Part # BWJCT Junction Box Installation Manual

2016 JUNCTION BOX INSTALLATION MANUAL

Junction Box Installation Manual

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Table of Contents

1. Introduction .......................................................................................................................................... 2

2. What is in the Box? ............................................................................................................................ 3

3. Tools Needed ...................................................................................................................................... 3

4. Installation Procedure ........................................................................................................................ 4

5. Connect Integrator Power ................................................................................................................. 8

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1. Introduction

A junction box is required when the integrator (primary scale controller) must be mounted

greater than 30 ft. from the scale components.

We strongly recommend wireless communications to a remote display whenever possible to

alleviate the long term maintenance issues associated with junction boxes and long cable

installations.

If it is not feasible to use wireless equipment, then our new digital junction box will offer the

best option to remotely monitor a single scale. The new Digital Junction box converts sensitive

analog signals (load cell, speed sensor, angle sensor) to a digital format.

All scale information can be transmitted over one 3 pair cable (6 wires). It is critical that you

follow all Company and government SAFETY procedures when installing this component in the

field. After reading this manual you require any assistance with the installation, wiring, and

setup of the junction box please contact our technical support department.

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2. What is in the Box?

Leave a minimum of 3" clearance on the left side to allow the door to open.

The mounting kit includes 4 feet and 4 - 2.36" (60mm) screws and nuts.

3.Tools Needed

The following basic tools will be needed: 1. 1 QTY – Phillips / Star Head Screw

Driver 2. 1 QTY - Small Flat Head Screw Driver 3. Wire Strippers 4. Lock-Out Tag

The following items are included: 1. 1 - Junction box 2. 4 - Mounting Feet and Screws 3. 3 pair extension cable

(if ordered with the Junction Box)

6.48 in

8.01 in

11.15 in 11.97 in

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4. Installation Procedure

Disconnect power to the integrator at the breaker or disconnect panel. Lock out the supply power while mounting the junction box and working inside the integrator.

STEP 1 Label and Mount Junction Box

Label the junction box on the provided spaces to specify the type and capacity of the scale. Mount the junction box in a secure location within 30 feet of the scale components. Make sure the cables are long enough to easily reach the junction box location. . Route the component cables so they are away from sources of high voltage. Be sure they are protected from falling material and the moving belt. Excess cable may be trimmed.

Step 2 Connect Component Cables to Junction Box Sensor Board

The shield wires on all components must be connected as shown below. Failure to do so will make the scale extremely susceptible to electrical interference.

Installing the shield wire as shown will ground it to the box and reduce interference from electrical noise. When installing 3 or more load cells you will need to strip the wiring back to get additional length and keep the shield wire out of the Integrator.

1. The complete cable needs to be fed through the

grommet hole. 2. The shield then needs to be wrapped backwards

over the grommet and fed through the cord grip nut. 3. Insert the cable through the hole in the integrator enclosure so that the cord grip presses the shield against the housing as the nut is tightened.

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Scale Component Wiring Terminals There are currently two generations of junction box sensor boards.

They function the same but have different style connectors.

Revision 3 Sensor Board Revision 4 Sensor Board

All Load Cells

- SUP - Black

+SUP - Red

- SIG - White

+SIG - Green

Speed Sensor

SIGB - Not Used

SIGA - Green

+5V - Red

GND - Black & White

GND - Not Used

SIGC - Not Used

Angle Sensor

SIG - Green

GND - White

+5V - Red

GND - Black

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STEP 3 Connect RS485 Cable to Junction Box and Integrator Control Box

DO NOT ROUTE THE CABLE NEAR SOURCES OF HIGH VOLTAGE! GROUND THE SHIELD WIRE ON BOTH ENDS OF THE COMMUNICATION CABLE!

SEE PAGE 4 FOR GROUNDING INSTRUCTIONS!

NOTE: Rev 3 Sensor Boards are compatible with Rev 3 Terminal Boards and

Rev 4 Sensor Boards are compatible with Rev 2 Terminal Boards

Disconnect the small ribbon cables labeled SENSOR POWER and SEN RS485 INTERFACE!

They are under the large ribbon cable at board locations P4 & P4_A. The scale will not function

properly with these cables and the junction box connected at the same time!

Junction Box Sensor Board

Revision 3

Integrator Terminal Board

Revision 2

Junction Box Sensor Board

Revision 4

Integrator Terminal Board

Revision 3

RS485 3 Pair Cable

RS485 3 Pair Cable

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Junction Box Sensor Board Integrator Terminal Board

+VIN = SNSR PWR

GND = GND

RX- = TX-

RX+ = TX+

TX- = RX-

TX+ = RX+

This wiring diagram assumes a shielded 3 pair (6 wire) cable is used.

Junction Box Sensor Board RS485 Connector:

Integrator Terminal Board RS485 Connector:

24 VDC Power Output

SNSR PWR - White

GND - Black (White & Black pair)

RS485

TX+ Green

TX - Black (Green & Black pair)

RX+ Red

RX - Black (Red & Black pair)

IMPORTANT - Connect the shield

wire to the cord connector as

shown on the next page.

24 VDC Power input

+VIN - White

GND - Black (White & Black pair)

RS485

RX- Black (Green & Black pair)

RX+ Green

TX- Black (Red & Black pair)

TX+ Red

IMPORTANT - Connect the shield

wire to the cord connector as shown

on the next page.

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5. Connect Integrator Power

OR

OR

Make sure the green LED's on the junction box sensor board are illuminated to

show it is powered up.

Return to the integrator and proceed with the calibration as described in the belt

scale manual.

Contact Belt-Way technical support with further questions.