Table of Contents
Related Manuals for Belt-Way Scales 45
Summary of Contents for Belt-Way Scales 45
- Page 1 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 2.4 Date: 7/2020 Phone: (815) 625-5573 beltwayscales.com sales@beltwayscales.com...
- Page 2 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.
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Page 3: Table Of Contents
Conveyor Belt Scale Product Manual 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. - Page 4 BELT SPEED This manual covers the following belt scale models: • Model 45 (Low capacity) • Model 100, Model 200 (Medium capacity) • Model 350, Model 500, Model 1000 (High Capacity) This manual pertains to scales operating on firmware 6.43 and above.
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Page 5: Scale Accessories
Conveyor Belt Scale Product Manual 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. -
Page 6: Integrator Specs & Scale Components
IO Option Board Part Number: BWIO ( Factory Installed) IO Option Board Kit Part Number: BWIOKIT (Field Installed) Display: 4.3" Color LCD Enclosure: Cast Aluminum Operating Temperature: -20C to 45C Required Power: 12-24 VDC, 55 Watts optional 110/240 AC power adapter Inputs: 8 Load Cells (millivolts) - Page 7 (IO option installed) 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. Page 7 of 40 Phone: (815) 625-5573 beltwayscales.com...
- Page 8 Conveyor Belt Scale Product Manual 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...
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Page 9: Mechanical Installation
▪ 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. - Page 10 Conveyor Belt Scale Product Manual 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. ▪...
- Page 11 Conveyor Belt Scale Product Manual 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. ▪...
- Page 12 Conveyor Belt Scale Product Manual 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. ▪...
- Page 13 Conveyor Belt Scale Product Manual 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 Remove and Modify Idler...
- Page 14 Conveyor Belt Scale Product Manual 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. ▪...
- Page 15 Conveyor Belt Scale Product Manual 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.
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Page 16: Wiring The Sensors / Integrator Installation
Conveyor Belt Scale Product Manual 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. - Page 17 Conveyor Belt Scale Product Manual WARNING! Always disconnect power before servicing the integrator. Make sure you LOCK OUT, TAG OUT 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.
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Page 18: Sensor Board
Conveyor Belt Scale Product Manual 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 –... -
Page 19: Terminal Board With Ac Power Supply
Conveyor Belt Scale Product Manual 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... -
Page 20: Terminal Board With Dc Power Supply
Conveyor Belt Scale Product Manual 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... -
Page 21: Integrator Board
Conveyor Belt Scale Product Manual 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 connected to a wireless 1.25 Amp... -
Page 22: Integrator Configuration
Conveyor Belt Scale Product Manual Integrator Configuration and Scale Calibration A. Integrator Navigation and Data Entry Returns to the Run Screen HOME: Displays the Main Menu MAIN MENU: Moves to previous screen only BACK: Initiate the Zero Calibration process ZERO CALIBRATION: Print ticket or save a screenshot to USB when no printer is installed PRINT TICKET:... -
Page 23: Setup Wizard
(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) - Page 24 Conveyor Belt Scale Product Manual 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:...
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Page 25: Scale Calibration
Conveyor Belt Scale Product Manual 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. -
Page 26: Test Weight 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... - Page 27 Conveyor Belt Scale Product Manual 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.
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Page 28: Material Test Calibration
Conveyor Belt Scale Product Manual 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. -
Page 29: Scale Totals
Conveyor Belt Scale Product Manual 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. - Page 30 Conveyor Belt Scale Product Manual 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.
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Page 31: Plant Connect
Conveyor Belt Scale Product Manual 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! Page 31 of 40 Phone: (815) 625-5573 beltwayscales.com sales@beltwayscales.com... -
Page 32: Administration
Conveyor Belt Scale Product Manual 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. -
Page 33: Routine Maintenance
Conveyor Belt Scale Product Manual 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. Maintenance Task Item Weighbridge Check rollers for flat spots, collapsed bearings and make Idlers... -
Page 34: Diagnostics / Troubleshooting
Conveyor Belt Scale Product Manual 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 –... - Page 35 Angle Sensor Problems / Invalid Angle Error ▪ Conveyors usually have an angle between 0 and 25 degrees. ▪ If the angle shows 45 degrees then most likely there is no angle sensor installed. ▪ Compare the angle reading to an external angle finder. ▪...
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Page 36: Message Icons / Error Messages
Conveyor Belt Scale Product Manual Message Line 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. -
Page 37: Calibration Logs
Conveyor Belt Scale Product Manual 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... - Page 38 Conveyor Belt Scale Product Manual 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...
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Page 39: Product Warranty
Product Warranty Belt-Way Scales, Inc. ("Belt-Way"), warrants its products only on the terms contained herein. No one has the right or authority to assume or create any obligation or responsibility, express or implied, on behalf of or in the name of Belt- Way Scales, Inc., or to bind Belt-Way Scales, Inc., in any manner whatsoever. - Page 40 Conveyor Belt Scale Product Manual Belt-Way Scales, Inc. 1 Beltway Rd. Rock Falls, IL 61071 USA Phone: (815) 625-5573 sales@beltwayscales.com www.beltwayscales.com Page 40 of 40 Phone: (815) 625-5573 beltwayscales.com sales@beltwayscales.com...
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