IT1000-AC-W-Ex2/22 IT1000-DC-W-Ex2/22 IT1000-BATT-W-Ex2/22...

Technical Manual

IT1000-AC-W-Ex2/22 IT1000-DC-W-Ex2/22

IT1000-BATT-W-Ex2/22 IT1000-AC-E-Ex2/22 IT1000-DC-E-Ex2/22

IT1000-BATT-E-Ex2/22

Industrial Weighing Terminal For Installation In Ex Zone 2 / 22

II 3G Ex ic nA IIC T4 Gc II 3D Ex ic tc IIIB T50°C Dc IP54

or II 3D Ex ic tc IIIC T50°C Dc IP65

December 2017

ST.2309.1312

Rev. 9

© SysTec Systemtechnik und Industrieautomation GmbH, Bergheim, Germany

2 Technical Manual IT1000-**-*-Ex2/22 Rev. 9

Technical Manual IT1000-**-*-Ex2/22 Rev. 9 3

Technical Manual IT1000-**-*-Ex2/22

Date: December 01, 2017

File: IT1000_EX222_THE.DOC

Program Version: IT1000 as of 2.25


Published By: © SysTec Systemtechnik und Industrieautomation GmbH, Bergheim, Germany All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, mechanical, photocopying, recording, or otherwise, without the prior written permission of SysTec GmbH. Terms and product names mentioned in this publication are trademarks, registered trademarks or service marks of their respective owners. Use of a term should not be regarded as affecting the validity of any trademark, registered trademark or service mark. EPSON ESC/P® is a registered trademark of the SEIKO EPSON Corporation. TOLEDO® is a registered trademark of Mettler-Toledo Inc.

Please Note: While every precaution has been taken in the preparation of this manual, SysTec GmbH assumes no responsibility for errors or omissions. Neither is any liability assumed for damages resulting from the use of the information contained herein. The publisher is grateful for any information and/or advice that may contribute to correct errors or omissions in following editions.


Contents 1 Introduction ........................................................................................................................... 9

1.1 About This Manual ......................................................................................................... 9 1.2 Safety Symbols Used In This Manual ............................................................................... 9 1.3 Safety Instructions ......................................................................................................... 9 1.4 Marking ...................................................................................................................... 11

2 System Description ............................................................................................................... 12 2.1 General ....................................................................................................................... 12 2.2 Basic Units And Options ............................................................................................... 13 2.3 Housing ...................................................................................................................... 14 2.4 Description Of Components .......................................................................................... 15

3 Intended Use ........................................................................................................................ 17

4 Assembly ............................................................................................................................ 18

5 Installation ........................................................................................................................... 19 5.1 General ....................................................................................................................... 19 5.2 Equipotential Bonding ................................................................................................... 19 5.3 Shielding ..................................................................................................................... 19 5.4 Connection Of Cables ................................................................................................... 20

6 Installation Of External Connections With Type Of Protection 'Ex-nA' ......................................... 21 6.1 Connection Of Power Supply To IT1000-AC-*-Ex2/22 ..................................................... 21 6.2 Connection Of Power Supply To IT1000-DC-*-Ex2/22 And IT1000-BATT-*-Ex2/22 ............ 22 6.3 Operation Of IT1000-BATT-*-Ex2/22 ............................................................................. 23 6.4 Connection Of Analog Scale To ADM ............................................................................. 26 6.5 Connection Of Serial Interface SIM ................................................................................ 29 6.6 Connection Of Parallel I/Os PIM ..................................................................................... 34 6.7 Connection Of Parallel I/Os IOM .................................................................................... 36 6.8 Connection Of 15-Bit Analog Output DAU15 .................................................................. 38

7 Commissioning ..................................................................................................................... 40

8 Installation Examples ............................................................................................................. 41 8.1 Installation Example IT1000-AC-*-Ex2/22 ....................................................................... 41 8.2 Installation Example IT1000-DC-*-Ex2/22 ....................................................................... 42 8.3 Installation Example IT1000-BATT-*-Ex2/22 With Akku-Box ............................................. 43

9 Service Mode ....................................................................................................................... 44 9.1 General ....................................................................................................................... 44 9.2 Display And Keyboard .................................................................................................. 45 9.3 Operator Prompting ...................................................................................................... 46 9.4 Weighing Functions ...................................................................................................... 48 9.5 Power Up ................................................................................................................... 49 9.6 Overview Service Mode ................................................................................................ 50

10 Calibrate Scale ................................................................................................................... 52 10.1 Entering Calibration Mode ........................................................................................... 52 10.2 Capacity & Interval .................................................................................................... 53 10.3 Span Adjust .............................................................................................................. 56 10.4 Linearization .............................................................................................................. 58 10.5 Zero Adjust ............................................................................................................... 59 10.6 Adaptation ................................................................................................................ 59


10.7 Show X10 ................................................................................................................. 61 10.8 Reset Calibration Parameters........................................................................................ 62 10.9 Calculate Span ........................................................................................................... 63 10.10 W&M Info ................................................................................................................ 64 10.11 Factory Calibration .................................................................................................... 65 10.12 Geo Values .............................................................................................................. 65 10.13 Configuration Of Scale Interface Module ...................................................................... 67

11 Adapt Mode ........................................................................................................................ 70

12 Interface Configuration ......................................................................................................... 71

13 Configuration Of Print Format (Format) .................................................................................. 73 13.1 Configuration Of Fields ................................................................................................ 73

14 General .............................................................................................................................. 74

15 Hardware Test .................................................................................................................... 78

16 Settings For Analog Output DAU ........................................................................................... 79

17 Reset General Parameters ..................................................................................................... 80

18 Protocol ............................................................................................................................. 81

19 Supervisor Mode ................................................................................................................. 82

20 Operating Modes ................................................................................................................. 84 20.1 Operating Mode 'BASIC' ............................................................................................. 84 20.2 Operating Mode 'COUNT' ............................................................................................ 85 20.3 Operating Mode 'FILL' ................................................................................................. 87 20.4 Operating Mode 'CHECK' ............................................................................................ 89

21 Online Mode SysTec Standard .............................................................................................. 91 21.1 Structure Of Data Strings ............................................................................................ 91 21.2 Summary Of Commands ............................................................................................. 91 21.3 Read Weight .............................................................................................................. 92 21.4 Taring ....................................................................................................................... 96 21.5 Select Scale ............................................................................................................... 97 21.6 Set Scale To Zero ....................................................................................................... 98 21.7 Error Codes ................................................................................................................ 98

22 Online Mode MP85 .............................................................................................................. 99 22.1 Interface Parameters ................................................................................................... 99 22.2 Structure Of Data Strings ............................................................................................ 99 22.3 Overview On Commands ............................................................................................. 99 22.4 Read Weights........................................................................................................... 100 22.5 Taring ..................................................................................................................... 100 22.6 Set Scale To Zero ..................................................................................................... 101 22.7 Status Bytes ............................................................................................................ 102

23 Online Mode BDI ............................................................................................................... 103 23.1 Interface Parameters ................................................................................................. 103 23.2 Structure Of Data String ............................................................................................ 103 23.3 Initialization ............................................................................................................. 103 23.4 Overview On Commands ........................................................................................... 104 23.5 Read Weights........................................................................................................... 105 23.6 Taring ..................................................................................................................... 107 23.7 Set Scale To Zero ..................................................................................................... 108


23.8 Error Codes ............................................................................................................. 108 23.9 Weight Status ......................................................................................................... 108

24 Multidrop Connection ........................................................................................................ 109 24.1 Establish And Terminate Connection .......................................................................... 109 24.2 Example (Polling Of Slave 1 And Slave 2) ................................................................... 110

25 Remote Display ................................................................................................................ 111 25.1 Interface Parameters ................................................................................................ 111 25.2 Connection To ITx000 .............................................................................................. 111 25.3 Connection To IT1000 ............................................................................................. 112

26 Multi-Remote-Display (Remote Display For IT2000P) ............................................................. 112 26.1 Interface Parameters ................................................................................................ 112 26.2 Connection Of IT2000P To IT1000 ............................................................................ 113 26.3 IT1000 Key Assignment ........................................................................................... 113

27 Configuration Example ....................................................................................................... 114 27.1 Factory Setting ........................................................................................................ 114 27.2 Example 'COUNT' .................................................................................................... 116 27.3 Field Length Of System Variables ............................................................................... 117 27.4 Form For Print Layouts (80 Columns) ......................................................................... 118 27.5 Form For Print Layouts (40 Columns) ......................................................................... 119 27.6 Form For Configuration ............................................................................................. 120

28 Data Transmission ............................................................................................................ 121 28.1 Protocol For Data Transmission ................................................................................. 121 28.2 Continuous Output ................................................................................................... 122

29 Transport, Maintenance And Cleaning ................................................................................. 126 29.1 Transport ................................................................................................................ 126 29.2 Maintenance ........................................................................................................... 126 29.3 Replacing The Battery (Realtime Clock DS1687-5) ....................................................... 126 29.4 Cleaning ................................................................................................................. 127 29.5 Security Check ........................................................................................................ 127 29.6 Functional Test ........................................................................................................ 127 29.7 Repair ..................................................................................................................... 127 29.8 De-Installation ......................................................................................................... 127 29.9 Disposal .................................................................................................................. 127

30 Trouble Shooting .............................................................................................................. 128 30.1 Error Messages ........................................................................................................ 128

31 Technical Data ................................................................................................................. 130 31.1 General Data ........................................................................................................... 130 31.2 Ex-Relevant Electrical Data For Type Of Protection 'Ex-nA' ........................................... 130

32 Dimensions ...................................................................................................................... 133


1 Introduction 1.1 About This Manual This manual contains information and Technical Data for the use, the installation and the operation of the industrial weighing terminals IT1000-AC-W-Ex2/22, IT1000-AC-E-Ex2/22, IT1000-DC-W-Ex2/22 and IT1000-DC-E-Ex2/22, IT1000-BATT-W-Ex2/22 and IT1000-BATT-E-Ex2/22. Information applicable to all versions refers to IT1000-Ex2/22. Specific information is marked with the full designation of the respective version, e.g. 'IT1000-AC-W-Ex2/22'. The weighing terminal must only be operated by trained personnel. For simple weighing transactions to be carried out by the enduser the Operating Instructions IT1000 (ST.2309.0603) are available.

1.2 Safety Symbols Used In This Manual Safety relevant information is shown with corresponding symbols as follows:

Ex

W A R N I N G Failure to observe this precaution could result in serious injuries or fatal accidents due to ignition of an explosive atmosphere (gas and/or dust). Please make absolutely sure that these precautions are observed in order to ensure safe operation of the equipment.

W A R N I N G Failure to observe this precaution could result in serious injuries or fatal accidents. Please make absolutely sure that these precautions are observed in order to ensure safe operation of the equipment.

CAUTION Failure to observe this precaution could result in damage to or destruction of the equipment or bodily harm! Please make absolutely sure that these precautions are observed in order to ensure safe operation of the equipment.

Note: This indicates an advice for the designated use of the equipment and/or additional information to avoid inappropriate handling.

1.3 Safety Instructions

Ex

W A R N I N G Before opening the housing make absolutely sure that all power sources to this instrument are disconnected and that no potentially explosive atmosphere can be present at any time! The de-energized state is reached by disconnecting the supply voltages to the instrument and to all external devices connected to the interfaces of the weighing terminal.

W A R N I N G Exercise utmost care when making checks, tests and adjustments that can actuate movable parts such as feeding devices, gates, flaps, conveyors etc. Make absolutely sure that nobody is within reach of movable parts.

Ex

W A R N I N G For installation, service and operation of the unit, the ATEX directive as well as all locally applicable regulations for safety and the prevention of accidents must be observed!


Ex

W A R N I N G This weighing terminal must not be used in Ex-Zone 0, 1, 20 and 21. It is the sole responsibility of the employer / operating company to classify the area of installation (zone, group, temperature class). To that effect, the assistance of the Technical Supervisory Service or any other technical authority may be utilized!

Ex

W A R N I N G When this unit is included as a component part of a system, the resulting system design must be reviewed by qualified personnel who are familiar with the construction and operation of all individual components in the system and the potential hazards involved.

Ex

W A R N I N G Input voltage of the instrument must comply with local mains supply!

Ex

W A R N I N G This module and its associated equipment must only be installed, adjusted and maintained by qualified personnel authorized by SysTec GmbH!

Ex

W A R N I N G Connection of peripheral devices to IT1000A-Ex2/22 is made in compliance with Ex type of protection 'Ex-nA'. The connection values must be observed. Connected peripheral devices installed in hazardous area must have appropriate Ex protection.

Ex

W A R N I N G When the instrument is permanently connected to the power supply, an easily accessible separator must be included in the supply circuit! It must either be located in safe area or -if installed in Ex area- have appropriate Ex protection for the place of installation.

Ex

W A R N I N G The weighing terminal must not be installed in areas where electrostatic charging is possible which may produce spark discharges, brush discharges or propagating brush discharges at the front panel. Comment: According to common knowledge, the use of the equipment and the cleaning with a damp cloth do not produce such a high surface charge density. However, the front panel must not be wiped with a dry cloth!

W A R N I N G Risk of electrical shock! When operating electrical devices, parts of this devices are connected to dangerously high voltages. Inappropriate use of such devices may lead to serious bodily injuries or substantial damages to property.

W A R N I N G The power supply unit of the weighing terminal provides SELV voltages in accordance with EN 60950. Make sure that any peripheral device connected to the weighing terminal containing its own power supply also uses SELV voltages!

W A R N I N G The device uses the short-circuit / overcurrent protection of the on-site mains supply.


1.4 Marking

Manufacturer

Systec Systemtechnik und Industrieautomation GmbH

Ludwig-Erhard-Straße 6

50129 Bergheim-Glessen

Designation

IT1000-AC-W-Ex2/22

IT1000-AC-E-Ex2/22

IT1000-DC-W-Ex2/22

IT1000-DC-E-Ex2/22

IT1000-BATT-W-Ex2/22

IT1000-BATT -E-Ex2/22

Serial-No. Ex yy nnnn (yy=year of construction / nnnn=consecutive number)

Range of ambient temperature –10 °C to +40 °C

Ex classification

II 3G Ex ic nA IIC T4 Gc II 3D Ex ic tc IIIB T50°C Dc IP54 or II 3D Ex ic tc IIIC T50°C Dc IP65

CE marking

Type examination certificate TÜV 11 ATEX 7618 X

Service Only by qualified service personnel authorized by SysTec GmbH

Addresses on request


2 System Description 2.1 General IT1000-Ex2/22 is a general purpose weighing terminal for use in a variety of applications such as data logging, data capturing, parts counting, setpoint control and filling, suitable for installation in Ex zones 2 and 22. The weighing module ADM is used to connect one scale base with strain gauge loadcells with an overall impedance of 21 Ω to 4500 Ω. In addition a battery-backed realtime clock can be installed. Power supply through the built-in wide-range power supply unit is either for 110–240 VAC or 12–30 VDC or 10–24 VDC (battery-powered version). Housings are available for both, desk-top/wall-mount and panel-mount installation. Cables of all external components are connected at screw terminals. Weight and additional information is indicated on a back-lit 13-character LCD, height of characters 14mm. Operation is made via a sealed membrane keyboard with 5 keys. Instead of operating the terminal locally via keyboard and display, full remote control is possible from a PC. In applications legal for trade data can be stored in an approved data archive on the PC's harddisk. This option requires the installation of the realtime clock in the weighing terminal and the PC program PC COM+.


2.2 Basic Units And Options IT1000-Ex2/22 is available in 4 basic versions:

Type Housing Description Article-No.

IT1000-AC-W-Ex2/22 Wall-mount/ desk-top

Basic unit for wall-mount / desk-top installation with 2.5 m line cord with free ends to connect to 110–240 VAC

X1SYS001

IT1000-AC-E-Ex2/22 Panel-mount Basic unit for panel-mount installation with 2.5 m line cord with free ends to connect to 110–240 VAC

X1SYS011

IT1000-DC-W-Ex2/22 Wall-mount/ desk-top

Basic unit for wall-mount / desk-top installation with screw terminals to connect to 12–30 VDC

X1SYS005

IT1000-DC-E-Ex2/22 Panel-mount Basic unit for panel-mount installation with screw terminals to connect to 12–30 VDC

X1SYS015

IT1000-BATT-W-Ex2/22

Wall-mount/ desk-top

Basic unit for wall-mount / desk-top installation with screw terminals to connect to 12–30 VDC

X1SYS006

IT1000-BATT-E-Ex2/22

Panel-mount Basic unit for panel-mount installation with screw terminals to connect to 12–30 VDC

X1SYS016

The following modules are available as options:

Option Description Article-No.

ADM Plug-on weighing module for connection of analog loadcells 13OPT100

SIM-RS232 Plug-on module with serial RS232 interface 10OPT220

SIM-20mA Plug-on module with serial 20mA interface 10OPT221

SIM-RS485.4 Plug-on module with serial RS485 4-wire interface 10OPT222

SIM-RS485.2 Plug-on module with serial RS485 2-wire interface 10OPT225

SIM-RS485.Opto Plug-on module with opto-isolated serial RS485 interface 10OPT230

DAU15 Plug-on module with analog 0/2–10 V or 0/4–20 mA output 10OPT231

PIM Plug-on module with two digital inputs/outputs 10OPT300

IOM Plug-on module with one digital input and 3 digital outputs 10OPT302

RTC DS1687-5 Plug-on module DS1687-5 with realtime clock, RAM and battery backup

13OPT500


2.3 Housing IT1000-Ex2/22 is incorporated in a stainless steel housing with cable glands to connect cables to peripheral devices. It is available in two versions: The housing for desk-top / wall-mount installation (IT1000-**-W-Ex2/22) is protected to IP65. The housing for panel-mount installation (IT1000-**-E-Ex2/22) is inserted in a suitable cutout of a switch cabinet and fixed from the rear with 6 mounting brackets. When installed accordingly, the front of the terminal -in combination with the circumferential gasket between terminal and switch cabinet- is protected to IP65. When installed in Ex zone 2 (as per II 3G Ex ic nA IIC T4 Gc) and Ex zone 22 with non-conductive dust (as per II 3D Ex ic tc IIIB T50°C Dc IP54) the surrounding housing must be protected to IP54 or better. When installed in Ex zone 22 with conductive dust (as per II 3D Ex ic tc IIIC T50°C Dc IP65) the surrounding housing must be protected to IP65 or better. The surrounding housing (e.g. switch cabinet) must conform to the requirements of EN60079-0 section 26.4. See section 'Dimensions' for space requirements.

Ex

The housings must be included in the equipotential bonding of the installation.


2.4 Description Of Components 2.4.1 Main Module CPU1000 The CPU1000 is the main module of the IT1000-Ex2/22 weighing terminal. It contains the microcontroller, the power supply and the display. It also has a sockets to plug on the weighing module ADM and a battery-backed realtime clock. An additional socket is provided that can be used alternatively for a serial interface (SIM) or two digital I/Os (PIM) or an analog output (DAU15).

The following versions are available:

Main board Description Used for

CPU1000-230V-Ex2/22 CPU1000 with 110–240 VAC PSU IT1000-AC-*-Ex2/22 Article-No. X1SYS0x1

CPU1000-24VDC-Ex2/22 CPU1000 with 12–30 VDC PSU IT1000-DC-*-Ex2/22 Article-No. X1SYS0x5

CPU1000-NTA-Ex2/22 CPU1000 with 12–30 VDC PSU and low-bat detection

IT1000-DC-*-Ex2/22 Article-No. X1SYS0x6

Layout of components on CPU1000 main module

Realtime clock Power supply

X3 / X4 Socket for

ADM weighing module

Terminal KL1 Terminal KL2 Terminal KL3 Keyboard power supply PE I/O interface


2.4.2 Battery-Backed Realtime Clock RTC DS1687-5 As an option a module with realtime clock and 240 bytes of battery backed memory (e.g. for totals) can be installed. The integrated lithium battery has a lifetime of approx. 10 years. The realtime clock is required for applications using the external data archive on PC harddisk because the ident-No. (which in conjunction with the date serves to identify a record in the archive) is stored in the memory of the module.

Insert with mark pointing to the left

Notes:

• For the storage of volatile data the module of the optional realtime clock contains a lithium battery. Dispose of used batteries as indicated by manufacturer.

• If no realtime clock is installed, entry of date and time is required on power up! • For replacing the module observe the instructions in section 'Replacing the battery'!


3 Intended Use

Ex

In compliance with RL 2014/34/EU appendix I, the weighing terminal IT1000-Ex2/22 is an apparatus of group II category 3G, that following RL 99/92/EG (ATEX 137), can be used in zone 2, as well as in gas groups IIA, IIB and IIC, which are at risk of explosion through combustible substances of temperature classes T1 to T4. The following section 'Installation of 'IT1000-**-E-Ex2/22 in switch cabinet' must be observed.

IT1000-Ex2/22 is also an apparatus of group II category 3D, that following RL 99/92/EG (ATEX 137) can be used in zone 22 (dust), the maximum surface temperature is 50°C. The following instructions on the installation of the IT1000-**-E-Ex2/22 in a surrounding housing must be observed.

Installation of 'IT1000-**-E-Ex2/22 in switch cabinet: The housing for panel-mount installation is inserted in a suitable cutout of a switch cabinet and fixed from the rear with 6 mounting brackets. If installed accordingly, the front of the terminal -in combination with the circumferential gasket between terminal and switch cabinet- is protected to IP65. When installed in Ex zone 2 (as per II 3G Ex ic nA IIC T4 Gc) and Ex zone 22 with non-conductive dust (as per II 3D Ex ic tc IIIB T50°C Dc IP54) the surrounding housing must be protected to IP54 or better. When installed in Ex zone 22 with conductive dust (as per II 3D Ex ic tc IIIC T50°C Dc IP65) the surrounding housing must be protected to IP65 or better. The surrounding housing (e.g. switch cabinet) must conform to the requirements of EN60079-0 section 26.4.

The weighing terminal must not be installed in areas where electrostatic charging is possible which may produce spark discharges, brush discharges or propagating brush discharges at the front panel.

All external connections are designed for type of protection Ex 'nA'. The connection values shown in chapter 'Installation of external connections with type of protection Ex-nA' must be observed.

When installed in hazardous area, all peripheral devices connected to IT1000-Ex2/22 must have appropriate Ex protection.

Ex

The metal housing of the IT1000-Ex2/22 terminal must be integrated at the PA stud into the equipotential bonding system of the installation. Use suitable serrated washers.

The permissible range of ambient temperature is –10 °C to +40 °C. When installing IT1000-**-E-Ex2/22 in a switch cabinet (panel-mount version), this temperature range also applies to the inside the switch cabinet.

Furthermore, for use and installation all requirements as per EN 60079-14 must be observed.

Any other but the intended use of the equipment, modifications and extensions must not be made without the explicit approval of the manufacturer and is deemed not to be intended. Part of the intended use is observance of this Technical Manual and the adherence to inspection and maintenance instructions and intervals. The manufacturer does not assume any liability whatsoever for damages resulting from non-intended use. Any risk resulting from non-intended use is solely borne by the user.

The weighing terminal and all connected components must be integrated into a common system of equipotential bonding.

Protective covers or other parts covering the housing completely or in part must not be used.

The housing must be protected against permanent exposure to ultraviolet radiation.


4 Assembly

Ex

It must be made sure that installation of the weighing terminal is only carried out when all power to the instrument is disconnected and no potentially explosive atmosphere is present. The weighing terminal must not be installed in areas where electrostatic charging is possible which may produce spark discharges, brush discharges or propagating brush discharges at the front panel.

Installation must be made in compliance with the generally accepted rules of technology. In particular for all work carried out on electrical installations the specific safety regulations must be observed. The weighing terminal may be installed in Ex zone 2 or 22. The terminal must not be damaged. The place of installation must be clean. The IT1000-**-W-Ex2/22 (wall-mount / desk-top version) has mounting brackets for wall or table-top installation. They must be fixed with suitable screws which are not part of the supply. All screws must be tightened securely. The IT1000-**-E-Ex2/22 (panel-mount version) has screw clamps to fix the terminal in the cutout of the switch cabinet. To connect the bonding conductor, an M5 stud is provided at the rear or bottom of the housing. Use serrated washers to prevent the nuts from becoming loose. The permissible temperature range is –10 °C to +40 °C at a max. of 95% relative humidity (non condensing). Direct exposure to ultraviolet radiation must be avoided. For wall-mount installation the unit can be fixed at the wall first and then the cables can be installed with the front lid open. Before the device is put into operation, the housing must be closed and tightened securely with the hexagonal nuts provided. The nuts must be tightened with a torque of 1.1 Nm.


5 Installation 5.1 General

Ex

This apparatus must only be installed by qualified personnel who are familiar with all regulations applicable to the different types of protection and the methods of installation, as well as the general principles for the classification of zones. This level of competence must correspond to the work that is to be carried out and appropriate training should be provided on a regular basis.

When the weighing terminal is to be installed in Ex zone 2 / 22 the regulations as per EN 60079-14 must be adhered to. The weighing terminal must not be installed in areas where electrostatic charging is possible which may produce spark discharges, brush discharges or propagating brush discharges at the front panel.

It must be made sure during installation of the weighing terminal that all power to the instrument is disconnected and that no potentially explosive atmosphere can be present at any time.

Installation must be carried out in compliance with applicable DIN/VDE regulations. Also, all country-specific regulations must be observed. Connection of supply voltage must be made in compliance with VDE 0100 and VDE 0160.

When the instrument is permanently connected to the power supply, an easily accessible separator must be included in the supply circuit! It must either be located in safe area or -if installed in Ex area- have appropriate Ex protection for the place of installation.

Ex

All cables are led into the housing through Ex cable glands. Strip cable jacket only as long as required for the wires to reach the screw terminals. Use wire end ferrules with plastic collar on stranded cable and avoid protruding wires. When assembling the cable glands make sure that shield of cable is connected inside the cable gland. Observe instructions in section 'Connection of cables'.

Before the device is put into operation, make sure that the housing is closed and tightened securely with all hexagonal nuts provided (torque: 1.1 Nm).

5.2 Equipotential Bonding

Ex

In compliance with EN 60079-14 the apparatus must be integrated into the equipotential bonding system of the installation. The bonding conductor must have a cross section of min. 4 mm². To connect the bonding conductor, an M5 stud with serrated washer is provided at the rear or bottom of the housing.

5.3 Shielding

Ex

Use only shielded connection cables. The shield must be connected at both sides in the cable glands. It is mandatory to additionally install equipotential bonding as per EN60079-14 paragraph 'additional requirements for the type of protection i-intrinsic safety' / section 'grounding of conductive shields' / exception b). The bonding conductor must have a cross section of min. 4 mm².


5.4 Connection Of Cables All cables are led into the housing through Ex cable glands.

Cable jacket Shield Compression nut Plastic insert Bushing Counter nut

1. Slide compression nut over cable jacket;

2. Slide plastic insert (retainer) over cable jacket until inner end is aligned with cut end of jacket;

3. Unravel shield, bend over retainer and push into retaining comb to ensure good conductive contact with housing. Cut wires of shield to length of comb, avoid protruding wires that would endanger tightness of cable gland;

4. Insert retainer with cable into bushing;

5. Screw compression nut onto bushing and use wrench to tighten securely.

Permissible diameter of cables and torque for cable glands:

Wrench size of counter nut

Permissible diameter of cable

Torque to tighten counter nut

17 mm 4–8 mm 6 Nm

20 mm 5–10 mm 5 Nm

22 mm 6–12 mm 8 Nm

Contact SysTec service for different cable diameters.

Ex

Use crimped wire end ferrules with plastic collar on stranded cable and avoid protruding wires.

Ex

All connecting cables must be firmly installed to avoid tension load at the cable glands and to comply with the requirements of EN60079-14 paragraph 'cables and lines for permanent installation'.


6 Installation Of External Connections With Type Of Protection 'Ex-nA'

6.1 Connection Of Power Supply To IT1000-AC-*-Ex2/22 IT1000-AC-*-Ex2/22 (article-No. X1SYS0x1) is supplied with a line cord with free ends for the supply voltage. Power supply unit

L1 N PE Terminal KL1 Terminal KL2 110 V (–15%) to 240 V (+10%), 50/60Hz

Nominal voltage UN 110–240 VAC –15 %/+10 %

Nominal current IN 100 mA

Frequency range 47–63 Hz

Type of protection Ex-nA

Color code free end of cable

brown L

blue N

green/yellow PE

Ex

The connection of the supply voltage at the free cable end of the weighing terminal IT1000-AC-*-Ex2/22 is designed for type of protection Ex-nA. The listed nominal connection values must be adhered to. For the connection of the line cord in hazardous area a suitable method must be chosen in compliance with EN60079-0 (e.g. Ex-e, Ex-d). A suitable protection against overload and short circuit in compliance with VDE regulations must be provided.


6.2 Connection Of Power Supply To IT1000-DC-*-Ex2/22 And IT1000-BATT-*-Ex2/22

The supply voltage for the weighing terminal IT1000-DC-*-Ex2/22 is connected at screw terminal KL1 of the CPU1000-24VDC-Ex2/22 (article-No. X1SYS0x5). The supply voltage for the weighing terminal IT1000-BATT-*-Ex2/22 is connected at screw terminal KL1 of the CPU1000-NTA-Ex2/22 (article-No. X1SYS0x6). DC/DC converter

+V 0 V PE Terminal KL1 Terminal KL2 12–30 VDC

Nominal voltage UN: 12–30 VDC +10 % / –15 %

Nominal current IN: 330–100 mA

Cross section (rigid wires): 0.75–1.5 mm2

Cross section (flexible wires with insolated wire end ferrule): 0.75–1.5 mm2

Length of stripped insolation: 6 mm

Fastening torque screw terminal: 0.5–0.6 Nm

Ex type of protection: Ex-nA

Terminal assignment KL1

+ V Supply voltage (+)

0 V Supply voltage (—)

Ex

The connection of the supply voltage to the weighing terminal IT1000-DC-*-Ex2/22 is designed for type of protection Ex-nA. The listed nominal connection values must be adhered to. For the connection of the supply cable in hazardous area a suitable method must be chosen in compliance with EN60079-0 (e.g. Ex-e, Ex-d). A suitable protection against overload and short circuit in compliance with VDE regulations must be provided.


6.3 Operation Of IT1000-BATT-*-Ex2/22 During the power up sequence the current charge state of the battery pack is briefly displayed, followed by program version, date and time. If the indicator is not fitted with a realtime clock module, data and time must be entered anew everytime the unit is switched on. The charge state can also be viewed during running operation. To call up this function briefly press F / Up key three times. The indicator is switched on by pressing the Print / Enter key once, to switch it off press F / Up key for approx. 3 sec. Battery life of a new, fully charged battery pack is max. 40 hours, depending on the connected loadcells and the use of the backlighting. Charge time of a discharged battery pack is approx. 3 hours. Battery life also depends on several other factors such as ambient temperature, number of charge cycles and hardware configuration of the IT1000 terminal.

Note: When the IT1000-BATT terminal is supplied from an external battery, under '\ Service Menu \ General \ Batt' the respective type must be chosen, this choice affects the automatic power off switching when battery is low:

Battery symbol lights up at approx.

Switching off at approx.

24Pb 24 V lead battery 23 V 22 V

12Pb 12 V lead battery 11.5 V 11 V

Line mains operation 10 V 9 V

When battery is low, this is indicated with a flashing symbol at the right hand side of the display. The operator should then recharge the battery. The charging of the rechargeable battery is indicated by a flashing triangle (version 2.29 or higher). To avoid deep discharge of the battery, the IT1000-BATT is automatically switched off when the voltage falls below the min. value. Before this happens, the message 'Low Battery' is shown for approx. 2 min. If the unit is switched on again, 'Low Battery' is shown for approx. 2 minutes and then the terminal is automatically switched off again to avoid deep discharge damage to the battery.


6.3.1 Connecting Cable With Ex Plug For Battery Operation The weighing terminal IT1000-BATT-*-Ex2/22 (article-No. X1SYS0x6) with CPU1000-NTA-Ex2/22 is suitable for connection to an external rechargeable battery box. To this effect the instrument can be supplied with an assembled connecting cable (E3KAB003) with ex plug. This cable must be ordered separately. The following notes must absolutely be observed:

Ex

Absolutely adhere to the operating instructions 'DXN' provided by Marechal

Components must have identical coding, or damages to connector / socket cannot be ruled out.

The connector cable must be firmly installed in a suitable way to protect it against mechanical damage. An appropriate type of cable must be chosen that complies with the thermal and mechanical requirements at the place of installation.

If connectors are not connected correctly, protection against risk of explosion is no longer ensured. Strictly follow the instructions!

Immediately after disconnecting, cover voltage-conducting components with protective cap!

The following rechargeable batteries can be used for the supply of the weighing terminal: 1) AkkuBox Ex; 12 VDC for use in Ex zone 2 and 22

Article-No. E3AKK002 / E3AKK003 2) The use of alternative 12 V batteries is possible. However, when used in hazardous

area they must have appropriate ex protection. The requirements of EN 60079-14 must be observed.

The operating instructions of the rechargeable battery must be observed.

6.3.2 Assignment DXN1 Connector

Top view socket Top view connector

DXN1 Pin Assignment

1 not used

2– GND

3+ +12 VDC

PE Shield

N not used


6.3.3 Instructions For Connecting And Separating Connectors

1. Open protective caps before plugging and check connector/socket for damages. 2. Align male/female connectors along red arrows and insert into groove.

1) 2)

3. Turn connector/socket right by approx. 45° to stop. 4. Plug in connector/socket until they click into place and are held by the blue hook.

3) 4)

Disconnect in reverse order.


6.4 Connection Of Analog Scale To ADM The Analog Digital Module ADM is plugged into the socket ADM on the CPU1000. It provides connection for one analog scale base.

Ex

The connection is designed compliant to type of protection 'Ex-nA'. If the loadcell is to be installed in hazardous area, compliance with the applicable Ex regulations is mandatory. The following connection values must be observed:

ADM Terminal KL1

Signal Description Nominal value

1 +Excitation Output 5 V / 240 mA

2 – Excitation Output 5 V / 240 mA

3 +Sense Input 5 V / 1 mA

4 – Sense Input 5 V / 1 mA

5 +Signal Input 5 V / 1 mA

6 – Signal Input 5 V / 1 mA

Cross section rigid wire: 0.25–1.5 mm2

Cross section flexible wire with insolated wire end ferrule: 0.25–1.5 mm2




Connection of weighing platforms and loadcells is to be made as specified below:

• Max. 16 strain gauge loadcells 350 Ω each • Overall impedance 21.5 Ω ...4500 Ω • W&M approved resolution of 6,000 e at a max. preload of 80%, internal resolution 524,000 d • Smallest permissible input signal for approved applications: 0.33 µV / e • Update rate 50 updates / second • Loadcell excitation: 5 V ±5 %, gated power supply • Connection in 4- or 6-wire mode.


Principal schematics of 6-wire and 4-wire strain gauge loadcell

6-wire loadcell

4-wire loadcell

Connection of 6-wire analog loadcell(s) to the ADM module:

Terminal Assignment

1 +Excitation

2 – Excitation

3 +Sense

4 – Sense

5 +Signal

6 – Signal

Connection of 4-wire analog loadcell(s) to the ADM module: To connect loadcells without sense lines (4-wire connection), two jump leads must be connected at terminal strip KL1 between terminal 1 and 3, and between terminal 2 and 4.

Terminal Assignment

1 +Excitation

2 – Excitation

3

4

5 +Signal

6 – Signal


6.4.1 Connection Cables For Analog Weighing Platforms For the installation of connection cables for analog weighing platforms please follow the recommendations listed below:

• Only use suitable loadcell cable, (e.g. SysTec cable 10KAB214, 3 x 2 x 0.75 mm², shielded) Nominal Voltage of cable ≥250 V. Unsuitable loadcell cable may affect accuracy.

• The shield of the loadcell cable must be connected all around the cable in the cable gland of the weighing terminal (see also chapter 'Installation' / 'Connection Of Cables'). If an extension of the loadcell cable is required use only metal junction boxes and cable glands. The shield on both sides must be connected in the same way as at the terminal. Loadcells and/or weighing platforms, junction boxes and the terminal must be included in the potential equalization of the components of a weighing system. Depending on the situation on site this may require the installation of a separate earth lead of appropriate diameter (e.g. 16 mm²) in parallel to the loadcell cable.

• Distance between loadcell cables and power lines: ≥0.5 m. Loadcell cables to be installed in grounded metal conduits, metal hoses or metal cable trays.

• Maximum length of connection cable between scale base and weighing terminal: 200 m. • If tension load is applied to loadcells instead of compression load, connection for +Signal and

–Signal must be transposed.

6.4.2 Securing Scale Parameters The scale parameters are stored in EEPROM and secured with the jumper W1:

Calibration data secured

Calibration and storing released

W&M approved applications require that the calibration parameters be protected against unauthorized modifications. To that effect the jumper can be sealed with thread and lead seal or adhesive label.

For a description of the scale calibration refer to the respective chapter.


6.5 Connection Of Serial Interface SIM In the SIM socket one of the following interface modules (SIM) can be inserted:

• SIM-RS232 • SIM-RS485 2-wire • SIM-RS485 4-wire • SIM-RS485.OPTO 2/4-wire opto isolated • SIM-20mA CL (passive). Note: If an interface module is installed in the SIM socket, the PIM socket must remain free!

Position of serial interface on CPU1000 board

Insert with notch pointing to the left!

Ex

Peripheral devices are connected at CPU1000 screw terminal KL3. The connection is designed compliant to type of protection 'Ex-nA'. The following connection values must be observed:

SIM-RS232:

CPU1000 Terminal KL3

Description Nominal value

1 GND ±12 VDC

2 — not used

3 — not used

4 — not used

5 TxD ±12 VDC

6 RTS ±12 VDC

7 RxD ±12 VDC

8 CTS ±12 VDC


SIM-RS485-2-wire:



1 — not used

2 — not used

3 — not used

4 — not used

5 A (TxD+/ RxD+) 5 VDC

6 B (TxD– / RxD–) 5 VDC

7 A (TxD+/ RxD+) 5 VDC

8 B (TxD– / RxD–) 5 VDC

SIM-RS485-4-wire: SIM-RS485-OPTO:



1 — not used

2 — not used

3 — not used

4 — not used

6 TxD+ 5 VDC

7 TxD– 5 VDC

8 RxD+ 5 VDC

9 RxD– 5 VDC

SIM-20mA:



1 — not used

2 — not used

3 — not used

4 — not used

6 TXIN 12 VDC / 20 mA

7 TXOUT 12 VDC / 20 mA

8 RXIN 12 VDC / 20 mA

9 RXOUT 12 VDC / 20 mA


The following connection values must also be adhered to:


Cross section flexible wire with insolated wire end ferrule:

0.25–0.5 mm2




Principal schematics of 20mA CL interface (IT1000 only passive)


Principal connecting diagram RS485 network: Terminal assignment: Some manufacturers of components with RS485 interface do not refer to the terminals TX+ and RX+ as 'A', but 'B' instead (correspondingly, the terminals TX– and RX– are not referred to as 'B', but 'A'). Termination resistors: In order to prevent reflection (baud rate 19,200 Baud or higher, and/or cable longer than 20 m) it is recommended to install termination resistors RTerm = 150 Ω on both ends of the cable. Use only twisted pair cables with a characteristic impedance of approx. 150 Ω.

Pull-up / pull-down resistors: When termination resistors are used, also 390 Ω pull-up and pull-down resistors must be installed at the master (see also following schematic).

Ex

If termination and pull-up / pull-down resistors are to be used in hazardous area, specific requirements apply. Contact SysTec service for details.

RS485 network with termination, pull-up and pull-down resistors


For the installation of connection cables for serial interfaces please follow the recommendations listed below:

• Install data cables to prevent capacitive or inductive interference from other cables, machines and/or electrical devices that could interrupt data transmission and lead to loss of data.

• Non-factory made cables must comply with the following specification::

Shielded twisted pair, e.g. LIYCY 3 x 2 x 0.25 mm², shield to be grounded on both sides;

Resistance ≤ 125 Ω/km

Cross section 0.25 mm2–0.5 mm2

Capacitance ≤ 130 nF/km

Cable length 20mA max. 100 m

Cable length RS232 max. 15 m

Cable length RS485 max. 1200 m

Impedance RS485 approx. 150 Ω

Nominal voltage ≥ 250 V


6.6 Connection Of Parallel I/Os PIM The parallel input/outputs on the CPU1000 can be activated by inserting a plug-on module PIM. The module provides drivers for two opto-isolated inputs and two opto-isolated outputs.

Principal schematics PIM

Parallel output Parallel input

Note: If an I/O module is inserted in the PIM socket, the SIM socket must remain free!

Position of parallel inputs/outputs PIM on CPU1000 board


Ex



CPU1000 Terminal KL3 Signal Function Nominal value

1 O V 0 V auxiliary voltage 10 VDC / 15 mA

2 +10 V +10 V auxiliary voltage 10 VDC / 15 mA

3 IN0 Input 0 24 VDC / 7 mA


5 In– Gnd for inputs 24 VDC / 14 mA

6 OUT0 Output 0 24 VDC / 100 mA


8 OUT+ External supply for outputs 24 VDC / 200 mA




0.25–0.5 mm2




Note: The internal 10 VDC supply (KL3, terminal 2) may be used to connect switches and push buttons to the digital inputs (15 mA max.). External devices connected to the digital outputs must always be supplied from an external 24 VDC power supply. If connected components are installed in hazardous area, they must comply with appropriate type of protection, e.g. 'Ex-d'.


6.7 Connection Of Parallel I/Os IOM By installing an IOM plug-on module in the PIM/SIM socket of the CPU1000, one optoisolated input and three optoisolated outputs can be activated. .

Principal schematics IOM

Parallel output Parallel input

Position of parallel input/outputs IOM on CPU1000 board


Ex


Terminal KL3 Signal Function Nominal value

1 O V O V auxiliary voltage 10 VDC / 15 mA

2 +10 V +10 V auxiliary voltage 10 VDC / 15 mA



5 In– Gnd for inputs 24 VDC / 7 mA



8 OUT+ External supply for outputs 24 VDC / 300 mA





0.25–0.5 mm2




Note: The internal 10 VDC supply (KL3, terminal 2) may be used to connect switches and push buttons to the digital inputs (15 mA max.). External devices connected to the digital outputs must always be supplied from an external 24 VDC power supply. If connected components are installed in hazardous area, they must comply with appropriate type of protection, e.g. 'Ex-d'.


6.8 Connection Of 15-Bit Analog Output DAU15 For the output of gross or net weight as analog signal, a plug-on module (DAU15) can be inserted instead of a parallel driver module. The output signal has a 15-bit resolution (32,768 steps. The output of the DAU15 module is active and potential free. Digital outputs and analog output are not possible at the same time. Note: If an analog module is inserted in the PIM socket, the SIM socket must remain free!

Position of analog output DAU15 on CPU1000 board


Ex


Terminal KL3 Signal Function Nominal values

1 – –

2 – –

3 I+ Current output 0/4–20 mA (+) 10 V / 20 mA

4 I– Current output 0/4–20 mA (–) 10 V / 20 mA

5 – –

6 U+ Current output 0/2–10 V (+) 10 V / 20 mA

7 U– Current output 0/2–10 V (–) 10 V / 20 mA

8 – –





0.25–0.5 mm2




Example for current output 0/4–20 mA:

Example for voltage output 0/2–10 V:


7 Commissioning Prior to start up follow the check list below:

Ex

Check to make sure that during commissioning no potentially explosive atmosphere can be present.

Check whether the conditions concerning the intended use are fulfilled (see section 'Intended use').

Check assembly as described in 'Assembly'.

Check of installation (equipotential bonding, connection of external components) as described in chapter 'Installation'.

Check whether installation has been carried out in compliance with EN 60079-14.

Check whether housing is thoroughly closed with all hexagonal srews tightly fastened (torque: 1.1 Nm).

Check to make sure that the components connected to the outputs and interfaces (valves, movable parts) cannot cause any damage, and whether they comply with applicable Ex regulations when they are installed in hazardous area.

Switch on supply voltage.

Configure weighing terminal (interface parameters...) in the Service Mode as described in section 'Service Mode'.

Calibrate scale as described in Calibration Instructions.

Test inputs/outputs, serial interface and scale function in Service Mode as described in section 'Hardware Test'.


8 Installation Examples Shown below are three typical system configurations with the weighing terminal IT1000-Ex2/22. These are principal schematics depicting the options to connect peripheral devices and the connections in hazardous area as well as in safe area. All devices installed in hazardous area must be designed compliant to an appropriate type of protection. All sections of this manual and the installation standard EN 60079-14 must be complied with in full detail.

8.1 Installation Example IT1000-AC-*-Ex2/22


8.2 Installation Example IT1000-DC-*-Ex2/22


8.3 Installation Example IT1000-BATT-*-Ex2/22 With Akku-Box


9 Service Mode 9.1 General The Service Mode is a program for configuration, calibration and hardware test of the IT1000 weighing terminal. The following sections give an introduction on how to operate the terminal via keyboard and display and describe the individual functions of the Service Mode.

Notes:

• IT1000 and its associated equipment must be installed, adjusted and maintained by qualified personnel only!

• Before accessing the Service Mode all peripheral devices must be installed and configured! • Access to the Service Mode is protected by the Service Password. • Inappropriate changes of Service Mode settings may cause malfunction of the instrument!

and

Press simultaneously in the initial step to reset the terminal (warm start).

Press during start sequence to access Service Mode.


9.2 Display And Keyboard

Left-most character on display

1,2,3 = Weighing range

P = Printing

ø = Scale in zero range (±0,2d)

~ = Motion

Indication of weight 3 right-most characters on display

580.1kg = Measured weight NET = Display of net weight, scale is tared

––––––– = Overload

Key Description

F key Show tare weight, enter target value

↑ key Back to previous program step

ClrTotal

Total key Show totals

Clr key Delete parameters (Clr)

+1

Tare key Autotare scale, or clear tare when scale is tared (repetitive tare is also possible)

+1 key Choose menu item or parameter (+1)

00

Zero key Set gross weight to zero (only within zero setting range)

0 key Append '0' in parameter entry (0)

Print

Print key Printing (Print)

↵ key Confirm parameter entry and proceed to next program step (Enter)


9.3 Operator Prompting The following sections describe the operating sequence of the weighing terminal with operator prompts and the requested entries. The display is always shown in a frame on the left hand side.

Passw. ????? Entry of Service Mode password

Prompts or entries that apply only under certain conditions are shown in an extra frame. The condition is shown in bold face in the upper left hand corner of the frame:

Wrong password entered:

Invalid Entry Error message: wrong password

Print key and F key In all program steps, unless otherwise specified, the Print key leads to the next step. Pressing the F key leads to the previous step.

9.3.1 Entry Of Numbers

Sp.1 9999999 Entry of numbers (without decimal point)

Press repeatedly until desired number appears

Press to append a zero, entry is shifted to the left by one digit

Press to proceed to next digit

Confirm entry

Example: Entry of the value 123:

Sp.1 ____100 Display shows the stored value, e.g. '100'

Press, display shows '1'

Press, display shows '10'

Press twice, display shows '12'

Press, display shows '120' display shows

Press three times, display shows '123'

Confirm entry

Note: To delete a digit press Clr key.


9.3.2 Enable / Disable Functions

Printer? 0 Display shows '0', function is disabled

Press to enable function (+1)

Printer? 1 Display shows '1', function is enabled

Press to disable function (0)

Printer? 0 Display shows '0', function is disabled

9.3.3 Choose From Parameter List

Int 999999 Choose from parameter list

Press repeatedly until desired parameter appears

Press to shift decimal point to the left, press repeatedly until desired position is reached

Confirm choice

Example 1: Choose value 0.002:

Int _____1 Display shows '1'

Press once, display shows '2'

Press three times, display shows '0.002'

Confirm choice

Example 2: Choose value 50:

Int _____1 Display shows '1'

Press four times, display shows '50'

Confirm choice


9.4 Weighing Functions The first step in all operating modes is the indication of the actual weight value. In this step scale functions are activated and displayed.

1 11.9kg Display of gross weight; For multi-range scales the number of the currently selected range (e.g. 1) is shown.

ø 0kg Set gross weight to zero (only within zero setting range), the zero range symbol ø is shown.

0kgNET Autotare: Press Tare key to autotare scale.

11.9kg Press Tare key once more to clear tare and return to display of gross weight (function depending on Service Mode settings)

11.9kgT Press F key to display tare weight (operating modes BASIC and COUNT only). Display returns to initial step after 3 sec.

X10 119.03 If F key is pressed once more while tare weight is displayed, the actual weight is shown with tenfold resolution (x10 function). Press F key again to return to initial step or display returns to initial step automatically after 5 sec.


9.5 Power Up When the terminal is switched on the power up messages are displayed and the program proceeds to its initial step.

Version 1.00 Program version

15.03.04 Date

15:06 Time

Basic Selected operating mode

11.9kg Initial step of operating sequence (in the operating modes CHECK and FILL first the target value must be entered).

and

Press simultaneously in the initial step to reset the terminal (warm start).

Press during start sequence to access Service Mode.

Servicemode

Passw. ????? Entry of Service Mode password.

Incorrect password entered:

Invalid Entry Press Print key twice to return to password entry and try again.

Interface Press Tare key to show the individual menu items. Press Print key to choose displayed menu item.

The following menu items can be chosen:

Interface Configure interfaces

Format Configure printout and operating sequence

General Enter parameters

Calibrate Calibrate scale

Test Test hardware

DAU Enter parameters for analog output DAU

Reset Reset parameters (except calibration parameters)

Protocol Print parameter settings

See next page for Service Mode overview.

Saving... Press F key to exit Service Mode and store settings, return to normal operation.


9.6 Overview Service Mode Part 1


Part 2


10 Calibrate Scale 10.1 Entering Calibration Mode Prior to power up the jumper W1 on the ADM board must be removed. Only in this position can the changed parameters be saved in memory after the calibration.

Calibration released

In Service Mode choose the following group:

Calibrate Calibrate scale

Press Zero and Tare key simultaneously to enter Adapt Mode (version V1.44 or higher) to optimize performance of digital filtering.

If jumper W1 is still in place:

Calbr.Locked

Jumper still in place, parameters cannot be saved! Press Print key to enter calibration mode without saving (e.g. to check settings).

The following menu items can be chosen:

Cap&Interval Scale Parameters

Span Adjust Calibration

Linearizat. Linearization

Zero Adjust Zero Adjust

Adaptation Adaptation to environment

Show X10 High Resolution

Reset Reset Parameter

Calc.Span Calculate Span

W&M Info W&M Info (check W&M relevant parameters)


On exiting the calibration, the entered or modified parameters are either stored or ignored:

Save Cal.? 1 Exit calibration, save parameters (1).

Wait... Calibration parameters are stored.

or

Save Cal.? 0 Exit calibration, ignore all changes, do not save data (o).

If jumper W1 still in place:

Err.Cal.Jump. Jumper still in place, parameters cannot be saved!

10.2 Capacity & Interval In this group the weighing range(s), scale interval(s) and the scale unit are selected. The scale can be configured as Single Range, Dual Range or Triple Range Scale. A Single Range Scale can be configured as Multi Interval Scale with two or three different scale intervals. For general information on multiple-range and multi-interval scales see chapter 'Connection Of Scale'.

Cap&Interval Scale Parameters

Single Range Single-range scale (single- or multi-interval scale)

Dual Range Dual-range scale

Triple Range Triple-range scale


10.2.1 Single-Range Scale A Single Range Scale can be configured as Single- or Multi-Interval Scale.

One Interval Scale with one interval

Two Interval Scale with two intervals

Three Interv Scale with three intervals

'One Interval' selected

Cap 999999 Enter capacity of single-interval scale

Int 9999.9

Enter interval of single-interval scale; scale interval list: 0.0001, 0.0002, 0.0005, 0.001, 0.002, 0.005, 0.01, 0.02, 0.05, 0.1, 0.2, 0.5, 1, 2, 5, 10, 20, 50.

Unit: kg Choose a unit. Options: kg, g, t, lb

or:

'Two Intervals' selected:

HiCap 999999 Enter capacity of highest range

HiInt 9999.9 Enter interval of highest range Note: The number of trailing decimals must be identical in all ranges. *)

LowCap 999999 Enter capacity of lowest range

LowInt 9999.9 Enter interval of lowest range. *)


or:

'Three Intervals' selected:



MidCap 999999 Enter capacity of middle range

MidInt 9999.9 Enter interval of middle range. *)





10.2.2 Dual-Range Scale






10.2.3 Triple-Range Scale



MidCap 999999 Enter capacity of middle range

MidInt 9999.9 Enter interval of middle range. *)




*) Intervals for multiple-range or multi-interval scales must be specified with identical number of trailing decimals for all intervals. If -for instance- a scale is to be calibrated with 3 ranges and increment sizes of 2 kg, 1 kg and 0.5 kg, these increments must be entered as 2.0 kg, 1.0 kg and 0.5 kg.


10.3 Span Adjust The zero calibration and maximum load calibration are performed in this group. Instead of calibrating to maximum load, a calibration with partial load is also possible. The Geo Value entry permits the calibration at one place even if the scale is to be operated at a different location. This compensates for the different forces of gravity without recalibration (not for W&M approved applications). By means of entering the rated signals (mV/V), a scale can also be precalibrated without test weights (see also chapter 'Calibration Without Test Weights').

Example for a calibration of a hopper scale:

• 3 loadcells with a capacity of 1,000 kg each with a sensitivity of 1.99995 mV/V, 2.00005 mV/V and 2.00000 mV/V are used.

• The scale capacity is 1,500 kg with a division of 0.5 kg. • The weight of the empty hopper is 600 kg.

Zero point Capacity point

Span Adjust Calibrate scale

If linearization points are already stored:

Fixp. active Warning: Linearization points are already set that may effect the following calibration. Display for approx. 2 sec.

Geo Value 20

Entry of Geo Value (0 to 31). Enter the applicable Geo Value of the calibration location (see also chapter Geo Values). If Geo Value of place of installation is different, that can be changed later.

Cal.Zero? 1 If calibration at zero is to be carried out (1), unload scale before proceeding; if zero is already calibrated, this step can be skipped (0).


'Cal.Zero? 1' selected (calibrate scale at zero):

Calibrating.. Zero calibration is carried out

Zero: 0.0 Weight display with tenfold resolution (for verification)

Z-mV 0.40000

Display of rated signal See 'Calculate Span'. Note: The signal in millivolt can be obtained by multiplying the displayed mV/V value with the 'Excitation' (5 V or 10 V).

Note: If Zero calibration parameters are to be stored before the Span calibration is carried out, the setup must be exited at this point of the sequence (in step 'Span Adjust' press F key and confirm question 'Save Cal.?' with '1'). After that 'Span Adjust' can be called up again to proceed with calibration, Zero calibration can now be skipped.

Cal.Load? 1

If calibration at load is to be carried out (1), load test weight; if load is already calibrated, this step can be skipped (0). For best results use the highest possible calibration load.

'Cal.Load? 1' selected (calibration with test weight):

Cal.W.____123 Proposed calibration weight. Default: capacity of highest weighing range. If required, clear displayed default value and enter desired calibration weight.

Calibrating.. Calibration is carried out.

Load: 0.0 Display of weight with tenfold resolution (for verification).

L-mV 1.40000

Display of rated signal See 'Calculate Span'. Note: The signal in millivolt can be obtained by multiplying the displayed mV/V value with the 'Excitation' (5 V or 10 V).

To store calibration parameters exit group 'Span Adjust' and answer question 'Save Cal.?' with '1'. Note: If changes of calibration parameters are to be ignored, setup must be exited and question answered with '0' before any other group of the calibration may be called up.


10.4 Linearization Certain weighing inaccuracies are the result of the inherent non-linearity of the load sensor. Up to 6 linearization points can be set freely to compensate this imperfection. Linearization points should be entered at the points of the weighing curve where the greatest deviations (i.e. max. non-linearity) are experienced. Linearization points must be smaller than the max. weighing range. The linearization algorithm interpret the sections between two neighboring linearization points as a straight line.

Linearizat. Linearize scale

No linearization points stored yet:

New Lpt.? 1 Enter new linearization point with (1).

Lpt.? __150.0 Enter linearization weight, presently loaded on scale.

Linearization Measuring the linearization signal.

X10: 150.00 Display of actual weight with tenfold resolution (for verification).

New Lpt.? 1 Continue with next linearization point (1) or exit linearization (0).

or

Linearization points already stored:

Lpt.1 1500.0 Display existing linearization points in rising order.

Lpt.2 2100.0 Next linearization point, up to 6 points can be stored.

New Lpt.? 1 Enter new linearization point with (1) or exit linearization (0).

Delete linearization point:

Lpt.1 1500.0 Choose linearization point that is to be deleted and press Clr key.

Del.Lpt.? 1 Delete linearization point with (1).

New Lpt.? 1 Enter new linearization point with (1) or exit linearization (0).

Note: A new fixpoint can be inserted between existing ones, after that all fixpoints are renumbered in rising order.


10.5 Zero Adjust In this group the scale's Zero point is readjusted. This feature is useful when the calibration load was applied on an auxiliary test rig (e.g. for overhead track scales). After removing the test rig, the absolute Zero point can be adjusted.

Zero Adjust Adjust zero point

If linearization points are already stored:

Fixp. active Warning: Linearization points are already set that may effect the following calibration. Display for approx. 2 sec.

Unload Scale Unload test rig or other loads. Press Print key to start adjustment.

Adjusting... Measuring zero signal.

Zero: 0.00 Display of the new zero point with tenfold resolution (for verification).

Z-mV 0.05701 Display of rated signal of the new zero point in mV/V

10.6 Adaptation In this group parameters are entered to adapt the scale to its environment.

Adaptation Adaptation to environment

MotWin 0.5D

Motion Window A stable weight is detected (no motion) when the number of consecutive weight readings (specified in the next step) are within this window. Window size: 3.0D, 2.0D, 1.0D, 0.5D OFF: motion detector off

MotCount 20

Motion Count Specify the number of consecutive weight readings for no motion detection. (Factory setting: 20)

Filter 11

Filter Size OFF: filter off 1 (light) to 20 (strong) filtering; Off: No filtering Default setting: 11 If the scale is very unstable (e.g. livestock scale) a strong filtering is recommended.

AZ Range 0.5D

Auto Zero Range Range for Automatic Zero Adjust, (e.g. choose 0.5D for a range from –0.5D to +0.5D). Zero tracking is enabled within the selected range. OFF: Disable Zero Adjust


PbZero + __2

Push Button Zero + Select +range for Pushbutton Zero and Auto Zero Tracking. The scale can be set to Zero by pressing the Zero key within the specified range. Factory setting: 2 %

PbZero - __2

Push Button Zero — Select —range for Pushbutton Zero and Auto Zero Tracking. The scale can be set to Zero by pressing the Zero key within the specified range. Factory setting: 2 %

PUZero +/-2 %

Power Up Zero Select range for automatic Zero setting after power up, (e.g. select 2% for a range from –2 % to +2 % of the scale capacity). After power up the scale will be automatically set to Zero if the weight is within the selected range.

Range: ±2 %, ±10 %; OFF: Disable Power Up Zero.

Overload ___9

Overload Blanking (in D) Select the threshold for overload blanking, (e.g. enter 9 to set the limit to capacity + 9d). The scale display shows 'Overload 9' when the scale weight exceeds the selected limit. (For multiple-range scales, 1d is equal to the increment size of the smallest weighing range.)

Incl.Swi.? 0

Connection of incline sensor for mobile weighing on parallel input IN1, options: 0 = no incline sensor 1 = incline sensor connected

• If an incline sensor is connected and the permissible inclination exceeded, the display of the indicator is blanked. Instead of the weight only a slash '/' is shown.

• When an incline sensor is connected, external taring via input IN1 is not possible.

NTEP App? 0

Set measuring parameters compliant to US regulations (National Type Evaluation Program) in accordance with Handbook 44. 0 Off (Default) 1 On Note: Must be set to Off for all applications outside the US and Australia!

Underld.20d 1

Display blanking for gross weights smaller than –20d (under zero): 0 Disabled 1 Enabled (default) For applications compliant to OIML R76 underload blanking must be enabled

With Taring 1

Enable / disable tare functions: 0: Tare functions disabled 1: Tare functions enabled (default) For scales working only in gross mode, the tare functions can be disabled to avoid the tests of the tared scale during W&M verification.


Upd.Rate 225

Choose update rate of digital filter: Range: 50–250 Hz Default setting: 225 Hz. If vibrations are experienced at the place of installation, the setting of the digital filter can be optimized. The update rate should be chosen to differ as much as possible from the frequency of the vibration and its harmonics.

10.7 Show X10 In this group the weight is shown with tenfold resolution. Use this group to check the scale accuracy.

Show X10 Weight display with tenfold resolution

X10: 7.77 Displays the actual weight with tenfold resolution (for information only).

Set zero


10.8 Reset Calibration Parameters In this group the scale parameters can be reset to default values. After resetting the parameters the scale must be reconfigured.

Reset Reset Parameters

Reset Cal.? 1 0: Do not reset parameters 1: Reset parameters (see table).

Note: By choosing (1) all parameters are overwritten immediately!

Table of default values:

Group Parameter Default Your settings

Cap&Interval Single/Dual/Triple Range Single Range

Interval One Interval

Capacity 3000

Interval 1

Unit kg

Span Adjust Geo Value 20

Zero (mV/V) 0.00000

Load (mV/V) 2.00000

Adaptation Motion Window 0.5D

Motion Counter 20

Filter Size 11

Auto Zero Range 0.5D

Pushbutton Zero (+) 2%

Pushbutton Zero (—) 2%

Power Up Zero ±2%

Overload 9

Incline Switch 0

NTEP approval 0

Underload 20d 1

With Taring 1

Update Rate 225


10.9 Calculate Span When the rated output signal of a scale's loadcell(s) is known, calibration can be made without test weights. This information is available, for instance, for loadcell types D1, C2 and C3 OIML, for which test reports are issued by the manufacturer stating the rated output in mV/V. A prerequisite is that the unloaded scale can be calibrated at zero, which is usually the case.

Calc.Span Calculate Span

Cal.Zero? 1 If calibration at zero is to be carried out (1), unload scale before proceeding; if zero is already calibrated, this step can be skipped (0).

'Cal.Zero? 1' selected (calibrate scale at zero):

Calibrating.. Zero calibration is carried out

Zero: 0.0 Weight display with tenfold resolution (for verification)

Z-mV 0.05701 Display of rated signal for zero

LC-Cap 999999 Enter nominal capacity of one loadcell

No.Of LCs Enter number of connected loadcells (max. 16)

S1-mV 9.99999 Enter rated signal of first loadce

Date post:	02-Feb-2021
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