Siemens Milltronics MMI Instruction Manual

Page 1
Instruction Manual September 2006
milltronics
MMI BELT SCALEMMI BELT SCALE
Page 2
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.
Unit Repair and Excluded Liability:
The user is responsible for all changes and repairs made to the device by the user or the user’s agent.
All new components are to be provided by Siemens Milltronics Process Instruments Inc.
Restrict repair to faulty components only.
Do not reuse faulty components.
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
Disclaimer of Liability
Instruments Inc. 2006. All Rights Reserved
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.smpi@siemens.com
For a selection of Siemens Milltronics level measurement manuals, go to: www. siemens.com/processautomation. Under Process Instrumentation, select
Measurement
For a selection of Siemens Milltronics weighing manuals, go to: www. siemens.com/processautomation. Under Weighing Technology, select
Weighing Systems
and then go to the manual archive listed under the product family.
and then go to the manual archive listed under the product family.
Level
Continuous
© Siemens Milltronics Process Instruments Inc. 2006
Page 3
Table of Contents
Milltronics MMI Belt Scale ..............................................................................................1
Safety Notes .............................................................................................................................................1
The Manual ...............................................................................................................................................1
Specifications ...................................................................................................................... 2
Operation ..............................................................................................................................4
Installation ...........................................................................................................................5
Welding ......................................................................................................................................................5
Load Cell Handling ..................................................................................................................................5
Installation Precautions .........................................................................................................................5
Installation Procedure ............................................................................................................................6
General Installation Requirements for Legal for Trade Applications .......................................10
Calibration .......................................................................................................................... 11
Test Load .................................................................................................................................................11
Zero ...........................................................................................................................................................11
Span ..........................................................................................................................................................11
Material Test ...........................................................................................................................................12
Re-Rating .................................................................................................................................................12
Maintenance ...................................................................................................................... 13
Idler Mounting ................................................................................................................... 14
Troughed Idler With Channel Spine ................................................................................................14
Troughed Idler With Pipe Spine .........................................................................................................15
Flat Idler ..................................................................................................................................................16
MMI Wiring ....................................................................................................................... 17
Outline Dimensions .......................................................................................................... 18
i
Page 4
ii
Page 5
Milltronics MMI Belt Scale
Milltronics MMI belt scale is a heavy-duty, high-accuracy multiple idler scale for critical process and load-out control. The MMI uses two Milltronics MSI belt scales in succession. The scales are designed to be inserted into belt conveyors for continuous weighing of dry bulk solids.
Each MSI includes:
one weighbridge c/w two load cells with leads run in liquid-tite conduit and 150 cm (5 ft.) of interconnecting cable terminated with lugs and conduit fitting
Siemens Milltronics test weight(s)
The addition of an idler (supplied and installed by the customer) to each weighbridge completes the weighing assembly. The MMI load cells provide an electronic signal, proportional to load, which is fed to the integrator. Thus, weighing is accomplished without interrupting the process and without affecting the process material. The MMI is used where conveyor belt speeds or belt loading charactistics result in conditions that necessitate extending the weighing time beyond the capibilities of a single idler scale. It is also well suited for applications that require higher sustained accuracies, such as production control inventory accountability or where certification for trade purposes is required.
The MMI is an accurate and repeatable force sensor. Its performance is ultimately dependent upon the conveyor system and the quality of the installation and alignment.
Safety Notes
Special attention must be paid to warnings and notes highlighted from the rest of the text by grey boxes.
WARNING means that failure to observe the necessary precautions can result in death, serious injury, and/or considerable material damage.
Note: means important information about the product or that part of the operating
manual.
The Manual
This instruction manual covers the installation, operation and maintenance of the MMI belt scale. Because the MSI belt scale is used in conjunction with an integrator and optional speed sensor, the instruction manual covering these components must be read as well.
Please refer to this manual for proper installation and operation of any component of the weighing system including the MMI. Adhering to the installation and operating procedures will ensure a quick, trouble-free installation and allow for the maximum accuracy and reliability of your weighing system.
If you have any questions, comments, or suggestions about the manual contents, please email us at techpubs.smpi@siemens.com.
For the complete library of Siemens Milltronics manuals, go to www.siemens.com/processautomation
7ML19985DR02 Milltronics MMI Belt Scale – INSTRUCTION MANUAL Page 1
.
Page 6
Specifications
Accuracy
• ± 0.25% of totalization over 5 to 1 operating range
Load Cell
• Construction: Stainless steel with superior moisture protection
• Excitation: 10 V DC nominal, 15 V DC maximum
• Output: 2 mV / V excitation at rated load cell capacity
• Non-linearity: 0.02% of rated output
• Hysteresis: 0.02% of rated output
• Non-repeatability: 0.01% of rated output
• Capacity: Maximum ranges: 50, 100, 250, 500, 750, 1000 lb
• Overload: Maximum 1000% of rated capacity
• Temperature: – 40 to +85 °C (– 40 to +185 °F) operating range
– 15 to +65 °C (0 to +150 °F) compensated
Belt Width
• 18" to 96" in 1” increments to suit CEMA sizes, equivalent to 500 to 200 0 mm in metric
sizes
• Refer to
Outline Dimensions
on page 18
Belt Speed
• Up to 4 m/s (80 0 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
Conveyor Idler
• Flat to 35°
• Up to 45° with reduced accuracy
Idler Diameter
• 50 to 180 mm (2 to 7")
Idler Spacing
• 0.5 to 1.5 m (1.5 to 5.0 ft)
Page 2 Milltronics MMI Belt Scale – INSTRUCTION MANUAL 7ML19985DR02
Page 7
Weight
See chart,
Outline Dimensions
on page 18
Hazardous Locations
• With the use of approved Intrinsically Safe barrier strips
Approvals
CSA certified for general purpose
Legal for Canadian Trade - Measurement Canada approved
Legal for US Trade - NTEP approved
7ML19985DR02 Milltronics MMI Belt Scale – INSTRUCTION MANUAL Page 3
Page 8
Operation
Each MSI weighbridge is designed to react only to the vertical component of the force being applied to it. Each MSI consists essentially of a fixed support frame (static) and a live frame (dynamic).
The static assembly is used to mount each MSI between the conveyor stringers and supports the weighing assembly via its load cells.
The weighing assembly supports the scale idler and transfers the weight of the material to the load cells. These are the active components in the weighing assembly.
As the material travels along the conveyor belt, a force is exerted through the suspended idler onto the weighing assembly. The weighing assembly is forced down proportionally. The movement in each load cell is sensed by its strain gauges when excited by voltage from the electronic integrator and produces a signal proportional to weight, which is returned to the integrator. The movement in each load cell is limited by the positive stop incorporated in the design of the load cell.
idler bracket
Page 4 Milltronics MMI Belt Scale – INSTRUCTION MANUAL 7ML19985DR02
test weight bar
force
idler clip
idler frame
scale mounting bracket
dynamic beam
static beam
weighbridge
Page 9
Installation
The MMI is shipped from the factory as a single unit attached to a shipping frame for protection. Each MSI weighbridge must be removed from its shipping frame and inspected for physical damage.
Be sure the conveyor design meets the installation requirements for the Milltronics MMI belt scale. The conveyor stringers must be rigid, straight, parallel to and square with the belt line in the area of the scale installation. The idler to be used on the scale and at least the next two approach and retreat idlers must be of the same style and manufacture and in good condition.
Prepare the site in accordance with the Siemens Milltronics drawing(s) provided or by referring to the Belt Scale Applications Guidelines (7ML19985GA01).
Welding
WARNING:: Use extreme care when arc welding in the area of the belt
scale. Ensure that no welding current can flow through the belt scale. Welding currents passing through the scale can functionally damage the load cells.
Load Cell Handling
The load cell can tolerate very little negative displacement without damaging the load cell.
When handling the individual MSIs, install both shipping stops to their vertical position to protect the load cells. Do not lift the MSI by the dynamic frame or subject it to shock from blows of a hammer when trying to position it.
Installation Precautions
The following precautions should be observed when handling the scale.
• Do not pry on the idler, its mountings, or the cells directly.
• Do not stand or lean on the scale.
• Overloading, shock, and twisting of the scal can damage the load cells.
• Do not lift the MMI by its idler.
7ML19985DR02 Milltronics MMI Belt Scale – INSTRUCTION MANUAL Page 5
Page 10
Installation Procedure
1. Remove the conveyor idler currently at the desired point of installation.
2. Remove the idler foot plate and modify the idler frame at both ends of the idler as shown below.
customer’s idler
12.7 mm (0.5”)
100 mm
(4”)
before
after
Page 6 Milltronics MMI Belt Scale – INSTRUCTION MANUAL 7ML19985DR02
Page 11
3. Insert the MSIs in the place of the removed idler. The MSI is designed to use the existing holes in the stringer and should not require further drilling. Install the mounting bolts and nuts but do not tighten. Remove the idler clips from the (see diagram below). Refer to
material flow
Outline Dimensions
location of removed idler
on page 18, for working dimensions.
test weight(s)
MSI belt scale
test weight(s)
Note: Be sure there is sufficient clearance between the return belt, MSI, and its test
weight (when used during the calibration procedure).
4. Position the individual MSIs so that they are centered and square to the stringer. Mount the modified idler so that it is centered on the scale using the idler clips. Tighten all mounting hardware. Refer to mounting arrangements.
Position the scale so that the large arrow on the scale mounting brackets is pointing in the direction of material flow.
Idler Mounting
on page14 for alternate idler
conveyor stringer
(typical)
idler clips
7ML19985DR02 Milltronics MMI Belt Scale – INSTRUCTION MANUAL Page 7
Page 12
5. Release the shipping stops on each MSI in order to free the weighing mechanism.
r
Loosen screws ‘A’ and rotate both shipping stops inward until the underside slots slide around the screws ‘B’. Tighten screws ‘A’ to secure in place.
‘A’ screws
shipping stop
‘B’ shoulder bolts
shipping stop
6. The idlers in the weighing area must be properly aligned and leveled by shimming the scale idler (S#), the two approach (A#) and the two retreat idlers (R#) until they are within ± 0.8 mm (1/32") of each other. Be sure to check that the idlers are centered and squared to the conveyor during the shimming process.
90°
CC
idlers must be square to stringers
S 1 S2
R 2R 1
alignment of idlers A2 to R2 to be within ± 0.8 mm (1/32”)
A 1A 2
material flow
center of idle to be in line
Page 8 Milltronics MMI Belt Scale – INSTRUCTION MANUAL 7ML19985DR02
Page 13
7. Precise idler alignment is very important if maximum accuracy of the weighing system is to be achieved. Misaligned idlers will result in unwanted forces being applied on each idler in the weighing area, causing calibration and measurement errors. Use a good quality wire or string to check for alignment. The wire or string must be able to withstand sufficient tension in order to eliminate any sag. Adjust shims so that all rolls of the A2 through to the R2 idlers are in line within 0.8 mm (1/32").
A 2
approach idlers
A 1
wire or string (for alignment)
MSI with modified scale idler
S 1
S 2
R 1
retreat idlers
R 2
Although the accepted tolerance for idler alignment is ± 0.8 mm (1/32"), the scale mounted idler should never be lower than the adjacent idlers. Establishing good idler alignment is the most important part of the installation procedure. Scale accuracy is directly affected by alignment.
7ML19985DR02 Milltronics MMI Belt Scale – INSTRUCTION MANUAL Page 9
Page 14
General Installation Requirements for Legal for Trade Applications
1. General Conveyor Requirements: a. Conveyor must be permanent construction.
b. The conveyor length shall be no longer than 100 0 ft (300 m) nor shorter than 40 ft
(12 m) from head to tail pulley.
c. The scale must be so installed, that the nearest weigh idler of the scale is at
least 20 ft or 5 idler spaces (whichever is greater) from either the end of the loading skirt boards or the head pulley.
d. Scale must be mounted a minimum of 40 ft from the tangent point of any curves
in the conveyor.
e. The conveyor must have a Gravity type take-up and that take-up must be
operating properly. f. Material feed to conveyor to be uniform and centered. g. The conveyor belting shall be no heavier than is required for normal use. h. The conveyor must be covered on the top and sides for a minimum distance of
30 ft each end of the scale idlers. The side covers must extend down to a
distance approximately 2 ft below the return belt line. i. The electrical power to the scale equipment must remain on at all times. j. The belt scale integrator must be located under cover, preferably in a control
room, not subject to direct sunlight.
2. Stringer Requirements: a. The MMI Scale shall be located close to a vertical conveyor support where
conveyor stringer deflection is near zero.
b. The conveyor Stringers in the scale area should be strong enough to limit
relative deflection to 0.8 mm (1\32").
c. The conveyor stringers must be straight to prevent any belt tracking problems.
3. Conveyor Idler Requirements: a. The user must purchase and Install "twelve (12) Scale Quality Idlers", two idlers
to be mounted on the MMI Weighbridge and 5 idlers to be mounted on the approach and retreat side of the MMI Weighbridge.
b. Do not use Scale Service Idlers use Scale Quality Idlers.
i. Scale Quality idlers are high tolerance idlers; for roll run-out, frame deflection and alignment; whereas ii. Scale Service idlers are choice idlers selected from a production run having the best roll run-out.
c. The two scale mounted idlers must be modified to ensure proper clearance for
belt scale deflection.
d. The twelve (12) Scale Quality Idlers must be aligned to within 0.5 mm (0.02") or
better of each other.
e. The belt must remain in contact with all three rollers (center and wing rollers) of
each of the aligned idlers.
f. Idlers must be flat, 20 or 35 degree trough angle. All idlers on the conveyor must
have the same trough angle.
g. Training idlers must not be located within 60 ft of any scale weigh idler.
Page 10 Milltronics MMI Belt Scale – INSTRUCTION MANUAL 7ML19985DR02
Page 15
Calibration
After the MSI has been properly installed, 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 supplied test load. Material tests are recommended to achieve maximum accuracy.
Tes t Load
The test load value for your MSI is given on the accompanying data sheet. The value is to be entered into the dedicated programming parameter of the integrator, in kilograms per meter or pounds per foot. An equal number and mass of weights must be applied to each suspension during the span calibration function.
If the actual idler spacing differs from that recorded on the design data sheet, the test load must be recalculated as follows. Failure to do so will cause the design test load value to be in error.
test load = Total weight of all test weights
idler spacing m ft
The above calculation must be performed for each MSI scale suspension using the weights designated for that particular suspension.
Enter the average value of the two calculations into the integrator’s Test Load Parameter (test load value “A” + test load value “B”)/2 in kilograms per meter or pounds per foot.
Kg or lb
)
(
)
(
Zero
Perform the zero calibration as described in the Calibration section of the integrator manual.
Span
The test load used in the calibration procedure is the two sets of test weights ( 1 to 12 ) supplied, one for each MSI suspension.
Place each set of the test weights onto the calibration weight bar of the respective MSI as shown. Perform the span calibration as described in the Calibration section of the integrator instruction manual.
After the span calibration has been completed, remove the test load and store it.
MSI
test weight(s)
7ML19985DR02 Milltronics MMI Belt Scale – INSTRUCTION MANUAL Page 11
Page 16
Material Test
The MMI is guaranteed to be accurate to ± 0.25% when installed on a conveyor in accordance with this manual and meeting the qualifications outlined in the Belt Scale Applications Guidelines (7ML19985GA01). This guarantee is based on calibrations performed using the test weights furnished with the scale and as referenced on the previous page.
When the existing conditions are such that the installation of the scale cannot meet the above mentioned requirements for an approved installation it is recommended that Material tests be performed. This will enable the user to compare the present scale results to the results of the material tests. The scale is then adjusted or factored so that subsequent scale calibrations with test weights will agree with actual run of material.
Re-Rating
To be sure that proper design parameters are maintained, consult your Siemens Milltronics representative for any significant change in rate, speed and /or idler spacing from original design specifications.
Page 12 Milltronics MMI Belt Scale – INSTRUCTION MANUAL 7ML19985DR02
Page 17
Maintenance
Keep each weighbridge clean. Accumulation of material between the fixed support frame (static) and the live frame (dynamic) as well as around each load cell could affect the scale accuracy.
Periodically check the alignment of the stringers and idlers in the weighing area.
When a problem arises in the conveyor, it is possible that the scale will be affected. Therefore, periodic conveyor maintenance is important to proper scale operation which should include:
lubrication of all pulleys and idlers
proper belt tracking and training
proper belt cleaning and scraping
proper take up operation
proper material feeding and spillage
•control.
You can observe the integrity of the load cells by performing zero and span calibrations. If the zero and span deviations display a continuous unidirectional drift or the system becomes uncalibratable for no apparent mechanical reason, the load cells may be suspect.
Spare Parts
The only spare part recommended for the MSI is the load cell. Refer to the load cell nameplate for the proper size and model number.
Re-balance any load cell that has been replaced. Refer to the Load Cell Balancing Procedure For Four Load Cells in the integrator manual.
Maintenance Precautions
When welding near the scale, do not allow current to pass through the belt scale.
Reset the shipping stops to reduce physical shock to the load cells during maintenance.
Recalibrate the scale after maintenance and prior to use.
7ML19985DR02 Milltronics MMI Belt Scale – INSTRUCTION MANUAL Page 13
Page 18
Idler Mounting
The MSI is usually installed in conveyors employing conventional rigid structure idlers. Within this type of idler, construction will vary depending on the manufacture and the application. The idler depicted in the angle iron spine. The following images depict alternate idler construction and tips on how they should be modified and installed.
Troughed Idler With Channel Spine
customer’s idler
foot pads welded to idler spine
Installation Procedure
gusset reinforcement if required. See
Installation Procedure
on page 6.
section on page 6 uses an
100 mm
(4”)
12.7 mm (0.5”)
before
before
after
idler modification
customer bolts
idler clip
(4 places)
idler installation
Page 14 Milltronics MMI Belt Scale – INSTRUCTION MANUAL 7ML19985DR02
Page 19
Troughed Idler With Pipe Spine
f t
customer’s idler
gusse t reinforcem ent if required. See
Installation Procedure,
on page 6.
12.7 mm (0.5”)
oot pads welded o idler spine
before
welded to idler pipe (be sure idler is square to scale & conveyor frame)
100 mm
(4”)
after
idler modification
customer bolts
(4 places)
idler clip
idler installation
7ML19985DR02 Milltronics MMI Belt Scale – INSTRUCTION MANUAL Page 15
Page 20
Flat Idler
customer’s idler
In most applications standard conveyor manufacturers’ brackets cannot be used, replacement brackets (as shown) are needed.
12.7 mm (0.5”)
before
after
idler modification
customer bolts
(4 places)
idler clip
idler installation
Page 16 Milltronics MMI Belt Scale – INSTRUCTION MANUAL 7ML19985DR02
Page 21
MMI Wiring
Load Cell
‘A’
Load Cell
‘A’ ( ‘C ’)
Load Cell
‘A’
MSI #1
MSI #2
belt travel
MSI #1
belt travel
Load Cell
‘B’
Load Cell
‘B’ (‘D’)
Load Cell
‘B’
Load Cell
‘A’
DETAIL ‘A’
MSI #2
conduit and box connector
DETAIL ‘A’
Load Cell
‘B’
r
r
e
e
d
d
‘A’
‘B’
+ E X C
b
b
w
l
l
h
k
k
t
‘A’
‘B’
‘A’
-
­S
E
I
X
G
C
A
To integrator
s
h
g
w
r
h
n
t
‘A’
‘B’
-
+
S
S
I
I
G
G
B
A
h
g
l
l
r
d
d
n
‘A’
‘B’
‘B’
+
S
S
H
I
I
G
E L
B
D
customer’s
junction box
r
r
b
b
w
e
e
l
d
d
k
‘A’
‘B’
‘A’
+
-
E
E
X
X
C
C
g
l
h
r
k
t
n
‘B’
‘A’
‘A’
+
­S
S
I
I G
G
A
A
To inte g r a t o r
s
s
h
w h t ‘B’
­S I G
B
h
g
l
l
r
d
d
n
‘A’
‘B’
‘B’
+
S
S
H
I
I
G
E L
B
D
s
7ML19985DR02 Milltronics MMI Belt Scale – INSTRUCTION MANUAL Page 17
Page 22
Outline Dimensions
conveyor
belt width
18”
(457 mm)
20”
(508 mm )
24”
(610 mm)
30”
(762 mm)
36”
(914 mm)
42”
(1067 mm)
48”
(1219 mm)
54”
(1372 mm)
60”
(1524 mm )
66”
(1676 mm)
72”
(1829 mm)
D
E
mounting
scale width A
27”
(686 mm)
29”
(737 mm)
33”
(838 mm)
39”
(991 mm)
45”
(1143 mm)
51”
(1295 mm)
57” (
1448 mm)
63”
(1600 mm)
69”
(1753 mm)
75”
(1905 mm)
81”
(2057 mm)
A
‘B’
minimum drop-
in width B
23.25”
(591 mm)
25.25”
(641 mm)
29.25”
(743 mm)
35.25”
(895 mm)
41.25”
(1048 mm)
47.25”
(1200 mm)
53.25”
(1353 mm)
59.25”
(1505 mm)
65.25”
(1657 mm)
71.25”
(1810 mm)
77.25”
(1962 mm)
C
C D E weight
9.5”
(241 mm)
9.5”
(241 mm)
9.5”
(241 mm)
9.5”
(241 mm)
9.5”
(241 mm)
9.5”
(241 mm)
9.5”
(241 mm)8”(203 mm)7”(178 mm)
12”
(305 mm)8”(203 mm)7”(178 mm)
12”
(305 mm)8”(203 mm)7”(178 mm)
12”
(305 mm)8”(203 mm)
12”
(305 mm)8”(203 mm)
5.5”
(140 mm)7”(178 mm)
5.5”
(140 mm)7”(178 mm)
5.5”
(140 mm)7”(178 mm)
5.5”
(140 mm)7”(178 mm)
5.5”
(140 mm)7”(178 mm)
5.5”
(140 mm)7”(178 mm)
8”*
(203 mm)
8”*
(203 mm)
82 lbs. (37 kg) 85 lbs. (39 kg) 90 lbs. (41 kg) 99 lbs. (45 kg)
107 lbs.
(49 kg)
116 lbs.
(53 kg)
125 lbs.
(57 kg)
175 lbs.
(79 kg)
193 lbs.
(88 kg)
229 lbs.
(104 kg)
247 lbs.
(112 kg)
Other widths available. Sizes are from 18 to 96” (457 to 2438 mm) in 1” (25.4 mm) increments. All sizes are nominal. *As shown for North America; 8.5” (216 mm) Europe.
Page 18 Milltronics MMI Belt Scale – INSTRUCTION MANUAL 7ML19985DR02
Page 23
Page 24
www.siemens.com/processautomation
Siemens Milltronics Process Instruments Inc. 1954 Technology Drive, P.O. Box 4225 Peterborough, ON, Canada K9J 7B1 Tel: (705) 745-2431 Fax: (705) 741-0466 Email: techpubs.smpi@siemens.com
Siemens Milltronics Process Instruments Inc. 2006 Subject to change without prior notice
*7ml19985DR02*
Printed in Canada
Rev. 2.0
Loading...