THAYER SCALE

BELT SCALE HANDBOOK

Application Guidelines for Installing a High
Accuracy Conveyor Belt Scale

A MESSAGE FROM THE PRESIDENT OF

THAYER SCALE
You need more than a belt scale to weigh accurately on a conveyor.
The THAYER line of conveyor weighing equipment represents the outgrowth of our companys total commitment
to provide industry with complete answers to continuous weighing problems. We emphasize the word complete
because we firmly believe that we have been addressing ourselves to many of the problems that others continue
to ignore.
Our organization and our facilities are unusually well suited to our endeavors and both represent the result of
over 62 years of success in following a philosophy of focusing on the areas of business that our people know
best.
Our typical equipment package consisting of scale suspension, load cell, belt speed transmitter, instrumentation
and calibration equipment has evolved from following an integrated system approach to providing accurate and
reliable weighing equipment. Many of our users express surprise when finding that our 4 and 6 idler scales
require very little, if any, correction after material testing. Think of the importance of this in those installations
where material testing cannot be accomplished in a practical manner.
We have prepared this material to be of use to you.
informative.

We trust that you will find it both interesting and

Frank S. Hyer
President

Frank S. Hyer is a graduate of Ripon College in 1956 with a B.A. degree in mathematics.
He earned his B.S.M.E. at the University of Delaware in 1958 and his M.S.M.E. at the
University of Wisconsin in 1968. His graduate thesis, which is entitled A Scientific Approach
to Conveyor Weighing, has been cited on numerous occasions as a reference in technical
journals dealing with the subject of conveyor weighing. He is an active member of the
American Society of Mechanical Engineers and the Instrument Society of America. He
has served as past director of the Process Weighing Committee of ISA, and he helped to
draft the committees input to the National Bureau of Standards Handbook 44. In addition,
he is an active patentee and contributor of technical articles in the fields of weighing and
materials handling.

Application Guidelines for Installing a Conveyor Belt Scale

The most important consideration in the use and installation of belt conveyor scales is the application of the
scale to the conveyor. The major cause for poor performance has been the misapplication of the scale to the
conveyor.
The key to successfully applying the scale to the conveyor is to avoid locating the scale in any area of the
conveyor where it is subjected to excessive belt tension or lifting of the conveyor belt.
Always remember that the conveyor belt is an integral part of the scale and, as such, must remain in contact with
the weigh bridge at all times.
THE GUIDELINES ON THE FOLLOWING PAGES MUST BE CLOSELY ADHERED
TO FOR APPLICATIONS REQUIRING A HIGH DEGREE OF ACCURACY AND
REPEATABILITY. ON PROCESS INSTALLATIONS WHERE ACCURACY IS
NOT OF PARAMOUNT IMPORTANCE, SOME OF THE REQUIREMENTS MAY
BE RELAXED.

BELT CONVEYOR TERMINOLOGY

Cover

Transition idlers

Carryng idlers

Scale

Load hopper

Drive pulley

Skirts

Snub pulley
Pressure
pulley

Bend Pulley
Return
pulley

Snub pulley

Tension pulley
with counterweight

Return
Idlers

Impact idlers

1.0 BELT TENSION

REA

SION A

ST TEN
LOWE

SCALE

FULL LOAD

BELT TENSION
NO LOAD
The first general rule that applies is to locate the scale in the area of lowest tension on the
conveyor. This location is normally near the tail pulley of the conveyor. High belt tension
adversely affects the accuracy of the scale.

2.0 MATERIAL TRANSITION

IS
MIN. D

TANCE

SCALE

2 IDLERS REQUIRED (Minimum) BETWEEN

END OF SKIRT AND SCALE
The material to be weighed must settle on the belt before it is weighed. This requires allowing a specified length of conveyor
for the material to accelerate up to the speed of the belt. The factors that influence this distance are:
1. Belt Speed
2. Conveyor Angle of Inclination
3. Material Lump Size
4. Type of Transition
Generally, the following guideline apply:
BELT SPEED MINIMUM DISTANCE
100-300 FPM 3-4 feet
300-450 FPM 6-8 feet
450-600 FPM 9-12 feet
600-750 FPM 12-15 feet
750- OVER 20 feet
The distance is measured from the end of the infeed skirtboards to the idler adjacent to the weigh bridge.
Note: A minimum of two idlers must be installed between the end of the infeed skirtboards and the first scale idler.

3.0 BELT TRANSITION

Flat Belt, Requires 2 idlers

20 Trough, Requires 2 idlers

35 Trough, Requires 3 idlers

45 Trough, Requires 4 idlers

On short conveyors, where the scale may be located close to the head pulley, there must be a minimum number for fixed
idlers between the scale weigh bridge and the head pulley to avoid the lifting effect created by transitioning from the
troughing idlers to the flat or crowned head pulley. The higher the troughing angle, the greater the effect - and the more
idlers needed between the scale and the head pulley.

4.0 BELT TAKE-UP

Screw Take-Up
NO GOOD

Horizontal Gravity
Take-up
OK

Vertical Gravity
Take-up

RECOMMENDED

An automatic take-up is recommended to maintain a uniform belt tension. The take-up should not be so heavy as to
introduce excessive belt tension, and should be designed to allow the addition or removal of weights. A vertical gravity takeup is recommended for higher accuracy installations. It is suggested a conveyor engineering handbook (such as Goodyear
Handbook on Conveyor Belting) be consulted for the derivation of the correct weight. If handbook is not available, a general
rule of thumb is: the take-up weight should be no greater than the weight required to prevent slippage at the drive pulley
when operating the conveyor fully loaded. If the sag between the carrying idlers is greater than 2% of the carrier idler
spacing, the spacing between the carrying idlers should be decreased.
If the conveyor is equipped with a manual (screw) take-up, it is recommended the belt tension not be increased beyond the
value that will produce less than 2% (of the idler spacing) sag between carrying idlers.

5.0 IDLERS

Flat single roll, or (3) roll in-line troughing idlers are required on the scale weigh bridge and 2-3 idlers on either side with 5
required before and after the scale on certified NTEP installations. The idler eccentricity tolerance should be 0.015 TIR for
high accuracy installations

FLAT SINGLE ROLL

3 ROLL IN-LINE

Catenary or cable idlers must be avoided as well as off-set idlers. Training idlers must not be located within 40 feet of either
side of the scale

OFF SET

CATINARY OR GARLAND

TRAINING

.015

6.0 SCALE SERVICE IDLERS

Idlers on the scale and 2 - 3 idlers on each side of scale must be uniform and
of the same make, troughing angle, CEMA rating and round (at 0.015TIR) to
meet specified accuracy.

Dial Indicator

Idlers on the scale and 5 idlers on each side of scale must be scale quality idlers
(0.015TIR) to achieve commercial certification per IAW NIST Handbook 44.

7.0 CONVEYOR INCLINE

The conveyor inclination must not exceed the angle at which the material will slide backward and be re-weighed. Normally,
most conveyor companies are aware of the critical angle.
The inclination of the conveyor should be fixed at one angle. Errors will result with changes in inclination.

Scale

8.0 CURVES-CONCAVE
Straight conveyors are much preferred over curved conveyors. If there is a concave curve in the conveyor, before
or after the scale, the scale shall be installed so that the belt is in contact with all the idler rollers at all times. The
scale must be located at least 40 ft from the point of tangency to avoid lifting effects of the belt.

PT

PT

40 ft

40 ft

point of tangency

Scale

9.0 CURVES-CONCAVE
If the conveyor has a convex curve, the scale should be located:
20 degree Idlers X = 8 feet or 2 idlers
35 degree Idlers X = 12 feet or 3 idlers
45 degree Idlers X = 16 feet or 4 idlers

PT
PT

Scale
Scale

Point of Tangency

10.0 TRIPPERS, STACKER/RECLAIMER

If the conveyor is provided with a tripper, the scale must not be located at a point 40 feet from the point of tangency of
the belt-with the tripper fully retracted toward the tail pulley.

40 ft min.

TRIPPER TRAVEL

PT

SCALE

Belt scales require a stable permanent structure for high belt scale accuracy. Any conveyor installed with a stacker/reclaimer
will vary in its incline, elevation or profile therefore this is not a good candidate for a belt scale.

11.0 MULTIPLE INFEED POINTS

Conveyors with multiple feed points should be avoided when high accuracy is required due to the variation in belt tension.

SCALE
1

FULL LOAD 1, 2 & 3

FULL LOAD 1 & 2
FULL LOAD 1
BELT TENSION

NO LOAD

12.0 NON-UNIFORM LOADING

If the feed to the conveyor is not-uniform, plows and leveling plates should be installed to re-shape and smooth out the load.
Apron feeders often create non-uniform loading. Ideally, actual loading should be between 50% and 90% of scale capacity,
with less than a 5% variation in feed rate.

MAX
CAPACITY

LOAD

TIME

13.0 WIND BREAKS

If the scale location will be subjected to wind velocities over 5 m.p.h., wind breaks should be installed. The wind break should
extend 40 feet to either side of the scale, and 4 feet above and below the belt line. The wind breaks should be attached to
the sides of the conveyor, and a section should be easily removable for inspection of the scale.

40 Ft

40 Ft
SCALE

WIND BREAK

NOTE: For outside applications, the conveyor must be fitted with a protective cover.

14.00 REVERSIBLE CONVEYORS:

The scale will not weigh accurately in both directions and any performance guarantee would be based on weighing in one
direction. Two complete scales are required for accuracy in both directions.

SCALE

No GOOD

OK

15.00 INFEEDS
The infeed to the conveyor must be interruptable to allow for empty belt calibration. If a prefeed device is used, electrical
circuitry should be provided to operate the scale conveyor independently of the prefeed device. If the conveyor drags the
material from a storage bin, the bin should be fitted with a cut-off gate.

16.00 SCALE ACCESS

The conveyor should be equipped with an adequate platform or catwalk to allow for inspection and servicing of the scale. It
is recommended that the platform, or catwalk, be erected on both sides of the conveyor in the scale area.

17.00 CONVEYOR STRINGERS

Conveyor stringers at the scale and for not less than 20 ft before and after the scale shall be continuous or securely joined
and of sufficient size and so supported as to eliminate relative deflection between the scale and adjacent idlers when under
load. The conveyor stringers should be so designed that the deflection between any two adjacent idlers within the weigh area
does not exceed 0.025 under load.

18.00 IDLER ALIGNMENT

Proper idler alignment is critical to the performance of a belt scale. All idlers on the scale and at least two directly before
and after the scale need to be properly shimmed and aligned within 1/32.
Precision alignment requires installation of scale and idlers to tolerances to 1/32 of an inch.
PIANO
WIRE

1/64

PIANO
WIRE

STATIONARY
IDLERS

WEIGH
IDLERS

19.00 THAYER CERTIFIED BELT SCALE MATERIAL TESTING LOGISTICS

NTEP / HANDBOOK 44 CERTIFICATION REQUIREMENT
See section 2.21 - Belt-Conveyor Scale Systems in Handbook-44 - published by the National Conference of Weights and
Measures (NIST) for specific details on Application,
Specifications, Notes, Tolerances and User Requirements.
APPLICATION
Handbook-44 Code Applies to Belt-Conveyor Scale Systems used for the weighing of bulk materials typically in a custody
transfer or legal for trade application or where one party is paying or being paid for the transfer of a bulk commodity.
SPECIFICATION
S-1 Design of Indicating and Recording Elements; The Master Weight Totalizer, Recording Element and Rate of Flow
Indicator.
S.2 Design of Weighing Elements; Load and Speed Sensors, Zero-Setting and Zero Sensitivity, Marking Requirements and
Sealing Provisions.
NOTES
N.1 General; Official and Simulated Test requirement.
N.2 Test Conditions; Initial and Subsequent Verification Testing and Minimum Test Load.
N.3 Test Procedures; Zero Load Tests, Zero Stability, Belt Consistency, Material Tests and Simulated Load Tests.
TOLERANCE
T.1 Tolerance Values; Maintenance and Acceptance Tolerance on Materials Tests shall be 0.25%.
T.2 Repeatability Tests; variation in values shall not exceed 0.25%.
T.3 Influence Factors; Temperature and Incoming Power.
USER REQUIREMENTS
UR.1 Use Requirements; 20 to 100% Rate of Flow, Minimum Totalized Load and Security Means.
UR.2 Installation Requirements; Conveyor Design Restrictions, Scale Installation Constraints and Belt Condition.
UR.3 Use Requirements; Loading of Belt and Maintenance of System.
UR.4 Compliance to Specification.
MATERIAL TEST LOGISTICS
REFERENCE SCALE should be tested and calibrated to the test tolerance of 0.1% within 24 hours of beginning the
BELT SCALE material test.
The Belt Scale test consists of either four runs at one rate (scale that is used for conveying material @ one rate, 10%,
@ least 80% of the time) or two runs at three rates (2 @ normal flow rate, two @ 35% of rated capacity and two inbetween (See N.2).
Must be able to pre-weigh or post-weigh any material used in test with a minimum of handling by other conveyences.
A Statutory Authority from a Railroad or State will normally be involved and a Scale Technician should be on-site for
assistance before, during and after the test.

TRANSFER
CONVEYOR
CERTIFIED BELT
SCALE
TRACK SCALE
DISPLAY

CONVEYOR SUPPLY
HOPPER
THAYER NTEP CERTIFIED BELT SCALE
INTEGRATOR

RAIL ROAD HOPPER

CAR

TRACK SCALE

THAYER SCALE- HYER INDUSTRIES, INC.

T
E
M
P
E
R
A
T
U
R
E

H35 T 2

H
U
M
I
D
I
T
Y

1
2
3
4

POWER

DISPLAY
CLOCK

CERTIFIED BELT SCALE

REPORT SOFTWARE

SCALE

CONFIG

CHART
SPEED

YES

MODE

ALARM
SET

% RH

7D

F
NO

LIGHT

TICKET
CHART
RECORDER PRINTER

MATERIAL POST- WEIGH USING RAILCARS

10

RAIL ROAD HOPPER

CAR

To Plant

TRACK SCALE

CERTIFIED BELT
SCALE

CONVEYOR SUPPLY
HOPPER

TRACK SCALE
DISPLAY

THAYER NTEP CERTIFIED

BELT SCALE INTEGRATOR

THAYER SCALE- HYER INDUSTRIES, INC.

T
E
M
P
E
R
A
T
U
R
E

H35 T 2

H
U
M
I
D
I
T
Y

MATERIAL PRE-WEIGH USING RAILCARS

1
2
3
4

POWER

CLOCK

CONFIG

SCALE

DISPLAY

CHART

YES

MODE

% RH

ALARM

SPEED

SET

7D

F
NO

LIGHT

CHART
RECORDER

TICKET
PRINTER

CERTIFIED BELT SCALE

REPORT SOFTWARE

TO PLANT

TRUCK SCALE
CERTIFIED BELT
SCALE

CONVEYOR SUPPLY
HOPPER
TRUCK SCALE
DISPLAY

THAYER NTEP CERTIFIED

BELT SCALE INTEGRATOR

THAYER SCALE- HYER INDUSTRIES, INC.

T
E
M
P
E
R
A
T
U
R
E

H35 T 2

H
U
M
I
D
I
T
Y

1
2
3
4

MATERIAL PRE-WEIGH USING TRUCKS

11

POWER

DISPLAY
CLOCK

SCALE

CONFIG

CHART
SPEED

YES

MODE

ALARM
SET

% RH

7D

F
NO

LIGHT

CHART
RECORDER

TICKET
PRINTER

CERTIFIED BELT SCALE

REPORT SOFTWARE

ABOUT THAYER BELT SCALES

THAYER is the only belt scale manufacturer that analyzes the customers conveyor and application data to predict realworld performance. The computer program essentially tailors each component of the scale and conveyor to maximize the
performance of the complete system based on the specific requirements of the application.
We consider the parameter variations that are normally experienced in conveyor installations, the lack of dimensional
precision of the conveyor components and installation imperfections occurring as the result of both the initial set up and
the subsequent conveyor maintenance activities, the most logical approach to designing and installing high accuracy
belt weighing equipment is to design for minimum error influences in every phase of the project. This involves conveyor
analysis work to seek out preferred locations for load and speed measurements within a conveyor, suspension system
configurations that are least affected by conveyor influences, particularly alignment factors (load deflection vs. installed
alignment conditions), and many other factors.
The typical computer analysis involves inputting eleven (11) key parameters which describe the application in sufficient
detail to estimate accuracy for the installation as initially defined. Major factors include:
Conveyor design,
Scale suspension design
Location of load and speed sensors in relation to both conveyor terminal equipment and loading points
Installed alignment conditions
Duration and constancy of loading cycle
Condition of rolling conveyor elements,
The uniformity and stiffness of the belt itself
Condition and size of take-up apparatus
The precision with which the system can be routinely calibrated & adherence to a calibration schedule
Operating environment.
Subsequent runs are performed to evaluate the effects under various conditions, using different belt scale weigh bridge
configurations, weigh bridge locations, idler spacing, weights and locations of gravity take-up, etc.
Actual bias error (offset between THAYER totalized weight and check scale weight) and as-found error (random error,
i.e. repeatability) can be calculated for a given conveyor application using Thayers belt scale performance math model.
This unique program was developed by THAYER, and is based on many years of experience in the field of high accuracy
continuous weighing. The objective of the program is quite simple: To provide a means of producing a high performance
Belt Scale installation.

CONVEYOR LENGTH

CONVEYOR
INCLINE
IDLER SPACING

DISTANCE FROM TAKE-UP

TO TAIL PULLEY

GRAVITY TAKE-UP
WEIGHT
DISTANCE FROM SCALE TO
TAIL PULLEY
ANGLE OF SURCHARGE

DISTANCE FROM EDGES

0.05 x N +25 mm

TROUGH SET
ANGLE

BELT WEIGHT lb/Ft

BELT WIDTH

12

THAYER CONVEYOR BELT SCALE SIZE MATRIX

THAYER MODEL
No.

No. of
Weigh
Idlers

Stringer
depth
(inches)

Belt
Width
(inches

1RF-3A-SG

N/A

18 - 30

1RF-4A-SG

N/A

1RF-4A

2RF-4A

2RF-6A

Idler Spacing
(inches

Idler Loading

Accuracy (%)
FULL SCALE

Accuracy (%)
3:1 Load

30- 60

300 lb max

36 - 48

30- 60

300 lb max

14 - 48

30- 60

7.2 - 300

14 - 48

30- 60

5.4 - 300

1/4

1/2

24 - 60

30- 60

12 - 800

1/4

1/2

3RF-6A

24 - 60

30- 60

8.8 - 600

1/4

1/2

3RF-8A

30 - 72

30- 60

8.8 - 1600

1/4

1/2

4RF-6AR

24 - 60

30- 60

6 - 525

1/8

1/4

GENERAL PURPOSE

RFS

24 - 60

30- 60

4.3 - 400

1/10

1/8

6RF-8AR

30 - 72

30- 60

4.3 - 1200

1/10

1/8

5.4 - 300

1/4

1/2

LIGHT LOADING SCALES

2LLRF-4A

14 - 48

42- 60

2RF-6ALA

24 - 72

42- 60

4.2 - 800

1/4

1/2

3RF-6ARLA

24 - 72

42- 60

3.2 - 600

1/4

1/2

4RF-6ARLA

24 - 60

42- 60

2.1 - 525

1/8

1/4

6RF-6ARLA

24 - 60

42- 60

1.6 - 400

1/10

1/8

34 - 525

1/10

1/8

NTEP CERTIFIED SCALES

NAR-4

24 - 60

36 - 60

NAR-6 (6 stringer)

24 - 60

36 - 60

34 - 400

1/10

1/8

NAR-6 (8 stringer)

30 - 96

36 - 60

34 -1200

1/10

1/8

NAR-8 (8 stringer)

30 - 96

36 - 60

34 -1200

1/10

1/8

SUPERIOR WEIGHING PERFORMANCE

THAYERS Belt Scales are specifically designed for high accuracy (1/10 to 1/2% typical) inventory control and throughput
totalization in severe applications with the worst possible environments in the fertilizer, mining, ore, copper and coal
industries. Special configurations are available specifically designed for light scale loading applications such as Biomass,
wood chips, saw dust, tobacco and land refuse. THAYERS Belt Scale weigh bridge features exclusive rocking flexure
suspension in the Approach and Approach/Retreat configurations. Measurement sensitivity is high, deflection is low, and
the single load cell is isolated from the error-inducing effects of extraneous lateral forces, off-center loading, foundation
distortion, inclination hold-back forces, and high sporadic shocks and overloads. Tare load is mass counterbalanced to
create superior signal -to-noise ratio in weight sensing, orders of magnitude better than belt scale designs supporting full
tare load on the load sensor.
Model RF BELT SCALE CONFIGURATION
There are two basic weighbridge configurations approach and approach-retreat. The selection depends on a number of factors. Among them are space available, belt
loading, idler spacing, belt tension, required accuracy and frequency of calibration.
APPROACH TYPE: An approach weigh bridge is suitable for most applications requiring an accuracy of 1/4% to 1% of full
scale. It is available in one, two and three-idler designs.
APPROACH-RETREAT TYPE: The approach-retreat weighbridge is designed principally for high accuracy applications
normally requiring certification for commercial weighing and accuracy as low as 1/10%... available in four and six idler
designs.

13

THAYER NAR Belt Scales are designed to deliver exceptional stability and accuracy for use in applications requiring
verifiable accuracy. They are recommended for applications requiring commercial certification for billing purposes. These
belts have been proven in service demanding 0.125% accuracy through independent certification. The weigh bridge
features exclusive rocking flexure suspension in the approach-retreat configuration. Measurement sensitivity is high,
deflection is low, and the single load cell is isolated from the error-inducing effects of extraneous lateral forces, off-center
loading, foundation distortion, inclination hold-back forces, and high sporadic shocks and overloads. Tare load is masscounterbalanced to create superior signal to noise ratio in weight sensing, orders of magnitude better than belt scale
designs supporting full tare load on the load sensors.

THAYERS Model RF Belt Scales are highly advanced and

extremely robust weight sensing technology based on the
marriage of the weighbridge, weight transducer (load cell),
embedded temperature sensing and proprietary linearizing
and temperature compensating control algorithms.

MODEL 2RF-4A

WEIGH BRIDGE
One of the most important components of a conveyor scale
system is the design of the weigh bridge itself. Regardless
of the type of load cell used, a belt scale will not be able to
weigh lightly loaded material and maintain its calibration for
long if certain design features are not in place.
SECONDARY LEVER
THAYER employs a secondary lever system, even though
it cost more to do so, because it permits the following:

MODEL 3RF-8A

1. We can add mass (weight) to counterbalance the dead

load (idler support frame, idlers, belts) and by using a
secondary lever, we do not load down the suspension
pivot.
2. The scale provides for complete mass counter-balancing
of the dead load (idlers and belt) of the conveyor permitting
the load sensor to react only to the net material load.
3. By positioning the load cell correctly, relative to the
secondary lever we can match load cell size to the net
loading. Only in this way can any capacity scale be
supplied to the same high accuracy standards.

MODEL 4RF-6AR

4. The resulting increased lever ratio of the secondary lever

reduces idler deflection, providing additional immunity to
errors associated with belt tension.
5. The secondary lever system utilizes stainless steel
aircraft cables as flexural elements to transmit and FOCUS
pure tension forces to the load cell. The cables, being nonextendable, but laterally yieldable connecting links, permit
the lever to align itself under conditions of varying stringer
distortion. This is a most significant feature. A belt scale
must use the conveyor stringers as its mounting base.
These stringers not only deflect under varying conveyor
loads, but may also rotate (or twist). A suspension system
having the least possible structural redundancy is therefore
essential.
6. This unique system is not affected by dirt, shocks or
vibration, and can withstand overloads in excess of 1,000
pounds without causing damage or affecting calibration.

MODEL NAR-6

THAYERs Patented ROCKING FLEXURE PIVOT

The axis position is permanent, being held in its horizontal
position by the flexure plate and in its vertical position by
the load rod which bears on the flexure plate, which in turn
is bolted to the bottom side of the square and elevated
suspension extension shaft.
There is insignificant rotational hysteresis. While the load
rod may be likened to a dull knife edge (it is round), the
flexure plate bearing surface directly in contact can rock
without sliding through small rotational displacement.
The reaction to lateral forces creates an insignificant
moment transfer to the weigh suspension (this is part of
the patent). Since the flexure plate (which is hardened blue
tempered steel) is also the upper bearing block of the pivot,
tensile or compressive forces reacting to lateral forces
therein have no moment arm distance to operate.

MODEL 8RF-6AR

14

THAYERS RF Belt Scales with FMSS Force

Measurement Suspension System mass counter balance
technology assures better than 80% Load Cell Utilization.
Provides :
Field adjustable mechanical TARE balancing of dead
loads typically as high as 200 times NET loads, thereby
providing the full utilization of the load cell force range.
Reduces deflection of load receptor to a fraction of load
cell deflection.
Reduces zero shifting as a result of foundation distortion.

150%

Load Cell Utilization

The performance of a load cell and its instrumentation is

specified on the basis of the load cells rated output. If the
load cell is supporting a quantity of dead-weight (i.e. idlers,
belting, suspension system) and has been further oversized
to accommodate problems of overload protection, off-center
conveying, shock, vibration and negative integration, then
the amount of range left to do the job of weighing is only
a fraction of the cells rated output. The percentage of
the load cells rated output reserved for the actual job of
weighing material is called the LOAD CELL UTILIZATION
FACTOR.

THAYER FMSS SCALE

100%

110%

Maximum Overload
367% of Scale Capacity

40%
10%

150%

Load Cell Utilization

THAYER Load Cell and Scale Utilization Factor

The distinct specification of continuous belt scale weighing
applications and the unique environment and operational
issues those applications typically encounter, places too
many requirements on the load sensing system for any
single technology to completely satisfy. Therefore, using
THAYERS exclusive FMSS technology in the design of its
belt scale suspension system allows the choice of using
either its LC-137 LVDT Load Cell or its LC-174 Strain
Gauge Load cell. This puts THAYER in a unique position
that allows us to offer equipment to match a wide range
of applications such as light material loading, severe
environmental conditions, and commercial certification.

30%

Scale Capacity

10%

Partial Tare Load

Direct Load Cell Weighing

50%

Maximum Overload
167% of Scale Capacity

100%
30%

Scale Capacity

70%

Tare Load

70%

Provides preferred access location of load cell for

inspection or removal.
Simplifies the application of test weights for calibration/
performance verification.
Provides for lower signal velocity and acceleration under
dynamic conditions.

BELT TRAVEL PULSER

PRECISION BELT SPEED MEASUREMENT

Accurate belt speed measurement requires the use of a
precision wheel and pulser. A spring is used to maintain
proper contact pressure of the wheel with the tension side
of the belt in all operating conditions. The THAYER belt
travel pulser assembly includes a precision cast/machined
wheel with a pre-calibrated circumferential tolerance
of 0.05% and a high resolution digital transmitter. The
transmitter produces pulses equivalent to 1/100 to 1/200 of
a foot of belt travel.
The speed pick-up wheel has a narrow face width so it is
less susceptible to material build-up, which can result in
speed measuring errors. Since belt stretch is not constant
throughout the length of the conveyor, and therefore, can
affect speed measurement, the speed pickup produces a
more accurate speed signal than that which is produced by
tail pulley mounted speed encoders.

BELT
STATIONARY
IDLER

PULSER

STRINGER

15

CALIBRATION
A belt scale should be thought of as a precision instrument
and its performance should be quickly and easily checked.
Accuracy and the method and frequency of calibration
are directly related. It is a well known fact that the only
positive way of verifying scale accuracy is to conduct a
material test using a static scale to check the weight of
material passed over the scale. The results of the material
test are used to factor the simulated test device which is
either a test chain or calibrating weight.
Thayer Scale is the only manufacturer that can provide
an accurate reliable calibration using a calibration weight
instead of test chains for all scale capacities. As a result
other manufacturers have had to resort to dummy signals
which (while providing a stable signal to calibrate the
integrator) result in very large scale calibration errors and
a false sense of security due to the fact that the scales
mechanical components are not exercised during the span
portion of the calibration.

THAYER TEST WEIGHT LIFT AND

STORAGE ASSEMBLY
The test weight lift and storage assembly was developed
by Thayer Scale in 1967 to provide a safe and convenient
method of accurately applying the calibration weight. It
provides a repeatable result and eliminates one of the
problems associated with test weights which were related
to the inconsistent placement of the test weights.

CALIBRATE

STORE

Thayer Scale developed and patented the first automatic

calibration system in 1971. Although there have been
attempts to develop non-infringing systems none of them
have achieved the simplicity or accuracy of the Thayer
method.

The test weight lift and storage assembly provides a safe,

convenient method of placing the calibration weight on
the scale weighbridge accurately -- test after test. It also
provides a convenient storage area that prevents loss or
damage to the test standard.

TEST WEIGHT CALIBRATION

Past experience with test weights has been generally poor
because none of the scale manufacturers were able to
correlate the value of weight with respect to the pounds
per foot loading it represented on the conveyor belt.
Consequently all sorts of false theories were generated
about test chains best simulating actual material on the
conveyor belt.

Provides these advantages:

Safe -- Eliminates need to go between belt strands.
Easy -- Permits one man to operate.
Convenient Storage -- Prevents loss or damage.
Repeatability -- Weight is always positioned in the
same location test after test.

Another problem relating to test weights is that on large

capacity scales such as those employing a full floating
weigh bridge, it is virtually impossible for most scale
manufacturers to use test weights because the size of the
weight required prohibits their use.
Thayer Scale pioneered the successful use of the test
weight calibration technique by a careful and thorough
analysis of the factors that relate to the methods of
simulated testing. Additionally, such large weights pose a
potential safety problem for plant personnel.
DEAD WEIGHT TEST
The only exact method of determining the value of the test
weight is by dead load testing the scale. This is done by
completely assembling the weighbridge and scale and
placing test weights on the idler mounting pads to duplicate
the idler belt and material weight. The counterbalance
weights are than adjusted to empty balance the scale.
After the scale has been calibrated and zeroed to the dead
weight, the value of the calibration weight is determined
by the substitution method. Very few manufacturers dead
load test the complete scale. Consequently, it is difficult
to predict how large an error may exist between actual
material weight and the simulated load. The use of a test
weight is the only assurance the user has against gross
weighing errors.

THAYER TEST WEIGHT USING SEE-SAW

SECONDARY LEVER
On high capacity scales where it is impractical to apply
the test weight directly to the end of the weighbridge because of the physical size of the test weight, a special arrangement of the secondary lever is used.
In this configuration, the test weight provides tare mass
counter-balance in its storage position on the secondary
lever and a test load of known value in its calibrate position. By taking advantage of ratios in the seconday lever,
smaller, easily manageable test weight(s) can be used to
produce significantly higher loading values. This method
of applying the test weight does not introduce error on inclined conveyors. Since the test weight is on the scale at
all times, its moments due to the sine component remains
constant regardless of the test weights position on the
lever.

CALIBRATION TEST
WEIGHT IN ZERO
POSITION

CALIBRATION TEST
WEIGHT IN SPAN
POSITION
SECONDARY
LEVER

LOAD
CELL

WEIGH IDLERS

16

FREQUENCY OF CALIBRATION
There is a correlation between frequency of calibration,
number of idlers on the scale weighbridge and the
accuracy required. While it may be possible to achieve a
reasonably high degree of accuracy for a short time with
a single idler scale in a good installation it is obvious that
the single idler scale is more susceptible to belt effects
and changes in alignment and therefore the calibration
should be checked more frequently. Likewise, a multiple
idler weighbridge will not have to be checked frequently if
1% accuracy is all that is required.
A common mistake made in the selection of belt scales is
choosing a single idler scale or short weighbridge because
the accuracy required is only 1%. It may be possible to
achieve 1% but it might require calibrating once a day.
HOW OFTEN SHOULD CALIBRATION BE CHECKED?
The frequency of calibration is best determined from
actual operating experience. Initially the tests should be
performed more frequently (once a week) to establish
a confidence level based on accuracy required and the
number of times an adjustment had to be made. The tests
should be based on the As-Found-Error (AFE).

MAINTENANCE TOLERENCE

1.5

1RF-3A, 1RF-4A
2RF--4A, 2RF-6A

% F.S.

3RF-6AR, 3RF-8AR
4RF-6AR, NAR-4

0.5

6RF-6AR,6RF-8AR
NAR-6, NAR-8

0.25
0.1
0

10

20

30

40

50

60

How important is accuracy and how much is it worth?

You can answer that question if you know how much your
material is worth. You probably wouldnt be considering the
purchase of Belt Scales if you werent concerned about
how much things cost. The information you receive from a
Belt Scale tells you a lot about what is happening in your
plant and, of course, one of the key bits of information is
how much material has passed over the scale.
This weight information may be used for many purposes-Invoicing, Production, Inventory, Waste Measurement,
Material Balance, Bonus Payments, Measuring Plant
Efficiency, etc. At the end of a year of operation, the
tonnage, and most importantly the dollars, can add up to a
considerable amount.
If you investigate the various belt scales available on
todays market, you will find that accuracy claims vary
anywhere from 1/2% to 1/4% based on either full scale or
on a range of operation that extends from as narrow as 3:1
to as wide as 15:1 (10% to 150%).

17

One major misunderstanding about K-Factoring is that it

is assumed that once done, there is no need for further concern. The following will describe the K-Factor in greater
detail and clarify why suspension design is important irrespective of the scales end use.
K1 Factor: Low belt tension, heavy loading, long idler spacing in weighing region, many weigh idlers, excellent alignment, low troughing angle, constant tension take-up, flexible belting, horizontal conveyor, good belt tracking.

RECOMMENDED CALIBRATION INTERVAL

(TYPICAL THAYER APPROVED INSTALLATION)

1.0

This might lead you to conclude that if you install and calibrate the scale per the manufacturers instructions it will
weigh your material to within the accuracy claimed. NOT
NECESSARILY SO. Better re-read those accuracy claims.
That is not what they say. It is left to you to determine
whether or not you are achieving the expected level of performance or not. One of the ways you can do this is to run
some form of a comparison test which is usually achieved
by statically weighing the material that has been run across
your belt scale on some other reference scale. If you do
find a discrepancy in the results it is suggested that you adjust your standard calibration procedure accordingly. This
is normally done by factoring the simulated loading value of
the Test Weight or Chain that has been provided with the
scale. Once this is done, the scale is said to have been
K-Factored. Unfortunately in the majority of installations
it is extremely difficult, if not impossible, to conduct such a
comparison test.

K2 Factor: A Test Load of specified loading value which

when applied to the installed scale suspension, produces
a weight signal from the load cell that is identical to the
signal that is generated by an idealized normal loading
pattern of same specified loading value acting through the
belt-to-weigh idler interfaces. In practice, this requires extraordinary attention to details in the manufacture and testing of hardware prior to shipment of the scale. Substitution weighing equipment of special design is required of the
manufacturer. Suspension details must provide for ability
to knock down for shipment and re-assemble for installation
in such a way as to not invalidate the established calibration
constants.
K3Factor: Locate the belt measurement interface on the
load carrying section of the belt adjacent to the scale but
far enough away as to not interact with load measurement.
Provide attention to details in arriving at linear-to-rotation
transfer function.
Breaking the K-Factor into three components
K1 (Conveyor Influences)
K2 (Test Load)
+K3 (Speed)
Lets look at the K-Factor as the sum of 3 separate
factors:

K = K1 + K2 + K3

K1= The correction constant that needs to be applied to the

simulated loading value of the Test Load (weight or chain)
to compensate for the magnitude and direction of the extraneous forces that arise from friction and the effects of
belt tension and stiffness acting on the suspension system owing to its configuration and overall condition of the
alignment of idlers throughout the weighing region of the
conveyor.
K2= The correction constant that needs to be applied to
the simulated loading value of the Test Load to compensate for the fact that when applied to the suspension it may
produce a force at the load cell which is not exactly the
same as the force produced by the actual conveyed material, exclusive of all conveyer influences.
K3= The correction constant that needs to be applied to
the simulated loading value of the Test Load (even though
the effect is primarily sensed at the belt speed measurement interface) to compensate for an error in measuring
belt speed due to belt stretch factors and/or incorrect measurement/calculation of initial calibration constants related
to the measurement of belt speed (i.e. an error in the assumed belt travel pulses per lineal foot) or to changes in
circumference of the measuring wheel owing to wear or
material build-up.
By looking at the K-Factor as a composite of three separate factors, we are better able to discuss accuracy in more
meaningful ways. Running material tests allows us the opportunity to establish a K-Factor for a given set of conditions. However, adequacy of a particular K-Factor selection for an extended period of operating time (i.e. months)
is dependent on the stability of the K1 factor and relatively
independent of the K2 and K3 factors.
If operating requirements and/or equipment layout rule out
the possibility for material testing, It is imperative that the
scale purchaser face up to the need for a total solution to
his weighing problem. This requires that no compromises
be made in any of the areas that are of key importance in
providing low K-Factor weighing equipment. If, on the
other hand, material testing can be accomplished, less
attention can be directed to the K2 and K3 factors since
these remain relatively constant.

This means that a relaxation in the care of determining

a loading value for the Test Load and in determining the
belt speed factors may be acceptable. Attention to the
K1 factor may also be relaxed somewhat if reproducibility
over very short periods of time are all that matters. This
suggests the use of the least expensive model of any particular manufacturer. However, if reproducible results are
important over reasonably long periods of time (i.e. weeks
and months) consideration should be given to upgrading
the suspension system to a longer weigh span design to
assure that a low and stable K1 factor is realized.
AN EXAMPLE
A 400 TPH single idler scale, operating at 350 FPM is
supplied with a test load (weight or chain) representing
30 pounds per foot loading (78.75% F.S.). The instruction
manual indicates that the calibration run should consist of
2 belt circuits which in this example is 620 feet. The integrator display resolution is 0.01 tons.
1. After zeroing the system, the integrator should advance
exactly 18,600 lbs (30 x 620) during a calibration run. If it
doesnt the span is to be adjusted accordingly.
2. After 30 days of operation the plant records show a
discrepancy between the belt scale readings and the readings of their accepted check scale.
Material checked by static scale = 102,501 tons
Belt scale totalization = 97,325 tons
Difference = 5,176 tons = -5.05%
3. After reporting the results to the scale supplier the
user is provided with instructions to change the existing
K-Factor in the scale instrumentations menu. The new KFactor is determined by the formula: actual weight / weight
on totalizer X existing K-Factor. In this case the K-Factor
would be 102,501 / 97,325 X 1.0 = 1.05318.
This scale has been K-Factored It is also assumed that
once factored all is well. Experience may prove otherwise.

JUST 1/4% ERROR CAN MAKE A BIG DIFFERENCE

COST OF MATERIAL LOST BY SCALE INACCURACIES OF ONLY 1/4% FOR AN 8 HOUR SHIFT, 5 DAYS A
WEEK, FOR 1 YEAR
cost/ton

@ 200 TPH

@ 500 TPH

$10

$10,400

$2,6000

$20

$20,800

$30

@ 1,000 TPH

@ 2,000 TPH

@ 5,000 TPH

@ 10,000 TPH

$52,000

$104,000

$260,000

$520,000

$52,000

$104,000

$208,000

$520,000

$1,040,000

$31,200

$78,000

$156,000

$312,000

$780,000

$1,560,000

$40

$41,600

$104,000

$208,000

$416,000

$1,040,000

$2,080,000

$50

$52,000

$130,000

$260,000

$520,000

$1,300,000

$2,600,000

$60

$62,400

$156,000

$312,000

$624,000

$1,560,000

$3,120,000

$70

$72,800

$182,000

$364,000

$728,000

$1,820,000

$3,640,000

$80

$83,200

$208,000

$416,000

$832,000

$2,080,000

$4,160,000

18

TANGIBLE RESULTS

USER:

U.S. STEEL

THAYER BELT SCALE THEORY

PUT TO THE TEST-1977

LOCATION:

Corbin, KY

THAYER SO #:

3430A

MODEL:

6RF-4-72

SERIAL #:

1200-885

The place: U.S. STEEL, CORBIN, KY

In 1977 Thayer Scale received and processed an order
for four 2-idler belt scales to be installed in U.S. Steels
Corbin, KY, coal preparation plant. One of the scales was
to be installed in the unit train loadout conveyor. It became
apparent that this scale had to be certified by the Southern
Weighing and Inspection Bureau to a tolerance of 0.25%
(+/- 1/8%). We knew that a 2-idler scale was not capable of
performing to this level of accuracy and decided that it was
time to put all our experience and theory to the test.

CONVEYOR DESIGN
Capacity:

Max: 4000 STPH

Min: 3000 STPH

Material:

Coal

Bulk Density:

50 lb/ft3

Particle Size:

3 x 0

Belt width:

72

Belt Speed:

550 FPM

Idler Spacing:

48

Idler Troughing Angle:

350

Conveyor Configuration:

Straight incline 180

Conveyor Length:

262 Feet--Pulley centers

Final acceptance is based on running material tests which

consist of three separate tests of ten railcars each. No
adjustments to the scale are permitted once the testing has
commenced. The tests were conducted on a track scale
owned and operated by the L&N Railroad. The track scale
had been previously tested and certified. Thayer Scale
passes certification test on Sept. 30, 1977, without requiring
K-factoring.

Conveyor Stringer:

8 Channel

# of Feed Points:

one

Scale location:

38 ft from tail pulley

Type of Take-up:

Vertical gravity

# of Belt splices:

One-Vulcanized

Many said we were lucky and that the true test would be if
the scale could maintain that accuracy for a year without
K-factoring.

Model:

THAYER 6RF-4-72

Weigh Bridge:

6-idler approach-retreat with

mass-counterbalance of dead
load

Weight Transducer:

Custom Built super precision

LVDT type applied in tension

Speed Pick-up:

Precision 2 ft wheel spring

loaded

Speed transmitter:

Tach with a resolution of 1/200

per ft

Integrator:

THAYER MODEL I-133

What is perhaps the BEST CONVEYOR SCALE IN THE

WORLD WAS BORN!
We put together a scale that included every conceivable
improvement to our existing equipment we could think of:
A 6-idler approach-retreat weighbridge.
A new steerable speed pick-up wheel.
A new simple two-board integrator using C-MOS circuitry.

After four years and several recertification tests the results

have proven we were correct.
In July, 1979, a third recertification test was run and the
result was an error of .08%. It was reported that we were the
only scale to pass recertification tests for the year. All the
competitors scales had to have their K-factors readjusted
for new values. This means that if a THAYER 6-idler belt
scale is properly applied to the conveyor an accuracy to
+/- 0.125% can be achieved. Proper conveyor application
is the only solution. You cannot depend on material tests
alone to solve the problem of large bias errors.

SCALE DESIGN:

TEST EQUIPMENT
Test Weight

64.269 lbs

Test Chain:

6973.875 lbs. x 38.79 ft long

ACCESSORIES

Circular Chart Recorder

Printer

19

FINDINGS:

TEST #1

TEST #2

TEST #3

THAYER Model RF

973.300 tons

971.200 tons

980.200 tons

* L & N Track Scale

973.105 tons

971.895 tons

979.825 tons

Scale Difference

+0.195 tons

+0.305 tons

+0.375 tons

% Error

+0.020%

+0.031%

+0.038%

THAYER BELT SCALE THEORY

REAFFIRMED - 2005

The place: Duke Energys Buck Steam Station, Salisbury,

North Carolina
The coal unloading scale at Buck Steam Station was used
for Thayer Scales *NTEP field certification site test.
In November of 2004 after successful completion of the
laboratory portion of the NTEP compliance testing, Thayer
Scales newest Integrator, the Series 5200 was ready for its
field trial. It was installed on an existing belt scale that had
been certified according to Handbook-44 since 1999.

USER:

DUKE POWER

LOCATION:

Salisbury, NC

THAYER SO #:

7883

MODEL:

NAR-6-72-48

SERIAL #:

1200-5913

CONVEYOR DESIGN
Capacity:

Max: 4800 STPH

Min: 1680 STPH

Material:

Coal

Bulk Density:

50 lb/ft3

Particle Size:

3 x 0

Belt width:

72

Belt Speed:

701 FPM

In May of 2005, after running for six months according to

the specifications and tolerances set in Handbook 44 and
the restrictions set by NTEP, and without any adjustment to
the scale, the second phase of the field test was completed.
The belt scale was again tested using 3, seven car unit
trains. Testing was in compliance with the Handbook and
NTEP (see below for results).

Idler Spacing:

48

Idler Troughing Angle:

350

Conveyor Configuration:

Straight incline 150

Conveyor Length:

240 Feet--Pulley centers

Also, in November 2005, 6 months following the completion

of the field test and 12 months following startup, the scale
again passed its routine recertification test without requiring
adjustments of any kind. The inherent advantages of the
THAYER Approach-Retreat suspension system and the
reliability of its built-in Test Weight Calibration Method,
permitted these tests to be completed at minimal cost in
terms of both labor and material. Each test was successfully
concluded after running only the minimum series of
material tests required. Since adjustments of any kind
were not required, the need for costly follow-up testing was
eliminated.

Conveyor Stringer:

8 Channel

# of Feed Points:

one

Scale location:

107 ft from tail pulley

Type of Take-up:

Vertical gravity

# of Belt splices

One-Vulcanized

On November 16, 2004 the six month field compliance test

began with 3, seven car unit trains used in the material
testing. Testing was in compliance with HB-44 and NTEP
procedures (see below for material test results).

* The NATIONAL TYPE EVALUATION PROGRAM (NTEP) is a program of cooperation between the NATIONAL CONFERENCE ON WEIGHTS & MEASURES
(NCWM), the NATIONAL INSTITUTE FOR STANDARDS AND TECHNOLOGY
(NIST), State Weights & Measures Officials, and the private sector for determining conformance of weighing equipment with the provisions of Handbook 44. NTEP
provides the testing procedures for each type of device, oversees its testing, and
issues a Certificate of Conformance (CC) upon acceptance. The range of operating
parameters that a family of devices covered by a single CC can have is restricted and
noted on the certificate

SCALE DESIGN:
Model

THAYER NAR 72 Weigh

Bridge

Weigh Bridge:

6-idler approach-retreat with

mass-counterbalance of dead
load

Weight Transducer:

Totalcomp, Inc. Model TS-150

(NTEP CC 93-028)

Speed Pick-up

Precision 2 ft wheel spring

loaded

Speed transmitter

Tach with a resolution of 1/200

per ft

Integrator

Series 5200

TEST EQUIPMENT
Test Weight

54.87 lbs

Belt Loading

186.713 #/ft

ACCESSORIES

Circular Chart Recorder

Printer

FINDINGS:

TEST #1

TEST #2

THAYER Model NAR

751.4 tons, 715.2 tons, 737.2 tons

813.6 tons, 822 tons, 821.7 tons

* On-site RR Track Scale

750.25 tons, 714.64 tons, 736.54 tons

814.22 tons, 821.71 tons, 820.97 tons

Scale Difference

1.15 tons, 0.56 tons, 0.66 tons

-0.62 tons, 0.29 tons, 0.73 tons

% Error

0.153%, 0.078%, 0.090%

-0.076%, 0.035%, 0.089%

* Certified by Norfork-Southern Corporation

20

THAYER SCALE Belt Scale Environmental Test Chamber

For conveyor belt scales installed outdoors, extreme temperature swings can adversely affect their performance. The
operating temperature limits of a weigh sensor can only be accurately determined and compensated for, by applying it to a
simulated installation and subjecting it to varying temperature ranges.
In order to better assure customers of a successful installation of our products, an Environmental Test Chamber, located
within the Thayer Scale manufacturing facility, provides a means for temperature testing of load cells, scale suspension
systems, instrumentation and entire weighing and feeding machines.
This test chamber is equipped with special suspension loading aids (for precise positioning of static weights on the pivoted
suspension members), for use in the manufacturing process of the RF Belt Scale and MD and MDL Weigh Belts.
The chamber finds use in Mechanical and Electrical Research and Development work, as well as in Production as a Quality
Assurance tool where particularly stringent temperature specification are called for. A distinguishing feature of these
confirmation tests is that they also include the effects of the lateral and longitudinal restraining elements required to hold
the suspension in place on inclined conveyors.
A quality control procedure using the test chamber assures that the particular equipment being tested either meets or
exceeds Thayers requirements for stable load cell output but in the case of commercial belt scales exceeds the stringent
temperature requirements dictated by the NTEP phase 1 test procedures. The chamber tests also go beyond the scope of
the present NTEP tests in that all active suspension elements, including those that are used to restrain the lateral motion of
the scale on inclined conveyors, are tested for their combined effects.

Belt Scale Suspension Testing Conveyor

To aid in scale and conveyor design THAYER maintains a Belt Scale Suspension Testing Conveyor at its corporate
headquarter in Pembroke, MA. This test conveyor was originally designed to study the effects of changing conveyor
parameters on the accuracy of a particular scales loading signal as well as to compare the long term stability and reliability
of speed measurements made at various locations within the conveyor. Currently it is used as an evolutionary development
tool, where proposed design recommendations are simultaneously tested under identical conditions against existing
configurations.
This test conveyor is 24 wide, 50 ft long, and can be equipped with 20 or 35 degree troughed idlers at variable spacing. It
can operate under controlled belt tension from 500 to 1500 pounds, and belt speeds from 10 to 400 fpm. The conveyor is0
located outdoors to best simulate a customers installation and the effects of the environment (temperature swings of -15
F to +90 0 F) on scale performance.
The conveyor is equipped with a THAYER single idler Model Quarry King and 4 idler Model RF, Rocking Flexure Belt
Scale. Both scales are outfitted with Thayers various instrumentation packages.
The potential performance level of a conveyor belt scale installation is dependent on things other than the belt scale
itself. Major factors include: conveyor design, scale suspension design, location of load and speed sensors in relation to
both conveyor terminal equipment and loading points, installed alignment conditions, duration and constancy of loading
cycle, condition of rolling conveyor elements, the uniformity and stiffness of the belting itself, condition and size of takeup apparatus, the precision with the system can be routinely calibrated, adherence to calibration schedule, and operating
environment.
While the Belt Scale Suspension Testing Conveyor can not simulate all the factors that directly effect a belt scales
performance, it does provide many of the crucial variations in order to assure that a THAYER Belt Scale is designed for
optimal accuracy and performance.

21

GLOSSARY OF CONVEYOR BELT SCALE TERMS

Access Side: The particular side of a continuous weighing
device from which servicing can best take place.
Accuracy: The degree of correctness with which a
continuous weighing device yields the true value of the
conveyed throughput or flow rate. It is assumed that the
true value always exists even though it may be impossible
to determine.
a) Accuracy of Totalized, Indicated or Recorded Value :
Expressed by the ratio of the error of the indicated value to
the true value, usually expressed in percent.
b) Accuracy Rating: Designates the accuracy classification
of the continuous weighing device. It is given as the limit,
usually expressed as a percentage of full-scale* value,
which errors will not exceed when the scale is used under
reference conditions.
*Sometimes as a percentage of actual load over a stated
operating range. Also sometimes expressed statistically.
Alignment: The degree to which the weigh idler(s) or the
weigh deck is co-planer with adjacent counterparts (idlers
or decks to either side).
Approach-Retreat Suspension: A pair of symmetricallyopposed pivoted weighbridges on which weigh idlers or weigh
decks are mounted, connected together at the centerline of
symmetry. The approach section of the suspension system
is that nearest the material loading point.
Backing Dimension: The elevation of the top surface of
the center roll making up a troughed idler as referenced
from the base mounting plane. Also called Idler Backing
Dimension.
Balance: See Zero.
Barometric Compensation: The application of design
principles to reduce or eliminate error effects due to
environmental changes in barometric pressure. Normally
applies to Load Cells.
Belt Circuit: The amount of conveyor belt movement or
travel that is equivalent to the total length of the conveyor
belt. Also referred to as belt revolution.
Belt Conveyor Scale: A device installed on a belt conveyor
for the purpose of measuring and/or totalizing bulk material
flow rate. Also called Belt Scale, Belt Meter, Conveyor
Scale or Conveyor Belt Scale.
Belt Load:
The weight of the material carried by the
conveyor belt expressed in terms of weight units per unit
of length i.e. pounds per foot, kilograms per meter. Also
called Belt Loading.
Belt Meter: See Belt Conveyor Scale.
Belt Revolution: See Belt Circuit.

Belt Scale: See Belt Conveyor Scale.

Belt Speed Sensor: General term used to describe the
transducer used in conjunction with a roll or wheel in contact
with the conveyor belt or the conveyor belt drive itself for
obtaining the speed of belt travel input required for material
flow rate measurement and/or totalization. Also called Belt
Speed
Pickup.
Belt Stiffness: The characteristic of belting which provides
resistance to transverse and longitudinal bending. Generally
evaluated on the basis of belt tension, carcass composition,
thickness and width and troughing shape.
Belt Stretch: The unit strain (elongation) of the belt as
a function of tension. Affects the accuracy of belt speed
(travel) measurements and take-up travel requirements.
Belt Tension: The tensile stress in the belt caused
by external forces such as friction, gravity, take-up and
inertia.
Belt Travel Pulser: A transducer used in conjunction with
a roll in contact with the conveyor belt or directly connected
to the conveyor belt drive for obtaining a train of pulses
proportional to belt travel. Also called Belt Travel Pickup.
Bend Pulley: A pulley on the return side of the conveyor.
Sometimes used as the belt speed or travel sensing roll.
Bias Error: A reoccurring error of relatively constant
magnitude and direction which is treated as a constant in
calibration procedures.
Bi-Directional Totalizer: A totalizer capable of counting
in both the forward and reverse direction. See Negative
Integration.
Calibrating Test Chain: Roller chain of known weight per
foot and length that is positioned on the belt over the weigh
idlers and beyond, which is held in place when the belt is
running empty. Used to simulate loading for calibration
purposes.
Calibrating Test Weight: A weight of known value that
is positioned on the scale suspension system to simulate
loading for routine calibration purposes.
Calibration: The procedure for adjusting a continuous
weighing device so that its output conforms to the accepted
value within a specified tolerance for a particular value of
the input.
Calibration Constant: A factor used to manipulate the
calibration calculations for compensation of bias error. Also
called a K factor. See Bias Error.
Calibration Error: The degree to which the device is found
to be out of calibration against the calibration standard i.e.
test weight, test chain or material run.
22

Calibration Point: Refers to the specific value represented

by the calibrating standard. Normally selected to fall in the
range of 2/3 to 3/4 of the full loading value for belt conveyor
scales.
Capacity: The maximum designed flow range of the
continuous weighing device.
Carcass: The structural or reinforcement material in a
conveyor belt. Normally cotton, nylon, rayon or a combination
thereof.
Concave Curve: A change in the angle of a belt conveyor
where the center of curvature is located above the
conveyor.
Continuous Weighing: Weighing material while it is in
motion. The weighing of loads without causing them to stop
on the load receiving element of a scale.
Convex Curve: A change in the angle of a belt conveyor
where the center of curvature is located below the
conveyor.
Conveyor Angle: The degree of inclination or declination
of a section of conveyor relative to horizontal. Also called
Inclination Angle or Slope Angle.
Conveyor Belt Scale/Conveyor Scale: See Belt Conveyor
Scale.
Count Rate: Advancement rate of totalizers unit digits when
operating at capacity. Usually stated in number of counts per
minute.
Count Transducer: Device adaptable to mechanical type
integrator for purpose of transducing mechanical rotation
(integrator output) into electrical pulses.
Counterbalance/Counterpoise/Counterweight:
An adjustable, removable, usually slotted weight intended
to balance against an applied load or designated weight
value.
Dash Pot: A damping device, sometimes adjustable; it
usually comprises a cylinder and piston relative motion of
which displaces air, oil or other fluid.
Deflection: The displacement from zero to full load of the
weigh deck or the most weight-sensitive idler on a belt
scale.
Deflection Errors: Errors associated with belt tension and
stiffness relative to the degree of scale deflection.
Digital Tachometer: A transducer whose output is a pulse
train having frequency proportional to input velocity.

23

Drag Link: A restraining member usually a section of chain,

rod or bar connected to the weighbridge to limit longitudinal
motion. Also see Stabilizing Plate and Stabilizing Flexure.

Drift: The output deviation of the continuous weighing device

over time with reference conditions remaining constant.
Effective Weigh Span: A span of conveyor belt equal to the
product of the idler spacing and the number of weigh idlers.
Under conditions of uniform loading the scale is subjected to
a force equivalent to the product of effective weigh
span and loading per unit length.
Empty Balance/Empty Belt Balance: See Zero.
Error: The difference between the indicated value and the
true value of the measurement. When the indicated value is
higher than the true value the sign of the error is positive.
Excitation Voltage: The recommended input voltage
applied to a transducer.
Expansion Joint: A joint between two conveyor stringers
designed to accommodate expansion and contraction of
structural parts.
Flexural Pivot: A part or group of parts utilizing one or more
elastic elements in place of frictional bearing surfaces to
produce a bearing or pivot-like action.
Flexure Plate: A single element flexural pivot.
Force Alignment: Aligning the scale so that its output
under simulated loading conditions does not change under
conditions of varying tension.
Frequency Response: Two relations between sets of
sinusoidal inputs and the resulting outputs. One relates
frequencies to the output-input amplitude rations; the
other to phase difference between output and input.
Fulcrum: The major support on or against which a lever
rests.
Full-Floating Suspension: A weighbridge that is totally
supported by the scale without ancillary support assistance.
Term commonly used to distinguish from pivoted type
weighbridges.
Gravimetric Measurement:
Measurement based on
the gravitational attraction or earth pull on a body (mass).
Distinguished from nuclear measurements which are based
on the absorption of radiation (gamma, beta radiation).
Gravity Take-Up: A horizontal pulley free to move in either
the vertical or horizontal direction with dead weights applied
to the pulley shaft to provide the belt tension desired in a
conveyor.
Handbook 44: The National Conference of Weights and
Measures text covering specifications, tolerances and
other technical requirements for commercial weighing and
measuring devices (see NIST)

Hydraulic Load Cell: A force transducer in which hydraulically

generated pressure becomes the counterbalancing force.

Low Load Alarm: An audible or visual indication that

instantaneous belt loading is below a pre-set limit.

Hysteresis: The maximum differences between the upscale

and downscale output values during a full range traverse in
each direction.

Low Load Cut-Out: Provisions for discontinuing the integration

of flow rate when instantaneous belt loading is below a preset limit. A means for eliminating the accumulation of zero
errors over long periods of empty conveyor operation.

Inclination Angle: See Conveyor Angle.

Instantaneous Rate: The product of the belt load and
speed signals at any given point in time. Expressed in units
of weight per unit of time, i.e. tons per hour, pounds per
minute, kilograms per minute, etc.
Integrator: A transducer whose output is the time integral
of its input. In a continuous weighing device instantaneous
flow rate is integrated with respect to time to yield total
throughput.

Low Rate Alarm: An audible or visual indication that

instantaneous flow rate is below a pre-set limit.
Low Rate Cut-Out:
Provisions for discontinuing the
integration of flow rate when instantaneous flow rate is below
a pre-set limit.
LVDT: Linear Variable Differential Transformer. A frictionless
AC displacement transducer designed to produce a linear
electric output over a given range of armature travel.

K Factor: The K-Factor is an integrator pre-programmed

span multiplier that affects the weigh measurement in the
weigh mode only. It allows automatic compensation of a
pre-established bias error, as determined through statistical
evaluation of material test data.

Mass: The amount of matter as measured by its inertia.

Linearity: The closeness to which a curve approximates a

straight line.

Material Slippage: The relative velocity of the conveyed

material with respect to the belt. For accurate weighing
slippage must not occur.

Load Button: A spherical load bearing element used

to provide point contact in contrast to a knife-edge which
provides line contact.
Load Cell: A transducer which provides an output signal
proportional to the applied force. Also called Force
Transducer, Load Transducer, Weight Transducer, Load
Reactor, Load Sensor.
Loading Point: Refers to the location on a conveyor where
the material is received by the belt. The location of a hopper,
chute or the discharge of pre-feed device used to supply
material to a conveyor.
Load Signal: An output signal corresponding to the
instantaneous load (lbs/feet) on a belt scale or weigh feeder.
Not to be confused with rate signal which is the product of
load and speed.
Load-Out Scale: A continuous weighing device used to
control the delivery of a pre-set weight of material.
Load Reactor: That which opposes or counterbalances an
applied load. Might be a load cell, simple spring or weight.
Location Error: That portion of bias error primarily
attributable to the difference in belt tension at the scale under
normal running and calibration conditions. The farther the
scale is from the loading point and the greater the conveyor
inclination, the higher the tension difference and hence the
larger the location error.

Master Weight Totalizer: the primary indicating element of

a continuous weighing device used to accumulate the weight
of material which has been measured.

Material Test: The calibration method from which bias errors

are evaluated and calibration constants derived. Either
pass a pre-weighed quantity of material over or through
the continuous weighing device in a manner as similar as
feasible to actual operating conditions, or statically weigh ona
suitable scale all material that has passed over or through
the continuous weighing device. Consult Handbook 44 for
specific precautions where commercial weighing is involved.
Mercury Pot & Float: A load reactor operating on buoyancy
principles.
Min. & Max. Loading: The defined loading limits for
preferred performance with a given belt conveyor scale or
weigh feeder installation. Usually expressed in percent of
rated capacity at constant speed or in weight units per unit
length of conveyor belt.
Misalignment: The degree to which weigh idlers or weigh
decks are not co-planner with adjacent idlers or decking to
either side of the scale.
Modulus of Elasticity Belting: The ratio of stress to strain
of belt carcass material over a defined tension range.
Multiplier: A device whose output is the product of its
inputs.
Negative Integration: Refers to the capability of a belt
conveyor scale or weigh feeder integrator to establish a
true (average) zero over both light and heavy sections of an
empty belt.

24

Non-Contacting Scale: A scale that does not physically

contact the conveyor belt. See Nuclear Scale.
Non-Linearity: The deviation of any functional relationship
from direct proportionality. The maximum deviation of the
calibration curve from a straight line drawn through the noload (zero) and the calibration point.
Normal Loading: The usual and accepted weight of
material per unit length along the conveyor belt under normal
operating conditions.
NTEP: National Type Evaluation Program. NTEP certification
is issued by NCWM upon successful completion of the
evaluation process. This Certificate indicates that the device
manufacturer has demonstrated the ability to meet applicable
requirements for commercial weighing and measuring
equipment in the U.S as specified in NIST Handbook 44.
NTEP certification is required in most states in the Unites
States and is a symbol of assurance for all.
Nuclear Scale: A device consisting of a source of nuclear
radiation and a detector for that radiation. Absorption of
radiation determines the mass of the material passing
between the source and the detector.
Null Balance: The act of counterbalancing the applied load
to a null position. A deflectionless load reactor.
Overload: An instantaneous belt loading that exceeds a
defined limit. Normally based on a structural limitation.
Overload Alarm: An audible or visual indication that
instantaneous belt loading exceeds a predefined limit.
Over-Range: Excess capacity of a continuous weighing
device.
OIML: Organisation Internationale de Mtrologie Lgale.
International organization for legal metrology, is responsible
for standardization of legal metrology in the associated
countries. The International Organization of Legal Metrology
(OIML) is an intergovernmental treaty organization whose
membership includes Member States, countries which
participate actively in technical activities, and Corresponding
Members, countries which join the OIML as observers.
OIML has developed a worldwide technical structure that
provides its members with metrological guidelines for the
elaboration of national and regional requirements concerning
the manufacture and use of measuring instruments for legal
metrology applications.
Peak Loading: The maximum instantaneous load the belt
scale or weigh feeder device must handle.
Peak Rate: The maximum instantaneous flow that the
continuous weighing device must handle.

25

Pendulum Weight: A rotating type load reactor in which the

counterbalancing moment increases as rotation swings a
known weight away from a fulcrum in a pendulum manner.

Pivoted Weighbridge: A weighbridge that is hinged or

pivoted at one end to the conveyor structure and attached
to the load reactor on the other. The load reactor therefore
sense the moment about the hinge or pivot as opposed to the
actual weight on the weighbridge. Term commonly used to
distinguish from full-floating type weighbridge.
Planar Moment of Inertia: refers to the moment of inertia of
the carcass cross sectional area with respect to its centroidal
axis.
Poise: A weight movable parallel to the longitudinal axis of
a weighbeam whose position referenced to a fixed index
constitutes the weight indication
Non-Contacting Scale: A scale that does not physically
contact the conveyor belt. See Nuclear Scale.
Non-Linearity: The deviation of any functional relationship
from direct proportionality. The maximum deviation of the
calibration curve from a straight line drawn through the noload (zero) and the calibration point.
Prototype Approval: The certification covering a specific
model of equipment that it meets the minimum design and
performance requirements of the applicable legal authority
for commercial weighing purposes. Example: NTEP approval
of belt conveyor scales.
Rate Signal: An output signal corresponding to the
instantaneous flow rate of a continuous weighing device. Not
to be confused with load signal.
Scale Service Idler: A conveyor belt idler that meets the
scale manufacturers requirements for accurate weighing.
Specifications normally cover dimensional tolerances on idler
concentricity and troughing profile.
Simulated Load Test: A span test using a calibrating test
chain or weight in the case of a belt conveyor scale or weigh
feeder, or a test plate in the case of a nuclear scale, to
simulate actual material loading.
Slope Angle: See Conveyor Angle.
Speed Compensation: Integration on the basis of both
belt loading and speed inputs. Distinguished from simple
integration of load only (speed assumed constant).
Speed Measurement Location: Point on the conveyor belt
where speed measurement is taken. Usually defined in
terms of distance from head or tail pulley, tension or slack
side of belt.
Speed Range: The maximum and minimum belt speed over
which a belt conveyor scale or weigh feeder operates.
Stabilizing Plate: A restraining plate-like member connected
to the weighbridge to counteract undesirable side forces.
.

Strain Gage: A device that changes its electrical resistance

proportional to strain.
Stringers: The primary longitudinal conveyor (structural)
members upon which the belt supporting idlers are
attached.
Suspended Idler(s): Weigh idler(s). The idlers supported
by the weighbridge.
Suspension Rods: The connecting link(s), usually vertical,
between the load reactor and the weighbridge through which
the force to be measured is transmitted.
Sway Stops: Mechanical stops placed adjacent to the
weighbridge to limit lateral motion.
Tachometer Generator: A transducer whose output is a
voltage proportional to input velocity.
Tare: The dead weight supported or sensed by the continuous
weighing device in addition to the weight of the bulk material
being weighed. Usually consists of the weighbridge, weigh
idlers, conveyor belting and material build-up on these parts.
Tare Build-Up: That portion of tare due to the adhesion or
support of spilled material.
Test Chain: See Calibrating Test Chain.
Test Chain Rack: A trough (upside down section of channel)
upon which a calibrating test chain is stored.
Test Chain Reel: A storage spool around which a calibrating
test chain is wound for storage purposes.
Test Plate: A plate having a fixed absorption factor used to
simulate material loading on a nuclear continuous weighing
device for calibration checks.

Tripper: A special device for unloading a belt conveyor at a

point between the loading point and the head pulley. Not to
be confused with a diverting plow.
Troughing Angle: The angle that the edges of the belt
are held up to reduce spillage or increase capacity. The
inclination of the side rolls with respect to the center roll of a
troughed idler.
Vernier: An auxiliary counter or dial, or equivalent function
thereof, used with the master weight totalizer to increase
resolution.
Weighbridge: The frame on which weigh idlers are secured.
Also called Weigh Carriage.
Weighing Bureaus: Inspecting or certifying agencies.
Weigh Carriage: See Weighbridge.
Weigh Deck: The section of plate that is weighed in a slider
plate type conveyor. Analogous to a weigh idler in a troughed
or flat idler type conveyor.
Weigh Idler(s): The idlers supported by the weighbridge.
Also called Suspended Idlers.
Weigh Length: See Effective Weigh Span.
Weigh Span: The distance between the two fixed idlers
adjacent to either side of the belt conveyor scale.
Wind Break: Shroud positioned to protect scale from effects
of wind and drafts.
Zero: Abbreviated term for empty balance, empty belt balance
or balance as pertains to the calibration of a continuous
weighing device. Properly adjusted zero infers a net zero
integration of the empty belt over an exact belt revolution.

Tolerance: The limit of allowable error or departure from true

performance or value.
Tolerance, Acceptance: Tolerances applied to new or newly
reconditioned or adjusted equipment. Usually one-half of the
maintenance tolerance.
Tolerance, Maintenance: Tolerance that provides for
additional range of inaccuracy within which equipment will be
approved on subsequent tests, permitting a limited amount of
deterioration before the equipment will be officially rejected
and before reconditioning or readjustment will be required.
Totalizer: A device used to indicate the weight of material
which has been conveyed over or passed through the
continuous weighing device.
Training Idler: An idler of special design who function is to
maintain central tracking of the belt.

26

PRODUCTS & MARKETS SERVED

Thayer Scale supplies the world with process measurement
& control equipment with emphasis on solids flow weighing
and metering. Our products include: Loss-In-Weight Feeder,
Weigh Belt Feeders, Conveyor Belt Scales, Measurement &
Control Instrumentation and Bin & Hopper Material Flow Aids.
The markets we serve include: Forest Products, Plastics,
Food, Chemicals and Cement to name a few.
MAJOR PRODUCTS & TECHNOLOGIES
Patented FMSS Force Measurement Suspension System Cable
Scales
TM

Patented Loss-In-Weight Differential Screw Feeder

Patented Nodal-Membrane Vibratory Tray Feeders.
Patented SpiralatorTM Hopper Agitator
Patented Rocking Flexure Belt Scales
Patented PF Volumetric Screw Feeder

SUPPORT SERVICES
TEST FACILITIES:
Thayer Scale operates three fully equipped dry particle
test centers in a dedicated wing of our Massachusetts
facility. A full time staff performs product application and
performance testing with user supplied materials. These
facilities are designed to duplicate as closely as possible
industrial processing conditions.
SERVICE:
Thayer Scale has a well trained professional service
department with an outstanding record of longevity,
experience and achievement. Thayers technicians are
available for start-up support, inspection, diagnosis and
repair service, routine maintenance and material testing
services.
TRAINING:
Thayer Scale offers formal training either here at the
factory in Pembroke, MA or at the customers plant. Each
training class is tailored to the specific instrumentation
and mechanical equipment used in their facility.

Patented Bridge BreakerTM Bin & Hopper Dischargers.

Low Feed Rate Miniature Weigh Belt & Loss-In-Weight Feeder.
NAR NTEP Approved commercial grade Conveyor Belt Scales
(approved for legal trade).
SI Insertion Weigh Belt Feeder and Scale.
MFLI Mass Flow Liquid Injection System.
High Capacity, Heavy Industry Weigh Belts.
Modular, Singular or Multi Feeder Continuous or Batch Control Systems.

THAYER SCALE-HYER INDUSTRIES, INC.

MADE IN USA

THAYER and the THAYER logo are Registered Trademarks of Hyer Industries, Inc.
Hyer Industries, Inc. 2004. All rights reserved

91 Schoosett St., Pembroke, MA 02359

Ph: 781-826-8101 Fax: 781-826-7944
e-Mail: [email protected]
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