Siemens Milltronics MCS User manual

Instruction Manual December 2003
MCS
milltronics
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© Siemens MilltronicsProcessInstruments Inc. 2003
Safety Guidelines
Warning notices must be observed to ensure personal safety as well as that of others, and to
protect the product and the connected equipment. These warning notices are accompanied
by a clarification of the level of caution to be observed.
Qualified Personnel
This device/system may only be set up and operated in conjunction with this manual.
Qualified personnel are only authorized to install and operate this equipment in accordance
with established safety practices and standards.
Warning: This product can only function properly and safely if it is correctly transported,
stored, installed, set up, operated, and maintained.
Note: Always use product in accordance with specifications.
Copyright Siemens Milltronics Process
Instruments Inc.2003.AllRights ReservedDisclaimer of Liability
This document is available in bound version and in
electronic version. We encourage users to
purchase authorized bound manuals, or to view
electronic versions as designed and authored by
Siemens Milltronics Process Instruments Inc.
Siemens Milltronics Process Instruments Inc. will
not be responsible for the contents of partial or
whole reproductions of either bound or electronic
versions.
While we have verified the contents of
this manual for agreement with the
instrumentation described, variations
remain possible. Thus we cannot
guarantee full agreement. The
contents of this manual are regularly
reviewed and corrections are included
in subsequent editions. We welcome
all suggestions for improvement.
Technical data subject to change.
MILLTRONICS®is a registered trademark of Siemens Milltronics Process Instruments Inc.
Contact SMPI Technical Publications at the following address:
Technical Publications
Siemens Milltronics Process Instruments Inc.
1954 Technology Drive, P.O. Box 4225
Peterborough, Ontario, Canada, K9J 7B1
Email: [e-mail]
For the libraryof SMPI instruction manuals, visitour Web site: www.siemens-milltronics.com

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Table of Contents
Table of Contents
Milltronics MCS Belt Scale ..............................................................................................1
The Manual ...............................................................................................................................................1
Specifications ......................................................................................................................2
Operation ..............................................................................................................................4
Installation ...........................................................................................................................4
Outline Dimensions .................................................................................................................................5
Installation Precautions .........................................................................................................................6
Installation Location ...............................................................................................................................7
Installation Procedure ..........................................................................................................................12
Idler Alignment .......................................................................................................................................14
Wiring ..................................................................................................................................16
Calibration ..........................................................................................................................17
Balancing ................................................................................................................................................17
Test Load .................................................................................................................................................18
Final Calibration .....................................................................................................................................18
Material Test ...........................................................................................................................................19
Maintenance ......................................................................................................................19
Milltronics MCS Bandwaage .........................................................................................21
Die Betriebsanleitung ...........................................................................................................................21
Technische Daten .............................................................................................................22
Betrieb .................................................................................................................................24
Installation .........................................................................................................................24
Abmessungen ........................................................................................................................................25
Sicherheitsvorkehrungen bei der Installation ................................................................................26
Einbauort .................................................................................................................................................27
Vorgehen beim Einbau .........................................................................................................................32
Ausrichtung der Rollenstationen ......................................................................................................34
Anschluss ...........................................................................................................................36
Kalibrierung .......................................................................................................................37
Abgleich ...................................................................................................................................................37
Prüflast .....................................................................................................................................................38
Abschlusskalibrierung .........................................................................................................................38
Materialtest ............................................................................................................................................39
Wartung ..............................................................................................................................39
Báscula de banda transportadora Milltronics MCS ..................................................41
Acerca del manual ................................................................................................................................41

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Table of Contents
Especificaciones técnicas ..............................................................................................42
Funcionamiento ................................................................................................................44
Instalación .........................................................................................................................44
Dimensiones principales .....................................................................................................................45
A tener en cuenta durante la instalación .......................................................................................46
Lugar de instalación .............................................................................................................................47
Procedimiento de instalación .............................................................................................................52
Alineación de los rodillos ....................................................................................................................54
Cableado .............................................................................................................................56
Calibración .........................................................................................................................57
Equilibrado ..............................................................................................................................................57
Carga de prueba ....................................................................................................................................58
Calibración final .....................................................................................................................................58
Prueba de material ...............................................................................................................................59
Mantenimiento ..................................................................................................................59
Bascule intégratrice Milltronics MCS ..........................................................................61
Le manuel d’utilisation .........................................................................................................................61
Caractéristiques Techniques ..........................................................................................62
Fonctionnement ................................................................................................................64
Installation .........................................................................................................................64
Dimensions .............................................................................................................................................65
Consignes et conseils pour l’installation .........................................................................................66
Emplacement pour l’installation ........................................................................................................67
Procédure d’installation .......................................................................................................................72
Alignement des rouleaux ....................................................................................................................74
Câblage ...............................................................................................................................76
Etalonnage .........................................................................................................................77
Equilibrage ..............................................................................................................................................77
Poids étalon ............................................................................................................................................78
Etalonnage final .....................................................................................................................................78
Essais matières ......................................................................................................................................79
Maintenance ......................................................................................................................79

7ML19985HN61 MCS Belt Scale – INSTRUCTION MANUAL Page 1
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Milltronics MCS Belt Scale
The Milltronics MCS belt scale is a compact, rugged belt scale with stainless steel load
cells for use in mobile crushers and aggregate screening plants.
The MCS belt scale includes:
• a left and a right weigh beam, with one load cell each
• calibration weight arm that mounts to the customer’s weighing idler
The addition of an idler (supplied and installed by the customer) completes the weighing
assembly. The MCS load cells generate an electrical signal proportional to load, which is
fed to the Siemens Milltronics belt scale integrator.
The Manual
This instruction manual covers the installation, operation and maintenance of the MCS
belt scale.
We strongly recommend that you read this manual before installing and starting up any
component of the weighing system to which the MCS is being applied. Adhering to the
installation and operating procedures ensures a quick, trouble-free installation and
allows for the maximum accuracy and reliability of your weighing system.
This manual covers only MCS installation and operating procedures. Integrator and
speed sensor instruction manuals are available for download from
www.siemens-milltronics.com.
We always welcome suggestions and comments about manual content, design, and
accessibility.
Please direct your comments to [email protected]om.
Note: The MCS belt scale is an accurate and repeatable force sensor. Its
performance is ultimately dependent on the conveyor system, the quality of the
installation, and the accuracy of the alignment.
calibration
weight
arm
optional
junction
box

Page 2 MCS Belt Scale – INSTRUCTION MANUAL 7ML19985HN61
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Specifications
Accuracy
• ± 0.5 to 1% of totalization over 4 to 1 operating range, application dependent
Load Cell
• construction stainless steel
• excitation 10 Vdc nominal, 15 Vdc maximum
• output 2 mV/V excitation at rated load cell capacity
• non-linearity 0.02% of rated output
• hysteresis 0.02% of rated output
• non-repeatability 0.01% of rated output
• capacity 50, 100, 2501lb stainless steel
• overload safe 150% of rated capacity, ultimate 300% of rated
capacity
• temperature: -40 to 65 °C (-40 to 150 °F) operating range
-10 to 40 °C (15 to 105 °F) compensated
Belt Width
• up to 1200 mm (48” CEMA) width (See Outline Dimensions on page 5 )
Belt Speed
• up to 3m/s (600 fpm)
Capacity
• up to 1200 t/h (1320 STPH) at maximum belt speed
Conveyor Incline
• ± 20° from horizontal, fixed incline
• up to ± 30° with reduced accuracy
Idler Profile
• flat to 35°
• up to 45° with reduced accuracy
Idler Diameter
• 100 to 150 mm (4 to 6”)
Idler Spacing
• 0.6 to 1.2 m (2.0 to 4.0 ft )
1. Size normally used for mobile crusher applications.

7ML19985HN61 MCS Belt Scale – INSTRUCTION MANUAL Page 3
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Hazardous Locations
• with the use of approved intrinsically safe barrier strips
Weight
• up to 20 kg (44 lb), 20 kg (22 lb)/side
Interconnection (to integrator)
• < 150 m (500 ft.) 18 AWG 6 conductor shielded cable
• > 150 m (500 ft.) to 300 m (1000 ft.) 20 AWG 8 conductor shielded cable
Approval
•CE

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Operation
The MCS belt scale works with an existing troughed conveyor and a Siemens Milltronics
integrator. As material moves along the conveyor belt and travels over the belt scale, it
exerts a force proportional to the material load through the belt and suspended idler to
the load cells.
The MCS reacts only to the vertical component of the applied force. The resulting
movement in each load cell is sensed by its strain gauges. When the strain gauges are
excited by voltage from the electronic integrator, they produce an electrical signal
proportional to weight, which is then returned to the integrator. The vertical movement of
the load cells is limited by the positive overload stop incorporated into the MCS design.
Installation
The MCS weighbridge components are shipped from the factory as a single unit in a
heavy-duty shipping container. The container is packed to separate each item and to
provide protection during shipment. Each item should be inspected as it is removed from
the container.
To avoid potential scale installation problems, please compare the site conditions with
the MCS installation drawings available on www.siemens-milltronics.com. If you have
any questions, please contact your Siemens Milltronics representative.
Follow the installation procedure carefully and read the related materials.
IMPORTANT: Before installation, be sure to determine the ideal position of your
MCS belt scale in relation to your conveyor system. See Installation Location on
page 7 for more information.
Notes:
• Adjust conveyor stringers to be rigid, straight, parallel to, and square with the belt
line in the area of the scale installation.
• Adjust pulleys to ensure that the conveyor belt tracks straight and centrally from
the head to the tail pulley.

7ML19985HN61 MCS Belt Scale – INSTRUCTION MANUAL Page 5
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Outline Dimensions
Note:A minimum of 2 approach and 2 retreat idlers should be aligned with the weigh
idler to within +1/32” (0.75 mm) to -0” (0 mm).
belt direction
View A-A
View A-A
150mm
(5.91”)
75 mm
(2.95”) 300 mm
(11.81”)
160mm
(6.30”)
idler
clamp
mounting
flange
Plan View Side View
124 mm
(4.9”)
standard base CEMA
idler or equivalent
(customer supplied)
shipping brackets 150mm
(5.91”)
to suit
up to 1200 mm (48”) belt width
95 mm
(3.74”)
10 mm
(0.39”)
75mm
(2.95”)
customer
supplied
stringer
Front View

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Installation Precautions
Welding
Load Cell Handling
Load cells are sensitive electro-mechanical transducers and must therefore be handled
with care. They can tolerate very little mechanical deflection without damage.
Although the load cells are protected by shipping stops that keep the cells from moving,
be careful when handling the scale to avoid damaging the cells. The stops are metal
strips about 38 mm (1.5”) long with holes at each end for screws. One screw holds the
stop to the dynamic beam while the other screw holds the stop to the weigh blocks static
structure.
When handling the MCS during installation and setup, make sure the stops remain in
place.
Reinstall both shipping stops during maintenance or prolonged shutdown.
Scale Handling
Observe the following precautions when handling the scale.
• Do not pry on the idler, its mountings, or the load cells directly.
• Do not stand or lean on the scale.
• Lift the scale by the weigh blocks only. Do not lift the scale by the idler or idler
mounting brackets.
• Never subject the scale to sudden impacts or shocks.
CAUTION: Use extreme caution when arc welding in the area of the belt
scale. To avoid damaging the load cells, ensure that no welding currents can
flow through the belt scale.

7ML19985HN61 MCS Belt Scale – INSTRUCTION MANUAL Page 7
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Installation Location
The ideal placement of the Siemens Milltronics belt scale depends on the conveyor
system. This section provides guidelines to determine MCS placement.
Mobile Crushers
The MCS is installed on mobile crushers because of its durability and low profile. A belt
scale can be used effectively in a conveyor of this type, but it requires special
consideration.
Control Gates
Conveyor Belting
Variations in the number of belt plies, the cover thickness, and the type and number of
splices in a given belt can cause considerable change in the weight per unit length of the
belt. During the course of zero calibrations, belt scales average the weight of the belt over
one complete circuit of the belt. Large deviations from the average adversely affect zero
calibrations.
Recommendation: Consult your Siemens Milltronics representative to discuss
using the MCS with mobile crushers.
Note:Ensure steady and uniform material loading to the belt at or near the same
speed as the conveyor belt. The installation of a material feed control gate or similar
device improves uniform flow of material.
belt scale
control gate
uniform material
distribution

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Head Pulley
Use caution when installing a scale in a short conveyor or when locating the scale near
the head pulley. Since head pulleys are flat-faced and carrying idlers are generally
troughed, the belt profile must change from troughed to flat in a short distance. To
accommodate this, the conveyor manufacturer designs a built-in vertical displacement of
the head pulley above the top of the center roll of the adjacent idler. To further ease this
transition, idlers of decreasing trough angles are inserted between the head pulley and
the normal run of idlers. If these measures are not taken, a considerable amount of stress
is exerted on the belt edges and the idlers adjacent to the head pulley. In turn, this stress
is transmitted to the scale causing an unreliable measurement.
.
Recommendation: On conveyors with 20° trough idlers throughout, install the
scale idler a minimum of two fixed 20° idlers away from the head pulley
Recommendation: On conveyors with 35° trough idlers throughout, install the
scale a minimum of two 35° and one 20° retreat idler away from the head pulley.
belt scale
20° idlers
minimum 3 idler spaces
head pulley
belt scale
35° idlers
minimum 4 idler spaces
head
pulley
35° idlers
20°
idler

7ML19985HN61 MCS Belt Scale – INSTRUCTION MANUAL Page 9
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Recommendation: On conveyors with 45° trough idlers throughout, install the
scale a minimum of two 45°, one 35°, and one 20° retreat idler away from the head
pulley.
Recommendation: The vertical displacement of the head pulley relative to the
adjacent retreat idler is normally higher than acceptable for belt scale installations.
We therefore suggest that when you install the scale close to the head pulley, allow a
maximum of 13 mm (½”) vertical displacement between the top of the head pulley and
the top of the center roll of the adjacent roll.
belt scale
35° idlers
minimum 5 idler spaces
head
pulley
35° idler
20°
idler
45° idlers
20° idler,
center roll
13 mm (1/2”)
maximum
head pulley

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Conveyor Curvature
Vertical curvature, whether concave (internal) or convex (external), disturbs the idler
alignment if the scale is installed in the area of curvature. Of the two types of curvature,
concave curvature is more difficult to manage because it may lift an empty belt off the
idlers around the curve, preventing a good empty belt zero balance for the scale. The
diagrams below illustrate the minimum distance the belt scale should be from the
curvature to obtain accurate results.
Concave
Convex
Belt Ploughs
We do not recommend the use of belt ploughs or any conveyor or material control device
that changes the profile of the carrying belt in or near the scale area. These devices have
a detrimental effect on the belt scale idler alignment and usually create drag on the belt
that the scale senses as a material force of load.
Recommendation: Avoid locating the scale within the tangents of scale curvature.
Recommendation: Do not install the scale within 9 m (30 ft.) of belt ploughs or
similar devices that contact the material or belt.
belt scale belt scale
minimum 12 m
(40 ft.)
tangents
minimum 12 m
(40 ft.)
minimum 6 m
(20 ft.) minimum 12m
(40 ft.)
belt scale
tangents
belt scale

7ML19985HN61 MCS Belt Scale – INSTRUCTION MANUAL Page 11
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Stacker Conveyors
Avoid installing the belt scale in any conveyor that is not a permanent structure. Because
stacker conveyors usually vary in incline, elevation, or profile, the accuracy of the belt
scale can be compromised under these conditions. A belt scale can be used effectively in
a conveyor of this type, but it requires special consideration.
Conveyor Trippers
Not as common as a conveyor with a vertical curvature, trippers can still be troublesome
to scales.
Skirt Boards and Sealing Strips
In some applications it is necessary to extend the infeed skirt boards and sealing strips
the full length of the conveyor. This can create problems in weighing accuracy caused by
the effects that the sealing strips exert when contacting the belt and indirectly upon the
idlers, especially where pinching occurs. In particular, this situation adversely affects the
zero calibrations.
Recommendation: Consult your Siemens Milltronics representative to discuss
using the MCS with stacker conveyors.
Recommendation: On a conveyor with a tripper car, locate the scale using the
recommendations for vertical curves, but with the tripper fully retracted.
Recommendation: If possible, remove the skirting in the scale area. If this is not
possible, adjust the skirting to ensure the sealing strip does not put excess force on
the belt or allow pinching of material.
skirt board
pinching can
occur here
sealing strip
idler

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Installation Procedure
1. Remove the idler at the chosen location on the conveyor.
2. Remove the idler mounting brackets and cut the spine as shown.
Notes:
• Cut the idler support as shown to allow clearance when the load is applied.
• Maximum allowable idler spine for fitting to an MCS is:
Angled spine: 75 mm (3”)
Channel spine: 100 mm (4”)
before after

7ML19985HN61 MCS Belt Scale – INSTRUCTION MANUAL Page 13
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3. Position the weigh beams so that the center of the scale idler is centered between
the adjacent approach and retreat idlers.
Ensure that the scale is centered and square to the stringers.
4. Mark the position of the weigh beams and make new mounting holes suited for M12
or ½” bolts. (Refer to
Outline Dimensions on page 5.)
5. Place the scale on the conveyor stringers with the arrows on the weigh blocks
pointing in the direction of belt travel (retreat idlers). Mount the modified idler onto
the scale using the clamping brackets.
nn
belt
travel
belt
travel
approach idlers
location of removed idler
retreat idlers
A3 A2 A1 R1 R2 R3
clamping
brackets

Page 14 MCS Belt Scale – INSTRUCTION MANUAL 7ML19985HN61
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6. Position the weigh blocks so that they are square to the stringer.
• Shim as required between the weigh block mounting flange and the conveyor
stringer.
• Level the weigh blocks to one another and tighten the bolts sufficiently to keep
the weigh blocks in place until final adjustment.
Idler Alignment
Precise alignment is very important for maximum accuracy of the weighing system.
Improperly aligned idlers could apply undesired forces onto the weighing idler, resulting
in measurement errors.
Alignment Procedure
1. Remove the shipping stops to free each weigh block mechanism.
• Keep the stops and screws stored in a convenient place for use during
maintenance or at times when protection of the load cells is necessary.
Note: Off-center or off-square installation can result in poor belt tracking and scale
inaccuracy.
reference
idlers must be square to
stringers belt
travel
belt
travel
center
of idlers
to be in
line
A2 to R2
±0.8mm
(1/32”)
adjust idler last, leaving the
MCS 0.75 mm (1/32”) high
nn
A3 A2 A1 R1 R2 R3
load cell mounting
screws
shipping stop in
run position
overload stop clearance
0.5 mm (0.02”)

7ML19985HN61 MCS Belt Scale – INSTRUCTION MANUAL Page 15
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2. Align and level the idler in the weighing area by raising or lowering the weigh blocks
in their mountings.
• The weighing area includes the scale and at least two idlers on each side of the
scale. For conventional flat idler roll conveyors, two additional idler rolls should
be included in the alignment procedure.
3. Adjust idlers vertically until they are all within ±0.75 mm (1/32") of each other.
• Stretch a line across the top surface of each idler roll in the scale area
approximately 25 mm (1") from each end of each side idler roll and at the centre
roll.
• Use good quality wire (0.5 mm [0.020"] diameter) or equivalent nylon line to
check for alignment. The wire or string aligning lines must be able to withstand
sufficient tension to eliminate sag in the line.
4. Check that the idlers are centered and squared to the conveyor as in step 6 of the
installation procedure on page 14.
5. Tighten the weigh blocks’ mounting bolts (34 to 40.8 Nm or 25 to 30 ft lbs).
6. Install the speed sensor as described in the speed sensor instruction manual.
7. Connect the speed sensor and the MCS to the belt scale integrator. Refer to the
integrator manual and its system interconnection diagram.
Note: Off-center or off-square installation can result in poor belt tracking and scale
inaccuracy.
R2
R1
S1
A1
A2
retreat
approach
belt travel
MCS with
modified idler
wire or string for
alignment

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Wiring
belt direction
loadcell
‘A’ load cell
‘B’
red
loadcell
‘A’ load cell ‘B’
black
white
green
shield
red
black
white
green
shield
red black white
green
green white shld
+exc -exc -sig A +sig A -sig B +sig B
stringer
mounted
junction box
(by customer)