Schenck process Intecont Tersus Beltweigher User manual

INTECONT®Tersus Beltweigher
Instruction Manual
BV-H2464 GB

PASS
-
Service you can rely on
Fast, comprehensive, anywhere in the world
Quality and reliability are the cornerstones of our company’s
philosophy. That is why we consider a comprehensive service
concept simply par for the course, from strict quality control,
installation and commissioning through to seamless support
across the entire product life cycle.
With over 30 service stations and over 180 service specialists,
you can count on us to be there whenever – and wherever –
you need us.
During office hours, service specialists from all divisions are
on hand to analyze problems and failures. Look at
www.schenckprocess.com for your nearest
Schenck Process Location.
Are you looking for individual, perfect-fit service solutions?
Then our service system PASS is the ticket. It covers the en-
tire service spectrum, from simple inspections through to full
service. Interested?
Then find out more about the individual components at
www.schenckprocess.com/en/service.
© by Schenck Process GmbH
Pallaswiesenstraße 100, 64293 Darmstadt, Germany
Phone: [phone] ; www.schenckprocess.com
All rights reserved. Any reproduction of this documentation,
regardless of method, without prior permission by
Schenck Process GmbH in writing, even by excerpt, is prohi-
bited.
Subject to change without prior notice.
Note: Translation of the original German Instruction
(origin: ST4, 36028797402626827 V5)

Table of Contents
INTECONT® Tersus Belt weigher, Instruction Manual
Schenck Process Group
BV-H2464GB, 1234
- i -
Table of Contents
Table of ContentsTable of Contents
Table of Contents
1
11
1
About This Manual
About This ManualAbout This Manual
About This Manual
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1
11
1
2
22
2
Safety notes
Safety notesSafety notes
Safety notes
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3
33
3
2.1
Signal Words
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4
2.1.1
Signal Words for Safety Warnings
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4
2.1.2
Signal Words for Application Notes
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5
2.2
Five Safety Rules of Electrical Engineering
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5
2.3
Damaged / Defective Electrical Components
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6
3
33
3
General Diagram
General DiagramGeneral Diagram
General Diagram
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7
77
7
3.1
An overview of the INTECONT Tersus
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7
3.2
Diagram of beltweigher and weighfeeder
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7
3.3
Method of Function
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8
3.4
Characteristics
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9
4
44
4
Operation
OperationOperation
Operation
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15
1515
15
4.1
Quick guide
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15
4.2
Function block
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17
4.3
Operating in Normal Operation
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18
5
55
5
Service Functions
Service FunctionsService Functions
Service Functions
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21
2121
21
5.1
Display Test and Version Number
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21
6
66
6
Counter functions
Counter functionsCounter functions
Counter functions
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23
2323
23
7
77
7
Mode functions
Mode functionsMode functions
Mode functions
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25
2525
25
7.1
Keyboard operation ON/OFF
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25
7.2
Prefeeder
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25
7.3
Simulation
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25
8
88
8
Calibration functions
Calibration functionsCalibration functions
Calibration functions
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27
2727
27
8.1
Starting the calibration functions
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27
8.2
Pulse/Belt circuit LB
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27
8.3
Tare TW
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29
8.4
Weight Check CW
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30
8.5
Setting the Time
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32
9
99
9
Parameter functions
Parameter functionsParameter functions
Parameter functions
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33
3333
33
9.1
Read Parameters
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33
10
1010
10
Printer functions
Printer functionsPrinter functions
Printer functions
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35
3535
35
10.1
Status Report
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35
11
1111
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Batching functions
Batching functionsBatching functions
Batching functions
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37
3737
37
11.1
Batching mode
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37
11.2
Record the batch
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39

Table of Contents
BV-H2464GB, 1234
- ii -
INTECONT® Tersus Belt weigher, Instruction Manual
Schenck Process Group
12
1212
12
Startup operation
Startup operationStartup operation
Startup operation
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41
4141
41
12.1
Weighing Platforms
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41
12.1.1
Effective Weighing Platform Length
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41
12.1.2
Calibration Weight
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42
12.1.3
Belt inclination
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44
12.2
Parameter Input
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45
12.3
Function Check
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46
12.4
Test With Calibration Weight
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46
12.5
Belt Velocity Check
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47
12.6
Test with Material
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47
13
1313
13
Parameters
ParametersParameters
Parameters
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49
4949
49
13.1
Abbreviations
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50
13.2
Configuring Event Messages
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50
13.3
Parameter Listing
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51
13.3.1
Parameter
Overview
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51
13.3.2
Parameter Details
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60
13.3.2.1
Parameter Block
01
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Dialog Behaviour
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60
13.3.2.2
Parameter Block
02
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Rated Data
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64
13.3.2.3
Parameter Block
03
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Calibration Data
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67
13.3.2.4
Parameter Block
04
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Calibrat. Results
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68
13.3.2.5
Parameter Block
05
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Analog Outputs
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69
13.3.2.6
Parameter Block
06
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Limit Values
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71
13.3.2.7
Parameter Block
07
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Filters
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73
13.3.2.8
Parameter Block
08
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AUTO Zero Set
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74
13.3.2.9
Parameter Block
09
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Batch Mode
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76
13.3.2.10
Parameter Block
10
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Printer Setting
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79
13.3.2.11
Parameter
Block
11
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Maintenance interval
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82
13.3.2.12
Parameter Block
12
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Feeder Control
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83
13.3.2.13
Parameter Block
13
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Belt Monitoring
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84
13.3.2.14
Parameter Block
14
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Events
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87
13.3.2.15
Parameter Block
15
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Linearization
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90
13.3.2.16
Parameter Block
16
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Digital Inputs
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92
13.3.2.17
Parameter Block
17
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Digital Outputs
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93
13.3.2.18
Parameter Block
18
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Communication EasyServe
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95
13.3.2.19
Parameter Block
19
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Communication Fieldbus
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96
13.3.2.20
Parameter Block
20
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Fixed mode configuration
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101
13.3.2.21
Parameter Block
21
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Ethernet
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103
13.3.2.22
Parameter Block
22
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Data Logging
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104
1
3.3.2.23
Parameter Block
23
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Configuration HMI Values
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1
06
13.3.2.24
Parameter Block
24
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Second Display
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108
14
1414
14
Even
EvenEven
Even
t messages
t messagest messages
t messages
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111
111111
111
15
1515
15
Events
EventsEvents
Events
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113
113113
113
15.1
Events Details
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113
15.1.1
Event Group:
Calibration
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113
15.1.2
Event Group:
Controller
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114
15.1.3
Event Group:
Electrical System
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114
15.1.4
Event Group:
Interlock
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115
15.1.5
Event Group:
Material Flow
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115
15.1
.6
Event Group:
MAX
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115

Table of Contents
INTECONT® Tersus Belt weigher, Instruction Manual
Schenck Process Group
BV-H2464GB, 1234
- iii -
15.1.7
Event Group:
Mechanic
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116
15.1.8
Event Group:
MIN
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117
15.1.9
Event Group:
Sequence Monitoring
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117
15.1.10
Event Group:
System Message
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118
16
1616
16
Hardware and technical data
Hardware and technical dataHardware and technical data
Hardware and technical data
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121
121121
121
16.1
Technical Data and Replacement Parts
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121
16.2
Connection Diagrams
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124
16.3
Replacing INTECONT PLUS with INTECONT Tersus
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126
16.4
PROFIBUS module (VPB8020)
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128
16.5
DeviceNet Module (VCB8020)
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130
16.6
Modbus Interface VSS8020
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132
16.7
LED diagnosis
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133
17
1717
17
Web server functions
Web server functionsWeb server functions
Web server functions
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135
135135
135
17.1
Web Server
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17.2
System Information
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136
18
1818
18
Appendix
AppendixAppendix
Appendix
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137
137137
137
18.1
Service Values
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137
18.2
Set option
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138
18.3
Function Check
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139
18.4
Test Connector
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140
18.5
Starting and Stopping
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141
18.6
Measuring at the Discharge Point VAP
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142
18.7
Belt Monitoring
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142
18.8
BIC belt impact compensation
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143
18.9
Linearization
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143
Index
IndexIndex
Index
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145
145145
145

About This Manual
INTECONT® Tersus Belt weigher, Instruction Manual
Schenck Process Group
BV-H2464GB, 1234
- 1 -
1
11
1 About This Manual
About This ManualAbout This Manual
About This Manual
This operating manual for belt weighersis intended for the service technician. It describes the functionality
of the VBW 20650-xxx software.
This manual is available in different forms:
▪A printed version
▪An electronic document in the platform-independent ADOBE format (file ending: *.PDF)
▪As online help in the Microsoft Windows HTMLHelp format (file ending: *.CHM)

Safety notes
INTECONT® Tersus Belt weigher, Instruction Manual
Schenck Process Group
BV-H2464GB, 1234
- 3 -
2
22
2 Safety notes
Safety notesSafety notes
Safety notes
To avoid personal injury and material damage, follow the safety regulations stated below.
Additionally you should also observe:
▪Safety information given in order-specific documentation
▪Safety information relating to mechanical components
▪Instructions and safety instructions for parts manufactured by thrid-party suppliers or parts that are not
part of Schenck's scope of delivery.
When performing installation, commissioning and service work, observe all applicable local regulations.
Intended Application
Intended ApplicationIntended Application
Intended Application
The measuring system and its connected mechanical components are exclusively designed for weighing
and controlling tasks. Any use other than originally intended is considered inappropriate.
Sources of Risk
Sources of RiskSources of Risk
Sources of Risk
If the measuring system has been correctly installed and commissioned, it does not pose any danger during
weigh operations.
Hazards may arise when the system is used for control operations or for transporting weighed goods. Po-
tential hazards may then arise from e.g. additional devices through which the weighed goods are passed or
metered. Minor risks may arise in these situations if the measuring system is used or operated by untrained
personnel.
The measuring system can be part of a more complex plant. The system operating company is fully respon-
sible for the operating safety of the system.
Personnel
PersonnelPersonnel
Personnel
Preparation, assembly, commissioning, operation, maintenance and servicing may only be carried out by
qualified personnel.
All persons working on the system are required to observe the safety hints and know the parts of the tech-
nical documentation relevant to their work.
The operating company is responsible for instructing his operators to observe all regulations and instruc-
tions given.
Changing Parameters
Changing ParametersChanging Parameters
Changing Parameters
The measuring system's functionality is determined by parameters. Only personnel familiar with the device's
mode of operation may alter these parameters (e.g. after training by Schenck Process). Incorrectly set pa-
rameters may cause injury or material damage. Furthermore they may also cause considerable disruption to
weigh operations.
Password
PasswordPassword
Password
Passwords safeguard the parameters against unauthorized alteration. The measuring system operating
company must ensure that the password is handled safely.
Acknowledging Event Messages
Acknowledging Event MessagesAcknowledging Event Messages
Acknowledging Event Messages
Error messages may be acknowledged only after cause of fault has been remedied.
Ensure that any connected peripheral devices are functioning correctly before acknowledging an event. Any
connected control systems in particular must be in safe state.

Safety notes
BV-H2464GB, 1234
- 4 -
INTECONT® Tersus Belt weigher, Instruction Manual
Schenck Process Group
Service and Maintenance
Service and MaintenanceService and Maintenance
Service and Maintenance
▪All warning and instruction signs on the scales must be observed.
▪The measuring system must be shut down before work is performed on mechanical equipment or peri-
pheral devices (control systems in particular). Take appropriate action to ensure that the measuring sys-
tem cannot be inadvertently restarted.
▪Before performing work on the electrical equipment, disconnect the power supply.
▪The devices may be operated only in the provided housings. There is danger of contacting live parts.
Moisture and Humidity
Moisture and HumidityMoisture and Humidity
Moisture and Humidity
All scales parts, electrical components in particular, must be protected from moisture and humidity when the
housing is opened for e.g. maintenance and service. In other respects the protection classes of the housing
must be observed.
Design Modifications
Design ModificationsDesign Modifications
Design Modifications
Unauthorized modifications to the system and/or use of replacement parts not supplied by Schenck Process
voids Schenck Process's liability for any resulting damages. This especially applies to alterations which
could affect the operating safety of the system.
Replacing Components
Replacing ComponentsReplacing Components
Replacing Components
Spare parts must meet the technical specifications indicated by Schenck Process. To ensure this require-
ment is met, only genuine Schenck Process spare parts should be used. When using other spare parts, the
warranty will be void.
2.1
2.12.1
2.1 Signal Words
Signal WordsSignal Words
Signal Words
2.1.1
2.1.12.1.1
2.1.1 Signal Words for Safety Warnings
Signal Words for Safety WarningsSignal Words for Safety Warnings
Signal Words for Safety Warnings
Potential hazards will always exist when working with technical devices. Hazards will arise if the machine
▪is incorrectly installed,
▪is started up incorrectly,
▪is operated by untrained personnel, or
▪is repaired by unqualified personnel.
In this manual the following signal words will indicate hazards that may arise when using this machine:
DANGER
This signal word indicates a danger that can immediately cause the
most severe injuries up to and including death.
Follow all instructions to prevent this from occurring.
WARNING
This signal word indicates a danger that can cause serious injur
ies up
to and including death.
Follow all instructions to prevent this from occurring.

Safety notes
INTECONT® Tersus Belt weigher, Instruction Manual
Schenck Process Group
BV-H2464GB, 1234
- 5 -
CAUTION
This signal word indicates a danger that can cause slight or medium
injuries.
Follow all instructions to prevent this from occurring.
2.1.2
2.1.22.1.2
2.1.2 Signal
Signal Signal
Signal Words for Application Notes
Words for Application NotesWords for Application Notes
Words for Application Notes
Signal words for information on material damages and on the optimal use of the machine
STRICTLY OBSERVE
Signal word used to identify situations in which material or enviro
n-
mental damage could occur.
Follow all instructions to prevent this from occurring.
HINT
Signal word used to identify information on using the product ec
o-
nomically and at an optimal level of efficiency.
2.2
2.22.2
2.2 Five Safety Rules of Electrical Engineerin
Five Safety Rules of Electrical EngineerinFive Safety Rules of Electrical Engineerin
Five Safety Rules of Electrical Engineering
gg
g
These fives safety rules must be followed in the order shown before work is begun on electrical systems.
Once the work is finished, they are to be applied in reverse order.
DANGER
Electric shock fr
om live components.
There is a danger of life from an electric shock.
– Take all possible precautions to ensure safety before work is begun on
live components. Observe, among other things, the following:
1. Disconnect the components.
2. Secure them against inadvertent restart.
3. Ensure that the components have been de-energized.
4. Above 1 KV: earth and bypass the cables.
5. Cover or shield adjacent, live components.

Safety notes
BV-H2464GB, 1234
- 6 -
INTECONT® Tersus Belt weigher, Instruction Manual
Schenck Process Group
2.3
2.32.3
2.3 Damaged / Defective Electrical Components
Damaged / Defective Electrical ComponentsDamaged / Defective Electrical Components
Damaged / Defective Electrical Components
DANGER
Live damaged or defective components
There is a danger of life from an electric shock.
– Always have qualified personnel ensure that the components are nei-
ther damaged nor defective.
1. Qualified personnel must immediately replace or, if possible, repair
damaged or defective electrical components.

General Diagram
INTECONT® Tersus Belt weigher, Instruction Manual
Schenck Process Group
BV-H2464GB, 1234
- 7 -
3
33
3 General Diagram
General DiagramGeneral Diagram
General Diagram
3.1
3.13.1
3.1 An overview of the INTECONT Tersus
An overview of the INTECONT TersusAn overview of the INTECONT Tersus
An overview of the INTECONT Tersus
INTECONT Tersus is an extension of and improvement on the INTECONT system that has proven its worth
for years and has been used in more than 50,000 scales all over the world.
INTECONT Tersus is a measuring and measurement processing system of continuous weighing and feed-
ing equipment for
▪weighfeeders
▪conveyor belt scales
▪differential feeding scales
▪Coriolis mass flow equipment and
▪solids flow equipment.
The basic hardware equipment is aligned to the needs of the application.
The following can be installed as optional equipment:
▪fieldbus modules
▪230 VAC power supply
▪module with additional analog outputs and analog inputs
3.2
3.23.2
3.2 Diagram of beltweigher and weighfeeder
Diagram of beltweigher and weighfeederDiagram of beltweigher and weighfeeder
Diagram of beltweigher and weighfeeder
Fig. 1: Basic diagram of the ITE inputs and outputs

General Diagram
BV-H2464GB, 1234
- 8 -
INTECONT® Tersus Belt weigher, Instruction Manual
Schenck Process Group
1 COUNTER Pulse output for connecting an external totalizing counter
2 ANALOG Analog output
3 SERIAL Serial interfaces for the printer or second display
4 24 V Power supply
5 MOTOR Control output for belt drive
6 PREFEEDER Control output for a prefeeder
7 FULL "Full feed“ relay output for batching
8 DRIBBLE "Dribble feed" relay output
9 MAX Relay output for maximum monitoring
10 MIN Relay output for minimum monitoring
11 FAULT Relay output for alarms
12 ON/OFF Switch scales and totalizing on/off
13 RELEASE Release signal for recording totalizing
LC Load cell for ascertaining belt load
Belt speed Speed pick-up (tachometer)
Belt sensor Sensor for belt drift
3.3
3.33.3
3.3 Method of Function
Method of FunctionMethod of Function
Method of Function
A belt weigher or weighfeeder continuously weighs the quantity of material transported by a conveyor belt.
The feed rate is regulated on a weighfeeder according to a setpoint. A belt weigher only measures and it
cannot influence the feed rate.
Definitions
DefinitionsDefinitions
Definitions
Q Belt load The weight of the material on a meter belt
V Speed The speed of the conveyor belt
I Feed rate The quantity of material transported by the conveyor belt per unit of time
Z Total Amount of material transported = Feed rate x feed time
Belt load Q and speed v are continuously measured and factored together. The result is the feed rate I, from
which the flow rate is determined.

General Diagram
INTECONT® Tersus Belt weigher, Instruction Manual
Schenck Process Group
BV-H2464GB, 1234
- 9 -
Fig. 2: The belt load of the weighbridge is not legal for trade
The material is transported over a weighing platform located beneath the belt, limited by 2 carrying idlers.
The load on the platform exerts a force on the load cell LC through one or more weighing idlers. The mea-
suring displacement is approximately 0.2 mm. The measuring rolls are linked with the frame construction via
parallel plate springs. The load cell output voltage is proportional to the platform load. It is recorded with a
suitable measuring amplifier.
The load distribution on a single-roll weighbridge is shown by the white triangle. Only half of the force from
the weight of the material is passed into the measuring idler. The following conversion formula applies to the
effective bridge length with single-roll weighbridges:
Leff = Lg / 2 Leff = effective weighing platform length
Lg = total weighing platform length
Weighing platforms with more than one weighing idler will have a different factor than 1/2.
Therefore the belt load in kg/m totals:
QB = total load on the weighbridge.
Belt speed
Belt speedBelt speed
Belt speed
The belt speed is recorded using velocity sensor D and converted into a corresponding pulse frequency.
Feed rate
Feed rate Feed rate
Feed rate
The readings Q and v are standardized in the unit to the physical quantities kg/m and m/s and multiplied
with one another. The product is feed rate I.
I in kg/s
Q in kg/m
v in m/s
QB in kg
Leff in m
I in kg/h
3.4
3.43.4
3.4 Characteristics
CharacteristicsCharacteristics
Characteristics

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INTECONT® Tersus Belt weigher, Instruction Manual
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Displays
The display of INTECONT Tersus consists of 4 parts:
1. You can give the technical name at the installation location in the header. A rotating symbol on the left
edge shows whether the weighfeeder is on or off.
2. The second line of the display is reserved for event messages.
3. The following two lines show readings that can be selected with the cursor buttons. These lines cor-
respond to the lines of the INTECONT PLUS display.
The lower half of the display is used for various visualizations: the large-scale display of an individual read-
ing, displaying 4 readings in line font size or displaying as many as 9 adjustable readings in the parameters
block Configuration HMI Values. They adapt their font size over 3 levels.
Event messages
▪Events and malfunctions are shown by an alphanumerical shorthand symbol and title.
▪The appropriate "uncoded text" for all subsequent events can be called up via the operating keyboard.
▪This distinguishes alarms (red) and warnings that either have to be acknowledged (orange) or do not
have to be acknowledged (yellow). Alarms will shut down the scales, warnings will not. All alarms are al-
so indicated with a relay output.

General Diagram
INTECONT® Tersus Belt weigher, Instruction Manual
Schenck Process Group
BV-H2464GB, 1234
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Fig. 3: Display warning 2
Fig. 4: Display warning 1
Fig. 5: Display alarm
Operating philosophy
▪Operator guidance through menus on several levels. Important configuration and calibration functions
are secured via password.
The dialog language for fault messages, operation and service programs
▪DEUTSCH, ENGLISH, FR-FRANCAIS, ES-ESPANOL, IT-ITALIANO, CN-CHINESE, JP-JAPANESE,
RU-RUSSIAN, HU-HUNGARIAN, NL-NETHERLAND at your choice or a loadable language (OTHER /
XX-NEW).
Dimensions
▪SI units (Metric): kg, kg/h, t, t/h, m and cm
▪NON SI units (English): lb, lb/h, t, t/h, f and inches
Turning recording the total or setpoint specification on or off

General Diagram
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INTECONT® Tersus Belt weigher, Instruction Manual
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▪This can be selected with the P02.06 Feeder Start and FALSE Feedrate Setpoint parameters (howev-
er, only with charging systems).
Monitoring for minimum and maximum limit values
▪For feed rate, belt load and belt speed The limit values, relay outputs and event classes can be sepa-
rately defined for all 6 possibilities.
Mains power failure
▪Scale data, calibration data, counter readings and quantity pulses not yet issued are kept for an unli-
mited time after a mains power failure and the time is kept for approx. 5 days.
Belt speed
▪The belt speed is recorded with a speed pick-up.
Zero settings
▪The zero point fault of the belt weigher comes from soiling that adheres permanently or from other con-
stant factors. The zero setting records the zero point fault on an empty belt over one or several whole-
number belt circuits. This corrects the regular measurement in normal operation.
▪Zero setting takes place with an empty belt conveyor with a program which runs automatically.
▪Zero setting should be started manually at regular intervals if automatic operation is not preselected.
▪The maximum permitted zero setting correction is monitored.
Zero drop out
▪Suppressing totalizing for measurements around zero so that the counter remains constant during no-
load belt operation. The function can be turned off.
Tare
▪Taring is a calibration procedure that determines the impact that the empty belt has on the measuring
signal, the basic tare. After taring, the total remains unchanged over one belt circuit with the empty belt.
Call-up is password protected.
Measuring at dispatch: VAP
▪The weighing platform is not located directly at the material discharge point for design reasons. This
means that if the belt load changes, the measurement for the feed rate will not precisely equal the cur-
rent feed rate at the dispatch point. Measurement is shifted to the material discharge point using a spe-
cial velocity-dependent delay element. No special measuring sensors are required to do this.
Batching mode
▪Batch mode conveys a preset amount of material. The conveying process ends once the batch setpoint
has been reached. The batching process can be controlled via the belt conveyor drive or bin feeder.
▪The turn-off point and dribble feed utilization can be adapted automatically.
BIC belt influence compensation and belt drift
▪This function makes it possible for the belt to record and compensate for dynamic zero point influence
with an additional belt circuit sensor and a metallic marking flag in the belt. This increases the scale's
short-term accuracy.

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INTECONT® Tersus Belt weigher, Instruction Manual
Schenck Process Group
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Display filters
▪For feed rate, belt load and belt speed
Maintenance guidelines by overlaying an event in the display
▪for the voltage supply's operating time, the scale's operating time and the next zero setting.
Calibration
▪It is not necessary to calibrate the pick-up input. Certain design data such as on the load cells, velocity
sensors and conveyor belt inclination must be entered. The system uses this data to calculate all stan-
dardizations required for the displays. It can be controlled or readjusted using two different methods.
▪Control with material: the result of a material inspection is entered into the system and it serves to cor-
rect the measurement result.
▪Control with calibration weight: standardization is controlled or can also be corrected if the technical data
(such as the lever ratio or belt conveyor inclination) is not precisely known.
In later operation, the program also becomes suitable for verifying mechanical changes such as the
weighing platform being twisted due to movement of the foundations.