INSTROTECH 6004BW Manuale utente
6004BW
Belt Weigher Transmitter
Introduction
Applications
!Loadcell Transmitter
!Loss-in-weight Transmitter
!Through-put Weigher
!Bag-filler
!Batchweigher
!Dynamometer
!Evolutions
!User-programmable function keys, digital inputs and relay outputs
!Precalibration of sensitivity and range, zero trim and deadweight span trim
!Lineariser 15-point, min/max hold, auto-zero maintenance, preset tare
!PI control with auto-manual setpoints, bumpless transfer, anti-reset windup
!Bootloader for remote internet firmware updates and program specials
!Outputs for isolated analog 1-5/0-10Volts or 0/4 - 20mA
!Power supply 90-260V switchmode or 10-30V isolated DC
!SD memory card for storing commissioning setup or data logging
!GPS, factory fit, for accurate position recording with on-board weighing
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!Belt Weigher
!Formats in serial ASCII
!Serial outputs, RS232 or RS485
!Clear 20mm 6-digit LED main display and auxiliary information LCD display
!Inputs from load cell/s, incremental encoder and 6 digital inputs
!Powerful ARM microprocessor with integral clock and USB I/O port
Options
!Output relays or photomos 2, 4 or 6, plug-and-play, programmable functions
!Programming from alphanumeric keypad using LCD prompts
Features
!Rugged, powder coated, cast aluminum housing with splashproof keypad
Welcome to the weighing electronics world of the Multi-Function Model 6004. Using the
latest ARM microprocessor technology we are able to offer a powerful, compact, field-
mount unit that you can select for a variety of weighing functions at a cost-effective price.
The main advantage to the user, servicing organisation or marketing company is having one
electronics unit that can be used for almost any application in the weighing industry.
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Contents
!Introduction Page 1
!Applications Page 1
!Features Page 1
!Options Page 1
!Throughout Weigher Page 5
!Dynamometer Page 5
!Bagfiller Page 5
!Batchweigher Page 5
!Safety Page 6
!Cleaning Page 6
!Guarantee Page 6
!Installation Page 7
!Overall dimensions Page 7
!Mounting Holes Page 7
!Wiring Links Page 8
!Wiring Connections Page 9
!Display and Controls Page 10
!Getting Start Page 11
!Contents Page 2
!Run Throughput Weigher Page
!Run Dynamometer Page
!Run Bag Filler Page
!Run Batchweigher Page
!Application Menus
!Run Loadcell Transmitter Page
!Run Beltweigher Page 12
!Run Loss-in-Weight Page
!Service Menu
!Setpoint Values Page 14
!Setpoint Configuration Page 16
!Analog Output Page 18
!Description of Units Available Page 4
!Loadcell Transmitter Page 4
!Belt Weigher Page 4
!Loss-in-Weight Transmitter Page 4
Contents
Page 3
!Correction Factor Page 56
!Function Keys Page 44
!Digital Inputs Page 46
!Display Page 48
!Span Trim Page 38
!Lineariser Page 40
!Simulate Page 42
!Security Level Page 32
!Precalibrate Page 34
!Zero Trim Page 36
!Tare Page 26
!Auto Zero Page 28
!Preset Tare Page 30
!Communication Page 20
!Max/Min Page 22
!Net/Gross Page 25
!Service Menu (continued)
!PI Control Page 50
!Transmitter Settings Page 52
!Beltweigher Settings Page 54
Description of the units available
A loadcell transmitter is used to convert loadcell outputs into a standard instrumentation
analog signal such as 4-20mA or 0-10volts, it will also supply power to excite one or more
loadcells. The 6004MF has many additional features such as displays for mass and
programming, digital communications for direct connection to control computers and alarms.
Our weighing electronics has always incorporated a precalibrate, zero trim and span trim
feature. This is a simple way to set up a strain-gauge loadcell system. All the variables, such
as sensitivity and range, are inserted in the precalibrate section so that the system is
reasonably accurate before adding test weights. The weighing system is then zero trimmed
(backbalanced) to offset the dead weight of weighbin, weighframe or weighbridge deck. With
known test weights the system can be span trimmed to get higher accuracy. In some
instances, such as very large weightanks where it is not possible to use test weights,
precalibration using factory test certificates for loadcell sensitivity results in an acceptable
overall system accuracy.
The ARM processor used incorporates a USB port and a real time clock with day/date. We
have made full use of these facilities and added an optional, factory fitted, global positioning
system (GPS) to cater for such applications as on-board truck weighing, positioning and data
logging. In refuse removal some countries are introducing legistration for customers to pay
by weight for this service. Farmers are starting to monitor crop production and fertiliser
distribution by location to improve farming efficiency. Logging contractors need to load for
maximum profit without incurring overweight fines.
Loadcell transmitter
Loss-in-weight is becoming a popular form of mass flow measurement or control as it
requires few moving or wearing parts. Measure a weighbin over time and you can can get a
material flow rate either emptying or filling. Although we sample the averaged weight every
second you can select the measurement comparison period from 10 to 480 seconds. A short
period is ideal for small bins and extended time for larger weighbins. The system can be
selected to run for one weighbin cycle then stop or can be set to hold the rate display and
output whilst it refills the weighbin. Totalisers and selectable PI control are also standard
features.
Loss-in-Weight Transmitter
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Belt Weigher
The belt weigher measures the weight of material on a conveyor belt and it's speed, from this
a mass flow is calculated in kg/min or tonnes/hr. The 6004BW allows you to set or measure a
belt speed, and, if measure, to set the pulley diameter, encoder pulses/rev and also to enter
the weighsection length. With this information and the precalibrate feature described above
the material flow rate will be calculated and displayed. Zero trim is selectable for length &
number of revolutions or time, and, if some form of check weighing is available, a rate
correction factor can be inserted. All rates have a main totaliser as well as a resettable
totaliser. The totaliser can be set for remote display through one of the setpoint outputs using
an optional photomos solid state relay which is ideal for this purpose. The PI control
selection used with a variable speed drive can convert the belt weigher into a flow controller.
Description of the units available
A throughput weigher makes use of a small weighbin to weigh and dump batches in quick
succession typically used in bulk handling of cereals. The flexibility of the 6004MF allows you
to set high and low levels of the weighbin and various time delays in order to tune the
throughput weigher for maximum efficiency. The main LED display can be the resettable
totaliser and a non-reset totaliser can be on the auxilliary LCD display
Throughput Weigher
The dynamometer application measures power of engines, electric motors or hydraulic
motors in conjunction with some form of braking. It makes use of the loadcell input to
measure torque normally in conjunction with a lever arm and the encoder input to measure
revolutions per minute (RPM). The loadcell can be precalibrated and the lever arm length
entered. For various shaft encoders the impulses per revolution can also be set. The
6004MF will then display kW (or horsepower), RPM and Torque. The Main LED display is
push-button selectable, kW, RPM or Torque and the aux LCD can show all three.
Dynamometer
Batchweighers are typically used for control of industrial concrete mixers but can also control
just about anything that requires a repetitive recipe mix. The freely programmable inputs,
function keys, displays and outputs results in a batchweighing system with tremendous
flexibility. The setup allows for a maximum of five ingredients. Each can be named (Sand,
Cement, etc), be a mass or count (say, from a water meter), have an interlock and time
delay. In the setpoint values section up to four recipes (A,B,C or D) can be set. With these
selections just about any batching system can be customised, even on site if need be.
Batchweigher
This application provides the control for bagfilling machines as used for measuring precise
weights of cement or flour, etc. It has setpoints for fast and slow fill, inputs for interlock and
footswitch and outputs for filling, vibrating and bag clamps. The settle, vibrate and waiting
times are adjustable to optimise the filling. In-flight correction is standard which will correct
any weighing error over a preset number of bags. Total can be bags filled or totalised weight
or both
Bagfiller
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Do not clean the instrument while the instrument is on. Harsh abrasives, solvents, scouring
cleaners and alkaline cleaning solutions, such as washing soda, should not be used
especially on the display window. The outside of the instrument may be wiped down with a
slightly damp clean cloth (lightly moistened with water only).
Under no circumstances should you attempt to wipe the inside of the instrument.
The manufacturer undertakes to replace without charge all defective equipment which is
returned to it (transportation costs prepaid) during the period of guarantee, provided there is
no evidence that the equipment has been abused or mishandled in any way.
The manufacturer reserves the right to alter any specification without notice.
Safety
Cleaning
Guarantee
This equipment is supplied by a mains voltage which can cause an electric shock injury.
Before removing the cover from the housing, switch the instrument off, isolate it from the
mains power supply and make sure that it cannot be connected inadvertently by other
persons.
If the cover is removed from the housing, do not apply power to the instrument unless
specifically instructed to do so in these instructions. When working on live equipment,
exercise great care, use insulated tools and test equipment, and do not work alone.
When handling circuit boards, ensure that full anti-static precautions are observed.
Replace mains fuse with one of an equivalent type or rating.
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This product is guaranteed against faulty workmanship or defective material, for a period of 2
(two) years from date of delivery.
Installation
Installation
Mounting holes
Overall dimensions
- The housing trim covers need to be removed to gain access to the mounting holes.
220 mm
130 mm
- Not to scale.
- Height of 130mm excludes cable glands
- Depth is 70 mm
Hole diameter 6 mm
Cable gland hole dimensions: 8mm diameter
202 mm
80 mm
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LOADCELL WIRING
The straingauge loadcell is basically a four-wire device. For short distances or lower accuracy
requirements the remote sense leads are not essential. However the sense and excitation must
be linked (S+ to Ex+ and S- to Ex-) at some point or there will be no control of the excitation
voltage and it will go to maximum. You can use the links J1 & J2. For better accuracy on a
four-wire connection cut J1 & J2 then put in links on the field side of the plug-in terminals.
For long distances, higher accuracies or using Intrinsically safe (Is) barriers use a six-wire
connection with the sense leads to the loadcell/s. These sense leads measure the excitation
voltage at the loadcell (or field junction box) and compensate for any lead or barrier volt drops.
Cut J1 & J2. No links on terminals.
For multiple loadcell systems join all loadcells in parallel. Make sure that the loadcells are
impedance matched and have the same sensitivity (mV/V). Use a field junction box to save
wiring and facilitate terminal connections.
EXCITATION VOLTAGE
10 Volts for up to 4 x 350Ω loadcells (factory default)
10 Volts for up to 8 x 1000Ω loadcells
5 Volts for up to 8 x 350Ω loadcells
5 Volts for Is (barriered) applications up to 2 x 350Ω loadcell
3.5Volts for Is (barriered) applications up to 4 x 350Ω loadcells
LINKS
Power off, change links, power on.
Programmable excitation voltage links J7 & J10 then set in Precalibrate menu.
Fixed excitation voltages link J9 = 3.5 Volts, J8 = 5 Volts, J7+J10 = 10 Volts.
Link J27 connects ground plane to earth. Normally off.
Link J5 is for encoder NPN or PNP selection.
Link J2 on top circuit board is a hardlock for programming.
HARDWARE OPTIONS
Power off, fit option, check alignment with standoff pillor, power on, activate option in Transmitter
Settings, Hardware Fitted.
Plug-in relays or photomos. Use R6 (photomos) for totaliser output.
Plug-in coms options on top circuit board. RS232, RS485, USB, Ethernet, RF.
Factory fit options Global Positioning System (GPS) and SD data card.
POWER SUPPLY
Power supply is factory supplied 90-260V AC/DC or 10-30VDC. These modules are not easily
field replaceable as they have to be soldered in.
Note: For critical applications or electrically noisy environments (heavy switch gear or large
variables speed drives) ensure the power supply to the instruments is clean and stable, you may
need to fit an external uninterruptible power supply (UPS).
Wiring and Links
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RELAY
2
RELAY
1
RELAY
3
RELAY
4
Wiring connections, jumpers and fuse replacement
Wiring Connections
J3J3
J7J7
J9J9
J8J8
J10J10
J4J4
J11
J12
+ SENSE
+ EXC
+ mV
- mV
- EXC
- SENSE
LOADCELL
J27J27
EARTHEARTH
GNDGND
DI 1DI 1
GNDGND
DI 2DI 2
DIGITAL INPUSDIGITAL INPUS
DI 3DI 3
DI 4DI 4
DI 5DI 5
DI 6DI 6
J5J5
V+V+
IGNDIGND
CURRENTCURRENT
ENCODERENCODER
IGNDIGND
VOLTSVOLTS
ENCODERENCODER
ANALOG OUTANALOG OUT
FUSEFUSE
REPLACE FUSE WITH
THE SAME RATING
REPLACE FUSE WITH
THE SAME RATING
NPN
PNP
NPN
PNP
6004MAIN-A
AC
VDC+
AC
VDC+
AC
VDC-
AC
VDC-
EARTHEARTH
AC SWITCHMODE
OR
DC SUPPLY
AC SWITCHMODE
OR
DC SUPPLY
NO
NC
COM
NO
NC
COM
NO
NC
COM
NO
NC
COM
NO
NC
COM
NO
NC
COM
RELAY
6
RELAY
5
Screen
Digital
Inputs
V out
RL
I out
+
+
-
-
+
SIG
GND
Power Supply
SUPPLY
PHOTOMOS
(NO Only)
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