Siemens Milltronics WD600 User manual

Instruction Manual May 2008
WD600
milltronics

© Siemens Milltronics Process Instruments Inc. 2008
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.
Unit Repair and Excluded Liability:
•The user is responsible for all changes and repairs made to the device by the user or the user’s
agent.
•All new components are to be provided by Siemens Milltronics Process Instruments Inc.
•Restrict repair to faulty components only.
•Do not reuse faulty components.
Warning: This product can only function properly and safely if it is correctly transported, stored,
installed, set up, operated, and maintained.
This product is intended for use in industrial areas. Operation of this equipment in a residential area
may cause interference to several frequency based communications.
Note: Always use product in accordance with specifications.
Copyright Siemens Milltronics Process
Instruments Inc. 2008. All Rights Reserved
Disclaimer 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 European Authorized Representative
at the following address:
Technical Publications Siemens AG
Siemens Milltronics Process Instruments Inc. Industry Sector
1954 Technology Drive, P.O. Box 4225 76181 Karlsruhe
Peterborough, Ontario, Canada, K9J 7B1 Deutschland
Email: [e-mail]
•For a selection of Siemens Milltronics level measurement manuals, go to:
www. siemens.com/processautomation. Under Process Instrumentation, select
Level
Measurement
and then go to the manual archive listed under the product family.
•For a selection of Siemens Milltronics weighing manuals, go to:
www. siemens.com/processautomation. Under Weighing Technology, select
Continuous
Weighing Systems
and then go to the manual archive listed under the product family.

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Table of Contents
Table of Contents
Safety Notes ...........................................................................................................................................1
The Manual ............................................................................................................................................1
WD600 ..................................................................................................................................2
Specifications ....................................................................................................................3
Operation ............................................................................................................................5
Installation ..........................................................................................................................6
Welding ...................................................................................................................................................6
Load Cell Handling ................................................................................................................................7
Installation Precautions ......................................................................................................................7
Installation Procedure .........................................................................................................................8
Calibration ........................................................................................................................11
General ..................................................................................................................................................11
Test Load ...............................................................................................................................................11
Zero ........................................................................................................................................................11
Span .......................................................................................................................................................11
Maintenance ....................................................................................................................12
Spare Parts ...........................................................................................................................................12
Wiring ................................................................................................................................13
Outline Dimensions .........................................................................................................14

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Table of Contents

7ML19985KM01 WD600 - INSTRUCTION MANUAL Page 1
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Introduction
Safety Notes
Special attention must be paid to warnings and notes highlighted from the rest of the text
by grey boxes.
The Manual
Milltronics WD600 weighdeck is used in conjunction with the selected integrator and
speed sensor. This manual covers only WD600 installation and operating procedures. For
the complete library of Siemens manuals, go to:
www.siemens.com/processautomation.
This manual will help you set up your WD600 for optimum performance. We always
welcome suggestions and comments about manual content, design, and accessibility.
Please direct your comments to te[email protected].
WARNING means that failure to observe the necessary precautions
can result in death, serious injury, and/or considerable material
damage.
Note: means important information about the product or that part of the operating
manual.
Note:
• Please follow the installation and operating procedures for a quick, trouble-free
installation, and to ensure the maximum accuracy and reliability of your Siemens
Milltronics weighing system.
• WD600 is to be used only in the manner outlined in this manual or protection pro-
vided to the equipment may be impaired.
• This product is intended for use in industrial areas. Operation of this equipment in
a residential area may cause interference to several frequency based communi-
cations.

Page 2 WD600 - INSTRUCTION MANUAL 7ML19985KM01
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Introduction
WD600
WD600 belt scale is a low-to-medium capacity scale for light-to-medium belt loading. It is
designed to be inserted into either a flat roll idler (non-troughing) belt conveyor or a flat
pan slider belt conveyor for continuous weighing of dry bulk solids. WD600 is suitable for
monitoring such products as fertilizer, tobacco, animal feed pellets, and sugar.
WD600 belt scale consists of the following:
• weighbridge (UHMW slider)
• two precision load cells on mounting pads with weighbridge mounts
WD600 load cells output an electrical signal proportional to load, which is applied to the
selected Siemens belt scale integrator. Thus, weighing is accomplished without
interrupting the process and without affecting the process material.
Important: WD600 is an accurate and repeatable force sensor. Its performance is
ultimately dependent upon the conveyor system and the quality of the installation and
accuracy of the alignment.

7ML19985KM01 WD600 - INSTRUCTION MANUAL Page 3
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Specifications
Specifications
Accuracy
• ± 0.5% to 1% totalization over 4 to 1 operating range, application dependent
Belt width
• 12, 18, 24, 30, 36, 42, 48” (300, 450, 600, 750, 900, 1000, 1200 mm)
Belt speed
•2.0m/s (400 fpm) maximum
Capacity
• up to 50 t/h
Conveyor incline
•±20° from horizontal, fixed incline
• up to ± 30° with reduced accuracy
Conveyor idler/slider profile
• horizontal
Loading
• Minimum 1.0 kg/m (0.6 lbs/ft)
• Maximum 60 kg/m (40 lbs/ft)
Load cell
• excitation: 10 V DC nominal, 15 V DC maximum
• output: 2 mV/V (nickel-plated alloy steel version)
3 mV/V (stainless steel version)
• non-linearity: 0.02% of rated output
• non-repeatability: 0.01% of rated output
• capacity: nickel-plated range: 10, 15, 20, 30 kg
stainless steel ranges: 6 kg (25, 50 lbs)
• overload: 150% of rated capacity
• temperature: – 40 to +65 °C (– 40 to +150 °F) operating range
– 10 to +40 °C (15 to +105 °F) compensated
• construction: stainless steel construction
UMHW - PE sliders

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Specifications
Hazardous locations
• with the use of approved Intrinsically Safe barrier strips
Approvals
•CE

7ML19985KM01 WD600 - INSTRUCTION MANUAL Page 5
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Operation
Operation
WD600 works with an existing flat belt conveyor and the selected Siemens integrator. As
material is moving along the conveyor belt and travels over the belt scale, it exerts a force
proportional to the material load through the suspended weighbridge to the load cells.
WD600 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 applied to the integrator. The vertical movement of
the load cells is limited by the positive overload stop incorporated into the design of the
load cell mount.

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Installation
Installation
WD600 is shipped from the factory as three units 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 limit the weight and dimensions of the weighbridge on the scale, Siemens builds the
weighbridge to definite specifications as part of the scale. If a substitute or a
replacement is required, please contact Siemens. Substituting or replacing this
weighbridge with a non-specific weighbridge could result in damage to the scale due to
overloading or improper fit.
To avoid potential scale installation problems, please compare the site conditions with
WD600 installation drawings available at www.siemens.com/processautomation.
If you have any questions, please contact your Siemens representative.
Welding
Notes:
• Be sure the conveyor design meets the installation requirements for the
WD600.
• 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.
WARNING: Use extreme care when arc welding in the area of the belt scale.
Ensure that no welding current can flow through the belt scale. Welding currents
passing through the scale can functionally damage the load cells.

7ML19985KM01 WD600 - INSTRUCTION MANUAL Page 7
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Installation
Load Cell Handling
WD600 is designed for low-to-medium capacity operation and is constructed using two
load cells. Although the load cells are protected by shipping screws that keep the cells
from moving, care should be taken when handling the scale to avoid damaging the cells.
The screws are bolts about 38 mm (1.5") long located beneath the load cell mount pads
and threading into the load cell.
When handling the WD600 during installation and setup, make sure the shipping screws
remain in place.
Reinstall both shipping screws during maintenance or prolonged shutdown.
Installation Precautions
The following precautions should be observed when handling the scale.
• Do not pry on the weighbridge, its mountings, or the cells directly.
• Do not stand or lean on the scale.
• Avoid shock from blows of a hammer when trying to position the scale during
installation.
• Do not lift the WD600 by its load cells.
weigh deck
belt
top load cell mount
overload screw
shipping screw
load cell
bottom load cell mount

Page 8 WD600 - INSTRUCTION MANUAL 7ML19985KM01
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Installation
Installation Procedure
1. Make sure the shipping stops are in place and secure.
2. Remove the existing flat roll idler (or flat slider pan) from the area selected to locate
the belt scale assembly.
3. Drill four 8 mm (5/16") diameter mounting holes. This will allow clearance for 6 mm
bolts.
4. Position the scale with the weighbridge towards the head end of the conveyor and
the load cells toward the tail end.
• Raise the conveyor belting to provide room for the installation of the scale.
5. Insert the scale (modules) onto the conveyor.
• Insert four M6x1 bolts through the conveyor frame and through the holes in the
sides of the load cell mount pads.
• Secure. Finger tight only.
6. Make sure there is at least 13 mm (½") of clearance between the return belt and the
WD600.
• In some conveyors, it may be necessary to install a return idler roller adjacent to
the scale to deflect the return belt past the scale.
7. Position the scale so that it is parallel to the conveyor and square to the stringer.
• Place the weighbridge on the top load cell mount.
• Level the weighbridge and tighten the bolts sufficiently to keep the load cell
mount pads in place until final adjustment.
Note: Slotting the holes vertically will permit greater adjustment capability.
CAUTION: Off-center or off-square installation can result in poor belt tracking and
scale inaccuracy.
minimum 4.75"
(121 mm),
must be equal.
both
sides
weigh span
product flow
weigh deck
16.00" (406 mm)
test weight
hanger bracket
load cell
belt
existing slider
belt support

7ML19985KM01 WD600 - INSTRUCTION MANUAL Page 9
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Installation
Idler Alignment
Precise alignment is very important to achieve maximum accuracy of the weighing
system. Improperly aligned idlers could cause unwanted forces to be applied to the
weighbridge, resulting in measurement errors.
Alignment Procedure
1. Remove the shipping stops to free the weighing mechanism.
• Keep the screws stored in a convenient place for use during maintenance or at
other times when protection of the cells is necessary.
2. Align and level the weighbridge in the weighing area by raising or lowering the load
cell mount pads in their slots.
• The weighing area includes the scale and the approach and retreat idler/sliders.
For conventional flat idler roll conveyors, two additional idler rolls should be
included in the alignment procedure.
3. Adjust idlers (pans on a slider pan conveyor) vertically until they are all within
±0.8 mm (1/32") of each other.
• Stretch a line across the top surface of each idler roll (pan) in the scale area at
approximately 25 mm (1") from each end of each idler roll (pan).
• Use good quality wire [0.5 mm (1/64") 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 7 of the
installation procedure.
5. Tighten the load cell mount pad bolts (34 to 40.8 Nm or 20 to 25 ft lbs).
6. Carefully lower the conveyor belt onto the scale and fixed idlers (pans).
Run the conveyor for at least fifteen minutes to limber the belt prior to calibration.

Page 10 WD600 - INSTRUCTION MANUAL 7ML19985KM01
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Installation
weigh deck
aligning
wire
existing slider
belt support
wire
WD600
existing slider

7ML19985KM01 WD600 - INSTRUCTION MANUAL Page 11
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Calibration
Calibration
General
After the WD600 has been installed in accordance with the installation procedure,
calibration of the weighing system must be done in conjunction with the selected
integrator. Refer to the integrator instruction manual for programming and calibration.
The calibration is initially done using a calibration test weight. Where possible, material
tests are recommended to achieve maximum accuracy. (For more information about
material tests refer to the integrator manual.)
Test Load
The test load (stated in kilograms per meter or pounds per foot) for the WD600 is
stamped on top of the calibration test weight. Enter this value into the integrator as the
test load programming parameter.
If the actual weigh span (see diagram on page 8) differs from the design data provided at
time of purchase, recalculate and re-enter a new test load value as follows:
test load (kg/m or lbs/ft) = weight of calibration weight (kg or lbs)
actual weigh span (m or ft)
Zero
Perform the zero calibration as described in the calibration section of the selected
integrator manual.
Span
1. Hang the calibration test weight from the hole in the top load cell mount.
2. Perform the span calibration as described in the calibration section of the selected
integrator instruction manual.
3. After the span calibration has been completed, remove the calibration test weight
and store it in a convenient location.
calibration test weight

Page 12 WD600 - INSTRUCTION MANUAL 7ML19985KM01
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Maintenance
Maintenance
Because the WD600 has no moving parts, the scale requires no active maintenance.
Once the scale is installed into the conveyor, the conveyor becomes part of the total
weighing system. If a problem develops with the conveyor, that problem may also affect
the scale. For this reason, we recommend that a periodic conveyor maintenance program
be established for any conveyor that incorporates a scale.
Spare Parts
The only spare part recommended for the WD600 is the load cell. Refer to the load cell
nameplate for the proper size and then specify as follows when ordering.
Note: Re-install the shipping stops during maintenance or any other time when pro-
tection of the cells is necessary.

7ML19985KM01 WD600 - INSTRUCTION MANUAL Page 13
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Wiring
Wiring
belt
travel
load cell "A"
load cell
"A" load cell "B"
load cell "B"
load cell
"A" load cell "B"
customer
junction box
R
E
D
‘A’
R
E
D
‘B’
B
L
K
‘B’
W
H
T
‘A’
G
R
N
‘A’
W
H
T
‘B’
G
R
N
‘B’
S
H
I
E
L
D
‘A’
+
S
I
G
B
-
S
I
G
B
-
E
X
C
+
E
X
C
S
H
I
E
L
D
‘B’
S
H
I
E
L
D
+
S
I
G
A
-
S
I
G
A
B
L
K
‘A’
to integrator
G
R
N
‘A’
W
H
T
‘A’
G
R
N
‘B’
B
L
K
‘B’
R
E
D
‘A’
R
E
D
‘B’
W
H
T
‘B’
S
H
I
E
L
D
‘B’
S
H
I
E
L
D
‘A’
+
E
X
C
-
E
X
C
-
S
I
G
A
+
S
I
G
A
-
S
I
G
B
+
S
I
G
B
S
H
I
E
L
D
to integrator
stainless steel
nickel-plated
customer
junction box
B
L
K
‘A’

Page 14 WD600 - INSTRUCTION MANUAL 7ML19985KM01
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Dimensions
Outline Dimensions
Belt Width A B
12” (300 mm) 13.25” (330 mm) 20.25” (510 mm)
18” (450 mm) 19.25” (485 mm) 26.25” (665 mm)
24” (600 mm) 25.25” (640 mm) 32.25” (815 mm)
30” (750 mm) 31.25” (790 mm) 38.25” (970 mm)
36” (900 mm) 37.25” (945 mm) 44.25” (1120 mm)
42” (1000 mm) 43.25” (1095 mm) 50.25” (1275 mm)
48” (1200 mm) 49.25” (1250 mm) 56.25” (1425 mm)
plan view
"A"
"B"
front view

IQ300IX.fm Page 5 Tuesday, October 2, 2001 1:43 PM

*7ml19985KM01* Rev. 1.2
www.siemens.com/processautomation
Siemens Milltronics Process Instruments Inc.
1954Technology Drive, P.O. Box 4225
Peterborough, ON, Canada K9J 7B1
Tel: [phone] Fax: [phone]
Email: [email protected]
Siemens Milltronics Process Instruments Inc. 2008
Subject to change without prior notice
Printed in Canada