Cardinal 220 Quick Setup Manual
(
220
WEIGHT INDICATING INSTRUMENT
QUICK SETUP GUIDE
8200-M317-O1 Rev B
03/02
http://www.cardinalscale.com
PO BOX 151 • WEBB CITY, MO 64870
417) 673-4631 • FAX (417) 673-5001
PH
Printed in USA
TABLE OF CONTENTS
INTRODUCTION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Page 2
FCC COMPLIANCE STATEMENT - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Page 2
SPECIFICATIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Page 3
Certifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Page 3
SITE PREPARATION REQUIREMENTS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Page 4
INSTALLATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Page 5
Mounting the 220 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Page 5
Load Cell Connection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Page 5
Load Cell Connections With Over 30 Feet Of Cable - - - - - - - - - - - - - - - - - - - - - Page 6
Load Cell Cable Shield Wire Connection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Page 6
Serial I/O Cable Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Page 6
Optically Isolated Inputs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Page 7
AC Input Relay Board(s) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Page 7
Preset Weight Comparator/Checkweigher Logic Level Output - - - - - - - - - - - - - - Page 8
AC Output Relay Board(s) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Page 9
Re-Installing The Rear Panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Page 9
I/O Functions and Relay Box Cable Wire To Relay Number Tables- - - - - - - - - - - Page 10
220 Main PCB (Figure No. 7) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Page 11
Main PCB Jumpers - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Page 12
KEYPAD FUNCTIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Page 13
SETUP AND CALIBRATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Page 15
CALIBRATION "C" NUMBERS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Page 22
SETUP REVIEW - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Page 23
TROUBLESHOOTING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Page 25
Error Codes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Page 25
Before You Call Service - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Page 28
CALIBRATION SEAL INSTALLATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Page 28
EUROPEAN DECLARATION OF CONFORMITY - - - - - - - - - - - - - - - - - - - - - - - - - - - Page 29
SERIAL NUMBER _____________________
DATE OF PURCHASE _________________
PURCHASED FROM __________________
____________________________________
____________________________________
____________________________________
RETAIN THIS INFORMATION FOR FUTURE USE
PRECAUTIONS
Before using this instrument, read this manual and pay special attention to
all "WARNING" symbols:
IMPORTANT
ELECTRICAL
WARNING
1
STATIC
SENSITVE
INTRODUCTION
Thank you for purchasing the Cardinal 220 Weight Indicating Instrument. This instrument was built
with quality and reliability at our factory in Webb City, Missouri.
The 220 incorporates the latest in digital technology and innovative features for the weighing
industry. Configuration and upgrades can easily be performed in the field, while still maintaining
the rigid control the most demanding installations require. This flexibility insures the 220 will be
able to meet your weight indicating needs for years to come.
The purpose of this guide is to provide you with a guide through installation and calibration of your
new weight indicating instrument. Please read it thoroughly before attempting to install your 220
Indicator and keep it handy for future reference.
For complete details on the features, functions and programming of your 220 Indicator, refer to the
220 Weight Indicating Instrument Technical and Operation Manual, 8200-M502-O1.
FCC COMPLIANCE STATEMENT
WARNING! This equipment generates, uses and can radiate radio frequency and if not installed
and used in accordance with the instruction manual, may cause interference to radio
communications. It has been tested and found to comply with the limits for a Class A computing
device pursuant to Subpart J of Part 15 of FCC rules, which are designed to provide reasonable
protection against such interference when operated in a commercial environment. Operation of
this equipment in a residential area may cause interference in which case the user will be
responsible to take whatever measures necessary to correct the interference.
You may find the booklet “How to Identify and Resolve Radio TV Interference Problems” prepared by the Federal
Communications Commission helpful. It is available from the U.S. Government Printing Office, Washington, D.C.
20402. Stock No. 001-000-00315-4.
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. While every precaution has been taken in the preparation
of this manual, the Seller assumes no responsibility for errors or omissions. Neither is any liability
assumed for damages resulting from use of the information contained herein. All instructions and
diagrams have been checked for accuracy and ease of application; however, success and safety
in working with tools depend to a great extent upon the individual accuracy, skill and caution. For
this reason the Seller is not able to guarantee the result of any procedure contained herein. Nor
can they assume responsibility for any damage to property or injury to persons occasioned from
the procedures. Persons engaging the procedures do so entirely at their own risk.
2
SPECIFICATIONS
Power Requirements: 90 to 264 VAC (50/60 Hz) at 0.4A
Enclosure Type: NEMA 4X/IP66:
Enclosure Size: 10 7/8"W x 8 3/16"H x 3 1/8"D (276mm W x 208mm H x 79mm D)
Weight: 9.2lbs (
Size and Weight DOES NOT include Gimbal
Operating Environment: Temperature: 14 to 104 ºF (-10 to +40 ºC)
Humidity: 90% non-condensing (maximum)
Display: 12-digit, 0.8" high, 14-segment LCD
Transducer Excitation: 12 VDC
Signal Input Range: 1.0 mV min. to 40 mV max. (with dead load boost)
Number of Load Cells: 14 each, 350 OHM minimum resistance
Load Cell Cable Length: 1500 feet maximum with sense lines.
30 feet maximum without sense lines
Maximum Displayed
9,999,999
Weight Value
Division Value: 1, 2, or 5 x 10, 1, 0.1, 0.01, 0.001 and 0.0001 commercial
0 to 99, non-commercial
Sensitivity:
NON-COMMERCIAL
NTEP
CANADA
OIML
Scale Divisions:
NON-COMMERCIAL
NTEP
CANADA
OIML
0.15 uV/e
0.3uV/e (Class III/IIIL)
0.3uV/e (Class III/IIIHD)
0.7 uV/e (Class III)
100 to 240,000
100 to 10,000 (Class III/IIIL)
100 to 10,000 (Class III/IIIHD)
100 to 10,000 (Class III)
Internal Resolution: 1 part in 16,777,216
Tare Capacity: Six Digits (999,999)
Sample Rate: 1 to 100 samples per second, selectable
Auto Zero Range: 0.5 or 1 through 9 divisions
Weighing Units: Tons, Pounds, Metric Tons, Kilograms, Grams, Ounces, Custom
Keypad: Membrane type with 27 color-coded keys
Standard I/O: (1) Bi-directional RS232 and 20mA
(1) RS232/20mA output only
(1) Infrared (IR) Data Port
Optional I/O: 14 bit Analog Output (0 to 10v, 4 to 20mA)
)
Consult factory for
other requirements
Certifications:
This equipment is certified to comply with the requirements for a Class III/IIIL device by the
National Conference on Weights and Measurements (Certificate No. 01-011)
•
Measurement Canada (Approval No. AM-5397)
•
• and for a Class III device by OIML R-76 (Certificate No. DK 0199.47).
3
SITE PREPARATION REQUIREMENTS
The 220 Weight Indicator is a precision weight measuring instrument. As with any precision
instrument, it requires an acceptable environment to operate at its peak performance and
reliability. This section is provided to assist you in obtaining such an environment.
Electrical Power
The 220 indicators has been designed to operate from 90 to 264 VAC at 50/60 Hz. Note that a
special order is not
CAUTION! - To avoid electrical hazard and possible damage to the indicator,
DO NOT, under any circumstance, cut, remove, alter, or in any way bypass the
power cord grounding prong.
On models requiring 230 VAC power,
electrician install the proper power cord plug which conforms to national electrical codes and local
codes and ordinances.
The power outlet for the indicator should be on a separate circuit from the distribution panel. This
circuit should be dedicated to the exclusive use of the indicator. The wiring should conform to
national and local electrical codes and ordinances and should be approved by the local inspector
to assure compliance.
To prevent electrical noise interference, make certain all other wall outlets for use with air
conditioning and heating equipment, lighting or other equipment with heavily inductive loads, such
as welders, motors and solenoids are on circuits separate from the indicator. Many of these
disturbances originate within the building itself and can seriously affect the operation of the
instrument. These sources of disturbances must be identified and steps must be taken to prevent
possible adverse effects on the instrument. Examples of available alternatives include isolation
transformers, power regulators, uninterruptible power supplies, or simple line filters.
CAUTION!
from all AC wiring.
required for operation at 230 VAC.
it is the responsibility of the customer
When in parallel runs, locate Load Cell cables a minimum of 24" away
to have a qualified
Environmental
In general, the 220 Indicator will perform well within a
temperature range of 14 to 104 °F (-10 to +40 °C ).
In order to keep cooling requirements to a minimum, the
indicator should be placed out of direct sunlight and to
provide adequate air circulation, keep the area around the
indicator clear.
Make certain the instrument is not directly in front of a
heating or cooling vent. Such a location will subject the
indicator to sudden temperature changes which may result
in unstable weight readings.
Insure that the indicator has good, clean AC power and is
properly grounded.
In areas subject to lightning strikes, additional protection to
minimize lightning damage, such as surge suppressors,
should be installed.
4
INSTALLATION
Before beginning installation of your Model 220 Weight Indicating Instrument, make certain that the
instrument has been received in good condition. Carefully remove the instrument from the
shipping carton and inspect it for any evidence of damage (such as exterior dents or scratches)
that may have taken place during shipment. Keep the carton and packing material for return
shipment if it should become necessary. It is the responsibility of the purchaser to file all claims for
any damages or loss incurred during transit.
Mounting the 220
NOTE! Should your 220 indicator come already installed on a scale, the following information
describing the installation of the instrument does not apply.
The Model 220 Indicator is housed in a NEMA 4X/IP66 stainless steel wall or desk-mount
enclosure. The 220 gimbal may be mounted on a desktop or other smooth, flat, horizontal surface
or may be mounted on a wall. Refer to Figure No. 1 for a layout of wall-mounting bolts.
If wall mounted, make certain the mounting surface is strong enough to support the instrument.
The mounting location should be where the display is easily viewed while being close enough to
provide the operator easy access to the keypad. Carefully lay out the mounting hole locations,
then drill and install the anchor bolts. Attach the gimbal to the wall and securely tighten the
retaining bolts.
6.00"
Clearance for
#10 size screw
Figure No. 1
Load Cell Connection
CAUTION! Disconnect any external load cell power supply before connecting load
cells to the instrument. Failure to do so will result in permanent damage to the
instrument.
1. Remove the 14 acorn nuts securing the
back panel to the main housing, then
loosen the bottom-right cable gland
connector for the load cell. This gland
connector is located on the rear panel
of the enclosure. Refer to Figure No. 2
for illustration of the connector layout.
2. Slip the single cable from the load cell
or load cell junction box through the
gland connector and into the enclosure.
3. Remove 2" of the outer insulation
jacket then remove 1/4" of insulation
from each of the 4 wires and shield
without sense leads or 6 wires and Figure No. 2
shield with sense leads (refer to Figure
No. 3).
5
Load Cell
4. Connect each of the wires to terminal block
P6 referring to the table on the circuit board
for terminal connections. Refer to Figure
No. 7 for terminal block location.
5. To terminate a wire, first press down on the
release bar for the terminal, insert the wire
into the terminal opening then allow the
release bar to return to its original position,
locking the wire in place.
6. Repeat the procedure until all of the wires
are in place.
7. Route the load cell cable through the two Figure No. 3
cable clips provided on the upper and left
sides of the enclosure interior.
LOAD CELL CONNECTOR P7
PIN NO. Function PIN NO. Function
1 + EXCITATION 5 - SIGNAL
2 + SENSE 6 - SENSE
3 + SIGNAL 7 - EXCITATION
4 SHIELD
Load Cell Connections With Over 30 Feet Of Cable
For installations with over 30 feet of cable between the indicator and the load cells, sense wires
should be used. The sense wires must be connected between the +SENS, -SENS terminals on the
indicator and the +EXCITATION, -EXCITATION wires of the load cells or the +SENS, -SENS
terminals of the load cell trim board or the section seal trim board. For the indicator to use the
sense wires, the +SENS jumper J12 and the -SENS jumper J13 must be open (see Figure No. 7).
Load Cell Cable Shield Wire Connection
The load cell cable shield wire should be connected to the
threaded stud inside the indicator. This stud is located on
the bottom inside of the indicator near the load cell
connector P7. See Figure No.4.
The shield wire should be wrapped around the stud
between the 2 flat washers and secured using the hex nut.
Figure No. 4
Serial I/O Cable Installation
The 220 may be connected to a printer to record weight and associated data or it may be
connected to a remote display or even to a computer for transmission of weight data. The
weight data may be transmitted on demand (pressing the PRINT key or on receipt of a
command from the computer). For complete details on the 220 Serial I/O, refer to the
Setup, SIO Serial I/O section of the 220 Weight Indicating Instrument Technical and
Operation Manual, 8200-M502-O1.
1. Loosen the cable gland connector(s) for the serial cable. The gland connector(s) for the
serial data are located on the rear panel of the enclosure. Refer to Figure No. 2 for an
illustration of the gland connector layout.
2. Slip the serial cable through the gland connector and into the enclosure.
Threaded Stud for
Shield Wire
6
3. Remove 2" of the outer insulation jacket then remove 1/4" of insulation from each of the
wires (refer to Figure No. 3).
4. Connect each of the wires to the Serial I/O terminal block (P10) referring to Figure No. 7 for
terminal block locations.
5. To terminate, first press down on the release bar for the terminal, insert the wire into the
opening then allow the release bar to return to its original position, locking the wire in place.
Repeat the procedure until all of the wires are in place.
BI-DIRECTIONAL SERIAL INTERFACE SERIAL OUTPUT
PIN NO. Function PIN NO. Function
1 TXD 1 - SRC 8 RXD 1 - RS232
2 TXD 1 - 20 mA + 9 TXD 1 – CTS
3 TXD 1 - 20 mA - 10 GND 1
4 RXD 1 - SRC 11 TXD 2 - 20 mA Active
5 RXD 1 - 20 mA + 12 TXD 2 - RS232
6 RXD 1 - 20 mA - 13 GND 2
7 TXD 1 - RS232
Optically Isolated Inputs
Included with the I/O are 7 programmable inputs that may be used to remotely (up to 100 feet)
initiate various functions within the indicator. These inputs are accessed via a terminal block (P9)
on the back of the PC board (see Figure No. 7). The 7 inputs are defined as follows:
PIN NO.
AC Input Relay Board(s)
The AC Input Relay Board(s) are mounted in an external junction box for use with the 220
Indicator. The RB4-IN (115 VAC) or RB4-INV (230 VAC) contain one board and supports 4 inputs
(jumper selectable). The RB8-IN (115 VAC) or RB8-INV (230 VAC) contain two boards and
supports 7 inputs. The relay board used in the 115 VAC version is Cardinal p/n 8200-C324-0A.
The 230 VAC version uses relay board Cardinal p/n 8200-C324-1A. Connect the devices as
shown in Figure No. 5.
•
• INPUT (IAC-5A) ……... 180 to 280 VAC @ 6mA maximum for each plug-in relay.
• OUTPUT ..…………..... 5VDC @ 12mA from the 220 main pc board assembly P9.
•
Function PIN NO. Function
1 + SRC 6 Not Used
2 ZERO 7 STOP
3 TARE 8 START
4 GROSS / NET 9 DUMP
5 PRINT 10 GND / SHIELD
Remember that the input must be connected to Gnd to initiate the function.
INPUT (IAC-5) ……….. 90 to 140 VAC @ 6mA maximum for each plug-in relay.
CONNECTION ............ Removable plug-in screw terminals for up to 14 AWG wire.
7
AC Input Relay Board(s)
Figure No. 5
NOTE! AC INPUT RELAYS ARE VOLTAGE DEPENDENT. A DIFFERENT RELAY IS
REQUIRED FOR 115 VAC AND 230 VAC!
Preset Weight Comparator/Checkweigher Logic Level Output
If you so choose, you may use the logic level outputs from your Model 220 indicator’s preset
weight comparators or checkweigher to control peripheral devices used to manage the flow of
material or signal when the weight is within preset limits. Note that these outputs are at logic level
and cannot drive external devices directly. Solid state relays can be used to accept the logic level
output from the 220 and in turn, drive the external device.
To connect the control cable to the preset weight comparator/checkweigher logic level output
connector P8, first loosen a gland connector located on the back of the 220. Refer to Figure No. 2
for the location of the connectors. Slip the cable through this connector and into the enclosure.
Remove 2 inches of the cable insulating jacket then 1/4 inch of insulation from each of the internal
wires (refer to Figure No. 3). Make the proper terminations on terminal block P8. To terminate a
wire, first press down on the terminal block release bar, insert the wire into the terminal and
remove pressure from the release bar locking the wire in place.
8
AC Output Relay Board(s)
The AC Output Relay Board(s) are mounted in an external junction box for use with the 220
Indicator. The RB4-OUT contains one board and supports 4 outputs (jumper selectable). The
RB8-OUT contains two boards and supports 8 outputs. The relay board used in both is (Cardinal
p/n 8539-C062-0A). Connect the devices to be controlled as shown in Figure No. 6.
The individual relays can be configured to be on (closed) or off (open) at weights under the preset
weight then switch at the preset weight from on-to-off or off-to-on by setting the under weight
condition to on or off during setup and calibration or setup review.
• OUTPUT (closed) ........ 28-240VAC @ 3A maximum for each plug-in relay.
CONTROL INPUT ....... 5VDC @ 12mA from the 220 main pc board assembly P8.
•
• CONNECTION ............ Removable plug-in screw terminals for up to 14 AWG wire.
Figure No. 6
NOTE!
All relays are the normally-open type that will open when power to indicator is lost.
Re-Installing The Rear Panel
After all terminations have been made, remove the excess cable from the instrument enclosure
and securely tighten each of the cable gland connectors. Do not over-tighten these connectors but
make certain they are snug.
gland connectors are plugged. Replace the rear panel and secure with the 14 acorn nuts removed
earlier.
NOTE!
Follow a diagonal pattern when tightening the acorn nuts.
DO NOT USE TOOLS!
9
Finger tighten only! Ensure any unused
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