INSTROTECH 6004BW, Manual

Page 1: ...6004BW Belt Weigher Transmitter ...

Page 2: ...hing Page 1 Belt Weigher Formats in serial ASCII Serial outputs RS232 or RS485 Clear 20mm 6 digit LED main display and auxiliary information LCD display Inputs from load cell s incremental encoder and 6 digital inputs Powerful ARM microprocessor with integral clock and USB I O port Options Output relays or photomos 2 4 or 6 plug and play programmable functions Programming from alphanumeric keypad ...

Page 3: ... Page 8 Wiring Connections Page 9 Display and Controls Page 10 Getting Start Page 11 Contents Page 2 Run Throughput Weigher Page Run Dynamometer Page Run Bag Filler Page Run Batchweigher Page Application Menus Run Loadcell Transmitter Page Run Beltweigher Page 12 Run Loss in Weight Page Service Menu Setpoint Values Page 14 Setpoint Configuration Page 16 Analog Output Page 18 Description of Units A...

Page 4: ... Page 38 Lineariser Page 40 Simulate Page 42 Security Level Page 32 Precalibrate Page 34 Zero Trim Page 36 Tare Page 26 Auto Zero Page 28 Preset Tare Page 30 Communication Page 20 Max Min Page 22 Net Gross Page 25 Service Menu continued PI Control Page 50 Transmitter Settings Page 52 Beltweigher Settings Page 54 ...

Page 5: ...ertiliser distribution by location to improve farming efficiency Logging contractors need to load for maximum profit without incurring overweight fines Loadcell transmitter Loss in weight is becoming a popular form of mass flow measurement or control as it requires few moving or wearing parts Measure a weighbin over time and you can can get a material flow rate either emptying or filling Although ...

Page 6: ...utton selectable kW RPM or Torque and the aux LCD can show all three Dynamometer Batchweighers are typically used for control of industrial concrete mixers but can also control just about anything that requires a repetitive recipe mix The freely programmable inputs function keys displays and outputs results in a batchweighing system with tremendous flexibility The setup allows for a maximum of fiv...

Page 7: ...s the right to alter any specification without notice Safety Cleaning Guarantee This equipment is supplied by a mains voltage which can cause an electric shock injury Before removing the cover from the housing switch the instrument off isolate it from the mains power supply and make sure that it cannot be connected inadvertently by other persons If the cover is removed from the housing do not appl...

Page 8: ...dimensions The housing trim covers need to be removed to gain access to the mounting holes 220 mm 130 mm Not to scale Height of 130mm excludes cable glands Depth is 70 mm Hole diameter 6 mm Cable gland hole dimensions 8mm diameter 202 mm 80 mm Page 7 ...

Page 9: ...or up to 8 x 1000Ω loadcells 5 Volts for up to 8 x 350Ω loadcells 5 Volts for Is barriered applications up to 2 x 350Ω loadcell 3 5Volts for Is barriered applications up to 4 x 350Ω loadcells LINKS Power off change links power on Programmable excitation voltage links J7 J10 then set in Precalibrate menu Fixed excitation voltages link J9 3 5 Volts J8 5 Volts J7 J10 10 Volts Link J27 connects ground...

Page 10: ...DI 5 DI 6 DI 6 J5 J5 V V IGND IGND CURRENT CURRENT ENCODER ENCODER IGND IGND VOLTS VOLTS ENCODER ENCODER ANALOG OUT ANALOG OUT FUSE FUSE REPLACE FUSE WITH THE SAME RATING REPLACE FUSE WITH THE SAME RATING NPN PNP NPN PNP 6004MAIN A AC VDC AC VDC AC VDC AC VDC EARTH EARTH AC SWITCHMODE OR DC SUPPLY AC SWITCHMODE OR DC SUPPLY NO NC COM NO NC COM NO NC COM NO NC COM NO NC COM NO NC COM RELAY 6 RELAY ...

Page 11: ...ize Label Units Label Keypad during run mode Auxilliary Display Max 4 as set in Display Menu Press 3 for operators menu Function Keys as set in service Menu Keypad for Setpoint Values Main Display Relay Status 1 2 3 4 Enter Clear or go back Relay energised Normal LED on Inverted LED off Scroll through menus Scroll through options Key Key in values Alpha numeric Display Display options Enter values...

Page 12: ...NFIGURATION ANALOG OUTPUT COMMUNICATION MAX MIN NET GROSS TARE AUTO ZERO PRESET TARE SECURITY LEVEL 01 02 03 04 05 06 07 08 09 10 PRECALIBRATE ZERO TRIM SPAN TRIM LINEARISER SIMULATE FUNCTION KEYS DIGITAL INPUTS DISPLAYS PI CONTROL TRANSMITTER SETTING 11 12 13 14 15 16 17 18 19 10 BELTWEIGHER SETTINGS CORRECTION FACTOR LOSS IN WEIGHT SETTINGS THROUGHPUT SETTINGS DYNAMOMETER SETTINGS BAG FILLER SET...

Page 13: ...n Trim The Beltweigher has a Rate Correction Factor that can be used later The Beltweigher Service menu contains the following function blocks Details and operation are listed in the Service menu section of this manual 01 Setpoint values Set values for setpoints 1 6 02 Setpoint configuration Select functions for setpoints 1 6 03 Analog output Select output 1 5V 0 10V 0 20mA or 4 20mA 04 Communicat...

Page 14: ...5 06 07 RESET MAX MIN RESET TOTALISER BELT SERVICE PASSWORD TIMEOUT WRONG TAG LAST CAL BY RESET RESET SP VALUES C C C C C 08 09 10 PRECALIBRATE ZERO TRIM SPAN TRIM LINEARISER 11 12 13 14 BELTWEIGHER SETTINGS DIGITAL INPUTS DISPLAYS PI CONTROL 15 16 17 19 C To Open Return to Load Service VIEW CALIBRATE HARDLOCK ON NEW CALIBRATION TAG DATE BY CORRECTION FACTOR SIMULATE FUNCTION KEYS RUN LOADCELL TRA...

Page 15: ...h keypad Enter Access via menu key for 3 seconds or by using Set Setpoints with a Function key or Digital input These values are stored until changed If PI Inc and PI Dec are activated F1 4 and or D1 6 then the Manual output can be ramped up or down when in Stop or Manual mode The Auto Setpoint value can only be ramped up or down when in Auto mode These values will default to the last keypad value...

Page 16: ...TION SETPOINT CONFIGURATION IF OK SET VALUES C 02 02 or C C SERVICE SERVICE SETPOINT VALUES ANALOG OUTPUT SP CONFIGURATION SP CONFIGURATION If preset selected If PI Control Selected TRANSMITTER SETTINGS SETPOINT CONFIGURATION Vibrate Bagclamp None Net Zero Total Beltspeed Fault Power Refill Feed As set in SP Configuration Note Preset on Loadcell transmitter only Preset and PI Control cannot be on ...

Page 17: ... 5A 250V AC change over contacts and photomos is 0 5A 400V AC DC Use relay outputs for higher current switching or for changeover contacts Use photomos for totaliser outputs and solenoids to prevent contact burnout Setpoint Tracks allows you to select which variable the setpoint is compared to Side arrows to select Gross Net Main display Count or Total Setpoint Hysteresis Use keypad to set 000 999...

Page 18: ...None Beltspeed Max Min Counts 000 999 Hysteresis Seconds 000 999 delay before activation Or inverted LED Off Relay On Or On F1 4 Function Keys None D1 6 Digital input None Set Values ANALOG OUTPUT 03 C SERVICE SETPOINT CONFIGURATION SERIAL INTERFACE ANALOG OUTPUT Off High Low Power Faulty Net Zero Total 1 out Liw feed Liw Refill Liw time Out SERVICE Key Key Display Display SETPOINT VALUES ANALOG O...

Page 19: ...t Use side arrows to select from 0 20mA 4 20mA 1 5V or 0 10V Tracks Use side arrows to select analog output tracking of Gross Net Rate main Display kW RPM Torque minimum maximum none Total 4mA value or 0mA 0V or 1V value Use keypad to insert lower scale value 20mA value or 5V or 10V value Use keypad to insert a full scale value NOTE This full scale value must be inserted when using PI Control with...

Page 20: ...r 0 10V 1 5V Low Scale Value High Scale Value Or high or Value or off In Value Or 0 or 1 Or 10 or 5 Set Values SERIAL INTERFACE 04 C SERVICE ANALOG OUTPUT MIN MAX HOLD SERIAL INTERFACE Service Menu Function Block Number 03 03 ANALOG OUTPUT If Value SERVICE SETPOINT CONFIGURATION COMMUNICATION Key Key Key Track None Gross Net Max Min Display Belt rate Belt speed Totaliser 1 Totaliser 2 Page 19 ...

Page 21: ...f NO or on YES in which case you can select Baud Rate Data Bits Stop Bits and Parity Press Enter to set and return to the Communications menu ASCIIBUS setup can be off NO or on YES in which case you can select Track None Gross Net Max Min Display Belt rate Beltspeed Totaliser 1 Totaliser 2 Time Date Off or On Mode Continuous or On demand If On demand the Print pushbutton and digital input will be ...

Page 22: ...ICATIONS BAUD RATE 1200 DATA BITS 7 STOP BITS 1 PARITY NONE ASCIIBUS SETUP NO TRACK NONE TIME DATE OFF MODE CONTINUOUS PRINT PB NONE PRINT DI NONE Key Display F1 4 Function Keys None Gross Net Max Min Display Belt Rate Belt Speed Totaliser 1 Totaliser 2 Or On Or on Demand Display D1 6 Digital Inputs None UNIT ADDRESS 00 PROTOCOL ASCIIBUS LINE SETTING NO 00 99 Or yes Or 2400 4800 9600 14 400 19 200...

Page 23: ...4 Min Reset Dig Input display only select in Service menu Digital Inputs D1 6 Max Reset PB display only select in Service menu Function Keys F1 4 Max Reset Dig Input display only select in Service menu Digital Inputs D1 6 When the entire block is ready press Enter This will set the whole block and move on to the next block in this case NET GROSS for Loadcell Transmitter and Batchweigher or SECURIT...

Page 24: ...n Keys None D1 6 Digital Inputs None F1 4 Function Keys None D1 6 Digital Inputs None F1 4 Function Keys None D1 6 Digital Inputs None NET GROSS 06 C MAX MIN TARE NET GROSS Service Menu Function Block Number 05 05 MAX MIN SERVICE SERVICE COMMUNICATIONS NET GROSS OR SECURITY LEVEL Display Display Display Display Display Display Gross Net Belt rate LIW rate Page 23 ...

Page 25: ...y used for batching in or out a specific mass We suggest that when Net Gross is selected that the Main display is set to Gross and the first auxiliary display is set to Net in Service menu Displays When Function key F1 4 or Digital input D1 6 is set to Net Gross then these two displays will swop over The Net Gross changeover can be activated through the Operator s menu Net Gross Pushbutton Display...

Page 26: ...NET OUTPUT NONE Gross Net Net Gross F1 4 Function Keys None D1 6 Digital Inputs None SP 1 6 SP Configuration None TARE 07 C NET GROSS AUTO ZERO TARE Service Menu Function Block Number 06 LTC 06 NET GROSS SERVICE SERVICE MAX MIN TARE Display Display Display Page 25 ...

Page 27: ...OSS block above Tare is defined as an instruction to zero the net value Tare Use side arrows to select for Off or On If ON then The Tare can be activated through the Operator s menu Tare Pushbutton Display of None or F1 4 if selected in function Keys Tare Digital input Display of None or D1 6 if selected in Digital Inputs When the entire block is ready press Enter This will set the whole block and...

Page 28: ...B F4 TARE DIGIN D4 Or Off F1 4 Function Keys None D1 6 Digital Inputs None AUTO ZERO 8 C TARE PRESET TARE AUTO ZERO Service Menu Function Block Number 07 LTC 07 TARE SERVICE SERVICE NET GROSS AUTO ZERO Display Display If On Page 27 ...

Page 29: ...arrows to switch Auto Zero Maintenance Off or On If On then Band Use keypad to select the number of counts 000 127 Delay Time Use keypad to select the time 000 999 seconds Example Band is 10 counts and Time is 30 seconds If the average deviation positive or negative is more than 10 counts over 30 seconds it is ignored If it is less than 10 counts in 30 seconds the reading is brought to zero Max Us...

Page 30: ...y Display PRESET TARE 09 C AUTO ZERO SECURITY LEVEL PRESET TARE Service Menu Function Block Number 08 LTC or 06 Beltweigher or 06 Loss in Weight 08 AUTO ZERO If On Delay SERVICE SERVICE TARE PRESET TARE Or On 000 127 Counts 000 999 Seconds 000 999 Counts SP1 6 SP Configure None Page 29 ...

Page 31: ... containers to determine the gross contents weight Pretare Use side arrows to select Off or On If On PRETARE xxx xxx will be displayed on first line of the LCD auxiliary display in the same units and with same decimal place as Gross on the main scale Press the down key for three seconds to go to Setpoint Values key in Pretare value and Enter to offset the Gross value on the main LED scale For this...

Page 32: ...PRETARE DI D1 Or On SECURITY LEVEL 10 C PRETARE Or MIN MAX Hold PRECALIBRATE SECURITY LEVEL Service Menu Function Block Number 09 LTC 09 PRESET TARE SERVICE SERVICE AUTO ZERO SECURITY F1 4 Function Keys None D1 6 Digital Inputs None Display Display Page 31 ...

Page 33: ...d Service Menu can be viewed or calibrated without a password but will still require the hardlock to be in place on the back of the display PCB for activation Level 1 View and activate Operators Menu Service Menu can be viewed WITHOUT PASSWORD and activated calibrated with hardlock link Level 2 View and activate Operators Menu Service menu can be viewed WITH PASSWORD and activated calibrated with ...

Page 34: ...u with password and hardlock on Or 1 Activate Operator s and service menu without password and with hardlock on PRECALIBRATE 11 C SECURITY LEVEL ZERO TRIM PRECALIBRATE Service Menu Function Block Number 10 LCT or 07 Beltweigher or 07 Loss in Weight 10 SECURITY LEVEL PRETARE 0R MAX MIN PRECALIBATE SERVICE SERVICE Page 33 ...

Page 35: ...V on the lable or specification sheet For higher accuracy use the mV V off the calibration certificate supplied with the loadcell For higher accuracies on multiple loadcell systems add all the mV V together and divide by the number of loadcells All sensitivities should be approximately the same on a multiple system Do not mix 2mV V with 3mV V Good quality loadcells have matched internal impedances...

Page 36: ... excitation Key in excitation required Loadcell sensitivity Select Decimal Place Low Range Full Scale Range or Tonne Newton lb 001 100 Value 0000 9999 Counts 9999 no effect 1 3 5 10 or 20 seconds ZERO TRIM 12 C C PRECALIBRATE SPAN TRIM PRECALIBRATE Service Menu Function Block Number 11 LCT or 08 Beltweigher or 08 Loss in Weight 11 PRECALIBRATE SECURITY LEVEL ZERO TRIM SERVICE SERVICE Key Key Key K...

Page 37: ...to 9999 seconds or Set the Zero Trim Time to 0000 press Enter and go back to the Zero Trim menu press Enter to start the zero trim and press Enter when you want the zero trim to end During this procedure the main display will show a minus sign and the number of seconds that the zero trim is taking place This value in seconds will now be stored and displayed on the Zero Trim Time in the Beltweigher...

Page 38: ...ce Menu Function Block Number 12 LCT or 09 Beltweigher or 09 Loss in Weight 12 ZERO TRIM PRECALIBRATE SPAN TRIM When Complete SERVICE SERVICE Busy with zero trim Normally 20 second except in Beltweigher settings LINEARISER OR SETTINGS PRESS ENTER TO START 12 Page 37 ...

Page 39: ...If this is not possible due to weighbin size or shortage of test weights then a partial load can be applied preferably as high as possible but should exceed 25 of the full scale value After applying test weights and keying in the test weight value press Enter The auxiliary LCD display shows a time bar for 20 seconds Do not move the system or add on extra weight whilst this span trimming is taking ...

Page 40: ...ber 13 LCT or 10 Beltweigher or 10 Loss in Weight 13 SPAN TRIM ZERO TRIM LINEARISE OR SETTING When Complete SPAN TRIM SPAN 000 000 Key in Test Weights Value Press Enter Busy With Span Trim SPAN TRIM SERVICE SERVICE Normally 20 seconds LOAD TEST WEIGHT ENTER LOAD TEST VALUE SPAN 000 000kg Page 39 ...

Page 41: ...weightanks or for inverting the output signal The linearising is relative to the Gross display and decimal point is as Gross If the Lineariser is selected On then up to 15 values in ascending order of actual input values can be keyed in with corresponding desired output values For example if a mid range only correction of 10 counts is required on a full scale range of 160 000 select 3 points 1 000...

Page 42: ...On 02 15 Lowest Input Actual Value Desired Value Next Actual Value Desired Value SIMULATE 15 C LINEARISER FUNCTION KEYS SIMULATE Service Menu Function Block Number 14 LCT or 13 Beltweigher or 12 Loss in Weight 14 LINEARISER SPAN TRIM SIMULATE OR SETTINGS If On Inputs must be in ascending order SERVICE SERVICE Key Key Key Key Page 41 ...

Page 43: ...ulate outputs default to inactive when not in the Simulate function block Select the Analog output to On and you can key in a value for the mA or Volt output which was selected in Analog Outputs Select any Setpoint output SP 1 6 and you can use the side arrows to select On Off or On Off which will cycle 1 second On and 1 second Off When you no longer need the simulate function press Enter This wil...

Page 44: ... or On Off Or On or On Off Or On or On Off Or On or On Off Or On or On Off Or On or On Off FUNCTION KEYS 16 C SIMULATE DIGITAL INPUTS FUNCTION KEYS Service Menu Function Block Number 15 LCT or 14 Beltweigher or 13 Loss in Weight 15 SIMULATE LINEARISER FUNCTION KEYS If On ALL SETTINGS DEFAULT TO OFF SERVICE SERVICE Key Page 43 ...

Page 45: ... add water Bat change A D Bat set Sps Note that in RUN mode pressing any function key first displays the function chosen Press it again to activate the function Default functions F1 F2 F3 F4 Loadcell Transmitter Set SPs Print Reset peak Tare Suggested Functions for other applications Loadcell PI Control Set SPs PI Start PI Man auto PI Stop Loadcell Tx Pretare Set Sps Print None None Beltweigher Se...

Page 46: ...TION KEYS SIMULATE DIGITAL INPUTS SERVICE SERVICE FUNCTION KEYS DISPLAYS No function Tare Toggle Net Gross Print SP Latch Reset Reset MAX Value Rese MIN Value Reset MAX MIN Reset total 1 Pretare PI MAN AUTO PI Start PI Stop PI INC crease PI DEC rease Belt Zero LIW Sar LIW Stop Throughput Start TPut Stop TPut Resisual Tput Zero Dyna mometer power Dyna RPM Dyna Torque Bat ch Start Bat Stop Bag Start...

Page 47: ...na RPM Dyna torque Bag start Bag stop Bag interlock Bag footswitch Bag pproduct sense Bat start Bat stop Bat add water Bat change A D Bat set SPs Default inputs D1 D2 D3 D4 D5 D6 Loadcell Tx None Net Gross M M reset Tare None None Suggested Digital Inputs for other applications LCT Pretare None Set Sps M M rese Print None None LCT PI Stop LCT None M M reset Print Start PI Man auto Beltweigher None...

Page 48: ...CONTROL SERVICE SERVICE FUNCTION KEYS DISPLAYS No function Tare Toggle Net Gross Print SP Latch Reset Reset MAX Value Reset MIN Value Reset MAX MIN Reset total 1 Pretare PI MAN AUTO PI Start PI Stop PI INC crease PI DEC rease Belt Zero LIW Start LIW Stop Throughput Start TPut Stop TPut Residual TPut Zero TPut Interlock Tput Footswitch Tput Discharge Bag Dyna mometer power Dyna RPM Dyna Torque Bat ...

Page 49: ...CD automatically becomes Manual Output 00 0 99 9 and the next line becomes Auto Setpoint 000 000 These values can be changed in the Setpoint Values menu hold down arrow 3 seconds or set F1 4 for setpoint values and you go into Operator s menu observe Security Level Values can be keyed in and entered when in run mode If Preset Tare Service menu function block 9 is selected then the Pretare Value wi...

Page 50: ...que DISPLAYS TRANSMITTER SETTINGS DIGITAL INPUTS PI CONTROLS None Gross Net MAX MIN Totaliser 1 Totaliser 2 Belt Rae LIW Rate Dyna RPM Dyna Power Dna Torque Bel Speed BeltFFreq Analog Out mV Ex Voltage Date Time PI Main Out PI Auto SP Setpoint 1 Sepoint 2 Setpoint 3 Setpoint 4 Sepoint 5 Setpoint 6 Tare Value Model Number Preset Tare Tag Number Message F1 F2 F3 F4 e 00000 If Preset on Then AUX1 Pre...

Page 51: ...ero Start Power 20 seconds after the power is applied to the 6004MF the analog output will go to the set manual value for one second and then change over bumplessly to PI Control and follow the Auto setpoint value Power off to stop The auxiliary LCD shows Man and Auto clear text when in Stop and dark background when in Manual or Auto respectively Manual output and Auto setpoint value can be set in...

Page 52: ...n If no oscillation occurs change the Setpoint slightly in order to trigger an oscillation Adjust the gain until the oscillation is sustained If the oscillation is increasing decrease the gain slightly If it is decreasing increase the gain slightly Note the gain which causes the sustained oscillation and measure the period of oscillation high peak to high peak Set the P Gain to 45 of this value To...

Page 53: ...p Contrast use side arrow for LCD screen contrast bar display Unit Information use side arrow to display Model Version and Serial number Change Password use side arrow to display Change Password menu Access Code use side arrow to display Access Code Key in the Password to enter the calibration menu and follow instructions for calibrating internal mV Excitation Voltage mA outputs and Voltage output...

Page 54: ...S CODE NO ACCESS CODE ENTER ACCESS CODE _ _ _ _ C WRONG TIMEOUT C CALIBRATION MENU mV INPUT NO EXCITE VOLTAGE NO mA OUTPUT NO VOLTS OUTPUT NO HARDWARE OPTIONS NO MENU TIME OUT OFF OR ON HARDWARE FITTED SP1 2 NO SP3 4 NO SP5 6 NO SD CARD NO GPS NO C Yes Yes Yes Yes Yes SERVICE C C C PI CONTROL SET SET C SET DATE TIME NO RESET TOTALISER 2 NO OR YES SET DATE TIME SET YEAR _ _ _ _ SET MONTH _ _ SET DA...

Page 55: ...d then you need to key in Pulley Diameter in mm Encoder Impulses revolution and Beltspeed will be displayed in m min When the entire block is ready press Enter again This will set the whole block and move on to the next block in this case RATE CORRECTION FACTOR To view or alter the Beltweigher Settings selection press Enter when the BELTWEIGHER SETTINGS function block is displayed All values can b...

Page 56: ...n tons hr Or tonnes 0 1 lbs tons Or 0 1kg tonnes 0 1 lbs tons F1 4 Function Keys None D1 6 Digital Inputs None Display SP 1 6 SP configuration None Key in 00001 99999 0001 9999 weighsection length see Drawing 000 00 999 99 Metres Min SP1 6 Set in SP configures None Belt Rate Fullscale value Analog ouput Set 0000 1 9999 9 meters min or display in measure 0001 9999 drum diameter 0001 9999 encoder im...

Page 57: ... only be obtained from running the beltweigher into or out of a weighsilo or measuring out into a truck or railcar and getting an accurate weight over time The Rate Correction factor is only applicable to the range of 50 to 200 The Rate Correction Factor should be set to 100 if no deadweight calibration test has been carried out The Beltweigher Rate reading is multiplied by the Rate Correction Fac...

Page 58: ... FACTOR FACTOR 100 00 LINEARIZER 13 C LINEARIZER Service Menu Function Block Number 12 Beltweigher 12 CORRECTION FACTOR SPAN TRIM OR RATE CF SIMULATE BELTWEIGHER SETTINGS LINEARISER SERVICE SERVICE Key 50 00 200 00 Beltweigher Page 57 ...