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Micro-Tech 3105
This document is confidential and is the property of Thermo Electron Corporation (Thermo). It may not be copied or reproduced in any way without the express written consent of Thermo. This document also is an unpublished work of Thermo. Thermo intends to, and is maintaining the work as confidential information. Thermo also may seek to protect this work as an unpublished copyright. In the event of either inadvertent or deliberate publication, Thermo intends to enforce its rights to this work under the copyright laws as a published work. Those having access to this work may not copy, use, or disclose the information in this work unless expressly authorized by Thermo.
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Thermo Electron Corporation th 501 90 Ave. NW Minneapolis, MN 55433 USA Tel (763) 783-2500 Fax (763) 783-2525 http://www.thermo.com
Revision History
Revision A Revision B Revision C April 2003 September 2003 October 2006 ECO 0091 Manual first released Updates relating to CE/CSA Certification Technical Specification Correction (Fusing)
Table of Contents
Table of Contents.................................................................................................................... i List of Figures ....................................................................................................................... ix List of Tables......................................................................................................................... xi About this Manual ................................................................................................................xiii Who Should Use this Manual ...........................................................................................xiii Organization of the Manual ..............................................................................................xiii Documentation Conventions ........................................................................................... xiv Safety Messages ............................................................................................................. xiv General Precaution .......................................................................................................... xv Occupational Safety and Health Act (OSHA) .................................................................. xvi Thermo Electron Warranty .............................................................................................. xvi Disclaimer........................................................................................................................xvii Chapter 1 Introduction to the Micro-Tech 3105 ..............................................................1-1 1.1 Unpacking and Inspection ....................................................................................1-1 1.2 Storage .................................................................................................................1-1 1.3 Application ............................................................................................................1-1 1.4 Micro-Tech 3105 Standard Features ....................................................................1-2 1.5 Configuration ........................................................................................................1-3 1.6 Feeder Controller General Description .................................................................1-4 1.6.1 Measuring Functions .....................................................................................1-4 1.6.2 Automatic Control Functions .........................................................................1-4 1.6.3 Monitoring Functions .....................................................................................1-5 1.6.4 Print Functions ..............................................................................................1-5 1.6.5 Communication Functions .............................................................................1-5 1.7 Functional Description ..........................................................................................1-6 1.7.1 Measuring Functions .....................................................................................1-6 1.7.1.1 Instantaneous Flow Rate Calculation.....................................................1-6 1.7.1.2 Flow Totalization ....................................................................................1-6 1.7.1.3 Zero and Span Automatic Calibrations...................................................1-6 1.7.1.4 Zero Tracking (AZT) ...............................................................................1-7 1.7.2 Current Output Signals ..................................................................................1-7 1.7.3 Automatic Control Functions .........................................................................1-7 1.7.3.1 Automatic Control of Instantaneous Value .............................................1-7 1.7.3.2 Regulation Interlock................................................................................1-8 1.7.3.3 PID Control Action..................................................................................1-8 1.7.3.4 P.E.I.C. Control ......................................................................................1-8 1.7.3.5 Analog Delay ..........................................................................................1-9 1.7.3.6 P.E.I.C. Increase/Decrease Controls .....................................................1-9 1.7.3.7 Automatic Manual ..................................................................................1-9 1.7.3.8 Batch Control (Optional).........................................................................1-9 1.7.4 Indication System ........................................................................................1-10
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1.7.4.1 Status Indications.................................................................................1-10 1.7.4.2 Process Alarms....................................................................................1-11 1.7.4.3 Programming Errors.............................................................................1-11 1.7.4.4 Equipment Failures ..............................................................................1-11 1.7.5 Print Functions ............................................................................................1-12 1.8 Symbol Identification ..........................................................................................1-12 1.9 Technical Specifications.....................................................................................1-13 Chapter 2 Installing the Micro-Tech 3105 ......................................................................2-1 2.1 Safety Precautions ...............................................................................................2-1 2.2 Incoming Power....................................................................................................2-3 2.2.1 Critical Wiring Conditions ..............................................................................2-4 2.3 Field Mount Installation ........................................................................................2-4 2.3.1 Mounting .......................................................................................................2-4 2.3.2 Connecting Incoming Power - Field Mount ...................................................2-5 2.4 Panel Mount Installation .......................................................................................2-6 2.4.1 Mounting .......................................................................................................2-6 2.4.2 Connecting Incoming Power Panel Mount .................................................2-7 2.5 Belt Feeder Controller Configuration....................................................................2-8 2.5.1 Mother Board Configuration Jumpers and Switches.....................................2-8 2.5.2 A/D Jumpers Load Cell Sense .................................................................2-11 2.5.3 Analog Output (Motherboard) .....................................................................2-13 2.5.4 Analog Input/Output Board..........................................................................2-14 2.5.5 Communications Configuration (Motherboard) COMM...............................2-14 2.6 Determining Installation Parameters ..................................................................2-17 2.6.1.1 Scale Capacity .....................................................................................2-17 2.6.1.2 Belt Scale Code Number .....................................................................2-17 2.6.1.3 Belt Scale Weighbridge Dimensions....................................................2-18 2.6.1.3.1 Pivot to Load Cell LA.....................................................................2-19 2.6.1.3.2 Number of Weigh Idlers on Scale Weighbridge(s) IDN .................2-19 2.6.1.3.3 Pivot to 1st Idler (Weigh Idler) LB1.................................................2-19 2.6.1.3.4 Pivot to 2nd Weigh Idler (Optional) ..................................................2-20 2.6.1.3.5 Pivot to 1st, 2nd, 3rd and 4th Weigh Idler .............................................2-20 2.6.1.4 Calibration Using Test Weights............................................................2-20 2.6.1.4.1 Pivot to Test Weight Height LE .....................................................2-21 2.6.1.4.2 Pivot to Test Weight Length LC.....................................................2-21 2.6.1.4.3 Pivot to Carriage Height LF ...........................................................2-22 2.6.1.4.4 Roll to Carriage Height LG ............................................................2-22 2.6.1.5 Number of Load Cells ..........................................................................2-22 2.6.1.6 Idler Spacing Scale Area LD.............................................................2-23 2.6.1.7 Conveyors Angle of Incline .................................................................2-23 2.6.1.8 Load Cell Capacity...............................................................................2-23 2.6.1.9 Load Cell Sensitivity.............................................................................2-23 2.6.1.10 Load Cell Resistance ...........................................................................2-23 2.6.1.11 Conveyor Belt Length ..........................................................................2-23
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2.7 Programming the Micro-Tech 3105 (Initial Setup) ..............................................2-25 2.7.1 Language ....................................................................................................2-25 2.7.2 Measure Units .............................................................................................2-26 2.7.3 Totalization Units .........................................................................................2-27 2.7.4 Length Units ................................................................................................2-27 2.7.5 Rate Units....................................................................................................2-28 2.7.6 Load Cell Units ............................................................................................2-28 2.7.7 Max. Scale Capacity....................................................................................2-29 2.7.8 Scale Divisions ............................................................................................2-29 2.8 Selecting the Weighbridge Model .......................................................................2-30 2.8.1 Detailing the Mechanical Parameters of the Frame ....................................2-30 2.8.1.1 Parameter LA: pivot to Load Cell Distance ..........................................2-30 2.8.1.2 Parameter LE: Pivot to Test-Weight Height .........................................2-34 2.8.1.3 Parameter LC: Pivot to Test-Weight Length.........................................2-34 2.8.1.4 Parameter LF: Pivot to Carriage Height. ..............................................2-35 2.8.1.5 Parameter LG: Carry Roll to Carriage Height.......................................2-35 2.8.2 Number of Load Cells..................................................................................2-35 2.9 Defining Dimensional Parameters of the Application..........................................2-36 2.9.1 Idler Spacing in Scale Area .........................................................................2-36 2.9.2 Angle of Inclination ......................................................................................2-36 2.9.3 Defining the Load Cell(s) .............................................................................2-37 2.9.4 Defining the Speed Input .............................................................................2-39 2.9.5 Defining the Calibration Test Duration.........................................................2-39 2.9.6 Full Test Duration Acquisition......................................................................2-40 2.9.7 Partial Test Duration Acquisition .................................................................2-42 2.9.8 Manual Entry of Test Duration.....................................................................2-43 2.9.9 Automatic Calibration of the Scale ..............................................................2-45 Chapter 3 Micro-Tech 3105 Operation...........................................................................3-1 3.1 Overview...............................................................................................................3-1 3.2 Operator Interface ................................................................................................3-1 3.3 Front Panel ...........................................................................................................3-2 3.3.1.1 System Status Lights..............................................................................3-2 3.3.1.2 LCD Graphic Display..............................................................................3-2 3.3.1.3 Keypad ...................................................................................................3-3 3.4 General Navigation ...............................................................................................3-3 3.5 Menu Displays ......................................................................................................3-4 3.6 Normal Power On .................................................................................................3-5 3.6.1 Hardware Configuration.................................................................................3-5 3.7 Run Menu .............................................................................................................3-6 3.7.1 Main Run .......................................................................................................3-6 3.7.2 Totals.............................................................................................................3-7 3.7.3 Print Key ........................................................................................................3-8 3.7.4 Material Calibration (MATL)........................................................................3-10 3.7.5 Alarm Pending .............................................................................................3-10
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3.7.6 Reset Total..................................................................................................3-11 3.8 Controller Output ................................................................................................3-12 3.8.1 Control #1....................................................................................................3-12 3.8.2 Control # 2...................................................................................................3-12 3.9 Load Out.............................................................................................................3-13 3.10 Calibration.......................................................................................................3-13 3.10.1 Zero Calibrate Scroll ...................................................................................3-13 3.10.2 Manual Zero ................................................................................................3-15 3.10.3 Span Calibration Scroll................................................................................3-15 3.10.3.1 Auto Span ............................................................................................3-16 3.10.3.1.1 Starting an R-Cal Calibration..........................................................3-16 3.10.3.1.2 Starting a Chain Calibration ...........................................................3-16 3.10.3.1.3 Starting a Test Weights Calibration................................................3-17 3.10.3.1.4 Executing the Span Calibration ......................................................3-18 3.10.3.1.5 Material Factor ...............................................................................3-18 3.10.3.1.6 Recording New Span .....................................................................3-20 3.10.3.1.7 Ending an Auto Span Procedure with Chains or Test Weights ......3-21 3.10.3.1.8 Ending an Auto Span Procedure with R-Cal ..................................3-21 3.10.3.2 Manual Span........................................................................................3-21 3.10.4 Material Span Calibration............................................................................3-22 3.11 Permanent Scroll Record Setup Scrolls ......................................................3-26 3.11.1 Main Menu 1 and Main Menu 2...................................................................3-26 3.11.2 Calibration Menu .........................................................................................3-28 3.11.3 Main Menu 3 ...............................................................................................3-29 3.11.4 Main Menu 4 ...............................................................................................3-30 3.11.5 Alarm Scroll.................................................................................................3-34 3.11.6 Load Out Scroll ...........................................................................................3-36 3.12 Permanent Field Record.................................................................................3-40 3.13 Routine Calibration Belt Scale .....................................................................3-41 3.13.1 Initial Calibration Procedure ........................................................................3-41 3.13.2 Routine Calibration Procedure ....................................................................3-41 3.14 Material Calibration.........................................................................................3-42 3.15 Calibration Report...........................................................................................3-42 Chapter 4 Micro-Tech 3105 Maintenance......................................................................4-1 4.1 Frequent Checkpoints ..........................................................................................4-1 4.2 Troubleshooting....................................................................................................4-1 4.3 Alarm Messages...................................................................................................4-2 4.3.1 Alarms List ....................................................................................................4-2 4.4 Micro-Tech 3105 Cold Start .................................................................................4-6 4.4.1 Forcing a Cold Start from Run Mode ............................................................4-6 4.4.2 Forcing a Cold Start from the Diagnostic Scroll ............................................4-7 4.5 Internal Test Procedure........................................................................................4-7 4.6 Load Cell Excitation and Signal Voltage ..............................................................4-8 4.7 Resetting Master Total .........................................................................................4-8
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4.7.1 No Password Installed...................................................................................4-9 4.7.2 Active Password ............................................................................................4-9 4.8 Removing a Forgotten Password .........................................................................4-9 4.9 Lithium Battery Replacement (Not Rechargeable) .............................................4-10 4.10 Disposal of Hazardous Waste.........................................................................4-10 4.11 Cleaning Instructions ......................................................................................4-11 Chapter 5 Micro-Tech 3105 Replacement Parts ............................................................5-1 5.1 Order Information..................................................................................................5-1 5.1.1 Parts List .......................................................................................................5-3 Appendix A Micro-Tech 3105 Menus ........................................................................... A-1 A.1. Menu Displays ..................................................................................................... A-1 A.2. Common Key Functions ...................................................................................... A-2 A.3. MAIN Menu 1 Calibration Menu........................................................................ A-2 A.3.1. Zero Calibration Scroll .................................................................................. A-3 A.3.2. Manual Zero ................................................................................................. A-4 A.3.3. Auto Span Calibration................................................................................... A-5 A.3.4. Manual Span .............................................................................................. A-10 A.3.5. Material Span Calibration ........................................................................... A-11 A.3.6. Entering the Reference Weight .................................................................. A-12 A.3.7. Updating the Span Constant ...................................................................... A-13 A.3.8. Acquiring the Material Factors.................................................................... A-13 A.4. Main Menu 2 Setup and Configuration Menus ............................................... A-15 A.5. Display ............................................................................................................... A-15 A.5.1. Measure Units ............................................................................................ A-15 A.5.2. Totalization Units ........................................................................................ A-15 A.5.3. Length Units ............................................................................................... A-16 A.5.4. Rate Units................................................................................................... A-16 A.5.5. Load Cell Capacity ..................................................................................... A-16 A.5.6. Defining Language ..................................................................................... A-17 A.5.7. Setting Time and Date................................................................................ A-17 A.5.8. Line Three (3) of the Run Menu ................................................................. A-17 A.5.9. Displayed Damping Factors ....................................................................... A-18 A.6. Scale Data ......................................................................................................... A-19 A.6.1. Scale Capacity ........................................................................................... A-19 A.6.2. Scale Divisions ........................................................................................... A-19 A.6.3. Selecting the Weighbridge Model............................................................... A-19 A.6.4. Detailing the Mechanical Parameters of the Frame ................................... A-20 A.6.5. Defining Dimensional Parameters of the Application ................................. A-24 A.6.6. Defining the Load Cell(s) ............................................................................ A-25 A.6.7. Defining the Speed Input ............................................................................ A-26 A.6.8. Setting Dead Band ..................................................................................... A-27 A.6.9. Weights and Measures Mode (Only if Audit Trail Option is Installed) ........ A-27 A.7. Calibration Data -............................................................................................... A-27 A.7.1. Defining the Calibration Mode .................................................................... A-27
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A.7.2. Entering a Calibration Interval.................................................................... A-29 A.7.3. Entering Material Factors ........................................................................... A-30 A.7.4. Defining the Calibration Test Duration ....................................................... A-30 A.7.5. Auto Cont Belt Revolutions ........................................................................ A-32 A.7.6. Partial Test Duration Acquisition ................................................................ A-33 A.7.7. Manual Entry of Test Duration ................................................................... A-34 A.7.8. Defining Auto Zero Tracking ...................................................................... A-35 A.7.9. Entering the Speed Capacity ..................................................................... A-36 A.7.10. Defining the Number of Calibrations....................................................... A-37 A.8. Main Menu 3...................................................................................................... A-37 A.8.1. Changing the Protection Level ................................................................... A-37 A.9. Diagnostics........................................................................................................ A-39 A.9.1. A/D Raw Data ............................................................................................ A-39 A.9.2. Readout Load Cell mV ............................................................................... A-39 A.9.3. Change Prescaler ...................................................................................... A-40 A.9.4. Change Passwords .................................................................................... A-41 A.9.5. Display Software Version ........................................................................... A-42 A.9.6. Setup Date and Time ................................................................................. A-42 A.9.7. Check Hardware Configuration .................................................................. A-42 A.9.8. Force Cold Start ......................................................................................... A-44 A.9.9. Lamp Test .................................................................................................. A-44 A.9.10. Self Test of the Unit ................................................................................ A-44 A.9.11. Test Digital Inputs................................................................................... A-45 A.9.12. Test Digital Outputs ................................................................................ A-45 A.9.13. Test Current Outputs .............................................................................. A-46 A.9.14. Test Current Inputs................................................................................. A-47 A.9.15. Test Communication A ........................................................................... A-47 A.9.16. Test Communication B ........................................................................... A-48 A.9.17. Test BCD Input Board ............................................................................ A-48 A.9.18. Test BCD Output Board.......................................................................... A-48 A.9.19. Simulated Control ................................................................................... A-48 A.9.20. Test the Keyboard and Switches............................................................ A-49 A.10. Main Menu 4 .................................................................................................. A-49 A.10.1. I/O Definition........................................................................................... A-49 A.10.2. Define Analog Inputs .............................................................................. A-51 A.10.3. Setup Moisture Compensation Input ...................................................... A-52 A.10.4. Setup Inclination Compensation Input.................................................... A-53 A.10.5. Remote Setpoint Input............................................................................ A-53 A.10.6. Process Variable .................................................................................... A-54 A.10.7. Define Digital Inputs ............................................................................... A-55 A.10.8. Define Digital Outputs............................................................................. A-58 A.10.9. Define Remote Totalizer Output ............................................................. A-61 A.10.10. Define BCD Output Data ........................................................................ A-62 A.10.11. Define BCD Input Data ........................................................................... A-62
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A.10.12. Clip Detector Option................................................................................ A-63 A.10.13. Define Load WTS (Weights) ................................................................... A-64 A.11. Alarms Definition ............................................................................................ A-64 A.11.1. Define Rate Alarm................................................................................... A-64 A.11.2. Define Load Alarm .................................................................................. A-65 A.11.3. Define Speed Alarm................................................................................ A-66 A.12. MAIN MENU 5 ............................................................................................... A-73 A.12.1. Communication A Scroll.......................................................................... A-73 A.12.2. Print ........................................................................................................ A-77 A.12.3. Periodical Printing ................................................................................... A-78 A.12.4. Define Print Format................................................................................. A-79 A.12.5. The PRINT Key....................................................................................... A-85 A.13. MAIN MENU 6 ............................................................................................... A-87 A.13.1. Audit Trail................................................................................................ A-87 A.13.2. Linearization ........................................................................................... A-88 A.14. MAIN MENU 7 ............................................................................................... A-89 A.14.1. Control .................................................................................................... A-89 Appendix B Weighbridge Physical Parameters............................................................ B-1 B.1. Rules for Entering the Parameters ...................................................................... B-4 B.2. Tables of Weighbridges ....................................................................................... B-5 Appendix C Linearization ............................................................................................. C-1 Appendix D Digital and Analog Input/Output ................................................................ D-1 D.1. Mother Board Digital I/O ...................................................................................... D-1 D.1.1. Digital Inputs................................................................................................. D-1 D.1.2. Digital Outputs .............................................................................................. D-2 D.2. Digital Input/Output Board Configuration ............................................................. D-3 D.2.1. 16 In/4 Out DIO Board Specifications........................................................... D-4 D.2.2. 4 In/16 Out DIO Board Specifications........................................................... D-4 D.3. BCD Input Option ................................................................................................ D-8 D.4. Analog I/O Boards ............................................................................................... D-9 D.5. Load Out Option ................................................................................................ D-14 D.5.1. Load Out (Optional) .................................................................................... D-14 D.6. Communications Options................................................................................... D-14 D.6.1. Standard Comm A Board ........................................................................... D-14 D.6.2. Allen-Bradley Remote I/O........................................................................... D-14 D.6.3. Profibus-DP ................................................................................................ D-14 D.6.4. DeviceNet ................................................................................................... D-14
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Appendix E MT 3000 Multi-Point Calibration ............................................................... E-1 E.1. Define Number of Calibration Points ................................................................... E-1 E.2. Selection of Calibration Point .............................................................................. E-2 E.2.1. Front Panel Keyboard .................................................................................. E-2 E.2.2. Digital Input Selection .................................................................................. E-3 E.2.3. Linearization................................................................................................. E-3 Appendix F MT 3105 Minor Scale Calibration ..............................................................F-1 Appendix G Optional Documentation ........................................................................... G-1 Appendix H Engineering Drawings .............................................................................. H-1 Appendix I Available Analog I/O and A/D Configuration Micro-Tech 3000 Series ........I-1 I.1. AVAILABLE A/D CONFIGURATION ON MICROTECH 3000...............................I-2
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List of Figures
Figure 1-1: Figure 1-2: Figure 2-1: Figure 2-2: Micro-Tech 3105 Field Mount Belt Feeder Controller ..................................... 1-2 Micro-Tech 3105 Panel Mount Belt Feeder Controller ................................... 1-3 Typical Micro-Tech 3105 Installation .............................................................. 2-4 Mounting Guidelines of the Micro-Tech Model 3105 (Field Mount) Belt Feeder Controller ....................................................................................................... 2-5 Figure 2-3: Field Mount Inside Front Panel....................................................................... 2-6 Figure 2-4: Mounting Guidelines Micro-Tech 3105 (Panel Mount) Belt Feeder Controller ....................................................................................................... 2-7 Figure 2-5: Installation Micro-Tech Model 3105 (Panel Mount) Belt Feeder Controller ..... 2-7 Figure 2-6: Micro-Tech Motherboard ............................................................................... 2-9 Figure 2-7: Area of Detail ................................................................................................ 2-11 Figure 2-8: Analog (TB4) Input/Output Board ................................................................. 2-14 Figure 2-9: Belt Scale Weighbridge ................................................................................ 2-18 Figure 2-10: Pivot to Load Cell ....................................................................................... 2-19 Figure 2-11: Pivot to 1st Idler .......................................................................................... 2-19 Figure 2-12: Pivot to 2nd Weigh Idler.............................................................................. 2-20 Figure 2-13: Pivot to 1st, 2nd, 3rd, and 4th Weigh Idler.................................................. 2-20 Figure 2-14: Pivot to Test Weight Height ........................................................................ 2-21 Figure 2-15: Pivot to Test Weight Length........................................................................ 2-21 Figure 2-16: Pivot to Carriage Height ............................................................................. 2-22 Figure 2-17: Roll to Carriage Height ............................................................................... 2-22 Figure 2-18: Measure of Incline ...................................................................................... 2-24 Figure 3-1: Micro-Tech 3105 Front Panel ......................................................................... 3-2 Appendix Figure B-1: Model 10-20-1 ................................................................................ B-3 Appendix Figure B-2: Model 10-22 ................................................................................... B-3 Appendix Figure B-3: Model 10-17-2 ................................................................................ B-3 Appendix Figure B-4: Model 10-17-4 ................................................................................ B-4 Appendix Figure B-5: Model 10-14-4 ................................................................................ B-4 Appendix Figure D-1: General Purpose Digital Inputs ......................................................D-1 Appendix Figure D-2: Isolated Relay Outputs...................................................................D-2 Appendix Figure D-3: Solid State Output ..........................................................................D-2 Appendix Figure D-4: Digital Inputs/Outputs.....................................................................D-7 Appendix Figure D-5: BCD Input Option Wiring................................................................D-8 Appendix Figure D-6: Current Output ...............................................................................D-9 Appendix Figure D-7: Current Output PC Board (Type A) ..............................................D-10 Appendix Figure D-8: Current Output Board Wiring Diagram (Type A) ..........................D-11 Appendix Figure D-9: Analog Input .................................................................................D-12 Appendix Figure D-10: Analog I/O PC Board (Type B)...................................................D-13
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List of Tables
Table 1-1: Symbol Identification...................................................................................... 1-12 Table 2-1: Programmable Input Choices ........................................................................ 2-10 Table 2-2: Programmable Output Choices...................................................................... 2-10 Table 2-3: Load Cell Jumper Settings............................................................................. 2-11 Table 2-4: Speed Input Jumper ...................................................................................... 2-11 Table 2-5: Micro-Tech 3105 Motherboard Jumpers........................................................ 2-12 Table 2-6: Terminal Wiring Configurations...................................................................... 2-12 Table 2-7: Relay Output Board ....................................................................................... 2-13 Table 2-8: Motherboard Current Output - TB 5 ............................................................... 2-13 Table 2-9: Speed Input Jumpers..................................................................................... 2-15 Table 2-10: Motherboard COMM 1 Communications Wiring Configuration - TB3 RS-485 .................................................................................................................... 2-15 Table 2-11: Motherboard Wiring Configuration TB 3 RS-232 Communications .......... 2-16 Table 2-12: Motherboard Wiring Configuration TB 3 20mA Serial Communications ... 2-16 Table 2-13: Mother Board Communication Jumper Settings .......................................... 2-17 Table 2-14: Belt Scale Weighbridge Legend................................................................... 2-18 Table 2-15: Angle of Incline ........................................................................................... 2-24 Table 3-1: Alarm Conditions ........................................................................................... 3-11 Table 5-1: Parts List.......................................................................................................... 5-3 Table 5-2: Optional Plugin Boards .................................................................................... 5-3 Appendix Table A-1: Password Protection Levels .......................................................... A-37 Appendix Table A-2: List of Optional Plug-in Board Types ............................................. A-43 Appendix Table A-3: Available Logical Selections .......................................................... A-55 Appendix Table A-4: Mother Board Inputs ....................................................................... A-56 Appendix Table A-5: Digital Input/Output Board Inputs .................................................. A-56 Appendix Table A-6: Available Logical Assignment........................................................ A-58 Appendix Table A-7: Relay Board and Motherboard Outputs......................................... A-60 Appendix Table A-8: Digital Input/Output Board Outputs................................................ A-60 Appendix Table A-9: Predefined Print Format 1 ............................................................. A-79 Appendix Table A-10: Predefined Print Format 2 ............................................................ A-80 Appendix Table B-1: Weighbridge Physical Parameters .................................................. B-2 Appendix Table B-2: Default Value for Scale Model Selections ....................................... B-5 Appendix Table D-1: DIO Board Jumper Settings (OP1/OP2)..........................................D-3 Appendix Table D-2: DIO Board Jumper Settings for Current Sourcing ...........................D-3 Appendix Table D-3: Communications Options Reference.............................................D-14
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Documentation Conventions
The following conventions are used in this manual to help easily identify certain types of information: Italic is used to introduce new terms and for emphasis. Italic/blue type is used for references to other sections of the manual and work as links on line and in pdf format. The names of setup, calibration displays, menu displays, and variables are shown in FULL CAPITALS. The names of keys on the front panel are shown in BOLD CAPITALS.
Safety Messages
Instructions in this manual may require special precautions to ensure the safety of the personnel performing the operations. Please read the safety information before performing any operation preceded by this symbol. There are two levels of safety messages: warnings and cautions. The distinction between the two is as follows:
WARNING
FAILURE TO OBSERVE COULD RESULT IN DEATH OR SERIOUS INJURY.
CAUTION
TO OBSERVE MAY CAUSE MINOR INJURY OR DAMAGE THE EQUIPMENT
FAILURE
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General Precaution
Do not install, operate, or perform any maintenance procedures until you have read the safety precautions presented.
WARNING
TO FOLLOW SAFE INSTALLATION AND SERVICING PROCEDURES COULD RESULT IN DEATH OR SERIOUS INJURY.
FAILURE
ALLOW ONLY QUALIFIED ELECTRICIANS TO OPEN AND WORK IN THE ELECTRONICS CABINET, POWER SUPPLY CABINET, CONTROL CABINET, OR SWITCH BOX. COVERS OVER THE ELECTRONICS AND ROTATING PARTS
MUST ALWAYS REMAIN IN PLACE DURING NORMAL OPERATION REMOVE ONLY FOR MAINTENANCE, WITH THE MACHINES POWER OFF. REPLACE ALL COVERS BEFORE RESUMING OPERATION.
DURING MAINTENANCE, A SAFETY TAG (NOT SUPPLIED BY THE FACTORY) IS TO BE DISPLAYED IN THE ON/OFF
SWITCH AREAS INSTRUCTING OTHERS NOT TO OPERATE THE UNIT (ANSI:B157.1).
WARNING
HIGH VOLTAGE THAT MAY BE PRESENT ON LEADS COULD CAUSE ELECTRICAL SHOCK. ALL SWITCHES MUST BE OFF WHEN CHECKING INPUT AC ELECTRICAL CONNECTIONS, REMOVING OR INSERTING PRINTED CIRCUIT BOARDS, OR ATTACHING VOLTMETERS TO THE SYSTEM. USE EXTREME CAUTION WHEN TESTING IN, ON, OR AROUND THE ELECTRONICS CABINET, PC BOARDS, OR MODULES. THERE ARE VOLTAGES IN EXCESS OF 115 V OR 230 V IN THESE AREAS.
WARNING
USE ONLY THE PROCEDURES AND NEW PARTS SPECIFICALLY REFERENCED IN THIS MANUAL TO ENSURE SPECIFICATION PERFORMANCE AND CERTIFICATION COMPLIANCE. UNAUTHORIZED PROCEDURES OR PARTS CAN RENDER THE INSTRUMENT DANGEROUS TO LIFE, LIMB, OR PROPERTY.
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WARNING
KEEP HANDS AND CLOTHING AWAY FROM ALL MOVING OR ROTATING PARTS.
WARNING
DO NOT PLACE OR STORE OBJECTS OF ANY KIND ON THE MACHINE.
WARNING
MACHINE SHOULD NOT BE OPERATED AT MORE THAN THE PRODUCTION RATE STATED ON YOUR EQUIPMENT SPECIFICATION SHEET OR USED IN APPLICATIONS OTHER THAN THOSE STATED IN THE ORIGINAL ORDER.
THIS
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Said warranty shall not apply if the equipment shall not have been operated and maintained in accordance with seller's written instructions applicable to such equipment, or if such equipment shall have been repaired or altered or modified without seller's approval; provided, however, that the foregoing limitation of warranty insofar as it relates to repairs, alterations, or modifications, shall not be applicable to routine preventive and corrective maintenance which normally occur in the operation of the equipment. EXCEPT FOR THOSE WARRANTIES SPECIFICALLY CONTAINED HEREIN, SELLER DISCLAIMS ANY AND ALL WARRANTIES WITH RESPECT TO THE EQUIPMENT DELIVERED HEREUNDER, INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR USE. THE SOLE LIABILITY OF SELLER ARISING OUT OF THE WARRANTY CONTAINED HEREIN SHALL BE EXCLUSIVELY LIMITED TO BREACH OF THOSE WARRANTIES. THE SOLE AND EXCLUSIVE REMEDY FOR BREACH OF THE WARRANTIES SET OUT ABOVE SHALL BE LIMITED TO THE REPAIR OR REPLACEMENT OF ANY DEFECTIVE ACCESSORY, PART OR MATERIAL WITH A SIMILAR ITEM FREE FROM DEFECT, AND THE CORRECTION OF ANY DEFECT IN WORKMANSHIP. IN NO EVENT SHALL SELLER BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES. Purchaser agrees to underwrite the cost of any labor required for replacement; including time, travel, and living expenses of Thermo Electron Field Service Engineer at closest factory base.
THERMO ELECTRON 501 90TH AVE. NW MINNEAPOLIS, MN 55433 PHONE: (763) 783-2500 FAX: (763) 783-2525
Disclaimer
Though the information provided herein is believed to be accurate, be advised that the information contained herein is not a guarantee for satisfactory results. Specifically, this information is neither a warranty nor guarantee, expressed or implied, regarding performance, merchantability, fitness, or any other matter with respect to the products, and recommendation for use of the product/process information in conflict with any patent. Please note that Thermo Electron reserves the right to change and/or improve the product design and specifications without notice .
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1.1
1.2
Storage
The Micro-Tech 3105 can be safely stored, with cover, latches secured and hole plugs installed, between -40 to +158 F (-40 to +70 C). The units should be protected against moisture.
1.3
Application
The Micro-Tech 3105 Field Mount Feeder (Figure 1-1) or Panel Mount Feeder (Figure 1-2) is a microprocessor based menu driven controller designed to control the feed rate of variable speed belt feeder, constant speed belt feeders or conveyor scales. The Belt Feeder Controller may be set up to control the following systems:
Feed rate control from a surge bin or pre-feeder Ratio control indicates the belt feeder controller can act as master or slave. Blending systems
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1.4
The Model 3105 Feeder has many hardware and software features necessary for controlling the processes listed above. The following main features are listed below. Other features are listed in specific sections of this manual. Menu driven scroll entries on a four line display Five LED status indicators Visible and electrical outputs representing rate or load of the material movement Visible and electrical output representing total amount of material that has passed the weighbridge Audit trail (option) Automatic zero and span calibration Auto zero tracking Several software options that may be turned on by keyboard entry or by installing optional plug-in PC boards Two process control modes: Conventional PID (Proportional, Integral, Derivative) and P.E.I.C. (Periodical Error Integral Control). Two independent control loops. Optically coupled digital inputs and outputs Alarms and failure detection Communication standards: RS232C, RS485 networking multidrop, 20 mA current loop passive Allen-Bradley DF1, Modbus RTU Figure 1-1: Micro-Tech 3105 Field Mount Belt Feeder Controller
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1.5
Configuration
The standard configuration of the Belt Feeder Controller includes the following: Single channel loadcell input to a max of 6 loadcells Single current output on Mother Board Dual channel current output, analog input board (2 analog in 2 analog out). 5 programmable digital inputs 4 programmable outputs 1 fault output Serial communications Solid state output 2 circuit board expansion slots that can accommodate the following boards if needed. 1. Single channel current output board 2. 16 digital inputs/4 digital outputs 3. 4 digital inputs/16 digital outputs 4. Serial communication board 5. Allen-Bradley remote I/O 6. Profibus-DP board 7. DeviceNet
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1.6
1.6.1
Measuring Functions
Up to 6 350 ohm loadcells can be directly connected to the Feeder Controller and receives the signal of a speed sensor to calculate belt speed, belt loading, and feed rate. Rate is integrated in time to calculate the amount of material conveyed by the belt (total), and is displayed in three individual registers: total, reset total, operator total. The Feeder Controller can perform automatic zero and span calibrations. When the belt is running and the rate is below a certain percentage, the Feeder Controller can perform auto zero tracking, to minimize the error of zero due to material and dust. Analog (current) output signals can be generated to transmit rate, speed or belt loading to other control devices. Displayed variables and analog outputs can be smoothed via damping filters, individually programmable.
1.6.2
The process variable under control can be feed rate, speed, or belt loading. The second loop can control one of the above or an external variable incoming through an analog input channel. The set point can be entered via keyboard, or received through a serial communication channel or an analog input. Control output can be either current or pulses. When the Feeder is not running, the control output is locked in position or forced to a preset value defined by the operator. This feature requires a belt feeder run contact.
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When the controller is switched from Manual or Automatic and vice versa, the integral therm is adjusted so the change does not generate jumps of the control outputs (bump-less). The Feeder can optionally operate the Load Out (Batch) software with full control or preset (high/low feed rate), pre-act and start delay to compensate for distance of feeding points when operating several belt feeders in ratio. For application in blending systems, where more belt feeders need to operate with one set point source, but different ratios, the ratio between the main set point and each belt feeder can be entered through the keyboard, analog input or serial link.
1.6.3
Monitoring Functions
The Feeder Controller includes internal diagnostics that generate alarms in case of hardware failures or programming errors. The following process alarms are also provided: High control deviation Alarms for high and low flow rate, speed and weight Alarms are visible on the display and can be acknowledged and reset through keyboard, digital input, or serial line. Alarms can be delayed to avoid intervention in case of short time peaks. Each individual alarm can be programmed to operate as alarm, shut down, or ignored. Two LEDs indicate the cumulative status of alarms and shut down. Digital outputs are also provided for the following: Hardware failure High control deviation Alarm cumulative Shut down cumulative
1.6.4
Print Functions
Periodical and command prints can be obtained by connecting a serial printer to the communication output on the motherboard or an optional communication board. Time and date are permanently stored in the battery-backed memory. The entire set up of the instrument can also be printed out.
1.6.5
Communication Functions
There are two types of standard communication functions. Each is discussed below: Serial Communications The communication protocol allows a remote intelligent device to read the contents of the registers and write to some registers. During the communication activity, the Micro-Tech 3105 always acts as a Slave, meaning it responds to a request from a Master device on the line, but never attempts to send messages out. One electrical interface may be selected and accessed through one communication port. Up to three communication boards may be installed. Field Bus I/O Allen-Bradley RIO or Profibus-DP I/O, or DeviceNet communication protocol board is typically used to transfer I/O images between a main PLC and the remote devices (normally remote I/O racks rack adapters) or to transfer (read and write blocks of data with intelligent remote devices (node adapters), the Micro-Tech 3105 in this case. The Remote I/O is a typical master/slave communication where the main PLC is the master or scanner and the remote devices are slaves or adapters.
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1.7
Functional Description
This section describes technically, how the Micro-Tech 3105 performs each particular duty.
1.7.1
1-6
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1.7.2
1.7.3
When the belt feeder starts, the Belt Feeder Controller begins the control action from the value at which the output was locked when the belt feeder stopped. Auto/manual switching is of bump-less type.
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The batch STAR/STOP commands are provided either by the keyboard or for external signals (manual pushbutton or relay contact from automatic system). The batch stop signal is used only as emergency to abort the batch cycle before its end. A delay time is provided between start command and actual start to compensate the difference in transport distance to the mixing point when several belt feeders are installed. If set to use the keyboard for START/STOP, there are two modes of operation available. Mode 1: START only assigned When START is pressed the output changes state and returns when STOP is pressed (i.e.; output is N.O., changes to N.C. when START is pressed, changes to N.C., when STOP is pressed. Output returns to stop condition at shutdown or power loss. Mode 2: START and STOP assigned Output is activated for two seconds when START Or STOP is selected. (Typical arrangement is START output N.O. and STOP output N.C. With this configuration the STOP output opens and remains so at shutdown command or power fail).
1.7.4
Indication System
The Feeder Controller is equipped with an indication and control system that is divided into four parts: Status Indicators Process Alarms Programming Errors Equipment Failures If any of the controlled conditions takes place, it is signaled by the lighting of a LED on the front and by a digital output. Using the keyboard, you can view all existing alarms and acknowledge them.
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Clock Calendar circuit failure Load Cell failure RAM failure ROM failure Speed Sensor failure Power on
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Default constants installed at power on Power down during calibration Calibration time expired General purpose external alarms Overflow of totalizer Auto Zero tracking limit Load Out deviation Communication error BCD error Mathematical error
1.7.5
Print Functions
Available print functions are: Print on command Print at pre-selected times of day (up to four) Print at pre-selected intervals of time Print Set-Up Print alarms
1.8
Symbol Identification
Table 1-1 describes the symbols used in this manual and associated drawings. Table 1-1: Symbol Identification
Symbol DESCRIPTION ALTERNATING CURRENT FRAME (GROUND) TERMINAL
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1.9
Technical Specifications
Enclosure Field Mount NEMA 4X (IP65), dust and watertight 17 x 13 x 7 inches Fiberglass reinforced polyester 2 position-mounting feet Steel chassis providing EMI/RFI shielding Panel Mount Size: 12 x 4 x 7.5 inches Material: Chromated mild steel Environmental Conditions Mounting Should be mounted as close to the loadcells as possible without being exposed to excessive heat or moisture Field Mount suitable for outdoor mounting Temperature (Ambient) Storage: -40 to +158 F (-40 to +70 C) Operating: +14 to +122 F (-10 to +50 C) Relative Humidity Up to 95%, non-condensing Pollution Degree Installation Category II Altitude Up to 6,561 ft (2000m) Power Requirements Voltage Range Nominal voltage +10%, -15% Nominal Voltage 115/230 VAC, selectable Nominal Frequency 50/60 Hz Fusing 400mA Slo-Blo, 110/120 VAC, Type T 200mA Slo-Blo 220/240 VAC, Type T Power Consumption 45 VA max
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Maximum Non-Destructive Input Voltage 150/300 VAC for 1 minute Over voltage Category Category II DC Power Supply Auxiliary Power Supply Output (Alarm Contacts, etc.) Output voltage: 24 VDC Isolation: Yes 500 volts Output ripple: 1.0 V peak to peak typical Output current: 600 mA maximum Short circuit protection Loader (Weight) Load cell input circuits Number: Up to six (6) 350-ohm loadcells in parallel. Cable distance 200 ft or less (3000 ft with sense) 0.5mV/V to 3.5 mV/V (keyboard selectable) 100 k-ohm minimum 114% of 3mV/V (3mV/V):112368 Non-isolated 6 V relative to ground Connected to earth ground
Sensitivity: Input Impedance: Maximum Usable Signal: Displayed A/D counts Isolation: Max non-destructive input voltage: Load Cell Cable Shield:
Load Cell Excitation Power Supply 10 VDC 10%, 220 mA Minimum load impedance (operating) 58 ohms Output short circuit, 1.5 A maximum Excitation Sense Circuit 6 Wire System; cable distance over 200 ft. (not to exceed 3000 ft.). Nominal input voltage: Input impedance: Jumper selectable: Speed Input Optically isolated Built in current source for dry contact use Powered by + 20 V SPU Supply 5 VDC (10 volts) 100 k-ohm minimum Local or remote sense
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Frequency Range Voltage/current type sensor: 0.25 to 2.0 kHz Contact closure type sensor: 0.25 to 30 Hz Low threshold: High threshold: Low or High Pulse Duration Voltage/current type sensor: 200 us min Contact closure type sensor: 15 ms min Hysteresis 0.5 VDC minimum Input Impedance 10 k-ohm typical, 500 ohm minimum Input Source Current -2 mA nom., 0 VDC Max. Non-destructive Input voltage 50 peak, continuous Digital Inputs 4 Optically Isolated Inputs Powered 24 VDC (internal) 6 mA Solid State Output on Motherboard Powered 24 VDC (internal) 50 mA Required Max 30 Hz Digital Outputs on Relay Board 3 configurable Digital Outputs 1 Failure Digital Output Relay Rated: 0.5 A, 33 VAC, 70VDC Current Output 1 current output on Motherboard Output range: User selectable 0 20 mA or 4-20 mA, representing 0 to 100% variable. Resistive load: 800-ohm max. Loop Capacitive load:No limit +1.0 VDC min +3.2 VDC max
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Analog I/O Board (B) (2) High level input Type: Differential voltage input. (0-20mA or 4-20mA with internal resistor, jumper selectable) Range: 0-5V, or V, programmable Maximum usable input voltage: 106% of full scale Nonisolated Maximum non-destructive input voltage: 12V peak (2) Current Outputs Optically isolated Isolated power source Voltage output by adding an internal dropping resistor Output range: User selectable 0-20mA or 4-20mA, representing 0 to 100% variable. Resistive load: 800 ohms maximum Capacitive load: no limit Standard Communication Serial Interface Type: Conforms to RS-232C, RS-485/422, and 20 mA standards; supports 2 and 4 wire multi-drop in RS485. 20 mA loop is passive ONLY. RS-485 supports 2-wire or 4-wire multi-drop networking; RS 232 C provides support for modem. 110 to 19200, operator selectable from the keyboard. Asynchronous, bit-serial, selectable parity, data length, and stop bits. 250 VRMS max. 30 Vdc max (RS-232C) 15/-10 Vdc max. (RS-485) 50 feet max. (RS-232C) 4000 feet max (Rs-485 and 20 mA)
Interfacing: Data rate: Data Format: Optical Isolation: Input Voltage: Cable Length:
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2.1
Safety Precautions
WARNING
FIELD MOUNT VERSION ONLY AN EXTERNAL BIPOLAR LINESWITCH (CSA-UL) MUST BE PROVIDED AT INSTALLAION TIME (115 OR 230 VAC, 5A) WITH MAGNETHERMAL SWITCH NORMAL CURRNT 16A. MAXIMUM DISTANCE FROM INSTRUMENT 1.5 M.
WARNING
FIELD MOUNT VERSION ONLY BEFORE OPENING THE INSTRUMENT DOOR, ENSURE THE EXTERNAL LINE SWITCH HAS BEEN SWITCHED OFF.
CAUTION
DO NOT INSTALL, OPERATE, OR PERFORM ANY MAINTENANCE PROCEDURES UNTIL YOU HAVE READ THE SAFETY PRECAUTIONS THAT FOLLOW.
CAUTION
DO NOT CONNECT POWER TO THE ELECTRONICS OR TURN
ON THE UNIT UNTIL YOU HAVE READ AND UNDERSTOOD THIS ENTIRE MANUAL. THE PRECAUTIONS AND PROCEDURES PRESENTED IN THIS MANUAL MUST BE FOLLOWED CAREFULLY IN ORDER TO PREVENT EQUIPMENT DAMAGE AND PROTECT THE OPERATOR.
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WARNING
DOOR SHOULD ALWAYS REMAIN CLOSED DURING OPERATION, AND ONLY OPENED FOR MAINTENANCE PROCEDURES. BE SURE TO CLOSE THE COVER BEFORE RESUMING OPERATION.
THE INSTRUMENT
WARNING
ALL SWITCHES (SUCH AS CONTROL OR POWER) MUST BE OFF WHEN CHECKING INPUT AC ELECTRICAL CONNECTIONS, REMOVING OR INSERTING PRINTED CIRCUIT BOARDS, OR ATTACHING VOLT METERS TO THE SYSTEM. INCOMING VOLTAGES VOLTMETER BEFORE ELECTRONICS.
MUST BE CHECKED WITH A BEING CONNECTED TO THE
WARNING
CAUTION MUST BE USED IN TESTING IN, ON, OR AROUND THE ELECTRONICS, PC BOARDS, OR MODULES. THERE ARE VOLTAGES IN EXCESS OF 115 V OR 230 V IN THESE AREAS. AVOID HIGH VOLTAGE AND STATIC ELECTRICITY AROUND THE PRINTED CIRCUIT BOARDS.
EXTREME
WARNING
MAINTENANCE PROCEDURES SHOULD BE PERFORMED ONLY BY QUALIFIED SERVICE PERSONNEL AND IN ACCORDANCE WITH PROCEDURES/INSTRUCTIONS GIVEN IN THIS MANUAL.
WARNING
DURING MAINTENANCE, A SAFETY TAG (NOT SUPPLIED BY THERMO ELECTRON) SHOULD BE DISPLAYED IN THE ON/OFF SWITCH AREAS AS A PRECAUTION INSTRUCTING OTHERS NOT TO OPERATE THE UNIT.
WARNING
QUALIFIED SERVICE TECHNICIANS SHOULD BE ALLOWED TO OPEN AND WORK IN THE ELECTRONICS, POWER SUPPLY, CONTROL, OR SWITCH BOXES.
ONLY
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WARNING
THIS EQUIPMENT SHOULD NOT BE OPERATED OR UTILIZED
IN APPLICATIONS OTHER THAN THOSE STATED IN THE ORIGINAL ORDER.
TO
ADAPT PRODUCTION RATES OR APPLICATIONS, CONSULT THERMO ELECTRON PRODUCTS CUSTOMER SERVICE FOR RECOMMENDATIONS.
WARNING
PANELS COVERING THE ELECTRONICS MUST BE IN PLACE AND TIGHT BEFORE WASH DOWN PROCEDURES. DAMAGE TO THE ELECTRONICS COULD RESULT FROM WATER, MOISTURE, OR CONTAMINATION IN THE ELECTRONICS HOUSING.
ALL
2.2
Incoming Power
CAUTION
VERIFY THAT THE AC VOLTMETER INSTRUMENT.
INPUT VOLTAGE IS CORRECT WITH AN BEFORE YOU CONNECT IT TO THE
CAUTION
EARTH GROUND MUST BE PROVIDED TO THE INSTRUMENT. DO NOT USE CONDUIT TO PROVIDE THIS GROUND.
CAUTION
PROTECTIVE GROUND MUST BE PROVIDED TO THE INSTRUMENT. DO NOT USE CONDUIT TO PROVIDE THIS GROUND.
CAUTION
A READILY ACCESSIBLE DISCONNECT DEVICE SHALL BE INCORPORATED IN THE FIELD WIRING. THIS DISCONNECT DEVICE SHOULD BE IN EASY REACH OF THE OPERATOR AND IT MUST BE MARKED AS THE DISCONNECTING DEVICE FOR THE EQUIPMENT.
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2.2.1
2.3
2.3.1
Mounting
Mount the Feeder Controller to a rigid, flat, vertical surface using four mounting holes provided on the back of the enclosure. Care should be taken to ensure the mounting surface is flat so as not to twist or warp the fiberglass enclosure when tightening the mounting bolts. Figure 2-1: Typical Micro-Tech 3105 Installation
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Figure 2-2: Mounting Guidelines of the Micro-Tech Model 3105 (Field Mount) Belt Feeder Controller
A92019
CAUTION
REFER TO THE FILED WIRING DIAGRAM AS A GUIDE IF YOU DO NOT HAVE A SPECIFIC WIRING DIAGRAM FOR YOUR SYSTEM. FOLLOW YOUR LOCAL ELECTRICAL CODES AND REGUATIONS FOR MINIMUM WIRE SIZE AND ROUTING.
2.3.2
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7. All additional field wiring operation at voltages less then 30 V must be located on the left bottom of the enclosure. Leave ample loose wiring (typically 8) to facilitate removing the terminal connectors. 8. Close the inside panel and tighten the screw to secure the cover. Note: Cable conduits AWG 18 and clamps must be CSA-UL certified. Mounting must preserve the IP 65 rating of the unit. Figure 2-3: Field Mount Inside Front Panel
Power Switch
A90869
2.4
2.4.1
Mounting
Provide a cutout in the panel and insert the Belt Feeder Controller after removing the holding brackets. From the back, insert the holding brackets on both sides of the Belt Feeder Controller. Tighten the holding brackets to support the Belt Feeder Controller and form the dust seal.
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Figure 2-4: Mounting Guidelines Micro-Tech 3105 (Panel Mount) Belt Feeder Controller
A92020
Figure 2-5: Installation Micro-Tech Model 3105 (Panel Mount) Belt Feeder Controller
A00884
See Figure 2-4 for panel cutout, outline, and mounting dimensions. The large rubber band shipped with the unit can be used to hold clamp brackets in place during installation.
Remove clamp brackets and slide chassis assembly through front of cut-out. Reinstall clamp brackets into chassis and tighten threaded rods against the back of the panel until the unit is secure.
2.4.2
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Note: All units shipped from the factory are configured for 115 VAC. If 230 VAC is desired, refer to Section 2.5.1, motherboard configuration Jumpers and Switches. For input power, use 14 AWG standard wire Wire the safety ground terminal located on the right backside of the enclosure. Wire the HOT to terminal labeled 1 of Terminal L on the Power Input Terminal. Wire the NEUTRAL to the terminal labeled 2 of Terminal N on the Power Input Terminal.
2.5
2.5.1
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OP 26 EPROM U66
A90870
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2. Digital Outputs A relay output board (all dry contacts) and is plugged into slot 4 of the motherboard. One of the relay outputs is permanently assigned as the fault output and cannot be programmed to any other function. The other 3 relays can be programmed to one of the choices shown below in either a normally open or normally closed position. There is an additional solid-state output (located on the motherboard), which can also be programmed to one of the functions shown below. The programmable output choices are listed in Table 2-2. Table 2-2: Programmable Output Choices
Alarm Cumulative Shutdown Cumulative Ready High Load Low Load High Rate Low Rate High Speed Low Speed Totalization Pulse (Remote Counter) ** Batch Preset Reach ** Batch End High Deviation Positive HHigh Deviation Positive High Deviation Negative HHigh Deviation Negative High Deviation Positive #2 HHigh Deviation Positive #2 High Deviation Negative #2 HHigh Deviation Negative #2 Alarm Installed Local / Remote Increase Decrease Auto / Manual Load WTS (Weights) Start Belt Stop Belt Increase #2 Decrease #2
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2.5.2
For distances greater than 200 feet and less than 3,000 feet, the jumper should be in position B". A special 6-wire cable is required. Refer to the field-wiring diagram for jumper requirement in the scale junction box. Table 2-3: Load Cell Jumper Settings
LOAD CELL JUMPERS Mode OP6 Less than 200 feet Greater than 200 feet A B OP7 A B DEFAULT
OP 13 OP 11
OP 10 OP 5
OP3
OP2
OP1
OP7
OP6
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SPU Contact Closure Input (Slow Speed) Sense Jumper A = Less than 200 ft Sense Jumper A = Less than 200 ft Comm A = RS-485/232 B = 20 mA
Comm A = Terminated B = Not Terminated C = 20 mA Comm A = Normal B = Multidrop OIML Calibration Jumper A = Allows Cal B = Restricts Cal
2 3 1 9 10 4 5 8 6 7
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1 2 3 4 5 6 7 8 9 10
Relay K2 Output #1
2.5.3
+ Shield
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2.5.4
Outputs The functions that can be selected for each output are: Off, Rate, Speed, Load, Control, Level. Figure 2-8: Analog (TB4) Input/Output Board
Analog (TB4) In/Out Board 2 3 1 9 10 4 5 8 6 7 + Out 2 Shield + Out 3 + In-1 Shield + In-2 -
2.5.5
2-14
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29 28 24 21 20
-RX +Rx
Common
+TX -TX
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23 24 22 21 20
Maximum cable length 50 ft Use Beldon 9538 or equivalent Table 2-12: Motherboard Wiring Configuration TB 3 20mA Serial Communications
26 27
+20 mA (out)
-20 mA (out)
28 24
+20 mA (in)
-20 mA (in)
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2.6
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2.6.1.3.1
As indicated in Figure 2-10, measure the distance from the pivot centerline to the loadcell centerline to the nearest 0.032 (1/32). Record the distance below. (Pivot to Load Cell Distance) Figure 2-10: Pivot to Load Cell
2.6.1.3.2
2.6.1.3.3
As indicated in Figure 2-11, measure the distance from the pivot centerline to the weigh idlers centerline to the nearest 0.032 (1/32). Record the distance below. (Pivot to Load Cell Distance) (Model 10-20 belt scale shown.) Figure 2-11: Pivot to 1st Idler
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2.6.1.3.4
As indicated in Figure 2-12, measure the distance from the pivot centerline to the second weigh idlers centerline to the nearest 0.032 (1/32). Record the distance below. (Pivot to 2nd Weigh Idler Distance) (Model 10-22 belt scale, 10-17-2 similar.) Figure 2-12: Pivot to 2nd Weigh Idler
Note: Up to six (6) weigh idlers on a single weighbridge may be entered during programming. Measure and record the same as Section 2.6.1.3.4 for each additional weigh idler.
2.6.1.3.5
As indicated in Figure 2-13, measure the distance from the pivot centerline to the weigh idlers centerline to the nearest 0.032 (1/32). Record the distance below. (Pivot to Weigh Idler Distance) Figure 2-13: Pivot to 1st, 2nd, 3rd, and 4th Weigh Idler
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2.6.1.4.1
As indicated in Figure 2-14, measure the distance from the centerline of the pivot to the actual point of test weight contact to the nearest 0.032 (1/32). Record the distance below. If contact point is below pivot, the value is negative (-). (Pivot to Test Weight Height Distance) Figure 2-14: Pivot to Test Weight Height
2.6.1.4.2
As indicated in Figure 2-15, measure the distance from the centerline of the pivot to the actual point of test weight contact to the nearest 0.032 (1/32). Record the distance below. (Pivot to Test Weight Length Distance) Figure 2-15: Pivot to Test Weight Length
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2.6.1.4.3
As indicated in, Figure 2-16 measure the distance from the centerline of the pivot to the top of the carriage rails to the nearest 0.032 (1/32). Record the distance below. (Pivot to Carriage Height Distance) Figure 2-16: Pivot to Carriage Height
2.6.1.4.4
As indicated in Figure 2-17, measure the distance from the top of the carriage rails to the top of the weigh idler carry roll where the belt makes contact on trough idlers. With flat idlers, measure to the centerline of the grease fitting to the nearest 0.032 (1/32) and record the distance below. (Roll to Carriage Height Distance) Figure 2-17: Roll to Carriage Height
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A90863
1. Choose a convenient distance AB and measure it in inches. 2. Hang a plumb line from B. 3. Measure the horizontal distance from A to plumb line in inches (AC). Divide AC by AB to get COS . 4. If the angle of incline in degrees is known, use the following table. Table 2-15: Angle of Incline
Angle 0 1 2 3 4 5 COS 1.0000 .9998 .9994 .9986 .9976 .9962 Angle 6 7 8 9 10 11 COS .9945 .9925 .9903 .9877 .9848 .9816 Angle 12 13 14 15 16 17 COS .9781 .9744 .9703 .9659 .9613 .9563
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2.7
CAUTION
VERIFY 115/230 VOLT SELECTION IS CORRECT. IMPROPER CONNECTION MAY RESULT IN DAMAGE TO YOUR INTEGRATOR.
Turn the weigh belt feeder conveyor belt on. Run the weigh belt feeder empty during setup and calibration. The programming mode begins the first time power is applied. Information requested by the instructional screens should be entered before moving to the next screen. The belt scale is calibrated at the end of this procedure provided the correct information is entered. The alarm light flashes during the programming procedure and clears when calibration is complete. The programming mode begins with the following instructional screens.
-- MEMORY ERASED -Chose the language key to continue to ESP USA
2.7.1
Language
The Micro-Tech 3105 is a dual language instrument. USA is always the first language. The standard configuration provides Spanish (ESP) as the second language. Other languages, such as German (GER), are available upon request (consult factory). Press the desired language.
Initial scale setup and calibration Press down SCROLL.
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Press key under HELP for more information. HELP Press the HELP soft key.
Key with dot (soft key) performs action of of word above it. MORE RETURN
HELP is flashing
When RETURN is pressed, the user is returned to the previous screen. Pressing MORE advances the system to the next screen. Press MORE
Use down SCROLL key to advance through the menus MORE RETURN
Pressing MORE or RETURN reverts the screen back to previous screens in the series. Press the DOWN SCROLL key.
2.7.2
Measure Units
Press SCROLL DOWN to accept the default unit, or CHOICES to scroll selections. Press ENTER to confirm your selection. Scroll down.
-- DISPLAY SCROLL 1 -Measure units > English < CHOICE ENTER
Default: Choices:
ENGLISH ENGLISH, METRIC, MIXED If English, all units in English If Metric, all units Metric If Mixed, units may be a combination of English and Metric
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Note: If the Measure units are changed from English to Metric (or vice versa) after the scale is calibrated, the span number changes but the calibration remains the same.
2.7.3
Totalization Units
The units to be used for Totalization are selected here. Press ENTER soft key to accept the default unit, or CHOICES soft key to scroll selections. Press ENTER to confirm your selection. Scroll down.
-- DISPLAY SCROLL 2 -Totalization Units > Tons < CHOICE ENTER
2.7.4
Length Units
Units used for parameters expressed in length are selected here. Selections are only available if MIXED units are in use. Press ENTER soft key to accept the default unit, or CHOICES soft key to scroll selections. Press ENTER to confirm your selection. Scroll down.
-- DISPLAY SCROLL 3 -Length Units > feet < CHOICE ENTER
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2.7.5
Rate Units
The rate is displayed according to the units selected here. Press ENTER soft key to accept the default unit, or CHOICES soft key to scroll selections. Press ENTER to confirm your selection. Scroll down.
-- DISPLAY SCROLL 4 -Rate Units > TPH < CHOICE ENTER
English/Mixed Default: Tph Choice: Tph, Ltph, Lb/mn, T/mn, LT/m, Percent %, Lb/h
If Mixed Default: Tph Choice: Tph, Ltph, kg/mn, t/mn, Lb/mn, t/mn, LT/mn, Percent kg/h, t/h
2.7.6
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2.7.7
500.00 1 200000
2.7.8
Scale Divisions
When the Scale capacity is entered, the number of decimal places is also defined. If, for example, the User enters 500.0, this sets the "Scale Divisions" parameter to 0.1. Advancing to the next scroll, the User then sees first the Scale Division corresponding to the just entered Scale Capacity (in the example 0.1). If required, the User is able to alter the Scale Division to any of the available options. Press the ENTER soft key to accept the default divisions, or the CHOICES soft key to scroll selections. Press ENTER to confirm your selection. Scroll down.
-- SC DATA SCROLL 2 -Scale Divisions > 0.1 < CHOICE ENTER
Default: Choice:
0.1 0.1, 0.2, 0.5, 1, 2, 5, 10, 20, 50, 0.01, 0.02, 0.05, 0.001, 0.002, 0.005
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2.8
1 0 500
Press ENTER to accept the displayed selection from the database listed in Appendix A/1, Weighbridge Parameters. If ENTER is used, the scrolls from 3A to 3J are not displayed. Skip to Step 12. Press DETAIL if you want to force the following scrolls #3A to 3O to be displayed even if ENTER was used. Enter 0 if you want to define the weighbridge not using the database. This should only be done for special weighbridges that are not part of the standard set of Thermo Ramsey scales. Entering 0 forces the following scrolls 3A to 3O to be displayed.
2.8.1
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Using the numeric keys, enter the distance recorded in Section 2.5.1 and press ENTER. For weighbridges, which do not have a pivot, enter zero.
-- SC DATA SCROLL 3A-Pivot to loadcell distance: 000.00 In ENTER
If English:
Default: 32 in Min: 0.00 in Max: 150.00 in Default: 1000 mm Min: 0 mm Max: 3800 mm
If Metric
1 1 6
Parameter LB1: Pivot to first weigh idler distance. Measure the distance between the pivot centerline and first weigh idler centerline. Enter the distance (within 0.032 inch or 1 mm) recorded in Section 2.6.1.3.3. For weighbridges, which do not have a pivot, enter zero.
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Default: 24 in Min: 0.00 in Max: 100.00 in Default: 800 mm Min: 0 mm Max: 2500mm
If the number of weigh idlers entered in scroll 3B is more than one, the following screens are displayed. Measure the distance between the pivot centerline and second weigh idler centerline. Enter the distance (within 0.032 inch or 1 mm) recorded in Section 2.5.1. For weighbridges, which do not have a pivot, enter zero. Only if # of weigh idlers >=2:
-- SC DATA SCROLL 3D-Pivot to 2nd idler distance 000.00 IN ENTER
Default: 0.00 in Min: 0.00 in Max: 100.00 in Default: 0 mm Min: 0 mm Max: 2500mm
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Default: 0.00 in Min: 0.00 in Max: 100.00 in Default: 0 mm Min: 0 mm Max: 2500mm
Note: All measurements must be (within 0.032 inch or 1 mm) recorded in Section 2.5.1. Enter the distance with the numeric keys and press ENTER.
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Default: 0.00 in Min: -20.00 in Max: +20.00 in Default: 0 mm Min: -500.0 mm Max: +500.0 mm
Default: 24.00 in Min: 0.00 in Max: 200.00 in Default: 0 mm Min: -0 mm Max: 5000 mm
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Default: 6.50 in Min: 0.00 in Max: 10.00 in Default: 0 mm Min: -0 mm Max: 250 mm
Default: 6.50 in Min: 0.00 in Max: 20.00 in Default: 0 mm Min: -0 mm Max: 250 mm
2.8.2
1 1 6
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2.9
Default: 36.00 in Min: 2.00 in Max: 120.00 in Default: 1000 mm Min: 50 mm Max: 2500 mm
2.9.2
Angle of Inclination
Enter the angle of inclination. If an inclination compensator is connected to the scale, after this preliminary set up has been completed, enable the automatic angle detection in I/O definition (Main Menu 4) and calibrate the incline compensator.
-- SC DATA SCROLL -5Conveyors angle 0.0 Degrees ENTER +/-
Note: Incline angles greater than 16 are not recommended, it restrict the system accuracy. Consult the factory on angles with installation greater than 16.
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2.9.3
Default: 250.0 Lbs Min: 1 Lb Max: 15000 Lbs Default: 100 kg Min: 1 kg Max: 5000 kg
The sensitivity was entered when the belt scale code was entered. If other (0) was selected, enter the loadcell sensitivity in mV/V as marked on the label of the loadcell. Thermo Ramsey loadcells are normally 1.800 or 3.000 mV/V.
-- SC DATA SCROLL -7Load cell sens. 3.000 mV/V ENTER
Load cell resistance is entered on this screen. The resistance for the loadcell has been recorded on the System Data Sheet in the front of your belt scale manual. (It is also stamped on the loadcell cable.) Enter the ohms for the loadcell. The number of scrolls depends on the number of loadcells specified in scroll 3O.
-- SC DATA SCROLL 8ALoad cell #1 res 350.000 Ohms ENTER
Default: 350 Ohms Min: 10 Ohms Max: 2000 Ohms If # of Load Cells is more than 2:
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Default: 350 Ohms Min: 10 Ohms Max: 2000 Ohms If # of Load Cells is more than 3:
-- SC DATA SCROLL 8CLoad cell # 3 res 350.000 Ohms ENTER
Default: 350 Ohms Min: 10 Ohms Max: 2000 Ohms If # of Load Cells is more than 4:
-- SC DATA SCROLL 8DLoad cell # 4 res 350.000 Ohms ENTER
Default: 350 Ohms Min: 10 Ohms Max: 2000 Ohms If # of Load Cells is more than 5:
-- SC DATA SCROLL 8ELoad cell # 5 res 350.000 Ohms ENTER
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If # of Load Cells is 6:
-- SC DATA SCROLL 8FLoad cell #6 res 350.000 Ohms ENTER
2.9.4
Default: Choice:
2.9.5
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Select ACQUIRE. Acquire is the recommended selection. Acquiring the Test Duration When selecting FULL, use a 100-foot tape to measure the belt length to the nearest 0.1 foot. Reference a fixed point (an idler) on the conveyor when counting belt revolutions. See Section 2.5.1 for the recorded conveyor belt length. The PARTIAL (belt length measurement) selection enables the operator to acquire test duration without the entire belt length measurement.
CAUTION
THIS OPTION SHOULD ONLY BE USED WHEN BELT LENGTH EXCEEDS 1000 FEET. ACQUIRE TEST DUR Choose belt length measurement method FULL PARTIAL
FULL is the recommended selection. If FULL is selected, continue with Step 16 below. If PARTIAL is selected, skip to Step 17.
2.9.6
Default: 1000.0 Ft Min: 1.0 Ft Max: 10000.0 Ft Default: 200 m Min: 0.5 m Max: 3000 m
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After the length of the belt has been entered, the system automatically moves to the following screen, which prompts the operator to press START when the mark passes the reference point. Pressing ABORT returns the screen to Cal Data Scroll 11. The belt must be running at the maximum speed before executing this function. If not, the prescaler will be improperly calculated.
Start belt. Press START when 1st mark passes reference. START ABORT
When START is pressed above, the system automatically moves to the next instructional screen. The operator presses COUNT each time the mark passes the reference point until minimum test load conditions are met (refer to belt scale installation manual for minimum test load requirements). When the last revolution passes the mark, the operator must press COUNT followed by pressing DONE. Pressing ABORT returns the screen to Cal Data Scroll 11. Zero Cal light illuminates indicating zero calibration is in progress.
Press COUNT each Time a mark passes. 00000 secs 000 revs COUNT ABORT DONE
Pressing ABORT returns the screen to Cal Data Scroll 11. When duration test is finished, the new values for length of belt and time are displayed. Press CONTINUE During the Acquire Test Duration, the Integrator performed an unassisted zero calibration and installed the new zero. Skip to Step 19.
TEST DURATION Length = 0000.0 Ft Time = 000 sec CONTINUE
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2.9.7
Default: 200 Ft Min: 1.0 Ft Max: 10000.0 Ft Default: 50.0 m Min: 0.5 m Max: 3000.0 m
After the length of the belt has been entered, the system automatically moves to the following screen, which prompts the operator to press START when the mark passes the reference point. The belt must be running at the maximum speed before executing this function. If not, the prescaler is improperly calculated. Pressing ABORT returns the screen to Cal Data Scroll 11.
Start belt. Press START when 1st mark passes reference START ABORT
When START is pressed above, the system automatically moves to the next instructional screen. The operator presses COUNT each time a mark passes the reference point until both marks have passed. Then press DONE. Pressing ABORT returns the screen to Cal Data Scroll 11. Zero Cal light illuminates indicating zero calibration in progress.
Press COUNT each Time a mark passes. 00000 secs 000 revs START ABORT
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When duration test is finished the new values for length of belt and time are displayed. Press CONITNUE.
TEST DURATION Length = 0000.0 Ft Time = 000 sec START ABORT
During the Acquire Test Duration, the Feeder Controller performed an unassisted zero calibration and installed the new zero. Skip to Step 19.
2.9.8
The operator is prompted to enter the length of one belt revolution. Pressing ABORT returns the screen to Cal Data Scroll 11.
ENTER length of one Belt revolution Length 000.0 Ft ENTER ABORT
Default: 200.0 Ft Min: 1.0 Ft Max: 10000.0 Ft Default: 200.0 m Min: 1.0 m Max: 1000.0 m
The number of belt revolutions to be timed is than entered. Pressing ABORT returns the screen to Cal Data Scroll 11.
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ENTER the number of Belt revolution to be timed 000.0 revs ENTER ABORT
1 1 100
The next menu is the time per revolution. Pressing ABORT returns the screen to Cal Data Scroll 11.
ENTER the time for Revolutions to pass reference 000.0 sec ENTER ABORT
When ENTER is pressed, the system times the belt travel according to the above entered parameters. Pressing ABORT returns the screen to Cal Data Scroll 11. Zero Cal light illuminates indicating zero calibration in progress.
Timing belt travel 000.0 sec ABORT
When the test duration test is finished, the new values for length of belt and time are displayed. Press CONTINUE
TEST DURATION Length = 000.0 Ft Time = 000 sec CONTINUE
During Acquire Test Duration the Feeder Controller performed an unassisted zero calibration and installed the new zero.
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2.9.9
The Alarm light stops flashing and the Ready light illuminates. The field data entered during this procedure enabled the Micro-Tech 3105 to perform an unassisted zero balance and span calibration. Assuming no mistakes were made, the scale is calibrated and is ready for use at this time. Note: The span number was calculated from the data that was entered during this programming procedure. This span number is based on a perfect mechanical alignment of the scale and its adjacent idlers. Therefore, verify this by performing a material span calibration (Section 3.10.4) or by performing a span calibration procedure (MAIN MENU 1, Section 3.10.3, and MAIN MENU 2, Section 3.10.3). In case the loadcell is not connected or a failure is detected, the following message is displayed:
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The problem causing the calibration to be aborted must be corrected before attempting another calibration. The information entered previously is still in memory and should not have to be reentered. After the problem has been corrected, press MENU. Main Menu 1 should appear. If not, continue to press MENU until Main Menu 1 appears. Proceed to Section 3.9, MAIN MENU 1, and conduct a Zero Calibration from 3.10.1 and a Span Calibration from Section 3.10.3. The scale is now calibrated using R-Cal as the simulated load. Press RUN to start or MENU for scrolls
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3.1
Overview
Micro-Tech 3105 Controller is a microcomputer-based instrument that accepts and conditions speed and weight signals and provides visual and electrical outputs for total weight and rate, control of flow. The Feeder Controller produces a stable 10-volt DC excitation voltage capable of exciting up to six strain gauge loadcells. Sense lead terminations are also provided for six wire loadcell cables. Auto Zero Track enables the belt scale system to automatically zero itself during extended periods when the conveyor belt is running empty. Auto Zero Track is menu selectable because some installations may not desire this option. A Z displays on the second line of the display to indicate the selection of this option. If the clip detector option is installed and AZT tack is enabled, the Belt Feeder Controller memorizes the weigh belt weight variations and smoothes out the rate signal. On light loaded weigh belts this option decreases controller output corrections due to belt weight changes and not belt loading changes. In Manual mode, the rate output is frozen when the belt splice is passing over the scale. The Feeder Controller output can be PID or P.E.I.C. control. P.E.I.C. control can be an analog output or time proportional increase / decrease digital output. Life expectancy of the RAM support battery is approximately ten years, if power is not applied. Under normal operation where power is on continuously, life expectancy is much longer. Errors may occur during initial calibration and their reason must be corrected during initial calibration. During normal operation, an error would most likely indicate a failure in system or improper operation.
3.2
Operator Interface
This section provides information about setting up and operating the Micro-Tech 3105. All operations are performed from the front panel of the electronic enclosure. The operator interface, including all keys, indicators, and displays. Procedures for initial setup and calibration are provided. . Detailed operating procedures are also included. All operations are performed from the front panel of the electronic enclosure. The Micro-Tech 3105 has been adjusted, configured, and inspected at the factory per the supplied customer data. Additional internal adjustments should not be necessary for satisfactory performance. If adjustments become necessary, refer to Chapter 4 Micro-Tech 3105 Maintenance.
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3.3
Front Panel
The front panel (see Figure 3-1) contains the necessary status indicators and keys to enable the operator to perform calibrations and all required operations after the Feeder Controller has been configured (see Section 2.5 for configuration procedures). Front panel operation, zero calibration, and span calibration are described in this chapter. A detailed description of all menus and their contents are found in Appendix A. The Feeder Controller front panel display includes the following features: System status lights that show the status of the weighing process. LCD graphic display Keypad
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3.3.1.3 Keypad
The keypad is comprised of pad touch keys consisting of the following: RUN gives access to the RUN menu and returns the Feeder Controller to Run mode whenever pressed, see Section 3.6 for a detailed description of RUN menu. MENU gives access to the Micro-Tech 3105 menus UP/DOWN ARROW KEYS scrolls up or down in the selected menu. SOFT KEYS selects the displayed function directly above the key. Also moves the cursor left and right during string editing. ALPHL/NUMERIC KEYS 1 THROUGH 0 used to enter letters and numerals when string editing. Similar to a telephone keypad. DECIMAL POINT KEY enters a decimal point CLEAR KEY removes incorrect entries prior to pressing ENTER. LOCAL / REMOTE KEY used to change the status of the Feeder Controller between LOCAL and REMOTE setpoint. It is inhibited when digital function LOC/REM is assigned. AUTO / MAN KEY - used to change the status of the Feeder Controller between AUTOMATIC and MANUAL control. It is inhibited when the digital function AUTO/ MAN is assigned. PRINT initiates a printout. START start key has two functions. It can start the belt feeder conveyor if assigned to an output or, if the loadout option is installed, the start key starts the loadout to batch and restarts if interrupted. STOP stop key has two functions. It can stop the belt feeder conveyor if assigned to an output or, if the loadout option is installed, the stop key interrupt the loadout or batch and aborts load if already interrupted. Note: START/STOP are only active with Load Out or Batch option.
3.4
General Navigation
Navigating the menus is the same throughout the setup and operation of the Micro-Tech 3105. To follow are a few general guidelines to help in menu navigation. Press the DOWN SCROLL key to advance through the menus, UP SCROLL key to return to the previous item displayed on the screen, RETURN to go back to the previous menu, CHOICES soft key to view the choices for a selected menu option, and ENTER to confirm you menu selection
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3.5
Menu Displays
The Feeder Controller is a menu driven machine that allows the operator to access all setup, test, and calibration parameters. Main menu screens 1 through 7 can be accessed at anytime by pressing MENU until the desired menu screen is displayed. Pressing the soft key directly below the desired scroll, and then using the UP/DOWN scroll key select menu scrolls. If the Feeder Controller is password protected, the appropriate password must be entered prior to making changes or performing routine calibration. Menus may be viewed without entering a password, but no entries are allowed unless the password is entered. Optional menu scrolls are only available if the option has been installed. The MENU key activates the following screens. See Appendix A for detailed description of all menus.
-- MAIN MENU 1 -Press MENU for more ZERO SPAN MATL CAL CAL CAL
-- MAIN MENU 2 -Press MENU for more SCALE CALIB DISPLAY DATA DATA
-- MAIN MENU 4 -Press MENU for more I/O ALARMS LOAD DEF. DEFIN. OUT
-- MAIN MENU 5 -Press MENU for more COMM A COMM B PRINT * *Can be AB RIO or PRO DP
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3.6
Normal Power On
When the Feeder Controller is powered on after initial programming, the Run menu is displayed unless the hardware configuration has been changed.
3.6.1
Hardware Configuration
If the hardware configuration detected at power on differs from the one recorded in memory, the following screen displays. This only happens if a circuit board has been added or removed during power off, or a board has failed.
This screen disappears after 10 seconds if the question is not answered. The Feeder Controller assumes the answer is NO. HW CONFIG. CHANGED alarm is on and cannot be reset. The above screen appears each time power is cycled. If a board is removed or added, and this is a permanent change in configuration, answer YES. 1. A board is removed and is not replaced: The Feeder Controller cancels from memory the setup data of the board that is removed. If the board is added again, the setup data for the board has to be entered again. 2. A board is added: The Feeder Controller acquires the new hardware configuration. Setup data for the new board must be entered.
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Note: Check the setup configuration in the I/O DEFINITION SCROLL if an I/O board is removed or added. I/O assignments change when the number of I/O boards change. If the reason for the message is not known, or if the change in configuration is temporary and the operator does not want to lose the original setup, answer NO. 1. A board is removed: 2. The Feeder Controller resumes operation, retaining setup data of the board that was removed. All other boards continue working normally. No change occurs in the I/O Definition. 3. A board is added: 4. The Feeder Controller resumes normal operation without recognizing the new board. If NO is pressed, the HW CONFIG CHANGED alarm stays on.
3.7
Run Menu
When the Feeder Controller is normally powered on after initial programming, the Run menu is displayed. The Run Menu consists of five different system menus, which can be viewed by pressing the scroll UP or DOWN keys. System menus are: Main Run, Reset Total, Controller Output, and Optional Load Out. Pressing the RUN key on the front panel will always access the RUN menu.
3.7.1
Main Run
Main RUN menu is the first system RUN menu. It appears after initial programming. Use the scroll UP or DOWN keys for access to the other system RUN menu or to return. Pressing RUN does not return to Main RUN.
The first line always displays the MASTER TOTAL, which is the number of tons totalized by the scale since installation. This number cannot be cleared. The second line always displays the rate. A "Z" appears on the left side if the "Auto Zero Tracking" optional function is enabled and the scale is unloaded. The "Z" is not flashing during the first half test duration, while the Feeder Controller is checking that the belt is unloaded. Then, during full test duration, the "Z" is flashing, indicating the Feeder Controller is averaging the signal from the loadcell to accurately re-zero the scale. The load must stay below the AZT max deviation set point during the cycle, otherwise auto zero is aborted. The third line is by default blank, but can be programmed to show the belt speed, the belt loading or the date and time. The selection is made in the DISPLAY MENU.
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3.7.2
Totals
Pressing the key below TOTALS allows scrolling between Master Total, Reset Total, Operator Total, and Batch Total (optional)
MASTER TOTAL SINCE 00-00-0000 0000000.0 Tons
Master Total cannot be reset. The date is entered during initial programming.
RESET TOTAL SINCE 00-00-0000 000000.0 Tons RESET
The RESET TOTAL can be reset at any time. No password is required for reset. When the RESET key is pressed, the following screen is displayed:
Do you wish to clear RESET total? YES NO
Password: Operator
Operator Total can be reset at any time. Operator password if used must be entered. The second line functions the same as Reset Total above. When the RESET key is pressed, the following screen is displayed:
Do you wish to clear OPERATOR total? YES
NO
Micro-Tech 3105
3.7.3
Print Key
The PRINT key is active if selected in COMM scroll. The following screen is displayed:
00000000 Tons 00000 Tph PRINT TOTALS
The second line is the status of the printer: NO DATA - indicates the printer is idle, no data is being sent to the printer. IS RUNNING - the system is sending data to the printer. The third line indicates what kind of data is printed, if the PRINT key is pressed. The UP and DOWN keys select between: TOTALS - print totals BATCH - only if load out option is active, print load out information SETUP - print the setup data of belt feeder controller TRAILS - if audit trails option is active, print audit trails data. Print starts after the PRINT key is pressed. The COM key allows printer selection if more than one printer is installed. Examples of data that can be printed: Print TOTALS: TOTALS REPORT DATE: TIME: 11-10-2002 8:12a 0.00 Tons 0.00 Tons 0.00 Tons 0.00 Tph
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Print BATCH: BATCH REPORT DATE: TIME: BATCH NR: SET PT: TOTAL: Print ALARM: 8:14a Clock fail Print SETUP The system prints out all data and setup. Print AUDIT TRAILS: TRAIL RECORD NR. 1 DATE 11-10-2002 TIME 11:59p VARIABLE scale cap NEW 400.00 OLD 500.00 TRAIL RECORD NR. 2 DATE 11-11-2002 TIME 11:35p VARIABLE span NEW 250000 OLD 300000 TRAIL RECORD NR. 3 DATE 11-11-2002 TIME 11:54p VARIABLE div (e) NEW 0.05 OLD 0.1 See Appendix for additional printer setup information. 11-10-2002 8:12a 0 0.00 Tons 0.00 Tons
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3.7.4
3.7.5
Alarm Pending
The message ALARM displays in the right of the screen if an alarm is pending. The alarm LED also flashes. The following menu displays after pressing ALARM.
ALARM NEW XXXXXXXXXXXXXXXXX MM-DD-YYYY HH:MM RESET NEXT
NEW indicates an alarm that has not yet been acknowledged. When the operator presses RESET to clear the alarm, the alarm disappears only if the alarm condition no longer exists. ACK displays if the alarm is still pending. Next is used to scroll between the pending alarms. The string XXXXXXXXXXXX stands for one of the following alarm conditions:
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3.7.6
Reset Total
The Reset Total Menu is similar to the Main RUN Menu except Master Total has been replaced by Reset Total. Press the DOWN scroll key for access.
RESET Z RESET 00000000 Tons 000.00 Tph
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3.8
Controller Output
3.8.1 Control #1
The CONTROL #1 allows the operator to view the belt feeder controllers setpoint, process variable and controller action. Press the DOWN scroll key for access or press the UP scroll keys to return to Reset Total or Main RUN Menu. Pressing RUN does not return to Main RUN.
# 1 pv 000.0 Tph cntrl 000.0 % 111111111><111111111 ENTER ADV
Password: Operator
The ENTER key is only displayed when the variable in line 2 is enterable. ADV changes from: CONTROL OUTPUT % - Controller output can be manually changed from 0 to 100% when AUTO/MAN selection is MAN. SETPOINT Setpoint can be entered from the controller front panel when LOCAL/REMOTE selection is LOCAL. ERROR % - Indicates error in percentage between setpoint and process variable. BAR GRAPH on line 3 displays process variable and setpoint deviation. The bars resolution is 2%.
3.8.2
Control # 2
Menu is only functional if second control loop is enabled.
# 2 pv 000.0 Tph cntrl 000.0 % 111111111><111111111 ENTER ADV
Password: Operator
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3.9
Load Out
The Load System Menu is visible if the Load Out option is installed. See Load Out, Appendix, for detailed description of the Load Out option. Press the DOWN or UP scroll key for access.
BATCH # 0 STOP TOTAL 00000.0 Tons SETPT 00000.0 Tons ENTER CLEAR
BATCH # increments by one after each batch. The status can be: STOP, RUN H, RUN L, WAIT S, and STABLE ENTER edits the setpoint CLEAR zeros the batch counter The symbol S is displayed if the batch is standing by.
3.10
Calibration
MAIN MENU 1 contains the CALIBRATION menu. MENU 1 is selected by pressing MENU until MAIN MENU 1 displays. Desired calibration scrolls are selected by pressing the soft keys directly below the desired scroll.
-MAIN MENU 1 -Press MENU for more ZERO SPAN MATL CAL CAL CAL
3.10.1
EXIT returns to MAIN MENU 1 MANUAL advances to Step 2 RUN at any time returns to the RUN menu
The belt must be running during Auto Zero, since complete zeroing procedure requires at least on full revolution of the belt to be averaged.
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During Auto Zero, resolution of the total is ten times higher than normal. The number of seconds in Line 2 is calculated based on the current speed and corresponds to the time remaining for completing the test. If the belt is not running when the test is started or it is stopped during the test, a message is displayed, indicating the procedure has been aborted.
WARNING Belt stopped Calibration aborted. EXIT
EXIT returns to MAIN MENU 1. When zero is reached, the system automatically displays the following screen.
AUTO ZERO COMPLETE Error 000.00% Change zero? YES NO ADV
COMPLETE flashes ADV changes from ERROR % to ACCUMULATED WEIGHT NO returns to MAIN MENU 1 without changing the zero number YES changes the zero number and the next screen displays
ZERO # CHANGED New zero #00000 Old zero #00000 RUN MENU ADV
ADV changes from OLD ZERO to RATE to ACCUMULATED WEIGHT and to ERROR % MENU repeats Auto Zero calibration. RUN returns to the RUN menu
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3.10.2
Manual Zero
The Manual Zero procedure shows the zero constant and allows direct entry if known. Press ENTER to confirm the new number.
-MANUAL ZERO -Rate 000.0 Tph Zero #00000 ENTER EXIT ADV Password: Operator
Default: 40000 Min: 0 Max: 120000 ADV displays only if Auto Zero Tracking is enabled. The AZT function accurately tracks the zero of the scale by calculating an additional zero constant. The portion of zero due to AZT is not incorporated in the zero constant, but is shown separately. When ADV is pressed, the system scrolls between Zero and AZT:
-MANUAL ZERO -AZT # 000000 AZT % 000000 ENTER EXIT ADV
When the AZT is displayed, the ENTER key incorporates the AZT number into the Zero constant so the displayed AZT number and percentage changes to zero.
3.10.3
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Pressing EXIT or MENU returns the screen to MAIN MENU 1. Press START to initiate R-Cal span calibration. There is not totalization for three seconds until the weight signal has stabilized. Go to Section 3.10.3.1.4
4. Press START to disengage the Master Tons counter. The following screen displays:
AUTO SPAN CHAIN Apply chain, then press START START EXIT MANUAL Password: Operator
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6. Restart conveyor belt and insure chain placement is proper. 7. Press START 8. Continue to Section 3.10.3.1.4
Password: Operator
3. Press START to disengage the Master Tons counter. The following screen displays:
AUTO SPAN Weights Apply weights, then press START. START EXIT MANUAL
Password: Operator
If LOAD WTS output was selected in the I/O Definition Scroll, test weights are automatically loaded after START is pressed. Wait for test weights to be loaded before proceeding. The following message displays:
AUTO SPAN Weights Press START to load test weights. START EXIT
Micro-Tech 3105
6. Restart the conveyor belt if it is not running 7. Press START 8. Continue to Section 3.10.3.1.4
During Auto Span, the resolution of the total is ten times higher than normal. The time remaining shown in Line 2 is calculated upon the current speed and is based on the test duration. If the belt is stopped during the test, a message is displayed indicating the procedure has been suspended. No action is required from the operator; wait until the test is completed.
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Use the following steps to incorporate the Material Factor. The following screen displays:
AUTO SPAN COMPLETE Error +/-00.00 % Unfactored Calcon EXIT FACTOR REPEAT
Complete is flashing There are three keys to choose from EXIT, REPEAT, and FACTOR.
EXIT If the operator chooses EXIT, the system acknowledges the Material Factor is not used. The system does not ask for a material factor any more for this calibration method until a manual span entry is performed. By pressing EXIT, the operator tells the system that material factor is not desired, but wants to use the test results for changing the span number. Proceed to Section 3.10.3.1.6. REPEAT If the operator chooses REPEAT, proceed to Section 3.10.3.1.4. FACTOR If the operator chooses FACTOR, the following screen displays:
XXX Matl FACTOR New factor: 000.00 % Change factor? YES NO ADV
ADV advances to Old Factor and again to New Factor. NO the Material Factor is set to 1.00 YES the following screen displays
XXX Matl FACTOR Old factor: 000.00 % New factor: 000.00 % RUN MENU REPEAT
REPEAT returns the operator to Section 3.10.3.1.4 RUN returns to the RUN menu main screen MENU returns to MAIN MENU 1
REC 4186
3-19
Micro-Tech 3105
Complete is flashing ADV advances to Accumulated Weight, Cal Con, Material Factor, and back to Error %. Note: If the Material Factor is invalid (never acquired before), it is not displayed. YES if the operator selects YES, the following screen displays:
SPAN # CHANGED Old span #: 00000 New span #: 00000 RUN REPEAT ADV
RUN returns to the RUN main menu REPEAT moves back to Section 3.10.3.1.4 and calibration restarts ADV changes from Error % to Accumulated Weight, Calcon, Old Span, and Material Factor (if not invalid). NO If the operator selects NO, the following screen displays:
SPAN UNCHANGED Old span #: 00000 New span #: 00000 RUN REPEAT ADV
RUN returns to the RUN main menu REPEAT moves back to Section 3.10.3.1.4 and calibration restarts. ADV changes from Error % to Accumulated Weight, Calcon, Old Span, and Material Factor (if not invalid). Note: The Old Span and New Span are equal because no change has been made to the span.
3-20
REC 4186
Micro-Tech 3105
2. Press RUN Totalization resumes and the Belt Feeder Controller returns to the RUN menu.
REC 4186
3-21
Micro-Tech 3105
3.10.4
1. At main Menu 2, select matl cal 2. Press the DOWN arrow. The following screen displays:
MATL CALIBRATION Run belt empty, then press start. START MENU
Run the belt for at least one minute or one belt revolution before proceeding. 3. Press START The Master Weight Totalizer is disengaged. The following screen displays:
Run quantity of material over scale CONTINUE
3-22
REC 4186
Micro-Tech 3105
During the Material Calibration procedure, the resolution of total tons counted is ten times higher than normal. 5. Wait until all material has passed over the scale, press done. ABORT forces the program back to the top of the MATL CAL scroll. 6. Entering the Reference Weight At the end of the test, the system asks the operator whether the (actual) weight of material is already known.
0000.00 Tons Ref. Weight known? YES NO
NO select no if the reference (actual) weight is not known for some time and the conveying systems need to be returned to run.
The RUN screen displays MATL flashes to remind the operator that the material test is incomplete. Press MATL when the reference weight is known and the following screen displays:
0000.00 Tons Enter reference weight 00.0 Tons ENTER ABORT
Enter the actual material weight in the same weight units setup in the Feeder Controller.
Example: Convert pounds to nearest hundredth (0.01) of a ton and enter the result if the Feeder Controller is set up for tenths (0.1) of a ton increment. Material Calibration is running at 10 times normal.
REC 4186
3-23
Micro-Tech 3105
Press ENTER
ABORT if abort is selected the information acquired during the test is lost and the system returns to MAIN MENU 1. 7. Updating the Span Constant After the amount of material has been entered, the following screen displays:
MATL CAL. COMPLETE Error 000.00 % change span? YES NO ADV
Complete flashes YES: see Section 8 ADV: changes from Error % to Actual Difference of Total NO: moves to the following screen:
MATL CALIBRATION Add reference weight to totals? YES NO
Yes: the reference weight is added to the totals and the Feeder Controller returns to MAIN MENU 1 NO: returns to MAIN MENU 1 8. Acquiring the Material Factors If yes was selected at the Updating the Span Constant screen, the following screen displays confirming the new span constant was installed.
SPAN # CHANGED New span # 000000 Old span # 000000 RUN MENU FACTOR
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Micro-Tech 3105
Run: returns to the RUN main menu Menu: returns to MAIN MENU 1 Factor: Of the three simulated load calibration methods, only the ones that have been already used are shown. It is not possible to calculate a material factor if a simulated test was not run before the material test. The following screen displays:
MATL CALIBRATION Automatic correction to Material Factors R-CAL WTS CHAIN
If none of the three was performed, FACTOR is not displayed. If R-CAL, WEIGHTS, or CHAINS is pressed, the following screen displays:
XXXX MATL FACTOR New factor 000.00 % Change factor? ADV YES NO XXXX = R-CAL, WEIGHTS, or CHAINS
ADV: advances to the Old Factor and again to the New Factor NO: select NO if the acquired material factor is not desired. This selection returns to Section 8 Yes: select YES if this specific simulated method of calibration has already been used and the related material factor will be recorded. This selection advances to the next scroll. The system is able to execute accurate calibrations in the future with this simulated method. The following screen displays:
XXXX MATL FACTOR Old factor 000.00 % New factor 000.00 % RUN MENU FACTOR XXXX = R-CAL, WEIGHTS, or CHAINS
FACTOR: repeats for all simulated tests previously run. RUN OR MENU: if RUN or MENU is selected, the following screen displays:
REC 4186
3-25
Micro-Tech 3105
YES: the amount of material used for the test is added to the master, reset, and operators totals. NO: the information is lost Note: Moisture compensation is inhibited during material calibration. This is done to make the check of the totalized quantity easier. The static scale provides the weight of the material including moisture. The weight of the water is removed immediately before adding to total at the end of the procedure, so the Master, Reset, and Operators totals are still correct.
3.11
3.11.1
MAIN MENU 1 ZERO SCROLL Zero # SPAN SCROLL Span # MAIN MENU 2 DISPLAY SCROLL 1 2 3 4 5 6 9 10 11 12 Measure Units Totalization Units Length Units Rate Units Loadcell Units Language Run Display, Line 3 Damping Display Rage Damping Display Load Damping Display Speed
3-26
REC 4186
Micro-Tech 3105 MAIN MENU 2 SCALE DATA SCROLL 1 2 3 3A 3B 3C 3D 3E 3F 3G 3H 3I 3L 3M 3N 3O 4 5 6 7 8A 8B 8C 8D 8E 8F 9 10 11 Max. Scale Capacity Scale Divisions Belt Scale Code # Pivot to Load Cell Number of Weigh Idlers Pivot to 1st Idler Pivot to 2nd Idler Pivot to 3rd Idler Pivot to 4th Idler Pivot to 5th Idler Pivot to 6th Idler Pivot to Test Weight Height Pivot to Test Weight Length Pivot to Carriage Height Roll to Carriage Height Number of Load Cells Idler Spacing Conveyors Angle Degrees Load Cell Capacity LoadCell Sensitivity LoadCell #1 Resistance LoadCell #2 Resistance LoadCell #3 Resistance LoadCell #4 Resistance LoadCell #5 Resistance LoadCell #6 Resistance Speed Input Zero Dead Band Range Weights & Measures Mode
REC 4186
3-27
Micro-Tech 3105
3.11.2
Calibration Menu
CALIBRATION DATA SCROLL 1 Calibration Mode 2 3 4 5 6 7 8 9 10 R-Cal: Resistance (OHMS) R-Cal: Cal Con Chain: Weight (Lbs/Ft) Chain: Cal Con Total Test Weights (Lbs) Weight: Cal Con Calibration Interval Calibration Date R-Cal: Matl Factor: Chain: Matl Factor: Weight: Matl Factor: 11 Test Duration Belt Length Number of Revolutions Test Time 12 12A 12B 13 14 Auto Zero Tracking Auto Zero Tracking Range Auto Zero Tracking Max. Dev. Max Speed Capacity Number of Calib, Yes No % % Full Partial Manual Days
3-28
REC 4186
Micro-Tech 3105
3.11.3
Main Menu 3
DIAGNOSITCS SCROLL 1 A/D Gross A/D Net 2 2A 2B 3 Weight on Load Cell Load Cell Output Zero Load Cell Output Span Prescale Pulses/Minute 3A 3B 4 5 6 9 10 11 12 13 14 Test Duration Total Pulses Test Duration Total Length Service Password Operator Password Software Version Board Type Slot #1 Board Type Slot #2 Board Type Slot #3
REC 4186
3-29
Micro-Tech 3105
3.11.4
MAIN MENU 4
Main Menu 4
I/O DEFINE SCROLL 1 Current Output #1 Define Current Output #2 Define Current Output #3 Define Current Output #4 Define 1A Current Output #1 Range Current Output #2 Range Current Output #3 Range Current Output #4 Range 1B Current Output #1 Delay Current Output #2 Delay Current Output #3 Delay Current Output #4 Delay 1C Current Output #1 Damping Current Output #2 Damping Current Output #3 Damping Current Output #4 Damping 2 2A 2B 2A 2B 2A 2B 2A 2B 3 3A Analog Input #1 Definition Conveyor Low Position Conveyor High Position Moisture Input Calibrate Moisture Input Calibrate Remote Setpoint Low Remote Setpoint High Process Variable Low Process Variable High Analog Input #2 Definition Conveyor Low Position Degrees % % % % % % Degrees Degrees V V V V V V sec sec sec sec mA mA mA mA L L L L sec sec sec sec
3-30
REC 4186
Micro-Tech 3105 MAIN MENU 4 3B 3A 3B 3A 3B 3A 3B 4 Conveyor High Position Moisture Input Calibrate Moisture Input Calibrate Remote Setpoint Low Remote Setpoint High Process Variable Low Process Variable High Digital Input Define External Alarm #1 External Alarm #2 External Alarm #3 Print Belt Running Reset Total Reset Alarm Auto Zero Clip Detector Batch Start Batch Stop Batch Standby Local or Remote Control Manual or Automatic Control Regulation Interlock Calibration Select 1 Calibration Select 2 Calibration Select 3 Calibration Select 4 Calibration Select 5 Calibration Select 6 Calibration Select 7 % % % % % % Physical Input/Status / / / / / / / / / / / / / / / / / / / / / / Degrees V V V V V V
REC 4186
3-31
Micro-Tech 3105 MAIN MENU 4 Calibration Select 8 Calibration Select 9 Calibration Select 10 5 Digital Output Define Alarm Shutdown Ready High Load Low Load High Rate Low Rate High Speed Low Speed Print Ready Totalizer Batch Preset Batch End High Deviation Positive HHigh Deviation Positive High Deviation Negative HHigh Deviation Negative High Deviation Positive #2 HHigh Deviation Positive #2 High Deviation Negative #2 HHigh Deviation Negative #2 Local/Remote Control Load WTS Increase Control Output Decrease Control Output Increase Control Output #2 / / / / / / / Physical Output/Status / / / / / / / / / / / / / / / / / / / / /
3-32
REC 4186
Micro-Tech 3105 MAIN MENU 4 Decrease Control Output #2 Start Belt Stop Belt 6 7 8 8A 8B 9 9A 10 10A Remote Counter Division Remote Counter Pulse Width BCD Output Variable BCD Output Polarity BCD Output Parity BCD Input Variable BCD Input Polarity Clip Detector Mode Clip Detector Length / / /
REC 4186
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Micro-Tech 3105
3.11.5
1 1A 1B 2 2A 2B 3 3A 3B 4 5 5A 6 6A 7 7A 8 8A 9 9A 10 10A 11 11A 12 12A 13
Alarm Scroll
Yes % % Yes % % Yes % % % Yes units % Yes units % Yes units % Yes units % Yes units % Yes units % Yes units % Yes units % Alarm Alarm Alarm sec Shutdown Shutdown Shutdown None None None sec No sec No sec No sec No sec No sec No sec No No sec sec No sec sec No sec sec sec No
ALARMS SCROLL Rate Alarm Low Rate Set High Rate Set Load Alarm Low Load Set High Load Set Speed Alarm Low Speed Set High Speed Set Belt Slip Set High Positive Deviation Alarm High Positive Deviation Set HHigh Positive Deviation Alarm HHigh Positive Deviation Set High Negative Deviation Alarm High Negative Deviation Set HHigh Negative Deviation Alarm HHigh Negative Deviation Set High Positive Deviation Alarm High Positive Deviation Set 2 HHigh Positive Deviation Alarm HHigh Positive Deviation Set 2 High Negative Deviation Alarm High Negative Deviation Set 2 High Negative Deviation Alarm HHigh Negative Deviation Set 2 Alarm Set As #1 #2 Clock Fail Load Cell Fail
3-34
REC 4186
Micro-Tech 3105 ALARMS SCROLL #3 #4 #5 #6 #7 #8 #9 #10 #11 #12 #13 #14 #15 #16 #17 #18 #19 #20 #21 #22 #23 #29 #30 #31 #32 #33 #40 #41 #42 RAM Fail ROM Fail Speed Sensor High Load Low Load High Rate Low Rate High Speed Low Speed Warm Start Cold Start P.D. Calibrate Calibrate Time Ext. Alarm #1 Ext. Alarm #2 Ext. Alarm #3 Overflow Totalizer AZT Limit Batch Deviation BCD Error Thru 28 HW Conf. Math Error Printer Error COMM Error Allen-Bradley RIO Error Profibus-DP Error High Pos Deviation HHigh Pos Deviation High Neg Deviation Alarm Alarm Alarm Alarm Alarm Alarm Alarm Alarm Alarm Alarm Alarm Alarm Alarm Alarm Alarm Alarm Alarm Alarm Alarm Alarm Alarm Alarm Alarm Alarm Alarm Alarm Alarm Alarm Alarm Shutdown Shutdown Shutdown Shutdown Shutdown Shutdown Shutdown Shutdown Shutdown Shutdown Shutdown Shutdown Shutdown Shutdown Shutdown Shutdown Shutdown Shutdown Shutdown Shutdown Shutdown Shutdown Shutdown Shutdown Shutdown Shutdown Shutdown Shutdown Shutdown None None None None None None None None None None None None None None None None None None None None None None None None None None None None None
REC 4186
3-35
Micro-Tech 3105 ALARMS SCROLL #43 #44 #45 #46 #47 HHigh Neg Deviation High Pos Deviation #2 HHigh Pos Deviation #2 High Neg Deviation #2 Alarm Alarm Alarm Alarm Shutdown Shutdown Shutdown Shutdown Shutdown None None None None None
3.11.6
1 2 2A 2B 2C 3 4 5 6 7 8 9
LOAD OUT SCROLL Preset Weight Pre Act Correction Pre Act Value Pre Act Range Pre Act Length Start Delay Coasting Time Batch Deviation Print Batch Position Batch Number Position Batch Quant. Position Batch Total X= X= X= Y= Y= Y=
3-36
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Micro-Tech 3105
MAIN MENU 5 COMM A SCROLL 1 2 3 4 5 5A 6 7 8 9 10 11 12 12A 13 14 1 2 3 4 5 6 7 8 9A 9B 9C Baud Rate Port #1 Set Parity Port #1 Stop Bits Port #1 Word Length Port #1 Protocol Port #1 Clear to Send #1 Address Port #1 Access Prot Port #1 Baud Rate Port #2 Set Parity Port #2 Stop Bits Port #2 Word Length Port #2 Protocol Port #2 Clear to Send #2 Address Port #2 Access Prot Port #2 Handshaking End of Line Delay End of Line Form Feed Print Interval Print Time #1 Print Alarms Totals Report Format Number of Strings Contents String #1 Position String Number #1
PRINT SCROLL
REC 4186
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Micro-Tech 3105 MAIN MENU 5 9D 9E 9F 9G 9H 9I 9J 9K 9L 9M 9N 9P Contents String #2 Position String #2 Contents String #3 Position String #3 Position Oper. Total Position Reset Total Position Master Total Position Date Position Time Position Rate Position Avg.Rate Position Running
MAIN MENU 6 AUDIT TRAIL SCROLL Audit Trails LINEARIZATION SCROLL Linearization Yes LOAD LIN Factor #1 LIN Factor #2 LIN Factor #3 Lin Factor #4 LIN Factor #5 No FACTOR Yes No
3-38
REC 4186
Micro-Tech 3105 MAIN MENU 7 CONTROL SCROLL 1 1A 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Start Out Set Control Value Start Delay High Control Limit Low Control Limit Proportional Band Integral Time Derivative Time PEIC Time Setpoint Source Setpoint Unit Setpoint Delay Percent of Ingredient Process Variable Process Variable Damping 2nd PID Loop CONTROL LOOP 2 1 1A 2 3 4 5 6 7 8 9 10 11 Start Out Set Control Value Start Delay High Control Limit Low Control Limit Proportional Band Integral Time Derivative Time PEIC Time Setpoint Source Setpoint Unit Setpoint Delay
REC 4186
3-39
Micro-Tech 3105 MAIN MENU 7 12 13 14 Percent of Ingredient Process Variable Process Variable Damping
3.12
Date 1 2 3
Scale Capacity Belt Feeder Scale Code Number Belt Feeder Scale Weighbridge Dimensions A B C Pivot to Load Cell Distance Number of Weigh Idlers Pivot to Weight Idler distance (Inches) 1st 2nd 3rd D E F G Pivot to Test Weight Height Pivot to Test Weight Length Pivot to Carriage Height Carry Roll to Carriage Height 4th 5th 6th
4 5 6 7 8
Number of Load Cells Idler Spacing Conveyors Angle of Incline Load Cell Capacity Conveyor Belt Length
3-40
REC 4186
Micro-Tech 3105
3.13
3.13.1
3.13.2
SCALE DATA (Main Menu 2) CALIB DATA (Main Menu 2) I/O DEFINE (Main Menu 4)
2. 3. 4. 5. 6. 7.
ALARMS DEFINE (Main Menu 4) Go to CALIB DATA SCROLL 1 and select the Calibration Mode. With the belt conveyor running empty, perform a Zero Calibrate procedure as described in Section 3.10.1. After completing the Auto Zero procedure, perform a Span Calibration procedure as described in Section 3.10.3. Repeat the Zero and Span Calibrate procedures as necessary to insure calibration accuracy. Record the Zero and Span numbers on the Calibration Report Permanent Record, Section 3.15. Press RUN to resume normal operation.
REC 4186
3-41
Micro-Tech 3105
3.14
Material Calibration
The Micro-Tech 3105 has a machine directed procedure to assist in performing Material Calibration. See Section 3.10.4 for this procedure.
3.15
Calibration Report
DATE BY SCALE CAPACITY BELT LENGTH TEST LENGTH TEST TIME CALIBRATION CONSTANT R-Cal Static Chain CALIBRATOIN MODE ZERO AS FOUND AS LEFT SPAN AS FOUND AS LEFT
3-42
REC 4186
4.1
Frequent Checkpoints
The Micro-Tech 3105 is a solid-state device and as such requires very little maintenance. The front panel can be wiped clean with a damp cloth, and if necessary, a mild detergent (never use abrasive cleaners, especially on the display window). As a preventative measure, check to ensure all wires, plugs, and integrated circuits are tight in their connectors. Also, keep the enclosure door tightly closed to prevent dirt infiltration. More often than not, a quick visual inspection leads to the source of trouble. If a problem develops, check the following before proceeding to more specific troubleshooting procedures: Check Power 1. Check the Line Voltage Selector Switches are set to the correct line voltage 2. Check the fuse 3. Check that the power switch in ON and that power is supplied to the unit. Check Connections 1. Check that all terminations are secure. 2. Check to ensure the Display Module and Keyboard connectors are firmly seated in their connectors. 3. Check that all Jumpers are in their correct position.
4.2
Troubleshooting
This unit has built-in troubleshooting capabilities. A number of possible problems are automatically detected and screen messages are displayed. Also, refer to the Diagnostics Test Scrolls in MAIN MENU 3.
REC 4186
4-1
Micro-Tech 3105
4.3
Alarm Messages
The ALARM message is assigned to the right hand soft key when an alarm is pending. The Alarm message and its LED flash at the same time. The following screen is displayed when the right hand soft key is pressed.
ALARM NEW xxxxxxxxxxxxxxxxxxxxxx MM-DD-YYYY HH:MM RESET NEXT
NEW indicates an alarm that has not yet been acknowledged. When the operator presses RESET to clear the alarm, the alarm disappears only if the trigger for the alarm does not exist any longer. If the alarm is still pending, ACK is displayed instead of NEW. NEXT is used to scroll between the pending alarms. XXXXXXXXXXXXXXXXX represents one of the conditions listed in Section.4.3.1.
4.3.1
Alarms List
1. Clock Fail The system has detected a failure on the clock calendar circuit.
Go to the DIAGNOSTICS screen and re-enter the date and time. Check the battery
Replace the motherboard. 2. Load Cell Fail The system has detected an error on the loadcell signal.
Check the loadcell(s). 3. RAM Fail The system has detected an error on the RAM (Random Access Memory) checksum during the internal periodic test. The RAM is used to store variables and set up data.
Replace the motherboard. 4. ROM Fail
The system has detected a failure on the ROM (Read Only Memory) checksum during the internal periodic test. The ROM is used to store the program.
4-2
REC 4186
Micro-Tech 3105
5. High Load The belt load has been detected to be higher than the maximum belt loading entered in the ALARM SET UP menu. 6. Low Load The belt load has been detected to be lower than the minimum belt loading entered in the ALARM SET UP men. 7. High Rate The rate has been detected to be higher than the maximum rate entered in the ALARM SET UP menu. 8. Low Rate The rate has been detected to be lower than the minimum rate entered in the ALARM SET UP menu. 9. High Speed The speed has been detected to be higher than the maximum rate entered in the ALARM SET UP menu. 10. Low Speed The speed has been detected to be lower than the minimum speed entered in the ALARM SET UP menu. 11. Warm Start The system has detected a power loss condition, or power was removed for an undefined period. 12. Cold Start
The system has detected the loss of the set up data after power was removed. The instrument needs to be setup and calibrated.
Replace the motherboard Note: The message COLD START never appears on the screen. This is because a Cold Start forces a start up procedure to be executed, and the alarm itself is cleared after the se up is completed. However, the alarm LED and the digital output will be showing an alarm during the initial set up procedure. 13. P.D. Calibrate When the system is powered off while a calibration sequence is in progress, the scale may not be properly calibrated.
Check calibration
REC 4186
4-3
Micro-Tech 3105
14. Calib Time If a calibration check time is entered and the time expires, this alarm occurs. The purpose is to remind the operator that the calibration has not been checked for a considerably long period. Check Calibration 15. Ext. Alarm 1
Digital inputs can be programmed to detect external alarm conditions such as emergency switches, max level switches or other. This alarm is associated to the external alarm #1. Check External alarm #1. 16. Ext. Alarm 2
This message indicates the output pulse generator for the remote mechanical totalizer has reached an overflow condition. The rate may be too high or the pulse divider has been set to small.
Check the rate. Check and eventually increase the pulse divider.
This message is also displayed if the Master Total rolls over. 19. AZT Limit The Auto Zero Tracking function has reached the maximum limit of tare that is automatically cleared. The scale may be dirty or misaligned.
This alarm is only visible if the optional Load Out board is installed. It is generated when a batch is run and the error detected at the end of the batch is higher than specified.
Adjust the preset value. 21. BCD Error This message is only displayed if the optional BCD output board is installed. If the variable to be converted in the BCD format has more than 4 digits, the alarm is generated.
4-4
REC 4186
Micro-Tech 3105
22. Through 28. HW Conf. Changed When a new board is installed or an old board removed, this message displays. 29. Math Error A divide by zero or overflow error is encountered during internal calculations. This message indicates some abnormal dimensional parameter is entered in setup. Check setup data. 30. Printer Error
This message is displayed if the system has data to print and the printer is disconnected or the paper feed is empty. 31. Communication Error Indicates a time out or handshake error is detected during a data transfer on the COMM line.
Check the COMM line setup data. 32. Allen-Bradley Remote I/O COMM Error
This message is displayed if communication is interrupted. The green LED on the A_B R I/O board will be flashing. The alarm does not come on if communication has never started. 33. Profibus-DP COMM Error This messages in only displayed if the optional Profibus board is installed. The following two conditions activate the alarm.
The Siemens SPC3 Controller installed on the Profibus interface board does not recognize any successful data transfer within the watchdog timer interval. The received data contains errors (value overlaps limits, register number does not exist, group number does not exist). Not assigned
34 Through 39
40. High Positive Deviation Deviation has been detected to be higher than the maximum deviation entered in the Alarm Setup Menu. 41. HHigh Positive Deviation Same as above 42. High Negative Deviation Same as above 43. HHigh Negative Deviation Same as above
REC 4186
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Micro-Tech 3105
44. High Positive Deviation 2 Same as above 45. HHigh Positive Deviation 2 Same as above 46. High Negative Deviation 2 Same as above 47. HHigh Negative Deviation Same as above
4.4
4.4.1
2. When this screen displays, all field entry data has been replaced by the factory default constants. Proceed to Section 2.5and follow the Initial Setup procedures. Note: If the software corruption was catastrophic and the memory will not erase do the following: Press and hold in the LEFT ARROW and the CLEAR key. While holding in both keys, cycle line power. In the event the MEMORY ERASED screen does not appear, consult the factory.
4-6
REC 4186
Micro-Tech 3105
4.4.2
RETURN returns to the DIAGNOSTIC SCROLL 15 YES, the following screen displays:
Install Factory Defaults YES RETURN
RETURN returns to the DIAGNOSTIC SCROLL 15 YES, clears all field entry data, and installs the factory default constants. The following screen displays:
-- MEMORY ERASED -Choose the language key to continue to ESP USA
4. Select a language and proceed to Section 2.7and follow the Initial Setup procedures.
4.5
Password: Service
REC 4186
4-7
Micro-Tech 3105
The message Test PASSED is displayed if the test runs correctly. If something wrong is detected, the message Test FAILED is displayed and the soft key CONTINUE is shown. Press CONTINUE and move to the next test. If the internal test has failed, call Thermo Electron Customer Service.
4.6
4.7
4-8
REC 4186
Micro-Tech 3105
4.7.1
No Password Installed
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. If there is no password installed, select MAIN MENU 3 Press DIAG soft key and scroll down to the SRVICE PASSWORD screen. Type in a password (example: 123) and press ENTER Re-enter the password and press ENTER Select MAIN MENU 3 Select PROT scroll, press PROT Press NONE Enter the password 7832500 and press ENTER. The protection level should be RAMSEY. Press TOTAL; scroll up or down if needed to reach the MASTER TOTAL screen. Press RESET and select YES to Reset Master Total? Select MAIN MENU 3. Press DIAG and scroll to SERVICE PASSWORD. Press ENTER twice, erasing the password installed in Step 3. Press RUN to return to normal operation. Select MAIN MENU 3 Select PROT scroll, press PROT Press NONE Enter the password 7832500 and press ENTER. The protection level should be RAMSEY. Press TOTAL; scroll up or down if needed to reach the MASTER TOTAL screen. Press RESET and select YES to Reset Master Total? Select MAIN MENU 3 Press PROT and choose the password level desired.
4.7.2
Active Password
1. 2. 3. 4. 5. 6. 7. 8.
4.8
REC 4186
4-9
Micro-Tech 3105
8. Press ENTER twice. The display should respond with NEW PASSWORD ACQUIRED. 9. Scroll down to OPERATOR PASSWORD. Press ENTER twice. The display should respond with NEW PASSWORD ACQUIRED. 10. Select MAIN MENU 3. The PROT soft key should not appear, indicating all passwords have been erased. If PROT does appear, repeat Steps 1 through 9. 11. See Section for entering new passwords.
4.9
WARNING
DANGER OF EXPLOSION INCORRECTLY REPLACED. IF BATTERY IS
Replace only with same or equivalent type recommended by Thermo Electron. Dispose of used battery according to manufactures instruction on battery or return to Thermo Electron. (Refer to Section 4.10.) 1. Record all configuration, setup, and calibration data before removing battery. All information is lost when the battery is removed. 2. Turn the Micro-Tech power off at the mains. 3. Remove the battery from its compression socket. 4. Observe the polarity markings on the battery socket base before inserting the new battery. The lithium battery is .3V, 1.2 AH, 2/3 A, Thermo Electron part number 037188. 5. Insert battery 6. Restore power to the Micro-Tech. 7. Cold start the Micro-Tech. See Section 4.4 for cold start procedures. 8. Re-enter all data recorded in Step 1.
4.10
4-10
REC 4186
Micro-Tech 3105
4.11
Cleaning Instructions
The Micro-Tech 3105 is a solid-state device requiring very little maintenance. The front panel can be wiped clean with a damp cloth, and if necessary, a mild detergent (never use abrasive cleaners, especially on the display window). As a preventative measure, check all wires, plugs, and integrated circuits are tight in their connectors. Keep the enclosure door tightly closed to prevent dirt infiltration.
REC 4186
4-11
Micro-Tech 3105
4-12
REC 4186
5.1
Order Information
For faster service when ordering parts, fax or telephone Products Parts Department. Your regional field service representative will also be happy to assist you with parts orders, but his normal scheduling time may delay shipment of your parts order. The recommended procedure for order parts is as follows: 1. Determine the broken or faulty part(s). 2. Locate the part(s) in the parts list given. 3. Find the part number(s) for the item(s) needed and determine the quantity you require. 4. Fax or telephone: Thermo Electron Customer Service Department 501 90th Ave. NW Minneapolis, MN 55433 Customers A through M Customers N through Z Repair and Returns Fax: (763) 783-2775 (763) 783-2773 (763) 783-2774 (763) 783-2525
Normal Customer Service hours are 8:00 a.m. to 4:30 p.m., Central time. 5. With your order, list the following information:
Machine model and serial number Purchase order number Date required Method of shipment preferred List of parts, including part number, description and quantity
REC 4186
5-1
(This RMA Number Must Be Marked On All Paperwork And On Outside Of Package) Reqd. By: Date: Return, Freight Prepaid To: Customer Thermo Electron Corporation Contact: 501 90th Avenue N.W. ( ) Minneapolis, MN 55433 Phone:
Area Code
Minimum Charge
Informed Customer of Service Requested: Repair & Return Return for Credit Warranty Repair or Replacement Original P.O. # Return Warranty/Exchange Unit Other: Disposition/Comments: (Thermo Electron Internal Use Only) Inspection Charge Per Item P.O. No.: E ti Original t P.O. or Thermo Order N Serial No: Original O d /J b Shipped on Thermo Order No.:
Micro-Tech 3105
5.1.1
EQUIPMENT
Parts List
PART NUMBER 073285 073279 073283 073281 073243 073289 001366 002443 073300 037188 068137 073280
REC 4186
5-3
REC 4186
A-1
A.1.
Menu Displays
Optional menu scrolls are only available if the option has been installed. Pressing menu activates the following screens:
-- MAIN MENU 1 -Press MENU for more ZERO SPAN MATL CAL CAL CAL
-- MAIN MENU 2 -Press MENU for more SCALE CALIB DISPLAY DATA DATA
-- MAIN MENU 4 -Press MENU for more I/O ALAMS LOAD DEF DEFIN. OUT
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A.2.
A.3.
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A.3.1.
EXIT: returns to Main Menu 1 MANUAL: advances to Step 2 RUN: at any time returns to the Run menu The belt must be running during Auto Zero, since complete zeroing procedure requires at least on full revolution of the belt to be averaged. 2. Press START The following screen displays:
AUTO ZEROING Time remaining 0000 Rate: 000.0 Tph Tot 000000 Tons
During Auto Zero, resolution of the total is ten times higher than normal. The number of seconds in Line 2 is calculated based on the current speed and corresponds to the time remaining for completing the test. If the belt is started or stopped during the test, a message is displayed, indicating the procedure has been aborted.
WARNING Belt stopped Calibration aborted. EXIT
EXIT returns to MAIN MENU 1. When zero is reached, the system automatically displays the following screen.
AUTO ZERO COMPLETE Error 000.00% Change zero? YES NO ADV
COMPLETE flashes ADV changes from ERROR % to ACCUMULATED WEIGHT NO returns to MAIN MENU 1 without changing the zero number YES changes the zero number and the next screen displays gHint: The percentage of error is related to full-scale capacity.
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ZERO # CHANGED New zero #00000 Old zero #00000 RUN MENU ADV
ADV changes from OLD ZERO to RATE to ACCUMULATED WEIGHT and to ERROR % MENU repeats Auto Zero calibration. RUN returns to the RUN menu
A.3.2.
Manual Zero
The Manual Zero procedure shows the zero constant and allows direct entry if known. Press ENTER to confirm the new number.
-MANUAL ZERO -Rate 000.0 Tph Zero #00000 ENTER EXIT ADV Password: Operator
Default: 40000 Min: 0 Max: 120000 ADV displays only if Auto Zero Tracking is enabled. The ZST function accurately tracks the zero of the scale by calculating an additional zero constant. The portion of zero due to AZT is not incorporated in the zero constant, but is shown separately. When ADV is pressed, the system scrolls between Zero and AZT:
-MANUAL ZERO -AZT # 000000 AZT % 000000 ENTER EXIT ADV
When the AZT is displayed, the ENTER key incorporates the AZT number into the Zero constant so the displayed AZT number and percentage changes to zero.
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A.3.3.
A.3.3.1
Starting an R-Cal Calibration Use the following steps to begin an R-Cal Calibration: 1. Press SPAN CAL The following screen displays
AUTO SPAN R CAL Run belt empty, then press START START EXIT MANUAL
Pressing EXIT or MENU returns the screen to MAIN MENU 1. Press START to initiate R-Cal span calibration. There is not totalization for three seconds until the weight signal has stabilized. Go to Section 3.10.3.1.4 Starting a Chain Calibration Use the following steps to begin a Chain Calibration: 1. Stop the conveyor belt 2. Apply chains on conveyor belt 3. Press SPAN CAL The following screen displays:
AUTO SPAN CHAIN Press START to begin chain calibration. START EXIT MANUAL
A.3.3.2
Password: Operator
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4. Press START to disengage the Master Tons counter. The following screen displays:
AUTO SPAN CHAIN Apply chain, then press START START EXIT MANUAL
Password: Operator
Pressing EXIT or MENU returns the screen to MAIN MENU 1. 5. Press START The following screen displays:
AUTO SPAN CHAIN Run belt, then press START START EXIT
6. Restart conveyor belt and ensure chain placement is proper. 7. Press START 8. Continue to Section 3.10.3.1.4 A.3.3.3 Starting a Test Weights Calibration Use the following steps to begin a Test Weights Calibration: 1. Stop the conveyor belt if necessary to apply test weights. 2. Press SPAN CAL The following screen displays:
AUTO SPAN Weights Press START to begin weight calibration. START EXIT MANUAL
Password: Operator
3. Press START to disengage the Master Tons counter. The following screen displays:
AUTO SPAN Weights Apply weights, then press START. START EXIT MANUAL Password: Operator
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If LOAD WTS output was selected in the I/O Definition Scroll, test weights are automatically loaded after START is pressed. Wait for test weights to be loaded before proceeding. The following message displays:
AUTO SPAN Weights Press START to load test weights. START EXIT
EXIT returns the screen to MAIN MENU 1 4. Apply test weights 5. Press START The following screen displays:
AUTO SPAN Weights Run belt, then press START. START EXIT
Password: Operator
Restart the conveyor belt if it is not running 6. Press START 7. Continue to Section 3.10.3.1.4 A.3.3.4 Executing the Span Calibration Whichever method has been used to start automatic span calibration, after start is pressed, the following screen displays:
AUTO SPANNING Time remaining 0000 Rate 0000.0 Tph Total 000000 Tons
During Auto Span, the resolution of the total is ten times higher than normal. The time remaining shown in Line 2 is calculated upon the current speed and is based on the test duration. If the belt is stopped during the test, a message is displayed indicating the procedure has been suspended. No action is required from the operator; wait until the test is completed.
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A.3.3.5
Material Factor Use this step only if a material calibration is done before and the current simulated load method has no material factor installed. Note: This section does not apply if one of the following exists: 1. A calibration with material has not been run before, 2. A manual span entry is done, or 3. This is not the first time the current simulated method is used. Proceed to Section 3.10.3.1.6. It is very important to understand when this procedure is executed; the system does not alter the span. The span is assumed correct because it was obtained from a test with material. The system acquires the Material Factor for the current calibration method instead. This means the Feeder Controller knows in the future how to use this method for correctly changing the systems span. Use the following steps to incorporate the Material Factor. The following screen displays:
AUTO SPAN COMPLETE Error +/-00.00 % Unfactored Calcon EXIT FACTOR REPEAT
1. Complete is flashing 2. There are three keys to choose from EXIT, REPEAT, and FACTOR. EXIT If the operator chooses EXIT, the system acknowledges the Material Factor is not used. The system does not ask for a material factor any more for this calibration method until a manual span entry is performed. By pressing EXIT, the operator tells the system that material factor is not desire, but wants to use the test results for changing the span number. Proceed to Section 3.10.3.1.6. REPEAT If the operator chooses REPEAT, proceed to Section 3.10.3.1.4. FACTOR If the operator chooses FACTOR, the following screen displays:
XXX Matl FACTOR New factor: 000.00 % Change factor? YES NO ADV XXX = R-Cal, WTS, or CHAINS
ADV advances to Old Factor and again to New Factor. NO the Material Factor is set to 1.00 YES the following screen displays
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XXX Matl FACTOR Old factor: 000.00 % New factor: 000.00 % RUN MENU REPEAT
A.3.3.6
REPEAT returns the operator to Section 3.10.3.1.4 RUN returns to the RUN menu main screen MENU returns to MAIN MENU 1 Recording New Span The Feeder Controller calculates the new span based on the result of the test performed with the simulated method.
AUTO SPAN COMPLETE Error +/-00.00 % Change span? YES NO ADV
Complete is flashing ADV advances to Accumulated Weight, Cal Con, Material Factor, and back to Error %. YES if the operator selects YES, the following screen displays: Note: If the Material Factor is invalid (never acquired before), it is not displayed.
SPAN # CHANGED Old span #: 00000 New span #: 00000 RUN REPEAT ADV
RUN returns to the RUN main menu REPEAT moves back to Section 3.10.3.1.4 and calibration restarts ADV changes from Error % to Accumulated Weight, Calcon, Old Span, and Material Factor (if not invalid). NO If the operator selects NO, the following screen displays:
SPAN UNCHANGED Old span #: 00000 New span #: 00000 RUN REPEAT ADV
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RUN returns to the RUN main menu REPEAT moves back to Section 3.10.3.1.4 and calibration restarts. ADV changes from Error % to Accumulated Weight, Calcon, Old Span, and Material Factor (if not invalid). Note: The Old Span and New Span are equal because no change has been made to the span. A.3.3.7 Ending an Auto Span Procedure with Chains or Test Weights After Auto Span has been run using chains or test weights follow these steps: 1. Press RUN The following screen displays
Remove chains (or weights) before returning to normal operation!! RUN Menu
2. Press RUN Totalization resumes and the Belt Feeder Controller returns to the RUN menu. Ending an Auto Span Procedure with R-Cal After Auto Span has been running using R-Cal, follow these steps: 1. Press RUN 2. The R-Cal relay is de-energized and the display is locked for three seconds. 3. Press RUN Totalization resumes and the Integrator returns to the RUN menu,
A.3.3.8
A.3.4.
Manual Span
If the span constant is known, the Manual Span procedure allows the operator to make a direct change of span. Use the following steps to enter the span constant. 1. Press MENU until you are returned to MAIN MENU 2. The following screen displays:
-MAIN MENU 2 -Press MENU for more ZERO SPAN MATL CAL CAL CAL
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A.3.5.
1. At MAIN MENU 2, select MATL CAL 2. Press the DOWN arrow. The following screen displays:
MATL CALIBRATION Run belt empty, then press start. START MENU
Run the belt for at least one minute or one belt revolution before proceeding.
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3. Press START The Master Weight Totalizer is disengaged. The following screen displays:
Run quantity of material over scale CONTINUE
During the Material Calibration procedure, the resolution of total tons counted is ten times higher than normal. 5. Wait until all material has passed over the scale, press DONE. ABORT forces the program back to the top of the MATL CAL scroll.
A.3.6.
NO select no if the reference (actual) weight is not known for some time and the conveying systems need to be returned to run. The RUN screen displays MATL flashes to remind the operator that the material test is incomplete. Press MATL when the reference weight is known and the following screen displays:
0000.00 Tons Enter reference weight 00.0 Tons ENTER ABORT
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1. Enter the actual material weight in the same weight units, as the Feeder Controller is setup to use. Example: Convert pounds to nearest hundredth (0.01) of a ton and enter the result if the Feeder Controller is set up for tenths (0.1) of a ton increment. Material Calibration is running at 10 times normal. 2. Press ENTER
ABORT if abort is selected the information acquired during the test is lost and the system returns to MAIN MENU 1.
A.3.7.
Complete flashes YES moves to the following screen ADV changes from Error % to Actual Difference of Total NO moves to the following screen:
MATL CALIBRATION Add reference weight to totals? YES NO
YES the reference weight is added to the totals and the Feeder Controller returns to MAIN MENU 1 NO returns to MAIN MENU 1
A.3.8.
At this point, the scale is calibrated to the actual material test. RUN returns to the RUN main menu MENU returns to MAIN MENU 1 FACTOR Of the three simulated load calibration methods, only the ones that have been already used are shown. It is not possible to calculate a material factor if a simulated test was not run before the material test. The following screen displays:
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If none of the three was performed, FACTOR is not displayed. If R-CAL, WEIGHTS, or CHAINS is pressed, the following screen displays:
XXXX MATL FACTOR New factor 000.00 % Change factor? ADV YES NO XXXX = R-CAL, WEIGHTS, or CHAINS
Adv ADVANCES TO THE OLD FACTOR AND AGAIN TO THE NEW FACTOR No SELECT no IF THE ACQUIRED MATERIAL FACTOR IS NOT DESIRED. Yes select YES if this specific simulated method of calibration has already been used and the related material factor will be recorded. This selection advances to the next scroll. The system is able to execute accurate calibrations in the future with this simulated method. The following screen displays:
XXXX MATL FACTOR Old factor 000.00 % New factor 000.00 % RUN MENU FACTOR XXXX = R-CAL, WEIGHTS, or CHAINS
FACTOR repeats for all simulated tests previously run. RUN or MENU if RUN or MENU is selected, the following screen displays:
MATL CALIBRATION Add reference weight to totals YES NO
YES the amount of material used for the test is added to the master, reset, and operators totals. NO the information is lost Note: Moisture compensation is inhibited during material calibration. This is done to make the check of the totalized quantity easier. The static scale provides the weight of the material including moisture. The weight of the water is removed immediately before adding to total at the end of the procedure, so the Master, Reset, and Operators totals are still correct.
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A.4.
A.5.
Display
The Display scroll sets up the parameters for how the information at the Feeder Controller interface will display.
A.5.1.
Measure Units
Measure units are displayed in English, Metric, or Mixed. Make your selection at this menu.
-- DISPLAY SCROLL 1 Measure units >ENGLISH< CHOICE ENTER --
Default: Choices:
ENGLISH ENGLISH, METRIC, MIXED English - all units in English Metric - all units in Metric Mixed units may be a combination of English and Metric.
Note: If the Measure units are changed from English to Metric or Metric to English after the scale is calibrated, the span number changes but the calibration remains the same.
A.5.2.
Totalization Units
-- DISPLAY SCROLL 2 Totalization units >TONS< CHOICE ENTER --
English = Tons Tons, Ltons, Pounds Metric = tonnes tonnes, kg Mixed = Tons Tons, Ltons, kg, Pounds, Tonnes
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A.5.3.
Length Units
-- DISPLAY SCROLL 3 -Length units >Pounds< CHOICE ENTER
Default: Choices:
A.5.4.
Rate Units
The rate is displayed according to the units selected here.
-- DISPLAY SCROLL 4 -Rate units >TPH< CHOICE ENTER Password: Service
ENTER accepts the default units Default: Choices: Default: Choices: Default: Choices: English = Tph Tph, LTph, Lb/h, Percent %, Lb/mn, T/mn LT/mn Metric = kg/h t/h, kg/h, kg/mn, t/mn, Percent % Mixed = Tph Tph, LTph, Lb/h, Percent %, t/h, kg/h, kg/mn, t/mn, lb/mn, T/mn, LT/mn
A.5.5.
Default: Choices:
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A.5.6.
Defining Language
The Micro-Tech 3105 is a dual language instrument. Use the following Display Scroll to select a language.
-- DISPLAY SCROLL 6 -Language >USA< CHOICE ENTER
Default: Choices:
A.5.7.
Default: Choices:
Default: Choices:
A.5.8.
Default: Choices:
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A.5.9.
Damping Display Load Display Scroll 11 is only visible if the Run display line 3 is set to Load (refer to Section A.5.8).
-- DISPLAY SCROLL 11 -Damping Display LOAD Damping = 2 sec ENTER
Damping Display Speed Display Scroll 12 is only visible if the Run display line 3 is set to speed (refer to Section A.5.8).
-- DISPLAY SCROLL 12 -Damping Displ SPEED Damping = 2 sec ENTER
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A.6.
Scale Data
Refer to Section 2.6 and Appendix B Weighbridge Physical Parameters.
A.6.1.
Scale Capacity
Scale capacity is the maximum rate at which the scale is allowed to work. This entry also defines the default number of decimal places used for displaying rate. Use the NUMERIC keys for entering the number. Confirm with ENTER; scroll DOWN.
-- SC DATA SCROLL 1 -Max. scale capacity 500.0 TPH CHOICE ENTER
500.0 1 200000
A.6.2.
Scale Divisions
When the SCALE CAPACITY is entered, the number of decimal places is also defined. For example, the user enters 500.0; this sets the SCALE DIVISIONS parameter to 0.1. At the SCALE DIVISIONS menu, the displayed SCALE DIVISION corresponds to the just entered SCALE CAPACITY. The user can change the pre-set SCALE DIVISIONS by pressing CHOICES.
-- SC DATA SCROLL 2 -Scale divisions >0.1< CHOICE ENTER
Default: Choices:
0.1 0.1, 0.2, 0.5, 1, 2, 5, 10, 20, 50, 0.01, 0.02, 0.05, 0.001, 0.002, 0.005
A.6.3.
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1 0 500
Press ENTER to accept the displayed selection (refer Appendix B, Thermo Electron Weighbridge Physical Parameters.). Note: If the default is used, the scrolls from 3A to 3J are not displayed. Press DETAIL if you want to force the following scrolls to be displayed even if the default was chosen. 3A 30 Enter 0 if you want to define the weighbridge not using the database. This should only be done for special weighbridges that are not part of the standard set of Thermo Electron scales. Entering 0 forces the following menus to be displayed:
A.6.4.
1000 mm 0 mm 3800 mm
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Number of Weigh Idlers The number of weigh idlers affixed to the scale weighbridge. Use the numeric keys to enter the number of weigh idlers and documented in Section 2.6.1.3.2, press ENTER.
-- SC DATA SCROLL 3B -# of weigh idlers ENTER
1 1 6
Pivot to First Weigh Idler Distance (Parameter LB1) Measure the distance between the pivot centerline and first weigh idler centerline. Use the numeric keys to enter the distance 0.032 inch (1/32) (1mm). (Refer to Section 2.6.1.3.3.) For weighbridges without a pivot, enter zero (0). Press ENTER
-- SC DATA SCROLL 3C -Pivot to first idler distance In ENTER
800 mm 0 mm 2500 mm
If the number of weigh idlers entered in Scroll 3B is more than one, the following screens are displayed. Measure the distance between the pivot centerline and the first weigh idler grease fitting. Enter the distance (within 0.032 inch or 1 mm). For weighbridges, which do not have a pivot, enter zero. Only if # of weigh idlers 2
-- SC DATA SCROLL 3D -Pivot to 2nd idler distance 000.00 In ENTER Password: Service
800 mm 0 mm 2500 mm
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English/Mixed Default: 0.00 in Min: 0.00 in Max: 100.00 in Only if # of weigh idlers 4
800 mm 0 mm 2500 mm
Password: Service
English/Mixed Default: 0.00 in Min: 0.00 in Max: 100.00 in Only if # of weigh idlers 5
800 mm 0 mm 2500 mm
Password: Service
English/Mixed Default: 0.00 in Min: 0.00 in Max: 100.00 in Only if # of weigh idlers = 6
800 mm 0 mm 2500 mm
Password: Service
800 mm 0 mm 2500 mm
Note: All measurements must be within 0.032 (1/32) in. (1 mm) and recorded in Section 2.6.1.3. Enter each distance with the numeric keys and press ENTER.
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Pivot to Test-Weight Height (Parameter LE) For weighbridges, which do not have a pivot, enter zero. 3I, L, M, and N only apply if test weights are provided.
-- SC DATA SCROLL 3I -Pivot to test-weight height 000.00 In ENTER +/Password: Service
Pivot to Test-Weight Length (Parameter LC) For weighbridges, which do not have a pivot, enter zero.
-- SC DATA SCROLL 3L -Pivot to test-weight length 000.00 In ENTER Password: Service
0 mm 0 mm 500.0 mm
Pivot to Carriage Height (Parameter LF) For weighbridges, which do not have a pivot, enter zero.
-- SC DATA SCROLL 3M -Pivot to carriage height 000.00 In ENTER Password: Service
0 mm 0 mm 250 mm
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Carry Roll to Carriage Height (Parameter LG) For weighbridges, which do not have a pivot, enter zero.
-- SC DATA SCROLL 3N -Roll to carriage height 000.00 In ENTER +/Password: Service
0 mm 0 mm 250 mm
1 1 6
A.6.5.
A.6.5.1
1000 mm 50 mm 2500 mm
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A.6.5.2
Angle of Inclination Enter the angle of inclination. If an inclination meter is connected to the scale, after this preliminary set up has been completed, enable the automatic angle detection in I/O DEFINITION (MENU 4) and calibrate the angle meter.
-- SC DATA SCROLL 5 -Conveyors angle 0 0 Degrees ENTER +/Password: Service
A.6.6.
A.6.6.1
English/Mixed Default: 250.0 Lbs Min: 1 Lbs Max: 15000 Lbs A.6.6.2 Load Cell Sensitivity
100 kg 1 kg 5000 kg
The sensitivity was entered when the belt scale code was entered. If other (0) was selected, enter the loadcell sensitivity in mV/V as marked on the label of the loadcell. Thermo Electron loadcells are normally 2.000 or 3.000 mV/V.
-- SC DATA SCROLL 7 -Load cell sens. 3.00 mV/V ENTER Password: Service
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A.6.6.3
Load Cell Resistance Load cell resistance is entered on this screen. The resistance for the loadcell has been recorded on the System Data Sheet in the front of your belt scale manual. (It is also stamped on the loadcell cable.) Enter the ohms for the loadcell. The number of scrolls depends on the number of loadcells specified in scroll 3O.
-- SC DATA SCROLL 8X -Load cell #N res 3.00 Ohms ENTER Password: Service
A.6.7.
Default: Choices:
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A.6.8.
0% 0% 5%
A.6.9. Weights and Measures Mode (Only if Audit Trail Option is Installed)
This scroll details certain parameters to conform to the approval agency.
-- SC DATA SCROLL 11 -W&M mode >NONE< CHOICE ENTER
Default: Choices:
A.7.
Calibration Data The CAL DATA scroll allows the operator to enter or set parameters, which relate to the calibration of the scale.
A.7.1.
Default: Choice:
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A.7.1.1
Defining the R-Cal Parameters This section only applies of R-Cal mode was selected as the preferred method. Enter the resistance in Ohms of the R-cal resistor installed in your Feeder Controller. Default value installed is 165000 Ohms. See the Data Sheet in front of this manual for exact resistance.
-- CAL DATA SCROLL 2 -R-CAL select Res 165000 ohms ENTER Password: Service
The system calculates the CALCON (Calibration Constant) based on the mechanical and electrical parameters entered in SCALE DATA. This menu is for reference only.
-- CAL DATA SCROLL 3 -R-CAL constant 00.00 MENU RUN
A.7.1.2
Defining the Chains Parameters This section only applies if CHAINS mode was selected as the preferred method. Enter the weight per foot or meter of the chains used for calibration.
-- CAL DATA SCROLL 4 Chain select. Weight 00.000 Lb/Ft ENTER Password: Service
English/Mixed Default: 0.000 Lbs/Ft Min: 0.000 Lbs/Ft Max: 1000.000 Lbs/FT
The system calculates the CALCON based on the mechanical and electrical parameters entered in SCALE DATA. This menu is for reference only.
-- CAL DATA SCROLL 5 -CHAIN CAL constant 00.00 MENU RUN
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A.7.1.3
Detailing the Test Weight Parameters This section only applies if TEST WEIGHTS mode was selected as the preferred method. Enter the weight of the test weights used for calibration.
-- CAL DATA SCROLL 6 -Total test weight on scale 20.000 LBS ENTER Password: Service
English/Mixed Default: 0.000 Lbs/Ft Min: 0.000 Lbs/Ft Max: Load cell size x no of loadcells
The system calculates the CALCON (Calibration Constant) based on the mechanical and electrical parameters entered in the SCALE DATA. This menu is for reference only.
-- CAL DATA SCROLL 7 -WEIGHT CAL constant 00.00 MENU RUN
A.7.2.
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The scroll displays the date of the last calibration and the expected date of the next one, based on the entry in the previous screen.
-- CAL DATA SCROLL 9-Calibration date Last: MM-DD-YYYY ENTER: MM-DD-YYYY
A.7.3.
0% -99.99% +99.99%
NEXT scrolls between material factors of R-Cal, Weights, and Chains INVALID displays if they have not been measured
A.7.4.
A.7.4.1
ACQuire is the recommended selection. Acquiring the Test Duration When selecting FULL, use a 100-foot tape to measure the belt length to the nearest 0.1-foot. Reference a fixed point (an idler) on the conveyor when counting belt revolutions. See Section 2.5.1 for the recorded conveyor belt length. The PARTIAL (belt length measurement) selection enables the operator to acquire test duration without the entire belt length measurement.
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Note: This option should only be used when belt length exceeds 1000 feet.
ACQUIRE TEST DUR Choose belt length measurement method. FULL PARTIAL
FULL is the recommended selection. A.7.4.2 Full Test Duration Acquisition If FULL is pressed, the operator is asked to enter the length of one belt revolution. Enter the length recorded in Section 2.5.1. Measure belt length to the nearest 0.1 feet.
Enter length of one belt revolution. Length 1000.0 Ft. ENTER ABORT Password: Service
After the length of the belt has been entered, the system automatically moves to the following screen, which prompts the operator to press START when the mark passes the reference point. Pressing ABORT returns the screen to CAL DATA SCROLL 11. Note: The belt must be running at the maximum speed before executing this function. If not, the prescaler will be improperly calculated.
Start belt. Pres START when 1st mark passes reference. START ABORT
Note: If a clip detector is installed and clip detector mode is set to AUTO in I/O DEFINITION SCROLL skip to Section A.7.5.
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When START is pressed, the system automatically moves to the next instructional screen. The operator presses COUNT each time the mark passes the reference point until minimum test load conditions are met (refer to the belt scale installation manual for minimum test level requirements). When the last revolution passes the mark, the operator must press COUNT followed by pressing DONE. Pressing ABORT returns the screen to CAL DATA SCROLL 11.
Press COUNT each Time a mark passes. 00000 secs 000 revs COUNT ABORT DONE
ABORT returns the screen to CAL DATA SCROLL 11. When test duration is finished, the new values for length of belt and time are displayed. Press CONTINUE
TEST DURATION Length = 0000.0 Ft Time = 000 SEC CONTINUE
A.7.5.
When the mark passes, the system automatically moves to the next instructional screen. The system counts each time a mark passes the reference point until the operator presses the DONE key.
Press DONE when ready. 0000 secs 000 revs ABORT DONE
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A.7.6.
After the length of the belt has been entered, the system automatically moves to the following screen, which prompts the operator to press START when the mark passes the reference point. NOTE: The belt must be running at the maximum speed before executing this function. If not, the prescaler is improperly calculated. Pressing ABORT returns the screen to CAL DATA SCROLL 11. Start belt. Press START when 1st mark passes reference. START ABORT When START is pressed, the system automatically moves to the next instructional screen. The operator presses COUNT each time a mark passes the reference point until both marks have passed. Then press DONE. Pressing ABORT returns the screen to CAL DATA SCROLL 11. Press COUNT each time a mark passes. 00000 secs 000 revs COUNT ABORT DONE
Note: The COUNT key is not displayed if the clip detector option is in Auto mode.
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When test duration is finished, the new values for length of belt and time are displayed. Press CONTINUES. TEST DURATION Length = 0000.0 Ft Time = 000 sec CONTINUE
A.7.7.
Password: Service
The operator is prompted to enter the length of one belt revolution. Pressing ABORT returns the screen to CAL DATA SCROLL 11. ENTER length of one belt revolution. Length 000.00 Ft ENTER ABORT
Password: Operator
The number of belt revolutions to be timed is than entered. Pressing ABORT returns the screen to CAL DATA SCROLL 11.
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ENTER the number of belt revolutions to be timed 000 revs ENTER ABORT Default: Min: Max: 1 1 100
The next entry is the time per revolution. Pressing ABORT returns the screen to CAL DATA SCROLL 11. ENTER the time for revolutions to pass reference 000 sec ENTER ABORT Default: Min: Max: 30 sec 1 sec 16200 sec
When ENTER is pressed, the system times the belt travel according to the above entered parameters. Pressing ABORT returns the screen to CAL DATA SCROLL 11. Timing belt travel 000 sec ABORT When test duration test is finished, the new values for length of belt and time are displayed. Press CONTINUE
A.7.8.
Password: Operator
Default: Selections:
NO YES, NO
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The following scrolls are only visible if Auto Zero Tracking is enabled. Define the range of action of the AZT with reference to the scale capacity (rate). A flow rate greater than the range setting deactivates AZT.
--CAL DATA SCROLL 12AAuto zero tracking Range 4.0 % ENTER
Password: Operator
4% 0% 10 %
Define the maximum amount of zero error (with reference to the scale capacity) that AZT can automatically compensate.
--CAL DATA SCROLL 12BAuto zero tracking Max Dev 4.0 % ENTER
Password: Service
4% 0% 10 %
A.7.9.
Password: Service
English/Mixed Default: 200.0 Fpm Min: 1.0 Fpm Max: 2000.0 Fpm
The maximum speed capacity is used to scale the current output when used to monitor the speed, and to allow entering the speed alarms in %.
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A.7.10.
Password: Service
1 1 10
A.8.
Main Menu 3
MAIN MENU 3 is used for protecting and un-protecting the system using passwords, and to perform diagnostic and test functions. The diagnostic functions can only be operated after removing all password protection, and should only be used by experienced technical personnel. Most test functions are not password protected.
-- -MAIN MENU 3 Press MENU for more PROT DIAG TEST
The PROTECTION menu only becomes visible after passwords have been defined (see the DIAGNOSTICS Menu).
A.8.1.
The Micro-Tech 3105 has three protection levels to which specific passwords are related. Appendix Table A-1: Password Protection Levels
Protection NONE Password SERVICE Status The system is completely unprotected; all data can be read or changed. Operator functions and data are unprotected. All setup and calibration data are protected except zero calibrate. The system is totally protected, process data can be read, no change allowed.
LIMITED
OPERATOR
PROTECTED
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A SERVICE password is required to access the NONE level. An OPERATOR or a SERVICE password is required to access the LIMITED level. Use the NONE key to access the NONE protection level. If the current level is not already ANY, the SERVICE password is required. Use the LTD key to access the limited protection level. If the system is in level NONE, change is immediate. If it is in PROT level, the SERVICE or OPERATOR password is required. Use the PROT key to access the protected level. No password is required. - PROTECTION LEVEL > NONE < NONE Default: Selections: Password: LTD PROT
NONE NONE, LIMITED, PROTECTED from NONE to LTD or PROT: not required from LTD to PROT: not required from LTD to NONE: SERVICE from PROT to NONE: SERVICE from PROT to LTD: OPERATOR or SERVICE
Pressing the soft key gives entry to desired level. Going from a low level to a higher level forces the password entry. A.8.1.1 Online Procedure for Changing Protection Level The protection level can be temporarily changed by entering a password "on the fly" during normal operation. When the operator tries to enter a variable or select a function, which is password protected, and the password is installed, the following screen is displayed. - SYSTEM PROTECTED PLEASE ENTER PASSWORD ENTER The operator can enter either the OPERATOR or the SERVICE passwords. However, if the operator enters the OPERATOR password and the variable or function requires the SERVICE password instead, the access is denied and the following screen is displayed. - SYSTEM PROTECTED PLEASE ENTER SERVICE PASSWORD ENTER
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If the operator fails to enter the correct password, the following screen displays. - SYSTEM PROTECTED INVALID PASSWORD ACCESS DENIED RETURN
Pressing RETURN returns the program to the previous function. If the operator enters the correct password, the previous screen appears and access is allowed. When the protection level is changed using the on line procedure, the system automatically returns to protected status if no keyboard entries are made within 60 seconds.
A.9.
Diagnostics
A.9.1. A/D Raw Data
Diagnostic Scroll 1 shows the raw data from the A/D converter of the Feeder Controller (A/D gross) and the net value after the zero constant has been subtracted. The range of the A/D converter is from 0 to 131070 numbers.
-DIAGNOST. SCROLL 1A/D gross 00000 A/D net 0000
A.9.2.
Password: Service
If CALIB is pressed, the next two scrolls are displayed and can be used to finetune the readout of mV/V.
-DIAGNOST. SCROLL 2A Loadcell output zero 0000000 A/D counts ENTER
Password: Service
15 0 10000
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Password: Service
3497 0 30000
A.9.3.
Change Prescaler
The prescaler is a number, which is used to divide the incoming frequency of the speed sensor(s) to achieve a usable input frequency of approximately 30 Hz. The prescaler is automatically calculated and should never be altered by the user. However, a direct entry has been made possible for quick replacement of the Feeder Controller.
-DIAGNOST. SCROLL 3Prescale 00000 00000.0 pls/min ENTER CALIB
Password: Service
10 1 100
-DIAGNOST. SCROLL 3A Test duration total pulses 0000000 ENTER
900 1 100000
-DIAGNOST. SCROLL 3B Test duration total length 00000.0 ft ENTER
Password: Service
200 m 1m 100000 m
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A.9.4.
Change Passwords
Change the password by entering a new one. The user can enter up to eight characters (numeric keys entries). The entered numbers are not echoed on the screen. Pressing just the ENTER key removes the password.
-DIAGNOST. SCROLL 4ENTER SERVICE PASSWORD ******** ENTER
Password: Service
Default:
No password
After the password has been entered, the system asks for confirmation. This prevents losing access control due to a typing mistake while entering passwords.
-DIAGNOST. SCROLL 4REENTER SERVICE PASSWORD ******** ENTER
If the password entered the second time matches the first, the following message confirms the entry.
-DIAGNOST. SCROLL 4NEW PASSWORD ACQUIRED RETURN
If the two passwords do not match, the system does not accept the new password.
-DIAGNOST. SCROLL 4INVALID PASSWORD RETURN
Password: Operator
Default: No password The OPERATOR password is double checked similarly to the service one. It is strongly suggested to write down the password and preserve a copy in a safe place. If the password is forgotten, refer to Section 4.3.7 to remove a forgotten password.
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A.9.5.
71.XX.XX.XX
A.9.6.
Time is entered in a similar way. The AM/PM key is used when time is in the English mode. See DISPLAY SCROLL 7 IN MAIN MENU 2.
-DIAGNOST. SCROLL 8Time: HH:MM HOURS:HH ENTER AM/PM
A.9.7.
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The following screen is displayed for each optional plugin board installed in each slot.
-DIAGNOST. SCROLL 9Board type slot #1 BOARD TYPE -DIAGNOST. SCROLL 10 Board type slot #2 BOARD TYPE
Optional current output board. - #1 Current output Serial communication board (RS232, RS485) Allen-Bradley Remote I/O PROFIBUS-DP
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A.9.8.
A.9.9.
Lamp Test
Press START to begin a Lamp Test of the Feeder Controller. All LED's and digits of the display blink for a number of seconds.
- TEST SCROLL 1 LAMP TEST START -
A.9.10.
The message "Test PASSED" is displayed if the test runs correctly. If something wrong is detected, then the message "Test FAILED" is displayed, and the soft key CONTINUE is shown. The operator has to press the key to go on to the next test.
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A.9.11.
Digit (displayed instead of slot#) identifies the four Digitizers inputs. Inputs are shown from left to right. If a board has 16 inputs, two screens are used to show the first and the second half, the lower half is shown first.
A.9.12.
To force an output, enter the desired number followed by ENTER. Then use the ON/OFF key to force it to the ON or OFF status. After the output has been forced, the CLEAR soft key appears in the middle position. Slots are numbered 1-3; slot 0 is the motherboard.
WARNING
FORCING THE DIGITAL OUTPUTS MAY CAUSE MACHINERY TO START. AFTER THE USER TRIES TO FOURCE AN OUTPUT, THE FOLLOWING MESSAGE DISPLAYS.
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WARNING
IF THE USER PRESSES CONTINUE, BE AWARE THE ACTION MAY CAUSE DAMAGE OR INJURY. IF THE USER PRESSES ABORT, THE SYSTEM RETURNS TO THE PREVIOUS SCROLL.
A.9.13.
To force the output, enter the desired number of milliamps and press ENTER. Press CLEAR to free the mA channel. The following screen is shown (two or more current output are detected).
- TEST SCROLL 6 Current output #2 should be 00.0 mA ENTER CLEAR
Password: Service
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Password: Service
A.9.14.
A.9.15.
Test Communication A
The following screen allows checking the installed serial lines using a loop back type test. The maximum line number is 2; Transmit must be tied to receive for this test. "Port 1" is standard and "Port 2" is shown only if optional Comm boards are detected.
- TEST SCROLL 10 Test Communication A Password: Service
Port 1
Port 2
By pressing the PORT 1 or the PORT 2 soft key, the test is initiated. A test pattern is sent out on the TX output and read on the RX input. If the test fails, the message "Test Failed" is shown; otherwise, the message "Test Passed" is displayed. A.9.15.1 Test RS232 To test RS232 the test requires a hardware jumper to be installed between terminals TB3-22 (RX) and TB3-21 (TX). A.9.15.2 Test RS485 To test the RS485 the test requires a hardware jumper to be installed between terminals TB3-21 and TB3-28 to TB3-20 and TB3-29.
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A.9.16.
Test Communication B
This test is similar to the previous one but works for the field bus version of the communication board.
- TEST SCROLL 11 Test communication B START Password: Service
A.9.17.
A.9.18.
To force the outputs, enter a number followed by ENTER. The CLEAR key appears indicating that the output is being forced to a value. By pressing CLEAR, the output is freed.
A.9.19.
Simulated Control
- TEST SCROLL 14 Simulated control NO CHOICE ENTER
Password: Service
Default: Min:
NO YES,NO
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Generates a simulated speed value, which increases and decreases following the setpoint variations. Only if a second Control Loop enabled:
- TEST SCROLL 15 Simulated control #2 NO CHOICE ENTER
Password: Service
Default: Min:
NO YES, NO
A.9.20.
Press the RUN key twice to exit. All other keys, including MENU, are displayed but not executed.
A.10.1.
I/O Definition
The following section explains how to configure I/O. However, the standard configuration as provided by the factory is normally satisfactory. A.10.1.1 Define Current Outputs The following menus are shown for configuring the current output(s). Use the CHOICE key to change the variable and the ENTER key to confirm. The NEXT key allows the operator to set up to four (4) current outputs if installed.
- I/O DEF SCROLL 1 Current Output define #1 > Cntrl 1 < CHOICES ENTER NEXT
Password: Service
Default: (1st) CONTROL1, (2nd) RATE, (3rd) OFF, (4th) OFF Selections: OFF, RATE, LOAD, SPEED, CONTROL 1, CONTROL 2, LEVEL
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(Only if #2 PID is enable in Control Menu). If the selection of the previous screen is not OFF, the operator can set up the range, delay and damping of the current output. The range is selectable between the standard 0 to 20 mA and 4 to 20 mA both in direct and reverse mode. Select 0-20 or 4-20 if an increase in current is desired for any increase of the variable. Select 20-0 or 20-4 if a decrease of current is desired for any increase of the variable.
- I/O DEF SCROLL 1ACurrent out range #1 > 4-20 mA < CHOICES ENTER NEXT
Password: Service
Default: (1st) 4-20 mA, (2nd) 4-20 mA, (3rd) 4-20 mA, (4th) 4-20 mA Selections: 0-20 mA, 4-20 mA, 20-0 mA, 20-4 mA Each current output can be delayed. This is typically needed in blending systems, to correct transport time differences. The delay can be set either in time or in length of belt travel. Belt travel is suggested for variable speed applications. Use the T/L soft key to switch between time and length.
I/O DEF SCROLL 1BCurrent out delay #1 0 sec ENTER T/L NEXT
Password: Service
(1st) 0 sec, (2nd) 0 sec, (3rd) 0 sec, (4th) 0 sec 0 sec 300 sec Min: Min: Max: (1st) 0 Ft, (2nd) 0 Ft, (3rd) 0 Ft, (4th) 0 Ft 0M 300 M
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A damping factor can also be selected for each current channel. The damping factor is the time for the output to stabilize after a step change. This damping only affects the current output, not the displayed variable, which has a separate damping factor, selectable in Main Menu 2, Display.
- I/O DEF SCROLL 1CCurrent out damping #1 4 ENTER NEXT
Password: Operator
(1st) 4 sec, (2nd) 4 sec, (3rd) 4 sec, (4th) 4 sec 0 sec 400 sec
UP and DOWN arrows move between range, delay, and damping. NEXT moves to the next current output.
A.10.2.
- I/O DEF SCROLL 2 Analog Input #1 def. > Inclination < CHOICES ENTER CALIB
Password: Service
Default: OFF Selections: OFF, INCLIN (ATION), MOISTURE, SETPOINT, PROCESS VARIABLE
- I/O DEF SCROLL 3 Analog Input #2 def. > Moisture < CHOICES ENTER CALIB
Password: Service
Default:
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A.10.3.
Password: Service
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A.10.4.
Password: Service
Password: Service
Note: Incline angles greater than 16 are not recommended and restrict the system accuracy. Consult the factory on angles with installation greater than 16.
A.10.5.
Password: Service
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Calibrate the high remote setpoint by pressing % SET and typing in the high setpoint in percentage that is equal to 5.0 volts. Confirm with ENTER. If other than 5 volts is desired, press VOLTS and type in the high setpoint in volts. Press ENTER to confirm. Press DOWN scroll key to continue in I/O DEF.
- I/O DEF SCROLL 2A/3ARemote setpoint high 100.0 %S = 5.0 V ENTER % SET VOLTS
Password: Service
5.0V 1.0V 5V
A.10.6.
Process Variable
If analog has been programmed for process variable input and CALIB was pressed, the following screens appear. The user can calibrate the low process variable by press % VAR and typing in the low P.V. in percentage. Confirm with ENTER. If other than 0.0 volts is desired, press VOLTS and type in the low P.V. in volts. Confirm with ENTER and press the DOWN scroll key to advance to high P.V. Only if ANALOG INPUT (process VARIABLE) OPTION IS ENABLED:
- I/O DEF SCROLL 2A/3AProcess var. low 00.0 %V = 0.0 V ENTER % VAR VOLTS
Password: Service
Calibrate the high P.V. by pressing % VAR and typing in the high P.V. in percentage. Confirm with ENTER. If other than 5.0 volts is desired, press VOLTS and type in the high P.V. in volts. Press ENTER to confirm. Press DOWN scroll to continue to I/O DEF.
- I/O DEF SCROLL 2A/3AProcess var. high 100.0 %V = 5.0 V ENTER % VAR VOLTS
Password: Service
5.0V 1.0V 5V
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A.10.7.
Password: Service
The following table shows the available logical selections that can be assigned to any available physical input. Typical field wiring drawings and customer specific field wiring drawings show Belt Running (Conveyor Run) defaulted to #3 NC. Default inputs can be reassigned to any physical input if desired. External alarms 1, 2, and 3 can be assigned to logical functions not on the list. Logical selections should not be reassigned after the physical inputs have been wired. CAUTION LOGICAL INPUTS RETURN TO THE DEFAULT IF THE BELT FEEDER CONTROLLER IS COLD STARTED. Appendix Table A-3: Available Logical Selections
Selections: External alarm 1 External alarm 2 External alarm 3 Print Belt Running (Conveyor run) Reset Totals Reset Alarms Auto Zero Clip Detector Batch Start Batch Stop Default: 0 NO 0 NO 0 NO 0 NO 3 NC 0 NO 0 NO 0 NO 0 NO 0 NO 0 NO (Only if Load Out installed) (Only if Load Out installed) (Only if AZT enabled) (Only if set to printer) 0 = function disabled
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Selections: Batch Standby Local or Remote Control Manual or Automatic Control Regulation Interlock Cal Sel. 1 Cal Sel. 2 Cal Sel. 3 Cal Sel. 4 Cal Sel. 5 Cal Sel. 6 Cal Sel. 7 Cal Sel. 8 Cal Sel. 9 Cal Sel. 10
Default: 0 NO 0 NO 0 NO 0 NO 0 NO 0 NO 0 NO 0 NO 0 NO 0 NO 0 NO 0 NO 0 NO 0 NO Locks control value Totalization continues (Only if Load Out installed)
Additional assignable logical inputs from the above table can be selected by adding optional I/O boards. Available options are 4in/16out, 16in/4out, or 20in/20out by adding both boards. Appendix Table A-5: Digital Input/Output Board Inputs
PHYSICAL INPUT NUMBER 6 7 8 9 A-56 ASSIGNED FUNCTION INSTALLED OPTIONS 4IN/16OUT 16IN/4OUT 4IN/16OUT ONLY ONLY AND 16IN/4OUT J15 - 2 J16 - 17 J15 - 2 J15 - 15 J15 - 3 J15 - 16 J16 - 5 J16 - 18 J16 - 6 J15 - 15 J15 - 3 J15 - 16 REC 4186
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ASSIGNED FUNCTION
INSTALLED OPTIONS 4IN/16OUT 16IN/4OUT 4IN/16OUT ONLY ONLY AND 16IN/4OUT J16 - 19 J16 - 17 J16 - 7 J16 - 20 J16 - 8 J16 - 21 J16 - 9 J16 - 22 J16 - 10 J16 - 23 J16 - 11 J16 - 24 J16 - 12 J16 - 5 J16 - 18 J16 - 6 J16 - 19 J16 - 7 J16 - 20 J16 - 8 J16 - 21 J16 - 9 J16 - 22 J16 - 10 J16 - 23 J16 - 11 J16 - 24 J16 - 12
WARNING CHANGING THE DEFINITION OF THE DIGITAL INPUTS MAY CAUSE MACHINERY TO START. AFTER THE USER TRIES TO CHANGE A DEFINITION, THE FOLLOWING MESSAGE IS DISPLAYED.
WARNING EQUIPMENT MAY START CONTINUE ABORT
IF THE USER PRESSES CONTINUE, BE AWARE THE ACTION MAY CAUSE DAMAGE OR INJURY. IF THE USER PRESSES ABORT, THE SYSTEM WILL RETURN TO THE PREVIOUS SCROLL.
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A.10.8.
The following table shows the available logical selections that can be assigned to any available physical output. Typical field wiring drawings and customer specific field wiring drawings show Ready defaulted to #1 NC, Alarm defaulted to #2 NC and Totalizer (remote counter) defaulted to #3 NO. Default selections can be reassigned to any physical output if desired. Logical selections should not be reassigned after the physical outputs have been wired.
CAUTION
LOGICAL SELECTIONS RETURN TO THE DEFAULT IF THE INTEGRATOR IS COLD STARTED.
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Selections Batch End Print Ready Load WTS (weights) High Deviation Positive HHigh Deviation Positive High Deviation Negative HHigh Deviation Negative High Deviation Positive #2
Default 0 NO 0 NO 0 NO 0 NO 0 NO 0 NO 0 NO 0 NO (Only if Load Out installed) (Only if W & M selected) (Only if test weight calib. is selected) (Only if High Pos. Dev. Alarm installed) (Only if HHigh Pos. Dev. Alarm installed) (Only if High Neg. Dev. Alarm installed) (Only if HHigh Neg. Dev. Alarm installed) (Only if High Pos. Dev. Alarm installed) (Only if HHigh Pos. Dev. Alarm installed) (Only if High Neg. Dev. Alarm installed) (Only if HHigh Neg. Dev. Alarm installed)
HHigh Deviation Positive #2 0 NO High Deviation Negative #2 0 NO HHigh Deviation Negative #20 NO Local/Remote Control Auto/Manual Increase Control Output Decrease Control Output 0 NO 0 NO 0 NO 0 NO
(Only if PEIC enabled) (Only if PEIC enabled) (Only if PEIC enabled) (Only if PEIC enabled)
Increase Control Output #2 0 NO Decrease Control Output #2 0 NO Start Belt Stop Belt 0 NO 0 NO
There are 5 outputs, 4 assignable, and 1 non-assignable Fault output standard on the motherboard.
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RELAY BOARD
NC 1 4 COM 2 5 7 9 NO 3 6 8 10
FAULT
1 2 3
FAULT
Additional assignable logical selections from the above table can be selected by adding optional I/O boards. Available options are 4in/16out, 16in/4out, or 20in/20out by adding both boards. Appendix Table A-8: Digital Input/Output Board Outputs
PHYSICAL OUTPUT NUMBER 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 ASSIGNED FUNCTION 4IN/16OUT ONLY J15-17 J15 - 5 J15 - 18 J15 - 6 J15 - 19 J15 - 7 J15 - 20 J15 - 8 J15 - 21 J15 - 9 J15 - 22 J15 - 10 J15 - 23 J15 - 11 J15 - 24 J15 - 12 INSTALLED OPTIONS 16IN/4OUT ONLY J16 - 2 J16 - 15 J16 - 3 J16 - 16 4IN/16OUT AND 16IN/4OUT J16 - 2 J16 - 15 J16 - 3 J16 - 16 J15 - 17 J15 - 5 J15 - 18 J15 - 6 J15 19 J15 7 J15 20 J15 8 J15 21 J15 9 J15 22 J15 10 J15 23 J15 11 J15 24 J15 12
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WARNING CHANGING
THE DEFINITION OF THE DIGITAL OUTPUTS MAY CAUSE MACHINERY TO START AFTER THE USER TRIES TO CHANGE A DEFINITION. THE FOLLOWING MESSAGE IS DISPLAYED.
IF THE USER PRESSES CONTINUE, BE AWARE THE ACTION MAY CAUSE DAMAGE OR INJURY. IF THE USER PRESSES ABORT, THE SYSTEM RETURNS TO THE PREVIOUS SCROLL.
A.10.9.
1 0.01 100
Enter the pulse width in seconds of the Totalizer. A higher pulse width limits the maximum frequency. The default 0.1 sec is recommended for frequencies lower than 5 Hz.
- I/O DEF SCROLL 7 Remote counter pulse width 0.100 sec ENTER Password: Service
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Default: OFF Selections: OFF, RATE, LOAD, SPEED If a selection other than OFF is made, the following screens allow the user to define the polarity and the parity check of the BCD output. The polarity selection reverses the signals from NO to NC and vice versa. If a parity criterion is selected, the most significant bit of the BCD output is used for parity check.
- I/O DEF SCROLL 8ABCD Output polarity > Positive < CHOICES ENTER Password: Service
Default:
OFF
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Selections: OFF, BATCH PRE-ACT, BATCH SETPOINT Only if BCD input is not set to OFF:
- I/O DEF SCROLL 9ABCD input polarity > Positive < CHOICES ENTER
Password: Service
Default: Choices:
In the MANUAL mode, the user must enter the length of belt, which is affected, by the belt splice. The system freezes the belt loading when the clip is detected and keeps it frozen until the specified belt length has passed.
- I/O DEF SCROLL 10AClip detect length 00.00 ft ENTER Password: Service
If the AUTO mode is selected, the system automatically detects belt weight variations and compensates for them. The Auto Zero Tracking then stores in memory a table of tare values, which are used to compensate the tare variations point by point. In addition, when the Acquire Test Duration is run in the ACQ FULL mode, the COUNT key is not displayed because the system automatically counts the clip detector pulses. (For proper operation, there can only be one clip used for the entire belt length.)
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A.11.1.
Password: Operator NO
YES
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If the selection in the previous screen was YES, enter the low and high set points for the alarm. Also, enter the desired delay time before the alarm is monitored. The UNITS key allows the user to specify the set points in engineering units. The % key selects set points in percent. The SET/DLY switches between the set point and the delay time.
- ALARM SCROLL 1A Low rate set 10 % 105 sec ENTER SET/DELAY UNITS/% Password: Operator
A.11.2.
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If the selection in the previous screen was YES, enter the low and high set points for the alarm. Also, enter the desired delay time before the alarm is monitored. The UNITS key allows the user to specify the set points in engineering units. The % key selects percent. The SET/DLY switches between the set point and the delay time.
- ALARM SCROLL 2A Low load set 10 % 10 sec ENTER SET/DELAY UNITS/% Password: Operator
- ALARM SCROLL 2B High load set 100 % 10 sec ENTER SET/DELAY UNITS/%
Password: Operator
100% 0% 200 %
A.11.3.
Default: NO Selections: YES, NO If the selection in the previous screen was YES, enter the low and high set points for the alarm. Also, enter the desired delay time before the alarm is monitored. The UNITS key allows the user to specify the set points in engineering units. The % key selects percent. The SET/DLY switches between the set point and the delay time.
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Password: Operator
If the Speed Mode that was defined in Main Menu 2, Scale Data, is Dual, the user has to enter the maximum acceptable difference in percent between the two speed inputs and the delay time before the alarm is generated.
- ALARM SCROLL 4A Belt slip set 1 % 10 sec ENTER DELAY UNITS Password: Operator
Use the CHOICE key to turn on or off the high positive deviation alarm. Confirm with ENTER.
- ALARM SCROLL 5 H Pos. dev alarm > NO < CHOICE ENTER Password: Operator
Default: NO Selections: YES, NO If the selection in the previous screen was YES, enter the high setpoint for the alarm. Also, enter the desired delay time before the alarm is monitored. The UNIT key allows the user to specify the setpoint in engineering units. The % key selects percent. The SET/DLY switches between the setpoint and the delay time.
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Password: Operator
Use the CHOICE key to turn on or off the high high positive deviation alarm. Confirm with ENTER.
- ALARM SCROLL 6 H H Pos. dev alarm > NO < CHOICE ENTER Password: Operator
Default: NO Selections: YES, NO If the selection in the previous screen was YES, enter the high setpoint for the alarm. Also, enter the desired delay time before the alarm is monitored. The UNIT key allows the user to specify the setpoint in engineering units. The % key selects percent. The SET/DLY switches between the setpoint and the delay time.
- ALARM SCROLL 6A H H Pos. dev set 20 % 10 sec ENTER DELAY
Password: Operator
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A.11.3.3
Use the CHOICE key to turn on or off the high negative deviations alarm. Confirm with ENTER
- ALARM SCROLL 7 H Neg. dev alarm > NO < CHOICE ENTER Password: Operator
Default: NO Selections: YES, NO If the selection in the previous screen was YES, enter the low setpoint for the alarm. Also, enter the desired delay time before the alarm is monitored. The UNIT key allows the user to specify the setpoint in engineering units. The % key selects percent. The SET/DLY switches between the setpoint and the delay time.
- ALARM SCROLL 7A H Neg.. dev set 10 % 10 sec ENTER DELAY Password: Operator
Use the CHOICE key to turn on or off the high high negative deviations alarm. Confirm with ENTER
- ALARM SCROLL 8 H H Neg. dev alarm > NO < CHOICE ENTER Password: Operator
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If the selection in the previous screen was YES, enter the low setpoint for the alarm. Also, enter the desired delay time before the alarm is monitored. The UNIT key allows the user to specify the setpoint in engineering units. The % key selects percent. The SET/DLY switches between the setpoint and the delay time.
- ALARM SCROLL 8A H H Neg.. dev set 10 % 10 sec ENTER DELAY Password: Operator
Default: 10% 10 sec Min: 0% 0 sec Max: 105 % 90 sec A.11.3.5 Define High Positive Deviation Alarm (Only if 2nd PID loop enabled) Use the CHOICE key to turn on or off the high positive deviation alarm. Confirm with ENTER.
- ALARM SCROLL 9H Pos. dev alarm 2 > NO < CHOICE ENTER
Password: Operator
Default: NO Selections: YES, NO If the selection in the previous screen was YES, enter the high setpoint for the alarm. Also, enter the desired delay time before the alarm is monitored. The UNIT key allows the user to specify the setpoint in engineering units. The % key selects percent. The SET/DLY switches between the setpoint and the delay time.
- ALARM SCROLL 9A H Pos. dev set 2 10 % 10 sec ENTER DELAY Password: Operator
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A.11.3.6
Define High High Positive Deviation (Only if 2nd PID loop enabled)
Use the CHOICE key to turn on or off the high high positive deviation alarm. Confirm with ENTER.
- ALARM SCROLL 10 H H Pos. dev alarm 2 > NO < CHOICE ENTER Password: Operator
Default: NO Selections: YES, NO If the selection in the previous screen was YES, enter the high setpoint for the alarm. Also, enter the desired delay time before the alarm is monitored. The UNIT key allows the user to specify the setpoint in engineering units. The % key selects percent. The SET/DLY switches between the setpoint and the delay time.
- ALARM SCROLL 10A H H Pos. dev set 2 20 % 10 sec ENTER DELAY Password: Operator
Default: 20% 10 sec Min: 0% 0 sec Max: 105 % 90 sec A.11.3.7 Define High Negative Deviation Alarm (Only if 2ND PID loop enable) Use the CHOICE key to turn on or off the high negative deviation alarm. Confirm with ENTER
- ALARM SCROLL 11 H Neg. dev alarm 2 > NO < CHOICE ENTER Password: Operator
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If the selection in the previous screen was YES, enter the low setpoint for the alarm. Also, enter the desired delay time before the alarm is monitored. The UNIT key allows the user to specify the setpoint in engineering units. The % key selects percent. The SET/DLY switches between the setpoint and the delay time.
- ALARM SCROLL 11A H Neg. dev set 2 10 % 10 sec ENTER DELAY
Password: Operator
Default: 10% 10 sec Min: 0% 0 sec Max: 105 % 90 sec A.11.3.8 Define High High Negative Deviation Alarm (Only if 2nd PID loop enabled) Use the CHOICE key to turn on or off the high high negative deviation alarm. Confirm with ENTER
- ALARM SCROLL 12 H H Neg. dev alarm 2 > NO < CHOICE ENTER
Password: Operator
Default: NO Selections: YES, NO If the selection in the previous screen was YES, enter the low setpoint for the alarm. Also, enter the desired delay time before the alarm is monitored. The UNIT key allows the user to specify the setpoint in engineering units. The % key selects percent. The SET/DLY switches between the setpoint and the delay time.
Password: Operator
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A.11.3.9
After three seconds, the ALARM screen is displayed. The user can use the CHOICE soft key to select the desired mode between ALARM (just a warning message), SHUT DOWN (Warning plus fault output), and NONE (no action). Confirm with ENTER. Use the NEXT key to scroll between alarms, or enter the alarm number. Alarms are listed in Section 4.3.
A.12.1.
Communication A Scroll
The MT 3105 has one serial channel, which can be configured using jumpers as an RS232 or an RS485 channel. The serial channel can be used for printing or for a serial communication with an intelligent device such as a PLC or a PC. An additional COMM A board can be installed and programmed, typically one for the printer and one for networking. The following screens define the communication parameters for the first and the second channel.
COMM A SCROLL Baud Rate port #1 > 9600 < CHOICE ENTER Password: Service
Default: 9600 Selections: 110, 150, 300, 600, 1200, 2400, 4800, 9600, 19200
- COMM. A SCROLL 2 Set parity port #1 > No parity < CHOICE ENTER Password: Service
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- COMM. A SCROLL 3 Stop bits port #1 > 1 stop bit < CHOICE ENTER
Password: Service
Default: 8 BITS Selections: 7 BITS, 8 BITS Some commonly used protocols are implemented in the system. See Communication Protocols, REC 3949, for the details. Possible selections are: PC-MASTER -Thermo Ramsey proprietary protocol: Multi Drop, Master Slave. SIEMENS 3964R - A proprietary protocol of Siemens. Point to point, Multi Master. ALLEN BRADLEY DF1 - A proprietary protocol of Allen Bradley. Multi Drop, Master Slave. MODBUS - A proprietary protocol of AEG. Multi Drop, Master Slave. PRINTER - Not a protocol, selects printer output.
-COMM. A SCROLL 5 Protocol port #1 > MODBUS < CHOICE ENTER
Password: Service
Default: Selections:
If the selected protocol is not PRINTER, the following screens define the ADDRESS of the device in the multi drop line, and the access permission from the remote supervisor. If NONE is selected, the supervisor has full access to the device. If LIMITED is selected; there is supervisor only access to those variables. If PROTECTED is selected, the unit is write protected.
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Password: Service
Default: Selections:
Password: Service
1 1 255
Password: Service
-COMM. A SCROLL 7 Access prot. port #1 > None < CHOICE ENTER
Default: Selections:
If an optional communication board is installed, the following screen appears. These screens operate exactly as the ones dedicated to Port 1.
- COMM. A SCROLL 8 Baud rate port #2 > 2400 < CHOICE ENTER Password: Service
Default: Selections:
9600 110, 150, 300, 600, 1200, 2400, 4800, 9600, 19200
Password: Service
- COMM. A SCROLL 9 Set parity port #2 > No parity < CHOICE ENTER
Default: Selections:
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- COMM. A SCROLL 10 Stop bits port #2 > 1 stop bit < CHOICE ENTER
Password: Service
Default: Selections:
Default: Selections:
Default: Selections:
Default: Selections:
1 1 255
- COMM. A SCROLL 14Access port. port #2 > None < CHOICE ENTER Password: Service
Default: Selections:
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A.12.2.
Print
The Micro-Tech 3105 has a fully programmable printer format. The following section explains how to program it according to the specific needs. 1. Define Handshaking The system can be configured to operate without a handshake (NONE), or using the Clear to Send signal (CTS) or the XON-XOFF sequence. Refer to the printer instruction manual to define which selection is required. The selection NONE is only used for testing purposes. It is not recommended for normal use. If NONE is selected, the system is not able to recognize if the printer is on line or not, or if the paper is empty. The most commonly used protocol is the CTS, which is a signal generated by the printer to indicate whether it is ready to receive data or not.
-PRINTER SCROLL 1 Handshaking > None < CHOICE ENTER Password: Service
Default: Selections:
Different printers use different end of line patterns. Select the one you need for your printer.
-PRINTER SCROLL 2 End of line > CR < CHOICE ENTER Password: Service
Default: Selections:
Some printers cannot accept characters while they are printing. In some cases, the handshake is not well controlled by the printer, so a delay at end of line is helpful.
-PRINTER SCROLL 3 Delay end of line 0 sec ENTER Password: Service
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A form feed character can be sent to the printer after each report to force the printer to eject the paper. If NO is selected, a normal END OF LINE character(s) is printed at the end of the report.
PRINTER SCROLL 4 Form Feed > NO < CHOICE ENTER Password: Service
Default: Selections:
NO NO, YES
A.12.3.
Periodical Printing
If you want to generate periodical printing, enter the number of minutes, hours, or days in the following screen. Entering 0 prevents periodical printing. Use the INTV key to switch from minutes to hours and to days.
-PRINTER SCROLL 5 Print interval 0 min ENTER INTV Password: Operator
The system can print at specific times during the day. Enter the time you want to obtain the printing. Use the NEXT key to scroll between the print times (maximum 4). The ON/OFF key enables or disables the displayed print time.
-PRINTER SCROLL 6 Print time # 1 time HH:MM ENTER ON/OFF NEXT Password: Operator
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A.12.4.
yy:yyz
Password: Operator
Default: Selections:
NO YES, NO
There are three ways for defining the printing format. The first two are predefined formats, which are as follows: Appendix Table A-9: Predefined Print Format 1
DEFAULT 1 TOTALS REPORT
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The format DEFAULT 2" is pre-selected when the weights and measures choice is NTEP. The third way is to define your own format using the printer setup screens listed. Select DEFAULT if you want the predefined format. Select USER DEFINED if you want to set up your own format.
- PRINTER SCROLL 8 Total report format > Default 1 < CHOICE ENTER Password: Service
Default: Selections:
DEFAULT 1 unless Weights and Measures option is selected, then DEFAULT 2. DEFAULT 1, DEFAULT 2, USER DEFINED
If your selection is USER DEFINED, the following screens are displayed. First, define the number of strings that you want to add to your report. You can enter a number from 1 to 3. Strings can be used to add the company name as well as other information that you want to include in the print format.
- PRINTER SCROLL 9ANumber of strings 3 ENTER Password: Operator
1 0 3
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If you specified a number of strings larger then zero, you can now enter the strings. Use the alphanumeric keypad, pressing the numeric key corresponding to the letter that you want to type. Every time you press a new key, the cursor moves to the right one place. If you need to use two times the same key (example for double letters), move the cursor right using the arrow keys (left and right soft keys).
- PRINTER SCROLL 9B Contents string #1 xxxxxxxxxxxxxxxxxxxx < ENTER > Password: Operator
Default:
xxxxxxxxxxxxxxxxxxxx
Once you have defined the string, specify where the string has to be placed on the printed report. The coordinate is given in the following way: 0000000000111111111122222222223... 0123456789012345678901234567890... +------------------------------------------------> Y 00|This line printed first 01|This line printed second 02| 03| 04| 05| 06| .v .X Use the X-pos and Y-pos keys to enter the X and Y coordinates. Confirm with ENTER. By specifying 0,0, the string is not printed.
- PRINTER SCROLL 9C Position string #1 X=0,Y=0 ENTER X\Y-pos Password: Operator
^ | DIRECTION OF | PAPER
Y 1 1 80
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If you specified more strings, enter the relevant data using the same procedure.
- PRINTER SCROLL 9D Contents string #2 xxxxxxxxxxxxxxxxxxxx < ENTER > Password: Operator
Default:
xxxxxxxxxxxxxxxxxxxx
- PRINTER SCROLL 9E Position string #2 X=0,Y=0 ENTER X\Y-pos Password: Operator
Y 1 1 80
Password: Operator
Default:
xxxxxxxxxxxxxxxxxxxx
- PRINTER SCROLL 9G Position string #3 X=0,Y=0 ENTER X\Y-pos Password: Operator
Y 1 1 80
Password: Operator
Y 1 1 80
In a similar way, you can position the following variables in the print format:
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Y 1 1 80
Y 1 1 80
Y 1 1 80
Y 1 1 80
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Y 1 1 80
The Average Rate Since the Last Print: The average rate is calculated only on the periods of time in which rate has been higher than 5% of capacity.
- PRINTER SCROLL 9NPosition avg. rate X=0,Y=0 ENTER X-Pos Y-Pos Password: Operator
Y 1 1 80
The Running Time Since the Last Print: The running time is the time in which rate has been higher than 5%.
- PRINTER SCROLL 9PPosition running tm X=0,Y=0 ENTER X-Pos Y-Pos Password: Operator
Y 1 1 80
If the optional load out board is installed, the batch quantity and the batch total can also be printed.
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A.12.5.
The second line gives the status of the printer: NO DATA Indicates the printer is idle, no data are being sent to the printer.
IS RUNNING The system is sending data to the printer. The third line indicates what kind of data is printed if the PRINT key is pressed. The UP and DOWN keys select between: TOTALS BATCH SETUP TRAILS Print totals. Only if load out option is active, print load out information. Print the setup data of the instrument. If audit trails option is active, audit trail data is printed
Print starts after the PRINT key is pressed. The COM key allows the operator to select the printer in case more than one is installed. Here are some examples of data that can be printed:
Print TOTALS TOTALS REPORT DATE: TIME: MASTER TOTAL: RESET TOTAL: RATE: 01-22-2003 8:12a 0.00 Tons 0.00 Tons 0.00 Tons 0.00 Tph
OPERATOR TOTAL:
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Print BATCH:
BATCH REPORT DATE: TIME: BATCH NR: SET PT: TOTAL: 01-22-2003 8:12a 0 0.00 Tons 0.00 Tons
Print ALARM: 01-22-2003 8:14a Clock fail Print SETUP: INSTRUMENT SETUP The system prints out all data and setups. Print AUDIT TRAILS: TRAIL RECORD NR 1 DATE 01-22-2003 TIME 11:59 VARIABLE scale cap NEW 400.00 OLD 500.00 TRAIL RECORD NR 2 DATE 01-22-2003 TIME 11:31 VARIABLE span NEW 250000 OLD 300000 TRAIL RECORD NR 3 DATE 01-22-2003 TIME 11:59 VARIABLE div (e) NEW 0.05 OLD 0.1
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A.13.1.
Audit Trail
This menu is only displayed if the Audit Trails option is installed. Audit trail meets NIST HB 44 Category 3: Remote configuration capability, access may be unlimited or controlled through a password. It consists of an event logger that includes an event counter (000 to 999), the parameter description, the date, and time of the change, and the old and new value of the parameter. Parameters may be configuration parameters or routine calibration. Events and changes may be viewed on the Integrator's display or printed out by an on-site printer. The Logger records all parameters affecting the calibration of the scale. It also records when calibration was performed. The Event Counter increments one count for each event. Audit trail records the time and displays the new and old data for any change in the items below, indicating each by an event number: ZERO SPAN CALIBRATION METHOD CHAIN WEIGHT TEST WEIGHT SCALE CAPACITY SCALE DIVISION SCALE MODEL NO. IDLER SPACING INCLINATION LOAD CELL SIZE LOAD CELL SENSITIVITY LOAD CELL RESISTANCE SPEED INPUT TYPE DEAD BAND MEASURE UNITS REMOTE COUNTER DIVIDER REMOTE COUNTER DURATION AZT TRACKING RANGE NOTE: Changes in zero by auto zero tracking are not recorded. However, if AZT limit is reached, is recorded. LINEARIZATION
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Password: Service
Default: No Selections:
Yes, No
If the audit trails are enabled, meaning YES is selected, the following screen appears for a short time (3 seconds):
- AUDIT TRAILS Use scroll keys or enter trail number
Time of change Date of change Parameter's name Parameter's values, after change new (N) and before change old (O)
Time and date are shown only if an optional Communication board is installed. The user can scroll between events, which are displayed in order of date, and time. The user can also enter a number to display a specific event.
A.13.2.
Linearization
Linearization is not normally used with conveyor belt scales. In case of extreme instances where calibration at multiple flow rates may be required, please consult the factory.
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A.14.1.
Control
The controller output is fully configurable as a PID or P.E.I.C. controller. The controller can act as Master or Slave or in closed loop. The following section explains how to configure the controller. Steps 1 through 11 configure PID Loop 1 and Steps 3 through 23 configure PID Loop 2. A.14.1.1 Control Action During Shutdown When the belt feeder is shutdown and the controller is in auto mode, the control output may correspond to one of the following programmable selections. Locked on the last value before shutdown or Locked on a vale from 1 to 100% as entered through the keyboard.
When the belt feeder is started, the controller begins the control action from the value at which the output was locked at shutdown.
- CNTRL 1 Start out
> Sel <
SCROLL 1 -
Password: Operator
CHOICE ENTER
LOCK, SEL
When the Feeder Controller is not running (regulation interlock inactive), the control output can be locked (LOCK) to the last value, or set (SEL) to the value entered in the next screen. Only if START OUT is set to SEL:
- CNTRL 1 SCROLL 1A Set control value
0%
Password: Operator
ENTER
0% 0% 100 %
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START DELAY The START delay is the time in seconds the controller output remains at the set or lock value after a restart or run is received.
- CNTRL 1 SCROLL 2 START delay
------sec
Password: Operator
ENTER
Default: 5 sec Min: 0 sec Max: 60 sec A.14.1.2 High Control Limit The control output, when in AUTO, cannot exceed this value
- CNTRL 1 SCROLL 3 High control limit
100 %
Password: Operator
ENTER
Default: 100 % Min: 0% Max: 100 % A.14.1.3 Low Control Limit The control output, when in AUTO, cannot be lower this value
- CNTRL 1 SCROLL 4 Low control limit
0%
Password: Operator
ENTER
0% 0% 100 %
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A.14.1.4
Proportional Band
Proportional control actions respond to the amount of process deviation from setpoint. It changes the position of the final control element, in direct proportion to the difference between process variable and setpoint. The proportional band is expressed as that percentage of the total scale range, which corresponds to the full corrective range of the final control element. If proportional band is set to 100%, then a 0 to 100% process variable change causes the output to change 100% of its range. If proportional band is set to 200%, then a 0 to 100% process variable change causes the output to change 50% of its range.
- CNTRL 1 SCROLL 5 Proportional band
200 %
Password: Operator
ENTER
200 % 50 % 900 %
Entering 0% turns off proportional band term. A.14.1.5 Integral (Reset) Time Reset action responds to a combination of the amount and duration of the process deviation. Integral time sets the slope of the output correction signal. A 100% change in process variable results in a 100% change in output correction signal at the integral time entered. Set integral time to 0 if control mode is P.E.I.C.
- CNTRL 1 SCROLL 6 Integral time
0.1 min
Password: Operator
ENTER
Entering 0 time turns off proportional integral term. A.14.1.6 Derivative (Rate) Time Rate action responds to the speed and direction of the process deviation. In most belt feeder applications. Derivative is set to zero. Set derivative time to 0 if control is P.E.I.C.
- CNTRL 1 SCROLL 7 Derivative time
0.0 min
Password: Operator
ENTER
Micro-Tech 3105
A.14.1.7
Process lag is the time duration following a change in the control element until the effect of that change can be measured at the source of the process variable signal. Lag may be measured in the process by making a small manual change in the final control element and observing the elapse time until the process variable display shows the effect of the change. P.E.I.C. control mode is always disabled when time is set to 0.Setting the time to other than zero enables raise and lower digital outputs to become active. Control output may be analog or time proportional.
- CNTRL 1 SCROLL 8 P.E.I.C. time
0 sec
Password: Operator
ENTER
When set to 0, there is not a P.E.I.C. action. Control output can be analog or time proportional. If time proportional, see Main Menu 4, I/O Definition scroll, digital outputs. A.14.1.8 Set Point Source Process control setpoint can be entered local through the keyboard in the RUN menu or by a remote analog input. Serial In is available (consult factory).
- CNTRL 1 SCROLL 9 Setpoint source
LOCAL
Password: Service
ENTER
Default: LOCAL Selections LOCAL, ANALOG IN, SERIAL IN A.14.1.9 Setpoint Units
- CNTRL 1 SCROLL 10 Setpoint units
ENGINEERING
Password: Service
CHOICE
ENTER
Default: ENGINEERING Selections ENGINEERING, PERCENT Only if setpoint source is REMOTE (Analog in, Serial in).
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Password: Service
ENTER
For control system where several belt feeders operate in ratio control, it may bet hat the transport lag time from each belt feeder to the mixing point is different. To insure a correct ratio at the mixing point, an analog delay can be entered for remote setpoint. Scales down the remote or local setpoint.
- CNTRL 1 SCROLL 12Percent of ingredient
0%
Password: Operator
ENTER
100 % 0% 100 %
Scales down the local or remote setpoint. A.14.1.10 Process Variable Source Process variable source may be internal from the belt scale integrator or it may be an external analog input.
- CNTRL 1 SCROLL 13Process variable
> RATE <
Password: Service
CHOICE
ENTER
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A.14.1.11 Process Variable Damping Process variable damping averages the process variable to avoid undesired jumps of the control output.
- CNTRL 1 SCROLL 14Process var damping
0 sec
Password: Operator
ENTER
Default: 0 sec Min: 0 sec Max: 120 sec A.14.1.12 Enable Second PID Loop A second PID control loop with independent setting from the first PID loop may be turned on and set up.
- CNTRL 1 SCROLL 152ND PID loop
> NO <
Password: Service
ENTER
SCROLL 1-
Password: Operator
CHOICE
ENTER
Default: SEL Selections LOCK, SEL When the Feeder Controller is not running (belt feeder running contact open), the control output can be locked (LOCK) to the last value, or set (SEL) to the value entered in the next screen. Only if START OUT is set to SEL:
- CNTRL 2 SCROLL 1ASet control value
0%
Password: Operator
ENTER
0% 0% 100 %
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START DELAY The START delay is the time in seconds the controller output remains at the set or lock value after a restart or run is received.
- CNTRL 2 SCROLL 2 START delay
5 sec
Password: Operator
ENTER
HIGH CONTROL LIMIT The control output, when in AUTO, cannot exceed this value
- CNTRL 2 SCROLL 3 High control limit
100 %
Password: Operator
ENTER
100 % 0% 100 %
LOW CONTROL LIMIT The control output, when in AUTO, cannot be lower this value
- CNTRL 2 SCROLL 4 Low control limit
0%
Password: Operator
ENTER
0% 0% 100 %
PROPORTIONAL BAND Proportional control actions respond to the amount of process deviation from setpoint. It changes the position of the final control element, in direct proportion to the difference between process variable and setpoint. The proportional band is expressed as that percentage of the total scale range, which corresponds to the full corrective range of the final control element. If proportional band is set to 100%, then a 0 to 100% process variable change causes the output to change 100% of its range. If proportional band is set to 200%, then a 0 to 100% process variable change causes the output to change 50% of its range.
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Password: Operator
ENTER
200 % 50 % 900 %
Entering 0% turns off proportional band term INTEGRAL (RESET) TIME Reset action responds to a combination of the amount and duration of the process deviation. Integral time sets the slope of the output correction signal. A 100% change in process variable results in a 100% change in output correction signal at the integral time entered. Set integral time to 0 if control mode is P.E.I.C.
- CNTRL 2 SCROLL 6 Integral time
0.1 min
Password: Operator
ENTER
Entering 0 time turns off proportional integral term. DERIVATE (RATE) TIME Rate action responds to the speed and direction of the process deviation. In most belt feeder applications. Derivative is set to zero. Set derivative time to 0 if control is P.E.I.C.
- CNTRL 2 SCROLL 7 Derivative time
0.0 min
Password: Operator
ENTER
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P.E.I.C. TIME (PROCESS LAG) Process lag is the time duration following a change in the control element until the effect of that change can be measured at the source of the process variable signal. Lag may be measured in the process by making a small manual change in the final control element and observing the elapse time until the process variable display shows the effect of the change. P.E.I.C. control mode is always disabled when time is set to 0.Setting the time to other than zero enables raise and lower digital outputs to become active. Control output may be analog or time proportional.
- CNTRL 2 SCROLL 8 P.E.I.C. time
0 sec
Password: Operator
ENTER
When set to 0, there is not a P.E.I.C. action. Control output can be analog or time proportional. If time proportional, see Main Menu 4, I/O Definition scroll, digital outputs. SET POINT SOURCE Process control setpoint can be entered local through the keyboard in the RUN menu or by a remote analog input. Serial In is available (consult factory).
- CNTRL 2 SCROLL 9 Setpoint source
LOCAL
Password: Service
ENTER
Default: LOCAL Selections LOCAL, ANALOG IN, SERIAL IN SET POINT UNITS
- CNTRL 2 SCROLL 10 Setpoint units
ENGINEERING
Password: Service
CHOICE
ENTER
Default: ENGINEERING Selections ENGINEERING, PERCENT Only if setpoint source is REMOTE (Analog in, Serial in).
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Password: Service
ENTER
For control system where several belt feeders operate in ratio control, it may bet hat the transport lag time from each belt feeder to the mixing point is different. To insure a correct ratio at the mixing point, an analog delay can be entered for remote setpoint. Scales down the remote or local setpoint.
- CNTRL 2 SCROLL 12Percent of ingredient
0%
Password: Operator
ENTER
100 % 0% 100 %
Scales down the local or remote setpoint. PROCESS VARIABLE SOURCE Process variable source may be internal from the belt scale integrator or it may be an external analog input.
- CNTRL 2 SCROLL 13Process variable
> RATE <
Password: Service
CHOICE
ENTER
Default: RATE Selections RATE, SPEED, LOAD, EXTERNAL PROCESS VARIABLE DAMPING
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Process variable damping averages the process variable to avoid undesired jumps of the control output.
- CNTRL 2 SCROLL 14Process var damping
0 sec
Password: Operator
ENTER
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SCALE DATA SCROLL POSITIONS 3 3A 3B 3C 3D 3E 3F 3G 3H 3I 3L 3M 3N 3O 4 5 6 7 Belt Scale Code # (LA) (IDL) (LB1) (LB2) (LB3) (LB4) (LB5) (LB6) (LE) (LC) (LF) (LG) (LD)
PARAMETER Pivot to Load Cell Distance No. of Weigh Idlers Pivot to 1st Idler Distance Pivot to 2nd Idler Distance Pivot to 3rd Idler Distance Pivot to 4th Idler Distance Pivot to 5th Idler Distance Pivot to 6th Idler Distance Pivot to Test Weight Height Pivot to Test Weight Length Pivot to Carriage Height Carry Roll to Carriage Height Idler Spacing
No. of Load Cells Conveyor's Angle Degrees Load Cell Capacity Load Cell Sensitivity mV/V
8A 8B 8C 8D 8E 8F
Load Cell No.1 Resistance ohms Load Cell No.2 Resistance ohms Load Cell No.3 Resistance ohms Load Cell No.4 Resistance ohms Load Cell No.5 Resistance ohms Load Cell No.6 Resistance ohms
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B.1.
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B.2.
Tables of Weighbridges
The tables at the end of this appendix show the default value for scale model selections, no value means the parameter is not useful for that scale model and it is not displayed.
Under scored dimensions are in metric. Appendix Table B-2: Default Value for Scale Model Selections
TABLE OF THERMO RAMSEY WEIGHBRIDGES for Version 3.09 # MODEL BELT WIDTH CAL KIT L.C. IDLERS LA LB1 LB2 LB3 LB4 LB5 LB6 24 22.75 24 22.75 18 24 24 22.75 24 22.75 54 18 71 80 63 21 72 24 48 48 -4.75 42 42 -4.75 LC LD LE LF LG mV/V
1 2 3 4 5 6 7 8 9 10 11 12 13
10-20-1 18-36 10-20-1 42-72 10-20-1 24-36 10-20-1 42-84 10-20-2 10-20-2 10-20-1 18-36 10-20-1 42-72 10-20-1 24-36 10-20-1 42-84 10-22 18-36 10-22 18-36 10-22 18-36
50-34 50-34 50-34 50-34 50-34 50-34 50-30 50-30 50-30 50-30 50-30 50-30 50-30
1 1 1 1 2 1 2 1 1 2 1 2 1 1 1 1 2 1 2 1 1 2 1 2 1 2
32 32 32 32 36 48 32 32 32 32 62
24 22.75 24 22.75 18 24 38 38 38 38 38
36 36 36 36 36 48 36 36 36 36 36
6.5 6.5 6.5 7 6.5 6.5 6.5 7 6.5 7 6.5 7 6.5 6.5 6.5 7 6.5 6.5 6.5 7 6.5 6.5 6.5 6.5 6.5 6.5
3.00 3.00 3.00 3.00 3.00 3.00 3.00 3.00 3.00 3.00 3.00 3.00 3.00
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TABLE OF THERMO RAMSEY WEIGHBRIDGES for Version 3.09 # MODEL BELT WIDTH CAL KIT L.C. IDLERS LA LB1 LB2 LB3 LB4 LB5 LB6 52.75 16.75 71 80 62 71 80 62 71 80 62 71 80 62 71 80 32 32 61.75 19.75 70.75 22.75 54 18 63 21 72 24 52.75 16.75 61.75 19.75 70.75 22.75 54 18 63 21 72 24 52.75 16.75 61.75 19.75 70.75 22.75 24 22.75 24 22.75 30 30 -2 -2 70.75 48 0 61.75 42 0 52.75 36 0 72 48 0 63 42 0 54 36 0 86 48 -4.5 77 42 -4.5 68 36 -4.5 86 48 -4.5 77 42 -4.5 68 36 -4.5 48 48 -4.75 42 42 -4.75 LC LD LE LF LG mV/V
14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
10-22 42-48 10-22 42-48 10-22 42-48 10-22 18-36 10-22 18-36 10-22 18-36 10-22 42-48 10-22 42-48 10-22 42-48 10-22 18-36 10-22 18-36 10-22 18-36 10-22 42-48 10-22 42-48 10-22 42-48 10-20-WF 10-20-WF
50-30 50-30 50-30 50-30 50-30 50-30 50-30 50-30 50-30 50-34 50-34 50-34 50-34 50-34 50-34 BAR BAR
1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 1 1 1
62
36
36
-4.75
6.5 7 6.5 7 6.5 7 6.5 6.5 6.5 6.5 6.5 6.5 6.5 7 6.5 7 6.5 7 6.5 6.5 6.5 6.5 6.5 6.5 6.5 7 6.5 7 6.5 7 4 4 4 4
3.00 3.00 3.00 3.00 3.00 3.00 3.00 3.00 3.00 3.00 3.00 3.00 3.00 3.00 3.00 3.00 3.00
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TABLE OF THERMO RAMSEY WEIGHBRIDGES for Version 3.09 # MODEL BELT WIDTH CAL KIT L.C. IDLERS LA LB1 LB2 LB3 LB4 LB5 LB6 24 22.75 54 18 76 88 70.70 88 64 76 88 70.70 88 63 21 72 24 57.06 19.68 72 24.75 54 18 63 21 72 24 57.06 19.68 70.86 23.62 47.24 39.37 1000 39.37 1200 47.24 36 42 48 0 0 48 48 0 42 42 0 36 48.38 39.37 1000 39.37 1200 47.24 36 0 -4.75 -4.75 48 48 -4.75 42 42 -4.75 LC LD LE LF LG mV/V
31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47
10-20-WF 10-20-WF 10-17-2 10-17-2 10-17-2 10-17-2 10-17-2 10-17-4 10-17-4 10-17-4 10-17-4 10-17-4 10-14-3 10-14-3 10-14-3
BAR BAR 50-17 50-17 50-17 50-17 50-17 50-17 50-17 50-17 50-17 50-17 50-14 50-14 50-14
1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 4 2 4 2 4 2 4 2 4 4 3 4 3 4 3
32 32 64
36 36 36
30 30 36
2 2 -4.75
4 4 4 4 6.5 7 6.5 7 6.5 7 6.5 7 6.5 7 6.5 7 6.5 7 6.5 7 6.5 7 6.5 7
3.00 3.00 3.00 3.00 3.00 3.00 3.00 3.00 3.00 3.00 3.00 3.00 3.00 3.00 3.00
10-14-4
50-14
4 4
36
3.00
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TABLE OF THERMO RAMSEY WEIGHBRIDGES for Version 3.09 # MODEL BELT WIDTH CAL KIT L.C. IDLERS LA LB1 LB2 LB3 LB4 LB5 LB6 LC LD LE LF LG mV/V
48 49 50 51 52 53 54 55 56 57 58 59 60 214
10-14-4 10-14-4 10-14-4 10-14-4 10-14-4 10-30 10-11 18-42 10-11 48-72 10-12 10-17-2D 10-17-2D 10-17-2D
50-14 50-14 50-14 50-14 50-14 50-30 WTS WTS WTS 50-17 50-17 50-17
4 4 4 4 4 4 4 4 4 4 1 1 1 1 1 1 1 2 2 2 2 2 2 2 28 34 40 24 24 21 21 18 18 18 21 24 66 48 40 56.5 48 40 55.5 48 40
3.00 3.00 3.00 3.00 3.00 1.80 3.00 3.00 3.00 3.00 3.00 3.00
50-30
1 1
2.00
215
50-30
2 1
2.00
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Appendix C Linearization
Request REC 3909 from the factory.
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D.1.2.
Digital Outputs
Four (4) programmable, and one (1) non-programmable failure, outputs (Appendix Figure D-2). Isolated Relay Outputs Solid state Output
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D.2.
Selectable jumpers OP1 and OP2 located on the lower right hand side of the DIO boards control internal or external 24 VDC power for the DIO boards. All inputs and outputs use the same selected power supply. Appendix Table D-1: DIO Board Jumper Settings (OP1/OP2)
DIO BOARD JUMPER SETTINGS POWER SOURCE OP1 OP2 INTERNAL EXTERNAL A B A: B
The isolated contact closure inputs are activated by completing the circuit from the input to the negative side of the 24 VDC supply. Approximately 6 mA of current flows out of each input during contact closure. The outputs of the DIO boards use 2803 current sinking (default) type ICs. The output ICs are installed in sockets to allow replacing the output IC only rather than the board if the IC is damaged. The output ICs can be replaced with 2981 type ICs for current sourcing applications. Wire jumpers W1 through W4 must be relocated for current sourcing. In most cases, it is recommended the boards be returned to the factory for converting from current sinking (default) to current sourcing. Appendix Table D-2: DIO Board Jumper Settings for Current Sourcing
CURRENT Sinking (default) Sourcing JUMPERS W1 W2 Yes No No Yes W3 Yes No W4 No Yes
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D.2.1.
Cable length: 150 ohm maximum (7500 ft of 20 AWG) (4) Programmable outputs See Section D.1.2 specifications
Able to drive TTL, CMOS, or relay solenoids Current sinking socket drivers
+24 VDC internal supply, 100 mA DC maximum output Connector 25 pin D connector (male). Connector is interchangeable with a 20 or 22 pin subminiature D connector dimensionally complying with MIL-C-24308.
D.2.2.
Cable length: 150 ohm maximum (7500 ft of 20 AWG) (16) Programmable outputs Able to drive TTL, CMOS, or relay solenoids Current sinking socket drivers
25 pin D connector (female). Connector is interchangeable with a 20 or 22 pin subminiature D connector dimensionally complying with MIL-C-24308.
D-4
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D-6
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A91022
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D.3.
BCD can remotely enter load sizes for load out or batching applications. An optional Load Out input board is required. See Appendix Figure D-5 for wiring instructions. Appendix Figure D-5: BCD Input Option Wiring
D-8
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D.4.
A00701
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D-9
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D-10
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Type B:
Analog Input/Output board has two 5 VDC differential inputs (Appendix Figure D-9) and two user definable 0-20/4-20 or 20-4/20-0 mA outputs (Appendix Figure D-6).
Inputs None Setpoint (S.P.) Process Variable (P.V.) Moisture Compensation Incline Compensation Outputs None Rate Speed, or Load Control Level
Analog inputs are +/-5 VDC. Jumpers W3 and/or W4 are used to select 240 ohm impedance for 0-20/4-20 mA inputs (see Appendix Figure D-10). Type: Differential voltage input (0-20 mA or 4-20 mA with internal resistor, jumper selectable) Range: 0-5 volt, or 5 volt, programmable Input impedance: 100 k nominal (differential) Maximum usable input voltage: 106% of full scale Non-isolated Max. non-destructive input voltage: 12 V peak Field wiring: Connections are made to the terminal strip on bottom edge of the analog board. Note that connector is removable for ease of termination.
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A00922a
2 current outputs (see Appendix Figure D-6). Same as described in Type A board
D-12
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D.5.
D.5.1.
D.6.
Communications Options
The following table gives references for specific communications options. Appendix Table D-3: Communications Options Reference
Part Number 068053 055517 056713 068147 Reference Manual Standard Comm A Board Allen Bradley RIO Profibus-DP DeviceNet REC Number REC 3949 REC 4012 REC 4063 REC 4150
Profibus-DP
Refer to Profibus-DP, REC 4063 if this option is installed.
DeviceNet
Refer to REC 4150 if this option is installed.
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E.1.
1 1 10
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If the number of calibration selected is greater than 1, the scale symbol is added in the run display with the active calibration number, as indicated below.
123.0 Tons 0.0 Tph
E.2.
E.2.1.
soft
Use the keypad to enter the calibration number to be activated Press ENTER The active calibration number is now in the lower left hand portion of the screen. If an auto or manual zero or span is performed at this time, only the active calibration number is affected. Note: If digital inputs are assigned to select calibration numbers, the calibration number cannot be changed via the front panel keyboard. Attempting to do so results in the following screen being displayed:
Selection calib. In remote mode 1 Return
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E.2.2.
The number of Cal Sel inputs is equal to the number of calibration numbers. When an input is activated, the corresponding calibration number and associated zero, span, and Linearization table is also activated. In the event more than one input is activated, the first input active is used. When an auto zero or auto span is executed, the results are saved to the active calibration number. Once a calibration test has been initiated, changing the active calibration number via the digital inputs has no effect; the calibration factors, zero, or span is saved to the calibration number that was active at the beginning of the test.
E.2.3.
Linearization
In the Linearization scroll, the table of Linearization factors displayed is only for the active calibration number.
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CAL
Press START
CAL
Press START
=Time Remaining Counts Down to Zero = When Zero Upper Display Auto Zero Complete Complete Flashing 4.0 5.0 Press YES Press RUN Zero Calibration Complete
=Time Remaining Counts Down When Zero Upper Display Auto Span Complete Complete Flashing 4.0 5.0 Press YES Press RUN Span Calibration Complete
To calibrate the controller for the unit, refer to manual sections beginning with Section 2.5.
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F-2
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Appendix I Available Analog I/O and A/D Configuration Micro-Tech 3000 Series
N1 Out on Mother Board N1 Out on Current Out Board (Type A) N2 Out N2 In on Analog I/O Board (Type B) Mod.3101/3102/3104/3105/3107 Analog Out #3 #4
Out 1 2nd Board (Type B) Out Board (Type A) Out 3rd Board (Type A)
Analog In #1 #2
In 1 In 2 Board (Type B) In 1 In 2 Board (Type B)
#1
On Mother Board On Mother Board On Mother Board
#2
Out 1 Out 2 1st Board (Type B) Out 1 Out 2 Board (Type B) Out Out 1st Board (Type A) 2nd Board (Type A)
Mod.3100 #1
On Mother Board On Mother Board On Mother Board
#2
Analog Out #3
#4
Out 1 2nd Board (Type B) Out Board (Type A) Out 3rd Board (Type A)
Analog In #1
In 1 Board (Type B) In 1 Board (Type B)
Out 1 Out 2 1st Board (Type B) Out 1 Out 2 Board (Type B) Out Out 1st Board (Type A) 2nd Board (Type A)
Analog In #4 #1 #2
In 1 In 2 Board (Type B)
#2
Out 1 Board (Type B) Out Board (Type A)
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I.1.
A/D Third
The program reads in this sequence: First the A/D channel(s) on Slot 1 Second A/D channel(s) on Slot 2 Third A/D channel on Motherboard Fourth A/D channel(s) on Slot 3 NOTES: 1. YOU CANNOT INSERT 1 CHANNEL A/D BOARDS IF A 2 CHANNEL A/D BOARD IS PRESENT. 2. 1 CHANNEL A/D BOARDS CAN BE INSERTED INTO ANY SLOT 3. 2 CHANNEL A/D BOARD (S) MUST BE INSERTED ONLY IN SLOT 1 OR 2. Mod.3100 Mod.3102 A/D INPUT #2 #3
A/D In on Motherboard
#1
#4
In1 In1 A/D Board (1ch.) A/D Board (1ch.) Slot 1 Slot 2 In1 In2 First A/D Board (2Ch.) Slot 1 In1 In2 A/D Board (2Ch.) Slot 1 or 2
In1 A/D Board (1ch.) Slot 3 In1 In2 Second A/D Board (2Ch.) Slot 2 A/D In on Not Available Motherboard
I-2
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#2
A/D In on Motherboard In #1 if A/D Board in Slot 3 A/D In on Motherboard
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