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Cardinal ARMOR Installation Manual

Portable digital truck scale
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Portable
Digital Truck Scale
Installation Manual
1
0330-0410-0M Rev D • Portable Digital Truck Scale

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  • Page 1 Portable Digital Truck Scale Installation Manual 0330-0410-0M Rev D • Portable Digital Truck Scale...
  • Page 2 0330-0410-0M Rev D • Portable Digital Truck Scale...
  • Page 3 Copyright All rights reserved. Reproduction or use, without expressed written permission, of editorial or pictorial content, in any manner, is prohibited. No patent liability is assumed with respect to the use of the information contained herein. Disclaimer While every precaution has been taken in the preparation of this manual, the Seller assumes no responsibility for errors or omissions.
  • Page 4 0330-0410-0M Rev D • Portable Digital Truck Scale...

  • Page 5: Table Of Contents

    TABLE OF CONTENTS INTRODUCTION ........... . . SITE PREPARATION REQUIREMENTS .
  • Page 6 TABLE OF CONTENTS, CONT. SETUP AND CALIBRATION ..........Digital Scale Setup and Configuration .
  • Page 7 TABLE OF CONTENTS, CONT. TROUBLESHOOTING GUIDE ......... . DISPLAYED ERROR MESSAGES .
  • Page 8 0330-0410-0M Rev D • Portable Digital Truck Scale...

  • Page 9: Introduction

    The NTEP legal-for-trade Armor® Portable Truck Scale arrives fully prepared for installation and includes Cardinal’s SmartCell® digital load cells and AXIS® heavy duty load cell stands with Frictionless Centering. Every Armor® Portable truck scale is 100% assembled, pre- calibrated, and tested before shipping.

  • Page 10: Site Preparation Requirements

    The purpose of this section is to explain how the user can provide such an environment. Electrical Power Most Cardinal instrumentation is designed to operate at 115 VAC, 50/60 Hz. Where required, the equipment may be ordered for operation at 230 VAC, 50/60 Hz.

  • Page 11: Ac Power Fluctuations

    All of the types listed are available in various sizes from Cardinal Scale or may be purchased locally. 0330-0410-0M Rev D • Portable Digital Truck Scale...

  • Page 12: Voltage

    PROVIDES PROTECTION AGAINST Type Outages Transients Fluctuations Cost Uninterruptible Power Supply High to Moderate    Voltage Regulator Moderate   Isolation Transformer Low to Moderate  Line Filters  Table B – Power Conditioning Device Voltage Voltage (steady state) variations shall not exceed plus (+) 10 percent or minus (-) 15 percent of the nominal value 115 VAC (plus or minus 8 percent for 230 VAC).

  • Page 13: Safety Considerations

    Grounding Installation Instructions, and other surge arresting devices. Heating and Cooling Most standard Cardinal weighing system instrumentations are designed for the office environment. Such an environment is free of excessive dust and moisture and provides a comfortable temperature.
  • Page 14 Scale Site, Cont. 0330-0410-0M Rev D • Portable Digital Truck Scale...

  • Page 15: Installation

    INSTALLATION At this point, the concrete slab or piers shall be in place as specified on the certified Pier Plan drawing. The top of piers shall be in a level plane and a minimum of 4 inches above the ground line. NOTE: Make sure the slab or top of piers are clear of debris and rough spots before setting the scale sections in place.

  • Page 16: Scale Section Installation

    Scale Section Installation The Armor portable digital truck scale is shipped pre-assembled and ready to be placed into position on a prepared and level site. The weighbridge is supplied in three sections. Each section can be lifted by attaching straps, cables or chains to the side rail mounts on each section.

  • Page 17: Load Cells And Load Cell Stands

    Load Cells and Load Cell Stands The load cells and load cell stands (which are bolted to the lower frame) are held in place with shipping brackets, and then the entire weighbridge is held in place in the lower frame with shipping straps for transporting.
  • Page 18 1. Establish the centerline of the concrete slab or pier. Snap a chalk line 5 feet, 7 inches off the centerline to each side. Snap a lateral chalk line 9 1/2 inches from the edge of the end slab or pier (1 foot, 3 1/2 inches if optional ramps are to be installed, refer to Pier Plan). These lines should be 71 feet, 3 inches apart.
  • Page 19 On an installation using the optional lifting lugs, remove them from the first scale section (End Bridge) and install them on the second scale section (opposite End Bridge). Attach the straps, cables or chains to the lifting lugs. Otherwise, attach the straps, cables or chains to the side rail mounts on the second scale section (opposite End Bridge).

  • Page 20: Lower Frame Spacers Installation

    Lower Frame Spacers Installation After the scale sections are in place, and the bridges level and square, install the bolt-on lower frame base spacers between the end weighbridges. Refer to the weighbridge schematic drawing for details. Lower Frame Spacer Attachment Points Lower Frame Spacer The lower frame base spacers are installed between the end weighbridges.

  • Page 21: Connect The Load Cell Cables

    Connect the Load Cell Cables Cardinal Scale’s ARMOR® Portable Digital Truck Scales are connected together with a daisy- chained CAN (Controller Area Network) cable. The load cell connection loop can begin at any load cell, and may continue clockwise as shown below or counter-clockwise if preferred. In the example shown below, note that there is not a connection between load cells 4 and 6.
  • Page 22 If needed, run the load cell cables through the conduit installed in the bridges between the load cells. Install the load cell cable connectors on the load cell fittings, and hand- tighten the connectors. If needed, insert load cell cable into Install load cell cable connectors on scale conduit.

  • Page 23: Install Homerun Cable

    Install Homerun Cable The Homerun Cable is installed between the 225D or 825D indicator and the first load cell in the loop (Start Node). Consult the chart below to determine the maximum Homerun Cable length. Note that the number of load cells in the scale determines the maximum length. Maximum Homerun Cable Length (Determined by Number of Load Cells in Scale) 0330-0410-0M Rev D •...
  • Page 24 5-pin spring cage connector, from the Home Run Cable Connector Pack. Refer to the table below for cable and connector information. Cable and Connector Information ITEM and DESCRIPTION CARDINAL PART NO. HOMERUN CABLE, 5 CONDUCTOR, SHIELDED PVC 6980-1092 (CONTAINS 2 x 18AWG, 2 x 22AWG, AND 1 x 22AWG)

  • Page 25: 225D Indicator Connection

    225D Indicator Connection The homerun cable should be routed through the metallic gland connector installed in 225D rear panel (lower right). Optional 2XX-USBA (Serial, Connectors Isolated Inputs or Outputs) AC Power 100-240 VAC (Serial, Isolated 0.4 Amp Max. Fiber Inputs or Optic Outputs) Cable...
  • Page 26 4. Route the homerun cable through the nut and plastic insert and into the enclosure. 5. With the homerun cable routed into the enclosure, remove approximately 2.0 inches (51 mm) of the cables’ outer jacket, exposing the internal wires. 6. Next, remove approximately 1/4 inch (6 mm) of insulation from each of the five wires. 7.

  • Page 27: Re-Installing The 225D Indicator Rear Panel

    Re-Installing the 225D Indicator Rear Panel 1. After all terminations have been made, remove the excess cable from the indicator enclosure, and finger-tighten each of the cable gland connectors. 2. Ensure any unused gland connectors are plugged and replace the rear panel. 3.
  • Page 28 LED 1-4 The LEDs are used for diagnostic purposes. For a complete explanation of their function, refer to the DIGITAL SCALE DIAGNOSTICS, Hardware Diagnostics section of this manual. Ethernet Port This port is used to connect the 225D to your network to send information to the cloud for iSite. Micro SD Card Slot The Micro SD card slot is not used at this time.

  • Page 29: 825D Indicator Connection

    825D Indicator Connection The homerun cable should be routed through the metallic gland connector installed in 825D rear panel (lower right). Ground AC Power 10/100 LAN I/O (Serial, Isolated 90-264 VAC and USB Inputs/Outputs) or 0.4 Amp Access Cover Additional Scales Digital Scale ATTENTION! OBSERVE PRECAUTIONS FOR HANDLING...

  • Page 30: Re-Installing The 825D Indicator Rear Panel

    4. Route the homerun cable through the nut and plastic insert and into the enclosure. 5. With the homerun cable routed into the enclosure, remove approximately 2.0 inches (51 mm) of the cables’ outer jacket, exposing the internal wires. 6. Next, remove approximately 1/4 inch (6 mm) of insulation from each of the five wires. 7.

  • Page 31: 825Dlc Controller Card

    825-DLC Controller Card Micro J3, J1 ICAN Ethernet D1, D2, D3, D4 Jumpers Port for iSite Homerun Cable Mounting P7, RS232 Edge Card Bracket Connector Serial Port End Node PWR End J2, End Node Jumper Jumper J2 is the CAN bus END NODE jumper and should be ON (installed). NOTE: The 825D is one end of the CAN bus connections and must be installed for the 825D communications to the scale to operate.
  • Page 32 P1, CAN Connection to Scale (Homerun Cable) The P1 terminal block is used to connect the homerun cable between the 825D indicator and the first load cell in the loop (Start Node in the scale). Refer to the table below for terminal connections.

  • Page 33: Load Cell Connection

    5-pin spring cage connector from the Homerun Cable Connector Pack. Refer to the table below for cable and connector information. Cable and Connector Information ITEM and DESCRIPTION CARDINAL PART NO. HOMERUN CABLE, 5 CONDUCTOR, SHIELDED PVC 6980-1092 (CONTAINS 2 x 18AWG, 2 x 22AWG, AND 1 x 22AWG)
  • Page 34 Refer to the Home run Connector Wiring Color Code Table below when performing steps 4 through 7. Homerun Connector Wiring Color Code Table Connector Homerun Cable Wire Color if using a Signal Wire Color Load Cell Cable Pin Number Lever Color BROWN SHLD GRAY...
  • Page 35 8. After all connections have been made, slide the black plastic and metal connector parts together, and then screw them together by hand-tightening. Slide both connector parts together and hand-tighten. 9. To complete the assembly, hold the black and metal parts of the connector housing, and then hand-tighten the cable clamp to the black plastic part of the connector housing.

  • Page 36: Grounding Installation Instructions

    Grounding Installation Instructions The ground rod shall be copper plated 0.5 in. (1.27 cm.) minimum diameter, with clean exterior surfaces, and shall not be covered with paint, enamel, or other materials, which are poor conductors. The ground rod shall be embedded below permanent moisture level at least 8 ft. (2.44 m.) where practicable.

  • Page 37: Access Plate Installation

    Access Plate Installation The access plates in the scale are at one end in the corner of the weighbridge. Before installing the access plates, perform the following steps: Replace the cable tray removed earlier. Roll up any excess load cell cable and place on the cable tray. Make sure the cables are clear of the access plate opening.

  • Page 38: Setup And Calibration

    SCALE SETUP AND CONFIGURATION Digital Scale Setup and Configuration The SmartCell® digital load cells used in Cardinal Scale’s ARMOR® Portable Digital Truck Scale are connected together using a daisy-chained CAN (Controller Area Network) cable. The load cell connection loop can begin at any load cell on the scale, and may continue clockwise or counter-clockwise if preferred.

  • Page 39: To Begin 225D Setup And Configuration

    To Begin 225D Setup and Configuration Addressing Cells Each cell has a serial number (S/N) marked on the cell. This is an 8-digit hexadecimal number. It is also known as the cell ID. Each cell ID must be matched with a cell address. In the example on the previous page, the addresses would be 1-8.

  • Page 40: 225D Calibration

    225D Calibration If, after test loading the scale, it is determined that adjustments are required, follow the procedure below. This section describes the procedure necessary to calibrate a Cardinal Digital Truck Scale. 1. Before any adjustments are made, turn on power to the digital weight indicator.

  • Page 41: Smart Calibration

    Center the weight over scale X and press ENTER to take a weight sample. Repeat steps 5, 6 for each cell in the order that the 225D prompts for. (This is the same order as other Cardinal scales e.g. 1, 3, 5, 7, 8, 6, 4, 2). ZERO CALIBRATION Zero Calibration does not affect the trimming of the cells or affect span.

  • Page 42: Trim Cells

    TRIM CELLS Individual cells or pairs of cells may be trimmed. This requires a test load weight. Press 3 and ENTER. The 225D will prompt for “Cell Number(s): “. To trim a single cell, enter the cell number, and press ENTER. To trim a pair of cells, enter both cells in the form “X + Y”, and press ENTER.

  • Page 43: To Begin 825D Setup And Configuration

    To Begin 825D Setup and Configuration 1. Press the ON/OFF key to turn on the 825D. The display will perform a short self-test and then change to the Startup screen showing the software versions and status of the main board and option cards. MnBd DLC IMPORTANT! The shown under Item, indicates the main board is...

  • Page 44: Login

    Login Login 1. With the screen and prompt displayed, use the alpha-numeric keys to enter the login, and then press the  Down Arrow to advance to the password prompt 2. Enter the password using the alphanumeric keys, and then press the ENTER key to proceed with Setup and Configuration.

  • Page 45: Setup Scale Number

    Setup Scale Number Setup Scale Number With the Setup Scale Number screen displayed, press the D key, or use the Navigation D. Configure DLC Keys to select (highlight) , and then press the ENTER key. The Setup DLC Card 1 display will change to show the screen.

  • Page 46: Setup Dlc Card 1

    Setup DLC Card 1 Scales: – Set the number of scales. Cells: – Set the total number of cells. First Cell: – Set the cell number that is connected to the 825D indicator. Last Cell: – Set the cell number of the end of the chain of load cells. iSITE SO: –...

  • Page 47: Dlc Card 1 Cell Assignment

    DLC Card 1 Cell Assignment The left side of the column shows the existing programmed IDs and scale number assigned for each cell. If any cells are detected on the bus that are not assigned, they will show on the right column Unassigned ID under the heading.
  • Page 48 DLC Card 1 Cell Assignment, Cont. The right navigation key may be used to select the unassigned column. The left navigation key may be used to select the existing cell IDs. The up/down navigation keys may be used to select a specific cell. Assign Cell Select the next cell to assign on the right column and press the A key to assign it to the next unassigned cell (cell ID 00000000).
  • Page 49 DLC Card 1 Cell Assignment, Cont. Cell IDs may also be entered manually and the scale to associate with the cell by selecting an item in the left column pressing the SPACE key. 0330-0410-0M Rev D • Portable Digital Truck Scale...
  • Page 50 DLC Card 1 Cell Assignment, Cont. Cell ID Type the if it is to be changed, press the down navigation key to select the Scale: prompt, and then enter the scale number. When finished press and release the SHIFT key, then press the ESC/← key. The display will return to the Setup Scale Number screen.

  • Page 51: Smart Calibration

    IMPORTANT! Before calibrating the scale, it is very important that the dead load of the weighbridge is evenly distributed between the pair of cells in a section. Refer to the Balancing Weighbridge Dead Load section on page 64 of this manual for more instructions. Smart Calibration 2.
  • Page 52 Smart Calibration, Cont. Scale 1 – Smart Calibration With the screen displayed, enter the weight value of the test weight to be used. 0330-0410-0M Rev D • Portable Digital Truck Scale...
  • Page 53 Smart Calibration, Cont. With an empty scale, press ENTER. This will capture the calibrated dead load weight of the scale. 0330-0410-0M Rev D • Portable Digital Truck Scale...
  • Page 54 Smart Calibration, Cont. The 825D display will change to show that it is calibrating. 0330-0410-0M Rev D • Portable Digital Truck Scale...
  • Page 55 Smart Calibration, Cont. Center the weight over load cell 1, and press ENTER. 0330-0410-0M Rev D • Portable Digital Truck Scale...
  • Page 56 Smart Calibration, Cont. The 825D display will change to show that it is calibrating the weight on load cell 1. 0330-0410-0M Rev D • Portable Digital Truck Scale...
  • Page 57 Smart Calibration, Cont. Move the test weight and center it over load cell 2, and press ENTER. The 825D display will change to show that it is calibrating the weight on load cell 2. 0330-0410-0M Rev D • Portable Digital Truck Scale...
  • Page 58 Smart Calibration, Cont. Move the test weight and center it over load cell 3, and press ENTER. The 825D display will change to show that it is calibrating the weight on load cell 3. 0330-0410-0M Rev D • Portable Digital Truck Scale...
  • Page 59 Smart Calibration, Cont. Move the test weight and center it over load cell 4, and press ENTER. The 825D display will change to show that it is calibrating the weight on load cell. If more than four cells, and the number of cells is even a number (such as for an eight-cell scale), the calibration pattern will be the odd number cells, then the even number cells in reverse to facilitate easy weight cart movement: 1, 3, 5, 7, 8, 6, 4, 2...

  • Page 60: Zero Calibration

    Zero Calibration 3. Zero Calibration Scale 1 – Calibration Options With the screen displayed, press the 3 key or 3. Zero Calibration use the Navigation Keys to select (highlight) , and then press the ENTER key. Scale 1 – Zero Calibration The display will change to show the screen.
  • Page 61 Zero Calibration, Cont. With an empty scale, press ENTER. Zero Calibration does not affect the trimming of the cells or affect span; it simply sets the dead load weight of the scale. 0330-0410-0M Rev D • Portable Digital Truck Scale...
  • Page 62 Zero Calibration, Cont. The 825D display will change to show that it is calibrating zero. 0330-0410-0M Rev D • Portable Digital Truck Scale...

  • Page 63: Trim Cells

    Trim Cells 4. Trim Load Cells Scale 1 – Calibration Options With the screen displayed, press the 3 key or 4. Trim Load Cells use the Navigation Keys to select (highlight) , and then press the ENTER key. Scale 1 – Trim Cells The display will change to show the screen.
  • Page 64 Trim Cells, Cont. Section Trim Mode Individual cells or a section (pairs of cells) may be trimmed. This requires a test load weight. M)ode – Press the M key to toggle between Section or Single Cell trim. Default is Section. Use the Navigation Keys to select (highlight) the section to trim.
  • Page 65 Trim Cells, Cont. Single Cell Mode Press the M key to select Single Cell trim. Use the Navigation Keys to select (highlight) the cell to trim. 0330-0410-0M Rev D • Portable Digital Truck Scale...
  • Page 66 Trim Cells, Cont. Single Cell Mode, Cont. With the desired cell selected, enter the Trim Value, and press the ENTER key to set the weight to adjust trim. 0330-0410-0M Rev D • Portable Digital Truck Scale...
  • Page 67 Trim Cells, Cont. Single Cell Mode, Cont. The 825D will automatically trim the cell to match the entered weight. 0330-0410-0M Rev D • Portable Digital Truck Scale...
  • Page 68 Trim Cells, Cont. Single Cell Mode, Cont. NOTE: If in the Single Cell mode, manually enter a trim value by pressing the FUNCT key, then press the (•) period key. This can be used to enter a slight adjustment, such as change 0.98411 to 0.98421.

  • Page 69: Span Adjust

    Span Adjust 5. Span Adjust Scale 1 – Calibration Options With the screen displayed, press the 3 key or 5. Span Adjust use the Navigation Keys to select (highlight) , and then press the ENTER key. Scale 1 – Span Adjust The display will change to show the screen.
  • Page 70 Span Adjust Span adjust allows you to tweak the span of the entire scale at once. The 825D will display the current live scale weight. Place the test weight at any location on the scale. Enter the value of the test weight and press the ENTER key. 0330-0410-0M Rev D •...
  • Page 71 Span Adjust After a brief delay, the span will be adjusted (trim will be adjusted for all cells of the scale) and Scale 1 – Calibration Options the 825D display will return to the screen. 0330-0410-0M Rev D • Portable Digital Truck Scale...

  • Page 72: Balancing Weighbridge Dead Load

    Balancing Weighbridge Dead Load Before calibration, it is very important that the dead load of the weighbridge be evenly distributed between the pair of cells in a section. Begin by powering up the indicator and proceeding to the Diagnostics Menu to the LOADCELL WEIGHTS screen on the 225D or the LIVE LOAD CELL WEIGHTS on the 825D.
  • Page 73 Insert Shim Insert Here Shim Here Insert Shim Here Install shims between the load cell pivot plate and the weighbridge load cell block to evenly distribute the deadload. 0330-0410-0M Rev D • Portable Digital Truck Scale...

  • Page 74: Diagnostics

    DIGITAL SCALE DIAGNOSTICS 225D Digital Scale Diagnostics There are four main components to the 225D Digital Scale Diagnostics: • On Screen Diagnostics – Critical errors that alert operator from main screen of setup issues or hardware problems. • Diagnostic Menu – A set of diagnostic tools that give a technician more information about each load cell.
  • Page 75 COMMUNICATION ERROR BETWEEN LOAD CELLS X AND Y NO WEIGHT  -------    COMMUNICATION ERROR BETWEEN LOAD CELLS 1 AND 3 COUNT Probable Cause Items to Check There is a loss of • Check that cable is connected correctly. communication between load •...
  • Page 76 LOAD CELL X HAS BEEN REPLACED NO WEIGHT -------    LOAD CELL 2 HAS BEEN REPLACED. SCALE NOT LEGAL FOR TRADE UNTIL CALIBRATED. PRESS ENTER TO CONTINUE Probable Cause Items to Check A load cell has been replaced. Replaced load cells are automatically detected as long as only one load cell was replaced.
  • Page 77 LOAD CELL ID 8F07E8F HAS NO ADDRESS NO WEIGHT  -------    LOAD CELL ID 8F07E8F HAS NO ADDRESS COUNT Probable Cause Items to Check A load cell is responding, but Go to the addressing menu and assign the load cell ID to it is not addressed in the an address.
  • Page 78 DIGITAL SCALE BOARD NOT DETECTED NO WEIGHT  -------   DIGITAL SCALE CARD NOT DETECTED COUNT Probable Cause Items to Check The 225D cannot • Check that the card is seated properly and fastened communicate with the option correctly. card or the option card is not •...

  • Page 79: Diagnostic Menu

    Diagnostic Menu To enter the diagnostic menu press SHIFT + CELL_DIAG soft key. All diagnostic information except software version update once per second. LIVE LOAD CELL WEIGHTS (This can be zeroed as needed.) LOAD CELL WEIGHTS -106 -120 PREVIOUS NEXT EXIT MINIMUM AND MAXIMUM WEIGHTS (This can be zeroed as needed.) MAXIMUM / MINIMUM WEIGHTS...
  • Page 80 SOFTWARE VERSION OF CELL LOADCELL SOFTWARE VERSIONS 1. 1.0.14 6. 1.0.14 2. 1.0.14 7. 1.0.14 3. 1.0.14 8. 1.0.14 4. 1.0.14 5. 1.0.14 PREVIOUS NEXT EXIT NOTE: The controller’s version number, in contrast, is displayed upon startup of the 225D indicator.
  • Page 81 DLC CARD COMMUNICATION ERROR COUNTS DLC CARD COMMUNICATION ERROR COUNTS Overflow Bus Off CAN Err PREVIOUS NEXT EXIT This is the count of any missed messages from the DLC card buffer that Overflow were not kept up with. This should not happen unless too many cells are connected with too high of a sample rate.
  • Page 82 CELL POWER SUPPLY VOLTAGES CELL POWER SUPPLY VOLTAGES *Approx. 14.355 14.191 13.950 14.530 14.334 14.260 14.211 14.267 * 0.184 Amps PREVIOUS NEXT EXIT NOTES: • The  on cell number 5, indicates the cell voltage measurement was not calibrated but is an approximate value based on the raw counts.
  • Page 83 SNAP COMMUNICATIONS DIAGNOSTICS When the SNAP SmartMedia Box communications is enabled, an additional page of the Digital Scale Diagnostics is available. This will scan and list the IDs of any SmartMedia boxes that it finds on the same channel that the indicator is set to.

  • Page 84: Hardware Diagnostics

    Hardware Diagnostics The digital controller (option card) has four LED’s for diagnostic purposes. LED1 LED2 LED3 LED4 LED1 (RED) – MAIN BOARD TX/RX: Toggles each time the DLC controller and the 225D Mainboard exchange messages. LED2 (RED) – TX TO LOAD CELL: Toggles each time a message is sent from the DLC controller to the load cells.

  • Page 85: Detecting 225D Board Replacements

    NEW card to the existing scale. 225DLC DIGITAL CONTROLLER CARD REPLACEMENT If an option card is replaced, the 225D will boot up to this screen: BY CARDINAL Revision 0.1.04 NEW CARD FOUND! WAS DIGITAL SCALE CARD REPLACED? NO The 225D indicator will check whether the option card has been replaced in order to reconfigure the new option card to the existing scale.

  • Page 86: 225Dlc Digital Controller Card Replacement

    225DLC Digital Controller Card Replacement Remove this screw, washer, and the ground wire Remove the remaining three screws and lock washers Align pins on 225DLC card with holes in 0330-0410-0M Rev D • Portable Digital Truck Scale...
  • Page 87 12. Re-insert the 225D power cord into the wall outlet. 13. Press the ON/OFF key on the 225D keypad to turn on the indicator. 14. The 225D will boot up to this screen: BY CARDINAL Revision 0.1.04 NEW CARD FOUND! WAS DIGITAL SCALE CARD REPLACED? NO 15.

  • Page 88: 825D Digital Scale Diagnostics

    825D Digital Scale Diagnostics On Screen Diagnostics The On Screen Diagnostics messages are critical errors that alert operator from main screen of setup issues or hardware problems. These messages will be shown to the operator on the main weight screen in real time when the error happens. COMMUNICATION ERROR BETWEEN INDICATOR AND SCALE Probable Cause Items to Check...
  • Page 89 COMMUNICATION ERROR BETWEEN LOAD CELLS X AND Y Probable Cause Items to Check There is a loss of • Check that cable is connected correctly. communication between load • Check cable for damage. cells. • Verify that connector is clear of debris. •...
  • Page 90 LOAD CELL X, Y, Z NOT RESPONDING Probable Cause Items to Check The 825D cannot detect the • Check that cable is connected correctly. exact communication problem • Check cable for damage. with the unresponsive load • Verify that connector is clear of debris. cell.
  • Page 91 LOW VOLTAGE DETECTED ON LOAD CELL X, Y, Z Probable Cause Items to Check Low power on a load cell. • Too many load cells on the chain. Load cells at the end of the • Check that cable is connected correctly. CAN daisy chain are most •...

  • Page 92: Diagnostic Menu

    Diagnostic Menu The Diagnostic Menu is a set of diagnostic tools that give a technician more information about each load cell. 6. DLC Diagnostics Scale 1 – Calibration Options With the screen displayed, press the 6 key or 6. DLC Diagnostics use the Navigation Keys to select (highlight) , and then press the ENTER key.
  • Page 93 LIVE LOAD CELL WEIGHTS Use the Navigation Keys to scroll the display to show all cells. Load Cell Weights Press the W key to jump to the screen from the other diagnostic screens. 0330-0410-0M Rev D • Portable Digital Truck Scale...
  • Page 94 ZERO LIVE LOAD CELL WEIGHTS The Z key (for Zero) may be used to zero the diagnostics display while in the diagnostics screen. It does not affect scale zero. Use the Navigation Keys to scroll the display to show all cells. Load Cell Weights Press the W key to jump to the screen from the other diagnostic...
  • Page 95 MINIMUM AND MAXIMUM WEIGHTS Use the Navigation Keys to scroll the display to show all cells. Maximum / Minimum Weights Press the X key to jump to the screen from the other diagnostic screens. 0330-0410-0M Rev D • Portable Digital Truck Scale...
  • Page 96 DEADLOAD SHIFT This shows the live shift from the original calibrated deadload. An asterisk () indicates that the deadload shift has been exceeded. Scale must empty for this to be valid. Use the Navigation Keys to scroll the display to show all cells. Deadload Shift Press the D key to jump to the screen from the other diagnostic...
  • Page 97 LOAD CELL IDS / SOFTWARE VERSIONS Use the Navigation Keys to scroll the display to show all cells. Load Cell IDs / Software Versions Press the R key to jump to the screen from the other diagnostic screens. 0330-0410-0M Rev D • Portable Digital Truck Scale...
  • Page 98 LOAD CELL COMMUNICATION ERROR COUNTS Use the Navigation Keys to scroll the display to show all cells. Load Cell Communication Error Counts Press the E key to jump to the screen from the other diagnostic screens. 0330-0410-0M Rev D • Portable Digital Truck Scale...
  • Page 99 ZERO LOAD CELL COMMUNICATION ERROR COUNTS Use the Navigation Keys to scroll the display to show all cells. Press the C key to clear the Communication Error Counts. Load Cell Communication Error Counts Press the E key to jump to the screen from the other diagnostic screens.
  • Page 100 WEIGHT ERROR COUNTS Weight Error Counts are analog errors that would normally indicate a bad cell. Use the Navigation Keys to scroll the display to show all cells. Press the C key to clear the Weight Error Counts. Weight Error Counts Press the G key to jump to the screen from the other diagnostic screens.
  • Page 101 LOAD CELL TEMPERATURES This is the temperature of the cells in Celsius. Use the Navigation Keys to scroll the display to show all cells. Load Cell Temperatures Press the T key to jump to the screen from the other diagnostic screens. 0330-0410-0M Rev D •...
  • Page 102 LOAD CELL MINIMUM / MAXIMUM TEMPS Use the Navigation Keys to scroll the display to show all cells. Load Cell Maximum / Minimum Temps Press the Q key to jump to the screen from the other diagnostic screens. 0330-0410-0M Rev D • Portable Digital Truck Scale...
  • Page 103 LOAD CELL MILLIVOLTS Use the Navigation Keys to scroll the display to show all cells. Load Cell Millivolts Press the M key to jump to the screen from the other diagnostic screens. 0330-0410-0M Rev D • Portable Digital Truck Scale...
  • Page 104 LOAD CELL ABSOLUTE MAXIMUM WEIGHTS Use the Navigation Keys to scroll the display to show all cells. Load Cell Absolute Maximum Weights Press the O key to jump to the screen from the other diagnostic screens. 0330-0410-0M Rev D • Portable Digital Truck Scale...
  • Page 105 SUPPLY VOLTAGE – RAW COUNT / VOLTAGE NOTE: An asterisk () indicates voltage determination is approximated based on raw count value. Use the Navigation Keys to scroll the display to show all cells. Supply Voltage – Raw Count / Voltage Press the V key to jump to the screen from the other diagnostic screens.
  • Page 106 LOAD CELL RAW COUNTS Use the Navigation Keys to scroll the display to show all cells. Load Cell Raw Counts Press the R key to jump to the screen from the other diagnostic screens. 0330-0410-0M Rev D • Portable Digital Truck Scale...

  • Page 107: Hardware Diagnostics

    Hardware Diagnostics The 825-DLC (Digital Load cell Controller) option card has four LED’s for diagnostic purposes. D1 – Blinking = Indicates the 825-DLC card is communicating with the 825D main board. D2 – Blinking = Indicates the 825-DLC card is transmitting messages is to the load cells. D3 –...

  • Page 108: Detecting 825D Board Replacements

    Detecting 825D Board Replacements The 825D will detect when a DLC controller or 825D mainboard has been replaced using checksums and unique board identification numbers. Based on several parameters, it can detect whether the option card was replaced, or the mainboard was replaced and then reconfigure the NEW card to the existing scale.
  • Page 109 825D MAIN PCB REPLACEMENT If an 825D main board is replaced, the 825D will boot up to this screen: The system will also check whether the 825D’s main board has been replaced, so the scale configuration can be downloaded from the controller to the main board. If the operator selects YES, then the scale configuration will be downloaded from the controller to the mainboard.

  • Page 110: 825-Dlc Digital Controller Card Replacement

    825-DLC Digital Controller Card Replacement CAUTION! OBSERVE THE PRECAUTIONS FOR HANDLING STATIC SENSITIVE DEVICES 1. Remove the 825D power cord from the wall outlet. 2. Remove the fourteen acorn nuts securing the rear panel to the main housing. 3. Lift the rear panel from the main housing, taking care not to stretch the cables and wires between the panel and main housing.
  • Page 111 12. The 825D will boot up to this screen: 13. The 825D will check whether the option card has been replaced, in order to reconfigure the new option card to the existing scale. 14. If the operator selects Y, then the 825D main board will upload the scale configuration to the new 825-DLC card, and the 825D will immediately be able to make weight again.

  • Page 112: Maintenance Instructions For High Usage Weighments

    Maintenance Instructions for High Usage Weighments 1. A High Usage Weighment Scale is one with 150 or more weighments per day. 2. A weekly maintenance inspection should be performed. A. Check all load cells for and clear debris around load cells. 3.

  • Page 113: Troubleshooting Guide

    Before calling Cardinal Scale for assistance, there are a few things to check first that can be done to get the system back up and running. Remember, that there is a logical explanation for all problems and for troubleshooting to be successful, it must be approached in a logical and rational manner.
  • Page 114 LOW VOLTAGE DETECTED CELL X, Cont. SOLUTION: I. If the system voltage is below 9 VDC, proceed as follows: J. First remove the White (V+ Bus) and Blue (V- Bus) wires from the Homerun cable on the DLC Card, and using a DVM, read the voltage on the connector. This should be minimum of 14 VDC on the 225DLC (11.5 VDC on the 825-DLC).

  • Page 115: Current Draw More Than 150% Of Capacity

    CURRENT DRAW MORE THAN 150% OF CAPACITY SOLUTION: A. Cut the end off of an extra load cell cable and strip back the wires to make a test cable. B. Ensure the scale is powered up. C. Remove the End Node (terminator) from the last load cell in the loop, and connect the test cable to the port on the load cell where the End Node (terminator) was.

  • Page 116: Load Cell X Not Responding

    IDs and their corresponding scale locations (NOT the location in the data loop). C. If a Cardinal Digital Load Cell Simulator is available, remove the Homerun cable from the first load cell in the loop and attach it to the simulator.
  • Page 117 COMMUNICATIONS ERROR BETWEEN INDICATOR AND SCALE, Cont. SOLUTION: H. If a NEST is not available, proceed with the following instructions to check the Homerun cable for shorts: 1. Disconnect the Homerun cable from the load cell (Start Node). 2. Starting with one wire, check the resistance between it and each of the other wires one at a time.

  • Page 118: Load Cell X Has No Address

    LOAD CELL X HAS NO ADDRESS SOLUTION: A. Go to the Scale Setup screen and enter the load cell ID in the correct scale location. COMMUNICATION ERROR BETWEEN LOADCELLS X AND Y SOLUTION: A. Use the NEST to test the suspect load cell cable for defects. B.

  • Page 119: Load Cell Or Scale Communication Problems

    LOAD CELL OR SCALE COMMUNICATIONS PROBLEMS SOLUTION: A. Go to the Diagnostics screen LOAD CELL COMMUNICATIONS ERRORS and observe the historical error counters for each load cell. B. Record these numbers. C. Press EXIT(?) to zero the counters on the 225D. For the 825D, press C)lear to zero the counters.

  • Page 120: Isite Configuration

    CONFIGURATION 225D iSite Configuration The 225D will periodically send indicator, scale, and cell data to the Cardinal iSite Webserver for diagnostic logging. This information will be used by the server to determine if there are problems with the scale(s) that need to be addressed.

  • Page 121: Isite Status Of Last Connection

    225D iSite Configuration, Cont. ISITE STATUS OF LAST CONNECTION, CONT. ISITE STATUS OF LAST CONNECTION IP = 10.1.3.109 ETHERNET DETECTED WAITING FOR SOCKET INIT HTTP RESP = 0 PREVIOUS NEXT EXIT The following information is available: A. IP address (if available). B.

  • Page 122: 825D Isite Configuration

    825D iSite Configuration The 825D will periodically send indicator, scale, and cell data to the Cardinal iSite Webserver for diagnostic logging. This information will be used by the server to determine if there are problems with the scale(s) that need to be addressed.

  • Page 123: Isite Status Of Last Connection

    825D iSite Configuration, Cont. ISITE STATUS OF LAST CONNECTION IP BINDING message is displayed for a long time, it may indicate no network connection is present. WAITING FOR SOCKET INIT PORT CONNECT FAIL COMM ESTABLISHED – successful connection 0330-0410-0M Rev D • Portable Digital Truck Scale...

  • Page 124: Enter Valid So Identifier For Isite

    825D iSite Configuration, Cont. ENTER VALID SO IDENTIFIER FOR ISITE Make sure valid SO identifier is entered for iSite. 0330-0410-0M Rev D • Portable Digital Truck Scale...

  • Page 125: Successful Comm Establish For Isite

    825D iSite Configuration, Cont. SUCCESSFUL COMM ESTABLISH FOR ISITE OKAY The 825D screen will display when a successful comm has been establish. 0330-0410-0M Rev D • Portable Digital Truck Scale...

  • Page 126: Parts Identification

    PARTS IDENTIFICATION 0330-0410-0M Rev D • Portable Digital Truck Scale...

  • Page 127: Weighbridge Assembly

    Weighbridge Assembly (Quantity shown for 70’ x 11’ scale) See Optional Lifting Lug See Detail D Lower Frame Base Spacer Assembly Detail See Grounding Detail 0330-0410-0M Rev D • Portable Digital Truck Scale...

  • Page 128: Optional Lifting Lug

    Weighbridge Assembly, Cont. (Quantity shown for 70’ x 11’ scale) QTY. ITEM DESCRIPTION 0330-0177-0A BRIDGE AND LOWER FRAME ASSEMBLY 0330-0182-0A WEIGHBRIDGE, DROP-IN MODULE 0330-0183-0A LOWER FRAME BASE SPACER 0330-0046-0A ACCESS PLATE ASSEMBLY Optional Lifting Lug Lifting lugs are available for the lifting of scale sections. Note that the lifting lugs are shipped on the last section loaded on the truck at the factory.

  • Page 129: Grounding Detail

    Grounding Detail ITEM QTY. DESCRIPTION 6980-0054 GROUND ROD .625" DIA X 10 FT. 6980-0036 GROUND WIRE, 1 1/2” FLAT BRAID #3 AWG 6980-0035 WIRE 10GA STRANDED, GREEN 6610-5023 GOUNDING CLAMP Lower Frame Base Spacer Assembly Detail DETAIL D – LOWER FRAME BASE SPACER ASSEMBLY 6024-0051 LOCK WASHER, 1/2"...

  • Page 130: Lower Frame Bolt-Down Anchor Assembly Detail

    Lower Frame Bolt-Down Anchor Assembly Detail QTY. ITEM DESCRIPTION 0330-0197-08 BOLT DOWN ANGLE, HR ANG. 4" X 4" X 3/16" X 4" 6007-0361 HEX HEAD BOLT, 1"-8 UNC 2A X 2 1/2" 6024-0060 LOCK WASHER, 1" HELICAL SPRING 6013-0160 HEX NUT, 1"-8 UNC 2A 0330-0410-0M Rev D •...

  • Page 131: Load Cell Stand And Parts Detail

    Load Cell Stand and Parts Detail Load Cell Stand and Parts Detail (Quantity shown for 70’ x 11’ scale) QTY. ITEM DESCRIPTION 0330-0178-0A LOWER FRAME ASSEMBLY 0331-0066-0A WEIGHBRIDGE, END MODULE 0330-0216-0A LOAD CELL STAND ASSEMBLY 0330-0125-18 PIVOT PLATE, TS FB 3/8 X 1-3/8 ANNEALED A-2 6007-0009 HEX HEAD BOLT, 1/4"-20 UNC 2A X 1/2"...

  • Page 132: Interconnection Cables

    Interconnection Cables (Quantity shown for 70’ x 11’ scale) ITEM QTY. DESCRIPTION HOMERUN CABLE, 5 CONDUCTOR, SHIELDED PVC 6980-1092 (CONTAINS 2 x 18AWG, 2 x 22AWG, AND 1 x 22AWG) CONNECTOR PACK, HOME RUN CABLE 3502-0681-0A INCLUDES 5-PIN SPRING CAGE CONNECTOR, 6610-1258 0330-0065-08 INTERCONNECT CABLE, 15’...

  • Page 133: Decal And Name Plate Mounting View Detail

    Decal and Name Plate Mounting View Detail 0330-0410-0M Rev D • Portable Digital Truck Scale...
  • Page 134 Decal and Name Plate Mounting View Detail (Quantity shown for 70’ x 11’ scale) ITEM DESCRIPTION QTY. 5930-D091-08 NAME PLATE 6680-0210 POP RIVET DECAL, "REMOVE SHIPPING ASSEMBLY" 0145-B453-08 DECAL, " CAUTION DO NOT WELD . . . " 0145-B393-08 DECAL SECTION 1 0145-B392-18 DECAL SECTION 2 0145-B392-28...
  • Page 135 STATEMENT OF LIMITED WARRANTY WARRANTY TERMS Cardinal Scale Manufacturing Company warrants the equipment we manufacture against defects in material and workmanship. The length and terms and conditions of these warranties vary with the type of product and are summarized below:...
  • Page 136 This warranty sets forth the extent of our liability for breach of any warranty or deficiency in connection with the sale or use of our product. Cardinal will not be liable for consequential damages of any nature, including but not limited to loss of profit, delays or expenses, whether based on tort or contract.
  • Page 137 0330-0153-0M Rev A • Digital Truck Scale...
  • Page 138 Cardinal Scale Mfg. Co. 203 E. Daugherty, Webb City, MO 64870 USA Ph: 417-673-4631 or 1-800-641-2008 Fax: 417-673-2153 www.cardinalscale.com Technical Support: 1-866-254-8261 E-mail: tech@cardet.com Printed in USA 0330-0410-0M Rev D 11/19 0330-0153-0M Rev A • Digital Truck Scale...

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