
See why Edge use
single point loadcells for converting retail space into sales
Edge NPD’s underStand is an Internet of Things hardware and software solution for both retailers and manufacturers. It is a weight sensor-based, cloud connected device which collects and processes data from POS in real time.
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See why FPGA Company use
Single point loadcells for innovative beehive weighing system
FPGA company developed an innovative beehive, they have called it HiveWatch. Zemic Europe developed and supplied FPGA company with a customized version of a single point loadcell for their beehive weighing system.
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See why the Elevator market uses
Elevator weighing systems for overload detection
The engineering teams at Zemic worked together with key elevator manufacturers to develop a new and innovative solution for elevator overload protection.
Read the case study
See why Innovend use
L6T Loadcells for suitcase selection
Innovend has started to install the Samsonite Cabin Size Scanner in several stores in City Centre and Airports. The Cabin Size Scanner has been developed by Innovend and helps consumers at Samsonite stores to select the right suitcase that is accepted by your airline as Cabin Size.
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See why Team Phidippides use
H3 S-type loadcells for brake force solution
The team has developed a roller bench to make a simulation of the track. In this way they can test the efficiency of new components and the car. To measure the force on this bench Team Phidippides made contact with Zemic Europe. With our H3 S-type load cell we managed to make a perfect solution.
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See why Rega use
Q70 miniature force sensors for Atlas tracking scale
Zemic force sensors used to enhance the quality of sound on turntables with the development of the Atlas tracking force scale.
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See why Omnidea use
H3G S-type loadcells to capture high altitude wind energy
Omnidea uses a Zemic H3G loadcell for High Altitudy Wind Energy Conversion. Until now electricity production from wind has been derived exclusively from wind turbines. H.A.W.E. offers a radical new alternative to current wind generators.
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See why Phenospex use
modified L6N Loadcells to measure transpiration of plants in any condition
In the first complicated project with a large amount of load cells that needed to reach high quality level in varying temperature, close communication was needed with engineers both in Europe and in China to enable deep understanding for Phenospex.
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See why Vitalgo use
modified H8C Loadcells for Total Lift Bed
Zemic Europe was honoured to help Vitalgo in the design of the Total Lift Bed new weighing system; one scale located in the sleep deck and one located in the patented Foot Lifter™ footboard.
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See why Novuqare use
modified 1B-S Miniature Sensors for sterile sealing of medical instruments
The miniature sensors in the Novuqare's sealing devices are used to measure the force applied during the sealing process. It is vital that the medical bags are sealed, under sterile conditions, using the correct amount of pressure.
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See why Zemic Europe takes
part in sustainable bicycle alternative
Together with the EBCC (E-Bike competence center) of the Acell Group, European marketleader of e-bikes, Zemic has developed a force sensor to measure the pedal force on electrical bikes.
Read the case study
See why Van Hees Machinery use
BM8H shearbeams and weight transmitters in agricultural allround machine.
Together with Zemic Europe, Van Hees Machinery has found a solution for their most efficient Nº1 BoxFilr machine.
Read the case studyYour partner for force measurement!
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Best quality /service /price ratio
90.000m2 hi-tech automated production facility
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Fast Delivery weighing parts
40.000 + loadcells on stock in European headquarter
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Custom made force sensors
225 + professional engineers -
Wide program of
sensors
1.000+ standardized force sensors 20grams - 1000t
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Product Search
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A Package
Cells custom1
Cells custom2
Cells custom3
-
Cells custom4
B Package
transducer aa1
transducer aa2
transducer ab1
transducer Bb1
- How can I contact Zemic Europe?
By phone: +31 76 503 94 80
By fax: +31 76 503 94 81
By e-mail: info@zemic.nl
Fill in the contact form
By skype
By online chat
By visiting exhibitions
- Where can I find the administration details for Zemic Europe?
Zemic Europe B.V.
Leerlooierstraat 8
4871 EN Etten-Leur
The NetherlandsTel: +31 765039480
Fax: +31 765039481Chamber of commerce nr.
32112172VAT Number Zemic Europe B.V.:
NL 815256152-B01Euro Bank Account Information:
Bank : ABN AMRO BANK
IBAN: NL53ABNA0811130290
BIC/SWIFT: ABNANL2A - What could be wrong with our loadcell?
LOAD CELL TROUBLESHOOTING
Introduction
Load cells are designed to sense force or weight under a wide range of adverse conditions; they are not only the most essential part of an electronic weighing system, but also the most vulnerable.
Load cells might be damaged because of (shock) overloading, lightning strikes or heavy electrical surges in general, chemical or moisture ingress, mishandling (dropping, lifting on cable, etc.), vibration or internal component malfunction. As a direct result the scale or system might (zero) drift, provide unstable / unreliable readings or not register at all.
This application note is written to assist users with potential load cell problems. It describes basic field tests which can be performed on site*, and provides the information necessary to interpret the results.
*Proper field evaluation is absolutely critical to prevent similarly induced damage in the future! Under no circumstances should fault location, as described below, be attempted on load cells installed in a hazardous area!IN GENERAL
Carefully check the system integrity before evaluating the load cells:
- check for force shunts (might be caused by dirt, mechanical misalignment or accompany¬ing components such as stay- or check rods.
- check for damage, corrosion or significant wear in the areas of load introduc¬tion.
- check cable connections to junction box and indicator.
- check the measuring device or indicator with an accurate load cell simulator.
Visually inspect the load cells before performing the tests as described on the following pages. Pay particular attention to signs of corrosion (especially around the critical gauge area), the integrity of the cable (might be compromised due to cuts, abrasions, etc) and the condition of the cable entry.The following test equipment is required to properly evaluate a load cell:
- A high quality, calibrated, digital volt- and ohmmeter with a measuring accuracy of ≤0.5Ω and ≤0.1 mV, to measure the zero balance and integrity of the bridge circuit.
- A megohm meter*, capable of reading 1000 Mohms with a resolution of 1 MΩ at 50 volts DC, to measure the insulation resistance.
*Do not use megohm meters which supply more than 50 volts to the load cell, in order to prevent permanent damage!
- Or use a portable multifunctional calog hand held tester.
- A means to lift the dead load (weighbridge, tank, hopper, conveyor, etc.) off the load cell to be able to measure the zero balance or to remove the load cell(s), i.e. a crane, hydraulic jack, etc.
Load cells are produced according to specifications and tolerances which are described in the applicable data sheet. More detailed information can be found on the calibration sheet which is packed with each load cell. The calibration sheet mentions the exact values for the input and output resistance, insulation resistance, zero balance, rated output and the correct wiring code; it provides an important reference for the values which can be measured and should be filed with the system documentation set.TEST PROCEDURES AND ANALYSIS
The diagram below represents a proposed sequence for testing load cells after a particular system malfunction. Isolate the fault location by moving a relatively small deadweight over each load cell, or by disconnecting load cell by load cell.TEST #1: ZERO BALANCE
The Zero Balance is defined as the load cell output in a "no-load" situation. Therefore, all weight (including deadload) has to be removed from the load cell. Low capacity load cells should be measured in the position in which the load cell is designed to measure force to prevent the weight of the element giving wrong results.
The load cell should be connected to a stable power supply, preferably a load cell indicator with an excitation voltage of at least 10 volts. Disconnect any other load cell for multiple load cell systems.
Measure the voltage across the load cell's output leads with a millivoltmeter and divide this value by the input or excitation voltage to obtain the Zero Balance in mV/V. Compare the Zero balance to the original load cell calibration certificate ( if available ) or to the data sheet.ANALYSIS
Changes in Zero Balance usually occur if the load cell has been permanently deformed by overloading and/or excessive shocks. Load cells that experience progressive zero output changes per time period are most likely undergoing a change in the strain gauge resistance because of chemical or moisture intrusion. However, in this case the insulation resistance and/or the bridge integrity will also be compromised.TEST #2: INSULATION RESISTANCE
The insulation resistance is measured between the load cell circuit and element or cable shield. Disconnect the load cell from the junction box or indicator and connect all input, output and sense (if applicable) leads together.
Measure the insulation resistance with a megohmmeter* between these four or six connected leads and the load cell body. Repeat the measurement between the same 4 or 6 leads and the cable shield. Finally measure the insulation resistance between the load cell body and cable shield.
*Never use a Megohmmeter to measure the input or output resistance, as it normally operates at a voltage which exceeds the maximum excitation voltage by far!
* If shield is connected to load cell body please skip housing / screen insulation test.ANALYSIS
The insulation resistance of all load cells should be 5000 megohms or more for bridge circuit to housing, bridge circuit to cable screen and load cell body to cable screen.
A lower value indicates electrical leakage, which is usually caused by moisture or chemical contaminations within the load cell or cable. Extremely low values (< 1kΩ ) indicate a short circuit rather than moisture ingress.
Electrical leakage results usually in unstable load cell or scale reading output. The stability might vary with temperature.TEST #3: BRIDGE INTEGRITY
The bridge integrity is verified by measuring the input and output resistance as well as the bridge balance. Disconnect the load cell from the junction box or measuring device.
The input and output resistance is measured with an ohmmeter across each pair of input and output leads. Compare the input and output resistance to the original calibration certificate ( if available ) or to the data sheet specifications.
The bridge balance is obtained by comparing the resistance from -output to -input, and -output to +input. The difference between both values should be ≤ 1Ω.ANALYSIS
Changes in bridge resistance or bridge balance are most often caused by a broken or burned wire, an electrical component failure or internal short circuit. This might result from over-voltage ( lightning or welding ), physical damage from shock, vibration or fatigue or excessive temperature.TEST #4: SHOCK RESISTANCE
The load cell should be connected to a stable power supply, preferably a load cell indicator with an excitation voltage of at least 10 volts. Disconnect all other load cells for multiple load cell systems.
With a voltmeter connected to the output leads, lightly rap on the load cell with a small mallet to mildly shock it. Exercise extreme care not to overload low capacity load cells while testing their shock resistance.
Watch the readings during the test. The readings should not become erratic, should remain reasonably stable and return to original zero readings.
ANALYSIS
Erratic readings may indicate a failed electrical connection or a damaged glue layer between strain gauge and element as a result of an electrical transient.,
- What is the complete description for Zemic Europe weighing components for export purposes (tariff code, description, country of origin)?
Product: load cells / electronics
HS code: 8423.9010.00
Origin: China - What is the complete description for Zemic Europe weighing components for export purposes (tariff code, description, country of origin)?
Product: load cells / electronics
HS code: 8423.9010.00
Origin: China - How can I connect more load cells to one transmitter?
By using a junction box you can connect more loadcells to one device.
- What kind of straingages does Zemic offer?
BF Series
Fully encapsulated Constantan foil strain gauges with modified Phenolic backing. Offers both Self-
Temperature (or elastic modulus) and creep compensation simultaneously. Has high accuracy and
excellent stability but only at room temperature. Especially suitable for accuracy class 3 transducers.
Easy to use and available in a resistance range of 60 up to 1000Ω.
ZF Series
Fully encapsulated Karma foil strain gauges with modified Phenolic backing. Offers both Self-
Temperature (or elastic modulus) and creep compensation simultaneously. Has high accuracy
and excellent stability over a wide temperature range. Especially suitable for accuracy class 0.02
transducers. Especially suitable for usage with DC/AC electronic weighing instruments.BA Series
Fully encapsulated Constantan foil strain gauges with a polyimide backing. Offers Self-Temperature
compensation. Has a high elongation rate and excellent heat resistance on a wide temperature
range. Primarily intended for both stress analysis and normal accuracy transducers with usage of
temperatures up to 150℃ .BAM Series
Fully encapsulated Constantan foil strain gauges with thin polyimide film backing. Offers both Self-
Temperature (or elastic modulus) and creep compensation simultaneously. Has a high elongation
rate and excellent heat resistance on a wide temperature range and low hydroscopicity. Shows good
specifications for creep and zero-return. The strain gauges are primarily intended for high accuracy
transducers at class 3 or better.BHB Series
Fully encapsulated Constantan foil strain gauges with glass fibre reinforced epoxy backing. Offers
both Self-Temperature (or elastic modulus) and creep compensation simultaneously. Has high
accuracy and excellent stability over a wide temperature range and high moisture resistant capability.
Has a low hydroscopicity and shows good specifications for creep and zero return. The strain gauges
are primarily intended for high accuracy transducers at class 3 or better.ZAM Series
Fully encapsulated Karma foil strain gauges with thin polyimide film backing. Offers both Self-
Temperature (or elastic modulus) and creep compensation simultaneously. Has high accuracy and
excellent stability over a wide temperature range and high moisture resistant capability. Has a low
hydroscopicity and shows good specifications for creep and zero return. The strain gauges are
primarily intended for high accuracy transducers at class 3 or better.BB (BAB) 250°C Series
Karma foil strain gauges with Glass Fibre Reinforced Polyimide Backing. Offers an excellent heat
resistance, good insulation and high stability. The strain gauges are primarily used for both high
precision stress analysis and accurate transducers with a usage temperature up to 250℃ .BYM Series
Fully encapsulated Constantan foil strain gauges with a special thin polyimide film backing. Offers
both Self-Temperature (or elastic modulus) and creep compensation simultaneously. Has a high
elongation rate and excellent heat resistance on a wide temperature range and low hydroscopicity.
Shows good specifications for creep and zero-return. The strain gauges are primarily intended for
high accuracy transducers at class 3 or better.
ZYM Series
Fully encapsulated Karma foil strain gauges with a special thin polyimide film backing. Offers both
Self-Temperature (or elastic modulus) and creep compensation simultaneously. Has high accuracy
and excellent stability over a wide temperature range and high moisture resistant capability. Has a
low hydroscopicity and shows good specifications for creep and zero return. In addition it can realise
high resistances with small size strain gauges which makes it excellent for usage in low power
devices. The strain gauges are primarily intended for high accuracy transducers at class 3 or better.
BKM Series
Fully encapsulation Constantan foil strain gauge with a special PEEK film backing. Offers both Self-
Temperature (or elastic modulus) and creep compensation simultaneously. Has high accuracy
excellent stability and high moisture resistant capability. Shows good specifications for creep and
zero return. The special PEEK film backing has an exceptional high toughness. The strain gauges are
primarily intended for high accuracy transducers at class 3 or better.
BEB Series
Fully encapsulation Constantan foil strain gauge with a Glass fibre reinforced epoxy backing.
Offers both Self-Temperature and creep compensation simultaneously. Has an elastic modulus
compensated backing. Has an excellent creep and zero return, responds quickly to applied load
and recovers directly to zero. In addition it has a high thermal stability and is used for high precision
transducers and high precision aluminium scales. - How can the change in Thermal output be kept very close to zero?
Strain gauges are usually installed on a surface whether it is for stress analyses or sensor production, without any external forces applied to the surface. When environmental temperature changes, the resistance of the strain gauge changes accordingly. This phenomenon is called the strain gauges thermal output. This thermal output is the result of interactions and superposition of the resistance
temperature coefficient of grid materials, the sensitive grid materials and the linear expansion coefficient. The effects of these factors is described in the formula below:
εt=[(αg/K)+(βs-βg)]△t
In this formula αg and βg refer to the resistance temperature coefficient of the grid material and the linear expansion coefficient of the strain gauge. K refers to the strain gauges gauge-factor and
βs refers to the linear expansion coefficient of the tested object . Δt refers to the relative change in temperature of the tested subject and environment. Common strain gauges often have a large thermal output as shown in figure 1. Thermal output is the biggest source of errors in static strain measurements. When temperature increases the dispersion and therefore the thermal output value increases. Ideally the thermal output of strain gauges should be zero. To meet this requirement a self-temperature compensating strain gauge is used. In figure 2 the typical thermal output of a constantan and a self-temperature compensating karma strain gauge are displayed.
Figure 1: Thermal output curve of strain gauges on different steel materials
Figure 2: Thermal output for Self-Temperature compensated Karma and Constantan alloy strain gauges
By adjusting the composition ratio of the alloys of the strain gauge sensitivity grid material, and make use of cold rolling and proper heat treatment, the internal crystalline structure of the gauge material can be altered in a way it will compensate the changes of the material due to temperature change. This way the change in Thermal output can be kept very close to zero and the standards for highprecision sensors and stress analysis can be met. Note that the self-temperature compensation is only in a small temperature range from approximately + 20℃ up to +250℃ .
Have a Technical Question?
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