Service Manual. Eclipse Scale Series. Model: PPI-HR5000 HR by Fairbanks Scales Inc. All rights reserved. Issue #8 7/03

Transcription

1 Service Manual Eclipse Scale Series Model: PPI-HR5000 HR by Fairbanks Scales Inc. All rights reserved Issue #8 7/03

2 Amendment Record Eclipse Scale Series PPI-HR5000, HR / SJ4609 Manufactured by Fairbanks Scales Inc. 821 Locust Kansas City, Missouri Created Issue #1 Issue #2 Issue #3 Issue #4 Issue #5 1/99 Addition of the 24 x 24, 200, 500, 1000 lb. Issue #6 10/99 New PCB, software, checkweighing options. Issue #7 6/01 Products are now ordered as distinct components, no complete assemblies New Pillar Kits Issue #8 7/03 Product Improvement - Additional capacities added to software /03 Issue #8

3 Table of Contents Forward: Section 1: Introduction Section 2: Description Section 3: Getting Started with the Indicator A. Installation B. Keys C. Switches D. Annunciators E. LED s Section 4: Setup & Programming A. Programming Access B. Keys and Switches in Programming C. Program Steps Section 5: Calibration A. Standard A/D Calibration, prom (since 10/99) B. Standard A/D Calibration, prom (before 10/99) C. Span Calibration Mode D. Analog Filtering SW4 (before 10/99) Section 6: Operation A. Basic Gross Weighing B. Net Weighing Using Autotare C. Batching/Blending D. Checkweighing Using the Weight Display E. Using the Checkweighing LEDs, PS3 Mode F. Checkweighing Setup G. Indicator RS232 Output Programming /03 Issue #8

4 Section 7: Parts Replacement A. Toggle Switch Replacement B. Main PC Board Replacement C. Display PC Board Replacement D. Load Cell Replacement, except 24x24 (before 06/01).. 34 E. Load Cell Replacement, 24x24 (before 06/01) F. Grounding G. Sealing the Scale Section 8: Parts A. HR5000 Instrument B. HR5000 with RS C. Pillar Support except 24x24 (before06/01) D. Platforms, All except 24x E. Pillar Support 24x24 Only (before 06/01) F. Platforms 24x24 Only Appendix I: Quick Reference Appendix II: Checkweighing Appendix III: Remote Wiring Appendix IV: Data Output Format & Pin-Outs for Interfacing Appendix V: Troubleshooting Flow Chart Appendix VI: Troubleshooting Appendix: VII: Original & Intermediate Eclipse Model Numbers. 53 A. Mode/Product Number B. Technical Specifications Disclaimer Every effort has been made to provide complete and accurate information in this manual. However, although this manual may include a specifically identified warranty notice for the product, Fairbanks Scales makes no representations or warranties with respect to the contents of this manual, and reserves the right to make changes to this manual without notice when and as improvements are made /03 Issue #8

5 Forward: Foreword: The Eclipse Series of scales/indicators continues to evolve. Original units were partially assembled integral units of platform and indicator, and pillar if chosen. They were factory wired and calibrated. Intermediate units (aprox. 10/99) were the same platform, indicator, and pillar complete scale a new PCB and upgraded software that included better O/U capabilities. Newer units (aprox. 06/01) are ordered as stand-alone components. Eclipse platforms, indicators, and pillars are ordered individually. You can use an Eclipse platform on any compatible indicator, and an Eclipse indicator on any compatible platform. Newer Pillar Kits (aprox. 06/01) are used to combine Eclipse platforms and any of four Fairbanks indicators to make an integral indicatorpillar-platform unit. Use Kit Installation Bulletin All Eclipse models and 'generations' are included in this service manual /03 Issue #8

6 Section 1: Introduction A. The information in this manual applies to the HR5000 Series indicator, including those with RS-232 output unless otherwise indicated. CAUTION: This product is shipped from the factory set for VAC operation. For VAC operation, settings must be changed before powering up. See setup below for VAC settings. 1. Ensure the AC power cord is disconnected from any power sources. 2. Remove the cover, disconnect all cables from the PC board and place the unit face down on a bench. 3. On the main PC board, locate the links at JP1 and JP2 between the power connector TB2 and the transformer (see picture below). Remove both JP1 and JP2 links. JP1 JP1 JP2 JP2 JP3 115 Volt 230 Volt Install a new link across JP3. 5. Remove the 120 VAC plug from the end of the power cord and attach a proper VAC plug. Connect the shield wire to the ground wire. 6. Reattach all cables and replace the front cover assembly. CAUTION : Improper connections at JP1, JP2, and/or JP3 can cause catastrophic failure of the indicator /03 Issue #8

7 Section 2: Description The HR5000 Series scales are designed for light capacity, highspeed weighing operations. The indicators have a bright, 6-digit vacuum florescent display with annunciators for center-of-zero, net weight, and weight units. The HR5000 Series indicators have a sealed toggle switch for ZERO and AUTOTARE, located on the side of the case. Two front panel pushbuttons are provided for switching between GROSS and NET weighing modes and changing the displayed units of weight. An internal terminal block can be used to remotely switch Zero, Autotare, and Print. The scale can be operated as a checkweighing system, with the UNDER, ACCEPT and OVER ranges controlled by the user from the front panel. The HR5000 Series can be interfaced to a printer or a computer with accessory When RS232 output is (factory) installed, the scale is equipped with a print switch located on the front of the indicator. When the switch is pressed, weight data is sent via the RS232 output to the connected device. Certifications: NTEP CC: CWM: AM /03 Issue #8

8 Section 3: Getting started with the Indicator A. Installation 1. Unpacking and Assembly: The indicator can be mounted on a pillar on the platform, or mounted with a bracket on the wall. 2. Pillar Mounting the Indicator (on an Eclipse base): a. Use the instructions in Bulletin for mounting the indicator to an Eclipse pillar and platform. 3. Wall Mounting the Indicator: a. Secure the wall mounting bracket to the wall, within reach of the power receptacle. b. Install the indicator on the wall bracket. c. Place the platform in a position within cable reach of the indicator. d. Route the cables so they are protected. 4. Load Cell/Platform Wiring: a. Remove the terminal block at TB1 on the main PCB and connect the load cell wires using a small screwdriver. Connections at TB1: Terminal # Description TB1-1 Excitation (-) TB1-2 Excitation (+) TB1-3 Sense (+) TB1-4 Sense (-) TB1-5 N/C TB1-6 Shield TB1-7 Output (+) TB1-8 Output (-) Note: If sense leads are used, locate jumpers TB6 & TB7, small wire links to the left of component C26, and to the upper left of TB1. Cut the jumpers being careful not to damage the small components. If you do NOT use the sensing circuit later on, use wire jumpers on the terminal block to connect TB1-1 to TB1-4, and TB1-2 to TB /03 Issue #8

9 B. Keys: 1. UNITS - Triple Function Key function 1: Switches the displayed weight between avoirdupois and metric weighing units. function 2: When the UNITS key is pressed and held for about 3 seconds, the indicator enters the front panel programming mode. function 3: When a value is shown on the display, pressing the key saves the value into the indicators memory. 2. GROSS/NET - Triple Function Key function 1: Selects weighing mode ( GROSS or NET) if AUTOTARE was enabled during service-programming: GROSS: Display indicates gross weight on platform and Net (NT) annunciator is OFF. NET: Display indicates net weight, derived by subtracting value in Tare Memory from weight on the platform, Net (NT) annunciator is ON. function 2. When the GROSS/NET key is pressed and held, the indicator enters the CHECKWEIGH mode. function 3. In Front Panel Programming Mode, the key is used to "skip" to the next program step without changing the current value /03 Issue #8

10 C. Switches : Side of the Indicator: The AUTO TARE and ZERO functions are controlled by a toggle switch on the side of the indicator. It is used to toggle through values when in the programming mode. PROG ENTER UNITS AUTO TARE CZ NT l b kg oz g UNDER ACCEPT OVER CHKWGH NEXT GROSS NET ZERO TOGGLE SWITCH OPERATION (SIDE OF INSTRUMENT) 2900 D. Annunciators: Various display annunciators are used in the display to indicate a function or mode, each is described below. 1. CZ: Annunciator will light when displayed weight is within +/- ¼ division of zero. 2. NT: Annunciator will light when displayed weight is Net, toggled ON and OFF using the GROSS/NET key. When the annunciator is OFF, displayed weight is Gross. The lb, kg, oz or g annunciator will light for the selected units using the UNITS key depending on indicator programming /03 Issue #8

11 E. LEDs UNDER: A steady yellow "UNDER" LED indicates that the weight on the scale is within a certain distance of the ACCEPT range on the low side (under range). The under (yellow) LED will flash when the weight on the scale is much less than the the "under" range (out-of-range-low). ACCEPT: A steady green "ACCEPT" LED will light when the weight on the platform is within the ACCEPT range. OVER: A steady red "OVER" LED indicates that the weight on the scale is within a certain distance of the ACCEPT range on the high side (over range). The OVER LED will flash red when the weight on the scale exceeds the "OVER" range (out-of-range-high) /03 Issue #8

12 Section 4: Setup and Programming A. Programming functions may be accessed from the front panel or PC Board switches. 1. To use front panel programming (with a "0" security level for full access): Press and hold the UNITS key for approximately 3 seconds. 2. To enter programming using the PCB switches, remove all screws holding the rear cover on the indicator and locate SW3. Pressing SW3 once enters the programming mode. Pressing SW3 twice enters the calibration mode. B. In the programming mode the keys and switches will operate as follows: 1. The UNITS key is used to store the displayed value and proceed to the next program step. If the GROSS/NET key is pressed, it will toggle to the next program step without changing the value. 2. The AUTOTARE/ZERO switch will toggle through the possible program values for the displayed program step. Moving the switch UP will increase the displayed value, moving the switch DOWN will decrease the displayed value. If the displayed step is not operator programmable, the switch will advance the program to the next step /03 Issue #8

13 C. Program Steps: Note : The steps marked with an " * " will show a display value, but can not be changed by the operator or from the front panel. Other steps may or may not be programmable based on the security level. Refer to step 12 for more information. *1. Program Number Display: This display will scroll the program number and revision level. This information should be recorded for reference should any problems arise with the operation of the scale. This is a non-programmable step. *2. A/D Counts Display: The display will show "Cxxxxx", where the "xxxxx" represents the A/D converter counts. Typically the display will read between 8000 and If the display reads outside this range, or shows a "- - UL - -" or "- - OL - -", the indicator may need to be re-calibrated. 3. Weight Units Selection: The display will read " U " and one to four of the units annunciator lights will be ON showing the current selection. Grad sizes of other weigh units are dependent on the primary unit grad size and are not independently programmable, i.e., a grad size of 1 on the primary unit (lbs) will be the same grad size for any other enabled unit. 4. Primary Weight Unit Selection: The display will read " PU " and one of the annunciator lights will be ON. The light indicates the primary weight unit. The primary weight unit determines the unit weight that the scale is calibrated in and the scale will start in this unit when the scale is powered up. NOTE : The primary weight unit must be one of the units selected in program step 3. *5. Scale Capacity: The display will read " CAPxxx ", where the " xxx " is the capacity of the scale. The capacity is displayed in either avoirdupois (lb) or metric(kg) units, based on the primary units selected in program step /03 Issue #8

14 6. Grad Size: This display will read " GSxxxx ", where the " xxxx " is the grad size. The grad size displayed is for the primary units selected in program step 4. Grad sizes of other weight units are dependent on the primary unit grad size and are not independently programmable. Grad sizes from to 500 can be selected. The grads sizes available are displayed when the " AUTOTARE/ZERO " switch is operated. If an unacceptable grad size is selected, an error message " E1L " or " E1H " will be displayed. A grad size is unacceptable if : 1. The number of divisions for any weight unit is less than The number of divisions for any weight unit is more than 10, AUTOZERO Tracking (AZT): The display will read " AO x.x ", where the " x.x " is the width of the AZT band in divisions. AZT enables the indicator to automatically zero off small changes in the zero balance of the scale within the AZT band. 8. Zero Limit Selection: The display will read " OL xxx ", where the " xxx " is 100 or 2. The Zero Limit controls the weight range over which the zero switch will operate. The weight range is either 100% or +/- 2% of the scale capacity. 9. AUTO TARE Selection: The display will read " AtArE x ", where the " x " will be a 1 or a 0. The "1" indicates the AUTOTARE feature is enabled and the "0" indicates the feature is disabled. NOTE : If the AUTOTARE is disabled, both the AUTOTARE switch and the GROSS/NET key will be disabled. The AUTOTARE feature allows the use of the switch to automatically tare off the current gross weight on the scale and switch to the NET weigh mode /03 Issue #8

15 10. Display Update Rate: The display will read " SEC x.x ", where the " x.x " represents the update rate in seconds. The rates available are 0.1, 0.3, 0.5, 0.8 and Digital Filter: The display will read " FF x ", where the " x " is the digital filter factor. The available values are 0,1, 2, 3, or 4. A "1" will give a minimum amount of filtering, 4 will give the maximum. The digital filter is used to stabilize the weight display, when it behaves erratically due to low signal levels or unstable weight on the platform. The more filtering, the more stable the display will be. 12. Security Level Selection: a. If Security Level "1", or "2" is selected at this step, Security Level "0" or greater can not be selected at a later time from the front panel. Be sure of your selection before you continue. b. If Security Level "1" is selected, program steps 6-8, grad size, AZT, and zero limit cannot be changed from the front panel. c. If Security Level "2" is selected, no parameters can be changed from the front panel. The display will read "SL x", where "x" is a "0", "1" or "2". The"0" enables full programming capability from the front panel. The "1" enables limited front panel programming. The "2" disables all front panel programming. 13. Commercial Scale: The display will show "C 44 x" where "x" is a "0" or a "1". 0 = Non-commercial 1 = Commercial If non-commercial (0) is selected, the scale can be recalibrated from the front panel. After step 12, the display will return to the normal operating mode unless step 5 was changed. If a new capacity was entered, the scale must be re-calibrated /03 Issue #8

16 Section 5: Calibration A. Standard A/D Calibration: Prom # Rev X Starting October From the weigh mode: Press SW3 on the main PCB TWICE to enter the counts mode, Front panel calibration, lift and hold the AUTOTARE/ZERO toggle switch up for 3 seconds. The display will show " E CAL". Press the UNITS key three times to enter the counts mode. 2. Remove all weight from the platform. When the display counts have stabilized, press the ZERO switch or the UNITS key to store the zero value. NOTE: At any time during the calibration routine, up to the time the calibration weight is entered, the process may be aborted by pressing the GROSS/NET key, repeatedly, until the indicator returns to the weigh mode. 3. The display will show "0" (+ / - 3) counts. If it does not, the indicator can repeatedly be re-zeroed by pressing the ZERO switch. 4. Place a test weight on the platform. The recommended test weight is approximately 80 percent of the scale capacity. When the counts display is stable, press the UNITS key to restore the calibration value in memory. Scale Cap. Test Wt Increments Scale Cap. Test Wt Increments 2 lb 1 lb 60 lb 5 lb 5 lb 1 lb 80 lb 5 lb 6 lb 1 lb 100 lb 5 lb 10 lb 1 lb 120 lb 5 lb 12 lb 1 lb 150 lb 10 lb 24 lb 2 lb 200 lb 10 lb 25 lb 5 lb 250 lb 10 lb 30 lb 5 lb 300 lb 20 lb 40 lb 5 lb 500 lb 50 lb 50 lb 5 lb 1000 lb 100 lb /03 Issue #8

17 5. The display will show a value for the test weight. If necessary, change the display to show the ACTUAL test weight used by using the AUTOTARE/ZERO switch. Press the UNITS key to store the calibration data. NOTE : If the calibration values are unacceptable, the display will show an error message, "E2L" or "E2H". Press any key to restart the calibration procedure. 6. If the calibration is successful, the display will now show a number, preceded by a flashing "0". This number represents the zero calibration point. Record this number for future reference. Press the UNITS key to advance to the next step. 7. The display will show a number, preceded by a flashing "S". This number represents the span A/D counts. The span A/D counts represent the difference between the capacity A/D counts and the zero A/D counts. Record this number for future reference. Press the UNITS key to exit the calibration mode. NOTE : If the calibration values are unacceptable, the display will show an error message, "E2L" or "E2H". Press any key to restart the calibration procedure. The calibration is unacceptable if: a. The number of A/D counts required to reach the scale capacity would exceed the range of the A/D converter. Error message "E2H". (zero counts + span counts > 132,000 Solution: There is too much gain, reprogram division size) b. There is less than the minimum number of counts required per division. Error message "E2L". The minimum number of counts per division is 3 for commercial applications (security levels 1 and 2) and, 1 for non-commercial applications (security level 0). Solution: Division size is too small. Exit the analog calibration mode by pressing the GROSS/NET key and reprogram division size. Then return to calibration to complete /03 Issue #8

18 B. Standard A/D Calibration: Prom # ( ) Rev X, Before October 1999 The A/D counts are the indicator internal counts to convert the weight on the platform to digital information in the display. The counts are set by manipulating the gain and offset switches to reach the desire range. The total range is from 0 counts to 40,000. However, it is necessary to maintain a buffer at both the top and bottom of the counts range. The display will show "40,000" if the A/D counts exceed 40,000. The display will show "00" if the A/D counts go below 0. To enter the counts calibration mode, press the SW3 (main PCB) button twice. The display will show "CAL LC". Press the UNITS key and the counts value will be displayed. Alternatively, hold the AUTOTARE toggle switch UP for 3 seconds. The display will show "ECAL". Press UNITS, the display will show "CP XX" where "CP" means capacity and the "XX" is the capacity value. Press UNITS again and the display will show "CAL LC". Press UNITS 1 more time to zero counts. 1. Set S2 positions 1, 2, 3, 6, and 9 ON, then 4, 5, 7, 8, and 10 OFF. 2. With no weight on the platform, toggle the ZERO switch (down). This will store the current zero reference, or press AUTOTARE to restore the old zero reference. 3. Apply a test weight to the platform, 25% or more of the scale capacity is recommended. The display will show the live load counts. 4. Record the displayed counts. (If there was no counts change or the change was negative, check the load cell wiring and correct the problem before proceeding). This recorded change is the count value for the weight applied to the platform. To determine the change that would occur if full capacity weight were applied to the platform, multiply this change using the following formula: Liveload Counts = Applied Wt Counts X Scale Capacity Test Weight /03 Issue #8

19 Example: Liveload Counts = 4290 X or- Liveload counts = 4290 X 4 (or) cts. The change in count value for full capacity weight should be between 30,000 and 39,000. Choose the appropriate gain setting from the chart below by selecting from the Gain Ratio chart below, the gain ratio closest to and less than the gain ratio established as follows: Gain Ratio = 39,000 Change X Counts Change Switch Settings (S2) Gain Ratio ON OFF Minimum 6,9 7,8,10 9 6,7,8,10 6,8 7,9,10 6,8,10 7,9, 8,10 6,7,9 6,7 8,9,10 7 6,8,9,10 6,7,8 9,10 6,7,8,10 9 7,9 6,8,10 6,7,9,10 8 7,8,10 6,9 Maximum 7,9,10 6,8 Once the switch setting is chosen establish the actual change in counts for full capacity by rechecking using the above formula. NOTE: Using the most counts available per division increases stability /03 Issue #8

20 5. With the gain switches properly set use the offset compensation chart below to select the deadload compensation. This compensation must be set to produce the lowest A/D count value with no weight on the platform, but not less than 1,000. Switch Settings (S2) Offset Compensation ON OFF Minimum 1, 2, 3 4, 5 1, 2, 4 3, 5 1, 2, 5 3, 4 2, 3 1, 4, 5 2, 4 1, 3, 5 2, 5 1, 3, 4 1, 3 2, 4, 5 1, 4 2, 3, 5 3 1, 2, 4, 5 1,5 2, 3, 4 4 1, 2, 3, 5 Maximum 5 1, 2, 3, 4 6. Verify correct operating range: a. By adding the A/D count value with no weight on the platform (deadload) to the calculated actual change in counts for full capacity (liveload). b. The sum (total counts) must not exceed 39,000. If so, reduce gain and reverify. This completes the A/D counts calibration. If the guidelines for gain and deadload compensation cannot be met, the scale will function properly under the following conditions: 1). The selected gain and deadload compensation satisfies the conditions specified in Step 6. 2). The ratio of A/D counts per displayed weight graduations* is greater than 3. * displayed weight graduations = Full Capacity Weight Smallest Weighing Increment /03 Issue #8

21 C. Span Calibration Mode 1. Enter the counts calibration mode by pressing SW3 twice, the display will show "CAL LC". 2. With no weight on the platform, press UNITS.The zero weight reference counts are displayed.toggle the ZERO switch down to set counts to "0" (+ / - 3). 3. Place the test weights (not exceeding the programmed or physical capacity) onto the platform. A test weight equal to the platform capacity will produce the most accurate calibration. Test weights less than platform capacity may be used. 4. Next, press the UNITS key. This stores the displayed A/D counts and changes the display to show the previous calibration weight value or the test weight value. 5. Enter the weight currently on the platform by scrolling up with the UP key or down with the DOWN key. These keys will change the value of the 3rd, 4th and 5th digits. 6. With the calibration weight on the scale and the correct value displayed, press the UNITS key to complete the calibration. Pressing UNITS three (3) times will return the indicator to the weighing mode. NOTE: At completion of installation make copies of the program values entered (including numbers related to calibration) date them, and place a copy inside the indicator. If the calibration values are unacceptable, the display will show an error message, "E2L" or "E2H". Press any key to restart the calibration procedure. The calibration is unacceptable if: a. The number of A/D counts required to reach the scale capacity would exceed the range of the A/D converter. Error message "E2H". Zero counts + span counts > 132,000 Solution: There is too much gain, reprogram division size /03 Issue #8

22 b. There is less than the minimum number of counts required per division. Error message "E2L". The minimum number of counts per division is 3 for commercial applications (security levels 1 and 2) and, 1 for non -commercial applications (security level 0). Solution: Division size is too small. Exit the analog calibration mode by pressing the GROSS/NET key and reprogram division size. Then return to calibration to complete. 7. If the calibration is successful, the display will now show a number, preceded by a flashing "0". This number represents the zero calibration point. Record this number for future reference. Press the UNITS key to advance to the next step. 8. The display will show a number, preceded by a flashing "S". This number represents the span A/D counts. The span A/D counts represent the difference between the capacity A/D counts and the zero A/D counts. Record this number for future reference. Press the UNITS key to exit the calibration mode. D. Analog Filter SW1 (EARLIER VERSION ONLY, PROM 11750, BEFORE Oct., 1999) Light analog filtering will give a fast display response time but makes the display less stable due to motion on the platform. Heavy analog filtering will give a slower display response time but will tolerate more platform motion. In general, light capacity scales use the light analog filtering, while large capacity scales use the heavy analog filtering. SW1 ON OFF Light Filtering 1, 2, 3, Medium 1, 3 2, 4 Heavy Filtering , 2, 3, /03 Issue #8

23 Section 6: Operation A. Basic Gross Weighing 1. If necessary, press GROSS/NET to select gross (NT annunciator OFF). 2. With the Platform empty, press the AUTOTARE/ZERO switch DOWN, the display will indicate 0.0 and the Center-of-Zero (CZ) annunciator will light. 3. Place the product on the platform. 4. Read the gross weight on the display. B. Net Weighing Using AUTOTARE 1. Place an empty container on the platform. 2. Press the AUTOTARE/ZERO toggle switch UP. The empty container weight is transferred to tare memory. The display then indicates "0.0" weight and the NT annunciator is ON. 3. Load the container on the platform and read the net weight on the display. 4. Repeat step 3 for containers of the same tare, repeat step 1 for other containers. 5. To read gross weight, push GROSS/NET, the NT annunciator will turn off. 6. When the load is removed from the platform, the display will read a negative (-) net value equal to the stored tare in memory. NOTE : Net weighing of pre-packaged products can be accomplished by first placing an empty package that is the same as the product package on the platform, and pressing the AUTOTARE/ZERO toggle switch UP before beginning weighing operations /03 Issue #8

24 C. Batching/Blending 1. Select the gross mode and place the empty container on the platform. Then press the AUTOTARE/ZERO toggle switch DOWN. 2. Add the first ingredient until its required weight is reached. Then press the AUTOTARE/ZERO toggle switch UP; display indicates "0.0" weight. NT annunciator is ON. 3. Add the second ingredient until its required weight is reached. Then press the AUTOTARE/ZERO toggle switch UP; display indicates "0.0" Net. 4. Add the third ingredient until its required weight is reached. Then press the AUTOTARE/ZERO toggle switch UP; display indicates "0.0" Net. 5. Continue with other ingredients as required, not exceeding the capacity of the scale. Remember to press the AUTOTARE/ZERO toggle switch UP after each ingredient is added. 6. To read the total weight press GROSS/NET. The indicator will switch to the gross mode and show the total weight of all ingredients and the container/package. D. Checkweighing Using the Weight Display: 1. Place a weight representing the target weight on the platform (If a carton or container is to be used, place an empty one on the platform along with the target weight). 2. Push the AUTOTARE/ZERO toggle switch UP; the target weight is transferred to memory.the display then reads "0.0" NET (NT annunciator is ON.) 3. Remove the target weight (and empty container). The display will read the target (and container) weight as negative, up to five active digits /03 Issue #8

25 4. Place the item to be checkweighed on the Platform. If the weight is correct, the display will read "0.0". If the weight is over, the display will read the overweight amount. If the weight is under, the display will read the underweight amount with minus sign. E. Using the Checkweigh LEDs, PS 3 Mode See Checkweighing Setup, next! The Checkweigh LEDs provide a visual indication that the weight on the scale is within one of five programmable weight ranges. Five weight ranges can be defined as shown below: Range Indication Out of Range Low Fashing yellow UNDER LED Under Range Steady Yellow UNDER LED Accept Range Steady Green ACCEPT LED Over Range Steady Red OVER LED Out of Range High Flashing Red OVER LED To define these five ranges, two values must be programmed, the start of the Accept Range, and the start of the Over Range. These values are programmed in the weight units (lb/kg/oz/g) in effect when the checkweigh calibration mode is entered /03 Issue #8

26 F. Checkweighing Setup Hold the G/N key for about 3 seconds. The display will momentarily show "CH CAL", followed by "CH x". Use the AUTOTARE or ZERO switch to select the desired mode. Mode 0 = Checkweigh mode off Mode 1 = Checkweigh following Gross weight only Mode 2 = Checkweigh following Gross or Net weight. Press the UNITS key to accept the entry. If mode 1, 2, or 3 is chosen, you will then continue on to the checkweigh setting program. See below for individual examples. If mode "0" is chosen, all checkweigh modes are disabled, and you will return to the weigh mode. 1. Checkweighing (mode 1 or 2) programming. When using either of these modes, the next prompt will be "PS x", where x is 1, or 2,. This stands for preferred sequence. This indicator has 2 methods of programming the checkweigh parameters. Use the AUTOTARE or ZERO switch to select the desired sequence. Press the UNITS key to accept the entry. For convenience, the checkweigh mode and preferred sequence is stored in memory, and will be your default method each time you enter the checkweigh programming unless changed. Sequence #1 is a method where you use a test sample to set the target weight, and scroll the amount of under/over tolerance for the accept range. Sequence #2 is a method, where you use a test sample to set it close to the target weight, and scroll to the exact weight limits that you want for the accept range. Sequence #3 is a more flexible method where one can program each individual under/accept/over weight ranges and widths as desired /03 Issue #8

27 a. Checkweigh programming example #1 (Using preferred sequence #1). Target weight of 10.0 lbs, under tolerance of 1.0 lbs over tolerance of 1.50 lbs (i.e. accept light is on from 9 to 11.5 lbs) With the "PS 1" prompt displayed, press UNITS to accept this as your preferred sequence. The accept (green) LED will be flashing at a high rate, and the display will indicate the current weight on the platform. Apply an exact desired target weight (10.0 lbs) to the platform and press the units key. The under (yellow) LED will now be flashing, and the current under tolerance will be shown on the display. This value is the same as the last time the checkweigh programming was performed. Use the AUTOTARE/ZERO switch to decrease/increase the value to show lbs. Pressing and holding the G/N key for 2 seconds will toggle the increment size used by the scroll function from fine to coarse. The display will momentarily flash when the size is toggled. Press the UNITS key to accept. The over (red) LED will now be flashing, and the current over tolerance will be shown on the display. This value is the same as the last time the checkweigh programming was performed. Use the AUTOTARE/ZERO switch to decrease/increase the value to show 1.5 lbs. Pressing and holding the G/N key for 2 seconds will toggle the increment size used by the scroll function from fine to coarse. The display will momentarily flash when the size is toggled. Press the UNITS key to accept. The indicator will return to the weigh mode and the Accept (green) LED will be illuminated. Remove the test load from the platform and begin checkweighing. When the weight is between 9 and 11.5 lbs the Accept light will be on. If the weight is less the Under light will be on. If the weight is more the OVER light will be on. IF the weight is much less or much more than the accept range, the appropriate under/over light will be flashing /03 Issue #8

28 b. Checkweigh programming example #2 (Using preferred sequence #2). Target weight of 10.0 lbs, accept range of 9.0 lbs to 11.5 lbs, same parameters as example 1. (i.e. accept light is on from 9 to 11.5 lbs) With the "PS 2" prompt displayed, press UNITS to accept this as your preferred sequence. The accept (green) LED will be flashing at a high rate, and the display will indicate the current weight on the platform. Apply a weight close to but not necessarily exact to the desired target weight (10.0lbs +/-) to the platform and press the units key. The under (yellow) LED and the accept (green) LED's will now be alternately flashing, and the current weight value for the lower limit of the accept range will be shown on the display. This value is the same difference in weight as the last time the checkweigh programming was performed. Use the AUTOTARE/ZERO switch to decrease/increase the value to show 9.0 lbs. Pressing and holding the G/N key for 2 seconds will toggle the increment size used by the scroll function from fine to coarse. The display will momentarily flash when the size is toggled. Press the UNITS key to accept. The over (red) LED and the accept (green) LED's will now be alternately flashing, and the current weight value for the upper limit of the accept range will be shown on the display. This value is the same difference in weight as the last time the checkweigh programming was performed. Use the AUTOTARE/ZERO switch to decrease/increase the value to show 11.5 lbs. Pressing and holding the G/N key for 2 seconds will toggle the increment size used by the scroll function from fine to coarse. The display will momentarily flash when the size is toggled. Press the UNITS key to accept. The indicator will return to the weigh mode and the Accept (green) LED will be illuminated. Remove the test load from the platform and begin checkweighing. When the weight is between 9 and 11.5 lbs the Accept light will be on. If the weight is less the Under light will be on. If the weight is more the Over light will be on. IF the weight is much less or much more than the accept range, the appropriate under/over light will be flashing /03 Issue #8

29 c. Checkweigh programming example #3 (Using preferred sequence #3). Target weight of 10.0 lbs, accept range of 9.0 lbs to 11.5 lbs, same parameters as example 1. (i.e. accept light is on from 9 to 11.5 lbs. Under on from 6.5 to 9.0 lbs Over on from 11.5 to 14.0 lbs) With the "PS 3" prompt displayed, press UNITS to accept this as your preferred sequence. The under (yellow) LED will be on, and the display will indicate the current start of under value. This value is the same value as last time the checkweigh programming was performed. Use the AUTOTARE/ZERO switch to decrease/increase the value to show 6.50 lbs. Pressing and holding the G/N key for 2 seconds will toggle the increment size used by the scroll function from fine to coarse. The display will momentarily flash when the size is toggled. Press the UNITS key to accept. The accept (green) LED will be on, and the display will indicate the current start of accept value. This value is the same value as last time the checkweigh programming was performed. Use the AUTOTARE/ZERO switch to decrease/increase the value to show 9.0 lbs. Pressing and holding the G/N key for 2 seconds will toggle the increment size used by the scroll function from fine to coarse. The display will momentarily flash when the size is toggled. Press the UNITS key to accept. The over (red) LED will be on, and the display will indicate the current start of over value. This value is the same value as last time the checkweigh programming was performed. Use the AUTOTARE/ZERO switch to decrease/increase the value to show 11.5 lbs. Pressing and holding the G/N key for 2 seconds will toggle the increment size used by the scroll function from fine to coarse. The display will momentarily flash when the size is toggled. Press the UNITS key to accept. The over (red) LED will be flashing, and the display will indicate the current end of over value. This value is the same value as last time the checkweigh programming was performed. Use the AUTOTARE/ZERO switch to decrease/increase the value to show 14.0 lbs. Pressing and holding the G/N key for 2 seconds will /03 Issue #8

30 toggle the increment size used by the scroll function from fine to coarse. The display will momentarily flash when the size is toggled. Press the UNITS key to accept. The indicator will return to the weigh mode and the appropriate LED's will be llluminated. Apply a weight and begin checkweighing. When the weight is between 6.5 and 9.0 lbs the under light will be on. When the weight is between 9.0 and 11.5lbs the Accept light will be on. When the weight is between 11.5 and 14.0 lbs the Over light will be on. If the weight is much less or much more than the under/over ranges, the appropriate under/over light will be flashing. G. HR5000 OUTPUT PROGRAMMING The HR5000 Series scales may have factory installed RS232 outputs. The output(s) will send weight information to either a printer or a computer. The output must be programmed before it can be used. The RS232 output is factory set to: data bits: 8 parity: none stop bit: 1 baud: To program the output function: a. Press and hold the UNITS key. The display will scroll: " XXXXX - X " program number and revision. b. Press the PRINT button and the display will show: "EA X" (enable) where X is a "0" or "1". Use the toggle switch to change the value of "X". "0" = output disabled "1" = output enabled c. With the appropriate choice displayed, press the UNITS key /03 Issue #8

31 The display will show: "XXXXX" where "xxxx" is the baud rate. Use the toggle switch to scroll through the available baud rates, 300, 600, 1200, 2400, 4800, 9600, and With the appropriate baud rate displayed, press the UNITS key. d. The display will show the selected device code. The codes are: "P" = printer "P A" = printer, auto mode "CP" = computer "CP CO" = computer, continuous output. 1). If "P" is selected, the weight on the scale will be printed each time the PRINT button is pressed. 2). If "P A" is selected, the weight on the scale will be sent to the printer when the scale has been stable for the programmed delay period. 3). If "CP" is selected, the weight on the scale will be sent to the computer when the scale is polled with a carriage return. If there is motion on the platform, the units legend will be lower case letters. If the platform is stable, the units will be displayed in upper case letters. 4). If "CP CO" is selected, the weight on the platform will be sent to the computer continuously with lower case letters indicating motion on the platform and upper case letters indicating stability. If "P" is selected the display will advance to step 6. If "P A" is selected, the display will advance to step 5 and then to step 6. With the appropriate choice displayed, press the UNITS key. If "CP" or "CP CO" was selected, the display will return to the weight mode /03 Issue #8

32 e. If AUTO PRINT was selected, the display will show: "OLA XX" where "XX" is the time delay for weight on the platform to be stable, before the weight is printed. Use the toggle switch to display a time delay from 0 to 10 seconds. With the appropriate time delay displayed, press the UNITS key. f. The display will show: "8P H" This is the logic level of the CTS/RTS lines. An "H" indicates high true and an "L" indicates low true Use the toggle switch to display the appropriate condition and press the UNITS key. g. The display will return to the weigh mode. 2. Print Operation PRINTER selected: Press the PRINT button and the weight on the platform will be printed when the platform is stable AUTO PRINT selected: The weight will be sent to the printer when the scale is stable for the programmed delay period. COMPUTER selected: The weight will be sent to the computer when the scale is polled with a carriage return. Lower case letters indicate motion on the platform, upper case letter indicate a stable platform. COMPUTER CONTINUOUS selected: The weight will be sent to the computer at each display update. Lower case letters indicate motion on the platform, upper case letter indicate a stable platform. NOTE: If CHECKWEIGH is enabled and the scale is in the AUTO PRINT mode, the weight will be printed when the weight on the platform is in the ACCEPT range and the programmed time delay is satisfied. The weight on the platform must change and be at least 10 grads above zero and drop below half of the last printed weight, before a new weight can be printed /03 Issue #8

33 Section 7: Parts Replacement A. Toggle Switch Replacement To replace the AUTOTARE/ZERO toggle switch on the side of the pillar: 1. Remove power to the indicator. 2. Remove the back cover. 3. Disconnect the toggle switch from the main PC Board at J2. 4. Remove the "booted" nut on the side of the pillar using a 5/8" wrench. 5. Remove the old switch, and install the new one. 6. Replace the "booted" nut. If the "boot" is damaged, a new "boot" and nut should be installed. 7. Reinstall the connector at J2. B. Main PC Board Replacement To replace the main PC Board: 1. Remove power to the indicator. 2. Remove the 12 bolts holding the back cover on to the pillar using a 5/16" nutdriver. 3. Remove the AC power cord from the PC Board at TB2. 4. Remove the AUTOTARE/ZERO switch connector at J2. 5. Remove the display PC Board connector at J1. 6. Disconnect the load cell cable at TB1. 7. Remove the 4 screws holding the PC Board in place 8. Using static precautions, remove the old PC board and install the new board. Remove the EPROM from the old PC board and install it on the new board *(U7). *Earlier versions use U8 for the EPROM. NOTE: The orientation notch on the EPROM should correspond to the orientation notch on the socket. 9. Reverse the process to re-assemble the indicator /03 Issue #8

34 C. Display PC Board Replacement To replace the display PC Board: 1. Remove power to the indicator. 2. Remove the bolts securing the back cover to the indicator. 3. Remove the main PC Board. See the previous section for instructions. 4. Remove the four screws holding the display board in place. 5. Using static precautions, remove and replace the display PCB. 6. Reinstall the main PCB and all connectors. 7. Reassemble the indicator. 8. Torque rear cover screws to 18 inch lbs. D. To replace the load cell assembly on all models EXCEPT 24 x 24 bases: 1. Remove power to the indicator. 2. Gain access to the load cell cable. 3. Disconnect the load cell cable from the indicator. Note the color and location of the load cells wires. 4. Loosen the gland nut at the bottom of the indicator and withdraw the load cell cable. 5. Remove the platform cover and locator plate. 6. Remove the bolts holding the "spider" to the load cell. Remove the "spider", the load cell cover, and the upper load cell block. 7. From the underside of the platform, remove the load cell bolts. 8. Remove any tie wraps securing the load cell cable to the base. 9. Remove the old load cell and the lower load cell block. 10. Clean all parts before reassembling, and use an anti-seize product on all bolts. 11. Place the lower load cell block under the new load cell and secure it to the bottom of the platform using the load cell bolts. 12. Route the load cell cable through the hole in the bottom of the platform. 13. Route the load cell cable through the water tight gland in the indicator and tighten the gland nut. 14. Replace the upper load cell block, the load cell cover and the "spider" and secure with bolts. 15. Replace the locator plate and the platform cover ensuring the ground clip (50517) is secure and will contact the platform cover /03 Issue #8

35 16. Wire as follows: Terminal # Description Wire Color TB1-1 Excitation (-) Black TB1-2 Excitation (+) Green TB1-3 Sense (+) --- TB1-4 Sense (-) --- TB1-5 N/C --- TB1-6 Shield Shield TB1-7 Output (+) White TB1-8 Output (-) Red 18. Recalibrate the indicator. 19. Replace the cover on the rear of the indicator and reconnect power. Torque rear cover screws to 18 inch lbs. E. Load cell Replacement for 24 x 24 Models 1. Remove power to the indicator. 2. Gain access to the load cell cable. 3. Disconnect the load cell cable from indicator. Note the color and location of the load cells wires. 4. Loosen the gland nut at the bottom of the indicator and withdraw the load cell cable. 5. Remove the platform cover. 6. Remove the "spider" then the support assembly and upper load cell spacer. 7. Remove any wire ties that secure the Load cell cable, loosen the gland nut at the bottom of the indicator and withdraw the load cell cable. 8. From the bottom, remove the bolts holding the bottom support plate, Load cell spacer and Load cell. 9. Clean all parts before assembling, and use an anti-seize product on all bolts 10. Reinstall the new Load cell fastening first to the base assembly /03 Issue #8

36 11. Route the Load cell cable through the base gland bushing, secure the cable using wire ties, then tighten the gland nut. 12. Reassemble the top assembly using spacer, support plate, then "spider". 13. Be sure the ground clip (15057) is secure and will contact the platform cover 14. Replace the cover 15. Wire as follows: Terminal # Description Wire Color TB1-1 Excitation (-) Black TB1-2 Excitation (+) Green TB1-3 Sense (+) --- TB1-4 Sense (-) --- TB1-5 N/C --- TB1-6 Shield Shield TB1-7 Output (+) White TB1-8 Output (-) Red 16. Recalibrate the indicator. 17. Replace the cover on the rear of the indicator and reconnect power. Torque rear cover screws to 18 inch lbs. F. Grounding There is a ground clip that is designed to ground the rear cover of the indicator to the rest of the indicator body. When re-assembling the indicator, be sure the ground clip touches the rear cover. G. Sealing the Scale The indicator is sealed using two sealing wires. Install one seal through the two center bolts on the left side of the back cover. Crimp the lead seal. Repeat the process on the two center bolts on the right side /03 Issue #8

37 Section 8: Parts List & Diagrams A. HR5000 Instrument Item Part No. Ref No. Description Enclosure Weldment * Main PCB Assembly (EARLIER Versions To 10/1999) ** Main PCB Assembly (Later Version From 10/1999 Includes Prom) PCB Assembly, Display Switch Assembly Cable Assembly Power Cord Assembly Overlay Cover, Enclosure Gasket, Enclosure Cover * Prom Kit (Prom 11750, Earlier Version. To 10/1999) ** Prom Kit (Prom 20010, Later Version. From 10/1999) Boot, Toggle Switch Spacer Spacer Spacer Connector, Liquid Tight Connector, Liquid Tight Gasket, Connector Clip, Ground Block,Terminal, Plug (3 Position) Block,Terminal, Plug (8 Position) Washer, Nylon A Screw, Cap, Hex Head x Screw, Sealing A Screw, Mach, PH Phil 8-32 x A Washer, Lock, Ext Tooth # A Nut, Hex 8-32 * Denotes earlier version TO 10/1999 (PCB and EPROM change). ** Denotes later version FROM 10/1999 (PCB and EPROM change) /03 Issue #8

38 Parts Diagram: CZ NT l b kg oz g UNDER ACCEPT OVER PROG ENTER CHKWGH NEXT UNITS GROSS AUTO TARE NET ZERO TOGGLE SWITCH OPERATION (SIDE OF INSTRUMENT) PPI-HR5000-A2, B2, C2 Series Only PPI-HR5000 and D,E,F,G Series Only /03 Issue #8