MASCON-2 BOS SERVICE MANUAL Nr. 2637E PRELIMINARY ‘Number of pages: 62. Enclosures : mone PRELIMINARY BREDA, 030696 John Gemei (MOLEN100} Mascon-2 BOS SERVICE MANUAL 030696 2637E 1‘TABLE OF CONTENTS 1 INTRODUCTION 4 1.1 GENERAL E 4 1.2 SERVICE PASSWORD . Ss 13 KEYBOARD LAYOUT .. 5 2 BOS CONFIGURATION «2.0... e eee cece cece seve eeee 6 3 FEED GATE CONFIGURATION «2.2.2.6... eee e cee ee ee aw 4 ERROR SIGNAL TABLE ..... 20... .0 000.002 eee c ee eeeeee 8 5 TEST WEIGHT... 2... eee e eee 9 6 PERIPHERAL EQUIPMENT ..............020-0ceseeeuee 10 7 DYNAMIC BOS SCREEN CONFIGURATION ........... 0.020. i 8 TABLESIZES 2... eee cece eee eee 12 9 INDICATOR MENU . 13 | 9.1 CALIBRATION PROCEDURE... - 1B | 9.2. INT.IB-1/0 (MICI/MICX) INDICATOR 4 | 9.2.1 MICI INFORMATION .. . 4 9.2.2 MICI GENERAL SETTINGS . 1S 9.2.3 MIC1 GENERAL SETTINGS 2 . 16 | 9.2.4 MICI CALIBRATION . . 17 9.2.5 MICI ZERO CALIBRATION ere 18 9.2.6 MICI ENHANCED SETTINGS MENU |... 19 | 9. 1 MICI ENHANCED SETTINGS 20 9.2.6.2 MICI ADC CONFIGURATION 24 | 9.2.6.3 MICI CALIBRATION UPDATE 25 9.2.6.4 MICI FACTORY SETTINGS . 26 9.2.7 MICI PRINT PARAMETERS ...... . ve 26 9.3. MICX (MICK NEW) INDICATOR... 10... 21 9.3.1 MICX INFORMATION ...... . . 27 9.3.2. MICX GENERAL SETTINGS . . 28 9.3.3. MICK GENERAL SETTINGS 2 29 9.3.4 MICX CALIBRATION ... . 30 9.3.5 MICX ZERO CALIBRATION . ; 31 9.36 MICX ENHANCED SETTINGS MENU |... 32 93.6.1 MICX ENHANCED SETTINGS. 33 9.3.6.2 MICX ADC CONFIGURATION . 37 93.6.3 MICX CALIBRATION UPDATE - 38 93.6.4 MICX CURRENT SETTINGS . . 39 9.3.6.5 MICX FACTORY SETTINGS 39 9.3.7 MICX PRINT PARAMETERS _ 39 [MOLEN100] Mascon-2 BOS SERVICE MANUAL, 030696 2637E 2 |10 PLC MENU Beer eos 40 10.1 ENABLE/DISABLE PLC . . 40 10.2 RECEIVE PROGRAM . 40 10.3 SEND PROGRAM one 41 10.4 EDIT PROGRAM.......... 41 10.4.1 PLC PROGRAMMING LANGUAGE |) ay 10.4.2 PLC INSTRUCTIONSET ...... 43 10.4.3 PLC PROGRAM SYNTAX peter 50 10.4.4 PLC PROGRAMMING; GENERAL INFORMATION ||| 3] 10.5 ENABLE/DISABLE MONITOR................. +) SL 11 MASTER PASSWORD ..........., 2 1. APPENDIX: Basics on how to configure a MASCON-2 BOS system 2... 53 TM. APPENDIX: PLC merker list... 0.00... c ccc ceee eee eer oA) [MOLEN100} Mascon-2 BOS SERVICE MANUAL 030696 2637E 31 NOTE: Depending on the type of indicator some items in the INDICATOR menu will INTRODUCTION GENERAL ‘This document describes the MOLEN SERVICE procedures: © on how to service the configuration and protected parameters of the Mascon-2 BOS © on how to maintain and calibrate the INT.JB-1/0 and MICX indicators, © on how to maintain and develop PLC programs. ‘The following configurations are allowed with the Mascon-2 BOS: ‘* Mascon-2 BOS + INT.JB-3/0 (MIC1/MICX) indicator. * Mascon-2 BOS + MICX (MICK NEW) indicator, ‘The MOLEN SERVICE menu can only be accessed by an authorized skilled engineer. ‘The MOLEN SERVICE menu is located inside the MAIN menu. ‘The structure below displays the menu tree of the service program. I [MAIN MENU —> SERVICE HEKU —-> ‘BOS CONFIGURATION FEEDGATE CONFIGURATION > ERROR SIGNAL TABLE Test WEIGHT > PERIPHERAL EQUIPHENT DYNAMIC 80S SCREEN CONFIGURATION > TABLE SIZES TNDICATOR NEMU > INFORKATION SSEWERAL SETTINGS ‘GENERAL SETTINGS 2 | ‘CALIBRATION ZERO CALIBRATION ENHANCED SETTINGS —-> ENHANCED SETTINGS > PRINT PARAMETERS [-> ADC CONFIGURATION CALIBRATION UPDATE i ‘CURRENT SETTINGS > FACTORY SETTINGS > PLC MENU ENABLE/DISABLE PLC RECEIVE PROGRAM ‘SEND PROGRAM EDIT PROGRAM ENABLE/DISABLE HONITOR MASTER PasswoRD not appear in the menu, [MOLEN100] Mascon-2 BOS SERVICE MANUAL 030696 2637E 41.2 SERVICE PASsworD The service password is used as the master password of the system, It uses an algorithm ‘0 Greate device dependent passwords. The password consists of 7 charger Characters 1 and 2 contain the number of the day ‘multiplied by 2 with a leading zero. Characters 3, 4 and 5 contain the last 3 digits of the serial nucahes added with 111. This sfial number is displayed during startup, For example S01-V2.35 Ose Characters 6 and 7 contain the number of the month ‘multiplied by 3 with a leading zero, 13 KEYBOARD LAYOUT ‘The picture below displays the key references which will be used during this manu Figure 1: Keyboard layout [MOLEN100] Mascon-2 BOS SERVICE MANUAL 030696 2687E 52 BOS CONFIGURATION This dialogue contains the system configuration settings. (TYPE] [BONR] [SILH] [MDCOB] [MOLEN100} TYPE of weighing scale. NETT-WEIGHER / GROSS-WEIGHER BOS identification code. 4AN type of scale SILHouette on the DBOS NETT-WEIGHER / GROSS-WEIGHER / BIG-BAG / DRUM-FILL system WaRMup Timer 2N Missing Discharge Condition Overshoot Enable NO / YES ‘When enabled the MDC message will be displayed. Mascon-2 BOS SERVICE MANUAL 030696 2637E 63 FEED GATE CONFIGURATION This dialogue contains the feedgate speed definitions [DRIBBLE] DRIBBLE speed feed gate setting CFG1 / CFG2 / CFG33N (0/1) [COARSE] COARSE speed feed gate setting CFGI / CFG2 / CFG33N (0/1) [MANUAL DRIBBLE] MANUAL DRIBBLE speed feed gate setting CFGI / CFG2 / CFG3. 3N M1) [MANUAL COARSE] MANUAL COARSE speed feed gate setting CFG1 / CFG2 / CFG3. 3N (/1) [MOLEN100} Mascon-2 BOS SERVICE MANUAL 030696 2637E, 7ERROR SIGNAL TABLE ‘This dialogue contains the system error messages. When selected a list of all error messages is displayed. Each message has its own unique name, sound, output and printer definition. The output option is connected with the digital = ALRM= output. To alter a setting select the error message. [PREFIX] Error number. The error number is fixed and can not be altered. 7AN [SCREEN TEXT] The SCREEN TEXT is display on the DBOS. 30AN [REPORT TEXT] The REPORT TEXT is printed on the report device. © SSAN [ALARM SOUND] The ALARM SOUND activates the internal buzzer of the BOS unit. NO / YES [ A LRM DIG .oO UT P UT ij ‘The ALaRM DiGital OUTPUT is the digital output =ALRM= at the RIO interface. NO / YES [TO PRINTER] ‘Send an error message to the printer. NO / YES [MOLEN100} Mascon-2 BOS SERVICE MANUAL 030696 263785 ‘TEST WEIGHT This dialogue is used to test the current weight. It will display the actual weight in large igits on the sereen, Also the weight flags will be shown in large digits. ‘The F5 key is used to perform a semi automatic zero setting. The F8 key is used to create a report with the actual test weight. [MOLEN100] Mascon-2 BOS SERVICE MANUAL 030696 2637E 96 PERIPHERAL EQUIPMENT The "Peripheral equipment’-file is used to define the hardware devices, connected to the Mascon-2 BOS. This file contains the following hardware devices: INR] [DEVICE] [DEVICE TYPE] [PORT] [BAUDRATE] [PARITY] [STOPBITS} [DATABITS] {PROTOCOL} [MODEL] [N. MODULES] Device number (fixed number) Device type (fixed name) Device type name 15 AN Communication port COMOA/COMOB/ COMOC/COMOD Baudrate 1200/2400/4800/9600/ 19200 Parity NO/ODD/EVEN Number of stopbits 12 Number of databits 118 Type of communication protocol DTR-ON/OFF, XON/XOFF, ACKINAK, FIXED Model of remote display 13mm/14mm/70mm/None ‘Number of connected RIO modules IN(1t04) ‘The default values have been standardized for each type of hardware device. All type of hardware devices can be specified in tables. [MOLEN100] Mascon-2 BOS SERVICE MANUAL 030696 2637E 107 DYNAMIC BOS SCREEN CONFIGURATION This dialogue contains all the setting which apply to the DBOS and keyboard [LERD] Last Error on Display. NO/ YES [PNT/COM] Decimal point notation. l, [KEY-CLICK} Enable keyclick, NO / YES [LCD TIMEOUT] — Time to activate screensaver option. 2N NOTE: LCD TIMEOUT will be disabled when ‘0' is entered. (MOLEN100] Mascon-2 BOS SERVICE MANUAL 030696 2637E AL8 ‘TABLE SIZES ‘This dialogue contains the maximum number of entries used in the file system, (No. PRODUCT RECORDS] The maximum number of PRODUCT RECORDS that can be used. 2N [No. PREPR RECORDS] ‘The maximum number of PREPaRe operation RECORDS that can be used. 2N > [No. PREPR RECORDS TNW] The maximum number of PREPare TNW operation RECORDS that can be used. 2N ‘The values can only be altered when the totalizers of the selected item are empty and the records of the selected item are not used by other tables. [MOLEN100] Mascon-2 BOS SERVICE MANUAL 030696 2637E 129 INDICATOR MENU The "INDICATOR" menu is used for configuration and calibration of the specific ‘metrological parameters of the A/D convertor, provided on the Mascon-2 BOS. o1 CALIBRATION PROCEDURE To perform a successful calibration in general the following steps must be taken into account: © Select the Indicator in the PERIPHERAL menu and set the parameters to their correct values. The table below shows the default settings. © INT.JB-1/0 (MICI/MICX) indicator Select a portnumber. Baudrate is not relevant at this stage because the Mascon-2 BOS will use the baudrate which is stored in the MICI indicator. Even parity. 1 stopbit. 8 data bits. Fixed protocol. Other parameters are not relevant. © MICX (MICX NEW) indicator Select a portnumber. Baudrate is not relevant at this stage because the Mascon-2 BOS will use the baudrate which is stored in the MICX indicator. Even parity. 1 stopt 8 data bits. Fixed protocol. Other parameters are not relevant. When the hardware parameters are correct and the portnumbers of the not-used indicators are put to "N.C.", reset the Mascon-2 BOS (power off/on). © The next step ig to set the different parameters to their correct values. This must be done in the INDICATOR menu. Skip the INFORMATION dialogue when configuring the indicator and start with menu item 2 followed by 3, 4....ete. © Finally you can enter the calibration procedure and perform a calibration. The contents of the INDICATOR menu is indicator sensitive. This means that depending on the indicator type a different menu will appear. The next paragraphs explains the different menu items. [MOLEN100} Mascon-2 BOS SERVICE MANUAL 030696 2637E 1392 921 INT.JB-1/0 (MICI/MICX) INDICATOR ‘Throughout the next paragraphs the INT.JB-1/0 will be referred to as the MICI indicator. ‘The MICI Indicator menu contains & selectable items. INFORMATION GENERAL SETTINGS GENERAL SETTINGS 2 CALIBRATION ZERO CALIBRATION ENHANCED SETTINGS MENU PRINT PARAMETERS, MIC1 INFORMATION ‘This menu item contains general information about the MIC1 indicator and can not be altered manually. Calibration date 6 N (fixed number) This item contains the date on which the MICI data was last updated. It will be automatically updated after each new setting. Checksum 7 N (fixed number) This item contains a unique checksum number of the MICI data and it allows the user to see if any setting has changed. It will change after each update of the MICI data, Serial number 8 N (fixed number) This item contains the unique serial number of the MIC1. Version number 8 N (fixed number) ‘The version number is used to identify the type of MIC1 software. (MOLEN100} Mascon-2 BOS SERVICE MANUAL 030696 2637E 14.9.2.2 MICI GENERAL SETTINGS ‘This menu contains the parameters needed to maintain the MIC] indicator. Max Load (maximum load) Maximum load of the weighing system in kg. (= Maximum Weight Capacity), e=d (Step size) 5N SN This parameter determines the smallest difference between two weight values in kg. Allowed values are: 0.001 | 0.002 | 0.005 0.01 | 0.02 | 0.05 Ot 0.2 0.5 1 2 5 10 20 50 Min Load (minimum load) SN Minimum load of the weighing system in kg. Not used on the Mascon-2 BOS. Should be "0" [MOLEN100} Mascon-2 BOS SERVICE MANUAL 030696 2637E 159.2.3 MICI GENERAL SETTINGS 2 This menu contains the parameters needed to maintain the MICI indicator. Cal. Pats. (number of calibration points) 2N This parameter determines the number of calibration points. Possible settings are 2..21 calibration points. In most cases a value of 2 can be used. Default = 2. Baudrate 5N Baudrate of the connection between Mascon-2 BOS and MIC1 indicator. Can be set to 1200, 2400, 9600 and 19200 Baud. Default = 19200 Baud. HighResFac (high resolution factor) ‘The high resolution factor determines the resolution of the weight during high resolution output. Valid values are: 1, 2, 4, 5 and 10. Default = 10. e=d (stepsize) HighResolution = ested [MOLEN100} Mascon-2 BOS SERVICE MANUAL 030696 2637E 169.2.4 MICI CALIBRATION The calibration menu is used to calibrate the MICI indicator. After calibration the MICI will send a calibrated weight to the Mascon-2 BOS. Before starting the calibration of the MIC1 indicator the calibration parameters should be set correctly (read previous paragraphs about the MIC! indicator). When the MICI calibration parameters are correct the next step should be the calibration of the MIC1. The following procedure should be done: © Select the data to be edited by moving the bar. The bar can be moved by using and , © Edit the calibration points table. To change a predefined weight value press the weight button icon on the lower left side of the screen (). © When an error has occurred (example: wrong counts), press to clear all the count samples on the selection bar. © Perform a calibration (weights on the scale etc.). Press to insert the actual weight counts (located behind MASTER label) in the table. Repeat this until all weights in the weight table have a count value in the master table. Do NOT press. when there is no standstill of the actual weight counts. The maximum distribution of weight samples to detect standstill can be altered in the "ENHANCED SETTINGS" menu, Valid count values are 10000 < value < 200000. The count values between 200000 and 250000 are used as a buffer zone to prevent overload of the AD convertor. ‘© Save the calibration data into the MIC1. Use SAVE option in the table. Before the calibration data is saved the data will be checked on linearity (see enhanced settings). ‘The calibration menu looks like: READY MINES OM B9:51 +t MHR : 6@80@ MASTER: 247399 e=d : 16 + WEIGHT MASTER w [MOLEN100] Mascon-2 BOS SERVICE MANUAL 030696 2637E 179.2.5 MICI ZERO CALIBRATION MIC! zero calibration performs a calibration without the use of calibration weights. It calculates the difference between the old and new zero setting. This difference is added to all the other calibration points. The result will be a shift of the whole calibration table. To perform a zero calibration remove all weight and press . WARNING: Do not use zero calibration when the MICI indicator has never been calibrated beforel!!! (MOLEN100] Mascon-2 BOS SERVICE MANUAL 030696 2637E 189.2.6 MIC ENHANCED SETTINGS MENU This menu item contains a submenu with settings which may only be altered by an authorised skilled engineer. ENHANCED SETTINGS ADC CONFIGURATION CALIBRATION DATA UPDATE, FACTORY SETTINGS ‘When the MICI contains default factory settings all the settings in the enhanced menu will contain values which allow a normal operation, [MOLEN100] Mascon-2 BOS SERVICE MANUAL 030696 2637199.2.6.1 MIC1 ENHANCED SETTINGS ‘This menu contains the parameters needed to maintain the MICI indicator. Filter length 2N This parameter defines the filter type used by the MICI. The figure below shows a diagram on how the 3 filters are connected together. i Figure 2 ‘The filters LENMx1 and LENMx2 contain both the filter length value. Filter LENMXx3 always contains a ‘1". “The principle of a moving average filter is: face MAQ@) = — Jz! On eX MA® = 2 on + x(a - 1) + x(n - 27) + ©. yg * Se 1 + x(aT- (N - YD] These filters are only used during when no feeding or discharging is taking place. Default = 40 Feeding Filter 3x2N The feeding filter is used during the feeding cycle. The filter consists out of 3 Moving Average filters. The feeding filter should not be to small or to large. When it becomes [MOLEN100] Mascon-2 BOS SERVICE MANUAL 030696 2637E 20to small the system will become unstable. When it becomes to large the feeding cycle will take too long. Default = 5. Predictive buffer 2N The predictive buffer is used to determine if the setpoints of the feeding cycle are going to be reached within the next 20ms. The size of the buffer should not be to small or to large. When the size is to small the system becomes inaccurate. On the other hand when the size is to large the feeding cycle takes too long. A good rule of thumb is to give it a value of the 3 feeding filters added together. Default = 12 All, Neg. Wght. (Allowed negative weight) 2N ‘This parameter is used to blank the actual weight (AWD) when it reaches to far below zero. Expressed in per cent of maximum weight. Allowed values are 0..10%. Default = 4%, Zero set Pos. (zero setting range positive) 2N Positive tolerance which is used to enable zero setting. Expressed in per cent of maximum weight. Allowed values are 0..10%. Default = 3%. ‘Zero set Neg, (zero setting range negative) 2N Negative tolerance which is used to enable zero setting. Expressed in per cent of maximum weight. Allowed values are 0..10%. Default = 1%. St.Still Time (standstill time) 4n ‘This parameter determines the time interval for checking stand still conditions (+d) expressed in milliseconds. Allowed values are 0,.5000 ms, Default = 1500 ms. St.Still Tol. (standstill tolerance) 3N ‘This parameter determines the tolerance of the standsti (e=d). Allowed values are 0..100%, Default = 50%. time in per cent of Step size Hires St.Still Time (high resolution standstill time) 4N ‘This parameter determines the time interval for checking stand still conditions (+ 4d) expressed in milliseconds. Allowed values are 0..5000 ms. Default = 1500 ms. Higher St.Still Tol. (high resolution standstill tolerance) 3N This parameter determines the tolerance of the standstill time in per cent of Step size (e=d). Allowed values are 0..100%. Default = 50%. [MOLEN100} Mascon-2 BOS SERVICE MANUAL 030696 26372Cal, St.Still Buff (Calibration standstill buffer) 3N During calibration the incoming weight samples may not be stable. This parameter determines the number of weight samples to be used to detect standstill. Allowed values are 1..100 samples. Default = 10 samples. Cal. St.Still Band (Calibration standstill bandwidth) 4N During calibration the incoming weight samples may not be stable. This parameter determines the maximum distribution of the weight samples. Allowed values are 0..9999 counts. Default = 50. A ee,” e calibration e e standstill : ; . e bandwidth Cal. Linearity (Calibration Linearity) 3N ‘This parameter determines the distribution of the linearity of the taken weight samples. Allowed values are 0..100%. When '0" no linearity will be checked. Default = 4%. counts calibration linearity 0 Warmup time 3N ‘This parameter defines the warmup time of the MICI indicator. During warming up time there will be no weight samples available. Valid values are 0..999s. Default = 20 seconds. [MOLEN100} Mascon-2 BOS SERVICE MANUAL 030696 2637E 22.Power sup. freq. (Power supply frequency) OH2/250Hz/S00Hz/1000Hz This parameter defines the power supply frequency of the loadcells. Possible settings are: OHz 250 Hz 500 Hz 1000 Hz Default = 250Hz [MOLEN100] Mascon-2 BOS SERVICE MANUAL. 030696 2637E 23,9.2.6.2. MICI ADC CONFIGURATION ‘This menu contains the parameters needed to maintain the AD convertor in the MICL | indicator. ‘Weht. Type (weight output type) STOP/ONCE/CONT (fixed text) ‘This parameter determines the type of weight that is created by the INT.JB. Possible ) settings are: Stop, Once, Cont (Continue). It can not be altered. | Output format ASCIBIN (fixed text) ‘This parameter determines the type of output of the INT.JB. Possible settings are: | ASC (ASCI) and BIN Binary). It can not be altered. Offset 2N F This parameter makes it possible to add or remove an offset to the analog input signal. With this it is possible to shift the zero point to any location within the ADC range without the loss of resolution. Possible values are -7..7. Default = 0. The actual offset will be actual setting (-7..7) multiplied by 25% of maximum ADC range. Offset Tr 8N This parameter makes it possible to add or remove an offset to the analog input signal With this it is possible to shift the zero point to any location within the ADC range without the loss of resolution. Possible values are any value within a 24 bit range. Default = 0. Gain 1N i ‘This parameter defines the gain amplifier of the ADC in the MIC1. Possible settings are 1, 2, 4 and 8, The total amplification can be determined by multiplying the gain value by 25. Default = 4. Gain R aN ‘This parameter defines the gain amplifier of the ADC in the MIC1. Possible settings are any value within a 24 bit range. Default = 1.000.000 ([MOLEN100] | Mascon-2 BOS SERVICE MANUAL 030696 2637E 24 |9.2.6.3 MICI CALIBRATION UPDATE The calibration update menu is used to calibrate, adjust span and edit the count weight samples of the MICI. After calibration the MICI will send a calibrated weight to the Mascon-2 BOS. Before starting the calibration update of the MICI, calibration Parameters should be set correctly (See also previous paragraphs about the MICI indicator), When the MICI calibration parameters are correct the next step should be the calibration of the MIC1. The following procedure should be done: © Select the data to be edited by moving the bar. The bar can be moved by using and . © Edit the calibration points table. To change a predefined weight value press the weight button icon on the lower left side of the screen (), © Euit the calibration points table, To change a recorded count value press the count button icon on the lower right side of the screen (). Valid count values are 10000 < value < 250000. The count values between 200000 and 250000 are used 3s a buffer zone to prevent overload of the AD convertor. © When an error has occurred (example: wrong counts), press to clear all count samples on the selection bar. © Save the calibration data into the MIC1 Use SAVE option in the table. Before the calibration data is saved the data will be checked on linearity (see enhanced settings 2. ‘The calibration update menu looks like: READY MOLINE 99:59 -— MWR gene MASTER: 38419 cc) ed WEIGHT MASTER Figure3 ELEN ee [>| [+] [MOLEN100} Mascon-2 BOS SERVICE MANUAL 030696. 2637E, 259.2.6.4 MIC1 FACTORY SETTINGS This menu makes it possible to reset all the settings in the MIC1 to their default values including calibration data. When a YES is answered all the current settings are lost and can not be restored. WARNING: This menu will overwrite all existing settings in the MIC1. 9.2.7 MICI PRINT PARAMETERS: ‘This menu item makes it possible to dump all the parameters which can be viewed and altered in the INDICATOR menu to a printer. [MOLEN100) , Mascon-2 BOS SERVICE MANUAL 030696 2637E 2693 MICX (MICX NEW) INDICATOR The MICX Indicator menu contains 8 selectable items, INFORMATION GENERAL SETTINGS GENERAL SETTINGS 2 CALIBRATION ZERO CALIBRATION ENHANCED SETTINGS MENU PRINT PARAMETERS. 9.3.1 MICX INFORMATION ‘This menu item contains general information about the MICX indicator and can not be altered manually, Calibration date 6N (fixed number) ‘This item contains the date on which the MICX data was last updated. It will be automatically updated after each new setting. Cheeksum_ TN (fixed number) This item contains a unique checksum number of the MICX data and it allows the user to see if any setting has changed. It will change after each update of the MICX data. Serial number 8 N (fixed number) ‘This item contains the unique serial number of the MICX, Version number 8 N (fixed number) ‘The version number is used to identify the type of MICX software. [MOLEN100] Mascon-2 BOS SERVICE MANUAL. 030696 2637E 27v 9.3.2 MICK GENERAL SETTINGS This menu contains the parameters needed to maintain the MICX indicator. Max Load (maximum load) SN Maximum load of the weighing system in kg. (= Maximum Weight Capacity). | e=d (Step size) SN | This parameter determines the smallest difference between two weight values in kg. | Allowed values are: | 0.001} 0.002 | 0.005 oor | 0.02 | 0.05 Ou 02 | os 1 2 5 10 20 | 50 Min Load (minimum load) 5N Minimum load of the weighing system in kg. Not used on the Mascon-2 BOS. Should be "0". I | | [MOLEN100} Mascon-2 BOS SERVICE MANUAL 030696 2637E 289.3.3 MICX GENERAL SETTINGS 2 This menu contains the parameters needed to maintain the MICX indicator Cal. Pats, (number of calibration points) 2N This parameter determines the number of calibration points. Possible settings are 2..21 calibration points, In most cases a value of 2 can be used. Default = 2. Baudrate SN Baudrate of the connection between Mascon-2 BOS and MICX indicator. Can be set to 1200, 2400, 9600 and 19200 Baud. Default = 19200 Baud. Hires fac. (High resolution factor) ‘The high resolution factor determines the resolution of the weight during hiresolution output. Valid values are: 1, 2, 4, 5 and 10. Default = 10. (stepsize) HighResoltion = 7 pResFactor [MOLEN100] Mascon-2 BOS SERVICE MANUAL 030696 2637E 2993.4 MICX CALIBRATION The calibration menu is used to calibrate the MICX indicator. After calibration the MICX will send a calibrated weight to the Mascon-2 BOS. Before starting the calibration of the MICX indicator the calibration parameters should be set correctly (read previous paragraphs about the MICX indicator). When the MICX calibration parameters are correct the next step should be the calibration of the MICX. The following procedure should be done: © Select the data to be edited by moving the bar. The bar can be moved by using and . © Edit the calibration points table. To change a predefined weight value press the weight button icon on the lower left side of the screen (). © When an error has occurred (example: wrong counts), press to clear all the count samples on the selection bar. © Perform a calibration (weights on the scale etc.). Press to insert the actual weight counts (located behind MASTER and SLAVE label) in the table. Repeat this until all weights in the weight table have a count value in the master table. Do NOT press when there is no standstill of the actual weight counts. The maximum distribution of weight samples to detect standstill can be altered in the “ENHANCED SETTINGS" menu. Valid count values are 10000 < value < 200000. The count values between 200000 and 250000 are used as a buffer zone to prevent overload of the AD convertor. © Save the calibration data into the MICX. Use SAVE option in the table. Before the calibration data is saved the data will be checked on linearity (see enhanced settings). ‘The calibration menu looks like: [READY MCLIBO DT OCO | G9: 51 +t MWR : 6@86G MASTER: 247399 7 e=d; 16 + WEIGHT MASTER a [MOLEN100] Mascon-2 BOS SERVICE MANUAL 030696 2637E 30[MOLEN100} Mascon-2 BOS SERVICE MANUAL. 030696, 2637E, 31° 93.8 MICX ZERO CALIBRATION MICX zero calibration performs a calibration without the use of calibration weights. Tt calculates the difference between the old and new zero setting. This difference is added to all the other calibration points. The result will be a shift of the whole calibration table. To perform a zero calibration remove all weight and press WARNING: Do not use zero calibration when the MICX indicator has never been calibrated before!!! (MOLEN100} Mascon-2 BOS SERVICE MANUAL 030696 2637E 32.93.6 MICX ENHANCED SETTINGS MENU This menu item contains a submenu with settings which may only be altered by an authorised skilled engineer. ENHANCED SETTINGS ADC CONFIGURATION CALIBRATION DATA UPDATE CURRENT SETTINGS FACTORY SETTINGS When the MICX contains default factory settings all the settings in the enhanced menu will contain values which allow a normal operation, [MOLEN100} Mascon-2 BOS SERVICE MANUAL 030696 2637E 339.3.6.1 MICX ENHANCED SETTINGS ‘This menu contains the parameters needed to maintain the MICX indicator. Filter length 2N ‘This parameter defines the filter type used by the MICX. The figure below shows a diagram on how the 3 filters are connected together. oo ‘The filters LENMx1 and LENMx2 contain both the filter length value, Filter LENMx3 always contains a ‘1’. ‘The principle of a moving average filter is: aie MA® = De NN %, MAQ = 3 [eaD) + xo - 1) + xT - 2) + +xaT-(V- DD] s 2, = Deample Om = ‘These filters are only used during when no feeding or discharging is taking place. Default = 40 Feeding Filter 3x2N ‘The feeding filter is used during the feeding cycle. The filter consists out of 3 Moving ‘Average filters. ‘The feeding filter should not be to small or to large. When it becomes [MOLEN100} Mascon-2 BOS SERVICE MANUAL 030696, 2637E 34Wil ee ee S3Stem will become unstable. When it becomes to large the feeding cycle will take to long. Default = 5 Predictive buffer 2N oe redictive buffer is used to determine if the setpoins ofthe feeding cycle are going to be reached within the next 20ms, The size of the buffer should not be to small.or ty large. When the size is to smal the system becomes inaccurate. On the other hand when the size is to large the feeding cycle takes to long. A. good rule of thumb isto give it a value of the 3 feeding filters added together. Default = 12 All. Neg. Weht. (Allowed negative weight) 2N ‘This parameter is used to blank the actual weight (AWD) when it reaches to far below zero. Expressed in per cent of maximum weight. Allowed values are 0..10%. Default = 4%, Zero set Pos. (zero setting range positive) 2N Positive tolerance which is used to enable zero setting. Expressed in per cent of maximum weight. Allowed values are 0..10%, Default = 3%. Zero set Neg. (zero setting range negative) 2N Negative tolerance which is used to enable zero setting. Expressed in er cent of maximum weight. Allowed values are 0..10%. Default = 1%. St.Still Time (standsti time) 4N ‘This parameter determines the time interval for checking stand still conditions (444d) expressed in milliseconds. Allowed values are 0..5000 ms, Default = 1500 ms. ‘St.Still Tol, (standstill tolerance) 3N This parameter determines the tolerance of the standstill time in per cent of Step size (e=d). Allowed values are 0..100%. Default = 50%. Hires St.Still Time (high resolution standstill time) ~. 4n ‘This parameter determines the time interval for checking stand still conditions (4a) expressed in milliseconds. Allowed values are 0..5000 ms. Default = 1500 ms. Higher St.Still Tol. (high resolution standstill tolerance) 3N This parameter determines the tolerance of the standstill time in per cent of Step size (e=d), Allowed values are 0.100%. Default = 50%. [MOLEN100} Mascon-2 BOS SERVICE MANUAL 030696 2637E, 35Cal. St.Still Buff (Calibration standstill buffer) 3N During calibration the incoming weight samples may not be stable. This parameter determines the number of weight samples to be used to detect standstill. Allowed values are 1..100 samples. Default = 10 samples. Cal. St.Still Band (Calibration standstill bandwidth) 4N During calibration the incoming weight samples may not be stable. This parameter determines the maximum distribution of the weight samples. Allowed values are 0..9999 counts. Default = 50. eles e © caitration e e \ standstill « bandwidth > Cal. Linearity (Calibration Linearity) 3N ‘This parameter determines the distribution of the linearity of the taken weight samples. ‘Allowed values are 0..100%. When °0° no linearity will be checked. Default = 4%. counts A calibration , | linearity 0 Warmup time 3N ‘This parameter defines the warmup time of the MICX indicator. During warming up time there will be no weight samples available. Valid values are 0..999s. Default = 20 seconds. [MOLEN100] Mascon-2 BOS SERVICE MANUAL 030696 2637E 36 oOPower sup. freq. (Power supply frequency) OHz/250Hz/500Hz/1000Hz ‘This parameter defines the power supply frequency of the loadcells. Possible settings OHZ 250 Hz © 500 Hz © 1000 Hz Default = 250Hz (MOLEN100} Mascon-2 BOS SERVICE MANUAL. 030696 2637TE 3793.6.2 MICX ADC CONFIGURATION ‘This menu contains the parameters needed to maintain the AD convertor in the MICX indicator. Weht.Type (weight output type) STOP/ONCE/CONT (fixed text) This parameter determines the type of weight that js created by the INT.JB. Possible settings are: Stop, Once, Cont (Continue). It can not be altered. Output format ASCIBIN (fixed text) ‘This parameter determines the type of output of the INT.IB. Possible settings are: ‘ASC (ASCID) and BIN (Binary). It can not be altered. Offset 2N “This parameter makes it possible to add or remove an offset to the analog inp signal. With this itis possible to shift the zero point to any location within the ADC range Without the lose of resolution. Possible values are ~7..7. Default = 0. The actual offset Vill be actual setting (-7..7) multiplied by 25% of maximum ADC range. Offset Tr 8N “This parameter makes it possible to add or remove an offset to the analog input signa) With this itis possible to shift the zero point to any location within the ADC range ‘without the loss of resolution. Possible values are any value within a 24 bit range. Default = 0. Gain IN ‘This parameter defines the gain amplifier of the ADC in the MICK. Possible settings fre 1. 2, 4 and 8, The total amplification can be determined by multiplying the gain value by 25. Default = 4. Gain R 8N ‘This parameter defines the gain amplifier of the ADC in the MICX, Possible settings are any value within a 24 bit range. Default = 8. 388.608 [MOLEN100] Mascon-2 BOS SERVICE MANUAL 030696 2637E 389.3.6.3 MICX CALIBRATION UPDATE The calibration update menu is used to calibrate, adjust span and edit the count weight famples of the MICX. After calibration the MICX will send a calibrated weight to the Mascon-2 BOS. Before starting the calibration update of the MICX, calibration parameters should be set Correctly (see also previous paragraphs about the MICX indicator), When the MICX calibration parameters are correct the nevi step should be the calibration of the MICX. The following procedure should be done: * Select the data to be edited by moving the bar. ‘The bar can be moved by using and , © Edit the calibration points table. To change a predefined weight value press the ‘Weight button icon on the lower left side of the screen ( ). 8 a buffer zone to prevent overload of the AD convertor. ® When an error has occurred (example: wrong counts), press to clear all count samples on the selection bar © Save the calibration data into the MICK Use SAVE option in the table. Before the Calibration data is saved the data will be checked on linearity (see enhanced settings 2). ‘The calibration update menu looks Ii [. [READY MINAS G9:59 neal + MWR i 6@860 MASTER: 38419 ead: 1@ HEIGHT MASTER EE eo TT [MOLEN100} Mascon-2 BOS SERVICE MANUAL 030696 2637E 39.9.3.6.4 MICX CURRENT SETTINGS ‘This menu makes it possible to rovrite the last actual settings, which are known by the MASCON, to the MICX. When a YES is answered all the current settings are lost and can not be restored. WARNING: This menu will overvrite all existing settings in the MICX 93.6.5 MICX FACTORY SETTINGS ‘This menu makes it possible to reset all the settings in the MICX to their default values including calibration data, When a YES is answered all the current settings are lost and can not be restored. WARNING: This menu will overwrite all existing settings in the MICK 9.3.7 MICX PRINT PARAMETERS ‘This menu item makes it possible to dump all the parameters which can be altered in the INDICATOR menu to a printer. [MOLEN100] Mascon-2 BOS SERVICE MANUAL 030696 2637E 4010 PLC MENU ‘This menu contains 5 selectable items. ENABLE/DISABLE PLC RECEIVE PROGRAM SEND PROGRAM EDIT PROGRAM ENABLE/DISABLE MONITOR 10.1 ENABLE/DISABLE PLC This dialogue is used to enable or disable the PLC function. The PLC function can only be enabled when the PLC program contains no Programming errors. If it does the MASCON-2 BOS will tell on which line an error ‘occurred. 10.2 RECEIVE PROGRAM BeayPzoRtam contains 2 files; AWLTRANS.EXP and RUN3S6,.EXE Both systems have to be connected by means of a 3-wire RS232 cable (Rx, Tx and GND). The operating principle is as follows, * Connect Mascon-2 BOS and PC. * Start up the AWLTRANS program with command: ¢:\RUN386, AWLTRANS, < path > ,, [enter] ‘ location of PLC program SFilename.AWL> = PLC program name with extension AWL = PC COM-port number (1 or 2) * Select menu item 2 [RECEIVE PROGRAM} and press {enter} Important: Never change the settings [DATA TRANSFER] in menu [PERIPHERAL EQUIPMENT] for AWLTRANS uses this default Values (19200Bd, Even Parity, 1 Stopbit, 7 Databits, ACK-NAK protocol) 10.3 [MOLEN100} Mascon-2 BOS SERVICE MANUAL 030696 2637E10.3 SEND PROGRAM ‘This dialogue is used to transmit the current PLC program to an external source. ‘The hard- and software requirements are as described in §10.2. Select menu item 3 [SEND PROGRAM] and press [enter] ‘The PLC program will be uploaded into the external PC. After closing the AWLTRANS program a filename (and path) should be entered to save the just received PLC program. Always use a name with extension AWL. 10.4 EDIT PROGRAM ‘This dialogue opens an editor in which the PLC can be programmed. In the editor all required functionality is available however the method is rather complex due to the limited keyboard of the Mascon-2 BOS. Adding an external PC keyboard to the Mascon-2 BOS resolves most of this problem. In general it is advised to develop PLC programs on an external PC (by means of a text- editor) and transfer them as described in section §10.2. The editor can be used to make small changes in the field. 10.4.1 PLC PROGRAMMING LANGUAGE ‘The instructionset supported by the Mascon-2 BOS PLC-simulator consists of a subset of the Siemens $5 language supplemented by specific instructions. ‘The main differences with SS are: * Use of datablocks and functionblocks NOT possible Only programblocks are supported. * 32 bit calculations and markers (e.g. weight values) * GOTO and SHIFT permitted within programblocks * L Kx instuctions (load constant) limited to commonly used types Nomenclature: ° Within the description of the intructionset the following definitions and abbreviations are used, VKE Result of most recent logic operation; 0 or 1 ERAB Flag. When set the next logic operation results in VKE: VKE:=(VKE operation x) ACCUI, ACCU2 16 bit accumulators ACCU3, ACCU4 32 bit accumulators x instead of [MOLEN100} Mascon-2 BOS SERVICE MANUAL 030696 2637E 42.OV Flags indicating the result of calculations, Can be used for conditional jumps Ex.x Fysical inputs (RO-interfaces) Axx Fysical outputs (RIO-interfaces) Mx.x Markers (internal) Zx Counters Tx Timers EB x Input byte (consists of inputs x.0 to x.7) AB x Output byte (consists of outputs x.0 to x.7) MB x Marker byte (consists of markers x.0 to x.7) EW x Input word (consists of input byte x and input byte x+1) Input byte x is most significant AW x See EW x MW x See EW x MD x 32 bit Marker (consists of marker word x and marker word x-+1) KB x Constant (byte) range -128 .. 255 Negative values are stored as 2’s complement values KF x Constant (word) range -32768 .. 65535 Negative values are stored as 2°s complement values KD x Constant (32 bit) range -2097152 .. 4194303 Negative values are stored as 2’s complement values KT x.b Constant (time value) Internally stored in BCD 4 decades b = most significant KZ x_ Constant (countervalue) range 0 .. 9999 Internally stored in BCD 4 decades PB x —Programblock x [MOLEN100} Mascon-2 BOS SERVICE MANUAL 030696 2637E 4310.4.2 PLC INSTRUCTIONSET V/O instructions: Instruction SExx SAXx SMxx RExx RAxx RMxx Exx Xx Mxx Description Set bit if VKE=1 Reset bit if VKE: Attach bit to VKE Logic instructions: Instruction UEKx UAXx UMxx UTxx UZxx OExx OAxx OMxx OTxx OZxx UNEXx UN Axx UNMxx. UNTx UNZx ONEXx ON Axx ON Mxx ONTx ONZx [MOLEN100] Description Logic AND Timer runs bit=1 Counter>0_ bit= Logic OR Logic NAND (NOT AND) Logic NOR (NOT OR) VKE dependant Mascon-2 BOS SERVICE MANUAL change change 030696 Set ERAB Set ERAB 2637E 44° Logic OR of following U instructions with actual VKE uC Logic AND of VKE and n result of instructions between () 0 Logic OR of VKE and on result of instructions between () ) End of U( or O( a instructions Load instructions; Instruction Description VKE dependant LEBx Load @)yte (Wyord orn LABx —— @)ouble word in ACCUL LMBx Bytes are placed in the LEWx LSB (MSB = 0). LAWx LMWx LMDx LTx Load actual timer or =n. LZx counter value in ACCUL LOTx OL = bi LCZx = LC = BCD LKBx oad constant in ACCU LKFx LET xb LKZx LKDx (MOLEN100} Mascon-2 BOS SERVICE MANUAL change 030696 Set ERAB 2637E 45‘Transfer instructions: Instruction Description VKE, VKE Set dependant change ERAB TEBx Transfer data from 1 a n TABx — ACCUL to entered TMBx destination (x) TEWx TAWx TMWx TMDx ‘Timer instructions: Instruction Description VKE VKE Set dependant change ERAB sITx Start timer on it a i jing edge of VKE VKE=0 stop timer VKE uF sIT svTx Start timer on it n i rising edge of VKE VKE=0 no influence VKE eS svt SETx Start timer on it a j rising edge of VKE ‘Timer runs as long 2s VKE=1 KE ot Go svt [MOLEN100] Mascon-2 BOS SERVICE MANUAL 030696 2637E 46.SST x Start timer on it a j rising edge of VKE After start VKE no influence VKE mm “to .—ssr SATx Start timer on it a i falling edge of VKE At VKE=I set timer to initial value 1 VKE al a foe 1 SAT ot ot 2 ot LUT RTx Setttimer and output j 2 j t00 Counter instructions: Instruction Description VKE VKE Set dependant change ERAB ZVZx Increase counter at jt a i rising edge of VKE ZRZx Decrease counter at jt 2 j rising edge of VKE SZx Set counter at value jt a ij in ACUI at rising edge of VKE RZx Reset counter if VKE=1_ j n j [MOLEN100} Mascon-2 BOS SERVICE MANUAL 030696 2637E 47Calculations: Instruction Description VKE VKE Set dependant change BRAB +F non a ¥ a a a <-32768 ANZ1=1 ANZ0=0 OV=1 -32768..-1 ANZ1=0 ANZ0=1 OV=0 0 ANZ1=0 ANZ0=0 OV=0 1.32767 ANZ1=1 ANZ0=0 OV=0 >32767 ANZ1=0 ANZO=1 OV=1 65536 ANZ1=0 ANZ0=0 OV=1 +DF As +E/-F for a n a DF ACCU3 and ACCU4 Flag limits at +2431 7 ccultaccuz «ono a IF at overflow or division by 0 ANZx flags always 0 “DF ‘As *F and /F for a a a IDF ‘ACCU3 and ACCU4 1=F ij n > ACCU2 >F Compare greater than. = ACCU2> ACCUL =F Compare greater or equal VKE:=ACCU2> =ACCUL [MOLEN100] Mascon-2 BOS SERVICE MANUAL 030696 2637E |I!=DF >DF =DF <=DF SRW x SLW x SRD x SLD x Conversions: Instruction D2BW B2DW D2BD B2DD (MOLEN100] , Compare smaller or equal VKE:=ACCU2< =ACCUL Flag OV no change ACCU2=ACCUI ANZ1=0 ANZO=0 ACCU2< >ACCUL ANZ1=0 ANZO=0 ACCU2> ACCUL ANZ1=0 ANZO=1 ACCU2ANZ1 Conditional jump to 2 label x if ANZI=1 and ANZO=0 Conditional jump to. label x if ANZ1=0 and ANZO=1 Conditional jump to 8 label x if OV=" End of Block a ‘Always last instruction of programblock a Unconditional End of Block ‘May be used within the programblock Conditional End of = j Block if VKE=1 Interrupt PLC cycle =m Mascon-2 BOS SERVICE MANUAL VKE. change 030696 Set ERAB 2637E 50Remaining Instructions: Instruction Description VKE VKE set dependant change ERAB SWAP Exchange contents of a a n ACCUI and ACCU2 SWAPD Exchange contents of a a a ACCU3 and ACCU4 W2D ACCU3:=ACCU22116 + ACCUL on n a Daw ACUI: = least significant n a a 16 bits of ACCU3 ACCU2:= most significant 16 bits of ACCU3 #BLOCK x Indicates start of new a a rogramblock x #END — End of Program a 1 n 10.4.3 PLC PROGRAM SYNTAX Mascon-2 BOS PLC programs must comply with the following syntax rules to be accepted by the Mascon-2 BOS and/or the AWLTRANS program. 7A PLC program makes no difference between capitals and small letters ~ A PLC program consists of 1 or more programblocks, Block "0" should always be resent in the program, ‘The sequence of programblocks within the program may be random, Evety programblock starts with instruction “#BLOCK x" and onde with instruction “BE'. 7 The last instruction of a PLC program should always be "END". ~ Text following a *;* will be considered as comment. Lines starting with "s" are allowed even if empty. ~ PLC instructions and parameters are separated by a space or tab. Only 1 instruction per line is allowed, ~ Labels (destination) must have the following syntax “rexccxx", “sexx” is the label name wich may be 10 characters in length, In the jump instruction the ":" must be left out, [MOLEN100} Mascon-2 BOS SERVICE MANUAL 030696 2637E, 5110.4.4 10.5 Example PLC program: 5 this is an example of a PLC prgram block 0 1kt 5.1 ue0.0 sstl utl spb pb 1 un m 0.0 spb = label! rtl 5 reset timer 1 rm0.0 slabell be #olock 1 weld wz0 1 kb 100 120 Ist sm0.0 120 be fend [comment] {programblock 0 obligatory] [load timer with 5 x timebase 100ms} {load state of input 0.0] [start timer] {load state of timer] {conditional jump to block 1} [conditional jump to "label" as long as marker 0.0 remains 0] {instruction + comment] {reset marker 0.0] ["label1" destination] [end of block 0] {increase counter O at rising edge of input 1.0] [load constant "100"] [load actual value of counter 0} {compare "equal”] {set marker 0.0} {reset counter 0] [end of block 1] [end of program] PLC PROGRAMMING; GENERAL INFORMATION The Mascon-2 BOS PLC has acces to internal as well as external I/O such as inputs outputs and markers. Most of these I/O can be used without restr well as writing. fon for reading as ‘Some I/O however have predefined functionality and can only be read by the PLC. ‘Appendix I contains a list of all available 1/0 within the Mascon-2 BOS with restrictions mentioned if applicable. ENABLE/DISABLE MONITOR This dialogue is used to enable or disable the PLC monitor function. The monitor is displayed in the DBOS. Use numeric keys 0 and 5 (type selection) to select: © Merkers per byte (8 bits) © Outputs per byte (8 bits) © Inputs per byte (8 bits) © Timers per timer * Counters —_per counter Use numeric keys 1 and 6 to select the [MOLEN100} Mascon-2 BOS SERVICE MANUAL ferent registers within a type selection. 030696 2637E 52u MASTER PASSWORD This dialogue contains the master password of the BOS unit. It can be used to enter all menus. The default master password is “00076”, [MOLEN100} 4 Mascon-2 BOS SERVICE MANUAL. 030696 2637E 531 APPENDIX: Basics on how to configure a MASCON-2 BOS system ee erase 10: A: 12: 13: 14: 15: 16: i: 18: 19: 20: 2: (MOLEN100] Insert all software eproms: ‘Tur power on and push upper left button (cold start). Keep the button pressed until the language selection appears. Choose language. ‘After some time the DBOS screen will appear. Press the DBOS key. Select “MOLEN SERVICE”. Enter the password. Read service manual for password description. Select item 1, 2, 3, 6 and 7 of the “MOLEN SERVICE” menu and configure as needed. Select item 5 of the “MOLEN SERVICE” menu, This peripheral list contains all the external hardware devices which can operate with a MASCON-2 BOS. ‘Configure the devices as needed. Remark: Only one indicator can be active at a time. The non-active indicators should be NC. Return to “MOLEN SERVICE” menu and switch off power. ‘Turn power on (without pressing the upper left button) to activate the configured hardware devices. ‘After some time the DBOS sereén will appear. Press the DBOS key. Enter the password. Read service manual for password description. Select item 8 of the “MOLEN SERVICE” menu and configure the A/D convertor (Read service manual for procedure description). Select item 9 of the “MOLEN SERVICE” menu and write or download the PLC program. When finished select “ENABLE/DISABLE PLC and press At this point the service part of the configuration is finished. Select “PARAMETERS” from the main menu. Make all the necessary adjustments. Congratulations you have successfully configurated the MASCON-2 BOS. Mascon-2 BOS SERVICE MANUAL 030696 2637E 54n. APPENDIX: PLC merker list "R’ = Read-only. May not be altered by PLC program. ‘The PLC program and the BOS process are linked as follows. Read E0.0 .. E7.7 from RIO Read push buttons (folie) Set A0.0 .. A0.6 Pass E0.0 .. E7.7 to PLC program, Pass A0.0 .. A7.7 to PLC program, Set markers, Pass markers to PLC program. Execute PLC program, Get markers from PLC program, Set inputs from M32.0 .. M32.7 Write 0.0 .. A7.7 to RIO digital inputs The digital inputs E0.0 up to and including E0.7 should me mapped by the PLC to ‘metker bytes M32.0 up to and including M32.7, The default mapping 0.0 -> M32.0 ; E0.1 -> M32.1; ete. M32,0 - DL-EMSI. Emergency Stop Input. ‘32.1 - DI-STRT. externe STart, M32.2 - DI-STOP. externe STOP. M32.3 - DI-CONT. CONTinue. Herstel noodstop/accept error. 'M32.4 - DI-SIMS. SIMulation Setpoint. M32.5 - DI-SDG. Switch Discharge Gate. ‘32.6 - DI-UPB. UPper Bin level. M32.7 - DI-SUPB, Simulation UPper Bin, E1.0 up to and including B7.7 are user defined. (MOLEN100} Mascon-2 BOS SERVICE MANUAL 030696 2637E 55digitale outputs When the PLC program is stats execution the digital outputs are defined as follows: ‘40.0 - DO-CFG1. Command Feed Gate 1 ‘0.1 - DO-CFG2. Command Feed Gate 2 ‘0.2 - DO-CFG3. Command Feed Gate 3 ‘03. - DO-CDG. Command Discharge Gate. 0.4 - DO-ALRM. ALarM. ‘A0.5 - DO-INA. IN Action, ) ‘40.6 - DO-LLUB. Low Level Upper Bin. AO.7 - reserved. ‘The PLC programm can make his own adjustments to the digital outputs. ‘After termination of the PLC cycle the digital outputs will be send to the RIO module. ‘ALO tim A7.7 are user defined. merkers Available: = 256 byte merkers (each 8 bits),. where of MO - M31 remanent. > | Gh double words (each 32 bits) merkers, where of MDO - MD31 remanent. [MOLEN100} Mascon-2 BOS SERVICE MANUAL 030696 2637E 56M33,M34,M35 - BOS state. M33.0-R POWER UP/INIT ‘33.1 - R MANUAL M33.2-R READY M33.3-R START M33.4-R START PROTOCOL M33.5 - R WAIT FEEDING M33.6 - R FEEDING M33.7 -R MANUAL DISCHARGING (during INA = 1 ‘M34.0 - R WEIGHT REGISTRATION M34.1-R MANUAL DOSING (during INA = 1) M34.2-R AUTOMATIC DOSING (luring INA = 1) ‘M34.3 -R TOLERANCE FAULT STOP M34.4-R STOP FULL. M34.5-R WAIT DISCHARGING M34.6 -R DISCHARGING ‘M34.7-R BATCH PROTOCOL M35.0-R LOT PROTOCOL ‘M35.1-R STOP EMPTY ‘M35.2 -R END PROTOCOL M36,M37_- Awd state; Comma position M36.0 - R Motion M36.1 - R Invalid/no data from ade M36.2 - R Indicator error M36.3 -R Too far below zero M36.4 -R Out of weighing area M36.5-R 0 = brutto / 1 = netto weight M36.6 - R Zero (within 1/4 d) & Stillstanding M36.7 -R Zero (within 1/4 d) M37.0- R Stillstanding M37.1-R Within zeroing range M37.2-R Within tare range M37.3 -R reserved M37.4-R No decimal point. M37.5 -R Ist digit after decimal point. M37.6 -R 2nd digit after decimal point. M37.7 - R 3rd digit after decimal point, M38 _- Run mode; BOS type; AUTO/MANUAL switch M38.0- R Normal operation. M38.1-R TNW operation. M38.2-R Nett weigher. M38.3-R Gross weigher, M38.4-R AUTO/MANUAL switch in MANUAL (MOLEN100} Mascon-2 BOS SERVICE MANUAL 030696, 2637EM39,M40. - M41 / M43 - (MOLEN100} 39.0 - 39.1 - M39.2 - M39,3 - 39.4 - 39.5 - 39.6 - 39.7 - 40.0 - 40.1 - M40.2 - M40.3 - 40.4 - M40.5 - 40.6 - M40.7 - M41.0- M411 - M41.2- M41. M41. M41.5- M416 - M417 - 42.0 - 42.1 - Ma2.2 - M42.3 - Ma2.4- Ma2.5 - M42.6 - 42.7 - M43.0- M43.1- 43.2 - M43.3 - 43.4 - Ma3.5 - M43.6 - M43.7 - Push buttons Push button upper bin pressed. Push button start pressed. Push button stop pressed. Push button stop full pressed. Push button stop empty pressed. Push button continue pressed. Push button manual coarse feeding pressed. Push button manual dribble feeding pressed. Push button manual discharging pressed. Push button set zero pressed. Push button AUTO/MANUAL pressed. Push button alarm sound off pressed. Push button set tare pressed. Push button simulation cut off points pressed. Push button tare switch pressed. Push button clear tare pressed. Flags. PLC start condition PLC feed condition PLC registration condition PLC discharge condition BLank AWD (BLAW). Generate Emergency Stop (RCNT). As long as this bit contains an *I’ fan emergency break is generated. The emergency break can not be solved. | Mascon-2 BOS SERVICE MANUAL 030696 2637E, 58‘M44 / M49 - Flags (read only) M44.0 - R Upper bin simulated, M44.1-R AWD released (niet binnen spertijd) M44.2 - R Stop empty pending M44.3-R Stop full pending, M44.4- R Emergency stop active (EMSC). M44.5 -R Set zero pending M44.6 - R Taro command pending (Set, Clr, Req and SW) M44.7 -R Warm start (0 = cold start). M45.0-R Coarse feeding activated (CFI). M4S5.1-R Dribble feeding activatec (CF2). M45.2 - R Cut off points reached (COPR). MAS.3 - R Start conditions Ok M45.4.-R Feed conditions Ok M45.5 -R Discharge conditions Ok M45.6 - R Current AWD used as ABW. M45.7-R Aftecflow regulation active M46.0 - R Dribble time regulation active M46.1-R AWD >= PLC setpoint 1 M46.2-R AWD >= PLC setpoint 2 M46.3-R AWD >= PLC setpoint 3 M46.4-R AWD <= RDW M46.5 -R Out of weighing range, M46.6 - R End of lot reached. M46.7 - R End of operation reached. ‘MA7.0 - R Exceeding filling time (FTW) M47.1-R Last batch of lot M47.2 -R Second last batch of lot M47.3-R ABW > (NBW + TOLP) M47.4-R ABW < (NBW - TOLN) M47.5-R AWD >= NBW M47.6 -R AWD <= NBW M47.7-R Charge einde pulse. M48.0-R M48.1-R Ready to start, All start conditions except PLC start condition, M48.2-R Ready to feed. All feeding conditions except PLC feed condition, M48.3 -R Ready to discharge. All discharge conditions except PLC discharge condition, M48.4 -R Weight recording released (RWTR). M48.5 -R Error Level I active M48.6 - R Error Level Il active M48.7 - R parameter TRST. Stop at tolerance failure. [MOLEN100} Mascon-2 BOS SERVICE MANUAL 030696 2637E 59.M49.0 - R parameter ADOS. Automatic dosing. M49.1 - R Weight recorded (ABW) with standstill M49.2 -R Max. dribble capacity (DCD) exceeded. M49.3 -R M49.4-R AWD >= PLC setpoint 4 M49.5 -R AWD >= PLC setpoint 5 M49.6 - R AWD >= PLC setpoint 6 M49.7-R MSO / M61 - Timer preset values (4 digits BCD) MS0,M51 -R Preset value Ist PLC timer, produkt afhankelijc. MS52,M53 -R Preset value 2nd PLC timer, * ‘MS4,M55 -R Preset value 3rd PLC timer, * 7 MS6,M57 -R Preset value 4th PLC timer, produkt onafhankelijk. MS58,M59 -R Preset value Sth PLC timer, " M60,M61 -R Preset value 6th PLC timer, * * MSO contains the high 2 BCD digits, M51 contains the low 2 BCD digits, etc. ‘The time base must be added by the PLC program. ‘M62 / M73 - Counter preset values (4 digits BCD) M62,M63 -R Preset value Ist PLC counter, commodity dependend. M64,M65 -R Preset value 2nd PLC counter, MO66,M67 -R Preset value 3rd PLC counter, M68,M69 -R Preset value 4th PLC counter, commodity independend. M70,.M71 -R Preset value Sth PLC counter, M72,.M73 -R Preset value 6th PLC counter, " ‘M62 contains the high 2 BCD digits, M63 the low 2 BCD digits, etc. M74 -R Active BOS error number (0 .. 99). No BCD value. M75 - PLC error number. Geen BCD. 6 tims ~ Error Level I 31 t/m 38 - Error level IL 61 tim 68. - Missing start conditions 76 tim 78 - Missing discharge conditions. 91 tim 98. - Warnings. When an errorlevel Il occures, an emergency stop is automaticaly generated by the BOS process. This emergency break can only be removed after the removal of the error which generated the emergency break. After clearance of the emergency break the error message on the LCD screen will disappear. ‘When an errorlevel I occures, the operation is terminated inmediately (operation end protocol)and an emergency break is generated. The emergency break can be removed by the standard errorlevel 1 reset procedure. After clearance of the emergency break the error message on the LCD sereen will disappear. All other numbers are reserved. (MOLEN100} Mascon-2 BOS SERVICE MANUAL 030696 2637E 60M76,M77 - R_ Requested nr of lots (4 digits BCD). M78,M79 - R_ Nr of completed lots (4 digits BCD). M80,M81-R_ Requested nr of batches/lot (4 digits BCD), M82,M83 - R_ Nr of completed batches for current lot (4 digits BCD). M76 contains the high 2 BCD digits, M77 the low 2 BCD digits, etc. M84,M85,M86_—-R__Batchcounter (6 digits BCD). ‘M84 contains the high 2 BCD digits, M86 the low 2 BCD digits. M87 -R Current operation record index (0..99). BCD. M88 -R Current produkt record index (1..99). BCD. M89 -R PLC function code (2 BCD digits). Produkt athankelijk, M90 - Weiging range. M90.0- Range 1 M90.1 - M91 - ‘Requested operation index. BCD. M92 /M94- Dialog control, M92.0- Load operation request. See also M91. M92.1- Lock DABS key (F12). M92.2- Lock manual feeding. M92.3- Lock manual discharging, M92.4 - M92.5 - M92.6 - ‘M92.7 - 93.0 - M93.1 - M93.2 - M93.3 - M914 - 93.5 - 93.6 - M93.7 - M94.0 - 94.1 - 94.2 - 94.3 - M94.4 - M94.5 - M946 - 94.7 - [MOLEN100} Mascon-2 BOS SERVICE MANUAL. 030696 2637E 61M95 / M99 M95 M96 M97 M98 M99 Example 1: = Disable of menu entries (2 digits BCD). = Ist Menu entry to lock (00 = no lock). = 2nd Menu entry to lock (00 - 3rd Menu entry to lock (00 = 4th Menu entry to lock (00 = no lock). = 5th Menu entry to lock (00 = no lock). "24° means headmenu entry 2, submenu entry 4. Example 2: '03" means headmenu entry 3. No submenu. long merkers MD32.-R Awd in kg. Example 45.23 is stored as 4523. MD33 -R Awd in kg x 100 (high resolution). Example 48.2346 is stored as. 482346. MD34.-R —'TNW. Total nominal (lot) weight in kg. Example 123456.78 is stored as 12345678. MD35 -R — TALW. Total actual lot weight in kg, Example 123456,78 is stored as 12345678. MD36 -R _ NBW. Gewenst vulgewicht in kg. Example 50.00 is stored as 5000. MD37 -R _RDW. Residugewicht in kg. Example 1.00 is stored as 100. MD38 -R ABW. Actual batch weight in kg. Example 49.93 is stored as 4993. counters ‘Available: 32 BCD counters (4 digits), where of ZO up to and including Z15 remanent, timers Available: 32 timers. [MOLEN100] Mascon-2 BOS SERVICE MANUAL 030696 2637E 62