Milltronics Accumass BW100 Instruction Manual
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Milltronics Accumass BW100 Instruction Manual

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Accumass BW100
33455310
Rev
1.5
Instruction Manual
PL-531
May 1997

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  • Page 1 Accumass BW100 Instruction Manual PL-531 May 1997 33455310...
  • Page 2 In 1997, Milltronics established a new business division - Mass Dynamics - dedicated to sales and development of continuous weighing, acoustic sensing and motion sensing products. This division will provide specialized support for these product lines.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS About This ... About This Manual About ACCUMASS BW100 Specifications Installation Dimesions Interconnection System Diagram Terminal Block Layout Load Cell - Single Load Cell - Dual Speed Sensor Auto Zero Remote Totalizer 1 Analog Output Remote Totalizer 2...
  • Page 4 Recalibration Belt Speed Compensation Material Tests Design Changes Recalibration Routine Zero Initial Zero Direct Zero Routine Span Initial Span Direct Span Factoring Linearization Operation Load Sensing Speed Sensing Modes of Operation Damping Analog Output Relay Output Totalization Auto Zero Communication Protocol Parameter Description Appendices...

  • Page 5: About This Manual

    ABOUT THIS ... ABOUT THIS MANUAL It is essential that this manual be referred to for proper installation and operation of your BW100 belt scale integrator. As BW100 must be connected to a belt scale, and optionally a speed sensor, refer to their manuals as well. Installation gives you step by step direction for the installation and interconnection of your BW100.
  • Page 6 The ACCUMASS BW100 is a microprocessor based integrator designed for use with Milltronics, or equivalent belt scales. The speed and load signals from the conveyor and scale, respectively, are processed to derive rate of material flow and totalization.

  • Page 7: Specifications

    SPECIFICATIONS » 100/115/200/230 V ac ±15%, 50/60 Hz, 15 VA Power: » standard: » optional: » 10 - 15 V dc, 15 W » 18 - 30 V dc, 15 W Application: » compatible with Mass Dynamics belt scales MSI, MSL, MMW and MIC, or equivalent Accuracy: »...
  • Page 8 » Dolphin: » Milltronics Windows based software interface and infrared ComVerter link. » CVCC: » Milltronics bipolar loop to RS-232 or RS-422 passive converter, communications interface » BIC-2: » Milltronics bipolar loop to RS-232 or RS-422 buffered converter, communications interface, max 6 BW100 per BIC-2 »...
  • Page 9 INSTALLATION Installation shall only be performed by qualified personnel and in accordance with local governing regulations. This product is susceptible to electrostatic shock. Follow proper grounding procedures. DIMENSIONS 270 mm (10.6") 254 mm (10") 138 mm (5.4") 69 mm (2.7") sealed enclosure integral junction box (cover removed)
  • Page 10 Specifications customer mA output device relay output customer alarm, or control device remote totalizer customer’s remote totalizing device bipolar current loop Milltronics BIC-2 (Milltronics communications) Typical system capability. Not all components or their maximum quantity may be required. PL-531...

  • Page 11: Terminal Block Layout

    TERMINAL BLOCK LAYOUT ac supply dc supply All field wiring must have insulation suitable for at least 250 V. dc terminals shall be supplied from an SELV source in accordance with IEC-1010-1 Annex H. PL-531...

  • Page 12: Load Cell - Single

    LOAD CELL - SINGLE Belt Scale customer junction box If load cells are supplied with sense wiring: terminate brown with black = T17 and blue with red = T20 at junction box. Where separation between the BW100 and belt scale exceeds 150 m (500 ft) : »...

  • Page 13: Load Cell - Dual

    LOAD CELL - DUAL Belt Scale ‘A’ loadcells ‘B’ customer junction box If load cells are supplied with sense wiring: terminate brown with black = T17 and blue with red = T20 at junction box. Where separation between the BW100 and belt scale exceeds 150 m (500 ft) : »...

  • Page 14: Speed Sensor

    SPEED SENSOR MD - 36A speed sensor TASS speed sensor Connect the BW100 TB1 – 7 to the MD - 36A speed sensor terminal: ‘2’ for clockwise speed sensor shaft rotation ‘3’ for counter-clockwise speed sensor shaft rotation. MD - 36A shaft rotation is viewed from the front cover side of the MD - 36A enclosure.

  • Page 15: Auto Zero

    AUTO ZERO prefeed activated dry contact REMOTE TOTALIZER 1 supply remote maximum 30 totalizer V dc, 100 mA ANALOG OUTPUT to customer instrumentation isolated mA output, 750 Ω maximum load ac models only mA output on dc models is not isolated PL-531...

  • Page 16: Remote Totalizer 2

    REMOTE TOTALIZER 2 supply, remote maximum 240 V totalizer ac / dc RELAY OUTPUT relay shown in de-energized state, contacts rated 5 A at 250 V non-inductive PL-531...

  • Page 17: Communication Cvcc

    COMMUNICATION CVCC BIC-2 Connect shield at one device only, e.g. BW100 TB1 – 21. Maximum loop length 3000 m (10,000 ft). PL-531...

  • Page 18: Power Connections

    POWER CONNECTIONS AC POWER The equipment must be protected by a 15 A fuse or a circuit breaker in the building installation. A circuit breaker or switch in the building installation, marked as the disconnect switch, shall be in close proximity to the equipment and within easy reach of the operator.

  • Page 19: Comverter

    COMVERTER Optional Dolphin Interface ComVerter ACCUMASS BW100 Refer to Dolphin instruction manual for interconnection details. UNITS STICKER Remove the appropriate ‘units’ sticker from the sheet supplied, and affix to your BW100 as shown. PL-531 98\03\09...
  • Page 20 PL-531...
  • Page 21 START UP For successful start up, insure that all related system components such as belt scale and speed sensor are properly installed and connected. ORIENTATION Display and Keypad balance switch ,SW2 balance potentiometer, P1 Keypad The BW100 operates under two modes: ‘run’ and ‘program’. When the unit is initially powered, it starts in the program mode.

  • Page 22: Program Mode

    Program Mode ‘change value’ parameter value accessed program parameter status icon, mode number refer to Run Mode KeyPad alternates program access scroll scroll mode between down ‘select parameter’ mode and ‘change value’ functions MANEUVERING To Select a Parameter: if not in the program mode from the run mode if in the program mode...
  • Page 23 Speed Scroll To speed scroll up or down press the up or down key and hold, then press the enter key and hold. Release to stop. To Change a Parameter Value : select parameter, e.g. P005 = 1 initiate change function Security Must Be Disabled increase or decrease to the desired value.
  • Page 24 Express : Parameter to jump back to P005 Value to jump to the factory setting e.g. P999 jump back to P005 To Access Run Mode : e.g. from the program mode, P005 exit and return to run mode PL-531...

  • Page 25: Master Reset

    To Access the Program Mode : from the run mode e.g. rate display last parameter from previous program session e.g. P005 MASTER RESET Prior to programming, balancing and calibration, a master reset of the BW100 should be done. Refer to Parameters \ P999. PL-531...

  • Page 26: Balance

    BALANCE If you are operating a dual load cell belt scale, it is recommended that the load cells be balanced electronically prior to initial programming and calibration, or after either or both load cells have been reinstalled or replaced. Unbalanced load cells adversely affect the performance of your belt conveyor weighing system.
  • Page 27 Place the BW100 into the program mode at P291. test weight on ‘A’ ‘B’ load cell ‘B’ side test weight ‘close’ select P291 ensure SW2 is closed enter and auto advance to P292, ‘open’ open SW2 enter and auto advance to P293, ‘open’...

  • Page 28: Quick Start

    QUICK START Quick Start parameters (P005 to P017) must be programmed for all applications. Have your design data sheet or program record handy! units design rate design speed speed constant belt length test load Upon completion of Quick Start programming, a Zero and Span calibration are required for successful entry into the run mode.

  • Page 29: Start Up

    100. P016, belt length e.g. 65.72 m P017, test load e.g. 55.56 Kg / m examples are typical Test load value should be less than design load (P952). If not, contact Milltronics or their agent. PL-531 98/03/10...
  • Page 30 Calibration Note The duration of Zero and Span Calibration is dependent upon speed (P014), length (P016) and revolutions (P360) of belt. To cancel a Zero or Span calibration in progress, and return to the run mode. PL-531...

  • Page 31: Zero Calibration

    Zero Calibration Run the conveyor for several minutes to warm up the belt and insure that it is empty. Test weights are not used during a zero calibraion. zero calibration required initial zero count zero calculation, frequency count displayed zero deviation calculated, initial deviation = 0 zero deviation accepted, initial zero count = ###...

  • Page 32: Span Calibration

    Span Calibration Run the conveyor until the belt is empty and stop it. Suspend the test weight from the scale per its instruction manual. Run the conveyor belt empty. initial span count span calculation, frequency count displayed span deviation calculated initial deviation = 0 span deviation accepted initial span count = ####...

  • Page 33: Run Mode

    Run Mode reading graph display scroll = relay status, totalization appears on alarm in process r = rate t1 = totalizer 1 1,2 = remote totalizer t2 = totalizer 2 flashes at rate L = load totaling S = speed 3 = parameter alert, zero and span calibration required...
  • Page 34 PL-531...

  • Page 35: Belt Speed Compensation

    RECALIBRATION BELT SPEED COMPENSATION In order to achieve optimum accuracy in the rate computation, the belt speed displayed must equal that of the actual belt speed. As the speeds are likely to differ, a belt speed compensation should be performed. Run the conveyor with the belt empty.

  • Page 36: Material Tests

    MATERIAL TESTS Material tests are performed to verify the accuracy of the of the span calibration. If the material tests indicate a repeatable deviation exists, a manual span adjust (P019) is then performed. This procedure automatically alters the span calibration and adjusts the test load (P17) value, yielding more accurate span recalibrations.

  • Page 37: Design Changes

    If the span adjust value is not acceptable, repeat the material test to verify repeatability. If the result of the second material test differs considerably, consult Milltronics or their agent. If the span adjust values are significant and repeatable, perform a manual span adjust:...

  • Page 38: Recalibration

    RECALIBRATION In order to maintain the accuracy of the weighing system, periodic zero and span recalibrations are required. Recalibration requirements are highly dependent upon the severity of the application. Perform frequent checks initially, then as time and experience dictate, the frequency of these checks may be reduced. Record deviations for reference.

  • Page 39: Initial Zero

    Initial Zero An initial zero can be performed if deemed as a proper response to E3 message. Refer to maneuvering for parameter selection and value change. select P377 invoke initial zero, enter ‘1’ current zero count zero calculation frequency count displayed zero deviation zero deviation accepted initial zero count = ####...

  • Page 40: Direct Zero

    Direct Zero Direct zero entry (P367) is intended for use when replacing software or hardware, and it is not convenient to perform an initial zero at that time. A record of the last zero count is required. Refer to maneuvering for parameter selection and value change. current zero count enter previously recorded zero count...

  • Page 41: Routine Span

    Routine Span To perform a routine span recalibration, run the conveyor until the belt is empty and stop it. Suspend the test weights from the belt scale per its instruction manual. Run the conveyor empty at maximum operating speed . From the zero calibration initiate span calibration...

  • Page 42: Initial Span

    Initial Span An initial span can be perform if deemed as a proper response to E4 message. Refer to maneuvering for parameter selection and value change. select P388 invoke initial span current span count = #### span calculation, frequency count displayed span deviation = ## zero deviation accepted initial zero count = ####...

  • Page 43: Direct Span

    Direct Span Direct span entry (P368) is intended for use when replacing software or hardware, and it is not convenient to perform an initial span at that time. A record of the last span count is required. Refer to maneuvering for parameter selection and value change. current span count enter previously recorded span count...

  • Page 44: Factoring

    Factoring In order to calculate the value of a new or unknown test weight to the current span, the factoring procedure is used. For optimum accuracy in the factoring results, a routine zero calibration is recommended. Refer to Maneuvering for parameter selection and value change. With the conveyor stopped and the belt empty: P359 selected enter...

  • Page 45: Linearization

    Linearization Conveyor applications where the belt scale is poorly located, or where there is a high degree of variation in belt tension, typically cause the belt scale to report load non-linearly. The BW100 provides a linearizing function (P390 - P396) in order to correct for the deficiency in the weighing system and to provide an accurate report of the actual process.
  • Page 46 Example : A non-linearity with respect to the ideal response exists in a belt scale application with design rate of 200 t/h. It is decided to do material tests at 25, 50 and 75% of the design rate. After performing a zero and a span calibration at 100% of the design rate, followed by material tests and manual span adjust, three material tests were performed at 50, 100 and 150 t/h, as indicated by the BW100.
  • Page 47 Program the BW100 as follows: P390 = 1 P391 = 11.6 P392 = - 14.3 P393 = 23.2 P394 = 10.5 P395 = 34.7 P396 = - 8 Often only one point of compensation is required, usually at a low load value. In the prior example, if compensation was only required at 11.6 kg/m, the programming could be as follows.
  • Page 48 PL-531...

  • Page 49: Operation Load Sensing

    OPERATION LOAD SENSING In order for the BW100 to calculate rate and hence totalize material flow along the belt conveyor, a load signal representative of weight of material on the belt is required. The load signal is provided by the belt scale. The BW100 is compatible with belt scales fitted with one or two strain gauge type load cells.

  • Page 50: Damping

    DAMPING Damping (P080) provides control over the speed at which the displayed readings and output functions respond to changes in their respective input function; load, speed and the internal rate signals. Changes in the displayed rate of material flow, material loading and belt speed are controlled by the damping.

  • Page 51: Relay Output

    RELAY OUTPUT The BW100 offers one single pole double throw (SPDT) relay that can be assigned (P100) to one of the following alarm functions: » rate: relay alarms on high and/or low material flow rate. » auto zero: relay alarms when an attempted auto zero calibration reports an out of range condition (E9).

  • Page 52: Totalization

    TOTALIZATION The totalization function is based on the internal rate (mass per unit time) signal proportional to belt speed and load on the associated belt scale. It is not affected by the damping function (P080). The rate signal is sampled several times a second to accurately count the mass of material conveyed.

  • Page 53: Auto Zero

    If material feed resumes during an auto zero function, the totalizing function is maintained. COMMUNICATION The BW100 bipolar current loop provides long distance communication to an RS-232 or RS-422 device via a local Milltronics CVCC or BIC-2 interface. BW100 host BIC-2 *...

  • Page 54: Protocol

    PROTOCOL Protocol refers to the format, sequence and value of the data fields used in communication messages. Each data field of a BW100 message contains one or more bytes of ASCII binary code. Each byte contains: » 8 data bits »...
  • Page 55 MESSAGE REQUESTS Message requests must be transmitted from the host to the BW100 in the following format. som DEVICE MT eom Example: Data ASCII Example Field Character Description start of message DEVICE for BW100 # 1 material flow rate request end of message MESSAGE RESPONSES The BW100 response to a flow rate (MT=50) load (MT=51) or speed (MT=52)
  • Page 56 PL-531...

  • Page 57: Parameter Description

    PARAMETER DESCRIPTION P000 lock Locks out the programming ’change value’ function such that the values of P001 through P999 cannot be changed. This however does not prevent the ’select’ function from use; i.e. for viewing values. Programming is locked out if the value of P000 is other than 1954.
  • Page 58 P014 design speed Specifies the design speed for the conveyor belt. Speed units are: metre/s P005 = 1 or 2 feet/min if P005 = 3, 4 or 5 P015 speed constant This value multiplied with the speed sensor frequency, calculates the actual belt speed.
  • Page 59 P018 speed constant adjust This parameter allows adjustment to the speed constant (P015). Initially, this parameter displays the dynamic speed of the belt. If the displayed speed is not equal to the actual speed, enter the actual belt speed. For speed sensor applications, the value of P015 is automatically adjusted.
  • Page 60 P080 damping Sets the speed of response to which the displayed readings (rate, load and speed), and outputs (alarm and mA) react to change.. Effect of damping (P080) on mA output can be overridden by mA output damping (P220). The greater the damping value, the slower the response. enter damping value, range 1 - 9999 P081 display mode...
  • Page 61 Relay/Alarm Function, P100 - P117 These parameter are specific to the use of the relay/alarm function. Refer to Operation\Relay Output. P100 relay set up Sets the alarm mode for the relay. entry: 0 = off 1 = rate 2 = auto zero 3 = belt speed 4 = belt load 5 = error...
  • Page 62 mA output parameters, P200 - P220 These parameters are specific to the use of the mA output. Refer to Operation \ mA Output for details. P200 mA range Sets the range for the mA output. entry: 1 = 0 - 20 mA 2 = 4 - 20 mA P201 mA function...
  • Page 63 P215 20 mA trim Adjusts the 20 mA output level to agree with a milliammeter or other external mA input device. enter trim value, range 0 - 9999 P220 mA output damping Sets the speed at which the mA output reacts to change. The greater the damping value, the slower the response.
  • Page 64 Load Cell Balancing Parameters, P291 - P295 These parameters are used for verifying or balancing the load cells (2) on the associated conveyor belt scale. Refer to Start Up\Balancing for details and procedure for use of these parameters. P291 calculator input 1 This register displays the count associated with the summation of load cell A and B signals, when balancing the A and B load cells of the associated belt scale.
  • Page 65 P341 run time The cumulative days that the application device has been in service. The time is recorded once daily in a non-resetable counter. Periods of less than 24 hr. are not recorded, nor accumulated. P350 calibration security This parameter provides additional security to the global lock (P000). entry: 0 = view parameters, perform zero and span, no reset of totalizer 1 1 = same as level 0, but cannot perform span...
  • Page 66 P368 direct span This parameter allows the span reference count to be viewed or entered directly. Direct entry is intended for use when replacing software or hardware and it is not convenient to perform an initial span at that time. P370 zero limit Sets the zero calibration deviation limit from the last initial zero.
  • Page 67 Linearization Parameters, P390 - P396 These parameters are used to compensate for non-linear response of the weighing system to the BW100. Refer to Recalibration\Linearization for details and example on the use of these parameters. P390 linearization Enables or disables the linearization function. entry: 0 = off 1 = on P391...
  • Page 68 Totalization, P619 - P648 The following parameters are specific to the use to the BW100 totalizers. Refer also to Operation\Totalization. If the resolution (P631 - P639) selected would cause the totalizer to lag behind the count rate, a message E2 is displayed after making the entry.
  • Page 69 P632 totalizer 2 resolution, internal This parameter sets the resolution of internal totalizer 2. entry: 1 = 0.001 (one thousandth) 2 = 0.01 (one hundredth) 3 = 0.1 (one tenth) 4 = 1 (unit) 5 = 10 (x ten) 6 = 100 (x hundred) 7 = 1000 (x thousand) P638 totalizer 1 resolution, external...
  • Page 70 P643 totalizer 1 contact closure, external The value of this parameter represents a multiple of 32 ms of contact closure for remote totalizer 1. The value is automatically calculated upon entry of P1 (design rate) and P638 (totalizer 1 resolution, external) so that the duration of contact closure allows the transistor switch response to track the total, up to the design rate.
  • Page 71 P647 totalizer display Selects the totalizer combination to be displayed, either manually through the scroll display key or automatically by control of the display mode (P081). entry: 1 = totalizer 1 2 = totalizer 2 3 = totalizers 1 and 2 P648 totalizer reset, internal Resets the internal totalizers.
  • Page 72 Sets the baud rate for the proprietary bi-polar current loop. This baud rate is not applicable to communication via Milltronics Comverter. entry: 300, 1200, 2400, 4800 or 9600 baud 4800 baud is required for Dolphin communications over the bi-polar current loop.
  • Page 73 FAIL = consult Mass Dynamics P907 programmer interface Tests the infrared communications link. Test is initiated by scrolling to the parameter or repeated by ’pressing enter’. display: PASS = normal FAIL = consult Milltronics infrared communication link mirror BW100 P911 mA output value Displays the value from the previous measurement.
  • Page 74 P940 load cell ’A’, mV Displays the mV signal input from the load cell. Range 0.00 - 60.00 mV. P941 load cell ’B’, mV Displays the mV signal input from the load cell. Range 0.00 - 60.00 mV. P942 V/F converter, V Displays the input voltage to the voltage to frequency converter.
  • Page 75 P951 span register Registers the number of span calibrations that have been done since the last master reset. P952 design load Displays the value of the design load, which corresponds to the full scale value for alarm and mA output functions. The design load is calculated, based on the design rate and design speed.
  • Page 76 PL-531...

  • Page 77: Appendices Alphabetical Parameter List

    APPENDICES ALPHABETICAL PARAMETER LIST parameter number Alarm Dead Band P117 Baud Rate P751 Belt Length P016 Calculator Input 1 P291 Calculator Input 2 P292 Calculator Input 3 P293 Calculator Input 4 P294 Calibration Duration P360 Calibration Security P350 Communication Mode P760 Compensation Point 1 P392...
  • Page 78 Initial Span P388 Linearization P390 Linearizer Point 1 P391 Linearizer Point 2 P393 Linearizer Point 3 P395 Load Cell “A”, mV in P940 Load Cell “B”, mV in P941 Load Cell Balance P295 Lock P000 Low Alarm P102 mA Function P201 mA Output Damping P220...
  • Page 79 Speed Constant Adjust P018 Test Load P017 Totalizer 1 Closure, External P643 Totalizer 2 Closure, External P644 Totalizer 1 Resolution, External P638 Totalizer 2 Resolution, External P639 Totalizer 1 Resolution, Internal P631 Totalizer 2 Resolution, Internal P632 Totalizer Display P647 Totalizer Drop out P619 Totalizer Reset, Internal...

  • Page 80: Troubleshooting

    TROUBLESHOOTING message diagnosis action E1 (program) security code required enter access code into P000 E2 (run) totalizer resolution too low increase value (P631 - P639) E3 (run) zero out of range consider an initial zero P377, refer to Recalibration\Initial Zero E4 (run) span out of range consider an initial span P388,...
  • Page 81 E103 (run) load cell check wiring E104 (run) memory checksum contact Mass Dynamics or their distributor no speed signal check speed circuit or run conveyor » Error messages are cleared when the condition is remedied. » Run mode errors are suppressed during program mode, zero or span calibration.

  • Page 82: Maintenance

    SOFTWARE UPDATES The software can be updated from a floppy disk by use of a PC (IBM Compatible) with Milltronics Dolphin software. It is recommended that a reset (P999) is done after the software update followed by zero and span calibrations.

  • Page 83: Program Record

    Program Record Parameter Value P005 Units P011 Design Rate P014 Design Speed P015 Speed Constant P016 Belt Length P017 Test Load P018 Speed Constant Adjust P019 Manual Span Adjust P022 Minimum speed Frequency P080 Damping P081 Display Mode P100 Relay Set Up P101 High Alarm P102...
  • Page 84 Program Record Parameter Value P639 Total 2 Resolution, Ext P643 Total 1 Closure, Ext P644 Total 2 Closure, Ext P647 Totalizer Display P648 Totalizer Reset, Int P751 Baud Rate P760 Communication Mode P761 Identification Number P900 Software Rev.# P949 Diagnostic Errors P950 Zero Register P951...

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