Siemens milltronics User manual

Milltronics Test Chain
Milltronics
Belt Scales Accessories
Milltronics Test Chain
Operating Instructions
10/2021
A5E32310082
-AB
Introduction
1
Safety notes
2
Description
3
Planning/Configuring
4
Installing/Mounting
5
Commissioning
6
Service and maintenance
7
Technical specifications
8
Product documentation and
support
A

Siemens AG
Digital Industries
Postfach 48 48
90026 NÜRNBERG
GERMANY
Document order number: A5E32310082
Ⓟ
10/2021 Subject to change
Copyright © Siemens AG 2021.
All rights reserved
Legal information
Warning notice system
This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent
damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert
symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are
graded according to the degree of danger.
DANGER
indicates that death or severe personal injury will result if proper precautions are not taken.
WARNING
indicates that death or severe personal injury may result if proper precautions are not taken.
CAUTION
indicates that minor personal injury can result if proper precautions are not taken.
NOTICE
indicates that property damage can result if proper precautions are not taken.
If more than one degree of danger is present, the warning notice representing the highest degree of danger will
be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to
property damage.
Qualified Personnel
The product/system described in this documentation may be operated only by personnel qualified for the specific
task in accordance with the relevant documentation, in particular its warning notices and safety instructions.
Qualified personnel are those who, based on their training and experience, are capable of identifying risks and
avoiding potential hazards when working with these products/systems.
Proper use of Siemens products
Note the following:
WARNING
Siemens products may only be used for the applications described in the catalog and in the relevant technical
documentation. If products and components from other manufacturers are used, these must be recommended
or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and
maintenance are required to ensure that the products operate safely and without any problems. The permissible
ambient conditions must be complied with. The information in the relevant documentation must be observed.
Trademarks
All names identified by ® are registered trademarks of Siemens AG. The remaining trademarks in this publication
may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.
Disclaimer of Liability
We have reviewed the contents of this publication to ensure consistency with the hardware and software
described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the
information in this publication is reviewed regularly and any necessary corrections are included in subsequent
editions.

Milltronics Test Chain
Operating Instructions, 10/2021, A5E32310082-AB 3
Table of contents
1 Introduction ........................................................................................................................................... 4
1.1 The manual ......................................................................................................................... 4
2 Safety notes........................................................................................................................................... 5
2.1 General safety instructions................................................................................................... 5
3 Description............................................................................................................................................. 6
3.1 Test chain calibration........................................................................................................... 6
4 Planning/Configuring............................................................................................................................. 7
4.1 Test chain and reel selection ................................................................................................ 7
4.2 Test chain assembly............................................................................................................. 8
5 Installing/Mounting ............................................................................................................................... 9
5.1 Installation guidelines.......................................................................................................... 9
5.2 Installation procedure.......................................................................................................... 9
5.3 Test chain design............................................................................................................... 10
5.4 Chain reel .......................................................................................................................... 11
5.5 Standard motorized test chain storage reel......................................................................... 13
5.6 Connection of motor.......................................................................................................... 15
5.7 Positioning the chain ......................................................................................................... 17
6 Commissioning .................................................................................................................................... 19
7 Service and maintenance .................................................................................................................... 21
7.1 Test chain.......................................................................................................................... 21
7.2 Storage reel....................................................................................................................... 21
8 Technical specifications....................................................................................................................... 22
8.1 Test chain.......................................................................................................................... 22
8.2 Storage reel....................................................................................................................... 23
A Product documentation and support................................................................................................... 24
A.1 Product documentation ..................................................................................................... 24
A.2 Technical support .............................................................................................................. 25
Index .................................................................................................................................................... 26

Milltronics Test Chain
4Operating Instructions, 10/2021, A5E32310082-AB
Introduction
1
1.1 The manual
This instruction manual is intended to provide the basic guidelines for installation, operation
and maintenance of the calibration test chain and storage reel compartment. Other weighing
instruction manuals are available for download from our website:
Siemens weighing (http://www.siemens.com/weighing)
Note
For industrial use only
This product is intended for use in industrial areas. Operation of this equ
ipment in a
residential area may cause interference to several frequency based communications.
Follow these operating instructions for quick, trouble-free installation, and maximum
accuracy and reliability of your weighing system.
We always welcome suggestions and comments about manual content, design, and
accessibility. Please direct your comments to:
Technical publications ([e-mail])

Milltronics Test Chain
Operating Instructions, 10/2021, A5E32310082-AB 5
Safety notes
2
2.1 General safety instructions
CAUTION
Correct, reliable operation of the product requires proper transport, storage, positioning and
assembly as well as careful operation and maintenance. Only qualified personnel should
install or operate this instrument.
Note
Alterations to the product, including opening or improper repairs of the product, are not
permitted.
If this requirement is not observed, the CE and UKCA marks and the manufacturer's warranty
will expire.

Milltronics Test Chain
6Operating Instructions, 10/2021, A5E32310082-AB
Description
3
3.1 Test chain calibration
Test chain calibration is used extensively for testing belt scales, and to calibrate high capacity
belt scales and weighfeeders that cannot be calibrated to material tests.
During the calibration, the test chain is applied to the conveyor belt and is secured at both
ends so that the chain remains stationary over the weigh length. The chain rolls on the
surface of the moving belt conveyor, providing dynamic scale loading of a known weight
value, and thus supplying the calibration reference.
Advantages
The roller test chain simulates live material loading by causing the belt’s structure to deflect in
much the same manner as when material is present.
A much greater test load can be applied to high capacity belt scales and weighfeeders
because most weighbridge designs can only accommodate a limited number of static weights
applied to the suspension. The high capacity test load is especially important on systems
using mechanical weighing elements and lever systems because they calibrate the systems
with test load values close to normal operating loads.
Note
•
Ensure accessibility to the top (load) side of the conveyer belt in the scale area.
•
Secure and remove the test chains each time they are used.
•
Provide routine inspection and maintenance.
•
Lubricate regularly and repair as necessary to ensure safe reliable service.
•
Weigh and measure chain annually to determine the correct and accurate load value
(required to compensate for wearing and stretching of the test chain components).

Milltronics Test Chain
Operating Instructions, 10/2021, A5E32310082-AB 7
Planning/Configuring
4
4.1 Test chain and reel selection
A calibration range is generally targeted between 50% to 80% of the maximum design load.
Use the belt scale’s design information to determine chain requirements.
Example
Belt scale design information
Belt scale’s capacity:
1500 MTPH
Design load maximum:
166.67 kg/m
Idler spacing:
1.0 m
Type of belt scale:
1 weigh idler (MSI)
Belt width:
1400 mm
Belt speed:
2.5 m/sec
The next larger chain is the preferred choice to retain the desired percent of maximum
loading.
In our example, the calculation is performed at 60%:
166.67 * .60 = 100 kg/m (67.05 lb/ft)
Using the nominal kg/m value of 100, the next larger chain is selected from the chart of
available test chains. The value selected is equivalent to 104 kg/m (70 lb/ft). Test Chain
design size is based at 62.5% belt loading.
The length is based on the idler spacing. The test chain should extend no less than two fixed
idlers beyond each end of the scale mounted idlers.
Nominal chain length = (# of scale idlers + 3) * idler spacing:
1 + 3 * 1 = 4m (13 ft.)
•Note that some chain pitches do not divide evenly into the nominal chain length. The
selected chain may require to be increased by a pitch or two to accommodate
construction.
•Stamped value is derived from the actual manufactured results.
•The motorized storage reel is sized for a 1400 mm belt width with a conveyor width
outside to outside of stringer channels of 1820 mm, "C" dimension as given by others.

Planning/Configuring
4.2 Test chain assembly
Milltronics Test Chain
8Operating Instructions, 10/2021, A5E32310082-AB
4.2 Test chain assembly
Test chains can be shipped in sections based on the length ordered. These sections allow for
easier handling of the chain. To connect or dis-assemble sections of the chain, remove the
pins from the roll shafts. The shaft can then be removed and links of chain can be connected
or removed for installation or storage.

Milltronics Test Chain
Operating Instructions, 10/2021, A5E32310082-AB 9
Installing/Mounting
5
5.1 Installation guidelines
The Siemens Milltronics test chain storage reel requires a support steel structure for installing
above the conveyor. Locate an area suitable for the storage reel for flat or inclined conveyors
upstream of the belt scale’s location toward the head pulley. For declined conveyors, the reel
should be located to the upper side of the conveyor, approach end. Use this structure to
gravity feed the test chain into place.
Once the location has been selected, ensure that the reel is centered over the center line of
the belt and that it will clear the maximum material bed depth anticipated for the application.
Material loads should not come in to contact with any portion of the storage reel.
Note
•
Support legs, gussets, brackets, and mounting bolts are to be supplied by customer.
•
A mechanical designer should oversee the installation and verify the support structure.
•
Provision for AC power is required for wiring of gear motor. Ensure the power source is
available. All wiring must be done in conjunction with approved conduit, boxes, and
fittings, and done to procedure in accordance with all governing regulations.
A 30 foot (9.14 m) length of stainless steel wire rope is supplied with clips. One end of the
cable is attached to the test chain shackle. The other end is attached to the spool piece of the
reel around the shaft.
5.2 Installation procedure
Position local control station within direct viewing of the storage reel and the belt scale.
Minimum requirements for the control station (supplied by customer):
•Forward / Reverse or Raise / Lower
•Three position (on, off, on) spring return configuration
Upright posts constructed of angle iron may be placed at opposite end of the test chain.
These may be welded to main conveyor stringers on both sides, for securing the test chain’s
free end while in use.
Use eye hooks attached to the posts to secure the wire rope cables from the test chain
shackle. This positions the test chain, allowing it to track centrally on the belt.
Refer to installation or outline diagrams, and review all areas of the installation to ensure that
the safety aspects of the mechanics have been met. All welding, hardware, fasteners, wiring
and location must be sound and secure.

Installing/Mounting
5.3 Test chain design
Milltronics Test Chain
10 Operating Instructions, 10/2021, A5E32310082-AB
5.3 Test chain design
Roller diagrams
Single roller bushed test chain
①
Test chain shackle
⑥
Shaft length
②
Test chain roller
⑦
Roller diameter
③
Test chain link
⑧
Roller pin
④
Washer
⑨
Roller shaft
⑤
Chain length to center line of last roller
⑩
Pitch
Double roller bushed test chain
①
Test chain shackle
⑥
Shaft length
②
Test chain roller
⑦
Roller diameter
③
Test chain link
⑧
Roller pin
④
Washer
⑨
Roller shaft
⑤
Chain length to center line of last roller
⑩
Pitch

Installing/Mounting
5.4 Chain reel
Milltronics Test Chain
Operating Instructions, 10/2021, A5E32310082-AB 11
5.4 Chain reel
Location
On incline conveyors, the chain reel must be carefully installed upstream of the scale
weighbridge so the chain rolls out with the movement of the belt. "Upstream" is when you
look from the conveyor tail or infeed end towards the head or discharge end of conveyor.
On a level conveyor, locate the reel prior to the scale position.
Facilitate chain rollout over the scale by jogging the belt until the chain is in position.
Mount the reel to the conveyor about 4 to 4.5 idler spaces from the scale center line. This
places the support legs of the reel about 1.5 spaces from the end of the test chain for easy
attachment to the restraining device.
Once the chain has been secured at both ends, the cable from the reel can be detached and
the belt restarted for the calibration process.

Installing/Mounting
5.4 Chain reel
Milltronics Test Chain
12 Operating Instructions, 10/2021, A5E32310082-AB
Reel size and compartment diameters
The size of the reel is determined by the requirements of the specific conveyor application
and the selected chain loading. The width of the conveyor (18" [46 cm] through 96" [244 cm]
belt conveyor), its incline, and its general construction determine the reel cross member
length and section sizing for that member.
Compartment disc diameter is determined by the following:
•Chain length, pitch, and roll diameter
•Wire rope and chain wrap around the reel drum
•Chain wrap around the successive wraps of chain
•The number of rolls in a given wrap increase with each revolution of the reel
•The number of wraps the reel disc holds depends on the given chain parameters (as few
as one to two wraps, to as many as nine wraps)
•Overall wrap diameter varies from about 12" (30.5 cm) for the shortest chain to about 60"
(152 cm) for the longest chain.
Specifications
•6" (15 cm) pitch test chain, 20 ft (609 cm) long
•42 rollers long, 41 pitches long
•roll diameter: 3.75" (9.5 cm)
•disc diameter: 36" (91.5 cm)

Installing/Mounting
5.5 Standard motorized test chain storage reel
Milltronics Test Chain
Operating Instructions, 10/2021, A5E32310082-AB 13
5.5 Standard motorized test chain storage reel
View "A-A"
①
"D" dimension to center line of belt scale
⑥
To suit
②
reel Ø
⑦
"B"
③
View "A"
⑧
Gusset (by customer)
④
"E"
⑨
Eyebolt for chain restraint
⑤
Belt travel direction
reel Ø
"B"
"E"
36" (91.5 cm)
20.5" (52 cm)
13.25" (34 cm)
42" (107 cm)
23.5" (60 cm)
13.25" (34 cm)
48" (122 cm)
26.5" (67 cm)
13.25" (34 cm)
60" (152 cm)
32.5" (83 cm)
17.75" (45 cm)
Reels may have from one to two chain compartments (widths vary according to the width of
the specific test chain).

Installing/Mounting
5.5 Standard motorized test chain storage reel
Milltronics Test Chain
14 Operating Instructions, 10/2021, A5E32310082-AB
View "A"
①
Center line of conveyer
⑦
By Siemens Milltronics
②36, 42, 48, or 60" (91.5, 106.5, 122 or 152
cm) reel
⑧By customer
③
4" (10.15 cm) shed 40 pipe
⑨
View "A"
④
Pillow block bearings
⑩
Conveyer stringer
⑤10" (25.4 cm) X 20Lb/ft (or kg/m equiv.)
support channel
⑪"C" width per order
⑥
Structural angle frame
⑫
Connecting bracket by customer
Note
•
Motor starters, push button stations, and support legs from the reel to the conveyer frame
are not supplied with the storage reel.
•
Vertical support legs from the reel frame to the conveyer are to be supplied by others.
Provision is made for direct attachment to the customer-furnished supports by short
vertical leg sections from the reel support cross members.

Installing/Mounting
5.6 Connection of motor
Milltronics Test Chain
Operating Instructions, 10/2021, A5E32310082-AB 15
5.6 Connection of motor
Single speed dual voltage with pre-connected D.C. brake - 230/460 V AC
①
Fast stopping option
②
Brake coil 105 V DC
③
Standard stopping
④
Brake coil 105 V DC
⑤
Thermal sensors (if installed)
Single speed dual voltage with pre-connected D.C. brake - 190/380 V AC
①
Fast stopping option
②
Brake coil 103 V DC
③
Standard stopping
④
Brake coil 103 V DC
⑤
Thermal sensors (if installed)

Installing/Mounting
5.6 Connection of motor
Milltronics Test Chain
16 Operating Instructions, 10/2021, A5E32310082-AB
Single speed with pre-connected D.C. brake - 575 V AC
①
Fast stopping option
②
Brake coil 250 V DC
③
Standard stopping
④
Brake coil 250 V DC
⑤
Thermal sensors (if installed)

Installing/Mounting
5.7 Positioning the chain
Milltronics Test Chain
Operating Instructions, 10/2021, A5E32310082-AB 17
5.7 Positioning the chain
Chain position is critical to accurate scale calibration. To ensure proper position, please
account for the following:
•The pitch should be evenly divisible into the conveyer idler spacing.
•Rollers should straddle the idlers.
•Chain placement must be repeatable. Make sure that the chain extends a minimum two
rollers before and after the weighing mechanism.
The use of appropriate chain restraints will help control longitudinal stability and is critical to
ensure proper and safe usage. Restraints should do the following:
•Be attached to the chain at one end and fixed to posts mounted to each side of the
conveyer at about one belt width from the end of the chain.
•Form a "V" shape when viewed from above.
•Cross over and clear the belt edges by approximately one to two inches (2.5 to 5.0 cm).
Tension in the restraints should:
•Prevent chain movement along the belt
•Not lift the ends of the chain
Note
Turnbuckles are recommended to permit adequate adjustment of tension to ensure the chain
is fully extended and each roller is turning freely.

Installing/Mounting
5.7 Positioning the chain
Milltronics Test Chain
18 Operating Instructions, 10/2021, A5E32310082-AB
①
3" X 3" (7.5 X 7.5 cm) mill angle
⑪
Heavy duty hook
②
Eye bolt
⑫
Eye bolt
③
Chain
⑬
Equal length cable
④
Heavy duty hook
⑭
Belt width
⑤
3" X 3" (7.5 X 7.5 cm) mill angle
⑮
1.5" (38 mm)
⑥
Eye bolt
⑯
Idler spacing
⑦
Turnbuckle
⑰
5 x idler spacing
⑧
Chain
⑱
Belt width
⑨
cable
⑲
Load binder
⑩
pulley
⑳
Load binder

Milltronics Test Chain
Operating Instructions, 10/2021, A5E32310082-AB 19
Commissioning
6
Note
•
Follow the calibration details for the manufacturer's belt scale to perform a Zero
calibration.
•
Check for and adjust to an acceptable repeatability and error. Ensure the free end of the
chain has been released from the storage reel.
•
Frequency of calibration is determined by the repeatability of the span results and the
monitoring of the scale's performance.
CAUTION
Stop conveyor belt
During this step, the conveyer belt must be stopped to prevent injury to operator.
1. Using the control station, lower the test chain onto the conveyor belt. Spread the test chain
out until it spans across the weigh idler suspension: two idlers from the approach side to
two idlers on the retreat side of the weigh suspension. (This is often referred to as the A2
approach idlers to R2 retreat idlers.) Refer to Positioning the chain (Page 17).
2. Secure both ends of the test chain using wire rope cables attached to the eye bolts of the
frame on the storage reel and at opposite end. The test chain should lay flat on the center
roll of each idler, with the links of the chain in a horizontal position to the conveyor belt.
3. Run conveyor at the normal operating belt speed and observe the performance of the test
chain. The rollers of the chain should run freely without incident and track centrally to the
middle of belt. No side motion or "snaking" should be observed.
4. Continue to run the conveyor and perform the span calibration as outlined in the scale
manufacturer's manual.
Note
Snaking causes the results to be non repeatable and varying. Eliminate by readjusting the
wire rope guide cable (stays) until the problem is solved. Tension should not be applied to the
retrieving cable.

Commissioning
Milltronics Test Chain
20 Operating Instructions, 10/2021, A5E32310082-AB
Ensure the following upon completing the exercise:
•Stop the conveyor.
•Retrieve the test chain by using the control station to raise the test chain onto the storage
reel.
•Leave the wire rope cable attached to the shackle.
•During raising, ensure the chain shackle is free to move and does not bind onto any
portion of the storage reel. Once completely retrieved, secure the free end of the chain
using the wire rope.
NOTICE
Remove power to gear motor
Disable the gear motor by removing power from the unit. This prevents unauthorized or
accidental release of the chain during normal belt operation. The test chains should never
be released while material is on the belt.