Field Operator Certification

Weigh Feeders
Learner Guide
 Weigh Feeders Learner Guide

Introduction
This lesson on Weigh Feeders, as with your other lessons on Auxiliary Equipment, consists of two
main learning components a self-directed/in-class component and an on-the-job component. You
are expected to complete both components as part of your Certification Program.

Review the remaining information contained in the Introduction section of this document prior to
beginning the Content section. If you have any questions about this information, speak with your
Instructor.

Objectives
Your learning objectives are broken down into two categories learning objectives for the self-
directed/in-class portion of your learning; and, learning objectives for the on-the-job portion of your
learning. They are listed below for your information.

Self-Directed/In-Class Learning Objectives

State the purpose of a Weigh Feeders
Name the main components of a Weigh Feeders
Explain the principle of operation of a Weigh Feeders
State applications for Weigh Feeders
State inspection points on a Weigh Feeders and possible causes of common problems
associated with Weigh Feeders
State safety concerns related to Weigh Feeders

On-the-job Learning Objectives

Perform an inspection on an operational Weigh Feeders
Perform an inspection on a static Weigh Feeders

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Lesson Outline
The first portion of the lesson, the self-directed/in-class portion, involves reviewing the following
information:

The purpose and basic principle of operation of a Weigh Feeders

A listing and description of the various components of a Weigh Feeders
Various applications of a Weigh Feeders
Inspection points of a Weigh Feeders and basic troubleshooting.
Safety concerns related to Weigh Feeders.
Pictures and graphics are included where appropriate to help you understand how Weigh Feeders
function. At the end of this section, there are a series of questions that you will be required to
answer and review with your Instructor.

The second portion of the lesson, the on-the-job portion, primarily involves the completion of
several inspections on belt conveyors, including both an operational and static Screw Conveyors
inspection and lockout procedures. When you are ready to perform these inspections, inform your
Instructor.

If you are a new Field Operator, you will complete a series of steps in your OJT portion of this
lesson. These steps are listed below for your information.

Step One
Your Instructor will walk through an inspection procedure with you. At that time
you can ask questions and take down any notes required.
This walkthrough may be completed out in the field or during a meeting with your
Instructor.
Step Two
Your Instructor will demonstrate an inspection procedure in the field.
Step Three
You will conduct an inspection procedure in the field under the supervision of your
Instructor.
Your Instructor will provide you with feedback about your performance during the
inspection.

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Step Four
You will complete a full inspection procedure without any assistance from your
Instructor.
This inspection will be assessed against the inspection checklist contained in this
document. If you achieve 100% on the inspection, you will be certified on it. If you do
not achieve 100% your Instructor will provide you with further feedback and you will
have the opportunity to be re-assessed.
If you are an experienced Field Operator, you may already be quite familiar with inspection
procedures. Discuss this with your Instructor and you may only be required to actually complete
Step Four as discussed above.

Reference Material
NA

Pre-requisites
NA

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Purpose
The purpose of the Weigh Feeder is to:

Accurately measure the mass flow of materials.

Control the flow rate of material into downstream equipment.
Integrate material consumption in order to verify product inventories.

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C OMPONENTS
Weigh Feeder Drive
System
Head and Tail Pulley

Belt Conveyor

Snub and Bend Pulleys

Impact Idlers

Belt Speed Sensor

Scale Quality Approach

Idlers
Weigh Scale Idlers

Weigh Carriage

Scale Reactor

Weigh Scale Electronics

Scale Quality Retreat Idlers

Return Rollers

Take Up

Side Travel Limit Switches

No Material Switch

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Weigh Feeders Learner Guide

Weigh Feeder
W EIGH F EEDER

W EIGH F EEDER

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Principle of Operation
Material for the Weigh Feeder is
supplied by a hopper or
storage bin
The hopper or storage bins
discharge is designed to
provide a constant material
profile on the Weigh Feeder
belt
The weighing system
generally consists of a single or
multiple idler support set
mounted between the stringers of
the conveyor
The dynamic frame supports the scale idler and transfers the weight of the material to load
cells
As the material moves along the length of the conveyor belt, a force is exerted through the
suspended idler set to the dynamic frame
The dynamic frame is forced downward or displaced proportionally to the force exerted by
the material load
The relative movement in the dynamic frame is transmitted to the units load cells. The force
on the load cells is sensed by its strain gauges when excited by an applied voltage. The
output from this strain gauge produces a signal that is proportional to the force exerted on the
load cell.
The strain gauge value along with belt speed indication is transmitted to the electronic
integrator which is used to calculate the conveyors mass flow, and totalized value

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Applications
Weigh Feeders are used in following applications:

Quarry Operations
Raw Grinding
Pryoprocessing
Finish Grinding
Bulk Loading

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Inspection Points
Weigh Feeders Running Inspection
Check For OK

Inspect the drive motor for material build up on

cooling fins
cooling fan inlet screen
Remove build up
Palm test the motor casing temperature
If too hot to touch, record temperature with hand pyrometer or contact thermometer
Inspect drive motor electrical connections for damage or strain
Palm test the drive reducer casing temperature
If too hot to touch, record temperature with hand pyrometer or contact thermometer
Inspect the condition of
the final drive
V-belt condition, tensioning
sheaves
direct coupling
chain and sprockets
Listen to the Weigh Feeder drive system for abnormal
noise
vibration
Inspect the condition and support integrity of all safety guards
Note general condition of Weigh Feeder
cleanliness
material leaks
lubrication leaks
Inspect the discharge chute for
material build-up
obstruction
Inspect the condition of all rollers for
Build-up
wear
damage
Remove any build-up

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Weigh Feeders Running Inspection

Check For OK

Inspect the condition of the conveyor belt. Check for

cuts
damaged splices
tracking, holes
Note condition of lagging
Inspect condition of head and tail pulley
Inspect the condition, integrity, and proper adjustment of
the safety cord
switch
Remove any obstructions for access
Inspect the following for damage
speed sensor
coupling
Inspect the weigh scale for
material build-up
material between static and dynamic load frames
Inspect the material loading and profile on the weigh feeder belt
Note the condition of shear gate
Inspect the hopper or bin discharge for
wear
damage

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Weigh Feeders Static Inspection

Check For OK

Inspect the drive motor for material build up on

cooling fins
cooling fan inlet screen
Remove build up
Palm test the motor casing temperature
If too hot to touch, record temperature with hand pyrometer or contact thermometer
Inspect drive motor electrical connections for damage or strain
Palm test the drive reducer casing temperature
If too hot to touch, record temperature with hand pyrometer or contact thermometer
Inspect the condition of
the final drive
V-belt condition, tensioning
sheaves
direct coupling
chain and sprockets
Inspect the condition and support integrity of all safety guards
Note general condition of Weigh Feeder
cleanliness
material leaks
lubrication leaks
Inspect the discharge chute for
material build-up
obstruction
Inspect the condition of all rollers for
Build-up
wear
damage
Remove any build-up
Inspect the condition of the conveyor belt. Check for
cuts
damaged splices
tracking, holes
Inspect condition of head and tail pulley

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Weigh Feeders Learner Guide

Weigh Feeders Static Inspection

Check For OK

Note condition of lagging

Inspect the condition, integrity, and proper adjustment of:
the safety cord
switch
Remove any obstructions for access
Inspect the following for damage
speed sensor
coupling
Inspect the weigh scale for
material build-up
material between static and dynamic load frames
Inspect the material loading and profile on the weigh feeder belt
Note the condition of shear gate
Inspect the hopper or bin discharge for
wear
damage

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Troubleshooting
Problem Probable Cause(s) Action
Weigh feeder Inaccuracy Weigh idler alignment Verify weigh idler alignment is as accurate as possible. Use a straight
edge along the edges of the idlers to measure. Improper alignment is
the most common mechanical problem affecting weigh feeder accuracy

Material build-up on weigh section or pulleys. Remove all build up of material from weigh scale frames and rollers.

Belt mis-tracking. Idlers or pulleys out-of-square with center line of conveyor

Idler rolls not turning
Improper loading, spillage
Material build up
Belt improperly spliced or wrong fasteners
Belt too tight Re-adjust belt tension to manufacturers specifications.

Speed sensor condition Inspect speed sensor electrical connection for damage or strain
Inspect speed sensor coupling for damage
Inspect speed sensor roller for buildup of material
Inspect speed sensor roller for slippage or seizing
Head or tail pulley too high or low, relative to idler The head and tail pulleys should be at least 1/8" lower than the
alignment. approach and retreat idlers to ensure proper belt tension at scale
location.
Skirt boards and Feed Chutes Inspect feed chutes for material jamming at pinch points between the
chute and the belt. Inspect skirt boards for excessive pressure
increasing belt tension

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Safety Work Page

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Safety
Before working on Weigh Feeders

Always lock out Weigh Feeder prior to performing any service on the conveyor
Be aware that Weigh Feeders are controlled automatically and can start and stop at any time
Be aware of all conveyor nip points
Never attempt to remove build-up off conveyor components while operating
Keep clothing, fingers, hair, and other parts of the body away from conveyor
Never climb, step, sit or ride on a conveyor at any time
Never shovel material onto a moving conveyor
Inspect conveyor guards for damage and support integrity
Know the location and function of all control stations
Keep all control stations free from obstructions to ensure access at all times
Keep area around conveyors clear of obstructions
Report all unsafe conditions or practices to your supervisor

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Lesson Review
Complete each of these questions and review your answers with your Instructor.

1. What are the 3 main functions of a Weigh Feeder?

2. Name 5 components of a Weigh Feeder

3. What 2 values are required to calculate mass flow?

4. Describe 3 applications for Weigh Feeders in cement manufacturing

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5. Describe 5 inspection points for a Weigh Feeder

6. Describe 3 conditions that would explain a loss of Weigh Feeder accuracy

7. Describe 3 safety hazards associated with a Weigh Feeder

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