Siemens Milltronics BW100 Instruction Manual
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Siemens Milltronics BW100 Instruction Manual

Integrator for belt scales
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Instruction Manual February 2004
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BW100
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  • Page 1 Instruction Manual February 2004 milltronics BW100...
  • Page 2 Contact SMPI Technical Publications at the following address: Technical Publications Siemens Milltronics Process Instruments Inc. 1954 Technology Drive, P.O. Box 4225 Peterborough, Ontario, Canada, K9J 7B1 Email: [email protected] For the library of SMPI instruction manuals, visit our Web site: www.siemens-milltronics.com © Siemens Milltronics Process Instruments Inc. 2004...

  • Page 3: Table Of Contents

    Table of Contents Milltronics BW100 ............................1 Milltronics BW100 Features .........................1 Safety Notes .............................2 The Manual ...............................2 Specifications ...............................3 Installation ..............................6 Dimensions ..............................6 Interconnection ............................7 System Diagram ..........................7 Terminal Block Layout .........................8 Load Cell - Single ...........................9 Load Cell - Dual ...........................10 Speed Sensor ..........................11...
  • Page 4 Routine Zero ..........................32 Initial Zero .............................33 Direct Zero ............................34 Routine Span ..........................35 Initial Span ...........................36 Direct Span ...........................37 Factoring ..............................38 Linearization ............................39 Operation ...............................42 Load Sensing ............................42 Speed Sensing ............................42 Modes of Operation ..........................42 Damping ..............................43 Analog Output ............................43 Relay Output ............................44 Totalization ..............................45 Auto Zero ..............................46 Communications...

  • Page 5: Milltronics Bw100

    Milltronics BW100 Note: The Milltronics BW100 is to be used only in the manner outlined in this instruction manual. The Milltronics BW100 is an economical integrator for use with belt scales. The speed and load signals from the conveyor and scale, are processed to derive rate of material flow and totalization.

  • Page 6: Safety Notes

    Modem configuration maintain accurate operation of the unit Note: The Milltronics BW100 is to be used only in the manner outlined in this instruction manual. If you have any questions, comments, or suggestions about the manual contents, please email us at [email protected].

  • Page 7: Specifications

    • optional: 10 - 15 V dc, 15 W 18 - 30 V dc, 15 W Application • compatible with Siemens Milltronics belt scales or equivalent Accuracy • 0. 1 % of full scale Resolution • 0.02% of full scale Environmental •...
  • Page 8 300 m (1000 ft.) max. • auto zero: Belden 8760, 1 pair, twisted/shielded, 18 AWG, 300 m (1000 ft.) max. • remote total: Belden 8760, 1 pair, twisted/shielded, 18 AWG, 300 m (1000 ft.) max. Page 4 Milltronics BW100 - INSTRUCTION MANUAL 7ML19985DJ01...
  • Page 9 Belden 8760, 1 pair, twisted/shielded, 18AWG, • t1 (dc) 300 m (1000 ft.) max. Options: • Speed Sensor: - Siemens Milltronics MD-36 series, or equivalent • Dolphin: - Milltronics Windows based software interface and infrared ComVerter link Approvals: • CE*, CSA...

  • Page 10: Installation

    74 mm (2.9") mounting hole 5 mm 6.4 mm (1/4") Ø (0.2") Note: Non metallic enclosure does not provide grounding between connections. Use grounding type bushings and jumpers. Page 6 Milltronics BW100 - INSTRUCTION MANUAL 7ML19985DJ01...

  • Page 11: Interconnection

    (Milltronics communications) Note: Typical system capability. Not all components or their maximum quantity may be required. 7ML19985DJ01 Milltronics BW100 - INSTRUCTION MANUAL Page 7...

  • Page 12: Terminal Block Layout

    MILLTRONICS MILLTRONICS BW100 BW100 All field wiring must have insulation suitable for at least 250 V. dc terminals shall be supplied from a SELV source in accordance with IEC- 1010-1 Annex H. Page 8 Milltronics BW100 - INSTRUCTION MANUAL 7ML19985DJ01...

  • Page 13: Load Cell - Single

    BW100 TB1 – 18 to scale ‘– EXC’ BW100 TB1 – 19 to scale ‘+ EXC’ If the load cell wiring colours vary from those shown, or if extra wires are provided, consult Siemens Milltronics. 7ML19985DJ01 Milltronics BW100 - INSTRUCTION MANUAL Page 9...

  • Page 14: Load Cell - Dual

    BW100 TB1 – 18 to scale ‘– EXC’ BW100 TB1 – 19 to scale ‘+ EXC’ If the load cell wiring colours vary from those shown, or if extra wires are provided, consult Siemens Milltronics. Page 10 Milltronics BW100 - INSTRUCTION MANUAL 7ML19985DJ01...

  • Page 15: Speed Sensor

    5 / 6. If a speed sensor is used, insure that the jumper is removed. Input device in the form of open collector transistor or dry contact across TB1 – 6 / 7 will also serve as a suitable speed signal. 7ML19985DJ01 Milltronics BW100 - INSTRUCTION MANUAL Page 11...

  • Page 16: Auto Zero

    30 totalizer V dc, 100 mA Analog Output BW100 LOWER to customer instrumentation Ω isolated mA output, 750 maximum load ac models only mA output on dc models is not isolated Page 12 Milltronics BW100 - INSTRUCTION MANUAL 7ML19985DJ01...

  • Page 17: Remote Totalizer 2

    Remote Totalizer 2 BW100 UPPER DC/AC TOTAL (2) supply remote maximum totalizer 240 V ac/dc Relay Output BW100 UPPER relay shown in de-energized n.o. state, contacts rated 5 A at 250V non-inductive n.c. 7ML19985DJ01 Milltronics BW100 - INSTRUCTION MANUAL Page 13...

  • Page 18: Communication

    Communication Bipolar Current Loop Customer Device BW100 25 24 23 22 LOWER SHIELD Connect shield at one device only, e.g. BW100 TB1 - 21 Maximum loop length 3000 m (10,000 ft.) Page 14 Milltronics BW100 - INSTRUCTION MANUAL 7ML19985DJ01...

  • Page 19: Power Connections

    LOWER LOWER 10 - 15 Vdc 18 - 30 Vdc " dc model indicated on lid nameplate. dc terminals shall be supplied from an SELV source in accordance with IEC-1010-1 Annex H. 7ML19985DJ01 Milltronics BW100 - INSTRUCTION MANUAL Page 15...

  • Page 20: Comverter

    Optional Dolphin Interface Comverter Milltronics 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. Page 16 Milltronics BW100 - INSTRUCTION MANUAL 7ML19985DJ01...

  • Page 21: Start Up

    The BW100 operates under two modes: RUN and PROGRAM. When the unit is initially powered, it starts in the PROGRAM mode. If the PROGRAM mode is idle, it reverts to the run mode after 10 minutes. 7ML19985DJ01 Milltronics BW100 - INSTRUCTION MANUAL Page 17...

  • Page 22: Program Mode

    PROGRAM down mode between mode select parameter and change value Maneuvering To Select a Parameter: if not in the PROGRAM mode from the RUN mode if in the PROGRAM mode Page 18 Milltronics BW100 - INSTRUCTION MANUAL 7ML19985DJ01...
  • Page 23 P005 = 3 must be pressed to save change 7ML19985DJ01 Milltronics BW100 - INSTRUCTION MANUAL Page 19...
  • Page 24 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 Page 20 Milltronics BW100 - INSTRUCTION MANUAL 7ML19985DJ01...

  • Page 25: Master Reset

    Load Cell Load Cell ’ A ’ ’B’ test weight bar belt travel typical dual load cell scale With the conveyor stopped and locked out, lift the belt off the weighing idlers. 7ML19985DJ01 Milltronics BW100 - INSTRUCTION MANUAL Page 21...
  • Page 26 Remove the test weight, insure that the BW100 SW2 is in ‘close’ position and that P1 is left as set. Note: Performing a balance procedure requires a subsequent zero and span recalibration. Page 22 Milltronics BW100 - INSTRUCTION MANUAL 7ML19985DJ01...

  • Page 27: Quick Start

    Record parameter in Program Record on page 70. 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. 7ML19985DJ01 Milltronics BW100 - INSTRUCTION MANUAL Page 23...

  • Page 28: Start Up

    TB1 - 5/6 e.g. 100.3 pulse / m jumpered, value is locked at 100. P016, belt length e.g. 65.72 m P017, test load * e.g. 55.56 Kg / m Examples are typical Page 24 Milltronics BW100 - INSTRUCTION MANUAL 7ML19985DJ01...
  • Page 29 Test load value should be less than design load (P952). If not, contact Siemens or their agent. Calibration Note: The duration of Zero and Span Calibration is dependent upon speed (P014), length (P016) and revolutions (P360) of belt. Note: To cancel a Zero or Span calibration in progress, press...

  • Page 30: Zero Calibration

    = 0 zero deviation accepted, initial zero count = ### Record this value for future reference Perform Span Calibration, see next page Page 26 Milltronics BW100 - INSTRUCTION MANUAL 7ML19985DJ01...

  • Page 31: Span Calibration

    = 0 span deviation accepted initial span count = #### Record this value for future reference Remove the test weight when the Span calibration is complete. successful entry into run, display rate 7ML19985DJ01 Milltronics BW100 - INSTRUCTION MANUAL Page 27...
  • Page 32 = totalizer 2 totaling L = load 3 = parameter alert, S = speed zero and span calibration required Keypad access initiate initiate scroll PROGRAM span zero display mode Page 28 Milltronics BW100 - INSTRUCTION MANUAL 7ML19985DJ01...

  • Page 33: Recalibration

    If a speed sensor is connected, the speed constant (P015) is automatically adjusted. The display speed (used in the rate computation) now equals the actual speed. Record the new value in Appendices/Program Record. 7ML19985DJ01 Milltronics BW100 - INSTRUCTION MANUAL Page 29...

  • Page 34: Material Tests

    BW100 total = _ _ _ _ _ _ material sample weight = _ _ _ _ _ _ • Calculate the span adjust value: % span adjust = BW100 total - material sample weight x 100 material sample weight Page 30 Milltronics BW100 - INSTRUCTION MANUAL 7ML19985DJ01...

  • Page 35: Design Changes

    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. 7ML19985DJ01 Milltronics BW100 - INSTRUCTION MANUAL Page 31...

  • Page 36: Routine Zero

    If the operator deems this deviation to be acceptable, set P377 to 1 to invoke an initial zero calibration. Further deviation limits are now based on this new initial zero. Page 32 Milltronics BW100 - INSTRUCTION MANUAL 7ML19985DJ01...

  • Page 37: Initial Zero

    18 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 = #### Perform Initial Span 7ML19985DJ01 Milltronics BW100 - INSTRUCTION MANUAL Page 33...

  • Page 38: Direct Zero

    A record of the last valid zero count is required. Maneuvering Refer to on page 18 for parameter selection and value change. current zero count enter previously recorded zero count new zero count accepted Page 34 Milltronics BW100 - INSTRUCTION MANUAL 7ML19985DJ01...

  • Page 39: Routine Span

    If the operator deems this deviation to be acceptable, set P388 to 1 to invoke an initial span calibration. Further deviations are now based on this new initial span. Note: Remove the test weight when the span calibration is complete. 7ML19985DJ01 Milltronics BW100 - INSTRUCTION MANUAL Page 35...

  • Page 40: Initial Span

    18 for parameter selection and value change. select P388 invoke initial span current span count = #### span calculation, frequency count displayed span deviation = ## span deviation accepted initial span count = #### return to run mode Page 36 Milltronics BW100 - INSTRUCTION MANUAL 7ML19985DJ01...

  • Page 41: Direct Span

    A record of the last valid span count is required. Maneuvering Refer to on page 18 for parameter selection and value change. current span count enter previously recorded span count new span count accepted 7ML19985DJ01 Milltronics BW100 - INSTRUCTION MANUAL Page 37...

  • Page 42: Factoring

    76.03 kg / m jumps to P017 dynamic test load value e.g. 76.03 kg / m return to run mode Page 38 Milltronics BW100 - INSTRUCTION MANUAL 7ML19985DJ01...

  • Page 43: Linearization

    % compensation = actual weight - totalized weight x 100 totalized weight Where: actual weight = material test totalized weight = BW100 total 7ML19985DJ01 Milltronics BW100 - INSTRUCTION MANUAL Page 39...
  • Page 44 *calculation example: % compensation = 4.2 - 4.9 x 100 = - 14.3 actual weight per material test totalized weight by BW100 belt scale response linearized BW100 response % compensation span (100%) -8.0 10.5 -14.0 load - kg / m Page 40 Milltronics BW100 - INSTRUCTION MANUAL 7ML19985DJ01...
  • Page 45 P394 = 0 P395 = 34.7 P396 = 0 actual weight per material test totalized weight by BW100 belt scale response linearized BW100 response % compensation span (100%) -14.0 load - kg / m 7ML19985DJ01 Milltronics BW100 - INSTRUCTION MANUAL Page 41...

  • Page 46: Operation

    Error interrupts are suppressed and the bar graph is disabled. If the PROGRAM mode is left idle for a period of ten minutes, it automatically reverts to the RUN mode. Page 42 Milltronics BW100 - INSTRUCTION MANUAL 7ML19985DJ01...

  • Page 47: Damping

    The BW100 LCD provides a bar graph as a function of analog output. It displays the mA value as percentage of the mA range. Parameter P911 The mA output value can be tested using parameter P911. Refer to page 62. 7ML19985DJ01 Milltronics BW100 - INSTRUCTION MANUAL Page 43...

  • Page 48: Relay Output

    Example: P014 = 2m/s, design speed P100 = 3, belt speed P101 = 100% (2m/s) high 100% 2 m/s actual OFF actual ON 0.4 m/s alarm ON is with relay de-energized Page 44 Milltronics BW100 - INSTRUCTION MANUAL 7ML19985DJ01...

  • Page 49: Totalization

    1 and 2, or totalizer 2 independently. • keypad: pressing simultaneously while in the RUN mode resets internal totalizer 1, as well as the internal counts for both remote totalizers. 7ML19985DJ01 Milltronics BW100 - INSTRUCTION MANUAL Page 45...

  • Page 50: Auto Zero

    (refer to page 44). The E9 error is cleared after five seconds. If material feed resumes during an auto zero function, the totalizing function is maintained. Page 46 Milltronics BW100 - INSTRUCTION MANUAL 7ML19985DJ01...

  • Page 51: Communications

    Each data field of a BW100 message contains one or more bytes of ASCII binary code. + 20 mA Each byte contains: » 8 data bits » no parity bit » 1 stop bit – 20 mA 7ML19985DJ01 Milltronics BW100 - INSTRUCTION MANUAL Page 47...

  • Page 52: Data Field Descriptions

    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 Page 48 Milltronics BW100 - INSTRUCTION MANUAL 7ML19985DJ01...

  • Page 53: Message Responses

    DEVICE MT READING UNITS eom Example: Data ASCII Example Field Character Description start of message DEVICE from BW100 # 1 material total response READING 129.2 is 129.2 UNITS metric tonnes end of message 7ML19985DJ01 Milltronics BW100 - INSTRUCTION MANUAL Page 49...

  • Page 54: Parameters

    LT = 2240 lb. T = 2000 lb. P011 Design Rate Specifies the design rate of material flow for the belt scale. Enter the design rate from the supplied design data sheet Page 50 Milltronics BW100 - INSTRUCTION MANUAL 7ML19985DJ01...
  • Page 55 = speed sensor pulses per revolution* pulley circumference (m or ft)/ revolution * refer to speed sensor nameplate or consult Siemens Milltronics or their agent. Note: Common speed sensor pulses per revolution: RBSS - 150.4 pulses/meter (45.8 pulses/ft.) TASS - 9.947 pulses/meter (3.03 pulses/ft.)
  • Page 56 Sets the display mode. Normally, the display shows rate, or the last manually selected function. If set to alternating, the display alternates between rate and totalizer (1 and/or 2, as programmed by P647). Entry: 0 = normal 1 = alternating Page 52 Milltronics BW100 - INSTRUCTION MANUAL 7ML19985DJ01...

  • Page 57: Relay/Alarm Function (P100 - P117)

    Enter the value in % of full scale End of relay/alarm parameters. mA Output Parameters (P200 - P220) Note: These parameters are specific to the use of the mA output. Refer to Operation on page 42 for details. 7ML19985DJ01 Milltronics BW100 - INSTRUCTION MANUAL Page 53...
  • Page 58 The greater the damping value, the slower the response. If the value is 0, the mA output assumes the damping set in P080. Enter the damping value, range 0 - 9999 End of mA output parameters. Page 54 Milltronics BW100 - INSTRUCTION MANUAL 7ML19985DJ01...

  • Page 59: Load Cell Balancing Parameters (P291 - P295)

    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. 7ML19985DJ01 Milltronics BW100 - INSTRUCTION MANUAL Page 55...
  • Page 60 Sets the zero calibration deviation limit from the last initial zero. If the accumulated deviation exceeds the limit, the zero calibration is aborted (E3). Entry: 0 = +/- 12.5% of initial zero 1 = +/- 2% of initial zero Page 56 Milltronics BW100 - INSTRUCTION MANUAL 7ML19985DJ01...

  • Page 61: Linearization Parameters (P390 - P396)

    0 = OFF 1 = ON P391 Linearizer, Point 1 Enter the load, in units of P017, for point 1 P392 Compensation, Point 1 Enter the calculated compensation, in percent, for compensation point 1 7ML19985DJ01 Milltronics BW100 - INSTRUCTION MANUAL Page 57...

  • Page 62: Totalization (P619 - P648)

    This parameter sets the limit, in percent of design rate, below which material rates are not totalized. The value of 0 is reserved to allow both negative and positive totalization. Enter drop out value in % of design rate. Page 58 Milltronics BW100 - INSTRUCTION MANUAL 7ML19985DJ01...
  • Page 63 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) 7ML19985DJ01 Milltronics BW100 - INSTRUCTION MANUAL Page 59...
  • Page 64 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 Page 60 Milltronics BW100 - INSTRUCTION MANUAL 7ML19985DJ01...

  • Page 65: Communication (P751 - P761)

    1 = bipolar current loop 2 = infrared link 3 = maintenance P761 Identification Number Sets the identification number for the unit. Enter the desired identification number, range 0 - 15. End of communication parameters. 7ML19985DJ01 Milltronics BW100 - INSTRUCTION MANUAL Page 61...

  • Page 66: Test And Diagnostic (P900 - P951)

    Upon returning to the RUN mode, the parameter assumes the actual mA output level. P940 Load Cell A, mV Displays the mV signal input from the load cell. Range 0.00 - 60.00 mV. Page 62 Milltronics BW100 - INSTRUCTION MANUAL 7ML19985DJ01...
  • Page 67 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. End of test and diagnostic parameters. 7ML19985DJ01 Milltronics BW100 - INSTRUCTION MANUAL Page 63...
  • Page 68 P999 Master Reset Resets parameters and totalizers to their factory setting. Page 64 Milltronics BW100 - INSTRUCTION MANUAL 7ML19985DJ01...

  • Page 69: Troubleshooting

    100% of design load E12 (factoring) (P952). Replace test weight with a heavier or lighter weight and try factoring again. 7ML19985DJ01 Milltronics BW100 - INSTRUCTION MANUAL Page 65...
  • Page 70 It is not a conclusive test, since even with incorrect wiring, the resulting input from the load cell may be within a valid range. Page 66 Milltronics BW100 - INSTRUCTION MANUAL 7ML19985DJ01...

  • Page 71: Maintenance

    Direct zero entry (P367) and direct span entry (P368) will suffice in lieu of dynamic zero and span calibrations. Therefore, zero and span counts should be recorded prior to doing the software update. 7ML19985DJ01 Milltronics BW100 - INSTRUCTION MANUAL Page 67...

  • Page 72: Appendix

    P390 Linearization P391 Linearizer Point 1 P393 Linearizer Point 2 P395 Linearizer Point 3 P940 Load Cell A, mV in P941 Load Cell B, mV in P295 Load Cell Balance P000 Lock Page 68 Milltronics BW100 - INSTRUCTION MANUAL 7ML19985DJ01...
  • Page 73 Totalizer 2 Resolution, Internal P647 Totalizer Display P619 Totalizer Drop out P648 Totalizer Reset, Internal P005 Units P942 V/F Converter, V in P943 V/F Converter, f out P950 Zero Register P370 Zero Limit 7ML19985DJ01 Milltronics BW100 - INSTRUCTION MANUAL Page 69...

  • Page 74: Program Record

    P368 Direct Span P370 Zero Limit P390 Linearization P391 Linearizer, Point 1 P392 Compensation, Point 1 P393 Linearizer, Point 2 P394 Compensation, Point 2 P395 Linearizer, Point 3 P396 Compensation, Point 3 Page 70 Milltronics BW100 - INSTRUCTION MANUAL 7ML19985DJ01...
  • Page 75 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 Span Register P952 Design Load 7ML19985DJ01 Milltronics BW100 – INSTRUCTION MANUAL Page 71...

  • Page 76: Index

    P648 totalizer reset, internal 45 P022 minimum speed frequency 52 P648 totalzier reset, internal 61 P080 damping display 43 P751 baud rate 61 P081 display scroll mode 60 P760 communication mode 61 7ML19985DJ01 Milltronics BW100 – INSTRUCTION MANUAL Page 72...
  • Page 77 27 direct 37 initial 33 manual 30 routine 35 test load 30 material 30 weight 27 weights 26 totalizer 45 functions 45 master 45 remote 1 zero auto 4 calibration 26 direct 34 initial 33 Page 73 Milltronics BW100 7ML19985DJ01...
  • Page 78 Siemens Milltronics Process Instruments Inc. Siemens Milltronics Process Instruments Inc. 2004 1954Technology Drive, P .O. Box 4225 Subject to change without prior notice Peterborough, ON, Canada K9J 7B1 Rev. 1.1 *7ml19985dj01* Tel: (705) 745-2431 Fax: (705) 741-0466 Email: [email protected]...

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