LOAD CELL TROUBLESHOOTING GUIDE
Electrical Tests
Any test result that does not match the parameters in the datasheet/calibration certificate of the load cell indicates a
problem.
a) Zero Balance:
With no load on the cell, connect it to a stable power source. Measure the output voltage with a multimeter, convert to
mV/V (output in mV divided by input in V), and compare against the load cell’s calibration certificate to ensure it’s within
specification.
b) Zero Return:
After checking zero balance, load the cell to 50-100% capacity for 5 seconds, then remove the load. The mV/V output
should return to within the specified tolerance, indicating proper function.
c) Insulation Resistance:
Measure the insulation resistance between the wire leads and the load cell’s metal body using a multimeter. A reading
below 2 GΩ suggests inadequate insulation, whereas an ideal reading exceeds 5 GΩ.
d) Resistance Measurements:
Check the input and output resistance values using a multimeter with at least 0.025 Ω accuracy. Values diverging by
more than 0.1 Ω from the calibration certificate indicate a fault.
e) Strain Gauge Resistance:
Individually test each strain gauge’s resistance, referencing the load cell’s wiring diagram for correct testing points.
Discrepancies here can pinpoint specific issues within the strain gauge array.
f) Input/Output Resistance:
Resistances exceeding 3 kΩ typically indicate damage from electrical surges or lightning strikes. Confirm with the
calibration sheet for expected resistance values.
Zero Balance Test:
Conduct this test if:
1. Instrument is showing Over-Range Error exceeding the total rated capacity of the load cell.
2. Instrument does not respond until a specific and consistent load is applied.
3. Other load cell symptoms that suggest damage, such as a constant Zero Shift.
Instructions:
Remove any dead load on the load cell and make sure there is nothing on the load cell. Connect the Ex+ and Ex− leads of
the load cell to a reliable and known voltage supplier (5-15VDC). Measure the Voltage between the Si+ and Si− using a
Voltmeter (mV range). Keep the load cell at no load condition when take the measurements.
Then, calculate the zero unbalance of the load cell as Voltmeter output(mV)/supply voltage.
Compare the results against the zero balance specifications on the load cell datasheet. For example:
Result 1: The zero unbalance is within the specification.
Conclusion: Load cell is functioning properly. No action needed.
Result 2: The zero unbalance is exceeded the specification.
Conclusion: The load cell has been stressed/overloaded, and the elastic range (useful range) of the load cell has been
altered. In this case, Anyload recommends replacingthis load cell to get the best performance from the weighing system.
And also,it is recommended to closely monitor the system to identify the root cause foroverloading to prevent this issue
happening again in the future.
Bridge Resistance Test (Overload Verification Test):
Conduct this test if:
1. Instrument is showing an Over-Range Error where the displayed load exceeds the total rated capacity of the load
cell(s).
2. Instrument does not respond until a specific and persistent load is applied to the scale.
Instructions:
Use an ohmmeter/multimeter and measure the terminal resistances below.
Ex+ to Si+
Ex+ to Si−
Ex− to Si+
Ex− to Si−
Result 1: The resistance readings are all almost equal.
Conclusion: Load sensor is functioning properly. No action needed.
Result 2: Two of above values are higher and almost equal while other two values are lower and almost equal.
Conclusion: Load cell has been overloaded.
