E-Z CAL (Serial) Manual Station and J-Box

Installation & Operation Guide

Firmware V1.01F & Later
Last Updated 12/27/16

www.commandalkon.com
 © Command Alkon Incorporated 2003-2017. All rights reserved.
The contents of this document are for informational purposes only and are subject to
change without notice. Command Alkon Incorporated ("CAI") may, without notice, modify
its products in a way that affects the information contained in this publication.
CAI HEREBY DISCLAIMS ALL REPRESENTATIONS OR WARRANTIES EITHER EXPRESSED
OR IMPLIED, INCLUDING WITHOUT LIMITATION ANY IMPLIED WARRANTY OF
MERCHANTABILITY, TITLE, NON-INFRINGEMENT, OR FITNESS FOR A PARTICULAR
PURPOSE. In no event will CAI be liable for any direct, indirect, or consequential damages
arising out of the use of, inability to use, or implementation of any information contained
in this publication, even if CAI has been advised of the possibility of such damages, or for
any claim by any other party.
The information contained herein is subject to change without notice and may contain
inaccuracies or errors. CAI assumes no responsibility for any errors that may appear in
this document. This publication is intended only for the direct benefit of authorized users
of CAI products. This publication may not be used for any purposes other than those for
which it is provided, and it is subject to the terms of the applicable software license or
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property of CAI, and, except for rights granted by written consent, may not be disclosed,
disseminated, or duplicated in whole or in part.

Command Alkon Incorporated

1800 International Park Drive, Suite 400
Birmingham, AL 35243-4232
1 (205) 879-3282
www.commandalkon.com
Main Customer Support Phone Number: 1 (800) 624-1872

COMMANDseries (and the names of its components, such as COMMANDconcrete and

COMMANDnetwork), Spectrum, Eagle, and COMMANDbatch are registered trademarks of
Command Alkon Incorporated. All rights reserved.
Microsoft and Windows are trademarks of Microsoft Corporation. Other names may be
trademarks of their respective owners.

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 Contents

Contents ........................................................................................ 3

Introduction .................................................................................. 5
Purpose ................................................................................................ 5
Audience ............................................................................................... 5
Revision Summary ................................................................................. 5

E-Z CAL (Serial-Only) Manual Station & J-Box ................................ 8

Overview of the E-Z CAL Manual Station .................................................. 10
Regulatory Compliance ......................................................................... 11
Offer of Source for GPL Software ............................................................ 12
E-Z CAL Major Hardware Components ..................................................... 13
Manual Station .................................................................................. 13
J-Box ............................................................................................... 16
Installation and Wiring Guidelines (E-Z CAL and J-Box) ............................. 20
Water and Moisture ............................................................................ 21
Mounting .......................................................................................... 21
Ventilation ........................................................................................ 21
Manual Station Power Source and Supply .............................................. 22
Manual Station - Inside View ............................................................... 24
Manual Station CPU with RS-232 Board ................................................ 25
J-Box - Inside View ............................................................................ 26
J-Box Supply Wiring ........................................................................... 27
J-Box Power Source 120VAC ............................................................... 27
J-Box Power Source 240VAC ............................................................... 27
J-Box Voltage Jumper Settings ............................................................ 27
IO Cable Connections ......................................................................... 29
120 Volt Power Connections ................................................................ 30
240 Volt Power Connections ................................................................ 31
E-Z CAL General Operation .................................................................... 32
Powering On and Off .......................................................................... 32
Operating Plant Equipment ................................................................. 33
E-Z CAL Displays ............................................................................... 34
Clearing Bad Cell and Bad Module Messages .......................................... 35
Testing the MPI Module in the E-Z CAL Manual Station ............................ 36
If Communication to the Batching PC is Lost ......................................... 38
Setup and Calibration Using the E-Z CAL ................................................. 39
Operating Modes ............................................................................... 39
Setup Buttons ................................................................................... 40
Calibration Enable Switch ................................................................... 41
Setup Procedures ................................................................................. 45

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 Do This First ..................................................................................... 46
Setup Scale ...................................................................................... 47
Setup Counter ................................................................................... 50
Setup Moisture Probe ......................................................................... 52
Setup Generic Analog Input ................................................................ 53
Calibration Procedures .......................................................................... 55
Do This First ..................................................................................... 56
Scale Calibration on the E-Z CAL .......................................................... 57
Moisture Probe Calibration on the E-Z CAL ............................................ 60
Generic Analog Input Calibration on the E-Z CAL .................................... 61
View Configuration Settings - Info Mode .................................................. 62
Technical Specifications ......................................................................... 64
Manual Station .................................................................................. 64
Scale Interface .................................................................................. 67
Meter Counter ................................................................................... 69
Moisture Probe Interface .................................................................... 69
J-Box ............................................................................................... 70
Input Modules ................................................................................... 72
Output Modules ................................................................................. 74
Load Cell Color Codes ........................................................................ 76
Mean Time Before Failure - Manual Station ............................................ 77
Mean Time Before Failure - J-Box ......................................................... 77
E-Z CAL Parts Replacement Guidelines .................................................... 78
Manual Station .................................................................................. 78
J-Box Fuses ...................................................................................... 79
Spare Parts List ................................................................................. 80

Index ........................................................................................... 81

4 12/27/16
 Introduction

Topics in This Section

Purpose
Audience
Revision Summary

Purpose
This guide provides instructions for installing Command Alkon’s E-Z CAL
Manual Station and I/O box. It also provides procedures for configuring and
calibrating equipment (scales, counters, moisture probes, and generic
counters) that use displays on the manual station.

Audience
This guide is intended to be used by Command Alkon installation and service
personnel, as well as plant personnel authorized to configure batching
software.

Revision Summary
Firmware
Date Version Revision
Nov. 1, 2004 1.01B+ Introduction section added, along with this Revision
Summary.
Removed note about a Command Alkon
representative inspecting the J-Box once a month.
Nov. 16, 2004 1.01B+ Corrected version number on title page. Was “Version
1.02”. Now reads “Firmware Version 1.01B+”.
Apr. 5, 2005 1.01B+ Added statement about the E-Z CAL supporting scale
capacities no larger than 60,000 lbs.
Dec. 2, 2005 1.01B+ Added scale, meter, and moisture probe specifications
that were inadvertently left out when the manual was
reformatted.
Jul. 17, 2006 1.01B+ Added block power wiring diagrams for 120V and
240V systems.
Aug. 8, 2006 1.01B+ • Corrected first sentence in Purpose section.
• Reviewed proofs for print vendor.

12/27/16 5
 Oct. 13, 2006 1.01B+ • Added new power supply photos.
• Added corrected block power wiring diagrams for
120V and 240V systems.
• Updated photos to show newer Manual Station
and J-Box.
• Added regulatory conformance statements for
NTEP and CE (European Union).
• Reformatted manual for use in online help.
Jul. 23, 2007 1.01C+ • Added “lb” and “ ” (blank) as UOM’s for U.S.
counters.
• Added “kg” and “ ” (blank) as UOM’s for metric
counters.
• Added sections on setting up and calibrating a
Generic Analog Input.
• Improved Notes, Tips, Cautions, and Warnings
with better icons and formatting.
• Minor formatting changes.
Jul. 31, 2007 1.01C+ • Fixed title page so the part number shows.
• Prepared the manual for the print vendor.
Apr. 22, 2008 1.01C+ Minor correction to section on calibrating a Generic
Analog Input.
Jul. 14, 2008 1.01C+ Prepared the manual for the print vendor.
Nov. 3, 2008 1.01C+ Corrected the text describing the drawing in the “IO
Cable Connections” section.
Jul. 1, 2009 1.01C+ Corrections made to the “E-Z CAL General Operation”
section regarding powering on and off.
Sep. 3, 2009 1.01D & Corrected some instructions in the “E-Z CAL General
Later Operation” section:
• Press Setup/Calib twice quickly to bypass the
waiting period when powering on the manual
station.
• Press AGG ZERO button twice quickly to reset the
Agg scale to zero. Same for Cem scale.
Added notes stating that the BAD LCIu and BAD LCIv
messages are only displayed if the E-Z CAL firmware
version is 1.01D and higher.
Jan. 4, 2010 1.01F & • Added description of BAD MPIu message.
Later • Incremented version number to V1.01F & Later.
Jun. 10, 2011 1.01F & Updated the technical specifications for input and
Later output modules.
Apr. 30, 2013 1.01F & Corrections to the moisture probe calibration
Later procedure.
Nov. 13, 2013 1.01F & Added notes about the calibration enable switch when
Later used with the V2.0 Processor Board.
Dec. 12, 2013 1.01F & For systems with the V2.0 Processor Board, added
Later information about the SYSTEM Setup option and a
step for disabling AZT.

6 12/27/16
 Feb. 27, 2014 1.01F & Changed NTEP certificate approval number to the
Later latest one.
Jun. 2, 2014 1.01F & Created a new E-Z CAL manual for the V2.x CPU
Later board.
Nov. 11, 2014 1.01F & Removed section on changing the Communication
Later Type (RS-232 or Ethernet) - which does not pertain to
current shipments of E-Z CAL which are still Serial.
Feb. 9, 2016 1.01F & Revised the specs on the maximum number of pulses
Later for AC and 24 vDC Opto Input Modules.
Jul. 22, 2016 1.01F & Reverted the scope of this manual to older Serial-Only
Later E-Z CAL hardware systems.
Nov. 8, 2016 1.01F & Added Load Cell Compatibility Chart to Technical
Later Specifications for Scale Interfaces.
Dec. 27, 2016 1.01F & Updated cover/title page.
Later

12/27/16 7
 E-Z CAL (Serial-Only) Manual Station &
J-Box

Overview of the E-Z CAL Manual Station

The E-Z CAL is used primarily as a backup control panel for plant devices in
the event of plant malfunction or batch computer failure.

Other uses for the E-Z CAL include:

• Quick and easy configuration and calibration of scales, meters, and

moisture probes.

• Convenient place to check scale, meter, and moisture probe readings

during automatic batching without the operator having to switch screens
on the batch computer.

8 12/27/16
 • Simplified system troubleshooting. For example, LED lights beside IO
modules in the J-Box indicate whether power is being provided or inputs
are being activated.

Caution!
If this equipment is used in a manner not specified in
this manual or marked on the equipment, the protection
provided by the equipment may be impaired.

12/27/16 9
 Regulatory Compliance
NTEP Certification
Certificate Number: 97-124A3
Issue Date: December 20, 2013
This device was evaluated under the National Type Evaluation Program (NTEP)
and was found to comply with the applicable technical requirements of
Handbook 44, “Specifications, Tolerances, and Other Technical Requirements
for Weighing and Measuring Devices.”

CE (European Union) Certification

The Spectrum VI Batching System, consisting of the E-Z CAL Manual Station
and IO Junction Box, is in effective conformance to the Directives, “Low
Voltage Directive (73/23/EEC)” and “EMC Directive (89/336/EEC)”, including
all amendments, as well as the Standards listed in the Declaration of
Conformance.

10 12/27/16
 Offer of Source for GPL Software
You may have received from Command Alkon, certain products that contain—
in part—some free software (i.e. software licensed in a way that allows you to
run, copy, distribute, change, and improve the software).
As part of these products, Command Alkon may have distributed to you
hardware and/or software, or made electronic downloads, that contain GPL
(General Public License) versions of Linux Kernel, LTIB, and Freescale BSD
which are free software developed by the Free Software Foundation.
With your purchase of the E-Z CAL Manual Station, Command Alkon has
granted you a license to the above-mentioned software under the terms of the
following licenses:

General Public License (GPL)

GNU GENERAL PUBLIC LICENSE
Version 3, 29 June 2007
Copyright (C) 2007 Free Software Foundation, Inc. <http://fsf.org/>
The full text of the General Public License can be found at:
http://www.gnu.org/licenses/gpl.html

Lesser General Public License (LGPL)

GNU LESSER GENERAL PUBLIC LICENSE
Version 3, 29 June 2007
Copyright (C) 2007 Free Software Foundation, Inc. <http://fsf.org/>
The full text of the Lesser General Public License can be found at:
http://www.gnu.org/licenses/lgpl.html

Command Alkon will provide the following information to anyone who requests
it (see our contact information below):
A copy of the complete corresponding machine-readable source code
that is distributed under the GNU GPL for the product(s) listed below.

Customers who choose to modify the original software delivered by Command

Alkon for the E-Z CAL product void all WARRANTY, SERVICE and SOFTWARE
SUPPORT agreements for said product.
Product(s) Incorporating GPL Software:
EZCal Manual Station

Contact Information for Requesting Source Code:

Command Alkon Inc.
5168 Blazer Parkway
Dublin, Ohio 43017-1339
Tel: +1 (614) 799-6650
Fax: +1 (614) 793-0608
Service Dept: +1 (614) 792-0677

12/27/16 11
 E-Z CAL Major Hardware Components
The E-Z CAL hardware is comprised of two major components: the Manual
Station and the J-Box.
The Manual Station is a backup control panel that allows you to manually
operate any plant device without depending on the batch control computer.
The J-Box (also called a J-Box) is an integral part of the E-Z CAL. Whereas the
Manual Station is the “operator interface”, the J-Box is the “electrical
interface”.

Manual Station

CAUTIONS!
This equipment was manufactured to operate under
normal “dry” industrial conditions. Extreme
temperature or weather conditions can and will cause
damage to the equipment and bodily harm.
Per IEC 61010, no operator access is permitted in this
unit! Service should only be performed by qualified
personnel.
A Circuit Breaker (rated at 20 Amperes 240 Volts AC)
should be installed near the J-Box, be easily
distinguishable from other controls, and labeled to
indicate that it is the Disconnect device.

Warning!
HAZARDOUS LIVE VOLTAGE PRESENT! This equipment
must be isolated or disconnected before it is accessed.

Description

The E-Z CAL Manual Station is a backup control panel that allows you to
manually operate any plant device without depending on the batch control
computer.

Each button, light, and display on the Manual Station is labeled to indicate its
function. If this is your first time using the E-Z CAL, spend a few moments to
locate the most commonly used controls such as scale displays and discharge
gate pushbuttons (see the E-Z CAL Front Panel drawing).

12 12/27/16
 E-Z CAL Front Panel

12/27/16 13
 Features
• Reliabilility: With easy to replace, low-voltage buttons, which can last up
to 20 times longer than the high-voltage types used by other companies,
and easily reassignable IO points, EZ-Cal is built for the long haul.
• Digital signals are used throughout E-Z CAL, making drifting scale values
next to impossible.

• Up to 12 Simultaneous Displays & 80 Manual Controls can be configured.

• E-Z CAL automatically tests for load cell failure, potentially preventing
bad loads, wasted material, and unhappy customers.

• E-Z cal uses a standard PC connected to the IO system with one proven,
reliable RS-232 cable.

• E-Z CAL is enterprise-upgradeable, meaning it can easily be connected to

a Dispatch system via a TCP/IP connection.

Nameplate Label
The manual station’s nameplate label is located at the top of the left side
panel as shown in the following picture. The nameplate label contains
important information such as the voltage range, frequency, current,
operating temperature, CE mark and NTEP certification number.
Nameplate Label - Manual Station

14 12/27/16
 J-Box

CAUTIONS!
This equipment was manufactured to operate under
normal “dry” industrial conditions. Extreme
temperature or weather conditions can and will cause
damage to the equipment and bodily harm.
Per IEC 61010, no operator access is permitted in this
unit! Service should only be performed by qualified
personnel.
A Circuit Breaker (rated at 20 Amperes 240 Volts AC)
should be installed near the J-Box, be easily
distinguishable from other controls, and labeled to
indicate that it is the Disconnect device.

Warning!
HAZARDOUS LIVE VOLTAGE PRESENT! This equipment
must be isolated or disconnected before it is accessed.

Description

The J-Box (also called a J-Box) is an integral part of the E-Z CAL. Whereas
the Manual Station is the “operator interface”, the J-Box is the “electrical
interface”. The J-Box fuses incoming plant power with a main fuse and
sectional hot power and neutral voltages. With the provided power cable, the
voltages of the plant power can be kept in phase and on the same source as
the computer power.

All plant control signals flow to and from the batch computer through the J-
Box. These signals include scale, meter, moisture probe and limit switch
inputs to the computer, as well as the on-off solenoid valve and motor control
signals from the computer to the plant. LED lights on the Power Supply Board
indicate whether power is on for the Supply Power and the Manual Station.
(See the J-Box Layout and Power Overview.)

The J-Box contains no electrical components such as motors, high-voltage

transformers, or solenoids (refer to your plant drawings for the location of
these components).

Plant devices not directly controlled by the batch computer can be wired to be
controlled from the J-Box. Examples are air compressors and cement
aerators.

12/27/16 15
 J-Box Layout and Power Overview

16 12/27/16
 Features
• Modular design.

• Pre-punched conduit holes (1/2” and 3/4”).

• Pre-punched holes near the Emergency Stop switch for additional manual
plant operation switches.

• LED lights to the left of each module to indicate that power is being
provided or that an input is being activated.
• Key-lock security of both the front door and the Plant Power switch.

• Sectional fuses with neon (Blown) lights per switch bank.

• Factory-installed Relay placement strip.

• Wire raceways to keep wiring neat and presentable.

• Clearly numbered module and plant connection points.

• Emergency Stop switch located on the front door that quickly

disconnects all power, along with a factory pre-wired emergency stop
block for customer use.

Nameplate Label
The J-Box’s nameplate label is located at the top of the left side panel. This
label contains important information such as the voltage range, frequency,
current, operating temperature, and CE mark.
Nameplate Label - J-Box

12/27/16 17
 Ground Label
The ground label (shown next) is located inside the J-Box in the lower left
corner of the back panel. This label indicates that the J-Box is earth-
grounded.
Ground Label - J-Box

Caution/Warning Stickers
The following Caution and Warning stickers are attached to the front door of
the J-Box.
J-Box Caution and Warning Stickers

18 12/27/16
 Installation and Wiring Guidelines (E-Z CAL and J-Box)
Topics
Water and Moisture
Mounting
Ventilation
Manual Station Power Source and Supply
J-Box Supply Wiring
J-Box Power Source 120VAC
J-Box Power Source 240VAC
J-Box Voltage Jumper Settings
IO Cable Connections
120 Volt Power Connections
240 Volt Power Connections

12/27/16 19
 Water and Moisture

The E-Z CAL Manual Station and J-Box must not be installed where they will
be subjected to moisture (for example, outdoors, near a sink or in a non-
weatherproof enclosure).

Mounting

Note: Use proper lifting techniques when lifting the Manual Station or
the J-Box. Always lift with your legs, keeping your back as
upright and as low as possible.

The Manual Station must be situated on a table or countertop large enough to

accommodate the four rubber feet. The surface must be of sufficient stability
and rigidity to prevent tilting or sagging.

The J-Box should be securely fastened to a rigid vertical structure such as a

wall. Alternatively, it may be mounted to some other permanent structure no
more than 45 degrees from vertical and sufficient in strength to support the
weight of the J-Box and associated wiring.

Ventilation

The Manual Station must be situated so that the following free-air clearances
can be maintained at all times:
— Rear: 5cm
— Top-Rear Edge: 15 cm (vertical)

The J-Box must be mounted so that the following free-air clearances can be
maintained at all times:
— Left Side: 15 cm
— Right Side, Top, and Bottom: 2 cm
— Front (Door): 65 cm

20 12/27/16
 Manual Station Power Source and Supply

The Manual Station, which is equipped with its own overcurrent protection, is
powered by an A.C. source from the J-Box.

See Also:
Power Cord Type and Rating
120 Volt Power Connections
240 Volt Power Connections

As shown in the following three drawings, the Manual Station power unit
consists of two power supplies:
• The Base Board power supply
• and a 12-Volt power supply for the AAEON 6810 and an optional Lanolinx
Ethernet switch (COMMANDbatch systems only).
Manual Station Power Supplies

12/27/16 21
 Base Board Power Supply for Manual Station

12-VDC Power Supply for AAEON and Lanolinx Switch (COMMANDbatch only)

22 12/27/16
 Manual Station - Inside View

12/27/16 23
 Manual Station CPU with RS-232 Board

24 12/27/16
 J-Box - Inside View

12/27/16 25
 J-Box Supply Wiring

The J-Box must be connected to its power source with wiring which conforms
to the following specifications: 12 AWG, 300 volts, 105 oC. All wiring must
conform to local electrical codes. In the absence of applicable codes, the use
of grounded metal conduit is strongly encouraged.

J-Box Power Source 120VAC

The J-Box must be connected to a power source of 110 to 120 Volts AC, 20
Amps, 50/60 Hz. The power source must be equipped with a disconnect
switch and overcurrent protection rated at 240 Volts AC, 20 Amps, 50/60 Hz.

An integrated switch/circuit breaker is recommended for an overcurrent

protection device.

Caution!
A Circuit Breaker (rated at 20 Amperes 240 Volts AC)
should be installed near the J-Box, be easily
distinguishable from other controls, and labeled to
indicate that it is the Disconnect device.

J-Box Power Source 240VAC

The J-Box must be connected to a power source of 200 to 240 Volts AC, 20
Amps, 50/60 Hz. The power source must be equipped with a disconnect
switch and overcurrent protection rated at 240 Volts AC, 20 Amps, 50/60 Hz.

An integrated switch/circuit breaker is recommended for an overcurrent

protection device.

Caution!
A Circuit Breaker (rated at 20 Amperes 240 Volts AC)
should be installed near the J-Box, be easily
distinguishable from other controls, and labeled to
indicate that it is the Disconnect device.

J-Box Voltage Jumper Settings

Caution!
A Circuit Breaker (rated at 20 Amperes 240 Volts AC)
should be installed near the J-Box, be easily
distinguishable from other controls, and labeled to
indicate that it is the Disconnect device.

26 12/27/16
 By making simple jumper changes on the Opto Board (see the 22821 Opto
Board Drawing), you can control which reference voltages (Hot Power,
Auxiliary, or Neutral) the modules in the J-Box will use.
22821 Opto Board Drawing

The non-detachable power cable (part number 21336) must be installed and
all peripherals must be connected to it. Also ensure that the Manual Station is
connected to the J-Box via power cable (part number 25409). See the 120
Volt Power Connections and 240 Volt Power Connections drawings.

During normal operation, the front door of the J-Box does not need to be
opened.

Each button, light, and display on the Manual Station has a corresponding LED
indicator light in the J-Box. Refer to the wiring diagrams shipped with your
system for the names and locations of these lights.

12/27/16 27
 IO Cable Connections
The following drawing shows the J-Box connections for the A/B and C/D cables
(Part Number 23645 or 23644-50P).
The A/B and C/D cable ends marked “To J-Box” connect to the J-Box.
The opposite ends of the A/B and C/D cables go to their corresponding
connectors on the back of the Manual Station.
J-Box Cable Connections

28 12/27/16
 120 Volt Power Connections

12/27/16 29
 240 Volt Power Connections

30 12/27/16
 E-Z CAL General Operation
Topics
Powering On and Off
Operating Plant Equipment
E-Z CAL Displays
Clearing Bad Cell and Bad Module Messages
Testing the MPI Module in the E-Z CAL Manual Station
If Communication to the Batching PC is Lost

Powering On and Off

Powering On
1. If the E-Z CAL displays are not lit, press the I (On) power switch
located on the rear panel. Wait approximately five minutes for the
flashing “POWER ON” message to disappear.

Tip!
To bypass the waiting period, press the “Setup/Calib” button twice
quickly. This puts the system into Calibration mode. Press “Setup/
Calib” once more to exit Calibration mode.

Manual Station Power Switch

Manual Station
Power Switch
(behind plug connector)

12/27/16 31
 2. On the front of the J-Box door, turn the Plant Power key switch to
the “On” position (12 o’clock) and make sure the red Emergency
Stop switch is not engaged (pull it until it clicks).
Power Key Switch on J-Box Door

Powering Off
On the front of the J-Box door, turn the Plant Power key switch to the 'Off'
position (9 o'clock).

Important!
• For highest reliability, scale stability, and convenience, leave E-
Z CAL power turned on 24 hours a day, 7 days a week, except
when servicing the equipment.
• For plants that use a generator: Before shutting down the
generator, first turn off power to the J-Box, then power off the
E-Z CAL. After starting up the generator, start the E-Z CAL,
then the J-Box.

Operating Plant Equipment

• To operate a piece of plant equipment such as a gate or an admix valve,
press its corresponding pushbutton. Most buttons are “momentary”,
meaning you must push and hold down on the button to energize the
solenoid valve, then release the button to de-energize the valve.
• To reset the Agg or the Cem scale value to zero, press the AGG ZERO or
CEM ZERO button twice quickly. This can be done to compensate for
material buildup on the scale gates. DO NOT do this while an
automatic batch is in progress, or batching errors may occur!
• To reset all counters to a zero value, press the RESET COUNTERS button.
DO NOT do this while an automatic batch is in progress, or
batching errors may occur!

32 12/27/16
 E-Z CAL Displays

Displays

• Normally the scale and meter readouts show the amount of material that
has been batched, along with the unit of measure (kg, lb, ml, etc.). If you
are manually weighing or metering a material, watch its scale or meter
readout closely so you can release the button in time to deliver the right
amount.
• Under certain conditions the readouts may display special messages,
which are described below.

POWER ON Power was off, then turned on. Please wait a minute for warm-up.
BAD CELL The load cell for that scale has failed, or the cable has been
unplugged. If you can’t quickly diagnose the problem, contact
Command Alkon Service.
-- -- (Dashes) No scale, probe, or counter has been configured for this
display.
NO CALIB This display has been set up for a scale or moisture probe, but no
calibration has been performed.
BAD LCIu Indicates that an update has not been received from the LCI (Load
Cell) module. Check the module.
Note: Displayed only if E-Z CAL firmware is V1.01D or higher.
BAD LCIv Indicates that updates are being received from the LCI module,
but the raw values are not changing. Check the module.
Note: Displayed only if E-Z CAL firmware is V1.01D or higher.
BAD MPIu Indicates that an update has not been received from the MPI
(Moisture Probe) module. Check the module.

See Also:
Clearing Bad Cell and Bad Module Messages

12/27/16 33
 Clearing Bad Cell and Bad Module Messages
The E-Z CAL performs a quick check of the load cells, cables, and electronics
approximately every 10 minutes. If a problem is detected, one of the following
messages flashes on the affected display, alternating with the scale weight or
moisture reading (which might be incorrect!):

BAD CELL
BAD LCIu
BAD LCIv
BAD MPIu

Notes: • See E-Z CAL Displays for a description of each message.

• The BAD LCIu and BAD LCIv messages will only be displayed if
the E-Z CAL firmware version is 1.01D or higher.

The message continues to be displayed after the problem is corrected. This

allows you to be aware of a problem that comes and goes by itself.
After you have diagnosed and fixed the problem, press the “Setup” button.
The displays show something like:

Bad cell found on Disp 1, Module 1

Is the problem fixed? No

Press the Up/Down buttons to select Yes and press Enter.

A message will be displayed for each scale or moisture probe that has a
problem. After all of the messages have been accepted with Yes or No, press
the “Setup” button to return the system to normal operation.

34 12/27/16
 Testing the MPI Module in the E-Z CAL Manual Station

To test the MPI module

1. Record the probe’s moisture display reading.

2. Move the switch on the MPI module to the down “Test” position.

3. Press the red Test button in the middle of the MPI module until
the display stops counting down.
— If the probe was calibrated for Sand, the display reading should
decrease 1.11%. For example, an initial reading of 2.00 should
decrease to .89.
— If the probe was calibrated for Coarse Aggregates, the display
reading should decrease .37%.
4. When you are finished, move the switch back up to the “Normal”
position.

12/27/16 35
 Notes:
• Typically MPI modules are calibrated with a Probe Factor of 1.00 for sand
or .33 for coarse aggregates (see the Moisture Probe Calibration on the E-
Z CAL for probe calibration details).
• The Probe Factor determines how much the moisture reading changes
during the MPI module test.

36 12/27/16
 If Communication to the Batching PC is Lost
Turn the ‘Manual Power’ key switch on the front of the E-Z CAL to the 3 o'clock
position. (Keyswitch is located left of the first switch bank).
Manual Station Key Switch

• This allows feed buttons to function without communicating with the

batching PC.
• Depending on local regulations and your company's policies, you may
have to turn the key to the 12 o'clock position before starting an
automatic load with the batching PC.

12/27/16 37
 Setup and Calibration Using the E-Z CAL
Topics
Operating Modes
Setup Buttons
Calibration Enable Switch
Setup Procedures
Calibration Procedures

Operating Modes
• In Setup mode, each E-Z CAL display can be configured to show
readings for one of the following: a scale, a meter, or a moisture probe. A
display can be configured to show scale, meter, or moisture probe
information with a variety of options such as unit of measure, decimal
point position, etc. Active displays can be disabled.

• In Calibrate mode, you adjust the E-Z CAL displays to match the actual
weight on the scales, or the actual value of aggregate moisture.

• In Info mode, you can view configuration settings for each display, view
system information such as firmware and software versions, and turn
scale certification (i.e. NTEP) on or off.

Note: Do not proceed beyond this point unless you intend to

reconfigure one or more scales or meters.

Caution!
If you plan to change any scale parameters, make sure you
have the proper test weights, training, and time to re-check
the weighing accuracy of those scales. Careless setup will
cause serious batching errors that the batch computer will
not be able to correct!

38 12/27/16
 Setup Buttons
You will use five special buttons in the upper right-hand row of the E-Z CAL to
enter the Setup, Calibration, and Info modes.
E-Z CAL Setup Buttons

Buttons used for

Setup and Calibration

Setup/Calib
Press this button to enter one of the operating modes. Press this button again
to exit the mode you are in and return to normal display, however, any
information you were entering/changing will be discarded.

Up/Down
During Setup, you will be presented with a list of items or with a numerical
parameter that you can change. Press the Up/Down buttons to move (“scroll”)
through the list of items, or to increase or decrease the number. Hold the
button down to scroll very fast through the choices.

Enter
After selecting the desired item or setting a parameter to the right value,
press this button to accept the setting and move on to the next option.

Check Grad
This button is used to view each scale’s full scale capacity and grad size
without entering Setup. Any time during normal display operation, you can
press and hold the “Grad” button to show each scale’s full scale capacity in its
display window. When you release the button, the grad size will be shown for
one second before the display reverts back to normal.

12/27/16 39
 Calibration Enable Switch
To prevent accidental changes to scale setup and calibration data, the E-Z CAL
has an internal Calibration Enable Switch that can be locked. Normally this
switch is set to the “locked” position by your system installer.

Note: You do not need to unlock the Calibration Enable Switch to change
the setup or calibration of counters or moisture probes.

To Unlock the Calibration Enable Switch

1. (Optional, depending on government regulations for your area):

Remove the calibration wire seal from the small blue metal tab on
the rear panel (see the following picture).

Caution!
Removing this seal invalidates your local Weights and
Measures certification and may prevent you from
shipping product to some or all customers.

Location of Weights & Measures Seal

Tab where
calibration wire
is attached.

2. Remove the two thumbscrews shown in the following picture and

lift off the top cover.

40 12/27/16
 Removing the Top Cover

Top Cover Thumbscrew

Locations

3. Swing the front panel and open until it stops as shown in the
following picture.
Swinging Open the Front Panel

4. Remove the 8 screws (4 along the top and 4 along the bottom)
from the RF Shield Cover shown in the following picture. Remove
the shield cover and set it aside, along with the 8 screws.

12/27/16 41
 Removing the RF Shield Cover

5. Carefully remove the LCI Module Cover Plate (shown in the

following picture) without touching the delicate circuit boards
underneath. Set the cover plate aside.
Removing the LCI Module Cover Plate

6. Locate the small blue and white slide switch located on the far left
side of the main circuit board (see the following picture). With a
small screwdriver or paper clip, slide the white switch downward
(toward you if you are at the front of the E-Z CAL).

42 12/27/16
 Calibration Enable Switch

7. Swing the front panel closed so you can get to the Setup
pushbuttons.

Notes: When the Calibration Enable Switch is in the “unlocked”

position:
• All displays that are set up for “Scales” will show a “C” as
the first character and an “E” as the last character. This
signifies that the switch is not in the locked position.
• Also when the Calibration Enable Switch is in the
“unlocked” position, and a scale is at “Center Zero” (less
than ¼ grad up or down from exact zero), an “@” symbol
is displayed before the weight.

8. Proceed with the Setup and Calibration Using the E-Z CAL
procedures of this guide.
9. When you are finished with setup and calibration, slide the white
calibration enable switch back up to the locked position.
10. Reinstall the LCI Module Cover Plate (no screws), then the RF
Shield Cover using the 8 screws.
11. Swing the front panel closed.
12. Reinstall the top cover and tighten the two thumbscrews.
13. Schedule a visit by a certified scale company or DOT
representative to re-seal the cover plate.

12/27/16 43
 Setup Procedures
Use these procedures to configure (set up) scales, counters, moisture probes,
and generic analog inputs.
• These devices should be configured in the E-Z CAL before you set them
up in the batch control software.
• For Scales, you can assign the measuring system (U.S. or SI), unit, grad
size, decimal point location, and allowed grads for re-zeroing the scale.
• For Counters, you can assign the measuring system (US or SI), unit,
grad size, and decimal point location.
• For Moisture Probes, all you need to do is select the probe module
position (choices are 1 - 8).
• For Generic Analog Inputs, you can assign the measuring system (U.S.
or SI), unit, grad size, decimal point location, and allowed counts for re-
zeroing the reading.

Topics in This Section

Do This First
Setup Scale
Setup Counter
Setup Moisture Probe
Setup Generic Analog Input

44 12/27/16
 Do This First
1. Press the “Setup/Calib” button. The displays show:

Info

Select Menu Option

• If the Calibration Enable switch is unlocked, you can set up any scale,
meter, or moisture probe.
• If this switch is locked, you can only configure counters and moisture
probes. You will not be permitted to cofigure scales.

2. Use the Up/Down buttons to select “Setup”, press Enter, and

continue with the following steps. The displays show:

Disp. 1

Select display to set up

3. Use the Up/Down buttons to move through the displays. (For

displays 7 -12 the message moves to the top line.) Select the
appropriate display and press Enter. The displays show the name
of the setup parameter, and its value. For example, if “Disp. 2” is
selected, the displays show:

None

Select Scale, Counter, Probe or Generic

4. Use the Up/Down buttons to select None, Scale, Counter, or

Moisture Probe then press Enter.
— If you selected Scale, continue with Setup Scale.
— If you selected Counter, continue with Setup Counter.
— If you selected Probe, continue with Setup Moisture Probe.
— If you selected Generic, continue with Setup Generic Analog Input.
— If you selected None, you will be given the choice of selecting
another display or quitting the Setup procedure.

12/27/16 45
 Setup Scale
This procedure assumes that the Calibration Enable switch is unlocked. If
this switch is locked, the display will flash “Setup Locked” for about one
second, and then will display:

Yes

Setup another display? Yes / No

(Refer to the Calibration Enable Switch section for instructions on unlocking

the Calibration Enable switch.)

1. If you selected Scale in step 4 of Do This First, the displays show:

Select Scale module position (1 - 8)

2. The first time you set up a scale, the number of the first
unassigned module is displayed. Use the Up/Down buttons to
select the Scale Module Position and press Enter. The displays
show:

SI

Select system of units

Scale vs. Probe Modules:

Scale and Probe Modules are small printed circuit boards which are
mounted in a row across the inside rear of the E-Z CAL. Probe Modules
are marked “MPI Module” (for Moisture Probe Interface); Scale Modules
are marked “LCI Module” (for Load Cell Interface). Modules are numbered
1 through 8, beginning at the left. Make sure you know which modules
are for scales and which are for moisture probes.

3. Use the Up/Down buttons to select the system of units. The

choices are “SI” (for metric), or “U.S.” Press Enter. The displays
show:

kg

Select unit

4. Use the Up/Down buttons to select the unit and press Enter.
Choices for U.S. units are “lb” and “oz”. Choices for SI (metric)

46 12/27/16
 units are “g”, “kg”, and “Mg”. If you selected “kg”, the displays
show:

5 kg

Enter grad size

5. Determine the proper “grad size”, which is the increment by

which the display will count. In the U.S., select 1, 2, 5, 10, or 20
to comply with Handbook-44. Use the Up/Down buttons to set the
grad size then press Enter. Grad size range is 0 to 125. If you
need a fractional grad size (e.g. .5 kg) enter it as a whole number
(5) and set the decimal point position in the next step.

5 kg

Select decimal places

6. Decimal place range is 0 to 0.000. For example, if you enter “1” as

the grad size, it can represent 1, 0.1, 0.01, or 0.001, depending on
the decimal placement. Use the Up/Down buttons to select the
decimal place and press Enter. The displays show:

20000 kg

Enter scale capacity

7. The maximum allowable scale capacity is 60000 lbs but can be set
to a smaller value as long as it is a multiple of the grad size.
(Example: 40000 lbs is a multiple of 1, 2, 5, 10, or 20 grads.) Use
the Up/Down buttons to set the value then press Enter. The
displays show:

20

Enter allowed grads to re-zero

12/27/16 47
 8. Use the Up/Down buttons to select the maximum allowed grads
to re-zero then press Enter. This parameter represents the
maximum number of scale divisions that can be re-zeroed up or
down via the front panel “Zero” button, without requiring
calibration. The displays show:

No

Disable AZT?

9. Use the Up/Down buttons to select “Yes” or “No” then press

Enter. AZT (Automatic Zero-Tracking) is an Automatic means
provided to maintain the zero balance indication, within specified
limits, without the intervention of an operator. The displays
show:

No

Setup another display? Yes / No

10. Use the Up/Down buttons to select “Yes” or “No” then press
Enter. “Yes” allows you to select another display to assign to a
scale. “No” exits setup.

11. Return the Calibration Enable switch to the “locked” position as

explained in the Calibration Enable Switch procedure to prevent
accidental changes.
12. Schedule a visit by a certified scale company or DOT
representative to re-seal the cover plate.

48 12/27/16
 Setup Counter

1. If you selected Counter in step 4 of Do This First, the displays

show:

A1

Select j-box input point

2. Each counter can be assigned up to five J-Box input points for

meter pulses. In other words, up to five water or admix meters
can share the same display if they have the same calibration (i.e.
the same number of ounces, milliliters, etc. per pulse). Use the
Up/Down buttons to select an input point for the meter wire and
press Enter. The displays show:

No

Select another input point ?

3. Use the Up/Down buttons to select “Yes” or “No” and press Enter.
“Yes” returns you to the previous step to select another input
point. This process can be repeated for up to five input points.
Select “No” when you are finished. The displays show:

SI

Select system of units

4. Use the Up/Down buttons to select the system of units. The

choices are “SI” (for metric), or “U.S.” Press Enter. The displays
show:

mL

Select unit

5. Use the Up/Down buttons to select the unit and press Enter.
Choices for U.S. liquid units are “oz”, “pt”, “qt”, “gl”, “ig”, “lb”,
and “ ” (blank). Choices for SI (metric) liquid units are “L”, “mL”,
“cL”, “dL”, “kg”, and “ ” (blank). The displays show:

1 mL

Enter grad size

12/27/16 49
 6. Determine the “grad size” (number of units per pulse) of the
meter(s) which will be connected to this counter. Use the Up/
Down buttons to select the grad size and press Enter. Grad size
range is 0 to 125. If you need a fractional grad size (e.g. .5 oz per
pulse) enter it as a whole number (e.g. 5) and select a decimal
point location in the next step.

10 mL

Select decimal place

7. Decimal place range is 0 to 0.000. For example, if you enter “1”, it

can represent an actual grad size of 1, 0.1, 0.01, or 0.001,
depending on the decimal placement. Use the Up/Down buttons
to select the decimal place and press Enter. The displays show:

Yes

Setup Another display? Yes / No

8. Use the Up/Down buttons to select “Yes” or “No” then press

Enter. “Yes” allows you to choose another display to assign to a
counter. “No” exits setup.

50 12/27/16
 Setup Moisture Probe

1. If you selected Probe in step 4 of Do This First, the displays show:

Select Probe module (1 - 8)

Scale vs. Probe Modules:

Scale and Probe Modules are small printed circuit boards which are
mounted in a row across the inside rear of the E-Z CAL. Probe Modules
are marked “MPI Module” (for Moisture Probe Interface); Scale Modules
are marked “LCI Module” (for Load Cell Interface). Modules are numbered
1 through 8, beginning at the left. Make sure you know which modules
are for scales and which are for moisture probes.

2. The first time you set up a probe, the number of the first
unassigned module is displayed. Use the Up/Down buttons to
select the Probe Module Position and press Enter.
There is nothing else to set up for a Moisture Probe. Probes are
automatically assigned a unit of “%”, a grad size of 0.01, and a maximum
capacity of 20.00 %. The displays show:

Setup another display?

Yes

3. Use the Up/Down buttons to select “Yes” or “No” then press

Enter. “Yes” allows you to choose another display to assign to a
probe. “No” exits setup.

12/27/16 51
 Setup Generic Analog Input
This procedure assumes that the Calibration Enable switch is unlocked. If
this switch is locked, the display will flash “Setup Locked” for about one
second, and then will display:

Yes

Setup another display? Yes / No

(Refer to the Calibration Enable Switch section for instructions on unlocking

the Calibration Enable switch.)

1. If you selected Generic in step 4 of Do This First, the displays

show:

Select Analog Input module (1 - 8)

Notes:
• Analog Input Modules are small printed circuit boards mounted in a row
across the inside rear of the E-Z CAL. Analog Input Modules are marked
“LCI Module” and are numbered 1 through 8, beginning at the left. Your
E-Z CAL may also have one or more Moisture Probe Interface Modules,
marked “MPI Module.” Make sure you know which modules are used for
generic analog inputs and which are used for moisture probes.
• Part numbers for Generic analog boards are: 24854 for 0-10v, 25503 for
4-20 ma.

2. The first time you set up a generic analog input, the number of
the first unassigned module is displayed. Use the Up/Down
buttons to select the Analog Input Module position and press
Enter. The displays show:

Select unit

3. Use the Up/Down buttons to select the unit and press Enter.
Choices are “%” and “ ” (blank). If you selected “%”, the displays
show:

1%

Enter grad size

52 12/27/16
 4. Press Enter to accept “1”. If you need a fractional grad size (.1 %,
for example), enter it as a whole number (1) and set the decimal
point position in the next step.

1%

Select decimal places

5. Decimal place range is 0 to 0.000. For example, if you enter “1” as

the grad size, it can represent a value of 1, 0.1, 0.01, or 0.001,
depending on the decimal placement. Use the Up/Down buttons
to select the decimal place and press Enter. The displays show:

100.0%

Enter max reading

6. Use the Up/Down buttons to set the maximum display reading

then press Enter. The displays show:

20

Enter allowed grads to re-zero

7. Use the Up/Down buttons to select the maximum number of

counts that can be re-zeroed up or down via the front panel
“Zero” button, without requiring calibration. After selection, the
displays show:

No

Setup another display? Yes / No

8. Use the Up/Down buttons to select “Yes” or “No” then press

Enter. “Yes” allows you to select another display to assign to a
scale. “No” exits setup.

12/27/16 53
 Calibration Procedures
Use this procedure to calibrate scales and moisture probes. You cannot
calibrate a counter.
• For Scales, you can zero the scale and set the correct weight using test
weights.
• For Moisture Probes, you can set the expected moisture and the span
value. (The span value determines the relative sensitivity of the Moisture
display.)
• For Generic, you can zero the display and set the correct display reading
using test signals.

Topics in This Section

Do This First
Scale Calibration on the E-Z CAL
Re-Span Scale
Full-Scale Calibration Completed
Moisture Probe Calibration on the E-Z CAL
Generic Analog Input Calibration on the E-Z CAL

54 12/27/16
 Do This First

1. Press the “Setup/Calib” button. The displays show:

Info

Select Menu Option

• If the Calibration Enable switch is unlocked, you can calibrate any scale
or moisture probe.
• If this switch is locked, you can only calibrate moisture probes. You will
not be permitted to calibrate scales.

2. Use the Up/Down buttons to select “Calib” and press Enter. The
displays show:

Disp. 1

Select display to calib

3. Use the Up/Down buttons to move through the displays. (For

displays 7 -12 the message moves to the top line.) Select the
appropriate display and press Enter.

• If the display is set up for a Scale, continue with Scale Calibration on the
E-Z CAL.
• If the display is set up for a Probe, continue with Moisture Probe
Calibration on the E-Z CAL.
• If the display is set up for Generic, continue with Generic Analog Input
Calibration on the E-Z CAL.

12/27/16 55
 Scale Calibration on the E-Z CAL
Note: When replacing an existing system with E-Z CAL, use the Load Cell
Compatibility Chart to ensure successful scale calibration.

This procedure assumes that the Calibration Enable switch is unlocked. If

this switch is locked, the display will flash “Calib Locked” for about one
second, and then display:

No

Calib another display?

(Refer to the Calibration Enable Switch section for instructions on unlocking

the Calibration Enable switch.)

1. If you selected Scale in step 3 of Do This First, and if the scale

was calibrated previously, you will be asked if you want to zero
the scale (see the following displays):

Yes

Zero scale?

2. Use the Up/Down buttons to select “Yes” or “No”.

— If you select “No”, go to the Re-Span Scale section for a simplified
procedure to readjust the full-scale calibration.
— If you select “Yes”, or if this is the first time this scale has been
calibrated, the displays show:

XXXX

Empty scale & press zero

Where: XXXX is the live raw scale reading.

3. Empty the scale, attach chains or a weight platform to hold the

test weights, and press the “Zero” or “Enter” button for that
scale. The displays show “Wait...” for several seconds then show:

2000 kg

Apply weight & enter value

4. Add calibrated test weights to the scale, and use the Up/Down
buttons to set the displayed weight to the proper value. When the

56 12/27/16
 scale is stable, press Enter. The displays show “Wait . . .” for
several seconds.
5. Go to the Full-Scale Calibration Completed section.

Re-Span Scale
If the scale was previously calibrated, and you selected “No” in step 2 of Scale
Calibration on the E-Z CAL, the displays show:

2000 kg

Apply weight & press enter

1. Add calibrated test weights to the scale. When the scale is stable,
press Enter. The displays show:

2000 kg

Enter correct value

2. Use the Up/Down buttons to set the displayed weight to the

proper value. Press Enter. The displays show “Wait . . .” for
several seconds then show:

No

Calib another display?

3. Use the Up/Down buttons to select “No” and exit calibration.

12/27/16 57
 Full-Scale Calibration Completed
At this point, one of three things can occur:
• The displays may show “Cell output too low.” This means the load cell
is grossly oversized or that there is a wiring problem. In technical terms,
it means that the load cell’s “span” (the difference in its output voltage
between zero and full scale) is less than 1.6 millivolts. A properly sized
load cell will have a span in the range of 5 to 15 millivolts. (The E-Z CAL
uses an excitation voltage of 5 volts.) Contact your scale manufacturer.
• The displays may show “Cell output too high.” This means the load cell
is grossly undersized or that there is a wiring problem. In technical terms,
it means that the load cell’s full-scale output voltage is greater than 23
millivolts. A properly sized load cell will never have an output more than
about 16 millivolts. Contact your scale manufacturer.
• Or, if all goes well, the displays show:

No

Calib another display?

If the scale is being calibrated with test weights whose total weight is less
than the full scale capacity of the scale, it is typical to perform a “build-up”
test at this point:

1. Use the Up/Down buttons to select “No” then press Enter. “No”
exits setup and returns to the normal weight display mode.

2. Remove the test weights from the scale, and verify that the
display goes back to its starting point.
3. Manually batch an amount of material which is approximately the
same as the total weight of the test weights.
4. Add the test weights back onto the scale. The E-Z CAL display
should show a value equal to the sum of the material weight in
step 3 plus the test weights.
5. Repeat steps 2 - 4 until the scale’s capacity is reached.
6. If the displays do not track with the expected weight values, you
may want to repeat the entire calibration process.
7. When calibration is completed, remove all material from the
hopper, and remove the chains or weight platform from the scale.
The displays show a negative value. Press the “Zero” button for
that scale.
8. When all scales and probes have been calibrated, go to
Calibration Enable Switch and finish the procedure, starting from
step 9.

58 12/27/16
 Moisture Probe Calibration on the E-Z CAL

1. If you selected Probe in step 3 of Do This First, the displays show:

Enter current moisture value

0.00 %

2. Use the Up/Down buttons to set the moisture to the expected

value and press Enter. The displays show:

Enter probe factor

1.00

3. Use the Up/Down buttons to set the probe factor. A value of 1.00
works for most concrete sands. Decrease this to .30 for coarse
aggregates. Increasing the probe factor makes the display more
sensitive. Press Enter when finished. The displays show:

No

Calib another display?

4. Use the Up/Down buttons to select “Yes” or “No” and press Enter.
“Yes” allows you to choose another display to calibrate. “No”
exits the calibration procedure.

12/27/16 59
 Generic Analog Input Calibration on the E-Z CAL

1. If you selected Generic in step 3 of Do This First, and if the Analog

Input was previously calibrated, the displays show:

Yes

Zero signal?

2. Use the Up/Down buttons to select “Yes” or “No”.

• If you select “Yes”, the displays show:

Zero signal & press zero

— Apply a signal to the Analog Input that corresponds to a

display value of zero then press Enter. The displays show
“Wait...” for several seconds then show:

100.0%

Apply signal & enter value

• If you select “No”, the displays show the information above.

— Apply a known analog signal to the input module and use the
Up/Down buttons to set the correct display reading. Press
Enter when finished. The displays show “Wait...” for several
seconds.

3. If the signal is too low or too high, the appropriate warning

message is displayed. Adjust the signal then press Enter. The
displays should now show:

No

Calib another display?

4. Use the Up/Down buttons to select “Yes” or “No” and press Enter.
“Yes” allows you to choose another display to calibrate. “No”
exits the calibration procedure.

60 12/27/16
 View Configuration Settings - Info Mode
In Info mode, you can view configuration settings without changing them.

To check configurations without changing any settings:

1. Press the “Setup” button. The displays show:

Info

Info, Setup, Calib, or Exit?

2. Press Enter to go into Info mode. The displays show:

Disp. 1

Select display to view

3. Use the Up/Down buttons to move through the displays. (For

displays 7 -12 the message moves to the top line.) Select the
appropriate display and press Enter. The displays show the name
of the setup parameter, and its value. For example, if “Disp. 1” is
selected, the display might show:

Scale

Display type

4. Press Enter successively to scroll through the parameters and

their values. You will see different parameters as listed in the
following table, depending on the type of device (scale, counter,
moisture probe, or generic).

Scale Counter Moisture Probe

Parameters Parameters Parameters Generic Parameters
Scale module J-box input point (up to 5) Probe module Input module
System of units System of units System of units
Unit Unit Unit
Grad size Grad size Grad size
Scale Capacity Max Display
Allowed grads to re-zero Allowed grads to re-zero
Ch. B value 0
Disable AZT (Yes/No)

12/27/16 61
 5. When you reach the end of the parameter list for the device, the
displays show:

No

View another display?

6. Use the Up/Down buttons to select “Yes” or “No” then press

Enter. “Yes” allows you to choose another display to view. “No”
exits Info mode.

62 12/27/16
 Technical Specifications
Topics
Manual Station
Scale Interface
Meter Counter
Moisture Probe Interface
J-Box
Input Modules
Output Modules
Load Cell Color Codes
Mean Time Before Failure - Manual Station
Mean Time Before Failure - J-Box

Manual Station

CAUTIONS!
This equipment was manufactured to operate under
normal “dry” industrial conditions. Extreme
temperature or weather conditions can and will cause
damage to the equipment and bodily harm.
Per IEC 61010, no operator access is permitted in this
unit! Service should only be performed by qualified
personnel.
A Circuit Breaker (rated at 20 Amperes 240 Volts AC)
should be installed near the J-Box, be easily
distinguishable from other controls, and labeled to
indicate that it is the Disconnect device.

Warning!
HAZARDOUS LIVE VOLTAGE PRESENT! This equipment
must be isolated or disconnected before it is accessed.

Note: A certified representative of Command Alkon should make

monthly inspections of this unit’s interior.

Voltage - when used with 120VAC J-Box

110 to 120 VAC.

12/27/16 63
 Voltage - when used with 240VAC J-Box
200 to 240 VAC.

Frequency
50/60 Hz.

Current
5 Amp.

Power Supply Range

90 to 260 VAC, 49.5 to 60.5 Hz.

Power Cord Type and Rating

SJTO, 3-conductor plastic detachable, black, 26’ with C19 female plug
Temperature Rating: 60 oC
AWG Stranding 14
Rating: 1250 Watts 10A-125V

Radio Frequency Interference

Displays will not change by more than one division in the presence of
“normal” RF fields. A normal scenario is defined as a 5-watt hand-held
radio operated at least one meter from the E-Z CAL, within the
commercial radio bands between 27 and 460 MHz.

Operating Temperature
+10oC to +40oC.

Storage Temperature
-20oC to +50oC.

Relative Humidity
10% to 90%, non-condensing.

Altitude
0 to 3000 m.

Weight
25 lbs.

Dimensions
Height: 17 5/8”, Width: 18 1/4”, Depth: 3 7/8” (5 1/4” with power
supply).

64 12/27/16
 Maximum Display Capacity
6 characters, including a decimal point.
Maximum scale capacity that can be entered:
— 60000 for whole integer precision graduations
— 6000.0 for one decimal precision graduations
— 600.00 for two decimal precision graduations
— 60.000 for three decimal precision graduations

Minimum Scale Division Size

0.001.

Maximum Scale Division Size

125 (You must limit your choice of scale division size to decimal multiples
of 1, 2, 5, 10, or 20 to comply with NIST Handbook - 44.)

Agency Sealing Method

Lead-wire seal, inserted through the protruding edge of a metal shield on
the underside of the enclosure. The shield prevents access to any
components that can affect the weighing integrity of the device.

Labeling
The names of the scale materials, scale capacities, and division sizes are
printed on labels which are inserted from the edge of the front control
panel, and are protected from abuse by a clear overlay.
All operator controls and field-installable connectors are labeled according
to their use.
The equipment identification label is a permanent, adhesive, destructible
mylar label at the top of the left side panel. A unique serial number is
added at the Command Alkon factory with an indelible ink marker or
stamp.

Cleaning
Clean the exterior of the Manual Station with a mild soap solution and a
soft towel. No liquids should be introduced to the interior of the
Manual Station!

12/27/16 65
 Scale Interface

Number of Scale Divisions

4000 maximum.

Under-Zero
The display shows negative weight values below the calibrated zero point.
The value "- 0" does not occur.

Over-Capacity
The display shows "OVER" if the weight value exceeds the programmed
scale capacity value.

Full-Scale Input
1.6 mV to 23.5 mV (11% to 155% of a 3 mV/V load cell).

Load Cell Excitation

5 VDC, 60 mA (4 350-ohm load cells).

Load Cell Wiring

Each load cell must be wired with a shielded 6-conductor cable,
terminating at the Command Alkon Manual Station or Calibration Box.
The cable must meet the following specifications:
— Wire Gauge: #20 - 24
— Overall Cable Diameter: 0.32" max
— Insulation Material: PVC, teflon
— Shield: 85% min, 100% preferred
— Length: 1300' max
— Suggested Type: Belden 9536 (Command Alkon PN-19320)
All load cell connections or cable splices must be made in waterproof
enclosures in accordance with accepted scale industry methods.

Dead-Load Offset
0 mV to 13 mV (0% to 85% of a 3 mV/V load cell).

Load Cell Compatibility Chart

When replacing an existing system with E-Z CAL, use the following table
to ensure that the calibration process will be successful.

66 12/27/16
12/27/16 67
 Meter Counter

Maximum Number of Counts

Limited only by display capacity.

Maximum Count Rate (at 50% Duty Cycle)

Opto Input Module (AC):

15 pulses per second

Opto Input Module (24 vDC):

20 pulses per second

Moisture Probe Interface

Capacity
20.00% x .01%.

Moisture Probe Wiring

The Moisture Probe must be wired with a shielded 6-conductor cable,
terminating at the Command Alkon Manual Station. The cable must meet
the following specifications:
— Wire Gauge: #l8 (1300' max) - #24 (300' max)
— Overall Cable Diameter: 0.32" max
— Insulation Material: PVC, teflon
— Shield: 85% min, l00 preferred
— Suggested Type:
Belden 9536 (Command Alkon PN-l9320) 300' max
Belden 9506 (Command Alkon PN-20393) l300' max

68 12/27/16
 J-Box

Caution!
This equipment was manufactured to operate under
normal “dry” industrial conditions. Extreme
temperature or weather conditions can and will cause
damage to the equipment and bodily harm.
Per IEC 61010, no operator access is permitted in this
unit! Service should only be performed by qualified
personnel.
A Circuit Breaker (rated at 20 Amperes 240 Volts AC)
should be installed near the J-Box, be easily
distinguishable from other controls, and labeled to
indicate that it is the Disconnect device.

Warning!
HAZARDOUS LIVE VOLTAGE PRESENT! This equipment
must be isolated or disconnected before it is accessed.

Note: An earth ground connection must be installed according to local

building code and industrial requirements.

Voltage - 120VAC J-Box

110 to 120 VAC.

Voltage - 240VAC J-Box

200 to 240 VAC.

Frequency
50/60 Hz.

Current
20 Amp.

Plant Outputs - 120VAC J-Box

3A Each Max. 10A Total.

Plant Outputs - 240VAC J-Box

1A Each Max. 10A Total.

Power Supply Range

90 to 260 VAC, 49.5 to 60.5 Hz.

12/27/16 69
 Weight
95 lbs.

Dimensions
Height: 30 1/4”, Width: 24 3/8”, Depth: 8 5/8”.

Note: Use proper lifting techniques when lifting the Manual Station or
the J-Box. Always lift with your legs, keeping your back as
straight up and down as possible. Two people should be used to
lift the J-Box.

Operating Temperature
+10oC to +40oC.

Storage Temperature
-20oC to +50oC.

Relative Humidity
10% to 90%, non-condensing.

Altitude
0 to 3000 m.

Maximum Number of Plant Connections per Board

24.

Cleaning
Clean the exterior of the J-Box with a mild soap solution and a soft towel.
No liquids should be introduced to the interior of the J-Box!

Labeling
All operator controls and field-installable connectors are labeled according
to their use.
The equipment identification label is a permanent, adhesive, destructible
mylar label at the top of the left side panel. A unique serial number is
added at the Command Alkon factory with an indelible ink marker or
stamp.

70 12/27/16
 Input Modules
Input Module Voltage CAI Part No.
Crydom M-IDC5N 12 VDC 24900-A
Crydom M-IDC5N 24 VAC 24900-A
Grayhill 70M-IAC5 120 VAC 22828
Grayhill 70M-IAC5A 240 VAC 22830

Crydom Input Modules - General Specs

Crydom Input Module M-IDC5N

12/27/16 71
 Grayhill Input Module 70M - General

Grayhill Input Module 70M-IAC5

Grayhill Input Module 70M-IAC5A

72 12/27/16
 Output Modules
Output Module Voltage CAI Part No.
Grayhill 70M-ODC5 12 VDC 24465
Crydom M-OACUA (M-OAC5A) 24 VAC 25524
Crydom M-OACUA (M-OAC5A) 120 VAC 25524
Crydom M-OACUA (M-OAC5A) 240 VAC 25524

Grayhill Output Module 70M - General

Grayhill Output Module 70M-OCD5

12/27/16 73
 Crydom Output Module M-OAC5A

74 12/27/16
 Load Cell Color Codes
Manufacturer +Excitation - Excitation +Signal - Signal Shield +Sense - Sense
A&D Engineering RED WHITE GREEN BLUE YELLOW

Allegany GREEN BLACK WHITE RED Bare

Artech RED BLACK GREEN WHITE Bare

Beowulf GREEN BLACK WHITE RED Bare

BLH GREEN BLACK WHITE RED YELLOW

Celtron RED BLACK GREEN WHITE Bare

Cardinal GREEN BLACK WHITE RED Bare

Dillon GREEN WHITE BLACK RED Orange

Electroscale RED BLACK GREEN WHITE Bare

Flintec GREEN BLACK WHITE RED YELLOW

Force Measurement RED BLACK GREEN WHITE Bare

GSE RED BLACK WHITE GREEN Bare

HBM GREEN BLACK WHITE RED YELLOW

Interface RED BLACK GREEN WHITE Bare

Kubota RED WHITE GREEN BLUE YELLOW

Mettler Toledo WHITE BLUE GREEN BLACK ORANGE YELLOW RED

National Scale GREEN BLACK WHITE RED YELLOW

NCI RED BLACK WHITE GREEN Bare YELLOW BLUE

Pennsylvania ORANGE BLUE GREEN WHITE Bare

Philips RED BLUE GREEN GRAY Bare

Revere Transducers RED BLACK GREEN WHITE ORANGE

Rice Lake Weighing RED BLACK GREEN WHITE Bare

Sensortronics RED BLACK GREEN WHITE Bare

Sensotec RED BLACK WHITE GREEN Bare

Strainsert RED BLACK GREEN WHITE Bare

T-Hydronics RED BLACK GREEN WHITE Bare

Tedea Huntleigh GREEN BLACK RED WHITE Bare BLUE BROWN

Toledo GREEN BLACK WHITE RED YELLOW

Totalcomp RED BLACK GREEN WHITE Bare

Transducers Inc. RED BLACK GREEN WHITE ORANGE

Weigh-Tronix GREEN BLACK WHITE RED WHITE/ORANGE

• Color code complies with ISA S37.8-1975 “Specifications for Tests for
strain gauge force transducers” also per Western Regional Strain Gauge
Committee Standard.
• This cross reference chart allows you to replace one brand load cell with
another when they have the same output (mv/v) and the same physical
size.
• To correct an instrument that displays a weight in the wrong direction,
interchange the +Output and -Output connections.

12/27/16 75
 Example: If the load on the scale is increasing and the instrument
display is decreasing, reverse the Output connections. Do not reverse
the Excitation connections. The readout should now display increasing
readings with increasing load.
This information was reprinted with the permission of Totalcomp, Inc., 13-01
Pollitt Drive, Fair Lawn NJ 07410
201-797-2718, 800-631-0347
©Copyright 1996 Totalcomp, Inc.
Not to be copied or duplicated for any purpose without consent of copyright
owner. All rights reserved.

Mean Time Before Failure - Manual Station

The total Mean Time Before Failure (MTBF) for the Manual Station, as
determined by Commercial/Bellcore Method 1, is 39,742.83 Hours.

Mean Time Before Failure - J-Box

The total Mean Time Before Failure (MTBF) for the J-Box, as determined by
Commercial/Bellcore Method 1, is 36,529.52 Hours.

76 12/27/16
 E-Z CAL Parts Replacement Guidelines
Topics
Manual Station
Boards
IO Modules
J-Box Fuses
Spare Parts List

Manual Station

Caution!
Parts located in the interior of the Manual Station are low
voltage and static sensitive. Only authorized service
personnel should replace these parts.

Boards

Risk of Electrical Shock!

High voltage is present in the power supply area once the
back cover has been removed! Use extreme caution when
working on the power supply. Improper replacement could
result in equipment damage or bodily injury and should
only be done by qualified service personnel!

Power down the Manual Station and disconnect the power cord. All boards
except for the base board and the power supply are attached with standoffs
and connectors. The base board and power supply are attached with screws.

IO Modules

Risk of Electrical Shock!

Before replacing any components in the Manual Station,
disconnect the power. Failure to comply with these
guidelines can result in severe equipment damage or bodily
injury! Only qualified service personnel should replace
components in this unit.

1. The output and input modules in the J-Box are located in the
center of the 22821 board. Carefully remove the clear milar strip
then gently pull out the old module. (See the 22821 Opto Board
Drawing for reference.)

12/27/16 77
 2. Insert a new module with the SAME electrical specifications as
the one being removed.
Input Module: Insert the Yellow IAC module into the socket and place
the three-position black jumper in the correct reference position.
Connect the proper gauge wire to the corresponding terminal at the
bottom of the board.
Output Module: Insert the Black OAC module into the socket and place
the three-position black jumper in the correct reference position.
Connect the proper gauge wire to the corresponding terminal at the
bottom of the board.
3. Mark up the appropriate wiring prints and send them to the
Command Alkon Service Department.

J-Box Fuses
As a troubleshooting aid, a neon bulb is located near each fuse or holder and
is lit if the fuse blows.

Warning!
Disconnect the power before replacing blown fuses.

Caution!
Use caution when removing the fuse so that the glass
doesn’t break and cause you bodily harm.
The new fuse must not be rated higher than what is
required for that fuse location. Fuse types and ratings
are shown in the Spare Parts List.

78 12/27/16
 Spare Parts List

Item Command Alkon Manufacturer’s

P/N P/N
Fuse, Time Delay, 10 Amp 250 Volt, 1/ 23626 BUSS MDA-10
4” x 1 1/4”
Fuse, GMA, Quck, 5 Amp 250 Volt, 5 x 23045 Little Fuse 217005
20 mm
Fuse, GDB, Quick Acting, 5 Amp 250 23045 BUSS GDB-5A
Volt, 5 x 20 mm
Relay, 8 Blade, DPDT, 120 VAC 16 Amp 23777
Relay, 11 Blade, EPDT, 120 VAC 16 23778
Amp
Socket, 8 Pin 23781
Socket, 11 Pin 23782
Module, mini opto, IAC5, 120 VAC, 22828
Input, Yellow
Module, mini opto, IAC5, 220 VAC, 22830
Input, Yellow
Module, mini opto, OAC5, 120 VAC, 22829
Input, Black
Module, mini opto, OAC5, 220 VAC, 22831
Input, Black

12/27/16 79
 Index

E
E-Z Cal 8
Calibration Procedure
Do This First 56
Generic Analog Input Calibration 61
Moisture Probe Calibration 60
Scale Calibration 57
Calibration Procedures 55
Components 13
I/O Box 16
Manual Station 13
Configuration Settings - Viewing 62
General Operation 32
Clearing a Bad Cell Message 35
E-Z Cal Displays 34
If Communication to the Batching PC is Lost 38
Operating Plant Equipment 33
Powering On/Off 32
GPL Software - Offer of Source Code 12
Installation and Wiring 20
120 Volt Power Connections 30
240 Volt Power Connections 31
I/O Box Power Source 120VAC 27
I/O Box Power Source 240VAC 27
I/O Box Supply Wiring 27
I/O Box Voltage Jumper Settings 27
I/O Cable Connections 29
J-Box - Inside View 26
Manual Station - Inside View 24
Manual Station CPU - Legacy 25
Manual Station Power Source and Supply 22
Mounting 21
Ventilation 21
Water and Moisture 21
Overview 10
Parts Replacement Guidelines 78
I/O Box 79
Manual Station 78
Spare Parts List 80
Regulatory Compliance 11
Setup and Calibration 39

12/27/16 81
 Calibration Enable Switch 41
Operating Modes 39
Setup Buttons 40
Setup Procedure
Do This First 46
Set Up Counter 50
Set Up Generic Analog Input 53
Set Up Moisture Probe 52
Set Up Scale 47
Setup Procedures 45
Technical Specifications 64
I/O Box 70
Input Modules 72
Load Cell Color Codes 76
Manual Station 64
Mean Time Before Failure - I/O Box 77
Mean Time Before Failure - Manual Station 77
Meter Counter 69
Moisture Probe Interface 69
Output Modules 74
Scale Interface 67
E-Z CAL IP
General Operation
Testing the MPI Module 36
I
Introduction 5
Audience 5
Purpose 5
Revision Summary 5
M
MPI Module - Testing 36
T
Testing 36

82 12/27/16