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MCR Technologies Weigh Shark Installation & Calibration Manual

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Installation &
Calibration
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Made in the USA
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  • Page 1 Installation & Calibration Manual Made in the USA...
  • Page 2 ® Belt Thank you for your purchase. Your Thank you for your purchase. Your Scale has been carefully designed to provide you with years of carefully designed to provide you with years of carefully designed to provide you with years of operation and accuracy.
  • Page 3 Table of Contents Page 1-5: Mechanical Installation Page 6: Idler Alignment Page 7-8: Electrical Wiring Page 9-11: Multi Scale Option Page 12-14: CALIBRATION - Auto Zero Page 15-18: CALIBRATION - Span Calibration Page 19: Material Test Page 20: Advanced Scale Calibration Page 21: Load % Page 22: Display Definitions Page 23: Real Time Performance...
  • Page 4 Page 34-35: Ticket Printer (Option) Page 36-38: Marquee Sign Page 39: Scale Network Quick Setup Page 40: Internet Access & Ethernet Diagram Example Page 41: Remote Display 3 Option & Antennae Wiring Page 42- 43: Mechanical & Integrator Data Page 50: WARRANTY Page 51: Belt Scale Maintenance Page 52-56: Trouble Shooting Guide Page 57: Installation Notes...
  • Page 5 * BELT SCALE OVERVIEW BELT SCALE OVERVIEW ADDENDUM * Mechanical Installation Mechanical Installation 1. Select an Idler at least 5 idlers up from drop zone and 5 idlers back from at least 5 idlers up from drop zone and 5 idlers back from at least 5 idlers up from drop zone and 5 idlers back from (See Illustration See Illustration Below)
  • Page 6 Weigh (Scale) Duty Idlers (RECOMMENDED) Idler misalignment amplifies the effect of belt tension and is the major contributor of errors on Electro-Mechanical (E/M) belt weighing systems. Idlers alignment can only be as good as the idler sets to be aligned. Standard idlers vary from unit to unit in;...
  • Page 7 - On application with higher belt speeds (in excess of approx. 300 feet/min) - The idler rolls are dynamically balanced - Additionally (steel rollers only) - The idler rolls are selected to meet the low breakaway torque required for weighing duty. 4.
  • Page 8 10. Go to the other side of the conveyor and repeat this process. 11. Your idler should now be supported by the load cell assemblies and should not be making contact with the conveyor frame. 12. Route your load cell cables to the side of the conveyor that you will be installing the control box.
  • Page 9 Run all three cables to the location where your control box is installed DO NOT ROUTE ALONG HIGH VOLTAGE POWER or near a VFD! Do Not Cut Cables Unless Absolutely Necessary. Weigh Shark Junction Box Soldering of Cable with Heat Shrink must be performed when extending cables.
  • Page 10 Shims are Shims are Included and MUST be used to Included and MUST be used to Raise 2 sets of Idlers directly Before & After the Scale Idler Idlers directly Before & After the Scale Idler Idlers directly Before & After the Scale Idler...
  • Page 11 Junction Box or Soldering of Wires with Heat Shrink Wrap. Wire Nuts or Butt Connectors are NEVER to be used. Please Contact Weigh Shark for Recommended Total Distance Load Cells Cables can be run. CIRCUIT BOARD DIAGRAM...
  • Page 12 CORRECT CIRCUIT BOARD & DISPLAY WIRING. Circuit Board Display...
  • Page 13 Our WEIGH SHARK integrator will support up to 8 Load Cells (4-pairs) Our Standard Weigh Shark Scale is a single idler scale. It can be converted to a Multi Idler Scale by the addition of pairs of load cell assemblies on adjacent idlers. Multi idler scales increase accuracy by weighing more material for a longer period of time.
  • Page 14 STRING LINING: -Very Important- All idlers including a minimum of one idler before and after idler scale are mounted on. Recommended String lining 2 Idlers Before & After Scale Idler! When calibrating your scale you will be asked to enter Idler Span Distance during the Span Test.
  • Page 15 Continue with Calibration Process-...
  • Page 16 CALIBRATION The calibration is divided into two categories. A) Auto Zero B) Span Calibration The display will take you step by step through both processes and instruct you on what is taking place during the process and what to do next. Auto Zero 1.
  • Page 17 5. Press the Arrow under START when your Empty Belt passes a reference point start to measure and weigh your belt. The display will show you information during this step. Watch your belt make one (1) revolution and press the arrow under END after completion of this one revolution. 6.
  • Page 18 PREVIOUS FEATURE Once you have established a Zero Number you have also established a belt length for your conveyor. By using the PRV (previous) feature on the screen, it will allow you to start a zero test without having to wait for your splice or mark on the belt.
  • Page 19 Span Calibration 1. Use the ▼ arrow key located to the right of the display to move the cursor arrow (>) down to the next line. “Span Test – Press Enter”. 2. Press ENTER 3. The screen will automatically change and instruct you to “Press START to perform a Span Calibration.
  • Page 20 10. The screen will change and ask you to “Verify the Test Weight” value. Again you can accept the default value (100 lbs.) NEXT or select EDIT and change the value. Enter the total weight of your test bar and weights. - If you are going to run a material test to calibrate your scale….
  • Page 21 When the Span Calibration process is complete the display will show you “Actual Accumulation” - “Calculated Accumulation” - "Old Span" & "New Span" and "Difference You want to correct the error by pressing APPLY. 16. Run Span Calibration process 2-3 times with test weights applied and starting @ Step 1 on page 12.
  • Page 22 TEST WEIGHT VALUE RECOMMENDATIONS Model 250 12 lbs. Model 150: lbs. Model 500 lbs. HD Scales: Call MCR Calibration Weight Set for Models 150 & 250 Installed Stored Set Includes: Mounting Bracket & 1 lb. Powder Coated Calibration Weights Weights Stored on Angle Iron Supplied by Customer Bar &...
  • Page 23 Zero Cutoff The Zero Cutoff (ZC) is designed to keep the Rate display at 0.00 TPH when the belt is running empty. The ZC value controls when the accumulator is turned ON and OFF. When the Load Cell AD is below the ZC value the accumulator is OFF.
  • Page 24 Zero Cutoff Settings The following settings affect the Zero Cutoff function Setting Name Menu Description Zero Cutoff CALIB This is the primary setting. When the Load Cell AD is above the Zero Cutoff the accumulator will be ON. Zero Cutoff (+/-) Setup ->...
  • Page 25 Rate Display Filter The Rate Display Filter allows the display of the Rate number on the main View screen to be filtered so that it has slower transitions and easier to read. The filter has various settings that control how much smoothing there is and when the filter resets to allow quick transitions to be seen when the rate changes quickly.
  • Page 26 D dZ/ > d^d • t ▲ ▼ ^W E EdZ ^W E ^W E < ^W E y K ^W E ^W E / / ^W E ^W E ^W E ^W E /d ▲ ◄ ▲ WW>z s/t...
  • Page 27 …”‡ƒ•‹‰ Ž‹˜‡ Ž‘ƒ† •‹‰ƒŽ ‹ Ž‹‰Š– Ž‘ƒ† ƒ’’Ž‹…ƒ–‹‘• > DWdz > >K  >K  >K  & > ' d ^ EdZ EdZ /d DWdz > DWdz > WW>z ZhEE/E' DWdz K&&^d EdZ /d WW>z t ZK d^d D ^W E d^d  ^W E d^d >K ...
  • Page 28 The default screen (View) shows your Load %. It is important that you have a reasonable load on the Weigh Shark scale to ensure the best opportunity for accuracy. Ideally we would like to see about 75% Load when you are running your normal rate.
  • Page 30 Weigh Shark ® Version 1.3.0 May 21, 2019 by Steven Keller...

  • Page 31: Table Of Contents

    Input Registers ......................... 4-1 Output Registers ........................4-1 Input and Holding Registers ..................... 4-2 Special Functions..........................5-1 Performing an Zero Calibration ....................5-1 Current Loop Output ......................... 5-1 Clearing Totals ......................... 5-2 Weigh Shark Modbus Interface 1.3.0 Table of Contents...

  • Page 32: Technical Description

    The Weigh Shark Modbus Slave interface allows a PLC, Operator Interface, PC or other Modbus Master device to access scale data over a RS-485 or Ethernet network. The Weigh Shark scale provides the Modbus Slave interface thru the RS-485 port (Port 2) or the 10/100 Base-T Ethernet network.

  • Page 33: Port Setup

    The RS-485 hardware port is a 3 pin terminal located at the top left side of the main circuit board. If the network cable is going to be run long distances it is recommended that it be isolated; contact factory for more details. Figure 1 Port Setup Weigh Shark Modbus Interface 1.3.0...

  • Page 34: Rs-485 Port Termination Resistor

    Locate the two jumpers (JP1) below and to the right of the 3 pin RS-485 terminal. Figure 2 - RS-485 Termination Jumpers ON Remove the 2 jumpers and place them on only 1 pin each for storage. Figure 3 - RS-485 Termination Jumpers OFF Port Setup Weigh Shark Modbus Interface 1.3.0...

  • Page 35: Ethernet Configuration

    If an error is made during the edit process press Default to return the IP address back to the factory default of 192.168.000.100. Pressing EXIT during the edit process will exit the screen without making changes. Repeat the process for setting the network mask, gateway and name server. Port Setup Weigh Shark Modbus Interface 1.3.0...

  • Page 36: Ethernet Hardware

    3.2.2 Ethernet Hardware The Weigh Shark Remote Display accepts standard RJ-12 10/100 Base-T Ethernet connection. The network port is located to the right of the 24Vdc power terminals. Figure 5 shows the empty port and the port with a network cable plugged in.

  • Page 37: Modbus Registers

    Print Total 3 Ticket 93:11 Print Total 4 Ticket 93:12 Truck Load Out Clear 93:13 Truck Load Out Start 93:14 Truck Load Out Stop 93:15 Clear Truck Total 94:0 Print Truck Ticket 94:1 Modbus Registers Weigh Shark Modbus Interface 1.3.0...

  • Page 38: Input And Holding Registers

    Total 2 Accumulator in Tenth of Tons long Total 3 Accumulator in Tenth of Tons long Total 4 Accumulator in whole Tons long Run Time 1 in Seconds long Run Time 2 in Seconds Modbus Registers Weigh Shark Modbus Interface 1.3.0...
  • Page 39 Unfiltered Load Cell AD value long Filtered Load Cell AD Value long Unused long Scale weight in Hundredth of Lbs. long Set point Value for Input 1 long Set point Value for Input 2 Modbus Registers Weigh Shark Modbus Interface 1.3.0...
  • Page 40 Truck Cutoff Weight in Hundredth of Tons unsigned long Truck Minimum Load in Hundredth of Tons unsigned long Truck Maximum Load in Hundredth of Tons unsigned long Current Truck Fill Time Modbus Registers Weigh Shark Modbus Interface 1.3.0...
  • Page 41 Average Rate in hundredth of tons based on Run Time 1. unsigned int Cutoff Value unsigned Int Standard Rate in tph char Total 1 Name (16 characters) char Total 2 Name (16 characters) char Total 3 Name (16 characters) Modbus Registers Weigh Shark Modbus Interface 1.3.0...
  • Page 42 ® Weigh Shark Modbus Interface v1.3.0 char Total 4 Name (16 characters) char Scale Name (26 Characters) char Truck ID (20 characters) char Software Version (20 characters) char Hardware Version (20 characters) Modbus Registers Weigh Shark Modbus Interface 1.3.0...
  • Page 43 2 - Down Counts unsigned int 2 - Previous Down Counts unsigned long 2 - Previous Clear long 2 - DO NOT USE - Factory use only unsinged long 2- Production Time in Seconds Modbus Registers Weigh Shark Modbus Interface 1.3.0...
  • Page 44 4 - Accumulator in tons long 4 - Previous Accumulator in tons long 4 - Run Time in Seconds long 4 - Previous Run Time in Seconds unsigned int 4 - Down Counts Modbus Registers Weigh Shark Modbus Interface 1.3.0...
  • Page 45 5 - Auxiliary Timer in Seconds unsigned int 5 - Last Auxiliary Counter unsinged int 5 - Last auxiliary Timer in Seconds Day Accumulator – Resets when new day starts long 6 - Accumulator in Lbs or Kg Modbus Registers Weigh Shark Modbus Interface 1.3.0...
  • Page 46 6 - Last Production Down Counts unsigned int 6 - auxiliary Counter unsigned long 6 - auxiliary Timer in Seconds unsigned int 6 - Last Auxiliary Counter unsinged int 6 - Last auxiliary Timer in Seconds 4-10 Modbus Registers Weigh Shark Modbus Interface 1.3.0...
  • Page 47 " unsigned int " unsigned int " unsigned int Password for Calibration Changes 44810 4-11 Modbus Registers Weigh Shark Modbus Interface 1.3.0...

  • Page 48: Special Functions

    Modbus master. The current loop is a 16bit DAC. The value written to register 95 will directly output to the DAC. The Analog Output settings, Action, Averaging and Range will still affect the output. Special Functions Weigh Shark Modbus Interface 1.3.0...

  • Page 49: Clearing Totals

    Clear All Totals Clear Total 1 Clear Total 2 Clear Total 3 Clear Total 4 Clear Truck Totals c. After total is clear Register will read -1. Totals can be cleared at any time. Special Functions Weigh Shark Modbus Interface 1.3.0...
  • Page 50 Real Time Performance (RT Prfm%) Real Time Performance % is also shown on the default (View) screen. This shows you your performance RATE you are running based on the Standard Rate (your goal). The factory default setting is 350 TPH. You can change your Standard Rate to allow you to see what you are doing in relationship to your goal.
  • Page 51 TOTALS There are four (4) independent totals with their own Production screen. They can be viewed, cleared and * printed separately. * (With optional ticket printer) Daily Total: This total is displayed on the default screen. It shows your accumulating total If you wish to clear off this total, press ENTER key while the cursor is pointing to the "Daily Total".
  • Page 52 Analog Outputs (mA) You may use the standard analog output (4-20 mA) for monitoring your production to a chart recorder, PLC or any device that accepts 4-20 mA. Press arrow located under I/O to access these setup screens. Press ENTER while the cursor (>) is next to Analog Output to go to the setup screen.
  • Page 53 When you have selected your desired functions; press the arrow under APPLY or EXIT to leave without saving the changes. To Isolate Current Loop Output Remove Jumpers J1 & J2 Current Loop Examples Output current Rate (TPH) Desired output: 500tph = 20mA 10tph = 4mA Set the following: Function: Rate...
  • Page 54 Digital Inputs Press ENTER under I/O to access the Digital Inputs screen. You have 4 Inputs labeled Input 1, Input 2, Input 3 and Input 4. 1. Press the ▼ to place the cursor (>) next to Input 1. 2. Press ENTER to open the screen for entering your information. 3.
  • Page 55 Digital Outputs You have 4 Digital Outputs labeled Output 1 through Output 4. They are located on the same screen as the Inputs. You will use the ▼to move your cursor to the Output you wish. 1. Press ENTER to go to the setup screen. 2.
  • Page 56 Changing from Belt Driven to Magnetic Encoder 80 Pulse Wiring Specifications for Extended Cable ENCODER EXTENDED CABLES CONTROL BOX White/Green Blue Wire GND(Blue) Red Wire +24 vdc(Brown) Gray Wire Black Speed In (Black) NOTE: Do NOT use Pink, Green, Yellow, White or Brown wires directly from Encoder. After Installing Encoder you will need to go to Control Box: Press SETUP button Press down arrow key to Calibration Setup...
  • Page 57 Use left arrow key to move the cursor to change to your pulley diameter (inches) Use the + or - buttons to set the pulses per revolution to 80 Press APPLY Arrow down one line to Pulses per Revolution Verify you have 80 pulses If not Press ENTER and EDIT to change this number Press APPLY Changes are complete…...
  • Page 59 Automatic Angle Compensator (OPTION) An Automatic Angle Compensator option is used if you have a stacker conveyor that elevation changes or moves side to side. The Automatic Angle Compensator is bolted to your conveyor frame. It measures the angle incline changes. The scale automatically adjusts for the angle change and the scale remains in calibration.
  • Page 60 Angle Information Displayed when Properly Set Up ERROR Message Showing NOT properly set up.
  • Page 61 TICKET PRINTER A Ticket Printer may be purchased and used to record Production Data. The ticket printer comes mounted inside a NEMA 4x fiberglass enclosure with clear window and lockable latch. The ticket printer can be used to print Production Data for any of the four (4) independent totalizers of the scale.
  • Page 62 CUSTOMIZE TICKET 1. To add/edit the Scale Name and User Fields……. 2. Select SETUP Menu. 3. Press ▲ or ▼ keys to select Scale Name or Use Fields. 4. Press ENTER to edit. Press EDIT to display the cursor. 5. Use + - keys to change the character in the active field. 6.
  • Page 63 Wiring Configuration RS-232 Connect the scale indicator using the appropriate diagram Indicator Display Indicators with Active +20mA CL (+) Green Wire (RS-232) 20 mA output -20mA CL (-) 232 RXD White Wire (RS-232) 232 TXD Indicators with Passive +20mA CL (-) 20 mA output -20mA CL (+)
  • Page 64 Matko Marquee Sign w/ RS-232 Wiring 1. White wire to Position 3 in Marquee Sign (232RXD). 2. Green wire to Position 2 in Marquee Sign (Ground). 3. Drain (bare) & Green wire to Ground of RS-232 connector inside. 4. White wire to TX of connector inside of Control Box. 5.
  • Page 65 • Connect 110/220 VAC, 12 VDC or 24 VDC to the sign. When marquee is powered up it should display its default message. • Connect sign to RS 485 serial plug in Weigh Shark scale. Refer to Wiring Diagram included.
  • Page 68 Scale Network Setup 1. IP Address The default IP address for all scales is 192.168.000.100. This should be changed to a unique value. If this will be on an existing network then refer to the network administrator for the proper ID address for this scale.
  • Page 69 ◄ o ► • Use the keys to move the Cursor Left and Right. • Use the +/- keys to change each character. • When the value correct name is set, press the Key under Apply. The will save the value and return back to the setup menu.
  • Page 70 REMOTE DISPLAY OPTION Power Over Ethernet Radio Wiring - RD 3 Power Over Ethernet Radio Wiring - INTEGRATOR...
  • Page 71 Weigh Shark Integrator Technical Data Analog Output (1) Display Current 0/4-20mA Type Graphical Dot Matrix Resolution 16bit( 0-20mA or 4-20mA) Wide Temperature LCD Load Size 240 x 64 pixels Isolation 2500 V rms 5.0” wide x 1.34” high visible (External 24Vdc supply required)
  • Page 73 Weigh Shark Warranty MCR TECHNOLOGIES GROUP, INC. manufactures the Weigh Shark Conveyor belt Scale and the Weigh Shark SI Dry Solids Impact Flow Meter. MCR TECHNOLOGIES GROUP, INC. offers a Year Limited Warranty on parts against defective workmanship and failure. MCR TECHNOLOGIES GROUP, INC.
  • Page 79 4. If this does not work replace battery. If you leave scale ON while you replace your battery you will not lose your settings ! 5. If problem persists contact Weigh Shark Technical Support have Serial # 815-622-3181 ext. 3 Available 6.
  • Page 80 NOTES Scale Model: ____________ Control Box #:_________________ Installation Date: _________________________ Scale Designation: Conveyor Name: ____________________ Product: ____________________________ Initial Settings: (after calibration is complete) Belt Speed__________ ADC Gain:______________ Zero Reading________ Span Reading___________ Other Notes:...
  • Page 81 BELT SCALE LOCATION BELT SCALE LOCATION The scale should be installed within 50 feet of the loading point but not closer The scale should be installed within 50 feet of the loading point but not closer The scale should be installed within 50 feet of the loading point but not closer than 6m (20 ft.) or 5 idler spaces to the end of the skirt board.
  • Page 82 If installed on a conveyor with a concave curve, the scale must be installed in a f installed on a conveyor with a concave curve, the scale must be installed in a f installed on a conveyor with a concave curve, the scale must be installed in a section of the conveyor where the belt is straight (not necessarily hori section of the conveyor where the belt is straight (not necessarily horizontal) section of the conveyor where the belt is straight (not necessarily hori...
  • Page 83 BELT SCALE ALIGNMENT RECOMMENDED PRACTICES FOR CALIBRATING, TESTING, AND OPERATING BELT SCALES Calibration and simulated load test methods 1. Calibration a. Weighed Load Test 2. Simulated Load Testing a. Roller Test Chain b. Static Test Weights c. Electronic Calibration...
  • Page 84 2. Requires accumulation, transportation to static scales, and static weighing 2. Requires accumulation, transportation to static scales, and static weighing 2. Requires accumulation, transportation to static scales, and static weighing of the test load material. Chain Test Roller Test Chains Advantages 1.
  • Page 85 Test Weights Static Test Weights Advantages 1. Simulates some conveyor belt effects. 1. Simulates some conveyor belt effects. 2. Easy to apply. 3. Conveyor belt does not have to be stopped to apply weights. Conveyor belt does not have to be stopped to apply weights. 4.

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