Siemens milltronics BW500 Instruction Manual

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Page 1

Instruction Manual May 2008

milltronics

BW500

Page 2

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.

Unit Repair and Excluded Liability:

• The user is responsible for all changes and repairs made to the device by the user or the user’s agent.

• All new components are to be provided by Siemens Milltronics Process Instruments Inc.

• Restrict repair to faulty components only.

• Do not reuse faulty components.

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

This product is intended for use in industrial areas. Operation of this equipment in a residential area may cause interference to several frequency based communications.

Note: Always use product in accordance with specifications.

Disclaimer of Liability

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.

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.

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

Contact SMPI Technical Publications European Authorized Representative at the following address:

Technical Publications Siemens AG Siemens Milltronics Process Instruments Inc. Industry Sector 1954 Technology Drive, P.O. Box 4225 76181 Karlsruhe Peterborough, Ontario, Canada, K9J 7B1 Deutschland Email: techpubs.smpi@siemens.com

• For a selection of Siemens Milltronics level measurement manuals, go to: www. siemens.com/processautomation. Under Process Instrumentation, select

Measurement

• For a selection of Siemens Milltronics weighing manuals, go to: www. siemens.com/processautomation. Under Weighing Technology, select

Weighing Systems

and then go to the manual archive listed under the product family.

Level

Continuous

Page 3

Table of Contents

Milltronics BW500 ..............................................................................................................1

Milltronics BW500 features ........................................................................................................1

Safety Notes .............................................................................................................................................2

The Manual ...............................................................................................................................................2

Specifications ......................................................................................................................3

Installation ........................................................................................................................... 6

Dimensions ...............................................................................................................................................6

Layout ........................................................................................................................................................7

Optional Plug-ins .....................................................................................................................................8

SmartLinx® Module .....................................................................................................................8

mA I/O board ...................................................................................................................................8

Interconnection .....................................................................................................................................10

System Diagram .........................................................................................................................10

Scale – One Load Cell ................................................................................................................11

Scale – Two Load Cell ................................................................................................................12

Scale – Four Load Cell ...............................................................................................................13

Scale – LVDT .................................................................................................................................14

Speed .......................................................................................................................................................15

Constant Speed (No Sensor) ....................................................................................................15

Main Speed Sensor ....................................................................................................................15

Auxiliary Speed Sensor .............................................................................................................16

Auxiliary Inputs .....................................................................................................................................17

Auto Zero .................................................................................................................................................17

RS-232 Port 1 ..........................................................................................................................................17

Printers ...........................................................................................................................................17

Computers and Modems ...........................................................................................................18

Remote Totalizer ....................................................................................................................................18

mA Output 1 ............................................................................................................................................18

Relay Output ...........................................................................................................................................19

RS-485 Port 2 ..........................................................................................................................................19

Daisy Chain ...................................................................................................................................19

Terminal Device ............................................................................................................................19

RS-232 Port 3 ..........................................................................................................................................20

Power Connections ..............................................................................................................................20

mA I/O Board ..........................................................................................................................................21

Installing/Replacing the Memory Back-up Battery ......................................................................21

Table of Contents

Start Up ...............................................................................................................................22

Orientation ..............................................................................................................................................22

Display and Keypad ....................................................................................................................22

PROGRAM Mode ..................................................................................................................................23

PROGRAM Mode Display .........................................................................................................23

To enter the PROGRAM mode .................................................................................................23

RUN Mode ....................................................................................................................................25

Initial Start Up ........................................................................................................................................25

Power Up .......................................................................................................................................25

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Programming ................................................................................................................................25

Load Cell Balancing ..............................................................................................................................28

Typical two load cell belt scale ................................................................................................29

Zero Calibration ...........................................................................................................................32

RUN Mode ....................................................................................................................................33

Recalibration ..................................................................................................................... 34

Belt Speed Compensation ..................................................................................................................34

Table o f C on t en t s

Material Tests ........................................................................................................................................35

% Change ......................................................................................................................................35

Material Test .................................................................................................................................37

Design Changes .....................................................................................................................................37

Recalibration ...........................................................................................................................................38

Routine Zero .................................................................................................................................38

Initial Zero .....................................................................................................................................39

Direct Zero ....................................................................................................................................39

Auto Zero .......................................................................................................................................40

Routine Span ................................................................................................................................41

Initial Span ....................................................................................................................................42

Direct Span ...................................................................................................................................43

Multispan ......................................................................................................................................43

On-line Calibration ................................................................................................................................46

Factoring .................................................................................................................................................50

Linearization ...........................................................................................................................................51

Operation ............................................................................................................................54

Load Sensing ..........................................................................................................................................54

Speed Sensing .......................................................................................................................................54

Differential Speed Detection ..............................................................................................................54

Moisture Compensation ......................................................................................................................55

Incline Compensation ..........................................................................................................................55

Modes of Operation ..............................................................................................................................56

Damping ...................................................................................................................................................57

mA I/O (0/4-20 mA) ................................................................................................................................57

Output .............................................................................................................................................57

Input ................................................................................................................................................57

Relay Output ...........................................................................................................................................58

Totalization ..............................................................................................................................................59

PID Control .........................................................................................................................61

Hardware .................................................................................................................................................61

Connections ............................................................................................................................................61

Setpoint Controller – Rate Control ..........................................................................................62

Setpoint Controller – Load Control ..........................................................................................62

Setpoint Controller – Master/Slave Control .........................................................................63

Setpoint Controller – Rate and Load Control .......................................................................64

Setup and Tuning ...................................................................................................................................64

Proportional Control (Gain), P ..................................................................................................64

Integral Control (Automatic Reset), I ......................................................................................65

Derivative Control (Pre-Act or Rate), D ..................................................................................66

Feed Forward Control, F ............................................................................................................66

PID Setup and Tuning ...........................................................................................................................67

Page 5

Initial Start-Up ..............................................................................................................................67

Programming ..........................................................................................................................................70

Batching ..............................................................................................................................73

Connections ............................................................................................................................................73

Typical Ladder Logic ...................................................................................................................73

Programming ..........................................................................................................................................74

Operation .................................................................................................................................................75

Pre-act Function ..........................................................................................................................75

Communications ............................................................................................................... 76

BW500 and SmartLinx® .....................................................................................................................77

Connection ..............................................................................................................................................77

Wiring Guidelines ........................................................................................................................77

Configuring Communication Ports ....................................................................................................78

P770 Serial protocols ..................................................................................................................78

P771 Protocol address ................................................................................................................79

P772 Baud Rate ............................................................................................................................79

P773 Parity .....................................................................................................................................79

P774 Data bits ...............................................................................................................................80

P775 Stop bits ...............................................................................................................................80

P778 Modem attached ...............................................................................................................80

P779 Modem idle time ...............................................................................................................81

P780 RS-232 Transmission interval .........................................................................................81

P781 Data message ....................................................................................................................82

P799 Communications Control .................................................................................................82

Dolphin Protocol ....................................................................................................................................83

Dolphin Plus Screen Shot ..........................................................................................................83

Modbus RTU/ASCII Protocol ..............................................................................................................84

How Modbus Works ...................................................................................................................84

Modbus RTU vs. ASCII ...............................................................................................................85

Modbus Format ............................................................................................................................85

Modbus Register Map ...............................................................................................................85

Modbus Register Map (cont’d) ................................................................................................88

Modems .........................................................................................................................................98

Error Handling ........................................................................................................................... 100

Table of Contents

Parameters ....................................................................................................................... 102

Start Up (P001 to P017) ..................................................................................................................... 102

Relay/Alarm Function (P100 - P117) ............................................................................................... 106

mA I/O Parameters (P200 - P220) ....................................................................................................110

Calibration Parameters (P295 – 360) ............................................................................................... 114

On-line Calibration Options (P355 to P358) ...................................................................................115

Linearization Parameters (P390 - P392) .........................................................................................117

Proportional Integral Derivative (PID) Control Parameters (P400 – P419) ............................119

Batch Control (P560 – P568) ..............................................................................................................122

Totalization (P619 - P648) ...................................................................................................................123

ECal Parameters (P693 – P698) ........................................................................................................127

Communication (P750 - P799) ...........................................................................................................129

SmartLinx Hardware Testing ............................................................................................................129

Test and Diagnostic (P900 - P951) ...................................................................................................130

iii

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Troubleshooting ............................................................................................................... 133

Generally ......................................................................................................................................133

Specifically ..................................................................................................................................133

Certification ..................................................................................................................... 136

Certification Printing .................................................................................................................136

Glossary ............................................................................................................................ 137

Table o f C on t en t s

Appendix I ........................................................................................................................ 140

Memory Backup ..................................................................................................................................140

Software Updates ...............................................................................................................................140

Calibration Criteria ..............................................................................................................................140

Zero ...............................................................................................................................................140

Span ..............................................................................................................................................140

PID Systems ................................................................................................................................140

Appendix II: Software Revision History ..................................................................... 141

Index .................................................................................................................................. 144

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Milltronics BW500

Note:

• The Milltronics BW500 is to be used only in the manner outlined in this instruction manual.

• This product is intended for use in industrial areas. Operation of this equipment in a residential area may cause interference to several frequency based communications.

The Milltronics BW500 is a full-featured integrator for use with belt scales and weigh feeders. 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.

BW500 supports Siemens Milltronics Dolphin Plus software and Modbus protocol on the two RS-232 ports and the RS-485 port for communication to customer PLC or computer. BW500 also supports Siemens SmartLinx communication systems.

Milltronics BW500 features

Reliable and robust user interface

• multi-field LCD display

• local keypad

for communication with popular industrial

Introduction

Instrumentation I/O

• two remote totalizer contacts

• five programmable relays

• five programmable discrete inputs

• two programmable isolated mA input, for PID* control

• three programmable isolated mA output for rate, load, speed or PID* control

Popular Windows®and Industrial communications

• two RS-232 ports

• one RS-485 port

Individual port configuration for:

•Dolphin

•Modbus ASCII

•Modbus RTU

•Printer

• SmartLinx

7ML19985DK03 Milltronics BW500 – INSTRUCTION MANUAL Page 1

compatible

Page 8

Controls and operation functions

*PID control, Moisture and Incline Compensation requires the optional mA I/O board.

Safety Notes

Special attention must be paid to warnings and notes highlighted from the rest of the text by grey boxes.

Introduction

Note: means important information about the product or that part of the operating

manual.

The Manual

• load linearization

• auto zero

• PID control*

• batch control

• multispan operation

• moisture compensation*

• incline compensation*

• differential speed detection

WARNING means that failure to observe the necessary precautions can result in death, serious injury, and/or considerable material damage.

It is essential that this manual be referred to for proper installation and operation of your BW500 belt scale integrator. As BW500 must be connected to a belt scale, and optionally a speed sensor, refer to their manuals as well.

The manual is designed to help you get the most out of your BW500, and it provides information on the following:

• How to install the unit

• How to program the unit

• How to operate the keypad and read the display

• How to do an initial Start Up

• How to optimize and maintain accurate operation of the unit

If you have any questions, comments, or suggestions about the manual contents, please email us at techpubs.smpi@siemens.com.

For the complete library of Siemens manuals, go to www.siemens.com/processautomation

Page 2 Milltronics BW500 – INSTRUCTION MANUAL 7ML19985DK03

• Outline diagrams

• Wiring diagrams

• Parameter values

• Parameter uses

• MODBUS register mapping

• Modem configuration

Page 9

Specifications

Power

• 100/115/200/230 V AC ±15%, 50/60 Hz, 31 VA

• fuse, FU1 2AG, Slo Blo, 2 A, 250 V or equivalent

Application

• compatible with Siemens belt scales or equivalent 1, 2 or 4 load cell scales

• compatible with LVDT equipped scales, with use of optional interface board

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

• Type 4X / NEMA 4X / IP 65

• 285 mm W x 209 mm H x 92 mm D (11.2” W x 8.2” H x 3.6” D)

• polycarbonate

Programming

• via local keypad and/or Dolphin Plus interface

Display

• illuminated 5 x 7 dot matrix liquid crystal display with 2 lines of 40 characters each

Memory

• program stored in non-volatile FLASH ROM, upgradable via Dolphin Plus interface

• parameters stored in battery backed RAM, battery P/N PBD-2020035 or use equivalent

3V Lithium battery, 5 year life

Specifications

7ML19985DK03 Milltronics BW500 - INSTRUCTION MANUAL Page 3

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Specifications

Inputs

• load cell: 0 - 45 m V DC per load cell

• speed sensor: pulse train 0 V low, 5-15 V high, 1 to 3000 Hz, or open collector switch, or relay dry contact

• auto zero: dry contact from external device

• mA see optional mA I/O board

• auxiliary: 5 discrete inputs for external contacts, each programmable for either display scrolling, totalizer 1 reset, zero, span, multispan, print, batch reset, or PID function.

Outputs

• mA: - 1 programmable 0/4 - 20 mA, for rate, load and speed output

- optically isolated

- 0.1% of 20 mA resolution

-750 Ω load max

- see optional mA I/O board

• load cell: 10 V DC compensated excitation for strain gauge type, 4 cells max, 150 mA max

• speed sensor: 12 V DC, 150 mA max excitation for each speed sensor

• remote totalizer 1: - contact closure 10 - 300 ms duration

- open collector switch rated 30 V DC, 100 mA max

• remote totalizer 2: - contact closure 10 - 300 ms duration

- open collector switch rated 240 V AC/DC, 100 mA max

• relay output: 5 alarm/control relays, 1 form 'A' SPST relay contact per relay, rated 5 A at 250 V AC, non-inductive

Communications

•two RS-232 ports

• one RS-485 port

• SmartLinx

compatible (see

Options

below)

Cable

• one 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

• two / four* load cells:

non-sensing: Belden 9260, 6 wire shielded, 20 AWG or equivalent,

150 m (500 ft.) max

Page 4 Milltronics BW500 - INSTRUCTION MANUAL 7ML19985DK03

Page 11

sensing: Belden 8418, 8 wire shielded, 20 AWG or equivalent,

300 m (1000 ft.) max

*for four load cell scale, run two separate cables of two load cell configuration

• speed sensor: Belden 8770, 3 wire shielded, 18 AWG or equivalent, 300m (1000 ft.)

• auto zero: Belden 8760, 1 pair, twisted/shielded, 18 AWG, 300 m (1000 ft.) max

• remote total: Belden 8760, 1 pair, twisted/shielded, 18 AWG, 300 m (1000 ft.) max

Options

• Speed Sensor: Siemens MD-36 / 36A / 256 or 2000A, or RBSS, or compatible

• Dolphin Plus: Siemens Windows associated product documentation)

• SmartLinx

• Siemens Milltronics Incline Compensator:

•mA I/O board:

® Modules: protocol specific modules for interface with popular

industrial communications systems (refer to associated product documentation)

- for load cell excitation compensation on variable incline conveyors

inputs: - 2 programmable 0/4 – 20 mA for PID, control

- optically isolated

- 0.1% of 20 mA resolution

-200 Ω input impedance

based software interface (refer to

Specifications

outputs: - 2 programmable 0/4 – 20 mA for PID control, rate, load

and speed output

- optically isolated

- 0.1% of 20 mA resolution

-750 Ω load max

• output supply: isolated 24 V DC at 50 mA, short circuit protected

• LVDT interface card: for interface with LVDT based scales

Weight

• 2.6 kg (5.7 lb.)

Approvals

•CE*, CSA

• Legal for Canadian Trade - Measurement Canada approved

• Legal for US Trade - NTEP approved

*EMC performance available upon request

7ML19985DK03 Milltronics BW500 - INSTRUCTION MANUAL Page 5

NRTL/C

Page 12

Installation

209

Notes:

• Installation shall only be performed by qualified personnel and in accordance with local governing regulations.

• This product is susceptible to electrostatic shock. Follow proper grounding procedures.

Dimensions

16 mm

(0.6")

(8.2")

172 mm

(6.8’)

lid screws

(6 pieces)

92 mm

(3.6")

285 mm

(11.2")

RUN

ALT DISP

PAR

ZERO

SPAN

RESET

CLEAR

ENTER

TOTAL

267 mm

(10.5")

Conduit entry area.

Recommend drilling the enclosure with

a hole saw and the use of suitable cable

glands to maintain ingress rating.

mounting hole

(4 places)

lid

enclosure

customer

mounting screw

Installation

Note: Non metallic enclosure does not provide grounding between connections.

Use grounding type bushings and jumpers.

Page 6 Milltronics BW500 - INSTRUCTION MANUAL 7ML19985DK03

Page 13

Layout

battery,

memory

back up

certification

switch

optional SmartLinx

module

port 3 (RJ-11)

optional

Analog I/O

board

SHLD

MADE IN CANADA PETERBOROUGH ONT

LCA

LCB

LCCLCD

LOAD CELL INPUTS

V+

S+

S-

EXCITATION

V-

LOAD CELL

SHLD

SIG

COM

CNST

+EXC

SPEED SENSOR

SHLD

MA+

MA-

COM

RS-232

SHLD

AUX1

AUX2

T1+

AUX3

T1-

AUX4

SHLD

T2+

AUX5

T2-

COM

A-Z

SHLD

MILLTRONICS

VENTURE ANALOG I/O

PN ________ -__

VOLT SELECT

200V

50/60HZ

230V

OFF

RLY3

COM

RLY4

RS485

RLY5

SHLD

RLY1

L2/N

RLY2

*To reduce communication interference, route SmartLinx®cable along right side of enclosure wall.

WARNING:

• All field wiring must have insulation suitable for at least 250 V.

• dc terminals shall be supplied from SELV source in accordance with IEC 10101-1 Annex H.

• Relay contact terminals are for use with equipment having no accessible live parts and wiring having insulation suitable for at least 250 V.

• The maximum allowable working voltage between adjacent relay contact shall be 250 V.

power switch

115V

fuse FU1

100

Installation

7ML19985DK03 Milltronics BW500 - INSTRUCTION MANUAL Page 7

Page 14

Optional Plug-ins

SmartLinx® Module

The BW500 is software/hardware ready to accept the optional Siemens SmartLinx industrial communications systems.

Your BW500 may be shipped to you without a SmartLinx later date.

If you are ready to install your SmartLinx instructions as outlined.

communications module that provides an interface to one of several popular

module, for installation at a

module, or want to change it, please follow the

Installation

1. Isolate power and voltages applied to the BW500.

2. Open the lid.

3. Install the module by mating the connectors and secure in place using the two screws provided.

4. Route communication cable to SmartLinx enclosure wall. This route will reduce communication.

module along the right side of the

Note: Refer to the SmartLinx® module documentation for any required hardware

settings prior to closing the lid.

5. Close the lid.

6. Apply power and voltage to the BW500.

Refer to:

• SmartLinx®Module in the

P750 – P769 SmartLinx® Module Specific Parameters

• manual,

• the SmartLinx® manual for wiring.

Specifications

section on page 3,

on page 129 in this

mA I/O board

Installation

The BW500 is software/hardware ready to accept the optional mA I/O board. The mA I/O board provides 2 programmable 0/4-20 mA outputs, 2 programmable 0/4-20 mA inputs and a nominal 24V DC supply for loop powered devices.

Your BW500 may be shipped to you without an mA I/O board, for installation at a later date.

If you are ready to install your mA I/O board, please follow the instructions as outlined.

Page 8 Milltronics BW500 - INSTRUCTION MANUAL 7ML19985DK03

Page 15

Installation

1. Isolate power and voltages applies to the BW500.

2. Open the lid.

3. Install the board by mating the connectors and secure the card in place using

4. Close the lid.

5. Apply power and voltage to the BW500.

Refer to:

•

the 3 screws provided.

Specifications mA I/O board

on page 3

on page 21

mA I/O Parameters (P200 - P220) mA I/O (0/4-20 mA)

in the

Operation

on page 110

section on page 57

mA I/O board

SmartLinx

route SmartLinx®cable

along right hand wall

Installation

7ML19985DK03 Milltronics BW500 - INSTRUCTION MANUAL Page 9

Page 16

Interconnection

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

same conduit as high voltage contact or power wiring. Ground shield at one point only. Insulate at junctions to prevent inadvertent grounding

System Diagram

Milltronics

BW500

optional SmartLinx®

optional analog I/O

belt scale, see Specifications

mA output to customer device

mA input from customer device

relay output, to customer device

speed sensor, optional, see Specifications

mA output to customer device

auxiliary inputs

customer remote totalizer

optional fieldbus connection

communication ports can be

Installation

configured for Siemens Milltronics Dolphin, print data, or Modbus ASCII or RTU protocol

Note: Typical system capability. Not all components or their maximum quantity may

be required

Page 10 Milltronics BW500 - INSTRUCTION MANUAL 7ML19985DK03

Page 17

Scale – One Load Cell

Siemens Belt Scale

load cell

Note: Colour code for load cells used on

Siemens weighfeeders may be different

customer

junction box

than shown. Please refer to the weighfeeder wiring diagram.

*Where separation between the BW500 and belt scale exceeds 150 m (500 ft.), or legal for trade certification:

Installation

1. remove the jumpers from BW500 terminal 11/12 and 13/14

2. run additional conductors from: BW500 terminal 12 to scale `red' BW500 terminal 13 to scale `blk'

If the load cell wiring colours vary from those shown, or if extra wires are provided, consult Siemens.

7ML19985DK03 Milltronics BW500 - INSTRUCTION MANUAL Page 11

Page 18

Scale – Two Load Cell

Siemens Belt Scale

Note: Colour code for load cells used on

Siemens weighfeeders may be different than shown. Please refer to the weighfeeder wiring diagram.

customer

junction box

load cell

R E D

load cell

Where separation between the BW500 and belt scale exceeds 150 m (500 ft.), or legal for

Installation

trade certification:

1. remove the jumpers from BW500 terminal 11/12 and 13/14

2. run additional conductors from: BW500 terminal 12 to scale `red' BW500 terminal 13 to scale `blk'

If the load cell wiring colours vary from those shown, or if extra wires are provided, consult Siemens.

Page 12 Milltronics BW500 - INSTRUCTION MANUAL 7ML19985DK03

Page 19

Scale – Four Load Cell

Siemens Belt Scale

customer

junction box

integrator

load cell

load cellCload cell

Where separation between the BW500 and belt scale exceeds 150 m (500 ft.), or legal for trade certification:

Installation

1. remove the jumpers from BW500 terminal 11/12 and 13/14

2. run additional conductors from: BW500 terminal 12 to scale `red' BW500 terminal 13 to scale `blk'

If the load cell wiring colours vary from those shown, or if extra wires are provided, consult Siemens.

7ML19985DK03 Milltronics BW500 - INSTRUCTION MANUAL Page 13

Page 20

Scale – LVDT

belt scale with

LVDT

maximum cable run LVDT to Conditioner 300 m (1000 ft.)

Siemens Milltronics

BW50 0

Siemens Milltronics LVDT Conditioner

Installation

Where separation between the BW500 and LVDT conditioner exceeds 150 m (500 ft.):

1. remove the jumpers from BW500 terminal 11/12 and 13/14

2. run additional conductors from: BW500 terminal 12 to integrator terminal block ‘+EXC’ BW500 terminal 13 to integrator terminal block ‘-EXC’

For further connection information on specific LVDT’s consult Siemens.

Page 14 Milltronics BW500 - INSTRUCTION MANUAL 7ML19985DK03

Page 21

Speed

Constant Speed (No Sensor)

If a speed sensor is not used, a jumper or contact closure must be connected across the BW500 terminals 17 / 18 when the conveyor is running. If a speed sensor is used, insure that the jumper is

removed.

Main Speed Sensor

-SPEED SENSOR-

SHLD

CONST

+EXC

SHLD

SIG

COM

Note: With contact closed or jumpered

when the conveyor is idle, the integrator will continue totalizing

MD Series RBSS or ENCODER

123

16 17

wht

blk

red

♦Shields are common, but not grounded to chassis. Run cable shields through SHLD terminals and ground at BW500 only.

Connect the BW500 terminal 16 to speed sensor terminal:

• ‘2’ for clockwise speed sensor shaft rotation

• ‘3’ for counter-clockwise speed sensor shaft rotation.

Speed sensor shaft rotation is viewed from the front cover of the speed sensor enclosure.

Input device in the form of open collector transistor or dry contact across BW500 terminals 16 / 17 will also serve as a suitable speed signal.

If a speed sensor other than the models shown is supplied, consult with Siemens for details.

A second speed sensor input can be added using the Auxiliary inputs: the second speed input allows calculation of Differential Speed. For more information, see

(P270)

on page 112.

Auxiliary Inputs

7ML19985DK03 Milltronics BW500 - INSTRUCTION MANUAL Page 15

Installation

Page 22

Auxiliary Speed Sensor

SPEED SENSOR

12OR3

SIG

COM

CNST

+EXC

SHLD

16 26

17 27

18 28

♦Shields are common, but not grounded to chassis. Run cable shields through SHLD terminals and ground at BW500 only.

Connect the BW500 terminal 24-28 to speed sensor terminal:

• ‘2’ for clockwise speed sensor shaft rotation

• ‘3’ for counter-clockwise speed sensor shaft rotation.

Speed sensor shaft rotation is viewed from the front cover of the speed sensor enclosure.

Input device in the form of open collector transistor or dry contact across BW500 terminals 24-28 will also serve as a suitable speed signal.

If a speed sensor other than the models shown is supplied, consult with Siemens for details.

Installation

Page 16 Milltronics BW500 - INSTRUCTION MANUAL 7ML19985DK03

Page 23

Auxiliary Inputs

Auto Zero

Customer dry contacts, or open collector transistor output supplied as required

Refer to

P270

on page 112 for

programming details.

Prefeed activated dry contact

Refer to

Auto Zero

on page 40.

RS-232 Port 1

Printers

Printer

receive

common

7ML19985DK03 Milltronics BW500 - INSTRUCTION MANUAL Page 17

Installation

Page 24

Computers and Modems

For connection to a PC compatible computer or modem, using no flow control, typical configurations are:

DB-9 DB-25

ComputerModem

Remote Totalizer

supply, 30V max

remote totalizer 1

supply,

240V max

remote totalizer 2

mA Output 1

Installation

Page 18 Milltronics BW500 - INSTRUCTION MANUAL 7ML19985DK03

to customer instrumentation, isolated mA output, 750 Ω maximum load

Page 25

Relay Output

Relays shown in de-energized state, contacts normally open, rated 5 A at 250 V noninductive.

RS-485 Port 2

Daisy Chain

customer device

Terminal Device

customer device

7ML19985DK03 Milltronics BW500 - INSTRUCTION MANUAL Page 19

Installation

Page 26

RS-232 Port 3

Note: Jumper pins 4-6 and 7-8 when using hardware flow control. Otherwise, leave

them open.

Power Connections

Notes:

1. The equipment must be protected by a 15 A fuse or a circuit breaker in the building installation.

2. 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

Installation

Page 20 Milltronics BW500 - INSTRUCTION MANUAL 7ML19985DK03

100 / 115 / 200 / 230V

50 / 60 Hz

select voltage via switch

Page 27

mA I/O Board

auxiliary supply output, isolated 24 V DC at 50 mA, short circuit protected

from customer instrumentation, isolated mA input, 200Ω

to customer instrumentation, isolated mA output, 750Ω maximum load

Installing/Replacing the Memory Back-up Battery

The memory battery (see Specifications, page 3) should be replaced every 5 years to insure memory back up during lengthy power outages. An on board capacitor provides 20

minutes of charge to preserve the memory while the battery is being changed.

Notes:

• Do not install the memory backup battery until the BW500 is installed, as it begins operation immediately.

• The unit is supplied with one battery (battery P/N PBD-2020035 or use equivalent 3V Lithium battery). Insert the battery into the holder as shown in the following diagram before using the BW500.

Disconnect power before installing or replacing the battery.

Installation Steps

1. Open the enclosure lid.

2. Slide the battery into the holder. Be sure to align the + and – terminals correctly.

3. Close and secure enclosure lid.

7ML19985DK03 Milltronics BW500 - INSTRUCTION MANUAL Page 21

Installation

Page 28

Start Up

Note: For successful start up, ensure that all related system components such as

thebelt scale and speed sensor are properly installed and connected.

Orientation

Display and Keypad

Program

Edit Mode:

numerical and

arithmetical keys

Press to enter RUN mode

ZERO

SPAN

PAR

RUN

RESET

ALT

CLEAR

ENTER

TOTAL

DISP

Press to enter PROGRAM mode

Press to scroll through RUN displays

RUN

ALT DISP

RUN

ALT DISP

PAR

ZERO

RESET

CLEAR

TOTAL

View mode:

press to scroll through parameter list

SPAN

Press to alternate

ENTER

between view and edit modes, and enter parameter

Press to initiate calibration

values

clear entry

Press to change PID local setpoint

SPAN

ENTER

values

PID auto/manual switch

Press to initiate calibration

PAR

ZERO

RESET

CLEAR

TOTAL

Start Up

Run

Press to reset

totalizer

Page 22 Milltronics BW500 - INSTRUCTION MANUAL 7ML19985DK03

Page 29

The BW500 operates under two modes: RUN and PROGRAM. When the unit is initially powered, it starts in the PROGRAM mode

PROGRAM Mode

The PROGRAM parameters define the calibration and operation of the BW500.

By entering the PROGRAM mode, the user can view the parameter values or edit them to suit the application.

PROGRAM Mode Display

VIEW

P001 Language V 1-Eng 1

EDIT

P001 Language E 1-Eng 1

To enter the PROGRAM mode

Press

P001 Language V 1-Eng 1

To select a parameter

Scroll:

Press to move up,

P002 Test Reference Selection V 1-Weight, 2-Chain, 3-Ecal 1

Press to move down.

P001 Language V 1-Eng 1

7ML19985DK03 Milltronics BW500 - INSTRUCTION MANUAL Page 23

The default of previous parameter view is displayed. e.g. P001 is the default parameter for initial start up.

e.g. scrolls up from P001 to P002.

e.g. scrolls up from P001 to P002

Start Up

Page 30

To access a parameter directly:

Press

View/Edit Parameter Enter Parameter Number

Press

in sequence.

P011 Design Rate: V Enter Rate 100.00 kg/h

Or press

P940-2 Load Cell mV Signal Test V mV reading for B 6.78

To change a parameter value

P011 Design Rate: V Enter Rate 100.00 kg/h

Press

P011 Design Rate: E Enter Rate 100.00 kg/h

Press

P014 Design Speed V Enter Speed 0.08 m/S

To reset a parameter value

e.g. access P011, design rate

For direct access to index parameters

e.g. access P940-2, load cell B mV signal

from the view mode

If edit mode is not enabled after pressing ENTER, Security is locked. Refer to

Parameters \ Security Lock (P000)

page 102 for instructions on disabling

Enter the new value

For P001 to P017, ENTER effects the change and scrolls to the next required parameter.

Press

P011 Design Rate: E

from the edit mode

Enter Rate 100.00 kg/h

Press

P011 Design Rate: V Enter Rate 0.00 kg/h

Enter the clear function

Value is reset to factory value. e.g. 0.00 kg/h

Start Up

Page 24 Milltronics BW500 - INSTRUCTION MANUAL 7ML19985DK03

Page 31

RUN Mode

To operate the BW500 in the RUN mode, the unit must undergo an initial programming to set up the base operating parameters.

Attempting to enter the RUN mode without satisfying the program requirements forces the program routine to the first missing item.

Initial Start Up

Initial start up of the BW500 consists of several stages, and assumes that the physical and electrical installation of the belt scale and speed sensor, if used, is complete:

• power up

• programming

• load cell balancing

• zero and span calibration

Power Up

Upon initial power up, the BW500 displays:

P001 Language V 1-Eng 1

The initial display prompts the user to select the preferred language.

Note: This manual only lists English as a choice of language. However, your BW500

will list additional languages.

Programming

Press

The BW500 then scrolls sequentially through the start up program as parameters P001 through P017 are addressed.

P002 Test Reference Selection V Select 1-Weight, 2-Chain, 3-Ecal 1

Press

P003 Number of Load Cells V Enter Number of Load Cells 2

e.g. Accept ’weight’ (supplied with scale) as the test reference.e.g.

e.g. Accept ’2’ as the number of load cells.

Start Up

7ML19985DK03 Milltronics BW500 - INSTRUCTION MANUAL Page 25

Page 32

Press

P004 Rate Measurement System V Select 1-Imperial, 2-Metric 2

Press

P005 Design Rate Units: V Select: 1-t/h, 2-kg/h, 3-kg/min 1

Press

P008 Date: V Enter YYY-MM-DD 1999-03-19

Press

P008 Date: E Enter YYY-MM-DD 1999-03-19

Press

P009 Time: V Enter HH-MM-SS 00-00-00

Press

e.g. Accept ’2’ for measurements in metric.

e.g. Accept ’1’ for units in t/h

default date

e.g. enter current date of October 19, 1999

factory set time 24 hour clock

P009 Time: E Enter HH-MM-SS 00-00-00

Press

P011 Design Rate: V

e.g. enter current time of 14:41

factory design rate

Enter Rate 0.00 t/h

Press

P011 Design Rate: E Enter Rate 0.00 t/h

Press

P014 Design Speed V

e.g. rate of 100 t/h

factory design speed

Enter Speed 0.00 m/s

Start Up

Page 26 Milltronics BW500 - INSTRUCTION MANUAL 7ML19985DK03

Page 33

Press

P014 Design Speed E Enter Speed 0.00 m/s

Press

e.g.speed of 0.8 m/s

P015-01 Speed Constant V Pulses/m 0.0000

If the speed input is configured for constant speed, display value reads ‘Jumpered’

press to advance.

Press

P690-01 Speed Constant Entry E 1-Calculated, 2-Sensor Data 1

P691-01 Step 1: Drive Pully Diameter:

Diameter 0.00 mm

P692-01 Step 2: Pulses per sensor Rev.

Enter Pulses 0.00

select: 1- calculated value, the program returns to P015. Calculate the value per Parameter P690.

select 2- sensor date, the

program advances through parameters P691 and P692 prompting entry from the sensor nameplate. From this data, the speed constant is calculated and

automatically entered into P015.

Press

P015-01 Speed Constant E Pulses/m 0.0000

Press

This value is calculated. For manual or automatic calculation, refer to

e.g. speed constant of 100.3 pulses per meter

P690

on page 126.

To program Differential Speed (P015-02), follow steps above for P015-01.

P016 Belt Length V Enter Length 0.000 m

factory set length

Press

P016 Belt Length E Enter Length 0.000 m

7ML19985DK03 Milltronics BW500 - INSTRUCTION MANUAL Page 27

Start Up

Page 34

Press

e.g. belt length of 25 m

P017 Test Load: Weight MS 1 V

factory set test load

Enter test load 0.00 kg/m

If P002 Test Load Reference had been set for 2-Chain, the display would read:

P017 Test Load: Chain MS 1 Enter test load

or if ECal

refer to

P017 Test Load: ECal MS 1 Enter test load

Par ame ter s\E Cal

Parameters (P693 - P699

page 127

) on

Press

P017 Test Load: Weight MS 1 E Enter test load 0.00 kg/m

Press

This value is calculated based on test weight and idler spacing. For manual or automatic

P017

calculation, refer to

on page 105.

The test load value should be less than the design load (P952). If not, contact Siemens.

P017 Test Load: Weight MS 1 V Enter test load 25.00 kg/m

e.g. test load of 25 kg/m

The initial programming requirements are now satisfied. To ensure proper entry of all critical parameter values, return to P002 and review parameters through to P017.

Load Cell Balancing

Load cell balancing is not required if the selected test reference is ECal (P002 = 3). In the case of ECal, the load cells are balanced by the ECal procedure.

If you are operating a two or four 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.

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

Start Up

Page 28 Milltronics BW500 - INSTRUCTION MANUAL 7ML19985DK03

Page 35

Typical two load cell belt scale

Belt

travel

load cell

’B’

Access P295

P295 Load Cell Balancing: E Select: 1-A&B, 2-C&D 0

Press

Load Cell Balancing A & B Place weight at cell B and press ENTER

’B’

test weight bar

option ’2’ enabled only if P0 03, number of load cells is 4

’A’

test weight

load cell

’A’

7ML19985DK03 Milltronics BW500 - INSTRUCTION MANUAL Page 29

Start Up

Page 36

Press

Load Cell Balancing A & B Place weight at cell A and press ENTER

’B’

Press

Load Cell Balancing A & B Load cells are now balanced.

if four load cell scale, press to continue

P295 Load Cell Balancing: V Select: 1-A&B, 2-C&D 1

Press

P295 Load Cell Balancing: E Select: 1-A&B, 2-C&D 1

’A’

test weight

Balancing the load cells requires a subsequent zero and span calibration

Press

Load Cell Balancing C & D Place weight at cell D and press ENTER.

Start Up

Page 30 Milltronics BW500 - INSTRUCTION MANUAL 7ML19985DK03

Page 37

’B’

’A’

’D’

Press

Load Cell Balancing C & D Place weight at cell C and press ENTER.

’B’

’D’

’C’

test weight

’A’

’C’

test weight

Press

Load Cell Balancing C & D Load cells are now balanced.

Balancing the load cells requires a subsequent zero and span recalibration

Balancing of the load cells is now complete, and is followed by a zero and span calibration.

7ML19985DK03 Milltronics BW500 - INSTRUCTION MANUAL Page 31

Start Up

Page 38

Zero Calibration

Note: To obtain an accurate and successful calibration, ensure that the required

criteria are met. Refer to

Press

Calibration Criteria

on page 140.

Zero Calibration: Current Zero 0 Clear belt. Press ENTER to Start

Press

Initial Zero Calibration. In progress Current Reading: #####

The duration of the Zero calibration is dependent upon speed (P014),length (P016) and revolutions (P360) of the belt.

Press

Calibration Complete. Deviation 0.00 Press ENTER to accept value: 551205

Press

Zero Calibration. Current Zero 551205 Clear belt. Press ENTER to Start

Accepting the Zero returns to start of Zero. A new Zero can be performed, or continue to

Span

the current zero count

the zero count being calculated while calibration is in progress

the deviation from previous zero. For an initial zero there is no previous zero; hence the deviation is 0.

for example, the new zero count, if accepted

Note: The moisture meter is ignored during calibration. If Inclinometer is used, then

calibration is adjusted based on incline angle.

Span Calibration

When performing a Span Calibration where the test reference is ECal (P002 = 3), the supplied test weight or test chain must not be applied, and the conveyor must be run

empty.

Note: To obtain an accurate and successful calibration, ensure that the required

criteria are met. Refer to

With the conveyor stopped and locked out, apply the test weight or chain to the scale as instructed in the associate manuals; Then start the conveyor.

Press

Start Up

Span Calibration. Current Span 0 Setup test. Press ENTER to Start

Page 32 Milltronics BW500 - INSTRUCTION MANUAL 7ML19985DK03

Calibration Criteria

on page 140.

the current span count

Page 39

Press

Initial Span Calibration. in progress 0 Current Reading ####

the span count being calculated while calibration is in progress

The duration of the Span calibration is dependent upon speed (P014), length (P016) and revolutions (P360) of the belt.

Span Count too Low. Press CLEAR to continue.

Press

Calibration Complete. Deviation 0.00 Press ENTER to accept value: 36790

Press

Span Calibration. Current Span 36790 Setup test. Press ENTER to Start

signal from load cell too low, insure proper test weight or chain is applied during calibration

check for proper load cell wiring

the deviation from the previous span. For an initial span, there is no previous span count; hence the deviation is 0.

for example, the new span count, if accepted.

for example, the current span count

Accepting the Span returns to start of Span. A new Span can be performed, or enter RUN mode. If calibrating with a test weight or test chain, remove it from the scale and store in a secure place before returning to RUN mode.

Note: The moisture meter is ignored during calibration. If the Inclinometer is used,

then calibration is adjusted based on incline angle.

RUN Mode

Proper programming and successful zero and span calibration allow entry into the RUN mode. Otherwise, entry is denied and the first missing item of programming or calibration is displayed.

Press

Rate 0.00 kg/h Total 1 0.00 kg

Once the initial programming is complete and the BW500 is operating in the RUN mode, you may now put the belt conveyor into normal service. The BW500 is functioning under its initial program and calibration, reporting rate of material flow and totalizing.

If the initial entry and operation in the RUN mode is successful, recalibrate the weighing system by performing a series of material tests. Material tests verify that the BW500 reporting accurately. Where inaccuracies exist, correct the system through a manual span adjustment (P019).

Perform recalibration of the zero and span routinley to maintain accurate reporting of rate and total.. Refer to

Recalibration

, page 34.

7ML19985DK03 Milltronics BW500 - INSTRUCTION MANUAL Page 33

e.g. if there is no material on the belt and the conveyor is running. The current rate is 0 and no material has been totalized.

Start Up

Page 40

Recalibration

Belt Speed Compensation

Recalibration

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.

Access P019 and enter EDIT mode

P018 Speed Adjust V Enter New Speed 0.60

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 = belt length m or ft.

Refer to the changing values.

Press

P018 Speed Adjust E Enter New Speed 0.60

Press

Start Up

section on page 22 for instructions on parameter selection and

time s min

e.g. current speed of 0.6 m/s

e.g. enter correct speed of 0.63 m/s

P015 Speed Constant V Pulses/m 97.5169

speed sensor constant, adjust for P015

P014 Design Speed V Enter Speed 0.63 m/s

The displayed speed (used in the rate computation) now equals the actual speed.

Page 34 Milltronics BW500 – INSTRUCTION MANUAL 7ML19985DK03

for constant speed (jumper), adjusts P014

Page 41

Material Tests

Perform material tests to verify the accuracy of the span calibration and compensate for material flow. 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 (P017) value, yielding more accurate span recalibrations.

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

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 Siemens or their agent.

If the span adjust values are significant and repeatable, perform a manual span adjust.

Note: Test weights are NOT used during material tests.

There are two methods of executing the manual span adjust:

% Change

and

Te st

•

% Change

material and the weight reported by the BW500 is calculated and entered into P019 as % change.

Material Test:

• P019

The method of execution is a matter of preference or convenience, and either way yields the same result.

: based on the material test, the difference between the actual weight of

based on material test, the actual weight of material is entered into

% Change

To run a %Change material test:

1. Run the belt empty.

2. Perform a zero calibration.

3. Put the BW500 into RUN mode

4. Record the BW500 total as the start value _ _ _ _ _ _

5. Run material at a minimum of 50% of design rate over the belt scale for a minimum of 5 minutes.

6. Stop the material feed and run the conveyor empty.

7. Record the BW500 total as the stop value _ _ _ _ _ _

8. Subtract the start value from the stop value to determine the BW500 total

9. Weigh the material sample if not already known.

BW500 total = _ _ _ _ _ _ –

Recalibration

Material

material sample weight = _ _ _ _ _ _ –

Calculate the span adjust value:

% span adjust =

BW500 – material sample weight x 100

material sample weight

7ML19985DK03 Milltronics BW500 – INSTRUCTION MANUAL Page 35

Page 42

Recalibration

start total

stop total

Access P019 and enter EDIT mode

P019 Manual Span Adjust E Select 1-% Change 2-Material Test 0

Press

P598 Span Adjust Percentage V Enter Calculated +/- error 0.00

Press

scale

P598 Span Adjust Percentage E Enter Calculated +/- error 0.00

Press

if % change is negative, remember to enter the minus sign, e.g. -1.3

P017 Test Load Weight: MS1 V Enter Test Load 56.78

e.g. the new test load value is displayed

Page 36 Milltronics BW500 – INSTRUCTION MANUAL 7ML19985DK03

Page 43

Material Test

Access P019 and enter EDIT mode

P019 Manual Span Adjust E Select 1-% Change 2-Material Test 0

Press

Material Test Add to Totalizer 0-No, 1-Yes

Press

Material Test Press ENTER to start

Press

Material Test #.### Press ENTER key to stop

Press

Material Test 964.032 Enter actual amount

Press

Material Test Deviation -1.19 Accept 0-No, 1-Yes

Recalibration

if yes, the weight of the material test will be added to the totalizer, if no, material is added to test totalizer (4) only.

e.g. do not add weight of material test to totalizer

the totalizer reading as the material test is run

e.g. the weight totalized by the belt scale and BW500

e.g. 975.633 kg is the actual weight of the material test

e.g. the calculated deviation is displayed as a % of the actual weight

Press

e.g. the new test load value is displayed.

P017 Test Load Weight: MS1 V Enter Test Load 56.78

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, they do not take effect until a recalibration is done.

If significant changes have been made, an initial zero (P377) and/or initial span (P388) may be required (see page 117).

7ML19985DK03 Milltronics BW500 – INSTRUCTION MANUAL Page 37

Page 44

Recalibration

To maintain the accuracy of the weighing system, periodic zero and span recalibration is 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.

Recalibration

The displayed deviations are referenced to the previous zero or span calibration. Deviations are continuously tallied for successive zero and span calibrations, and when exceed their limit, indicate an error messages that the deviation or calibration is out of range.

Routine Zero

Note: To obtain an accurate and successful calibration, ensure that the required

criteria are met. Refer to

Press

Calibration Criteria

on page 140.

Zero Calibration. Current Zero. 551205 Clear belt. Press ENTER to start

Press

Zero Calibration in progress Current Reading: 0.01 kg/m

Calibration complete. Deviation 0.02 Press ENTER to accept value 551418

Calibration is out of range Deviation report: 403.37

This indicates that the mechanical system is errant. Use P377, initial zero, 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 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.

Press

e.g. the current zero count

e.g. the load reported while calibration is in progress

e.g. the calculate deviation in % of full span

e.g. the new zero count, if accepted

if unacceptable, press

to restart

Zero Calibration. Current Zero 551418 Clear belt. Press ENTER to start

Page 38 Milltronics BW500 – INSTRUCTION MANUAL 7ML19985DK03

e.g. zero calibration is accepted and displayed as the current zero

Page 45

Note: This is the end of zero calibration. Proceed with zero or span recalibration or

return to RUN.

Initial Zero

Perform an initial zero if necessary when a calibration is out of range message is shown.

Access P377 and enter EDIT mode

P377 Initial Zero E Enter 1 to start initial Zero 0

Recalibration

Press

Zero Calibration. Current Zero 530560 Clear belt. Press ENTER to start

Press

Initial Zero Calibration in progress Current Reading: #####

Calibration complete. Deviation 0.00 Press ENTER to accept value 551413

Press

Zero Calibration. Current Zero 551413 Clear belt. Press ENTER to start

e.g. the current zero

the zero count being calculated while calibration is in progress

e.g. the deviation from the previous zero

e.g. the new zero count if accepted

if unacceptable, press

e.g. the current zero count

Note: This is the end of zero calibration. Proceed with span recalibration or return to

RUN.

Direct Zero

to restart

Use direct zero entry (P367) when replacing software or hardware, if it is not convenient to perform an initial zero. A record of the last valid zero count is required.

Access P367 and enter EDIT mode

P367 Direct Zero Entry E Enter Zero Count 0

7ML19985DK03 Milltronics BW500 – INSTRUCTION MANUAL Page 39

Page 46

Press

Auto Zero

Recalibration

Zero Calibration. Current Zero V Enter Zero Count 551401

The Auto Zero function provides automatic zero calibration in the RUN mode under the following conditions.

• the auto zero input (terminals 29/30) is in a closed state; jumper or remote contact

• the load on the belt is less than

• the terminal and load status coincide for at least one belt revolution

The rate display is interrupted by the Auto Zero routine

Rate 0.00 t/h Total 1: 0.0 0 tonnes AZ

Calibration Complete. Deviation 0.0 Auto-Zero value 551410

The duration of the auto zero is one or more belt revolutions (P360). If either condition is interrupted during that period, the auto zero is aborted and the RUN display is resumed. After one belt revolution, another auto zero will be attempted if the input and load conditions are met.

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 error message is displayed. The error message is cleared after five seconds, however if a relay is programmed for diagnostics, it remains in alarm so long as the Auto Zero conditions are being met.

If material feed resumes during an auto zero function, the totalizing function is maintained.

± 2% of the design load (P952)

e.g. the last valid zero count

(AZ flashes on and off)

e.g. typical zero and deviation values

Page 40 Milltronics BW500 – INSTRUCTION MANUAL 7ML19985DK03

Page 47

Routine Span

Note: To obtain an accurate and successful calibration, ensure that the required

criteria are met. Refer to

Press

Span Calibration. Current Span 41285 Setup test. Press ENTER to start

Calibration Criteria

on page 140.

e.g. the current span count

Zero should be done prior to Span Setup test. Press ENTER to start.

Press

Span Calibration in progress Current Reading: 55.56 kg/m

Calibration complete. Deviation 0.03 Press ENTER to accept value 41440

Span Count too Low. Press CLEAR to continue.

do a zero calibration or press

the load reported while calibration is in progress.

e.g. the deviation from the previous span

e.g. the new span count, if accepted

if unacceptable, press

signal from load cell too low, insure proper test weight or chain is applied during span

check for proper load cell wiring

to restart

Recalibration

Calibration aborted Belt speed is too low:

Calibration is out of range Deviation Error:

This indicates 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.

Find and rectify the cause of the increased or decreased deviation. Then re-try a span recalibration.

If this deviation is still unacceptable, set P388 to 1 to invoke an initial span calibration. Further deviation limits are now based on this new initial span.

7ML19985DK03 Milltronics BW500 – INSTRUCTION MANUAL Page 41

Page 48

Press

Initial Span

Recalibration

Span Calibration. Current Span 4144 Setup test. Press ENTER to start

e.g. span calibration is accepted and displayed as the current value

Note: Perform an initial span i when a calibration out of range message appears.

A zero calibration should be performed prior to performing a span calibration.

Access P388 and enter EDIT mode

P388-01 Initial Span E Enter 1 to start INitial Span 0

Press

Span Calibration. Current Span 41440 Setup test. Press ENTER to start

Press

Initial Span Calibration in progress Current Reading: #####

Zero should be done prior to Span Setup test. Press ENTER to start

e.g. the current span count

do a zero calibration or clear

the span count being calculated while calibration is in progress

Calibration complete. Deviation 0.00 Press ENTER to accept value 41900

the deviation is reset

e.g. the new span value if accepted

if unacceptable, press

to restart

Press

Span Calibration. Current Span 41900

e.g. the current span count

Setup test. Press ENTER to start

Note: End of span calibration. Remove the test weight and return to RUN.

Page 42 Milltronics BW500 – INSTRUCTION MANUAL 7ML19985DK03

Page 49

Direct Span

Direct span entry (P368) is intended for use when replacing software or hardware, and when it is not convenient to perform an initial span. A record of the last valid span count is required.

Access P368 and enter EDIT mode

P368 Direct Span Entry E Enter Span Count 0

Press

P368 Direct Span Entry V Enter Span Count 4190

e.g. the last valid span count

Multispan

The BW500 offers a multispan function, which allows the BW500 to be calibrated for up to eight different feed conditions that would produce varying load characteristics. Different feed conditions are typically related to the running of different materials or multiple feed locations. The varying load characteristic often has a bearing on the belt tension, and is observed especially when in close proximity to the scale. To accommodate such scale applications, a span correction can be made by selecting and applying the appropriate span.

Since every material has its own unique physical properties, and may load the belt differently, a span calibration may be required for each material to realize maximum accuracy.

Recalibration

In the case of different feeder locations, a span calibration may be required to match each feedpoint or combination of feedpoints.

Each time one of the eight conditions is in effect, the corresponding multispan is selected prior to putting the BW500 into the RUN mode. The selection is made by either changing the multispan operation number, accessed via P365, or by external contacts connected to the Auxiliary input, and programmed via P270.

To enable multispan operation, the following must be addressed.

• connections

• programming

• calibration

•operation

7ML19985DK03 Milltronics BW500 – INSTRUCTION MANUAL Page 43

Page 50

Connections

Recalibration

Programming

If the span selection is to be done by remote contact, the following connections would apply. Otherwise, no additional connections to the BW500 are required.

Multispan Selection of Spans 1 and 2 Multispan Selection of Spans 1 to 8

*Remote contact can be from relay or open collector switch.

Access P365 and enter EDIT mode

P365 Multispan E Select [1-8] 0

Span 1 will have already been set as part of the Start Up and initial calibration. Therefore, select 2.

Access P017 and enter EDIT mode

P017 Test Load: Weight MS2 E Enter test load 0

Enter the test load value, and press to do a span calibration.

To do a span calibration for another condition, (i.e. span 3 or 4 etc.), access P365 and repeat these steps for each condition. As with any initial span, follow the span calibration for each multispan with a material test and factoring.

To use remote span selection, auxilliary Inputs, 1 and/or 2 or 3, are programmed to read the contact state as the span selection. Remote selection overrides the keypad (or Dolphin Plus) selection. The auxilliary inputs override the keypad selection.

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Access P270 and enter EDIT mode

P270-01 Auxiliary Input Function E Select Function [0-13] 0

Enter . This programs Auxiliary Input 1 (terminal 24) to read the contact state for

span selections: 1 or 2.

If spans 3 and/or 4 are to be used:

Access P270 and enter EDIT mode (when using spans 3

and/or 4

P270-02 Auxiliary Input Function E Select Function [0-13] 0

Enter . This programs Auxiliary Input 2 (terminal 25), in conjunction with Auxiliary

input 1 to read the contact state for span selections 3 and 4.

If spans 5, 6, 7, and/or 8 are to be used:

Access P270 and enter EDIT mode (when using spans 5 to 8

P270-03 Auxiliary Input Function E Select Function [0-13] 0

Enter . This programs Auxiliary Input 3 (terminal 26), in conjunction with Auxiliary

input 1 and Auxiliary input 2 to read the contact state for span selections 5, 6, 7, and 8.

Remote selection of a span is not enabled until a span calibration has been done. Initial span selection must be done via the Multispan parameter, P365.

Recalibration

Initial multispan calibration or span selection is made via the Multispan parameter (P365).

Operation

When span calibration is done, press to revert to the RUN mode.

Rate kg/h 0.00 kg/h MS 2 Total 1: 0.0 0 kg

When the material to be run on the belt changes, the multispan is changed to the corresponding span. This is completed either by changing the span value entered in P365, or by closing the appropriate contacts connected to the programmed Auxiliary inputs.

7ML19985DK03 Milltronics BW500 – INSTRUCTION MANUAL Page 45

multispan 2

e.g. if there is no material on the belt and the conveyor is running. The current rate is 0 and no material has been totalized.

Page 52

Span

Recalibration

It may be required to reset or note the totalizer value, as the process materials being conveyed change. Refer to

Linearization applies concurrently to spans.

On-line Calibration

The On-line Calibration feature may be used to routinely check, and if necessary adjust, the Span calibration in RUN mode, without interrupting the material flow.

Max. (e.g. 90%)

High (e.g. 70%)

reference weight: (the amount of material held between High and Low levels)

Low (e.g. 30%)

Auxiliary Input

Aux 1

Operation

feeder

10 t

Multispan

Selection Aux 2

on page 54.

Install a weigh bin, (bin or silo equipped to provide a 4 to 20 mA output proportional to weight), preceding the material infeed.

Connect the weigh bin to one of the mA inputs on the optional mA I/O board of the Milltronics BW500: either mA input 1, terminals 5 and 6; or mA input 2, terminals 7 and 8.

Install a material feed control device, preceding the weigh bin.

Multispan

Selection

Aux 3

Note:

• Press twice, to enter a parameter number directly.

• Whenever you wish to change a value, press to enable the EDIT mode.

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P355 On-line Calibration Feature E Select: 0-Off, 1-On 0

Select the On-line Calibration feature:

Access

P355 On-line Calibration Features V Select: 0-OFF, 1-ON 1

EDIT mode: value can be changed

Value is accepted

Recalibration

Press

Enter the weigh bin reference weight, (the amount of material the bin holds between the High and Low levels), in units selected in P005.

Access

P356 On-line Calibration V Enter Reference Weight 10.000

Press

Enter the Max., High, and Low limit setpoints as a percentage in parameter 357.

e.g. reference bin weight

Access

P357-01 On-line Calibration Limits V MAX Limit: 90.0

Press

limit as a percentage

Access

P357-02 On-line Calibration Limits V HIGH Limit: 70.0

Press

Access

P357-03 On-line Calibration Limits V LOW Limit: 30.0

Press

Calibrate the mA inputs on the BW500 to the 4 and 20 mA levels of the weigh bin. 4 mA is calibrated with the weigh bin empty, using P261-01 or –02. 20 mA is calibrated with the weigh bin full, using P262-01 and P262-02.

Assign one of the mA inputs for the On-line Calibration function.

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Access

P255-01 mA Input Function V Select 0, 1-PID SP, 2-PID FV, 3-OCAL 3

e.g. mA input 1 set to 3

Recalibration

Press

Assign one of the 5 relays, P100-01 to P100-05, to the On-line Calibration function.

Access

P100-01 Relay Function V Select Function [0-9] (see manual) 9

Press

e.g. relay 1 set to 9

Program the assigned relay using P118, relay logic, so that when you connect the assigned relay to the weigh bin material feed control device, the weigh bin material feed stops when the On-Line relay is energized.

Activate On-line Calibration.

Access

P358 On-line Calibration Features V 0-OFF, 1-ACTIVE 1

Press

Note: For remote access, On-line Calibration can also be activated using one of the

Auxiliary inputs (refer to

When the On-line Calibration is activated, normal operation continues until the weigh bin fills to the maximum level, (90% in the example shown). During the filling stage, the current level is displayed as a percentage.

On-line Calibration - LOW > 19% Wait for LEVEL > MAX RLY

P270

on page 112).

current level displayed as percentage

When the maximum limit is reached, the relay assigned to the On-line Calibration function energizes to stop the weigh bin material feed.

On-line Calibration - 94% > MAX Wait for LEVEL < HIGH RLY 1

Material continues to be discharged from the weigh bin, and when the level drops to the High limit (70% in the example) the On-Line totalizer is automatically activated.

On-line Calibration - TOTAL 3.71 tonnes

running total

Calibration in progress RLY 1

When the Low limit (30%) is reached, the totalizer is deactivated and the assigned relay is de-energized, which reopens the material feed to the weigh bin.

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The BW500 On-line material total, the amount of material totalized between the High and Low limits, is compared to the value entered in P356. The deviation percentage between

these values and the new Span count value is displayed.

Recalibration

On-line Calibration - Deviation 2.51% Press ENTER to accept New span 22280

deviation percent

new Span count value

Press to accept the results.

On-line Calibration Complete Press ENTER to accept New span 22280

Note:

• Deviation must be no greater than ± 12% of the initial span or it will not be accepted.

• For remote access, On-line Calibration can be accepted using one of the Auxiliary

P270

inputs: refer to

on page 112.

If you want to reject the results and return to RUN mode, press .

Rate 0.00 t/h Total 1: 10.15 t

Note: For remote access, to return to RUN mode, program one of the Auxiliary

inputs: refer to

P270

on page 112

If you want to reject the results and perform another on-line calibration, press

return to P358.

Access

P358 On-line Calibration Features V 0-OFF, 1-ACTIVE 1

Press

If the deviation is greater than ± 12%:

Calibration is out of range Deviation Error:

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Recalibration

Factoring

1. Rerun on-line calibration to verify the deviation: press

to return to P358.

2. Verify the mechanics of the belt scale: carry out material tests to ensure the readings are correct. (See page 35,)

3. If the mechanics are functioning correctly, perform an initial span using P388. (See page 42.)

Note: For optimum accuracy in the factoring results, a routine zero calibration is

recommended.

To calculate the value of a new or unknown test weight to the current span, the factoring procedure is used.

With the conveyor stopped and the belt empty:

Access P359 in VIEW mode

P359 Factoring Select 1-Weight, 2-Chain

Press

Factoring Weight

e.g. factor the test weight

Place weight and press ENTER.

Press

Factoring Weight

the load reported while factoring is in progress.

Factoring in progress ##.## kg/m

Factoring Weight Press ENTER to accept value 45.25

Press

P017 Test Load Weight: V Enter Test Load 45.25

e.g. the new factor, if accepted

e.g. the current test load value

factoring is complete. Return to RUN mode if so desired

Note: If multispan function is used, the test load value is stored for the current

multispan only.

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Linearization

Conveyor applications where the ideal belt scale location has been compromised, or where there is a high degree of variation in belt tension, typically cause the belt scale to report load non-linearly. The BW500 provides a linearizing function (P390 - P392) 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.

• Lift the belt off of the scale and suspend various test weights to the scale to verify mechanical linearity. If the load reported by the BW500 at these tests is non-linear, a mechanical problem is indicated. Refer to the belt scale manual to resolve the nonlinearity 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 5 intermediary flow rates where compensation is required.

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

• calculate the percentage compensation for each flow rate tested.

% compensation = actual weight - totalized weight x 100

totalized weight

Recalibration

where:

actual weight = material test totalized weight = BW500 total

Note:

• After the compensation has been programmed into the BW500, a material test should be run to verify the effect of linearization.

• If additional compensation is required, it must be based on new material tests performed with the linearization turned off (P390 = 0).

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Recalibration

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 15, 30, 45, 60 and 75% of the design load. After performing a zero and a span calibration at 100% of the design load, followed by material tests and manual span adjust, five material tests were performed at 30, 60, 90, 120 and 150 t/h, as indicated by the BW500. 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 BW500 load display during running conditions or by calculation.

load = rate

speed

BW500 load material test BW500 total compensation*

kg/m tonnes tonnes %

6.94 2.5 2.8 -10.7

13.89 5.0 4.5 11.1

20.83 7.5 7.9 -5.1

27.78 10.0 9.2 8.7

34.72 12.5 13.3 -6.0

*calculation example: % compensation = 2.5 – 2.8

= - 10.7

Weight = Tonnes

♦

-5.1

♦

11.1

-10.7

♦

-6.0

♦

8.7

♦

Load - kg/m

x 100

2.8

actual weight per material test totalized weight by BW500 belt scale response linearized BW500 response internal response 100% - 150% of span % compensation span (100%)

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Program the BW500 as follows:

Parameter Function

P390 = 1 linearization – on P391-01 = 6.94 point 1, load P391-02 = 13.89 point 2, load P391-03 = 20.83 point 3, load P391-04 = 27.78 point 4, load P391-05 = 34.72 point 5, load P392-01 = - 10.7 point 1, compensation P392-02 = 11.1 point 2, compensation P392-03 = - 5.1 point 3, compensation P392-04 = 8.7 point 4, compensation P392-05 = -6.0 point 5, compensation

Note: Often only one point of compensation is required, usually at a low load

value. In the prior example, if compensation was only required at 6.94 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 linearization on P391-01 = 6.94 point 1, load P391-02 = 20.00 point 2, load P392-01 = -10.7 point 1, compensation P392-02 = 0 point 2, compensation

Recalibration

actual weight per material test totalized weight by BW500

Weight = Tonnes

♦

-10.7

Load - kg/m

belt scale response linearized BW500 response internal response 100% - 150% of span % compensation span (100%)

For Parameter reference, go to Parameters on page 102.

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Operation

Load Sensing

For the BW500 to calculate rate and 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 BW500 is compatible with belt scales fitted with one, two, or four strain gauge type load cells. To function with LVDT type load cells, an optional LVDT conditioning card is required.

Refer to and connection.

Speed Sensing

Operation

For the BW500 to calculate rate and totalize material flow along the belt conveyor, a speed signal representative of belt speed is required. For optimum accuracy of the weighing system, and both constant and variable speed applications, a speed sensor is required. The design speed (P014) and speed constant (P015) need to be programmed.

In constant speed applications (no speed sensor), the BW500 can be programmed to provide an internal speed signal. This is achieved by entering the design speed (P014) and providing a contact closure across speed input terminals (17/18). The speed constant (P015) defaults to ‘jumpered’. This contact should change to open when the conveyor is idle to prevent errant totalization.

In applications with two speed sensors, the BW500 can be programmed to provide differential speed. % slip can be calculated, using the difference between the two speed signals with reference to the first speed.

Refer to requirements and connection.

Specifications

on page 3, and

on page 3 and

Installation

on page 6 for belt scale requirements

on page 6 for speed sensor

Differential Speed Detection

Dual point speed sensing is used for monitoring speed at two points in the system where a difference in speed can be detrimental to the equipment or its operation. The two speed sensors are typically applied on belt conveyors to give an alarm if excessive slip between the head pulley and tail pulley is detected. The secondary speed sensor is especially useful on variable speed conveyors, and may also be used to detect a malfunction in the primary speed sensor.

The BW500 provides a 12 Vdc, 150 mA maximum, regulated power supply for both speed sensors. The primary speed sensor is used for all "Run" display integration, and is the reference value for differential speed detection. The primary speed sensor is generally reserved for the driven device (tail pulley). The second speed sensor is generally reserved for the driving device (head pulley), and is used for comparison to the primary speed sensor, for differential speed detection only.

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The second speed signal is compared to the primary speed signal, and will initiate an alarm condition if the second speed signal is outside the programmed high and low alarm setpoints.

Connect the second speed sensor as shown in the Installation section (refer to

Speed Sensor

following steps:

1. Program one of the Auxiliary Inputs as a Speed Sensor input P270-01 to 05 = 16 (Speed Sensor).

2. Program second speed sensors speed constant P015-02 = pulses per meter or foot (Refer to

3. Program one of the alarms for Differential Speed Detection alarm P100-01 to 05 = 10 (Speed Differential).

4. Program the High Alarm setpoint P101-01 to 05 = 110% (default).

5. Program the Low Alarm setpoint P102-01 to 05 = 90% (default).

on page 16), and program the second speed sensor as described in the

Start Up

on page 22, for speed sensor programming).

Moisture Compensation

Moisture Compensation is used to compensate for the moisture component of the material being weighed. It factors out the moisture component of load, rate and total for all multispans selected. The factored value is meant to report the dry mean values of the material being conveyed.

The BW500 receives the static load cell signal, and adjusts the value of the load being displayed and integrated by the moisture percentage. The mA I/O card is required to accept the mA signal from the Moisture Meter. This mA signal can represent 0 to 100% moisture. The moisture percentage is displayed in P398-01. Using P398-02, the moisture percentage can be represented as a percentage of mass to be deducted from the total mass.

Example:

Setting P398-02 = 30% will allow the 4 - 20 mA input to correspond to 0 - 30% moisture.

Auxiliary

Operation

The Zero and Span calibration is not affected by the presence of a moisture meter. It is understood that the calibrations are performed using dry static weights.

The Moisture Meter must be connected to the appropriate mA input and programmed as described in the following steps:

1. Enable mA input function for moisture compensation P255-01 or 02 = 4 (moisture compensation).

2. Set appropriate mA input range P250-01 or 02 = 2 (default is 4 - 20 mA).

3. Set mA input moisture ratio P398-02 = 100% (default).

4. Observe moisture percentage using P398-01.

Incline Compensation

Incline compensation is used to compensate for the varying vertical force component applied to the belt scale due to varying inclination of the conveyor. The BW500 receives

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Page 62

the static load cell signal, and adjusts the load displayed and integrated, by a factor of COSINE of the angle of incline.

The Inclinometer should be mounted to the conveyor stringer, parallel to the center of the belt scale. The mA I/O card is required to accept the mA signal from the Inclinometer. This mA signal must represent -30 ° to 30 °. The incline angle is displayed in P399.

The dynamic load cell signal will vary with the incline of the conveyor. The BW500 load display and integration values will remain constant for the given load on the belt scale through the specified range of inclination.

The Zero and Span calibrations of the BW500 will be adjusted based on the angle of incline of the conveyor. The Zero and Span calibration can be performed at any angle. However, if incline compensation will be used, it must be enabled for all Zero and Span calibrations.

The Inclinometer must be connected to the appropriate mA input and programmed as described in the following steps:

Operation

1. Enable mA input function for incline compensation P255-01 or 02 = 5 (Incline compensation).

2. Set appropriate mA input range P250-01 or 02 = 2 (default is 4 - 20 mA).

3. Observe incline angle using P399.

Modes of Operation

RUN is the normal or reference mode of operation. It continuously processes the load and speed signals from the belt scale to produce internal load, speed and rate signals, which are in turn used as the basis for totalization, mA output, relay control, and communication data. The RUN display is programmed (P081) to scroll through rate, totalization (P647), load and speed; either manually by pressing the enter key, or automatically.

Rate Rate Load Total 1 Tot a l 2 Speed

If the BW500 is programmed for batch control, the batch display is added to the display scroll. Refer to

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), editing parameter values. During PROGRAM, RUN mode functions are still active, i.e.: rate, relay, mA output and totalization.

If the PROGRAM mode is left idle for a period of ten minutes, it automatically reverts to RUN mode.

Zero and span calibrations effectively halt the RUN mode while they are in progress. During this time, totalization ceases, and all mA outputs, except for PID, fall to zero.

Page 56 Milltronics BW500 - INSTRUCTION MANUAL 7ML19985DK03

Batch Control

on page 122 for more information.

Page 63

Damping

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 rate, load and speed, respond to the damped value.

Damping consists of a first order filter applied to the signal (reading or output value).

If mA damping (P220) is enabled (value other than 0), then the damping (P080)

pertains to the mA function

mA output damping rate (P220).

is overridden, and responds independently at the specified

as it

Note: Damping (P080 or P220) is not applicable to the mA output when programmed

for PID function (P201 = 4).

mA I/O (0/4-20 mA)

Output

The standard BW500 provides one isolated mA 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 mA 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 P215 respectively) to agree with a milliammeter or other external mA device.

The mA output value can be tested to output a prescribed value using parameter P911.

P911

Refer to

The optional mA I/O board provides two additional mA outputs, programmable as outputs 2 and 3, using the same parameters as the standard output (1). If programmed for PID control, output 2 is assigned to PID control loop 1 and output 3 is assigned to PID control loop 2.

Input

on page 131.

Operation

The optional mA I/O board provides two mA inputs, programmable as inputs 1 and 2. If programmed for PID control, generally, input 1 is assigned to PID control loop 1 and input 2 is assigned to PID control loop 2.

The input range can be set to 0-20 mA or 4-20 mA (P250), and assigned a function (P255), e.g. PID setpoint. The 4 and 20 mA levels can be trimmed (P261 and P262) to agree with an external device. The external device could be a moisture sensor, or an inclinometer.

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Relay Output

The BW500 offers five single pole single throw (SPST) relays that can be assigned (P100) to one of the following alarm functions:

• rate: relay alarms on high and/or low material flow rate.

• load: relay alarms on high and/or low belt load.

• speed: relay alarms on high and/or low belt speed.

• differential speed:relay alarms if second speed signal outside high and/or low alarm

setpoints.

• diagnostic: relay alarms on any error condition as it is reported.

Troubleshooting

Refer to

• PID: PID control setpoint deviation*

• batch pre-warn

• batch setpoint

*is offered only if the PID system (P400) is enabled.

on page 133.

Operation

For rate, load and speed alarm functions, the high and low alarm setpoints (P101 and P102 respectively) are required and must be entered in the appropriate units. The high alarm setpoint acts as the setpoint deviation alarm for relays programmed for PID setpoint deviation.

The on/off actuation at both high and low 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; holding the normally open (n.o.) contact closed (can be programmed for reverse operation, P118). Upon an alarm condition, the relay is deenergized and the relay contact is opened. Once in alarm, the relay remains in alarm state until the alarm condition is removed.

Example:

P014 = 2m/s, design speed P100 = 3, belt speed P101 = 100% (2 m/s) P102 = 20% (0.4 m/s) P117 = 2% (0.04 m/s)

high 100%

2 m/s

actual low alarm ’off’ = 22%

’on’ = 20%

0.4 m/s

low 20%

2 %

alarm ‘on’ is with relay de-energized

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Totalization

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 BW500 provides several separate totalizer functions:

Internal totalizers

• local display (totalizers 1 and 2)

• verification totalizer (totalizer 3)

• material test totalizer (totalizer 4)

• batch total (totalizer 5)

External totalizers

• totalizer outputs (remote totalizers 1 and 2)

To avoid totalizing material at flow rates below the low flow rate limit, the totalizer drop out limit (P619) is set to a percentage of the design load. 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 internal (P631) and external (P638) totalizer* resolution parameters.

*If the resolution selected causes the totalizer to lag behind the count rate, the next possible resolution is automatically entered.

Example:

Operation

Internal totalizer 1

Given: P005 = 1 (t/h)

P631 = 4

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

External totalizer 1

Given: P005 = 1 (t/h)

P638 = 5

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

For remote totalization, the contact closure duration (P643) is automatically calculated upon entry of the design rate (P011) and remote totalizer (P638) parameters, so that the duration of contact closure allows the relay response to track the total up to 150% of the design rate. The value can be changed to suit specific contact closure requirements, such as in the case of programmable logic controllers. If the duration selected is inappropriate, the next possible duration is automatically entered.

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Operation

External Totalizer Calculation Example:

Design Rate = 50 t/h (P011) External Totalizer Resolution Selected = 0.001 (P638 = 1) External Totalizer Contact Closure Time selected = 30 msec (P643 = 30) External Totalizer Cycle Time = 60 msec (External Totalizer Contact Closure Time X 2)

1. Calculate the maximum number of pulses per second for the Contact Closure Time selected (P643). Maximum Number of pulses per second

= 1 / External Totalizer Cycle Time

= 1 / 0.060

= 16.6 (which is rounded to a whole number of 16 in the BW500)

2. Calculate the pulses per second required for the External Totalizer Resolution selected (P638). Pulses Per Second = Design Rate X 150%

External Totalizer Resolution X 3600

= 50 t/h X 150%

0.001 X 3600

= 20.83

Because the required 20.83 pulses per second is greater than the maximum 16 pulses per second, the External Totalizer Resolution of 0.001 will not allow the External Totalizer to track up to 150% of the design rate. The External Totalizer Resolution will have to be increased to 0.01 or the External Totalizer Contact Closure Time will have to be decreased.

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 1 and 2, or

totalizer 2 independently. Resetting the internal totalizers 1 and 2 resets the internal registers for external totalizers 1 and 2.

• keypad: pressing

while in the RUN mode resets internal totalizer 1

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.

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PID Control

The PID control algorithm in the BW500 is designed specifically to work for feed rate control applications. It is based on motor control type algorithms and includes several anti-wind up provisions.

One way to prevent wind up is to monitor the input speed frequency from the weighfeeder. If the input frequency drops below 5 Hz, the PID control output freezes at its current value. Otherwise, the output winds up to 100% if the feeder is shut off while there is still a set point greater than zero. When the feeder is turned back on, there would be a surge of product flow until the system regains stability. With anti-wind up, the feeder can be stopped and started with minimal disruption to the controlled flow rate.

To operate the BW500 as a controller, address the following:

• hardware

• connections

• setup and tuning

• programming

Hardware

For the BW500 to operate as a controller, install the optional mA I/O board. Refer to

Installation

on page 6.

Connections

Connections to process instruments, in addition to standard operating connections, must be made.

Refer to:

•

Installation Relay Output

•

mA I/O board

•

Auxiliary Inputs

Connect the BW500 as either a:

1. setpoint controller – load control

2. setpoint controller – rate control

3. setpoint controller – rate and load control

4. setpoint controller – external process variable with or without rate and load control

on page 6, specifically:

on page 19, for relay connections

on page 8, for mA input and output connections

on page 17, for optional remote control

PID loop mA output

1 21 & 215 & 6

2 33 & 427 & 8

terminals

(mA I/O)

mA input

terminal (mA I/O)

PID Control

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Page 68

Setpoint Controller – Rate Control

shearing weighfeeder

belt scale

load speed sensor

speed

PID 1 process value source - rate (P402-01 = 1)

motor speed controller

control output (P201-02 = 4)

optoinal remote setpoint - rate

PAR

ZERO

SPAN

RUN

RESET

CLEAR

ENTER

DISP

TOTAL

(P255-01 = 1)

Setpoint Controller – Load Control

PID Control

motor speed controller

belt scale

speed sensor

speed

PID 1 process value source - load (P402-01 = 2)

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load

control output (P201-02 = 4)

optoinal remote setpoint - rate

PAR

RESET TOTAL

ZERO

CLEAR

ENTER

SPAN

(P255-01 = 1)

RUN

DISP

Page 69

Setpoint Controller – Master/Slave Control

belt scale

load

speed sensor

SLAVE

motor speed controller

control output rate (P201-02 = 4)

speed sensor

MASTER

speed

PID 1 process value source - rate (P402-01 = 1)

speed

PID 1 process value source - load (P402-01 = 1)

belt scale

load

RUN

PAR

ZERO

SPAN

ALT

RESET

CLEAR

ENTER

DISP

TOTAL

remote ratio setpoint rate (P255-01 = 1 P418-01 to suit)

PID Control

motor speed controller

control output (P201-02 = 4)

rate*

ZERO

SPAN

PAR

RUN

RESET

ALT

CLEAR

ENTER

TOTAL

DISP

(P201-01 = 1)

remote setpoint rate (P255 - 01 = 1)

*P201-03 = 1 also applicable

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Page 70

Setpoint Controller – Rate and Load Control

belt scale

speed sensor

speed

PID 1 process value source - load

PID Control

(P402-01 = 2)

PID 1 process value source - late (P402-01 = 1)

load

motor speed controller

- rate

PID 1 control output, (P201-02 = 4)

RUN

PAR

ZERO

SPAN

RESET

CLEAR

ENTER

DISP

TOTAL

motor speed controller

- load

PID 2

control output,

(P201-03 = 4) PID 1 remote setpoint - load (P255-01 = 1)

PID 2 remote setpoint - rate (P255-02 = 1)

Setup and Tuning

Before proceeding, it would be beneficial to qualify and quantify the terms you will encounter in the setup and tuning of the control system.

Proportional Control (Gain),

The P term on the BW500 adjusts the control output based on the difference between the set point and the measured flow rate. A higher P term makes the BW500 more sensitive and faster to react to changes or disturbances. If set too high, the BW500 becomes less stable, and more susceptible to oscillations in the control output.

• allowable input range: 0.000 to 2.000

• typical operating range: 0.300 to 0.600

• default value: 0.400

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Page 71

The control output cannot reach the setpoint using only the P term. Since the P term acts on the difference between the setpoint and process variable, a small difference between

these two always exist and the difference is never zero. A small process very close to set point, but it would take a very long time. At the very least, an I

term is required to eliminate the offset created by the

term.

term can get the

Integral Control (Automatic Reset), I

The I term on the BW500 is used to increase or reduce the amount of control output to

eliminate the offset caused by the error over small increments of time. As the process reaches setpoint and the error becomes small, the effect of the I term decreases. A higher I term makes the BW500 faster to react to changes, but can also make it less stable.

• allowable input range: 0.000 to 2.000

• typical operating range: 0.100 to 0.300

• default value:0.200

and I terms together can make a suitable control algorithm and for many

The applications, they work fine. However, if faster response to changes is desired, it is

necessary to use larger unstable. A derivative term is needed to influence the control output as the process variable approaches the set point.

and I terms. Unfortunately, larger terms can make the system

term. The I term acts on the

accumulation

of the

PID Control

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Page 72

Derivative Control (Pre-Act or Rate),

The D term on the BW500 influences the control output based on changes in the magnitude and direction of the change in error. If there is a constant error, the no effect. As the error gets larger, the D term combines with the P term to make the BW500 control output respond faster. When the error is getting smaller, the D term acts to reduce the amount of control output to help prevent overshooting the set point. In

general, a higher

term will require a larger D term.

term has

Error

Decreasing Error

Direction of Proportional Action

Direction of Derivative Action

PID Control

• allowable input range: 0.000 to 1.000

• typical operating range: 0.010 to 0.100

• default value:0.050

The result of the derivative action is that it can make a system more responsive and more stable at the same time.

Feed Forward Control,

On the BW500, the F term is used to adjust the control output based on a setpoint change. The use of this term can make the system reach the new setpoint faster. If the term is not used, the system responds using the new setpoint and the process variable is the error and the control algorithm responds to eliminate this new error.

When the between the new setpoint and the process variable is automatically added on to the control output. This shifts the process variable closer to the new setpoint faster than using the

• allowable input range: 0.000 to 1.000

• typical operating range: 0.250 to 0.550

• default value: 0.300

term is used and a new setpoint is entered, a proportion of the difference

P, I

and D terms alone. This is done on a one time basis.

Increasing Error

Setpoint

Decreasing Error

, I and D terms only. The difference between the

Increasing Error

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Page 73

The PID control function of the BW500 can be configured to operate in several modes.

• controller output: direct acting

• feedback: rate, load or external

• control: local or remote (ratio) setpoint

PID Setup and Tuning

Proper tuning of the control PID terms is essential to system operation and optimum performance from the feeder. The recommended procedures for tuning the PID control terms at initial start-up are described in this section.

Initial Start-Up

Although the default values of the P, I, D and F terms will suit the majority of applications, shearing weigh feeders in particular, some tuning will be necessary nonetheless.

There are several techniques and procedures for tuning conventional PID controllers, some work better depending upon the application. We recommend using "closed-loop cycling" for the BW500 integrator/controller for feed rate control. This technique focuses on tuning the P term first while disabling the I and D terms. This is followed by adding and tuning the I term, then the D term. To outline this procedure:

1. With the P term set to its default value of 0.400, disable the I, D and F terms by setting them to 0.000.

2. Enter a feed rate setpoint that is 30% of the designed maximum flow rate.

3. Having applied the test weights or chain provided, start the feeder and observe the time it takes the feeder to reach setpoint, also observe the oscillation around setpoint.

4. Adjust the P term accordingly for consistent oscillation and error. Progressively decrease the P term value if there is too much oscillation and error. Likewise, increase the value if the error is not consistent and oscillating around the setpoint. Refer to fig 1, 2, & 3 below.

PID Control

Figure 1

P term is too high SETPOINT

7ML19985DK03 Milltronics BW500 - INSTRUCTION MANUAL Page 67

Page 74

Figure 2

Figure 3

SETPOINT

P term is too low

SETPOINT

P term is correctly set

PID Control

5. Once the P term value is set to give the control output of the BW500 consistent oscillation and the error is at its minimum, turn the feeder off.

6. The I term value can now be set. Begin by entering the default value of 0.2.

7. Restart the feeder (test weights or chains still applied) and feed rate setpoint entered.

8. Again observe the oscillation of the control output. Compare results to the figures 4,5 and 6 below.

Figure 4

I term is too high

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SETPOINT

Page 75

Figure 5

Figure 6

SETPOINT

I term is too low

SETPOINT

I term is correctly set

PID Control

9. The D term is not critical in typical shearing type weigh feeder applications. The purpose of the D term is to anticipate where the process is heading by looking at the

time rate and direction of change of the process variable. The useful in applications where the material control point is far away from the measuring point. An example of this would be a weigh belt or conveyor with a belt scale (constant speed) being fed from a pre-feeder some distance or more than a few seconds process time from the scale.

A properly set in figure 6. A

term, or set too low, shows no effect on the system.

the

10. The above closed loop cycling procedure allows ease in start up, but final adjustments may be necessary in actual process operation.

7ML19985DK03 Milltronics BW500 - INSTRUCTION MANUAL Page 69

term will make the initial oscillations around the setpoint smaller, as

term set too high induces high oscillations, as in figure 4. Omission of

term becomes very

Page 76

Programming

The BW500 is software ready, however the controller function must be specifically programmed in addition to programming of parameters P001 through P017.

The BW500 offers programming for two separate PID controls, 1 and 2. The controller being programmed is identified by the suffix to the parameter number. e.g. P400-01 indicates that PID for control system 1 is accessed.

Note: All programming should be done in the PID manual mode.

Access

P400-01 PID System E Select: 0-Off, 1-Manual, 2-Auto 0

Off disables the PID parameter set, P401 to P418. They are not accessible.

Manual: the control output is the manual output P410.

Auto: engages the PID controller function. This can also be done using the key.

Select manual to program PID parameters.

Note:

For the mA input:

• mA output 2 (P201-02) is normally reserved for controller 1. The signal is output at terminals 1 and 2 on the mA I/O board.

• mA output 3 (P201-03) is normally reserved for controller 2. The signal is output at terminals 3 and 4 on the mA I/O board.

PID Control

P201-02 mA Output Function E Select: 1-Rate, 2-Load, 3-Speed, 4-PID 1

Select the PID function.

Note:

For the mA input:

• mA input 1 is an external signal normally reserved for controller 1. The signal is input at terminals 5 and 6 on the mA I/O board.

• mA input 2 is an external signal normally reserved for controller 2. The signal is input at terminals 7 and 8 on the mA I/O board.

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P250-01 mA Input Range E Select 1- 0 to 20, 2-4 to 20 2

Select the appropriate range for the mA input signal

P255-01 mA Input Function E Select: 0, 1-PID SP, 2-PID PV 0

P401-01 PID Update Time E Readings between PID Updates 1

P402 Process Variable Source E 1-Rate, 2-Load, 3-mA In

P405-01 Proportional Term E Enter 0.40

P406-01 Integral Term E Select 1- 0 to 20, 2-4 to 20 0.2

P407-01 Derivative Term E Enter 0.05

P408-01 Feed Forward Term E Enter 0.3

Assign either:

1, PID setpoint, or 2, process variable as the function of the mA input

Enter the value, e.g. nominal value of 1

Select the source. Rate and load are internal values.

Enter the value for the proportional term, e.g. nominal value of 0.4

Enter the value for the integral term, e.g. nominal value of 0.2

PID Control

Enter the value for the derivative term, e.g. nominal value of 0.05

Enter the value for the feed forward term, e.g. nominal value of 0.3

P410-01 Manual Mode Output E Current Output Value 0

P414-01 Setpoint Configuration E 0-Local, 1mA In 0

% value of output during manual operation, P400 = 1

Selection of setpoint source:

0 = local (keypad or Dolphin Plus) 1 = mA input

Local: the setpoint is the value entered into P415.

mA Input 1: the setpoint is the mA value on input 1, terminals 5 and 6 on the mA I/O board.

mA Input 2: the setpoint is the mA value on input 2, terminals 7 and 8 on the mA I/O board.

P415-01 Local Setpoint Value E Enter Setpoint 0

Enter the setpoint value in engineering units.

Not applicable if P414 = 1

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Page 78

P416-01 External Setpoint E Setpoint 0

Current setpoint value in engineering units, obtained from the mA input

P418-01 Remote Setpoint Ratio V Enter % of Master Output 100.000

P250-01 mA Input Range E Select 1- 0 to 20, 2-4 to 20 2

P255-01 mA Input Function E Select 0, 1-PID SP, 2-PID PV 0

Increase or decrease to scale input setpoint, if desired.

Select the appropriate range for the mA input signal

Assign either:

1, PID setpoint, or 2, process variable as the function of the mA input

Note: The PID setpoint can be modified while in RUN mode using the up/down

arrow keys.

PID Control

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Batching

The batching process, as it relates to the BW500 operation, can be defined as the transfer of a predetermined quantity of material.

The process supports a count up operation (P560), in that the total (totalizer 5) begins at zero and increments up to the programmed setpoint (P564). A relay (RL1 through 5) programmed as the batch setpoint function (P100 = 8) is actuated when the material total reaches the setpoint. The relay contact acts as an interlock to the material feed to end the batch.

Another relay can be programmed as a pre-warn alarm (P100 = 7), to alert the process that batch end is near. The relay is actuated when the material total reaches the prewarn setpoint (P567) at some practical value below the batch setpoint). The pre-warn function is enabled / disabled from the batch process through P566.

For batch operations, the following must be addressed.

• connections

• programming

•operation

Connections

Typical Ladder Logic

BW500 / RL1*

batch stop

47 48

stop

start

motor contactor /

MC1

BW500 / RL2*

pre-warm

MC1

alarm

BW500/

aux 1

♦

RUN

ALT DISP

PAR

ZERO

RESET

CLEAR

TOTAL

♦

SPAN

ENTER

batch reset

* Typical relay assignment. Relays 1-5 are available for batch setpoint or pre-warm alarm function.

♦

Typical auxiliary input assignment.

Inputs 1- 5 are available for batch reset.

7ML19985DK03 Milltronics BW500 - INSTRUCTION MANUAL Page 73

Batching

Page 80

Programming

The pre-warn function is optional.

The setpoint associated with the pre-warn relay is entered in P564, batch setpoint.

The setpoint associated with the batch relay is entered in P567, batch pre-warn setpoint.

Batch Operation

access P100, relay function

Access P560 Batch Mode Control Select 1, enable batch operation

if batch pre-warn is selected

access P567, batch pre-warn setpoint

Access P568 Batch Pre-act Set to OFF (0) or AUTO (1) or manual (2)

Relays

Access P100, Relay Function

select relay (1 – 5) select function 7, pre-warn

enter the pre-warn total

Select relay (1 – 5) Select function 7, Pre-Warn

Batching

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Operation

Once the BW500 relays are connected to the process logic, and it is programmed, the BW500 is ready for totalizing the batch and stopping the process when the batch setpoint is reached. The batch operation: start, pause, resume, and cancel are controlled externally by the process control (e.g. PLC)

Place the unit in the RUN mode.

Press ALT DISP until the batch screen is displayed.

Rate 0.00 kg/h SP: 20.000 Batch 0.00 kg

Start running the batch.

The display will show the rate of material flow and the batch total, as well as the batch setpoint. If pre-warn is used, relay contact is open.

When the batch total reaches the pre-warn setpoint, if programmed, the alarm event is removed and the assigned relay contact is closed.

Rate 123.4 kg/h SP: 20.000 Batch 17.0 0 kg ALM 1

The process continues, and when the batch total reaches the batch setpoint, the alarm event is displayed and the assigned relay is actuated (contact opened). Typically the relay contact would be integrated into the batch control logic to end the process.

Rate 123.4 kg/h Batch 20.00 kg ALM 12

When the next batch is to be run, pressing

providing a momentary contact closure across an auxiliary input (programmed as batch reset, P270 = 8), sets the alarm display and resets the batch total to zero, and the relay contact to its closed state.

Rate 0.00 kg/h SP: 20.000 Batch 0.00 kg

e.g relay 1 is programmed for pre-warn, P100-1=7

e.g. relay 2 is programmed for batch setpoint, P100-2=8

and then on the local keypad, or

Batching

Notes:

• The batch totalizer can be viewed as a read-only parameter (931-05), using single Parameter access through any programmed communication port.

• The batch setpoint can be modified in RUN mode using the up/down arrow keys.

Pre-act Function

If repetitive batches are being run, the pre-act function (P568) can be enabled to automatically trip the setpoint relay before or after the batch setpoint is reached to assure best batch accuracy.

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Page 82

Communications

The BW500 is an sophisticated belt scale integrator that can communicate status back to a SCADA system using a serial device such as radio modems, leased lines, or dial up modems.

radio modem

RUN PAR ZERO SPAN

RESET

ALT

ENTERCLEAR

TOTAL

DISP

dial-up modem

leased line modem

The BW500 supports two protocols: Dolphin and Modbus. Dolphin is a proprietary Siemens Milltronics protocol designed to be used with Dolphin Plus. Modbus is an industry standard protocol used by popular SCADA and HMI systems.

Communications

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BW500 and SmartLinx

In addition to three onboard communication ports, the BW500 is compatible with Siemens’ SmartLinx industrial communication systems.

This section only describes the onboard communications. For more information on SmartLinx

communication modules which provide an interface to popular

, please consult the appropriate SmartLinx® manual.

Connection

WARNING: When a SmartLinx® card is installed and P799 = 1, the parameters that the SmartLinx be continuously updated. Therefore, if you connect a SmartLinx card to the BW500, set P799 = 1 and not write anything to the SmartLinx

There are three serial communication ports on the BW500:

card, your setpoints will be 0.

Port Description

Refer to the

RS-232, Terminals 31 to 34

RS-485, terminals 41 to 46

RS-232, RJ-11 modular telephone jack

Installation

on page 6 for wiring diagrams specific to each port.

card is writing to the BW500 will

Wiring Guidelines

Improper wiring and choice of cables are the most common sources of communication problems. Listed below are some suggested guidelines:

• 15 meters (50 feet) for RS-232

• 1200 meters (4000 feet) for RS-485

• Ensure that communication cable is run separately from power and control cables (i.e. do not tie wrap your RS-232 cable to the power cable or have them in the same conduit).

• cable is shielded and connected to ground at one end only

• 24 AWG (minimum)

• follow proper grounding guidelines for all devices on the bus

• use good quality communication grade (shielded twisted pairs) cable that is recommended for RS-232.

7ML19985DK03 Milltronics BW500 – INSTRUCTION MANUAL Page 77

Communications

Page 84

Configuring Communication Ports

The BW500 communications ports are setup by a series of parameters (P770 – P789) which are indexed by port.

The communication parameters are indexed to the following:

Port Description

indicates the factory setting.

Note: Changes to these parameters are not effected until the power to the unit is

turned off and then back on.

P770 Serial protocols

The communications protocol used between the BW500 and other devices for the selected port, ports 1 to 3 (P770-01 to –03).

The BW500 supports Siemens Milltronics’ proprietary “Dolphin” data format plus the internationally recognized Modbus standard in both ASCII and RTU formats. It also supports direct connection of a printer.

The Siemens Milltronics protocol is compatible with the Dolphin Plus configuration program. See the Siemens web site for information on this PC product (http://www.siemens.com/processautomation).

The Modbus protocol is an open standard developed by AEG Schneider Automation Inc. Specifications are available from their web site (http://www.modicon.com/).

Other protocols are available with optional SmartLinx

Val ues

0 communications disabled 1 Siemens Milltronics "Dolphin" protocol 2 Modbus ASCII slave serial protocol 3 Modbus RTU slave serial protocol 4printer

RS-232, Terminals 31 to 33

RS-485, terminals 41 to 45

RS-232, RJ-11 modular telephone

-01 and -02

-03

cards.

Note: BW500 must be in RUN mode to allow for the print operation.

Communications

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Page 85

P771 Protocol address

Note: Applicable only to ports programmed for Modbus RTU or Modbus ASCII

(Parameter 770).

The unique identifier of the BW500 on the network for the selected port, ports 1 to 3 (P771-01 to -03).

For devices connected with the Siemens Milltronics protocol this parameter is ignored.

For devices connected with a serial Modbus protocol this parameter is a number from 1-

247. It is up to the network administrator to ensure that all devices on the network have

unique addresses.

Do not use the value “0” for Modbus communications as this is the broadcast address and is inappropriate for a slave device.

Values

0 to 9999 (f = 1)

P772 Baud Rate

The communication rate with the master device for the selected port, ports 1 to 3 (P77201 to –03).

The baud rate chosen should reflect the speed of the connected hardware and protocol used.

Values

1 4800 baud 2 9600 baud 3 19,200 baud 4 38,40 0 baud

f-03

P773 Parity

The serial port parity for the selected port, ports 1 to 3 (P773-01 to –03).

Ensure that the communications parameters are identical between the BW500 and all connected devices.

For example many modems default to N-8-1 which is No parity, 8 data bits, and 1 stop bit.

Values

0none 1even 2odd

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Communications

Page 86

P774 Data bits

The number of data bits per character for the selected port, ports 1 to 3 (P774-01 to –03).:

Protocol P744 Value

Modbus RTU

Modbus ASCII

Dolphin Plus

7 or 8

Note: If using port 2, 8 data bits must be used.

Values

5 to 8 (f = 8)

P775 Stop bits

The number of bits between the data bits for the selected port, ports 1 to 3 P775-01 to -03).

Values

1 or 2 (f = 1)

P778 Modem attached

Sets port 1 (P778-01) to use an external modem.

Any connected modem must be set up to auto-answer incoming calls. The BW500 does not automatically configure the modem.

Autobaud (enabled by P778=1)

When the BW500 is powered up or the P779 Modem Inactivity Timeout expires three carriage returns are sent to the modem to allow it to set its serial connection to P772 Baud Rate.

If a connection is made with the modem at a different baud rate the BW500 will attempt to use that rate instead of the P772 value. For troubleshooting purposes the baud rate on the modem can be hard-coded to the rate set on the BW500. See your modem documentation for information on fixing the baud rate.

Values

0 *no modem connected 1 modem connected

Communications

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Page 87

P779 Modem idle time

Sets the time in seconds that the BW500 will keep the modem connected even though no activity is happening.

To use this parameter ensure that P778=1.

This parameter allows for reconnection to the BW500 unit after an unexpected disconnect. Ensure that the value is low enough to avoid unnecessary delays when an unexpected disconnect occurs but long enough to avoid timeout while you are still legitimately connected.

Hanging Up

If the line is idle and the P779 Modem Inactivity Timeout expires then the modem is directed to hang up the line. This is done with the Hayes commands:

• two second delay

• +++

• two second delay

•ATH

Ensure that P779 is set longer than the standard polling time of the connected master device.

0 disables the inactivity timer.

Values

0-9999: 0 (f = 1)

P780 RS-232 Transmission interval

Note: Applicable only to ports programmed for printer communication

(parameter 770).

Sets the interval between transmissions to be applied to the selected port, ports 1 to 3 (P780-01 to –03).

Enter the period in minutes. (

7ML19985DK03 Milltronics BW500 – INSTRUCTION MANUAL Page 81

= 0)

Communications

Page 88

P781 Data message

Note: Applicable only to ports programmed for printer communication (parameter

770).

Sets the data message to be delivered via the selected port, ports 1 to 3 (P781-01 to -03).

All messages and printouts include time and date.

Entry:

0 = no message 1 = rate 2 = total* 3 = load 4 = speed 5 = rate, total*, load and speed 6 = rate and total* 7 = batch total (totalizer 5) 8 = rate and speed 9 = quick start parameters (P001 – P017) 10 = all parameters

*totalizer 1 and/or 2 as set by P647, Totalizer Display

P799 Communications Control

Assigns programming control either locally through the keypad or Dolphin Plus (P770 = 1), or remotely through Modbus protocol (P770 = 2 or 3) or SmartLinx

Entry:

0 = local 1 = remote

WARNING: When a SmartLinx® card is installed and P799 = 1, the parameters that the SmarlLinx

card is writing to the BW500 will be continuously updated. Therefore, if you connect a SmartLinx card to the BW500, set P799 = 1 and not write anything to the SmarLinx

card, your setpoints will be 0.

Communications

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Page 89

Dolphin Protocol

The protocol is available on all communications ports on all units. This protocol is not available for third party use.

The primary use of this protocol is to connect the BW500 to Siemens Milltronics’ Dolphin Plus configuration software.

Dolphin Plus Screen Shot

Tabs show groups

of parameters

Paramet ers have

roll-overs which

show number

Paramet ers can

be tracked while

the BW500 is

running

The attached device can be programmed,

debugged, and monitored from

Dolphin Plus

The status bar informs you of

program actions

and data transfer

status

7ML19985DK03 Milltronics BW500 – INSTRUCTION MANUAL Page 83

Communications

Page 90

Modbus RTU/ASCII Protocol

Modbus is an industry standard protocol owned by Schneider Automation Inc.1 and is used throughout process control industries for communication between devices. Modbus RTU and Modbus ASCII are both master-slave type protocols. BW500’s Modbus is a slave unit.

BW500 supports both the RTU and ASCII version of Modbus and attempts to automatically detect the type when a connection is made.

A brief description of Modbus RTU and Modbus ASCII is given in this manual. For a full description of the Modbus protocol, contact your local Schneider representative. Also you may try their web site at:

http://www.modicon.com

At the time of publication of this manual, the Modbus Protocol was located under products / technical publications / communications products / Modbus protocol.

Note: Siemens does not own the Modbus RTU protocol. All information regarding

that protocol is subject to change without notice.

How Modbus Works

As mentioned above, Modbus is a master-slave type protocol. This can also be referred to as a query-response protocol. What both of these terms mean is that on the network, there is one master which requests information from multiple slave devices. The slave devices are not permitted to talk unless they have been asked for information. When responding, the slaves will either give the information that the master has requested or give an error code consisting of why it can not give the information or that it did not understand the request. Refer to

Error Handling

on page 100.

All BW500 information is mapped into the Modbus holding registers so that Modbus function code 03 can read from them and Modbus function code 06 and 16 can write to them.

Communications

Modicon is a registered trademark of Groupe Schneider.

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Modbus RTU vs. ASCII

There are two main differences between Modbus RTU and Modbus ASCII. The first is that Modbus RTU encodes the message in 8-bit binary, while ASCII encodes the message in ASCII characters. Therefore, one byte of information would be encoded into 8 bits for RTU and into two ASCII characters for ASCII (which would be two 7-bit units). The second difference is that the error checking method is different (see below).

Modbus RTU has the advantage that it has a much greater data throughput than ASCII. Modbus ASCII has the advantage that it allows time intervals of up to one second to occur between characters without causing an error. Either protocol works with the BW500.

Modbus Format

Note: When using a commercial Modbus driver all of the message details are

handled for you.

To give you a better idea of how a Modbus message works, a master on network would send a message in a format similar to this:

Station

address

Where:

Station address the network address of the slave being accessed

Function Code number that represent a Modbus command, either:

Information depends on function code

Function

code

03 read function 06, 16 write functions

Information

check

Error

Error Check Cyclical Redundancy Check (CRC) for RTU and Longitudinal

Redundancy Check (LRC) for ASCII

There is more to the frame than is described above, this is shown to give the user a general idea of what is going on. For a full description, refer to the Modbus specifications.

Modbus Register Map

The memory map of the BW500 occupies the Modbus holding registers (R40,001 and up).

The BW500 was designed to make it easy for users to get useful information via Modbus. The following chart gives an overview of the different sections.

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Map Legend Description

Type: Arbitrary classification of registers.

Description: Brief description or title of associated register.

Start:

Number R:

Parameter Values: Refer to

Read: Identifies the read / write capability for the register being addressed.

Reference: Provides reference documentation for the register being addressed.

Provides the starting address for the register(s) where the parameter values are to be read from or written to.

The number of registers required to read or write the complete parameter value. Where the number of registers (6) are addressed in incrementing sequence from the start register.

Paramete r Values

, page 96.

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Ty pe Description Start # R

Format

Handshaking

Area

(Parameter

Access)

Date and Time

Process Values

I/O

Diagnostic Diagnostic State 41,200 1 number code r see page 133

Format Word for 32 bit variables

ID Device Identifier 40,064 1 2 r see page 88

Parameter 40,090 1 0-999 r/w Primary Index 40,091 1 0 - 9 r/w Secondary Index 40,092 1 0 - 9 r/w Format Word 40,093 1 bit mapped r/w Read Value (word 1) 40,094 2 32 bits r Write Value (word 1) 40,096 2 32 bits r/w YYYY 41,000 1 1996-2069 r/w MM 41,001 1 1 - 12 r/w DD 41,002 1 1 - 31 r/w hh 41,003 1 00 - 23 r/w mm 41,004 1 00 - 59 r/w ss 41,005 1 00 - 59 r/w

Time Zone 41,006 1 -12 - 12 r/w

Rate 41,010 2 32 bits r Load 41,012 32 bits r Speed 41,014 2 32 bits r Total 1 41,016 2 32 bits r Total 2 41,018 2 32 bits r Device State 41,020 1 bit mapped r see page 92 Command Control 41,022 1 bit mapped r/w see page 93

Multi-Span Selection 41,024 1 1 - 8 r/w

Total 1 decimal places 41,025 1 1 - 3 r/w see page 94 Total 2 decimal places 41,026 1 1 - 3 r/w see page 94 PID 1 Setpoint 41,040 2 32 bits r/w PID 2 Setpoint 41,042 2 32 bits r/w

Batch Setpoint 41,044 2 32 bits r/w

Batch Prewarn Setpoint 41,046 2 32 bits r/w

Discrete Input 41,070 1 bit mapped r Relay Outputs 41,080 1 bit mapped mA Inputs 41,090 2 0000 - 20,000 r mA Outputs 41,110 3 0000 - 20,000 r

40,062 1 0 - 1 r/w see page 88

Parameter

Values

Read Reference

see page 88

see P008

page 103 and

page 91

see P009

page 104 and

page 91

see P739

page 129

see page 92

see page 43 and P365 on

page 116

see P415

page 119

see P564

page 122

see P567

page 122

see page 95

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Ty pe Description Start # R

PID 1 Proportional Term 41,400 2 32 bits r/w PID 2 Proportional Term 41,402 2 32 bits r/w PID 1 Integral Term 41,404 2 32 bits r/w PID 2 Integral Term 41,406 2 32 bits r/w PID 1 Derivative Term 41,408 2 32 bits r/w

PID Tuning

PID 2 Derivative Term 41,410 2 32 bits r/w PID 1 Feed Forward Term 41,412 2 32 bits r/w PID 2 Feed Forward Term 41,414 2 32 bits r/w PID 1 Remote Setpoint Ratio PID 2 Remote Setpoint Ratio

41,416 2 32 bits r/w

41,418 2 32 bits

Parameter

Values

Read Reference

r/w

Modbus Register Map (cont’d)

Format (R40,062)

This value determines the format of all unsigned, double-register integers (UINT32),

except for those in the direct parameter access

0 indicates that the most significant byte (MSB) is given first 1 indicates that the least significant byte (LSB) is given first

For more information on this data format see page 96

Device Identifier (R40,064)

see P405

page 120

see P406

page 120

see P407

page 120

see P408

page 120

see P418

page 121

This value identifies the Siemens Milltronics device type and is “2” for the BW500.

Handshaking Area (Parameter Access)

Built into BW500 is an advanced handshaking area that can be used to read and write 32 bit parameters.

Mapping Parameter Read and Write (40,090 – 40,095) is a series of six registers that are used for reading and writing parameter values to and from the BW500. The first three registers are always unsigned integers representing parameters and index values. The second three registers are the format and value(s) of the parameter.

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All parameters normally accessed through the hand-held programmer are available through these registers.:

Address Description

40,090 Parameter (integer)

40,091 Primary Index (integer)

40,092 Secondary Index (integer)

40,093 Format word (bit mapped)

40,094 Read value, word 1

40,095 Read value, word 2

40,096 Write value, word 1

40,097 Write value, word 2

Reading Parameters

To read parameters through Modbus follow these steps:

1. Send the parameter, its primary index, and its secondary index (usually 0) and format to registers 40,090, to 40,093.

2. Wait until you can read the above values from the registers (40,090 to 40,093).

3. Read the value from registers 40,094 and 40,095.

Writing Parameters

To set parameters through Modbus follow these steps:

1. Send the parameter, its primary index, and its secondary index (usually 0) to registers 40,090, 40,091, and 40,092.

2. Write the value to registers 40,096 and 40,097

3. Write the desired format word to register 40.093 to enable the BW500 to interpret the value correctly.

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Format Register:

Bits Values Description

1 - 8 0 - 2 Error Code

9 - 11 0 - 7 decimal offset*

12 0/1 decimal shift*, Right (0) or Left (1)

13 0/1 Numeric format: Fixed (0) or FLoat (1)

14 0/1 Read or Write of data, Read (0), Write (1)

15 0/1

16 Reserved

The bits listed above are in order from least to most significant:

15 14 13 12 11 10 987654321

For example, to format the level reading so that it is shown in percent with two decimal places shifted left the format bits would look like this:

15 14 13 12 11 10 987654321

001001000000000

Word order: Most Significant word first (0), Least Significant Word first (1)

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reserved

read

float format

most significant first

decimal offset of +2

no error code

The value sent to the BW500 is 0001001000000000 binary or 4608 decimal. The value 4608 is sent as an integer to register 40,093 to format the output words 40,094 and 40,095 accordingly.

If the numeric data type is set for integer and the value contains decimal places they are ignored. In this situation use the decimal offset to ensure that you have an integer value and then write your code to recognize and handle the decimal offset. Bits 9 to 11 indicate the number of place by which the decimal is to be shifted. Bit 12 indicates the direction by which the decimal point is shifted, left or right. For example, if the decimal offset (value of bits 9 to 11) is ‘2’ and the shift (value of bit 12 is ‘0’), then the decimal point is shifted two places to the right.

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Error Codes

The error codes returned in the format area are 8-bit integers found in the lowest 8 bits of the format word. This allows for 256 potential error codes.

Currently the BW500 has two error codes available:

Values Description

0No error

1 Data not available as percent (available as units)

2-255 Reserved

Date and Time (R41,000 – 41,006)

The date and time can be read or written in registers 41,000 to 41,006 as defined in the table above.

Example: If you are located in Toronto, Canada and would like to set the date and time to February 14, 1999, 1:30 p.m. and 42 seconds, you would write the following:

Bits Values

R41,000 1999

R41,001 2

R41,002 14

R41,003 13

R41,004 30

R41,005 42

R41,006 -5

Note: The time zone register is used only as a reference and does not affect the

operation of the BW500.

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Process Values (R41,010 – R41,048)

Rate, Load, Speed and Total (R41,010 – R41,019)

The associated registers provide the readings of rate, load, and speed. Totalizer 1 and Totalizer 2 in engineering units as displayed in the local BW500 display.

Device State (41,020 – 41,020)

The Device State word is used to feedback the current operating state of the product. Each bit gives the state of different parts of the product, some mutually exclusive, others are not. The state should be checked to verify any device commands.

Bit # Description Bit Clear Bit Set (1)

1 PID 1 Mode Manual Auto

2 PID 1 Freeze No Yes

3 PID 1 Setpoint Source Local Remote

4 PID 2 Mode Manual Auto

5 PID 2 Freeze No Yes

6 PID 2 Setpoint Source Local Remote

7 Zero No In progress

8 Span No In progress

9---

10 - - -

11---

12 - - -

13 Write Privileges No Yes

14 System Configured Not Configured Ye s

15 Mode Calibration Mode RUN Mode

16 Tot a li z i ng Not Totalizing To ta l iz i n g

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Command Controls (41,022 – 41,022)

The command control word is used to control the unit. Each bit gives access to a command or state as if the operator was using the keypad.

Bits initiating a command (7-12) must change state to cause the command the begin. For example, to reset totalizer 1, Bit 9 must be set to 0, then changed to 1. It can stay set or clear for any period:

Bit # Description Bit Clear Bit Set (1)

1 PID 1 Mode Manual Auto

2 PID 1 Freeze No Yes

3 PID 1 Setpoint Source Local Remote

4 PID 2 Mode Manual Auto

5 PID 2 Freeze No Yes

6 PID 2 Setpoint Source Local Remote

7 Zero No change Start

8 Span No change Start

9 Reset Totalizer 1 No change Reset

10 Reset Totalizer 2 No change Reset

11 Reset Batch Totalizer No change Reset

12 Print - Print

13---

14 - - -

15---

16 - - -

WARNING: Before the BW500 can be commanded remotely, parameter P799 must be set for remote control.

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Read/Write (R41,025 – R41,026) Total Decimal Places

Sets the number of decimal places (0-3) being read for Total 1, (words 41,016 and 41,017) and Total 2, (words 41,018 and 41,019).

With 3 decimal places, the largest value that can be read is 2,147,483.648. With 2 decimal places, the largest value that can be read is 21,474,836.48. With 1 or 0 decimal places, the largest value that can be read is 100,000,000.

Example: R41,025

Bits 0 and 1 are used to indicate the number of decimal places being read in Total 1, Words 7 and 8.

Bit 15 is used to indicate if the decimal place is too large to read the total value correctly.

If three decimal places are being read in Total 1:

Bits 15 14 13 12 11 10 9876543210

0010010000000011

If three decimal places are being read in Total 1, and the value is too large to be read with three decimal places:

Bits

15 14 13 12 11 10 9876543210

1010010000000011

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