BRC--BCS Weighng System

1) LOAD CELLS
The overall dimensions of load cells series CN are shown in. the enclosed drawing A-5390.
It is recommended that the load cells are installed in vertical position, between parallel
surfaces. An earthing wire has to be provided, to connect the weighed structure to earth; in
any case any welding on the weighed structure after installing the load cells is prohibited.
Each load cell is provided with a 4-wires shielded connecting cable; con- necting pattern as
follows:
• EXCitation blue ~- EXCitation black
• §IGnal red
• SIGnal white
If any reason occurs to think that a load cell is damaged (the indication is erratic, or utterly
unreliable), perform the following tests for each load cell, using a digital multimeter:
• Disconnect completely the load cell from the junction box, and measure the resistance
values at the ends of the measuring bridge: -

• the output resistance (between + and - signal wires) must match the nominal value
written on the plate (350 ohm), + 2 ohm

• the input resistance (between + and - excitation wires) must be higher (370+420
ohm); different load cells can have different resistance values, due to the fact that the
calibration resistors are calculated for each load cell.

If different values are measured (twice the above values, or 0), it means that the measuring
bridge is, respectively, broken or in short-circuit
• Measure the resistance between one wire and ground; this value must be high (at least
20 Mohms); if it is lower, it means that the isolation is reduced.
Caution: a test voltage higher than 40 V must never be used for the isola- tion test
• Connect the +/-EXC wires and measure the output signal; if it is higher than 10 mV, it
means that the load cell calibration is altered.
In any case, if a failure is detected, the repair and tests shall be carri- ed out in the
manufacturer's laboratory.
The resistance values have to be measured after disconnecting the instru- mentation; the
above values will be measured if each load cell is discon- nected from the junction box,
 BRC--BCS Weighng System

otherwise these values should be divided by the number of load cells which are parallel
connected in each weighing sys- tem (usually four). Saeed
BCS tals
The load cell is giving an output signal which is proportional both to the applied load and to
the excitation voltage; the normal sensitivity is 2 mV/V at rated load, which means that a
load cell having a rated load of 150 tons, if the supply voltage is 5 V DC, will give an ouput
signal of 10 mv when subject to a compression force of 150 tons.
A problem concerning the load cells can be supposed if the following events are occurring:
The indicator is displaying the overrange failure (the central segments of all digits are lit),
but the weight on the load cells is not exceeding the instrument range. In this case, the first
thing to do is checking the continuity and polarity of all the electric connections.
If all connections are OK (this means that the supply voltage of 5 V DC reaches the
excitation wires of the load cells, the output signal (mV) has to be measured: if a very high
signal is detected (some hundreds of mV), a measuring bridge is likely to be interrupted;
this will. be found out by disconnecting all load cells and measuring the resistance values of
each one (a load cell whose bridge is broken will have a resistance value about the double
of the nominal one, or infinite).
If the output signal of a load cells is higher than the normal (more than 10 mV), but the
resistance value is correct, it means that a damage has occurred (an overload would be the
likely cause of this failure).
The signal received by the instrument is always zero: if the supply vol- tage is OK, the cause
could be a short circuit of the signal wires along . the connections.
The indication is somewhat erratic, while the weight on the load cells is steady: this can be
due to a low isolation between the measuring circuit and ground; disconnect the cable from
the indicator, and measure the re- sistence between one wire and ground; this value must
be high (at least 20 Mohms); if it is lower, it means that the isolation is reduced. The
measure has to be repeated after disconnecting the load cells and the various sections of
cables, in order to find the origin of the problem.
The signal from the load cells is steady, but the weighing measures of the same weight are
not repeteable and/or the indication is not returning to zero when the weight is removed.
In this case, the problem is likely to be due to mechanical factors, such
a
s, for instance:
the object to be weighed is in touch with fixed structures outside the load cells, so that
some weight is not measured
 BRC--BCS Weighng System

the beams on which the object is put is not free to deliver the force on the load cells due to
pieces of scrap, liquid steel projections, and so on, which are forced between the beams and
the main structures
the ties - if any - which prevent displacement of the load cells are generating frictional
forces that affect the measurement bP a aa) cS toe ee tal
2) JUNCTION BOXES
Three junction boxes are provided for each arm: in the first two boxes each pair of load
cells has to be connected, while the cables coming from these boxes will be connected in
the third box.
The grey painted aluminium junction boxes (overall dimensions per enclosed dwg. A-4262)
are provided with cable clamps: two boxes have two PG7 clamps for load cells cable, and a
PG11 clamp for output cable; the third box has three PG1l1 cable clamps.
The wiring diagram is shown in the enclosed dwg. A-4263: the 6-wires cables used for
connection among the junction boxes will be connected putting together the wires EXC-
and SEN- (ap post EXC-) and the wires EXC- and SEN- (at post EXC-) in the entry posts of
the third box, while the output cable of this box will be connected at six wires, both in the
output posts of the box and at the terminal board of the electronic apparatus.
3) INSTRUMENT INSTALLATION
Digital indicator M748 is set in an aluminium box, IP55 protection, overall dimensions
253x217x95 mms (see enclosed dwg. A-4577).
The front of the instrument consists of a polycarbonate keyboard with a red window for
the 7 segment LED display. The binding post connectors for the supply voltage line, the
transducers and I/O connection are located at the lower side; the wiring diagram is shown
in the enclosed drawing A-6742. :
Note: the instrument can be provided with a second analog input (not in this
configuration): the posts SIG2+ and SIG2- must be not connected.
The AC supply voltage shall not differ more than + 10% from nominal value written on the
rear plate, and it will be, as much as possible, noiseless.
Warnings according to IEC 348 safety requirements for electronic apparatus:
The instrument shall be connected to a supply circuit, including a line switch or another
suitable device to switch off the line power.
Before energizing the instrument, be sure that it is configured for the supply circuit voltage,
and that all the connections have been properly carried out according to the connecting
pattern.
When the instrument is connected to the supply circuit, the binding posts can become
dangerous, and the opening of covers or the moving of parts (ex- cept for those accessible
by hand) can expose dangerous parts.
 BRC--BCS Weighng System

Be sure that only fuses of the required current rating are employed as spa- re parts. The
use of refurbished fuses and the short circuiting of the fuse holder is prohibited. =
The instrument shall be disconnected from all voltage supplies before ope- ning for
adjustment, replacement, maintenance or repair; the inside capaci- tors can remain
charged also after disconnecting the instrument from the voltage supply.
T=D=12-1287 0607
Every adjustment, maintenance and repair of the instrument open and with line power on
shall be avoided as far as possible, and, if it is necessary, shall be performed only by skilled
personnel, fully aware of the hazard involved in the operation.
If any reason occurs to fear that the instrument is unsafe (when it shows physical damages,
or does not function anymore, or it is stressed beyond the tolerable limits during storage or
transportation), the instrument shall be turned out of service, and any accidental operation
shall be prevented; the damage identification, repair and tests must be performed by the
manufacturer.
4) INSTRUMENT SETUP The instrument is delivered with the required range and reading
resolution; these parameters can be changed as follows:
• press the key [S] and, keeping it pressed, press the key {Enter}: all
LEDs are blinking; enter the number 5, then confirm it with [Enter]; the current resolution
(the increment of LSD) is displayed:
Using the numeric keys, set the new desired value (1, or 2, or 5) chec- king that the value is
correct, then confirm it pressing [Enter].
• press the key [S] and, keeping it pressed, press the key [Enter]: all LEDs are blinking;
enter the number 6, then confirm it with [Enter]; the current number of decimal digits
is displayed:
Using the numeric keys, set the new desired value, checking that the va- lue is correct, then
confirm it pressing [Enter].
After installing and connecting, switch on the apparatus and wait at least 15 minutes, so
that the thermal steady condition is reached.
In order to suppress the tare weight, press the key [S] and, keeping it pressed, press the key
[0]: all LEDs are blinking; enter the number 1, then confirm pressing [Enter].
This operation is zeroing both gross and net weight (see § 6 further on).
The value indicating the transducers signal (A/D converter output, 16000 corresponding to
zero signal) can be displayed by pressing the key [0]; when the key is released, the normal
indication is restored.
The suppressed tare weight is stored into a permanent memory; it is saved also in case of
power failure or instrument de-energization.
 BRC--BCS Weighng System

5) CALIBRATION CHECKING
The instrument is delivered with the right calibration to match the requi- red range,
according with number (4), rated load (150 tons) and sensitivi- ty (2 mV/V) of the load
cells; a calibration checking in-field will be car- ried out as follows: gob ty 5 j “ean”
a, es a
I-D-12.128/0607
~- after zeroing the gross weight, place a known, significant weight (at least 50% of the
measuring range)
take note of the displayed vaiue: if it is not correct, start the cali- bration procedure
pressing the key [S] and, keeping it pressed, pressing the key [Enter]: all LEDs are blinking;
press the key [1], then confirm pressing [Enter]
• enter the value of the known weight using the numeric keys; check that the
programmed value is correct
confirm the weight pressing the key [Enter]; the instrument ends the program mode, and
the correct weight is displayed;
If no weight has been programmed before pressing [Enter], the calibration is unchanged; if
a wrong weight has been entered, the calibration procedure has to be repeated.
6) AUTOMATIC TARE
The Automatic Tare function allows to display, by choice, the net or qross weight and set to
zero the net weight; two keys are used for this function:
• the key [N] is used to display the net: the gross weight is the weight variation respect
to the digital zeroing operated with the keys [S]+[0] (see § 4), while the net weight is
the weight variation respect to the digital zeroing operated with the key [T];

• pressing otgether the keys [S] and [T] the present value of net weight is zeroed.

The net weight is displayed as long as the key [N] is pressed; normally the gross weight is
displayed.
The keys [S]+[T] perform the Automatic Tare function also when the gross weight is
displayed; the effect on the net weight indication will appear only when pressing the key
[N].
The net weight suppressed with keys [S]+(T] is stored into a permanent me- mory; it is
saved also in case of power failure or de-energization.
The net weight can be zeroed also by means of an external free (pulse) con- tact: the action
of this contact is the same of the keys [S]+I{[T].
7) ALARM
 BRC--BCS Weighng System

The instrument is provided with an alarm which is activated when the input signal from
load cells (displayed by pressing the [2] key) is exceeding the indicator range (positive or
negative): the LED on the key [1] is lit when the alarm is activated; moreover, the central
segments only of the display digits are lit.
The alarm is provided with an SPDT relay, 2 A capacity @ 110/220 V; the relay is operating
as normally energized, de-energized in alarm condition. 88 ine thee s.rl.
ee ce ital
I-D-12.128/70607
8) ANALOG OUTPUT
Each indicator is provided with an analog output, O to 20 or 4 to 20 mA, max. load 1000
ohm.
The output will be configured according to the following procedure:
• press the key [S] and, keeping it pressed, press the key [Enter]: all LEDs are blinking;
enter the number 16, then confirm it with [Enter]; the current output configuration is
displayed:
0= output proportional to gross weight, 0 + 20 mA
1= output proportional to net weight, 0 + 20 mA
2= output proportional to gross weight, 4 + 20 mA
3= output proportional to net weight, 4 + 20 mA
• after programming the new value, press the key [Enter] to confirm.
The analogic output can be programmed, so that the full scale value of the output is
corresponding to a desired weight value, as follows:
• press the key [S] and, keeping it pressed, press the key [Enter]: all LEDs are blinking;
enter the number 17, then confirm it with [Enter]; the current output full scale value is
displayed:

• Using the numeric keys, set the new desired value, checking on the di- splay that the
value is correct, then confirm it pressing [Enter].

POWER SUPPLY [ ] 110 [X] 220 v AC

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L—|—+-|N+ 3 = ON ) N , 0 in ~ NC 2 NO | cu a | ALARM —t oO — Sp] ma output D . tn w oy
Ql — pears — —_ = Oo a BE “|SO ie) LOAD CELLS + m ad a Denominazione INDICATOR
M748 — WIRING DIAGRAM ind. Modlfiche Data | Firma | Dis. RB | Data 03/07 | Contr. A
termini di legge e’ rigorosamente vietato riprodurre Mater. Quantita’ Toll. 4 cormunicare a
 BRC--BCS Weighng System

ter2i il contenuta del presente disegno. Finitura Note Gener. BCcSs Italia. sw, DIS. N.* A-
6742 | SCALA =

LOAD CELL JUNCTION BOX

SHIELD BCS tay SHIELD 4 SIG- 4 SIG— 3 SIG+ Lc1 LC2 3 SIG+ 2 EXC— 2 EXC- 1 EXC+ nL. 1
EXC+ 1 EXC+ 1 EXC+ 2 EXC 2 EXC-— 3 SIG+ LCS) s«LC4 3 SIG+ 4 SiG- 4 SIG— SHIELD
SHIELD OUTPUT +i +, $1, Oo O oO CD zz amr xn nna wb = - NOT WO wo HM | LOAD CELLS
CABLE EXC + |BLUE BLUE | GREEN EXC — {BLACK BLACK YELLOW SIG + |RED RED RED
SIG — WHITE WHITE WHITE SEN + | GREEN — seat ee SEN — | BROWN sat pas TYPE |
CV6N[ ]|T4 [x] |cv4F [ J
AT BINDING POSTS OF LOAD CELLS WHEN A 6—WIRES CABLE IS USED
NOTE: CONNECT WIRES EXC+ WITH SEN+ AND EXC— WITH SEN—
Denominazione
JUNCTION BOX 4262
Ind,
Modifiche
Data
Firma | Dis.
RB
Data 05/90
Contr.
A termini di legge @ rigorasamente vietato riprodurre © comunicare a terzi'il contenuto
de! presente disegno.
Mater,
Quantita
BCS
Finitura
Note
DIS. N.
2 A-4263
scaLA =
 BRC--BCS Weighng System

Toil. Gener.