Load Cell Color Code

Meaning of the LEDs

There is a series of LEDs in DISOBOX Plus they help diagnose the state of the
system particularly when
There is a fault.
4 Instructions for operating with DISOPLAN VPL
2043Instructions 20430
The DISOPLAN PC program enables you to conveniently configure and
parameterize the systems of the
DISOMAT family.
The equipment that can be connected now: - DISOMAT Opus - DISOMAT Satus
– DISOBOX –
DISOBOX plus - DISOMAT Tersus
The following operating systems can be used:
▪ WINDOWS XP
▪ WINDOWS 2000
▪ WINDOWS Vista
▪ Windows 7
You can do the following with DISOPLAN:
▪ Parameterize connected devices
▪ displaying the scale weights and operating the scale
▪ Show group and channel weights and their status (only DISOBOX / DISOBOX
Plus)
▪ Select the language files and load them into DISOMAT
▪ Read out the entire system configuration (back-up) and store it in a PC
▪ Load this stored data into a DISOMAT (restore) for fast substitute system set-
up.
DISOPLAN installation is self-explanatory.

Instructions for operating with DISOPLAN VPL 20430

The figure below shows an example where a DISOBOX Plus was found. Other
detected device types are
Displayed in the window with different symbols. Either the symbol is double
clicked or the specific equipment
is switched via Show Selection to configure a piece of equipment.
4.4.2 DISOBOX Plus overview window
An overview window for the specific piece of equipment appears after selecting
the equipment. This shows
The window for DISOBOX Plus as an example.
4.2.4.2.1 Password entry
It makes sense to key in a suitable password right into the overview window.

4.2.4.2.2 Setting up the Scale

This function parameterizes the DISOBOX measuring channels and assigns
them to the scale.
The first step is configuring the number of measuring modules (one or two).
Generally, this ex works setting
Matches the DISOBOX Plus model (4- or 8-channel).
These are what the specific parameters mean:
▪ F-mechanical: the ratio between the load on the scale and the load on the load
cell(s), conditional on a
Lever ratio. Typically, F-mechanical = 1
▪ F-adjustment: adjusting factor for all imperfections on the scale (such as load
application, load distribution,
Loadcells,). Typically, F-calibration is calculated automatically with the span
calibration or corner
Balancing and is approximately 1
▪ Load cell rated load: the rated capacity of the load cell(s) connected
▪ Load cell K [mV/V]: the characteristic value of the load cells (see the load cell
technical data [➙75])
▪ Number of Load Cells: the number of load cells connected to this channel
(typically 1).
▪ Function: indicates in which of the DISOBOX scales this channel is active. If a
two-bridge twin scale is
Used, each load cell is active in e.g. scale 1 or scale 2 and also scale 3. You can
adjust scales 1 – 8 and
Combinations of them.
▪ Dead weight: the load on this channel when there is no load on the scale.
Typically, this is calculated
Automatically during dead weight calibration.
▪ Serial number: the serial number of a connected load cell can be entered here.
This parameter does not
Have any function.

4.2.4.2.3 Calibration Parameters:

This item leads you through calibration parameters. This takes in all scales to
which channels were assignedin the previous item.

Meaning of the individual data fields:

▪ Unit: dimension of the display Possible values: g, kg, t, lb. N and kN. CAUTION:
all scales configured
For one device must have the same dimensions!
▪ Terminal value: the maximum display range
▪ Display interval: the displayed values are rounded off to this value. 1, 2, 5 and
orders of magnitude of
These values are permissible. The terminal value and display interval are given
in the current dimension
(For instance, kg)
▪ No-motion difference: if the weight on the scale changes during the 'no-motion
time' by not more than the
No-motion difference, the scale will identify a no-motion state. Given in’d’, i.e. the
units of the display interval.
▪ Zero setting range: The zero range function can be used to set the scale to zero
in a selected range
Around zero. This is generally 4 % with scales capable for trade use certification
(–1 % to +3 %).
▪ Extended range: permissible display range above the 'terminal value'. Given
in’d’, i.e. the units of the
Display interval.
▪ Legal-for-trade: yes/no

Subsequently, part 2 of the calibration parameters are edited for scale 1.

These parameters apply to allScales on one device.

The following mean:

▪ Scale identification: a text string that identifies the device. This text can be e.g.
used as a reference in the
Calibration labeling.
▪ Class: Verification class of the scale (class III commercial scale, class IIII rough
scale, SWA and scale
With user-defined minimum load). In the first 3 settings, the scale uses the legal-
for-trade provisions toAutomatically calculate the minimum load (in Europe).
▪ G-deviation. Correction for gravity. Used if the scale is not adjusted and
calibrated at the installation
Location.
▪ User-defined minimum load: this is used, for example, with a SWA to set the
minimum load higher than
Can be seen in the legal-for-trade regulations.
Fieldbus communication
In this menu item you can define the bus communication type used.
4.6 Display scale
This item branches off to an overview screen of all configured scales. Beyond
this, this page is the point
Where you branch off to the diagnostic functions and signal recording.

DISOBOX Plus weight display

The individual weights of the channels along with the scale weight and status are
displayed in the lower partOf the window.
The example shows a scale involving 2 measuring channels (channels 1 and 2).
You can clear any event messages
With the Acknowledge Event button.
Fig. 30: DISOBOX scale display

4.6.2 Operating the scale

The scale functions Set Tare / Clear Tare / Manual Tare / Zero are actuated
using the control buttons. Furthermore,
Events can be acknowledged and the display can be switched to highest-
resolution mode (x10).
4.6.3 Parameterization
The following can be set in the Parameter menu:
The scale's calibration parameters (identical to settings in Chapter Calibration
Parameters: [➙23])
▪ the scale's operating mode
The scale's parameters:
The scale parameters may also be changed after verification in contrast to the
calibration parametersAnd mode of operation:

Display filter: individual filter time for each scale. This has an impact on any
display or values transferred
By computer
▪ No-motion time: see above under 'Calibration Parameters'
▪ Zero: scale zeroing properties
▪ Switch delay: for multi-range and multi-interval scales, this value shows the time
waited before ranges or
Intervals are switched. Avoids switching triggered by short weight peaks.
▪ Filter time dG/dt: filter time for the value, material flow. 'dG/dt'. Given in
seconds.
The model is defined for each scale: normal / multi-interval (2 ranges) / multi-
range (2 ranges) / multi-interval
(3 ranges) / Multi-range (3 ranges) in the Mode of Operation item on the menu.
Also, the terminal value and scale interval are defined for the other range(s) for
scales with more than one
Range. The data under 'Legal-for-trade Parameters' always describe the largest
measuring range.

4.6.4. Calibration
The calibration menu allows:
▪ Dead weight calibration
▪ Calibration of span
▪ Corner balancing
▪ Linearity correction
▪ Display resistance values (diagnostic function)

Dead Weight Calibration:

A zero balance is performed with unloaded scale. Dead weight calibration is
automatically performed forevery channel on the scale.
Results are stored in the channel data.
Channels involved in more than one scale should undergo a dead weight
calibration once only, i.e. please doNot perform for twin scales.
After starting dead weight calibration, you see the query 'Include Resistance
Measurement?' We recommend
Measuring resistance to be able to diagnose the load cells later.
Afterwards it adjusts immediately without any other query. It might take a couple
of seconds to carry out the
Function depending upon the number of load cells.

Corner balancing (only DISOBOX Plus) Corner Plus):

The corners of the scale are balanced in the F Adjustment Departure item on the
menu.
Corner balancing is designed to balance the different sensitivities of specific load
cells including load application
So that scale display is independent of the position of the load on the scale.
Follow these steps:
1. Enter the test weight into the space – at least 20 % of the maximum scale load
2. Load down the first corner with the test weight. Then click the channel button
of the specific measuring
Channel. It records the weight and shows the departure for this corner.
3. Repeat this process for all corners.
4. Press OK to exit the function at the end. It accepts the calculated values and
corner balancing is completed.
Calibration of Span:
Calibration of Span Calibration Span:
This equalizes the displayed value to the weight. The calibration weight should
be as large as possible, butAt least 20 % of the maximum scale load.
Linearization:
The Linearization function permits the scale characteristic curve to be corrected
at three sampling points
(25 %, 50 %, 75 % of full scale value) by increments of as much as ± 9.9.
The dead weight and range of the scale have to be adjusted before linearization

Determine the deviation in the characteristic curve at every interpolation point

and key in the corrected value.
▪ Apply 25 % of range as calibration weight.
▪ Read the actual weight and make a note of it.
▪ Calculate the correction value in terms of scale intervals (scale interval e can be
found on the upper left-hand
Side in the display) according to the formula: correction value = (required weight -
actual
Weight)/scale interval (for multi-range/multi-interval scales this is the scale
interval of the large range)
▪ Enter the correction factor into the input window.
▪ Check the deviation. Repeat the procedure if necessary.
▪ Resume from next support point (50 %, 75 %).
Impedance Control
In this item, the impedance (resistance) of the connected measuring channel
supply circuit is calculated and
Compared with the reading at last dead weight calibration. This helps to
determine if a load cell defect may
Have contributed to a malfunction should one arise in the scale.
4.7 Recording signals
It records and shows signal characteristics from the unit overview shield under
Record Display/Signals. You
Can store the signals recorded as a file for further processing with DISOPLAN or
also with Excel.
The Trend function records weight characteristics online, i.e. concurrently. It is
recorded once every second.
The query can be made more quickly in the 'Record signals' operating mode (as
often as 132 times a
Second), although the values can only be shown after completing recording (off-
line operation).
Both operating modes allow recording from channel and scale values.
The wizard queries a couple of parameters when starting signal recording.
▪recording scale or channel values
▪recording gross or net values (only the trend)
▪ Filename for recording
▪ Filter used (switching or display filter; only recording signals and only for scale
values)
▪ Measuring rate (only recording signals)
▪ Trigger threshold - it starts recording after crossing the threshold (only recording
signals)
▪ starting with external contact (only with several recording channels). This is
urgently recommended
When recording time-critical signals for synchronizing channels.
▪ Duration of recording (only recording signals)
You can evaluate the registered curves with 'Analyze Signal Recording'. You can
do the following after opening
One of the files stored:
▪ Make a frequency analysis (Fourier transformation). They can be used to
identify interference
Frequencies in the scale.
▪ lay a linear regression through the data. This can be used to identify trends.
▪ Simulate a filter.
The first of the following figures shows a test signal of an unloaded scale with a
linear regression overlaid.
The second figure shows the frequency analysis of this signal before and after
simulating a low pass at 1 Hz
Cut-off frequency. This very effectively suppresses the interference frequency at
3.5 Hz. You can achieve the
Same effect by means of a band pass with the appropriate center frequency.
The filter values ascertained in this fashion can be set in the unit now without a
lot of testing
The Parameter Tree
Other useful parameters are accessible from DISOBOX's main screen with
Configuration / Parameters or
With the SETTINGS menu of the other units.
This shows a tree with all of the parameters.
Some of the important functions are explained below.
All of the others are described in the operating manuals
Of the specific units.
Switch filter
You can use Parameters/Channels/Switch Filters to set a filter time common to
all channels. This time
Interval also affects the switching behavior of the fast comparators (switching
thresholds).
Value range: 0.06 - 4.7 s
4.9 Maintenance
The options in the Maintenance menu are:
▪ Data saving: Store the program (firmware) and data (parameters) from the unit
into a back-up file.
NOTE: This file does not contain the calibration parameters. This function is also
available from the
Overview screen of the units.
▪ Data restore: load (restore) the data from the back-up file into the unit.
Restore does not contain the
Calibration parameters.
It also does not overwrite any of the unit's adjustment data or serial numbers or
Activation options.
NOTE: Some of the old firmware versions do not run in new equipment
hardware.
DISOPLAN independently replaces the common versions with compatible follow-
up versions in a
Back-up. It gives a fault message if there is no corresponding version available.
▪ Flash loading: loading a new software version.
Loading procedures are registered in the device (log file). NOTE: After flash
loading, customized
Application programs (SMALL) are deleted and have to be reloaded.
▪ loading the SMALL program: load the customized software in the unit.
6 Diagnostics Function
DISOBOX has a range of diagnostics functions that allow load cell and load
distribution monitoring on theScale during operation.
You can activate the functions where necessary in the scale overview window
underConfiguration/Symmetry Monitoring
6.1 Zero-point monitoring
When zero-point monitoring is activated and the scale is reset, the system
monitors to ensure that the zero
Signal of each individual load cell is sufficiently near zero.
This allows load cells with a zero-point error – for instance, due to the penetration
of moisture – to be identified
Long before scale operation makes it impossible to zero any more.
To do this, the DISOBOX assigns each channel its own 'zero range'.
This zero range results from the zero
Setting range (ZSR) of the scale divided by the number of channels and
multiplied by 1.5
(Channel ZSR = 1.5 x scale ZSR / number of channels).
The proportion by weight of every channel at the moment of zeroing must lie
within these limits. If the proportion
By weight lies beyond these limits, the channel will be declared invalid, making
the weight on the scalealso invalid.
6.2 Symmetry Monitoring
Load cells can be grouped together in symmetry groups for symmetry monitoring.
The load cells within a
Symmetry group must generate the same signal within a specified tolerance
range. The symmetry groupsmust be selected to match the application.
The symmetry groups are monitored every 2 seconds, as long as the higher-
order scale are in no-motion!
If a channel deviates from the defined symmetry conditions in a symmetry group,
it is declared invalid.
AllScales in which this channel is involved show invalid weight readings.
Zero point and symmetry monitoring are configured using DISOPLAN.
The figures below show several typical configuration examples.
Example 1: scale with zero point monitoring but no symmetry monitoring

6.6.3 Channel Simulation

If a channel deviates from the defined symmetry conditions in a symmetry group,
or if the zero point monitoring
Identifies a defect load cell, it is declared invalid. All scales in which this channel
is involved show invalid
Weight readings.
The defective channel can be replaced by the mean value of the remaining
channels in the same symmetry
Group.
This requires starting the Control Terminal function in DISOPLAN.
Menu item 5b27 Channel Simulation allows the invalid channel to be
synthesized.
The synthesized channel is assigned the mean value of the valid channels within
the symmetry group.
All scales the channel participates in display the NO DIMENSION weight values
and the scale identifier 'ply'
(In the control terminal).
If a symmetry violation or an excessive zero adjustment value for a channel is
identified, the channel reading
Remains invalid even after the defect is rectified. The system only starts with
valid weight readings again after
The DISOBOX is switched off and on.

IMPORTANT Channels can be validly weighted only if the associated channel

status has the value 0, i.e. all
Of the above-mentioned bits must have the value 0!

Legal-for-Trade Operation (Optional)

8.1 Sealing
The configuration and calibration of a DISOBOX can safeguarded for legal-for-
trade operation as follows:
▪ Once the DISOBOX has been completely parameterized, the jumper on the
VKE board is set to wprot
(= write protect).
This jumper setting can also be used in non-legal-for-trade systems to prevent
unintended parameter
Changes.
▪ there is also a security mechanism without replugging the jumper in
combination with Schenck
DISOMAT or DISOVIEW systems. This means that it is no longer necessary to
open the DISOBOX when
Doing adjustment work. Refer to BV-H2335 for details
▪ in any event, access to the connections must be prevented by sealing the
intermediate plate (see figure).
▪ the housing does not need to be sealed.
The main board VFE or the measuring board VME can be replaced without
affecting the calibration or
Legal-for-trade status.
Both of the following figures indicate the location and the type of legal-for-trade
labeling and the
Legal-for-trade safeguards. Plates and stamps can be supplied by Schenck
Process if required.