Rice Lake BCi Belt Scale User Manual
In-Motion Belt Scale System
To be the best by every measure
#$
Version 2.00
Installation & Operation
Manual
94805
Contents
Technical training seminars are available through Rice Lake Weighing Systems.
Course descriptions and dates can be viewed at www.ricelake.com or obtained
by calling 715-234-9171 and asking for the training department.
Integrator Hardware Setup ..............................................................................................................................26
1.0 Introduction and Overview........................................................................................................... 1
1.1 Belt Conveyor Scale System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3 Application Brief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4 Selecting a Mounting Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.5 Poor Choices for Belt Scale Installations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
6 Handbook 44 Requirements for Belt Scales . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.
2.0 Integrator Hardware Installation ............................................................................................... 14
2.1 Unpacking and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.2 Scale Carriage Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3 Junction Box Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4 Attaching the Idlers to the Scale Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.5 Speed Sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.6 Scale Carriage Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.0 Integrator Hardware Setup ........................................................................................................ 26
3.1 Enclosure Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.2 Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3 Enclosure Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.4 CPU Board Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.5 Fuse Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.6 Battery Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.7 Parts Kit Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.8 Replacement Parts and Assembly Drawings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
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4.0 Supervisor Mode Parameters.................................................................................................... 38
4.1 Admin. Passcode (numeric) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.2 Scale Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3 Load Cell MV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4 Total Load Cell Build . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.5 Rate Unit Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.6 Filter (s). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.7 Filter Threshold (divisions) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.8 Speed Unit Time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.9 Fixed Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.10 Unit of Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.11 Unit of Rate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.12 Rate Count By . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.13 Totalizer Count By . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.14 Load Display Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.15 Load Count By . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.16 Auto Zero Tracking (%) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.17 Auto Zero Tracking Percentage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
18 Dead Band . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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4.19 Cal. Test Weight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.20 Cal. Test Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.21 Calibration Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.22 Material Factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.23 Zero Error% . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.24 Zero Counts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.25 Span Error% . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.26 Idler Spacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.27 Number of Idlers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.28 Belt Test Revolutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.29 Pulses per Revolution. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.30 Belt Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.31 Pulses Per Unit Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.32 Test Duration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.33 Tons per Pulse (output) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.34 Pulse Duty Cycle (in seconds) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.35 Alarm - Low Rate Alarm Value (%) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4.36 Maximum Speed Value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.37 Low Rate Alarm Bit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.38 High Rate Alarm Bit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.39 Speed Alarm Bit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.40 Totalizer Pulse Bit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.41 Fill Output Bit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.42 Remote Print Input Bit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.43 Print Output Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.44 Print Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.45 Stream Output Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.46 Stream Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.47 Clear Totalizer with Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.48 Remote Totalizer Reset Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.49 Integrator Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.50 Preact Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.51 Enable Batching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.52 Analog 1 Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.53 Analog 2 Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.54 Setting Time and Date . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.55 Interfacing a PLC to the Belt Scale System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
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5.0 Calibration ................................................................................................................................. 46
5.1 Speed Sensor Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
5.2 Integrator Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3 Complete System Calibration Test Used In Conjunction with integrator Calibration . . . . . . . . . . . . . 49
. . . . 47
6.0 Run Sequence ............................................................................................................................ 53
6.1 Target Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
6.2 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.3 Reset Totalizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.4 Start Fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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7.0 Handbook 44 Requirements for Belt-Conveyor Scales ............................................................. 55
7.1 Reference Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
7.2 Conditions of Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 BCi Installation Manual
. . . . 55
8.0 Maintenance .............................................................................................................................. 56
8.1 Maintenance Checkpoints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
8.2 Belt Scale Troubleshooting Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.3 BCi Integrator Troubleshooting Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
. 58
9.0 Appendix .................................................................................................................................... 60
9.0 BCi Permanent Field Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
9.0 BCi integrator Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 64
4 BCi Installation Manual
Rice Lake continually offers web-based video training on a growing selection
of product-related topics at no cost. Visit www.ricelake.com/webinars.
About This Manual
Intern et
Warning
This manual is intended for use by service technicians responsible for installing and servicing the BCi In-Motion
Belt Scale System Installation & Operation Manual.
This manual can be viewed and downloaded from the Rice Lake Weighing Systems web
site at
company.
Some procedures described in this manual require work in and around working parts of the
belt scale. These procedures are to be performed by qualified service personnel
www.ricelake.com. Rice Lake Weighing Systems is an ISO 9001 registered
only .
1.0 Introduction and Overview
A belt conveyor scale is a device that continuously measures bulk material as it moves along a conveyor. The
system requires two general parameters to operate:
•It needs to know the weight of the material being moved along the conveyor belt
It needs to know the speed at which it’s moving along the conveyor belt.
•
The weight of the material on the belt is determin
and then subtracting the average weight of the unloaded belt. The speed at which the material is moving is
determined by measuring the speed of an idler or wheel in contact with the conveyor belt. The weight and speed
is combined to give a running total and a rate of flow of the material. The correct operation of the scale system
requires the components to be installed correctly, periodically calibrated, and properly maintained.
Typical applications where a belt conveyor scale can be used are:
• Mining
• Quarries
• Bulk Material Blending
• Truck/Barge/Rail Loading
• Process Control Applications
A belt conveyor scale is also able to compute the tota
of time and while it is in motion.
The BCi In-Motion Belt Scale System is durable and one of the mos
handles capacities up to 10,000 tons per hour with unsurpassed accuracy. It’s innovative integrator fits a wide
variety of applications - from simple inventory reporting to automated load-out.
ed by weighing a section of conveyor belt loaded with material
l mass of the material that is conveyed over a given period
t accurate scales in its class. The BCi easily
1.1 Belt Conveyor Scale System Components
The main components of a basic belt conveyor scale include:
• Scale carriage
• Load cells
• Belt travel pickup speed sensor (not shown)
• Electronic integrator
BCi Installation & Operation Manual - Introduction and Overview 1
BCi Electronic Integrator
Load Cells
Scale Carriage
Figure 1-1. Component Parts of the BCi Belt Conveyor Scale System
2 BCi Installation & Operation Manual
Scale Carriage
1
2
3
4
5
6
The scale carriage is mounted to a conveyor structure and transmits the forces resulting from the belt load and
directs those forces to the load sensor(s). The following picture and table illustrate the component parts shipped
with the scale carriage.
Figure 1-2. Scale Carriage Components
RLWS Part
Number
1 - - - - - End Plate Assembly (2)
2 - - - - - Uni-Strut Middle Bars (2)
3 - - - - - Uni-Strut Closure Strips (2)
4 38557 Home Run Cable (1)
5 88956 Junction Box w/ Grounding Lug (1)
6 16863 Metal Serial Tag (1)
Nuts (2)
Bolts (2)
Lock Washers (2)
97416 Shim Kit
Description (Qty.)
Table 1-1. Scale Carriage Component Part Numbers
BCi Installation & Operation Manual - Introduction and Overview 3
Load Cells
There are four strain gauge load cells located on the corners of the weigh idler. These sensors support the weight
of the conveyor belt and the material moving along on the belt. The weight signals from the load cells are
combined and processed by the integrator.
Figure 1-3. Load Cell Location on Scale Carriage
4 BCi Installation & Operation Manual
Belt Travel Speed Wheel - Optional
The belt travel speed wheel is located near the weigh frame. Positive contact must be maintained between the roll
and the belt for proper operation. The speed sensor should never come in contact with material that is being
conveyed along the belt nor the belt itself. The signal generated by the speed wheel is converted by the integrator
into a value that represents belt travel distance. Various devices used for sensing belt travel include AC and DC
generators, mechanical belt or chain drives, photo-optical segmented disks, and electromagnetic pulse
generators. Installation procedures for the speed wheel are explained in detail on page 24. The graphic below
illustrates the major component parts of the speed wheel.
Figure 1-4. Speed Wheel
RLWS Part Number Description (Qty)
94969 Complete Speed Wheel Assembly (1)
96543 Speed Wheel (1) (wheel only)
94979 Speed Proximity Sensor (1)
94970 Speed Wheel Bracket Assembly (1) (wheel not included)
Cabling to integrator (1)
94980 U-Bolts (2)
21161 Splice Box (1)
98501 Expansion Cable - 20’
100038 Magnetic Shaft Encoder
Table 1-2. Speed Wheel Assembly Component Part Numbers
Magnetic Shaft Encoder - Optional
Another option besides the belt travel speed wheel is a magnetic shaft encoder which can also be used to
determine belt travel distance like the speed wheel. The magnetic shaft encoder should never come in contact
with material that is being conveyed along the belt nor the belt itself. The signal generated by the encoder is
converted by the integrator into a value that represents belt travel distance.
Figure 1-5. Magnetic Shaft Encoder
BCi Installation & Operation Manual - Introduction and Overview 5
Electronic Integrator
13*/5
6/*54
40'5,&: 40'5,&:
40'5,&:
40'5,&: 40'5,&:
Outputs from the belt travel speed sensor and from the load cell carriage are combined in the integrator to
produce a running total of material passed over the belt conveyor scale. Using the BCi HMI as a calibrated
electronic integrator allows signals to be converted into values that represent the weight and speed of the material
that is traveling on the conveyor.
1.2 Operation
The BCi front panel, shown below consists of a 27-button keypad with a large backlit LCD display. The keys are
grouped as five configurable softkeys, five primary scale functions keys, four navigational keys, and numeric
entry keys. It should be noted that the scale parameters and calibration values cannot be changed without first
pressing the
settings. Pressing
TARE key and unlocking the parameters. After pressing the TARE key, press enter to unlock the
ZERO when the display is on the main menu will clear the Reset Total.
Figure 1-6. BCi Front Panel
The following sections describe the front panel key operation of the belt scale integrator.
Zero
This parameter will initiate the front panel zero mechanism. Periodic use of the zero parameter is required due to
weather conditions.
This will print the custom ticket if the print port is configured.
Reset Totalizer
Often during this operation of a belt scale, the totalizer will need to be reset. This is known as the reset totalizer.
Press the
operator will press
Diagnostics
Reset Totalizer softkey to access this parameter. The integrat or will prompt the user, “Clear Totalizer?” The
Yes to clear the totalizer, or No to leave the accumulated weight in the totalizer.
This softkey displays the current mV input, PPS (pulses per second from the speed sensor), current analog output
(if installed), current A/D counts, and the master total. This is just informational data that the operator or a
technician can use from troubleshooting purposes.
Supervisor Mode
Use this softkey to enter the Supervisor Mode. If there is no passcode configured the BCi will enter into the
Setup Mode. If a passcode is configured, the operator will need to enter the passcode before the BCi will switch
to the Supervisor Mode. To configure a passcode, see the Supervisor’s Parameters.
6 BCi Installation & Operation Manual
1.3 Application Brief
There are four factors used to determine a suitable belt scale application on a given conveyor.
• Load cell size
• Belt speed
•Idler spacing
• Belt splicing
Load Cell Size
The capacity of the belt scale is rated on the maximum continuous load that can be carried across the weigh idler.
The capacity of the conveyor shou ld be known p rior to determining the components of the scale system. The load
cells should be sized to operate across a loading range with a marginal safety factor. The minimum net loading
should be greater than 10% of the rated capacity and the maximum loading should be less than 65%. The load
applied to the loadcell can be calculated with the following formula:
Net load = (conveyor capacity / belt speed) x idler spacing
Gross load = net load + (idler weight + belt weight + mounting hardware)
Examples:
Net load = (50,000 lbs per minute / 400 feet per minute) x 4 foot spacing
Net load = (125 lbs per foot) x 4 foot spacing
Net Load = 500 lbs.
Gross load = 500 lbs + (175 lb idler + 48 lb belt + 24 lbs hardware)
Gross Load = 747 lbs.
Net Load > 10% of total load cell capacity
(4) x 500 lb load cells x 10% = 200 lbs 500 lbs > 200 lbs (500 lb load cells are okay)
(4) x 1000 lb load cells x 10% = 400 lbs 500 lbs > 400 lbs (500 lb
(4) x 2000 lb load cells x 10% = 800 lbs 500 lbs > 800 lbs (2000 lb load cell
Gross Load < 65% of total load cell capacity
load cells are okay)
s are too large)
(4) x 250 lb load cells x 65% = 650 lbs 747 lbs > 650 lbs (250 lb load cells are too small)
(4) x 500 lb load cells x 65% = 1300 lbs 74
(4) x 1000 lb load cells x 65% = 2600 lbs 74
The example listed would require 500 lb or 1000 lb load
Belt Speed
7 lbs < 1300 lbs (500 lb load cells are okay)
7 lbs < 2600 lbs (1000 lb load cells are okay)
cells.
The belt speed is defined as the maximum velocity of the unloaded conveyor belt. The belt speed can be variable,
but for sizing requirements the maximum speed is required.
BCi Installation & Operation Manual - Introduction and Overview 7
Idler Spacing
The spacing between idlers should conform to the recommendations of the idler manufacturer and the Conveyor
Equipment Manufacturer’s Association specifications. A general rule of thumb is the idler supports the belt half
the distance from the previous idler to half the distance to the following idler as shown in the example below.
Figure 1-7. Idler Spacing Example
The number of weigh idlers required to accurately weigh the material being conveyed is determined by the
velocity of the conveyor belt. The scale born time of the material should be greater than 400 mSec. If the belt
speed multiplied by the idler spacing is less than 400 mSec, the idler spacing must be increased or multiple weigh
idlers must be used. Scale born time can be calculated with the following formula:
Scale Time = (Idler Spacing / Belt Speed)
Example: Scale Ti
me = (4 feet / 8.33 fps) = 480 mSec
Belt Splicing
Belt splices also have a contributing factor in limiting the belt scale’s capacity. Mechanical belt splices can shock
load and damage load cells on high speed conveyors. Vulcanized splices are preferred for proper scale operation.
Figure 1-8. Mechanical Belt Splicing Example
8 BCi Installation & Operation Manual
1.4 Selecting a Mounting Location
It is very important to select the right mounting location for the scale carriage along the conveyor structure and
the location of the speed sensor. There are several factors that must be taken into consideration when selecting a
mounting location. Those factors will determine the overall long-term and short-term accuracy you might expect.
Those factors include the following:
• Tension
• Uniform Belt Loading
• Single Load Point on Belt
• Material Slippage
• Convex Curves
• Concave Curves
Tension
The transfer of weight along the conveyor belt can be greatly affected by belt tension. By locating the scale
carriage in an area of the conveyor with the least amount of tension, the scale will be more accurate and achieve
better performance. An ideal location to mount the scale carriage is near a tail section of the conveyor, but far
enough forward so as not to be influenced by infeed skirts boards, etc. Figure 1-9 illustrates the proper belt
tension.
•Trippers
• Speed Sensor Mounting Location
• Electronic Wiring Location
• Speed Wheel
• Troughing Angle
Figure 1-9. Proper Belt Tension Example
Uniform Belt Loading
It is desirable that the belt loading be as uniform as possible to prevent unequal shifts in material. To minimize
surges or feed variations, hoppers should be equipped with depth limiting gates or other flow control devices
such as a feeder.
Single Load Point on Belt
On high accuracy installations, the conveyor should be loaded at one and the same point. This assures constant
belt tension at the scale during all loading conditions.
Material Slippage
The belt scale system processes belt loading and belt travel to arrive at an accurate weight. Product speed must be
equal to the belt speed at the scale. So the conveyor speed and slope should not exceed that at which material
slippage occurs. This is typically less than a 20% pitch for most materials.
Convex Curves
Conveyors that have convex curves should be avoided or the scale should be located in a section of the conveyor
that is not affected by the curve.
Convex curves are permissible at a distance of 20 feet or a m
inimum of five idler spaces beyond the scale area
idlers.
BCi Installation & Operation Manual - Introduction and Overview 9
Figure 1-10. Convex Curved Conveyor
Concave Curves
Conveyors that have concave curves should be avoided or the scale should be located in a section of the conveyor
that is not affected by the curve. If there is a curve, the belt must remain in contact with the idler rollers at all
times for at least 20 feet (6m).
Figure 1-11. Concave Curved Conveyor
Trippers
Tripper belts, mechanical sweep samplers, training idlers, feed points, skirt boards and other device that also
affect belt tension should be located away from the scale carriage.
If the scale must be installed on a conveyor with a tripper, then the same rules apply as for an installation in a
ncave conveyor.
co
nce
The following table offers basic guidelines for minimum dista
s and applies to both horizontal and incline
conveyors.
Type of Conveyor Distance from Scale Carriage
End of skirt boards or feed point 15’ or 4 idler spaces whichever is greater
Training idler or sweep sampler 30’ or 8 idler spaces, whichever is greater
Tripper or concave curve 40’ from the first idler affected by the curve
Convex curve or head pulley 20’ or 5 idler spaces
Table 1-3. Distance Points from Conveyor to Scale Carriage
Speed Sensor or Magnetic Shaft Encoder Mounting Location - (Optional items)
The optional speed sensor location is not as critical as scale carriage location, however improper installation of
the speed sensor will significantly affect the performance of the scale system. The speed sensor must give an
accurate representation of the speed of the material and travel of the belt.
10 BCi Installation & Operation Manual
The favorable location for the speed sensor is the tail roll of the conveyor, provided that the conveyor is not
driven from the tail, and that the tail roll is accessible.
Figure 1-12. Speed Sensor Pulley
If the tail roll is not accessible then the speed sensor can be mounted on a tailing wheel that rides on the return
side of the belt, or on a live shaft roller . If a trailing wheel is used, the wheel should be located on a section of the
belt in which belt vibration will not add movement to the wheel. The preferable location would be directly
opposite a conveyor return roll.
If a live shaft roller is installed to sense the belt speed, the roller
should have positive contact with the belt. The
preferred location would be between two retu rn idlers with the speed roller being installed on the top side of the
returning belt and the return idlers installed on the bottom side.
Electronic Wiring Location
The location for the electronics to be mounted is determined by accessibility, wire routing, and environment. The
scale electronics require a clean and stable 120 VAC supply. The enclosure for the electronics is rated NEMA
4X. The electronics can be mounted up to 2000’ away from the scale carriage provided the optional load cell
sense wiring is installed. If the electronics are to be installed within 200’ of the scale carriage, the optional sense
wiring is not required. To reduce the effects of signal interference, the scale signals should not be ru n in conduit
or cable trays in conjunction with high voltage cables.
are
The digital input and output signals
compatible with OPTO 22 G4 5VDC relay modules and can be
controlled with AC, DC or dry contact signals. The analog output signal for rate of flow can be wired for 0-10
VDC, 2-10 VDC, 0-20mA current or 4- 20mA current. The printer signal can be RS-232, RS-485, or 20 mA
current loop.
Speed Wheel
If an optional speed wheel is used, the wheel should be located on a section of the belt in which belt vibration
will not add movement to the wheel. The preferable location would be directly opposite a conveyor return roll.
Figure 1-13. Optional Speed Wheel Assembly
BCi Installation & Operation Manual - Introduction and Overview 11
Troughing Angle
The use of idlers with steep troughing angles causes many problems. Not only does the bean or catenary effect of
the belt become more pronounced as the toughing increases, but the effect of idler misalignment is amplified as
well. The graphics below show an example of a correct and an incorrect troughing angles.
Troughing angles of 35 degrees or less are preferred for all h
igh accuracy installations. Troughing angles of 45
degrees are acceptable under certain conditions.
Figure 1-14. Troughing Angle Examples
1.5 Poor Choices for Belt Scale Installations
There are several instances where a belt scale installation would not be the best solution. The following list
points these out.
• Conveyors with multiple loading points
• Conveyors with convex or concave curves
• Conveyors with different stringer members i
• Conveyors that do not receive periodic inspections and housekeeping
• Conveyors where there is no facility to conduct a simulat
• Conveyors that are used in cold weather that are not i
• Tripper convey ors
• Radial stacking conveyors
• Applications where the belt scale results are compared w
• Applications where the belt scale weighment is subject to certific
Handbook 44 requirements.
• Applications where plant personnel are unwilling or unable to perfo
• Conveyors with more than 2-ply belting
• Conveyors that are installed outdoors, but are not equipped with a cover over the c
n troughing rolls
ed test
nstalled in a heated conveyor gallery
ith a marine draft survey
ation but the conveyor does not meet
rm routine conveyor maintenance
arry belt.
12 BCi Installation & Operation Manual
1.6 Handbook 44 Requirements for Belt Scales
The following is a listing of various Handbook 44 requirements for belt scales.
• Minimum divisions shall not be greater than 0.1 of the minimum
• On test, the recorder must show the initial totalizer reading; the final tota
measure and the quantity delivered along with the time and date.
• The integrator master totalizer shall not be reset
• In the event of loss of power of up to 24 hours, the accumulated me
totalizer shall be retained in memory during that power loss.
• An audio or visual alarm indication shall be activated when the flow rate
in excess of 98% of the rated capacity.
• The totalizer can only advance when the belt conveyor
on the belt, the totalizer could not register).
• The master totalizer shall not be re-settable without breaking a security seal.
Means shall be provided that the totalizer reading shall be retained
•
event of a power failure.
• The belt scale integrator must factor in belt speed as a function
• Zero is to be limited to +/- 2% without breaking the security sea
• Auto zero mechanism shall be designed to operate only after a whole number of belt r
• An indication shall be provided for when the auto zero adjustment
• Belt speed device shall be designed so that there is no slip.
• An event logger must provide an audit trail of all calibration adjustment with a prin
demand. It shall have the capacity to retain records equal to ten times the number of sealable parameters
in the device, but not more than 1000 records are required, (ie: time and date of change; the parameter
value; the parameter ID).
• A zero circuit should provide for an average of one belt revolution (track +/-).
• Remote outputs record for (digital and analog), the total tons,
• Front panel calibration that is password protected w/ audit trail.
• Ability to enter the belt length and indicate in feet.
•
Ability to accept pulse input for belt speed indication.
the master totalizer without breaking a security seal.
is running (ie: if the belt is shut down with coal
totalized load.
asured quantity on the master
equals or falls below 35% or is
for a minimum of 24 hours in the
of calculating tons per hour weight.
l.
has reached its maximum limit.
rate in% of full cap, and the belt speed.
lizer reading, the unit of
evolutions.
ted copy available on
BCi Installation & Operation Manual - Introduction and Overview 13
2.0 Integrator Hardware Installation
Warning
Note
End plate
assembly (x2)
Uni-Strut center
bars
Note
This section describes procedures for assembling the scale carriage, adding the idlers to the scale carriage, speed
sensor connections, and any associated wiring.
Installation instructions for the integrator (BCi) are explained starting on page 25.
Take all necessary safety precautions when setting up the BCi In-motion belt scale system, including
wearing safety shoes, protective eye wear and
2.1 Unpacking and Assembly
Upon receipt of the shipping pallet, visually inspect all components to make sure that they are included and
undamaged. The shipping carton should contain the scale carriage, the integrator, this manual, and a parts kit. If
any parts were damaged in shipment, notify Rice Lake Weighing Systems and the shipper immediately.
To ensure that all products received from the manufacturer are in good shape upon arrival, it is
recommended to fully inspect all contents and properl
2.2 Scale Carriage Installation
The proper location must be chosen for installation of the scale carriage prior to installation. Information on page
12 helps choose the correct location for the scale carriage.
Once the correct location for the scale carriage is chosen, use the following steps to assemble the carriage as
there is mini
to work with the junction box. Figure 2-1 shows the component parts for the scale carriage that need to be
assembled.
mal assembly required. Tools required for assembly include a 3/4" wrench and a small screwdriver
using the proper tools.
y complete the bill of lading.
The exact steps for assembling the scale carriage may vary depending on the site location and size of carriage.
14 BCi Installation & Operation Manual
Figure 2-1. Scale Carriage Component Parts
1. Space the two end plate assemblies far enough apart
so that the uni-strut center bars will slide into the
channels on the end plate assembly making sure that the uni-strut center bar is centered equally from
both ends.
There should be roughly a 5/8" gap on each side and the drilled mounting holes (for junction box
placement), should be facing upwards.
.
Figure 2-2. Slide the Uni-Strut Center Bars onto the End Plate Assembly
2. Using a 3/4" wrench, tighten the bolts on each end of the uni-strut center bars on both ends of the end
plate assembly.
Figure 2-3. Tighten Bolts
BCi Installation & Operation Manual - Integrator Hardware Installation 15
2.3 Junction Box Installation
The BCi In-Motion Belt Scale uses the TuffSeal JB4SS (PN 88956) junction box. It is a four -channel sig nal trim
junction box with an expansion board enclosed. The junction box is a stainless steel NEMA 4X enclosure that
comes with a standard Prevent
or environmental changes.
Use the following steps to install the junction box.
1. Set the junction box onto the uni-strut center bar an
2. Attach the ground lug (shown below).
®
breather vent which inhibits the buildup of pressure cause by sudden temperature
Figure 2-4. TuffSeal Junction Box
d attach to the bar using the enclosed screws.
Figure 2-5. Attach the Ground Lug onto the Junction Box
16 BCi Installation & Operation Manual
Wiring the Junction Box
Run load cell
cable
through
scale
carriage
channel
The four channel TuffSeal JB4SS has been designed to connect and trim up to four load cells per board.
However, it is possible to use this junction box with other combinations.
Run the load cell cables from the load cells through the channels
Figure 2-6. Route Load Cell Cable From Load Cell to Junction Box
on the scale carriage over to the junction box.
3. Open the cover to the junction box to expose the interior.
4. Wire the junction box by running the load cell
Figure 2-7. Junction Box Interior
cable inside of the junction box.
Use the following table to wire the load cell cables.
Wire Color Signal
Red +EX
Black -EX
Green +SIG
White -SIG
Silver Braid SHIELD
Table 2-1. Load Cell Wiring
BCi Installation & Operation Manual - Integrator Hardware Installation 17
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