D 500BC-BOS: Bagging Scale Controller

Technology and reliability that carries weight
D 500BC-BOS
BAGGING SCALE CONTROLLER
REFERENCE MANUAL
ANNEX A containing installation drawings and connector pin outs comprises of 8 pages.
This manual contains proprietary information, protected by international copyright laws. No part
of this document may be reproduced without the written agreement of the publisher, LEON
ENGINEERING.
The information herein is believed to be both accurate and reliable. LEON ENGINEERING,
however, would be obliged to be informed if any errors occur. LEON ENGINEERING cannot
accept any liability for direct or indirect damages resulting from the use of this manual.
LEON ENGINEERING reserves the right to revise this manual and alter its content without
notification at any time.
Document Date Code Rev. Page
D500 BC-BOS REFERENCE MANUAL 13.10.98 D5BC_BOS.UM 0 1 of 47

TABLE OF CONTENTS
1. INTRODUCTION 3
2. EXTENT OF SUPPLY 4
3. SOFTWARE DESCRIPTION 5
4. FRONT PANEL SURVEY 10
5. DEFINITION OF TERMS 14
6. FUNCTION DESCRIPTION 17
7. INSTALLATION 24
7.1. MOUNTING 24
7.2. WIRING 24
7.3. AC POWER 24
8. POWER-UP 24
9. EQUIPMENT SET-UP 25
9.1. GENERAL 25
9.2. SETUP & CALIBRATION 25
10. OPERATION 32
11. ACCUMULATED RECIPE TOTALS 34
12. ERRORS 35
13. MAINTENANCE 38
14. SPECIFICATIONS 39
15. PROCESS INPUTS-OUTPUTS DESCRIPTION 42
16. SERIAL COMMUNICATION PORT 1 44
17. SERIAL COMMUNICATION PORT 2 45

1. INTRODUCTION
The LEON D500 BC is a autonomous microprocessor controlled unit specifically designed for
handling automatic filling of bags.
The standard configuration includes :
1. High accuracy analog to digital converter.

2. Front panel with high intensity LED indication, 23 key keyboard for data entry and
output.
3. Digital input-output (max 20) optoisolated to 2,5 KV.
4. CMOS memory for operational data files and real time clock with battery back-up.
5. Non volatile memory for system parameters and calibration data.
6. Printer output RS232C for data logging.
7. Serial communication 20mA for connecting to remote hosts, printers, displays.
8. All connections to the instrument are made with connectors for quick removal -
replacement
The microprocessor technology allows the instrument to perform in software all measuring
functions, operator input-output, automatic controls and sequences necessary for bag filling.
The setting of the unit is done through a guided keyboard operation, enabling the adaptation to
operating environment and system requirements.
Operation can be manual, local automatic, remote automatic.

Logging of batch and error protocols is standard (may be disabled).
The unit features internal diagnostics, software and hardware watchdog for resetting the process
outputs, in case of processor failure, and programmable alarms.
The operational data file handles 100 product recipes as standard, but may be modified on
request to handle other combinations (up to 300 recipes).
A recipe describes product dosing quantities, filling parameters and timing.
On start and during batching processor peripherals and operational data files are continuously
checked for validity thus ensuring a high standard of security.
The units supports both gross and net weight bag filling (setup selectable).

2. EXTENT OF SUPPLY
2.1. The standard supply includes :
1. The connection plug for the load cell cable.

2. The mains supply cable.
3. Spare fuses.
4. The process input - output connector(s).
5. The Printer connector.
6. The Host interface connector
7. This manual
2.2. Prior to unpacking the equipment, examine the carton for exterior shipping damage. If
any notify the carrier immediately. Remove the equipment from the carton and plastic bag.
Inspect extent of supply for any sign of damage. Save packaging material.
2.3. CAUTION : Do not run the unit until you have completed all installation procedures,
i.e.
1. Install the hardware.

2. Apply AC Power.
3. Calibrate the equipment.
4. Setup system parameters.
5. Setup recipe data.
6. Operate the control panel.

3. SOFTWARE DESCRIPTION
The performed functions may be divided into seven main groups : measuring, operational data,
control, logging, monitoring, setup, tests.
3.1. Measuring functions allow the direct connection of load cells or 0-10V or 0-20 mA
signals, and include :
- Instantaneous calculation of weight.

- Automatic Zero - Tare devices, plus Auto-Zero tracking
- Adjustable digital filter for optimum signal damping.
- Zero and SPAN calibrations.
3.2. Operational data functions aid the handling of recipe and results memory and include :
- Recipe inspect - modify.

- Zero tolerance - Settling time.
- Preact adjust - Tolerance control - Jogging time.
- Totalisers and batch counter inspect - clear - print - send to host.
- Print of - batch report - totalisers - recipe setpoints.
- Date time inspect - modify.
3.3. Control functions generate the dosing sequence and include :
- Operating modes - Enable/Disable Batching.

- Batching sequence with Coarse-Fine control and max dosing time.
- Tolerance control with automatic additional dosing.
- Remote recipe select.
- Discharge control.
- Gross or Net mode filling.
3.4. Logging functions

The unit may be connected to a printer to produce reports of batch protocols and error
messages.
The protocols printed may also be transmitted to a host computer.
Either none, anyone or both printer and host interface can be active at the same time.
3.5. Monitoring functions

The unit incorporates internal diagnostics, which alarm hardware failures operational
data corruption, and programming errors. During entry all system and operational
variables are validity checked with appropriate error indication.
During operation these values are continuously being checked.
All errors act on a cumulative alarm output.

Monitoring is performed on following :
- Processor and Peripherals.

- Analog to digital converter.
- Memory.
- Recipe execution (checksum - capacity ).
- Weight increasing / decreasing.
- Date-time
- Printer. Busy control with retransmit capability and time out.
- Host interface ACK/NAK, time out.
3.6. Set-up functions

The setup is performed entirely through the keypad and contains :
- Init Installation of default parameters to enable operation.

- Store Permanent store of parameters
- S-Cal Calibration of Zero and Span.
- Set-up System parameters inspect modify.
- A-Cal Analog output setup and calibration.
3.7. Test functions

Software routines have been built in to assist service personnel in pinpointing failures
and include :
- Display test.
- Keyboard test.
- Input test.
- Output test.
- Printer interface test.
- Host interface test.
- Analog to digital converter test.
- Analog output test.

3.8. BATCHING FUNCTIONS

The unit incorporates a number of batching features that make adaptation in different
operational situations possible.
A table of these functions is listed below. A description of the function follows in the
next pages of this chapter.
1 IN FLIGHT COMPENSATION IFC
2 REFEED / JOGGING JOG
3 FEEDING TIME MONITOR FTM
4 WEIGHT DECREASING SENSOR WDS
5 WEIGHT COMPARE INHIBIT TIMER WCI
6 FINE DELAY FDV
7 FINE - COARSE – FINE FCF
3.8.1 IN FLIGHT COMPENSATION ( IFC )

The inflight compensation function modifies the setpoint of each automatically dosed ingredient
to correct for material in flight after cut off.
The IFC function is enabled if SETUP 5.5 = 1 and maybe operated in two modes according to
SETUP 5.6.
i. PREACT MODE SETUP 5.5 = 1 SETUP 5.6 = 0

Preact values for each ingredient are programmed with FN 1.
During ingredient dosing the final cut off point is calculated subtracting the preact value
from the setpoint. The preact value is not modified.
If the preact value is greater than the setpoint, the preact value is zeroed.
ii. AUTOMATIC MODE SETUP 5.5 = 1 SETUP 5.6 = 1

Preact values for each ingredient are calculated after dosing and are stored in memory.
The next time an ingredient is dosed the newly calculated preact value will be subtracted
from the setpoint.
The preact values are dynamically calculated and updated provided they remain within
reasonable limits.
FN 1 allows the user to inspect / modify them.
NOTE : The IFC limit is programmable through Fn 04 to a max value of 50% of the
setpoint. If the correction is greater than 50%, a dosing error is assumed and the
preact value is zeroed.

3.8.2 REFEED / JOGGING ( JOG )

The JOG function operates when the ingredient was dosed below tolerance. It allows automatic
REFEEDING up to the setpoint without operator intervention.
The JOG function is enabled if SETUP 7.5 = 1 and maybe operated in two modes according to
SETUP 5.7.
i. NORMAL SETUP 7.5 = 1 SETUP 5.7 = 0

If the dosed ingredient is found below tolerance, a reefed cycle is started where Coarse
or Fine feeding is activated until the setpoint is reached. The reefed cycle will be
repeated until the weight setpoint is reached.
ii. JOGGING SETUP 7.5 = 1 SETUP 5.7 = 1

In this mode the reefed cycle operates with ON/OFF pulses governed by the duty ratio
T8/T7.
Jogging will be active until the weight setpoint is reached.
Jogging time is programmed in FN 8 if common jog parameters are selected for all
ingredients (SETUP 5.8 = 0) or during recipe editing if jog parameters are selected per
ingredient (SETUP 5.8 = 1).
NOTE : - Jogging times are in tenths of a second.

- Preact value is not used to the calculation of the setpoint on the refill
cycle.
3.8.3 FEEDING TIME MONITOR ( FTM )

FTM allows time control of a batch.
The maximum feeding time is programmed for each ingredient, in recipe programming.
The function is enabled by SETUP 7.1 =1.
During feeding the time is monitored and if it exceeds the max programmed in the ingredient, the
system stops and displays Error 11. The operator may continue feeding with the same ingredient
or in case the silo is empty change to another silo and complete the batch.
When STOP is pressed on the keyboard or the STOP INPUT is activated the max feeding time is
restarted.
3.8.4 WEIGHT DECREASING SENSOR ( WDS )

WDS detects a negative rate of change of weight during dosing of an ingredient, that maybe
caused by hardware malfunction.
The function will operate if enabled by SETUP 7.6 = 1.
If a weight decrease is detected during filling the system will stop and display Error 48. The
operator must acknowledge the error and may proceed as with a normal STOP sequence.
The WDS tolerance is programmed with Fn 3.

3.8.5 WEIGHT COMPARE INHIBIT TIMER ( WCI )

The WCI function is useful in overcoming difficulties generated by severe mechanical and/or
electrical disturbances when ingredients with small quantities are dosed.
WCI inhibits weight comparison for a programmable time starting from start of filling.
The function is enabled by SETUP 6.7 =1
The time t9 is programmed in FN 8 in tenths of a sec and is common to all ingredients. The max
value of t9 at execution will be limited to 5 sec automatically.
WCI operation is as follows :
Step 1 - start filling, weight is not compared
Step 2 - start timer 9 (max 5 sec)
Step 3 - wait timer 9, weight is not compared
Step 4 - filling continues with weight comparison
.............
.............
3.8.6 FINE DELAY FOR ELECTRIC VANES (FDV)

The FDV function allows coarse - fine operation using one electric vane. The fine output is
delayed ON for a time TF, causing the vane to remain partly open until the setpoint is reached.
TF is programmed in FN 9 in tenths of a sec.
The function is enabled by SETUP 6.1 = 1 and SETUP 6.4 = 1.
3.8.7 FINE - COARSE - FINE (FCF)

The FCF function allows slow filling during a preset time at the start of each recipe step to avoid
for amforming.
It is enabled if setup 6.5=1.
At the start of each step FINE OUTPUT is turned ON for t8 tenths of seconds. When t2 is
elapsed recipe steps continuous as normal.
T8 (Jog ON time) is programmed at each step.
Note: Jog operation should be disabled (setup 5.7=0).

4. FRONT PANEL SURVEY
4.1. DISPLAYS
WEIGHT DISPLAY
Six 6-segment high intensity LED displays, 14 mm high, for the display of measured
weight (gross or net). Colour RED.
Over-range is indicated by "vvvvvv" on the weight display.
Under-range is indicated by "uuuuuu" on the weight display.
THE WEIGHT DISPLAY IS ALSO USED FOR OPERATOR PROMPTING AND

ERROR MESSAGES.
M NO MOTION led : It lights when the scale is stable.
N NET led : It lights when the scale has been tared.
j CENTER OF ZERO : When illuminated the scale is within 1/4

division of zero and the zero tracking device is
activated.
k BATCH DISABLE
FLAG : The top horizontal segment of the first display
digit is used to indicate when the system is in
Batch disable mode.

4.2. KEYBOARD
It contains 11 function keys as well as a numeric keypad.
The text in inverted quotes next to the pictograms is the name of the key referred to from
now on in the following pages of this manual.
The description of each key is as follows :
U "POWER ON" : Reserved for battery models.
O "ZERO" : ZERO setting of scale. It functions only when the scale

is stable, in gross mode and the weight is within +2% of
the nominal weighing capacity.
T "TARE" : TARE setting of scale. It functions when the scale is

stable and the gross weight positive. The gross weight
is
stored in the memory and the weight display is reset to
zero. Taring may be repetitive and 100% of scale
capacity. The Net led indicates an active taring
function.
If the scale is already tared it clears the tare memory
and
restores the weight display to Gross mode.
S "MANUAL TARE" :
or “TARE RECALL” Used to key in a preset tare value
If the scale is already tared, the tare in use will be
displayed briefly.
P “PRINT” : It is used to initiate printouts.
Y “ENABLE” : ENABLE: Enables batch execution. Also moves

or “BACKWARD” to previous step during editing procedures.
l "NEXT STEP" : UP arrow. Used in operational data entry routines.

Moves to next step. Toggle display between
Weight/Rate/Total/Count.
[ "SELECT" : Selects recipe number. (Product selection).
] "STOP" : STOP the current batch cycle. The program displays

STOP and awaits response. Press STOP again to
continue.
` “ESC”
or “ABORT” : ESCAPE. This key is used to exit from data input-
o
u
t

p
u
t
routines.
ABORT. Used to abort a recipe when in STOP mode.
Also ABORT will disable batch execution if pressed
when system is in standby.
0-9 : 10 Numeric keys.
C “CE" : CLEAR. Erases a keyboard entry. Also it

ACKNOWLEDGES when an error code is displayed.
Z “AE" : ACCEPT ENTRY. Enters the information displayed.

Also used to proceed to next program step.
A "Fn" : FUNCTION KEY . It allows the selection of a number

of
software functions 00-99.
While the display indicates weight press FN. Display
blanks and FN appears on leftmost. Key in the two
numeric digits for function desired and press AE. The
corresponding program will be activated. When the
program is ended display returns to FN_____. Select
the
next function desired or press "ESC" to exit. This is
equivalent of having 100 different keys to activate the
different functions.
The following is a list of the software functions that are called using the function menu.
F.N. Description
01 EDIT PRODUCT/RECIPE FILE

02 EDIT ZERO TOLERANCE - HIGH SETPOINT
03 EDIT WEIGHT DECREASING TOLERANCE-BATCH SETTLING TIME
04 EDIT PREACT PERCENT
05 PRINT BATCH PARAMETER FILE
06 EDIT DYNAMIC OVERWEIGHT PERCENT
07 EDIT DISCHARGE TIMERS
08 EDIT JOG & WEIGHT COMPARE INHIBIT TIMERS
09 EDIT FINE DELAY TIMER
13 PRINT INDICATED WEIGHT
15 EDIT DATE - TIME - SN
30 ACTIVATE - DEACTIVATE PROTOCOL OUTPUT
35 ACTIVATE - DEACTIVATE PRINTER OUTPUT
45 PRINT SETUP PARAMETERS
48 CALIBRATION Nr. CHECK
49 EDIT SYSTEM PARAMETERS
53 PRINT PRODUCT/RECIPE FILE

57 CHECK PRODUCT/RECIPE FILE

59 ERASE PRODUCT/RECIPE FILE
70 VIEW RECIPE TOTALISER SUBTOTAL
71 PRINT RECIPE TOTALISER FILE
72 VIEW RECIPE TOTALISER TOTAL
74 VIEW/PRINT BATCH TOTALISER
76 DELETE ALL TOTALISERS
77 CHECK RECIPE TOTALISER FILE
78 RESET RECIPE TOTALISER TOTAL
79 RESET RECIPE TOTALISER SUBTOTAL
80 LOADCELL mV/V METER
81 A/D CONVERTER TEST

82 DISPLAY VERSION
83 ROM-RAM TEST
84 BCD RECIPE SELECTION TEST
85 BATCH - WEIGHT SIMULATION ENABLE
86 BATCH - WEIGHT SIMULATION DISABLE
87 D/A CONVERTER TEST
88 PRINT MEMORY BLOCK
90 DISPLAY TEST
91 KEYBOARD TEST
92 PROCESS INPUT TEST
93 PROCESS OUTPUT TEST
94 PRINTER OUTPUT TEST
96 SERIAL PORT 1,2 TEST
98 CLEAR RAM
99 SOFTWARE RESET

5. DEFINITION OF TERMS
The terms used in system setup and operational data input - output together with display prompts
are explained below :
DISPLAY DESCRIPTION
FN FUNCTION : This is the prompt to enter the two digit code to select the desired
function.
E EMPTY TOLERANCE . The allowable weight of material in the weigh vessel
at the beginning of a batch.
Prod PRODUCT RECIPE . Batch product parameters and timing.
C COARSE weight. Final weight setpoint of an ingredient. Fast dosing takes place
for ( C - F ) kg.
F FINE dosing. The quantity up to the final setpoint at which only slow dosing
will take place.
t TOLERANCE . The allowable variation from predetermined batch weight
(+ or -). If the system is out of tolerance the batch is stopped and an operator
must intervene to continue or cancel the current batch.
t0 RUN TO FILL DELAY. The time after the run (bag clamp) signal is activated
for the coarse-fine outputs to turn ON (time in 1/10 sec).
t1 INGREDIENT DOSING TIME . This is the max time for dosing of an
ingredient. If it is exceeded the batch is stopped and an operator must intervene
(time in sec).
t2 INGREDIENT SETTLING TIME . The period of time between the completion
of one ingredient and starting of the next. This action allows the in-flight
material to settle so that an accurate weight measurement can be made (time in
1/10 sec).
t3 DISCHARGE SETTLING TIME. The time after the SCALE EMPTY signal is
activated for the DISCHARGE OUTPUT to turn OFF (time in sec).
t4 BATCH SETTLING TIME between two successive batches of the same recipe
(not used).
t5 DISCHARGE VIBRATOR DELAY. Time for the DISCHARGE output to turn
on after the Discharge input is given (time in sec).
t6 MAXIMUM DISCHARGE TIME (time in sec).
t7,t8 JOGGING TIME . When an ingredient is completed during a batch, the system
awaits for the settling time and then checks if it was completed in tolerance.
If it is below the batch weight, the system will automatically perform additional
dosing. The jogging time set the duty ration t7=OFF t8=ON between additional
dosings (time in 1/10 sec).
t9 WEIGHT COMPARE INHIBIT TIMER. The time from start filling of an
ingredient during which the weight is not compared to setpoint (time in 1/10
sec).
tF FINE DELAY TIMER. The delay ON time to activate the FINE feed output
(time in 1/10 sec).

P PREACT . This is the quantity subtracted from the ingredient setpoint to

account for in-flight material.
d WEIGHT DECREASING SENSOR TOLERANCE. If during filling the
weight is found to decrease by more than this tolerance the batch is stopped and
an operator must intervene.
ACCESS The service security code required to enter several software functions.
PASS The opreator security code required to enter several software functions.
Stop This prompt is displayed whenever a batch is stopped. The batch may be
continued by pressing START or cancelled by pressing Esc.
Abort This prompt is displayed when batch is stopped and escape was pressed. Press
STOP followed by START to continue batch or AE to abort batch.
dEL? DELETE or NOT ? . Confirm delete action.
If CE is pressed the relevant data memory is erased.
If any other key is pressed no change is made.
dELEtE DELETED . Answer from the system to confirm that data memory was
erased.
Print PRINT or NOT . This message appears after a printer error. You may try to print
again by pressing AE or escape by pressing CE.
Print 1 PRINTER IN ACTION. Processor is busy with printing.
Proto PROTOCOL or NOT . This message appears after a protocol error. You may try
again by pressing AE or escape by pressing CE.
Proto 1 PROTOCOL IN ACTION. Processor is busy with communicating with device
connected to Protocol output.
tot TOTALISER . This is the prompt to enter the two digit code to select a
totalising register for inspection or printout.
Stot SUBTOTAL .This is the prompt to enter the two digit code to select a
subtotal for inspection or printout.
Pro on PROTOCOL SWITCHED ON
Pro off PROTOCOL SWITCHED OFF. The protocol output may be switched ON or
OFF from the operator following a PROTO prompt.
SETUP 1 |
SETUP 2 |
SETUP 3 |
SETUP 4 |
SETUP 5 |-> Setup mode menu.
SETUP 6 |
SETUP 7 |
Par Scale parameters menu.
S-CAL Scale calibration menu.
Init Default parameters
StorE Save new parameters entered.
A-CAL Analog output parameters menu.

RECIPE FILE
The recipe file consists of 99 recipes as shown below :
RECIPE FILE EACH PRODUCT

RECIPE 1 ----> C = Setpoint
RECIPE 2 F = Fine cut off
RECIPE 3 t = tolerance
| t1 = Filling time
| t2 = Stabilisation time
| P = Preact weight
| t8 = Jog time ON
RECIPE 99 t7 = Jog time OFF
Recipes can be edited, printed, deleted using the following operations from the function menu :
Inspect/modify recipe FN 01
Inspect/modify currently executed recipe FN 50
Print selected recipe FN 52
Print all recipes FN 53
Checksum recipe file FN 57
Erase recipe file FN 59
Please refer to function description for detailed explanation of recipe file operations.
NOTE :If AUTO in flight compensation is selected in setup Preact values are modified by the system
after dosing of each ingredient.
BATCHING PARAMETER FILE

This file contains all system data necessary in batching and the ingredient preact file and is
organised as shown below :
Use
EMPTY HIGH SETPOINT FN 2

PREACT LIMIT (%) FN 4
DISCHARGE ON TIME T5 MAX DISCHARGE TIME T6 DISCHARGE SETTLING TIME T3 FN 7
WEIGHT COMPARE INHIBIT FN 8

TIMER
WEIGHT DECREASING BATCH SETTLING TIME RUN TO FILL DELAY t0 FN 3
TOLERANCE T4
Batching parameter data maybe inspected / modified using the relevant function menu operation.

6. FUNCTION DESCRIPTION
For functions 1 - 9 and 80 – 99 the operator code (772149) must be entered if setup 1.8 = 1.
6.1. EDIT PRODUCT/RECIPE FILE

1. Display shows. Prod. 00 .
Enter the recipe number and press AE.
The already programmed values of the selected recipe are displayed in sequence.
2. Display shows Cxxxxx where xxxxx the final weight setpoint. Press CE to erase, numeric
keys to change and AE to accept and proceed to step 3.
3. Display shows Fxxxxx the fine quantity, i.e. the weight before the final setpoint which will
be dosed with dribble speed only. Press CE to erase, numeric keys to change and AE to
accept and proceed to step 4.
4. Display shows txxxxx the ingredient tolerance.

Press CE to erase, numeric keys to change and AE to accept and proceed to step 5.
5. Display shows t1.xxx the maximum dosing time in sec for this product. Press CE to erase,
numeric keys to change and AE to accept and proceed to step 6. t1 is not required if
setup 7.1 = 0 (Feeding time monitor).
6. Display shows t2.xx.x the settling time after dosing of this product in 0,1 sec.
Press CE to erase, numeric keys to change and AE to accept.
7. Display shows Pxxxxx the current preact value. Press CE to erase, numeric keys to
change and AE. Preact is not required if setup 5.5 = 0 (In flight compensation).
The preact value is adjusted automatically after each batch.
The value entered should be less than the preact limit programmed in Fn 4.
8. Display shows t8.xx.x the jogging ON time in tenths of sec. Press CE to erase, numeric
keys to change and AE. Required only if setup 5.7 = 1 (JOG) or if setup 6.5 = 1 (fine before
coarse time).
9. Display shows t7.xx.x the jogging OFF time in tenths of sec. Press CE to erase, numeric
keys to change and AE. Required only if setup 5.7 = 1.
Press Esc to exit from recipe programming.
NOTE: Only weight values less than the nominal capacity of the scale are accepted.
If during programming, an error code appears, press CE and continue with
editing.
The total recipe weight is checked and must not exceed the nominal capacity of
the scale.
The fine dosing must not be greater than the setpoint for any component.

6.2. EDIT EMPTY TOLERANCE - HIGH SETPOINT

1. Display shows Exxxxx where xxxxx the existing value of the Empty tolerance. Press CE
to erase, numeric keys to change and AE to accept and store in memory.
If the weigh out / Hopper fill mode is selected the program moves to step 2, else it exits to
function menu.
2. Display shows Hxxxxx where xxxxx is the existing value of the high limit.
Press CE to erase numeric keys to change and AE to accept and store in memory.
3. Program exits to function entry.
If Esc is pressed instead of AE the program is terminated with the old values unchanged
in memory.
The high setpoint is used in GROSS FILL mode of operation to check bag presence.
The bag weight must be within empty tolerance and high setpoint.
6.3 EDIT WEIGHT DECREASING TOLERANCE - BATCH SETTLING

TIME
Active only if the weight decreasing sense feature is enabled setup 7.6 = 1:
Display shows dxxxxx. Press CE to erase, numeric keys to change and AE to accept and
store in memory.
Display shows t4 xxxx. Press CE to erase, numeric keys to change and AE to store in memory.
Program exits to function menu.
If you press Esc instead of AE the old value remains in memory.
6.4. VIEW/EDIT PERCENT OF MAXIMUM RECIPE PREACT

Display shows PPl xx. (xx = 00 to 99). Press CE to erase, numeric keys to change and
AE to accept and store in memory. Program exits to function menu.
A value of 00 equals 50%
6.5. PRINT BATCH PARAMETER FILE

Prints the batching parameter file.
Program returns to function menu.
6.7. EDIT DISCHARGE TIMERS

1. Display shows t5 xxxx. (Time delay for the DISCHARGE output to turn ON).
Press CE to erase, numeric keys to change and AE to store in memory.
2. Display shows t6 xxxx. (Time out). Press CE to erase, numeric keys to change and AE to
store in memory.
3. Display shows t3 xxxx. (Delay after scale is empty for the “DISCHARGE” output to turn
off). Press CE to erase, numeric keys to change and AE to store in memory.

6.8. EDIT JOG & WEIGHT COMPARE INHIBIT TIMERS

1. Display shows t8 xx.x. (JOG ON). Press CE to erase, numeric keys to change and AE to
store in memory.
2. Display shows t7 xx.x. (JOG OFF). Press CE to erase, numeric keys to change and AE to
store in memory.
3. Display shows t9 xx.x (weight compare inhibit). Press CE to erase, numeric keys to change
and AE to store in memory.
TIMERS T7, T8 & T9 ARE IN TENTHS OF SEC.
6.9. VIEW/EDIT FINE DELAY TIMER

Display shows tF xxxx. Press CE to erase, numeric keys to change and AE to
store in memory. Program returns to function menu. TIMER TF IS IN TENTHS OF SEC.
6.13. PRINT INDICATED WEIGHT.

The indicated weight is printed with a date time stamp. No action will occur if the printer
output has been disabled in setup. Activated in standby mode only.
6.15. EDIT DATE - TIME - SN

1. Display shows “date” briefly. Then shows ddmmyy = day - month - year.
2. Display shows “time” briefly. Then shows hhmmss = hour - minutes - seconds.
3. Display shows n 1234 = number of printout.
Program exits to function menu.
If Esc is pressed program exits to function menu without altering the data.
6.30. ACTIVATE - DEACTIVATE PROTOCOL OUTPUT

Display shows Proto . Press AE to switch ON (display shows Pro on) or CE to
switch OFF (display shows Pro off).
The protocol output will become ON always following a power failure or soft reset.
If the protocol is switched OFF no further transmission will occur until switched ON again.
6.35. ACTIVATE - DEACTIVATE PRINTER OUTPUT

This function is active only if programmed in system setup. (SETUP 2.8 = 1).
Display shows Print . Press AE to switch ON (display shows Pri on) or CE to
switch OFF (display shows Pri off).
The printer output will operate according to SETUP 2t following a power failure or a soft reset.
6.45. PRINT SETUP PARAMETERS

Prints a list of all setup parameters on the local printer.
6.48. CALIBRATION Nr. CHECK

For details refer to section 9.1.

6.49. EDIT SYSTEM PARAMETERS

Described in equipment, setup in section 9.
6.53. PRINT RECIPE BOOK

Activated in programming mode only, it produces a print out of all operational data
programmed.
Recipes - tolerances - etc.
6.57.CHECK RECIPE BOOK

A checksum is performed on the operational data memory. If no error is encountered program
returns to function menu, else Err 07 is displayed. Press CE to exit to function menu.
No batching can be started if an error exists in the selected recipe.
6.59. ERASE RECIPE BOOK

1. Display shows “PASS” briefly . Use numeric keys to enter the operator access code and
AE to accept. If an incorrect access code is entered display returns to Fn 00.
2. Display shows dEL? . Confirm erasure by pressing AE or press ESC to exit with
no change.
6.70. VIEW PRODUCT TOTALISER SUBTOTAL

Activated only if totalising function has been enabled in setup.
1. Display shows Stot 00. Key in the recipe number you wish to inspect and AE, or Esc to
return to function menu.
2. Display shows 123456 the totaliser weight content. Only the 6 least significant
digits are displayed . Press d to display the 3 Most Significant Digits.
3. Press AE to continue or Esc to return to function menu.
4. Display shows C 1234 the number of times dosing has taken place with this
product/recipe.
5. Press AE to return to step 1 above or ESC to exit.
6.71. PRINT PRODUCT TOTAL

If a printer is connected it produces a printout of all subtotal total and count of batches.
6.72. VIEW PRODUCT TOTALISER TOTAL

1. Display shows tot 00. Key in the recipe number you wish to inspect and AE, or Esc to
return to function menu.
2. Display shows 123456 the totaliser weight content. Only the 6 least significant
digits are displayed . Press d to display the 3 Most Significant Digits.
3. Press AE to continue or Esc to return to function menu.
4. Display shows C 1234 the number of times dosing has taken place with this
product/recipe.
5. Press AE to return to step 1 above or ESC to exit.
6.74. VIEW/PRINT BATCH TOTALISER

Display shows total weight and counter of completed batches, aborted batches and total batches
in sequence. AE must be pressed between each number displayed.
While aborted count is displayed press AE to print or Esc to exit.

6.76. DELETE ALL TOTALISERS

Display shows “PASS” briefly. Key in the operator access code and AE.
Display shows “del?”. Press AE to delete the contents product/ recipe totalisers or Esc
to exit.
6.77.CHECK PRODUCT TOTALISER FILE

A checksum is performed on the totalising memory. If no error is encountered program
returns to function menu, else Err 67 is displayed. Press CE to exit to function menu.
No batching can be started if an error exists in the totaliser file..
6.78. RESET PRODUCT TOTALS

Display shows “del?”. Press AE to reset the contents of all product totalisers to zero
(subtotal & total) or Esc to exit.
6.79. RESET PRODUCT SUBTOTALS

Display shows “del?”. Press AE to reset the contents of all product totalisers to zero (subtotal
only subtotal or Esc to exit.

NOTE : Functions 80 to 99 are for diagnostic purposes and may be used by trained service
personnel only.
6.80. LOADCELL mV/V METER

The actual mV/V output of the scale sensors is displayed. Press ESC to end. Actual value
depends
on installation. System loads ROM calibration data to enable mV/V sensing. Upon exiting the
function the unit will restart in order to load the proper calibration data.
6.81. A/D CONVERTER TEST

The display shows the analog to digital converter internal counts.
6.82. DISPLAY VERSION

Program number is displayed briefly, then blanks, then the version is displayed briefly and
finish.
6.83. ROM-RAM TEST

The system ROM is summed modulo HEX 100. If the result is not zero Err 01 will be
displayed.
Then the system and data RAM are checked for write-read at each location.
Contents are saved before test and restored afterwards.
If any failure is detected Err 02 will be displayed.
6.84. BCD RECIPE SELECTION TEST

Displays the status of the BCD switch. Product select on the two right most digit. The recipe
selected from inputs 1 - 4.
6.85. BATCH - WEIGHT SIMULATION ENABLE

Used to simulate filling of an ingredient for check and training purposes. No response to the
operator is given.
From now on when the COARSE - FINE outputs are activated the weight will be increasing
accordingly (Fast – Slow). When the DISCHARGE output is activated the weight will be
decreasing. Thus a batch may be simulated.
6.86. BATCH - WEIGHT SIMULATION DISABLE

Weight simulation initiated with FN 85 will be disabled. No response is given to the operator.
6.87. D / A CONVERTER TEST

Use numeric keys and AE to output a value to the digital to analog converter port.
Valid entries are from 0 to 65535 corresponding to min., max. (0 – 24 mA).
6.88. PRINT MEMORY BLOCK

Display shows A______.
Key in address of memory block to print and AE. A block consisting of 8 x 16 bytes will be
printed in Hex. An offset of 8000 h is added to the address entered.
Press "ESC" To terminate test.
or Y to display previous memory block.

or l to display next memory block.

or P to reprint current memory block.
6.90. DISPLAY TEST .

Program number is displayed, then blanks, then all segments light up, then all digits go through
a 0 - 9 display routine in sequence.
6.91. KEYBOARD TEST
Display shows Cod __.
When a key is pressed the corresponding two digit-code appears on the two rightmost digits.
The codes should be a follows :
[ = 07 ] = 06 ` = 04
7 = 37 8 = 38 9 = 39
Y = 09 4 = 34 5 = 35 6 = 36
l = 05 1 = 31 2 = 32 3 = 33
A = 08 CE = 7F 0 = 30 AE = 5D
O = 00 T = 01 S = 02 P = 03
Press ESC to terminate test.
6.92. PROCESS INPUT TEST
Display shows the state of the inputs as the position of the vertical segments.
| |
| | |. | | |
Input 1 corresponds to the left most vertical segment and input 8 to the right most.
The segment position shows the status of the input. In the above case inputs 2 & 7 are high.
Press ESC to terminate test.
6.93. PROCESS OUTPUT TEST
Display shows the state of the outputs as the position of the vertical segments.
| | | |
| | |. | | | . | |
Output 1 corresponds to the left most vertical segment and output 12 to the right most.
The segment position shows the status of the output. In the above case outputs 2, 7, 11 & 12 are
high. Changing the status of the output is possible from the numeric keyboard.
Key 1 corresponds to output 1, key 9 to output 9, key 0 to output 10, key START to output 11
and key STOP to output 12. CE to reset all outputs, AE to set all outputs. Press ESC to exit.
6.94. PRINTER OUTPUT TEST
An ASCII file (20-BF) is output to the printer port with error control.
6.96. SERIAL PORT 1,2 TEST
All characters received are displayed as ASCII HEX codes and echoed.
The two leftmost digits display character codes received from Serial Port 1.
The third digit displays “c” if CTS line is ON.
The two rightmost digits display character codes received from Serial Port 2.
Any key pressed will be transmitted.
Press "ESC" to terminate Test.
6.98. CLEAR RAM
System and Data RAM contents are cleared and a system reset is forced.
6.99. SOFTWARE RESET
Restarts the system. This is equivalent to a power failure

7. INSTALLATION
7.1. MOUNTING
The mounting location must be such that the instrument is not subject to excessive vibrations,
heat or humidity.
Avoid direct sunlight on the front of the instrument.
The unit has to be installed indoor at the right height to allow an easy reading of the display
and keyboard operation.
Installation dimensions are indicated on attached drawing (ANNEX A).
7.2. WIRING
FLUSH MOUNT VERSION : All wiring to the instrument is done through the rear panel
connectors and is soldered. Strain reliefs are supplied with the connectors.
Use load cell cable 6 x 0.5 mm2 shielded for the sensor (s).
Use 3 x 0,34 mm2 shielded for the printer connection.
Use 2 x 2 x 0,34 mm2 twisted and shielded for computer connection.
Use 0,34 mm2 shielded for the process input-output connection(s).
CAUTION : Do not run signal cables together with power cables.
Connect the shielding where indicated on the drawing only.
Never use a megger to check wiring.
7.3. AC POWER
Because the instrument is computer controlled it requires clean power for reliable operation.
AC power supplied should come from a source that is isolated from other process equipment.
LEON ENGINEERING recommends the use of a power conditioner for noise attenuation and
voltage regulation with a capacity of approximately 70 VA.
The electrical supply must include a good ground (less than 1 Ohm).
8. POWER-UP
Upon power-up the unit goes through a series of self tests after which :
1. The program number and version are displayed.
2. All display segments are turned ON, then OFF for 2 sec.
3. Operational data check. If Err 07 or Err 67 is displayed a checksum error has been detected. In this
case all operational data must be programmed and totals must be cleared.
4. Zeroing depending on par 8.2. If the scale is within zero range, it will be set to zero and the
instrument will be ready for batching.
If not Err 15 will be displayed. Clear the error, empty the scale and set to zero (with key O).
5. Batching is performed according to the mode of operation in chapter 11.
If an error occurs refer to ERROR DESCRIPTION chapter 13 for the action to be taken.

9. EQUIPMENT SET-UP
9.1. GENERAL
Once the instrument has been installed setup and calibration must be performed before any
operation of the system can begin. Setup is required also whenever the requirements of the
batching system change.
The instrument is normally supplied with a factory set for the required functions. However it is
possible for the process supervisor to change the settings. All setup parameters are saved in
EEPROM, which has a life of 10.000 write cycles.
To prevent unauthorised calibration a calibration lock facility is provided.
This is a jumper JP1 placed inside the unit on the main board (PCB 603). With this jumper
inserted the user may only change the SETUP. Parameter and Calibration menus can not be
accessed.
D500 BC units are shipped with CAL LOCK jumper not inserted.
The CAL LOCK facility also appears on pins 7, 8 of Loadcell connector J1 on the
rear panel. If the pins are shorted the calibration is locked.
To calibrate the unit follow the instructions below.
- Power up the instrument.
- Allow 10 min for warm up.
- Proceed with setup and calibration as described in the next pages.
- After storage of calibration data remove the lid and insert the CAL LOCK jumper.
- Replace the lid.
- Seal the unit.
The parts of the enclosure can be sealed by means of either a wire and lead seal or a self-
adhesive
label.
The seal bears the mark of the manufacturer or the mark of the verification officer.
The position of the CAL LOCK jumper maybe checked by performing Fn48.
If the CAL LOCK is inserted the display will show SEALEd briefly.
Then the display shows CA.XXYY
where : XX = Calibration data check characters
YY = Setup data check characters
Press any key to exit.
If the CAL LOCK jumper is not inserted the display will show directly CA.XXYY.
9.2. SETUP AND CALIBRATION

In the setup dialogue the following two numeric scroll edit procedures are used.
1. SINGLE DIGIT EDIT
S = INCREMENT DISPLAYED DIGIT
P = ACCEPT DISPLAYED VALUE
2. MULTI DIGIT EDIT

T = MOVE ONE DIGIT TO THE RIGHT (CYCLIC)
S = INCREMENT FLASHING DIGIT
P = ACCEPT DISPLAYED NUMBER
or PRESS NUMERIC KEYS & AE

To enter the setup & calibration procedure power on the unit.

During the self test routine while all display segments are on (all 8 on the display) press P
momentarily followed by T momentarily.
Display shows ACCESS briefly.
Key in code 532299 and then Z to get into the calibration menu.
Use S to step through SETUP
Par
S-Cal
STORE
INIT dialogues if CAL LOCK is off.
A-Cal
or
SETUP
STORE dialogues if CAL LOCK is on.
While displayed, each dialogue can be accessed with P .
THE SETUP & CALIBRATION MENU MAY ALSO BE ACCESSED VIA FN 49.
9.2.1. DIALOGUE Par (Scale Parameters)

While in the Par menu use key S to change value, T to change digit,
P to accept entry and proceed to next step or Y to backstep .
Parameters are defined as follows :
1.P = No of display digits (4,5)
2.P = Position of decimal point (Nr of decimal digits). (0-5)
3.P = Display resolution (1-200)
4.P = Two first digits of weighing range (00-99)
5.P = Digital filter (0=No filter, 4=Highest filter) (0-4)
6.P = Number of conversion per second. (5-70)
7.P = No motion samples. (If entry is x then samples = 2x). (1-7)
8.1 = Autozero maintenance 0 = NO 1 = YES
8.2 = Power up Zero 0 = NO 1 = YES
8.3 = Dual digital filter 0 = NO 1 = YES
8.4 = Antiflicker device 0 = NO 1 = YES
8.5 = Display update rate 0 = LOW 1 = HIGH
8.6 = Leading zero blank 0 = NO 1 = YES
8.7 = Key klick 0 = NO 1 = YES
8.8 = Zeroing range 0 = 2% 1 = 10%
8.9 = Clear A/D converter error (error 05) 0 = Manual 1 = Auto
8.Α = A/D converter cyclic self calibration 0 = NO 1 = YES
9.P = Weight unit 0 = kg 1 = gr 2 = Tn 3 = lb
0.P = Dual interval (00-99)
The first two digits of the weighing range for which the lower display division
will be selected automatically.
00 = Dual interval not active.

9.2.2. DIALOGUE S-CAL (Scale Calibration)

Display shows Zero Press S to go to SPAN
or
press O to exit to S-CAL
Press P to measure the dead load.
Display shows E Scl a reminder to empty the scale.
Press P .
Display counts down for 64 samples then it displays zero.
Repeat the procedure if the zeropoint is not accurate.
Press P to proceed.
Display shows SPAn Press S to go to Zero.
or
press O to exit to S-CAL.
Press P for SPAN calibration.
Display shows C xxxx where xxxx = Maximum capacity of scale.
Enter calibration weight, to be used.
To enter the weight use numeric keyboard.
Display shows Add Id a reminder to load the calibration weight on the platform.
Load scale.
Press P . Display counts down for 64 samples.
Then it shows the calibration weight.
Repeat the SPAN procedure if the calibration is not accurate.
Calibration is complete but factors obtained not protected in case of mains failure.
Press P to exit to S - CAL menu.
9.2.3. DIALOGUE STORE (Save in EEPROM)

Press P to permanently save all the calibration data.
Program exits calibration and reinitialises. (up to 10.000 storage cycles allowed).

9.2.4. DIALOGUE SETUP
Display shows SETUP Press P to enter the dialogue.

or
press S to scroll through Par e.t.c.
When in the setup press P to enter a dialogue.

dialogue or
press S to scroll through.
or
press Y to scroll back.
SETUP 1 SYSTEM PARAMETERS

SETUP 2 SERIAL PORT 1 PARAMETERS
SETUP 4 CONFIGURATION PARAMETERS 1
SETUP 7 CHECK PARAMETERS
While in a SETUP dialogue use key S to change the displayed value and key P to accept entry
and proceed to the next step or press Y to proceed to the previous step.
Press O to exit to setup.
SETUP 1 SYSTEM PARAMETERS
1.1 TOTALISERS 0 = Disable 1 = Enable

1.2 RECIPE SELECTION 0 = BCD option 1 = 1 - 4 inputs
1.3 RESERVED 0= 1=
1.4 RECIPE SELECTION 0 = Inputs 1 = Keyboard
1.5 RESERVED 0= 1=
1.6 REAL TIME CLOCK 0 = Disable 1 = Enable
1.7 RESERVED 0= 1=
1.8 OPERATOR CODE 0 = Disable 1 = Enable
1.9 RESERVED 0= 1=
1.A SCROLL DISPLAY KEY d 0 = No 1 = Yes


2.t TYPE :
00 SERIAL OUTPUT DISABLED
01 PRINTER OUTPUT
02 WEIGHT OUTPUT Continuous transmission of weight
03 DEMAND Print demand by transmitting scale Address
code
2.L LINE FEEDS AFTER PRINTOUT
2.1 RESERVED 0= 1=
2.2 RESERVED 0= 1=
2.3 RESERVED 0= 1=
2.4 RESERVED 0= 1=
2.5 RESERVED 0= 1=
2.6 RESERVED 0= 1=
2.7 PRINTER ERROR CONTROL 0 = NO 1 = YES
2.8 OPERATOR TYPE CHANGE 0 = NO 1 = YES
(Activate- deactivate via Fn 35)
2.b BAUDRATE SERIAL CHANNEL 1 06 = 600 b/s

12 = 1200 b/s
24 = 2400 b/s
48 = 4800 b/s
96 = 9600 b/s
2.d DATA BITS SERIAL CHANNEL 1 07 = 7 data bits/no parity

08 = 8 data bits/no parity
17 = 7 data bits/even parity
18 = 8 data bits/even parity
3.t TYPE:
00 SERIAL OUTPUT DISABLED
01 WEIGHT OUTPUT Continuous transmission of weight
02 EDP PROTOCOL OUTPUT
03 PRINTER PROTOCOL OUTPUT
3.1 ERROR CONTROL 0 = NO 1 = YES
3.2 RETRY 0 = NO 1 = YES
3.3 DISABLE PROTOCOL 0 = NO 1 = YES
3.4 TRANSMIT BATCH RESULT 0 = NO 1 = YES
3.5 WAIT TRANSMISSION ACKNOWLEDGE 0 = NO 1 = YES
3.6 RESERVED 0= 1=
3.7 BUFFER 0 = NO 1 = YES
3.8 DEBUG PROTOCOL 0 = NO 1 = YES
3.b BAUDRATE SERIAL CHANNEL 2
3.d DATABITS SERIAL CHANNEL 2

4.1 RESERVED 0= 1=
4.2 RESERVED 0= 1=
4.3 RESERVED 0= 1=
4.4 RESERVED 0= 1=
4.5 RESERVED 0= 1=
4.6 ZERO SCALE AT START OF BATCH 0 = No 1 = Yes
4.7 RESERVED 0= 1=
4.8 TARE SCALE AT START OF BATCH 0 = No 1 = Yes
5.1 RESERVED 0= 1=
5.2 RESERVED 0= 1=
5.3 RESERVED 0= 1=
5.4 RESERVED 0= 1=
5.5 IN FLIGHT COMPENSATION 0 = Disable 1 = Enable
5.6 IN FLIGHT COMPENSATION 0 = Manual 1 = Auto
5.7 AUTOREFILL 0 = Normal 1 = JOG
5.8 INGREDIENT JOGGING TIME 0 = Common 1 = Individual
6.1 DELAY FINE 0 = No 1 = Yes

6.2 DELAY RUN TO FILL (t0, Bag clamp) 0 = No 1 = Yes
6.3 WAIT NO MOTION CONDITION 0 = No 1 = Yes
6.4 COARSE-FINE OPERATION 0 = Separately 1 = Together
6.5 FINE FILLING AT START OF STEP 0 = No 1 = Yes
6.6 EMPTY TOLERANCE 0 = Positive only 1 = Symmetric to zero
6.7 WEIGHT COMPARE INHIBIT TIMER (t9) 0 = Disable 1 = Enable
6.8 RESERVED 0= 1=
SETUP 7 CHECK PARAMETERS
7.1 FEEDING TIME MONITOR 0 = Disable 1 = Enable

7.2 RESERVED 0= 1=
7.3 TOLERANCE CHECK 0 = No 1 = Yes
7.4 INGREDIENT TOLERANCE 0 = Symmetric 1 = Positive
only
7.5 AUTO REFILL BELOW TOLERANCE 0 = Disable 1 = Enable
7.6 WEIGHT DECREASING SENSOR 0 = Disable 1 = Enable
7.7 BAG FILLING MODE 0 = Gross 1 = Net
7.8 RESERVED

9.2.5 DIALOGUE INIT (Installation of Default Parameters)

Loads default calibration data for checking purposes. The weight display will act as a mV/V meter
of the Loadcell output.
Press O to exit the init mode and restart the instrument.
Press S to exit but remain in the set up and calibration menu.
Be aware that the default parameters and calibration constants will remain in memory.
If a subsequent StorE operation is performed previous calibration data will be lost.
9.2.6 DIALOGUE ACAL (D/A Analogue output calibration)

Used to set the analogue output parameters and calibrate the output if a calibration other than the
standard
is required.
A.1 CALIBRATION STANDARD/USER 0=Standard 1=User defined

(20mA on max) Zero & Span
A.2 RESERVED
A.3 SCALE ERROR OUTPUT 0=Low (0 mA) 1=High (24mA)
A.4 CURRENT / VOLTAGE 0=Current 1=Voltage
A.5 NET / GROSS 0=Net weight 1=Gross weight
A.6 0-20 / 4-20 0=0-20mA 1=4-20mA
A.7 RESOLUTION 0=Display 1=Internal
A.8 OPERATION 0=Disabled 1=Enabled
Dialogue ACAL continues below only if A.1 = 1.
Display shows Zero briefly.
Then display shows 0 XX.XXX Key in the D/A output in mA or Volt (depending on A.4) using the
“ NUMERIC SCROLL ENTRY “ procedure.
To define the D/A output for max weight indication.
Press P to define the analogue output for Zero weight indication and go to FULL.
or Press O to escape from D/A calibration
Display shows FULL briefly.
Then display shows F XX.XXX Key in the D/A output in mA or Volt (depending on A.4) using the
“ NUMERIC SCROLL ENTRY “ procedure.
The program ends after definition of FULL.
For selection of current or voltage output the jumpers JP2, JP3 on PCB (662) should be
placed properly (see drawing D500BC/662/040).

10. OPERATION
This section contains information on operating procedures for the D500 BC Batch Controller.
NOTE : Before attempting to operate the system, be sure to complete all Installation,
Configuration
and Calibration procedures.
Operation involves :
1. Programming of operational data
2. Batching (Automatic or manual)
3. Printing reports
4. Displaying accumulated Ingredient or RECIPE totals
5. Remote Host Communication
Batching may be enabled by FN 46, or by pressing Y key.

Batching may be disabled by the operator using FN 47, or automatically in case of fatal error or Abort
sequence.
Also batching may be disabled if Esc key is pressed when the system is in standby.
10.1. PROGRAMMING OF OPERATIONAL DATA

Operational data is the input data necessary to enable batching, which contains :
1. Product recipe file (Fn 1)

2. Batching parameter file (Fn 2, 3, 4, 7)
3. Date – Time (Fn 15)
4. Production order (Key [ )
All operational data is accessed via the function menu.

Refer to chapter 6 for detailed description of the functions.
10.2. BATCHING - MODES OF OPERATION

The following rules apply to all modes of operation.
- A batch can not be started if there is an error in hardware.

- A batch can not be started if there is an error in operational data relevant to mode of operation
(recipe-Production).
- A batch can not be started if the scale is not empty.
- A batch will never be started if the unit is in programming or manual mode.
- The use of an uninterruptible power source protects the batching sequence in the event of power
failure.
- A batch report will be printed and a transmission to Host will take place (if programmed in set-
up)
when batch completed.

10.2.1 GROSS MODE (setup 7.7 = 0) – Product is weighed in the bag.

1. Select recipe (setup 1.4 = 0 (inputs), setup 1.4 = 1 (key [ )).
2. Set mode switch to AUTO.
3. Operator places bag and presses “START”.
4. Output “BAG HOLD” is activated. Wait t0 for bagclamp to operate.
5. To start filling the following conditions should be fulfilled:
- Weight is between empty and high setpoint (Fn2).
- Scale is stable.
- Input “EXT. OK” is ON.
6. Bag filled, stabilised, tolerance is checked, totalised, output “READY” goes On.
7. When input “BAG RELEASE” is ON, output “BAG HOLD” is deactivated and bag is released.
8. Continues to step 3 above.
10.2.2 NET MODE (setup 7.7 = 1) – Product is weighed in the hopper, then
discharged into the bag.
1. Select recipe (setup 1.4 = 0 (inputs), setup 1.4 = 1 (key [ )).
2. Set mode switch to AUTO.
3. To start filling the following conditions should be fulfilled.
- Scale is empty.
- Scale is stable.
- T0 has timed out.
4. Bag filled, stabilised, tolerance is checked, totalised, output “READY” goes On.
5. Operator places bag and presses “START”.
6. “BAG HOLD” is activated.
7. Wait input “EXT. OK” and t5.
8. Discharge scale until empty or t6 timeout.
9. Wait t3.
10. When input “BAG RELEASE” is on, output “BAG HOLD” is deactivated and bag is released.
11. Continues to step 3 above.
10.3. REPORT PRINTING

The following reports may be printed to the local printer, if the printer output is activated.
1 Batch parameter file Manual Fn 5
2 Batch report Automatically or FN 41
3 Selected recipe Manual FN 52
4 All recipes Manual FN 53
5 Scale weight Manual FN 13
6 Subtotal & total per Recipe Manual FN 71
7 Power Up event Automatic
8 Error event Automatic
10.4. PRODUCT TOTALS

Refer to chapter 11 for detailed description of the totalising operations.
10.5. REMOTE HOST COMMUNICATION

Power up, Error and Batch reports maybe uploaded to a host computer and product recipes
maybe downloaded. Operation of the host communication is defined in SETUP 3.

For the REMOTE MASTER mode of operation refer to “LESIP” (LEON ENGINEERING
STANDARD SERIAL INTERFACE PROTOCOL).

11. ACCUMULATED PRODUCT RECIPE TOTALS
Batching results maybe accumulated in totalising registers, one for each recipe.
Each register contains SUBTOTAL (9 digit), TOTAL (9 digit), and COUNT (5 digit).
Enable all totalising functions by SETUP 1.1 = 1. If SETUP 1.1 = 0 all totalising operations are
disabled and are not sensed by the operator.
The number of recipe is applied in order to call up the corresponding totaliser i.e.
Product 1 - Totaliser 1
Product 20 - Totaliser 20, etc.
The following operations are available to make use of the totalisers, performed with the function menu.
1. RESET the contents of the totalisers and counters to zero. A operators access code must be
entered before any reset operation to avoid operational errors.
2. VIEW TOTALS. The contents of a selected totaliser are displayed on the front panel display.
3. PRINT TOTALS. A report of all totalisers and their contents is printed (if a printer is attached).
If the totals are printed and reset daily then a daily production/consumption report is taken.
If every week, then a weekly report is taken.
It is recommended that a daily hard copy report is taken. If this is not possible please check
that the totalising registers do not overflow.
Please refer to the function menu for a detailed description of the totalisers functions 60-79.
During operation the following error messages may appear on the display :
Err 67 TOTALISER CHECKSUM ERROR

Err 69 TOTALISER OVERFLOW ERROR
If a Checksum error appears ALL totalisers should be reset. An Overflow error is not critical, it only
alerts the user that the totaliser capacity has been exceeded. Totalising continues normally afterwards
as shown below :
TOTALISER BEFORE Err 69 : 99999 kg

Weight added 120.00 kg
TOTALISER AFTER Err 69 : 00119.00 kg
Note : Because the display is only 6 digits only the least significant digits of the totaliser are
displayed. Press l to see the most significant digits.

12. ERRORS
If an error occurs during the operation, it will be displayed in the form Err xx where xx is the Error
code.
Program is halted. Press CE to acknowledge the error and proceed as indicated in the error operator
response.
The errors are subdivided as follows :
NUMBER OF ERROR ERROR DUE TO
00 - 06 Equipment failure
07 - 09 Operational data memory
10 - 19 Process monitoring
20 - 29 Printer output
30 - 39 Protocol output
40 - 49 Process control
50 - 59 Set-up
60 - 69 Totalising memory
70 - 79 Weighing memory
80 - 99 Miscellaneous errors
Errors may occur during set-up, programming, power-up and during operation.
All errors activate the alarm output until acknowledged.
In case of critical errors operation is halted and all outputs disabled.
All errors may be logged to a printer and / or computer (if enabled in set-up).
12.1. ERRORS DUE TO HARDWARE

ERROR POSSIBLE CAUSE ACTION TAKEN
DISPLAY
Err 01 SYSTEM ROM : Faulty EPROM Contact manufacturer
Err 02 DATA RAM : Faulty RAM Contact manufacturer
Err 03 SYSTEM RAM : Faulty CPU Contact manufacturer
Err 04 CALIBRATION DATA : Faulty EEPROM Recalibrate or

Contact manufacturer
Err 05 SCALE EXTREMELY OUT OF RANGE Check scale, cables,

connectors, LC, excitation,
A/D converter.
Err 06 REAL TIME CLOCK Disable real time clock with
Setup 1.6=0.
O O O A/D converter can not initialise due to excessive noise Power up again. If problem
O O O
or loadcell not connected during power up. remains check loadcell
connection.

12.2. OPERATIONAL DATA ERRORS

DISPLAY
Err 07 CHECKSUM FAILURE. May be caused by : Input all operational data and
. RAM back up battery failure reset totalisers
. Extreme power supply transient
Err 08 RECIPE OVER CAPACITY Check and program recipe
The sum of the ingredient weights exceeds the capacity correctly
of the scale
12.3. PROCESS MONITORING ERRORS

DISPLAY
Err 09 OVER CAPACITY Follow Abort sequence to abort batch or press
There is not enough scale capacity to dose “START” to continue.
ingredient. It may occur if a recipe total
weight is close to capacity and the ingredient
batched at high tolerance.
Err 11 DOSING RATE LOW. Either silo is empty Press "START" to continue .
or feeding equipment not operating
Err 12 TOLERANCE CONTROL. The ingredient Press "START" to continue or abort sequence
has been batched out of tolerance. to end.
Err 15 POWER-UP / ZERO Zero scale

System has been initialised due to power
failure or soft reset.
Err 16 SCALE CAN NOT BE ZEROED OR Check - empty scale
TARED. Weight value out of normal range.
Err 17 SYSTEM DATE-TIME is wrong Enter new date-time.
Err 18 INCORRECT RECIPE NUMBER Program correct one.
Err 40 ABORT RECIPE Press “START” to abort batch. The recipe is
Operator break or Dynamic overweight discontinued and further batches are disabled.
control Execute Fn 46 to enable batch.
Err 41 NO RECIPE STEPS TO EXECUTE Program recipe.
Err 42 NO RECIPE WEIGHTS PROGRAMMED Program recipe weights.
Err 43 NO BAG PRESENT Empty bag weight should be between empty and
high setpoint. Input “EXT. OK” should be ON.
Err 44 SCALE HAS BEEN TARED Press ESC
Err 45 SCALE IN MOTION Check mechanical and/or electronic scale parts
No weight value can be registered because the
scale is unstable.
Err 46 WRONG TIMER Program timers
Err 47 DOSING STEP CHECKSUM Check all batch parameters
Err 48 WEIGHT DECREASING Check scale outlet for possible leakage. Press
A negative weight change was sensed during START to continue or Esc and AE repeatedly to
filling go through Abort steps

12.4. PRINTER - PROTOCOL - TOTALISING MEMORY ERRORS

DISPLAY
Err 20 PRINTER IS NOT ON-LINE. Check printer, cables.
Either not connected or out of paper or failed Press CE to abandon print.
Err 30 PROTOCOL NOT ON-LINE. Check computer, cables.
Computer not connected or communication link failed. Press AE to transmit again (Pro ON)
or CE to abandon transmission (Pro
OFF). If nothing is pressed for 10 sec.
protocol output is automatically
enabled and retransmissions will
occur.
Err 33 PROTOCOL NOT ACKNOWLEDGE. The same action as with
No correct response has been received from the Err 30.
computer even after four (4) retransmissions
Err 34 PROTOCOL NACK. The same action as with
Computer response is always NACK. Err 30.
Err 67 TOTAL CHECKSUM. Clear totalising memory with FN 78.
Memory error.
Err 69 TOTALISER OVERFLOW. Print clear totalisers. Overflow is not
Because totalisers have not been cleared for long time. critical, but remember that 1 total
capacity must be added to the
indication, each time an overflow
occurs.

13. MAINTENANCE
The unit does not require any routine maintenance. It may be necessary to perform periodic checks of the
calibration of the scale due to mechanical reasons. The frequency of the calibration checks depends on
the
application condition and on the required measuring accuracy.
It may happen that, in exceptional conditions, the unit locks on a wrong memory location and it is not
possible to restart because the keyboard is not operative.
To restart it is necessary to switch the power OFF then ON again.
13.1. SERVICE
LEON ENGINEERING maintains a fully trained staff of field service engineers who provide :
- Technical assistance by telephone.

- Application assistance on-site or by telephone
- Start up assistance on-site
- Troubleshooting on-site or by telephone
- Warranty (replacement) or spare parts assistance
- Training on-site or at out service centre
- Equipment updates to our latest configuration.
Our engineers will check repair, mechanical, electrical, electronic, wiring and calibration errors.

14. SPECIFICATIONS
14.1. ENVIRONMENTAL AND ELECTRICAL CONSIDERATIONS

14.1.1. AMBIENT
TEMPERATURE : Storage - 20 to + 55 o C
Operating - 10 to + 40 o C
No direct sunlight to fall on the equipment.
14.1.2. HUMIDITY : 40 to 90% RH (non condensing)
14.1.3. VIBRATION : Severe vibration can affect the accuracy of weighing and damage
electric / electronic components.
14.1.4. AIR : The surrounding air should be dust free and not contain any
corrosive gasses or materials which could adversely affect the
equipment.
14.1.5. PROTECTION : IP 40 for front panel. IP 55 and IP 65 on request.
14.1.6. ELECTROMAGNETIC
FIELDS : Heavy electrical equipment should not be installed close to the
weighing equipment.
14.1.7. POWER SUPPLY : . 220 VAC ± 10%, 50 Hz ± 2%, 5% max distortion

. Consumption 5 VA max.
. Insulation 10 MW min (at 500 Vdc) between AC
terminal and housing.
. Noise immunity 1000 Vp-p/100 ns/rise time 1ns.
14.1.8. INCOMING AND

OUTGOING
SIGNALS : Relays and contactors connected to our equipment must have
reliable and effective interference suppression. This also applies
to
other equipment located within a distance of 3m from our
equipment. Cabling must be performed according to normal
practice.
14.1.9. NOTES : . WELDING on or in the vicinity of the equipment is strictly

prohibited.
. STATIC loads, caused by thunderstorms, have to prevented
from
developing by use of reliable lightning conductors.
. ENSURE that the cooling of the equipment is not obstructed.

14.2. TECHNICAL SPECIFICATIONS

14.2.1. CPU
CHARACTERISTICS : MPU, 64180/6, 64K ROM, 32K-128K RAM serial
EEPROM. Real time clock.
MEMORY PROTECTION : Reset disable and battery backed for two years. Write
protect on recipe memory.
KEYBOARD : 23 key flat membrane, with acoustic feedback.
SELF DIAGNOSTICS : Hardware and Software, CPU watchdog.

Memory failure
I/O failure
Program check
DISPLAY : 6 digit, 14mm high seven segment LED red.
14.2.2. COMMUNICATIONS : COM 1 Serial RS232C for printer

COM 2 Serial or 20mA for Host
14.2.3. INPUTS : . 24 Vdc ± 20 %, positive common.

. Input impedance 3,3 KW
. ON voltage 15 Vdc
. OFF voltage 5 Vdc
. ON delay 2 msec max. OFF delay 2msec max.
. All inputs optoisolated to 2,5 KV
14.2.4. OUTPUTS : . 24 Vdc ± 10 % transistor

(SOURCE) darlington, positive common.
. Max current 200 mA
. Max off - state voltage 30 Vdc.
. leakage current 100 mA.
. ON delay 2 msec max
. OFF delay 2 msec max
. All output optoisolated to 2,5 KV.
14.2.5. LOAD CELL

ANALOG INPUT : . Autozeroed, full scale 30mV/V
. Sensitivity 0,35mV/ digit
. Input impedance 20mW typical
. Input bias current 10nA typical
. Input noise voltage 0,35mV p-p typical
. Analogue filter 2-pole 5Hz

14.2.6. LOAD CELL EXCITATION : - Voltage + 5Vdc, with sense.

- Current 350 mA max.
14.2.7. ANALOG TO DIGITAL
CONVERTER : - Ratiometric
- 5 to 70 conversions / sec configurable.
- Resolution internal 20 bit.
- Display resolution, any programmable
according
to application.
14.2.8. ACCURACY & STABILITY : - Linearity better than 0.002% of full scale.
- Temperature Coefficient of SPAN < 2 ppm /
o
C.
- Temperature Coefficient of ZERO < 3 ppm /
o
C.
- Long term stability 0.01% of full scale per
year.
14.2.9. HIGH LEVEL ANALOG

INPUT : - Full scale 0 - 10Vdc
- Sensitivity 10mV
- Input impendance 10K / 1nF
- Input bias current 1 n A
14.2.10.ANALOG OUTPUT : CURRENT : 0-20mA or 4-20mA

setup selectable.
Hardware selectable Max resistance 1KW
between current or Voltage (line +termination).
Optoisolated to 2,5KV
Software programmable Zero
and range.
VOLTAGE : 1-10 Volt into 10KW load.
Sofware programmable Zero
and range.

15. PROCESS INPUTS-OUTPUTS DESCRIPTION
15.1. DIGITAL INPUTS : 24 Volt optoisolated.
1-4. RECIPE SELECT : SELECT VIA BCD option.

Sampled at the beginning of each batch cycle only.
5. START / RUN : In gross mode starts a batch cycle. In net mode

activates
“BACK HOLD”.Must stay active for 200 msec to be
accepted.
6. TARE : Enables Tare key
7. AUTO/MANUAL : If switched to manual the current batch will be

terminated, and starting a new batch is not possible.
8. EXT OK : External conditions OK. (Bag is present, air pressure).
CONNECTIONS : (J5) DB 25 male.

Pins 16 - 23 = Inputs 1 - 8 respectively
Pins 24, 25 = Input common (OV)
RAIL TERMINALS 17 - 24 = Inputs 1 - 8
25 = Common (OV)
15.2. ANALOG INPUT : 0-10V for other analogue inputs except loadcells.
Zero and range are software programmable.
CONNECTIONS : (J1) DB15 female.

Pin 9 = + Vin
Pin 10 = COMMON
RAIL TERMINALS 41 = +Vin
42 = COMMON

15.3. OUTPUTS : 24Vdc optoisolated
1 - 4 RESERVED :
5. BAG HOLD : Holds bag until the correct quantity is weighed.
6. SCALE EMPTY : Activated when the scale is within zero tolerance and
stable. It will remain ON even if the scale is not stable
as long as the scale is in empty tolerance and is not
tared.
7. COARSE : Dosing at high speed. It is activated for each ingredient
during batching. It is deactivated when the scale weight
exceeds the (setpoint - fine) quantity.
8. FINE : Dosing at low speed. It is activated for each ingredient
during batching.It is deactivated when the scale weight
exceeds the setpoint.
9. BATCH COMPLETE : Filling is complete signal. Activated after completion
of dosing of all ingredients and printout of batch report.
It is not activated if a filling cycle is terminated (by
Esc).
It is deactivated in discharging when the scale weight
is decreased by 20% (from the total value).
10. DISCHARGE : Discharging of the scale enabled. Activated in the
batch complete position by input Discharge. It will
remain ON until the scale is empty.
11. SCAN BCD : Toggled after a “START” to select the two nibles of
recipe Nr when recipe selection is from inputs (setup
1.4=0).
12. ALARM : Activated whenever there is an error. It is deactivated
when acknowledging the error (key CE = CLEAR).
CONNECTIONS : J5 DB25 male.
Pins 1-12 = Output 1-12 respectively
13, 14, 15 = Output common (24Vdc)
RAIL TERMINALS 26-37 = Output 1-12
respectively
38 = COMMON (24Vdc)
15.4. ANALOG OUTPUT : 16 bit D/A output current or voltage hardware selected.
Current may be 0-20mA or 4-20mA setup selectable.
Voltage may be 1-10 V.
CONNECTIONS : (J6) DB 9 female.
Pin 1 = I +
Pin 2 = V +
Pin 3 = COMMON (I or V)
RAIL TERMINALS 39 = +I or V
40 = COMMON

16. SERIAL COMMUNICATION PORT 1. (RS232C)

The port is used to connect to serial printers or personal computers. Data output and handshake
requirements are defined by SETUP 2.
TYPE Asynchronous serial ASCII, RS232C standard, full duplex.
PROTOCOL 1200 - 9600 baud, 1 start, 7 or 8 data, no or even parity, 1 stop bit.
Default is 2400 baud, 8 data and even parity.
HANDSHAKE DTR BUSY per character for fanfold printers.
CONNECTION DB9 male on rear panel. (J4) RAIL TERMINAL
Tx = Pin 3 8
Rx = Pin 2 9
GND= Pin 5 10
RTS = Pin 7 11
CTS= Pin 8 12
Cable 4 conductor shielded max distance 15m
DATA The data output of serial port 1 is selectable via SETUP 8, and maybe
one of printer output, continuous weight output, or demand weight
output
16.1. PRINTER OUTPUT (SETUP 2 2.t=01)

The data to be printed, printer type and paper dimensions is defined in SETUP 8.
16.2. CONTINUOUS WEIGHT OUTPUT (SETUP 2 2.t=02)

The indicated weight and status information is transmitted continuously. No handshake is required.
Connect Pin 7 to Pin 8 of connector J4 if the CTS input is not connected to the host.
DATA BLOCK COMPOSITION

STATUS, POLARITY, WEIGHT, SYNC (P+123.4500000CR)
BYTE NAME DESCRIPTION
1 WEIGHT Bit0 0=NORMAL 1=NO WEIGHT DISPLAY
STATUS Bit1 0=GROSS 1=NET
Bit2 0= 1=AUTO ZERO
Bit3 0=WITHIN RANGE 1=OUT OF RANGE
Bit4 0=NO STANDSTILL 1=STANDSTILL
Bit5 0=NORMAL 1=UNDER MIN. WEIGHING RANGE
Bit6 ALWAYS 1 TO OBTAIN PRINTABLE CHARACTERS
Bit7 ZERO OR PARITY
2 POLARITY "+" OR "-"
3-8 WEIGHT 6 DIGITS DEPENDING ON D500BC SET-UP
9 SPACE INCLUDING DECIMAL POINT IF ANY
10-11 DIGITAL 2 BYTES REFLECTING THE STATUS OF THE INPUTS IN ASCII HEX
INPUTS (MSD FIRST)
12-14 DIGITAL 3 BYTES REFLECTING THE STATUS OF THE OUTPUTS IN ASCII HEX
OUTPUTS (MSD FIRST)
15 SYNC CR (0d hex) FOR SYNCHRONISATION
16.3. PRINT ON DEMAND (SETUP 2.t=03)

The weight data is transmitted every time a character is received from the connected peripheral.
The demand character is programmed in SETUP 3 3.t., “INSTRUMENT COMMUNICATION TYPE”
e.g. “1” 49d or 31 hex.

17. SERIAL COMMUNICATIONS PORT 2 (20mA Current Loop)
The port is used for connection with Host computer, remote printer, remote display etc.
The mode of operation is selected in SETUP 3.
1: 3.t = 00 Disable
2: 3.t = 01 Continuous weight output
3: 3.t = 02 EDP protocol output
4: 3.t = 03 Printer protocol output
5: 3.t = 65 - 89 Master / Slave operation
TYPE Asynchronous serial ASCII, 20mA full duplex, passive.

PROTOCOL 600-9600 baud, 1 start, 7 or 8 data, no or even parity, 1 stop bit.
Default is 2400 baud, 8 data and even parity.
CONNECTION DB9 female on rear panel. (J3). RAIL TERMINAL
+ Tx = Pin 2 13
- Tx = Pin 3 14
+ Rx = Pin 4 15
- Rx = Pin 5 16
SHIELD= Pin 1
Cable 4 conductor twisted pair and shielded max distance 600m.
17.1 CONTINUOUS WEIGHT OUTPUT (SETUP 3.t = 01)
The indicated weight and status information is transmitted continuously. No handshake is required.
DATA BLOCK COMPOSITION

STATUS, POLARITY, WEIGHT, SYNC (P+123.4500000CR)
BYTE NAME DESCRIPTION
1 WEIGHT Bit0 0=NORMAL 1=NO WEIGHT DISPLAY

STATUS Bit1 0=GROSS 1=NET
Bit2 0= 1=AUTO ZERO
Bit3 0=WITHIN RANGE 1=OUT OF RANGE
Bit4 0=NO STANDSTILL 1=STANDSTILL
Bit5 0=NORMAL 1=UNDER MIN. WEIGHING RANGE
Bit6 ALWAYS 1 TO OBTAIN PRINTABLE CHARACTERS
Bit7 ZERO OR PARITY
2 POLARITY "+" OR "-"
3-8 WEIGHT 4 TO 6 DIGITS DEPENDING ON D500BC SET-UP
9 SPACE INCLUDING DECIMAL POINT IF ANY
10-11 DIGITAL 2 BYTES REFLECTING THE STATUS OF THE INPUTS IN ASCII HEX
INPUTS (MSD FIRST)
12-14 DIGITAL 3 BYTES REFLECTING THE STATUS OF THE OUTPUTS IN ASCII HEX
OUTPUTS (MSD FIRST)
15 SYNC CR (0d hex) FOR SYNCHRONISATION

17.2 EDP PROTOCOL OUTPUT (SETUP 3.t = 02)

This mode is used to transmit the data printed to a host computer. Transmission will begin after completion of
printing. ACK / NAK handshake or no handshake may be used.
The host must reply with ACK (06 h) if it received the data correctly or NAK (15 h) to enable retransmissions.
DATA BLOCK COMPOSITION : STX = (02 h) = start of text character

DATA = Printable ASCII data identical to the data printed.
ETX = (03 h) = End of text character.
BCC = Block check character.(XORSUM of all data
characters STX, ETX inclusive)
HANDSHAKE : ENQ (05 h) from host within 5 sec of protocol initialisation.

ACK (06 h) from host within 5 sec after the end of transmission.
or NAK (15 h) from host within 5 sec after the end of transmission
to enable retransmissions of the block. The number of repeats is
unlimited.
ERRORS : Err 30 : Host not ready

Err 33 : Host not Acknowledge
Refer to Error chapter for details on error response.
17.3 MASTER / SLAVE OPERATION
Used to connect several D500 BC units in a local network to a higher level computer which acts as the
master.
Refer to LEON ENGINEERING SERIAL INTERFACE PROTOCOL (LESIP) for details.

GUARANTEE CERTIFICATE
We guarantee the proper operation and either cover free restoration of any probable
malfunction of the electronic indicator at our premises or replace of the electronic indicator
(according to our company's judgement) for the period of 18 months from the delivery day
of the scale, provided that:
1. The damage did not occur from the buyer's fault or from not following the
instructions.
2. No intervention of non authorised by LEON ENGINEERING S.A. personnel has

taken place for checking or repairing the equipment.
3. The WARRANTY RETURN CARD has been returned to LEON ENGINEERING.
In case of fault the unit should be returned to LEON ENGINEERING at the buyer's
expenses.
EQUIPMENT MODEL: D500 BC
SERIAL NUMBER: .................
Warranty Return Card

Please complete and return this card to LEON ENGINEERING S.A. in order to have your new D500BC
Indicator registered for warranty. Please keep Guarantee Certificate for your records.
Model Serial Number Date Received P.O. Number

Dealer from which this scale was purchased ?
Individual responsible for this purchase

Your Company's Name
Address
City State Postal Code Country
Telephone Fax
Where did you hear of LEON ENGINEERING's products?
Local Dealer Magazine Add Direct Mail Exhibition Other
How many additional scales of this type will you require ?
Will you be purchasing any of the below in One month Three months Six months Over six
months
Weighbridges
Platform Scales
Batching systems
Weighing machines
Computer based weighing systems


D 500BC-BOS: Bagging Scale Controller

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D 500BC-BOS: Bagging Scale Controller

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Technology and reliability that carries weight

Document Date Code Rev. Page

D500 BC-BOS REFERENCE MANUAL 13.10.98 D5BC_BOS.UM 0 1 of 47

4. FRONT PANEL SURVEY 10

11. ACCUMULATED RECIPE TOTALS 34

15. PROCESS INPUTS-OUTPUTS DESCRIPTION 42

16. SERIAL COMMUNICATION PORT 1 44

17. SERIAL COMMUNICATION PORT 2 45

Document Date Code Rev. Page

D500 BC-BOS REFERENCE MANUAL 13.10.98 D5BC_BOS.UM 0 2 of 47

The standard configuration includes :

1. High accuracy analog to digital converter.

Operation can be manual, local automatic, remote automatic.

Document Date Code Rev. Page

D500 BC-BOS REFERENCE MANUAL 13.10.98 D5BC_BOS.UM 0 3 of 47

2.1. The standard supply includes :

1. The connection plug for the load cell cable.

1. Install the hardware.

Document Date Code Rev. Page

D500 BC-BOS REFERENCE MANUAL 13.10.98 D5BC_BOS.UM 0 4 of 47

- Instantaneous calculation of weight.

- Recipe inspect - modify.

3.3. Control functions generate the dosing sequence and include :

- Operating modes - Enable/Disable Batching.

3.4. Logging functions

3.5. Monitoring functions

Document Date Code Rev. Page

D500 BC-BOS REFERENCE MANUAL 13.10.98 D5BC_BOS.UM 0 5 of 47

Monitoring is performed on following :

- Processor and Peripherals.

3.6. Set-up functions

- Init Installation of default parameters to enable operation.

3.7. Test functions

Document Date Code Rev. Page

D500 BC-BOS REFERENCE MANUAL 13.10.98 D5BC_BOS.UM 0 6 of 47

3.8. BATCHING FUNCTIONS

1 IN FLIGHT COMPENSATION IFC

2 REFEED / JOGGING JOG

3 FEEDING TIME MONITOR FTM

4 WEIGHT DECREASING SENSOR WDS

5 WEIGHT COMPARE INHIBIT TIMER WCI

6 FINE DELAY FDV

7 FINE - COARSE – FINE FCF

3.8.1 IN FLIGHT COMPENSATION ( IFC )

i. PREACT MODE SETUP 5.5 = 1 SETUP 5.6 = 0

ii. AUTOMATIC MODE SETUP 5.5 = 1 SETUP 5.6 = 1

Document Date Code Rev. Page

D500 BC-BOS REFERENCE MANUAL 13.10.98 D5BC_BOS.UM 0 7 of 47

3.8.2 REFEED / JOGGING ( JOG )

i. NORMAL SETUP 7.5 = 1 SETUP 5.7 = 0

ii. JOGGING SETUP 7.5 = 1 SETUP 5.7 = 1

NOTE : - Jogging times are in tenths of a second.

3.8.3 FEEDING TIME MONITOR ( FTM )

3.8.4 WEIGHT DECREASING SENSOR ( WDS )

Document Date Code Rev. Page

D500 BC-BOS REFERENCE MANUAL 13.10.98 D5BC_BOS.UM 0 8 of 47

3.8.5 WEIGHT COMPARE INHIBIT TIMER ( WCI )

3.8.6 FINE DELAY FOR ELECTRIC VANES (FDV)

3.8.7 FINE - COARSE - FINE (FCF)

Note: Jog operation should be disabled (setup 5.7=0).

Document Date Code Rev. Page

D500 BC-BOS REFERENCE MANUAL 13.10.98 D5BC_BOS.UM 0 9 of 47

4. FRONT PANEL SURVEY