Motoweigh Dynamic In-motion Checkweighing System. Installation Manual

Transcription

1 Motoweigh Dynamic In-motion Checkweighing System TM Installation Manual

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3 Contents About This Manual Introduction and Theory of Operation Hardware Requirements Installation instructions Unpacking the Crate Installation Overload Stop Bolt Adjustment Preventative Maintenance Troubleshooting Procedures Photoeye Troubleshooting Assembly Drawing Load Cell Information Appendix - Electrical Drawings System Wiring and Logic Photocell Wiring i Load Cell Connections and Photo Cell I/O Scale Motor Connections System Component Layout Motoweigh Dynamic In-Motion Checkweighing System Limited Warranty Rice Lake Weighing Systems. All rights reserved. Printed in the United States of America. Specifications subject to change without notice. January 2009 i

4 About This Manual This manual is intended for use by service technicians responsible for installing and servicing the Motoweigh Dynamic In-Motion Checkweighing System. Operation of the Motoweigh Integrator is explained in the integrator manual, PN Configuration and calibration of the Dynamic Conveyor Scale Integrator can be accomplished using serial commands or the indicator front panel keys. See the 920i Installation Manual, PN 67887, for more information about configuration methods. only. The Motoweigh dynamic in-motion checkweighing system has many moving parts so great care must be used when working on the unit. Procedures are to be performed by qualified service personnel Authorized distributors and their employees can view or download this manual from the Rice Lake Weighing Systems distributor site at Introduction and Theory of Operation The Motoweigh dynamic in-motion checkweighing system is a continuous process weighing instrument which can be used for product sortation and data collection. the system averages the weights on the scale, displays the averaged weight, and sends the average weight information out using the DSCI (Dynamic Conveyor Scale Integrator) using a serial port. The system utilizes the following main components. A scale merged with a conveyor and drive mechanism. Two photo eyes to trigger start and stop operation. An integrator (920i HMI) linked and programmed to average the weight signal at the rate of 60 times per second between the start and stop photo eye inputs. After the object passes in front of the entrance photo eye, it starts the scale integrator (920i), averaging the weight on the scale. At this time, the scale display shows dashes [ ]. The object proceeds down the scale conveyor until it passes in front of the exit photo eye, at which time the integrator s averaging process is stopped and the averaged weight is displayed. A smooth product transition and matching belt speeds are absolutely necessary to achieve accurate results. Photo eyes and reflectors must be kept clean for optimal performance. Even though the equipment is wash down rated, extreme water pressure should be avoided around the electronic components. 1.1 Hardware Requirements Heavy duty tubular construction 230V variable speed motors x 3 3 phase 1/2 horsepower 1 full load 460 VAC 100% overload protection Adustable line height +/- 2 RS-232 real time straight weight transmission Industrial grade belting Introduction and Theory of Operation 1

5 2.0 Installation instructions Use the following steps to properly install the Motoweigh dynamic in-motion checkweighing system. 2.1 Unpacking the Crate Immediately after unpacking, visually inpsect the unit to ensure all components are included and undamaged. The shipping carton should contain the checkweigher, and this manualt. If any parts were damaged in shipment, notify Rice Lake Weighing Systems and the shipper immediately. 2.2 Installation 1. Once the crate is open, find a suitable place to set up the checkweigher. 2. Level the feet so that there is no gap between the floor and the foot. 3. Set the gap between the checkweigher belts as close as possible without touching so that product is conveyed as smoothly as possible. 4. Loosen the overload stop bolts on the checkweigher conveyor. There are four bolts, one on each corner of the scale spider. If these are not loosened, the scale will not weigh accurately. (See Figure 3-2 for bolt location). 5. Supply 230/460 VAC 3-phase power to the variable frequency drive. This frequency drive will control the speed of all three motors. 6. Supply 120 VAC power to the integrator. See Appendix for wiring diagrams. 7. Do not run the checkweigher without all the guards, guides and shields in place and attached where necessary. 2 Motoweigh Dynamic In-Motion Checkweighing Installation Manual

6 3.0 Overload Stop Bolt Adjustment The Motoweigh dynamic in-motion checkweighing system has load cells which have a self-contained load cell protection system for preventing the load cell from being loaded beyond its rated capacity. Use the following steps to adjust the overload stop bolt if needed. 1. Place a test weight 102% of capacity in the center of one of the quadrants of the conveyor platform, as shown in Figure 3-1. The weight integrator (DSCI) should display a reading above the capacity or O-Cap. Scale Platform X Figure 3-1. Place Test Weight in Quadrant 2. Loosen the stop bolt jam nut corresponding to the quadrant supporting the test weight. Overload stop bolts x 4 Figure 3-2. Overload Stop Bolt Location 3. Adjust the overload stop bolt so that it contacts the overload stop block on the bottom of the frame and the integrator (DSCI) reads slightly less than the applied weight. 4. Tighten the overload stop bolt jam nut. 5. Repeat steps one and two for each of the remaining corners of the scale. Overload Stop Bolt Adjustment 3

7 4.0 Preventative Maintenance To maximize performance of the Motoweigh dynamic in-motion checkweighing system a few simple steps will help extend the life of the product and will maintain performance. Grease all bearings on the conveyor system Check the belt tension and alignment of the conveyors periodically to ensure maximum scale and conveyor performance. Belt tension can be adjusted on the idler end if needed. Check the setscrews on the driveshafts. Once the numbers are set in the integrator (DSCI), keep those numbers documented in a manual that is accessible to maintenance personnel at all times so they can be re-entered if necessary. Photo eyes and reflectors must be kept clean and free of debris. They should also be properly aligned for optimum scale performance. The conveyor equipment is wash-down rated, but extreme water pressure should be avoided around the electrical components of the unit. 4 Motoweigh Dynamic In-Motion Checkweighing Installation Manual

8 5.0 Troubleshooting Procedures Table 5-1 lists general troubleshooting tips for various hardware error conditions. Problem Cause Remedy Scale does not get weights or the weights seem to be off. Product is spaced too close to each other Photoeyes are spaced too close together Exit photoeye is past the end of the scale Photoeyes are not working Load cell is not working properly Scale overload stops are touching at the corners of the scale spider Integrator does not go into averaging Table 5-1. Troubleshooting Tips Correct the product spacing Move entrance eye back towards the beginning of the scale Move the exit photoeye Clean the lens on the photoeyes, clean the reflective tape, check for power (yellow LED is lit), and check alignment of photoeye beam on reflector (red LED it lit at optimum alignment). When the beam is interrupted LED s should transition between green and red Watch for load cell drift and/or perform load cell tests. Replace the load cell. Adjust the overload stop bolts by placing 105% of capacity in each quadrant of the scale and adjust overload stop bolts in each corner until they contact the block above them. Integrator has wrong software or is configured wrong, bad connection between the integrator and the photoeyes. Replace faulty photoeyes. Troubleshooting Procedures 5

9 5.1 Photoeye Troubleshooting Start Indicator lights up and program is working change indicator yes Are there dashes on the indicator? set photo eye switch to dark no Is photo eye set too dark? yes adjust the sensitivity potentiometer no Is photo eye sensitivity control set correctly? adjust eye or reflector so photo eye is reflecting no yes is photo eye reflecting off of the reflector? replace photo eye yes Go to 2 Go to 2 Go to 2 6 Motoweigh Dynamic In-Motion Checkweighing Installation Manual

10 From 1 From 1 From 1 flag first photo eye no dashes appear no is photo light on? yes with photo eye not flagged is there 5 V between I/01 and GND? yes no END is there 24 V between J volts and GND? yes change photo eye charge indicator are photo lights on now? change cable change cable yes no does the 5 V become 0 V now? change photo eye no does the 5 V become 0 V? change photo eye no does the 5 V become 0 V when the photo eye is flagged? yes Troubleshooting Procedures 7

11 6.0 Assembly Drawing 8 Motoweigh Dynamic In-Motion Checkweighing Installation Manual

12 7.0 Load Cell Information RL1250 Potted Single Point, Aluminum NTEP 1:5000 Class III Single Cell Picture is a representation of actual product RATED DIMENSIONS CAPACITY A B C D E F G H J K L M N P kg/mm /16-18UNC X 15 DP lb/inches /16-18UNC X 0.59 DP SPECIFICATIONS: Full Scale Output: 2.0 mv/v Bridge Resistance: 350 ohms, nominal Material/Finish: Anodized aluminum Temperature: Compensated range 14 F to 104 F/-10 C to 40 C Safe Overload: 200% of full scale at center loading point Rated Excitation: 10V AC/DC (15V max i mum) Total Error:.02% Full scale Insulation Resistance: 5000 megohms Deflection at Capacity: kg.4mm/.015" Seal Type: Environmentally-sealed, potted Cable Length: 3.1 m/10' Cable Color Code: Green...+ Excitation Black... Excitation Blue...+ Sense Brown... Sense Red...+ Signal White... Signal Max Platform Size: 24' x 24' Warranty: Two-year limited warranty Rice Lake Weighing Systems RL1250 ORDER INFORMATION Load Rating Part # Price NTEP 1: kg (110.2 lb) $ kg (165.4 lb) $ kg (220.5 lb) $ kg (330.7 lb) $ kg (440.9 lb) $ kg (551.2 lb) $ kg (661.4 lb) $ kg ( lb) $ kg (1400 lb) $ kg (2205 lb) $ Manufacturer INTERCHANGEABLE PRODUCTS Model Vishay Revere Transducers...(see page 286) 652 Vishay Tedea-Huntleigh...(see page 344) 1250 Vishay Celtron...(see page 197) LOC Flintec... (see page 218) PCB* HBM... (see page 245) PW12 Rice Lake...RLPWM12 * Stainless steel, Hermetically-sealed Shim plate-part number Load Cell Information 9

13 8.0 Appendix - Electrical Drawings 8.1 System Wiring and Logic Figure 8-1. System Wiring and Logic Drawings 10 Motoweigh Dynamic In-Motion Checkweighing Installation Manual

14 8.2 Photocell Wiring Figure 8-2. Photocell Wiring Appendix - Electrical Drawings 11

15 i Load Cell Connections and Photo Cell I/O Figure i Load Cell Connections and Photo Cell I/O 12 Motoweigh Dynamic In-Motion Checkweighing Installation Manual

16 8.4 Scale Motor Connections Figure 8-4. Scale Motor Connections Appendix - Electrical Drawings 13

17 8.5 System Component Layout Figure 8-5. System Component Layout 14 Motoweigh Dynamic In-Motion Checkweighing Installation Manual

18 Motoweigh Dynamic In-Motion Checkweighing Limited Warranty Rice Lake Weighing Systems (RLWS) warrants that all RLWS equipment and systems properly installed by a Distributor or Original Equipment Manufacturer (OEM) will operate per written specifications as confirmed by the Distributor/OEM and accepted by RLWS. All systems and components are warranted against defects in materials and workmanship for two years. RLWS warrants that the equipment sold hereunder will conform to the current written specifications authorized by RLWS. RLWS warrants the equipment against faulty workmanship and defective materials. If any equipment fails to conform to these warranties, RLWS will, at its option, repair or replace such goods returned within the warranty period subject to the following conditions: Upon discovery by Buyer of such nonconformity, RLWS will be given prompt written notice with a detailed explanation of the alleged deficiencies. Individual electronic components returned to RLWS for warranty purposes must be packaged to prevent electrostatic discharge (ESD) damage in shipment. Packaging requirements are listed in a publication, Protecting Your Components From Static Damage in Shipment, available from RLWS Equipment Return Department. Examination of such equipment by RLWS confirms that the nonconformity actually exists, and was not caused by accident, misuse, neglect, alteration, improper installation, improper repair or improper testing; RLWS shall be the sole judge of all alleged non-conformities. Such equipment has not been modified, altered, or changed by any person other than RLWS or its duly authorized repair agents. RLWS will have a reasonable time to repair or replace the defective equipment. Buyer is responsible for shipping charges both ways. In no event will RLWS be responsible for travel time or on-location repairs, including assembly or disassembly of equipment, nor will RLWS be liable for the cost of any repairs made by others. THESE WARRANTIES EXCLUDE ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING WITHOUT LIMITATION WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. NEITHER RLWS NOR DISTRIBUTOR WILL, IN ANY EVENT, BE LIABLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES. RLWS AND BUYER AGREE THAT RLWS S SOLE AND EXCLUSIVE LIABILITY HEREUNDER IS LIMITED TO REPAIR OR REPLACEMENT OF SUCH GOODS. IN ACCEPTING THIS WARRANTY, THE BUYER WAIVES ANY AND ALL OTHER CLAIMS TO WARRANTY. SHOULD THE SELLER BE OTHER THAN RLWS, THE BUYER AGREES TO LOOK ONLY TO THE SELLER FOR WARRANTY CLAIMS. NO TERMS, CONDITIONS, UNDERSTANDING, OR AGREEMENTS PURPORTING TO MODIFY THE TERMS OF THIS WARRANTY SHALL HAVE ANY LEGAL EFFECT UNLESS MADE IN WRITING AND SIGNED BY A CORPORATE OFFICER OF RLWS AND THE BUYER Rice Lake Weighing Systems, Inc. Rice Lake, WI USA. All Rights Reserved. Appendix - Electrical Drawings 15