manualEMC 1

MW95A Belt Weigher System
Setup Manual
MW95A_Setup_Manual_SV3.60a EMC INDUSTRIAL GROUP LTD

THIS MANUAL APPLIES TO
MW95 Weigh Belt P-Module
MT6x & MT8x Transmitters
MW99d4 Flowrate Indicator
Transmitter software version number 3.60 onwards

EMC INDUSTRIAL GROUP LTD
MW95A_Setup_Manual_SV3.60a Page 2 of 27

AVAILABLE DOCUMENTATION

COPYRI GHT 2006 by EMC I ndustrial Group Ltd
56 Tarndale Grove, Albany, North Shore, Auckland 0632
PO Box 101 444 North Shore, Auckland 0745, New Zealand
Telephone +64-9-415 5110, Facsimile +64-9-415 5115
E-mail sales@emc.co.nz Web www.emc.co.nz

As we are continuously improving our products, changes to this specification may occur without notice.
PRODUCT DESCRIPTION DOCUMENTATION
MW61 Weigher Systems Setup Manual
Setup Summary
Operator Manual
MW93 Weight Change Systems Setup Manual
Setup Summary
Operator Manual
MW95 Belt Weigher Systems Setup Manual
Setup Summary
Operator Manual
MW96 Weighfeeder Systems Setup Manual
Setup Summary
Operator Manual
EMC INDUSTRIAL GROUP LTD Contents
Contents

Contents....................................................3
Introduction..............................................4
Application............................................................................ 4
Features....................................................4
Basic .................................................................................... 4
Inputs................................................................................... 4
Internal Signals..................................................................... 4
Outputs ................................................................................ 4
Communications & Display..................................................... 5
ModWeigh Concepts .................................6
Connection Principles............................................................. 6
Setup Principles..................................................................... 6
Installation ...............................................9
MT6x Installation................................................................... 9
MT8x Installation................................................................. 10
MW95 Connection Diagram.................................................. 11
Setup Using MW99 Display.....................12
MW99 operating elements ................................................... 12
Displaying the Setup Menus................................................. 13
Selecting a Menu Item (using Quick Keys or ENTER) ............. 13
Description of Menus........................................................... 13
Adjusting a Setting (using the EDIT key and Passwords)........ 14
Adjusting a Design .............................................................. 15
Setup - Basic Settings.............................16
Engineering units ................................................................ 16
Measuring range ................................................................. 16
Display resolution................................................................ 16
Setup - I nputs.........................................17
Digital inputs....................................................................... 17
Tacho & Belt lengths ........................................................... 17
Loadcell input (platform weight)........................................... 18
Current/Voltage input.......................................................... 19
Setup - I nternal Signals..........................20
Weight ............................................................................... 20
Flowrate............................................................................. 20
Totaliser ............................................................................. 20
Limits/Batching................................................................... 21
Events................................................................................ 21
Control ............................................................................... 21
Setup Outputs......................................21
Analog Output 1 (flowrate) .................................................. 21
Analog Output 2 (platform weight) ....................................... 22
Digital outputs .................................................................... 22
Setup - Communications & Display.........23
Comms port 1 RS232........................................................ 23
Comms port 2 RS485........................................................ 23
Interface registers............................................................... 23
Printing & Design................................................................ 23
Display (MW99)................................................................... 25
Setup Information & Resets ................26
Transmitter Information....................................................... 26
P-Module Information.......................................................... 26
Reset settings..................................................................... 26
Reset designs...................................................................... 27

EMC INDUSTRIAL GROUP LTD Introduction

Introduction
Application

An EMC MW95 Belt Weigher System is used to measure the flowrate of material carried by a belt
conveyor.
It measures the belt loading and belt speed and calculates the material flowrate.

Features
Basic
Units & Resolution
The units for each variable type (weight etc.) can be selected from a list of metric and imperial units.
The resolution of each variable type can be adjusted, this alters the count by e.g 100kg displayed in
0.2kg increments.
OI ML Approvals
Mk3 only: The instrument has OI ML approvals (pending), for trade weighing applications.
Inputs
Direct & Dynamic Calibration
Dynamic calibration uses the loadcell capacity and loadcell sensitivity to calibrate the weight signal.
Dynamic calibration allows calibration of the weight while the belt is moving knowing the platform
weight (kg) or the belt loading (kg/m). This is useful when calibrating is done using chains.
Corner Adjustment
The excitation voltage can be adjusted on up to four loadcells, allowing differences in loadcell
sensitivities to be corrected.
Digital I nputs IN1..I N8
The digital inputs are programmable to a range of function including aquire zero, print etc.
Tacho Input
The tacho input is used to measure the belt speed and belt travel. Basic calibration is done using a
tacho constant setting.
The system can be used to calibrate the tacho by measuring the number of pulses as a known length
of belt passes a point. Other belt lengths can be measured in a similar manner.
Zeroing
The weight of the unloaded belt is averaged over one complete belt revolution and the resulting value
is stored as the dynamic zero.
The zeroing can be semi-automated by using an output signal to stop the material feed onto the belt,
waiting until the belt is empty, performing the zero averaging, restarting the feed and waiting until
material has reached the weigh point before returning to flow control.
Auto zeroing continuously monitors the platform weight. Any small drift in the weight measurement or
material build up on the weigh platform is automatically zeroed out. This ensures that with no product
on the belt, a zero flowrate is recorded.
Signal Filtering
Filtering for the weight and other signals can be adjusted to get the optimum compromise between
reduction of plant vibration and response speed.
Limits
The high and low limits have adjustable setpoints which may be programmed to operate on any
internal signal.
Batching
The system can be used to batch out a desired weight by stopping the conveyor when the weight has
passed the weigh platform. A pre-act weight can be adjusted to shut off the conveyor before the target
weight is reached allowing time for the conveyor to stop and allowing the correct batch weight to be
reached.
Event Collection
Process events are collected for operation with external equipment (PLCs etc.)
Internal Signals
Material Total
The processor incorporates a totaliser which totalises the weight of material through the system. The
totaliser can be reset to zero. A pulse output is available to operate external counters. A low flow
cutout ensures that low flows do not cause false counts. The total is retained after a power failure.
Outputs
Material Flowrate
An analog flowrate output signal is available for connection to other instruments.
Analog I / O Scaling
The analog output range can be adjusted over the full 0 to 20mA range. The output will drive to a
slight negative mA, allowing a live zero to be achieved when using a 0 to 20mA range. A voltage output
is easily produced by connecting a resistor to the output.
In addition the analog output signal is selectable to come from any internal signal in the instrument e.g
weight, flowrate etc.
EMC INDUSTRIAL GROUP LTD Features
Digital Outputs OUT1..OUT8
The digital outputs are programmable to operate from any internal signal. These signals include the
digital input states, status conditions (running, paused etc) and any fault conditions that are detected.
This makes it easy connect into other systems.
Communications
& Display
Comms
RS232 and RS485 ports are available. These are used to connect display to transmitter and also to
connect to other systems. The protocol is either ASCII output for example to drive a printer or Modbus
for interactive communications. Baud rates and node addresses are programmable.
Printouts & Designs
Printouts can be triggered by a key press or set up to occur at set times during the day or week. Data
may also be output continuously for data collection purposes. Data is output on the COM1 RS232 port.
The content of the printouts is fully programmable using Designs.
Designs are programs used to customise printouts, but can also be used to perform arithmetic
calculations. The Design language also contains conditional terms for more advanced programming.
Display Customisation
Locks may be set to prevent unauthorised use of the operator keys and restrict entry to the operator
menu. The keys are individually lockable and optionally a passcode can be used to allow authorised
operators to use the keys.
The operator MENU can be customised to make additional settings or signals available to the operator.
The contents of the main display can be set to suit any condition, from a comprehensive display
showing all operating parameters to a simple display showing the basic signals.

EMC INDUSTRIAL GROUP LTD ModWeigh Concepts

ModWeigh Concepts
Connection
Principles

Part of the flexibility in the ModWeigh architecture is in the way it can be connected up.
The following diagram shows the sorts of connections that can be made. With only one transmitter and
one display, the units are typically connected using COM2 (the RS485 port) of each instrument.

Figure 1 Connection Principles

Setup Principles
ModWeigh instruments must be calibrated for each specific application. The parameters stored are
collectively known as the Setup.
The transmitter and the display each have their own setup parameters. The transmitter setup contains
the setup for the system, the display contains setup related to the display.
The setup menus are reached by holding down (for about 3 seconds) either the MENU key or DISPLAY
key as shown in the following diagram.

Figure 2 Setup Menus
The setup is divided into sections as shown in the following diagram.

Figure 3 Setup Diagram
The exact number of inputs and outputs depends on which hardware platform is being used, the MT2x,
MT4x, MT6x or MT8x.
The Setup contains Settings and Designs which are described next.
Settings
Most of the setup for a system involves setting calibration constants which for example calibrate the
loadcell input, the 4-20mA outputs and the operation of relays etc. These settings are simple numeric
values.
Designs
Designs are used to store short programs which are used to construct text strings to output to the
printer, perform arithmetic calculations and other special control functions. Designs are a collection of
program segments which can call one another as subroutines. They have structured if/then/else
statements and program looping constructs.
A design is a sequence of numbers (bytes with values of 0 to 255).
Menus
All the setup parameters are contained within a menu structure which follows the setup sections.
Basic Settings
Inputs
Internal Signals
Outputs
Communications & Display
Information & Resets
Factory Settings
Basic Settings
The basic settings are settings which generally must be set first and often affect other settings through
the controller. They for example set the engineering units and measuring range for the application.
I nputs
The inputs are settings and calibration which effect the basic inputs signals. For example the loadcell
input, tacho input (where used) and digital inputs.
Internal Signals
This section contains the main calculations for the instrument. Most signals are here, for example the
weight, zero weight, total weight etc. Much of the instruments configuration is done in this section.
Outputs
The output are settings and calibration which effect the basic output signals. For example the 4-20mA
outputs and digital outputs. These change the calibration range and select the signal to appear on the
digital outputs.
Communications & Display
This section sets the baud rates etc for the communications ports. It sets the key locks for the MW99
Display. It also contains the Designs for the instrument.
I nformation & Resets
This section contains information about the transmitter, including its serial number, the product type etc.
There are also settings which allow all the settings & designs to be reset back to their default values.
Factory Settings
The factory settings are used to calibrate the basic instrument in the factory. These are password
protected and are not usually required once the instrument has left the factory.
EMC INDUSTRIAL GROUP LTD Installation

Installation
MT6x Installation
The transmitter has a field housing (model MT6F), is DIN-rail mounted (model MT6R) or has a field
housing and is DIN rail mounted (model MT6FR) as shown in the following diagram.

80mm
170mm
70mm
MWX4-01
58mm
DIN
RAIL
FIELD
MOUNT

1 P-Module with the correct product function.
2 COM 1 RJ -11 connector (RS 232 communications port).
3 COM2 termination ON/OFF switch. Turn on when device is at end of communications cable.
4 COM2 activity light. Flashes when data is transmitted.
5 Turn ON (up) only when using a NAMUR device at I N1. Connect from D3 (+) to F7 (-).
6 MO2 fitted, indicates whether the analog card option is fitted (power must be applied)
7 On when power is applied. Flashes if there is a fault. Flashing stops when fault is cleared.
8

COM RESET, hold down for more than 5 seconds to reset baud rates and Modbus addresses.
COM1 = 19200, COM2 = 115,200, address = 1
A Terminals A1 to A7 (CN1, power supply, COM2 and AO1).
B Terminals B1 to B7 CN2 terminals.
C Terminals C1 to C7 CN3 terminals.
D Terminals D1 to D6 CN4 terminals.
F Terminals F1 to F7 CN5 terminals.
H Terminals H1 to H6 CN6 terminals.

A B C D F
1
H
2 7 6 3 4 5 8
MT8x Installation
The transmitter has a field housing (model MT8F), is DIN-rail mounted (model MT8R) or has a field
housing and is DIN rail mounted (model MT8FR) as shown in the following diagram.

80mm
230mm 70mm
MWX5-01
58mm
FIELD
MOUNT
DIN
RAIL

1 P-Module with the correct product function.
2 COM2 termination ON/OFF switch. Turn on when device is at end of communications cable.
3 COM 1 RJ -11 connector (RS 232 communications port)
4 COM2 activity light. Flashes when data is transmitted.
5 On when power is applied. Flashes if there is a fault. Flashing stops when fault is cleared.
6 MO-2 fitted, indicates whether the analog card option is fitted (power must be applied)
7

COM RESET, hold down for more than 5 seconds to reset baud rates and Modbus addresses.
COM1 = 19200, COM2 = 115,200, address = 1
A Terminals A1 to A7 (CN1, power supply, COM2 and AO1).
B Terminals B1 to B7 CN2 terminals.
C Terminals C1 to C7 CN3 terminals.
D Terminals D1 to D6 CN4 terminals.
E Terminals E1 to E6 CN5 terminals.
F Terminals F1 to F7 CN6 terminals.
G Terminals H1 to H7 CN7 terminals.
H Terminals H1 to H6 CN8 terminals.

C D E
1
F G H
2
A B
7 6 5 3 4
MW95 Connection
Diagram

Keep all wiring separated from mains wiring
Use shielded cable where indicated
All 0V terminals internally connected

EMC INDUSTRIAL GROUP LTD Setup Using MW99 Display

Setup Using MW99 Display
MW99 operating
elements
1 UP key.
2 FUNCTION key.
3 EDIT key.
4 BACK key.
5 MENU key / DOWN key.
6 ENTER key.

MENU key
Press and hold this key for 5 seconds to view the setup menus.
ALPHANUMERIC keypad
When the MENU key has been pressed, the keys operate according to the blue legends above each
key eg. the START key becomes the 1 key. Some keys have an extra function depending on the
context eg. the ZERO key becomes the EDIT key when a menu setting is displayed. Once editing is
enabled, the key becomes the 0 key for changing the setting.
EDI T key
Use the EDIT key to enable editing of a setting. If a setting is locked, a password will be required
before editing is enabled.
UP and DOWN keys
Use these keys to move up and down a menu, or to increase or decrease a setting when editing is
enabled.
ENTER key
Use this key to move forwards through the menu, or to confirm a change to a setting
BACK key
Use this key to move backwards through the menu, or to cancel a change to a setting. Hold the key
to exit completely out of the menus and back to normal operation.

2 3 4 5 6
1
Displaying the
Setup Menus
Press and hold the MENU key until the unit beeps and displays the setup menus.

Selecting a Menu
Item (using Quick
Keys or ENTER)

To the left of each menu item is a single digit. This is the Quick Key number. Simply key in this
number to select the corresponding menu item. Items which have a + to the left will then display a
sub-menu in the same format. Continue pressing Quick Keys to navigate to the desired setting. Refer
to the Setup Summary for the sequence of Quick Keys to go directly to each setting.
Alternatively, repeatedly press the ENTER key to step through all the menus, sub-menus and settings
in turn.
You can use the UP and DOWN keys to highlight a menu or sub-menu item, then press the ENTER
key to continue from there. When viewing a setting, the UP and DOWN keys will move between all
the settings in that sub-menu.

1 Menu name.
2 Quick Key number. Press key with same number to directly enter the named menu.
3

Menu item descriptor.
Element Description
+ Selecting this menu item will open a sub-menu.
(blank) Selecting this menu item will display the corresponding setting, or will
return from a sub-menu

The action described will be implemented directly either if the ENTER
key is pressed when item is highlighted or when the items Quick Key is
pressed. (Quick Key number is the left most number shown in the item
line)
4 Name of menu item.

Description of
Menus

Quick setup
Quick setup menu contains the most important settings, and is a shortened version of the Main setup
menu. Use the Quick setup menu for initial setup of the transmitter. In many applications, no further
setup will be needed.
Main setup
Main setup menu contains all standard information and settings. Use this menu to view transmitter
information (eg serial number), and adapt the transmitter for the application (eg change the speed
demand output to 0 to 20mA)
Service
Service menu contains all standard settings as well as settings for advanced configuration and
diagnostics. Use this menu if there are special application requirements, or if special diagnostics are
required. This menu includes the Factory settings, for which certified equipment is required.
Altered settings
Altered settings menu lists all settings that are different from the default. Use this menu to fill in the
field settings on the Setup Summary
1
2 3 4
Adjusting a Setting
(using the EDIT key
and Passwords)
Press the EDIT key to allow changes to the selected setting.
If editing is locked, a password will be requested. For Quick setup and Main setup, the password is
111. For Service the password is 9713. For Altered settings there is no password as settings are
display only.
Use the keypad and/or UP and DOWN arrow keys to increase or decrease the displayed setting. Some
settings allow only one method, and some are display only.
Holding either key down will automatically continually increase or decrease the value.

1 Menu item.
2 Setting name.
3

Gives information about the settings and indicates active keys or the prefered method of making a
value change while editing.

Icon Description

The setting is locked. Password must be entered to edit.

The setting can only be viewed.

The setting has been changed from the default.

Press key for menu of special settings.

Press EDIT key to edit setting.

The setting is being edited.

Use numbered keys to change setting value.

Use UP & DOWN keys to scroll through selection list.

Use UP & DOWN keys to turn setting on or off.
4

Sequence of quick-keys used to reach this setting. Not editable. The left-most digit identifies the current
menu as follows: 1 for Quick setup, 2 for Main setup, 3 for Service, and 4 for Altered settings.
5 Hint line which reveals extra information about the setting.
6

Setting value. To change press EDIT key. If editing is locked, a password will be requested. Key in the
password and press the ENTER key. The setting will become highlighted by a black background. Key in
changes then press ENTER key. For Quick setup and Main setup, the password is 111. For Service the
password is 9713.
7 Engineering unit setting is displayed in.
8 Modbus address of this setting. Not editable.

1
5
3 2
7 8 4 6
Adjusting a Design

A design is a list of numbers representing ASCII characters and instructions codes. Each number is
edited separately, and is entered either as a number using the numeric keys, or as an ASCII
character using the letter keys much like a cell phone. There are three data entry modes, instruction,
lower case text and upper case text.

1 Menu item.
2 Setting name.
3

Gives information about the design and indicates active keys or the prefered method of
making a value change while editing.
Icon Description

The design is locked. Password must be entered to edit.

The design has been changed from the default.

Press key for menu of special functions.

Press EDIT key to edit design.

Use UP & DOWN keys to move the cursor back and forth through the
design.

The design is being edited.

Use UP & DOWN keys to adjust the code value and the BACK and ENTER
keys to move the cursor back and forth through the design.

Use numeric keys to enter instruction or ASCII codes (e.g. 65 =A).

Use letter keys to enter lower case text.

Use letter keys to enter upper case text.

Press this key to swap between numeric entry and text entry modes.

4

Sequence of quick-keys used to reach this design. Not editable. The left-most digit
identifies the current menu as follows: 1 for Quick setup, 2 for Man setup, 3 for Service,
and 4 for Altered settings.
5

Shows the design. ASCII characters are displayed normally, instruction codes are shown
displayed as a small icon as shown below. A cursor highlights the code currently
displayed.
Icon Description

A register instruction like RECALL or STORE.

A calculation instruction like VALUE, ADD, MUL etc.

A print instruction, like PRINT_VALUE, PRINT_UNITS etc.

A looping or control instruction like GOSUB, IF, LOOP etc

6

Code value of the item at the cursor position. It is either as ASCII code value or an
instruction code value.
7 Displays the ASCII character or instruction description for the code value displayed.
8 Modbus address of the design. Not editable.

5 6
3 2
7 8 4
1
EMC INDUSTRIAL GROUP LTD Setup - Basic Settings

Setup - Basic Settings

This is the setup in the Service menu (which includes all settings in the Quick and Main setup
menus).
Refer to the Setup Summary for the Quick Key, Default Setting, Setting Range, and Modbus Address
of these settings.
Engineering units
These settings affect the engineering units that will be used for many other settings. The
engineering units can be changed at any time. Note that you must enter settings in the same units
as set here eg 750 g calibration weights must be entered as 0.75 kg if the weight units are kg.
units metric/ imperial
Selects between metric units, imperial units or any if a mixture of metric and imperial units is
required.
weight units
These are the engineering units that will be used for all weight settings except the totaliser (eg kg).
belt speed units
These are the engineering units that will be used for all belt speed settings (eg m/min).
flowrate units
These are the engineering units that will be used for all flowrate settings (eg t/h).
totaliser units
These are the engineering units that will be used for the totaliser (eg t).
length units
These are the engineering units that will be used for all lengths (eg m).
Measuring range
These settings affect the way many other settings are stored and displayed. These other settings are
stored internally as a percentage of the relevant capacity. Once these capacities are set, the other
settings, eg the analog output, will automatically work. Note that, in particular, the weight capacity
must be set before any other weight settings are entered.
weight capacity
Set this to the maximum weight that will normally be displayed. The display will show over-range for
higher weights.
belt speed capacity
Set this to the maximum belt speed that will normally be displayed. The display will show over-range
for higher belt speeds.
flowrate capacity
Set this to the maximum flowrate that will normally be displayed. The display will show over-range
for higher flowrates.
Display resolution
weight divisions
The weight capacity is divided by the number of weight divisions to determine the resolution to
which weights will be displayed eg for a capacity of 100 kg and for 2000 divisions, weights will be
displayed to the nearest 0.05 kg, which is equivalent to 2 decimal places with a count-by of 5.
For most practical weighing systems, the total number of weight divisions will be within the range
500 to 3000 divisions.
belt speed divisions
The belt speed capacity is divided by the number of belt speed divisions to determine the
resolution to which belt speeds will be displayed eg for a capacity of 10 m/s and for 200 divisions,
belt speeds will be displayed to the nearest 0.05 m/s, which is equivalent to 2 decimal places with a
count-by of 5.
flowrate divisions
The flowrate capacity is divided by the number of flowrate divisions to determine the resolution to
which flowrates will be displayed eg for a capacity of 100 kg/h and for 2000 divisions, flowrates will
be displayed to the nearest 0.05 kg/h, which is equivalent to 2 decimal places with a count-by of 5.
Basic Settings

Inputs

Internal
Signals

Outputs
Communications
& Display
EMC INDUSTRIAL GROUP LTD Setup - Inputs
Digital inputs
The following settings select the function of the digital inputs. The hint line shows (off) when there is
no voltage present, and (on) when voltage is applied to the input.
The UP and DOWN keys can be used to select the function from the available list.
The list is shown in the Setup Summary manual in the I/O Function & Alarm Table.
I N1 function (& state)
Tacho & Belt
lengths
The tacho must be calibrated and some belt lengths must be known. The values for these can be
entered directly and/or measured using a running belt.
Direct belt calibration
With direct belt calibration, the tacho and belt length constants are entered directly. If no tacho is
used, the internal belt speed can be set as a constant.
tacho constant
This is the distance travelled by the belt for 1000 tacho pulses. Adjust for correct belt speed reading.
platform length
This is the platform length. It is the effective length over which material is weighed. For a single idler
weigh platform the platform length is half the distance between the two fixed idlers which are on
either side of the weigh idler. For a multi idler weigh platform the platform length is the distance
between the two outside weighing idlers plus half the sum of the distances from each outside weigh
idler to the first fixed idler either side of the weigh platform.
belt unload length
This is the length of belt that will pass before a zeroing is started, to ensure that the belt is clear of
all material. The Totaliser operates during this time.
belt calibration length
This is the belt length used for zeroing. During zeroing the weight is averaged while the belt runs for
this length. The averaged weight becomes the new zero. Set the belt length to the length of one belt
revolution. The Totaliser does not operate during this time.
internal belt speed
Set to 0 when using a tacho to measure the belt speed. If a tacho is not fitted, set the internal belt
speed to the measured fixed speed of the belt. If the speed of the belt is not fixed, then a tacho is
required.
Tacho cal at known speed
belt speed
Displays the belt speed.
The belt speed reading can be adjusted by entering the correct belt speed value. This alters the
tacho constant. This can only be done when a speed is being measured.
Measured belt calibration
The following settings allow the tacho constant and belt lengths to be measured by running the belt.
known belt length
This settings is the length of belt that will be measured to calculate the tacho constant using the
measure tacho constant setting below.
measure tacho constant
To use this setting, press EDIT to enable the measurement. The 1 key is then used to start and stop
the measurement of the tacho pulses as the belt travels. The belt can be marked with a known
length (which is entered as the known belt length above), and the measurement started and
stopped as the marks pass a fixed point. After the measurement is made, press ENTER to update the

Setup - Inputs

Basic Settings

Inputs

Internal
Signals

Outputs
Communications
& Display

tacho constant or press BACK to make no change.
measure unload length
measure calibration length
measure reload length
The above three settings can be used to measure the specified belt lengths after the tacho
calibration constant has been set. To use these settings, press EDIT to enable the measurement.
The 1 key is used to start and stop the measurement. After the measurement is made, press ENTER
to update the length setting or press BACK to make no change.
Loadcell input
(platform weight)
AI1 response time
The response time for the weight signal. A larger value will help reduce variations in the weight
reading caused by vibrations or movement on the weighing system.
Loadcell input / Calibration with weights
The basic procedure is to remove all weight from the weighing system and set the zero setting to 0.
Then a known weight is applied to the weighing system and the span setting adjusted to this weight.
AI 1 zero
Used to set the zero point. Remove all weight and then set the display to read 0 (This may require
pressing the EDIT key first, and entering the password). Press the ENTER key and wait while the
display shows Calibrating, please wait Once the display has returned to normal, press the ENTER
key twice to move to the span setting.
AI 1 span
Used to span the system. Apply calibration weights and then set the display to equal the calibration
weight value. (This may require pressing the EDI T key first, and entering the password). Press the
ENTER key and wait while the display shows Calibrating, please wait Once the display has
returned to normal, the transmitters loadcell input is calibrated.
Loadcell input / Direct loadcell calibration
It is possible to calibrate the loadcell input by using loadcell test sheets or specifications. This avoids
the need to load and unload test weights onto the weighing system. The accuracy of this method is
only as accurate as the loadcell data is. You must know (1) the total loadcell(s) capacity (2) the
loadcell(s) sensitivity. If the transmitter has already been calibrated using test weights, the actual
dead load and loadcell sensitivity are displayed. These settings should not then be adjusted.
loadcell capacity
Set to be equal to the total capacity of all the loadcells in the weighing system. If there are two 50
kg loadcells, this setting should be 100.
This setting can be adjusted even if the transmitter has been calibrated with test weights, and it will
not alter the calibration. If set correctly, the system sensitivity and deadload settings will then
show how the instrument has been calibrated.
system sensitivity
Shows the loadcell sensitivity (if the loadcell capacity has been set correctly first).
If calibrating without test weights, set this value to the loadcell sensitivity. If there is more than one
loadcell and if each loadcell has a slightly different sensitivity, use the average value. For example, if
there are two loadcells with sensitivities 2.003 and 2.007 mV/V, set the system sensitivity to 2.005
mV/V.
Deadload
Shows the approximate dead weight on the loadcell(s), provided the loadcell capacity has been set
correctly first.
If calibrating without test weights, then set this value to the weighing systems weight when there is
no material load.
Loadcell input / Dynamic loadcell calibration
Similar to Calibration with Weights, except that the belt is running and calibration is timed over one
belt length. This means that belt tension effects are taken into account during calibration, although
the setting of flowrate correction following a material test does this also.
dynamic zero
Used to set the zero point. Remove all weight, run the belt at normal speed and then set the display
to read 0 (This may require pressing the EDIT key first, and entering the password). Press the
ENTER key and wait while the display shows Calibrating, please wait Once the display has
returned to normal, press the ENTER key twice to move to the span setting.
dynamic span by weight
Used to span the system. Apply calibration weights, run the belt at normal speed and then set the
display to equal the calibration weight value. (This may require pressing the EDIT key first, and
entering the password). Press the ENTER key and wait while the display shows Calibrating, please
wait Once the display has returned to normal, the transmitters loadcell input is calibrated.
dynamic span by belt loading
Used to span the system. Apply a known loading to the belt (usually by chains of known weight per
length), run the belt at normal speed and then set the display to equal the loading. (This may
require pressing the EDIT key first, and entering the password). Press the ENTER key and wait while
the display shows Calibrating, please wait Once the display has returned to normal, the
transmitters loadcell input is calibrated.
Loadcell input / Loadcell signals
These settings are used for diagnostics and fault detection on the loadcell input.
AI 1 signal
Displays the loadcell signal in mV/V.
loadcell 4/ 6 wire connection
Displays whether the loadcell(s) are connected as 4-wire or 6-wire (automatically detected).
calibration sequence no.
This is a number which is altered each time the loadcell calibration is changed. This allows a check to
be made if a calibration has occurred since this value was last recorded.
Loadcell input / Excitation adjustment
These settings are used to adjust the excitation voltage for each of up to four loadcells. This can be
used to correct for sensitivity differences when using 2, 3 or 4 loadcells. A typical application is
corner adjustment of a platform scale. The loadcells must be connected so that the ve excitations
are connected to -EX1, -EX2, -EX3 and -EX4.
excitation 1
excitation 2
excitation 3
excitation 4
These four settings are set to 251 when not in use, and set the excitation voltages to their
maximum.
Corner adjustment procedure:
1. Set excitation 1 through to excitation 4 to the value 0.
2. Calibrate the scale (zero and span) with the test weights applied centrally.
3. Apply the test weight as close to loadcell1 as possible (the loadcell connected to EX1),
adjust the setting excitation 1 so that the weight reading corresponds to the test weight
value.
4. Repeat for each of the remaining loadcells.
Current/ Voltage
input
When the analog I/O option, MO1 or MO2 is fitted, a remote setpoint signal can be connected as
either a current (eg 4 to 20mA) or as a voltage (eg 0 to 10V). The transmitter auto-detects whether
the current or voltage input is active and uses the relevant calibration from the following settings.
AI 2 current low
This is the low point of the analog signal (when using the current input) within the range 0 to 20 mA
(typically set this variable to 4 mA).
AI 2 current high
This is the high point of the analog signal (when using the current input) within the range 0 to 20
mA (typically set this variable to 20 mA).
AI2 voltage low
This is the low point of the analog signal (when using the voltage input) within the range 0 to 10 V
(typically set this variable to 0 V).
AI2 voltage high
This is the high point of the analog signal (when using the voltage input) within the range 0 to 10 V
(typically set this variable to 10 V).
AI 2 signal type
This allows correct units and ranging to be applied to the AI2 signal. For example a setting of 1
converts the signal to a weight, a setting of 3 converts the signal to a flowrate.
AI 2 signal low
This is the signal that should correspond with the AI2 current low or AI2 voltage low point.
AI 2 signal high
This is the signal that should correspond with the AI2 current high or AI2 voltage high point.
AI 2 current/ voltage
Displays the remote analog signal as a current or voltage.
AI 2 signal
Displays the remote analog signal in engineering units.

EMC INDUSTRIAL GROUP LTD Setup - Internal Signals

Setup - Internal Signals

Weight
Weight / Basic weight
platform weight
Displays the platform weight.

belt loading
Displays the weight per unit length currently on the belt.
Weight / Weight zeroing
zero range
The maximum range as a percentage of the Weight Capacity over which a zero may be acquired.
This restricts the operation of both an operator initiated zero (pressing the ZERO key) or an
automatic zero when the zero tracking band is enabled.
zero tracking band
Zero tracking is disabled if set to 0.
When not set to zero, automatic zeroing is enabled. When enabled, the average weight is
continuously measured over the belt length setting. The last three of these are recorded and
compared to the zero tracking band. If all three are within the band, the zero is adjusted to the
second value. This process helps to ensure that a zero is not automatically taken with a starting or
finishing product tailing.
During normal operation, the status of zero tracking is displayed as a bar showing the belt revolution
and three dots. The dots indicate which of the three average weights are within the zero tracking
band.
un-zeroed weight
Display of un-zeroed weight (ie not affected by the zero).
zeroing progress
Displays the percentage progress through the zeroing cycle.
zero weight
Displays the amount of weight that has been zeroed out.
zero deviation
Displays the standard deviation of the zero measured during the last belt zeroing process. The
purpose is to give an indication of the quality of the belt. A large deviation indicates that there is a
large variation in the weight of the belt around its length.
Flowrate
flowrate correction
When first operated, up to 5 % error in the totalised weight is possible due to the loaded belt
passing over the weigh idlers. Zero the belt then reset the total weight. Pass a known weight of
material over the belt. Calculate the percentage error as follows;
% 100 1 [%]
=
weight true
weight totalised
error percentage
Take the current value of the flowrate correction setting and subtract the percentage error
determined above. The result is the new flowrate correction setting. For example if the error is 1.0
% and the correction factor is already 0.4 % then the new flowrate correction is (0.4-1.0) which is -
0.6 %. The measured flowrate will then appear to decrease by 1.0%.
flowrate
Displays the flowrate.
dynamic filter
Additional flowrate filtering. Only effects the displayed flowrate.
flowrate raw
The flowrate before the dynamic filter.
Totaliser
low flow cutout
Stops totalising if flowrate less than this value.
Basic Settings

Inputs

Internal
Signals

Outputs
Communications
& Display

EMC INDUSTRIAL GROUP LTD Setup Outputs
totaliser max. count rate
Set this to the maximum rate that the internal totaliser should be pulsed at.
OUT1 max. count rate
Set this to the maximum rate that the external totaliser should be pulsed at.
total weight
Displays the weight totaliser. The total is retained after a power failure.
running total
Displays a running weight total. This total is not reset by the RESET TOTAL operation.
totaliser digits
Sets the number of digits the totaliser counts to.
Limits/ Batching

Limits/ Batching / Limit setpoints
setpoint 1 high limit
Set the high limit here.
setpoint 2 low limit
Set the low limit here.
Limits/ Batching / Limit sources
setpoint 1 source
Set this to the modbus address of the transmitters signal that will be compared with Setpoint 1 eg
the weight.
setpoint 2 source
Set this to the modbus address of the transmitters signal that will be compared with Setpoint 2 eg
the weight.
Limits/ Batching / Batching
batch setpoint
Set the target batch weight here.
batch preact
Stop when the total weight is this amount before batch setpoint. Set the batch preact so that the
total weight just reaches the batch weight by the time the system has come to a complete stop.
Events
Various events can be triggered by the inputs (eg to capture the weight) or automatically when
certain situations are detected by the transmitter. Each event has an ID and produces a value.
event ID
ID of most recent event.
event value
Value of most recent event.
alarm list
Scroll through a list of all possible alarms.
delay time
A timer used by the designs.
Control
Control / Speed demand
speed demand
Displays the control signal for the flowrate control.

Setup Outputs
Analog Output 1
(flowrate)
These variables select which signal should appear on the analog output and how it is to be scaled.
The speed demand varies from 0 to 100 % where 0 % means belt stopped and 100 % means
maximum belt speed. This demand is converted to an analog signal for connection to the motor
speed controller. As an example, a speed demand ranging from 0 to 100 % is to be converted to an
analog signal ranging from 4 to 20 mA.
AO1 source
Set this to the address of the transmitters signal that will be output via AO1.
Basic Settings

Inputs

Internal
Signals

Outputs
Communications
& Display

EMC INDUSTRIAL GROUP LTD Setup Outputs
AO1 signal low
This is the low point of the signal to corresponding to the AO1 current low setting (typically set to
0).
AO1 signal high
This is the high point of the signal corresponding to the AO1 current high setting (typically set to
the capacity of the signal).
AO1 current low
This is the low point of the analog output signal within the range 0 to 20 mA (typically set to 4mA).
AO1 current high
This is the high point of the analog output signal within the range 0 to 20 mA (typically set to 20mA).
AO1 current
Displays AO1 current. This setting may be altered to temporarily manually set the output current.
This is useful to test the analog output. The output will return to normal after you exit from the
settings.
AO1 signal
Displays the signal currently being output. If this value is altered, the output is set to a value
corresponding to the signal. This is useful to test the analog output. The output will return to normal
after you exit from the settings.
Analog Output 2
(platform weight)
These variables select which signal should appear on the analog output and how it is to be scaled.
The flowrate is converted to an analog signal for connection to remote equipment. As an example, a
flowrate ranging from 0 to 100 t/h is to be converted to an analog signal ranging from 4 to 20 mA.
AO2 source
Set this to the address of the transmitters signal that will be output via AO2.
AO2 signal low
This is the low point of the signal corresponding to the AO2 signal low setting (typically set to 0).
AO2 signal high
This is the high point of the signal corresponding to the AO2 signal high setting (typically set to the
capacity of the signal).
AO2 current low
This is the low point of the analog output signal within the range 0 to 20 mA (typically set to 4mA).
AO2 current high
This is the high point of the analog output signal within the range 0 to 20 mA (typically set to 20mA).
AO2 current
Displays AO2 current. This setting may be altered to temporarily manually set the output current.
This is useful to test the analog output. The output will return to normal after you exit from the
settings.
AO2 signal
Displays the signal currently being output. If this value is altered, the output is set to a value
corresponding to the signal. This is useful to test the analog output. The output will return to normal
after you exit from the settings.
Digital outputs
The following settings select the function of the digital outputs. The hint line shows (off) when the
output is at 0V, and (on) when it is at +V1.
The UP and DOWN keys can be used to select the function from the available list.
The list is shown in the Setup Summary manual in the I/O Function & Alarm Table.
OUT1 function (& state)
EMC INDUSTRIAL GROUP LTD Setup - Communications & Display

Setup - Communications & Display

Comms port 1
RS232
COM1 baud rate
(8 data, no parity, 2 stop).
COM1 modbus address
modbus address.
COM1 handshake enable
When set to 1, hardware handshaking is enabled. Set to 0 to disable hardware handshaking.
COM1 Error count
Comms port 2
RS485
COM2 baud rate
(8 data, no parity, 2 stop).
COM2 modbus address
modbus address.
COM2 Error count
Interface registers
These registers are the recommended registers to use for extracting the basic signals from the
transmitter via Modbus. The advantage of using these registers is that multi-register Modbus
commands can be used to make the interface more efficient.
Registers1
platform weight
belt speed
speed demand
no function
total weight
flowrate
control1 & control2
control3 & status1
status2 & status3
I Ox & faults
Registers2
no function
no function
no function
no function
speedC
ratioC
setpointC
control2 & control3
control1C & control1G
no function
Printing & Design

print settings and designs
Used to start a print out of the settings or of the designs. Select the number of the print out
required.
number printout
1 print quick settings
2 print main settings
3 print service designs
4 print altered settings
5 print altered designs
Basic Settings

Inputs

Internal
Signals

Outputs
Communications
& Display

6 print all designs

Printing & Design / Print options
print continuous rate
Sets the rate at the which the print continuous design is run. Use the UP and DOWN keys to select
the rate.
disable designs
Disables all designs from running. This includes the system name design.
Printing & Design / Designs
print key design
This design is run when the PRINT KEY of the MW99 Display is pressed.
print total key design
This design is run when the PRINT TOTAL KEY of the MW99 Display is pressed.
print remote design
This design is run when a digital input with the function print, is activated.
print total remote design
This design is run when a digital input with the function print total, is activated.
times to print
This design sets the times of the day and week when the print at times design is run. This design
contains a list of times and optionally days of the week. Examples of how it may be set follows.
design print at times design runs
0:00 8:00 12:00 20:00 At midnight, 8am, midday and 8pm
9:00 15:00 M-F; 12:00 SA At 9am & 3pm Monday to Friday and 12pm Saturday
:30 At half past the hour, every hour
Time specifications are separated with a space or comma (,). A semicolon (;) is used to separate
time specifications. The days of the week are identified using the following letters M, TU, WE, TH, F,
SA, SU. Upper or lower case letters may be used.
print at times design
This design runs at the times specified by the times to print design.
print settings design
This is the design run when the print settings & designs is set.
print continuous design
This design runs when the print continuous rate is not set to off.
Printing & Design / Design subroutines
system name design
This design sets the transmitters name. This name is displayed by the MW99 Display to identify the
transmitter.
print key sub design
A subroutine used by the print key design.
print total key sub design
A subroutine used by the print total key design.
settings sub design
A subroutine used by the print settings design.
designs sub design
A subroutine used by the print settings design.
heading sub design
A subroutine used by the several designs to identify the transmitter on the printout.
information sub design
A subroutine used by several designs to print information about the system.
user 1 sub design
This design is not used by default, and is free for the user to use.
user 2 sub design
This design is not used by default, and is free for the user to use.
Printing & Design / Event Designs
capture weight design
This design is run when an input set to the capture weight function is activated.
event design
This design runs when any change is detected in the following registers. Control1, Control2,
Control3, Status1, Status2, Status3 or IOx. (see the I/O Function & Alarm Table in the Setup
Summary manual). This corresponds to the Input & Output Function 0 through 111. Exceptions to
this are changes on the pulse input and/or pulse output bits 0, 96 & 104 when they are used.
In the design, the IF_EVENT <condition> can be used to select an event to react to. The argument
<condition> refers to the input/output function 0 to 111.
temp 1
temp 2
These settings are temporary storage areas which can be accessed by the designs. These are not
retained when the power is removed from the controller.
perm 1
perm 2
These settings are permanent storage areas which can be accessed by the designs. These are
retained when the power is removed from the controller.
date
time
Displays the date and time as a number of the forms YYMMDD and HHMM.
Display (MW99)
Display (MW99) / keys 0 to 9 locks
These settings allow functions assigned to the number keys to be locked (ie password protected, or
locked out entirely).
setting lock function
0 Never locked
1 a pass code is required before the key may be used
2 the key is always locked and cannot be used
key 1 lock
key 2 lock
key 3 lock
key 4 lock
key 5 lock
key 6 lock
key 7 lock
key 8 lock
key 9 lock
key 0 lock
Display (MW99) / other key locks
These settings allow functions assigned to other keys to be locked (see above).
decimal point key lock
back key lock
display key lock
alarm key lock
Display (MW99) / menu item locks
These settings allow operator menu items to be locked (see above).
menu item 1 lock
menu item 2 lock
menu item 3 lock
menu item 4 lock
menu item 5 lock
menu item 6 lock
menu item 7 lock
menu item 8 lock
menu item 9 lock
Display (MW99) / Display customisation
identification line
Allows the top display line (identification line) to be turned off. This line shows the name of the
EMC INDUSTRIAL GROUP LTD Setup Information & Resets
transmitter currently in use, and optionally shows the time or current alarm number.
main line bar graph
Allows the main display bar graph to be turned off.
secondary line options
Controls the secondary line, below the main large display.
Add up the numbers in the following table to change the display as described.
Value Display Description
1 hide current setpoint
2 hide total/batch weight
4

hide material feed stopped icon
8

hide speed demand bar graph and icons
32 t/h hide setpoint (flowrate) units
64 t hide total/batch weight units
128 total weight include total name
256

include limit icons
1024 do not display secondary line
display select sourceA
display select sourceB
The above two settings allow up to two additional settings to be added to the items displayed in the
bottom line of the display. These items are selected during normal use with the DISPLAY key.
menu sourceA
menu sourceB
The above two settings allow up to two additional settings to be added to the operator menu. These
items will appear in the menu shown when the MENU key is pressed during normal operation.

Setup Information & Resets

Transmitter
Information
These settings can only be viewed, and show important features of the transmitter.
system name
Displays the name of the transmitter. It is also automatically displayed in the top line of any MW99
Display that has selected the transmitter. It is a combination of the built-in name and the COM2
modbus address eg Weighfeeder 1.
transmitter serial number
Displays the serial number of the transmitter
software version number
Displays the version number of the software currently installed in the transmitter.
CPU type
Displays the CPU type.
CPU circuit number
Displays the code number of the CPU card in the transmitter.
terminal circuit number
Displays the code number of the terminal card in the transmitter.
P-Module
Information
These settings can only be viewed, and show important features of the P-Module.
P-Module serial number
Displays the serial number of the P-Module.
Last version used
Displays the version number of the software currently installed in the transmitter.
Reset settings
reset loadcell calibration
Set to 1 to reset the loadcell calibration to the default.
Basic Settings

Inputs

Internal
Signals

Outputs
Communications
& Display
EMC INDUSTRIAL GROUP LTD Setup Information & Resets

reset comms settings
Set to 1 to reset the comms settings back top their defaults.
reset other settings
Set to 1 to reset all user settings to the defaults. A Quick or Main setup is required next. Does not
reset the loadcell calibration, comms settings or any of the designs.
Reset designs
reset all designs
Set to 1 to reset all the designs to the defaults. Does not reset any settings.

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MW95A Belt Weigher System

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