INTECONT Satus Commissioning and Set-Up Assistant - Schenck ...

BV-H5123GB 

INTECONT Satus 

Commissioning and Set-Up Assistant

Service: 

Quality and reliability form the basis for Schenck’s corporate philosophy all over the world. 

In House Support (Monday through Friday from at least 8 o’clock to 5 p.m. CST) 

Service specialists are available for technical assistance to answer your questions or assist you in 

trouble shooting. 

Heavy Industry 

Phone: 800-558-0184 

Fax: 262-473-2489 

Light Industry 

Phone: 800-558-0184 

Fax: 262-473-2489 

Spare Parts and Components 

Phone: 800-558-0184 

FAX: 262-473-2489 

MKTG@ACCURATEFEEDERS.com - Light Industry 

MKTG@Schenckamericas.com - Heavy Industry 

24 hour Emergency Support 

You have a malfunction or problem outside of our normal business hours. You can reach our service 

technician at any time outside of our office hours for after hour emergency support. 

Phone: 800-558-0184 (Please listen closely to menu for after hours support.) 

Copyright 2008 

SCHENCK AccuRate, USA-PO Box 208, Whitewater, WI, http://www.sarinc.com 

a subsidiary of Schenck Process GmbH, Pallaswiesenstraße 100, 64293 Darmstadt, Germany 

www.schenckprocess.com 

All rights reserved. Any reproduction of this documentation, regardless of method, without prior 

permission by Schenck Process GmbH in writing, even by excerpt, is prohibited. 

Subject to change without prior notice.

Table of Contents 

1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 

1.1 What is the INTECONT Satus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 

1.2 Purpose of Commissioning and Set-Up Assistant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 

1.3 Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 

2 Basic Components of the INTECONT Satus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 

2.1 INTECONT Satus Operator Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 

2.2 Basic Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54 

3 INTECONT Satus Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 

3.1 Verify Mechanical and Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 

3.2 Powering-Up and Awaiting System Start. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 

3.3 Setting Parameters for Blocks A, B,C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 

3.4 Executive Set-Up Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 

3.4.1 Impulse/Belt Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 

3.4.2 Taring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 

3.4.3 Weight Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 

3.5 Setting Limit Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 

INTECONT Satus Commissioning and Set-Up BV-H5123GB / 0852 

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1.3 Safety 

1 Introduction 

1.1 What is the INTECONT Satus? 

The INTECONT Satus is an electronic weigh system for a belt 

weigher. 

The INTECONT Satus is supplied with specification sheets including 

customer parameters and design specifications. Electrical Drawings 

are also included for customer specific wiring. 

1.2 Purpose of Rapid Start Manual 

The purpose of this manual is to provide the information necessary to 

make the initial set-up of the INTECONT Satus as easy as possible. 

NOTE: This manual is meant as a quick reference only. For more 

detailed information, see your INTECONT Satus Operating Manual 

(BV-H2346GB). 

1.3 Safety 

Preparation, installation, commissioning, operation, maintenance, and 

servicing of the INTECONT Satus may be performed by skilled 

persons only. All persons working on the INTECONT Satus are 

required to observe the saftey instructions. Refer to your INTECONT 

Satus Operating Manual (BV-H2346GB) for further safety instructions. 

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1.3 Safety 

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2.1 INTECONT Satus Operator Interface 

2 Basic Components of the INTECONT Satus 

2.1 INTECONT Satus Operator Interface 

The operator interface is used for direct operation of the INTECONT 

Satus. Figure 1 below shows the operator interface. The two parts of 

the operator interface are the display and keypad areas. 

Figure 1: Operator Interface 


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2.2 Basic Definitions 

2.2 Basic Definitions 

Letter Coding 

I = Feed rate 

Material amount discharged from belt per unit of time (kg/h) 

V = Speed of conveyor belt (m/s) 

Q = Belt load 

Material weight on one belt meter (kg/m) 

Measuring Principles 

Belt load (Q) and speed (V) are continuously measured and factored 

together. The result is feed rate (I) from which the flowrate is 

determined. 

I = Q x V x 3600 


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3 INTECONT Satus Commissioning 

This section will describe the procedures necessary to commission 

the INTECONT Satus. There are 5 steps for commissioning. 

Figure 2: Commissioning Steps 

NOTE: If you are following along with the BEMP Training Video, go to 

Section 3.3, page 9. 


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3.1 Verify Mechanical and Electrical Installation 


Mechanical Installation 

The first step is to verify the mechanical installation. Refer to the 

BEMP mechanical drawings. 

Electrical Installation 

Refer to your electrical drawings found in the documentation binder for 

customer specific wiring. 

Below are examples of electrical connections for the INTECONT 

Satus. 

Load Cell Connections 

Figure 3: Load Cell Connections 


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Speed Input Connections 

Speed input is the input from the speed sensor that indicates how fast 

the belt is moving. 

Figure 4: Speed Input Connections 

Digital Input Connections 

Digital inputs are inputs that the user will push a button to perform a 

specific action on the controller. 

Figure 5: Digital Input Connections 

Pulse Output Point for Totalizing Counter-Impulse 

Pulse output is a digital signal that the INTECONT Satus is sending to 

a PLC or other device indicating the total material passing through the 

belt. 

Figure 6: Pulse Output Connections 


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3.2 Powering-Up and Awaiting System Start 

Relay Output Connections 

Figure 7: Relay Output Connections 

Overall BEMP System Connections 

Figure 8: Overall BEMP System Connections 

3.2 Powering-Up and Awaiting System Start 

Once the Mechanical and Electrical Installation is complete, power-up 

the system. 


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3.3 Setting Parameters for Blocks A,B,C 


Customer parameters have been pre-set at SCHENCK AccuRate. 

Check the program against your parameter data sheet. 

The 14 parameters listed below may require adjustment. 

Figure 9: Parameter List 

Follow the steps below to set Parameter C 02: 

1. With the BEMP turned OFF, use a piece of brown masking tape 

and pick a spot on the belt where it is easily accessible and 

place the piece of tape on it. 

2. Turn the BEMP ON. The belt must be running for the next step. 

3. Measure and record the time (in seconds) required for one belt 

circuit as accurately as possible and enter this time for 

parameter C 02. 

NOTE: Please note that the belt drive is not controlled by the set-up 

program and the set-up program will be interrupted with a 

corresponding message if one of the preconditions are not met. 

4. To begin entering data, press the Function key. 

5. Using the or keys, select Programming. 

6. Press Enter. 

7. Using the or keys, select Enter Parameter. 


9. Confirm the selection by pressing Enter. 

10. The system will prompt for a password. Use the default 

password 07734. Use thekeys to move the cursor to the 

digit that is to be changed. Use the or keys to increase or 

decrease that digit. 


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NOTE: Controller will not prompt for password if you have entered a 

password before and the duration of the password time has not 

expired. This will apply through out the calibration process. 


12. Use the or key to select Block C. 


14. Use the or key to select C O2. 

15. Use the key and move the cursor to the value and change it to 

the value determined in step 3. 

16. Once the change is done, confirm it by pressing Enter. 

17. Escape to the Main Operation Screen by pressing the Function 

key twice. 

NOTE: If the INTECONT Satus is purchased with a BEMP, the 

parameters have been set accordingly. However, if the INTECONT 

Satus is purchased as a replacement or part, the parameters in the list 

below need to be checked and modified if necessary. 

Figure 10: Parameter List 2 


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3.4 Executive Set-Up Programs 


3.4.1 Impulse/Belt Sequence 

The Executive Set-Up Programs include the Impulse/Belt Sequence, 

Taring, and Weight Check. 

NOTE: You must perform this calibration program before the tare or 

weight check calibration programs. 

In this procedure, the amount of impulses given by the speed sensor 

for one belt circuit is calculated and entered in the INTECONT Satus. 

Perform the impulse/belt sequence for the following reasons: 

1. You are at the initial setting. 

2. If a new belt is fitted or the belt tension has been altered 

significantly. 

3. If one of the parameters B 04 (characteristic value vs) or B 05 

(nominal speed) have been altered on scales which do or do not 

measure velocity. 

NOTE: The BEMP must be running. If not, turn it on. 

Follow the steps below to begin the Impulse/Belt Sequence: 

1. Press the Function key. 

2. Using the or keys, select the Calib. Function. 






NOTE: Controller will not prompt for password if you have entered a 

password before and the duration of the password time has not 

expire. This will apply through out the calibration function. 


6. Use the or keys to select the LB: Imp/Belt routine. 

7. Press Enter to activate the routine. The display will display LB: 

xxx sec (counting down time and impulse value will be displayed 

alternately). 


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NOTE: The system will prompt you to “Start!” the belt conveyor if it is 

not running. If this occurs, the system will default back to the operation 

screen. You will need to start all over again from the beginning of this 

routine. This will apply to the rest of the calibration. 

8. Once the count down is completed, press Enter to confirm the 

values. The system will escape to the Main Operation Screen. 

NOTE: This procedure is identical for BEMP belt conveyors without 

speed sensors. 

3.4.2 Taring 

The taring program acquires the zero point error of the BEMP over one 

belt circuit and the resulting value is used to correct the continuous 

measuring results in normal operation. 

Preconditions to executing the taring function: 

1. Under no circumstances may there be any material on the belt. 

2. The mechanical equipment within the scales area must be 

cleaned. 

3. Belt conveyor must be runnning. If not, turn it on. 

Follow the steps below to tare: 




4. The system prompts for a password. Use the default password 

07734. Use thekeys to move the cursor to the digit that is 

to be changed. Use the or keys to increase or decrease that 

digit. 


6. Use the or keys to select the TW: Tare routine. 

7. Press Enter to activate the routine. The display will display TW: 

xxx % (counting down and tare value will be displayed 

alternately). 

8. Once Tare is completed, press Enter to confirm the Abw. Value. 

The tare result is accepted and automatically stored in parameter 

D 03. The system will escape to the Main Operation Screen. 


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NOTE: The tare may exceed 100% by using the nominal belt load as 

a reference. Additionally, a mechanical error may be at fault if the 

deviation ‘Dev.’ is 20% or greater. If this occurs, inspect the weighing 

platform for stuck particles of material. 

3.4.3 Weight Check 

The weight check CW program is used to control the INTECONT 

Satus measuring range by loading the weighing platform with a known 

calibration weight and automatically calculating the average platform 

load over one belt circuit. The result is compared to a predetermined 

reference value and then displayed. No automatic correction is 

performed. 

Preconditions to executing the Check Weight function: 

1. System has been tared. 

2. The calibration weight has been entered in parameter C 08. The 

calibration weight should be between 30-100% of the nominal 

platform load Q0. 

a. To enter calibration weight, press the Function key. 

b. Using the or keys, select Programming. 

c. Press Enter. 

d. Using the or keys, select Enter Parameter. 

e. Press Enter. 

f. Confirm the selection by pressing Enter. 

g. The system will prompt for a password. Use the 

default password 07734. Use thekeys to 

move the cursor to the digit that is to be changed. 

Use the or keys to increase or decrease that 

digit. 

h. Press Enter. 

i. Use the or key to select Block C. 

j. Press Enter. 

k. Use the or key to select C 08. 

l. Use the key and move the cursor to the value and 

enter the calibration weight. 

m. Confirm it by pressing Enter. 

n. Escape to the Main Operation Screen by pressing 

the Function key twice. 

3. The calibration weight has been hung from the test weight hole 

on the BEMP. Refer to the BEMP Manual for location. 


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WARNING: For safety reasons, please turn off the belt prior to 

hanging the calibration weight. 

4. Belt conveyor should be running. If not, turn it on. 

Follow the steps below to run the check weight program: 




4. The system prompts for a password. Use the default password 

07734. Use thekeys to move the cursor to the digit that is 

to be changed. Use the or keys to increase or decrease that 

digit. 


6. Use the or keys to select the CW: Weight Check routine. 

7. Press Enter to activate the routine. The display will display CW: 

xxx % (CW will be counting down and Set/Act value will be 

displayed alternately). 

8. Once the CW is done, the CW: value and the KOR value will be 

displayed. Record the KOR value on a piece of paper and then 

enter this value into parameter block D 02. 

a. To enter the KOR value, press the Function key. 

b. Using the or keys, select Programming. 

c. Press Enter. 

d. Using the or keys, select Enter Parameter. 

e. Press Enter. 

f. Confirm the selection by pressing Enter. 

g. The system will prompt for a password. Use the 

default password 07734. Use thekeys to 

move the cursor to the digit that is to be changed. 

Use the or keys to increase or decrease that 

digit. 

h. Press Enter. 

i. Use the or key to select Block D. 

j. Press Enter. 

k. Use the or key to select D 02. 

l. Use the key and move the cursor to the value and 

enter the KOR value. 

m. Confirm it by pressing Enter. 

n. Escape to the Main Operation Screen by pressing 

the Function key twice. 


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3.5 Setting Limit Values 

3.5 Setting Limit Values 

The following Limit Values should be set. 

F 05 Q-MIN Value 

F 07 Q-MAX Value 

F 09 V-MIN Value 

20.0 % Q 

120.0 % Q 

5.0 % V 

Follow the steps below to set the Limit Values: 

1. To set the limit values, press the Function key. 

2. Using the or keys, select Programming. 


4. Using the or keys, select Enter Parameter. 








9. Use the or key to select Block F. 


11. Use the or key to select the desired limit value parameter. 

12. Use the key and move the cursor to the value and enter the 

desired limit value. 

13. Confirm it by pressing Enter. 

14. Escape to the Main Operation Screen by pressing the Function 

key twice. 


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