MCR Technologies Weigh Shark User manual

Shark kW
ion Manual
nologies Group, Inc.
g, IL. 61081
om
Weig W
Inst
T , Inc.
Ster
www.we
om
1, 2017
Weigh Shark
Weigh Shark kW
Installation Man
Technologies Grou
sales@weig
MCR Technologies Group, Inc.
Sterling, IL. 61081
www.weighshark.shark.com [email protected]
Marc
July. 8, 2020

Thank you for your purchase. Your
Scale has been
carefully designed to provide you with years of
operation and accuracy. We have designed features to allow
simple installation, calibration and operation of your scale.
Our standard features should provide you with the tools to
monitor and record your im
The software was designed and written with you in mind.
Operation is simple with the use of minimal buttons. No
formulas must be calculated and no switches must be set for
operation. Everything needed to calibrate your scale
accomplished via our software and
simply enter your calibration data, perform a couple simple
steps and your scale is calibrated.
Sincerely,
Mark Humphreys
President
, CEO, Founder
This is
not
Thank you for your purchase. Your
carefully designed to provide you with years of
operation and accuracy. We have designed features to allow
simple installation, calibration and operation of your scale.
Our standard features should provide you with the tools to
monitor and record your im
portant production data.
The software was designed and written with you in mind.
Operation is simple with the use of minimal buttons. No
formulas must be calculated and no switches must be set for
operation. Everything needed to calibrate your scale
accomplished via our software and
high-speed
processor. You
simply enter your calibration data, perform a couple simple
steps and your scale is calibrated.
, CEO, Founder
not
a
Legal for Trade Scale.
® Belt
carefully designed to provide you with years of
operation and accuracy. We have designed features to allow
simple installation, calibration and operation of your scale.
Our standard features should provide you with the tools to
portant production data.
The software was designed and written with you in mind.
Operation is simple with the use of minimal buttons. No
formulas must be calculated and no switches must be set for
operation. Everything needed to calibrate your scale
is
processor. You
simply enter your calibration data, perform a couple simple
Legal for Trade Scale.

Much of the world estimates the main resistances with a single overall friction factor,
based on history, though each of the main resistances is affected differently by the
specific material, design and construction details. The Conveyor Equipment
Manufacturers Association (CEMA) has long recognized the individual impact of various
parts and configurations and include a set of power prediction equations addressing
each in its “Belt Conveyors for Bulk Materials,” especially in the sixth edition in 2005 and
the seventh edition. This design and analysis approach has proven to provide a better
foundation for design accuracy and optimization for complex conveyors, especially since
computers have allowed the many calculations and checks needed for thorough design
over a wide range of cooperating conditions.
The main friction losses and their relative contributions as percentage of total power on
a flat conveyor are:
1. Belt rubber indentation rolling resistance from the belt internal hysteresis. It is affected
by load, temperature and compounding of the durable, filled rubbers used on conveyors
(25% to 80%).
2. Idler alignment from imperfect angular alignment during installation and manufacturing
(10% to 50%).
3. Idler rotating resistance from the design and manufacture including seal and
temperature sensitive grease drag (10% to 60%).
4. Bulk material friction due to internal movement from belt sag between each pair of
idlers, especially with belts with fabric carcasses and at lower tension (1% to 55%).
In addition, miscellaneous component can contribute from 2% to 10%. Inclines or
declines dominate the power loss categories and belt tension when the slope is much
greater than 5°, but the above still have an absolute effect on power.

kW Belt Scale Installation
The Weigh Shark kWbelt scale uses the power draw of the conveyor drive motor to calculate
the amountofmaterial that is flowing over the conveyor. The integrator works in conjunction
with apower meter to measure thepower usage of theconveyor. This document covers the
basic setup ofthe kWbelt scale. The more advanced settings and features are covered in the
standard belt scale manual.
WARNING! All high voltage electrical connections should be
done by aqualified electrician!
Electrical Installation
1. High Voltage connections
a. Refer to the included manual for the power meter for detailed
installation instructions.
b. Current Transformers (CT) – the CT’s should be sized for the
maximum current draw of the drive motor.
2. Connections to Weigh Shark integrator.
a. The integrator requires software version KW4.1.0 or greater.
b. Power meter connections.
c. Integrator connections.
Color
Terminal
White
P1
Green
COM
Color
Terminal
Green / Drain
GND
10K resistor
+24Vdc
White / 10K resistor
Speed In

Settings
1. Setup – VERY IMPORTANT DON’T SKIP THIS STEP
a. Go to menu Setup -> Calibration Setupand press ENTER.
b. Use the UP arrow key until theCT Amps option is shown. This should
match the amp value found on the current transformers for your
applications.
i. To Change: press ENTER
ii. Press EDIT.The cursor will be displayed under the New value.
iii. Use the + / -keys tochange the number.
iv. Use the Left and Right arrow keysto move the cursor.
v. Press Apply to accept the changes.
2. Basic Information
a. View Screen
i. Daily Total – The total weight accumulated since the total was
last cleared.
ii. Rate – the real time Tons PerHour
iii. Watts – the real time Watts being consumed by the motor.
b. Misc. Screen
i. Amps – the calculated amps being drawn by the motor.
ii. Input Hz– the pulse frequency being read from the power
meter.
Calibration: Comprised of Two (2) Steps.
1. STEP 1: Zero Calibration
a. Run belt empty atnormal operational speed.
b. Go tomenu Calib -> ZeroTest and press Enter.
c. Press key underSTART when the splice ormark on the belt passes a
fixed point.
d. Press END when the splice ormark makes one complete revolution.
e. The screen will show the old and the new Zero numbers.Press
APPLY to accept the changes.
f. For future Zero test go to the menu Calib -> ZeroTestand use the
PRV option to use the stored time for 1 belt revolution.
g. The Zero Test can be run anytime that the scale isshowing a rate
when the belt isrunning empty.

SETTINGS: Go to SETUP > Scroll to Calibration Setup then Press ENTER.
You must confirm or enter in the correct voltage of your system.
If your Nominal Voltage value is correct you can scroll down to next line. If not,
use down arrow key to scroll to move the > pointing at the line and use + /- to
change value.
Now you must confirm you have the correct Phase and CT Value
In our example we have 3 Phase Power and our CT’s are 50 Amp units.

IF your Phase Per Output is not correct in photo above then with the > pointing at
the line use the + or – button to change to be correct.
IF your CT value is not correct then Arrow Down to CT Amp line. Press ENTER.
Select EDIT. The screen will change to the photo above. A small line will appear
under the last number. Use the Left or Right Arrows to move this line to the
below the number you wish to change. Use the + or – keys to change your
number. Once you have entered in the correct value Press APPLY.
(In our example we have entered in for a 50 Amp CT.)
4/3/2019

Example
5. Press the Arrow under START when your Empty Belt passes a reference
point start to measure and weigh your belt. The display will show you
information during this step. Watch your belt make one (1) revolution and
press the arrow under END after completion of this one revolution.
6. The screen will automatically change. It will show Belt Length (feet), Old
Zero Value and New Zero Value. It will instruct you to press the arrow under
APPLY. This will establish your Auto Zero value. The screen automatically
goes back to the main calibration screen.

PREVIOUS FEATURE
Once you have established a Zero Number you have also established a belt
length for your conveyor. By using the PRV (previous) feature on the
screen, it will allow you to start a zero test without having to wait for your
splice or mark on the belt. Keep in mind that the belt MUST be empty and
no calibration weights or bar applied.
This feature is only used for recalibrating your zero number with your
existing belt length.
If you lose your settings for any reason, you will need to run a New Zero
Test following the instructions beginning on page 9.

IMPORTANT
Calibration Options
With the kW electric scale, you have two (2) options for the SPAN calibration
process.
1. MATERIAL TEST: This is the preferred method since you are
either running a known amount of material over the scale or you
are catching material and weighing it over a legal for trade scale.
If you are able to perform a Material Test then please proceed to
the next page for instructions.
2. BELT CUT: In this step you will perform a belt cut where you
remove material from a specific length of belt. We recommend 4
to 5 feet of material. Please contact us in advance and we will
email you our Excel spread sheet where you will enter in
information necessary to calculate your SPAN (multiplier)
required to manually calibrate the scale. You will still perform the
ZERO TEST with the belt empty for one revolution first then follow
the instructions on the Excel sheet.
Remember a Belt Cut is a small representation of the weight on
the belt at the given time that you stop the belt and remove the
product.
If you have any questions please contact us.
Sincerely,
Mark Humphreys
President

2. STEP 2: Span Calibration – The Span Calibration is used to calibrate
the integrator to accumulate the correct weight based on a known
amount of material passing over the conveyor. This step will
require a known amount of weight to either be run over the
conveyor orcaught into a truck or loader that canbe weighed.
The larger the material test the better. The material flow during
the test should be as close as possible to the actual conditions.
INSTRUCTIONS
Under the Calib. menu use the Down Arrow to move the cursor arrow (>)
to the line SPAN TEST - PRESS ENTER
Press ENTER
Start the material Flow over the conveyor.
When the material flow is complete press the NEXT Key.
The screen will change and ask you to enter in the Actual Weight Value.
(This is where you enter in the weight that you ran or caught. )
When you have correctly entered in the value press the NEXT key.
This will set the correct SPAN number.
CALIBRATION IS COMPLETE

Real Time Performance (RT Prfm%)
Real Time Performance % is also shown on the default (View) screen. This
shows you your performance RATE you are running based on the Standard Rate
(your goal). The factory default setting is 350 TPH. You can change your
Standard Rate to allow you to see what you are doing in relationship to your goal.
This will give you instant information to allow you to understand your production.
Steps to change your Standard Rate:
1) Go to SETUP
2) Arrow down to CALIBRATION SETUP
3) Press ENTER
4) Arrow down to STANDARD RATE
5) Press ENTER
6) Press EDIT
7) Use the + or – buttons to raise or lower the number.
8) Press APPLY
9) COMPLETED
You Do Not have to Recalibrate your Scale.

TOTALS
There are four (4) independent totals with their own Production screen. They
can be viewed, cleared and * printed separately. *(With optional ticket printer)
Daily Total: This total is displayed on the default screen. It shows your
accumulating total.
If you wish to clear off this total, press ENTER key while the cursor is
pointing to the "Daily Total". This will access your Production Screen.
Press Arrow Button below CLEAR to clear off this total.
Press ESCAPE button or EXIT to go back to Default Screen
Scroll Down (using arrows on right of faceplate) 4 times to “Weekly Total”.
Weekly Total: This is also an accumulating total for you to use. You can view the
weekly production screen by pressing ENTER.
Monthly Total: This accumulating total is listed next and can be cleared by pressing
ENTER to go to its production screen.
Yearly Total: Located is located on the next screen, just press the down arrow key to
move cursor to this line and Press ENTER.
Any of your totals can be printed while viewing the production screen.
You can customize your ticket. (See Ticket Printer Pg. 28)
CHANGING FROM ENGLISH TONS TO METRIC TONS
1. Press Setup 2. Scroll to Units
3. Press Enter 4. Press Edit
5. Press +/- to change Units 6. Press Apply

Analog Outputs (mA)
You may use the standard analog output (4-20 mA) for monitoring your production
to a chart recorder, PLC or any device that accepts 4-20 mA.
Press arrow located under I/O to access these setup screens.
Press ENTER while the cursor (>) is next to Analog Output to go to the setup
screen.
Press the arrow under EDIT. The cursor (>) moves next to “Rate”. This cell is
active and you can select your function. Press the + or – keys to view your
options.
The Current Loop configuration screen displays all the settings that pertain to the
current loop.
Setting
Description
Function Function of the output (i.e. Rate, Belt Speed, Load%, etc.)
Direction Direction of the output (Forward or Reverse).
Minimum Minimum value for the output
Maximum Maximum value for the output
Averaging The number of samples to average (1 to 65000)
Range 4-20mA or 0-20mA output
To make changes press the EDIT button. Use the ▲and ▼keys to move the cursor
through the settings. To edit the number values use the ◄and ►keys to move through
the individual digits of the number. Use the + and – keys to change the values.
Press the ▼arrow key to move your cursor to “Forward”. Use the + key to select
Forward or Reverse.
Press the ▼arrow key again to move your cursor next to “Minimum” Press the ►arrow
key to move your cell line over to the location where you want to enter your TPH. The
cell is active at the location of the short line. Use the + key to enter in the value for this
cell.
(Example) If you wish to have your Minimum Rate (at 4 mA) be 100 TPH. Press the ►
arrow key until the short line is directly left of the 0. Press the + key to select 0. Press
the ◄arrow key 1 time to move the short line to the left. Press the + key to place a 1 in
that cell. You should now see 100 TPH.
Press the ▼arrow key to move the cursor (>) next to “Maximum” Follow the same
procedure to enter your desired Rate at 20 mA.
Current Loop Tips:
•Increasing the Averaging value slows the response time of the output. For
blending or control applications the number should be lowered to increase the
response time.
•When connecting to a PLC or Data Acquisition device, it might be helpful to output
a Total; this would allow the calculation of the Rate and Total.
•The 0-20mA and 4-20mA settings both have the same output resolution (16bit).

When you have selected your desired functions; press the arrow under APPLY or
EXIT to leave without saving the changes.
To Isolate Current Loop Output Remove Jumpers J1 & J2
Current Loop Examples
Output current Rate (TPH)
Desired output: 500tph = 20mA 10tph = 4mA
Set the following:
Function: Rate
Direction: Forward
Minimum: 10 TPH Maximum: 500 TPH
Range: 4 to 20mA
Output current Belt Speed (fpm)
Desired output: 250fpm = 0mA 0fpm = 20mA
Set the following:
Function: Belt Speed
Direction: Reverse
Minimum: 0 fpm Maximum: 250 fpm
Range: 0 to 20mA
Output current Total 4
Desired output: 10,000tons = 20mA 0tph = 0mA
Set the following:
Function: Total 4
Direction: Forward
Minimum: 0 tons Maximum: 10000 tons
Range: 0 to 20mA

Digital Inputs
Press ENTER under I/O to access the Digital Inputs screen. You have 4 Inputs
labeled Input 1, Input 2, Input 3 and Input 4.
1. Press the ▼to place the cursor (>) next to Input 1.
2. Press ENTER to open the screen for entering your information.
3. Press EDIT to make your entries. You will see the > next to the word
Function: This cell is active.
4. Use your + or – keys to scroll your options.
5. Press the ▼to select if you want your Input to be ON or OFF
6. When you have selected your Function, press APPLY
7. Press EXIT to go back to your I/O screen.
8. If you wish to use more than 1 Input, you will use the ▼to move the cursor
down to the next line (Input 2). Repeat the above procedure etc.

Digital Outputs
You have 4 Digital Outputs labeled Output 1 through Output 4. They are
located on the same screen as the Inputs. You will use the ▼to move your
cursor to the Output you wish.
1. Press ENTER to go to the setup screen.
2. Press the arrow under EDIT to make your entries. The cursor (>) will
appear next to “Function:”
3. Use the + or – keys to scroll your options. (1 Ton Pulse, .1 Ton Pulse…..)
4. Press the ▼to move the cursor down one line to “Set point:” This cell is
active and this value may be changed. Press the + or – keys to change the
value.
5. Press the ▼to move the cursor to the line “Action”: You can select ON or
OFF.
6. Press the arrow under APPLY to set your changes.
Let’s say you want the scale to stop your conveyor when a certain weight is
reached. You would select “Daily Total”, and enter you set point (15 tons). You
would go to the normal screen. While the cursor (>) is pointing to “Daily Total” you
would press ENTER to go to the screen to clear off this total and set it back to 0.
Press CLEAR to clear off your “Daily Total”, when you start running material the
accumulation will show your production. When you reach your set point of 15
tons, Output 1 would turn ON to stop your conveyor. You can wire up a “remote
clear” button to Input 1. Each time you would press your button your “Daily Total”
would clear to 0.

TICKET PRINTER
A Ticket Printer may be purchased and used to record Production Data. The
ticket printer comes mounted inside a NEMA 4x fiberglass enclosure with clear
window and lockable latch. The ticket printer can be used to print Production
Data for any of the four (4) independent totalizers of the scale.
1. Wire Ticket Printer according to diagram located in the back of the printer
enclosure (RS 232)
2. Connect printer to 110 VAC
power.
3. Select I/O menu.
4. Scroll down to line stating:
SERIAL PORTS
5. Press ENTER.
6. Select Port 1 (RS 232)
7. Press ENTER than Press EDIT
8. Use + and _- to select Function:
TICKET PRINTER
9. Confirm BAUD RATE = 19200
10.Press APPLY
11.Turn scale control box OFF and
ON to cycle power.
MUST CHANGE TIME
1. Go to Setup Screen – Scroll to Time Setup – PRESS ENTER
2. Use +/- Button to set time to 00:00 GMT time
3. Exit Screen.
4. Got to Miscellaneous Screen – PRESS ENTER – PRESS EDIT
5. Enter In the Current Correct time at your location using the +/- buttons
6. Press Apply to Recycle Power
PRINTING TICKET
1. Select the TOTAL to be printed. Use ▲or ▲keys to move the cursor to the
TOTAL you wish to view and print.
2. Press ENTER (Here you will see Production Data information for your
current TOTAL and the previous TOTAL).
3. Press PRINT to print ticket.