Milltronics MWL User manual

MWL
MilltronicsWeight Lifter
Instruction Manual June 2001
MILLTRONICSWEIGHT LIFTER

© Siemens Milltronics Process Instruments Inc. 2001
Safety Guidelines
Warning notices must be observed to ensure personal safety as well as that of others, and to
protect the product and the connected equipment. These warning notices are accompanied
by a clarification of the level of caution to be observed.
Qualified Personnel
This device/system may only be set up and operated in conjunction with this manual.
Qualified personnel are only authorized to install and operate this equipment in accordance
with established safety practices and standards.
Warning: This product can only function properly and safely if it is correctly transported,
stored, installed, set up, operated, and maintained.
Note: Always use product in accordance with specifications.
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instrumentation described, variations
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Technical data subject to change.
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7ML19981CR01 Milltronics Weight Lifter MWL – Instruction Manual Page 1
Table of Contents
Milltronics Weight Lifter (MWL): Introduction ..............................................................2
Applications .............................................................................................................................................. 2
MWL Components ..................................................................................................................................3
Calibration Weight Arrangement ..............................................................................................4
Specifications ......................................................................................................................5
Belt Width .....................................................................................................................................5
Idler Spacing ................................................................................................................................5
Calibration Weight Capacity .....................................................................................................5
Crank Arm .....................................................................................................................................5
Calibration Weight Dimensions ..............................................................................................5
Mounting Dimensions ................................................................................................................5
Approvals ......................................................................................................................................5
Installation........................................................................................................................... 6
Drill left and right crank body mounting holes .....................................................................6
Mount left-handed and right-handed crank body ...............................................................7
Mount torque shaft / Check clearance for conveyor belt .................................................8
Install crank handle ....................................................................................................................9
Test the unloaded MWL / Align crank bodies ...................................................................10
Install calibration weights / Check for clearance .............................................................11
Test the loaded MWL ...............................................................................................................14
Shim the MWL (if required) / Recheck base-bar weight for clearance ......................15
Operation ............................................................................................................................17
Applying calibration weights ..................................................................................................17
Storing calibration weights .....................................................................................................17
Storing crank handle ................................................................................................................17
Maintenance Procedures ................................................................................................19
Removing material accumulation ...........................................................................................19
Greasing......................................................................................................................................... 19
Appendix I: Installation Drawings .................................................................................20
MWL Installation Drawing for the MUS-STD Standard Duty Belt Scale ................................20
MWL Installation Drawing for the MUS-HD Heavy Duty Belt Scale .......................................21
Retrofitting an MUS-HD Heavy Duty Belt Scale: ...............................................................22
MWL Installation Drawing for the MSI or MMI Belt Scale ........................................................23
Retrofitting an MSI or MMI Belt Scale: ...............................................................................23
Appendix II: Customer Calculation Sheet .................................................................... 27
Calculation of Total Calibration Weight Mass ...................................................................27
Calculation of Load Reference Values .................................................................................27
Using the Factoring Function of the Belt Scale Integrator .............................................28
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Page 2 Milltronics Weight Lifter MWL – Instruction Manual 7ML19981CR01
Milltronics Weight Lifter (MWL):
Introduction
The Milltronics Weight Lifter (MWL) mechanically raises and lowers the static
calibration weights used to calibrate Milltronics belt scales. It stores the weights
securely between the belt strands, above the calibration-weight support arms, and
allows the operator to lower and apply the weights safely without having to lean into the
conveyor.
The MWL is manually operated, and utilizes a high mechanical advantage to enable
weights up to 225 Kg (500 lb) to be applied with very limited effort. The crank handle can
be attached to either the left or right crank body. It uses 4 revolutions for full range of
motion, and can be removed and stored for safety on the locking ball-pin which secures
the MWL when it is not in use.
Two lifting pads support a base-bar weight above the calibration-weight supports of the
belt scale: either flat bar or horseshoe style calibration weights are available. Locating
notches in the base-bar weight engage the calibration weights securely on the lifting pads
in the stored position, and the worm gear drive locks the lifting pads in place. A manually-
applied locking-pin secures the MWL when the calibration-weights are in the stored
position.
Applications
The MWL is designed to work with the following Milltronics belt scales:
• MUS-STD MIlltronics Standard Universal Scale
• MUS-HD Milltronics Heavy-Duty Universal Scale
• MSI Milltronics Single Idler Scale
• MMI Milltronics Multiple Idler Scale (combination of 2 MSI Scales)
Belt Scale Manuals can be downloaded from the Milltronics website at:
www.Milltronics.com
Note: Please follow the installation and operating procedures to ensure a quick,
trouble-free installation, and to allow for the maximum accuracy and reliability of your
Milltronics Weighing System.
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7ML19981CR01 Milltronics Weight Lifter MWL – Instruction Manual Page 3
MWL Components
• a left-handed and right-handed crank body, each connected to a lifting-pad with guide-pin
• torque tube, to connect the left and right crank shafts
• crank handle, to be mounted to either the left or right input shaft
• optional shaft extension; adds 102mm (4") to handle shaft length
• base-bar weight (either flat bar or horshoe style) to support other supplied calibration
weights
• U-clamp to secure flat bar calibration weights
Base-bar Weight
Torqu e Tube
Crank
Handle
Shaft Extension
(optional)
Right-handed
Crank Body
Guide-pin (2)
Lifting-pad (2)
Connecting Shaft (2)
Input Shaft (2) Left-handed Crank Body
Input Shaft
Guide-pin
Removable
Crank Handle
Lifting-pad (lifts
as it rotates)
Worm Gear
Output Shaft
Drive Plate
Torque Tube
Plate Guide
Travel Stop
Travel Stop
Connecting Shaft
Cut-away view of Gear Drive
(Left-hand, clockwise-rotating crank-body shown)
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Page 4 Milltronics Weight Lifter MWL – Instruction Manual 7ML19981CR01
Calibration Weight Arrangement
offset
The horseshoe weights are not symmetrical:
an offset channel locates them on the base-bar weight.
Rotate alternate weights through 180o so that the weights
are staggered, to stabilize the base-bar weight.
Horseshoe Style Calibration Weights
Horseshoe-style
Base-bar Weight
Horseshoe-style Calibration Weights
Flat Bar Base-bar Weight
Flat Bar Calibration Weights
U-bracket
(supplied with
MWL)
Flat Bar Style Calibration Weights
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7ML19981CR01 Milltronics Weight Lifter MWL – Instruction Manual Page 5
Specifications
Belt Width
• MUS-STD Standard Duty: up to 1000mm; CEMA width 42"
• MUS-HD Heavy Duty: 1200mm and up; CEMA width 48" : can also be applied to
narrower conveyors
• MSI Single Idler: 500 to 2000mm; CEMA width 18" to 84" (prepared for use
with MWL)
• MMI Dual Idler: consists of 2 MSI scales, 2 MWL units are required
Idler Spacing
• Minimum of 610mm (24")
Calibration Weight Capacity
• MUS-STD: up to 175 lb (80 kg)
• MUS-HD: up to 350 lb (160 kg)
• MSI singly, (or MMI system): up to 500 lb (225 kg)
Crank Arm
• Mechanical Advantage: 20:1
• Number of Revolutions required for raising or lowering: 4
Calibration Weight Dimensions
Mounting Dimensions
• See detail installation drawings on page 20, page 21, and page 23, for MUS-STD
Standard Duty, MUS-HD Heavy Duty, and MSI Single Idler belt scales.
Approvals
• The MWL Milltronics Weight Lifter is in compliance with Directive 98/37/EC.
Idler Mounting Stance + 65mm (2.56")
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Page 6 Milltronics Weight Lifter MWL – Instruction Manual 7ML19981CR01
Installation
The Milltronics belt scale must be completely installed before you install the MWL.
Please refer to the belt scale installation manual for installation details.
The MWL installation has eight stages:
• Drilling the crank body mounting holes
• Mounting the crank bodies
• Mounting the torque shaft
• Installing the crank handle
• Testing the unloaded MWL
• Installing the calibration weights
• Testing the loaded MWL
• Shimming the MWL (if required)
1. Drill left and right crank body mounting holes
• Refer to the appropriate MWL installation drawing for your Milltronics belt
scale.
• Measure and mark the locations of the mounting holes for each of the crank
bodies. The left-handed unit turns clockwise to raise weights and the right-
handed unit turns counter-clockwise: handing is marked on the crank bodies.
• Drill these holes as specified for 12mm (1/2") mounting hardware.
Note: Check that there will be sufficient clearance for the MWL. (See detail, Check
Clearance for Conveyor Belt: page 8.) Clearance can be created artificially by
shimming the idlers in the scale area.
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7ML19981CR01 Milltronics Weight Lifter MWL – Instruction Manual Page 7
2. Mount left-handed and right-handed crank body
• Refer to the shim thickness tables on page 15 to determine whether you need to
shim the MWL. Shimming is not always required: it is more likely to be required
with the MUS scale, and less likely with the other models.
• If necessary, select and position the appropriate size shim(s).
• Loosely mount each crank body to the conveyor stringers using 12mm (1/2")
bolts, nuts, and washers.
Locking ball-
pin tethered
to crank body
Input shaft
Crank body
Shim (if required)
Bolt
Right-hand (counter-clockwise rotating) Crank Body Shown
Nut
Washer
Note: The crank bodies must be left loose to allow for the torque shaft installation.
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Page 8 Milltronics Weight Lifter MWL – Instruction Manual 7ML19981CR01
3. Mount torque shaft / Check clearance for conveyor belt
• Leave the locking ball-pins in place to hold the lifting pads of both crank bodies
in the raised position.
• Place the torque tube over the connecting shafts of the left and right crank
bodies.
• Loosely install the bolts, nuts, and washers that hold the torque tube onto the
connecting shafts.
• Hand tighten the bolts, nuts, and washers that mount the crank bodies to the
stringers.
• Hand tighten the bolts, nuts, and washers that hold the torque tube onto the
connecting shafts.
Check Clearance for Conveyor Belt
• Ensure there is 10mm (0.38") minimum clearance from the top of the torque tube
to the underside of the return belt: inadequate clearance will cause the belt to
wear.
• Allow additional clearance for belt sag.
• If necessary, shim the idlers in the scale area until the clearance is adequate.
(See the Belt Scale Instruction Manual for detailed shim procedures.)
Lifting-pad in raised position (2)
Torq ue Tu be
Connecting shaft (2)
Min.10mm (0.38") clearance to underside
of return belt + allowance for belt sag
Top of torque tube
176mm (6.94")
Top of stringers
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7ML19981CR01 Milltronics Weight Lifter MWL – Instruction Manual Page 9
4. Install crank handle
• Determine whether it will be more convenient to have the handle attached to the
left-handed or the right-handed crank body, and if the shaft extension is
required.
• Remove the plastic cap from the input shaft on the selected side.
• If the shaft extension is required, slide the female end of the extension over the
exposed input shaft, and secure the extension with a bolt, nut, and washer.
• Slide the female end of the handle over the exposed input shaft (or shaft
extension).
• Secure the handle in place using the tethered locking ball-pin provided.
Shaft Extension Bolt
Locking ball-pin
(tethered to
Crank Body)
Crank Handle
(female end)
Nut
Washer
Input Shaft
Locking ball-pin
(tethered to Crank Handle)
Hole for storage
on locking ball-pin
Bolt
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Page 10 Milltronics Weight Lifter MWL – Instruction Manual 7ML19981CR01
5. Test the unloaded MWL / Align crank bodies
• Remove the locking ball-pins from each of the crank bodies. The ball-pin on the
access side will serve as a locking safety pin when the weights are stored.
• Turn the crank handle and watch the lifting pads move up and down.
• Check to see whether any binding occurs during the process. If there is any
binding or hesitation, the crank bodies need to be aligned to each other.
Align the crank bodies to each other, if necessary
a. Loosen the two bolts that mount each crank body.
b. Turn the crank handle until the lifting pads have completed at least one
complete cycle from a raised to a lowered position: this process should
automatically align the crank bodies.
c. Retighten the bolts that mount the two crank bodies.
d. Check again, and repeat the process until the MWL operates smoothly, with no
resistance.
Calibration weight support (2)
Lifting-pads raised
Lifting-pads lowered
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7ML19981CR01 Milltronics Weight Lifter MWL – Instruction Manual Page 11
6. Install calibration weights / Check for clearance
• Turn the crank handle until the lifting pads are fully lowered.
• Place the base-bar weight into position on the calibration-weight supports of
the Milltronics belt scale.
• Ensure there is 10mm (0.38") minimum clearance between the underside of the
base-bar weight and the top of the lowered MWL lifting pads. If necessary, shim
the belt scale and adjacent idlers to achieve this clearance.
Note:Ensure adequate base-bar weight clearance before adding calibration weights.
Lifting-pads down
Base-bar weight
applied
Lifting-pad lowered
10mm (0.38") minimum gap
Calibration-weight support
Underside of base-bar weight
Top surface of lifting-pad
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Page 12 Milltronics Weight Lifter MWL – Instruction Manual 7ML19981CR01
• Gently turn the crank handle until the lifting pads are fully raised: you may need
to guide the notches in the base-bar weight onto the round guide-pin initially.
• Ensure there is 10mm (0.38") minimum clearance between the underside of the
base-bar weight and the top surface of the calibration-weight support when the
lifting pads are fully raised. If necessary, shim the MWL to achieve this
clearance.
Round guide pin engages the notch
on the end of the base-bar weight
Underside of base-bar weight
10mm (0.38")
minimum clearance
Lifting pad raised
Top surface of calibration-
weight support
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7ML19981CR01 Milltronics Weight Lifter MWL – Instruction Manual Page 13
• Ensure there is sufficient clearance between the side of the base-bar weight
and the vertical arms of the calibration-weight support arm, or support bracket:
(see dimensions shown below). If necessary, move the two crank bodies further
from the calibration-weight supports to achieve this clearance.
• Recheck the crank body alignment: (See “Align the crank bodies to each other, if
necessary” on page 10).
Minimum clearance on MUS Scales: 10mm (0.38")
on MSI Scales: 12.5mm (0.5")
Vertical arm
of calibration-weight support
Base-bar weight
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Page 14 Milltronics Weight Lifter MWL – Instruction Manual 7ML19981CR01
7. Test the loaded MWL
• Keep the lifting-pads raised, and add the other calibration weights
• Check again to ensure there is 10mm (0.38") minimum clearance between the
side of the stacked weights and the vertical arms of the calibration-weight
supports. If necessary, move the two crank bodies further from the calibration-
weight supports to achieve this clearance.
• Recheck the crank body alignment: (See “Align the crank bodies to each other, if
necessary” on page 10)
Lifting pads raised
Calibration weights
applied
Calibration-weight support (2)
Calibration weights
Vertical arm of calibration-
weight support
Minimum clearance on MUS scales: 10mm (0.38")
on MSI Scales: 12.5mm (0.5")
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7ML19981CR01 Milltronics Weight Lifter MWL – Instruction Manual Page 15
8. Shim the MWL (if required) / Recheck base-bar weight for clearance
When the MWL is used with the MUS belt scale, due to the wide variety of idler types
and sizes, it may be necessary to shim the MWL for proper operation.
• Compare your idler spine to the spine type and size in the tables above, for a
guide to the size of shims you may require.
• Select shims that will allow you to adjust the MWL crank bodies to the correct
level.
• Remove the bolt, nut, and washer on one crank body and position the shim
between the crank body and the conveyor stringer: it should not be necessary to
loosen or remove the torque tube connecting the two crank bodies.
• After the shim is in position, re-install and tighten the bolt, nut, and washer.
• Repeat the same procedure with the other crank body, then recheck the crank
body alignment. (See next page for details.)
Note:These tables are provided as a guideline only: shimming is often not required
Angle Spine:
Angle Size Shim
Thickness Number of shims
2" none
2-1/2" 0.31" (8mm) 1
3 " 0.31" (8mm) 2
3-1/2" 0.31" (8mm) 3
4" 0.31" (8mm) 4
Channel Spine:
Channel
Size Shim Thickness Number of shims
3" none
4" 0.31" (8mm) 1
5" 0.31" (8mm) 1
6" 0.31" (8mm) 2
Shim, if required
Bolt
Washer
Nut
Shim Tables
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Page 16 Milltronics Weight Lifter MWL – Instruction Manual 7ML19981CR01
Recheck crank body alignment
• After shimming, raise and lower the lifting pads to check whether there is any
binding or hesitation. If there is, repeat the alignment procedure on page 10.
• Raise the lifting pads again and check the clearance between the underside of
the base-bar weight and the top surface of the calibration-weight support.
• Repeat the shimming procedure until the lifting pads raise the calibration
weights at least 10mm (0.38") above the calibration-weight supports.
• Tighten the torque shaft bolts and the crank-body mounting bolts, then recheck
all clearances.
The MWL installation is now complete.
Underside of base-bar weight
10mm (0.38")
minimum clearance
Lifting pad raised
Top surface of calibration-
weight support
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7ML19981CR01 Milltronics Weight Lifter MWL – Instruction Manual Page 17
Operation
Applying calibration weights
Simply turn the crank handle until the calibration weights are fully lowered onto the
calibration-weight supports of the belt scale. (Please see the manuals for the Milltronics
Belt Scale and the Integrator, for the appropriate calibration procedures.)
Storing calibration weights
After you have completed the scale calibration procedure, turn the crank handle until the
lifting-pads are fully raised.
Storing crank handle
Remove the crank handle and store it. (See next page for details.)
Note:To ensure accurate calibration, you must keep the area between the MWL
lifting pads and the calibration weights clear of buildup during the calibration routine.
(See Maintenance procedures on page 19.)
Lifting pads down
Flat bar calibration
weights applied
Calibration-weight supports (2)
Lifting-pads
raised
Crank Handle stored on far side of
Crank Body, with locking ball-pin
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Page 18 Milltronics Weight Lifter MWL – Instruction Manual 7ML19981CR01
Remove the crank handle and store it, to prevent it from impeding traffic or material when
the conveyor is in operation.
• Remove the locking ball-pin tethered to the crank handle, and remove the handle.
• Use the locking ball-pin tethered to the crank body nearest to the handle to secure
the MWL from unintended use and to store the crank handle.
• Insert the locking ball-pin through the hole in the crank handle, and into the
insertion point in the center of the crank body. Two clips on the side of the crank
body help to hold the handle in position.
• Cover the input shafts with a guard, if they present a hazard to personnel when the
MWL is not in use.
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