Scaletron AccuPro-5000, Operator'S Manual

Page 1: ...ined in this document is confidential to Scaletron Industries Ltd No license is expressed or implied under any patent copyright or trade secret right is granted or implied by the conveyance of this document No part of this document may be reproduced transmitted transcribed stored in a retrieval system translated into any language or computer language in any form or by any means electronic mechanic...

Page 2: ...ns 11 3 1 Factory Configuration 12 3 2 Control Panel Preparation and Mounting 12 3 3 External Connections 13 4 System Hardware 14 4 1 Liquid Crystal Display LCD Board 14 4 2 Backplane Board 15 4 3 Main Processor Board 17 4 4 Analog Input Board 19 4 5 Analog Output Board 4 20 mA Output 20 4 6 Analog Output Board 0 5V 10V Output 22 4 7 Relay Output Board Dual or Quad Relays 24 5 User Controls 25 5 1...

Page 3: ...ig 43 8 8 Liquid Mass 45 8 9 Tare Adjust Tare Secured 47 8 10 Relay Setpoint 49 8 11 mA V Output 52 8 12 Real Time Clock 54 8 13 About 57 9 Maintenance 59 9 1 Cleaning 59 9 2 Servicing the Control Panel 59 9 3 Removing Installing a Printed Circuit Board 59 9 4 Removing Installing PCB Wire Connections 60 10 Troubleshooting 60 10 1 The Control Panel is Not Receiving Power 60 10 2 The Measurement Val...

Page 4: ...e 16 DEAD WEIGHT Menu Option 35 Figure 17 DEAD WEIGHT Control Flow Diagram 36 Figure 18 CALIBRATE WEIGHT Menu Option 37 Figure 19 CALIBRATE WEIGHT Control Flow Diagram 38 Figure 20 CAPACITY WEIGHT Menu Option 39 Figure 21 CAPACITY WEIGHT Control Flow Diagram 40 Figure 22 SYSTEM CONFIGURATION Menu Option 41 Figure 23 SYSTEM CONFIGURATION Control Flow Diagram 42 Figure 24 CHANNEL CONFIGURATION Menu ...

Page 5: ...r_Manual Copyright 2021 Scaletron Industries Ltd All Rights Reserved Page 5 of 63 Table 1 External Alarm Interface 17 Table 2 System Mode Controls 17 Table 3 Load Cell Interface 19 Table 4 Leak Detect Sensor Interface 19 Table 5 Current Loop Interface 21 Table 6 Voltage Output Interface 23 Table 7 Relay Interface 24 Table 8 Alerts Alarms Priority Levels 27 Table 9 Operational Menu Tree 31 ...

Page 6: ...d information for the Scale Base is available in a separate document 1 2 Acronyms and Abbreviations AC Alternating Current reference to power supply type ADC Analog to Digital Converter AIB Analog Input Board AOB Analog Output Board either mA or V AWG American Wire Gauge DAC Digital to Analog Converter DC Direct Current reference to power supply type DCS Distributed Control System EEPROM Electrica...

Page 7: ...me style push button membrane switches used to navigate and operate the AccuPro 5000 menus Main Menu A collection of high level user control categories from which a user can access one or more submenu control options for system calibration configuration and data entry Measurement System A term that describes a complete AccuPro 5000 Measurement System consisting of the Control Panel and Scale Base ...

Page 8: ...ve Humidity 20 to 90 non condensing Enclosure Control Panel Nominal Size 8 x 8 x 4 Inches LxWxD with hinged cover Weight 6 lbs approx maximum Material Opaque Polycarbonate UL Listed Type 4X NEMA Location Recommendation The Control Panel should be operated in a location that protects it from being soaked with liquids or exposed to extreme weather conditions If the system is to be located outdoors y...

Page 9: ...stem accuracy is 0 1 to 0 25 Full Scale Liquid Crystal Display Size 16 Characters x 2 Row supports simultaneous measurement display of 2 channels Backlighting 16 user adjustable LED brightness levels via menu Contrast User adjustable via potentiometer on LCD Board Indicators 2 bi color LED status indicators 1 for each channel Each indicator yields up to four prioritized states as described herein ...

Page 10: ...0 VDC Loop Current Range 3 5 mA to 20 5 mA 28 mA maximum for 2 minutes Resolution 0 001 mA Configuration Options Programmable Setpoints User defined net measurement thresholds that define the loop s 4 mA and 20 mA output positions The output current follows a linear interpolation for all measurements that lie between the two Setpoints Analog Output Board V Voltage Output Range Selected via on boar...

Page 11: ...l or Liter L Programmable Setpoints User defined net measurement thresholds that will trigger relay switching Low or High Defines whether relay assertion will occur in the net measurement region below Low or above High the programmable Setpoint value Free Run or Latch Defines whether assertion of the selected relay will continuously track the current net measurement Free Run or if an assertion sta...

Page 12: ...ling All drilled holes MUST be sealed to prevent both liquids and gasses from penetrating the enclosure and damaging the electronics Avoid using fittings that do not provide a tight seal It is recommended that all fittings be liquid tight and 4X NEMA rated If there is a gap or opening in the enclosure s wall that isn t sealed by the connector design use a silicon caulk to seal the opening and elim...

Page 13: ... block Next position the board s slider switch to select the correct configuration for the loop s power source Observe all warnings as outlined in section titled Analog Output Board 4 20 mA Output When finished carefully re insert the PCB following the procedure previously referenced If applicable carefully remove the Analog Output Board AOB V for the desired channel Connect appropriate wires to t...

Page 14: ...ovided via a high efficiency triple output AC to DC supply that features short circuit protection 4 1 Liquid Crystal Display LCD Board With reference to Figure 1 the LCD Board manages the HMI controls and indicators The on board AVR processor continuously scans the control panel for Keypad switch closures and or Rotary Knob rotation which the software first debounces for mechanical noise These con...

Page 15: ...switch matrix Other configurations remain undefined at the time of this printing Serial Debug Port This port is for factory use only Rotary Knob Interface s Supports an optional rotary control used for menu navigation and data entry Local Reset Pressing this button resets the AVR Processor LCD Module An alpha numeric 2 row by 16 character monochrome Liquid Crystal Display LCD Limited graphic capab...

Page 16: ...ision 02 Effective Date 10 05 2021 File 5000 00 00 002 r2_ AccuPro_5000_Operator_Manual Copyright 2021 Scaletron Industries Ltd All Rights Reserved Page 16 of 63 Figure 2 Backplane Board DC Power Supply Interface Audible Buzzer Channel 2 Slots Channel 1 Slots DC to DC Converter Processor Slot Locking Card Guide ...

Page 17: ...upply Audible Buzzer A piezo device used to signal keypress events and or alarm conditions Jumper fields are available to disable the buzzer function or to select maximum volume 4 3 Main Processor Board With reference to Figure 3 the Main Process Board utilizes a SAM processor that executes the primary system code It is responsible for interpreting user control activity and updating all menus and ...

Page 18: ...s Reserved Page 18 of 63 Figure 3 Main Processor Board 4 3 1 Features External Alarm Interface A 3 pin relay port that includes a normally open NO common COM and normally closed NC contact allows for the use of an external AC DC indicator for USER FACTORY External Alarm Interface RS 232 Serial Interface Programmer Interface System Mode Controls LCD Board Interface Real Time Clock Flash Memory Seri...

Page 19: ...evice includes Flash Memory for storage of system configuration data SAM Processor Atmel ATSAMD21J18A AU containing internal EEPROM and SRAM SRAM Battery backed static memory 4 4 Analog Input Board With reference to Figure 4 an AIB defines the existence of an active scale or channel The board includes two terminal block connectors for attaching load cell and leak detect sensor optional wires The l...

Page 20: ...ack their summed output signal Flash Memory Non volatile memory space used to store channel specific calibration and configuration data for both the AIB and ROB Bridge Transducer A 24 bit Sigma Delta Analog to Digital Converter ADC that filters amplifies and converts a low voltage analog load cell signal into a digital value Excitation Voltage Regulator Configured for 7 5 VDC 184 mA maximum Offers...

Page 21: ...op s power is derived internally by the scale the text SCALE is visible next to the slider or externally by a loop source the text LOOP is visible next to the slider It s possible to power multiple loops using a common supply if the circuit is wired as depicted in Figure 5 Note that 24 VDC is the most common supply rating for this application Figure 5 Multiple Current AOBs with Shared Loop Power S...

Page 22: ...beneath the slider the power is sourced internally by the AOB If the text LOOP is visible power is sourced externally by the user s loop supply Flash Memory 2k bit of non volatile memory used to store calibration and configuration data 16 bit DAC A voltage output Digital to Analog Converter 4 6 Analog Output Board 0 5V 10V Output With reference to Figure 7 the AOB V is an optional board that suppo...

Page 23: ...0V To select a 0 5V voltage output range install a jumper shunt on Jumper Field P3 Remove any jumper shunt to select a 0 10V voltage output range Flash Memory 2k bit of non volatile memory used to store calibration and configuration data 16 bit DAC A voltage output Digital to Analog Converter whose output feeds a gain stage voltage output operational amplifier Voltage Output Op Amp An operational ...

Page 24: ...gh 4 The contacts of each relay are wired in a SPDT configuration as shown in Table 7 with external wire connections made accessible via a 3 position terminal block CONTACT LABEL DESCRIPTION NO Normally Open contact COM Common contact NC Normally Closed contact Table 7 Relay Interface The relays are initialized in a negated or de energized state following power up They are independently asserted o...

Page 25: ... current state as energized ON or de energized OFF Relay Interface A 3 position relay port that includes a normally open NO common COM and normally closed NC contact 5 User Controls A simplified set of external user interface controls are utilized for both data entry and navigation through multiple calibration configuration and operational menus Options include a multi switch Keypad as depicted in...

Page 26: ...b initiates a repeat function of the respective function Rotary Knob rotation is speed sensitive meaning that the faster its rotational speed the faster the repeat function is performed For example a large numerical value can easily be entered by a rapid rotation of the Rotary Knob to place the value close to target followed by a slower rotation to settle in on a final value Once a desired menu op...

Page 27: ...ghlight events as configured by the user but it can further assist a factory technician while performing calibration and configuration of a channel It may also indicate a condition considered to be outside the recommended or operational parameters of the channel Finally the Green State has the lowest priority which indicates that a channel is calibrated configured and ready for normal operation Ta...

Page 28: ...e Mode Slider Switch into the Run Mode position which is when the text RUN is visible beneath the slider The configuration of the Setup Mode Jumper has no effect while in Run Mode 7 2 Setup Mode This mode enables additional control options depending on a specific purpose It is selected by moving the Mode Slider Switch into the Setup Mode position which is when the text SETUP is visible beneath the...

Page 29: ...en a submenu is first entered in a multi channel system the user must identify the channel for which to perform the respective option The display will indicate all applicable channels for the specific menu selection with a blinking cursor hovering over the lowest numbered channel Non applicable channel locations are indicated by a dash The user must use the Arrow Keys or Rotary Knob to scroll thro...

Page 30: ...vision 02 Effective Date 10 05 2021 File 5000 00 00 002 r2_ AccuPro_5000_Operator_Manual Copyright 2021 Scaletron Industries Ltd All Rights Reserved Page 30 of 63 Figure 11 Action Canceled Display Table 9 summarizes System Menu options as a function of the System Mode configuration CAPACITY Wt ACTION CANCELED ...

Page 31: ...t Liquid Mass Value X X Tare Adjust Set Units X 5 X X Set Value X 5 X X Relay Setpoint 6 Select Relay X X Set Status X X Set Units X X Set Setpoint Value x2 x4 X X Set Limit High or Low x2 x4 X X Set Mode Free Run or Latching x2 x4 X X Set Audible Alarm 7 x2 x4 X X mA V Output 8 mA Volts Output Calibration x2 X Set mA V Setpoints x2 X X Real Time Clock Set Time X X Set Date X X Set Trim Value Osci...

Page 32: ...available active channels The number of the respective active channel s will be presented as the left most character of each applicable row of the display as shown in Figure 13 Figure 13 Single versus Dual Channel Measurement Display Whenever a given channel is configured to enable its proportional bar graph See main menu option titled Channel Config only the data for that channel will be displaye...

Page 33: ...Status LED notification Alert notifications represent a real time status meaning they are free running and able to update as trigger conditions change In contrast an Alarm condition is one that carries a higher priority than an Alert An Alarm can be viewed as a latching Alert that is one that requires the user to first acknowledge before the notification is reset even if the condition s that first...

Page 34: ...ator LT3042 device on the respective channel s Analog Input Board AIB FLASH Err Alarm Indicates a possible Flash memory write operation error to the respective channel s Analog Input Board AOB FLASH Err Alarm Indicates a possible Flash memory write operation error to the respective channel s Analog Output Board RTC FLASH Err Alarm Indicates a possible Flash memory write operation error to the syst...

Page 35: ...rted them still remain In a dual channel system the display will identify which channels are indicating an Alerts Alarms condition The user must first select a desired channel to be evaluated before scrolling through all the messages for the respective channel Whenever the displayed message pertains to an Alarm condition its respective latched state is negated or reset Upon exiting the Alerts Alar...

Page 36: ...tion of the internal 6 bit DAC Offset value is displayed on the bottom line left side This is a bipolar value in mV units having 31 steps in each direction from zero yielding a range of 77 5 mV to 77 5 mV with a step size of 77 5 31 2 5 mV This voltage is internally added to the input voltage from the selected channel s load cell s d The decimal representation of the real time raw 24 bit ADC count...

Page 37: ...Select this menu option by pressing the Enter Key while the display appears as shown in Figure 18 Figure 18 CALIBRATE WEIGHT Menu Option Entry of Calibration Weights generally requires that known accurate weight s be physically placed on the scale The purpose is to correlate a unitless value read from the AD7730 to an actual absolute measurement value Given there are four transfer curves one for e...

Page 38: ...w diagram to first enter any missing required parameters EXIT Four Gain Levels A B C D Full Scale Path taken following a short delay Path taken when ENTER Key pressed Path taken when ARROW Key pressed Changes Value in Selected Units Changes Value in Selected Units Changes Value in Selected Units Changes Value in Selected Units 1 CALIBRATE Wt RU Sure Yes 1 CALIBRATE Wt RU Sure No 1 CALIBRATE Wt Uni...

Page 39: ...ment is near zero a load cell may be shorted Each of these scenarios will cause the message Check Load Cells to be temporarily displayed before returning back to the calibration procedure Inspect the load cell s before continuing f By definition a Calibration Weight value must exceed the respective Dead Weight value for each analog gain level If this condition is not met an Invalid Entry message i...

Page 40: ...onduct the procedure The number of any chosen active channel will be indicated in the upper left corner of the display for the remainder of this submenu c Select and enter the desired units for Capacity Weight Only pounds lb or kilograms kg are valid d Enter the gross Capacity Weight in the previously selected units The displayed default value will match the Calibration Weight entered when the ana...

Page 41: ...channel specific but rather general in scope and apply to all active channels Option selections are saved to non volatile memory located on the Main Processor Board Once this menu has been entered the user is forced to answer the entire suite of submenu configuration options even if the intent is to modify only one of them The default configuration for each option is its current value thus pressin...

Page 42: ...esponse will continue a No response will exit the option The Factory Restore operation is intended to read back all the channel specific calibration and configuration data previously saved to protected Flash memory via a Factory Save operation If a Factory Save operation was not previously performed on a given channel the Factory LCD Backlight Intensity 15 through 0 Not All Shown Serial Out Port B...

Page 43: ... response to a keypress d Select and enter the desired state of the Alarm Buzzer If Enable is selected the Internal Buzzer will be energized to signal Alarm conditions some of which are user selectable If Disable is selected the Internal Buzzer will remain de energized or OFF during active alarm states e Select and enter an LCD backlight intensity to 1 of 16 levels with 15 corresponding to the bri...

Page 44: ...d to confirm their selection to access the menu via an RU Sure prompt for Are You Sure A Yes response will continue a No response will skip the option The Factory Restore operation is intended to read back all of the channel specific calibration and configuration data previously saved to protected Flash memory via a Factory Save operation If a Factory Save operation was not previously performed on...

Page 45: ...If the material being measured is a sloshing liquid then an increased number of samples per average may be desirable to stabilize the measured value Note that as the number of samples per average is increased the measurement update rate is proportionally reduced Finally if the system detects a large instantaneous measurement change of 50 or more it will reset the moving average data buffers to yie...

Page 46: ...n Industries Ltd All Rights Reserved Page 46 of 63 Figure 27 LIQUID MASS Menu Option This menu supports scale measurement in volumetric units thus it is only made available if an active channel is configured to display its averaged measurement in units of volume either gallons or liters 8 8 1 Procedure The procedure for navigating the Liquid Mass submenu follows the control flow diagram depicted i...

Page 47: ...itless value If this submenu is being entered for the first time or if a change in the unit is detected the default Liquid Mass value will be that of pure water whether it be represented as a density 8 34540 lb gal or specific gravity 1 00000 c If a Liquid Mass density is to be entered select whether the density units are pounds gallon lb gal or kilograms liter kg l d Enter a Liquid Mass value as ...

Page 48: ...r tare First with nothing on the scale the user can enter a known tare value in selectable weight or volume units Second with an empty container of unknown weight placed on the scale the user can adjust the tare value until the net measurement display reads zero 8 9 1 Procedure The procedures for navigating the TARE ADJUST and TARE SECURED submenus follow the control flow diagrams as depicted in F...

Page 49: ...Units of Pound lb Kilogram kg Gallon gal and Liter ltr are supported If a unit change is detected the default tare value is reset to zero Otherwise the starting tare value is set to the previously entered value Note that the selected tare units do not have to match the selected scale measurement units f Enter a Tare value in the previously selected units using one of the two methods previously des...

Page 50: ...ll Rights Reserved Page 50 of 63 Figure 32 RELAY SETPOINT Menu Option This menu provides a means to configure either 2 Dual Relay Output Board or 4 Quad Relay Output Board relay setpoints The user is able to define an independent trigger measurement and set of behavior criteria for each relay port 8 10 1 Procedure The procedure for navigating the Relay Setpoint submenu follows the control flow dia...

Page 51: ...cedures be completed User is prompted via a display message Not shown on Control Flow diagram to first enter any missing required parameters Path taken when ENTER Key pressed Path taken when ARROW Key pressed Changes Value in Selected Unit Changes Relay Selection Relay 1 Selected as Shown EXIT EXIT 1 RELAY SETPt 1 Mode Latch 1 RELAY SETPt 1 Unit Kilogram 1 RELAY SETPt 1 Unit Liter 1 RELAY SETPt 1 ...

Page 52: ...nus tare in the previously selected units The minimum value is 0 and the maximum value corresponds to the previously entered Capacity Weight i Select and enter whether the Setpoint value represents either a Low or High Limit A Low Limit will cause the selected relay to become energized when the respective scale s averaged measurement value falls below the previously entered Setpoint value Likewise...

Page 53: ...nd 20 5mA on the high end yielding a 0 5mA margin 8 11 1 Procedure The procedure for navigating the mA V Output submenu follows the control flow diagram depicted in Figure 35 Figure 35 mA V OUTPUT Control Flow Diagram a This menu option is only available if an active channel is configured with an Analog Output Board mA or V Option selections are saved to non volatile memory located on the Analog O...

Page 54: ... mA or 0 V scale measurement Setpoint in the previously selected units Any previously entered Setpoint will be presented as the default value unless a change of units was detected in a previous step in which case the Setpoint value will be reset to zero The value is always positive in the range from zero through Capacity Weight 1 The number of decimal points of the displayed value represents the u...

Page 55: ...E CLOCK Menu Option The system includes a Real Time Clock RTC intended for tagging logged events with a time stamp Select the menu by pressing the Enter Key which will cause the current time to be displayed in the format HH MM SSxm where xm is either am or pm The date is also tracked and displayed in the format MM DD YY 8 12 1 Procedure for Setting the Time Date The procedure for navigating the Re...

Page 56: ...ions are am for ante meridiem or pm for post meridiem It s important to note that the clock oscillator and battery backup will be enabled at the moment this entry is selected This allows the user to synchronize the start of the RTC with an external time reference It is typical to enter a future time about 10 seconds ahead of actual time then wait until the actual time catches up to press the Enter...

Page 57: ...e the oscillator to improve its accuracy It represents a signed oscillator correction which is added once every minute Calibration is performed by measuring the averaged oscillator output frequency at Test Point TP32 CLKOUT which is configured to be 4 096 kHz The Trim value to be entered is computed as Fideal Fmeasured x 32768 Fideal x 60 2 Use the controls to modify the signed value then press EN...

Page 58: ...ith indicates that the attempt to query the LCD Board s processor had either failed or not taken place Current Time Displays the current time of the Real Time Clock The time should be actively incrementing else the RTC oscillator is not running Current Date Displays the current date of the Real Time Clock System Mode Displays the real time System Mode as defined by the Mode Slider Switch and Setup...

Page 59: ... the four corners of the door Carefully remove the screws and open the latch to gain access to the internal circuitry and connectors 9 3 Removing Installing a Printed Circuit Board It is imperative that power be OFF during the removal or installation of a printed circuit board within the Control Panel All removeable boards are secured in their sockets via two push pins located in the upper region ...

Page 60: ...pen the contacts While holding the button pressed insert the wire into the contact opening and maintain insertion while slowly releasing the button Gently tug on the wire to verify proper connection To remove a wire connection gently tug on the wire while pinching the spring loaded button as previously described 10 Troubleshooting When experiencing unexpected behavior please read the following sce...

Page 61: ... accuracy of the measurement must be questioned The immediate solution is to reduce the load on the Scale Base until the blinking stops Call the factory for options of a long term solution 10 3 The 4 to 20 mA Reading is Incorrect Confirm that the current output is properly configured within the mA V Output menu Pay particular attention to the selection of units and setpoint options Next with power...

Page 62: ...Common COM and Normally Closed NC Confirm that sufficient insulation was removed from the wires to prevent the spring loaded connector contacts from pinching the insulation rather than the wire itself The wires should stay in the connector even when gently tugged Lastly restore power to the Control Panel and create the conditions that should cause the relay to energize Confirm whether or not the r...

Page 63: ...n Industries Ltd All Rights Reserved Page 63 of 63 11 Revision Log Rev Page s Description Date Name 01 All Create Document 08 05 2021 Mark Z 02 1 4 5 8 31 27 34 Updated company mailing address Added list of Figures and Tables Relocated Wattage and Fuse specifications to Main Power section Corrected reference to Note 2 in Operation Menu Tree table Added Flash Error notifications in Alerts Alarms se...