CONTENTS

01. SPECIFICATIONS

02. DESCRIPTION

03. INSTALLATION

04. OPERATION & CALIBRATION

05. SYMPTOMS & FAULTS

06. REPLACEABLE SPARES

07. TEST REPORTS

1. TRACEABILITY CERTIFICATE

2. SYSTEM CALIBRATION REPORT

3. LOADCELL CALIBRATION REPORT

 1.0 DESCRIPTION

INDICATOR
The system consists of 8 Nos seprate platform which is resting on 4No.s of highly
precession Double ended shear beam Loadcell of 10 ton capacity each . the Rails are
mounted on the I beam to avoid shearing of Load. 4 loadcell of platform is connected to the
Junction Box and loadcell output is taken to the programmable digital load indicator .

The Load indicator Model EW/PF/752/14 is a field programmable indicator designed to be used with strain gauge
based transducers to measure parameters like load, pressure, torque etc. It can take an input of 30 mV DC and
can read up to a maximum of 60000 counts with selectable resolution of 0 / 5. Each indicator has different address
starting from 01 to 08. The RS485 output of the indicator is connected to each indicator serialwise and it is
converted to RS232 through a convertor and it connected to the Computer. The Computer software program is
made to identify the each platform and scan the weight.

The main features of the indicator are :

1. Programmable range up to 60000
2. Calibration through keyboard.
3. Taring through keyboard.
4. Program and tare retention facility.
5. RS485 output.

The indicator can be programmed through keyboard for range, resolution, calibration, zero track
value and decimal point. The front panel has got a digital display and a keyboard. The display
can indicate the following.

1. Tare facility - "TArE"

2 Range - " rAnGE "
3. Resolution - "rSn"
4. Calibration - "S-CAL "
5. Zero Track - “ O-trAC”
6. Address - “ Addr ”
 02. SPECIFICATIONS

LOAD INDICATOR

1. Type : Microprocessor Based

2. Input sensitivity : Last digit-2.5 micro volt
3. Nominal input : 30 milli volt
4. Range : Programmable
5. Accuracy : 0.5% of F.S.
6. Input impedance : Greater than 10 Meg.ohms
7. Address : 0001 to 0008
8. Range : 10000
9. Resolution : 10

LOADCELL

1. Type : Double ended Shear beam

2. Capacity : 10 Tons
3. Sensitivity : 2.5mV/V
4. Guage : 350Ω
5. Excitation : 10 V Black & green
6. Output : 0 – 25mV Red & white

******
 Programmable parameters

Range selection : Through keyboard

Tare : Through keyboard
Decimal points : None to three

Bridge excitation : +/-5V dc for a max. 4 load cells.

: of 350 ohms of input impedance.

Display : 6 digit, 13 mm height, 7 segment high

intensity Red LED.
Output
RS485 Port : 9600 baud, N,8,1
Transmission : TXD, GND (2 wire)
Format : ‘ ‘ or ’-‘, MSD - - - - LSD

REMOTE DISPLAY : Provision for 6 digit serial remote display.

Power supply : 230V ac +/-10%, 50Hz, 12VA

General

Operating temp. : 5 to 50 deg.C.

Physical : metal enclosure with enamel paint finish
 03. INSTALLATION

The power supply should be made available with a proper earthing within 2 meters of the indicator.
Connect the instrument to ac mains through the connector provided at the rear of the indicator. Mains
voltage to be used is given in the specification

INSTALLATION:_

Connect the transducer to the equipment through the connector provided at the back of the
indicator. Connect the Remote display. Switch on the Indicator.
Now the equipment is ready to be configured for measurement as given in the following
sections.
04. OPERATION & CALIBRATION

System configuration may be carried out using the keyboard.

CONFIGURING THE SYSTEM
4.1. RANGE SETTING:
1. Press SET/PGM key, the display shows “ ---- “. This is PASSWORD Mode.
Press INC(^), SHIFT( > ) Key, SET & STR keys in that sequence.
2. The display shows `rAnge'. Press STR key the display changes to `x0000' with 1st digit
blinking (X may be set to 0 to 6) by using (^) increment key. (See NOTE).
3. Use the SHIFT (>) key to move the blinking to the right side digit. Change the value by
using INC key. Continue this step till the required value is entered.
4. Press TARE/STR key to store the set value of range. Now the instrument automatically
goes to the next programming parameter i.e. resolution.

4.2. RESOLUTION SETTING:

The display shows `rSn-X' with ‘r’ blinking and the X is the previous resolution. If no change
is required press INC key and the display will go to next programming parameter Decimal
Point. If a change is required, press STR key and the blinking display changes to ‘X'.
1. Use increment key (^) and set the last digit to any one of the values given viz 5, 0.
2. Press TARE/STR to store the above setting. Display goes automatically to next
programming parameter i.e. DECIMAL POINT.

4.3. DECIMAL POINT SETTING: N/A

The decimal point for weigh bridge application is not implemented.
Display shows dP- X with ‘d’ blinking. If no change is required press INC key and the
display will go to next programming parameter S-CAL. If a change is required, press
STR key and the blinking display changes to ‘X'.
1. Press increment key (^) for selecting the decimal point (i.e. 0 to 5).
2. Press TARE/STR key and store the set value, display automatically goes to next
programming parameter viz. S-CAL (Software Calibration). This is for software calibration,
which is explained later. Now Press the INC key. The system goes to the next parameter
Zero Track Value.
 4.4. ZERO TRACK VALUE SETTING N/A
The display shows `O-trAC’ with ‘-’ blinking. If no change is required press SET key and the
system will come out of programming mode. If a change is required, press STR key and the
blinking display changes to ‘ XY', where XY is the previous value.
1. Press the increment key (^) and the value changes by one count and Pressing and holding the
INC key will continuously increases the value. The maximum O-track value is 09.
2. Press TARE/STR to store the above setting. Display goes automatically to next
programming parameter i.e. DECIMAL POINT.
3. Use the SHIFT (>) key to move the blinking to the right side digit. Change the value by using
INC key. Continue this step till the required value is entered.
4. Press TARE/STR key to store the set value of range. Now the instrument automatically comes
out of programming mode and shows the weight.
Note: Any Zero Track value above 100 is limited to 100 only.
4.5 ADDRESS SETTING
The display shows “Addr - ” ‘-’ blinking. If no change is required press SET key and the
system will come out of programming mode. If a change is required, press STR key and the
blinking display changes to ‘ XY', where XY is the previous value.
1. Press the increment key (^) and the value changes by one count and Pressing and holding the
INC key will continuously increases the value. The maximum O-track value is 09.

4.5. CALIBRATION :
Ensure that there is no load on the transducer. Keep TARE/STR key pressed and switch ON the
instrument with the switch provided at the back panel. The system will display `H-CAL’. Release
TARE/STR key once the ‘H-CAL’ has appeared. Now the equipment is ready for Hardware
TARE & CALIBRATION and will display a reading corresponding to initial unbalance of transducer.

Should the unbalance be more than 5% of the Range then switch OFF the indicator and open the
equipment. Switch ON and adjust TARE potentiometer on ADC card to zero the display.

Place a known weight of more than 60% of the capacity. Now the indicator should read the same value.
If not adjust the SPAN pot meter on the ADC Card to get the correct value an remove the
Load. This completes the Hardware Tare & Calibration operation and close the Indicator.
Switch the equipment ON again. It will show ” EUUI “ momentarily and then zero or some reading.
Now press TARE key, the display will show TARE . Now press the INC(^) key. The reading will be
zeroed and indicator will read zero value.
SOFTWARE CALIBRATION:-

With out any load on the load cell, make the reading zero by pressing the TARE & INC keys and load
the load cell with a known weight approximately 60 – 80% of the capacity. If the displayed value is
equal to the load then no further calibration is required. If the displayed value is not equal to the load
and the difference is more than +/- 10% of the actual load, the Hardware Calibration is required.
If the difference is less than +/- 10%, then proceed with the Software Calibration as given below.

Press the SET key, the display will show go to PASS WORD Mode and will show “ ----“.
Now Press SHIFT(>), INC (^), SET and STR keys successively. Now the display shows ‘S-CAL’
with ‘S’ blinking. If no change is required press SET key and the display will come out of the
Calibration mode will display the load.
If a change is required, press STR key and the display changes to ‘Xxxxx', which is the
previously programmed CAL VALUE, where `X' blinks, using INC (^) and SHIFT(>) keys , set the
display value equal to the Load on the load cell. Now Press `TARE/STR' key. It now comes to
weighing mode, display shows the load on the load cell.

Now the indicator is ready for operation. The indication displayed on the front panel is also

transmitted to the Remote Display and also through RS485 port to a computer.

The RS232 port transmits at 9600 baud rate No Parity 8 Data bits and 1 Stop bit.

The data is transmitted in ASCII.

The First character is the polarity of the indication. Space for +ve and – for negative readings.

The Second to Seventh characters are the indication from MSD to LSD.
 05. SYMPTOMS & FAULTS

SYMPTOMS POSSIBLE FAULT

1. Blinking display or a. Low power supply

unsteady readings b. Bad earthing
c. Loadcell cable not connected in the same sequence as in the drawing.

2. The display shows `OR’ a. Loadcell cable open (in this condition
(over range) indicator will not sense any key
(operation)
b. System overload.
c. Loadcell not connected in the same
sequence as shown in the drawing.

3. The indicator display other a. Calibration disturbed.(required

than actual reading, but steady re-calibration)

4. The display shows ‘OL’ a. Over loaded. The indicated load is

greater than Range + 9 times the
resolution.

06. REPLACEABLE SPARES

1. ADC CARD - MRS-ADC-01

2. DISPLAY CARD - DT-DIS-6DIG-LED
3. DRIVER CARD - DT IO card as R Display driver.
4. TRANSFORMER - DT-T05
5. COMMUNICATION - DT RS485 Card.
 CONTENTS

01. DESCRIPTION

02. SPECIFICATIONS

03. INSTALLATION

04. OPERATION & CALIBRATION

05. SYMPTOMS & FAULTS

06. REPLACEABLE SPARES

 TECHNICAL SPECIFICATION

SYSTEM : RAIL WHEEL WEIGHING SYSTEM

TOTAL CAPACITY : 60 TONNES

NO. OF WEIGHING PLATFORM : 8

SIZE OF WEIGHING PLATFORM : 1200 X 300mm

CAPACITY OF EACH PLATFORM : 7.5TONNES

SAFE OVERLOAD : 150% OF RATED CAPACITY

MEASURING TRACK : STANDARD GUAGE – 1435MM

BROAD GUAGE - 1676MM

NO. OF L0ADCELL PER PLATFORM : 4Nos.

TOTAL NO. OF LOADCELL : 32 Nos.

TYPE OF LOADCELL : STRAIN GUAGE BASED DOUBLE

ENDED SHEAR BEAM

CAPACITY OF EACH LOADCELL : 10 TONNES

DISPLAY : DIGITAL 13MM LED

RESOLUTION : 10 Kg

ACCURACY : 0.5% OF F.S.

NO. OF INDICATORS : 8

COMPUTER INTERFACE : RS232

OPERATING TEMPARATURE : 5º C to 55º C

METHOD OF WEIGHING : STATIC

POWER SUPPLY : 230V 50Hz SINGLE PHASE

****
 CALIBRATION CERTIFICATE GROUP = D

INDICATOR LOADCELLS
JOB ORDER : 049/08 MODEL NO : EW/PF/752/14 MODEL NO : EDSBS
CUSTOMER: M/s B.E.M.L SERIAL NO : 44708 CAPACITY : 10TON
CAPACITY : 7500Kg SL. NO. : 081157, 081158
RESOLUTION : 10Kg 081159, 081160
______________________________________________________________________________
Actual load Observed Reading Reference Indicator Error
in Kg in Kg reading in Kg in Kg
______________________________________________________________________________

750 750 750 Nill

1500 1500 1500 Nill

2250 2250 2250 Nill

3000 3000 3000 Nill

3750 3750 3750 NIll

4500 4510 4506 10

5250 5260 5257 10

6000 6000 6000 Nill

6750 6750 6749 Nill

7500 7500 7500 Nill

______________________________________________________________________________

Loading Device = UTM Std .Loadcell Ref := SL NO. : 5140

MODEL NO, : CC100
Std. Indicator Ref : = SL. No.5142B CAPACITY. : 20Ton
MODEL NO. : LI450

TESTED BY :-
H.O.D :-
DATE :-
 CALIBRATION CERTIFICATE GROUP = H

INDICATOR LOADCELLS
JOB ORDER : 049/08 MODEL NO : EW/PF/752/14 MODEL NO. : EDSBS
CUSTOMER : M/s B.E.M.L SERIAL NO : 44808 CAPACITY. : 10TON
CAPACITY : 7500Kg SERIAL NO. : 081169,081170
RESOLUTION : 10Kg 081171,081172
___________________________________________________________________________________
Actual load Observed Reading Reference Indicator Error
in Kg in Kg reading in Kg in Kg
___________________________________________________________________________________

750 750 750 Nill

1500 1510 1508 10

2250 2250 2250 Nill

3000 3000 3000 Nill

3750 3740 3745 - 10

4500 4500 4500 Nill

5250 5250 5250 Nill

6000 6000 6000 Nill

6750 6750 6749 Nill

7500 7500 7500 Nill

________________________________________________________________________

Loading Device = UTM Std .Loadcell Ref := SL NO. : 5140

MODEL NO, : CC100
Std. Indicator Ref : = SL. No.5142B CAPACITY. : 20Ton
MODEL NO. : LI450

TESTED BY :-
H.O.D :-
DATE :-
 CALIBRATION CERTIFICATE GROUP = E

INDICATOR LOADELLS
JOB ORDER : 049/08 MODEL NO : EW/PF/752/14 MODEL NO. : EDSBS
CUSTOMER : M/s B.E.M.L SERIAL NO : 44908 CAPACITY. : 10TON
CAPACITY : 7500Kg SERIAL NO. : 081145,081146
RESOLUTION : 10 Kg 081147, 081148
_____________________________________________________________________________________
Actual load Observed Reading Reference Indicator Error
in Kg in Kg reading in Kg in Kg
______________________________________________________________________________________

750 750 750 Nill

1500 1500 1502 Nill

2250 2250 2250 Nill

3000 2990 2994 -10

3750 3750 3751 Nill

4500 4500 4500 Nill

5250 5260 5257 10

6000 6000 6000 Nill

6750 6750 6753 Nill

7500 7500 7500 Nill

____________________________________________________________________________________

Loading Device = UTM Std .Loadcell Ref := SL NO. : 5140

MODEL NO, : CC100
Std. Indicator Ref : = SL. No.5142B CAPACITY. : 20Ton
MODEL NO. : LI450

TESTED BY :-
H.O.D :-
DATE :-
 CALIBRATION CERTIFICATE GROUP = C

JOB ORDER : 049/08 MODEL NO : EW/PF/752/14 MODEL NO. : EDSBS

CUSTOMER : M/s B.E.M.L SERIAL NO : 45008 CAPACITY. ; 10 TON
CAPACITY : 7500Kg SERIAL NO. : 081141,081142
RESOLUTION : 10Kg 081143,081144
___________________________________________________________________________________
Actual load Observed Reading Reference Indicator Error
in Kg in Kg reading in Kg in Kg
___________________________________________________________________________________

750 750 750 Nill

1500 1500 1500 Nill

2250 2240 2247 -10

3000 3000 3000 Nill

3750 3750 3751 Nill

4500 4500 4500 Nill

5250 5250 5251 Nill

6000 6000 6000 Nill

6750 6750 6752 Nill

7500 7510 7508 10

________________________________________________________________________________

Loading Device = UTM Std .Loadcell Ref := SL NO. : 5140

MODEL NO, : CC100
Std. Indicator Ref : = SL. No.5142B CAPACITY. : 20Ton
MODEL NO. : LI450

TESTED BY :-
H.O.D :-
DATE :-
 CALIBRATION CERTIFICATE GROUP = F

INDICATOR LOADCELLS
JOB ORDER : 049/08 MODEL NO : EW/PF/752/14 MODEL NO. : EDSBS
CUSTOMER : M/s B.E.M.L SERIAL NO : 45108 CAPACITY. : 10 TON
CAPACITY : 7500Kg SERIAL NO. : 081149,081150
RESOLUTION : 10 Kg 081151,081152
_____________________________________________________________________________________________
Actual load Observed Reading Reference Indicator Error
in Kg in Kg reading in Kg in Kg
______________________________________________________________________________________

750 750 750 Nill

1500 1500 1501 Nill

2250 2250 2250 Nill

3000 3000 3000 Nill

3750 3750 3752 Nill

4500 4500 4500 Nill

5250 5250 5250 Nill

6000 6000 6000 Nill

6750 6740 6744 -10

7500 7500 7500 Nill

______________________________________________________________________________________
Loading Device = UTM Std .Loadcell Ref := SL NO. : 5140
MODEL NO, : CC100
Std. Indicator Ref : = SL. No.5142B CAPACITY. : 20Ton
MODEL NO. : LI450

TESTED BY :-
H.O.D :-
DATE :-
 CALIBRATION CERTIFICATE GROUP = A

INDICATOR LOADCELLS
JOB ORDER :049/08 MODEL NO : EW/PF/752/14 MODEL : EDSBS
CUSTOMER :M/s B.E.M.L SERIAL NO : 45208 CAPACITY : 10TON
CAPACITY : 7500Kg SERIAL NO. : 081165,081166
RESOLUTION : 10Kg 081167,081168
___________________________________________________________________________________
Actual load Observed Reading Reference Indicator Error
in Kg in Kg reading in Kg in Kg
____________________________________________________________________________________

750 750 750 Nill

1500 1490 1494 -10

2250 2250 2250 Nill

3000 3000 3000 Nill

3750 3750 3750 Nill

4500 4510 4507 10

5250 5250 5250 Nill

6000 6000 6000 Nill

6750 6750 6752 Nill

7500 7500 7500 Nill

____________________________________________________________________________________

Loading Device = UTM Std .Loadcell Ref := SL NO. : 5140

MODEL NO, : CC100
Std. Indicator Ref : = SL. No.5142B CAPACITY. : 20Ton
MODEL NO. : LI450

TESTED BY :-
H.O.D :-
 DATE :-

CALIBRATION CERTIFICATE GROUP = G

INDICATOR LOADCELLS
JOB ORDER : 049/08 MODEL NO : EW/PF/752/14 MODEL. : EDSBS
CUSTOMER : M/s B.E.M.L SERIAL NO : 45308 CAPACITY. : 10 TON
CAPACITY : 7500Kg SERIAL NO.: 081161,081162
RESOLUTION. : 10 Kg 081163,081164
___________________________________________________________________________________
Actual load Observed Reading Reference Indicator Error
in Kg in Kg reading in Kg in Kg
___________________________________________________________________________________

750 750 750 Nill

1500 1510 1508 10

2250 2250 2250 Nill

3000 3000 3000 Nill

3750 3750 3752 Nill

4500 4500 4500 Nill

5250 5250 5251 Nill

6000 6000 6002 Nill

6750 6750 6750 Nill

7500 7500 7500 Nill

______________________________________________________________________________________

Loading Device = UTM Std .Loadcell Ref := SL NO. : 5140

MODEL NO, : CC100
Std. Indicator Ref : = SL. No.5142B CAPACITY. : 20Ton
MODEL NO. : LI450

TESTED BY :-
H.O.D :-
DATE :-
 CALIBRATION CERTIFICATE GROUP = B

INDICATOR LOADCELLS
JOB ORDER : 049/08 MODEL NO : EW/PF/752/14 MODEL NO. : EDSBS
CUSTOMER : M/s B.E.M.L SERIAL NO : 45408 CAPACITY. : 10 TON
CAPACITY : 7500Kg SERIAL NO. : 081153,081154
RESOLUTION : 10 TON 081155,081156
___________________________________________________________________________________
Actual load Observed Reading Reference Indicator Error
in Kg in Kg reading in Kg in Kg
____________________________________________________________________________________

750 740 743 - 10

1500 1500 1502 Nill

2250 2250 2250 Nill

3000 3000 3000 Nill

3750 3750 3748 Nill

4500 4490 4494 -10

5250 5250 5250 Nill

6000 6000 6000 Nill

6750 6760 6758 10

7500 7500 7500 Nill

_____________________________________________________________________________________

Loading Device = UTM Std .Loadcell Ref := SL NO. : 5140

MODEL NO, : CC100
Std. Indicator Ref : = SL. No.5142B CAPACITY. : 20Ton
MODEL NO. : LI450

TESTED BY :-
H.O.D :-
DATE :-
 CALIBRATION CERTIFICATE

JOB ORDER : 019/08 MODEL NO : EW/WB/44/14

CUSTOMER : M/s B.E.M.L BANGALORE SERIAL NO : 44008
CAPACITY : 40000Kg
RESOLUTION : 10Kg
_____________________________________________________________________
Actual load Observed Reading Error
in Kg in Kg in Kg
___________________________________________________________________

4000 4000 Nill

8000 08000 Nill

12000 12010 10

16000 16000 Nill

20000 20000 Nill

24000 24000 Nill

28000 28000 Nill

32000 32000 Nill

36000 36010 10

40000 40000 Nill

________________________________________________________________________

Loading Device = UTM

TESTED BY :-
H.O.D :-

DATE :-
JOB NO : 049/08
CUSTOMER : M/s B.E.M.L
SYSTEM : RAIL WHEEL WEIGHING SYSTEM

THE INDICATOR WAS TESTED FOR

01.VISUAL : No damage found.

02.DIMENSIONAL : Found within tolerance as per

relevant drgs.

03.VIBRATION TEST : System was subjected to vibration

for 15 min and performance thereafter checked and found ok.

04.TEMPERATURE TEST : Drift due to high temp checked

and found within limits.

05.SUPPLY VOLTAGE : 230 VAC +/- 10% ,50Hz +/-2%.

06.ACCURACY : Found within +/- 0.5% of F.S.

07.DISPLAY & READ OUT : Checked and found ok.

08.KEYPAD FUNCTIONS : Checked and found ok.

09.LINEARITY & REPEATABILITY : Checked and found ok.

10.RS232 COMMUNICATION : Checked and found ok

TESTED BY :-
H.O.D :-

DATE :-
JOB NO : 019/08
CUSTOMER : M/s B.E.M.L
SYSTEM : LORRY WEIGHBRIDGE

THE INDICATOR WAS TESTED FOR

01.VISUAL : No damage found.

02.DIMENSIONAL : Found within tolerance as per

relevant drgs.

03.VIBRATION TEST : System was subjected to vibration

for 15 min and performance thereafter checked and found ok.

04.TEMPERATURE TEST : Drift due to high temp checked

and found within limits.

05.SUPPLY VOLTAGE : 230 VAC +/- 10% ,50Hz +/-2%.

06.ACCURACY : Found within +/- 0.5% of F.S.

07.DISPLAY & READ OUT : Checked and found ok.

08.KEYPAD FUNCTIONS : Checked and found ok.

09.LINEARITY & REPEATABILITY : Checked and found ok.

10.RS232 COMMUNICATION : Checked and found ok

TESTED BY :-
H.O.D :-

DATE :-
07. 1. TRACEABILITY CERTIFICATE
07. 2. SYSTEM CALIBRATION REPORT
07. 3. LOADCELL CALIBRATION REPORT