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MAINTENANCE MANUAL

Wall-mounted and Embedded BFC

SBS, SAS integrator BFC.941.001-E.c


GRAN and FLOW flowmeter
Technical Department
If you need assistance, please call your local service center :

or
HASLER International SA Tel. +33 (0)4 74 16 11 50
F- 38780 PONT-EVÊQUE Fax +33 (0)4 74 16 11 55

HASLER Suisse Sàrl Tel. +41 (0)32 720 23 00


CH-2000 NEUCHÂTEL Fax +41 (0)32 720 23 90

HASLER Deutschland GmbH Tel. +49 (0)54 81 80 50


D-49525 LENGERICH Fax +49 (0)54 81 80 51 10

HASLER Industrial Equipment (Shanghai) Co., Ltd Tel. +86 21 607 66 718
CN-201816 SHANGHAI Fax +86 21 607 66 716

Before you call …


Do you have alarm displays?
Are you able to eliminate the cause of the alarm displays?

Have you modified part of the system, feeder, product or operating mode?

Have you tried to remedy the fault in accordance with the operating and service instructions?

Please note:
- the facility number
- the type of feeder
- the motor control type

“No part of this publication may be reproduced or transmitted in any form or by any means electronic
or mechanical including photocopy, facsimile or computer generated distribution without written
permission from Hasler International. All translation rights are reserved by Hasler International. Hasler
International has made every effort to ensure the accuracy and validity of this document. However,
errors or emissions cannot be excluded and may be transmitted to one of the Hasler divisions.

Information in this manual is correct as of the date of publication. Hasler International assumes
no responsibility for damages resulting from misuse of the equipment or negligence on the part of
operating personnel.

Copyright
HASLER International SA
Z.I. de L'Abbaye
F - 38780 Pont-Evêque

Prepared and edited by


Technical Documentation Department
Hasler Suisse Sàrl

Order no.: BFC.941.001-E.c


Date: 09.10.14

Hasler Suisse Sàrl, a Hasler International Sa Company.


MAINTENANCE MANUAL

Contents
1 SAFETY RULES...................................................................... 4
1.1 Compliant use........................................................................... 4
1.2 Measures relating to organisation............................................. 4
1.3 Operator's responsibilities........................................................ 4
1.4 Working in complete safety....................................................... 5
1.5 After sales and repair service................................................... 5

2 GENERAL INFORMATION...................................................... 6
2.1 General description................................................................... 6

3 TECHNICAL SPECIFICATIONS.............................................. 7
3.1 General specifications.............................................................. 7

4 ASSEMBLING THE WALL-MOUNTED / CABINET BFC ....... 9


4.1 Assembling the wall-mounted BFC........................................... 9
4.2 Assembling the cabinet BFC.................................................... 12

5 OPENING THE CONTROLLER HOUSING............................. 15

6 LOCATION OF BFC CONNECTORS...................................... 16

7 CONNECTING THE INTERFACES.......................................... 17


7.1 X24 and X2 input/output interface............................................ 17
7.2 X21 speed sensor input interface ............................................ 18
7.3 X1 analog weighing interface.................................................... 19
7.4 Digital weighing interface SFT X22, X23.................................. 20
7.5 X25 power supply connections................................................. 21
7.6 Supervisor communication interfaces ...................................... 22

8 MOUNTING SHIELDED CABLES........................................... 24


8.1 PREPARING THE CABLES .................................................... 24
8.2 MOUNTING CABLES .............................................................. 24
8.3 MAXIMUM CABLE LENGTH ................................................... 25

9 ADJUSTING SW SELECTORS............................................... 26

10 CONTROLLER SETTING........................................................ 27

11 MAINTENANCE AND FUNCTIONALITY................................. 28


11.1 General information ................................................................. 28
11.3 X9 RJ45 Ethernet maintenance port......................................... 29
11.4 X8 MMC/SD memory card........................................................ 32

BFC.941.001-E.c Page 1
MAINTENANCE MANUAL

12 MAIN KEYBOARD FUNCTION .............................................. 35


12.1 BFC for Dynamic measurement .............................................. 35
12.2 Description of the BFC keyboard keys..................................... 35
12.3 Summary of the main keyboard functions................................ 37
12.4 Modification of parameters....................................................... 38
12.4.1 Digital parameters..................................................................... 38
12.4.2 Parameters with selection choices........................................... 39

13 ALARMS.................................................................................. 40
13.1 List of Alarms............................................................................ 41
13.2 Specific alarms......................................................................... 43
13.3 ALARM menu........................................................................... 44

14 HOME PAGE ........................................................................... 47


14.1 HOME Page ............................................................................ 47
14.2 Main page Config. menu .......................................................... 47

15 ADJUSTMENT (FILTERING)................................................... 48
15.1 ANALOG weight filtering........................................................... 49
15.2 DIGITAL weight filtering............................................................ 51
15.3 SPEED filtering......................................................................... 53
15.4 MASSFLOW filtering................................................................. 54

16 OPERATION MENU ................................................................ 56

17 METROLOGY MENU .............................................................. 57

19 SCALE MENU ......................................................................... 60


19.1 CELL TYPE .............................................................................. 60
19.2 WEIGHTBRIDGE...................................................................... 60
19.3 SFT DETAIL ............................................................................. 63

20 CALIBRATION AND TARING.................................................. 65


20.1 Purpose of calibration............................................................... 65
20.2 When to perform calibration...................................................... 66
20.3 Purpose of taring...................................................................... 67
20.4 When to perform taring............................................................. 67
20.5 COEFFICIENT.......................................................................... 68
20.6 ANALOG LOAD CELL.............................................................. 69
20.6.1 CELL REPLACEMENT............................................................. 70
20.6.2 Analog load cell Calibration Procedure..................................... 72
20.7 Taring........................................................................................ 77
20.7.1 Initial taring............................................................................... 77
20.7.2 Empty Belt Taring...................................................................... 78
20.8 Calibration using chains............................................................ 79
20.8.1 Chain calibration organization chart......................................... 81
20.9 Material test calibration............................................................. 82
20.9.1 Material test calibration............................................................. 83

Page 2 BFC.941.001-E.c
MAINTENANCE MANUAL

21 INPUT / OUTPUT INTERFACE ............................................... 85


21.1 INPUT / OUTPUT PARAMETERS............................................ 86

22 MACHINE................................................................................. 88
22.1 MECHANICS............................................................................ 88
22.2 SPEED RECORDING............................................................... 89

23 SYSTEM................................................................................... 91
23.1 GENERAL................................................................................. 91
23.2 SOFTWARE VERSION ........................................................... 91
23.3 SECURITY................................................................................ 91
23.4 MAINTENANCE........................................................................ 94
23.5 COMMUNICATION................................................................... 95

24 DIAGNOSTIC........................................................................... 96

27 MAINTENANCE....................................................................... 99

BFC.941.001-E.c Page 3
MAINTENANCE MANUAL

1 SAFETY RULES

The installation, commissioning and programming of the


controller using the BFC console must be performed by
suitably trained personnel.

1.1 Compliant use

Only use the BFC console with feed equipment provided or


approved by HASLER.
Only use the BFC console respecting the technical
characteristics.

1.2 Measures relating to organisation

Take note of the safety rules which govern the use of feeders
connected to the controller and BFC console.
As a complement to the user guide, observe the general
regulations that apply for preventing accidents and protecting
the environment.
Always keep the user guide close at hand where the installation
is used. Check that the user guide is complete and legible.

1.3 Operator's responsibilities

Check that only qualified and suitably trained personnel may


use the BFC console.
Determine the personal responsibilities concerning the
operation and maintenance of the controller.
Check that the personnel who work with the controller and
BFC console have understood the instructions to use all
the components installed and especially all the safety rules
indicated in this chapter.
Immediately replace any damaged or missing component.
The user of the controller with the BFC console guarantees that
the safety and accident prevention regulations that apply are
respected.

Page 4 BFC.941.001-E.c
MAINTENANCE MANUAL

1.4 Working in complete safety

Indicate immediately any modifications (even concerning


performance) that affect safety to management.
Systematically accord priority to safety aspects when
carrying out work.
Do not make any adjustments to the BFC controller when
the feeder is operating without measuring the effect on the
behaviour of the piloted machine.

1.5 After sales and repair service

The BFC controller may only be repaired


• by a HASLER approved after sales service centre
or
• by qualified personnel, trained by HASLER.
Only use original spare parts, delivered by HASLER.

BFC.941.001-E.c Page 5
MAINTENANCE MANUAL

2 GENERAL INFORMATION

2.1 General description

Two versions of the BFC controller are available, one Plug-in


version designed to be fitted inside a cabinet, the other used for
direct installation in wall-mounted machines.
The sealing constraints are identical for both versions.

This controller withstands the following limits:

• Operating temperature:
-10°C to 50°C without condensation
• Storage temperature:
-30°C to 80°C
• Protection:
IP65 on the parts of the housing in contact with water and
dust.
Fig. 1 View of the Plug-in BFC controller

The different BFC variants

1. Plug-in BFC controller (Cabinet)


2. Wall-mounted BFC controller (Machine)

Fig. 2 View of the Wall-mounted BFC controller

Page 6 BFC.941.001-E.c
MAINTENANCE MANUAL

3 TECHNICAL SPECIFICATIONS

3.1 General specifications

Manufacturer: HASLER International


Designation: BFC (Belt Flowmeter Controller)
Dimensions: H x D x L 210 x 162 x 149.5 mm for the Cabinet version
H x D x L 210 x 162 x 170 mm for the Machine version
H x D x L 192 x 144 panel opening for Cabinet version
Net weight: 3.4 Kg
Power supply:
Voltage: 115 V AC + 10% or 230 V AC + 15%
Power supply with 12V DC possible.

Frequency: 47 to 63 Hz
Max consumption: 25 W
Start-up current: 2 A max for 2 complete periods

Electric standards:
EMC: EN50081-2 Generic Electrical
Emissions
EN50051-2 Generic Electrical
Immunity
US 47CFR Part 18 US Electromagnetic
Compatibility Stand.

Safety: EN 61010-1 Electrical Safety (EU)


National Electrical Code
Electrical Safety (NA)

Approval:
Europe: CE

Environmental specifications:
Operating temperature: -10°C to 50°C without condensation
Storage temperature: -30°C to 80°C
Maximum altitude: 3.000 m
Maximum humidity: 95% at 25°C without condensation
(DIN 40040 Class F)
Protection class: IP 65 Cabinet version and Machine version

BFC.941.001-E.c Page 7
MAINTENANCE MANUAL

3.2 Specifications of the electric interfaces

Weighing functions:
Digital weighing Up to 4 SFT digital cells (24-bit resolution) with automatic cell
addressing system (version O and next).

Analog weighing 1 analog/digital converter with 24-bit resolution, for up to 4 sensors of


the paired spring balance type. Minimum impedance 50 Ω.

Analog output:
0 to 20 mA (< 500 Ω)
Resolution 12 bits
insulated

Digital inputs:
2 digital inputs 24 VDC, 10 mA, Maximum frequency 10 Hz, Insulated, insulation
voltage 1000 V rms
2 specific inputs for speed sensor
Frequency from 2 Hz to 3 khz maximum
Pulse width > 50 µs, insulated, insulation voltage 1000 V rms
24 or 12 VDC power supply, 10 mA, selectable individually, + 12V on
digital input for HASLER speed sensor

Output:
1 digital output 230 VAC, 6 A, Insulated, insulation voltage 1000 V rms
spco type open contact relay.
1 digital output 230 VAC, 6 A, Insulated, insulation voltage 1000 V rms
spco type closed contact relay.
1 digital output 24 VDC to 230 VAC, 100 mA, Insulated, insulation voltage 1000 V rms
open gate transistor.

Interface:
Monitor on controller Colour LCD, 3.5 inch, 320 H * 240 V pixels
Host Modbus TCP (Ethernet)
Modbus RTU, Profibus DP

Maintenance: Specific communication port, Ethernet RJ45, USB, MMC Flash Card.

Page 8 BFC.941.001-E.c
MAINTENANCE MANUAL

4 ASSEMBLING THE WALL-MOUNTED / CABINET BFC

Usually, BFC controllers are supplied as a kit, requiring proper assembly to ensure their sealing
and maintenance specifications are met.
Apply the following instructions when assembling the different elements included to the kit.

4.1 Assembling the wall-mounted BFC

Assembling the bracket and controller:

BFC Rear View

X2

X2

BFC Rear / Bottom View

BFC.941.001-E.c Page 9
MAINTENANCE MANUAL

BFC Side View

BFC side view / hinge

Page 10 BFC.941.001-E.c
MAINTENANCE MANUAL

BFC wall mounting, Side view / hinge half open

BFC wall mounting, Side view / hinge open for access to rear panel

BFC.941.001-E.c Page 11
MAINTENANCE MANUAL

4.2 Assembling the cabinet BFC

Mounting the fasteners on the BFC

BFC Rear View


X2

X2
Page 12 BFC.941.001-E.c
MAINTENANCE MANUAL

BFC Rear / Bottom View

X1 X1

X1
BFC.941.001-E.c Page 13
MAINTENANCE MANUAL

BFC complete mounting, Top view

BFC cabinet mounting, Rear view without back plate

Page 14 BFC.941.001-E.c
MAINTENANCE MANUAL

5 OPENING THE CONTROLLER HOUSING

Remove the housing back panel as shown in


the drawing below.

Unscrew the four


back screws

Lid to screw off for access to RJ45,


maintenance port

Position 2

Position 1
Position 3

Position 4 Position 5

Pos 1, 2, 3 (1&3 option) M16x1.5: Ø 4,5..9 mm


Pos 4,5 M20X1.5: Ø 7..12.5 mm

Pos 2: power supply cable gland


Pos 4: shielded cable gland for input an output interface
Pos 5: shielded cable gland for weighing station

BFC.941.001-E.c Page 15
MAINTENANCE MANUAL

6 LOCATION OF BFC CONNECTORS

The BFC connectors are located on two boards, i.e. the input and output board, and the
processor and communication board, below is the location and functions of the connectors:

Connector for
MMC board
X8

USB Host
connector
X3

SFT Digital Cell Analog Output Ethernet Modbus


Connector connector TCP connectors
X22 X2 X5
Connector
HASLER X4
X11 Analog Load
Cell connector Connector
Profibus or
Modbus RTU
X7

Connector
Tacho connector HASLER
X21 X6

Parameter writing Input/output


locking screw interface connector
OML version X24

Cable gland SFT power supply


Position 5 Distribution
For Weighing connector
station cable X23

Power supply
connector
Cable gland Cable gland Position
X25
Position 2 4
For Power supply For input/output
cable interface cable

Page 16 BFC.941.001-E.c
MAINTENANCE MANUAL

7 CONNECTING THE INTERFACES

7.1 X24 and X2 input/output interface

The digital inputs and outputs as well as the analog input are insulated galvanically.

X24 BFC controller


0V External 1 E2

Input 2 24V External Programmable 2

7 to 27V DC/10mA = "1", <3V DC = "0"


0V External 3 E1

Input 1 24V External Programmable 4

5
000000
Output 3 24V DC - 230 V AC External Programmable
6

7
Programmable
RE2
===
Output 2 24V DC / 230 V AC 8
9
Output 1 24V DC / 230 V AC
RE1

Programmable ==
10

The I/Os are indicated in the


idle state (non activated)
X2
+ Ana 1
Ana Programmable
TR

max 500 Ω, 0/4..20 mA 2


SANA1

output 1
- Ana

To program a digital output for a material totalizer counter, use output 3.


The pulse width is modifiable using the parameter "Pulse width Tot Ext1" as well as the step
value on which the output will be activated "Ext1 Totalizer Inc.".
By default, the parameters are auto-initialized with the following values:
Pulse width Tot Ext1 = 2000 ms
Ext1 Totalizer Inc. = 1 kg
2000 ms

Max frequency = 5 Hz

BFC.941.001-E.c Page 17
MAINTENANCE MANUAL

7.2 X21 speed sensor input interface

The specific inputs for measuring speed used on a belt integrator offer different connection
possibilities to allow various sensors to be used.
7.2.1 HASLER speed sensor (12VDC) X21 BFC controller

HASLER Tacho SW21


8 Pulses per turn 1 E1

╓ WHITE 2
X╜
SW21
3 E2

╓ BROWN 4
X╜
5

HASLER Tacho => SW21


GREEN 6 12V

TR
7

YELLOW 8 0V

Max current 125 mA

X21 BFC controller


7.2.2 Off-the-shelf speed sensor (24VDC)

GHM9, GHM5 Tacho SW21


╓ GREEN 1 E1
X╜
2
SW21
╓ YELLOW 3 E2
X╜
4

BROWN 5 24V
GHM9, GHM5 Tacho => SW21
6 12V
TR

WHITE 8 0V

Max current 125 mA

Page 18 BFC.941.001-E.c
MAINTENANCE MANUAL

7.3 X1 analog weighing interface

The specific inputs for measuring weight through the analog load cell offer different connection
possibilities to allow various cells to be used.
If several analog load cells are present, just wire them in parallel while using paired cells.

6-wire cell wiring SW7 open


X1 BFC controller
Machine terminal strip
Weight sensor Power
SW7 supply 5V 1

SW7

TR
Power
supply 0V 2
Measure + 3
L-C
IC
Measure - 4

Return + 5
6-wire cell IC
without the Return - 6
bridges

4-wire cell wiring SW7 closed


X1 BFC controller
Machine terminal strip
Weight sensor Power
supply 5V 1
SW7

SW7
TR

Power
supply 0V 2
Measure + 3
L-C
IC
Measure - 4

Return + 5
IC
Return - 6

BFC.941.001-E.c Page 19
MAINTENANCE MANUAL

7.4 Digital weighing interface SFT X22, X23

Inputs specific to weight measurement on digital cell (SFT) offer various connection possibilities.
To allow automatic programming of the cells, apply the following wiring when several cells are
used.
1 SFT cell 6-wire wiring X22 BFC controller
Machine terminal strip
Weight sensor
RX+ 1
en 2
/ gre RX-
+
TX llow
- / ye
TX TX+ 3
white
RX+ /
RX- / brown TX- 4
Vcc / grey Power supply 12V 5
Co
m /
pin
k

TR
Note: Power supply 0V 6
If a single SFT is used,
the power supply is
connected to the X22
terminal strip.

2 SFT cells 8-wire wiring


for example on SBS TWIN and SBS DUAL
X22 BFC controller
Machine terminal strip
Weight sensor
RX+ 1
green 2
TX+ / RX-
ellow
TX- / y
RX+ / white TX+ 3
RX- / brown
TX- 4
Vcc
/ gre
Co y
m / X23
pin
k
SFT Power supply 12V 1
RX / y reen
RX + ellow

TR
/ b hite
wn
/g

SFT Power supply 0V 2


- / w
ro
TX +
TX
-

SFT2 Power supply 12V 3

y
/ gre
TR

Vcc
SFT2 Power supply 0V 4
Com / pink

Page 20 BFC.941.001-E.c
MAINTENANCE MANUAL

7.4.1 SFT digital weighing summary

This section summarizes the connections for digital weighing on SFT.


To use automatic programming of SFT cell address numbers, use a separate power supply for
each cell linked to the X23 terminal strip.

X23 Distribution of SFT power supplies


Terminal Function
1 +12V SFT1
2 GND SFT1
3 +12V SFT2
4 GND SFT2
5 +12V SFT 3
6 GND SFT 3
7 +12V SFT 4
8 GND SFT4

X22 SFT cell communication


Terminal Function
1 485 RX+ The 5 +12V SFT1 and 6 GND SFT1 terminals are a transfer
2 485 RX - of the power supplies of the X23 terminal strip, they are used
3 485 TX + when a single SFT cell is connected to the BFC controller.
4 485 TX -

7.5 X25 power supply connections

The mains power supply of the BFC controller must be connected to the X25 3-pole connector.
The supply voltage accepted is 230 VAC 50 Hz or 115 VAC 60 Hz, without adaptation .
For other supply voltages, please call HASLER.
The position 2 cable gland is designed for passing the shielded or non shielded power supply
cable.
X25 BFC controller
X25
E = Ground M4*
L = Phase E
N = Neutral Ground*
L Fuse 2AT
L
M4 connection / Wall-mounted
TR

M4 connection / Embedded N
N
Fuse 2AT

*The Cabinet and Wall-mounted BFC


controllers must be grounded via an M4
fastening screw fitted on the housing.

BFC.941.001-E.c Page 21
MAINTENANCE MANUAL

7.6 Supervisor communication interfaces

The BFC controller supports all industrial protocols used by the supervisors, a single protocol
can be selected at a time.
In the example below, only the wiring is defined, for the configuration of the protocols please
refer to the documentations specific to each protocol.

7.6.1 Profibus X7 Half duplex RS485

Terminal Function X7 Controller BFC


1,2,7 NC
3 RXD / TXD-P VP +5VL
1 6
4
5 D GND B
6 VP +5V 3
3 Line B RXD/TX-P
8 RXD / TXD-N 8 A
8 Line A RXD/TX-N
9 SW2
9
5 B
RS485 Half duplex SW2 closed (off)
A

D-GND

SW2 The shielding of the Profibus or Modbus cable


must be connected to the frame through the
cable gland position 1 or 3 (chap.8.2)!

7.6.2 Modbus RTU X7 Full duplex RS422

Terminal Function
1,2,7 NC X7 Controller BFC
3 TX+
VP +5VL
4 RX- 1 6
5 D GND View from BFC controller
6 VP +5V B
8 TX- 3 Line TX+ 3 TX
9 RX+ 8 Line TX- 8
4 Line RX- 4 A
9 Line RX+ 9
B
5 RT RX
RS422 Full duplex SW2 open (on) A

D-GND
100 Ω 0Ω
SW3

SW3 Modbus line termination resistor, only on


SW2 terminal 9 and 4 + 100Ω

Page 22 BFC.941.001-E.c
MAINTENANCE MANUAL

7.6.3 Modbus TCP (Ethernet) X5

Shielded RJ45 connector

Pin Function
1 TXP
2 TXN The shielding of the Modbus TCB cable must
3 RXP be connected to the frame through the cable
4 TXC gland position 1 or 3 (chap.8.2)!
5 RXC
6 RXN
7 NC
8 THEV TERM

The type of cable used depends on the type of connection with the supervisor, i.e.

1 supervisor on one BFC connected to X6 take a twisted cable 1 .


1 supervisor on several BFCs through an Ethernet switch use a straight cable 2 .

Twisted Straight

1 2
RJ-45
connector

BFC.941.001-E.c Page 23
MAINTENANCE MANUAL

8 MOUNTING SHIELDED CABLES

8.1 PREPARING THE CABLES

The interfaces are connected using shielded cables. These cables are passed through the
different controller cable glands.

1. Prepare the cables.


Diameter 9 to 12 mm.
For the interface of the analog spring balance and analog output: X = 170 mm
For the interface of the SFT and I/O digital cells: X = 150 mm
For the supervisor communication interface: X = 170 mm
For the interface of the Tacho + cell on 1 cable: X = 170 mm


8.2 MOUNTING CABLES

Contact washers (D): Nickel-plated brass.


The threaded fitting connects the shielding harness to the grounding unit.
OR

1 2
D

üüü

Cable specifications: (c)


Shielding: braided copper
Number of wires: 5 or more twisted pairs according to the number of load cells.
Maximum distance: 1000 m
Wire resistance: < 40 Ω/km
Important:
The cable's shielding (c) must be connected at both its ends to the appropriate terminals,
provided the differential voltage is below 30 V
Page 24 BFC.941.001-E.c
MAINTENANCE MANUAL

8.3 MAXIMUM CABLE LENGTH

The BFC controller and the different sensors are interconnected through different connectors.

The length of the cables between the BFC controller and the different interfaces must not
exceed the values indicated hereafter:

Maximum length for:

Analog load cell on SBS X1 300m


Digital load cell SFT X21, X23 1000m
Speed sensor X21 1000m

I/O interface X24, X2 300m

Supervisor communication interface X4, X5, X6, X7 1000m

USB interface X3 10m


Maintenance Ethernet port RJ45 10m

The cable length depends also on the quality of the cables, the following electrical specifications
must be considered:

Wire resistance: < 40 Ω/km

Shielded cables require one shielding per metallic harness minimum

Important:
The cable's shielding must be connected at both its ends through specific cable glands, see
chapter 8.2, provided the differential voltage is below 30 V

BFC.941.001-E.c Page 25
MAINTENANCE MANUAL

9 ADJUSTING SW SELECTORS

Different selectors SW have been described in the previous chapters, the following summarizes
the selectors and their associated functions. SW21
I/O board
SW21 (I/O board)
Selects the 12V power supply for the HASLER
speed sensor on pins 3 and 1 of the X21 connector.

SW1 (CPU board)


Resets the controller.
SW2 (CPU board)
Selects full or half duplex for Modbus RTU communication over the X7 connector.
SW3 (CPU board)
Selects the termination resistors on Modbus communication for the X7 connector.
SW5 position Start from or on input
SW5 (CPU board)
Rotating selector for starting the Normal position, start from,
BFC program on different 0 1 memory board if present
inputs see table. 2 internal flashes
Force start-up from SD /
2
MMC memory board
SW7 (CPU board) Communication with USB port for
9
Selects analog cell wiring over BIOS update
4 or 6 wires.

SW7 SW1 SW5

SW3

SW2

CPU board

Page 26 BFC.941.001-E.c
MAINTENANCE MANUAL

10 CONTROLLER SETTING

Important indication before programming! The parameters described


Please consider the elements described below before setting
below are valid for
software releases from
the parameters and functions.
version 2.0.0.0
1. Check the installation of the mechanical elements, position
of the belt scale, check the weighing bridge, proper flow of
material on the flowmeter, both at the entry and exit.
2. Check that the weighing system of the belt integrator and
flowmeter are not under the influence of degassing disturbance.
3. Check that the mechanical elements are not disturbed by
important vibrations.

BFC controller basic setting


Checking and entry of the parameters depend on the type of mechanical unit connected to the
controller, only the two main types of mechanical units give the changes of parameters and
functions.
Below is a partial indication on the different steps to be performed for an installation providing
maximum accuracy on the Machine controller assembly.
Integrator configuration Flowmeter setting
belt or metallic apron

1. Measure and insert the length of the weighing


bridge. 1. Select the GRAN, FLOW mechanical unit
2. Measure and insert the tilt angle if ≠ 0. 2. Remove any material from the impact plate.
3. Measure and insert the discharge point 3. Calibrate the load cell if analog weighing.
distance. 4. Perform initial zero.
4. Indicate the theoretical integrator speed. 5. Adapt the filtering parameters if necessary
5. Enter the type of speed measurement and its 6. When possible, perform a material test and
parameters as described in chapter 22.2 correct the material coefficient.
6. Empty the belt or metallic apron. 7. Save your parameters.
7. Calibrate the load cell if analog weighing.
8. Perform initial taring.
9. Adapt the filtering parameters if necessary
10. When possible, perform a material test and
correct the material coefficient.
11. Save your parameters.

BFC.941.001-E.c Page 27
MAINTENANCE MANUAL

11 MAINTENANCE AND FUNCTIONALITY

11.1 General information

The BFC controller offers different possibilities to perform maintenance tasks, except for the
use of the console to change parameters and launch functions specific to the type of machine
it is connected to, tasks can also be run to save the work performed onto external media.

The following functionalities are proposed:

PC communication over USB maintenance port


Update the BIOS from the PC via the appropriate software

PC communication over RJ45 maintenance port


Save the parameters to the PC
Save the parameters from the PC
Update the software from the PC

Memory card (Recommended by HASLER, Ref HASLER 2514.0100)


Save parameters from an SD/MMC memory card
Save parameters to an SD/MMC memory card
Update the software from an SD/MMC memory card

Page 28 BFC.941.001-E.c
MAINTENANCE MANUAL

11.3 X9 RJ45 Ethernet maintenance port

In the Ethernet standard on RJ45 connector, the maintenance port is used with the off-the-shelf
standard RJ45 - RJ45 cables to connect the BFC X9 RJ45 connector to the PC over a standard
1:1 type connection, the cable length must not exceed 10 m.
Straight
This link is used to back up and restore the parameters
of the BFC controller.
Access to the maintenance port does not require
removing the BFC rear panel, just unscrew the plug
using a large screwdriver or a coin.

This link provides access to the web server present in the


BFC controller, which is compatible with all browsers allowing to view web sites,
such as Internet Explorer, Firefox etc.
The different functions can be activated on the web site merely by clicking them

Shielded RJ45 Ethernet port

Terminal Function
1 TXP
2 TXC
3 TXN
4 RXP
5 RXC
6 RXN
7 NC
8 NC

Note:
Standard off-the-shelf cables
with two RJ45 shielded
connectors are compatible,
RJ45 maintenance port
connection 1:1

11.3.1 Maintenance port parameter

To use the browser to access the maintenance functions, use either the addressing of the
preconfigured web server or use your own configuration, in which case the following parameters
must be used:

To use preprogrammed parameters, open your browser and insert the following IP adress in
the search bar:

http://169.254.000.002

BFC.941.001-E.c Page 29
MAINTENANCE MANUAL

To use a different address use the following parameters to enter your data:
To access the parameters, use the menu:

System
Maintenance
Service port

IP address 169.254.000.002 Note:


Network Mask 255.255.000.000 The parameters indicated
Gateway 255.255.255.255 here are the auto initialized
MAC address 00-02-A2-xx-xx-xx values.

In your browser, the following page will be displayed to provide different functions:

Controller reset, same operation as the SW1 selector.

Save or view parameters.


Save or view metrological parameters.
Save or view alarm configurations.
Save or view alarm archives.

Saving the files to your PC:

1. Connect the PC to the X9 RJ45 port after unscrewing the panel.


2. Enter the IP address chosen in the service port in the web browser.
3. In the BFC WebServer Access, select the file to save in the Upload file list and indicate the backup
location.

If you have several BFC controllers, create a directory for each controller to avoid mixing files.

Page 30 BFC.941.001-E.c
MAINTENANCE MANUAL

Restoring the files on the BFC controller:


Note:
The files present on the BFC controller are overwritten by the transferred files,
without any warning being issued.
File transfers are taken into consideration once the BFC controller initialized.

1. Connect the PC to the X9 RJ45 port after unscrewing the panel.


2. Enter the IP address chosen in the service port in the web browser.
3. In the BFC WebServer Access, select File System.
4. The Upload page below then appears in the browser.
5. Select the file to save in the BFC controller in the Upload or Store part.
6. Launch the upload function.
7. Proceed identically with the other files.
8. Launch a reset of the BFC controller for the file transfers to be considered.

File / extension Description

BFC.NXF Firmware, BFC program file


MAIN.SHT Web Access server home page
WS Directory containing the webserver files
BFC.PSF BFC parameter file
BFC.ALM Alarm configuration file
BFC.ALH Alarm history file
BFC.ISF Not used

BFC.941.001-E.c Page 31
MAINTENANCE MANUAL

11.4 X8 MMC/SD memory card

The BFC controller features a port supporting SD and MMC memory cards with a maximum
capacity of 2 Gb, reference HASLER 2514.0100. bfc-mmc card

Memory cards can be


used from firmware
1.5.0.3
The memory cards can be formatted in FAT 16 to ensure they
are compatible with the BFC controller.
Under Windows 7, formatting must be set to Fat, 2048 bytes
before the first use.
Note: SDHC memory cards over 2Go are compatible
with firmware from 2.0.0.5.
11.4.1 Saving the parameters onto a memory card

To save the BFC controller's parameters onto the memory card


present on the X8 port, apply the following procedure:

1. Open the rear panel of the BFC controller's housing.


2. Insert the MMC or SD card into the X8 connector on the CPU board until it clicks.

3. Press the menu key

4. Select the SYSTEM menu, then MAINTENANCE and FILE SYSTEM.


5. Select the COPY RAM TO FILE function.

Available 15:47 Available 15:47 System 15:48

System Maintenance
Mass Flow Diagnostic Communication
123.47 T/h General
Belt Speed 4,7 m/s Config.Page Prin. Software version
Belt load 23,33 Kg/m Alarm Safety
Totalizer 134 T Setting
Operation

System 15:48 System 15:48

FILE SYSTEM COPY RAM TO FILE


Service port COPY FILE TO RAM
System file

Any parameters
present on the card
will be erased!

Page 32 BFC.941.001-E.c
MAINTENANCE MANUAL

11.4.2 Restoring the parameters to the BFC controller

Any parameters present on the controller will be erased!

To restore the parameters of the memory card present on the X8 port to the BFC controller,
apply the following procedure:
1. Open the rear panel of the BFC controller's housing.
2. Insert the MMC or SD card into the X8 connector on the CPU board until it clicks.

3. Press the menu key

4. Select the SYSTEM menu, then MAINTENANCE and FILE SYSTEM.


5. Select the COPY FILES TO RAM function.

Available 15:47 Available 15:47 System 15:48

System Maintenance
Mass Flow Diagnostic Communication
123.47 T/h General
Belt Speed 1.47 m/s Config.Page Prin. Software version
Belt load 23,33 Kg/m Alarm Safety
Totalizer 134 T Setting
Operation

System 15:48 System 15:48

FILE SYSTEM COPY FILE TO RAM


Service port COPY RAM TO FILE
System file

BFC.941.001-E.c Page 33
MAINTENANCE MANUAL

11.4.3 Updating the BFC controller software by memory card

If the controller software requires to be updated, using the memory card facilitates this operation.

This software update procedure erases the controller's configuration, do not omit
to save the controller's configuration before updating it.

The update software is usually transmitted by the customer department, it comprises two files,
one directory named Backup and a file named Startup.

The BACKUP
directory contains the
subdirectories named
PORT_0 to PORT_5
only the PORT_0
directory contains
the files used by the
controller

Copy the files received onto the MMC or SD memory card (SDHC non compatible) formatted
in FAT16, the memory card can contain only the two files linked with the update.

1. Power off the controller's mains supply.


2. Open the rear panel of the BFC controller's housing.
3. Insert the MMC or SD card into the X8 connector on the CPU board until it clicks.

4. Restore mains power.

5. The green and yellow LED flashes rapidly for 15 seconds then stays yellow for 1 minute.

6. Once the software update operation is complete, the controller restarts automatically.

7. Remove the SD / MMC memory card.

Note: If the memory card does not include the installation's parameters, the controller uses the
auto initialized parameters.
If the parameters are already present on the card, the controller uses them immediately.

Page 34 BFC.941.001-E.c
MAINTENANCE MANUAL

12 MAIN KEYBOARD FUNCTION


12.1 BFC for Dynamic measurement

Ready 15:47

Mass Flow
123.47 T/h
Belt Speed 1.47 m/s
Belt load 23,33 Kg/m
Totalizer 134 T

12.2 Description of the BFC keyboard keys


The (permanently) backlit screen enables the different menus, sub-menus and
parameters related to the type of integration or flowmeter to be displayed.
The elements displayed in the home page are programmable, the first line is
displayed with characters larger than the other four lines.
The home page can be configured by the user by fast programming of up to 4
parameters, the which have a fixed size according to their position.

The up and down browsing keys move to the next or previous line in the menu
hierarchy.
Pressing the UP when starting the product forces reinitialization of all
parameters without confirmation!

The three "Software keys" located below the display screen are activated or not
according to the procedure being displayed.

Pressing the software keys 1 and 3 simultaneously while on


Ready 15:47

Deck flow

the home page goes to the language selection page.


123.47 T/h
Speed 1.47 m/s
Deck load 23,33 Kg/m
Totalizer 134 T

BFC.941.001-E.c Page 35
MAINTENANCE MANUAL

The menu key is used to display the menus, sub-menus and parameters related to
the feeder.

The main page key is used to return to the home page.

The totalizer key calls the daily totalizer of the BFC controller, resetting the daily
totalizer is performed using software keys.

The return or erase key is used to go back in the menu hierarchy or parameters
displayed or to erase a value in the case of programming a parameter.

The red alarm LED enables the detection of a new alarm if it is flashing, or if it is on
steady, an alarm is still present.
The alarm key is used to display one or more alarms after the key is pressed, then
after the alarms present are noted and the problem resolved, pressing the software
keys acknowledges the alarms.
Note: If the LED remains on after the acknowledgement, the alarm has not disappeared or other alarms
are still active. This LED will go off on its own even when the alarms acknowledged have disappeared.

The entry key is used to validate or descend one line in the menu hierarchy or to
validate a new parameter modification.

The F1 key launches Empty belt taring for a belt integrator or metallic apron or
launches Zero taring for a flow meter.

The F2 key launches the reset function of the daily totalizer.

The "BFC OK" LED is lit when the scale or flow meter is completely set, calibrated
and tared properly.
This LED switches off when the load cell or speed sensor is faulty, also see the other
functions in the following table.

The "SPEED" LED flashes when the speed sensor is moving, the frequency is steady
whatever the belt speed.

The LED is lit when the weighing system detects an overloaded material level, it
flashes when the level of material is below the empty threshold.
Symbol Colour On Off Flashing
Green Totalizing Available
Yellow Taring in progress Not available
Blue Belt stopped Belt moving
Yellow Material overload OK Empty threshold reached
Red Alarm still present No alarm New alarm

Page 36 BFC.941.001-E.c
12.3
Backlit LCD display monitor

BFC.941.001-E.c
Ready 15:47

Direct function Browsing


keys Deck flow Up / Down
123.47 T/h
Speed 1.47 m/s
Deck load 23,33 Kg/m
Totalizer LED Totalizer 134 T 3 Software keys

Speed LED Alarm


key + LED
Belt material load LED
Enter key
Summary of the main keyboard functions
MAINTENANCE MANUAL

Back key Menu key Totalizer key Home page key

Information linked to the LEDs


Symbol Colour On Off Flashing
Green Totalizing Available
Yellow Taring in progress Not available
Blue Belt stopped Belt moving
Yellow Material overload OK Empty threshold reached
Red Alarm still present No alarm New alarm

Page 37
MAINTENANCE MANUAL

12.4 Modification of parameters


The explanations below cover the modifications of parameters used in the different menus.
According to the evolution of menus, you may have to modify parameters, several families of
parameters are present in the BFC, i.e.

1. Digital parameters
2. Parameters with selection choices

Parameter modifications are possible only when:


1. In the Maintenance or HASLER safe mode.
2. The OIML flash memory write locking screw is not
present!
For OIML versions, this screw is sealed!

12.4.1 Digital parameters

These parameters are accessible in the different menus using the up and down browsing keys
to select the menu, then the parameter to modify, then the enter key to modify the parameter.

Once the parameter selected, you can modify it with the right or left software keys to select the
unit to change, then the up and down keys to increment and decrement the value, the enter
key validates the modification.
Available 15:47

Weighbridge length
Current value 2.04 m

New value
_____m

At any time in the procedure, pressing one of the four keys below once triggers the following
action:

Back to the initial parameter Back to the home page

Back to menu selections Access to the alarm page

Page 38 BFC.941.001-E.c
MAINTENANCE MANUAL

12.4.2 Parameters with selection choices

These parameters are accessible in certain menus, such as for example configuration of digital
inputs-outputs, use the up and down browsing keys to select the menu, then the enter key to
modify the parameter.

Once the parameter selected, the up and down keys allow to show the choices available, the
enter key validates the modification.

Available 15:47

Output number 1
Function Gen Alarm
Output state Low level
Polarity Normal

Available 15:47

Current function General Alarm


The Up and Down
New Function General Alarm
arrows scroll the list of
options available.

At any time in the procedure, pressing one of the four keys below once triggers the following
action:

Back one step

Back to menu selections

Back to the home page

Access to the alarm page

BFC.941.001-E.c Page 39
MAINTENANCE MANUAL

13 ALARMS

In case of alarm, apply the following procedure for viewing


and processing alarms.
New Alarm
When the new alarm appears, the red LED on the Available 15:47
alarm key flashes.
When pressing the alarm key, the New Alarm NEW ALARM
window appears on the LCD monitor, and the
"General alarm" digital output is disabled. 05.02.2012
AL 203 MATERIAL MISSING
If you are in the alarm viewing page and a new
alarm appears, just press the alarm page call key
again to disable the "General alarm" digital output. Reset Help Archive

If the red LED is lit steady, the alarm must be Available 15:47
acknowledged, although it is still present, the
problem has not been resolved, once the problem NEW ALARM
resolved, it switches off automatically.
05.02.2012
In the New Alarm page, you will find the information AL 203 MATERIAL MISSING
linked with the alarm(s) present, if more than one 1/2
alarm is present, the x/y symbol appears at the Reset Help Archive
bottom of the page, the x represents the alarm
number displayed, the y the number of alarms
present, the Up and Down software keys allow to
view the different alarms.

The New Alarm page provides access to the


Reset Acknowledgement software key, which is used to
acknowledge the alarm after having corrected the
fault.
The New Alarm page provides access to the
Archive Archive software key, which is used to view the
alarm history pages.

A Help software key allows to display on the LCD a


Help help text explaining how to resolve the alarm.

Displaying Archive pages

To access the archive pages, just press the alarm


key and select the "Archive" software key.

Page 40 BFC.941.001-E.c
MAINTENANCE MANUAL

13.1 List of Alarms


This list describes alarm definitions, probable causes and possible corrective actions.

No. Alarm Cause Remedy = HELP


8 MMC / SD card A memory card is
present in the connector
for more than one minute
10 Flow Too High The massflow is greater Check massflow. Check the
than alarm reference. "Massflow too high" in the Limits
Sub-Menu of the Alarm Menu.
11 Flow Too Low The massflow is smaller Check massflow. Check the
than alarm reference. "Massflow too low" in the Limits
Sub-Menu of the Alarm Menu.
21 Host Link Error Host link inactive. Check for data exchange to the
host.
39 Incorrect # SFT Number of SFTs found Check SFTs and the wiring, Repoll
during a poll don’t agree
with the number of SFTs
required.
42 Temp. too High BFC internal temperature Check BFC internal temperature,
limit exceeded. check external temperature.
56 SFT Status SFT Status shows alarm. Check wiring. Change the SFT.
57 Belt Taring Err. Alarms on weight Stop the conveyor and correct the
acquisition or speed alarms.
measurement
60 A/D Fail A/D converter error Check load cell wiring.
67 Scale Overrange Gross weight exceeds Reduce weight on the scale.
load cell capacity.
68 Scale Underrange Net weight below 0 on Increases weight on the scale,
load cell. adjust the tare.
80 Belt Drift Excessive belt drift. Check the belt's position on
conveyor, check the BDs
82 Belt Drift Left Excessive left belt drift. Check the belt's position on
conveyor, check the BDs
83 Belt Drift Right Excessive right belt drift. Check the belt's position on
conveyor, check the BDs

BFC.941.001-E.c Page 41
MAINTENANCE MANUAL

No. Alarm Cause Remedy = HELP


85 Slip Index Fail Slip index sensor not Check index sensor, wiring and
responding. metal plate inserted in the belt.
86 Speed Sensor Error If the signals received Check the speed sensor, check the
on the two phases are wiring.
contradictory
90 Belt Taring Err Belt tare factor is out of Clean the belt and perform another
range. tare. Check the "Belt length for
taring" parameter in the Calibration
and Taring menu.
101 Belt Load Low Belt loading is too low. Increase material weight on the
weigh belt. Check the "Belt Load
Thrs Low" setting in the Limits Sub-
Menu of the Alarm Menu.
102 Belt Load High Belt loading is too high. Reduce material weight on the
weigh belt. Check the "Belt Load
Thrs High" setting in the Limits Sub-
Menu of the Alarm Menu.
104 Belt not Empty Belt loaded Empty threshold used for belt
taring.
200 Thr. Prog 1 The value of the Adapt the value of the parameter if
parameter inserted in the alarm is not to have this value.
Prog threshold value.1
has been reached
201 THR. Prog 2 The value of the Adapt the value of the parameter if
parameter inserted in the alarm is not to have this value.
Prog threshold value.2
has been reached
203 Low Speed The time between two Check that the speed measurement
tacho pulses exceeds wheel turns freely, and the conveyor
10 seconds during one has started. Minimum measurement
tacho wheel revolution of the standard speed sensor
reached, if speed below 0.05 m/s,
change the speed sensor.
204 High Speed The tacho pulse interval Check whether a rated speed
is below 20ms and speed change was made on the conveyor,
cannot be measured if the sensor was changed, if so
check the parameters and make a
new initial taring. Check the value
of the tacho divider.

Page 42 BFC.941.001-E.c
MAINTENANCE MANUAL

No. Alarm Cause Remedy = HELP Softkey


205 Instab Belt Tare. The weight difference Check material clogging on the belt.
of the belt between
2 tarings exceeds
the "Maximum drift"
parameter
206 Belt Taring Fault Evolution of the Check material clogging on the belt
different idle belt tarings and clean it.
exceeding the "Maximum
tare" parameter
207 Power ShutDown Reported at each mains Check the mains power supply.
power off
208 Memory 1 Internal alarm Customer service
209 Memory 2 Internal alarm Customer service
210 Memory 3 Internal alarm Customer service
211 Chain Calib Err Coefficient outside Check the parameters chain calib.
the limits of the chain weight, check the parameter Chain
calibration Calib Dev MAX corresponding to
the limit acceptable of the coefficient.

13.2 Specific alarms

With the "Prog 1 and 2 threshold" parameters you may check the level of the two parameters,
permanently, and generate a specific alarm according to the level required, see chapter 13.3
Alarm menu.

Alarm 81 Belt sliding is generated as follows:

Signals used:
Sliding and speed measurement index

Installation:
The two measurements must be made at two different locations, e.g. the tacho for measuring
speed is fitted on the motor and index on the driven drum, or speed measurement is installed
tacho on the belt and index on the drive drum.

Principle:
The references are measured during initial taring, then a difference of more than x% (Sliding
Limit parameter) indicates sliding of the conveyor belt, this principle is very precise.

BFC.941.001-E.c Page 43
MAINTENANCE MANUAL

13.3 ALARM menu

This menu allows complete management of all alarms Available 15:47


linked with controller operation.
ALARM HISTORY
ALARM
05.02.2012
AL 203 MATERIAL MISSING
HISTORY 1/2

The History submenu is used to display the alarms RESET HELP ARCHIVE
archived, which appear in descending order with respect
to the time base hour, minute, second, day, month, year.
The alarm passes in the history where it is processed and
resolved.
The alarm history can contain up to 256 alarms then, each new input eliminates the oldest
archive.

This Alarm history can be exported to the external memory card, or read through the
maintenance port, refer to chapter 11.3 and 11.4.
LIMITS
Belt Load Thrs Low
The Material Lack Threshold parameter is used as limit for the 101 Belt Load Low alarm.
This alarm is displayed whenever the material quantity on the belt or in the flowmeter is below
this Material lack threshold. When this alarm is displayed, the Alarm indicator flashes.
The Material lack threshold parameter is displayed in percent Maximum load for a belt integrator,
and displayed in percent maximum flow in the case of an impact plate flowmeter.

Belt Load Threshold Low initialized at = 0.0 %, for an integrator the threshold should rather
be initialized at 0%, as usually the machines often run idle, the Material Lack alarm can also
be deconfigured or "Timed"

Belt Load Thrs High


The Material Excess Threshold is used as limit for the 102 Belt Load High alarm.
This alarm is displayed whenever the material quantity on the belt or in the flowmeter is above
this Material excess threshold. When this alarm is displayed, the Alarm indicator flashes.
The Material excess threshold parameter is displayed in percent Maximum load for a belt
integrator, and displayed in percent maximum flow in the case of an impact plate flowmeter.

Belt Load Threshold High initialized at = 80.0 %, by auto-initializing the value at 80%, there
is a margin of manoeuvre to avoid overloading the load cell, but allows to issue a warning for
checking.

Page 44 BFC.941.001-E.c
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Reference Massflow too high

This value sets the maximum deviation of massflow from a reference value
necessary before an alarm occurs. The reference value is entered in the same units
as that of the massflow display, alarm 10 Massflow too high is generated when the
massflow value exceeds the reference value.

Reference Massflow too low


This reference value is used to generate alarm 11 Massflow too low if actual
massflow is below this reference.

Prog. Threshold Parameter 1
Prog. Threshold Parameter 2

These programmable thresholds are used to enable or disable the digital outputs
on relays 1 and 2, which requires to configure the thresholds on the digital outputs.
The first operation consists in indicating the parameter the threshold is to be selected
on, according to the type of belt integrator or flowmeter application, a selection list
will be available, i.e.
None, Massflows above, Massflows below, Net cell weight above, Net cell weight
below, Gross cell weight above, Gross cell weight below, Load per metre above,
Load per metre below, Belt speed above. Belt speed below.

The two "Threshold parameter progr. 1" and 2 generate the alarms 201 and 202
together with the activation of digital outputs 1 and 2, these alarms are inhibited by
default, and configured if required in the Alarm Configuration menu.

Prog. threshold value 1
Prog. threshold value 2
These thresholds are used to define the value the outputs and alarms will be
activated at.

Hysteresis 1
Hysteresis indicating the threshold the conditions must be at to activate the digital
output and alarm associated with the Programmable Threshold 1 function

Hysteresis 2
Hysteresis indicating the threshold the conditions must be at to activate the digital
output and alarm associated with the Programmable Threshold 2 function

Sliding limit

This parameter indicates the maximum sliding value tolerated, beyond this limit,
alarm 81 is activated. Default value: [2] Unit: [%]

BFC.941.001-E.c Page 45
MAINTENANCE MANUAL

SETUP
ALARM DELAY

This is the time a process alarm can be present before the alarm relay is activated. The default
value is 30 s.

STOP/ALARM
Function deactivating the stop on alarm of all alarms configured. The function is reactivated
after BFC controller power down.
ALARM number
With an alarm number entered in this position, its functionality can be changed with the
following parameters.

Alarm MODE

Once entered in this menu using the up and down software keys, you can scroll the BFC's
alarm list, with the description and number of each alarm.

Once the alarm to configure selected, press enter and select the type of action required for this
alarm.

The different actions are:

Ignore: the alarm specified is ignored.


Timed: Displayed alarm message that may disappear of its own accord if the condition having
generated the alarm is resolved during the time delay. If the alarm is still present at the end of
the time period, the horn digital output is activated.
Immediate: immediate display of the alarm, the horn is activated.
Timing-stop: Displayed alarm message that may disappear of its own accord if the condition
having generated the alarm is resolved during the time delay. If the alarm is still present at the
end of the time period, the horn is sounded and the massflow and totalisation calculation is
stopped.
Immediate-stop: immediate display of the alarm and simultaneous stop of massflow calculation
and totalisation, the horn is activated.

Page 46 BFC.941.001-E.c
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14 HOME PAGE
14.1 HOME Page

The Home page is displayed when the "Home Page" is Available 15:47
pressed regardless of the current location or function, if a
function is ongoing, calling the Home page generates a
Mass Flow
message asking you whether you wish to stop the current
procedure, if you answer yes, the procedure is stopped and 123.47 T/h
Belt Speed 1.47 m/s
the home page is displayed. Belt load 23,33 Kg/m
The parameters displayed in this page can be selected in the Totalizer 134 T
Config menu. Home Page, maximum 4 parameters can be
selected.
7.1 Displaying the home page

14.2 Main page Config. menu

Configuring the parameters displayed in the home page is Available 15:47


performed through the "Main Page Config." menu, the latter
allowing to configure 4 parameters maximum displayed in Home page Config.
text mode. Parameter 1
Parameter 2
For each of these four parameters, you can select a parameter Parameter 3
in a scrolling list, these will be displayed in the text mode, the Parameter 4
selection must be made in this list, then confirmed with the
"Enter" key.
Example of list: 7.1 Displaying the configuration page
Massflow, Massflow at dis, Belt Load, Belt Load at dis, belt
speed, erasable totalizer, permanent totalizer, dynamic use
rate, Net weight on the load cell, etc., this list is partial.

Note:
Parameter 1 will be displayed with a character font larger
than the parameters 2, 3 and 4 (see 7.1 Displaying the home
page).
Main Page Config.
Parameter 1 => parameter scrolling list
Parameter 2 => parameter scrolling list
Parameter 3 => parameter scrolling list
Parameter 4 => parameter scrolling list

BFC.941.001-E.c Page 47
MAINTENANCE MANUAL

15 ADJUSTMENT (FILTERING)

Important indication before filtering!


Please consider the elements described below before setting
the filtering parameters.

To allow to read the value without external error, the


following points must be checked, before any filtering
operation:
1. Check the positioning of the integrator scale.
2. Check the parameters linked with the weighing bridge or flowmeter.
3. Check and if necessary recalibrate the weight in the case of an
analog cell.

Introduction to filtering the BFC

Filtering is very important to have a perfect measurement of the gross weight value read
through the load sensor, whether in analog or digital, stability of this measurement will provide
a better general result.

HASLER has been at the forefront of digital filtering technology over the years with the SFT
sensor, the BFC also provides this technology to analog sensors.

The auto initialized parameters, whether for digital sensors or analog sensors are adapted for
most cases, nevertheless if modifications are required, adapt the modifications on a single
parameter at a time, as the different filters are linked to one another, this approach will allow
for better comprehension of the different filters.

Principle of the BFC filtering modules

Two separate bases are used for measuring the weight on the BFC controller:

1. The first is the one associating one or several analog load cell(s) of the balance type.

2. The other is the use of SFT type digital cells.

The distinction between these two possibilities gives two different filtering combinations, as the
digital cell integrates part of the filters directly into the cell, the "Filtering" menu differs according
to the type of cell.

Page 48 BFC.941.001-E.c
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15.1 ANALOG weight filtering

Organisation of the analog filtering

ANALOG weight filtering on the BFC controller is organised as follows:

A 1 Lowpass Averager 4
type filter filter
weight Averaged gross weight
D 2 3

Median Filter
Weight 8 Display
type filter switch LCD
threshold difference +
5 filter
6 7 Output
Ana

The averaged gross weight 4 is issued directly from the analog digital converter 1 , through
a double stage filter:
A "lowpass" type filter 2 is used to remove all disturbing frequencies above the value of the
filter set by "Weight Acquisition Filter", this first filter is then followed with a filter of the "median"
type 3 configurable by "Weight averager", the output indicates the filtered gross weight 4 .
To increase the speed of the first "lowpass" type filter 2 following the fast changes of the
weight measurement, which can be reset by a second filter of the "median" type 5 working in
parallel, with the same input data of the AD converter. The outputs of the lowpass filters 2 and
median filter 5 are compared permanently 6 and if the difference between the filters exceeds
the threshold parameter "filter switch threshold" 6 , the filtering table of the lowpass filter 2 is
reset with the values of the median filter 5 .

This system allows to combine strong filtering when in a "tunnel", configurable via a "filter switch
threshold" and more responsive filtering (median) when leaving the tunnel, allowing to follow
weight increase or decrease rapidly.

To display the values of averaged gross weight 4 a filter called a weight difference filter is used
7 to display data on the BFC monitor and the analog output 8 , this filter works on a difference
allowing to shorten the value displayed.

The value of the averaged gross weight 4 is then used for calculating massflow.

All filters are paced at the same frequency: 25ms.


They are desynchronized by the A/D converter conversation rate.
A MEDIAN filter configured with a value of 101 allows filtering on 101x25ms = 2.525 seconds.

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15.1.1 ANALOG weight filtering parameters

Description of the Settings menu parameter


The parameters below are displayed only
when the analog sensor is configured
Weight Display Step 7
Display filter allowing to shorten the value displayed on the BFC monitor as well as the analog
output. the value corresponds to the maximum gap in which weight will not vary.
Default value: [0.05]
Unit: []
Limits: [0.001...10000]

Sample Time 1
This value corresponds to the sampling time of the analog digital converter between two
acquisitions of the weight signal, given in ms. The acquired value is the average of all
measurements made by the converter during the interval.
Default value: [33,33]
Unit: [ms]
Limits: [list: 8.33-16.66-33.33-66.66-133.33]

Wgt Filter Cutoff 2


Value in Hertz of the low pass filter. All frequencies above the value entered are automatically
filtered. A value of 0.3-0.6 is considered normal.
Default value: [0.35]
Unit: [Hz]
Limits: [0.001...10]

Wght Med Fltr Size 5


Weight filtering per median filter, the parameter value corresponds to the filter size, the value
entered must always be odd.
Default value: [31]
Unit: []
Limits: [1...101]

Filter Switch Thr. 6


Percentage value corresponding to the amplitude of the tunnel outside which the filter "Acq.
Filter Weight" is reset by the value of the "Median type Filter". If the value is at 0% the "Median
type Filter" median filtering is applied permanently, if the value is at 100% the filtering "Acq.
Filter Weight" is applied permanently.
Default value: [5]
Unit: [%]
Limits: [0...100]

Weight Avg Time 3


This value corresponds to the time of the average sliding filter, used to generate an average
weight value to calculate the load on the belt, or the weight on the impact plate for a flowmeter.
Default value: [5]
Unit: [s]
Limits: [1...101]
Row Gross Weight Display the gross weight
Avg Gross Weight Display the Averaged gross weight

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15.2 DIGITAL weight filtering

Organisation of the digital filtering

Digital weight filtering on the BFC controller is organised as follows:

Time
Low-
Median 5
pass
of sampling ms type type filter Averaged gross weight
filter

1 2 3 4 Weight Display
difference LCD
filter + 7
6 Output
Ana

The averaged gross weight 5 is issued directly from the SFT type digital weight sensor 1 ,
filtered with a median type filter 4 .
The SFT digital weight sensor includes a large part of filtering, a "lowpass" type filter 3 is used
to remove all disturbing frequencies above the filter value set by "Weight Acquisition Filter", this
filter is then followed with a "median" type filter 4 configurable by "Average time", the output
gives the filtered gross weight 5 .

To display the values of averaged gross weight 5 a filter called a weight difference filter is used
6 to display data on the BFC monitor and the analog output 7 , this filter works on a difference
allowing to shorten the value displayed.

The value of the averaged gross weight 5 is then used for calculating massflow.

All filters are paced at the same frequency: 25ms.


They are desynchronized by the SFT sensor conversation rate.
A MEDIAN filter configured with a value of 101 allows filtering on 101x25ms = 2.525 seconds.

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15.2.1 DIGITAL weight filtering parameters

Description of the Settings menu parameter

The parameters below are displayed only


when the digital sensor is configured
Wgt Display Step 6
Display filter allowing to shorten the value displayed on the BFC monitor as well as the analog
output. the value corresponds to the maximum gap in which weight will not vary.
Default value: [0,05]
Unit: []
Limits: [0.001...10000]

Sample Time 2 This parameter is not accessible !


This value corresponds to the sampling time of digital SFT between two acquisitions of the
weight signal, given in ms. The acquired value is the average of all measurements made by the
converter during the interval.
Default value: [160]
Unit: [ms]
Limits: [8.889...4542]

Wgt Filter Cutoff 3 This parameter is not accessible !


Value in Hertz of the low pass filter. All frequencies above the value entered are automatically
filtered. A value of 0.4-0.6 is considered normal.
Default value: [0,4]
Unit: [Hz]
Limits: [0.001...10]

Avg Time 4
This value corresponds to the time of the average sliding filter, used to generate an average
weight value to calculate the load on the belt, or the weight on the impact plate for a flowmeter.
Default value: [5]
Unit: [s]
Limits: [1...101]

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15.3 SPEED filtering

Speed filtering is ensured on a sliding average filter, the filter is used only when the measuring
wheel placed on the belt is disturbed.

15.3.1 Speed Filtering Parameters

Filter size
This value corresponds to the number of filtering table samples to generate an average speed
value. Averaged speed considers the Tacho Divider.
Default value: [20]
Unit: [ ]
Limits: [1...100]

Belt Speed Dt *
This value corresponds to the average time between two pulses after tacho divisor.
Default value: [ ]
Unit: [μs]
Limits: [ ]

Belt Speed *
This value corresponds to the average belt speed after filtering to see the effect of parameter
change.
Default value: [ ]
Unit: [m/s]
Limits: [ ]

Mass Flow *
This value corresponds to the display of the flow to see the effect of parameter change.
Default value: [ ]
Unit: [kg/h, t/h, lb/h, lb/min, T/h]
Limits: [ ]

The parameters abow are displayed only


when the belt scale machine is configured

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15.4 MASSFLOW filtering

Organisation of massflow filtering

Massflow filtering on the BFC controller is organised as follows:

Averaged gross weight


OR Filtering
Time
Stabilised
Filter time 4 Filter Display
6
Massflow LCD
Display
Dynamic Dynamic step +
Span Time Stability Output
3 5 tunnel
8 Ana
7 9
OR Filtering
Averaged speed

The massflow calculation is made with the averaged gross weight 1 and averaged speed 2 ,
the value is then filtered by a filter of the dynamic RC type including the parameters 3 allowing
to give filtering force and time 4 and the 5 parameter giving the filtering time to obtain 70%
the filter output value.
To obtain prompter monitoring of filtering in the case of major changes present n the weight or
speed, resetting the dynamic RC filter table is ensured by measuring the difference in massflow
7 over a stability time 6 , if the value exceeds the value of the parameters, the filter is reset.
To display the values of averaged massflow a filter called a Flow Display Step filter is used 8
to display data on the BFC monitor and the analog output 9 , this filter works on a difference
allowing to shorten the value displayed.

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15.4.1 Massflow Filtering Parameters Only the HASLER safety level


allows to set all parameters.
Flow Display Step 8
Display filter allowing to shorten the value displayed on the BFC monitor as well as the analog
output. the value corresponds to the maximum gap in which massflow will not vary.
Default value: [0,0]
Default value: [0]
Unit: [t/h]
Limits: [0.001...10000]

Filter time 4
This value corresponds t the rated loss of the RC filter, the higher the value of this parameter,
the stronger the filtering.
Default value: [2]
Unit: []
Limits: [0...99999]

Dynamic Span 3
This value corresponds to the multiplier ratio between the rated slope and the slope of the
"Rapid" and "Stable" modes.
Default value: [10]
Unit: []
Limits: [0...99999]

Dynamic Time 5
Parameter giving the value of the RC filter time constant, the time required for the filer output
to reach 70 % input value.
The higher the value, the more important the filter.
Default value: [10]
Unit: []
Limits: [0...99999]

Stability Tunnel Wdt 7


Parameter indicating the tunnel in which the filtered massflow does not reset the Dynamic RC
filter table.
Default value: [5]
Unit: [%]
Limits: [0...100]

Stability Time 6
Stability time for the Stability Tunnel parameter. The value corresponds to the time during
which massflow must remain within the Stability Tunnel parameter without the Dynamic RC
filter being reset.
Default value: [10]
Unit: []
Limits: [0...99999]

Filter Status
This value displays the current filter state, i.e. Fast, normal or stable.

Current Filter Time


This value displays the current time of the applied filter, this value is included between "Filter
time" / "Ramp Factor" and "Filter time" X "Ramp Factor"

Mass Flow 9
Average massflow allowing to display changes applied to filtering parameters.
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16 OPERATION MENU
Available 15:47
Daily Totalizer
Totalizer of the material load on the belt at deck or flowmeter
=>Totalizer<=
output. This totalizer can be reset upon request. It is reset
automatically when its value exceeds 999’999 scales or 6.03.2012 / 14:43
999’999 units. Daily Tot. 178 t
Default value: ()
Unit: [kg, t, lb, T], Limits: [ ] 999’999 units.
Erase
Note
The keyboard's totalizer key provides direct access to the daily
totalizer page.

Permanent Totalizer
Totalizer of the material load on the belt at deck or flowmeter
output. This totalizer can be reset to the "programming" mode.
It is reset automatically when its value exceeds 999’999 steps
or 999’999 units.
Default value: [ ]
Unit: [kg, t, lb, T], Limits: [ ]

Control Totalizer
Control totalizer used in a calibration procedure. It is reset
automatically when its value exceeds 999’999 steps or
999’999 units, or when the daily totalizer is reset.
Default value: [ ] Certain parameters
Unit: [kg, t, lb, T], Limits: [ ] are displayed only in the
maintenance mode.
Belt Speed
Belt speed measured by the speed sensor.
Default value: [ ] read only
Unit: [m/s, ft/s], Limits: [ ]

Belt Load According to the type of


Material load on the belt. machine used Integrator
Default value: [ ] with belt, metallic apron or
Unit: [kg/m; lb/ft], Limits: [ ] flowmeter, only parameters
linked with the machine
Mach Running Rate selected are displayed
Loaded belt operating time, expressed in percent of total
operating time. This value can be reset in the "programming"
mode.
Default value: [ ] read only Certain parameters
Unit: [%], Limits: [ ]
are displayed only in the
maintenance mode.

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17 METROLOGY MENU

Daily Totalizer Inc.


Erasable totalizer scale.
Default value: [xxxx]
Unit: [kg; lb]
Increment: [1 x 10n; 2 x 10n; 5 x 10n ] n=integer number

Perm. Totalizer Inc.


Non erasable totalizer scale.
Default value: [xxxx]
Unit: [kg; lb]
Increment: [1 x 10n; 2 x 10n; 5 x 10n ] n=integer number

Ext1 Totalizer Inc.


Scale of the totalizer programmable on a digital output.
Default value: [xxxx]
Unit: [kg; lb]
Increment: [1 x 10n; 2 x 10n; 5 x 10n] n=integer number

Ctrl. Totalizer Inc.


Control totalizer scale. Certain parameters
Default value: [xxxx] are displayed only in the
Unit: [kg; lb] maintenance mode.
Increment: [1 x 10n; 2 x 10n; 5 x 10n] n=integer number

Pulse Width Tot Ext1
External totalisation pulse width in ms.
Default value: [2000]
Unit: [ms]
Limits: [100...3000] per 100 ms steps

Initial tare
Average weight on the belt or impact plate measured during Initial taring.
The value measured during taring is used as a reference to calculate taring drift.
Default value: [ ] non modifiable
Unit: [kg, lb]
Limits: [ ]

Current tare
Average weight on the belt or impact plate measured during empty belt taring or the last zero
on the flowmeter.
Default value: [ ] non modifiable
Unit: [kg, lb]
Limits: [ ]

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Taring drift
Average weight difference between two empty belt tarings or two successive zero tarings.
To be used as reference to generate alarm 205 belt taring instability or alarm 205 Zero taring
instability.
Default value: [ ]
Unit: [%] Maximum load
Limits: [ ] According to the type of
machine used Integrator
Zero Variance with belt, metallic apron or
Difference between weight measured on the empty belt and flowmeter, only parameters
initial tare. If this value exceeds the maximum tare, linked with the machine
incident 206 Belt taring fault is reported. selected are displayed
Default value: [ ] non modifiable
Unit: [%] Maximum load
Limits: [ ]

Zero Variance (Flowmeter)


Difference between weight measured on the empty impact plate and
Initial Zero. If this value exceeds the maximum tare,
incident 206 Taring fault is reported.
Default value: [ ] non modifiable
Unit: [%] Maximum load
Limits: [ ]

Maximum Drift
Maximum difference authorized between the average weight of the belt or impact plate, and the
value obtained at empty belt taring or previous zero. To be used as reference for incident 205
Belt taring instability or 205 Zero taring instability.
Default value: [3,0]
Unit: [%] maximum load
Limits: [ ]

Maximum tare
Maximum difference authorized between the average belt weight and the value obtained at
Initial taring. To be used as reference for incident 206 Belt taring instability or 206 Zero taring
instability.
Default value: [3,0]
Unit: [%] Maximum load
Limits: [ ]

Maximum Flowrate
Maximum massflow calculated by the controller after each initial taring.
The value is calculated with the speed measured during initial taring and the value of the
weighing system capacity.
Default value: [rated load x noms]
Unit: [kg/h, t/h, lb/h, lb/min, T/h]
Limits: [ ]

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Maximum Load
Maximum material load on the belt, equal
to the maximum Massflow calculated divided by Speed
rated, calculated at the end of initial taring.
Default value: [ ]
Unit: [kg/m or lb/ft]

Empty threshold
Empty threshold for massflow calculation and totalisation.
Threshold below which the load on the belt or impact plate is considered as non existent. The
value of the empty threshold parameter represents directly the weight in kg on the weighing
bridge or impact plate.
Default value: [0,1]
Unit: [kg]
Limits: [0..999999]

If Empty threshold > 0.0: Totalisation is performed only when the load exceeds the value
inserted in Empty threshold
If Empty threshold = 0.0: Totalisation is performed permanently whenever the load exceeds
0 kg, if the load is below the initial tare (negative value), totalisation is blocked.

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19 SCALE MENU

The scale menu shows all parameters linked with the weighing system, as well as all elements
used to calibrate then check the complete weighing system on the machine.

19.1 CELL TYPE

CELL TYPE
Parameter used for defining the type of cell, among the following:

- SFT type digital cell

- Sensor balance type analog cell

The cell type chosen changes the display of certain menus.

19.2 WEIGHTBRIDGE

Menu used for reading and configuring elements making up the single or multiple weighing
bridge.

NET WEIGHT Read only
Gross weight minus the tare value.
Default value: [ ] not editable
Unit: [kg, lb]
Limits: [ ]

NET WEIGHT DISCHARGE Read only


NET weight reported at discharge point.
Default value: [ ] not editable
Unit: [kg, lb]
Limits: [ ]

WEIGHT TARE Tare value


The tare value is measured while the Weighing bridge is being tared dynamically on the belt
integrator and in static in the flowmeters.
Default value: [ ] noteditable
Unit: [kg, lb]
Limits: [ ]

RAW GROSS WEIGHT Read only


Gross weight measured on the level of the weight sensor(s).
For SFT sensors based on the ACQUISI filter. WEIGHT.
For analog weight sensors without any active filtering.
Default value: [ ] not editable
Unit: [kg, lb]
Limits: [ ]

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AVG GROSS WEIGHT Read only


Gross weight passed through the filtering parameters, see Filtering adjustment chapter.
Default value: [ ] not editable
Unit: [kg, lb]
Limits: [ ]

WEIGHIBRIDGE LENGTH Parameter identical to the mechanical menu


Distance between the two rollers adjacent to the weighing rollers. This distance corresponds
to the weighing bridge length.
Default value: [2,0]
Unit: [m, ft] Single station weighing
Material direction
Direction matière
Limits: [ ]
Longueur
Bridge du pont
length

Station amont
Upstream station Station aval
Downstream station
Stations
Weighingpesées
stations

ROLLER INTERVAL
If the measurement bridge is made of two or more weighing stations, enter the centre distance
between the extreme weighing rollers.
The default value is 0 m for
an integrator with only one weighing station.
Default value: [0,0]
Unit: [m, ft]
Limits: [ ] Dual station weighing
Direction
Material matière
direction

Longueur du pont
Bridge length

Roller
Entraxe
Interval

rouleau

Station amont
Upstream station Station aval
Downstream station

Stations
Weighingpesées
stations

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LEVER ARM
Lever arm used when the weighing cell is not in a lever ratio of 1, used for weighing with SFT
type digital cell.
Lever arm of the multiplier type equal to B/A in the example below.
Default value: [1,0]
Unit: [ ]
Limits: [ ] weighter roll

Lever arm = B/A Load cell

LEVER ARM GRAN/FL


Lever arm used on the flowmeter allowing to view the correct flow values with the weights laid at
the calibration hook locations. The reference values allowing to test the flowmeter are indicated
in the list of parameters supplied with the installation.
Do not confuse with the calibration arm described in chapter 20.6!
Lever arm equal to B/A in the example below on GRAN or FLOW type flowmeter.
Default value: [1,3354]
Unit: [ ]
Limits: [ ]

Lever arm for Gran


and Flow flowmeter

A
B

Lever arm equal to B/A

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19.3 SFT DETAIL

This sub-menu is used for configuring all the load cells connected to the BFC controller.

SFT Weight 1 Read only


SFT Weight 2 Read only
SFT Weight 3 Read only Gross weight reading on each cell
SFT Weight 4 Read only connected to the BFC controller.

19.3.1 SFT CONFIG

SFTs Read only


This value displays the addresses of all active SFTs on the integrator.
Example = -1 2 3 4 - - - - - - -
If any of the following are displayed, an error is indicated.
" ? " = invalid response generated by the SFT
" - " = no SFT at this address
" T " = the SFT no longer responds to the BFC controller
" f " = the SFT communicates, but is faulty

NB SFT REQUIRED
This parameter selects the number of SFT sensors required for proper operation of the
integrator. For a single belt integrator without options one (1) or two (2) sensor(s) is
normal. A higher value is used in multiple station integrators.
One cell only is used in flowmeters.

SFT SELECTED
This parameter selects the address of the SFT sensor, whose parameters will be
displayed.

SFT ADDRESS
Modifies the address of the SFT selected (0...12).
The request is ignored when the address is already being used by another SFT.

SFT RANGE Read only
This gives the nominal capacity of the load cell.

SFT TYPE Read only


This value indicates the measuring range of the selected SFT. The measuring range
is given by the last numbers indicated in kilos.

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SFT STATUS Read only


This parameter indicates the operating status of the SFT.
Its normal value is 181 or 183.
181 = SFT operating in synchronous mode
183 = SFT is synchronous mode address leader.
Status numbers other that that shown may indicate a faulty SFT. Call the HASLER
technical department in case of alarms linked with the sensor.

SFT S/W Read only


Reference of the software on the SFT sensor.

REPOLL SFT
By pressing the ENTER key, the BFC controller detects all the SFT sensors connected
to, the weight transmission channels. The BFC controller assigns the weight
measurement sensors to existing connections, the weight sensor power
supplies are switched automatically during this allocation. This function is only
used when putting a new load cell into service, by switching the power supplies
of the cells connected.
The controller forces the address of the SFTs found starting with address 1, and
adding 1 after each SFT found.

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20 CALIBRATION AND TARING

Indication on taring and calibration!


Before any operation related to calibration and taring,
check the following elements to have a base allowing
to read the value without external error.

1. Check the positioning of the integrator scale of flowmeter mechanical set.


2. Check the parameters linked with the weighing bridge or flowmeter.
3. Ensure the weighing system is free of any clogging, friction or mechanical friction before calibrating or
taring.

What is the difference between Calibration and Taring?

Two separate bases are used for measuring the weight on the BFC controller:

1. The first is the one associating one or several analog cell(s) of the spring balance type.

2. The other is the use of SFT type digital cells.

The difference between these two possibilities results in different parameter setting
combinations.
The calibration function (use a calibre or reference) is used only when weighing with an
anaolog load cell on the balance (1), whereas the taring functions are common to both weight
measurement possibilities (1 and 2).
20.1 Purpose of calibration

The measurement chain is made of one or several stress gages called analog load cells. The
latter converts the mechanical stress applied to it into an electric signal representative of this
constraint, "A/D Voltage" parameter on the BFC. This electric signal is then transmitted to
the BFC through a shielded cable. The BFC amplifies this signal and converts it into a digital
representation displayed under the "A/D Value" parameter on the BFC.

Schematic diagram of analog weight measurement on the BFC:

A Calibration
Filtering Gross weight
ratio
D

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This measurement chain must be calibrated, to ensure the resulting numeric conversion value
is an accurate representation of the quantity of material on the analog load cell.

Calibration is performed by measuring the variation of the "A/D Value" digital measurement, for
a load variation equal to the reference weight of the "Reference weight" parameter on the BFC.
Therefore, calibration aims at matching the "A/D Value" digital measurement of
the material weight on the analog load cell at a known reference value "Calibration
Reference weight".
Diagram describing the relationship between converter points and actual weight:
Poids = f (points convertisseur)
Weight = f (converter points)

points convertisseurs
A/D converter points value
VCA1
The BFC controller also
uses and displays the
values in mV for the
converter
points points analog spring balance
convertisseur
Zero
zéro

weightappliqué
poids applied
reference
poids weight
de référence

poids de référence
reference weight
Calibration
Coefficient coefficient =
d'étalonnage converter points
points convertisseur

Note on analog cells (1):


To prevent the voltage drop in the spring balance supply wires from biasing the weight
measurement, a 6-wire connection is required, based on the following principle:
2 power supply wires (X1, terminal 1 +5V and terminal 2 GND), 2 power supply return wires (X1
terminal 5 power supply return + and terminal 6 power supply return -) for measuring voltage
actually applied to the analog load cell and 2 measurement wires (X1 terminal 3 signal + and
terminal 4 signal -).

Switching between a 6-wire or 4-wire link is performed with the SW7 selector, which is
systematically set to 6 wires, see also Chapter 7.3.
20.2 When to perform calibration

This calibration must be performed upon:


- commissioning
- changing the analog load cell(s)
- changing or repositioning the weighing mechanical set

- changing the electric signal transmission cables


- changing the BFC controller

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20.3 Purpose of taring

The measurement chain is made of one or several stress gages called spring balances or SFT
type digital load cells. The latter convert the mechanical stress applied to them into a numeric
representation displayed under the "A/D Value" parameter on the BFC.

Schematic diagram of analog or digital weight measurement on the BFC:

A Calibration
Filtering Gross Tare Net weight
ratio
D weight

Or

Calibration
Filtering Filtering ratio Gross Tare Net weight
weight

Taring is required to have correct measurement references, in order to ensure the resulting
digital conversion value is an accurate representation of the quantity of material on the belt or
the flowmeter plate.

This taring is performed by measuring the measurement chain's empty weight, using one of
two types of operations:
- the first is used as a reference for calculating taring drift
- the second is used for current taring, hence increasing the measurement accuracy due to
material clogging the elements such as the belt or impact plate.

Therefore, taring aims at defining the reference tare to calculate the net weight, as well
as the current tare to increase the BFC's measurement accuracy.

20.4 When to perform taring

Taring must be performed upon:


- commissioning
- changing the analog load cell(s)
- changing or repositioning the weighing mechanical set
- after calibration in the case of an analog cell (taring reset!)
- changing the electric signal transmission cables for spring balances
- changing the BFC controller

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20.5 COEFFICIENT

Three different coefficients are available in the BFC:


- the "Internal Calib Coef" coefficient is calculated when calibrating the analog cell, it is not
modifiable, it is not present when a digital cell is used.
- the "Calibration Coefficient" is used by the client to modify the weight chain measurement
after material tests.
- the "HASLER Calib Coef" is used only by engineers when modifying the weight measurement
chain, allowing to return an installation with a calibration coefficient at the 100% value.

Principle of the measurement chain of analog or digital weight coefficients on the BFC:

A Internal Calib HASLER calib


Filtering Calibration
coefficient coefficient coefficient Gross
D weight

Or

Internal Calib HASLER calib


Filtering Filtering coefficient Gross
coefficient
weight

CALIBRE COEFFICIENT
Calibration coefficient related with the weighing bridge expressed in percent, used with all types
of cell.
Default value: [100], Unit: [%], Limits: [ 50 + 150 ]

INTERNAL CALIB COEF
Coefficient calculated only with calibration using the reference weight for the analog spring
balance.
Default value: [1.0], Unit: [ ], Limits: [ -1 +1 ]

HASLER CALIB. COEF


Coefficient used by HASLER engineers to correct a measurement error of the weighing system
when commissioning the installation, this coefficient allows to leave the calibration coefficient
at 100% a commissioning.
Accessibility in HASLER mode
Default value: [1.0], Unit: [ ], Limits: [-0,5 +0,5 ]

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20.6 ANALOG LOAD CELL

REFERENCE WEIGHT
Value of the reference weight used for calibrating the analog weighing cell.
Default value: [10]
Unit: [kg, lb]
Limits: [ ]

ARM CALIBRATION
Lever arm used when the weighing cell is not in a lever ratio of 1 with the calibration
weight, used for weighing analog cell for calibration with calibre weight.
The lever arm allows to check the weight by hanging reference weights to the
specific hooks of the flowmeter, and reading the net weight parameter.
Default value: [SBS, SAS 1.0 - GRAN, FLOW 0,50743]
Unit: [ ]
Limits: [ ]

Calibration arm for Gran Calibration arm


an d F l o w fl o wm eter for belt integrator

Calibre
weight

Lever arm equal to B/A

Lever arm equal to B/A

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A/D VALUE
Gross value of the points of the analog / digital converter.
Default value: [ ] non modifiable
Unit: [pts]
Limits: [0..1'700'000]

A/D VOLTAGE
Gross value of the mv indicated by the analog weighing cell.
Default value: [ ] non modifiable
Unit: [mV]
Limits: [0..40]

SCALE USAGE
Value in percent of the spring balance capacity usage, 0% = no weight 100% rated
capacity reached.
Default value: [ ] non modifiable
Unit: [%]
Limits: [0..100]

ANA CELL CAPACITY


Rated capacity of the spring balance calculated after calibrating the analog spring
balance.
The value can be adapted subsequently.
Default value: [ ]
Unit: [Kg]
Limits: []

CELL SENSIVITY
Value of sensitivity of the analog load cell in mV/V, used with stress gages.
Default value: [ ]
Unit: [mV/V]
Limits: [1 - 3]

20.6.1 CELL REPLACEMENT

Procedure for changing the analog cell without recalibrating.


This procedure uses the sensitivity and rated capacity values of the two old and
new weighing cells, then a new coefficient is calculated and applied based on the
calibration coefficient of the cell to be changed.
This procedure does not produce the best weighing result, as it ignores any new
friction in the weighing system after changing the weighing cell, however it ensures
the prompt proper system running.

HASLER recommends to use the calibration procedure with calibre reference for
higher weighing accuracy, see chapter 20.6.2.1

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20.6.1.1 Diagram Changing an analog load cell


S01 Display on LCD
"Cell
Replacement "
procedure Home page Analog spring balance
procedure aborted

Display on LCD Spring balance


rated capacity
Old spring balance = xxx kg
New spring balance = xxx kg

Display on LCD Spring balance sensitivity


Old spring balance
= xxx mv/v
New spring balance
= xxx mv/v

Coefficient
calculation with
value according
Weight on Scale = xxxx kg
to S02 S03

S05
save and apply new
calibration coefficient, parameter
"Internal spring balance cal coefficient"

If the "Backspace" key


is pressed at any time
Display on LCD Status of successful
during the procedure
calibrations + BFC
controller ready for use

Do you really wish to abort


Display on LCD the procedure?

End of procedure Back to Home page

YES NO

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20.6.2 Analog load cell Calibration Procedure

20.6.2.1 Calibrating an analog load cell with reference weight

With Reference weight


Procedure for calibrating the analog load cell with calibre weight (reference), this
procedure performs the entire sequence of steps required to defining the weighing
reference.
This calibration produces the best weighing reference as it takes into consideration
the frictions in the weighing mechanical assembly.

20.6.2.2 Calibrating an analog load cell with sensitivity

With sensitivity
Procedure for calibrating the analog load cell without the reference of a calibre
weight, this procedure uses the references written on the spring balance.
Sensitivity in mV/V as well as the rated capacity of the spring balance will be used.
This function is used only if using a calibre weight is not possible.

HASLER recommends to use the calibration procedure with calibre reference for
higher weighing accuracy, see chapter 20.6.2.1

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20.6.2.3 Diagram Calibrating an analog load cell with calibre reference


LCD display
S00
" Cell calibration "
with reference weight Home page
procedure Calibration procedure
aborted

Reference weight value


LCD display
= xx kg

Do you wish to change?

YES NO

S02
LCD display
Counter = 0

Enter the calibration Counter


weight value = xx kg 120 to 0

S03.1
LCD display

S03
Belt stopped Stop the belt for (another)
check second before aborting
speed = 0 the procedure

LCD display
Empty point
memorisation Measuring the empty belt
point, please wait

Place the calibration


LCD display
weight at the appropriate
location on the weighing
bridge and press OK

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LCD display
and max point
memorisation
Measurement of load cell
weight and calibration
reference point

LCD display Weight on scale


Coefficient = xxxx kg
calculation
with value Spring balance capacity
according to = xxx kg
S04 S06
Accept Refuse

LCD display

Do you really wish to abort


the procedure?

S08 YES NO
save and apply new calibration coefficient,
parameter "Internal spring balance cal
coefficient"

Test of former coefficient


available = OK

LCD display Status of successful


calibrations + BFC
controller ready for use
Old coef = OK

Calibration not performed


LCD display BFC controller not
available

S10
End of procedure

Back to Home page

Do you really wish to abort


If the "Stop" key is LCD display the procedure?
pressed at any time
during the procedure
YES NO

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20.6.2.4 Diagram Calibrating an analog spring balance with sensitivity


S01 LCD display
"Cell calibration"
with sensitivity Analog spring balance
procedure Home page
changing procedure
aborted

LCD display Enter the spring balance's


rated capacity
Rated capacity = xxx kg

LCD display
Enter the spring balance's
sensitivity
Sensitivity = xxx mv/v

LCD display
Coefficient New calibration coefficient
calculation calculation = xx
with value
according to
S02 S03

Counter = 0

Counter
120 to 0
S05
Belt stopped check
speed = 0 LCD display

Stop the belt for (another)


second before aborting
the procedure

LCD display
Saving the
empty point
Measuring the empty belt
point. Please wait.

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save and apply new calibration coefficient parameter


"Internal spring balance cal coefficient"

S08
Test calibrations present
Load cell = OK
Or
Sensitivity calibration = OK
+
Initial taring = OK
Or
Automatic calibration = OK

LCD display Status of failed LCD display Status of successful


calibrations + BFC controller calibrations + BFC controller
not available available ready to use

End of procedure

Back to Home page

If the "Stop" key is pressed


at any time during the
procedure

Do you really wish to abort


LCD display
the procedure?

YES NO

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20.7 Taring

Trim Factor
Factor to adjust the calculation of the flow rate.
Accessibility in HASLER mode
Default value: [100]
Unit: [%]
Limits: [50 - 200]

Product Factor
Factor related to the product.
Default value: [120]
Unit: [%]
Limits: [50 - 200]

Initial zero (Reference) for flowmeter


This taring defines the zero reference on which the different dynamic parameters of the
GRAN or FLOW flowmeter will be calculated and measured.
Reference also used to calculate zero taring drift.
This reference is independent from the load cell calibration reference, and can hence
be used to reset the zero after flowmeter clogging.
Present only on the flowmeter

Zero
Parameter used in GRAN and FLOW flowmeter applications, allowing to reset the
weight measurement when the flowmeter is stopped.
It allows to increase measurement accuracy in the case of a very dusty environment.
Present only on the flowmeter

20.7.1 Initial taring

Initial Taring (Reference)


Initial taring measures and memorizes the weight of the weighing station, plus the
empty belt weight in dynamic (when the belt is moving).
If this function is requested when the belt is stopped, the message "Belt stopped error
please start the belt" appears, and the function is cancelled.
During Initial taring, the controller measures and memorizes the average weight of
the empty belt. This average will be used as reference value for Empty belt and taring
and alarm limit.

Belt length for taring


Initial and empty belt taring are performed on a belt length of X m. This taring length
can be modified with this parameter.
Default value: [20]
According to the type of machine used
Unit: [m]
Integrator with belt, metallic apron or
Limits: [0 - 10000]
flowmeter, only parameters linked with
the machine selected are displayed

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Taring evolution
When performing the initial and empty belt taring, the controller displays the
percentage belt length already measured.
This parameter is displayed only when taring directly on the display.
Default value: [ ] Non modifiable
Unit: [%]
Limits: [0 - 100]

20.7.2 Empty Belt Taring

The Empty belt taring submenu allows manual or automatic setting of empty belt taring.

Empty Belt Taring


Empty belt taring measures and calculates the average belt weight.
This taring allows the controller to compensate weight variations due to material
clogging and those resulting from belt tension differences. This function should be
used regularly, but once per week as a minimum in the case of a clogging product.

Empty belt taring operating mode
(E.B.T. Funct. Mode)
Manual: Operation launched by the Empty belt taring function, or by digital input, or
communication from a supervisor.
Automatic: Permanent operating mode based on the Empty threshold for empty belt
taring, if the automatic mode is defined, once the material level is below the Empty
Threshold parameter for empty belt taring, empty belt taring is started.
Default value: [Manual]

Empty Threshold for empty belt taring


(E.B.Ta. Threshold)
Empty belt taring can be started only when the value of the weight on the weighing
bridge is below the Empty threshold parameter for empty belt taring.
During empty belt taring, if the belt weight exceeds the empty threshold for empty belt
taring, current taring is stopped and the average belt weight memorised beforehand
remains used as a reference value. A new taring is performed automatically when the
belt is considered as empty and the belt is running.
Default value: [5,0]
Unit: [kg, lb]
Limits: [none or 50 - 100 % rated load cell]

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20.8 Calibration using chains The function described


below are valid for
software releases from
version 2.0.0.6

Calibration using chains with a known weight per meter enables the BFC to take
the dynamic effect of the belt into account.
The weight of the chains must be at least equal to 25 % of the Maximum load.
The totalization measured is compared to the theoretical totalization
corresponding to the known weight of the chains.
This calibration method is not recommended for inclined conveyors.

Procedure :
Unload the belt.
Program the weight per meter of the chains using the parameter Chain Calib
Weight.

CALIBRATION AND TARING


Chain Calibration
Chain Calib Weight
Weight per meter calibration chain, the value must be precise to avoid an coefficient
error calculation.
Default value : [50.0]
Unit: [kg]
Limits: [ ]

Place the chain in a straight line along the belt. The chain must extend over at least
two stations on each side of the weighbridge.

Weighing station

Weighing bridge

The BFC controller totalizes a lenght of belt equal to the lenght of belt taring, see
parameter Belt Length Taring for calibrations.
The effective length used in the chain calibration is related to the next belt segment
for the totalization.

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CALIBRATION AND TARING


Belt Length Taring
Chain calibration is carried on a length of belt X m.
The belt length can be changed with this parameter.
Default value : [200]
Unit : [m]
Limits: [0 - 10000]

CALIBRATION AND TARING


Chain Calibration
Chain Calibration

Use this function to start the execution of the calibration with chains, during this
calibration the BFC displays the percentage of taring completed 0 to 100%.

As soon as the calibration is completed the BFC comtroller compares the measured
totalization with the theoretical value (Belt Length x Chains calibrations Weight) and
calculates the new coefficient calibration.

chain weight * taring Belt lenght


New calib coef = coeff calibration x --------------------------------------------------------------
totalizer

If this new coefficient is greater than the maximum allowed value


(10% + / - 10%), it will be refused and the old coefficient will be retained. In this case,
the alarm message 211 max exceeded variation coefficient will be displayed.

CALIBRATION AND TARING


Calib Coef

Coefficient calculated with the chain calibration function.


Default value : [100.0]
Unit : [%]
Limits : [ 50 +150 ]

CALIBRATION AND TARING


Chain Calibration
Chain Calib Dev MAX

Maximum allowed correction for the calibration chain coefficient, only used with the
calibration chain.
Default value : [10.0]
Unit : [%]
Limits : [ 0 +100 ]

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20.8.1 Chain calibration organization chart

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20.9 Material test calibration

The material test is one of the best ways to verify and eventually adjust the accuracy of
SBS, this calibration takes into account all the dynamics of the conveyor with integrated
SBS.
Before starting any material test, it is mandatory to check the following points, this will
save your time later :

Check list before testing :


1. The mechanical installation of the SBS must be vibration free, and this with all plant
equipment in operation (material transport, mills etc.).
2. Check if there is a by-pass device at the conveyor discharge point, permitting to
divert the material during the material test. If not, install a suitable arrangement to
divert and collect the material
3. Make sure that the diversion arrangement is leak proof (by-pass for truck loading);
analyze the material transport route and identify any dead zones in which material
could stagnate, i.e. lower half of screw conveyors, chutes etc. Measure the time
necessary to fill the various dead zones

Procedure : see end print complete procedure on 20.9.1


1. Empty the belt.
2. Set this daily totalizer or the control totalizer to zero.
OPERATION
Control totalizer or daily totalizer = 0.0 kg
3. Turn on the conveyor.
4. Load a quantity of material on the belt equal to at least 25% of the maximum load,
but without exceeding the limits, this during a revolution of the band.
5. Weigh the material and the result to Check totalizer (Control or daily) value.
6. Calculate the calibration coefficient (calib coef) :

Weight of material
Test material Coefficient = -------------------------------------- * 100
Control or daily Totalizer

Introduce this calibration coefficient in :

CALIBRATION AND TARING


Calib Coef

Coefficient calculated with the material test calibration.


Default value : [100.0]
Unit : [%]
Limits : [ 50 +150 ]

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20.9.1 Material test calibration


Preparation
To prevent wasting time during the material
tests, it’s important to check the points listed
hereafter before starting:

1. Check
1. The mechanical installation of the SBS
must be vibration free, and this with all
plant equipment in operation (material
SBS
transport, mills etc.)
2. Check if there is a by-pass device at the
conveyor discharge point, permitting to 2. Check that the weigh bridge is perfectly
divert the material during the material aligned, allowing the same accuracy
test. If not, install a suitable arrangement independent of the requested feedrate.
to divert and collect the material
3. Make sure that the diversion arrangement
is leak proof (by-pass for truck loading);
analyze the material transport route
and identify any dead zones in which
material could stagnate, i.e. lower half of
screw conveyors, chutes etc. Measure
the time necessary to fill the various
dead zones
3. By positioning different known weights
2. Optimizations on the central weighbridge idler, the
1. Check that the weighing roller of the weighbridge weight measurement can
weigh bridge is free of any hard point be checked by reading parameter
(blocking due to matter residues etc). “Gross weight”.
4. Check with the parameter " discharge
Free of any hard point point " that the calculation of the
totalization is carried out at the matter
point of fall. The parameter must be
equal to the distance between the
weighbridge (weigh idler station) and the
fall of the matter in end of conveyor.
5. Check the speed measurement by
making two reference marks on the belt
and measuring the time interval between
these marks. Calculate the beltspeed,
dividing the distance between the marks
(m) by the time (s). The result must
correspond to parameter Belt speed.

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Material tests 9. If the system allows to change the setpoint,


select a setpoint between 20 and 100% of
If the various material tests must be realized with the nominal feedrate.
the help of several persons, it's recommended to 10. Start the machine until the desired batch size
make a short briefing to explain the material test has been reached, then stop.
procedure : 11. Weigh the container. If it's a truck, weigh it
without the driver and take into account the
fuel consumption (see point 5)
3. Material tests Define the net material weight, subtracting
1. The necessary material quantity for the the previously weighed empty weight from
material tests is determined as follows : the now measured gross weight.
• Accuracy to be achieved = i.e. 0,5 % 12. Read the daily totalizer.
• Resolution (measurement increment step)
of the scale used for the check weighing
(customer) = i.e. 20 Kg
• The weighing accuracy of the check weigh
4. Results
1. Calculate the absolute error on the basis of
scale must be 2 x higher than the accuracy
the totalizer reading and the net material
to be achieved = 2
weight:
• Measurement increment step * 100 *
wieghing accuracy / accuracy to be achieved
Net material weight
= necessary material quantity (batch size).
Error in % = --------------------------------- * 100
In our example: 20 * 100 * 2 / 0,5 = 8000 Kg
Daily totalizer
minimum
2. Obviously, the larger the material quantity (>
2. To confirm the calculated result, make at
calculated value), the better the result. On
least one more material test with the same
the other hand, the min. material test time
setpoint and recalculate the error.
must not be less than 2 minutes.
3. If the 2nd error calculation differs considerably
3. If the material transport route after the
from the 1st result, make a 3rd material
SBS includes equipment such as screw
test.
conveyors, belt conveyors, chutes etc., the
dead zones of these equipment must be
filled by operating the installation at least for 5. Coefficient Correction on BFC
the time measured under point 1.5. . 1. With totalizer values ​​and net weight of the
4. Prepare a container (truck), large enough to test material, and the coefficient present
hold the material quantity calculated under in the parameter coefficient "Calib Coef",
point 1 calculate the error to apply :
5. Weigh or detare the empty container. If it's
a truck, weigh the empty truck, without the Net material weight
driver and take into account the distance coefficient =old coef * ------------------------------
between the check weigh scale (customer) Daily totalizer
and the material test site. A heavy duty truck
consumes approx. 30 to 50 liters of fuel per 2. To correct the measurement system on
hour. At a fuel density of 0.88kg/l, one hour BFC, calculate the average error to be
of running already accounts for an error of compensated and add it to the parameter
0.55% on a 8000kg batch. “Calib. Coeff” in menu Balance and taring =>
6. Adjust the daily totalizer increment step, Coef. calib.
parameter “Daily Totalizer. inc.”, to 1 Kg.
7. Reset the daily totalizer to zero.
8. Make sure that the container is in place and
that it's totally empty.

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21 INPUT / OUTPUT INTERFACE

Indication on input and output interfaces!


Please consider the elements described below before setting
the input and output interface parameters. ===

Before any operation linked with programming input and


output interfaces, ensure the wiring and maximum voltage
/ current values linked with the interfaces are applied.
See chapter on connection of the interfaces.
1. Check that the input or output is free and not already used by another function.
2. Check electrical polarity of the wiring for inputs and outputs on transistor.
3. Check which type of idle state is used by your system, ideally the idle state is contact open on an output,
and input non activated (no current flowing) on an input.

Example of configuration of a digital output

Configuration of the BFC's digital output number 2 with the general alarm function:

1. Select output number 2 using the OUTPUT NUMBER(1-3) function.

2. Use the FUNCTION parameter to select the general alarm function.

3. Check the state of the output, activated when the alarm is present, or conversely the output state with the
output POLARITY parameter deactivated when the alarm is present.
Example of analog output configuration

Configuration of the BFC's analog output with the integrator massflow over a range from 4 to
20 mA and this for a massflow reference from 100 t/h to 400 t/h:

1. Use the FUNCTION parameter to select the massflow function.

2. Enter 400 in the MAX SOFT VALUE parameter.

3. Enter 100 in the MIN SOFT VALUE parameter.

4. In the MAXIMUM VALUE parameter, enter the maximum current value required for the analog output, i.e. 20
in our example.

5. In the MINIMUM VALUE parameter, enter the minimum current value required for the analog output, i.e. 4 in
our example.

6. The HYSTERESIS parameter sets the accuracy of modifications of the output according to the value
assigned in the function parameter, 0% being maximum accuracy.

7. The Coef Ana Output parameter is used to amplify or reduce the amplitude of the signal applied to the
analog output independently between 50 and 150 % (visible in HASLER mode).

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21.1 INPUT / OUTPUT PARAMETERS

21.1.1 ON/OFF OUTPUTS

OUTPUT NUMBER [1-3]


This parameter configures the output to program for the specific output numbers 1 to
3. Output 1 is linked with relay 1 of the BFC, output 2 with relay 2 and output 3 is a
transistorised output.

FUNCTION
This parameter configures the function allocated to the output selected: None, totalizer,
General alarm, stop on alarm, programmable threshold 1, programmable threshold 2,
PSR table, ASR table.

OUTPUT STATUS Read only


This parameter indicates the output status low level, high level.

MAP NUM
This parameter appears only when the MAP ASR or PSR function is selected in the
Function parameter.
Enter the PSR or ASR bit map number to be assigned to the output.

POLARITY
Select Normal or Reverse. Select reverse to reverse the polarity of an output.

21.1.2 ON/OFF INPUTS

INPUT NUMBER [1-2]


This parameter configures the input to program for the specific input numbers 1 to 2.
Input 1 is linked to the controller's physical input "signal 1", input 2 to the "signal 2"
input.

FUNCTION
This parameter sets the function of the selected input: None, Reset daily totalizer, Clear
alarm, Acknowledge horn, Locking, On/Off, Empty belt taring, Main / operating mode,
Inhibit totalizer, Belt drift 1, Belt drift 2, Belt drift, Slide index, Input map.

INPUT STATE
This parameter indicates the input's state: low level, high level, non assigned.

BIN MAP.
This parameter appears only when the MAP PSR function is selected in the Function
parameter.
For entering the numbers of functions not included in the above list.

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POLARITY
Select Normal or Reverse. Select Reverse to reverse the polarity of an input. An
input can be simulated by changing the polarity.

21.1.3 ANALOG OUTPUT

FUNCTION
This parameter sets the function assigned to the selected analog output: None,
Massflow, Belt Load, net cell weight, speed.

OUTPUT VALUE Read only


This parameter indicates the output's level in %, 0 % for 0 mA and 100 % for
20 mA.
The analog output is updated every second.

MAX SOFT VALUE


Maximum reference of the value assigned under FUNCTION indicating the
value entered under MAXIMUM VALUE of the analog output.
Default value: []
Unit: [kg/h, t/h, lb/h, lb/min, T/h]
Limits: [ ]

MIN SOFT VALUE


Minimum reference of the value assigned under FUNCTION indicating the
value entered under MINIMUM VALUE of the analog output.
Default value: []
Unit: [kg/h, t/h, lb/h, lb/min, T/h]
Limits: [ ]

MAXIMUM VALUE
Sets the maximum value for the analog output expressed in mA.

MINIMUM VALUE
Sets the minimum value for the analog output expressed in mA.

HYSTERESIS
This parameter defines the level of acceptable signal difference (Hysteresis)
assigned under "FUNCTION" to ensure the output selected changes value,
expressed in full scale percentage.

Coef Ana Output


This parameter allows to amplify or reduce the value of the electrical signal
programmed under the function parameter independently (Visible with the
HASLER safety level only).

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22 MACHINE According to the type of


machine used Integrator
22.1 MECHANICS with belt, metallic apron or
flowmeter, only parameters
This submenu allows to select the physical characteristics linked with the machine
of the machine connected tot he controller. selected are displayed

MACHINE TYPE
According to the machine type selected, certain parameters and menus will be configured
and activated automatically.
Belt, Gran, Flow

Discharge point
This parameter indicates the distance between the center of the weighing bridge and the
conveyor discharge point.

WEIGHBRIDGE LENGTH Parameter identical to the scale menu


Distance between the two rollers adjacent to the weighing rollers. This distance
corresponds to the weighing bridge length.
Single station weighing Material
Directiondirection
matière
Default value: [2,0]
Weighbridge
Longueur dulength
pont
Unit: [m, ft]
Limits: [ ]
Upstream station Station amont Station aval
Downstream station
ROLLER INTERVAL Stations
Weighingpesées
stations
If the measurement bridge is made of two
or more weighing stations, enter
the centre distance between the extreme weighing rollers.
The default value is 0 m for an
Dual station weighing
integrator with one weighing station. Material
Directiondirection
matière

Default value: [0,0] WeighBridge


Longueur dulength
pont

Unit: [m, ft] Roller


Interval
Entraxe
Limits: [ ] rouleau

Station amont
Upstream station Station aval station
Downstream

Weighing stations Stations pesées


CONVEYOR ANGLE (Present with digital cell)
Angle formed between the conveyor at the weighing bridge location and horizontal.
Default value: [0]
Unit: [°]
Limits: [0 - 89 ]

IMPACT PLATE ANGLE (Only with flowmeter machine type)


Angle of the impact plate for flowmeters.
Available only for GRAN, FLOW flowmeters
Default value: [55]
Unit: [°]
Limits: [0 - 89 ]

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DRIFT LENGHT
Distance during which the band drift sensor must be enabled to generate the alarm
belt drift.
Default value: [0,3]
Unit: [m, ft]
Limits: [ ]

22.2 SPEED RECORDING


According to the type of machine
SENSOR POSITION used Integrator with belt,
Position of the sensor to calculate belt speed. metallic apron or flowmeter,
Belt, Motor, Drum, None only parameters linked with the
machine selected are displayed
PULSES / REVOLUTION
Number of tacho pulses for one turn
Default value: [8]
Unit: [m,ft], Limits: [0..999999]

WHEEL DIAMETER
Diameter of the speed measurement wheel, if belt selected.
Default value: [0,159]
Unit: [m,ft], Limits: [0..100 ]

GEARBOOX RATIO
Visible only of Sensor position = Motor or Drum.
This parameter indicates the transmission reduction between the speed sensor and the
drive drum. This value is found from the Engineering Spec Sheets or by multiplying the
gear reductions shown on the nameplates of the different reduction levels
Default value: [1]
Unit: [ ], Limits: [ ]

DRUM DIAMETER
Visible only of Sensor position = Motor or Drum.
This parameter defines the diameter of the drum the speed recording sensor is fitted
on.
Default value: [1]
Unit: [cm, ft ], Limits: [ ]

TACHO DIVISOR
This auto-calculated parameter defines the pulse division of the speed sensor used
internally by the programme.
The automatic calculation is based on the theoretical speed entered under the
"Theoretical speed" parameter.
This parameter can also be modified manually.
Default value: [ ]
Unit: [], Limits: [2..10000]

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NOMINAL SPEED
Value corresponding to the rated belt speed measured at initial taring.
This speed is used to calculate the rated massflow and rated load of the feeder.
Default value: [read only]
Unit: [m/s, ft/s ], Limits: [0,00001..10000]

THEORETICAL SPEED
On the belt integrator as:
Value corresponding to the theoretical belt rated speed for the definition of the tacho
divider, and also when no speed measurement is installed.
Default value: [ ],
Unit: [m/s, ft/s ], Limits: [0..10000]

OR

On the flowmeter as:


Value corresponding to the theoretical material speed on the impact plate.
The value differs according to the type of flowmeter (GRAN 6.1 m/s, FLOW 4.39 m/s),
Default value: [GRAN 6.1 - FLOW 4.39 ]
Unit: [m/s, ft/s ], Limits: [0..10000]

The theoretical speed parameter is very important, as it ensures proper definition of


the tacho divider for the belt integrator.
It is also very important in the flowmeter for accuracy of the massflow calculation and
material totalization.

MINIMAL SPEED
Value corresponding to the minimal speed to generate an Low speed alarm.
Default value: [0,05]
Unit: [m/s, ft/s ], Limits: [0,00..1000]

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23 SYSTEM

23.1 GENERAL

Controller dynamic running time


Dyn. Operation Time Read Only
Number of operating hours in controller dynamic measurement mode (belt running,
flowmeter in measurement).

Controller operating time


Ctrl Operation Time Read only
Number of hours operation of the controller.

UNITS kg/h / t/h / lb/h / lb/min


Integrator TYPE Belt / Flowmeter
LANGUAGE Français / English / Deutch / Italiano / Portugese /
Espanol / Pycckий / Chinese
DATE System date, used for history.
TIME System time, used for history.

CLEAR MEMORY
When memory is asked to be cleared, the controller asks for
confirmation of this function with a message such as "Do you wish
to restore the default parameters?" if you answer yes, the controller
parameters will return to their default values (auto initialized
parameter), calibrations and taring will be cleared and must be
repeated.

23.2 SOFTWARE VERSION


CPU BOARD SW Version of the software running
CPU BOARD HW TYPE Hardware version of the CPU / COM board

23.3 SECURITY
SECURITY LEVEL Operator / Maintenance / HASLER
The password is required to change the security level. The security level returns to the
operator level after one hour.
After a CLEAR MEMORY, the password is auto initialised automatically to 1000.

The Maintenance and HASLER security levels allow to display and modify menus and
parameters specific to the BFC controller maintenance.
Back to
Security
Access to menus and parameters operator
level
level
Operator Access to operating menus and parameters Never
after 60
Maintenance Full access to menus, parameters and functions of the BFC controller
minutes
HASLER Permanent HASLER engineer mode without automatic initialisation After 24H

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Additional locking is possible by configuring a digital input with the locking function, if
the input is active, changing the security level is not possible.

PASSWORD Password modification.


Apply the following procedure to replace the password auto-initialised at 1000 with
another password:

Example of initial password modification


Configuring a new password:

1. Select the PASSWORD parameter in the SYSTEM => SECURITY menu.

2. Enter the password 1000 and confirm with Enter.

3. Enter the new password chosen and confirm with Enter.

Example of password modification


Configuring a new password:

1. Select the PASSWORD parameter in the SYSTEM => SECURITY menu.

2. Enter the password used in point 3 in the example above and confirm by pressing Enter.

3. Enter the new password chosen and confirm with Enter.

Please memorize your new password properly before confirming your selection, as the
new password will be used to select the security levels, or change the password.

If you have forgotten your password, please call customer service, who will
guide you in the procedure to be applied to implement a new password.

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Command origin Main / Maintenance

The BFC controller receives different commands, such as for example launching empty
belt taring, or can also receive real time data to adjust the massflow and totalisation
calculations, as for example measuring the tilt angle of the integrating scale.

To avoid having to reprogram the origins of commands according to whether the


machine is in maintenance or production, these can be pre-programmed on the BFC
and can have two different origins, i.e. Main or Maintenance.
Programming the sources is performed with the Com. Orig. Config. menu, allowing to
configure the details of the origins.

Command origin Operation

Principal Normal operating mode, used in production.

Maintenance Operating mode used by maintenance technicians.

Command origin configuration


Com. Orig.Config.. Principal / Maintenance
Angle Source BFC / I/O / Host

Angle Source SRC ANGLE


BFC

Inputs / Outputs

Host Protocol

Control source BFC / I/O / Host


Control source SRC CTRL BFC

Inputs / Outputs

Host Protocol

All possibilities

Example of configuration of command origins


Complete configuration for the Main mode with angle from the BFC and commands of
all sources available on the BFC:
1. Select the parameter Com. Orig. Config. in the SYSTEM => SECURITY menu.

2. Select the Principal mode in our example.

3. Select the Angle source parameter.

4. Select BFC and confirm by pressing Enter

5. Select the Control source parameter.

6. Select All and confirm by pressing Enter

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23.4 MAINTENANCE

Indication on the maintenance menu


Please consider that the functions and parameters described below are used within start-up
and overhauling your installation, modifying the following parameters may result in running
errors in the controller!

Reset_Ctrl Function performing a full controller reset, function equivalent to the SW1
selector.

Service port (Ethernet) see chapter 11.3

IP Address
Network Mask
Gateway
MAC Address

Possibility to run a series of functions from or on


the pc, such as (partial list):
Transfer software application from pc
Transfer parameters to pc
Transfer parameters from pc
Transfer alarm archives to pc
Transfer all to pc
Transfer all from pc

Information service through HTTP


This service uses an IP link to provide access to different pages using a commercial web
browser, these pages provide information such as for example all data linked with the
integrator or flowmeter, as well as any alarm information and state messages.

File System see chapter 11.4

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23.5 COMMUNICATION

The protocols are described in the manual accompanying the configuration of the type of
communication and its parameter setting. This manual is supplied separately.

Host Protocol configuration

None

PROFIBUS
MODBUS TCP
MODBUS RTU


The address of the BFC controller used in communication protocols varies
according to the protocol selected, after selecting and resetting the BFC
controller, please enter the parameters according to the documentation of the
communication protocol used.

Reset controller
Function allowing to reset the controller after selecting the protocol desired under the
Config.Prot.Supervision parameter.

Host Protocol Diagnostic

State Communication state, Start,Stop, Unknown


Heart Bit Control parameter counting on the BFC side
Host Heart Bit Control parameter counting in supervisor side

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24 DIAGNOSTIC

Indication on the Diagnostic menu


This menu indicates all controller operating states in real time.
The submenus provide interesting information to have an accurate idea about a particular
problem.
The submenus also allow to perform tests on the lcd display and keyboard keys, as well as the
input-output activation functionalities.

CALIBRATION STATE
analog load cell Read only (OK or —)
Initial taring Read only (OK or —)
Empty belt taring Read only (OK or —)

PARAMETER ON INDEX
INDEX SERVICE Read / write

SIMULATION
Using simulation during tests with supervision provides dynamic values evolving on
the different parameters of the BFC controller.

Simulation is deactivated automatically after 60 minutes or after mains failure.

Weight simulation (yes or no) Reset to no if network failure


Speed simulation (yes or no) Reset to no if network failure

BELT PARAMETERS
GROSS weight Read only of the instant value
Belt tare Read only
Positive belt weight peak Read only
Negative belt weight peak Read only

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HARDWARE TEST

TEST HMI
Man Machine Interface (MMI) function allowing to test the LCD display and all
LEDs, once the test initiated, the LEDs are lit, and the keys as well as the LCD are
tested, as each key lights one part of the LCD.

To quit the test, press simultaneously both keys and

Ready 15:47

Deck flow
123.47 T/h
Speed 1.47 m/s
Deck load 23,33 Kg/m
Totalizer 134 T
To quit the test, press
simultaneously the keys
indicated

I/O TEST
Testing the digital and analog input / output interfaces in automatic mode.
When the Enter key is pressed on I/O TEST, the digital outputs and analog output
are activated with a 2-second cycle.

Output 1 state Enabled / Tripped


Output 2 state Enabled / Tripped
Output 3 state Enabled / Tripped
Output value Permanent variation between 0 and 20 mA
Input 1 state Real state measured permanently
Input 2 state Real state measured permanently

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26 WHAT SHOULD YOU DO WHEN A PROBLEM OCCURS?

26.1 Troubleshooting

Note
Any reset or change of one of the programming variables must be performed with the greatest
of care if nothing has previously been backed up.

Information
The BFC controller has a system to help with the repair and malfunction of your installation.
To do this, it is vital to read the information on the display console of the BFC controller. These
messages may be of two types, i.e.:

1. Information message related to a procedure wait state (for example waiting for a locking
signal to start the action).

2. Alarm message related to a breakdown or malfunction. To resolve the breakdown or malfunction,


read the type of alarm and its associated number and refer to the maintenance manual to find the
procedure to follow to correct the fault or refer to the help menu displayed on the screen of the
BFC controller.

26.2 Changing fuses

The following fuses are used:


F5 and F6 5 x 20 delayed 2 A / 230V.
If a 115 VAC power supply is used, replace them with:
F5 and F6 5 x 20 delayed 2 A / 115 V.
• Power down the BFC Panel controller.
• Replace the defective fuse(s)

Fuse F5 and F6

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27 MAINTENANCE

27.1 Cleaning
The dust outside the BFC controller box may be removed using a damp cloth and an industrial
cleaning product.

Caution
Do not use corrosive detergents and check that you do not use any liquid products that may
get into the BFC controller box.

27.2 Preventive maintenance

Preventive maintenance work must be carried out every 10 000 operating hours:

1. Checktightening of the grounding screws on the controller and machine.


2. Check the operation of the external safety switches and the locks.

BFC.941.001-E.c Page 99

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