BVH2222GB - Belt Weight Feede

MULTIBELT Belt Weigher BMC
Installation and Operating Instructions
BV-H2222 GB
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Copyright 2005
SCHENCK PROCESS GmbH
Measuring and Process Systems
Landwehrstrae 55, D-64293 Darmstadt
http://www.schenck-process.com
All rights reserved. Any reproduction of manual, regardless of method, without prior permission by
SCHENCK PROCESS GmbH in writing, even by excerpt, is prohibited.
Subject to change without prior notice.
BV-H2222 GB
0335
MULTIBELT Belt Weigher BMC, Installation & Operating Instructions

SCHENCK PROCESS GmbH, Darmstadt
Contents
1 General Information ..........................................................................1

1.1 Hints for Delivery.......................................................................................................1
1.2 Information on Documentation..................................................................................2
2 Overview ............................................................................................4
2.1 General Information on Belt Weighers......................................................................4
2.2 Specific Information on BMC Type ...........................................................................5
2.2.1 Constructional Features .....................................................................................5
2.2.2 Applicational Hints..............................................................................................7
3 Planning-in Hints (The 10 Rules)......................................................8

3.1 General Information ..................................................................................................8
3.2 The 10 Rules.............................................................................................................9
3.2.1 Overview ............................................................................................................9
3.2.2 Rules in Detail ..................................................................................................10
3.3 Hints for Special Conveyors ...................................................................................23
3.3.1 Movable Conveyors .........................................................................................23
3.3.2 Rail-based Conveyors......................................................................................23
3.3.2.1 Rail Joint Design........................................................................................23
3.3.2.2 Rail Calibration ..........................................................................................24
3.3.2.3 Rules for Apron Conveyors .......................................................................24
4 Installation and Operating ..............................................................25

4.1 Installation Instructions ...........................................................................................25
4.1.1 Items Supplied..................................................................................................25
4.1.2 Installation Prerequisites ..................................................................................26
4.1.3 Mounting Belt Weigher.....................................................................................26
4.1.4 Installation ........................................................................................................27
4.1.4.1 Preparations ..............................................................................................27
4.1.4.2 Selecting Carrying Idler Sets for Installation in Weigher Influential Zone .28
4.1.4.3 Idler Sets Permanent Alignment................................................................30
4.1.4.4 Installation of Weigher Supports ...............................................................30
4.1.4.5 Installation of Belt Stringers and Load Cell Supports................................31
4.1.4.6 Installation of Load Cells ...........................................................................32
4.1.4.7 Installation of Tie-rods ...............................................................................33
4.1.4.7.1 Aligning Tie-rods .................................................................................34
4.1.4.8 Installation of Carrying Idler Sets ..............................................................35
4.1.4.9 Installation of Speed Transducer...............................................................36
4.1.5 Aligning.............................................................................................................36
4.1.6 Acquiring Effective Platform Length .................................................................37
4.1.7 Cabling .............................................................................................................38
4.2 Operating Instructions.............................................................................................39
4.2.1 Construction and Operating Principle ..............................................................39
4.2.1.1 Belt Weigher ..............................................................................................39
4.2.1.2 Tie-rods .....................................................................................................40
4.2.1.3 Load Cell and Measuring Load Application...............................................41
4.2.1.3.1 Load Cell Dismantling and Installing...................................................41
4.2.1.3.2 Load Cell Data ....................................................................................42
4.2.2 Maintaining Belt Weigher .................................................................................43
4.2.2.1 Maintenance ..............................................................................................43
4.2.2.2 Inspection ..................................................................................................44
4.2.2.2.1 Ensuring Carrying Idler Alignment ......................................................44
4.2.2.2.2 Aligning Longitudinal and Transverse Tie-rods ..................................46
4.2.2.2.3 Checking Load Cell Signal..................................................................47
4.2.2.2.4 Checking Load Cell.............................................................................48
5 Speed Transducer (Option) ............................................................49

5.1 FGA20-RSLE Type .................................................................................................49
5.1.1 Installation Instructions.....................................................................................49
5.1.1.1 Installing Speed Transducer......................................................................49
5.1.1.1.1 Further Installation Instructions...........................................................50
5.1.1.2 Cabling ......................................................................................................50
SCHENCK PROCESS GmbH , Darmstadt
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Contents
5.1.2 Operating Instructions......................................................................................51

5.1.2.1 FGA 20-RSlE for Legal-for-trade Belt Weighers .......................................51
5.1.2.2 Maintenance..............................................................................................51
5.1.2.3 Inspection and Repair ...............................................................................52
5.2 FGA24A Type.........................................................................................................52
5.2.1 Installation Suggestions ...................................................................................52
5.2.1.1 Suitability ...................................................................................................53
5.2.1.2 Mounting Pole Wheel ................................................................................54
5.2.1.3 Mounting Proximity Switch ........................................................................54
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General Information
Hints for Delivery
1 General Information
1.1 Hints for Delivery
Inspection of incoming goods
Carefully inspect packaging for any damage during transit.
If damage is discovered, contact your carrier immediately and file a claim

for damages.
Check items supplied for completeness. For information on items supplied,

please refer to Item 4.1.1 'Items Supplied'.
Warranty
Our warranty exclusively covers the component and planning documents
supplied by SCHENCK Process. We do not assume any liability whatsoever
for any part added by the customer.
The specified accuracy can be achieved only if your belt weigher is properly
installed, and operated under the conditions additional specified by
SCHENCK Process.
For design variants and custom adaptions, we recommend to use the
Schenck engineering service. Contact us, and we will be pleased to
prepare a quotation tailored to your requirements (at extra charge).
Storage hints
Check to see whether the admissible limit temperatures of - 25 oC or + 55 oC can
possibly be exceeded:
If no, store the items supplied in their genuine packaging in dry and clean
rooms whose relative humidity does not exceed 75%.
If yes, remove load cell, (optional) speed transducer and terminal box, and
store the electronic components in rooms meeting the above requirements.
Additionally observe the

'Guideline for Storage and Handling of Components
and Machines Supplied' (BV-R2000 AA).

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General Information
Information on Documentation
1.2 Information on Documentation

The present manual readies comprehensive information on multi-idler belt weighers
of the BMC type (standard variant).
For quick overview, refer to Chapter 2.
Item 2.1 offers general information on belt weighers.
Application
Construction
Operating Principle
Accuracy
For specific information on the constructional design of belt weighers, BMC type,
refer to Item 2.2:
Operating principle
Dimensions
Load cell type
Possible belt widths
Feed rates
Accuracies
Applications
Optimal planning-in is essential for obtaining the specified data and ensuring
proper functioning of your belt weigher.
Before mounting, please read the 'Planning-in Hints (The 10 Rules)' item.
For detailed description of belt weigher, see Chapter 4 'Installation and

Operation':
Installation Instructions
Operating Instructions
Setting Instructions
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General Information
Information on Documentation
Hints on Options:
If your belt weigher is equipped with optional devices, the variants of the particular
type as well as the relevant Installation and Operating Instructions are referenced
accordingly:
Speed measurement system:
See chapter 5
'Speed Transducer (Option)'

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Overview
General Information on Belt Weighers
2 Overview
2.1 General Information on Belt Weighers
Belt weighers are components designed for installation in user's belt conveyor
systems. The systems are designed and documented so that the user can perform
installation and commissioning single-handedly. However, advanced mechanical skills
and utmost care are required to provide the proper environment for the belt weighers.
Proper mounting is an important consideration for system accuracy.

Therefore, we recommend to have commissioning and inspections
performed by a SCHENCK engineer.
Application
Used for continuous acquisition of feed rates and totalized amounts, the belt weighers
are designed for installation in continuously operating belt conveyor systems. There is
a broad range of applications:
Throughput and consumption measurement in production plants
Balancing of amounts fed in and out
Reporting of load limits
Batching in load-out stations
Legal-for-trade weighing
Prefeeder control
The rugged design of the system ensures a high degree of operating safety and
availability.
Construction
A belt weighers comprises:
Weighing platform for accommodation of user's idler sets
Overload protected load cell(s) with a high degree of protection
Cable junction box for connection of sensors
Fixing elements for the installation
Various speed transducers (e.g. frequency generators with friction wheel) for
speed measurement (optional)
Weighing electronics
Operating Principle
Belt weighers are designed to acquire continuous material flows of varying strengths.
Load cells are used to acquire the weight of the load on a certain belt section. With
increasing length of this belt section, external influences are loosing importance for the
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Overview
Specific Information on BMC Type
measuring result. In addition to belt load, a speed transducer measures the belt speed
(up to approx. 6 m/s). The product of the two measured variables results in the current
feed rate. Totalization of feed rate results in the material amount fed.
If belt speed acquisition is omitted (belt load measuring system), a constant

speed value must be transferred to the weighing electronics in form of a
parameter. However, this procedure has the potential to adversely affect
weighing accuracy.
Accuracy
The stated accuracies assume that the belt weigher is mounted in suitable belt
conveyor systems and that the weighed idler set is installed and calibrated in
accordance with our installation and calibration instructions.
For accuracy data, please refer to the following documention:

BV-D2105 AA 'Definition of Belt Weigher System Accuracy'
2.2 Specific Information on BMC Type

2.2.1 Constructional Features
Operating principle:
Platform (weighing platform between conveyor belt

stringers, supported on four load cells)
Weigh span:
Multi idlers
Application:
Belt conveyors
Rail-based conveyors (i.e. troughed belt conveyors,
apron conveyors)
Strengths:
Easy integration into user's belt stringers, no

interruption of belt stringers
Designed for big weigh spans and belt widths
Designed for heavy loads
Insensitive to vibrations (high mass, low natural
frequency)
Insensitive to crosswise belt stringers instabilities
Others:
Belt tensioning forces absorbed via longitudinal and

transverse tie-rod systems
Legal-for-trade variants available

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Overview
The weighers of the BMC series are always designed and

constructed order-specifically.
Therefore this documentation only presents a typical BMC weigher
variant.
Determined:
Load cells and mounts :
Types, design principle (RTN and VPN based)
Frame:
Design principle
Length and width:
As a function of conveyor size and type

ATTENTION: With apron conveyors, select length
as an integer multiple of aprons.
Superstructures:
As a function of conveyor type
Tie-rods arrangement:
Against direction of travel or take-off with inclined

conveyors
As near as possible to tensile force axis
Rated capacities
Adjusted (to conveyor):
Load cells:
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Overview
Belt weigher with weighing platform suitable for

DIN belt widths from 500 to 2000 mm
Weighed idler set inside belt stringers
Insensitive to crosswise belt stringers
instabilities: extended weigh span
Load cells of the RTN type (ring-torsion load
cells)
Feed rates up to approx. 20,000 t/hr
Accuracy 0.25 % of actual feed rate
2.2.2 Applicational Hints

Thanks to the advantages of the BMC belt weighers, e.g.
big belt width (--> bulk quantities fed)
big platform length (--> more than four weighed idler stations)
installation in inclined conveyor systems (ascending and descending)
suitability for trade use
low natural frequency (--> insensitivity to vibrations)
rail-based conveyors
typical scenarios are found in
harbours
loading stations (e.g. for ships)
mining
where bulk quantities have to be weighed with high accuracy.

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Planning-in Hints (The 10 Rules)
General Information
3 Planning-in Hints (The 10 Rules)

3.1 General Information
The specified accuracies assume that your belt weigher is regularly and carefully
maintained and calibrated in accordance with the instructions and planning-in hints
supplied.
Carefully plan the integration of the weighed idler set into your belt
conveyor system using the 10 rules. This is an important consideration
for obtaining the specified measuring accuracy.
General Information
The stricter these rules are followed, the lower is the risk of adversely affecting
functioning and measuring accuracy of your belt weigher.
To achieve highest accuracies (related to actual value), rules 4, 5, and 9 are of
special import. The weighed idler sets themselves are designed stable and rigid.
The installation, calibration and commissioning instructions for the individual weigher
types detail installation and alignment.
To be observed
With legal-for-trade belt weighers, additionally observe the applicable

regulations of the Verification Ordinance.
Never change belt stringers when using belt conveyors to DIN 22107.
The accuracy of belt weighers without speed transducer (v-measurement)

varies as a function of belt speed.
Verify accuracy by check measurements under load. Ensure that the check
amount is at least 10% of the hourly amount fed at nominal feed rate (Inom)
over at least one belt circuit.
Ensure that the location of your belt weigher is fully accessible to installation
work.
Particularly observe the relation

'Feed rate measuring accuracy' 'number of carrying idlers in the
weigher influential zone'
o
Accuracies related to nominal value require the presence of 2

carrying idlers approach and retreat of weighed idler set.
Accuracies related to actual value require the presence of 3

carrying idlers approach and retreat of weighed idler set.
Depending on type of weigher, the weighed idler set is equipped with one or multiple
carrying idler sets.
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The 10 Rules
3.2 The 10 Rules

3.2.1 Overview
No. Meaning
1
2
3
4
5
6
7
Install belt weigher in a straight belt section (horizontal or rising).

Ensure that the ascending or descending slope of the belt conveyor (angle of
inclination) is selected so that relative movements of the material are excluded.
Install belt weigher with sufficient distance from prefeeder, so that the material
flow is settled and no relative material movements can occur.
Ensure that the minimum distance of belt weigher from the belt pulley in a
troughed belt is given.
Depth and shape of troughing are important considerations for accuracy.
Ensure that the belt is fully troughed in the weigher influential zone.
Accurately align idler sets in the weigher influential zone.
Sets with offset idlers (viewed from above) have the potential to adversely
affect measuring accuracy.
8 Ensure that the belt stringers are mounted on a solid and level base.
9 Provide gravity take-up.
your system against wind, weather, extreme temperature variations
10 Safeguard
and vibrations.

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The 10 Rules
3.2.2 Rules in Detail
Please note:
For simplicity reasons, the measuring station in the following sketches
consists of one idler station only ("single-idler belt weigher"). All statements
anologously apply to multi-idler belt weighers that feature a measuring
station composed of multiple idler stations.
Install belt weigher in a straight belt section

(horizontal or rising).
Rule 1:
Ensure that the unloaded conveyor belt also fully rests on all carrying idlers,
i.e.
o
in weigher influential zone
and, if possible, in two further sets approach and retreat of weigher

influential zone.
Garlands are not suitable.
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The 10 Rules
The figures below show belt conveyor systems with typical belt weigher locations. The
circled numbers refer to a valuation scale (1= preferred to 7=unfavourable) used to
judge the influence of location on accuracy.
Horizontal belt conveyor
Rising belt conveyor

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The 10 Rules
Belt conveyor with curved belt
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Rule 2:
The 10 Rules
Ensure that the ascending or descending slope of the belt conveyor

(angle of inclination) is selected so that relative movements of the
material are excluded.
If conveyors are designed for adjustable slope, any change fully enters into
measurement as error (see 'Movable Conveyors' item).
Caution! Relative movements may occur:
o
with fines and uniformly shaped materials

('grain size' max. 100 mm)
with high belt speeds
right downstream of feed units
upon loading gaps.

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Rule 3:
The 10 Rules
Install belt weigher with sufficient distance from prefeeder, so that

the material flow is settled and no relative material movements can
occur.
Ensure that the complete weigher influential zone is outside the prefeeder
area.
The required distance is influenced by

o
belt speed
belt inclination
type of material infeed, and
material properties.
(*) Make sure the minimum distance corresponds to the belt travel per
second, however, to minimum 2 m.
Arrange skirt boards in weigh span so that the weighing accuracy is not
affected.
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The 10 Rules
Rule 4:
Ensure that the minimum distance of belt weigher from the belt
pulley in a troughed belt is given.
Rule 5:
Depth and shape of troughing are important considerations for

accuracy.
A flat belt (small belt troughing angle ) increases the measuring accuracy.
A V-shaped belt (*) is unfavourable.
(*) Deep or V-shaped belts are suitable only if more approximate measurement will
suffice.

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The 10 Rules
Ensure that the belt always rests on the carrying idlers of the sets. This is best
achieved by
o
small troughing
flexible belt.
Provide for high belt load.
Ensure correct belt tracking and avoid off-centre load that could lead to belt
slip and inaccurate weighing results.
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Rule 6:
The 10 Rules
Ensure that the belt is fully troughed in the weigher influential zone.
Avoid the use of belt conveyors whose pulleys are arranged higher than the
carrying idlers. If need be, increase distance between pulley and weigher
influential zone.

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Rule 7:
The 10 Rules
Accurately align idler sets in the weigher influential zone.

Sets with offset idlers (viewed from above) have the potential to
adversely affect measuring accuracy.
Arrange carrying idlers in the weigher influential zone elevated by 3 to 5 mm.
Secure aligned carrying idler sets against displacement and lowering.
Mean the carrying idlers' out-of-round tolerance during alignment.
Maximum admissible out-of-round tolerance = 0.2 mm; identify location of

mean out-of-round tolerance on idler shell on either side.
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The 10 Rules
Ensure that the spindles of the weighed and limiting idlers are perfectly level
viewed from above.
(also applies to V-shaped belts)
Weighed and limiting idler sets with offset spindles do not produce any exact
weigh span.

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Rule 8:
The 10 Rules
Ensure that the belt stringers are mounted on a solid and level base.
Ensure that the belt stringers impact points in the weigher influential zone are
welded.
Select belt stringers and support so that the carrying idler alignment is
secured (see Rule 6). If need be, reinforce or shim belt stringers accordingly.
Wire-rope-suspended belt conveyors are unsuitable for the installation of belt

weighers.
Avoid vibrations in the weigher influential zone.
Always install belt tracking idlers for correction of belt run outside the weigher
influential zone.
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Rule 9:
The 10 Rules
Provide gravity take-up.
The potential measuring error increases along with varying belt tension.

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Rule 10:
The 10 Rules
Safeguard your system against wind, weather, extreme temperature

variations and vibrations.
Wind falsifies the measurement.
Direct insolation can excessively raise load cell temperature.
Moisture, ice and snow give rise to material build-ups and cause misalignment
in the weigher influential zone.
One-sided insolation of belt weigher has the potential to cause twisting and
temperature drifts.
Protect foundation from strong vibrations.
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Hints for Special Conveyors
3.3 Hints for Special Conveyors

3.3.1 Movable Conveyors
Movable conveyors (mobile systems, crushers1) are normally of light-weight design.
The lacking stiffness has the potential to cause additional issues (vibrations).
Here, the constancy of the slope is an important consideration for accuracy. With
stationary conveyors, the influence resulting from the slope is considered upon
calibration.
If the belt slope is changed with mobile conveyors (e.g. on vehicles) or in adjustable
conveyors (e.g. booms), there are two possibilities:
Angle measurement and correction of measured value via cosine pendulum

(option)
Calibration at mean slope and specification of accuracy at maximum

adjustment angle.
Ensure constant power supply.
3.3.2 Rail-based Conveyors
Ensure proper platform length !

With rail-based conveyors (troughed belt conveyors or apron conveyors), the
length of the platform rails should be an integer multiple of the space
between two adjacent wheels.
3.3.2.1 Rail Joint Design

To prevent stones from jamming, the rail joints are designed as 'freely cut rail joints'
(see Detail X).

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Hints for Special Conveyors
To maintain your belt weigher at peak functionality over the entire operating period,
the design of the contact surface in rail joint area is an important consideration. Strictly
observe the following details:
3.3.2.2 Rail Calibration

Alignment
In the requested alignment area, a length of 3 wheel divisions (min. 3 m

overall length) approach and retreat of weighing platform must be acquired.e
Align relevant rail strands and weighing platform rails to 0.5 mm.c
Ensure this section is elevated over adjacent rails by min. 2 mm.
Levelling
Make sure the surfaces of weighing platform rails and running rails are
perfectly level. Maximum tolerance is 0.1 mm.d
If need be, use thicker shims or grind down the existing ones.
Ensure that rail and tie-rods run perfectly parallel.
3.3.2.3 Rules for Apron Conveyors
When loading hot material on apron conveyor, protect load cells from the
effects of heat.
Ensure 2 mm static inclination of support plates over the entire alignment

range.
Check to see that chain links run smoothly and feature little wear.
With troughed belt conveyors, watch out for material jammed between
troughs.
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Installation and Operating
4 Installation and Operating

4.1 Installation Instructions
4.1.1 Items Supplied
Documentation
Manual
'MULTIBELT Belt Weigher BMC, Installation and Operating

Instructions' (BV-H2222GB)
Manual
'Load Cells and Load Application Elements' (DKI 200GB)
Data Sheet
'Compact Ring-Torsion Load Cells RTN' (BV-D2019GB)
Guideline
'Guideline for Storage and Handling of Components and

Machines Supplied' (BV-R2000 AA)
Dimensioned
drawing
BMC drawing no. (custom-engineered)
Mechanical Equipment
Qty Type Name
Comments
4 pc.
Load cell, RTN type (ring-torsion load cell)
4 pc.
Load cell mount, VPN type (pendulum contact plate,

contact plate, foot plate)
2 pc.
Weigher longitudinal beam
(*)
4 pc.
Weigher cross-beam
(*)
4 pc.
U-shaped head piece
(*)
4 pc.
Load cell support with fixing angles for belt stringers
(*)
2 pc.
U-shaped cross-beam
(*)
4 pc.
Tension/compression tie-rod
1 set
Screws
1 pc.
Speed transducer (**)

with friction wheel and rocker
1 pc.
Terminal box
for summation of load cell, transducer and weighing
electronics cables
1 set
Shims
for alignment of carrying idler sets in weigher influential
zone
optional
Limiting blocks
Thick shims
Shims
(*) Normally provided by user; can also be supplied by SCHENCK.

**) See 'Speed Transducer (Option)' item

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4.1.2 Installation Prerequisites

SAFETY HINT:
Ensure work protection on device by using it as originally intended, in
accordance with order specification, and having it installed by skilled
technicians.
Admissible lowering of site (e.g. varying environmental loads): 0.5 mm.
Plan arrangement of weighed idler set in belt conveyor in accordance with

the 10 RULES. The latter ensure that the measuring accuracy will be
obtained. See 'Planning-in Hints (The 10 Rules)' item.
Belt widths from 1600 to 2000 mm are suitable.
No modifications to belt stringers are required if belt conveyors meet the DIN
22107 standard.
4.1.3 Mounting Belt Weigher

Preferred Distance L = 1000 mm.
The holes used to affix the weigher idlers to the belt weigher longitudinal beams are
drilled using this distance.
The width of the belt weighers and the length of its cross-beams is designed for
installation in belt conveyors to DIN 22107 with preferred belt widths from 1600 to
2000 mm. Other belt widths can be chosen as well.
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4.1.4 Installation
Prerequisites for work to be provided by user:

1. Stiffening of weighing table
Weighing table components should be designed so that the deflection (in
mm) caused by dead weight and material load is the maximum admissible
calibration error (in mm).
(See Item 3.3.2.2 'Rail Calibration')
2. The load cell bracket alignment error should be the maximum
admissible load cell inclination.
4.1.4.1 Preparations
Choose belt weigher location in accordance with the considerations outlined in

the 10 RULES. The check list will help you ensure that relevant criteria are
met.
Item
Rules
Location on conveyor
1 2 3 5 8 10
Stability
Belt tension
Idler sets requirements (profile, out-of-round) 4 5 6
If the conveyor belt is already in position, you may have to release its tension,
and lift it from the carrying idlers with the help of suitable lifting tackle to be
able to slide the measuring modules on the belt stringers.

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Further preparations:
o
If required, provide extra supports, in addition to the belt stringers and

the supports in belt weigher area, cf. 'Mounting Belt Weigher' item.
Optional: Use hole pattern if the speed transducer is to be bolted in

place (instead of being welded on).
Debur ties of carrying idler sets in support points.
4.1.4.2 Selecting Carrying Idler Sets for Installation in Weigher

Influential Zone
Select carrying idler sets for installation in weigher influential zone in accordance with
following criteria, and prepare for installation:
Use carrying idlers with an out-of-round of 0.2 mm only
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Ensure that weighed and limiting idler sets meet the following additional
requirements:
Shim carrying idler sets using the shims supplied. Arrange carrying idler sets
in weigher influential zones elevated by 3 to 5 mm as described at the
'Mounting Carrying Idler Sets' item.
Recess tie ends of weighed idler sets.

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4.1.4.3 Idler Sets Permanent Alignment
To secure carrying idler alignment:

o
Secure foundation against settlement.
Anchor stringer supports in foundation.
4 supports for the load cells,
Provide reinforced belt stringers or additional supports, if required.
Weld belt stringers impact points all around.
If necessary, cut out return belt cover plates on belt stringers in idler set shim
area, weigher influential zone and speed transducer area.
4.1.4.4 Installation of Weigher Supports
Use the two U-shaped cross-beams as mounting aids.

Safety hint! Protect U-shaped cross-beams from displacement or
slipping off belt stringers.
BV-H2222 GB
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0335

Shim U-shaped cross-beams by 3 to 5 mm and horizontally align after

mounting of belt stringers using spirit level. Use shims supplied.
Ensure right-angled alignment of weigher supports by diagonal
measurement:
4.1.4.5 Installation of Belt Stringers and Load Cell Supports

Align load cell supports on belt stringers symmetrically to weigher cross-beams, drill
off with belt stringers and bolt and/or weld in place c.
Bolt U-shaped head pieces sturdy for subsequent load cell mounting.

0335
BV-H2222 GB
- 31 -
4.1.4.6 Installation of Load Cells
Observe documentation of load cells and load cell mounts (see Item 4.1.1
'Items Supplied').
Screw torques : M4 = 2.4 Nm

M6 = 8.0 Nm
Mount load cells onto base plates such that type plates of cable junction
boxes point to the outside.
o
Observe hole pattern arrangement of set screws in foot plate - load

cell support - cable junction box
Check to see that surfaces are absolutely clean and deburred.
Tighten bolts stepwise to proper torque.
When assembling load cell mounts as described in steps (1) to (4), apply CRC
copper paste (supplied with each load cell) to compression surfaces of
pendulum contact plate, head plates and load cells to protect them from
corrosion.
Place load cell mounts on load cell supports as described in step (5):
Hold in place with set screws,
Bolt head plates to U-shaped head pieces.
Position pendulum contact plates vertically or square to weigher by aligning Ushaped head pieces accordingly. Bolt U-shaped head pieces in place.
BV-H2222 GB
- 32 -
0335

Align load cell mounts with finger-tip control to ensure even load distribution
on all 4 load cells and secure with lock nut.
o
Check to see that base plates are in horizontal position, i.e. parallel to
weigher, to permit measuring force to enter vertically into load cell.
Run load cell cable and connect in cable junction box; see 'Cabling' item.
To perform welding work, and in order to protect the load cell, connect
the minus pole direct to the point of welding.
4.1.4.7 Installation of Tie-rods
Tie-rods arrangement:
Arrange tie-rods so that they absorb
the dead weight of the BMC frame if belt weigher is installed with
upward inclination
the belt traction force, or dead weight, if belt weigher is installed
horizontally or with downward inclination.
To ensure measuring accuracy, check to see that the 4 tie-rods are installed in
parallel, crosswise and lengthwise to weigher.
With reversible conveyor systems, consider the reversed force direction.
Remove one U-shaped cross-beam (mounting aid) from weigher longitudinal

beams and bolt or weld in place in appropriate location on belt stringers.
As a rule, never dismount second U-shaped cross-beam before
tie-rods have been mounted.
Attach tie-rod angles to weigher parts provided with fixing holes.

o
Weld or bolt angles in place on belt stringers.

0335
BV-H2222 GB
- 33 -
Ensure that mid axes of tie-rods and load cell load application points
are perfectly level.
Mount concave and convex washers as shown in illustration (cotter

lock nuts):
4.1.4.7.1 Aligning Tie-rods
First adjust transverse tie-rods free from play, then longitudinal tie-rods.
Check to see that tie-rods can still be turned by hand.
Secure with lock nuts, drill off and cotter.
Dismount second U-shaped cross-beam.
Check pendulum contact plates for vertical position to load cells.
BV-H2222 GB
- 34 -
0335

4.1.4.8 Installation of Carrying Idler Sets
Use shims and packing plates supplied to align carrying idler sets in influential
zone, and later to align and fix idler sets.
Fit hoist and remove belt from idler sets in belt weigher mounting area.
Arrange carrying idler sets in weighing influential zone elevated by 3 to 5 mm.
Place prepared carrying idler sets (troughing profile, out-of-round tolerance)

on premade shims on belt stringers.
Align all idler sets in the influential zone (also consider the adjacent nonelevated carrying idler sets):
Ensure squareness to belt stringers.
Align sets relative to one another.
Observe preset 5-times idler spacing between the carrying idler sets
adjacent to the weighed idler set.
VERY IMPORTANT: Make sure the two limiting idler sets adjacent to
the weighed idler set are parallel c.
Provisionally bolt carrying idler sets onto belt stringers.

0335
BV-H2222 GB
- 35 -
4.1.4.9 Installation of Speed Transducer

See Chapter 5.
4.1.5 Aligning
Align carrying idler sets arranged in the weigher influential zone elevated by 3
to 5 mm for max. 0.2 mm tolerance.
o
Remove all idlers from carrying idler sets 1, 2 and 3 and from weighed
idler set.
Tension six (*) 0.5 mm steel wires.
Insert first idler in one of carrying idler sets 3, and align as described
below.
Align one idler after the other terminating with the idlers of the
weighed idler set.
Align every idler side with meaned out-of-round tolerance (mark on idler shell
turned towards the steel wires) by adjusting the spindle seat of the idler in the
carrying idler set on the particular idler side.
o
To lower, refile idler side.
To raise, shim idler side, e.g. by deposit welding with subsequent

refiling.
(*) Flat belt conveyors can be aligned with 2 steel wires only.
BV-H2222 GB
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0335

Upon alignment, ensure that

o
carrying idler sets adjacent to the weighed idler sets are parallel
all carrying idler sets are square to belt stringers in the weigher
influential zone
idler spacing = 5 x L 5 mm, or N x L 5 mm, if L is unequal to 1000

mm.
Affix carrying idler sets to belt stringers by welding shims and limiting blocks
in place.
Before removing steel wires, check bolted connections for tight fit, and recheck idler alignment.
Take suitable steps to protect the surfaces of the belt stringers and measuring
modules affected by welding or other work against corrosion.
4.1.6 Acquiring Effective Platform Length

When installation is complete, acquire the effective platform length 'lng'.
Measure spindle spacings on either side of your belt conveyor and compute
as mean values:
a = (spindle spacing side a1 + side a2) / 2 = __________
b = (spindle spacing side b1 + side b2) / 2 = __________
c = (spindle spacing side c1 + side c2) / 2 = __________

0335
BV-H2222 GB
- 37 -
Effective platform length:
Enter acquired value with proper unit into the weighing electronics as shown in the
Electrical Equipment manual.
4.1.7 Cabling
Install the junction box at desired belt weigher side.
Above circuit diagram is a proposition for sensor interconnection. For cable junction,
please refer to the order-specifically instructions given in Weighing Electronics
manual.
Also observe the following:
Lead cables of load cells and (optional) speed transducer to cable junction
box (terminal box) in the protected belt stringers areas.
ATTENTION: Observe cable end lengths:
Load cell = 5 m
Transducer = 6 m
Never shorten ready-to-connect cable ends; if need be, arrange in loops.
Ground all load cells and pay heed to the local regulations.
Check to see that cable connector of (optional) speed transducer does not
affect the positive contact of friction wheel on return belt.
BV-H2222 GB
- 38 -
0335

4.2 Operating Instructions

4.2.1 Construction and Operating Principle
The specified weighing accuracy of a belt weigher relates to -10 to +40 C
nominal temperature range.
4.2.1.1 Belt Weigher

Belt Weighers of the BMC type consist of longitudinal beams, cross-beams and 4 load
cells with base plates and measured load application elements. If weigher is mounted
in inclined position, load cells only measure the portion of platform load QB vertically
acting on them. The longitudinal force resulting from the force triangles, as well as the
belt tracking forces, are picked up by the four tie-rods.
Admissible lowering of site (e.g. varying environmental loads): 0.5 mm.

0335
BV-H2222 GB
- 39 -
4.2.1.2 Tie-rods
Position weigher in belt stringers. Check to see that carrying idler set ist still properly
aligned. Its parallel alignment to belt stringers on the plane of load cell load application
also minimizes measuring errors caused by belt tracking forces.
Reliable operation requires careful and torsion-free adjustment with minimum play.
c Check to see that tie-rods can still be turned by hand.
Concave and convex washers in the represented arrangement are meant to

compensate slight displacements in height and on sides.
Cotter lock nuts to ensure the defined alignment of carrying idler sets.
BV-H2222 GB
- 40 -
0335

4.2.1.3 Load Cell and Measuring Load Application
Observe documentation of load cells and load cell mounts (see Item 4.1.1
'Items Supplied').
Screw torques: M4 = 2.4 Nm

M6 = 8.0 Nm
4.2.1.3.1 Load Cell Dismantling and Installing

To remove and install a load cell, safely support the weigher corner point and ensure
that it does not lift off by more than 1 to 2 mm.
Loosen load cell cable in cable junction box and load cell earthing cable.
Dismount U-shaped head piece and remove load cell.
If need be, mount new load cell on base plate such that type plate of cable
junction boxes point to the outside,
Observe hole pattern arrangement of set screws in foot plate - load

cell support - cable junction box.
Check to see that surfaces are absolutely clean and deburred.
Tighten bolts stepwise to proper torque.
Assemble load cell mounts as described in steps (1) to (4), apply CRC copper
paste (supplied with each load cell) to compression surfaces of pendulum
contact plate, head plates and load cells to protect them from corrosion.

0335
BV-H2222 GB
- 41 -
Place load cell mounts on load cell supports as described in step (5),
o
hold in place with set screws,
if need be, bolt new head plate onto U-shaped head piece.
Position pendulum contact plate vertically or square to weigher by aligning Ushaped head piece accordingly. Then bolt U-shaped head piece in place.
Align load cell mount with finger-tip control to ensure even load distribution
and secure with lock nut.
o
Check to see that base plate are in horizontal position, i.e. parallel to
weigher, to permit measuring force to enter vertically into load cell.
Run load cell cable and connect in cable junction box. Also connect load cell
ground cable. See 'Cabling' item.
To perform welding work after installation of load cells, and in order to
protect the load cell, connect the minus pole direct to the point of
welding.
4.2.1.3.2 Load Cell Data

Depending on nominal feed rate of belt weigher, SCHENCK load cells with the
following rated capacities are used:
0.15t / 0.22t / 0.33t / 0.47t / 0.68t or, in special cases 1.0t.
For the exact type designation, please refer to the load cell type plate.
Essential load cell characteristics:
Rated capacity: see type plate
Rated charact.: 2.85 mV/V
Maximum load:
Max. load
at
1.5 t
1.5 t
3.0 t
3.0 t
3.0 t
5.0 t
rated capacity
0.15 t
0.22 t
0.33 t
0.47 t
0.68 t
1.00 t
Note:
The stated limit values apply in conjunction with the load cell overload protection and
foot plates.
Protected to:
IP 67
Rated temperature:
-10 C to + 40 C
Service temperature:
-30 C to + 80 C
Reference temperature: + 22 C
Cable length:
5 m
BV-H2222 GB
- 42 -
0335

4.2.2 Maintaining Belt Weigher

SAFETY HINT:
Before performing maintenance, inspection and/or repair work, remove and
lock out power to the belt weigher.
4.2.2.1 Maintenance
Regularly remove material build-ups
between the recessed carrying idler sets and belt stringers (1)
in load cell area (2).
Do not remove build-ups recurring in other areas of the weighed idler set because of
the associated change in tare.

0335
BV-H2222 GB
- 43 -
4.2.2.2 Inspection
Inspect belt weigher when inspecting your conveyor system.
4.2.2.2.1 Ensuring Carrying Idler Alignment
Lift conveyor belt in weigher influential zone.
Align carrying idler sets arranged in weigher influential zone elevated by 3 to 5

mm for max. 0.2 mm tolerance.
Remove all idlers from carrying idler sets 1, 2 and 3 and from weighed
idler set.
Replace all idlers with an out-of-round exceeding 0.2 mm.
Remove material build-up from all idlers.
Tension six (*) 0.5 mm steel wires.
Insert first idler into one of the carrying idler sets 3, and align this idler
as described below.
Align one idler after the other terminating with the idlers of the
weighed idler set.
Align every idler side with meaned out-of-round tolerance (mark on idler shell
turned towards the steel wires) by adjusting the spindle seat of the idler in the
carrying idler set on the particular idler side.
o
To lower, refile idler side.
To raise, shim idler side, e.g. by deposit welding with subsequent

refiling.
BV-H2222 GB
- 44 -
0335

(*) Note: Flat belt conveyors can be aligned with 2 steel wires only.
Keep the idlers free from material build-up in the weigher influential zone.
Ensure full troughing of the unloaded conveyor belt on the carrying idlers:
o
in the weigher influential zone, and
at two further idler sets upstream and downstream of the influential

zone.

0335
BV-H2222 GB
- 45 -
4.2.2.2.2 Aligning Longitudinal and Transverse Tie-rods
c Check to see that tie-rods can still be turned by hand.
Any change in tie-rod adjustment requires carrying idler sets in the

weigher influential zone to be realigned.
BV-H2222 GB
- 46 -
0335

4.2.2.2.3 Checking Load Cell Signal
Ensure that check is performed by a skilled measuring and control

engineer !
Ensure that weighing electronics is ready to operate and conveyor
cut off.
Check load cell measured load signal (totals output signal of the 4 load cells)
in the load range between preload and preload + belt load using commercial
weights. (For load cell rated capacity [kg] and characteristic value [mV/V], see
load cell type plate.)
Display load cell signal of preload.
Place graded weights on the measuring station, if possible with the conveyor
belt lifted off.
Record load diagram as illustrated. The measuring points connecting line

should result in a straight line.
If you note bigger deviations from straight line, follow these steps.

0335
BV-H2222 GB
- 47 -
4.2.2.2.4 Checking Load Cell
Place graded weights next of every load cell, one after the other.
Record load diagram for every load cell.
Result: The load cell significant deviating from straight line, if any, requires
further testing.
The sample circuit diagram (proposition) shows the summation box of load cells and
speed transducer:
Repeat the above steps with load cell connecting cables disconnected.
Any damaged load cell should now be clearly identified.
Replace the load cell in accordance with the instructions given at Item
4.2.1.3.1 'Load Cell Dismantling and Installing'.
BV-H2222 GB
- 48 -
0335

Speed Transducer (Option)
FGA20-RSLE Type
5 Speed Transducer (Option)

5.1 FGA20-RSLE Type
5.1.1 Installation Instructions
SAFETY HINTS:
Ensure work protection at this device by having it installed by skilled
technicians and using it as originally intended only, in accordance with
supply specification, and by operating it in accordance with the
suggestions to follow.
Ensure that the rocker joint cannot detach from belt stringers and
damage your belt weigher.
5.1.1.1 Installing Speed Transducer

The speed transducer of the FGA 20-RSLE type equipped with friction wheel and
rocker is designed to acquire the belt speed at the inside of the return belt.
Mount speed transducer on weighed idler set direct or max. 5 m away.
Avoid vibration of the return belt in speed transducer area. Arrange return idler
towards transducer in return belt direction of travel as shown in sketch.

0335
BV-H2222 GB
- 49 -
FGA20-RSLE Type
Ensure 1 mm maximum out-of-round tolerance of return idler.
Remove build-ups from return idler and/or avoid build-ups, e.g. by using
rubber-coated idlers.
To avoid slip between friction wheel and belt, keep belt interior clean using
appropriate devices, so as to avoid errors in measurement.
5.1.1.1.1 Further Installation Instructions
Carefully align speed transducer with friction wheel relative to belt run. Slip
causes wear of the running ring.
Securely bolt speed transducer with joint to the provided location on weighed
idler set or belt stringers or weld in place; ensure that rocker joint does not
detach from belt stringers and damage your belt conveyor.
To ensure positive contact of friction wheel on return belt, check to see that
o
loops of sensor cable in rocker spindle area are sufficiently long
rocker joint freely moves
friction wheel is perfectly level with return belt.
5.1.1.2 Cabling
Connect cables as described in the Weighing Electronics manual and observe

the following additional hints:
Run load cell and speed transducer cables to terminal box supplied using
cable ducts. Mount terminal box in a safe location.
ATTENTION!
Observe cable end lengths:
Load cell = 5 m
Transducer = 6 m
o
Never shorten ready-to-connect cable ends; if need be, arrange in

loops.
Pay heed to the local regulations.

Check to see that the speed transducer cable does not affect
the positive contact of friction wheel and return belt and
does not interfere with the rocker spindle.
BV-H2222 GB
- 50 -
0335

FGA20-RSLE Type
5.1.2 Operating Instructions

Rolling on the interior of the return belt, the webs of the friction wheel dampen an
inductive proximity switch, thus causing the latter to output a pulse frequency
proportional to belt speed.
The number of pulses per belt meter is the speed characteristic vs-K used to
acquire the belt weigher's feed rate.
Enter this value into the weighing electronics in form of a parameter; for details, see
Weighing Electronics manual.
5.1.2.1 FGA 20-RSlE for Legal-for-trade Belt Weighers
The counter pulses of the second switch are

offset with respect to those of the first switch
by measure 'O'. The weighing electronics
continuously compares counter results and
reports error when a deviation is detected. T
is the pulse interval.
5.1.2.2 Maintenance
Ensure free movement of the rocker joint; if necessary, dismount and clean.
Check friction wheel rubber ring for wear, and replace if necessary.
Ensure positive contact with return belt.

0335
BV-H2222 GB
- 51 -
FGA24A Type
5.1.2.3 Inspection and Repair
Measure 'X':
Mild steel variant (galvanized)
= 2 ... 3 mm
Stainless steel variant
= 1 ... 1.5 mm
The friction wheel is mounted in sealed grooved ball bearings lubricated for
life. If you note bearing damage, replace speed transducer.
When replacing proximity switch, ensure proper switching distance.
When running sensor cable, observe the instructions given at the 'Installation
Instructions' item.
5.2 FGA24A Type

5.2.1 Installation Suggestions
SAFETY HINT:
Ensure work protection at this device by having it installed by skilled
technicians and using it as originally intended only, in accordance with supply
specification, and by operating it in accordance with the suggestions to follow.
The speed transducer of the FGA 24 A type is designed for measuring the belt speed
on the belt conveyor tail pulley.
BV-H2222 GB
- 52 -
0335

FGA24A Type
5.2.1.1 Suitability
Make sure the following

prerequisite is given:
DTr =
Pulley diameter in [m]
tbelt =
Belt thickness in [m]
fmin =
Smallest frequency the weighing electronics can measure

( 0.04 Hz with INTECONT and DISOCONT,
10% safety allowance for running message, etc. included)
24 =
Number of pulses per pole wheel / belt pulley revolution
Related to the pulley diameters below and assuming 10 mm belt thickness, the
following minimum belt speeds Vbelt result:
Belt conveyor
DTr
Vbelt
[m]
[m/s]
Comments
0.200 0.250 0.315 0.400 0.500 0.630
as per DIN
22101
0.15 0.19 0.23 0.30 0.37 0.46
determines
calibration
vs-characteristic [I/m] 36.38 29.38 23.51 18.63 14.98 11.94
accuracy
(*)
(*) Having been computed with 10 mm assumed belt thickness, the vs-characteristics
in table can only serve as mean values .

0335
BV-H2222 GB
- 53 -
FGA24A Type
Decisive for feed rate determination

is the vs-characteristic (number of
pulses per belt meter) to be
computed using the formula on the
right, to be then entered into the
weighing electronics.
5.2.1.2 Mounting Pole Wheel

Best mount pole wheel on webs in the belt pulley protected area. Weld or bolt in place.
The pole wheel is equipped with a centre hole d=8mm serving for adjustment to the
required diameter. Ensure min. 20 mm distance from pulley bottom in order to prevent
the pulse quality from being affected.
5.2.1.3 Mounting Proximity Switch

Mount proximity switch on belt stringers using the mounting angle. The provided hole
pattern allows for universal arrangement; two possibilities are depicted in the figure.
Arrange switch centrally to pole wheel windows. Protect the switch cables from
mechanical damage by using cable ducts.
BV-H2222 GB
- 54 -
0335

Index
Acquiring Effective Platform Length 37

Aligning 36
Aligning Longitudinal and Transverse Tie-rods 46
Aligning Tie-rods 34
Applicational Hints 7
Belt Weigher 39
Cabling 38, 50
Checking Load Cell 48
Checking Load Cell Signal 47
Construction and Operating Principle 39
Constructional Features 5
Ensuring Carrying Idler Alignment 44
FGA 20-RSlE for Legal-for-trade Belt Weighers 51
FGA20-RSLE Type 49
FGA24A Type 52
Further Installation Instructions 50
General Information 1, 8
General Information on Belt Weighers 4
Hints for Delivery 1
Hints for Special Conveyors 23
Idler Sets Permanent Alignment 30
Information on Documentation 2
Inspection 44
Inspection and Repair 52
Inspection of incoming goods 1
Installation 27
Installation and Operating 25
Installation Instructions 25, 49
Installation of Belt Stringers and Load Cell Supports 31
Installation of Carrying Idler Sets 35
Installation of Load Cells 32
Installation of Speed Transducer 36
Installation of Tie-rods 33
Installation of Weigher Supports 30
Installation Prerequisites 26
Installation Suggestions 52
Installing Speed Transducer 49
Items Supplied 25
Load Cell and Measuring Load Application 41
Load Cell Data 42
Load Cell Dismantling and Installing 41
Maintaining Belt Weigher 43
Maintenance 43, 51
Mounting Belt Weigher 26
Mounting Pole Wheel 54
Mounting Proximity Switch 54
Movable Conveyors 23
Operating Instructions 39, 51
Overview 4, 9
Planning-in Hints (The 10 Rules) 8
Preparations 27
Rail Calibration 24
Rail Joint Design 23
Rail-based Conveyors 23
Rules for Apron Conveyors 24
Rules in Detail 10
Selecting Carrying Idler Sets for Installation in Weigher Influential Zone 28
Specific Information on BMC Type 5
Speed Transducer (Option) 49
Storage hints 1
Suitability 53
The 10 Rules 9
Tie-rods 40

0335
BV-H2222 GB
- 55 -

BVH2222GB - Belt Weight Feede

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MULTIBELT Belt Weigher BMC

Installation and Operating Instructions

24h Emergency hotline:

+49 (0) 172 - 650 17 00 Discontinuous Weighing Technology

Light Duty Weighing & Feeding

Transport & Logistics

Components & Spare Parts

MULTIBELT Belt Weigher BMC, Installation & Operating Instructions

1 General Information ..........................................................................1

3 Planning-in Hints (The 10 Rules)......................................................8

4 Installation and Operating ..............................................................25

5 Speed Transducer (Option) ............................................................49

5.1.2 Operating Instructions......................................................................................51

MULTIBELT Belt Weigher BMC, Installation & Operating Instructions

Hints for Delivery

Carefully inspect packaging for any damage during transit.

If damage is discovered, contact your carrier immediately and file a claim

Check items supplied for completeness. For information on items supplied,

Additionally observe the

MULTIBELT Belt Weigher BMC, Installation & Operating Instructions

1.2 Information on Documentation

Load cell type

Possible belt widths

For detailed description of belt weigher, see Chapter 4 'Installation and

MULTIBELT Belt Weigher BMC, Installation & Operating Instructions

Speed measurement system:

MULTIBELT Belt Weigher BMC, Installation & Operating Instructions

General Information on Belt Weighers

Proper mounting is an important consideration for system accuracy.

Throughput and consumption measurement in production plants

Balancing of amounts fed in and out

Reporting of load limits

Batching in load-out stations

Weighing platform for accommodation of user's idler sets

Overload protected load cell(s) with a high degree of protection

Cable junction box for connection of sensors

Fixing elements for the installation

MULTIBELT Belt Weigher BMC, Installation & Operating Instructions

Specific Information on BMC Type

If belt speed acquisition is omitted (belt load measuring system), a constant

For accuracy data, please refer to the following documention:

2.2 Specific Information on BMC Type

Platform (weighing platform between conveyor belt

Easy integration into user's belt stringers, no

Belt tensioning forces absorbed via longitudinal and

MULTIBELT Belt Weigher BMC, Installation & Operating Instructions

Specific Information on BMC Type

The weighers of the BMC series are always designed and

Types, design principle (RTN and VPN based)

Length and width:

As a function of conveyor size and type

As a function of conveyor type

Against direction of travel or take-off with inclined

Adjusted (to conveyor):

MULTIBELT Belt Weigher BMC, Installation & Operating Instructions

Specific Information on BMC Type

Belt weigher with weighing platform suitable for

2.2.2 Applicational Hints

big belt width (--> bulk quantities fed)

installation in inclined conveyor systems (ascending and descending)

suitability for trade use

low natural frequency (--> insensitivity to vibrations)

typical scenarios are found in