Milltronics CompuScale III Instruction Manual

COMPUSCALE III

INTEGRATOR

I

Instruction Manual PL-367

1263957

TOTAL

-50%
0% 50% 100% 150%

January 2001

R2:RATEHI R1:SPEED LOMULTI S PAN NO: 1

T

33453670
Rev. 1.4

Safety Guidelines

Warning notices must be observed to ensure personal safety as well as that of others, and to protect the product and the connected equipment.
These warning notices are accompanied by a clarification of the level of caution to be observed.

Qualified Personnel

This device/system may only be set up and operated in conjunction with this manual. Qualified personnel are only authorized to install and
operate this equipment in accordance with established safety practices and standards.

This product can only function properly and safely if it is correctly transported, stored, installed, set up, operated, and maintained.

Warning

Note

:

:

Always use product in accordance with specifications.

Copyright Siemens Milltronics Process

Disclaimer of Liability

Instruments Inc. 2000. All Rights Reserved

This document is available in bound version and in
electronic version. We encourage users to purchase
authorized bound manuals, or to view electronic versions as
designed and authored by Siemens Milltronics Process
Instruments Inc. Siemens Milltronics Process Instruments
Inc. will not be responsible for the contents of partial or
whole reproductions of either bound or electronic versions.

MILLTRONICS®is a registered trademark of Siemens Milltronics Process Instruments Inc.

While we have verified the contents of this
manual for agreement with the instrumentation
described, variations remain possible. Thus we
cannot guarantee full agreement. The contents of
this manual are regularly reviewed and
corrections are included in subsequent editions.
We welcome all suggestions for improvement.

Technical data subject to change.

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: [e-mail]

For the library of SMPI instruction manuals, visit our Web site:

© Siemens Milltronics Process Instruments Inc. 2001

www.milltronics.com

TABLE OF CONTENTS

TITLE PAGE #

General Information

About the CompuScale III 1 – 1
About this Manual

General 1 – 2
Conventions 1 – 3

Specifications

CompuScale III 2 – 1
Options 2 – 2

Installation

CompuScale III 3 – 1
Interconnection 3 – 1

Hazardous Locations 3 – 1

Start Up

Hardware Set Up 4 – 1
Pre Start Up Checks 4 – 3
Initial Start Up 4 – 3

Programming

Calibration

General 5 – 1
Keypad 5 – 1
Parameter Entry 5 – 2

Direct Parameter Access 5 – 2
Automatic Parameter Access 5 – 2
Altering Parameter Values 5 – 3

Parameter Reset 5 – 3
Programming Sequence 5 – 3
Quick Start Guide 5 – 3

General 6 – 1

Initial Calibration References 6 – 1
Zero 6 – 1
Span 6 – 2
Calibration Accuracy 6 – 2
Calibration Alternatives 6 – 3

Auto Zero 6 – 3

Certification Mode 6 – 3

Alternate Test References 6 – 3

ECAL Calibrations 6 – 4

PL-367 i

Parameters

General 7 – 1
Parameters 7 – 1

Programming Chart 8 – 1

Operation

Initial Operation 9 – 1
Normal Operation

Start Up 9 – 1
Zero Calibration Check 9 – 2
Span Calibration Check 9 – 2
Reset Total 9 – 2
Run 9 – 2

Communication

General 10 – 1

Host Communication 10 – 2
Remote Communication 10 – 2
Serial Printer Communication 10 – 2

Protocol 10 – 2

Data Field Descriptions 10 – 3
Message Requests 10 – 3
Message Responses 10 – 4

Appendices

Figures

Alphabetical Parameter Listing
Maintenance and Spare Parts
Maintenance
Spare Parts
Error Messages
Trouble Shooting

FIG. 1 Outline and Mounting 12 – 1
FIG. 2 Layout 12 – 2
FIG .3 CompuScale III / Belt Scale Interconnection 12 – 3
FIG. 4 CompuScale III / Belt Scale Interconnection (cont’d) 12 – 4
FIG. 5 CompuScale III / Speed Sensor Interconnection 12 – 5
FIG. 6 Power, Auto Zero, & Rate Output Wiring 12 – 6
FIG. 7 Relay Wiring 12 – 7
FIG. 8 Communication Wiring 12 – 8

■

PL-367 ii

GENERAL INFORMATION

ABOUT THE COMPUSCALE III

The Milltronics CompuScale III is a
microprocessor based integrator designed
specifically for bulk dry solids in-line
weighing applications.

The CompuScale III utilizes a load signal
(from a belt scale such as the Milltronics
MSI), and a speed input (from a speed
sensor such as the Milltronics MD-36, or a
programmed constant speed), to calculate
the material rate. This rate is integrated over
time to provide material totalization.

The CompuScale III provides:

» Load, Speed, Rate, and Total displays
» an analog mA output proportional to rate
» a relay contact for remote totalizer or PLC operation
» 2 alarm/control relays based on load, speed, or rate
» 2 ports for computer, remote terminal, PLC, or serial printer

1263957

TOTAL

-50%

0% 50% 100% 150%

R2:RATE HI R1:SPEED LOMULTI SPAN NO: 1

T

The CompuScale III has three modes of operation; program, calibrate, and run.

The operator programs the CompuScale III via the keypad to provide displays and outputs in the desired units
of measure. The CompuScale III displays the name, range of acceptable values, (and additional
information/instruction) of the parameter (programming feature) accessed.

In the calibrate mode, the system Zero (empty belt) and Span (100% material rate) calibration is established.
A test reference (test weight, test chain, or ECAL) is used to simulate the force of material applied to the belt
scale during the Span calibration. A material test is normally performed to verify the calibration accuracy. If
necessary, the material test results may be used to correct any deviation in calibration accuracy.

Calibration accuracy may be checked at any time. The results of this check are automatically compared to
system calibration and the deviation is displayed. The operator may choose to continue operation with the
previous calibration or the results of the calibration check.

All programming and calibration information is stored in non-volatile memory. If desired, the security
parameter may be set to ensure the CompuScale III programming and calibration is not inadvertently altered
in the run mode.

The run mode is the normal operating mode, providing dynamic measurement displays, analog mA output,
and a variety of other features.

PL-367 1 – 1

ABOUT THIS MANUAL

GENERAL

This instruction manual contains information essential to successful CompuScale III operation.

SPECIFICATIONS, includes CompuScale III environmental, physical, and operational characteristics.
INSTALLATION, indicates the typical mounting and interconnection procedure.
START UP, prepares the CompuScale III for programming.
PROGRAMMING, details the activities required to tailor the CompuScale III to the particular application.
CALIBRATION, includes the CompuScale III input signal to output feature correlation procedure.
PARAMETERS, describes the function, factory setting, and range of possible settings, of

each parameter.

PROGRAMMING CHART, provides a space to record programmed parameter values for future reference.
OPERATION, describes initial and normal CompuScale III operation.
COMMUNICATION, provides CompuScale III serial communication information.
APPENDICES, Alphabetical Parameter List, Maintenance and Spare Parts, Error Messages,

Trouble Shooting.

FIGURES, includes a complete set of installation and interconnection drawings.

CONVENTIONS

Throughout this instruction manual the following symbols and presentation practices have been utilized:

[1234567ABCDEFG] alpha numeric characters enclosed within these brackets represents information

displayed by the CompuScale III display.

[T/h] units of measure were arbitrarily chosen from the imperial set. The actual units

displayed or otherwise applicable will be dependent upon operator programming.

indicates the following CompuScale III keypad button is to be pressed.

"RUN" or alpha numeric characters enclosed within quotation marks or this symbol represent

ENTER

a key on the CompuScale III keypad.

Italics are used to identify the defined word(s) or phrase within a definition statement.

Information of a higher order of importance, is indented from

both left and right margins and in bold print.

PL-367 1 – 2

■

SPECIFICATIONS

COMPUSCALE III

Power: » 100/115/200/230 V AC ± 10%, jumper

selectable, 50/60 Hz, 65 VA

Fuses: » Main (FU1) » 3/4 Amp MDL SLO-BLO or equivalent

» Speed Sensor (FU2) » 1/4 Amp MDL SLO-BLO or equivalent

Operating » -20 to 50°C (-5 to 122°F)
Temperature:

Accuracy: » ± 0.1% of span, typical
Resolution: » ± 0.02% of span, typical
Inputs: » Load cell: » -20 to +45 mV DC per load cell

» 4 load cells max.
» LVDT: » 0 to 0.75 Vrms, 3 kHz
» Speed Sensor: » 5-15 V DC pulses, 2 Hz to 10 kHz
» Multispan: » 4 contact inputs for up to 8 spans
» Auto Zero » contact input for enable
» Keypad » 20 key sealed membrane with tactile feedback
» Printer » contact input for print request

Outputs: » Load cell: » 10 V DC, 250 mA max.

(excitation)
» LVDT: » 2.0 Vrms, 3 kHz, 50 mArms max.

(excitation)
» Speed Sensor: » 15 V DC, 150 mA max.

(excitation)
» Analog: » 4-20 mA (0-25 mA scaleable), isolated, proportional to rate

» 0.1% resolution

» 750 Ω max. load
» Remote » SPST sealed relay

Totalizer:

» 1 form "A" contact rated 2A at 250V AC, 100 VA max.

» 25 msec. minimum contact closure duration

» 15 closures per second max.

PL-367 2 – 1

» Alarm: » 2 multipurpose relays for rate, load, or speed

» 1 Form "C" SPDT contact per relay, rated 5A at 230 V AC

» Communication: » 1 relay, 4PDT used for communication loop dropout,

» rated 1A at 230 V AC

» Display: » illuminated 256 x 128 dot matrix

Communication: » 2 serial ports

» RS232C and ± 20 mA current loop

Enclosure: » NEMA4 style, steel construction with polycarbonate window

» 330 mm W x 406 mm H x 102 mm D

(13" W x 16" H x 4" D)

Shipping Weight: » 11.0 Kg (24.3 lbs), no options

OPTIONS

Cable: » Single load cell, 150m (500 ft) max. 20 AWG, 4 wire shielded,

Belden 8404 or equivalent

» Single load cell, 300m (1000 ft) max. 20 AWG, 6 wire shielded,

Belden 8426 or equivalent

» Dual load cell, 150 m (500 ft) max. 20 AWG, 6 wire shielded,

Belden 8426 or equivalent

» Dual load cell, 300 m (1000 ft) max. 20 AWG, 8 wire shielded,

Belden 8418 or equivalent

» LVDT, 150 m (500 ft) max. 20 AWG, 4 wire shielded,

Belden 8404 or equivalent

» Speed Sensor, 300 m (1000 ft) max. 18 AWG, 3 wire shielded,

Belden 8770 or equivalent
Speed Sensor: » Milltronics MD36 or MD2000A for speed input
LCPA-08 » For connection to MMI-3 or MMI-4 scale configurations

interface:
Incline Compensator: » For variable incline conveyors
Barrier Strips: » For hazardous location belt scales
Enclosure Heater: » Recommended for operating temperatures below -10°C (14°F),

or excessive humidity.
Relay: » Food Grade remote totalizer relay
CVCC: » For bipolar current/RS-232C interface
BIC-II: » For 6 port bipolar current loop/RS-232C or RS-422 interface.

PL-367 2 – 2

■

INSTALLATION

COMPUSCALE III

The CompuScale III should be mounted in an area that is within the specified temperature range, and that is
suitable for Nema 4 style enclosures. The front cover should be accessible for keypad operation, display
viewing, and have sufficient room to swing open.

It is advisable to keep the CompuScale III away from high voltage or current runs, contactors, SCR control
drives and RF interference.

For proper totalizer relay operation, the CompuScale III must be mounted within 30° from vertical.
Refer to FIGURES.
Do not mount the CompuScale III in direct sunlight without the use of a sun shield.

INTERCONNECTION

Remove the enclosure bottom plate prior to drilling or punching cable/conduit entrance(s), to ensure metal
filings do not come in contact with the CompuScale III electronics.

Load cell or LVDT, speed sensor, rate output, communication, and low voltage contact wiring may be run in a
common conduit separated from power and high voltage contact wiring. Refer to Figures.

The power ground (TB1-50) is internally connected to SHLD connections (TB1-13,26 and TB2-5), and to the
mother board bottom mounting lugs. COM connections (TB1-15,29,32,36,37, and TB2-8) are connected to
power ground via jumper J2, (below TB1, between the mounting lugs). If the COM connections must be
isolated from power ground, remove J2.

Refer to FIGURES.
All wiring must be performed in accordance with all governing regulations.

HAZARDOUS LOCATIONS

The CompuScale III cannot be mounted in an area classed as hazardous. Where the associated belt scale is
mounted in a hazardous area, barrier strips must be used to isolate the CompuScale III from the hazardous
area for intrinsic safety. Contact Milltronics or your local representative for hazardous application information.

PL-367 3 – 1

■

START UP

HARDWARE SET UP

Prior to programming, SW1 and SW2 contacts must be
set as required.

UNIT I.D.

The CompuScale III identification code factory setting is
00, as set by SW1 contacts 1 - 4.

When more than one CompuScale III is connected to a
host computer or PLC, the identification code of each
CompuScale III must be set to a different value.

UNIT

I. D.

00 O O O O
01 C O O O
02 O C O O
03 C C O O
04 O O C O
05 C O C O
06 O C C O
07 C C C O

O = switch contact open C = switch contact closed

UNITS OF MEASURE

Two sets of Units are available; Imperial and Metric. Leave SW1 contact 5 (SW1-5) in the open position for
Imperial, or closed for Metric units. Refer to PARAMETERS/P0 RATE UNITS for the Rate Unit options
available.

SW1-5 must be set to the desired position

To alter the Units of Measure of a programmed CompuScale III, set SW1-5

as desired, then perform a Reset. Refer to Parameters / P99 Reset.

CERTIFICATION

SW 1

1 2 3 4

before initial programming is performed.

UNIT

I. D.

08 O O O C
09 C O O C
10 O C O C
11 C C O C
12 O O C C
13 C O C C
14 O C C C
15 C C C C

SW 1

1 2 3 4

Leave SW1 contact 6 (SW1-6) in the open position for normal applications. Close SW1-6 for Certified Mode
operation, after all programming and calibration is complete. Refer to Calibration / Calibration Alternatives.

TOTALIZER RESET

Leave SW1 contact 7 (SW1-7) in the open position for normal operation. When this contact is closed, the
Main Total Display cannot be reset.

TEST MODE

Leave SW1 contact 8 (SW1-8) in the open position for normal operation. The closed position is reserved for
Milltronics service personnel.

PL-367 4 – 1

PORT 2 BAUD RATE

Baud SW2

Rate 1 2

300 O O
1200 C O
2400 O C
9600 C C

LANGUAGE
Leave SW2 contact 3 (SW2-3) in the open position for English, or closed for alternate language,

CompuScale III displays.

REMOTE COMMUNICATION

Leave SW2 contact 6 (SW2-6) open for normal operation. If a remote mounted CompuScale III is used,
SW2-6 of the remote CompuScale III (only) must be closed.

The CompuScale III TB2 communication port baud rate is
independant of the PORT 1 baud rate, and is set by SW2
contacts 1 and 2. Set the baud as required by the device
connected. The factory setting is 300 baud.

O = switch contact open
C = switch contact closed

PORT 2 COMMUNICATION MODE

Leave SW2 contact 7 (SW2-7) open for normal operation, or closed if a serial printer is connected to Port 2.

TEST/ADJUST MODE

Leave SW2 contact 8 (SW2-8) in the open position for normal operation. In the closed position, a test menu is
displayed.

When the keypad test is selected, a graphical representation of the keypad is displayed. As each keypad
button is depressed, the display indicates successful operation.

When the display contrast adjustment is selected, pressing "4" increases, and pressing "8" decreases the
display contrast.

PL-367 4 – 2

95/11/09

PRE START UP CHECKS

After the CompuScale III has been properly installed and interconnected, the following checks should be
performed prior to connecting power:

» all cable connections are correct and secure.
» the proper voltage has been selected (J1 on the mother board).
» SW1 and SW2 have been set as required.
» the POWER switch is in the OFF position.

Connect power to TB1-51,52 and ground to TB1-50 of the CompuScale III. Ensure all connections are secure.

Do not operate the CompuScale III with the

ground (earth) wire disconnected.

INITIAL START UP

Set the CompuScale III POWER switch to the ON position. The CompuScale III will enter the following
initialization routine.

COMPUSCALE/FLO III (REV DATE) (EPROM 2 REV)
TEST : (MESSAGES)

PL-367 4 – 3

When the display initialization routine is complete, the display reverts to the last operating mode accessed. If
the CompuScale III is not programmed, the parameter entry display is accessed.

The CompuScale III display is divided into the following fields:

MULTISPAN

FEATURE

ECAL

VALUE

RELAY
CALIB.

BELT REV.

UNITS

AUX 1

AUX 2

-50%

150%100%RATE0%

RATE BAR
GRAPH

FIELD DESCRIPTION

MULTISPAN current span calibration selected. If Multispan 0 is selected, the field is blank.
RELAY current relay status (run mode). If relays are not used, or in non-alarm, the field is blank.
FEATURE parameter number (parameter entry), calibration type (calibrate mode), Load, Speed,

Rate or Total (run mode)
ECAL indicates ECAL (simulated rate signal) is on. If ECAL is off, the field is blank.
BELT REV. full belt revolutions remaining before calibration completion (calibrate mode).
CALIB calibrate mode indicator. When displayed, totalizers are on HOLD (unless otherwise specified).
VALUE the current value associated with the feature selected.
UNITS the units of measure associated with the value displayed
AUX 1 parameter name (parameter entry), auxiliary message (calibrate mode), not used (run mode).
AUX 2 parameter value range (parameter entry), additional information or error message (any mode).
BAR GRAPH represents current rate, displayed as percent of span (run mode).

■

PL-367 4 – 4

PROGRAMMING

GENERAL

Information specific to a particular application is entered into the CompuScale III memory, via the keypad,
prior to the calibration procedure.

KEYPAD

Button Operation Function

–

0

9

parameter entry numeric entries

4

8

RUN

PAR

ZERO

SPAN

ALT

DISP

RESET
TOTAL

parameter entry increase: analog mA output (P17 and P18 only), ECAL value (P22 only)

parameter entry decrease: analog mA output (P17 and P18 only), ECAL value (P22 only)

parameter entry decimal point

parameter entry negative entry or display previous parameter

any mode enter the run mode, return to previously selected display

any mode enter the program mode, access parameter for entry or viewing

any mode access zero calibration, view current zero count

any mode access span calibration, view current span count

any mode enter the run mode, select rate, total, load, or speed display

any mode enables a Total display reset (refer to Start Up\Hardware

Set Up\Totalizer Reset)

CLEAR

parameter entry clear display
calibrate mode abort calibration

ENTER

parameter entry display parameter value, or store altered parameter value,

or display next parameter
calibrate mode activate zero or span calibration, or accept calibration results
any mode with total displayed, switch to alternate total (main or sub)

PL-367 5 – 1

PARAMETER ENTRY

Application information must be entered into the appropriate CompuScale III memory locations. These
locations are identified by a Parameter Number (P#). The information entered is referred to as a Parameter
Value (Value). To enter information, the operator accesses the desired parameter number, views the
parameter value displayed, and then accepts or alters the current parameter value.

Common Parameter Entry Display Fields.

FEATURE

VALUE

UNITS

AUX 1
AUX 2

-50%

150%100%RATE0%

RATE BAR
GRAPH

DIRECT PARAMETER ACCESS

To directly access any parameter, , followed by the parameter number.

PAR

Only valid parameter numbers will be accepted. Refer to PARAMETERS for the list of valid parameter
numbers.

e.g. [PARAMETER ] is displayed in the FEATURE field, if PARAMETER 0 is desired

PAR

0

[PARAMETER 0 ] is displayed in the FEATURE field,
[RATE UNITS ] is displayed in the AUX 1 field.

To view the current parameter value and auxiliary messages for the displayed parameter,

ENTER

[PARAMETER 0 ] is displayed in the FEATURE field
[ 1 ] is displayed in the VALUE field (unless previously altered)
[RATE UNITS ] is displayed in the AUX 1 field

[1:T/h;2:LT/h;3:lb/h;4:lb/min ] is displayed in the AUX 2 field (with SW1-5 open)

AUTOMATIC PARAMETER ACCESS

Upon accessing any parameter value, pressing "ENTER" will automatically access the next parameter in the
programming sequence. Pressing "-" will automatically access the previous parameter.

e.g. with the VALUE field of PARAMETER 0 displayed...

ENTER

[PARAMETER 1 ] is displayed in the FEATURE field
[ 0.0000 ] is displayed in the VALUE field (unless previously altered)
[T/h] is displayed in the UNITS field (SW1-5 OPEN)
[RATE ] is displayed in the AUX 1 field
[ENTER VALUE ] is displayed in the AUX 2 field

all fields associated with PARAMETER 0 are displayed

PL-367 5 – 2

ALTERING PARAMETER VALUES

Once the desired parameter number is accessed, the parameter value may be accepted or altered as
required.

e.g. if the VALUE field of PARAMETER 0 is 1 (T/h), however 2 (LT/h) is desired

2

ENTER

[ 2 ] is displayed in the value field
the new value (2) is now stored in memory

LAST PARAMETER RECALL

From the Calibrate or Run mode, the last parameter accessed in the Program mode, may be recalled.

the last parameter accessed is displayed.

ENTER

PAR

PARAMETER RESET

To reset parameters to factory settings, refer to PARAMETERS/P99 Reset.

PROGRAMMING SEQUENCE

Typically, the CompuScale III is programmed as follows:

a) Referring to the Belt Scale Design Summary and PARAMETERS section, copy the appropriate

parameter values to the spaces provided on the PROGRAMMING CHART fold out.
b) Perform a MASTER RESET (P99).
c) Access each parameter in sequence from P0 and enter the

parameter values from the PROGRAMMING CHART.
d) Perform a Zero and Span calibration (refer to CALIBRATION)
e) Perform Span Adjust (P8), or Factoring (P9), and Speed Adjust (P19) procedures, as required.

Remember to copy any parameter value alterations onto the

PROGRAMMING CHART for future reference.

QUICK START GUIDE

A Quick Start Guide is shipped in the CompuScale III integrator enclosure. This guide describes the minimum
start up, programming, and calibration requirements of the CompuScale III, to obtain successful RUN mode
operation for most applications.

If desired, follow the Quick Start Guide procedure. Parameters which are not included in the guide may be
programmed after the RUN mode is entered.

■

PL-367 5 – 3