Ramsey MINI CK101 Integrator

Ramsey MINI CK101 Integrator
Ramsey
MINI CK101
Integrator
Operating And Service Manual
MINI CK101
Part No.:
Ramsey
MINI CK101
Integrator
This document is confidential and is the property of Thermo Fisher Scientific. It may not be copied or
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Revision History
Rev.E
Rev.D
Rev.C
Rev.B
Rev.A
January 2011
April 2010
November 2009
October 2008
March 2008
Update for SW release 86.00.00.04
General Revision
General Revision
First Issue
PRELIMINARY
Table of Contents
Table of Contents …………………………………………………………………………………………… i
List of Figures …………………………………………………………………………………………………. v
List of Tables
………………………………………………………………………………………………...v
About this Manual ............................................................................................................... v
Who Should Use this Manual ................................................................................................................. v
Organization of the Manual..................................................................................................................... v
Documentation Conventions.................................................................................................................. vi
Safety Messages ................................................................................................................................... vi
General Precaution................................................................................................................................vii
Warranty ...............................................................................................................................................viii
Disclaimer .............................................................................................................................................. ix
Chapter 1 - Introduction to the MINI CK101 ...................................................................... 1
1.1
Unpacking and Inspection........................................................................................................... 1
1.2
Storage ....................................................................................................................................... 1
1.3
Application .................................................................................................................................. 1
1.4
MINI CK101 Functional Description............................................................................................ 2
1.5
Configuration............................................................................................................................... 3
1.6
Integrator General Description.................................................................................................... 4
1.7
Symbol Identification................................................................................................................... 5
1.8
Technical Specifications ............................................................................................................. 6
Chapter 2 Installing the MINI CK101 .................................................................................. 1
2.1
Safety Precautions...................................................................................................................... 1
2.2
Incoming Power .......................................................................................................................... 3
2.2.1
2.3
Critical Wiring Condition ..................................................................................................4
Installation................................................................................................................................... 4
2.3.1
2.3.2
2.3.3
Mounting............................................................................................................................4
Connecting Incoming Power 100/240 VAC (+/-10%) ......................................................6
Connecting Incoming Power 24VDC (ON REQUEST) ...................................................6
Chapter 3 MINI CK101 Operation ....................................................................................... 1
3.1
Operator Interface....................................................................................................................... 1
3.2
Front Panel ................................................................................................................................. 1
3.2.1
3.2.2
3.2.3
3.2.4
3.3
Mode of Data Insert .................................................................................................................... 3
3.3.1
3.3.2
3.4
3.5
3.6
3.7
System Status Lights (Leds) ..............................................................................................2
Keypad...............................................................................................................................2
LCD Graphic Display ........................................................................................................3
Contrast Display Adjust.....................................................................................................3
Selection ............................................................................................................................3
Data Entry..........................................................................................................................3
Menu Displays ............................................................................................................................ 4
First Power On ............................................................................................................................ 4
Normal Power On ....................................................................................................................... 5
Run Menu ................................................................................................................................... 5
3.7.1
3.7.1.1
3.7.1.2
3.7.1.3
3.7.2
3.7.3
Main Run Functions ..........................................................................................................5
Screen 1 ............................................................................................................................5
Screen 2 .............................................................................................................................6
Screen 3 .............................................................................................................................6
Material Calibration...........................................................................................................7
Alarm Pending ...................................................................................................................7
i
3.8
3.9
Start-Stop General Purpose Key ................................................................................................ 8
Calibration................................................................................................................................... 8
3.9.1
Zero Calibration Scroll ......................................................................................................8
3.9.2
Manual Zero.....................................................................................................................10
3.9.3
Span Calibration Scroll....................................................................................................10
3.9.3.1 Auto Span ........................................................................................................................10
3.9.3.1.1 Calibration with R-Cal...............................................................................................11
3.9.3.1.2 Calibration with Chain Calibration............................................................................11
3.9.3.1.3 Calibration with Test Weights ...................................................................................12
3.9.3.1.4 Span Calibration ........................................................................................................13
3.9.3.1.5 Material Factor...........................................................................................................13
3.9.3.1.6 Recording New Span .................................................................................................14
3.9.3.1.7 Ending an Auto Span Procedure with Chains or Test Weights .................................15
3.9.3.1.8 Ending an Auto Span Procedure with R-Cal............................................................15
3.9.3.2 Manual Span ....................................................................................................................16
3.9.4
Material Span Calibration................................................................................................16
3.9.4.2
Acquiring the Material Factors........................................................................................18
3.10
3.11
Main Menu 2 – Setup and Configuration Menus....................................................................... 20
Display ...................................................................................................................................... 20
3.11.1
3.11.2
3.11.3
3.11.4
3.11.5
3.11.6
3.11.7
3.11.8
3.11.9
3.11.10
3.11.11
3.12
Scale Data Scroll ..................................................................................................................... 25
3.12.1
3.12.2
3.12.3
3.12.4
3.12.5
3.12.6
3.12.6.4
3.12.6.5
3.13
Measure Units..................................................................................................................20
Totalization Units ............................................................................................................20
Lenght Units ....................................................................................................................20
Rate Units ........................................................................................................................21
Load Cell Units................................................................................................................21
Speed Units......................................................................................................................21
Language..........................................................................................................................22
Time and Date ( ONLY WITH SERIAL BOARD ) .......................................................22
Line Three (3) of the Run Menu......................................................................................22
Displayed Damping Factors ............................................................................................23
Screen Saver ....................................................................................................................24
Max. Scale Capacity ........................................................................................................25
Scale Divisions ................................................................................................................25
Selecting the Weighbridge Model (Belt scale code) .......................................................25
Detailing the Mechanical Parameters of the Frame.........................................................26
Defining Dimensional Parameters of the Application.....................................................30
Defining the Load Cell(s) ................................................................................................30
Defining the Speed Input .................................................................................................31
Setting Dead Band ...........................................................................................................32
Calibration Data Scroll .............................................................................................................. 32
3.13.1
3.13.1.1
3.13.2
3.13.3
3.13.4
3.13.6
3.13.7
3.13.8
3.13.9
3.13.10
Defining the Calibration Mode........................................................................................32
Defining the R-Cal Parameters ........................................................................................32
Entering Calibration Interval (Only with OPTION Serial Board)...................................34
Entering Material Factors ................................................................................................34
Defining the Calibration Test Duration ...........................................................................35
Partial Test Duration Acquisition ....................................................................................37
Manual Entry of Test Duration........................................................................................38
Defining Auto Zero Tracking ..........................................................................................39
Entering the Speed Capacity............................................................................................40
Defining the Number of Calibrations ..............................................................................40
ii
3.14
Main Menu 3 ............................................................................................................................. 41
3.14.1
3.15
3.15.1
3.15.2
3.15.3
3.15.4
3.15.5
3.15.6
3.15.7
3.15.8
3.15.9
3.15.10
3.15.11
3.15.12
3.15.13
3.15.14
3.15.15
3.15.16
3.15.17
3.15.18
3.15.19
3.15.20
3.16
Changing Protection Level ..............................................................................................41
Diagnostics ............................................................................................................................... 42
A/D Raw Data..................................................................................................................42
Readout Load Cell mV ....................................................................................................42
Change Prescaler .............................................................................................................43
Change Passwords ...........................................................................................................44
Display Software Version................................................................................................45
Display RedBoot Version ................................................................................................45
Display Cpld Version ......................................................................................................45
Setup Date and Time (Only with OPTION Serial Board )..............................................45
Check Hardware Configuration.......................................................................................46
Force Cold Start...............................................................................................................46
Firmware Update .............................................................................................................47
Lamp Test ........................................................................................................................48
Test Digital Inputs ...........................................................................................................48
Test Digital Outputs.........................................................................................................48
Virtual Inputs Test ...........................................................................................................49
Virtual Outputs ................................................................................................................49
Current Output Test .........................................................................................................49
Test communication A.....................................................................................................50
Test Profibus....................................................................................................................50
Test Keyboard..................................................................................................................50
Main Menu 4 ............................................................................................................................. 51
3.16.1
I/O Definition...................................................................................................................51
3.16.3 Network..................................................................................................................................... 62
3.17 MAIN MENU 5 .......................................................................................................................... 64
1.
Define Handshaking ....................................................................................................................67
3.18 MAIN MENU 6 LOAD OUT (BATCH) SCROLL ....................................................................... 76
3.19 MENU 6 LINEARIZATION ....................................................................................................... 80
Chapter 4 MINI CK101 Maintenance .................................................................................. 1
4.1
Frequent Checkpoints................................................................................................................. 1
4.2
Troubleshooting .......................................................................................................................... 1
4.3
Cold Start .................................................................................................................................... 1
4.4
Load Cell Excitation and Signal Voltage ..................................................................................... 2
4.5
Lithium Battery Replacement...................................................................................................... 2
4.6
Disposal of Hazardous Waste..................................................................................................... 2
4.7
Cleaning Instructions .................................................................................................................. 2
Chapter 5 MINI CK101 Replacement Parts ........................................................................ 1
5.1
Order Informations ...................................................................................................................... 1
5.2
Parts List ..................................................................................................................................... 2
Appendix A MINI CK101 Digital Input / Output ................................................................. 1
A.1
Mother Board Digital I/O ............................................................................................................. 1
A.1.1
A.1.2
Digital Inputs .....................................................................................................................1
Digital Outputs...................................................................................................................2
Appendix B MINI CK101 Optional Boards ......................................................................... 1
B.1
Analog Out Board ....................................................................................................................... 1
B.2
Profibus Board ........................................................................................................................... 1
B.3
Comm RS232/485 Board........................................................................................................... 1
Appendix C Drawings .............................................................................................................................. 1
iii
LIST of FIGURES
Figure 1-1:
Figure 1-2:
Figure 2-1:
Figure 2-2:
Figure 3-1:
MINI CK101 (Panel Version) …………………………………………………………………..1-2
MINI CK101 (Field Version) .…………………………………………………………………..1-3
MINI CK101 Overall Dimensions (Panel Version)……………………………………………...2-5
MINI CK101 Overall Dimensions (Field Version).……………………………………………...2-5
MINI CK101 Front Panel
……………………………………………………………..3-1
Appendix Figure A-1:
Appendix Figure A-2:
Appendix Figure A-3:
Appendix Figure A-4:
Appendix Figure B-1:
General Purpose Digital Inputs ……………………………………………………A-1
State Speed Input
……………………………………………………………A-2
Digital Outputs
………………………………………………………………A-2
State Output TTL
…………………………………………..A-3
State Current Output
……………………………………………...…B-1
LIST of TABLES
Table 1-1:
Table 3-1:
Table 3-2:
Table 3-3:
Table 3-4:
Table 3-5:
Table 5-1:
Symbol Identification
…………………………………………………………………… 1-5
Alarm Conditions
………………………………………………………………………….. 3-7
Protection Levels
……………………………………………………………….3-40
Available Logical Selections
……………………………………………………3-51
Mother Board Input
……………………………………………………........ 3-51
Available Logical Assignement
…………………………………….. 3-52
Parts List
……………………………………5-2
iv
About this Manual
This manual provides the information you need to install, operate and maintaining of the
MINI CK101.
Read this manual before working with the product. For personal and system safety, and for the
best product performance, make sure you thoroughly understand the manual before installing
or using this product.
Who Should Use this Manual
The MINI CK101 manual is a learning resource and reference for anyone concerned with
installing, operating, or maintaining MINI CK101.
Read this manual before working with the system. For personal and system safety, and for the
best product performance, make sure you thoroughly understand the manual before installing,
operating, or maintaining this machine.
Organization of the Manual
This manual is organized into five chapters and three Appendixes.
Chapter 1: Introduction to the MINI CK101 gives an overview of the device’s capabilities,
describes its functions, and lists its technical specifications.
Chapter 2: Installing the MINI CK101 provides information about installing the MINI CK101
including procedures for mounting, wiring, and configuration of the instrument.
Chapter 3: MINI CK101 Operation provides an overview of the MINI CK100 front panel, a
description of how the menus operate, and information about setting up, calibrating, and
operating the MINI CK101.
Chapter 4: MINI CK101 Maintenance provides an overview of standard maintenance
associated with the MINI CK101.
Chapter 5: MINI CK101 Replacement Parts- provides a list of replacement parts for the MINI
CK100 and part ordering information.
Appendix A: MINI CK101 Digital Input/Output
Appendix B: MINI CK101 Optional Boards
Appendix C: MINI CK101 Drawings
v
Documentation Conventions
The following conventions are used in this manual to help easily identify certain types of
information:
• Italic is used to introduce new terms and for emphasis.
• Italic/blue type is used for references to other sections of the manual and work as links on
line and in pdf format.
• The names of setup, calibration displays, menu displays, and variables are shown in FULL
CAPITALS.
• The names of keys on the front panel are shown in BOLD CAPITALS.
Safety Messages
Instructions in this manual may require special precautions to ensure the safety of the
personnel performing the operations.
Please read the safety information before performing any operation preceded by this symbol.
There are two levels of safety messages: warnings and cautions. The distinction between the
two is as follows:
WARNING
FAILURE
TO OBSERVE COULD RESULT IN DEATH OR
SERIOUS INJURY.
CAUTION
FAILURE
TO OBSERVE MAY CAUSE MINOR INJURY OR
DAMAGE THE EQUIPMENT
vi
General Precaution
Do not install, operate, or perform any maintenance procedures until you have read the safety
precautions presented.
WARNING
FAILURE
TO FOLLOW SAFE INSTALLATION AND SERVICING
PROCEDURES COULD RESULT IN DEATH OR SERIOUS
INJURY.
ƒ MAKE SURE ONLY QUALIFIED PERSONNEL PERFORM
INSTALLATION AND MAINTENANCE PROCEDURES IN
ACCORDANCE WITH THE INSTRUCTIONS IN THIS MANUAL.
ƒ ALLOW ONLY QUALIFIED ELECTRICIANS TO OPEN AND
WORK IN THE ELECTRONICS CABINET, POWER SUPPLY
CABINET, CONTROL CABINET, OR SWITCH BOX.
ƒ COVERS OVER THE ELECTRONICS AND ROTATING PARTS
MUST ALWAYS REMAIN IN PLACE DURING NORMAL
OPERATION REMOVE ONLY FOR MAINTENANCE, WITH
THE MACHINE’S POWER OFF. REPLACE ALL COVERS
BEFORE RESUMING OPERATION.
ƒ DURING MAINTENANCE, A SAFETY TAG (NOT SUPPLIED
BY THE FACOTRY) IS TO BE DISPLAYED IN THE ON/OFF
SWITCH AREAS INSTRUCTING OTHERS NOT TO OPERATE
THE UNIT (ANSI:B157.1).
WARNING
HIGH
VOLTAGE THAT MAY BE PRESENT ON LEADS COULD
CAUSE ELECTRICAL SHOCK.
ƒ ALL SWITCHES MUST BE OFF WHEN CHECKING INPUT
AC ELECTRICAL CONNECTIONS, REMOVING OR
INSERTING PRINTED CIRCUIT BOARDS, OR ATTACHING
VOLTMETERS TO THE SYSTEM.
ƒ USE EXTREME CAUTION WHEN TESTING IN, ON, OR
AROUND THE ELECTRONICS CABINET, PC BOARDS, OR
MODULES. THERE ARE VOLTAGES 100 V OR 230 V IN
THESE AREAS.
WARNING
USE
ONLY THE PROCEDURES AND NEW PARTS
SPECIFICALLY REFERENCED IN THIS MANUAL TO ENSURE
SPECIFICATION
PERFORMANCE
AND
CERTIFICATION
COMPLIANCE. UNAUTHORIZED PROCEDURES OR PARTS
CAN RENDER THE INSTRUMENT DANGEROUS TO LIFE,
LIMB, OR PROPERTY.
vii
WARNING
KEEP HANDS AND CLOTHING AWAY FROM ALL MOVING OR
ROTATING PARTS.
WARNING
DO
NOT PLACE OR STORE OBJECTS OF ANY KIND ON THE
MACHINE.
WARNING
THIS
MACHINE SHOULD NOT BE OPERATED AT MORE THAN
THE PRODUCTION RATE STATED ON YOUR EQUIPMENT
SPECIFICATION SHEET OR USED IN APPLICATIONS OTHER
THAN THOSE STATED IN THE ORIGINAL ORDER.
Warranty
The seller agrees, represents, and warrants that the equipment delivered hereunder shall be free from
defects in material and workmanship. Such warranty shall not apply to accessories, parts, or material
purchased by the seller unless they are manufactured pursuant to seller's design, but shall apply to the
workmanship incorporated in the installation of such items in the complete equipment. To the extent
purchased parts or accessories are covered by the manufacturer's warranty, seller shall extend such
warranty to buyer.
Seller's obligation under said warranty is conditioned upon the return of the defective equipment,
transportation charges prepaid, to the seller's factory in Minneapolis, Minnesota, and the submission of
reasonable proof to seller prior to return of the equipment that the defect is due to a matter embraced
within seller's warranty hereunder. Any such defect in material and workmanship shall be presented to
seller as soon as such alleged errors or defects are discovered by purchaser and seller is given
opportunity to investigate and correct alleged errors or defects and in all cases, buyer must have notified
seller thereof within one (1) year after delivery, or one (1) year after installation if the installation was
accomplished by the seller.
Said warranty shall not apply if the equipment shall not have been operated and maintained in
accordance with seller's written instructions applicable to such equipment, or if such equipment
shall have been repaired or altered or modified without seller's approval; provided, however,
that the foregoing limitation of warranty insofar as it relates to repairs, alterations, or
modifications, shall not be applicable to routine preventive and corrective maintenance which
normally occur in the operation of the equipment.
“EXCEPT FOR THOSE WARRANTIES SPECIFICALLY CONTAINED HEREIN,
SELLER DISCLAIMS ANY AND ALL WARRANTIES WITH RESPECT TO THE
EQUIPMENT DELIVERED HEREUNDER, INCLUDING THE IMPLIED WARRANTIES
OF MERCHANTABILITY AND FITNESS FOR USE. THE SOLE LIABILITY OF SELLER
ARISING OUT OF THE WARRANTY CONTAINED HEREIN SHALL BE
EXCLUSIVELY LIMITED TO BREACH OF THOSE WARRANTIES. THE SOLE AND
EXCLUSIVE REMEDY FOR BREACH OF THE WARRANTIES SET OUT ABOVE
SHALL BE LIMITED TO THE REPAIR OR REPLACEMENT OF ANY DEFECTIVE
ACCESSORY, PART OR MATERIAL WITH A SIMILAR ITEM FREE FROM DEFECT,
AND THE CORRECTION OF ANY DEFECT IN WORKMANSHIP. IN NO EVENT
SHALL SELLER BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL
DAMAGES.”
viii
Purchaser agrees to underwrite the cost of any labor required for replacement; including time,
travel, and living expenses of Thermo Ramsey Field Service Engineer at closest factory base.
Disclaimer
Though the information provided herein is believed to be accurate, be advised that the
information contained herein is not a guarantee for satisfactory results. Specifically, this
information is neither a warranty nor guarantee, expressed or implied, regarding performance,
merchantability, fitness, or any other matter with respect to the products, and recommendation
for use of the product/process information in conflict with any patent. Please note that Thermo
Ramsey reserves the right to change and/or improve the product design and specifications
without notice.
ix
Chapter 1
Introduction to the MINI CK101
This instruction manual contains information on the installation, operation, calibration, and
maintenance of the MINI CK101 Integrator.
1.1
Unpacking and Inspection
The MINI CK101 has been properly packaged for shipment and storage, when necessary.
Inspect all packages for damage before opening; sometimes the carrier may be responsible for
shipping damage.
1.2
Storage
The MINI CK101 can be safely stored, with cover, latches secured and hole plugs installed,
between -40° to +158° F (-40° to +70° C). The units should be protected against moisture.
1.3
Application
The MINI CK101 is a bus-based microcomputer driven instrument used for Belt Weighing
Systems.
The Belt Weighing System includes the following principal components :
1. BELT SCALE WEIGHBRIDGE WITH LOAD CELL
The belt scale weighbridge and weight transducer (load cell) are installed on the conveyor
frame with a minimum of structural modification to the frame. The weight of the material on
the belt is trasmitted by load cell to integrator.
The Belt Scale type and the load cell number are defined with reference to conveyor type and
the accuracy system.
2. SPEED SENSOR
The speed sensor is a device used to detect the speed of belt conveyor. The speed sensor must
be connected with a drum shaft which turns at true conveyor belt speed.
3. WEIGHT INTEGRATOR MINI CK101
The MINI CK101 Integrator is a micro-computer driven instrument used for deriving rate and
quantity of flowing material from signals representing the weight of a segment (pounds/foot)
of moving material and its velocity (feet/minute). By suitable processing of these two input
signals the MINI CK101 delivers visible and electrical output representing the rate of material
movement and visible and electrical output representing total amount of material whic has
passed on belts scale.
1-1
1.4
MINI CK101 Functional Description
•
•
•
•
•
•
•
•
•
The MINI CK101 is availabile with the following configuration hardware and software.
Menu driven scroll entries on a four line display.
Five LED status indicators.
Automatic zero and span calibration.
Auto zero Tracking.
Several software options that may be turned on by keyboard entry or installing optional
board.
Optically couplet digital inputs and outputs.
Relay Board – Mounted on the Field Version
(OPTIONAL) External for the Panel Version
Alarms and failure detection.
Ethernet Line
• (OPTIONAL) Communication : RS232C, RS485, Profibus
• (OPTIONAL) 20mA Current Loop passive.
• (OPTIONAL) Relay Board (External for panel version – mounted inside the instrument for
field version).
Figure 1-1: MINI CK101 (Panel Version)
1-2
Figure 1-2: MINI CK101 (Field Version)
1.5
Configuration
The standard configuration of the MINI CK101 includes the following:
• Single channel load cell input to a max of 6 load cells
• 1 programmable digital inputs
• 1 speed input (SPU)
• 1 programmable digital output
• 4 optically digital outputs (TTL) programmables for Panel Version
• 4 digital outputs (relay contact) programmables for Field Version
• 1 Ethernet Line
• 1 slot for insert one of the following optional board :
1. Current Output Board (20mA Current Loop passive)
2. Serial Communication Board
3. Profibus-DP Board
1-3
1.6
Integrator General Description
The MINI CK101 is designed for belt weighing systems..
The base functions are located on the instrument software. Function accessories are activated
when the correspondent hardware are mounted , or after activation from keyboard by operator.
Instrument parameters programming is executed from keyboard. A menu driven allows the
operator to access all setup, test and calibration parameters.
Static weight indicator is designed to convert force signals from max 6 strain gauge load cells
(350ohm ).
The process variables displayed can be damped by a programmable factor.
The Integrator has built-in troubleshooting capabilities. A number of possible internal alarms
are automatically detected and screen messages are displayed. The alarms can be acknowledged
and by keyboard or remote digital input is possible to clear the alarms.
The alarms can be programmed and defined to be :
ALARM , SHUT DOWN process or NONE (ignored).
The front panel shows the led status (Alarm) illuminated .
Are availables digital output for the following conditions:
•
Cumulative Alarms
•
Cumulative Shut Down
With the serial communication (optional) is possible by command to have a periodical and
instantaneous printing format on printer of data sistem. Is available the clock function
maintained by lithium battery.
Are availables three type of communications :
•
Ethernet Modbus TCP (Standard) – The protocol allows a remote intelligent device to read
and write data of the registers. During the communication activity, the MINI CK100 will
always act as slave, meaning it will respond to a request from a master device on the line, but
will never attempt to send messages out.
•
Serial Communication (Optional) – The protocol allows a remote intelligent device to read
and write data of the registers. During the communication activity, the MINI CK100 will
always act as slave, meaning it will respond to a request from a master device on the line, but
will never attempt to send messages out.
•
Profibus DP (Optional) – The protocol allows a remote intelligent device to read and write
data of the registers. During the communication activity, the MINI CK100 will always act as
slave, meaning it will respond to a request from a master device on the line, but will never
attempt to send messages out.
1-4
1.7
Symbol Identification
Table 1-1 describes the symbols used in this manual.
Table 1-1: Symbol Identification
Symbol
Description
ALTERNATING CURRENT
EARTH (GROUND) TERMINAL
PROTECTIVE CONDUCTOR
TERMINAL
CAUTION, RISK OF ELECTRIC SHOCK
CAUTION (REFER TO
ACCOMPANYING DOCUMENTS)
1-5
1.8
Technical Specifications
Enclosure
Panel Version
Dimensions: 96 x 96 x 124mm
Frontal Protection IP65
Enclosure IP00
Field Version
Dimensions: 300 x 250 x 160mm
Renforced Fiberglass Housing Protection IP65
Environmental Conditions
Mounting
Should be mounted as closet o the load cells as possibile without being exposed to
excessive heat or moisture
Temperature (Ambient)
Storage: -40° +70° C
Operating: -10° +50° C
Relative Humidity
Up to 95%, non-condensing
Pollution Degree
2
Altitude
Up to 2000mt.
Power Requirements
Nominal Voltage (VAC)
100/240 VAC
Nominale Frequency
50/60 Hz
Fusing
0.4 Amp SB Type C
Power Consumption
26 VA Max
Nominal Voltage (VDC) on Request
24 VDC
Fusing
0.4 Amp SB Type C
Power Consumption
26 VA Max
1-6
Maximum Non-Desstructive Input Voltage
From 100 to 230 VAC +10%
Over Voltage Category
Category II
DC Power Supply
Auxiliary Power Supply Output
Output Voltage:
24 VDC
Isolation:
500 Volt
Output ripple:
200 mV peak to peak typical
Output Current:
400 mA max. - Short Circuit Protection
Load Cell (Weight)
Load cell input circuits
Number:
Sensitivity:
Input Impedance:
Maximum Usable Signal:
Displayed A/D counts
Isolation:
Max non-destructive input voltage:
Load Cell Cable Shield:
Up to six (6) 350-ohm load cells in parallel.
Cable distance 200 ft or less (3000 ft with sense)
0.5mV/V to 3.5 mV/V (keyboard selectable)
100 k-ohm minimum
114% of 3mV/V
(3mV/V):112368
Non-isolated
± 6 V relative to ground
Connected to earth ground
Load Cell Excitation Power Supply
10 VDC ±10%, 120 mA
Minimum load impedance (operating) 58 ohms
Output short circuit, 1.5 A maximum
Excitation - Sense Circuit
6 Wire System; cable distance over 200 ft. (not to exceed 3000 ft.).
±5 VDC (10 volts)
Nominal input voltage:
Input impedance:
100 k-ohm minimum
Jumper selectable:
Local or remote sense
Speed Sensor Input
Optically isolated
Powe Supply +20V SPU internal
Frequency Range
Voltage / current speed sensor 0.25 to 2.0 KHz
Contact 0.25 to 30 Hz
1-7
Digital Input
(1) High Frequency Input Optocoupled (DC)
(1) Optocoupled
Internal Power Supply for dry contact input
Power Supply : +24V external
Cable Lenght : 2500m section. 1.5 mm2 (150 Ohm max.)
Digital Output
Panel Version - (4) Digital Output (TTL) programmable 40mA used with positive or
negative logic mounted on socket for easy replacement
Field Version – (4) Relay Contact programmable (Relay Contact NA on Relay Board)
each contact can drive240VAC – 48VDC 0,5A
(1) Output Optocoupled (interface with RELAY)
Interface with TTL, CMOS, RELAY
Technical Data : 24 VDC, 40mA DC max.
Current Output (Option)
1 Current Output (20mA Current Loop Passive)
Output range:
User selectable 0 – 20 mA or 4-20 mA, representing 0 to 100%
variable.
Resistive load:
800 ohm max. Loop
Capacitive load:
No limit
Communication
Ethernet (Standard)
10 Base T
Seriale Interface (Optional)
Type:
Conforms to RS-232C, RS-485; supports 2 and 4 wire multi-drop.
Interfacing:
RS-485 supports 2-wire or 4-wire multi-drop networking;
RS 232 C provides support for modem.
Data rate:
110 to 19200, operator selectable from the keyboard.
Data Format:
Asynchronous, bit-serial, selectable parity, data length, and stop
bits.
Optical Isolation:
250 VRMS max.
Input Voltage:
±30 Vdc max. (RS-232C)
±15/-10 Vdc max. (RS-485)
Cable Length:
50 feet max. (RS-232C) - 4000 feet max (Rs-485)
Profibus DP (Optional)
Type:
Profibus DP Slave (Siemens SPC3 Controller).
Optical Isolation:
250 VRMS max.
Input Voltage:
+5VDC
Baud Rate:
9600 – 12 Mbps
1-8
Chapter 2
Installing the MINI CK101
This chapter describes the Integrator installation procedure, hardware configuration, and initial
programming. Initial programming is a machine directed procedure prompting the operator to
enter required conveyor and belt scale parameters. After all parameters have been entered, the
Integrator performs an unassisted zero and span calibration.
2.1 Safety Precautions
CAUTION
DO NOT INSTALL, OPERATE, OR PERFORM ANY
MAINTENANCE PROCEDURES UNTIL YOU HAVE READ THE
SAFETY PRECAUTIONS THAT FOLLOW.
CAUTION
DO NOT CONNECT POWER TO THE ELECTRONICS OR TURN
ON THE UNIT UNTIL YOU HAVE READ AND UNDERSTOOD
THE PRECAUTIONS AND
THIS ENTIRE MANUAL.
PROCEDURES PRESENTED IN THIS MANUAL MUST BE
FOLLOWED
CAREFULLY
IN
ORDER
TO
PREVENT
EQUIPMENT DAMAGE AND PROTECT THE OPERATOR.
2-1
WARNING
ALL SWITCHES (SUCH AS CONTROL OR POWER) MUST BE
OFF WHEN CHECKING INPUT AC ELECTRICAL
CONNECTIONS, REMOVING OR INSERTING PRINTED CIRCUIT
BOARDS, OR ATTACHING VOLT METERS TO THE SYSTEM.
INCOMING VOLTAGES
VOLTMETER BEFORE
ELECTRONICS.
MUST BE CHECKED WITH A
BEING CONNECTED TO THE
WARNING
EXTREME
CAUTION MUST BE USED IN TESTING IN, ON, OR
AROUND THE ELECTRONICS, PC BOARDS, OR MODULES.
THERE ARE VOLTAGES OF 100 V OR 230 V IN THESE
AREAS. AVOID HIGH VOLTAGE AND STATIC ELECTRICITY
AROUND THE PRINTED CIRCUIT BOARDS.
WARNING
MAINTENANCE
PROCEDURES SHOULD BE PERFORMED
ONLY BY QUALIFIED SERVICE PERSONNEL AND IN
ACCORDANCE WITH PROCEDURES/INSTRUCTIONS GIVEN IN
THIS MANUAL.
WARNING
DURING MAINTENANCE, A SAFETY TAG (NOT SUPPLIED BY
THERMO RAMSEY) SHOULD BE DISPLAYED IN THE
ON/OFF SWITCH AREAS AS A PRECAUTION INSTRUCTING
OTHERS NOT TO OPERATE THE UNIT.
WARNING
ONLY
QUALIFIED SERVICE TECHNICIANS SHOULD BE
ALLOWED TO OPEN AND WORK IN THE ELECTRONICS,
POWER SUPPLY, CONTROL, OR SWITCH BOXES.
2-2
WARNING
THIS EQUIPMENT SHOULD NOT BE OPERATED OR UTILIZED
IN APPLICATIONS OTHER THAN THOSE STATED IN THE
ORIGINAL ORDER.
ADAPT PRODUCTION RATES OR APPLICATIONS,
CONSULT THERMO RAMSEY PRODUCTS CUSTOMER
SERVICE FOR RECOMMENDATIONS.
TO
WARNING
ALL PANELS COVERING THE ELECTRONICS MUST BE IN
PLACE AND TIGHT BEFORE WASH DOWN PROCEDURES.
DAMAGE TO THE ELECTRONICS COULD RESULT FROM
WATER, MOISTURE, OR CONTAMINATION IN THE
ELECTRONICS HOUSING.
2.2 Incoming Power
CAUTION
VERIFY THAT THE INPUT VOLTAGE IS CORRECT WITH AN
AC/DC VOLTMETER BEFORE YOU CONNECT IT TO THE
INSTRUMENT.
CAUTION
EARTH GROUND MUST BE PROVIDED TO THE INSTRUMENT.
DO NOT USE CONDUIT TO PROVIDE THIS GROUND.
CAUTION
A READILY ACCESSIBLE DISCONNECT DEVICE SHALL BE
INCORPORATED IN THE FIELD WIRING. THIS DISCONNECT
DEVICE SHOULD BE IN EASY REACH OF THE OPERATOR
AND IT MUST BE MARKED AS THE DISCONNECTING DEVICE
FOR THE EQUIPMENT.
2-3
2.2.1 Critical Wiring Condition
1. Ensure power is off at the mains
2. Do not route load cell and signal cables in the same conduit with power cables or any large
source of electrical noise.
3. Earth ground all enclosures and conduits. A ground connection between all conduits is
required.
4. Connect the shields ONLY where shown.
5. Check that all wires are tight in their connections.
6. Never use a “megger” to check the wiring.
7. A readily accessible disconnect device (Max 10A) shall be incorporated in the field wiring.
This disconnect should be in easy reach of the operator and it must be marked as the
disconnecting device for the equipment.
8. All conduits should enter the bottom of the enclosure. Do not run conduit through the top or
sides of the enclosure.
CAUTION
REFER TO THE FILED WIRING DIAGRAM AS A GUIDE IF YOU
DO NOT HAVE A SPECIFIC WIRING DIAGRAM FOR YOUR
SYSTEM. FOLLOW YOUR LOCAL ELECTRICAL CODES AND
REGUATIONS FOR MINIMUM WIRE SIZE AND ROUTING.
2.3 Installation
The MINI CK101 is available for mounting in a control panel or for field mounting.
2.3.1 Mounting
The mounting place must be carefully selected, avoiding places where there are vibrations,
high temperature or humidity.
The MINI CK101 (Panel Version) is supplied for mounting on a covered front panel with any
inclination compared to the orizontal position.
The MINI CK101 (Field Version) is supplied for mounting in open air. It is suggested a
mounting in a protected position against rain about, in a place with strong vibrations, it is
better to provide a mounting using non vibrating devices.
The instrument must be positioned with a suitable height in order to easily read the display and
con veniently access to the key board.
2-4
Figure 2-1: MINI CK101 Overall Dimensions (Panel Version)
FRONT VIEW
SIDE VIEW
BACK VIEW
Figure 2-2: MINI CK101 Overall Dimensions (Field Version)
FRONT VIEW
SIDE VIEW
2-5
INTERNAL VIEW
2.3.2 Connecting Incoming Power 100/240 VAC (+/-10%)
To connect incoming power use the following procedure.
•
For input power use cable 14AWG
•
Wire the safety ground terminal locate on the backside of the enclosure (Protection GND PE).
•
Wire the HOT to terminal labelled of Terminal L on the Power Input Terminal.
Wire the NEUTRAL to the terminal labeled of Terminal N on the Power Input Terminal.
2.3.3 Connecting Incoming Power 24VDC (ON REQUEST)
•
•
•
•
To connect incoming power use the following procedure.
For input power use cable 14AWG
Wire the safety ground terminal locate on the backside of the enclosure (Protection GND PE).
Wire the POSITIVE (+24VDC) to Terminal (+) on the Power Input Terminal.
Wire the NEGATIVE (-24VDC) to Terminal (-) on the Power Input Terminal.
2-6
Chapter 3
MINI CK101 Operation
The MINI CK101 is capable of accurate belt weighing system, provided it is installed,
calibrated, operated, and maintained in complete accordance with the instructions contained in
this manual.
3.1 Operator Interface
This section contains information on set up and operation of the MINI CK101.
Operator interface is composed of keypad, status indicators (led) and display.
Figure 3-1: MINI CK101 Front Panel
3.2
Front Panel
The MINI CK101 Front Panel contains:
• 5 System Status Lights (Leds).
• LCD Graphic Display
• Keypad
3-1
3.2.1 System Status Lights (Leds)
The five red status indicators show the status of the Mini CK101 Integrator :
READY
Ready indication lighted if the scale is calibrated (zero and span calibration complete) and no
SHUT DOWN conditions are active
ALARM
Alarm indication lighted if an alarm is pending, either the alarm is NEW or has been
ACKNOLOWLEDGED.
SPAN CALIBRATION
Lighted when SPAN Calibration is running.
ZERO CALIBRATION
Lighted when AUTO ZERO is running. Does not flash when Auto Zero Track is auto zeroing.
RUN
Lighted when RUN phase.
3.2.2 Keypad
The keypad is comprised of pad touch keys consisting of the following
F1
F2
F3
^
v
RUN / SETUP
Function Key 1
Function Key 2
Function Key 3
Scroll Up
Scroll Down
Selection mode RUN / SETUP
On the interface scroll, the fourth display row is composed of three sections. Each section shows
the action of the corresponding key.
Baud Rate
<F1 Descr.>
> 9600 <
<F2 Descr.> <F3 Descr.>
The Scroll Keys (UP or DOWN) allow change the page displayed.
The RUN/SETUP Key allows selection of the menu modes. RUN is the operative mode with
indication of variables and status scale. SETUP is the configuration and calibration mode of the
instrument.
3-2
3.2.3 LCD Graphic Display
The display is composed of 4 rows (20 alphanumeric characters each row).
Two main modes displyed : RUN and SETUP. The following section describes the menus.
3.2.4 Contrast Display Adjust
It is possible to adjust the contrast display by the trimmer located :
- at the top on the right side on the internal edge of the display (for Panel version)
- on the right side internal of the Front Panel (for Field version)
3.3
Mode of Data Insert
Are available two mode for to insert data by keypad : SELECTION , DATA ENTRY
3.3.1 Selection
Allows to select the value from a list available. See the following example :
Division
> 0,1 <
ENTER
CHOICE
CHOICE
ENTER
scroll the list of the value availables
allows the selection and the confirm of the value displayed.
The data into ‘> <’ is the value active for the selection.
3.3.2 Data Entry
Is necessary for to insert a numerical value.
MAX RATE
500.00 KG
ENTER
ENTER
has a double function:
- Press the first time allows the start of the data entry procedure.
- Press the second time confirms the data entry and finish the procedure.
In the data entry procedure the number that must be modified is flashing.SCROLL UP /
SCROLL DOWN keys allow to modify the value. The F2 and F3 keys (are activated
from the first press of ENTER key) allow the scroll to former or following number.
MAX RATE
ENTER
500.00 KG
<
>
In the same mode is possibile to insert of negative value.
OFFSET
+10.00 KG
ENTER
<
>
3-3
3.4
Menu Displays
The interface is a menu driver machine that allows the operator to access all setup, test and
calibration parameters.
The following table shows the menu structure.
The functions highlighted are optional and are availables only if the corresponding option hardware
or software has been installed.
Mode
Menu
SETUP
MAIN MENU 1
MAIN MENU 2
MAIN MENU 3
MAIN MENU 4
F1
F2
F3
ZERO CAL
DISPLAY
PROTECTION
I/O DEF
SPAN CAL
SCALE DATA
DIAG
DEF.
ALLARM
EXPANSION
CARDPROFIBUS
LINEAR
MAT’L CAL
CALIB DATA
TEST
ETHERNET
MAIN MENU 5
EXPANSION
CARD-RS232
MAIN MENU 6
LOAD OUT
BATCH
SCREEN 1
SCREEN 2
SCREEN 3
MAT’L /PRINT
MAT’L /PRINT
ENTER
PRINT
RUN
CALIBR.
ALARM
RESET
TOTALS
CLEAR/STOP START
The following keys allows the scroll through the menus :
•
•
•
•
Press RUN/SETUP key to change Mode
Press DOWN SCROLL key to advance through the menus.
Press UP SCROLL key to return to the previous item displayed.
Press F1 / F2 / F3 key to access sub-menus or to activate the function displayed.
If the MINI CK101 is password protected, the appropriate password must be entered prior to
making changes or performing routine calibration. Menus may be viewed without entering a
password, but no entries are allowed unless the password is entered.
3.5
First Power On
When power is first applied to the MINI CK101, the system steps the operator through menus
and options that bring the system to a weighing state. After the initial programming the
instrument executes a simulate scale calibration than the system is ready for the weighing.
For to obtain a better accuracy is necessary a calibration with test weights
The data request are available on menu Display, Scale Data, Calibration Data.
3-4
3.6
Normal Power On
When the MINI CK101 is powered on after initial programming, the RUN MENU 1 is displayed
unless the hardware configuration has been changed.
3.7
Run Menu
When the Integrator is normally powered on after initial programming, the RUN (RUN MENU
1) is displayed. The RUN menu can always be accessed by pressing the RUN/SETUP key on
the front panel.
3.7.1 Main Run Functions
The Run Menu consists of three operations, main Run menu, Reset Total and Batch
(Load Out). They can be scrolled using the scroll UP or DOWN keys.
3.7.1.1
Screen 1
The usual screen is the following:
Z
0000000 t
0000000 t/h
The first line always displays the MASTER TOTAL, which is the number of tons totalized by
the scale since installation. This number is factory preset and requires a factory password to
reset.
The second line always displays the rate. A "Z" appears on the left side if the "Auto Zero
Tracking" optional function is enabled in MAIN MENU 2 (Calibration Data Scroll) and the
scale is unloaded. The "Z" is on steady during the first half test duration, while the Integrator
is checking that the belt is unloaded. Then, during full test duration, the "Z" is flashing,
indicating the Integrator is averaging the signal from the load cell to accurately re-zero the
scale. The load must stay below the AZT max deviation set point during the cycle, otherwise
auto zero is aborted.
The third line is by default blank, but can be programmed to show the belt speed, the belt
loading or the date and time. The selection is made in the MAIN MENU 2 (Display Scroll).
3-5
3.7.1.2 Screen 2
The screen 2 is the following :
0000000 t
0000.00 t/h
z
RESET
The RESET TOTAL MENU is similar to the main RUN MENU except Reset Total has
replaced Master Total. Press the DOWN scroll key for access.
When the RESET key is pressed, the following screen is displayed:
Do you wish to clear
RESET TOTAL ?
YES
NO
Press YES to clear the total, press NO to skip clearing.
3.7.1.3 Screen 3
The screen 3 display the LOAD OUT information (if the function is qualified).
BATCH
0 STOP
TOTAL
000.0 t
SETPT
0.0 t
ENTER CLEAR START
The first line always displays the batch number and the batch status;the second line display the
batch total which is the number of tons totalized by the scale from the start command;.the third
line display the batch set point and the last line allows the operator to change set point, clear
the batch number and start or stop the batch cycle. After the cycle is started, the START soft
key is erased and the CLEAR key is replaced by STOP key. When STOP key is pressed to
STANDBY the cycle , the START key is displayed again.
3-6
3.7.2 Material Calibration
The word MAT’l flashes in the left of the display screen after a material calibration if the static
scale reference weight is not known. When the reference weight is known, press MAT’L to
resume and complete the material calibration procedure.
3.7.3
Alarm Pending
The message ALARM displays in the right of the screen if an alarm is pending. The ALR
LED also flashes.
The following menu displays after pressing ALARM.
ALARM
NEW
………………………………
MM-DD-YYYY
HH:MM
RESET
NEXT
The DATE and HOUR appear only if a serial card is plugged in the expansion slot.
•
•
•
However must be properly set the clock.
NEW indicates an alarm that has not yet been acknowledged. When the operator presses
RESET to clear the alarm, the alarm disappears only if the alarm condition no longer
exists.
ACK displays if the alarm is still pending
Next is used to scroll between the pending alarms.
The string …………………. stands for one of the following alarm conditions
Table 3-1: Alarm Conditions
Clock Fail ( only with serial card )
Low Rate
EEPROM Fail
Low Speed
High Load
Cold Start
High Rate
Calibrate Time ( only with serial card )
High Speed
External Alarm
Warm Start
Batch Deviation
Power Down Calibrate
Speed sensor error
Overflow Totalizer
COMM Error
AZT Limited
PROFIBUS-DP Error
Math Error
Dinamic Data Lost
Load Cell Fail
Set Up Data Lost
Low Load
PROFIBUS Config. Changed
Refer to Chapter 4 for more information.
3-7
3.8 Start-Stop General Purpose Key
When LOAD OUT function is enabled, and the cycle is stopped, the following general
pourpose key are displayed in the RUN MENU 3 :
ENTER
CLEAR
START
The first line always displays the batch number and the batch status;the second line display
the batch total which is the number of tons totalized by the scale from the start command;.the third
line display the batch set point and the last line allows the operator to change set point, clear the
batch number and start or stop the batch cycle.
When LOAD OUT function is started , the general pourpose CLEAR key is changed
to STOP key in order to stop the LOAD OUT if necessary and the START key is
erased..
When the STOP button is pressed one time the batch is suspended in STANDBY mode
and START key is displayed again.
Remember that is necessary press two times the STOP button in order to abort the
batch cycle
When batch cycle is aborted , the STOP key is again replaced by CLEAR key
3.9 Calibration
MAIN MENU 1 contains the CALIBRATION menu. MENU 1 is selected by pressing MENU
until MAIN MENU 1 displays. Desired calibration scrolls are selected by pressing the soft
keys directly below the desired scroll.
-MAIN MENU 1
-Press MENU for more
ZERO
SPAN MAT’L
CAL
CAL
CAL
3.9.1 Zero Calibration Scroll
The zeroing process is implemented as a machine directed procedure.
1. Press ZERO CAL at Main Menu 1
The following screen displays:
-ZERO CAL
-Run belt empty, then
press START
START EXIT MANUAL
Press EXIT returns to Main Menu 1
Press MANUAL advances to Step 2
Press RUN/SETUP returns to Main Menu 1. Press RUN/SETUP again returns to RUN
The belt must be running until the zeroing procedure is completed requires at least on full
revolution of the belt to be averaged.
3-8
2.
Press START, the next screen is shown :
The following screen displays:
AUTO ZEROING
Time remaining
Rate:
Tot
0000
000.0 t/h
00.0 t
During Auto Zero, resolution of the total is ten times higher than normal. The number of
seconds in Line 2 is calculated based on the current speed and corresponds to the time
remaining for completing the test.
If the belt is not running at the moment the test is started or it is stopped during the test, a
message is displayed, indicating the procedure has been aborted.
WARNING Belt stopped
Calibration aborted.
EXIT
EXIT returns to MAIN MENU 1. When zero is reached, the system automatically
displays the following screen.
AUTO ZERO COMPLETE
Error
±000.00%
Change zero?
YES
NO
ADV
COMPLETE flashes
ADV changes from ERROR % to ACCUMULATED WEIGHT
gHint: The percentage of error is related to full-scale capacity.
NO returns to MAIN MENU 1 without changing the zero number
YES changes the zero number and the next screen displays
ZERO # CHANGED
New zero
#00000
Old zero
#00000
RUN
MENU
ADV
ADV changes from OLD ZERO to RATE to TOTALIZED WEIGHT and to ERROR %
MENU repeats Auto Zero calibration.
RUN/SET UP returns to the MAIN MENU 1
3-9
3.9.2
Manual Zero
The Manual Zero procedure shows the zero constant and allows direct entry if known. Press
ENTER to confirm the new number.
-MANUAL ZERO
-Rate
000.0 t/h Password: Operator
Zero
#00000
ENTER
EXIT
ADV
Default: 40000
Min:
0
Max:
120000
• ADV displays only if Auto Zero Tracking is enabled. The AZT function accurately tracks
the zero of the scale by calculating an additional zero constant. The portion of zero due to
AZT is not incorporated in the zero constant, but is shown separately.
When ADV is pressed, the system scrolls between Zero and AZT:
-MANUAL ZERO
-AZT # ±000000
AZT % ±000000
ENTER
EXIT
ADV
When the AZT is disaplyed, the ENTER key incorporates the AZT number into the Zero
constant so the displayed AZT number and percentage changes to zero.
3.9.3 Span Calibration Scroll
Three simulated load calibration options are available:
• R-Cal
• Test Weights
• Test Chains
Test weights or test chains require additional hardware and handling equipment.
The Integrator allows the operator to select which of the three methods is to be used for
routine calibration. The selection is made in MAIN MENU 2, CAL DATA SCROLL 1.
-- CAL DATA 1
Calibration
> R-CAL <
--
Default: R-CAL
Selection: Test Weights, Test Chain
3.9.3.1
Auto Span
3-10
3.9.3.1.1 Calibration with R-Cal
Use the following steps to begin an R-Cal Calibration:
1. Press SPAN CAL
The following screen displays
AUTO SPAN R CAL
Run belt empty, then
press START
START EXIT MANUAL
Pressing EXIT or RUN/SETUP returns the screen to MAIN MENU 1.
Press START to initiate R-Cal span calibration. There is not totalization for three seconds
until the weight signal has stabilized.
3.9.3.1.2 Calibration with Chain Calibration
Use the following steps to begin a Chain Calibration:
1. Stop the conveyor belt
2. Apply chains on conveyor belt
3. Press SPAN CAL
The following screen displays:
AUTO SPAN CHAIN
Press START to begin
chain calibration.
START EXIT MANUAL
Password: Operator
4. Press START
The following screen displays:
AUTO SPAN CHAIN
Apply chain, then
press START
START EXIT MANUAL
Password: Operator
Pressing EXIT or RUN/SETUP returns the screen to MAIN MENU 1.
5. Press START
The following screen displays:
AUTO SPAN CHAIN
Run belt, then
press START
START EXIT
6. Restart conveyor belt and insure chain placement is proper.
7. Press START
8. Continue to following section.
3-11
3.9.3.1.3 Calibration with Test Weights
Use the following steps to begin a Test Weights Calibration:
1. Stop the conveyor belt if necessary to apply test weights.
2. Press SPAN CAL
The following screen displays:
AUTO SPAN Weights
Press START to begin
weight calibration.
START EXIT MANUAL
Password: Operator
3. Press START
The following screen displays:
AUTO SPAN Weights
Apply weights, then
press START.
START EXIT MANUAL
Password: Operator
If LOAD WTS output was selected in the I/O Definition Scroll, test weights are
automatically loaded after START is pressed. Wait for test weights to be loaded before
proceeding. The following message displays:
AUTO SPAN Weights
Press START to load
test weights.
START EXIT
EXIT or RUN/SETUP returns the screen to MAIN MENU 1
4. Apply test weights
5. Press START
The following screen displays:
AUTO SPAN Weights
Run belt, then
press START.
START EXIT
6. Restart the conveyor belt if it is not running
7. Press START
8. Continue to following section.
3-12
Password: Operator
3.9.3.1.4 Span Calibration
Whichever method has been used to start automatic span calibration, after START is pressed,
the following screen displays:
AUTO SPANNING
Time remaining
0000
Rate
0000.0 Tph
Total
000000 Tons
During Auto Span, the resolution of the total is ten times higher than normal. The time
remaining shown in Line 2 is calculated upon the current speed and is based on the test
duration.
If the belt is stopped during the test, a message is displayed indicating the procedure has been
suspended.
No action is required from the operator; wait until the test is completed.
3.9.3.1.5 Material Factor
Use this step only if a material calibration is done before and the current simulated load
method has no material factor installed.
Note: If a calibration with material has not been run before; a manual span entry is done; or
this is not the first time the current simulated method is used, this section does not apply.
Proceed to following section.
It is very important to understand when this procedure is executed; the system does not alter
the span. The span is assumed correct because it was obtained from a test with material.
The system acquires the Material Factor for the current calibration method instead. This
means the Integrator knows in the future how to use this method for correctly changing the
system’s span.
Use the following steps to incorporate the Material Factor. The following screen displays:
AUTO SPAN COMPLETE
Error +/-00.00 %
Unfactored Calcon
EXIT FACTOR REPEAT
•
•
Complete is flashing
There are three keys to choose from EXIT, REPEAT, and
FACTOR.
EXIT – If the operator chooses EXIT, the system acknowledges the
Material Factor is not used. The system does not ask for a material factor any more for this
calibration method until a manual span entry is performed. By pressing EXIT, the operator tells
the system that material factor is not desired, but wants to use the test results for changing the span
number. Proceed to Section 3.93.1.6. .
REPEAT – If the operator chooses REPEAT, proceed to Previous Section..
FACTOR – If the operator chooses FACTOR, the following screen
displays:
3-13
XXX Matl FACTOR
New factor: 000.00 %
Change factor?
YES
NO
ADV
XXX = R-Cal, WTS, or CHAINS
ADV – advances to Old Factor and again to New Factor.
NO – the Material Factor is set to 1.00
YES – the following screen displays
XXX Matl FACTOR
Old factor: 000.00 %
New factor: 000.00 %
RUN
MENU REPEAT
XXX = R-Cal, WTS, or CHAINS
REPEAT – returns the operator to Previous Section
RUN – returns to the RUN menu main screen
MENU – returns to MAIN MENU 1
3.9.3.1.6 Recording New Span
The Integrator calculates the new span based on the result of the test performed with the
simulated method.
AUTO SPAN COMPLETE
Error +/-00.00 %
Change span?
YES
NO
ADV
Complete is flashing
ADV – advances to Accumulated Weight, Cal Con, Material Factor, and back to Error %.
Note: If the Material Factor is invalid (never acquired before), it is not displayed.
• YES – if the operator selects YES, the following screen displays:
SPAN # CHANGED
Old span #: 00000
New span #: 00000
RUN
REPEAT
ADV
REPEAT – moves back and calibration restarts
ADV – changes from Error % to Accumulated Weight, Calcon, Old Span, and Material Factor
(if not invalid).
RUN – The following screen displays
Remove chains (or weights)
before returning to
normal operation!!
RUN
Menu
RUN – returns to the RUN menu main screen
MENU – returns to MAIN MENU 1
3-14
NO – If the operator selects NO, the following screen displays:
SPAN UNCHANGED
Old span #: 00000
New span #: 00000
RUN
REPEAT
ADV
REPEAT – moves back and calibration restarts
ADV – changes from Error % to Accumulated Weight, Calcon, Old Span, and Material Factor
(if not invalid).
RUN – The following screen displays
Remove chains (or weights)
before returning to
normal operation!!
RUN
Menu
RUN – returns to the RUN menu main screen
MENU – returns to MAIN MENU 1
Note: The Old Span and New Span are equal because no change has been made to the span.
3.9.3.1.7 Ending an Auto Span Procedure with Chains or Test Weights
After Auto Span has been run using chains or test weights follow these steps:
1. Press RUN
The following screen displays
Remove chains (or weights)
before returning to
normal operation!!
RUN
Menu
2. Press RUN
Totalization resumes and the Integrator returns to the RUN menu.
3.9.3.1.8
Ending an Auto Span Procedure with R-Cal
After Auto Span has been running using R-Cal, follow these steps:
1. Press RUN
2. The R-Cal relay is de-energized and the display is locked for three seconds.
3. Press RUN
Totalization resumes and the Integrator returns to the RUN menu.
3-15
3.9.3.2
Manual Span
If the span constant is known, the Manual Span procedure allows the operator to make a direct
change of span. Use the following steps to enter the span constant.
1. Press MENU until you are returned to MAIN MENU 2.
The following screen displays:
-MAIN MENU 2 -Press MENU for more
ZERO
SPAN
MAT’L
CAL
CAL
CAL
2. Select SPAN CAL
The following screen displays:
AUTO SPAN XXXX
Run belt empty, then
press START
START EXIT MANUAL
XXXX = R-Cal, Chains or Weights
3. Select MANUAL
The following screen displays:
Manual Span
Rate:
000.0 Tph
Span # 00000000
ENTER EXIT RUN
Default:
Min:
Max:
3.9.4
300000
222223
20000002
Material Span Calibration
Material span calibration is a machine directed procedure for calibrating the belt scale using
actual material
Pre-weighted or post-weighed material, having been weighed to a known accuracy on a static
scale, passes across the belt scale. This procedure automatically adjusts the Integrator span
and factors all simulated load test Calibration Constants (Cal Con) if the operator prefers they
be factored.
Use the following steps to perform a Material Span Calibration
-MAIN MENU 1 -Press MENU for more
ZERO
SPAN
MAT’L
CAL
CAL
CAL
3-16
1. At MAIN MENU 2, select MAT’L CAL
2. Press the DOWN arrow. The following screen displays:
MAT’L CALIBRATION
Run belt empty, then
press start.
START
MENU
Run the belt for at least one minute or one belt revolution before proceeding.
3. Press START
The Master Weight Totalizer is disengaged. The following screen displays:
Run quantity of
material over scale
CONTINUE
4. Press CONTINUE
The following screen displays:
00000.0 Tons
0000.0 Tph
Press DONE to end
DONE
ABORT
During the Material Calibration procedure, the resolution of total tons counted is ten times
higher than normal.
5. Wait until all material has passed over the scale, press DONE.
ABORT forces the program back to the top of the MATL CAL scroll.
At the end of the test, the system asks the operator whether the (actual) weight of material is
already known.
0000.00 Tons
Ref. Weight known?
YES
NO
NO – select no if the reference (actual) weight is not known for some time and the conveying
systems need to be returned to run.
The RUN screen displays MAT’L flashes to remind the operator that the material test is
incomplete.
Press MAT’L when the reference weight is known and the following screen displays:
0000.00 Tons
Enter reference
weight
00.0 Tons
ENTER
ABORT
YES – if the operator selected yes, the screen above displays.
1. Enter the actual material weight in the same weight units, as the Integrator is setup to use.
3-17
Example: Convert pounds to nearest hundredth (0.01) of a ton and enter the result if the
Integrator is set up for tenths (0.1) of a ton increments. Material Calibration is running at
10 times normal.
2. Press ENTER

ABORT – if abort is selected the information acquired during the test is lost and the system
returns to MAIN MENU 1.
3.9.4.1
Updating the Span Constant
After the amount of material has been entered, the following screen displays:
MAT’L CAL. COMPLETE
Error 000.00 %
change span?
YES
NO
ADV
Complete flashes
YES – moves to the following screen
ADV changes from Error % to Actual Difference of Total
NO moves to the following screen:
MAT’L CALIBRATION
Add reference
weight to totals?
YES
NO
YES – the reference weight is added to the totals and the Integrator returns to MAIN
MENU 1
NO – returns to MAIN MENU 1
3.9.4.2
Acquiring the Material Factors
If yes was selected at the Updating the Span Constant screen, the following screen displays
confirming the new span constant was installed.
SPAN # CHANGED
New span # 000000
Old span # 000000
RUN
MENU FACTOR
At this point, the scale is calibrated to the actual material test.
RUN – returns to the RUN main menu
MENU – returns to MAIN MENU 1
FACTOR – Of the three simulated load calibration methods, only the ones that have been
already used are shown. It is not possible to calculate a material factor if a simulated test was
not run before the material test. The following screen displays:
MAT’L CALIBRATION
Automatic correction
to Material Factors
R-CAL
WTS CHAIN
3-18
If none of the three was performed, FACTOR is not displayed.
If R-CAL, WEIGHTS, or CHAINS is pressed, the following screen displays:
XXXX MAT’L FACTOR
New factor
000.00 %
Change factor?
ADV
YES
NO
XXXX = R-CAL,
WEIGHTS, or CHAINS
Adv – ADVANCES TO THE OLD FACTOR AND AGAIN TO THE NEW FACTOR
No – SELECT no IF THE ACQUIRED MATERIAL FACTOR IS NOT DESIRED.
Yes – select YES if this specific simulated method of calibration has already been used
and the related material factor will be recorded. This selection advances to the next scroll.
The system is able to execute accurate calibrations in the future with this simulated
method. The following screen displays:
XXXX MAT’L FACTOR
Old factor
000.00 %
New factor
000.00 %
RUN
MENU FACTOR
XXXX = R-CAL,
WEIGHTS, or CHAINS
FACTOR – repeats for all simulated tests previously run.
RUN or MENU – if RUN or MENU is selected, the following screen displays:
MAT’L CALIBRATION
Add reference
weight to totals
YES
NO
YES – the amount of material used for the test is added to the master, reset, and operator’s
totals.
NO – the information is lost
Note: Moisture compensation is inhibited during material calibration. This is done to make
the check of the totalized quantity easier. The static scale provides the weight of the material
including moisture. The weight of the water is removed immediately before adding to total at
the end of the procedure, so the Master, Reset, and Operator’s totals are still correct.
3-19
3.10
Main Menu 2 – Setup and Configuration Menus
MAIN MENU 2 contains the SETUP AND CONFIGURATION MENUS. MENU 2 is
selected by pressing MENU until MAIN MENU 2 displays. Desired SETUP AND
CONFIGURAITON scrolls are selected by pressing the SOFT keys directly below the desired
scroll. Scrolls for MAIN MENU 2 consist of the following:
• Display
• Scale Data
• Calibration Data
3.11 Display
The Display menu contains system and Integrator parameters.
3.11.1 Measure Units
Measure units are displayed in English, Metric, or Mixed. Make your selection at this menu.
-- DISPLAY SCROLL 1
Measure units
>ENGLISH<
CHOICE
ENTER
Default:
Choices:
--
ENGLISH
ENGLISH, METRIC, MIXED
English - all units in English
Metric - all units in Metric
Mixed – units may be a combination of English and Metric.
Note: If the Measure units are changed from English to Metric or Metric to English after the
scale is calibrated, the span number changes but the calibration remains the same.
3.11.2 Totalization Units
-- DISPLAY SCROLL 2
Totalization units
>TONS<
CHOICE
ENTER
Default:
Choices:
English = Tons
Tons, Ltons, Pounds
Default:
Choices:
Metric = tonnes
tonnes, kg
Default:
Choices:
Mixed = Tons
Tons, Ltons, kg, Pounds, Tonnes
3.11.3 Lenght Units
-- DISPLAY SCROLL 3 -Length units
>Pounds<
CHOICE
ENTER
3-20
--
Default:
Choices:
English/Mixed = Pounds
Metric = kg
Pounds, kg
3.11.4 Rate Units
The rate is displayed according to the units selected here.
-- DISPLAY SCROLL 4 -Rate units
>TPH<
CHOICE
ENTER
Password:
Service
ENTER – accepts the default units
Default:
Choices:
English = Tph
Tph, LTph, Lb/h, Percent %, Lb/mn, T/mn LT/mn
Default:
Choices:
Default:
Choices:
LT/mn
Metric = kg/h
t/h, kg/h, kg/mn, t/mn, Percent %
Mixed = Tph
Tph, LTph, Lb/h, Percent %, t/h, kg/h, kg/mn, t/mn, lb/mn, T/mn,
3.11.5 Load Cell Units
The units used for entering the load cell capacity are specified here. In this case, the use of
English or Metric units is always allowed.
-- DISPLAY SCROLL 5 -Load cell Units
>Pounds<
CHOICE
ENTER
Default:
Choices:
English or Mixed = Lbs.
Metric = kilograms
Lbs, kg
3.11.6 Speed Units
The speed is displayed according to the units selected here.
-- DISPLAY SCROLL 6 -Speed Unit
>m/s<
CHOICE
ENTER
Default:
Choices:
m/s
m/s, m/min ,FPM
3-21
3.11.7 Language
The Mini-CK 101 is a multi language instrument. Use the following Display Scroll to select a
language.
-- DISPLAY SCROLL 7 -Language
>USA<
CHOICE
ENTER
Default:
Choices:
USA
USA, ESP (Spanish), ITA, FRA, GER,HOL
3.11.8 Time and Date ( ONLY WITH SERIAL BOARD )
The user has to define the format for displaying and printing time and date .
-- DISPLAY SCROLL 8 -Time
> am/pm <
CHOICE
ENTER
Default:
Choices:
USA = am/pm
other languages = 24 h
am/pm, 24 h
-- DISPLAY SCROLL 9 -Date
> MM-DD-YYYY <
CHOICE
ENTER
Default:
Choices:
USA = MM-DD-YYYY
other languages = DD-MM-YYYY
DD-MM-YYYY, MM-DD-YYYY, YYYY-MM-DD
3.11.9 Line Three (3) of the Run Menu
The third line of the RUN MENU display can be set to display Belt Loading, Speed, Date and
Time, or nothing. Use Display Scroll 9 to determine the third line display.
-- DISPLAY SCROLL 10 -Run display line 3
> No Display <
CHOICE
ENTER
Default:
Choices:
No display
No display, load, speed, date/time
3-22
3.11.10
Displayed Damping Factors
The process variable when displayed on the screen can be damped by a programmable factor to
filter out variations that can be introduced by mechanical vibrations.
To tune a damping filter, enter the number of seconds corresponding to the desired time
constant.
Example: 10 seconds is entered for a damping factor. Following a step change, the process
variable reaches 60% of the final value in 10 seconds. This damping factor only affects the
display, not the current output variable, which has a separate damping factor.
-- DISPLAY SCROLL 11 -Damping Display RATE
Damping = 2 sec
ENTER
Default:
Min:
Max:
Password:
Operator
2 sec
0 sec
400 sec
Damping Display Load
Display Scroll 11 is only visible if the Run display line 3 is set to Load.
-- DISPLAY SCROLL 12 -Damping Display LOAD
Damping = 2 sec
ENTER
Default:
Min:
Max:
2 sec
0 sec
400 sec
Damping Display Speed
Display Scroll 12 is only visible if the Run display line 3 is set to speed.
-- DISPLAY SCROLL 13 -Damping Display SPEED
Damping = 2 sec
ENTER
Default:
Min:
Max:
2 sec
0 sec
400 sec
3-23
3.11.11
Screen Saver
The MiniCK is supplied with a Screen Saver feature implemented in order to increase the life
of display. As DEFAULT after about 5 minuts of inactivity on the Keyboard the backlight of
the LCD display is turned off. With this menù is possible to disable this feature.
-- DISPLAY SCROLL 14 -Screen Saver
> Yes <
CHOICE
ENTER
Default:
Choices:
Yes
Yes, No
3-24
Password:
Operator
3.12
3.12.1
Scale Data Scroll
Max. Scale Capacity
Scale capacity is the maximum rate at which the scale is allowed to work. This entry also
defines the default number of decimal places used for displaying rate.
-- SC DATA SCROLL 1 -Max. scale capacity
500.0
TPH
ENTER
Default:
Min:
Max:
500.0
1
200000
3.12.2 Scale Divisions
When the SCALE CAPACITY is entered, the number of decimal places is also defined. For
example, the user enters 500.0; this sets the SCALE DIVISIONS parameter to 0.1.
At the SCALE DIVISIONS menu, the displayed SCALE DIVISION corresponds to the just
entered SCALE CAPACITY. The user can change the pre-set SCALE DIVISIONS by
pressing CHOICES.
-- SC DATA SCROLL 2 -Scale divisions
>0.1<
CHOICE
ENTER
Default: 0.1
Choices: 0.1, 0.2, 0.5, 1, 2, 5, 10, 20, 50, 0.01, 0.02, 0.05, 0.001, 0.002,
0.005
Make your choice and press ENTER to save the choice.
3.12.3 Selecting the Weighbridge Model (Belt scale code)
By entering the code number of your Thermo Fisher scale, the Integrator automatically
calculates parameters of the system such as number of load cells and number of weigh idlers.
(Refer for further information regarding specific weighbridges.)
This menu items is also used for internal calibration calculations. The default model number is
1, which corresponds to belt scale model 10-20-1.
-- SC DATA SCROLL 3 -Belt scale code #
>1<
ENTER
DETAIL
Default:
Min:
Max:
1
0
500
3-25
Press ENTER to accept the displayed selection (refer Appendix B, Thermo Electron
Weighbridge Physical Parameters.).
Note: If the default is used, the scrolls from 3A to 3J are not displayed.
Press DETAIL if you want to force the following scrolls to be displayed even if the default
was chosen.
• 3A – 30
Enter 0 if you want to define the weighbridge not using the database. This should only be done
for special weighbridges that are not part of the standard set of Thermo Fisher scales.
Entering 0 forces the following menus to be displayed:
3.12.4
Detailing the Mechanical Parameters of the Frame
These menus only display if OTHER or DETAIL was selected in the Section.
Pivot to Load Cell Distance (Parameter LA)
The distance from the pivot to load cell should be measured to within 0.032 inch (1/32”)
(1mm). Using the numeric keys enter the distance recorded in the Section and press ENTER.
For weighbridges, which do not have a pivot, enter zero (0).
-- SC DATA SCROLL 3A -Pivot to load cell
distance:
IN
ENTER
English/Mixed
Default: 32 in
Min:
0.00 in
Max:
150.00 in
Metric
Default:
Min:
Max:
1000 mm
0 mm
3800 mm
Number of Weigh Idlers (Parameter LB1)
The number of weigh idlers affixed to the scale weighbridge. Use the numeric keys to enter
the number of weigh idlers and documented in the Section, press ENTER.
-- SC DATA SCROLL 3B -# of weigh idlers
ENTER
Default:
Min:
Max:
1
1
6
3-26
Pivot to First Weigh Idler Distance (Parameter LB1)
Measure the distance between the pivot centerline and first weigh idler centerline. Use the
numeric keys to enter the distance 0.032 inch (1/32”) (1mm).
For weighbridges without a pivot, enter zero (0). Press ENTER
-- SC DATA SCROLL 3C -Pivot to first idler
distance
In
ENTER
English/Mixed
Default: 24 in
Min:
0.00 in
Max:
100.00 in
Metric
Default:
Min:
Max:
800 mm
0 mm
2500 mm
If the number of weigh idlers entered in Scroll 3B is more than one, the following screens are
displayed. Measure the distance between the pivot centerline and the first weigh idler grease
fitting. Enter the distance (within 0.032 inch or 1 mm). For weighbridges, which do not have
a pivot, enter zero.
Only if # of weigh idlers ≥ 2
-- SC DATA SCROLL 3D -Pivot to 2nd idler
distance
000.00 In
ENTER
English/Mixed
Default: 0.00 in
Min:
0.00 in
Max:
100.00 in
Metric
Default:
Min:
Max:
Password:
Service
800 mm
0 mm
2500 mm
Only if # of weigh idlers ≥ 3
-- SC DATA SCROLL 3E -Pivot to 3rd idler
distance
000.00 In
ENTER
English/Mixed
Default: 0.00 in
Min:
0.00 in
Max:
100.00 in
Metric
Default:
Min:
Max:
Password:
Service
800 mm
0 mm
2500 mm
Only if # of weigh idlers ≥ 4
-- SC DATA SCROLL 3F -Pivot to 4th idler
distance
000.00 In
ENTER
English/Mixed
Default: 0.00 in
Min:
0.00 in
Max:
100.00 in
Metric
Default:
Min:
Max:
3-27
Password:
Service
800 mm
0 mm
2500 mm
Only if # of weigh idlers ≥ 5
-- SC DATA SCROLL 3G Pivot to 5th idler
distance
000.00 In
ENTER
English/Mixed
Default: 0.00 in
Min:
0.00 in
Max:
100.00 in
Metric
Default:
Min:
Max:
Password:
Service
800 mm
0 mm
2500 mm
Only if # of weigh idlers = 6
-- SC DATA SCROLL 3H -Pivot to 6th idler
distance
000.00 In
ENTER
English/Mixed
Default: 0.00 in
Min:
0.00 in
Max:
100.00 in
Metric
Default:
Min:
Max:
Password:
Service
800 mm
0 mm
2500 mm
Enter each distance with the numeric keys and press ENTER.
Pivot to Test-Weight Height (Parameter LE)
For weighbridges, which do not have a pivot, enter zero. 3I, L, M, and N only apply if test
weights are provided.
-- SC DATA SCROLL 3I -Pivot to test-weight
height
000.00 In
ENTER
+/-
English/Mixed
Default: 0.00 in
Min:
-20.00 in
Max:
+20.00 in
Metric
Default:
Min:
Max:
Password:
Service
0.0 mm
-500.0 mm
+500.0 mm
Pivot to Test-Weight Length (Parameter LC)
For weighbridges, which do not have a pivot, enter zero.
-- SC DATA SCROLL 3L -Pivot to test-weight
length
000.00 In
ENTER
English/Mixed
Default: 24.00 in
Min:
0.00 in
Max:
200.00 in
Metric
Default:
Min:
Max:
3-28
Password:
Service
0 mm
0 mm
500.0 mm
Pivot to Carriage Height (Parameter LF)
For weighbridges, which do not have a pivot, enter zero.
-- SC DATA SCROLL 3M -Pivot to carriage
height
000.00 In
ENTER
English/Mixed
Default: 6.50 in
Min:
0.00 in
Max:
10.00 in
Metric
Default:
Min:
Max:
Password:
Service
0 mm
0 mm
250 mm
Carry Roll to Carriage Height (Parameter LG)
For weighbridges, which do not have a pivot, enter zero.
-- SC DATA SCROLL 3N -Roll to carriage
height
000.00 In
ENTER
+/-
English/Mixed
Default: 6.50 in
Min:
0.00 in
Max:
20.00 in
Metric
Default:
Min:
Max:
Password:
Service
0 mm
0 mm
250 mm
Number of Load Cells for the Weighbridge
-- SC DATA SCROLL 3O -# of load cells
0
ENTER
Default:
Min:
Max:
1
1
6
3-29
Password:
Service
3.12.5
Defining Dimensional Parameters of the Application
3.12.5.1 Idler Spacing in Scale Area
For better accuracy, average the distance between the idlers across the scale on both sides.
Measure to within 0.032 inch or 1 mm with the numeric keys and press ENTER.
-- SC DATA SCROLL 4 -Idler spacing
36.00 In
ENTER
English/Mixed
Default: 36.00 in
Min:
2.00 in
Max:
120.00 in
Metric
Default:
Min:
Max:
Password:
Service
1000 mm
50 mm
2500 mm
3.12.5.2 Angle of Inclination
Enter the angle of inclination. If an inclination meter is connected to the scale, after this
preliminary set up has been completed, enable the automatic angle detection in I/O
DEFINITION (MENU 4) and calibrate the angle meter.
-- SC DATA SCROLL 5 -Conveyor’s angle
0 0 Degrees
ENTER
+/-
Default:
Min:
Max:
Password:
Service
0.0
-25.00°
+25.00°
3.12.6
Defining the Load Cell(s)
3.12.6.1 Load Cell Capacity
Enter the load cell capacity as it appears on the label placed on the load cell.
-- SC DATA SCROLL 6 -Load cell capacity
250 Lbs
ENTER
English/Mixed
Default: 250.0 Lbs
Min:
1 Lbs
Max:
15000 Lbs
Metric
Default:
Min:
Max:
3-30
Password:
Service
100 kg
1 kg
5000 kg
3.12.6.2 Load Cell Sensitivity
The sensitivity was entered when the belt scale code was entered. If other (0) was selected,
enter the load cell sensitivity in mV/V as marked on the label of the load cell. Thermo
Electron load cells are normally 2.000 or 3.000 mV/V.
-- SC DATA SCROLL 7 -Load cell sens.
3.00 mV/V
ENTER
Default:
Min:
Max:
Password:
Service
3.0 mV/V
0.500 mV/V
3.500 mV/V
3.12.6.3 Load Cell Resistance
Load cell resistance is entered on this screen. The resistance for the load cell has been
recorded on the System Data Sheet in the front of your belt scale manual. (It is also stamped
on the load cell cable.) Enter the ohms for the load cell. The number of scrolls depends on the
number of load cells specified in scroll 3O.
-- SC DATA SCROLL 8X -Load cell #N res
3.00 Ohms
ENTER
Password:
Service
X = A, B, C, D, E, or F
n = 1, 2, 3, 4, 5, or 6
Default:
Min:
Max:
350 Ohms
10 Ohms
2000 Ohms
Note: One screen displays for each load cell
3.12.6.4 Defining the Speed Input
The speed input screen allows the operator to select the single speed sensor input (default
value) or a simulated value using an internal timer.
Simulation allows operation without a speed sensor. When simulated speed is selected, a
conveyor running input is required (refer to the field wiring diagram).
Note: If speed is selected as the third line display in the RUN screen, the line will be blank in
RUN mode when simulated speed is selected.
-- SC DATA SCROLL 9 -Speed signal
>input<
CHOICE
ENTER
Default:
Choices:
INPUT
INPUT , SIMULATED
3-31
3.12.6.5 Setting Dead Band
The dead band is a percentage of the scale capacity (rate) in which the rate is ignored (if any)
and a zero rate is forced. In addition, Totalization is frozen when rate is below dead band.
-- SC DATA SCROLL 10 -Zero dead-Band Range
0 %
ENTER
Default:
Min:
Max:
Password:
Service
0%
0%
5%
3.13 Calibration Data Scroll
The CAL DATA scroll allows the operator to enter or set parameters, which relate to the
calibration of the scale.
3.13.1
Defining the Calibration Mode
Select the method of simulated automatic calibration. The selected method is the only one
displayed in the calibration section of MENU 1.
-- CAL DATA SCROLL 1 -Calibration mode:
< R-CAL<
CHOICE
ENTER
Default:
Choice:
Password:
Service
R-CAL
R-CAL, CHAIN, WEIGHTS
3.13.1.1 Defining the R-Cal Parameters
This section only applies of R-Cal mode was selected as the preferred method. Enter the
resistance in Ohms of the R-cal resistor installed in your Integrator. Default value installed is
165000 Ohms. See the Data Sheet in front of this manual for exact resistance.
-- CAL DATA SCROLL 2 -R-CAL select
Res
165000 ohms
ENTER
Default:
Min:
Max:
Password:
Service
165000 Ohms
10 Ohms
1000000 Ohms
The system calculates the CALCON (Calibration Constant) based on the mechanical and
electrical parameters entered in SCALE DATA. This menu is for reference only.
-- CAL DATA SCROLL 3 -R-CAL constant
00.00
MENU
RUN
3-32
3.13.1.2 Defining the Chains Parameters
This section only applies if CHAINS mode was selected as the preferred method. Enter the
weight per foot or meter of the chains used for calibration.
-- CAL DATA SCROLL 4 -Chain select. Weight
00.00 Kg/m
ENTER
English/Mixed
Default: 0.000 Lbs/Ft
Min:
0.000 Lbs/Ft
Max:
1000.000 Lbs/FT
Password:
Service
Metric
Default:
Min:
Max:
0.000 kg/m
0.000 kg/m
3000 kg/m
The system calculates the CALCON based on the mechanical and electrical parameters entered
in SCALE DATA. This menu is for reference only.
-- CAL DATA SCROLL 5 -CHAIN CAL constant
00.00 t
MENU
RUN
3.13.1.3 Detailing the Test Weight Parameters
This section only applies if TEST WEIGHTS mode was selected as the preferred method.
Enter the weight of the test weights used for calibration.
-- CAL DATA SCROLL 6 -Test weight
0.000 kg
ENTER
English/Mixed
Default: 0.000 Lbs/Ft
Min:
0.000 Lbs/Ft
Max:
Load cell size x no
of load cells
Password:
Service
Metric
Default:
Min:
Max:
0.000 kg/m
0.000 kg/m
3000 kg/m
The system calculates the CALCON (Calibration Constant) based on the mechanical and
electrical parameters entered in the SCALE DATA. This menu is for reference only.
-- CAL DATA SCROLL 7 -WEIGHT CAL constant
00.00
MENU
RUN
3-33
3.13.2
Entering Calibration Interval (Only with OPTION Serial Board)
The system can be programmed to prompt the operator when the next calibration is due. If this
option is not desired, confirm the default 0 days interval, otherwise enter the number of days.
The calibration date displayed in Scroll 9 is automatically updated whenever a calibration is
performed. If a non-zero value is entered, an alarm appears after the time is elapsed. The
alarm can only be cleared after a calibration check is executed.
-- CAL DATA SCROLL 8 -CALIBRATION interval
365
Days
ENTER
Default:
Min:
Max:
Password:
Operator
0 Days
0 Days
365 Days
The scroll displays the date of the last calibration and the expected date of the next one, based
on the entry in the previous screen.
-- CAL DATA SCROLL 9-Calibration date
Last:
MM-DD-YYYY
ENTER:
MM-DD-YYYY
3.13.3
Entering Material Factors
The material factor is a number in percent, which is used to correct the CALCON to the real
value. Entering 0 makes the material factor INVALID.
-- CAL DATA SCROLL 10-Material FACTOR
R-Cal
INVALID
ENTER
±
NEXT
Default:
Min:
Max:
0%
-99.99%
+99.99%
NEXT scrolls between material factors of R-Cal, Weights, and Chains “INVALID” displays if
they have not been measured
3-34
3.13.4
Defining the Calibration Test Duration
Zero and Span calibrations are more accurate if executed on an entire belt revolution or
multiple of it. Press ACQUIRE (the recommended selection) or MANUAL (skip to Section
Errore. L'origine riferimento non è stata trovata.Errore. L'origine riferimento non è
stata trovata.Errore. L'origine riferimento non è stata trovata.0.)
-- CAL DATA SCROLL 11-Establish test
duration
ACQ
MANUAL
ACQuire is the recommended selection.
3.13.4.1 Acquiring the Test Duration
When selecting FULL, use a 100-foot tape to measure the belt length to the nearest 0.1-foot.
Reference a fixed point (an idler) on the conveyor when counting belt revolutions. See Section
for the recorded conveyor belt length.
The PARTIAL (belt length measurement) selection enables the operator to acquire test
duration without the entire belt length measurement.
Note: This option should only be used when belt length exceeds 1000 feet.
ACQUIRE TEST DUR
Choose belt length
measurement method.
FULL
PARTIAL
FULL is the recommended selection.
3.13.4.2 Full Test Duration Acquisition
If FULL is pressed, the operator is asked to enter the length of one belt revolution. Enter the
length recorded in Section . Measure belt length to the nearest 0.1 feet.
Enter length of one
belt revolution.
Length
1000.0 Ft.
ENTER
ABORT
English/Mixed
Default: 1000.0 Ft
Min:
1.0 Ft
Max:
10000 Ft
Metric
Default:
Min:
Max:
Password:
Service
200.0 m
0.5 m
3000 m
After the length of the belt has been entered, the system automatically moves to the following
screen, which prompts the operator to press START when the mark passes the reference point.
Pressing ABORT returns the screen to CAL DATA SCROLL 11.
Note: The belt must be running at the maximum speed before executing this function. If not,
the prescaler will be improperly calculated.
3-35
Start belt. Pres
START when 1st mark
passes reference.
START
ABORT
Note: If a clip detector is installed and clip detector mode is set to ‘AUTO’ in I/O
DEFINITION SCROLL skip to Section.
When START is pressed, the system automatically moves to the next instructional screen.
The operator presses COUNT each time the mark passes the reference point until minimum
test load conditions are met (refer to the belt scale installation manual for minimum test level
requirements). When the last revolution passes the mark, the operator must press COUNT
followed by pressing DONE.
Pressing ABORT returns the screen to CAL DATA SCROLL 11.
Press COUNT each
Time a mark passes.
00000 secs 000 revs
COUNT
ABORT
ABORT returns the screen to CAL DATA SCROLL 11.
When test duration is finished, the new values for length of belt and time are displayed. Press
CONTINUE
TEST DURATION
Length = 0000.0 Ft
Time
= 000 SEC
CONTINUE
3.13.5
Auto Count Belt Revolutions
If a clip detector is installed and clip detector mode in I/O Definition is set to "AUTO", the
system automatically counts belt revolutions without the need for pressing the COUNT key.
The two screens for Acquiring Test Duration are displayed as follows:
Start belt. Wait
until 1st mark
passes reference
ABORT
When the mark passes, the system automatically moves to the next instructional screen. The
system counts each time a mark passes the reference point until the operator presses the DONE
key.
Press DONE when
ready.
0000 secs 000 revs
ABORT
DONE
3-36
3.13.6
Partial Test Duration Acquisition
If PARTIAL is pressed, the operator is asked to enter the length between two marks on the
belt.
Pressing ABORT returns the screen to CAL DATA SCROLL 11.
Enter length between
two marks on belt.
Length
200.0 Ft.
ENTER ABORT
English/Mixed
Default: 200.0 Ft
Min:
1.0 Ft
Max:
1000.0 Ft
Metric
Default:
Min:
Max:
50.0 m
0.5 m
3000.0 m
After the length of the belt has been entered, the system automatically moves to the following
screen, which prompts the operator to press START when the mark passes the reference point.
NOTE: The belt must be running at the maximum speed before executing this function. If
not, the prescaler is improperly calculated.
Pressing ABORT returns the screen to CAL DATA SCROLL 11.
Start belt. Press
START when 1st mark
passes reference.
START
ABORT
When START is pressed, the system automatically moves to the next instructional screen.
The operator presses COUNT each time a mark passes the reference point until both marks
have passed. Then press DONE.
Pressing ABORT returns the screen to CAL DATA SCROLL 11.
Press COUNT each
time a mark passes.
00000 secs 000 revs
COUNT ABORT DONE
Note: The COUNT key is not displayed if the clip detector option is in Auto mode.
When test duration is finished, the new values for length of belt and time are displayed. Press
CONTINUES.
TEST DURATION
Length = 0000.0 Ft
Time
= 000 sec
EXIT
3-37
3.13.7
Manual Entry of Test Duration
This procedure allows direct entry of parameters that would otherwise be generated by the
acquire Test Duration modes. This menu is generally used when the operator cannot see the
belt while standing at the front panel.
If MANUAL is pressed, the system prompts the operator to run the belt at its maximum speed.
Press CONTINUE
Pressing ABORT returns the screen to CAL DATA SCROLL 11.
Start Belt. Press
CONTINUE when belt
is at maximum speed.
ABORT CONTINUE
Password: Service
The operator is prompted to enter the length of one belt revolution.
Pressing ABORT returns the screen to CAL DATA SCROLL 11.
ENTER length of one
belt revolution.
Length 000.00 Ft
ENTER
ABORT
English/Mixed
Default: 100.0 Ft
Min:
1.0 Ft
Max:
10000.0 Ft
Metric
Default:
Min:
Max:
Password: Operator
200.0 m
1.0 m
10000.0 m
The number of belt revolutions to be timed is than entered.
Pressing ABORT returns the screen to CAL DATA SCROLL 11.
ENTER the number of
belt revolutions to
be timed 1 revs
ENTER
ABORT
Default:
Min:
Max:
1
1
100
The next entry is the time per revolution.
Pressing ABORT returns the screen to CAL DATA SCROLL 11.
ENTER the time for
revolutions to pass
reference 000 sec
ENTER
ABORT
Default:
Min:
Max:
30 sec
1 sec
16200 sec
3-38
When ENTER is pressed, the system times the belt travel according to the above entered
parameters.
Pressing ABORT returns the screen to CAL DATA SCROLL 11.
Timing belt travel
000 sec
ABORT
When test duration test is finished, the new values for length of belt and time are displayed.
Press CONTINUE
3.13.8
Defining Auto Zero Tracking
A periodic auto zero procedure can be automatically executed by the system if the Auto Zero
Tracking option is set to YES. If YES is selected, Auto Zero Tracking is enabled anytime the
belt is running at a flow rate less than the range setting selected below.
-- CAL DATA SCROLL 12-Auto zero tracking
> Yes <
CHOICE
ENTER
Default:
Selections:
Password: Operator
NO
YES, NO
The following scrolls are only visible if Auto Zero Tracking is enabled.
Define the range of action of the AZT with reference to the scale capacity (rate). A flow rate
greater than the range setting deactivates AZT.
--CAL DATA SCROLL 12AAuto zero tracking
Range ± 4.0 %
ENTER
Default:
Min:
Max:
Password: Operator
±4%
±0%
± 10 %
Define the maximum amount of zero error (with reference to the scale capacity) that AZT can
automatically compensate.
--CAL DATA SCROLL 12BAuto zero tracking
Max Dev ± 4.0 %
ENTER
Default:
Min:
Max:
±4%
±0%
± 10 %
3-39
Password: Service
3.13.9
Entering the Speed Capacity
The user can ENTER the maximum speed capacity or ACQuire it. To acquire the speed, run
the belt at maximum speed and then press the ACQ key.
--CAL DATA SCROLL 13Max speed capacity
200.0 Fpm
ENTER
ACQ
English/Mixed
Default: 200.0 Fpm
Min:
1.0 Fpm
Max:
2000.0 Fpm
Metric
Default:
Min:
Max:
Password: Service
1.0 m/s
0.1 m/s
10 m/s
The maximum speed capacity is used to scale the current output when used to monitor the
speed, and to allow entering the speed alarms in %.
3.13.10
Defining the Number of Calibrations
This screen allows the operator to specify the number of calibrations to be defined. If a
number higher than 1 is entered, the digital inputs for calibration selection can be defined.
--CAL DATA SCROLL 14Number of calib.
1
ENTER
Default:
Min:
Max:
1
1
2
3-40
Password: Service
3.14 Main Menu 3
MAIN MENU 3 is used for protecting and un-protecting the system using passwords, and to
perform diagnostic and test functions. The diagnostic functions can only be operated after
removing all password protection, and should only be used by experienced technical personnel.
Most test functions are not password protected.
-- -MAIN MENU 3
Press MENU for more
PROT
DIAG
TEST
The PROTECTION menu (Selection PROT) only becomes visible after passwords have
been defined (see the DIAGNOSTICS Menu).
3.14.1 Changing Protection Level
The Mini-CK101 has three protection levels to which specific passwords are related.
Tab. 3-2: Password Protection Levels
Protection
NONE
Password
SERVICE
Status
The system is completely unprotected; all data
can be read or changed.
LIMITED
OPERATOR
Operator functions and data are unprotected. All
setup and calibration data are protected except
zero calibrate.
PROTECTED
The system is totally protected, process data can
be read, no change allowed.
A SERVICE password is required to access the NONE level. An OPERATOR or a
SERVICE password is required to access the LIMITED level.
Use the NONE key to access the NONE protection level. If the current level is not already
NONE, the SERVICE password is required.
Use the LTD key to access the limited protection level. If the system is in level NONE,
change is immediate. If it is in PROT level, the SERVICE or OPERATOR password is
required. Use the PROT key to access the protected level. No password is required.
- PROTECTION LEVEL
> NONE <
Default:
Selections:
Password:
NONE
NONE, LIMITED, PROTECTED
from NONE to LTD or PROT: not required
from LTD to PROT:
not required
from LTD to NONE:
SERVICE
from PROT to NONE:
SERVICE
from PROT to LTD:
OPERATOR or SERVICE
Pressing the soft key gives entry to desired level. Going from a low level to a higher level
forces the password entry.
3-41
3.14.1.1
Online Procedure for Changing Protection Level
The protection level can be temporarily changed by entering a password "on the fly" during
normal operation. When the operator tries to enter a variable or select a function, which is
password protected, and the password is installed, the following screen is displayed.
- SYSTEM PROTECTED
PLEASE ENTER
PASSWORD
ENTER
The operator can enter either the OPERATOR or the SERVICE passwords. However, if the
operator enters the OPERATOR password and the variable or function requires the SERVICE
password instead, the access is denied and the following screen is displayed.
- SYSTEM PROTECTED PLEASE ENTER SERVICE
PASSWORD
ENTER
If the operator fails to enter the correct password, the following screen displays.
- SYSTEM PROTECTED
INVALID PASSWORD
ACCESS DENIED
Pressing RETURN returns the program to the previous function. If the operator enters the
correct password, the previous screen appears and access is allowed.
When the protection level is changed using the on line procedure, the system automatically
returns to protected status if no keyboard entries are made within 60 seconds.
3.15
3.15.1
Diagnostics
A/D Raw Data
Diagnostic Scroll 1 shows the raw data from the A/D converter of the Integrator (A/D gross)
and the net value after the zero constant has been subtracted. The range of the A/D converter
is from 0 to 131070 numbers.
-DIAGNOSTIC SCROLL 1A/D gross 00000
A/D net 0000
3.15.2
Readout Load Cell mV
The system displays the mV output of the load cell. The reading must be positive and must
increase when the load increases.
-DIAGNOSTIC SCROLL 2Weight on load cell
0.000 mV
CALIB
3-42
Password:Service
If CALIB is pressed, the next two scrolls are displayed and can be used to fine-tune the
readout of mV/V.
-DIAGNOST. SCROLL 2A
Loadcell output zero
0000000 A/D counts
ENTER
Default:
Min:
Max:
Password: Service
4096
0
10000
-DIAGNOST. SCROLL 2B
Loadcell output span
Password: Service
0000000
ENTER
Default:
Min:
Max:
3.15.3
3400
0
30000
Change Prescaler
The prescaler is a number, which is used to divide the incoming frequency of the speed
sensor(s) to achieve a usable input frequency of approximately 30 Hz. The prescaler is
automatically calculated and should never be altered by the user. However, a direct entry has
been made possible for quick replacement of the Integrator.
-DIAGNOST. SCROLL 3Prescale 00000
00000.0 pls/min
ENTER
CALIB
Default:
Min:
Max:
Password: Service
10
1
100
If CALIB is pressed, the following screens appear.
-DIAGNOST. SCROLL 3A
Test duration total
pulses 0000000
ENTER
Default:
Min:
Max:
900
1
100000
3-43
Password: Service
-DIAGNOST. SCROLL 3B
Test duration total
length 00000.0 ft
ENTER
English/Mixed
Default: 200 feet
Min:
1 foot
Max:
100000 feet
3.15.4
Password: Service
Metric
Min:
Max:
Default:
200 m
1m
100000 m
Change Passwords
Change the password by entering a new one. The user can enter up to eight characters (numeric
keys entries). The entered numbers are not echoed on the screen. Pressing just the ENTER
key removes the password.
-DIAGNOST. SCROLL 4ENTER SERVICE
PASSWORD ********
ENTER
Default:
Password : Service
No password
After the password has been entered, the system asks for confirmation. This prevents losing
access control due to a typing mistake while entering passwords.
-DIAGNOST. SCROLL 4REENTER SERVICE
PASSWORD ********
ENTER
If the password entered the second time matches the first, the following message confirms the
entry.
-DIAGNOST. SCROLL 4NEW PASSWORD
ACQUIRED
RETURN
If the two passwords do not match, the system does not accept the new password.
-DIAGNOST. SCROLL 4INVALID PASSWORD
RETURN
3-44
-DIAGNOST. SCROLL 5ENTER OPERATOR
PASSWORD ********
ENTER
Password :Operator
Default: No password
The OPERATOR password is double checked similarly to the service one.
It is strongly suggested to write down the password and preserve a copy in a safe place. If the
password is forgotten, refer to Section 4.3.7 to remove a forgotten password.
3.15.5
Display Software Version
The software version is displayed for reference only.
-DIAGNOST. SCROLL 6Software version
86.XX.XX.XX
3.15.6
Display RedBoot Version
The RedBoot version is displayed.
-DIAGNOST. SCROLL 7RedBoot version:
X.X
3.15.7
Display Cpld Version
The Cpld version is displayed.
-DIAGNOST. SCROLL 8Ver. CPLD CPU : 0xc5
Ver. CPLD LCD : 0xd1
3.15.8
Setup Date and Time (Only with OPTION Serial Board )
The user can set the current date and time. A battery operated clock calendar then maintains
time and date even if power is removed. Day, Month, and Year are entered in sequence.
-DIAGNOST. SCROLL 9Date: DD-MM-YYYY
DAY: DD
ENTER
Default:
Min:
Max:
00-00-0000
01-01-0000
31-12-2096
3-45
Time is entered in a similar way. The AM/PM key is used when time is in the English mode.
See DISPLAY SCROLL 7 IN MAIN MENU 2.
-DIAGNOST. SCROLL 10Time:
HH:MM
HOURS:
HH
ENTER AM/PM
Default:
Min:
Max:
3.15.9
24-hour
am/pm
00.00
00.00
23:59
01.00
01.00
12:59
Check Hardware Configuration
The system automatically recognizes when expansion boards is installed. The following scroll
is used to show the configuration.
The following screen is displayed when optional plugin board is installed on expansion slot.
-DIAGNOST. SCROLL 11Board Type slot
COMUNICATION 232/485
List of Optional Expansion Plugin Board Types
- Communication
Optional Output Board
Serial communication (RS232, RS485)
- Analog I/O
Optional Output Board
- #1 Analog Current outputs
- Profibus DP
Optional Output Board
Profibus communication.
3.15.10
Force Cold Start
This scroll is used to force a cold start of the instrument in the event the software becomes
corrupted. Factory default constants will be installed when the instrument restarts; all field
entry data will be replaced.
-DIAGNOST.SCROLL 12Force cold start
ENTER
3-46
3.15.11
Firmware Update
This NEW scroll has been introduced to allow an easy future update of the firmware.
Since this function must be used in combination with an external software, it must be used very
carefully and only by the maintenance people or Thermo Fisher field engineeer.
The Help button gives a quick explanation how to use this function.
-DIAGNOST.SCROLL 13Firmware Update
UPDATE
HELP
Pressing UPDATE the following Scroll appears:
ATTENTION
ARE YOU SURE ?
YES
RETURN
Pressing RETURN is possible to go back with the operation and exit from the function.
Pressing YES the following Scroll appears:
IT IS NOW POSSIBLE
UPDATING
THE FIRMWARE
WARNING
ONCE THE INSTRUMENT SHOWS THE INDICATION ABOVE
IS NOT POSSIBLE TO GO BACK.
AT THIS POINT IS ONLY POSSIBLE TO UPDATE THE FIRMWARE OR
TURN OFF THE INSTRUMENT.
ALL THE DYNAMIC DATA WILL BE LOST.
3-47
3.15.12
Lamp Test
Press START to begin a Lamp Test of the Integrator. All LED's and digits of the display
blink for a number of seconds.
- TEST SCROLL 1
LAMP TEST
-
START
3.15.13
Test Digital Inputs
The next screen is used to check the digital input circuitry. The display shows a 1 if the
specific input is closed, 0 if open.
- TEST SCROLL 3 Digital Input test
-----00
The instrument have to handle logical input besides phisycal inputs. These one has to be
separated from phisycal.
3.15.14
Test Digital Outputs
This test shows the status of each digital output ( phisycal ) and allows the operator to
force the output for testing purposes. The output, when forced, stays on until the CLEAR soft
key is pressed or the Run Menu is entered. If an output is forced and the scroll key is used for
reaching some other menu, the output stays in the forced status until RUN is pressed. This
allows the operator to check inputs while outputs are still in the forced status.
- TEST SCROLL 4 Dig output test
output # 1 : ON/OFF
ENTER
ON/OFF
Password: Service
To force an output, enter the desired number . Then use the ON/OFF key to force it to the ON
or OFF status. After the output has been forced, the CLEAR soft key appears in the middle
position.
The same management has to be done with logical outputs.
WARNING
FORCING THE DIGITAL OUTPUTS MAY CAUSE
MACHINERY TO START. AFTER THE USER TRIES
TO FOURCE AN OUTPUT, THE FOLLOWING
MESSAGE DISPLAYS.
WARNING
EQUIPMENT MAY START
CONTINUE
ABORT
3-48
WARNING
IF THE USER PRESSES CONTINUE, BE AWARE
THE ACTION MAY CAUSE DAMAGE OR INJURY.
IF THE USER PRESSES ABORT, THE SYSTEM
RETURNS TO THE PREVIOUS SCROLL.
3.15.15
Virtual Inputs Test
- TEST SCROLL 5 Virtual Inputs 1
00000000
Password: Service
ADV
The virtual inputs are used to compensate for the limited number of physical inputs available.
Is possible to use a virtual input rather than a physical not available to enable a function.
They can be used with all types of communication.(PROFIBUS, SERIAL, ETHERNET ).
3.15.16
Virtual Outputs
- TEST SCROLL 6 Virtual Outputs 1
00000000
Password: Service
ADV
The virtual outputs are used to compensate for the limited number of physical outputs
available.Is possible to use a virtual output rather than a physical not available to enable a
function.If the release date is not set up is enabled output virtual. "If the release date is not set
up is enabled output virtual
3.15.17
Current Output Test
This menu shows the value of current output in relation to the process variable configured in
the menu I / O capacity : rate, linear weight and speed.
- TEST SCROLL 7 Current Output
#1
4.00 mA
ENTER CLEAR
Password: Service
It is possible by the ENTER key to force the output to a desired value.
In this case you'll see a new function key ( CLEAR ) that will bring out the real value of the
associated variable.
3-49
3.15.18
Test communication A
The following screen allows checking the installed serial lines (option).
- TEST SCROLL 8 Communication Test A
Password: Service
PORT1
By pressing the PORT1 soft key, the test is initiated. A test pattern is sent out on the TX output
and read on the RX input. If the test is fails, the message “Test Failed” is shown ; otherwise,
the message “Test Passed” is displayed.
3.15.19
Test Profibus
The baud rate is automatically detected by the Mini-CK 101 and is displayed in Main Menu 3, TEST
Scroll. Press the MENU key repeatedly until Main Menu 3 appears.
Press the TEST key and scroll down.
- TEST SCROLL 9 Test communication
19.2 Kb Wait Prm
The baud rate and status are dynamically displayed. The status \can be:
WAIT PRM
The Mini-CK 101 is waiting for the PARAMETER message.
WAIT CFG
The Mini-CK 101 is waiting for the CONFIGURATION message.
DATA EXC
The Mini-CK 101 is in the DATA EXCHANGE phaseThe configuration and
parameterization have been completed successfully.
If the baud rate displayed value changes continuously, it means there are problems on the line or the
CPU is off.
Press RUN to return to the RUN menu or MENU for more menus.
3.15.20
Test Keyboard
- TEST SCROLL 7 Keyboard
Key: ______
Press the RUN key twice to exit. All other keys, including MENU, are displayed but not
executed.
3-50
3.16
Main Menu 4
The following section defines the input output (I/O) and alarms.
MENU 4 Press MENU for more
I/O
ALARM NET
DEFINE DEFINE
3.16.1
I/O Definition
The input output section of the system is fully configurable. All inputs and outputs are
conventionally numbered and can be assigned to physical input and output terminals
depending on the needs. The following section explains how to configure I/O. However, the
standard configuration as provided by the factory is normally satisfactory.
3.16.1.1 Define Current Outputs (Only with OPTION Output Current Board)
The following menus are shown for configuring the current output(s) if board is installed on
expansion board.. Use the CHOICE key to change the variable and the ENTER key to
confirm. The NEXT key allows the operator to set up to four (4) current outputs if installed.
- I/O DEF SCROLL 1 Current Output define
> Rate <
CHOICES ENTER
Password: Service
Default: RATE,
Selections: RATE, LOAD, SPEEDIf the selection of the previous screen is not OFF, the
operator can set up the range, delay and damping of the current output. The range is selectable
between the standard 0 to 20 mA and 4 to 20 mA both in direct and reverse mode. Select 0-20
or
4-20 if an increase in current is desired for any increase of the variable. Select 20-0 or 20-4 if
a decrease of current is desired for any increase of the variable.
- I/O DEF SCROLL 1ACurrent out range
> 4-20 mA <
CHOICES ENTER
Password: Service
Default: 4-20 mA,
Selections: 0-20 mA, 4-20 mA, 20-0 mA, 20-4 Ma
3-51
Each current output can be delayed. This is typically needed in blending systems, to correct
transport time differences. The delay can be set either in time or in length of belt travel. Belt
travel is suggested for variable speed applications. Use the T/L soft key to switch between
time and length.
I/O DEF SCROLL 1BCurrent out delay
0 sec
ENTER T/L
Default:
Password: Service
0 sec
If TIME:
Min:
0 sec
Max:
300 sec
If LENGTH:
English
Min:
0 Ft
Max: 10000 Ft
Metric
Min:
0M
Max: 300 M
A damping factor can also be selected for each current channel. The damping factor is the
time for the output to stabilize after a step change. This damping only affects the current
output, not the displayed variable, which has a separate damping factor, selectable in Main
Menu 2, Display.
- I/O DEF SCROLL 1CCurrent out damping
4 sec
ENTER
Default:
Min:
Max:
Password: Operator
4 sec
0 sec
400 sec
UP and DOWN arrows move between range, delay and damping.
3-52
3.16.1.2
Define Digital Inputs
Digital inputs can be programmed. The following screen shows one logical function per time,
and allows the user to assign it to a physical input. The NEXT key scrolls between the logical
functions. The NC/NO/R key selects:
•
Normally Open (NO): Input normally OPEN (not active when disconnected)
•
Normally Closed (NC): Input normally CLOSE (active when disconnected)
•
Remote (R): status of Input comes from remote communication (Ethernet, Serial or
Profibus); for more details please refere to the specific communication manual.
To program a function, scroll with NEXT until the function is displayed, then enter the
physical input number and confirm with ENTER; finally scroll with NC/NO/R until the
desired mode is displayed. By assigning a function to 0, the function is disabled.
- I/O DEF SCROLL 4 Dig. Input def.
Ext Alarm 0 NC
ENTER NC/NO/R NEXT
Password: Service
The following table shows the available logical selections that can be assigned to any available
physical input.
Logical selections should not be reassigned after the physical inputs have been wired.
Tab.3 -3: Available Logical Selections
Selections:
Default:
External alarm
0 - NO 0 = function disabled
Print
0 - NO (Only with serial card if set to printer)
Belt Running (Conveyor run)
0 - NO
Reset Totals
0 - NO
Reset Alarms
0 - NO
Auto Zero
0 - NO (Only if AZT enabled)
Clip Detector
0 - NO
Batch Start
0 - NO (Only if batch is enabled )
Batch Stop
0 - NO (Only if batch is enabled )
Batch Standby
0 - NO (Only if batch is enabled )
Tab.3-1: Mother Board Inputs
PHYSICAL
INPUT
NUMBER
ASSIGNED
FUNCTION
1
BELT SPEED INPUT
2
Input 1
3-53
3.16.1.3
Define Digital Outputs
Digital outputs can be programmed. The following screen shows one logical function per
time, and allows the user to assign it to a physical output. The NEXT key scrolls between the
logical functions. The NC/NO key selects the Normally Open (NO) or Normally Closed (NC)
status of the output. Normally Open means the output is not energized in normal conditions.
To program a function, scroll with NEXT until the function is displayed, then enter the number
of the physical output and confirm with ENTER; finally scroll with NC/NO until the desired
mode is displayed. By assigning a function to 0, the function is disabled.
- I/O DEF SCROLL 5 Dig. Output def.
Alarm: 0 NC
ENTER NC/NO NEXT
Password: Service
The following table shows the available logical selections that can be assigned to any available
physical output. Typical field wiring drawings and customer specific field wiring drawings
show Ready defaulted to #1 NC, Alarm defaulted to #2 NC and Totalizer (remote counter)
defaulted to #3 NO. Default selections can be reassigned to any physical output if desired.
Logical selections should not be reassigned after the physical outputs have been wired.
CAUTION
LOGICAL SELECTIONS RETURN TO THE DEFAULT IF THE
INTEGRATOR IS COLD STARTED.
Tab.3 -2: Available Logical Assignment
Selections
Alarms
Default
0 - NC
Shut down
0 - NO
Ready
0 - NO
High Load
0 - NO
(Only if Load Alarm enabled)
Low Load
0 - NO
(Only if Load Alarm enabled)
High Rate
0 - NO
(Only if Rate Alarm enabled)
Low Rate
0 - NO
(Only if Rate Alarm enabled)
High Speed
0 - NO
(Only if Speed Alarm enabled)
Low Speed
0 - NO
(Only if Speed Alarm enabled)
Totalizer
0 - NO
Batch Preset
0 - NO
(Only if Load Out enabled)
Batch end
0 - NO
(Only if Load Out enabled)
Print
0 - NO
(Only with serial card if set to printer)
Dev. alarms
0 - NO
Out of range
0 - NO
3-54
3.16.1.4
Define Remote Totalizer Output
If the TOTALIZER output function is assigned to an output, the following screens allow the
user to set up related parameters. Set the divider according to the maximum rate the scale will
run. The divider is entered in Totalization units (T.U.). The pulse frequency generated in
normal conditions should not exceed 10 Hz. Higher frequencies are possible, however they do
not improve accuracy.
- I/O DEF SCROLL 6 Remote counter div.
1
ENTER
Default:
Min:
Max:
Password: Service
1
0.01
100
Enter the pulse width in seconds of the Totalizer. A higher pulse width limits the maximum
frequency. The default 0.1 sec is recommended for frequencies lower than 5 Hz.
- I/O DEF SCROLL 7 Remote counter pulse
width 0.100 sec
ENTER
Default:
Min:
Max:
3.16.1.5
Password: Service
0.1 sec
0.005 sec
1 sec
Clip Detector Option
The clip detector option reduces flow rate errors on light loaded belts caused by conveyor belt
weight variances. Turning on Auto Zero Tracking in the Cal Data Scroll enables the clip
detector. The clip detector is normally a proximity switch that senses a metal target attached to
the belt. In manual mode, the clip detector freezes the flow rate when the clip is detected and
maintains it frozen for the programmed length. Totalization is not affected. In automatic, the
Integrator automatically detects tare variations and compensates for them.
If the clip detector is assigned to one digital I/O input, the following screens appear.
- I/O DEF SCROLL 8Clip detector mode
MANUAL
CHOICE ENTER
Default:
Choices:
Password: Service
MANUAL
MANUAL, AUTO
In the MANUAL mode, the user must enter the length of belt, which is affected, by the belt
splice. The system freezes the belt loading when the clip is detected and maintains it frozen
until the specified belt length has passed.
3-55
- I/O DEF SCROLL 8AClip detect length
00.00 ft
ENTER
English/Mixed
Default: 1.0 Ft
Min:
0.5 Ft
Max:
10 Ft
Metric
Default:
Min:
Max:
Password: Service
0.30 m
0.10 m
3.00 m
If the AUTO mode is selected, the system automatically detects belt weight variations and
compensates for them. The Auto Zero Tracking then stores in memory a table of tare values,
which are used to compensate the tare variations point by point. In addition, when the Acquire
Test Duration is run in the ACQ FULL mode, the COUNT key is not displayed because the
system automatically counts the clip detector pulses. (For proper operation, there can only be
one clip used for the entire belt length.)
3.16.2
Alarms Definition
The alarms of the Mini-CK 101 can be programmed. Process alarms such as low and high rate
can be set to the desired range. In addition, all alarms can be defined to be:
• ALARM-When an alarm occurs, the front panel ALARM status indicator illuminates. An
ALARM message flashes in the lower, right hand RUN display. Pressing ALARM
displays the alarm.
• Pressing RESET clears the alarm message if the alarm parameter has cleared. If the alarm
parameter has not cleared, the message "ACK" appears when RESET is pressed. When
the alarm parameter clears, the alarm indication clears.
Pressing RUN at any time returns the operator to the RUN menu.
•
•
3.16.2.1
Alarms can be automatically printed if the print option is enabled.
SHUT DOWN The alarm handler operates as above except the READY status indicator
goes off and the SHUTDOWN physical output changes state at the same time as the
ALARM status indicator comes on.
In the I/O definition scroll, alarm and ready can be assigned to N/C or N/O physical
outputs. The output activates and deactivates at the same time as the front panel status
indicators.
NONE Alarm is deactivated.
Define Rate Alarm
Use the CHOICE key to turn on or off the rate alarm. Confirm with ENTER.
- ALARM SCROLL 1 Rate alarm
>SI<
CHOICE ENTER
Default: NO
Selections: YES, NO
3-56
Password: Operator
If the selection in the previous screen was YES, enter the low and high set points for the alarm.
Also, enter the desired delay time before the alarm is monitored. The UNITS key allows the
user to specify the set points in engineering units. The % key selects set points in percent. The
SET/DLY switches between the set point and the delay time.
- ALARM SCROLL 1A Low rate set
10 %
105 sec
ENTER SET/DELAY UNITS/%
Default:
Min:
Max:
10% 10 sec
0%
0 sec
105 % 90 sec
- ALARM SCROLL 1B High rate set
100 %
10 sec
ENTER SET/DELAY UNITS/%
Default:
Min:
Max:
3.16.2.2
Password: Operator
Password: Operator
10 % 10 sec
0%
0 sec
150 % 90 sec
Define Load Alarm
Use the CHOICE key to turn on or off the belt loading alarm. Confirm with ENTER.
- ALARM SCROLL 2 Load Alarm
> NO <
CHOICE ENTER
Password: Operator
If the selection in the previous screen was YES, enter the low and high set points for the alarm.
Also, enter the desired delay time before the alarm is monitored. The UNITS key allows the
user to specify the set points in engineering units, the % key selects percent. The SET/DLY
switches between the set point and the delay time.
- ALARM SCROLL 2A Low load set
10 %
10 sec
ENTER SET/DELAY UNITS/%
Default:
Min:
Max:
10% 10 sec
0%
0 sec
105 % 90 sec
3-57
Password: Operator
- ALARM SCROLL 2B High load set
100 %
10 sec
ENTER SET/DELAY UNITS/%
Default:
Min:
Max:
3.16.2.3
100%
0%
200 %
Password: Operator
10 sec
0 sec
90 sec
Define Speed Alarm
Use the CHOICE key to turn on or off the belt speed alarm. Confirm with ENTER.
- ALARM SCROLL 3 Speed Alarm
> NO <
CHOICE ENTER
Password: Operator
Default: NO
Selections: YES, NO
If the selection in the previous screen was YES, enter the low and high set points for the alarm.
Also, enter the desired delay time before the alarm is monitored. The UNITS key allows the
user to specify the set points in engineering units, the % key selects percent. The SET/DLY
switches between the set point and the delay time.
- ALARM SCROLL 3A Low speed set
10 % 10 sec
ENTER SET/DELAY UNITS/%
Default:
Min:
Max:
10% 10 sec
0%
0 sec
105 % 90 sec
- ALARM SCROLL 3B High speed set
100 % 10 sec
ENTER SET/DELAY UNITS/%
Default:
Min:
Max:
Password: Operator
100% 10 sec
0%
0 sec
150 % 90 sec
3-58
Password: Operator
3.16.2.4 Setup Alarm Modes
The following message is displayed for three seconds.
- ALARM SCROLL 5
- ALARM DEFINITION Use NEXT key or
enter alarm number
After three seconds, the ALARM screen is displayed. The user can use the CHOICE soft key
to select the desired mode between ALARM (just a warning message), SHUT DOWN
(Warning plus fault output) and NONE (no action). Confirm with ENTER soft key. Use the
NEXT key to scroll between alarms, or enter the alarm number.
3.16.2.5 Alarms List
1. Clock Fail ( only if serial card is plugged in )
The system has detected a failure on the clock calendar circuit.
Go to the DIAGNOSTICS screen and re-enter the date and time.
Check the battery
Replace the motherboard.
2.
Load Cell Fail
The system has detected an error on the load cell signal.
Check the load cell connections.
Check the load cell(s).
3. RAM Fail
The system has detected an error on the RAM (Random Access Memory) checksum during
the internal periodic test. The RAM is used to store variables and set up data.
Replace the motherboard.
4. ROM Fail
The system has detected a failure on the ROM (Read Only Memory) checksum during the
internal periodic test. The ROM is used to store the program.
Replace the mother board
5. Speed Sensor Error
The system has detected a failure on the speed input.
6. High Load
The belt load has been detected to be higher than the maximum belt loading entered in the
ALARM SET UP menu.
7. Low Load
The belt load has been detected to be lower than the minimum belt loading entered in the
ALARM SET UP men.
8. High Rate
The rate has been detected to be higher than the maximum rate entered in the ALARM
SET UP menu.
9. Low Rate
The rate has been detected to be lower than the minimum rate entered in the ALARM SET
UP menu.
3-59
10. High Speed
The speed has been detected to be higher than the maximum rate entered in the ALARM
SET UP menu.
11. Low Speed
The speed has been detected to be lower than the minimum speed entered in the ALARM
SET UP menu.
12. Warm Start
The system has detected a power loss condition, or power was removed for an undefined
period.
13. Cold Start
The system has detected the loss of the set up data after power was removed. The
instrument needs to be setup and calibrated.
Replace the motherboard
Note: The message COLD START never appears on the screen. This is because a Cold Start
forces a start up procedure to be executed, and the alarm itself is cleared after the se up is
completed. However, the alarm LED and the digital output will be showing an alarm during the
initial set up procedure
14. P.D. Calibrate
When the system is powered off while a calibration sequence is in progress, the scale may
not be properly calibrated.
Check calibration
15. Calib Time ( Only if serial card is plugged in )
If a calibration check time is entered and the time expires, this alarm occurs. The purpose
is to remind the operator that the calibration has not been checked for a considerably long
period.
Check Calibration
16. Ext. Alarm
Digital inputs can be programmed to detect external alarm conditions such as emergency
switches, max level switches or other. This alarm is associated to the external alarm
Check External alarm
17. Overflow Tot.
This message indicates the output pulse generator for the remote mechanical totalizer has
reached an overflow condition. The rate may be too high or the pulse divider has been set
to small.
Check the rate.
Check and eventually increase the pulse divider.
This message is also displayed if the Master Total rolls over.
18. AZT Limit
The Auto Zero Tracking function has reached the maximum limit of tare that is allowed to
be autmatically cleared. The scale may be dirty or misaligned.
Check and clean the scale.
Perform an Auto Zero.
3-60
19. Batch Deviat.
This alarm is only visible if the optional Load Out board is installed. It is generated when
a batch is run and the error detected at the end of the batch is higher than specified.
Check the parameters of the load out.
Adjust the preset value.
20. Math Error
A divide by zero or overflow error is encountered during internal calculations. This
message indicates some abnormal dimensional parameter is entered in setup.
Check setup data.
21. Printer Error.
This message is displayed if the system has data to print and the printer is disconnected
or the paper feed is empty.
22. Communication Error
This message is only displayed if the Communication board (option) is installed.
Indicates a time out or handshake error is detected during a data transfer on the COMM
line.
Check the COMM line connections
Check the COMM line setup data
23. Profibus-DP COMM Error
This messages in only displayed if the expansion Profibus board (option)is installed. The
following two conditions activate the alarm.
The Siemens SPC3 Controller installed on the Profibus interface board does not recognize
any successful data transfer within the watchdog timer interval.
The received data contains errors (value overlaps limits, register number does not exist,
group number does not exist).
24. Dinamic data lost.
This messages in only displayed if the there was a problem during shutdown of the
instrument.
25. Profibus configuration changed.
This messages in only displayed if the expansion Profibus board (option) is installed.
This message appears only after you have changed the size of the buffer read and write.

Restart the instrument.
26. Set up data lost.
This message appears only after switching off the instrument without first saving the
setup data. The setup data are stored in the EEPROM when you go menu, SETUP to the
RUN ."
3-61
3.16.3
Network
An IP address is a number that uniquely identifies a device connected to a network.
IP addresses can be assigned locally to make a LAN (Local Area Network).
More precisely, the IP address is assigned to a network adapter.
- ETHERNET 1 Address IP
__.__.__.__
ENTER
Default:
169.254.1.3
The subnet mask is the method used to define the range of membership of a host in an IP
network in order to reduce network traffic and facilitate the search for a specific IP address
thereof.
The subnet mask allows the network device to search for the recipient in of a range welldefined without having to use a router to act as a gateway to another network.
- ETHERNET 2 Subnet mask
__.__.__.__.
ENTER
Default:
255.255.255.0
The gateway is a router or other routing device that connects a LAN usually to the
internet. When a host requires connection to an IP address outside the local network, the
request is turned automatically to a gateway in charge.
When there is not a specially configured for application this automatically switches to
the default gateway.
The parameter "Gateway Address” is typical of the TCP/IP and is an important
indication that allows the routing of data packets on the Internet.
Each machine ( PC or otherwise) connected to the Internet must have a default gateway
reference in its settings if you must have the ability to send data on the Net.
- ETHERNET 3 Gateway address
__.__.__.__.
ENTER
Default:
169.254.1.3
3-62
The MAC address ( in English MAC address , where MAC stands for Media Access
Control) , also called physical address ethernet or LAN address, is a 48 bit code (6 byte)
uniquely assigned to each ethernet card produced in the world.
It represents a name for a particular network device: for example, two network cards on
two different computers will have two different names and therefore different MAC
addresses.
- ETHERNET 4 Mac address
__:__:__:__:__:__
ENTER
Default: Network card dependant
The selection variables can indicate which flow value , loading the tape, the speed must
be used in communications.The selection possibles are: data unfiltered , filtered data,
the displayed data.
- ETHERNET 5 Variables Selection
>No dumped<
SCELTA ENTER
Default: no dumped
Selection : no dumped, dumped, displayed
It is commonly known that a 16-bit integer occupies two bytes of memory. However ,
there is no standard order in which computers and means of managing these two bytes
stored in memory or transmit them. The computers that use a storage method can not
transmit data integer to devices that use another method of storage without first
exchanging any pair of bytes.
- ETHERNET 6 Swap Integer data
>No swap<
CHOICE
ENTER
Default: No swap
Selection : No swap, swap bytes
3-63
The same philosophy used for the reversal of the integers must also apply to the real
values remembering that these are composed of 4 bytes and then the possible
combinations are maggiori. Per this, in addition to the pair of bytes is possible to
exchange also the pairs of words.
- ETHERNET 7 Swap Float Data
>No swap<
CHOICE ENTER
Default: No swap
Selection : No swap, swap bytes, swap words, swap bytes + words
For long integers is valid the description for real values as they also consist of 4 bytes.
- ETHERNET 8 Swap Long Integer
>No Swap<
CHOICE ENTER
Default: No swap
Selection : No swap, swap bytes, swap words, swap bytes + words
3.17
MAIN MENU 5
Main Menu 5 is dedicated to the serial option. COMM is used to set up the serial line and
PRINT is used for setting up the printer output. These options does not appear unless an
optional COMMUNICATION card is installed.
3.17.1
Communication Scroll (Future) ( Only with Option Serial Board )
The Mini-CK 101 has one serial channel, which can be configured using jumpers as an RS232
or an RS485 channel. The serial channel can be used for printing or for a serial
communication with an intelligent device such as a PLC or a PC. .
The following screens define the communication parameters :
COMM A SCROLL
Baud Rate
> 9600 <
CHOICE
ENTER
Password: Service
Default: 9600
Selections: 110, 150, 300, 600, 1200, 2400, 4800, 9600, 19200
3-64
- COMM. A SCROLL 2 Set parity
> No parity <
CHOICE ENTER
Password: Service
Default: NO PARITY
Selections: EVEN PARITY, ODD PARITY, NO PARITY
- COMM. A SCROLL 3 Stop bits
> 1 stop bit <
CHOICE ENTER
Password: Service
Default: 1 STOP BIT
Selections: 1 STOP BIT, 2 STOP BITS
- COMM. A SCROLL 4 Wordlength
> 8 bits <
CHOICE ENTER
Password: Service
Default: 8 BITS
Selections: 7 BITS, 8 BITS
One only protocol is implemented in the system. Possible selections is:
• MODBUS - A proprietary protocol of AEG. Multi Drop, Master Slave.
• PRINTER - Not a protocol, selects printer output.
-COMM. A SCROLL 5 Protocol
> MODBUS <
CHOICE ENTER
Default:
Selections:
Password: Service
MODBUS
MODBUS, PRINTER
If the selected protocol is not PRINTER, the following screens define the CTS signal
management :
-COMM. A SCROLL 6 Clear to send
> disabled <
CHOICE ENTER
Default:
Selections:
DISABLED
DISABLED, ENABLED
3-65
Password: Service
If the selected protocol is not PRINTER, the following screens define the ADDRESS of the
device in the multi drop line, and the access permission from the remote supervisor. If NONE
is selected, the supervisor has full access to the device. If LIMITED is selected; there is
supervisor only access to those variables. If PROTECTED is selected, the unit is write
protected.
-COMM. A SCROLL 7 Address
1
ENTER
Default:
Min:
Max:
Password: Service
1
1
255
-COMM. A SCROLL 8 Access prot.
> None <
CHOICE ENTER
Default:
Selections:
Password: Service
NONE
NONE, LIMITED, PROTECTED
This parameters allows the software to delay response message
-COMM. A SCROLL 9 Half duplex delay
0 mSec
ENTER
Default:
Min:
Max:
3.17.2
Password: Service
0 mSec
0 mSec
50 mSec
Profibus ( Only with Option Profibus Board )
If a PROFIBUS card is installed on expansion board the MENU 5 display a menu entry for
for PROFIBUS communication :.
The following screens define the communication parameters :
- PROFIBUS SCROLL 1 Address
1
ENTER
Default:
Min:
1
1
Max: 126
3-66
Password: SERVICE
Defines the address of the Mini-CK101 in the PROFIBUS net.
In the next two scrolls, the operator can define independently the read and write buffer dimensions.
This feature is very useful since it allows reducing the address space to the minimum need. The
dimension should be entered in number of words. This number includes the header of the telegram
taking four words (see Table 3-1), so the minimum is five words.
-
PROFIBUS SCROLL 2 Read buffer dim.
48 words
ENTER
Password: SERVICE
Default: 48
Min:
5
Max: 48
Type in the number of words and press ENTER. The following screen appears.
-
PROFIBUS SCROLL 3 Write buffer dim.
48 words
ENTER
Password: SERVICE
Default: 48
Min:
5
Max: 48
Type in the number of words and press ENTER. Press RUN to return to the RUN
menu or MENU for more menus.
3.17.3
Print ( Only with Option Serial Board )
The Mini-CK101 has a fully programmable printer format. The following section explains
how to program it according to the specific needs.
1. Define Handshaking
The system can be configured to operate without a handshake (NONE), or using the Clear
to Send signal (CTS) or the XON-XOFF sequence. Refer to the printer instruction manual
to define which selection is required. The selection NONE is only used for testing
purposes. It is not recommended for normal use. If NONE is selected, the system is not
able to recognize if the printer is on line or not, or if the paper is empty.
The most commonly used protocol is the CTS, which is a signal generated by the printer to
indicate whether it is ready to receive data or not.
-PRINTER SCROLL 1 Handshaking
> None <
CHOICE ENTER
Default:
Selections:
Password: Service
NONE
NONE, CTS, XON-XOFF
3-67
Different printers use different end of line patterns. Select the one you need for your printer.
-PRINTER SCROLL 2 End of line
> CR <
CHOICE ENTER
Default:
Selections:
Password: Service
CR
CR, LF, CR+LF
Some printers cannot accept characters while they are printing. In some cases, the handshake
is not well controlled by the printer, so a delay at end of line is helpful.
-PRINTER SCROLL 3 Delay end of line
0 sec
ENTER
Default:
Min:
Max:
Password: Service
0 sec
0 sec
5 sec
A form feed character can be sent to the printer after each report to force the printer to eject the
paper. If NO is selected, a normal END OF LINE character(s) is printed at the end of the
report.
PRINTER SCROLL 4 Form Feed
> NO <
CHOICE ENTER
Default:
Selections:
3.17.4
Password: Service
NO
NO, YES
Periodical Printing
If you want to generate periodical printing, enter the number of minutes, hours, or days in the
following screen. Entering 0 prevents periodical printing. Use the INTV key to switch from
minutes to hours and to days.
-PRINTER SCROLL 5 Print interval
0 min
ENTER
INTV
Default:
Min:
Max:
Password: Operator
0 min
0 min, 0 hour, 0 days
59 min, 23 hour, 365 days
The system can print at specific times during the day. Enter the time you want to obtain the
printing. Use the NEXT key to scroll between the print times (maximum 4). The ON/OFF key
enables or disables the displayed print time.
3-68
-PRINTER SCROLL 6 Print time # 1
time HH:MM
ENTER ON/OFF NEXT
If 24 hours
Default:
Min:
Max:
3.17.5
Password: Operator
If am/pm
OFF
00:00
23:59
OFF
01:00
12:59
Define Print Format
By selecting YES in the following screen, the system is instructed to print one line each time a
new alarm condition occurs. The alarm is printed as follows:
xx-xx-xxxx yy:yyz
kkkkkkkkkkkkkkkkkkkk
Where:
xx-xx-xxxx
Day, Month, Year, printed according to the
local format as defined in Main Menu 2 Display Scroll, Section 4.2 of this Appendix.
yy:yyz
Hour, Minutes, am/pm printed according to
the local format as defined in Main Menu 2 Display Scroll, Section 4.3 of this Appendix.
kkkkkkkkkkkkkkkkkkkk Alarm message, same message
appearing on the screen
For example:
01-22-1998 8:14a
Clock Fail
- PRINTER SCROLL 7 Print alarms
> No <
CHOICE ENTER
Default:
Selections:
Password: Operator
NO
YES, NO
There are three ways for defining the printing format. The first two are predefined formats,
which are as follows:
3-69
Predefined Print Format 1
DEFAULT 1
TOTALS REPORT
DATE: 01-22-1998
TIME: 8:12a
MASTER TOTAL:
0.00 Tons
RESET TOTAL:
0.00 Tons
OPERATOR TOTAL:
0.00 Tons
RATE:
0.00 Tph
Predefined Print Format 2
DEFAULT 2
DATE: 01-22-1998
TIME: 8:12a
MASTER START TOTAL:
0.00 Tons
MASTER STOP TOTAL:
0.00 Tons
QUANTITY:
0.00 Tons
The format “DEFAULT 2" is pre-selected when the weights and measures choice is NTEP.
The third way is to define your own format using the printer setup screens listed.
Select DEFAULT if you want the predefined format. Select USER DEFINED if you want to
set up your own format.
- PRINTER SCROLL 8 Total report format
> Default 1 <
CHOICE ENTER
Default:
Password: Service
DEFAULT 1 unless Weights and Measures
option is selected, then DEFAULT 2.
Selections:
DEFAULT 1, DEFAULT 2, USER DEFINED
3-70
If your selection is USER DEFINED, the following screens are displayed.
First, define the number of strings that you want to add to your report. You can enter a number
from 1 to 3. Strings can be used to add the company name as well as other information that
you want to include in the print format.
- PRINTER SCROLL 9ANumber of strings
3
ENTER
Default:
Min:
Max:
Password: Operator
1
0
3
If you specified a number of strings larger then zero, you can now enter the strings. Use the
alphanumeric keypad, pressing the numeric key corresponding to the letter that you want to
type. Every time you press a new key, the cursor moves to the right one place. If you need to
use two times the same key (example for double letters), move the cursor right using the arrow
keys (left and right soft keys).
- PRINTER SCROLL 9B Contents string #1
xxxxxxxxxxxxxxxxxxxx
< ENTER >
Default:
Password: Operator
xxxxxxxxxxxxxxxxxxxx
Once you have defined the string, specify where the string has to be placed on the printed
report. The coordinate is given in the following way:
0000000000111111111122222222223...
0123456789012345678901234567890...
+------------------------------------------------> Y
00|This line printed first
01|This line printed second
^
02|
| DIRECTION OF
03|
| PAPER
04|
05|
06|
.v
.X
Use the X-pos and Y-pos keys to enter the X and Y coordinates. Confirm with ENTER. By
specifying 0,0, the string is not printed.
3-71
- PRINTER SCROLL 9C Position string #1
X=0,Y=0
ENTER
X\Y-pos
Default:
Min:
Max:
X
Y
1,
0,
24,
1
1
80
Password: Operator
If you specified more strings, enter the relevant data using the same procedure.
- PRINTER SCROLL 9D Contents string #2
xxxxxxxxxxxxxxxxxxxx
<
ENTER >
Default:
xxxxxxxxxxxxxxxxxxxx
- PRINTER SCROLL 9E Position string #2
X=0,Y=0
ENTER
X\Y-pos
Default:
Min:
Max:
X
Y
2,
0,
24,
1
1
80
- PRINTER SCROLL 9F Contents string #3
xxxxxxxxxxxxxxxxxxxx
< ENTER >
Default:
Password: Operator
Password: Operator
xxxxxxxxxxxxxxxxxxxx
- PRINTER SCROLL 9G Position string #3
X=0,Y=0
ENTER
X\Y-pos
Default:
Min:
Max:
Password: Operator
X
Y
3,
0,
24,
1
1
80
3-72
Password: Operator
- PRINTER SCROLL 9H Position oper. total
X: 0 Y: 0
ENTER
X-Pos
Y-Pos
Default:
Min:
Max:
X
Y
4
0
24
1
1
80
Password: Operator
In a similar way, you can position the following variables in the print format:
The Reset Total:
- PRINTER SCROLL 9I Position reset total
X: 0 Y: 0
ENTER X-Pos Y-Pos
Default:
Min:
Max:
X
Y
5
0
24
1
1
80
Password: Operator
The Master Total:
- PRINTER SCROLL 9J Position master total
X: 0 Y: 0
ENTER X-Pos Y-Pos
Default:
Min:
Max:
X
Y
6
0
24
1
1
80
Password: Operator
The Current Date:
- PRINTER SCROLL 9K Position date
X=0,Y=0
ENTER X-Pos Y-Pos
Default:
Min:
Max:
X
Y
7,
0,
24,
1
1
80
3-73
Password: Operator
The Current Time:
- PRINTER SCROLL 9LPosition time
X=0,Y=0
ENTER X-Pos Y-Pos
Default:
Min:
Max:
X
Y
8,
0,
24,
1
1
80
Password: Operator
The Instantaneous Value of Rate:
- PRINTER SCROLL 9MPosition rate
X=0,Y=0
ENTER X-Pos Y-pos
Default:
Min:
Max:
X
Y
9,
0,
24,
1
1
80
Password: Operator
The Average Rate Since the Last Print:
The average rate is calculated only on the periods of time in which rate has been higher than
5% of capacity.
- PRINTER SCROLL 9NPosition avg. rate
X=0,Y=0
ENTER X-Pos Y-Pos
Default:
Min:
Max:
X
Y
9,
0,
24,
1
1
80
Password: Operator
The Running Time Since the Last Print:
The running time is the time in which rate has been higher than 5%.
- PRINTER SCROLL 9PPosition running tm
X=0,Y=0
ENTER X-Pos Y-Pos
Default:
Min:
Max:
X
Y
0,
0,
24,
1
1
80
Password: Operator
If the optional load out board is installed, the batch quantity and the batch total can also be
printed.
3-74
3.17.6
The PRINT Key
The PRINT general pourpose key enables the printer to print data.
The following screen is displayed:
- PRINTER SCROLL Com
no data
Start print
TOTALS
PRINT
Password: Not required
The second line gives the status of the printer:
NO DATA
Indicates the printer is idle, no data are being sent to the printer.
IS RUNNING The system is sending data to the printer.
The third line indicates what kind of data is printed if the PRINT key is pressed. The UP and
DOWN keys select between:
TOTALS
Print totals.
BATCH
Only if load out option is active, print load out information.
SETUP
Print the setup data of the instrument.
Print starts after the PRINT key is pressed.
Here are some examples of data that can be printed:
Print TOTALS
TOTALS REPORT
DATE:
01-22-2003
TIME:
8:12a
MASTER TOTAL: 0.00 Tons
RESET TOTAL:
0.00 Tons
OPERATOR TOTAL:
RATE:
0.00 Tons
0.00 Tph
Print BATCH:
BATCH REPORT
DATE:
01-22-2003
TIME:
8:12a
BATCH NR:
0
SET PT:
0.00 Tons
TOTAL:
0.00 Tons
3-75
Print ALARM:
01-22-2003
8:14a
Clock fail
Print SETUP:
INSTRUMENT SETUP
The system prints out all data and setups.
3.18
MAIN MENU 6 LOAD OUT (BATCH) SCROLL
Main Menu 6 is dedicated to the LOAD OUT function. The MAIN MENU6 / LOAD OUT
submenu look like this.
-- LOAD OUT -LOAD OUT
>Yes<
CHOICE ENTER
This menu allows to enable LOAD OUT function
1. The PRESET WEIGHT is the amount of material batched at low rate near to the end of the
batch:
-- LOAD OUT SCROLL 1
Preset weight
00.0 t
ENTER
--
Password : operator
Default :
0
Min
:
0
Max
: 10000
2. The PRE-ACT CORRECTION is the amount of material which flows on the belt scale
after the batch has been turned off. Select the method you want to use :
-- LOAD OUT SCROLL 2
Pre-act correction
>MANUAL<
CHOICE ENTER
Default
Selections
--
: MANUAL
: MANUAL, AUTO, AUTO LEARN
If the selection in the previous screen was manual, the following screen is displayed; the
operator can directly enter the PRE-ACT weight :
3-76
-- LOAD OUT SCROLL 2A Pre-act value
0.0 t
ENTER
Password : operator
Default :
0
Min
:
0
Max
: 10000
If the PRE-ACT correction is set to AUTO the following screen is visible.The operator must
enter the maximum correction that the system is allowed to perform to the cutoff value.
-- LOAD OUT SCROLL 2B -Pre-act range
0.0 t
ENTER
Password : operator
If the PRE-ACT correction mode is set to AUTO LEARN the following screen allows the
operator to enter the length of belt travel between the scale and the feeding point :
-- LOAD OUT SCROLL 2C -Pre-act length
0.000 m
ENTER
Password : operator
ENGLISH or MIXED :
Default : 0 Ft
Min : 0 Ft
Max : 300 Ft
METRIC :
Default : 0 m
Min
:0m
Max
: 100 m
3. Enter START DELAY. After the start command has been given , the system waits the start
delay activating the batch command
3-77
-- LOAD OUT SCROLL 3 -Start delay
5 sec
ENTER
Password : operator
Default : 5 sec
Min
: 0 sec
Max
: 600 sec
4. Enter the COASTING TIME .After the batch command has been turned off at end of batch
, the system waits the coasting time before freezing the batch total and printing the batch
data.
-- LOAD OUT SCROLL 4 -Coasting time
5 sec
ENTER
Password : operator
Default : 5 sec
Min
: 0 sec
Max
: 600 sec
5. Enter the batch deviation alarm.At the end of the batch , the system checks the error.If
error is larger than the batch deviation entered here, an alarm is generated.
-- LOAD OUT SCROLL 5 -Batch deviation
alarm
0%
ENTER
Password : operator
Default : 0 %
Min
:0%
Max
: 100 %
6. Enable printing batch data.If an optional serial communication board is installed.and it is
configured as PRINT selection the operator can turn on the print batch function by
selecting YES in the following screen :
-- LOAD OUT SCROLL 7 -Print batch
>YES<
CHOICE ENTER
Default : NO
Selections : YES,NO
3-78
Password : operator
7. If an optional serial communication board is installed, if .it is configured as PRINT
selection and the “total report format” selection ( MAIN MENU 5 / PRINTER SCROLL 8
) is set to “user defined” the following selection are possibles :
-- LOAD OUT SCROLL 8 -Position batch num.
X=4
Y=1
ENTER
X-pos
Y-pos
Password : operator
Default : 4,1
Min
: 0,1
Max
: 24,80
-- LOAD OUT SCROLL 9 -Position batch quant.
X=5
Y=1
ENTER
X-pos
Y-pos
-- LOAD OUT SCROLL 10 -Position batch total
X=6
Y=1
ENTER
X-pos
Y-pos

Notes :

hour and time has to be displayed when serial card is plugged in

The RUNNING STATE is enabled by RUNNING DIGITAL INPUT if it
is configures else it is enabled by virtual input else by pulses
The alarm is set only with RUNNING input

The numbers of calibration is 2.It is possible do the calibration with only
one input: state “0” enable CALIB 1 , state “1” enable CALIB 2

Linearization don’t appears on menu but it is active
3-79
3.19
MENU 6 LINEARIZATION
The function linearization can be enabled through the following menu:
LINEARIZ. 1
Linearization
> Yes <
CHOICE
ENTER
Default:
Selection:
-
Password: Service
NO
NO, YES
On the next page you can put the first weight value linear and the first correction
value. ( factor ):"
You can enter all five loads and five correction values.
LINEARIZ. # 1
Load
0.0 Kg/m
Factor
1.000000
ENTER ACQ FACT/WEIGHT
Factor :
Default:
1.000
Min:
0
Max:
1.500
Load :
Default:
0.0 Kg/m
Min:
0.0
Max:
MAX LOAD
3-80
Password: Service
Chapter 4
MINI CK101 Maintenance
The maintenance information in this manual should meet your service needs. If problems
occur requiring technical assistance, please call Tel. 02 -9595141.
Thermo Ramsey has a repair center located at Rodano (MI) Tel. 02 -9595141. Contact our
Repair Representative for assistance. To expedite your service request, please have your
machine model and serial number available.
4.1 Frequent Checkpoints
As a preventative measure, check to ensure all wires, plugs, and integrated circuits are tight in
their connectors. Also, keep the enclosure door tightly closed to prevent dirt infiltration.
More often than not, a quick visual inspection leads to the source of trouble. If a problem
develops, check the following before proceeding to more specific troubleshooting procedures:
• Check Power
1. Check the Line Voltage Selector Switches are set to the correct line voltage
2. Check the fuse
•
3. Check that the power switch in ON and that power is supplied to the unit.
Check Connections
4. Check that all terminations are secure.
4.2 Troubleshooting
This unit has built-in troubleshooting capabilities. A number of possible problems are
automatically detected and screen messages are displayed. Also, refer to the Diagnostics Test
Scrolls in MAIN MENU 3.
4.3 Cold Start
It may be necessary to cold start the MINI CK101 in the event memory becomes corrupted. In
the event of a cold start, you have the option of installing the factory default constants or
simply returning the instrument to its previous running state.
The cold start can be forced through the menu DIAGNOSITCS SCROLL (see Errore.
L'origine riferimento non è stata trovata.)
When the following screen displays, all field entry data has been replaced by the factory default
constants.
-- MEMORY ERASED -Choose the language
key to continue to
SPA
USA
Select the language and follow the initial setup procedures.
4-1
4.4 Load Cell Excitation and Signal Voltage
1. Measure excitation voltage across terminal 21 negative and 20 positive in the scale
junction box. This should be 10 VDC ± 5%.
2. If the excitation voltage is incorrect then measure the excitation voltage in the MINI
CK101 across terminal 6 negative and the 1 positive.This should be 10 VDC ± 5%.
3. Measure DC millivolt signal voltage across terminal 22 positive and 23 negative in the
scale junction box. This should be within 0-30 millivolts DC (3 mV/V load cell).
4. Measure DC millivolt signal voltage across terminal 3 positive and 4 negative in the
MINI CK101. This should be the same as Step 3 above.
5. The millivolt output is in direct relation to weight applied. As weight is increased,
output should increase.
4.5 Lithium Battery Replacement
The MINI CK101 volatile memory backup battery can be replaced without any special tools.
WARNING
DANGER OF EXPLOSION
INCORRECTLY REPLACED.
IF
BATTERY
IS
Replace only with same or equivalent type recommended by Thermo Ramsey. Dispose of
used battery according to manufactures instruction on battery or return to Thermo Ramsey.
1. Turn the MINI CK101 power off at the mains.
2. Remove the battery from its compression socket.
3. Observe the polarity markings on the battery socket base before inserting the new battery.
4. Insert battery
5. Restore power to the MINI CK100.
6. Re-enter date and time on instrument set up.
4.6 Disposal of Hazardous Waste
Disposal of Lithium batteries and soldered print circuit boards should be in accordance with
your local Hazardous Waste Policy.
As an alternative, you may return product supplied by Thermo Ramsey, freight prepaid for
disposal. Contact Repair Department for a Return Authorization Number before shipping any
product for disposal.
4.7 Cleaning Instructions
The front panel can be wiped clean with a damp cloth, and if necessary, a mild detergent (never
use abrasive cleaners, especially on the display window). As a preventative measure, check all
wires, plugs, and integrated circuits are tight in their connectors. Keep the enclosure door
tightly closed to prevent dirt infiltration.
4-2
Chapter 5
MINI CK101 Replacement Parts
This section gives information on how to order replaceable parts for MINI CK101.
5.1 Order Informations
For faster service when ordering parts, fax or telephone Products Parts Department. Thermo
Ramsey. Your regional field service representative will also be happy to assist you with parts
orders, but his normal scheduling time may delay shipment of your parts order.
The recommended procedure for order parts is as follows:
1. Determine the broken or faulty part(s).
2. Locate the part(s) in the parts list given.
3. Find the part number(s) for the item(s) needed and determine the quantity you require.
4. Fax or telephone Products Parts Department Thermo Ramsey.
5. With your order, list the following information:

Machine model and serial number

Purchase order number

Date required

Method of shipment preferred

List of parts, including part number, description and quantity
Your parts order will be handled as expeditiously as possible.
5-1
5.2 Parts List
Table 5-1: Parts List
Equipment
ENCLOSURE ONLY (FIELD VERSION)
KEY BOARD PANEL VERSION
KEY BOARD FIELD VERSION
PART NUMBER
CK10XF-CASSA
CK100KBD
CK100KBDF
INPUT CELL BOARD
CK100LCINSCH
POWER SUPPLY UNIT 100-230VAC
CK100PSU240AC
POWER SUPPLY UNIT 24VDC
CK100PSU24DC
Fuse 0,4Amp SB Type C
-
RELAY BOARD (For FIELD VERSION)
CK100RELESCH
PROFIBUS BOARD (OPTION)
CK100PROFSCH
COMM BOARD RS232/485 (OPTION)
CK100COMSCH
CURRENT LOOP BOARD (OPTION)
CK100IOUTSCH
5-2
Appendix A
MINI CK101 Digital Input / Output
The MINI CK101 has provision for up to 2 programmable digital inputs and 5 programmable
digital outputs. Standard I/O includes one speed input, one programmable inputs and five
programmable outputs.
A.1 Mother Board Digital I/O
A.1.1 Digital Inputs
(1) Programmable digital (DC) inputs (1) Speed input
• Optically isolated
• Powered by internal 24 VDC supply, 400 mA
• Cable Length: 150 ohm maximum (2500m with 1.5mmq)
Appendix Figure A-1: General Purphose Digital Inputs
B-1
Appendix Figure A-2: State Speed Input
A.1.2 Digital Outputs
Appendixe Figure A-3: Digital Outputs
N°1 Digital output programmable, and N°4 output programmables as following :
Panel Version – (4) TTL Powered by internal 24 VDC supply, 400 mA
Cable Length: 150 ohm maximum (2500m with 1.5mmq)
Field Version – (4) Relay Contact (on Relay Board) 240VAC-48VDC 0,5A
A-2
Appendix Figure A-4: State Output TTL
For the digital outputs is used (default) an open collector integrate UNL2803 that is mounted on
socket for an easy opereation of replacement. The UNL2803 can be replacement with an open
emitter integrate UDN2981A. In this case is necessary to execute the jumpers indicated on the
Figure a-4.
A-3
Appendix B
MINI CK101 Optional Boards
B.1 Analog Out Board
The analog I/O board is available in the configuration described below.
Type A:
Current Output Board is a user definable 0-24/4-20 or 20-4/20-0 mA
output for the following functions :
Net Weight, Gross Weight, Tare, Peak
Optically isolated
Isolated power source
Voltage output by adding an internal dropping resistor
Output range:
User selectable 0-20mA or 4-20 mA, representing 0 to 100%
variable.
Resistive load:
800 ohms max.
Capacitive load:
No limit
Appendix Figure B-1: State Current Output
B.2
Profibus Board
Refer to Profibus-DP manual, if this option is installed..
B.3
Comm RS232/485 Board
Refer to Serial Communication manual, if this option is installed..
B-1
Appendix C
Drawings
¾ Wiring Diagram CK-0000101-E001D
C-1
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