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Skov DOL 99-2 feed weigher User manual

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DOL 99-2 Feed Weigher
User Manual
User Manual
DOL 99-2 Feed Weigher
Program version
The product described in this manual holds software. This manual corresponds to:
SOFTWARE VERSION 2.00
Released in January 1993.
Product revision
SKOV A/S retain the right to revise this document and the product therein described without prior
notice. SKOV A/S cannot guarantee that you will receive information about revision of the product or
the manual. In case of doubt please get in touch with SKOV A/S.
NOTICE
• All rights reserved. Reproduction of any part of this manual in any form whatsoever
without SKOV A/S' express written permission is forbidden.
• The contents of this manual are subject to change without notice.
• All efforts have been made to assure the accuracy of the contents of this manual.
However, should any error be detected, SKOV A/S would greatly appreciate being
informed.
• Notwithstanding the above, SKOV A/S can assume no responsibility for any errors in
this manual or their consequence.
• Copyright 1993 by SKOV A/S.
4 User Manual
PRODUCT DESCRIPTION 6
OPERATING INSTRUCTIONS 8
1 Daily operation ............................................................................................. 8
2 Use of display switch .................................................................................. 9
2.1 Adjustment of mixing ratio ................................................................................................... 9
MAINTENANCE 10
3 Adjustments ............................................................................................... 10
3.1 Adjustment of drum stop position ...................................................................................... 10
3.2 Adjustment of batch (degree of filling) .............................................................................. 11
3.3 Adjustment of weight amplifier (offset) ............................................................................. 11
CALIBRATION 12
4 Check of accuracy ..................................................................................... 13
MECHANICAL INSTALLATION 14
ELECTRICAL INSTALLATION 15
5 Cabling ........................................................................................................ 15
6 Electrical connection ................................................................................. 16
7 Alarm ........................................................................................................... 18
8 Remote control of DOL 99-2 ..................................................................... 18
9 Remote setting of the mixing ratio ........................................................... 20
TESTING
10 Functional tests ......................................................................................... 21
FUNCTIONAL DESCRIPTION 22
11 Circuit description ..................................................................................... 22
12 Control principles ...................................................................................... 23
12.1 After power failure .............................................................................................................. 23
12.2 By feed requirement a WEIGHING CYCLE begins ........................................................ 23
12.3 Check of calibration switch ................................................................................................. 23
12.4 Position of rest ...................................................................................................................... 23
User Manual 5
DOL 99-2 Feed Weigher
TROUBLESHOOTING AND SERVICE 24
13 Testing ........................................................................................................ 26
13.1 Testing of inductive sensor .................................................................................................. 26
13.2 Testing of load cells .............................................................................................................. 26
13.3 Testing of cells via control panels ....................................................................................... 26
14 Manual control ........................................................................................... 27
15 Replacement of gear motor ...................................................................... 27
TECHNICAL DATA 29
DIMENSIONED SKETCH 30
6 User Manual
PRODUCT DESCRIPTION
DOL 99-2 is used for accurate dosing of two different feed types. It is often used in broiler houses,
where wheat is added to the normal diets. The set mixing ratio in percentages is being weighed very
accurately, the weigher correcting for tails (the feed falling into the drum after the feed conveyor has
stopped).
It consists of a dust- and water proof housing with feed supply at the top and feed outlet at the bottom.
In the housing there is a drum (weighing vessel), which is emptied when turned round by a gear motor.
The drum and the motor are suspended in load cells. A microcomputer controls and computes the feed
quantity. Through the inspection cover at the top it is possible to place 4 x 5 kg weights in the weigher.
The weights are used for control and calibration in connection with a built-in testing program. The
transparent end covers facilitate inspection of the feed supply and the functions of the weigher.
The display has several functions, depending on the position of the display switch. The total feed
consumption of each feed component, the set mixing ratio in percentages, size of batches that are
weighed at a time, and calibration of the weigher can be shown on the display. The weighing data is
stored, even after power failure. For each 10 kg weigh-out a weighing impulse for central registration
(e.g. computer, counter) is transmitted. DOL 99-2 has control relays for on/off feed supply of 2
different feed components.
Normally the mixing ratio is set by a knob on the control box; however, remote setting via a 0-10V dc
control voltage is also possible.
Via the RESET-button the electronic counter of the weigher can be reset.
Has no feed supply been required for 5 minutes and 30 seconds, the drum automatically turns upside
down thus preventing dust and moisture from getting into the drum.
IMPORTANT
• Remove transport protection (foamed plastic material) around the drum before power is
connected.
• Remount transport protection whenever weigher is moved in order to avoid overloading
of load cells. Therefore keep the instructions.
• High-pressure cleaner should under no circumstances be used for internal cleaning of
weigher.
User Manual 7
DOL 99-2 Feed Weigher
Figure 1: DOL 99-2 detailed drawing
8 User Manual
OPERATING INSTRUCTIONS
1 Daily operation
DOL 99-2 is constructed for operation without supervision.
DOL 99-2 measures the feed consumption and the mixing ratio accurately, and the total quantity of
each feed component (A and B) can be read on the display. Display switch in positions 0, 1 and 2
shows total quantity of feed A weighed. In positions 3, 4 and 5 the corresponding total feed
consumption of feed B is shown. Positions 0 and 3 (normal) show the figures in tons, in positions 1
and 4 the figures are in tons x 100, and in positions 2 and 5 in grams.
Example:
Position 1 = 0001
Position 0 = 24.25
Position 2 = 9700
Position 4 = 0003
Position 3 = 76.54
Position 5 = 4567
Position 6 = 033.0
This means that the weight of feed A is:
000124.259700 tons or 124 tons, 259 kg and 700 grams.
and of feed B:
000376.544567 tons or 376 tons, 544 kg and 567 grams.
Position 6 shows that the weigher is set to weigh 33% of feed A (and thus 67.0% of feed B).
On the left side of the control box there is a pushbutton for resetting the weigher. It is the values of
positions 0, 1, 2, 3, 4 and 5 which are reset.
NB NOTE that the drum will rotate once when the button is released.
If for some reason the weigher is required to stop, the big safety switch can be used. Besides
interrupting the drum motor, it will also cut off the "feed requirement" signal to the weigher
User Manual 9
DOL 99-2 Feed Weigher
2 Use of display switch
The display switch which is placed on the left side
of the control box can be used by read-out of feed
values:
Figure 2: Setting of display switch
Position of
display switch
Total quantity
No. of digits
Max. figure
0
Feed A weighed in tons
2 digits before and after the comma
99.99 tons
1
Feed A weighed in tons x 100
Without a comma
999900 tons
2
Feed A weighed in grams
Without a comma
9999 grams
3
Feed B weighed in tons
2 digits before and after the comma
99.99 tons
4
Feed B weighed in grams
Without a comma
999900 tons
5
Feed B weighed in grams
Without a comma
9999 grams
6
Mixing ratio %
A/(A+B) x 100 (%).
The mixing ratio can be set
between 0 and 100%
3 digits before and one digit after
the comma
IMPORTANT: Irrespective of the position of the display switch, it does NOT influence the
function of the weigher. The display switch may be set to any position
without damaging the weigher.
2.1 Adjustment of mixing ratio
1) Set display switch to position 6.
2) Use a screwdriver to turn the knob on the left side of the front panel, opposite the symbol %A,
until the required mixing ratio is shown in the display.
The mixing ratio can be set between 0% (only feed B is supplied) and 100% (only feed A is supplied).
Example: The ratio is set to 20.0%.
The quantity (batch) is set to 20 kg.
The computer will now in connection with each weighing aim at filling 4.0
kg of feed A and 16.0 kg of feed B into the drum.
In principle the mixing ratio can be set between 0 and 100% with great accuracy. However,
adjustments close to the two extreme positions will not be quite accurate, if the tails (the quantity of
feed coming after the power to the auger was cut off) exceed the small quantity to be weighed.
Adjustments below 0.8% will be monitored as 0% and adjustments above 98.2% as 100%
Due to the capacity of the weigher it is recommended to set the feed type of the smaller share to be
feed type A. If, for instance, the weigher is used for adding wheat to complete diet mix, the wheat
should be chosen as feed type A
10 User Manual
MAINTENANCE
Once a year the end plates should be removed and the weigher cleaned by a blow gun. Check wearing
of flexible cables and wires and replace if necessary.
Check calibration (sect.4.2) at the same time and calibrate, if necessary. The function of DOL 99-2 is
described in sect. 8.
3 Adjustments
3.1 Adjustment of drum stop position
Figure 3: Adjustment of inductive
sensor
Figure 4: Adjustment of stop plate
User Manual 11
DOL 99-2 Feed Weigher
3.2 Adjustment of batch (degree of filling)
The batch of each weighing (feed A + feed B) is adjustable. Adjustment is made on the rear of the panel.
See Fig. 5.
• Quite to the left gives approx. 10 kg
• Middle position (normal position) approx. 20 kg
• Quite to the right approx. 30 kg
Figure 5: Rear of the DOL 99-2 control panel
3.3 Adjustment of weight amplifier (offset)
In case the control panel or the load cells are replaced, the weight amplifier should be adjusted.
1) The adjustment screw is placed on the rear of the control panel in the top left corner. See Fig.
5.
2) There may be some silicone in the hole. Remove silicone by a small screwdriver.
3) Connect a voltmeter between the two test points placed to the right of the batch adjustment
(degree of filling). The left test point is frame (negative).
4) When the weigher is empty, adjust by a small screwdriver until the voltage is between +0.8V
DC and +1.2V DC.
12 User Manual
CALIBRATION
DOL 99-2 should be switched on for at least 30 minutes before the calibration starts.
1) Unscrew the panel of the control box and push the switch at
the bottom of the box upwards.
If the weigher is in position rest, opening downwards, the drum turns
to position opening upwards.
The display now shows a figure with flashing commas.
2) Remount the panel.
Figure 6
NB The adjustments for 0 kg and 20 kg are blocked by two screws. Remove screws before
adjustment and remount after adjustment.
3) Unscrew the calibration lid (the lid at the top of the
weigher).
IMPORTANT Push the red safety switch in order to avoid
unintentional drum motor operation during the calibration.
Figure
7
4) When the drum is at rest, turn adjustment for 0 kg until
the figure in the display is as close to 000 as possible
(between 010 and -010).
Vibrations should be avoided as they will make calibration
difficult.
Figure 8
5) Now place 4 weights of 5 kg each in the drum.
6) The weights shall be distributed evenly in the drum.
7) When the drum is at rest, turn adjustment for 20 kg until
the figure in the display is as close to 000 as possible
(between 010 and -010).
8) Remove weights and remount calibration lid.
9) Loosen the panel of the control box, push the switch
down and remount panel.
10) The safety switch is deactivated by turning the knob.
Figure 9
IMPORTANT The calibration cannot be more accurate than the accuracy of the weights.
User Manual 13
DOL 99-2 Feed Weigher
4 Check of accuracy
It is possible to check the calibration accuracy. The same procedure as mentioned in section 4.2,
CALIBRATION, is to be followed; however the two adjustment screws should not be touched.
1) Note the figure in the display when the weigher is empty. Write down the figure.
2) Put four 5 kg weights in the drum.
3) Distribute the weights evenly at the bottom.
4) When the weigher is at rest, read the figure.
The difference between the two figures indicates the calibration accuracy of the weigher:
Fault = (Figure at 20 kg less figure at empty drum) / 130 (%)
Example:
By 20 kg in the drum display shows -033 and by empty drum 023.
The fault is in this case = (-33 - 23) / 130 = -0.4%.
When the calibration accuracy has been checked, it is always worth while to recalibrate the weigher,
see sect. 4.2.
A check of the absolute accuracy of DOL 99-2 can only be made if the exact weight of the supplied
feed and the weighing accuracy of it are known. The given quantity of feed should be compared to the
total quantity (A+B) shown in the display of DOL 99-2.
14 User Manual
MECHANICAL INSTALLATION
The weigher should be placed in such a way that both ends of the weigher are easily accessible. The
feed from the silos is led into the top of the weigher. In case of special conditions, the inlet pipe branch
could be replaced by an inlet funnel - delivered as an optional extra. The feed should fall vertically
into the drum, as this will ensure an even distribution in the drum.
From the bottom of the weigher the feed falls down into the feeder, or it will be carried on by a
distributing worm, see Fig. 10. The weigher should stand on a horizontal base, deviation not more than
1 cm/m in all directions. Vibrations from the feeding system, etc. MUST be avoided.
The best solution would be to place DOL 99-2 on a separate platform, which is bolted on to the wall or
floor in order to avoid vibrations disturbing the function of the weigher.
Suspension from the ceiling may cause slow vibrations upsetting the weighing
Figure 10: Example of installation DOL 99-2
1) Dismount both end covers.
2) Remove the transport protection (foamed plastic materials) and move the drum from the
transport fittings to the load cells.
3) Loosen the transport fittings, turn them 180° and retighten them.
4) Follow the instructions on the weigher. Check that the weighing drum is hanging freely, not
hanging in the wires or bumping against the end covers.
5) Take care that all the feed falls vertically down into the drum and distributes evenly.
6) Be sure that the wires are hanging freely when there is feed in the drum.
User Manual 15
DOL 99-2 Feed Weigher
ELECTRICAL INSTALLATION
5 Cabling
To facilitate service we recommend mounting a separate switch for DOL 99-2. Fig. 11 shows a
cabling plan for a typical installation
Figure 11: DOL 99-2 cabling plan
IMPORTANT To obtain max. noise protection of DOL 99-2 it is important to earth the
weigher correctly. If the electrical system does not have any earth wire
available, an earth connection should be made close to the weigher.
Also it is important that the feed supply motor is connected to the same
earth connection. See Fig. 11.
16 User Manual
6 Electrical connection
All electrical connections should be made to the bottom print of the control box.
1) Unscrew the panel of the control box.
2) Pull off the cable connector of the earth connection on the screen plate.
The panel can be removed by pulling out the plug.
3) Please note that the two locking wings should be released before the plug can be pulled out.
4) Loosen and remove the screen plate.
Now the bottom print is accessible. See Fig. 12.
Low voltage
High voltage
Figure 12: DOL 99-2 bottom print
Connection of supply voltage, feed requirement, alarm and remote counter should be made according
to the diagram, Fig. 14.
NB Please note that the earth connection MUST be made to the special earth terminal on the
bottom print. From there the earth connection to the drum motor is established. See Fig. 13.
Reset
Digital
Encoder
White
Braun
Yellow
Green
Strain module
+
Sensor
Supply
Motor
B
Supply
Motor
A
Supply
Motor Drum
Motor Mains
Supply
ImpulsAlarmFeed
Demand
N F N F N FNF
+
User Manual 17
DOL 99-2 Feed Weigher
Figure 13: Earth connection of bottom print
Figure 14: Electrical connection DOL 99-2
Supply voltage 220V/240V is connected to the terminals V23 and V24. Feed requirement of the house
is supplied to the terminals V13 and V14. If the feed requirement signal should be cut off via the
safety switch, the signal should be looped through the switch via the loose terminal block marked
"14".
Reset
Digital
Encoder
White
Braun
Yellow
Green
Strain module
+
Sensor
Supply
Motor
B
Supply
Motor
A
Supply
Motor Drum
Motor Mains
Supply
ImpulsAlarmFeed
Demand
N F N F N FNF
+
18 User Manual
• No voltage = no feed requirement
• 220V = feed requirement from the house
The motor which supplies feed A to the weigher is controlled from the terminals V15 and V18.
The motor which supplies feed B to the weigher is controlled from the terminals V15 and V16.
When feed supply is required, these terminals will be supplied with 220V.
NB NOTE that the terminals V13 and V15 are connected internally.
The terminals V19 and V20 can be connected to remote counter or to other external registration
equipment for remote reading of the weigher (e.g. the DOL 91 or DOL 92 computers). The relay has a
potential free contact which closes 1.2 sec. for each weight impulse (10 kg) of feed type B and 2.4 sec.
for each weight impulse of feed type A.
The system which transfers the signal of feed requirement to the weigher can be based on a capacitive
sensor (DOL 33R), placed in the vessel under the weigher.
By mounting separate switches for the DOL 99-2 weigher and the feed supply system, emergency
operation will be possible, if the weigher should be out of operation.
Switch off DOL 99-2 and make sure that the drum turns upside down. Short-circuit terminals V14 and
V16, and the DOL 33R sensor will alone control the feed supply to the vessel.
IMPORTANT: The position of the sensor in the vessel should allow room for at least one
entire portion of weighed feed above it. This is important because, if not,
the drum of the weigher would be blocked by accumulated feed.
For the sake of the auger which carries the feed away from the weigher, it is
also important that there is sufficient room for feed below the sensor in
order not to empty the vessel entirely.
When resetting the weigher, the button should be activated for at least 5 seconds. When the button is
released, the drum rotates once.
1) Remount the screen plate and the plug in the panel.
2) Connect the cable to the screen plate.
3) Remount the panel and the weigher is ready for use.
7 Alarm
By means of an extra sensor, DOL 33R, DOL 99-2 may be connected to an alarm system. The alarm is
given in connection with e.g. lack of feed in the house, owing to, say, an empty silo, defect auger or
weigher. If the vessel under the weigher is empty for more than 5 minutes, the sensor causes an alarm
to be given. In connection with power failure the sensor will not release any alarm.
Placing: See figure 10. The sensor, DOL 33R, is placed in the vessel below the feed
requirement sensor DOL 33R.
Setting: The time lag of the sensor is set to approx. 5 minutes.
Connection: The supply wire of the sensor is connected to 220V permanently.
Wires 1 and 4 are normally ON but will be OFF in case of alarm. To be
connected to an alarm system, e.g. DOL 2000.
8 Remote control of DOL 99-2
If the control panel of the weigher is not easily accessible for daily operation due to the position of the
weigher, the entire control box can be moved away from the weigher. The distance between the
weigher and the control box should not exceed 25 metres. The connection between the weigher and
User Manual 19
DOL 99-2 Feed Weigher
the control box is made by a power cable and a control cable. See Fig. 15. A connection box to be
mounted on the weigher and the necessary 6-core control cable can be supplied by SKOV. The
connection box contains a terminal block, to which the weigher cables and the extension cables are
connected.
Figure 15: Cabling plan for remote control
There should be no connection between the earth wires of the weigher and the control panel. The screen of
the control cable should be earthed on the panel and should not be earthed via the weigher. Consequently,
the weigher and the control panel should be earthed separately. See Fig. 16.
Figure 16: Wiring diagram for remote control
Figure 17: Wiring diagram for remote control
12
11
10
9
8
7
23
21
22
Reset
Digital
Encoder
White
Braun
Yellow
Green
Strain module
+
Sensor
Supply
Motor
B
Supply
Motor
A
Supply
Motor Drum
Motor Mains
Supply
Impuls
Alarm
Feed
Demand
N F N F N F
NF
+
Front panel
Connection box
screen
(drum motor)
Connection box
(Feed weigher)
Earth wire should not be led through
Max. 25 m.
This earth connection
is required
Min. 6x0,34mm2 with screen
Power cable
2x1,2mm2
3x1,5mm2
Control box (remote control)
Capacitor
Motor
Sensor
Load cell
Brown
Black
Blue
Green
Yellow
Brown
White
Yellow/green
Brown
Black
Blue
20 User Manual
9 Remote setting of the mixing ratio
Instead of setting the mixing ratio of feed types A and B directly on the control panel, the ratio can
alternatively be remote adjusted via an external control voltage, 0-10V DC. The control voltage should be
connected to terminals V2-V3, and the computers automatically select the external control voltage instead
of the value set by the knob.
By remote adjustment the set mixing ratio can be read on the display of the control panel. If the control
voltage is adjusted to a value which shows more than 104% on the display, the computer will change from
working according to the knob setting instead of the control voltage adjustment. At the same time the
display changes to show the setting of the knob.
On the relay panel of the control box the resistance R3 should be cut off. See Figure 18.
Figure 18: Remote control of mixing ratio
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