Table of Contents
Advertisement
OPERATION MANUAL
Conveyor Scales
Model: WY10, WY10HD, WY15, WY20, WY25,
HY15, HY25
Weight Processor
Tecweigh 20 (WP20) Weight Processor
Firmware Version 8.XX
MP400 main PCB
Tecweigh 20
(WP20)
Signal Conditioner
Model: SC300 (WY15, WY25, HY15, HY25)
SC400 (WY10, WY10HD & WY20)
WY15
WY10
Tecnetics Industries Inc.
Manufacturer of
Tecweigh Products
1201 N Birch Lake Boulevard
Saint Paul, MN 55110
HY15
Ph (651) 777-4780
Fax (651) 777-5582
www.tecweigh.com
P/N 20984330 [Last Update, February 16, 2012]
Advertisement
Table of Contents
Troubleshooting
Summary of Contents for Tecnetics Industries Tecweigh WY10
- Page 1 Tecweigh 20 (WP20) Signal Conditioner Model: SC300 (WY15, WY25, HY15, HY25) SC400 (WY10, WY10HD & WY20) WY15 WY10 Tecnetics Industries Inc. Manufacturer of Tecweigh Products 1201 N Birch Lake Boulevard Saint Paul, MN 55110 HY15 Ph (651) 777-4780 Fax (651) 777-5582 www.tecweigh.com...
- Page 2 - 1 -...
-
Page 3: Table Of Contents
1.06 Scale over-loading 1.07 Environment 1.08 Printed Circuit Board (PCB) Precautions 1.09 Welding precautions CHAPTER 2 - Introduction 2.00 Tecnetics Industries vs. Tecweigh 2.01 Contacting Tecnetics Industries Inc. 2.02 Wording conventions in this manual 2.03 Basic operation 2.04 Conveyor Scales (WY10/WY10HD/WY15/WY20/WY25) 2.05 Modular Conveyor Scales (H15 &... - Page 4 4.15 Interposing Relay, External 120 vac power 4.16 Interposing Relay, Internal 30 vdc power CHAPTER 5 - WP20 User Interface 5.00 Display 5.01 Windows 5.02 Calibration Pushbutton Keys 5.03 Totalizing Pushbutton Keys 5.04 Programming Pushbutton Keys CHAPTER 6 - WP20 Parameters 6.01 The Parameter Table and Settings 6.02 Parameter definitions...
-
Page 5: Chapter 1 - Safety
CHAPTER 1 - SAFETY This symbol is intended to alert the user of the presence of uninsulated dangerous voltage within the product’s enclosure that may be of sufficient magnitude to constitute a risk of electric shock. This symbol is intended to alert the user to the presence of important operating and maintenance (servicing) instructions in the literature accompanying the product. -
Page 6: Hazardous Environments
1.05 Hazardous Environments WARNING! The standard scale is not “explosion-proof”. The standard scale must not be operated in an environment where conditions exist that could cause an explosion of dust or gas. Specially built explosion proof scales, signal conditioner enclosures, and speed sensors are available from Tecnetics for hazardous environments. -
Page 7: Chapter 2 - Introduction
CHAPTER 2 - INTRODUCTION Tecnetics Industries, Inc. and Tecweigh. Tecnetics Industries, Inc., is the legal name for Tecnetics. Tecweigh is the product brand name. They are frequently used interchangeably in this manual and within the company. 2.01 Contacting Tecnetics (Tecweigh) Industries, Inc. -
Page 8: Basic Operation
2.03 Basic Operation A conveyor scale's primary function is to continuously measure the material weight on the belt at any particular instant in time and then display the material flow RATE and TOTAL weight. The main components of the scale system are the scale carriage, the Tecweigh 20 Weight Processor (WP20), speed sensor, signal conditioner (SC), load cells or LVDT sensors, calibration weights with lifter arm(s), and the weigh idler. -
Page 9: Conveyor Scales (Wy10/Wy10Hd/Wy15/Wy20/Wy25)
2.04 Conveyor Scales (WY10/WY10HD/WY15/WY20/WY25) A Tecweigh conveyor scale typically consists of a carriage, load cell(s) (or LVDT(s)) for sensing weight, a belt speed sensor, a signal conditioner, and a weight processor (FC20 or WP20). Most are also equipped with self storing calibration weight(s) and a mechanism for easy manipulation. -
Page 10: I/O Quick Reference Guide
2.09 I/O Quick Reference Guide - 9 -... -
Page 11: Chapter 3 - Scale Installation
CHAPTER 3 – SCALE INSTALLATION 3.01 Proper Installation, WY & HY Belt Scale Models Proper scale installation is critical for high accuracy and repeatability. A properly mounted scale should be located on a rigid, horizontal conveyor. If the conveyor is at an incline, assure it is not so steep that material rolls back on itself causing it to be weighed twice. -
Page 12: Idler Preparation, Wy Models
3.02 Idler Preparation, WY Models After finding a suitable location for the scale, reduce the conveyor belt tension. Raise the belt so it is supported at least one foot above the idler where the scale will be located and also one foot above the three idlers before and after the scale. -
Page 13: Scale Mounting, Wy Models
3.03 Scale Mounting, WY Models Place the scale carriage with the modified idler on the conveyor stringers. Center and align the scale between the stringers and mark the location of the mounting holes. Alternatively, you can use the dimension drawings in Section 10 for marking hole locations, but using the scale as a template is preferred. -
Page 14: Speed Sensor Installation, Wy Models
IMPORTANT!!! On the WY15 and WY20 scale models, remove the two safety plates on both ends of the idler mounting bar. These plates prevent overloading of the load cells during shipment. When using a portable conveyor, use the safety plates during transportation. Refer to the diagram in section 9.06. -
Page 15: Modular Scale Description, Hy Models
3.05 Modular Scale Description, HY Models The HY15 is different from our other scales in that it a modular design. It does not have a single rigid frame that an idler can be mounted on before scale installation. Instead it is a left and right hand module that needs to be mounted on the conveyor structure and then the idler is mounted between the modules. -
Page 16: Scale Mounting, Hy Models
3.07 Scale Mounting, HY Models The HY design utilized a asymmetric design in that the left and right mounts are slightly different. One side incorporates a rigid mount that bolts directly to the load cell. The other side uses a spherical rod end bearing to allow some flex in the mounting structure while minimizing drift and inaccuracies associated weak or flexing structures. - Page 17 Mount the modules directly across from each other using a square or common reference point. The mounts should also be centered between the closest idlers on either side of the weighing idler(s). Once centered and squared tighten down the mounting bolts for the left and right modules.
-
Page 18: Speed Sensor Installation, Hy Models
4) Use elastic cords and/or weight to hold the fish line in place. 5) Measure with a shim the distance between the weigh idler and the fish line on the weigh idlers. It should be 1/16 inch gap between weigh idler and fish line. 6) If modification to the weighing idler height to attain 1/16”... -
Page 19: Tecweigh 20 (Wp20) Installation
4) Place the arm rest and spring holder in a suitable location and weld to the stringer. 5) Tighten the coupling onto the shaft stub. 6) Slide speed sensor shaft into the coupling and tighten. 7) Attach spring to speed sensor arm and spring holder. 8) Run conveyor. - Page 20 - 19 -...
-
Page 21: Chapter 4 - Wp20 System Wiring
CHAPTER 4 – SYSTEM WIRING 4.00 Wiring Precautions The following is a list of important precautions that should be observed during field wiring. - Wiring should be compliant with all applicable electrical codes. - Input power must be 100 to 240 VAC, 47-63 HZ, 60 watts. - Only apply input power after assuring all wiring is correct. - Page 22 Relay Outputs Two configurable relays provide dry contact outputs for a remote totalizer, high/low RATE alarm, high/low speed alarm, or a calibration weight lifter interlock. The relay contacts are SPST and should not be used to control more than 250 VA. When a relay is used as a totalizing pulse relay, limit the frequency of operation to 6 pulses per second for reliable operation.
-
Page 23: Load Cell Wiring (Wy15 And Wy25)
Serial ports For RS-232, two RJ-25 modular jack ports are available plus a selectable output (RS-232 or RS- 422/485) at terminals 90-93. RS-422/RS-485 is available at terminals 90-93 only. All these ports are capable of sending and receiving data and also receiving commands. Refer to Section 4.03 for a wiring diagram and Section 9 for operational information. -
Page 24: Wy15 And Wy25 Scale Wiring (Load Cells)
4.03 WY15 and WY25 Scale Wiring (load cells) - 23 -... -
Page 25: Hy15 And Hy25 Field Wiring
4.04 HY15 and HY25 Field Wiring - 24 -... -
Page 26: Wy10, Wy10Hd And Wy20 Scale Wiring (Lvdts)
4.05 WY10, WY10HD and WY20 Scale Wiring (LVDTs). - 25 -... -
Page 27: Chart Recorder & Data Logger Using The 4-20 Ma Output
4.06 Chart Recorder & Data Logger using the 4-20 ma output. - 26 -... -
Page 28: Chart Recorder & Data Logger Using The Hfr Output
4.07 Chart Recorder & Data Logger using the HFR output. - 27 -... -
Page 29: Remote Rate/Total Display
4.08 Remote Rate/Total Display. 4.09 Remote Tons Counter. - 28 -... -
Page 30: Radio Transceivers, Local Scale, Remote Processor
4.10 Radio Transceivers, Local Scale, Remote Processor. - 29 -... -
Page 31: Radio Transceivers, Local Processor, Remote Plc, Pc, Or Display
4.11 Radio Transceivers, Local Processor, Remote PLC, PC, or Remote Display. - 30 -... -
Page 32: Radio Transceivers, Local Dc Generator, Remote Processor
4.12 Radio Transceivers, Local DC Generator, Remote Processor. - 31 -... -
Page 33: Radio Transceivers, Local Dc Generator And Processor
4.13 Radio Transceivers, Local DC Generator and Processor. - 32 -... -
Page 34: Multiple Processors To Tecweigh Multi-Scale Display (Msd)
4.14 Multiple Processors to Tecweigh Multi-Scale Display (MSD). - 33 -... -
Page 35: Interposing Relay, External 120 Vac Power
4.15 Interposing Relay, External 120 vac Power. 4.16 Interposing Relay, Internal 30 vdc Power. - 34 -... -
Page 36: Chapter 5 - Wp20 User Interface
CHAPTER 5 – USER INTERFACE 5.00 Display At this point, the scale should be installed and the WP20 Weight Processor mounted and wired. Now power up the system. The display windows should light up with information. Since the WP20 has not yet been set up, disregard any error messages or incorrect values on the displays. The figure below shows the WP20 user interface front panel. -
Page 37: Calibration Pushbutton Keys
5.02 Calibration Pushbutton Keys AUTO ZERO - Initially calibrates the scale to read zero when there is no material running on the belt. An Auto Zero calibration might also need to be done after setup to compensate for material build-up, change in belt tension, or other effects that cause a non-zero rate when the belt is empty. -
Page 38: Chapter 6 - Wp20 Parameters
CHAPTER 6 – PARAMETERS 6.01 The Parameter Table and Settings The Parameter Table (Section 11.02) is a list of all the settings that are available to be applied to the specific application at hand. To enter the WP20‘s Parameter Table (Program Mode) from Run Mode, press and hold the FUNCTION key for five seconds, to return to Run Mode do the same. - Page 39 Cal Factor - The Calibration Factor accounts for physical differences between scale types. Select the appropriate value for the scale model at hand, or select 0.03 if a calibration chain will be used instead of the calibration weight supplied with the scale. WY10 WY20 WY10HD...
- Page 40 the P/P Wt parameter. The WP20 TOTAL and the stationary scale weight total will be compared and a tuning adjustment made. This test is discussed more in Chapter 7, Calibration. AZT +/- - Auto Zero Tracking or AZT compensates for material build-up or other conditions that cause the RATE to fluctuate from zero even when the belt is empty.
- Page 41 Zero Revs - When AUTO ZERO is pressed, the WP20 will zero the scale. For this Parameter enter the number of belt revolutions to be used for an Auto Zero cycle. In general, the more time (more belt revolutions) allowed for an AUTO ZERO cycle, the more accurate it will be.
- Page 42 Speed Spn - Speed Spn is used to calibrate the belt SPEED if the WP20 displayed SPEED does not equal the tested or calculated belt SPEED. Increase Speed Spn to increase the SPEED value or decrease it to decrease the SPEED value. mA Damp - Enter the damping factor for the RATE current loop output if used.
- Page 43 RLY 1 Func - Relay 1 can perform four different functions. Select the function desired. - Total Pulse Repeater, relay 1 is activated in increments of the TOTAL. HLRA - High/Low Rate Alarm, relay 1 is activated when the RATE is outside a specified range.
- Page 44 HLRA - High/Low Rate Alarm, relay 2 is activated when the RATE is outside a specified range. HLSA - High/Low Speed Alarm, relay 2 is activated when the SPEED is outside a specified range. SPAN - Auto Span output, relay 2 is activated during an Auto Span to lower or raise the calibration weight.
- Page 45 Station ID - When using the WP20’s serial communication features with multiple scales, each scale must have a unique Station ID (or address). Station ID’s are designated A through P. Select a different station ID from A to P for each scale. Normally the WP20 is Station A. Parity - When using the WP20’s serial communication features, select the same parity as the remotely connected communications device.
- Page 46 Lock Reset - Select YES to protect the RESET key from unauthorized use. Lock Code - A Lock Code can be entered to prevent unauthorized personnel from entering any of the Parameter Menus. This feature, combined with the key locks above, give a high level of security to the WP20.
- Page 47 Params – The four following Parameter selections allow the user’s Parameter Table to be saved to and retrieved from memory, thereby allowing its restoration if it is inadvertently erased or corrupted due to battery failure or an electrical spike. It also allows the retrieval of the default Parameter Table when necessary.
-
Page 48: Chapter 7 - Calibration
CHAPTER 7 – CALIBRATION 7.01 Apply Power to the System Assuming that all the entered Parameters are correct and all the equipment is installed properly, the scale must now be calibrated. Without calibration, the scale will only approximate the RATE. First, however, on scales with LVDT(s) (Linear Voltage Differential Transformer), a procedure needs to be performed to verify that the LVDTs are in alignment. -
Page 49: Scale Calibration
The LVDTs are aligned one at a time. The goal is to attain 2.50 +/- 0.02 VDC across the test points for each LVDT. First, set SW3 and SW4 to the positions shown in the chart at line three, “Aligning LVDT “A” Only”. Next, loosen the clamp screw slightly (see the following figure) to loosen the LVDT and slide the LVDT up or down until the voltmeter reading is 2.50 +/- 0.02 VDC. -
Page 50: Auto Span
7.03.2 Auto Span AUTO SPAN is the next calibration step to perform. This procedure calibrates the scale using a known weight, so the WP20 can accurately determine the material weight as it passes over the weigh idler. With the conveyor running, press and hold the AUTO SPAN button for five seconds. -
Page 51: Material (Pre/Post) Test
Check the label on the load cells to see if they are rated at 165 pounds (75 KG). If it is found that the scale is not using 165 pound load cells, a calibration weight must be provided by the user, and it’s weight entered in Parameter 5, Cal Wt. - Page 52 displayed. Resume running material and the ZERO BELT SPEED message should disappear and the RATE units or SPEED display should reappear. Refer to Section 9.01 for the definitions of any messages that appear in the MODE window. If the system is determined to be running properly, auxiliary equipment such as a recorder can now be added.
-
Page 53: Chapter 8 - Serial Communication
CHAPTER 8 - SERIAL COMMUNICATIONS 8.01 Overview The WP20's RS232C and RS485 serial communications interfaces allow remote computers and PLC’s to access RATE, TOTAL, SPEED, and Status data, in addition to requesting basic calibration functions. The WP20 can be configured to send data either automatically (every 1/10 second fixed) or upon request (manually). -
Page 54: Manual Transmission
Data sent from the WP20 in automatic (or manual) modes will be in the following format: [Station ID] [Data Value(s)] [Carriage Return] The station ID is a single ASCII character from A to P specifying the unit address. When status is sent, it is a single ASCII character defined as follows: Positive RATE (normal operation, positive rate) Negative RATE AUTO ZERO in progress... -
Page 55: Tecweigh Protocol
8.04 Tecweigh Protocol There are two different approaches that serial users can employ for the following Remote Calibration Section (8.05). The Protocol Parameter (Section 6.02.45) permits two selections, they are TEC STD and TEC OLD. The differences between these two styles, detailed in section 8.05 below, gives the user more secure communications when set to TEC STD, and historical commands when set to TEC OLD. -
Page 56: Chapter 9 - Troubleshooting
CHAPTER 9 – TROUBLESHOOTING 9.01 Status Messages Every time the WP20 is powered up it immediately performs two functions. The first function is a scan to determine if an optional plug-in field-bus communications interface card is installed. The following message will be displayed: “SCANNING FOR BUSCARD”... - Page 57 Additional explanations: An AUTO ZERO must be done before an AUTO SPAN! If the Load Count Parameter (Section 6.02.57) does not meet the criteria given, then the load cell(s) or LVDT(s) might be damaged or there might be a problem with the signal conditioner. See Section 9.06 or 9.07 for load cell or LVDT testing and replacement.
- Page 58 Refer to Section 9.06 for load cell testing and replacement if required. Refer to Section 4.03 for wiring. WY10 and WY20 scales: For the WY10 (1 LVDT) and the WY20 (2 LVDTs) scales, this message indicates a faulty LVDT signal. Check the Load Count Parameter (Section 6.02.57) and make sure the load counts increase when the calibration weight is lowered.
- Page 59 "SELF TEST" This message always appears when power is first applied to the WP20. The WP20 performs a quick self-diagnostic routine and then the message disappears. This message might also appear if terminals are shorted or if there is excessive power use by attached auxiliary equipment. It also could appear if the WP20 power or communications wiring is too close to other devices or wiring (high voltage power wiring, high voltage motor wiring, 120 vac, etc.).
-
Page 60: Electrical Troubleshooting
9.02 Electrical troubleshooting This section provides methods of diagnosing lower level electrical problems. If this is a first time installation, verify that it is correctly wired and that all wires are secure in their terminals. For reference for the following paragraphs, the following three figures show the layout of the MP400 PCB and the SC300 and SC400 signal conditioner PCB’s. - Page 61 SC300 PCB (WY15 and WY25) SC400 PCB (WY10 and WY20) - 60 -...
- Page 62 Display failure… There are two display failure scenarios: it does not light up at all, or it does light up but is acting abnormally. If it does not light up at all, first observe the green and red Light Emitting Diodes (LED)s on the WP20 printed circuit board (PCB).
- Page 63 • Do not run power or communication wires near equipment that is a source of electrical “noise”. This includes not only 240/480 VAC motor wires, but also 120 VAC wires. • Always take static precautions when handling PCB’s (grounded wrist straps, static bags, etc.)(See Section 1.08).
-
Page 64: Operation Troubleshooting
9.03 Operation Troubleshooting If the system is electrically functional, but it does not seem to be calculating the correct RATE or TOTAL, first verify that all the Parameters are correct. Leaving Weigh Spn = 0 or Belt Len = 0 (Section 6.02.7 &... -
Page 65: Auxiliary Outputs Troubleshooting
• Rain water increases the weight after the scale weighs it and before the truck is weighed. • There are incorrect or invalid Parameter settings (Chapter 6). • There was material on the belt during calibration. • The belt speed was not calibrated properly (Section 7.03). •... - Page 66 The most common error made when setting up the Total Pulse Repeater (TPR) function (Sections 6.02.27,34) is to request that the relay open and close too frequently (Sections 6.02.29- 30,36-37). This can cause it to remain always open or always closed. The most common error made when setting up the relays for High/Low RATE or High/Low SPEED Alarms (Section 6.02.27,34) is that the selected limits (Sections 6.02.31-32,38-39) are not realistic.
-
Page 67: Load Cell Testing / Replacement
HFR failure… The High Frequency RATE (HFR) output transmits a square wave signal at a frequency equal to 10 times the calculated RATE. The HFR output requires no calibration, however it does have its own damping factor (Section 6.02.24), as does the RATE display (Section 6.02.15), and the RATE analog output (Section 6.02.19). -
Page 68: Lvdt Testing / Replacement
9.06 LVDT Testing and Replacement The following explains how to test and replace a LVDT(s). First stop the conveyor and disconnect power from the WP20. Then remove the side cover on the scale carriage to allow access to the SC400 signal conditioner (SC). Next, disconnect the green connector from the SC that the LVDT wires are connected to. -
Page 69: Scale Data Error" Trouble Shooting Procedure
LVDT Center Wiring Plunger LVDT Clamp Screw Clamp Bolts LVDT Possible Spring Pitting 9.07 “scale data error” Trouble Shooting Procedure The “scale data error” message indicates a communications problem between the Tecweigh WP20 and the scale’s signal conditioner (SC). The following is a list of processors and SC’s that apply. - Page 70 same voltages as before, but at the wire ends, using the wire colors for terminal identification. If the voltages are not correct, the cable is defective. Contact the Tecweigh Service or Parts Departments (Section 2.01) for a replacement. If the voltages are correct, reconnect the four wires (or the plug-in connector) to the SC PCB, and measure the same voltages at the SC PCB terminals.
-
Page 71: Chapter 10 - Dimensions
CHAPTER 10 – DIMENSIONS 10.01 WY10 Dimensions - 70 -... -
Page 72: Wy10Hd Dimensions
10.02 WY10-HD (Heavy Duty) Dimensions - 71 -... -
Page 73: Wy15 Dimensions
10.03 WY15 Dimensions - 72 -... -
Page 74: Wy20 Dimensions
10.04 WY20 Dimensions - 73 -... -
Page 75: Wy25 Dimensions
10.05 WY25 Dimensions - 74 -... -
Page 76: Hy15/25 Dimensions
10.06 HY15 and 25 Dimensions - 75 -... -
Page 77: Chapter 11 - Factory Setup Sheet And Parameter Table
- CHAPTER 11 – FACTORY SETUP SHEET AND PARAMETER TABLE 11.01 Factory Setup Sheet Job Number: Customer: TECWEIGH 20: Model: , S/N: _____________ Signal Conditioner: Model: , S/N: _______________ Scale Carriage: Model: , Carriage number: Date Shipped: , Set-up by: PRELIMINARY DATA: (order information) Unit of measurement: Feed Rate:... -
Page 78: Parameter Table W/Factory Settings
11.02 PARAMETER TABLE Default Factory Field Parameter Parameter Description Setting Setting Setting Simulation An artifical RATE for calibrating other equipment Sim Rate Artificial RATE shown when Simulation is ON 0000 Units Selects unit of measure Tons/Hr Cal Factor Calibration value for a given scale type 0.36 Cal Wt Calibration weight value (lbs. -
Page 79: Chapter 12 - Warranty And Service Policies
FITNESS PARTICULAR PURPOSE. Tecnetics Industries, Inc., shall not be liable for damage to equipment, property or person due to improper installation or through attempts to utilize the goods under conditions that exceed the designated capabilities. It is the user’s responsibility to determine the suitability of the equipment to his needs.
Need help?
Do you have a question about the Tecweigh WY10 and is the answer not in the manual?
Questions and answers