Milltronics CompuScale III Instruction Manual

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COMPUSCALE III

INTEGRATOR

Instruction Manual PL-367

33453670

Rev. 1.4

January 2001

MULTI SPAN NO: 1

R2:RATE HI R1:SPEED LO

1263957

TOTAL

-50%

50%

100%

150%

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Page 1 COMPUSCALE III INTEGRATOR Instruction Manual PL-367 January 2001 MULTI SPAN NO: 1 R2:RATE HI R1:SPEED LO 1263957 TOTAL -50% 100% 150% 33453670 Rev. 1.4...
Page 2 We welcome all suggestions for improvement. Technical data subject to change. MILLTRONICS®is a registered trademark of Siemens Milltronics Process Instruments Inc. Contact SMPI Technical Publications at the following address: Technical Publications Siemens Milltronics Process Instruments Inc.
Page 3: Table Of Contents
TABLE OF CONTENTS TITLE PAGE # General Information About the CompuScale III 1 – 1 About this Manual General 1 – 2 Conventions 1 – 3 Specifications CompuScale 2 – 1 Options 2 – 2 Installation CompuScale III 3 – 1 Interconnection 3 –...
Page 4 12 – 2 FIG .3 CompuScale III / Belt Scale Interconnection 12 – 3 FIG. 4 CompuScale III / Belt Scale Interconnection (cont’d) 12 – 4 FIG. 5 CompuScale III / Speed Sensor Interconnection 12 – 5 FIG. 6 Power, Auto Zero, & Rate Output Wiring 12 –...
Page 5 The CompuScale III has three modes of operation; program, calibrate, and run. The operator programs the CompuScale III via the keypad to provide displays and outputs in the desired units of measure. The CompuScale III displays the name, range of acceptable values, (and additional information/instruction) of the parameter (programming feature) accessed.
Page 6 START UP, prepares the CompuScale III for programming. PROGRAMMING, details the activities required to tailor the CompuScale III to the particular application. CALIBRATION, includes the CompuScale III input signal to output feature correlation procedure. PARAMETERS, describes the function, factory setting, and range of possible settings, of each parameter.
Page 7 SPECIFICATIONS COMPUSCALE III » 100/115/200/230 V AC ± 10%, jumper Power: selectable, 50/60 Hz, 65 VA Fuses: » Main (FU1) » 3/4 Amp MDL SLO-BLO or equivalent » Speed Sensor (FU2) » 1/4 Amp MDL SLO-BLO or equivalent Operating » -20 to 50°C (-5 to 122°F) Temperature: »...
Page 8 Belden 8404 or equivalent » Speed Sensor, 300 m (1000 ft) max. 18 AWG, 3 wire shielded, Belden 8770 or equivalent Speed Sensor: » Milltronics MD36 or MD2000A for speed input LCPA-08 » For connection to MMI-3 or MMI-4 scale configurations interface: Incline Compensator: »...
Page 9: Hazardous Locations
INSTALLATION COMPUSCALE III The CompuScale III should be mounted in an area that is within the specified temperature range, and that is suitable for Nema 4 style enclosures. The front cover should be accessible for keypad operation, display viewing, and have sufficient room to swing open.
Page 11: Start Up
SW1-5 must be set to the desired position before initial programming is performed. To alter the Units of Measure of a programmed CompuScale III, set SW1-5 as desired, then perform a Reset. Refer to Parameters / P99 Reset. CERTIFICATION Leave SW1 contact 6 (SW1-6) in the open position for normal applications.
Page 12: Remote Communication
Leave SW2 contact 3 (SW2-3) in the open position for English, or closed for alternate language, CompuScale III displays. REMOTE COMMUNICATION Leave SW2 contact 6 (SW2-6) open for normal operation. If a remote mounted CompuScale III is used, SW2-6 of the remote CompuScale III (only) must be closed. PORT 2 COMMUNICATION MODE Leave SW2 contact 7 (SW2-7) open for normal operation, or closed if a serial printer is connected to Port 2.
Page 13: Pre Start Up Checks
» SW1 and SW2 have been set as required. » the POWER switch is in the OFF position. Connect power to TB1-51,52 and ground to TB1-50 of the CompuScale III. Ensure all connections are secure. Do not operate the CompuScale III with the ground (earth) wire disconnected.
Page 14 When the display initialization routine is complete, the display reverts to the last operating mode accessed. If the CompuScale III is not programmed, the parameter entry display is accessed. The CompuScale III display is divided into the following fields: MULTISPAN...
Page 15 PROGRAMMING GENERAL Information specific to a particular application is entered into the CompuScale III memory, via the keypad, prior to the calibration procedure. KEYPAD Button Operation Function – parameter entry numeric entries parameter entry increase: analog mA output (P17 and P18 only), ECAL value (P22 only)
Page 16: Direct Parameter Access
PARAMETER ENTRY Application information must be entered into the appropriate CompuScale III memory locations. These locations are identified by a Parameter Number (P#). The information entered is referred to as a Parameter Value (Value). To enter information, the operator accesses the desired parameter number, views the parameter value displayed, and then accepts or alters the current parameter value.
Page 17: Altering Parameter Values
PROGRAMMING CHART for future reference. QUICK START GUIDE A Quick Start Guide is shipped in the CompuScale III integrator enclosure. This guide describes the minimum start up, programming, and calibration requirements of the CompuScale III, to obtain successful RUN mode operation for most applications.
Page 19: Initial Calibration References
A calibration should only be performed after the belt has been run as long as practical, and is sufficiently limber. When the CompuScale III is first commissioned, several Zero and Span calibrations are normally performed to verify the calibration results are repeatable.
Page 20: Calibration Accuracy
With [CALIB] displayed in the CALIB field, apply the Test Weight to the belt scale (as described in the belt scale manual). If [CALIB] is not displayed, respond to the CompuScale III display prompts until this indicator is obtained, before applying the Test Weight.
Page 21: Calibration Alternatives
This feature automatically performs a Zero calibration, whenever material flow ceases in the RUN mode. If the Auto Zero feature is desired, provide a dry contact input to the CompuScale III terminals TB1-34 and TB1-37. The contact may be activated by a material feed controlling device such as a motor control, material control gate, or valve.
Page 22: Ecal Calibrations
ECAL Adjust. Refer to Parameters/P22 ECAL Adjust. ECAL CALIBRATION (Alternate Reference) After the CompuScale III Span calibration is completed with a Test Weight (or Test Chain), ECAL may be used for subsequent Span calibration checks. Using ECAL as a Secondary Reference is especially useful when frequent Span calibration checks are required but using a Test Weight (or Test Chain) all the time would be impractical.
Page 23 The SW1-5 position and the value of P0 should be set before any other programming. To alter the Rate Units of a programmed CompuScale III, set SW1-5 as desired, perform a Reset (refer to Parameters/P99 Reset) and set P0 to the desired value.
Page 24 Speed Sensor Pulses Per Revolution* Pulley Circumference (m or ft) Per Revolution * see speed sensor nameplate or consult Milltronics BELT LENGTH (E) Defines the length of the conveyor belt which passes over the belt scale. Range = 0.0001 to 99999.
Page 25 Adjusts the Test Reference value (P7) of the Test Reference selected (P20). After the CompuScale III is calibrated utilizing a known Test Reference (e.g.Test Chain), the load represented by an unknown Test Reference (e.g. Test Weight(s) not supplied by Milltronics), may be established. This feature may also be used if Span calibrations performed with one Test Reference, tend to consistently provide greater accuracy than Span calibrations with another Test Reference.
Page 26 LOW TOTAL CUTOFF Defines the minimum belt scale load to be processed for Local Total values and Remote Total contact closures. Range = 0.0 to 100.0 This eliminates totalizer activity caused by the variable loading effect of an empty running belt.
Page 27 RATE OUTPUT AVERAGE Defines the period in seconds between Rate Output updates. The value held, corresponds to the averaged Rate of the previous period. Range = 0 to 999. A value of 0 may be entered if Rate output averaging is not desired.
Page 28 SPEED ADJUST Displays the measured belt speed. If the belt speed displayed is incorrect, the actual belt speed may be entered. The value entered must be in the same units of measure as P4. To determine the actual belt speed: a) Measure the belt length with a measuring tape.
Page 29 ECAL is adjusted in the RUN mode with no material on the belt, or Test Weight applied to the belt scale. When the adjust option is selected, the simulated belt scale input is applied to the CompuScale III. Record all totalizer values before and after adjusting ECAL.
Page 30 MULTISPAN Defines the calibration result to be used for subsequent measurements. Range = 0 to 8. This feature may be used to store the Span calibration results associated with different operating conditions, (e.g. change in conveyor incline, when an incline compensator is not utilized). To perform a Span calibration for a specific operating condition: a)Select the Multispan number to be associated with the current operating condition.
Page 31 Defines the time lapse in minutes between unsolicited data message transmissions. Range = 0 to 99999 The Data Transmit Interval may be adjusted as required to control the level of message traffic between the CompuScale III and the external device(s) connected to the PORT 1 and/or PORT 2 bipolar current loop or RS-232C communications connections.
Page 32 DATA MESSAGE Defines the ASCII message to be transmitted after every Data Transmit Interval (P41) or when TB1-35,37 contacts are closed. The current time and date are transmitted with each message. The System message includes the value of parameters P0,1,2,3,4,5,6,7, and 21. enter: 0 = no message (F) 1 = RATE...
Page 33 RELAY 2 Defines the operation of Relay 2 as a Rate, Load, or Speed Alarm. The High Limit is the high alarm set point value which will cause the relay to de-energize. If a high alarm is not required, set the High Limit to 0. The Low Limit is the low alarm set point value which will cause the relay to de-energize.
Page 34 ZERO RECORD (V) Displays the number of operator initiated Zero calibrations performed since the last Reset (P99) or Initial Zero. Reset (P77), (F = 0). SPAN RECORD (V) Displays the number of operator initiated Span calibrations performed since the last Reset (P99) or Initial Span. Reset (P88), (F = 0).
Page 35 V/F CONVERTER OUTPUT (V) Displays a reference count proportional to the input level from the belt scale. Range = 0 to 131,000. This feature is normally used to verify the integrity of the belt scale load sensors and cables. LOAD CELL A (V) Displays the input from the load cell connected to TB1-1,2 in mV.
Page 36 MSI NUMBER Identifies the MSI to be balanced by advancing through parameters P91 through P95. This parameter may only be accessed when Sensor Type (P21) is set to a value greater than 1. Prior to initial calibration or following an MSI (dual load cell belt scale) load cell replacement, the load cell balancing procedure should be performed.
Page 37 This feature clears memory locations and restores parameter values to their original factory settings. The implementation of a Reset requires CompuScale III reprogramming and calibration. Neither Reset Level affects the Clock / Calender settings. A Partial Reset maintains the previous, P17, P18, P20, P21, P22, P40, P41, P42 and P43, and load cell balancing settings.
Page 39: Programming Chart
PROGRAMMING CHART NAME VALUE VALID RANGE (F or _ = factory setting) RATE UNITS IMP: 1(T/h),2(LT/h),3(lb/h),4(lb/min) Metric: 1(t/h),2(kg/h),3(kg/min) RATE 0.0001 to 99999 (F = 0.000) LOCAL TOTAL 1,2,or 5 x .0001,.001,.01,.1,1,10,100,or 1000 REMOTE TOTAL 1,2,or 5 x .0001,.001,.01,.1,1,10,100,or 1000 BELT SPEED 0.0001 to 99999 (F = 0) SPEED CONSTANT 0.0001 to 99999 (F = 0 for variable speed, 100 for constant speed)
Page 41: Initial Operation
All personnel should be instructed on the safe and proper operation of the CompuScale III and be instructed when and if a calibration check should be performed, what level of zero and span deviation is acceptable, and when to reset the totalizer(s).
Page 42: Normal Operation
NORMAL OPERATION START UP Ensure power is supplied to the CompuScale III. The following procedures may be performed on a routine basis, as required. Access to the Zero and Span calibration, and Reset Total functions may be restricted. ZERO CALIBRATION CHECK Ensure the belt scale test reference (Test Weight, ECAL, or Test Chain) is removed.
Page 43 The Bipolar Current Loop may be utilized for cable runs up to 1500 metres (5000 ft). If communication with an RS-232C device is required, the Milltronics BIC-II or CVCC may be used to convert the Bipolar Current Loop to RS-232C. The BIC-II is also capable of Bipolar Current Loop to RS-422 conversion.
Page 44: Host Communication
REMOTE COMMUNICATION This mode provides complete access to all CompuScale III functions via a remote mounted CompuScale III. To receive communication from the local CompuScale III PORT 1 or PORT 2 connection, SW2-6 of the remote CompuScale III must be closed.
Page 45: Data Field Descriptions
PROTOCOL Protocol refers to the format, sequence and value of the data fields utilized in Host Mode communication messages. Each data field of a CompuScale III message contains one or more bytes of ASCII binary code. Each byte contains: +20 mA »...
Page 46: Message Requests
CompuScale III # 1 material flow rate request end of message MESSAGE RESPONSES The CompuScale III response to a flow rate (MT=50) load (MT=51) or speed (MT=52) message request will be in the following format. som DEVICE MT READING eom Example:...
Page 47: Alphabetical Parameter Listing
ALPHABETICAL PARAMETER LISTING PARAMETER PARAMETER PARAMETER PARAMETER NAME NUMBER NAME NUMBER Baud Rate Multispan Belt Length Parameter List P100 Belt Speed Rate Calibration Duration Rate Output Average Clock/Calendar Rate Output Max Converter Input (V/F) Rate Output Min Converter Output (V/F) Rate Units Damping, Load Display Record, Zero...
Page 48: Maintenance And Spare Parts
The CompuScale III memory backup and calibrator batteries should be replaced annually. The 3.6 Volt lithium battery (located on the mother board top right corner) should only be replaced while the CompuScale III power is ON. The 9 Volt calibrator battery is located on the back of the CompuScale III door.
Page 49: Error Messages
ERROR MESSAGES The following messages may be encountered during CompuScale III programming, calibration, or operation. DISPLAY MESSAGE DESCRIPTION [ABORTED] The activated process or procedure was not completed correctly (or before "CLEAR" was pressed). Retry the feature attempted. [AUTO ZERO ABORTED] The Auto Zero was more than 2% of span from the last operator Zero before SW1-6 was closed.
Page 50: Trouble Shooting
TROUBLE SHOOTING Every CompuScale III integrator is subjected to extensive quality assurance procedures to ensure the highest possible degree of quality, reliability, and performance is achieved. The following listing indicates the probable cause, and proper course of action to be taken should the specified fault symptom occur.
Page 51 OUTLINE and MOUNTING 330 mm ( 13" ) 11 mm dia. 101 mm ( 0.4" ) 178 mm 4 places ( 4" ) ( 7" ) 435 mm 406 mm ( 17.1" ) ( 16" ) enclosure bottom plate ( for cable / conduit entrance ) FIG.
Page 52 COMPUSCALE III LAYOUT calibrator battery calibrator (door mount) memory / clock MILLTRONICS CALIBRATOR IV PN 24751327-01 ML 51026351 PETERBOROUGH ONTARIO MADE IN CANADA battery SW 1 EPROM 1 TIME / DATE / MEMORY EPROM 1 3.6 VOLT LITHIUM BATTERY PIN 1...
Page 53 CompuScale III LVDT CompuScale III Where a belt scale must be installed in a hazardous area consult Milltronics or your distributor for wiring instructions. Where the integrator to load cell belt scale cable exceeds 150m (500 ft): A) remove jumpers from Compuscale III, TB1 - 9,10 and TB1 - 11,12 B) run an additional shielded conductor to the junction box nearest the load cell(s) from: »...
Page 54 LCPA-08 (Refer to the LCPA-08 instruction manual for LCPA-08 / Belt Scale Interconnection) Where a belt scale must be installed in a hazardous area consult Milltronics or your distributor for wiring instructions. Where the integrator to load cell belt scale cable exceeds 150m (500 ft):...
Page 55 Connect Compuscale III TB1 - 31 to the speed sensor junction: Position 2 for clockwise speed sensor shaft rotation Position 3 for counter clockwise speed sensor shaft rotation If a speed sensor is not used the Compuscale III TB1 - 32,33 jumper must be in place. shaft FIG. 5 PL-367 12 –...
Page 56 750 Ω Max load Ensure the Compuscale III J1 position matches power to be applied to TB1 - 51,52. The Auto Zero contact must be closed when the material feed is stopped, if Auto Zero calibration is desired.
Page 57: Fig. 1 Fig
RELAY WIRING ALARM / CONTROL RELAYS Compuscale III Relay contacts are shown in de-energized condition to alarm / control devices REMOTE TOTALIZER RELAY CompuScale III CompuScale III CompuScale III 48 49 CompuScale III 48 49 * POWER * POWER SOURCE...
Page 58: Fig. 4 Fig
RS-232 device Unit I.D. # 01 CompuScale III Unit I.D. # N (max N=15) Power may be disconnected from any CompuScale III in a multiple current loop without affecting the communication of the other CompuScale III’s. FIG.8 PL-367 12 – 8...
Page 59 Siemens Milltronics Process Instruments Inc. 2001 Subject to change without prior notice Siemens Milltronics Process Instruments Inc. *7ml19981DY01* 1954 Technology Drive, P .O. Box 4225 Peterborough, ON.Canada K9J 7B1 Tel: (705) 745-2431 Fax: (705) 741-0466 Printed in Canada www.milltronics.com...