Alfalaval 5024 User manual

Instruction manual for 5024 Weighing Terminal
Basic system with automatic dosing
Original manual
Software: STDLIM.140630.2v3
ESE02162EN8
Date of issue: November 2019
First published: November 2011

Instruction Manual, 5024 Weighing Terminal Page 1
IM-TE91K012-EN8
1) Contents
1) Contents.........................................................................................................................................................1
2) Operation........................................................................................................................................................4
2.1 Introduction...............................................................................................................................................4
2.2 Power-up sequence..................................................................................................................................4
2.2.1 Zeroing during power up....................................................................................................................4
2.3 Operator panel..........................................................................................................................................4
2.4 Keyboard lock...........................................................................................................................................4
2.5 Menus.......................................................................................................................................................5
2.6 Screens overview......................................................................................................................................5
2.7 Data entry .................................................................................................................................................5
2.7.1 Locking and unlocking parameters ....................................................................................................6
2.7.2 Entry using selection list.....................................................................................................................6
2.7.3 Entry of numbers................................................................................................................................7
3) Screens ........................................................................................................................................................10
3.1 Normal display........................................................................................................................................10
3.2 Dosing.....................................................................................................................................................11
3.2.1 Setting Coarse and Fine limits.........................................................................................................12
3.2.2 Start/Stop of dosing..........................................................................................................................12
3.3 Totals ......................................................................................................................................................12
3.3.1 Totals menu......................................................................................................................................13
3.4 System Information.................................................................................................................................13
3.5 System settings.......................................................................................................................................14
3.6 Loadcell status........................................................................................................................................14
3.7 Service mode..........................................................................................................................................15
3.7.1 Setting date and time.......................................................................................................................15
3.8 System....................................................................................................................................................16
3.9 Weighing.................................................................................................................................................17
3.9.1 Weighing range modes....................................................................................................................17
3.9.2 Configuring weighing ranges............................................................................................................17
3.10 Loadcell parameters .............................................................................................................................18
3.10.1 Loadcell type..................................................................................................................................18
3.10.2 Number of loadcells .......................................................................................................................18
3.10.3 Number of supports........................................................................................................................18
3.11 Coarsetare............................................................................................................................................19
3.11.1 Performing coarsetare....................................................................................................................19
3.12 Zeroing..................................................................................................................................................20
3.13 Calibration.............................................................................................................................................20
3.13.1 Calibration factor............................................................................................................................21
3.13.2 Calibration load ..............................................................................................................................21
3.13.3 Perform calibration.........................................................................................................................21
3.13.4 Corner calibration...........................................................................................................................22
3.13.5 Corner calibration factor.................................................................................................................22
3.13.6 Reset corner calibration factors .....................................................................................................22
3.13.7 Corner calibration procedure..........................................................................................................23
3.14 Linearization..........................................................................................................................................24
3.14.1 Load points.....................................................................................................................................25
3.14.2 Up/Down corrections......................................................................................................................25
3.14.3 Hysteresis limit...............................................................................................................................25
3.14.4 Reset linearization..........................................................................................................................25
3.15 Weight display.......................................................................................................................................25
3.15.1 Interval............................................................................................................................................26
3.15.2 Filters..............................................................................................................................................26
3.15.3 Steady/stability detection ...............................................................................................................26
3.16 Analog output........................................................................................................................................26
3.16.1 Output type.....................................................................................................................................27
3.16.2 Output value...................................................................................................................................27
3.16.3 Full-scale value ..............................................................................................................................27
3.16.4 Error output value...........................................................................................................................27

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3.16.5 Test output .....................................................................................................................................27
3.17 Analog adjustment................................................................................................................................28
3.17.1 Analog Gain parameter..................................................................................................................28
3.17.2 Analog Offset parameter................................................................................................................28
3.17.3 Analog trim procedure....................................................................................................................29
3.18 Dosing parameters................................................................................................................................30
3.18.1 Registration period.........................................................................................................................30
3.18.2 Afterflow status...............................................................................................................................30
3.18.3 Afterflow correction ........................................................................................................................31
3.19 Ethernet ................................................................................................................................................31
3.20 External module....................................................................................................................................31
4) Ethernet communication...............................................................................................................................32
4.1 Ethernet specification..............................................................................................................................32
4.1.1 Registration or display......................................................................................................................32
4.2 Ethernet ..................................................................................................................................................33
4.2.1 Ethernet settings ..............................................................................................................................33
4.3 Ethernet Protocols ..................................................................................................................................33
4.3.1 Ethernet protocol settings ................................................................................................................34
5) External modules..........................................................................................................................................35
5.1 Introduction.............................................................................................................................................35
5.2 External module......................................................................................................................................35
5.3 External module data..............................................................................................................................36
5.4 External communication using PPO.......................................................................................................37
5.5 MOD........................................................................................................................................................38
5.5.1 MDS .................................................................................................................................................38
5.6 PCV Description......................................................................................................................................38
5.6.1 PCA..................................................................................................................................................38
5.6.2 PNU..................................................................................................................................................39
5.6.3 PVA..................................................................................................................................................39
5.7 PCD Description .....................................................................................................................................39
5.7.1 CTW/STW........................................................................................................................................40
5.7.2 MRV/MAV.........................................................................................................................................40
5.8 Communication overview........................................................................................................................40
5.9 RS –Reference Value Selector, MRV – Main Reference value .............................................................40
5.10 AS –Actual Value Selector, MAV – Main Actual value.........................................................................40
5.11 CTW –Control Word..............................................................................................................................41
5.12 STW –Status Word...............................................................................................................................41
5.13 Parameters ...........................................................................................................................................42
5.14 Optional Battery Backup.......................................................................................................................43
6) Hardware description ...................................................................................................................................45
6.1 Rear view................................................................................................................................................45
6.2 Connection of power...............................................................................................................................45
6.3 Loadcell connection................................................................................................................................46
6.4 Digital I/O connector ...............................................................................................................................46
6.5 RS485 communication connector (external modules)............................................................................47
6.6 Analog output connector.........................................................................................................................47
6.7 Ethernet connector..................................................................................................................................47
6.8 Jumper settings.......................................................................................................................................48
6.9 Light Emitting Diodes (LEDs)..................................................................................................................48
6.10 MCE2035 Profibus-DP module.............................................................................................................49
6.10.1 MCE2035 Profibus-DP specification..............................................................................................49
6.10.2 MCE2035 Checklist during installation ..........................................................................................49
6.10.3 MCE2035 Connection....................................................................................................................49
6.10.4 MCE2035 DIP-switch settings........................................................................................................50
6.10.5 MCE2035 Jumpers ........................................................................................................................50
6.10.6 MCE2035 Light Emitting Diodes....................................................................................................51
6.10.7 MCE2035 PROFIBUS-DP connector.............................................................................................51
6.11 2070 PROFINET module......................................................................................................................51
6.11.1 2070 Checklist during installation...................................................................................................52
6.11.2 2070 Connection without MCE9601 ..............................................................................................52
6.11.3 2070 Connection with MCE9601....................................................................................................52
6.11.4 2070 DIP-switch settings................................................................................................................53

Instruction Manual, 5024 Weighing Terminal Page 3
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6.11.5 2070 Jumper settings.....................................................................................................................54
6.11.6 2070 Light Emitting Diodes............................................................................................................55
6.11.7 2070 PROFINET connector...........................................................................................................56
6.12 MCE9637 DeviceNet module ...............................................................................................................57
6.12.1 MCE9637 DeviceNet specification.................................................................................................57
6.12.2 MCE9637 Checklist during installation ..........................................................................................57
6.12.3 MCE9637 Connection....................................................................................................................57
6.12.4 MCE9637 DIP-switch settings........................................................................................................58
6.12.5 MCE9637 Jumpers ........................................................................................................................59
6.12.6 MCE9637 Light Emitting Diodes....................................................................................................59
6.12.7 MCE9637 DeviceNet connector.....................................................................................................60
6.13 2x50 Ethernet-IP module......................................................................................................................61
6.13.1 2x50 Ethernet-IP specification .......................................................................................................61
6.13.2 2x50 Checklist during installation...................................................................................................61
6.13.3 2x50 Connection without MCE9601...............................................................................................61
6.13.4 2x50 Connection with MCE9601....................................................................................................62
6.13.5 2x50 DIP-switch settings................................................................................................................63
6.13.6 2x50 Light Emitting Diodes ............................................................................................................63
6.13.7 2x50 RS232 connector (J4) ...........................................................................................................65
6.13.8 2x50 Ethernet connector (J8).........................................................................................................65
7) Appendices...................................................................................................................................................66
7.1 Appendix A: 5024 Installation checklist ..................................................................................................66
7.2 Appendix B: Filters..................................................................................................................................67
7.2.1 Sampling filter...................................................................................................................................67
7.2.2 Display and steady filters.................................................................................................................68
7.3 Appendix C – 2x50 Setup with Terminal Interface .................................................................................70
7.3.1 IP Address setting............................................................................................................................70
7.4 Appendix D – 2x50 Ethernet-IP connection to Allen Bradley.................................................................72
7.4.1 Ethernet-IP communication – Master input......................................................................................72
7.4.2 Ethernet-IP communication – Master output....................................................................................72
7.5 Appendix E – 2070 Tips for PROFINET Configuration...........................................................................73
7.5.1 MAC addresses................................................................................................................................73
7.5.2 GSDML file.......................................................................................................................................73
7.5.3 Factory settings................................................................................................................................73
7.5.4 Setting DeviceName, IP Address etc...............................................................................................73
7.5.5 Data sizes.........................................................................................................................................73
8) How to contact Alfa Laval Kolding A/S.........................................................................................................74
9) EC Declaration of Conformity.......................................................................................................................75

Page 4 Instruction Manual, 5024 Weighing Terminal
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2) Operation
2.1 Introduction
This document is an overview of the 5024 Weighing Terminal from Alfa Laval Kolding A/S. With the
software version stated on the front page the system has automatic dosing (coarse/fine), an Analog
output and Ethernet connection as well as possible Profibus-DP, PROFINET, DeviceNet or Ethernet-
IP connectivity using external communication modules.
The system is operated by a series of screens, menus and selections lists.
2.2 Power-up sequence
When power is applied to the system, the following steps will be performed:
The display will show the logo for 5 seconds.
The display will show its program identification (software name, date and revision).
The weighing terminal is ready and enters the NORMAL screen.
2.2.1 Zeroing during power up
If a zeroing is to be performed during power up (with extended zeroing range), must be pressed
while the program identification (software name, date and revision) is shown. Pressing before
this is ignored. If the keyboard lock is activated (see later), you will immediately be asked to unlock
the keyboard for the zero to take place.
2.3 Operator panel
The operator panel holds a keyboard and a LCD display. The display will show the actual state of
the controller and the user entries possible. Below the display seven keys are located. The function
of these keys depends on the actual screen selected. The function of the key will always be shown
directly above the key. Normally the keys are used to switch between the different screens or to
initiate other user actions. Depending on the actual screen the following keys can be used:
Selects a menu depending on the actual screen.
Increases a value or moves cursor up in a menu.
Decreases a value or moves cursor down in a menu.
Selects entry or accept of a value, or selects an action from a menu.
Return to previous screen. Exits menu without action. Clears entered digit.
Autotare scale (set net weight to zero).
Zero scale (set gross weight to zero).
The functions stated above are the general function of the keys. Below the specific use of each key
will be described depending on the actual screen.
2.4 Keyboard lock
The weighing terminal is equipped with a keyboard lock feature. This feature can be enabled or
disabled using the “Keyboard unlock length” parameter in the SYSTEM screen. This parameter also
indicates how many keys are to be pressed to unlock the normal functions of the keyboard.
If the keyboard lock is disabled, then the keyboard functions will always be active.
If the keyboard lock is enabled, and the weighing terminal is in the NORMAL screen without any key
activation for 10 minutes, then the keyboard will automatically lock. When the keyboard is locked,
the symbols normally shown above the keys will blank out, and you canNOT use the normal function
on the keys until the keyboard is unlocked again. NOTE: A locked keyboard is unlocked by pressing
>0<
>0<
F
Print
Clr
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>0<

Instruction Manual, 5024 Weighing Terminal Page 5
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a key, and then pressing a number of keys one at a time matching the indicated keys until the re-
quired sequence is completed without error.
2.5 Menus
Menus are selected by pressing . When a menu is active the current item is changed by and
, and the item action is selected by pressing . The menu can be exited without any action by
pressing or by selecting the “Exit menu” menu item. Above each key is an icon illustrating the
actual function for the key in the different screens.
2.6 Screens overview
The system has the following screens, which are selected using the menu system:
NORMAL ─┬─ TOTALS
│
├─ DOSING
│
├─ SYSTEM INFO ─┬── SYSTEM SETTINGS
││
│└── LOADCELLS
│
└─ SERVICE MODE ─┬─ SYSTEM
│
├─ WEIGHING ──────┬── LOADCELLS
││
│├── COARSETARE
││
│├── ZEROING
││
│├── CALIBRATION ── CORNER CAL.
││
│├── LINEARIZATION
││
│├── DISPLAY
││
│└── ANALOG – ANALOG ADJUST
│
├─ DOSING PAR.
│
├─ ETHERNET ───────── PROTOCOLS
│
└─ EXTERNAL MODULES ── DATA
During normal use it is only necessary to use the NORMAL and the DOSING screen. The other
screens are used during installation and calibration.
2.7 Data entry
The following chapter describes how data are entered using the keyboard on the weighing terminal.
There are two main ways to enter data from the keyboard. Data can be entered by selecting the
desired value from a selection list of predetermined values. Data can also be entered by entering
the desired value using a data entry screen. The layout of this data entry screen may vary depending
on the actual parameter to be entered.
F
Clr

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2.7.1 Locking and unlocking parameters
When the power is turned on all parameters changing the event counter are locked. These parame-
ters can be unlocked in the SYSTEM screen.
2.7.2 Entry using selection list
Some parameters (such as resolution and decimal point position of the weighing range) are entered
using a selection list. When change of this type of parameter is requested, a special pull-down menu
will appear with a list of predetermined (allowed) values as shown:
The keys can be used as follows:
Moves the cursor down in this selection list.
Moves the cursor up in this selection list.
Moves the cursor down in this selection list.
Accepts the selected/marked value as the new desired value.
Aborts the entry without change of parameter. This can also be done by se-
lecting the “CANCEL” entry form the selection list.
Not used.
Not used.
Example - Changing resolution from 0.050 to 0.010:
The screen shown above appears once change of resolution is requested from the SETUP WEIGH-
ING screen by moving the cursor using and so the “Resolution” parameter is selected and then
pressing . In order to change the “Resolution” parameter to 0.010 perform the following:
or Press repeatedly until ”0.010” is selected in the selection list.
Press to accept selection.
F
Print
Clr
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>0<

Instruction Manual, 5024 Weighing Terminal Page 7
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2.7.3 Entry of numbers
Some parameters (such as minimum and maximum weight of the weighing range) are entered using
a data entry screen. When change of this type of parameter is requested, a data entry screen will
appear. Please note the layout of the data entry screen may vary slightly depending on the actual
parameter to be changed. The data entry screen could look as shown:
The actual parameter changed is indicated in the upper left part of the display. The current parameter
value and the currently entered value is shown in the upper right part of the display. The currently
entered value is also shown in the middle of the display in large font.
The keys can be used as follows:
Aborts the entry without change of parameter.
Increases the value of the digit currently being entered (digit to the right).
Decreases the value of the digit currently being entered (digit to the right).
Accepts the entered value as the new desired value.
Deletes most right digit and moves all remaining digits one position to the
right.
Moves digits one position to the left and inserts a zero on the most right po-
sition. This new digit can subsequently be changed using and .
Clears all entered digits setting them to zero as if the data entry screen has
just been entered.
When entering a value the digits are entered left to right. This means that leftmost digit is entered
first. The active digit is changed by and . When the correct value is entered press to advance
to the next digit. If an error is made, press to return to the previous digit. When the complete
value is entered press to accept it. To abort without any changes press .
F
Clr
T
>0<
T
Clr
F

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Example - Changing maximum weight from 10.000 to 10.090:
The screen shown above appears once change of maximum weight is requested from the SETUP
WEIGHING screen by moving the cursor using and so the “Maximum” weight parameter is
selected and then pressing .
In order to change the “Maximum” weight parameter to 10.090 perform the following:
Press once until ” . 1” is shown in the display.
Press three times until ” 1.000” is shown in the display.
Press once until ” 1.009” is shown in the display.
Press once until ” 10.090” is shown in the display.
Press to accept ” 10.090” as the new desired value.
Example - Changing minimum weight from -1.000 to -0.090:
A similar screen to the screen shown above appears once change of minimum weight is requested
from the SETUP WEIGHING screen by moving the cursor using and so the “Minimum” weight
parameter is selected and then pressing .
In order to change the “Minimum” weight parameter to -0.090 perform the following:
Press once until ”- . 9” is shown in the display.
Press once until ”- . 90” is shown in the display.
Press to accept ”- 0.090” as the new desired value.
Example - Changing date to 11.06.01:
A similar screen to the screen shown above appears once change of date (YY.MM.DD) is requested
from the SETUP MENU by moving the cursor using and so the “SET DATE” entry is selected
and then pressing . The layout of the data entry screen is a bit different as date is entered with
two decimal points.
In order to change the date (YY.MM.DD) to 11.06.01 perform the following:
Press once until ” . .10” is shown in the display.
Press once until ” . .11” is shown in the display.
Press two times until ” .11.01” is shown in the display.
Press four times until ” .11.06” is shown in the display.
Press two times until ”11.06.01” is shown in the display.
Press to accept ”11.06.01” as the new desired value.
Example - Changing time to 23:45:00:
A similar screen to the screen shown above appears once change of time (HH:MM:SS) is requested
from the SETUP MENU by moving the cursor using and so the “SET TIME” entry is selected
and then pressing . The layout of the data entry screen is a bit different as time is entered with
two colons.
In order to change the time (HH:MM:SS) to 23:45:00 perform the following:
Press two times until ” : : 2” is shown in the display.
Press once until ” : :20” is shown in the display.
Press three times until ” : :23” is shown in the display.
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