IM 6000 Series In-Motion Scale System with FB3000

Operators Manual
IM 6000 Series
In-Motion Scale System
with FB3000
Model: IM 6000
© 2005 by Fairbanks Scales Inc.
All rights reserved
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Issue #1 05/05
Amendment Record
IM 6000 In-Motion Scale System
50792
Manufactured by Fairbanks Scales Inc.
821 Locust
Kansas City, Missouri 64106
Issue #1
05/05
Created Manual
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.
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Table of Contents
Section 1: General Specifications
A. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
4
Section #1: General Information
A. General Policy . . . . . . . .
B. Overview . . . . . . . . . . .
C. Instrument Location . . .
D. Safety
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E. Grounding
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Section 4: Operation
A. Basic Operations Summary . . . . . . . . . . . . . . . . . . . . . . . . .
21
Section 5: Service and Maintenance
A. Errors
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22
Section 6: Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23
APPENDIX I: Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Section 3: Programming
A. Menu Navigation . . . . . . . . . . . . .
B. General Programming Instructions
C. Options Menu
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D. Configuration Menu . . . . . . . . . . .
E. Service Menu . . . . . . . . . . . . . . . .
F. Special Functions Menu . . . . . . . .
System Backup . . . . . . . . . . .
System Restore . . . . . . . . . . .
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Issue #1
Section 1: General Specifications
A.
Introduction
The Fairbanks IM 6000 is a high speed In-Motion weighing system and is the next generation
of In-Motion weighing systems for Fairbanks Scales. The IM 6000 uses Fairbanks FB3000 instrument
featuring a PC/104 internal structure which can process boxes at speeds of up to 360 ft/min depending upon conveyor and scale conveyor configurations.
B.
Specifications
1.
Instrument Specifications
CPU
VIA Ezra/Eden (ECBA package) 1 GHz processor
BIOS
Award® 256K Flash BIOS
Chipset
VIA VT8606 + VT82C686B
I/O Chipset
Built-in VT82C686B + Winbond 83977EF
Memory
One (1) 144-pin SDIMM socket support up to 512 MB SDRAM
Enhanced IDE
Support up to two (2) IDE devices ( Ultra DMA 33/66/100)
FDD Interface
Supports up to two (2) floppy disk drives (34-pin header)
Parallel Port
One (1) Bi-directional parallel port. Supports SPP/ ECP/ EPP
Serial Port
Three (3) RS232 and one (1) RS232/ 422/ 485 serial ports
KB/ Mouse Connector
Supports PC/AT keyboard
Power Management
APM 1.1 Compliant
PC/104 Connector
One (1) PC/104 Connector
Digital I/O
Eight (8) digital inputs and outputs
Watchdog Timer
Can generate a system reset. Supports software selectable time-out
interval.
Battery
Lithium battery for data retention up to ten (10) years under normal operating conditions.
Software Driver
Microsoft® XP Home
Ethernet Interface
PCI 100/10 Mbps Ethernet Controller
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Chipset
Dual Intel® 82559ER
SDD Interface
One (1) 50-pin Compact FlashTM socket
Hard Drive
40 GB Industrial Hard drive backed by Compact FlashTM.
2.
Flat Panel/ CRT Interface
Resolution
Flat panel display support up to 1024 x 768 @ 18bpp TFT panel and
CRT monitors to 1024 x 768 16bpp or 120 x 1024 @ 8bpp.
Interface
4x AGP VGA/LCD interface, support for 9,12,15,18,24,36 bit TFT and
optional 15 or 24 bit DSTN panels.
Display Memory
Shares system memory 8/ 16 / 32MB.
Chipset
VIA Twister chip with integrated Savage 4 2D/ 3D/ Video Accelerator
3.
Scale Specifications
Number of scales
Up to four (4) scales simultaneously.
Load cells
Up to forty (40) load cells maximum.
Display
10.4” SVGA Color LCD-TFT with Touch Screen.
Display Resolution
640 x 480
Remote Configuration
Integrated Web Browser allows for configuration from a remote
location.
Display Rate
0.1 to 10 seconds in 0.1 intervals
Zero
Disabled, 2% or 100%
4.
Environmental
Power Supply
+5 (4.75V to 5.25V), +12(11.4V to 12.6V)
Max Power Requirements
4A @ 5V, 200mA/ +12V ( No Scale Attached)
Operating Temperature
-10 to 104 F (0 to 40 C) Fanless
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Section 2: General Information
A.
General Policy
It is the customer / operator's responsibility to ensure the equipment provided by Fairbanks is
operated within the parameters of the equipment's specifications and protected from accidental or
malicious damage. Other than the procedures authorized in the Operating manual, no service,
repair, or adjustments may be performed by unauthorized / untrained service personnel. Any unauthorized repairs will void any verbal, implied, or written warranties.
B.
Overview
1.
These instructions apply to the instrument and its specific installation procedures. The procedures for instruments, printers and other peripherals are given in manuals specifically provided for
those units.
2.
Absolutely no physical, electrical or program modifications are to be made to this equipment.
Electrical connections other than those specified may not be performed, and physical alterations
(holes, etc.) are not allowed.
Note :
The equipment consists of printed circuit assemblies which must be handled using ESD handling procedures, and must be replaced as units. Replacement of individual components are not
allowed. The assemblies must be properly packaged in ESD protective material and returned intact
for replacment credit per normal procedures.
C.
Instrument Location
1.
The Instrument should be positioned away from direct sunlight.
D.
Safety
As is the case with any material handling equipment, certain safety precautions should be
observed during operation:
1.
Never load the platform beyond its rated capacity. Refer to the rating on the serial number
plate of the platform.
2.
Ensure that any structure which supports the platform is capable of withstanding the weight of
the platform plus its rated capacity load.
3.
Do not load the platform if there is any evidence of damage to the platform or supporting
structure.
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4.
Use safety chains or other suitable restraining devices if there is any possibility of the load
shifting, falling, or rolling from its position on the platform.
E.
Grounding
For proper protection against damage, all of the components of the system must be properly
grounded. The grounding system contains one (1) ground rod for the scale location. The following
steps must be performed to correctly ground the system:
a. It is recommended to use 8 AWG or larger wire or braided
ground straps.
b. All of the ground connections should be 2 feet or less.
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Section 3: Programming
A.
Menu Navigation
Arrows
These keys move the cursor in the display in the direction indicated. They are also
used for scrolling.
Menu
This key changes the display to the Operation Menu. This key can also be used to
return the display to the last menu screen that was shown.
Zero
This key zeroes the scale.
Print
When pressed, a Gross Weight ticket will be printed with a manually entered Tare and
the Net will be calculated.
Units
Changes the units of weight displayed, depending on the selection made in the
Calibration Menu.
0 to 9
Used to enter numeric data, such as tares and IDs.
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Enter
Used to store selections into memory during programming. The scale can be setup to
operate in one of two modes: GROSS, TARE, NET weighing and IN/OUT weighing.
Lamps
Green
Red
The On scanner has detected a box being on the scale.
The Off scanner has detected a box exiting the scale.
f1
Save As - Saves data file to your designated file name and location.
f2
Sample or Trace - Samples weight on the platform or traces box from on to off scanners.
f3
Timed Dependancy Test - Performs a one (1) hour test of weights captured.
f4
Start - Time Dependancy Test Start which can vary by entering duration time.
f5
Stop - Time Dependancy Test End which will manually stop any test.
f6
View - Allows viewing of records of a test which was performed. Pressing the F6 a second time allows viewing of A/D counts from the PC104 card.
B.
General Programming Instructions
The programming menus that contain all of the parameters for the system are listed below.
1. Options Menu - Accessible without a password by pressing the MENU key. This menu is
used for general weighing operations and accessing further programming menus.
2. Configuration Menu - This menu is used to enter the parameters for the Keyboard Tare,
AutoTare, Select Scale, Format Ticket, and view the Load Cell Diagnostics. These adjustments are made by authorized personnel only and is password protected.
3. Service Menu - This menu is used to program the technical parameters of the system,
such as scale capacity, span, and load cell data. These adjustments are made by authorized personnel onlyand is password protected.
4. The following instructions apply to all of the menus.
a. In all menus, the UP or DOWN arrows move the cursor in the indicated direction.
b. To make an entry, place the cursor beside the item to be selected and press the ENTER
key. The operator will be prompted for the data to be entered.
c. A Enter Password prompt means the menu item is locked and can only be accessed
with a password.
d. Data may be entered through the keypad.
e. When the appropriate data has been entered, press the ENTER key to record the data into
memory.
f, Data may also be selected by pressing the right arrow key to toggle to the appropriate
value.
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C.
Options Menu Programming
Weigh Mode
Returns the display to the normal weight processing display.
Time & Date
Highlight the desired date item, month, day or year, scroll or enter the desired
value. The date may also be selected by scrolling to the desired month and year
and select the day upon the calendar.
Select the desired date format from the drop down box list. Highlight the
desired format and enter.
Select the desired date seperator.
Highlight the desired time item, hour, minutes, or seconds, scroll or enter the
desired value.
Select the desired date format from the drop down box list. Highlight the desired
format and enter.
The revision number at the top right of the screen is the program version number
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Ticket Number Enter the ticket number required via the indicator’s numeric keypad or through a
external keyboard accessory.
IN-Motion
Options
These values adjust the performance of the systems operation. Once these are
configured at installation, the values should not require any further changes.
These adjustments should be made by authorized factory trained personnel only.
Enable Weight
This value is the weight threshhold which begins the weighing process. This setting will enhance stability if the Gross weight is less than Enable Weight, the dis
play will indicate 0.00 weight . Also if the Gross weight is less than the Enable
Weight for a count equal to the Idle Counter setting, an Auto Zero is performed.
Idle Counter
This value is dependant on the speed of the A/D and is used for Auto Zeroing.
Spacing
Adjustment
This value is used to shift the start and stop points for weights to be included in
box weight calculations. A buffer of box weights (most recent at the top of the
list) is kept for each box from the time it triggers the On Scanner to the time it
triggers the Off Scanner. If there are two boxes on the scale at the same time
a two box error is transmitted. The weights in the final calculation are offset to
exclude two box weighments. The offset value cannot be greater than the spacing adjustment setting.
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Range
The number of weights to include in the calculation before trimming.
Performance
Factor
Default = 1.0000. If this value is not 1.0000, the final box weight calculation =
box weight + (box weight * Performance Factor). If the Performance Factor
is greater than 1.0000, the final box weights are increased, if less than 1.0000,
the final box weights are decreased.
Box Tolerance
If this value is other than the default value of 0.00, any weights read for the box
on the scale that are outside the initial average box weight calculation for this
box are discarded when the final box weight is derived.
Use Peak
Weight Only
After Trim Min/Peak trimming has occurred, the Peak Weight of the remaining
box weights are used as the final box weight calculation.
Trim Peak
The greatest box weight(s) gathered from On to Off Scanner is discarded.
Trim Min
The lightest box weight(s) gathered from On to Off Scanner is discarded.
On Scanner 1
Port setting on the Digital I/O card for the on sensor. Default setting: A0
On Scanner 2
Not Used. Port setting for a second on sensor.
Off Scanner
Port setting on the Digital I/O card for the off sensor. Default setting: A2
Invert Sensors
This setting is for the various types of photoelectric sensors. Some sensors are
NPN and others are PNP. NPN sensors = unchecked box. PNP = checked
box.
Default setting: [BLANK].
AutoTare
This feature will store the tare of the item on the scale when selected. this feature is disabled for use with the in motion process. This setting will effect scale
perfomance. For authorized personnel only.
Configuration
Menu
This menu accesses general configuration functions of the indicator.
This setting will effect scale perfomance. For authorized personnel only.
Service Menu
This menu accesses calibration and other metrological functions of the indicator.
This setting will effect scale perfomance. For authorized personnel only.
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D.
Configuration Menu Programming
IN-Motion
Options
See Options Menu for parameter descriptions and programming.
AutoTare
This feature will store the tare of the item on the scale when selected.This set
ting will effect scale perfomance. For authorized personnel only.
Select Scale
This feature will list the number of the scale the indicator is controlling.
Title
Field Names
Product ID
Mail ID
Prompts
Reports
Not Available
Not Available
Not Available
Not Available
Not Available
Not Available
Load Cell
Diagnostics
This is a diagnostic status display as to the functionality and programming of the
load cell.
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System
System
System
System
System
System
configuration
configuration
configuration
configuration
configuration
configuration
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Communications Ports
The settings for the ports are fixed settings and are not accessible. The data output string for
RS232 / RS422 is shown below:
Baud: 19200
Data Bits: 8
Parity: None
Stop Bits: 1
<STX>[Sequence Number]<D>[Track Number][Error][Box Weight][CRC]<CR><LF*>
STX = 0x02
Sequence Number = one (1) character; 1-9 auto incrementing
D = 0x44
Track Number = six (6) characters (6); 1- 999999 auto incrementing
Error = one (1) character. See Error Codes.
Box Weight = four (4) characters. 4 digit box weight. No decimal point.
CRC = four (4) characters. CRC check digit.
CR = 0x0D
LF* = 0x0A; Only added to data string if the file “Include.LF” exists in the c:\NewScale directory.
Error Codes
Bit 0 =
Bit 1 =
Bit 2 =
Bit 3 =
Bit 4 =
Bit 5 =
Bit 6 =
Bit 7 =
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1
0
0
0
1
=
=
=
=
=
=
=
=
too few box weighments.
more than two (2) boxes on the scale.
two (2) boxes on the scale.
error calculating box weight.
always zero (spare bit)
always zero (spare bit)
always zero (spare bit)
always one.
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E.
Service Menu Programming
Update Rate
This setting will effect scale perfomance. For authorized personnel only.
Zero Mode
This setting will effect scale perfomance. For authorized personnel only.
Tare Mode
This setting will effect scale perfomance. For authorized personnel only.
Number of
Scales
This setting will effect scale perfomance. For authorized personnel only.
Cell Output
(Counts)
When this item is selected, the display
will show “Calibration” zero counts and
“Current” zero counts. This display is for
diagnostic information only. Values cannot be changed from this display. The
chart will list all of the cells by number.
Cells which the internal diagnostics
deem suspect or defective will be
highlighted.
Calibration
This setting will effect scale perfomance. For authorized personnel only.
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Write Password This selection allows entry of a password
which can be up to twelve (12) characters
in length. The Write Password function
secures the Configuration, Calibration
and Special Functions programming
areas. Upon entry of the correct value
access is allowed to all of the secured
menu areas. The security is reset upon
exiting to the weight processing screen
This setting will allow changes to the
password. For authorized personnel only.
Print
Calibration
Report
Special
Functions
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This selection will allow viewing or
printing of the calibration and configura
tion parameters of the indicator. It is
recommended a printed copy of this
report be kept by the customer and a
second copy retained by the Service
Center.
This selections allows for special
features and functions to be enabled or
performed. See the Special Functions
Menu Programming section for more
details. This setting will effect scale perfomance. For authorized personnel only.
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F.
Special Functions Menu Programming
Span (Corners) This setting will effect calibration. For authorized personnel only
System Options This selection allows the keyboard display to be viewed or hidden. The
selection for Touch Panel (screen)
enable or disable is made in this screen
A check box for the enabling of float
switch detection is also available for
heavy capacity scales.
The Backup and Restore utilities are
located in this menu also. This utility
will perform back ups and will also
restore transactions and the configuration of the system.
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1. System Backup Proceedure
1. Press MENU key and select the Service Menu choice.
2. Select the Special Functions Menu item.
3. Choose System Options.
4. Press the Backup System Settings button. The system will automatically name the backup file by
date and time performed (yyyymmdd_hhmm.bak).
example: 20041129_1730.bak (November 29, 2004@5:30pm)
The screen will display the backup status.
5. Upon a successful backup, press the MENU key repeatedly until the display is in the weighment
processing screen.
6. The scale is ready to process weights.
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2. System Restore Proceedure
1. Press MENU key and select the Service Menu choice.
2. Select the Special Functions Menu item.
3. Choose System Options.
4. Press the down arrow in the data box beside the Restore System Settings button. Select the back
up file required. The box will list the backups by date and time performed (yyyymmdd_hhmm.bak).
example: 20041129_1730.bak (November 29, 2004@5:30pm)
5. Upon selection of the backup file, press the Restore System Settings button to restore the settings.
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6. Press the Yes button to confirm the restore process. Warning ! This will change the system
settings to the values in the backup file selected.
7. The Backup files will be restored in to the scale system. The instrument will re-intialize and return
to the weigh processing screen.
8. The restore process is now complete.
9. The scale calibration should be verified before processing weights. Upon verification, the system
will be ready to process weights
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Section 4: Operation
A.
Basic Operations Summary
There are two options available, In-Motion Gross Weighing and Static Gross-Tare-Net
Weighing.
1. In-Motion Gross Weighing
a.
Press the ZERO key to zero the scale.
b.
Place the object to be weighed on the approach conveyor. The object will
be moved by the conveyor onto the scale and where it will pass the On
Scanner. The In-Motion system will begin the weighing process and
derive a weight based upon the In-Motion configuration parameter settings. The final processed weight will be displayed upon the object pass
ing the Off Scanner. The final weight will be stored in the transaction
record file and a record will be sent to a monitoring computer.
2. Static Gross Weighing
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a.
Press the ZERO key to zero the scale.
b.
Place the container on the platform.
c.
Manually record the weight.
d.
Remove the container from the platform.
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Section 5: Service and Maintenance
A.
Errors
Symptom
Solution
Load Cell Failure(s)
Weight is behind zero by a large
amount. Check for binds in the
platform.
Load cell has failed. Replace
cell.
No indication from
Green or Red Lamps
for Scanners
Check for +12vdc.
No Scale Port Found...
Check output from High Speed
A/D.
Check sensor wiring connections
or check for damage.
Check interface cable for broken
wires.
Check COM 2 for proper operation.
Check for loose interface connections
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Check sensor wiring connections
or check for damage.
Two boxes on the scale
Check physical box spacing and
spacing programming.
Error calculating box weight
Check scale calibration.
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Section 6: Parts List
A. Replacement Parts
Item
Part Number
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
24713
24712
24836
25765
25428
25362
25363
10919
10890
25482
25483
25369
11212
11164
25617
25498
25499
25212
25645
24117
Cover assembly
Enclosure
Instrument bracket
Connector plate
Power terminal block plate
Terminal block; 6 terminals
Terminal block plug; 6 terminals
Lock washer int. tooth No. 4
Machine screw 4-40 x.25
Connector; 3 pos.
Contact, female
Rocker switch
Fully insulated quick disconnect
Lug
Hard Disk Drive
Mini keyboard
Mouse
Disk drive plate
Power cord assembly
RJ45 - RJ45 cable assembly
22
24
26
27
30
31
32
25548
24890
24892
24894
24895
25404
25470
25388
Cable Kit Assembly includes:
Keyboard extension cable
LVDS Data cable assembly
LPT cable assembly
LCD Backlight cable assembly
PS2 Keyboard- Mouse cable assembly
USB cable assembly
IDE cable assembly
33
34
35
39
101
123
130
131
132
133
134
135
136
137
138
139
140
141
142
N/S
N/S
N/S
N/S
12342
17534
25504
26152
24888
24891
25109Q
25389Q
25754
25769Q
25768Q
25387
25285
25213Q
15745
12621
25793
15169
25347
25876Q
94384
25674Q
25675Q
O-ring
Liquid tight connector
Fully insulated quick disconnect
Embedded SBC pcb 1GHz
Touchscreen controller pcb
Touchscreen cable assembly
USB Digital I/O Interface pcb
USB A-B cable assembly
Power supply pcb
Sensor power and signal cable assembly
Power and signal cable assembly
COM 2 cable assembly
Weight controller pcb
Digital I/O mounting plate
Knob
Retainer washer
Weight controller mounting plate
3/4” hole plug
1/2” hole plug
Load cell damped 50 kg capacity 2 mv/v
Load cell Junction board
Source Sensor
Detector Sensor
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1
COVER ASSY
27
123
24
101
FROM
TB1
ON
CONVEYOR
FRAME
24
4
3
2
R
W
G
BK 1
CN8
27
CN16
140
TB1
TB2
J3
22
20
CN3 CN5
136
C75
J4
131
123
CN6
PCB ASSY
WEIGHT CONTROLLER
J1
134
CN2
39
PCB ASSY
COMMUNICATION
31
CN22
CN18
CN21
134
14
32
16
SW1 A B
BLK
WHT
G/Y
17
19
JP1
6
1
FS1
DB25
26
AC/L
AC/N CN1
TB1
POWER
CORD
AC
ACC
GND
BLK 5"
11
10
1
3
13
W 11.5"
GRN 9"
BLK 11.5"
26
E1
135
12 35
CN9
CN11
CN15
6
8
5
4
2
USB
31
J6
32
133
3
DB9
135
134
29
21
22
23
ETHERNET
20
18
INCOMING
INTERFACE
CABLE
TO 25284 TB1
1
20
FOR IN MOTION
GAP 453124
3000 SERIES EMBEDDED PC
30
22
15
DISK DRIVE
CA06297 B304
131
130
DIGITOL I/O
PMD 1024LS
KEYBD
4
DB9F MOUSE
133
137
21
BR
R
OR
BOTTOM CONNECTOR PLATE
USB
1
31
7
9
132
PCB ASSY
POWER SUPPLY
133
40
BK
Appendix I: Communications
PCB ASSY
COMMUNICATION
CN11
CN9
CN15
COM 2 JUMPER SETTINGS
CN11
6 2
1
5 1
CN9
{
{
2
JP 2
COM 2 Mode Select
JP2 Settings Definition
1-2
RS-232
3-4
RS-422
5-6
RS-485
Definition
DCD
DSR
RX
RTS
TX
CTS
DTR
RI 5V 12V
Ground
NC
485 TX +
485 TX 485 RX +
485 RX 50792
JP 5
RI / Voltage Select COM 2
JP5 Settings Definition
1-2
RI (Default for RS232 and RS422)
3-4
+ 5V
5-6
+ 12V
COM 2 (A)
RS232 DB9
1
6
2
7
3
8
4
9
5
or
COM 2
(B)
RS422/485 DB9
5
2
1
3
4
25
05/05
Issue #1
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