M82 PXCX NOT XxxA XXX CAT2 X e

LLD300M82 PxCx NOT xxxA xxx CAT2 _x
Load/moment sensing system with pressure

transducers
Index
1 What families of boards are included in this manual .................................................... 2
2 Operating ............................................................................................................. 2
3 Operating mode .................................................................................................... 2
4 Technical data ....................................................................................................... 3
5 Safety .................................................................................................................. 4
5.1 Electrical safety circuits and system checks ........................................................ 4
5.2 Conformity ..................................................................................................... 4
6 Circuit board map .................................................................................................. 5
7 Electrical connections ............................................................................................. 6
7.1 Setup ............................................................................................................ 6
7.2 Terminal block J4/J5: power supply and safety output .......................................... 7
7.2.1 J4: free/safe polarized contact output (P0C1) ............................................... 7
7.2.2 J5: positive contact output (P1C0) .............................................................. 7
7.3 Terminal block J6: digital outputs ...................................................................... 8
7.4 Terminal block J7: Inputs for 3 and 4 transducers ............................................... 8
7.5 Terminal block J9: digital inputs n. 1, 2, 3 .......................................................... 8
7.6 Terminal block J10: digital inputs n. 4, 5, 6, 7, 8 ................................................. 9
7.7 Terminal block J11: Transducer n. 1 .................................................................. 9
7.8 Terminal block J12: serial port RS-232 ............................................................... 9
7.9 Terminal block J14: setting terminal block .......................................................... 9
7.10 Terminal block J15: Transducer n. 2 .................................................................. 9
7.11 Terminal block J20: round connection ................................................................ 9
8 Calibration .......................................................................................................... 10
8.1 Calibration instructions for boards with one curve (_1) ....................................... 10
8.2 Calibration instructions for boards with two alarm levels (“_2” and “i2”) ............... 11
8.2.1 Calibration for board with two alarm levels selected by an input (“_2”) .......... 11
8.2.2 Calibration for board with two alarm levels at the same time (“i2”) ................ 11
9 Error visualization ................................................................................................ 12
10 Precaution, checks and maintenance ...................................................................... 13
10.1 Precautions .................................................................................................. 13
10.2 Checks and maintenance ............................................................................... 13
M82_PxCx_NOT_xxxA_xxx_CAT2_x_e.doc Ver.2.20.1 - 07/04/2010 1/13
BPE S.r.l. – Novellara (RE) - Italy

 ++39 0522 662357/654175  ++39 0522 653740  bpecom@bpe.it  www.bpe.it
transducers
1 What families of boards are included in this manual
This manual is for all the electronic boards with the followin speaking code:
PxCx NOT xxxA xxx CAT2 _x

Ove:
PxCx Is the number of positive (P) or free/safe xxx RES: reset command available
relay (C) outputs available. Example: RST: reset and restore commands available
P1C0 means only one positive output. NOT: without reset or restore
NOT Not used for this applications. CAT2 Safety output cat. 2 (see chap. «Safety»)
xxxA One or more TPA-X pressure transducers _x _1: One alarm level
series that work in parallel or in
_2: Two alarm levels
differential mode
The more simple version is the following:

P1C0 NOT 1TPA NOT CAT2 _1
By request are available supplementary functions (see chap. «Operating logic»).
2 Operating
The limiting system is composed by a LLD300M82 electronic board, and one, two or four pressure transducers
(working in parallel or differential mode) with current output amplification (4÷20 mA), correctly installed.
The board it goes in alarm when it senses that the alarm limit, set during calibration, is exeeded. A pre-alarm level is
avaible. Available options on request:
• until two alarm and pre-alarm levels
• input to reset the alarm level
• inputs to reset the alarm and super alarm levels
• more inputs and outputs for custom functions
The system is simply set by push buttons and LEDs on the board.
In case of replacement of components of the system, these parts must be original parts by BPE.
3 Operating mode
The operating mode covered by this manual are the following:
Mode Transducers n. Description

Mode 0A 1o2 One or two independent transducers
DMode 2 Two transducers that work in differential mode (rod and bottom)
D2Mode 2+2 Two independent couples of transducers that work in differential mode (rod and
bottom)

transducers
4 Technical data
Fig.1: board dimensions
Power supply 9÷30 Vdc -

Digital inputs 8 -
four 4 to 20 mA or 0.5 to 4.5 Vdc types
Protected against short circuits or bad
Analog inputs or two 4 to 20 mA or 0.5 to 4.5 Vdc
manoeuvres
types or 1 differential type
Digital outputs Imax = 1 A. Protected against short
3 positive
circuit and overloading.
Digital outputs for display 1 negative For BPE Series VPM LEDs display.
Imax = 2 A. Protected against short
Digital power outputs (P1C0) 1 positive relay (terminal J5)
circuit.Category 2 (EN 954-1).
1 relay with free/safe polarized contact Imax = 2 A. Protected against short
Digital power outputs (P0C1)
(terminal J4) circuit.Category 2 (EN 954-1).
Operating temperature -20÷70 °C -
(*)
Standard protection grade IP 55 With BPE box.
(*)
If you do not use a BPEbox, you must warrant a protection grade above or equal to IP55.

transducers
5 Safety
5.1 Electrical safety circuits and system checks
The board runs a non stop autocheck to find any breakdown, failure or damage. If any problem is found, the board goes
into the alarm condition. The board is protected against:
• polarity reversal
• inputs overvoltage according to EN 60204 (via autoreset poliswitch fuse on board)
• outputs overvoltage, overloading, short circuits according to EN 60204 (via autoreset poliswitches fuse on
board)
• transducers cable breakaway, damage or short circuit (the board goes into alarm condition)
The slave microcontroller runs a non stop check of board functions.
5.2 Conformity
The system meets the following specifications:
EN 61000-6-2
EN 50081-1
Case of vehicle frame electrically connected to battery negative
Box Kind of electrical connection to the frame
Metal, supplied by BPE • Electrically connect the box to the frame
Plastic, supplied by BPE -
None, but mounted in a customer’s metal box Fix the electronic board to the box with metal screws or connect
the terminal J20 to the box
Electrically connect the box to the frame
None, but mounted in a customer’s plastic box Electrically connect the fixing holes M0, M1 or terminal J20 to
the frame or to the battery negative
Case of vehicle frame NOT electrically connected to battery negative

Box Kind of electrical connection to the frame
Metal, supplied by BPE • Electrically connect the box of terminal J20 to the battery negative
• Electrically insulate the box from the frame
Plastic, supplied by BPE -
None, but mounted in a customer’s • Fix the electronic board to the box with metal screws or connect the
metal box terminal J20 to the box
• Electrically connect the box or the terminal J20 to the battery negative
• Electrically insulate the box from the frame
None, but mounted in a customer’s • Electrically connect the fixing holes M0, M1 or terminal J20 to the battery
plastic box negative
• Electrically insulate the electronic board from the frame
The system is manufactured to category 2 (EN 954-1) according to the following conditions:
• system as described in chapter “Operating logic”
• automatic or manual zero check. It is a customer choice, function of the custom application.
For systems manufactured to category 2 or 3 (EN 954-1) on every power on the board made a short integrity check.
During the check the safety output is disabled.

transducers
6 Circuit board map

Push buttons
SW1 Calibration push button
Terminal blocks
J4 Power supply and e relay
outputs (P0C1)
J5 Power supply and e relay
outputs (P1C0)
J6 Digital outputs
J7 Transducer n. 3 e n. 4 input
J9 Digital inputs
J10 Digital inputs
J11 Transducer n. 1 input
J12 RS-232 serial port
J14 Setting jumper
J15 Transducer n. 2 input
J20 Ground connection
LEDs
D3 Green. Main board power
supply
D10 Green. Transducer power
supply
D19 Green. Calibration and
transducers errors
D20 Red. Calibration and alarm
condition.
D21 Yellow. Calibration and
category errors.
Relays
LS1 Relay 1
LS2 Relay 2
LS3 Double relay 1 and 2
Fig. 2: board map
Used for P0C1 boards – free/safe polarized contact
Used for P1C0 boards – positive contact

transducers
7 Electrical connections
All positive inputs must be connected to service positives and not be connected directly to power
supply battery.
Dot not use service positives to power supply external devices.
7.1 Setup
Selection of wires
Cabling has to be realized so as to warrant a correct wiring insulation of all parts accessible from operator or however
from unskilled workers (insulation resistance > 1 GΩ x cm). Installation has to be made without wires having hard
bends and without machine moving cause crushes or tractions.
The cables properties must be function of the custom application.
Section of wires
Power supply: 1,5 mm2 for linkages lower than 1,5 m, 2 mm2 otherwise
Connections: standard RS-232
Digital input: 0,5 mm2
Digital and proportional outputs: 0,5 mm2 for low power outputs, 1 mm2 for high power outputs (see section
“Technical features”)
Analogue input: see the connected transducer specific manual

transducers
7.2 Terminal block J4/J5: power supply and safety output
7.2.1 J4: free/safe polarized contact output (P0C1)

For free/safe polarized contact boards (P0C1), the terminal block used is the J4:
Terminal Meaning Notes
1 Positive power supply The contact must be directly connected to the power supply
2 Negative power supply The contact must be directly connected to the power supply
3 Safety output with NC polarized contact From actuator
4 Must be connected to a positive. Observe polarity.
5 Safety output with NC polarized contact From actuator
6 (optional) Must be connected to a positive. Observe polarity.
Fig. 3.1: connection diagram with solenoid valve and free-wheel diode at J4
7.2.2 J5: positive contact output (P1C0)

For positive contact boards (P1C0), the terminal block used is the J5:
1 Positive power supply The contact must be directly connected to the power supply
2 Negative power supply The contact must be directly connected to the power supply
3 Positive safety output Service negative
4 Positive
5 Positive safety output (optional) Service negative
6 Positive
Fig. 3.2: Connection diagram with solenoid valve at J5

transducers
7.3 Terminal block J6: digital outputs
1 Alarm indicator The contact must be connected at the other end to a service
negative. Maximum deliverable current 1 A.
2 Pre-alarm indicator The contact must be connected at the other end to a service
negative. Maximum deliverable current 1 A.
3 - -
4 Custom serial port For BPE series VPM LED display.
5 Service negative -
6 Service negative -
7.4 Terminal block J7: Inputs for 3 and 4 transducers

This terminal block is for transducers of button and rod second differential.
G Signal 4÷20 mA – rod 2 White or blue , or n. 2 wire.
B Signal 4÷20 mA – bottom 2 White or blue , or n. 2 wire.
N - -
R Positive transducer rod 2 e bottom 2 Red, or brown, or n. 1 wire.
7.5 Terminal block J9: digital inputs n. 1, 2, 3

1 Service positive -
2 Reset (alarm reset) (*) The contact must be connected at the other end to a service positive.
3 Restore (super-alarm reset) (**) The contact must be connected at the other end to a service positive.
4 Zero check (***) The contact must be connected at the other end to a service positive.
(*)
Not available on all operation modes (it is available in RES and RST operation modes only)
(**)
Not available on all operation modes (it is available in RST operation mode only)
(***)
Some zero check configurations are available and must be selected with BPE Srl.

transducers
7.6 Terminal block J10: digital inputs n. 4, 5, 6, 7, 8

1 Service positive -
2 - -
3 Alarm level correction (*) The contact must be connected at the other end to a service positive
4 Curve selection (**) The contact must be connected at the other end to a service positive
5 - -
6 - -
(*)
The correction is a percentage of the alarm level set. Three corrections are available, by selecting J10.3 and J10.4
inputs. The percentages correction can be:
• loaded in factory if the customer comunicate them bifore shippment.
• Modified by the customer with a PC/Psion via RS-232 serial port, terminal block J12
(**)
When you select a positive signal you will select the first curve (the maximum one). Without positive signal the
selected curve is the second one.
7.7 Terminal block J11: Transducer n. 1

This terminal block is for transducer n. 1 (button).
1 Positive Red or brown or n. 1 wire
2 - -
3 Signal 4÷20 mA White or blue or n. 2 wire.
7.8 Terminal block J12: serial port RS-232
7.9 Terminal block J14: setting terminal block

Must be inserted bifore calibration and removed after it.
7.10 Terminal block J15: Transducer n. 2

Use this terminal block with the second pressure transducer (second bottom or first rod).
1 Positive Red or brown or n. 1 wire.
2 - -
3 Signal 4÷20 mA White or blue or n. 2 wire.
7.11 Terminal block J20: round connection

1 System ground connection See instructions in charter “Conformity”.

transducers
8 Calibration
During this phase, never cut off power suply to the board so as not to lose data storage.
Carry out the after assembly checks, if you have not completed them, as shown in chapter “Checks and maintenance”.
For systems manufactured to category 2 or 3 (EN 954-1) on every power board made a short integrità check. During
the check the safety output is disabled.
Be carefully! The calibration is not accessibile when the green LED (D19) is blinking.
If the yellow LED (D21) is blinking, carry out all checks to remove all errors.
PLEASE The setting procedure may change in function of the system transducers and the alarm levels number.
See the “model code” of your electronic board to know how many alarm levels are available for your
NOTE system.
8.1 Calibration instructions for boards with one curve (_1)

Let’s now look at the setting procedure:
1. Turn off the power supply to the board
2. Insert terminal block J14.
3. Power on the board: the green LED (D3) will be ON. The red LED (D20) may be ON: go ahead with the
calibration.
4. Calibration start . Press push botton SW1: LEDs yellow (D21) and red (D20) will be blinking.
5. Alarm level. Position the machine in its condition n.1 (maximum load). Press SW3: green LED (D19) will be on
for a short time.
6. Calibration end. Press push button SW1: Red LED (D20) will remain on: re-enter from alarm condition and
check the red LED (D20) switch off.
7. Turn off the power supply to the board.
8. Remove terminal block J14.
9. Power on the system and verify its right working: position the machine in its alarm condition and check the
lighting of the red LED (D20) and the deactivation of safety alarm output.

transducers
8.2 Calibration instructions for boards with two alarm levels (“_2” and “i2”)
We have two kind of two alarm levels electronic boards, the one with:
• two independent alarm levels selected by an input (“spoking code”: “_2”)
• two independent alarm levels ever available (“spoking code”: “i2”)
The calibration procedure are similar, the only difference is the the alarm levels storing sequence. Identify your version
and carry out the right procedure.
8.2.1 Calibration for board with two alarm levels selected by an input (“_2”)
When the system has two alarm levels selected by an input, it has ever only one transducer (or more but connected in
parallel, as only one).

11. Insert jumper J14.
calibration.
13. Calibration start. Press push button SW1: LEDs yellow (D21) and red (D20) will be blinking.
14. Alarm level 1. Position the machine in its alarm condition (maximum load for first curve). Press push button
SW3: green LED (D19) will be ON for a short time.
15. Press push button SW1 to select the second curve, yellow LED (D21) will be OFF.
16. Alarm level 2. Position the machine in its alarm condition (maximum load for second curve). Press push button
17. Calibration end. Press push button SW1 to end calibration procedure, yellow LED (D21) will be OFF. The red
LED (D20) stay ON not blinking: re-enter from alarm condition and check the red LED (D20) switch off.
19. Remove jumper J14.
8.2.2 Calibration for board with two alarm levels at the same time (“i2”)
2. Insert jumper J14.
calibration.
4. Calibration start. Press push button SW1: LEDs yellow (D21) and red (D20) will be blinking.
5. Alarm level 1. Position the machine in its alarm condition (maximum load for first curve). Press push button
6. Press push button SW1 to select the second curve, yellow LED (D21) will be OFF.
7. Alarm level 2. Position the machine in its alarm condition (maximum load for second curve). Press push button
8. Calibration end. Press push button SW1 to end calibration procedure, yellow LED (D21) will be OFF. The red
LED (D20) stay ON not blinking: re-enter from alarm condition and check the red LED (D20) switch off.
10. Remove jumper J14.

transducers
9 Error visualization
Error codes are from two types:
• transducers errors: green LED (D19)
• board errors: yellow LED (D21)
as per the following schemas:
Transducers errors – green LED (D19)

Blinks Meanings
- No errors
1 Error line transducer 1
5 Signal from transducer below to minimum
6 Zero check (or check point) failed
7 Calibration not correctly stored
Board errors – yellow LED (D21)

Blinks Meanings
- No errors
1 Board error: contact BPE srl
2 Board error: contact BPE srl
3 Check the relay connection polarity (terminal J4 and J5)
4 Check all boards inputs: they must be connect to positives
service and not directly to the power supply
5 Replace board

transducers
10 Precaution, checks and maintenance
10.1 Precautions
• You must connect power supply wires directly to the battery.
• Cut off power supply before every check or replacement.
• Do not weld on machine structure before removing power supply (positive and negative) and detaching boxes from
vehicle frame or possible connections towards vehicle frame.
• Provide suitable mechanical protections for connection wires, paying particular attention for transducers.
• Do not place board, transducers or cabling close to sources of heat, electromagnetic interferences or power
transmissions.
• Do not touch directly boards, transducers and boxes with flushing or degreaser fluids under pressure.
• Do not hole the board box.
10.2 Checks and maintenance

A correctly mounted system will not need special maintenance through its operative life.
In this chapter you can find some checks for system functionality. Due to the safety functions of the system, if these
checks are not carried out it can be very dangerous for the operator.
After assembly checks

When you assemble the system for the first time you must make some checks:
• Check the power supply to verify its rightness (range and noise absence).
• Check the box lock and glands clamping.
• Check the board shut down through main power supply switch.
• Check that the electrical connection with machine structure follow the instructions of the tables in the “Safety–
Conformity” chapter.
Ordinary maintenance to be made at the beginning of every duty cycle

• Visual check of transducers, board (box) and connection wires.
• Check of power supply to verify it is correct.
• Check of the equipment correct operation, by simulating a locked condition and correspondent rearming.
Extraordinary maintenance
Made by skilled workers. Ask BPE S.r.l. or its reseller/or importer. Extraordinary maintenance is considered to be
everything that is not described in ordinary maintenance and in procedure of device installation. Warning: only skilled
workers are allowed to make this type of maintenance; sanction: loss of every responsibility by BPE S.r.l..


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LLD300M82 PxCx NOT xxxA xxx CAT2 _x

Load/moment sensing system with pressure

M82_PxCx_NOT_xxxA_xxx_CAT2_x_e.doc Ver.2.20.1 - 07/04/2010 1/13

BPE S.r.l. – Novellara (RE) - Italy

PxCx NOT xxxA xxx CAT2 _x

The more simple version is the following:

Mode Transducers n. Description

M82_PxCx_NOT_xxxA_xxx_CAT2_x_e.doc Ver.2.20.1 - 07/04/2010 2/13

BPE S.r.l. – Novellara (RE) - Italy

Fig.1: board dimensions

Power supply 9÷30 Vdc -

M82_PxCx_NOT_xxxA_xxx_CAT2_x_e.doc Ver.2.20.1 - 07/04/2010 3/13

BPE S.r.l. – Novellara (RE) - Italy

Case of vehicle frame NOT electrically connected to battery negative

M82_PxCx_NOT_xxxA_xxx_CAT2_x_e.doc Ver.2.20.1 - 07/04/2010 4/13

BPE S.r.l. – Novellara (RE) - Italy

6 Circuit board map

Fig. 2: board map

Used for P0C1 boards – free/safe polarized contact

Used for P1C0 boards – positive contact

M82_PxCx_NOT_xxxA_xxx_CAT2_x_e.doc Ver.2.20.1 - 07/04/2010 5/13

BPE S.r.l. – Novellara (RE) - Italy

M82_PxCx_NOT_xxxA_xxx_CAT2_x_e.doc Ver.2.20.1 - 07/04/2010 6/13

BPE S.r.l. – Novellara (RE) - Italy

7.2 Terminal block J4/J5: power supply and safety output

7.2.1 J4: free/safe polarized contact output (P0C1)

7.2.2 J5: positive contact output (P1C0)

Fig. 3.2: Connection diagram with solenoid valve at J5

M82_PxCx_NOT_xxxA_xxx_CAT2_x_e.doc Ver.2.20.1 - 07/04/2010 7/13

BPE S.r.l. – Novellara (RE) - Italy

7.4 Terminal block J7: Inputs for 3 and 4 transducers

7.5 Terminal block J9: digital inputs n. 1, 2, 3

M82_PxCx_NOT_xxxA_xxx_CAT2_x_e.doc Ver.2.20.1 - 07/04/2010 8/13

BPE S.r.l. – Novellara (RE) - Italy

7.6 Terminal block J10: digital inputs n. 4, 5, 6, 7, 8

7.7 Terminal block J11: Transducer n. 1

7.8 Terminal block J12: serial port RS-232

7.9 Terminal block J14: setting terminal block

7.10 Terminal block J15: Transducer n. 2

7.11 Terminal block J20: round connection

M82_PxCx_NOT_xxxA_xxx_CAT2_x_e.doc Ver.2.20.1 - 07/04/2010 9/13

BPE S.r.l. – Novellara (RE) - Italy

8.1 Calibration instructions for boards with one curve (_1)

M82_PxCx_NOT_xxxA_xxx_CAT2_x_e.doc Ver.2.20.1 - 07/04/2010 10/13

BPE S.r.l. – Novellara (RE) - Italy

Let’s now look at the setting procedure:

M82_PxCx_NOT_xxxA_xxx_CAT2_x_e.doc Ver.2.20.1 - 07/04/2010 11/13

BPE S.r.l. – Novellara (RE) - Italy

Transducers errors – green LED (D19)

Board errors – yellow LED (D21)

M82_PxCx_NOT_xxxA_xxx_CAT2_x_e.doc Ver.2.20.1 - 07/04/2010 12/13

BPE S.r.l. – Novellara (RE) - Italy

10 Precaution, checks and maintenance

10.2 Checks and maintenance

After assembly checks

Ordinary maintenance to be made at the beginning of every duty cycle

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BPE S.r.l. – Novellara (RE) - Italy

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