Milltronics - Gilson Eng
Instruction Manual February 2004 milltronics MUS BELT SCALE
Safety Guidelines Warning notices must be observed to ensure personal safety as well as that of others, and to protect the product and the connected equipment. These warning notices are accompanied by a clarification of the level of caution to be observed. Qualified Personnel This device/system may only be set up and operated in conjunction with this manual. Qualified personnel are only authorized to install and operate this equipment in accordance with established safety practices and standards. Warning: This product can only function properly and safely if it is correctly transported, stored, installed, set up, operated, and maintained. Note: Always use product in accordance with specifications. Copyright Siemens Milltronics Process Instruments Inc. 2004. All Rights Reserved Disclaimer of Liability This document is available in bound version and in electronic version. We encourage users to purchase authorized bound manuals, or to view electronic versions as designed and authored by Siemens Milltronics Process Instruments Inc. Siemens Milltronics Process Instruments Inc. will not be responsible for the contents of partial or whole reproductions of either bound or electronic versions. While we have verified the contents of this manual for agreement with the instrumentation described, variations remain possible. Thus we cannot guarantee full agreement. The contents of this manual are regularly reviewed and corrections are included in subsequent editions. We welcome all suggestions for improvement. Technical data subject to change. MILLTRONICS is a registered trademark of Siemens Milltronics Process Instruments Inc. Contact SMPI Technical Publications at the following address: Technical Publications Siemens Milltronics Process Instruments Inc. 1954 Technology Drive, P.O. Box 4225 Peterborough, Ontario, Canada, K9J 7B1 Email: techpubs@siemens-milltronics.com For the library of SMPI instruction manuals, visit our Web site: www.siemens-milltronics.com Siemens Milltronics Process Instruments Inc. 2004
Table of Contents Milltronics MUS Belt Scale . 1 The Manual .1 Specifications . 2 Outline dimensions æ Standard Duty . 4 Side View .4 Front View .5 Outline dimensions æ Heavy Duty . 6 Side View .6 Front View .7 Conveyor Considerations . 8 Control Gates .8 Conveyor Belting .8 Head Pulley .8 Conveyor Curvature .11 Belt Ploughs .11 Stacker Conveyors .12 Conveyor Trippers .12 Skirt Boards and Sealing Strips .12 Installation . 13 Welding .13 Load Cell Handling .13 Installation Procedure .14 MUS Wiring . 17 Calibration . 18 Balancing .18 Test Load .18 Final Calibration .19 Material Test .20 Maintenance .20 1
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Milltronics MUS Belt Scale Milltronics MUS belt scale is a modular-design, medium-duty scale for process indication. The MUS includes a left and a right weigh beam, with one load cell each An idler (supplied and installed by customer) and test weights (ordered separately) complete the weighing assembly. The MUS load cells provide an electric signal proportional to load, which is fed to the integrator. Weighing occurs without interrupting the process or affecting the process material. The MUS belt scale operates in conjunction with an integrator and optional speed sensor. The Manual This instruction manual covers the installation, operation and maintenance of the Milltronics MUS belt scale. We strongly recommend that you read this manual before installing and starting up any component of the weighing system to which the MUS is being applied. Adhering to the installation and operating procedures ensures a quick, trouble-free installation and allows for the maximum accuracy and reliability of your weighing system. This manual covers only MCS installaton and operating procedures. Integrator and speed sensor instruction manuals are available for download from www.siemens-milltronics.com. We always welcome suggestions and comments about manual content, design, and accessibility. Please direct your comments to techpubs@siemens-milltronics.com. 7ML19985CQ01 Milltronics MUS Belt Scale – INSTRUCTION MANUAL Page 1
Specifications Note: This section provides details on the standard duty and heavy duty MUS scales. Accuracy: 0.5 to 1% of totalization over 3 to 1 operating range, application dependent Load Cell: excitation: output: non-linearity: hysteresis: non-repeatability: capacity: overload: temperature: mounting dimensions 10 V DC nominal 15 V DC maximum 2 mV/V excitation at rated load cell capacity 0.02% of rated output 0.02% of rated output 0.01% of rated output standard duty ranges: 20, 30, 50, 75, 100 kg (aluminum or stainless steel) heavy duty ranges: 50, 100, 150, 200, 500 kg (aluminum only) safe 150% of rated capacity, ultimate 300% of rated capacity -40 to 65 C (-40 to 150 F) operating range -10 to 40 C (15 to 105 F) compensated see details for standard and heavy duty versions Belt Width: standard duty up to 1000 mm (CEMA width up to 42”) heavy duty 1200 mm and up (CEMA width 48” and up) (may also be used with narrower conveyors) refer to the outline dimension section Belt Speed: up to 3 m/s (600 fpm) Capacity: up to 5000 t/h (5500 STPH) at maximum belt speed Conveyor Incline: 20 from horizontal, fixed incline up to 30 with reduced accuracy Page 2 Milltronics MUS Belt Scale – INSTRUCTION MANUAL 7ML19985CQ01
Idler Profile: flat to 35 up to 45 with reduced accuracy Idler Diameter: 50 to 180 mm (2 to 7”) Idler Spacing: 0.6 to 1.5 m (2.0 to 5.0 ft) Weight: standard duty up to 20 kg (44 lbs.), 10 kg (22 lbs.) per side heavy duty up to 30 kg (64 lbs.), 15 kg (32 lbs.) per side Interconnecting Wiring (to integrator): 100 m (300 ft.) 0.75mm2 (18 AWG) 6 conductor shielded cable 100 m (300 ft.) to 300 m (1000 ft.) 0.75 to 0.34 mm2 (18 to 22 AWG ) 8 conductor shielded cable Hazardous Locations: with the use of approved intrinsically safe barrier strips Approvals CE 7ML19985CQ01 Milltronics MUS Belt Scale – INSTRUCTION MANUAL Page 3
Outline dimensions Standard Duty Standard duty: 450 to 1000 mm (18” to 42”) maximum weight: 20 kg (44 lbs.), 10 kg (22 lbs.) per side Side View belt direction for all flat or inclined conveyors calibration bar support (test weight) ½" (M12) mounting bolts 184 mm (7.25") 19 mm (0.75") 168 mm (6.63") 140 mm (5.50") 522 mm (20.56") weigh idler Note: (2) approach and (2) retreat idlers should be aligned with the weigh idler to within 1/32" (0.8) to -0" (0). Call your Siemens Milltronics representative with any questions. Page 4 Milltronics MUS Belt Scale – INSTRUCTION MANUAL 7ML19985CQ01
Front View shipping brackets standard base CEMA idler, or equivalent (customer supplied) 122 mm (4.81") existing conveyor stringers 76 mm (3.00") belt width 230 mm (9")* (or to suit) * based on CEMA sizes 7ML19985CQ01 Milltronics MUS Belt Scale – INSTRUCTION MANUAL Page 5
Outline dimensions Heavy Duty Heavy Duty: 1200 to 2000 mm (48” to 84”) although can be applied to narrower conveyors maximum weight: 30 kg (64 lbs.), 15 kg (32 lbs.) per side Side View shipping brackets belt direction for all flat or inclined conveyors calibration bar support (test weight) ½ (M12) mounting bolts 180 mm (7.31") weigh idler 19 mm (0.75") 203 mm (8.00") 159 mm (6.25") 616 mm (24.25") Notes: Page 6 (2) approach and (2) retreat idlers should be aligned with the weigh idler to within 1/32” (0.8) to -0” (0). Call your Siemens Milltronics representative with any questions. Milltronics MUS Belt Scale – INSTRUCTION MANUAL 7ML19985CQ01
Front View shipping brackets standard base CEMA idler, or equivalent (customer suppliied) 143 mm (5.62") * based on CEMA sizes 7ML19985CQ01 existing conveyor stringers 89 mm (3.50") belt width 230 mm (9")* (or to suit) Milltronics MUS Belt Scale – INSTRUCTION MANUAL Page 7
Conveyor Considerations The ideal placement of the Milltronics Universal Scale depends on the conveyor system. This section provides guidelines to determine MUS placement. Control Gates uniform material distribution control gate belt scale Note: Ensure steady and uniform material loading to the belt at or near the same speed as the conveyor belt. The installation of a material feed control gate or similar device improves uniform flow of material. Conveyor Belting Variations in the number of belt plies, the cover thickness and the type and number of splices in a given belt cause considerable change in the weight per unit length of the belt. During the course of zero calibrations, belt scales average the weight of the belt over one complete circuit of the belt. Large deviations from the average adversely affect the zero calibrations. Head Pulley Use caution when installing a scale in a short conveyor, or when locating the scale near the head pulley. Since head pulleys are flat faced, and carrying idlers are generally troughed, the belt profile must change from troughed to flat in a short distance. To accommodate this, the conveyor manufacturer designs a built-in vertical displacement of the head pulley above the top of the center roll of the adjacent idler. To further ease this transition, idlers of decreasing trough angles are inserted between the head pulley and the normal run of idlers. If these measures are not taken, a considerable amount of stress is exerted on the belt edges and the idlers adjacent to the head pulley. The stress is transmitted to the scale. Page 8 Milltronics MUS Belt Scale – INSTRUCTION MANUAL 7ML19985CQ01
Recommendation: On conveyors with 20 trough idlers throughout, a minimum of two fixed 20 idlers must be located between the scale idler and the head pulley. minimum 3 idler spaces 20 idlers head pulley belt scale Recommendation: On conveyors with 35 trough idlers throughout, a minimum of two 35 and one 20 retreat idlers must be located between the scale and the head pulley. minimum 4 idler spaces 35 idlers 20 idler head pulley 35 idlers belt scale 7ML19985CQ01 Milltronics MUS Belt Scale – INSTRUCTION MANUAL Page 9
Recommendation: On conveyors with 45 trough idlers throughout, a minimum of two 45 , one 35 and one 20 retreat idlers must be located between the scale and the head pulley. minimum 5 idler spaces 45 idlers 20 idler head pulley 45 idler belt scale 35 idler Recommendation: The vertical displacement of the head pulley relative to the adjacent retreat idler is normally in excess of that which is acceptable for belt scale installations. It is suggested that when locating the scale close to the head pulley, a maximum of 13mm (½”) vertical displacement between the top of the head pulley and the top of the center roll of the adjacent roll be allowed. 13 mm (1/2") maximum 20 idler, center roll Page 10 head pulley Milltronics MUS Belt Scale – INSTRUCTION MANUAL 7ML19985CQ01
Conveyor Curvature Vertical curvature (varied heights on one belt) is common in conveyor design, but creates difficulties for belt scales if not dealt with correctly. The curvature, whether concave (internal) or convex (external), disturbs the idler alignment, if the scale is installed in the area of curvature. The concave curve tends to lift the belt off of the idlers in the area of curvature as belt loading decreases, adversely affecting the zero calibration. Recommendation Avoid locating the scale within the tangents of scale curvature. Concave minimum 12 m (40 ft.) minimum 12 m (40 ft.) tangents belt scale belt scale Convex minimum 6m (20 ft.) minimum 12 m (40 ft.) tangents belt scale belt scale Belt Ploughs The use of belt ploughs or any conveyor or material control device that changes the profile of the carrying belt in or near the scale area is not recommended. These devices can negatively affect the belt scale idler alignment and usually create drag on the belt which the scale senses as a material force of load. Recommendation Do not install the scale within 9 m (30 ft.) of belt ploughs or similar devices that contact the material or belt. 7ML19985CQ01 Milltronics MUS Belt Scale – INSTRUCTION MANUAL Page 11
Stacker Conveyors Any conveyor that is not a permanent structure, which varies in its incline, elevation or profile is not considered a good installation for an accurate belt scale. A belt scale can be used effectively in this conveyor type, but requires special setup. Conveyor Trippers Not as common as a conveyor with vertical curvature, trippers can still be troublesome to scales. Recommendation On a conveyor with a tripper car, locate the scale under the recommendations for vertical curves, but with the tripper fully retracted. Skirt Boards and Sealing Strips Sometimes it is necessary to extend the infeed skirt boards and sealing strips the full length of the conveyor. This can create problems in weighing accuracy if the sealing strips exert excess force when contacting the belt and indirectly upon the idlers, especially where pinching occurs. The situation adversely affects the zero calibrations. skirt board pinching can occur here sealing strip dragging along belt idler Recommendation If possible, remove skirting in scale area. If not, adjust skirting so sealing strip does not put excess force on the belt or allow pinching of material. Page 12 Milltronics MUS Belt Scale – INSTRUCTION MANUAL 7ML19985CQ01
Installation Welding CAUTION: Use extreme caution when arc welding in the area of the belt scale. To avoid damaging the load cells, ensure that no welding currents can flow through the belt scale. Load Cell Handling Load cells are sensitive electro-mechanical transducers and must be handled with care. They can tolerate very little mechanical deflection without damage. Lift the scale by the mass blocks only. Do not lift the scale by the idler or idler mounting brackets. Never subject the scale to sudden impacts or shocks. 7ML19985CQ01 Milltronics MUS Belt Scale – INSTRUCTION MANUAL Page 13
Installation Procedure 1. Remove the idler at the chosen location on the conveyor. 2. Remove the idler foot plates and cut the spine as shown. before after see Note A below Notes: A B Cut idler support as shown to allow clearance when the load is applied. Maximum allowable idler spine for fitting to an MUS is: Angled spine: 75mm (3”) Channel spine: 100mm (4”) Page 14 Milltronics MUS Belt Scale – INSTRUCTION MANUAL 7ML19985CQ01
3. Position the weigh beams so that the center of the scale idler is centered between the adjacent approach and retreat idlers. Ensure that the scale is centered and square to the stringers. n n belt travel belt travel approach idlers 4. 5. location of removed idler retreat idlers Mark the position and make new mounting holes suited for M12 (½”) bolts. Refer to the Outline Dimensions. Place the scale on the conveyor stringers with the arrows on the mass blocks pointing in the direction of belt travel (retreat idlers) and mount the modified idler onto the scale using the clamping bracket. clamping brackets 7ML19985CQ01 Milltronics MUS Belt Scale – INSTRUCTION MANUAL Page 15
6. The idlers in the weighing area (A2 through R2) must be aligned to and square to the stringers, and levelled to a common reference such as a string or wire (refer to subsequent figures). Ensure that the reference is taut (no sagging). If necessary, shim these idlers to be in line with the reference. Alignment and levelling are important parts of the installation procedure and have a direct effect on scale performance. Proper care and attention is recommended. center of idlers to be in line belt travel A2 to R2 " idlers must be square to stringers 0.8mm (1/32") reference adjust idler last, leaving the MUS 1.6mm (1/16") high MUS with modified idler retreat R2 R1 belt travel S1 A1 approach A2 wire or string for alignment Page 16 Milltronics MUS Belt Scale – INSTRUCTION MANUAL 7ML19985CQ01
MUS Wiring ’B’ ’A’ load cells, complete with cable and ½" NPT conduit connection belt travel 'B' r e d ’B’ customer junction box 7ML19985CQ01 e x c 'A' b l k ’B’ r e d ’A’ e x c w h t ’B’ b l k ’A’ s i g ’B’ s i g ’B’ w h t ’A’ g r n ’B’ s i g ’A’ g r n ’A’ s i g ’A’ s h l e l d ’B’ s h l e l d ’A’ s h l e l d Milltronics MUS Belt Scale – INSTRUCTION MANUAL Page 17
Calibration After the MUS, the speed sensor and the integrator have been properly installed and wired, calibration of the weighing system must be done in conjunction with the integrator. Refer to the integrator instruction manual for programming and calibration. The calibration is initially done using the test weight. Material tests are recommended to achieve the greatest accuracy. Balancing For applications where the conveyor loading does not repeat in location across the width of the belt, such as side to side loading, electronic balancing of the two load cells is recommended. This procedure is done during the start-up phase, but should be redone if either load cell is reinstalled or replaced. Refer to the associated integrator manual for details on completing the balancing procedure. When balancing load cells, apply the test weight flat bar(s) to the extreme sides (side A and B), as required, while supported by the two test weight support arms. Reverse position of bar to balance second load cell. test weight bracket test weight (calibration flat bar) Note: Position the test weight flush with the sides of the brackets when balancing load cells. Reverse position of bar to balance other load cell. Test Load The test load value is required for calibration of the integrator. The calculated value is entered into the associated programming parameter of the integrator, in kilograms per meter or pounds per foot. Page 18 Milltronics MUS Belt Scale – INSTRUCTION MANUAL 7ML19985CQ01
The test load value is calculated as follows: Test load test weight idler spacing kg m or lb ft. Where: idler spacing L/2 [minimum 0.6 m (2.0 ft.)] Belt travel A2 A1 S1 R1 R2 L Final Calibration Once the installation and load cell balancing are completed, the belt can be released and be allowed to ride normally on the conveyor. The belt speed sensor should be installed as described in its instruction manual and the speed sensor and belt scale should be interconnected with the belt scale integrator as shown in its instruction manual and the system interconnection diagram. Program the belt scale integrator as suggested in its instruction manual and with parameters suitable for the application. With programming complete, the system is ready for calibration. A zero calibration can be performed after sufficient running of the conveyor allows the belt to limber up and take its natural formation. A zero calibration is performed in accordance to the belt scale integrator instruction manual with the conveyor running empty. Zero Perform the zero calibration as described in the Calibration section of the integrator manual. After the completion of the zero calibration, a span calibration, as described in the belt scale integrator instruction manual, can be performed with the test weight applied. Be sure to stop the conveyor when applying and removing the test weight. Span 1. 2. 3. The span reference (test load) is simulated using the test weight (calibration flat bar). Place the test weight onto the test weight bracket with equal length over both ends. Perform the span calibration as described in the Calibration section of the integrator instruction manual. 7ML19985CQ01 Milltronics MUS Belt Scale – INSTRUCTION MANUAL Page 19
After completing the span calibration, remove the test weight and store it. With a successful zero and span calibration, and with the test weight no longer applied to the belt scale, the MUS belt scale system is ready for operation. Ensure that the belt scale integrator is left in the run mode. Material Test To achieve accuracy with respect to absolute values, perform material tests. Refer to the associated integrator manual. Re-Rating If the rate, speed or idler spacing is changed from the original design, you may need to reprogram the integrator. Please contact your regional Milltronics service office. Maintenance The MUS is virtually a maintenance-free device. In dusty or granular applications, periodically check the load cell stops for material build up. Remove any build up in the mechanism to insure that the load cell maintains free movement. load cell stop Page 20 Milltronics MUS Belt Scale – INSTRUCTION MANUAL 7ML19985CQ01
Index A I Accuracy operating range .2 Idler Diameter specifications .3 Idler Spacing specifications .3 Installation information .13 procedure .14 Interconnecting Wiring specifications .3 B Balancing information . 18 Belt Ploughs recommendations . 11 Belt Speed specifications .2 Belt Width specifications .2 C Calibration information . 18 Capacity specifications .2 Components list .1 Concave curve recommendations . 11 Control Gates recommendations .8 Convex curve recommendations . 11 Conveyor Belting recommendations .8 Conveyor considerations .8 Conveyor Curvature recommendations . 11 Conveyor Idler specifications .3 Conveyor Incline specifications .2 Conveyor Trippers recommendations . 12 Conveyors application information .8 F Final Calibration information . 19 H Hazardous Locations specifications .3 Head Pulley recommendations .8 Page 22 L Load Cell specifications .2 Load Cell Handling caution .13 M Material Test information .20 MUS components .1 MUS belt scale .1 O Overview The manual .1 The MUS .1 R Recommendations belt ploughs .11 concave curve .11 control gates .8 convex curve .11 conveyor belting .8 conveyor curvature .11 conveyor trippers .12 head pulley .8 skirt boards and sealing strips .12 stacker conveyors .12 Re-Rating information .20 S Skirt Boards and Sealing Strips recommendations .12 Span calibration .19 Specifications Milltronics MUS Belt Scale – INSTRUCTION MANUAL 7ML19985CQ01
belt speed .2 belt width .2 capacity .2 conveyor idler .3 conveyor incline .2 harardous locations .3 idler diameter .3 idler spacing .3 interconnecting wiring .3 load cell .2 weight .3 Stacker Conveyors recommendations . 12 T Test Load calculation . 19 information . 18 The manual .1 W Weight specifications .3 Welding caution . 13 welding . 13 Z Zero calibration . 19 7ML19985CQ01 Milltronics MUS Belt Scale – INSTRUCTION MANUAL Page 23
IQ300IX.fm Page 5 Tuesday, October 2, 2001 1:43 PM
www.siemens-milltronics.com Siemens Milltronics Process Instruments Inc. 1954Technology Drive, P.O. Box 4225 Peterborough, ON, Canada K9J 7B1 Tel: (705) 745-2431 Fax: (705) 741-0466 Email: techpubs@siemens-milltronics.com Siemens Milltronics Process Instruments Inc. 2004 Subject to change without prior notice *7ml19985CQ01* Printed in Canada Rev. 1.1
7ML19985CQ01 Milltronics MUS Belt Scale ΠINSTRUCTION MANUAL Page 1 Milltronics MUS Belt Scale Milltronics MUS belt scale is a modular-desi gn, medium-duty scale for process indication. The MUS includes a left and a right weigh beam, with one load cell each An idler (supplied and installed by customer) and test weights (ordered separately)
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