BELT CONVEYOR SCALE "S4a"

APPLICATIONS
The belt conveyor scale of "S" line is a microprocessor based equipment specifically designed for industrial plant applications. Typical applications may be: - Stock pile plant handling - Belt feeder flow control - Blending and batching systems

MAIN FEATURES
No modifications to the conveyor structure Weighing area spans from 1 to 4 idler stations Pulse generating speed transmitter Optoisolated RS485 serial ports Optoisolated 4-20 mA flow rate output Failure alarm hardware output Optoisolation of all digital inputs/outputs Periodic self corrections of thermal drift

LOAD RECEPTOR SPECIFICATION

Nominal capacity Combined error Zero thermal drift Span thermal drift Maximum load Max Off-center load Operating temp. Stocking temp. Protection Weight/packed volume 100 kg 0,1 % of nom. capacity 0,0025 % f.s./C 0,0025 % /C 150% of nom. capacity 10 kgm -20 +50 C -40 +80 C IP67 4 kg / 19 dm3

ELECTRONIC UNIT SPECIFICATION

Power supply Load cell supply Load cell quantity Measuring range Overload Speed input Serial outputs Digital outputs Analog output A/D converter Nonlinearity Combined error Thermal drift Auto zero range Flow rate alarm set Alarm differential Measuring period Display Key board Operating temp. Stocking temp. Connections Protection 24 V ca, +10% -15%, 50/60 Hz, 15 VA 11 V d.c., max 140 mA 4 max 3 mV/V + 5% 1 - 50 Hz RS485 PNP, max 50 mA / 40 V 0/4-20 mA, 750 ohm max 16 bit "sigma-delta" 0,005 % 0,02 % of the span selfcompensated 0-5% 0 - 100% f.s. 0 - 100 % f.s. 13 - 255 msec 9 mm LCD, 2 rows, 16 digits 8 functional keys - 20 + 50 C - 40 + 80 C Screw terminals 2,5 mm2 IP00 IP55 in metal box Ip55 in resine box

SPEED TRANSMITTER TVN1 SPECIFICATION

Power supply Nominal sensitivity Operating temp. Stocking temp. Protection 24 V d.c. 20 mA 10 mm to steel -20 +50 C -40 +80 C IP65

CELMI s.r.l. Tel +39-0245712209

Largo Brugnatelli 13/16 Fax +39-0245705836

20090 BUCCINASCO (MI) ITALY Internet: www.celmi.com

OPERATING PRINCIPLE
A conveyor scale measures the flow rate and quantity of material transported by a belt conveyor. The "S" conveyor scale uses the most updated thecniques and is made by three key parts: the belt load sensor, the speed transmitter and the electronic unit. The belt load receptor supports one or more idler stations and delivers an electrical signal proportional to belt load. The speed transmitter is installed on a free running drum of the conveyor and delivers a pulse signal proportional to the drum speed and, thus, to the belt speed. The electronic unit receives both signals and calculates flow rate and total quantity passed over the scale. Actually a modern conveyor scale have to perform other standard functions absolutely necessary such as the automatic zero and span calibration proceedures, the measurement of the speed and belt load, the self diagnostic of the operation, etc. The "S" conveyor scale performs, over all standard functions, the following unique features: Separate weight measurement of each load cell: The instrument measures the output of each load cell allowing, thus, an easy understanding of system problems such as uncorrect load distribution among the load cells. Span self-calibration: The instrument performs the weight and flow rate measurements directly on the basis of load cells and conveyor data entered and, thus, may not need field calibration depending on required accuracy and good quality of installation. Span self calibration guaranties system accuracy similar to those obtained by test weight calibration. Complete instrument handling by serial ports: All instrument setting, calibration and control operations may be performed directly by the control room supervisor through the RS485 serial port or locally, by a portable PC, through the RS232 port. Load cell and wiring failure control: The instrument continuously controls load cell operation and will alarm through the hardware output or serial port any interruption or short circuit inside a load cell or relevant wiring.

THE BELT LOAD RECEPTOR

The belt load receptor model RCN3 is a ready-tomount assembly made by a stainless steel, plasma welded load cell with necessary horizontal constraints and load cell overload control, which can directly support one idler station. The design guaranties an accurate belt load measurement independent from variations of the belt load center of gravity. The conveyor scale may include one or two belt load receptor and one or more weighed idler stations depending on flow rate, belt speed and accuracy required. Normally for belt width over 800 mm and belt loading over 50 kg/m, is necessary to install two belt load receptors on one idler station, while over 2 m/sec is necessary to measure the belt load over two idler stations. High accuracy scales (0,5%) always require two belt load receptors, while superior accuracy scales (0,25%) require the use of the model RCN4 belt load receptor, which is a complete self supporting platform scale with four load cells at the corners and four weighed idler stations.

THE SPEED TRANSMITTER

The speed transmitter model TVN1 is made by a high sensitivity proximity switch, which senses metal pieces mounted on a free running drum of the conveyor (tail or counterweight drum), thus guaranting no error measurement produced by slippage. The transmitter generates one pulse per metal piece in such a way thet the frequency of the signal is proportional to belt speed; this method guaraties zero error also in case of wide speed variations (belt feeders). The operating frequency of the "S" conveyor scale is from 1 to 50 Hz. Low speed conveyors require the installation of model TVE1 speed transmitter (encoder type) which has a shaft connection and produces 50 or more pulses per revolution depending on the requirement of the application.

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THE ELECTRONIC UNIT

HARDWARE
The hardware of the instrument is made by: The base board equipped with a load cell input multiplexer, a "sigma delta" 16 bits A/D converter for ratiometric measurement, an eight bit "RISC" microprocessor, EEPROM memory for power failure-proof data retention, optoisolated RS485 serial ports, load cell power supply with short circuit protection and an auxiliary 24 V d.c. isolated power supply for external input contacts and one analog 0/4-20 mA output. Remote indicator, 16 characters, 2 rows, LCD display plus eight key keyboard. The optoisolated input/output board with four contact inputs, 1 open collector failure alarm output, 10 open collector outputs and one analog 0/4-20 mA output.

THE MAN / INSTRUMENT COMUNICATION

It should be noted that any operation required (set-up, calibration and controls) may be performed both locally or remotly by means of the optional indicator and/or by the serial ports. The instrument is equipped with a RS485 port for network connection to other equipments. The instrument may be supplied with a program (Window environments) which includes, in addition to all standard procedures (set-up, calibration and controls), several functions for problem analisys and complete instrument access.

SCALE ACCURACY
The accuracy of a conveyor scale is strongly dependent on application conditions and calibration method available; thus, on approved applications, the accuracy guarantied by Celmi (typical value ranging from 0,25% to 1%) on the totalized value refers to the following test conditions: - at least three complete belt revolutions - at least 500 totalizer counts - at least 10 minutes of conveyor run - flow rate between 25% and 100% of full scale

SOFTWARE
The software of the "S" conveyor scale is quite wide and, over all commonly used conveyor scale functions, has several other functions which allow an easy integration in any plant general control systems, the analysis of installation problems and an easy setting of operating parametes specific to the actual plant conditions. Main functions provided are the followings: - Flow rate, belt speed and belt load measurement - Resettable and non-resettable totalizer - Automatic zero tracking - Automatic zero and span calibration proceedures - Electronic span self-calibration - Span calibration proceedures for test weight, calibration chain and material test - Measurement of tare and weight of each load cell - High/low flow rate alarm - Failure alarm output - Load cell current measurement - Load cell and relevant wiring failure alarm - Lack of speed transmitter pulse alarm - Contact input for totalizer reset - Contact input for alarm reset

MODEL NUMBER
The electronic unit and the remote indicator may have different hardware options as indicated in the model number composition. Specify, also, the required functions to allow correct writing or interpretation errors. ELECTRONIC UNIT S4a X X X X mA output No 1 Yes 2 Input load cell N 2 load cell 2 N 4 load cell 4 Housing No 0 Yes painted steel 1 Yes stainless steel 2 Yes resine box 3 Software Conveyor scale 3

REMOTE INDICATOR I/O board Yes - with mA out Yes - without mA out Software Conveyor scale Power supply 110/220 Vac 24 Vac

S3 X X X 1 2 3 0 1

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INSTALLATION
The load receptor have to be installed and accuratly aligned as specified in the instruction manual. The speed transmitter have to be installed on a high diameter driven drum (tail or counterweight drum) to avoid slippage. The electronic unit have to be installed on a vertical plane at an height suitable for easy operation (1 - 1,8 meters) in environments with temperature within spec. limits and without humidity condensation, aggressive or explosive vapours. The supporting structure must not have high vibrations; eventually vibration smoothers should be provided. The electronic unit is normally installed near the load receptor and can be directly connected to load cell cables, thus, avoiding the need for an additional junction box. Long distance installation (such as intrinsecally safe applications) may be easily accomplished by suitable cable sizing and installation design.

WIRING
Wiring have to be done on the basis of terminal board connection diagram and according to local standard and regulations. Always use needle type wire terminator and install an external switch with fuse on power supply connection (eventually common to other instruments). WARNING: Load cell, analog output and serial signal cables must run separate from power cables.

SPEED TRANSMITTER

ELECTRONIC UNIT

BELT LOAD RECEPTOR

S4a

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