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Troubleshooting
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Summary of Contents for Rice Lake BCi
- Page 1 Presented By Dallas Ft Worth Austin Houston NicolScales.com 800.225.8181 Contact Us Nicol Scales & Measurement is an ISO Accredited Calibration Company that has provided calibration, repair and sales of all types of weighing and measurement products since 1931.
- Page 2 In-Motion Belt Scale System Version 2 Installation & Operation Manual PN 94805...
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Page 4: Table Of Contents
Course descriptions and dates can be viewed at www.ricelake.com/training or obtained by calling 715-234-9171 and asking for the training department. @ Rice Lake Weighing Systems. All rights reserved. Printed in the United States of America. Version 2 Rice Lake Weighing Systems is an ISO 9001 registered company. - Page 5 4.41 Load Cell Alarm Bit ............. 41 Rice Lake continually offers web-based video training on a growing selection of product-related topics at no cost.
- Page 6 4.42 Totalizer Pulse Bit ............. . 42 4.43 Fill Output Bit .
- Page 7 BCi Integrator Installation Manual...
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Page 8: Introduction
Do not operate or work on this equipment unless you have read and understand the instructions and warnings in the Installation, Operation and Service Manuals. Failure to follow the instructions or heed the warnings could result in injury or death. Contact any Rice Lake Weighing Systems dealer for replacement manuals. Proper care is your responsibility. -
Page 9: Overview
Belt Conveyor Scale System Components The main components of a basic belt conveyor scale include: • Scale carriage • Load cells • Belt travel pickup speed sensor (not shown) • Electronic integrator (BCi) Electronic Integrator Load Cells Scale Carriage Figure 1-1. Component Parts of the Integrator Belt Conveyor Scale System... -
Page 10: Scale Carriage
1.3.1 Scale Carriage The scale carriage is mounted to a conveyor structure and transmits the forces resulting from the belt load and directs those forces to the load sensor(s). The following picture and table illustrate the component parts shipped with the scale carriage. Figure 1-2. -
Page 11: Load Cells
There are four strain gauge load cells located on the corners of the weigh idler. These sensors support the weight of the conveyor belt and the material moving along on the belt. The weight signals from the load cells are combined and processed by the integrator. Figure 1-3. Load Cell Location on Scale Carriage BCi Integrator Installation Manual... -
Page 12: Belt Travel Speed Wheel - Optional
1.3.3 Belt Travel Speed Wheel - Optional The belt travel speed wheel is located near the weigh frame. Positive contact must be maintained between the roll and the belt for proper operation. The speed sensor should never come in contact with material that is being conveyed along the belt. -
Page 13: Electronic Integrator
Use this softkey to enter the Supervisor Mode. If there is no passcode configured the integrator will enter into the Setup Mode. If a passcode is configured, the operator will need to enter the passcode before the integrator will switch to the Supervisor Mode. To configure a passcode, see the Supervisor’s Parameters. BCi Integrator Installation Manual... -
Page 14: Application Brief
Application Brief There are four factors used to determine a suitable belt scale application on a given conveyor. • Load cell size • Belt speed • Idler spacing • Belt splicing 1.5.1 Load Cell Size The capacity of the belt scale is rated on the maximum continuous load that can be carried across the weigh idler. The capacity of the conveyor should be known prior to determining the components of the scale system. -
Page 15: Idler Spacing
Belt splices also have a contributing factor in limiting the belt scale’s capacity. Mechanical belt splices can shock load and damage load cells on high speed conveyors. Vulcanized splices are preferred for proper scale operation. Figure 1-8. Mechanical Belt Splicing Example BCi Integrator Installation Manual... -
Page 16: Selecting A Mounting Location
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. -
Page 17: Convex Curves
30’ or 8 idler spaces, whichever is greater Tripper or concave curve 40’ from the first idler affected by the curve Convex curve or head pulley 20’ or 5 idler spaces Table 1-3. Distance Points from Conveyor to Scale Carriage BCi Integrator Installation Manual... -
Page 18: Speed Sensor Or Magnetic Shaft Encoder Mounting Location - (Optional Items)
1.6.8 Speed Sensor or Magnetic Shaft Encoder Mounting Location - (Optional items) The optional speed sensor location is not as critical as scale carriage location, however improper installation of the speed sensor will significantly affect the performance of the scale system. The speed sensor must give an accurate representation of the speed of the material and travel of the belt. -
Page 19: Troughing Angle
• Applications where plant personnel are unwilling or unable to perform routine conveyor maintenance. • Conveyors with more than 2-ply belting • Conveyors that are installed outdoors, but are not equipped with a cover over the carry belt. BCi Integrator Installation Manual... -
Page 20: Handbook 44 Requirements For Belt Scales
Handbook 44 Requirements for Belt Scales The following is a listing of various Handbook 44 requirements for belt scales. • Minimum divisions shall not be greater than 0.1 of the minimum totalized load. • On test, the recorder must show the initial totalizer reading; the final totalizer reading, the unit of measure and the quantity delivered along with the time and date. -
Page 21: Integrator Hardware Installation
The shipping carton should contain the scale carriage, the integrator, this manual and a parts kit. If any parts were damaged in shipment, notify Rice Lake Weighing Systems and the shipper immediately. To ensure that all products received from the manufacturer are in good shape upon arrival, it is recommended to fully inspect all contents and properly complete the bill of lading. - Page 22 Figure 2-2. Slide the Uni-Strut Center Bars onto the End Plate Assembly 2. Using a 3/4" wrench, tighten the bolts on each end of the uni-strut center bars on both ends of the end plate assembly. Figure 2-3. Tighten Bolts Integrator Hardware Installation...
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Page 23: Junction Box Installation
1. Set the junction box onto the uni-strut center bar and attach to the bar using the enclosed screws. 2. Attach the ground lug (shown below). Figure 2-5. Attach the Ground Lug onto the Junction Box BCi Integrator Installation Manual... -
Page 24: Wiring The Junction Box
2.3.1 Wiring the Junction Box The four channel TuffSeal JB4SS has been designed to connect and trim up to four load cells per board. However, it is possible to use this junction box with other combinations. Run the load cell cables from the load cells through the channels on the scale carriage over to the junction box. Run load cell cable through... -
Page 25: Trimming Procedure
Figure 2-9 for the location of jumpers JP1, JP2, JP3 and JP4. Note that you will need to remove jumpers for any unused cells. 3. Set all potentiometers fully clockwise to give maximum signal output from each cell (see below for location of potentiometers). Figure 2-9. Potentiometer Location BCi Integrator Installation Manual... -
Page 26: Attaching The Idlers To The Scale Carriage
Refer to the TuffSeal Installation manual (PN 91909) for additional information on the junction box. Once all of the cables are attached and the scale carriage is completely assembled, take the uni-strut closure strip and seal up the middle bars. Insert Uni- strut closure strip into uni-... - Page 27 The 3rd idler before and the 3rd idler after the scale should be shimmed 1/4" higher than the adjacent idlers. These will be the first and last idlers in the scale area. BCi Integrator Installation Manual...
- Page 28 The first and last scale idlers should be shimmed level across the conveyor. If the idlers adjacent to the scale area are greater than 1/4" lower than the scale area, the adjacent idlers should be shimmed to ramp up to the scale area in 1/4"...
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Page 29: Speed Sensor Installation
The installation of the speed sensor will vary based upon accessibility to the tail roller, belt speed and distance from the electronic integrator (BCi). There are a variety of scenarios that can be used to install the speed sensor depending on accessibility. The following steps go through various types of speed sensor installations but individual applications vary for each job. -
Page 30: Scale Carriage Replacement Parts
Scale Carriage Replacement Parts Table 2-2 below lists replacement parts for the integrator In-Motion Belt Scale System. Item 500 Lb 1000 Lb Part Number Description (quantity) Capacity Capacity - - - - - Unistrut spacer bar (2) Consult Factory Consult Factory - - - - - Unistrut closure strip (2) Consult Factory Consult Factory... - Page 31 Figure 2-18. Belt Scale Assembly, View B Figure 2-19. Belt Scale Assembly, View C Figure 2-20. Belt Scale Assembly, View D BCi Integrator Installation Manual...
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Page 32: Integrator Hardware Setup
Integrator Hardware Setup Enclosure Disassembly The integrator enclosure must be opened to install option cards and to connect cables for installed option cards. The integrator has no on/off switch. Before opening the unit, ensure the power cord is disconnected from WARNING the power outlet. -
Page 33: Load Cells
For 6-wire load cell connections to connector J1, remove jumpers JP1 and JP2. • For 6-wire load cell connections to connector J2 (dual A/D cards), remove jumpers JP3 and JP4. Table 3-1. A/D Card Pin Assignments BCi Integrator Installation Manual... -
Page 34: Pulse Input Card
3.2.3 Pulse Input Card Use the following procedure to install pulse input cards in the BCi integrator: 1. Disconnect the integrator from power source. WARNING Disconnect power before removing integrator backplate. 2. Place integrator face-down on an anti-static work mat. Remove screws that hold the backplate to the enclosure body. -
Page 35: Serial Communications
RS-485 communications. Both ports on the expansion card can support RS-232 or 20mA connections. Figure 3-5. Interface Board Connections DB-9 Pin Signal Table 3-4. DB-9 Connector Pin Assignments BCi Integrator Installation Manual... - Page 36 OPTION CARD OPTION CARD CONNECTOR CONNECTOR BATTERY SLOT 2 SLOT 1 POWER EXPANSION BUS SUPPLY +6VDC PIEZO BUZZER OPTION OPTION CARD LOCATIONS REMOTE INTERFACE SETUP BOARD PORT 2 SWITCH CONNECTION BOOT PORT 3 PORT 4 MODE DIGITAL I/O PORT 1 Figure 3-6.
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Page 37: Digital I/O
Once cabling is complete, position the backplate over the enclosure and reinstall the backplate screws. Use the torque pattern shown below to prevent distorting the backplate gasket. Torque screws to 15 in-lb (1.7 N-m). Figure 3-7. Integrator Enclosure Backplate BCi Integrator Installation Manual... -
Page 38: Cpu Board Removal
CPU Board Removal If you must remove the CPU board, use the following procedure: 1. Disconnect power to the integrator. Remove backplate as described on page 25. 2. Unplug connectors J9, J10, and J11 (serial communications), J2 (digital I/O), P1 (power supply), and connectors to any installed option cards. -
Page 39: Parts Kit Contents
Cord grips, PG9 (6) 15628 Cord grips, 1/2 NPT (2) 67795 Power cord assembly, 115 VAC and 230 VAC North American units (1) 69998 Power cord assembly, 230 VAC European units (1) Table 3-7. Replacement Parts BCi Integrator Installation Manual... - Page 40 Item Part No. Description (Quantity) 68425 Fuse access coverplate (1) 68621 Fuse access coverplate gasket (1) 69898 Nylon spacers (2) 58248 Lock nuts, 6-32NC nylon (2) 14822 Machine screws, 4-40NC x 1/4 (11) 68662 Ribbon cable to interface board (1) 82856 Power supply bracket (1) 16861...
- Page 41 GROUND WIRE (34) FROM CHASSIS GROUND Figure 3-9. 920i Deep Enclosure Model Assembly BCi Integrator Installation Manual...
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Page 42: Supervisor Mode Parameters
Supervisor Mode Parameters Various parameters can be set by using the softkey from the main menu. Supervisor Mode All parameters must be entered prior to calibrating the unit. 11/23/2011 08:13AM SCALE #1 Rate tn/hr 293467.2 43.21 Speed ft/min Load 47.5 lb/ft Supervisor Mode Softkey... -
Page 43: Admin. Passcode (Numeric)
Exit=> Time/Date Totalizer Calibration Calibration Figure 4-4. Main Supervisor Screen Use the arrows on the integrator to scroll through the menu items. The available parameters are down displayed by pressing the key on the integrator. enter BCi Integrator Installation Manual... -
Page 44: Scale Capacity
• Total load cell build The other parameters that are commonly set are the filtering values but they can be done after setup and calibration. The angle of inclination is not required with Rice Lake Weighing Systems frames due to laterally opposed shearbeams. -
Page 45: Fixed Speed
1, 2, 0.1, 0.01, etc. To change the load count by value, press the key on the integrator and a prompt appears. Using the numeric keypad on the enter load count by integrator, enter the value and press again to save that value. enter BCi Integrator Installation Manual... -
Page 46: Auto Zero Tracking Range (%)
4.16 Auto Zero Tracking Range (%) This is the percentage of full scale that zero tracking is attempted. If the rate is larger than this value, the zero tracking is turned off. 4.17 Auto Zero Tracking Deviation (%) This is the percentage of full scale allowed to zero track off. Example: If set to 2% of full scale and the capacity is 100, 2 would be the maximum rate that would be automatically zeroed off. -
Page 47: Idler Spacing
The default value for this parameter is: 600. 4.31 Belt Angle This is the angle of the conveyor measured in degrees. this should be used when using the BCi integrator with weigh frames containing only one or two load cells. -
Page 48: Pulses Per Unit Measure
4.32 Pulses Per Unit Measure This parameter is a result of how many pulses the integrator needs to count for the belt to move just one unit of measure. The integrator calculates this during a speed calibration. The default value for this parameter is: 6.0. 4.33 Test Duration This parameter is the value used for a timed calibration. -
Page 49: Totalizer Pulse Bit
<MTU> Master totalizer units <NL> New line <TI> Time <DA> Date <TD> Time and date <DT> Date and time <CR> ASCII carriage return <LF> ASCII line feed <FF> ASCII form feed Table 4-1. Available Print Tokens BCi Integrator Installation Manual... -
Page 50: Stream Output Port
4.47 Stream Output Port This parameter defines which serial port the stream format will be sent from. The integrator will only stream if this is set to a valid port with a value greater than zero. The default value for this parameter is: 0. 4.48 Stream Format This parameter defines the format of the stream (or continuous) serial output. -
Page 51: Master Totalizer Reset
Those commands are shown in Table 4-3 Command Function F#1=MT Master total F#1=BT Batch total F#1=MR Master reset F#1=BR Batch total reset F#1=TPH Tons per hour F#1=UID Integrator ID F#1=RT Set totalizer Table 4-3. Key Press Serial Commands BCi Integrator Installation Manual... -
Page 52: Calibration
There are two components of the Belt Scale Conveyor system that need to be calibrated for the system to work. Those component parts include: • Speed sensor • Integrator (BCi) The speed sensor calibration must be done prior to the integrator calibration. Speed Sensor Calibration A belt conveyor scale shall be equipped with a belt speed or travel sensor that will accurately sense the belt speed or travel whether the belt is empty or loaded. -
Page 53: Integrator Calibration
All three calibration methods are described in the following sections as are their softkey locations. 11/23/2011 08:13AM Test Time 13.50 Test Accumulator 117.4 Old Span Error % 3574 Span Error % 25.00 Progress Auto Cal Material Zero Cal Exit=> Figure 5-3. Calibration Method Softkeys BCi Integrator Installation Manual... -
Page 54: Auto Cal Mode
Zero Cal Calibration Mode By selecting this mode will calibrate the integrator based on a zero test. A zero calibration is based on the number of belt revolutions as established during the belt speed sensor calibration. Use the following steps to perform a Zero Cal calibration. 1. -
Page 55: Material Calibration Mode
Test Time 13.50 Test Accumulator 147.4 Old Span Error % 3274 Span Error % 25.00 Accept New Span Figure 5-7. Accept New Span The process can be aborted at any time by pressing the softkey. Exit => BCi Integrator Installation Manual... -
Page 56: Complete System Calibration Test Used In Conjunction With Integrator Calibration
Complete System Calibration Test Used In Conjunction With Integrator Calibration There are two types of tests that are also used in conjunction with calibrating the complete system. They are: • Material testing • Maintenance testing Material testing is used only with the material calibration and the simulated load testing is used only with the Auto calibration. -
Page 57: Simulated Testing
5. The system is now ready for normal operation. If a convenient material test method is available, the simulated test need not be performed. The material test is then performed on a weekly basis. Test results should be kept for the applicable regulatory agency. BCi Integrator Installation Manual... -
Page 58: Run Sequence
Run Sequence Once configuration of the supervisor’s parameters are all entered, the integrator should be ready for daily operation. The following sub-sections give an overview of how to use the integrator during a normal work shift. The main screen is shown below. 11/23/2011 08:13AM SCALE #1... -
Page 59: Diagnostics
Stop Fill operator the softkey. Re-Start Abort Pressing will resume the fill process. Re-Start Pressing will halt the filling process and returns the integrator to normal operation. Abort BCi Integrator Installation Manual... -
Page 60: Handbook 44 Requirements For Belt-Conveyor Scales
Handbook 44 Requirements for Belt-Conveyor Scales A belt conveyor scale system must be tested after it is installed according to Handbook 44. It must be tested on the conveyor system with which is to be used and under such environmental conditions as may normally be expected. Each test shall be conducted with test loads no less than the minimum test load. -
Page 61: Maintenance
Maintenance The maintenance information in this manual is designed to cover all aspects of maintaining and troubleshooting the integrator in-motion belt scale. Should you encounter a problem that requires technical assistance, phone Rice Lake Weighing Systems’ service department at 1-800-472-6703. - Page 62 Belt Scale Maintenance Checklist Item Daily Weekly Monthly Quarterly Annually Description Scale area - debris Clean scale area. Determine cause of debris and take steps to remedy Zero calibration Perform zero calibration procedure. If change is greater than .25%, identify cause and correct. Record results. Condition of idler Inspect idlers for wear and damage.
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Page 63: Belt Scale Troubleshooting Tips
• 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 the grounding of all cable shields is made at only the locations as specified in the installation drawings. BCi Integrator Installation Manual... -
Page 64: Integrator Troubleshooting Tips
Integrator Troubleshooting Tips The following table lists general troubleshooting tips for various hardware and software error conditions regarding the integrator in-motion belt scale. Symptom Remedy integrator does not power up Possible blown fuse or bad power supply. Check fuses and replace if necessary. If fuses are good, check all voltages on CPU board. -
Page 65: Appendix
AB Remote I/O Remote Display Rate: Panel Mount Wall Mount RS-232 Device Net Load Out Control Explain details _______________________ Ethernet TCP/IP Profibus-DP _______________________________________________________________ Ethernet IP Printer Model _____________________________________ 0736 Rev. 5 6/10 Page 1 of 2 BCi Integrator Installation Manual... - Page 66 Belt Scale Questionnaire 0736 Rev. 5 6/10 Page 2 of 2 Appendix...
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Page 67: Integrator Permanent Field Record
Integrator Permanent Field Record Keep this record in a handy place in the event of having to do maintanence on the BCi. Conveyor Number _______________________________________________ Date _______________________________________________ Scale Capacity (Tons per Hour) _______________________________________________ Load Cell mv/v (Average) _______________________________________________ Total Load Cell Build = #4 x #7... -
Page 68: Integrator Specifications
Integrator Specifications Power Keyboard 27-key membrane panel, PS/2 port for external Line Voltages 115 or 230 VAC keyboard connection Frequency 50 or 60 Hz Environmental Power Consumption Operating Temperature 115 VAC 400 mA (46 W) Legal –10 to +40°C (14 to 104°F) 230 VAC 250 mA (53 W) Industrial... - Page 69 BCi Integrator Installation Manual...
- Page 71 Specifications subject to change without notice. Rice Lake Weighing Systems is an ISO 9001 registered company. 230 W. Coleman St. • Rice Lake, WI 54868 • USA U.S. 800-472-6703 • Canada/Mexico 800-321-6703 • International 715-234-9171 • Europe +31 (0)26 472 1319 www.ricelake.com www.ricelake.mx www.ricelake.eu www.ricelake.co.in...