8200-M535-O1 Rev B 225-DS
1
225-DS
225 Dual Scale Input Card
Installation Manual
8200-M535-O1 Rev B
203 E. Daugherty, Webb City, MO 64870 USA
Printed in USA
10/09
Ph: 417-673-4631 Fax: 417-673-2153
www.cardinalscale.com
8200-M535-O1 Rev B 225-DS
2
8200-M535-O1 Rev B 225-DS
I
TABLE OF CONTENTS
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page 1
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page 2
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page 3
Load Cell Cable Connection with RFI Suppression . . . . . . . . . . . . . . . . . . . . . . .
Page 6
Load Cell Cable Connection without RFI Suppression . . . . . . . . . . . . . . . . . . . .
Page 9
Load Cell Cable Connections with Over 30 Feet of Cable . . . . . . . . . . . . . . . . . .
Page 9
Sense Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page 10
Dead Load Boost Jumper (DLB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page 10
Gnd to Chassis Jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page 10
INDICATOR SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page 11
CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page 13
MULTI-SCALE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page 14
FCC COMPLIANCE STATEMENT
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.
PRECAUTIONS
Before beginning installation of this option card, read this manual and pay
special attention to all "WARNING" symbols:
IMPORTANT
ELECTRICAL
WARNING
STATIC
SENSITVE
I
II
8200-M535-O1 Rev B 225-DS
1
INTRODUCTION
Thank you for purchasing the Cardinal 225-DS Dual Scale Input Card. This option card for the
Cardinal 225 Weight Indicating Instrument was built with quality and reliability and has been
designed to meet the requirements of simultaneous weight data display from a total of two or
three scales to a single 225.
Analog and programmable digital filtering is used for stable weight readings. The customer
can easily configure the 225 for two or three scales, with or without totalizing, with the use of
the 225-DS without the need for complicated programming devices.
The 225-DS card resides in the 225 main enclosure and has a 16 pin dual in-line Internal Bus
connector to provide an easy connection to the 225 internal hardware. The 225-DS card has
two 7 position spring cage clamp connectors for connecting to strain gage transducers.
The purpose of this manual is to guide you through the installation and setup of the 225-DS
Dual Scale Input Card (if the 225 indicator was not purchased with the option installed).
Please read it thoroughly before attempting to install it in your indicator and keep it handy for
future reference.
225-DS (Dual Scale Input Card)
8200-M535-O1 Rev B 225-DS
2
SPECIFICATIONS
Number of Scale Inputs:
Two
Load Cells:
Resistive strain gage load cells.
Up to 16ea, 350 load cells total / 24ea 800 load cells total
External Connections:
Dual 7 position spring cage clamp (24 to 16ga wire)
Temperature Range:
14° to 104° F (-10° to +40° C)
Displayed Resolution:
100 to 10,000 divisions (commercial)
240,000 divisions (maximum, non-commercial)
Internal Resolution:
16, 777, 216 divisions
Sample Rate:
selectable 1 to 100 samples per second
Auto Zero Range:
0.5 divisions or 1 through 9 divisions
Excitation Voltage:
12.0VDC
Signal Input Range:
1.0 mV min. to 40 mV max. (with dead load boost)
Load Cell Cable Length:
1500 feet maximum. Consult factory for other requirements
30 feet maximum without sense lines
Sensitivity:
NON-COMMERCIAL
NTEP
CANADA
OIML
0.15uV/e
0.3uV/e (Class III/IIIL)
0.3uV/e (Class III/IIIHD)
0.7uV/e (Class III)
Scale Divisions:
NON-COMMERCIAL
NTEP
CANADA
OIML
100 to 240,000
100 to 10,000 (Class III/IIIL)
100 to 10,000 (Class III/IIIHD)
100 to 10,000 (Class III)
Division Value:
Programmable
Weighing Units:
Programmable
8200-M535-O1 Rev B 225-DS
3
ATTENTION!
OBSERVE PRECAUTIONS FOR HANDLING
ELECTROSTATIC SENSITIVE DEVICES
INSTALLATION
1. Press the ON/OFF key to turn the 225 OFF.
2. Remove the AC power cord and disconnect any external load cell power supplies.
3. Referring to Figure No. 1, remove the 14 acorn nuts securing the rear panel assembly to
the main housing.
4. Lift the back panel from the main housing, taking care not to stretch the cable and wires
between the panel and main housing. Lay the back panel on the workbench next to the
indicator.
IMPORTANT! You may need to loosen the gland connectors for the scale and/or I/O
cables to allow enough slack in the cable and wires to avoid stretching them.
5. Referring to Figure No. 2, on the 225 main board, locate the 4 threaded mounting spacers
and connector P2 on the main board.
Figure No. 1
I/O
(Serial,
Isolated
Inputs or
Outputs)
Fiber
Optic
Cable
I/O
(Serial,
Isolated
Inputs or
Outputs)
AC Power
90-264 VAC
0.4 Amp Max.
Current Scale
Additional
Scale
Additional
Scale
8200-M535-O1 Rev B 225-DS
4
INSTALLATION, CONT.
Figure No. 2
6. Next, referring to Figures No. 2 and 3,
locate the 6-32 threaded stud in the
lower right corner of the enclosure
securing the main board. NOTE! This is
where the ground wire from the 225-DS
will be connected.
7. To attach the ground wire, remove the
6-32 nut and washer and then place the
ring terminal from the 225-DS ground
wire over the 6-32 threaded stud.
Reinstall the washer and 6-32 nut and
tighten. Refer to Figure No. 3.
NOTE! Position the ring terminal with
the wire extending away from the main
board as shown to prevent shorting.
8. To install the Dual Scale Input Card,
carefully align the dual row of pins on
the top of the 225-DS card (on the trace
side of the card) with connector P2 on
the main board and apply even
downward pressure to the edge of the
225-DS. See Figure No. 4.
Threaded
Mounting
Spacers
Connector
P2
6-32
Threaded
Stud
Figure No. 3
6-32
Threaded
Stud
225-DS
Ground
Wire
Figure No. 4
Align pins
with holes
in P2
8200-M535-O1 Rev B 225-DS
5
INSTALLATION, CONT.
9. Align the holes in the 225-DS with the threaded mounting spacers on the main board and
using the four lock washers and screws supplied with the 225-DS, secure the card to the
main board. Refer to Figure No. 5.
Figure No. 5
Secure with 4
screws and
lock washers
8200-M535-O1 Rev B 225-DS
6
INSTALLATION, CONT.
Load Cell Cable Connection with RFI Suppression
To eliminate RFI, the additional load cell cables should be routed through the special metallic
gland connectors included with the 225-DS and the shield wire from the load cell cables must
be connected to these gland connectors for grounding.
1. Referring to Figure No. 1, remove the plastic gland connectors identified for the additional
scales.
2. Next, install the metal gland connectors for Scale 2 and Scale 3 as shown in Figure No. 6.
3. Loosen and remove the metal gland connector
nut and remove the plastic insert.
4. Referring to Figure No. 7, route the single cable
from the load cell or load cell junction box
through the nut and plastic insert and into the
enclosure.
5. With the load cell cable routed into the
enclosure, refer to Figure No. 8 and then remove
approximately 5 to 6 inches of the cable outer
insulating jacket exposing the internal wires.
6. Next, cut the shield wire so that it extends past the outer jacket approximately 3/4 inch.
7. Now, remove 1/4 inch of insulation from the end of each of the four wires (without sense
leads) or six wires with sense leads.
Figure No. 7
Scale 2
Scale 1
Scale 3
Figure No. 6
8200-M535-O1 Rev B 225-DS
7
INSTALLATION, CONT.
8. Referring to the table below (or on the circuit board) for terminal connections, connect each
wire to terminal block P2 or P3. Refer to Figure No. 12 for terminal block location.
Load Cell Wiring Table – P2 or P3
Board Label
Function
Board Label
Function
+EXC
+ EXCITATION
-SIG
- SIGNAL
+SEN
+ SENSE
-SEN
- SENSE
+SIG
+ SIGNAL
-EXC
- EXCITATION
SHLD
SHIELD (Not used, the shield wire is connected to metal gland).
9. To terminate a wire, use a small flat blade screwdriver and press down on the release bar
for the terminal. Insert the wire into the opening and remove the screwdriver, allowing the
release bar to return to its original position, locking the wire in place. See Figure No. 9.
10. Repeat the procedure until all wires are in place.
11. After all terminations have been made, remove the excess cable from the enclosure.
3/4 inch
Figure No. 8
5 to 6 inches
1/4 inch
Insert
Wire
Press
Down
Figure No. 9
8200-M535-O1 Rev B 225-DS
8
INSTALLATION, CONT.
12. Referring to Figure No. 10, fold the shield wire back over the plastic insert and then insert
the plastic insert (with the shield wire) into the gland connector.
Figure No. 10
13. The shield wire is secured when tightening the gland connector nut. See Figure No.11.
14. Do not over-tighten the connector but make certain it is snug.
Figure No. 11
Shield
Wire
8200-M535-O1 Rev B 225-DS
9
INSTALLATION, CONT.
Load Cell Cable Connection UwithoutU RFI Suppression
The following instructions describe the load cell connection using the existing plastic gland
connectors. Note that using the plastic gland connectors does not provide RFI Suppression.
1. Referring to Figure No. 1, choose a gland connector for the load cell cable and loosen it.
2. Slip the single cable from the load cell or load cell junction box through the gland connector
and into the enclosure.
3. Referring to Figure No. 7, remove 3 inches (not 5 to 6 inches) of the outer insulation jacket
4. Next, remove 1/4 inch of insulation from each of the four wires and shield (without sense
leads) or six wires and shield (with sense leads).
5. Referring to the table below (or on the circuit board) for terminal connections, connect each
of the wires to terminal block P2 or P3. Refer to Figure No. 12 for terminal block location.
Load Cell Wiring Table – P2 or P3
Board Label
Function
Board Label
Function
+EXC
+ EXCITATION
-SIG
- SIGNAL
+SEN
+ SENSE
-SEN
- SENSE
+SIG
+ SIGNAL
-EXC
- EXCITATION
SHLD
SHIELD (Connect the load cell cable shield wire here).
6. To terminate a wire, use a small flat blade screwdriver and press down on the release bar
for the terminal. Insert the wire into the terminal opening. Remove the screwdriver,
allowing the release bar to return to its original position, locking the wire in place. See
Figure No. 9.
7. Repeat the procedure until all wires are in place.
Load Cell Connections with Over 30 Feet of Cable
On installations with over 30 feet of cable between the 225-DS and the load cells, sense wires
should be used. The sense wires must be connected between the +SENS, -SENS terminals
on the 225-DS (Dual Scale Input Card) 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). Refer to Figure No. 12 for the location of these jumpers.
8200-M535-O1 Rev B 225-DS
10
INSTALLATION, CONT.
Figure No. 12
Sense Jumpers (+SEN, -SEN)
If the sense leads are NOT used, you must install plug-in jumpers at +SEN and -SEN adjacent
to the terminal block. These jumpers attach the sense leads to the excitation leads. If sense
leads ARE used (as in motor truck scales), these plug-in jumpers should be positioned on one
plug in pin only or removed and stored for later use.
SCALE 2
To use the sense wires for Scale 2, the +SENS (J5) and -SENS (J6) jumpers on the
225-DS must be open (on one pin only) or removed.
SCALE 3
To use the sense wires for Scale 3, the +SENS (J3) and -SENS (J4) jumpers on the
225-DS must be open (on one pin only) or removed.
Dead Load Boost Jumper (DLB)
For very low dead loads (less than 10% of the combined load cell capacity) connect the dead
load boost (DLB) jumper on the printed circuit board. Refer to Figure No. 12. For Scale 2, the
DLB jumper is J2. For Scale 3, the DLB jumper is J1.
GND to Chassis Jumper
When installed, this jumper connects the analog circuit ground to the indicator chassis ground.
Refer to Figure No. 12. For Scale 2, the GND to Chassis jumper is to the right of P2 (near the
ground wire). For Scale 3, the GND to Chassis jumper is to the left of P3.
Scale 2 – P2
Scale 3
GND to
Chassis
Jumper
Scale 2
GND to
Chassis
Jumper
P3 – Scale 3
J3, +SEN
for Scale 3
J1, DLB
for Scale 3
J4, – SEN
for Scale 3
J5, + SEN
for Scale 2
J2, DLB
for Scale 2
J6, – SEN
for Scale 2
8200-M535-O1 Rev B 225-DS
11
INDICATOR SETUP
For additional information on setup and calibration, refer to the 225 WEIGHT
INDICATOR Installation and Technical Manual, 8200-M538-O1.
With the indicator ON, press the SHIFT key and then press the Navigation ENTER key (red
square key in center of the Navigation arrows). The display will change to show the
SETUP/REVIEW MENU.
SETUP/REVIEW MENU
1.ENTER CALIBRATION AND SETUP
2.VIEW AUDIT TRAIL COUNTERS
3.CALIBRATE SCALE 1
9.DEL CUSTOM TICKET
10.PRINT SETUP
Enter Selection: 1 ^ EXIT
SETUP MENU #1
With the SETUP/REVIEW MENU displayed, press the 1 key and then the ENTER key. The
display will change to show SETUP MENU #1.
SETUP MENU #1
1. USA=XXX
6. CLR TARE=XXX
2. NSC=XXX
7. CLEAR ID=XXX
3. LFT=XXX
8. NO OF SCALES=X
4. OIML=XXX
9. TOTALIZE=XXX
5. TIME=XX
10. MODE OF OP=0 NORM
Enter Selection: 0 ` NEXT ^ EXIT
8. NO OF SCALES=X (NUMBER OF SCALES)
With SETUP MENU #1 displayed, the current setting for the NO OF SCALES= parameter
will be shown. Note that X is the current value.
Press the 8 key, the ENTER key and then using the numeric keys, enter the number of
scales and then press the ENTER key to save the new setting and return to SETUP
MENU #1. Allowable values are: 1, 2 or 3. Note that the 225 will check for the 225-DS
card. If the card is not found, it will display an error message and default back to 1 scale.
8200-M535-O1 Rev B 225-DS
12
INDICATOR SETUP, CONT.
9. TOTALIZE=XXX (SCALE TOTALIZER)
With the 225-DS (Dual Scale) Card installed and the number of scales set for 2 or 3, the 225
can sum the weights of two or more scales and make the total available to be displayed.
The totalizer can be referenced as if it were another scale. NOTE! The totalizer's scale
number will always be 4 regardless of the actual number of scales attached to the indicator.
With SETUP MENU #1 displayed the current setting for the TOTALIZE= parameter
will be shown. Note that XXX is the current value. If the setting displayed is acceptable,
proceed to the next setup parameter.
Otherwise, press the 9 key, the ENTER key, YES or NO (on the soft keys) and then the
ENTER key to save the new setting and return to SETUP MENU #1.
10. MODE OF OP=X XXXX (MODE OF OPERATION)
IMPORTANT! The Mode Of Op is limited to options 0. NORM (Normal Indicator),
1. IDS (ID Storage) or 3. Preset Weight Comp (Preset Weight Comp).
Refer to the 225 Weight indicator Installation and Technical Manual, 8200-M538-O1, for
information and instructions on Mode of Operation.
SETUP MENU #2
With SETUP MENU #1 displayed, press NEXT (Navigation Keys Down Arrow) to
proceed to SETUP MENU #2.
SETUP MENU #2
1. SERIAL 6. SETUP SCALE 2
2. DIO 7. CALIBRATE 2
3. PRINT TABS 8. SETUP SCALE 3
4. SETUP SCALE 1 9. CALIBRATE 3
5. CALIBRATE 1 10. TOT CAP=XXXXXXX
Enter Selection: 0 ` NEXT ^ PREV
Parameters 8 and 9 will only be shown if 3 has been entered for the number of scales.
IMPORTANT! If YES was selected for the TOTALIZE parameter (refer to SETUP
MENU #1), then the following parameter will be shown on SETUP MENU #2.
8200-M535-O1 Rev B 225-DS
13
INDICATOR SETUP, CONT.
10. TOT CAP=XXXXXXX (TOTAL SCALE CAPACITY)
With SETUP MENU #2 displayed the current setting for the TOT CAP= parameter will be
shown. Note that XXXXXXX is the current value for the scale capacity. If the setting
displayed is acceptable, proceed to the next setup parameter.
Otherwise, press the 1 and 0 keys, the ENTER key and then using the numeric keys, enter
the value for the total scale capacity and then press the ENTER key to save the new setting
and return to SETUP MENU #2. Allowable values are 1 through 9,999,999. Note that the
total capacity can not exceed 7 digits or 9,999,999.
With the SETUP MENU #2 displayed, proceed to setup scale X for the setup of each scale.
IMPORTANT! All scales to be included in the totalizer must have identical settings
for: BASE UNITS, CNVT UNITS, INTERVAL, DDP, SAMPLES, STABLE
and STBL CNT. If these are not the same, an error message will be displayed.
CALIBRATION
For additional information on setup and calibration, refer to the 225 WEIGHT
INDICATOR Installation and Technical Manual, 8200-M538-O1.
With the SETUP/REVIEW MENU displayed, press the key corresponding to the scale to be
calibrated and then press the ENTER key. The display will change to show the SCALE X
CALIBRATION MENU, where X is the scale to be calibrated.
SETUP/REVIEW MENU
1.ENTER CALIBRATION AND SETUP
2.VIEW AUDIT TRAIL COUNTERS
3.CALIBRATE SCALE 1
4.CALIBRATE SCALE 2 9.DEL CUSTOM TICKET
5.CALIBRATE SCALE 3 10.PRINT SETUP
Enter Selection: 1 ^ EXIT
NOTE! Parameter 5 will only be shown if a 3 has been entered for the number of scales.
8200-M535-O1 Rev B 225-DS
14
MULTI-SCALE OPERATION
Operation with TOTALIZE=NO
12000
1
lb
G
6000
2
lb
G
11999
3
lb
G
ID=
ID
The Navigation (arrow) keys are used to select the “active” scale when NO has been selected
for TOTALIZE parameter in SETUP MENU #1.
Pressing any of the Navigation Keys, Down Arrow, UP Arrow, Left Arrow or Right
Arrow will switch to the next scale, highlight the weight display for that scale and then that
scale will become the active scale.
Zero the Scale with TOTALIZE=NO
Active Scale
Press the ZERO key. Only the active scale will be zeroed.
Zero Scale 1
Press the 1 key and then the ZERO key.
Zero Scale 2
Press the 2 key and then the ZERO key.
Zero Scale 3
Press the 3 key and then the ZERO key.
Printing with TOTALIZE=NO
The weight data from the “active” scale will be printed when the PRINT key is pressed.
Example printout
(Exact printout depends on the settings in PRINT TABBING
MENU #1 and #2).
10:10 12/09/2008
12000 lb G (Scale 1)
10:10 12/09/2008
6000 lb G (Scale 2)
10:10 12/09/2008
11999 lb G (Scale 3)
8200-M535-O1 Rev B 225-DS
15
MULTI-SCALE OPERATION, CONT.
Operation with TOTALIZE=YES
12000
1
lb
G
12000
2
lb
G
2000
3
lb
G
26000
TOT
lb
G
ID=
ID
Zero the Scale with TOTALIZE=YES
All Scales
Press the ZERO key. ALL scales will be zeroed at the same time.
Only Scale 1
Press the 1 key and then the ZERO key.
Only Scale 2
Press the 2 key and then the ZERO key.
Only Scale 3
Press the 3 key and then the ZERO key.
IMPORTANT! Note that the SCALE TOTALIZER cannot be manually zeroed. It will only
show a zero weight when all the scales are at zero.
Printing with TOTALIZE=YES
The weight data from the TOTAL scale will be printed when the PRINT key is pressed.
Example printout
(Exact printout depends on the settings in PRINT TABBING
MENU #1 and #2).
10:13 12/09/2008
26000 lb G (Total)
8200-M535-O1 Rev B 225-DS
16
8200-M535-O1 Rev B 225-DS
17
/