +5V, -5V, +12V, and 24V.

ADC and Processor Card (9830 FR02)

This card consists AT89C51RC controller, data acquisition circuit, loadcell excitation
circuit, current output section, tacho pulse shaping circuit, digital input circuit,
memory, interfacing circuit for port expansion and key board/display interfacing
circuit. It has got a capability of accessing a 4X4 keypad, and driving an LED. This card
provides 4-20 mA current corresponding to flow rate.

Relay Card (9830C)

This card housed four-sugar cube relays rated for 5A, 250V AC and opto-couplers for
isolation. It receives control signals from processor card for activation of relays. Supply
is provided from power supply card (9823D). The potential free contacts are for
underload, overload, totaliser set achieved and totaliser pulse.

Display card (7060)

This module is a 7-digit 7-segment LED display with various separate LED
annunciation for power ON, belt ON, underload, overload, totaliser pulse, set achieved
and fault.

REMOTE INDICATOR

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Remote indicator. Model RD165A0 shows “rate” on a 5 digit display and totalised
quantity on a 6 digit display. The rate and totaliser signals are transmitted from main
panel to remote by RS485 standard signals. Two soft touch keys F1 and F2 are provided
on the front to clear the totaliser and to recall the totaliser value.

Controller card 9825C

The controller card (9825C) used in remote indicator is with RS 485 serial input and two
serial outputs for display. This card also provides isolation for RS 485 signals. The
controller receives the string from belt scale panel and converts back to BCD format to
display totaliser and rate

Display card 9825B

This is a display card with a 6 digit totaliser and a 5 digit rate display. The card also has
two keys F1 for clearing the totaliser and F2 to recall the cleared value.

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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.

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Remote Indicator: Remote indicator is a slave unit which receives data from Belt scale
on RS485 bus and indicates instantaneous rate of flow and cumulative quantity.

The diagram below shows the Remote indicator front panel.

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KEY FUNCTIONS:
Numeric keys 0 to 9 are used to enter/modify the value of the Parameter.

SET
This key is used to enter into Set mode. From which all the
SET parameters can be programmed.
1

2
CON E This key is used to enter into Con mode. From which all the
T configuration parameters can be programmed.
2
1

CAL This key is used to enter into Calibration mode and the
system calibration can be performed.
3

TARE
This key is used to perform Tare.
RUN
4

TOT.RST
This key is used to Reset the totaliser.
5

SYS. RST This key is used to Reset the system.

F1
This key is used to perform Self-test
7

F2
Used as a Numeric key.
8

F3

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Instruction manual for Belt scale

Used as a Numeric key.

ESC This key is used to Exit from the present

level or mode.

Used as a Numeric key.

This key is used to View /Modify the parameters

and store the parameters.

This key is used to move back to the

Previous Parameter/level.

This key is used to move forward to

the Next parameter/level.

This key is used to Shift the blink digit right.

This key is used to Shift the blink digit left.

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POWER ON SCREENS:

When the system is Switched ON, the Display shows the following message
momentarily

Ipa

The display then changes to

The display shows

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
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Instruction manual for Belt scale

- 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 Parameter Table

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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.

Setting CON LOAD parameters:

Press the key marked CON. The display will show

u
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Instruction manual for Belt scale

Then Enter password 14673

The display changes to

o L

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

Then enter the desired value using the numeric keys and press ↵ key to record the
value. Then the display will show next parameter.

Resolution

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.

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FILTER VALUE`
This system incorporates an averaging method of displaying. This parameter can be set
from 00 to 99, which are the minimum and maximum values respectively. The damping
would be maximum at 99 and hence the rate at which speed value is updated will be
minimum (i.e., reading update will be slower) and vice versa when time constant is set
at 00.

Setting CON SPEED parameters:

Enter into CON mode (as mentioned previously)
Press the key marked CON. The display will show

Then Enter password 14673

The display changes to

o L

Press the key. display will show

o S

Press ↵ key.
Then the display changes to

Decimal Point

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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

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

Then Enter password 14673

The display changes to

o L

Press the twice, display will show

o
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Instruction manual for Belt scale

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

Setting CON TOTALISER Parameter:

Press the key marked CON. The display will show

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Then Enter password 14673

The display changes to

o L

Press the thrice, display will show

o L

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

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• 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
client’s 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.

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Totaliser set : This is the set value. On achieving which (by the totaliser), the “set
achieved” P.F contact operates to give pulse output.

Setting of SET parameters

Press the key marked SET key. The display will show

Then Enter password 14673

The display changes to

Under load

U L

Press ↵ key then the display changes to

XXXXX
Use numeric key to change the value.
Press ↵ key to record the change.
Then the display will show next parameter.

Over load

OU L

Press ↵ key then the display changes to

XXXXX
Use numeric key to change the value.
Press ↵ key to record the change.
Then the display will show next parameter.

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Set speed

S 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.

Speed type

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

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

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Press ↵ key then the display changes to

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

S- S-

Press ↵ key then the display changes to

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

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Press ↵ key to record the change.

Press ESC key to come out of programming loop.
Note: From any of the levels if ↵ key is pressed the parameter value is automatically
stored in the system memory and display changes to the next parameter. Press ESC key
to come out of programming loop.

SYSTEM RESET
Press SYS RESET key and the system displays

Enter the password ‘42391’

Then the display shows momentarily

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.

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Before connecting loadcells and tachogenerator to the electronic panel, switch

on the unit and check up the functions of the unit by shorting the
tachogenerator and the Red & White wires of each loadcell at the terminal
block connector in the control panel. The indicator reading should be zero.

Now, connect the loadcells and the tachogenerator to the electronic unit.
Allow the belt to run and adjust the weighing frame.

Keeps the belt running for half-an-hour to see the stability of the reading.

Now perform tare using the keypad.

Allow the belt to run continuously for half an hour and see whether the
reading remains zero. If it does not, check whether the idlers is running freely
and also check the loadcell connection.

Now the system is ready for calibration.

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.

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The process of calibration involves two steps

a) Tare run operation
b) Calibration

a) Tare run operation

This is carried out when there is no load on the belt. Make sure the belt is empty and
clean. Run the empty belt for at least 15 minutes.
Make sure that all weighing pre/post idlers are in line and in contact with the belt.
Carry out tare operation as explained under the “CALIBRATION” section in the user
manual for BCW55L0
b) Load calibration
After performing tare run operation load calibration is done. Load calibration may be
carried out using Calibration chain or Calibration rods or both. All of these are
explained in the following sections.
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.

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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.

From belt scale panel

TARE RUN:
Make sure there is no material on the Belt. Start the conveyor
Press the TARE RUN key. The Display will show

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Then Enter password 14673

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..

Then Enter password 14673

The display changes to

Press ↵ key then the display changes to

XXXX

Enter the actual load value in kg/m and press ↵ key.

Display then shows..

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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..

Then Enter password 14673

The display then enters into calibration mode.
Press / key till 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..

Then Enter password 14673

The display then enters into calibration mode.

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Press / key till the display shows

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 = rate ( in tph ) x time ( in s )

60 x 60

Calculate the Totaliser calibration factor ti / ta

Enter this value as the calibration factor.

Note:
1) The default calibration value is 1.0000 and normally no change will be required.

DIP SWITCH SELECTION FOR SPEED MEASUREMENT

Set the required resolution for speed readout by selecting decimal point through
key pad.
If the speed of the conveyor is 1m/s, select decimal point as ‘2’ so that the read
out shall be 1.00m/s
Set cal speed to 0000 in calibration speed parameter and the dip switch position
to 1
Ensure the conveyor is running & speed sensor pick up wheel/tacho is also
running.
Observe the speed readout on the display. The readout shall be ten times more
than the actual speed.

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If the readout is more than ten times then adjust the dipswitch such that the
readout shall be closer to ten times the actual speed.
Once the read out gets stable, calibrate the speed to actual speed.

PRECAUTIONS FOR CALIBRATION:

1. 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.
2.* 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.
3. 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.
4.* 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.
5. Place the calibration rod at the specified position on the weighing frame.
6.* Make sure that the chain runs steadily on the belt at the center without any
sliding and that all the chain rollers are rotating.
7.* 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.

*Applies only when calibration is done using chain.

CALIBRATION DETAILS
LOAD CALIBRATION

Capacity of the system : 600tph

Belt speed : 1.8m/s
Rate in tph X 1000
Material load on the belt in Kg/m (Wm) : -----------------------------
Speed in m/s X60 X 60
: 92.59 kg/m

Total material load on loadcells : Wm X Idler spacing X No. of Idlers

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: 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) = -------------------------
ΠxD
= ------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 = ------------------------
ΠxD
= 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
X Cap (rated) in terms of
100
tph is allowed in the operating range specified [generally 25 to 100% of rated capacity
in comparison between the totalised quantity and the actual material weight (collected
for minimum 15 minutes duration)

This acceptance test subjected to the following

♦ Fulfillment of pre-requisite conditions

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♦ System in under healthy and calibrated

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.

Running the System

Now the system should be ready to run. With the calibration weights up, the rate
should be zero. Reset the total as explained below.

CLEARING THE TOTALISER

Press the TOT RST key. The Display then shows..

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Then Enter password 14673

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

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There are many messages that may appear in the panel display that either indicate a
potential problem or give status information. Many of the messages were discussed as
needed throughout the manual already. The following list expands on a few of those
previous messages and also includes messages that were not yet discussed.
On power up the system performs a check on the memory chip and the chip that stores
the “flash” parameters to assure no information has been corrupted. When this is
complete SELF TEST PASS message will appear in the panel display
SELF TEST:
This system incorporates an internal self-test feature. This is carried out whenever the
system is POWER ON. The user can also initiate the self-test by pressing F1 key.
Press the F1 key. The Display will show

Then Enter password 14673

The display shows

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

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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.

Blinking display or unsteady readings

Low power supply
Bad earthing
Loadcell cable not connected in the same sequence as in the drg

The indicator display other than the actual reading, but steady.
Calibration disturbed (requires re-calibration)

Fluctuations in readings
Input voltage is below 180 V.
Loadcell & speed sensor are not connected properly.

Speed indication fluctuates

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Speed sensor wires are open.

No proper feedback from speed sensor

System is inaccurate…

Here are several potential problems that can lead to System inaccuracy:
Weigh idler are not aligned properly
Weigh idler rollers do not spin freely.
Speed sensor does not spin freely.
Panel is subject to high vibration near a crusher or screen.
System is mounted on an incline causing material to roll back and be weighed
twice.
Conveyor belt has many splices, repairs and irregularities.
High temperature fluctuations cause scale, conveyor and belt deformation.
High winds cause fluctuations in weighing.
Rain increases weight of material after the scale weighs it and before truck is
weighed.
Incorrect or invalid parameter settings
Material on belt during calibration.
Material test was never performed
Belt speed not calibrated properly.
Electrical interference causes false speed or load signal
Parameters are incorrect

Section 12 Parameter Entry Table

Parameter Default settings Factory settings

Under load 0010.0 0000.0

Over load 0800.0 0800.0
Set speed 01.00 01.80
Speed type 0 0
Span rate 500.0 720.0
Load factor 1.0000 1.0000
Address 000 001

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Speed measurement time 01 01

Totaliser set 099999 000002
Decimal point 1 1
Filter value (load) 000 000
Resolution 1 1
Decimal point (speed) 2 2
Filter value (speed) 10 01
Decimal point (rate) 1 1
Decimal point (totaliser) 0 0

Section 13 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

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Line filter : EP-42-1

Transformer : TR-314
SMPS card : 9823D
ADC card : 9830 FR02
Display card : 7060
Relay card : 9830C
Keypad : 4X4 type

Remote Indicator
Transformer : TR-305
Controller card : 9825C
Display card : 9825B
Loadcell
Model : BR071H0

Speed sensor
Make : INFRA
Model : IS41

Section 14 Dip Switch Positions

ADC Card 9830FR02

SWITCH 1 (Speed sensor Selection Switch)

PIN
POSITION
ON OFF
1 √
2 √ SPEED SENSOR
3 √
4 √
SWITCH 2 (Frequency Selection Switch)

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PIN POSITION
ON OFF
1 √
2 √
3 √
4 √ SPEED SENSOR
5 √
6 √
7 √
8 √

SWITCH 3 (Current Selection Switch)

PIN POSITION
ON OFF
1 √ 4-20mA
2 √
3 √
4 √

Section 15 Maintenance Schedule

Item/ Period of Type of problem Cause Remedy
Component Verification
Idler Once in six i) Excess run out a) Bearing and / or Replace idler
months Bearing seal wear out
Belt Everyday i) Excess belt a) Belt loose Adjust takeup
sway a) Skirt plate Touching Lift skirt plate
ii) Undue wear the belt
out b) Lump getting stuck Remove lump
between feed chute manually and
& belt and /or skirt clean
& belt
Load cell Everyday i) No load or a) Check for foreign Remove foreign
Excess load body causing load body and set
shunting right

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a) Load cell wire open Reconnect

b) Insulation failure Change loadcell

Tacho Everyday i) Speed a) Tacho wheel or Set right
fluctuates coupling not making
proper contact
b) Loose connection
a) Tacho coupling Align coupling
ii) Sudden jump loose/missing
in signal pulse
Speed Everyday i) Speed a) Pick wheel
Sensor fluctuates alignment not ok
ii) Sudden jump b) Loose connection
in signal c) Speed sensor
iii) No speed coupling loose Align coupling
feedback d)Sensor is not in
proximity with pick up
wheel

Item/ Period of Type of problem Cause Remedy

Component Verification
Coupling Everyday i) Undue noise a) coupling loose Tighten bolt
b) Axial or angular Align coupling
misalignment
Weighing Weekly Material a)Material may fall Clean it at
Frame accumulation from belt regular interval
Idler/Pulley Once in six i)Wobbling a) Bearing and /or Clean bearing
months ii)Excess heat in Bearing seal wear Apply grease/
bearing block out Replace bearing

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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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Instruction manual for Belt scale

Damages resulting from accidents, mishandling or negligence on the part of

customer.
Breakage or damage of back light, proclaim, glass part, indicator lamp, power
card, plating, chipping or peeling of enamel and denting of the equipment.

After Sales Service

We can also service/ maintain the system supplied by entering into an ANNUAL
SERVICE CONTRACT at nominal charges available on request after the guarantee
period.

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