Instruction Manual PL-367 January 2001 MULTI SPAN NO: 1 R2:RATE HI R1:SPEED LO 1263957 T TOTAL -50% 0% 50% 100% 150% OMPUSCALE II COMPUSCALE III INTEGRATOR
Safety Guidelines Warning notices must be observed to ensure personal safety as well as that of others, and to protect the product and the connected equipment. These warning notices are accompanied by a clarification of the level of caution to be observed. Qualified Personnel This device/system may only be set up and operated in conjunction with this manual. Qualified personnel are only authorized to install and operate this equipment in accordance with established safety practices and standards.
TABLE OF CONTENTS TITLE PAGE # General Information About the CompuScale III About this Manual General Conventions 1–1 1–2 1–3 Specifications CompuScale Options III 2–1 2–2 Installation CompuScale III Interconnection 3–1 3–1 3–1 Hazardous Locations Start Up Hardware Set Up Pre Start Up Checks Initial Start Up 4–1 4–3 4–3 General Keypad Parameter Entry Direct Parameter Access Automatic Parameter Access Altering Parameter Values Parameter Reset Programming Sequence Quick Start Guide 5–1 5–1 5–2 5–2
Parameters General Parameters 7–1 7–1 Programming Chart 8–1 Operation Initial Operation Normal Operation Start Up Zero Calibration Check Span Calibration Check Reset Total Run 9–1 9–1 9–2 9–2 9–2 9–2 Communication General Host Communication Remote Communication Serial Printer Communication Protocol Data Field Descriptions Message Requests Message Responses 10 – 1 10 – 2 10 – 2 10 – 2 10 – 2 10 – 3 10 – 3 10 – 4 Appendices Alphabetical Parameter Listing Maintenance and Spare Parts Maintenance Spare P
GENERAL INFORMATION ABOUT THE COMPUSCALE III The Milltronics CompuScale III is a microprocessor based integrator designed specifically for bulk dry solids in-line weighing applications. MULTI SPAN NO: 1 R2:RATE HI R1:SPEED LO 1263957 T TOTAL The CompuScale III utilizes a load signal (from a belt scale such as the Milltronics MSI), and a speed input (from a speed sensor such as the Milltronics MD-36, or a programmed constant speed), to calculate the material rate.
ABOUT THIS MANUAL GENERAL This instruction manual contains information essential to successful CompuScale III operation. SPECIFICATIONS, includes CompuScale III environmental, physical, and operational characteristics. INSTALLATION, indicates the typical mounting and interconnection procedure. START UP, prepares the CompuScale III for programming. PROGRAMMING, details the activities required to tailor the CompuScale III to the particular application.
SPECIFICATIONS COMPUSCALE III » 100/115/200/230 V AC ± 10%, jumper selectable, 50/60 Hz, 65 VA Power: Fuses: » Main (FU1) » 3/4 Amp MDL SLO-BLO or equivalent » Speed Sensor (FU2) » 1/4 Amp MDL SLO-BLO or equivalent Operating Temperature: » -20 to 50°C (-5 to 122°F) Accuracy: » ± 0.1% of span, typical Resolution: » ± 0.02% of span, typical Inputs: » Load cell: » -20 to +45 mV DC per load cell » 4 load cells max. Outputs: » LVDT: » 0 to 0.
» Alarm: » 2 multipurpose relays for rate, load, or speed » 1 Form "C" SPDT contact per relay, rated 5A at 230 V AC » Communication: » 1 relay, 4PDT used for communication loop dropout, » rated 1A at 230 V AC » Display: Communication: » illuminated 256 x 128 dot matrix » 2 serial ports » RS232C and ± 20 mA current loop Enclosure: » NEMA4 style, steel construction with polycarbonate window » 330 mm W x 406 mm H x 102 mm D (13" W x 16" H x 4" D) Shipping Weight: » 11.0 Kg (24.
INSTALLATION COMPUSCALE III The CompuScale III should be mounted in an area that is within the specified temperature range, and that is suitable for Nema 4 style enclosures. The front cover should be accessible for keypad operation, display viewing, and have sufficient room to swing open. It is advisable to keep the CompuScale III away from high voltage or current runs, contactors, SCR control drives and RF interference.
START UP HARDWARE SET UP Prior to programming, SW1 and SW2 contacts must be set as required. UNIT I.D. The CompuScale III identification code factory setting is 00, as set by SW1 contacts 1 - 4. When more than one CompuScale III is connected to a host computer or PLC, the identification code of each CompuScale III must be set to a different value. UNIT I. D. 00 01 02 03 04 05 06 07 SW 1 1234 OOOO COOO OCOO CCOO OOCO COCO OCCO CCCO UNIT I. D.
PORT 2 BAUD RATE Baud Rate 300 1200 2400 9600 The CompuScale III TB2 communication port baud rate is independant of the PORT 1 baud rate, and is set by SW2 contacts 1 and 2. Set the baud as required by the device connected. The factory setting is 300 baud. SW2 12 OO CO OC CC O = switch contact open C = switch contact closed LANGUAGE Leave SW2 contact 3 (SW2-3) in the open position for English, or closed for alternate language, CompuScale III displays.
PRE START UP CHECKS After the CompuScale III has been properly installed and interconnected, the following checks should be performed prior to connecting power: » all cable connections are correct and secure. » the proper voltage has been selected (J1 on the mother board). » SW1 and SW2 have been set as required. » the POWER switch is in the OFF position. Connect power to TB1-51,52 and ground to TB1-50 of the CompuScale III. Ensure all connections are secure.
When the display initialization routine is complete, the display reverts to the last operating mode accessed. If the CompuScale III is not programmed, the parameter entry display is accessed. The CompuScale III display is divided into the following fields: RELAY MULTISPAN FEATURE CALIB. BELT REV. UNITS ECAL VALUE AUX 1 AUX 2 -50% FIELD 0% RATE 100% 150% RATE BAR GRAPH DESCRIPTION MULTISPAN current span calibration selected. If Multispan 0 is selected, the field is blank.
PROGRAMMING GENERAL Information specific to a particular application is entered into the CompuScale III memory, via the keypad, prior to the calibration procedure.
PARAMETER ENTRY Application information must be entered into the appropriate CompuScale III memory locations. These locations are identified by a Parameter Number (P#). The information entered is referred to as a Parameter Value (Value). To enter information, the operator accesses the desired parameter number, views the parameter value displayed, and then accepts or alters the current parameter value. Common Parameter Entry Display Fields.
ALTERING PARAMETER VALUES Once the desired parameter number is accessed, the parameter value may be accepted or altered as required. e.g. if the VALUE field of PARAMETER 0 is 1 (T/h), however 2 (LT/h) is desired [ 2 2 ] is displayed in the value field the new value (2) is now stored in memory ENTER LAST PARAMETER RECALL From the Calibrate or Run mode, the last parameter accessed in the Program mode, may be recalled. PAR ENTER the last parameter accessed is displayed.
CALIBRATION GENERAL As belt and material load can vary with temperature and humidity, frequent calibration may be required to maintain system accuracy. A calibration should only be performed after the belt has been run as long as practical, and is sufficiently limber. When the CompuScale III is first commissioned, several Zero and Span calibrations are normally performed to verify the calibration results are repeatable. A Zero or Span calibration (in progress) may be aborted by .
ZERO The average load applied to the belt scale by the empty running belt is calculated and stored in memory as a Zero count. After the belt has run empty for sufficient time (15 minutes or more)... [ZERO] is displayed in the FEATURE field. The current Zero counts are displayed in the VALUE field. [ENTER: CALIBRATE MODE] is displayed in the AUX 2 field. ENTER to initiate the calibration. [CALIB] is displayed in the CALIB field and [ZERO IN PROGRESS] is displayed in the AUX 2 field.
CALIBRATION ALTERNATIVES AUTO ZERO This feature automatically performs a Zero calibration, whenever material flow ceases in the RUN mode. If the Auto Zero feature is desired, provide a dry contact input to the CompuScale III terminals TB1-34 and TB1-37. The contact may be activated by a material feed controlling device such as a motor control, material control gate, or valve. The contact must be closed when the material feed is stopped.
ECAL CALIBRATION (Initial Reference) With Essential Parameters (P0 through P7, and P21) programmed as required, select the ECAL Test Reference (P20=1). Access P7 again, [PARAMETER 7E] is displayed. (The "E" indicates the P7 value displayed is associated with the ECAL Test Reference). Perform a Zero and Span calibration. (A Test Weight is not required as ECAL is automatically applied for Span calibrations when P20=1). To obtain an accurate ECAL/belt scale signal correlation, perform a material test.
PARAMETERS GENERAL (F) indicates the parameter value factory setting (where applicable) (V) indicates the parameter value may be viewed only. (E) indicates the parameter value is essential for basic operation. PARAMETERS P0 RATE UNITS (E) Defines the desired Rate display engineering units of measure.
P4 BELT SPEED (E) Defines the design speed of the conveyor belt. Range = 0.0001 to 99999. If SW1, contact 5 (SW1-5) is in the open position (Imperial units), the value is entered in feet/minute (ft/min). If (SW1-5) is in the closed position (Metric units), the value is entered in metres/second (m/s). enter: P5 Design Speed from Design Data Sheet (F = 0) SPEED CONSTANT (E) Defines the constant to be multiplied to the speed sensor output frequency to establish the current belt speed. Range = 0.
P8 SPAN ADJUST Adjusts the test reference calibration results to improve material flowrate measurement accuracy. % CHANGE » Calculate the deviation between the CompuScale III Total and the actual material weight. A positive value reduces (negative increases) the Rate displayed. % Span Error = CompuScale III Total - Actual Material Weight x 100 Actual Material Weight MATERIAL TEST » Alternatively, the automatic method may be used.
P10 LOW TOTAL CUTOFF Defines the minimum belt scale load to be processed for Local Total values and Remote Total contact closures. Range = 0.0 to 100.0 This eliminates totalizer activity caused by the variable loading effect of an empty running belt. With calibration complete, the belt running empty, and the Load displayed, observe the highest display value. Enter the value as a percent of LOAD (material load from Design Data Sheet or P55 display).
P15 RATE OUTPUT AVERAGE Defines the period in seconds between Rate Output updates. The value held, corresponds to the averaged Rate of the previous period. Range = 0 to 999. A value of 0 may be entered if Rate output averaging is not desired. enter: P16 desired value (F = 0) RATE BAR GRAPH ASSIGNMENT Defines the output value the Rate Bar Graph Display represents, as a percent of span.
P19 SPEED ADJUST Displays the measured belt speed. If the belt speed displayed is incorrect, the actual belt speed may be entered. The value entered must be in the same units of measure as P4. To determine the actual belt speed: a) Measure the belt length with a measuring tape. b) Mark a point on the edge of the belt. c) Run material on the belt at normal speed. d) Monitor the time required for 1 or more* complete belt revolutions. *Accuracy improves with the number of belt revolutions monitored.
P21 SENSOR TYPE (E) Defines the type and number of load sensors providing the load signal(s) to the CompuScale III. enter: 0 = LVDT (linear variable differential transformer) 1 = 1 load cell(MIC) 2 = 2 load cells (F)(MSI) 4 = 4 load cells(MMI-2) 8 = 8 load cells(MMI-3 or 4, LCPA-08 option required) P22 ECAL ADJUST Applies and permits the adjustment of the internal electronic test reference. Refer to Calibration\Alternate Test References for ECAL Span calibration instructions.
P26 MULTISPAN Defines the calibration result to be used for subsequent measurements. Range = 0 to 8. This feature may be used to store the Span calibration results associated with different operating conditions, (e.g. change in conveyor incline, when an incline compensator is not utilized). To perform a Span calibration for a specific operating condition: a)Select the Multispan number to be associated with the current operating condition.
P31 VERIFICATION TOTALIZER Activates a secondary internal totalizer which totals the amount of material conveyed during the number of belt revolutions set by P30. (The P30 value must be a whole number.) This feature may be used to verify calibration accuracy from the RUN mode without stopping material flow. The amount of material totalized by the verification totalizer may be included or excluded from the main totalizer counts.
P42 DATA MESSAGE Defines the ASCII message to be transmitted after every Data Transmit Interval (P41) or when TB1-35,37 contacts are closed. The current time and date are transmitted with each message. The System message includes the value of parameters P0,1,2,3,4,5,6,7, and 21. enter: 0 = no message (F) 1 = RATE 2 = TOTAL 3 = LOAD 4 = SPEED 5 = RATE, TOTAL, LOAD, and SPEED 9 = SYSTEM P43 SERIAL PRINTER Sets the communication mode to suit a serial printer.
P52 RELAY 2 Defines the operation of Relay 2 as a Rate, Load, or Speed Alarm. The High Limit is the high alarm set point value which will cause the relay to de-energize. If a high alarm is not required, set the High Limit to 0. The Low Limit is the low alarm set point value which will cause the relay to de-energize. If a low alarm is not required, set the Low Limit to 0.
P64 ZERO RECORD (V) Displays the number of operator initiated Zero calibrations performed since the last Reset (P99) or Initial Zero. Reset (P77), (F = 0). P65 SPAN RECORD (V) Displays the number of operator initiated Span calibrations performed since the last Reset (P99) or Initial Span. Reset (P88), (F = 0). P66 SECURITY LEVEL Defines the level of operator access permitted. This feature may be utilized to ensure the programming and/or calibration is not inadvertently altered.
P80 V/F CONVERTER OUTPUT (V) Displays a reference count proportional to the input level from the belt scale. Range = 0 to 131,000. This feature is normally used to verify the integrity of the belt scale load sensors and cables. P81 LOAD CELL A (V) Displays the input from the load cell connected to TB1-1,2 in mV. Range = 0.00 to 50.00. Access to this parameter is gained when SENSOR TYPE (P21) is set to any value greater than 1.
P90 MSI NUMBER Identifies the MSI to be balanced by advancing through parameters P91 through P95. This parameter may only be accessed when Sensor Type (P21) is set to a value greater than 1. Prior to initial calibration or following an MSI (dual load cell belt scale) load cell replacement, the load cell balancing procedure should be performed. When the load cell signals are balanced, variations in lateral material load distribution on the belt have less effect on measurements.
P93 POS A L/C (B) (V) Displays the load cell input counts for load cell: B (P 90 = 1), D (P90 = 2), F (P90 = 3), or H (P90 = 4). Move the test weight to the load cell: A (P90 =1), C (P90 =2), E (P90 = 3), or G (P90 = 4) side of the test weight bar. Leave the LCPA-08 SW3 contacts undisturbed. enter : the displayed value (when stable) to advance to P94.
PROGRAMMING CHART PAR NAME VALUE VALID RANGE (F or _ = factory setting) P0 P1 P2 P3 P4 P5 P6 P7 P8 P9 P10 P11 P12 P13 P14 P15 P16 P17 P18 P19 P20 P21 P22 P26 P30 P31 P32 P40 P41 P42 P43 P51 RATE UNITS RATE LOCAL TOTAL REMOTE TOTAL BELT SPEED SPEED CONSTANT BELT LENGTH TEST REFERENCE SPAN ADJUST FACTORING LOW TOTAL CUTOFF RATE DISPLAY DAMPING LOAD DISPLAY DAMPING SPEED DISPLAY DAMPING RATE OUTPUT DAMPING RATE OUTPUT AVERAGE RATE BAR GRAPH ASSIGNMENT RATE OUTPUT MIN RATE OUTPUT MAX SPEED ADJUST TEST REFE
OPERATION INITIAL OPERATION Prior to the initial operation of the CompuScale III the following checks should be made: » the test reference should be removed from the belt scale. » the totalizer(s) should be reset to zero. The CompuScale III is now ready for service. Ensure the CompuScale III is in the RUN mode. To enter the RUN mode, The CompuScale III assumes the last RUN mode display accessed. If necessary, to display Load. Apply material to the running belt, ensuring the Design Load is not exceeded.
NORMAL OPERATION START UP Ensure power is supplied to the CompuScale III. The following procedures may be performed on a routine basis, as required. Access to the Zero and Span calibration, and Reset Total functions may be restricted. ZERO CALIBRATION CHECK Ensure the belt scale test reference (Test Weight, ECAL, or Test Chain) is removed. Run the belt empty at normal speed until sufficiently limber. ENTER to initiate a zero calibration.
COMMUNICATION GENERAL The CompuScale III may be operated in one of the following serial communication modes: » Remote (via an additional CompuScale III) » Host (IBM PC compatible computer or PLC) » Serial Printer The Bipolar Current Loop may be utilized for cable runs up to 1500 metres (5000 ft). If communication with an RS-232C device is required, the Milltronics BIC-II or CVCC may be used to convert the Bipolar Current Loop to RS-232C.
REMOTE COMMUNICATION This mode provides complete access to all CompuScale III functions via a remote mounted CompuScale III. To receive communication from the local CompuScale III PORT 1 or PORT 2 connection, SW2-6 of the remote CompuScale III must be closed. HOST COMMUNICATION Host communication permits up to 16 CompuScale III’s (serially connected via PORT 1), to communicate with a computer or Programmable Logic Controller. Refer to Start Up\Hardware Set Up\Unit I.D. Code.
PROTOCOL Protocol refers to the format, sequence and value of the data fields utilized in Host Mode communication messages. Each data field of a CompuScale III message contains one or more bytes of ASCII binary code. Each byte contains: +20 mA » 8 data bits » no parity bit » 1 stop bit 0 s 1 2 3 4 5 6 7 8 s t s n r t t t t t t a t d d h h h h h o r p t -20 mA DATA FIELD DESCRIPTIONS The following data fields are utilized in CompuScale III, host mode messages.
MESSAGE REQUESTS Message requests must be transmitted from the host to the CompuScale III in the following format. som DEVICE MT eom Example: Data Field som DEVICE MT eom ASCII Character STX 01 50 CR Example Description start of message for CompuScale III # 1 material flow rate request end of message MESSAGE RESPONSES The CompuScale III response to a flow rate (MT=50) load (MT=51) or speed (MT=52) message request will be in the following format.
ALPHABETICAL PARAMETER LISTING PARAMETER NAME PARAMETER NUMBER PARAMETER NAME PARAMETER NUMBER Baud Rate P40 Multispan P26 Belt Length P6 Parameter List P100 Belt Speed P4 Rate P1 Calibration Duration P30 Rate Output Average P15 Clock/Calendar P70 Rate Output Max P18 Converter Input (V/F) P83 Rate Output Min P17 Converter Output (V/F) P80 Rate Units P0 Damping, Load Display P12 Record, Zero P64 Damping, Rate Bar Graph P16 Record, Span P65 Damping, Rate Display P11 R
MAINTENANCE AND SPARE PARTS MAINTENANCE The CompuScale III requires no maintenance. However, a program of periodic preventative maintenance should be initiated. This should include regular inspection, general cleaning and good housekeeping practices. Enclosures and printed circuit boards should be cleaned only when the power is disconnected at the main breaker. The use of a vacuum cleaner to remove foreign material dislodged with a clean dry paint brush is recommended.
ERROR MESSAGES The following messages may be encountered during CompuScale III programming, calibration, or operation. DISPLAY MESSAGE DESCRIPTION [ABORTED] The activated process or procedure was not completed correctly (or before "CLEAR" was pressed). Retry the feature attempted. [AUTO ZERO ABORTED] The Auto Zero was more than 2% of span from the last operator Zero before SW1-6 was closed. Refer to Calibration/Certification Mode.
TROUBLE SHOOTING Every CompuScale III integrator is subjected to extensive quality assurance procedures to ensure the highest possible degree of quality, reliability, and performance is achieved. The following listing indicates the probable cause, and proper course of action to be taken should the specified fault symptom occur.
OUTLINE and MOUNTING 330 mm ( 13" ) 11 mm dia. ( 0.4" ) 4 places 178 mm ( 7" ) 406 mm ( 16" ) 101 mm ( 4" ) 435 mm ( 17.1" ) enclosure bottom plate ( for cable / conduit entrance ) FIG.
COMPUSCALE III LAYOUT D1 calibrator battery RC1 Q1 R1 C2 LD1 CR1 R2 Q2 C3 U1D2 R3 calibrator (door mount) C1 B1 memory / clock battery ML 51026351 MILLTRONICS CALIBRATOR IV PN 24751327-01 PETERBOROUGH ONTARIO MADE IN CANADA SW 1 EPROM 1 SW1 TIME / DATE / MEMORY EPROM 1 3.6 VOLT LITHIUM BATTERY PIN 1 47 SW 2 EPROM 2 PIN 1 P24V N24V 7 20 ML 51026331 SN PN 24751325-04 1 COM EPROM 2 SW2 P5V display display board 1263957 N5V2 N8V -50% COM R1:RATE HI R2:RATE LO SPAN No.
COMPUSCALE III / BELT SCALE INTERCONNECTION MSI (DUAL LOAD CELLS) CompuScale III TB1 MIC (SINGLE LOAD CELL) CompuScale III TB1 LVDT CompuScale III TB1 1. Where a belt scale must be installed in a hazardous area consult Milltronics or your distributor for wiring instructions. 2.
COMPUSCALE III / BELT SCALE INTERCONNECTION MMI-2 APPLICATIONS scale wiring customer’s MSI # 1 junction box (nearest tail pulley) COMPUSCALE III scale wiring customer’s MSI # 2 junction box (nearest head pulley) COMPUSCALE III / LCPA-08 INTERCONNECTION COMPUSCALE III LCPA-08 (Refer to the LCPA-08 instruction manual for LCPA-08 / Belt Scale Interconnection) 1. Where a belt scale must be installed in a hazardous area consult Milltronics or your distributor for wiring instructions. 2.
COMPUSCALE III / SPEED SENSOR INTERCONNECTION MD - 2000A MD - 36 1. Remove the Compuscale III TB1 - 32,33 jumper prior to connecting ther speed sensor. 2. Connect Compuscale III TB1 - 31 to the speed sensor junction: Position 2 for clockwise speed sensor shaft rotation Position 3 for counter clockwise speed sensor shaft rotation 3. If a speed sensor is not used the Compuscale III TB1 - 32,33 jumper must be in place. shaft CW CCW FIG.
POWER, AUTO ZERO & RATE OUTPUT WIRING POWER Compuscale III TB1 Power Connection 100/115/200/230 V AC 65 VA Voltage Select AUTO ZERO prefeed activated dry contact RATE OUTPUT Compuscale III TB1 to mA input of device 750 Ω Max load 1. Ensure the Compuscale III J1 position matches power to be applied to TB1 - 51,52. 2. The Auto Zero contact must be closed when the material feed is stopped, if Auto Zero calibration is desired. PL-367 12 – 6 FIG.
RELAY WIRING ALARM / CONTROL RELAYS Compuscale III TB1 Relay contacts are shown in de-energized condition to alarm / control devices REMOTE TOTALIZER RELAY CompuScale CompuScaleIIIIII TB1 TB1 CompuScale CompuScaleIIIIII TB1TB1 48 49 R1 48 49 C1 R2 C2 AC + * POWER SOURCE DC * POWER SOURCE Shaded area recommended for inductive load (L) R1 = R2 = 20 to 30 W C1 = .01 to .1 mFd, 500 V C2 = .001 to .01 mFd, 500 V * Some totalizers have an internal power source. FIG.
COMMUNICATION WIRING RS - 232 CompuScale III CompuScale III to device RS-232 port to device RS-232 port CURRENT LOOP CompuScale III CompuScale III to device current loop connection to device current loop connection MULTIPLE CURRENT LOOP CompuScale III Unit I.D. # 00 CVCC or BIC II TX TX CompuScale III Unit I.D. # 01 RX to RS-232 device RX CompuScale III Unit I.D. # N (max N=15) 1.
c Siemens Milltronics Process Instruments Inc. 2001 Subject to change without prior notice Siemens Milltronics Process Instruments Inc. 1954 Technology Drive, P.O. Box 4225 Peterborough, ON.Canada K9J 7B1 Tel: (705) 745-2431 Fax: (705) 741-0466 www.milltronics.
