Belt-Way Scales, Inc.

Conveyor Belt Scale

Product Manual

Belt-Way Scales, Inc.

1 Beltway Rd.
Rock Falls, IL 61071 USA
Phone: (815) 625-5573
beltwayscales.com

Revision 2.5 Date: 3/2021

Phone: (815) 625-5573 beltwayscales.com sales@beltwayscales.com

 Conveyor Belt Scale
Product Manual

Safety and Warnings

All Belt-Way components MUST be used as described in this manual!

Please note the labels on the integrator and in the manual denote
dangerous voltage. Failure to take safety precautions may result in
serious injury or death.

The protective conductor terminal (Earth Ground) is signified by the

following label. It must be properly connected to earth ground per
local electrical codes.

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Table of Contents
Scale Accessories ............................................................................... 5
Integrator Specs & Scale Components ............................................. 6-8
Mechanical Installation .................................................................... 9-15
Wiring the Sensors / Integrator Installation................................................... 16-21
A. Sensor Board ................................................................................................................................... 18
B. Terminal Board with AC Power Supply .............................................................................................. 19
C. Terminal Board with DC Power Supply.............................................................................................. 20
D. Integrator Board .............................................................................................................................. 21
E. IO Board .......................................................................................................................................... 21

Integrator Configuration ................................................................ 22-36

A. Integrator Navigation ....................................................................................................................... 22
B. Setup Wizard .................................................................................................................................. 23
C. C. Scale Setup ............................................................................................................................. 23-24
D. Scale Calibration ......................................................................................................................... 25-28
Zero Calibration.................................................................................................................................... 25
Test Weight Calibration ................................................................................................................... 26-27
Material Test Calibration ...................................................................................................................... 28
E. Scale Totals ..................................................................................................................................... 29
F. Device Setup ............................................................................................................................... 29-30
Plant Connect ....................................................................................................................................... 31
G. Administration................................................................................................................................. 32

Routine Maintenance ......................................................................... 33

Diagnostics / Troubleshooting ..................................................... 34-36
Message Icons / Error Messages ........................................................................................................... 36

Calibration Logs ........................................................................... 37-38

Product Warranty ......................................................................... 38-39

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Introduction
The Belt-Way conveyor belt scale is a highly accurate and cost effective in -
motion weighing system. It is designed to measure material flow over a
conveyor belt in real-time. The primary components are the integrator (AKA,
controller, display, indicator), load cell assemblies, and speed sensor. The
scale system processes speed and load signals to accumulate weight and
calculate flow rate.

BELT
LOAD
ACCUMULATED
WEIGHT
+
FLOW RATE

BELT
SPEED

This manual covers the following belt scale models:

• BW45 - (Model 45 Low Capacity Single Idler)

• BW45D - (Model 45 Low Capacity Dual Idler)
• BW100 - (Model 100 Medium Capacity Single Idler)
• BW100D - (Model 100 Medium Capacity Dual Idler)
• BW200 - (Model 200 High Capacity Single Idler)
• BW200D - (Model 200 High Capacity Dual Idler)
• BW350 - (Model 350 High Capacity Single Idler)
• BW350D - (Model 350 High Capacity Dual Idler)
• BW500 - (Model 500 Super High Capacity Single Idler)
• BW500D - (Model 500 Super High Capacity Dual Idler)
• BW1000 - (Model 1000 Super High Capacity Single Idler)
• BW1000D - (Model 1000 Super High Capacity Dual Idler)

This manual pertains to scales operating on firmware 6.43 and above.

A manual for previous versions may be found at beltwayscales.com

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Scale Accessories

Call or visit beltwayscales.com for a complete list of all the accessories

that Belt-Way has to offer.

▪ Angle Sensor

The angle sensor eliminates the need for constant recalibration

when the scale is installed on a variable angle conveyor or portable
machine.

▪ RS485 Junction Box

A Smart junction box can be installed on the conveyor to place

the scale integrator up to 1000 ft. from the scale.

▪ IO Board

The IO board allows the scale to interface with a PLC system, automate
loadout of trucks or rail cars, control a VFD, and blend multiple products.

▪ Self-Storing Test Weight Kit

The test weight kit remains installed on the conveyor.

It is activated from one side for easy, safe calibration.

▪ Outdoor Protection Enclosure

Heavy duty enclosure offers extra protection for the scale integrator.
Includes power switch.

▪ Wireless Multi-Scale Remote Display

The remote display allows multiple scales to be viewed from one

location. Monitor production, clear weight, and perform zero calibrations.
Wireless communication makes installation simple and cost effective.

▪ Plant Connect - Online Scale Production Reporting

Our Plant-Connect website allows users to monitor belt

scale production on a PC, tablet or smart phone.

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Integrator Specifications

Replacement Part Number: BWINT

100-240 AC Power Supply Factory Installed Part Number: BWPS-AC
100-240 AC Power Supply Field Installation Kit Part Number: BWPSKIT-AC
9-30 DC Power Supply Factory Installed Part Number: BWPS -DC
9-30 DC Power Supply Field Installation Kit Part Number: BWPSKIT -DC
IO Option Board Part Number: BWI O (Factory Installed)
IO Option Board Kit Part Number: BWIOKIT (Field Installed)

Display: 4.3" Color LCD

Enclosure: Cast Aluminum
Operating Temperature: -20C to 45C
Required Power: 12-24 VDC, 55 Watts
optional 110/240 AC power adapter
Inputs: 8 Load Cells (millivolts)
1 Speed Sensor (0-5 VDC Pulse)
1 Angle Sensor (0- 4 VDC)
Outputs: 1 RS232 (Printer Port)
1 RS232 (Display Port)
1 Ethernet Port (Modbus TCP)
1 USB 2.0 Client

Optional IO Outputs:
4-20 mA outputs (Tons Per Hour)
Digital Pulsed Output (Total Weight)
Min / Max Speed
Min / Max Tons Per Hour
Zero Calibration
Loadout
Optional IO Inputs:
Clear Weight
Print Ticket
Zero Calibration

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Electrical Ratings

Input Power to
12-30 VDC, 24 VDC 2.25A Max
Belt-Way Integrator:

AC Power option: Input:100-240VAC 50/60Hz, 1A Max

Output: 24VDC, 2.25A Max

Use of the factory supplied AC Power option is recommended.

AC control power over-current protection with isolated circuit, and

disconnect point such as a breaker or switch box, is recommended.
Conformance to local electrical codes is required.

Digital Inputs: 12-24VDC, 50mA sink

(IO option installed)

Digital Outputs: 12 - 24VDC, 100mA sink

(IO option installed)

Analog Outputs: 4-20mA, 24VDC powered loop

(IO option installed)

220VDC, 0.24A, 60W

Relay Outputs, UL
125VDC, 0.24A, 30W
contact ratings:
(IO option installed) 250VAC, 0.25A, 62.5VA
125VAC, 0.5A, 62.5VA
30VDC, 2A, 60W

Environmental

▪ Temperature: Normal operating range -20⁰C to +45⁰C.

▪ Humidity: The unit is suitable for outdoor use.
▪ Altitude: The unit is suitable for use to elevation of 2000m.

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Scale Components

The single idler scale consists of the following components

1 - Integrator 2 - Load Cell 2 - Mounting pipes 1 - Speed Sensor with

Assemblies 1- Hardware Kit mounting arm

The dual idler scale consists of the following components

1 - Integrator 4 - Load Cell 4 - Mounting pipes 1 - Speed Sensor with

Assemblies 2 – Hardware Kits mounting arm

Unpacking the Scale

Each scale is comprised of at least three boxes

26” x 10” x 8” - Integrator and Speed Sensor 26” x 10” x 8” - Load Cells and Hardware kit

48”, 60” or 72” long boxes for mounting pipe

and various sizes for angle sensors and other accessories

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Mechanical Installation

V-Block
MODIFIED
CEMA IDLER

MOUNTING PIPE LOAD CELL

AND ASSEMBLIES
LEVELING
PLATES

CONVEYOR SPEED
FRAME SENSOR

2D component and installation drawings are available at beltwayscales.com

3D drawings are available by request.

A. Recommended Tools

▪ Cutting torch and grinder (remove idler mounting feet)

▪ Heavy duty drill or magnetic drill press (drill u-bolt holes)
▪ Tape Measure (measure idler distance)
▪ Angle finder or phone app (measure conveyor angle)
▪ 1/2” socket and wrench (load cell and speed sensor brackets)
▪ 9/16” deep socket and wrench (V-block, u-bolts, leveling bolts)
▪ String (to level weighbridge idlers)
▪ Shim kit (to adjust idler height)
▪ 4 way screwdriver (integrator mounting, integrator door, hose clamps)
▪ Small Belt-way screwdriver (integrator wiring)

B. Conveyor Design Recommendations

The following design suggestions are essential for best scale accuracy and repeatability.
▪ Reduce speed whenever possible to maximize belt load. Slow moving, heavily loaded belts
work better than fast moving, lightly loaded belts.
▪ Proper belt tension must result in 1%-2% deflection between idlers.
For example, 2% deflection is 1 inch sag in the belt over a 4 ft. idler spacing.
▪ Lower trough angles, 0-35, are preferred. Avoid 45 troughed idlers.
▪ Install a belt scraper to keep the belt clean.
▪ Cover the conveyor to shelter it from wind, rain and snow.

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C. Scale Placement

▪ Install the scale where it is easily accessible for maintenance purposes.

▪ Choose a very rigid section of conveyor such as an idler over a brace.
▪ The scale must be at least 40 ft. away from curves in the conveyor.
▪ Stay at least three idlers away from the head pulley, tail pulley, and loading points.

Material must not impact the belt near the scale !

AVOID

GOOD

AVOID

D. Define the Weighbridge

The Weighbridge is the section of belt actively being weighed by the scale .

▪ The weighbridge idlers must be in good mechanical condition.

▪ The weighbridge idlers must be the same trough angle, and diameter.
▪ The weighbridge idlers should be an equal distance apart.
▪ Skirting should not make contact with the belt in the weighing area.
▪ A single idler weighbridge consists of 5 idlers.
Scale must be installed on the center idler
▪ The dual idler weighbridge consists of 6 idlers.
The scale must be installed on the 2 center idlers.

5 Idler Weighbridge 6 Idler Weighbridge

Single Idler Scale Dual Idler Scale

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E. Attach Load Cell Assemblies to idler

▪ Bolt the load cell assemblies to the idler as shown using the V -Block.
▪ The load cell cable should point downhill.
▪ Leave plenty of clearance between the load cell assembly and conveyor frame.
▪ Do not overtighten the V-Block bolts.
▪ The bolts should be tightened ¼ turn after compressing the lock washer .
▪ Position the load cell assemblies an equal distance from the conveyor frame.
▪ This balances the load of the belt evenly between the load cells.

NOTE: Stainless Steel Load Cells – Do not use a full thread bolt,
or over tighten the existing V-Block bolt on a stainless steel load cell.
This will damage the load cell cable.

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F. Install Scale Support Pipes

This step is extremely important to ensure long term scale accuracy.

▪ The mounting pipe must touch the strap on the uphill side of load cell assembly.
▪ The strap on the downhill side must create an oval opening.
▪ Center the pipe in the oval hole.
▪ The load cell assembly must be free to move up and down slightly on the pipes.
This eliminates torque on the conveyor frame, which allows automatic alignment
of the weighing elements.
▪ Install the four hose clamps onto the pipe with the screw fitting directly over the
top of the pipe, but do not tighten the clamps at this time.

Uphill side: Downhill side:

Retaining strap Retaining strap
fits tightly around the pipe. forms oval hole around the pipe.

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G. Drill U-bolt Holes

▪ Use the leveling plate as a drill template for the U -bolts.
▪ The leveling plates and pipe centers should measure 15” apart.
▪ The holes should be at least 7/16” to clear the 3/8” -16 U-bolts.

15 inches

15 inches
H. Remove and Modify Idler

▪ Unbolt idler from frame.

▪ Remove the idler mounting feet to create clearance above the conveyor frame.
▪ If the idler feet are not removed, all other weighbridge idlers must be shimmed up 3/8”.
▪ Make sure the idler is centered from left to right on the conveyor.

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I. String-Line Idlers to level the Weighbridge:

This is an extremely important step in the installation process.

▪ The empty belt must rest uniformly on all idlers within the weighbridge.
▪ Use a minimum of three strings to align all 5 or 6 weighbridge idlers.
▪ Shim idlers if necessary to bring them into alignment.

▪ Use the 3/8-16 leveling bolts to adjust the scale idler height .
▪ Tighten U-bolts evenly so pipes remain parallel and oval clearance
around bottom pipe is maintained.
▪ Tighten the jam nuts against the leveling plate to lock the pipes in place.

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J. Install Hose Clamps:

▪ Install the hose clamps on the outside of the load cell

assembly.
▪ Leave clearance so the clamps don’t bind between the
pipe and load cell bracket.
▪ Rotate the screw barrels away from the gaps between
the hanger brackets and the pipes.

K. Install Speed Sensor Assembly

Hose Clamps
▪ The standard speed sensor assembly may hang
from either pipe. It must point downhill.
▪ The wheel must ride smoothly on the belt.
▪ Avoid installing it near return idlers that may cause the
wheel to bounce.
▪ A small amount of weight may be added to the speed
wheel arm to hold the wheel firmly on the belt.
▪ Use two hose clamps to retain the mounting arm .
▪ Secure the cable to the arm with cable ties. Route the
cables carefully along the conveyor frame so they are
protected from falling debris and pinch points.

L. Optional Angle Sensor

Any conveyor that frequently changes angle m ust have an angle sensor installed.

▪ Mount the Angle Sensor directly on the conveyor frame.

▪ Mount in the direction of the head pulley.
▪ Reference the UP arrow indicator on the sensor.

Caution: Excessive vibration

will interfere with Angle Sensor
performance.

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Wiring the Sensors

A. Extending the sensor cables
▪ Standard load cells, speed sensors, and angle sensors have 30 ft cables.
▪ 50 ft. cables are available upon request for an additional charge.
▪ Factory supplied cables may be extended up to 100 ft. in one of four ways:
1. Solder and waterproof a similar shielded cable onto the original.
2. Use a waterproof terminal strip. Do NOT sum multiple load cells into a single
cable. Each load cell must individually connect to the integrator.
3. Belt-Way RS485 Junction box.
4. Belt-Way RS485 Junction box with Quick Disconnect option

▪ Distances greater than 100 ft should utilize the Belt -Way RS485 Junction box.
▪ Use of any style crimp connector or wire nuts to extend sensor cables is
unacceptable and will void the warranty!
▪ Use of unshielded cable is unacceptable and will void the warranty!

B. Connecting the sensors to the integrator or junction box .

Use a small screwdriver to gently pry the connector
out of the terminal strip.

Insert the connector at an angle to snap

It back into place

C. Connecting the shield wire

All sensor wires MUST be connected as shown below.

Properly terminating the shield wire is required to prevent electrical interference.

Route the cable through the rubber grommet

and loop the shield wire back out so it touches the aluminum connector.

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WARNING!
Always disconnect power before servicing the integrator.
Make sure you LOCK OUT, TAG OUT and TRY OUT the electrical system before any maintenance
or service. Please follow all Federal, State and Company Safety procedures and policies when
working with this product.

Integrator Installation
The mounting kit includes four mounting feet and four M6 x 1mm x 60mm screws with nuts to attach
mounting feet to the integrator. Customer must supply fasteners from mounting feet to mounting
location. Leave a minimum of 3” clearance on the hinge side to allow the door to open.

The integrator is weatherproof, but should be installed in a

protective enclosure whenever possible.
Physical damage to the integrator is not covered under warranty.

Do not install the integrator where it is subject to vibration.

Damage from vibration is not covered under warranty

Rubber or neoprene should be used to dampen the Integrator

effects of vibration. This is especially important on
portable machines. Vibration Mounting Kits are
available from Belt-Way.
Order part number BWVIBRATIONMT. Rubber Mount

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A. Sensor Board
The load cells, the speed sensor, and the angle sensor
all connect to the sensor board unless a junction box is required.

.80 A Fuse

Speed Sensor Wiring

SIGA – GREEN
+5V – RED
GND – BLACK & WHITE

Angle Sensor Wiring

SIG – GREEN
GND - WHITE
+5V – RED
GND - BLACK

Load Cell Wiring

-SUP – BLACK
+SUP – RED
-SIG - WHITE
+SIG – GREEN

A Single Idler Scale must use LC1 and LC2.

A Dual Idler Scale must use LC1 to LC4.
DO NOT SUM THE LOAD CELL WIRES BEFORE
CONNECTING TO THE INTEGRATOR!

The load cells are processed independently and require

individual wires for each load cell connector.
Summing the wires will cause the scale to malfunction.

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B. Terminal Board with 110 / 240 AC Power Supply

All power wiring must conform to local and national electrical codes.
Always disconnect power before servicing the integrator.

The AC Power supply is installed below the Sensor Board. It converts 110/240 AC to 24 VDC.

Ethernet Port
Power Over Ethernet 1.25 A Fuse 24 VDC
Only install this fuse when using From Power Supply
a wireless transmitter. See page 21

110 AC - To Power Supply

GND = BLACK
+24V = RED
6 A Fuse
LINE – BLACK
NEUTRAL - WHITE
EARTH GROUND – GREEN

The user must supply a minimum

16-gauge 3 wire power cord.
Ferrite Bead Installation

Each scale includes a

Ferrite Bead to meet
CE emission requirements.

Run all AC wires through

Connect to a properly grounded it as shown to the right.
receptacle that is rated for at least
15 Amps at 110 VAC.

NOTE FOR GENERATOR POWER

A generator may produce unstable power during the startup or shutdown sequence.

The integrator is sensitive to power fluctuations and should be disconnected at startup and
shutdown to prevent data loss. Use a breaker or simply unplug the power cord from the
outlet until the generator is fully powered up.

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C. Terminal Board with DC Power Supply

The DC Power supply is installed below the Sensor Board.

It boosts 9-24 VDC up to 24 VDC and regulates the voltage during engine cranking.

9-24 VDC Landing Board

+ 9-24 VDC
- VDC
7.5 A Fuse
-VDC = BLACK
+24 VDC = RED Input from Battery
( Output from to Power Supply
Power Supply
To Integrator

User should supply a toggle switch to isolate the integrator from the battery.

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D. Integrator Board
The scale firmware and programmable settings are stored in the integrator board.

USB Port
The pouch on the door includes
a power over ethernet fuse
for the terminal board.

The fuse should be installed

only when the integrator is
1.25 Amp connected to a wireless
Fuse transmitter.

E. IO Board
The IO board is optional. It provides 4-20mA outputs,
3 digital outputs, 4 digital inputs and 2 relay outputs.

The IO board mounts to the bottom of the enclosure.

If it is installed, then there will be black wires connected on top of the terminal board.

The most common use of the IO board is to remotely monitor the scale from a PLC system.

The 4-20 mA output mirrors the tons per hour.

The output is powered by the integrator. PLC
Connect IOUT1 + AGND or IOUT2 + AGND 4-20 mA
to the PLC input. Input

The digital pulsed output is used as a remote counter.

A 24 VDC solid-state control relay is required if the PLC has a 110 VAC digital input.
This may be purchased from Belt-Way or a 3rd party electrical supplier.
Use SNSR PWR to supply 24 volts to positive relay terminal.
Install a jumper wire between GND and DOGND.
Connect DOUT1 to the other side of the relay.

The pouch 24 VDC to 110 AC

Solid State Relay
PLC
110 VAC
Digital Input

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Integrator Configuration and Scale Calibration

A. Integrator Navigation and Data Entry

HOME: Returns to the Run Screen

MAIN MENU: Displays the Main Menu

BACK: Moves to previous screen only

ZERO CALIBRATION: Initiate the Zero Calibration process

PRINT TICKET: Print ticket or save a screenshot to USB when no printer is installed

CLEAR WEIGHT: Press TWICE to reset the accumulated weight to 0

ENTER KEY (Middle Arrow): Press to select menu options or accept value changes

ARROW KEYS: Use to navigate menus

Editing Numeric Values

Various integrator functions require the

user to edit numeric values: (Idler distance,
test weight calibration, IP address etc.)
When prompted, use the arrow keys and follow
the on screen instructions.

Editing Alphanumeric Values

Various integrator functions require the user to edit

alphanumeric values: (scale name, password, etc.)

Use the arrow keys to highlight desired letter and

press Enter to select. When the word is complete,
use the virtual enter button to save. Virtual Enter Button

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B. Setup Wizard
The Setup Wizard is a step by step guide for
the the initial setup of the integrator.
Record the following information before beginning the wizard.

▪ Number of weigh idlers

(1 for single idler scale and 2 for dual idler scale)
▪ Load cell capacity found on Load cell assembly label
(45 kg, 100 kg, 200kg, etc. one box will be punched out)

▪ Idler spacing distance (Measure as shown below)

Single Idler:
Distance A Distance B

Dual Idler

Distance A Distance B Distance C

▪ Conveyor Angle if an automatic angle sensor is not used.
Note: If the conveyor angle is not known, leave the angle at the default of 12 degrees.
Pulley diameter if using shaft mount speed sensor instead of the wheel speed sensor.

C. Scale Setup
View or edit scale parameters at the Scale Setup Menu.

Run Mode: Weight / Rate, Loadout, Weight Units: Tons, Long Tons, Speed Sensor Wheel Diameter: 7.97
Rate Control, Blending Pounds, Tonnes, Kilograms Pulses per Revolution: 100
Number of Idlers: 1,2,3,4 Rate Time Units: Hour, Minute Decimal Places: 0, 0.0, 0.00, 0.000
Load Cell: Conveyor Angle: 12 (factory default)
I/O Board: Not Installed / Installed
45,50,100,150,200,350,500,1000 kg or install Angle Sensor
Distance Units: English, Metric Idler Distance: 48 (factory default)
Use the following page to record all the initial scale setup values.

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Dealer Contact Information

Dealer Name:
Contact Name:
Contact Phone:
Contact Email:
Address:
City, State, Zip

Scale Information
Serial Number: BWINT-
Date of Install:
Conveyor Type: Stationary Stacker Mobile (track mounted)
Conveyor Make:
Conveyor Model:

Initial Scale Setup Parameters

Run Mode:
Number of Idlers:
Load Cell Size:
Units: Distance: Weight: Rate-Time:
Conveyor Angle: Angle Sensor Installed? YES
Idler Distance: Dist A: Dist B: Dist C:
Speed Sensor:
Decimal Places:
I/O Option Board: Installed

Initial Calibration Parameters

Trim Factor: Zero Value: Belt Length:

Test Weight Calibration

Test Weight TPH with Test
Belt Speed
Amount Weight Installed

Material Test Calibration

Belt Scale
Weights
Truck Scale
Weights

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D. Scale Calibration
Navigate to Main Menu > Calibration

i. Perform Length and Zero (if not completed during the Setup Wizard)
Navigate to Calibration > Belt Length Cal > Length & Zero and follow instructions.

The Length and Zero measures the belt length

and weight of the empty belt. It must be performed
once at startup and whenever the belt length
changes significantly. Paint a mark on the belt to
easily determine one revolution.

Run the belt empty and Press Enter when you see Press Enter when you see the mark
press Enter once. the mark on the belt. again. This ends the belt measurement

Press Enter to accept the Press Enter to accept the

length calibration. zero calibration.

If the belt length is less than 60ft and the belt speed is more than 400 fpm, we suggest
increasing the belt length to improve zero stability. Allow the belt to run 2 or 3 revolutions
during the Length and Zero procedure.

ii. Perform Zero Calibration from Keypad

The Zero Calibration weighs one revolution of the empty belt and
calculates a new zero weight. Start the belt running empty and
press the Zero Calibration button on the keypad. You do not have
to wait for a specific mark because the belt length is already established.
Follow the instructions on the screen.
▪ The Zero Calibration should be performed at least once per day.
▪ The Zero Calibration should be performed whenever a conveyor moves.
▪ Pay attention to the accumulated weight when the belt is running empty.
▪ If it adds or subtracts a significant amount then perform a new zero calibration.
▪ If multiple zero calibrations don’t correct the problem, review the maintenance checklist
and inspect the scale for mechanical problems.

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iii. Test Weight Calibration

The Test Weight Calibration adjusts the Trim Factor to properly calibrate the scale.
The calibration should be performed at startup and several times per year on a stationary conveyor.
A portable conveyor should be calibrated each time it is moved.
A Test Weight Calibration is quick and easy, but a repeatable Material Test is typically the most
accurate method of calibration. A scale may seem properly calibrated with test weights, but may be
inaccurate when running material if the idlers and belt are not properly aligned or the belt is too
tight.

Suggested test weight amounts by scale model:

Model 45 or 50 Model 100 or 150 Model 200 Model 350 Model 500 Model 1000
20-40 lbs. 40-100 lbs. 50-125 lbs. 75-150 lbs. 200+ lbs. 200+ lbs.

Option 1: Hang weights on the load cells

Obtain a bar that extends past the edge of the

conveyor and barbell or hand weights.
Make sure to weigh the weights on a certified scale
to get an accurate total.
You must include the weight of the bar in the test
weight total. If you don’t know the weight of the bar
you can perform a zero calibration with the bar on the
load cells. Repeat the zero calibration without the bar
when the test weight calibration is complete.

Make sure the weights don’t touch the belt or conveyor frame!

Option 2: Self-Storing Test Weight Kit

Rotate the test weights from the storage position to the calibration position.

Storage position Calibration position

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Navigate to Main Menu > Totals & Diagnostics > Live Weight

Live Weight shows the current force on the load cells

in pounds or kilograms. Trimmed Live Weight adjusts the
value by the Trim Factor.
Confirm the Live Weight shows the correct test weight amount.
If the Live Weight isn’t close, then check to make sure that
nothing interfering with the idler, test weight bar, or load cells.
Measure the test weights out to 2 decimal places. For example, 50.25 pounds.
Check all other parameters including model number, idler distance, and angle.
When the weight is correct then proceed with the calibration.

Navigate to Main Menu > Calibration > Test Weight. Enter the test weight amount.

Start the belt running empty and follow the instructions on the screen.
The calibration will run for several belt revolutions and then stop.
Pay close attention to the Old Trim Factor and New Trim Factor on the Accept Cal screen.

The Trim Factor will ideally be between .90 and 1.10.

If the Trim Factor is close to 1.000, use the following formula to verify the calibration.
((Test Weight Amount / Idler Distance) * Belt Speed * 60) / 2000 = Tons Per Hour

Example: ((100 lbs. / 4 ft.) x 400 feet per minute x 60) / 2000 = 300 TPH

Record calibration information on pages 37-38.

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iv. Perform Material Test Calibration

The Material Test Calibration verifies the belt scale against a certified scale.
The calibration is typically performed with a legal for trade truck scale. It is also possible to do a
material test comparison with a loader scale, rail scale, barge draft, or other very accurate weight.

1. Weigh the truck EMPTY to get an accurate tare weight.

2. Reset the weight on the belt scale or record the starting weight.
3. Start the test and make sure all material is caught in the truck.
Larger tests are better. A minimum of 10 tons per test is recommended.
4. Allow belt to run empty for 10-15 seconds prior to recording the accumulated weight.
Complete 3 or more tests in a row without changing anything on the scale.
Run the belt empty and perform a Zero Calibration prior to each material test load.
5. Compare the results to prove the scale is repeatable. See the example below.

Belt Scale Truck Scale Difference

Test 1 14.00 tons 11.00 tons 21.43 %
Test 2 10.75 tons 11.25 tons -4.65 %
Test 3 13.00 tons 13.50 tons -3.85 %
Test 4 12.00 tons 12.50 tons -4.17 %
6. Discard any tests that are unreasonably different from the rest. Test 1 is excluded in the example.

7. Navigate to Calibration > Material Test.

8. Enter the Belt Scale Weight.

Add tests 2-4 to calculate
Belt Scale Total of 35.75

9. Choose the Certified Units.

Units in example are Tons

10. Enter the Certified Weight.

Add tests 2-4 to calculate
Truck Scale Total of 37.25

11. Follow the instructions and

press Enter several times
until you reach the Accept Cal screen. The New Trim Factor will typically be range from .90 to
1.10. The example changes the Trim Factor from 1.000 to 1.042. A 4.2% change in the
calibration. If the trim is out of range make sure the correct weights and units were used.
Reject and Repeat the calibration if incorrect values were entered.
Record calibration changes on page 37-38.

If multiple truck loads vary greatly from one to the next then there is most likely a
mechanical problem. Review the mechanical installation and maintenance checklist!

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E. Scale Totals
Navigate to Totals & Diagnostics > Totals

Job Total: Accumulates until it is manually reset.

Press Clear Weight twice to reset the Job Total to Zero.
Daily Total: Automatically resets each day.
Weekly Total: Automatically resets each week.
Monthly Total: Automatically resets each month.
Yearly Total: Automatically resets each year.
Master Total: The Master total will never reset.

F. Device Setup
Navigate to Main Menu > Device Setup

CONTACT BELT-WAY FOR ADDITIONAL

DOCUMENTATION COVERING THESE ACCESSORIES

i. USB Data Logging

The integrator saves to a periodic_log.txt file once per minute.
Up to 40 days of records are saved to the internal memory.
The data files can be manually downloaded to a USB flash drive.
Insert a maximum 32 Gb USB flash drive into the
USB port on the integrator board.
Look for the USB indicator in the bottom right corner of the Message line.

Navigate to > Device Setup > USB > Report Data

Press Enter on Sync Periodic Logs to copy all historical data from the scale memory to the USB.
The Sync can take up to 15 minutes. The Message line will show when the Sync is complete.
The files can be opened on a PC in any spreadsheet software. The files are stored in the following folder
on the USB. BeltwayScales/Belt Scale/Periodic Logs

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ii. Backup & Restore Function

Navigate to Device Setup > USB > Report Data

This feature saves the scale’s current settings to a USB.
It is ideal to create a backup file after the initial scale setup and calibration is complete.
Choose CREATE BACKUP. The file is saved on the USB at Beltway Scales/Belt Scale/Backups

To restore the scale confiruation, choose RESTORE BACKUP and select the desired backup file.

iii. IO Board
Configure 4-20 mA output and Pulsed output
Navigate to Main Menu > Device Setup > IO Board.

Analog Outputs

The Analog Setpoint will usually be 100%.

The Maxrate is in tons per hour.
It sets the top of the 4-20 mA range.
It must match the PLC or the scale tph will
not agree with the PLC display.

Example: A scale configured to Maxrate of 500 will show

4 mA at 0 TPH, 12 mA at 250 TPH, and 20 mA at 500 tph

Digital Outputs

Configure the output for Pulsed Output.

Weight per Pulse controls how frequently pulses are generated.
Pulse on Time controls how long each pulse is ON.
Example: A scale configured to 1.00 Tons and 250 ms generates
1 pulse for each ton of weight and the pulse stays on for 250 milliseconds.

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web-based production monitoring:

iPhone / Android App

Unlimited Scales
+
Unlimited Users

Historical Data
Realtime Dashboard

Production Reports

Contact Belt-Way for more information about how to sign up!

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G. Administration
Navigate to Main Menu > Administration

i. Security
Navigate to Administration > Security
Create a password to restrict access certain scale functions.
Any locked item requires the password. The default password is 1.
Contact Belt-Way if you forget your password.

ii. Set the Time and Date

Navigate to Administration > Settings
Time must be in 24 hour format.
The Date can be MM/DD/YYYY or DD/MM/YYYY format.

iii. Ethernet
The IP address must be changed when connecting the integrator
to a Local Area Network or Remote Display.

Navigate to Administration > Ethernet

DHCP Client controls how the IP address is assigned.

DHCP Enabled - Set dynamically from a network router.
DHCP Disabled - User must enter a static IP address.

iv. Scale Restart

Navigate to Administration > Restart

This feature allows the user to

restart the integrator firmware
without disconnecting power.

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Routine Maintenance Checklist

The scale will only perform as well as the surrounding envirnment allows.
Inspect the scale, belt, idlers, etc on a regular basis to ensure all
components are functioning properly.

As Needed
Monthly
Weekly
Daily
Maintenance
Task
Item

Weighbridge Check rollers for flat spots, collapsed bearings and make
X
Idlers sure the rollers spin freely.
Make sure there is no material build up between the idler
Scale Idler and conveyor frame. Make sure the scale idler is not bent X
or twisted.
Make sure there is no material build up around the load
Scale Frame X
cell assemblies or mounting pipes.
Restring line when replacing idlers. The idlers need to be
String Line the same type & angle. They also need to be square and X
equally spaced. +/- 1/16th Inch
Make sure they are in good condition and in position.
Return Rollers They must also be clean & free from any material build X
up.
Check for wear & flat spots on the wheel. Ensure that the
Speed Sensor wheel spins freely. Make sure wheel remains in contact X
with belt at all times when running.
Make sure belt is in good condition and repair or replace
Belt Condition X
as needed.
Make sure belt tension is NOT too tight or too loose and
Belt Tension X
that it touches all idlers in the weighbridge.
Make sure belt tracking is good, especially across the
Belt Tracking X
weighbridge area.

Zero Calibration Perform a Zero Calibration. X

Test Weights Perform a Test Weight Calibration. X X

Material Test Perform a Material Calibration test and adjust as needed. X X

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H. Diagnostics
Navigate to Totals & Diagnostics > Diagnostics

i. Calibration
Navigate to Totals & Diagnostics > Diagnostics > Calibration

▪ Trim Factor (Calibration Multiplier)

Should be close to 1.000
▪ Zero Value (Empty Belt Weight)
Typically, 75 – 150 pounds.
This varies based on belt width, idler spacing, idler weight, etc.
▪ Belt length

ii. Voltages
Navigate to Totals & Diagnostics > Diagnostics > Voltages
▪ Load Cell Supply - Typically 9 - 9.15VDC
▪ +5v - Typically 4.95 - 5.10VDC
▪
iii. Sensors
Navigate to Totals & Diagnostics > Diagnostics > Sensors
▪ Load cells 1-8
▪ Speed Sensor
▪ Angle Sensor
▪

Load Cell mV signal diagnostics.

▪ Each load cell should show 1.0 - 7.0 mV when the belt is empty.
▪ The mV reading varies based on the zero value. Review the mechanical
installation if there is more than 1.0 mV difference between load cells.
▪ 31 mV is the maximum and is usually caused by a wiring error.
▪ Negative values mean the load cell is wired wrong or could be damaged.
▪ Check weighbridge for material buildup below the scale idler.
▪ Check pipes for proper alignment to make sure the load cells aren’t in a bind.
▪ Remove the V-Block and raise the idler and belt off of the load cells. Recheck the
mV readings with no load to make sure they read close to 0 mV.

Testing the Load Cells

If mV readings are out of range use a volt meter to manually check the load cells.
Measure Actual Excitation Voltage at the Sensor Board
+Sup and -Sup should should be 9 - 9.10VDC

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Measure Actual Load Cell mV Signal

Set your meter to DC mV (or DC Volts on auto ranging meter)
Place the Black Lead on White Wire (-SIG)) and Red lead on Green Wire (+SIG)
The reading should match the integrator Sensor screen.
If a load cell reads negative or a very high positive mV signal with no weight
on the belt, it is probably damaged and should be replaced.

Measure Load Cell Resistance (Ohms)

Disconnect the load cell from the sensor board.
Set your meter to Ω (OHMS)
Test Supply wires - Black and Red should measure approximately 420 Ω
Test Signal wires - White and Green should measure approximately 350 Ω
If the Ohms are out of range then it could mean there is damage to the cable.
Inspect the cable and solder any broken wires.
Do not use crimp connections or wire nuts to repair broken wires!
Belt Speed Diagnostics
If there is no belt speed:
▪ Confirm the belt is running.
▪ Confirm the speed sensor wheel is touching the belt and turning.
▪ Confirm that the wheel is not excessivley worn or bouncing.
▪ Shaft Mount – Check the shaft for pulley shaft damage.
Check Speed Sensor Supply Voltage
▪ Set Meter to VDC and measure between +5V and (GND) Ground.
▪ Check for damaged wires.
▪ Set Meter to Ω (OHMS) or Ringer.
▪ Remove cover from the speed wheel.
▪ Perform checks for an open circuit or broken wire.
▪ If the cable is not damaged then the encoder board may be damaged.

Angle Sensor Problems / Invalid Angle Error

▪ Conveyors typically have an angle between 0 and 25 degrees.
▪ If the Angle Sensor is connected make sure it is “Installed” in Scale Setup menu.
▪ If the angle shows 45 degrees then most likely there is no angle sensor installed.
▪ Compare the angle reading to an external angle finder or phone app.
▪ Manually move the angle sensor up and down to see if the angle changes.
▪ Make sure the Arrow on the angle sensor is Pointing UP.
▪ Check Angle Sensor Supply Voltage.
▪ Supply voltage should be about 5 VDC. Set Meter to VDC and measure
between +5V and (GND) on the angle sensor terminal.

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Power Problems
The integrator requires a minimum of 12 VDC to operate properly. Underpowered AC
transformers or DC batteries will not work. We strongly suggest use of the Belt-Way AC or
DC power supply. A toggle switch may be installed so the integator can be turned off prior
to startup and shut down.
AC Power Supply Spec: DC Power Source:
▪ Input: 100-240 VAC 50/60 Hz. ▪ Input: 9-30 VDC
▪ Output: 24VDC, 2.25A Max. ▪ Output: 24VDC, 2.25A Max.

Message Icons
Ethernet Connection: A remote display or another
Modbus Client device is connected to the integrator.

Ethernet Failure: The ethernet port is damaged. The

scale should work normally other than ethernet
communications. The integrator board must be
repaired to resume ethernet communications.

USB Installed: A USB drive is currently installed in

the integrator.

WIFI SYMBOL: The integrator is Corrupt USB: The integrator has detected a corrupt
connected to the Plant Connect server. USB. The scale will work normally but will not save
any data to the USB. Remove the USB and format it
Wire mod: The integrator board was or try a different USB.
produced after 2017.

Error Messages
No Comm with Sensor Board / INF error
If the Rate and Belt Speed show inf then there
is no sensor data coming from the Sensor Board.
▪ Check supply voltage and +VIN and GND on the Sensor Board.
The Sensor board stops working below 12 VDC.
Check the following if using
▪ Unplug SENSOR PWR and SEN RS485 INTERFACE ribbon cables if using a junction box.
▪ Check the cable running from integrator to the junction box. Confirm the RS485 wiring is correct.
▪ Test for 24 VDC on SNSR PWR and GND.
▪ Check the fuse above SNSR PWR to make sure it is good.

No Com with IO Board

▪ IO board is not installed. Change IO setting in Scale Setup menu.
▪ Check ribbon cable from integrator board to IO board.

Problem with the Angle Sensor

▪ Review Angle Sensor troubleshooting steps.

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Calibration Logs
Calibrated by:

Zero Calibration
Previous Zero Value: New Zero Value:

Test Weight Calibration

Test Weight Amount: Belt Speed:
TPH with Test Weight
Calculated TPH:
Installed:
Old Trim Factor: New Trim Factor:

Material Test Calibration

Test 1 Test 2 Test 3 Test 4 Test 5
Belt Scale
Weights
Truck Scale
Weights
Old Trim Factor: New Trim Factor:

Calibration Logs
Calibrated by:

Zero Calibration
Previous Zero Value: New Zero Value:

Test Weight Calibration

Test Weight Amount: Belt Speed:
TPH with Test Weight
Calculated TPH:
Installed:
Old Trim Factor: New Trim Factor:

Material Test Calibration

Test 1 Test 2 Test 3 Test 4 Test 5
Belt Scale
Weights
Truck Scale
Weights
Old Trim Factor: New Trim Factor:

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Statement of Limited Warranty

WARRANTY TERMS
Cardinal Scale Manufacturing Company warrants the equipment we manufacture against defects in material and
workmanship. The length and terms and conditions of these warranties vary with the type of product and are summarized below

LIGHTNING WATER LIMITATIONS

PRODUCT MATERIAL AND CORROSION ON-SITE
TERM DAMAGE DAMAGE AND
TYPE WORKMANSHIP See note 4 LABOR
See note 9 See note 7 REQUIREMENTS

90 DAY
WEIGHT REPLACEMENT 1, 2, 3, 5, 6
---------- YES YES YES YES NO
INDICATORS A, B, C, D
1 YEAR PARTS

LOAD CELLS 1 1, 2, 3, 5, 6
(Excluding YES YES YES YES NO
YEAR A, B, C, D
Hydraulic)

HYDRAULIC
LOAD CELLS 1, 5, 6, 8
(When purchased LIFE YES YES YES YES 90 DAYS
A, B, C, D
with Guardian
Vehicle Scale)
HYDRAULIC
LOAD CELLS 10 1, 5, 6, 8, 9
YES YES YES YES NO
(When purchased YEARS A, B, C, D
separately)

VEHICLE
SCALE 5 1, 2, 3, 5, 6
YES YES YES YES 90 DAYS
(Deck and Below YEARS A, B, C, D, E
Excl. PSC Series)

PSC and LSC

SCALE 3 1, 2, 3, 5, 6, 11
YES YES YES YES 90 DAYS
STRUCTURES YEARS A, B, C, D
(Deck and Below)

GUARDIAN 10 1, 2, 3, 5, 6, 9, 10
YES YES YES YES NO
FLOOR SCALES YEARS A, B, C, D

ALL OTHER
1 1, 2, 5, 6
CARDINAL YES YES YES YES NO
YEAR A, B, C, D, E
PRODUCTS

REPLACEMENT 90 1, 2, 4, 5, 6
YES YES YES YES NO
PARTS DAYS A, B, C, D

IN-MOTION
1 1, 2, 5, 6
VEHICLE YES YES YES YES 90 DAYS
YEAR A, B, C, D
SCALES
90 1, 6
SOFTWARE YES N/A N/A N/A NO
DAYS B, C, D
CONVEYOR BELT
1 1, 2, 3, 5, 6
SCALES YES YES YES YES NO
YEAR A, B, C, D, E, F
(Including Belt-Way)

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APPLICABLE LIMITATIONS AND REQUIREMENTS

1. This warranty applies only to the original purchaser. The warranty does not apply to equipment that has been tampered
with, defaced, damaged, or had repairs or modifications not authorized by Cardinal or has had the serial number altered,
defaced or removed.
2. This warranty is not applicable to equipment that has not been grounded in accordance with Cardinal’s
recommendations.
3. This equipment must be installed and continuously maintained by an authorized Cardinal / Belt-Way dealer.
4. Applies only to components constructed from stainless steel.
5. This warranty does not apply to equipment damaged in transit. Claims for such damage must be made with the
responsible freight carrier in accordance with freight carrier regulations.
6. Warranty term begins with date of shipment from Cardinal.
7. Only if device is rated NEMA 4 or better or IP equivalent.
8. Lifetime warranty applies to damages resulting from water, lightning, and voltage transients and applies only to the
hydraulic load cell structure itself (does not include pressure transducers, rubber seals, o-rings, and associated wiring).
9. 10 Year prorated warranty on hydraulic load cells.
10.1 Year warranty for scale structure.
11. PSC models’ warranty coverage applies only to agricultural installations on farms up to 3,000 acres
(LSC models not limited in this manner).
12. Load cell kits MUST be installed in accordance with Cardinal Scale instructions.
Failure to follow these instructions will void the warranty.

EXCLUSIONS

A. This warranty does not include replacement of consumable or expendable parts. The warranty does not apply to any item
that has been damaged due to unusual wear, abuse, improper line voltage, overloading, theft, fire, water, prolonged
storage or exposure while in purchaser’s possession or acts of God unless otherwise stated herein.
B. This warranty does not apply to peripheral equipment not manufactured by Cardinal. This equipment will normally be
covered by the equipment manufacturer’s warranty.
C. This warranty sets forth the extent of our liability for breach of any warranty or deficiency in connection with the sale or use
of our product. Cardinal will not be liable for consequential damages of any nature, including but not limited to loss of
profit, delays or expenses, whether based on tort or contract. Cardinal reserves the right to incorporate improvements in
material and design without notice and is not obligated to incorporate said improvements in equipment previously
manufactured.
D. This warranty is in lieu of all other warranties expressed or implied including any warranty that extends beyond the
description of the product including any warranty of merchantability or fitness for a particular purpose. This warranty
covers only those Cardinal products installed in the forty-eight contiguous United States and Canada.
E. This warranty does not cover paint coatings due to the variety of environmental conditions.
F. Do not cut load cell cables on load cells returned for credit or warranty replacement. Cutting the cable will void the
warranty.
G. Software is warranted only for performance of the functions listed in the software manual and/or the Cardinal proposal.
H. The software warranty does not cover hardware. Warranties on hardware are provided from the hardware vendor only.
I. The software warranty does not cover interfacing issues to non-Cardinal supplied hardware.
J. The software warranty does not include automatic software upgrades unless purchased separately.

BELT-WAY is a registered trademark of Belt-Way Scales, Inc.

Covered by U.S. PATENT 5,696,354

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Belt-Way Scales, Inc.

1 Beltway Rd.
Rock Falls, IL 61071 USA
Phone: (815) 625-5573
sales@beltwayscales.com
www.beltwayscales.com

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