Cooper Instruments DFI-4215 Installation Manual
DFI 4215
DIGITAL INDICATOR
USER’S GUIDE
www.cooperinstruments.com
PH: 540-349-4746 • FAX: 540-347-4755
CONTENTS
1.0 INTRODUCTION .................................................................................................................. 1
2.0 QUICK START ..................................................................................................................... 1
3.0 RUN MODE .......................................................................................................................... 2
3.1 Item Button .................................................................................................................................... 3
3.2 Tare Button.................................................................................................................................... 3
3.3 Reset Button.................................................................................................................................. 3
3.4 View Button ................................................................................................................................... 3
3.5 Print Button ................................................................................................................................... 4
3.6 Unit Button .................................................................................................................................... 4
4.0 SETUP MODE SUMMARY................................................................................................... 4
5.0 SETUP MODE ...................................................................................................................... 6
5.1 Entering Numerical Data .............................................................................................................. 6
5.2 User Data Entry ............................................................................................................................. 6
5.3 Analog Output ............................................................................................................................... 7
5.4 Sensor Select ................................................................................................................................ 7
5.5 Sensor Delete ................................................................................................................................ 7
5.6 Calibration ..................................................................................................................................... 7
5.6.1 Cal Check................................................................................................................................ 8
5.6.2 Cal by mV/volt......................................................................................................................... 8
5.6.3 Cal by Masses......................................................................................................................... 8
5.6.4 Cal by Shunt Val..................................................................................................................... 8
5.6.5 Counts per Inch...................................................................................................................... 8
5.7 Limits ............................................................................................................................................. 8
5.8 System Options............................................................................................................................. 9
5.8.1 Printer Baud............................................................................................................................ 9
5.8.2 Auto Identify ........................................................................................................................... 9
5.8.3 Auto Zero Ch A/B ................................................................................................................... 9
5.8.4 Com Address.......................................................................................................................... 9
5.8.5 Com Baudrate....................................................................................................................... 10
5.8.6 Com Line Feed...................................................................................................................... 10
5.8.7 Retain Tare............................................................................................................................ 10
5.9 Display Options........................................................................................................................... 10
5.9.1 Filter Select........................................................................................................................... 10
5.9.2 Decimals Ch A/B................................................................................................................... 10
5.9.3 Count By Ch A/B .................................................................................................................. 10
5.9.4 Second Line.......................................................................................................................... 10
6.0 REMOTE OPERATION ...................................................................................................... 11
6.1 Digital Inputs ............................................................................................................................... 11
6.2 RS232 Operation ......................................................................................................................... 11
6.2.1 RS232 Run Mode Command Summary .............................................................................. 11
6.2.2 RS232 Run Mode Commands ............................................................................................. 12
6.2.3 RS232 Setup Mode command Summary............................................................................ 14
6.2.4 RS232 Setup mode commands........................................................................................... 15
7.0 SYSTEM CALIBRATION MODE........................................................................................ 25
APPENDIX A – MODEL 4215 SPECIFICATIONS ................................................................... 26
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APPENDIX B -- CABLES AND CONNECTORS...................................................................... 28
Sensor Connectors........................................................................................................................... 28
Serial Port Connector ....................................................................................................................... 28
Serial Port Connector / RS485 Option Only.................................................................................... 28
Digital I/O Connector ........................................................................................................................ 29
Chart Rec. Connector ....................................................................................................................... 29
APPENDIX C -- PRECISION SHUNT CALIBRATION RESISTORS ....................................... 30
WARRANTY REPAIR POLICY ................................................................................................ 30
DFI 4215 iii ver 1.0.8
1.0 INTRODUCTION
The Model 4215 is a versatile precision instrument intended for the digital readout of strain gage sensors such as
load cells. Optical encoders are also supported.
Here is a quick listing of its features:
• Full bi-polar 6 digit display (±999,999) using two line, 20 character, vacuum fluorescent display for clear,
precise indication of measured quantities and limit status.
• No knobs or dials. No internal jumpers. All adjustment and calibration is done using user-friendly front panel
menus. Keylock option to prevent accidental or unauthorized changes to the unit’s setup.
• Measure load in pounds, kilograms, Newtons, PSI, MegaPascals, kilo-pounds, kilo-Newtons, metric tons, or
mV/V. User defined base area for PSI and MPa. Tare at any time.
• Capture the load peak and valley, display in pounds, kilograms, Newtons, PSI, MegaPascals, kilo-pounds,
kilo-Newtons, metric tons, or mV/V. Reset at any time.
• Measure position and velocity with optional encoder input. Display in English units, metric units, or in
percent of a user defined base length. Reset at any time.
• Four contact closure Limit switches. You can set which signal drives the limit (load, peak, valley, position, or
velocity), normally open / normally closed, set point, and manual reset (latched) or automatic reset (not
latched).
• Print current readings of load, peak, valley, position, and velocity using the currently selected units at the
touch of one button.
• Automatic identification of calibrated load cells with auto-id option.
• Calibration for load cells using manufacturer’s milli-volt per volt calibration factor, 5 point milli-volt per volt, 2
or 5 point known mass, or internal precision shunt calibration. A back panel switch allows you to choose
between two values used for the shunt calibration so there is no need to open the unit.
• Analog output of any signal (load, peak, valley, position, velocity) with user defined scale factor and offset.
Large, buffered ± 10.00 volt output.
• Remote operation using standard RS232 ASCII command set.
• Back panel digital inputs for tare, peak and valley reset, position reset, and print. Other functions available
as custom programmed options.
2.0 QUICK START
This section will help you get your Model 4215 set up and operating in just a couple of minutes.
The back panel is shown below. You will need to make at least two connections here. First be sure that the power
switch is off (the lower part of the rocker should be pressed in). Connect the AC power line and plug it in.
MODEL 4215 BACK PANEL
Next connect a load cell to the 9 pin female connector labeled “Sensor A”. You should use the cabling supplied with
your Model 4215 and load cell. If you do not have a factory supplied cable see Appendix B for the recommended
load cell connection.
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You are now ready to turn on the power. Each time power is applied to the Model 4215 you will see a sequence of
6 messages appear on the front display. For example,
# Message Meaning
1 Cooper .X.Y.Z This is the version number.
2 Serial # 12345
Option # 114236
3 Last ID A 90437
Last ID B 12030
4 Ch A Max 4.00Lb
Ch B Max 10.00In
5 Ch A Cal 4.00000
mVv
Ch B Cal 4.00000
mVv
6 Ch A Exc 5.00 Volt
Ch B Exc 2.50 Volt
Each of these messages will be displayed for about 3 seconds. After that the front display will start showing the
current readings from the load cell and sensor.
To change what item is being displayed press the leftmost button. This will cycle through the list of items (load A,
peak A, valley A, load B, peak B, valley B, pos, velocity, lim).
The rightmost button will change the units that are being used. Repeated presses of this button will cycle through
the list of units available for the currently displayed item. For example, with Load A showing you would see Lb, kg,
N, PSI, MPa, Klb, kN, t, mV/V, and then back to Lb.
This is the serial number.
This is the option number.
The serial number of the load cell on Ch A.
The serial number of the sensor on Ch B
Maximum rated load of the sensor on channel A.
Maximum rating of the sensor on channel B.
The mV/V constant used with the load cell on channel A.
The mV/V constant used with the sensor on channel B.
Note: If either of these sensors was calibrated by 5 –Point Mass, then 4 mV/V
constants will be displayed here.
Excitation voltage used with the load cell on channel A.
Excitation voltage used with the sensor on channel B.
3.0 RUN MODE
The Model 4215 has three modes of operation, Run mode, Setup mode, and System Calibration mode. At poweron it will be in Run mode.
The first line of the display shows an item label (Load A), a value (0.0000), and a unit label (Lb).
The second line of the display can show the status of the 4 contact closure limit switches, show another display,
show text, or be blank.
To change what item is being displayed press the leftmost button. This will cycle through the list of items (Load A,
Peak A, Vall A, Load B, Peak B, Vall B, Pos, Vel, and Limits).
The rightmost button will change the units that are being used. Repeated presses of this button will cycle through
the list of units available for the currently displayed item. For example, with Load showing you would see Lb, kg, N,
PSI, MPa, Klb, kN, t, mV/V, and then back to Lb.
The table below summarizes the options.
Load A Pounds, Kilograms, Newtons, PSI, MegaPascals, Kilo-Pounds, Kilo-Newtons, Metric Tons,
mV/V.
Peak A Pounds, Kilograms, Newtons, PSI, MegaPascals, Kilo-Pounds, Kilo-Newtons, Metric Tons,
mV/V.
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Valley A Pounds, Kilograms, Newtons, PSI, MegaPascals, Kilo-Pounds, Kilo-Newtons, Metric Tons,
mV/V.
Load B Pounds, Kilograms, Newtons, PSI, MegaPascals, Kilo-Pounds, Kilo-Newtons, Metric Tons,
mV/V.
Peak B Pounds, Kilograms, Newtons, PSI, MegaPascals, Kilo-Pounds, Kilo-Newtons, Metric Tons,
mV/V.
Valley B Pounds, Kilograms, Newtons, PSI, MegaPascals, Kilo-Pounds, Kilo-Newtons, Metric Tons,
mV/V.
Position Inches, Centimeters, Percent of Base Length.
Velocity Inches per Minute, Centimeters per Minute.
Limits Shows state of each switch, 1 for on, 0 for off, dash for disabled, asterisk for source error.
All of these measurements are acquired by the Model 4215 at all times. The display just selects which particular
item you wish to see and what units are used to display or print this data.
The row of buttons have the functions indicated by the upper set of labels (Item, Tare, Reset, View, Print, Unit).
Each of these is described below.
3.1 Item Button
The Item button cycles through the list of different items that can be displayed (Load A, Peak A, Vall A, Load B,
Peak B, Vall B, Pos, Vel, Limits). Use the Unit button to change the units that are used for the currently displayed
item.
3.2 Tare Button
The Tare button sets the current load to zero for channel A, channel B, or channels A and B. A submenu will allow
you to select what channel you want to tare. It does not matter what is being displayed when you press this button.
The load is always reset to zero. A single channel unit will automatically set Load A to zero.
3.3 Reset Button
The Reset button brings up a list of things that you might want to set to zero:
If this is a 2-channel unit, the following menu will appear:
> Reset Ch A + Ch B will reset the peak, valley, max, min for channels A and B.
> Reset Ch A Only will reset the peak and valley for channel A.
> Reset Ch B Only will reset the max and min for channel B.
> Reset Position will reset the position to zero.
> Reset Limits will reset any limits that require manual resetting.
For a single channel unit, the following menu will appear:
> Reset Peak+Vall will reset the peak and valley measurements.
> Reset Peak Only will reset the peak measurement.
> Reset Vall Only will reset the valley measurement.
> Reset Position will reset the position to zero.
> Reset Limits will reset any limits that require manual resetting.
Pressing either the “+” button or the “>“ button will scroll forward through this list. Pressing either the “-” button or
the “<“ button will scroll backward through the list. Pressing “Enter” will reset the currently displayed item. Pressing
“Esc” will return to Run Mode without resetting anything. Note that all menu lists on the Model 4215 start with the
“>“ symbol and that the Esc button will always back out of a menu without making any changes.
3.4 View Button
The View button switches between two virtual displays stored in the memory. Each of these displays will remember
the units you have selected for each item, and which item is currently being shown. This may save you from
scrolling through the list of items if there are two particular results that you often use. For instance you might set the
display to show Load in Lb, press View, and then set the display for Peak in PSI. Repeated presses of the View
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button will now switch back and forth between Load in Lb and Peak in PSI with a single button push. If you choose
to have the second line show a display, then the View button toggles between the display currently being activated.
The activated display will have a “>” symbol to the left of it.
3.5 Print Button
The Print button will send a set of data to the printer. This will contain the current readings of load, peak, valley,
position, velocity, and limit status. The units used for printing will be the units last selected on the numerical display.
The printer must be a serial printer that supports ESC/P protocol. Many Epson printers with serial ports are known
to be compatible.
Appendix B gives the pin assignments on the serial connector.
3.6 Unit Button
The Unit button cycles through the list of units that are available for the item that is currently being displayed.
4.0 SETUP MODE SUMMARY
The table below summarizes the setup mode menus. Detailed information about each individual item is presented
in the following sections.
Setup mode
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>User Data Entry
>>Base Area Ch A/B
>>Base Length
>Analog Output
Source → Units → Full → Zero.
>Sensor Select
Channel → Serial Number List → Cal Info.
>Calibration
>>Cal Check
>>Cal by mV / volt
>>Cal by Points
>>Cal by Shunt
>>Counts / Inch
>Limits
Select → NO/NC → Enable →
>System Options
>Display Options
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Source → Units →Set → Trip →
Latch → Reset → Done.
>>Printer Baud
>>Auto Identify
>>Auto Zero Ch A/B
>>Com Address
>>Com Baudrate
>>Com Line Feed
>>Filter Select
>>Decimals Ch A/B
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>>Count By Ch A/B
>>Second Line
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5.0 SETUP MODE
Setup mode is used to change the setup of the Model 4215. To enter setup mode press the two end buttons at the
same time ( “<“ and “>“ ). The row of four buttons will now function as indicated by the lower set of labels (Plus,
Minus, Enter, and Escape).
If the optional keylock is in the locked position you will see “>Setup is Locked” when you try to enter setup mode.
This prevents accidental or unauthorized changes to the setup of the unit.
To exit from setup mode and return to run mode press the escape button (Esc). When you are entering numerical
data or selecting options from a sub-menu the escape button will back you out without making any changes.
The main menu in setup mode contains the following 6 entries which will be described in detail in the following
sections. Note that all main menu items begin with the “>“ symbol and that all submenu items begin with the “>>“
symbol.
• User Data Entry -- allows you to set any common math options such as the base area used to display load
in PSI or the base length used to display position in percent.
• Analog Output -- is used to select the source and scaling for the standard analog output channel.
• Sensor Select -- lets you manually set which load cell calibration data is used. If you use auto-id load cells
you will never need this menu.
• Calibration -- provides access to calibration for load cells, extension sensor, or optical encoders.
• Limits -- allows you to set the source and options for the 4 contact closure switches.
• System Options -- contains entries to set the printer baud rate, enable or disable automatic sensor
identification, enable or disable automatic load zeroing, and to set the serial communications address, baud
rate, and line feed options.
• Display Options -- lets you choose the filtering that is applied to the load measurements, the number of
decimal digits that are shown on the display and on the print, the count by values for channels A and B (1, 2,
5, 10, or 20), and whether the second line of the display shows the limit switch status, a blank line, another
display, or text.
The Plus or Right button (“+” or “>“) will scroll forward through this menu. The Minus or Left button (“-” or “<“) will
scroll backward through this menu. The Enter button selects the currently displayed menu item. The Esc button will
return you to Run Mode.
5.1 Entering Numerical Data
At times you will need to enter numerical data into the Model 4215. The method is consistent in all cases. A number
is presented on the left side of the display with an underline cursor.
• Left (“<“) moves the cursor left one position. If you are on the leftmost digit a new zero will be added. Thus
1
0.000 will become 010.00 where the cursor has moved from the tens place to the hundreds place.
• Right (“>“) moves the cursor right one position. If you are at the far right a new decimal will be added if there
is room. Thus 12.34
place.
• Plus (“+”) increments the digit above the cursor. Thus 12
to 0.
• Minus (“-”) decrements the digit above the cursor. Thus 12
to 9.
• Plus and Minus (both “+” and “-” at the same time). This will change the sign of the number. Thus 12
becomes -12.34. Note that cursor position does not matter when you change the sign.
• Enter accepts the currently displayed number.
• Esc escapes from numerical entry and discards any changes that have been made.
will become 12.340 where the cursor has moved from the tenths to the hundredths
.34 becomes 13.34. Note that 9 will “wrap around”
.34 becomes 11.34. Note that 0 will “wrap around”
.34
5.2 User Data Entry
This menu is used to enter numerical constants used by the math options. These constants are listed in a submenu
that works exactly like the main setup mode menu. Typical items in this submenu are:
>>Base Area Ch A
This is the area in square inches that is used to calculate load in pounds per square inch (PSI) or Mega Pascals
DFI 4215 6 ver 1.0.8
(MPa).
>>Base Length
This is the length in inches that is used to calculate position in percent.
5.3 Analog Output
This menu is used to set up the standard analog output. Instead of a submenu there is a series of selections.
Pressing escape at any time will leave the analog output unchanged and return you to the setup mode main menu.
1. Source: -- This entry allows you to scroll through a list (using the left/right or plus/minus buttons) to select the
source of the data that will drive the analog output. The standard list will include load, peak, valley, position,
and velocity. Press enter to select the displayed item.
2. Units: -- This entry allows you to scroll through the list of available units for the data source you have chosen in
the previous step.
3. Full -- This entry specifies the value of source data (in the selected units) that will cause the Model 4215 to
output positive full scale analog voltage (+10.0 volts).
4. Zero -- This entry specifies the value of source data (in the selected units) that will cause the Model 4215 to
output zero analog voltage (0.0 volts).
Once you have entered these 4 selections the analog output is setup.
5.4 Sensor Select
This menu is used to manually select load cell calibration data from a list stored in the Model 4215. When you
select this menu on a 2 channel unit, you are asked to select Channel A or B. The load cell serial number of the
selected channel is displayed. Use either the left/right or plus/minus buttons to page through the list. The escape
button will return to the setup mode main menu without changing the load cell that is selected. The enter button will
select the currently displayed load cell and briefly display the rated load, last calibration date, and excitation
voltage.
To add new load cells to this list use the Calibration entry on the setup mode main menu described below.
If you are using auto-id load cells this menu will allow you to see which load cell is selected but will not allow you to
change the selection. This ensures that the correct calibration information is always used when you use Auto-ID
load cells.
5.5 Sensor Delete
The Model 4215 can store calibration data for 4 different load cells / sensors (25 slots optional). To delete a load
cell from this list choose “>Sensor Select” from the setup mode main menu. Press the left/right or plus/minus keys
until the serial number of the cell you wish to delete is displayed. (You may need to shut off auto-id if it is on, see
the System Options menu for details). Then press both the plus and minus keys at the same time. The Model 4215
will ask “Delete Sensor?” to be sure that you intend to delete this calibration data. Pressing Enter will delete the cell
data from the list. Pressing Escape will return to the load cell select without changing the list.
5.6 Calibration
This menu is used to access all methods of calibration that are supported by the Model 4215. Selecting calibration
from the setup mode main menu will bring up a submenu. This submenu is used exactly like the main menu. Press
left/right or plus/minus to change the menu item. Press escape to return to the setup mode main menu. Press enter
to select the displayed menu item.
If you are re-calibrating a load cell, the Model 4215 will recognize it using either the auto-id or a manually entered
serial number. Any time you overwrite existing load cell calibration data you will first be warned with the “Overwrite
Data?” message. Pressing enter will overwrite; pressing escape will cancel the calibration. Another method of
overwriting existing data is to delete the sensor first and then calibrate.
If a load cell with a new serial number (or new auto-id) is calibrated the data is added as a new entry in the load cell
list.
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