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]

1 Hoi Wan Street, Suite 602, Quarry Bay, Hong Kong
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.

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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