INSTROTECH 4004 Manuale utente
Programmable
Load Cell Indicator /
Controller
Operating Manual for Models
Model 4004 / Model 5004
Cleaning
Do not clean the instrument while the instrument is on.
Harsh abrasives, solvents, scouring cleaners and alkaline
cleaning solutions, such as washing soda, should not be
used especially on the display window. The outside of the
instrument may be wiped down with a slightly damp clean
cloth (lightly moistened with water only).
Under no circumstances should you attempt to wipe the
inside of the instrument.
Safety
This equipment is supplied by a mains voltage which can
cause an electric shock injury. Before removing the circuit
board from its housing, switch the instrument off, isolate it
from the mains power supply and make sure that it cannot
be connected inadvertently by other persons.
If the circuit board is removed from its housing, do not
apply power to the instrument unless specifically instructed
to do so in these instructions. When working on live
equipment, exercise great care, use insulated tools and test
equipment, and do not work alone.
When fitting option boards, always put the circuit boards
back in the housing with the back-plate securely fastened
before powering up the instrument.
When handling circuit boards, ensure that full anti-static
precautions are observed.
Replace external mains fuse with one of an equivalent type.
Contents
See last few pages for details of options fitted / available
Introduction ......................................................................... Page 3
Electrical specifications ....................................................... Page 3
Input ranges ........................................................................ Page 3
Load cell excitation............................................................... Page 3
Power supply ....................................................................... Page 4
Programmable specifications ...............................................Page 4
Other specifications ............................................................. Page 4
Installation - Panel Cutout ................................................... Page 5
Installation - Fastening ........................................................ Page 5
Display & keypad during normal display mode ................... Page 5
Display & keypad during programming mode ..................... Page 5
Hardware links & general layout - model 4004.................... Page 6
Hardware links & general layout - model 4005..................... Page 7
Load cell & option connections ............................................ Page 8
RS232 / RS485 option ......................................................... Page 8
Power supply links ............................................................... Page 8
Setup procedure & calibration ............................................. Page 9
Programming chart .............................................................. Page 11
Display codes explained ...................................................... Page 12
Programming example ........................................................ Page 13
Asciibus protocol ................................................................. Page 14
Options................................................................................. Page 15
Option 3000 ............................................................... Page 15
Option 3001-P, 3001-M, 3002, 3003 .......................... Page 16
Option 3004-P, 3004-M, 3006, 3008, 3009..................Page 17
Option 3010, 3012, 3013, 3014...................................Page 18
Option 3016, ...............................................................Page 19
Option 3017-P, 3017-M, 3018-P, 3018-M,................... Page 20
Option 3022, 3025,3026,.............................................Page 21
Option 3029 ............................................................... Page 22
Diagram “P” ......................................................................... Page 24
Diagram “M” ........................................................................ Page 24
Declaration of conformity .................................................... Page 24
Guarantee ........................................................................... Page 24
Page 2
-10 to +10mV (1 mV/V), -20 to +20mV (2 mV/V), -30 to +30mV
(3 mV/V), -100 to +100mV (up to 10 mV/V). See note 1.
Electrical Specifications
Load Cell Excitation
Accuracy & linearity : 0.03% of F.S., or 1 count
Internal resolution (Model 4004) : 20000 counts (bi-polar)
Internal resolution (Model 5004) : 24 bits
Temperature drift : 0.1µV / °C typically
Conversion / settling time : 0.15 secs approx. (no filtering)
Input amplifier impedance : 2 MW (differential)
Operating temperature range : -10 to +50°C
Storage temperature range : -40 to +80°C
Humidity : < 85% non-condensing
Warm-up time : 10 minutes
Electro-mechanical relays : 250V AC, 30V DC, 2A, PF=1
Solid state relays : 400 V AC/DC, 0.5A, PF=1
Analog output accuracy : 0.1% of full scale
Current analog output load : 500 W maximum
Voltage analog output load : 1 kW minimum
Memory retention : Full non-volatile operation
Option 3006 isolation rating : 1500 V
Declaration of conformity : See last page
Introduction
Input Ranges
Sense feedback : Yes
Voltage : ± 5V (bipolar), 10 volts total
Temp. coefficient : 10ppm typical
Max. number of LC's : 1 x 350W load cell (standard)
Max. number of LC's : 4 x 350W load cells (with optional power supply)
NOTE (1) : These 4 input sensitivities cover the vast majority
of applications. For specialised requirements, please consult
the factory.
The Model 4004 is a 4 digit (-1999 to 9999) LED indicator &
Model 5004 is a 5 ½ digit (-199999 to 199999) LED indicator.
These DIN 48 x 96, high accuracy, high-quality load cell
indicators are designed for mV inputs from load cells, strain
gauges & strain gauge pressure transmitters.
The stable bridge excitation voltage includes sense feedback
to compensate for line variations. The precision differential
instrumentation op amp front end input ensures high stability
and accuracy.
Options include programmable voltage or current analog
output, alarm setpoints up to four alarms, tare function (front
pushbutton & remote), peak / valley (max / min) hold, RS 232 &
RS485 serial interfaces & lots more.
A feature of this programmable indicator / controller is the
calibration method. Pre-calibrated ranges can be allocated
zero and full scale values and these can be adjusted on site to
allow for back-balance (deadweight) offset and span
calibration (test weight calibration).
The instrument meets European Community EMC directive
89/336/EEC and Low Voltage directive 73/23/EEC.
Page 3
Programmable Specifications
Model 5004
Zero & full scale setting : -199999 to 199999
Decimal point : Adjustable on all digits
Input sensitivity : Programmable 0 - 10mV/V
Balance range adjustment : 100% of load cell capacity
Tare range adjustment : 100% of load cell capacity
Filtering range : 0 - 10.0 seconds
Options :
Analog output zero & span : -199999 to 199999
Alarm setpoint values : -199999 to 199999
Alarm hysteresis : 0 to 255 (default 1)
Alarm delay : 0 to 255 seconds (default 0)
Alarm relay settings : Selectable HIGH or LOW alarm
Alarm relay state : Selectable NO or NC
Unit address : 1 to 127
Baud rate : 2400, 4800, 9600, 19200
Standard
95 - 265V AC/DC power supply option, 8VA typical
Optional
8 - 30 VDC isolated power supply , 8VA typical (Option 3008)
The standard power supplies provide power for up to four load
cells.
Power Supply
Model 4004
Zero & full scale setting : -1999 to 9999
Decimal point : Adjustable on all digits
Input sensitivity : 1, 2, 3 or 10mV/V
Balance range adjustment : 100% of load cell capacity
Tare range adjustment : 100% of load cell capacity
Filtering range : 0 - 10.0 seconds
Options :
Analog output zero & span : -1999 to 9999
Alarm setpoint values : -1999 to 9999
Alarm hysteresis : 0 to 255 (default 1)
Alarm delay : 0 to 255 seconds (default 0)
Alarm relay settings : Selectable HIGH or LOW alarm
Alarm relay state : Selectable NO or NC
Unit address : 1 to 127 (0 is for factory use)
Baud rate : 2400, 4800, 9600, 19200
Other Specifications
DIN 48 x 96 housing, 147mm depth
Industrial strength single piece housing
Housing is flame retardant ABS plastic that meets UL94 V-0
Circuit board is flame retardant material that meets UL94 V-0
Front facia rating : IP65 (with o-ring seal supplied as standard)
Page 4
Fastening
The supplied fastening
clips may be fitted on
the side or the top /
bottom of the housing.
Ensure that the clip &
screw is mounted as
shown here.
Caution : Do not
overtighen the screws.
Min
12
45
92
Installation
To gain access to the
circuit boards, switch
power off and remove
terminals from the
back of the housing.
Observe safety
precautions. Use a
screwdriver to clip the
back-plate off.
During programming mode Display & Keypad
147
Panel Cutout
Installation
48
96
Enter
Programming menu
Move to next digit
Increment digit / change selection
Alarm LEDs
(illuminated whenever
relays are energised)
48
96
2 3 41
kg
Tare function (option 3014 only)
Print on demand (comms option only)
Reset peak value (option 3012 only)
Toggle peak / normal mode
(option 3012 only)
2 3 41
kg
All dimensions in mm
During normal display mode Display & Keypad
Page 5
O-ring sealing
gasket supplied
as standard
DIN 1/8 cutout
Min
12
Hardware Links & General Layout
Remember : Configuring this instrument requires two steps:
(1) Select the correct hardware links as shown. (2) Program the instrument with the programming chart on page 10.
Page 6
5
7
8
6
9
11
12
10
1
3
4
2
N
L
J4
Select Sensitivity Link
on Circuit Board (Model 4004 only)
Option
board
connector
Up to 3 mV / V
Interposing relays
recommended for
heavy duty
applications
Alarm 1 or Data - (Tx)
Alarm 2 or Data + (Rx)
Alarm Common
+ Sense
- Sense
Remote peak / valley hold reset
Neutral (+ DC supply input)
Ground (common)
Live (- DC supply input)
+mV input
DISPLAY BOARD
+ Excitation
- mV input
Up to 2 mV / V
Up to 1 mV / V
Up to 10 mV / V
Remote tare
- Excitation
J1
J2
Model 4004
5
7
8
6
9
11
12
10
1
3
4
2
N
L
J4
Select Excitation Link
on Circuit Board (Model 5004 only)
Option
board
connector
Alarm 1 or Data - (Tx)
Alarm 2 or Data + (Rx)
Alarm Common
+ Sense
- Sense
Remote peak / valley hold reset
Neutral (+ DC supply input)
Ground (common)
Live (- DC supply input)
+mV input
DISPLAY BOARD
+ Excitation
- mV input
A and C is 10V excitation
Remote tare
- Excitation
J1
Model 5004
ABC
3.3 V excitation(Link A only)
5.0 V excitation(Link C only)
Hardware Links & General Layout
Page 7
10V excitation(Link A and C)
Interposing relays
recommended for
heavy duty
applications
No links.
RS232 / RS485 Option
Load Cell & Option Connections
1. - mV
3. + Exc
4. +Sense
7. Reset
5. - Sense
2. + mV
8. Tare
9. DGND
10.
6. - Exc
Neut (+)
11. - D(Tx)
12. +D(Rx)
Live (-)
Circuit board
Alarm connections
for option 3001/4-P only.
Solid state relays,
400V AC/DC,
0.5 A max, PF=1
Interposing relays
recommended for
heavy duty applications
Link Sense to Excitation
if remote sense is
not used.
Remote tare (option 3014)
Place hardware links as shown in the diagrams.
Remember : Configuring the 4004 requires two steps. (1) Select the
correct hardware links as shown. (2) Program the instrument with
the programming chart on page 10.
Power Supply Links
If the RS232 or RS485 option is ordered, then
the alarm relays can be found on the option
card that slots in the top part of the housing.
See diagram “P” or “M” on the last page.
For RS485,
use pins 11 & 12.
For RS232,
use pins 9, 11, 12.
Alarm 1
Alarm 2
Alarm com
9. DGND
10
11
12
Remote peak / valley hold reset (option 3012)
Page 8
The load cell can be pre-calibrated by entering the zero and load cell full scale capacity in the programming menu. The load cell
system zero value can normally left at 0 for the pre-calibration. The load cell full scale capacity is then entered.
Example 2:
For a 3 x 1000 kg load cell system with 2mV/V each.
Carefully remove the circuit board from the housing and link for
2mV/V on jumper J4 (see step 1 above).
Program the instrument as follows:
- Go to the “Inp” and “Cal” menu.
- Set “2 mV” which represents the load cell sensitivity.
- Set decimal point to “oooo” (no decimal point).
- Set load cell “zero” to “0”.
- Set "LC.FS" to "3000" (as there are 3 x 1000 kg load cells).
The system has now been pre-calibrated.
Setup Procedure & Calibration
REFER TO THE PROGRAMMING FLOW CHART on page 10 while using this setup procedure.
This instrument offers an easy & straightforward way to pre-calibrate and field calibrate the load cell system. Follow the steps below:
Step 1 : Setting instrument sensitivity
The load cell sensitivity must be set in via jumper link J4 on the circuit board (see circuit board layout diagram on page 6). The
sensitivity setting must also be set in the programming menu (use the programming chart on page 10 to assist you, as well as the
examples below). If the load cell system sensitivity is not exactly one of the pre-determined ranges of 1mV/V, 2mV/V, 3mV/V or
10mV/V, then use the next highest sensitivity. E.g. if the load cell sensitivity is 1.6mV/V, then use the 2mV/V range. Remember to set
the sensitivity link (J4) on the circuit board as well.
See example 1 and 2 below.
Example 1:
For a 1 x 5.000 ton load cell that has a 3mV/V sensitivity.
Carefully remove circuit board from the housing and link for
3mV/V on jumper J4 (see step 1 above).
Program the instrument as follows:
- Go to the “Inp” and “Cal” menu.
- Set “3 mV” which represents the load cell sensitivity.
- Set decimal point to "o.ooo” (three decimal places).
- Set load cell "zero" to "0.000".
- Set load cell full scale capacity "LC.FS" to "5.000".
The instrument has now been pre-calibrated.
Step 2 : Entering the decimal point, the load cell zero, and the full scale capacity value
Page 9
Once steps 1 - 4 above have been completed, the instrument automatically alters the pre-calibration parameters “Zero” and “LC.FS”
in the “CAL” sub-menu (entered in step 2 above). These altered parameters may not resemble the original values entered by the user.
This is normal as these parameters fully characterise the weighing system.
DO NOT change these parameters. It is suggested that these parameters be noted for future use, especially if the instrument is
replaced. These parameters can be re-entered into the new instrument with the result that reasonable accuracies can still be obtained
without re-doing a field calibration. This is especially useful when minimum downtime is critical, and to avoid wastage if failure occurs
when the bin / hopper still contains materials. It is still recommended that complete field calibration is done when the situation permits.
Step 5 : Store away calibrated instrument parameter for future use
Make sure that steps 1 & 2 on the previous page have been completed before proceeding with step 3.
The following procedure removes the deadweight from the weighing system (which is normally the bin / hopper / scale weight), and
returns the display reading to show zero with the bin empty.
Make sure that the bin / hopper is empty. Use the programming chart to go to “Inp”, followed by “Tare”. Press enter. The display will
flash “Tare” indicating that the instrument is measuring and averaging the bin weight. Allow for a few seconds of averaging, then press
the enter (star) button to stop the process. The instrument will exit programming mode and the display should read zero.
Step 3 : Field calibration of load cell system for back-balance (deadweight)
Make sure step 3 above has been completed before proceeding with step 4.
The following procedure allows the weighing system to be accurately calibrated using test weights.
Place the test weights on the bin / hopper / scale. The instrument should read the weight of the test weights. If the reading is not of
sufficient accuracy, then use the programming chart to go to "Inp", followed by "LOAD" and press enter. The instrument now prompts
you to enter the weight of the test weights. Then press enter. The display will flash “LOAD” for a few seconds, indicating that the
instrument is measuring and averaging the tests weights in the bin / hopper / scale. The instrument automatically exits programming
mode after a few seconds.
Step 4 : Field calibration of span (test weight calibration)
Page 10
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