The integrator combines the load-cell signal and belt speed to calculate flow rate and total tonnes. When choosing a belt weigher integrator for an Australian mine or quarry, consider the installation environment, display, power recovery, spare parts and ongoing calibration support. We supply and calibrate the Schenck INTECONT Tersus and the EMC ModWeigh MP1 and MP2, so those are the worked examples below. The same questions apply to other makes.
What ambient temperature is it rated for, at the enclosure, not just the electronics?
Every integrator has an operating temperature range on its data sheet. The number to ask for is the one that applies to the whole unit in its enclosure, because that is where it will live. A rating quoted for the electronics alone, out of the case, tells you nothing about a steel box in the sun in January.
Direct sunlight can heat a steel enclosure above the outside air temperature. The integrator, power supply and other equipment also add heat inside the enclosure. Assess the temperature around the instrument under the expected site conditions, including summer heat and solar loading. A temperature rating alone does not establish that a particular outdoor enclosure will be suitable.
As worked examples, Qlar’s INTECONT Tersus data sheet lists an operating range of −25 to +60 °C for standard use, with a narrower −20 to +40 °C range for legal-for-trade and ATEX applications. EMC’s MW95A manual lists −10 to +45 °C for the ModWeigh hardware it covers, including MP1 and MP2. Check the documentation for the exact supplied variant. These instrument ratings do not guarantee that an unshaded enclosure will stay within range: the enclosure may need shading or another suitable thermal-management arrangement. Any ventilation or cooling must also suit the required dust and moisture protection.
Can the display be read in direct sunlight, and will it still be readable in five years?
Check display readability in the intended mounting position, including glare, dust and the viewing angle. An operator should be able to see the required readings without opening the enclosure or standing in an unsafe location.
Ask to see the unit outdoors, or ask for the display type and the backlight life. Ask what the display does after five summers: some technologies fade, some develop dead segments, some lose contrast as the backlight ages. Ask how the display is replaced and what it costs, because on some units a failed display means a whole new integrator.
Ask for evidence of display performance in a comparable installation and check the manufacturer’s sunlight precautions. For example, Qlar advises protecting the INTECONT Tersus TFT display from prolonged direct sunlight. Ask about replacement displays and current lead times before choosing the unit.
How long does it take to boot after a power dip, and does the totaliser survive one?
Site power is not clean. A conveyor drive starting, a storm, or a switchboard trip puts a dip through every panel on the plant, and an integrator is a small computer. Ask two things: how long the unit takes to come back to weighing after power returns, and whether the totaliser and the calibration survive the interruption.
Totaliser and calibration retention matter because missing data can affect production reporting and incorrect settings can affect subsequent measurements. Ask how the particular unit retains its data, how it restarts after a supply interruption and what faults must be checked before returning it to service. Do not assume that every power disturbance is harmless: the EMC MW95A manual includes a power-down error that can indicate invalid data or totals. Keep a configuration backup and arrange any power-recovery test as part of controlled commissioning, with the consequences for connected plant equipment assessed first.
Are spare parts held in Australia, and by whom?
Ask which replacement boards, displays, power supplies and input modules are available, where they are held and the current lead times. The practical repair options matter as much as the original purchase price.
Ask us about spare parts for the integrators we supply and service. Availability depends on the make, model, age and part required, so confirm current stock and lead times before planning a repair or replacement. A failed component does not automatically mean the complete integrator needs replacing.
Who will calibrate it in five years, and will they have the manual?
A belt weigher integrator is only as good as its next calibration. Ask who will service the unit in five years, whether they will still have the manual and the software, and what happens if the supplier's service arm changes hands or the model is discontinued. Product lines get sold and dropped; a unit that is orphaned from support is a unit you replace early.
Ask who can support the exact model, what documentation is available and how calibration and configuration records will be retained. Accurate Industries services a range of belt weigher brands and can provide relevant manuals from our technical library. For assets we maintain, AIMM retains service history and recorded equipment information. Confirm the support scope and available records for your installation.
What else should be on the list?
These five questions establish a useful starting point. A few more are worth asking once those are answered:
- Speed input flexibility. Does the unit accept the speed sensor type already on the conveyor, or does a sensor swap follow the integrator swap? See our belt weigher speed sensor guide.
- Communications. Can it talk to the plant control system the way the old unit did, so the tonnes reach the control room without a rewire? See our belt weighing and integrator options.
- Calibration workflow. How is zero and span done on it, and can the as-found and as-left figures be recorded without a laptop? See what happens during a calibration visit.
- The frame it is going on. A new integrator does not fix a worn weigh frame or a sticking pivot. Mechanical and electrical faults can both affect performance; see common belt weigher faults before blaming the electronics.
Frequently asked questions
Can we keep our existing weigh frame and just replace the integrator?
The existing weigh frame, load cells and speed sensor may be retained if they are serviceable and compatible with the replacement integrator. Check the sensor signals, excitation, wiring and control-system interfaces before selecting the unit. The replacement must then be configured, calibrated and verified on the installed system.
Do you only fit the two integrators you supply?
We supply Schenck INTECONT Tersus and EMC ModWeigh equipment and service a range of other makes. Send the fitted or proposed model so we can confirm compatibility, the work required and current parts availability. For maintenance, calibration and manual enquiries, see our Schenck INTECONT Tersus servicing guide.
Is a cheaper integrator a false economy?
Not necessarily. Compare the complete installed and supported cost, including enclosure requirements, sensor compatibility, communications, commissioning and spare parts. A lower purchase price can be good value when the unit suits the application and has dependable support.
Can you answer these questions for a unit we are looking at?
Yes. Send us the model and where it is going, and we will tell you what we know from the field, including which of these questions it answers well and which it does not.
Confirm communications and the supplied enclosure
A physical Ethernet connection does not establish support for the plant protocol you need. On the INTECONT Tersus, distinguish PC service access from optional industrial communications such as Modbus TCP. Specify the protocol and fitted option before ordering. EMC MP1/MP2 arrangements also need the correct hardware and interface for the required plant connection.
Accurate Industries’ integrator interface PCB is included when we supply a complete integrator kit in an enclosure. Confirm the scope when comparing a standalone instrument with an assembled kit. Our own weigh frames are made in Australia; sourced integrators retain their respective manufacturers and origins. Equipment enquiries are welcome worldwide.
Need the manual for your integrator?
Accurate Industries can provide manuals from our technical library for the equipment covered in this guide. Send the make, model, serial number and software version, where shown, so we can identify the appropriate document. Email the details or a photo of the equipment label, or contact us to request a manual.