Rice Lake BCi User manual

Presented By
Dallas HoustonAustinFt Worth
NicolScales.com
800.225.8181
Contact Us
Nicol Scales & Measurement is an ISO Accredited Calibration
Company that has provided calibration, repair and sales of all types
of weighing and measurement products since 1931.

In-Motion Belt Scale System
Version 2
Installation & Operation
Manual
BC
PN 94805

Contents i
Technical training seminars are available through Rice Lake Weighing Systems.
Course descriptions and dates can be viewed at www.ricelake.com/training
or obtained by calling 715-234-9171 and asking for the training department.
Contents
1.0 Introduction..................................................................................................................................... 1
1.1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 Belt Conveyor Scale System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
1.3.1 Scale Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.3.2 Load Cells. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.3.3 Belt Travel Speed Wheel - Optional. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3.4 Magnetic Shaft Encoder - Optional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3.5 Electronic Integrator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.4 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.4.1 Zero . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.4.2 Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.4.3 Reset Totalizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.4.4 Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.4.5 Supervisor Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.5 Application Brief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.5.1 Load Cell Size. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.5.2 Belt Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.5.3 Idler Spacing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.5.4 Belt Splicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.6 Selecting a Mounting Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.6.1 Tension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.6.2 Uniform Belt Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.6.3 Single Load Point on Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.6.4 Material Slippage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.6.5 Convex Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.6.6 Concave Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.6.7 Trippers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.6.8 Speed Sensor or Magnetic Shaft Encoder Mounting Location - (Optional items) . . . . . . . . . . . . . . . . . . . 11
1.6.9 Electronic Wiring Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.6.10 Speed Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.6.11 Troughing Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.7 Poor Choices for Belt Scale Installations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.8 Handbook 44 Requirements for Belt Scales . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.0 Integrator Hardware Installation .................................................................................................. 14
2.1 Unpacking and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.2 Scale Carriage Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.3 Junction Box Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.3.1 Wiring the Junction Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.3.2 Trimming Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.4 Attaching the Idlers to the Scale Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.5 Speed Sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.5.1 Encoder Speed Sensor Located on the Tail Pulley or Live Shaft Roller . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.5.2 Proximity Sensor Located on Idler Pulley. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.5.3 Proximity Sensor Located on Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.6 Scale Carriage Replacement Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.0 Integrator Hardware Setup ........................................................................................................... 25
3.1 Enclosure Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
@ Rice Lake Weighing Systems. All rights reserved. Printed in the United States of America.
Version 2 Rice Lake Weighing Systems is an ISO 9001 registered company.
April 19, 2016

ii BCi Integrator Installation Manual
Rice Lake continually offers web-based video training on a growing selection
of product-related topics at no cost. Visit www.ricelake.com/webinars
3.2 Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.2.1 Cable Grounding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.2.2 Load Cells. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.2.3 Pulse Input Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.2.4 Serial Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.2.5 Digital I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.3 Enclosure Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.4 CPU Board Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.5 Battery Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.6 Parts Kit Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.7 Replacement Parts and Assembly Drawings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.0 Supervisor Mode Parameters....................................................................................................... 35
4.1 Admin. Passcode (numeric) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4.2 Scale Capacity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.3 Load Cell MV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.4 Total Load Cell Build . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.5 Rate Unit Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.6 Filter (s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.7 Filter Threshold (divisions) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.8 Speed Unit Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.9 Fixed Speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4.10 Unit of Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4.11 Unit of Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4.12 Rate Count By . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4.13 Totalizer Count By . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4.14 Load Display Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4.15 Load Count By . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4.16 Auto Zero Tracking Range (%) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.17 Auto Zero Tracking Deviation (%) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.18 Dead Band . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.19 Cal. Test Weight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.20 Cal. Test Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.21 Calibration Load. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.22 Material Factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.23 Span Error%. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.24 Zero Counts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.25 Zero Error% . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.26 Idler Spacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.27 Number of Idlers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.28 Belt Test Revolutions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.29 Pulses per Revolution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.30 Belt Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.31 Belt Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.32 Pulses Per Unit Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.33 Test Duration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.34 Tons per Pulse (output) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.35 Pulse Duty Cycle (in seconds). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.36 Low Rate Alarm Value (%) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.37 Maximum Speed Value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.38 Low Rate Alarm Bit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.39 High Rate Alarm Bit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.40 Speed Alarm Bit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.41 Load Cell Alarm Bit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Contents iii
4.42 Totalizer Pulse Bit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.43 Fill Output Bit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.44 Remote Print Input Bit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.45 Print Output Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.46 Print Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.47 Stream Output Port. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4.48 Stream Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4.49 Clear Totalizer with Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4.50 Remote Totalizer Reset Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4.51 Integrator Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4.52 Preact Length. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4.53 Enable Batching. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4.54 Analog 1 Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4.55 Analog 2 Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4.56 Master Totalizer Reset. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
4.57 Interfacing a PLC to the Belt Scale System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
4.58 Special Serial Commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
5.0 Calibration .................................................................................................................................... 45
5.1 Speed Sensor Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
5.2 Integrator Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
5.2.1 Auto Cal Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5.2.2 Material Calibration Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
5.3 . . . . . . . . . .Complete System Calibration Test Used In Conjunction With Integrator Calibration 49
5.3.1 Material Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
5.3.2 Simulated Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
5.3.3 Maintenance Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
6.0 Run Sequence ............................................................................................................................... 51
6.1 Target Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
6.2 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
6.3 Reset Totalizer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
6.4 Start Fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
7.0 Handbook 44 Requirements for Belt-Conveyor Scales ................................................................ 53
7.1 Reference Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
7.2 Conditions of Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
7.2.1 Handbook 44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
7.2.2 AAR Scale Handbook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
8.0 Maintenance ................................................................................................................................. 54
8.1 Maintenance Checkpoints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
8.1.1 Housekeeping Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
8.2 Belt Scale Troubleshooting Tips. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
8.2.1 Calibration Shifts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
8.2.2 Zero Calibration Shifts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
8.2.3 Span Calibration Shifts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
8.2.4 Field Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
8.3 Integrator Troubleshooting Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
9.0 Appendix ....................................................................................................................................... 58
9.1 Integrator Permanent Field Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
9.2 Integrator Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

iv BCi Integrator Installation Manual

Introduction 1
1.0 Introduction
This manual is intended for use by service technicians responsible for installing and servicing the integrator In-
Motion Belt Scale System Installation & Operation Manual.
This manual can be viewed and downloaded from the Rice Lake Weighing Systems website at
www.ricelake.com.
Warranty information can be found on the website at www.ricelake.com/warranties
1.1 Sa fet y
Safety Symbol Definitions:
Indicates an imminently hazardous situation that, if not avoided, will result in death or serious injury.
Indicates a potentially hazardous situation that, if not avoided could result in death or serious injury, and
includes hazards that are exposed when guards are removed.
Indicates a potentially hazardous situation that, if not avoided may result in minor or moderate injury.
Indicates information about procedures that, if not observed, could result in damage to equipment or
corruption to and loss of data.
General Safety
Do not operate or work on this equipment unless you have read and understand the instructions and
warnings in the Installation, Operation and Service Manuals. Failure to follow the instructions or heed
the warnings could result in injury or death. Contact any Rice Lake Weighing Systems dealer for
replacement manuals. Proper care is your responsibility.
Failure to heed may result in serious injury or death.
Some procedures described in this manual require work inside the indicator enclosure. These procedures are to be
performed by qualified service personnel only.
Take all necessary safety precautions when installing the scale carriage including wearing safety shoes, protective eye
wear, and using the proper tools.
Do not allow minors (children) or inexperienced persons to operate this unit.
Do not operate without all shields and guards in place.
Do not jump on the scale.
Do not use for purposes other then weight taking.
Do not place fingers into slots or possible pinch points.
Do not use any load bearing component that is worn beyond 5% of the original dimension.
Do not use this product if any of the components are cracked.
Do not exceed the rated load limit of the unit.
Do not make alterations or modifications to the unit.
Do not remove or obscure warning labels.
Do not use near water.
Keep hands, feet and loose clothing away from moving parts.
DANGER
CAUTION
WARNING
Important
WARNING

2BCi Integrator Installation Manual
1.2 O ver vie w
A belt conveyor scale is a device that continuously measures bulk material as it moves along a conveyor. The
system requires two general parameters to operate:
•Itneeds to know the weight of the material being moved along the conveyor belt.
•It needs to know the speed at which it’s moving along the conveyor belt.
The weight of the material on the belt is determined by weighing a section of conveyor belt loaded with material
and then subtracting the average weight of the unloaded belt. The speed at which the material is moving is
determined by measuring the speed of an idler or wheel in contact with the conveyor belt. The weight and speed is
combined to give a running total and a rate of flow of the material. The correct operation of the scale system
requires the components to be installed correctly, periodically calibrated, and properly maintained.
Typical applications where a belt conveyor scale can be used are:
•Mining
•Quarries
•Bulk material blending
•Truck/barge/rail loading
•Process control applications
A belt conveyor scale is also able to compute the total mass of the material that is conveyed over a given period of
time and while it is in motion.
The integrator In-Motion Belt Scale System is durable and one of the most accurate scales in its class. The
integrator easily handles capacities up to 10,000 tons per hour with unsurpassed accuracy. It’s innovative integrator
fits a wide variety of applications - from simple inventory reporting to automated load-out.
1.3 Belt Conveyor Scale System Components
The main components of a basic belt conveyor scale include:
•Scale carriage
•Load cells
•Belt travel pickup speed sensor (not shown)
•Electronic integrator (BCi)
Figure 1-1. Component Parts of the Integrator Belt Conveyor Scale System
Electronic
Integrator
Load Cells
Scale Carriage

Introduction 3
1.3.1 Scale Carriage
The scale carriage is mounted to a conveyor structure and transmits the forces resulting from the belt load and
directs those forces to the load sensor(s). The following picture and table illustrate the component parts shipped
with the scale carriage.
Figure 1-2. Scale Carriage Components
Item
No. Part Number Description (Quantity)
1 - - - - - End Plate Assembly (2)
2 - - - - - Uni-Strut Middle Bars (2)
3 - - - - - Uni-Strut Closure Strips (2)
4 38557 Home Run Cable (1)
5 88956 Junction Box w/ Grounding Lug (1)
6 16863 Metal Serial Tag (1)
Nuts (2)
Bolts (2)
Lock Washers (2)
97416 Shim Kit
Table 1-1. Scale Carriage Component Part Numbers
1
2
3
4
5
6

4BCi Integrator Installation Manual
1.3.2 Load Cells
There are four strain gauge load cells located on the corners of the weigh idler. These sensors support the weight of
the conveyor belt and the material moving along on the belt. The weight signals from the load cells are combined
and processed by the integrator.
Figure 1-3. Load Cell Location on Scale Carriage

Introduction 5
1.3.3 Belt Travel Speed Wheel - Optional
The belt travel speed wheel is located near the weigh frame. Positive contact must be maintained between the roll
and the belt for proper operation. The speed sensor should never come in contact with material that is being
conveyed along the belt. The signal generated by the speed wheel is converted by the integrator into a value that
represents belt travel distance. Various devices used for sensing belt travel include AC and DC generators,
mechanical belt or chain drives, photo-optical segmented disks and electromagnetic pulse generators. Installation
procedures for the speed wheel are explained in detail on page 23. Figure 1-4 illustrates the major component parts
of the speed wheel.
Figure 1-4. Speed Wheel
1.3.4 Magnetic Shaft Encoder - Optional
Another option besides the belt travel speed wheel is a magnetic shaft encoder which can also be used to determine
belt travel distance like the speed wheel. The magnetic shaft encoder should never come in contact with material
that is being conveyed along the belt nor the belt itself. The signal generated by the encoder is converted by the
integrator into a value that represents belt travel distance.
Figure 1-5. Magnetic Shaft Encoder
Part Number Description (Quantity)
94969 Complete Speed Wheel Assembly (1)
96543 Speed Wheel (1) (wheel only)
94979 Speed Proximity Sensor (1)
94970 Speed Wheel Bracket Assembly (1) (wheel not included)
Cabling to integrator (1)
94980 U-Bolts (2)
21161 Splice Box (1)
98501 Expansion Cable - 20’
100038 Magnetic Shaft Encoder
Table 1-2. Speed Wheel Assembly Component Part Numbers

6BCi Integrator Installation Manual
1.3.5 Electronic Integrator
Outputs from the belt travel speed sensor and from the load cell carriage are combined in the integrator to produce
a running total of material passed over the belt conveyor scale. Using the integrator HMI as a calibrated electronic
integrator allows signals to be converted into values that represent the weight and speed of the material that is
traveling on the conveyor.
1.4 Operation
The integrator front panel, shown below consists of a 27-button keypad with a large backlit LCD display. The keys
are grouped as five configurable softkeys, five primary scale functions keys, four navigational keys and numeric
entry keys. It should be noted that the scale parameters and calibration values cannot be changed without first
pressing the TARE key and unlocking the parameters.After pressing the TARE key, press enter to unlock the settings.
Pressing ZERO when the display is on the main menu will clear the Reset Total.
Figure 1-6. integrator Front Panel
The following sections describe the front panel key operation of the belt scale integrator.
1.4.1 Zero
This parameter will initiate the front panel zero mechanism. Periodic use of the zero parameter is required due to
weather conditions.
1.4.2 Print
This will print the custom ticket if the print port is configured.
1.4.3 Reset Totalizer
Often during this operation of a belt scale, the totalizer will need to be reset. This is known as the reset totalizer.
Press the Reset Totalizer softkey to access this parameter. The integrator will prompt the user, “Clear Totalizer?” The
operator will press Yes to clear the totalizer, or No to leave the accumulated weight in the totalizer.
1.4.4 Diagnostics
This softkey displays the current mV input, PPS (pulses per second from the speed sensor), current analog output
(if installed), current A/D counts, and the master total. This is just informational data that the operator or a
technician can use from troubleshooting purposes.
1.4.5 Supervisor Mode
Use this softkey to enter the Supervisor Mode. If there is no passcode configured the integrator will enter into the
Setup Mode. If a passcode is configured, the operator will need to enter the passcode before the integrator will
switch to the Supervisor Mode. To configure a passcode, see the Supervisor’s Parameters.
13*/5
6/*54
40'5,&: 40'5,&: 40'5,&: 40'5,&: 40'5,&:

Introduction 7
1.5 Application Brief
There are four factors used to determine a suitable belt scale application on a given conveyor.
•Load cell size
•Belt speed
•Idlerspacing
•Belt splicing
1.5.1 Load Cell Size
The capacity of the belt scale is rated on the maximum continuous load that can be carried across the weigh idler.
The capacity of the conveyor should be known prior to determining the components of the scale system. The load
cells should be sized to operate across a loading range with a marginal safety factor. The minimum net loading
should be greater than 10% of the rated capacity and the maximum loading should be less than 65%. The load
applied to the loadcell can be calculated with the following formula:
Net load = (conveyor capacity / belt speed) x idler spacing
Gross load = net load + (idler weight + belt weight + mounting hardware)
Examples:
Net load = (50,000 lbs per minute / 400 feet per minute) x 4 foot spacing
Net load = (125 lbs per foot) x 4 foot spacing
Net Load = 500 lbs.
Gross load = 500 lbs + (175 lb idler + 48 lb belt + 24 lbs hardware)
Gross Load = 747 lbs.
Net Load > 10% of total load cell capacity
(4) x 500 lb load cells x 10% = 200 lb 500 lb > 200 lb (500 lb load cells are okay)
(4) x 1000 lb load cells x 10% = 400 lb 500 lb > 400 lb (500 lb load cells are okay)
(4) x 2000 lb load cells x 10% = 800 lb 500 lb > 800 lb (2000 lb load cells are too large)
Gross Load < 65% of total load cell capacity
(4) x 250 lb load cells x 65% = 650 lb 747 lb > 650 lb (250 lb load cells are too small)
(4) x 500 lb load cells x 65% = 1300 lb 747 lb < 1300 lb (500 lb load cells are okay)
(4) x 1000 lb load cells x 65% = 2600 lb 747 lb < 2600 lb (1000 lb load cells are okay)
The example listed would require 500 lb or 1000 lb load cells.
1.5.2 Belt Speed
The belt speed is defined as the maximum velocity of the unloaded conveyor belt. The belt speed can be variable,
but for sizing requirements the maximum speed is required.

8BCi Integrator Installation Manual
1.5.3 Idler Spacing
The spacing between idlers should conform to the recommendations of the idler manufacturer and the Conveyor
Equipment Manufacturer’s Association specifications. A general rule of thumb is the idler supports the belt half the
distance from the previous idler to half the distance to the following idler as shown in the example below.
Figure 1-7. Idler Spacing Example
The number of weigh idlers required to accurately weigh the material being conveyed is determined by the velocity
of the conveyor belt. The scale born time of the material should be greater than 400 mSec. If the belt speed
multiplied by the idler spacing is less than 400 mSec, the idler spacing must be increased or multiple weigh idlers
must be used. Scale born time can be calculated with the following formula:
Scale Time = (Idler Spacing / Belt Speed)
Example: Scale Time = (4 feet / 8.33 fps) = 480 mSec
1.5.4 Belt Splicing
Belt splices also have a contributing factor in limiting the belt scale’s capacity. Mechanical belt splices can shock
load and damage load cells on high speed conveyors. Vulcanized splices are preferred for proper scale operation.
Figure 1-8. Mechanical Belt Splicing Example
Idlers on 4’spacings, means the
weigh idler will see the weight
over this 4’section of the belt.

Introduction 9
1.6 Selecting a Mounting Location
It is very important to select the right mounting location for the scale carriage along the conveyor structure and the
location of the speed sensor. There are several factors that must be taken into consideration when selecting a
mounting location. Those factors will determine the overall long-term and short-term accuracy expected. Those
factors include the following:
•Tension
•Uniform belt loading
•Single load point on belt
•Material slippage
•Convex curves
•Concave curves
•Trippers
•Speed sensor mounting location
•Electronic wiring location
•Speed wheel
•Troughing angle
1.6.1 Tension
The transfer of weight along the conveyor belt can be greatly affected by belt tension. By locating the scale
carriage in an area of the conveyor with the least amount of tension, the scale will be more accurate and achieve
better performance. An ideal location to mount the scale carriage is near a tail section of the conveyor, but far
enough forward so as not to be influenced by infeed skirts boards, etc. Figure 1-9 illustrates the proper belt tension.
Figure 1-9. Proper Belt Tension Example
1.6.2 Uniform Belt Loading
It is desirable that the belt loading be as uniform as possible to prevent unequal shifts in material. To minimize
surges or feed variations, hoppers should be equipped with depth limiting gates or other flow control devices such
as a feeder.
1.6.3 Single Load Point on Belt
On high accuracy installations, the conveyor should be loaded at one and the same point. This assures constant belt
tension at the scale during all loading conditions.
1.6.4 Material Slippage
The belt scale system processes belt loading and belt travel to arrive at an accurate weight. Product speed must be
equal to the belt speed at the scale. So the conveyor speed and slope should not exceed that at which material
slippage occurs. This is typically less than a 20% pitch for most materials.
The next best place to
put the scale.
Highest Belt Tension
The least belt tension is here, but it is
hard to weigh product being carried.

10 BCi Integrator Installation Manual
1.6.5 Convex Curves
Conveyors that have convex curves should be avoided or the scale should be located in a section of the conveyor
that is not affected by the curve.
Convex curves are permissible at a distance of 20 feet or a minimum of five idler spaces beyond the scale area
idlers.
Figure 1-10. Convex Curved Conveyor
1.6.6 Concave Curves
Conveyors that have concave curves should be avoided or the scale should be located in a section of the conveyor
that is not affected by the curve. If there is a curve, the belt must remain in contact with the idler rollers at all times
for at least 20 feet (6m).
Figure 1-11. Concave Curved Conveyor
1.6.7 Trippers
Tripper belts, mechanical sweep samplers, training idlers, feed points, skirt boards and other device that also affect
belt tension should be located away from the scale carriage.
If the scale must be installed on a conveyor with a tripper, then the same rules apply as for an installation in a
concave conveyor.
Table 1-3 offers basic guidelines for minimum distances and applies to both horizontal and incline conveyors.
Type of Conveyor Distance from Scale Carriage
End of skirt boards or feed point 15’ or 4 idler spaces whichever is greater
Training idler or sweep sampler 30’ or 8 idler spaces, whichever is greater
Tripper or concave curve 40’ from the first idler affected by the curve
Convex curve or head pulley 20’ or 5 idler spaces
Table 1-3. Distance Points from Conveyor to Scale Carriage
20'
or
5 spaces
R
Before
Curve
40'
40'
PT
PT
R
After
Curve

Introduction 11
1.6.8 Speed Sensor or Magnetic Shaft Encoder Mounting Location - (Optional items)
The optional speed sensor location is not as critical as scale carriage location, however improper installation of the
speed sensor will significantly affect the performance of the scale system. The speed sensor must give an accurate
representation of the speed of the material and travel of the belt.
The favorable location for the speed sensor is the tail roll of the conveyor, provided that the conveyor is not driven
from the tail, and that the tail roll is accessible.
Figure 1-12. Speed Sensor Pulley
If the tail roll is not accessible then the speed sensor can be mounted on a tailing wheel that rides on the return side
of the belt, or on a live shaft roller. If a trailing wheel is used, the wheel should be located on a section of the belt in
which belt vibration will not add movement to the wheel. The preferable location would be directly opposite a
conveyor return roll.
If a live shaft roller is installed to sense the belt speed, the roller should have positive contact with the belt. The
preferred location would be between two return idlers with the speed roller being installed on the top side of the
returning belt and the return idlers installed on the bottom side.
1.6.9 Electronic Wiring Location
The location for the electronics to be mounted is determined by accessibility, wire routing, and environment. The
scale electronics require a clean and stable 120 VAC supply. The enclosure for the electronics is rated NEMAType
4X. The electronics can be mounted up to 2000 feet away from the scale carriage provided the optional load cell
sense wiring is installed. If the electronics are to be installed within 200 feet of the scale carriage, the optional
sense wiring is not required. To reduce the effects of signal interference, the scale signals should not be run in
conduit or cable trays in conjunction with high voltage cables.
The digital input and output signals are compatible with OPTO 22 G4 5VDC relay modules and can be controlled
with AC, DC or dry contact signals. The analog output signal for rate of flow can be wired for 0-10 VDC, 2-10
VDC, 0-20mA current or 4- 20mA current. The printer signal can be RS-232, RS-485, or 20mAcurrent loop.
1.6.10 Speed Wheel
If an optional speed wheel is used, the wheel should be located on a section of the belt in which belt vibration will
not add movement to the wheel. The preferable location would be directly opposite a conveyor return roll.
Figure 1-13. Optional Speed Wheel Assembly
The speed sensor pulley
must be on the clean
side of the return belt
with 15-30 wrap.
15°

12 BCi Integrator Installation Manual
1.6.11 Troughing Angle
The use of idlers with steep troughing angles causes many problems. Not only does the beam or catenary effect of
the belt become more pronounced as the toughing increases, but the effect of idler misalignment is amplified as
well. The graphics below show an example of a correct and an incorrect troughing angles.
Troughing angles of 35 degrees or less are preferred for all high accuracy installations. Troughing angles of 45
degrees are acceptable under certain conditions.
Figure 1-14. Troughing Angle Examples
1.7 Poor Choices for Belt Scale Installations
There are several instances where a belt scale installation would not be the best solution. The following list points
these out.
•Conveyors with multiple loading points.
•Conveyors with convex or concave curves.
•Conveyors with different stringer members in troughing rolls.
•Conveyors that do not receive periodic inspections and housekeeping.
•Conveyors where there is no facility to conduct a simulated test.
•Conveyors that are used in cold weather that are not installed in a heated conveyor gallery.
•Tripper conveyors
•Radial stacking conveyors
•Applications where the belt scale results are compared with a marine draft survey.
•Applications where the belt scale weighment is subject to certification but the conveyor does not meet
Handbook 44 requirements.
•Applications where plant personnel are unwilling or unable to perform routine conveyor maintenance.
•Conveyors with more than 2-ply belting
•Conveyors that are installed outdoors, but are not equipped with a cover over the carry belt.
Troughing idlers shape the belt to
support a moving load without
spillage or damage to the belt.
= 0°-35° Preferred
= 45° Acceptable under certain conditions

Introduction 13
1.8 Handbook 44 Requirements for Belt Scales
The following is a listing of various Handbook 44 requirements for belt scales.
•Minimum divisions shall not be greater than 0.1 of the minimum totalized load.
•On test, the recorder must show the initial totalizer reading; the final totalizer reading, the unit of measure and
the quantity delivered along with the time and date.
•The integrator master totalizer shall not be reset the master totalizer without breaking a security seal.
•In the event of loss of power of up to 24 hours, the accumulated measured quantity on the master totalizer
shall be retained in memory during that power loss.
•An audio or visual alarm indication shall be activated when the flow rate equals or falls below 35% or is in
excess of 98% of the rated capacity.
•The totalizer can only advance when the belt conveyor is running (ie: if the belt is shut down with coal on the
belt, the totalizer could not register).
•The master totalizer shall not be re-settable without breaking a security seal.
•Means shall be provided that the totalizer reading shall be retained for a minimum of 24 hours in the event of
a power failure.
•The belt scale integrator must factor in belt speed as a function of calculating tons per hour weight.
•Zero is to be limited to +/- 2% without breaking the security seal.
•Auto zero mechanism shall be designed to operate only after a whole number of belt revolutions.
•An indication shall be provided for when the auto zero adjustment has reached its maximum limit.
•Belt speed device shall be designed so that there is no slip.
•An event logger must provide an audit trail of all calibration adjustment with a printed copy available on
demand. It shall have the capacity to retain records equal to ten times the number of sealable parameters in the
device, but not more than 1000 records are required, (ie: time and date of change; the parameter value; the
parameter ID).
•A zero circuit should provide for an average of one belt revolution (track +/-).
•Remote outputs record for (digital and analog), the total tons, rate in% of full cap, and the belt speed.
•Front panel calibration that is password protected with audit trail.
•Ability to enter the belt length and indicate in feet.
•Ability to accept pulse input for belt speed indication.