Saimo 6105 Belt Feeder Integrator

6105 Belt Feeder integrator User’’s Guide ---
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6105 Belt Feeder integrator
Installation, Operating and Service

Manual
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Declaration
Thanks for purchasing SAiMO products. This manual guides you through the application of your
selected products, covering the information necessary for installation, operation, maintenance and
service. This document may not be copied or reproduced in any way without the express written
consent of SAiMO. Please note that SAiMO reserves the right to change and/or improve the product
design and specifications without notice. Thanks for your understanding and support.
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.
PROMPT
HELPS YOU USE THE INFORMATION INDICATED ON THE EQUIPMENT BETTER.
· Please read through all the documents dispatched together with the equipments before you start
to work with the equipments.
· For the sake of personal safety and normal operation of the equipments, it is imperative to assure
that only the designed AC power supply is to be used. Reliable 3-pin earthed power outlets must
be used to avoid electric shock when touching the enclosure. Ensure that the rated voltage of the
display or other peripheral devices is compatible with your local AC power requirements.
· The equipment must be protected against thunderstrike.
· Disconnect all the cables from the equipment before you attempt to move the equipment.
· Do not attempt to change any components or external connections on the equipment before the
equipment is powered off.
· Avoid inadvertent power interruption during normal operation.
· Only qualified technicians can be allowed to open the enclosure of the equipment.
· keep the equipment from moisture. Shut off power from the equipment immediately if it is splashed
with water or other liquids occasionally.
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Table of Contents
Chapter 1 Introduction................................................................................................................................................
Introduction................................................................................................................................................ 1
................................................................................................................................................1
1.1 General.................................................................................................................................................................1
1.2 Technical Specifications....................................................................................................................................... 3
1.3 Features................................................................................................................................................................3
1.3.1 Measuring Function.................................................................................................................................. 4
1.3.2 Monitoring Function.................................................................................................................................. 5
1.3.3 Printing Function....................................................................................................................................... 6
1.3.4 Communications (Optional)..................................................................................................................... 6
Chapter 2 Belt scale Installation Guidelines ..............................................................................................................

Guidelines..............................................................................................................
..............................................................................................................77
2.1 General.................................................................................................................................................................7
2.2 Wind and Weather Influence.................................................................................................................................7
2.3 Conveyor Support.................................................................................................................................................7
2.4 Location of the Belt scale..................................................................................................................................... 7

2.4.1 Belt Tension................................................................................................................................................7
2.4.2 Conveyor With Concave Curve...............................................................................................................8
2.4.3 Conveyor with Convex Curve..................................................................................................................8
2.4.4 Tripper.........................................................................................................................................................8
2.4.5 Consistent Belt Loading........................................................................................................................... 8
2.4.6 Single Loading Point.................................................................................................................................8
2.4.7 Material Slippage.......................................................................................................................................8
2.5 Gravity Type Belt Tensioner................................................................................................................................. 8
2.6 Belt Troughing Angle............................................................................................................................................9
2.7 Weigh Area Idler...................................................................................................................................................9

2.7.1 Weigh Area Idler Construction.................................................................................................................9
2.7.2 Troughing Angle of Idler........................................................................................................................... 9
2.7.3 Self-aligning Idler (preventing belt misalignment)................................................................................ 9
2.7.4 Idler Alignment........................................................................................................................................... 9
Chapter 3 Belt scale Installation Procedures...........................................................................................................

Procedures........................................................................................................... 10
...........................................................................................................10
3.1 N62-1 Belt scale Installation..............................................................................................................................10

3.1.1 Overview...................................................................................................................................................10
3.1.2 Terminology..............................................................................................................................................10
3.1.3 Location of N62 Belt scale..................................................................................................................... 11
3.1.4 Field Preparation for Installation........................................................................................................... 11
3.1.5 Weighbridge Installation......................................................................................................................... 11
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3.2.1 Overview...................................................................................................................................................12
3.2.2 Terminology..............................................................................................................................................13
3.2.6 Scale Idler Installation............................................................................................................................ 15

3.3.1 Overview...................................................................................................................................................16
3.3.2 Terminology..............................................................................................................................................17
3.3.6 Scale Idler Installation............................................................................................................................ 18
3.4 Load Cell Installation........................................................................................................................................ 19

3.4.1 Overview...................................................................................................................................................19
3.4.2 Inspection, Unpacking and Storage..................................................................................................... 19
3.4.3 Installation................................................................................................................................................ 20
3.4.4 Principle of Operation............................................................................................................................. 21
Chapter 4 6105 Integrator Installation.................................................................................................................... 22

Installation....................................................................................................................
4.1 General...............................................................................................................................................................22
4.2 6105 Integrator Installation............................................................................................................................... 22

4.2.1 Mounting................................................................................................................................................... 22
4.2.2 Safety Precautions.................................................................................................................................. 22
4.2.3 Wiring (External Power Supply)............................................................................................................ 23
Chapter 5 Operation..................................................................................................................................................
Operation.................................................................................................................................................. 25
..................................................................................................................................................25
5.1 Keypad............................................................................................................................................................... 25
5.2 Run Menu........................................................................................................................................................... 26

5.2.1 Reset Total............................................................................................................................................... 26
5.2.2 Alarm Menu..............................................................................................................................................27
5.3 Main Menu......................................................................................................................................................... 27

5.3.1 Initial Setup Menu................................................................................................................................... 28
5.3.2 Calibration................................................................................................................................................ 37
5.3.3 System Data Menu................................................................................................................................. 45
5.3.4 I/O Definition Menu................................................................................................................................. 52
5.3.5 Communication Menu.............................................................................................................................61
5.3.6 Alarm Setup Menu.................................................................................................................................. 63
5.3.7 Loadout Setup Menu.............................................................................................................................. 66
5.3.8 Password Setup Menu........................................................................................................................... 66
5.3.9 Diagnostics Menu....................................................................................................................................68
5.3.10 Statistics Menu........................................................................................................................................ 69
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Chapter 6 Integrator Maintenance ...........................................................................................................................

Maintenance........................................................................................................................... 72
...........................................................................................................................72
6.1 Daily Maintenance Routines of 6105 Integrator................................................................................................72
6.2 6105 Integrator Troubleshooting --- Fault Isolation..........................................................................................72

6.2.1 Power Supply Examination....................................................................................................................74
6.2.2 Speed Input..............................................................................................................................................74
6.2.3 Load Cell Input.........................................................................................................................................74
6.2.4 Current Output (Optional)...................................................................................................................... 75
6.2.5 Constant Setup........................................................................................................................................ 77
6.3 Usual Troubleshooting....................................................................................................................................... 77
Chapter 7 Speed Sensor .............................................................................................................................................

Sensor............................................................................................................................................. 78
.............................................................................................................................................78
7.1 General...............................................................................................................................................................78
7.2 Inspection, Unpacking and Storage................................................................................................................... 78
7.3 Installation......................................................................................................................................................... 79
7.3.1 Mechanical Part Installation...................................................................................................................79
7.3.2 Electrical Part Installation.......................................................................................................................79
7.4 Working Principle.............................................................................................................................................. 80
Chapter 8 Belt Scale Maintenance ............................................................................................................................

Maintenance............................................................................................................................ 81
............................................................................................................................81
8.1 General...............................................................................................................................................................81
8.2 Daily Maintenance Routine for Belt Scale......................................................................................................... 81
8.3 Troubleshooting the Belt Scale...........................................................................................................................82
Chapter 9 Belt Scale Installation Parameters ..........................................................................................................

Parameters.......................................................................................................... 83
..........................................................................................................83
9.1 Scale Capacity....................................................................................................................................................83
9.2 Belt Scale Dimensions........................................................................................................................................83
9.3 Load Cell Data...................................................................................................................................................88
Chapter 10 Permanent Field Record ..........................................................................................................................

Record.......................................................................................................................... 89
..........................................................................................................................89
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Chapter 1 Introduction
1.1 General
Incorporating the latest technologies and years of industry, Saimo Weigh Belt Feeder Systems provide
accurate and reliable solutions for weighing, totalizing, flow rate control for industries such as
metalliferous ore blending, power generation, quarry, cement, chemical and food, etc.
The belt feeder senses and weighs the material passing through the weighbridge to determine unit
weight (in kgs/m) of the material on the belt. Belt speed is continually measured with a digital speed
sensor whose pulse output is proportional to belt speed. The speed sensor is mounted on the tail-pulley
to assure accurate belt speed measurement and detection of any possible slippage. The speed signal
and weight signal are combined into the 6105 microprocessor-based integrator which generates and
displays a true-rate signal in TPH and the total of material fed. An internal controller compares the
flowrate signal to the feedrate setpoint derived from an industrial computer and sends necessary output
signal to the frequency converter, consequently changing the feeder’s belt speed to maintain the
desired constant rate of material fed. The total of material fed is monitored by the computer which
submits shutoff signal when a setup total is reached.This manual provides the information necessary
for installation, operation, maintenance and service of the 6105 integrator.
The 6105 integrator is available in panel mount and field mount. By processing the weight signal from
the load cell and the speed signals from the speed sensor, It calculates and displays flowrate and total
of the material fed.
Figure 1-1 6000 Series Integrator -- Panel Mount
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Figure 1-2 6000 Series Integrator --- Field Mount
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1.2 Technical Specifications

(a) Chinese / English menu
(b) Weighing Capability
· The 6105 integrator is capable of connecting up to eight 350Ω loads and acquiring a speed signal
from the speed sensor, to calculate flow rate and total.
· The 6105 integrator has the function of automatic zero calibration.
(c) Ambient Environment
· Location: Indoor or outdoor, as close as possible to the load cells, free from damp and dust.
· Temperature:
Storage temperature: -40~+70ºC
Operating temperature -10~+50ºC
· Maximum Relative Humidity: 95%
(d) Power Requirements
· 220VAC±10% or 110VAC±10% 50Hz
· Fuse: 2A
· EMI / RFI filter
(e) Load Cell
· offers 10VDC(+/-10%), 500mA excited power, up to 8 load cells
· Sensitivity: 0.5mV/V ~ 3.5mV/V
· Max. input signal 33mV
· Load cell shield grounding
· Excitation compensation circuit is employed when the cable distance is over 60 meters but less
than 900 meters.
· Local or remote compensation can be selected by a jumper set.
(f) Mainboard Digital Input
The mainboard provides 6 programmable inputs for receiving dry contact on-off signal
(g) Mainboard Digital Output
The mainboard provides 8 programmable outputs.
(h) Outline Dimensions
Panel mount: Outliner dimensions: 288mm x 144mm x185mm
Front panel dimensions: 284mm x140mm
Field mount: Outline dimensions: 312mm x 380mm x 150mm
Mounting hole dimensions: 240mm x 450mm
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1.3 Features
Saimo 6105 integrator is specially designed for belt scales, meeting all measuring and control
requirements on typical applications.
The software has been solidified into the memory chip. Each preprogrammed function can be activated
automatically by operating from the keypad or installing the optional expansion board.
Saimo 6105 integrator has a powerful and user friendly operating interface, easy for function selection,
data setup, operation and maintenance.
The following functions have been completed into Saimo 6105 integrator.
· Measuring
· Monitoring
· Printing
· Communication
Figure 1-3 Front Panel
1.3.1 Measuring Function

1. Instantaneous Flowrate Calculation
The signal delivered by the load cell(s), which represents the weight per unit length of the belt(kg/m), is
multiplied by the signal delivered by the speed sensor which represents the belt speed (m/s). The result
of this operation is the instantaneous flowrate (kg/m x m/s=kg/s) which is then multiplied by suitable
constant to obtain the value in the required engineering units (kg/h or ton/h, etc.). An adjustable
damping filter is provided separately for displayed rate and current outputs.
2. Flow Totalization
The total is accumulated by multiplying mass per unit length by incremental length and totalizing the
result in engineering units.
3. Zero and Span Automatic Calibration

Zero and span calibrations are based on belt length defined by a number of belt revolutions.
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To calculate the exact number of revolutions, the instrument counts the pulses delivered by the speed
sensor (one pulse represents a specific belt length); when the required number of pulses is reached,
the instrument ends the calibration test, and compares the actual totalized value to the theoretical one
(0 for zero calibration), and calculates the calibration constant.
The calibration constant is a calculated value that can be factored based on an actual material test.
- Electronic Calibration (R-Cal)
Allows the operator to perform the calibration without the need of applying test weights or test chain
on the weighbridge. The electronic calibration checks all the circuitry including the load cell, and is
performed by unbalancing the load cell bridge using a precision resistor. The calibration constant is
calculated on the basis of the load cell and the scale data.
- Test Weight Calibration
Requires the positioning of test weights on the weighbridge
- Chain Calibration
Requires the application of calibrated chains on the belt. This method is the nearest to actual
operating conditions.
- Material Calibration
Is performed by running a known quantity of material on the scale and weighing that quantity on a
static scale of known accuracy.
4. Zero Tracking (AZT)

Under a preset minimum flowrate when enabled, the instrument makes subsequent automatic zero
calibrations with the following sequence:
- performs automatic zero for one test duration.
- continuously repeats above zero calibration as long as feed rate remains below AZT preset value.
5. Current Output Signals

An optional current output/analog input board is available. Each current output may be programmed via
the keyboard to deliver one of the following signals:
- flowrate
- belt loading
- belt speed
- control signal
1.3.2 Monitoring Function

Saimo 6105 integrator is equipped with an indication system. Indication can be in the form of:
- status indications
- process alarms
- programming errors
- equipment failures
The integrator includes internal diagnostics that will generate alarms in case of hardware failures or
programming errors. The following process alarms are also provided:
· Belt slip (two speed sensors recommended)
· Alarms for high and low flowrate, speed and weight
These alarms are visible on the display and can be acknowledged and reset through keyboard, digital
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input or serial line. Alarms can be delayed to avoid intervention in case of short time peaks. Each
individual alarm can be programmed to operate as alarm, shut down or to be ignored.
1.3.3 Printing Function

Periodical and under command prints can be obtained by connecting a serial printer to an optional
communication board.
1.3.4 Communications (Optional)

· Serial Communications
The communication protocol allows a remote intelligent device to read and eventually write the
contents of the registers.
During the communication activity, the 6105 integrator always acts as a Slave. This means it
responds to a request from a Master device on the line, but never attempts to send messages out.
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Chapter 2 6105 Integrator Installation

nstallation
2.1 General
This chapter contains the information about the installation, configuration and initial programming of the
6105 belt feeder integrator. Initial programming is a machine directed procedure prompting the operator
to enter required conveyor and belt scale parameters. After all parameters have been entered, the
integrator performs an unassisted zero and span calibration.
The controller should not be installed at a place subject to severe variation environmentally. It is
preferred to be installed indoors, otherwise proper protective measures should be taken to prevent it
from exposure to direct sunlight, moisture, collision and severe mechanical vibration.
2.2 6105 Integrator Installation

The 6105 integrator must be installed indoors, not be exposed to excessive vibration, heat or moisture.
The panel mount integrator should be installed in a control panel. After installation, dustproof measures
should be taken for the front panel of the integrator and the control cabinet.
2.2.1 Mounting
The 6105 field mount feeder controller can be vertically secured to the rigid and flat wall through the 4
mounting holes at the back of the enclosure. Care should be taken to insure the mounting surface is flat
so as not to twist or warp the fiberglass enclosure when tightening the mounting holes.
The 6105 panel mount integrator should have a clearance of at least 5cm at the top and bottom to allow
air circulation. In case that the integrator must be positioned under the heat sources, proper space
around the integrator should be reserved. Sufficient space should be kept behind the integrator to
facilitate wiring and changing fuse. The side clearance should be easy for securing the holding brackets
after the 6105 has been put in place. Disconnect power supply from the integrator when mounting the
bracket. From the back, insert the holding brackets on both sides of the integrator firstly, then screw
down tightly to secure the integrator and prevent dust ingress.
2.2.2 Safety Precautions

Do not install, operate, or perform any maintenance procedures until you have read the safety
precautions which follow.
1. Do not connect power to the electronics or turn on the unit until you have read and understood this
entire manual. The precautions and procedures presented in this manual must be followed carefully
in order to prevent equipment damage and protect the operator from possible injury.
2. CAUTION
Hands and clothing must be kept away from all moving or rotating parts.
3. WARNING
Covers over the electronics should always remain in place during operation. They should be
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removed only fro maintenance procedures with the machine’s power OFF. Be sure to replace all
covers before resuming operation.
4. WARNING
All switches (such as control or power) must be OFF when checking input AC electrical connections,
removing or inserting printed circuit boards, or attaching voltmeters to the system.
5. Incoming voltages must be checked with a voltmeter before being connected to the electronics.
6. WARNING
Extreme caution must be used in testing in, on, or around the electronics, PC boards, or modules.
There are voltages in excess of 115V or 230V in these areas. Avoid high voltage and static
electricity around the printed circuit boards.
7. Maintenance procedures should be performed only by qualified service personnel and in

accordance with procedures / instructions given in this manual.
8. During maintenance, a safety tag (not supplied by Saimo) should be displayed in the ON/OFF
switch area as a precaution instructing others not to operate the unit.
9. Only qualified service technicians should be allowed to open and work in the electronics, power
supply, control, or switch boxes.
10. Objects should never be placed or stored on the integrator.
11. This equipment should not be operated nor utilized in applications other than those stated in the
original order. (To adapt production rates or applications, consult Saimo for recommendations.)
12. All panels covering the electronics must be in place and tight before wash down procedures.
Damage to the electronics could result from water, moisture, or contamination in the electronics
housing.
2.2.3 Wiring (External Power Supply)

Do not connect power unit until you have read and understood this entire section. Improper connection
may result in damage to your integrator.
CAUTION
Verify that the input voltage is correct with an AC voltmeter before you connect it to the integrator.
Earth ground must be provided to the integrator. Do not use conduit to provide this ground.
A readily accessible disconnect device (such as breaker, maximum 20A) shall be incorporated in the
field wiring. This disconnect device should be in easy reach of the operator and it must be marked as
the disconnecting device for the equipment.
1. Critical wiring conditions:

A. Insure power is off.
B. Do not route load cell and signal cables in the same conduit with power cables or any large source of
electrical noise.
C. Earth ground all enclosures and conduits. A ground connection between all conduit is required.
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D. Wiring should be long enough to allow the field terminal entry panel to swing down for circuit board
access.
E. Connect the shields ONLY where shown.
F. Check that all wires are tight in their connections.
G. Never use a “megger” to check the wiring.
H. A readily accessible disconnect device (such as breaker, maximum 20A) shall be incorporated in the
field wiring. This disconnect device should be in easy reach of the operator and it must be marked
as the disconnecting device for the equipment.
I. All conduits should enter the bottom of the enclosure. Do not run conduit through the top or sides of
the enclosure.
2. The following figure shows the wiring diagram of the 6105 integrator.:
6105
Figure 4-1 6105 Integrator Wiring Diagram
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Chapter 3 Opera tion

Operation
3.1 Keypad
This chapter describes operating procedures for the 6105 integrator.
The keypad on the front panel includes hard keys and five soft keys. Hard keys located on the right half
side of the front panel perform specific functions as assigned. Below is a list of the keys and their
functions:
1. “RUN” – enter the running mode, the controller can enter the running mode whenever the key is
pressed.
2. “MENU” – enter the main menu
3. “CHK” – self-check function (disabled)
4. “DEL” – delete the digit or punctuations
5. Numeric keys 0~9—input the data parameter
6. Decimal“.”—input the decimal
7. “UP”, “DOWN”, “RIGHT”, “LEFT” arrow key — move cursor in different directions
The five soft keys located under the LCD perform different functions depending on the menu being
Figure 5-1 Front Panel
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3.2 Run Menu
2006-3-21 12:00:00 Scale#1
8000000 t
888 t/h
1m/s
System running!
ZERO PID BAT SYS RSET

CAL BMP RUN ALRM TOT
3.2.1 Reset Total

Press “RSET TOT” from the Run Menu, the following screen is displayed:
2006-3-21 12:00:00 Scale#1
8000000 t
888 t/h
1m/s
System running!
ZERO TOT MAIN

CAL RSET TOT
Press TOT RSET soft key, the integrator will display ”Press ENT to reset total.” Then Press ENT key to
reset the total.
If ENT key is pressed, the reset total will be zero, but the master total remains not changed.
To reset the master total, enter “System Password Setup” menu to get the access to this function.
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3.2.2 Alarm Menu

On the Run Menu, pressing “SYS ALRM” soft key enters the following screen:
2006-3-21 12:00:00 Scale#1
ALARM DETAILS
ALARM NAME: [LO SPEED ]
ALARM DATE: [ 2005-06-08 ]
ALARM TIME: [ 12:00:00 ]
ALARM ACTION: [ NEW ]
System running!
RUN ALRM PAGE PAGE

RSET DOWN UP
Use Up/Down scroll keys to move the cursor to the desired item and press ENT to confirm and then
change the settings.
3.2.3 PID Control Menu

In the Run Menu, pressing “PID BMP” soft key enters the following screen:
2006-3-21 12:00:00 Scale#1
SET RATE : [ 800 t/h ]

800 t/h
OUTPUT : [ 100 % ]
Press ↑ or ↓ key, then press ENT!
ZERO PREV
CAL RUN
Use Up/Down scroll keys to move the cursor to the desired item and press ENT to confirm and then
change the settings.
There are two parameters settable on this screen. “Set Rate” represents the flow rate setting value.
“Output” represents the control output.
When the “Setting Mode” is set to “LOCAL”, the “Set Rate” setting is allowed to be manually input.
When the “Control Mode” is set to “MANU”, the “Output” setting is allowed to be manually input.
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3.3 Main Menu

Press ”MENU” button on the front panel, the following screen is accessible.
2006-3-21 12:00:00 Scale#1
1. INITIAL SETUP
2. CALIBRATION
3. SYSTEM DATA
4. I/O DEFINITION
5. COMMUNICATION
Press a numeric key to select!
RUN PAGE USA

DOWN CHR
Press a numeric key (1-5) to select the submenu. Press “RUN” to return to Run Menu. Use the USA
CHR soft key to switch between Chinese and English.
Press “PAGE DOWN” soft key, the second page of the Main Menu is displayed as follows:
2006-3-21 12:00:00 Scale #1
6. ALARM SETUP
7. LOADOUT SETUP
8. PASSWORD SETUP
9. DIAGNOSTICS
10. STATISTICS
Press a numeric key to select!
PREV PAGE
RUN UP
Press numeric keys (6-10) to select the submenu. Press “PREV RUN” to return to Run Menu. Press
“PAGE UP” soft key to return to the first page of the Main Menu.
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3.3.1 Initial Setup Menu
5.3.1.1 Initial Setup 1

Press “1” from the first page of the Main Menu, the screen shows:
2006-3-21 12:00:00 Scale #1
INITIAL SETUP 1
Measure Units: [ METRIC ]
Total Units: [ t ]
Length Units: [ METERS ]
Rate Units: [ t/h]
Press ENTR to select, then press ENT!
MAIN PAGE
MENU DOWN
Pressing “MAIN MENU” soft key can return to the Main Menu.
Move the cursor to “MEASURE UNIT” with the up/down scroll keys; then press ENT, the following
screen is displayed.
2006-3-21 12:00:00 Scale #1
INITIAL SETUP 1
Measure Units: METRIC
Total Units: [ t ]
Length Units: [ METERS ]
Rate Units: [ t/h]
Press ENTR to select, then press SURE!
MAIN ENTR SURE PAGE

MENU DOWN
In this menu, if Up/Down scroll keys are pressed, the default unit “Metric” is accepted and the cursor
moves to other variables.
Otherwise, if “ENTR” soft key is pressed, the measure unit value changes among “English”, “Metric ”
and “Mixed”. When the desired option is displayed, press “SURE” soft key to input the value. At this
time the screen returns to the first page of Initial Setup 1 menu.
You can use the same method to setup other units listed in the menu.
Measure Units: English, Metric, Mixed
Total Units: t, kg
Length Units: Meters
Flow Rate Units: t/h, kg/h, t/m, kg/m
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Press “PAGE DOWN” soft key from the first page of the Initial Setup 1 Menu, the first page of the Initial
Setup 2 Menu is shown as follows:
2006-3-21 12:00:00 Scale #1
INITIAL SETUP 2
Loadcell Units: [ kg]
Scale Capacity: [ 500 kg/h ]
Scale Division: [1]
Scale Code: [1]
MAIN CODE PAGE PAGE

MENU DATA DOWN UP
Use Up/Down scroll keys to move the cursor to the desired variable, and press ENT to enter the
following screen.
2006-3-21 12:00:00 Scale #1
INITIAL SETUP 2
Loadcell Units: [ kg]
Scale Capacity: 500
Scale Divison: [1]
Scale Code: [1]
MAIN SURE PAGE PAGE

MENU DOWN UP
If a digital value is entered, and press “SURE” soft key, the screen return to the first page of Initial Setup
2 menu. You can use the same method as described in section 5.3.1.1 to setup other parameters listed
in the menu.
Load Cell Unit: kg
Scale Capacity: Min:1 Max:200000
Scale Division: 0.1、0.2、0.5、1、2、5、10、20、50、0.01、0.02、0.05、0.001、0.002、
0.005
Scale Code: Min:0 Max:500
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5.3.1.3 Scale Code Data

Press “CODE DATA” from the first page of Initial Setup 2 Menu, the following screen is displayed.
2006-3-21 12:00:00 Scale #1
SCALE CODE DATA 1

P to L : [ 1000mm]
# OF Idlers: [1]
P to 1 st: [ 800mm ]
P to 2 nd: [ 800mm ]
MAIN PAGE PAGE

MENU DOWN UP
Use the same method as described in section 5.3.1.2 to set the digital value for each variable.
P to L (Pivot to load cell distance): Min:0 Max:3800mm
# of weigh idlers: Min:1 Max:6
P to 1st (Pivot to the 1st weigh idler distance): Min:0 Max:2500mm
P to 2nd (Pivot to the 2nd idler distance): Min:0 Max:2500mm
Press “PAGE DOWN” soft key to enter the second page of the Scale Code Data Menu.
2006-3-21 12:00:00 Scale #1
SCALE CODE DATA 2

P to 3 rd: [ 800mm ]
P to 4 th: [ 800mm ]
P to 5 th: [ 800mm ]
P to 6 th: [ 800mm ]
MAIN PAGE PAGE

MENU DOWN UP
P to 3rd (Pivot to the 3rd weigh idler distance): Min:0 Max:2500mm
P to 4th (Pivot to the 4th weigh idler distance): Min:0 Max:2500mm
Press “PAGE DOWN” soft key to enter the third page of the Scale Code Data Menu.
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2006-3-21 12:00:00 Scale #1
SCALE CODE DATA 3

P to Test High: [ 100mm ]
P to Test Len: [ 100mm ]
P to carry: [ 100mm ]
R to carry: [ 100mm ]
MAIN PAGE PAGE

MENU DOWN UP
P to test hi (Pivot to test weight height): Min:0 Max:250mm
P to test le (Pivot to test weight length): Min:0 Max:250mm
P to carry (Pivot to carriage height): Min:0 Max:250mm
R to carry (Carry roll to carriage height):Min:0 Max:250mm

Press “PAGE DOWN” soft key from the Initial Setup 2 Menu described in Section 5.3.1.2, the first page
of Initial Setup 3 Menu is displayed as follows:
2006-3-21 12:00:00 Scale #1
INITIAL SETUP 3
# of Loadcells: [1]
Idler Spacing: [ 100mm ]
Conveyor Angle: [ 10 ]
Loadcell Cap: [ 100 kg ]
MAIN PAGE PAGE

MENU DOWN UP
#of Loadcells: Min:1 Max:6
Idler Spacing: Min:50 Max:2500mm
Conveyor Angle: Min:-25 Max:25
Loadcell Cap: Min:1kg Max:5000kg
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Press “PAGE DOWN” soft key from the Initial Setup 3 Menu described in Section 5.3.1.4, the first page
of Initial Setup 4 Menu is displayed as follows:
2006-3-21 12:00:00 Scale #1
INITIAL SETUP 4
Sensitivity: [ 3 mv/v ]
1# Resistor: [ 350 Ohms]
MAIN PAGE PAGE

MENU DOWN UP
Sensitivity: Min:0.5 Max:3.5
#1 load cell resistor: Min:0 Max:350

Press “PAGE DOWN” soft key from the Initial Setup 4 Menu described in Section 5.3.1.4, the fifth page
of Initial Setup Menu is displayed as follows:
2006-3-21 12:00:00 Scale #1
INITIAL SETUP 5
Weight Channel: [ CHANNEL 1 ]
MAIN PAGE PAGE

MENU DOWN UP
Weight channel: Channel 1, Channel 2, Dual
18
--- User
Note: When Dual channels are used for the weight channel, the two load cells should be connected to
the channel 1 and channel 2 separately on the A/D board.

Press “PAGE DOWN” soft key from the Initial Setup 5 Menu described in Section 5.3.1.5, the sixth page
of Initial Setup Menu is displayed as follows:
2006-3-21 12:00:00 Scale#1
INITIAL SETUP 6
Speed Mode: [ SIMULATE ]
Speed Channel: [CHANNEL 1]
MAIN PAGE PAGE

MENU DOWN UP
Note: the setting value of the speed mode is “Simulated” and “Actual”. When “Simulated” is selected,
the integrator will generate an analog signal for speed input. In case that “Actual” is selected, the speed
input is an actual speed signal. Simulation allows operation without a speed sensor.
There are two channels for selection: Channel 1 and Channel 2.
5.3.1.7 Establishing Test Duration

Press “PAGE DOWN” soft key from the Initial Setup 6 Menu, the first page for establishing test duration
appears.
2006-3-21 12:00:00 Scale#1
8000000 t
888 t/h
1m/s
Establish test duration!
AUTO MANL PAGE

DURA DURA UP
19
--- User
Because the belt scale is a dynamic measuring equipment. The weighing accuracy has a close relation
with the conveyor. Select a certain period of running time to measure the tare and calculate the average
value.
The test duration should be set to a value equivalent to over one belt revolution or greater than 6min.
Pressing “MANL DURA” soft key enters the following screen:
2006-3-21 12:00:00 Scale#1
MANUAL TEST DURATION DATA

Belt Length: [ 10 m ]
Revolutions: [ 1 ]
Running Time: [ 10 s ]
BGIN PAGE
DURA UP
Input the settings for Belt Length, Revolution and Running time on this menu.
Pressing “BGIN DURA” soft key enters the following screen:
2006-3-21 12:00:00 Scale #1
8000000 t
888 t/h
1m/s
Establishing test duration, Please wait!
[ 10 ]
BGIN PAGE
DURA UP
20
--- User
When test duration acquisition is finished, the following screen appears:
2006-3-21 12:00:00 Scale #1
8000000 t
Full Length: 100 m
Running Time: 100 sec
Test duration is established!
[ 10 ]
BGIN EXIT PAGE PAGE
DURA DURA DOWN UP
If press “AUTO DURA” soft key from the first screen described in section 5.3.1.7, the following screen
appears:
2006-3-21 12:00:00 Scale #1
8000000 t
Revolutions:1
Running Time:1
Establishing test duration, Please wait!
BGIN DONE EXIT MARK PAGE

DURA DURA DURA CNT UP
Press “FULL DURA” or “PART DURA”, the following screen is displayed.
2006-3-21 12:00:00 Scale #1
8000000 t
Revolutions: 1
Running Time: 1
Establishing test duration, Please wait！

21
--- User
When the test duration acquisition is finished, the fourth screen described in section 5.3.1.7 appears.
5.3.1.8 Initial Calibration
Press “PAGE DOWN” soft key from the first screen mentioned in section 5.3.1.7, the following menu
displays:
2006-3-21 12:00:00 Scale #1
8000000 t
888 t/h
1m/s
Auto span station!
[ 100 ]
MAIN
MENU
When the calibration is finished the following screen will appear:
2006-3-21 12:00:00 Scale #1
8000000 t
888 t/h
1m/s
Scale calibrated, press RUN to start!
MAIN
MENU
When the calibration is finished, the screen returns to Run Menu as described in section 5.2..
22
--- User
3.3.2 Calibration
Pressing “2” from Main Menu enters the Calibration Menu.
2006-3-21 12:00:00 Scale #1
CALIBRATION
2.1 ZERO CALIBRATION

2.2 SPAN CALIBRATION
2.3 MATL CALIBRATION
MAIN
MENU
Move the cursor to the desired item with Up/Down scroll keys and press ENT key to select it.
5.3.2.1 Zero Calibration

Zero Calibration menu is accessible by selecting “2.1 ZERO CALIBRATION” from the Calibration Menu
as shown in section 5.3.2.
2006-3-21 12:00:00 Scale #1
8000000 t
888 t/h
1m/s
Zero calibration mode!
AUTO EXIT MANL

ZERO ZERO ZERO
23
--- User
a. Automatic Zeroing
Press “AUTO ZERO “ soft key to enter the following screen.
2006-3-21 12:00:00 Scale #1
8000000 t
888 t/h
1m/s
Zero calibration mode!
BGIN EXIT
ZERO ZERO
Press “BGIN ZERO “ soft key to enter the following screen.
2006-3-21 12:00:00 Scale #1
8000000 t
888 t/h
1m/s
Auto zero in progress, please wait！
[ 100 ]
BGIN EXIT
ZERO ZERO
In case that the belt is interrupted during the zero calibration procedure, the following screen will be
displayed.
2006-3-21 12:00:00 Scale #1
8000000 t
888 t/h
1m/s
Belt stops!
BGIN EXIT
ZERO ZERO
24
--- User
When auto-zeroing is finished, the following screen appears.
2006-3-21 12:00:00 Scale #1
8000000 t
Old zero:[ 888 ]
New zero:[ 1000 ]
Auto zero complete!

Error:[ -11.2% ]
BGIN EXIT SURE
ZERO ZERO ZERO
When “SURE ZERO” is pressed, the following prompt message is displayed.
2006-3-21 12:00:00 Scale #1
8000000 t
888 t/h
1m/s
Auto zero mode!
BGIN EXIT
ZERO ZERO
b. Manual Zeroing
If press “MANL ZERO” soft key from the Zero Calibration Menu mentioned in section 5.3.2.1, the
Manual Zeroing screen appears:
2006-3-21 12:00:00 Scale #1
8000000 t
Old zero: [ 888 ]
New zero:
Manual zero mode!
Input zero:
BGIN EXIT SURE SURE

ZERO ZERO ZERO
25
--- User
Press numeric keys to enter the new zero and press “SURE ZERO” to validate it.
5.3.2.2 Span Calibration

Span is also called as weigh span, i.e. indication response to change of standard weight on the load
receptor. The purpose of span calibration is to remedy the difference between the reading and the
standard weight on the load receptor.
There are two different system calibration modes: simulated calibration and material calibration.
Three simulated span calibration methods are available: R-cal, test weights and test chains. For these
methods, it is important to determine the simulated constant which can be calculated using some
formulas. When performing span calibration, the calibration method should be firstly selected, and the
relevant resistor or test weights / chain weights parameters should be entered into the integrator.
The following Span Calibration menu is accessible by selecting “2.2 SPAN CALIBRATION” from the
Calibration Menu as shown in section 5.3.2.
2006-3-21 12:00:00 Scale #1
8000000 t
888 t/h
1m/s
Span! Load reference weight!
AUTO EXIT MANL

CAL CAL CAL
There are two spanning modes available: automatic spanning and manual spanning.
a. Auto Spanning
Pressing STRT soft key enters the following screen:
2006-3-21 12:00:00 Scale #1
8000000 t
888 t/h
1m/s
Auto span in progress, please wait!
[ 100 ]
BGIN EXIT
CAL CAL
In case that the belt is interrupted during the calibration procedure, the following screen will be
displayed.
26
--- User
2006-3-21 12:00:00 Scale #1
8000000 t
888 t/h
1m/s
Belt stops, Cal stop !
BGIN EXIT
CAL CAL
When the automatic span calibration is finished, the screen returns to the first menu of Auto Span.
b. Manual Spanning
If press “MANL SPAN” soft key from the Span Calibration Menu mentioned in section 5.3.2.2, the
Manual Spanning screen appears:
2006-3-21 12:00:00 Scale #1
8000000 t
Old span:[ 888 ]
New span:
Manual span mode!
Input span:
BGIN EXIT SURE

CAL CAL SPAN
Press numeric keys to enter the new span and press “SURE SPAN” to validate it.
5.3.2.3 Material Calibration

Material Calibration menu is accessible by selecting “2.3 ZERO CALIBRATION” from the Calibration
Menu as shown in section 5.3.2.
27
--- User
2006-3-21 12:00:00 Scale #1
8000000 t
888 t/h
1m/s
Materiel calibration!
BGIN EXIT
CAL CAL
Pressing “BGIN CAL” soft key enters the following screen:
2006-3-21 12:00:00 Scale #1
8000000 t
888 t/h
1m/s
Material calibration, please wait!
[8]
BGIN EXIT DONE
CAL CAL CAL
Pressing “DONE CAL” soft key enters the following screen:
2006-3-21 12:00:00 Scale #1
8000000 t
Old span:[ 888 ]
New span:
Materiel calibration! Please wait!
Refer weight:
BGIN RE- SURE
CAL INPT
28
--- User
When material calibration is finished, input the standard weight value and press “SURE” soft key to
validate it and enter the following screen.
2006-3-21 12:00:00 Scale #1
8000000 t
Old span: [ 888 ]
New span: [ 1000 ]
Material calibrationing! Please wait!
Span err: [ -11.2% ]
BGIN MATL SURE
CAL FACR SPAN
Pressing “MATL FACR” soft key enters the following screen.
2006-3-21 12:00:00 Scale #1
8000000 t
Old factor: [ 0% ]
New factor: [1.0 ]
Sure new factor!
BGIN EXIT SURE

CAL FACR FACR
Press numeric keys to enter the new material factor and press “SURE FACR” to validate it. Pressing
“EXIT FACR” soft key enters the following screen.
2006-3-21 12:00:00 Scale #1
8000000 t
Old span: [ 888 ]
New span: [1000]
Materiel calibration complete!
Span err: [ -11.2% ]
BGIN MATL SURE
CAL FACR SPAN
29
--- User
Pressing “SURE SPAN” soft key enters the following screen.
2006-3-21 12:00:00 Scale #1
8000000 t
888 t/h
1m/s
Materiel calibration complete!
Span err: [ -11.2% ]
BGIN EXIT ADD
CAL CAL REFR
Pressing “ADD REFR” soft key enters the following screen:
2006-3-21 12:00:00 Scale #1
8000000 t
888 t/h
1m/s
Materiel calibration!
BGIN EXIT
CAL CAL
Pressing RUN key enters Run Menu.
30
--- User
3.3.3 System Data Menu
5.3.3.1 Display Data

Pressing “3” from Main Menu enters the first page of the System Data Menu.
2006-3-21 12:00:00 Scale #1
DISPLAY DATA 1
Zero Dead: [ 0% ]
Supplementary: [ SPEED ]
Filt Constant: [ 10 ]
Language: [ ENGLISH ]
MAIN PAGE
MENU DOWN
Press the Up/Down scroll keys to scroll the cursor to the item desired to be set and press ENT key to
enable changing the settings:
Zero Dead: 0-9
Supplementary: SPEED, LOAD
Filt Constant: 0-100
Language: CHINESE, ENGLISH
Pressing “PAGE DONE” soft key enters the second page of the System Data Menu.
2006-3-21 12:00:00 Scale #1
DATE SETUP
Year: [6]
Month: [3]
Date: [ 21 ]
MAIN PAGE PAGE

MENU DOWN UP
31
--- User
Pressing “PAGE DONE” soft key enters the third page of the System Data Menu.
2006-3-21 12:00:00 Scale #1
TIME SETUP
Hour: [ 12 ]
Minute: [0]
Second: [0]
Press ↑ or ↓ key，then press ENT!
MAIN PAGE PAGE

MENU DOWN UP
Pressing “PAGE DONE” soft key enters the fourth page of the System Data Menu.
2006-3-21 12:00:00 Scale #1
SCALE DATE
Max Speed: [3 m/s ]
Press ↑ or ↓ key，then press ENT!
MAIN PAGE PAGE

MENU DOWN UP
5.3.3.2 Calibration Data

Press “PAGE DOWN” soft key, the first page of the Calibration Data Menu is displayed.
2006-3-21 12:00:00 Scale #1
CALIBRATION DATA 1
Simulated: [ELECTRIC ]
Resistor: [ 165000Ohms ]
Weights: [ 100kg ]
Chain: [ 100kg/m ]
MAIN PAGE PAGE

MENU DOWN UP
32
--- User
Simulated: ELECTRIC, WEIGH, CHAIN

Resistor: 0-1000000
Weights: 0-1000000
Chain: 0-1000000
Press “PAGE DOWN” soft key, the second page of the Calibration Data Menu is displayed.
2006-3-21 12:00:00 Scale #1
CALIBRATION DATA 2
Constant: [ 800 ]
Matl Factor: [ 2% ]
Zero Track: [ 3% ]
Zero Range: [ 4% ]
MAIN PAGE PAGE

MENU DOWN UP
Constant: 0-1000000
Matl Factor: 0-100%
Zero Track: 0-100%
Zero Range: 0-100%
Press “PAGE DOWN” soft key, the third page of the Calibration Data Menu is displayed.
2006-3-21 12:00:00 Scale #1
CALIBRATION DATA 3
Linear: [ NO ]
0 ~ 30%: [ 100% ]
30%~ 70%: [ 100% ]
70%~ 100%: [ 100% ]
MAIN PAGE PAGE

MENU DOWN UP
Linear: YES, NO
0~30%: 0-100%
30%~70%: 0-100%
70%~100%: 0-100%
33
--- User
5.3.3.2 Control Data

Press “PAGE DOWN” soft key, the first page of the Control Data Menu is displayed.
2006-3-21 12:00:00 Scale #1
CONTROL DATA 1
Control Mode : [ MANU ]
Setting Mode : [ LOCAL ]
High Limit : [ 80% ]
Low Limit : [ 20% ]
MAIN PAGE PAGE

MENU DOWN UP
Control Mode: MANU, AUTO

Setting Mode: LOCAL, REMOTE
High Limit: 0-100%
Low Limit: 0-100%
When the Control Mode is set to Manu, the manual control output mode will be used.
When the Control Mode is set to Auto, the automatic PID control mode will be used.
Press “PAGE DOWN” soft key, the second page of the Control Data Menu is displayed.
2006-3-21 12:00:00 Scale #1
CONTROL DATA 2
Proportional : [ 200 % ]
Integral: [ 2 sec ]
Derivative: [ 0 sec ]
MAIN PAGE PAGE

MENU DOWN UP
Proportional: 0-1000000%
Integral: 0-1000000%
Derivative (differential): 0-1000000%
34
--- User
Press “PAGE DOWN” soft key, the third page of the Control Data Menu is displayed.
2006-3-21 12:00:00 Scale #1
CONTROL DATA 3
Volume : [ NO ]
Difference: [ 10% ]
Delay: [ 5 sec ]
MAIN PAGE PAGE

MENU DOWN UP
Volume: NO, YES

Difference: 0-100%
Delay: 0-200
The 6105 integrator has a volumetric measuring function. Under normal operation condition, the 6105
compare the 2-way load cell signals with each other. If both signals are within the normal setting range,
the instantaneous flow rate and total can be calculated by integration of the load cell signals and the
speed signal. In case that the load cell fails, i.e. the load cell signal is out of range, the volumetric
measuring function can be activated automatically.
The working principle of volumetric measuring system can be described as follows:
The 6105 integrator calculates flow rate and belt speed on the basis of 1 hour period. Then the flow rate
is divided by the belt speed to obtain the weight per unit length per hour which is then multiplied by the
average speed per hour to get the average flow rate per hour. When the load cell fails, the present
weight per length per hour can be automatically used for the load cell signal. The value is then
multiplied by the present speed to obtain the present flow rate.
When the Volume is set to NO, the volumetric measuring function is disabled.
The Difference represents comparative difference for volumetric measuring function.
When the volumetric measuring function is enabled, the difference measuring function automatically
activates in case that the difference between the two load cell signals continuously exceeds the preset
Difference value within a period of the preset Delay time. The 6105 integrator exits volumetric
measuring mode when the difference between the two load cell signals becomes less than the preset
Difference value.
35
--- User
5.3.3.3 Establishing Test Duration
Press “PAGE DOWN” soft key, the fourth page of the Calibration Data Menu is displayed.
2006-3-21 12:00:00 Scale #1
8000000 t
888 t/h
1m/s
AUTO MANL PAGE

DURA DURA UP
Press “AUTO DURT” soft key, the following screen is displayed.
2006-3-21 12:00:00 Scale #1
AUTO TEST DURATION DATA

Belt Length: [ 20m ]
Part Length: [ 10m ]
FULL PART PAGE

DURA DURA UP
36
--- User
Press “FULL DURA” or “PART DURA”, the following screen is displayed.
2006-3-21 12:00:00 Scale #1
8000000 t
Revolutions:
Running Time:

Press “BGIN DURA” to start establishing the test duration. Press “MARK CNT” each time the mark
passes the reference point. Then press “DONE DURA” to finish establishing test duration.
If press “MANL DURT” soft key from the first screen described in section 5.3.3.5, the following screen
appears:
2006-3-21 12:00:00 Scale #1
MANUAL TEST DURATION DATA

Belt Length: [ 20m ]
Revolutions: [ 1]
Running Time: [ 80]
BGIN PAGE
DURA UP
37
--- User
5.3.3.3 Calculation of Simulated Constant

The Simulated Constant must be calculated by a proper method depending on the selected calibration
mode.
1) For electronic calibration mode, the calculation formula is
L.C.S ⎛ 1 ⎞
•⎜ ⎟ ( kg )
2 K ⎜⎝ 2RR1S +1 ⎟⎠
Equivalent weight =
In which: L.C.S —— Load cell capacity（kg）
K —— Load cell sensitivity（mv/V）
RS —— Resistor used in electronic calibration (Ohms)
R1 —— Load cell input resistor (Ohms)
Take the following conditions for example:

L.C.S=200kg
K=0.003V/V
RS=100000Ω
R1=350Ω
200 ⎛ 1
⎞
• ⎜ 2×100000 ⎟
2 × 0.003 ⎝ 350 +1 ⎠
Then Equivalent weight = =58.23kg
kg d 1
× 1×
Equivalent weight on unit length =
cos ϕ d 2 D （kg/m）
In which kg——Equivalent weight

ϕ —— Angle between the scale on the conveyor and the horizontal plane
d1 —— Distance from trunnion pivot centerline to load cell centerline (mm)

d2 —— Distance from trunnion pivot centerline to weigh idler centerline (mm)
D —— Measuring section length (m)
Take the following conditions for example:

kg=58.23kg
ϕ =15o
d1=812.8mm
d2=609.6mm
D=3m
58.23 812.8 1
× ×
Then Equivalent Weight = 0.966 609.6 3 =26.79kg/m
The Simulated Constant = Equivalent weight on unit length X Test length
= Equivalent weight on unit length X (Belt full length X revolutions)
= 26.79kg/m X (100m X 25 revs = 26790kg = 26.79t
38
--- User
2) For test weights calibration mode, the following method should be used:
TestWeights（Kg）
a) The Equivalent Load (Kg/m) =
WeighSpanLength（D）
Test Weights = Static weight applied on the weigh idlers
Weigh Span Length = Idler spacing X Number of weigh idlers
For example:
Kg = 100
D = 2.4m
Kg/m = 41.67 kg/m
b) Simulated Constant For Test Weights can be calculated using the following formula:
(kg / m)×BeltLengthforTestDuration(m)
The Simulated Constant =
1000
For example:
The Belt Length for Test Duration = 180m
The Simulated Constant = 41.67×180 = 7.5t

1000
3) For test chains calibration mode, the following method should be used:
a) The Equivalent Load (Kg/m) is specified at the tail of the test chains
b) Simulated Constant For Test Chains can be calculated using the following formula:
(kg / m)×BeltLengthforTestDuration(m)
The Simulated Constant =
1000
For example:
The Belt Length for Test Duration = 180m
Kg/m = 30
The Simulated Constant = 30×180 = 5.4t

1000
Note: The system setup is intended to program some basic parameters which determine whether
correct result can be achieved from the belt scale. These parameters include scale number and scale
capacity etc.
The following is an explanation to a part of these parameters.
[Zero Tracking]: Zero may drift due to various influence factors. When Zero Tracking is set, automatic
zeroing will be implemented in case of a total lower than the preset value.
[Zero Dead]: During a run period, a total lower than the preset Zero Dead will not be added into the
master total.
[Accumulated Pulses]: When the total is up to the preset Accumulated Pulses, an accumulated pulse
signal will be emitted.
[Pulse Width]: This option defines the ratio of high voltage level [1] and low voltage level [0] of pulse
width
[Control Mode]: There are two control modes selectable: automatic and manual.
[Set Mode]: When automatic control mode is selected, two set modes are available for selection: local
and remote.
39
--- User
[Set Flowrate]: This option defines the preset flowrate.

[P Gain], [I Gain], [G Gain]: the three parameters are used for control function. Typically, [P Gain] is set
to 1, [I Gain] is set to 10, and [G Gain] is set to 0.
[Control High Limit], [Control Low Limit]: The two parameters limit the flowrate range.
3.3.4 I/O Definition Menu
Pressing “4” from Main Menu enters the first page of the I/O Definition Menu.
2006-3-21 12:00:00 Scale#1
INPUTPORT SETUP 1
In port 1: [NO DEFINE ] [OPEN ]
Inport 3: [NO DEFINE ] [OPEN ]
MAIN PAGE
MENU UP
Pressing ENT key enters the following screen.
2006-3-21 12:00:00 Scale #1
INPUTPORT SETUP 1
In port 1: BAT RUN [OPEN ]
MAIN ENTR SURE PAGE

MENU DOWN
Move the cursor with scroll keys to the item you want to program, then press “ENTR” soft key to view
the options for this variable. The middle column is used to define the function of each input port. And the
right column defines the Normally Open (OPEN) or Normally Closed (CLOSE) status of the input.
Normally open means the input is inactive when disconnected.
40
--- User
The options of input port function include: “BAT RUN”, “BAT READY” and “NO DEFINE”. Press “ENTR”
to make the options display circularly. When the desired option is displayed, press “SURE” soft key to
input the value.
Pressing Right scroll key from the first page of I/O Definition menu enters the following screen.
2006-3-21 12:00:00 Scale #1
INPUTPORT SETUP 1
In port 1: [NO DEFINE] [ OPEN ]
In port 3: [NO DEFINE ] [ OPEN ]
Press↑or↓ key, then press ENT!
MIAN PAGE
MENU DOWN
2006-3-21 12:00:00 Scale #1
INPUTPORT SETUP 1
In port 1: [NO DEFINE] OPEN
Press↑or↓ key，then press ENT！
MAIN ENTR SURE PAGE

MENU DOWN
If “ENTR” soft key is pressed, the status changes between “OPEN”(Normally Open) and
“CLOSE”(Normally Closed). When the desired option is displayed, press “SURE” soft key to input the
value. At this time the screen returns to the first page of Input Definition 1 menu. You can use the same
method to setup other units listed in the menu.
41
--- User
Pressing “PAGE DOWN” soft key from the first page of I/O Definition 1 Menu enters the second page of
the I/O Definition Menu. This is the second page for Input Definition.
2006-3-21 12:00:00 Scale#1
INPUTPORT SETUP 2
In port 5: [ NO DEFINE ] OPEN
MAIN PAGE PAGE

MENU DOWN UP
Set the input ports 5 through 8 in the same way as mentioned above.
Pressing “PAGE DOWN” soft key enters the third page of the I/O Definition Menu. This is the first page
for Output Definition.
2006-3-21 12:00:00 Scale#1
OUTPUTPORT SETUP 1
Out por 1: [ NO DEFINE ] [ OPEN ]
MAIN PAGE PAGE

MENU DOWN UP
Set the output port 1 through 4 in the same way as mentioned above.
The options of output port function include: “Alarm 1”, “Alarm 2”, “Alarm 3”, “Alarm 4”, “Alarm 5”, “Alarm
6”, “Alarm 7”, “Alarm 8”, “No Define”, “Totalizer”, “Batch Start”, “Batch Complete”.
Pressing “PAGE DOWN” soft key enters the fourth page of the I/O Definition Menu. This is the second
page for Output Definition.
42
--- User
2006-3-21 12:00:00 Scale #1
OUTPUTPORT SETUP 2
Out por7: [NODEFINE] [OPEN]
Press↑or↓ key，then press ENT！
MAIN PAGE PAGE

MENU DOWN UP
Set the output ports 5 through 8 in the same way as mentioned above.
Pressing “PAGE DOWN” soft key enters the fifth page of the I/O Definition Menu. This is the third page
for Output Definition.
2006-3-21 12:00:00 Scale #1
OUTPUTPORT SETUP 3
MAIN PAGE PAGE

MENU DOWN UP
Set the output port 9 through 12 in the same way as mentioned above.
Notes:
1. [BAT READY] is a pulse input signal. When the 6105 integrator receives this signal, a measuring
period for a batch of material is started.
2. [BAT RUN] is also a pulse input signal. Upon acceptance of this signal, the system switches to start
running status with the switch turning to BAT RUN.
3. When the discharged material is up to the target weight, Discharge End signal is sent from the 6105
integrator.
4. When the measurement is up to the target weight, discharge signal is sent from the 6105 integrator.
5. If a port is not used, set it to [NO DEFINE].
43
--- User
Pressing “PAGE DOWN” soft key enters the sixth page of the I/O Definition Menu.
2006-3-21 12:00:00 Scale#1
SIMULATED OUTPUT #1
Type: [RATE ]
Range: [ 4-20 mA ]
Delay: [ 0 sec ]
Filter: [0]
MAIN PAGE PAGE

MENU DOWN UP
Move the cursor to “Delay” with Up/Down scroll keys and press ENT key, the following screen appears:
2006-3-21 12:00:00 Scale #1
SIMULATED OUTPUT #1
Type: [ RATE ]
Range: [ 4-20 mA ]
Delay: 0
Filter: [0]
MAIN PAGE PAGE

MENU DOWN UP
Press numeric keys to input the desired value, and press “ENTR” soft key to confirm. Then the screen
return to the first page of Simulated Output #1 menu.
Use the same method to set the Output Filter.
44
--- User
In the first page of Simulated Output #1 menu, move the cursor to “Type” with Up/Down scroll keys and
press ENT key, the following screen appears:
2006-3-21 12:00:00 Scale#1
SIMULATED OUTPUT #1
Type: Rate
Range: [ 4-20 mA ]
Delay: [0]
Filter: [0]
Press↑or↓ key, then present!
MAIN ENTR SURE PAGE PAGE

MENU DOWN UP
When press “ENTR” soft key, the output type value changes among “No define”, “Rate ”, “Load” and
“Speed”. When the desired option is displayed, press “SURE” soft key to input the value. At this time the
screen returns to the first page of Simulated Output #1. You can use the same method to setup other
units listed in the menu. The Range has two options: 4-20mA and 0-20mA.
From the first page of Simulated Output #1, press “PAGE DOWN” soft key to enter the seventh page of
the I/O Definition Menu.
2006-3-21 12:00:00 Scale#1
SIMULATED OUTPUT #2
Type: [Rate]
Range: [ 4-20 mA ]
Delay: [0]
Filter: [0]

MENU DOWN UP
45
--- User
Set the simulated output port 2 in the same way as mentioned above.
Pressing “PAGE DOWN” soft key enters the eighth page of the I/O Definition Menu.
2006-3-21 12:00:00 Scale#1
SIMULATED INPUT
Input #1: [ NO DEFINE ]
Input #2: [ NO DEFINE ]
Press↑or↓ key，then press ENT!
MAIN PAGE PAGE

MENU DOWN UP
The simulated input value changes among “No Define”, “Moisture ” and “Inclination”.
Pressing “PAGE DOWN” soft key enters the ninth page of the I/O Definition Menu.
2006-3-21 12:00:00 Scale#1
COMPENSATION EFFECT
Inclinations: [ NO ]
Moisture: [ NO ]
MAIN PAGE PAGE

MENU DOWN UP
Press ENT key, the following screen appears:
2006-3-21 12:00:00 Scale #1
COMPENSATION EFFECT
Inclinations: NO
Moisture: [ NO ]

MENU DOWN UP
46
--- User
When press “ENTR” soft key, the output type value changes between “YES” and “NO ”. When the
desired option is displayed, press “SURE” soft key to input the value.
Pressing “PAGE DOWN” soft key enters the tenth page of the I/O Definition Menu.
2006-3-21 12:00:00 Scale #1
ANGLE COMPENSATION
Min Angle: [ - 25 ]
Max Angle: [ 25 ]
MAIN SURE PAGE PAGE

MENU DOWN UP
2006-3-21 12:00:00 Scale#1
ANGLE COMPENSATION
Min Angle: - 25
Max Angle: [ 25 ]
MAIN +/ - SURE PAGE PAGE

MENU DOWN UP
Use the numeric keys to input the settings firstly, then press “SURE” soft key to confirm.
Pressing “PAGE DOWN” soft key enters the eleventh page of the I/O Definition Menu.
2006-3-21 12:00:00 Scale #1
MOISURE COMPENSATION
Min Moisture: [ 10 % ]
Min Voltage: [ 2 V ]
Max Moisture: [ 80 % ]
Max Voltage: [ 5 V ]
MAIN PAGE PAGE

MENU DOWN UP
47
--- User
Pressing “PAGE DOWN” soft key enters the twelfth page of the I/O Definition Menu.
2006-3-21 12:00:00 Scale #1
OUPUT DATA
Totalizer: [ 1t ]
Width: [ 0.1sec ]
MAIN PAGE PAGE

MENU DOWN UP
Pressing “PAGE DOWN” soft key enters the thirteenth page of the I/O Definition Menu.
2006-3-21 12:00:00 Scale #1
CLIP DETECTOR DATA

Mode: [ MANU ]
Length: [1m]
MAIN PAGE
MENU UP
3.3.5 Communication Menu

Pressing “5” from Main Menu enters the first page of the Communication Menu.
2006-3-21 12:00:00 Scale #1
COMMPORT 1 SETUP
Function: [ MODBUS ]
Baud Rate: [ 115200 ]
Word Length: [ 8 BIT ]
Stop Bit: [ 1 BIT ]
MAIN PAGE
MENU DOWN
48
--- User
Press the Up/Down scroll keys to move the cursor to the item that to be set, followed by [ENT] key.
Press ENTR soft key to view the optional settings and press SURE soft key until the desired value is
displayed.
Function: NO DEFINE, MODBUS, PRINT
Baud Rate: 4800, 9600, 19200, 38400, 115200
Word Length: 8 BIT, 7 BIT
Stop Bit: 1 BIT, 2 BIT
Pressing “PAGE DOWN” soft key enters the second page of the Communication Menu.
2006-3-21 12:00:00 Scale#1
COMMPORT 1 SETUP
Parity: [ NONE ]
Address: [1]
MAIN PAGE PAGE

MENU DOWN UP
Parity: NONE, EVEN, ODD

Address: 1-255
Pressing “PAGE DOWN” soft key enters the third page of the Communication Menu.
2006-3-21 12:00:00 Scale#1
COMMPORT 2 SETUP
Function: [ MODBUS ]
Baud Rate: [ 115200 ]
Word Length: [ 8 BIT ]
Stop Bit: [ 1 BIT ]
MAIN PAGE PAGE

MENU DOWN UP
49
--- User
Pressing “PAGE DOWN” soft key enters the fourth page of the Communication Menu.
2006-3-21 12:00:00 Scale #1
COMMPORT 2 SETUP
Parity: [ NONE ]
MAIN PAGE
MENU UP
Function has three options: [No Define], [Modbus] and [Print]. Baud Rate can be set to one of the
following figures: 4800, 9600, 19200, 38400 or 115200. Word Length can be set to [7 bits] or [8 bits].
Stop Bit can be set to [1 bit] or [2 bits]. Parity is selectable among [None], [Even] and [Odd]. Address
can be set between 1 and 255.
3.3.6 Alarm Setup Menu
Pressing “6” from the second page of Main Menu enters the first page of the Alarm Setup Menu.
2006-3-21 12:00:00 Scale#1
ALARM SETUP 1
Alarm 1: [ NO DEFINE ]
MAIN PAGE
MENU DOWN
The options of output port function include: “High Rate”, “Low Rate”, “High Load”, “Low Load”, “High
Speed”, “Low Speed”, “Belt Slipage”.
50
--- User
Pressing “PAGE DOWN” soft key enters the second page of the Alarm Setup Menu.
2006-3-21 12:00:00 Scale#1
ALARM SETUP 2
MAIN PAGE PAGE

MENU DOWN UP
Pressing “PAGE DOWN” soft key enters the third page of the Alarm Setup Menu.
2006-3-21 12:00:00 Scale#1
RATE ALARM SETUP

High Rate: [ 80 %]
Delay: [ 1 sec ]
Low Rate: [ 20 % ]
Delay: [ 1 sec ]
MAIN PAGE PAGE

MENU DOWN UP
Pressing “PAGE DOWN” soft key enters the fourth page of the Alarm Setup Menu.
2006-3-21 12:00:00 Scale #1
LOAD ALARM SETUP

High Load: [ 80 %]
Delay: [ 1 sec ]
Low Load: [ 20 % ]
Delay: [ 1 sec ]
MAIN PAGE PAGE

MENU DOWN UP
51
--- User
Pressing “PAGE DOWN” soft key enters the fifth page of the Alarm Setup Menu.
2006-3-21 12:00:00 Scale #1
SPEED ALARM SETUP

High Speed: [ 80 %]
Delay: [ 1 sec ]
Low Speed: [ 20 % ]
Delay: [ 1 sec ]
MAIN PAGE PAGE

MENU DOWN UP
Pressing “PAGE DOWN” soft key enters the sixth page of the Alarm Setup Menu.
2006-3-21 12:00:00 Scale #1
SLIPPAGE ALRM SETUP

Deviation: [ 80 %]
Delay: [ 1 sec ]
MAIN PAGE PAGE

MENU DOWN UP
Pressing “PAGE DOWN” soft key enters the seventh page of the Alarm Setup Menu.
2006-3-21 12:00:00 Scale #1
ALARM RESET SETUP

Reset: [ AUTO ]
MAIN PAGE PAGE

MENU DOWN UP
52
--- User
3.3.7 Loadout Setup Menu
Pressing “7” from the second page of Main Menu enters the first page of the Loadout Setup Menu.
2006-3-21 12:00:00 Scale#1
LOADOUT SETUP 1
Weight: [ 50 t ]
Correct: [ AUTO ]
Pre Value: [ 5 t]
Pre Range: [ 10% ]
MAIN PAGE
MENU DOWN
Pressing “PAGE DOWN” soft key enters the second page of the Loadout Setup Menu.
2006-3-21 12:00:00 Scale #1
LOADOUT SETUP 2
Pre Length: [5m]
Delay: [ 2 sec ]
MAIN PAGE
MENU DOWN
53
--- User
3.3.8 Password Setup Menu
Pressing “8” from the second page of Main Menu enters the first page of the Password Menu.
2006-3-21 12:00:00 Scale #1
SYSTEM PASSWORD SETUP

System word: [ ]
Operate word: [ ]
MAIN PAGE
MENU DOWN
Press the Up/Down keys to move the cursor to the item that to be set, followed by [ENT] key. Use
numeric keys to input the password settings and press [ENT] to confirm.
The defaulted password is null. Enter “0” or just leave it blank to access enter the next page.
Inputting the correct passwords enters the second page of the Password Menu.
2006-3-21 12:00:00 Scale #1
OPERAT PASSWORD SETUP

System Word: [ NO PROTECT ]
Operate Word: [ NO PROTECT ]
Correct!
If clear main Tot, press TOT RSET!
MAIN TOT PAGE
MENU RSET DOWN
Press TOT RSET soft key to reset the master total.
Pressing “PAGE DOWN” soft key enters the third page of the Password Menu.
54
--- User
2006-3-21 12:00:00 Scale #1

System : [ NO PROTECT ]
Operate: [ NO PROTECT ]
MAIN PAGE
MENU DOWN
Pressing “PAGE DOWN” soft key enters the fourth page of the Password Menu.
2006-3-21 12:00:00 Scale #1
SYSTEM PASSWORD SETUP

System word: [ ]
Sure word: [ ]
MAIN SAVE PAGE PAGE

MENU WORD DOWN UP
Pressing “PAGE DOWN” soft key enters the fifth page of the Password Menu.
2006-3-21 12:00:00 Scale #1

Operate word: [ ]
Sure word: [ ]
Press↑or↓key, then press ENT!
MAIN SAVE PAGE

MENU WORD UP
55
--- User
3.3.9 Diagnostics Menu

Pressing “9” from the second page of Main Menu enters the first page of the Diagnostics Menu.
2006-3-21 12:00:00 Scale #1
DIAGNOSTICS
Weight: [ 1000000 ]
Speed: [ 200 ]
Pulses: [10000]
MAIN
MENU
numeric keys to input the settings and press [ENT] to confirm.
3.3.10 Statistics Menu
Pressing “0” from the second page of Main Menu enters the first page of the Statistics Menu.
2006-3-21 12:00:00 Scale #1
CLASS 1 SETUP
Start hour: [0]
Start min: [0]
End hour: [5]
End min: [ 59 ]
MAIN PAGE
MENU DOWN
This screen defines the working system for the first shift (Class indicated in the menus). Press the
Up/Down keys to move the cursor to the item that to be set, followed by [ENT] key. Use numeric keys to
input the settings and press [ENT] to confirm.
56
--- User
Pressing “PAGE DOWN” soft key enters the second page of the Statistics Menu.
2006-3-21 12:00:00 Scale #1
CLASS 2 SETUP
Start hour: [6]
Start min: [0]
End hour: [ 11 ]
End min: [ 59 ]
MAIN PAGE PAGE

MENU DOWN UP
This screen defines the working system for the second shift.
Pressing “PAGE DOWN” soft key enters the third page of the Statistics Menu.
2006-3-21 12:00:00 Scale #1
CLASS 3 SETUP
Start hour: [ 12 ]
Start min: [0]
End hour: [ 17 ]
End min: [ 59 ]
MAIN PAGE PAGE

MENU DOWN UP
This screen defines the working system for the third shift.
Pressing “PAGE DOWN” soft key enters the fourth page of the Statistics Menu.
2006-3-21 12:00:00 Scale #1
CLASS 4 SETUP
Start hour: [ 18 ]
Start min: [0]
End hour: [ 23 ]
End min: [ 59 ]
MAIN PAGE PAGE

MENU DOWN UP
57
--- User
This screen defines the working system for the fourth shift.
Pressing “PAGE DOWN” soft key enters the fifth page of the Statistics Menu.
2006-3-21 12:00:00 Scale #1
CLASS STATISTIC
Start hour: [ 18 ]
Date: [1]
MAIN CLAS PAGE

MENU STAT UP
numeric keys to input the settings and press [ENT] to confirm.
Pressing “CLAS STAT” soft key enters the sixth page of the Statistics Menu.
2006-3-21 12:00:00 Scale#1
CLASS STATISTIC
Total: [ 1 00 ]
MAIN TOT CLAS CLAS

MENU PRNT PRNT RSET
58
--- User
Chapter 4 Integrator Maintenance
4.1 Daily Maintenance Routines of 6105 Integrator

This chapter describes preventive maintenance practice for the 6105 integrator that should be done to
minimize downtime and extend the life of the equipment. Developing a preventive maintenance
schedule will ensure that critical maintenance procedures are not missed.
A. Check power supply

· Check that the voltage selector switch is set to the correct position.
· Check that the fuse is good.
· Check that the power is switched ON to energize the 6105.
B. Check all wire connections carefully.

· Check that all the terminals are tightly connected.
· Check that the remote counter and the optional input/output module are firmly plugged in system
slots.
· Check that the display board and keypad interface is secured.
· Check that all the jumpers are set correctly.
4.2 6105 Integrator Troubleshooting --- Fault Isolation

To locate the fault of the belt scale, a specified troubleshooting routine should be executed. The
following troubleshooting flow chart (Figure 6-1) helps understand the operation of the system, and
locate the trouble component among the following hardware accordingly.
· Load cell
· Speed sensor
· Power supply assembly
· CPU board
· Display board
· Power output board
59
--- User
6105 fails
Visual inspection
No Bad
Display illuminates Check power supply Repair power supply
Yes Normal
Touchkeys act correctly Set up the 6105 again Repair CPU board
Yes Yes
Display fault Record and reset
error
No No
Internall test is normal
Yes
Flowrate indication is No Bad
Check speed input
normal
Normal
Normal
Check load cell input
No
Total indication is normal
Yes
No Yes No
Remote Total is normal Check relay actions
Yes No
Current output is normal Repair current baord
Yes
End
Figure 6-1 6105 Integrator Troubleshooting Flow Chart
60
--- User
4.2.1 Power Supply Examination
Measure the AC voltage at the output terminal of the transformer using the two probes of the AC
voltmeter. Check that the measurement is in line with that specified on the transformer.
4.2.2 Speed Input
Check speed input signal according to the flowchart in Figure 6-2. This examination should be
performed after the belt scale is powered on and has been running in normal speed. The speed signal
is in the form of pulses emitted by the speed sensor. The number of speed pulses can be learnt from
the Diagnostics menu of the 6105.
Start
Repair or replace
Speed input examination No speed input

menu→Diagnostics→ Check speed
Observe change of speed sensor and its
signal (Refer to 5.3.10) wiring
Speed input
part of CPU
Speed input is normal.
board fails
End
Figure 6-2 Troubleshooting the Speed Input
4.2.3 Load Cell Input

Check load cell input signal according to the flow chart in Figure 6-3 based on the following conditions:
· Powered connected equipments
· At normal belt speed
· Empty load
· Normal load cell input signal
Check that the weight indication displayed in Diagnostics menu of the 6105 integrator is between 1 and
16777216. The weight indication should be changed in the same direction as the sense of desired
result. If the weight indication is beyond the given range, there may be problems with load cell, wire
connection or CPU board. In this case, press RUN key to stop the examination of load cell input.
61
--- User
Start
Check load cell input, Power on the

Repair and replace
6105 and enter Diagnostics menu
The load indication is between 1 and

Yes
16777216, and increases as the Load cell input is
actual load increases normal
No
No load cell input End

Check load cell and wire conntection
Normal
The excitation voltage on the load No Bad excitation input

cell should be DC 9.5 to 10.5V on the CPU
The voltage between signal leads of No Damaged load cell

the load cell should be lower than 30mV
Yes
Bad load cell input on
the CPU board
Figure 6-3 Troubleshooting Load Cell Input
4.2.4 Current Output (Optional)

Refer to Figure 6-4 Current Output Diagnostics Flow Chart, check the flowrate at different current
output ranging from 4mA to 20mA (full range) at a certain interval. In order to check the flowrate at 4mA
current output, power up the 6105 and run the belt empty. If the flowrate indication is not zero, reset it
by performing zero calibration. Remove the connections from the current output terminals which are
then connected to the DC milli-amperometer correctly (Note that the range of milli-amperometer should
exceed 20mA). At this time the current output on the milli-amperometer should be 4mA. If a minor
62
--- User
deviation is found, the reading can be corrected by adjusting the potentiometer. However, in case that a
remarkable deviation exists, the current output board is bad and needs to be changed.
When the 6105 gives correct current output at zero flowrate, the current output at various known
flowrates should be checked. Apply reference weights on the scale and press RUN key on the 6105
integrator to determine the flowrate at a percentage of the full load. For example, a belt scale with scale
capacity of 100t/h displays “10”, then the reference weight is 10% of the scale capacity. In this case the
milli-amperometer shall give a reading with the same percentage of the full scale. For this example, the
reading of the milli-amperometer shall be 16 (20-4)X10%+4mA = 5mA. If incorrect reading occurs, the
current output board should be repaired or changed.
Start
Check the current output. Connect power supply to the system. Run the belt empty
at the normal speed, the flowrate indication should be zero. Remove the
connections on the signal output terminals which are then connected to a
milli-amperometer.
Check the flowrate indication at current output of 4mA, which should be zero.
Otherwise, perform zero calibration.
The reading of milli-amperometer should be 4mA

No Bad current
Yes output board
The current output is normal – 4mA
Check the current output at a known flowrate. Apply reference weights on the scale
and press RUN key to determine the flowrate at a percentage of the scale capacity.
Check the milli-amperometer gives a reading No

with the same percentage
The current output baord functions well
End
Figure 6-4 Troubleshooting Current Output
63
--- User
4.2.5 Constant Setup

For the integrator which is newly put into service or just replaced the battery module, the constant
should be input according to the initial calibration.
· Power the integrator on
· Input belt speed (establish test duration in calibration menu, the belt must have been running for over
30 minutes with no load.)
· Input other constants (zero, span, scale capacity, etc)
4.3 Usual Troubleshooting

When the material is smoothly delivered but the flowrate indication in integrator varies greatly, there
may be various reasons such as: broken load cell, damaged speed sensor, bad integrator, defective
mechanical construction, signal interference, etc. The former three factors have been mentioned
hereinbefore. The defective mechanical structure on the site mainly contains: inactive trunnion (adjust
the trunnion screw to improve), loose pull bar (fasten the set nut to improve), material blockage (clear
off material to improve). Eliminate any potential problems perceptible. Signal interference is mainly
caused by electromagnetic field. The preventative measures is to route the signal cable separate from
power cable far away, and ensure that the integrator is grounded well (comply with the grounding
specification).
64
--- User
Chapter 5 Speed Sensor
5.1 General
The speed sensor monitors the belt speed. It is directly coupled to a rotary shaft which drives a signal
generator. The speed sensor submits an output signal at a frequency directly proportional to the shaft
speed.
Figure 7-1 N60 Speed Sensor
5.2 Inspection, Unpacking and Storage

Prior to unpacking the speed sensor, inspect the packages for damage. The shipping carrier may be
responsible for the damage.
Check the equipment for any signs of damage in shipment. Be sure to look for any accessories such as
coupling sleeve, shock absorber arm, control arm spring, etc.
If the speed sensor is not installed on the site recently, it can be safely stored in ambient temperatures
of 0 to 50ºC away from moisture.
65
--- User
5.3 Installation
5.3.1 Mechanical Part Installation
Comply with the following guidance for installation of the speed sensor.
1. The N60 speed sensor must be mounted on a belt-driven pulley to ensure an accurate belt-travel
readout. In most applications, the conveyor tail pulley, bend pulley or snubbing roll is the ideal
location. If it is not suitable to install the speed sensor directly on the tail pulley or bend pulley, an
special roller must be used to mount the N60 speed sensor.
Note: Do not mount the N60 speed sensor on the drive pulley.
2. In case that a special roller is applied to mount the N60 speed sensor, the following guidelines must
be observed.
1) The selected roller should have suitable diameter. The rotary speed of the pulley should be kept
within the detection range of the N60 speed sensor.
2) The roller should be mounted at the clean area of the return belt to minimize material build-up on
the roller.
3) The roller installed in this way should have the contact surface inclined at an angle of at least 30
degrees, because any slippage between the belt and the roller may cause reduced accuracy of the
belt scale.
3. To keep freely floating movement, the speed sensor should be flexibly jointed to the conveyor frame
by performing the following steps.
1) Provide a protruding shaft end with 32mm exterior diameter. Directly insert the sleeved speed
sensor into it, alternatively insert the speed sensor (12.8mm dia.) into the coupling sleeve, then
tighten the bolt.
2) Use two M8X30 bolts to fasten the anti-rotate arm to the N60 speed sensor. A support plate should
be welded on the conveyor frame for placing the anti-rotate arm on it parallelly. Then fasten an end
of the spring into the round hole at the tail of the anti-rotate arm. And the other end of the spring
should be connected to the conveyor frame. The spring should be lightly tensioned when
installation.
5.3.2 Electrical Part Installation

Go through the following steps to perform electrical installation:
1. Remove the cover of the terminal block and dust plug of the interior conduit on the speed sensor.
2. Connect a 12mm conduit to the speed sensor cover.
3. Route a 2-conductor cable into the speed sensor cover through the conduit.
4. Perform wiring and replace the cover of the terminal block.
Note: The three leads of the speed sensor should be shieled when wired to the integrator. The shielded
cable should be RVVP2X0.2 or the equivalent. And the shielded line should only be connected to
the interator end (not to the speed sensor end).
66
--- User
5.4 Working Principle

The speed sensor is virtually a step motor which generates an output signal proportional to the rotary
speed of the input shaft. The speed sensor signal and load cell signal are combined into the
microprocessor-based integrator which, by multiplying both, generates and displays a true-rate signal in
TPH and the total of material fed.
67

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6105 Belt Feeder integrator User’’s Guide ---

6105 Belt Feeder integrator

Installation, Operating and Service

1.2 Technical Specifications....................................................................................................................................... 3

Chapter 2 Belt scale Installation Guidelines ..............................................................................................................

2.2 Wind and Weather Influence.................................................................................................................................7

2.3 Conveyor Support.................................................................................................................................................7

2.4 Location of the Belt scale..................................................................................................................................... 7

2.5 Gravity Type Belt Tensioner................................................................................................................................. 8

2.6 Belt Troughing Angle............................................................................................................................................9

2.7 Weigh Area Idler...................................................................................................................................................9

Chapter 3 Belt scale Installation Procedures...........................................................................................................

3.1 N62-1 Belt scale Installation..............................................................................................................................10

3.2 N63-3 Belt scale Installation..............................................................................................................................12

3.3 N64-4 Belt scale Installation..............................................................................................................................16

3.4 Load Cell Installation........................................................................................................................................ 19

Chapter 4 6105 Integrator Installation.................................................................................................................... 22

4.2 6105 Integrator Installation............................................................................................................................... 22

5.2 Run Menu........................................................................................................................................................... 26

5.3 Main Menu......................................................................................................................................................... 27

Chapter 6 Integrator Maintenance ...........................................................................................................................

6.1 Daily Maintenance Routines of 6105 Integrator................................................................................................72

6.2 6105 Integrator Troubleshooting --- Fault Isolation..........................................................................................72

6.3 Usual Troubleshooting....................................................................................................................................... 77

Chapter 7 Speed Sensor .............................................................................................................................................

7.2 Inspection, Unpacking and Storage................................................................................................................... 78

7.4 Working Principle.............................................................................................................................................. 80

Chapter 8 Belt Scale Maintenance ............................................................................................................................

8.2 Daily Maintenance Routine for Belt Scale......................................................................................................... 81

8.3 Troubleshooting the Belt Scale...........................................................................................................................82

Chapter 9 Belt Scale Installation Parameters ..........................................................................................................

9.1 Scale Capacity....................................................................................................................................................83

9.2 Belt Scale Dimensions........................................................................................................................................83

9.3 Load Cell Data...................................................................................................................................................88

Chapter 10 Permanent Field Record ..........................................................................................................................

Figure 1-1 6000 Series Integrator -- Panel Mount

Figure 1-2 6000 Series Integrator --- Field Mount

1.2 Technical Specifications

(b) Weighing Capability

· The 6105 integrator has the function of automatic zero calibration.

(c) Ambient Environment

Figure 1-3 Front Panel

1.3.1 Measuring Function

3. Zero and Span Automatic Calibration

4. Zero Tracking (AZT)

5. Current Output Signals

1.3.2 Monitoring Function

1.3.3 Printing Function

1.3.4 Communications (Optional)

Chapter 2 6105 Integrator Installation

2.2 6105 Integrator Installation

2.2.2 Safety Precautions

7. Maintenance procedures should be performed only by qualified service personnel and in

10. Objects should never be placed or stored on the integrator.

2.2.3 Wiring (External Power Supply)

1. Critical wiring conditions:

Figure 4-1 6105 Integrator Wiring Diagram

Chapter 3 Opera tion

Figure 5-1 Front Panel

3.2 Run Menu

2006-3-21 12:00:00 Scale#1

ZERO PID BAT SYS RSET

3.2.1 Reset Total

2006-3-21 12:00:00 Scale#1