KERN & Sohn GmbH
Ziegelei 1
E-Mail: info@kern-sohn.com
Phone: +49-[0]7433- 9933-0
Internet: www.kern-sohn.com
Installation instructions weighing bridge
KERN KFP V40
Version 1.2
10/2014
GB
D-72336 Balingen
Fax: +49-[0]7433-9933-149
KFP V40-IA-e-1412
GB
KERN KFP V40
Installation instr uctions weighing bridge
Version 1.2 10/2014
Contents
1 General ........................................................................................................... 3
2 Technical data ................................................................................................ 3
3 Basic instructions .......................................................................................... 3
3.1 Documentation ........................................................................................................................... 3
3.2 Proper use .................................................................................................................................. 3
3.3 Improper Use .............................................................................................................................. 3
3.4 Warranty ..................................................................................................................................... 4
3.5 Monitoring of Test Resources .................................................................................................... 4
4 Basic Safety Precauti o ns .............................................................................. 5
4.1 Pay attention to the instructions in the Operation Manual.......................................................... 5
4.2 Personnel training ....................................................................................................................... 5
5 Transport and storage ................................................................................... 5
5.1 Testing upon acceptance ........................................................................................................... 5
5.2 Packaging / return transport ....................................................................................................... 5
6 Unpacking, Setup and Commissioning ....................................................... 6
6.1 Installation Site, Location of Use ................................................................................................ 6
6.2 Unpacking, Scope of delivery ..................................................................................................... 7
6.3 Assembly, levelling ..................................................................................................................... 8
6.4 Connecting a display unit ........................................................................................................... 9
7 Operation ........................................................................................................ 9
7.1 Operation limits ......................................................................................................................... 10
7.2 Operation with access ramps ................................................................................................... 10
7.3 Load/unload weighing system .................................................................................................. 10
8 Service, maintenance, disposal .................................................................. 11
8.1 Daily check ............................................................................................................................... 11
8.2 Cleaning ................................................................................................................................... 11
8.3 Service, maintenance ............................................................................................................... 11
8.4 Disposal .................................................................................................................................... 11
8.5 Instant help ............................................................................................................................... 12
9 Service documentation ............................................................................... 13
9.1 Overview, setting regulation, tolerances .................................................................................. 13
9.2 Check and adjustment of the corner load................................................................................. 14
10 Preload, Deadload and Overload settings ................................................. 16
KFP V40-IA-e-1412 2
1 General
Max
d
e
Min
approx.
kg g g
kg m kg
These installation instructions contain all data necessary for placing and
commissioning the weighing bridge KERN KFP 1500V40M.
2 Technical data
Model
KFP 1500V40M
KFP 1500V40SM
KFP 1500V40M
KFP 3000V40M
Weighing
range
600 200 200 4 5 85
1500 500 500 10 5 85
1500 500 500 10 5 150
3000 1000 1000 20 5 150
Readability
Verificatio
n value
Minimum
load
Cable
length
Net weight
approx.
3 Basic instructions
3.1 Documentation
These installation instruction contain all data necessary for placing and
commissioning the weighing bridges KERN KFP V40.
In combination with a display unit, described below as weighing system, for operation
configuration, please refer to the operating instructions of the display unit.
3.2 Proper use
The balance you purchased is intended to determine the weighing value of material
to be weighed. It is intended to be used as a “non-automatic balance”, i.e. the
material to be weighed is manually and carefully placed in the centre of the weighing
plate.. As soon as a stable weighing value is reached the weighing value can be
read.
3.3 Improper Use
Do not leave permanent load on the weighing bridge. This may damage the
measuring system.
Impacts and overloading exceeding the stated maximum load (max) of the weighing
system, minus a possibly existing tare load, must be strictly avoided. The weighing
system could be damaged.
Never operate in an explosive environment. The serial version is not explosion
protected.
Changes to the weighing system's design are not permitted. This may lead to
incorrect weighing results, safety-related faults and destruction of the balance.
The weighing system unit may only be operated in accordance with the described
default s ettings. Other areas of use must be released by KERN in writing.
3 KFP V40-IA-e-1412
3.4 Warranty
Warranty claims shall be voided in case
• Our conditions in the operation manual are ignored
• The appliance is used outside the described uses
• Structural changes of the device
• Mechanical damage and damage caused by media, liquids
• Natural wear and tear
• The appliance is improperly set up or incorrectly electrically connected
• Overload of the measuring system
3.5 Monitoring of Test Resources
In the framework of quality assurance the measuring-related properties of the
weighing system and, if applicable, the testing weight, must be checked regularly.
The responsible user must define a suitable interval as well as type and scope of this
test. Information is available on KERN’s home page (www.kern-sohn.com with regard
to the monitoring of weighing system test substances and the test weights required
for this. In KERN's accredited DKD calibration laboratory test weights and weighing
systems may be calibrated (return to the national standard) fast and at moderate
cost.
KFP V40-IA-e-1412 4
4 Basic Safety Precautions
Carefully read this operation manual before setup and commissioning,
even if you are already familiar with KERN balances.
4.1 Pay attention to the instructions in the Operation Manual
4.2 Personnel training
The appliance may only be operated and maintained by trained personnel.
The installation of a display unit must only be carried out by a well acquainted
specialist with the workings of weighing balances.
5 T ransport and storage
5.1 Testing upon acceptance
When receiving the appliance, please check packaging immediately, and the
appliance itself when unpacking for possible visible damage.
5.2 Packaging / return transport
Keep all parts of the original packaging for a possibly
required return.
Only use original packaging for returning.
Prior to dispatch disconnect all cables and remove
loose/mobile parts.
Reattach possibly supplied transport securing devices.
Secure all parts agains t shi fting and damage.
5 KFP V40-IA-e-1412
6 Unpacking, Setup and Commi s si oning
6.1 Installation Site, Location of Use
The weighing bridges are designed in a way that reliable weighing results are
achieved in common conditions of use.
You will work accurately and fast, if you select the right location for your weighing
system.
On the installation site observe the following:
• Place the weighing bridge on a firm, level surface.
The floor at the installation site must be able to carry safely the weight of the
maximally loaded weighing bridge at the resting points. At the same time it
should be sufficiently stable, that no vibrations may occur during weighing
work.
• In the installation site possibly no vibrations, e.g. by neighbouring machines
should occur.
• Do not use the weighing bridge in an explosive environment.
• Avoid extreme heat as well as temperature fluctuation caused by installing
next to a radiator or in the direct sunlight.
• Protect the weighing bridge against direct draughts e.g. due to open windows
and doors.
• Use weighing bridge only in dry environment, protect it against high humidity,
vapours and dust.
• Do not expose the device to extreme dampness for longer periods of time.
Non-permitted condensation (co ndensation of air humidity on the appliance)
may occur if a cold appliance is taken to a considerably warmer environment.
In this case, acclimatize the disconnected appliance for ca. 2 hours at room
temperature.
• Avoid jarring during weighing.
• Avoid static charge of goods to be weighed or weighing container.
• Keep away chemicals (such as liquids or gasses), which could attack and
damage the balance inside or from outside.
• Keep IP protection of the device.
• Major display deviations (incorrect weighing results) may be experienced
should electromagnetic fields (e.g. due to mobile phones or radio equipment),
static electricity accumulations or instable power supply occur. Change
location or remove source of interference.
KFP V40-IA-e-1412 6
6.2 Unpacking, Scope of delivery
+
Danger for the back!
+ Do not step under the suspended load, risk of injury!
Ensure that the contents of package is complete.
(optional) must be available:
(A) 2 access ramps
or
(B ) 1 access ramp and 1 foot plate set
or
(C) 2 foot plate sets
The weighing bridge is relatively heavy. Always use a suitable
CAUTION
lifting device to lift it out of the packaging or to transport it to
the required installation site.
Scope of delivery:
• Weighing bridge with assembled connection cable
• 4 weighing cell feet
• Operating instructions
According to the version, for assembling the weighing bridge the following accessories
7 KFP V40-IA-e-1412
6.3 Assembly, levelling
+ The weighing bridge must be aligned with the help of a
In case of verified weighing systems the weighing bridge must be
Accurate weighing results require a weighing bridge with perfect horizontal
alignment. During initial installation and after each change of work area it is
necessary to level the weighing bridge.
Placing the weighing bridge:
1. Prior to the final placing, install the four weighing cell feet.
2. Place the weighing bridge equally on the installation site and check if it is in an
even position and all four feet are in contact with the floor. Level the weighing
bridge by turning the weighing cell feet. For this purpose use an external levelling
appliance, e.g. a water level.
3. Ensure that the connecting cable is not damaged or squeezed during lifting and
placing.
Placing the weighing bridge with access ramps and/or foot plates:
Prior to step 2 (see Placing the weighing bridge) mark and fix the position of the
ramps or the foot plates.
Place the weighing bridge equally on the installation site. In the area of the
installation site of the weighing bridge, especially in the area of the weighing cell
feet, observe the evenness and the horizontal alignment of the foot pl ates and
ramps. Compensate minor height differences with the help of the adjustable
weighing cell feet. For this purpose use an external levelling appliance, e.g. a
water level.
Ensure that the connecting cable is not damaged or squeezed during lifting and
placing.
water level.
+ All setting feet must rest equally.
Verified weighing systems:
firmly fixed on the floor. This is essential for the reproducibility of
the measuring results. Optionally using two access ramps or two
pairs of foot plates or a combination of both.
KFP V40-IA-e-1412 8
6.4 Connecting a display unit
Attention
Put the connecting cable to the display unit in a manner that it is protected against
damage.
Description of the connection cable:
terminal Color State
EXC+ [IN+] red voltage +
SIG + [OUT+] green signal +
SIG -[OUT-] white signal EXC -[IN- ] black voltage -
7 Operation
Information about
• Network connection (power is supplied via the connecting cable of the
display unit)
• Initial Commissioning
• Connection of peripheral devices
• Adjustment, linear ization and verification (only the complete balance is
verifiable, i.e. weighing bridge in conjunction with a suitable display unit)
and the correct operation you will in the operating instructions included in the scope
of delivery of the display unit.
So a continuous optimal performance is guaranteed:
• Avoid falling load, shock loads and impac ts from the side!
• For weighing operation, all objects must be placed
centrically of the weighing bridge and may not hang over
the edges or the ramps.
• Check adjustment at regular intervals.
9 KFP V40-IA-e-1412
7.1 Operation limits
• The weighing bridges are designed extremely robust. However the load limits
according to the following table should not be exceeded!
• Depending on the type of load receptacle, the static carrying capacity, i.e. the
maximum admissible load is :
Weighing ranges 1500kg
With centrical load
With side stress 3000kg
With one-sided loading 1500kg
With single-wheel load 800kg
7.2 Operation with access ramp s
• The load plate of the weighing bridge is an active weighing element, the access
ramps are passive, i.e. during the weighing process all wheels of the conveying
vehicles must rest on the load plate.
4500kg
• The air gap between the load plate and the access ramps must be free. Especially
for weighing of grainy or small-piece weighing goods, the gap should be controlled
regularly and kept clear.
7.3 Load/unload weighing system
• Place the load on the scales using a lifting truck, a crane or a forklift truck. Ensure
that the load is not swinging when it is placed onto the scales.
• Lift the load first vertically at least 10 cm above the scales before it is removed or
newly placed.
KFP V40-IA-e-1412 10
8 Service, maintenance, disposal
Before any maintenance, cleaning and repair work disconnect the
appliance from the oper ati ng v ol tag e.
8.1 Daily check
Ensure that all four feet are in contact with the floor.
Ensure that the connecting cable to the display unit and the network connection
cable of the display unit are not damaged.
Ensure that the balance is free from dirt, especially under the edges of the
balance.
8.2 Cleaning
Remove regularly corrosive substances.
Keep IP protection.
Protect weighing cells against splash water.
When using optional ramps or foot plates, keep clean the air gap at the edge of
the weighing bridge.
Wipe the surfaces with a damp cloth.
Only use common household cleaners.
Do not use water jet or high-pressure cleaner.
8.3 Service, maintenance
The appliance may only be opened by trained service technicians who are
authorized by KERN.
Ensure that the weighing system is regularly calibrated, see chap. 3.5 Testing
instruments control.
8.4 Disposal
Disposal of packaging and appliance must be carried out by operator according
to valid national or regional law of the location where the appliance is used.
11 KFP V40-IA-e-1412
8.5 Instant help
In case of an error in the program process, briefly turn off the balance and disconnect
from power supply. The weighing process must then be restarted from the beginning.
Help:
Fault Possible cause
The displayed weight is permanently
changing
The weighing result is obviously
incorrect
Should other error messages occur, switch balance off and then on again. If the error
message remains inform manufacturer.
• Draught/air movement
• Floor vibrations
• Weighing plate has contact with other
objects.
• Electromagnetic fi elds / stati c c harging
(choose different location/switch off
interfering device if possible)
• No zero display with unloaded balance
• Adjustment is no longer correct.
• Great fluctuations in temperature.
• Weighing bridge on an uneven surface.
• Electromagnetic fi elds / stati c c harging
(choose different location/switch off
interfering device if possible)
KFP V40-IA-e-1412 12
9 Service documentation
• This chapter is only intended for a balance specialist!
-1
-0,75
-0,5
-0,25
0
0,25
0,5
0,75
1
0 500 1000 1500
[kg]
[g]
1500 kg
• The weighing bridges are carried out in DMS sensor technology, at
9.1 Overview, setting regulation, tolerances
every corner a DMS weighing cell is installed.
• The analogue-digital transformation occurs in the display unit. Also all
the balance and country-specific data are stored there.
Testing and setting regulations:
Capacity 1500 kg
Readability 500 g
Min 10 kg
Max 1500 kg
1/3 corner load 500 kg
Tolerance 500 g
Verification data and tolerances as per OIML
13 KFP V40-IA-e-1412
9.2 Check and adjustment of the corner load
adjust this corner
even after several adjustment sequences.
Check of the corner load:
• Place the test weights in the centre of the load plate
and tare.
• The balance displays -0-.
• Place the test weights successively on all four
corners.
• Now the deviations are displayed with sign, write
down the values. If there are deviations out of the
tolerances (see chap. 9.1), an adjustment will be
necessary.
Adjustment of corner load:
Preparation:
• For a better control of the modifications which occur
during adjustment, select in the configuration menu
the highest readability for control purposes.
• Open connection box
Adjustment rule:
The corner (weighing cell) with the biggest negative
deviation must be set to zero. Do not re-
Adjustment on the analogue print
KFP V40-IA-e-1412 14
1.
2.
3.
4.
Adjustment of weighing cell J2 takes place at the potentiometer VR1.
Increase the value turning to the right, reduce the value turning to the left.
Adjustment of weighing cell J3 takes place at the potentiometer VR2.
Adjustment of weighing cell J4 takes place at the potentiometer VR3.
Adjustment of weighing cell J5 takes place at the potentiometer VR4.
15 KFP V40-IA-e-1412
KFP 600V40SM
90
NA
N/A
500kg
KFP 1500V40SM
90
NA
N/A
1000kg
KFP 1500V40M
120
NA
N/A
1000kg
KFP 3000V40M
120
NA
N/A
1500kg
Loadcell
TC
Max
E
max
E
min
Y
n
Dead-load
T
min
T
max
Cable-
Type
No.
Preload
-1
-4 -3
(kg)
-6
length
(kg)
(kg)
(g)
(m)
KFP
600V40SM
KFP
1500V40SM
KFP
1500V40M
KFP
3000V40M
10 Prel oad, Deadload and Overload settings
Kern model Deadload** (kg)
**= already applied preload
Platform type Platform dimension
(mm)
1000x1000x80
CZL-8C-
0.5T
1000x1000x80 SQB TC6911 C3 750 1000 0 10000 3000 750 -10 40 5
1500x1250x90 SQB TC6911 C3 750 1000 0 10000 3000 750 -10 40 5
1500x1250x80 SQB TC6911 C3 1500 1500 0 10000 3000 1500 -10 40 5
Center Overload
Protection circa (kg)
Class
Corner Overload
Protection circa (kg)
Loadcell
Capacity (kg)
-5
D09-03.19 C3 300 500 0 10000 3000 300 -10 40 5
16 KFP V40-IA-e-1412
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