HASTE COMMISSIONING MANUAL BFC CONTROLLER BFC.943.001-E.bY//ASLE Servicing Please contact your nearest Hasler Servicing centre if you require assistance = or HASLER International SA Tél, +33 (0)4 74 16 11 60 F-98780 PONT-EVEQUE Fax +33 (0)4 74 16 11 55 HASLER Suisse Sarl Tel. +41 (0)32 720 23 00 CH-2000 NEUCHATEL Fax +41 (0)32 720 23 90 HASLER Deutschland GmbH Tel. +49 (0)54 81 80 50 -49525 LENGERICH Fax +49 (0)54 61 80 51 10 HASLER Industrial Equipment (Shanghai) Co., Ltd Tel, +8621 607 66718 CN-201816 SHANGHAL Fax +86 21 607 66 716 Please clarify the following points before calling : ‘Are there any alarm messages? Can you eliminate the cause of these alarm messages ? Have your modified any of the components in the system, metering unit, products or operating processes ? Have you attempted to correct the fault following instructions in the user and maintenance manuals ? Please write down - the installation number 7 - the type of metering unit the type of engine control The use, reproduction or disclosure of this document in part of in full, by electronic or mechanical means, including photocopy, facsimile and scanning, without prior writen consent from HASLER international, is. prohibited, Translation rights reserved to HASLER International. HASLER Intemational has made every effort to ensure the quality and reliability of this document. It may however contain errors or omissions, in which case please notify one of the HASLER Divisions. {Al information herein was updated before going to press. HASLER International cannot however be hel responsible for damages resulting from misuse of equipment or negligence on the part of users. Copyright HASLER International SA Zl. de L’Abbaye F - 38780 Pont-Eveque Produced and published by the Technical documentation division HASLER Suisse Sarl Order n® : BFC.943.001-E.b Date: 07.09.12 HASLER Suisse Sarl, a HASLER International SA subsidiaryTable of Contents 4. SAFETY RULES Conforming Use , Measures relating to organisation ..... Operator's responsbbilities .... Working in complete safety After sales and repair service aeons 2. INTRODUCTION... INSTALLING THE CONTROLLER. 3. 4. OPENING THE CONTROLLER UNIT. 5. CONNECTION OF THE MONO-STATION SCALES WEIGHING ‘STATION... 6. CONNECTION OF THE DOUBLE WEIGHING STATION OR MULTI-STATIONS. 11 7. MOUNTING SHIELDED CABLES IN THE CABLE GLANDS 7A CABLE PREPARATION .... 7.2 CABLE MOUNTING... 8. BFC CONNECTOR MARKING 9. CONNECTING THE WEIGHING STATION TO THE BFC CONTROLLER 9.1 FOR STATION WITH SFT DIGITAL CELL... - non 9.2 FOR STATION WITH ANALOG LOAD CELL. 40. CONNECTING THE POWER SUPPLY... 44. INTERFACE CONNECTION... 42. COMMISSIONING. 12.4 GENERAL PROCESS 12.2 DETAILED PROCESS .......-+ 12.2.1 Select the display language - 42.22 Select the controller in MAINTENANCE mode. 42.2.3 Program the analog or digital SFT load cell type 122.4 SFT digital cell Enter the correction coefficient 422.5 Enter the weigh deck length if not 2 1 ....s-s- 422.6 Weighing with two stations weighed enter the roll spacing 122.7 Enter the conveyor angle (digital weighing only) .... 42.2.8 Analog weighing run the scale weight calibration ... 42.2.9 Run the Initial taring crocs 12.3 EMPTY BELT TARING..... pereerar 12.3.1. EMPTY BELT TARING IN AUTOMATIC MODE... 42.3.2 EMPTY BELT TARING IN MANUAL MODE..... eae 13.3.3 CHECKS CARRIED OUT DURING THE BELT TARING PROCESSES 36 BFC.943.001-E.b page 3/37MY 41. SAFETY RULES The installation, commissioning and programming of the BFC flow controller must be performed by staff who are trained to perform these tasks. 1.1 Conforming use Only use the BFC controller with metering equipment that has been supplied or approved by HASLER. Only use the BFC controller in accordance with its technical specifications. 4.2 Measures relating to organisation Consider safety rules applicable to the use of metering units connected to the BFC controller, In addition to the instructions, please follow all regulations currently in force in matters concerning accident prevention and environmental protection ‘Always keep the instructions easily accessible at the installation’s operating site. Ensure that the instructions are complete and legible. 1.3 Operator's responsibilities The BFC controller may only be used by qualified, trained staff. . Assign staff responsibilities concerning controller operating and maintenance tasks. Make sure that all members of staff working with the BFC controller have fully understood the instructions of use for all installed components, especially the safety Tules indicated in this chapter. Replace any damaged or missing components immediately. The user of the BFC controller must ensure compliance with all current safety and accident prevention regulations. 1.4 Working in complete safety Notify the manager immediately if any changes are made (even if these are productivity- related) that are liable to affect safety. Always prioritise safety aspects when executing works Do not adjust the BFC controller with the conveyor running without first gauging the impact of doing so on the machines's behaviour. 1.5 After sales and repair service The BFC controller must only be repaired by + an approved HASLER after-sales servicing centre or + qualified staff, trained by HASLER. Only use original spare parts delivered by HASLER, page 4/37 BFC.943.001-E.bY///PASIR f 2. INTRODUCTION The BFC controller (Belt Flowmeter Controller) is a measuring instrument designed to be connected to analog or digital load cells. It is principally used for measuring and processing data generated by belt scales of the type SBS (Smart Belt Scales) and with metallic aprons of the type SAS (Smart Apron Scale). The BFC controller connected to an SBS integrator scale forms a unit that is certifiable according to OIML standard No. 50. Storage temperature: -25°C to +70°C Storage: away from bad weather and avoid storage in chemically environments. On reception check conformity of the delivery with your order. BFC.943.001-E.b page 5/37Y//PASIE f 3. INSTALLING THE CONTROLLER WALL MOUNTED VERSION dimensions in mm 162 when tipped. AVOID: Temperatures below -10°C and above +50°C ENVIRONMENT: Protection class to IP 65 PROVIDE: Enough side space for the tipping and accessibility of the controller on right side part. Provide an extra 150 mm of cable to enable the unit to open 100 page 6/37 BFC.943.001-E.bYASIR f PANEL VERSION Panel opening 144 mm x 192 mm dimensions in mm * Maintenance port, unscrew the cap to access the RJ45 connector PROVIDE: Panel opening 144 x 192 mm. Enough space to access the cables. Provide 100 mm to access the maintenance port *. AVOID: Temperatures below -10°C and above +50°C FRONT PANEL PROTECTION DEGREE: IP 65. BFC.943,001-E.b page 7/37MUR Check the equipment before installation Below is the equipment for a BFC controller with SBS Wall mounted version Panel version 1 Seal 1 Mounting support 4 fixing screws wy ~ = ea ~ a Cable characteristics: (c) Shielding: copper braid Number of wires: 5 twisted pairs Maximum distance: 1000 m Wire resistance: < 40 O/km Important: The cable shielding (c) must be connected at both ends to the corresponding terminals for the differential voltage to be lower than 30V Terminal box with connection for electronic controller cable Example for SBS The speed sensor has a system to avoid the belt's normal confused with its oscillation. movement from being The controller therefore does not use an additional interlocking contact or belt start Page 8/37 response, BFC.943,001-E.b 3 Mounting brackets 6 bracket fixing screws 3 adjustment screws FFs | ~~ 3PCC a Y//PASIER f 4, OPENING THE CONTROLLER UNIT Remove the unit base lid as shown. Unscrew the four base screws The standard interface connection scheme is inside the lid. Position 2 Position 4 Position 5 M16x1.5 @ 4.5..9mm Pos 1,2,3 (1&3 option) M20x1.5 @ 7..12.5mm Pos Pos2: cable gland for power supply Posd: shielded cable gland for input and output interface Pos5: shielded cable gland for weighing station BFC.943,001-E.b page 9137Y//PASIER f 5. CONNECTION OF THE MONO-STATION SCALES WEIGHING STATION Panel version controller Wall mounted version controller Max dist. Cable 1000m ] terminal box fixed on the belt Max dist. Cable 1000m terminal box fixed on the belt © Sg page 10/37 BFC.943,001-E.b a a a i lect alllI MR 6. CONNECTION OF THE DOUBLE WEIGHING STATION OR MULTI-STATIONS Connection to a wall mounted or panel version controller on double station: Use the 5 pair cable and connect it directly to the BFC controller © Use the standard 5 pair cable between the scales connection units with 1:1 type cabling Connection to a double weighing scales (2 load cells on 1 station): ‘* Use the 5 pair cable and connect it directly to the BFC controller Direct connection to the BFC controller Total cable length 1000 m _ | 6 © BFC.943.001-E.b page 11/37MEY 7. MOUNTING SHIELDED CABLES IN THE CABLE GLANDS 7.1 CABLE PREPARATION The interfaces are connected by shielded cables. These cables pass through shielded cable glands. 4. Prepare the cable. Diameter 9 to 12 mm. For the weighing station interface X=170 mm @Ialemm nm, x pom, 7.2 CABLE MOUNTING Contact disks (D): Nickel plated brass. The threaded connector connects the shielding braid to the earthed unit. OR Cable characteristics: (c) Shielding: braided copper Number of wires: 5 twisted pairs Maximum distance: 1000 m Wire resistance: < 40 alm page 12/37 Important: The cable shielding (c) must be connected at both ends to the corresponding terminals for the differential voltage to be lower than 30 V BFC.943.001-E.bMWEEEY 8. BFC CONNECTOR MARKING X11 : analog load cell connector X2 : analog output connector X23 : SFT power X24 : digital X22 : digital load supply distribution ___Inputioutput 21: speed sensor \ cell connector connector interface connector connector (SFT) | o : X25 main power supply connector Cable gland Cable gland Position 5 Position 4 For Weighing For input output station cable interface cable Cable gland Position 2 For power supply cable BFC.943,001-E.b page 13/37MY 9. CONNECTING THE WEIGHING STATION TO THE BFC CONTROLLER 9.1 FOR STATION WITH SFT DIGITAL CELL BFC controller Connect. Loadcell X22 Connect. Tacho X21 Cable gland Position 5 Cable shielding 7 i os Terminal box fixed on the belt *R: Line termination (equip the most distant controller terminal box) TOAD CELL SPEED SENSOR page 14/37 BFC.943.001-E.bPASTE: f 9. CONNECTING THE WEIGHING STATION TO THE BFC CONTROLLER 9.1 FOR STATION WITH SFT DIGITAL CELL BFC controller Connect. Loadcell X22 Connect. Tacho X21 Cable gland Position 5 Terminal box fixed on the belt, *R: Line termination (equip the most distant controller terminal box) Shielding k jel ala co ae 43 “= [vonwcet [ree secon page 14/37 BFC.943.001-E.b eeeMEY 9.2 FOR STATION WITH ANALOG LOAD CELL BFC controller Connect. Loadcell X11 Connect. Tacho X21 Cable gland Position 5 Terminal box fixed on the belt BFC.943,001-E.b page 15137 a celal ala eeeMR 10. CONNECTING THE POWER SUPPLY Fuses Important : “To aold the electromagnetic eld Earth connection to unit by M4 screws Power supply connection diagram Cable gland pos 2X25 a 230V, 50 Hz ee * csr or = N |—e 115V, 60 Hz Cera) [ace L@ te — ATTENTION to the power supply voltage. BFC Panel/Wall version Model No. 2514.1000. Powerraing = PNL-PE~50.60 Hz 90.260 V eager Hea ees eee identification Fuse WEST label After connecting the power supply, check: that the display and the status indicators LED are on, then product identification for 2 seconds. Ifnot, check that the power supply is 230 V or 115 V. Check the power supply unit LED. page 16/37 BFC.943.001-E.b aie a ce sca ee ee ee ee et, ae) aeeel ‘eet saatY// HASLER f 11. INTERFACE CONNECTION You will find all the information for the connections and the controller programming in the maintenance manual. oO BFC.943,001-E.b page 17/37YASIR f a* Page 18/37 BFC.943.001-E.b | | | | | | | | | | | | | | | ! | |I // HASLER f 42. COMMISSIONING 12.1 GENERAL PROCESS The general process for commissioning the BFC is as follows: « Select the display language, English, French, German, Italian, Portuguese, Spanish, Chinese or Russian. «Select the controller in MAINTENANCE MODE. Program the analog or digital type load cell (SFT type). Enter the load cell correction coefficients for a digital cell (SFT type). « Measure the length of the weighbridge. If this length is not 2.00 m., enter the real length in the corresponding parameter. «If the scales are also equipped with a weighing station, measure the distance between the stations weighed and enter this value into the corresponding parameter. «If you use digital load cell and the conveyor is not horizontal, enter its inclination (see below). If you use an analog load cell, make calibration of analog load cell. Run the Initial Taring. Attention: the belt must be completely unloaded before starting this Initial Taring. 42.2 DETAILED PROCESS Commission your belt scale as follows: 12.2.1 Select the display language Press the “Main page " then press simultaneously the "softwares 1 ® nas and 3 ” keys to go to the language selection page; select the ® ) language with the up and down keys and press Enter to confirm. BFC.943.001-E.b page 19/37MEY 42.2.2 Select the controller in MAINTENANCE mode. Press the "Menu" key by pressing then select the "System" menu confirm by pressing Enter Select the "Security" parameter confirm by pressing Enter. cd ero Peace oct acheern Then using the left and right and up and down software keys, enter the value 1000 into the password and press enter. Select the "Maintenance" security level with the up @ and down ©) software keys and confirm by pressing Enter. The "Maintenance" security mode will enable you to modify the parameters and launch the calibrations. Note: The password and security level are automatically cancelled after an hour and the security level returns to operator mode. page 20/37 BFC.943.001-E.bMARY If your belt scale have one or more load cell type analog cells, go directly to point 12.2.5; the load cell type parameter is auto-initialised with the analog cell type. 12.2.3 Program the analog or digital SFT load cell type Load Cell type Analog Cell ‘SFT type Digital Cell Press the " key then select the "Scale" menu or Then select the type of load cell; you can choose between SFT digital load cell type or analog load cell type. © Then confirm your selection with G) ® Note: Selecting the type of cell will modify the display of certain menus. Note: The compatibility of SFT digital cells from version M or SFT type 2. BFC.943,001-E.b page 21/37MY 42.2.4 SFT digital cell Enter the correction coefficient [SFT type Digital Cell If your belt cells have one ore more SFT digital cells, you can enter the correction coefficient for the whole weighing system, SFT cell plus Parallelogram, the coefficient is marked on the parallelogram that supports the station(s) weighed. If your station has several SFT digital weighing units, you must multiply the coefficients to obtain the parameter to be entered in SFT Coefficient. @) i — - . | Note: This operation is not necessary if you carry out a material test to | check the installation's accuracy; during this test you can use the coefficient parameter to correct the accuracy if necessary. I I I I I | I I I | | page 22/37 BFC.943,001-E.bMMEY 12.2.5 Enter the weigh deck length if not 2m == a Load cell type Analog Cell ‘SFT type Digital Cell If the weigh deck length is not 2 meters, enter this value. 'f your installation has a second weighing station, the weighbridge length corresponds to the diagram in 12.2.6. The weighbridge length parameter is extremely important, The accuracy of your scales depends on the accuracy of the measurement of this length. a en) Cer Upstream station Downstream station Stations weighed BFC.943,001-E.b page 23/37Y//PASIER f 12.2.6 Weighing with two stations weighed enter the roll spacing Load cell type Analog Cell SFT type Digital Cell If the BFC is only equipped with a single weighing station, the roller distance parameter must be left at zero. The roller distance parameter is extremely important. The accuracy of your scales depends on the accuracy of the measurement of this length pee eel Ty The diagram below shows the weight deck for scales with two single weighing stations, Weighing with two stations —> Material direction Weightbridge Lenght Upstream station Downstream station Stations weighed page 24/37 BFC.943,001-E.bYASIR 12.2.7 Enter the conveyor angle (digital weighing only) ‘SFT type Digital Cell If the conveyor is not horizontal, enter its angle. Ae CNET @) @ The angle is expressed in degrees (°) and only applies to the SFT type digital load cell BFC.943,001-E.b page 25/37MY 42.2.8 Analog weighing run the scale weight calibration Ifyour scales have SFT type digital load cell, go directly to step 12.2.9. Load cell type Analog Cell omen fi Wo 12.2.8.1 Enter the reference weight value The reference weight is normally delivered by HASLER. It is attached near the belt scale. If this is not the case, use a reference weight that corresponds to 30 to 80% of the nominal measurement weight of your load cell Trio Note: This operation may also be carried out during the first weighing cell calibration function step. page 26/37 BFC.943,001-E.b12.2.8.2 Enter the "Arm calibration” lever arm Load cell type Analog Cell Indication of the lever arm calculation: Weigher roll ‘T\ Reference weight hi | The lever arm is: Arm calibration = scales depends on the accuracy of the measurement of this length. The “Arm calibration” parameter is extremely important. The accuracy of your | If the lever arm is not 1.0, enter its value into the corresponding parameter. | ter meat eT ol ‘- ea -) BFC.943.001-E.b page 27/37YASIR f 12.2.8.3 Calibrate the scale weight sme ii Load cell type Analog Cell : The load cell calibration defines the ratio between the A/D converter value and a known reference force, i.e. the reference weight. Before starting this function, prepare your reference weight without putting it on the hook at the end of the lever arm. ee eee Neco ‘The Successful calibration message appears at the end of the function During the tare calibration, the Tare |___—___- light comes on yellow. The ‘Successful calibration message appears once the function is complete. page 28/37 BFC.943,001-E.bMEX Follow the steps on the BEC display in the chart below: so Perit ex )) < tan t00 Roe “sar =| Display on LCD Stops he beltagsin (counter for eecondsbelxe the procedures abancones + \ Sone on BFC.943,001-E.b page 29/37 eeMaxey page 30/37 BFC.943.001-E.b lees ———12.2.9 Run the Initial taring == Ss SFT type Digital Cell Load cell type Analog Cell This Initial taring is carried out on a 100 m belt length. This taring length may be modified with the following parameter: ec The taring length is expressed in metres. To launch the initial taring, run the following operations: tc 7 7 The Initial taring measures and stores the weigh station weight plus the empty belt weight. Run the belt empty for a few minutes until it takes its normal position. If this function is requested when the belt is stopped, the Start the belt without a weight and restart the procedure message is displayed and the function Is cancelled, an alarm is also generated alarm 203 under speed BFC.943.001-E.b page 31/37Y//PASIER f During the Initial taring, the controller measures and stores the average empty belt weight. This average will be used as the reference value for the empty bell taring If this Initial taring function is not run, the totalisation will not be calculated and the mass flow will not be displayed. While this function is run, the controller displays the percentage of belt length already measured automatically from 0 to 100%. After this function is run, the controller displays the tare measured; this may be consulted at any time in the metrology menu. ee A) tear) oe a Pcie fear See cre xch. When this Tare is carried out, your scale is ready to be used. page 32/37 BFC.943,001-E.b12.3 EMPTY BELT TARING Load cell type Analog Cell SFT type Digital Cell The empty belt Taring measures and calculates the average belt weight. This taring enables the BFC to compensate weight variations due to material clogging and those due to differences in belt tension. It is recommended that this function be run regularly, but at least once per week. The Empty belt taring is carried out on a 100 m belt length. This taring length may be modified with the following parameter: Cri) Coo acy The tare length is expressed in metres. To obtain optimum accuracy, carry out this taring on a whole number of belt rotations. This empty band taring function may be run automatically or manually. By default, the empty belt taring is run automatically. BFC.943,001-E.b page 33/37YASIR f 12.3.1 EMPTY BELT TARING IN AUTOMATIC MODE In this mode, taring is run each time the belt is empty. The belt is considered empty if the load on the belt is smaller than the empty belt tare threshold. The default value of this threshold is 5 kg. Depending on the belt quality, this threshold may be adjusted by: Cer Sea aWeenae This value is expressed in kg of materials on the belt. The taring is run automatically and during execution only the yellow LED lights up OS ‘A message indicates that the taring is successful at the end of the process steady indicating that a taring is in progress During the empty belt taring, if the belt weight exceeds the empty belt tare threshold, the current taring is stopped and the average belt weight previously stored is used as the reference value. A new taring will be run automatically when the belt is considered as empty. page 34/37 BFC.943.001-E.bMEXZEY 42.3.2 EMPTY BELT TARING IN MANUAL MODE if an automatic empty belt taring is not desired, this taring may be run manually. In this ‘daa. the belt is considered as empty if its weight is lower than the absolute empty belt tare threshold value. The default value of this threshold is 5 kg. Depending on the belt quality, this threshold may be adjusted by oo meso erin) Cran wis This value is expressed in kg of materials on the belt. The empty belt manual mode is selected with the "T.B.V. Op Mode" empty belt tare operating mode parameter. Reed The manual selection must be confirmed after the mode is selected To run the manual mode belt taring, run the function: Ee BFC.943.001-E.b page 35/37Y//PASIE: f While this function is run, the controller displays the percentage of belt length already measured automatically from 0 to 100%. ‘After this function is run, the controller displays the tare measured; this may be consulted at any time in the metrology menu. (eos eae Corio If the belt is not empty, the controller displays the message "High tr. load" and the taring is cancelled. This message is also displayed if the load becomes too large during the tare process. 42.3.3 CHECKS CARRIED OUT DURING THE BELT TARING PROCESSES To determine if the belt is empty, the controller uses the average weight calculated during the Initial tare, ec) Cee cal Pemieeionc) page 36/37 BFC.943,001-E.b aneMGR To detect a clogging on the belt, the controller compares the values of the average belt weight with the average weight measured during the Initial taring. The difference is stored in the Belt variance parameter. coy Ce er SOT Tine} Tot permanent ‘This parameter is displayed as a percentage of the Maximum load. If its value is greater than the Maximum tare, the 206 Belt tare fault incident is displayed. This incident indicates a material clogging on the belt. This clogging affects the accuracy of the weight measurement. ‘After each tare process, the average weight calculated is compared with the value obtained during the previous tare. The difference is stored in the Tare drift parameter. (cea cer ee This parameter is displayed as a percentage of the Maximum load. If its value is greater than the Maximum drift, the 205 Belt tare instability incident is displayed. This incident indicates an instability of the weight measurement. This instability may be due to an incorrect alignment of the weight bridge or a significant variation in the belt tension. BFC.943,001-E.b page 37/37