INSTROTECH 4004 Manuel utilisateur

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

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

Enter

Programming menu

Move to next digit

Increment digit / change selection

Alarm LEDs

(illuminated whenever

relays are energised)

2 3 41

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

All dimensions in mm

During normal display mode Display & Keypad

Page 5

O-ring sealing

gasket supplied

as standard

DIN 1/8 cutout

Min

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

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

Model 4004

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

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

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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