Siemens MWL Weight Lifter, MUS STD, MUS HD, MBS, MCS, MSI, MMI Belt Scale Operating Instructions

Belt Scales
Milltronics MWL Weight Lifter
Operating Instructions 11/2011
Milltronics
Safety Guidelines
Warning notices must be observed to ensure personal safety as well as that of others, and to protect the product and the connected
equipment. These warning notices are accompanied by a clarification of the level of caution to be observed.
Qualified Personnel
This device/system may only be set up and operated in conjunction with this manual. Qualified personnel are only authorized to install
and operate this equipment in accordance with established safety practices and standards.
Unit Repair and Excluded Liability:




The user is responsible for all changes and repairs made to the device by the user or the user’s agent.
All new components are to be provided by Siemens Milltronics Process Instruments.
Restrict repair to faulty components only.
Do not reuse faulty components.
Warning: Cardboard shipping package provides limited humidity and moisture protection. This product can only function properly
and safely if it is correctly transported, stored, installed, set up, operated, and maintained.
This product is intended for use in industrial areas. Operation of this equipment in a residential area may cause interference to
several frequency based communications.
Note: Always use product in accordance with specifications.
Copyright Siemens AG 2011. All Rights Reserved
Disclaimer of Liability
This document is available in bound version and in
electronic version. We encourage users to purchase
authorized bound manuals, or to view electronic versions as
designed and authored by Siemens Milltronics Process
Instruments. Siemens Milltronics Process Instruments will
not be responsible for the contents of partial or whole
reproductions of either bound or electronic versions.
While we have verified the contents of this
manual for agreement with the instrumentation
described, variations remain possible. Thus we
cannot guarantee full agreement. The contents of
this manual are regularly reviewed and
corrections are included in subsequent editions.
We welcome all suggestions for improvement.
Technical data subject to change.
MILLTRONICS®is a registered trademark of Siemens Milltronics Process Instruments.
Contact SMPI Technical Publications
at the following address:
European Authorized Representative
Technical Publications
Siemens AG
Siemens Milltronics Process Instruments
1954 Technology Drive, P.O. Box 4225
Peterborough, Ontario, Canada, K9J 7B1
Email: [email protected]
Siemens AG
Industry Sector
76181 Karlsruhe
Deutschland


For a selection of Siemens Milltronics level measurement manuals, go to:
www. siemens.com/processautomation. Under Process Instrumentation, select Level Measurement and then go to the manual
archive listed under the product family.
For a selection of Siemens Milltronics weighing manuals, go to:
www. siemens.com/processautomation. Under Weighing Technology, select Continuous Weighing Systems and then go to the
manual archive listed under the product family.
© Siemens AG 2011
Milltronics MWL Weight Lifter
1
___________________
Introduction
2
___________________
Safety notes
Milltronics
Belt Weighing Accessories
Milltronics MWL Weight Lifter
3
___________________
Description
4
___________________
Installing/Mounting
___________________
5
Connecting
___________________
6
Commissioning
Operating Instructions
___________________
7
Operation
___________________
8
Service and maintenance
___________________
9
Technical data
___________________
10
Dimension drawings
Appendix A: Customer
___________________
A
calculations
11/2011
7ML19985CR03-03
Legal information
Legal information
Warning notice system
This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent
damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert
symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are
graded according to the degree of danger.
DANGER
indicates that death or severe personal injury will result if proper precautions are not taken.
WARNING
indicates that death or severe personal injury may result if proper precautions are not taken.
CAUTION
with a safety alert symbol, indicates that minor personal injury can result if proper precautions are not taken.
CAUTION
without a safety alert symbol, indicates that property damage can result if proper precautions are not taken.
NOTICE
indicates that an unintended result or situation can occur if the relevant information is not taken into account.
If more than one degree of danger is present, the warning notice representing the highest degree of danger will
be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to
property damage.
Qualified Personnel
The product/system described in this documentation may be operated only by personnel qualified for the specific
task in accordance with the relevant documentation, in particular its warning notices and safety instructions.
Qualified personnel are those who, based on their training and experience, are capable of identifying risks and
avoiding potential hazards when working with these products/systems.
Proper use of Siemens products
Note the following:
WARNING
Siemens products may only be used for the applications described in the catalog and in the relevant technical
documentation. If products and components from other manufacturers are used, these must be recommended
or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and
maintenance are required to ensure that the products operate safely and without any problems. The permissible
ambient conditions must be complied with. The information in the relevant documentation must be observed.
Trademarks
All names identified by ® are registered trademarks of Siemens AG. The remaining trademarks in this publication
may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.
Disclaimer of Liability
We have reviewed the contents of this publication to ensure consistency with the hardware and software
described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the
information in this publication is reviewed regularly and any necessary corrections are included in subsequent
editions.
Siemens AG
Industry Sector
Postfach 48 48
90026 NÜRNBERG
GERMANY
Order number: 7ML19985CR03
Ⓟ 11/2011
Copyright © Siemens AG 2011.
Technical data subject to change
Table of contents
1
Introduction................................................................................................................................................ 5
1.1
2
Safety notes............................................................................................................................................... 7
2.1
3
4
5
6
General safety instructions ............................................................................................................7
Description................................................................................................................................................. 9
3.1
Milltronics MWL Weight Lifter ........................................................................................................9
3.2
Applications....................................................................................................................................9
3.3
MWL components ........................................................................................................................10
3.4
Calibration weight arrangement ...................................................................................................11
Installing/Mounting................................................................................................................................... 13
4.1
Introduction ..................................................................................................................................13
4.2
4.2.1
4.2.2
4.2.3
4.2.4
4.2.5
4.2.6
4.2.7
4.2.8
Installation procedure...................................................................................................................14
Drill crank body mounting holes...................................................................................................14
Mount crank bodies......................................................................................................................15
Mount torque shaft .......................................................................................................................16
Install crank handle (manual version) ..........................................................................................17
Test the unloaded MWL...............................................................................................................19
Install calibration weights .............................................................................................................20
Test the loaded MWL...................................................................................................................23
Shim the MWL..............................................................................................................................24
Connecting .............................................................................................................................................. 27
5.1
Connecting the MWL (electronic version)....................................................................................27
5.2
Connection diagram.....................................................................................................................29
5.3
5.3.1
5.3.2
5.3.3
5.3.4
5.3.5
Connection procedure..................................................................................................................30
Connect input power ....................................................................................................................30
Connect the control transformer ..................................................................................................31
Connect the motor and brake ......................................................................................................32
Connect the sensor junction box..................................................................................................33
Connect the remote PLC (optional) .............................................................................................34
Commissioning ........................................................................................................................................ 35
6.1
7
The manual ....................................................................................................................................5
Verifying MWL electrical connections ..........................................................................................35
Operation................................................................................................................................................. 37
7.1
Operation (manual version) .........................................................................................................37
Milltronics MWL Weight Lifter
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3
Table of contents
7.2
7.2.1
7.2.2
7.2.3
8
9
Service and maintenance ........................................................................................................................ 41
8.1
Removing material accumulation................................................................................................ 41
8.2
Technical support........................................................................................................................ 43
Technical data ......................................................................................................................................... 45
9.1
10
Operation (electronic version)..................................................................................................... 39
Electronic control panel............................................................................................................... 39
Local mode.................................................................................................................................. 39
Remote mode.............................................................................................................................. 40
Specifications .............................................................................................................................. 45
Dimension drawings ................................................................................................................................ 47
10.1
Calibration weight dimensions .................................................................................................... 47
10.2
10.2.1
10.2.2
10.2.3
10.2.4
10.2.5
10.2.5.1
10.2.6
Installation drawings.................................................................................................................... 48
MWL installation drawing for the MUS-STD standard duty belt scale ........................................ 48
MWL installation drawings for the MUS-HD heavy duty belt scale............................................. 49
MWL installation drawing for the MBS belt scale........................................................................ 50
MWL installation drawing for the MCS belt scale ....................................................................... 51
MWL installation drawing for the MSI or MMI belt scale............................................................. 52
Retrofitting an MSI or MMI belt scale.......................................................................................... 53
MWL (electronic version) dimensions ......................................................................................... 56
A
Appendix A: Customer calculations ......................................................................................................... 57
4
Operating Instructions, 11/2011, 7ML19985CR03-03
Milltronics MWL Weight Lifter
Introduction
1
Note
Safety
 The Milltronics MWL Weight Lifter is to be used only in the manner outlined in this
manual, otherwise protection provided by equipment may be impaired.
 It is your responsibility to read this manual before installing and starting up any
component of the weighing system to which the weight lifter is being applied.
NOTICE
For industrial use only
This product is intended for use in industrial areas. Operation of this equipment in a
residential area may cause interference to several frequency based communications.
1.1
The manual
This manual covers only weight lifter installation, operation, and maintenance procedures. Belt
scale and integrator instruction manuals are available for download from our web site:
Siemens weighing (http://www.siemens.com/weighing)
Follow these operating instructions for quick, trouble-free installation, and maximum accuracy
and reliability of your weighing system.
We always welcome suggestions and comments about manual content, design, and
accessibility. Please direct your comments to:
Technical Publications (mailto :[email protected])
Milltronics MWL Weight Lifter
Operating Instructions, 11/2011, 7ML19985CR03-03
5
Introduction
1.1 The manual
Milltronics MWL Weight Lifter
6
Operating Instructions, 11/2011, 7ML19985CR03-03
2
Safety notes
2.1
General safety instructions
CAUTION
Correct, reliable operation of the product requires proper transport, storage, positioning and
assembly as well as careful operation and maintenance. Only qualified personnel should
install or operate this instrument.
Note
Alterations to the product, including opening or improper repairs of the product, are not
permitted.
If this requirement is not observed, the CE mark and the manufacturer's warranty will expire.
Milltronics MWL Weight Lifter
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Safety notes
2.1 General safety instructions
Milltronics MWL Weight Lifter
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Operating Instructions, 11/2011, 7ML19985CR03-03
Description
3.1
3
Milltronics MWL Weight Lifter
Milltronics MWL Weight Lifter is a mechanical calibration weight lifter for MUS, MBS, MCS, MSI
and MMI belt scales. The MWL mechanically raises and lowers the static calibration (test)
weights used to calibrate Milltronics belt scales. It stores the weights securely between the belt
strands, above the calibration weight support arms, and allows the operator to lower and apply
the weights safely without having to lean into the conveyor.
The MWL can be manually or electronically operated, and uses a high mechanical advantage to
enable weights up to 340 kg (750 lbs) to be applied with very limited effort. The manual crank
handle or AC gearmotor can be attached to either the left or right crank body. The MWL uses 12
revolutions for full range of motion, and can be secured for safety when the MWL is not in use.
Two lifting arms support a base-bar weight above the calibration weight supports of the belt
scale: either flat bar or round bar style calibration weights are available. Locating notches in the
base-bar weight engage the calibration weights securely on the lifting arms in the stored
position, and the threaded shaft drive locks the lifting arms in place. A mechanical stop secures
the MWL when the calibration weights are in the stored position.
3.2
Applications
The MWL is designed to work with the following Milltronics belt scales:
● MUS-STD MIlltronics Universal Scale, Standard Duty
● MUS-HD Milltronics Universal Scale, Heavy Duty
● MBS Milltronics Base Scale
● MCS Milltronics Crusher Scale
● MSI Milltronics Single Idler Scale
● MMI Milltronics Multiple Idler Scale (combination of 2 or more MSI Scales)
Belt scale manuals can be downloaded from
Siemens weighing (http://www.siemens.com/weighing)
Milltronics MWL Weight Lifter
Operating Instructions, 11/2011, 7ML19985CR03-03
9
Description
3.3 MWL components
3.3
MWL components
The Milltronics MWL Weight Lifter consists of the following components:
● left-handed and right-handed crank body, each connected to a lifting arm with guide-pin
● torque tube, to connect the left and right crank shafts
● crank handle, to be mounted to either the left or right input shaft (manual version only)
● optional shaft extension which adds 102 mm (4") to the handle shaft length
● base-bar weight to support other supplied calibration weights, or base-bar with integrated
round bar weight
● U-brackets to secure flat bar calibration weights (not required for round bar style)
①
②
③
④
⑤
⑥
⑦
⑧
⑨
Input shaft (2)
Right-handed crank body
Torque tube
Base-bar weight
Connecting shaft (2)
Left-handed crank body
Crank handle
Guide-pin (2)
Lifting arm (2)
Note
Manual version shown. The electronic version features an AC gearmotor in place of the
crank handle.
Milltronics MWL Weight Lifter
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Operating Instructions, 11/2011, 7ML19985CR03-03
Description
3.4 Calibration weight arrangement
3.4
Calibration weight arrangement
Flat bar calibration weights
①
②
③
flat bar base-bar weight
flat bar calibration weights
U-bracket (supplied with MWL)
Round bar calibration weight
Milltronics MWL Weight Lifter
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11
Description
3.4 Calibration weight arrangement
Milltronics MWL Weight Lifter
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Operating Instructions, 11/2011, 7ML19985CR03-03
Installing/Mounting
4.1
4
Introduction
Note
Installation shall only be performed by qualified personnel and in accordance with local
governing regulations.
The Milltronics belt scale must be completely installed before you install the MWL. Please refer
to the belt scale operating instructions for installation details.
Note
Check that there will be sufficient clearance for the MWL. See Check clearance for conveyor
belt (Page 16). Clearance can be created artificially by shimming the idlers in the scale area.
The MWL installation has eight stages:
1. Drilling the crank body mounting holes
2. Mounting the crank bodies
3. Mounting the torque shaft
4. Installing the crank handle (manual version)
5. Testing the unloaded MWL
6. Installing the calibration weights
7. Testing the loaded MWL
8. Shimming the MWL (if required)
Note
Electronic Version
 The crank handle is only required for the manual version of the MWL. The electronic
version comes with an AC gearmotor already installed in place of the handle.
 The control panel for the electronic version has four mounting holes on the back which
must be sealed and rigidly mounted.
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Installing/Mounting
4.2 Installation procedure
4.2
Installation procedure
4.2.1
Drill crank body mounting holes
Refer to the appropriate MWL installation drawing (Page 48) for your Milltronics belt scale.
1. Measure and mark the locations of the mounting holes for each of the crank bodies. The lefthanded unit turns clockwise to raise weights and the right-handed unit turns counterclockwise.
2. Drill the holes as specified for 12 mm (1/2") mounting hardware.
Milltronics MWL Weight Lifter
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Operating Instructions, 11/2011, 7ML19985CR03-03
Installing/Mounting
4.2 Installation procedure
4.2.2
Mount crank bodies
1. Refer to the shim thickness tables (Page 24) to determine whether you need to shim the
MWL; shimming is not always required.
2. If necessary, select and position the appropriate size shim(s).
3. Loosely mount each crank body to the conveyor stringers using 12 mm (1/2") bolts, nuts, and
washers.
①
②
③
④
⑤
⑥
⑦
locking ball-pin tethered to crank body
crank body
input shaft
shim (if required)
bolt
washer
nut
Note
The crank bodies must be left loose to allow for the torque shaft installation.
Milltronics MWL Weight Lifter
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Installing/Mounting
4.2 Installation procedure
4.2.3
Mount torque shaft
1. If lifting arms are not in the raised position, rotate the input shafts until both units have
reached the mechanical stop.
2. Place the torque tube over the connecting shafts of the left and right crank bodies.
3. Loosely install the bolts, nuts, and washers that hold the torque tube onto the connecting
shafts.
4. Hand tighten the bolts, nuts, and washers that mount the crank bodies to the stringers.
5. Hand tighten the bolts, nuts, and washers that hold the torque tube onto the connecting
shafts.
①
②
③
④
torque tube
connecting shaft (2)
lifting arm in raised position (2)
locking pin installed, locking MWL in storage position
Milltronics MWL Weight Lifter
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Operating Instructions, 11/2011, 7ML19985CR03-03
Installing/Mounting
4.2 Installation procedure
Check clearance for conveyor belt
1. Ensure there is 10 mm (0.38") minimum clearance from the top of the torque tube to the
underside of the return belt: inadequate clearance will cause the belt to wear.
2. Allow additional clearance for belt sag.
3. If necessary, shim the idlers in the scale area until the clearance is adequate. (See the belt
scale operating instructions for detailed shim procedures.)
①
②
③
④
4.2.4
minimum 10 mm (0.38") clearance to underside of return belt + allowance for belt sag
top of torque tube
155 mm (6.11")
top of stringers
Install crank handle (manual version)
Note
The crank handle is only required for the manual version of the MWL. The electronic version
comes with an AC gearmotor already installed in place of the handle. The motorized crank
bodies allow for mounting of the electronic components on the left or right side. IF the MWL
has been ordered incorrectly, these parts will need to be removed from one side and
installed on the other. For mounting the proximity switches, a gap of 0.635 to 1.016 mm
(0.025" to 0.04") must be maintained.
1. Determine whether it will be more convenient to have the handle attached to the left-handed
or the right-handed crank body, and if the shaft extension is required.
2. Remove the plastic cap from the input shaft on the selected side.
3. If the shaft extension is required, slide the female end of the extension over the exposed
input shaft, and secure the extension with a bolt, nut, and washer.
Milltronics MWL Weight Lifter
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Installing/Mounting
4.2 Installation procedure
4. Slide the female end of the handle over the exposed input shaft (or shaft extension).
5. Secure the handle in place using the tethered locking ball-pin provided.
①
②
③
④
⑤
⑥
⑦
locking ball-pin (tethered to crank body)
input shaft
optional shaft extension
locking ball-pin (tethered to crank handle)
crank handle (female end)
bolt
hole for storage on locking ball-pin
Milltronics MWL Weight Lifter
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Operating Instructions, 11/2011, 7ML19985CR03-03
Installing/Mounting
4.2 Installation procedure
4.2.5
Test the unloaded MWL
1. Turn the crank handle, or use the control buttons, and watch the lifting arms move up and
down.
2. Check to see whether any binding occurs during the process. If there is any binding or
hesitation, the crank bodies need to be aligned to each other.
①
②
③
lifting arms lowered
lifting arms raised
calibration weight support (2)
Align the crank bodies to each other, if necessary
1. Loosen the two bolts that mount each crank body.
2. Turn the crank handle, or use the control buttons, until the lifting arms have completed at
least one complete cycle from a raised to a lowered position: this process should
automatically align the crank bodies.
3. Retighten the bolts that mount the two crank bodies.
4. Check again, and repeat the process until the MWL operates smoothly, with no resistance.
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Installing/Mounting
4.2 Installation procedure
4.2.6
Install calibration weights
Note
When using flat bar weights, ensure adequate base-bar weight clearance before adding
calibration weights. When using the round bar weight, the bar weight is an integrated part of
the base-bar.
①
②
base-bar weight applied
lifting arms lowered
1. Turn the crank handle, or use the control buttons, until the lifting arms are fully lowered.
2. Place the base-bar weight into position on the calibration weight supports of the Milltronics
belt scale.
Milltronics MWL Weight Lifter
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Installing/Mounting
4.2 Installation procedure
3. Ensure there is 10 mm (0.38") minimum clearance between the underside of the base-bar
weight and the top of the lowered MWL lifting arms. If necessary, shim the belt scale and
adjacent idlers to achieve this clearance.
①
②
③
④
calibration weight support
10 mm (0.38") minimum gap
lifting arm lowered
underside of base-bar weight
4. Gently turn the crank handle, or use the control buttons, until the lifting arms are fully raised:
you may need to guide the notches in the base-bar weight in line with the lifting arms initially.
①
lifting arm engages the notch on the end of the base-bar weight
Milltronics MWL Weight Lifter
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Installing/Mounting
4.2 Installation procedure
5. Ensure there is 10 mm (0.38") minimum clearance between the underside of the base-bar
weight and the top surface of the calibration weight support when the lifting arms are fully
raised. If necessary, shim the MWL to achieve this clearance.
①
②
③
④
10 mm (0.38") minimum clearance
top surface of calibration weight support
lifting arm raised
underside of base-bar weight
6. Ensure there is sufficient clearance between the side of the base-bar weight and the vertical
arms of the calibration weight support arm, or support bracket: see dimensions shown below.
If necessary, move the two crank bodies further from the calibration weight supports to
achieve this clearance.
①
②
③
minimum clearance
- on MUS, MBS, MCS scales: 10 mm (0.38")
- on MSI scales: 12.5 mm (0.5")
vertical arm of calibration weight support
base-bar weight
7. Recheck the crank body alignment: if necessary, see Align the crank bodies to each other
(Page 19).
Milltronics MWL Weight Lifter
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Operating Instructions, 11/2011, 7ML19985CR03-03
Installing/Mounting
4.2 Installation procedure
4.2.7
Test the loaded MWL
①
②
③
calibration weights applied
lifting arms raised
calibration weight support (2)
1. Keep the lifting arms raised, and add the other calibration weights
2. Check again to ensure there is 10 mm (0.38") minimum clearance [12.5 mm (0.5") on MSI
scales] between the side of the stacked weights and the vertical arms of the calibration
weight supports. If necessary, move the two crank bodies further from the calibration weight
supports to achieve this clearance.
①
②
③
minimum clearance
- on MUS, MBS, MCS scales: 10 mm (0.38")
- on MSI scales: 12.5 (0.5")
vertical arm of calibration weight support
calibration weights
3. Recheck the crank body alignment: if necessary, see Align the crank bodies to each other
(Page 19).
Milltronics MWL Weight Lifter
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Installing/Mounting
4.2 Installation procedure
4.2.8
Shim the MWL
When the MWL is used with the MUS, MBS, or MCS belt scale, due to the wide variety of idler
types and sizes, it may be necessary to shim the MWL for proper operation.
Note
These tables are provided as a guideline only: shimming is often not required.
Angle spine idler
Angle size
Shim thickness
2" (50 mm)
Number of shims
none
2-1/2" (60 mm)
0.31" (8 mm)
1
3 " (75 mm)
0.31" (8 mm)
2
3-1/2" (90 mm)
0.31" (8 mm)
3
4" (100 mm)
0.31" (8 mm)
4
Shim thickness
Number of shims
4" (100 mm)
0.31" (8 mm)
1
5" (125 mm)
0.31" (8 mm)
1
6" (150 mm)
0.31" (8 mm)
2
Channel spine idler
Channel size
3" (75 mm)
none
1. Compare your idler spine to the spine type and size in the tables above, for a guide to the
size of shims you may require.
2. Select shims that will allow you to adjust the MWL crank bodies to the correct level.
3. Remove the bolt, nut, and washer on one crank body and position the shim between the
crank body and the conveyor stringer: it should not be necessary to loosen or remove the
torque tube connecting the two crank bodies.
Milltronics MWL Weight Lifter
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Operating Instructions, 11/2011, 7ML19985CR03-03
Installing/Mounting
4.2 Installation procedure
4. After the shim is in position, re-install and tighten the bolt, nut, and washer.
5. Repeat the same procedure with the other crank body, then recheck the crank body
alignment. See Recheck crank body alignment (Page 24).
①
②
③
④
bolt
shim, if required
washer
nut
Milltronics MWL Weight Lifter
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Installing/Mounting
4.2 Installation procedure
Recheck crank body alignment
1. After shimming, raise and lower the lifting arms to check whether there is any binding or
hesitation. If there is, repeat the alignment procedure (Page 19).
2. Raise the lifting arms again and check the clearance between the underside of the base-bar
weight and the top surface of the calibration weight support.
①
②
③
④
10 mm (0.38") minimum clearance
top surface of calibration weight support
lifting arm raised
underside of base-bar weight
3. Repeat the shimming procedure until the lifting arms raise the calibration weights at least 10
mm (0.38") above the calibration weight supports.
4. Tighten the torque shaft bolts and the crank-body mounting bolts, then recheck all
clearances.
The MWL installation is now complete.
Milltronics MWL Weight Lifter
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5
Connecting
5.1
Connecting the MWL (electronic version)
Note
 This chapter applies only to the electronic version of MWL. The manual version has no
electrical components.
 Installation shall only be performed by qualified personnel and in accordance with local
governing regulations.
 Suggested grounding/bonding wiring: ground per the following diagram.
①
②
③
④
⑤
secondary bond enclosure door ground wire
enclosure ground stud M8 (15MM) copper
M8 nut
lockwasher
secondary bond back plate ground wire
⑥
⑦
⑧
⑨
⑩
main bond provision "PE"
enclosure wall
star or serrated washer
lockwasher
M8 nut
Milltronics MWL Weight Lifter
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27
Connecting
5.1 Connecting the MWL (electronic version)
The electronic version of the Milltronics MWL Weight Lifter comes with an AC gearmotor, two
magnetic proximity sensors, and an optional electronic control panel. The motor is available in
two different three-phase power configurations: 220-240/380-420/440-480 and 500-600 V AC. It
can be controlled locally using the pushbuttons on the panel, or remotely by the customer's PLC
or DCS.
Note
Use the M10 ground stud in the backplate for secondary (outgoing) bonding to such parts as
the AC gearmotor.
The following connections must be made to ensure correct operation:
● incoming power
● control transformer
● motor and brake
● proximity sensors
● remote PLC (optional)
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Connecting
5.2 Connection diagram
5.2
Connection diagram
H1
H2
H3
H4
H5
--
SIEMENS ENERGY AND AUTOMATION
MT150L TRANSFORMER
X4
X3
X2
+ + - -
L1 N
Input:
AC 100-240V
99V 91V
95V 85V
120V
115V
110V
100V
130V
125V
120V
110V
600V
575V
550V
500V
480V
460V
440V
416V
400V
380V
240V 220V
230V 208V
X1
--
XF
L+ M I1 I2 I3 I4 I5 I6 I7 I8
Output:
DC 24V/4A
24V ok
LOGO! Power
LOGO!
6EP1331-1SH51
1
22.2...26.4 V
Q1
2
12/24RC
1
Q2
2
1
Q3
2
1
Q4
2
1 L1 3 L2 5 L3 21 NC A1+
1 L1 3 L2 5 L3 21 NC A1+
3RT
1 L1 3 L2 5 L3 21 NC A1+
3RT
3RT
A2
A2
A2
A2
A2
TB1-16
TB1-15
TB1-5
2 T1 4 T2 6 T3 22 NC A2-
TB1-2
2 T1 4 T2 6 T3 22 NC A2-
TB1-1
A2
2 T1 4 T2 6 T3 22 NC A2-
STOP RESET
95
①
②
③
④
⑤
⑥
96
NC
97
NO
2 T1 4 T2 6 T3
98
A2
14/22
NO/NC
panel mount disconnect
3-phase power connection terminal [See Connect input power (Page 30) ]
control transformer voltage connection terminals [See Connect the control transformer
(Page 31) ]
remote relay connection terminals [See Connect the remote PLC (Page 34) ]
magnetic proximity sensor connection terminals [See Connect the sensor junction box
(Page 33) ]
motor and brake connection terminals [See Connect the motor and brake (Page 32) ]
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29
Connecting
5.3 Connection procedure
5.3
Connection procedure
5.3.1
Connect input power
Connect the input power supply to the 3-phase power connection terminal on the control panel
as shown below. Refer to the connection diagram (Page 29) for more details.
L1
L2
L3
T1
T2
T3
①
incoming power
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Connecting
5.3 Connection procedure
5.3.2
Connect the control transformer
MWL (electronic version) comes with the H1 (common) connection from the control transformer
to the input fuse block already made. Refer to the table and diagram below to determine which
terminal on the control transformer to connect as the second primary lead. Refer to the
connection diagram (Page 29) for more details, if necessary.
CAUTION
Failure to connect the second primary lead on the control transformer correctly may result
in damage to the components of the control panel.
H1
H2
H3
H4
H5
SIEMENS ENERGY AND AUTOMATION
MT150L TRANSFORMER
H1
H2
240V 220V
230V 208V
H3
416V
400V
380V
480V
460V
440V
--
H4
H5
600V
575V
550V
500V
Power supply
Control transformer connection
208 - 240 V
H2
380 - 420 V
H3
440 - 480 V
H4
500 - 600 V
H5
CAUTION
Fuses have been supplied with the control panel for all configurations of supply voltage.
Install fuses as follows:
 Class CC ATDR1 (600 V, 1.0 A) fuse across terminals X1 - XF of the Secondary of the
MT150L control transformer.
 Class CC ATDR4 (600 V, 4.0 A) fuse for 220-240/380-420/440-480 V 3-phase supply
OR
 Class CC ATDR2-1/2 (600 V, 2.5 A) fuse for 500-600 V 3-phase supply.
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31
Connecting
5.3 Connection procedure
5.3.3
Connect the motor and brake
1. Connect the motor to the control panel using an appropriate power cable (3-phase with
ground), as shown in the diagram below.
3RU1611-0DB0
2 T1
①
②
4 T2
6 T3
TB1-1
2. Connect the brake release to the control panel using an appropriate 2-conductor cable, as
shown in the diagram below.
14/22
NO/NC
motor
brake coil
Refer to the connection diagram (Page 29) for more details.
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Connecting
5.3 Connection procedure
5.3.4
Connect the sensor junction box
Referring to the table and diagram below, connect terminal block 2 (TB2) on the proximity
sensor junction box to terminal block 1 (TB1) on the control panel, using an appropriate 4conductor cable. Refer to the connection diagram (Page 29) for more details.
Sensor
Sensor to junction box (TB2)
Sensor junction box (TB2)
Control panel (TB1)
DOWN
BLACK
TB2-4
TB1-2
TB2-3
TB1-5
TB2-2
TB1-15
BLACK
TB2-4
TB1-2
TB1-5
TB1-16
TB1-16
TB2-3
TB2-1
TB1-15
RED
WHITE
TB1-5
TB1-2
UP
RED
WHITE
TB2-1
TB2-2
TB2-3
TB2-4
①
②
③
proximity sensor connections to control panel (TB1)
to sensor DOWN connections on TB2
to sensor UP connections on TB2
④
⑤
⑥
wiring from UP sensor
wiring from DOWN sensor
proximity sensor junction box
Note
Depending on your configuration and the orientation of the sensor junction box, the sensor
signals may be reversed. The input of these switches is set at the factory; check the
termination of the wires to ensure the up and down switches are properly connected.
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33
Connecting
5.3 Connection procedure
5.3.5
Connect the remote PLC (optional)
Note
The connections described in this section are only required if you will be using a remotely
located PLC or DCS to run the MWL.
Connect the remote relay outputs on the MWL control panel to your remotely located PLC using
the diagram below. Refer to the connection diagram (Page 29) for more details, if necessary.
313 213 113
313 213 113
314 214 114
314 214 114
A31 A21 A11
A31 A21 A11
A2
A2
A2
A2
A2
A2
①
②
③
④
PLC ENABLE signal (314)
PLC signal DOWN (214)
PLC signal UP (114)
local relay
⑤
⑥
⑦
⑧
remote relay
to terminal block 1 (TB1-1)
to key switch LOC
to key switch REM
Note
The connections between terminals labeled A2 have already been made internally.
CAUTION
If the control panel is connected for use remotely, a series circuit for emergency stop
operation should be included in the system.
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Operating Instructions, 11/2011, 7ML19985CR03-03
Commissioning
6.1
6
Verifying MWL electrical connections
Note
This chapter applies only to the electronic version of MWL. The manual version has no
electrical components.
After completing the electrical connections described in the Connecting chapter (Page 27) , and
prior to using the MWL in normal operation, verify that the UP and DOWN proximity sensors and
the motor are connected correctly.
Verify proximity sensor connections
Verify that the proximity sensors have been connected correctly using the following procedure:
1. Remove the top cover on the MWL module that the gearmotor is installed on.
2. With power applied to the control panel, place a ferrous object (for example, a screwdriver)
on the face of the UP sensor. The green UP indicator on the control panel should light.
3. Repeat for the DOWN sensor. The red DOWN indicator should light.
4. If the sensor indicator lights are incorrect, turn off the power to the control panel, and switch
the TB2-1 and TB2-2 connections on the proximity sensor junction box. [See Connect the
sensor junction box (Page 33) ]
5. Repeat steps 2 and 3 to ensure that the sensors are now connected correctly.
Verify motor connections
Verify that the motor has been connected correctly using the following procedure:
1. With power applied to the control panel, turn the key switch to the LOC position.
2. Press the UP pushbutton and observe the direction of travel.
3. If the MWL is moving UP, the motor is connected correctly and you may now proceed to
operate the MWL in a normal fashion.
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35
Commissioning
6.1 Verifying MWL electrical connections
4. If the motor is moving DOWN, do the following:
– Press the EMERGENCY STOP button.
– Remove and lock out the main power from the MWL control panel.
– Reverse two of the motor phase wires to reverse the direction of the motor.
5. Apply main power and repeat steps 1 and 2 to ensure that the direction of motor control is
now correct.
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Operating Instructions, 11/2011, 7ML19985CR03-03
7
Operation
Note
To ensure accurate calibration, you must keep the area between the MWL lifting arms and
the calibration weights clear of build-up during the calibration routine. See Removing
material accumulation (Page 41).
7.1
Operation (manual version)
Applying calibration weights
Simply turn the crank handle until the calibration weights are fully lowered onto the calibration
weight supports of the belt scale. (Please see the manuals for the Milltronics Belt Scale and
Integrator, for the appropriate calibration procedures.)
①
②
③
flat bar calibration weights applied
lifting arms lowered
calibration weight supports (2)
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37
Operation
7.1 Operation (manual version)
Storing calibration weights
After you have completed the scale calibration procedure, turn the crank handle until the lifting
arms are fully raised.
①
②
crank handle stored on far side of crank body, with locking ball-pin
lifting arms raised
Storing crank handle
Remove the crank handle and store it to prevent it from impeding traffic or material when the
conveyor is in operation.
1. Remove the locking ball-pin tethered to the crank handle, and remove the handle.
2. Use the locking ball-pin tethered to the crank body nearest to the handle to secure the MWL
from unintended use and to store the crank handle.
3. Insert the locking ball-pin through the hole in the crank handle, and into the insertion point in
the center of the crank body. Two clips on the side of the crank body help to hold the handle
in position.
4. Cover the input shafts with a guard if they present a hazard to personnel when the MWL is
not in use.
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Operating Instructions, 11/2011, 7ML19985CR03-03
Operation
7.2 Operation (electronic version)
7.2
Operation (electronic version)
7.2.1
Electronic control panel
The electronic version of MWL uses an AC gearmotor to lift and lower the belt scale calibration
weights. The motor is operated from an electrical panel with the following controls:
● Operator key switch: OFF, LOC (local), REM (remote)
● UP pushbutton with green indicator
● DOWN pushbutton with red indicator
● EMERGENCY STOP pushbutton
Note
Motor overload protection
 Should the motor run up against a physical stop, the internal overload relay will trip and
the motor will stop, preventing damage.
 If the proximity sensor is not activated within a specified time, the motor will be
deactivated and the brake applied. If this happens, check for mechanical restrictions and
malfunctioning sensors.
7.2.2
Local mode
Applying calibration weights
1. Turn the key switch to the LOC position. The Local Relay coil will be energized providing an
enable signal to the LOGO relay, releasing the brake and allowing the motor to move freely.
2. Push the DOWN button. The MWL will move down until the DOWN sensor activates,
disabling the reversing contactor and bringing the motor to a rest position.
While the MWL is moving, the red DOWN indicator will blink. Once it stops, the indicator will
remain on.
3. Refer to the manuals for the Milltronics Belt Scale and Integrator, to perform the appropriate
calibration procedures.
Milltronics MWL Weight Lifter
Operating Instructions, 11/2011, 7ML19985CR03-03
39
Operation
7.2 Operation (electronic version)
Storing calibration weights
1. After you have performed the scale calibration procedure, push the UP button. The MWL will
move up until the UP sensor activates, disabling the reversing contactor, bringing the motor
to a stop and engaging the brake.
While the MWL is moving, the green UP indicator will blink. Once it stops, the indicator will
remain on.
2. Turn the key switch to the OFF position.
CAUTION
The green UP indicator will turn off if the MWL has drifted down from the UP position.
Note
The signal from the UP proximity switch can be used as an alarm input to a remote PLC or
DCS.
7.2.3
Remote mode
Remote mode provides the same control functionality as local mode, however the control
functions are provided by a PLC or DCS system.
To operate the electronic version of MWL in remote mode, set the key switch to the REM
position. This energizes the remote relay coil and closes the 3 contacts required for the PLC
ENABLE signal and the UP and DOWN operation signals.
Note
In remote mode, the front panel pushbuttons, with the exception of the EMERGENCY STOP
button, are disabled.
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Operating Instructions, 11/2011, 7ML19985CR03-03
8
Service and maintenance
8.1
Removing material accumulation
To ensure that the belt scale will provide optimal accuracy, periodically inspect the area around
the calibration weights and remove any material build-up.
The calibration weights must remain consistent to calibrate the scale correctly. If material
accumulates on top of them, the added weight will cause the calibration procedure to produce
poor results. The top surface of the calibration weight supports must also be kept clean for the
scale to produce accurate results.
Material should not accumulate inside the crank body housings under normal operating
conditions, but it is a good idea to inspect them periodically.
Note
Before starting a calibration procedure, be sure to check that there is no material
accumulation in the three areas described below.
①
②
③
top surface of calibration weights
top surface of calibration weight support
inside crank body housing
Milltronics MWL Weight Lifter
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41
Service and maintenance
8.1 Removing material accumulation
1. Remove any material build-up from the top of the calibration weights.
2. Remove any material build-up from the top surface of the calibration weight supports
between the calibration weights and the conveyor scale.
3. Check inside the MWL crank body and inspect the threaded shaft drive: if material has
accumulated here, remove it with an air stream or other suitable device.
Note
The threaded shaft and guide plates are normally not accessible to the human hand: do
not force any foreign matter into the area during operation.
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Operating Instructions, 11/2011, 7ML19985CR03-03
Service and maintenance
8.2 Technical support
8.2
Technical support
If you have any technical questions about the device described in these Operating Instructions
and do not find the right answers, you can contact Customer Support:
● Via the Internet using the Support Request:
Support request (http://www.siemens.com/automation/support-request)
●
Via Phone:
– Europe: +49 (0)911 895 7222
– America: +1 423 262 5710
– Asia-Pacific: +86 10 6475 7575
Further information about our technical support is available on the Internet at
Technical support (http://support.automation.siemens.com/WW/view/en/16604318)
Service and support on the Internet
In addition to our documentation, we offer a comprehensive knowledge base online on the
Internet at:
Service and Support (http://www.siemens.com/automation/service&support)
There you will find:
● The latest product information, FAQs, downloads, tips and tricks.
● Our newsletter, providing you with the latest information about your products.
● Our bulletin board, where users and specialists share their knowledge worldwide.
● You can find your local contact partner for Industry Automation and Drives Technologies in
our partner database.
● Information about field service, repairs, spare parts and lots more under "Services."
Additional support
Please contact your local Siemens representative and offices if you have additional questions
about the device
Find your contact partner at:
Local contact person (http://www.siemens.com/automation/partner)
Milltronics MWL Weight Lifter
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Service and maintenance
8.2 Technical support
Milltronics MWL Weight Lifter
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9
Technical data
9.1
Specifications
Belt width
MUS-STD Standard Duty
up to 1000 mm; CEMA width 42"
MUS-HD Heavy Duty
up to 1600 mm; CEMA width 60"
MBS
up to 1000 mm; CEMA width 42"
MCS
up to 1600 mm; CEMA width 60"
MSI
500 to 2000 mm; CEMA width 18" to 96"
MMI
consists of 2 or more MSI scales, 2 or more MWL
units
Note
Some belt scales require specific order configurations for use with the MWL.
Idler spacing
minimum of 610 mm (24")
Calibration weight capacity
750 lbs. (340 kg)
Crank arm (manual version)
mechanical advantage
20:1
number of revolutions required for raising or
lowering
12
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45
Technical data
9.1 Specifications
AC gearmotor (electronic version)
0.55 kW (0.74 hp), TEFC with integral brake
voltage
220-240/380-480/575 V AC, 3-phase, 50/60 Hz
degree of protection
IP55
insulation class
F
Proximity sensors (electronic version)
12 mm magnetic proximity switches, NPN
Control panel (electronic version)
local or remote interface with up, down buttons and indicators for indoor or outdoor use
input
220-240/380-420/440-480/500-600 V AC, 3phase, 50/60 Hz, 2 kVA
outputs
220-240/380-420/440-480/500-600 V AC, 3phase, 50/60 Hz, 0.55 kW (0.74 hp);
24 V DC, 30 W
temperature
-20 to +40 ° C (-4 to +104 °F)
degree of protection
NEMA 4/Type 4, IP66
dimensions
15.75 x 19.68 x 8.27" (400 x 500 x 210mm)
Approvals (manual version)
General
CE, C-TICK
Approvals (electronic version)
General
CE, C-TICK
CSAUS/C
The Milltronics MWL Weight Lifter is in compliance with Directive 98/37/EC.
Milltronics MWL Weight Lifter
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Operating Instructions, 11/2011, 7ML19985CR03-03
10
Dimension drawings
10.1
Calibration weight dimensions
①
conveyor A dimension + 65 mm (2.56")
Milltronics MWL Weight Lifter
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47
Dimension drawings
10.2 Installation drawings
10.2
Installation drawings
10.2.1
MWL installation drawing for the MUS-STD standard duty belt scale
C
①
14 mm (0.56") diameter holes (4 places)
⑤
②
③
133 mm (5.22")
214 mm (8.43")
⑥
⑦
④
522 mm (20.55")
⑧
belt width + 229 mm (9") or to suit (A
dimension)
belt
10 mm (0.38") minimum clearance from
vertical arm to weights
base-bar weight centered on lifting arm
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Dimension drawings
10.2 Installation drawings
10.2.2
MWL installation drawings for the MUS-HD heavy duty belt scale
①
②
③
④
⑤
belt width + 229 mm (9") or to suit (A dimension)
belt
246 mm (9.67")
⑥
⑦
608 mm (23.92)
⑧
14 mm (0.56") diameter holes (4
places)
133 mm (5.22")
10 mm (0.38") minimum clearance from vertical arm
to weights
base-bar weight centered on lifting arm
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Dimension drawings
10.2 Installation drawings
10.2.3
MWL installation drawing for the MBS belt scale
①
②
③
④
⑤
belt width + 229 mm (9") or to suit (A dimension)
⑥
⑦
belt
214 mm (8.43")
525 mm (20.67")
⑧
base-bar weight centered on lifting arm
14 mm (0.56") diameter holes (4
places)
133 mm (5.22")
10 mm (0.38") minimum clearance from vertical
arm to weights
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Dimension drawings
10.2 Installation drawings
10.2.4
MWL installation drawing for the MCS belt scale
①
②
③
④
⑤
⑥
belt
133 mm (5.22")
214 mm (8.43")
⑦
base-bar weight centered on lifting arm
14 mm (0.56") diameter holes (4 places)
10 mm (0.38") minimum clearance from
vertical arm to weights
belt width + 229 mm (9") or to suit (A
dimension)
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Dimension drawings
10.2 Installation drawings
10.2.5
MWL installation drawing for the MSI or MMI belt scale
C
①
②
③
④
⑤
⑥
belt
133 mm (5.22")
265 mm (10.42")
⑦
base-bar weight centered on lifting arm
14 mm (0.56") diameter holes (4 places)
13 mm (0.5") minimum clearance from
vertical arm to weights
belt width + 229 mm (9") or to suit (A
dimension)
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Dimension drawings
10.2 Installation drawings
10.2.5.1
Retrofitting an MSI or MMI belt scale
Two new calibration weight brackets are required with the MWL to replace the existing
calibration weight bar. New bolts are supplied, but you will also need a C-clamp, metric Allen
keys, and metric wrenches.
CAUTION
Take care to protect the load cells from impact or prying forces during installation of the
new calibration weight brackets.
1. Rotate the shipping stops on the MSI into a vertical position, and tighten screws A to secure
the stops in place. This will help to protect the load cells from damage while the calibration
weight brackets are being installed.
①
②
③
screws A
screws B
shipping stop in free position
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Dimension drawings
10.2 Installation drawings
2. Remove the idler.
①
②
③
④
⑤
idler removed
shipping stops in vertical position
calibration weight bar removed
calibration weight brackets
bolts (step 6)
3. Remove the two socket-head cap-screws that secure the calibration weight bar, then remove
the calibration weight bar from the dynamic beam of the belt scale.
4. Clamp the bottom of the idler support angle-brackets to the dynamic beam, using two Cclamps.
①
②
③
④
angle-bracket
dynamic beam
C-clamp (customer supplied)
calibration weight bracket
5. Remove the four socket head bolts that secure the idler support angle-brackets.
6. Mount the new calibration weight brackets using the same holes as the idler support angle
brackets. Use the new bolts and nuts supplied with the calibration weight brackets, and handtighten the nuts.
7. Align the new calibration weight brackets with each other vertically and horizontally.
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Dimension drawings
10.2 Installation drawings
8. Tighten the nuts and bolts firmly to secure all four brackets.
Torque value = 54.6 Nm (40 ft-lbs).
9. Remove the C-clamps.
10.Re-install the idler and check idler alignment as described in the belt scale operating
instructions.
11.Free the weight mechanism: loosen screws A and rotate the 2 shipping stops inward and
down, over screws B (see step 1). Tighten screws A to secure them in place.
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55
Dimension drawings
10.2 Installation drawings
10.2.6
MWL (electronic version) dimensions
Note
This drawing shows the dimensions unique to the electronic version of MWL. All other
dimensions are as shown in previous drawings.
①
②
③
④
⑤
⑥
257.1 mm (10.12")
proximity sensor junction box
AC gearmotor
214.4 mm (8.44")
430.9 mm (16.96")
motor junction box
Milltronics MWL Weight Lifter
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Operating Instructions, 11/2011, 7ML19985CR03-03
A
Appendix A: Customer calculations
Calculation of total calibration weight mass
Record the value of the base-bar and weights to be attached. The weights should be recorded in
either kilograms or pounds. In the case of flat bar weights, the U-brackets which secure the bars
each weigh 0.43 kg (0.95 lb).
Weight of base-bar
________________________________ kg or lb
Mass of calibration weights
________________________________
________________________________
________________________________
________________________________
________________________________
________________________________
________________________________
________________________________
________________________________
________________________________
________________________________
________________________________
________________________________
________________________________
________________________________
________________________________
________________________________
________________________________
Grand total ________________________ kg or lb
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57
Appendix A: Customer calculations
Calculation of load reference values
Calibration reference value in kg/m = grand total in kg
idler spacing in m
OR
Calibration reference value in lb/ft = grand total in lb
idler spacing in ft
Using the factoring function of the belt scale integrator
If the belt scale system has been pre-calibrated, as in the case of an MWL retrofit, the belt scale
system should be zeroed. The Factor function of the integrator should be used to accurately
determine the value of the calibration weights in terms of the existing span calibration. (See the
integrator manual for more detail.)
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Operating Instructions, 11/2011, 7ML19985CR03-03
www.siemens.com/processautomation
For more information
www.siemens.com/level
www.siemens.com/weighing
Siemens AG
Subject to change without prior notice
Industry Sector
7ML19985CR03 Rev. 3.0
1954 Technology Drive
© Siemens AG 2011
P.O. Box 4225
Peterborough, ON
Canada K9J 7B1
email: [email protected]
www.siemens.com/processautomation
*7ml19985CR03*
Printed in Canada