y € Gp PROCESS AUTOMATION Fidstid Base Moan & Col equpret Operator Manual EMBC-220 Physical Address: 148 Epsom Avenue, North Ricng A/H, Randburg 2169 Postal Address: RO. Box 1915, Randburg 2125, South Africa el +27 11 62 0222 Fae. +27 11 4620615, www. rocess-auto.comOperator Manual Series 220 Belt Scale Systems with UNIPRO™ Transmitter Table of Contents Des:ription Page SECTION 1: system Deseiption 3 Geners 2 SECTION 2: Component Descriptions 4 UNIPRO™ Transmitter 4 Weigh Feomes 5 ett Speed Sensors 7 Boum ingle Compensation wa SECTION 3: Postable Terminal Unit (>TU") u SECTION &: UUNIPRO" Operation 2 General 2 Normal Display Mode And Access To Functions 1“ SECTIONS: —_Acsess Codes 2 SECTIONS: Scale Configuration & Calibration 2 Apaleation Cetais 2 Weigh Feames 23 inal Calibration Set-Up) 24 SECTION7: Special Functions Py Function Na, 0 "Smulation Of Input Signal’ 38 Function No, 1 "Fierin_ Of Input/Output Signals 38 Function No, 2 "Alarms Settings 2 Function Na, 3 “UCB 4-20 Ms Output Set-Up 33 Function No, 4 "Real Time Clock S2ttngs 40 Function No, 5 “Totlier Fictions 40 Function Na. 6 “Seada Communications” “4 Function No. 7“Cunpersations! 45 Function No. 8 “Sampler Set-Up" 46 Function Ne, 9“Frowustion Reports” 46 |Description Page SECTION: Special Low Temperature Applications Low Temperature Operation SECTIONS: libration checks Frequency Of Calibration Checks ‘Quick check On Calibration (Full Calibration Checks And Tests As-Founst-Error(AFE) SECTION 10: Typical Conveyor Scale Log Book SECTION 11: Calibration & Application Data Viewing OF Calibration Constants Entry (Manuel) OF Calibration Constants Backup Calibration Constants Recall Of Eacked Up Cal Constants 59 Reports Of Cal/Application Data 59 Calioration Constante 59 -pplcation Data 59 Allocated 0 (Expansion /0 Bus} 6 Map Of Allocated /0 [Expansion 1/0 Bus) 6 SECTION 12: Belt Load Statistics a General 6 (a=) Belt Loading 62 (2 Prine state Report 6 (5) Reset statistics 6 SECTION 13: Production Reports 66 Reports 66 ‘Stored Report Configuration 67 SECTION 14: | Routine Maintenance 6 Physical Maintenance 63 Load cal 6 Special Tolerance Conveyor (Weigh Class) Idlers 7 Care Of Test Weight 70 ‘Weigh Platform Alignment n Speed Sensor Orive Assembly n Lubrication Requirements n Electronic Maintenance 2 SECTION 15: EMBC-220 Software / Hardware Compatibility ™ SECTION 16: Software (Revision) List ws SECTION 17: Drawings 90 SSsecnon: “BD System Description General The Process Automation EMBC-220 Bet Scale ystems are used to measure, and (optionally to control) the mass throughput rate and total of material as transported on @ conveyor bet. The moss of material on the belt is measured by a strain gauge type load cell which I coupled tothe conveyor system through a weigh frame, dlrs and the conveyor belt. The speed of the material \s measured by a speed sensor (tachometer) which ray be coupled to the conveyor system via speed sensor drive assembly or via any convenient non-drven pulley. The precision Tachometer Drive Assembly (TDU) has been designed to provide a rugged bet / tachometer intertace while keeping speed measurement errors to & minimum, In the event that a speed sensor Is not used, the load cel board has an input which can allow connection ofa cigital input o act as @ speed sensor replacement sensor. Whenever the conveyor runs, the contact is closed. When the conveyor stopped the contacts should open. In those applications where the inclination angle of the conveyor may change (Stacker/Reclaimer apolications), optional Soom Angle Compensation is possible using our Model ICL-102incinemeter. ‘The UNIPRO" transmitter performs the task-cf manipulating these measured variables in order to abtain Rate, Total and other information.oe section: ©@D Component Descriptions UNIPRO” Trans: ‘The UNIPROW transmitter is identical fr all the scale models and. mult be mounted within the eable distance ofthe load cell supplied LUNIPRO™ provides a single 420 mA (Neld programmable for ether Feed Rate or PID Contr output and single relay output (programmable to beelther a Totaliser or Sompler Contro! output). The max count rate from UNIPRQY atalser is $0 000 per hour (25, counts/second), With a setting of 1 tonne per pule.thls Means a theoretical maximum of 90.000 t/h. The mass per pulse resolution is programmable. Kindly nate that the width of the tataliser pulses are not freely selectable-The higher the maximum count rate the smaller must be the pulse wicth ‘The totaliser(cigital) output isin the forrh of ether: ‘+ Standard - 2 volt free relay (dry contact) capable of switching up to 2A at 48 VOC ‘max. The lifespan of te relays fixed [typically >5 millon operations mechanical & 200 000 electra} - at Yul loae) The max sitehing rate for the relay output is 10, ‘operations per second, However due tothe lifetime limitations of the relay output i 's recommended that te totaliser count rate be set not to exceed 1000 counts per hour. At count yates higher than 1000 per hour, the lifetime ofthe relay wil be less than 2 years for24 hour operation at full count rte, A good “rule 0 thuma” is never se a.plass per pulse setting less than 0.1% of the maximum hourly count rate. Eg For 1000 tf, use @ mass per pulse of 1000/1000 = 1 tonne. Likewise for 10 000 t/h suse 10000/1000 = 10 & per pulse, This wil greatly extend the lfe of the totaliser| vey. + “Optional - a solid state relay (SSR) capable of switching 250 mA at 24 ¥ AC/DC (24 \VAC max & 36 VOC max). The lfespan ofthe SSRs very much grater than that of 2 ‘mechanical relay (typically tens of millions of operations}. it is also capable of ‘witching much faster than a relay (<3 mS, ON and OFF times), and i able to switeh| {tthe maximum rate that UNIPRO' ean autput the pulses, ‘A digital input (24 VDC) input is also provided for Speed Sensor Replacement. This allows the Speed Sensor to be ignored (in the event a speed sensor is either not used: or in the event the speed sensors out of service for repair et.) Guyane Gara us iv tga Sale bagcomponent Oeztons secron2 © ED ‘The standard configuration of the transmitter is “Blind” ie. no local depay/keyboars, requiring the use of the PTU (Portable Terminal Unit). Local keyboard & display (LTU), i available 3s an optional extra Features In acidition to the normal features availabe from a scale transmitter, the following are provided additionally ‘+ Aux 1/P — Inputs from Foreign Devices ~ to allow cost effective transfer of miscellaneous data via any Feld Bus equipped UNIPRO" (requires the appropriate ‘optional input Modules be installed in UNIPRO") ‘+ Aux O/P — Outputs to Foreign Devices = to allow cost effective transfer of ‘miscellaneous data via any Field Bus equipped UNIPRON [requites the appropriate ‘optional Output Modules be installed into UNIPRO” ‘salt Load Statistics. since its rarely known what the materia ow fate, belt load tc is overtime, prior tothe purchase of a scale, this Feature périts fine tuning of the scale configuration, by analysing the belt loading statistics sometime after ‘operation, ‘© Support forthe PTUI. The PTU! has a duality of fundigh. It acts as a Hand Held Terminal (replacing the model PTU) 25 well 2s providing the functionalty of a data Jogger. The information is stored in cois state memary. This allows this information| 1t0.be downloaded toa PC for electronic fling ee ‘Weigh Frames ‘The Process Automation family Bf Weigh frames are designed to cater for the wide variations in application fequirements, These range from the low cost single weigh idler system through the super ateurate mult weigh ile system vz, ECA - single weigh ier weigh frame. G2" al weigh idler weigh frame, ECB triple weigh idler weigh frame EC-A- four weigh idler weigh frame. EG sic weigh idler weigh frame. Easyweight -counter-balanced single weigh idler weigh frame. -Accuweigh® One -counter-balanced Single weigh icler weigh frame. Accuweigh® Two -counter-balanced Dual weigh idler weigh frame. -Accuwelgh? Three - counter-balanced Three weigh idles weigh frame. Accuweigh® Four -counter-alanced Four weigh idler weigh frame. “Accuweigh® Six counterbalanced Six weigh ler weigh frame.component Depo secron2 ©@D toad cells 08.220 Belt Scale Systems employ high accuracy Stain Gauge Load Cells The load cells supplied in the Accuweigh’ and Zasyweigh’ counter-balances scale ~wodels sce fitted to a Load ell Assembly which additionally provides protecticn to the load cell against mechanical overload and mechanical shock. The load cells used are from stainless ‘The load cell supplied in the EC .cale models are from Nickel plated mild stee!congonan eos secron2 © ED Belt Speed Sensors ‘The speed sensor is used to provide conversion of conveyor belt speed into an electrical signal for use by UNIPRO" Weighing transmitter. ‘Two variations are curenty available. Vit: PF-500/@T-50015, ‘The mode! PT-500/PT-5001S are our premium model speed sensors, used whefe the best pessiole accuracy requires ‘The PT-500/PT-50OLS speed sensors may be coupled, drecty witha solid Coupling, to any (non-drven) pulley or simiar drive mechanism, or it may be supplied with our proprietary Drive Assembly (see below). Picture shows optional junction box and cable ‘The PT.SO0/ET'5OOLS is supplied with a stainless stel shaft which is 150 mm long and 15 movin diameter. The shaft length may be trimmed in length to sut the coupling used ‘The PT-S00 has an operational speed range of 25 to 2000 RPM, ‘The PT-SOOIS Isa higher resolution device and Is used for ower speed applications inthe range of 1.01050 RPM. ae a Ba aeee secron2 ©@D Drive Assembly for PT-500/T-S0OLS Speed Sensors Picture shows optional Junction box and cable ‘Tachometer Drive Assembiy(s}(TOA) are available as an option to simply installation ofthe PT.SOO/PT-SOOLS speed sensors, ito the conveyor system and to provide an accurate ‘conversion of linear conveyor speed to rtationa velocity. ae ‘Gera hal Seas 0 pra Beee section: ©@D Pr-SO1/PT-SOUS, ‘The PT-SO1/PT-SOILS speed sensor isa low cost altemative with integrated drive assembly that allows bolting drectly to the conveyor stringer (via stringer customer supplied brackets) ‘This provides a lower cost solution of providing a Seed sensor with a drive arrangement. ‘The PT-S01 has an operational speed range of 2$ to 2000 4PM, The PT-SOOLS is a higher resolution device providing 15000 pulses per revolution for lower speed applications in the range of 1.0050 RPM. Due to limitations ofthe power supply iMUN/PRO™, the tachometer should be installed no further than 100 metres from UNIPRO. Longer distances are possible with an external power supply forthe tachometer ‘ers ial Seas Conn a Be eree section: ©@D Boom Angle Compensation "where the inclination angle of an installed scale mayibs change, compensation for this is required. This is because the force applied load cells (9 the weigh frame Is dependent on ‘the conveyor inclination angle. ur model ICL102 is a precision inclinomefer Used to sense inclination angle of the conveyor in order to provide Boom Angle Compensation, ‘ers ial Seas Conn a Be ete eee |mu secrons © ED Portable Terminal Unit (PTU") ‘The PTU! provides all the functionality ef the model PTU,/with the added feature of datz capturing ‘The PTU" plugs into a quick connect (Rl type) socket\on the 3000 CPU situated inside the LUNIPRO” enclosure, ‘The PTU! connection point may also be IGeated remotely by making use of a Portable ‘Terminal Connection Unit (PTCU} locatedata more convenient location.secnons © ED UNIPRO" Operation General In order to provide a simple “man-machine Interface", the EMBC-220 Belt Scale is completely menu driven. For each operation (Set-up, Re-l, etc.) a suite of messages {uides the urer and provides instructions forthe action requires, The low charts provides ‘ill help one to understand the operation and all he functions avalable in the instrument. ‘The following conventions have been employed and are used throughout the gauge software Auto-epeat: Aan auto-repeat function forall keys is provided. The repeat action accelerated the longer ‘the key is depressed Entering of variables: It the instrument prompts for an entry of avaiable the "ENT key has to follow the input of figures. The variable sctherwise discarded It ic relevant where the cursor e-etated within the variable: once the “ENT” key ie depressed the variable is accepted as displayed. The "CEL" key moves the cursor tothe left by one position and resets that eharactr to zero For certain variables th entering ofa value is restricted by 2 lower and upper limit. if an attempt Is made to 8iceedthose limits the variable is lscarded and the cursors placed at ‘the beginning of he variable, If anegative variable needs tobe entered, use the +\-key which will toggle the sgn Previous/next menu: The software allows forthe following: F4-= step on tothe next dsplay 3 = display previous menu,‘This convention Is however not desirable In certain stations (eg. time-out calibrations) and hence in these cases not applie. Selection procedure: In a menu where one item out of several items has to be selected, the one currently selected wil fash ESC. Key: ‘The function ofthe "ESC" key serves to either abort a timed pro€édlre (without alteration ‘to any calibration data) or to bring the programme back to the nearest sub-menu It should, however, be noted that any variable Keyedcin under a specticeislay stays valid even f the "ESC' key is used to continue. ‘Special Key Combinations ‘The following key combinations are supparted st present: crRuFL From the rif dlsplay (MSG. 2) - displays Screen (MES 154) for ‘communications clagnostics on the PAL BUS. Tis screen indicates the ‘otal number of packets (TOT) and the number af error‘e packets (ERA) ‘hat the PAL bus master has transmitted and received, TRU? Displays the Version ofthe software installed (MSG. 0}. crRLeES Normal (software reset of the 3000 CPU, Simultaneous depressing ofall the odd keys on the numeric keypad will result in 3 Master Reset Ythe gauge Is renitilsed and all calibration constants are reset to thelr default values and all totals ae reset to 2er0)Normal Display Mode and Access To Functions Sheet 1 of the flow charts shows the Normal cliplay modes. Since the information required may be more than is avaiable for dspay on the limited 4x20 display, multiple screens are avalable to display this data. The Fl key allows one to toggle between these display In the basic configuration the main display may be toggled between 3 splay screens only S05 toview either; © Rate a Total or 4+ Belt load ane Saeed or; ‘+ ote Set point/Contral inf. ‘Should additonal features such a8 Moisture Compensation, er Boom Angle Compensation be invoked, then further cisplays screens wl be available. In the event that Moisture Compensation is Invoked (see Specal\cunetions) then the Totalizer and Rate data will be preceded with the label Ory. Briefly the normal cisplay screens are as folows:- Mag 1 (basi eae information) Tas: Tiss the instrument idee 6 TAS. RATE: ‘The throughput rate ab.computed by the gauge from the two primary measurements of belt loading and belt speed. The label FRATE HIGH" or “RATE LOW" wil lah Inthe event of a HIGH oF LOW flow rate alarm. The RATE data wil be prececes by the label Dry inthe event Moisture Compensation is invoked. Rate units can be'selected a ether t/nor kg/h inthe setup, Tora: The (integrated mass throughput rate, This value is normally expressed. a5 “wet” units Le, without «ny vompensition for moisture. The Total data wil be preceded with the label Dry inthe vent Moisture Compensation 's invoked. The Totaliser can be Gisabled when the belt scale is designated as a Control Sco. The {otaliser value Is replaced by the text “CONTROL SCALE” when the totals is csablea FLETOSGLE: —Vepressing Fl toggles the dsplay between the Normal Operating display streens of Scale Information (msgs. 1 & 2), Rate Contra [rmsg. 151), Secondary Control (mse 303), Moisture Correction (rmse. 220} and. Soom angle Compensation (msg. 241). Note IMessoges 305, 220 and 241 will nly be avaliable if ond when these features are enabled in SET-UP}. FAEMENU: Selecting £4 wl call up the Main Menu (msg. 3). Note: ‘The letter “C’ ashes in the upper right hand comer of the main operating sreen (MES 1) co nace hats removely started test wet ting me anism AurTest Soquerce isin propestLUNIPRO" Operation SECTION 4 [Msg 2 (optional scale info) Mass SPEED: FL =TosGLe: AG, ‘The instantaneous (wet) belt loading on the weigh frame as measured by UNIPRO". The label "MASS HIGH” or "MASS LOW" wil flash in the event of a HIGH or LOW Belt loacing alarm. The Tabels "MASS" and "SIMUL" wil be lashed aterately fhe loads being simulated ‘The instantaneous belt speed as measured bythe tachometer ane determined by the UNIPRO™. The labels “SPEED” and “SIMUL” wl, be flashed alternately the belt speed is being simulated. The Iabele "SPEED" and REPLACE” wil be flashed aternately, i the belt speed sensor has been replaced by an input from afelay on the conveyor starter, Depressing F toggles the disolay between the Normal Operating Aisplay screens of Seale Information (msgs. 1 & 2), Rate Contr [rmsg. 151), Secondary Control (msg. 308), Moisture Correction lise. 220) and Soom Angle Compensation (msg. 241), Note: IMessoges 305,220 and 241 will nly be avaliable and when these features are enabled in SET-UP}. Display a diagnostic screen to indicates STATUS: (ether OK or Initiizing fut) Vi: Harduare & Software Version qumber ofthe load cell board cell Diatised measurement from the load cel (counts). SC: Samples counts (sample rate fixed at 57 H2 for EMB-220, ystems). ‘acho: Frequency (Hz) a read from the speed sensor. ae a Ba eisLUNIPRO" Operation SECTION 4 Msg, 151 (Rate Set point contrlie information) RATE: ser POINT: oureur: AUTO/MAN: FL=Tossts: Fae MENU: Note ‘The throughput rate as computed by the gauge from the two primary measurements of belt loading and bel speed. The RATE Sata will be preceded with the label Dry In the event Molsture Compensation isinvaked, ‘hiss the Set point or Target value forthe Rote controler. When the Rate controller is configured for operation in Local mode, the Setpoint value is entered via the local Keypad (ether LTU, RTU oF PTUD, Depressing F3 brings the cursor fo me Set Point field and allows the operator to enter/ater the Set point value. When the Controller is configured for aperation in Remote Set Point mode, the depiay label “SET POINT” Ic replaced by a flashing “REM SET POINT” In the Remate Set Point mode, the Set point value Is derived froma 4-20 mA input signal ‘The value of the UNIPRO™ Rete controler output [220 ma) In per cent, 2 toggles the gauge between Automatic od Manual control ‘made. The controller moge as currently set will ath. When in AUTO itis possible to enter the set poi via the Keypad (Set Pont ‘made Local). When in MAN the output may be programmed from the keyoac. Depressing toggles the diolay between the Normal Operating display screens of scale Information (msgs. 1. & 2), Rate Contra (msg. 151), Secondary Control (msg 305), Moisture Correction (rmsg_ 220) snd. Soom Angle Compensation (msg. 241). Note IMestoges 205,220 and 241 will nly be avaliable f ond when these feotures are enabled in SET-UP). Selecting F from ertner ofthe above screens wil alu the main menu (msg 31 “STOPPED! flashes when the controller isin AUTO made and the run feedaackie not active.Msg. 305 (Secondary Set point controller information) Pv: The name of the PV (Process Variable) selected when the Secondary controller was Setup Is ncleates SETPOINT: This ie the Set point or Target value for the Secondary controller. When the Secondary contraller ie configured for oneraton in Local made, the set point value is entered va the local keypad (ether TU, ATU or PTU), Depressing #3 brings the cursor tothe Set Point feld and allows the operator to enter/alter the Set point value When the controler is configured for operation in Remote Set Point mode, the display label "SET POINT” is replaced by a flashing "REM! SET POINT”. in the Remote Set Point made, the Set point value i derives trom 4-20 ma input signal. ourrur: ‘The value ofthe UNIPROIV Secondary controller output (8:20 mA) =inper cent. AUTO/MAN: _F2 toggles the Secondary controller operation betvigen Automatic and Manval control made, The contraller mote a: currently set wil flash. When in AUTO i is possible to enter the setpoint via the keypad (Set point mode Local). When In MAN the output may be programmed from the Keypad FL=TOGGLE: Depressing Fl toggles the display between the Normal Operating display screens of Scale Information (msgs. 8 2), Rate Control limsg. 154), Secondary Control (msg. 208), Moisture Correction (rmse. 220) snd. Soom Angle Compensation (msg. 241). Note Messager 305.220 and 241 will only be avaliable f and when these feotures are enabled in SET-UP). FA=MENU: Selecting Fa from Bither of the above screens wil call up the malin menu (mse. 3), Note: “STOPPED” flashes when the-controllr isin AUTO mode and the run feedback is Msg. 220 (Moisture(carspensation info - only avaliable when the transmitter enclosure door Interlock i either not instolled or when it i installed ond the transmitter enclosure doors open) ]OISTURE: Depressing F2 allows then keypad entry of the moisture per cent to be used (wet bass). This data ls used by the transmitter In Order to compute Liy mass Loading, Rate and Total HLS TOGGLE: Depressing Fl toges the display between the Normal Operating display screens of Scale information (msgs. 1&2), Rate Control {imsg. 181), Secondary Control (msg. 308), Molsture Correction (rmse. 220) snd. Soom Angie Compensation (msg. 241). Note Messager 305.220 and 241 will only be avaiable if and when these feotures are enabled in SET-UP}. FAEMENU: Selecting Fd from either of the above screens wil call up the malin menu (ms. 3)[Msg 281 (Boom angle Compensation - only avaloble when the transmitter enclosure door Interlock is either not instolled or when Iti installed and the transmitter enclosure door is open) ANGLE: ‘This displays the inclination angle of the conveyer in degrees. This angle information i obtained from the model ICLi02. angle transmitter Factor: This is the factor that needs be applied to the gauge calibration in order to compensate for the incination of the conveyer. FL=TOGGLE: Depressing Fl toggles the display between the Normal Operating display sereens of Scale Information (msgs. 1 & 2), Rate Contra (rmig. 151), Secondary Control (msg 205), Moisture Correction [rmsB. 220) and soom Angle Compensation (msg. 241). “Note: Messages 305, 220 and 241 will only be available jf and when these feotures ave enobied in SET-UP). FASMENU: Selecting Fa from ether of the above screens willl up the main menu (mse. 3) Msg. 125 (PTU" Uploads) Depressing the PRT Key from the rain cisplaiy (mie. 1) brings up the PRINTOUTS splay sereen (meg. 123) where further options are presented as folows:~ sCurrent Total: Depressing “1” results the Wisplay of a message indicating "Busy Printing” and printing of the current totalser value. Printing may be aborted by pressing the ESC key. 2 Stored report: Selecting "2" brings up msg. 126 which allows the further election ofthe report type. Selecting the report type [ether Shit, Weekly of Monthy) will result in the printing of the sparopriate report Printing may be aborted by pressing the ESC key. Should fo reports be available for printing msg. 128 will be cleplayed After completion of the printout msg. 128 wil prompt for whether ‘me printed report may be clearee from the gauge memory or not. INote: Tris Pri outs only possible when elther the enclosure door Interlock i either not fitted or, when the enclosure dor interlock i {ited but this door i open 43 CalConsiants: Depressing “3” results inthe dlsnlay ofa message Indcating “Busy Printing and printing ofthe Cal constant wll commence. Printing may be aborted by pressing the ESC ke.secnons © ED Selecting “A” results in the display of @ message indicating “Busy Printing" and printing ofthe equipment Serial numbers will commence. Printing may be aborted by pressing the ESC key Note: Calibration Appiicotion and other dat, ls stored Ino RAM Ic. Since the NVRAM (battery backed up RAN) is another Integrated circu. a physical movement must be made to copy the data fram RAM to NVRAM. However, ing to imitations ofthe memory backed up by battery, the Serial Numbers and ‘Application Data are notable tobe stored in battery backed-up RAM. Instead this information is now stored in EEPROM. This eons tht after entering/edtting Serial Numbers and Application Doxa the user should Store them fo EEPROM. Ifthe UNIPRO" loses power before the data is saved wil fost. fhe user wants fo View ar Print-out the Sera| Numbers or Application Data t should ‘loys be recalled from EEPROM frst. The Store and Recall Dptions are availabe inthe same menus which alow their entry. Se App. Data: Selecting "S” results in the dsplay of a messagainélcsting “Busy Printing? and printing of the details of the-epplication will commence. Printing may be aborted by pressing the ESC key. Note: Colibation, Application and other Ueto Is stored ino RAN IC, Since the NVRAM® (battery backed. up RAM) is another Integrated cre, o physical movement must be made to copy the data from RAM to NVRAN Hower, owing to limitations of the memory backed up by battery. the Serial Numbers ond Roplication Data are not able the stored in battery backed-up RAW. Instead this Information is now stored in EEPROM. This rmeons that after entering/editng Serial Numbers and Application Doty the user should Store them to EEPROM. I the UNIPRO' loses Dower before the deca saved, t wil be lost. If the user wonts to View or Prit-out the Serial Numbers or Application Dot, It should tlways be recaled from EEPROM fist. The Store and Recall fptions are byolabie in the some menus which alow their entry. Belt Load Stats: Seating “5" results in the display of a message indicating ‘Busy. Printing” and printing of a Selt Losd statstics report Printing may be aborted by presing the ESC key, T= 1/0 Map: \seletong, "7" resuts in the display of a message indicating "Busy Printing” and printing of /0 Allocation on the expandea /0 wil commence. The /0 allocation defines how the UNIPRO™ has been Configured - which physial Input or Output is connected to which Input or Output on UNIPRO™ The transmitter has a maximum of 32 slots avalable (RO to #33), Each carrier board has provision for 4 slots. These slots are always numbered 2 to 4. The absolute (computer Identified sot numbers are offset by the carrer boars adress. Eg Carrier board with address "0" will contain absolute slot #5 1 through 4, carier board with address "2" wil contain Absolute slot #s 5 through 8, carier Board with address "4" wil, Eontain absolute sot W's 17 through 20 ete. Printed behind the Sbtolute slot number wil be the UNIPRO™ variable assigned to that particular output, Note: While may be prudent to have any carrier boards installed set so a5 to have thelr adaresses start from “OY this isnat essentialsecnons © ED ingle Comp: Selecting “8” results in the daplay of 2 message incicating “Busy Printing” and printing of Angle Compensation callration info. Ss Print Al: Selecting "9" results in the dsplay of a message indicating “Busy Printing” and the sequential printing of al of the printouts th the exception ofthe stored reports. Mse3 Depressing the F4 key from the main display (msg. 2) brings up the MAIN MENU clsplay sereen (msg 3] where further options are presented as foliows:- sSetup: Depressing “1” brings up msg. 4 prompting forthe SETUP! abcess cove 2zCalChecks: Depressing “2” beings up mse. 5 prompting fr the ackess code for CALIBRATION CHECKS! ‘3eSpecial Funct: Depressing “3” brings up mse. 6 prompting forthe access code for SPECIAL FUNCTIONS! 42cal Const: Depressing “2” brings up ms. 7 prompting forthe access code for CALIBRATION CONSTANTS" SeControk: Depressing “SY brings up msg. 15D prompting for the access code for SET POINT CONTROL: GsStatistes: Depressing “6” brings up sg. 280, the sub menu for BELT LOAD STATISTICS (access code not require) Notes: 4. Some menu items are not acchsible when the door interlock is active. MENU ACCESS DENIED — THE DOOR INTERLOCK ACTIVE I indicated when access i attempted. 2. Reduced functionality @ckes is avalable to Calibration Checks when the door interlock is 3. Calibration Constants can be viewed (but not entered) when the door iterock i active 4. Messages 3, 4,5, 6,7, 50 ond 280 time-out. Ifthe gouge is left in any one of these display scteens for more than thirty seconds it wil revert to the next (previous) higher disploy If this higher display too has a time-out, this wil be repeated and so on. Once the gadoe has occepted an access code the time-out wil be de-actvored.ee secnons © BD Access Codes LUNIPRO™ is protected by coded access. The follwing Ia lt of codes which are required in order to access the gue. Technical data 3008 Special Functions 3985 Set-up /Intial Calibration 3946 Calibration checks 3987 Calibration Constants 3948, Control Functions 3989 ‘ers ial Seas Conn a BeScale Configuration & Calibration Application Details Prior ta placing the system in operation, the design criteria submitted by the purchaser at the time of order and the actual application details must be verified. These measurements, adjustments and calculations should require attention only at inital start-up; when troubleshooting; or whenever any ofthe following cneltions should change + Measurement (calibration) Range Belton which the gauge is mounted ‘The belt speed operating range s changed, The bett loading operating range is chances. Tachometer drive whee! is changed. Change in /0 requirements. ‘The design criteria (Appicetion Data) to which the system wafroriginally designed is avalabe from the transmitter (see Report/Printout options msg125} Test Weight When equipped with an (optional test weight the weight sensor calibration may be quicly and easily checked The test weight Is provided as a means or “Tocking In” the calibration, once the scale has been accurately calibrated (using teste involving bulk mater) The Test Weight may be operated by elther; + mpafsRaniting or, ‘© manually ia lever mechanism for larger test weights or +> automatically using a single test weight and single electric motor driven actuator. The redtlweizht must be positioned in one of two (r three In special cases) postions TARE position On counter-alanced scale types, this is the normal or ‘operating postion for the test weight 26 the test weight i= Used as part of the counterbalance mass. For non-counter- balanced scales the Tare position is with all the test weights removedSPAN positon: In this postion the test weight represents specific belt loading which is used as a reference for calibration checks The value of the bel loading represented by this test weight ‘may be determined in one of to ways. A theoretical determination of the representative belt loading Is possible using the physical detalls of the scale and weight of the test weight, as detaled inthe Section covering Calibration Calculations, After the scale has been accurately calibrated using. a bulk material test, the test weight may be weighed (meatuted) by the scale. This measured value of the tet weight may then be store for future reference by the scale Calibration Calibration entals the matching (scaling) ofthe measured Bi Computed information trom the Primary sensors, to that of the actual value of the measured variable. In most of the Calibration procedures the gauge samples the incoming Signal fr a period anc then requires ‘that the user inform the gauge what value this ingut signal represents. The user is guided through all the calibration processes with simple’ menu type deplays. elt scales normally have two sensors namely Weight and Speed, Weigh Frames ‘The weight sensor atsémBly has been engineered forthe application as specified atthe time of order. This includes the computer optimisation of the weigh frame arrangement, load cell capacities ete Many gifferEncveizh frame models are avaliable - from the single welgh idler type, through counterbalanced types with up to sik weighing ders. The UNIPRO" transmitter i suitable for use onal these scale models ‘The integrated load cell amplifier requires no gain jumpers or switches to scale the amplifier output. The gain of the amplifier is automatically set under software by the UNIPRO™ transmitter, during calibration.Configuration & Calibration - UNIPRO™ SECTIONS Initial Calibration (Set-Up) Prior to attempting a calibration of the gauge, it s important to ensure that the random access memory (RAM) ofthe gauge Is reset tothe default condition, so as to ensure proper operation of the gauge. This procedure is known as = Moster Reset and is achieved by simultaneously depressing (for approximately 2 seconds) all the odd numbered numerical keys on any Terminal Unit (LTU, PTU or RTU), This procedure Is also required whenever new software is installed The calibration ofthe Bet Scale is simple and is performed as follows. Selecting SET-UP from the main menu (mse. 3} and entering the appropriate acceds.code ‘rom any terminal (LTU, RTU or PTU) wil result in the Set-up menu (msg 8) being Bresented, ‘The SET-UP menu offers the following options:- 12 Full calioration 2= Resolution and Range. 3 Speed Sensor calibration, ‘Weight Sensor calibration. Rescalibration (Test Weight) setup, 1/0 allocation. 4-20mA (output) set-up on extantion /0. Test weight Set-up. YO diagnostics. AL Bus Setup. Note:The Function keys"F3" and “4” wil have the folowing meaning throughout the Set- Lup programme: F3 wil take one to the menu previcusto the one currently being splayed; Fa will take one tothe next menu to the one being displayed,Con (2) Full calibration Selecting “t” from the Set-up menu, guides the operator through the Full Calibration. The {ull calloration involves the configuration & selection of variables essential forthe gauge's proper operation vi Msg. 11 Allows forthe entering of the Equipment Tag. This Tag may be an alpha numeric descriptor upto fourteen characters in ength Msg. 119 _Usedito set the time and date ofthe rea time clock Mse. 276 Allows the selection of tons per hour = t/h (default) or kilograms per hour ~ kg/h as the mass throughput rate engineering units ‘This setting decides on the rate engineering units for all the rate Variables on the dislay sereens, Msg. 12 Allows the selection of the resolution (postion of the decimal) require for the sisplay ofthe mass throughput rate This setting 2iso decides on the positon of the decimal comme for al the measured variables on the allay zereene, Msgs. 13, 14 & 15 Allow the setting ofthe measurement raiges (top of scale for the fate, Belt Speed and Belt ood. Msg. 15 Allows the entering of the amount. of mass in tonnes) to be represented by each output pulse. This outputs normally used t rive remote ttalisers Msg. 27 Allows the entering of thé'altfation belt length. Ths isthe length over which the gauge will make its measurements when Performing a Tore Cheek or span Calibration Check. The belt length "entered Is: normally the exact belt length or, whole muftipies thereof in cases where the belts very short and the belt Completes one fevoltion In less than 3 minutes. Msgs. 1820 Allows the tiring ofthe two extremities of the 4 -20 mA from the Load eel board (proportional to Rate). After completing ths initial sectioh of the Set-up, the gauge wil continue with the sensor colorations and Re-Cal Set-Up 2s listed below (2) Resolution ‘Seleéting"2" trom the Set-up menu, guides the operator through the same message/input Screens.a5 above in Full Cliration with the difference being that after completion it ill return tothe SETUP menu whereas in Ful Callration, it vl continue with the Set-up ofthe Mss & Speed sensors as well as the Re-col Set-up as listed below. The full calibration involves the configuration & selection of variables essential forthe gauge'spraper operation(G+) speed Sensor calibration Selecting "3" from the Set-up menu, brings up the Speed Sensor Calibration menu (mse. 24) ‘hich in turn allows forthe calibration of the speed sensor at two known points c (2) Ahigh point calibration; either a fll speed ofthe belt or, at some constant speed lose to maximum speed Notes: 1) The transmitter will allow 2 5 time constant delay before starting measurements, In order to ensure the measured variables have settled to thee tna values. | A zero Calibration fra stationary bet and 2) The filter time constant for the (rau) input from the speed sehisorhas 3 Gefault setting of 2 seconds. This may be altered under Special Functions Msg, 25 Speed Sensor Zero Calibration. The gauge will determine the Input counts from the tachometer which represent. «a stationary belt. "Note: The counts from a stotionary belt should normally be zero Msg, 26 & 27 Speed Sensor Span Calbration, This entallsthe) measurement, by the transmitter, ofthe input counts from the speed sensor and assigning to it of the value ofthe actual belt speed a5 determined by (simultaneous) accurate measurement. Actual belt speed may be messured by measuring the distance travelled by the belt in 3 minutes. The distance travelled may be measuré@-by an accurate Odometer (avallable ‘rom Process Automation)(=) Weight sensor calibration The callbration of the mass sensor entals performing both 2 Zero (tare) and Span callbrtion. The gauge will determine the calibration curve from this data, Since conditions vary from installation to installation, different calibration techniques may be required and provision (msg. 128) is made to allow the mass sensor to be calibrated with either a (2=) stationary (static belt or (1=) witha running (dynamic) belt (msg. 28). When using the static calavation option, the calibration is performed over a time period 3s. determined by the operator (ay manually starting and stopping the measurement from the keypad). This time period should ideally be over 200 20 seconds When using the dynamic callration option, the entered Calibration belt length wil beused for thi ealioration, Note: 2) The transmitter wil allow a5 tim constont delay before starting measurements in order to ensure the measured vonables have Sette to thelr fina volves. 2). The fiter time constant for the (row) input from the weight sensor hos a defoult setting of 2 seconds. This may be altered under Special Functions.Con Weight Sensor Dynamic Calibration From the dynamic calibration menu (msg. 23), perform either a (dynamic) Zero Calibration followed by a (dynamic) Span Calibration, Msg. 30 ‘Allows the calibration of the weight sensor tothe empty beit Condition, The measurement le made over the Calibration Length entered (normally complete revoluton(s) of the conveyor). The transmitter will assign the value of zero (kg/m) tothe average of this measurement. The overage 2ero value forthe whole bel il ‘hus be determines Should the seale be set-up to allow for Automated Calibration checking via anlectritally actuated Test weight Urting mechanism (see msg, 21 from selection °&” under the main ‘Set-Up menu), then;> Msg. 82 Allows the further. selection/confiematioa) ot whether an Automoted electrically actuated test weight operation of ‘Manual aperation of the test weight sreautred Selecting "I" wil, bring msg. 3 to allow inition of the Sequence using the ENT key, Selecting “2” wil allow intistion ofthe sequence using the ENT key after manually positioning the Test Weight - where after sg. 32 wil splayed (see below), Ms. 83 Ensure the conveyor is empty ahd clean. Depress the ENT key to Initiate the Span Checking. Mse. 85 Displays the status of the automated test (measured count and bl length left to go unt completion cf the test. Mse.32 Allows the (span clitration ofthe weight sensor tothe On Board ‘Test Weight, The measurement made In meg. £5 above, = made over the Calibration Belt Length (normally complete revolutions) Of the conveyor). This msg. (msg. 32) wll prompt forthe input of the belt loading represented by the Test Weight (kg per met). This eth value UNIPRO™ ‘wil assign the average of It ‘measurement to. The (theoretical value of lineal bet loading Fepresented by the Test Weght may be determined trom the force calculations applicable to the weigh frame type/model ‘These force calculations are shown on the General Arrangement Drawing ofthe Weigh Frame Should. the Seale not be set-up to allow for Automated Calibration checking vis an Electrically actuated Test weight Lifting mechanism (see msg. 2 from selection ‘the main Set-Up menu}, then:+ underCon Msgs. 318.32 Allows the (Span calibration of the weight sensor to the manuslly operated On Board Test Weight. The measurement is made over the entre calibration bel length (normally a complete revolution ofthe conveyor) ater which time ft will prompt for the input of the belt loading represented by the Test Weight (ke per metre). This is the value UNIPROY will assign the average of its Ietsurement to, The value of lineal bet loading represented by the Test Weight may be determined from the force calculations applicable to. the weigh frame type/model. These force faleulations are shown on the General Arrangement Drawing of the Weigh Frame Weight Sensor Static Calibration From the stati (Belt cut) weight sensor calibration menu (msg. 33), perform a (static) Zero Calibration followed by 3 static) Span Calibration Msgs. 348.35 Allows the calibration of the weight sensor ta\the empty belt Condition. The meacurement is made at in Calibration Check Menu - msg. 42) the totalzercbt-of is automaticaly disabled uring the Bulk Test, ‘The Totalser can be dissbied when the bel scale is designated a 3 Control Scole. The totaliser value in the main operating screen i= replaced by the text CONTROL SCALE" when the totaiser I isabled, ae a Ba me‘Special Functions o secnon? © BD ‘The digtal output on the 3000 Load Cell Board (a sampler output may be configured adeitionally, sla the excansion /0, should this ‘output onthe 3000 LC board be used for totalser pulses) may be configured to provide a sampler control output in pace ofthe normal totaiser output, should it be requted. Depressing “A” from this menu will togele allocation ofthis output between Totaier and ‘Sample. The flashing identifier willincicate the current allocation. In the event this digital output on the load cell board is used to control ‘0 sampler it must stil be turned “ON” under Special Functions #8 Notes: 4)While the expanded /0 may be used to drive a sampler, ony the git output on the Load Cell Board may be used to ceive o remote totaiser (dv tothe pulse width contro requirements). 2s required thatthe Mass Sample Interval be greater than the ‘amount of material between the scale and the sampler Bee no ‘output wil ever occur This limits the downstream distance thet the sampler canbe located from the scale, ie. stance between scale & zampler (mi < Mass Somple Interval [kg)/ maximum bel oading kg/m 3)The sampler must always be located after (downstream of) the sole,Note: The UNIPRON remote totalisr isan intelligent totalier in that will only pass on to any remote totaliser, postive tonnage. L¢. should the belt tae be that the stale counts down (subtracts) tonnage from the local totaiser under empty belt conditions, UNIPROLV ‘will only pass on a count to the remote totaliser once UNIPROIV has made up for the amount previously subtracted. For example, assume the belt runs empty for some time and results in the local tonnage counter removing 2 tonnes. When material next passes over the scale, it will require that 2 tonnes pass over the scale before iti in a postion to pass on pulses for remote ttalseion. This feature allows the use of inexpensive "add only” type Femete counters and saves on cable cost - only 2 conductors are required, and wil cditionaly ensure the local and remote totalisers remain synchronise. Likewise, ifthe remote totalser pulse width is set too long forthe count rate (tonned per hour and totaler resolution), the remote totalzer wil appear to lag behing the local totaliser. The remote totaliser will continue counting (pulsng] even with lite etna material flow) until the rematetotaliser equals the local totalser. I is important ta take care when configuring the totaliser resolution and the remote totaliser pulse wrath, to avoid the remote totais lagging, since theoretically the butfer for the remote totaliser could ‘verfiow resulting ina mismatch between the local and remote totaisers. It should also be noted thatthe max count rate avallablefroff the UNIPROIV is 25 pulses per second When the minimum oulze width of 20ms is get [a maximum of 90000 pulses per hour). 50% duty cycle is enforced on these pulses «the minimum OFF time isthe same as, ‘the ON time. For count rates > 1000 per hour, the optional Solid State Relay outout should be used in pace ofthe dry contact rela. Care should be taken when selecting the tonnes per pulse soas to be a practical compromise between relay ifetime and required resolution. The pulse width seting is also important when’ connecting to other devices such as PLC ete. since at high count retes the PLC may miss pulses due to restrictions on the scan time/window of the PLC. For highest integrity, totalsers are best read using a field bus connection,Function No. 6 “SCADA Communications” Msgs. 88,120,219,225-228,242-246,264 & 263. Mse.219 Allows the selection of (1=) U-NET" Set-up, (2) Fleld Bus Setup or {3s) Enable or Disable Whites from SCADA (reade by SCADA sre always allowed) Msg. 242 Allows selection of (1=) U-NET! Settings or (25) U-NET! Diagnostics. Mse. 88 Allows the setup of the UNIPRO™ transmitter address (Slave No) 235 required In U-NET! Tor SCADA network type applications Mse.120 Provides U-NET! diagnostic information by eispavin information ‘rom the UNET Te ana Rx Buers, Mse.225 Selecting Fleld Bus Set-up from msg. 219 brings up this msg. This sg. allows forthe farther selection of (1=] View parameters, ( View Settings and (3=) Diagnostics, Msg, 226 This displays parameters applicable to the Field Bs card used Msg. 243 Allows the selection ofthe type of Field’ Sus Setting required. (1=) Profibus DP Format, (2=)Pinormation |3=) Modbus Format. Mse.227 ‘Allows the selection of the Profibus OP floating point format to be Used By the host PLC. This may.be either as in 7/0” SS series Siemens PLC Msg. 264 Allows selection ofthe prtiaty Ethernet Comms protacal. Ether Modbus TCP/IP (default) or EtherNet/P may be selected. The primary Ethernet protocol must be selected because there may be ‘multiple simultaneous types of protocol connection toa UNIPRO™ Via the same Ethernet interface, The user may need to correctly ormat the variables in the PLC/SCADA f secondary protocel Is employes. Msgs. 244 2 245. Allowthe entry of IP adresses for Ethemet based protocols (not titale when PROFINET IDs employed) Msg. 266 ‘The UNIPROY must be reset for changes tothe IP information to {ake effect. This sreen allows the operator to reset the UNIPRO™. Msg, 246 Allows the selection of the Modbus floating point format to be used by the host PLC, Msge228 ‘These are diagnostic screens to act the debuasing of a ANYBUS network. Eg. The Tx is Used in Profibus networks to dlepiay & Variable from the reserved vatlables to check what i receive at the other end. The Bx may be used likewise by having the host add number such as 115.3 tothe Tr value and returned tothe gauge. ‘The number of updates indeates the sumer of updates fo this particular UNIPRO™,Function No. 7 “Compensations” Msg. 238 Selecting "7" results in mse. 239 which allows selection of the type of load compensation to be applied. Two alternatives are possible ve; Moisture and Angle compensation. Note: No compensation is possible if the door interlocks ited. Selecting 1= "Moisture Compensation” Msg. 217 ‘The moisture compensation (wet basis facilty allows the scale to determing and totalise the dry weight from the measured wet product The limits in mse. 247 define the range ofthe moisture correction ‘The F2 key scrolls the source of the moisture signal e. Of, Keyag, Remote Remote Sera, Note: “OF turns the moisture compensation of Selecting 2= “Iucinaton Angle Compensation” ase. 240, Ensure that the ncinometer has been callcatéd and connected to the expanded 1/0 and the input allocated appropriately (see Expanded /0 Allocation) This seen allows the selection offonétions dealing withthe operation and set-up of angle compensation. (1=) ICL-102 Inelnemeter Setup, (2=) Angle Compensation Linearser Calibration (3=) Angle Compensation Linesriser Calitration Reset or [4=) Printout of the ‘Angle Compensation Lnearzer Calibration point. Mse.272 Pressing FA/F2 turns Angle compensation ON or OFF. Msg. 267, Pressing F4_ or FB allows the user to step forwards (FA) or backwards (F3) through she callorates linearier points. The falipration can be Viewed or values can be entered. The nearer Can be calibrated a a point by pressing F2. FL sabes the point, Femoving it from the linearser calculation. Mise. 268 Pressing ENTER causes the UNIPRO to average the belt loacing and angle over the entered belt length Msg. 269 Te result ofthe averaging process from mg. 268 s dlsplayed and can be accepted by pressing F Mse.273 Pressing Fl sets the Angle Compensation parameters to default values. Mse.270 The UNIPRO™ sends a print report of the Angle Compensation parameters (to PTU') ‘The procedure to setup the Boom Angle Compensation feature is described in the section covering Weight Sensor Set-up.Function No. 8 “Sampler Set-up” Ms 121 ‘The distance between the sampler and the scale is required to be entered so as to ensure thatthe sample is initiated, at exactly that point on the conveyor bel, where the setpoint tonnage and/or bel loading was achieves. The sampler control outout is avalable, either from the digta output on the 3000 load cell board of via the expanded /O. In either event depressing Flin this ceplay screen, toggles the Sampler output option between ON (enabled) and OFF isabed) Notes: 1) The use of Sampler Control will quire the use of «digital output, Inthe eve the ‘gta! output on the 3000 (cad Cell Board is used for a remote totale, Jt wil Decesstate the use of the expansion /0 and the allocation of this variable to a particular Digital Cutput card ~ sze option #5 in the SET-UP MENU-When using the Expanded /O the duration of the output pulse 1s fixed at, 500) millseconds 2) tis required thatthe Mass Sample Interval be greater than the amount of materia) Between the scale and the sampler else no output will ever occur. This limits the ‘ownstream dstonce that the sampler con be located from the scale. e. distance between scale & sampler [m] < Mass Sample Interval [xg] / maximum belt loading kg/m. 5) The sompler must olwoys be located ofter (downstream ofthe scale. Function No. 9 “Production Reports” Msgs, 122-124 “The transmitter has builtin certain production reports to asit the owner in the analysis of his conveyor operation. ‘This function allows the eoifiguration of these Production Reports. Ako refer to the appropriate Section cSvering the PTU' Reports Msg. 122 Allows the setup ofthe start and stop times ofthe shits Msgeazs Allows the setup ofthe day and time ofthe week report. Magi24 ‘Allows the set-up ofthe day of the month and te of the monthly report Msg. 247 Allows the set-up of the over- and under-ange limits for the logging ofthe Runtime statistics.Low Taree apeatins secrons © ED Special Low Temperature Ap} Low Temperature operation The stoncard £148-220 system can be made to operate in low temperatures provided: Special (designed for low temperature operation) load cells are employed [rated to ore} + thelow temperature speed sensor option is used (rated to -30°C) and + the UNIPRO® transmitter is mounted ina protected aea (remotely n a substation, MCC tc), in ambient temperatures of not less chan O°C for UNIPRO® transmitters equipped lth an LTU (iguic crystal epay) and not less than —20°C when not equipped with an ou. ‘This configuration allows the weigh frame to be situated inthe harsh environment (down to -10°C) whist the transmitter is more protected. It should be bornain mind however that the UNIPHO transmitter should ideally be located closer than approx. 50 metres (cable distance) from the weigh frame and tachometer. For greater cigtances remote sensing of the load cell excitation vil be require.secrons © ED Calibration Checks Frequency Of Calibration Checks ‘The frequency at which calibration checks should be performed depends on a number of factors: 4, The rate st which material collects onthe “weighed parts 2, The rate at which the Speed sensor Drive wheel wears down, 3, Conveyor maintenance (belt repair or replacement, repair ofitake-up, weigh idler, ete) 44. Changes in conveyor parameters (structural alignment, temberature effect on belt stness, racking, ete) 5. Stabilty of scale and instrumentation. 6, Required system accuracy: 7. Available man-power or degree of automation. There is correlation between frequency of calbration, numbe? of ilers onthe scale weigh briige and the accuracy required. While t may be BOssbIe to achieve a reasonably high degree of accuracy for a short time with a single ler scale In a good instalation It I obvious that the single idler scale Is more susceptible to belt effects and changes in alignment and therefore the calibration should be checked more frequently. Likewise, 2 ‘multiple idler weighordge will not have tobe checked frequently if 1% is all that Is requires AA common mistake made in the selection of belt scales is chocsing a single idler scale or short weigh bridge because the accuracy required is only 1%. it may be possible to achieve 1% butt might require calbrating once 2 day! ‘The frequency of alloration i best determined from actual operating experience. Initilly the tests should be performeld more frequently (once a week) to establish a confidence level based on accuracy required and the number of times an adlustment had to be made. The ‘tests shouldbe based on the As-Found-Eror (AFE}catbeston Chace secrons © ED Quick Check on Calibration The exact nature of the calibration checking procedure will depend on the options purchased with the scale, For automated checking refer tothe section covering Calibration, For manual peration the folowing willbe # useful guide Pror to performing calibration checks, operate the conveyor belt for a minimum time Period of 20 minutes to "warm-up" the beling. At temperatures below 0 degrees Celsius, longer warm up pened may be required ifthe bet has been idle for longer than 1 hour. ‘© Visually inspect the weigh carriage for pebbles or rocks that may have become jammed between the weigh carriage and supporting stringers. Should the scale be equipped with antrspllage covers, this wll necessitate 2 more careful Inspection since the covers hise much of the weigh carriage from view. A further place to Keep an eve om ls below the ller supports onthe ilers ited to the scale welgh carriage. This clearance Is normally smal ané small fuantties of dre Bulld-up here will cause rauble. Also check the tachometer deve assembly for proper contact withthe bet and forapy spilage that ™ay have become wedged in the mechanism. Now with the Belt Empty and stationary ‘+ Note the belt loading as indicated by the UNIPROY transmiter ‘© Place the test weight in the SPAN postion 1+ Note the belt loading as indieated by the UNIPRO™ transmitter ‘The difference between the fgurt on UNIPROY should be within 2% of the value of the test weight as recorded on the calibration data sheet (and also recorded in the UNIPRO” transmitter)catbeston Chace secrons © ED With the dele Running Ematy ‘+ With the bett cunning empty, check for proper contact between the belt and all ‘the idler in the welgh area (3 llers before the welgh frame through 3 ldlers Biter the weigh frame), Le ldlers should be well lignes, ‘+ With the conveyor stil running empty, monitor the belt loading on the LUNIPRO" display [kg/m]. This should be around the zero point. Do not be concerned if the belt load runs positive for_a while and then negative, this merely shows thatthe average belt loading is "null. a proper zero. Note: (fthe average belt loading i not close to zero fist check fora meckanical couse Le stones, damaged idlers et. before making any electronic corrections (tar) ‘+The test weight may now be located inthe "SPAN" position, nd the overage belt loading noted. should this be cloze to the figure on the calbraton dats sheet then ale ell withthe scale and nething further needs tose done, Note: Ifthe overage belt loading inlcated 's moresthaii 2% ifferent from the figure entered on the calibration sheet, do.not proceed until the couse for this has been established ie. check for stones, mechanical obstruction, diamaged ici sets, mechanical failure te ‘+ Replace the test weight inthe "ZERO" positon ae a Ba eeCalibration checks SecTION9 (Full) Calibration Checks and Tests Prior to performing normal calibration checks, operate the conveyor belt for a minimum time period of 20 minutes to "warm-up" the belting. At temperatures below O degrees Celsius, longer warm up period may be require if the belt has been idle for longer than 1 hour Visually inspect the weigh cariage for pebbles or rocks that may have become jammed between the weigh carriage and supporting stringers. Should the scale be equipped with antispilage covers, this wil necessitate a more careful inspection since the covers hide much ofthe weigh cariage from view. A further place to keep an eye on is below the idler supports on the iders fitted to the scale weigh cariage. This clearance is normally srall and small quantities of drt buildup here will cause trouble. Also check the tachometer Arve assembly fr proper contact with the belt and for any spillage that may have become wedged inthe mechanism The normal Calibration Check involves 2 Speed Calibration zero cheek, Speed Calibration span check, Tare (Mass zero) and Mass Reference (span) check. The Calibration Check and Tests routine Is the function mést Hequently used on the transmitter and provides for most of the routine adjustments-reauired by the Belt Scale system. Selecting this option from the Main menu (messa@e:3) prompts forthe input of an access code (message 5) where after it wil bring up the Calibration Check menu (message 42), ‘This menu allows the following choices Weight sensor sero check 2 Weight sensor spaicheck 3 Speed sendor zero theck speed sent span check clk material test. Gallortion correction (weight ‘These Fautiies alow normal maintenance/calibration checks to be performed on the Weight and Speed sensors. These routines allow for the independent checking of both the 2er0 and span of e2ch sensor to allow the determination of "As Found Errors” - AE).oe secrons © ED ls provided as an aid in the performance of a bulk materia test on the belt scale, Function (6=) allows for the correction to the calibration of the belt sale weight sensor, found to bein error. Note:The automatic callratin correction is an opproximation thet is correct proving the belt scale As Found Tare Error i 2ro. If this tare eror isnot zero, on error in the ‘pplication ofthe calbation correction will cur. This is due to the nature of the ‘mathematics involved and may be ignored fr zero offsets (tare errors of ess than 5 1%, Should there be doubt a: to the conditions at hand this may be resolved by performing a weight sensor zero calleration. This will effectively reset the tare error 1t02e70, thereby removing any possible problems inthis regard (1=) Weight sensor Zero (Tare) Check (messages 43 & 46) ‘This selection will result in the transmitter performing a Tare (riass zero) check of the ‘weight sensor over the defined (calibation) bet length, Ensure any Test Weight i inthe "TARE" (or normal) pesto. Run the belt conveyor empty of all material prir to initiating ths function. This feature is very powerful since it wl display the value ofthe average zero condition as measured {in "signed" kg/m and Per cent Erfor~teferenced to the Full Scale calibration of the belt loading). It is possible to autornatiglly correct the weight sensor zero calibration (auto tare if this s desired. Any corcetion thus entered willbe stored asa "zero (weight) offset" and may be read from the Ist of calibration constants. For mathematical reasons, ‘this zero offeet should not be allowed to exceed the value of 5%. Should this figure of 5% or [greater be attained & mass sensor aer9 calioration should be effected (which wil eset this figure to zero) “The gauge may be insvutted to correct any discrepancies in the indication if desired (Auto Corecton) Should the Tate Etror be found to exceed the pre-set allowable value (as defined in Recaliration Set-up msg. 263), no correction will be permitted (mses. 264 & 265). The problem must be corrected and the check repeated. Note: tis passble thatthe Test Weight ‘may have been left inthe Span postion!catbeston Chace secrons © ED This selection wil result inthe transmitter performing a weight Sensor Span Check using the Test weight (a5 previously setup under RE-CAUBRATION SET-UP). Measurement is made over the Callration Belt Length and totalsation will not occur Operation will depend on whether the scale has been configured for Automated Test Weight operation or not. If AUTOMATED TESTING is invoked i wll esult in msg, 65 being displayed. Mse. 66 Will prompt for the selection of automated or manual operation ofthe Test Weight. Selection “2” wil recut in mags, 45 & 96 being Gisplayed — as f Automated operation had not been selected Selecting 2" from this seen will bring Up mse 84 Weight Sensor Span Check Msg. 84 This prompts for the inspection to verify that thé conveyor is empty and clean. Depressing ENT wil initiate the est and bring up msg. 85. Mse. 85 This screen displays the status of the\testwith 2 continuous Indication of the instantaneous weight measurement (count) and the belt length remaining forthe tester the measurement has been completed msg. 46 vile aisolayed. Ms. 46 ‘The average loading represented by the Test Weight will be Aisplayed together withthe ert J from the store value and the Eauge wil now prompt Whether automatic coreecton, to the Eauge weight calloration, is requred or not. ‘Should the Span Error be found to exceed the pre-set allowable value (as defined in Recalibration Set-up ms. 253), no correction will be permitted (mses. 266 & 267). The problem must be corrected and the check repeated. I AUTOMATED TESTING isnot invoked ft wil esult in msg, 45 being displayed. Ms. 45 Ensufe te Get is running empty end clean. Place the Test Weight inte Spon postion. low sufficient time for the tvansmiter indication to Stabilse and depress ENT to start the measurement ‘The: instantaneous welght measurement (count) and the belt length remaining for the test will be displayed. After the essurement has been completed msg, 46 willbe displayed Msg. 46 ‘The average loading represented by the Test Weight will be displayed together with the error % from the stored value. This 2 powerful feature since it will display the average value of the Test Weight (in "signed" kg/m and Per cent Error referenced to the Ful Scale calloraton ofthe belt load). The transmitter may be Instructee to automatically correct the seale, welght calloration, {or any. discrepancies. in the Indication, desired (Auto Correction). Hereafter the display will revert to msg. 42 the CALIBRATION CHECKS Menu, Replace the st Weight tothe normal (Tare) positon.oe secrons © ED cal This routine is performed on a keypad intated start/stop bass Selecting "3" from the Aalbration Check Menu resus in meg. 47 being displayed. Speed Sensor Check for Zero Calibration Msg. 47 ‘The speed sensor zero signal is measured by UNIPROY while the belts stationary and display the speed as computed. Dearess the ENT key to Intate the zero speed measurement, Hereafter mse 4B is splayed Msg. 48 ‘The speed sensor zero signal is measured by UNIPRO™ while the belt is stationary unt the ENT key Is depressed once more. Ms. 49 ‘The average speed sensor zer0 signal is displayed, plus any @rror (in 9) asceciated with it.The transmitter may be instructed to automatically correct the scale, Speed Zero calibration, for any Giscrepancies in the indication, if desired (Auto. Coirection). Hereafter the display will revert to msg. 82) the CALIBRATION CHECKS Men ‘This routines performed on 2 keypad initiated start/stop bass. Selecting “8” from the Calibration Checks Menu result in msg. 50 being displayed. Msg. 50 The speed sensor'ero signal is measured by UNIPRO™ while the belt is running, empty and clean, atthe maximum speed UUNIPRO" alsplaysine speed as computed. Depress the ENT Key £0 initiste the speed measurement, while concurrently makine = physical speed measurement using 2 callorted odometer of Eirlar device. Hereafter meg. 51s displayed, Msg. 51 Tihe Speed sensor zero signal Is measured by UNIPROY while the belt. continues running atthe constant maximum speed) until the ENT key is depressed once more to complete the measurement Hereafter msg 52s displayed Msg. 52 [After the measurement UNIPRO" will display the average speed measured and computed based on the exsting calbration data and wil prompt for an input ofthe actual speed measured. Key in the actual speed as determined from the physical measurement and the error (in %) will be csplayed. The transmitter may be Instructea' to automaticaly correct the. scale, Speed Span Calibration, for any discrepancies inthe indication, f desired (Auto Correction). Hereafter the sisplay will revert to msg. 42, the CALIBRATION CHECKS Menu, Speed Sensor Check fr Span Calibration Note: Since actuo belt speed varies with time it is essential thatthe manual measurement >be made simultaneously with the meosurement by UNIPRO" zo ato eliminate any possible source of error inthis regard. Also its important to ensure that the device ‘used to perform a speed calibration 's accurate and traceable to some calibration stondard,catbeston Chace secrons © ED This extremely useful faclity Is avallable to assst with the weight sensor span calbraton, using the bulk (material test method. Bulk (Material) Test (message 53 through $7) ‘The gauge will prompt for a weight sensor Tare Check/adjustment and belt Speed (zero and span) check/adjustment prior to any bulk test, since any error found from the bulk test will be treated as a weight Sensor span calibration error only. leis possible to select whether the material used forthe test, sto be added to the normal (operating) totaliser or not. Ie Is also possible to configure UNIPRO” to always make measurements over a éoflete evolution of the belt. Since the Tore is determined over an exact numberof belt revolutions, theoretically the Span should be checked over this same length. When enabled, 'UNIPRO™ wil ingieste the bel length stil o be travelled before the completion of a bulk ‘test (the totaliser wil continue to operate unt the belt has completée a whole number of revolutions). “After the bulk tests complete itis possible to correct the Weight Sensor Span calibration Using option 6 (2 Calibration Corrections). \Note:-In the event that the scole is operated with Moiiture Correction invoked, this ‘Moistire Correction function wil be automatiallp disobled during the performance of bulk test Le, moisture correction wil be tuned off!catbeston Chace secrons © ED Note: should the door interlock be installed (Assize Applications) no Weight Span Colibotions ore permitted. LUNIP2OY will prompt for two figures viz. Those “indicated” andjor measured by UNIPRO” fd the “octue mass as determined from a weigh bridge or similar high accuracy cheeks weigh system (which has, in turn, had its ealbration verified no later than 2 months previously), It the belt seale was tested by a bulk material test (menu 5) immetiately prior to this cotrection, the figure as totalled during the test, wil be recalled for convenience (Will not be necessary to key these Figures in again). Should this nat be the case, sim Kevin the sppliable figures. |All that remains is to keyn the Actual Mass and to request the geuge to apply Me necessary calibration corrections to remove any error. Alternatively production and figures from the scale may be keyed in to provide a calibration correction. The transmitter wl also automaticaly adjust the Test (Reference) Weight, as used in the Welght sensor RE-CALIBRATION SET-UP, for any Weight Sensor Span correction applied "Note: The automatic calibration correction is an approximation that iscorect providing the belt scole “As Found Tare Error” zero. If his tare eror isnot zero an errr in the ‘pplication ofthe calbation correction wil eur. This Is de to the nature of the ‘mathematics involved but may be ignared for zero offsets tare errors) less than 5 % ‘Should there be doubt as tothe situation on hand this may be resolved by performing {2 Weight Sensor Zero Calibration under the “Scole Set up Menu". Ths will efectivey ‘reset the tore error to zero, thereby removing any possible problems inthis rege Weight Sensor Calibration Corrections (message 58 & 59) ‘As-Found-Error (AFE) ‘The As-Found-Errar calibration check provides @ means to determine the error inthe scale prior to maldng any adjustment. UNIPROY not only provides for the automatic determination ofthe overall “As-Foune-rror”, but also allows the further determination of what the components ofthis "As-Found-Error” are viz: Mass Zero, Mass Span, Speed aero and Speed Span, NOTE: FOR ISO 9000/1400 AND ON HIGH ACCURACY INSTALLATIONS, A LOG BOOK IS, MANDATORY,Sele og took secrono ©@D Typical Conveyor Scale Log Book CcoNveYoR NO . FULL SCALE CAPACITY RATE ‘TEST WEIGHT (kg/m) = FULLSCALE CAPACITY (kg/m) CALIBRATION CHECK TIME = FULL SCALE SPEED (myn = (CALIBRATION LENGTH (m) Date | allowable | As | speed | speed | speed | speec | toad-| toad zero | toad | LoadSpan | Remarks trror(%) | Found | zero | zero | span | span | zero (lJeorrection | span | correction Error | Error | correction | Error | correction |“Errar’| pertorme | Error | performed 0) | G9 | performe | (5) | pertormes| (%) | a(WNor | Gx | (Y/Nor d(yNor aqviner value) value) value) value) ‘eats pr ar 0 Conor Se 2 Peer SSJon Apestion Oats secon ©BD cal Calibration & Application Data The proper operation of the scale Is dependent on the configuration and other data 25. determined during the deslgn/set-up/caibration ofthe scale. Ths information is stored In the UNIPRO” tranemittr for reference. This information includes all the necessary specications of the actual hardware supplied and will asistn the definition ef any spare parts that may need ordering, Should a measuring transmitter fall itis possible to install a spare unit and using the calibration data (al constants, the syste may be brought into operation speedy without ‘the need to re-callsrate the gauge orto perform lengthy set-up pracecure, Thins achieved by inputting tis data into the replacement electronics. Cal constants may only Ba viewed when the door interlock input is ative, Message $0 allows access to the following sub Viewing Of Calibration Constants ‘This selection will alow the viewing of all the Calibration Constant. Keys F3 and Fallow cone to scroll forwards and backwards thraugh thecalibration data list. Entry (Manual) Of Calibration Constants This selection allows the onerator 10 enter one or ll of the constants manually. Keys F3 and F4 allow one to scroll fornards and backwards through the calibration data. The DEL / ENT keys have the function of moving the cutsor left of right, while the FL and F2 key wil ero the variable identfed by the cursor. The "Tag number’, which is a 24 alpha-numeric character sting Used to uniquely identify the gauge, may be edited in this programme menu. The TAG wile reflected on the UNILOG® callration data printout. Backup Calibration Constants ‘This selection allows the operator to backup the Calibration Constants after completion of ‘the gauge set-up or ater any change to the caloration of the gauge. The three most recent sets of backed up Calibration Constants are stored and each set of data is identified by time and date of storage. After the store procedure has been completed the gauge will verity the Information stored and advise if the store procedure was succesfulcateron &Aspeaton Oat secon ©BD Recall Of Backed Up Cal Constants This selection allows the operator the opportunity to select by time/date any one of the three most recent previously backed up calibrations (msg, 92). This is handy for situations ‘when 2 calibration may have been incorrectly applied (er totally messed up) and subsequent backed up. By providing a history of three calibrations it should always be possible to recall an older calibration which although not completely correct may be much more acceptable than the situation the gauge i currenty in, Reports Of Cal/Application Data Its possible to obtain a copy of the certain data as recorded withthe gage using the Prut prut Operation is identical tothe above, except that the PTU! requliés Connection to UNIPRO"™ Using the RI connector. The information is stored in nonaVoatle memory of the PTU' and may be uploaded into a PC for recording and printout. ‘The items that may be printed / recorded include: Calibration Constants The calbration data printout provides a hard copy of all the parameters required to properly setup the gauge. This data may be flled with the Scale Log for use as an aid for maintenance or to comply withthe requirements of 150 9000/2, which requires certificates calibration, ‘Application Data ‘The technical specification and Serial Numbers ofall the equipment as originally shipped, together withthe Application Detolls ‘Should there be a need to order spare parts or should there be 2 need to alter the application/ calibration, 2 copy of ths print out should be faxed to the factory This will ensure compatibility of spares and make the verification of range/appliction changes sreatly simplifiedcateron &Aspeaton Oat secon ©BD Allocated 1/0 (Expansion 1/0 Bus) This printout provides a recor the YO as allocated forthe application, All the slot numbers available are printed together with the allocated /O - using the VO descriptor asin /0 allocation Set-Up. Map Of Allocated 1/0 (Expansion 1/0 Bus) Selecting "4" results in the display of mse. 127 indicating "Busy Printing” and printing ofthe 4etals ofthe connections to the expanded I/O. Ths printout defines how the UNIPRO has been configure - which physical input or Output is connected to which Input or Output on LUNIPROY. The transmitter has a maximum of 32 slots available (H0:to #31), Each carrer board has provision for 4 slots, These slots are slays numbered 2 to 4. The absolute (computer identified} slot numbers are offset by the carrier Board address. Eg. Carrer board with address “0” will contain absolute slot Ws 1 through eatrer board with address "1" will contain absolute slot Hs 5 trough 8, carter board with adcress “A” vl contain absolute slot #5 17 through 20 etc. Printed behind the absolute slat number will be the LUNIPaO variable assigned to that particular output: Nate: While it may be prudent to have any carrier boards instolied set 0 as to have their addresses stort from 0", ths is not essentiaload ties secnonn © BD Belt Load Statistics General ‘Selecting option {6=) STATISTICS from the main menu (access code not required) wll result in the Statistics menu (msg. 280) being presented. The STATISTICS menu offers the feliowing options:- el Loading, 2 = Print Staite eset Statistics. (Access Code Required) Note: msg. 280 is subject ta a time-out af 20 seconds. fan option is not selected during this period the display will automatically revert tothe previous cep}. Note: Function keys "F3" and "Fa have the following meaning throughout the Sttistles programme: F3 will take one to the message previous to the ane currently being lisplayed; Fa will take one tothe next message to the one being displayed,