Version 1.00

Calibration Guide

165860

Contents i

Technical training seminars are available through Rice Lake Weighing Systems.

Course descriptions and dates can be viewed at www.ricelake.com/trainingor obtained by calling 715-234-9171 and asking for the training department.

Contents

1.0 Introduction..................................................................................................................................... 12.0 Overview ......................................................................................................................................... 1

2.1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

3.0 Calibration ...................................................................................................................................... 33.1 Speed Sensor Calibration (Belt Sensor Calibration) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.2 Integrator Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

3.2.1 Zero Cal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53.2.2 Auto Cal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73.2.3 Material Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

© 2013 Rice Lake Weighing Systems. All rights reserved. Printed in the United States of America. Specifications subject to change without notice.

Rice Lake Weighing Systems is an ISO 9001 registered company. October 22, 2014

ii BCi In-Motion Belt Scale System

Rice Lake continually offers web-based video training on a growing selection

of product-related topics at no cost. Visit www.ricelake.com/webinars.

Introduction 1

1.0 IntroductionThis quick setup guide is intended for use by technicians responsible for calibrating the integrator.

WARNINGSome procedures described in this manual require work in and around working parts of the belt scale. These procedures are to be performed by qualified service personnel only.

2.0 OverviewThe integrator front panel, Figure 2-1, consists of a 27-button keypad with a large back-lit LCD display. The keys are grouped as five configurable softkeys, five primary scale functions keys, four navigational keys, and numeric entry keys. It should be noted that the scale parameters and calibration values cannot be changed without first pressing the TARE key and unlocking the parameters. After pressing the TARE key, press enter to unlock the settings. Pressing ZERO when the display is on the main menu will clear the Reset Total.

Figure 2-1. Front Panel

The following sections describe the front panel key operation of the belt scale integrator.

ZeroThis parameter initiates the front panel zero mechanism. Periodic use of the zero parameter is required due to conveyor use and weather conditions.

PrintThis will print the custom ticket if the print port is configured.

Reset TotalizerOften during this operation of a belt scale, the totalizer will need to be reset. This is known as the reset totalizer. Press the Reset Totalizer softkey to access this parameter. The integrator will prompt the user, “Clear Totalizer?” The operator will press Yes to clear the totalizer, or No to leave the accumulated weight in the totalizer.

DiagnosticsThis softkey displays the current mV input, PPS (pulses per second from the speed sensor), current analog output (if installed), current A/D counts, and the master total. This is just informational data that the operator or a technician can use from troubleshooting purposes.

Supervisor ModeUse this softkey to enter the Supervisor Mode. If there is no passcode configured the integrator will enter into the Setup Mode. If a passcode is configured, the operator will need to enter the passcode before the integrator will switch to the Supervisor Mode. To configure a passcode, see the Supervisor’s Parameters.

2 BCi In-Motion Belt Scale System

2.1 SafetySafety Symbol Definitions

DANGER Indicates an imminently hazardous situation that, if not avoided, will result in death or serious injury.

Important

CAUTION

WARNINGIndicates a potentially hazardous situation that, if not avoided, could result in serious injury or death, and includes hazards that are exposed when guards are removed.

Indicates a potentially hazardous situation that, if not avoided may result in minor or moderate injury.

Indicates information about procedures that, if not observed, could result in damage to equipment or corruption to and loss of data.

General Safety

WARNING

Do not operate or work on this equipment unless you have read and understand the instructions and warnings in this manual. Failure to follow the instructions or heed the warnings could result in injury or death. Contact any Rice Lake Weighing Systems dealer for replacement manuals. Proper care is your responsibility.

Failure to heed may result in serious injury or death.

These procedures are to be performed by qualified service personnel only.

Ensure everyone is clear of the scale before applying power

Take all necessary safety precautions when operating the belt scale, including wearing safety shoes, protective eye wear, and using the proper tools.

DO NOT perform maintenance on this scale unit until electrical, air, hydraulic and gravity energy sources have been locked out or blocked.

DO NOT allow minors (children) or inexperienced persons to operate this unit.

DO NOT operate without all shields and guards in place.

DO NOT place fingers into slots or possible pinch points.

DO NOT use any load bearing component that is worn beyond 5% of the original dimension.

DO NOT use this product if any of the components are cracked.

DO NOT exceed the rated load limit of the unit.

DO NOT make alterations or modifications to the unit.

DO NOT remove or obscure warning labels.

Keep hands, feet and loose clothing away from moving parts.

Calibration 3

3.0 CalibrationTo begin calibration, press the Supervisor Mode softkey.

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Supervisor

Mode

Reset

Totalizer

SCALE #1

Diagnostics

Rate

Speed

Totalizer

Load

tn/hr

ft/min

lb/ft

tn

Belt Scale SW PN 154789 1.00

Figure 3-1. Supervisor Mode Softkey

3.1 Speed Sensor Calibration (Belt Sensor Calibration)Use the following steps to calibrate the speed sensor.

1. Press the Belt Calibration softkey from the supervisor’s menu.

Exit=>

SCALE #1

MasterTotalizer

IntegratorCalibrati

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Admin. Passcode (numeric)

Scale Capacity (Max Rate)

Load Cell MV

Total LC Build

Rate Unit Time

Filter (s) Filter Threshold (divisions)

Speed Unit TimeFixed Speed

Unit of Measure

420.00

1.99900

800

hr7.0

2min

0.00ft

BeltCalibration

Time/Date

Figure 3-2. Belt Calibration Softkey

2. The integrator will change the softkeys to Start, Finish and Exit.

Exit=>

SCALE #1

Start Finish

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Admin. Passcode (numeric)

Scale Capacity (Max Rate)

Load Cell MV

Total LC Build

Rate Unit Time

Filter (s) Filter Threshold (divisions)

Speed Unit TimeFixed Speed

Unit of Measure

420.00

1.99900

800

hr7.0

2min

0.00ft

Figure 3-3. Start, Finish and Exit Softkeys

A reference point needs to be marked on the conveyor belt and a reference point needs to be marked on the conveyor frame. This will give the operator a reference to count the number of revolutions the belt travels during the speed calibration. The more revolutions in a test, the better the speed and distance accuracy.

4 BCi In-Motion Belt Scale System

3. Press the Start softkey. This will cause the integrator to change screens displaying the number of pulses counted, the frequency of pulses and the time the test is running, Figure 3-4.

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Exit=>Start

SCALE #1

Time Running

Finish

769 Pulses

122 Per Sec

6.2

Figure 3-4. Start Softkey

The screen illustrates a live display of how the belt is working. If the pulses and frequency are not changing then there is a problem with the speed sensor and can be a sign that either the wiring or the sensor itself is bad. During this cycle of the calibration procedure, the operator needs to count the number of belt revolutions.

4. Press the Finish softkey when the marks are properly aligned and this will stop the speed sensor calibration. The integrator will then prompt the user to Enter The Number of Revolutions (Figure 3-5).

5. The default number is 3 and to change this number, press the CLR key to erase that number and then enter a numeric value from the integrator keypad to enter the new number of revolutions.

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EndHome

SCALE #1

Time Running

Cancel

2282 Pulses

122 Per Sec

18.6

Enter Number of Revolutions

=> 3

Figure 3-5. Enter Number of Revolutions

6. Press the enter key on the integrator to save the value and return to the main supervisor menu.

Calibration 5

3.2 Integrator CalibrationThere are three modes of integrator calibration.

• Zero Cal• Auto Cal• Material Cal

All three calibration methods are described in the following sections.

3.2.1 Zero CalBy selecting this mode it will calibrate the integrator based on a zero test. A zero calibration is based on the number of belt revolutions is established during the belt speed sensor calibration.

Use the following steps to perform a Zero Cal calibration.

1. To access the mentioned softkeys, press the Integrator Calibration softkey.

Exit=>

SCALE #1

MasterTotalizer

IntegratorCalibrati

5/30/2013 08:13AM

Admin. Passcode (numeric)

Scale Capacity (Max Rate)

Load Cell MV

Total LC Build

Rate Unit Time

Filter (s) Filter Threshold (divisions)

Speed Unit TimeFixed Speed

Unit of Measure

420.00

1.99900

800

hr7.0

2min

0.00ft

BeltCalibration

Time/Date

Figure 3-6. Integrator Calibration Softkey

2. Press the Zero Cal softkey on the integrator.

Exit=>

SCALE #1

Auto Cal

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Admin. Passcode (numeric)

Scale Capacity (Max Rate)

Load Cell MV

Total LC Build

Rate Unit Time

Filter (s) Filter Threshold (divisions)

Speed Unit TimeFixed Speed

Unit of Measure

420.00

1.99900

800

hr7.0

2min

0.00ft

Zero CalMaterial

Figure 3-7. Zero Cal Softkey

6 BCi In-Motion Belt Scale System

3. Press the Start softkey.

Exit=>

SCALE #1

Start

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Admin. Passcode (numeric)

Scale Capacity (Max Rate)

Load Cell MV

Total LC Build

Rate Unit Time

Filter (s) Filter Threshold (divisions)

Speed Unit TimeFixed Speed

Unit of Measure

420.00

1.99900

800

hr7.0

2min

0.00ft

Figure 3-8. Start Softkey

The Zero Cal test will run, and will show a progress screen, Figure 3-9.

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Exit =>Start

SCALE #1

Progress

Test Time

Test Accumulator

Old Zero Error %

Zero Error %

6.2

0.3

-0.03

Figure 3-9. Zero Cal Test Running

After the test is completed the new zero error % will be shown on the display.

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NoYes

SCALE #1

Progress

Test Time

Test Accumulator

Old Zero Error %

Zero Error %

6.2

66.7

38.58

Accept New Zero

0.00%

Figure 3-10. Zero Error % Complete

Calibration 7

4. Press Yes to accept the value. Repeat the zero cal until the zero percent error is very near to zero error percent

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Exit=>Start

SCALE #1

Progress

Test Time

Test Accumulator

Old Zero Error %

Zero Error %

6.2

66.7

38.58

0.00%

Figure 3-11. Exit Zero Cal

5. Press the Exit softkey to exit back to the integrator weigh screen.

3.2.2 Auto CalPress the Auto Cal softkey to move on to Auto Cal.

Exit=>

SCALE #1

Auto Cal

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Admin. Passcode (numeric)

Scale Capacity (Max Rate)

Load Cell MV

Total LC Build

Rate Unit Time

Filter (s) Filter Threshold (divisions)

Speed Unit TimeFixed Speed

Unit of Measure

420.00

1.99900

800

hr7.0

2min

0.00ft

Zero CalMaterial

Figure 3-12. Enter Auto Cal

A. Test Weight Procedure1. Place a known weight on the weight hangers.2. Press the Test Weights softkey.

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Exit =>Test

Weights

SCALE #1

Progress

Test Time

Test Accumulator

Old Span Error %

Span Error %

6.2

0.0

2.55

0.00%

Test Chain

Figure 3-13. Test Weights Procedure

8 BCi In-Motion Belt Scale System

3. Press the Start softkey

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Exit =>Start

SCALE #1

Progress

Test Time

Test Accumulator

Old Span Error %

Span Error %

6.2

0.00

2.55

0.00%

Figure 3-14. Start Auto Cal with Test Weights

4. The Auto Cal test will run, and progress is shown on the screen. A prompt to enter a test weight value will display.

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EndHome

SCALE #1

Progress

Test Time

Test Accumulator

Old Span Error %

Span Error %

18.8

62

0.00

Enter Test Weight Value=> 10.0

Cancel

Figure 3-15. Enter Test Weight Value

5. Press the CLR key on the integrator to clear off the current value, enter a new test weight value using the numeric keypad.

6. Press the enter key on the integrator to accept the next test weight value. After the test the test weight value is entered, the new span error is displayed.

7. Press the Yes softkey to accept that value.8. Repeat the test until the new span percent error is very near zero and then accept the new span value by

pressing the Yes softkey.

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NoYes

SCALE #1

Progress

Test Time

Test Accumulator

Old Span Error %

Span Error %

18.8

62

95.00

0.10

Accept New Span Value

Figure 3-16. Accept Span Value

9. Press the Exit softkey to exit back to the integrator weigh screen.

Calibration 9

B. Test Chain Procedure10. Place test chain on conveyor, spanning over the weighing area.

11. Press the Test Chain softkey.

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Exit =>Test

Weights

SCALE #1

Progress

Test Time

Test Accumulator

Old Span Error %

Span Error %

6.2

0.0

2.55

0.00%

Test Chain

Figure 3-17. Test Chain Procedure

12. Press the Start softkey

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Exit =>Start

SCALE #1

Progress

Test Time

Test Accumulator

Old Span Error %

Span Error %

6.2

0.00

2.55

0.00%

Figure 3-18. Start Test Chain Procedure

The Auto Cal test will run, and will show a progress screen. A prompt to enter a test chain value will display. The test chain value is noted in lb/ft.

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EndHome

SCALE #1

Progress

Test Time

Test Accumulator

Old Span Error %

Span Error %

18.8

62

0.00

Enter Test Chain Value=> 10.0

Cancel

Figure 3-19. Enter Test Chain Value

13. Press the CLR key on the integrator to clear off the current value, enter a new test chain value using the numeric keypad.

14. Press the enter key on the integrator to accept the next test chain value. After the test chain value is entered, the new span error is displayed.

10 BCi In-Motion Belt Scale System

15. Press the Yes softkey to accept that value.

16. Repeat the test until the new span percent error is very near zero and then accept the new span value by pressing the Yes softkey.

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NoYes

SCALE #1

Progress

Test Time

Test Accumulator

Old Span Error %

Span Error %

18.8

62

95.00

0.10

Accept New Span Value

Figure 3-20. Accept New Span Value

17. Press Exit until back at the integrator weigh screen.

3.2.3 Material CalibrationUse this calibration mode to calibrate the scale with a known amount of material. The material must be pre-weighed or post weighed.

To perform a material calibration, choose the Material Cal softkey and follow the same steps as a Span Calibration and instead of entering a test weight value, enter the weight of the material used in tons.

230 W. Coleman St. • Rice Lake, WI 54868 • USAU.S. 800-472-6703 • Canada/Mexico 800-321-6703 • International 715-234-9171 • Europe +31 (0)26 472 1319

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