BS Belt Scale

User Manual
BS Belt Scale
User Manual
 BS Belt Scale – User Manual
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BS BELT SCALE
BS1000 - BS2000 - BS6000

LEGAL WARNING!
If the product you use, is used in commercial operations such as buying, selling and
fining operations, it must be controlled with a seal according to the Law on Measures
and Settings with the number 3516 and 2004/22/AT Directive. It must be sealed by
periodically inspecting in once in every two years.

Please consult ESIT with this regard.

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WARNINGS:

• Moving parts (exp: tachometer) on the system constitute danger, do not

touch moving parts while the system is running.

• Maximum care must be shown for preventing damage to the system and the
component while they are carried and placed.

• Expert manufacturer (ESIT) installation personnel or supervision service is required

for the mechanical installation of the system.

• Expert manufacturer (ESIT) personnel is required for installing, commissioning the

system automation.

• Storing and maintaining the system components before the installation;

Indoor and humid free dry area for the electronic parts,

Preferable indoor, if not possible, enclosed, protected outdoor place is required for
the mechanical parts.

• Do not carry our maintenance and repair while the machine is

running.

• Do not press, apply force onto the belt or system during the machine calibration and
operation.

• Do not remain the J-Box and Load cell covers open.

• Failing to follow following consideration may cause life threat or

material damage:

- Not using for the intended purpose,

- Improper assembly or use,

- Use, maintenance and repair by unauthorized persons.

• Removing/cancelling the equipment on the system.

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Table of Contents

WARNINGS: ............................................................................................................................................ 2
Table of Contents .................................................................................................................................... 3
WARNING SIGNS IN THE OPERATING MAINTENANCE MANUAL AND THEIR MEANINGS ........... 4
INTRODUCTION: .................................................................................................................................... 5
GENERAL INFORMATION: ............................................................................................................ 5
TECHNICAL DRAWINGS: ...................................................................................................................... 7
................................................................................................................................................................. 9
TECHNICAL AND GENERAL SPECIFICATIONS: ............................................................................... 10
GENERAL SPECIFICATIONS: .................................................................................................... 10
INSTALLATION: .................................................................................................................................... 11
LOCATION SELECTION FOR THE BELT SCALES AND CODES OF PRACTICE: .......... 11
BELT SCALE INSTALLATION STAGES: ............................................................................................. 14
........................................................................................................................................................... 16
COMMISSIONING ................................................................................................................................. 21
USING ECI-BS DEVICE: ....................................................................................................................... 21
SYSTEM REQUIREMENTS ......................................................................................................... 22
MAIN PROGRAM SCREEN .................................................................................................................. 23
Keys ....................................................................................................................................................... 23
Symbols ................................................................................................................................................. 24
BELTSCALE MENU .............................................................................................................................. 25
TECHNICAL DATA: ............................................................................................................................... 33
WEIGHING BRIDGE: ..................................................................................................................... 33
TACHOMETER (CONVEYOR BELT SPEED SENSOR):........................................................ 34
JUNCTION BOX : ........................................................................................................................... 34
LOAD CELL: .................................................................................................................................... 35
TERMINOLOGY: ................................................................................................................................... 36
PERIODICAL MAINTENANCE, PROBLEMS AND SOLUTIONS ......................................................... 37

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WARNING SIGNS IN THE OPERATING MAINTENANCE MANUAL

AND THEIR MEANINGS

It is absolutely necessary to follow the measures and warnings stated in this document.

Electrical Shock Danger : Possible results: Death and severe injuries

Danger : Possible results: Death and severe injuries

Caution: Possible results: Improper operation of the device and the system

Hazardous Situation: Possible results: Damage in the system and environment.

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INTRODUCTION:

GENERAL INFORMATION:

Esit BS Belt Scale is a weighing system, which weighs flow quantity in terms of weight dependent to
time (ton/h, kg/sec) at the points, where it is compulsory to be known by the producer or the consumer
while it is on the belt, for the weight of the some bulk materials in the mining, fertilizer, iron-steel,
chemical, concrete and food industry, that can be conveyed on belt. Measuring the bulk material on
the belt, not only provides important information for the Corporation, but also saves time and labour.

Esit BS- Electronic Belt scales can be easily mounted to a suitable part on the current conveyor
systems of the users.

The system is composed of the weighing bridge where the weight information is received; the
tachometer sending the speed information, belt sensor and the indicator where these information are
monitored. While the conveyor belt is in operation, the weight of the good passing over the weighing
unit and the speed value of the belt are transmitted to the ECI-BS Control Terminal.

Operation of the belt scale is based on measuring and processing two basic magnitudes. One of them
is the speed and the other one is the weight. The flow rate of the good passing is found by processing
the weight information coming from load cells and the speed information from the belt speed sensors,
in the controller.

It is shown in the indicator as instant and total values in capacity (kg/sec) or (ton/h), belt speed
(m/sec).

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Figure 1-Overview of the BS Belt Scale

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TECHNICAL DRAWINGS:

Figure 2 – Technical Drawing of BS 1000 Belt Scale

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Figure 3 - Technical Drawing of BS 2000 Belt Scale

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Figure 4 - Technical Drawing of BS 6000 Belt Scale

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TECHNICAL AND GENERAL SPECIFICATIONS:

Model BS 1000 BS 2000 BS 6000

Capacity 10-100 kg/m 20-200 kg/m 100-550 kg/m
Belt Width (max) 800 mm 1000 mm 2000 mm
Flow rate (max) 1000 t/h 2000 t/h 6000 t/h
Belt Speed (max) 3 m/s
Accurcy Class 0.5 , 1 , 2
Belt Angle (max) 18 0
Distance Between the Rollers 500-1000 mm 1000-1500 mm 1500-2500 mm
Loadcell Type SSP SP SP
Tachometer 10 pulse

Figure 5- BS Belt Scale Model Specifications

GENERAL SPECIFICATIONS:
• Fast and very sensitive measuring
• Industrial type box with IP 66 protection class
• Gain setting suitable for the sensor output
• Digital filter
• Easy setting and calibration with keys
• Analogue 0-10V or 4-20mA output
• 1 relay output (ready to adjust in m/s, t/h, kg/m, for batch or device)
• Relay output or device ready output for 1 mechanical register
• Remote Access to all internal parameters via computer
• RS 485 / RS 232 serial output
• Stainless structure for the corrosive environments
• ex-proof structure for the inflammable environments
• Computed automation depending on the need
• DLMS_NW PC software (a computer software capable of monitoring more than one device
simultaneously, providing network and internet support, storing weighing data)

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INSTALLATION:
LOCATION SELECTION FOR THE BELT SCALES AND CODES OF
PRACTICE:
• The belt thickness and weight of the belt scale must be same along the belt.

• Belt scale tensioning mechanism must be vertically weighted as tensioning

mechanism with horizontal weight my cause loosening of the belt depending on the
load. This adversely affects measurement.

• Belt scale bridge location must be selected in a location with the deflection on not
more than 1 mm under full load. The belt scale is not installed on the constructions
equipped with a sieve, breaker, vibro-feeder or device operating with vibration.

• When the material carried on the belt scale arrives to the effective measuring zone,
the material must be spread and placed completely. There must not be any material
flow, rolling on the measuring zone and the material must enter with a proper section.

• The material passing on the belt must be distributed homogenousy and there must be
no accumulation and gap.

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• In V and triangular section belts, the scale bridge will be 3 or more rollers away from
the tile or head roller.

• Belt cutting angle (x) directly affects the weighing accuracy. Starting from 200 until
450, the accuracy is affected as ± 2% of its nominal capacity.

The ideal condition is the straight belt. While designing the belt, it must be taken care
that, this angle in the weighing belt group is minimum.

• Effective measuring zone is composed of the 3 entry rollers and 3 exit rollers at the
beginning and at the end of the scale bridge.

This area and the weighing bridge shall be completely manufactured 3 mm above the
other rollers.

The rollers in this area shall be at the same plane provided that the distance between
each other is not more than 10,2 mm.

• The point where the belt of the belt scale is stretched at most is the parts that are
near to the main drive drum. While selecting the belt scale, the furthest place from the
main drive drum is the most suitable place.

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• The belt length must be minimum 6 metre and maximum 120 meter. The climbing
angle of the belt must be 180 or below. While selecting the location, angle-free belt
means less measuring mistakes.

• In single piece belts with two or more elevations, the bridge location selection can be
made by leaving 12 meters for the upwards bends and 6 meters fort he backwards
bends.

• The skirts of the side routers, if any, must be adjusted in a manner that they do not
contact with the weighing belt. The skirt, which is elevated too much, may affect
negatively and the material penetrating the gaps affects the weighing.

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BELT SCALE INSTALLATION STAGES:

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COMMISSIONING
• Mechanical and electrical installation is made.
• Conformity check of the partition ratio of the load cell is made for the belt scale.
Weighing bridge is tested and calibrated. Repeatability and corner test is performed.
• Actual capacity and speed is measured as the preliminary work. It compliance to the
request type is checked (Maximum Capacity- Ambient conditions- Minimum Capacity-
Homogeneity)
• Pulse counter (Encoder) settings are made. The speed is checked by keeping the
time and belt length.
• The belt is operated and zero belt tests are carried out.
• Material tests are made. After calculating the coefficient values, repeatability is tested
for three different flow rates, which are two pairs in maximum and minimum flow rates
and on paid in the medium flow rate.
• Output parameters are set.

USING ECI-BS DEVICE:

ECI-BS Electronic conveyor belt scale system enables the weighing of bulk materials carried
by conveyor belts during the conveying process. The flow amount (capacity) is proportional
to the speed and the material on the belt.

• High internal resolution (24 bits)

• Digital filter
• 3 total values (Total1 and Total2 are resettable . Total is non-resettable)
• Actual Flowrate t/h, belt speed, kg per meter values can be displayed
• Internal RTC and battery circuitry to hold Totalizing data
• Belt working simulator
• Alibi Memory

Model ECI, E Series

Load cell Input +/- 2.50-160mV/V
A/D Speed (/saniye) 1600
Display contrast 6 digits (1/1.000.000)
Feed 12-24V DC
Display LCD (101X33 pixel graphics, 4.5inch)
Communication Terminal (Standard) RS-232 (9600-115200bps)
Communication Remote Display (Standard) For Remote Display(Opto-Coupler)
Communication Module (Optional) RS-232-RS-485 / RS-442 (E-MDL-COM Isolated)
Load Cell Feeding 10 VDC (280mA, max 10 load cell)
Operating Temperature -10 / +50C
Protection Class IP65 (Front panel)

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SYSTEM REQUIREMENTS
Additionally for different purposes of use;

JUNCTION BOX : If more than one load cells are connected to the LCA-B device, a module
where the load cell connections are gathered, will be needed.

Load Cell
Connections

ECI(1) ECI(2) ECI(3) ECI(253) ECI(254)

• RS232/485 CONVERTER :
If RS-485 will be used for communication, a 232/485 converter, which ensures
compliance between the computers and device(s) will be used

NOTE: RS-485 communication is used for communicating with more than one device
on the same line. Furthermore, in case of long distance communication, RS-485 must
be made even if there is a single device. RS-232 is used for communications up to 50
meters and RS-485 is used for the communications with more than 50 meters.

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MAIN PROGRAM SCREEN

Beltscale program main screen shot will be as shown at side;

Screen Layout

1) Totalized weight
2) Total indicator index
3) Unit 2
1 3
4) Belt Motion Simulator
5) Flow percentage, Min flow, Max flow indicator 4 5 7
6) Zero Zone indicator 6 8
7) Flowrate ,Auto zero or Weight 9
8) Speed, load per meter
9) Keys

Keys

Reset Total Key Used to reset Total1 and Total2 values (T1 ve T2)

Used to swich between Total1, Total2 and general Total

Change Total Index indications for totalization indications. And also the
Key measurement values shown on the 7 and 8 area are
toggles.

x10 Resolution Key Used to activate x10 resolution for Totalize indications

It is used for bringing the menu where the settings related

BeltScale Menu Key
to the beltscale are made.

Used for bringing the menu screen where the device

Setting Menu Key
settings are made.

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Symbols

Belt Animation symbol It is used for simulating the belt conveyor is running.

Belt Animation symbol It is used for simulating the belt conveyor is stopped.

This symbol appears on the screen when the

Minimum Flowrate
measured flowrate value is under the “Minimum
symbol
Flowrate”.

This symbol appears on the screen when the

Maximum Flowrate
measured flowrate value is above the “Maximum
symbol
Flowrate”.

This symbol appears on the screen while AutoZero

process is in operation. The symbol is not shown,
Auto Zero Operation
when Autozero is Off state or measured weight
symbol
above 2% of the “Maximum Capacity” or Interlock
input is not valid.

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1. Initial Setup 2. Coefficients 3. ZeroingPasswd 4.Report

Singed Total Min.Flowrate Total1 Records

Weight Length Coefficient1 Total2 Period.Report

Speed Sensor Max.Flowrate

Pulse Distance Coefficient2

Sensor Timeout

Belt Length

Auto Zero

Belt Oscillation

BELTSCALE MENU

Beltscale Menu Usage

Initial Setup
It is an ordered type menu that contains the Initial Setup settings for the beltscale program.
The sub-menus are the Signed Total, Weight Length, Speed Sensor, Pulse Distance and
Sensor Time Out.

Signed Total

The options are;

1) Standard: Negative loadings are added to totalization.
2) PositiveOnly: Negative loadings are not added to
totalization.

Note: This menu is not shown when Security Type is selected as

“LegalForTrade” (It is fixed Standart mode).

WeightLength
Platform measurement area. Length of the
measurement platform. Sum of the half distance between
the left roller and weighing roller (a) and half distance
between right roller and the weighing roller
(b).WeightLength= a/2 + b/2

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Speed Sensor
Selection of the Input type selection for speed
measurement. The options are;
1) Encoder: Encoder is used for speed measurement.
2) Fixed Speed: Used for fixed speed systems.

Note: The valid signal has to be applied to the speed sensor input (Input1) to notify that belt is running.

Pulse Distance
Distance per pulse value. In this parameter the
Distance for every pulse is defined in “mm”.

Sensor TimeOut
Time out information for speed sensor pulse intervals
If the belt turning starts and stops continuosly, itis hard to
estimate that the belt is stopped. This parameter
determines the accceptable time period of pulse
inputs.

(Note: If you are not sure about the value, please enter 1.00 second. If something wrong with speed please enter 2.50
second)

Design Speed
It contains belt speed info. System speed at a constant
speed system is determined by this parameter.

Belt Length
Total length of the belt.

Note: This parameter used for calibration and autozero calculations. Please enter correctly.

Auto Zero
It contains auto zero selection. The options are;

1) Off: Auto zero is disabled.

2) On: Auto zero enabled.

Note:If the “LegalForTrade” option is selected in the “Security Type” menu, this option is not shown and AutoZero option
is fixed On state.

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Belt Oscillation
It is the zero belt value. The weight is not added to
total if it is below this value.

Flow Filter
Standard digital filtering option for flow rate.
The moving average method is used.

Coefficients
Belt multipliers defined in the section. According to uncertanity of the Weight Length and
Pulse Distance, the multipliers has to be defined to correct the system.

Note: This submenus are locked when "LegalForTrd" is selected in the "Security Type" menu.

Min.Flowrate
Minimum flowrate value. symbol appears on the
screen when the flowrate is less then the minimum
flow rate.

Coefficient1
Multiplier for minimum Flowrate condition.

Max.Flowrate

Maximum flowrate value. symbol appears on the

screen when the flowrate is more then the maximum flow
rate.

Coefficient 2

Multiplier for maximum Flowrate condition.

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ZeroingPasswd
Passwords settings menu.

Total1
Used to clear “Total1” value.
This value shown as 0 when entered to this
Parameter screen. And user can change it everytime.
When entered on mainscreen correctly the totalized
value is cleared.

Total2
Used to clear “Total2” value.
This value shown as 0 when entered to this
Parameter screen. And user can change it everytime. When entered
on mainscreen correctly the totalized value is cleared.

Report
This is the menu where you can see the ALIBI records or take a new ALIBI record for the belt
scale program.

Records
Record Number Date/Time Total and Status values
Can be seen. Use and keys to move
Between records.

To acces the desired record, use key.

For taking a record manually, use key.

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Report Period
In this menu, the period for the USB records is determined.
The options are;

1) Off: No USB record is taken.

2) 1 hour: USB records period.
3) 6 hours: USB records period.
4) 12 hours: USB records period.
5) 24 hours: USB records period.

Alibi Memory
All information and other pertinent information is stored in the Real-Time Clock unit on the
device. To keep this information in case of a power failure, there is a battery circuit in the ECI
device. Information regarding the device's production date and calibration date is stored in
the EEPROM memory. During calibration, the new calibration date will be automatically
saved to permanent memory. ECI device can store the last 1000 totalization records
(minimum flow, maximum flow and memory error conditions) and error log. An Alibi record
contains the following information: Date + Time + Total + Status

Status

Manual Record: With button, a manual record can be taken.

Minimum Flow: When the measured Flow value is lower than the “Minimum Flow” value in
the Coefficients menu, that info gets recorded automatically.
Maximum Flow: When the measurd Flow value is higher than the “maximum Flow” value in
the Coefficients menu, that info gets recorded automatically.
Memory Error: When the system cant acces the memory, that info gets recorded
automatically.
Period. Report: Info gets recorded periodically, according to the period time choosen by the
user.

Auto Zero
Autozero feature can be enabled by setting the
“Auto Zero” parameter in “Initial Setup” menu or
in “Security Type” menu, “LegalForTrade” option is
choosen. Additionally the “AutoZero Interlock input”
has to be activated to validate the zeroing process.

Zeroing process is explained below;

System awaits until the measured weight value falls under the
%2 of the capacity. If the measured weight value stays under
%2 of capacity for a period of belt length and sign blinks. Then auto zero process
starts.
measured weight value to measured under the%2 of the capacity, in the meanwhile,
sign blinks.

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Auto zero process continues for 3 belt length period, meanwhile sign shown
permanently, if the measured weight value gets out of range, auto set proces gets cancelled.

At the end of Auto zeroing process, device waits for a period of belt once more, it is expected
to see that the measured weight value to measured under the%2 of the capacity, in the
meanwhile, sign blinks. When the proces is done, zero value on screen is updated. If
the measured weight value gets out of the range before a period of belt is completed, auto
zero proces gets cancelled.

Note: Auto zero value can be displayed on the screen. The Picture above shows the position.

Calibration of BeltScale

Load Calibration

It is the operation of identification of a mass with a known weight to the device. It must be
made by using real
weights. Calibration must be done while belt is running. Device automatically calculates belt
movement
distance.
1)Enter the menu 2.5 for the calibration.
2) Load cell type is selected. The options are;

1) Esit (2 mV/V)
2) 2.5mV/V
3) 5.0mV/V
4) 10.0mV/V
5) 20.0mV/V
6) 160.0mV/V
mV/V selection is made depending on the load cell model.

3) For entering the Calibration Type menu is pressed.

4) Calibration Type is selected. The options are;

1) Load Calibr.
2) mV/V Calibr.
3) CoeffCalibr.
4) Zero Calibr.

5) After selecting the Calibration Type as the "Load

Calibration”, proceeded to the next screen by
pressing first, then key. The information screen
shown at side is displayed.

If you select the “Calib. Type” incorrect, you can return the previous screen by pressing key.

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6) key is pressed for starting the zeroing

operation.

7) After Zeroing operation is completed. Press

key to continue the operations.

8) For a proper calibration operation, the load used

must not be less than the amount recommended
on the screen.

9) The weight value to be used in calibration is

stated in this screen. For confirming the weight value
entered key is pressed and proceeded to the calibration screen.

10) By placing the load equal to the calibration weight

Stated in the message screen and pressing the key, the
calibration process is initiated.
The

11) General information screen indicates that the

Calibration is completed. Key is pressed for
proceeding to the next screen.

12) key is pressed to store the calibration values

or is pressed to exit from the menu without storing
the calibration values.

Zero Calibration

The following operations must be performed respectively for the zero calibration. It is entered
to menu 2.5 for the zero calibration:

1) Load cell type is selected. The options are;

1) Esit(2 mV/V)
2) 2.5mV/V
3) 5.0mV/V
4) 10.0mV/V
5) 20.0mV/V
6) 160.0mV/V

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2) For entering to Calibration Type menu key is pressed. “Zero Calibration” is selected
as the calibration type. The options are;

1) Load Calibration
2) mV/V Calibration
3) Coefficient Calibration
4) Zero Calibration

3) For proceeding to the zeroing screen key is pressed.

4) Weighing platform is emptied and key is pressed for

starting the zeroing operation.

The screen shown at side is displayed during the zeroing operation.

5) Key is pressed to proceed to the calibration

confirmation screen.

6) Key is pressed to store the calibration values

or Is pressed to exit from the menu without storing the
calibration values.

BeltScale Connections
Note: When the BeltScale program is selected, the settings of the Relay modules in Slot 4 and Slot5 and the EXP
Module in Slot 6 cannot be changed and related menus will be locked. The connections of these modules must be made
as follows.

Input Connections Output Connections

Slot 4 Input Connections Slot 4 Output Connections

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TECHNICAL DATA:

WEIGHING BRIDGE:
It is the mechanical construction detecting the load on the belt and transmitting it to the load
cells.

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TACHOMETER (CONVEYOR BELT SPEED SENSOR):

It is the method of calculating the belt velocity by directly attaching a pulley with a certain
diameter to the conveyor belt and transmitting a full rotation of 360O as a signal, in other
word dividing the distance taken by the time lapsed. This data is directly sent to the
controller. Its structure is protected against dust, humidity and all external factors.

Wheel: Steel

Output: 10 pulse/round Tachometers with higher pulse/round ratio can be used for lower belt
velocities)

JUNCTION BOX :

Brand :ESİT

Model : J-2

Protection : IP65

Body : Aluminium casting

Origin : Turkey

Esit J Box Junction Box ensures bringing the signals received from the load cells together
and sending them to the indictor.

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LOAD CELL:

Brand : ESİT

Model : SSP

Capacity : 20-40-80 kg

Protection : IP68

Body : Stainless Steel

Measuring Class : C3

Failure : % 0,05

Origin : Turkey

Brand : ESİT

Model : SP

Capacity : 200-500 kg

Protection : IP68

Body : Steel

Measuring Class : C3

Failure : % 0,05

Origin : Turkey

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TERMINOLOGY:

Straight Roller V- Roller Triple Roller

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PERIODICAL MAINTENANCE, PROBLEMS AND SOLUTIONS

Belt scale is a sensitive measuring component and it runs with its environment.
Therefore a conveyor belt, which is applied belt scale will require a more careful
maintenance. This maintenance is essential for weighing performance.

DAILY MAINTENANCE:

• Note that the bet surface is clean and the belt drums are free of materials
sticking on them.
• Check that the tachometer wheel presses on the belt surface and rotates
synchronous with the belt.

MONTHLY MAINTENANCE:

• Lubricate the drums and drum assemblies

• Adjust the belt tension and slide. The distance between the belt and the
weighing bridge must be 1-2 mm when there is no load and must contact with
the weighing bridge for detection when loaded. Take necessary measures for
the belt slide.
• Notice that the periodical maintenance of the engine redactor assembly is
made and your belt velocity remains the same before and after the
maintenance.

ANNUAL MAINTENANCE:

• System calibration must be made. (See. CALIBRATION)

CONSIDERATIONS:

• The rules must be followed at belt start up,

• No welding should be made on and around the belt bridge,
• Weighing bridge must be protected from overloading during the maintenance.
• any addition or patch on the belt adversely affect the weighing accuracy.
• If the belt, where the weighing will be performed is in an area that is open to
the wind, it must be protected with wind panels, starting and finishing from one
meter away from the start and finish points of the weighing bridge on both
sides, in a manner that prevents the wind.
• A new setting to be made on the tensioning system of the belt requires the
repetition of the calibration.
• The electrical assembly board of your belt scale must be located in a
protected area. Care must be taken that, no other devices are used on the
same lie as the grounding line must also be installed separately.

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A Nisantepe Mh. Gelin Cicegi Sk. No:36 Cekmekoy 34794 İstanbul T (216) 585 1818 F (216) 585 1819 W www.esit.com.tr

BS-ECI User Manual- R00