Step8 -ConnectCableShields

Step 1-Mount Load Cell Assemblies

HolesforTestWeights

FoldShield Over Grommet

(All Cables - Belden 8723 or equivalent)

Step 9-Calibrate Scale

Step 2-Drill Mounting Holes

Step 4-Align the Scale

1 2 3 4 5

PowerSupply

Top ofConveyor Frame

Step 3-Mount Speed Sensor

U-Bolts

Plastic Pipe Caps

LoadCellAssbl.Overload Stop

Makesuretheseboltsdonotprotrudethroughmountingplateandhittheloadcelltube!

Your Idler

V-Block

Leveling Boltsand Jam Nuts

Leveling Pad

Center pipe inrectangular opening

1/4” minimumclearence required.(Cut mounting feetoff if needed)

Idler Mounting Plate withOverload & Underload Stops

PlasticPipeClamps

INSTRUCTION MANUALR

Step 8-Connect Cable Shields

Step 7-Install Angle Sensor (Optional)

Step 6-Mount Control and Power Supply

Step 5-Install Plastic Pipe Clamps

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BELT - WAY INSTRUCTION MANUALR

Sauk Valley Systems One Belt Way Rock Falls, IL 61071 Phone 815 625-5573 Fax 815 625-5593

Table of Contents

READ THIS PAGE FIRST

MECHANICAL INSTALLATION Page 3 - 4

OPTIONAL ANGLE SENSOR Page 5

CONFIGURATION SWITCHES Page 5

ELECTRICAL INSTALLATION Page 6

THE NETWORK Page 7

DISPLAYS Page 8

AMPLIFIER GAIN TABLE Page 9

ANALOG CALIBRATION Page 10

DIGITAL CALIBRATION Page 11-13

ALTERNATE SET ZERO Page 14

FUNCTION KEY F1 Page 15F1 is used to enter test weight, idlerspan, and low speed alarm / interlock

FUNCTION KEY F2 Page 16-22F2 is used to control analog outputsand set up a PID loop

FUNCTION KEY F3 Page 23-24F3 is used to set log rate, view logtime, send rate to other scales, andto use special speed encoders

FUNCTION KEY F4 Page 25F4 is used for master total, time, date

FUNCTION KEY F5 Page 26-27F5 is used for loading trucks or batching

FUNCTION KEY F6 Page 28F6 is used to control pulsed output,auto zero, and long belts

FUNCTION KEY F7 Page 29-31F7 is used to control the RS-232serial output

FUNCTION KEY F8 Page 32F8 is used to print tickets

TEST KEY T1 Page 33T1 is used to view analog todigital converter outputs

TEST KEY T2 Page 33T2 is used to view configurationswitches and software version

TEST KEY T3 Page 33T3 is used to view belt load andtotal weight on the scale

TROUBLESHOOTING Page 34-36

MODEM DATA COLLECTION Page 37-38

TEST MODE Page 39

CONVEYOR DESIGN Page 40

WARRANTY Page 41

MODEM MENU Page 42

ERROR MESSAGES Page 42

WIRING DIAGRAMS Page 42

BELT - WAY INSTRUCTION MANUAL

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Read This Page First

SCALE LOCATION GUIDELINES

If you select the wrong idler to mount the scale, the rest of this book will not matter.

Normally, for accessibilty, mount the scale in the lower 1/3 of the conveyor. Two idlers before the scaleidler, the scale idler, and two idlers after the scale constitute the weighing area.

Scale Idler

Five Idler Weighing Area

These five idlers must be the same width, trough angle, and diameter.

Replace any idlers in bad mechanical condition.

Skirting must not make contact with the belt in this area.

Loading (impacting the belt) must not take place in this area.

All five idlers in this area must be string lined. Shim if necessary.

Avoid locations where the belt may lift off the weighing area idlers due to upward curve of the conveyoror proximity to the head pulley.

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Mechanical Installation

Before you begin, circle the model number of yourscale above. It is located on each load cell tube.Write down the date. Select the idler to mount onthe scale. Be sure to read the previous page.

The bolt on the bottom center of the load cellassembly is an overload stop. There are twoshoulder bolts under cover plates at the ends of theidler mounting plate. These are overload andunderload stops. DO NOT ADJUST THESEBOLTS.

See Photo Step #1 to mount the two load cells.Mount the load cell assemblies on the idler. The endwith the cable should be mounted on the low sidefor drainage. This hanger has a rectangular hole tomake alignment easier. Center the pipe in therectangle. Use the "V" blocks to attach the loadcells to the angle iron frame of the idler. The hole inthe V block should be on the high side of theconveyor. This hole is used for test weights. Don'ttighten the bolts at this time. Mount the load cells sothey are slightly in from the edge of the belt. Thiswill keep rocks falling off the edge of the belt fromhitting the load cells. If your idler frame uses angleiron less than 2 1/2" you may need shorter bolts.Make sure the bolts do not project through the idlermounting plate and touch the load cell tube. Thiswould prevent the scale from working. The boltssupplied are 3/8 - 16 by 3 1/2 inches long. You canturn the V notch up if your idler frame is channeliron.

Slide the two pipes through the load cell hangers.Use the leveling pads as a drill template. Align thepads so the holes for the "U" bolts are centeredunder the pipes. Center the pipe in the hangers withthe rectangular hole. Use welding clamps or Cclamps to hold the pads and drill through the twoinner holes using a 3/8" drill bit. The outer threadedholes are used for the leveling bolts. The frame mustnot be drilled in these locations. A total of 8 holesare required. See the drawing at the end of thismanual for hole details.See Photo Step #3 to mount the speed sensor.Mount the digital speed sensor on either the frontpipe as shown or on the rear pipe with the wheel incontact with the return belt. If it is not possible tomount the speed sensor on either of the pipesbecause of mechanical obstructions, you may use athird pipe to locate the sensor where it will fit.

See Photo #2 to drill the mounting holes.Cut the 1 1/4" galvanized pipes to fit the outerwidth of your conveyor.

See Photo Step #4 to align the scale.Install the leveling bolts and jam nuts in the levelingpads. Install the "U" bolts and leveling pads on bothpipes. DO NOT TIGHTEN THE "U" BOLTSAT THIS TIME. Tighten the load cell assembliesto the idler assembly. Use the leveling bolts to bringthe leveling pads up to just touch the bottom of thepipes. Do not tighten them. Warning ... if youtighten the leveling bolts or "U" bolts with awrench at this time you will damage the loadcells since the idler feet are still fastened to theconveyor frame. The leveling pads should all bethe same distance above the conveyor frame forgreatest accuracy. At this point you have twooptions. You can cut the mounting feet off the idlerassembly so it is supported only by the load cells.Remove the bolts holding the feet to the conveyorand discard the feet.

MODEL # 30 45 100 200 DATE _______


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Make sure all cables are securely tied and protectedso they will not be damaged by rocks falling fromthe conveyor and be sure they can not come incontact with any moving parts. Secure cables to theunder side of angles or braces to protect them.Youmay want to run your load cell cables and speedsensor cable in conduit. In that case you can removethe existing fittings from the ends of the load celltubes and speed sensor tube and attach your conduitin the same holes.

Route the cables from the two load cell assemblies,the digital speed sensor, and angle sensor to thecontrol box. Keep the scale wiring at least 2 feetfrom any high voltage wiring.

See Photo #6 to mount control and power supply.Mount the control box near the conveyor. Use themounting feet supplied. Do not drill through thebox. The display will be much easier to read if thesun does not shine directly on it. You can mount thecontrol box and power supply up to 1000 feet awayfrom the conveyor. Extend the two load cell cables,the speed sensor cable, and the angle sensor cable.You should use Belden 8723 or equivalent cable.All splices must be soldered or fastened using screwterminals in a junction box. Do not use wire nuts orcrimp connectors. Mount the power supplytransformer housing near the control box closeenough to be sure the power supply cable will reachthe control box. Mount it with the cables at thebottom to prevent water from entering the box.

pipe clamps so the entire weigh bridge can move onthe pipes. This is important for proper weighing.Install the plastic caps in both ends of the pipe.

Mechanical Installation

Align at least 5 idlers, using a string, so all five idlersare in line within 1/32". You may need to shim theidler assemblies. Use the leveling bolts to align theidler on the scale. The leveling pads should all beabout the same height above the conveyor frame.Tighten the "U" bolts and leveling bolt jam nuts.IMPORTANT: When you are finished you shouldbe able to lift each load cell assembly about 1/32" oneach pipe mount. If you can not, the pipes may notbe parallel or may be at different heights. Carefullyadjust the leveling bolts and "U" bolts until the loadcells are free to move up and down slightly on thepipes. This is important for accurate weighing.

Idler 1 Idler 2 Scale Idler Idler 4 Idler 5

If you choose not to cut the feet off remove the boltsholding the idler assembly to the conveyor. Use theleveling bolts to raise the idler attached to the loadcells so there is at least 1/4" clearance between thefoot and the conveyor. Shim at least the two idlerson each side of the scale to align with the idler on thescale. You may need to shim other idlers as well.

See Photo Step #5, install the plastic pipe clamps.Install two pipe clamps to keep the digital speedsensor from moving on the pipes. The wheel shouldtrack near the center of the belt. Install the otherfour pipe clamps on the pipes near the inside of eachload cell hanger. You should leave about 1/16clearance between each load cell hanger and the

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Automatic Angle Compensation Configuration Switches

.

See Photo #7 if you purchased an angle sensor.The automatic angle sensor option allows you tochange the angle of the conveyor without having tocalibrate your scale again. The angle sensor hasbeen calibrated at the factory to read 0.0 degreeswhen the top of the sensor is level. The sensor ismounted in a plastic box riveted to an angle bracket.Simply mount the angle bracket to the top of theconveyor frame using 3/8 bolts and nuts. This willenable the sensor to accurately measure the angle ofyour conveyor. The angle sensor is set up to readpositive angles when mounted on the right handside of the conveyor when looking in the directionof belt travel. If you mount the sensor on the otherside of the conveyor the angle will read negative,but the sensor will still work properly. Route thecable to the control box so that it will not bedamaged by rocks which may fall from the conveyor.The control is shipped with a jumper wire betweenangle sensor terminals marked SIG and A-GND.Remove this jumper if you install an angle sensor.Cable grip #2 is shipped with a metal disk installedto keep the box waterproof. Remove this metal diskwhen you wire the angle sensor. When you configureand calibrate the scale, you will be instructed to turnon a switch SW1 position 5 which enables the anglesensor. This switch is located on the circuit boardon the inside of the control box door.

Configuration switches SW1 and SW2 are locatedon the circuit board on the inside of the door.

9 Not used Switch SW28 Enable oscillator test mode7 Enable load cell test mode6 Enable alternate set zero5 Enable clearing log time4 Disable changing load weights3 Enable COLOR BRITE display2 Enable analog outputs 3 & 41 Set zero always enabled

9 Turn on display backlight Switch SW18 Enable I/O & 2 analog outputs7 Enable minute time base6 Enable metric units5 Enable angle sensor4 Use special encoder3 Enable clear master total2 Enable clear weight1 Enable keypad except clear weight

If you turn on switch SW1 position 8 but do nothave an I/O option board, the display and thekeypad will not work. If you turn on switch SW2position 2 but do not have channels 3 and 4 in yourI/O option board, the display and the keypad willnot work. If this condition occurs, turn off thepower to the control box. Turn off SW1 position 8or SW2 position 2. Turn the power on.

Switches SW2 position 7 & 8 activate test modeand should be turned off for normal operation.

The backlight switch, SW1 position 9, and thecontrast adjust control, TP1, are used with controlswhich have liquid crystal displays. If your controlhas a blue green vacuum fluorescent display, theseitems are not used.


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Power SupplyRoute the cable from the power transformer throughthe cable grip 3. Connect the positive wire identifiedby a colored stripe or rib to the terminal marked+12VDC. Connect the other wire to the terminalmarked 12V GND. If these wires are connectedbackwards the control will not work. Don't connectthe 120 volt AC power to the transformer yet.Load Cell #2Route one of the load cell cables through cable grip4. Connect the black wire to the load cell #2terminal marked -SUP. Connect the red wire to theterminal marked +SUP. Connect the white wire tothe terminal marked -SIG. Connect the green wireto the terminal marked +SIG.Load Cell #1Route the other load cell cable through cable grip 5and connect the wires to load cell #1. Route eachcable neatly so it has a little slack and tighten all thecable grips.The terminals marked - and + areswitched 12VDC to power the I/O option board.The terminals marked P5 and P6 are not used.Connect AC power to the Power Supply

Electrical Installation

NOTE: If you splice any of the cables be sure tosolder and insulate each connection. A junctionbox is available which will eliminate soldering.

See Photo Step #8 to connect the cable shields.Fold the shield back over the rubber grommet in thecord grip so it is pressed against the metal cord grip.This is important to keep interference from radiosor motors from affecting the scale. This applies toload cell, speed sensor, and angle sensor cables.Speed SensorEach of the terminal blocks can be pulled out of theterminal strip for easier access or trouble shooting.Connect the cable from the digital speed sensor toTS1. Route the cable through the cable grip 1. Seephoto #6. Connect the black wire and the white wireto the terminal marked GND on the digital speedsensor terminal block. Connect the red wire to theterminal marked +5VDC. Connect the green wireto the terminal marked SIG A. SIG B and LED 3are not used.Angle Sensor (optional)If you purchased an angle sensor, route the cablethrough cable grip 2. Remove the metal disk fromthe cable grip. Connect the black wire to the anglesensor terminal marked GND. Connect the redwire to the terminal marked +5VDC. Remove thejumper between SIG and A-GND. Connect thewhite wire to the terminal marked A-GND. Connectthe green wire to the terminal marked SIG.RS-232 outputIf you are using the RS-232 serial port, connectyour cable to the RS-232 terminal block. Use cablegrip 2 if you do not have an angle sensor. Connectblack to GND, red to RXD, and white to TXD. Ifyou are using a printer, you only need GND andTXD. You also need RXD with a modem or PC.

After all cables are connected, wire the 120 volt ACpower to the transformer. The transformer is housedin a small waterproof electrical box. Connect your120 volt AC wiring to the socket provided. If youare using a generator for power, install a switch inthe 120 volt AC line to the power supply. Toprevent possible loss of data at startup turn thegenerator on first and then the control. At shutdownturn the control off first and then the generator. The12 volt cable exits the box through a waterproofcord grip. The 120 volt wiring enters the boxthrough a separate cord grip. Replace the cover onthe plastic box and tighten the screws.

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The second configuration is called a star. It uses acentral hub which is not used in a bus configuration.Assume the hub is an 8 port active hub. You canhave 8 devices connected. One device connects toeach port. You can run the cable 2000 feet for eachdevice. You can connect more than 8 devices bymaking one of the devices another active hub.

Network Connections

The terminals marked BNC 1 and BNC 2 at thebottom of the circuit board have BNC connectorsthat extend through the bottom of the box. Theconnectors may have vinyl caps over them to protectthem. You must connect the network using coaxialcable type RG62A/U. BNC connectors are availablein several styles. Some solder on to the cable. Somecrimp on to the cable. Others simply twist on to thecable. It is important to use a high quality connector.Most network problems can be traced to poorconnections between the cable and the connector.We provide a high quality cable capable of beingburied in the ground. We recommend using aconnector that solders on to obtain the bestconnection. See the drawing at the end of themanual.

the controls is run the cable from one device to thenext. It does not matter which connector you usefor the cable coming in and the cable going out. Atone end of the cable the last control will have a cablegoing in but none going out. You must connect a 93ohm terminator to the last connector. This is simplya BNC connector with a terminating resistor in it.At the other end of the cable may be a PC in an officeor trailer. It must be connected with a BNC "T"connector and a 93 ohm terminator. The center ofthe "T" goes to the PC. One end of the "T" goes tothe cable, and the other end has a 93 ohm terminator.Instead of a PC, you may have a remote display oranother scale. Install a 93 ohm terminator on theunused BNC connector. Remember, the maximumcable length is 1000 feet and the maximum numberof devices is 8.

The network is an industry standard network. Thereare 3 possible cable configurations. The simplestand least costly is called a bus configuration. Thetotal length of cable in one bus is 1000 feet. You canconnect up to 8 stations on one bus. If your layoutmeets these requirements, the easiest way to connect

If you are using the network to collect data in a PC,or you are using a remote display, you must set eachcontrol box to a unique station node. Node 0 is notallowed. Node 255 is reserved for a PC or remotedisplay. Valid nodes you can use are 1 to 254. Wesuggest using node 1 for scale 1, node 2 for scale 2,etc.

To set the network station node, press the NODE key.Then press the SELECT key and a small arrow willappear after the word node. Use the arrow keys toset the node for this scale. Be sure no two scales areset to the same node. If any two scales have the samenode the network will not work.

The third configuration mixes both the star and thebus. In a typical quarry you may have five or sixscales within 1000 feet of each other. You may wantto put the PC in an office some distance away. Youcan connect the scales in a bus configuration andhave the last device on the bus be an active hub. Youcan then run 2000 feet of cable from the hub to theoffice. If the office is farther than 2000 feet you canuse additional active hubs every 2000 feet. The totallength of the network cannot exceed 4 miles. Theactive hubs will require 120 volt AC power.


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Display Screens

WEIGHT RATE keyWhen you turn on the control, the display defaultsto the WEIGHT RATE display. It is shown below.

WEIGHT 1234.567RATE TPH 210.123SPEED 325.472NODE 1 LOAD 7.5%

If you have pressed another key which changeswhat you see on the display, you can press theWEIGHT RATE key to return to this display.

The top line shows the total accumulated weightsince you last cleared the weight. To clear theweight, press the CLEAR WEIGHT key twice within 2seconds while viewing this display. Switch SW1position 2 must be on to clear the weight.

Line 2 shows the current rate in tons per hour ormetric tons per hour. If the rate is negative becausethe belt is empty or the scale is not calibratedproperly, a minus sign (-) will appear after TPH.

Line 3 shows the current belt speed.

Line 4 shows the network node and also the loadcell signal as a per cent from 0.0% to 102.3%. Theload per cent is used to calibrate the scale and is alsouseful in finding load cell problems.

CAL DATA key

The cal data key shows the digital calibration. It isshown below.

RATE TPH 210.123ZERO 600SPAN 3295LENGTH 10897

Rate is the same rate seen on the weight rate screen.Zero is the number that makes the scale accuratewith the belt empty.

Span is what makes the scale accurate with a loadon the belt. Length is the number of pulses from thespeed sensor over one revolution of empty belt.

TARE ANGLE keyPress the tare angle key. The display appears

TARE 0 NO ANGLE SENSOR PID SHIFT 0 RESET I MIN RATE .00

The tare is a number used with the angle sensor.If you have an angle sensor, the angle appears online 2.PID SHIFT is a method of making the PID loopmore sensitive with light belt loads.RESET I is a method of resetting the PID loop.MIN RATE is a number used when a belt scale is amaster in a master/slave situation and the masterbelt runs empty. Optional output PWM0 will turnon when the rate is equal to or above MIN RATE.NODE keyPress the NODE key. The display appears

NETWORK NODE 1 PLANT NUMBER 2 PRODUCT NUMBER 3 MODEM TIME OFF

The top line is used to program the network node.It is only useful if you have your scales on ournetwork or are printing tickets. In that case, pressthe SELECT key and use the arrow keys to be sureeach scale has a different node number. The nexttwo lines allow you to program a plant number andproduct number. These items are useful only if youare collecting data in the modem buffer. The last lineallows you to enter a modem time which controlswhen data is collected in the buffer. The second timeyou press the NODE key, the screen displays networktroubleshooting data, and also allows you to clearthe modem buffer if that ever becomes necessary.

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Amplifier Gain Table

0 0 0 0 0 0 0 136 0 0 0 0 0 0 1 137 0 0 0 0 0 1 0 138 0 0 0 0 0 1 1 139 0 0 0 0 1 0 0 140 0 0 0 0 1 0 1 141 0 0 0 0 1 1 0 142 0 0 0 0 1 1 1 143 0 0 0 1 0 0 0 144 0 0 0 1 0 0 1 145 0 0 0 1 0 1 0 146 0 0 0 1 0 1 1 147 0 0 0 1 1 0 0 148 0 0 0 1 1 0 1 149 0 0 0 1 1 1 0 150 0 0 0 1 1 1 1 152 0 0 1 0 0 0 0 153 0 0 1 0 0 0 1 154 0 0 1 0 0 1 0 155 0 0 1 0 0 1 1 156 0 0 1 0 1 0 0 157 0 0 1 0 1 0 1 159 0 0 1 0 1 1 0 160 0 0 1 0 1 1 1 161 0 0 1 1 0 0 0 163 0 0 1 1 0 0 1 164 0 0 1 1 0 1 0 165 0 0 1 1 0 1 1 167 0 0 1 1 1 0 0 168 0 0 1 1 1 0 1 169 0 0 1 1 1 1 0 171 0 0 1 1 1 1 1 172

7 6 5 4 3 2 1 7 6 5 4 3 2 1

SWITCH GAIN SWITCH GAIN

1 = SWITCH ON 0 = SWITCH OFF


7 6 5 4 3 2 1 7 6 5 4 3 2 1

SWITCH GAIN SWITCH GAIN



1 0 0 0 0 0 0 241 1 0 0 0 0 0 1 244 1 0 0 0 0 1 0 247 1 0 0 0 0 1 1 250 1 0 0 0 1 0 0 253 1 0 0 0 1 0 1 256 1 0 0 0 1 1 0 260 1 0 0 0 1 1 1 263 1 0 0 1 0 0 0 267 1 0 0 1 0 0 1 270 1 0 0 1 0 1 0 274 1 0 0 1 0 1 1 278 1 0 0 1 1 0 0 282 1 0 0 1 1 0 1 286 1 0 0 1 1 1 0 290 1 0 0 1 1 1 1 294 1 0 1 0 0 0 0 299 1 0 1 0 0 0 1 303 1 0 1 0 0 1 0 308 1 0 1 0 0 1 1 313 1 0 1 0 1 0 0 317 1 0 1 0 1 0 1 323 1 0 1 0 1 1 0 328 1 0 1 0 1 1 1 333 1 0 1 1 0 0 0 339 1 0 1 1 0 0 1 345 1 0 1 1 0 1 0 351 1 0 1 1 0 1 1 357 1 0 1 1 1 0 0 364 1 0 1 1 1 0 1 370 1 0 1 1 1 1 0 377 1 0 1 1 1 1 1 385

0 1 0 0 0 0 0 174 0 1 0 0 0 0 1 175 0 1 0 0 0 1 0 177 0 1 0 0 0 1 1 179 0 1 0 0 1 0 0 180 0 1 0 0 1 0 1 182 0 1 0 0 1 1 0 183 0 1 0 0 1 1 1 185 0 1 0 1 0 0 0 187 0 1 0 1 0 0 1 189 0 1 0 1 0 1 0 190 0 1 0 1 0 1 1 192 0 1 0 1 1 0 0 194 0 1 0 1 1 0 1 196 0 1 0 1 1 1 0 198 0 1 0 1 1 1 1 200 0 1 1 0 0 0 0 202 0 1 1 0 0 0 1 204 0 1 1 0 0 1 0 206 0 1 1 0 0 1 1 208 0 1 1 0 1 0 0 211 0 1 1 0 1 0 1 213 0 1 1 0 1 1 0 215 0 1 1 0 1 1 1 217 0 1 1 1 0 0 0 220 0 1 1 1 0 0 1 222 0 1 1 1 0 1 0 225 0 1 1 1 0 1 1 227 0 1 1 1 1 0 0 230 0 1 1 1 1 0 1 233 0 1 1 1 1 1 0 235 0 1 1 1 1 1 1 238

1 1 0 0 0 0 0 392 1 1 0 0 0 0 1 400 1 1 0 0 0 1 0 408 1 1 0 0 0 1 1 417 1 1 0 0 1 0 0 426 1 1 0 0 1 0 1 435 1 1 0 0 1 1 0 444 1 1 0 0 1 1 1 455 1 1 0 1 0 0 0 465 1 1 0 1 0 0 1 476 1 1 0 1 0 1 0 488 1 1 0 1 0 1 1 500 1 1 0 1 1 0 0 513 1 1 0 1 1 0 1 526 1 1 0 1 1 1 0 541 1 1 0 1 1 1 1 556 1 1 1 0 0 0 0 571 1 1 1 0 0 0 1 588 1 1 1 0 0 1 0 606 1 1 1 0 0 1 1 625 1 1 1 0 1 0 0 645 1 1 1 0 1 0 1 667 1 1 1 0 1 1 0 690 1 1 1 0 1 1 1 714 1 1 1 1 0 0 0 741 1 1 1 1 0 0 1 769 1 1 1 1 0 1 0 800 1 1 1 1 0 1 1 833 1 1 1 1 1 0 0 870 1 1 1 1 1 0 1 909 1 1 1 1 1 1 0 952 1 1 1 1 1 1 1 1000


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ZE

RO

GA

IN

Analog Calibration

Switch SW4 contains 7 switches labeled Z1 to Z7.Z1 will change the reading the least. Z7 will changethe reading the most. Turning any switch on willdecrease the reading. Start with all 7 switches off(to the left). Begin with switch Z7. Turn it on. If theload % on line 4 of the WEIGHT RATE display goesbelow 7.5% turn it off. If not leave it on. Continuewith switches Z6 through Z1. In each case, ifturning on a switch takes the load % below 7.5%,turn the switch off. If turning on a switch leaves theload % above 7.5%, leave the switch on. You mayhave any combination of switches Z1 - Z7 on whenyou are finished.

Now using the following procedure,set the analog zero to about 7.5%.The exact number is not critical.Any number between 5.0% and10.0% will work. Get as close to7.5% as you can.

Refer to the amplifier gain table. Find the gainclosest to 325, which would be 323. Set the switcheson SW3 to the values shown in the table. In thisexample switches S1, S3, S5, and S7 would be on.Switches S2, S4, and S6 would be off. If the gaincalculates to over 1000, set it to 1000.Setting the Zero SwitchesNext you must set the analog zero. The goal here isto be sure when there is nothing on the belt that theload the computer sees is always above 0.0%. Thiswill ensure that the computer will always see anaccurate representation of the empty belt. Look atthe empty belt load on line 4 of the normal display.Start with all 7 switches Z1 through Z7 on SW4turned off.

2223 x 468 800 x 4

3248 x 468

800 x 4= 475

Turn on the scale and the conveyor. The powerswitch SW5 is inside the box. Line 3 of the normaldisplay is your belt speed. Write this number down.

gain =

Constant is a number from the table belowBelt speed is in feet (meters) per minuteMaximum Rate is in tons (metric tons) per hourIdler Spacing is feet (meters) from scale idler toadjacent idler (If your idlers are on 4 foot centersuse 4 feet in the formula and 8.000 on the F1 key)

English Units Metric Units PB11 PB9 PB11 PB9Model 45 1000 1461 909 1328Model 100 2223 3248 2021 2953Model 200 4446 6496 4042 5906

The following example is for a model 100 usingEnglish units. Using the formula calculate the desiredgain. For example, if your belt speed is 468 feet perminute, your maximum rate is 800 tons per hour,and your idlers are on 4 foot centers, and yourcircuit board in the control is a PB11 or later, then

gain = = 325

For a PB9 board or earlier,

Constant x Belt Speed

Maximum Rate x Idler Spacing

gain =

If you change the belt tension, or change the conveyorangle and do not have an angle sensor, you mustrecalibrate the scale.Setting the Gain Switches

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Set Tare.If you purchased the automatic angle compensationoption you m ust set the tare now. If not, go to SET

ZERO. To set the tare press the SET TARE key. Thedisplay appears as shown below.

Enable the calibration keys.Turn on switch SW1 position 1 on the door.

WITH BELT STOPPED WRITE DOWN SW4 Z1-Z7 TURN SW4 Z1-Z7 OFF PRESS SET TARE AGAIN

Stop your belt. Switch SW4 is the one you used toset analog zero. Write down the way each switchZ1 - Z7 is set. Then turn all of them off and press theSET TARE key again.

Now the display will appear as shown.

WITH BELT STOPPED RESET SW4 Z1-Z7 TO SETTINGS YOU WROTE PRESS SET TARE AGAIN

Now reset all 7 switches Z1 to Z7 on SW4 back tothe positions you wrote down. With the belt stillNOT running press the SET TARE key again.Now thedisplay will appear as shown below.

SET TARE COMPLETE TARE 1234 PRESS WEIGHT RATE KEY TO CONTINUE

The set tare function is complete. Proceed to the SET

ZERO function.

Set Zero.Switch SW2 position 6 must be off. Press F6 toselect a belt length up to 662 feet, 2648, 5297, 7945,or 10594 feet or the equivalent in meters. As yourun the set zero test watch the pulses on the display.The maximum is 65535. If you see the pulses reach65535 and then start over from 0 your belt is longerthan you have set up for. You must use F6 to resetyour belt length to the next longer belt and start overor zero will be wrong.

Mark a spot on the belt, either using a splice or othermethod of marking. The belt must be runningempty. When the mark passes a fixed point such asa spot on the conveyor frame in front of you, pressthe SET ZERO key. The display will appear as shownbelow.

The display shows the weight of the empty belt andidler accumulating during the test. The display alsoshows the number of pulses from the digital speedsensor increasing as the belt rotates.

When the mark on the belt passes the referencepoint again, press the SET ZERO key again. If youhave been careful, you have now accuratelymeasured the length of the belt and the computerhas calculated the correct digital zero. If the F6display shows belts up to 662 feet, each pulserepresents approximately 1/8" of belt travel. A totalbelt length of 150 feet will be about 14845 pulses.The display will appear as shown.

WEIGHT 123 PULSES 56 PRESS SET ZERO AFTER 1 REVOLUTION OF BELT

Digital Calibration


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The computer will determine how many beltrevolutions to use for the test. It will be a numberfrom 1 to 6. With the weights installed and the beltrunning empty, press the CHECK SPAN key. Thedisplay will appear as shown.

WEIGHT IS .123 PULSES 14200 REVOLUTIONS LEFT 4 CHECK SPAN TEST

The weight will begin accumulating. The number ofpulses per revolution and revolutions required forthe test count down on the display. When there is 1revolution of the belt left and the pulses havecounted down to 0 the test will end. The display willappear as shown.

Digital Calibration

Press the CAL DATA key to view the digital zero thatthe computer has calculated. It is on line 2 of thedisplay. As the belt runs empty the computer mayadjust this number up or down by one number eachrevolution of the belt.

Press the WEIGHT RATE key. You probably willnotice that as the belt rotates the weight increasesfor a while and decreases for a while. That isbecause the weight of the belt is not uniform. Thegoal here is to accumulate no weight and lose noweight during a revolution of an empty belt. That isthe purpose of the digital zero. Again, the computerwill automatically adjust this number to compensatefor changes in the belt weight such as wet productsticking to the belt. This automatic adjustmentrequries the belt to make a revolution emptyoccasionally.

Set zero is complete. Proceed to check span.

Check Span. See Photo #9 to hang test weights.Press the F1 key to make sure the value of your testweight and idler span has been correctly entered.See the instructions for the F1 key.

WEIGHT 70166 PULSES 14483 PRESS WEIGHT RATE KEY TO CONTINUE

Weights for a Model 100 or 200 can be two or four20 or 25 pound barbell weights and a 5 foot bar. Fora Model 45 scale use two or four 10 pound weights.If you decide to use this type of test weight you mustaccurately weigh the total weight of all the weightsand the bar used to hold the weights. NOTE:Depending on SW3 gain settings, four weights mayshow OVERLOADED 102.3% on line 4. In thatcase, you must use less weight. Reduce your testweight, press F1, and enter the new weight value.

The V blocks used to attach the load cell to youridler have a hole in them. You can slide the bar foryour test weights through this hole in both V blocksand then slide the weights on the bar putting thesame amount of weight on each side of the conveyor.

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Digital Calibration

Press the CHECK SPAN key again. The display willappear as shown below.

NEW SPAN IS 2323 OLD SPAN WAS 2100 PRESS WEIGHT RATE KEY TO CONTINUE

The accumulated weight is due to the test weighthanging on the scale.

The first time you run the test, the new span and oldspan may differ greatly. After you run the test twoor three times the new span and old span will differby only a few numbers. Then remove the weights.

The formula says divide the weight on the certifiedscale by the weight on the belt scale. Multiply thisresult by the span. The result is the new span. To seethe current span press the CAL DATA key. You canchange the span by using the SELECT key to selectspan and then using the up and down arrow keys. Inorder to do this switch SW1 position 1 must beturned on to enable the keypad.

New span = x Old spanweight on certified scale

weight on belt scale

To check the accuracy by doing a material test,press the WEIGHT RATE key. Zero the weight bypressing the CLEAR WEIGHT key twice. You willneed to use a truck or end loader to catch thematerial as it comes off the belt. You should firstweigh the truck or end loader empty. Now runmaterial over the belt, catching it in the truck or endloader. Run as much material as you can safelycatch. Weigh the load on a certified scale andsubtract the weight of the empty truck or endloader. Compare the certified weight with theweight accumulated on the belt scale.

If the results are not the same use the followingformula:

WEIGHT IS 6.750 SHOULD BE 7.468 PRESS CHECK SPAN KEY AGAIN TO CHANGE SPAN

Using test weights will get you fairly close.However, there is no substitute for a materialstest using a certified scale to verify yourcalibration. Calibration is complete. Press the CAL DATA key and

write down zero, span, and length values. Thesenumbers are your calibration. If you purchased anangle sensor press the TARE ANGLE key and writedown your tare. Press the WEIGHT RATE key andwrite down your belt speed with the belt running.Write down your load % with the belt empty and full.Write down the date you calibrated the scale. If youneed to solve a problem later these numbers willhelp. Turn off switch SW1 position 1.

Press the WEIGHT RATE key at any time if you wantto abort this test.


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Alternate Set Zero

SET ZERO WT 123 USING 12345 PULSES SET ZERO IN PROCESS PLEASE WAIT

The first time you ran the set zero function you wereinstructed to turn switch SW2 position 6 off. Withthis switch off the set zero requires you to mark areference spot on the belt and press the SET ZERO keywhen your reference passes a fixed point on theconveyor. You then let the belt run one revolutionempty and press the SET ZERO key again. Thismethod of running the set zero measures the lengthof the empty belt in pulses and weighs one revolutionof the empty belt. Now the integrator knows thelength of the empty belt.

As long as the length of the belt does not change,you can run this alternate method of set zero. Youmust run the original set zero at least one time so theintegrator measures the number of pulses in thelength of your belt. The alternate set zero will usethe existing belt length in pulses. The test will weighthe empty belt by counting the number of pulses inyour belt length. The advantage of the alternate setzero is that you can simply press the set zero key andlet the test run itself. You do not need to wait for thebelt to run one revolution. This could be useful ifyour belt is very long and takes several minutes torun one revolution.

To run the alternate set zero turn on switch SW2position 6. This enables the alternate set zero. Nowwith the belt running empty press the SET ZERO key.The display will appear as shown below.

The number of pulses will be the number of pulsesin your belt length. This number will be countingdown toward zero while the set zero weight will beincreasing. Simply let the belt run empty. When allthe pulses have been counted down to 0 the belt hasmade one revolution and the display will appear asshown below.

The display is telling you what the value of zero isand what it should be. If you press the SET ZERO keyagain zero will be changed to the correct value. Thedisplay will appear as shown below.

ZERO IS 751 ZERO SHOULD BE 682 PRESS SET ZERO AGAIN TO CHANGE ZERO

NEW ZERO IS 682 OLD ZERO WAS 751 PRESS WEIGHT RATE KEY TO CONTINUE

You may leave switch SW2 position 6 turned on ifyou intend to run the alternate set zero in the future.Any time you want to run a set zero which measuresyour belt length again, simply turn off switch SW2position 6 and run the set zero again.

IMPORTANT: When you first calibrate the scaleyou must press function key F6 and select a beltlength up to 662 feet, 2648, 5297, 7945, or 10594feet or the equivalent in meters. When you first ranthe set zero you pressed the CAL DATA key and wrotedown the value of zero, span, and length. Youshould verify that your F6 setting and length are stillcorrect before running an alternate set zero.

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Function Key F1Test Weight and Idler Span

If you have the I/O option board press the SELECT

key again. Now the small arrow appears after theword ALARM. You can use the arrow keys tochange from low speed alarm to speed interlock.Press the select key again. The arrow appears afterSPEED. You can use the arrow keys to set the valueof the belt speed you want to use for the low speedalarm or speed interlock. If you have chosen lowspeed alarm, whenever the belt speed is below theprogrammed speed, output P4.3 will be on. Whenthe belt speed is equal or greater than theprogrammed value output P4.3 will be off. If youselected speed interlock, output P4.3 will be offwhen the belt speed is below the programmedspeed. Output P4.3 will be on if the belt speed isequal to or greater than the programmed speed.Press the WEIGHT RATE key to return to the normaldisplay.

Press the F1 function key. The display will appearas shown below.

TEST WT 100.000 LB IDLER SPAN 8.000 F LOW SPEED ALARM SPEED 350.000

If you have turned switch SW1 position 6 on you areusing metric units. The LB will be KG and the F willbe M. If you do not have the I/O option board thebottom two lines will be blank.

Press the SELECT key one time. A small arrow willappear after the word TEST WT. This arrow tellsyou that the arrow keys on the keypad will changethe value of the test weight. Use the arrow keys toenter the value of your test weights. Switch SW1position 1 must be on.Press the SELECT key again. Now the small arrowappears after the word SPAN. Use the arrow keyson the keypad to enter the distance between theidlers on each side of the scale idler. For example,if your idlers are on 4 foot centers you must enter8.000 feet. In all the formulas used to calculate gainand to select the correct model of the scale for yourapplications you use the distance from the scaleidler to the next idler which would be 4 feet in thisexample. But when you enter the idler span in thisstep you must enter the distance between the idlerson each side of the scale idler which would be 8.000feet.

Measure your idler spacing in inches. Then divideby 12. Remember, you must enter the distance infeet, not feet and inches.


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Function Key F2

Function key F2 is used to control the optionalanalog outputs. You must have the IO option boardinstalled in the scale and switch SW1 position 8must be turned on. Otherwise if you press the F2 keythe display will say KEY DISABLED on line 4 ofthe current display.

The following assumes you have the IO optionboard installed with the two additional outputs. Ifyou do not have the additional two outputs, lines 3and 4 on the display will be blank.

Press function key F2. The display will appear asshow below. No configuration switches need to beon to program setpoints. Using the setpoint, maxrate,output select, and PID loop will be described later.

#1 SETPOINT 100.00% #2 SETPOINT 10.00% #3 SETPOINT 5.50% #4 SETPO INT 2.25%

Press the SELECT key. A small arrow will appearafter the word SETPOINT on line 1. Use the adjustkeys to enter your setpoint for analog output 1.

Press the SELECT key again. The small arrow appearson line 2. Each time you press SELECT the arrowmoves to the next line. If the arrow is on the last linethe next time you press SELECT the arrow willdisappear. Program the setpoint for each output.See the examples that follow to use the analogoutputs.

Press the SELECT key. A small arrow appears afterthe word MAXRATE on line 1. Use the adjust keysto enter the desired maximum rate for output 1.Press the SELECT key again and the small arrowappears on line 2. Repeat for lines 3 and 4. Maxrateis normally in tons per hour. Enter values for eachoutput installed. Switch SW1 position 1 must be on.

Press function key F2 a third time. The display willappear as shown below.

#1 OUTPUT 4 TO 20 MA #2 OUTPUT 0 TO 20 MA #3 OUTPUT 4 TO 20 MA #4 OUTPUT 4 TO 20 MA

Press function key F2 a second time. The displaywill appear as shown below.

#1 MAXRATE 500.00 #2 MAXRATE 10.00 #3 MAXRATE 7.50 #4 MAXRATE 4.25

Analog Outputs

Press the SELECT key. A small arrow appears afterthe word OUTPUT on line 1. Press either up arrowkey to select 0 to 20 mA. Press either down arrowkey to select 4 to 20 mA. Repeat for all outputs.Switch SW1 position 1 must be on. Normally, if youare using a current loop, you will select 4 to 20 mA.If you are using a voltage output, normally you willselect 0 to 20 mA. Then, by inserting a resistorbetween the current loop - and + outputs, andwiring from + to GND, you will have a voltageoutput instead of current. The value of the resistordetermines the voltage output. See the wiringdiagrams for more information on voltage output.

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Function Key F2

Press function key F2 a fourth time. The display willappear as shown below.

PID CHANNEL OFF

Press the SELECT key. A small arrow appears afterthe word CHANNEL. If you want to use one of theIO channels as a PID loop control use either uparrow key to change the word OFF to the channelyou want to use as a PID loop. For example, if youwant to use channel 1, press either up arrow keyonce. MAXRATE is not used for the PID channel.The display will now appear as shown

. PID CHANNEL 1 PID ACTION REVERSE PID SETPOINT LOCAL P = 10 I = 100 D = 3

After you have selected the desired channel pressthe SELECT key again. The small arrow will appearafter the word ACTION. Press either down arrowto select reverse action. Press either up arrow toselect forward action. Most applications will usereverse action. This means that if the rate goesabove the programmed rate the output will go downto slow down the belt or feeder to reduce the rateback to the programmed rate. The electrical outputgoes in the reverse direction from the rate error.You may find a situation where increasing theelectrical output will decrease the rate. In this caseif the rate goes above the set rate the electrical signalmust also go up to reduce the feed rate. Since theelectrical signal goes in the same direction as therate error the action is called forward action.

Press the SELECT key again. The small arrow willappear after the word SETPOINT. Press eitherdown arrow to select local setpoint. Press either uparrow to select remote setpoint. Normally you willselect local setpoint. This means you will programthe rate crossing this scale in this control box. If youhave two or more BELT-WAY scales you canprogram one to be the master and several others tobe slaves. You then set up each slave as a remotesetpoint. Then each slave will run a programmedper cent of the master.

Press the SELECT key again. The small arrow willreplace the = after the P. Use the adjust keys to enterthe P value. Press the SELECT key again. The smallarrow will replace the = after the I. Use the adjustkeys to enter the I value. Press the SELECT key again.The small arrow will replace the = after the D. Usethe adjust keys to enter the D value. The large arrowkeys will change P, I, and D by 50. The small arrowkeys will change P, I, and D by 1. The action of P,I, and D are described later.

Analog Outputs

Press F2 a fifth time. The display will appears below

#1 OUTPUT 149 #2 OUTPUT 220 #3 OUTPUT 75 #4 OUTPUT 92

0 = 0 mA 153 = 12 mA51 = 4 mA 204 = 16 mA102 = 8 mA 255 = 20 mA

The SELECT key is not used with this display sincethere is nothing to program on this screen.


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Function Key F2

SET RATE 120.32 RATE TPH 120.318 #1 OUTPUT 127 P = 10 I = 100 D = 3

EXAMPLESA CHART RECORDERAssume you want to control a chart recorder onoutput #1 using a 4 to 20 mA signal. First set yoursetpoint for output 1 to 100.00%. Next assume themaximum rate you will run will be about 475 tonsper hour. Set your maxrate for output 1 to 500 tonsper hour. This will cause your chart pen to be near100 % of full scale when you are running near 500tons per hour. If you set your maxrate to 1000 tonsper hour then at 500 tons per hour your pen wouldbe at 50 % of full scale and it would never use theupper 50 % of the chart paper. This makes yourchart harder to read because it is compressed. Thatis the reason you want to set maxrate to slightlymore than you normally will be running at full load.Select 4 to 20 mA for the desired output andconnect the wires from - and + output #1 to thechart recorder as shown on the wiring diagram atthe end of the book.

Analog Outputs

Press F2 a sixth time. The display appears below. Ifyou are using a PID loop with local setpoint, youcan change the set rate here using the SELECT keyand arrow keys. You can also change the values ofP, I, and D. As you make changes you can see whatthe actual rate is doing in relation to your set rate.You can also see how changes in P, I, and D affectthe actual rate as well as the output. Use this screento tune your PID loop.

CONTROLLING A FEEDER (OPEN LOOP)Assume you have a feeder that is controlled by a 4to 20 mA signal. At 20 mA the feeder has amaximum rate of 5.00 tons per hour. You want thefeeder to add 10 % additive to the material crossingthe scale. You are using analog output 2. First setyour setpoint for output 2 to 10.00%. Next set yourmaxrate for output 2 to 5.00 tons per hour. Finallyselect 4 to 20 mA for output #2. Connect the feederto the - and + terminals on current loop #2. If youdo a material test and find the actual per cent ofadditive is not 10.00%, adjust MAXRATE until theadditive is really 10.00%. Increase MAXRATE todecrease the output. Decrease MAXRATE toincrease the output. After getting MAXRATEcorrect, if you change the setpoint to 5.00% the percent will remain accurate. Keep in mind that if 100tons crosses the scale, and your additive is 10%, 10tons of additive will be used. Your total combinedweight is now 110 tons. 10 tons of additive out ofa total of 110 tons is 9.09%. So, although youprogrammed the additive to be 10% of the mainingredient, the additive is only 9.09% of the totalmix. If you want the additive to be 10% of thecombined mix, use the formula (100/(100-%) ) * %where % represents the additive per cent of the totalcombined weight. In the above example, if youwant the additive to be 10% of the total weight, 100divided by (100 - 10), times 10 = 11.11%. Programyour setpoint for 11.11%.

USING VOLTAGE OUTPUTAssume the feeder in example above uses 0 - 5 or0 - 10 volts DC instead of 4 to 20 mA. Program thesetpoint and maxrate the same as above, but select0 to 20 mA for the output. Put a resistor between

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Function Key F2Analog Outputs

the - and + outputs on current loop #2. The resistorvalue determines the output voltage. A 375 ohmresistor will give you an output of 10 volts. A 125ohm resistor will give you an output of 5 volts. Thenwire your device from the + output to GND.

Current loops and voltage outputs ARE NOTISOLATED and reference or use a commonground. The negative current loop terminal willvary in voltage above ground from .5VDC at 4 mAto 2.5VDC at 20 mA. The voltage at the positivecurrent loop terminal is dependent on the externalresistance of the device it is tied to. If the device youuse is also not isolated but has the same ground asthe scale, then use the voltage configuration insteadof a current loop. If the scale and external devicehave different ground potentials you must purchasea separate isolation unit to properly isolate the beltscale and the external device.

USING THE PID LOOP (CLOSED LOOP)

The previous example used an open loop to controla feeder. The scale puts out a 4 to 20 mA signal ora voltage signal to control a feeder based on the ratecrossing the belt scale. There is no device measuringthe actual output of the feeder. The scale has no wayof knowing if the additive is even connected.

A PID loop control actually measures the outputfrom the device it controls, and varies the output tokeep the actual rate equal to the set rate.

LOCAL SETPOINT

Assume you have one belt scale with some methodof controlling the amount of material on the belt.You could be controlling the belt speed or a separatefeeder putting material on the belt. Set the PID loopup for local setpoint. You can program the set rateon the sixth press of F2 or on the WEIGHT RATE

screen. Pressing the WEIGHT RATE key a second timewill change line 3 from belt speed to set rate if youhave an IO board using a PID loop. Now the scalecontrol will constantly compare the rate crossingthe scale with your programmed set rate and varythe output to keep the actual rate equal to the setrate.

NETWORK BLENDING (REMOTE SETPOINT)

Assume you have one belt scale and want to addanother ingredient on another belt scale to the firstingredient. The main scale will be called the master.The second ingredient will be called the slave. Youmight have other ingredients being measured byother belt scales, or solids impact flowmeters, orliquid controllers. You want all these ingredients tobe added by some per cent to the main ingredient.

You must program the network node for all theslave scales in consecutive order. Assume you haveone belt scale which is the master, one solids impactflowmeter, and one liquid control. Program the beltscale as node 1. Program the flowmeter as node 2.Program the liquid control as node 3.

Before setting up the PID loops for blending,calibrate each device. Once you enable the PIDloops, it is more difficult to calibrate the devices.Each device must be connected using the BNCconnectors at the bottom of the control box. Thecable must be RG62A/U coaxial cable. It is a 93ohm cable. You must have a 93 ohm terminator onone of the BNC connectors at each end of thenetwork.


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First program the master scale to send its rate to theslave scales. On the master, press the F3 key. Thebottom two lines saySEND RATE TO NODESIS TURNED OFF

We need to change this. Turn on switch SW1position 1 to enable the keypad. This switch is on theinside of the door. Next press the SELECT key 3 times.You should see an arrow after the word OFF. Pressthe small up arrow key until the number after theword FROM is 2. Press the SELECT key again. Thearrow moves to the word TO. Press the small uparrow key until the number after the word TO is 3.Think of the numbers on the bottom line as thebeginning and ending numbers of a list of scales thatthe master is going to send its rate. In this example,the list begins at scale 2 and ends at scale 3, since wehave two slaves programmed as node 2 and node 3.Remember, you program this in the master scale, notthe slaves.

Now we need to set up the PID loops in the slaves.Normally, you are not using the PID loop in themaster, although you could as a local setpoint. Nowset up each slave PID loop to be a remote setpoint.If you have wired output #1 to your device, programthe PID loop for channel 1 and program the per centof additive you want as the #1 setpoint. If you wiredyour device to output #2, use PID channel 2 and #2setpoint.

Now, three times every second, the master will sendthe rate crossing the belt scale to the flowmeter andalso to the liquid control. The flowmeter will multiplythe rate from the master times the setpoint per centyou want to add. This becomes the set rate for thePID loop in the flowmeter. The flowmeter controlwill vary its output to keep the actual rate equal tothe set rate. The same thing occurs in the liquidcontrol. Since each additive is actually measured,the system is called a closed loop.

Once you have completed the programming justdescribed, the PID loops will begin working. If yourun material over the belt, the rate from the masterwill be sent to each slave. If you have disabled theflowmeter or liquid control from actually runningmaterial, then the control for that device will try torun the correct per cent you programmed. Since nomaterial can flow because you have not turned onthe power to the device, or because you are out ofmaterial, the control will increase its output until itreaches maximum. Then the control will display analarm message MAX OUT NODE x, where x is thenode which is putting out its maximum output.When you finally turn on the power, or get morematerial, the control will try to make up some ofwhat it lost when no material was available. If thisoccurs, and you do not want the control to make upfor lost material, press the TARE ANGLE key. Pressthe SELECT key until the arrow appears after RESETI. Press the CLEAR WEIGHT key.

You can see if the network is operating by watchingthe set rate on the WEIGHT RATE screen or the sixthpress of the F6 key on each slave scale. If line 3 ofthe WEIGHT RATE screen shows belt speed, press theWEIGHT RATE key again to change line 3 to set rate.Each slave set rate should be the rate on the mastertimes the setpoint % of the slave. If the set rate iscorrect for the slave, but the slave product is notrunning the correct rate, the problem is in the slave,not the network. You can also see what the slaveis trying to do by watching the output on the sixthpress of the F6 key. If the master is running a rateof 0, the slave should also be running a rate of 0. Ifthe slave output is 0 or 51, the slave is not trying torun anything. If your device is still running,something else is causing it to run. See if yourmotor control has a minimum speed set which isincorrect.

When a belt on a belt scale runs empty, the rate isnever exactly 0.00 tons per hour. It will vary bothplus and minus, and the plus variations will be sent

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to the slaves. If your master belt never runs empty,there is no problem. But if it does, the slaves will tryto run their per cent of the positive belt variations.To prevent this, press the TARE ANGLE key. Press theSELECT key until the arrow appears on line 4 afterMIN RATE. If your belt running a full load is 100tons per hour, and empty it varies up to 2 tons perhour, set MIN RATE to about 5 tons per hour.Now, when the belt is empty, any rate below MINRATE will not be sent to the slaves. Instead, a rateof 0 will be sent, which will keep the slaves fromrunning.

If you want to prevent a scale from running itsprogrammed setpoint, you can ground input P4.7.This input tells the control to use a set rate of 0instead of the actual set rate. Remember, the devicestill has power applied and could start unexpectedly.When P4.7 is no longer grounded, the programmedset rate will return.

If you are using two or more controls in a masterslave setup, there are two conditions when alarmoutput PWM1 may turn on. First, if any of thecontrols using the PID loop is running at maximumoutput, the alarm output will turn on in that controlbox and also in the master control. Next, if there isa network problem, the alarm output in the masterwill turn on. The slave that does not receive amessage from the master will turn off by itself. Themaster will detect the problem and force the rest ofthe slaves to turn off. If the master is running thePID loop, then the master feeder belt will also turnoff. However, if the master is not running the PIDloop, but is simply measuring what is crossing thescale, then the control cannot shut off the masterfeeder belt. In this case, you can use the batchingoutput to interlock the master feeder motor starter.First press the F5 key and press the SELECT key to

position the small arrow after the words LOADWT. Press the CLEAR WEIGHT key to set the loadweight to .000. Then press the small down arrowkey to set the load weight to 9999999.999. Now thebatching output P4.0 will turn on and stay on. Ifthere is a network failure the batching output willturn off until the problem is resolved. You can usethis output and a solid state relay to interlock yourmaster feeder motor starter. Now, if there is anetwork problem, the master not running the PIDloop and all slaves will turn off.

You can also use the batching output to actually runa specific amount of material over the master scale.When the master scale reaches the load weightminus the cutoff, the batching output will turn off.This will shut off the master feeder, so the rate willdrop to zero. This will cause all the slaves to dropto zero as well.

If you accidentally program the PID loop as aremote setpoint, but you do not have the networkcable attached to another scale set up as a master,then if you were looking at SET RATE on line 3, themessage will be replaced by NET FAIL and the setrate will be changed to .00. If you were looking atbelt speed on line 3 you will not see the NET FAILmessage. A remote setpoint PID loop needs thenetwork and the rate from a master scale to determinethe correct setpoint.

On the TARE ANGLE screen, line 3 shows PID SHIFTand a number, normally 0. If you are running verylight loads, and your PID loop is not responding fastenough, try increasing PID SHIFT one number at atime. If you go too far, the system becomes erratic.



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PID LOOP FUNDAMENTALS

The control uses the PID loop to calculate what theoutput should be to make the actual rate equal to theset rate. The output is calculated by this formula:(P*(set rate - actual rate)) +(I*(theoretical weight total - actual rate total)) -(D*(present rate - last rate))

The output is made up of 3 components. First,subtract the actual rate from the set rate, andmultiply the result by the number entered for P.When the process first starts up, the actual rate is 0so there is a large difference. When the actual rateis near the set rate, the difference is very small.Increasing the value of P will cause the feeder tostart out faster when it is first turned on, but it maystart so fast that it overshoots the desired set rateand then slows down too much to compensate andcontinues to oscillate.

The second component uses your programmed setrate to determine every second how much materialshould have crossed the scale at that point in time.Then the weight which actually did cross the scaleis subtracted. The difference, where you are versuswhere you should be, is multiplied by the numberyou entered for I. If the feeder stops runningmaterial, either because you ran out of material oryou turned off power to a motor, the weight whichshould have accumulated each second is still added.But no weight is subtracted since no material isrunning. So the second component of the outputwill keep getting larger, and the control will drive itsoutput to the maximum of 255 trying to get thematerial. This "I term" has memory. If you ran out

of material, the I term will simply keep growinguntil it reaches the maximum. When you finally getmore material, the control will keep running atmaximum for some time. It is trying to make up forlost time. If you want to stop this, press the TARE

ANGLE key, use the select key to move the arrow toRESET I, and press the CLEAR WEIGHT key. The Iterm will be cleared. To prevent this, when youwant to stop the PID loop from running its set rate,ground input P4.7. This will make the control run aset rate of 0.

The third component of the PID output is calculatedby subtracting the rate a second ago from the ratenow, and multiplying this by the number you enteredfor D. This component acts like a brake. If the rateis changing too fast, this component will slow itdown.

The numbers you enter for P, I, and D are simplymultipliers. They let you control how eachcomponent contributes to the final output number.We recommend starting with P = 10, I = 100, andD = 3. The PID loop will work even if P and D are0. It will not work if I is 0. The values for P, I, andD can be too aggressive or too lax. If they are tooaggressive, you can get wild oscillations in rate. Ifthey are too lax, it will take too long for the actualrate to equal the set rate. If you are running a verylight load, and your PID loop takes too long torespond, press the TARE ANGLE key, and increase thePID SHIFT by one number at a time, testing theresult. A higher number will make the controlrespond faster. But if you make this number toohigh, the control will cause the feeder to oscillate.If that happens, reduce the number by one and tryagain.

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Function Key F3Log Rate and Send Rate

Press function key F3. The display appears asshown below.

LOG RATE 350.00 LOG TIME 12H 45M SEND RATE TO NODES IS TURNED OFF

Press the SELECT key. A small arrow appears afterthe word RATE. You can use the CLEAR WEIGHT

key to set the log rate to .00 or use the adjust keysto enter your desired log rate. Switch SW1 position1 must be on to change log rate. Be sure to turnswitch SW1 position 1 off when you are donesetting log rate so nobody can accidentally changeyour scale calibration. The control will keep trackof the hours and minutes that the scale is running ata rate equal to or higher than the log rate you enter.In other words, if you enter a log rate of 300 tons perhour, the log time will show you how many hoursand minutes your production was at or above 300tons per hour.

Press the SELECT key again. Now the arrow appearsafter the word TIME. You can use the CLEAR

WEIGHT key to set the log time to 0H 0M. In orderto be able to clear log time switch SW2 position 5must be turned on.

Press the select key again. The small arrow appearsafter the word OFF or after the word FROM if sendrates to nodes is turned on. If the word OFF appears

then the control is not sending its rate to any othercontrols. This is the normal mode and this featuremust be OFF unless you have one or more additionalcontrols set up as slaves to the master control andthe network is connected. If this scale is a masterscale in a blending situation, see function key F2 toprogram the send rates feature.


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Function Key F3

Press function key F3 again. The display appears asshown below if you are using English units.

PULLEY DIAMETER IN INCHES 7.719 ENCODER PULSES PER REVOLUTION 200

If you are using metric units the display appears asshown below.

PULLEY DIAMETER IN CENTIMETERS 19.606 ENCODER PULSES PER REVOLUTION 200

The standard scale is furnished with a wheel whichrolls on the return belt. The wheel is 7.719 inches(19.606 cm) in diameter. If switch SW1 position 4is off, the control will use the above value. You canchange the values shown on the display but whenyou turn the control off and back on the valueshown will return to the default value.

Occasionally a special encoder that may be connectedto the head or tail pulley is used. In that case, youmust turn on switch SW1 position 4. Otherwise itshould be turned OFF. When you turn switch SW1position 4 on, the values shown on the display willbe used. You should enter the diameter of the pulleythat the encoder is attached to. This is necessary sothe belt speed will be correct.

The standard encoder will generate 200 pulses perrevolution. If Sauk Valley Systems supplies a shaftmounted encoder, it normally will also generate 200

pulses per revolution. If a special encoder is furnishedyou must set the pulses per revolution to matchwhat the encoder generates.

Any special custom encoders should operate on 5volts DC and have TTL compatible outputs. If youuse a quadrature output encoder, select only one ofthe channels (either A or B) and wire that to thedigital speed sensor SIG A input.

If you are using a special encoder and have turnedon switch SW1 position 4, press the SELECT key. Asmall arrow appears after the word INCHES (orCENTIMETERS). Use the arrow keys to enter thediameter of the pulley your encoder is connected to.

Press the SELECT key again. A small arrow appearsafter the word REVOLUTION. If your encodergenerates pulses other than 200 use the arrow keysto make this number match the pulses your encodergenerates.

Special Speed Encoders

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Function Key F4

Press function key F4. The display appears asshown below. MASTER TOTAL IS 1234.567 TIME 11:08:24 DATE 11/16/99

Every time you clear the scale total weight, the totalis added to the master total before it is cleared. Ifyou want to clear the master total, you must haveswitch SW1 position 3 turned on. Then if you pressthe CLEAR WEIGHT key twice within two seconds,while you are looking at the master total, it will beset to zero. You can prevent someone from clearingthe master total by keeping switch SW1 position 3turned off. You do not need to press the SELECT keyto clear the master total.

If you press the SELECT key a small arrow willreplace the : after the hours. At this time you can setthe hour to 0 using the CLEAR WEIGHT key or you canuse the adjust keys to set the hours to the correcttime. Each time you press the SELECT key the arrowwill move to minutes, seconds, month, date, andfinally year. In this manner you can set the time anddate.

Master Total, Time, and Date

Time and date are only used if you are printingtickets, logging data, or using the modem buffer.


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Function Key F5Loading Trucks, Barges, and Rail Cars

The load weight is the amount you want to put in thetruck. In this example it is 25.000 tons. The cutoffweight allows the feeder to turn off before all thematerial has crossed the scale. Otherwise each loadwould be over weight.

Press the SELECT key again. The display will appearas shown below.

Function key F5 is used if you want to use the scalefor loading trucks, barges, or rail cars. You musthave the optional IO board installed in order to usethis feature. If you do not have the optional IOboard you can still program this screen but theoutput will not function.

Press the F5 function key. The display appears asshown below.

LOAD WT 25.000 WEIGHT 12.345

CUTOFF .000

LOAD #1 .000 LOAD #2 .000 LOAD #3 .000 LOAD #4 .000

The small arrow will appear after #1. Use the adjustkeys to program load 1. Press the SELECT key andcontinue to program loads 2, 3, and 4. When youpress the SELECT key after the arrow is on #4 thedisplay will change to show loads 5,6,7, and 8. Inthis manner you can program eight different loadweights. Switch SW1 position 1 must be on toprogram the eight preset load weights. Be sure toturn off switch SW1 position 1 when you are doneto prevent somebody from accidentally changingyour calibration or preset load weights.

Once you have pressed function key F5 the eightfunction keys are used to select preset load weights1 - 8. To escape from this feature so that you can usethe other function keys to perform their normalfunctions, press the WEIGHT RATE key. Now, whenyou press any function keys other than F5, they willperform their normal function. Once you press F5the eight function keys again will select preset loadweight 1 - 8. F1 will select load preset 1, F2 willselect load preset 2, etc.

You may change the values of the load weight andcutoff weight any time. You do not need to haveswitch SW1 position 1 turned on. This allows youto change load size and cutoff while preventingsomeone from accidentally changing the scalecalibration. If you do not want your operators to beable to change the load weight, turn on switch SW2position 4. This will disable the adjust keys so theload cannot be changed and selecting one of eightpreset load weights will also be disabled.

Press the SELECT key. A small arrow appears afterthe WT. Set your load weight using the adjust keys.After setting the correct load weight press theSELECT key again. Now the arrow appears on line 4.Use the adjust keys to set your cutoff. You mayneed to experiment with the cutoff to find thecorrect value. The cutoff is used to shut off thefeeder early to allow for material already on the beltto cross the scale.

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Function Key F5Loading Trucks, Barges, and Rail Cars

1. Press function key F5 to enter the load mode.2. Use the rotary selector switch to select 1 of 8preset load weights.3. Press the enter load pushbutton. The selectedpreset load weight will appear on the control displayline 1.4. Press the clear pushbutton on the start / stopstation. The scale weight total will go to .000 andthe ready light will turn on.Whenever the scaleweight total is less than the load weight minus thecutoff weight, the batching output will be on. Whenthe scale weight total is equal to or greater than theload weight minus the cutoff weight, the batchingoutput will be off.5. Press the start pushbutton. The run light will turnon and the feeder or belt will start running.6. If you need to stop the feeder or belt for anyreason before the load is complete press the stoppushbutton. The feeder or belt will stop and the runlight will turn off. The ready light will stay on. Pressthe start pushbutton to continue loading the truck.7. When the weight on the scale reaches the loadweight minus the cutoff weight, the feeder or beltwill turn off automatically. The run light and the

If you are not using an angle sensor, the angle sensorinput can be used to connect a selector switch whichwill allow your operators to select preset loadweights 1 - 8. Sauk Valley Systems has available aremote start / stop station which will allow yourdrivers to load their trucks without ever touchingthe scale control keypad. If you are using an anglesensor then you must select your preset load usingthe function keys F1 - F8. You may want to writedown the load weight for presets 1-8 and perhapslaminate it to keep it weatherproof.BATCHING WITH A START/STOP STATION

ready light will turn off.8. If you have a printer connected to the scale youwould have already set the control up to printtickets following the instructions for the F7 key.Simply press the print pushbutton to print a ticket.

The batching output must be connected to anoptional start / stop station. See the wiring diagramin the section of wiring diagrams for details on howto connect the batching output. You can purchasea start / stop station from Sauk Valley Systems ormake your own. The start / stop station should bemounted next to the scale control box.


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Function Key F6

Press function key F6. The display appears asshown below.

TONS PER PULSE OFF PULSE ON TIME 50% AUTO ZERO 1.0% BELTS UP TO 662 FT

Press the SELECT key. A small arrow appears afterthe word PULSE. You can now use the adjust keysto select from the following options:

TONS PER PULSE OFF .01 .10 1.0 10

If you select OFF the pulse output will be disabled.Any other selection requires the optional IO board.If you select .01 you will get a pulse every time theweight increases .01 tons. This will work up toabout 150 tons per hour. A pulse every .10 tons willwork up to about 1500 tons per hour.

Press the SELECT key again. A small arrow appearsafter the word TIME. You can now use the adjustkeys to select from the following options:

PULSE ON TIME 50% 10 MS --- 500 MS

If you select 50% you will have a true quadraturewave output on P4.1 and P4.2. This will drive aremote display or a PLC with quadrature input . Theadvantage of using quadrature waveform is that ifthe scale is losing weight the remote counter or PLCwill detect this and maintain the correct weight. Seethe wiring diagram in the wiring section for details.

Pulsed Output, Auto Zero, and Long Belts

Press the select key again. The small arrow appearsafter the word TO. You can use the adjust keys toselect from the following options:

BELTS UP TO 662 2648 5297 7945 10594 FT orBELTS UP TO 201 807 1614 2421 3229 M

The belt length is the total length of the belt. It is notthe length of the conveyor.

AUTO ZERO 1.0% .75% .50% .25% OFF

Normally you will want the auto zero set at 1.0%.If you occasionally run very light belt loads, youmay find the auto zero attempts to zero the weighton the belt because it has decided the belt is empty.In that case you can tighten the tolerance that thecomputer uses to decide if the belt is empty. Theauto zero will still work but the belt must be loadedless as you select a smaller per cent before auto zerowill decide that the belt is empty. If you select OFFauto zero will be disabled.

If you select pulse on times from 10 to 500milliseconds use either output P4.1 or P4.2. Thepulse will remain on for the programmed time. Youwill not have a true quadrature waveform, so do notselect pulse on times other than 50% if you areconnecting the pulsed output to a device with aquadrature input.

Press the SELECT key again. A small arrow appearsafter the word ZERO. You can now use the adjustkeys to select from the following options:

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Function Key F7

The scale number will be the node you programmedthe scale. To print the ticket press the function keyF8. If you have an IO board, you can connect apushbutton to the remote print input P4.5. You canuse the CLEAR WEIGHT key to set any of the specialcodes to 00 after using the select key to select thecode. You cannot use FF for a special code since itis the end of message marker.

The ticket can be used for loading trucks. Yourticket printer may need a few line feeds or a formfeed to advance the ticket out of the printer. Youcan select from 0 to 10 line feeds to follow the ticketor you can select one form feed. If you have unusualconditions you can select up to 12 characters to besent to the printer after the ticket. For example, oneprinter uses the following codes to advance thepaper and cut the ticket off.

ESCAPE "a" n will advance the paper n linesESCAPE "d" 0 will cut the paper off

To program the scale to send these codes select 6special codes. Then use the select key to move thesmall arrow to follow each of the first 6 codes anduse the adjust keys to make them be as follows:1B 61 8 1B 64 00

This will cause the printer to advance 8 lines and cutthe ticket off. The ticket printed appears below.

SCALE # 1TIME 09:25:42DATE 07/28/94WEIGHT 797.504

RS-232 Serial Output

Function key F7 is used to control the RS-232output to a printer, a remote display terminal, aremote scoreboard display, or a PLC using 8 databits, no parity, 1 stop bit, no handshake. Press the F7key. The display appears as shown below.

RS-232 OFF

Press the SELECT key. A small arrow appears afterthe word RS-232. You can use the adjust keys toselect from the following options:RS-232 OFF TICKETS WEIGHT RATE or WEIGHT&RATEPress either of the up arrow keys. The displayappears as shown below.

RS-232 TICKETS USE 0 LINE FEEDS

Press the select key again. Now the small arrowappears after the word USE. You can use the adjustkeys to select from the following options:

USE 0 - 10 LINE FEEDS orUSE 1 FORM FEED orUSE 1 - 12 SPECIAL CODES

If you select 1 - 12 SPECIAL CODES the followingtwo lines will appear on lines 3 and 4 of the display.

00 12 54 7A F3 DE FA 03 1B 45 A0 FF

In this section of the instructions you areprogramming the RS-232 output to print tickets.


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Function Key F7

Again press the select key until the small arrow isback on line 1. Use either of the up arrow keys tochange the word TICKETS to WEIGHT. Now thedisplay appears as shown below.

RS-232 WEIGHT FORM STX WT CR LF AFTER CR OFF LOG DATA OFF

Use the SELECT key to move the small arrow to line2 after the word FORM. You can now select fromthe following options:

FORM STX WT CR or WT CR

This allows you to send an STX if the data is goingto a PLC or disable STX if the data is going to sometype of display.

Use the select key to move the small arrow to line3 after the word CR. You can now use the adjustkeys to select from the following options:

LF AFTER CR OFF YES BOTH

If you select off no line feed will follow the carriagereturn. If you select yes a line feed will follow thecarriage return at the end of the message. If youselect both a line feed will follow each carriagereturn if you have selected weight and rate.

The above discussion shows you how to send thescale weight out the RS-232 port once each second.You can use the select key to move the small arrowback to line 1 and select RATE instead of WEIGHT.

If you do select RATE then once each second thecurrent rate will be sent out the serial port. You canalso use the adjust keys to select WEIGHT&RATE.If you do then the weight will be sent followed bythe rate, once each second. If you selectWEIGHT&RATE then you have the followingoptions for the format of the message.

STX WEIGHT RATE CR WEIGHT RATE CRSTX WEIGHT CR RATE CR WEIGHT CR RATE CR

Again, on line 3 LF AFTER CR allows you to selectsending no line feed after the carriage return byselecting OFF. You can send one line feed after thefinal CR by selecting YES. Or you can send a linefeed after each CR by selecting BOTH.

Use the select key to move the small arrow to line4 after the word DATA. If you select OFF theneither weight, rate, or weight and rate, dependingon what you have selected, will be transmitted onceeach second. You have the option of using theadjust keys to change LOG DATA from OFF tofrom 1 to 255 MIN. In that case data will betransmitted once every X minutes where X is thenumber you have programmed. In addition to thenormal message time and date are added. Theformat of a data log is

WEIGHT RATE TIME DATEif you selected sending both weight and rate. Loggingdata allows you to collect data from the scale in atime frame you can select yourself.

RS-232 Serial Output

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Function Key F7RS-232 Serial Output

If you press the F7 key a second time the display willappear as shown below.

BAUD 1200 COLOR RED

If you have not turned on switch SW2 position 3 thesecond line will be blank. Press the SELECT key anda small arrow appears after the word BAUD. Youcan use the arrow keys to select 1200, 2400, 4800,or 9600 baud. Keep in mind there is no handshake,so characters may be lost if you select a high baudrate.

The scale control supports a low cost large displaycalled a COLOR BRITE sign Model SW-214CR.This display is made up of red and green lightemitting diodes. You can select the color you wantfrom red, green, and orange. The characters are twoinches high. You can display either the total weightthat has crossed the scale or the current rate crossingthe scale. The display is updated once each second.This display is designed to be used indoors. It is notwaterproof or weather proof so it must be protectedby mounting it in a suitable housing. The display isvery bright indoors but in direct sunlight you cannotread it. If you use it outdoors, you must shield itfrom direct sunlight. In spite of its limitations, it willallow you to read the scale from at least 25 feetaway and it is very low cost. If you are using thisoption you must turn on SW2 position 3. Thisswitch is on the door. It must be off if you are notusing the sign since the message format is special.

You may contact Sauk Valley Systems forinformation on where to purchase this display. Youwill need a special cable to connect the display to thecontrol. One end has a telephone style connector toplug into the display. The other end connects toterminals in the control box labeled TXD and GND.You can purchase a cable from Sauk ValleySystems.You must set the baud rate to 2400 tomatch the COLOR BRITE display.


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Function Key F8

Function key F8 is used to print a ticket if you haveset the RS-232 port to printing tickets. When youwant to print a ticket simply press the F8 key.

You can also print a ticket using the remote printinput located on the optional IO board. It is inputP4.5. Of course you must have the optional IOboard installed.

In this discussion of the RS-232 port STX meansstart of transmission. It's value is 2. CR meanscarriage return. It's value is 13. LF means line feed.It's value is 10.

If you are using the 12 special codes to send controlcodes to your printer you will need to refer to yourprinter manual to tell you what the codes are. Thecodes you will program use the hexadecimal numbersystem. You may also need to refer to an ASCIIchart to find the hexadecimal values of letters usedin the control codes. All the information you needshould be in your printer manual.

Print a Ticket

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Test Keys T1 T2 T3

Press test key T1. The display appears as shownbelow.

ANGLE A/D 512 LOAD CELL A/D 750 LC SUPPLY A/D 804 LC ADJUSTED 5865

The angle a/d reading is the value of the data thecomputer is getting from the angle sensor. It will bea number between 0 and 1023. If you have an anglesensor, this number is used to determine the conveyorangle.

The load cell a/d is the value of the data thecomputer is getting from the load cells. It will be anumber between 0 and 1023. This information canbe used in testing load cells.

The load cell supply a/d is measuring the voltage thecomputer is supplying to the load cells. This numberis normally between 800 and 850 and should notvary more than about one number from its value.

The load cell adjusted reading displays the load celldata after the computer has adjusted it for variationsin load cell supply voltage and angle changes if youare using the angle sensor.


SWITCH SW2 0 SWITCH SW1 3

VERSION 1.25

This display shows what configuration switches areturned on and also the version of the software.


BELT LOAD 25.000 LB/FT or KG/M SCALE WEIGHT 100.000 LB or KG

This display shows the belt load and also the totalweight on the scale. It uses the value youprogrammed for idler span using the F1 functionkey to calculate the scale weight.

A properly calibrated scale should show a valuenear 0 for the scale weight when the belt is empty.When you calibrate the scale this display should benearly equal to the value of your test weight whenyour weight is hanging on the scale.


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TroubleshootingBefore a belt scale will work you must have a belt speed and a load % which is not 0.0% or 102.3%.

Belt Speed ProblemsBelt speed is 0 (line 3 of the weight rate display)Make sure the belt is running.1. Is the wheel and shaft turning?2. Turn the power off and unplug the speed sensor.3. Turn the power on. Is LED2 on or off?4. If LED2 is on replace the 7414 (U16).5. If LED2 is off, put a jumper wire between GNDand SIG A on the digital speed sensor terminal strip.6. If LED2 remains off with the jumper connected,replace 7414 (U16).7. Measure the voltage between GND and +5VDCon the digital speed sensor terminal. It should bevery close to 5.0 volts DC. If not, there is a problemon the processor board.8. If LED2 turns on with the jumper connected andoff with the jumper removed, and the 5.0 voltreading in step 7 is correct, the problem is not in thecontrol box. It is in the speed sensor or wiring.9. Turn the power off, plug the speed sensor backin, and turn the power on.10. Again measure the voltage between GND and+5VDC as you did in step 7. If the voltage was near5.0 volts in step 7 and now it is not, turn the poweroff. Look for a short in the cable from the controlbox to the speed sensor. Look for cuts caused byrocks or by the cable rubbing on the belt. If the cablehas been extended beyond the 25 feet supplied onthe sensor, be sure to check all splices.11. If the cable is good, the wheel rolls freely, andthe shaft is not loose in the bearings, then theproblem is on the circuit board inside the speedsensor. This is a small board which can be replacedvery easily. If the shaft is loose in the bearings, thesensor will have to be replaced.

Low or intermittent belt speed.

If the speed is low and erratic the encoder diskinside the sensor is probably loose on the shaft. Thespeed sensor will have to be replaced. If the speedis high and erratic you probably have electronicinterference from a motor or radio.

Load Cell ProblemsLoad % on line 4 of weight rate screen is 0.0% or102.3%.1. Chances are one load cell is working properly andone is not.2. Write down which zero switches SW4 Z1 - Z7are turned on (slid to the right).3. Turn off all zero switches.4. Unplug one load cell.5. If the load % is still 0.0% or 102.3% there may bea problem with the cell still plugged in.6. If the load % is no longer 0.0% or 102.3% the cellyou unplugged has a problem.7. Unplug the cell still plugged in and plug in the cellyou previously unplugged.8. If cell 1 reads a normal % and cell 2 reads 0.0%or 102.3%, then cell 2 has a problem.9. Look for a broken or cut wire from the cell to theintegrator.10. If you extended the cables from the scale to theintegrator, check your connections carefully.11. Be sure the cables are connected to the correctterminals.12. Any splices must be soldered and insulated orscrew terminals must be used.13. Crimp connectors or wire nuts will not work.14. Be sure no moisture has penetrated any splices.15. With both cells plugged in measure the voltageon either cell from -SUP to +SUP (black to redwires). You should get about 9.6 volts DC.16. With only one cell plugged in, and all the zeroswitches off, and the belt empty, measure the voltagebetween -SIG and +SIG (white to green wires).You should get about 2 millivolts DC (.002 volts)The +SIG (green wire) should be positive. Repeatthe test for the other load cell.17. If you still have not isolated the problem unplugone cell. Measure its resistance using a digitalvoltmeter.18. Between the red and black wires you should seeabout 420 ohms.19. Between the white and green wires you shouldsee close to 350 ohms.

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Troubleshooting

20. Some auto ranging meters change scales at399.9 ohms. You may see 350.0 ohms from greento white and .42 k ohms from red to black. The kmeans thousands of ohms, so .42 k ohms is 420ohms.21. Repeat the resistance test for the other load cell.22. The resistance tests show if a cell has a brokenwire or the cell itself may have an electrical problem.Resistance tests will not show if a cell is bent. Themillivolt test in item 16 will show if a cell is bent.

Load % is 0.0%.1. A reading of 0.0% indicates something may bepushing up on the load cell so the reading is negative.Since the integrator cannot read negative numbers,the load appears as 0.0%.2. Look for a rock wedged under the scale idler.3. Make sure the bolts holding the "V" block to theidler do not stick through the idler mounting plateso far that they press against the load cell tube,lifting up on the idler.4. Make sure the overload bolt on the bottom of theload cell assembly has not been tampered with andis pressing up on the load cell. If you can press downon the load cell by pressing down on the idler overthe load cell in question, and the voltmeter readingbetween the green and white wires becomes lessnegative or more positive, the load cell is notpressing down on the overload bolt.5. Repeat the above test on the overload bolts ateach end of the idler mounting plate. There is ashoulder bolt under each plate bolted on top of theends of the idler mounting plate. The top andbottom of the bolt head provide additional overloadand underload protection. If either shoulder bolt isnot aligned properly, the scale may be in a mechanicalbind.6. If you have found one cell is bad, but cannotdetermine the cause, something has probably bentthe cell up and it will no longer return to its normalposition. It will have to be replaced.

Load % is 102.3%1. A reading of 102.3% means something is probablypushing down on the load cell.2. Look for a rock wedged in a manner that pressesdown on the scale idler.3. Be sure the overload bolts at the ends of the idlermounting plate are not adjusted wrong and arepulling down on the idler mounting plate.4. If you have found one cell bad, but cannotdetermine the cause, something has probably bentthe cell down and it will no longer return to itsnormal position. It will have to be replaced.

Weight is not consistent1. If the load % is not 0.0% or 102.3%, and itincreases with increasing load, the problem isprobably mechanical. Try to lift up on each load cellassembly. Each should move on the mounting pipesabout 1/32". If the load cell tubes are in a bind, themounting pipes are not parallel, or one may behigher than the other. Loosen the "U" bolts, adjustthe leveling bolts, and tighten the "U" bolts.2. If the load % is around 7.5% with the belt empty,and only 10.0 to 15.0% with the belt fully loaded,the scale is not getting enough change in load cellsignal to work properly. Try turning on all the gainswitches. Remember, on is to the right. Then youwill have to reset the zero switches, run a set tare ifyou have an angle sensor, run a set zero, and run acheck span or do a material test. If all the gainswitches are already on, the load on the belt is toolight for the model scale you have. Try to slow thebelt down, if possible, to increase the belt load. Youcan contact Sauk Valley Systems, Inc. to see if alighter capacity load cell will solve the problem.3. If the load % wanders all over between 0.0% and102.3%, make sure moisture has not entered any ofthe connections. Moisture in splices can cause theload cell signal to drift a great deal. You may alsohave an intermittent connection on one of the wiresin either load cell cable. Look for terminals pressingon insulation instead of wire, loose connections, ora break inside one of the load cell cables.

Check your belt length on the cal data screen. A very small number may keep the scale auto zeroing.


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Troubleshooting

Weight is consistent but wrong.You have calibrated the scale and the weight isconsistent, but it is not correct.1. Before a scale can be accurate with a full beltload, it must be accurate with an empty belt.2. Run the belt empty. Is your rate near 0 tons perhour on line 2 of the WEIGHT RATE screen? If the rateis near 0, then you need to adjust the span to getcorrect readings under load.

Before you can change the calibration, you mustturn on switch SW1 position 1. This switch islocated on the inside of the door. Be sure to turn itoff when calibration is complete.

Rate is near 0 with the belt running empty.1. Run a CHECK SPAN or material test to adjust thespan. If the belt scale is light when compared to atruck scale, the span is too small. If the belt scale isheavy when compared to a truck scale, the span istoo large. You can see the span number by pressingthe CAL DATA key. See the formula in the manual toadjust the span.

Rate is not 0 with the belt running empty.1. When you calibrated the scale, did you writedown the following data? Zero, span, length on CAL DATA screen Tare on TARE ANGLE key Load % empty and full beltIf you did, compare the data with current data. Didsomething change?2. If you have an angle sensor, run a new SET TARE.3. Next run a SET ZERO.4. Finally run a CHECK SPAN or material test.

Network Problems1. Most network problems are caused by cableproblems. Make sure you are using RG62A/Ucable, which is 93 ohm coaxial cable. If the networkhas been working and has stopped working, see if acable has been cut or run over or kinked.2. The minimum cable length is 6 feet. A shortercable can cause the network to fail or be intermittent.3. Make sure the two ends of the network have 93ohm terminators installed.4. If a PC is on the network, the network card mustbe connected using a "T". The center of the "T"goes to the PC. One end of the "T" goes to thescales. Normally, the PC is at one end of thenetwork, so the other end of the "T" must have a 93ohm terminator installed.5. Make sure every scale on the network has adifferent node number.6. If you have several scales networked to a PC ora remote display, leave the scale connected to thePC or remote display connected. Disconnect thecable from that scale to the rest of the scales. Movethe terminator from the last scale to the one scalestill connected to the PC or remote display. If youget one scale to work, add the rest, one at a time,moving the terminator as you go. Eventually youmay find one scale that causes the network to fail.

Before calling for technical help, try to have thefollowing information with you.

1. Is this a new installation?2. Is this an installation which worked before but nolonger works?3. Has the scale been moved recently?4. Has the belt tension been changed recently?5. Do you have an angle sensor?6. Do you have a belt speed with the belt running?7. What is the load % with the belt empty?8. What is the load % with the belt full?9. What model scale do you have? A label on eachload cell will identify the scale model.10. What is your zero, span, length, tare?

Remember, zero on the CAL DATA screen is whatmakes the scale accurate with an empty belt. Spanon the CAL DATA screen is what makes the scaleaccurate under load.

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USING A MODEM TO COLLECT DATA

Beginning with version 1.19, the scale can be usedto collect data using the internal memory. This datacan be downloaded into a personal computer usinga modem from anywhere in the world or you can usea serial cable and a portable computer to collect thedata locally.

1. Press the NODE key. If you only have one scale atthis location you can set the node to 1. If you haveseveral scales at this location you should set each toa different node number. Press the SELECT key onceto move the programming arrow to the word node.Switch SW1 position 1 must be on to program thenode number.

2. Press the SELECT key again to move theprogramming arrow to plant. If you are collectingdata from several plants enter a unique number toidentify this plant. Switch SW1 position 1 must beon to program the plant number.

3. Press the SELECT key again to move theprogramming arrow to product. If you want toidentify each different product crossing this scaleenter a unique number to identify this product.Switch SW1 position 1 does NOT need to be on toprogram the product number. This allows youroperator to change the product number when theactual product changes without opening the dooron the control. If you do use the product number toidentify your different products it is up to youroperator to have the correct product number enteredfor the product being weighed.

4. Press the SELECT key again to move theprogramming arrow to modem time. Enter the timeinterval you wish to record data. The standard scalewill store 120 records. If you set the modem time to1 minute increments you can store 120 minutes or2 hours of data. After 2 hours older data will bereplaced with new data. If you set your modem timeto 6 minutes (.1 hour) you can store 12 hours of databefore older data will be replaced. This is because

you will be storing 10 records per hour. Dividing120 records by 10 records per hour is 12 hours.

The data is in the following format:

001,002,003,00007543.142,08:48:01,03/26/97crlfwhere the scale number is 1, the plant number is 2,the product number is 3, the weight is 7543.142, thetime is 08:48:01, and the date is 03/26/97. The cr lfat the end of the line is carriage return line feed. Theformat of this data should be able to be importedinto any spread sheet or data base program. Thedata is in comma delimited ASCII format. Leadingzeroes will be replaced with spaces.

Once the data is collected in the scale integrator youmust use the RS-232 port to download the data toa personal computer. First press the F7 key twiceand set the baud rate to 9600 for the fastesttransmission. If you are using a modem it must beprogrammed to use 9600 baud between the scaleintegrator and the modem. Let the modem autodetect the speed between the two modems. Programthe baud rate from your personal computer to youroffice modem for as fast as possible. It must befaster than 9600 baud or you may lose characters.If you lose characters you may have to slow downthe baud rate at the integrator.

The scale integrator RS-232 port is a simple 3 wireinterface. It does not support handshaking signalslike RTS, CTS, DCD, etc. Connect our transmitdata pin TxD to the modem receive data. Connectour receive data RxD to the modem transmit data.Connect our ground to the modem signal ground.You must connect the modem that will be used withthe scale integrator to a personal computer toprogram the modem. It must be set to the correctbaud rate, usually 9600, 8 data bits, 1 stop bit, noparity, using your terminal program. You mustprogram the modem to auto answer, send numericresponse, send only short form messages, disableflow control, and DTR assumed on.


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USING A MODEM TO COLLECT DATA

If you do not use a modem, you can connect apersonal computer directly to your scale integratorusing a 3 wire cable. The scale transmit data TxDmust be connected to the computer receive data.The scale receive data RxD must be connected tothe computer transmit data. The scale ground mustbe connected to the computer signal ground.

When you use a modem set to auto answer, it willsend the scale the number 1 to indicate the modemhas connected. The scale sees the 1 and waits 5seconds and then sends the modem menu. This iswhy your modem must be set for numeric responsesand short form messages. Once you see the menusimply enter the letter of the function you wantdownload. Your responses MUST be LOWERCASE. If you enter c for current data the data willinclude the current rate. Before you enter b fordownload the 120 record buffer you want to setyour terminal program to store the buffer data onyour hard drive.

Once you have the data on your hard drive you willwant to import it into your spread sheet or data baseprogram. Some of the data may be a repeat of datayou downloaded last time. This depends on yourmodem time and how often you actually downloadthe data. You should remove duplicate recordsfrom your data base.

If you are not using a modem, but instead are usinga direct cable connection, enter a lower case lettera to bring up the menu. If you enter the number 1 themenu will appear after about 5 seconds. Once yousee the menu simply enter the lower case commandfor the function you want to perform.

Example: Configuring a Zoom 360 fax modem

These steps will configure the following settings ona model 360 Zoom fax modem. Other modems willbe similar but there will be differences. Consult themanual with your modem. We need to configure themodem as follows:

Auto answer on first ring (S0=1)Send numeric response (V0)Send only short form messages (X0)Disable flow control (&K0)DTR assumed on (&D0)Save configuration as profile 0 (&W0)Use profile 0 on startup (&Y0)Reset modem to profile 0 (Z0)

Connect the modem to the serial port of a computer.

Start a communication program (Hyperterm, xtalk,Windows Terminal, etc).

Configure the software for 9600 baud, 8 data bits,no parity, 1 stop bit (8,none,1).

Turn the modem on.

Type AT and press the enter key.

The screen should display OK. If not, check yourcommunications program settings.

Type ATV0X0&K0S0=1&D0&W0&Y0Z0 andpress the enter key.

A 0 should display on the screen. Turn off themodem and disconnect it from the PC.

Some modems use Y0, not &Y0, to select profile 0on reset. Some use separate transmit and receiveflow controls. In this case you need to disable flowcontrol for both transmit and receive (&H0&R1 fora US Robotics instead of &K0).

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Test Mode

Test mode is made up of two components. They are oscillator test and load cell test. Oscillator test modeis activated by turning on switch sw2 position 8. Load cell test mode is activated by turning on switch sw2position 7. Either can be used by itself or both can be activated for complete test mode. These two switchpositions are only read on reset. Therefore, you must turn off the power, then turn on the desired switches,and then turn the power back on. If you change these switches with the power on, they will not have anyeffect until the computer is reset.

If either switch is on, the word NODE on line 4 of the weight rate screen will be replaced with the wordTEST. If switch sw2 position 8 is on, the speed sensor will be ignored. Instead pulses will be generatedby a timer in the microprocessor. These pulses will have the same effect on the integrator as pulses whichnormally come from the speed sensor. You can see the speed on line 3 of the weight rate screen. If switchsw1 position 1 is on, you can press the select key and an arrow will appear after the word speed. You canthen use the arrow keys to change the speed. The large arrows will change the speed about 60.6 feet perminute and the small arrows will change the speed about .606 feet per minute. The maximum speed is about620 feet per minute. The minimum speed is 0. The clear key will set the speed to 0. The next time you turnon the integrator in oscillator test mode the speed will be whatever it was when you last used the oscillatortest mode.

If switch sw2 position 7 is on, the load cell signal will be ignored. Each time you enter load cell test modethe load percent will default to 7.5%. You can use the select key to change the % sign to an arrow andthen use the arrow keys to change the load percent. The large arrows will change the load by 10% andthe small arrows will change the load by .1%. the clear key will set the load percent to 0.0%.

By changing the load percent and belt speed you can simulate any desired rate. All outputs will functionas if the scale is actually weighing material. You can run a set zero if desired. You cannot activate the PIDloop in the simulation mode because the PID output cannot actually change either the speed or loadpercent. The result would be the 4 to 20 mA signal would either go to maximum or minimum.

If you want to run a simulation using the actual speed sensor and simulated load cell readings, activateonly switch sw2 position 7. If you want to run a simulation using the load cells and simulated speedreadings, activate only switch sw2 position 8. If you want to run a simulation using both simulated speedreadings and simulated load cell readings, activate both switches.

To exit test mode turn the power off. Turn both switch sw2 position 7 and 8 off. Turn the power backon. The scale will be in normal mode. This feature is not present in versions prior to 1.20.


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* Sufficient impact location idlers should be provided under each feeding location so as not to cause any deflection of thebelt at the feed point.

* The conveyor belt should be equipped with a gravity type belt wiper system if material buildup on the belt could be aproblem.

* The conveyor should be designed with a straight run without a vertical curve. The conveyor may be horizontal, incliningor declining in slope.

* If the scale is located within 25 feet of the head pulley, the top of the carry rolls within the scale area must be a minimumof 1/2 inch above the crown of the head pulley.

Conveyor Design Requirements

Your conveyor may not meet all of these requirements and still give good accuracy readings. Use these as guidelines for gooddesign and realize that violating good design will probably reduce accuracy.

* Avoid high speed, lightly loaded belts for scale applications. Lowering the belt speed, which increases belt load, will curemost scale problems.

* The idler used at the scale as well as preceding and following the scale should turn true (concentric) and the scale idlershould be reasonably balanced (especially with high speed belts) so as not to generate an out of balance vibration. (Someidler manufacturers make idlers specifically for scale duty.)

* Idlers should be on equal centers a minimum of two before and two after the scale and must be string lined to be level forthis span. Skirt boards must be avoided in the scale area.

* The conveyor should not exceed 1000 feet in length.

* The belt speed should not exceed 300 feet per minute on a belt 25 feet long or less.

* The conveyor should be rigid in design and reasonably free from vibration. The conveyor must not be subject to stress thatwill cause structural deflection.

* The conveyor should have an automatic belt tightener. A gravity take up system is preferred.

* The belt must be in contact with the scale idler at all times and should track in the center both empty and full.

* If the conveyor is subject to excessive winds, the scale location should be sheltered by the use of a wind break.

* The idler troughing angle should be 35 degrees or less.

* Conveyor inclination must not exceed the material angle of slide.

* Conveyor loading should be reasonably uniform and loading can not take place on the area of belt being used as theweighing platform.

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Warranty

Products manufactured by Sauk Valley Systems, Inc. are warranted to be free of manufacturing defectsfor a one year period after the original date of purchase. This warranty does not include damage to theproduct resulting from accident, misuse, improper installation or operation. If a component shouldbecome defective within the warranty period, we will repair or replace it free of charge at our option.Defective components must be returned freight prepaid to Sauk Valley Systems, Inc. or to an authorizedSauk Valley Systems, Inc. service center.

Complete products included with our system that are not manufactured by Sauk Valley Systems, Inc. suchas computers, printers, chart recorders, active hubs for network expansion, etc. are warranted to theextent that they are warranted to us.

The customer's sole remedy shall be such repair or replacement as is expressly provided above, and weshall in no event be liable for any incidental or consequential damages arising out of the use or inabilityto use this product for any purpose whatsoever.

Some states do not allow the exclusion or limitation of incidental or consequential damages, so the abovelimitation or exclusion may not apply to you.

This warranty gives you specific legal rights. You may also have other rights which vary from state to state.

For products purchased outside the United States, see your distributor for warranty.

BELT-WAY is a registered trademark of Sauk Valley Systems, Inc.FLO-WAY is a registered trademark of Sauk Valley Systems, Inc.Covered by U.S. PATENT 5,696,354

This scale is not designed or sold as a legal for trade scale. It does not meet some of the legal for tradescale requirements defined in NIST Handbook 44.

This warranty is in lieu of any and all other warranties, expressed or implied.


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Wiring Diagrams and DrawingsThe following pages contain wiring diagrams for the IO option board and the remote start / stop stationused for loading trucks. Use these diagrams in conjunction with the description in the manual to connectthe wiring for these options. Also included are drawings showing the hole layout for mounting the scale.

Belt-Way Modem Menu

If you connect the scale to a PC using a modem, this menu should appear on your screen. If you make adirect connection using a cable, enter a lower case letter a to see the menu.

BELTWAY MODEM MENU SCALE # 1 PLANT #2 PRODUCT # 3 a SEND THIS MENU j F3 KEY b SEND DATA BUFFER k F4 KEY c SEND CURRENT DATA l F5 KEY d WEIGHT RATE KEY m F6 KEY e CAL DATA KEY n F7 KEY f TARE ANGLE KEY o T1 KEY g NODE KEY p T2 KEY h F1 KEY q T3 KEY i F2 KEY

Error MessagesNET FAIL NODE x on line 4 of the WEIGHT RATE display. Press the F3 key. If lines 3 and 4 do not saySEND RATE TO NODES IS TURNED OFF, this control is trying to send its rate to other scales. If youdo not have other controls networked, turn on switch SW1 position 1. Press the F3 key. Press the SELECT

key 3 times so the arrow appears after the word FROM. Press the CLEAR WEIGHT key. Turn off SW1-1.

NET FAIL on line 3 of the WEIGHT RATE display. The PID loop is set up as a remote setpoint, and thenetwork is not providing a rate from a master scale. See if the master control is turned off, or has its sendrates to nodes on the F3 screen turned off. Check the network cable and terminators. If the PID loop isnot supposed to be a remote setpoint, change it to local setpoint.

MAX OUT NODE x on line 4 of the WEIGHT RATE display. If x is the node for this scale, the control PIDloop is at maximum output and is not getting enough material. If x is not this scale, this scale is probablya master and its slave node x is at maximum.

KEY DISABLED on line 4. Switch SW1 position 1 is probably off. You must have an IO board for F2.

Step8 -ConnectCableShields

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