FMS BMGZ 610A User manual

Operating Manual BMGZ
610A / 611A / 620A
Digital Microprocessor Controlled Belt Scale
Version 1.20 03/2011 pw / ff
Firmware Version: 3.03
Hardware Rev. D / GDS 1.03
This operation manual is also available in German
Please contact your local FMS representative.
Diese Bedienungsanleitung ist auch in Deutsch erhältlich.
Bitte kontaktieren Sie Ihren nächstgelegenen FMS Vertreter.
© by FMS Force Measuring Systems AG, CH-8154 Oberglatt – All rights reserved.

Operating manual BMGZ 600A
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1 Safety Instructions
1.1 Description Conditions
a) High danger of health injury or loss of life
Danger
This symbol refers to high risk for persons to get health injury or loss life. It has
to be followed strictly.
b) Risk of damage of machines
Caution
This symbol refers to information, that, if ignored, could cause heavy
mechanical damage. This warning has to be followed absolutely.
c) Note for proper function
Note
This symbol refers to an important information about proper use. If not followed,
malfunction can be the result.
1.2 List of Safety Instructions
Proper function of the FMS belt scale is only guaranteed with the
recommended application of the components. In case of other
arrangement, heavy malfunction can be the result. Therefore, the
installation instructions on the following pages must be followed strictly.
Local installation regulations are to preserve safety of electric equipment.
They are not taken into consideration by this operating manual. However,
they have to be followed strictly.
Bad earth connection may cause electric shock to persons, malfunction of
the total system or damage of the control unit! It is vital to ensure that
proper earth connection is done.
Some contacts on the terminal board of the 230VAC version are under
230V tension! Mortal danger! Disconnect power supply before open the
housing!

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Table of contents
1 Safety Instructions .................................................................................. 2
1.1 Description Conditions 2
1.2 List of Safety Instructions 2
2 Definitions ............................................................................................... 5
3 System Components ............................................................................... 5
4 System Description ................................................................................. 7
4.1 Functional Description 7
4.2 Measuring Roller 7
4.3 Evaluation Electronic Unit 7
4.4 External Displays 8
4.5 Block Diagram 8
5 Dimensions ............................................................................................. 9
6 Installation and Wiring ......................................................................... 12
6.1 Determination of Mounting Place of the Measuring Roller 12
6.2 Mounting the Measuring Roller 14
6.3 Mounting the Electronic Unit 17
6.4 Mounting the BMGZxxA.S 17
6.5 Wiring of the Connection Cable 19
6.6 Wiring Information 20
6.7 Wiring of Main Supply 22
6.8 Wiring Diagram External Displays 22
6.9 Wiring of the Additional Digital Inputs and Outputs 23
7 Operation............................................................................................... 25
7.1 View of the Operating Panel 25
7.2 State Diagram of Main Operating Menu 25
7.3 Setting the Installation-specific Parameters 26
7.4 Tare Program (Zero Alignment) 27
7.5 Calibration 27
7.6 Weighing a Charge Manually 28
7.7 Weighing a Charge Automatically (only BMGZ611A) 28
7.8 Operating the Printer (optional) 29
8 Serial Interface RS232 ......................................................................... 30
8.1 RS232 Interface Commands for BMGZ600 Series 30
9 Parametrization .................................................................................... 31
9.1 Parameter List System 31
9.2 Parameter List Roller 1/22) 31
9.3 State Diagram Parameter Setting 32
9.4 Description of the Parameters 33
9.5 Service Mode 1 37
9.6 Service Mode 2 38
10 PROFIBUS Interface .............................................................................. 39

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10.1 Wiring of the PROFIBUS Data Cable 39
10.2 Setting the PROFIBUS Address 40
11 PROFIBUS Interface Description .......................................................... 41
11.1 GSD File 41
11.2 BMGZ610A/611A/620A DP Slave Functional Description 41
11.3 Initial Parameters 41
11.4 Configuration 42
11.5 Function Code 42
12 Trouble Shooting ................................................................................... 43
12.1 Position of the Fuses 43
13 List of Spare Parts ................................................................................ 44
13.1 Assembly Drawing Flat Measuring Roller 44
13.2 Assembly Drawing Troughed Measuring Roller 46
13.3 Part List 47
14 Technical Data ...................................................................................... 48

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2 Definitions
Measuring uncertainty: Each measuring device has some inaccuracy, but
however, inaccuracy is in a small, defined range of tolerance. This deviation of the
measuring value referring to the effective value is called measuring uncertainty.
Measuring accuracy: Its behaviour is the contrary to the measuring uncertainty:
Increases the uncertainty, decreases the accuracy, and also in reverse mode.
Force measuring bearing: Measuring device using strain gauges, which converts
the load of the measuring roller into electric signals.
Proxy switch: Inductive distance sensor which is used for gearless and contact-
less switching
3 System Components
The Belt scale for bulk conveyors BMGZ600A consists of the following components
(refer also to fig. 1):
Measuring roller
 For acquisition of roll load and belt speed
 Flat or troughed measuring roller
 Simple mounting also to existing systems thanks to the all-purpose mounting
elements
 All parts are fully zinc galvanized
Evaluation electronic unit
 For excitation of the sensors and amplifying of the measuring signal
 With operation panel for parametrization
 It is possible to connect external displays
 Interface RS232
 Interface PROFI-BUS®
 Some different housings available
 For 1 measuring roller (BMGZ610A/611A) or 2 measuring rollers (BMGZ620A)
 Additional digital inputs and outputs for extended functions such as
proportioning belt weighers, etc. (BMGZ611A)
External display
 Telecounter to show the charge value
 Analogue display to show the actual flow rate
External printer
 For printing of charge values or daily output
 driven by RS232 interface

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(components in italic letters are option)

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4 System Description
fig. 1: Basic structure of the belt scale BMGZ600A B620001e
4.1 Functional Description
The belt scale for bulk conveyors works according to the principle:
Flow rate = weight * speed
The measuring roller measures the load on the belt and the belt speed. This
information are transmitted to the electronic unit, which calculates actual flow
rate, charge weight and daily output. Using a printer, the raised quantity can be
printed to a charge protocol at any time.
4.2 Measuring Roller
The measuring roller is mounted between 2 support rollers under the belt. The
measuring roller whose shape corresponds to the shape of the belt is supported
on both sides on FMS force measuring bearings. The measuring bearings take up
the force directly at its origin and do not show any sensitivity to belt direction.
Therefore, no force decoupling gear is necessary.
The measurement of belt speed is achieved by means of a pulse generator which
is integrated in one of the force measuring bearings.
The maintenance-free, robust and compact design provides high reliability and
durability.
4.3 Evaluation Electronic Unit
The evaluation electronic unit contains a micro-processor to handle all
calculations and communications, the highly accurate sensor power supply and
the signal amplifier for the measuring value. As operation interface it provides 6
keys and a 2x16 characters display in the front of the electronic unit. All inputs are
saved in an EEPROM. The evaluation electronic unit has no jumpers or trimmers to
keep most accurate long-time and temperature stability.

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The versions BMGZ610A/611A provide evaluation of 1 measuring roller; version
BMGZ620A provide evaluation of 2 measuring rollers. Versions BMGZ611A
provide additional digital inputs and outputs which can be used for extended
control functions such as proportioning belt scales, etc.
All versions support an RS232 interface. For ex. a master computer (PC) or an
external printer may be connected to the RS232 interface. As options, an
additional board with PROFI-BUS® interface and a printer are available.
4.4 External Displays
Analogue displays can be connected to the analogue outputs to show the actual
flow rate. Telecounters can be connected to the digital pulse outputs (relays) to
show the charge value.
4.5 Block Diagram
fig. 2: Block diagram of belt scale BMGZ611A B611004e
The block diagram above shows the function of the belt scale BMGZ611A. The
BMGZ610A has no outputs Min. limit 1, Max. limit 1, Pre detect charge 2 and Ref.
charge 2, and has no inputs and as charge activ 1.
The belt scale BMGZ620A is designed according to the same principle, but all
components are doubled to evaluate 2 measuring rollers.

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5 Dimensions
fig. 3: Dimensions of flat measuring roller B600014e
fig. 4: Dimensions of troughed measuring roller B600015e
belt
width
type L E E1 H1 H2
flat measuring
roller:
400 BMGZ 021.020...
1)
400 620...970 580 150
500 BMGZ 021.030... 500 720...1070 680 150
650 BMGZ 021.040... 650 870...1220 830 150
800 BMGZ 021.050... 800 1020...1370 980 150
1000 BMGZ 021.060... 1000 1220...1570 1180 150
troughed
measuring roller:
500 BMGZ 041.02....
1)
200 640...990 600 180 232
650 BMGZ 041.03.... 250 740...1090 700 180 250
800 BMGZ 041.04.... 315 850...1200 810 180 250
1000 BMGZ 041.05.... 380 1065...1415 1025 240 352
1200 BMGZ 041.06.... 465 1200...1550 1160 240 352
1) suffix for measuring bearing dimension will be determined basing on the
application data.
(other versions on request.)

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fig. 5: Dimensions of mounting brackets for measuring rollers B600016e
fig. 6a: Dimensions of the electronic unit (housing „W“). B600006e

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fig. 6b: dimensions of the electronic housing (panel mounting BMGZxxA.S)
B600033e
Housing variant description
BMGZ6xxA.W standard housing for wall mounting (fig. 6a)
BMGZ6xxA.S housing for panel mounting (fig. 6b)
BMGZ6xxA.K standard housing with additional steel cabinet
400x400x275mm

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6 Installation and Wiring
Caution
Proper function of the FMS belt scale is only guaranteed with the recommended
application of the components. In case of other arrangement, heavy malfunction
can be the result. Therefore, the installation instructions on the following pages
must be followed strictly.
Caution
Local installation regulations are to preserve safety of electric equipment. They
are not taken into consideration by this operating manual. However, they have
to be followed strictly.
6.1 Determination of Mounting Place of the Measuring Roller
To preserve fault-free operation and best accuracy, the following points should be
observed when designing the conveyor and determining the location for the
measuring roller:
 Belt tension should be kept constant. A weighted belt tensioner should be
provided for this, if possible. Deviations of the belt tension have direct influence
to the measuring result.
 Belt rise must be only as high as the bulk material on the belt cannot move
downwards.
 Flow rate should be within a range of 20...100% of the rated nominal
performance. If flow rate is lower, measuring accuracy will be less.
 The belt scale should be placed as far away as possible from the material feed
to allow the bulk material to settle.
 The belt scale should be placed as far away as possible from the drive roller to
minimize the influence of belt tension.
 The belt scale may only be installed in a straight section of belt with constant
trough.
Note
Movement of the bulk material on the belt or changes of the belt tension will
cause immediately and non-controllable changes of the measuring value and
will therefore enlarge the measuring uncertainty. Proper operation is provided
only if the points above are followed.
Mounting position
There are in fact three mounting positions possible: horizontal conveyor (fig. 7),
inclined conveyor (fig. 8), and angled conveyor (fig. 9). In any way, the
measuring roller should be located as far away as possible from the drive roller.

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fig. 7: The measuring roller has to be placed as far away from the material feed as
the bulk material may settle before passing the measuring roller. B600001e
fig. 8: To minimize influences of the belt tension, the measuring roller should be
located as far away as possible from the drive roller. B600002e
fig. 9: The measuring roller has to be placed as far away from the turn as the belt
will be supported in the whole weighing range (measuring roller ±2...3m) under all
conditions. B600003e
Note
When designing the belt scale, the size of the force measuring bearings was
determined based on the maximum flow rate, belt speed and distance between the
support rollers (dimension „a“). Therefore, the measuring roller has to be mounted
equidistant to the neighbouring rollers (±25mm). Axis of measuring roller and
neighbouring rollers must be parallel.

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6.2 Mounting the Measuring Roller
fig. 10: The mounting devices are adjustable in many ways to fit best to the channels.
B600018e
The measuring rollers have a sliding part on each side of the support for easy and
flexible adapting to the width of the channels (fig. 10). The sliding parts allow
variable adjusting of the width in a range of 350mm. They will be fixed with 4 fixing
screws M12 (Pos. „1“ in fig. 12).
The sliding parts may be combined in any way with the mounting brackets, so that
many different mounting positions are possible (fig. 11).
fig. 11: By good combination of the mounting devices, many different mounting
positions are possible B600019e

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Aligning the height of the measuring roller
fig. 12: The middle part of the measuring roller must be aligned with the
neighbouring support rollers. B600004e
After mounting the measuring roller on the channels, the height of the roller must
be aligned to the neighbouring support rollers (fig. 12). This is done as follows:
 Lift belt with wooden block or equivalent.
 Put up 2 cords across the neighbouring support rollers.
 Loosen the sided fixing screws „2“ on mounting brackets and sliding parts
carefully (Attention: Don’t loosen the fixing screws „1“ again!)
 Adjust the height of the measuring roller by knocking with a plastic hammer the
sliding part until the measuring roller will just reach the cord.
 Tighten the sided fixing screws „2“ again.
Aligning the bevelled side disks (only troughed measuring roller)
fig. 13: The side disks (only troughed measuring roller) have to be adjusted laterally
until they are aligned with the neighbouring side rollers B600005e
The bevelled side disks have to be aligned as follows (fig. 13):
 Lift belt with wooden block or equivalent.
 Put up a cord across the neighbouring angled support rollers.
 Loosen the set screw on the set collar.
 Adjust the bevelled side disk.
 Tighten the set screw on the set collar.

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 Repeat the procedure for the 2nd side disk.

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6.3 Mounting the Electronic Unit
The evaluation electronic unit is available in variants as follows:
 BMGZ6xxA.W : Housing for wall mounting (aluminium; IP54) (fig. 6)
 BMGZ6xxA.S : Housing for panel mounting (aluminium; Front IP54,
Back IP00)
 BMGZ6xxA.K : mounted in steel cabinet 400x400x275 (IP55)
Protection class IP55 is achieved only by closed cover otherwise IP54. For
outdoor mounting, the robust steel cabinet version (BMGZ6xxA.K) is
recommended.
6.4 Mounting the BMGZxxA.S
fig. 13b: mounting BMGZ610A, BMGZ611A, BMGZ620A B600029d
Mounting of the housing for panel:
1. Unscrew all 4 side screws (“Eckschrauben” see fig. 13b)
2. Remove all cables which are connected with the electronic board of the front
panel (cables connectors).
3. Unscrew the earth cable of the electronic board.
4. Take away the front panel from the box.
5. Put the front panel into the opening in the cabinet from the front side.
6. Mount back and front side of the box on the back side of the cabinet
7. Put in place and screw the 4 fixations screw.

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8. Replace the earth cable and all the cables with connectors back to place.

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6.5 Wiring of the Connection Cable
Wiring between measuring roller and evaluation electronic unit must be done with
the shipped 8-wired, shielded twisted-pair cable (4x2x0.75mm2). Length of the
cable is done according to customer specification (specify when ordering). The
cable must be installed separate from power lines to prevent any inductive
disturbances.
On the measuring roller
side, the plastic sheath will
be removed on a length of
about 14cm. The white wire
is not used. The shield will
be connected to terminal 5.
On the electronic unit side,
the plastic sheath will be
removed on a length of
about 25-54cm. The white
wire is not used. The shield will be connected to the PG gland referring to fig. 14.
The contacts will be made referring to fig. 15 or wiring table. The shield of the
cable must be connected on both sides.
If a housing version „K“ (with steel cabinet) is used, the cable will be led through the
steel cabinet using a 8-pole plug („13.3 List of parts“, Pos. 64).
fig. 15: Wiring of the measuring roller to the evaluation electronic unit B610002e
fig. 14: Shield connection to the electronic unit
B600024e

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6.6 Wiring Information
fig. 16: Terminal arrangement on terminal board B600007