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
BPS-A2-MxG & BPS-A2-S 2

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

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, regula-
tions, provisions and standards.
The documentation has been carefully prepared. The products described are, however, un-
dergoing 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 re-
quired 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.

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.

General Notes
Fundamental safety measures
Before the control system is completely disconnected from the

Note 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!!
Before the opening of the control system housing and whenever the
control system is not being used for control purposes, for example
Warning 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.
• Do not open or disconnect or connect the power supply units

when they are energized!
Danger • 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, dam-

age 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.

General Notes
Duty of owner/operator to take care
The owner/operator must ensure that
• 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 rele-
vant 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 detec-
tion system is used, there are national regulations which the own-
National regulations de-
pending on the type of unit er/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
Warning
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
Measures in the event of a determined on the basis of the list in the section ‘Troubleshooting’
malfunction
what measures are to be taken.
Requirements for the operating personnel
Read the operating

Every user of the belt rip detection system must have read these
instructions operating instructions.
Every user must be acquainted with all of the functions of the control
Software knowledge
system and of the industrial PC which can be reached by him/her.

Accessories
Accessories
Structure
The belt rip detection system in combination with the Master Type
BPS-A2-MxG is designed for the monitoring of two danger points on
Use for the intended pur-
pose 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-A2-

MxG belt rip detection system can be optionally extended. In addi-
tion, it is possible to connect up to four transmitter/receiver pairs to
the BPS-A2-MxG direct. The distance between the transmit-
ter/receiver pairs must, however, not exceed a maximum distance of
250 meters.

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.

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 trouble-
shooting
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 keyboard-

display module via which the control system is operated.

Accessories
Further components included in the scope of supply of the belt rip

detection system type BPS-A2-MxG (see photos below) are 1x
Further accessories 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

Accessories
Receiver BPS-T/8
Receiver BPS-R/8
Connection box
CC-CB1212

Accessories
Mounting bracket
BPS-MBX
Proximity switch
Ni15 (Ni15T optional)
Rotary encoder
CC-RE1024 (optional)

Installation Instructions
Also read the Chapter General Notes.
Transport, warehousing and unpacking
Transporting
Despite the robust structure, the components installed in the com-

puter 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 approx-
imately 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 pur-
chase 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.

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 chap-
ter on Technical data).
For mounting the computer unit, four securing lugs with an oblong
Securing of the computer
unit hole bushing (see chapter Fitting dimensions) are available.
For mounting transmitter and receiver for mounting the Mounting

Securing of sensors brackets also supplied should be used in each case in order to per-
mit optimum mounting below the conveyor belt (see chapter Fitting
dimensions).
For the mounting of the proximity switches it is urgently recom-

Securing of
proximity switches
mended that the dimensions stipulated be adhered to in order to
permit optimum operation (see chapter Fitting dimensions). Like-
wise, the tapping box also supplied should be used for connecting
the proximity switches to the computer unit.
Note 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 com-
puter unit:
• Position the control system in such a way that reflections on the
display screen are largely avoided.
Warning
• With regard to the correct fitting height, take the position of the dis-
play 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.

Technical data BPS-A2-MxG

Dimensions [mm] 450 x 450 x 230
Dimensions [in] 17,72 x 17,72 x 9,06
Technical data Temperature range [°C] 0 - 40
BPS-A2-MxG
Temperature range [°F] 32 - 104
Protection class IP 66, NEMA 4X
Cable entries 13
Technical data 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
Technical data
BPS-A2-S
Temperature range [°F] 32 - 104
Protection class IP 66, NEMA 4X
Cable entries 9

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 construct-
ed 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.
Fuse terminal
Technical data
X20 (L1, N, GND)
Conductor cross-section [mm²] 0,2 - 6
Table of connecting Conductor cross-section [AWG] 24 - 10
terminals for voltage
supply Mains voltage [AC] 100 - 240 V
Mains voltage from [DC] 140 - 300 V
Frequency 50 / 60 Hz
The technical connected loads are limited to the connecting data of

the power supply units arranged downstream in the circuit.

Power supply unit, internal

Master 12 V / 24 V
Output data
Power supply unit 12 VDC
Table of connecting Output voltage [DC] 11.0 – 15.0 V
terminals for voltage supply
Output current up to 2.5 A
Output up to 30.0 W
Output data
Power supply unit 24 VDC
Table of connecting
Output voltage 22.0 – 28.8 V
terminals for voltage supply
Output current up to 1.3 A
Output up to 31.2 W

Transmitter/Receiver
For the connection of the transmitter and the receiver there is a

male-type connecting socket on the housing of the respective sen-
sor. 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 4-
core 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

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 BPS-
MBX Mounting brackets included in the scope of supply. Additional-
ly, 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 Polyester Polyester
Use for belt width [mm] ≥ 1000 ≥ 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 Stainless steel Stainless steel
Use for belt width [mm] < 1000 < 1000
Despite the robust type of construction, strong vibrations or mechan-

ical damage can damage the electrical components used inside the
sensor equipment.
In order to avoid damage, the firm fit of the sensors and the
Note
Mounting brackets should be checked at regular intervals.
Loose components can be damaged by contact with the con-
veyor belt.

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 con-
nected 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.
Plug Connection BPS-A2- BPS-A2- BPS-A2- BPS-A2-

8-pin box M1G M2G M3G M4G
BPS- CC- X40 X40 X40 X40

Terminal assignment
transmitter BPS-T… PLUG/8 CB1212
at master
1 1 1 8 15 22
3 2 2 9 16 23
4 3 3 10 17 24
Shield gre/yel gre/yel gre/yel gre/yel gre/yel
For mounting of the transmitter please see the enclosed drawings.
Plug 8-pin Connection box BPS-A2-S
Terminal assignment
transmitter BPS-T… BPS-PLUG/8 CC-CB1212 X40
at slave
1 1 1
3 2 2
4 3 3
Shield gre/yel gre/yel
For mounting of the transmitter please see the enclosed drawings.

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 contin-

uously 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 sensi-
tivity.
Adjusting screw of the

potentiometer
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 sen-
sor loop via the transmitter and the receiver being in place, the sen-
Adjustment of the sensitivity sitivity 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 oc-
curring, the adjusting screw must be turned back, as can be seen in
the picture, by about an additional 15° in an anti-clockwise direction.

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.
Plug Connection BPS-A2- BPS-A2- BPS-A2- BPS-A2-

8-pin box M1G M2G M3G M4G
BPS- CC- X40 X40 X40 X40

Terminal assignment of PLUG/8 CB1212
BPS-R… receiver 1 4 4 11 18 25
at master
2 5 5 12 19 26
3 6 6 13 20 27
4 7 7 14 21 28
Shield gre/yel gre/yel gre/yel gre/yel gre/yel
For the mounting of the receiver please see the enclosed drawings.
Plug 8-pin Connection box BPS-A2-S
Terminal assignment of
BPS-PLUG/8 CC-CB1212 X40
BPS-R… receiver
at slave 1 4 4
2 5 5
3 6 6
4 7 7
Shield gre/yel gre/yel
For the mounting of the receiver please see the enclosed drawings.
Frequency generators can have a negative influence on the receiv-

Warning er. Therefore care must be taken to ensure that the transmit-
ter/receiver pairs are installed at a distance apart of at least 10 - 15
meters.

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.
Phase PS PS2
1 Free Free
4-phase sequence
2 Covered Free
3 Covered Covered
4 Free Covered
The proximity switches have an approximately two meter-long con-

necting 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.
PS1 CC-CB1212 BPS-A2

Terminal assignment
of proximity switch PS 1 brown 1 X30.1
blue 2 X30.2
PS2 CC-CB1212 BPS-A2

Terminal assignment
of proximity switch PS 2
brown 3 X30.3
blue 4 X30.4
For the mounting of the proximity switches please see the enclosed
drawings.
Frequency generators can have a negative influence on the proximi-

Warning ty switches. Therefore care must be taken to ensure that the prox-
imity switches are installed at a distance of approximately 10 - 15
meters apart

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 introduc-
tion of the transmitter/receiver connection cables and for the intro-
duction 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] 0,2 – 2,5
Conductor cross-section [AWG] 25 – 13
Recommended cable specification shielded

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 posi-
tion 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 be-
tween 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 brack-
et 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 absorb-
er must be correctly installed as otherwise incorrect measurement
can occur and the entire unit will not work trouble-free.
Technical data Rotary encoder

Designation CC-RE1024
Type of connection 8-pin plug with 5 m connection cable
Connection cable 8 x 0,37 mm² shielded
Rotary encoder Dimensions total [mm] Approx.
CC-RE1024
Diameter wheel [mm] 160
Weight [kg] 8,5
Protection rate IP 67
‘up’ ‘down’

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 CC-
DEC1024 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 Terminal block
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

Connection of the encoder to the decoder can be seen from the fol-
lowing table.
Rotary encoder Decoder

CC-RE1024 CC-DEC1024
Signal Connection cable J

GND white 2.12
+5 VDC brown 2.11
Channel A (RS 422) green 2.7
Terminal assignment
of decoder inputs Channel –A (RS 422) yellow 2.10
Channel B (RS 422) grey 2.9
Channel –B (RS 422) pink 2.8
A (RS 485) blue 1.3
B (RS 485) red 1.4
Shield Shield
You can see the connection of the decoder to the belt rip detection
system from the following table.
Decoder BPS-A2
CC-DEC1024
Signal J X21 X30

GND 1.1 -
+12 VDC 1.2 +
Terminal assignment
of decoder outputs
Channel A (RS 422) 4.20 1
Channel –A (RS 422) 4.19 2
Channel B (RS 422) 4.22 3
Channel –B (RS 422) 4.21 4
A (RS 485) n.c.
B (RS 485) n.c.
Shield gre/yel

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 sub-D9 color

A 8 gn
B 3 rt

Connection of data communication via fiber optic

cable (optional)
For the remote maintenance of the BPS-A2-S1G unit via an option-

ally 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 ex-
tended 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 sys-
tem; 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
BPS-A1-IES BPS-A1-IES BPS-A1-IES

Technical data
M1xSC M2xSC 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
Technical data
Ethernet switches Transmission mode Multi-mode Multi-mode Single-mode
Power input [DC] 12 – 48 V 12 – 48 V 12 – 48 V
4x RJ45 4x RJ45 4x RJ45
Ethernet connectors
1x SC 2x SC 2x SC
Dimensions [mm] 37x140x95
Mounting DIN rail wall

Output contacts Relay terminals X12
The signal output for the selected operating mode, the tripping con-
tact, 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
Technical data
X12
Wire stripping length [mm] 6
Table of
relay terminals X12 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

BPS-A2-MxG terminals X12
Terminal Function
X12.1.11
Operation Mode: LIMITED Conveyor #1
X12.1.14
X12.2.11
Operation Mode: BYPASS Conveyor #1
X12.2.14
X12.5.11
Feeder Signal Message Conveyor #1
X12.5.14
X12.7.11
Outputs wiring
Belt Release Conveyor #1
X12.7.14
X12.9.11
OK Message Detection Pair #1
X12.9.14
X12.10.11
X12.10.14
X12.11.11
X12.11.14
X12.12.11
X12.12.14
BPS-A2-S terminals X12
Terminal Function
X12.1.11
Belt Release Conveyor #1
X12.1.14
X12.2.11
Outputs wiring X12.2.14
X12.5.11
Operation Mode: LIMITED Conveyor #1
X12.5.14
X12.7.11
Operation Mode: BYPASS Conveyor #1
X12.7.14

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.
X12.7 is to be used mandatorily as the tripping contact for

Note 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.

Operating Instructions
Operating Instructions BPS-A2-MxG
Switching-on and switching-off
The BPS-A2-MxG belt rip detection system does not have its own
Switching-on mains switch. For switching-on the unit or connection to the power
supply the control system is started up.
Running-down and When the control system is switched off or it is disconnected from its
switching-off own power supply the entire control system is also switched off.
Control software as is typically used on industrial PCs makes it pos-

sible for all users to assign different rights. A user who must not ter-
Warning minate the software is not allowed to switch off the industrial PC,
either, because, as a result of switching-off with the software run-
ning, 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 dam-
age will be caused as a result of switching-off with the software run-
ning.
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 start-
ed up.

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.

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 Pass: 98765

Login: User 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 indi-
cated below the T on the display screen. If the transmitter is not cor-
rectly 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 dis-
played.
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 correct-
ly connected, is defective or it is receiving direct from the transmitter,
a little red box is displayed permanently. In the event of a malfunc-
tion, 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.

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.

Inputs and outputs

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

1.1
1.2 NO Reset push button
Reset push button activation
1.3 NO (resistor 2,7kΩ)
1.4
Outputs A1-DFI
Address 1
1.5
1.6
1.7 NO/NC Belt run signal (1), Belt standstill (0)
Belt run message activation (resistor
1.8 NO 2,7kΩ) (optional)

Outputs - Module A1-DO Adr. 1
Address Function
1.1 Operating mode – Normal
1.2 Operating mode – Limited
Outputs A1-DO 1.3 Operating mode - Bypass
Address 1
1.4 Belt standstill (0), Belt running (1)
1.5
1.6
1.7 Belt Release Conveyor #1
1.8
Outputs - Module A1-DO Adr.: 2
Address Function
2.1 OK Message Detection pair #1
2.2
Outputs A1-DO 2.3 OK Message Detection pair #2
Address 2
2.4
2.6
2.8
Outputs - Module A1-DO Addr.: 3
Address Function
3.1
3.2
Outputs A1-DO
Address 3 3.3
3.4
3.5
3.6
3.7
3.8 Feeder Signal Conveyor #1

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 pre-
fixed 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 me-
chanical 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 iden-
tified 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 indicat-
ed.
2 Conveyor belt
If the unit is in a fault-free condition and the conveyor belt is in oper-
ation, 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.

3 Error and warning message

Error messages or warning messages are displayed on the main
display screen. If several faults or warnings are shown simultane-
ously, the messages are displayed in rotation in each case for sev-
eral 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 re-
lease 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.

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 de-
leted. 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.

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 administra-
tion, 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

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

Reset Button
Under the menu item RESET Button, the RESET function on the
main display screen of the RIP CONTROL V2 software can be ena-
RESET Button
bled 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 de-
clared as detection pair # 2 and hence the number of detection pairs
is set to 2.
Number of detection pairs

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 win-
dow. 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 dimen-
sion.
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 effi-
cient 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.

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 con-

sidered in particular and must, if necessary, be adjusted. If the dis-
tance between the sensor loop before the defective loop and the
distance behind the defective loop is larger than the maximum dis-
tance set to date, the parameter must be adjusted to the new condi-
tions.
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

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 nor-
mal cases this must be set to 0. If there is a wish to stop the con-
veyor belt at a certain sensor loop, if necessary, for example, to car-
ry 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.
Ensure that the parameter Stop at loop is set to 0 in order to

Note 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 ma-
terial 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.

Loops out of protection

Click the Loops out of protection button, on order to exclude defec-
tive sensor loops from protection. If a sensor loop has been dis-
played 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 re-
ports recorded.
Putting the loop back into protection

If a sensor loop has to be put back into protection, mark the appro-
priate 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.

COM-Port
Click the COM-Port button in order to adjust the interface for com-
munication 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 pa-
rameterization of the optionally connected detection pairs. The con-
figuration of the detection pairs is carried out in a similar way to the
detection pair # 1.
The numbering of detection pair is dependent upon the number

Note
of transmitter /receiver pairs connected to the master unit.
Also read the chapter on Parameter settings.

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 al-
teration 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 mes-
sage 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.

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

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 Instruc-
tions and provides information on the software version.
Close tab
Click the Close button in order to end the RIP CONTROL V2 soft-
ware 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.

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.
After successful administrator login all of the Windows rights

Note
are at your disposal. Incorrect handling can lead to permanent
system failure.
Click the button to log out again.

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

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.

Operating instructions BPS-A2-S
Switching on and switching off
The BPS-A2-S belt rip detection system has no mains switch of its
Switching on own. When the unit is switched on or when it is connected to the
power supply the control system is started up.
Switching off 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.

If the reference distance has not yet been recognized, up to then all
loops are identification marked with the abbreviation REF. If the ref-
erence 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 dis-
tances 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 puls-
es on a belt pulley. If the reference distance has not been detected,
the set value of the parameter maximum distance between two sen-
sor loops is indicated.
If the conveyor belt is moving in a forward direction, this value be-

comes 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 coun-
ter jumps over to the next real distance value and is counted down-
wards 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 quali-
ty 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.

The level of the analog value is not only determined by the

Note
quality of the sensor loop. Also the installation of the transmit-
ter / 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 Op-
eration 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.

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 dis-
played. 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

Parameter settings
Language settings
Language
The language selection is displayed in the first window of the pa-

rameter 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.

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.

Parameter settings

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 be-
fore 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.

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 (de-
pending 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 al-

ready described in the menu item Maximum gap between two loops.

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 al-

ready described in the menu item “Maximum gap between two
loops”.

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 re-

moval 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 pro-
vides information about the loop number currently indicated and the
total number of the unprotected loops.

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 win-
dows 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.

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 individ-
ual 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 se-
lected and confirmed by pressing the A key.

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 re-
quired. 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.
If the BPS-A2-S unit is connected to a computer system, the

Note
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.
In the event of malfunctions which can only be remedied with

Note the help of Coal Control Service, the software version must be
stated.

Parameter settings
Inputs and outputs

The information window of the inputs and outputs provides infor-
mation 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
Address Contact Function

1.1
1.2 NO Reset push button
Reset push button activation (resistor
Outputs A1-DFI
1.3 NO
2,7kΩ)
Address 1
1.4
1.5
1.6
1.7 NO/NC Belt run signal (1), Belt standstill (0)
Belt run message activation (resistor 2,7kΩ)
1.8 NO
(optional)
Outputs - Module A1-DO Adr. 1
Address Function
1.1 Belt Release Conveyor #1
1.3
Outputs A1-DO
Address 1 1.4
1.5
1.6
1.7 Operating mode – Limited
1.8 Operating mode - Bypass

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 con-
figure 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 Parameter
Maximum distance between two loops 9999
Minimum reference distance 1
Maximum reference distance 2
Table Parameters
for first putting Number of pulses / 100m run of belt Calculated value
into operation
Stop belt at loop number 0
Number of loops in belt 999
Warning message analog signal under 20
If several monitoring stations are connected, also click the button

No. of detection pairs > Parameter button(s) in order to set the pa-
rameters 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 warn-

ing 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.

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 evalua-
tion can take place.
After several rotations have been documented by the software you

can evaluate the sensor loop report as follows:

Number of loops
Reference distance
In the Distance column look for a unique distance between two sen-
sor 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 ob-
tained in which the reference distance can move.

Parameter settings
Important - no more distances between loops may be located in

Note 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.

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.

Parameter settings
Example of the selection of the parameters
Excerpt from a loop report
Parame-
Description Measured
ters
Max. distance between two loops 120 125
Minimum reference distance 25 22
Example table
Maximum reference distance 25 28
Number of loops 15 15

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 > Mas-
ter > 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 be-
tween 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 monitor-
ing 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

Parameter settings
Example of parameters
If the distance between loops 2 and 4 is now greater than the previ-
ously 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 puls-
es.
60 pulses + 65 pulses + 10 pulses (tolerance) = 135 pulses
Changing the maximum

distance between two loops

Parameter settings
Putting sensor loop back into protection
In order to put a sensor loop removed from protection back into pro-
tection, click Settings > Detection pair # x > Loops out of protection.
Select the loop which is to be put back into protection. Click the col-
umn with the loop number and delete the contents of the Loop num-
ber, 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

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.
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
Danger
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), mainte-

nance and/or cleaning work is to be carried out.
Maintenance
The industrial PC requires no maintenance.

Troubleshooting
Troubleshooting
Also read the chapter General Notes.
Stop the conveyor belt for maintenance work on the transmitters,

receivers and proximity switches! Work on these components may
Warning
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 sup-
ply
• 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

ply
• 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
Proximity switch Ni15

ply
• Loosen the M32 locknuts in opposite directions to each other
• Disconnect the connecting leads

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 ad-
dress is set as on the module previously removed.
Module A1-XXX

Troubleshooting
Remedying defects
Fault Cause Action
After switching-on
Black display screen Main switch of the panel PC Switch on panel PC

to 0 position
No voltage supply Check +24 V DC on X22 termi-

nals
Defective fuse Check fuse on the rear of the

panel PC, if necessary, replace
Check external voltage supply

85-264 V AC or 110-370 V DC
Check input fuses on X20 termi-

nals, if necessary, replace
RIP CONTROL V2 software RIP CONTROL V2 was re- Startup RIP CONTROL V2 man-
was not automatically started moved under Start → Pro- ually
after booting of the panel PC grams → Auto start Start → Programs → RIP CON-
TROL V2 l → RIP CONTROL V2
By holding down the left-hand

mouse button and pulling into the
folder Auto start automatic execu-
tion takes place after the boot
sequence
Notify Coal Control Service

Other causes

Troubleshooting
Remedying faults with messages displayed
Message Cause Action
Transmitter defec-
tive
(LED does not light No power supply Check correct and proper connection of
up) the eight-pin plug
Supply lead damaged Check supply lead and, if necessary, re-

pair it
Transmitter has been mechani- Check transmitter for mechanical damage

cally damaged If necessary, replace
Other causes Notify Coal Control Service
Also read the chapter Transmitter/Receiver.

Receiver defective
(LED does not light No power supply Check and correct faulty connection be-
up) tween the eight-pin connector to the con-
nection box and from connection box to
the unit

pair
Receiver has been mechanically Check receiver for mechanical damage

damaged and, if necessary, replace
(LED burns perma- Direct transmission between Reduce sensitivity or Increase the dis-
nently red) transmitter and receiver tance between transmitter and receiver
Also read the chapter Transmitter/Receiver.

Distance pulse Check pulse counting on module A1-BPS
fault or on the graphic display
(Pulses are dis- Distance between both proximity Check to ensure firm and correct fas-
played) switches pulse markers too big tening of the proximity switches
Check to ensure firm and correct fas-

tening of the pulse markers
Check the distance from the pulse mark-

ers and correct, if necessary

Troubleshooting
Distance pulse No power supply Check +12 V DC on X21 terminals

fault
(Pulses are not dis- Distance between both proximity Check pulse counting on module A1-BPS
played) switches and pulse markers is or on the graphic display
too big
tening of the proximity switches

tening of the pulse markers
Check distance from the pulse markers

and correct, if necessary

pair or replace proximity switches
Proximity switch has been me- Check proximity switches for mechanical
chanically damaged damage and replace, if necessary
Incorrect pulse counting Check to ensure firm and correct fas-

tening of the proximity switches
(Sensor loop is iden- Belt movement abnormal Check to ensure firm and correct fas-
tified too early) Loop is detected several times tening of the pulse markers
in rapid succession
Check distance from the pulse markers
and correct, if necessary
Also read the Chapter Proximity Switches.

Troubleshooting
Communication Incorrect or no display/CPU Select tab Settings → Detection Pair # X

failure interface has been selected → Com Port

pair
Incorrect Parameters/Settings Check parameters/settings

Invalid parameters
selected Select tab Settings → Detection Pair # X
→ Parameters

No. of loops incor- Too many or too few loops were Select tab Settings → No. of loops
rect set in the parameter Number of Change No. of Loops
loops(Quantity)

Loop Failure Belt RIP Check the Conveyor Belt Surface
Damaged Loop or Bad Quality Select tab Settings → Detection Pair # X

Signal → Loop out of Protection
Bus-Connection Wrong BPS-A1-Module Address Check the Module Address

Fault 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

Reference Distance The selected Ref. Distance is Check the actually report if the Ref. Dist.
Incorrect incorrect or not unique. Is a unique value.
Select tab Settings → Detection Pair # X
→ Parameters

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 ser-
vice:
• On-the-spot service
• Repair service
• Spare parts service
Phone: +49(0)2103/951-882
Fax: +49(0)2103/951-829
E-Mail: service@coal-control.de
State equipment
Should you require service, please state the equipment number of your belt
number 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: info@coal-control.de
Internet: http://www.coal-control.de

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

1 2 3 4 5 6 7 8
BPS-RX/7 BPS-RX/7
Empfänger Empfänger
Receiver Receiver
BPS-TX/7 Ni15(T) BPS-TX/7 Ni15(T)
A Sender Näherungschalter Sender Näherungschalter A
Transmitter Prox. switches Transmitter Prox. switches
*¹ *¹ *¹ *¹ *¹ *¹
BPS-A2-MxG BPS-A2-S(1G)
(Master) (Slave)
Spannungsversorgung Spannungsversorgung
B Power supply Power supply
B
AC100 - 240 V AC100 - 240 V
1 2 3 4 5 6 7 8 1 2 3 4
C C
Ausgänge zur PLC Ausgänge zur PLC
Output contacts to PLC Output contacts to PLC
(max. 250VAC/5A) (max. 250VAC/5A)
Die Kommunikation zwischen Master und Slave
X12 kann je nach Konfiguraton der Anlage in drei verschiedenen X12
2
1 Detection mode: LIMITED Varianten ausgeführt sein * 1 Belt Release Slave
2 Detection mode: BYPASS 2 Fault Slave
Depending on the Configuration the Master-Slave connection
3 Belt Release Master and Slave 2 3 Detection mode: LIMITED
is build in three different options *
4 Fault Master and Slave 4 Detection mode: BYPASS
5 Belt Release Master
6 Fault Master
D 7 Belt Release Slave D
8 Fault Slave
*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
Recommended cable type: HELUKABEL type F-CY-OZ 4x 0,75mm² shielded Name :
or comparable cable type with max. outside diameter ≤ 8 mm, max. cable length: 250 m BPS-A2-MxG / BPS-A2-S(1G)
Part no.: 13056
- Master - Slave
2
*
Option 1: Per Moxa-Konverter über RS485
Option 2: Per Ethernet über CAT5/6-Kabel oder LWL-Leitung Datum Name
Option 3: Per Profibus
Konstr. 05.05.2014 M. Nowak
Option 1: Via Moxa-Converter by use of RS485
Option 2: Via Ethernet by use of CAT5/6 Cable Geprüft 05.05.2014 A. Herrmann
Option 3: Via Profibus
F Genehm. Seite 1 / 12 F
Massstab Version Anschluss-
schema
F Zeichnungs Nr.: BPSA2MxGS.150612.AA04.F
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
Plant Control System

*2
zutreffend für / applicable for BPS-A2-M2G
OK Message Detection Pair #2 *2,3,4

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


*4
A A
Operation mode: LIMITED
Operation mode: BYPASS

*5
Feeder Signal Message
Belt Release Conveyor

zutreffend für / applicable for BPS-A2-M2G-RE
Warning Message *5
*5
BPS-A2-MxG Verbindung zwischen Panel-PC und Moxa via Ethernet: CAT5 oder CAT6 Kabel
Conection between Panel-PC and Moxa via Ethernet: CAT5 or CAT6 cable
11 14 11 14 11 14 11 14 11 14 11 14 11 14 11 14 11 14
13" Panel PC *6
über Twisted Par Leitung 2x2x0,75 mm² bis 2 km
B via Twisted Pair 2x2x0.75 mm² up to 2 km B
X12
K1 K2 K5 K7 K9 K10 K11 K12 K13
A1A2 A1A2 A1A2 A1A2 A1A2 A1A2 A1A2 A1A2 A1A2 C3 zur Slave-Einheit *6
C4 to Slave Unit
3 4 - X21
123456789
RS485 D+
RS485 D-
+24V
GND
Externer Reset-Schalter Moxa N-Port Panel-PC Moxa
External Reset push button 10/100/Ethernet *5 10/100/Ethernet
C1C2 12VDC
C *2,4 *3,4
C
RS485
2,7 K
2,7 K
2,7 K
2,7 K
2,7 K
+ X21 X21 + X21 +
RS485-B
RS485-A
X0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 X1.1 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 X2.2 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-CPU Module A1-DFI Module A1-DO Module A1-DO Module A1-DO
Address 1 Address 1 Address 1 Address 2 Address 3
D D
1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5
X0
+12V 1 1 1 1 1 1 1 1 1
1
GND 2 2 2 2 2 2 2 2 2
2
RESET 3 3 3 3 3 3 3 3 3
3
RS485-A 4 4 4 4 4 4 4 4 4
4
RS485-B 5 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 Name

Geprüft 05.05.2014 A. Herrmann
schema
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8

*2
zutreffend für / applicable for BPS-A2-M2G(-MV)

*3


*4
A A

*5

Warning Message *5
Belt Release
BPS-A2-MxG *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
11 14 11 14 11 14 11 14 11 14 11 14 11 14 11 14 11 14 via LWL-Leitung Single-Mode bis max 30 km
13" Panel PC
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
B
X12
K1 K2 K5 K7 K9 K10 K11 K12 K13 via fiber-optic cable Single-Mode up to 30 km
A1A2 A1A2 A1A2 A1A2 A1A2 A1A2 A1A2 A1A2 A1A2
3 4 - X21
RS485 D+
RS485 D-
+24V
GND
Externer Reset-Schalter
Panel-PC Verbindung zur Slave-Einheit *¹
External Reset push button Ethernet - Switch 10/100th/Ethernet Connection to Slave-Unit
C1C2 Ethernet Switch
C *2,4 *3,4
C
RS485
2,7 K
2,7 K
2,7 K
2,7 K
2,7 K
+ X21 X21 + X21 +
RS485-B
RS485-A
X0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 X1.1 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 X2.2 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-CPU Module A1-DFI Module A1-DO Module A1-DO Module A1-DO
Address 1 Address 1 Address 1 Address 2 Address 3
D D
1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5
X0
+12V 1 1 1 1 1 1 1 1 1
1
GND 2 2 2 2 2 2 2 2 2
2
RESET 3 3 3 3 3 3 3 3 3
3
RS485-A 4 4 4 4 4 4 4 4 4
4
RS485-B 5 5 5 5 5 5 5 5 5
5
E E
Name :
- Master <-> Slave Kommunikation per Ethernet-Kabel
- Master <-> Slave Communication via Ethernet-Cable
Datum Name

schema
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8

*2
zutreffend für / applicable for BPS-A2-M2G(-MV)

*3


*4
A A

*5

Warning Message *5
Belt Release
BPS-A2-MxG *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 11 14 11 14 11 14
13" Panel PC
B B
X12
K1 K2 K5 K7 K9 K10 K11 K12 K13
A1A2A1A2 A1A2 A1 A2 A1 A2 A1 A2 A1 A2 A1 A2 A1A2
3 4 - X21
RS485 D+
RS485 D-
+24V
GND
External Reset push button
C1C2
C *2,4 *3,4
C
RS485
B / rt
1
Profibus - RS485 CPU - RS485 Profibus - Slave *
A / gn
2,7 K
2,7 K
2,7 K
2,7 K
2,7 K
+ X21 X21 + X21 +
RS485-B
RS485-A
gn
ge
ge
gn
X0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 X1.1 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 X2.2 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 X3.1 1 2 3 4 5 6 7 8 9 3 8

sub-D9
Module A1-CPU Module A1-DFI Module A1-DO Module A1-DO Module A1-DO Module A1-PB
Address 1 Address 1 Address 1 Address 2 Address 3 Address 1
D D
1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5
X0
+12V 1 1 1 1 1 1 1 1 1 1 1
1
GND 2 2 2 2 2 2 2 2 2 2 2
2
RESET 3 3 3 3 3 3 3 3 3 3 3
3
RS485-A 4 4 4 4 4 4 4 4 4 4 4
4
RS485-B 5 5 5 5 5 5 5 5 5 5 5
5
E E
Name :
- Master <-> Slave Kommunikation per Profibus
- Master <-> Slave Communication via Profibus
Datum Name

schema
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
OK Message Conv. #1 Detection Pair #1
OK Message Conv. #2 Detection Pair #1

Operation mode: LIMITED Conveyor #1
Operation mode: LIMITED Conveyor #2

Operation mode: BYPASS Conveyor #1
Operation mode: BYPASS Conveyor #2

A A
Warning Message
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 11 14 11 14 11 14
13" Panel PC
B B
X12
K1 K2 K3 K4 K5 K6 K9 K10 K13
A1A2A1 A2 A1 A2 A1 A2A1A2 A1 A2 A1 A2 A1 A2 A1A2
3 4 - X21
RS485 D+
RS485 D-
+24V
GND
External Reset push button
C1C2
C *2,4 *3,4
C
RS485
1
Profibus - RS485 CPU - RS485 Profibus - Slave *
2,7 K
2,7 K
2,7 K
2,7 K
2,7 K
+ X21 X21 + X21 +
RS485-B
RS485-A
X0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 X1.1 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 X2.2 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 X3.1 1 2 3 4 5 6 7 8 9
Module A1-CPU Module A1-DFI Module A1-DO Module A1-DO Module A1-DO Module A1-PB
Address 1 Address 1 Address 1 Address 2 Address 3 Address 1
D D
1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5
X0
+12V 1 1 1 1 1 1 1 1 1 1 1
1
GND 2 2 2 2 2 2 2 2 2 2 2
2
RESET 3 3 3 3 3 3 3 3 3 3 3
3
RS485-A 4 4 4 4 4 4 4 4 4 4 4
4
RS485-B 5 5 5 5 5 5 5 5 5 5 5
5
E E
Name :
BPS-A2-MxG-MV
Datum Name

schema
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
Näherungsschalter
Proximity switch
Schurre Schurre Laufrichtung / Running direction Schurre Schurre
Ni15(T)
Chute Chute Chute Chute
+ 2
-
Sender Empfänger Sender Empfänger Sender Empfänger Sender Empfänger
Transmitter Transmitter Receiver Transmitter Transmitter
A +
-
1 BPS-T(X)/8
1 3 4
Receiver
BPS-R(X)/8
1 2 3 4
BPS-T(X)/8
1 3 4
BPS-R(X)/8
1 2 3 4
BPS-T(X)/8
1 3 4
Receiver
BPS-R(X)/8
1 2 3 4
BPS-T(X)/8
1 3 4
Receiver
BPS-R(X)/8
1 2 3 4
A
bn = braun / brown
bn
br
bl
bl
bl = blau / blue
Spannungsversorgung
1 2 3 4 1 2 3 4 5 6 7 1 2 3 4 5 6 7 1 2 3 4 5 6 7 1 2 3 4 5 6 7
Power supply
CC-CB1212 CC-CB1212 CC-CB1212 CC-CB1212 CC-CB1212 AC 85 - 264 V
DC 110 - 370 V
1 2 3 4 1 2 3 4 5 6 7 1 2 3 4 5 6 7 1 2 3 4 5 6 7 1 2 3 4 5 6 7 50 - 60 Hz
B B
BPS-A2-MxG X30 1 2 3 4 1 2 3 4 5 6 7 X40 8 9 10 11 12 13 14 X40 15 16 17 18 19 20 21 X40 22 23 24 25 26 27 28 X40 X20 AC

(L)
AC
(N) GND
C B1
2A/250V C
Netzteil Netzteil
Power supply Power supply
PBA30F-12 PBA30F-24
12V/2,5A 24V/1,3A
AC AC AC AC
X21.1 + - FG (L) (N) X22.1 + - FG (L) (N)
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 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
Analog
Digital
+12V
Analog
Digital
+12V
Analog
Digital
+12V
Analog
Digital
+12V
IN
GND
IN
GND
GND
Digital
+12V
GND
IN
GND
IN
GND
GND
Digital
+12V
GND
IN
GND
IN
GND
GND
Digital
+12V
GND
IN
GND
IN
GND
GND
Digital
+12V
GND
Module A1-BPS Module A1-BPS Module A1-BPS Module A1-BPS AC
(L)
AC
(N) X20 AC
(L)
AC
(N) X20 X20
Address 1 Address 2 Address 3 Address 4
M1G M2G M3G M4G

D D
1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 X21 + - X22 + -
1 1 C1C2
2 2
3 3
4 4
5 5
E E
Name :
Datum Name

schema
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
Näherungsschalter Näherungsschalter
Proximity switch Proximity switch
Ni15(T) Schurre Laufrichtung / Running direction Ni15(T) Schurre Laufrichtung / Running direction
Chute Chute
+ 2 + 2
- -
Sender Empfänger Sender Empfänger
A +
-
1 Transmitter
BPS-T(X)/8
1 3 4
Receiver
BPS-R(X)/8
1 2 3 4
+
-
1 Transmitter
BPS-T(X)/8
1 3 4
Receiver
BPS-R(X)/8
1 2 3 4
A
bn = braun / brown
bn
bn
br
br
bl
bl
bl
bl
bl = blau / blue
Spannungsversorgung
1 2 3 4 1 2 3 4 5 6 7 1 2 3 4 1 2 3 4 5 6 7
Power supply
Abzweigdose CC-CB1212 Abzweigdose CC-CB1212 AC 85 - 264 V
Connection Box CC-CB1212 Connection Box CC-CB1212
DC 110 - 370 V
1 2 3 4 1 2 3 4 5 6 7 1 2 3 4 1 2 3 4 5 6 7 50 - 60 Hz
B B
BPS-A2-MxG-MV X30 1 2 3 4 1 2 3 4 5 6 7 X40 X30 5 6 7 8 8 9 10 11 12 13 14 X40 X20 AC

(L)
AC
(N) GND
C B1
2A/250V C
Netzteil Netzteil
Power supply Power supply
PBA30F-12 PBA30F-24
12V/2,5A 24V/1,3A
AC AC AC AC
X21.1 + - FG (L) (N) X22.1 + - FG (L) (N)
X8.1 1 2 5 6 3 4 7 16 14 13 12 10 11 9 8 15 X8.2 1 2 5 6 3 4 7 16 14 13 12 10 11 9 8 15
Analog
Digital
+12V
IN
GND
IN
GND
GND
Digital
+12V
GND
Analog
Digital
+12V
IN
GND
IN
GND
GND
Digital
+12V
GND
Module A1-BPS Module A1-BPS AC
(L)
AC
(N) X20 AC
(L)
AC
(N) X20 X20
Address 1 Address 2
M1G M2G
D D
1 2 3 4 5 1 2 3 4 5 X21 + - X22 + -
1 1 C1C2
2 2
3 3
4 4
5 5
E E
Name :
BPS-A2-MxG-MV
Datum Name

schema
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
BPS-A2-MxG
BPS-A2-S(1G)
B B
C C
D X20 L1 N GND D
L
Spannungsversorgung
Power supply N
E AC 100 - 240 V
E
Name :
GND BPS-A2-MxG / BPS-A2-S(1G)
- Sender / Empfänger
- Transmitter / Receiver
Datum Name

schema
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A BPS-A2-MxG A
BPS-A2-S(1G)
B B
Anschlußleitung
C Connection line
C
Ni15(T) X30 1 2 3 4 GND
br = braun / brown
bl = blau / blue
1
*
Näherungsschalter #1 Abschirmung / shielding
Proximity switch #1 br 2
Ni15(T)
D bl 3 D
Näherungsschalter #2
Ni15(T)
bl
Connection box
CC-CB1212
E * E
Empfohlenes Kabel: HELUKABEL Typ F-CY-OZ 4x0,75 mm² geschirmt Name :
max. Aussendurchmesser 8 mm, max Kabellänge 250 m - Näherungsschalter / Proximity Switch
Art.Nr.: 13056 - Sender & Empfänger / Transmitter & Receiver
Datum 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 Konstr. 05.05.2014 M. Nowak
Part no.: 13056
schema
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A BPS-A2-MxG A
B B
Anschlußleitung
C Connection line
C
Ni15(T) X30 5 6 7 8 GND
br = braun / brown
bl = blau / blue
1
*
Näherungsschalter #1 Abschirmung / shielding
Ni15(T)
D bl 3 D
Näherungsschalter #2
Ni15(T)
bl
Connection box
CC-CB1212
E * E
Empfohlenes Kabel: HELUKABEL Typ F-CY-OZ 4x0,75 mm² geschirmt Name :
BPS-A2-MxG-MV
BPS-A2-MxG Band 2 / 2nd Belt
/ BPS-A2-S(1G)
max. Aussendurchmesser 8 mm, max Kabellänge 250 m - Näherungsschalter / Proximity Switch
Art.Nr.: 13056 - Sender & Empfänger / Transmitter & Receiver
Datum Name
or comparable cable type with max. outside diameter ≤ 8 mm, max. cable length: 250 m Konstr. 05.05.2014 M. Nowak
Part no.: 13056
schema
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
BPS-A2-M1G(-MV)
BPS-A2-S(1G)
B B
X40 1 2 3 GND X40 4 5 6 7 GND

C C
Schirm / Shielding
*
D Empfohlenes Kabel: HELUKABEL Typ F-CY-OZ 4x0,75 mm² geschirmt D
1 2 3 4 5 6 7 Art.Nr.: 13056

CC-CB1212 or comparable cable type with max. outside diameter ≤ 8 mm, max. cable length: 250 m
Part no.: 13056
1 2 3 4 5 6 7
E E
Name :
1 3 4 1 2 3 4 BPS-A2-MxG
1 / BPS-A2-S(1G)
- Sender & Empfänger / Transmitter & Receiver
Datum Name
Sender #1 Empfänger #1 Konstr. 05.05.2014 M. Nowak

Transmitter #1 Receiver #1 Geprüft 05.05.2014 A. Herrmann
F BPS-T(X)/8 BPS-R(X)/8 F
Genehm. Seite 11 / 12
schema
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
BPS-A2-MxG(-MV)
A A
B B
X40 1 2 3 GND X40 4 5 6 7 GND X40 8 9 10 GND X40 11 12 13 14 GND X40 15 16 17 GND X40 18 19 20 21 GND X40 22 23 24 GND X40 25 26 27 28 GND
*1 Abschirmung *1 *1 Abschirmung *1 *1 Abschirmung *1 *1 Abschirmung *1

Shielding Shielding Shielding Shielding
C C
1 2 3 4 5 7 8 1 2 3 4 5 7 8 1 2 3 4 5 7 8 1 2 3 4 5 7 8
Connection Box CC-CB1212 Connection Box CC-CB1212 Connection Box CC-CB1212 Connection Box CC-CB1212
1 2 3 4 5 7 8 1 2 3 4 5 7 8 1 2 3 4 5 7 8 1 2 3 4 5 7 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
Sender #1 Empfänger #1 Sender #2 Empfänger #2 Sender #3 Empfänger #3 Sender #4 Empfänger #4

D Transmitter #1 Receiver #1 Transmitter #2 Receiver #2 Transmitter #3 Receiver #3 Transmitter #4 Receiver #4 D
BPS-T(X)/8 BPS-R(X)/8 BPS-T(X)/8 BPS-R(X)/8 BPS-T(X)/8 BPS-R(X)/8 BPS-T(X)/8 BPS-R(X)/8
*2 *3 *4
*1
Empfohlenes Kabel: HELUKABEL Typ F-CY-OZ 4x0,75 mm² geschirmt
E Art.Nr.: 13056
E
Name :
- Sender & Empfänger / Transmitter & Receiver
or comparable cable type with max. outside diameter ≤ 8 mm, max. cable length: 250 m
Part no.: 13056
Datum Name
*2 Bestandteil von / part of M2G, M1G-MV, M3G, M4G
*3 Bestandteil von / part of M3G, M4G Konstr. 05.05.2014 M. Nowak
*4 Bestandteil von / part of M4G Geprüft 05.05.2014 A. Herrmann
schema
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
Näherungsschalter
Proximity switch
Ni15, Ni15T Schurre
Plant Control System Laufrichtung
Chute Running direction
+
- 2
Sender Empfänger
+ Transmitter Receiver
- 1
Detection mode: LIMITED
Detection mode: BYPASS

BPS-T(X)/8 BPS-R(X)/8
A bn = braun / brown
1 3 4 1 2 3 4 A
br
br
bl = blau / blue
bl
bl
1 2 3 4 5 6 7
OK Message
Belt Release
CC-CB1212
1 2 3 4 1 2 3 4 5 6 7
CC-CB1212
INP
INP
INP
INP
INP
INP
INP
INP
1 2 3 4
BPS-A2-S(1G)
11 14 11 14 11 14 11 14
B B
BPS-A1-S-LCD X12
K1 K2 K3 K4
4x20 digits Display
A1 A2 A1 A2 A1 A2 A1 A2
1 2 3 4
External Reset push button - X21 X30 1 2 3 4 1 2 3 4 5 6 7 X40
C C
Moxa Aktivierung Reset-Funktion X21
2,7 K
2,7 K
*1
C3 C4 Reset activation
+
X 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 X1.1 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 X 8 . 1 1 2 5 6 3 4 7 16 14 13 12 10 11 9 8 15
Analog
Digital
+12V
IN
GND
IN
GND
GND
Digital
+12V
GND
Module A1-CPU Module A1-DFI Module A1-DO Module A1-BPS
Address 1 Address 1 Address 1 Address 1
D D
1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5
X0
+12V 1 1 1 1 1 1 1
1
GND 2 2 2 2 2 2 2
2
RESET 3 3 3 3 3 3 3
3
RS485-A 4 4 4 4 4 4 4
4
RS485-B 5 5 5 5 5 5 5
5
E E
Name :
1
BPS-A2-S(1G)
*
Der Moxa-Konverter befindet sich je nach Master-Slave Entfernung in der Master-
oder 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 Datum Name
Konstr. 04.2014 M. Nowak

Geprüft 04.2014 S. Przegendza
Massstab Version Block-
-schaltbild
1 Zeichnungs Nr. : BPSA2S1G.140901.AA07.2
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
Spannungsversorgung
Power supply
AC 100 - 240 V
50 - 60 Hz
B B
BPS-A2-S(1G)
GND
AC AC
X20 (L) (N)
B1
2A/250V
1 Moxa N-Port
10/100/Ethernet
RS232/422/485
Spannungsversorgung 2
Power supply C3 3
Port1
C4 4
PBA30F-12 5 Master Panel PC
12V/2,5A 6
7
8
C X21.1 + - FG
AC AC
(L) (N) 9 C
1 2
AC AC
(L) (N) X20 X20
X21 + -
D Verbindung zwischen BPS-A2-MxG und BPS-A2-S (max. 100 m) per CAT5 oder CAT6 Kabel D
Bei größeren Distanzen entfällt der Moxa-Konverter in der Slave-Einheit
1 1 1
2 2 2
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
3 3
4 4
5 5
E E
Name :
BPS-A2-S(1G)
Datum Name

Massstab Version Block-
-schaltbild
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A 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
Datum Name
Konstr. 05.2013 M.Nowak

Massstab Version Bemaßung
A Zeichnungs Nr.: BPSATR.140710.AA02.5

1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A 50 - 120 mm A
~ 300 mm
~ 250 mm
B B
~ 250 mm
C C
D D
min. 300 mm
E E
Name :
BPS-ATR
Datum Name


1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
~ 300 mm
B 50 - 120 mm B
C C
D D
E E
Name :
BPS-ATR
Datum Name


1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B B
C C
Sender / Empfänger
D Transmitter / Receiver D
E E
Name :
BPS-ATR
Datum Name


1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
120 mm
120 mm
B 80 mm B
ca 180° einstellbar
adjustable approx. 180 °
350 mm
C C
einstellbar 360°
300 mm adjustable 360 °
D D
E E
Name :
BPS-ATR
Datum Name


1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
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
42 mm - Transmitter / Receiver
Datum Name


1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A 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. Datum Name

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 Geprüft 05.2013 S. Przegendza
Massstab Version Übersicht /
Overview
A Zeichnungs Nr. : BPSA1APS.130611.AA01.2
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A Das Bedecken der Näherungsschalter hat in den dargestellten 4 Phasen zu erfolgen. A

(Seitenansichten der Sensoren)
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 D
die Puls-Marken, direkt auf der Rolle montiert werden. Siehe Zeichnung.
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
Datum Name

Overview
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A Vorgaben:
A
- 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
B Näherungsschaltern angebracht sein.
B
- Die Länge der Pulsmarken muss 150 mm betragen und gewährleisten, dass beide Näherungsschalter gleichzeitig ab-
gedeckt werden.
- Die Positionierung und die Anzahl der Puls-Marken sollte 1m Pulsabstand entsprechen.
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
C - Important: The attached distance pulse marks need to be mounted in the same angle to each other; C
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.
D 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
E 1,57 m / 1 m = 1,57 enspricht 2 Puls-Marken E
Name :
Rollendurchmesser 1,2 m
1,2 m * 3,14 = 3,768 m entspricht der Bandlänge pro Rollenumumdrehung
BPS-A1-APS
3,768 m / 1m = 3,768 entspricht 4 Puls-Marken - Näherungsschalter / Montagebeispiel
Worked sample for quantity of the distance pulse marks:
Datum Name
diameter of the drum 0.5 m
0.5 m * 3.14 = 1.57 m corresponds to the belt length per revolution Konstr. 05.2013 M. Nowak
1.57 m / 1 m = 1.57 corresponds to 2 distance pulse marks
F diameter of the drum 1.2 m
1.2 m * 3.14 = 3.768 m corresponds to the belt length per revolution Genehm. Seite 3 / 5 F
3.768 m / 1 m = 3.768 corresponds to 4 distance pulse marks
Overview
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
Seitenansicht / Side view Vorderansicht / Frontal view
< 10 mm 60 mm
B B
90 mm 150 mm
C C
D D
E E
Name :
BPS-A1-APS
Datum Name

Overview
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B N B
Montagehinweise / Minimalabstände
Mounting instructions / minimum distances
D 90 mm
C C
S 45 mm
N 30 mm
D D
D
E E
Name :
BPS-A1-APS
Datum Name

Overview
1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
B BPB-A1-PS-Ni15(T) B
30 mm 40 mm
Form / Design Gewinderohr / Threaded barrel, M30 x 1.5
Abmessung / Dimensions 44 mm
Gehäuse Material / Housing material Messing / Brass
C Anzugsdrehmoment / Tightening torque 5 Nm C

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
36/5 Schutzart / Protection class IP67

D D
Umgebungstemperatur / Ambient temperature Ni15 -25 ... + 70 °C
Umgebungstemperatur / Ambient temperature Ni15T -40 ... + 70 °C
E E
Name :
BPS-A1-PS-Ni15(T)
- Näherungsschalter / Proximity Switch
Datum Name

Geprüft 05.2013 A. Herrmann
F Genehm. F
Massstab Version Übersicht
A Zeichnungs Nr. : BPSA1PSNi15.130528.AA01.1

1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
498
mm
417
163 mm
mm
30 mm
163 mm
B B
49 mm
139 mm
60 mm
C 140 mm C
429 mm
114 mm
D D
Gewindestange M10 x 400 mm

threaded rod M10 x 400 mm
E E
Name :
Rotary Encoder 1024
- CC-RE1024
243 mm
Datum Name

F Genehm. F
1:5 4 Zeichnungs Nr.: CCRE1024.150311.AA02.4

1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
450 mm
A A
Ø10,5 mm 230 mm
300 mm
B B
450 mm
490 mm
C C
D D
E E
Name :
BPS - A2 - MxG
Gehäuse: rostfreier Edelstahl - Gehäuse / Housing
IP66 / NEMA 4X
Housing: stainless steel Datum Name

IP66 / Nema 4X
1:5 1 Zeichnungs Nr. : BPSA2MxG.140403.AA02.1

1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
654 mm
355 mm
A A
Ø12 mm
300 mm
B B
490 mm
450 mm
C C
D D
450 mm 230 mm
E E
Name :
BPS - A2 - MxG
Gehäuse: rostfreier Edelstahl - Gehäuse / Housing
IP66 / NEMA 4X - mit Sonnen- bzw Regendach / with sunroof resp. rain shelter
Housing: stainless steel Datum Name
IP66 / NEMA 4X
1:5 1 Zeichnungs Nr. : BPSA2MxG.140403.AA02.1

1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
400 mm
A 300 mm A
200 mm
B B
440 mm
400 mm
C C
D D
E E
Name :
BPS-A2-S(1G)
- Gehäuse
- Housing
Datum Name

F Genehm. F
Massstab Version Übersicht

1 2 3 4 5 6 7 8
1 2 3 4 5 6 7 8
A A
104 mm
120 mm
B B
75,0 mm
C C
104 mm
D
120 mm D
E E
Name :
CC-CB1212
- Abzweigdose
- Connection box
Datum Name

F Genehm. F
1:2 1 Zeichnungs Nr.: CCCB1212.141124.AA02.1

1 2 3 4 5 6 7 8

Coal Control Belt Rip PDF

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Operating instructions and technical information

Belt Rip Detection System

Fully automatic computer-assisted belt rip detection system

BPS-A2-MxG & BPS-A2-S 2

BPS-A2-MxG & BPS-A2-S 3

Service and support ...........................................................................................................83

Conditions regarding liability

BPS-A2-MxG & BPS-A2-S 4

Explanation of the safety symbols

Note This symbol draws attention to information which contributes to

BPS-A2-MxG & BPS-A2-S 5

Fundamental safety measures

Before the control system is completely disconnected from the

The switched-off unit should be protected to prevent inadvertent

• Do not open or disconnect or connect the power supply units

As a result of assembly work in the belt rip detection system, dam-

• if metal objects such as screws or tools fall on printed-circuit

BPS-A2-MxG & BPS-A2-S 6

Duty of owner/operator to take care

The owner/operator must ensure that

• the control system is used only for the intended purpose

The owner/operator must arrange for this inspection in good time.

Requirements for the operating personnel

Read the operating

BPS-A2-MxG & BPS-A2-S 7

The BPS-A2-MxG control system is equipped with a touch panel PC

Internal view of the

In order to monitor a belt unit at multiple danger points, the BPS-A2-

BPS-A2-MxG & BPS-A2-S 8

For greater distances, as an option the BPS-A2-S belt rip detection

BPS-A2-MxG & BPS-A2-S 9

A slave is connected to the master unit via Ethernet connection

Internal view of the

The BPS-A2-S control system is equipped with an internal keyboard-

BPS-A2-MxG & BPS-A2-S 10

Further components included in the scope of supply of the belt rip

BPS-A2-MxG & BPS-A2-S 11

BPS-A2-MxG & BPS-A2-S 12

BPS-A2-MxG & BPS-A2-S 13

Transport, warehousing and unpacking

Despite the robust structure, the components installed in the com-

Warning Danger of damage to the equipment!

Store all components in dry conditions and over the temperature

During the unpacking of the belt rip detection device proceed as

BPS-A2-MxG & BPS-A2-S 14

Mounting the control system and the accessories

The computer unit is designed for mounting on a wall or in a switch

For mounting transmitter and receiver for mounting the Mounting

For the mounting of the proximity switches it is urgently recom-

Note When mounting on a wall or fitting in a closed switch cabinet,

BPS-A2-MxG & BPS-A2-S 15

Technical data BPS-A2-MxG

Technical data BPS-A2-S

BPS-A2-MxG & BPS-A2-S 16

Connection of power supply

The phase and the neutral conductor must be connected to L1 and

The master is equipped with two power supply units as a standard

The technical connected loads are limited to the connecting data of

BPS-A2-MxG & BPS-A2-S 17

Power supply unit, internal

BPS-A2-MxG & BPS-A2-S 18

For the connection of the transmitter and the receiver there is a

Connection and assembly of the connection cables are carried out in