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SMART BELT SCALE SBS INSTRUCTION MANUAL SBS.940.001-E.c
REVISION SBS.940.001-E.c
DATE 24.09.2012
IMPORTANT Any copy or reproduction, complete or partial, done without the authorization of HASLER International, or its representative is a copyright infringement. HASLER International furnishes this document without any guarantee, either implied or explicit. HASLER International reserves the rights to modify equipment, products, programs, and procedures described in this manual at any time without prior notice.
Prepared and edited by Technical Documentation HASLER International
September 24th, 2012
Table of contents : 1.
THE SBS PACKAGE .......................................................................... 2
2.
DELIVERY AND STORAGE ............................................................... 3
3.
OPERATING CONDITIONS AND DIMENSIONS ................................ 3
4.
LOAD CELL SELECTION ................................................................... 5
5.
SMART BELT SCALE ......................................................................... 6
6.
WHERE TO INSTALL THE SMART BELT SCALE ............................. 6
7.
SBS SINGLE IDLER ........................................................................... 9
8.
INSTALLATION OF SINGLE IDLER BELT SCALE ........................... 10
9.
DOUBLE OR MULTI-IDLER SBS ..................................................... 17
10. INSTALLATION OF DOUBLE OR MULTI-IDLER BELT SCALE ....... 18 11. MOUNTING INSTRUCTIONS FOR BELT SCALES WITH LOW IDLER STATIONS ............................................................................ 26 12. MOUNTING INSTRUCTIONS FOR OTHER TYPES OF WEIGHING STATIONS..................................................................... 27 13. MOUNTING INSTRUCTIONS FOR OTHER CONVEYORS ............. 28 14. SBS 3-7 ASSEMBLY ........................................................................ 30 15. SBS 2 ASSEMBLY ........................................................................... 32
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1. THE SBS PACKAGE DOCUMENTATION
SMART BELT SCALE SBS
PANEL VHRS CONTROLLER
WALL MOUNTED VHRS CONTROLLER
OR
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2. DELIVERY AND STORAGE Temperature range : -25°C to +80°C Environment : Avoid storage in chemically hostile environments Check that these components conform as specified in your order form
3. OPERATING CONDITIONS AND DIMENSIONS OPERATING CONDITIONS Temperature range
- 25°C to + 60°C
Protection class
IP 65
Belt speed
standard : 0.05 to 3 m/s
Flowrate
standard : up to 2500 t/h
Belt inclination
material should not tumble backwards, maximum acceptable slope 20°
Maximum acceptable trough angle
35°
TYPE
Idler station (SH)
Distance between girders (DG)
Belt width
Weight of mechanics SBS
Weight of Total electronics weight BFC packed
SBS 2
H L
≥ 145 mm 75 - 144 mm
390 -
500 mm
200 -
300 mm
34 kg
6,5 kg
54 kg
SBS 3
H L
≥ 145 mm 75 - 144 mm
500 -
600 mm
300 -
400 mm
38 kg
6,5 kg
58 kg
SBS 4
H L
≥ 145 mm 75 - 144 mm
600 -
800 mm
400 -
600 mm
42 kg
6,5 kg
62 kg
SBS 5
H L
≥ 145 mm 75 - 144 mm
800 - 1000 mm
600 -
800 mm
50 kg
6,5 kg
70 kg
SBS 6
H L
≥ 145 mm 75 - 144 mm
1000 - 1300 mm
800 - 1050 mm
60 kg
6,5 kg
80 kg
SBS 7
H L
≥ 145 mm 75 - 144 mm
1300 - 1600 mm
1050 - 1350 mm
70 kg
6,5 kg
90 kg
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4. LOAD CELL SELECTION a)
Definition of weighbridge (WB) The lenght of the weighbridge is the distance between the up and downstream idlers adjacent to the weighing station. material direction
WB example mono-idler
weighing station
b)
Belt speed
c)
Tare (T)
WB =
m
Belt speed =
m/s
Tare T = belt weight + idler station weight + weight of yellow supports (belt weight : convert all belt weight data into weight per linear meter i.e. weight per m2) Belt weight = belt weight per linear meter X WB / 2 =
kg/m X ——————————————————— 2
m =
+ Idler station weight including idlers
=
+ Weight of yellow supports = Tare d)
kg
= 3.5 kg ---------------------------= kg ==================
T
Material weight (M)
Flowrate : Q =
t/h Q [t/h]
Load per meter =
Material weight =
3,6 X
Load per meter X WB
X M=
=M
Load cell choosen
+
C = Material weight + Tare =
kg
2
Required SFT load cell capacity
C=M+T=
kg/m
=
= 3,6 X Belt speed [m/s]
2 e)
kg
30 kg
kg
60 kg
120 kg
300 kg
NB : For an accurate measurement : 1) the ratio M/T should not be less than 0,5 2) the ratio M/C should not be less than 0,15 3) the load variation during testing shall not exceed 15 % 4) the speed variation during testing shall not exceed 15 %
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5. SMART BELT SCALE Terminal box for the BFC electronic controller cable Cross beam, adjustable in width Load cell Idler station supports Digital speed sensor Weighing station height adjustment screws
6. WHERE TO INSTALL THE SMART BELT SCALE 1) The smart belt scale must be installed on a straight part of the conveyor. 2) To obtain accurate measurements, do not mount the weighing station in the following zones : C2
A1 A2
C1
B2 B1 B2
C
A
B
A : Loading zone : The loading zone length includes the material area (A1) + 5 times the belt length covered in 1 second at the maximum belt speed (A2). B : Transfer zone : The transfer zone is the curved zone between the horizontal and inclined belt (or vice versa). The transfer zone length includes the length of the curved zone (B1) + a safety margin (B2) corresponding to 2 of 3 idlers in straight areas of the conveyor. C : Unloading zone : The unloading zone length includes the length of the belt where the through flattens out to go around the drum (i.e. the area where the through angle is reduced) (C1) + 2 to 3 preceding idlers (C2). D : Areas subject to excessive vibrations.
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3) Influence zone
The influence zone of the weigh idler includes two idler stations upstream and downstream from the weigh idler.
Weigh idler Upstream idler stations
Downstream idler stations
influence zone of belt scale 2 stations upstream and 2 stations downstream from the weigh idler
The empty belt should rest on every idler of the idler station in the influence zone.
YES
NO
4) Weighbridge zone Make sure that the idler stations forming the weighbridge are perpendicular to the conveyor Smart Belt Scale
Weighbridge
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In order to guarantee constant alignment, check the eccentricity of the weighbridge idlers. Their radial deviation must be less than 0,2 mm
comparator
Maximum of 0.2 mm radial deviation for one rotation of the idler.
weighbridge idler
5) Conveyor rigidity In the influence zone, the conveyor frame must be rigid and have a solid foundation (no risk of sinking). If necessary, reinforce the frame. 6) Belt tension The belt scale accuracy is influenced by changes in the belt tension. Make sure that the conveyor in which the belt scale is installed has a constant belt tension device. i.e. gravity take-up or similar. 7) Speed sensor The most favourable contact zone for the speed friction wheel is shown on the drawing below. f the speed wheel does not remain in contact with the belt, weigh down the wheel arm. Use the two 10 mm holes for this purpose. Maximum weight : 1 kg
10 mm
200 mm
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7. SBS SINGLE IDLER
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8. INSTALLATION OF SINGLE IDLER BELT SCALE After having chosen a good location for installing the belt scale in accordance with the chapter 6, carry out the following installation procedure : 1) Slacken the belt 2) Select the idler station which is to be used as the weigh idler station. Measure the distance between the up and downstream idlers which will be the future weighbridge limiting idlers. The weighbridge length (WB) is usually 1.6, 2 or 2.4 m.
WB
Upstream idler
Weigh idler
material direction
Downstream idler
3) Raise the up and downstream idler station by 4 mm using shims (not supplied by Hasler International). Fasten these two idlers to the conveyor and check that they remain perpendicular and parallel to the conveyor girders (weld if necessary).
WB
material direction
4 mm
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4) Loosen the belt and use wooden wedges (about 100 mm) to prop it up as shown.
5) Remove the idler station (which will be used as weigh idler) from the conveyor.
6) If the idler station height SH is < 145 mm see chapter 11. To prevent contact between the weigh idler station and conveyor girders, modify this idler station by mill-cutting a passage (see "A") or by cutting out a section at the end (see "B").
SH
"A"
"B"
10 mm
10 mm
If not possible see chapter 12. 7) Adjust the smart belt scale to the conveyor width. 8) Fasten the speed sensor loosely to the cross beam on the opposite side of the load cell.
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9) Plan how to fasten the weigh idler to the yellow supports. a) By screws (M8) b) By clamps c) By welding If a) : for load cell of 60 kg or 120 kg drill 10 mm holes, 321 mm centered, as shown; for load cell of 300 kg capacity this distance is 399 mm. entraxe 395 mm pour cellule de pesage 300 kg.
321 mm / 399 mm
10 mm
If b) : use two clamps according to the width of the weigh idler station.
2 mm space
clamp's dimension : 30 x 6 x 1 mm
If c) : prepare for welding : earth the weigh station idler to prevent that electric current destroys the load cell. 10) Place the smart belt scale (without its weigh idler) on the conveyor girders. Center the weighing station supports exactly between the up and down stream idler stations (the axes of the three idler stations which form the weighbridge must be perpendicular to the conveyor girders). The load cell should be located downstream (as the belt travels) from the weighing idler. material direction load cell
Upstream idler station
Downstream idler station
Center the smart belt scale between the two conveyor girders. page 12/33
SBS.940.001-E.c
11) Mark the girders. Then drill four 13 mm diameter holes in the girders.
13 mm
12) Fasten the smart belt scale to the conveyor girders. 13) Now place the weigh idler station on the yellow supports. Check that it is perpendicular to the conveyor girders.
14) Fasten the smart belt scale onto the yellow supports as shown on page 12. 15) Unfasten the speed wheel. 16) Align the weighbridge. Use a ruler to check the alignment of the three idler stations forming the weighbridge. Adjust the height of the weighing station using the 8 mm Allen key on each of the four height adjustement eccentrics as shown below.
eccentric Allen key 8 mm
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17) Check the alignment of all idlers forming the trough. If necessary, adjust these by placing small wedges under their axes.
Uptstream idler station
Weigh idler station
Downstream idler station
Wedges
18) Tighten the bracket screws.
bracket screws
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19) Fasten the speed friction wheel arm. NB : place it at the center of the belt for a better efficacity.
load cell
material direction
If obstructed or on large belts, use an optional fastening arm
load cell
material direction
20) Remove the wedges used to raise the belt. 21) Tighten the belt. SBS.940.001-E.c
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9. DOUBLE OR MULTI-IDLER SBS
Several smart belt scales can be used as a multi-idlers belt scale. Place the smart belt scales into the conveyor according to the chapter 10. Only the first smart belt scale is equiped with the speed friction wheel. Connect the smart belt scales to each other using the specific cable.
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10. INSTALLATION OF DOUBLE OR MULTI-IDLER BELT SCALE The explanation below is given for a double idler SBS, it is the same for a multi-idler SBS.The idler stations are represented closer and the shims bigger than in reality for better comprehension. After having chosen an appropriate location for installing the belt scales, carry out the following procedure : 1) Slacken the belt. 2) Select the idlers stations which are to be used as the weigh idler stations. Measure the distance between the internal up and downstream idler stations. The weighbridge length (WB) is usually 2,4 m, 3 m or 3,6 m. WB material direction
external upstream idler station
internal upstream idler station
future weigh idler stations
internal downstream idler station
external downstream idler station
3) Raise the external up and downstream idler stations by 4 mm, using shims (not supplied by Hasler International). Raise the internal up and downstream idler stations (adjacent to the weigh idler stations) by 9 mm (4 + 5 mm) using wedges (not supplied by Hasler International).
4 mm shim
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4 + 5 mm shims
4 + 5 mm shims
4 mm shim
SBS.940.001-E.c
Check that these stations remain perpendicular to the conveyor girders. Fasten these four stations to the conveyor (weld if necessary).
4) Loosen the belt and use wooden wedges (about 100 mm) to prop it up as shown.
WB material direction
5) Remove the idlers stations (which are to be used as weigh idler) from the conveyor. WB
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6) Modification of the stations. If the station height SH is
145 mm see chapter 11.
To prevent contact between the weigh idler and conveyor girders, modify this idler station as per examples "A" and/or "B". If not possible see chapter 9.
SH
"A"
"B"
10 mm
10 mm
7) Adjust the smart belt scale to the conveyor width. 8) Fasten the speed sensor of the 1st station loosely to the beam opposite the load cell. Only the first station must be equipped with the speed sensor wheel. 9) Plan how to fasten the weighing station to the belt scale's yellow support. a) by screws (M 8) b) by clamps c) by welding If a)
for load cell of 60 kg or 120 kg drill 10 mm holes, 321 mm centered, as shown; for load cell of 300 kg capacity this distance is 399 mm.
321 mm / 399 mm
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10 mm
SBS.940.001-E.c
If b)
use two clamps according to the width of the weigh idler station.
2 mm space
Clamp's dimension : 30 x 6 x 1 (mm)
If c)
prepare for welding : earth the weigh station idlers to prevent that electric current destroys the load cells.
10) Place the first smart belt scale (without its weigh idler) on the conveyor girders. Center the weighing stations supports exactly at 1/3 of the up and down stream idlers stations (the axes of the four idler stations which form the weighbridge must be perpendicular to the conveyor girders ). The load cell should be located downstream (as the belt travels) from the weighing idler. material direction
Load cell
WB / 3
WB / 3
WB / 3
WB
Center the smart belt scale between the two conveyor girders. 11) Mark the girders. Then drill four 13 mm diameter holes in the girders. 13 mm
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12) Fasten the first belt scale to the conveyor girders. 13) Proceed the same for the second weighing station.
material direction
14) Now place the weigh idler stations on yellow supports, using 5 mm wedges. Check that it is perpendicular to the conveyor girders.
speed wheel friction
5 mm wedges
5 mm wedges
15) Fasten the weighing station onto the yellow supports as shown on page 12. 16) Unfasten the speed wheel.
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17) Align the weighbridge. Use a piano wire to check the alignment of the 4 x three idler station forming the weighbridge. Adjust the height of the weighing station using the 8 mm Allen key on each of the four height adjustment eccentrics as shown below on each station.
eccentric Allen key 8 mm
18) Check the alignment of the through idlers. If necessary, adjust these by placing small wedges under their axes. material direction
upstream idler station
st
1 weigh idler station
nd
2 weigh idler station
downstream idler station
upstream idler station
1st weigh idler station
2nd weigh idler station
downstream idler station
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Wedges
19) Tighten the bracket screws.
bracket screws
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20) Fasten the speed friciton wheel arm. NB : place it at the center of the belt for a better efficacity.
load cell
material direction
If obstructed or on large belts, use an optional fastening arm
load cell
material direction
21) Remove the wedges used to raise the belt. 22) Tighten the belt.
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11. MOUNTING INSTRUCTIONS FOR BELT SCALES WITH LOW IDLER STATIONS The idler station height SH is between 75 mm and 144 mm. These low idler stations must be raised by 70 mm with two supports.
supports
In order to enable a lower position of the scale in the conveyor, use the specific fastening brackets as shown below. eccentric
50 mm
Fastening bracket for low idler stations
Then position the weighing station as shown :
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12. MOUNTING INSTRUCTIONS FOR OTHER TYPES OF WEIGHING STATIONS If the outer edges of the idler station cannot be modified as described in point 8.6/10.6, as is the case in the following example, proceed as follows.
Use 5 mm wedges to raise the three idler stations forming the weighbridge as well as the two adjacent stations up and downstream from the weighbridge. A total of 5 shims as shown below.
5mm shim
5 mm + 4 mm shims
5 mm shim
5 mm + 4 mm shims
5 mm shim
Use 4 mm shims, in addition to the 5 mm shims, to raise the up and downstream idler stations adjacent to the weigh idler (not the weigh station idler, which is only raised by 5 mm).
keep free
keep free
5mm shim brackets
Be careful that no falling material obstructs the weighing station.
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13. MOUNTING INSTRUCTIONS FOR OTHER CONVEYORS The smart belt scale can be mounted in most conveyors; no special additional parts or instructions are required as long as the top of the conveyor chassis has a flat profile.
This is the case for 60 to 70 % of all commercially available conveyors. Other types of conveyor chassis are formed of tubes or have a rigit outer shell. Mount them as shown below : A. Conveyors with tube shaped chassis
Frame
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Frame
B. Conveyors with rigid outer shells
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14. SBS 3-7 ASSEMBLY ITEM NO
NO. PIECES
1
1 SBS 3-4
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DESIGNATION (E) Cross support with weighing system (SFT load cell)
SBS 5-6-7
100
4
8
M12x35 Hex-head bolt
101
4
8
M12 Spring washer
2
1
Left side support
3
1
Right side support
4
1
Idler support bracket (right)
5
1
Idler support bracket (left)
500
4
M8x20 Hex-head bolt
501
4
M8 Spring washer
6
4
Conveyor rail mounting bracket
600
8
M10x25 Hex-head bolt
601
4
M10 Flat washer
602
8
M10 Spring washer
603
8
M10 Nut
7
1
Speed pick-up mounting bracket
8
1
Speed pick-up fastening arm, remote
9
4
Eccentric levelling disk
901
0
M10 Flat washer
902
4
M10 Spring washer
903
4
M10 Nut
10
1
Speed pick-up assembly
1000
1
Shoulder bolt D12/M10x40
1001
1
M10 Spring washer
1002
1
M10 Nut
11
2
Spacer (option)
1100
4
M8x20 Hex-head bolt
1101
4
M8 Flat washer
1102
4
M8 Spring washer
1103
4
M8 Nut
12
1
Upper protection plate
1200
2
M12x20 Hex-head bolt
1201
2
M12 Spring washer
1202
2
M12 Spring washer
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15. SBS 2 ASSEMBLY
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ITEM NO
NO. PIECES
DESIGNATION (E)
1
1
Cross support with weighing system (SFT load cell)
2
1
Idler support bracket (right)
3
1
Idler support bracket (left)
300
4
M8x20 Hex-head bolt
301
4
M8 Spring washer
4
4
Conveyor rail mounting bracket
400
8
M10x25 Hex-head bolt
401
8
M10 Spring washer
402
4
M10 Flat washer
403
8
M10 Nut
5
1
Speed pick-up fastening arm, remote
6
4
Eccentric levelling disk
601
4
M10 Spring washer
602
4
M10 Nut
7
1
Speed pick-up assembly
700
1
Shoulder bolt D12/M10x40
701
1
M10 Spring washer
702
1
M10 Nut
8
1
Upper protection plate
800
2
M12x20 Hex-head bolt
801
2
M12 Spring washer
802
2
M12 Flat washer
9
2
Spacer (option)
900
4
M8x20 Hex-head bolt
901
4
M8 Spring washer
902
4
M8 Flat washer
903
4
M8 Nut
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