EBOOK - Integrators Milltronics BW500 and BW500L - Operating Instructions (SIEMENS)


The Milltronics BW500 is a full-featured integrator for use with belt scales and weighfeeders. The speed and load signals from the conveyor and scale, respectively, are processed to derive rate of material flow, and totalization. The primary values of speed and load, and the derived values of rate and total are available for display on the local LCD, or as output in the form of analog mA, alarm relay and remote totalization.


CONTENTS:

1  Safety Notes ......................................... 11
2  The Manual ............................................................. 13
3  Milltronics BW500 and BW500/L ................................................................ 15
4  Specifications .................................................................... 17
5  Installation ......................... 21
5.1  Dimensions ............................................................................................................................. 21
5.2  Layout ..................................................................................................................................... 23
5.3  Optional Plug-ins ..................................................................................................................... 25
5.3.1  SmartLinx Module ................................................................................................................... 25
5.3.2  mA I/O board ........................................................................................................................... 25
5.3.3  LVDT Conditioner Card........................................................................................................... 26
5.3.4  Optional Components and their Locations ............................................................................. 27
5.4  Interconnection ....................................................................................................................... 27
5.4.1  System Diagram ..................................................................................................................... 28
5.4.2  Scale - One Load Cell ............................................................................................................. 29
5.4.3  Scale - Two Load Cells ........................................................................................................... 30
5.4.4  Scale - Four Load Cells .......................................................................................................... 32
5.4.5  Scale - Six Load Cells ............................................................................................................. 33
5.4.6  Scale - LVDT ........................................................................................................................... 34
5.5  Speed ...................................................................................................................................... 35
5.5.1  Constant Speed (No Sensor) .................................................................................................. 35
5.5.2  Main Speed Sensor ................................................................................................................ 36
5.5.3  Auxiliary Speed Sensor........................................................................................................... 37
5.6  Auxiliary Inputs ........................................................................................................................ 38
5.7  Auto Zero ................................................................................................................................ 38
5.8  RS232 Port 1 .......................................................................................................................... 39
5.8.1  Printers .................................................................................................................................... 39
5.8.2  Computers and Modems ........................................................................................................ 39
5.9  Remote Totalizer ..................................................................................................................... 40
5.10 mA Output 1 ............................................................................................................................ 40
5.11  Relay Output ........................................................................................................................... 40
5.12  RS485 Port 2 .......................................................................................................................... 41
5.12.1  Daisy Chain ............................................................................................................................. 41
5.12.2  Terminal Device ...................................................................................................................... 41
5.13  RS232 Port 3 .......................................................................................................................... 41
5.14  Power Connections ................................................................................................................. 42
5.15  mA I/O Board Connections ..................................................................................................... 43
5.16  Installing/replacing the back-up battery ................................................................................. 44
6  Start Up ................................................................................................................................................ 47
6.1  Keypad ................................................................................................................................... 47
6.2  Program Mode ....................................................................................................................... 48
6.2.1  Program Mode Display .......................................................................................................... 48
6.2.2  To enter PROGRAM mode .................................................................................................... 49
6.2.3  RUN Mode ............................................................................................................................. 51
6.3  Initial Start Up ......................................................................................................................... 51
6.3.1  Power Up ............................................................................................................................... 52
6.3.2  Programming .......................................................................................................................... 52
6.4  Load Cell Balancing ............................................................................................................... 57
6.4.1  Typical Two Load cell belt scale ............................................................................................ 58
6.4.1.1  Access P295 .......................................................................................................................... 58
6.4.2  Balancing six load cell belt scales.......................................................................................... 62
6.4.2.1  Balancing for A and B ............................................................................................................ 62
6.4.2.2  Balancing for C and D ............................................................................................................ 62
6.4.3  Zero Calibration...................................................................................................................... 63
6.4.4  RUN Mode ............................................................................................................................. 65
7  Recalibration ......................................................................................................................................... 67
7.1  Belt Speed Compensation ..................................................................................................... 67
7.1.1  Access P018 .......................................................................................................................... 67
7.2  Material Tests ......................................................................................................................... 68
7.2.1  %Change ............................................................................................................................... 69
7.2.1.1  Access P019 and enter EDIT mode ...................................................................................... 70
7.2.2  Material Test .......................................................................................................................... 70
7.3  Design Changes..................................................................................................................... 72
7.4  Recalibration .......................................................................................................................... 72
7.4.1  Routine Zero .......................................................................................................................... 72
7.4.2  Initial Zero .............................................................................................................................. 74
7.4.3  Direct Zero ............................................................................................................................. 75
7.4.4  Auto Zero ............................................................................................................................... 76
7.4.5  Routine Span ......................................................................................................................... 77
7.4.6  Initial Span ............................................................................................................................. 78
7.4.7  Direct Span ............................................................................................................................ 80
7.4.8  Multispan ................................................................................................................................ 81
7.4.8.1  Programming .......................................................................................................................... 82
7.5  Online Calibration................................................................................................................... 85
7.5.1  Online Calibration feature ...................................................................................................... 86
7.5.2  Activate Online Calibration ..................................................................................................... 88
7.6  Factoring ................................................................................................................................ 90
7.6.1  Access P359 in VIEW mode .................................................................................................. 91
7.7  Linearization ........................................................................................................................... 92
8  Operation .............................................................................................................................................. 97
8.1  Load Sensing ......................................................................................................................... 97
8.2  Speed Sensing ........................................................................................................................ 97
8.3  Differential Speed Detection ................................................................................................... 98
8.4  Moisture Compensation .......................................................................................................... 98
8.5  Incline compensation .............................................................................................................. 99
8.6  Modes of Operation .............................................................................................................. 100
8.7  Damping ................................................................................................................................ 100
8.8  mA I/O (0/4-20 mA) ............................................................................................................... 101
8.9  Relay Output ......................................................................................................................... 102
8.10  Totalization ............................................................................................................................ 103
8.10.1  Internal Totalizer ................................................................................................................... 103
8.10.2  External Totalizer .................................................................................................................. 104
9  PID Control ......................................................................................................................................... 107
9.1  Hardware .............................................................................................................................. 107
9.2  Connections .......................................................................................................................... 107
9.2.1  Setpoint Controller – Rate Control ........................................................................................ 108
9.2.2  Setpoint Controller – Load Control ........................................................................................ 109
9.2.3  Setpoint Controller – Master/Slave Control........................................................................... 110
9.2.4  Setpoint Controller – Rate and Load Control ........................................................................ 111
9.3  Setup and Tuning .................................................................................................................. 112
9.3.1  Proportional Control (Gain), P .............................................................................................. 112
9.3.2  Integral Control (Automatic Reset), I .................................................................................... 112
9.3.3  Derivative Control (Pre-Act or Rate), D ................................................................................ 113
9.3.4  Feed Forward Control, F ....................................................................................................... 113
9.4  PID Setup and Tuning........................................................................................................... 114
9.4.1  Initial Start-Up ....................................................................................................................... 114
9.5  Programming ........................................................................................................................ 117
10  Batching ............................................................................................................................................. 121
10.1  Connections .......................................................................................................................... 122
10.1.1  Typical Ladder Logic ............................................................................................................. 122
10.2  Programming ........................................................................................................................ 123
10.3  Operation .............................................................................................................................. 123
10.3.1  Pre-act Function .................................................................................................................... 124
11  Communications ................................................................................................................................. 125
11.1  BW500 and BW500/L and SmartLinx ................................................................................... 125
11.2  Connections .......................................................................................................................... 126
11.2.1  Wiring Guidelines .................................................................................................................. 126
11.3  Configuring Communication Ports ........................................................................................ 127
11.3.1  P770 Serial protocols ............................................................................................................ 127
11.3.2  P771 Protocol address.......................................................................................................... 128
11.3.3  P772 Baud Rate .................................................................................................................... 128
11.3.4  P773 Parity ........................................................................................................................... 128
6  Operating Instructions, 12/2016, A5E33482052-AD
11.3.5  P774 Data bits...................................................................................................................... 129
11.3.6  P775 Stop bits ...................................................................................................................... 129
11.3.7  P778 Modem attached ......................................................................................................... 129
11.3.8  P779 Modem idle time ......................................................................................................... 130
11.3.9  P780 RS-232 Transmission interval .................................................................................... 130
11.3.10  P781 Data message ............................................................................................................ 131
11.3.11  P799 Communications Control ............................................................................................ 131
11.4  Dolphin Protocol ................................................................................................................... 132
11.5  Modbus RTU/ASCII Protocol ............................................................................................... 133
11.5.1  How Modbus Works ............................................................................................................. 133
11.5.2  Modbus RTU vs. ASCII ........................................................................................................ 134
11.5.3  Modbus Format .................................................................................................................... 134
11.5.4  Modbus Register Map .......................................................................................................... 134
11.5.5  Modbus Register Map (cont’d) ............................................................................................. 138
11.6  Modems ............................................................................................................................... 147
11.6.1  Example Setup ..................................................................................................................... 147
11.7  Error Handling ...................................................................................................................... 149
12  Parameters .......................................................................................................................................... 153
12.1  Start Up (P001 to P017) ....................................................................................................... 153
12.1.1  P001 Language .................................................................................................................... 153
12.1.2  P002 Test Reference Selection ........................................................................................... 153
12.1.3  P003 Number of Load Cells ................................................................................................. 154
12.1.4  P004 Rate Measurement System ........................................................................................ 154
12.1.5  P005 Design Rate Units ....................................................................................................... 154
12.1.6  P008 Date ............................................................................................................................ 154
12.1.7  P009 Time ............................................................................................................................ 155
12.1.8  P011 Design Rate ................................................................................................................ 155
12.1.9  P014 Design Speed ............................................................................................................. 155
12.1.10  P015 Speed Constant .......................................................................................................... 155
12.1.11  P016 Belt Length.................................................................................................................. 156
12.1.12  P017 Test Load .................................................................................................................... 156
12.1.13  P018 Speed Adjust .............................................................................................................. 157
12.1.14  P019 Manual Span Adjust ................................................................................................... 157
12.1.15  P022 Minimum Speed Frequency ........................................................................................ 157
12.1.16  P080 Display Damping ........................................................................................................ 157
12.1.17  P081 Display Scroll Mode .................................................................................................... 158
12.2  Relay/Alarm Function (P100 - P117) ................................................................................... 158
12.2.1  P100 Relay Function ............................................................................................................ 158
12.2.2  P101 High Alarm / Deviation Alarm ..................................................................................... 159
12.2.3  P102 Low Alarm ................................................................................................................... 159
12.2.4  P107 Relay Alarms .............................................................................................................. 159
12.2.5  P117 Relay Dead Band ....................................................................................................... 160
12.2.6  P118 Relay Logic ................................................................................................................. 160
12.2.7  P119 Override ...................................................................................................................... 160
12.3  mA I/O Parameters (P200 - P220) ....................................................................................... 161
12.3.1  P200 mA Output Range ....................................................................................................... 161
12.3.2  P201 mA Output Function .................................................................................................... 161
12.3.3  P204 mA Output Average .................................................................................................... 161
Operating Instructions, 12/2016, A5E33482052-AD  7
12.3.4  P212 mA Output Minimum .................................................................................................... 162
12.3.5  P213 mA Output Maximum ................................................................................................... 162
12.3.6  P214 4 mA Output Trim ........................................................................................................ 162
12.3.7  P215 20 mA Output Trim ...................................................................................................... 162
12.3.8  P220 mA Output Damping .................................................................................................... 162
12.3.9  P250 mA input range ............................................................................................................ 163
12.3.10  P255 mA Input Function ....................................................................................................... 163
12.3.11  P261 4 mA Input Trim ........................................................................................................... 163
12.3.12  P262 20 mA Input Trim ......................................................................................................... 164
12.3.13  P270 Auxiliary Input Function ............................................................................................... 165
12.4  Calibration Parameters (P295 – P360) ................................................................................. 167
12.4.1  P295 Load Cell Balancing .................................................................................................... 167
12.4.2  P341 Days Of Service........................................................................................................... 167
12.4.3  P350 Calibration Security ..................................................................................................... 168
12.5  Online Calibration Options (P355 - P358) ............................................................................ 168
12.5.1  P355 Online Calibration Feature .......................................................................................... 168
12.5.2  P356 Online Calibration Reference Weight .......................................................................... 168
12.5.3  P357 Online Calibration Limits ............................................................................................. 169
12.5.4  P358 Online Calibration Activation ....................................................................................... 169
12.5.5  P359 Factoring ...................................................................................................................... 169
12.5.6  P360 Calibration Duration ..................................................................................................... 169
12.5.7  P365 Multispan ..................................................................................................................... 170
12.5.8  P367 Direct Zero Entry ......................................................................................................... 170
12.5.9  P368 Direct Span Entry ........................................................................................................ 170
12.5.10  P370 Zero Limit Deviation % ................................................................................................ 171
12.5.11  P371 Auto Zero Initiation Upper Limit ................................................................................... 171
12.5.12  P377 Initial Zero .................................................................................................................... 171
12.5.13  P388 Initial Span ................................................................................................................... 171
12.6  Linearization Parameters (P390 - P392) .............................................................................. 172
12.6.1  P390 Linearizer ..................................................................................................................... 172
12.6.2  P391 Linearizer Load Points ................................................................................................. 172
12.6.3  P392 Linearizer Compensation % ........................................................................................ 172
12.6.4  P398-01 Moisture Content .................................................................................................... 172
12.6.5  P398-02 Moisture Content .................................................................................................... 172
12.6.6  P399 Incline Sensing ............................................................................................................ 173
12.7  Proportional Integral Derivative (PID) Control ...................................................................... 173
12.7.1  P400 PID System .................................................................................................................. 173
12.7.2  P401 PID Update Time ......................................................................................................... 173
12.7.3  P402 PID Process Value Source .......................................................................................... 174
12.7.4  P405 Proportional Term ........................................................................................................ 174
12.7.5  P406 Integral Term ............................................................................................................... 174
12.7.6  P407 Derivative Term ........................................................................................................... 174
12.7.7  P408 Feed Forward Term ..................................................................................................... 174
12.7.8  P410 Manual Mode Output ................................................................................................... 175
12.7.9  P414 Setpoint Configuration ................................................................................................. 175
12.7.10  P415 Local Set point Value .................................................................................................. 175
12.7.11  P416 External Setpoint ......................................................................................................... 176
12.7.12  P418 Remote Setpoint Ratio ................................................................................................ 176
12.7.13  P419 PID Freeze Option ....................................................................................................... 176
8  Operating Instructions, 12/2016, A5E33482052-AD
12.8  Batch Control (P560 – P568) ............................................................................................... 176
12.8.1  P560 Batch Mode Control .................................................................................................... 176
12.8.2  P564 Batch Setpoint ............................................................................................................ 177
12.8.3  P566 Batch Pre-Warn .......................................................................................................... 177
12.8.4  P567 Batch Pre-Warn Setpoint ............................................................................................ 177
12.8.5  P568 Batch Pre-Act ............................................................................................................. 177
12.8.6  P569 Manual Batch Pre-Act Amount ................................................................................... 178
12.8.7  P598 Span Adjust Percentage ............................................................................................. 178
12.9  Totalization (P619 - P648) ................................................................................................... 178
12.9.1  P619 Totaling Dropout ......................................................................................................... 178
12.9.2  P620 Display Zero Dropout .................................................................................................. 178
12.9.3  P621 mA Zero Dropout ........................................................................................................ 179
12.9.4  P631 Totalizer Resolution .................................................................................................... 179
12.9.5  P634 Communication Totalizer Resolution .......................................................................... 180
12.9.6  P635 Verification Totalizer ................................................................................................... 180
12.9.7  P638 External Totalizer Resolution...................................................................................... 181
12.9.8  P643 External Contact Closure ............................................................................................ 182
12.9.9  P647 Totalizer Display ......................................................................................................... 182
12.9.10  P648 Totalizer Reset, Internal ............................................................................................. 182
12.9.11  P680 Test Load: Weight (Options)....................................................................................... 183
12.9.12  P681 Total Mass of Test Weights ........................................................................................ 183
12.9.13  P682 Average Idler Spacing ................................................................................................ 183
12.9.14  P690 Speed Constant Entry ................................................................................................ 183
12.9.15  P691 Drive Pulley Diameter ................................................................................................. 184
12.9.16  P692 Pulses Per Sensor Revolution .................................................................................... 184
12.10  ECal Parameters (P693 – P698) .......................................................................................... 184
12.10.1  P693 Load Cell Capacity Units ............................................................................................ 184
12.10.2  P694 ECal Load Cell Capacity ............................................................................................. 184
12.10.3  P695 ECal Load Cell Sensitivity .......................................................................................... 185
12.10.4  P696 ECal Load Cell Excitation ........................................................................................... 185
12.10.5  P697 ECal Idler Spacing ...................................................................................................... 185
12.10.6  P698 ECal Conveyor Inclination .......................................................................................... 185
12.10.7  P699 ECal mV Span ............................................................................................................ 186
12.10.8  P735 Back Light ................................................................................................................... 186
12.10.9  P739 Time Zone................................................................................................................... 186
12.11  Communication (P740 - P799) ............................................................................................. 187
12.11.1  P742 Word Order Parameter ............................................................................................... 187
12.11.2  P750 – P769 SmartLinx Module Specific Parameters ......................................................... 187
12.11.3  P770 – P789 Local Port Parameters ................................................................................... 187
12.12  SmartLinx Hardware Testing ............................................................................................... 187
12.12.1  P790 Hardware Error ........................................................................................................... 188
12.12.2  P791 Hardware Error Code ................................................................................................. 188
12.12.3  P792 Hardware Error Count ................................................................................................ 188
12.12.4  P794 SmartLinx Module Type .............................................................................................. 188
12.12.5  P795 SmartLinx Protocol ..................................................................................................... 189
12.12.6  P799 Communications Control ............................................................................................ 189
12.13  Test and Diagnostic (P900- P951) ...................................................................................... 189
12.13.1  P900 Software Revision ....................................................................................................... 189
12.13.2  P901 Memory Test ............................................................................................................... 189
Table of contents
BW500 and BW500/L
Operating Instructions, 12/2016, A5E33482052-AD  9
12.13.3  P911 mA Output Test ........................................................................................................... 190
12.13.4  P914 mA Input Value ............................................................................................................ 190
12.13.5  P918 Speed Input Frequency ............................................................................................... 190
12.13.6  P931 Running Totalizer ........................................................................................................ 190
12.13.7  P940 Load Cell mV Signal Test ............................................................................................ 191
12.13.8  P943 Load Cell A/D Reference ............................................................................................. 191
12.13.9  P948 Error Log ...................................................................................................................... 191
12.13.10  P950 Zero Register ............................................................................................................... 191
12.13.11  P951 Span Register .............................................................................................................. 191
12.13.12  P952 Design Load ................................................................................................................ 192
12.13.13  P999 Master Reset ............................................................................................................... 192
13  Troubleshooting .................................................................................................................................. 193
13.1  Generally ............................................................................................................................... 193
13.2  Specifically ............................................................................................................................ 193
14  Certification ......................................................................................................................................... 197
14.1  Certification ........................................................................................................................... 197
14.2  Parameters unlocked when certification switch is set: ......................................................... 197
14.3  Certification Printing .............................................................................................................. 198
A  Appendix............................................................................................................................................. 199
A.1  Appendix I ............................................................................................................................. 199
A.1.1  Memory Backup .................................................................................................................... 199
A.1.2  Software Updates ................................................................................................................. 199
A.1.3  Calibration Criteria ................................................................................................................ 199
A.2  Appendix II ............................................................................................................................ 200
A.3  Technical support .................................................................................................................. 205
Glossary ............................................................................................................................................. 207
Index................................................................................................................................................... 211

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