Siemens milltronics BW500 Instruction Manual
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Siemens milltronics BW500 Instruction Manual

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Instruction Manual May 2008
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BW500

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  • Page 1 Instruction Manual May 2008 milltronics BW500...
  • Page 2 The user is responsible for all changes and repairs made to the device by the user or the user’s agent. • All new components are to be provided by Siemens Milltronics Process Instruments Inc. • Restrict repair to faulty components only.

  • Page 3: Table Of Contents

    Table of Contents Milltronics BW500 ......................1 Milltronics BW500 features ......................1 Safety Notes .............................2 The Manual ...............................2 Specifications ........................3 Installation ........................... 6 Dimensions ...............................6 Layout ................................7 Optional Plug-ins .............................8 SmartLinx® Module ........................8 mA I/O board ...........................8 Interconnection .............................10 System Diagram .........................10 Scale –...
  • Page 4 Programming ..........................25 Load Cell Balancing ..........................28 Typical two load cell belt scale ....................29 Zero Calibration ...........................32 RUN Mode ............................33 Recalibration ........................34 Belt Speed Compensation ........................34 Material Tests ............................35 % Change ............................35 Material Test ..........................37 Design Changes .............................37 Recalibration ............................38 Routine Zero ..........................38 Initial Zero .............................39 Direct Zero ............................39 Auto Zero ............................40...
  • Page 5 Initial Start-Up ..........................67 Programming ............................70 Batching ..........................73 Connections ............................73 Typical Ladder Logic ........................73 Programming ............................74 Operation ..............................75 Pre-act Function ..........................75 Communications .......................76 BW500 and SmartLinx® ........................77 Connection ..............................77 Wiring Guidelines ........................77 Configuring Communication Ports ....................78 P770 Serial protocols ........................78 P771 Protocol address ........................79 P772 Baud Rate ..........................79 P773 Parity .............................79 P774 Data bits ..........................80...
  • Page 6 Troubleshooting ....................... 133 Generally ............................133 Specifically ..........................133 Certification ........................136 Certification Printing .........................136 Glossary ..........................137 Appendix I ........................140 Memory Backup ..........................140 Software Updates ..........................140 Calibration Criteria ..........................140 Zero ...............................140 Span ..............................140 PID Systems ..........................140 Appendix II: Software Revision History ..............141 Index ..........................

  • Page 7: Milltronics Bw500

    Milltronics BW500 Note: • The Milltronics BW500 is to be used only in the manner outlined in this instruction manual. • This product is intended for use in industrial areas. Operation of this equipment in a residential area may cause interference to several frequency based communications.

  • Page 8: Safety Notes

    If you have any questions, comments, or suggestions about the manual contents, please email us at techpubs.smpi@siemens.com. For the complete library of Siemens manuals, go to www.siemens.com/processautomation. Page 2 Milltronics BW500 – INSTRUCTION MANUAL...

  • Page 9: Specifications

    • fuse, FU1 2AG, Slo Blo, 2 A, 250 V or equivalent Application • compatible with Siemens belt scales or equivalent 1, 2 or 4 load cell scales • compatible with LVDT equipped scales, with use of optional interface board Accuracy •...
  • Page 10 Belden 9260, 6 wire shielded, 20 AWG or equivalent, 300 m (1000 ft.) max • two / four* load cells: non-sensing: Belden 9260, 6 wire shielded, 20 AWG or equivalent, 150 m (500 ft.) max Page 4 Milltronics BW500 - INSTRUCTION MANUAL 7ML19985DK03...
  • Page 11 • remote total: Belden 8760, 1 pair, twisted/shielded, 18 AWG, 300 m (1000 ft.) max Options • Speed Sensor: Siemens MD-36 / 36A / 256 or 2000A, or RBSS, or compatible ® • Dolphin Plus: Siemens Windows based software interface (refer to associated product documentation) ®...

  • Page 12: Installation

    (4 places) customer glands to maintain ingress rating. mounting screw Non metallic enclosure does not provide grounding between connections. Note: Use grounding type bushings and jumpers. Page 6 Milltronics BW500 - INSTRUCTION MANUAL 7ML19985DK03...

  • Page 13: Layout

    • Relay contact terminals are for use with equipment having no accessible live parts and wiring having insulation suitable for at least 250 V. • The maximum allowable working voltage between adjacent relay contact shall be 250 V. 7ML19985DK03 Milltronics BW500 - INSTRUCTION MANUAL Page 7...

  • Page 14: Optional Plug-Ins

    ® SmartLinx Module The BW500 is software/hardware ready to accept the optional Siemens SmartLinx ® communications module that provides an interface to one of several popular industrial communications systems. Your BW500 may be shipped to you without a SmartLinx ® module, for installation at a later date.
  • Page 15 I/O Parameters (P200 - P220) • on page 110 mA I/O (0/4-20 mA) Operation • in the section on page 57 ® SmartLinx ® route SmartLinx cable along right hand wall mA I/O board 7ML19985DK03 Milltronics BW500 - INSTRUCTION MANUAL Page 9...

  • Page 16: Interconnection

    Siemens Milltronics Dolphin, print data, or Modbus ASCII or RTU protocol Typical system capability. Not all components or their maximum quantity may Note: be required Page 10 Milltronics BW500 - INSTRUCTION MANUAL 7ML19985DK03...

  • Page 17: Scale - One Load Cell

    BW500 terminal 12 to scale `red' BW500 terminal 13 to scale `blk' If the load cell wiring colours vary from those shown, or if extra wires are provided, consult Siemens. 7ML19985DK03 Milltronics BW500 - INSTRUCTION MANUAL Page 11...

  • Page 18: Scale - Two Load Cell

    BW500 terminal 12 to scale `red' BW500 terminal 13 to scale `blk' If the load cell wiring colours vary from those shown, or if extra wires are provided, consult Siemens. Page 12 Milltronics BW500 - INSTRUCTION MANUAL 7ML19985DK03...

  • Page 19: Scale - Four Load Cell

    BW500 terminal 12 to scale `red' BW500 terminal 13 to scale `blk' If the load cell wiring colours vary from those shown, or if extra wires are provided, consult Siemens. 7ML19985DK03 Milltronics BW500 - INSTRUCTION MANUAL Page 13...

  • Page 20: Scale - Lvdt

    BW500 terminal 11/12 and 13/14 run additional conductors from: BW500 terminal 12 to integrator terminal block ‘+EXC’ BW500 terminal 13 to integrator terminal block ‘-EXC’ For further connection information on specific LVDT’s consult Siemens. Page 14 Milltronics BW500 - INSTRUCTION MANUAL 7ML19985DK03...

  • Page 21: Speed

    Input device in the form of open collector transistor or dry contact across BW500 terminals 16 / 17 will also serve as a suitable speed signal. If a speed sensor other than the models shown is supplied, consult with Siemens for details.

  • Page 22: Auxiliary Speed Sensor

    Input device in the form of open collector transistor or dry contact across BW500 terminals 24-28 will also serve as a suitable speed signal. If a speed sensor other than the models shown is supplied, consult with Siemens for details.

  • Page 23: Auxiliary Inputs

    P270 Refer to on page 112 for programming details. Auto Zero Prefeed activated dry contact Auto Zero Refer to on page 40. RS-232 Port 1 Printers Printer receive common 7ML19985DK03 Milltronics BW500 - INSTRUCTION MANUAL Page 17...

  • Page 24: Computers And Modems

    For connection to a PC compatible computer or modem, using no flow control, typical configurations are: DB-9 DB-25 Remote Totalizer supply, 30V max remote totalizer 1 supply, 240V max remote totalizer 2 mA Output 1 to customer instrumentation, isolated mA output, 750 Ω maximum load Page 18 Milltronics BW500 - INSTRUCTION MANUAL 7ML19985DK03...

  • Page 25: Relay Output

    Relay Output Relays shown in de-energized state, contacts normally open, rated 5 A at 250 V non- inductive. RS-485 Port 2 Daisy Chain customer device Terminal Device customer device 7ML19985DK03 Milltronics BW500 - INSTRUCTION MANUAL Page 19...

  • Page 26: Port 3

    100 / 115 / 200 / 230V 50 / 60 Hz select voltage via switch Page 20 Milltronics BW500 - INSTRUCTION MANUAL 7ML19985DK03...

  • Page 27: Ma I/O Board

    Disconnect power before installing or replacing the battery. Installation Steps Open the enclosure lid. Slide the battery into the holder. Be sure to align the + and – terminals correctly. Close and secure enclosure lid. 7ML19985DK03 Milltronics BW500 - INSTRUCTION MANUAL Page 21...

  • Page 28: Start Up

    PID auto/manual switch Print Press to initiate calibration ZERO SPAN Press to enter PROGRAM mode Press to scroll through RUN displays RESET CLEAR ENTER DISP TOTAL Press to reset totalizer Page 22 Milltronics BW500 - INSTRUCTION MANUAL 7ML19985DK03...

  • Page 29: Program Mode

    Press to move up, e.g. scrolls up from P001 to P002. P002 Test Reference Selection 1-Weight, 2-Chain, 3-Ecal Press to move down. e.g. scrolls up from P001 to P002 P001 Language 1-Eng 7ML19985DK03 Milltronics BW500 - INSTRUCTION MANUAL Page 23...
  • Page 30 P011 Design Rate: Enter Rate 100.00 kg/h Press Enter the clear function Value is reset to factory value. P011 Design Rate: e.g. 0.00 kg/h Enter Rate 0.00 kg/h Page 24 Milltronics BW500 - INSTRUCTION MANUAL 7ML19985DK03...

  • Page 31: Run Mode

    Accept ’weight’ (supplied with Select 1-Weight, 2-Chain, 3-Ecal scale) as the test reference.e.g. Press P003 Number of Load Cells e.g. Accept ’2’ as the number of load Enter Number of Load Cells cells. 7ML19985DK03 Milltronics BW500 - INSTRUCTION MANUAL Page 25...
  • Page 32 P011 Design Rate: factory design rate Enter Rate 0.00 t/h Press P011 Design Rate: Enter Rate 0.00 t/h Press e.g. rate of 100 t/h P014 Design Speed factory design speed Enter Speed 0.00 m/s Page 26 Milltronics BW500 - INSTRUCTION MANUAL 7ML19985DK03...
  • Page 33 This value is calculated. For manual or automatic calculation, refer to on page 126. To program Differential Speed (P015-02), follow steps above for P015-01. P016 Belt Length factory set length Enter Length 0.000 m Press P016 Belt Length Enter Length 0.000 m 7ML19985DK03 Milltronics BW500 - INSTRUCTION MANUAL Page 27...

  • Page 34: Load Cell Balancing

    This value is calculated based on test weight and idler spacing. For manual or automatic P017 calculation, refer to on page 105. The test load value should be less than the design load (P952). If not, contact Siemens. P017 Test Load: Weight MS 1 e.g. test load of 25 kg/m Enter test load 25.00 kg/m...

  • Page 35: Typical Two Load Cell Belt Scale

    P295 Load Cell Balancing: load cells is 4 Select: 1-A&B, 2-C&D Press Load Cell Balancing A & B Place weight at cell B and press ENTER ’B’ ’ A ’ test weight 7ML19985DK03 Milltronics BW500 - INSTRUCTION MANUAL Page 29...
  • Page 36 P295 Load Cell Balancing: Select: 1-A&B, 2-C&D Press P295 Load Cell Balancing: Select: 1-A&B, 2-C&D Press Load Cell Balancing C & D Place weight at cell D and press ENTER. Page 30 Milltronics BW500 - INSTRUCTION MANUAL 7ML19985DK03...
  • Page 37 Load Cell Balancing C & D subsequent zero and span recalibration Load cells are now balanced. Balancing of the load cells is now complete, and is followed by a zero and span calibration. 7ML19985DK03 Milltronics BW500 - INSTRUCTION MANUAL Page 31...

  • Page 38: Zero Calibration

    With the conveyor stopped and locked out, apply the test weight or chain to the scale as instructed in the associate manuals; Then start the conveyor. Press the current span count Span Calibration. Current Span Setup test. Press ENTER to Start Page 32 Milltronics BW500 - INSTRUCTION MANUAL 7ML19985DK03...

  • Page 39: Run Mode

    Where inaccuracies exist, correct the system through a manual span adjustment (P019). Perform recalibration of the zero and span routinley to maintain accurate reporting of rate Recalibration and total.. Refer to , page 34. 7ML19985DK03 Milltronics BW500 - INSTRUCTION MANUAL Page 33...

  • Page 40: Recalibration

    P015 Pulses/m 97.5169 P014 Design Speed for constant speed (jumper), adjusts P014 Enter Speed 0.63 m/s The displayed speed (used in the rate computation) now equals the actual speed. Page 34 Milltronics BW500 – INSTRUCTION MANUAL 7ML19985DK03...

  • Page 41: Material Tests

    If the span adjust value is not acceptable, repeat the material test to verify repeatability. If the result of the second material test differs considerably, consult Siemens or their agent. If the span adjust values are significant and repeatable, perform a manual span adjust.
  • Page 42 0.00 Press if % change is negative, remember to enter the minus sign, e.g. -1.3 P017 Test Load Weight: MS1 e.g. the new test load value is displayed Enter Test Load 56.78 Page 36 Milltronics BW500 – INSTRUCTION MANUAL 7ML19985DK03...

  • Page 43: Material Test

    Where parameters have been changed with a resultant impact on the calibration, they do not take effect until a recalibration is done. If significant changes have been made, an initial zero (P377) and/or initial span (P388) may be required (see page 117). 7ML19985DK03 Milltronics BW500 – INSTRUCTION MANUAL Page 37...

  • Page 44: Recalibration

    Further deviation limits are now based on this new initial zero. Press e.g. zero calibration is accepted and Zero Calibration. Current Zero 551418 displayed as the current zero Clear belt. Press ENTER to start Page 38 Milltronics BW500 – INSTRUCTION MANUAL 7ML19985DK03...

  • Page 45: Initial Zero

    Use direct zero entry (P367) when replacing software or hardware, if it is not convenient to perform an initial zero. A record of the last valid zero count is required. Access P367 and enter EDIT mode P367 Direct Zero Entry Enter Zero Count 7ML19985DK03 Milltronics BW500 – INSTRUCTION MANUAL Page 39...

  • Page 46: Auto Zero

    Auto Zero conditions are being met. If material feed resumes during an auto zero function, the totalizing function is maintained. Page 40 Milltronics BW500 – INSTRUCTION MANUAL 7ML19985DK03...

  • Page 47: Routine Span

    Find and rectify the cause of the increased or decreased deviation. Then re-try a span recalibration. If this deviation is still unacceptable, set P388 to 1 to invoke an initial span calibration. Further deviation limits are now based on this new initial span. 7ML19985DK03 Milltronics BW500 – INSTRUCTION MANUAL Page 41...

  • Page 48: Initial Span

    Press e.g. the current span count Span Calibration. Current Span 41900 Setup test. Press ENTER to start End of span calibration. Remove the test weight and return to RUN. Note: Page 42 Milltronics BW500 – INSTRUCTION MANUAL 7ML19985DK03...

  • Page 49: Direct Span

    P365, or by external contacts connected to the Auxiliary input, and programmed via P270. To enable multispan operation, the following must be addressed. • connections • programming • calibration • operation 7ML19985DK03 Milltronics BW500 – INSTRUCTION MANUAL Page 43...
  • Page 50 To use remote span selection, auxilliary Inputs, 1 and/or 2 or 3, are programmed to read the contact state as the span selection. Remote selection overrides the keypad (or Dolphin Plus) selection. The auxilliary inputs override the keypad selection. Page 44 Milltronics BW500 – INSTRUCTION MANUAL 7ML19985DK03...
  • Page 51 When the material to be run on the belt changes, the multispan is changed to the corresponding span. This is completed either by changing the span value entered in P365, or by closing the appropriate contacts connected to the programmed Auxiliary inputs. 7ML19985DK03 Milltronics BW500 – INSTRUCTION MANUAL Page 45...

  • Page 52: On-Line Calibration

    Connect the weigh bin to one of the mA High (e.g. 70%) inputs on the optional mA I/O board of the Milltronics BW500: either mA input 1, reference weight: terminals 5 and 6; or mA input 2, terminals 10 t...
  • Page 53 P261-01 or –02. 20 mA is calibrated with the weigh bin full, using P262-01 and P262-02. Assign one of the mA inputs for the On-line Calibration function. 7ML19985DK03 Milltronics BW500 – INSTRUCTION MANUAL Page 47...
  • Page 54 TOTAL 3.71 tonnes Calibration in progress RLY 1 When the Low limit (30%) is reached, the totalizer is deactivated and the assigned relay is de-energized, which reopens the material feed to the weigh bin. Page 48 Milltronics BW500 – INSTRUCTION MANUAL 7ML19985DK03...
  • Page 55 If you want to reject the results and perform another on-line calibration, press return to P358. Access P358 On-line Calibration Features 0-OFF, 1-ACTIVE Press If the deviation is greater than ± 12%: Calibration is out of range Deviation Error: 7ML19985DK03 Milltronics BW500 – INSTRUCTION MANUAL Page 49...

  • Page 56: Factoring

    P017 Test Load Weight: factoring is complete. Return to Enter Test Load 45.25 RUN mode if so desired If multispan function is used, the test load value is stored for the current Note: multispan only. Page 50 Milltronics BW500 – INSTRUCTION MANUAL 7ML19985DK03...

  • Page 57: Linearization

    • If additional compensation is required, it must be based on new material tests performed with the linearization turned off (P390 = 0). 7ML19985DK03 Milltronics BW500 – INSTRUCTION MANUAL Page 51...
  • Page 58 BW500 ♦ belt scale response ♦ -5.1 linearized BW500 response internal response 100% - 150% of span ♦ 11.1 % compensation ♦ span (100%) -10.7 Load - kg/m Page 52 Milltronics BW500 – INSTRUCTION MANUAL 7ML19985DK03...
  • Page 59 BW500 belt scale response linearized BW500 response internal response 100% - 150% of span % compensation span (100%) ♦ -10.7 Load - kg/m For Parameter reference, go to Parameters on page 102. 7ML19985DK03 Milltronics BW500 – INSTRUCTION MANUAL Page 53...

  • Page 60: Operation

    (tail pulley). The second speed sensor is generally reserved for the driving device (head pulley), and is used for comparison to the primary speed sensor, for differential speed detection only. Page 54 Milltronics BW500 - INSTRUCTION MANUAL 7ML19985DK03...

  • Page 61: Moisture Compensation

    Observe moisture percentage using P398-01. Incline Compensation Incline compensation is used to compensate for the varying vertical force component applied to the belt scale due to varying inclination of the conveyor. The BW500 receives 7ML19985DK03 Milltronics BW500 - INSTRUCTION MANUAL Page 55...

  • Page 62: Modes Of Operation

    If the PROGRAM mode is left idle for a period of ten minutes, it automatically reverts to RUN mode. Zero and span calibrations effectively halt the RUN mode while they are in progress. During this time, totalization ceases, and all mA outputs, except for PID, fall to zero. Page 56 Milltronics BW500 - INSTRUCTION MANUAL 7ML19985DK03...

  • Page 63: Damping

    PID setpoint. The 4 and 20 mA levels can be trimmed (P261 and P262) to agree with an external device. The external device could be a moisture sensor, or an inclinometer. 7ML19985DK03 Milltronics BW500 - INSTRUCTION MANUAL Page 57...

  • Page 64: Relay Output

    P101 = 100% (2 m/s) P102 = 20% (0.4 m/s) P117 = 2% (0.04 m/s) high 100% 2 m/s actual low alarm ’off’ = 22% ’on’ = 20% 0.4 m/s alarm ‘on’ is with relay de-energized Page 58 Milltronics BW500 - INSTRUCTION MANUAL 7ML19985DK03...

  • Page 65: Totalization

    The value can be changed to suit specific contact closure requirements, such as in the case of programmable logic controllers. If the duration selected is inappropriate, the next possible duration is automatically entered. 7ML19985DK03 Milltronics BW500 - INSTRUCTION MANUAL Page 59...
  • Page 66 RUN mode resets internal totalizer 1 Placing the internal totalizers on to the display scroll of the RUN mode is controlled by the totalizer display parameter (P647); displaying either one or both totalizers. Page 60 Milltronics BW500 - INSTRUCTION MANUAL 7ML19985DK03...

  • Page 67: Pid Control

    – external process variable with or without rate and load control terminals terminal PID loop mA output mA input (mA I/O) (mA I/O) 1 & 2 5 & 6 3 & 4 7 & 8 7ML19985DK03 Milltronics BW500 - INSTRUCTION MANUAL Page 61...

  • Page 68: Setpoint Controller - Rate Control

    (P201-02 = 4) optoinal remote speed setpoint - rate (P255-01 = 1) ZE R O SPAN PID 1 process value source - load RESET CLEAR ENTE R DISP TOTAL (P402-01 = 2) Page 62 Milltronics BW500 - INSTRUCTION MANUAL 7ML19985DK03...

  • Page 69: Setpoint Controller - Master/Slave Control

    R E SE T C LE A R E N T E R D IS P T O TA L (P402-01 = 1) (P255 - 01 = 1) *P201-03 = 1 also applicable 7ML19985DK03 Milltronics BW500 - INSTRUCTION MANUAL Page 63...

  • Page 70: Setpoint Controller - Rate And Load Control

    If set too high, the BW500 becomes less stable, and more susceptible to oscillations in the control output. • allowable input range: 0.000 to 2.000 • typical operating range: 0.300 to 0.600 • default value: 0.400 Page 64 Milltronics BW500 - INSTRUCTION MANUAL 7ML19985DK03...

  • Page 71: Integral Control (Automatic Reset), I

    I terms. Unfortunately, larger terms can make the system unstable. A derivative term is needed to influence the control output as the process variable approaches the set point. 7ML19985DK03 Milltronics BW500 - INSTRUCTION MANUAL Page 65...

  • Page 72: Derivative Control (Pre-Act Or Rate), D

    I and terms alone. This is done on a one time basis. • allowable input range: 0.000 to 1.000 • typical operating range: 0.250 to 0.550 • default value: 0.300 Page 66 Milltronics BW500 - INSTRUCTION MANUAL 7ML19985DK03...

  • Page 73: Pid Setup And Tuning

    P term value if there is too much oscillation and error. Likewise, increase the value if the error is not consistent and oscillating around the setpoint. Refer to fig 1, 2, & 3 below. Figure 1 P term is too high SETPOINT 7ML19985DK03 Milltronics BW500 - INSTRUCTION MANUAL Page 67...
  • Page 74 Restart the feeder (test weights or chains still applied) and feed rate setpoint entered. Again observe the oscillation of the control output. Compare results to the figures 4,5 and 6 below. Figure 4 SETPOINT I term is too high Page 68 Milltronics BW500 - INSTRUCTION MANUAL 7ML19985DK03...
  • Page 75 10. The above closed loop cycling procedure allows ease in start up, but final adjustments may be necessary in actual process operation. 7ML19985DK03 Milltronics BW500 - INSTRUCTION MANUAL Page 69...

  • Page 76: Programming

    5 and 6 on the mA I/O board. • mA input 2 is an external signal normally reserved for controller 2. The signal is input at terminals 7 and 8 on the mA I/O board. Page 70 Milltronics BW500 - INSTRUCTION MANUAL 7ML19985DK03...
  • Page 77 Input 2: the setpoint is the mA value on input 2, terminals 7 and 8 on the mA I/O board. Enter the setpoint value in engineering P415-01 Local Setpoint Value units. Enter Setpoint Not applicable if P414 = 1 7ML19985DK03 Milltronics BW500 - INSTRUCTION MANUAL Page 71...
  • Page 78 2, process variable as the Select 0, 1-PID SP, 2-PID PV function of the mA input The PID setpoint can be modified while in RUN mode using the up/down Note: arrow keys. Page 72 Milltronics BW500 - INSTRUCTION MANUAL 7ML19985DK03...

  • Page 79: Batching

    ♦ alarm function. RU N ZERO SPAN Typical auxiliary input assignment. RESE T CLEA R ENT ER ♦ DI SP TOT AL Inputs 1- 5 are available for batch reset. 7ML19985DK03 Milltronics BW500 - INSTRUCTION MANUAL Page 73...

  • Page 80: Programming

    P567, batch pre-warn setpoint Access P568 Batch Pre-act Set to OFF (0) or AUTO (1) or manual (2) Relays Select relay (1 – 5) Access P100, Relay Function Select function 7, Pre-Warn Page 74 Milltronics BW500 - INSTRUCTION MANUAL 7ML19985DK03...

  • Page 81: Operation

    If repetitive batches are being run, the pre-act function (P568) can be enabled to automatically trip the setpoint relay before or after the batch setpoint is reached to assure best batch accuracy. 7ML19985DK03 Milltronics BW500 - INSTRUCTION MANUAL Page 75...

  • Page 82: Communications

    The BW500 supports two protocols: Dolphin and Modbus. Dolphin is a proprietary Siemens Milltronics protocol designed to be used with Dolphin Plus. Modbus is an industry standard protocol used by popular SCADA and HMI systems. Page 76 Milltronics BW500 –...

  • Page 83: Bw500 And Smartlinx

    BW500 and SmartLinx In addition to three onboard communication ports, the BW500 is compatible with Siemens’ SmartLinx ® communication modules which provide an interface to popular industrial communication systems. This section only describes the onboard communications. For more information on SmartLinx ®...

  • Page 84: Configuring Communication Ports

    The Siemens Milltronics protocol is compatible with the Dolphin Plus configuration program. See the Siemens web site for information on this PC product (http://www.siemens.com/processautomation). The Modbus protocol is an open standard developed by AEG Schneider Automation Inc.

  • Page 85: P771 Protocol Address

    The unique identifier of the BW500 on the network for the selected port, ports 1 to 3 (P771-01 to -03). For devices connected with the Siemens Milltronics protocol this parameter is ignored. For devices connected with a serial Modbus protocol this parameter is a number from 1- 247.

  • Page 86: P774 Data Bits

    P772 value. For troubleshooting purposes the baud rate on the modem can be hard-coded to the rate set on the BW500. See your modem documentation for information on fixing the baud rate. Values *no modem connected modem connected Page 80 Milltronics BW500 – INSTRUCTION MANUAL 7ML19985DK03...

  • Page 87: P779 Modem Idle Time

    Applicable only to ports programmed for printer communication Note: (parameter 770). Sets the interval between transmissions to be applied to the selected port, ports 1 to 3 (P780-01 to –03). Enter the period in minutes. ( = 0) 7ML19985DK03 Milltronics BW500 – INSTRUCTION MANUAL Page 81...

  • Page 88: P781 Data Message

    ® be continuously updated. Therefore, if you connect a SmartLinx card to the BW500, set P799 = 1 and not write anything to the ® SmarLinx card, your setpoints will be 0. Page 82 Milltronics BW500 – INSTRUCTION MANUAL 7ML19985DK03...

  • Page 89: Dolphin Protocol

    The protocol is available on all communications ports on all units. This protocol is not available for third party use. The primary use of this protocol is to connect the BW500 to Siemens Milltronics’ Dolphin Plus configuration software. Dolphin Plus Screen Shot...

  • Page 90: Modbus Rtu/Ascii Protocol

    At the time of publication of this manual, the Modbus Protocol was located under products / technical publications / communications products / Modbus protocol. Siemens does not own the Modbus RTU protocol. All information regarding Note: that protocol is subject to change without notice.

  • Page 91: Modbus Rtu Vs. Ascii

    The memory map of the BW500 occupies the Modbus holding registers (R40,001 and up). The BW500 was designed to make it easy for users to get useful information via Modbus. The following chart gives an overview of the different sections. 7ML19985DK03 Milltronics BW500 – INSTRUCTION MANUAL Page 85...
  • Page 92 Parameter Values Parameter Values: Refer to , page 96. Read: Identifies the read / write capability for the register being addressed. Reference: Provides reference documentation for the register being addressed. Page 86 Milltronics BW500 – INSTRUCTION MANUAL 7ML19985DK03...
  • Page 93 41,070 bit mapped Relay Outputs 41,080 bit mapped see page 95 mA Inputs 41,090 0000 - 20,000 mA Outputs 41,110 0000 - 20,000 Diagnostic Diagnostic State 41,200 number code see page 133 7ML19985DK03 Milltronics BW500 – INSTRUCTION MANUAL Page 87...

  • Page 94: Modbus Register Map (Cont' D )

    For more information on this data format see page 96 Device Identifier (R40,064) This value identifies the Siemens Milltronics device type and is “2” for the BW500. Handshaking Area (Parameter Access) Built into BW500 is an advanced handshaking area that can be used to read and write 32 bit parameters.
  • Page 95 Send the parameter, its primary index, and its secondary index (usually 0) to registers 40,090, 40,091, and 40,092. Write the value to registers 40,096 and 40,097 Write the desired format word to register 40.093 to enable the BW500 to interpret the value correctly. 7ML19985DK03 Milltronics BW500 – INSTRUCTION MANUAL Page 89...
  • Page 96 For example, if the decimal offset (value of bits 9 to 11) is ‘2’ and the shift (value of bit 12 is ‘0’), then the decimal point is shifted two places to the right. Page 90 Milltronics BW500 – INSTRUCTION MANUAL 7ML19985DK03...
  • Page 97 February 14, 1999, 1:30 p.m. and 42 seconds, you would write the following: Bits Values R41,000 1999 R41,001 R41,002 R41,003 R41,004 R41,005 R41,006 The time zone register is used only as a reference and does not affect the Note: operation of the BW500. 7ML19985DK03 Milltronics BW500 – INSTRUCTION MANUAL Page 91...
  • Page 98 Manual Auto PID 2 Freeze PID 2 Setpoint Source Local Remote Zero In progress Span In progress Write Privileges System Configured Not Configured Mode Calibration Mode RUN Mode Totalizing Not Totalizing Totalizing Page 92 Milltronics BW500 – INSTRUCTION MANUAL 7ML19985DK03...
  • Page 99 No change Reset Reset Totalizer 2 No change Reset Reset Batch Totalizer No change Reset Print Print WARNING: Before the BW500 can be commanded remotely, parameter P799 must be set for remote control. 7ML19985DK03 Milltronics BW500 – INSTRUCTION MANUAL Page 93...
  • Page 100 If three decimal places are being read in Total 1: Bits If three decimal places are being read in Total 1, and the value is too large to be read with three decimal places: Bits Page 94 Milltronics BW500 – INSTRUCTION MANUAL 7ML19985DK03...
  • Page 101 4,000 to 20,000. If the 4 or 20 mA values have been trimmed, then the register value is adjusted accordingly; e.g. an I/O value of 22 mA would be registered as 22,000. Diagnostic (R41,200) Troubleshooting Refer to on page 133. 7ML19985DK03 Milltronics BW500 – INSTRUCTION MANUAL Page 95...
  • Page 102 The whole is read as a 32-bit integer. The most significant byte (MSB) and least significant byte (LSB) can be reversed to accommodate some Modbus drivers. See Format Word for BW500 on page 88 for details. Page 96 Milltronics BW500 – INSTRUCTION MANUAL 7ML19985DK03...
  • Page 103 Text Messages If a Siemens Milltronics device parameter returns a text message, that message is converted to a number and provided in the register. The numbers are shown in the table below: Number Text Message as Displayed on LCD 22222...

  • Page 104: Modems

    RS-232 port on the modem and send special commands. The most popular command set is called the AT, or Hayse, command set. Your modem manual should give details on how to configure it. Page 98 Milltronics BW500 – INSTRUCTION MANUAL 7ML19985DK03...
  • Page 105 P778, port 1, to the value 1 (Communications through Modem) • set P779, port 1, to the value 300 (Modem Inactivity of 300 seconds) Parameters are defined the in the Installation section (page 6). Note: 7ML19985DK03 Milltronics BW500 – INSTRUCTION MANUAL Page 99...

  • Page 106: Error Handling

    The slave is processing a long-duration program com- Slave Device Busy mand. The slave attempted to read extended memory, but Memory Parity Error detected a parity error in the memory. Service may be required on the slave. Page 100 Milltronics BW500 – INSTRUCTION MANUAL 7ML19985DK03...
  • Page 107 If the user attempts to write one or more registers that are out of range, an exception response code 2 will be generated. • If using an unsupported function code, undocumented results may occur. The user is encouraged not to do this. 7ML19985DK03 Milltronics BW500 – INSTRUCTION MANUAL Page 101...

  • Page 108: Parameters

    Entry: 1 = weight 2 = chain 3 = ECal Page 102 Milltronics BW500 - INSTRUCTION MANUAL 7ML19985DK03...
  • Page 109 P003 Number of Load Cells Siemens belt scales are available in models of one, two or four load cell design. Select the number of load cells corresponding to the belt scale connected. If using the optional remote LVDT conditioner card, for LVDT based scales, select the “1”...
  • Page 110 Length units are: feet: if the imperial system of measurement has been selected, P004 = 1 metres: if the metric system of measurement has been selected, P004 = 2 Enter the belt length. Page 104 Milltronics BW500 - INSTRUCTION MANUAL 7ML19985DK03...
  • Page 111 % change into P598, or as the weight of the material test. Entry: 1 = % change 2 = material test Recalibration Refer to on page 34. 7ML19985DK03 Milltronics BW500 - INSTRUCTION MANUAL Page 105...

  • Page 112: Relay/Alarm Function (P100 - P117)

    Entry: 0 = OFF 1 = ON Relay/Alarm Function (P100 - P117) Operation These parameters are specific to the use of the relay/alarm function. Refer to on page 54. Page 106 Milltronics BW500 - INSTRUCTION MANUAL 7ML19985DK03...
  • Page 113 Enter the value in % of setpoint. Differential Speed (f = 110) For differential speed functions, P100 = 10, this parameter sets the high alarm setpoint for the relay selected, relays 1 to 5 (P100 -01 to -05). 7ML19985DK03 Milltronics BW500 - INSTRUCTION MANUAL Page 107...
  • Page 114 Normal Operation In software, all relays are programmed the same way; with ON setpoints always indicating relay action. This parameter allows the reversal of the operation. Normally, P118 = 2 for each relay. Page 108 Milltronics BW500 - INSTRUCTION MANUAL 7ML19985DK03...
  • Page 115 This function allows the user to simulate an alarm condition: ON or OFF, which will override normal operation until P119 setting is returned to normal. Values P119 Condition Display (alarm field) normal normal alarm on ALM # alarm off blank 7ML19985DK03 Milltronics BW500 - INSTRUCTION MANUAL Page 109...

  • Page 116: Ma I/O Parameters (P200 - P220)

    The instantaneous mA values are averaged for the set period, and then the average value is output during the next period while a new average is being calculated. Entry: 0 = OFF 1 – 999 = averaging period Page 110 Milltronics BW500 - INSTRUCTION MANUAL 7ML19985DK03...
  • Page 117 Sets the mA range for the input selected, inputs 1 to 2 (P250 - 01 to - 02). Entry: 1 = 0 - 20 mA 2 = 4 - 20 mA 7ML19985DK03 Milltronics BW500 - INSTRUCTION MANUAL Page 111...
  • Page 118 (P365)*. Page 112 Milltronics BW500 - INSTRUCTION MANUAL 7ML19985DK03...
  • Page 119 10 = PID setpoint source 11 = PID mode 12 = external alarm 13 = remote communication write 14 = Initiate On-line Calibration 15 = Accept new on-line calibration span** 16 = Auxiliary speed sensor 7ML19985DK03 Milltronics BW500 - INSTRUCTION MANUAL Page 113...

  • Page 120: Calibration Parameters (P295 - 360)

    The cumulative days that the application device has been in service. The time is recorded once daily in a non-resetable counter. Periods of less than 24 hours. are not recorded, nor accumulated. ( = 0) Page 114 Milltronics BW500 - INSTRUCTION MANUAL 7ML19985DK03...

  • Page 121: On-Line Calibration Options (P355 To P358)

    HIGH LIMIT, range 0.0 to 100.0 ( = 0%) P357.3 LOW LIMIT, range 0.0 to 100.0 ( = 0%) P358 On-line Calibration Activation Initiates on-line calibration. Entry: 0 = OFF 1 = ON 7ML19985DK03 Milltronics BW500 - INSTRUCTION MANUAL Page 115...
  • Page 122 Direct entry is intended for use when replacing software or hardware and it is not convenient to perform an initial zero at that time. ( = 0) Recalibration Refer to on page 34 for execution. Page 116 Milltronics BW500 - INSTRUCTION MANUAL 7ML19985DK03...

  • Page 123: Linearization Parameters (P390 - P392)

    BW500. Refer to on page 51 for execution, and example on the use of these parameters. In the case of multispan operation, the linearizer is applied to all Note: spans. 7ML19985DK03 Milltronics BW500 - INSTRUCTION MANUAL Page 117...
  • Page 124 -30 to 30 °. The Parameter P399 can also be used for a constant angle if a mA input is not configured. Otherwise, P399 will contain the current value corresponding to the mA input. Page 118 Milltronics BW500 - INSTRUCTION MANUAL 7ML19985DK03...

  • Page 125: Proportional Integral Derivative (Pid) Control Parameters (P400 - P419)

    The process value is the value that the controller is trying to match with the setpoint. = 1) Enter: 1 = rate 2 = load 3 = mA input 1 4 = mA input 2 7ML19985DK03 Milltronics BW500 - INSTRUCTION MANUAL Page 119...
  • Page 126 Determines the source for the PID’s setpoint. If local, the setpoint value is entered into P415. The setpoint can be set from the mA input 1 or 2. The mA value is scaled to the full scale value of the process value (P402). Page 120 Milltronics BW500 - INSTRUCTION MANUAL 7ML19985DK03...
  • Page 127 If the input speed frequency drops below 5 Hz, the PID control output Note: freezes at its current value. Enables or disables the PID freeze option described in the note above. Entry: 0 = OFF 1 = ON 7ML19985DK03 Milltronics BW500 - INSTRUCTION MANUAL Page 121...

  • Page 128: Batch Control (P560 - P568)

    The activity is internally limited to ±10% of the batch setpoint Entry: 0 = OFF 1 = Auto 2 = Manual Page 122 Milltronics BW500 - INSTRUCTION MANUAL 7ML19985DK03...

  • Page 129: Totalization (P619 - P648)

    Enter drop out value in % of design load. P631 Totalizer Resolution This parameter sets the resolution of the totalizer selected. Totalizers are: -01, totalizer 1 -02, totalizer 2 -03, verification totalizer -04, material test totalizer -05, batch totalizer 7ML19985DK03 Milltronics BW500 - INSTRUCTION MANUAL Page 123...
  • Page 130 It is used to verify the accuracy of the scale. If a printer is connected to a port and the required programming is in order, a printout of the activity is automatically done on completion of the verification process. Page 124 Milltronics BW500 - INSTRUCTION MANUAL 7ML19985DK03...
  • Page 131 P647 Totalizer Display Selects the totalizer combination to be displayed, either manually through the scroll display key or automatically by control of the display mode (P081). 7ML19985DK03 Milltronics BW500 - INSTRUCTION MANUAL Page 125...
  • Page 132 For speed constant entry (P690 = 2), this parameter is enabled for entry of the pulses per revolution that the speed sensor delivers (P692-01 or 02). Enter the pulses per revolution from the speed sensor nameplate. Page 126 Milltronics BW500 - INSTRUCTION MANUAL 7ML19985DK03...

  • Page 133: Ecal Parameters (P693 - P698)

    Determines the excitation applied to the load cells. Nominally this value is 10 V. However, a measurement of the voltage at the load cell provides the most accurate entry. Enter the load cell excitation in volts dc. 7ML19985DK03 Milltronics BW500 - INSTRUCTION MANUAL Page 127...
  • Page 134 Upon entry, display jumps to P017 to display the design load value as the test load. P699 ECal mV Span Applicable only for Siemens belt scales not listed in P693, or scales other than Siemens (P693 = 4). Enter the mV span corresponding to 0 to 100% full scale load.

  • Page 135: Communication (P750 - P799)

    Error occurred communicating with card; device will try to reinitial- FAIL ize communications with card. If message continues, record values in P791 and P792 and contact your local Siemens representative. No module installed, or module not supported; communications ERR1 have been disabled If FAIL or ERR1 is displayed in P790 (Hardware Error), go to P791 (Hardware Error Code) and P792 (Hardware Error Count) for information about the error.

  • Page 136: Test And Diagnostic (P900 - P951)

    No errors Error code; provide this code to your Siemens representative for Any other value troubleshooting P792 Hardware Error Count A count that increments by 1 each time Fail is reported in P790 (Hardware Error). Values Description Error count; provide this number to your Siemens representative for Range: 0 to 9999 troubleshooting.
  • Page 137 – 02 = C and D – 03 = A and B plus C and D – 04 = A – 05 = B – 06 = C – 07 = D 7ML19985DK03 Milltronics BW500 - INSTRUCTION MANUAL Page 131...
  • Page 138 The design load is calculated, based on the design rate and design speed. ( = 0.00) P999 Master Reset Resets parameters and totalizers to their factory setting. ( = 0) Enter 9 to execute the reset. Page 132 Milltronics BW500 - INSTRUCTION MANUAL 7ML19985DK03...

  • Page 139: Troubleshooting

    Specifically Q1: I tried to set a Siemens Milltronics device parameter, but the parameter remains unchanged. Try setting the parameter from the keypad. If it can’t be set using the...

  • Page 140: Error Codes

    Load Cell AD’s are not func- Consult Siemens. tioning Err: 227 No process data available. Consult Siemens. Batch pre-act adjustment Pre-act adjustment is ignored. Tune process to limit batch > 10% error. Integrator not configured...
  • Page 141 Batch has been set up, but no relay has been configured No batch setpoint relay for a setpoint. Displayed at the bottom right corner of the display if Power Failure power is interrupted after the integrator has been calibrated. 7ML19985DK03 Milltronics BW500 - INSTRUCTION MANUAL Page 135...

  • Page 142: Certification

    The printout must consist of the following: Start Total: End total of previous print End Total: Accumulated totalizer including Start Total Net Total: End total minus Start Total Page 136 Milltronics BW500 - INSTRUCTION MANUAL 7ML19985DK03...

  • Page 143: Glossary

    Usually the first zero performed, it is used as reference for all other zeros to determine whether they have deviated beyond the Zero Limit (P370). Input/Output Trim Allows the 4 and 20 mA values to be adjusted and verified with an external source (meter). 7ML19985DK03 Milltronics BW500 - INSTRUCTION MANUAL Page 137...
  • Page 144 Setpoint A value that the integrator is trying to match. SmartLinx An interface to popular industrial communication systems. Single Parameter Access, used to view or edit parameters through the available communication ports. Page 138 Milltronics BW500 - INSTRUCTION MANUAL 7ML19985DK03...
  • Page 145 A calibrated weight which will represent a certain load on the scale. Totalizer An incremental counter that records the total of material that has been monitored. Zero Register Shows the number of zero calibrations that have been performed since the last master reset. 7ML19985DK03 Milltronics BW500 - INSTRUCTION MANUAL Page 139...

  • Page 146: Memory Backup

    • shut off the prefeed to conveyor In process where a prefeed device is included, it must be turned off to ensure that no material is fed onto the belt. Page 140 Milltronics BW500 - INSTRUCTION MANUAL 7ML19985DK03...

  • Page 147: Appendix Ii: Software Revision History

    • Auto Zero alarm relay will now reset toggling from program to run mode • Updated calibration error so that it will 2.06 February 17, 2001 not displaya negative 0 error, -0.00% 7ML19985DK03 Milltronics BW500 – INSTRUCTION MANUAL Page 141...
  • Page 148 • Added power failure indicator on display, "PF" • On-line calibration added • SmartLinx memory map increased 3.05 November 11, 2002 • Improve external totalizer contact closure duration Page 142 Milltronics BW500 – INSTRUCTION MANUAL 7ML19985DK03...
  • Page 149 • Moisture meter added • Inclinometer feature added • Remote totalizer exceeded error fixed 3.09 August 8, 2006 • Totalizer dropout (P619) now limited to 3% or less when certification switch enabled 7ML19985DK03 Milltronics BW500 – INSTRUCTION MANUAL Page 143...

  • Page 150: Index

    70 output 4 logic 59 output test 131 PID 67 maximum separation 77 setpoint 61 Modbus 78 protocol 76 data modbus advanced access 88 how modbus works 84 bits 80 responses 100 Page 144 Milltronics BW500 – INSTRUCTION MANUAL 7ML19985DK03...
  • Page 151 P117 relay dead band 58 P560 batch mode control 73 P118 relay logic 58 P564 batch setpoint 74 P119 relay override 109 P566 batch pre-warn 73 P200 mA output range 57 P567 batch pre-warn setpoint 73 7ML19985DK03 Milltronics BW500 – INSTRUCTION MANUAL Page 145...
  • Page 152 P999 master reset 60 mV 128 parameters recalibration 33 read and write 88 remote 44 reading 89 routine 41 SmartLinx hardware testing 129 verification 124 values 96 stop bits 80 writing 89 Page 146 Milltronics BW500 – INSTRUCTION MANUAL 7ML19985DK03...
  • Page 153 UINT32 order 88 unsigned double precision integer 96 web site 84 wiring 9-pin to RJ-11 20 guidelines 77 zero 4 auto 40 calibration 32 direct 39 initial 38 recalibration 33 verification 124 7ML19985DK03 Milltronics BW500 – INSTRUCTION MANUAL Page 147...
  • Page 154 Siemens Milltronics Process Instruments Inc. Siemens Milltronics Process Instruments Inc. 2008 1954Technology Drive, P .O. Box 4225 Subject to change without prior notice Peterborough, ON, Canada K9J 7B1 Rev. 3.2 Tel: (705) 745-2431 Fax: (705) 741-0466 *7ml19985DK03* Email: techpubs.smpi@siemens.com...

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