Saimo 6105 Service manual

6105
6105
6105
6105 Belt
Belt
Belt
Belt Feeder
Feeder
Feeder
Feeder integrator
integrator
integrator
integrator ---
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--- User
User
User
User ’
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Guide
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6105
6105
6105
6105 Belt
Belt
Belt
Belt Feeder
Feeder
Feeder
Feeder integrator
integrator
integrator
integrator
Installation,
Installation,
Installation,
Installation, Operating
Operating
Operating
Operating and
and
and
and Service
Service
Service
Service
Manual
Manual
Manual
Manual

6105
6105
6105
6105 Belt
Belt
Belt
Belt Feeder
Feeder
Feeder
Feeder integrator
integrator
integrator
integrator ---
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User
User
User ’
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Declaration
Thanks for purchasing SAiMO products. This manual guides you through the application of your
selected products, covering the information necessary for installation, operation, maintenance and
service. This document may not be copied or reproduced in any way without the express written
consent of SAiMO . Please note that SAiMO reserves the right to change and/or improve the product
design and specifications without notice. Thanks for your understanding and support.
Please read and observe the following safety precautions found throughout this manual.
DANGER
DANGER
DANGER
DANGER
FAILURE TO OBSERVE WILL CAUSE VERY SERIOUS PERSONAL INJURY OR DEATH.
WARNING
WARNING
WARNING
WARNING
FAILURE TO OBSERVE COULD CAUSE SERIOUS PERSONAL INJURY.
PROMPT
PROMPT
PROMPT
PROMPT
HELPS YOU USE THE INFORMATION INDICATED ON THE EQUIPMENT BETTER.
·Please read through all the documents dispatch ed together with the equipments before you start
to work with the equipments.
·For the sake of personal safety and normal operation of the equipments, it is imperative to assure
that only the designed AC power supply is to be used. Reliable 3-pin earthed power outlets must
be used to avoid electric shock when touching the enclosure. Ensure that the rated voltage of the
display or other peripheral devices is compatible with your local AC power requirements.
·The equipment must be protected against thunderstrike.
·Disconnect all the cables from the equipment before you attempt to move the equipment.
·Do not attempt to change any components or external connections on the equipment before the
equipment is powered off.
·Avoid inadvertent power interruption during normal operation.
·Only qualified technicians can be allowed to open the enclosure of the equipment.
·keep the equipment from moisture. Shut off power from the equipment immediately if it is splashed
with water or other liquids occasionally.

6105
6105
6105
6105 Belt
Belt
Belt
Belt Feeder
Feeder
Feeder
Feeder integrator
integrator
integrator
integrator ---
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User
User
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Table of Contents
Chapter
Chapter
Chapter
Chapter 1
1
1
1 Introduction
Introduction
Introduction
Introduction ................................................................................................................................................
................................................................................................................................................
................................................................................................................................................
................................................................................................................................................ 1
1
1
1
1.1 General ................................................................................................................................................................. 1
1.2 Technical Specifications ....................................................................................................................................... 3
1.3 Features ................................................................................................................................................................ 3
1.3.1 Measuring Function .................................................................................................................................. 4
1.3.2 Monitoring Function .................................................................................................................................. 5
1.3.3 Printing Function ....................................................................................................................................... 6
1.3.4 Communications (Optional) ..................................................................................................................... 6
Chapter
Chapter
Chapter
Chapter 2
2
2
2 Belt
Belt
Belt
Belt scale
scale
scale
scale Installation
Installation
Installation
Installation Guidelines
Guidelines
Guidelines
Guidelines ..............................................................................................................
..............................................................................................................
..............................................................................................................
.............................................................................................................. 7
7
7
7
2.1 General ................................................................................................................................................................. 7
2.2 Wind and Weather Influence ................................................................................................................................. 7
2.3 Conveyor Support ................................................................................................................................................. 7
2.4 Location of the Belt scale ..................................................................................................................................... 7
2.4.1 Belt Tension ................................................................................................................................................ 7
2.4.2 Conveyor With Concave Curve ............................................................................................................... 8
2.4.3 Conveyor with Convex Curve .................................................................................................................. 8
2.4.4 Tripper ......................................................................................................................................................... 8
2.4.5 Consistent Belt Loading ........................................................................................................................... 8
2.4.6 Single Loading Point ................................................................................................................................. 8
2.4.7 Material Slippage ....................................................................................................................................... 8
2.5 Gravity Type Belt Tensioner ................................................................................................................................. 8
2.6 Belt Troughing Angle ............................................................................................................................................ 9
2.7 Weigh Area Idler ................................................................................................................................................... 9
2.7.1 Weigh Area Idler Construction ................................................................................................................. 9
2.7.2 Troughing Angle of Idler ........................................................................................................................... 9
2.7.3 Self-aligning Idler (preventing belt misalignment) ................................................................................ 9
2.7.4 Idler Alignment ........................................................................................................................................... 9
Chapter
Chapter
Chapter
Chapter 3
3
3
3 Belt
Belt
Belt
Belt scale
scale
scale
scale Installation
Installation
Installation
Installation Procedures
Procedures
Procedures
Procedures ...........................................................................................................
...........................................................................................................
...........................................................................................................
........................................................................................................... 10
10
10
10
3.1 N62-1 Belt scale Installation .............................................................................................................................. 10
3.1.1 Overview ................................................................................................................................................... 10
3.1.2 Terminology .............................................................................................................................................. 10
3.1.3 Location of N62 Belt scale ..................................................................................................................... 11
3.1.4 Field Preparation for Installation ........................................................................................................... 11
3.1.5 Weighbridge Installation ......................................................................................................................... 11
3.2 N63-3 Belt scale Installation .............................................................................................................................. 12

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3.2.1 Overview ................................................................................................................................................... 12
3.2.2 Terminology .............................................................................................................................................. 13
3.2.3 Location of N63 Belt scale ..................................................................................................................... 13
3.2.4 Field Preparation for Installation ........................................................................................................... 14
3.2.5 Weighbridge Installation ......................................................................................................................... 14
3.2.6 Scale Idler Installation ............................................................................................................................ 15
3.3 N64-4 Belt scale Installation .............................................................................................................................. 16
3.3.1 Overview ................................................................................................................................................... 16
3.3.2 Terminology .............................................................................................................................................. 17
3.3.3 Location of N64 Belt scale ..................................................................................................................... 17
3.3.4 Field Preparation for Installation ........................................................................................................... 17
3.3.5 Weighbridge Installation ......................................................................................................................... 18
3.3.6 Scale Idler Installation ............................................................................................................................ 18
3.4 Load Cell Installation ........................................................................................................................................ 19
3.4.1 Overview ................................................................................................................................................... 19
3.4.2 Inspection, Unpacking and Storage ..................................................................................................... 19
3.4.3 Installation ................................................................................................................................................ 20
3.4.4 Principle of Operation ............................................................................................................................. 21
Chapter
Chapter
Chapter
Chapter 4
4
4
4 6105
6105
6105
6105 Integrator
Integrator
Integrator
Integrator Installation
Installation
Installation
Installation ....................................................................................................................
....................................................................................................................
....................................................................................................................
.................................................................................................................... 22
22
22
22
4.1 General ............................................................................................................................................................... 22
4.2 6105 Integrator Installation ............................................................................................................................... 22
4.2.1 Mounting ................................................................................................................................................... 22
4.2.2 Safety Precautions .................................................................................................................................. 22
4.2.3 Wiring (External Power Supply) ............................................................................................................ 23
Chapter
Chapter
Chapter
Chapter 5
5
5
5 Operation
Operation
Operation
Operation ..................................................................................................................................................
..................................................................................................................................................
..................................................................................................................................................
.................................................................................................................................................. 25
25
25
25
5.1 Keypad ............................................................................................................................................................... 25
5.2 Run Menu ........................................................................................................................................................... 26
5.2.1 Reset Total ............................................................................................................................................... 26
5.2.2 Alarm Menu .............................................................................................................................................. 27
5.3 Main Menu ......................................................................................................................................................... 27
5.3.1 Initial Setup Menu ................................................................................................................................... 28
5.3.2 Calibration ................................................................................................................................................ 37
5.3.3 System Data Menu ................................................................................................................................. 45
5.3.4 I/O Definition Menu ................................................................................................................................. 52
5.3.5 Communication Menu ............................................................................................................................. 61
5.3.6 Alarm Setup Menu .................................................................................................................................. 63
5.3.7 Loadout Setup Menu .............................................................................................................................. 66
5.3.8 Password Setup Menu ........................................................................................................................... 66
5.3.9 Diagnostics Menu .................................................................................................................................... 68
5.3.10 Statistics Menu ........................................................................................................................................ 69

6105
6105
6105
6105 Belt
Belt
Belt
Belt Feeder
Feeder
Feeder
Feeder integrator
integrator
integrator
integrator ---
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Chapter
Chapter
Chapter
Chapter 6
6
6
6 Integrator
Integrator
Integrator
Integrator Maintenance
Maintenance
Maintenance
Maintenance ...........................................................................................................................
...........................................................................................................................
...........................................................................................................................
........................................................................................................................... 72
72
72
72
6.1 Daily Maintenance Routines of 6105 Integrator ................................................................................................ 72
6.2 6105 Integrator Troubleshooting --- Fault Isolation .......................................................................................... 72
6.2.1 Power Supply Examination .................................................................................................................... 74
6.2.2 Speed Input .............................................................................................................................................. 74
6.2.3 Load Cell Input ......................................................................................................................................... 74
6.2.4 Current Output (Optional) ...................................................................................................................... 75
6.2.5 Constant Setup ........................................................................................................................................ 77
6.3 Usual Troubleshooting ....................................................................................................................................... 77
Chapter
Chapter
Chapter
Chapter 7
7
7
7 Speed
Speed
Speed
Speed Sensor
Sensor
Sensor
Sensor .............................................................................................................................................
.............................................................................................................................................
.............................................................................................................................................
............................................................................................................................................. 78
78
78
78
7.1 General ............................................................................................................................................................... 78
7.2 Inspection, Unpacking and Storage ................................................................................................................... 78
7.3 Installation ......................................................................................................................................................... 79
7.3.1 Mechanical Part Installation ................................................................................................................... 79
7.3.2 Electrical Part Installation ....................................................................................................................... 79
7.4 Working Principle .............................................................................................................................................. 80
Chapter
Chapter
Chapter
Chapter 8
8
8
8 Belt
Belt
Belt
Belt Scale
Scale
Scale
Scale Maintenance
Maintenance
Maintenance
Maintenance ............................................................................................................................
............................................................................................................................
............................................................................................................................
............................................................................................................................ 81
81
81
81
8.1 General ............................................................................................................................................................... 81
8.2 Daily Maintenance Routine for Belt Scale ......................................................................................................... 81
8.3 Troubleshooting the Belt Scale ........................................................................................................................... 82
Chapter
Chapter
Chapter
Chapter 9
9
9
9 Belt
Belt
Belt
Belt Scale
Scale
Scale
Scale Installation
Installation
Installation
Installation Parameters
Parameters
Parameters
Parameters ..........................................................................................................
..........................................................................................................
..........................................................................................................
.......................................................................................................... 83
83
83
83
9.1 Scale Capacity .................................................................................................................................................... 83
9.2 Belt Scale Dimensions ........................................................................................................................................ 83
9.3 Load Cell Data ................................................................................................................................................... 88
Chapter
Chapter
Chapter
Chapter 10
10
10
10 Permanent
Permanent
Permanent
Permanent Field
Field
Field
Field Record
Record
Record
Record ..........................................................................................................................
..........................................................................................................................
..........................................................................................................................
.......................................................................................................................... 89
89
89
89

6105
6105
6105
6105 Belt
Belt
Belt
Belt Feeder
Feeder
Feeder
Feeder integrator
integrator
integrator
integrator ---
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--- User
User
User
User ’
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Guide
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1
Chapter
Chapter
Chapter
Chapter 1
1
1
1Introduction
Introduction
Introduction
Introduction
1.1
General
General
General
General
Incorporating the latest technologies and years of industry, Saimo Weigh Belt Feeder Systems provide
accurate and reliable solutions for weighing, totalizing, flow rate control for industries such as
metalliferous ore blending, power generation, quarry, cement, chemical and food, etc.
The belt feeder senses and weighs the material passing through the weighbridge to determine unit
weight (in kgs/m) of the material on the belt. Belt speed is continually measured with a digital speed
sensor whose pulse output is proportional to belt speed. The speed sensor is mounted on the tail-pulley
to assure accurate belt speed measurement and detection of any possible slippage. The speed signal
and weight signal are combined in to the 6105 microprocessor-based integrator which generates and
displays a true-rate signal in TPH and the total of material fed. A n internal controller compares the
flow rate signal to the feedrate setpoint derived from an industrial computer and send s necessary output
signal to the frequency converter, consequently changing the feeder ’ s belt speed to maintain the
desired constant rate of material fed. The total of material fed is monitored by the computer which
submits shutoff signal when a setup total is reached. This manual provides the information necessary
for installation, operation, maintenance and service of the 6105 integrator.
The 6105 integrator is available in panel mount and field mount. By processing the weight signal from
the load cell and the speed signals from the speed sensor, It calculates and displays flowrate and total
of the material fed.
Figure 1-1 6000 Series Integrator -- Panel Mount

6105
6105
6105
6105 Belt
Belt
Belt
Belt Feeder
Feeder
Feeder
Feeder integrator
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integrator
integrator ---
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Figure 1-2 6000 Series Integrator --- Field Mount

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6105
6105 Belt
Belt
Belt
Belt Feeder
Feeder
Feeder
Feeder integrator
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integrator ---
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1.2
Technical
Technical
Technical
Technical Specifications
Specifications
Specifications
Specifications
(a) Chinese / English menu
(b) Weighing Capability
· The 6105 integrator is capable of connecting up to eight 350 Ωloads and acquiring a speed signal
from the speed sensor, to calculate flow rate and total.
· The 6105 integrator has the function of automatic zero calibration.
(c) Ambient Environment
· Location: Indoor or outdoor, as close as possible to the load cells, free from damp and dust.
· Temperature:
Storage temperature : -40~+70
º
C
Operati ng temperature -10~+50 ºC
· Max imum Relative Humidity: 95%
(d) Power Requirements
·220VAC ±10% or 110VAC ±10% 50Hz
·Fuse: 2A
·EMI / RFI filter
(e) Load Cell
· offers 10VDC (+/- 10% ), 5 00mA excited power , up to 8 load cell s
· Sensitivity : 0.5mV/V ~ 3.5mV/V
· Max. input signal 33mV
· L oad cell shield grounding
· E xcitation compensation circuit is employed when the cable distance is over 60 meters but less
than 900 meters .
· Local or remote compensation can be selected by a jumper set.
(f) Mainboard Digital Input
The mainboard provides 6 programmable inputs for receiving dry contact on-off signal
(g) Mainboard Digital Output
The mainboard provides 8 programmable outputs.
(h) Outline Dimensions
Panel mount: Outliner dimensions: 288mm x 144mm x185mm
Front panel dimensions: 284mm x140mm
Field mount: Outline dimensions: 312mm x 380mm x 150mm
Mounting hole dimensions: 240mm x 450mm

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6105
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6105 Belt
Belt
Belt
Belt Feeder
Feeder
Feeder
Feeder integrator
integrator
integrator
integrator ---
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1.3
Features
Features
Features
Features
Saimo 6105 integrator is specially designed for belt scales, meeting all measuring and control
requirements on typical applications.
The software has been solidified into the memory chip. Each preprogrammed function can be activated
automatically by operating from the keypad or installing the optional expansion board.
Saimo 6105 integrator has a powerful and user friendly operating interface, easy for function selection,
data setup, operation and maintenance.
The following functions have been completed into Saimo 6105 integrator.
·Measuring
·Monitoring
·Printing
·Communication
Figure 1-3 Front Panel
1.3.1
1.3.1
1.3.1
1.3.1 Measuring
Measuring
Measuring
Measuring Function
Function
Function
Function
1. Instantaneous Flowrate Calculation
The signal delivered by the load cell(s), which represents the weight per unit length of the belt(kg/m), is
multiplied by the signal delivered by the speed sensor which represents the belt speed (m/s). The result
of this operation is the instantaneous flowrate (kg/m x m/s=kg/s) which is then multiplied by suitable
constant to obtain the value in the required engineering units (kg/h or ton/h, etc.). An adjustable
damping filter is provided separately for displayed rate and current outputs.
2. Flow Totalization
The total is accumulated by multiplying mass per unit length by incremental length and totalizing the
result in engineering units.
3. Zero and Span Automatic Calibration
Zero and span calibrations are based on belt length defined by a number of belt revolutions.

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6105 Belt
Belt
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Belt Feeder
Feeder
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Feeder integrator
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To calculate the exact number of revolutions, the instrument counts the pulses delivered by the speed
sensor (one pulse represents a specific belt length); when the required number of pulses is reached,
the instrument ends the calibration test, and compares the actual totalized value to the theoretical one
(0 for zero calibration), and calculates the calibration constant.
The calibration constant is a calculated value that can be factored based on an actual material test.
- Electronic Calibration (R-Cal)
Allows the operator to perform the calibration without the need of applying test weights or test chain
on the weighbridge. The electronic calibration checks all the circuitry including the load cell, and is
performed by unbalancing the load cell bridge using a precision resistor. The calibration constant is
calculated on the basis of the load cell and the scale data.
- Test Weight Calibration
Requires the positioning of test weights on the weighbridge
- Chain Calibration
Requires the application of calibrated chains on the belt. This method is the nearest to actual
operating conditions.
- Material Calibration
I s performed by running a known quantity of material on the scale and weighing that quantity on a
static scale of known accuracy.
4. Zero Tracking (AZT)
Under a preset minimum flowrate when enabled, the instrument makes subsequent automatic zero
calibrations with the following sequence:
- performs automatic zero for one test duration.
- continuously repeats above zero calibration as long as feed rate remains below AZT preset value.
5. Current Output Signals
An optional current output/analog input board is available. Each current output may be programmed via
the keyboard to deliver one of the following signals:
- flowrate
- belt loading
- belt speed
- control signal
1.3.2
1.3.2
1.3.2
1.3.2 Monitoring
Monitoring
Monitoring
Monitoring Function
Function
Function
Function
Saimo 6105 integrator is equipped with an indication system. Indication can be in the form of:
- status indications
- process alarms
- programming errors
- equipment failures
The integrator includes internal diagnostics that will generate alarms in case of hardware failures or
programming errors. The following process alarms are also provided:
·Belt slip (two speed sensors recommended)
·Alarms for high and low flowrate, speed and weight
These alarms are visible on the display and can be acknowledged and reset through keyboard, digital