Coal Control Belt Rip.pdf

Operating instructions and technical information

Belt Rip Detection System BPS-A2-MxG and BPS-A2-S

Fully automatic computer-assisted belt rip detection system for the monitoring of longitudinal rips in two separate conveyor belts

General Notes

Table of contents Table of contents................................................................................................................. 2 General Notes ...................................................................................................................... 4 Notes on the documentation ........................................................................................... 4 Conditions regarding liability ........................................................................................... 4 Explanation of the safety symbols .................................................................................. 5 Fundamental safety measures ....................................................................................... 6 Duty of owner/operator to take care ............................................................................... 7 Requirements for the operating personnel ...................................................................... 7 Accessories ......................................................................................................................... 8 Structure ............................................................................................................................ 8 Installation Instructions .....................................................................................................14 Transport, warehousing and unpacking ............................................................................14 Transporting ..................................................................................................................14 Warehousing .................................................................................................................14 Unpacking ....................................................................................................................14 Mounting the control system and the accessories .........................................................15 Connection of power supply ..............................................................................................17 Transmitter/Receiver.........................................................................................................19 Transmitter BPS-TX/8 and BPS-T/8 ..............................................................................21 Receiver BPS-RX/8 and BPS-R/8 .................................................................................22 Proximity switch Ni15, (Ni15T optional) .............................................................................24 Connection box CC-CB1212 .............................................................................................25 Rotary encoder CC-RE1024 (optional) .............................................................................26 Decoder CC-DEC1024 ..................................................................................................27 Profibus module A1-PB (optional) .....................................................................................29 Connection of data communication via fiber optic cable (optional) ....................................30 Output contacts Relay terminals X12 ................................................................................31 Operating Instructions BPS-A2-MxG ................................................................................34 Switching-on and switching-off..........................................................................................34 First run down, and then switch off! ...............................................................................34 First switching-on ..........................................................................................................34 After switching on ..........................................................................................................35 Structure of the RIP CONTROL V2 interface ....................................................................35

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General Notes

Login

....................................................................................................................35

Settings tab ...................................................................................................................43 Reports tab....................................................................................................................51 Display Parameters tab .................................................................................................52 Language tab ................................................................................................................53 Help tab

....................................................................................................................53

Close tab ....................................................................................................................53 Windows 7 tiles .................................................................................................................54 Operating instructions BPS-A2-S......................................................................................57 Switching on and switching off ..........................................................................................57 Software menu ..............................................................................................................57 Main screen...................................................................................................................57 Parameter menu ...............................................................................................................60 Login

....................................................................................................................60

Language settings .........................................................................................................61 Mode settings ................................................................................................................61 Number of sensor loops ................................................................................................62 Parameter settings ........................................................................................................62 Display unprotected loops .............................................................................................64 Taking sensor loop out of protection ..............................................................................65 Putting sensor loop back into protection ........................................................................65 Display fault messages .................................................................................................66 Address settings ............................................................................................................66 Date and time settings ...................................................................................................67 Display software version................................................................................................67 Parameter settings .............................................................................................................69 Example of the selection of the parameters ...................................................................72 Taking sensor loop out of protection ..............................................................................73 Putting sensor loop back into protection ........................................................................75 Maintenance .......................................................................................................................76 Cleaning the belt rip detection system ...........................................................................76 Maintenance..................................................................................................................76 Troubleshooting .................................................................................................................77 Replacement of components .........................................................................................77 Remedying defects........................................................................................................79 Remedying faults with messages displayed ..................................................................80

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General Notes

Service and support ...........................................................................................................83 Spare parts....................................................................................................................84

General Notes Notes on the documentation This description is intended exclusively for trained and qualified specialist personnel in the area of control and automation technology familiar with the applicable national standards. For installation and commissioning of the components it is absolutely essential that the following notes and explanations are observed.

Conditions regarding liability The specialized personnel must ensure that the application and/or the use of the products described meet all safety requirements including compliance with all applicable laws, regulations, provisions and standards. The documentation has been carefully prepared. The products described are, however, undergoing constant further development. Therefore, the documentation has not in every case been completely checked to ensure conformity with the performance data, standards or other features described. None of the declarations included in this manual represents a guarantee in the meaning of Art. 443 of the German Civil Code (BGB) or any indication of the use required in accordance with the contract in the meaning of Art. 434, para. 1, sentence 1, No. 1 of the German Civil Code (BGB). If it contains technical mistakes or typing errors, we reserve the right to make changes at any time and without prior announcement. No claims can be made for alteration of products already supplied on the basis of the details, illustrations and description in this documentation.

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General Notes

Explanation of the safety symbols In the present operating instructions, the following safety symbols are used. These symbols are to draw the reader’s attention above all to the text of the safety note next to it.

Danger

This symbol indicates that there are dangers for life and limb of persons.

Warning

This symbol indicates that there is a danger for the machine, the material or the environment.

Note

This symbol draws attention to information which contributes to better understanding.

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General Notes

Fundamental safety measures

Note

Before the control system is completely disconnected from the mains, the industrial PC should be switched off. Otherwise data on the hard disc can be lost. On this read the section ‘Switching the industrial PC on and off’.

Switch off the control system before other system components are uncoupled!!

Warning

Before the opening of the control system housing and whenever the control system is not being used for control purposes, for example during a functional check after a repair, the control system must first be switched off in order to replace or to service components from the control system. The switched-off unit should be protected to prevent inadvertent switching on again. The power supply units of the belt rip detection system are supplied with a voltage of 100 V AC – 240 V AC.

• Danger

• •

Do not open or disconnect or connect the power supply units when they are energized! Do not replace any live parts! During the fitting and removal of components the supply voltage must be switched off.

As a result of assembly work in the belt rip detection system, damage can arise •

if metal objects such as screws or tools fall on printed-circuit boards which are in operation.. • if PC-internal connecting cables are removed or plugged in during operation. • if printed wiring cards are removed or installed with the PC switched on.

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General Notes

Duty of owner/operator to take care The owner/operator must ensure that • • • • •

•

National regulations depending on the type of unit

Warning

Measures in the event of a malfunction

the control system is used only for the intended purpose (cf. on this the chapter Product description). the control system is only operated in a fault-free, functionally efficient state. the operating instructions are always in a legible condition and are available in the complete state at the place of use of the belt rip detection system. only sufficiently qualified and authorized personnel operate, service and repair the control system. this personnel is given regular instruction on all of the relevant issues of safety at work and environmental protection, and is familiar with the operating instructions and in particular with the safety notes included in them. all of the safety and warning signs attached to the control system are not removed and remain legible.

Depending on the machine and unit type in which the belt rip detection system is used, there are national regulations which the owner/operator must observe. These regulations govern, among other things, at what intervals the control system must be inspected. The owner/operator must arrange for this inspection in good time. Only qualified specialist personnel may open the housing of the belt rip detection system! The owner/operator must take care to ensure that only trained and qualified electricians open the housing of the control system. In the event of malfunctions in the belt rip detection system, it can be determined on the basis of the list in the section ‘Troubleshooting’ what measures are to be taken.

Requirements for the operating personnel Read the operating instructions

Every user of the belt rip detection system must have read these operating instructions.

Software knowledge

Every user must be acquainted with all of the functions of the control system and of the industrial PC which can be reached by him/her.

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Accessories

Accessories Structure

Use for the intended purpose

The belt rip detection system in combination with the Master Type BPS-A2-MxG is designed for the monitoring of two danger points on two conveyor belt units. The computer unit was designed in such a way that it is suitable for vertical mounting on a wall in a control room or it can be installed in a switch cabinet of the conveyor belt unit. The BPS-A2-MxG control system is equipped with a touch panel PC via which the control system is operated.

Internal view of the BPS-A2-MxG

In order to monitor a belt unit at multiple danger points, the BPS-A2MxG belt rip detection system can be optionally extended. In addition, it is possible to connect up to four transmitter/receiver pairs to the BPS-A2-MxG direct. The distance between the transmitter/receiver pairs must, however, not exceed a maximum distance of 250 meters.

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Accessories

For greater distances, as an option the BPS-A2-S belt rip detection system is additionally offered which communicates as a slave via Ethernet with the master BPS-A2-MxG. A slave is equipped with one transmitter/receiver pair. To one master unit up to seven slaves can be connected. The distance between master and slave may be up to 35 km.

Slave BPS-A2-S

The unit was designed in such a way that it is suitable for vertical mounting on a wall in a control room or it can be installed in a switch cabinet of the conveyor belt unit.

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Accessories

A slave is connected to the master unit via Ethernet connection (standard). In the case of fault-free communication between the two units, a regular data exchange takes place. All of the connected slaves communicate with the master unit. The panel PC of the master unit is used for the monitoring of the whole master-slave unit. The entire application is mapped by the BPS-A2 system software RIP CONTROL V2 .This makes troubleshooting and the exchange of information easier. All parameter changes for master and slave can be carried out on the master. A slave serves as a local display and information unit of a detection point. Locally parameter changes can be carried out on the slave. These are immediately updated on the master

Internal view of the BPS-A2-S

The BPS-A2-S control system is equipped with an internal keyboarddisplay module via which the control system is operated.

BPS-A2-MxG & BPS-A2-S

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Accessories

Further accessories

Further components included in the scope of supply of the belt rip detection system type BPS-A2-MxG (see photos below) are 1x transmitter with 8-pin plug and 5 m connection cable, 1x receiver with 8-pin plug and 5 m connection cable, 2x proximity switch, 2x mounting brackets, 2x connection box.

Transmitter BPS-TX/8

Transmitter BPS-RX/8

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Accessories

Receiver BPS-T/8

Receiver BPS-R/8

Connection box CC-CB1212

BPS-A2-MxG & BPS-A2-S

12

Accessories

Mounting bracket BPS-MBX

Proximity switch Ni15 (Ni15T optional)

Rotary encoder CC-RE1024 (optional)

BPS-A2-MxG & BPS-A2-S

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Installation Instructions

Installation Instructions Also read the Chapter General Notes.

Transport, warehousing and unpacking Transporting Despite the robust structure, the components installed in the computer unit are sensitive to strong vibrations and impact. Therefore protect your belt rip detection system in operation or during transport from any great mechanical strain. Warning

Danger of damage to the equipment! During transport in cold weather or if the equipment is exposed to extreme temperature variations ensure that no moisture (moisture condensation) is precipitated on and in the equipment. The equipment is to be adjusted to room temperature slowly before it is put into operation. In the case of moisture condensation, the equipment may only be switched on after a waiting period of approximately 12 hours.

Warehousing Store all components in dry conditions and over the temperature range 0°C to +40°C (32°F to 104°F).

Unpacking During the unpacking of the belt rip detection device proceed as follows: 1. Remove the packaging. 2. Check the completeness of the delivery on the basis of your purchase order. 3. Please preserve the documents supplied without fail, since they contain important information on the handling of your equipment. 4. Check the contents of the package for any visible damage in transit. 5. Should you find any damage in transit or discrepancies between the package contents and your purchase order, please inform Coal Control Service.

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Installation Instructions

Mounting the control system and the accessories The computer unit is designed for mounting on a wall or in a switch cabinet of the belt unit. Observe the ambient conditions prescribed for operation (see chapter on Technical data).

Securing of the computer unit

Securing of sensors

Securing of proximity switches

Note

Warning

For mounting the computer unit, four securing lugs with an oblong hole bushing (see chapter Fitting dimensions) are available.

For mounting transmitter and receiver for mounting the Mounting brackets also supplied should be used in each case in order to permit optimum mounting below the conveyor belt (see chapter Fitting dimensions).

For the mounting of the proximity switches it is urgently recommended that the dimensions stipulated be adhered to in order to permit optimum operation (see chapter Fitting dimensions). Likewise, the tapping box also supplied should be used for connecting the proximity switches to the computer unit.

When mounting on a wall or fitting in a closed switch cabinet, ensure that a sufficient volume is available for the opening of the computer unit.

Please also note the following points for the mounting of the computer unit: • Position the control system in such a way that reflections on the display screen are largely avoided. • With regard to the correct fitting height, take the position of the display screen as the basis; this should always be visible for the user in an optimum way. • Do not expose the display screen to any direct sunshine. • Avoid extreme ambient conditions as far as possible. Protect the front end of the housing from dust and moisture.

BPS-A2-MxG & BPS-A2-S

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Installation Instructions

Technical data

Technical data BPS-A2-MxG

BPS-A2-MxG

Dimensions [mm]

450 x 450 x 230

Dimensions [in]

17,72 x 17,72 x 9,06

Temperature range [°C]

0 - 40

Temperature range [°F]

32 - 104

Protection class

IP 66, NEMA 4X

Cable entries

13

Technical data

Technical data BPS-A2-S

BPS-A2-S

Dimensions [mm]

400 x 400 x 200

Dimensions [in]

15,75 x 15,75 x 7,87

Temperature range [°C]

0 - 40

Temperature range [°F]

32 - 104

Protection class

IP 66, NEMA 4X

Cable entries

9

BPS-A2-MxG & BPS-A2-S

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Installation Instructions

Connection of power supply For the connection of the power supply inside the control system; terminal X20 is located inside of master unit. The phase and the neutral conductor must be connected to L1 and N of the fuse terminals. The earth line is connected to one of the three green/yellow earthing terminals of X20 (for connection data see the table below). The fuse terminals are in each case constructed with two 2 A, 250 V fine-wire fuses. The master is equipped with two power supply units as a standard feature. Please see the tables listed below for the connection data of the power supply units.

Conductor cross-section [mm²]

Fuse terminal X20 (L1, N, GND) 0,2 - 6

Conductor cross-section [AWG]

24 - 10

Mains voltage [AC]

100 - 240 V

Mains voltage from [DC]

140 - 300 V

Frequency

50 / 60 Hz

Technical data

Table of connecting terminals for voltage supply

The technical connected loads are limited to the connecting data of the power supply units arranged downstream in the circuit.

BPS-A2-MxG & BPS-A2-S

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Installation Instructions

Power supply unit, internal Master 12 V / 24 V

Output data Power supply unit 12 VDC Table of connecting terminals for voltage supply

Output voltage [DC]

11.0 – 15.0 V

Output current up to

2.5 A

Output up to

30.0 W

Output data Power supply unit 24 VDC Table of connecting terminals for voltage supply

Output voltage

22.0 – 28.8 V

Output current up to

1.3 A

Output up to

31.2 W

BPS-A2-MxG & BPS-A2-S

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Installation Instructions

Transmitter/Receiver For the connection of the transmitter and the receiver there is a male-type connecting socket on the housing of the respective sensor. The socket is of eight-pin design. During mounting, note the coding of the socket and of the plug. The respective plug is to be secured in such a way that it points vertically downwards after the completion of mounting (see picture). The 8-pin plugs are fitted with a 5 meter 4-core shielded connection cable. One of the connection boxes is used for the connection of the two 4core connection cables of transmitter/receiver and the connection cable to the BPS-A2 Master/Slave unit. Connection and assembly of the connection cables are carried out in accordance with the enclosed assembly instructions.

Socket 8-pin

Plug 8-pin

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Installation Instructions

The electronics of the transmitters and the receivers are located inside an impact-resistant polyester or stainless steel housing. Both sensors are equipped with stainless screws for fastening to the BPSMBX Mounting brackets included in the scope of supply. Additionally, the sensors are equipped with pilot light-emitting diodes (LED). The receiver differs from the transmitter in that there is an additional adjusting screw on the left-hand edge of the housing. The transmitters/receivers are of type of enclosure IP 67 and are designed for operation in a dusty and moist environment. For further data on the transmitter and receiver, please see the table presented below. Technical data

Transmitter

Receiver

Designation

BPS-TX/8

BPS-RX/8

Type of connection

8-pin

8-pin

Dimensions [mm]

90x90x120

90x90x120

Protection class

IP67, NEMA 6

IP 67, NEMA 6

Temperature range

-20°C - +60°C

-20°C - +60°C

Lamp

Green

Green and red

Enclosure Use for belt width [mm]

Polyester ≥ 1000

Polyester ≥ 1000

Technical data

Transmitter

Receiver

Designation

BPS-T/8

BPS-R/8

Type of connection

8-pin

8-pin

Dimensions [mm]

230x70x40

230x70x40

Protection class

IP 67, NEMA 6

IP 67, NEMA 6

Temperature range [°C]

-20°C - +60

-20°C - +60

Lamp

Green

Green and red

Enclosure Use for belt width [mm]

Stainless steel < 1000

Stainless steel < 1000

Despite the robust type of construction, strong vibrations or mechanical damage can damage the electrical components used inside the sensor equipment.

Note

In order to avoid damage, the firm fit of the sensors and the Mounting brackets should be checked at regular intervals. Loose components can be damaged by contact with the conveyor belt.

BPS-A2-MxG & BPS-A2-S

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Installation Instructions

Transmitter BPS-TX/8 and BPS-T/8 The transmitter is designated BPS-TX/8 or BPS-T/8 and is equipped with a green light-emitting diode. The control system supplies the transmitter with approx. 12 V DC. If the transmitter is correctly connected and the control system is switched on, the pilot LED burns green continuously. During operation of the control system, the transmitter continuously transmits a frequency signal which is transmitted via the sensor loops, which have been vulcanized into the belt, to the receiver.

Terminal assignment transmitter BPS-T… at master

Plug 8-pin

Connection box

BPS-A2M1G

BPS-A2M2G

BPS-A2M3G

BPS-A2M4G

BPSPLUG/8 1 3 4 Shield

CCCB1212 1 2 3 gre/yel

X40

X40

X40

X40

1 2 3 gre/yel

8 9 10 gre/yel

15 16 17 gre/yel

22 23 24 gre/yel

For mounting of the transmitter please see the enclosed drawings.

Terminal assignment transmitter BPS-T… at slave

Plug 8-pin

Connection box

BPS-A2-S

BPS-PLUG/8 1 3 4 Shield

CC-CB1212 1 2 3 gre/yel

X40 1 2 3 gre/yel

For mounting of the transmitter please see the enclosed drawings.

BPS-A2-MxG & BPS-A2-S

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Installation Instructions

Receiver BPS-RX/8 and BPS-R/8 The receiver is designated BPS-RX/8 or BPS-R/8. It is equipped with one green and one red LED. If the receiver has been correctly connected and the control system is switched on, the LED lights up green if a sensor loop has been detected on the receiver. If a sensor loop stands simultaneously over the transmitter and the receiver the transmitter’s frequency signal is transmitted to the receiver with the help of the sensor loop. In this case, the red LED of the receiver lights up for about 1 second. Should an over-sensitivity of the receiver arise (LED remains continuously red, direct reception between transmitter and receiver), the sensitivity of the receiver can be adjusted via the adjusting screw of the potentiometer. The movement in a clockwise direction means higher sensitivity; in an anti-clockwise direction it means lower sensitivity.

Adjusting screw of the potentiometer

Adjustment of the sensitivity

In order to adjust the correct sensitivity of the receiver for putting into operation for the first time, the sensitivity is turned up to the stop on the right. If the diode now remains continuously red, without a sensor loop via the transmitter and the receiver being in place, the sensitivity must be reduced to such an extent that the diode changes over from red to green. In order to select the optimum setting and in order to prevent direct transmission between the transmitter and the receiver coming about during operation as a result of vibrations occurring, the adjusting screw must be turned back, as can be seen in the picture, by about an additional 15° in an anti-clockwise direction.

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Installation Instructions

If the sensitivity on the receiver has been turned up as far as the right-hand stop without the diode lighting up red, the sensitivity can remain set to the maximum value.

Terminal assignment of BPS-R… receiver at master

Plug 8-pin

Connection box

BPS-A2M1G

BPS-A2M2G

BPS-A2M3G

BPS-A2M4G

BPSPLUG/8 1 2 3 4 Shield

CCCB1212 4 5 6 7 gre/yel

X40

X40

X40

X40

4 5 6 7 gre/yel

11 12 13 14 gre/yel

18 19 20 21 gre/yel

25 26 27 28 gre/yel

For the mounting of the receiver please see the enclosed drawings.

Terminal assignment of BPS-R… receiver at slave

Plug 8-pin

Connection box

BPS-A2-S

BPS-PLUG/8 1 2 3 4 Shield

CC-CB1212 4 5 6 7 gre/yel

X40 4 5 6 7 gre/yel

For the mounting of the receiver please see the enclosed drawings.

Warning

Frequency generators can have a negative influence on the receiver. Therefore care must be taken to ensure that the transmitter/receiver pairs are installed at a distance apart of at least 10 - 15 meters.

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Installation Instructions

Proximity switch Ni15, (Ni15T optional) The proximity switches of type Ni15 and Ni15T are used for pulse counting. The four proximity switches must be correctly installed as otherwise incorrect pulse counting can occur and the entire unit will not work trouble-free. Ensure that the distance between the proximity switches and the pulse marker(s) installed on a drum are not greater than 15 mm / .0,59 in (Ni15, Ni15T). It is important that the pulse marks and the support for the proximity switches are designed in such a way that the four phases listed in the table occur.

4-phase sequence

Phase

PS

PS2

1 2 3 4

Free Covered Covered Free

Free Free Covered Covered

The proximity switches have an approximately two meter-long connecting cable and must therefore be connected to the master unit BPS-A2-MxG with the help of the connection boxes BPS-CB. From BPS-A2-MxG the proximity switches are supplied with 12VDC.

Terminal assignment of proximity switch PS 1

Terminal assignment of proximity switch PS 2

PS1

CC-CB1212

BPS-A2

brown blue

1 2

X30.1 X30.2

PS2

CC-CB1212

BPS-A2

brown blue

3 4

X30.3 X30.4

For the mounting of the proximity switches please see the enclosed drawings.

Warning

Frequency generators can have a negative influence on the proximity switches. Therefore care must be taken to ensure that the proximity switches are installed at a distance of approximately 10 - 15 meters apart

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Installation Instructions

Connection box CC-CB1212 The connection box of type CC-CB1212 is used for the connection of transmitter/receiver and BPS-A2 unit as well as for the connection of proximity switches and BPS-A2 unit. The connection box is fitted with two cable glandes M16 and one cable gland M20. The M16 cable glands are used for the introduction of the transmitter/receiver connection cables and for the introduction of the two proximity switches supply lines. The M20 cable gland is used for the introduction of the connection cable between box and BPS-A2 unit.

Connection box CC-CB1212

Technical data

Connection box

Designation

CC-CB1212

Dimensions [mm]

120x120x70

Temperature range [°C]

-40 - +60

No. of cable glands

3

Cable gland

2x M16, 1x M20

Cable diameter [mm]

5 - 10 (M16)

Cable diameter [mm]

7 - 13 (M20)

Type of connection

Terminal block

Conductor cross-section [mm²] Conductor cross-section [AWG]

0,2 – 2,5 25 – 13

Recommended cable specification

shielded

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Installation Instructions

Rotary encoder CC-RE1024 (optional) The rotary encoder of type CC-RE1024 is used for accurate position and distance measurements. By the use of the rotary encoder position and distance measurement becomes considerably more precise as compared with the use of the standard position and distance measurement with proximity switches. In addition, the position and distance measurement makes it possible to indicate distances between conductor loops in meters, inches and impulses. The rotary encoder is intended for fitting directly on a take-up pulley or for fitting directly on the conveyor belt. With the help of the bracket the rotary encoder is installed in such a way that it is pressed against or onto the conveyor belt or take-up pulley. With the help of the threaded bar the lever arm can be aligned ‘up’ and ’down’. The robust rotary encoder with mounting bracket and shock absorber must be correctly installed as otherwise incorrect measurement can occur and the entire unit will not work trouble-free. Rotary encoder

Technical data

Rotary encoder CC-RE1024

Designation

CC-RE1024

Type of connection

8-pin plug with 5 m connection cable

Connection cable Dimensions total [mm]

8 x 0,37 mm² shielded Approx.

Diameter wheel [mm]

160

Weight [kg]

8,5

Protection rate

IP 67

Temperature range [°C]

-40 - +60

‘up’

BPS-A2-MxG & BPS-A2-S

‘down’

26

Installation Instructions

Decoder CC-DEC1024 The rotary encoder is supplied together with a shielded 5 meter-long 8 x 0.37 mm² power supply cable and connected to the CCDEC1024 decoder included in the scope of supply. The decoder is used for signal processing between the encoder and the BPS-A2 unit

Decoder CC-DEC1024

Technical data

Decoder

Designation

CC-DEC1024

Type of connection Conductor cross-section [mm²] Conductor cross-section [AWG]

Terminal block 0,2 – 2,5 25 – 13

Recommended connection cable

6 x 0,5 mm² shielded

No. of cores

6

Min. cross-section [mm²]

0,5

Cable specification

shielded

Cable diameter [mm]

7 - 13

Cable gland

M20x1,5

Temperature range [°C]

-40 - +60

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Installation Instructions

Connection of the encoder to the decoder can be seen from the following table. Rotary encoder CC-RE1024 Signal

Terminal assignment of decoder inputs

Decoder CC-DEC1024

Connection cable

J

white brown green yellow grey pink blue red Shield

2.12 2.11 2.7 2.10 2.9 2.8 1.3 1.4 Shield

GND +5 VDC Channel A (RS 422) Channel –A (RS 422) Channel B (RS 422) Channel –B (RS 422) A (RS 485) B (RS 485)

You can see the connection of the decoder to the belt rip detection system from the following table. Decoder CC-DEC1024

Terminal assignment of decoder outputs

Signal GND +12 VDC Channel A (RS 422) Channel –A (RS 422) Channel B (RS 422) Channel –B (RS 422) A (RS 485) B (RS 485)

BPS-A2

J 1.1 1.2 4.20 4.19 4.22 4.21 n.c. n.c. Shield

BPS-A2-MxG & BPS-A2-S

X21 +

X30

1 2 3 4

gre/yel

28

Installation Instructions

Profibus module A1-PB (optional) Profibus DP-V0 field bus communication module Operating mode Modbus RTU

Profibus module A1-PB

Image similar

Profibus Module A1-PB Terminal assignment

Signal A B

sub-D9 8 3

BPS-A2-MxG & BPS-A2-S

color gn rt

29

Installation Instructions

Connection of data communication via fiber optic cable (optional) For the remote maintenance of the BPS-A2-S1G unit via an optionally used Ethernet switch with a fiber optic connection the Ethernet connection between a notebook / PC can be established. By the use of the optional Ethernet switch the connection distance can be extended from the standard 100 m (Ethernet / CAT6) to up to 30 km (Ethernet / fiber optic cable).

For the connection of the data communication inside the control system; the Ethernet switch is located inside of the unit. Depending on the distance and the connection intention the Ethernet switches listed in the table below are used.

Ethernet switch BPS-A1-IES

Technical data

Technical data Ethernet switches

BPS-A1-IES M1xSC

BPS-A1-IES M2xSC

BPS-A1-IES S2xSC

Coal Control article no.

CC2021

CC2021.1

CC2021.2

Transmission distance [km]

2

2

30

Transmission speed [Mbps]

10/100

10/100

10/100

Transmission mode

Multi-mode

Multi-mode

Single-mode

Power input [DC]

12 – 48 V

12 – 48 V

12 – 48 V

Ethernet connectors

4x RJ45 1x SC

4x RJ45 2x SC

4x RJ45 2x SC

Dimensions [mm]

37x140x95

Mounting

DIN rail wall

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Installation Instructions

Output contacts Relay terminals X12 The signal output for the selected operating mode, the tripping contact, the fault messages and the loading signal contact takes place via the floating relay contacts (NO) which are designated as X12. Please see the tables listed below for the connection data of the terminals X12. Relay terminals X12

Technical data

Table of relay terminals X12

Conductor cross-section [mm²]

0,08 – 2,5

Conductor cross-section [AWG]

28 – 14

Wire stripping length [mm]

6

Wire stripping length [inch]

0,22

Maximum switching voltage [AC]

250 V

Maximum continuous current

5A

Outputs – wiring potential-free N/O contacts, Terminals X12

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Installation Instructions

BPS-A2-MxG terminals X12

Outputs wiring

Terminal X12.1.11 X12.1.14 X12.2.11 X12.2.14 X12.5.11 X12.5.14 X12.7.11 X12.7.14 X12.9.11 X12.9.14 X12.10.11 X12.10.14 X12.11.11 X12.11.14 X12.12.11 X12.12.14

Function Operation Mode: LIMITED Conveyor #1 Operation Mode: BYPASS Conveyor #1 Feeder Signal Message Conveyor #1 Belt Release Conveyor #1 OK Message Detection Pair #1 OK Message Detection Pair #2 OK Message Detection Pair #3 OK Message Detection Pair #4

BPS-A2-S terminals X12

Outputs wiring

Terminal X12.1.11 X12.1.14 X12.2.11 X12.2.14 X12.5.11 X12.5.14 X12.7.11 X12.7.14

Function Belt Release Conveyor #1 OK Message Detection Pair #1 Operation Mode: LIMITED Conveyor #1 Operation Mode: BYPASS Conveyor #1

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Installation Instructions

Relay contacts X12.1 (LIMITED) and X12.2 (BYPASS) are closed when one of the two operating modes has been selected. This serves to remind the equipment operator that the belt rip detection system BPS-A2-MxG is not in a one hundred percent monitoring mode. In the NORMAL operating mode no separate relay output is switched. Relay contacts X12.7 is the shutdown contact in the event of a fault. If the belt rip detection system BPS-A2-MxG is not in a fault-free operating condition, this relay contacts is open.

Note

X12.7 is to be used mandatorily as the tripping contact for shutdown of the conveyor belt. Relay contacts X12.9, X12.10, X12.11 and X12.12 can be used as fault messages. In a similar way to the case of the tripping contact a single message for each detection pair can be output. Relay contact X12.5 is used as a signal output for loading stop. In the menu item Settings of the RIP CONTROL V2 software it is stated when and for what length of time the relay contact is to be closed. Also read the chapter Operating Instructions.

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Operating Instructions

Operating Instructions BPS-A2-MxG Switching-on and switching-off

Switching-on

The BPS-A2-MxG belt rip detection system does not have its own mains switch. For switching-on the unit or connection to the power supply the control system is started up.

Running-down and switching-off

When the control system is switched off or it is disconnected from its own power supply the entire control system is also switched off.

Warning

Control software as is typically used on industrial PCs makes it possible for all users to assign different rights. A user who must not terminate the software is not allowed to switch off the industrial PC, either, because, as a result of switching-off with the software running, data on the hard disc can be lost.

First run down, and then switch off! If the industrial PC is switched off while the software is writing a data file to the hard disc, that data file is destroyed. The control software usually automatically writes something on the hard disc at intervals of a few seconds which is why the probability is very high that damage will be caused as a result of switching-off with the software running. If you have run the PC down, you must de-energize it for at least 10 seconds in order to be able to start it up again! After switching the power voltage on again, the industrial PC then automatically starts up. First switching-on When you switch on the industrial PC for the first time, the operating system and the RIP CONTROL V2 software are automatically started up.

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Operating Instructions

After switching on The RIP CONTROL V2 software is in normal cases automatically started up after booting of the panel PC. Should automatic start-up of the software interface not come about, the program can be started up by clicking the RIP CONTROL V2 icon.

Structure of the RIP CONTROL V2 interface

Login

Login

Click the Login button, in order to log in for the RIP CONTROL V2 interface. Only admin users are able to make alterations, to take loops out of protection and to acknowledge fault messages. The standard user is just allowed to view settings and parameters and to reset the fault relays. If not logged-in, the viewer is just allowed to view the main screen. The viewer is also allowed to reset the fault relays if the reset function is enabled. Also read the chapter Settings.

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Operating Instructions

The name of the logged-in user is indicated at the left-hand edge of the display screen. If no action is performed within 10 minutes, the user is automatically logged out after the time has expired. Login information

Login: Admin Login: User

Pass: 98765 Pass: 12345

Monitoring station The monitoring station shows the individual states of the transmitter, the receivers, the proximity switches and provides information on the loop number of the last sensor loop detected.

Monitoring station

Transmitter (T) If the transmitter has been connected fault-free to the BPS-A1 and 12VDC is supplied from the control system, a little green box is indicated below the T on the display screen. If the transmitter is not correctly connected during normal monitoring operation, not supplied with voltage or is malfunctioning, it is shown in red. In the event of a malfunction, the message Transmitter No. x malfunctioning is displayed.

Receiver (R) In the case of faulty operation of the receiver, a little green box is displayed below the R. If a sensor loop is identified on the receiver, the box lights up red for about 2 seconds. At the same time, the loop number in the Loop field is increased by one and the field has a green background for about 2 seconds. If the receiver is not correctly connected, is defective or it is receiving direct from the transmitter, a little red box is displayed permanently. In the event of a malfunction, the message Receiver No. x malfunction is displayed.

Proximity switches If both proximity switches are working faultlessly, the symbol is shown in green when the conveyor belt is moving. If one proximity switch is defective or both proximity switches are defective or not correctly connected, the symbol is displayed in red.

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Operating Instructions

In the event of a malfunction, the message Position sensor pulse malfunction is displayed. If the conveyor belt is not moving, but the proximity switches are functionally efficient, the symbol is shown in grey.

Info

To view the operating display, click the symbol of the monitoring station.

Operating data

In the line “Custom name“, the designation of the monitoring station can be entered. In the factory the first monitoring station connected to the master unit is designated as “Detection pair #1”. When the button “Software version” is clicked a dialog window opens in which the software versions of the A1-XXX modules used are displayed.

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Operating Instructions

Inputs and outputs The information window of the inputs and outputs provides information on their states. The information displayed can vary and is dependent on the configuration of the BPS-A2-MxG belt rip detection system. Inputs - Module A1-DFI Adr. 1

Outputs A1-DFI Address 1

Address 1.1 1.2

Contact

Function

NO

1.3 1.4 1.5 1.6 1.7

NO

Reset push button Reset push button activation (resistor 2,7kΩ)

1.8

NO

NO/NC

Belt run signal (1), Belt standstill (0) Belt run message activation (resistor 2,7kΩ) (optional)

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Operating Instructions

Outputs - Module A1-DO Adr. 1

Outputs A1-DO Address 1

Address 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8

Function Operating mode – Normal Operating mode – Limited Operating mode - Bypass Belt standstill (0), Belt running (1)

Belt Release Conveyor #1

Outputs - Module A1-DO Adr.: 2

Outputs A1-DO Address 2

Address 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8

Function OK Message Detection pair #1 OK Message Detection pair #2 OK Message Detection pair #3 OK Message Detection pair #4

Outputs - Module A1-DO Addr.: 3

Outputs A1-DO Address 3

Address 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8

Function

Feeder Signal Conveyor #1

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Operating Instructions

Last loop number Shows the number of the last sensor loop identified. If a reference distance was specified and the reference distance has not yet been recognized after the system has been switched on again or after reset following an error message, the loop number with REF prefixed to it is shown. The first loop after identification of the reference distance is marked with the number 1. Analog value last loop Provides information on the value of the analog sensor loop signal. The signal provides information on the sensor loop itself, but also on the quality of the installation of the transmitter and the receiver. If on all sensor loops an analog value of less than 50 is shown, the mechanical installation of the transmitter and the receiver should be checked and, if necessary, alterations should be made. Pulses before The distance between the last sensor loop identified and the sensor loop before it. Measured Gives information on the distance between the last sensor loop identified and the sensor loop following next. The value is counted down to zero. Before the reference distance has been identified, the distance value always starts with the maximum distance set between two sensor loops. After the reference distance has been found, the distances are saved during the first rotation. From the second belt rotation the genuine distances between the individual sensor loops are indicated.

2 Conveyor belt If the unit is in a fault-free condition and the conveyor belt is in operation, a green arrow indicating the respective running direction is shown. If the conveyor belt runs contrary to the running direction set, the arrow is shown in red. If the control system is active, but the belt system is not in operation, no arrow is shown. If required, the desired designation of the belt can be altered. In the factory, the designation ‘Conveyor’ is set.

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Operating Instructions

3 Error and warning message Error messages or warning messages are displayed on the main display screen. If several faults or warnings are shown simultaneously, the messages are displayed in rotation in each case for several seconds. Faults which lead to belt shut-down are red, warning messages which only give information on a condition and do not lead to shut-down are shown in yellow. With this status the belt release contact is opened and the conveyor belt cannot be started again until the fault has been rectified. Also read the chapter Troubleshooting.

4 Buttons

Reset

Click the Delete button in order to acknowledge fault messages and to reset the belt rip detection system back to trouble-free operation. Fault messages to optionally connected slaves, type BPS-A2-S can also be acknowledged by the actuation of the RESET button. The button is displayed if a user or administrator is logged-in and can be activated via the RIP CONTROL V2 software so that you could use the RESET button in the logged out state. Settings → Reset button → Enable/Disable

Faults

Click the faults button to display the fault messages which occurred since the last start of the RIP CONTROL V2 software. Faults are displayed with time and date information.

Start parameter report

Click the parameter report button to generate an actual loop report. The last conveyor belt revolution is saved including all parameters and loops out of protection. A message displays the save location and filename upon completion.

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Operating Instructions

Loop report

Click the loop report button to display the last 10 belt revolutions.

Graphical report

Click the Loop report graphical button in order to select the graphical version of the analog values and that of the sensor loop distances.

Loop report - graphical Click the Loop report graphical button in order to select the graphical version of the analog values and that of the sensor loop distances.

By clicking the Delete button all of the graphical values can be deleted. By clicking the Print button a screen shot of the current display screen can be taken. This can be appropriately processed and saved.

Keyboard button

Push the Keyboard button at the front panel in order to display the onscreen keyboard. It is required in order for entries to be made when no additional keyboard is connected to the belt rip detection system.

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Operating Instructions

Keyboard

Minimize

By actuation of the minimize button the RIP CONTROL V2 interface is minimized to the windows task bar. The operation of BPS-A2-MxG is thus not influenced by this.

Close

Click the Close button to close the RIP CONTROL V2 interface.

5 Menu bar The menu bar at the upper edge of the display screen contains the menu items Settings, Reports, Display parameters, User administration, Language, Help and Quit. Settings tab The menu item Settings includes the most important menu items for the configuration of the BPS-A2-MxG.

Settings tab

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Operating Instructions

Number of loops Click the No. of Loops button in order to set the number of loops located in the conveyor belt.

No. of loops

Premonition Analog signal Click the Premonition Analog signal in order to set the value at which an advance warning for a low loop signal is to be displayed. As a standard this value is set to 10. If a sensor loop with an analog value lower than the set value is detected, a warning message is output. This message serves only as information and does not lead to any opening of the belt release contact. The conveyor belt remains in operation. The display of the warning message means that the loop indicated is possibly damaged and can fail in the near future.

Premonition Analog signal

Also read the chapter on Parameter settings. Conveyor settings Conveyor settings

Via the menu item Conveyor Settings the graphic view of the conveyor belt illustrated and the conveyor belt designation can be changed.

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Operating Instructions

Reset Button

RESET Button

Under the menu item RESET Button, the RESET function on the main display screen of the RIP CONTROL V2 software can be enabled or disabled. If the RESET function has not been enabled, the belt rip detection system BPS-A2-MxG can only work from a logged-in admin. By means of the activation of the RESET button this is active at all times.

Running direction Running direction

Click the Running direction button in order to select the direction in which the conveyor belt is moved. Number of detection pairs Click the No. of detection pairs button in order to determine the number of the additionally connected transmitter / receiver pairs. Generally two transmitter / receiver pairs are connected directly to the BPS-A2-MxG master unit. That means, for example, that if two transmitter / receiver pairs are directly connected to the master, the first pair is declared as detection pair # 1, the second pair is declared as detection pair # 2 and hence the number of detection pairs is set to 2.

Number of detection pairs

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Operating Instructions

Detection pair #X Click the Detection pair # 1 button to carry out the parameterization of the first transmitter / receiver pair which is directly connected to the BPS-A2-MxG, to set Parameters, to remove sensor loops from the detection mode as well as the selection of the COM interface.

Parameters

Parameters Click the Parameters button in order to call in the Parameter window. The parameters shown in this window apply to all transmitter / receiver pairs. Most of the parameters are given in pulses which are generated by the proximity switches. The pulses indicate a distance which can, for example, be converted into an ordinary meter dimension. The date and the time are taken over from the CPU card A1-CPU of the computer unit.

Minimum reference distance The reference distance is a distance between two functionally efficient sensor loops which is unique. It should deviate at least approx. 5 - 10 pulses from the other distances (depending on the pulse counting). The minimum reference distance is set 2 - 3 pulses smaller than the real reference distance Maximum reference distance The maximum reference distance is selected 2 - 3 pulses larger than the real distance. That way a search window of approx. 4 - 6 pulses arises in which the reference distance is searched for.

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Operating Instructions

Maximum distance between two loops The parameter Maximum distance between two loops indicates the greatest distance which exists between two functionally efficient sensor loops in the conveyor belt. The maximum reference distance is 2-3 pulses larger than the real distance. In the case of a damaged sensor loop this parameter is to be considered in particular and must, if necessary, be adjusted. If the distance between the sensor loop before the defective loop and the distance behind the defective loop is larger than the maximum distance set to date, the parameter must be adjusted to the new conditions.

Pulses per 100m belt Counted pulses per 100 meter belt run. This is used for measuring the speed for display on the display screen and in the loop report. As a result of an inexact entry, the value displayed can deviate from the real value. The distance between pulses per 100 meters of belt is used for the calculation of the speed in the loop reports.

Parameters

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Operating Instructions

Under the menu field Operating mode you can choose between three operating modes. The operating modes Normal, Limited as well as Bypass can be selected. •

Normal –

the control system is in the proper operating state

•

Limited –

protection is only provided with the pre-set maximum distance between two sensor loops

•

Bypass –

no protection is provided

Operating mode

STOP at loop number The parameter Stop at loop number can be set, if required. In normal cases this must be set to 0. If there is a wish to stop the conveyor belt at a certain sensor loop, if necessary, for example, to carry out a visual check, the number of the sensor loop required can be set. If the parameter is not set to 0, the unit is stopped during every rotation at the transmitter / receiver pair # 1 of the master unit.

Note

Ensure that the parameter Stop at loop is set to 0 in order to prevent any undesirable switching-off.

Relay contact X12.5 The parameter Relay contact X12.5 can be set, if required. In normal cases the parameter Loop no. [x] as well as No. of pulses must be set to 0. If there is a wish to not load the conveyor belt # 1 with material in a certain part of the conveyor belt, if necessary, for example, to not load a damaged belt part, the Loop no. and length in pulses can be set. If Loop no. [x] is not set to 0, the relay contact X12.5 toggles for the length of the set number of pulses. Also read the chapter Parameter settings.

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Operating Instructions

Loops out of protection Click the Loops out of protection button, on order to exclude defective sensor loops from protection. If a sensor loop has been displayed as being defective on the main monitor and/or damage has been determined, a sensor loop should be removed from protection. In order to remove a sensor loop from protection, enter the loop number, the pulses before and the pulses behind. The parameter Pulses before states the number of the pulses which were measured between the previous functionally efficient loop and the defective loop. The parameter Pulses behind states the number of pulses which have been measured between the defective loop and the next functionally efficient loop. The values can be seen from the loop reports recorded. Putting the loop back into protection If a sensor loop has to be put back into protection, mark the appropriate line of a sensor loop and remove it from the list. After you have closed the window by clicking the OK button, the change is made.

Loops out of protection

Also read the chapter Reports tab.

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Operating Instructions

COM-Port Click the COM-Port button in order to adjust the interface for communication between the CPU board and the PC panel. This is the standard setting specified by the works.

COM-Port

Detection pair # 1-8 Click the Detection pair # 1 – 8 button in order to carry out the parameterization of the optionally connected detection pairs. The configuration of the detection pairs is carried out in a similar way to the detection pair # 1.

Note

The numbering of detection pair is dependent upon the number of transmitter /receiver pairs connected to the master unit. Also read the chapter on Parameter settings.

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Operating Instructions

Reports tab Click the Reports tab in order to display the Report menu.

Reports

Loop reports Click the Loop reports button in order to view the reports recorded.

Parameter reports Click the Parameter reports button in order to select an overview of all of the monitoring stations connected to the master unit. For each new start of the software interface as well as for each alteration of the parameters or the deletion of fault messages, a new parameter report is saved in the Parameter report folder. The file is saved in the format Year/Month/Day/Time.

Fault reports Click the Fault reports button to get an overview of the faults saved. During every malfunction of the computer unit the current fault message is included in the last fault report and saved as a new file. The file is saved in the format Year/Month/Day/Time. Diagram reports Click the Diagram reports button in order to display the recorded Pulse and distance diagram.

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Operating Instructions

Display Parameters tab The menu item Parameters permits the display of the monitoring stations. Click the appropriate button in order to display the work parameters, the sensor loops taken out of protection and the operating mode of the respective monitoring station.

Display Parameters

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Operating Instructions

Language tab The menu item Language makes it possible to select the language version. After you have changed the language version, a re-start of the RIP CONTROL V2 software is necessary. The language choice offered is dependent upon the respective software version

Help tab The menu item Help includes the displaying of the Operating Instructions and provides information on the software version.

Close tab Click the Close button in order to end the RIP CONTROL V2 software interface. During the monitoring function the software must be active. Note

Closing of the RIP CONTROL V2 interface should take place only in exceptional cases.

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Operating Instructions

Windows 7 tiles If the RIP CONTROL V2 Software has been quit and/or minimised, the Windows tiles are shown. Here the user has two options at its disposal. By clicking the RIP CONTROL tile you call in the software. For maintenance and documentation purposes the internal Windows Snipping Tool is available for screenshots.

Windows 7 tiles

For administrators there are further function possibilities available. For this click the button and log in with the login: Admin and the password: 98765.

Note

After successful administrator login all of the Windows rights are at your disposal. Incorrect handling can lead to permanent system failure.

Click the

button to log out again.

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Operating Instructions

Administrator Desktop

After successful administrator login further tiles are at your disposal. • • •

Adobe Acrobat Reader Windows Calculator Snipping Tool

• •

Configuration Center (Panel PC configuration) Windows Taskbar

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Operating Instructions

Unlocking the Front USB port As default security feature the front USB port is locked on delivery. If an USB device is plugged in, the following message will appear.

USB Port locked

In order to unlock the port please follow this procedure:

Configuration Center

Open the Configuration Center and choose USB lock Push the Front USB switch to the left. Klick OK and enter the administrator password. Please ensure to LOCK the Front USB port after using.

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Operating Instructions

Operating instructions BPS-A2-S Switching on and switching off

Switching on

Switching off

The BPS-A2-S belt rip detection system has no mains switch of its own. When the unit is switched on or when it is connected to the power supply the control system is started up. When the control system is switched off or disconnected from its own power supply likewise the whole control system is switched off.

Software menu As the BPS-A2-S belt rip detection unit has no master switch, after the power supply is switched on the computer unit is automatically started up. During booting, the current software status of the modules A1-CPU and A1-LCD becomes visible on the display for a short time. After verification of the software, as a standard feature the main display screen is shown.

Main screen

BPS-A2-S main screen

Loop In the Loop line the last sensor loop number detected by the belt rip detection system is indicated.

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Operating Instructions

If the reference distance has not yet been recognized, up to then all loops are identification marked with the abbreviation REF. If the reference distance set has been determined, the display jumps to 001. At this point in time, the so-called mapping of sensor loops and of the conveyor belt starts. At that moment, a sensor loop number is allocated to the sensor loops. At the same time, storage of the distances between the individual sensor loops takes place. Once the reference distance is determined a second time by the computer unit, the mapping of the conveyor belt has been completed.

Measured The Measured line represents a counter which provides information on the measured distance between the individual sensor loops. This value is indicated in the pulse unit. The size of a pulse is dependent upon the installation of the proximity switches which record the pulses on a belt pulley. If the reference distance has not been detected, the set value of the parameter maximum distance between two sensor loops is indicated. If the conveyor belt is moving in a forward direction, this value becomes steadily smaller. During backward movement of the belt the pulses are counted upwards. Upon detection of a sensor loop the value jumps back to the preset parameter value again. Once the mapping of the conveyor belt has been completed, the counter starts with the real distance value between two sensor loops. In forward running counting starts from the starting value and runs towards 0. After successful detection of the next loop, the counter jumps over to the next real distance value and is counted downwards again.

R.analog xx% DIG.xx Upon successful detecting of a sensor loop on the transmitter /receiver pair, the signal evaluation of the sensor loop is carried out. At the same time the analog value provides information on the quality of the sensor loop. The maximum value is 99. In addition a digital signal is exchanged between the transmitter and the receiver and indicated as SS.

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Operating Instructions

Note

The level of the analog value is not only determined by the quality of the sensor loop. Also the installation of the transmitter / receiver pair is dependent upon it.

Information line The Information line provides information on the operating condition of the control system. If the unit is free of malfunctions the word Operation and the current time are displayed. In the event of a fault this line provides information on the type of malfunction. Also read the chapter Troubleshooting.

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Operating Instructions

Parameter menu In order to carry out parameter changes for the type BPS-A2-S slave, a login is necessary. To activate the Login window press the F key on the A1-LCD display unit inside the control unit for about 3 seconds.

Login

Login

Now press the B (User) or A (Admin) key again and key in the password 12345 or 98765 with the help of the keyboard. Once the correct password has been keyed in, the parameter menu is displayed. In the event of a wrong input the Login window is closed and the process has to be repeated.

Parameter menu Note

F = page forwards E = page backwards D = scroll within the current page C = leave parameter menu

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Parameter settings

Language settings

Language

The language selection is displayed in the first window of the parameter menu. By actuation of keys 1 to 4 the desired language is selected. The currently set language version is displayed in the first line of the menu window. The languages which can be set are dependent upon the software version and can deviate from this window.

Mode settings

Mode

For selection of the mode press the appropriate number. The arrow on the right-hand edge of the display screen indicates the selection. The following modes can be chosen from: Normal The Normal mode monitors the conveyor belt with the parameters set. Limited The sensor loops are only monitored by the parameter Maximum distance between two sensor loops.

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Parameter settings

Bypass The conveyor belt and the sensor loops are not monitored. If the Type BPS-A1 belt rip detection unit is malfunctioning the conveyor belt is not stopped.

Number of sensor loops

Number of loops

Selection of the number of sensor loops in the conveyor belt. The first line indicates the value currently set. In the New line your change is indicated. To confirm your input press the A key. In that way the value in the first line is overwritten with the value input. If the page is left before confirmation by the A key, the value is not taken over.

Parameter settings

Parameter

All of the parameters are given in pulses which are generated by the proximity switches. The pulses give a distance which, for example, can also be converted into a usual measure in metres.

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Parameter settings

Maximum distance between two loops The parameter Maximum gap between two loops gives the biggest distance between two functionally efficient sensor loops existing in the conveyor belt. The maximum reference distance is chosen 2-3 pulses larger than the real distance. The arrow on the left-hand side of the display indicates the selected line. When the value currently set is overwritten, on the right-hand side edge of the display a star is shown. This provides information about the fact that the value has not yet been taken over. Takeover takes place only after actuating of the D key and the arrow jumps into the next line. In the case of a damaged sensor loop, the Maximum gap between two sensor loops parameter is particularly to be noted and must if necessary be adjusted. If the distance between the sensor loop before the defective loop and the distance after the defective sensor loop is larger than the maximum distance set to date, the parameter must be adjusted to the new situation.

Minimum reference distance The reference distance is a distance between functionally efficient sensor loops which occurs only once in the conveyor belt. It should deviate at least about 5-10 pulses from the other distances (depending on the pulse counting). The minimum reference distance is set 2-3 pulses smaller than the real reference distance. The change in the minimum reference distance takes place as already described in the menu item Maximum gap between two loops. Maximum reference distance The maximum reference distance is chosen 2-3 pulses larger than the real distance. In that way a search window of about 4-6 pulses is obtained in which the reference distance is searched for. The change in the maximum reference distance takes place as already described in the menu item “Maximum gap between two loops”.

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Parameter settings

Number of pulses / 100m belt run is used for the measurement of speed for display on the screen and in the loop report. Due to an imprecise input the value indicated can deviate from the real value. The distance pulses per 100-metre belt is used for the calculation of the speed in the loop reports. The change in the number of pulses / 100m belt run takes place as already described in the menu item Maximum gap between two loops.

Display unprotected loops

Unprotected loops

In the event of a sensor loop being displayed as defective, the removal of this loop from protection is necessary. This menu window shows all of the so far unprotected sensor loops. If several sensor loops are unprotected you can, with the help of the D key, scroll between the individual loops. The indication 00/00 provides information about the loop number currently indicated and the total number of the unprotected loops.

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Parameter settings

Taking sensor loop out of protection

Removing loops

For removing a new sensor loop from protection first of all the loop number is given. As also already described in the other menu windows the arrow at the left-hand edge of the display indicates the current cursor position. After the loop number has been input, the cursor automatically jumps into the next line. For removal from protection the inputting of the distance between the previous and the following sensor loop is necessary. To confirm the input actuate the A key at the end. Then the indication “New elimination” (= New removal from protection) jumps over to 02. If the removal of a further sensor loop from protection is not required, by actuation of the C key the parameter menu is left or by actuation of the F key scrolling to the next parameter page is possible. Also read the Chapter Parameter settings.

Putting sensor loop back into protection

Back to protection

If a sensor loop has been replaced or an incorrect loop has been removed from protection, in this menu the loop can be returned to the protection mode again. With the help of the D key the desired loop number can be selected.

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65

Parameter settings

By actuation of the A key the loop is returned to the monitoring mode again and removed from the menu Loops removed from protection.

Display fault messages

Fault messages

The last 150 fault messages are stored in the system memory. The fault messages are displayed with date and time stamp. With the help of the D key it is possible to scroll between the individual fault numbers.

Address settings

Slave address

If the slave is connected to a PC / Notebook, the address must be set to 2 in order to ensure communication between PC / Notebook and unit. To make a change, with the help of the 0-9 keys the address is selected and confirmed by pressing the A key.

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66

Parameter settings

Date and time settings

Date and time

The time and the date currently set are indicated in the first line. To change the date and/or the time the keys 2, 4, 6 and 8 are required. The arrow below the second line indicates the position of the cursor. Keys 2 and 8 are used for counting the value up and/or down. By means of the keys 4 and 6 the cursor position can be changed to the left and/or to the right. With the help of key A the input is confirmed.

Note

If the BPS-A2-S unit is connected to a computer system, the time is updated by the system time of the computer.

Display software version

Software version

The last parameter menu window provides information about the software status of the modules A1-CPU and A1-BPS inside the BPS-A2-S type control system.

Note

In the event of malfunctions which can only be remedied with the help of Coal Control Service, the software version must be stated.

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67

Parameter settings

Inputs and outputs The information window of the inputs and outputs provides information on their states. The information displayed can vary and is dependent on the configuration of the BPS-A2-S belt rip detection system. Inputs - Module A1-DFI Adr. 1

Outputs A1-DFI Address 1

Address 1.1 1.2

Contact NO

1.3

NO

1.4 1.5 1.6 1.7

NO/NC

1.8

NO

Function Reset push button Reset push button activation (resistor 2,7kΩ)

Belt run signal (1), Belt standstill (0) Belt run message activation (resistor 2,7kΩ) (optional)

Outputs - Module A1-DO Adr. 1

Outputs A1-DO Address 1

Address 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8

Function Belt Release Conveyor #1 OK Message Detection pair #1

Operating mode – Limited Operating mode - Bypass

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68

Parameter settings

Parameter settings When the BPS-A2-MxG is switched on for the first time, the display screen structure on the panel PC is displayed in the factory settings. In order to carry out changes in the structure, the Settings menu must be opened by clicking the Settings button. First of all you select the Layout tab and configure the conveyor belt structure according to your situation. After you have determined the display screen structure, click the button Master > Parameters. Set the parameters to the values specified in the table.

Description

Table Parameters for first putting into operation

Maximum distance between two loops Minimum reference distance Maximum reference distance Number of pulses / 100m run of belt Stop belt at loop number Number of loops in belt Warning message analog signal under

Parameter 9999 1 2 Calculated value 0 999 20

If several monitoring stations are connected, also click the button No. of detection pairs > Parameter button(s) in order to set the parameters from the table shown above. The value for the ‘number of pulses/100 m belt’ is calculated with a simple formula which you can see from the enclosed drawing. Click the “Number of loops“ button and set the value for the first belt rotations to 999 sensor loops and confirm the entry with OK. Click the Premonition – analog signal button and set this value to 20 and confirm the entry with OK. If the analog value of a sensor loop under 20 is determined, a warning message on the main display screen is triggered. This warning message is, however, only used as information to the effect that the loop could possibly become functionally inefficient in the near future. It does not lead to a shut-down of BPS-A2-MxG.

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Parameter settings

Generate Reference Loop report Click the Reference Loop report button to prepare a loop report. The loop report is required for finding the operating parameters. After you have clicked Start – Loop report, a Windows window opens in which the file is saved. Give the file a name and confirm with OK. At the top left-hand display screen edge, the recording symbol and the file name selected by you now appear. Record loop report

If the conveyor belt moves and the sensor loops are detected by the transmitter / receiver pairs, each sensor loop will be included in the report. In order to determine the parameters following the reading-out of the loop report, you should record at least three consecutive rotations of the conveyor belt. As the next step, start up a loop report under the Reports tab. In order to be able to read out sensor loops, the conveyor belt must be in operation. For the evaluation of a loop report it is recommended that at least three to four belt rotations be carried out before evaluation can take place. After several rotations have been documented by the software you can evaluate the sensor loop report as follows: Minimum reference distance Maximum reference distance Number of loops Maximum distance between two loops Reference distance In the Distance column look for a unique distance between two sensor loops. It is important that this distance is unique and deviates at least ± 5 to 10 pulses (depending on the installation of the pulse markers) from the remaining loop distances. The minimum reference distance is set with about 2-3 pulses fewer, the maximum reference distance with 2-3 pulses more. In that way a search window is obtained in which the reference distance can move.

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Parameter settings

Note

Important - no more distances between loops may be located in this search window.

Number of loops If you have found a special, unique distance, count the number of sensor loops until the value selected appears in the loop report again. The number of loops counted at the same time represents the value for the ‘number of loops’ parameter.

Maximum distance between two loops The greatest distance can also be seen from the Distance column. It is important that if one of the sensor loops is defective it can happen that the distance between two functionally efficient sensor loops is larger than the distance which has been specified in the parameters up to this point in time. In this case, the parameter must be adjusted to the new distance. The Maximum distance between two loops parameter is set at +10 pulses from the value actually determined.

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71

Parameter settings

Example of the selection of the parameters

Excerpt from a loop report

Description

Example table

Max. distance between two loops Minimum reference distance Maximum reference distance Number of loops

BPS-A2-MxG & BPS-A2-S

Measured 120 25 25 15

Parameters 125 22 28 15

72

Parameter settings

Taking sensor loop out of protection To remove a defective sensor loop from the protection mode and in order to exclude further malfunction messages, click Settings > Master > Take loops out of protection. Now click on the first free field under “Loop number” in the table. In the first column of the window the number of the loop is entered. Columns two and three state the respective distance in pulses between the loop before it and the loop behind it. This distance is taken from the previously produced sensor loop report and entered. Taking out of protection has the effect that a defective sensor loop is ignored by the RIP CONTROL V2 software, but that precise monitoring of the other sensor loops is ensured. Example of the removal of loop number 3. The report shows 60 pulses before the loop and 65 pulses behind the loop. Before Pulses between loops numbers 2 and 3 Behind Pulses between loops numbers 3 and 4

Excerpt from a loop report

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73

Parameter settings

Example of parameters

If the distance between loops 2 and 4 is now greater than the previously set maximum distance between two sensor loops, the value must, if necessary, be adjusted. Example for the parameter Max. distance between two sensor loops: the maximum distance was so far 120 pulses. Through the removal of loop 3 from protection the distance must now be set to 135 pulses. 60 pulses + 65 pulses + 10 pulses (tolerance) = 135 pulses

Changing the maximum distance between two loops

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Parameter settings

Putting sensor loop back into protection In order to put a sensor loop removed from protection back into protection, click Settings > Detection pair # x > Loops out of protection. Select the loop which is to be put back into protection. Click the column with the loop number and delete the contents of the Loop number, Pulses before and Pulses behind cell. Confirm your selection by clicking the OK button. Bear in mind that parameters previously entered must, if necessary; be adjusted to the new conditions.

Putting loop back into protection

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75

Maintenance

Maintenance Also read the chapter General Notes.

Cleaning the belt rip detection system Switch off the BPS-A2-MxG belt rip detection system and all of the equipment connected to it.

Danger

The stainless steel casing of the control unit as well as the built-in industrial PC can be cleaned with a moist soft cleaning rag. Do not use any caustic cleansers, any thinners, scouring agents or hard objects which could produce scratches. For cleaning the additional components such as proximity switches, rotary encoder, transmitters and receivers likewise a damp, soft cleaning rag can be used. As a result of the higher protection class of the additional components cleaning with hose water not under pressure is permitted. At regular intervals (as a function of the degree of fouling), maintenance and/or cleaning work is to be carried out. Maintenance The industrial PC requires no maintenance.

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76

Troubleshooting

Troubleshooting Also read the chapter General Notes.

Warning

Stop the conveyor belt for maintenance work on the transmitters, receivers and proximity switches! Work on these components may only be carried out with a stationary belt as contact during operation can lead to mechanical damage to the sensors. Replacement of components Should individual components have to be removed (e.g. in case of repair), please proceed as follows: BPS-TX/8 or BPS-T/8 transmitter • • • •

Disconnect the belt rip detection system from the power supply Loosen the locknut of the 8-pin plug-in connector in an anti-clockwise direction The transmitter can be detached by loosening of the two M10 nuts and by removing it from the support Re-installation is then carried out in reverse order.

All transmitters of the type BPS-T… have the same structure and hence can be interchanged without any restrictions BPS-RX/8 or BPS-R/8 receiver • • • •

Disconnect the belt rip detection system from the power supply Loosen the locknut of the 8-pin plug-in connector in an anti-clockwise direction The receiver can be detached by loosening the two M10 nuts and removing it from the support Re-installation is then carried out in reverse order.

Proximity switch Ni15 • • • •

Disconnect the belt rip detection system from the power supply Loosen the M32 locknuts in opposite directions to each other Disconnect the connecting leads Re-installation is then carried out in reverse order.

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77

Troubleshooting

Module A1-XXX • • • • •

Disconnect the belt rip detection system from the power supply Pull away the terminals downwards with a narrow screwdriver for slotted screws With the screwdriver for slotted screws pull away the spring mechanism on the lower casing cover downwards Now the module can be pulled out upwards with the bottom side first. Re-installation then takes place in reverse order.

Modules with the same designation have the same structure and can hence be interchanged without restrictions. Important is that, on the modules on which address switches are located, the same address is set as on the module previously removed.

Module A1-XXX

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78

Troubleshooting

Remedying defects

Fault

Cause

Action

Main switch of the panel PC to 0 position

Switch on panel PC

No voltage supply

Check +24 V DC on X22 terminals

Defective fuse

Check fuse on the rear of the panel PC, if necessary, replace

After switching-on Black display screen

Check external voltage supply 85-264 V AC or 110-370 V DC Check input fuses on X20 terminals, if necessary, replace RIP CONTROL V2 software was not automatically started after booting of the panel PC

RIP CONTROL V2 was removed under Start → Programs → Auto start

Startup RIP CONTROL V2 manually Start → Programs → RIP CONTROL V2 l → RIP CONTROL V2 By holding down the left-hand mouse button and pulling into the folder Auto start automatic execution takes place after the boot sequence Notify Coal Control Service

Other causes

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79

Troubleshooting

Remedying faults with messages displayed

Message

Cause

Action

No power supply

Check correct and proper connection of the eight-pin plug

Supply lead damaged

Check supply lead and, if necessary, repair it

Transmitter has been mechanically damaged

Check transmitter for mechanical damage If necessary, replace

Other causes

Notify Coal Control Service

Transmitter defective (LED does not light up)

Also read the chapter Transmitter/Receiver. Receiver defective (LED does not light up)

(LED burns permanently red)

No power supply

Check and correct faulty connection between the eight-pin connector to the connection box and from connection box to the unit

Supply lead damaged

Check supply lead and, if necessary, repair

Receiver has been mechanically damaged

Check receiver for mechanical damage and, if necessary, replace

Direct transmission between transmitter and receiver

Reduce sensitivity or Increase the distance between transmitter and receiver

Other causes

Notify Coal Control Service

Also read the chapter Transmitter/Receiver. Distance pulse fault (Pulses are displayed)

Check pulse counting on module A1-BPS or on the graphic display Distance between both proximity switches pulse markers too big

Check to ensure firm and correct fastening of the proximity switches Check to ensure firm and correct fastening of the pulse markers Check the distance from the pulse markers and correct, if necessary

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80

Troubleshooting

Message

Cause

Action

Distance pulse fault

No power supply

Check +12 V DC on X21 terminals

(Pulses are not displayed)

Distance between both proximity switches and pulse markers is too big

Check pulse counting on module A1-BPS or on the graphic display Check to ensure firm and correct fastening of the proximity switches Check to ensure firm and correct fastening of the pulse markers Check distance from the pulse markers and correct, if necessary

(Sensor loop is identified too early)

Supply lead damaged

Check supply lead and, if necessary, repair or replace proximity switches

Proximity switch has been mechanically damaged

Check proximity switches for mechanical damage and replace, if necessary

Incorrect pulse counting

Check to ensure firm and correct fastening of the proximity switches

Belt movement abnormal Loop is detected several times in rapid succession

Check to ensure firm and correct fastening of the pulse markers Check distance from the pulse markers and correct, if necessary

Other causes

Notify Coal Control Service

Also read the Chapter Proximity Switches.

BPS-A2-MxG & BPS-A2-S

81

Troubleshooting

Message

Cause

Action

Communication failure

Incorrect or no display/CPU interface has been selected

Select tab Settings → Detection Pair # X → Com Port

Supply lead damaged

Check supply lead and, if necessary, repair

Other causes

Notify Coal Control Service

Incorrect Parameters/Settings selected

Check parameters/settings Select tab Settings → Detection Pair # X → Parameters

Other causes

Notify Coal Control Service

Invalid parameters

Also read the Chapter Parameter settings. No. of loops incorrect

Too many or too few loops were set in the parameter Number of loops(Quantity)

Select tab Settings → No. of loops Change No. of Loops

Also read the Chapter Parameter settings. Loop Failure

Bus-Connection Fault

Belt RIP

Check the Conveyor Belt Surface

Damaged Loop or Bad Quality Signal

Select tab Settings → Detection Pair # X → Loop out of Protection

Other causes

Notify Coal Control Service

Wrong BPS-A1-Module Address

Check the Module Address DFI:1, DO:1,2,3, BPS:1,2,3,4,

Damaged BPS-A1-Module

Check the module on the Bus Connector and if necessary, replace

Other causes

Notify Coal Control Service

Also read the Chapter Parameter settings. Reference Distance Incorrect

The selected Ref. Distance is incorrect or not unique.

Check the actually report if the Ref. Dist. Is a unique value. Select tab Settings → Detection Pair # X → Parameters

Also read the Chapter Parameter settings.

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82

Service and Support

Service and support Coal Control provides a comprehensive service and support which makes quick and competent support available for all questions relating to Coal Control products and system solutions. Coal Control Service Coal Control Service supports you on all matters involving after-sales service: • • •

On-the-spot service Repair service Spare parts service

Phone: +49(0)2103/951-882 Fax: +49(0)2103/951-829 E-Mail: [email protected] State equipment number

Should you require service, please state the equipment number of your belt rip detection system which you can see from the rating plate. Coal Control Support Support provides you with extensive technical support which assists you not only with the use of individual Coal Control products, but also with other comprehensive services: •

World-wide support

•

Planning, programming and commissioning of belt rip detection systems and automation systems

•

Extensive training program on Coal Control system components

Company head office Coal Control Gesellschaft für Automation mbH Reisholzstraße 15 40721 Hilden Germany Phone: +49(0)2103/951-0 Fax: +49(0)2103/951-829 E-Mail: [email protected] Internet: http://www.coal-control.de

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83

Service and Support

Spare parts Article no.

Description

Designation

CC4101.1

Transmitter

BPS-TX/8

CC4111.1

Receiver

BPS-RX/8

CC4100.1

Transmitter

BPS-T/8

CC4110.1

Receiver

BPS-R/8

CC4130.1

Mounting bracket

BPS-MBX

CC4050.1

8-pin plug with 5 m cable

BPS-PLUG/8

CC4034

Proximity switch

Ni15

CC4036

Rotary encoder

CC-RE1024

CC4013

Decoder

CC-DEC1024

CC4150

Connection box

CC-CB1212

CC4012.1

Industrial Panel PC

CC-PPC13

CC2000

Module

A1-CPU

CC2008

Module

A1-BPS

CC2004

Module

A1-DFI

CC2005

Module

A1-DO

CC4040

Power supply 12 VDC

CC-PS/12V

CC4041

Power supply 24 VDC

CC-PS/24V

BPS-A2-MxG & BPS-A2-S

84

1

3

2

4

5

6

7 BPS-RX/7 Empfänger Receiver

BPS-RX/7 Empfänger Receiver BPS-TX/7 Sender Transmitter

A

Ni15(T) Näherungschalter Prox. switches

*¹

*¹

8

BPS-TX/7 Sender Transmitter *¹

*¹

Ni15(T) Näherungschalter Prox. switches *¹

A

*¹

BPS-A2-MxG

BPS-A2-S(1G) (Slave)

(Master)

B

Spannungsversorgung Power supply AC100 - 240 V

Spannungsversorgung Power supply AC100 - 240 V

1

C

2

3

4

5

6

7

1

8

Ausgänge zur PLC Output contacts to PLC (max. 250VAC/5A)

2

3

4

C

Ausgänge zur PLC Output contacts to PLC (max. 250VAC/5A)

Die Kommunikation zwischen Master und Slave kann je nach Konfiguraton der Anlage in drei verschiedenen 2 Varianten ausgeführt sein *

X12 1 Detection mode: LIMITED 2 Detection mode: BYPASS 3 Belt Release Master and Slave 4 Fault Master and Slave 5 Belt Release Master 6 Fault Master 7 Belt Release Slave 8 Fault Slave

D

B

X12 1 Belt Release Slave 2 Fault Slave 3 Detection mode: LIMITED 4 Detection mode: BYPASS

Depending on the Configuration the Master-Slave connection 2 is build in three different options *

D

*¹ Empfohlenes Kabel: HELUKABEL Typ F-CY-OZ 4x0,75 mm² geschirmt oder vergleichebarer Typ. max. Aussendurchmesser 8 mm, max Kabellänge 250 m Art.Nr.: 13056

E

E Name :

Recommended cable type: HELUKABEL type F-CY-OZ 4x 0,75mm² shielded or comparable cable type with max. outside diameter ≤ 8 mm, max. cable length: 250 m Part no.: 13056

BPS-A2-MxG / BPS-A2-S(1G) - Master - Slave

2

* Option 1: Per Moxa-Konverter über RS485 Option 2: Per Ethernet über CAT5/6-Kabel oder LWL-Leitung Option 3: Per Profibus

Datum

Option 1: Via Moxa-Converter by use of RS485 Option 2: Via Ethernet by use of CAT5/6 Cable Option 3: Via Profibus

F

Name

Konstr.

05.05.2014

M. Nowak

Geprüft

05.05.2014

A. Herrmann

Massstab

Version

Anschlussschema

F 1

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Seite 1 / 12

Genehm.

Zeichnungs Nr.: BPSA2MxGS.150612.AA04.F

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1

3

2

5

4

6

8

*2 zutreffend für / applicable for BPS-A2-M2G *3 zutreffend für / applicable for BPS-A2-M3G *4 zutreffend für / applicable for BPS-A2-M4G *5 zutreffend für / applicable for BPS-A2-M2G-RE

Warning Message *5

OK Message Detection Pair #3 *3,4

OK Message Detection Pair #4 *4

OK Message Detection Pair #1

OK Message Detection Pair #2 *2,3,4

Belt Release Conveyor

Feeder Signal Message

Operation mode: LIMITED

A

Operation mode: BYPASS

Plant Control System

7

A

*5 Verbindung zwischen Panel-PC und Moxa via Ethernet: CAT5 oder CAT6 Kabel

BPS-A2-MxG

Conection between Panel-PC and Moxa via Ethernet: CAT5 or CAT6 cable 11 14 11 14

13" Panel PC

11 14

11 14

11 14 11 14 11 14 11 14 11 14

*6 über Twisted Par Leitung 2x2x0,75 mm² bis 2 km via Twisted Pair 2x2x0.75 mm² up to 2 km

B

B

X12

K1

K2

A1A2 A1A2

K5

K7

K9 K10 K11 K12 K13

A1A2

A1A2

A1A2 A1A2 A1A2 A1A2 A1A2 X21

123456789 RS485 D-

GND

RS485 D+

+24V

C3 zur Slave-Einheit *6 C4 to Slave Unit -

3 4

Externer Reset-Schalter External Reset push button

Moxa

Panel-PC 10/100/Ethernet

Moxa N-Port 10/100/Ethernet *5

C1C2

2,7 K

2,7 K

2,7 K

2,7 K

RS485-B

RS485-A

X0

C

*2,4 *3,4

RS485

C

12VDC

2,7 K

X1.1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

+

X21

+

X21

X2.2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

X2.1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

+

X2.3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Module A1-DO Address 3

Module A1-DO Address 2

Module A1-DO Address 1

Module A1-DFI Address 1

Module A1-CPU Address 1

X21

D

D 1

2

3

4

5

1

2

3

4

1

5

2

3

4

1

5

2

3

4

1

5

2

3

4

5

X0

1 2 3 4 5

+12V

1

1

1

1

1

1

1

1

1

GND

2

2

2

2

2

2

2

2

2

RESET

3

3

3

3

3

3

3

3

3

RS485-A

4

4

4

4

4

4

4

4

4

RS485-B

5

5

5

5

5

5

5

5

5

E

E Name :

BPS-A2-MxG / BPS-A2-S(1G) - Master <-> Slave Kommunikation per RS485 - Master <-> Slave Communication via RS485 Datum

F

Name

Konstr.

05.05.2014

M. Nowak

Geprüft

05.05.2014

A. Herrmann

Massstab

Version

Anschlussschema

F 1

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Seite 2 / 12

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BPS-A2-MxG 11 14 11 14

13" Panel PC

11 14

11 14

11 14 11 14 11 14 11 14 11 14

A1A2 A1A2

K5

K7

K9 K10 K11 K12 K13

A1A2

A1A2

A1A2 A1A2 A1A2 A1A2 A1A2

-

GND

+24V

RS485 D+

RS485 D-

3 4

Externer Reset-Schalter External Reset push button

*¹

C

2,7 K

2,7 K

2,7 K

2,7 K

RS485-B

RS485-A

X0

Verbindung zur Slave-Einheit Connection to Slave-Unit

Ethernet Switch

*2,4 *3,4

RS485

C

X21

Panel-PC 10/100th/Ethernet

Ethernet - Switch

C1C2

B

Connection between Master and Slave by use of according Switch via CAT5 or CAT6 cable up to max. 100 m via fiber-optic cable Multi-Mode up to 2 km via fiber-optic cable Single-Mode up to 30 km

X12

K2

A

*¹ Verbindung zwischen Master und Slave über ensprechenden Switch via CAT5 oder CAT6 Kabel bis max. 100 m via LWL-Leitung Multi-Mode bis max 2 km via LWL-Leitung Single-Mode bis max 30 km

B K1

8

*2 zutreffend für / applicable for BPS-A2-M2G(-MV) *3 zutreffend für / applicable for BPS-A2-M3G *4 zutreffend für / applicable for BPS-A2-M4G *5 zutreffend für / applicable for BPS-A2-M2G-RE

Warning Message *5

OK Message Detection Pair #3 *3,4

OK Message Detection Pair #4 *4

OK Message Detection Pair #1

OK Message Detection Pair #2 *2,3,4

Belt Release

Feeder Signal Message

Operation mode: LIMITED

A

Operation mode: BYPASS

Plant Control System

7

2,7 K

X1.1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

+

X21

+

X21

X2.2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

X2.1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

+

X2.3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Module A1-DO Address 3

Module A1-DO Address 2

Module A1-DO Address 1

Module A1-DFI Address 1

Module A1-CPU Address 1

X21

D

D 1

2

3

4

5

1

2

3

4

1

5

2

3

4

1

5

2

3

4

1

5

2

3

4

5

X0

1 2 3 4 5

+12V

1

1

1

1

1

1

1

1

1

GND

2

2

2

2

2

2

2

2

2

RESET

3

3

3

3

3

3

3

3

3

RS485-A

4

4

4

4

4

4

4

4

4

RS485-B

5

5

5

5

5

5

5

5

5

E

E Name :

BPS-A2-MxG / BPS-A2-S(1G) - Master <-> Slave Kommunikation per Ethernet-Kabel - Master <-> Slave Communication via Ethernet-Cable Datum

F

Name

Konstr.

05.05.2014

M. Nowak

Geprüft

05.05.2014

A. Herrmann

Massstab

Version

Anschlussschema

F 1

2

3

4

5

F

Seite 3 / 12

Genehm.

Zeichnungs Nr.: BPSA2MxGS.150612.AA04.F

6

7

8

1

3

2

5

4

6

8

*2 zutreffend für / applicable for BPS-A2-M2G(-MV) *3 zutreffend für / applicable for BPS-A2-M3G *4 zutreffend für / applicable for BPS-A2-M4G *5 zutreffend für / applicable for BPS-A2-M2G-RE

Warning Message *5

OK Message Detection Pair #3 *3,4

OK Message Detection Pair #4 *4

OK Message Detection Pair #1

OK Message Detection Pair #2 *2,3,4

Belt Release

Feeder Signal Message

Operation mode: LIMITED

A

Operation mode: BYPASS

Plant Control System

7

BPS-A2-MxG

A

*¹ Verbindung zwischen Master und Slave via Datenbuskabel bis max. 15 km Connection between Master and Slave via databus cable cable up to 15 km 11 14 11 14

13" Panel PC

11 14

11 14

11 14 11 14 11 14 11 14 11 14

K5

K7

K9 K10 K11 K12 K13

A1A2

A1 A2

A1 A2 A1 A2 A1 A2 A1 A2 A1A2

B

B X12

K1

K2

A1A2A1A2

-

GND

+24V

RS485 D+

RS485 D-

3 4

X21

Externer Reset-Schalter External Reset push button

C1C2

B / rt

Profibus - RS485

Profibus - Slave *

X21

X21

+

X21

+ gn

+

X2.3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Module A1-DO Address 2

Module A1-DO Address 1

Module A1-DFI Address 1

Module A1-CPU Address 1

X2.2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

X2.1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

ge

2,7 K

2,7 K

X1.1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

1

A / gn

2,7 K

2,7 K

2,7 K

RS485-B

RS485-A

gn

CPU - RS485

ge

X0

C

*2,4 *3,4

RS485

C

X3.1 1 2 3 4 5 6 7 8 9

3 8 sub-D9

Module A1-PB Address 1

Module A1-DO Address 3

D

D 1

2

3

4

5

1

2

3

4

1

5

2

3

4

1

5

2

3

4

5

1

2

3

4

1

5

2

3

4

5

X0

1 2 3 4 5

+12V

1

1

1

1

1

1

1

1

1

1

1

GND

2

2

2

2

2

2

2

2

2

2

2

RESET

3

3

3

3

3

3

3

3

3

3

3

RS485-A

4

4

4

4

4

4

4

4

4

4

4

RS485-B

5

5

5

5

5

5

5

5

5

5

5

E

E Name :

BPS-A2-MxG / BPS-A2-S(1G) - Master <-> Slave Kommunikation per Profibus - Master <-> Slave Communication via Profibus Datum

F

Name

Konstr.

05.05.2014

M. Nowak

Geprüft

05.05.2014

A. Herrmann

Massstab

Version

Anschlussschema

F 1

2

3

4

5

F

Seite 4 / 12

Genehm.

Zeichnungs Nr.: BPSA2MxGS.150612.AA04.F

6

7

8

1

3

2

5

4

6

7

8

A Warning Message

OK Message Conv. #1 Detection Pair #1

OK Message Conv. #2 Detection Pair #1

Feeder Signal Message Conveyor #1

Feeder Signal Message Conveyor #2

Operation mode: LIMITED Conveyor #2

Operation mode: BYPASS Conveyor #2

A

Operation mode: BYPASS Conveyor #1

Operation mode: LIMITED Conveyor #1

Plant Control System

BPS-A2-M2G-MV

*¹ Verbindung zwischen Master und Slave via Datenbuskabel bis max. 15 km Connection between Master and Slave via databus cable cable up to 15 km 11 14 11 14 11 14 11 14 11 14 11 14

13" Panel PC

11 14 11 14

11 14

K9 K10

K13

A1 A2 A1 A2

A1A2

B

B X12

K1

K2

K3

K4

K5

K6

A1A2A1 A2 A1 A2 A1 A2A1A2 A1 A2

-

GND

+24V

RS485 D+

RS485 D-

3 4

X21

Externer Reset-Schalter External Reset push button

C1C2

C

*2,4 *3,4

RS485

C Profibus - RS485

2,7 K

2,7 K

2,7 K

2,7 K

RS485-B

RS485-A

X0

Profibus - Slave *

CPU - RS485 2,7 K

X1.1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

+

X21

+

X21

X2.2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

X2.1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

+

X2.3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Module A1-DO Address 2

Module A1-DO Address 1

Module A1-DFI Address 1

Module A1-CPU Address 1

X21

1

X3.1 1 2 3 4 5 6 7 8 9

Module A1-PB Address 1

Module A1-DO Address 3

D

D 1

2

3

4

5

1

2

3

4

1

5

2

3

4

1

5

2

3

4

5

1

2

3

4

1

5

2

3

4

5

X0

1 2 3 4 5

+12V

1

1

1

1

1

1

1

1

1

1

1

GND

2

2

2

2

2

2

2

2

2

2

2

RESET

3

3

3

3

3

3

3

3

3

3

3

RS485-A

4

4

4

4

4

4

4

4

4

4

4

RS485-B

5

5

5

5

5

5

5

5

5

5

5

E

E Name :

BPS-A2-MxG-MV BPS-A2-MxG / BPS-A2-S(1G) Datum

F

Name

Konstr.

05.05.2014

M. Nowak

Geprüft

05.05.2014

A. Herrmann

Massstab

Version

Anschlussschema

F 1

2

3

4

5

F

Seite 5 / 12

Genehm.

Zeichnungs Nr.: BPSA2MxGS.150612.AA04.F

6

7

8

1

3

2 Näherungsschalter Proximity switch Ni15(T)

bl

bl

br

bn

A

+ -

2

+ -

1

5

4 Schurre Chute

Schurre Chute

6

Schurre Chute

Laufrichtung / Running direction

7

8

Schurre Chute

Sender Transmitter BPS-T(X)/8

Empfänger Receiver BPS-R(X)/8

Sender Transmitter BPS-T(X)/8

Empfänger Receiver BPS-R(X)/8

Sender Transmitter BPS-T(X)/8

Empfänger Receiver BPS-R(X)/8

Sender Transmitter BPS-T(X)/8

Empfänger Receiver BPS-R(X)/8

1 3 4

1 2 3 4

1 3 4

1 2 3 4

1 3 4

1 2 3 4

1 3 4

1 2 3 4

4 5 6 7

1 2 3

4 5 6 7

1 2 3

4 5 6 7

1 2 3

A

bn = braun / brown bl = blau / blue

1 2 3

1 2 3 4

CC-CB1212

CC-CB1212 1 2 3

1 2 3 4

CC-CB1212 1 2 3

4 5 6 7

CC-CB1212 1 2 3

4 5 6 7

Spannungsversorgung Power supply AC 85 - 264 V DC 110 - 370 V 50 - 60 Hz

4 5 6 7 CC-CB1212

1 2 3

4 5 6 7

4 5 6 7

B

B

BPS-A2-MxG

X30 1

1 2 3 4 5 6 7

2 3 4

X40

8 9 10 11 12 13 14

X40

15 16 17 18 19 20 21

X40

22 23 24 25 26 27 28

X20

X40

C

AC (L)

AC (N) GND

C

B1 2A/250V

Netzteil Power supply PBA30F-12 12V/2,5A X21.1

Module A1-BPS Address 2

Module A1-BPS Address 3

Module A1-BPS Address 4

M1G

M2G

M3G

M4G

1

2

3

4

1

5

2

3

4

1

5

2

3

4

1

5

2

3

-

FG

AC (L)

AC (N)

AC (L)

AC (N)

X22.1

+

-

FG

AC (L)

AC (N)

AC (L)

AC (N)

+12V

Digital

Analog

GND

GND

+12V

Digital

GND

IN

IN

GND

+12V

GND

Digital

Analog

GND

+12V

Digital

IN

IN

GND

GND

Module A1-BPS Address 1

D

+

1 2 5 6 3 4 7 16 14 13 12 10 11 9 8 15

1 2 5 6 3 4 7 16 14 13 12 10 11 9 8 15

+12V

Digital

Analog

GND

GND

+12V

Digital

GND

IN

IN

1 2 5 6 3 4 7 16 14 13 12 10 11 9 8 15 GND

GND

+12V

Digital

Analog

GND

+12V

Digital

GND

IN

IN

GND

1 2 5 6 3 4 7 16 14 13 12 10 11 9 8 15

Netzteil Power supply PBA30F-24 24V/1,3A

X20

X20

X20

D 4

5

X21 + -

X22 + -

1

1

2

2

3

3

4

4

5

5

C1C2

E

E Name :

BPS-A2-MxG / BPS-A2-S(1G) Datum

F

Name

Konstr.

05.05.2014

M. Nowak

Geprüft

05.05.2014

A. Herrmann

Massstab

Version

Anschlussschema

F 1

2

3

4

5

F

Seite 6 / 12

Genehm.

Zeichnungs Nr.: BPSA2MxGS.150612.AA04.F

6

7

8

3

2

+ -

1

Sender Transmitter BPS-T(X)/8

Empfänger Receiver BPS-R(X)/8

1 3 4

1 2 3 4

bn = braun / brown bl = blau / blue

1 2 3

1 2 3 4 Abzweigdose Connection Box

Näherungsschalter Proximity switch Ni15(T)

Laufrichtung / Running direction

bn

bl

bl

br

bn

A

+ -

Schurre Chute

4 5 6 7

1 2 3

1 2 3 4

+ -

2

+ -

1

Schurre Chute

4 5 6 7

7

8

Laufrichtung / Running direction Sender Transmitter BPS-T(X)/8

Empfänger Receiver BPS-R(X)/8

1 3 4

1 2 3 4

1 2 3

1 2 3 4 Abzweigdose Connection Box

CC-CB1212

CC-CB1212

6

A

bl

Näherungsschalter Proximity switch Ni15(T)

5

4

bl

2

br

1

Spannungsversorgung Power supply AC 85 - 264 V DC 110 - 370 V 50 - 60 Hz

4 5 6 7 CC-CB1212

CC-CB1212 1 2 3

1 2 3 4

4 5 6 7

B

B

BPS-A2-MxG-MV

X30 1

1 2 3 4 5 6 7

2 3 4

X40

X30 5

8 9 10 11 12 13 14

6 7 8

X20

X40

C

AC (L)

AC (N) GND

C

B1 2A/250V

Netzteil Power supply PBA30F-12 12V/2,5A X21.1

Module A1-BPS Address 2

M1G

M2G

1

2

3

4

5

1

2

3

-

FG

AC (L)

AC (N)

AC (L)

AC (N)

X22.1

+

-

FG

AC (L)

AC (N)

AC (L)

AC (N)

+12V

Digital

Analog

GND

GND

+12V

Digital

GND

IN

IN

GND

+12V

Digital

Analog

GND

+12V

Digital

IN

IN

GND

Module A1-BPS Address 1

D

+

1 2 5 6 3 4 7 16 14 13 12 10 11 9 8 15 GND

X8.2

1 2 5 6 3 4 7 16 14 13 12 10 11 9 8 15 GND

X8.1

Netzteil Power supply PBA30F-24 24V/1,3A

X20

X20

X20

D 4

X21 + -

5

X22 + -

1

1

2

2

3

3

4

4

5

5

C1C2

E

E Name :

BPS-A2-MxG-MV BPS-A2-MxG / BPS-A2-S(1G) Datum

F

Name

Konstr.

05.05.2014

M. Nowak

Geprüft

05.05.2014

A. Herrmann

Massstab

Version

Anschlussschema

F 1

2

3

4

5

F

Seite 7 / 12

Genehm.

Zeichnungs Nr.: BPSA2MxGS.150612.AA04.F

6

7

8

1

3

2

5

4

6

7

8

A

A

BPS-A2-MxG BPS-A2-S(1G)

B

B

C

C

D

X20

Spannungsversorgung Power supply AC 100 - 240 V

E

L1 N

D

GND

L N

E Name :

GND

BPS-A2-MxG / BPS-A2-S(1G) - Sender / Empfänger - Transmitter / Receiver Datum

F

Name

Konstr.

05.05.2014

M. Nowak

Geprüft

05.05.2014

A. Herrmann

Massstab

Version

Anschlussschema

F 1

2

3

4

5

F

Seite 8 / 12

Genehm.

Zeichnungs Nr.: BPSA2MxGS.150612.AA04.F

6

7

8

1

3

2

5

4

6

A

7

8

A

BPS-A2-MxG BPS-A2-S(1G)

B

B

Anschlußleitung Connection line Ni15(T)

C

C X30

1

2

3

4

GND

br = braun / brown bl = blau / blue

*

1 Näherungsschalter #1 Proximity switch #1 Ni15(T)

D

Näherungsschalter #2 Proximity switch #2 Ni15(T)

br

2

bl

3

br

4

Abschirmung / shielding

D

bl Connection box CC-CB1212

E

E

* Empfohlenes Kabel: HELUKABEL Typ F-CY-OZ 4x0,75 mm² geschirmt oder vergleichebarer Typ. max. Aussendurchmesser 8 mm, max Kabellänge 250 m Art.Nr.: 13056

Name :

BPS-A2-MxG / BPS-A2-S(1G) - Näherungsschalter / Proximity Switch - Sender & Empfänger / Transmitter & Receiver Datum

Recommended cable type: HELUKABEL type F-CY-OZ 4x 0,75mm² shielded or comparable cable type with max. outside diameter ≤ 8 mm, max. cable length: 250 m Part no.: 13056

F

Name

Konstr.

05.05.2014

M. Nowak

Geprüft

05.05.2014

A. Herrmann

Massstab

Version

Anschlussschema

F 1

2

3

4

5

F

Seite 9 / 12

Genehm.

Zeichnungs Nr.: BPSA2MxGS.150612.AA04.F

6

7

8

1

3

2

5

4

6

A

7

8

A

BPS-A2-MxG

B

B

Anschlußleitung Connection line Ni15(T)

C

C X30

5

6

7

8

GND

br = braun / brown bl = blau / blue

*

1 Näherungsschalter #1 Proximity switch #1 Ni15(T)

D

Näherungsschalter #2 Proximity switch #2 Ni15(T)

br

2

bl

3

br

4

Abschirmung / shielding

D

bl Connection box CC-CB1212

E

E

* Empfohlenes Kabel: HELUKABEL Typ F-CY-OZ 4x0,75 mm² geschirmt oder vergleichebarer Typ. max. Aussendurchmesser 8 mm, max Kabellänge 250 m Art.Nr.: 13056

Name :

BPS-A2-MxG-MV Band 2 / 2nd Belt BPS-A2-MxG / BPS-A2-S(1G) - Näherungsschalter / Proximity Switch - Sender & Empfänger / Transmitter & Receiver Datum

Recommended cable type: HELUKABEL type F-CY-OZ 4x 0,75mm² shielded or comparable cable type with max. outside diameter ≤ 8 mm, max. cable length: 250 m Part no.: 13056

F

Name

Konstr.

05.05.2014

M. Nowak

Geprüft

05.05.2014

A. Herrmann

Massstab

Version

Anschlussschema

F 1

2

3

4

5

F

Seite 10 / 12

Genehm.

Zeichnungs Nr.: BPSA2MxGS.150612.AA04.F

6

7

8

1

3

2

A

5

4

6

7

8

A

BPS-A2-M1G(-MV) BPS-A2-S(1G)

B

B

X40

1

2

3

X40

GND

4

5

6

7

GND

C

C

*

Schirm / Shielding

D

1 2 3

4

5

6

7

1 2 3 3

1

4

4

D

Recommended cable type: HELUKABEL type F-CY-OZ 4x 0,75mm² shielded or comparable cable type with max. outside diameter ≤ 8 mm, max. cable length: 250 m Part no.: 13056

CC-CB1212 E

* Empfohlenes Kabel: HELUKABEL Typ F-CY-OZ 4x0,75 mm² geschirmt oder vergleichebarer Typ. max. Aussendurchmesser 8 mm, max Kabellänge 250 m Art.Nr.: 13056

1

5 2

6 3

7

E Name :

4

BPS-A2-MxG 1 / BPS-A2-S(1G) - Sender & Empfänger / Transmitter & Receiver Datum

Sender #1 Transmitter #1 BPS-T(X)/8

F

Empfänger #1 Receiver #1 BPS-R(X)/8

Konstr.

05.05.2014

M. Nowak

Geprüft

05.05.2014

A. Herrmann

Version

Anschlussschema

F 2

3

4

5

F

Seite 11 / 12

Genehm. Massstab

1

Name

Zeichnungs Nr.: BPSA2MxGS.150612.AA04.F

6

7

8

1

3

2

5

4

6

7

8

BPS-A2-MxG(-MV)

A

A

B

B

X40

1

2

3

*1

GND

X40

Abschirmung Shielding

4

5

6

7

GND

X40

8

9

10

*1

*1

X40

GND

Abschirmung Shielding

11 12 13 14

GND

X40

15 16 17

*1

*1

X40

GND

Abschirmung Shielding

18 19 20 21

GND

X40

22 23 24

*1

*1

X40

GND

Abschirmung Shielding

25 26 27 28

GND

*1

C

C 1 2 3 4 5 7 8 Connection Box CC-CB1212 1 2 3 4 5 7 8 1

3

4

Sender #1 Transmitter #1 BPS-T(X)/8

D

1

2

3

1 2 3 4 5 7 8 Connection Box CC-CB1212 1 2 3 4 5 7 8

4

Empfänger #1 Receiver #1 BPS-R(X)/8

1

3

4

1

Sender #2 Transmitter #2 BPS-T(X)/8

2

3

4

Empfänger #2 Receiver #2 BPS-R(X)/8

1 2 3 4 5 7 8 Connection Box CC-CB1212 1 2 3 4 5 7 8 1

3

4

1

Sender #3 Transmitter #3 BPS-T(X)/8

*2

E

2

3

1 2 3 4 5 7 8 Connection Box CC-CB1212 1 2 3 4 5 7 8

4

1

3

4

1

Sender #4 Transmitter #4 BPS-T(X)/8

Empfänger #3 Receiver #3 BPS-R(X)/8

*3

*1 Empfohlenes Kabel: HELUKABEL Typ F-CY-OZ 4x0,75 mm² geschirmt oder vergleichebarer Typ. max. Aussendurchmesser 8 mm, max Kabellänge 250 m Art.Nr.: 13056

Empfänger #4 Receiver #4 BPS-R(X)/8

D

*4

BPS-A2-MxG / BPS-A2-S(1G) Datum

F

Name

Konstr.

05.05.2014

M. Nowak

Geprüft

05.05.2014

A. Herrmann

Massstab

Version

Anschlussschema

F 4

5

F

Seite 12 / 12

Genehm.

3

4

- Sender & Empfänger / Transmitter & Receiver

*2 Bestandteil von / part of M2G, M1G-MV, M3G, M4G *3 Bestandteil von / part of M3G, M4G *4 Bestandteil von / part of M4G

2

3

E Name :

Recommended cable type: HELUKABEL type F-CY-OZ 4x 0,75mm² shielded or comparable cable type with max. outside diameter ≤ 8 mm, max. cable length: 250 m Part no.: 13056

1

2

Zeichnungs Nr.: BPSA2MxGS.150612.AA04.F

6

7

8

1

3

2

5

4

6 Näherungsschalter Proximity switch Ni15, Ni15T

Belt Release

bl

bl

br

br

+ -

2

+ -

1

Schurre Chute

8

Laufrichtung Running direction Sender Transmitter BPS-T(X)/8

Empfänger Receiver BPS-R(X)/8

1 3 4

1 2 3 4

1 2 3

4 5 6 7

A

bn = braun / brown bl = blau / blue

CC-CB1212

1 2 3 4

1 2 3

4 5 6 7

CC-CB1212

INP

INP

INP

INP

INP

INP

INP

INP

OK Message

A

Detection mode: BYPASS

Detection mode: LIMITED

Plant Control System

7

1 2 3 4

BPS-A2-S(1G) 11 14 11 14 11 14 11 14

B BPS-A1-S-LCD

X12

K1

K2

K3

B

K4

4x20 digits Display A1 A2 A1 A2 A1 A2 A1 A2

1 2 3 4

Externer Reset-Schalter External Reset push button

X30 1 2 3 4

- X21

1 2 3 4 5 6 7

X40

+

X2.1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Module A1-CPU Address 1

+12V

GND

Digital

Analog

GND

+12V

Module A1-BPS Address 1

Module A1-DO Address 1

Module A1-DFI Address 1

Digital

X 8 . 1 1 2 5 6 3 4 7 16 14 13 12 10 11 9 8 15 GND

X1.1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

IN

X 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

X21

Aktivierung Reset-Funktion Reset activation

IN

*1

GND

Moxa C3 C4

2,7 K

C 2,7 K

C

D

D 1

2

3

4

1

5

2

3

4

1

5

2

3

4

1

5

2

3

4

5

X0

1 2 3 4 5

+12V

1

1

1

1

1

1

1

GND

2

2

2

2

2

2

2

RESET

3

3

3

3

3

3

3

RS485-A

4

4

4

4

4

4

4

RS485-B

5

5

5

5

5

5

5

E

E Name :

BPS-A2-S(1G)

1

* Der Moxa-Konverter befindet sich je nach Master-Slave Entfernung in der Masteroder in der Slave-Einheit und wird entsprechend per RS485 an den Klemmen C3 und C4 verdrahtet. Depenting on the distance between Master and Slave the Moxa-Converter is mounted in the Slave- or Master-Unit and connected at the ports C3 and C4

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Datum

Name

Konstr.

04.2014

M. Nowak

Geprüft

04.2014

S. Przegendza

Massstab

Version

Block-schaltbild

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Seite 1 / 2

Genehm.

Zeichnungs Nr. : BPSA2S1G.140901.AA07.2

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A

A Spannungsversorgung Power supply AC 100 - 240 V 50 - 60 Hz

B

BPS-A2-S(1G)

X20

AC AC (L) (N)

GND

B

C4

PBA30F-12 12V/2,5A

C

X21.1

+

-

FG

1 2 3 4 5 6 7 8 9

C3

AC AC (L) (N)

Moxa N-Port

10/100/Ethernet

Spannungsversorgung Power supply

Port1 RS232/422/485

B1 2A/250V

Master Panel PC

C

1 2

AC AC (L) (N)

X21

D

X20

X20

+ -

D

Verbindung zwischen BPS-A2-MxG und BPS-A2-S (max. 100 m) per CAT5 oder CAT6 Kabel Bei größeren Distanzen entfällt der Moxa-Konverter in der Slave-Einheit 1

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Connection between BPS-A2-MxG and BPS-A2-S (max 100 m) via CAT5 or CAT6 cable In case larger distances between Master and Slave the Moxa-Converter ist mounted in the Slave-Unit

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E Name :

F

BPS-A2-S(1G) Datum

Name

Konstr.

04.2014

M. Nowak

Geprüft

04.2014

S. Przegendza

Massstab

Version

Block-schaltbild

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Zeichnungs Nr. : BPSA2S1G.140901.AA07.2

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A

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A

80 - 250 mm

50 - 120 mm

min. 300 mm

min. 300 mm

B

B min. 700 mm

C

C

Die Laufrichtung des Bandes ist für die Funktion von Sender und Empfänger unerheblich. The belt direction of movement is not relevant for the function of transmitter and receiver.

D

D

E

E Name :

BPS-ATR - Sender / Empfänger - Transmitter / Receiver Datum

F

Name

Konstr.

05.2013

M.Nowak

Geprüft

05.2013

S. Przegendza

Massstab

Version

Bemaßung

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Zeichnungs Nr.: BPSATR.140710.AA02.5

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50 - 120 mm

A

A ~ 300 mm

~ 250 mm

B

B ~ 250 mm

C

C

Die Laufrichtung des Bandes ist für die Funktion von Sender und Empfänger unerheblich. The belt direction of movement is not relevant for the function of transmitter and receiver.

D

D

min. 300 mm

E

E Name :

BPS-ATR - Sender / Empfänger - Transmitter / Receiver Datum

F

Name

Konstr.

05.2013

M.Nowak

Geprüft

05.2013

S. Przegendza

Massstab

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Bemaßung

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Zeichnungs Nr.: BPSATR.140710.AA02.5

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A

A

~ 300 mm 50 - 120 mm

B

B

C

C

Die Laufrichtung des Bandes ist für die Funktion von Sender und Empfänger unerheblich. The belt direction of movement is not relevant for the function of transmitter and receiver.

D

D

E

E Name :

BPS-ATR - Sender / Empfänger - Transmitter / Receiver Datum

F

Name

Konstr.

05.2013

M.Nowak

Geprüft

05.2013

S. Przegendza

Massstab

Version

Bemaßung

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Zeichnungs Nr.: BPSATR.140710.AA02.5

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A

A

B

B

C

C

Sender / Empfänger Transmitter / Receiver

D

D

Die Laufrichtung des Bandes ist für die Funktion von Sender und Empfänger unerheblich. The belt direction of movement is not relevant for the function of transmitter and receiver.

E

E Name :

BPS-ATR - Sender / Empfänger - Transmitter / Receiver Datum

F

Name

Konstr.

05.2013

M.Nowak

Geprüft

05.2013

S. Przegendza

Massstab

Version

Bemaßung

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Zeichnungs Nr.: BPSATR.140710.AA02.5

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A

A

120 mm 120 mm

B

B

80 mm

ca 180° einstellbar adjustable approx. 180 ° 350 mm

C

C

einstellbar 360° adjustable 360 °

300 mm

D

D

E

E Name :

BPS-ATR - Sender / Empfänger - Transmitter / Receiver Datum

F

Name

Konstr.

05.2013

M.Nowak

Geprüft

05.2013

S. Przegendza

Massstab

Version

Bemaßung

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Zeichnungs Nr.: BPSATR.140710.AA02.5

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A

A

B

B

C

C

∅ 7 mm

D

D

42 mm

Befestigungsmaterial ist nicht im Lieferumfang enthalten. Mounting hardware is not within the scope auf supply.

E

E Name :

BPS-ATR - Sender / Empfänger - Transmitter / Receiver

42 mm

Datum

F

Name

Konstr.

05.2013

M.Nowak

Geprüft

05.2013

S. Przegendza

Massstab

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Bemaßung

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Zeichnungs Nr.: BPSATR.140710.AA02.5

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A

Rolle / Pulley

B

B

*

*

C

C

D

D

Näherungsschalter Typ Ni15(T) Proximity switch type Ni15(T)

E

E Name :

BPS-A1-APS - Näherungsschalter / Montagebeispiel - Proximity Switches / Mounting Example

* Alle Abstands- und Längenmaße können der Zeichnung BPSA1APS.130521.AA02.1 entnommen werden. Measures for the distances between the proximity switches and the length of the distance pulse marks are to be taken from the drawing no. BPSA1APS.130521.AA02.1

F

Datum

Name

Konstr.

05.2013

M. Nowak

Geprüft

05.2013

S. Przegendza

Massstab

Version

Übersicht / Overview

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Zeichnungs Nr. : BPSA1APS.130611.AA01.2

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Das Bedecken der Näherungsschalter hat in den dargestellten 4 Phasen zu erfolgen. (Seitenansichten der Sensoren)

A

A

The cover of the proximity switches has to proceed as shown in the phases 1 - 4. (Side view of the sensors)

1.

2.

3.

4.

B

B

C

C

D

Die Puls-Marken sollten als Kreuz-Anordnung in der Mitte der Achse montiert werden. Ist dies nicht möglich, können die Puls-Marken, direkt auf der Rolle montiert werden. Siehe Zeichnung.

D

There are two different kinds of mounting the distance pulse marks. The better option is the mounting in the middle of the axle where the distance pulse marks arranged like a cross. If this option is not operable, the distance pulse marks can be arranged directly on the drum like shown in the example.

E

E Name :

BPS-A1-APS - Näherungsschalter / Montagebeispiel - Proximity Switches / Mounting Example

F

Datum

Name

Konstr.

05.2013

M. Nowak

Geprüft

05.2013

S. Przegendza

Massstab

Version

Übersicht / Overview

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Seite 2 / 5

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Zeichnungs Nr. : BPSA1APS.130611.AA01.2

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A

Vorgaben: - Für die Phasen 1 - 4 sind mindestens 60 ms Dauer nötig - Jeder Näherungsschalter kann maximal 15 Pulse pro Sekunde erfassen. - Wichtig: Alle Puls-Marken müssen im gleichen Winkel zueinander montiert sein. Beispiel: 2 Puls-Marken: 180° 3 Puls-Marken: 120° 4 Puls-Marken: 90° usw. - Wichtig: Die Puls-Marken müssen, in der Reihenfolge in der sie erfasst werden sollen, parallel zu den Näherungsschaltern angebracht sein. - Die Länge der Pulsmarken muss 150 mm betragen und gewährleisten, dass beide Näherungsschalter gleichzeitig abgedeckt werden. - Die Positionierung und die Anzahl der Puls-Marken sollte 1m Pulsabstand entsprechen.

B

B

Terms: - Min. approx. 60 ms are needed for the operating sequence of phases 1 - 4 - A maximum quantity of 15 pulses per second can be taken up by the respective proximity switch - Important: The attached distance pulse marks need to be mounted in the same angle to each other; For example: 2 distance pulse marks 180° 3 distance pulse marks 120° 4 distance pulse marks 90° etc. - Important: The distance pulse marks need to be mounted parallel to the proximity switches, in order to being recorded over the complete length. - The length of the distance pulse marks need to be 150 mm, assuring that both proximity switches are covered simultaneously.

C

D

C

D

Rechenbeispiele für die Ermittlung der benötigten Puls-Marken: Rollendurchmesser 0,5 m 0,5 m * 3,14 = 1,57 m entspricht der Bandlänge pro Rollenumumdrehung 1,57 m / 1 m = 1,57 enspricht 2 Puls-Marken

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E Name :

Rollendurchmesser 1,2 m 1,2 m * 3,14 = 3,768 m entspricht der Bandlänge pro Rollenumumdrehung 3,768 m / 1m = 3,768 entspricht 4 Puls-Marken Worked sample for quantity of the distance pulse marks:

F

BPS-A1-APS - Näherungsschalter / Montagebeispiel - Proximity Switches / Mounting Example Datum

Name

Konstr.

05.2013

M. Nowak

Geprüft

05.2013

S. Przegendza

diameter of the drum 0.5 m 0.5 m * 3.14 = 1.57 m corresponds to the belt length per revolution 1.57 m / 1 m = 1.57 corresponds to 2 distance pulse marks diameter of the drum 1.2 m 1.2 m * 3.14 = 3.768 m corresponds to the belt length per revolution 3.768 m / 1 m = 3.768 corresponds to 4 distance pulse marks

Genehm. Massstab

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Übersicht / Overview

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Seite 3 / 5

Zeichnungs Nr. : BPSA1APS.130611.AA01.2

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A

A Seitenansicht / Side view

Vorderansicht / Frontal view < 10 mm

60 mm

B

B

150 mm

90 mm

C

C

D

D

E

E Name :

BPS-A1-APS - Näherungsschalter / Montagebeispiel - Proximity Switches / Mounting Example

F

Datum

Name

Konstr.

05.2013

M. Nowak

Geprüft

05.2013

S. Przegendza

Massstab

Version

Übersicht / Overview

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Seite 4 / 5

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Zeichnungs Nr. : BPSA1APS.130611.AA01.2

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A

A

N

B

B

Montagehinweise / Minimalabstände Mounting instructions / minimum distances

C

D

90 mm

S

45 mm

N

30 mm

C

S D

D

D

E

E Name :

BPS-A1-APS - Näherungsschalter / Montagebeispiel - Proximity Switches / Mounting Example

F

Datum

Name

Konstr.

05.2013

M. Nowak

Geprüft

05.2013

S. Przegendza

Massstab

Version

Übersicht / Overview

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Seite 5 / 5

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Zeichnungs Nr. : BPSA1APS.130611.AA01.2

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A

A

BPB-A1-PS-Ni15(T)

B 40 mm

30 mm

C

36/5

D

B

Form / Design

Gewinderohr / Threaded barrel, M30 x 1.5

Abmessung / Dimensions

44 mm

Gehäuse Material / Housing material

Messing / Brass

Anzugsdrehmoment / Tightening torque

5 Nm

Anschlußart / Connection

Kabel / Cable

Anschlußleitung / Supply line

5,2mm, blau, 2 m / 5.2 mm, blue, 2 m

Leitungsquerschnitt / Cable cross section

2 x 0.5 mm

Schutzart / Protection class

IP67

Umgebungstemperatur / Ambient temperature Ni15

-25 ... + 70 °C

Umgebungstemperatur / Ambient temperature Ni15T

-40 ... + 70 °C

C

D

E

E Name :

BPS-A1-PS-Ni15(T) - Näherungsschalter / Proximity Switch

F

Datum

Name

Konstr.

05.2013

M. Nowak

Geprüft

05.2013

A. Herrmann

F

Genehm. Massstab

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Übersicht

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Zeichnungs Nr. : BPSA1PSNi15.130528.AA01.1

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A

A

mm

163 mm

417

mm

30 mm

498

163 mm

49 mm

B

60 mm

139 mm

429 mm

C

140 mm

B

C

114 mm

D

D

Gewindestange M10 x 400 mm threaded rod M10 x 400 mm

E

E Name :

243 mm

F

Rotary Encoder 1024 - CC-RE1024 Datum

Name

Konstr.

03.2015

M. Nowak

Geprüft

03.2015

A. Herrmann

F

Genehm. Massstab

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Version

Bemaßung

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Zeichnungs Nr.: CCRE1024.150311.AA02.4

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450 mm

A

A Ø10,5 mm

230 mm

300 mm

C

490 mm

B

450 mm

B

C

D

D

E

E Name :

Gehäuse: rostfreier Edelstahl IP66 / NEMA 4X

BPS - A2 - MxG - Gehäuse / Housing

Housing: stainless steel IP66 / Nema 4X

F

Datum

Name

Konstr.

04.2014

M. Nowak

Geprüft

04.2014

A. Herrmann

Massstab

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Seite 1 / 2

Genehm. Version

Bemaßung

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Zeichnungs Nr. : BPSA2MxG.140403.AA02.1

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654 mm 355 mm

A

A Ø12 mm 300 mm

B

450 mm

490 mm

B

C

C

D

D

450 mm

230 mm

E

E Name :

Gehäuse: rostfreier Edelstahl IP66 / NEMA 4X

BPS - A2 - MxG - Gehäuse / Housing - mit Sonnen- bzw Regendach / with sunroof resp. rain shelter

Housing: stainless steel IP66 / NEMA 4X

F

Datum

Name

Konstr.

04.2014

M. Nowak

Geprüft

04.2014

A. Herrmann

Massstab

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Seite 2 / 2

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Zeichnungs Nr. : BPSA2MxG.140403.AA02.1

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400 mm

A

A

300 mm

200 mm

B

400 mm

440 mm

B

C

C

D

D

E

E Name :

BPS-A2-S(1G) - Gehäuse - Housing

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Datum

Name

Konstr.

04.2014

M. Nowak

Geprüft

04.2014

S. Przegendza

F

Genehm. Massstab

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Übersicht

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Zeichnungs Nr. : BPSA2S1G.140404.AA02.1

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B

75,0 mm

B

120 mm

A

104 mm

A

C

C

104 mm 120 mm

D

D

E

E Name :

CC-CB1212 - Abzweigdose - Connection box Datum

F

Name

Konstr.

11.2014

M.Nowak

Geprüft

11.2014

A. Herrmann

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Genehm. Massstab

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Bemaßung

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Zeichnungs Nr.: CCCB1212.141124.AA02.1

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