Manual 1

Instruction Manual February 2004
MILLTRONICS BW100
milltronics
BW100
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.
Warning: This product can only function properly and safely if it is correctly transported,
stored, installed, set up, operated, and maintained.
Note: Always use product in accordance with specifications.
Copyright Siemens Milltronics Process Disclaimer of Liability

Instruments Inc. 2004. All Rights Reserved
This document is available in bound version and in While we have verified the contents of
electronic version. We encourage users to this manual for agreement with the
purchase authorized bound manuals, or to view instrumentation described, variations
electronic versions as designed and authored by remain possible. Thus we cannot
Siemens Milltronics Process Instruments Inc. guarantee full agreement. The
Siemens Milltronics Process Instruments Inc. will contents of this manual are regularly
not be responsible for the contents of partial or reviewed and corrections are included
whole reproductions of either bound or electronic in subsequent editions. We welcome
versions. all suggestions for improvement.
Technical data subject to change.
MILLTRONICS®is a registered trademark of Siemens Milltronics Process Instruments Inc.
Contact SMPI Technical Publications at the following address:
Technical Publications
Siemens Milltronics Process Instruments Inc.
1954 Technology Drive, P.O. Box 4225
Peterborough, Ontario, Canada, K9J 7B1
Email: [email protected]
For the library of SMPI instruction manuals, visit our Web site: www.siemens-milltronics.com
© Siemens Milltronics Process Instruments Inc. 2004

Table of Contents
Table of Contents
Milltronics BW100 ......................................................................................................................................1
mmmmm
Milltronics BW100 Features .................................................................................................................1
Safety Notes .............................................................................................................................................2
The Manual ...............................................................................................................................................2
Specifications ...............................................................................................................................................3
Installation .....................................................................................................................................................6
Dimensions ..............................................................................................................................................6
Interconnection ........................................................................................................................................7
System Diagram .............................................................................................................................7
Terminal Block Layout .................................................................................................................8
Load Cell - Single ...........................................................................................................................9
Load Cell - Dual ...........................................................................................................................10
Speed Sensor ...............................................................................................................................11
Auto Zero ......................................................................................................................................12
Remote Totalizer 1 ......................................................................................................................12
Analog Output .............................................................................................................................12
Remote Totalizer 2 ......................................................................................................................13
Relay Output ................................................................................................................................13
Communication ......................................................................................................................................14
Bipolar Current Loop ..................................................................................................................14
Power Connections ..............................................................................................................................15
AC Power ......................................................................................................................................15
DC Power ......................................................................................................................................15
Comverter ................................................................................................................................................16
Optional Dolphin Interface ........................................................................................................16
Units Sticker ................................................................................................................................16
Start Up ...........................................................................................................................................................17
Orientation ..............................................................................................................................................17
Display and Keypad ...................................................................................................................17
PROGRAM Mode ..................................................................................................................................18
Maneuvering ................................................................................................................................18
Master Reset ..........................................................................................................................................21
Load Cell Balancing ..............................................................................................................................21
Quick Start ..............................................................................................................................................23
Start Up ....................................................................................................................................................24
Zero Calibration ..........................................................................................................................26
Span Calibration ..........................................................................................................................27
Recalibration ...............................................................................................................................................29
Belt Speed Compensation ..................................................................................................................29
Material Tests ........................................................................................................................................30
Design Changes .....................................................................................................................................31
Recalibration ...........................................................................................................................................31
i
Routine Zero .................................................................................................................................32
Initial Zero .....................................................................................................................................33
Direct Zero ....................................................................................................................................34
Routine Span ................................................................................................................................35
Initial Span ...................................................................................................................................36
Direct Span ...................................................................................................................................37
Factoring ..................................................................................................................................................38
Linearization ...........................................................................................................................................39
Operation .......................................................................................................................................................42
Load Sensing ..........................................................................................................................................42
Speed Sensing .......................................................................................................................................42
Modes of Operation ..............................................................................................................................42
Damping ...................................................................................................................................................43
Analog Output ........................................................................................................................................43
Relay Output ...........................................................................................................................................44
Totalization ..............................................................................................................................................45
Auto Zero .................................................................................................................................................46
Communications ........................................................................................................................................47
Protocol ....................................................................................................................................................47
Data Field Descriptions ..............................................................................................................48
Message Requests .....................................................................................................................48
Message Responses ..................................................................................................................49
Parameters ....................................................................................................................................................50
Quick Start (P005 to P017) ..................................................................................................................50
Relay/Alarm Function (P100 - P117) .................................................................................................53
mA Output Parameters (P200 - P220) ..............................................................................................53
Load Cell Balancing Parameters (P291 - P295) .............................................................................55
Linearization Parameters (P390 - P396) ..........................................................................................57
Totalization (P619 - P648) .....................................................................................................................58
Communication (P751 - P761) .............................................................................................................61
Test and Diagnostic (P900 - P951) ....................................................................................................62
Troubleshooting ..........................................................................................................................................65
Maintenance ..........................................................................................................................................67
Software Updates .................................................................................................................................67
Appendix ........................................................................................................................................................68
Alphabetical Parameter List ...............................................................................................................68
Program Record .....................................................................................................................................70
Index .................................................................................................................................................................72
ii
Milltronics BW100
Introduction
Note: The Milltronics BW100 is to be used only in the manner outlined in this
mmmmm
instruction manual.
The Milltronics BW100 is an economical integrator for use with belt scales. The speed
and load signals from the conveyor and scale, are processed to derive rate of material
flow and totalization.
The primary values of speed and load, and the derived values of rate and total are
available for display on the local LCD, or as output in the form of analog mA, alarm relay
and remote totalization. BW100 supports Milltronics proprietary bipolar current loop for
long distance communication to PLC or computer. It is also compatible with Milltronics
Dolphin interface for remote display, programming and software upgrading.
Milltronics BW100 Features

• multi-field LCD display
• two remote totalizer contacts
• current loop for communications
• Dolphin compatibility
• programmable relay
• isolated mA output
• rate linearization
• local keypad
• Auto Zero
Load Speed
M aterial
total
7ML19985DJ01 Milltronics BW100 - INSTRUCTION MANUAL Page 1

Safety Notes
Special attention must be paid to warnings and notes highlighted from the rest of the text
Introduction
by grey boxes.
mmmmm
WARNING means that failure to observe the necessary precautions

can result in death, serious injury, and/or considerable material
damage.
Note: means important information about the product or that part of the operating
manual.
The Manual
It is essential to refer to thismanual for proper installation and operation of your BW100
belt scale integrator. As the BW100 must be connected to a belt scale, and optionally a
speed sensor, refer to their manuals as well.
The manual is designed to help you get the most out of your BW100, and it provides
information on the following
• How to install the unit • Outline diagrams
• How to program the unit • Wiring diagrams
• How to operate the keypad • Parameter values
and read the display • Parameter uses
• How to do an initial Start Up • Modbus register mapping
• How to optimize and • Modem configuration
maintain accurate operation
of the unit
Note: The Milltronics BW100 is to be used only in the manner outlined in this
instruction manual.
If you have any questions, comments, or suggestions about the manual contents, please
email us at [email protected].
For the complete library of Siemens Milltronics manuals,

go to www.siemens-milltronics.com.
Page 2 Milltronics BW100 - INSTRUCTION MANUAL 7ML19985DJ01

Specifications
Power
• standard: 100/115/200/230 Vac ± 15%, 50/60 Hz, 15VA
• optional: 10 - 15 V dc, 15 W
18 - 30 V dc, 15 W
Application
• compatible with Siemens Milltronics belt scales or equivalent
Specifications
Accuracy
mmmmm
• 0.1% of full scale
Resolution
• 0.02% of full scale
Environmental
• location: indoor / outdoor
• altitude: 2000 m max
• ambient temperature: -20 to 50 °C (-5 to 122 °F)
• relative humidity: suitable for outdoor
• installation category: II
• pollution degree: 4
Enclosure
• polypropylene alloy
• Type 4X / NEMA 4X / IP 65
• sealed electronics compartment
• integral junction box with termination block for 0.2 - 4 mm solid or
0.2 - 2.5 mm stranded (12 - 24 AWG)
Programming
• via local 4 member keypad with silicone boot and/or Dolphin interface
Display
• 38 x 100 mm (1.5 x 4") multi-field liquid crystal display
Memory
• program stored in non-volatile FLASH memory, upgradable via Dolphin interface
• parameters stored in non-volatile EEPROM

Inputs
• load cell: 0 - 45 mV dc per load cell
• speed sensor: pulse train: 0-5 V low, 5-15 V high, 1 to 2000 Hz,
or
open collector switch
or
relay dry contact
• auto zero: dry contact from external device
Outputs
• analog: - optically isolated 0/4 - 20 mA
- 750 Ω max loading
Specifications
• resolution: - 0.1% of 20 mA
mmmmm
• load cell: - 10 Vdc compensated for strain gauge type, 2 cells max
• speed sensor: - 12 Vdc, 50 mA max excitation
• remote totalizer 1: - contact closure 32 - 288 ms duration
- open collector switch rated 30 Vdc, 100 mA max
• remote totalizer 2: - contact closure 32 - 288 ms duration
- open collector switch rated 240 Vac/dc, 100 mA max
• relay output: programmable function 1 form C SPDT relay contact rated
5 A at 250 Vac, non-inductive
Communications
• Dolphin compatible
• proprietary bipolar current loop
Cable/Separation:
• one load cell/LVDT:
non-sensing: Belden 8404, 4 wire shielded, 20 AWG or equivalent,
150 m (500 ft.) max.
sensing: Belden 9260, 6 wire shielded, 20 AWG or equivalent,
300 m (1000 ft.) max.
• two load cells:
non-sensing: Belden 9260, 6 wire shielded, 20 AWG or equivalent,
150 m (500 ft.) max.
sensing: Belden 8418, 8 wire shielded, 20 AWG or equivalent,
300 m (1000 ft.) max.
• speed sensor Belden 8770, 3 wire shielded, 18 AWG or equivalent,
300 m (1000 ft.) max.
• auto zero: Belden 8760, 1 pair, twisted/shielded, 18 AWG, 300 m
(1000 ft.) max.
• remote total: Belden 8760, 1 pair, twisted/shielded, 18 AWG, 300 m
(1000 ft.) max.

• analog output: Belden 8760, 1 pair, twisted/shielded, 18 AWG or
equivalent
• bipolar current: Belden 9552, 2 pair, twisted/shielded, 18
• (comm. port) AWG, 3000 m (10,000 ft.) max. loop
• remote total Belden 8760, 1 pair, twisted/shielded, 18AWG,
• t1 (dc) 300 m (1000 ft.) max.
Options:
• Speed Sensor: - Siemens Milltronics MD-36 series, or equivalent
• Dolphin: - Milltronics Windows based software interface and
infrared ComVerter link
Approvals:
Specifications
• CE*, CSA NRTL/C
mmmmm
*EMC performance available upon request

Installation
Notes:
• Installation shall only be performed by qualified personnel and in
accordance with local governing regulations.
• This product is susceptible to electrostatic shock. Follow proper
grounding procedures.
Dimensions
270mm
(10.6")
254 mm
(10")
138 mm
(5.4")
69 mm
(2.7")
Installation
mmmmm
integral junction box

sealed (cover removed)
enclosure with terminal block and
voltage selection switch
Conduit entry area. Recommend drilling the enclosure with a hole

saw and the use of suitable cable glands to maintain ingress rating.
74 mm
(2.9")
mounting hole
6.4 mm (1/4") Ø 5 mm
(0.2")
Note: Non metallic enclosure does not provide grounding between connections.
Use grounding type bushings and jumpers.

Interconnection
Note: Wiring may be run via common conduit. However these may not be run in
the same conduit as high voltage contact or power wiring.
System Diagram
Siemens
Milltronics
1 belt scale, see
Specifications,
Milltronics page 3
BW100
1 speed sensor,
optional, see
Specifications,
page 3
1 mA output customer
device
2 relay output customer alarm,

or control device
remote
Installation
2 totalizer customer’s
remote
mmmmm
totalizing device
bipolar current
1 loop
customer device
(Milltronics communications)
Note: Typical system capability. Not all components or their maximum quantity
may be required.

Terminal Block Layout
ac supply
1 - SIG B 17 - EXC
LOAD CELL
LOAD CELL
2 + SIG B 18 - SEN
3 - SIG A 19 +SEN
4 + SIG A 20 + EXC
5 CNST. SPD. 21 SHIELD
6 COM. 22 TX1
SPEED
COM. PORT
7 + SIG 23 TX2
8 + EXC 24 RX1
9 + AUTO 25 RX2
ZERO
10 26 DC
11 SHIELD 27 + TOTAL (1)
12 DC/AC
28 + mA
TOTAL(2) OUT
13 29
14 N.O. 30
ALARM
15 COM 31 L2/N
16 N.C. 32 L1
MILLTRONICS BW100
dc supply
Installation
mmmmm
1 - SIG B 17 - EXC
1 - SIG B 17 - EXC
LOAD CELL
LOAD CELL
2 + SIG B 18 - SEN LOAD CELL
LOAD CELL
2 + SIG B 18 - SEN
3 - SIG A 19 +SEN
3 - SIG A 19 +SEN
4 + SIG A 20 + EXC
4 + SIG A 20 + EXC
6 COM. 22 TX1
SPEED
6 COM. 22 TX1
SPEED
COM. PORT
COM. PORT
7 + SIG 23 TX2
7 + SIG 23 TX2
8 + EXC 24 RX1
8 + EXC 24 RX1
9 + 25 RX2
9 + 25 RX2
AUTO
AUTO
ZERO
10 26 10 ZERO
26
DC DC
11 SHIELD 27 + TOTAL (1) 11 SHIELD 27 + TOTAL (1)
12 DC/AC
28 +
mA 12 28 + mA
DC/AC
TOTAL(2) OUT TOTAL(2) OUT
13 29 13 29
14 N.O. 30 14 N.O. 30
ALARM
ALARM
15 COM 31 - 15 COM 31 -
24 V
16 N.C. 32 + 16 N.C. 32 +
MILLTRONICS BW100 MILLTRONICS BW100
All field wiring must have insulation suitable for at least 250 V.
dc terminals shall be supplied from a SELV source in accordance with IEC-

1010-1 Annex H.

Load Cell - Single
Belt Scale
+ +
S S E E
I I X X
G G C C
s
h g w r b
l r h e l
d n t d k
BW100
TB1
UPPER
SIG B
customer
LOADCELL
+ SIG B junction box
SIG A
+ SIG A
CNST. SPD.
BW100
TB1
Installation
LOWER
mmmmm
EXC
* Note: If load cells are supplied with

LOADCELL
SEN
sense wiring:
+ SEN
terminate brown with black = T17
+ EXC * and blue with red = T20
at junction box
SHIELD
Where separation between the BW100 and belt scale exceeds 150 m (500 ft.):
1. remove the jumpers BW100 TB1 – 17/18 and TB1 19/20
2. run additional conductors from:
BW100 TB1 – 18 to scale ‘– EXC’
BW100 TB1 – 19 to scale ‘+ EXC’
If the load cell wiring colours vary from those shown, or if extra wires are provided,
consult Siemens Milltronics.

Load Cell - Dual
’A’ Belt Scale ’B
load cells
s
h r b w g w g
l e l h r h r
d d k t n t n
BW100
TB1
UPPER
SIG B
customer
LOADCELL
+ SIG B junction
box
SIG A
+ SIG A
CNST. SPD.
BW100
TB1
LOWER
Installation
EXC
Note: If load cells are supplied with
mmmmm
LOADCELL
SEN
sense wiring:
+ SEN terminate brown with black = T17
and blue with red = T20
+ EXC
at junction box
SHIELD
Where separation between the BW100 and belt scale exceeds 150 m (500 ft.):
1. remove the jumpers BW100 TB1 – 17/18 and TB1 19/20
2. run additional conductors from:
BW100 TB1 – 18 to scale ‘– EXC’
BW100 TB1 – 19 to scale ‘+ EXC’
If the load cell wiring colours vary from those shown, or if extra wires are provided,
consult Siemens Milltronics.

Speed Sensor
MD - 36 series
speed sensor
P
1 C C G
5 C C O N
V W W M D
BW100
TB1
UPPER
+ SIG A
CNST. SPD. RBSS
or
COM OR
SPEED
encoder
+ SIG r w b
e h l
+ EXC d t k
AUTO
+
ZERO
SHIELD
OR
Installation
TASS
mmmmm
b b b
r l l
n k u
! Connect the BW100 TB1 – 7 to the MD - 36 series speed sensor terminal:

• ‘2’ for clockwise speed sensor shaft rotation
• ‘3’ for counter-clockwise speed sensor shaft rotation.
MD shaft rotation is viewed from the front cover side of the MD enclosure.
# If a speed sensor is not used, a jumper must be connected across the BW100 TB1 –
5 / 6. If a speed sensor is used, insure that the jumper is removed.
! Input device in the form of open collector transistor or dry contact across TB1 – 6 / 7
will also serve as a suitable speed signal.

Auto Zero
BW100
TB1
UPPER
+
AUTO prefeed activated dry contact
ZERO
Remote Totalizer 1
BW100
TB1
LOWER
26
DC
TOTAL (1) +
27
Installation
28 + -
mmmmm
29
supply remote
30 maximum 30 totalizer
V dc, 100 mA
Analog Output
BW100
TB1
LOWER
+ to customer instrumentation
mA
OUT isolated mA output, 750 Ω maximum load ac
models only
mA output on dc models is not isolated

Remote Totalizer 2
BW100
TB1
UPPER
DC/AC
TOTAL (2)
supply remote
maximum totalizer
240 V ac/dc
Relay Output
Installation
mmmmm
BW100
TB1
UPPER
relay shown in
n.o. de-energized
state, contacts
com rated 5 A at 250V
non-inductive
n.c.

Communication
Bipolar Current Loop
T
R R
A S E
N H C
S I E
M E I
I L V
T D E
Customer
Device
BW100
TB1 25 24 23 22
LOWER
SHIELD 21
TX1 22
TX2 23
RX1 24
Installation
RX2 25
mmmmm
Connect shield at one device only, e.g. BW100 TB1 - 21

Maximum loop length 3000 m (10,000 ft.)

Power Connections
AC Power
230 V
OFF
200 V 1 - SIG B 17 - EXC
LOAD CELL
LOAD CELL
2 + SIG B 18 - SEN
3 - SIG A 19 +SEN
4 + SIG A 20 + EXC
6 COM. 22 TX1
SPEED
COM. PORT
100 V 115 V 7 + SIG 23 TX2
8 + EXC 24 RX1
9 + 25 RX2
AUTO
BW100 10
ZERO
26
DC
TB1 11 SHIELD 27 +
TOTAL (1)
LOWER
12 DC/AC
28 + mA
TOTAL(2) OUT
13 29
14 N.O. 30
ALARM
15 COM 31 L2/N
16 N.C. 32 L1
L2/N MILLTRONICS BW100

L1
Note: The equipment must be protected by a 15 A fuse or a circuit breaker in the

building installation.
Installation
A circuit breaker or switch in the building installation, marked as the disconnect
mmmmm
switch, shall be in close proximity to the equipment and within easy reach of the
operator.
DC Power
12 Vdc Model 24 Vdc Model
26
DC 26
DC
11 SHIELD 27 + TOTAL (1) TOTAL (1)
11 SHIELD 27 +
12 28 +
DC/AC mA 12 28 + mA
TOTAL(2) OUT DC/AC
13 29 TOTAL(2) OUT
13 29
14 N.O. 30
"
14 N.O. 30
ALARM
"
15 COM 31
ALARM
12 V 15 COM 31
16 N.C. 32 + 24 V
MILLTRONICS BW100
é 16 N.C.
MILLTRONICS BW100
32 +
é
BW100 BW100
TB1 TB1
LOWER LOWER
30 30
31 31
32 32
10 - 15 Vdc 18 - 30 Vdc
" dc model indicated on lid nameplate.
dc terminals shall be supplied from an SELV source in accordance with

IEC-1010-1 Annex H.

Comverter
Optional Dolphin Interface
Comverter
Milltronics BW100
Refer to Dolphin instruction manual for interconnection details.

Installation
Units Sticker
mmmmm
Remove the appropriate units sticker from the sheet supplied, and affix to your BW100 as
shown.

Start Up
Note: For successful start up, ensure that all related system components such as
belt scale and speed sensor are properly installed and connected.
Orientation
Display and Keypad
LCD
balance switch, SW2
balance potentiometer, P1
Installation
mmmmm
Keypad
The BW100 operates under two modes: RUN and PROGRAM. When the unit is initially
powered, it starts in the PROGRAM mode.
1 2 3
If the PROGRAM mode is idle, it reverts to the run mode after 10 minutes.

PROGRAM Mode
LCD parameter value ’change value’
accessed
1 2 3
PROGRAM status icon, parameter

mode refer to number
RUN Mode
KeyPad
alternates
access scroll scroll
PROGRAM
RUN up down
mode between
mode
select parameter
and change value
Maneuvering
To Select a Parameter:
if not in the PROGRAM

mode
from the
RUN mode 1 2
Start Up
mmmmm
1 2 3
if in the PROGRAM
mode
1 2 3

Speed Scroll
OR
To speed scroll up or down press the up or down key and hold, then press the ENTER key
and hold. Release to stop.
To Change a Parameter Value:
select parameter,
e.g. P005 = 1
1 2 3
initiate change function

1 2 3
security must be disabled
increase or decrease
to the desired value.
if no response,
security not disabled
Start Up
mmmmm
save and return to select

parameter function,
e.g. P005 = 3
must be pressed to
save change

Express:
Parameter
to jump back to P005
or
Value
to jump to the factory setting
e.g. P999
jump back to P005
To Access RUN Mode:
e.g. from the PROGRAM

mode, P005
exit and return

to RUN mode
Start Up
mmmmm
1 2

To Access the PROGRAM Mode:
from the run mode e.g. rate display

1 2
last parameter from

previous PROGRAM session
e.g. P005
Master Reset
Prior to programming, balancing and calibration, a master reset of the BW100 should be
done.
Refer to Parameter P999 on page 64.
Load Cell Balancing

If you are operating a two load cell belt scale, it is recommended that the load cells be
balanced electronically prior to initial programming and calibration, or after either or both
load cells have been reinstalled or replaced.
Note: Unbalanced load cells adversely affect the performance of your belt
conveyor weighing system.
Load Cell Load Cell

’A’ ’B’
Start Up
test weight bar mmmmm
belt travel
typical dual load cell scale
With the conveyor stopped and locked out, lift the belt off the weighing idlers.

Place the BW100 into the PROGRAM mode at P291.
test weight on
load cell B side
’B’ ’A’
SW2
closed
test weight
select P291 ensure SW2
is closed
SW2
open
enter and auto advance to P292,
open SW2
SW2
open
’B’ ’A’
leave SW2 open
test weight on
load cell A side
test
weight
SW2
closed
Start Up
close SW2
mmmmm
P1
adjust until
enter and auto advance to P295 ## = 0 +/- 5
Remove the test weight, insure that the BW100 SW2 is in ‘close’ position and that P1 is
left as set.
Note: Performing a balance procedure requires a subsequent zero and span

recalibration.

Quick Start
Quick Start parameters (P005 to P017) must be programmed for all applications.
Record parameter in Program Record on page 70.
units
design rate
design speed
speed constant
belt length
test load
1 2 3
Upon completion of Quick Start programming, a Zero and Span calibration are
required for successful entry into the RUN mode.
Start Up
mmmmm

Start Up
Program P005 - P017
program mode P005, units
refer to Maneuvering e.g. 1, t/h
on page 18 for
parameter selection
and changing values.
P011, design rate *

e.g. 200 t/h
* from design data P014, design speed *

sheet, if provided e.g. 0.5 m/s
#for constant speed

applications, TB1 - 5/6 P015, speed constant * #
jumpered, value is e.g. 100.3 pulse / m
locked at 100.
P016, belt length

Start Up
e.g. 65.72 m
mmmmm
P017, test load *

e.g. 55.56 Kg / m
Examples are typical

Test load value should be less than design load (P952). If not, contact Siemens or their
agent.
Calibration Note: The duration of Zero and Span Calibration is dependent upon
speed (P014), length (P016) and revolutions (P360) of belt.
1 2 3 1 2
Note: To cancel a Zero or Span calibration in progress, press
Start Up
mmmmm

Zero Calibration
Note: Run the conveyor for several minutes to warm up the belt and insure that it
is empty. Test weights are not used during a zero calibration.
zero calibration required

1 2 3
initial zero count

1 2 3
zero calculation,
frequency count displayed
1 2
zero deviation calculated,

initial deviation = 0
1 2
Start Up
mmmmm
zero deviation accepted,

initial zero count = ###
Record this value for future
1 2
reference
Perform Span Calibration,

see next page

Span Calibration
Run the conveyor until the belt is empty and stop it. Suspend the test weight from the
scale per its instruction manual. Run the conveyor belt empty.
initial span count
1 2
span calculation,
frequency count
displayed
1 2
span deviation
calculated
initial deviation = 0
1 2
span deviation accepted

initial span count = ####
Record this value for
future reference
1 2
Remove the test weight when the Span calibration is complete.

Start Up
mmmmm
successful entry
into run,
display rate
1 2

RUN Mode
LCD
reading
mA
bar
graph
1 2 3
totalization = relay status, display scroll

in process appears on alarm r= rate
1,2 = remote totalizer t1 = totalizer 1
$ flashes at rate t2 = totalizer 2
totaling L = load
3 = parameter alert, S = speed
zero and span
calibration required
Keypad
access initiate
scroll initiate
PROGRAM span
display zero
mode
Start Up
mmmmm

Recalibration
Belt Speed Compensation

In order to achieve optimum accuracy in the rate computation, the belt speed displayed
must equal that of the actual belt speed. As the speeds are likely to differ, a belt speed
compensation should be performed.
Run the conveyor with the belt empty.
run mode /speed display,

View the belt speed e.g. 0.750 m/s
1 2
Stop the conveyor and measure a length of the belt; marking the forward end (start time)
and the back end (stop time). Use the belt scale as the stationary reference.
Run the belt and measure the time for the belt length to pass over the scale.
speed = belt length m or ft.
time s min.
Refer to Maneuvering on page 18 for parameter selection and value change.
PROGRAM mode -
with conveyor
assumed speede.g.
running empty
0.75 ms
%
enter calculated speed
Start Up
e.g. 0.8 m/s mmmmm
jumps to P014 or P015

showing new value
If the BW100 constant speed input (TB1-5/6) is jumpered, the design speed (P014) is
automatically adjusted.
If a speed sensor is connected, the speed constant (P015) is automatically adjusted.
The display speed (used in the rate computation) now equals the actual speed.
Record the new value in Appendices/Program Record.

Material Tests
Perform material tests to verify the accuracy of the of the span calibration. If the material
tests indicate a repeatable deviation exists, a manual span adjust (P019) is then
performed. This procedure automatically alters the span calibration and adjusts the test
load (P017) value, yielding more accurate span recalibrations.
Note: Test weights are NOT used during material tests.
1. Run the belt empty.

2. Perform a zero calibration.
3. Put the BW100 into RUN mode
4. Record the BW100 total as the start value _ _ _ _ _ _
5. Run material at a minimum of 50% of design rate over the belt scale for a minimum
of 5 minutes.
6. Stop the material feed and run the conveyor empty.
7. Record the BW100 total as the stop value _ _ _ _ _ _
8. Subtract the start value from the stop value to determine the BW100 total
9. Weigh the material sample if not already known.
kg / lb
0
BW500
start total
scale
kg / lb
BW500
stop total
scale
BW100 total = _ _ _ _ _ _ material sample weight = _ _ _ _ _ _

• Calculate the span adjust value:
% span adjust = BW100 total - material sample weight x 100
material sample weight
Recalibration
mmmmm

If the span adjust value is within the accuracy requirements of the weighing system, the
material test was successful and normal operation can be resumed.
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 Milltronics or its agent.
If the span adjust values are significant and repeatable, perform a manual span adjust:
refer to Maneuvering,
page 18 for PROGRAM
parameter selection mode,
and value change P019
if % span adjust is enter %

negative, be sure span adjust,
to enter as e.g. 0.05
negative value
jumps to P017 adjusted

test load, e.g. 97.95
Verify the results of the span adjust by material test or return to normal operation
Design Changes
Where parameters have been changed with a resultant impact on the calibration or do
not take effect until a recalibration is done, the parameter warning icon is displayed. In
order to clear the icon, perform a zero and span recalibration after the reprogramming
session is complete.
If significant changes have been made, an initial zero (P377) and/or initial span (P388)
may be required.
Recalibration
Recalibration
In order to maintain the accuracy of the weighing system, periodic zero and span
mmmmm
recalibrations are required. Recalibration requirements are highly dependent upon the
severity of the application. Perform frequent checks initially, then as time and experience
dictate, the frequency of these checks may be reduced. Record deviations for reference.

Routine Zero
Run the conveyor empty for several minutes to warm up the belt and insure that it is
empty. Test weights are not used during a zero calibration.
From the initiate zero calibration

run mode current zero count = ####
1 2
zero calculation,
load value displayed
1 2
zero deviation calculated

1 2
accept deviation
new zero count = ####
1 2
return to run mode

1 2
Note: E3 is an indication that the mechanical system is errant. The use of P377,
initial zero, should be used judiciously and only after a thorough mechanical
investigation has been exercised.
The cause of the increased deviation must be found and rectified. A zero recalibration as
previously described can then be retried.
If the operator deems this deviation to be acceptable, set P377 to 1 to invoke an initial
zero calibration. Further deviation limits are now based on this new initial zero.
Recalibration
mmmmm

Initial Zero
Perform an initial zero if necessary when a calibration is out of range message is shown.
select P377
invoke initial
zero, enter 1
current zero count
1 2
zero calculation
frequency count
displayed
1 2
zero deviation
1 2
zero deviation accepted

initial zero count = ####
1 2
Recalibration
Perform Initial Span

mmmmm

Direct 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.
current zero count
enter previously recorded

zero count
new zero count accepted

Recalibration
mmmmm

Routine Span
To perform a routine span recalibration, run the conveyor until the belt is empty and stop
it. Suspend the test weights from the belt scale per its instruction manual.
Run the conveyor empty at maximum operating speed.
Initiate span
From the calibration
zero calibration current span count
1 2 = ####
span calculation,
load value
displayed
1 2
span deviation = ##
1 2
accept deviation
new span count = ####
1 2
return to run mode

1 2
Notes:
• E6 is a reminder that a zero calibration is strongly suggested before a span
calibration is initiated. Press ENTER to bypass this message.
• E4 is an indication that the mechanical system is errant. The use of P388, initial
span, should be used judiciously and only after a thorough mechanical
investigation has been exercised.
The cause of the increased deviation must be found and rectified. A span recalibration as
previously described can then be retried.
Recalibration
If the operator deems this deviation to be acceptable, set P388 to 1 to invoke an initial
mmmmm
span calibration. Further deviations are now based on this new initial span.
Note: Remove the test weight when the span calibration is complete.

Initial Span
Note: Perform an initial span when a calibration out of range message appears.
select P388
invoke initial span
current span count = ####

1 2
span calculation,
frequency count displayed
1 2
span deviation = ##
1 2
span deviation accepted

initial span count = ####
1 2
return to run mode

1 2
Recalibration
mmmmm

Direct Span
Direct span entry (P368) is intended for use when replacing software or hardware, and
when it is not convenient to perform an initial span. A record of the last valid span count
is required.
current span count
%
enter previously recorded
span count
new span count accepted
Recalibration
mmmmm

Factoring
In order to calculate the value of a new or unknown test weight to the current span, the
factoring procedure is used.
Note: For optimum accuracy in the factoring results, a routine zero calibration is
recommended.

With the conveyor stopped and the belt empty:
P359 selected
enter
initiated Factoring,
current test load value
e.g. 76.11 kg / m
hang new test weight
onto belt scale, then
run the conveyor empty
dynamic test load value

e.g. 76.03 kg / m
jumps to P017
dynamic test load value
e.g. 76.03 kg / m
return to run mode

Recalibration
1 2
mmmmm

Linearization
Conveyor applications where the belt scale is poorly located, or where there is a high
degree of variation in belt tension, typically cause the belt scale to report load non-
linearly. The BW100 provides a linearizing function (P390 - P396) in order to correct for the
deficiency in the weighing system and to provide an accurate report of the actual
process.
To verify that the cause of the non-linearity is not mechanical:

1. Run the conveyor belt empty and stop it.
2. Suspend various test weights to the scale to verify mechanical linearity. If the load
reported by the BW100 at these tests is non-linear, a mechanical problem is
indicated. Refer to the belt scale manual in order to resolve the non-linearity by
improved installation or repair.
If it is determined that the non-linearity is due to the weighing application,

and not the actual belt scale, apply linearization by performing the
following:
• zero calibration
• span calibration at 90 to 100% of design rate
• material tests at 90 to 100% of design rate
• manual span adjust if required
• material tests at 1 to 3 intermediary flow rates where compensation is required.
Notes:
• Compensation points must be at least 10% of the design load apart.
• E8 message occurs if a point is less than 10% of full scale or if points are less
than 10% apart.
• calculate the percentage compensation for each flow rate tested.

% compensation = actual weight - totalized weight x 100
totalized weight
Where: actual weight = material test

totalized weight = BW100 total
Recalibration
mmmmm

Example:
A non-linearity with respect to the ideal response exists in a belt scale application with
design rate of 200 t/h. It is decided to do material tests at 25, 50 and 75% of the design
rate. After performing a zero and a span calibration at 100% of the design rate, followed
by material tests and manual span adjust, three material tests were performed at 50, 100
and 150 t/h, as indicated by the BW100. The following data was tabulated. (This example
is exaggerated for emphasis).
The material tests should be run at same belt speed, representative of normal operation;
in this case 1.2 m/s. For each rate, record the corresponding load value by scrolling to the
BW100 load display during running conditions or by calculation.
load = rate
speed
BW100 load material test BW100 total compensation*

kg/m tonnes tonnes %
11.6 4.2 4.9 -14.3
23.2 8.4 7.6 10.5
34.7 12.6 13.7 -8.0
*calculation example: % compensation = 4.2 - 4.9 x 100

4.9
= - 14.3
20 actual weight per material test

totalized weight by BW100
belt scale response
linearized BW100 response
% compensation
15 span (100%)
weight = tonnes
-8.0
10
10.5
5 3
-14.0
Recalibration
0 10 20 30 40 50
mmmmm
load - kg / m

Program the BW100 as follows: P390 = 1
P391 = 11.6
P392 = -14.3
P393 = 23.2
P394 = 10.5
P395 = 34.7
P396 = -8
Often only one point of compensation is required, usually at a low load value. In the prior
example, if compensation was only required at 11.6 kg/m, the programming could be as
follows. Compensation is optimized by establishing the next load value that agrees with
the material test, hence where compensation is zero and entering it as the next
compensation point.
P390 = 1
P391 = 11.6
P392 = -14.3
P393 = 23.2
P394 = 0
P395 = 34.7
P396 = 0
20 actual weight per material test

totalized weight by BW100
belt scale response
linearized BW100 response
% compensation
15 span (100%)
weight = tonnes
10
5
-14.03
Recalibration
0 10 20 30 40 50
load - kg / m
mmmmm

Operation
Load Sensing
In order for the BW100 to calculate rate and hence totalize material flow along the belt
conveyor, a load signal representative of weight of material on the belt is required. The
load signal is provided by the belt scale. The BW100 is compatible with belt scales fitted
with one or two strain gauge type load cells.
Refer to Specifications on page 3 and Installation/Load Cell on page 6 for belt scale
requirements and connection.
Speed Sensing
In order for the BW100 to calculate rate and hence totalize material flow along the belt
conveyor, a speed signal representative of belt speed is required. In constant speed
applications (no speed sensor), the BW100 can be programmed to provide an internal
speed signal. This is achieved by entering the design speed (P014) and providing a jumper
across speed input terminals (TB1-5/6). Speed constant (P015) defaults to 100.
For optimum accuracy of the weighing system, both constant and variable speed
applications, a speed sensor is required. Again, the design speed and speed constants
need to be programmed, however the jumper across the speed input has to be removed
and the speed sensor connected.
Refer to Specifications on page 3 and Installation/Speed Sensor on page 6 for speed
sensor requirements and connection.
Modes of Operation
RUN is the normal or reference mode of operation. It continuously processes the load
signal from the belt scale to produce internal load and rate signals, which are in turn used
as the basis for totalization, mA output and relay control. The RUN display is programmed
(P081) to scroll through rate, totalization, load and speed; either manually by pressing the
ENTER key, or automatically. A bar graph is continuously displayed. It is proportional to
the analog output as programmed (see Analog Output on page 43).
From the RUN mode, access to the PROGRAM mode on and zero and span calibration is
made.
The PROGRAM mode allows viewing and, with security permission (P000), changing
parameter values. During PROGRAM, RUN mode functions are still active, i.e.: rate, relay,
analog output and totalization. Error interrupts are suppressed and the bar graph is
Recalibration
disabled.
mmmmm
If the PROGRAM mode is left idle for a period of ten minutes, it automatically reverts to
the RUN mode.

Damping
Damping (P080) controls the speed at which the displayed readings and output functions
respond to changes in their respective input function; load, speed and the internal rate
Operation
signals. Changes in the displayed rate of material flow, material loading and belt speed
mmmmm
are controlled by the damping. Relay alarm functions based on input functions of flow,
load and speed, respond to the damped value.
If the specific mA output damping parameter (P220) is enabled (value other than 0), then
the damping (P080) as it pertains to the mA function is overridden, and the output value
and bar graph respond independently at the specified mA output damping rate (P220).
Analog Output
The BW100 provides one isolated analog output. The output can be assigned (P201) to
represent rate, load or speed. The output range can be set to 0 - 20 mA or 4 - 20 mA
(P200). The 0 or 4 mA value corresponds to empty or zero condition, whereas the 20 mA
value corresponds to the associated design value: rate (P011), load (P952) or speed
(P014). The analog output can be limited for over range levels of 0 mA minimum and 22
mA maximum (P212 and P213 respectively). The output 4 and 20 mA levels can also be
trimmed (P214 and P215 respectively) to agree with a millammeter or other external mA
input device.
The BW100 LCD provides a bar graph as a function of analog output. It displays the mA
value as percentage of the mA range.
The mA output value can be tested using parameter P911. Refer to Parameter P911 on
page 62.

Relay Output
The BW100 offers one single pole double throw (SPDT) relay that can be assigned (P100)
to one of the following alarm functions:
Operation
mmmmm
• rate: relay alarms on high and/or low material flow rate.

• auto zero: relay alarms when an attempted auto zero calibration reports an out of
range condition (E9).
• speed: relay alarms on high and/or low belt speed.
• load: relay alarms on high and or low belt load.
• error: relay alarms on any error condition as it is reported.
• Refer to Troubleshooting, page 65.
Except for alarm on ‘auto zero’ and ‘error’, the high and low alarm setpoints (P101 and
P102 respectively) are required and must be entered in the appropriate units.
The on / off actuation at both setpoints is buffered by the damping (P080) and the
programmable dead band (P117), to prevent relay chatter due to fluctuations. The relay is
normally energized; i.e. the normally closed (n.c.) contact held open. Upon an alarm
condition, the relay is de-energized and the alarm icon on the BW100 display appears.
Once in alarm, the relay and icon remain in alarm status until the alarm condition is
removed.
Example:
P014 = 2m/s, design speed
P100 = 3, belt speed
P101 = 100% (2m/s)
high
100%
2 m/s
actual OFF
22%
low
2% actual ON
20%
20%
0.4 m/s
alarm ON is with relay de-energized

Totalization
The totalization function is based on the internal rate (mass per unit time) signal
proportional to belt speed and load on the associated belt scale. It is not affected by the
Operation
damping function (P080). The rate signal is sampled several times a second to accurately
mmmmm
count the mass of material conveyed. The count is held in the master totalizer used to
increment the internal totalizers and to produce a pulse signal for the remote totalizers.
The BW100 provides four separate totalizer functions:
• internal totalizer 1
• internal totalizer 2
• remote totalizer 1
• remote totalizer 2
To avoid totalizing material at low flow rates, the totalizer drop out limit (P619) is set to a
percentage of the design rate. Below this limit, totalization stops. When material flow
returns to a rate above the drop out limit, totalization resumes.
Totalizer resolution or count value is set by the respective control parameters, P631 --
P639. If the resolution selected causes the totalizer to lag behind the count rate, an E2
error is displayed after making the parameter entry. The error is rectified by selecting a
greater resolution value.
Example: Internal totalizer 1
Given: P005 = 1 (t/h)
P631 = 4
Then: totalizer count increments by 10 for each 10 metric tonnes registered
External totalizer 1
Given: P005 = 1 (t/h)
P638 = 5
Then: contact closure occurs once for every 10 metric tonnes registered
For remote totalization, the contact closure duration is set by the respective control
parameters, P643 and P644. The value is automatically calculated upon entry of the
design rate (P011) and remote totalizer parameters (P638 and P639), so that the duration
of contact closure allows the relay response to track the total up to the design rate. The
value can be changed to suit specific contact closure requirements, such as in the case
of programmable logic controllers. If an E2 error is displayed, P638 or P639 has to be
increased.
The totalizers are reset through the master reset (P999), the totalizer reset (P648) or
through the keypad.
• master reset: the reset of all totalizer functions is included in the master reset.
• totalizer reset: totalizer reset can be used to resets internal totalizers 1 and 2, or
totalizer 2 independently.
• keypad: pressing simultaneously while in the RUN mode resets
internal totalizer 1, as well as the internal counts for both remote
totalizers.

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.
Auto Zero
Operation
mmmmm
The Auto Zero function allows a zero calibration to be initiated automatically under the
following conditions.
• the auto zero input (TB1-9/10) is in a closed state; jumper or remote switch
• the load is less than 2% of the design load
If the resulting zero deviation is less than an accumulated 2% from the last operator
initiated zero, the auto zero is accepted.
If the deviation is greater than an accumulated 2%, an E9 error is displayed and the relay,
if so programmed, goes into alarm (refer to Operation/Relay Output, page 44). The E9
error is cleared after five seconds.
If material feed resumes during an auto zero function, the totalizing function is
maintained.

Communications
Operation
The BW100 bipolar current loop provides long distance communication to a customer
mmmmm
device.
BW100
host
device
Bipolar
Converter
The BW100 communication port (TB1-21 to 25) is software set for baud (P751) and mode
enable (P760). Refer to Installation/Communication on page 14 for wiring details.
Note: If communicating via Milltronics Dolphin software, the baud rate must be
set to 4800.
Protocol
Protocol refers to the format, sequence and value of the data fields used in
communication messages. Each data field of a BW100 message contains one or more
bytes of ASCII binary code.
+ 20 mA
Each byte contains: s 1 2 3 4 5 6 7 8 s
t s n r t t t t t t
» 8 data bits a t d d h h h h h o
0
» no parity bit r p
» 1 stop bit t
– 20 mA

Data Field Descriptions
The following data fields are used.
som
BW100 start of message, ASCII character = STX (Hex Value = 02).
DEVICE
Identifies the BW100 to which the message applies. The device is a 2 character number
that equals the Unit I.D. code, (P761). ASCII characters = 00 to 15.
MT
Identifies the 2 character message type transmitted, ASCII characters:
Communications
50 = material flow rate

51 = material load
mmmmm
52 = belt speed
53 = totalizer 1, internal
54 = totalizer 2, internal
READING
Contains the measurement value in the engineering units of measure selected during
BW100 programming. The number of bytes in this data field varies dependent upon the
reading value. Up to 8 ASCII characters including the decimal point may be transmitted.
UNITS
Three ASCII characters identify the totalizer engineering units (MT=53 and MT=54). The
first character is always a space. The remaining characters may be:
t = tonnes
T = tonnes
LT = long tonnes
kg = Kilograms
lb = pounds
eom
BW100 end of message, ASCII character = CR (Hex Value = 0D).
Message Requests
Message requests must be transmitted from the host to the BW100 in the following
format.
som DEVICE MT eom
Example:
Data ASCII Example
Field Character Description
som STX start of message
DEVICE 01 for BW100 # 1
MT 50 material flow rate request
eom CR end of message

Message Responses
The BW100 response to a flow rate (MT=50) load (MT=51) or speed (MT=52) message
request is in the following format.
som DEVICE MT READING eom
Example:
Data ASCII Example
DEVICE 00 from BW100 # 0
Communications
MT 50 material flow rate response
READING 392.5 is 392.5
mmmmm
The response to a material total (MT=53) message request is in the following format.
som DEVICE MT READING UNITS eom
Example:
Data ASCII Example
DEVICE 01 from BW100 # 1
MT 53 material total response
READING 129.2 is 129.2
UNITS t metric tonnes

Parameters
Note: f denotes factory default.
P000 Security lock

Locks out the programming change value function such that the values of P001 through
P999 cannot be changed. This however does not prevent the select function from use; i.e.
for viewing values.
Programming is locked out if the value of P000 is other than 1954.
Communications
Entry:
mmmmm
1954 = unlockedf
1954 = locked
Quick Start (P005 to P017)

Note: Quick Start is the minimum parameter programming required before
attempting a calibration and successful entry into the RUN mode.
P005 Design Rate Units

Determines the units for programming and measurement.
Entry:
1f = t/hr (tonnes per hour)
2 = kg/hr (kilograms per hour)
3 = LT/Hr (long tons per hour)
4 = T/h (short tons per hour)
5 = lb/hr (pounds per hour)
Changing this parameter does not affect the rate (P011), belt speed (P014) or belt length
(P016) parameters. These parameters should be re-entered for conformity in units.
t = 1000 kg
LT = 2240 lb.
T = 2000 lb.
P011 Design Rate

Specifies the design rate of material flow for the belt scale.
Enter the design rate from the supplied design data sheet

P014 Design Speed
Specifies the design speed for the conveyor belt.
Speed unit s are:
metre/s if P005 = 1 or 2
feet/min. if P005 = 3, 4 or 5
P015 Speed Constant

This value multiplied with the speed sensor frequency, calculates the actual belt speed.
Entry: If speed input is wired for constant speed (TB1 5/6 jumpered), value defaults to
100.
Enter the speed constant = from the supplied design data sheet
or
= speed sensor pulses per revolution*
pulley circumference (m or ft)/ revolution
* refer to speed sensor nameplate or consult Siemens Milltronics or their agent.
Note: Common speed sensor pulses per revolution:
Parameters
RBSS - 150.4 pulses/meter (45.8 pulses/ft.)
TASS - 9.947 pulses/meter (3.03 pulses/ft.)
mmmmm
P016 Belt Length
The length of the conveyor belt (one belt revolution).
Length units are:
metre if P005 = 1 or 2
feet if P005 = 3, 4 or 5
Enter the belt length
P017 Test Load

The load to be referenced when performing a span.
Load units are:
kg/m if P005 = 1 or 2
lb./ft. if P005 = 3, 4 or 5
The value for P017 can be calculated as follows:
Test Load=Total weight of of all test weights (kg) or (lb)
idler spacing (m) (ft)
End of Quick Start parameters. A calibration can now be performed.

P018 Speed Constant Adjust
This parameter allows adjustment to the speed constant (P015).
Initially, this parameter displays the dynamic speed of the belt. If the displayed speed is
not equal to the actual speed, enter the actual belt speed.
For speed sensor applications, the value of P015 is automatically adjusted.
For constant speed (TB1 5/6 jumper) the value of P014 is automatically adjusted.
P019 Manual Span Adjust

This parameter allows adjustment to the span calibration.
The adjustment value is generally determined by performing material tests. Refer to
Recalibration/Material Tests, page 30.
Enter the calculated adjustment.
P022 Minimum Speed Frequency

Sets the minimum frequency that the speed sensor can reliably read. Signals at low
frequencies are erratic, adversely affecting the performance of the weighing system.
Entry:
Parameters
1 = 1 Hz (at 1 Hz, it takes 1 sec before defaulting to 0 speed)

mmmmm
2 = 2 Hz (at 2 Hz, it takes 0.5 sec before defaulting to 0 speed)
P080 Damping
Sets the speed of response to which the displayed readings (rate, load and speed), and
outputs (alarm and mA) react to change.
Note: The effect of damping (P080) on mA output can be overridden by mA output

damping (P220).
The greater the damping value, the slower the response.

Enter damping value, range 1 - 9999.
P081 Display Mode

Sets the display mode. Normally, the display shows rate, or the last manually selected
function. If set to alternating, the display alternates between rate and totalizer (1 and/or
2, as programmed by P647).
Entry:
0 = normal
1 = alternating

Relay/Alarm Function (P100 - P117)
Note: These parameter are specific to the use of the relay/alarm function. Refer
to Operation/Relay Output, page 13.
P100 Relay Set Up

Sets the alarm mode for the relay.
Entry:
0 = off
1 = rate
2 = auto zero
3 = belt speed
4 = belt load
5 = error
P101 High Alarm

Sets the high alarm setpoint for relay functions P100 = 1, 3 or 4.
Enter the value in % of full scale.
Parameters
P102 Low Alarm
mmmmm
Sets the low alarm setpoint for relay functions P100 = 1, 3 or 4.
Enter the value in % of full scale.
P117 Alarm Dead Band

Sets the dead band to prevent relay chatter due to fluctuations at the high or low
setpoint.
Enter the value in % of full scale
End of relay/alarm parameters.
mA Output Parameters (P200 - P220)

Note: These parameters are specific to the use of the mA output. Refer to
Operation on page 42 for details.

P200 mA Range
Sets the range for the mA output.
Entry:
1 = 0 - 20 mA
2 = 4 - 20 mA
P201 mA Function
Assigns the mA output to track one of the integrator functions.
Entry:
1 = rate
2 = load
3 = speed
P212 mA Min Limit

Limits the lower mA range (0 or 4 mA) to a minimum output value.
Enter limit value, range 0 - 22.
P213 mA Max Limit

Parameters
Limits the upper mA range (20 mA) to a maximum output value.

mmmmm
Enter limit value, range 0 - 22.
P214 4 mA Trim
Adjusts the 4 mA output level to agree with a milliammeter or other external mA input
device.
Enter trim value, range 0 - 9999.
P215 20 mA Trim
Adjusts the 20 mA output level to agree with a milliammeter or other external mA input
device.
Enter trim value, range 0 - 9999
P220 mA Output Damping

Sets the speed at which the mA output reacts to change.
The greater the damping value, the slower the response. If the value is 0, the mA output
assumes the damping set in P080.
Enter the damping value, range 0 - 9999
End of mA output parameters.

Load Cell Balancing Parameters (P291 - P295)
Note: These parameters are used for verifying or balancing the load cells (2) on
the associated conveyor belt scale. Refer to Start Up, page 17, for details and
procedure for use of these parameters.
P291 Calculator Input 1

This register displays the count associated with the summation of load cell A and B
signals, when balancing the A and B load cells of the associated belt scale.

This register displays the count associated with the load B signal, when balancing the A
and B load cells of the associated belt scale.

This register displays the count associated with the load cell B signal, when balancing
the A and B load cells of the associated belt scale.
Parameters
mmmmm
This register displays the count associated with the summation of load cell A and B
signals, when balancing the A and B load cells of the associated belt scale.
P295 Load Cell Balance

Used in conjunction with balance calculator parameters (P291 - P 294), this parameter
displays the adjustment required to complete the load cell balance procedure.
End of balancing parameters
P341 Run Time

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 hr. are not recorded, nor
accumulated.

P350 Calibration Security
This parameter provides additional security to the global lock (P000).
Entry:
0 = view parameters, perform zero and span, no reset of totalizer 1
1 = same as level 0, but cannot perform span
2 = same as level 0, but cannot perform zero and span
P359 Factoring
Factoring is used as a method of calculating the value of the test load (P017) to a new
physical test weight.
Entry:
0 = idle
1 = factor
Note: Totalization is halted during the factoring procedure, and resumed only
upon return to the RUN mode.
P360 Calibration Duration

Parameters
Sets the number of belt revolutions to use during a zero or span calibration.
mmmmm
Enter number of belt revolutions, range 1 - 99.
P367 Direct Zero

This parameter allows the zero reference count to be viewed or entered directly.
Direct entry is intended for use when replacing software or hardware and it is not
convenient to perform an initial zero at that time.
P368 Direct Span

This parameter allows the span reference count to be viewed or entered directly.
Direct entry is intended for use when replacing software or hardware and it is not
convenient to perform an initial span at that time.
P370 Zero Limit

Sets the zero calibration deviation limit from the last initial zero. If the accumulated
deviation exceeds the limit, the zero calibration is aborted (E3).
Entry:
0 = +/- 12.5% of initial zero
1 = +/- 2% of initial zero

P377 Initial Zero
The initial zero is the reference zero to which all subsequent operator initiated zero
calibrations are compared in determining whether they have deviated beyond the zero
limit (P370).
Entry:
0 = idle
1 = initial zero
Note: Refer to Recalibration/Initial Zero on page 33 for use of this function.
P388 Initial Span

The initial span is the reference to which all subsequent span calibrations are compared
in determining whether they have deviated beyond 12.5% of the initial span.
Entry:
0 = idle
1 = initial span
Note: Refer to Recalibration/Initial Span on page 36 for use of this function.
Parameters
mmmmm
Linearization Parameters (P390 - P396)
Note: These parameters are used to compensate for non-linear response of the
weighing system to the BW100. Refer to Recalibration/Linearization for details and
example on the use of these parameters.
P390 Linearization
Enables or disables the linearization function.
Entry:
0 = OFF
1 = ON
P391 Linearizer, Point 1

Enter the load, in units of P017, for point 1
P392 Compensation, Point 1

Enter the calculated compensation, in percent, for compensation point 1

Enter the load, in units of P017, for point 2.

Enter the calculated compensation, in percent, for compensation point 2.

Enter the load, in units of P017, for point 3.

Enter the calculated compensation, in percent, for compensation point 3.
End of Linearization Parameters.
Totalization (P619 - P648)

The following parameters are specific to the use to the BW100 totalizers. Refer also to
Parameters
Operation/Totalization, page 45.

mmmmm
Note: If the resolution (P631 - P639) selected would cause the totalizer to lag
behind the count rate, a message E2 is displayed after making the entry.
Select a greater resolution value.

Example
Given: P005 = 1 (t/h)

P631 = 5
Then: totalizer count increments by 10 for each 10 metric tonne registered
P619 Totalizer Drop Out

This parameter sets the limit, in percent of design rate, below which material rates are
not totalized.
The value of 0 is reserved to allow both negative and positive totalization.
Enter drop out value in % of design rate.

P631 Totalizer 1 Resolution, Internal
This parameter sets the resolution of internal totalizer 1.
Entry:
1 = 0.001 (one thousandth)
2 = 0.01 (one hundredth)
3 = 0.1 (one tenth)
4 = 1 (unit)
5 = 10 (x ten)
6 = 100 (x hundred)
7 = 1000 (x thousand)
P632 Totalizer 2 Resolution, Internal

This parameter sets the resolution of internal totalizer 2.
Entry:
3 = 0.1 (one tenth)
4 = 1 (unit)
5 = 10 (x ten)
6 = 100 (x hundred)
Parameters
P638 Totalizer 1 Resolution, External
mmmmm
This parameter sets the resolution of external totalizer 1.
Entry:
3 = 0.1 (one tenth)
4 = 1 (unit)
5 = 10 (x ten)
6 = 100 (x hundred)
P639 Totalizer 2 Resolution, External

This parameter sets the resolution of external totalizer 2.
Entry:
3 = 0.1 (one tenth)
4 = 1 (unit)
5 = 10 (x ten)
6 = 100 (x hundred)

P643 Totalizer 1 Contact Closure, External
The value of this parameter represents a multiple of 32 ms of contact closure for remote
totalizer 1. The value is automatically calculated upon entry of P1 (design rate) and P638
(totalizer 1 resolution, external) so that the duration of contact closure allows the
transistor switch response to track the total, up to the design rate.
The value can be changed to suit specific contact closure requirements, such as in the
case of programmable logic controllers. If a message E2 is displayed, P638 has to be
increased.
Entry:
1 = 32 ms
2 = 64
3 = 96
4 = 128
5 = 160
6 = 192
7 = 224
8 = 256
9 = 288
P644 Totalizer 2 Contact Closure, External

Parameters
The value of this parameter represents a multiple of 32 ms of contact closure for remote
totalizer 2. The value is automatically calculated upon entry of P1 (design rate) and P639
mmmmm
(totalizer 2 resolution, external) so that the duration of contact closure allows the
transistor switch response to track the total, up to the design rate.
The value can be changed to suit specific contact closure requirements, such as in the
case of programmable logic controllers. If a message E2 is displayed, P639 has to be
increased.
Entry:
1 = 32 ms 6 = 192
2 = 64 7 = 224
3 = 96 8 = 256
4 = 128 9 = 288
5 = 160
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).
Entry:
1 = totalizer 1
2 = totalizer 2
3 = totalizers 1 and 2

P648 Totalizer Reset, Internal
Resets the internal totalizers.
Entry:
0 = idle
1 = reset totalizer 2
2 = reset totalizers 1 and 2
End of Totalization parameters.
Communication (P751 - P761)

These parameters are specific to the use of the communication parameters. Refer also to
Communications, page 47.
P751 Baud Rate

Sets the baud rate for the proprietary bi-polar current loop. This baud rate is not
applicable to communication via Milltronics Comverter.
Entry:
300, 1200, 2400, 4800 or 9600 baud
4800 baud is required for Dolphin communications over the bi-polar current loop.
Parameters
mmmmm
P760 Communication Mode
Selects the communication mode.
• bi-polar current loop: interface with the host device (PLC or computer)
• infrared link: communication is made using the Milltronics ComVerter.
• maintenance: communication is made via the bi-polar current loop for
RUN mode operations and infrared link for PROGRAM
mode operations
Entry:
1 = bipolar current loop
2 = infrared link
3 = maintenance
P761 Identification Number

Sets the identification number for the unit.
Enter the desired identification number, range 0 - 15.
End of communication parameters.

Test and Diagnostic (P900 - P951)
Note: These parameters are used for test and diagnostic purposes.
P900 Software Revision

Displays the EPROM (Flash ROM) software revision level.
P901 Memory
Tests the memory. Test is initiated by scrolling to the parameter or repeated by pressing
ENTER.
Display:
PASS = normal
FAIL = consult Siemens Milltronics.
P907 Programmer Interface

Tests the infrared communications link. Test is initiated by scrolling to the parameter or
repeated by pressing ENTER.
Parameters
Display:
mmmmm
PASS = normal
FAIL = consult Siemens Milltronics.
infrared communication
link
mirror
BW100
P911 mA Output Value

Displays the value from the previous measurement. A test value can be entered and the
displayed value is transmitted to the output. Upon returning to the RUN mode, the
parameter assumes the actual mA output level.
P940 Load Cell A, mVin

Displays the mV signal input from the load cell. Range 0.00 - 60.00 mV.

P941 Load Cell B, mVin
Displays the mV signal input from the load cell. Range 0.00 - 60.00 mV.
P942 V/F converter, Vin

Displays the input voltage to the voltage to frequency converter.
Range 0 - 3.98 V
P943 V/F converter, fout

Displays the output frequency of the voltage to frequency converter.
Range 0 - 131,072
P944 Power sensor

Displays a voltage supply reference for diagnostic purposes.
P949 Diagnostic Errors

Enables or disables diagnostic error checking, E101 - E104
Entry:
Parameters
0 = disable
mmmmm
1 = enable
Refer to Troubleshooting on page 65.
P950 Zero register

Registers the number of zero calibrations that have been done since the last master
reset.
P951 Span Register

Registers the number of span calibrations that have been done since the last master
reset.
P952 Design Load

Displays the value of the design load, which corresponds to the full scale value for alarm
and mA output functions. The design load is calculated, based on the design rate and
design speed.
End of test and diagnostic parameters.

P999 Master Reset
Resets parameters and totalizers to their factory setting.
Parameters
mmmmm

Troubleshooting
message diagnosis action
E1 (program) security code required enter access code into P000
E2 (run) totalizer resolution too low increase value (P631 - P639)
zero out of range consider an initial zero P377,
E3 (run) refer to Recalibration/Initial
Zero on page 33
span out of range consider an initial span P388,
E4 (run) refer to Recalibration/Initial
Span on page 36
parameter not entered check parameters P005 - P017
E5 (run)
for entry
E6 (run) zero calibration required do a zero calibration
E7 (run) span calibration required do a span calibration
E8 (program) parameter value error check that value is valid
auto zero out of range auto zero has accumulated
deviation beyond 2% from last
operator initial zero. If error is
E9(run)
not caused by material on belt,
then do an operator initiated
Parameters
zero.
mmmmm
rate or span out of range loading on belt is 300% of rated
load or greater. Investigate and
E10 (run) if no mechanical cause, check
to see if re-rating the design
rate is required.
speed greater than twice the check design belt speed
design speed against actual belt speed,
E11 (run) check speed constant, per-
form speed constant adjust
(P018) if necessary
span out of range test load is either too low or
beyond 100% of design load
E12 (factoring) (P952). Replace test weight
with a heavier or lighter weight
and try factoring again.

message diagnosis action
load cell A mV reading is out error will appear if:
E101 (run)
of range • mV signal from load cell A or
B is out of the 0-50 mV range
• the mV signal from load cell
A or B is less than the zero
calibration mV level minus
load cell B mV reading is out one half the span mV level
• A or B mV is greater than 4
E102 (run) of range
times the span mV value
check load cell mV signal and

ensure that it is within range
check wiring
error will appear if the com-
bined mV signal from load cell
A and B is too low
combined mV signal from
E103 (run) load cell A and B is out of check both load cell signals
range and ensure that they are
greater than 0 mV
check wiring
cycle power and perform mem-
ory test (P901)
E104 (run) faulty memory location found
if error reappears, the BW 100
must be repaired or replaced.
no speed signal check speed circuit or run con-
OF
veyor
• Error messages are cleared when the condition is remedied.

• RUN mode errors are suppressed during PROGRAM mode, zero or span calibration.
Troubleshooting
• Zero and span errors are cleared when zero or span is initiated. Errors that happen
mmmmm
during the calibration require re-starting the procedure.

• Program errors are cleared when any key is pressed.
• The messages E101 through E104 can be turned off (P949).
• The load cell errors are detected by certain conditions where it is apparent that the
load cell is not functioning or incorrectly wired. It is not a conclusive test, since even
with incorrect wiring, the resulting input from the load cell may be within a valid
range.

Maintenance
The BW100 requires no maintenance.
The external surface of the enclosure may be cleaned using a vacuum cleaner and a
clean dry paint brush. The display window should be cleaned with a moist non-abrasive
cloth.
It is a good idea to check the associated load sensing device, according to its instruction
manual.
Software Updates
The software can be updated from a floppy disk by use of a PC (IBM Compatible) with
Milltronics Dolphin software. It is recommended that a reset (P999) is done after the
software update followed by zero and span calibrations.
Direct zero entry (P367) and direct span entry (P368) will suffice in lieu of dynamic zero
and span calibrations. Therefore, zero and span counts should be recorded prior to doing
the software update.
Troubleshooting
mmmmm

Appendix
Alphabetical Parameter List
Parameter Number
Alarm Dead Band P117
Baud Rate P751
Belt Length P016
Calculator Input 1 P291
Calibration Duration P360
Calibration Security P350
Communication Mode P760
Compensation Point 1 P392
Damping P080
Design Rate P011
Design Speed P014
Direct Span P368
Direct Zero P367
Display Mode P081
Factoring P359
High Alarm P101
Identification Number P761
Initial Zero P377
Initial Span P388
Linearization P390
Linearizer Point 1 P391
P940
Appendix
Load Cell A, mV in
mmmmm
Load Cell B, mV in P941

Load Cell Balance P295
Lock P000

Parameter Number
Low Alarm P102
mA Function P201
mA Output Damping P220
ma Output Value P911
mA Maximum Limit P213
mA Minimum Limit P212
mA Range P200
mA Trim, 20 P215
mA Trim, 4 P214
Manual Span Adjust P019
Master Reset P999
Memory P901
Minimum Speed Frequency P022
Power Sensor P944
Programmer Interface P907
Relay Set Up P100
Run Time P341
Software Revision Number P900
Span Register P951
Speed Constant P015
Speed Constant Adjust P018
Test Load P017
Totalizer 1 Closure, External P643
Totalizer 2 Closure, External P644
Totalizer 1 Resolution, External P638
Totalizer 2 Resolution, External P639
Totalizer 1 Resolution, Internal P631
Totalizer 2 Resolution, Internal P632
Totalizer Display P647
Totalizer Drop out P619
Totalizer Reset, Internal P648
Units P005
P942
Appendix
V/F Converter, V in
mmmmm
V/F Converter, f out P943

Zero Register P950
Zero Limit P370

Program Record
Program Record
Parameter Value
P005 Units
P011 Design Rate
P014 Design Speed
P015 Speed Constant
P016 Belt Length
P017 Test Load
P018 Speed Constant Adjust
P019 Manual Span Adjust
P022 Minimum speed Frequency
P080 Damping
PO81 Display Mode
P100 Relay Set Up
P101 High Alarm
P102 Low Alarm
P117 Alarm Dead Band
P200 mA Range
P201 mA Function
P212 mA Min Limit
P213 mA Max Limit
P220 mA Output Damping
P341 Run Time
P350 Calibration Security
P360Calibration Duration
P367 Direct Zero
P368 Direct Span
P370 Zero Limit
P390 Linearization
Appendix

mmmmm


Program Record
Parameter Value
P619 Totalizer Dropout
P631 Total 1 Resolution, Int
P632 Total 2 Resolution, Int
P638 Total 1 Resolution, Ext
P639 Total 2 Resolution, Ext
P643 Total 1 Closure, Ext
P644 Total 2 Closure, Ext
P647 Totalizer Display
P648 Totalizer Reset, Int
P751 Baud Rate
P760 Communication Mode
P761 Identification Number
P900 Software Rev.#
P949 Diagnostic Errors
P950 Zero Register
P951 Span Register
P952 Design Load
7ML19985DJ01 Milltronics BW100 – INSTRUCTION MANUAL Page 71

Index
A P101 high alarm/deviation alarm 53
alarm P102 low alarm 53
condition 44 P117 alarm dead band 53
B P200 mA output range 43
belt P200 mA range 54
speed compensation 29 P201 mA function 54
belt scale 3 P212 mA output minimum 43, 54
C P213 mA output maximum 43, 54
controller P214 mA output trim 43, 54
logic 45 P215 20 mA output trim 54
D P220 mA damping 43, 54
damping P291 calculator input 1 55
value 52 P292 calculator input 2 55
Dolphin 1, 3, 47 P293 calculator input 3 55
P295 load cell balancing 55
E
P341 run time 55
EEPROM 3
P350 calibration security 56
F
P359 factoring 56
factoring 38
P360 calibration duration 56
function
P367 direct zero entry 34, 56
alarm 43
P368 direct span entry 37, 56
output 43
P370 zero limit deviation 56, 57
I P377 initial zero 57
inearizer 58 P388 initial span 57
L P390 linearizer 39, 57
linearization 39 P391 linearizer, point 1 57
rate 1 P392 compensation, point 1 57
load cell 21 P393 linearizer, point 2 58
M P394 compensation, point 2 58
mA P395 linearizer, point 3 58
analog 1 P396 compensation, point 3 58
input 54 P619 totalling dropout 45, 58
Master 64 P631 totalizer resolution 45, 59
P P632 totalizer 2 resolution, internal 59
parameter P638 external totalizer resolution 45,
P000 security lock 50, 56 59, 60
P005 design rate units 50 P639 totalizer 2 resolution, external 59
P011 design rate 43, 45, 50 P643 external contact closure 45
P014 design speed 51 P643 totalizer 1 contact closure, exter-
P015 speed constant 51 nal 60
P016 belt length 51 P644 totalizer 2 contact closure, exter-
P017 test rate 51, 56 nal 60
P018 speed adjust 52 P647 totalizer display 46, 60
P019 manual span adjust 30, 52 P648 totalizer reset, internal 45
P022 minimum speed frequency 52 P648 totalzier reset, internal 61
P080 damping display 43, 52 P751 baud rate 61
P081 display scroll mode 60 P760 communication mode 61
7ML19985DJ01 Milltronics BW100 – INSTRUCTION MANUAL Page 72

P761 identification number 61
P900 software revision 62
P901 memory test 62
P907 programmer interface 62
P940 load cell ’A’, mVin 62
P941 load cell ’B’, mVin 63
P942 V/F converter, Vin 63
P943 V/F converter, fout 63
P944 power sensor 63
P949 diagnostic errors 63
P999 master reset 45
relay set up 53
paramter
P396 linearizer compensation % 39
R
relay
alarm 44
reset
master 45
S
span 37, 56
adjust 30, 31
calibration 27, 30, 39
direct 37
initial 33, 37, 57
manual 30
routine 35
T
test
load 30, 56
material 30
weight 27, 35
weights 26, 32
totalizer 45
functions 45
master 45
remote 1
Z
zero
auto 4
calibration 26, 38
direct 34
initial 33, 34, 57
Page 73 Milltronics BW100 7ML19985DJ01

www.siemens-milltronics.com
Siemens Milltronics Process Instruments Inc. Siemens Milltronics Process Instruments Inc. 2004
1954Technology Drive, P.O. Box 4225 Subject to change without prior notice
Peterborough, ON, Canada K9J 7B1
Rev. 1.1
*7ml19985dj01*
Tel: (705) 745-2431 Fax: (705) 741-0466
Email: [email protected]
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Instruction Manual February 2004

Note: Always use product in accordance with specifications.

Copyright Siemens Milltronics Process Disclaimer of Liability

Technical data subject to change.

MILLTRONICS®is a registered trademark of Siemens Milltronics Process Instruments Inc.

Contact SMPI Technical Publications at the following address:

© Siemens Milltronics Process Instruments Inc. 2004

Milltronics BW100 Features

7ML19985DJ01 Milltronics BW100 - INSTRUCTION MANUAL Page 1

WARNING means that failure to observe the necessary precautions

For the complete library of Siemens Milltronics manuals,

Page 2 Milltronics BW100 - INSTRUCTION MANUAL 7ML19985DJ01

7ML19985DJ01 Milltronics BW100 - INSTRUCTION MANUAL Page 3

Page 4 Milltronics BW100 - INSTRUCTION MANUAL 7ML19985DJ01

7ML19985DJ01 Milltronics BW100 - INSTRUCTION MANUAL Page 5

integral junction box

Conduit entry area. Recommend drilling the enclosure with a hole

Page 6 Milltronics BW100 - INSTRUCTION MANUAL 7ML19985DJ01

2 relay output customer alarm,

7ML19985DJ01 Milltronics BW100 - INSTRUCTION MANUAL Page 7

2 + SIG B 18 - SEN LOAD CELL

MILLTRONICS BW100 MILLTRONICS BW100

dc terminals shall be supplied from a SELV source in accordance with IEC-

Page 8 Milltronics BW100 - INSTRUCTION MANUAL 7ML19985DJ01

+ SIG B junction box

* Note: If load cells are supplied with

7ML19985DJ01 Milltronics BW100 - INSTRUCTION MANUAL Page 9

Page 10 Milltronics BW100 - INSTRUCTION MANUAL 7ML19985DJ01

! Connect the BW100 TB1 – 7 to the MD - 36 series speed sensor terminal:

7ML19985DJ01 Milltronics BW100 - INSTRUCTION MANUAL Page 11

Page 12 Milltronics BW100 - INSTRUCTION MANUAL 7ML19985DJ01

7ML19985DJ01 Milltronics BW100 - INSTRUCTION MANUAL Page 13

Connect shield at one device only, e.g. BW100 TB1 - 21

Page 14 Milltronics BW100 - INSTRUCTION MANUAL 7ML19985DJ01

200 V 1 - SIG B 17 - EXC

L2/N MILLTRONICS BW100

Note: The equipment must be protected by a 15 A fuse or a circuit breaker in the

" dc model indicated on lid nameplate.

dc terminals shall be supplied from an SELV source in accordance with

7ML19985DJ01 Milltronics BW100 - INSTRUCTION MANUAL Page 15

Refer to Dolphin instruction manual for interconnection details.

Page 16 Milltronics BW100 - INSTRUCTION MANUAL 7ML19985DJ01

balance switch, SW2

7ML19985DJ01 Milltronics BW100 - INSTRUCTION MANUAL Page 17

PROGRAM status icon, parameter

if not in the PROGRAM

Page 18 Milltronics BW100 - INSTRUCTION MANUAL 7ML19985DJ01

To Change a Parameter Value:

initiate change function

security must be disabled

save and return to select

7ML19985DJ01 Milltronics BW100 - INSTRUCTION MANUAL Page 19

jump back to P005

To Access RUN Mode:

e.g. from the PROGRAM

exit and return

Page 20 Milltronics BW100 - INSTRUCTION MANUAL 7ML19985DJ01

from the run mode e.g. rate display

last parameter from

Load Cell Balancing