Weigh Feeder Ref Manual

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INDEX
Section
1. Introduction
2. System Overview
Page
No.
2
3. Technical Specifications
4
34
4. Installation
53
5. Operation Instructions
65
6. Preventive Maintenance Checklist
83
7. Symptoms and Faults
90
8. Factory Settings
94
9. Bill of Materials
100
10. Drawings And Documents
107
11. Your contact at Sartorius
109
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Project Manual for Weigh Feeder & Bin Level Measuring System
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SECTION 1
INTRODUCTION
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Sartorius Mechatronics India Pvt. Ltd., headquartered at Bangalore, is 100% owned subsidiary
of Sartorius AG, a 135-year-old company, with its headquarters at Gottingen, Germany. Its
manufacturing activities include Mechatronics, Biotechnology, Hydro Dynamic Bearings and
Environmental Technology.
The Mechatronics division deals with almost all type of weighing system like
ULTRA AND HIGH PRECISION LAB BALANCES.
GOLD AND CARAT BALANCES.
PLATFORM SCALES.
ELECTRO CHEMISTRY PRODUCTS.
HIGHLY ACCURATE AND RELIABLE LOAD CELLS.
WEIGHT INDICATORS
ADVANCED BATCHING CONTROLLERS.
WEIGHING ACCESSORIES LIKE MOUNTING KIT, JUNCTION BOX ETC.
SOFTWARE (CUSTOM & STANDARD)
TANK WEIGHING SYSTEM
WEIGHBRIDGES
BELT SCALES
BATCHING SYSTEMS
HOPPER WEIGHING SYSTEMS
WEIGH FEEDERS
LOSS IN WEIGHT FEEDERS
Weighing System For Special Application.
Owing to its sustained accuracy and reliability, Sartorius have installation of various types of
weighing system in almost all types of industries like, Steel, Power, Petrochemicals, Ports, RTO
Check Posts, Fertilizers, Refinery, Petrochemical, Glass, Food & Beverage, Pharmaceuticals,
Chemicals etc.
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SECTION 2
SYSTEM OVERVIEW
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2.1 System Description
The system consists of
Bin level measuring system
Weigh feeder
Bin level measuring system
Bin level Measuring system continuously monitors the weight of material contained.
The vessel rests on 4 supports. The system consists of two live load cell and two fixed
bearings. Junction boxes used to interconnect load cells and weight indicator.
The direction of the mounting kit is such that it will arrest horizontal movement in any
direction. . The weight of material in the bin is measured with the help of high precision strain
gauge based load cells. Each load cell has an integral cable of 12 Mtrs. This cable from each
load cell is connected to the cable junction box. The average output from the load cell, thus
derived, is fed to the indicator via a load cell extension cable. The indicator is calibrated in
such a way that, the weight of the Bin is made to zero and the display shows only the contents
of the Bin i.e. material to be weighed. As an analog output module is installed, it will give an
isolated analog output, proportional to the calibrated scale.
The weight indicator [PR1613/00] is a microprocessor based with vacuum fluorescent
display for load indication. The controller provides P.F contacts for lim-1, lim-2 and ADC error.
The indicator has profibus output for communicating with customers PCS.
A 6 digit, 100mm large figure display (LFD) is provided to view the weight of material
in the bin at remote place.
The Junction box (es) takes the load cell output, and gives the average signal to the weight.
Weigh Feeder
Weigh feeders ensures the flow of material at a preset rate. The material passing over the belt
feeder exerts a downward force proportional to the weight. The weight is continuously
measured over a defined length of the belt by load cells and a speed sensor (encoder) gives
signals proportional to velocity of the belt. These two quantities are multiplied to get actual
rate of flow. Actual rate (measured rate) is compared with set rate and the error signal is given
to the Drive to control the rate of flow. The amount of belt load at each pulse is integrated
with respect to time to give the totaliser.
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The mechanical part consists of weigh feeder assembly, two bending beam type load cells,
speed sensor, calibration chain and junction box for interconnection.
The controller displays the belt load in kg/mtr, speed in mtr/sec, set/actual rate of flow in TPH
and cumulative totaliser in tones in a vacuum fluorescent display. Configuration and
calibration of the controller is through soft touch keys. P.F contacts are provided for feeder on,
material starvation, Fault and totaliser pulse. The controller gives a profibus output and
potential free contacts which can be connected to PCS.
An 8 digit 100mm large figure display is provided to view rate and totaliser.
The Junction box(es) takes the load cell output, and gives the average signal to the weight
indicator that shows the actual weight digitally.
The remote panel houses Bin level indicator PR1613/00 indicator as well as Weigh feeder
electronics X4-process controller, variable frequency AC drive to control the speed of the
driving motor, step down transformer, relays, MCCBS, CONTACTORS, MPCBS, MCBs and
annunciation LEDs. The indicator PR1613/00 and controller PR5510/00 provides digital
outputs, which are connected to relays to provide potential free contacts to customers PCS.
The RS232 outputs are converted to current loop for interfacing with large figure display.
A local panel is provided with control switches for feeder on/off, remote/local panel selections.
Selection, set/actual selection, gravimetric/volumetric, emergency off etc. The weigh feeder can
be operated from the remote panel/Local panel/PCS.
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2.2 Basic Blocks of system
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Bin level Measuring level
Bin level measuring system, which includes the following

1. Compression type load cell (PR6201)
2. Mounting kit for above load cell (ST2501).
3. Fixed bearings supports (ST2552)
4. Junction box for load cell (ST2620/03)
5. Digital indicator (PR1613/00) with following option cards
PR1601 CL card for large figure display
PR1606/02 Analog output card
PR1621 Profibus interface card
6. 6 digit, 100mm Large figure display (ST2521/10)
1.0 Load cell (PR6201):
Load cells are heart of the system. They are strain gauge based transducers, which converts
mechanical force (strain) into electrical signal (mV) when given an excitation voltage.
Strain gauges are arranged in a wheat stone bridge network by bonding to the specially
designed/machined steel membrane. This is housed in an SS enclosure with inert gas filled and
comes with a protection of IP68.When load is applied the resistivity in strain.
Gauges changes proportional to applied load. The change in resistance is converted to
electrical signal by giving an excitation voltage. Loadcell will have an integral 4-core cable of
standard length. Two cores are connected for supply voltage to the load cell & other two for the
measuring voltage from the load cell
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2.0
Mounting Kit (ST2501):
Mounting kits are mechanical parts used to mount the load cell. The basic purpose of the
mounting kit is to ensure proper seating / installation of the load cell. These are made of
machined plates made to very narrow tolerances. This leads to better measuring of the
weight and thus ensures better accuracy.
Mounting kit (ST 2501/28) For PR 6201/35N(300T)
Mounting kit (ST 2501/29) For PR 6201/55N(500T)
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3.0 Fixed bearings (ST2552):
The fixed bearings are mechanical supports provided to the bin. These bearings share the load
of the bin. In each system two live load cell and two fixed bearings are used. The fixed
bearings are used in bin weighing where the load is equally shared by all the supports.
Fixed Bearing (ST 2552/08) for loadcell PR 6201/35N(300T)
Fixed Bearing (ST 2552/09) for loadcell 500T
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4.0 Junction Box (ST 2620/03):
When more than one load cells are used, the output of each load cell has to be measured.
Instead of taking all the load cell cables to the indicator, a single cable is connected to the
indicator. In this case all the load cell cable is terminated at a place near the level indicating
system. For this purpose a Cable Junction Box is used. It has a PCB with connectors, where in
the individual load cell cable is terminated. Internally all the load cells cables are connected in
parallel. Thus we get an average output, which is fed to the indicator via a special cable.
Junction Box is made out of Die Cast Aluminum and comes with a protection class of IP65.
This ensures that there is no effect of moisture / dust.
Salient Features Of Sartorius Junction Box (ST 2620/03):
IP 65 protection class.
Made out of Die Cast Aluminum thus corrosion free.
Powder quoted painting for surface protection.
Double compression gland for cable entry.
Good quality connectors reduce problems arising out of bad contacts.
Paralleling of load cell done by a PCB, thus eliminating problem due to loose cable
connections.
5.0 Weight Indicator (PR1613/00):
The PR1613/00 are microcomputer-controlled weight indicators, which are designed especially
for industrial weights & measures application. The units are particularly suitable for cranes,
platform, weighbridges, tanks and vessels, batching systems and s weight indicators in
intelligent control systems.
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Special features and functions are:
EC type approval,
EC certificate conformity acc. to directives 90/384/EEC and EN 45501,
EC certificate of conformity acc. to directives 89/336/EEC (EMC),
EC certificate of conformity acc. to directives 73/23/EEC,
Multi-range weighing applications can be realized easily
Built-in-self-test and analog test function.
2 adjustable limit values,
Load cell supply voltage 12V or 20V,of
Built-in software clock for printing time and date on reports,
High long-term stability and reliability,
Input signal filter can be switched on and off via software,
Bright vacuum fluorescent displays,
Sequences for easy calibration and configuration,
Calibration without calibration weights possible,
Subsequent dead load suppression without re-calibration,
Calibration data can e stored in non-volatile EPROMs, and protected against overwriting by
switch.
Configuration data are protected against power failure by back-up battery and can be
protected against overwriting by code number.
The indicator has got built in 6 digital inputs and 12 digital outputs. The digital outputs that
are configured are as follows.
Limit 1
LIMIT 1 output is active if weight > set value
LIMIT 1 output is switched off if weight
set value
Limit 2
LIMIT 2 outputs is active if weight < set value
LIMIT 2 output is switched off if weight set value
For programming the parameters (C25 to C28) refer operation manual PR1613
ADC Err
Adc error is displayed when the ADC is faulty, when the load cell signal is high or low.
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Current loop converter card for Large figure display (PR1601):
The current loop converter card (PR1601) is interfaced with PR 1613 weight indicator for
conversion of RS 232 output to 20mA current loop for communication with large figure
display.
Analog output card (PR 1606/02):
The PR 1606 converts the binary value of the PR 1613 into a respective analogue value. The
kind of value (gross, net, etc) can be defined by means of parameter C12 during configuration.
By means of parameter C17 the offset can be set to 2.+10V DC, and 4.+20mA during
configuration.
Profibus Interface Card (PR1621/00):
The profibus interface card (PR1621) supports data rates up to 12 Mbaud. Communication is
bi-directional. It acts as a profibus slave.
6.0 Large Figure display 100mm(ST2521/10):
The Large Figure display (2521/10) is a 100mm, 6 digit, 7 segment Red LED operating at
230V, 1, AC supply. The display is interfaced to view the weight at field. This is interfaced
with weight indicator by 20mA current loop. The display has selectable baud rate setting.
Note: For Economy and ease of operation the bin level indicator is housed in the weigh feeder
panel.
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Weigh feeder
Weigh Feeder is an electromechanical system and includes the following

1.0
Mechanical Assembly
2.0
Bending beam load cell (MP 47/51 C3, 21 C3, 12 C3)
3.0
Calibration chain
4.0
Junction Box for load cell (ST 2620/05)
5.0
Junction Box for encoders and limit switch (ST 2620/16)
6.0
X4 Process Controller (PR5510/00) with following option cards

Control I/O 6/12 Opto (PR5510/12)
Analog output card (PR5510/06)
Profibus interface card (PR1721/31)
7.0
Current loop converter module (ST5011/00)
8.0
Encoder (ST 5013/13)
9.0
Encoder Interface Module (ST 5010/00)
10.0
AC Drive ( ST 5020)
11.0
Remote Panel (ST 5010/21)
12.0
Local Panel (ST 5000/00)
13.0
8 digit, 100mm large Figure Display (ST 2521/11)
1.0
Mechanical Assembly:
The mechanical assembly consists of a endless belt, drive and driven pulleys, impact idlers,
carrying idlers, return idler, gravity roller, take up, skirt board, scraper, motor, gear box,
couplings, bending beam type load cells, encoders, structural frame, feed and discharge chute,
material presence detector and calibration chain.
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a) Pulleys are of welded construction with rim rolled out of MS plates and shaft of
EN8 quality. They are machined, statically balanced & rubber lagged. These pulleys are
supported on roller bearings housed in plummer block.
b) Idler are made out of ERW Seamless pipes with EN8 shaft & deep groove ball bearings
housed in pressed CRCA housings. All idlers are grease packed for life.
b.1) Impact idler: are provided with rubber rings over the idler pipe to absorb shock
when material is dropped from the feed chute.
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b.2) Carrying & weighing idler: - These idlers are made out of seam less pipes, duly
machined to limit the radial run out.
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b.3) Return idler:- These idlers are made out of seam less pipes, duly machined to limit
the belt sag.
c) Belts are standard conveyor belts of nylon and rubber material. They are made endless
by hot vulcanizing with required tolerance.
d) Drive Assembly
d.1) Motor: Standard squirrel cage induction Motor, 3ph, 50Hz.TEFC,F Class
insulation, foot mounted adequately sized for the duly requirement.
d.2) Primary gearbox: standard helical gearbox adequately sized for torque and motor
rating.
d.3) Secondary gearbox: standard worm gear box adequately designed for torque and
Weigh feeder rating.
d.4) Coupling: Flexible pin & bush coupling suitable for transferring torque.
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The drive assembly for feeder with primary and secondary gearbox.
The drive assembly for feeder with primary gearbox.
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e) Gravity roller: Belt being flexible and elongates while in use. In order to maintain
constant tension gravity roller has been introduced. This is machined out of shaft and
is supported on bearing. The frame is pivoted at one end and shaft is made to rest on
return belt.
f) Feed chute: Feed chute is designed to guide the material from bin to weigh feeder. A
vertical gate provided at front side of chute to adjust the material bed height (during
start up of feeder). The chute is also provided with replaceable liner to prevent wear out
of main chute plate and also assist in easy flow of material. In addition chute is also
fitted with bin vibrator. In the event of material choking, vibrator gets energized and
enables the flow of material (Ref sketch). For isolation feeder from chute(during
maintenance) a plate gate is provided.
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The weigh feeder feed side figure is shown below .
The plate gate below feed hopper figure is shown below.
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g) Material presence Detector: - Its a lever mechanism fitted with a limit switch, When
there is insufficient material, this limit switch gives a I/p to the controller to switch on
the vibromotor
h) BeltSway switch :-It is a limit switch fitted on the bottom support. Where ever there is
sway in the belt, this switch gives a i/p to the controller.
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i) Discharge chute : is provided to guide material from weigh feeder to receiving
conveyor. This is fabricated out of MS plate.
j) Scrapers: are fabricated steel with rubber strip to clean both carry and return side of
belt.
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k) Skirt board: are fabricated out of steel plates with end rubber skirting to prevent
material spillage from feeder.
l) Take up: Screw take-ups are provided to adjust and provide suitable tail tension of belt.
They are machined out of MS rods fitted with take up bearing unit at tail pulley.
2.0
Load cell:
Load cells are heart of the system. They are strain gauge based transducers, which converts
mechanical force (strain) into electrical signal (mV) when given an excitation voltage.
Strain gauges are arranged in a wheat stone bridge network by bonding to the specially
designed/machined steel membrane. This is housed in an SS enclosure with inert gas filled and
comes with a protection of IP68.When load is applied the resistivity in strain
Gauges changes proportional to applied load. The change in resistance is converted to
electrical signal by giving an excitation voltage. Loadcell will have an integral 4-core cable of
standard length. Two cores are connected for supply voltage to the load cell & other two for the
measuring voltage from the load cell.
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The figure below shows the mounting arrangement of the loadcell.
3.0
Calibration Chain:
The calibration chain is used for calibrating the system. The chain is made with numbers of MS
rollers. These chains can be used for period checking and calibration of the system. The weight
of the chain in kg/mtr is punched on the chain.
4.0
Junction Box for load cell (ST 2620/05):
The junction box has connectors for termination of load cell near weigh feeder When more
than one load cells are used, the output of each load cell has to be measured. Instead of
taking all the load cell cables to the indicator, a single cable is connected to the indicator. It
has connector, where in the load cell cable is terminated. The load cells cables are connected in
parallel. Thus we get an average output, which is fed to the indicator via a special cable.
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5.0
Junction Box for encoder and limit switches (ST 2620/16):
The junction box has connectors for termination of encoders & beltway near weigh feeder. The
encoders and the belt sway switches are terminated to the remote panel through this junction
box.
6.0 X4 Process Controller(PR 5510/00):
The instrument is microprocessor controlled with a multitasking operating system consisting
Bios and Firmware. Equipped with a high precision fast weigh point-Analog Digital Converter,
Operator-Interface multiline VCF-display and a multi foil key keyboard at front side and the
process-interface at rear side (after wards connectable plug-in option cards, flexible
combinable). In addition to firmware are several Sartorius-Application programs (B.W, W.F,
L.W.F, PRO, LOG, BATCH, FLOW, TRUCK.) loadable or own customized programs. It
combines the functions of a highly convenient operator interface, weighing and batching
controller, PLC and interfaces. The device is programmable conform to IEC61131 standard
With PR1750 it is possible to adapt PR 5510 easily to custom applications.
Basic Features
One internal weighing point, accuracy 6000 d OIML
13mm fluorescent display for weight
Additional 2-line 5mm dot matrix, each for 20-digit alphanumeric. Text programmable for
messages, operator guidance, values...
front panel controls, multi-function keys and soft keys.
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Closed aluminum-steel housing, front panel protection type IP 65, IP 30 for the rest of the
instrument.
Suitable for panel mounting (inserted through the panel cutout and easy to by clamped from
rear)
Plug able rear panel connectors for load cell, in-output, communication and supply
Compact wide-range supply 115230V for electronic and load cell supply
An optional normal PC keyboard (PS2) instead of the front panel keypad can be connected.
A simple serial RS 232 interface is built in (Built-in) and available on the DSUB-9 socket.
Configurable for e.g. printer, remote display, terminal, communication and Flash It (not for
Modem).
RS 232, analog output PR5510/06 and BCD output excepted, all outputs are galvanically
isolated.
1MByte Flash EEPROM for Firmware and IEC61131-Programms, not volatile
1MByte SRAM-memory for work data including system, data, tables and ALIBI, volatile
backup permanently by Lithium-Battery
2kByte EAROM-memory for CALIBRATION and Configuration-data, not volatile.
Analog test for the analog-digital converter.
Configurable for e.g. printer, remote display, terminal, communication and Flash It (not for
Modem).
RS 232, analog output PR5510/06 and BCD output excepted, all outputs are galvanically
isolated.
1MByte Flash EEPROM for Firmware and IEC61131-Programms, not volatile
1MByte SRAM-memory for work data including system, data, tables and ALIBI, volatile
backup permanently by Lithium-Battery
2kByte EAROM-memory for CALIBRATION and Configuration-data, not volatile.
Analog test for the analog-digital converter.
Control I/O 6/12 Opto (PR5510/12):
This module converts the external binary process signals into the internal signal levels of the
weighing controller or vice versa (DIGITAL INPUTS or DIGITAL OUTPUTS in short DIO)
This module has 12 digital outputs for process control, galvanically isolated with passive optocoupler outputs (max. 25mA) each with two pole potential free outputs and 6 digital inputs
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for process control, galvanically isolated by means of opto-couplers. The input signal is
logic0 with open input each with two pole potential free input.
Analog out card (PR5510/06):
The module is used for analog value of the displayed weight this is a single output 20mA(10V
output only with external 500Ohm resistor. The range is 0/420mA configurable via software
SETUP.
This current output corresponds to error output & this is fed to drive for controlling the motor.
Profibus interface card (PR1721/31):
The profibus interface card (PR1721/31) is a profibus_DP slave module. The module contains
powerful circuitry for connection to Profibus DP according to IEC61158, ASIC SPC3 chip
technology with transfer rates upto12 Mbit/s.
7.0
Current loop converter module (ST5011/00):
The current loop converter card is interfaced with PR 5510 controller for conversion of RS 232
output to 20mA current loop for communication with large figure display.
8.0
Speed sensor (Encoder)(ST 5013/13):
The speed sensor coupled to an idler senses the speed of the feeder with 5V DC supply from
the controller. The pulse output is fed to the controller. An additional encoders is coupled to
the drive pulley for ref speed to check for belt slip if any. If pulley speed is more than belt
speed (i.e. belt slip) an alarm is displayed
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Encoder mounted at drive pulley figure is shown below
Encoder mounted at return idler figure is shown below.
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9.0
Encoder Interface Module (ST 5010/00):
Encoder interface is a module for dividing the frequency of the encoder output to required
frequency the input frequency is 0 to 10 kHz and output frequency is 0 to 55 HZ. The divider
setting can be selected with the dipswitch selection depending on the requirement. The is also
annunciation for power ON, pulse out, Error and pulse IN and pulse OUT. If the frequency
exceeds 55 Hz there is an error output.
10.0
AC Drive (ST 5020)
The Ac Drive is housed inside the panel, the speed of the motor is controlled by the drive. 0/4- 20mA current input or. 4.20mA error input is fed externally from the controller
corresponding to the difference between the set rate and actual rate. This in turn controls the
speed of the motor. The Drive has digital inputs for start, stop, reset etc. It also provides fault
output, drive ready output, which are programmable.
11.0
Remote Panel (ST 5010/21)
The remote panel is common to both the BLMS and weigh feeder for economy and ease of
operation and houses the following
Digital indicator (PR1613/00) with option cards.
X4 Process Controller (PR5510/00) with option cards.
Current loop converter module (ST 5011/00)
Encoder Interface module (ST 5010/00)
The remote panel also houses the switchgears like MCCB, MPCB, Contactors, MCB, Relays, AC
Drive, Input & output Reactors, PR 1613/00, X4 controller, Terminal blocks, Panel lamp, Fan &
filter, Annunciation Lamps, 24V DC power supply Unit & Service socket. The various
input/outputs configured in the panel are as follows.
Annunciations:
230V AC Cluster LED Lamps for Red, Yellow, Blue (Phase Presence indication) and CV ON
24V DC Cluster LED lamps for DC ON, Feeder ON, Vibro ON, Local selected & Fault.
Controls:
E.off
Stay put push button
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Analog inputs/outputs
1. Load cell Input:
mV input from load cell corresponding to load on load cell for BLMS.
mV input from load cell corresponding to load on load cell for weigh feeder.
2. Analog Outputs:
4-20mA corresponding to load from PR 1613/00 indicator.
4-20mA corresponding to error output to drive from X4 controller.
Digital Input/Output
1. Digital Input/Output - PR1613/00 indicator
Inputs: No connection
Outputs
Limit1
Limit2
Adc Err
2. Control I/O 6/12 Opto (PR5510/12) card1 - X4 controller
Inputs:
Encoder1
: field
Encoder2
: field
Set/Actual
: local panel
Local/Remote selection
: local panel
Volumetric/gravimetric
: local panel
Belt sway
: field (limit switch)
Outputs:
Profibus Feeder ON: To switch on the feeder from customers PCS by profibus connectivity.
Material starvation: It is a condition (fault) that occurs when feeder fails to achieve set rate
even after feeder running at maximum speed. i.e. there is insufficient material. This fault
occurs after vibro motor on (through MPD switch) and still material not available.
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Totaliser Pulse: This is the totaliser pulse output. This interval can be set from the controller.
i.e. pulse for every 1,2,5or 10 increment.
Cumulative fault: This is output from the controller for drive fault & controller fault. When
there is a cumulative fault from the controller the feeder will trip.
Vibromotor ON: When there is no material,MPD switch gives signal and the vibro motor is
switched ON and after the preset time delay it is switched OFF.
Belt Overload : The actual belt load is more than the set value in the controller.
Profibus Feeder OFF : To switch off the feeder from customers PCS with profibus input.
Feeder ready: Controller healthy
3. Control I/O 6/12 Opto (PR5510/12) card2 - X4 controller
Inputs:
Increment
: local panel
Decrement
: local panel
Mat presence
: field
Drive fault
: AC Drive
Feeder ON
: Feeder ON relay
Spare
Outputs
: No connection
Output potential free contacts :

FEEDER ON
MATERIAL STARVATION
TOTALISER PULSE
CUMULATIVE FAULT
BELT OVERLOAD
VIBROMOTOR ON
FEEDER READY
LIMIT1
LIMIT2
ADC ERR
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RS 232 communication
1. CL output from PR 1601 card PR 1613
The indicator communicates with LFD via this card, as the distance is more
2. Built-in RS 232 from X4 controller
The controller communicates with LFD via built-in RS 232 after conversion to Current Loop by
converter module, as the distance is more.
12.0
Local Panel (ST 5000/00)
The local panel is a wall-mounted panel with dimension 380X300X155mm(WXHXD). This panel
has control switches and LED annunciations. When Local mode is selected the feeder can be
stated from local panel.
The controls in the local panel are
1.0
Remote/Local selector switch
When remote mode is selected the Feeder can switched ON from PCS or through profibus.
If local is selected the feeder can be switched ON from local panel.
2.0
Feeder ON/OFF by spring return switch.
When local panel is selected the Feeder can switched ON by this Feeder ON switch
But feeder can be switched OFF from any panel irrespective of the selection made.
3.0
Gravimetric/volumetric by selector switch
The feeder can be run in gravimetric or volumetric depending on the selection made by this
selector switch.
4.0
Set/Actual by selector switch
In large figure display the set value and actual value can be viewed depending on the selection
made by this switch.
5.0
E-Off stayput push button to put off the total system during emergency
condition.
6.0
Increment & Decrement push buttons
These push buttons are provided to increment and decrement the set value.
The panel is also provided with annunciations for Feeder ON, VIB ON and Fault
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Setting from local panel:

The rate and speed in gravimetric and volumetric mode can be respectively set from the local
panel.
The setting and controls from the local panel are as follows:
1. Select the remote/local switch as local.
2.For gravimetric mode select the selector switch as gravimetric.
3.Select the set/actual switch as set.
4.Using increment and decrement pushbuttons set the value.
5.Now select actual to display the actual rate in LFD.
6.Switch ON the Feeder.
7.For Volumetric mode, select the selector switch as volumetric.
13.0
Large Figure Display (ST2521/11)
The Large Figure display (2521/11) is a 100mm, 8 digit, 7 segment Red LED operating at
230V, 1, AC supply. The display is interfaced to view the weight at field. This is interfaced
with weight indicator by 20mA current loop. The display has selectable baud rate setting. The
rate and totaliser values can also be viewed.
Note:
To view the totaliser reading in large figure display select ACTUAL in set/actual selector switch
and press increment and decrement pushbutton at the same time.
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SECTION3
TECHNICAL SPECIFICATION
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BIN LEVEL MEASURING SYSTEM

Load cell:
Make
Sartorius
Type Of Load cell
Compression type
Type No.
PR6201
Housing Construction
Full stain less steel construction, hermetically

sealed (IP 67), filled with inert gas
Type No.
ST 2620/03
MOC
Die Cast Aluminum
Protection
IP 65
Painting
Powder Quoted
Glands
4 Nos, Double Compression
Type No.
PR 1613/00
Housing
Aluminum.
Protection
IP 65
Weighment Display
7 Digits, 7 Segment plus dimension signs and

status. Height 12.5 mm. Vacuum
fluorescent display. Bright green.
Load cell Input
6 Wires
Load cell Supply
12 / 20 VDC
Minimum Load cell

Impedance
< 100 .
Junction Box:
Weighing Indicator
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EC Type Approval
As per EN 45 501 OIML R76
Linearity
< 0.007%
Internal Resolution
1,80,000 Counts
Conversion Time
50 ms
Input Signal Range (Net)
2.4 mV To 36mV
Input Signal Range (Tare)
0 mV To 33.6 mV
Temperature Effect On Zero
< 0.1 V / K RTI
Temperature Effect On Span
< 0.006% / 10K
Analog Filter
Active Butter worth Low Pass, 40dB / Decade.

Fcut= 2 Hz.
Mains Voltage
110V / 220VAC, -15% / +10%, 50/60 Hz.
Power Consumption
22.5 W / 30 VA
Operating Temperature
-10C To +55C
Serial Interface
Other Interface
Max 4 Nos (Depends On Configuration)

RS 232
RS 485
Current Loop
Analog Input / Output
Parallel Printer Interface
BCD Output
Profibus DP Slave
Software Options
Weighbridge Application
Batching Application
Communication Protocol.
Keyboard
Integrated
Integrated PLC Function
Inbuilt 6 Digital Inputs / 12 Digital Outputs
Programmability
Freely, as per customers requirement
Calibration & Configuration
Totally through software.
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Large Figure Display
Type
6 Digit Large Figure Display
Model
ST 2521/10
Voltage
110 /230 V AC, 1 Ph, Main power.
Power
2555 Watts max
Operating Temp
5 to 55 C
Storage Temp
5 to 65 C
Relative Humidity
Upto 95% RH Non condensing.
Size
700(L)X140(H)X65(D) mm
Character Size
100mm height, 7 segments+ dp
LED Color
Red
Characters table
ASCII CHAR. (Code 30H to 5 FH)
Protocol
Full duplex, ASCII coded, STX-ETX
20 mA current loop and RS 232

communication.
Selectable 50,110,300,600,1200,2400,4800,
9600 baud
Bits/character
7 or 8 selectable.
Stop Bits
One
Parity
Even/Odd/None.
Setup parameters storage
In an EEPROM- Non volatile MEM.
Message Format
STX, MODE, STATUS, WEIGHT, ETX as per

remote display format.
Interface by
Data Transfer Rate
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RS-232 to Current Loop Converter Card

Model
Application
PR1601
20 mA bidirectional,serial,optocoupler isolated
current loop interface for balanced
transmission line, Galvanically separated from
external device. Optionally the interface card
can be interfaced with a relay which prevents
an interruption of Tx current loop via more
than one unit in case of a defect
Supply of loops
By non regulated internal 910V DC from

PR1613
at 66 in active mode
By 1231v DC externally in active mode
Voltage Drop Tx/Rx
4V minimum with 200 burden and per loop
Signal level
Logic high (mark) =18.22 mA

Logic low (space)=0.1mA
Baud Rate
Settable to 300,600,12002400 or 4800 baud
Cable length
1000 meters to maximum, using a pair wisely

twisted and screened cable
Connection
Line 2 of Pr1613
PR 1606 /02
Current Output Card

Model
Application
Interface Module for analog output signals of

gross or net or tare weight valves as shown in
At the front display. See parameter C12 of
PR1613 for configuration
Voltage loops
010V
2-10V
Rl > 5k
Current output
020mA
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420mA
burden 0.500
Resolution
Accuracy
Approx 1%(2% for current output)
Connection
Line 3 of PR1613
Default values
Output
Zero
f.s.d at 5000d
4096 bit provided f.s.d
4096 divisions
Gross weight
0V and 0mA, or 2V and 4mA
10V and 20mA
Profibus Interface card

Type
Profibus DP slave
Model
PR 1621
Rate
2Mbaud
Communication
Bi-Directional
Write into
Register PA
Write From
Register PC, PD, PB
Connection
To line 3 of PR1613
Note: The option cards PR 1621 and PR 1606/02 cannot be used together as they are
connected to same line of PR 1613/00.
For equipment wise rating ref enclosed chart-BLMS
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WEIGH FEEDER
Conveyor type
: Belt
Remote Panel :
Model
: ST5010/21
Mounting
: Floor mounted
Dimension
: 2100X800X600(HXWXD) mm
Paint shade
: RAL 7032
Display
: 7 Digits, 7 Segment plus dimension signs

and status. Height 12.5 mm. Vacuum
fluorescent display. Bright green for Bin
level measuring system.
: 7 Digit plus status symbols text: 2 line, 20
characters, multiline VCF-display for weigh
feeder
Inputs
Power supply
: 415V, 50Hz 3, AC
230V, 50Hz, 1, AC to controller
Load signal
: corresponding to material load on the belt

from loadcell
Speed signal
: corresponding to speed from encoder.
Belt sway
: limit switch
Material presence
: limit switch.
PF contacts from local panel
: for Feeder ON/OFF, Set/Actual,

Gravi/volumetric, increment, decrement and
E.OFF
PF contacts from PCS
: Feeder ON/OFF, External interlock
Outputs
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Excitation
: 12V to loadcells.
5V to encoder
3, 415V controlled AC
: conveyor motor
3, 415V AC
: vibro motor
Potential free contacts from

weigh feeder
: Feeder ON.
Fault.
Material starvation.
Totaliser pulse.
Belt Overload.
Feeder ready.
Vibro motor ON.
Potential free contacts from

BLMS
: ADC Err
Limit1
Limit2
Communication
: 6 digit Large figure display for BLMS

8 digit Large figure display for weigh feeder
Digital output to local panel

(annunciation).
Analog output (4..20mA)
: To drive
Profibus communication
: To customers PCS
24V Fault, vibro ON & Feeder ON
Local Panel:
Model
: ST5000/00
Mounting
: Wall mounted
Dimension
: 300X380X155(HXWXD)mm
Paint shade
: RAL 7032
Inputs
For Annunciation from Remote
panel
: 24V Fault, vibro ON & Feeder ON
Outputs
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outputs to Remote panel
: Feeder on/off
Set/Actual
Gravimetric/volumetric
Increment/decrement
Remote/local
E.off
24V Fault, vibro ON & Feeder ON
Load cells :
Make
Sartorius
Type Of Load cell
Bending Beam
Quantity
2 Nos per system
Type No.
MP 47
Accuracy
0.03 %
Minimum dead load
0% rated capacity
Safe Overload
150%rated capacity
Rated Output
2 mV/V
Tolerance On Rated Output
+/- 0.257% Cn
Tolerance On Zero Signal
+/- 1% Cn
Repeatability
< 0.01% Cn
Creep (During 30 Min)
< 0.017% Cn
Temperature effect on Zero
< 0.023% Cn / 10K
Temperature effect on output
< 0.011% Cn / 10K
Input Impedance
400 +/- 20
Output Impedance
350 +/- 3.5
Insulation Impedance
<2000 X 106
Recommended Supply Voltage
10 V
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Maximum Supply Voltage
15 V
Normal ambient temp. range
- 10 C To + 40 C
Resistance Against Vibration
20g, 100h, 10Hz. 150 Hz
Usable ambient temp range
- 20 C To + 65 C
Integral Load cell Cable
3m, 4 wires with screen
Ingress Protection
IP 67
Junction Boxes:
Type No.
ST 2620/05 & ST 2620/16
Quantity
1 No each.
MOC
Die Cast Aluminum
Protection
IP 65
Painting
Powder Quoted
Glands
Double Compression
RV158-011AAA66N-01024
Make
PEPPERL+FUCHS
Supply voltage
5V DC
Max.per channel 20 mA, conditionally short

circuit proof
Output type
RS422, incremental
Rise time
100ns
Out put frequency
Max 200kHz
Encoder:
Model No.
Operating Consumption
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Rotation speed
: Max 12000 min1
Starting torque
Shaft loading
Axial
Radial
1.5 Ncm
40N at max 6000 min1

10 N at max 12000 min1
Moment of inertia
25 gcm2
Maximum PPR
Max 5000
Connector
Type 9416,12 _pin, type 9416L, 12 pin
Weight
Approx 350g
Ambient conditions
Operating temperature
Glass disk
:
-5...80C [movable cable]
-20... 80C [fixed cable]
-5... 60C [movable cable]
-20... 60C [fixed cable]
Plastic disk
Cable
7.8mm, 6x 2x0.14 mm2, 1m
Vibration resistance
. DIN EN 60068-2-6,10g, 10---2000Hz
Model
ST 5010/00.
Input Signal.
HT Push pull / RS422.
Low 0 to 3V
High 7 to 24V (X4/1713)
Division Factor
1 to 256 (in step of 1)
Input Frequency
0 to 10 kHz.
Output Frequency
0 to 55 Hz.
Error Output
If the freq exceeds 55 Hz.
Encoder Interface Module:
Output Signal
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:
Power ON.
Pulse In
Pulse OUT
Error
Make
Siemens
Model
Micromaster 440
Supply Voltage
3, 415 +/- 10% V AC
Make
SIEMENS
Supply Voltage
415 +/- 10%
Speed
1450rpm
Type of Protection
IP 65
Frequency
50+/- 5%
Type
3 Phase, squirrel cage, Induction Motor
Make
Bonfiglioli Group
Type
Helical
Make
Elecon
Type
Worm
LED Indication for
AC Drive:
Motor:
Gear Box (Primary):
Gear Box(Secondary):
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Vibro Motor:
Make
Italvibras
Type
MVSI 3/200-S02
Rate
0.22KW
Supply voltage
415 +/- 10%
Speed
3000rpm
X4 Controller:
Type No.
PR 5510/00
Quantity
1 No per system
Material
Aluminum.
Protection Class
IP 30
Front Panel
IP65
Power Supply
115-230VAC 50-60 Hz+10%/-15%

max. 19VA
Accuracy
6000e OIML R76

min. verification interval 0.5V
Display
7 Digit plus status symbols text:2 line, 20

characters.
Load cell Input
6 Wire or 4 Wire
Load cell Supply
12 VDC
Minimum Load cell

Impedance
75 .
Conformity
EN61000-6-2 and EN61000-6-4
Vibration
According to IEC 60068-2-6
Electrical Safety
According to IEC 61010-1
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Linearity
: < 0.002%
Resolution
2.5 Micro.counts for 1 mV/V
Input Signal Range
0...36 mV
Temperature Effect On Zero
< 0.05 V / K RTI
Temperature Effect On Span
< +/-4 ppm/K
Measuring time
10...160ms, adjustable
Filter
4-pole digital filter 0.1 to 5 z..
Operating Temperature
-10C To +40C
Interface
Built-in bi-directional serial interface

RS 232, User selectable protocols: remote
display, printer
Keyboard interface PS2
Other Interface
Serial Interface(RS 232/485)

6 dig. In/12 dig Outputs(Opto)
1 analog Output
4 Analog Input /1 Output
BCD open emitter
BCD open collector
Ethernet
Profibus DP
Interbus S
DeviceNet
CC-Link
Keyboard
Integrated
Programmability
Freely, as per customers requirement
Calibration & Configuration
Totally through software.
PR 5510/06
1 current output 20mA(10V output only with

external 5000 resistor
Gross, net weight or application dependent
Analog output card

Model
No of outputs
Output
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:
0/420mA,configurable through software

setup
Resolution
16 bits binary, 20.000 internal divisions
Temp
:
:
:
:
:
<100ppm/k
@ 0-20mA; 0.04%
@ 4-20mA ;0.02%
0.04%
Yes
150m current output
Model
PR 5510/12
No of inputs/outputs used
Input 6 , output 12
Low: 05V or open

High:1031V
Passive external power supply required
< 7 mA @ 24V
< 3 mA @ 12V protected against wrong
polarity
passive external power supply required
Max.switching voltage:32V
Max.switching current:25mA
Voltage drop @25mA :3V
Range
Linearity
Zero error
Potential Isolation
Cable length(screened)
Control I/O 6/12 Opto card:
Input signal
Input Current
Output
Profibus interface card

Model
PR 1721/31
Connection Type(internal)
34 pole multi pin connector on flat cable only

for slot 4
Connection type(external)
Transfer Rate
:
:
:
Std 9pin Dtype in the mounting plate

9.6 kbits/s up to 12Mbits/sec
Profibus Network connect/disconnect
without to other station
PROFIBUS DP-VO SLAVE
Connection Mode
Protocol
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TO EN 50170
Mono/multi master systems are supported
Master and slave devices, max 126 knots are
possible
Transport
: EIA Rs485 ,profibus DIN 19245 PART1
: Special profibus, colour violet, twisted pair,
Cable
Common screening
Cable impedance
: 150 Ohms
Large Figure Display:
Type
8 Digit Large Figure Display
Model
ST 2521/11
Voltage
110 /230 V AC,1 Ph, Main power.
Power
18 Watts max
Operating Temp
5 to 55 C
Storage Temp
5 to 65 C
Relative Humidity
Upto 95% RH Non condensing.
Size
850(L)X145(H)X65(D) mm
Character Size
100mm height, 7 segments+ dp
LED Color
Red(optionally green)
Characters table
ASCII CHAR. (Code 30H to 5 FH)
Protocol
Full duplex, ASCII coded, ASYN
20 mA current loop and RS 232

communication.
Selectable 300,600,1200,2400,4800, 9600

19200,57600 baud
Bits/character
7 or 8 selectable.
Stop Bits
One
Parity
Even/Odd/None.
Interface by
Data Transfer Rate
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Setup parameters storage
In an EEPROM- Non volatile MEM.
Message Format
Accessories
Protection
STX, MODE, STATUS, WEIGHT(8), ETX as per

ST2521WF Format
Communication cable 10mtr power cable 02
meter & fixing screw
IP 55
Red.
+ supply
White
- supply
Green
+ signal
Blue
- signal
Connection Details of Load cell
Cable screen
Connection Details of Encoder
Pin No.
Connection
12
Vcc(+5V)
10
Gnd
For equipment wise rating ref enclosed chart-weigh feeder
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SECTION 4
INSTALLATION
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Installation Checklist:
1.0 We request you to ensure that following things are ready and available (as the case may
be) at your site before a Sartorius Engineer visits the site. This help in avoiding delay in
commissioning of the system.
2.0 All the material supplied to you have been checked and found as per P.O. and packing
list. (YES / NO).
3.0 Set of drawings for load cell-mounting arrangement of the Bin Weighing System is
available at site and jobs have been completed according to the points mentioned in the
drawing. (YES / NO).
4.0 Control room with stable power supply (UPS / Servo Stabilizer / CVT) is available. (YES /
NO).
5.0 Proper earthing is done. (YES / NO).
6.0 Grouting/Fixing of foundation plates over. (YES / NO)
7.0 Leveling of the foundation plates as per the drawing is done (YES / NO)
8.0 Bin weighing system is installed on Mounting Kit with Dummy/Temporary Support as
indicated in drawing. Only to be tag welded. (YES / NO).
9.0 Bin weighing system is free from all sides except the load cell placement points. (YES /
NO)
10.0 All connections to and from the Bin Weighing system are flexible and properly
supported at the fixed end. (YES / NO)
11.0 All the welding jobs are completed, except full welding of mounting kits. (YES / NO)
12.0 Standard weights are available. (Std. Wt > = 10% Of FSD). (In case linearity is to be
checked for the full-scale range, standard weights up to that range should be made
available to Sartorius Engineer). (YES / NO)
13.0 Arrangement to put the standard weights symmetrically on the Bin Weighing system is
available. (YES / NO)
14.0 Junction box is mounted. (YES / NO)
15.0 Extension Cable from junction Box location to indicator is already laid. (YES / NO)
16.0 Panel is mounted at appropriate location. (YES / NO )
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17.0 Welding machine / Gas-cutter set / Hydraulic jack / Spirit Level / Water tube
is available. (YES / NO)
18.0 Skilled and unskilled labour available. (YES / NO)
Installation Procedure:
A typical Bin Weighing installation would involve following process:
1.0 Site inspection.
2.0 Installing Bin Weighing System on temporary support with top and bottom pad plates as
per the load cell orientation drawing.
3.0 Leveling Of Bin Weighing system: Leveling of the Bin Weighing System has to be done by
using suitable shim sheets, then top and bottom pad plates tack welding work to be
completed.
4.0 Installing of junction box.
5.0 After all the other mechanical jobs like welding, piping etc are completed following jobs
are to be carried out:
6.0 Installation of mounting kit with load cells and ensure verticality.
7.0 Replace all mounting kit with temporary support with one by one and complete top
and bottom welding works.
8.0 Re-install the mounting kit with loadcell.
9.0 Earthing of the mounting kit and Bin Weighing system.
10.0 Installing the load cell.
11.0 Conduiting of cable.
12.0 Installing the indicator.
13.0 Termination of all the cables.
14.0 mV equalization.
15.0 Calibration.
16.0 Configuring re-transmission outputs.
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Inspection of Site and preparing to install:
Before starting the installation of the Bin Weighing System the site where the Bin Weighing
System will be installed should be inspected for following points:
1.0
The Bin Weighing System is rested on the Temporary support.
2.0
Support structure is approved by Sartorius.
3.0
The support is completed in all respect.
4.0
Load cell mounting arrangement drawing given by Sartorius is available.
5.0
Installation items required as per the above drawing are arranged.
6.0
All the tools and tackle required for installation are available.
7.0
All safety procedure are followed and arranged for.
Installing Bin Weighing System On Temporary Support:

Make an assembly out of the top pad plate, dummy support and bottom pad plate. As shown
in the Fig. Lift legs of the Bin Weighing System using a jack /or a chain pulley, such that this
temporary support assembly can be inserted under it. Install this assembly under each leg in
such a way that they are oriented as shown in drawing
Leveling Of Bin Weighing system:

It is assumed that the support structure is leveled properly. The leveling is now required to take
care the differences in pad plates and legs. Take water tube of 10mm inner diameter and fill it
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with water. Ensure that no air bubbles are formed. By using a spirit level align one bottom pad
plate perfectly. IF it is out of level, then shims are to be used to level it properly. Now using
the water tube and this plate as a reference, level the other plates. After all the plates are
leveled perfectly, tag weld top and bottom plate.
Installing Junction Box:
Fix an appropriate location near the vicinity of the Bin Weighing System and install the
junction box. Care should be taken such that the material to be weighed does not get spilled
on it. Moreover it should be easy to access it for maintenance work. The location of it should
also be decided considering the length of the integral cable of the load cell.
Now all the mechanical jobs like welding on the Bin Weighing system, piping etc are to be
completed before moving ahead with the installation of the Weighing system.
All the piping going to and from this Bin Weighing System has to be isolated by a Flexible
hoses. The hoses should be installed in horizontal direction. Care should be taken that there is
no rigid connection to the Bin Weighing system.
Cable Routing:
For long-term trouble free operation of the system, cable routing should be done keeping the
following points in mind.
1.0
Never run any of the signal cables along with a power line. The distance of the signal
from a power line should be at least one meter.
2.0
Do not route signal cables beside relays, or electrical equipment.
3.0
Do not expose the cables to sun or rain as this may cause deterioration of insulation
resistance. High insulation resistance is necessary for accurate operation.
4.0
Use a small piece of flexible conduit at the cable termination point, in order to avoid
straining.
5.0
Joining of cables are to be done either by proper soldering or by cable connectors and
not by twisting them together. At the joining point they are to be properly insulated by
insulation tape of high quality and closing the joints using general purpose mseal .
6.0
For trouble free operation of the equipment proper earthing is essential which improves
signal to noise ratio, as well as minimizes transmitting of spikes.
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7.0
In many cases the power line earth (not neutral) may prove to be satisfactory. But
sometimes, this may also carry a voltage due to some return current from different
equipment connected to it.
8.0
If one is not sure about the earth, make a separate earth connection for the equipment.
9.0
Connect the earth wire to the earthing bar provided inside the panel.
Commissioning:
1.0
Once above jobs are completed, again check the level of the bottom pad plates. If
found satisfactory, completely weld the top and bottom pad plates. If not again re-level
them as per the procedure explained above and completely weld the pad plates.
2.0
Now remove all the bolts put on the Temporary support on one leg. Lift the leg with
the help of the jack and/or chain pulley. Replace the temporary support with mounting
kit and active load cells. As per the GA drawing with two active load cell with Mounting
kit and two numbers of Fixed bearing support. Ensure that the load cells are perfectly
vertical as shown in GA drawings. This can be checked with the help of a spirit level.
3.0
On installing all the load cell connect the earth strap and external earthing as per the
drawing given. The Bin Weighing System also has to be earthed. This will ensure that
any stray current does not damage the load cell.
4.0
The load cell cable has to be laid till junction box. To protect the cable conduiting has
to be done. Care should be taken not to cut the load cell cable. If the cable is extra
then it has to be folded and kept. If the cables were made short by cutting, then this
would induce an error in weighing results.
5.0
Lay all the cables till the panel.
6.0
Connect the cables in the junction box and at the indicator side as per terminal
connection details.
7.0
Check if all the option cards are inserted in their respective slots.
Connect option card PR1613 to line2 of PR 1613/00.
Connect option card PR 1621 or PR 1606/02 to line3 of Pr 1613/00.
8.0
After reading the instruction and operating manual turn on the indicator. The indicator
should display some non-zero weight.
9.0
Do all the settings as per requirement(ref PR1613/00 manual).
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10.0 Configure various parameters like decimal point, resolution, range, current setting,
profibus slave ID in the indicator.
11.0
Make sure that there are no error messages.
12.0
Now check up the mV signal of each load cell. Shim the load cell wherever the output
is low. The max difference between the mV of each load cell should not exceed 0.2
mV. It there is eccentric loading on the Bin Weighing System then the mV signals
would have huge difference. In such case there is no need to adjust the mV.
13.0
14.0
Now the system is ready for calibration. Arrange the required amount of standard
weights
Become familiar with the calibration procedure by reading the instruction and
operational manual of the indicator.
System calibration
Bins being supported on 2 numbers live load cell and 2 numbers Fixed Bearings, half
the portion of bin load acts on loadcell. As such care to be taken to ensure standard
weights are uniformly placed on the Bin(to ensure uniform load sharing).After placing
the standard weight, enter the total weight in the indicator and calibrate. For detailed
calibration procedure refer manual of 1613/00.In case standard weights are not
available,system can be calibrated by filling bin with raw material and calculate the
weight of raw material(volume x density of material).
The detailed calibration and operation procedure are given in 1613/00 manual.
Calibrate the system and note down the readings and document it.
15.0
Configure the indicator for all the outputs.
16.0
The system is now commissioned and ready for operation
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WEIGH FEEDER
Installation of a Weigh Feeder System can be classified into following steps:

1
Checking of consignment.
Installation of Weigh Feeder mechanicals.
Cable Laying and termination in junction box.
Installation of PR 5510/00.
Termination of cables in PR 5510/00.
Calibration of controller PR 5510/00.
General Guidelines:
Load cell: Load cells should be carefully handled during installation as the bellows may get
damaged.
Load cell cables: Ensure that the load cell cables are neither short nor connected anywhere
during welding. Never cut the load cell cable. Never hold the load cell with its cable.
Safety: Always follow proper safety norms. Sartorius is not responsible for any consequences
due to non-conformance of safety norms.
Instructions: It is mandatory to read the instructions given in the drawings and procedures
carefully and clarifying doubts before starting any activity.
Mistakes: Though it is intended to provide correct information in the drawings, procedures and
manuals to the best of our knowledge, there may be some unintentional mistakes and missouts. Please check before carrying out any major activities and bring to the knowledge of
Sartorius immediately.
This manual and drawings are meant for reference only. In case of a contradiction between
this manual and a formal contract the latter will hold good.
Checking Of Consignment Received:
It is necessary to check the consignment received. The check can be carried out on the basis of
the packing list and / or purchase order.
If any discrepancy is noticed the same is to be intimated to Sartorius.
This will help in saving installation time due to short supply / missing items.
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Installation of Weigh Feeder mechanicals:

Refer GA drawing for dimensional details and fitment/location
The feeder mechanicals are dispatched in semi-assembled condition
Feed Chute Assembly
1.Assemble the circular chute on to the bottom of rod gate of bin
2.Assemble vertical feed chute supporting frame on to the bin.
3.Assemble anti vibration mounted on to supporting frame
4.Now mount the feed chute to rest on anti vibration mount.
5.Assemble the dust curtain.
Feeder
1.Locate the feeder mechanicals sent in assembled condition as per layout
2.Remove side guard of feeder and partially the skirt board
3.Mount the load cell on the bracket provided on the stringer
4.Position the weigh idler along with load cell mounting pin
5.Assemble the Encoder on to the pulley with its coupling after removing the respective guard.
6.Replace the Encoder Guard
7.Assemble encoder mounting idler on return belt with bearing & bracket.
8.Assemble the encoder with encoder guard.
9.Position the drive base stool at its location.
10.Couple the drive pulley with its base and support it on the stool
11.After properly aligning secure all the fasteners.
12.Check and carry out vertical alignment of carrying and weighing idler with a string by
adjusting carry bracket with the help of respective bolts
13.Fully secure and Tighten carrying idler bracket on to stringer after completing all the
alignments.
14.Assemble skirt board side corner limit switch for Material Presence Detecting Device.
15.Assemble belt sway switch.
16.Assemble junction box to the side guard of feeder.
17.Route the load cell, Encoder cable through the pipe provided and terminate in the Junction
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box.
18.Route cable of Encoder, Load cell, Limit switch and Motor to the panel as explained under
electrical section.
19.Fill worm gear box with required quantity of lubricant. Primary helical gearbox is filled with
grease hence no separate lubricant is required.
20.start the feeder and check
1.Proper direction of belt
2.Belt sway (if found adjust take up screws)
3.Any Vibration (Secure all fasteners properly)
21.Now fix the discharge chute with stool along with external scraper.
22.Now the feeder is ready for commissioning.
Installation of Vibromotor
The vibrator must be fixed to perfectly flat surface(Fig 9,page 3 of vibromotor manual) using
boltsand nuts .Use a dynamometric wrench(Fig 10,page 3) of manual adjusted according to
that stated in the coupling torque table on page no 102.The diameter of the bolt, on the basis
of the type of vibrator to install must correspond to that indicated in the table on page 81.It is
also indispensable to control that the bolts are tightened fully home. This control is particularly
necessary during the initial functioning period.
The most damage and faults are due to irregular fixing or badly performed tightening.
Re-control tightening after a brief functioning period.
It is advised to fix the installed vibrator to a steel safety cable with opportune diameter and a
length that will support the vibrator in the case of its accidental detachment. Max.fail of
15cm(6)(Fig 11,page 3 of manual)
Do not carry out welding to the structure with the vibrator mounted and connected, Welding
could cause damage to windings and bearing.
Note : For further details refer Vibromotor manual.
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Cable Laying And Termination:
Lay the load cell and encoder integral cable.
Insert flexible metal conduit wherever the load cell cable is exposed.
Do not cut the excess load cell cable. Either insert in the conduit or roll it and hang it
near the junction such that it will not get damaged.
Make the cable to enter the junction box through the glands provided. Gland the cable
properly so as the ensure IP 65 protection and prevent tension on the connector in
event the cable is pulled.
Terminate each cable of the load cell as per the colour coding on the connectors.
Terminate the load cell ,encoders & belt sway limit switch cables at the junction box as
shown in the drawing. Lay the load cell, encoder, limit switches and belt sway extension
cable from junction box to the panel.
Gland these cables in the junction box properly.
Terminate it as per the drawing and colour coding of individual cables. Do not cut the
screen of any of the cable. Terminate these as shown in the drawing.
Connect the motor to the panel as per the terminal details provided.
Connect local panel and LFD to the remote panel as per the drawing.
Connect all the other input/output of the remote panel as per the drawing.
Installing PR 5510/00:
Read the operating and installation manual supplied along with PR551/00 before
installing the same.
Follow the safety procedures laid down in the manual.
Mount PR551/00 as shown in the wiring diagram.
Care should be taken to avoid any damage to the display while mounting PR5510/00.
Termination of Cables In PR 5510/00:
Study the drawing carefully.
Terminate the load cell cable in the load cell connector.
Check the connection for correctness.
As soon as it is turned on a positive non zero reading should be displayed on the
weighment display.
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Calibrating PR 5510/00:
Please read the operating manual of PR 5510/00 before calibrating it.
Also refer to the calibration procedure given in next section.
Calibrate PR 5510/00 for required capacity.
Verify the calibration and record the readings.
Ensure proper parameters setting for the communication.
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SECTION 5
OPERATION INSTRUCTIONS
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Operation Procedures
Before proceeding with operation ensure the following
Ensure that the load cells are not subjected to any corrosive material and are safe
against any type of physical damage.
Keep the area where the load cell is installed clean.
Ensure that the load cell cable is well protected.
The earthing connection is secure.
Check the earth-pit resistance regularly and document it. The resistance should be less
than 1.
The flexible hoses should be checked periodically for its flexibleness.
The Bin Weighing System should not be hammered to take out the material from it.
The junction box should be protected, by covering it suitably.
Terminations in the junction box and at indicator side should be checked for any loose
contact.
The load cell extension cable should be protected from any potential damage.
The operator should be well trained on the operation of the system.
When seeing the gross weight, one should ensure that, it was not tarred earlier.
No welding should be permitted on the Bin Weighing System after the load cells are
installed.
All the calibration and configuration data of the indicator has to be noted.
Do not tamper with the system in case of any problem. Call authorized person to
attend the problem.
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MANUAL FOR PR1613/00
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Profibus Configuration
Configure the profibus DP slave ID in the indicator.
When there is a write request 01 from the Master PLC, then in the reply field byte2 and byte3
will have the data ie. Byte1 with the Level of the bin and byte1 will have the status. The
following are the status bits.
b0
ADC Out of Range
b1
Weight tared
b2
Bit stand still
b3
Within Zero but 1/4D
b4
Above scale but within tolerance range
b5
b6
b7
b5 and b7 high Negative Bit
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WEIGH FEEDERS
The weigh feeder can be operated in two modes.

Gravimetric
Volumetric.
The gravimetric/volumetric mode can be selected with the help of a selector switch provided in
the local panel.
In gravimetric mode the rate of flow is controlled. Upon receiving the feeder on command,
the controller calculate the rate of flow and compare it with the preset rate and provides an
error signal proportional to the difference in rates by PID algorithm, which is fed to the AC
drive to control the speed of the motor.
In volumetric mode the feeder will run at a fixed preset speed regardless of the rate of flow.
The feeder trips automatically in occurrence of fault.
The weigh feeder can be operated from Remote/Local/PCS Panel . The set rate can be set from
PCS through profibus communication.
The operation like Feeder start/stop, Set input can be either from remote panel/local panel/PCS
depending on the switch selection on the local panel. E. off and feeder off can be done from
any panel irrespective of the selection made.
Whenever there is no input from material presence limit switch the Vibro motor will be
switched ON. This will be put OFF once the set value is achieved. Even after the vibro motor is
ON if the set value is not reached the system goes into material starvation thereby tripping the
feeder.
Key pad Functions:
For the entry, front panel is provided with alpha numeric keypad with 16 keys. Following are
the keypad functions.
Key
:
:
Functions
Open the indicated menu item.
Store the edited parameters
Displace cursor left during value selection.
To select between options (Applicable where
Is present) /left shift key
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: Displace cursor right during value selection.
To select between options (Applicable where
Is present /right shift key
:
Scroll up in menu tree.
Scroll down in menu tree.
Leave the menu item
This is a function key.

Program text on the display indicates the function,
which can be called up.
To clear the Totaliser
Parameter Menus
When Pro- X4 controller is turned on, the display shows
The three main menus are

Start
Setup
Prod
Start menu
Start menu contains the control parameters used for closed loop control of the weigh feeder.
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:
Press
key to access Start menu,
the display will show,
: This is the set value of rate at which the
feeder will run in gravimetric mode
: This is the proportional gain in %.

Range of values: 0 1000
: This is the integral time Constant

Range of values: 0.1 1000
: This is the minimum output % at which

the feeder Will run.
: This is the maximum output % at which

the feeder will run.
Setup menu
Using setup menu, all the configuration parameters are to be set before calibration of the
weigh feeder.
Select Setup Menu, Indicator shows
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Config. Menu contains the following

Basic Parameters
Process Parameters
Calibration Parameters
: Used for configuration of Basic
Parameters, Process Parameters, and Cal.
Parameters
: This Menu contains all the Design
parameters of Weigh Feeder.
: To select different units for Rate

display.i.e g/hr, kg/hr, t/hr.
: The designed capacity of the Weigh

Feeder.
: The designed speed of Weigh Feeder in

m/sec.
: Effective Weigh length
: The total length of belt in meters
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: To Enable / Disable internal weighment
display
: To select Analog DC Encoder input.
: Minimum output of Analog DC Encoder.
: Maximum output of Analog DC Encoder
: Maximum rated RPM of Analog DC

Encoder
: Encoder Mounting Idler Dia.
: To select Proximity Sensor Input.
: Wheel Dia of Proximity Sensor mounting

assembly.
: Pulley Dia of Proximity Sensor mounting.
The Dia of Head Pulley
: No. of holes on the wheel of Proximity

Sensor mounting assembly
: To select encoder input.
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: Encoder mounting Idler Dia in meters
: Dia of the Head Pulley, to which the

Proximity sensor is mounted.
: Rated PPR of Encoder.
Encoder Interface Module Factor of

Encoder which is connected to Tail Pulley
Encoder Interface Module Factor of

Encoder, which is connected to Head
Pulley.
To select constant speed option in case of

speed sensor failure.
Actual Speed of the conveyor in m/Sec.
To select Analog Encoder input.
The minimum value of analog input
The maximum value of analog input
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: The designed speed of conveyor
The menu contains all the parameters

related to operation of the Weigh Feeder
The minimum belt load as a percentage of

rated belt load, recommended by the
weigher.
Empty-belt recognition as a percentage of

rated belt load.
To Enable / Disable Slip alarm function.
Maximum practical belt load, above which

the weigher should not be operated.
Time delay for Material starvation output

in sec.
On time for Vibro motors
Decimal places for the rate display
Decimal places for the totaliser display
Configuration of Analog Output-1

corresponding to Speed / Rate
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: To select the range for Analog output 1
which is taken from slot2
Configuration of Analog Output-2

corresponding to Speed / Rate
: To select the range for Analog output 2

which is taken from slot3
: Totaliser pulse output
: Totaliser pulse duration.
: The menu contains parameters related to

Calibration.
: Totaliser correction factor for fine-tuning

of totaliser value
Prod Menu
Prod menu contains all the production information, which are shown below. Up or down
arrow is used for scrolling through different Production Parameters.
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Calibration Guidelines
The method of calibration process is
Static calibration
Static calibration is the process where the feeder is calibrated without running i.e. in BELT OFF
condition with calibration chain/rod.
Calibration is done in two steps
Tare operation
Span adjustment
Tare operation
Ensure that there is no material on the belt.
Perform Tare operation
Span Adjustment
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The load of the calibration chain coming on the loadcell is necessary to perform span
calibration.
Place the calibration chain. Enter the value punched on the chain.
Calibrating PR 5510/00:
Please read the operating manual of PR 5510/00 before calibrating it.
Also refer to the calibration procedure given in next section.
Calibrate PR 5510/00 for required capacity.
Verify the calibration and record the readings.
Make sure to enter license number for relevant communication. Also ensure proper parameters
setting for the communication.
After the proper installation of Load cells, the speed sensor and the controller, calibrate the
weighing system. Internal weigh point should be enabled for doing the calibration. Refer to the
Pro-X4 instruction manual for programming and calibration.
The process of calibration involves two steps
Static Zero Calibration
Static Span calibration
Static Zero Calibration
This is carried out when there is no load on the belt at Conveyor off condition.
Select Weighing Point from Config Menu. Controller Displays Calibration menu. For
performing a new calibration select New from the list and perform Zero Calibration when
there is no load on the conveyor. Pro-X4 operation manual can be referred for performing the
Calibration.
Static Span Calibration
Span calibration should be done, after performing Zero Calibration. Span calibration could be
carried out using Calibration chain . All of these are explained in the following sections.
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Chain calibration
Measure the weight of the Calibration chain using a weighing scale. Place the Calibration chain
on the conveyor and set the Span Value according to the weight of Calibration chain. After the
Span Calibration Press Exit button, Controller provides an option for saving the Calibration.
Now the system is ready for use.
Rate Calculation
Let
Belt speed
= S m/sec.
Weight of the chain
= W kg/m
Actual Rate in TPH
= W x S x 3600
1000
Reset the totaliser and start the stopwatch simultaneously. Take the reading of the quantity for
a known time. The quantity should agree with the rate reading. The tests are repeated three
times and the average value is calculated on the basis of these tests.
Totaliser Reset:
Totaliser reset can be done only trough Prod Menu, Press
The totaliser will display 000.00 t
key to reset the totaliser.
NOTE:
Take drop test (in case possible) to ensure the calibration is done properly.
Error calculation :
1.With Actual Material
Conduct drop test with the actual material and calculate the error as follows :
Specified accuracy = 0.5% of full scale
Let R1 be the rated capacity of the system in tph
Then the allowable error will be 0.5/100 X R1 = say Er in Kg or Tonnes
Let R2 be the set rate.
Let Td be the duration of time in minutes for which the drop test was conducted and Wc be
the weight of material collected.
Calculated material wt =R2 * Td/60= say Wa
Now the error will be Wa-Wc
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This should be within or equal to Er
2.With calibration chain
Place the chain on the conveyor.
Let R2 be the set rate.
Clear the totaliser value. Check the totaliser value for three revolution of belt and let this
Time duration be Td and the Totaliser reading Wc.
calculated totaliser value is =R2 * Td/60= say Wa
Now the error will be Wa-Wc
This should be within or equal to Er
Profibus Configuration
For Read operation
For any data to be read ,a write request has to come from master(PLC,PCS,PC) requesting the
data to be read. data type to be read is written in byte 4 of the write window, Slave replies
with the data in byte 0 to Byte 3 of the READ window. Request type is echoed back in byte 4
of READ Window, indicating successful transmission requested data
Read Window
Byte
Bit Position
Bits 7
Bit 6
Bit 5
Bit 4
Bit 3
Bit 2
Description
Bit 1
Bit 0
0
1
Read_ value
Actual Flow
3
4
Read_ Value_ Selected
Belt
O/L
Drive
fault
Belt
Sway
Under
load
Vib.
Motor
on
Feeder
On
F/b
Over
load
Genera
l
fault
Grav/V
ol
Eg.Actual
Flow(20)
Adc error Status-A
Mat
starv
Status-B
Locl/Rem Status-C
Note:- Bytes 0....3,MSB......LSB

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For Writing Operation
For writing data ie Set Flow to the slave ,Master writes the data type(240 to be written in Byte
5)Of the WRITE window.Value to be written is put in Bytes 0 to 3.
Write Window
Byte
Bit Position
Bits 7
Bit 6
Bit 5
Bit 4
Bit 3
Bit 2
Descriptio
n
Bit 1
Bit 0
0
1
Set
Flow_rate
Write_ value
2
3
4
Read_Value_Select
Write _Value_ Select
Tot.
Reset
X
Grav
Vol
X
Local/
Rem
X
Feeder
Stop
X
Feeder
Start
X
Eg.Actual
Flow(20)
Eg.Set
Flow
Rate(24)
Status-D
X
Note :- Bytes 0....3,MSB.....LSB

Functions No. to be set in write Window
Read function
23
24
25
26
27
Byte No.4
Description
Actual Flow(tph)
Set Flow(tph)
Control O/p (%)
Totalizer (Tons)
Actual Speed(m/s)
Write
Function
24
Byte No,5
Description
Set Flow
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MANUAL FOR PR 5510/00
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SECTION 6
PREVENTIVE MAINTENANCE
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6.1Maintenance
The bin level measuring system is virtually a maintenance-free device. In dusty or granular
applications, periodically check the load cell over load protection area for material build-up.
Remove any build-up in the mechanism to ensure that the load cell maintains free movement.
Note: Re-install the overload protection during maintenance or any other time for protection
of Load cell.
6.2 Calibration Check and its Periodicity
To calibrate the system refer calibration procedure explained in the earlier section.. Precautions
to be followed strictly.
Bin Level Measuring System :

Load cells:
Checks
Frequency
1. Load cell cable is intact, free from damage
6 Months
2. Verticality of load cell
6 Months
3. Checking tightness of mounting kit bolts.
6 Month
4. Noting mV output and resistance of the load cells
6 Months
Junction Box:
Checks
Frequency
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1.
Cable terminations are secure
6 Months
2.
Junction box is clean from inside and free of moisture and

dust.
6 Months
3.
Checking the conditions of cable, to and from the junction box
6 Months
PR1613/00:
Checks
Frequency
1. The indicator is clean & connections are secure
6 Months
2. Check conditions of cables to and from the indicator
1 Year
3. Check battery voltage
1 Year
4. Calibration
1 Year
5. Configuration
1 Year
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Weigh Feeder :
Checks
Frequency
Free running of all idlers
1Month
2.
Alignment of idlers
1Month
3.
Alignment of Encoder, mounting, idlers & coupling
1Month
Tightening of fastener
1Month
5.
Checking of Drive alignment & coupling bolts
1Month
6.
Belt Condition
3 Month
Gear oil
1 Week
Pully Bearings
1Month
10
Cleaning of feeder/bin/discharge chute etc.
1 Year
11. Cleaning Of Load cells / area in vicinity
1 Month
12
1 Year
1 Year
Painting Of structure
13. Calibration check with chain
Load cells and Encoder:

Checks
Frequency
1. Load cell and Encoder cable is intact, free from damage
6 Months
2. Verticality of load cell
6 Months
3. Checking tightness of mounting kit bolts.
6 Month
4. Noting mV output and resistance of the load cells
6 Months
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Junction Box:
Checks
Frequency
1.
Cable terminations are secure
6 Months
2.
Junction box is clean from inside and free of moisture and

dust.
6 Months
3.
Checking the conditions of cable, to and from the junction

box
6 Months
Process Controller:
Checks
Frequency
1. The indicator is clean & connections are secure
6 Months
2. Check conditions of cables to and from the indicator
1 Year
3. Check battery voltage
1 Year
4. Calibration
1 Year
5. Configuration
1 Year
Earthing Connections:
Checks
Frequency
1. Water earth pit continuously for full day
3 Months
2. Check earth resistance
6 Months
3. Earth connections to load cell base plate
6 Months
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4. Earth connection to weigh feeder
: 6 Months
Lubrication of gearbox:
1.Use only recommended grade of oil as specified by the gear box manufacturer.
2.Do not mix two grades of oil.
3.Use only required Quality of oil, do not over fill. Too much oil will cause excess heat due to
churning of oil.
4.Drain the first fill of oil after approximate 200hrs of operation. Flash the gem box with a
good grade of flushing oil & refill with recommended grade of oil to the correct level.
5. Inspect oil level. The correct level (when stationery) is marked on the dip stick or indicated
by oil level plug. Top up oil (same grade)to the required level when ever necessary.
6. Subsequent oil changes to be made after approx 200hrs of running time or 3 months
7. Regreasing of pulley bearing to be done once a week..
Mineral Oil
BRAND
GRADE
International Brands
British petroleum
CS 320 or Gr-Xp320
Castro
Alpha Zn 320 or Alpha Sp 320 or Tribol 110/320 IGQA
Caltex
Meropa 320
Esso
Teresso 320 or Spartan 320
Fuchs
Renolin CKC 320
Mobil Oil co
Mobil DTE Oil AA or Mobil gear 632
Shell Co
Vitera Oil 320 or Omela 320
Kluber
Kluber oil GEM 1-320
Indian Brands
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Bharat Petroleum
Cabol 320
Fuchs
Renolin CKC 320
Castrol
Alpha Zn 320 or Alpha Sp 320 or Tribo
Gulf
Gulf harmony 320 or Gulf EP 320
Hindustan Petroleum
Enklo 320 or Parthan EP 320
Indian Oil
Servomesh SP 320 or Servosystem 320 or Servomesh EE320
Veedol
Avalon 320
Kluber
Kluber Oil GEM 1-320
APPROXIMATE OIL CAPACITY FOR SNU GEAR UNIT IN LITRES

Gear Size
1 5/8
1 1/4
2 1/4
3.54
10.5
SNU-U
0.3
0.4
0.6
0.7
2.2
2.1
2.5
9.5
11
16
21
SNU-O
1.4
0.5
0.7
0.8
3.8
6.1
13.5
18
19
41
45
SNU-V
0.3
0.4
0.6
0.7
3.5
4.0
5.7
8.5
18
20
25
26
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SECTION 7
SYMPTOMS AND FAULTS
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Bin level Measuring system

Sr. No.
1.
Symptoms
Fluctuations In Reading
Wrong Reading
Shift In calibration
No Re-Transmission Output
Error In Indicator Display
Indicator does not Power on

PR1613 indicator - cannot set zero
Remedy
Check for any loose connection in JB and
or at indicator side.
Check for moisture content in the JB.
Check load cells.
Check indicator by simulator.
Verify calibration.
Check piping.
Check load cell
Check mounting kit.
Check for loose connection.
Check piping.
Check mounting kit.
Check configuration parameters.
Check wiring.
Read the corresponding description of
error from the manual.
Correct the fault.
Check the fuse.
PR1613 ADC faulty: Indicator ADC faulty.
Check by analog test key.
Small zero shift in PR1613: Small zero
shift can be corrected by increasing zero
setting range in parameter C42.
If the problem faced is not appearing in above list, please contact Sartorius Service division.
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Weigh feeder
Sr
No
01
Symptoms
Solution
Load not sensing.
No excitation to load cell :Check the excitation at the

panel and then at the junction box.
No signal from load cell :Check for connection of load
cell with color code at panel and junction box.
Load cell impedance, mV output not OK: Isolate the load
cell and check the impedances at the input and output
terminals. If it is not as per specification the load cell is
not functioning .Replace the load cell and recheck.
02
Feeder is not switching ON
Check for proper selection of the RP/LP switch at local

panel.
Check if any of the E.OFF switch is pressed.
Check if external interlock is provided.
Check for feeder ready pf contact.
03
a
General Faults
Mat. Starvation
Belt overload
Belt Sway
Movement of belt in either sides.
Trip
Mat. starvation for more then the set delay .

Belt sway exceeding the time delay.
Belt overload.
Controller fault.
Non availability of material :. Ensure that there is

sufficient material in the storage bin.
Feeder is overloaded : Check the overload setting in the
controller.
Check the milli volt of the load cell separately at the
junction to ensure that the load cell are not damaged.
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Drive fault.
Speed Error.
04
a
b
c
Sr
No
d
e
f
g
h
05
Error messages
Belt under load
Belt over load
ADC fault
Belt load is less than the set value.

Belt load is more than the set value.
Load cell open
Symptoms
Solution
Below zero
Speed Error
Slip Error
Ref Encoder Error
Material Starvation
If the load is less than 5 kg

Actual encoder is open.
Difference between actual encoder & ref encoder
Ref encoder is open or faulty
Non availability of material.
No Commn
(LFD)
Check the connection from remote panel to LFD.

Check whether the TXD LED on the RS232 to CL
converter module is glowing.
If the problem faced is not appearing in above list, please contact Sartorius Service division.
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SECTION 8
FACTORY SETTINGS
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Setting - Weigh Feeder

Start Menu parameters:
Parameter Name
Description
Set Range
Unit
Set rate (t/hr)
Set rate in Grv mode
T/hr
Kp (%)
Proportional gain in
%
Integral time
constant
Min o/p %
Max o/p %
0.00 to
10000.00
0 to 1000
Factory
Setting
10
1.2
0.1 to
1000
0 to 100
0 to 100
%
%
0
100
Factory
Setting
T/hr
Ti
O/p, Low Limit (%)
O/p, High Limit (%)
Your
Setting
Config Menu Parameters

(1) Basic Parameter
Parameter Name
Description
Set Range
Unit
Unit of Rate
Rate Unit
Rated Capacity.
(Tph)
Rated Speed (m/s)
Designed Capacity
of Weigh Feeder
Designed Speed of
Weigh Feeder
Effective Weigh
Length
Total belt length
0 - 5000
T/hr,
kg/hr,
g/hr
T/hr
0.1 to 4.0
m/sec
2.5
0.4 to 2.4
Mtr
1.6
1.0 to
100000.0
Enable /
Disable
Mtr
Enable
0.01 to
Mtr
0.24
Weigh Span (mtr)

Belt Length (mtr)
Main Display
Idler Dia. (mtr)
To Enable or
Disable Weighing
point A
Dia of Encoder
Your
Setting
10
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Pulley Dia. (mtr)
Encoder, PPR
EIM Factor (act)
EIM factor (ref)
Fixed Speed
(m/sec)
Analog i/p -Min
Analog i/p -Max
Rated Speed (m/s)
Encoder o/p-Min
Encoder o/p-Max
Encoder Speed Range
Idler Dia. (mtr)
Wheel Dia. (mtr)
Pulley Dia. (mtr)
No. of Holes
mounting Idler
Dia of
Max. Encoder
output
Encoder interface
module factor
Encoder interface
module factor ref.
Fixed Speed for
Rate calculation
Min. analog input
value
Max. analog input
value
Designed speed of
conveyor
Min. output of
Encoder
Max output of
Encoder
Speed range of
Encoder
Dia of Encoder
mounting Idler
Dia of proximity
mounting wheel
Dia of mounting
pulley
Number of
proximity sensing
holes
1.0
0.01 to 2
50 to
2000
1-512
Mtr
-
1000
1-512
0.01 to
5.0
0.0 to
20.0
0.0 to
21.0
0.1 to 4.0
m/sec
2.5
mA
mA
20
m/sec
2.5
mA
mA
20
rpm
1500
mtr
0.24
0.0 to
20.0
0.0 to
21.0
0 to 3000
0.01 to
1.0
0.01 to
1.0
0.01 to 2
mtr
0.25
mtr
0.01
1 to100
(2)Process Parameter
Parameter Name
Description
Set Range
Unit
Min. under load

(%)
Min. under load in

%
Belt empty value in
%
1.0 to
10.0
1 to 10
Factory
Setting
2
Enable /
Disable
1 to 75
5 to 50
Disable
15
10
1 to 60
sec
10
1.0 to
60.0
0 to 3
min
Belt Empty (%)

Slip Alarm
Belt Slip (%)
Belt Overload
Starvat. Delay (s)
Vmotor on time
(m)
Dec P1 - Rate
Overload value of
Belt
Delay for material
starvation
Vibro motor on time
Decimal Places for
Your
Setting
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Dec P1 - Tot
Analog out1 (s-2)
Analog1 span (s-2)
Analog Out2 (s3)

Analo g2 Span (s3)
Pulse Every (t)

Pulse Dur (msec)
Rate
Decimal Places for
Totaliser
Configuration of
analog1 out value
Analog1 out value
Configuration of
analog2 out value
Analog2 out value
Configuration of
totaliser pulse
output
Duration of Totaliser
pulse output
0 to 5
%Y, Rate
%Y
4-20, 020
%Y, Rate
mA
4-20
%Y
4-20, 020
0.1 to
500.0
mA
4-20
Tonne
200 to
5000
msec
200
Factory
Setting
1
(3) Cal Parameter

Parameter Name
Description
Set Range
Unit
T. Factor
Totaliser Factor
0.8 to 1.2
Your Setting
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SECTION 9
BILL OF MATERIALS
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SECTION 10
DRAWINGS AND DOCUMENTATION
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Following drawings and documents enclosed for reference:

1. Data Sheet of Loadcell.
2. Catalog of PR 1613/00, Weighing Terminal.
3. Catalog of PR5510/00(X4 Controller)
4. Data sheets of Encoder.
5. Data sheet of Profibus.
6. Data sheet of Large figure display.
7. Data sheet of Junction box.
8. Data sheet of AC Drive.
9. Data sheet of Profibus connector.
10. Drawings
GA Drawings for Bin level measuring system and Weigh feeder.
System Block Diagrams
GA and front facia of panel
Panel- AC Power supply distribution diagram
Control input/output wiring diagram
Wiring details of load cell,profibus.Lfd
PR5510/00 cutout details
ST 2620/05 Junction Box Details
ST 2620/16 Junction Box Details
GA Drawings of LFD and Local Panel.
Cutout Details of PR1613/00 weighing interface
GA Drawings of ST2521/10 Large Figure Display 100mm.
Terminal Block Details of AC Drive
Terminal Block Details
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9. Test reports
SECTION 11
YOUR CONTACTS IN SARTORIUS
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________________________________________________________________
For Service:
Your Contact
Mr. Sethumadhavan.V.S
Tel: (080) 41272741/41272742/41272743
Fax: (080) 41171142
Address
M/s. Sartorius Mechatronics India Pvt.Ltd.,

#17/A, 5th Main, IIIrd Phase,
Peenya, KIADB Indl Area,
Bangalore 560 058
Email: sethu.madhavan@sartorius.com
Email: smi.service@sartorius.com
For New Requirement:

Your Contact
: Mr. Ashwin Srirangaraj

Tel: (080) 41272741/41272742/41272743
Fax: (080) 41171142
Mobile : (0)9342509003
Address

#17, 5th Main, 3rd Phase,
Bangalore 560 058
Email:ashwin.srirangaraj@sartorius.com
Corporate Office:
Your Contact
Mr. Mohan Bhat

Tel: (080) 28375381-85
Fax: (080) 28378716
Address

#10, 6th Main, 3rd Phase,
Bangalore 560 058
Email: mohan.bhat@sartorius.com
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Page 113 Of 112

Weigh Feeder Ref Manual

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6. Preventive Maintenance Checklist

7. Symptoms and Faults

10. Drawings And Documents

11. Your contact at Sartorius

Bin level Measuring level

Bin level measuring system, which includes the following

Mounting kit (ST 2501/29) For PR 6201/55N(500T)

Fixed Bearing (ST 2552/09) for loadcell 500T

Weigh Feeder is an electromechanical system and includes the following

Bending beam load cell (MP 47/51 C3, 21 C3, 12 C3)

Junction Box for load cell (ST 2620/05)

Junction Box for encoders and limit switch (ST 2620/16)

X4 Process Controller (PR5510/00) with following option cards

Current loop converter module (ST5011/00)

Encoder (ST 5013/13)

Encoder Interface Module (ST 5010/00)

Remote Panel (ST 5010/21)

Local Panel (ST 5000/00)

8 digit, 100mm large Figure Display (ST 2521/11)

The drive assembly for feeder with primary gearbox.

The plate gate below feed hopper figure is shown below.

Junction Box for load cell (ST 2620/05):

Current loop converter module (ST5011/00):

Speed sensor (Encoder)(ST 5013/13):

Encoder mounted at return idler figure is shown below.

AC Drive (ST 5020)

Remote Panel (ST 5010/21)

Stay put push button

: field (limit switch)

Output potential free contacts :

Local Panel (ST 5000/00)

Remote/Local selector switch

Feeder ON/OFF by spring return switch.

Gravimetric/volumetric by selector switch

Set/Actual by selector switch

Increment & Decrement push buttons

Setting from local panel:

Large Figure Display (ST2521/11)

BIN LEVEL MEASURING SYSTEM

Type Of Load cell

Full stain less steel construction, hermetically

Die Cast Aluminum

4 Nos, Double Compression

7 Digits, 7 Segment plus dimension signs and

Load cell Input

Load cell Supply

Minimum Load cell

As per EN 45 501 OIML R76

Input Signal Range (Net)

Input Signal Range (Tare)

Temperature Effect On Zero

< 0.1 V / K RTI

Temperature Effect On Span

< 0.006% / 10K

Active Butter worth Low Pass, 40dB / Decade.

110V / 220VAC, -15% / +10%, 50/60 Hz.

Max 4 Nos (Depends On Configuration)

Integrated PLC Function

Inbuilt 6 Digital Inputs / 12 Digital Outputs

Freely, as per customers requirement

Calibration & Configuration

Totally through software.

6 Digit Large Figure Display