Manual Bascula N-62 JMHS9105F JNE60P
Manual Bascula N-62 JMHS9105F JNE60P
Bulk Pro Systems, LLC – 13361 Aberdeen Street NE – Ham Lake – MN – 55304
Ph: 763-767-0003 – Fax: 763-767-3282 – Web: www.bulkprosystems.com
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Bulk Pro Systems, LLC – 13361 Aberdeen Street NE – Ham Lake – MN – 55304
Ph: 763-767-0003 – Fax: 763-767-3282 – Web: www.bulkprosystems.com
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Table of Contents
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1.0 Introduction and Overview
A belt conveyor scale is a device that continuously measures bulk material as it moves along a conveyor.
The system requires two general parameters to operate, one being it needs to know the weight of the
material being moved along the conveyor belt and second, it needs to know the speed at which it’s
moving along the conveyor belt. The weight of the material on the belt is determined by weighing a
section of conveyor belt loaded with material and then subtracting the average weight of the unloaded
belt. The speed at which the material is moving is determined by measuring the speed of an idler or
wheel in contact with the conveyor belt. The weight and speed is combined to give a running total and a
rate of flow of the material. The correct operation of the scale system requires the components to be
installed correctly, periodically calibrated, and properly maintained.
• Mining
• Quarries
• Bulk Material Blending
• Truck/Barge/Rail Loading
• Process Control Applications
A belt conveyor scale is also able to compute the total mass of the material that is conveyed over a given
period of time and while it is in motion.
• Scale carriage
• Load cells
• Belt travel pick-up speed senor
• Electronic Integrator
The scale carriage is mounted to a conveyor structure and transmits the forces resulting from the belt
load and directs those forces to the load sensor(s).
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1.1.2 Load Cells
There is one strain gauge load cell located in the model N-61 belt scale. The sensor supports the weight
of the conveyor belt and the material moving along on the belt. The weight signal from the load cell is
combined and processed by the integrator.
The belt travel speed sensor is installed directly to a non-driven pulley. In most cases this is the tail
pulley of the conveyor belt. The signal generated by the speed sensor is converted by the integrator
into a value that represents belt travel distance. Various devices used for sensing belt travel include AC
and DC generators, mechanical belt or chain drives, photo-optical segmented disks, and electromagnetic
pulse generators.
A.L.N
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1.2 Selecting a Mounting Location
It is very important to select the right mounting location for the scale carriage along the conveyor
structure and the location of the speed sensor. There are several factors that must be taken into
consideration when selecting a mounting location. Those factors will determine the overall long-term
and short-term accuracy you might expect. Those factors include the following:
• Tension
• Uniform Belt Loading
• Single Load Belt (Contact factory if multiple load points)
• Material Slippage
• Convex Curves
• Concave Curves
• Trippers
• Speed Sensor Mounting Location
• Electronic Wiring Location
• Speed Sensor
• Other Mitigating Factors
1.2.1 Tension
The transfer of weight along the conveyor belt can be greatly affected by belt tension. By locating the
scale carriage in an area of the conveyor with the least amount of tension, the scale will be more
accurate and achieve better performance. An ideal location to mount the scale carriage is near a tail
section of the conveyor, but far enough forward so as not to be influenced by in-feed skirts boards, etc.
It is desirable that the belt loading be as uniform as possible to prevent unequal shifts in material. To
minimize surges or feed variations, hoppers should be equipped with depth limiting gates or other flow
control devices such as a feeder.
On high accuracy installations, the conveyor should be loaded at one and the same point. This assures
constant belt tension at the scale during all loading conditions. (Contact factory about multiple feed
points.)
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1.2.4 Material Slippage
The belt scale system processes belt loading and belt travel to arrive at an accurate weight. Product
speed must be equal to the belt speed at the scale. So the conveyor speed and slope should not exceed
that at which material slippage occurs, which is approximately at 18° angle.
Conveyors that have convex curves should be avoided or the scale should be located in a section of the
conveyor that is not affected by the curve.
Convex curves are permissible at a distance of 20 feet or a minimum of five idler spaces beyond the
scale area idlers.
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Figure 1-5. Convex Curved Conveyor
Conveyors that have concave curves should be avoided or the scale should be located in a section of the
conveyor that is not affected by the curve. If there is a curve, the belt must remain in contact with the
idler rollers at all times for at least 20 feet (6m).
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1.2.7 Trippers
In any installation, where weighing accuracy is important, the scale should not be applied to a conveyor
that has a movable tripper. If the scale must be installed on a conveyor with a tripper, then the same
rules apply as for an installation in a concave conveyor. The minimum distances outlined in the above
paragraph must be adhered to with the tripper in its fully retracted position. It is also of extreme
importance that the belt tracks centrally at the scale area for all tripper locations.
The speed sensor location is just as critical as scale carriage location. Improper installation of the speed
sensor will significantly affect the performance of the scale system. The speed sensor must give an
accurate representation of the speed of the material and travel of the belt.
If the tail roll is not accessible then the speed sensor can be mounted on a tailing wheel that rides on the
return side of the belt, or on a live shaft roller. If a trailing wheel is used, the wheel should be located
on a section of the belt in which belt vibration will not add movement to the wheel. The preferable
location would be directly opposite a conveyor return roll.
If a live shaft roller is installed to sense the belt speed, the roller should have positive contact with the
belt. The preferred location would be between two return idlers with the speed roller being installed
on the top side of the returning belt and the return idlers installed on the bottom side.
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Figure 1-7. Speed Sensor Pulley
The location for the electronics to be mounted is determined by accessibility, wire routing, and
environment. The scale electronics require a clean and stable 120 VAC supply. The enclosure for the
electronics is rated NEMA 4X. The electronics can be mounted up to 3000’ away from the scale carriage
provided the optional load cell sense wiring is installed. If the electronics are to be installed within 200’
of the scale carriage, the optional sense wiring is not required. To reduce the effects of signal
interference, the scale signals should not be run in conduit or cable trays in conjunction with high
voltage cables.
The digital input and output signals are compatible with OPTO 22 relay modules and can be controlled
with AC, DC or dry contact signals. The analog output signal for rate of flow can be wired for 0-10 VDC,
2-10 VDC, 0-20mA current or 4- 20mA current. The printer signal can be RS-232, RS-485, or 20mA
current loop.
The scale and conveyor at the scale will be protected from wind and weather effects. The magnitude of
weighing errors caused by wind is dependent on wind velocity.
The entire conveyor frame should be isolated from bins, feeders, crushers, and other mechanical
equipment. This is to prevent bin loading from causing conveyor deflections and to protect the
weighing equipment from vibrations and shocks imposed by mechanical equipment.
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In the design of the scale, several deflections are taken into consideration. These are the deflection of
the load cells, the deflection of the scale carriage and bridge assembly, and the deflection of the
supporting conveyor structure. It is of utmost importance that these deflections not be excessive. In
the manufacture of the scale, the amount of deflection in the load cells and the carriage and bridge
assembly is controlled. The only variable is the deflection of the conveyor itself. Therefore, the
conveyor stringers supporting the scale and five idlers to either side of the scale should be of ample size
and be adequately supported to limit the relative deflection between two adjacent idlers to no more
than 0.025 inches (0.6 mm). No conveyor expansion joints or stringer splices should be located in this
region of the conveyor. Refer to field installation drawing for required mechanical supports.
Installation instructions for the integrator are explained in the separate integrator manual.
Take all necessary safety precautions when setting up the Bulk Pro Systems, LLC In-
motion belt scale system, including wearing safety shoes, protective eyewear and using the proper
tools.
2.1 Storage
The Belt Scale and associated equipment can be safely stored, with cover latches secured and hole plugs
installed, between -58° to +185° F (-50º and +85º C). The units should be protected against moisture.
Upon receipt of the shipping pallet, visually inspect all components to make sure that they are included
and undamaged. The shipping carton should contain the scale carriage, the indicator, this manual, and a
parts kit. If any parts were damaged in shipment, notify Bulk Pro Systems and the shipper immediately.
NOTE: To ensure that all products received from the manufacturer are in good shape upon arrival, it is
recommended to fully inspect all contents and properly complete the bill of lading.
This section is to be used as a guide in the installation of the Bulk Pro Systems Model N-61 Weighbridge
and associated scale area idlers. All belt widths are installed in the same manner. Overall structure
deflection must be maintained within 0.025 inches (0.6 mm) between adjacent idlers.
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2.3.1 Terminology
Select the scale location by following the outline in Chapter 1, Mounting Location Criteria. A partial
listing of the required guidelines follows:
• The scale conveyor should not be attached to, or have vibrating devices installed on it.
• Install the scale on a rigid conveyor.
• The approach weigh idler should not be located closer than 20 feet or five idler spaces;
whichever is greater, from loading point or skirting.
• The scale must not be placed in concave or convex curves.
• The scale must not be installed where conveyor speed and slope causes material slippage to
occur.
• Locate the scale where it has maximum protection from the elements.
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2.3.3 Worksite Preparation
After determination of scale location in the conveyor, proceed with site preparation as follows:
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Figure 2-1. Weigh Idler Modification
Figure 2–2. Weigh Idler Modification 42" through 54" Belt Width
Notes:
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2.3.4 Weighbridge Installation
After selection of the scale location and preparation of the site, proceed with installation as follows:
1. Determine scale area section criteria: locate and mount the minus -3 and plus 3 idler. Shim
idlers, using one of the ¼ (largest)and one of 1/8” (2nd largest) shims provided) each of these
idlers 3/8” (9-10mm) on both sides so they are above the adjacent idlers. By using the diagonal
method (see figure 2-5) and some measurements, make sure that D1=D2 and the
measurement is equal to 6 times of conveyor idler spacing, the error between D1 and D2 be
less than 1mm;(1/16”) and the error between L1 and L2 less than 1mm (1/16”). After 3 above
steps, solidly bolt the plus 3 and minus 3 idlers on conveyor. Do not weld!
2. Measure halfway between the +3 and -3 idlers and make a mark. This is the location of the
weigh idler. Drill the module mounting holes in the stringer starting with the 2 holes each
approximately 3 ½” from the weigh idler location mark. The third stringer hole is
approximately 4” downstream of the other two as shown in Figure 2-6. Install the right and
left side (PLR & PLL) so they are symetrical and level, Shims, if necessary can be used to
level the modules to each other.
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3. Place and loosely (do not tighten) bolt the 2 joint plates on to the weighing modules. Then
weld the 2 new scale idler feet to the weigh idler to match the width of the mounting holes of
the modules; make sure the outside edges of the weigh idler still matches the existing idlers.
Then mount tne weigh idler to the modules
4. Adjust the weigh idler so that it aligns (same distance from edges and center) with the +3 and
-3 idlers.
5. Using a string line (heavy duty fish line or piano wire) install a minimum of 3 lines parallel
between the +3 and -3 idlers. You can use tie off one end and hang a weight on the other. A
notch (center punch) can be used to mark the +3 and -3 diler to hold the string line parallel.
For reference (see figure 2-7)
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6. Measure and adjust all seven idlers so they are equal distance apart. This distance is
important during calibration of the integrator
7. Using the shim kit supplied bring each of the idlers (+2, +1, weigh idler, -1, and -2) with in
1/32” (0.8 mm) of all the string lines. The smallest shim provided is 1/32” or 0.8 mm. When
finished remove string line. Then remove the 1/8” shim from under the +3 and -3 idler.
Double check distances between idlers then tighten and secure idlers in place. Finally
tighten and secure the joint plates.
8. Remove the “ Install Protection Bolt” shown in figure 2-8 and the belt can now be lowered
back on to the idlers.
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9. Wire the load cell cable to the junction box
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3.0 Maintenance
3.1 Check Points
Calibration should only be performed after the belt has been running for at least 30 minutes. Optimum
time is immediately after it has been used.
1. Cleaning : Keep scale area clean of rocks, dust, and material build-up.
2. Lubrication: The weigh idlers should be greased once or twice yearly. Overloading the weigh
idlers with grease may change the tare weight and place the scale out of calibration. Zero
calibration is necessary after greasing.
3. Belt Training: The belt must be trained to run true to the centerline of the idlers in the area of
the scale while running empty, as well as under loaded conditions. Where this cannot be
accomplished due to off-center loading, the loading should be modified. Where a belt does not
train while empty but does train while loaded, it will be necessary to train the belt over the scale
area at least during the calibration checks.
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4. Belt Tension: It is important that conveyor conditions remain constant at all times. Therefore,
gravity-type take-ups are recommended on all conveyors where belt scales are installed.
Conveyors, which do not have a constant tension device, will require calibration whenever the
belt tension changes and the take-up are readjusted.
5. Belt Loading: Extreme loading conditions, which cause flow rate of material above the range of
the instrument, must be avoided. Belt loading should be adjusted to stay within the instrument
range. Belt loading equal to 80 percent of range is recommended.
6. Conversely, very low flow rates, with respect to full scale range, may produce low accuracy.
Where extreme high or low flow rates, as described above, persist, the scale range should be
changed.
7. Material sticking to the belt: Material may form a film on the belt, which is carried continually
around the belt and is never discharged. This condition is often true when handling wet, fine
material. Belt scrapers may correct this condition.
8. If the film cannot be removed, the Tare will have to be adjusted. Any change in the build-up of
the film adhering to the belt will require further adjustment
9. Skirt Boards and Covers: Skirt boards should never be placed closer to the weigh idlers than are
necessary in the weighing area, they must not place any though the skirts are clear of the belt
under "no load" conditions, the boards and the belt when the conveyor is operating. Errors of
where such conditions exist. Note load cell damage may occur.
4.0 Troubleshooting
If your belt scale fails to operate correctly during or after performing set up and calibration, it is
suggested to perform the procedure again and if the problem persists follow the troubleshooting
procedures below.
Zero shifts are normally associated with the conveying system. When a Shifts zero shift occurs, the span
will shift by a like number of TPH, this then appears as a span shift.
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Common causes of zero shifts:
Span shifts are normally associated with the electronic measuring of components of the system, with
one exception, which is conveyor belt tension. A span shift is present if both points change by the same
percentage TPH.
Check for proper interconnection between components of the system. All wiring must be as specified
on the Field Wiring drawing.
• Check all wiring and connections for continuity, shorts, and grounds using an ohmmeter.
• Loose connections, poor solder joints, shorted or broken wires and unspecified grounds in
wiring will cause erratic readings and shifts in weight readings.
• Check that grounding of all cable shields is made at only the locations as specified on the Field
Wiring drawing.
Bulk Pro Systems uses precision strain gauge load cells with 2 mV/volt sensitivity. To verify its operation,
use the following procedure.
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4.5 Load Millivolt Check
5.0 Warranty
Bulk Pro Systems, LLC (BPS)warrants that all BPS equipment and systems properly installed by a
Distributor or Original Equipment Manufacturer (OEM) will operate per written specifications as
confirmed by the Distributor/OEM and accepted by BPS. All systems and components are warranted
against defects in materials and workmanship for one (1) year.
BPS warrants that the equipment sold hereunder will conform to the current written specifications
authorized by BPS. BPS warrants the equipment against faulty workmanship and defective materials. If
any equipment fails to conform to these warranties, BPS will, at its option, repair or replace such goods
returned within the warranty period subject to the following conditions:
• Upon discovery by Buyer of such nonconformity, BPS will be given prompt written notice with a
detailed explanation of the alleged deficiencies.
• Individual electronic components returned to BPS for warranty purposes must be packaged to
prevent electrostatic discharge (ESD) damage in shipment.
• Examination of such equipment by BPS confirms that the nonconformity actually exists, and was
not caused by accident, misuse, neglect, alteration, improper installation, improper repair or
improper testing; BPS shall be the sole judge of all alleged non-conformities.
• Such equipment has not been modified, altered, or changed by any person other than BPS or its
duly authorized repair agents.
• BPS will have a reasonable time to repair or replace the defective equipment. Buyer is
responsible for shipping charges both ways.
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• In no event will BPS be responsible for travel time or on-location repairs, including assembly or
disassembly of equipment, nor will BPS be liable for the cost of any repairs made by others.
THESE WARRANTIES EXCLUDE ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING WITHOUT
LIMITATION WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. NEITHER
BPS NOR DISTRIBUTOR WILL, IN ANY EVENT, BE LIABLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES.
BPS AND BUYER AGREE THAT BPS’S SOLE AND EXCLUSIVE LIABILITY HEREUNDER IS LIMITED TO REPAIR
OR REPLACEMENT OF SUCH GOODS. IN ACCEPTING THIS WARRANTY, THE BUYER WAIVES ANY AND ALL
OTHER CLAIMS TO WARRANTY.
SHOULD THE SELLER BE OTHER THAN BPS, THE BUYER AGREES TO LOOK ONLY TO THE SELLER FOR
WARRANTY CLAIMS.
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