6105 Belt Feeder integrator --- User ’s...

6105610561056105 BeltBeltBeltBelt FeederFeederFeederFeeder integratorintegratorintegratorintegrator ------------ UserUserUserUser’’’’ssss GuideGuideGuideGuide ------------

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6105610561056105 BeltBeltBeltBelt FeederFeederFeederFeeder integratorintegratorintegratorintegrator

Installation,Installation,Installation,Installation, OperatingOperatingOperatingOperating andandandand ServiceServiceServiceServiceManualManualManualManual


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Declaration

Thanks for purchasing SAiMO products. This manual guides you through the application of yourselected products, covering the information necessary for installation, operation, maintenance andservice. This document may not be copied or reproduced in any way without the express writtenconsent of SAiMO. Please note that SAiMO reserves the right to change and/or improve the productdesign and specifications without notice. Thanks for your understanding and support.

Please read and observe the following safety precautions found throughout this manual.

DANGERDANGERDANGERDANGER

FAILURE TO OBSERVE WILL CAUSE VERY SERIOUS PERSONAL INJURY OR DEATH.

WARNINGWARNINGWARNINGWARNING

FAILURE TO OBSERVE COULD CAUSE SERIOUS PERSONAL INJURY.

PROMPTPROMPTPROMPTPROMPTHELPS YOU USE THE INFORMATION INDICATED ON THE EQUIPMENT BETTER.

· Please read through all the documents dispatched together with the equipments before you startto work with the equipments.

· For the sake of personal safety and normal operation of the equipments, it is imperative to assurethat only the designed AC power supply is to be used. Reliable 3-pin earthed power outlets mustbe used to avoid electric shock when touching the enclosure. Ensure that the rated voltage of thedisplay or other peripheral devices is compatible with your local AC power requirements.

· The equipment must be protected against thunderstrike.· Disconnect all the cables from the equipment before you attempt to move the equipment.· Do not attempt to change any components or external connections on the equipment before the

equipment is powered off.· Avoid inadvertent power interruption during normal operation.· Only qualified technicians can be allowed to open the enclosure of the equipment.·keep the equipment from moisture. Shut off power from the equipment immediately if it is splashed

with water or other liquids occasionally.


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Table of Contents

ChapterChapterChapterChapter 1111 IntroductionIntroductionIntroductionIntroduction................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................1111

1.1 General.................................................................................................................................................................1

1.2 Technical Specifications....................................................................................................................................... 3

1.3 Features................................................................................................................................................................31.3.1 Measuring Function.................................................................................................................................. 41.3.2 Monitoring Function.................................................................................................................................. 51.3.3 Printing Function....................................................................................................................................... 61.3.4 Communications (Optional)..................................................................................................................... 6

ChapterChapterChapterChapter 2222 BeltBeltBeltBelt scalescalescalescale InstallationInstallationInstallationInstallation GuidelinesGuidelinesGuidelinesGuidelines........................................................................................................................................................................................................................................................................................................................................................................................................................................................7777

2.1 General.................................................................................................................................................................7

2.2 Wind and Weather Influence.................................................................................................................................7

2.3 Conveyor Support.................................................................................................................................................7

2.4 Location of the Belt scale..................................................................................................................................... 72.4.1 Belt Tension................................................................................................................................................72.4.2 Conveyor With Concave Curve...............................................................................................................82.4.3 Conveyor with Convex Curve..................................................................................................................82.4.4 Tripper.........................................................................................................................................................82.4.5 Consistent Belt Loading........................................................................................................................... 82.4.6 Single Loading Point.................................................................................................................................82.4.7 Material Slippage.......................................................................................................................................8

2.5 Gravity Type Belt Tensioner................................................................................................................................. 8

2.6 Belt Troughing Angle............................................................................................................................................9

2.7 Weigh Area Idler...................................................................................................................................................92.7.1 Weigh Area Idler Construction.................................................................................................................92.7.2 Troughing Angle of Idler........................................................................................................................... 92.7.3 Self-aligning Idler (preventing belt misalignment)................................................................................ 92.7.4 Idler Alignment........................................................................................................................................... 9

ChapterChapterChapterChapter 3333 BeltBeltBeltBelt scalescalescalescale InstallationInstallationInstallationInstallation ProceduresProceduresProceduresProcedures............................................................................................................................................................................................................................................................................................................................................................................................................................................10101010

3.1 N62-1 Belt scale Installation..............................................................................................................................103.1.1 Overview...................................................................................................................................................103.1.2 Terminology..............................................................................................................................................103.1.3 Location of N62 Belt scale..................................................................................................................... 113.1.4 Field Preparation for Installation........................................................................................................... 113.1.5 Weighbridge Installation......................................................................................................................... 11

3.2 N63-3 Belt scale Installation..............................................................................................................................12


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3.2.1 Overview...................................................................................................................................................123.2.2 Terminology..............................................................................................................................................133.2.3 Location of N63 Belt scale..................................................................................................................... 133.2.4 Field Preparation for Installation........................................................................................................... 143.2.5 Weighbridge Installation......................................................................................................................... 143.2.6 Scale Idler Installation............................................................................................................................ 15

3.3 N64-4 Belt scale Installation..............................................................................................................................163.3.1 Overview...................................................................................................................................................163.3.2 Terminology..............................................................................................................................................173.3.3 Location of N64 Belt scale..................................................................................................................... 173.3.4 Field Preparation for Installation........................................................................................................... 173.3.5 Weighbridge Installation......................................................................................................................... 183.3.6 Scale Idler Installation............................................................................................................................ 18

3.4 Load Cell Installation........................................................................................................................................ 193.4.1 Overview...................................................................................................................................................193.4.2 Inspection, Unpacking and Storage..................................................................................................... 193.4.3 Installation................................................................................................................................................ 203.4.4 Principle of Operation............................................................................................................................. 21

ChapterChapterChapterChapter 4444 6105610561056105 IntegratorIntegratorIntegratorIntegrator InstallationInstallationInstallationInstallation................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 22222222

4.1 General...............................................................................................................................................................22

4.2 6105 Integrator Installation............................................................................................................................... 224.2.1 Mounting...................................................................................................................................................224.2.2 Safety Precautions.................................................................................................................................. 224.2.3 Wiring (External Power Supply)............................................................................................................ 23

ChapterChapterChapterChapter 5555 OperationOperationOperationOperation........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................25252525

5.1 Keypad............................................................................................................................................................... 25

5.2 Run Menu........................................................................................................................................................... 265.2.1 Reset Total............................................................................................................................................... 265.2.2 Alarm Menu..............................................................................................................................................27

5.3 Main Menu......................................................................................................................................................... 275.3.1 Initial Setup Menu................................................................................................................................... 285.3.2 Calibration................................................................................................................................................ 375.3.3 System Data Menu................................................................................................................................. 455.3.4 I/O Definition Menu................................................................................................................................. 525.3.5 Communication Menu.............................................................................................................................615.3.6 Alarm Setup Menu.................................................................................................................................. 635.3.7 Loadout Setup Menu.............................................................................................................................. 665.3.8 Password Setup Menu........................................................................................................................... 665.3.9 Diagnostics Menu....................................................................................................................................685.3.10 Statistics Menu........................................................................................................................................ 69


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ChapterChapterChapterChapter 6666 IntegratorIntegratorIntegratorIntegratorMaintenanceMaintenanceMaintenanceMaintenance............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................72727272

6.1 Daily Maintenance Routines of 6105 Integrator................................................................................................72

6.2 6105 Integrator Troubleshooting --- Fault Isolation..........................................................................................726.2.1 Power Supply Examination....................................................................................................................746.2.2 Speed Input..............................................................................................................................................746.2.3 Load Cell Input.........................................................................................................................................746.2.4 Current Output (Optional)...................................................................................................................... 756.2.5 Constant Setup........................................................................................................................................77

6.3 Usual Troubleshooting....................................................................................................................................... 77

ChapterChapterChapterChapter 7777 SpeedSpeedSpeedSpeed SensorSensorSensorSensor....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................78787878

7.1 General...............................................................................................................................................................78

7.2 Inspection, Unpacking and Storage................................................................................................................... 78

7.3 Installation......................................................................................................................................................... 797.3.1 Mechanical Part Installation...................................................................................................................797.3.2 Electrical Part Installation.......................................................................................................................79

7.4 Working Principle.............................................................................................................................................. 80

ChapterChapterChapterChapter 8888 BeltBeltBeltBelt ScaleScaleScaleScale MaintenanceMaintenanceMaintenanceMaintenance................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................81818181

8.1 General...............................................................................................................................................................81

8.2 Daily Maintenance Routine for Belt Scale......................................................................................................... 81

8.3 Troubleshooting the Belt Scale...........................................................................................................................82

ChapterChapterChapterChapter 9999 BeltBeltBeltBelt ScaleScaleScaleScale InstallationInstallationInstallationInstallation ParametersParametersParametersParameters........................................................................................................................................................................................................................................................................................................................................................................................................................................83838383

9.1 Scale Capacity....................................................................................................................................................83

9.2 Belt Scale Dimensions........................................................................................................................................83

9.3 Load Cell Data...................................................................................................................................................88

ChapterChapterChapterChapter 10101010 PermanentPermanentPermanentPermanent FieldFieldFieldField RecordRecordRecordRecord........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................89898989


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ChapterChapterChapterChapter 1111 IntroductionIntroductionIntroductionIntroduction

1.1 GeneralGeneralGeneralGeneral

Incorporating the latest technologies and years of industry, Saimo Weigh Belt Feeder Systems provideaccurate and reliable solutions for weighing, totalizing, flow rate control for industries such asmetalliferous ore blending, power generation, quarry, cement, chemical and food, etc.

The belt feeder senses and weighs the material passing through the weighbridge to determine unitweight (in kgs/m) of the material on the belt. Belt speed is continually measured with a digital speedsensor whose pulse output is proportional to belt speed. The speed sensor is mounted on the tail-pulleyto assure accurate belt speed measurement and detection of any possible slippage. The speed signaland weight signal are combined into the 6105 microprocessor-based integrator which generates anddisplays a true-rate signal in TPH and the total of material fed. An internal controller compares theflowrate signal to the feedrate setpoint derived from an industrial computer and sends necessary outputsignal to the frequency converter, consequently changing the feeder’s belt speed to maintain thedesired constant rate of material fed. The total of material fed is monitored by the computer whichsubmits shutoff signal when a setup total is reached.This manual provides the information necessaryfor installation, operation, maintenance and service of the 6105 integrator.

The 6105 integrator is available in panel mount and field mount. By processing the weight signal fromthe load cell and the speed signals from the speed sensor, It calculates and displays flowrate and totalof the material fed.

Figure 1-1 6000 Series Integrator -- Panel Mount


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Figure 1-2 6000 Series Integrator --- Field Mount


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1.2 TechnicalTechnicalTechnicalTechnical SpecificationsSpecificationsSpecificationsSpecifications

(a) Chinese / English menu

(b) Weighing Capability

· The 6105 integrator is capable of connecting up to eight 350Ω loads and acquiring a speed signalfrom the speed sensor, to calculate flow rate and total.

· The 6105 integrator has the function of automatic zero calibration.

(c) Ambient Environment

· Location: Indoor or outdoor, as close as possible to the load cells, free from damp and dust.· Temperature:

Storage temperature: -40~+70ºCOperating temperature -10~+50ºC

· Maximum Relative Humidity: 95%(d) Power Requirements

· 220VAC±10% or 110VAC±10% 50Hz· Fuse: 2A· EMI / RFI filter

(e) Load Cell· offers 10VDC(+/-10%), 500mA excited power, up to 8 load cells· Sensitivity: 0.5mV/V ~ 3.5mV/V· Max. input signal 33mV· Load cell shield grounding· Excitation compensation circuit is employed when the cable distance is over 60 meters but less

than 900 meters.· Local or remote compensation can be selected by a jumper set.

(f) Mainboard Digital InputThe mainboard provides 6 programmable inputs for receiving dry contact on-off signal

(g) Mainboard Digital OutputThe mainboard provides 8 programmable outputs.

(h) Outline DimensionsPanel mount: Outliner dimensions: 288mm x 144mm x185mm

Front panel dimensions: 284mm x140mmField mount: Outline dimensions: 312mm x 380mm x 150mm

Mounting hole dimensions: 240mm x 450mm


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1.3 FeaturesFeaturesFeaturesFeatures

Saimo 6105 integrator is specially designed for belt scales, meeting all measuring and controlrequirements on typical applications.The software has been solidified into the memory chip. Each preprogrammed function can be activatedautomatically by operating from the keypad or installing the optional expansion board.Saimo 6105 integrator has a powerful and user friendly operating interface, easy for function selection,data setup, operation and maintenance.The following functions have been completed into Saimo 6105 integrator.· Measuring· Monitoring· Printing· Communication

Figure 1-3 Front Panel

1.3.11.3.11.3.11.3.1 MeasuringMeasuringMeasuringMeasuring FunctionFunctionFunctionFunction

1. Instantaneous Flowrate CalculationThe signal delivered by the load cell(s), which represents the weight per unit length of the belt(kg/m), ismultiplied by the signal delivered by the speed sensor which represents the belt speed (m/s). The resultof this operation is the instantaneous flowrate (kg/m x m/s=kg/s) which is then multiplied by suitableconstant to obtain the value in the required engineering units (kg/h or ton/h, etc.). An adjustabledamping filter is provided separately for displayed rate and current outputs.

2. Flow TotalizationThe total is accumulated by multiplying mass per unit length by incremental length and totalizing theresult in engineering units.

3. Zero and Span Automatic CalibrationZero and span calibrations are based on belt length defined by a number of belt revolutions.


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To calculate the exact number of revolutions, the instrument counts the pulses delivered by the speedsensor (one pulse represents a specific belt length); when the required number of pulses is reached,the instrument ends the calibration test, and compares the actual totalized value to the theoretical one(0 for zero calibration), and calculates the calibration constant.The calibration constant is a calculated value that can be factored based on an actual material test.- Electronic Calibration (R-Cal)

Allows the operator to perform the calibration without the need of applying test weights or test chainon the weighbridge. The electronic calibration checks all the circuitry including the load cell, and isperformed by unbalancing the load cell bridge using a precision resistor. The calibration constant iscalculated on the basis of the load cell and the scale data.

- Test Weight CalibrationRequires the positioning of test weights on the weighbridge

- Chain CalibrationRequires the application of calibrated chains on the belt. This method is the nearest to actualoperating conditions.

- Material CalibrationIs performed by running a known quantity of material on the scale and weighing that quantity on astatic scale of known accuracy.

4. Zero Tracking (AZT)Under a preset minimum flowrate when enabled, the instrument makes subsequent automatic zerocalibrations with the following sequence:- performs automatic zero for one test duration.- continuously repeats above zero calibration as long as feed rate remains below AZT preset value.

5. Current Output SignalsAn optional current output/analog input board is available. Each current output may be programmed viathe keyboard to deliver one of the following signals:- flowrate- belt loading- belt speed- control signal

1.3.21.3.21.3.21.3.2 MonitoringMonitoringMonitoringMonitoring FunctionFunctionFunctionFunction

Saimo 6105 integrator is equipped with an indication system. Indication can be in the form of:- status indications- process alarms- programming errors- equipment failuresThe integrator includes internal diagnostics that will generate alarms in case of hardware failures orprogramming errors. The following process alarms are also provided:· Belt slip (two speed sensors recommended)· Alarms for high and low flowrate, speed and weightThese alarms are visible on the display and can be acknowledged and reset through keyboard, digital


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input or serial line. Alarms can be delayed to avoid intervention in case of short time peaks. Eachindividual alarm can be programmed to operate as alarm, shut down or to be ignored.

1.3.31.3.31.3.31.3.3 PrintingPrintingPrintingPrinting FunctionFunctionFunctionFunction

Periodical and under command prints can be obtained by connecting a serial printer to an optionalcommunication board.

1.3.41.3.41.3.41.3.4 CommunicationsCommunicationsCommunicationsCommunications (Optional)(Optional)(Optional)(Optional)

· Serial CommunicationsThe communication protocol allows a remote intelligent device to read and eventually write thecontents of the registers.During the communication activity, the 6105 integrator always acts as a Slave. This means itresponds to a request from a Master device on the line, but never attempts to send messages out.


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ChapterChapterChapterChapter 2222 6105610561056105 IntegratorIntegratorIntegratorIntegrator IIIInstallanstallanstallanstallationtiontiontion


This chapter contains the information about the installation, configuration and initial programming of the6105 belt feeder integrator. Initial programming is a machine directed procedure prompting the operatorto enter required conveyor and belt scale parameters. After all parameters have been entered, theintegrator performs an unassisted zero and span calibration.

The controller should not be installed at a place subject to severe variation environmentally. It ispreferred to be installed indoors, otherwise proper protective measures should be taken to prevent itfrom exposure to direct sunlight, moisture, collision and severe mechanical vibration.

2.2 6105610561056105 IntegratorIntegratorIntegratorIntegrator InstallationInstallationInstallationInstallation

The 6105 integrator must be installed indoors, not be exposed to excessive vibration, heat or moisture.The panel mount integrator should be installed in a control panel. After installation, dustproof measuresshould be taken for the front panel of the integrator and the control cabinet.

2.2.12.2.12.2.12.2.1 MountingMountingMountingMounting

The 6105 field mount feeder controller can be vertically secured to the rigid and flat wall through the 4mounting holes at the back of the enclosure. Care should be taken to insure the mounting surface is flatso as not to twist or warp the fiberglass enclosure when tightening the mounting holes.The 6105 panel mount integrator should have a clearance of at least 5cm at the top and bottom to allowair circulation. In case that the integrator must be positioned under the heat sources, proper spacearound the integrator should be reserved. Sufficient space should be kept behind the integrator tofacilitate wiring and changing fuse. The side clearance should be easy for securing the holding bracketsafter the 6105 has been put in place. Disconnect power supply from the integrator when mounting thebracket. From the back, insert the holding brackets on both sides of the integrator firstly, then screwdown tightly to secure the integrator and prevent dust ingress.

2.2.22.2.22.2.22.2.2 SafetySafetySafetySafety PrecautionsPrecautionsPrecautionsPrecautions

Do not install, operate, or perform any maintenance procedures until you have read the safetyprecautions which follow.

1. Do not connect power to the electronics or turn on the unit until you have read and understood thisentire manual. The precautions and procedures presented in this manual must be followed carefullyin order to prevent equipment damage and protect the operator from possible injury.

2. CAUTIONHands and clothing must be kept away from all moving or rotating parts.

3. WARNINGCovers over the electronics should always remain in place during operation. They should be


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removed only fro maintenance procedures with the machine’s power OFF. Be sure to replace allcovers before resuming operation.

4. WARNINGAll switches (such as control or power) must be OFF when checking input AC electrical connections,removing or inserting printed circuit boards, or attaching voltmeters to the system.

5. Incoming voltages must be checked with a voltmeter before being connected to the electronics.

6. WARNINGExtreme caution must be used in testing in, on, or around the electronics, PC boards, or modules.There are voltages in excess of 115V or 230V in these areas. Avoid high voltage and staticelectricity around the printed circuit boards.

7. Maintenance procedures should be performed only by qualified service personnel and inaccordance with procedures / instructions given in this manual.

8. During maintenance, a safety tag (not supplied by Saimo) should be displayed in the ON/OFFswitch area as a precaution instructing others not to operate the unit.

9. Only qualified service technicians should be allowed to open and work in the electronics, powersupply, control, or switch boxes.

10. Objects should never be placed or stored on the integrator.

11. This equipment should not be operated nor utilized in applications other than those stated in theoriginal order. (To adapt production rates or applications, consult Saimo for recommendations.)

12. All panels covering the electronics must be in place and tight before wash down procedures.Damage to the electronics could result from water, moisture, or contamination in the electronicshousing.

2.2.32.2.32.2.32.2.3 WiringWiringWiringWiring (External(External(External(External PowerPowerPowerPower Supply)Supply)Supply)Supply)

Do not connect power unit until you have read and understood this entire section. Improper connectionmay result in damage to your integrator.

CAUTIONVerify that the input voltage is correct with an AC voltmeter before you connect it to the integrator.Earth ground must be provided to the integrator. Do not use conduit to provide this ground.A readily accessible disconnect device (such as breaker, maximum 20A) shall be incorporated in thefield wiring. This disconnect device should be in easy reach of the operator and it must be marked asthe disconnecting device for the equipment.

1. Critical wiring conditions:A. Insure power is off.B. Do not route load cell and signal cables in the same conduit with power cables or any large source of

electrical noise.C. Earth ground all enclosures and conduits. A ground connection between all conduit is required.


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D. Wiring should be long enough to allow the field terminal entry panel to swing down for circuit boardaccess.

E. Connect the shields ONLY where shown.F. Check that all wires are tight in their connections.G. Never use a “megger” to check the wiring.H. A readily accessible disconnect device (such as breaker, maximum 20A) shall be incorporated in the

field wiring. This disconnect device should be in easy reach of the operator and it must be markedas the disconnecting device for the equipment.

I. All conduits should enter the bottom of the enclosure. Do not run conduit through the top or sides ofthe enclosure.

2. The following figure shows the wiring diagram of the 6105 integrator.:

Figure 4-1 6105 Integrator Wiring Diagram

6105


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ChapterChapterChapterChapter 3333 OperaOperaOperaOperationtiontiontion

3.1 KeypadKeypadKeypadKeypad

This chapter describes operating procedures for the 6105 integrator.

The keypad on the front panel includes hard keys and five soft keys. Hard keys located on the right halfside of the front panel perform specific functions as assigned. Below is a list of the keys and theirfunctions:

1. “RUN” – enter the running mode, the controller can enter the running mode whenever the key ispressed.

2. “MENU” – enter the main menu3. “CHK” – self-check function (disabled)4. “DEL” – delete the digit or punctuations5. Numeric keys 0~9—input the data parameter6. Decimal“.”—input the decimal7. “UP”, “DOWN”, “RIGHT”, “LEFT” arrow key — move cursor in different directionsThe five soft keys located under the LCD perform different functions depending on the menu being

Figure 5-1 Front Panel


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3.2 RunRunRunRun MenuMenuMenuMenu

3.2.13.2.13.2.13.2.1 ResetResetResetReset TotalTotalTotalTotalPress “RSET TOT” from the Run Menu, the following screen is displayed:

Press TOT RSET soft key, the integrator will display ”Press ENT to reset total.” Then Press ENT key toreset the total.If ENT key is pressed, the reset total will be zero, but the master total remains not changed.To reset the master total, enter “System Password Setup” menu to get the access to this function.

2006-3-21 12:00:00 Scale#1

8000000 t888 t/h1m/s

System running!

ZERO PID BAT SYS RSETCAL BMP RUN ALRM TOT

2006-3-21 12:00:00 Scale#1

8000000 t888 t/h1m/s

System running!

ZERO TOT MAINCAL RSET TOT


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3.2.23.2.23.2.23.2.2 AlarmAlarmAlarmAlarm MenuMenuMenuMenu

On the Run Menu, pressing “SYS ALRM” soft key enters the following screen:

Use Up/Down scroll keys to move the cursor to the desired item and press ENT to confirm and thenchange the settings.

3.2.33.2.33.2.33.2.3 PIDPIDPIDPID ControlControlControlControl MenuMenuMenuMenu

In the Run Menu, pressing “PID BMP” soft key enters the following screen:

Use Up/Down scroll keys to move the cursor to the desired item and press ENT to confirm and thenchange the settings.There are two parameters settable on this screen. “Set Rate” represents the flow rate setting value.“Output” represents the control output.When the “Setting Mode” is set to “LOCAL”, the “Set Rate” setting is allowed to be manually input.When the “Control Mode” is set to “MANU”, the “Output” setting is allowed to be manually input.

2006-3-21 12:00:00 Scale#1

ALARM DETAILSALARM NAME: [LO SPEED ]ALARM DATE: [ 2005-06-08 ]ALARM TIME: [ 12:00:00 ]

ALARMACTION: [ NEW ]

System running!

RUN ALRM PAGE PAGERSET DOWN UP

2006-3-21 12:00:00 Scale#1

800 t/hSET RATE : [ 800 t/h ]OUTPUT : [ 100 % ]

Press ↑ or ↓ key, then press ENT!

ZERO PREVCAL RUN


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3.3 MainMainMainMain MenuMenuMenuMenu

Press ”MENU” button on the front panel, the following screen is accessible.

Press a numeric key (1-5) to select the submenu. Press “RUN” to return to Run Menu. Use the USACHR soft key to switch between Chinese and English.

Press “PAGE DOWN” soft key, the second page of the Main Menu is displayed as follows:

Press numeric keys (6-10) to select the submenu. Press “PREV RUN” to return to Run Menu. Press“PAGE UP” soft key to return to the first page of the Main Menu.

2006-3-21 12:00:00 Scale#1

1. INITIAL SETUP2. CALIBRATION3. SYSTEM DATA4. I/O DEFINITION5. COMMUNICATION

Press a numeric key to select!

RUN PAGE USADOWN CHR

2006-3-21 12:00:00 Scale #1

6. ALARM SETUP7. LOADOUT SETUP8. PASSWORD SETUP9. DIAGNOSTICS10. STATISTICS

Press a numeric key to select!

PREV PAGERUN UP


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3.3.13.3.13.3.13.3.1 InitialInitialInitialInitial SetupSetupSetupSetup MenuMenuMenuMenu

5.3.1.15.3.1.15.3.1.15.3.1.1 InitialInitialInitialInitial SetupSetupSetupSetup 1111

Press “1” from the first page of the Main Menu, the screen shows:

Pressing “MAIN MENU” soft key can return to the Main Menu.Move the cursor to “MEASURE UNIT” with the up/down scroll keys; then press ENT, the followingscreen is displayed.

In this menu, if Up/Down scroll keys are pressed, the default unit “Metric” is accepted and the cursormoves to other variables.

Otherwise, if “ENTR” soft key is pressed, the measure unit value changes among “English”, “Metric ”and “Mixed”. When the desired option is displayed, press “SURE” soft key to input the value. At thistime the screen returns to the first page of Initial Setup 1 menu.You can use the same method to setup other units listed in the menu.

Measure Units: English, Metric, MixedTotal Units: t, kgLength Units: MetersFlow Rate Units: t/h, kg/h, t/m, kg/m

2006-3-21 12:00:00 Scale #1

INITIAL SETUP 1Measure Units: [ METRIC ]

Total Units: [ t ]Length Units: [ METERS ]Rate Units: [ t/h]

Press ENTR to select, then press ENT!

MAIN PAGEMENU DOWN

2006-3-21 12:00:00 Scale #1

INITIAL SETUP 1Measure Units: METRIC

Total Units: [ t ]Length Units: [ METERS ]Rate Units: [ t/h]

Press ENTR to select, then press SURE!

MAIN ENTR SURE PAGEMENU DOWN


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Press “PAGE DOWN” soft key from the first page of the Initial Setup 1 Menu, the first page of the InitialSetup 2 Menu is shown as follows:

Use Up/Down scroll keys to move the cursor to the desired variable, and press ENT to enter thefollowing screen.

If a digital value is entered, and press “SURE” soft key, the screen return to the first page of Initial Setup2 menu. You can use the same method as described in section 5.3.1.1 to setup other parameters listedin the menu.

Load Cell Unit: kgScale Capacity: Min:1 Max:200000Scale Division: 0.1、0.2、0.5、1、2、5、10、20、50、0.01、0.02、0.05、0.001、0.002、

0.005Scale Code: Min:0 Max:500

2006-3-21 12:00:00 Scale #1

INITIAL SETUP 2Loadcell Units: [ kg]Scale Capacity: 500Scale Divison: [ 1 ]Scale Code: [ 1 ]


MAIN SURE PAGE PAGEMENU DOWN UP

2006-3-21 12:00:00 Scale #1

INITIAL SETUP 2Loadcell Units: [ kg]Scale Capacity: [ 500 kg/h ]Scale Division: [ 1 ]Scale Code: [ 1 ]


MAIN CODE PAGE PAGEMENU DATA DOWN UP


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5.3.1.35.3.1.35.3.1.35.3.1.3 ScaleScaleScaleScale CodeCodeCodeCode DataDataDataData

Press “CODE DATA” from the first page of Initial Setup 2 Menu, the following screen is displayed.

Use the same method as described in section 5.3.1.2 to set the digital value for each variable.P to L (Pivot to load cell distance): Min:0 Max:3800mm# of weigh idlers: Min:1 Max:6P to 1st (Pivot to the 1st weigh idler distance): Min:0 Max:2500mmP to 2nd (Pivot to the 2nd idler distance): Min:0 Max:2500mm

Press “PAGE DOWN” soft key to enter the second page of the Scale Code Data Menu.

Use the same method as described in section 5.3.1.2 to set the digital value for each variable.P to 3rd (Pivot to the 3rd weigh idler distance): Min:0 Max:2500mmP to 4th (Pivot to the 4th weigh idler distance): Min:0 Max:2500mmP to 5th (Pivot to the 5th weigh idler distance): Min:0 Max:2500mmP to 6th (Pivot to the 6th weigh idler distance): Min:0 Max:2500mm

Press “PAGE DOWN” soft key to enter the third page of the Scale Code Data Menu.

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SCALE CODE DATA 2P to 3 rd: [ 800mm ]P to 4 th: [ 800mm ]P to 5 th: [ 800mm ]P to 6 th: [ 800mm ]


MAIN PAGE PAGEMENU DOWN UP

2006-3-21 12:00:00 Scale #1

SCALE CODE DATA 1P to L : [ 1000mm]# OF Idlers: [ 1 ]P to 1 st: [ 800mm ]P to 2 nd: [ 800mm ]




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Use the same method as described in section 5.3.1.2 to set the digital value for each variable.P to test hi (Pivot to test weight height): Min:0 Max:250mmP to test le (Pivot to test weight length): Min:0 Max:250mmP to carry (Pivot to carriage height): Min:0 Max:250mmR to carry (Carry roll to carriage height):Min:0 Max:250mm


Press “PAGE DOWN” soft key from the Initial Setup 2 Menu described in Section 5.3.1.2, the first pageof Initial Setup 3 Menu is displayed as follows:

Use the same method as described in section 5.3.1.2 to set the digital value for each variable.#of Loadcells: Min:1 Max:6Idler Spacing: Min:50 Max:2500mmConveyor Angle: Min:-25 Max:25Loadcell Cap: Min:1kg Max:5000kg

2006-3-21 12:00:00 Scale #1

INITIAL SETUP 3# of Loadcells: [ 1 ]Idler Spacing: [ 100mm ]

Conveyor Angle: [ 10 ]Loadcell Cap: [ 100 kg ]



2006-3-21 12:00:00 Scale #1

SCALE CODE DATA 3P to Test High: [ 100mm ]P to Test Len: [ 100mm ]

P to carry: [ 100mm ]R to carry: [ 100mm ]




18

Press “PAGE DOWN” soft key from the Initial Setup 3 Menu described in Section 5.3.1.4, the first pageof Initial Setup 4 Menu is displayed as follows:

Use the same method as described in section 5.3.1.2 to set the digital value for each variable.Sensitivity: Min:0.5 Max:3.5#1 load cell resistor: Min:0 Max:350#2 load cell resistor: Min:0 Max:350#3 load cell resistor: Min:0 Max:350


Press “PAGE DOWN” soft key from the Initial Setup 4 Menu described in Section 5.3.1.4, the fifth pageof Initial Setup Menu is displayed as follows:

Use the same method as described in section 5.3.1.2 to set the digital value for each variable.#4 load cell resistor: Min:0 Max:350#5 load cell resistor: Min:0 Max:350#6 load cell resistor: Min:0 Max:350Weight channel: Channel 1, Channel 2, Dual

2006-3-21 12:00:00 Scale #1

INITIAL SETUP 54# Resistor: [ 350 Ohms]5# Resistor: [ 350 Ohms]6# Resistor: [ 350 Ohms]

Weight Channel: [ CHANNEL 1 ]



2006-3-21 12:00:00 Scale #1

INITIAL SETUP 4Sensitivity: [ 3 mv/v ]1# Resistor: [ 350 Ohms]2# Resistor: [ 350 Ohms]3# Resistor: [ 350 Ohms]




19

Note: When Dual channels are used for the weight channel, the two load cells should be connected tothe channel 1 and channel 2 separately on the A/D board.


Press “PAGE DOWN” soft key from the Initial Setup 5 Menu described in Section 5.3.1.5, the sixth pageof Initial Setup Menu is displayed as follows:

Note: the setting value of the speed mode is “Simulated” and “Actual”. When “Simulated” is selected,the integrator will generate an analog signal for speed input. In case that “Actual” is selected, the speedinput is an actual speed signal. Simulation allows operation without a speed sensor.There are two channels for selection: Channel 1 and Channel 2.

5.3.1.75.3.1.75.3.1.75.3.1.7 EstablishingEstablishingEstablishingEstablishing TestTestTestTest DurationDurationDurationDuration

Press “PAGE DOWN” soft key from the Initial Setup 6 Menu, the first page for establishing test durationappears.

2006-3-21 12:00:00 Scale#1

8000000 t888 t/h1m/s

Establish test duration!

AUTO MANL PAGEDURA DURA UP

2006-3-21 12:00:00 Scale#1

INITIAL SETUP 6Speed Mode: [ SIMULATE ]Speed Channel: [CHANNEL 1]




20

Because the belt scale is a dynamic measuring equipment. The weighing accuracy has a close relationwith the conveyor. Select a certain period of running time to measure the tare and calculate the averagevalue.

The test duration should be set to a value equivalent to over one belt revolution or greater than 6min.

Pressing “MANL DURA” soft key enters the following screen:

Input the settings for Belt Length, Revolution and Running time on this menu.

Pressing “BGIN DURA” soft key enters the following screen:

2006-3-21 12:00:00 Scale #1

8000000 t888 t/h1m/s

Establishing test duration, Please wait![ 10 ]

BGIN PAGEDURA UP

2006-3-21 12:00:00 Scale#1

MANUAL TEST DURATION DATABelt Length: [ 10 m ]Revolutions: [ 1 ]

Running Time: [ 10 s ]


BGIN PAGEDURA UP


21

When test duration acquisition is finished, the following screen appears:

If press “AUTO DURA” soft key from the first screen described in section 5.3.1.7, the following screenappears:

Press “FULL DURA” or “PART DURA”, the following screen is displayed.

2006-3-21 12:00:00 Scale #1

8000000 tFull Length: 100 m

Running Time: 100 sec

Test duration is established![ 10 ]

BGIN EXIT PAGE PAGEDURA DURA DOWN UP

2006-3-21 12:00:00 Scale #1

8000000 tRevolutions: 1

Running Time: 1

Establishing test duration, Please wait！

BGIN DONE EXIT MARK PAGEDURA DURA DURA CNT UP

2006-3-21 12:00:00 Scale #1

8000000 tRevolutions:1

Running Time:1

Establishing test duration, Please wait!



22

When the test duration acquisition is finished, the fourth screen described in section 5.3.1.7 appears.

5.3.1.85.3.1.85.3.1.85.3.1.8 InitialInitialInitialInitial CalibrationCalibrationCalibrationCalibration

Press “PAGE DOWN” soft key from the first screen mentioned in section 5.3.1.7, the following menudisplays:

When the calibration is finished the following screen will appear:

When the calibration is finished, the screen returns to Run Menu as described in section 5.2..

2006-3-21 12:00:00 Scale #1

8000000 t888 t/h1m/s

Auto span station![ 100 ]

MAINMENU

2006-3-21 12:00:00 Scale #1

8000000 t888 t/h1m/s

Scale calibrated, press RUN to start!

MAINMENU


23

3.3.23.3.23.3.23.3.2 CalibrationCalibrationCalibrationCalibrationPressing “2” from Main Menu enters the Calibration Menu.

Move the cursor to the desired item with Up/Down scroll keys and press ENT key to select it.

5.3.2.15.3.2.15.3.2.15.3.2.1 ZeroZeroZeroZero CalibrationCalibrationCalibrationCalibration

Zero Calibration menu is accessible by selecting “2.1 ZERO CALIBRATION” from the Calibration Menuas shown in section 5.3.2.

2006-3-21 12:00:00 Scale #1

8000000 t888 t/h1m/s

Zero calibration mode!

AUTO EXIT MANLZERO ZERO ZERO

2006-3-21 12:00:00 Scale #1

CALIBRATION

2.1 ZERO CALIBRATION2.2 SPAN CALIBRATION2.3 MATL CALIBRATION


MAINMENU


24

a. Automatic ZeroingPress “AUTO ZERO “ soft key to enter the following screen.

Press “BGIN ZERO “ soft key to enter the following screen.

In case that the belt is interrupted during the zero calibration procedure, the following screen will bedisplayed.

2006-3-21 12:00:00 Scale #1

8000000 t888 t/h1m/s

Zero calibration mode!

BGIN EXITZERO ZERO

2006-3-21 12:00:00 Scale #1

8000000 t888 t/h1m/s

Auto zero in progress, please wait！[ 100 ]

BGIN EXITZERO ZERO

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8000000 t888 t/h1m/s

Belt stops!

BGIN EXITZERO ZERO


25

When auto-zeroing is finished, the following screen appears.

When “SURE ZERO” is pressed, the following prompt message is displayed.

b. Manual ZeroingIf press “MANL ZERO” soft key from the Zero Calibration Menu mentioned in section 5.3.2.1, theManual Zeroing screen appears:

2006-3-21 12:00:00 Scale #1

8000000 t888 t/h1m/s

Auto zero mode!

BGIN EXITZERO ZERO

2006-3-21 12:00:00 Scale #1

8000000 tOld zero: [ 888 ]New zero:Manual zero mode!Input zero:

BGIN EXIT SURE SUREZERO ZERO ZERO

2006-3-21 12:00:00 Scale #1

8000000 tOld zero:[ 888 ]New zero:[ 1000 ]

Auto zero complete!Error:[ -11.2% ]

BGIN EXIT SUREZERO ZERO ZERO


26

Press numeric keys to enter the new zero and press “SURE ZERO” to validate it.

5.3.2.25.3.2.25.3.2.25.3.2.2 SpanSpanSpanSpan CalibrationCalibrationCalibrationCalibration

Span is also called as weigh span, i.e. indication response to change of standard weight on the loadreceptor. The purpose of span calibration is to remedy the difference between the reading and thestandard weight on the load receptor.There are two different system calibration modes: simulated calibration and material calibration.Three simulated span calibration methods are available: R-cal, test weights and test chains. For thesemethods, it is important to determine the simulated constant which can be calculated using someformulas. When performing span calibration, the calibration method should be firstly selected, and therelevant resistor or test weights / chain weights parameters should be entered into the integrator.The following Span Calibration menu is accessible by selecting “2.2 SPAN CALIBRATION” from theCalibration Menu as shown in section 5.3.2.

There are two spanning modes available: automatic spanning and manual spanning.

a. Auto SpanningPressing STRT soft key enters the following screen:

In case that the belt is interrupted during the calibration procedure, the following screen will bedisplayed.

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8000000 t888 t/h1m/s

Span! Load reference weight!

AUTO EXIT MANLCAL CAL CAL

2006-3-21 12:00:00 Scale #1

8000000 t888 t/h1m/s

Auto span in progress, please wait![ 100 ]

BGIN EXITCAL CAL


27

When the automatic span calibration is finished, the screen returns to the first menu of Auto Span.

b. Manual SpanningIf press “MANL SPAN” soft key from the Span Calibration Menu mentioned in section 5.3.2.2, theManual Spanning screen appears:

Press numeric keys to enter the new span and press “SURE SPAN” to validate it.

5.3.2.35.3.2.35.3.2.35.3.2.3 MaterialMaterialMaterialMaterial CalibrationCalibrationCalibrationCalibration

Material Calibration menu is accessible by selecting “2.3 ZERO CALIBRATION” from the CalibrationMenu as shown in section 5.3.2.

2006-3-21 12:00:00 Scale #1

8000000 t888 t/h1m/s

Belt stops, Cal stop !

BGIN EXITCAL CAL

2006-3-21 12:00:00 Scale #1

8000000 tOld span:[ 888 ]New span:Manual span mode!Input span:

BGIN EXIT SURECAL CAL SPAN


28

Pressing “BGIN CAL” soft key enters the following screen:

Pressing “DONE CAL” soft key enters the following screen:

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8000000 t888 t/h1m/s

Materiel calibration!

BGIN EXITCAL CAL

2006-3-21 12:00:00 Scale #1

8000000 t888 t/h1m/s

Material calibration, please wait![ 8 ]

BGIN EXIT DONECAL CAL CAL

2006-3-21 12:00:00 Scale #1

8000000 tOld span:[ 888 ]New span:Materiel calibration! Please wait!Refer weight:

BGIN RE- SURECAL INPT


29

When material calibration is finished, input the standard weight value and press “SURE” soft key tovalidate it and enter the following screen.

Pressing “MATL FACR” soft key enters the following screen.

Press numeric keys to enter the new material factor and press “SURE FACR” to validate it. Pressing“EXIT FACR” soft key enters the following screen.

2006-3-21 12:00:00 Scale #1

8000000 tOld span: [ 888 ]New span: [ 1000 ]Material calibrationing! Please wait!Span err: [ -11.2% ]

BGIN MATL SURECAL FACR SPAN

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8000000 tOld factor: [ 0% ]New factor: [1.0 ]

Sure new factor!

BGIN EXIT SURECAL FACR FACR

2006-3-21 12:00:00 Scale #1

8000000 tOld span: [ 888 ]New span: [1000]

Materiel calibration complete!Span err: [ -11.2% ]

BGIN MATL SURECAL FACR SPAN


30

Pressing “SURE SPAN” soft key enters the following screen.

Pressing “ADD REFR” soft key enters the following screen:

Pressing RUN key enters Run Menu.

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8000000 t888 t/h1m/s

Materiel calibration complete!Span err: [ -11.2% ]

BGIN EXIT ADDCAL CAL REFR

2006-3-21 12:00:00 Scale #1

8000000 t888 t/h1m/s

Materiel calibration!

BGIN EXITCAL CAL


31

3.3.33.3.33.3.33.3.3 SystemSystemSystemSystem DataDataDataData MenuMenuMenuMenu

5.3.3.15.3.3.15.3.3.15.3.3.1 DisplayDisplayDisplayDisplay DataDataDataData

Pressing “3” from Main Menu enters the first page of the System Data Menu.

Press the Up/Down scroll keys to scroll the cursor to the item desired to be set and press ENT key toenable changing the settings:

Zero Dead: 0-9Supplementary: SPEED, LOADFilt Constant: 0-100Language: CHINESE, ENGLISH

Pressing “PAGE DONE” soft key enters the second page of the System Data Menu.

2006-3-21 12:00:00 Scale #1

DISPLAY DATA 1Zero Dead: [ 0% ]

Supplementary: [ SPEED ]Filt Constant: [ 10 ]Language: [ ENGLISH ]


MAIN PAGEMENU DOWN

2006-3-21 12:00:00 Scale #1

DATE SETUPYear: [ 6 ]

Month: [ 3 ]Date: [ 21 ]




32

Pressing “PAGE DONE” soft key enters the third page of the System Data Menu.

Pressing “PAGE DONE” soft key enters the fourth page of the System Data Menu.

5.3.3.25.3.3.25.3.3.25.3.3.2 CalibrationCalibrationCalibrationCalibration DataDataDataData

Press “PAGE DOWN” soft key, the first page of the Calibration Data Menu is displayed.

2006-3-21 12:00:00 Scale #1

TIME SETUPHour: [ 12 ]Minute: [ 0 ]Second: [ 0 ]

Press ↑ or ↓ key，then press ENT!


2006-3-21 12:00:00 Scale #1

SCALE DATEMax Speed: [3 m/s ]

Press ↑ or ↓ key，then press ENT!


2006-3-21 12:00:00 Scale #1

CALIBRATION DATA 1Simulated: [ELECTRIC ]Resistor: [ 165000Ohms ]Weights: [ 100kg ]Chain: [ 100kg/m ]




33

Simulated: ELECTRIC, WEIGH, CHAINResistor: 0-1000000Weights: 0-1000000

Chain: 0-1000000

Press “PAGE DOWN” soft key, the second page of the Calibration Data Menu is displayed.

Constant: 0-1000000Matl Factor: 0-100%Zero Track: 0-100%Zero Range: 0-100%

Press “PAGE DOWN” soft key, the third page of the Calibration Data Menu is displayed.

Linear: YES, NO0~30%: 0-100%

30%~70%: 0-100%70%~100%: 0-100%

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CALIBRATION DATA 2Constant: [ 800 ]

Matl Factor: [ 2% ]Zero Track: [ 3% ]Zero Range: [ 4% ]



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CALIBRATION DATA 3Linear: [ NO ]0 ~ 30%: [ 100% ]

30%~ 70%: [ 100% ]70%~ 100%: [ 100% ]




34

5.3.3.25.3.3.25.3.3.25.3.3.2 ControlControlControlControl DataDataDataData

Press “PAGE DOWN” soft key, the first page of the Control Data Menu is displayed.

Control Mode: MANU, AUTOSetting Mode: LOCAL, REMOTE

High Limit: 0-100%Low Limit: 0-100%

When the Control Mode is set to Manu, the manual control output mode will be used.When the Control Mode is set to Auto, the automatic PID control mode will be used.

Press “PAGE DOWN” soft key, the second page of the Control Data Menu is displayed.

Proportional: 0-1000000%Integral: 0-1000000%

Derivative (differential): 0-1000000%

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CONTROL DATA 1Control Mode : [ MANU ]Setting Mode : [ LOCAL ]High Limit : [ 80% ]Low Limit : [ 20% ]



2006-3-21 12:00:00 Scale #1

CONTROL DATA 2Proportional : [ 200 % ]

Integral: [ 2 sec ]Derivative: [ 0 sec ]




35

Press “PAGE DOWN” soft key, the third page of the Control Data Menu is displayed.

Volume: NO, YESDifference: 0-100%

Delay: 0-200

The 6105 integrator has a volumetric measuring function. Under normal operation condition, the 6105compare the 2-way load cell signals with each other. If both signals are within the normal setting range,the instantaneous flow rate and total can be calculated by integration of the load cell signals and thespeed signal. In case that the load cell fails, i.e. the load cell signal is out of range, the volumetricmeasuring function can be activated automatically.The working principle of volumetric measuring system can be described as follows:The 6105 integrator calculates flow rate and belt speed on the basis of 1 hour period. Then the flow rateis divided by the belt speed to obtain the weight per unit length per hour which is then multiplied by theaverage speed per hour to get the average flow rate per hour. When the load cell fails, the presentweight per length per hour can be automatically used for the load cell signal. The value is thenmultiplied by the present speed to obtain the present flow rate.When the Volume is set to NO, the volumetric measuring function is disabled.The Difference represents comparative difference for volumetric measuring function.When the volumetric measuring function is enabled, the difference measuring function automaticallyactivates in case that the difference between the two load cell signals continuously exceeds the presetDifference value within a period of the preset Delay time. The 6105 integrator exits volumetricmeasuring mode when the difference between the two load cell signals becomes less than the presetDifference value.

2006-3-21 12:00:00 Scale #1

CONTROL DATA 3Volume : [ NO ]

Difference: [ 10% ]Delay: [ 5 sec ]




36

5.3.3.35.3.3.35.3.3.35.3.3.3 EstablishingEstablishingEstablishingEstablishing TestTestTestTest DurationDurationDurationDuration

Press “PAGE DOWN” soft key, the fourth page of the Calibration Data Menu is displayed.

Press “AUTO DURT” soft key, the following screen is displayed.

2006-3-21 12:00:00 Scale #1

8000000 t888 t/h1m/s


AUTO MANL PAGEDURA DURA UP

2006-3-21 12:00:00 Scale #1

AUTO TEST DURATION DATABelt Length: [ 20m ]Part Length: [ 10m ]


FULL PART PAGEDURA DURA UP


37

Press “FULL DURA” or “PART DURA”, the following screen is displayed.

Press “BGIN DURA” to start establishing the test duration. Press “MARK CNT” each time the markpasses the reference point. Then press “DONE DURA” to finish establishing test duration.

If press “MANL DURT” soft key from the first screen described in section 5.3.3.5, the following screenappears:

2006-3-21 12:00:00 Scale #1

8000000 tRevolutions:Running Time:



2006-3-21 12:00:00 Scale #1

MANUAL TEST DURATION DATABelt Length: [ 20m ]Revolutions: [ 1]

Running Time: [ 80]


BGIN PAGEDURA UP


38

5.3.3.35.3.3.35.3.3.35.3.3.3 CalculationCalculationCalculationCalculation ofofofof SimulatedSimulatedSimulatedSimulated ConstantConstantConstantConstant

The Simulated Constant must be calculated by a proper method depending on the selected calibrationmode.1) For electronic calibration mode, the calculation formula is

Equivalent weight =

( )1

12 1

. .2 SR

R

LC S kgK +

⎛ ⎞⎜ ⎟•⎜ ⎟⎝ ⎠

In which: L.C.S —— Load cell capacity（kg）K —— Load cell sensitivity（mv/V）RS —— Resistor used in electronic calibration (Ohms)R1 —— Load cell input resistor (Ohms)

Take the following conditions for example:L.C.S=200kgK=0.003V/VRS=100000ΩR1=350Ω

Then Equivalent weight =

12 100000 1

350

2002 0.003 ×

+

⎛ ⎞•⎜ ⎟

× ⎝ ⎠=58.23kg

Equivalent weight on unit length =

1

2

1cos

dkgd Dϕ

× ×（kg/m）

In which kg——Equivalent weight

ϕ—— Angle between the scale on the conveyor and the horizontal plane

d1 —— Distance from trunnion pivot centerline to load cell centerline (mm)d2 —— Distance from trunnion pivot centerline to weigh idler centerline (mm)D —— Measuring section length (m)

Take the following conditions for example:kg=58.23kgϕ =15od1=812.8mmd2=609.6mmD=3m

Then Equivalent Weight =

58.23 812.8 10.966 609.6 3

× ×=26.79kg/m

The Simulated Constant = Equivalent weight on unit length X Test length= Equivalent weight on unit length X (Belt full length X revolutions)= 26.79kg/m X (100m X 25 revs = 26790kg = 26.79t


39

2) For test weights calibration mode, the following method should be used:

a) The Equivalent Load (Kg/m) =）（

）（DengthWeighSpanL

KgsTestWeight

Test Weights = Static weight applied on the weigh idlersWeigh Span Length = Idler spacing X Number of weigh idlersFor example:

Kg = 100D = 2.4mKg/m = 41.67 kg/m

b) Simulated Constant For Test Weights can be calculated using the following formula:

The Simulated Constant = 1000)()/( mationforTestDurBeltLengthmkg ×

For example:The Belt Length for Test Duration = 180m

The Simulated Constant = 100018067.41 × = 7.5t

3) For test chains calibration mode, the following method should be used:a) The Equivalent Load (Kg/m) is specified at the tail of the test chainsb) Simulated Constant For Test Chains can be calculated using the following formula:

The Simulated Constant = 1000)()/( mationforTestDurBeltLengthmkg ×

For example:The Belt Length for Test Duration = 180mKg/m = 30

The Simulated Constant = 100018030× = 5.4t

Note:Note:Note:Note: The system setup is intended to program some basic parameters which determine whethercorrect result can be achieved from the belt scale. These parameters include scale number and scalecapacity etc.The following is an explanation to a part of these parameters.[Zero Tracking]: Zero may drift due to various influence factors. When Zero Tracking is set, automaticzeroing will be implemented in case of a total lower than the preset value.[Zero Dead]: During a run period, a total lower than the preset Zero Dead will not be added into themaster total.[Accumulated Pulses]: When the total is up to the preset Accumulated Pulses, an accumulated pulsesignal will be emitted.[Pulse Width]: This option defines the ratio of high voltage level [1] and low voltage level [0] of pulsewidth[Control Mode]: There are two control modes selectable: automatic and manual.[Set Mode]: When automatic control mode is selected, two set modes are available for selection: localand remote.


40

[Set Flowrate]: This option defines the preset flowrate.[P Gain], [I Gain], [G Gain]: the three parameters are used for control function. Typically, [P Gain] is setto 1, [I Gain] is set to 10, and [G Gain] is set to 0.[Control High Limit], [Control Low Limit]: The two parameters limit the flowrate range.

3.3.43.3.43.3.43.3.4 I/OI/OI/OI/O DefinitionDefinitionDefinitionDefinition MenuMenuMenuMenu

Pressing “4” from Main Menu enters the first page of the I/O Definition Menu.

Pressing ENT key enters the following screen.

Move the cursor with scroll keys to the item you want to program, then press “ENTR” soft key to viewthe options for this variable. The middle column is used to define the function of each input port. And theright column defines the Normally Open (OPEN) or Normally Closed (CLOSE) status of the input.Normally open means the input is inactive when disconnected.

2006-3-21 12:00:00 Scale#1

INPUTPORT SETUP 1In port 1: [NO DEFINE ] [OPEN ]In port 2: [NO DEFINE ] [OPEN ]Inport 3: [NO DEFINE ] [OPEN ]Inport 4: [NO DEFINE ] [OPEN ]


MAIN PAGEMENU UP

2006-3-21 12:00:00 Scale #1

INPUTPORT SETUP 1In port 1: BAT RUN [OPEN ]In port 2: [NO DEFINE ] [OPEN ]Inport 3: [NO DEFINE ] [OPEN ]Inport 4: [NO DEFINE ] [OPEN ]




41

The options of input port function include: “BAT RUN”, “BAT READY” and “NO DEFINE”. Press “ENTR”to make the options display circularly. When the desired option is displayed, press “SURE” soft key toinput the value.

Pressing Right scroll key from the first page of I/O Definition menu enters the following screen.


If “ENTR” soft key is pressed, the status changes between “OPEN”(Normally Open) and“CLOSE”(Normally Closed). When the desired option is displayed, press “SURE” soft key to input thevalue. At this time the screen returns to the first page of Input Definition 1 menu. You can use the samemethod to setup other units listed in the menu.

2006-3-21 12:00:00 Scale #1

INPUTPORT SETUP 1In port 1: [NO DEFINE] [ OPEN ]In port 2: [NO DEFINE] [ OPEN ]In port 3: [NO DEFINE ] [ OPEN ]In port 4: [NO DEFINE ] [ OPEN ]

Press↑or↓ key, then press ENT!

MIAN PAGEMENU DOWN

2006-3-21 12:00:00 Scale #1

INPUTPORT SETUP 1In port 1: [NO DEFINE] OPENIn port 2: [NO DEFINE] [ OPEN ]In port 3: [NO DEFINE ] [ OPEN ]In port 4: [NO DEFINE ] [ OPEN ]

Press↑or↓ key，then press ENT！



42

Pressing “PAGE DOWN” soft key from the first page of I/O Definition 1 Menu enters the second page ofthe I/O Definition Menu. This is the second page for Input Definition.

Set the input ports 5 through 8 in the same way as mentioned above.

Pressing “PAGE DOWN” soft key enters the third page of the I/O Definition Menu. This is the first pagefor Output Definition.

Set the output port 1 through 4 in the same way as mentioned above.The options of output port function include: “Alarm 1”, “Alarm 2”, “Alarm 3”, “Alarm 4”, “Alarm 5”, “Alarm6”, “Alarm 7”, “Alarm 8”, “No Define”, “Totalizer”, “Batch Start”, “Batch Complete”.

Pressing “PAGE DOWN” soft key enters the fourth page of the I/O Definition Menu. This is the secondpage for Output Definition.

2006-3-21 12:00:00 Scale#1

INPUTPORT SETUP 2In port 5: [ NO DEFINE ] OPENIn port 6: [NO DEFINE] [ OPEN ]In port 7: [NO DEFINE] [ OPEN ]In port 8: [NO DEFINE] [ OPEN ]



2006-3-21 12:00:00 Scale#1

OUTPUTPORT SETUP 1Out por 1: [ NO DEFINE ] [ OPEN ]Out por 2: [ NO DEFINE ] [ OPEN ]Out por 3: [ NO DEFINE ] [ OPEN ]Out por 4: [ NO DEFINE ] [ OPEN ]




43

Set the output ports 5 through 8 in the same way as mentioned above.

Pressing “PAGE DOWN” soft key enters the fifth page of the I/O Definition Menu. This is the third pagefor Output Definition.

Set the output port 9 through 12 in the same way as mentioned above.

Notes:Notes:Notes:Notes:1. [BAT READY] is a pulse input signal. When the 6105 integrator receives this signal, a measuring

period for a batch of material is started.2. [BAT RUN] is also a pulse input signal. Upon acceptance of this signal, the system switches to start

running status with the switch turning to BAT RUN.3. When the discharged material is up to the target weight, Discharge End signal is sent from the 6105

integrator.4. When the measurement is up to the target weight, discharge signal is sent from the 6105 integrator.5. If a port is not used, set it to [NO DEFINE].

2006-3-21 12:00:00 Scale #1

OUTPUTPORT SETUP 2Out por 5: [ NO DEFINE ] [ OPEN ]Out por 6: [ NO DEFINE ] [ OPEN ]Out por7: [NODEFINE] [OPEN]Out por 8: [ NO DEFINE ] [ OPEN ]

Press↑or↓ key，then press ENT！


2006-3-21 12:00:00 Scale #1

OUTPUTPORT SETUP 3Out por 9: [ NO DEFINE ] [ OPEN ]Out por 10: [ NO DEFINE ] [ OPEN ]Out por 11: [ NO DEFINE ] [ OPEN ]Out por 12: [ NO DEFINE ] [ OPEN ]




44

Pressing “PAGE DOWN” soft key enters the sixth page of the I/O Definition Menu.

Move the cursor to “Delay” with Up/Down scroll keys and press ENT key, the following screen appears:

Press numeric keys to input the desired value, and press “ENTR” soft key to confirm. Then the screenreturn to the first page of Simulated Output #1 menu.

Use the same method to set the Output Filter.

2006-3-21 12:00:00 Scale#1

SIMULATED OUTPUT #1Type: [RATE ]Range: [ 4-20 mA ]Delay: [ 0 sec ]Filter: [ 0 ]



2006-3-21 12:00:00 Scale #1

SIMULATED OUTPUT #1Type: [ RATE ]Range: [ 4-20 mA ]Delay: 0Filter: [ 0 ]




45

In the first page of Simulated Output #1 menu, move the cursor to “Type” with Up/Down scroll keys andpress ENT key, the following screen appears:

When press “ENTR” soft key, the output type value changes among “No define”, “Rate ”, “Load” and“Speed”. When the desired option is displayed, press “SURE” soft key to input the value. At this time thescreen returns to the first page of Simulated Output #1. You can use the same method to setup otherunits listed in the menu. The Range has two options: 4-20mA and 0-20mA.

From the first page of Simulated Output #1, press “PAGE DOWN” soft key to enter the seventh page ofthe I/O Definition Menu.

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SIMULATED OUTPUT #1Type: RateRange: [ 4-20 mA ]Delay: [ 0 ]Filter: [ 0 ]

Press↑or↓ key, then present!

MAIN ENTR SURE PAGE PAGEMENU DOWN UP

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SIMULATED OUTPUT #2Type: [Rate]Range: [ 4-20 mA ]Delay: [ 0 ]Filter: [ 0 ]




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Set the simulated output port 2 in the same way as mentioned above.Pressing “PAGE DOWN” soft key enters the eighth page of the I/O Definition Menu.

The simulated input value changes among “No Define”, “Moisture ” and “Inclination”.Pressing “PAGE DOWN” soft key enters the ninth page of the I/O Definition Menu.

Press ENT key, the following screen appears:

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SIMULATED INPUTInput #1: [ NO DEFINE ]Input #2: [ NO DEFINE ]

Press↑or↓ key，then press ENT!


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COMPENSATION EFFECTInclinations: [ NO ]Moisture: [ NO ]



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COMPENSATION EFFECTInclinations: NOMoisture: [ NO ]




47

When press “ENTR” soft key, the output type value changes between “YES” and “NO ”. When thedesired option is displayed, press “SURE” soft key to input the value.Pressing “PAGE DOWN” soft key enters the tenth page of the I/O Definition Menu.


Use the numeric keys to input the settings firstly, then press “SURE” soft key to confirm.Pressing “PAGE DOWN” soft key enters the eleventh page of the I/O Definition Menu.

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ANGLE COMPENSATIONMin Angle: [ - 25 ]Max Angle: [ 25 ]


MAIN SURE PAGE PAGEMENU DOWN UP

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ANGLE COMPENSATIONMin Angle: - 25Max Angle: [ 25 ]


MAIN +/ - SURE PAGE PAGEMENU DOWN UP

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MOISURE COMPENSATIONMin Moisture: [ 10 % ]Min Voltage: [ 2 V ]Max Moisture: [ 80 % ]Max Voltage: [ 5 V ]




48

Pressing “PAGE DOWN” soft key enters the twelfth page of the I/O Definition Menu.

Pressing “PAGE DOWN” soft key enters the thirteenth page of the I/O Definition Menu.

3.3.53.3.53.3.53.3.5 CommunicationCommunicationCommunicationCommunication MenuMenuMenuMenuPressing “5” from Main Menu enters the first page of the Communication Menu.

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OUPUT DATATotalizer: [ 1t ]Width: [ 0.1sec ]



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CLIP DETECTOR DATAMode: [ MANU ]Length: [ 1 m ]


MAIN PAGEMENU UP

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COMMPORT 1 SETUPFunction: [ MODBUS ]Baud Rate: [ 115200 ]

Word Length: [ 8 BIT ]Stop Bit: [ 1 BIT ]


MAIN PAGEMENU DOWN


49

Press the Up/Down scroll keys to move the cursor to the item that to be set, followed by [ENT] key.Press ENTR soft key to view the optional settings and press SURE soft key until the desired value isdisplayed.

Function: NO DEFINE, MODBUS, PRINTBaud Rate: 4800, 9600, 19200, 38400, 115200Word Length: 8 BIT, 7 BITStop Bit: 1 BIT, 2 BIT

Pressing “PAGE DOWN” soft key enters the second page of the Communication Menu.

Parity: NONE, EVEN, ODDAddress: 1-255

Pressing “PAGE DOWN” soft key enters the third page of the Communication Menu.

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COMMPORT 1 SETUPParity: [ NONE ]

Address: [ 1 ]



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COMMPORT 2 SETUPFunction: [ MODBUS ]Baud Rate: [ 115200 ]

Word Length: [ 8 BIT ]Stop Bit: [ 1 BIT ]




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Pressing “PAGE DOWN” soft key enters the fourth page of the Communication Menu.

Function has three options: [No Define], [Modbus] and [Print]. Baud Rate can be set to one of thefollowing figures: 4800, 9600, 19200, 38400 or 115200. Word Length can be set to [7 bits] or [8 bits].Stop Bit can be set to [1 bit] or [2 bits]. Parity is selectable among [None], [Even] and [Odd]. Addresscan be set between 1 and 255.

3.3.63.3.63.3.63.3.6 AlarmAlarmAlarmAlarm SetupSetupSetupSetup MenuMenuMenuMenu

Pressing “6” from the second page of Main Menu enters the first page of the Alarm Setup Menu.

The options of output port function include: “High Rate”, “Low Rate”, “High Load”, “Low Load”, “HighSpeed”, “Low Speed”, “Belt Slipage”.

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COMMPORT 2 SETUPParity: [ NONE ]


MAIN PAGEMENU UP

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ALARM SETUP 1Alarm 1: [ NO DEFINE ]Alarm 2: [ NO DEFINE ]Alarm 3: [ NO DEFINE ]Alarm 4: [ NO DEFINE ]


MAIN PAGEMENU DOWN


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Pressing “PAGE DOWN” soft key enters the second page of the Alarm Setup Menu.

Pressing “PAGE DOWN” soft key enters the third page of the Alarm Setup Menu.

Pressing “PAGE DOWN” soft key enters the fourth page of the Alarm Setup Menu.

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ALARM SETUP 2Alarm 5: [ NO DEFINE ]Alarm 6: [ NO DEFINE ]Alarm 7: [ NO DEFINE ]Alarm 8: [ NO DEFINE ]



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RATEALARM SETUPHigh Rate: [ 80 %]

Delay: [ 1 sec ]Low Rate: [ 20 % ]

Delay: [ 1 sec ]



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LOADALARM SETUPHigh Load: [ 80 %]

Delay: [ 1 sec ]Low Load: [ 20 % ]

Delay: [ 1 sec ]




52

Pressing “PAGE DOWN” soft key enters the fifth page of the Alarm Setup Menu.

Pressing “PAGE DOWN” soft key enters the sixth page of the Alarm Setup Menu.

Pressing “PAGE DOWN” soft key enters the seventh page of the Alarm Setup Menu.

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SPEEDALARM SETUPHigh Speed: [ 80 %]

Delay: [ 1 sec ]Low Speed: [ 20 % ]

Delay: [ 1 sec ]



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SLIPPAGEALRM SETUPDeviation: [ 80 %]

Delay: [ 1 sec ]



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ALARM RESET SETUPReset: [ AUTO ]




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3.3.73.3.73.3.73.3.7 LoadoutLoadoutLoadoutLoadout SetupSetupSetupSetup MenuMenuMenuMenu

Pressing “7” from the second page of Main Menu enters the first page of the Loadout Setup Menu.

Pressing “PAGE DOWN” soft key enters the second page of the Loadout Setup Menu.

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LOADOUT SETUP 1Weight: [ 50 t ]Correct: [ AUTO ]

Pre Value: [ 5 t]Pre Range: [ 10% ]


MAIN PAGEMENU DOWN

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LOADOUT SETUP 2Pre Length: [ 5 m ]

Delay: [ 2 sec ]


MAIN PAGEMENU DOWN


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3.3.83.3.83.3.83.3.8 PasswordPasswordPasswordPassword SetupSetupSetupSetup MenuMenuMenuMenu

Pressing “8” from the second page of Main Menu enters the first page of the Password Menu.

Press the Up/Down keys to move the cursor to the item that to be set, followed by [ENT] key. Usenumeric keys to input the password settings and press [ENT] to confirm.The defaulted password is null. Enter “0” or just leave it blank to access enter the next page.

Inputting the correct passwords enters the second page of the Password Menu.

Press TOT RSET soft key to reset the master total.

Pressing “PAGE DOWN” soft key enters the third page of the Password Menu.

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SYSTEM PASSWORD SETUPSystem word: [ ]Operate word: [ ]


MAIN PAGEMENU DOWN

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OPERAT PASSWORD SETUPSystem Word: [ NO PROTECT ]Operate Word: [ NO PROTECT ]

Correct!If clear main Tot, press TOT RSET!

MAIN TOT PAGEMENU RSET DOWN


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Pressing “PAGE DOWN” soft key enters the fourth page of the Password Menu.

Pressing “PAGE DOWN” soft key enters the fifth page of the Password Menu.

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SYSTEM PASSWORD SETUPSystem word: [ ]Sure word: [ ]


MAIN SAVE PAGE PAGEMENU WORD DOWN UP

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OPERAT PASSWORD SETUPOperate word: [ ]

Sure word: [ ]

Press↑or↓key, then press ENT!

MAIN SAVE PAGEMENU WORD UP

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OPERAT PASSWORD SETUPSystem : [ NO PROTECT ]Operate: [ NO PROTECT ]


MAIN PAGEMENU DOWN


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3.3.93.3.93.3.93.3.9 DiagnosticsDiagnosticsDiagnosticsDiagnostics MenuMenuMenuMenuPressing “9” from the second page of Main Menu enters the first page of the Diagnostics Menu.

Press the Up/Down keys to move the cursor to the item that to be set, followed by [ENT] key. Usenumeric keys to input the settings and press [ENT] to confirm.

3.3.103.3.103.3.103.3.10 StatisticsStatisticsStatisticsStatistics MenuMenuMenuMenu

Pressing “0” from the second page of Main Menu enters the first page of the Statistics Menu.

This screen defines the working system for the first shift (Class indicated in the menus). Press theUp/Down keys to move the cursor to the item that to be set, followed by [ENT] key. Use numeric keys toinput the settings and press [ENT] to confirm.

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DIAGNOSTICSWeight: [ 1000000 ]Speed: [ 200 ]Pulses: [10000]


MAINMENU

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CLASS 1 SETUPStart hour: [ 0 ]Start min: [ 0 ]End hour: [ 5 ]End min: [ 59 ]


MAIN PAGEMENU DOWN


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Pressing “PAGE DOWN” soft key enters the second page of the Statistics Menu.

This screen defines the working system for the second shift.Pressing “PAGE DOWN” soft key enters the third page of the Statistics Menu.

This screen defines the working system for the third shift.Pressing “PAGE DOWN” soft key enters the fourth page of the Statistics Menu.

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This screen defines the working system for the fourth shift.Pressing “PAGE DOWN” soft key enters the fifth page of the Statistics Menu.

Press the Up/Down keys to move the cursor to the item that to be set, followed by [ENT] key. Usenumeric keys to input the settings and press [ENT] to confirm.Pressing “CLAS STAT” soft key enters the sixth page of the Statistics Menu.

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CLASS STATISTICTotal: [ 1 00 ]


MAIN TOT CLAS CLASMENU PRNT PRNT RSET

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CLASS STATISTICStart hour: [ 18 ]

Date: [ 1 ]


MAIN CLAS PAGEMENU STAT UP


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ChapterChapterChapterChapter 4444 IntegratorIntegratorIntegratorIntegrator MaintenanceMaintenanceMaintenanceMaintenance

4.1 DailyDailyDailyDaily MaintenanceMaintenanceMaintenanceMaintenance RoutinesRoutinesRoutinesRoutines ofofofof 6105610561056105 IntegratorIntegratorIntegratorIntegrator

This chapter describes preventive maintenance practice for the 6105 integrator that should be done tominimize downtime and extend the life of the equipment. Developing a preventive maintenanceschedule will ensure that critical maintenance procedures are not missed.

A. Check power supply· Check that the voltage selector switch is set to the correct position.· Check that the fuse is good.· Check that the power is switched ON to energize the 6105.

B. Check all wire connections carefully.· Check that all the terminals are tightly connected.· Check that the remote counter and the optional input/output module are firmly plugged in system

slots.· Check that the display board and keypad interface is secured.· Check that all the jumpers are set correctly.

4.2 6105610561056105 IntegratorIntegratorIntegratorIntegrator TroubleshootingTroubleshootingTroubleshootingTroubleshooting ------------ FaultFaultFaultFault IsolationIsolationIsolationIsolation

To locate the fault of the belt scale, a specified troubleshooting routine should be executed. Thefollowing troubleshooting flow chart (Figure 6-1) helps understand the operation of the system, andlocate the trouble component among the following hardware accordingly.

· Load cell· Speed sensor· Power supply assembly· CPU board· Display board· Power output board


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No Bad

Yes Normal

Yes Yes

No No

YesNo Bad

NormalNormal

No

YesNo Yes No

Yes No

Yes

Figure 6-1 6105 Integrator Troubleshooting Flow Chart

End

Display illuminates Check power supply

Touchkeys act correctly

Repair power supply

Set up the 6105 again Repair CPU board

Visual inspection

6105 fails

Display fault Record and reseterror

Internall test is normal

Flowrate indication isnormal Check speed input

Total indication is normal

Check load cell input

Remote Total is normal Check relay actions

Current output is normal Repair current baord


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4.2.14.2.14.2.14.2.1 PowerPowerPowerPower SupplySupplySupplySupply ExaminationExaminationExaminationExamination

Measure the AC voltage at the output terminal of the transformer using the two probes of the ACvoltmeter. Check that the measurement is in line with that specified on the transformer.

4.2.24.2.24.2.24.2.2 SpeedSpeedSpeedSpeed InputInputInputInput

Check speed input signal according to the flowchart in Figure 6-2. This examination should beperformed after the belt scale is powered on and has been running in normal speed. The speed signalis in the form of pulses emitted by the speed sensor. The number of speed pulses can be learnt fromthe Diagnostics menu of the 6105.

Figure 6-2 Troubleshooting the Speed Input

4.2.34.2.34.2.34.2.3 LoadLoadLoadLoad CellCellCellCell InputInputInputInputCheck load cell input signal according to the flow chart in Figure 6-3 based on the following conditions:· Powered connected equipments· At normal belt speed· Empty load· Normal load cell input signalCheck that the weight indication displayed in Diagnostics menu of the 6105 integrator is between 1 and16777216. The weight indication should be changed in the same direction as the sense of desiredresult. If the weight indication is beyond the given range, there may be problems with load cell, wireconnection or CPU board. In this case, press RUN key to stop the examination of load cell input.

Start

Speed input examinationmenu→Diagnostics→

Observe change of speedsignal (Refer to 5.3.10)

Speed input is normal.

End

No speed inputCheck speedsensor and its

wiring

Speed inputpart of CPUboard fails

Repair or replace


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Yes

No

Normal

No

No

Yes

Figure 6-3 Troubleshooting Load Cell Input

4.2.44.2.44.2.44.2.4 CurrentCurrentCurrentCurrent OutputOutputOutputOutput (Optional)(Optional)(Optional)(Optional)Refer to Figure 6-4 Current Output Diagnostics Flow Chart, check the flowrate at different currentoutput ranging from 4mA to 20mA (full range) at a certain interval. In order to check the flowrate at 4mAcurrent output, power up the 6105 and run the belt empty. If the flowrate indication is not zero, reset itby performing zero calibration. Remove the connections from the current output terminals which arethen connected to the DC milli-amperometer correctly (Note that the range of milli-amperometer shouldexceed 20mA). At this time the current output on the milli-amperometer should be 4mA. If a minor

Start

Check load cell input, Power on the6105 and enter Diagnostics menu

The load indication is between 1 and16777216, and increases as the

actual load increases

No load cell inputCheck load cell and wire conntection

Repair and replace

Load cell input isnormal

End

The excitation voltage on the loadcell should be DC 9.5 to 10.5V

The voltage between signal leads ofthe load cell should be lower than 30mV

Bad excitation inputon the CPU

Damaged load cell

Bad load cell input onthe CPU board


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deviation is found, the reading can be corrected by adjusting the potentiometer. However, in case that aremarkable deviation exists, the current output board is bad and needs to be changed.

When the 6105 gives correct current output at zero flowrate, the current output at various knownflowrates should be checked. Apply reference weights on the scale and press RUN key on the 6105integrator to determine the flowrate at a percentage of the full load. For example, a belt scale with scalecapacity of 100t/h displays “10”, then the reference weight is 10% of the scale capacity. In this case themilli-amperometer shall give a reading with the same percentage of the full scale. For this example, thereading of the milli-amperometer shall be 16 (20-4)X10%+4mA = 5mA. If incorrect reading occurs, thecurrent output board should be repaired or changed.

NoYes

No

Figure 6-4 Troubleshooting Current Output

Start

Check the current output. Connect power supply to the system. Run the belt emptyat the normal speed, the flowrate indication should be zero. Remove theconnections on the signal output terminals which are then connected to amilli-amperometer.

Check the flowrate indication at current output of 4mA, which should be zero.Otherwise, perform zero calibration.

The reading of milli-amperometer should be 4mA

The current output is normal – 4mA

Check the current output at a known flowrate. Apply reference weights on the scaleand press RUN key to determine the flowrate at a percentage of the scale capacity.

Check the milli-amperometer gives a readingwith the same percentage

The current output baord functions well

End

Bad currentoutput board


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4.2.54.2.54.2.54.2.5 ConstantConstantConstantConstant SetupSetupSetupSetup

For the integrator which is newly put into service or just replaced the battery module, the constantshould be input according to the initial calibration.· Power the integrator on· Input belt speed (establish test duration in calibration menu, the belt must have been running for over

30 minutes with no load.)· Input other constants (zero, span, scale capacity, etc)

4.3 UsualUsualUsualUsual TroubleshootingTroubleshootingTroubleshootingTroubleshooting

When the material is smoothly delivered but the flowrate indication in integrator varies greatly, theremay be various reasons such as: broken load cell, damaged speed sensor, bad integrator, defectivemechanical construction, signal interference, etc. The former three factors have been mentionedhereinbefore. The defective mechanical structure on the site mainly contains: inactive trunnion (adjustthe trunnion screw to improve), loose pull bar (fasten the set nut to improve), material blockage (clearoff material to improve). Eliminate any potential problems perceptible. Signal interference is mainlycaused by electromagnetic field. The preventative measures is to route the signal cable separate frompower cable far away, and ensure that the integrator is grounded well (comply with the groundingspecification).


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ChapterChapterChapterChapter 5555 SpeedSpeedSpeedSpeed SensorSensorSensorSensor


The speed sensor monitors the belt speed. It is directly coupled to a rotary shaft which drives a signalgenerator. The speed sensor submits an output signal at a frequency directly proportional to the shaftspeed.

Figure 7-1 N60 Speed Sensor

5.2 Inspection,Inspection,Inspection,Inspection, UnpackingUnpackingUnpackingUnpacking andandandand StorageStorageStorageStorage

Prior to unpacking the speed sensor, inspect the packages for damage. The shipping carrier may beresponsible for the damage.

Check the equipment for any signs of damage in shipment. Be sure to look for any accessories such ascoupling sleeve, shock absorber arm, control arm spring, etc.

If the speed sensor is not installed on the site recently, it can be safely stored in ambient temperatures

of 0 to 50ºC away from moisture.


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5.3 InstallationInstallationInstallationInstallation

5.3.15.3.15.3.15.3.1 MechanicalMechanicalMechanicalMechanical PartPartPartPart InstallationInstallationInstallationInstallation

Comply with the following guidance for installation of the speed sensor.

1. The N60 speed sensor must be mounted on a belt-driven pulley to ensure an accurate belt-travelreadout. In most applications, the conveyor tail pulley, bend pulley or snubbing roll is the ideallocation. If it is not suitable to install the speed sensor directly on the tail pulley or bend pulley, anspecial roller must be used to mount the N60 speed sensor.Note: Do not mount the N60 speed sensor on the drive pulley.

2. In case that a special roller is applied to mount the N60 speed sensor, the following guidelines mustbe observed.

1) The selected roller should have suitable diameter. The rotary speed of the pulley should be keptwithin the detection range of the N60 speed sensor.

2) The roller should be mounted at the clean area of the return belt to minimize material build-up onthe roller.

3) The roller installed in this way should have the contact surface inclined at an angle of at least 30degrees, because any slippage between the belt and the roller may cause reduced accuracy of thebelt scale.

3. To keep freely floating movement, the speed sensor should be flexibly jointed to the conveyor frameby performing the following steps.

1) Provide a protruding shaft end with 32mm exterior diameter. Directly insert the sleeved speedsensor into it, alternatively insert the speed sensor (12.8mm dia.) into the coupling sleeve, thentighten the bolt.

2) Use two M8X30 bolts to fasten the anti-rotate arm to the N60 speed sensor. A support plate shouldbe welded on the conveyor frame for placing the anti-rotate arm on it parallelly. Then fasten an endof the spring into the round hole at the tail of the anti-rotate arm. And the other end of the springshould be connected to the conveyor frame. The spring should be lightly tensioned wheninstallation.

5.3.25.3.25.3.25.3.2 ElectricalElectricalElectricalElectrical PartPartPartPart InstallationInstallationInstallationInstallation

Go through the following steps to perform electrical installation:1. Remove the cover of the terminal block and dust plug of the interior conduit on the speed sensor.2. Connect a 12mm conduit to the speed sensor cover.3. Route a 2-conductor cable into the speed sensor cover through the conduit.4. Perform wiring and replace the cover of the terminal block.Note: The three leads of the speed sensor should be shieled when wired to the integrator. The shielded

cable should be RVVP2X0.2 or the equivalent. And the shielded line should only be connected tothe interator end (not to the speed sensor end).


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5.4 WorkingWorkingWorkingWorking PrinciplePrinciplePrinciplePrinciple

The speed sensor is virtually a step motor which generates an output signal proportional to the rotaryspeed of the input shaft. The speed sensor signal and load cell signal are combined into themicroprocessor-based integrator which, by multiplying both, generates and displays a true-rate signal inTPH and the total of material fed.

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