Kistler-Morse Weigh II Installation And Operation Manual Download

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Appendix F. Technical Drawings

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Summary of Contents for Weigh II

Page 1: ...llowed precisely to ensure proper operation of the equipment 97 1120 01 Rev D January 2005 15 00 U S O Or rd de er r f fr ro om m C C A A B Br ri ig gg gs s C Co om mp pa an ny y 622 Mary Street Suite...

Page 2: ...gnal processor To avoid damage follow these precautions 1 Disconnect the sensor transducer cables from the signal processor 2 Ground the welder as close to the welding joint as possible 3 Always groun...

Page 3: ...ling Holes in Enclosure 2 1 Wiring Power 2 2 Wiring for Optional PCBs 2 2 Sealing Openings in Enclosure 2 2 Power Fuse Information 2 3 Installing PCBs 2 3 Chapter 3 Menu Tree Keyboard Functions and Qu...

Page 4: ...uction 5 1 SetPt 5 1 Descriptions 5 1 Set 5 1 Report 5 2 Delete 5 3 Add 5 3 Setting Up the Setpoints 5 3 Setpoint Report 5 4 Iout 5 5 Descriptions 5 5 Set 5 5 Mode 5 6 Rprt 5 6 Delete 5 6 Add 5 6 Sett...

Page 5: ...ters 6 7 Manual 6 8 Displaying the Manual Calibration Parameters 6 9 Resetting the Manual Calibration Parameters 6 9 Linear 6 9 Chapter 7 Service 7 1 Introduction 7 1 K M Service Code 7 1 ADC 7 2 Disp...

Page 6: ...sum Calculation C 3 Examples C 4 Command K M Product Identification Number C 4 W Command Engineering Units gross C 4 B Command Engineering Units net C 4 T Command Tare Addressed Vessel C 4 u1 Command...

Page 7: ...of Programmable Logic Controllers PLCs The motherboard inside the Weigh II enclo sure has three Printed Circuit Board PCB card positions Optional modular PCBs plug onto the motherboard and are accesse...

Page 8: ...tion of the quantity of material in the vessel However the Weigh II can be set up to display weight level volume percentage voltage or current associ ated with the material quantity see Chapter 4 Dis...

Page 9: ...cations for environmental specifica tions before mounting the Weigh II Follow this procedure to mount the Weigh II 1 Hold the Weigh II enclosure against the wall in the desired location and mark the p...

Page 10: ...ly for the Weigh II are as follows AC Powered Versions 100 VAC or 115 230 VAC switch selectable DC Powered Version 24 V 10 2A Refer to the following drawings in Appendix F TI SP W2 02 for single point...

Page 11: ...he following items PCB Two 4 40 x 1 4 PHS screws to secure the PCB to the Weigh II motherboard Refer to the applicable drawing in Appendix F for PCB slot locations and wiring details and follow this p...

Page 12: ...2 4 Chapter 2 Hardware Installation...

Page 13: ...tracking functions to reduce the effect of noise and drift reset param eters to default values calibrate 0 4 20 mA output and set up a user access code The menu tree in Figure 3 1 shows the Main Menu...

Page 14: ...Timed PDly lbs gal V Kgs Ltr ft mV tns Brl in mA Val Dead Disp Chapter4 I O Chapter5 Net Grs Fsafe Hi Lo 0 20ma 4 0ma 20ma Net Grs Baud Addr Mode Printer Slave Menu Level 4 Figure 3 1 Weigh II Menu T...

Page 15: ...l Chapter6 Service Chapter7 LoSpan HiSpan Zero_Cal Disply Reset On Off Set Test Enabe Step Qlfy DSPfact Win Matrl Rate Dflt Dlim Mon IDrst Prnt RsRAM KeyT RamT ScfCnt ScfWgt Zero_Cnt Disply Reset User...

Page 16: ...odes When the Weigh II is in the Auto Mode the display remains on one vessel for a preset period of time before scrolling to the next vessel The preset display time can be changed to suit the operator...

Page 17: ...the Disp Menu pressing the Esc Key while the display is vessel monitoring in the Manual Mode Auto LED off briefly displays the factory set ID Tare Net Gross Key The Tare Net Gross Key is used when ves...

Page 18: ...y is also used in conjunction with other keys on the panel to provide additional alphanu meric characters The Shift Key is also used in conjunction with the Tare Net Gross Key Enter Key The Enter Key...

Page 19: ...d for selecting these parameters for each vessel 2 Calibrate the system for each vessel using one of the following methods If you can move at least 25 of the vessel s maximum live load as part of the...

Page 20: ...3 8 Chapter 3 Menu Tree Keyboard Functions and Quick Start...

Page 21: ...gs from 1 to 255 the Weigh II averages for each display reading while vessel monitoring The Weigh II calcu lates a running average The larger the number of individual readings in the running average t...

Page 22: ...th the accuracy of the system and reduce display flickering Example For a 10 000 lb maximum weight with a Form of XXXXX a Cntby of 1 would only be meaningful if your system accuracy was 01 of maximum...

Page 23: ...he Main Menu The display shows 4 Press the F1 Key to access the Display Menu The display shows 5 Press the F3 Key to access the Units Menu The display shows 6 Press the F1 Key to access the common Men...

Page 24: ...the Auto Man Key to put the system in Manual Mode The Auto LED turns off 2 Use the Up Arrow or Down Arrow Keys to scroll to the desired channel 3 Press the Menu Key to display the Main Menu The displa...

Page 25: ...ssel monitor ing The current selection is indicated by an asterisk If enabled the bar graph displays for the vessel while vessel monitoring in both Manual and Auto modes While in Manual mode pressing...

Page 26: ...y pressing the Enter Key The display flashes a message acknowledging your selection and returns to 12 Press the Esc Key to scroll up the menu tree or press the Auto Man Key to return the display to ve...

Page 27: ...display If you do not set a non zero Lo value the display may show a small negative gross weight when the vessel is near empty if the calibration of the system is not 100 percent accurate The Zclmp fu...

Page 28: ...Auto Man Key to return to vessel monitor ing While in vessel monitoring in the Manual Mode press the Shift Key Shift LED illuminated and then press the 9 Key to enable the Hide function The display a...

Page 29: ...he setpoint value is the weight measurement in a vessel where you wish a device for example a pump to activate or deactivate The setpoint setup functions for each vessel are accessed in this menu They...

Page 30: ...the setpoint relay changes state can be entered This value is entered directly with the Alpha numeric Keys or scrolled to with the Up and Down Arrow Keys The Key is used to toggle between the positiv...

Page 31: ...the Weigh II is in Auto Mode Auto LED illuminated press the Auto Man Key to put the system in Manual Mode The Auto LED turns off 2 Use the Up Arrow or Down Arrow Keys to scroll to the desired channel...

Page 32: ...ion and then returns to 17 Press the Menu Key to access the second page of the menu The display shows 18 Press the F1 Key to access Net Grs The display shows An asterisk indicates the current selectio...

Page 33: ...ints where the transmitter outputs the currents designate those values as net or gross weights and define a fail safe condition for the current outputs The 4 0ma Menu sets the low current 4 mA or 0 mA...

Page 34: ...ber The bottom line shows the slot number of the 4 0 20 PCB and the channel number for the current output on the 4 0 20 PCB Pressing any key other than Esc or Auto Man toggles between the assigned cur...

Page 35: ...ey for 0 to 20 mA The display flashes a message acknowledging your selection and returns to 12 Press the F1 Key to access the Set Menu If you added one output proceed to Step 13 If you added two outpu...

Page 36: ...dditional outputs if desired 24 Press the Esc Key to scroll up the menu tree or press the Auto Man Key to return the display to vessel monitoring Current Output Report The Weigh II allows you to view...

Page 37: ...cribed below Baud The baud rate bits per second is set up in the Baud Menu The baud rate determines the speed with which the Weigh II communi cates with the PLC printer etc There are five baud rates a...

Page 38: ...eight time and date GO ALL This menu allows the user to print out the current gross weight and net weight for all enabled vessels The printout looks the same as for GO1 Timed This menu allows the user...

Page 39: ...ion data 3 Linear used to set up and turn on and off the linearization table Use of this function may be required if your vessel s structure responds non linearly but consistently to changes in load r...

Page 40: ...y empty the vessel 2 If the Weigh II is in Auto Mode Auto LED illuminated press the Auto Man Key to put the system in Manual Mode The Auto LED turns off 3 Use the Up Arrow or Down Arrow Key to scroll...

Page 41: ...e greater the resulting error The location of the line can be adjusted to the solid line by setting zero point 3 in Figure 6 3 see Refining the Calibration by Setting Zero in this section 9 Add a know...

Page 42: ...lashes a message acknowledging your selection and returns to 8 Add a known quantity of material repre senting at least 25 of the vessel s total capacity to the vessel 9 Press the F3 Key to access HiSp...

Page 43: ...in Figure 6 3 Similarly to the other calibration methods the greater the known quantity of material moved during the calibration procedure the greater the accuracy Removing 50 of the total capacity re...

Page 44: ...ibration of the Weigh II when it is practical to empty the vessel and refine the calibration The Zero_Cal function may be used to compensate for the following circumstances The estimated weight value...

Page 45: ...digital counts corresponding to the hi span weight L_SPAN_C lo span counts number of digital counts corresponding to the lo span weight ZERO_WGT entered zero calibration weight if performed Zero_Cal o...

Page 46: ...D turns off 2 Use the Up Arrow and Down Arrow Keys to scroll to the desired vessel 3 Press the Menu Key to display the Main Menu The display shows 4 Press the F3 Key to access the Cal Menu The display...

Page 47: ...key other than the Esc or Auto Man Key to cycle through the parameters 4 Press the Esc Key to scroll up the menu tree or press the Auto Man Key to return the display to vessel monitoring Resetting th...

Page 48: ...ffect on the Weigh II even if linearization is On Raw Value Corrected Value 1048576 1048576 1112576 1112576 1176576 1176576 1240576 1240576 1304576 1304576 Table 6 1 Default Linearization Table Consul...

Page 49: ...ay then switches to a display that looks like this 11 Repeat Steps 9 and 10 as desired until you have completed your setup of the linearization table 12 Press the Esc Key to scroll up the menu tree or...

Page 50: ...6 12 Chapter 6 Calibration...

Page 51: ...o default parameters and test the non volatile RAM 5 Access allows you to set up a user defined access code also allows you to enter the KM Mfg Code which is needed when performing certain troubleshoo...

Page 52: ...roed by pressing the Enter Key while viewing this display The maximum value is 255 When d exceeds 255 the number is replaced by on the display The third page of the display looks like this 04 is the f...

Page 53: ...all of the channels in the system Effective Resolution Conversion Time bits mS 16 25 17 50 18 83 19 125 20 250 21 512 Table 7 1 Effective Resolution Gain Adjusting the gain increases or decreases sens...

Page 54: ...ial output as well as the vessel monitoring display Filter has four submenus Enabe Enabe turns the filter function on and off The default is Off Step Step is a window of equal counts above and below t...

Page 55: ...r gain and sensor drift is accomplished by comparing the total drift to a user defined limit The Weigh II limits the maximum correction to this user defined limit so that the tracking function does no...

Page 56: ...s the zero calibration point The default value is 00 mV at this default value zero tracking is turned off Matrl This function turns material tracking on and off The default is Off Rate This function s...

Page 57: ...isplay shows 2 Next F1 scrolls the display forward through all the current channels Back F2 scrolls the display backward through all the current channels Scroll to the desired current channel using th...

Page 58: ...for each vessel test the nonvolatile RAM and reset the nonvolatile RAM to default parameters It has the following submenus IDrst This function resets the user defined ID for all channels After this fu...

Page 59: ...010 to access this function unless you have already entered it during this Manual Mode session and requests verification before it resets the NVRAM to prevent accidental reset of the NVRAM Access This...

Page 60: ...is required to access hidden menus which are typically only used by Kistler Morse personnel for troubleshoot ing and testing the equipment The KM Mfg Code also allows the user to change values in the...

Page 61: ...feet to provide additional information on the vessel contents When in the Math Menu the display shows the math equation on the top line and the available functions on the bottom line For a single poin...

Page 62: ...nnel 5 Left parenthesis function Used with right parenthesis to group math func tions together Right parenthesis function Used with left parenthesis to group math functions together CLR Clear function...

Page 63: ...rrect equation with more than three constants and the use of multiple math channels to create a correct equation Incorrect contains more than 3 constants C5 10 C3 100 C2 1000 C4 10000 C1 Correct C6 10...

Page 64: ...f 2 Use the Up Arrow or Down Arrow Key to scroll to the desired math channel Note that for a single point system channels 2 through 8 are available for math channels For a multi point system channels...

Page 65: ...After you input the equation and press the Enter Key the Weigh II will not be able to compile the equation and will respond with a compile error code After you input the equation and press the Enter K...

Page 66: ...h error code suggestions for correcting the error are included where applicable 1 Equation tries to divide by zero 2 Equation tries to take a square root of a negative number that is calculated as par...

Page 67: ...Span 5 ppm C Common Mode Rejection 92 db min DC 150 db min at 60 Hz Normal Mode Rejection 100 db min 60 Hz Option Cards Input card 4 vessel input card PLC Interface Option Allen Bradley RIO 32 channel...

Page 68: ...A 2 Appendix A Product Specifications...

Page 69: ...et Weight or vice versa Make sure the Shift Key is off Shift LED is not illuminated Then press the Tare Net Gross Key Switch from Numerical display to Bar Graph display or vice versa for a particular...

Page 70: ...B 2 Appendix B Summary of Commands Used When Vessel Mounting Hot Keys...

Page 71: ...mmand Table Command Function Transmitted by Received by Master to Master from Weigh II Weigh II Hex ASCII 23 KM product identification number aa ssr Addssr A8068r for Weigh II 57 W Request engineering...

Page 72: ...added between or A and checksum characters See Checksum Calculation in this chapter for an explanation of how checksum is calculated Note that the character in place of the checksum characters is a wi...

Page 73: ...the Hex values of all characters between and ss 03W ASCII 30 Hex 33 Hex 57 hex BA Hex 0 3 W Therefore the ASCII string transmitted to the Weigh II is 0 3 W B A CR 3E 30 33 57 42 41 0D Hex Response The...

Page 74: ...ddssr Format 01WB8r A 000710386r Example B Command Engineering Units net This command is sent by the master to request the Weigh II to send the net engineering units weight level etc For this example...

Page 75: ...ces at your request Contact Kistler Morse for rate and scheduling informa tion for the following services Technical application startup and troubleshooting assistance on site Training on site or at ou...

Page 76: ...eshoot systems for mechanical electrical calibration and wiring errors Normal component repair and wiring errors will be corrected including replace ment of non repairable printed circuit boards Servi...

Page 77: ...Appendix E E 1 This appendix not used at this time...

Page 78: ...Appendix E E 2...

Page 79: ...ifications TI SP W2 02 Interconnect Diagram Single Point Weigh II TI SP W2 03 Interconnect Diagram Multi Point Weigh II TI SP W2 CMB 01 RevA Wiring Diagram Relay Setpt 4 20mA Output Weigh II AC TI SP...

Page 80: ...Appendix F Technical Drawings F 2...

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Page 111: ...vessel What makes a pre calibration not as accurate as a calibration procedure performed when you actually move material A pre calibration does not take into account the actual struc tural response t...

Page 112: ...Write down an estimate of the current live load in the vessel and call it EstLL 4 Write down the maximum live load for the vessel and call it MaxLL 5 Calculate the values for the pre calibration Scale...

Page 113: ...ity has units of mV Rated Load lb Also write down the Rated Load for your sensor 2 Calculate the values for the pre calibration Scale Factor Weight Load Cell Rated Load x the number of legs Scale Fact...

Page 114: ...play shows 5 Press the F3 Key to access the Cal Menu The display shows 6 Press the F3 Key to access the Manual Menu The display shows 7 Press the Menu Key to access the second page of the Manual Menu...

Page 115: ...00 lbs of material the actual weight change is 47 600 lbs 47 600 lbs 50 000lbs current scf_cnt corrected scf_cnt 47 600 50 000 952 952 current scf_cnt corrected scf_ent This procedure will change the...

Page 116: ...Appendix G Calculation of Maunal Calibration Parameters G 6...

Page 117: ...Hi Span Solutions 1 Verify that you entered the correct weight for the Lo Span Reenter the Lo Span if necessary 2 Verify that the correct amount of material was actually moved 3 If the Lo Span you en...

Page 118: ...other chan nels 6 ADC Overrange Explanation The sensor input is causing the counts to go above 2 097 151 if or to 0 if because one of the legs of the excitation voltage is not functioning Solutions 1...

Page 119: ...ximum value of 99999900 Make sure that the form is consistent with the maximum expected value 2 Check the Units you selected for the channel For example a value in tons is 2000 times greater than a va...

Page 120: ...s a problem with the input equation Solution See Chapter 8 Math Channels for a detailed list of the math error messages and solutions O Or rd de er r f fr ro om m C C A A B Br ri ig gg gs s C Co om mp...

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