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Digital Junction Box
Type KAL-4
Flintec GmbH
Bemannsbruch 9
74909 Meckesheim
GERMANY
www.flintec.com
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RIGHTS AND LIABILITIES
All rights reserved.
No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by
any means, mechanical, photocopying, recording, or otherwise, without the prior written permission of Flintec
GmbH
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 book, FLINTEC assumes no responsibility for errors or
omissions. Neither is any liability assumed for damages resulting from the use of the information contained
herein.
The information herein is believed to be both accurate and reliable. FLINTEC, however, would be obliged to
be informed if any errors occur. FLINTEC cannot accept any liability for direct or indirect damages resulting
from the use of this manual.
FLINTEC reserves the right to revise this manual and alter its content without notification at any time.
Neither FLINTEC nor its affiliates shall be liable to the purchaser of this product or third parties for damages,
losses, costs, or expenses incurred by purchaser or third parties a s a re sult of: accident, misuse, or abuse of
this product or unauthorized modifications, repairs, or alterations to this product, or failure to strictly comply
with FLINTEC operating and maintenance instructions.
FLINTEC shall not be liable against any damages or problems arising from the use of any options or any
consumable products other than those designated as Original FLINTEC Prod ucts.
NOTICE: The contents of this manual are subject to change without notice.
Copyright © 2010 by Flintec GmbH, 74909 Meckesheim, Bemannsbruch 9, Germany
SAFETY INSTRUCTIONS
CAUTION READ this manual BEFORE operating or servicing this equipment. FOLLOW
these instructions carefully. SAVE this manual for future reference. DO NOT allow untrained
personnel to operate, clean, inspect, maintain, service, or tamper with this equipment.
ALWAYS DISCONNECT this equipment from the power source before cleaning or performing
maintenance. CALL FLINTEC ENGINEERING for parts, information, and service.
WARNING ONLY PERMIT QUALIFIED PERSONNEL TO SERVICE THIS EQUIPMENT.
EXERCISE CARE WHEN MAKING CHECKS, TESTS AND ADJUSTMENTS THAT MUST BE
MADE WITH POWER ON. FAILING TO OBSERVE THESE PRECAUTIONS CAN RESULT
IN BODILY HARM.
WARNING FOR CONTINUED PROTECTION AGAINST SHOCK HAZARD CONNECT
TO PROPERLY GROUNDED OUTLET ONLY. DO NOT REMOVE THE GROUND PRONG.
WARNING DISCONNECT ALL POWER TO THIS UNIT BEFORE REMOVING THE
FUSE OR SERVICING.
WARNING BEFORE CONNECTING/DISCONNECTING ANY INTERNAL ELECTRONIC
COMPONENTS OR INTERCONNECTING WIRING BETWEEN ELECTRONIC EQUIPMENT
ALWAYS REMOVE POWER AND WAIT AT LEAST THIRTY (30) SECONDS BEFORE ANY
CONNECTIONS OR DISCONNECTIONS ARE MADE. FAILURE TO OBSERVE THESE
PRECAUTIONS COULD RESULT IN DAMAGE TO OR DESTRUCTION OF THE
EQUIPMENT OR BODILY HARM.
CAUTION OBSERVE PRECAUTIONS FOR HANDLING ELECTROSTATIC SENSITIVE
DEVICES.
Digital Junction Box Type KAL-4 – Technical Manual, Rev. 1.00 Dezember 2010
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INTRODUCTION AND TECHNICAL DATA
The painted aluminium junction box KAL-4 is designed to connect up to 4 load cells in parallel. A socket on
the printed circuit board is prepared for accommodating one type LDU xx.x Load Cell Digitizing Unit.
Type No. of load cells Housing size Inputs Outputs
KAL-4 up to 4 80 x 250 x 52 mm 4x M16 3x M16
Housing material: Aluminium
Protection class: IP66
Cable connection: With clamping terminals
Corner correction: By exchangeable resistors
MECHANICAL INSTALLATION
Look for a mounting location which is more or less dry and protected from environmental stress.
ELECTRICAL CONNECTIONS
Figure 1: Dimensions in [mm]
The connection sequence of the load cells should correspond to the corners of the scale, i.e
Corner 1 = Load cell 1, Corner 2 = Load cell 2, etc.
LOAD CELL CABLE CONNECTION
First the cable gland (see in fig.1) must be loosened. Then you have to feed the load cell cable through the
cable gland unless the shrink tube is fully disappeared in the box. The wires have to run below the printed
circuit board and will be pulled back to the top at the upper end of the printed circuit board. Afterwards you can
connect the cables to the clamping terminals as indicated below:
Cable coulour Description Terminal designation
yellow = Cable shield Shield / Schirm
red = Signal – (Output –) red / rot
white = Signal + (Output +) white /weiss
black = Excitation – (Input –) black / schwarz
(if applicable, brown)* = Sense – black / schwarz
green = Excitation + (Input +) green / grün
(if applicable, blue)* = Sense + green / grün
* if load cell is equiped with 6-wire conductor cable
After all conductors have been clamped to the terminals, the cable glands must be tightened. Please verify
that all cable glands are tight and the cable is fully stress relieved.
Digital Junction Box Type KAL-4 – Technical Manual, Rev. 1.00 Dezember 2010
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OUTPUT CABLE CONNECTION
(
)
(
)
12 V
Connector for LDU power supply
LDU requires 12...24 V DC at 60 mA max. current
0 V Shield
RS422/RS485 connector
full-duplex or half-duplex
Figure 2: Power supply and connection to external electronics
Depending on cable routing and the LDU’s communication settings the connection cable between junction box
and external electronics will be executed as shielded 4 wires, shielded 6 wires or separate cables for power
supply and bus communication (see also technical manual of corresponding LDU amplifier).
CORNER CORRECTION A T SCALES WITH FLINTEC LOAD CELLS
Flintec load cells are manufactured with rather tight tolerances, so in most cases an additional corner
correction is not required. The best conditions are achieved if you use load cells of the same class
(Designation is done with capital letters A to I on the load cell package besides the type label).
Hint: Corner errors can have a mechanical background, e.g. sloped mounting surface of the load cell.
Procedure:
1. The 0 Ohm jumpers instead of the correction resistors must be in place (shipment status).
2. Get the display value for each corner. Use the highest possible display resolution (e.g. factor 10 or higher)
or, if this is not possible, measure the the digital weight increment using corresponding weights.
3. The corner with the lowest display value is the starting point for the corner correction. The differences of
the other corners are calculated with reference to this “basic corner”.
4. Calculate the correction resistance as follows:
Correction resistance [] =
* 1100 input resistance for:
400 input resistance for:
Example 1: 1100 load cell
0.1 kg corner error with 500 kg test load
Example 2: 400 load cell
10 kg corner error with 5000 kg test load
5. Install the correction resistor into the junction box instead of the 0 Ohm jumper for the corresponding load
cell excitation.
6. Check the corners again. If required repeat the procedure.
Hint:
50 ppm resistors for corner correction are available as a set of 14 values from 0.22 to 4.7 (10 pcs.
for each value; article no. 5200-030).
In the junction box you can also find a dry tablet in a plastic bag. Open the bag and leave the tablet in the
junction box. This will absorb moisture up to a certain degree. Check the cover sealing and install the cover of
the box.
Deviation in [kg]
Test load in [kg]
X Input resistance of the load cell [] *
BK2, SB4, SB5, SB6, SB14, SLB, ZLB, UB1, UB5, UB6, PB, RC3
RC1, SB2
0.1 kg
500 kg
10 kg
5000 kg
x
x
1100
400
=
0.22
=
0.8
Digital Junction Box Type KAL-4 – Technical Manual, Rev. 1.00 Dezember 2010
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