Milltronics BW100 Instruction Manual

Accumass BW100

33455310
Rev 1.5

Instruction Manual

PL-531

May 1997

T

hank you for purchasing Milltronics’ products.
We are committed to satisfying our customers’ needs with innovative

equipment that is designed for reliability and ease of use.
Our products are distributed in 91 countries through a worldwide network of

offices, representatives and distributors. We continually refine our processes
to provide our customers with first rate sales information, engineering
assistance and after sales service and support.

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.

For further details on Milltronics' products and service, please contact us at
one of the locations listed below for the office or representative nearest you.

1954 Technology Dr., P.O. Box 4225, Peterborough, Ontario, Canada K9J 7B1
Tel.: [phone] Fax: [phone]

182 Normanby Rd., Box 339, South Melbourne, Australia
Tel.: [phone] Fax: [phone]

August van de Wielelei 97, 2100 Deurne, Antwerp, Belgium
Tel.: [phone] Fax: [phone]

Century House, Bridgwater Road, Worcester, England WR4 9ZQ
Tel.: [phone] Fax: [phone]

Parc de la Sainte Victoire, Bât. 5, 13590 Meyreuil, France
Tel.: [phone] Fax: [phone]

Werftstrasse 47, D-40549, Dusseldorf, Germany
Tel: [phone] Fax: [phone]

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Tel.: [phone] Fax: [phone]

Amores No. 1155, Col. Del Valle, 03100 Mexico D.F., Mexico
Tel.: [phone] Fax: [phone]

Nikkelstraat 10, NL-4823 AB Breda, The Netherlands
Tel.: [phone] Fax: [phone]

709 Stadium Drive, Arlington, Texas U.S.A. 76011
Tel.: [phone] Fax: [phone]

A joint venture in Singapore, a sales offices in Brazil
and distributors in 56 countries.

Internet : http://www.milltronics.com

Printed in Canada

TABLE OF CONTENTS

About This ...

About This Manual 5
About ACCUMASS BW100 6

Specifications 7

Installation

Dimesions 9
Interconnection System Diagram 10

Terminal Block Layout 11
Load Cell - Single 12
Load Cell - Dual 13
Speed Sensor 14
Auto Zero 15
Remote Totalizer 1 15
Analog Output 15
Remote Totalizer 2 16
Relay Output 16
Communication CVCC 17

BIC-2 17
Power Connections 18
Comverter 19
Units Sticker 19

Start Up

Orientation 21
Program Mode 22
Maneuvering 22
Master Reset 25
Balance 26
Quick Start 28

Start Up 29

PL-531 3

Zero Calibration 31
Span Calibration 32
Run Mode 33

Recalibration

Belt Speed Compensation 35
Material Tests 36
Design Changes 37
Recalibration 38

Routine Zero 38
Initial Zero 39
Direct Zero 40
Routine Span 41
Initial Span 42
Direct Span 43
Factoring 44
Linearization 45

Operation

Load Sensing 49
Speed Sensing 49
Modes of Operation 49
Damping 50
Analog Output 50
Relay Output 51
Totalization 52
Auto Zero 53
Communication 53
Protocol 54

Parameter Description 57

Appendices

Alphabetical Parameter List 77
Troubleshooting 80
Maintenance 82
Software Updates 82
Program Record 83

PL-531 4

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.

ABOUT THIS ....

Installation

gives you step by step direction for the installation and

Start Up

Recalibration

Operation

Parameters

Appendices

what manual would be complete without one! Ours has an

interconnection of your BW100.
instructs you how to operate the keypad, read the display, do a

Quick Program, and perform the calibration for a successful entry
into the run mode.

emphasizes how to optimize and maintain accurate operation of your
weighing system through material tests and routine recalibrations.

offers an overview of the BW100 features and functions that allow
you to take full advantage of your weighing system.

lists the parameters available to you, with a description of their
function and use. You are urged to read this section; to familiarize
yourself with the parameters available to you and get your BW100
working to its fullest.

alphabetical cross reference of the parameters to their numbers, a
diagnostic help with the list of error messages, a maintenance
reminder, and a record sheet for jotting down parameter values.

PL-531 5

ABOUT THE ACCUMASS BW100

ABOUT THIS ...

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. 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.

BW100 supports Milltronics proprietary bipolar current loop for long distance
communication to PLC or computer via BIC-2, RS -232 or RS -422 converter. It is also
compatible with Milltronics Dolphin interface for remote display, programming and
software upgrading.

ACCUMASS BW100 features:

✓ multi-field LCD display
✓ two remote totalizer contacts
✓ current loop to RS-232 or RS-422
✓ Dolphin compatibility
✓ programmable relay
✓ isolated mA output
✓ rate linearization
✓ local keypad
✓ auto zero

The ACCUMASS BW100 is to be used only in

the manner outlined in this instruction manual.

PL-531 6

98/03/10

SPECIFICATIONS

Power: » standard: » 100/115/200/230 V ac ±15%, 50/60 Hz, 15 VA

» 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: » 0.1% of full scale

Resolution: » 0.02% of full scale

Environmental: » location: » indoor / outdoor

» altitude: » 2000 m max
» ambient temperature: » -20 to 50 °C (-5 to 122 °F)
» relative humidity: » suitable for outdoor (Type 4X /

NEMA 4X / IP 65 enclosure)
» installation category: » II
» pollution degree: » 4

Enclosure: » polypropylene alloy

» Type 4X / NEMA 4X / IP 65
» sealed electronics compartment
» integral junction box with termination block for 0.2 - 4 mm
» or 0.2 - 2.5 mm

2

stranded (12 - 24 AWG)

2

solid

Programming: » via local 4 member keypad with silicone boot and/or Dolphin interface

Display: » 38 x 100 mm (1.5 x 4") multi-field liquid crystal display

Memory: » program stored in non-volatile FLASH memory,

upgradable via Dolphin interface

SPECIFICATIONS

» parameters stored in non-volatile EEPROM

Inputs: » load cell: » 0 - 45 mV dc per load cell

» speed sensor: » pulse train: 0-5 V low, 0-15 V high, 1 to 2000 Hz,

» auto zero: » dry contact from external device

Outputs: » analog: » optically isolated 0/4 - 20 mA

» load cell: » 10 V dc compensated for strain gauge type,

» speed sensor: » 12 V dc, 50 mA max excitation

PL-531 7

or

» open collector switch,

or

» relay dry contact

» 750 Ω max loading

» resolution: 0.1% of 20 mA

2 cells max

97/07/07

» remote totalizer 1:» contact closure 32 - 288 ms duration

» open collector switch rated 30 V dc,
100 mA max

» remote totalizer 2:» contact closure 32 - 288 ms duration

» open collector switch rated 240 V ac/dc,
100 mA max

» relay output: » programmable function

» 1 form ’C’ SPDT relay contact rated 5 A
at 250 V ac, non- inductive

SPECIFICATIONS

Communications: » proprietary bipolar current loop via BIC-2 or CVCC loop length

(refer to Options) » Dolphin compatible

Cable/Separation:» single load cell: » non-sensing:» Belden 8404, 4 wire shielded,

20 AWG or equivalent, 150 m
(500 ft) max

» sensing: » Belden 9260, 6 wire shielded,

20 AWG or equivalent, 300 m
(1000 ft) max

» dual load cell: » non-sensing:» Belden 9260, 6 wire shielded,

20 AWG or equivalent, 150 m
(500 ft) max

» sensing: » Belden 8418, 8 wire shielded,

20 AWG or equivalent, 300 m
(1000 ft) max

» speed sensor: » Belden 8770, 3 wire shielded, 18 AWG or

equivalent, 300 m (1000 ft)

» auto zero: » Belden 8760, 1 pair, twisted/shielded, 18 AWG,

300 m (1000 ft) max

» bipolar current: » Belden 9552, 2 pair, twisted/shielded, 18 AWG,

(comm. port) 3000 m (10,000 ft) max loop

» remote total » Belden 8760, 1 pair, twisted/shielded, 18 AWG,
t1 (dc) 300 m (1000 ft) max

Options: » Speed Sensor: » Mass Dynamics MD-36 or TASS, or equivalent

» Dolphin: » Milltronics Windows based software interface

» CVCC: » Milltronics bipolar loop to RS-232 or RS-422

» BIC-2: » Milltronics bipolar loop to RS-232 or RS-422

» Mass Dynamics Incline Compensator, for signal compensation
on variable incline conveyors

Approvals: » CE*, CSA

*EMC performance available upon request

PL-531 8

and infrared ComVerter link.

passive converter, communications interface

buffered converter, communications interface,
max 6 BW100 per BIC-2

NRTL/C

INSTALLATION

Installation shall only be performed by qualified personnel

and in accordance with local governing regulations.

This product is susceptible to electrostatic shock.

DIMENSIONS

Follow proper grounding procedures.

270 mm

(10.6")

254 mm

(10")

138 mm

(5.4")

sealed enclosure

integral junction box
(cover removed)
with terminal block and
voltage selection switch

Conduit entry area. Recommend drilling the enclosure with a hole saw and
the use of suitable cable glands to maintain ingress rating.

69 mm

(2.7")

INSTALLATION

74 mm

(2.9")

mounting hole

6.4 mm (1/4") Ø

Non metallic enclosure does not provide grounding between connections.

PL-531 9

5 mm
(0.2")

Use grounding type bushings and jumpers.

98\03\09

INTERCONNECTION

Mass Dynamics
belt scale, see
Specifications

customer’s remote
totalizing device

Wiring may be run via common conduit. However these may not be run in the

same conduit as high voltage contact or power wiring.

SYSTEM DIAGRAM

ACCUMASS
BW100

speed sensor, optional,
see Specifications

INSTALLATION

mA output

relay output

remote totalizer

bipolar current loop
(Milltronics communications)

customer
device

customer alarm, or
control device

Milltronics BIC-2

Typical system capability. Not all components or their

maximum quantity may be required.

PL-531 10

TERMINAL BLOCK LAYOUT

ac supply

dc supply

INSTALLATION

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 11

LOAD CELL - SINGLE

Belt Scale

customer

junction box

INSTALLATION

*

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) :

» remove the jumpers BW100 TB1 – 17/18 and TB1 19/20

» run additional conductors from :

» BW100 TB1 – 18 to scale ‘– EXC’
» BW100 TB1 – 19 to scale ‘+ EXC’

:

PL-531 12

08/24/99

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) :

» remove the jumpers BW100 TB1 – 17/18 and TB1 19/20

» run additional conductors from :

» BW100 TB1 – 18 to scale ‘– EXC’
» BW100 TB1 – 19 to scale ‘+ EXC’

INSTALLATION

:

PL-531 13

08/24/99

SPEED SENSOR

MD - 36A

speed sensor

INSTALLATION

▼ Connect the BW100 TB1 – 7 to the MD - 36A speed sensor terminal:

OR

‘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.

TASS

speed sensor

▲ If a speed sensor is not used, a jumper must be connected across the BW100

TB1 – 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.

PL-531 14

AUTO ZERO

REMOTE TOTALIZER 1

prefeed activated dry contact

ANALOG OUTPUT

supply

maximum 30

V dc, 100 mA

to customer instrumentation

INSTALLATION

remote

totalizer

PL-531 15

isolated mA output, 750 Ω maximum
load ac models only

mA output on dc models is not isolated

REMOTE TOTALIZER 2

INSTALLATION

RELAY OUTPUT

supply,

maximum 240 V

ac / dc

relay shown in
de-energized state,
contacts rated 5 A at
250 V non-inductive

remote

totalizer

PL-531 16

COMMUNICATION
CVCC

BIC-2

INSTALLATION

Connect shield at one device only, e.g. BW100 TB1 – 21.
Maximum loop length 3000 m (10,000 ft).

PL-531 17

POWER CONNECTIONS
AC POWER

INSTALLATION

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.

DC POWER

12 V dc Model

10 - 15 V dc

24 V dc Model

18 - 30 V dc

dc model indicated on lid nameplate.

dc terminals shall be supplied from an SELV source in accordance
with IEC-1010-1 Annex H.

PL-531 18

97/07/07

COMVERTER

Optional Dolphin Interface

ACCUMASS BW100

Refer to Dolphin instruction manual for interconnection details.

ComVerter

UNITS STICKER

INSTALLATION

Remove the appropriate ‘units’ sticker from the sheet supplied, and affix
to your BW100 as shown.

PL-531 19

98\03\09

INSTALLATION

PL-531 20

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

LCD

Keypad

The BW100 operates under two modes: ‘run’ and ‘program’. When the unit is initially
powered, it starts in the program mode.

balance switch ,SW2

balance potentiometer, P1

If the program mode is idle, it reverts to the run mode after 10 minutes.

PL-531 21

START UP

98\03\09

Program Mode

LCD

KeyPad

access
run
mode

program

mode

parameter value

status icon,

refer to

Run Mode

alternates program
mode between
‘select parameter’
and ‘change value’
functions

parameter

number

scroll
up

‘change value’

accessed

scroll
down

MANEUVERING

To Select a Parameter:

if not in the program mode

from the
run mode

START UP

if in the program mode

PL-531 22

Speed Scroll

select parameter,
e.g. P005 = 1

OR

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 :

initiate change function

Security Must Be Disabled

Must Be Pressed to
Save Change!

increase or decrease
to the desired value.

if no response,
security not disabled

save and return to select
parameter function,

e.g. P005 = 3

START UP

PL-531 23

Express :

e.g. from the program
mode, P005

Parameter

to jump back to P005

or

Value

to jump to the factory setting

e.g. P999

jump back to P005

To Access Run Mode :

START UP

exit and return
to run mode

PL-531 24

To Access the Program Mode :

last parameter from
previous program session
e.g. P005

from the run mode

e.g. rate display

MASTER RESET

Prior to programming, balancing and calibration, a master reset of the BW100 should
be done.

Refer to Parameters \ P999.

START UP

PL-531 25

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.

test weight bar

With the conveyor stopped and locked out, lift the belt off the weighing idlers.

START UP

Belt Travel

typical dual load cell scale

PL-531 26

96/07/07

Place the BW100 into the program mode at P291.

‘close’

SW2

‘close’

SW2

‘open’

‘open’

‘B’

test weight

‘A’

enter and auto advance to P292,

test weight on
load cell ‘B’ side

select P291 ensure SW2

is closed

open SW2

SW2

SW2

‘B’

test weight

enter and auto advance to P293,

leave SW2 open

‘A’

test weight on

load cell ‘A’ side

enter and auto advance to P294,

close SW2

enter and auto advance to P295

adjust until

## = 0

± 5

START UP

P1

Remove the test weight, insure that the BW100 SW2 is in ‘close’ position and that P1
is left as set.

Performing a balance procedure requires a subsequent

PL-531 27

zero and span recalibration.

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.

START UP

PL-531 28

START UP

Program P005 - P017

refer to Maneuvering for
parameter selection
and changing values.

program mode P005, units
e.g. 1, t/h

from design data

*

sheet, if provided

▲

for constant speed
applications, TB1 - 5/6
jumpered, value is
locked at 100.

P011, design rate

*

e.g. 200 t/h

P014, design speed

*

e.g. 0.5 m/s

P015, speed constant *
e.g. 100.3 pulse / m

▲

Test load value should be less than design load (P952). If not, contact Milltronics or
their agent.

PL-531 29

P016, belt length
e.g. 65.72 m

P017, test load

*

e.g. 55.56 Kg / m

examples are typical

98/03/10

START UP

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.

START UP

PL-531 30

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

Perform Span Calibration,

see next page

zero calculation,
frequency count displayed

zero deviation calculated,

initial deviation = 0

zero deviation accepted,
initial zero count = ###

Record this value for
future reference

START UP

PL-531 31

99/07/24

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

START UP

Remove the test weight when the Span calibration is complete.

Run

span deviation accepted
initial span count = ####

Record this value for
future reference

successful entry into run,
display rate

PL-531 32

97/07/07

Run Mode

initiate
span

display scroll
r = rate

t1 = totalizer 1
t2 = totalizer 2
L = load
S = speed

LCD

reading

mA
bar
graph

totalization
in process

Keypad

access
program
mode

= relay status,

appears on alarm

1,2=remote totalizer

flashes at rate
totaling

3=parameter alert,

zero and span
calibration required

scroll
display

START UP

initiate
zero

PL-531 33

START UP

PL-531 34

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.

View the belt speed.

Stop the conveyor and measure a length of the belt; marking the forward end (start
time) and the back end (stop time). Use the belt scale as the stationary reference.

Run the belt and measure the time for the belt length to pass over the scale.
speed =

Refer to maneuvering for parameter selection and value change.

with conveyor
running empty

belt length m or ft

time s min

run mode \ speed display,
e.g. 0.750 m/s

program mode –
assumed speed

e.g. 0.75 m/s

If the BW100 constant speed input (TB1-5/6) is jumpered, the design speed (P014) is
automatically adjusted.

If the 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.

PL-531 35

enter calculated speed
e.g. 0.8 m/s

jumps to P014 or P015
showing new value

RECALIBRATION

97/07/07

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.

Test weights are NOT used during material tests.

» Run the belt empty.
» Perform a zero calibration.
» Put the BW100 into run mode

» Record the BW100 total as the start value _ _ _ _ _ _
» Run material at a minimum of 50% of design rate over the belt scale

for a minimum of 5 minutes.
» Stop the material feed and run the conveyor empty.

» Record the BW100 total as the stop value _ _ _ _ _ _
» Subtract the start value from the stop value to determine the BW100 total
» Weigh the material sample if not already known.

start total

✍

✍

scale

RECALIBRATION

BW100 total = _ _ _ _ _ _

» Calculate the span adjust value:

% span adjust =

PL-531 36

stop total

scale

✍ material sample weight = _ _ _ _ _ _ ✍

BW100 total - material sample weight x 100

material sample weight

If the span adjust value is within the accuracy requirements of the weighing system,
the material test was successful and normal operation can be resumed.

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:

refer to maneuvering for
parameter selection
and value change

program mode,
P019

if % span adjust is
negative, be sure
to enter as

enter % span adjust,
e.g. 0.05

negative value

jumps to P017 adjusted
test load,

e.g. 97.95

Verify the results of the span adjust by material test or return to normal operation.

DESIGN CHANGES

Where parameters have been changed with a resultant impact on the calibration or do
not take effect until a recalibration is done, the parameter warning icon is displayed. In
order to clear the icon, perform a zero and span recalibration after the reprogramming
session is complete.

RECALIBRATION

If significant changes have been made, an initial zero (P377) and/or initial span
(P388) may be required.

PL-531 37

98/03/10

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.

Routine Zero

Run the conveyor empty for several minutes to warm up the belt and insure that it is
empty. Test weights are not used during a zero calibration.

From the
run mode

initiate zero calibration
current zero count = ####

zero calculation,
load value displayed

zero deviation calculated

accept deviation
new zero count = ####

RECALIBRATION

E3 is an indication that the mechanical system is errant. The use of P377,

initial zero

The cause of the increased deviation must be found and rectified. A zero recalibration
as previously described can then be retried.

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.

PL-531 38

, should be used judiciously and only after a thorough

mechanical investigation has been exercised.

return to run mode

97/07/07

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 = ####

RECALIBRATION

PL-531 39

Perform Initial Span

99/08/24

Direct Zero

enter previously recorded
zero count

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

RECALIBRATION

new zero count accepted

PL-531 40

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
current span count = ####

span calculation,
load value displayed

span deviation = ##%

accept deviation
new span count = ####

return to run mode

E6 is a reminder that a zero calibration is strongly suggested before a span

calibration is initiated. Press enter to bypass this message.

E4 is an indication that the mechanical system is errant. The use of P388,

initial span

, should be used judiciously and only after a thorough

mechanical investigation has been exercised.

The cause of the increased deviation must be found and rectified. A span recalibration
as previously described can then be retried.

RECALIBRATION

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.

Remove the test weight when the span calibration is complete.

PL-531 41

97/07/07

Initial Span

invoke initial span

current span count = ####

span calculation,
frequency count displayed

return to run mode

select P388

An initial span can be perform if deemed as a

proper response to E4 message.

Refer to maneuvering for parameter selection and value change.

RECALIBRATION

PL-531 42

span deviation = ##

zero deviation accepted
initial zero count = ####

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

new span count accepted

RECALIBRATION

PL-531 43

Factoring

enter

initiated Factoring,
current test load value

e.g. 76.11 kg / m

dynamic test load value
e.g. 76.03 kg / m

P359 selected

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:

hang new test weight onto
belt scale, then run the
conveyor empty

RECALIBRATION

jumps to P017,
new test load value

e.g. 76.03 kg / m

return to run mode

PL-531 44

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.

To verify that the cause of the non-linearity is not mechanical:

» run the conveyor belt empty and stop it.
» Suspend various test weights to the scale to verify mechanical linearity. If the

load reported by the BW100 at these tests is non-linear, a mechanical problem
is indicated. Refer to the belt scale manual in order to resolve the non-linearity
by improved installation or repair.

If it is determined that the non-linearity is due to the weighing application, and not the
actual belt scale, apply linearization by performing the following:

» zero calibration
» span calibration at 90 to 100% of design rate
» material tests at 90 to 100% of design rate
» manual span adjust if required
» material tests at 1 to 3 intermediary flow rates where compensation is required.

Compensation points must be at least 10% of the design load apart.

E8 message occurs if a point is less than 10% of

full scale or if points are less than 10% apart.

» calculate the percentage compensation for each flow rate tested.
% compensation =

where: actual weight = material test

totalized weight = BW100 total

actual weight - totalized weight x 100

totalized weight

RECALIBRATION

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97/07/07

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. The following data
was tabulated. (This example is exaggerated for emphasis).

The material tests should be run at same belt speed, representative of normal
operation; in this case 1.2 m/s. For each rate, record the corresponding load value by
scrolling to the BW100 load display during running conditions or by calculation.

load =

rate

speed

BW100 load material test BW100 total compensation*

kg/m tonnes tonnes %

11.6 4.2 4.9 -14.3

23.2 8.4 7.6 10.5

34.7 12.6 13.7 - 8.0

*calculation example: % compensation =

weight = tonnes

RECALIBRATION

4.2 - 4.9 x 100

4.9
= - 14.3

actual weight per material test
totalized weight b y BW 1 0 0
belt scale response
linearized BW100 re sp o n se
% compensation
span (100%)

PL-531 46

load - kg / m

97/07/07

Program the BW100 as follows: P390 = 1

actual weight per material test
totalized weight by BW100
belt scale response
linearized BW100 response
% compensation
span (100%)

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. Compensation is optimized by establishing the next load value
that agrees with the material test, hence where compensation is zero and entering it
as the next compensation point.

P390 = 1
P391 = 11.6
P392 = - 14.3
P393 = 23.2
P394 = 0
P395 = 34.7
P396 = 0

weight = tonnes

PL-531 47

RECALIBRATION

load - kg / m

RECALIBRATION

PL-531 48

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.

Refer to Specifications and Installation\Load Cell for belt scale requirements
and connection.

SPEED SENSING

In order for the BW100 to calculate rate and hence totalize material flow along the
belt conveyor, a speed signal representative of belt speed is required. In constant
speed applications (no speed sensor), the BW100 can be programmed to provide
an internal speed signal. This is achieved by entering the design speed (P014) and
providing a jumper across speed input terminals (TB1-5/6). Speed constant (P015)
defaults to 100.

For optimum accuracy of the weighing system, both constant and variable speed
applications, a speed sensor is required. Again, the design speed and speed
constants need to be programmed, however the jumper across the speed input has to
be removed and the speed sensor connected.

OPERATION

Refer to Specifications and Installation\Speed Sensor for speed sensor requirements
and connection.

MODES OF OPERATION

Run is the normal or reference mode of operation. It continuously processes the load
signal from the belt scale to produce internal load and rate signals, which are in turn
used as the basis for totalization, mA output and relay control. The run display is
programmed (P081) to scroll through rate, totalization, load and speed; either
manually by pressing the enter key, or automatically. A bar graph is continuously
displayed. It is proportional to the analog output as programmed (see Analog Output).

From the run mode, access to the program mode, and zero and span calibration
is made.

The program mode allows viewing and, with security permission (P000), changing
parameter values. During program, run mode functions are still active, i.e.: rate,
relay, analog output and totalization. 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.

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97/07/07

DAMPING

OPERATION

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. Relay alarm functions based on
input functions of flow, load and speed, respond to the damped value.

If the specific mA output damping parameter (P220) is enabled (value other than 0),
then the damping (P080)
output value and bar graph respond independently at the specified mA output
damping rate (P220).

ANALOG OUTPUT

The BW100 provides one isolated analog output. The output can be assigned (P201)
to represent rate, load or speed. The output range can be set to 0 - 20 mA or 4 - 20
mA (P200). The 0 or 4 mA value corresponds to empty or zero condition, whereas the
20 mA value corresponds to the associated design value: rate (P011), load (P952) or
speed (P014). The analog output can be limited for over range levels of 0 mA
minimum and 22 mA maximum (P212 and P213 respectively). The output 4 and 20
mA levels can also be trimmed (P214 and 215 respectively) to agree with a
milliammeter or other external mA input device.

The BW100 LCD provides a bar graph as a function of analog output. It displays the
mA value as percentage of the mA range.

as it pertains to the mA function

is overridden, and the

The mA output value can be tested using parameter P911. Refer to Parameter
Description\P911.

PL-531 50

97/07/07

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).
» speed: relay alarms on high and/or low belt speed.
» load: relay alarms on high and or low belt load.
» error: relay alarms on any error condition as it is reported.

Refer to Appendices \ Troubleshooting.

Except for alarm on ‘auto zero’ and ‘error’, the high and low alarm setpoints (P101 and
P102 respectively) are required and must be entered in the appropriate units.

The on / off actuation at both setpoints is buffered by the damping (P080) and the
programmable dead band (P117), to prevent relay chatter due to fluctuations. The
relay is normally energized; i.e. the normally closed (n.c.) contact held open. Upon an
alarm condition, the relay is de-energized and the alarm icon on the BW100 display
appears. Once in alarm, the relay and icon remain in alarm status until the alarm
condition is removed.

OPERATION

Example:

P014 = 2m/s, design speed
P100 = 3, belt speed
P101 = 100% (2m/s)

high

100%

low

20%

actual ‘off ’

22%

actual ‘on’

20%

PL-531 51

alarm ‘on’ is with relay de-energized

97/07/07

TOTALIZATION

OPERATION

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. The count is held in the master
totalizer used to increment the internal totalizers and to produce a pulse signal for
the remote totalizers.

The BW100 provides four separate totalizer functions: internal totalizer 1, internal
totalizer 2, remote totalizer 1 and remote totalizer 2.

To avoid totalizing material at low flow rates, the totalizer drop out limit (P619) is set to
a percentage of the design rate. Below this limit, totalization stops. When material flow
returns to a rate above the drop out limit, totalization resumes.

Totalizer resolution or count value is set by the respective control parameters, P631 ­P639. If the resolution selected causes the totalizer to lag behind the count rate, an
E2 error is displayed after making the parameter entry. The error is rectified by
selecting a greater resolution value.

e.g.:

internal totalizer

given: P005 = 1 (t/h)

then: totalizer count increments by 10 for each 10 metric tonnes registered

1

P631 = 5

external totalizer

given: P005 = 1 (t/h)

then: contact closure occurs once for every 10 metric tonnes registered

For remote totalization, the contact closure duration is set by the respective control
parameters, P643 and P644. The value is automatically calculated upon entry of the
design rate (P011) and remote totalizer parameters (P638 and P639), so that the
duration of contact closure allows the relay response to track the total up to the design
rate. The value can be changed to suit specific contact closure requirements, such as
in the case of programmable logic controllers. If an E2 error is displayed, P638 or
P639 has to be increased.

The totalizers are reset through the master reset (P999), the totalizer reset (P648) or
through the keypad.

» master reset: the reset of all totalizer functions is included in the master reset.
» totalizer reset: totalizer reset can be used to resets internal totalizers

» keypad: pressing simultaneously while in the run mode

1

P638 = 5

1 and 2, or totalizer 2 independently.

resets internal totalizer 1, as well as the internal counts
for both remote totalizers.

Placing the internal totalizers on to the display scroll of the run mode is controlled by
the totalizer display parameter (P647); displaying either one or both totalizers.

PL-531 52

97/07/07

AUTO ZERO

The Auto Zero function allows a zero calibration to be initiated automatically under the
following conditions.

- the auto zero input (TB1-9/10) is in a closed state; jumper or remote switch

- the load is less than 2% of the design load
If the resulting zero deviation is less than an accumulated 2% from the last operator

initiated zero, the auto zero is accepted.
If the deviation is greater than an accumulated 2%, an E9 error is displayed and the

relay, if so programmed, goes into alarm (refer to Operation\Relay Output). The E9
error is cleared after five seconds.

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.

OPERATION

host

device

* maximum 6 BW100 per BIC-2

BW100

BIC-2 *

or

CVCC

The BW100 communication port (TB1-21 to 25) is software set for baud (P751) and
mode enable (P760). Refer to Installation\Communication for wiring details.

If communicating via Milltronics Dolphin software,

PL-531 53

the baud rate must be set to ’4800’.

98\03\09

PROTOCOL

OPERATION

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:

DATA FIELD DESCRIPTIONS

The following data fields are used.
som
BW100 start of message, ASCII character = STX (Hex Value = 02).

DEVICE
Identifies the BW100 to which the message applies. The device is a 2 character

number that equals the Unit I.D. code, (P761). ASCII characters = 00 to 15.

» 8 data bits
» no parity bit
» 1 stop bit

MT
Identifies the 2 character message type transmitted, ASCII characters:

50 = material flow rate
51 = material load
52 = belt speed
53 = totalizer 1,

internal

54 = totalizer 2, internal

READING
Contains the measurement value in the engineering units of measure selected

during BW100 programming. The number of bytes in this data field varies dependent
upon the reading value. Up to 8 ASCII characters including the decimal point may
be transmitted.

UNITS
Three ASCII characters identify the totalizer engineering units (MT=53 and MT=54).

The first character is always a space. The remaining characters may be:

t = tonnes
T = tons
LT = long tons
kg = Kilograms

lb = pounds
eom
BW100 end of message, ASCII character = CR (Hex Value = 0D).

PL-531 54

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

som STX start of message
DEVICE 01 for BW100 # 1
MT 50 material flow rate request
eom CR end of message

MESSAGE RESPONSES

The BW100 response to a flow rate (MT=50) load (MT=51) or speed (MT=52)
message request is in the following format.

som DEVICE MT READING eom

Example:

OPERATION

Data ASCII Example
Field Character Description

som STX start of message
DEVICE 00 from BW100 # 0
MT 50 material flow rate response
READING 392.5 is 392.5
eom CR end of message

The response to a material total (MT=53) message request is in the following format.

som DEVICE MT READING UNITS eom

Example:

Data ASCII Example
Field Character Description

som STX start of message
DEVICE 01 from BW100 # 1
MT 53 material total response
READING 129.2 is 129.2
UNITS t metric tonnes
eom CR end of message

PL-531 55

OPERATION

PL-531 56

PARAMETER DESCRIPTION

P000 lock

Locks out the programming ’change value’ function suc h t hat t he values of
P001 through P999 cannot be changed. This however does not prevent t he
’select’ function from use; i.e. for viewing values. Programming is locked out
if the value of P000 is other than 1954.

entry: 1954 = unloc ked

1954 = locked

Ouick Start, P005 to P017

’Ouick Start ’ is the minimum parameter programming required bef ore

attempting a calibration and successful ent ry into the run mode.

P005 units

Determines the units for programmi ng and meas urement .

entry: 1 = t/ h, t onnes per hour

2 = kg/h, kilograms per hour
3 = LT/h, long tons per hour
4 = T/h, short tons per hour
5 = lb/h, pounds per hour

PARAMETER DESC.

Changing this parameter does not affect t he rate (P011), belt speed (P014)
or belt length (P016) parameters. These parameters shoul d be re-ent ered f o r
conformity in units.

P011 design rate

Specifies the design rate of material f l ow f or t he bel t scal e.

enter the design rate from the supplied design data sheet

PL-531 57

t = 1000 kg
LT = 2240 lb.
T = 2000 lb.

P014 design speed

Specifies the design speed for the conveyor bel t .

Speed units are: metre/s if P005 = 1 or 2

P015 speed constant

feet/min if P005 = 3, 4 or 5

PARAMETER DESC.

This value multiplied with t he speed sens or f requenc y, calculates the
actual belt speed.

* refer to speed sensor nameplate or consult Mas s Dynamics or their agent

P016 belt length

The length of the conveyor belt (one belt revolution).

Length units are: metre if P005 = 1 or 2

entry: I f speed i nput i s wi red for constant speed

(TB1 5/6 jumpered), value defaults to ’100’.

enter the speed constant = from the supplied design data sheet

or

=

speed sensor pulses per revolution*

pulley circumference (m or ft)/ revolution

ft if P005 = 3, 4 or 5

enter the belt length

P017 test load

The load to be referenced when performing a span.

Load units are: kg/m if P005 = 1 or 2

End of ’short program’ parameters. A calibration can now be perf ormed.

PL-531 58

lb/ft if P005 = 3, 4 or 5

P018 speed constant adj us t

This parameter allows adjustment to t he speed cons t ant (P 015).

Initially, this parameter displays t he dynamic speed of the belt.
If the displayed speed is not equal to the ac t ual speed, enter
the actual belt speed.

For speed sensor applications, the value of P015 is
automatically adjusted.

For constant speed (TB1 5/6 jumper) the value of P014
is automatically adjusted.

P019 manual span adjust

This parameter allows adjustment to t he span cal ibration.

The adjustment value is generally determined by perf orming
material tests. Refer t o Rec alibration\Material Tests.

enter the calculated adjust ment

P022 minimum speed frequenc y

Sets the minimum frequency that the speed sens or can rel iably read.
Signals at low frequencies are erratic, adversel y affecting the performance
of the weighing system.

PARAMETER DESC.

entry: 1 = 1 Hz

PL-531 59

2 = 2 Hz

note:at 1 Hz, it takes 1 sec before defaulting t o 0 speed

at 2 Hz, it takes 0.5 sec before defaulting to 0 speed

P080 damping

Sets the speed of response to which t he di spl ay ed readi ngs
(rate, load and speed), and outputs (alarm and mA) react t o change. .

The greater the damping value, the slower the response.

PARAMETER DESC.

P081 display mode

Sets the display mode. Normally, the di spl ay shows rate, or the
last manually selected function. I f set to alternating, the display
alternates between rate and totalizer (1 and/or 2, as programmed
by P647).

Effect of damping (P080) on mA output can be

overridden by mA output damping (P 220).

enter damping value, range 1 - 9999

entry: 0 = normal

1 = alternating

PL-531 60

Relay/Alarm Function, P100 - P117

These parameter are specific to the use of the rel ay / alarm f unction.

Refer to Operation\Relay Output.

P100 relay set up

Sets the alarm mode for the relay.

entry: 0 = off

P101 high alarm

Sets the high alarm setpoint f or rel ay functions P100 = 1, 3 or 4.

enter the value in % of full scale

P102 low alarm

Sets the low alarm setpoint for relay f unctions P100 = 1, 3 or 4.

enter the value in % of full scale

1 = rate

PARAMETER DESC.

2 = auto zero
3 = belt speed
4 = belt load
5 = error

P117 alarm dead band

Sets the dead band to prevent relay chatter due t o f luctuations
at the high or low setpoint.

enter the value in % of full scale

PL-531 61

End of relay/alarm parameters.

mA output parameters, P200 - P220

These parameters are specific to the use of t he mA out put .

Refer to Operation \ mA Output for detai ls.

P200 mA range

Sets the range for the mA output.

PARAMETER DESC.

P201 mA functi on

Assigns the mA output to track one of t he int egrat or f unc t i ons .

P212 mA min limit

Limits the lower mA range (0 or 4 mA) to a mi ni mum out put value.

entry: 1 = 0 - 20 mA

2 = 4 - 20 mA

entry: 1 = rate

2 = load
3 = speed

enter limit value, range 0 - 22

P213 mA max limit

Limits the upper mA range (20 mA) to a max imum out put value.

enter limit value, range 0 - 22

P214 4 mA trim

Adjusts the 4 mA output level to agree with a milliammeter or
other external mA input device.

enter trim value, range 0 - 9999

PL-531 62

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 react s t o change.

The greater the damping value, the slower the response.
If the value is 0, the mA output as sumes t he damping set in P080.

enter the damping value, range 0 - 9999

End of mA output parameters.

PARAMETER DESC.

PL-531 63

Load Cell Balancing Parameters, P291 - P295

These parameters are used for verifying or balancing t he load cel ls (2)

on the associated conveyor belt scal e. Ref er t o St art Up\ Bal anc ing

P291 calculator input 1

This register displays the count assoc iated with the summation of

PARAMETER DESC.

load cell A and B signals, when balancing the A and B load cells
of the associated belt scal e.

P292 calculator input 2

This register displays the count assoc iated with the load B signal,
when balancing the A and B load cells of the associated belt scale.

for details and procedure for use of thes e parameters.

P293 calculator input 3

This register displays the count assoc iated with the load cell B signal,
when balancing the A and B load cells of the associated belt scale.

P294 calculator input 4

This register displays the count assoc iated with the summation
of load cell A and B signals, when balancing the A and B load
cells of the associated belt scale.

P295 load cell balance

Used in conjunction with balanc e cal c ul at or parameters (P291 - P 294),
this parameter displays the adjustment required to complete the load
cell balance procedure.

PL-531 64

End of balancing parameters

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. Peri ods of les s
than 24 hr. are not recorded, nor accumulated.

P350 calibration securit y

This parameter provides additional sec urity to the global lock (P000).

entry: 0 = view parameters , perf orm zero and span, no reset

of totalizer 1
1 = same as level 0, but cannot perform span
2 = same as level 0, but cannot perform zero and span

P359 factoring

Factoring is used as a method of calc ul ating the value of the test
load (P017) to a new physical test weight.

PARAMETER DESC.

entry: 0 = idle

1 = factor

Totalization is halted during the factoring procedure,

and resumed only upon return to the run mode.

P360 calibration duration

Sets the number of belt revolutions t o us e during a zero or span calibration.

enter number of belt revolutions, range 1 - 99

P367 direct zero

This parameter allows the zero reference count to be viewed
or entered directly.

Direct entry is intended for use when replac ing sof t ware or hardware
and it is not convenient to perform an initial zero at t hat time.

PL-531 65

P368 direct span

97\10\29

This parameter allows the span reference count to be viewed or ent ered di rec t ly.

Direct entry is intended for use when replac ing sof t ware or hardware
and it is not convenient to perform an initial span at t hat time.

P370 zero limit

PARAMETER DESC.

Sets the zero calibration deviation limit f rom t he las t initial zero. If the
accumulated deviation exceeds the limi t , t he zero cal ibrat ion is aborted (E3).

P377 initial zero

The initial zero is the reference zero to which all subs equent operat or
initiated zero calibrations are compared in determini ng whet her t hey
have deviated beyond the zero limit (P370)

entry: 0 = ± 12. 5% of initial zero

1 = ± 2% of initial zero

entry: 0 = idle

1 = initial zero

Refer to Recalibration\Init ial Zero f or use of this function.

P388 initial span

The initial span is the reference to which all subs equent span cal i brat ions
are compared in determining whether they have deviated bey ond 12. 5%
of the initial span.

entry: 0 = idle

1 = initial span

Refer to Recalibration\Init ial Span f or use of this function.

PL-531 66

Linearization Parameters, P390 - P396

These parameters are used to compensate for non-linear response of the weighing

system to the BW100. Refer to Recalibration\ Li neari zat i on f or det ai ls and ex ampl e on

the use of these parameters.

P390 linearization

Enables or disables the linearizat i on f unc t i on.

entry: 0 = off

1 = on

P391 linearizer, point 1

enter the load, in units of P017, for point 1

P392 compensation, point 1

PARAMETER DESC.

enter the calculated compensation, in perc ent , f or compens at ion poi nt 1

P393 linearizer, point 2

enter the load, in units of P017, for point 2

P394 compensation, point 2

enter the calculated compensation, in perc ent , f or compens at ion poi nt 2

P395 linearizer, point 3

enter the load, in units of P017, for point 3

P396 compensation, point 3

enter the calculated compensation, in perc ent , f or compens at ion poi nt 3

PL-531 67

End of Linearization Parameters.

Totalization, P619 - P648

The following parameters are specific to the us e t o the BW100 t ot al izers .

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.

Refer also to Operation\Totalization.

PARAMETER DESC.

Select a greater resolution value.

e.g. given: P005 = 1 (t/h)

then: totalizer count increments by 10 for each 10 metric

P619 totalizer drop out

This parameter sets the limit, in percent of design rate, below which
material rates are not total ized.

The value of ’0’ is reserved to allow both negative and pos it ive t ot al izat ion.

P631 totalizer 1 resolut ion, internal

P631 = 5

tonne registered

enter drop out value in % of design rate

This parameter sets the resolution of int ernal t ot alizer 1.

entry: 1 = 0.001 (one t hous andt h)

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)

PL-531 68

P632 totalizer 2 resolut ion, internal

This parameter sets the resolution of int ernal t ot alizer 2.

entry: 1 = 0.001 (one t hous andt h)

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 resol ution, external

This parameter sets the resolution of ex t ernal t ot alizer 1.

entry: 1 = 0.001 (one t hous andt h)

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)

PARAMETER DESC.

P639 totalizer 2 resol ution, external

This parameter sets the resolution of ex t ernal t ot alizer 2.

entry: 1 = 0.001 (one t hous andt h)

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)

PL-531 69

P643 totalizer 1 contact clos ure, external

The value of this parameter represents a multiple of 32 ms of contact closure
for remote totalizer 1. The value is automatically cal c ul at ed upon ent ry of P1
(design rate) and P638 (totalizer 1 resolution, ex t ernal) so that the duration
of contact closure allows the trans ist or swi t ch res pons e t o t rac k t he t ot al ,
up to the design rate.

The value can be changed to suit specific contact clos ure requi rement s,
such as in the case of programmable logic controllers . I f a mes sage E2
is displayed, P638 has to be increased.

PARAMETER DESC.

P644 totalizer 2 contact clos ure, external

entry: 1 = 32 ms 6 = 192

2 = 64 7 = 224
3 = 96 8 = 256
4 = 128 9 = 288
5 = 160

The value of this parameter represents a multiple of 32 ms of contact closure
for remote totalizer 2. The value is automatically cal c ul at ed upon ent ry of P1
(design rate) and P639 (totalizer 2 resolution, ex t ernal) so that the duration
of contact closure allows the trans ist or swi t ch res pons e t o t rac k t he t ot al ,
up to the design rate.

The value can be changed to suit specific contact clos ure requi rement s,
such as in the case of programmable logic controllers . I f a mes sage E2
is displayed, P639 has to be increased.

entry: 1 = 32 ms 6 = 192

2 = 64 7 = 224
3 = 96 8 = 256
4 = 128 9 = 288
5 = 160

PL-531 70

P647 totalizer display

Selects the totalizer combination to be displ ay ed, ei t her manual ly t hrough
the scroll display key or automatically by cont rol of the display mode (P081).

entry: 1 = tot alizer 1

2 = totalizer 2
3 = totalizers 1 and 2

P648 totalizer reset, int ernal

Resets the internal totalizers.

entry: 0 = idle

1 = reset totalizer 2
2 = reset totalizers 1 and 2

End of Totalization parameters.

PARAMETER DESC.

PL-531 71

Communication, P751 - P761

These parameters are specific to the use of t he communi cat i on paramet ers .

P751 baud rate

Sets the baud rate for the proprietary bi-pol ar current loop. This baud
rate is not applicable to communication via Milltroni cs Comverter.

PARAMETER DESC.

P760 communication mode

Selects the communication mode.

Refer also to Appendices\Communication.

entry: 300, 1200, 2400, 4800 or 9600 baud

4800 baud is required for Dolphin communications ov er t he
bi-polar current loop.

» bi-polar current loop: interface with the host device (PLC or computer)

» infrared link: communication is made using the

» maintenance: communicat ion is made via t he bi -polar current

entry: 1 = bipol ar 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

is made through the Milltronics BIC-2 or CVCC.
Refer to Operation\Communication.

Milltronics ComVerter.

loop for run mode operations and infrared link
for program mode operations

PL-531 72

End of communication parameters.

Test and Diagnostic, P900 - P951

These parameter are used for test and diagnostic purposes.

P900 software revision

Displays the EPROM (Flash ROM) software revision level.

P901 memory

Tests the memory. Test is initiated by scrolling to the parameter
or repeated by ’pressing enter’

display:PASS = normal

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

PARAMETER DESC.

infrared communication link

mirror

P911 mA output value

Displays the value from the previous measurement. A test value can be
entered and the displayed value is transmitted to the output. Upon returning
to the run mode, the parameter assumes the actual mA output level.

PL-531 73

BW100

98\03\09

P940 load cell ’A’, mV

Displays the mV signal input from t he load cel l . Range 0. 00 - 60. 00 mV .

in

P941 load cell ’B’, mV

Displays the mV signal input from t he load cel l . Range 0. 00 - 60. 00 mV .

PARAMETER DESC.

P942 V/F converter, V

Displays the input voltage to t he vol t age t o f requenc y conv ert er.
Range 0 - 3.98 V

P943 V/F converter, f

Displays the output frequency of t he vol t age t o f requenc y converter.
Range 0 - 131,072

P944 power sensor

in

in

out

Displays a voltage supply reference f or di agnostic purposes.

P949 diagnostic errors

Enables or disables diagnost ic error chec king, E 101 - E 104

entry: 0 = disable

1 = enable

P950 zero register

Registers the number of zero calibrations t hat hav e been done sinc e
the last master reset.

Refer to Troubleshooting.

PL-531 74

97/07/07

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, whi ch corres ponds t o t he f ul l scal e
value for alarm and mA output funct i ons . The design load is calculated,
based on the design rate and design speed.

P999 master reset

Resets parameters and totalizers to thei r f ac t ory setting.

PARAMETER DESC.

End of test and diagnostic parameters.

PL-531 75

PARAMETER DESC.

PL-531 76

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
Compensation Point 2 P394
Compensation Point 3 P396
Damping P080
Design Rate P011
Design Speed P014
Direct Span P368
Direct Zero P367
Display Mode P081
Factoring P359

APPENDICES

High Alarm P101
Identification Number P761
Initial Zero P377

PL-531 77

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
mA Output Value P911

APPENDICES

mA Maximum Limit P213
mA Minimum Limit P212
mA Range P200
mA Trim, 20 P215
mA Trim, 4 P214
Manual Span Adjust P019
Master Reset P999
Memory P901
Minimum Speed Frequency P022
Power Sensor P944
Programmer Interface P907
Relay Set Up P100
Run Time P341
Software Revision Number P900
Span Register P951
Speed Constant P015

PL-531 78

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 P648
Units P005
V/F Converter, V in P942
V/F Converter, f out P943

APPENDICES

Zero Register P950
Zero Limit P370

PL-531 79

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,

refer to Recalibration\Initial Span

E5 (run) parameter not entered check parameters P005 - P017

for entry
E6 (run) zero calibration required do a zero calibration
E7 (run) span calibration required do a span calibration
E8 (program) parameter value error check that value is valid

APPENDICES

E9(run) auto zero out of range auto zero has accumulated

E10 (run) rate or span out of range loading on belt is 300% of

E11 (run) speed greater than twice check design belt speed against

E12 (factoring) span out of range test load is either too low or

E101 (run) load cell ’A’ check wiring

deviation beyond 2% from

last operator initial zero. If

error is not caused by material

on belt, then do an operator

initiated zero.

rated load or greater.

Investigate and if no mechanical

cause, check to see if re-rating

the design rate is required.

the design speed actual belt speed,check speed

constant, perform speed constant

adjust (P018) if necessary.

beyond 100% of design load

(P952). Replace test weight with

a heavier or lighter weight and try

factoring again.

E102 (run) load cell ’B’ check wiring

PL-531 80

E103 (run) load cell check wiring
E104 (run) memory checksum contact Mass Dynamics or

their distributor

OF 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.

» Zero and span errors are cleared when zero or span is initiated. Errors

that happen during the calibration require re-starting the procedure.
» Program errors are cleared when any key is pressed.
» The messages E101 through E104 can be turned off (P949).
» The load cell errors are detected by certain conditions where it is apparent

that the load cell is not functioning or incorrectly wired. It is not a conclusive

test, since even with incorrect wiring, the resulting input from the load cell

may be within a valid range.

APPENDICES

PL-531 81

MAINTENANCE

The BW100 requires no maintenance.
The external surface of the enclosure may be cleaned using a vacuum cleaner

and a clean dry paint brush. The display window should be cleaned with a moist
non-abrasive cloth.

It is a good idea to check the associated load sensing device, according to its
instruction manual.

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.

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.

APPENDICES

PL-531 82

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 Low Alarm
P117 Alarm Dead Band
P200 mA Range
P201 mA Function
P212 mA Min Limit
P213 mA Max Limit
P220 mA Output Damping
P341 Run Time
P350 Calibration Security
P360 Calibration Duration
P367 Direct Zero
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

APPENDICES

P396 Compensation, Point 3
P619 Totalizer Dropout
P631 Total 1 Resolution, Int
P632 Total 2 Resolution, Int
P638 Total 1 Resolution, Ext

PL-531 83

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 Span Register
P952 Design Load

APPENDICES

PL-531 84

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97/07/07