Model 10-101R

Belt Scale

REC 4031 Rev C Part #057133

II
III
 REVISION HISTORY

REVISION A OCTOBER 1997

REVISION B DECEMBER 1997
REVISION C JANUARY 2003

COPYRIGHT 1997 BY THERMO SCIENTIFIC

THIS DOCUMENT IS CONFIDENTIAL AND IS THE PROPERTY OF THERMO SCIENTIFIC . IT

MAY NOT BE COPIED OR REPRODUCED IN ANY WAY WITHOUT THE EXPRESS WRITTEN
CONSENT OF THERMO SCIENTIFIC. THIS DOCUMENT ALSO IS AN UNPUBLISHED WORK
OF THERMO SCIENTIFIC. THERMO SCIENTIFIC INTENDS TO AND IS MAINTAINING THE
WORK AS CONFIDENTIAL INFORMATION. THERMO SCIENTIFIC ALSO MAY SEEK TO
PROTECT THIS WORK AS AN UNPUBLISHED COPYRIGHT. IN THE EVENT OF EITHER
INADVERTENT OR DELIBERATE PUBLICATION, THERMO SCIENTIFIC INTENDS TO
ENFORCE ITS RIGHTS TO THIS WORK UNDER THE COPYRIGHT LAWS AS A PUBLISHED
WORK. THOSE HAVING ACCESS TO THIS WORK MAY NOT COPY, USE OR DISCLOSE THE
INFORMATION IN THIS WORK UNLESS EXPRESSLY AUTHORIZED BY THERMO SCIENTIFIC.

PLEASE READ AND OBSERVE THE FOLLOWING SAFETY

PRECAUTIONS FOUND THROUGHOUT THIS MANUAL.

DANGER

FAILURE TO OBSERVE WILL CAUSE VERY SERIOUS PERSONAL INJURY OR DEATH.

WARNING

FAILURE TO OBSERVE COULD CAUSE SERIOUS PERSONAL INJURY.

CAUTION

FAILURE TO OBSERVE MAY CAUSE MINOR OR MODERATE PERSONAL INJURY

OR DAMAGE TO THE EQUIPMENT.

IV
 SYSTEM DATA SHEET

THERMO SCIENTIFIC

MODEL 10-101R BELT SCALE

CUSTOMER: ______________________________________________________________

END USER: ______________________________________________________________

P.O. NO.: ______________________________________________________________

FILE NO.: ______________________________________________________________

CONVEYOR DATA SCALE DATA

Conveyor No.:___________________ Weigh Span: ___________________Ft (mt)

Equip, Tag No.: _________________
Product: _______________________
Capacity: ______________________
Belt Speed: _________FPM (mt/sec)
Speed Pulley Dia.: ________IN. (mt)
Belt Width:_____________________
Idler Spacing_____________IN. (mt)
Idler Trough Angle:______________
Tare Load: ____________________lbs (kg)
Net Load: _____________________lbs (kg)
Gross Load: ___________________lbs (kg)
Load Cell Size: _________________lbs (kg)
Belt Loading________________lbs/ft (kg/mt)

INSTRUMENT DATA CALIBRATION DATA

Integrator Model: ________________ Load Cell Resistance______________ohms

Speed Sensor: Model_____________ R-CAL Resistor Value______________ohms
Pulse Output = __________________ R-CAL Equiv. Lbs (kg)__________________
Current Output = ________________

Integrator S/N___________________

Load Cell S/N___________________

Speed Sensor S/N_______________

V
1.0 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.3 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.3.1 Scale Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.4 UNPACKING AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.5 STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.6 WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

2.0 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2 SCALE LOCATION CRITERIA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2.1 Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2.2 Uniform Belt Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.2.3 Material Slippage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.2.4 Convex Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.2.5 Concave Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.2.6 Trippers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.3 CONVEYOR DESIGN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.3.1 Vibration and Deflections . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.3.2 Cable Conveyors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.3.3 Belt Tracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.4 BELT SCALE AREA IDLERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2.4.1 Idler Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2.4.2 Training Idlers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2.4.3 Idler Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

2.5 SINGLE OR DUAL SCALE MODULE INSTALLATION . . . . . . . . . . . . 2-7

2.5.1 Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2.5.2 Site Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2.5.3 Mechanical Installation Single Scale Module . . . . . . . . . . . 2-9
2.5.4 Mechanical Installation Two Scale Modules . . . . . . . . . . . 2-11
2.5.5 Scale Area Idler Alignment . . . . . . . . . . . . . . . . . . . . . . . . 2-13

VI
 2.6 LOAD CELL WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

3.0 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2 SERVICE & REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.3 FREQUENT CHECKPOINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.4 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.4.1 Calibration Shifts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.4.2 Zero Calibration Shifts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.4.3 Span Calibration Shifts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.4.4 Field Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.4.5 Load Cell Excitation and Signal Voltage . . . . . . . . . . . . . . . 3-3

4.0 REPLACEMENT PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.2 ORDERING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.2.1 Return Material Authorization . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.2.2 Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

VII
 LIST OF ILLUSTRATIONS

FIGURE NO. TITLE PAGE

1-1 Model 10-101R-1 Belt Scale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1-2 Model 10-101R-2 Belt Scale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

2-1 Recommended Installation Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2-2 Depth Limiting Gate Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2-3 Conveyor Speed and Slope Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2-4 Convex Curve Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2-5 Concave Curve Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2-6 Tripper Location Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2-7 Cable or Rope Conveyor Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2-8 Belt Tracking Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2-9 Idler Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2-10 Weigh Idler Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
2-11 Single Module Scale Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2-12 Weigh Idler Mounting Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2-13 Dual Module Scale Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
2-14 Load Cell Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

APPENDIX

NO. TITLE

A/1 Installation and Alignment, Belt Scale Model 10-101R-1 D07295A-C001

A/2 Installation and Alignment, Belt Scale Model 10-101R-2 D07295A-C002

VIII
 CHAPTER 1.0
INTRODUCTION

1.1 GENERAL
This instruction manual contains information on the installation and maintenance of your
Model 10-101R Belt Scale.
The Model 10-101R Belt Scale is available with a wide range of useful analog and digital
outputs for applications in a variety of process operations.

1.2 DESCRIPTION
The Model 10-101R Belt Conveyor Scale consists of one or two completely assembled
scale modules.
! Model 10-101R-1 single scale module is for conveyors having belt widths of 36" or
less. A support beam between the conveyor stringers is required for mounting the
scale module in the center of the conveyor. The support beam can be fabricated from
structural tubing, steel channel or other structural configurations in the field at the time
of installation. A C5 steel channel mounting bracket is available as an option from
Thermo Scientific (see Figure 1-1).
! Model 10-101R-2 is for conveyors with belt widths up to 60". The scale consists of
two identical modules with right and left hand cast steel mounting brackets. The
brackets mount directly to the conveyor stringers. No support beam between the
conveyor stringers is required (see Figure 1-2).
Both scales require two approach and two retreat idlers to be aligned along with the
weight idler to provide the necessary “weighing platform” in order to achieve accurate
weighing results.

1.3 SPECIFICATIONS
1.3.1 Scale Module
Minimum Net Load @ Rated Capacity: 15% of load cell capacity
Maximum Gross Load @ Rated Capacity: 80% of load cell capacity
Load Cell Capacity: See data sheet.
Maximum Belt Width: 10-101R-1 = 36"
10-101R-2 = 60"
Load Cell:
Output: 2.0 Mv/V
Excitation: 10 VDC
Temperature Range: Safe: -22° to +194° F
(-30° to +90° C)
Compensated: +14° to +104° F
(-10° To +40° C)
Environmental Protection: Hermetically sealed, IP67
Load Cell Construction: Stainless steel
Cable: 6 conductor shielded, 10 ft.
DO NOT ALTER LENGTH of cable

1-1
MODEL 10-101R-1 BELT SCALE
FIGURE 1-1

1-2
MODEL 10-101R-2 BELT SCALE
FIGURE 1-2

1-3
1.4 UNPACKING AND INSPECTION
The Model 10-101R scale module(s) and installed load cells have been aligned at the
factory for installation in your conveyor and has been properly packaged for shipment.
Inspect all packages for damage before opening, as oftentimes the carrier may be
responsible for shipping damage.

1.5 STORAGE
The Model 10-101R scale module(s) and associated equipment can be safely stored, with
cover latches secured and hole plugs installed, between -58° to +158° F (-50° to +85° C).
The units should be protected against moisture.

1-4
1.6 WARRANTY
THERMO SCIENTIFIC
WARRANTY
The seller agrees, represents, and warrants that the equipment delivered hereunder shall be free
from defects in material and workmanship. Such warranty shall not apply to accessories, parts, or
material purchased by the seller unless they are manufactured pursuant to seller's design, but shall
apply to the workmanship incorporated in the installation of such items in the complete equipment.
To the extent purchased parts or accessories are covered by the manufacturer's warranty, seller
shall extend such warranty to buyer.
Seller's obligation under said warranty is conditioned upon the return of the defective equipment,
transportation charges prepaid, to the seller's factory in Minneapolis, Minnesota, and the
submission of reasonable proof to seller prior to return of the equipment that the defect is due to
a matter embraced within seller's warranty hereunder. Any such defect in material and
workmanship shall be presented to seller as soon as such alleged errors or defects are discovered
by purchaser and seller is given opportunity to investigate and correct alleged errors or defects and
in all cases, buyer must have notified seller thereof within one (1) year after delivery, or one (1) year
after installation if the installation was accomplished by the seller.
Said warranty shall not apply if the equipment shall not have been operated and maintained in
accordance with seller's written instructions applicable to such equipment, or if such equipment
shall have been repaired or altered or modified without seller's approval; provided, however, that
the foregoing limitation of warranty insofar as it relates to repairs, alterations, or modifications, shall
not be applicable to routine preventive and corrective maintenance which normally occur in the
operation of the equipment.
"EXCEPT FOR THOSE WARRANTIES SPECIFICALLY CONTAINED HEREIN, SELLER
DISCLAIMS ANY AND ALL WARRANTIES WITH RESPECT TO THE EQUIPMENT DELIVERED
HEREUNDER, INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS
FOR USE. THE SOLE LIABILITY OF SELLER ARISING OUT OF THE WARRANTY CONTAINED
HEREIN SHALL BE EXCLUSIVELY LIMITED TO BREACH OF THOSE WARRANTIES. THE
SOLE AND EXCLUSIVE REMEDY FOR BREACH OF THE WARRANTIES SET OUT ABOVE
SHALL BE LIMITED TO THE REPAIR OR REPLACEMENT OF ANY DEFECTIVE ACCESSORY,
PART OR MATERIAL WITH A SIMILAR ITEM FREE FROM DEFECT, AND THE CORRECTION
OF ANY DEFECT IN WORKMANSHIP. IN NO EVENT SHALL SELLER BE LIABLE FOR ANY
INCIDENTAL OR CONSEQUENTIAL DAMAGES."
FIELD SERVICE
Purchaser agrees to underwrite the cost of any labor required for replacement; including time,
travel, and living expenses of Thermo Scientific Field Service Engineer at closest factory base.
THERMO SCIENTIFIC
501 90th Avenue N.W.
Minneapolis, MN 55433
Phone: (763) 783-2500
Fax: (763) 783-2525

1-5
 CHAPTER 2.0
INSTALLATION

2.1 GENERAL
All Thermo Scientific Belt Conveyor Scale Systems, regardless of their applications, are
manufactured to the same high degree of accuracy and reliability. However, it is the
application and installation of these systems that determine the overall system operating
capabilities and accuracy that can be realized.

2.2 SCALE LOCATION CRITERIA

In applying belt conveyor scales one must always consider external influences originating
from the material handling system and belt conveyor. Regardless of stated accuracies,
these two factors will determine the overall long-term and short-term accuracy you may
expect. The following guidelines should be adhered to in order to optimize belt scale
performance and weighing accuracy.
2.2.1 Tension
In all installations, the belt scale should be installed in an area where belt tension
and tension variations are minimal. For this reason, the belt scale should be
installed near the tail section of the conveyor, but far enough forward so as not to
be influenced by infeed skirt boards.

RECOMMENDED INSTALLATION AREA

FIGURE 2-1

2-1
2.2.2 Uniform Belt Loading
Although in most applications the scale system is capable of operating accurately
over a 4 to 1 range, it is desirable that the belt loading be as uniform as possible.
To minimize surges or feed variations, hoppers, if possible, should be equipped
with depth limiting gate.

DEPTH LIMITING GATE ILLUSTRATION

FIGURE 2-2

2.2.3 Material Slippage

The belt scale system processes belt loading and belt travel to arrive at an
accurate weight. Product speed must equal belt speed at the scale. For this
reason, the conveyor speed and slope should not exceed that at which material
slippage occurs.

CONVEYOR SPEED AND SLOPE ILLUSTRATION

FIGURE 2-3

2-2
2.2.4 Convex Curves
Convex curves are permissible at a distance of 20 feet or a minimum of five idler
spaces beyond the scale area idlers.

CONVEX CURVE ILLUSTRATION

FIGURE 2-4

2.2.5 Concave Curves

If there is a concave curve in the conveyor before or after scale, the scale should
be installed so that the belt is in contact with all the idler rollers at all times for at
least 20 ft (6 m) or 5 idler spaces, whichever is greater, before and after the scale.
A concave curve should start no closer than 40 ft (12 m) from the scale to the
tangent point of the curve.

CONCAVE CURVE ILLUSTRATION

FIGURE 2-5

2-3
 2.2.6 Trippers
In any installation where weighing accuracy is important, the scale system should
not be applied to a conveyor that has a movable tripper. If the scale must be
installed on a conveyor with a tripper, then the same rules apply as for an
installation in a concave conveyor. The minimum distances outlined in the above
paragraph must be adhered to with the tripper in its fully retracted position.

TRIPPER LOCATION ILLUSTRATION

FIGURE 2-6

2.3 CONVEYOR DESIGN

In the design of the scale system, several deflections are taken into consideration. These
are the deflection of the load cell, scale module 10-101R, and the supporting conveyor
structure. It is of utmost importance that these deflections not be excessive. No conveyor
expansion joints should be located in the scale area.
2.3.1 Vibration and Deflections
The entire conveyor frame should be isolated from bins, feeders, crushers, and
other mechanical equipment. This is to prevent bin loading from causing conveyor
deflections and to protect the weighing equipment from vibrations and shocks
imposed by mechanical equipment.

2-4
2.3.2 Cable Conveyors
Conveyors commonly known as "cable" or "rope" conveyors are not suitable for
electro-mechanical belt conveyor scale weighing unless a rigid conveyor section
long enough to support the scale and scale service idlers is added.

CABLE OR ROPE CONVEYOR ILLUSTRATION

FIGURE 2-7

2.3.3 Belt Tracking

One problem in attaining optimum belt scale accuracy is the effect of belt tracking
from an empty to a fully loaded condition. To enhance belt tracking, the
construction of the belting should have the necessary flexibility to assure contact
with all scale area idler rolls when the belt is running empty. In addition, this also
assures that the conveyed material is being supported by the weigh idler rather
than by the carcass of the conveyor belting.

BELT TRACKING ILLUSTRATION

FIGURE 2-8

2-5
2.4 BELT SCALE AREA IDLERS
Idlers in the weighing area (minimum +2 to -2 idlers and on scale) should be round,
uniform and of same make, troughing angle and rating.
2.4.1 Idler Type
The selection of the idlers used within the scale area is important. This pertains
not only to the idler type, but the idler construction itself. Since idler alignment
plays an important role in the accuracy of a belt conveyor scale, it is important that
all idlers be manufactured as nearly alike as possible. It is also important that
certain types be avoided, such as "V" types and rope or cable types.

IDLER TYPES
FIGURE 2-9

2.4.2 Training Idlers

It is important that the belt tracks centrally from no load to full load conditions.
Training idlers are normally accepted if located at least eight idler spaces either
side of the scale-mounted idlers.
2.4.3 Idler Alignment
The scale mounted idlers and a minimum of two idlers to either side should be
dimensionally aligned. Good idler alignment throughout the entire conveyor is
important to assure adequate and true belt tracking under all load conditions.

2-6
2.5 SINGLE OR DUAL SCALE MODULE INSTALLATION
This section is to be used as a guide in the installation of the 10-101R Scale Modules.
2.5.1 Location
Select the scale location by following Scale Location Criteria, Section 2.2. A
partial listing of the required guidelines follows:
1. Install the scale system on a rigid section of the conveyor.
2. The scale should not be located closer than 20 feet from feeders, hoppers,
and skirt boards.
3. The scale must not be placed in concave or convex curves.
4. The scale should not be installed where conveyor speed and slope causes
material slippage to occur.
5. Locate the scale where it has maximum protection from the elements.
6. The scale conveyor should not be attached to or have vibrating devices
installed on it.
2.5.2 Site Preparation
After determination of scale location in the conveyor, proceed with site preparation
as follows:
1. All scale area idlers must be the same make, style, and model, and should be
in free-rolling and otherwise good mechanical condition.
2. Locate the exact center of the carry roll on all idlers from minus 2 to plus 2.
Permanently scribe or punch this center position on each carry roll. In
addition, perform the same procedure on the minus and plus 2 troughing rolls.
3. Select one idler for the weigh idler and modify if necessary. Refer to weigh
idler modification drawing, Figure 2-10.
4. For ease in equipment installation and alignment, elevate or remove the
conveyor belting from the belt scale area. Belt clearance will be needed from
at least the minus 3 to plus 3 idler.

2-7
WEIGH IDLER MODIFICATION
FIGURE 2-10

2-8
2.5.3 Mechanical Installation Single Scale Module
After scale location selection and site preparation, proceed with installation as
follows. Refer to the installation diagram and system data sheet for idler spacing.
1. Dimensionally locate the minus 2 and plus 2 idler using a known reference
point or the diagonal method. At the same time, shim these idlers 1/4 (0.25)
inch above the belt line. Place a level on the carry rolls and shim as
necessary.
NOTE: Make all dimension measurements from the center of the grease
fittings on the idlers.
2. Mount the scale module to the supporting cross beam. Do not tighten the
scale module mounting bolts (1, 2, and 5) (see Figure 2-11).
3. Scribe a reference mark on both sides of the conveyor an equal distance
between the plus 2 and minus 2 idler.
4. Remove the weigh idler mounting clamps from the mounting plate and scribe
a line in the center of the weigh idler mounting plate (3) (see Figures 2-11 and
2-12).
5. Locate and install the scale module supporting beam (2) on the conveyor
matching the reference marks in steps 3 and 4 above (see Figure 2-11).
6. Level the weigh idler mounting plate by rotating the scale module and/or
shimming under the supporting beam mounting feet. Tighten the scale
module mounting bolts (5) (see Figure 2-11).
7. Modify weigh idler if not already modified by removing the mounting feet and
making a 3/8 (.0375) inch cutout for stringer clearance (see Figure 2-10).
8. Attach modified weigh idler to mounting plate with supplied clamps and
hardware (see Figure 2-12).
9. Remove the load cell shipping bolt (6) (see Figure 2-11).
10. Dimensionally align weigh idler between plus and minus 2 idlers. Proceed to
Section 2.5.5, Scale Area Idler Alignment.

2-9
SINGLE MODULE SCALE ASSEMBLY
FIGURE 2-11

WEIGH IDLER MOUNTING BRACKET

FIGURE 2-12

2-10
2.5.4 Mechanical Installation Two Scale Modules
After scale location selection and site preparation, proceed with installation as
follows. Refer to the installation diagram and system data sheet for idler spacing.
1. Dimensionally locate the minus 2 and plus 2 idler using a known reference
point or the diagonal method. At the same time, shim these idlers 1/4 (0.25)
inch above the belt line. Place a level on the carry rolls and shim as
necessary.
NOTE: Make all dimension measurements from the center of the grease
fittings on the idlers.
2. Scribe a reference mark on both sides of the conveyor an equal distance
between the plus 2 and minus 2 idler.
3. Remove the weigh idler mounting clamps from both mounting plates and
scribe a line in the center of the weigh idler mounting plates (3) (see Figures
2-12 and 2-13).
4. Locate and install the right and left scale modules (2) on the conveyor
stringers matching the reference marks in steps 2 and 3 above (see Figure 2-
13). Scale module supports go on the inside of the stringers.
5. Loosen the scale module mounting bolts (5) (see Figure 2-12).
6. Level the weigh idler mounting plate of one module by rotating the scale
module. Tighten the scale module mounting bolts (5) (see Figure 2-12).
Leave the other side loose.
7. Modify weigh idler if not already modified by removing the mounting feet and
making a 3/8 (.0375) inch cutout for stringer clearance (see Figure 2-10).
8. Attach modified weigh idler to mounting plate of both scale modules with
supplied clamps and hardware (see Figure 2-12).
9. Tighten the scale module mounting bolts on the second scale module.
10. Remove the load cell shipping bolts (6) from both scale modules (see Figure
2-13).
11. Dimensionally align weigh idler between plus and minus 2 idlers. Proceed to
Section 2.5.5, Scale Area Idler Alignment.

2-11
DUAL MODULE SCALE ASSEMBLY
FIGURE 2-13

2-12
2.5.5 Scale Area Idler Alignment
The scale area idlers are composed of the weigh idler and the idlers located
adjacent to and on either side of the weigh idler. The idlers are identified as plus
(+) or minus (-) on the installation drawings. The weigh idler and fixed idlers have
to be considered a part of the scale.
1. Tie a high quality 30 round test monofilament line or equivalent to the base of
the plus 3 idler. Run this alignment wire across the center mark on the plus 2
carry roll through the scale area and across the center mark on the minus 2
carry roll. Attach a 30 pound weight to the end of the wire to maintain
constant tension.
2. Check for clearance between the line and the carry roll of the weigh idler. If
the wire is touching, additional shimming in 1/16 (.0625) inch increments
should be inserted under the plus 2 and minus idlers.
3. Prior to proceeding, a check of the foregoing steps should be reviewed.
a. Plus 2 and minus 2 idler are dimensionally aligned.
b. The scale module and weigh idler are dimensionally aligned to the plus 2
and minus 2 idler.
4. Install additional alignment lines across the plus 2 and minus 2 troughing or
wing rolls. Reference points for alignment wires were established in Step 2 of
Section 2.5.4.
5. Shim and dimensionally align the plus 1 and minus 1 idlers one at a time. The
measurement between each idler and the weigh idler must be accurate to
within ±1/32 (.031) inch. All idlers must be shimmed to within ±1/32 (.031)
inch of the alignment lines.
6. Shim the weigh idler to within 1/32 (.031) inch of the alignment lines.
NOTE: A combination of shimming and movement of the idler may be
necessary to bring the troughing and wing rolls up to the wires.
EXAMPLE: Center roll elevation - OK
Left wing roll elevation - too high
Right wing roll elevation - too low
This indicates one of two conditions:
a. The idler is tipped down to the right. (Remedy: Add shims to the right end
of the idler and remove shims from the left end.)
b. The idler is located too far to the right of the conveyor center. (Remedy:
Shift idler to the left.)

2-13
2.6 LOAD CELL WIRING
The load cell cable is encased in a sealtight flex conduit for protection of the load cell
cable. The load cell cable length should not be altered. Refer to Figure 2-14 below for
load cell connections.

LOAD CELL WIRING

FIGURE 2-14

2-14
 CHAPTER 3.0
MAINTENANCE

3.1 GENERAL
The 10-101R Belt Scale may normally be expected to operate satisfactorily and hold its
calibration for weeks with a minimum of maintenance. However, on a new installation,
some calibration shifts may be expected due to changes in measuring components,
conveyor belt, or idlers.

3.2 SERVICE & REPAIR

The maintenance information in this manual is adequate to meet your service needs.
However, if you run into problems requiring technical assistance, please call 800-
227–8891.
Thermo Scientific has a repair center located at our plant in Minneapolis, Minnesota.
Please contact our Repair Representative at 800-227-8891 for assistance.
Please have available your machine model and serial number as this will expedite your
service request.
When returning parts for repair, please use the Return Material Authorization form located
in the parts section, Chapter 4.0, of this manual.

3.3 FREQUENT CHECKPOINTS

Each installation should be checked frequently to determine when calibration is required.
It is recommended that zero be checked every other day and that calibration be checked
every week for several months after installation. Observe the results and lengthen the
period between calibration checks, depending upon the accuracy desired.
1. Cleaning
Keep scale area clean of rocks, dust, and material build-up.
2. Greasing
The weigh idlers should be greased once or twice yearly. Overloading the weigh
idlers with grease may change the tare weight and place the scale out of calibration.
Zero calibration is necessary after greasing.
3. Belt Training
The belt must be trained to run true to the centerline of the idlers in the area of the
scale while running empty, as well as underloaded conditions. Where this cannot
be accomplished due to off-center loading, the loading should be modified.
Where a belt does not train while empty but does train while loaded, it will be
necessary to train the belt over the scale area at least during the calibration checks.
4. Belt Tension
It is important that conveyor conditions remain constant at all times. Conveyors
which do not have a constant tension device will require calibration whenever the
belt tension changes and the take-up is readjusted.

3-1
 5. Belt Loading
Extreme loading conditions which cause flow rate of material to be above 125
percent of the instrument range must be avoided. Any load capacity above this
amount cannot be measured. Belt loading should be adjusted to stay within the
instrument range.
Belt loading equal to 80 percent of range is recommended.
Conversely, very low flow rates, with respect to full scale range, may produce low
accuracy.
Where extreme high or low flow rates, as described above, persist, the scale range
should be changed.
6. Material Sticking to the Belt
Material may form a film on the belt which is carried continually around the belt and
is never discharged. This condition is often true when handling wet, fine material.
Belt scrapers may correct this condition.
If the film cannot be removed, the zero will have to be adjusted. Any change in the
build-up of the film adhering to the belt will require further adjustment.
7. Skirtboards and Covers
Skirtboards should never be placed closer to the weigh idlers than the +3 or -3 idler.
If skirts or covers are absolutely necessary in the weighing area, they must not
place any external forces on the scale. Even though the skirts are clear of the belt
under "no load" conditions, material will jam or slide between the boards and the
belt when the conveyor is operating. Errors of several percent must be expected
where such conditions exist.

3.4 TROUBLESHOOTING
If your belt scale fails to operate correctly during or after performing set up and calibration
it is suggested to perform the procedure again and if the problem persists follow the
troubleshooting procedures below.
3.4.1 Calibration Shifts
Frequent calibration shifts should be isolated to zero shifts or span shifts.
3.4.2 Zero Calibration Shifts
Zero shifts are normally associated with the conveying system. When a zero shift
occurs, the span will shift by a like number of TPH, this then appears as a span
shift.
Common causes of zero shifts:
1. Material build-up on the weigh idler.
2. Rocks lodged in the scale module or weigh idler.
3. Conveyor belt tracking.
4. Non-uniform conveyor belting.
5. Conveyor belt belting stretch due to material temperature variations.
6. Trouble in the electronic measuring components.
7. Severely overloaded load cell.

3-2
3.4.3 Span Calibration Shifts
Span shifts are normally associated with the electronic measuring of components
of the system, with one exception, which is conveyor belt tension. A span shift is
present if both points change by the same percentage of TPH.
Common causes of span shifts:
1. Change is conveyor belting tension.
2. Speed sensor roll build-up and/or slipping.
3. Conveyor scale alignment.
4. Severely overloaded load cell.
5. Trouble in electronic measuring components.
3.4.4 Field Wiring
1. Check for proper interconnection between components of the system. All
wiring must be as specified on the Field Wiring drawing.
2. Check all wiring and connections for continuity, shorts, and grounds using an
ohmmeter.
CAUTION
DO NOT USE A MEGGAR FOR CHECKING FIELD WIRING.
3. Loose connections, poor solder joints, shorted or broken wires and
unspecified grounds in the wiring will cause erratic readings and shifts in
weight readings.
4. Check that grounding of all cable shields is made at only the locations as
specified on the Field Wiring drawing.
3.4.5 Load Cell Excitation and Signal Voltage
1. Measure excitation voltage across the load cell blue and black leads.
2. Measure DC millivolt signal voltage across the load cell red and white leads.
3. The millivolt output is in direct relation to weight applied. As weight is
increased, output should increase.

3-3
 CHAPTER 4.0
REPLACEMENT PARTS

4.1 GENERAL
This section gives information on how to order replaceable parts for your 10-101R Belt
Scale.

4.2 ORDERING INFORMATION

For faster service when ordering parts, write or telephone Thermo Scientific Parts
Department.
The recommended procedure for ordering parts is as follows:
1. Determine the broken or faulty part(s).
2. Locate the part(s) in the parts list given.
3. Find the part number(s) for the item(s) needed and determine the quantity you
require.
4. Write or telephone:
Thermo Scientific
Customer Service Department
501 90th Avenue N.W.
Minneapolis MN 55433
Phone: 800-227-8891
Telefax: (763) 783-2525

Normal Customer Service hours are 8:00 a.m. to 4:30 p.m., Central Time.
5. With your order, list the following information:
Machine model and serial number
Purchase order number
Date required
Method of shipment preferred
List of parts, including part number, description and quantity.

Your parts order will be handled as expeditiously as possible.

4-1
501 90th Avenue N.W. Minneapolis MN 763-783-2500
Return Material Authorization
RMA No. : -
(This RMA Number Must Be Marked On All
Paperwork And On Outside Of Package)
Req’d. By:
Date: Return, Freight Prepaid To:
Customer Thermo Fisher Scientific
Contact: 501 90th Avenue N.W.
Phone: ( ) Minneapolis, MN 55433
Area Code

Bill To Customer # : Ship To # :

Returned From: Return To:

Description Of Material Being Returned:

Describe Equipment Malfunction Or Defect, If Any; Symptoms:

Minimum Charge
G Informed Customer of G Inspection Charge Per Item

Service Requested:
G Repair & Return G Estimate Required P.O. No.:
G Return for Credit G Original P.O. or Thermo Order No.:

G Warranty Repair or Replacement Serial No:

Original P.O. # Original Order/Job #

G Return Warranty/Exchange Unit Shipped on Thermo Order No.:

G Other:

Disposition/Comments: (Thermo Fisher Scientific Internal Use Only)

REC-G-118 Rev. C 4-2

4.2.2 Parts List

EQUIPMENT PART NUMBER

LOAD CELL

Load Cell, Bending Beam, 50kg 056768

Load Cell, Bending Beam, 100kg 056769

Load Cell, Bending Beam, 200kg 056770

Bracket, Mtg., Idler, 10-101R-2 057030

Bracket, Mtg., Idler, 10-101-R-1 057029