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Lift Truck Scales WITH DR2100AN INDICATOR NTEP TECHNICAL MANUAL Blank Page LTS Scale Company, LLC 2 Rev B 1/26/16 Owner Statistics Warranty Technical Bulletin Lift Truck Scale Installation 1. Unpacking 2. Scale Base Installation Figures 1 – 4 3. Side Shift Bracket Installation 4. Indicator Installation Base Adjustment, Service and Repair 5. Flexure Replacement and Adjustment 6. Top Flexure 7. Bottom Flexures 8. Final Adjustment of Flexure Retaining Plates 9. Scale Balancing - Adjusting Heal-to-Toe Shift 10. Load Cell Removal 11. Load cell Replacement Re-assembly DR2100AN Technical Manual General Information 1. Standard Features 2. Indicator Options 3. Display Description 4. DR2100AN Keyboard Layout 5. Keyboard Controls 6. Operation Sequences 7. Display Messages 8. Main PC Board Layout 9. Connector Pin Outs - Main Board 10. Operating Voltage – Filter Board 11. Load Cell Cable Pin Outs 12. Set-Up Code Screens Indicator Setup 13. Configuration Codes 14. Code 2100 – Keyboard Lockout 15. Code 2104 – Expand Test Mode X10 16. Code 2105 – Restore Default Name 17. Code 2169 – Load Default Settings 18. Code 6969 – Initialize Clock Chip 19. Code 9080 – Indicator Setup 20. Code 9081 – Four-Point Calibration 21. Code 9083 – Configure Remote Inputs 22. Code 9084 – Configure Print 23. Code 9085 – Setting Time & Date (Optional) 24. Code 9086 – Raw A/D, Battery Test 25. Code 9087 – Auto Shut Off and Backlight Timer 26. Code 9088 – Entry of Average Part Weight 27. Code 9089 – Program Name Through Serial Port 28. Code 9090 – Single-Point Calibration 29. Code 9091 – View / Store Calibration Factors 30. Code 9092 - View / Store Angle Zero and Span Factors 31. Code 9093 – View / Set Angle Factors 32. Code 9094 – Out-of-Level Calibration 45 Calibration LTS Scale Company, LLC 5 6 7 9 9 9-10 11-12 13-14 15-16 17 17 17 17 18 18 19 20 21 23 23 24 25 25 26 27-28 29 30 30-31 31 32 33-35 36 36 37 37 37 38 38 38-39 40 40 40-41 41 42 42 42 42 43 43 43 43 43 3 Rev B 1/26/16 33. Code 9090 – Single-Point Calibration 34. Code 9081 – Four-Point Linearity Calibration 35. Out-of-Level Calibration 36. Calibration Verification 37. Calibration Numbers 38. Angle Cal. Numbers LTS Scale Company, LLC 4 45 46 47-48 49 50 51 Rev B 1/26/16 Owner Statistics Please enter the appropriate base and indicator serial numbers prior to installation. Please refer to the numbers below for information, orders or service. Scale Base Indicator Model # Indicator Serial # Base Model # Base Serial # Capacity x Grad. Part Number Quantity Top Flexure Bottom Flexure LTS Scale Company, LLC 5 Rev B 1/26/16 LTS SCALE COMPANY WARRANTY POLICY LTS SCALE COMPANY, LLC warranties the equipment that we manufacture for a period of twelve months, from date of shipment from our factory, against defects in materials and workmanship. LTS Scale warrants to the original purchaser of the equipment. This warranty is limited to the repair or replacement of the defective parts and the associated labor for the repair. All warranty work must be performed by an authorized LTS Scale Company distributor. Note: LTS Scale reserves the right to modify the policy at any time as it sees fit. LTS Scale Company, LLC 6 Rev B 1/26/16 TECHNICAL BULLETIN Subject: Safety Plate Retaining Bolts & Flexure Bolts When installing or servicing an LTS Scale Company Lift Truck Scale it is critical that the safety plate retaining bolts are torqued properly. The correct torque value for these bolts is 125 ft-lb. When replacing or servicing the flexures on an LTS Scale Company Lift Truck Scale or EnviroScale it is critical that the bolts are torqued properly. The correct torque value for these bolts is 125 ft-lb. WARNING: !! Failure to properly torque the Safety Plate Retaining Bolts may result in Bodily Harm or Damage to the Equipment. Failure to properly torque the flexure bolts can result in future flexure failure. Please contact LTS SCALE COMPANY Technical department at 1-844-425-0544 with any questions or comments. LTS Scale Company, LLC 7 Rev B 1/26/16 Blank Page LTS Scale Company, LLC 8 Rev B 1/26/16 LIFT TRUCK SCALE INSTALLATION 1. Unpacking The LTS Lift Truck Scale is shipped on a pallet. A standard system will include the following components: 1. 2. 3. 4. 5. 6. One (1) scale carriage assembly with safety plates One (1) load cell cable assembly with mounting bracket One (1) power cable One (1) electronic indicator with mounting hardware One (1) Operator / Installation manual One (1) Side Shift Bracket (Optional) Upon receipt of shipment, inspect to make sure the above listed parts are present. 2. Scale Base Installation 2.2. Remove safety plate(s) from bottom of scale carriage assembly. Place the scale in a vertical position on the edge of the shipping pallet, with the rear side outward. Examine the back plate of the scale base at this time to locate the carriage alignment bolts. (Ref. figure: 1) The head of a bolt that protrudes from the rear of the scale is known as the fixed carriage alignment bolt. There are also several adjustable carriage alignment bolts protruding from the rear of the scale. These adjustable bolts have a red lock nut located between the two plates. These bolts will be adjusted in step #4. Note: If the lift truck has a take-up-reel device ensure that the Load Cell Cable Mounting Bracket is located on the opposite side of the lift truck. Relocate the longer mounting bolt to the correct side of the base prior to installing the base. 2.3. Remove forks from the lift truck, and position the truck behind the scale assembly. Warning: 2.4. Raise or lower the lift truck carriage and tilt the mast forward to a position that aligns the anti-shift pin on the scale assembly with the center notch on the lift truck carriage. Tilt the mast back to catch the scale assembly and carefully raise the carriage to a comfortable working position. Reattach the safety plates to the bottom of the scale assembly, so that the lip of the safety plate is behind the original carriage (Refer to Figure #3). Torque the Safety Plate Retaining Bolts to 125 Ft-Lbs. Warning: Note: To avoid bodily harm care must be exercised while handling the scale base prior to applying the safety plates. Failure to properly torque the Safety Plate Retaining Bolts may result in Bodily Harm or Damage to the Equipment. The Center Cleat with Anti-Shift Pin should be centered with the middle notch of the truck carriage. Verify that the Anti-Shift Pin is adjusted so that the Pin is located well within the center notch area of the carriage. DO NOT OVERADJUST. The anti-shift pin should not touch the bottom of the notch on the original carriage; this will cause side to side tilting of the scale. To LTS Scale Company, LLC 9 Rev B 1/26/16 properly adjust the Anti-Shift Pin, tighten the Pin down until it bottoms out then back the Pin off 1/8 of a turn. 2.5. To assure firm and level mounting, the fixed carriage alignment bolt of the scale assembly should be resting on the lift truck carriage. To attain a secure mounting, loosen the lock nuts (painted red for easy identification), then back the alignment bolts off until the center pad is resting against the lift truck carriage. Next, adjust the carriage alignment bolts so that they are just touching the lift truck carriage, and then tighten the lock nuts (Ref. Figure #1). 2.6. Remove the two (2) fork stop bolts, located in the upper corners of the front plate. Now reattach the lift truck forks to the scale assembly, and re-insert the fork stop bolts. 2.7. Position the load cell cable assembly to either the right or left side of the scale assembly. Select the side opposite any hose or reel-type take-up device. Secure the load cell cable assembly to the longest mounting bolt. This bolt can be moved to either side of the scale (Note: A special load cell-mounting bracket is mounted at the factory for NTEP applications). LTS Scale Company, LLC 10 Rev B 1/26/16 Carriage alignment bolt Figure: 1 Safety Plate and Carriage Alignment Bolt Aprox. 1/16" Figure: 2 Side view of Safety Plate attached to scale base and shim assembly Flexure Retaining Clamp Flexure Carriage Alignment Bolt Safety Plate Shim Saftey Plate Carriage Plate Safety Plate Figure: 3 Attaching safety plate to bottom of scale assembly ½-13 washer and bolts LTS Scale Company, LLC 11 Rev B 1/26/16 Figure: 4 Attachment of Clino Box Clino Box LTS Scale Company, LLC 12 Rev B 1/26/16 3. Side Shift Bracket Installation 3.1. Locate #9 (cable guard mounting bracket), to the bottom of the existing cable guard bracket using one of the two extra holes on the end of the existing load cell bracket. The cable guard bracket #9 must be mounted under the existing standard cable guard to keep the bracket from rotating. 8 1/2-13 nut existing standard cable guard bracket 9 bracket, cable guard mount 10 1/2-13 bolt hex head 3.2. Inspect the rear carriage for pre-drilled and tapped holes on rear carriage. 3.2.1. If there is a hole on the end of the carriage then use #5 (bracket, side shift angle). One of the #7 bolts provided should fit (1/2”, 5/8”, or 14mm). Run bolts all the way in until they hit the back plate and the bracket is vertically straight, then tighten the jam nuts. Caution: if bracket #5 is mounted too high, side sifter will bend bracket as it goes past end of rear carriage. 3.2.2. If there is a hole on the back of the carriage then discard #5 (bracket, side shift angle) and attach bracket #1 (bracket, side shift) directly to the rear carriage using one of the #7 bolts provided (1/2”, 5/8”, or 14mm). 3.3. Use the cable ties provided to secure the load cell cable to the front and rear bracket. Operate side shifter all the way to the left and right and make sure there is enough cable slack left between brackets. Caution: Operate side shifter slowly in both directions and up and down. Check clearance from moving parts. Make sure to leave enough slack in the load cell cable between brackets. LTS Scale Company, LLC 13 Rev B 1/26/16 Side Shift Bracket KOP – P.N. 3100 LT-K 11 8 9 Std. Cable Guard Brkt. 10 1 2 3 4 5 6 7 abc Side Shift Bracket KOP – Part Number: 3100 LT-K Symbol QTY Part Number Description 1 1 3100LT-2 Bracket, side shift 2 2 3082 5/16-18 x 1-1/2 bolt, hex head 3 2 3043 5/16 nut, hex head 4 2 3033 5/16 washer, flat 5 1 3100LT-1 Bracket, side shift angle 6 1 3048 5/8 washer, flat 7A 1 3053 ½ –13 x 1 bolt, hex head B 1 3054 5/8 x 1-1/4 bolt, hex head C 1 3081 M14-1.5 x 25 bolt, metric, hex head 8 1 3065 ½-13 nut 9 1 3100LT-3 Bracket, cable guard mount 10 1 3053 ½ x 1 bolt, hex head 11 3 Nylon cable tie LTS Scale Company, LLC 14 Rev B 1/26/16 4. Indicator Installation 4.1. Location of the indicator is a matter of operator preference. The universal-mounting bracket (included) enables it to be mounted to the safety cage or on the truck’s dashboard. Mount the indicator at the preferred location using the supplied hardware. Run the load cell cable from scale assembly to the indicator, securing it with cable ties where necessary, but DO NOT plug connector into back of scale until power hook-up is completed. For most installations the load cell cable is secured with cable ties at the roll cage and at the top of the mast, however, each installation must be reviewed to determine the best method of securing the load cell cable. Slowly and carefully raise and lower the carriage and watch load cell cable for possible pinch points. Make sure there is enough slack in load cell cable if mast is fully extended. If scale has side shifter see installation instructions for installing side shift bracket Note: 4.2. Lift trucks that are equipped with side-shift require an extra bracket. Hook up power to the system. The power hook up procedure depends upon the type of lift truck, gas/propane or electric. Follow the respective steps: Note: To avoid damage to the indicator it is necessary to ensure that the indicator is setup for the corresponding lift truck voltage. This input voltage is preset at the factory per the customer supplied voltage specification. 4.2.1. Gas/Propane Truck. Run the power cable (two-conductor) from the indicator to the battery power supply of the truck. When routing the power cable avoid all contact with any moving or hot parts of the lift truck. The power cable is normally routed behind the dashboard or under the floor of the cab. Use wire ties to secure it in a safe position. Make sure all electrical connections match the polarity and voltage of the battery posts. Power cable inputs are white (+) and black (-). Ensue power cable is routed away from distributor cap, spark plug coil and spark plug wires. Failure to route cable away from these noise sources could cause intermittent operation or damage the indicator. Note: Do not use instrument gauges for hook up. Due to internal impedance, this could cause indicator problems or failure. Warning: Lift trucks with ignition systems (gas/propane) require carbon noise suppressed spark plug wires, and resistor-type spark plugs. Failure to have all parts installed correctly will damage the scale indicator. Also, copper or stainless wires on ignition systems will damage the scale indicator. 4.2.2. Electric Lift Truck. Be sure the indicator is equipped for the proper voltage. Run the power cable (two-conductor) from the indicator to the battery of the truck. The power cable is normally routed behind the dashboard or under the floor of the cab. When routing the power cable avoid all contact with any moving or hot parts of the lift truck. Use wire ties to secure it in a safe position. Make sure all electrical connections match the polarity and voltage of the battery posts. Power cable inputs are white (+) and black (-). Important: Connect the power cable inputs to the first two lugs coming off of the battery power supply. This will ensure that you are hooked up to a clean power supply and avoid damaging the equipment. Warning: Electric lift trucks do not have a chassis ground. A connection using the chassis as a ground will damage the scale indicator. LTS Scale Company, LLC 15 Rev B 1/26/16 4.3. Plug in the power cable and load cell cable into the back of the indicator. Re-check the safety plates and fork stop bolts to be sure they are properly secured. Turn the indicator ON and lift the forks off the ground. Carefully raise and lower the carriage and check the load cell cable to be sure it does not catch on anything. Use wire ties to secure the load cell cable in a clear position. Press “ZERO” key on the indicator. The indicator should zero and be ready for use. Forks must be in a level position to ensure accurate readings. Do not make any calibration adjustments until the scale has been exercised several times, with a load of at least 50% of capacity. After exercising the scale, repeat adjustment of the carriage alignment bolts. LTS Scale Company, LLC 16 Rev B 1/26/16 Base Adjustment Service and Repair 5. Flexure Replacement and Adjustment In order to replace flexures, it is necessary to remove the entire scale assembly from the lift truck. Prior to replacing the flexures, perform the following steps: 5.1. Make sure the indicator is turned off. 5.2. Remove the forks from the scale assembly. 5.3. Disconnect the load cell cable from the indicator. 5.4. Remove the safety plates from the bottom of the scale and truck carriage. 5.5. Position the lift truck so that the scale assembly can be lowered onto a sturdy work surface. (A heavy gauge-shipping pallet works well) Back the lift truck away from the work surface, leaving the scale assembly on the pallet in a vertical position. Secure the scale so that it does not fall. 6. Top Flexures 6.1. If it is necessary to replace more than one flexure on the scale, be sure to remove and replace only one flexure (or set of flexures) at a time. When replacing a flexure, it is important to return all retainer clamps and any shims to their original position. 6.2. It may be necessary to use two large “C” clamps at the bottom to draw the scale assembly together. If clamping is necessary, do not exert excessive clamping force. 6.3. It may also be necessary to ream holes in the replacement flexures, to prevent bolts in flexure retainer clamps from binding. Note: Do not tighten the flexure retainer clamps all the way. Positioning and tightening will follow in Final Adjustment of Flexure Retaining Plates. 7. Bottom Flexures 7.1. Replacement of bottom flexures is more complex than the top flexures. Most shims used for achieving heel-to-toe balancing are located in the bottom row of flexures. Carefully remove flexures from the bottom row and look for shims beneath. Shims must be returned to their original position between flexure and scale. (Ref. figure: 2) 7.2. After all lower flexures are replaced and shims are in proper locations, tighten all lower bolts on the retainer clamps, but do not tighten them completely. LTS Scale Company, LLC 17 Rev B 1/26/16 8. Final Adjustment of Flexure Retaining Plates 8.1. Place two “C” clamps on the bottom of the plate assembly between center and outer flexures and tighten the clamps. Locate the two stop-bolts and back them out so they are tight against the front plate. Check to ensure that all flexure-retaining clamps are flush with the front plate. Do not allow the retaining clamps to extend beyond the surface of the front plate. When all retaining clamps are flush, torque all bolts to approximately 125 ft.-lbs. 8.2. After all flexure retainer bolts have been tightened, inspect flexure support clamps to determine that a gap of approximately 1/16-inch is maintained between both ends of the support clamp and the inside of the plate assemblies. It may be necessary to either reposition the support clamp, or to remove and grind (either side of) the clamp to give the approximate 1/16-inch gap. If grinding is necessary, remove the entire support clamp (top and bottom) and grind together as one unit. 8.3. Inspect again to ensure that no flexures are extending beyond the surface of the front or rear plate. If a flexure extends beyond a plate surface, grind off until surface is flush. 8.4. Remove “C” clamps and reinstall scale on lift truck (refer back to the installation procedure). Exercise scale with a load approximately 50% of scale’s capacity prior to calibration and testing. 9. Scale Balancing - Adjusting Heal-to-Toe Shift 9.1. Heel-to-toe or shift in weighing may be adjusted by adding or removing shims between the lower flexures and front plate. If weight on heel of fork is higher than the weight on the toe (tip) of the fork, remove shims (if any) from the lower flexure on the front plate, or add shims to the lower flexure on the rear plate. 9.2. If the weight on the toe of the fork is higher than on the heel, add shims to the lower flexure on the front plate. One pound of error equals approximately 0.001-inch shim. Heel and toe adjustments can be performed at all three flexures on the front plate, by moving the forks on top of the flexure being tested (left, center, and right, respectively). Important: If you add or remove shims, exercise the scale and reset the carriage alignment bolts. LTS Scale Company, LLC 18 Rev B 1/26/16 10. Load Cell Removal Tools required. A. B. C. D. Digital Voltmeter (capable of reading milli-volts) ¾” box Wrenches ¾, 1-1/16”, 1-3/8 open end wrenches 3/16” Allen wrench CALIBRATION INSTRUCTIONS FOR INDICATOR: 10.1. Turn indicator power OFF. 10.2. Disconnect load cell cable at indicator and the base. 10.3. Remove forks. top suspension bolt dust seal top suspension bracket rubber, shock absorber washer, flat jam nut check for gap between ! bolt end and cell body ! loadcell assy. jam nut jam nut washer, flat bottom suspension bracket load cell access plate Load cell Jam Nuts bottom suspension bolt 10.4. Loosen Jam nuts at the bottom of load cell, 2 or 3 jam nuts depending on type of scale. Hold cell from turning and damaging load cell cable. 10.5. Remove Safety plate(s) on bottom of scale. 10.6. Remove scale from forklift. 10.7. Loosen jam nuts at the top of the load cell, 1 or 2 jam nuts depending on type of scale. Use the access slot in the back of the scale to hold load cell from turning. 10.8. Remove bottom center flexure. Observe mounting brackets, flexure and shim locations. 10.9. Remove bottom suspension bolt. Observe location off all nuts and washer. 10.10. Remove Top Suspension Bolt. Observe load cell height and location of all nuts and washer. 10.11. Remove load cell with cable. Note direction of load cell and cable. Dead-end of load cell to the top of the scale. LTS Scale Company, LLC 19 Rev B 1/26/16 11. Load Cell Replacement Re-assembly 11.1. Install new load cell. Note direction of load cell and cable. Dead-end of load cell to the top of the scale. 11.2. Install top suspension bolt and hardware. Make sure top suspension bolt does not bottom out against the load cell center. CAUTION: Bottoming out suspension bolt can damage load cell. 11.3. 11.4. 11.5. Install bottom suspension bolt with hardware finger tight. Tighten jam nut on top suspension bolt against load cell. Hold cell from turning. Install bottom center flexure and hardware. Make sure shims are returned to same location and position as were removed. 11.6. Install scale base back on forklift. If not familiar with installing base in lift truck, review the installation instructions. 11.6.1. Anti-Shift Pin should be centered with the middle notch of the truck carriage. 11.6.2. Install safety plate(s). Plate(s) that keep scale from falling off. Tighten bolts to 125 ft-lbs. 11.6.3. Adjust alignment bolts per scale installation directions. 11.7. Connect load cell cable at base end. 11.8. Set Voltmeter to read DC millivolts. Connect Voltmeter to test points inside indicator. See indicator manual for Main Board test points. 11.9. Power up the indicator. 11.10. Tighten bottom suspension bolt until voltmeter reads 1.2-1.4 mV (.0012-0.0014 volts DC) Make sure bottom suspension bolt does not bottom out against load cell center. CAUTION: Bottoming out suspension bolt can damage load cell. 11.11. 11.12. 11.13. 11.14. 11.15. 11.16. 11.17. 11.18. 11.19. Tighten jam nut on bottom suspension bolt against bottom of load cell. Hold cell from turning. Tighten jam nut on bottom suspension bolt against flat washer. Tighten middle jam nut against bottom nut (if present). Install load cell cover plate. If signal wires were disconnected in previous step power down indicator and reconnect signal leads. Install forks and fork stop bolts (bolts that keep forks from sliding off the end). Exercise scale with a load equal to at least 25% of scale capacity. Re-adjust alignment bolts per scale installation directions. Re-calibrate. LTS Scale Company, LLC 20 Rev B 1/26/16 DR2100AN Technical Manual LTS Scale Company, LLC 21 Rev B 1/26/16 Blank Page LTS Scale Company, LLC 22 Rev B 1/26/16 General Information This section details the general information concerning the standard LTS SCALE DR2100AN indicator. This indicator was specifically designed for industrial on-board weighing system applications. The rugged design of this unit will provide reliability and durability required in these environments. 8-3/16" 6-11/16" 3-3/16" DR2100A OFF ON LTS SCALE TWINSBURG, OHIO SCALE NET STORE WEIGH ZERO GROSS TARE COUNT 0 1 2 3 APW ID ACCUM PRINT DEL 4 5 6 7 8 MENU ENTER 8-3/4" 9 8-7/8" 6-11/32" 4" 1. Standard Features The versatile DR2100AN digital indicator offers the following standard features: New Smaller Enclosure Size Rugged Steel Enclosure Water and Dust Resistant 1.0 Inch LCD Display 2 Line Alphanumeric Display 16 Characters/Line Back-lit Display Universal Mounting Bracket 12 VDC Operation Low Power Indication Zero Tracking Push Button On/Off Auto Shut Off Timer (Optional) Motion Detection Push-button Zero Push-button Tare Dummy Zero Push-button Weight Accumulation Push-button Print LTS Scale Company, LLC NET/GROSS Switching Keyboard ID Number Entry Pounds/Kilograms Switching Average Part Weight (APW) Entry Piece Count Capabilities Function Lockout Capabilities Custom Printout Setup Capabilities Keyboard Calibration Four-Point Linearity Calibration Single-Point Calibration 23 Rev B 1/26/16 2. Indicator Options The following options are available for the DR2100A indicator: ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ Custom Software Time & Date Remote Push-button Operation Multiple Setpoint Controls RS232C Output Barcode Scanning Radio Frequency Operation Ticket Printing Roll Tape Printing Barcode Printer LTS Scale Company, LLC 24 Rev B 1/26/16 3. Display Description The display has two display lines. Each line is capable of displaying 16 alphanumeric characters. The display is equipped with a backlight. 4. DR2100AN Keyboard Layout DR2100A R OFF ON LTS SCALE TWINSBURG, OHIO SCALE NET STORE WEIGH ZERO GROSS TARE COUNT 0 1 2 3 APW ID ACCUM PRINT DEL 4 5 6 7 8 MENU ENTER 9 Figure: 1 LTS Scale Company, LLC 25 Rev B 1/26/16 5. Keyboard Controls This section examines the functions of the various keyboard operations that can be performed on the DR2100AN indicator. There are 21 keys on the keyboard; 10 numeric key (0-9), 10 function keys plus RESET Key. Label ON SCALE ZERO Keyboard Function Optional key Press to zero scale (with no load on the scale and forks off of the floor). NET GROSS Press to display Net or Gross weight (only displays net when a tare is entered). STORE TARE Enter the weight of the empty container. Press STORE TARE key. -Or- pick up empty container press STORE TARE key. To clear tare: press 0 key. Press STORE TARE key. WEIGH COUNT Press to toggle between weigh and count modes. APW ID Used to enter the Average Part Weight for piece counting purposes. Press APW key. Key in the average part weight. Press ENTER Key. See WEIGH/COUNT key. To enter an ID number, key in an ID number. Press ID key. Recall the ID number, press and hold ID key. To clear the ID number, press 0. Press ID key. ACCUM Lift load, press ACCUM key. Weight and count are stored. Remove load. Lift second load, press ACCUM key. Weights and counts will be added to previous values. Press and hold ACCUM key to display accumulated weight. To clear, press 0. Press ACCUM key. PRINT Press PRINT key to send data out the data port. DEL Press DEL key to backspace one digit when entering a numeric value, also used to toggle between selections. MENU ENTER Clears erroneous numbers that were keyed in. For lb/kg switching press once and then press DEL key. Press twice to recall a stored tare weight. OFF R Used to reset the indicator. To reset, hold down DEL and the R keys, push and release R key, wait 2 seconds to reset LTS Scale Company, LLC 26 Rev B 1/26/16 6. Operation Sequences 6.1. Gross Weighing • Raise empty forks off ground and level • Press SCALE/ZERO key • Press STORE/TARE key (clears previous tare value) • Lower forks and lift load • Gross weight displayed 6.2. Net Weighing - Push-button Tare • Raise empty forks off ground and level • Press SCALE/ZERO key • Press STORE/TARE key (clears previous tare value) • Lower forks and lift load • Press STORE/TARE key • Add additional weight to lift • Net weight displayed 6.3. Net Weighing - Keyboard Tare • Raise empty forks off ground and level • Press SCALE/ZERO key • Press STORE/TARE key (clears previous tare value) • Lower forks and lift load • Key in tare value • Press STORE/TARE key • Net weight displayed 6.4. Piece Counting • Raise empty forks off ground and level • Press SCALE/ZERO • Press STORE/TARE key (clears previous tare value) • Lower forks and lift load • Press APW key • Key in APW value or accept displayed value • Press APW key • Press WEIGHT/COUNT key • Read count on top line and weight on bottom line 6.5. Gross Weight Accumulation • Raise empty forks off ground and level • Press SCALE/ZERO • Press STORE/TARE key (clears previous tare value) • Lower forks and lift load • Read weight • Press ACCUM key (weight value added) • Repeat for additional loads To view: Press and hold ACCUM key To Clear: Press 0 key Press ACCUM key LTS Scale Company, LLC 27 Rev B 1/26/16 6.6. Net Weight Accumulation • Raise empty forks off ground and level • Press SCALE/ZERO • Press STORE/TARE key (clears previous tare value) • Key in tare value • Press STORE/TARE key • Lower forks and lift load • Read weight • Press ACCUM key (weight value added) • Repeat for additional loads To view: Press and hold ACCUM key To Clear: Press 0 key Press ACCUM key 6.7. Counting Accumulation • Raise empty forks off ground and level • Press SCALE/ZERO • Press STORE/TARE key (clears previous tare value) • Press APW key • Key in APW value or accept displayed value • Press APW key • Press WEIGHT/COUNT key • Key in tare value • Press STORE/TARE key • Lower forks and lift load • Read weight • Press ACCUM key (count value added) • Repeat for additional loads To view: View displays weight total only Total data can be sent to printer To Clear: Press 0 key. Press ACCUM key 6.8. Printing Press PRINT key at any time to send data to printer. Program setup determines what will be printed. See Technical Manual for programming data output. Note: Unit must have optional RS232 option installed. LTS Scale Company, LLC 28 Rev B 1/26/16 7. Display Messages ERROR Messages DESCRIPTION *ERROR* OUT OF LEVEL Scale is tipped beyond the maximum weighing angle. OUT OF RANGE Indicates an overload condition exists. The weight signal is far beyond the scale capacity. ****OVERLOAD**** DR21-190B EXCEEDS CAPACITY INHIBIT ITEM LOCKED OUT LOW BATTERY LTS Scale Company, LLC Indicates an overload condition. The Gross weight as measured from the zero value 105% of scale capacity. Displayed on power-up. Indicates Model and program number. A number may have been entered and not cleared. Bad Power. Tried to enter a tare larger than the Scales Capacity. Remote Input 1 or 2 is closed and Input function has been configured to prevent all scale weighing functions. Displayed if functions have been disabled (LOCKED OUT). Input power to the DR2100AN has dropped below 11 VDC. 29 SOLUTION Tilt mast until forks are level. If off left to right then move truck to a level position. 1) Bad Load cell cable. 2) Bad Angle sensor. 3) Incorrect Angle settings If there is weight on the scale it should be removed immediately. If no weight is on the scale check for: 1) Bad or damaged Load Cell Cable. 2) Bad internal wiring harness. Check load cell signal. Consult Factory. Weight in question should be immediately removed from the scale. If the total weight on the scale is known to be less than capacity then check scale calibration. If indicator display does not continue past this display then: 1) Press DEL then ENTER key 2) Check power supply. 3) Turn truck off and power up if OK check truck ignition wires and distributor cap. Tare value must be less than the calibrated weighing capacity of the scale. Consult factory. Function will not operate without enabling function. Correct low voltage condition. Reset indicator by holding DEL and R keys Rev B 1/26/16 8. Main PC Board Layout Figure: 2 Main Board Layout (P# P10014) 9. Connector Pin Outs - Main Board J6 Pin 1 2 3 4 J2 Pin 1 2 3 4 5 LTS Scale Company, LLC Power +DC IN, 12 VDC GND GND +DC IN, 12 VDC Clino Inputs +5 VDC X-axis Y-axis GND SHIELD 30 Rev B 1/26/16 J8 Pin 1 2 3 4 5 J5 Pin 1 2 3 4 5 RS232 PA6 (TTL INPUT) RS232 OUT GND RS232 IN +5VDC LOAD CELL +EX +SIG -SIG -EX SHIELD J11 Pin 1 2 RS485 485+ 485- 10. Operating Voltage - Filter Board (P# DR2100AFB) 10.1. Remove cover from back of indicator. Jumper guides show how jumpers must be set for: 12 VDC 24 VDC 36 - 48 VDC 24 V 12 V CR1 36 OR 48 V R2 Set both jumpers to select proper voltage input. Q1 C1 1 R1 C3 VOLTAGE SELECT POS. NEG. T1 F2 2 AMP MDL FUSE NEG. OUT 1 F1 IN 1 2 AMP MDL FUSE POS. P2 P1 Figure: 5 Voltage Selections 10.2. Determine input voltage indicator will be operating on. Example: Most propane powered lift trucks operate on 12 VDC. While electric powered lift trucks operate on 12, 24, 36 or 48 VDC. A DC-DC converter (P# P10006) is used in line with filter board for trucks that operate on 24-48 VDC. If you need assistance determining what the operating voltage is and how the jumpers are to be set, please contact LTS SCALE COMPANY Technical department with any questions. 10.3. Use jumper guide printed on to edge of Filter Board to determine jumper positions. LTS Scale Company, LLC 31 Rev B 1/26/16 10.4. Move voltage selection jumpers to match the specific voltage of the truck. 11. Load Cell Outs NTEP Trade) 12. LTS Scale Company, LLC NTEP LC Cable– Black Coiled Cord Pin Color Description 1 + Excitation Red 2 + Signal Green 3 - Signal White 4 Shield Shield 5 X Axis Brown 6 - Excitation Black 7 Y Axis Blue 32 Cable Pin (Legal-for- Rev B 1/26/16 12. Set-Up Code Screens 1 KEYBOARD 2100 KEYBOARD 2104 LOCK KEYBOARD? YES = LOCK OUT KEYBOARD 9080 KEYBOARD 9081 KEYBOARD 9083 DEL FACTORY CAL? YES *NO REMOTE INPUT 1 PRINT SELECT COUNTBY NUMBER = 5 ARE YOU SURE ? YES *NO REMOTE INPUT 2 ACCUM SELECT DECIMAL NUMBER= 0 CAL STEP # WEIGHT = 1 XXXX SELECT FIXED ZRO YES *NO CAL STEP # NUMBER= 2 XXXX INCREMENTS NUMBER = 1000 CAL STEP # WEIGHT = 3 XXXX PRINT YES *NO USE ENTER OR DEL NUMBER= 5005 CAL STEP # NUMBER= 4 XXXX ACCUM YES *NO LEGAL FOR TRADE *YES NO MENU YES *NO SELECT MOTION #D NUMBER = 1 SETUP YES *NO SELECT MOT DELAY SECONDS= 1.0 CALIBRATE YES *NO DISPLAY MOTION ? *YES NO CONFIG REMOTE IN YES *NO SELECT TRACK #D NUMBER = 1 KEYBOARD TARE YES *NO I.D. YES *NO KGS ONLY YES *NO ZERO TRACK *YES NO EXPAN= GROSS= SCALE ZERO YES *NO PUSH BUTTON TARE YES *NO 0.0 0 LB CONFIG PRINT YES *NO SET TIME & DATE YES *NO RAW A/D BAT TEST YES *NO OFF TIMERS YES *NO PIECE COUNT YES *NO PROGRAM NAME YES *NO **************** LTS Scale Company, LLC 33 Rev B 1/26/16 Set-Up Code Screens 2 KEYBOARD 9084 KEYBOARD SELECT BAUD 9085 9600 SET TIME & DATE YEAR = XX # TOP LINE FEEDS NUMBER = 2 SET TIME & DATE MONTH = XX PRINT ITEM # 1 TIME & DATE SET TIME & DATE DAY = XX # SPACES OVER NUMBER = 1 SET TIME & DATE HOURS = XX # CR LF NUMBER = 1 SET TIME & DATE MINUTES= XX KEYBOARD 9086 KEYBOARD 9087 BACK LIGHT TIME MINUTES= 30.0 12V BV = RAW A/D= XXX XXXXXX 10 KEYBOARD # SPACES OVER NUMBER = 1 # CR LF NUMBER = 1 1 # CR LF NUMBER = 1 PRINT ITEM # 4 TARE # SPACES OVER NUMBER = 1 # CR LF NUMBER = 1 PRINT ITEM # 5 NET # SPACES OVER NUMBER = 1 # CR LF NUMBER = 1 PRINT ITEM # 6 ACCUM # SPACES OVER NUMBER = # CR LF NUMBER = 1 # SPACES OVER NUMBER = 1 1 # CR LF NUMBER = 1 PRINT ITEM # 7 PIECE COUNT # SPACES OVER NUMBER = # CR LF NUMBER = PRINT ITEM # 9 NAME 1 # SPACES OVER NUMBER = 1 1 # CR LF NUMBER = 1 PRINT ITEM # 8 TOTAL COUNT LTS Scale Company, LLC 9089 PROGRAMMING THRU SERIAL PORT PRINT ITEM # 3 GROSS # SPACES OVER NUMBER = 9088 AVERAGE PIECE WT LB = 1.0000 OFF TIMERS MINUTES= 30.0 FILTER WEIGHT = PRINT ITEM # 2 I.D. KEYBOARD # BTM LINE FEEDS NUMBER = 1 34 Rev B 1/26/16 LTS Scale Company, LLC 35 Rev B 1/26/16 Set-Up Code Screens 3 KEYBOARD 9090 KEYBOARD 9091 KEYBOARD 9092 KEYBOARD 9093 KEYBOARD 9094 SINGLE POINT CAL YES *NO LINEARITY STEP 1 OFFSET = 0 GROSS= 0 FB=-0.0 LR=-0.0 ZONE 1 FACTOR NUMBER=1.0000000 CALIB ANGLE FTRS YES *NO ARE YOU SURE ? YES *NO LINEARITY STEP 1 ADD-WT = 0 SET ANGLE ZERO YES *NO ZONE 2 FACTOR NUMBER=1.0000000 CALIB ANGLE FTRS *YES NO SET SCALE ZERO ? YES *NO LINEARITY STEP 1 FACTOR = 400000 FB ANGLE ZERO NUMBER= 128 ZONE 3 FACTOR NUMBER=1.0000000 TEST LOAD VALUE WEIGHT = 1000 CAL MODE WEIGHT = 0 LINEARITY STEP 2 OFFSET = 0 LR ANGLE ZERO NUMBER= 128 ZONE 4 FACTOR NUMBER=1.0000000 CAL MODE WEIGHT = 1000 LINEARITY STEP 2 ADD-WT = 0 FB ANGLE SPAN FACTOR= 42667 ZONE 5 FACTOR NUMBER=1.0000000 LINEARITY STEP 2 FACTOR = 400000 LR ANGLE SPAN FACTOR= 42667 ZONE 6 FACTOR NUMBER=1.0000000 REAR UP 1000 FB= 3.0 LR= 0.0 LINEARITY STEP 3 OFFSET = 0 FRONT TO FRONT YES *NO ZONE 7 FACTOR NUMBER=1.0000000 RIGHT UP 1000 FB= 0.0 LR=-3.0 LINEARITY STEP 3 ADD-WT = 0 ZONE 8 FACTOR NUMBER=1.0000000 FRONT UP 1000 FB=-3.0 LR= 0.0 LINEARITY STEP 3 FACTOR = 400000 ZONE 1 ANGLE SP NUMBER= 3.50 LEFT UP 1000 FB= 0.0 LR= 3.0 LINEARITY STEP 4 OFFSET = 0 ZONE 2 ANGLE SP NUMBER= 3.50 LTS SCALE GROSS= 1000 LB LINEARITY STEP 4 ADD-WT = 0 ZONE 3 ANGLE SP NUMBER= 3.50 LINEARITY STEP 4 FACTOR = 400000 ZONE 4 ANGLE SP NUMBER= 3.50 SINGLE POINT CAL FACTOR = 100000 ZONE 5 ANGLE SP NUMBER= 3.50 NOMINAL ZERO NUMBER= 0 ZONE 6 ANGLE SP NUMBER= 3.50 SCALE ZERO NUMBER= ZONE 7 ANGLE SP NUMBER= 3.50 0 PRINT LTS Scale Company, LLC ZONE 8 ANGLE SP NUMBER= 3.50 36 Rev B 1/26/16 INDICATOR SETUP This section provides setup and calibration instructions for the DR2100A indicator. The indicator setup and calibration is accomplished by entering various configuration codes through the keyboard. 13. Configuration Codes Note: The indicator must be placed in the program mode prior to entering a configuration code. See the following list of configuration codes that may be accessed. To enter the program mode, Key 9080 and The display will indicate [ PRESS CAL SWITCH ], Press CAL switch once. This switch is located on the main board and can be accessed by removing the rear cover of the indicator. Code Listing 2100 2104 2105 2169 6969 9080 9081 9083 9084 9085 9086 9087 9088 9089 9090 9091 9092 9093 9094 Function NTEP Keyboard Lockout Expanded Test Mode ( X10 ) Restore Name On Top Line Load Defaults Initialize Clock Chip Setup Four-Point Calibration Configure Remote Inputs Configure Print Set Time & Date Raw A/D, Battery Test Auto Shut Off and Backlight Timer APW Recall/Store Program Name Through Serial Port Single-Point Calibration View / Store Calibration Factors View / Set Angle Zero and Span View / Set Angle Factors Out-of-Level Calibration Note: if display shows “LOCKED OUT” use configuration Code 2100 to unlock specific function or key to enable viewing or changing. LTS Scale Company, LLC 37 Rev B 1/26/16 14. Code 2100 - Keyboard Lockout Note: Keyboard functions and the 90xx codes may be individually locked out. LOCK KEYBOARD? YES = LOCKOUT Press keys 2100. Press ENTER key. KEYBOARD TARE *YES NO Top display line shows the item to be enabled or disabled. Bottom display line shows the current status indicated by the asterisk. Disabled or lockout = YES Enabled or accessible = NO To lock or unlock a function: Use DEL key to toggle selection between YES and NO. Press ENTER to accept selection and proceed to the next function. Available Lockout Functions Keyboard Tare I.D. Scale Zero Push Button Tare Print Accumulate Menu ( lb./kg, Recall Tare ) Code 9080; Setup Code 9081; Calibration Code 9083; Configure Remote Inputs Code 9084; Configure Print Code 9085; Set Time & Date – Option Code 9085; Raw A/D, Battery Test Code 9087; Auto Shut Off and Backlight Timer Code 9088; Piece Count/ APW Code 9089; Program Name Note: in the event that the indicator locks up or does not respond properly, hold down DEL and R keys. 15. Code 2104 - Expand Test Mode X10 Expand mode is used for testing with a finer graduation size than normally displayed. Example: if the Graduation size is set for 5 lb. then expanded mode will display 0.5 lb. graduations. To enter expand mode: Press keys 2104. Press ENTER. ZERO TRACK ZERO TRACK Disables Zero Tracking in test mode. Re-enabled upon expand mode exit. *YES NO Press DEL key to select mode. Press ENTER key to accept the selected setting. Top display line shows the expanded weight. Bottom display line shows the normal weight. To exit and return to normal operation, simply press ENTER key. EXPAN= GROSS= 0.0 0 LB 16. Code 2105 - Restore Default Name Restore the default name [ LTS SCALE ] to the top display line. Press numeric keys 2105. Press ENTER key. The top display line will display the default name in the Gross weigh mode. LTS Scale Company, LLC 38 !@#%^&*&^%$#@#@! GROSS= 0 LB LTS SCALE GROSS= 0 LB Rev B 1/26/16 17. Code 2169- Load Default Settings CAUTION! This code clears calibration and other setup settings. Consult factory prior to entering the load default settings mode. The load default setting code is used to initialize the main board. Default values loaded may not be the settings required for your application. Press numeric keys 2169. Press ENTER key. The indicator display will briefly flash when loading is complete. Configure indicator to required specifications. Four-Point Calibration must be done before the Single-Point calibration can be performed. 18. Code 6969 - Initialize Clock Chip Initializes the clock on units equipped with the Time & Date option. See Setup – Code 9085 to set time and date. To initialize the clock: Press keys 6969. Press ENTER key. Units ordered with the Time & Date option are initialized before being shipped. 19. Code 9080 - Indicator Setup Note: indicator setup has been performed at the factory. This section is provided in the event that these settings need to be changed. Press keys 9080. Press ENTER key. Press CAL switch at the rear end of board PRESS CAL SWITCH KGS ONLY Calibrate and weigh in Kilograms only select YES. Press DEL key to select mode. Press ENTER key to accept the selected setting. If changing mode (LB/KG to KGS ONLY) or (KGS ONLY to LB/KG) the indicator MUST be reconfigured and Four-Point calibration MUST be done. KGS ONLY YES *NO COUNTBY Available counts by values are 1 2 5 Press DEL key to select Count-By value. Press ENTER key to accept the selected setting. DECIMAL POSITION Available decimal positions are 0 1 Key in decimal positions value. Press ENTER key to accept setting. 2 CTBY 1 , 2 , 5 NUMBER = 2 3 SELECT DECIMAL NUMBER = 0 FIXED ZERO Select YES to count by 10, 20, of 50’s. Press DEL key to select the number of fixed zeroes. Press ENTER key to accept setting. Note: if there are decimals selected, the fixed zeros are not available. LTS Scale Company, LLC 39 SELECT FIXED ZRO YES *NO Rev B 1/26/16 INCREMENTS Display shows: Standard Values for Number of increments are: 500 600 1000 1200 1500 2500 3000 4000 5000 6000 Press DEL key to select increments value. Press ENTER key to accept setting. SELECT INCREMENT NUMBER = 1000 2000 10000 Displays shows capacity, plus the count-by factor. Example: Count by factor: = 5 Decimal positioning value: = 0 Increments: = 1000 2500 (increments) x 2 (count-by) = 5000 Display shows: 5005 USE ENTER OR DEL 5005 If the capacity and count-by factor are correct then, press ENTER key to accept these settings. If not press DEL, and return to the beginning. LEGAL FOR TRADE LEGAL FOR TRADE Press DEL key to select YES or NO. *YES NO Press ENTER key to accept setting. If set to yes features like calibration the back cover must be removed and the SELECT MOTION Available motion settings are: Legal-for-Trade = YES: 1 2 3 Legal-for-Trade = NO: 1 2 3 4 5 6 7 8 9 Press DEL key to select motion setting. Press ENTER key to accept setting. SELECT MOTION #D NUMBER = 1 MOTION DELAY Available motion delay settings are: SELECT MOT DELAY SECONDS = 1.0 0.5 1.0 1.5 2.0 2.5 3.0 Press DEL key to select the motion delay setting. Press ENTER key to accept setting. Note: an analog filter is available on the main board. Potentiometer (R19) is located at the bottom left-hand corner of the main board. Adjusting this potentiometer may require re-calibration after adjustment. Counterclockwise will slow the update rate while clockwise will speed the rate up. DISPLAY MOTION YES Weight is displayed during motion conditions. NO Weight is only displayed when within the motion band. Press DEL key to select YES or NO. Press ENTER key to accept setting. DISPLAY ON TOP LINE YES Weight is displayed on top line NO Weight is not displayed on top line ZERO TRACK DIGITS Numbers of graduations for zero tracking are: LTS Scale Company, LLC 40 DISPLAY MOTION *YES NO DISPLAY TOP LINE *YES NO SELECT TRACK #D NUMBER = 1 Rev B 1/26/16 .6 1 3 Press DEL key to select the motion delay setting. Press ENTER key to accept setting. End of Indicator Setup - Code 9080. Enter another configuration code to review or change parameters or 20. Code 9081 – Four-Point Calibration A Four-Point linearity calibration is generally not required after initial installation. Single-Point calibration should be used. The Four-Point calibration may be required in the event of load cell replacement or weight loads of increasing value are not linear. 21. Code 9083 - Configure Remote Inputs Press keys 9083. Press ENTER key. REMOTE INPUT 1 Functions available for Remote Input #1 are: PRINT ACCUMULATE INHIBIT SCALE ZERO PUSH-BUTTON TARE Press DEL key to select function for Remote Input #1. Press ENTER key to accept setting. REMOTE INPUT 2 Functions available for Remote Input #2 are: PRINT ACCUMULATE INHIBIT SCALE ZERO PUSH-BUTTON TARE Press DEL key to select function for Remote Input #2. Press ENTER key to accept setting. REMOTE INPUT PRINT 1 REMOTE INPUT ACCUM 2 22. Code 9084 - Configure Print Note: The RS232 data format is 8 data bits, 1 stop bit and No parity. Data, Stop and Parity are not selectable. Press keys 9084. Press ENTER key. SELECT BAUD Available baud rates are: 1200 2400 4800 9600 For IR or RF load cell cables set to 9600. Press DEL key to select baud rate. Press ENTER to accept setting. SELECT BAUD 9600 # TOP LINE FEEDS Set to print blank lines (feed paper down) prior to printing selected data fields. Use the numeric keypad to enter the value of top line feeds. # TOP LINE FEEDS NUMBER = 2 Press ENTER key to accept setting. PRINT ITEM # 1 Available items to be printed are: Gross weight ID (Identification Number) Tare weight Accumulate Net weight Name LTS Scale Company, LLC 41 Piece count Total count No print Rev B 1/26/16 Time & Date (option) Press DEL key to select item. Press ENTER key to accept setting. # SPACES OVER Sets the starting point on the left-hand margin for the selected print field. Key in the value for the starting point for Print Item 1. Press ENTER key to accept setting. # SPACES OVER NUMBER = 1 # CR LF # CR LF NUMBER = Sets the vertical spacing between lines of data. 0 = next line of data will be printed on the same line 1 = data will be printed on the next line 2 = double spacing, one blank line between print field More line feeds results in a bigger vertical space between data lines. Use the numeric keypad to enter the value. Press ENTER key to accept setting. 1 PRINT ITEM #1 to PRINT ITEM #9 must be configured to print any of the ten print items in any order desired. Repeat Print Item, # spaces and # CR LF for all nine Print Items before next prompt is displayed. # BTM LINE FEEDS NUMBER = 1 # BTM LINE FEEDS Set to print blank lines (feed paper down) after printing selected data fields. Use the numeric keypad to enter the required value. Press ENTER key to accept setting. 23. Code 9085 - Setting Time & Date (Optional) Note: this indicator utilizes the 24-hour clock (military time). Press keys 9085. Press ENTER key. YEAR 1 or 2 digit year entry (0 to 99). Use the numeric keypad to enter the Year. Press ENTER to accept setting. MONTH Use the numeric keypad to enter the Month. Press ENTER to accept setting. DAY Use the numeric keypad to enter the Day. Press ENTER to accept setting. SET TIME & DATE YEAR = 3 SET TIME & DATE MONTH = 1 SET TIME & DATE DAY = 1 HOURS Use the numeric keypad to enter the Hour. Press ENTER to accept setting. SET TIME & DATE HOUR = 1 Use the numeric keypad to enter the Minutes. Press ENTER to accept setting. SET TIME & DATE MINUTES = 1 MINUTES LTS Scale Company, LLC 42 Rev B 1/26/16 LTS Scale Company, LLC 43 Rev B 1/26/16 24. Code 9086 – Raw A/D, Battery Test Troubleshooting tool used to view the voltage value and the raw A/D counts. Press keys 9086. Press ENTER. Press ENTER to exit. 12V BV = XXX RAW A/D= XXXXXXX Press ENTER key to exit. Display lower line shows raw A/D counts. Reading should be positive and increase as weight is applied. Maximum is approximately 400,000 counts 25. Code 9087 – Auto Shut Off and Backlight Timer Press keys 9087. Press ENTER key. BACK LIGHT TIME BACK LIGHT TIME Use numeric keypad to enter the time value. MINUTES= 30.0 Press ENTER key to accept value. 0.1 minutes = 6 seconds. Jumper JP5 must be set for backlight to turn off. OFF TIMER OFF TIMERS Use numeric keypad to enter the time value. MINUTES= 30.0 Press ENTER key to accept value. If keyboard ON/OFF is used unit will turn off automatically when time expires. Note: Any motion outside the motion band will reset the timers. This keeps the scale from turning off during usage. 26. Code 9088 - Entry Of Average Part Weight Press keys 9088. Press ENTER. Use the numeric keys to enter an Average Part Weight (APW). Press ENTER key to accept the displayed value. AVERAGE PIECE WT LB. = X.XX 27. Code 9089 - Program Name Through Serial Port Allows a 16-character alpha-numeric string to enter for a custom name. This name is displayed on the top line of the display when in the Gross weigh mode. This header can also be selected to be printed, see Code 9084. You need the RS232 option installed, data cable, and a PC running a terminal emulation program. Configure PC COMM port to match baud rate selected in Code 9084 (default 9600 baud), 8 data bits, NO parity, 1 stop bit. Press keys 9089. Press ENTER. Display on PC will show: [ LTS SCALE ...CHANGE NAME ? Y/N] To change: Send capitol “Y” from the PC to DR2100A. Indicator sends: [ENTER ALL 16 CHARACTERS ] [---------------] Send all 16 characters. Fill to end with spaces if needed. [YOUR NAME HERE ...CHANGE NAME ? Y/N] If name is correct, then press any key to end, if not return to step I). NOTE: To exit this mode from the keyboard: Press and hold DEL and R keys, LTS Scale Company, LLC 44 PROGRAMMING THRU SERIAL PORT Rev B 1/26/16 28. Code 9090 – Single-Point Calibration Single-Point Calibration can only be done after the Four-Point calibration has been completed at least one time. If the display shows ERROR when this code is entered then the Four-Point calibration must be completed first. See Calibration section. 29. Code 9091 - View / Store Calibration Factors View / Store Calibration Factors This is not a substitute for test weight calibration. Recorded Calibration factors can be entered to put the indicator back to a known working condition. The Calibrations Factors stored will change after every Single-Point and Four-Point Calibration. Recording of these factors is the last thing to be done before putting the scale in service. See Calibration section. 30. Code 9092 - View / Set Angle Zero and Span NTEP See Out-of-Level Calibration. View and set Angle Zero and Angle Span values. 31. Code 9093 – View / Set Angle Factors See Calibration section. 32. Code 9094 – Out-of-Level Calibration See Calibration section. LTS Scale Company, LLC 45 Rev B 1/26/16 Blank Page LTS Scale Company, LLC 46 Rev B 1/26/16 CALIBRATION Note: A Four-Point Linearity Calibration (code 9081) has been performed at the factory. In most cases, the Single-Point Calibration (code 9090) is the only calibration that will be required after installation. 33. Code 9090 – Single-Point Calibration Single-Point Calibration should be used to make minor calibration adjustments. Four-Point Linearity Calibration should be done if the load cell is being replaced. Allow ample time for the indicator to warm up, generally 15-20 minutes. 33.1. Unload scale, ensure that they are not touching the floor and are level. Press SCALE ZERO key. 33.2. Remove rear cover plate from the indicator. 33.3. Enable calibration by pressing the cal button, located in the upper right hand corner of the main board. This button is usually white. 33.4. Press keys 9090. Press ENTER key. 33.5. SINGLE POINT CAL Press DEL to select YES. Press ENTER key. 33.6. ARE YOU SURE? Press DEL key to select YES. Press ENTER key. 33.7. SET SCALE ZERO? Press DEL key to select YES. Press ENTER key. Note: If emptying the scale is impossible select NO otherwise reset the scale zero by selecting YES. 33.8. WEIGHT = Apply test load (for best results apply at least 25% of scale capacity). Wait until motion ceases. Enter the value of the applied test load. Press ENTER key. SINGLE POINT CAL YES *NO ARE YOU SURE ? YES *NO SET SCALE ZERO ? YES *NO CAL MODE WEIGHT = Single-Point Calibration is finished. LTS Scale Company, LLC 47 Rev B 1/26/16 0 34. Code 9081 - Four-Point Linearity Calibration A Four-Point Linearity Calibration is generally not required after initial installation. Single-Point Calibration should be used. The Four-Point Calibration may be required in the event of load cell replacement or weight loads of increasing value are not linear. 34.1. Unload scale, ensure that they are not touching the floor and are level. 34.2. Press SCALE ZERO key. Remove rear cover plate from the indicator 34.3. Press keys 9081. Press ENTER key. Note: Pressing ENTER will use current value on the scale as zero value. 34.4. DEL FACTORY CAL Press DEL key to select YES. Press ENTER key. DEL FACTORY CAL YES *NO 34.5. ARE YOUR SURE? Press DEL key to select YES. Press ENTER key. ARE YOU SURE? YES *NO 34.6. CALIBRATION STEP #1 - Apply first test load. For best results apply approximately 25% of scale capacity. Wait until motion ceases. Key in the value of the applied test load. Press ENTER key. 34.7. CALIBRATION STEP #2 - Apply second test load. For best results apply approximately 50% of scale capacity. Wait until all motion ceases. If the reading is correct, press ENTER key. If not, key in the value of the test load. Press ENTER key. 34.8. CALIBRATION STEP #3 - Apply third test load. For best results apply approximately 75% of scale capacity. Wait until all motion ceases. If the reading is correct, press ENTER key If not, key in the value of the test load. Press ENTER key. 34.9. CALIBRATION STEP #4 Apply fourth test load. For best results apply approximately 100% of scale capacity. Wait until all motion ceases. If the reading is correct, press ENTER key. If not, key in the value of the test load. Press ENTER key. CAL STEP # 1 WEIGHT = XXXX CAL STEP # 2 WEIGHT = XXXX CAL STEP # 3 WEIGHT = XXXX CAL STEP # 4 WEIGHT = XXXXX Calibration Complete This completes the Four-Point Linearity Calibration. LTS Scale Company, LLC 48 Rev B 1/26/16 35. Out-of-Level Calibration This procedure is to calibrate the DR2100AN indicator with a Clinometer for Out-of-Level weighing. The scale base and DR2100AN indicator should be installed per the installation instructions prior to performing this procedure. Out-of-Level calibration should be done after installation and before unit is placed into service. Warning: Once this procedure has been started it MUST be completed in all 4 directions. Before starting, read through this procedure completely. Make sure you understand the procedure and can tip the mast 3 degrees in all directions. 35.1. Apply power to the indicator. Allow 15-20 minutes for warm up. 35.2. Remove the cover from the back of the indicator. 35.3. Press keys 9092. Press ENTER key. Top display line shows the gross weight. Bottom display line shows: FB (front-to-back) angle LR (left-to-right) angle. No load should on the scale at this time. The clinometer is mounted on top of the scale base. Note: All references to the position of the truck while calibrating are made while sitting in the driver seat. GROSS = 0 FB= X.X LR= X.X 35.4. Level truck so both FB and LR angles are within 0.0SYMBOL 176 \f "Symbol" \s 10 +/0.2SYMBOL 176 \f "Symbol" \s 10. GROSS = 0 FB=+0.0 LR= +0.0 Level is obtained by tilting forks for Front-to-Back And moving to a flat location or tip truck for Left-to-Right. Move truck, (level condition) until: FB = +0.0SYMBOL 176 \f "Symbol" \s 10 (+/0.2SYMBOL 176 \f "Symbol" \s 10) LR = +0.0SYMBOL 176 \f "Symbol" \s 10 (+/0.2SYMBOL 176 \f "Symbol" \s 10) 35.5. Press DEL key. Note: DO NOT select “YES”. Angle zero has been set at the factory. Do not change any of the numbers in the following steps unless instructed. 35.6. Press ENTER key. SET ANGLE ZERO YES *NO 35.7. Press ENTER key. FB ANGLE ZERO NUMBER = XXX 35.8. Press ENTER key. LR ANGLE ZERO NUMBER = XXX 35.9. Press ENTER key. FB ANGLE SPAN FACTOR = XXX 35.10. Press ENTER key. LR ANGLE SPAN FACTOR = XXX FRONT TO FRONT YES *NO 35.11. Press ENTER key. LTS Scale Company, LLC 49 Rev B 1/26/16 35.12. Press keys 9094. Press ENTER key. 35.13. Press DEL key to place the asterisk next to YES. Press ENTER key. 35.14. Key in the value of the test weight to be used. Press ENTER key. Note: CALIB ANGLE FTRS YES *NO TEST LOAD VALUE WEIGHT = XXXXX All references to position are made while sitting in the driver seat. CAUTION: Care must be taken while applying weights in an out-of-level condition. Bodily harm may occur from shifting weight. Top display line shows the position the truck is to be placed in. Bottom display line shows: FB (front-to-back) angle LR (left-to-right) angle Press SCALE ZERO key if weight value is not zero. REAR UP 0 FB=+0.0 LR= 0.0 REAR UP XXXX 35.15. Lift test load (value entered above for TEST LOAD VALUE). FB=+3.0 LR=+0.0 Tilt forks forward 3 degrees and tip truck so level left-to-right. FB = +3.0SYMBOL 176 \f "Symbol" \s 10 (+/- 0.2SYMBOL 176 \f "Symbol" \s 10) LR = +0.0SYMBOL 176 \f "Symbol" \s 10 (+/- 0.2SYMBOL 176 \f "Symbol" \s 10) Weigh value shown is the non-corrected weight. Wait for motion no motion. Press ENTER key. RIGHT UP XXXX FB=+0.0 LR=-3.0 35.16. Tilt forks until level front-to-back and tip truck so right side up 3 degrees. FB = +0.0SYMBOL 176 \f "Symbol" \s 10 (+/- 0.2SYMBOL 176 \f "Symbol" \s 10) LR = -3.0SYMBOL 176 \f "Symbol" \s 10 (+/- 0.2SYMBOL 176 \f "Symbol" \s 10) Wait until all motion ceases. Press ENTER key. FRONT UP XXXX FB=+0.0 LR=-3.0 35.17. Tilt forks backward 3 degrees and tip truck so level left-to-right. FB = -3.0SYMBOL 176 \f "Symbol" \s 10 (+/- 0.2SYMBOL 176 \f "Symbol" \s 10) LR = +0.0SYMBOL 176 \f "Symbol" \s 10 (+/- 0.2SYMBOL 176 \f "Symbol" \s 10) Wait until all motion ceases. Press ENTER key. LEFT UP XXXX FB=+0.0 LR=+3.0 35.18. Tilt forks until level front-to-back and tip truck so left side up 3 degrees. FB = +0.0SYMBOL 176 \f "Symbol" \s 10 (+/- 0.2SYMBOL 176 \f "Symbol" \s 10) LR = +3.0SYMBOL 176 \f "Symbol" \s 10 (+/- 0.2SYMBOL 176 \f "Symbol" \s 10) Wait until all motion ceases. Press ENTER key. Out-of-Level calibration is complete. LTS Scale Company, LLC 50 Rev B 1/26/16 36. 36.1. Calibration Verification Press keys 9092. Press ENTER key. GROSS = 0 36.2. FB=+0.0 LR=+0.0 Tilt forks front-to-back until level and position truck so left-to-right is level. FB = +0.0SYMBOL 176 \f "Symbol" \s 10 (+/- 0.2SYMBOL 176 \f "Symbol" \s 10) LR = +0.0SYMBOL 176 \f "Symbol" \s 10 (+/- 0.2SYMBOL 176 \f "Symbol" \s 10) Press ZERO SCALE key if necessary. 36.3. GROSS = XXXXX Lift known test load. FB=+0.0 LR=+0.0 Tilt forks front-to-back until level and position truck so left-to-right is level. FB = +0.0SYMBOL 176 \f "Symbol" \s 10 (+/- 0.2SYMBOL 176 \f "Symbol" \s 10) LR = +0.0SYMBOL 176 \f "Symbol" \s 10 (+/- 0.2SYMBOL 176 \f "Symbol" \s 10) Reading in tolerance? Repeat Single-Point calibration if necessary. 36.4. GROSS = XXXXX FB=+3.0 LR=+0.0 Tilt forks forward 3 degrees and tip truck so level left-to-right. FB = +3.0SYMBOL 176 \f "Symbol" \s 10 (+/- 0.2SYMBOL 176 \f "Symbol" \s 10) LR = +0.0SYMBOL 176 \f "Symbol" \s 10 (+/- 0.2SYMBOL 176 \f "Symbol" \s 10) Reading in tolerance? Repeat Out-of-Level calibration if necessary. GROSS = XXXXX FB=+0.0 LR=-3.0 36.5. Tilt forks until level front-to-back and tip truck so right side up 3 degrees. FB = +0.0SYMBOL 176 \f "Symbol" \s 10 (+/- 0.2SYMBOL 176 \f "Symbol" \s 10) LR = -3.0SYMBOL 176 \f "Symbol" \s 10 (+/- 0.2SYMBOL 176 \f "Symbol" \s 10) Reading in tolerance? Repeat Out-of-Level calibration if necessary. 36.6. FB=-3.0 LR=-0.0 Tilt forks backward 3 degrees and tip truck so level left-to-right. FB = -3.0SYMBOL 176 \f "Symbol" \s 10 (+/- 0.2SYMBOL 176 \f "Symbol" \s 10) LR = +0.0SYMBOL 176 \f "Symbol" \s 10 (+/- 0.2SYMBOL 176 \f "Symbol" \s 10) Reading in tolerance? Repeat Out-of-Level calibration if necessary. GROSS = XXXXX 36.7. Tilt forks until level front-to-back and tip truck so left side up 3 degrees. FB = +0.0SYMBOL 176 \f "Symbol" \s 10 (+/- 0.2SYMBOL 176 \f "Symbol" \s 10) LR = +3.0SYMBOL 176 \f "Symbol" \s 10 (+/- 0.2SYMBOL 176 \f "Symbol" \s 10) Reading in tolerance? Repeat Out-of-Level procedure if necessary. GROSS = XXXXX FB=-0.0 LR=+ 3.0 LTS Scale Company, LLC 51 Rev B 1/26/16 37. Weight Calibration Numbers Standard and NTEP This procedure can only be used after the initial calibration has been performed in the field and all numbers in this section have been recorded. Entering calibration numbers can be performed in the event that an electronics problem is encountered. This does not guarantee calibration is correct or within tolerance. Scale should always be tested using known test weight before placing unit back into service. This is not a substitute for a periodic calibration utilizing test weights. 37.1. Press 9091 then press ENTER Key. 37.2. Record value. LINEARITY STEP 1 0FFSET = 37.3. Press ENTER key. Record value. LINEARITY STEP 1 ADD-WT = 37.4. Press ENTER key. Record value. LINEARITY STEP 1 FACTOR = 37.5. Press ENTER key. Record value. LINEARITY STEP 2 0FFSET = 37.6. Press ENTER key. Record value. LINEARITY STEP 2 ADD-WT = 37.7. Press ENTER key. Record value. LINEARITY STEP 2 FACTOR = 37.8. Press ENTER key. Record value. LINEARITY STEP 3 0FFSET = 37.9. Press ENTER key. Record value. LINEARITY STEP 3 ADD-WT = 37.10. Press ENTER key. Record value. LINEARITY STEP 3 FACTOR = 37.11. Press ENTER key. Record value. LINEARITY STEP 4 0FFSET = 37.12. Press ENTER key. Record value. LINEARITY STEP 4 ADD-WT = 37.13. Press ENTER key. Record value. LINEARITY STEP 4 FACTOR = 37.14. Press ENTER key. Record value. SINGLE POINT CAL FACTOR = 37.15. Press ENTER key. Record value. SCALE ZERO NUMBER = 9091 37.16. Standard Unit,Recording complete. NTEP unit, continue to Angle Calibration Numbers, next section. LTS Scale Company, LLC 52 Rev B 1/26/16 38. Angle Calibration Numbers 38.1. Press keys 9092. Press Enter Key. 38.2. Press DEL key. 38.3. 9092 GROSS = 0 FB=+X.X LR=+X.X Press ENTER key. Note: DO NOT select “YES”. Angle Zero set at the factory. SET ANGLE ZERO YES *NO 38.4. Press ENTER key. Record value. FB ANGLE ZERO NUMBER = 38.5. Press ENTER key. Record value. LR ANGLE ZERO NUMBER = 38.6. Press ENTER key. Record value. FB ANGLE SPAN FACTOR = 38.7. Press ENTER key. Record value. LR ANGLE SPAN FACTOR = 38.8. Press ENTER key. Record value. 38.9. Press 9093 keys. Press ENTER key. FRONT TO FRONT *NO YES 9093 38.10. Record value: ZONE 1 FACTOR NUMBER =1.0000000 38.11. Press ENTER key. Record value. ZONE 2 FACTOR NUMBER =1.0000000 38.12. Press ENTER key. Record value. ZONE 3 FACTOR NUMBER =1.0000000 38.13. Press ENTER key. Record value. ZONE 4 FCTOR NUMBER =1.0000000 38.14. Press ENTER key. Record value. ZONE 5 FACTOR NUMBER =1.0000000 38.15. Press ENTER key. Record value. ZONE 6 FACTOR NUMBER =1.0000000 38.16. Press ENTER key. Record value. ZONE 7 FACTOR NUMBER =1.0000000 38.17. Press ENTER key. Record value. ZONE 8 FACTOR NUMBER =1.0000000 38.18. Press ENTER key. Record value. ZONE 1 ANGLE SP NUMBER =3.50 CHANGE TO 4.80 38.19. Press ENTER key. Record value. ZONE 2 ANGLE SP NUMBER =3.50 CHANGE TO 4.80 38.20. Press ENTER key. Record value. ZONE 3 ANGLE SP NUMBER =3.50 CHANGE TO 4.80 38.21. Press ENTER key. Record value. ZONE 4 ANGLE SP NUMBER =3.50 CHANGE TO 4.80 38.22. Press ENTER key. Record value. ZONE 5 ANGLE SP NUMBER =3.50 CHANGE TO 4.80 38.23. Press ENTER key. Record value. ZONE 6 ANGLE SP NUMBER =3.50 CHANGE TO 4.80 38.24. Press ENTER key. Record value. ZONE 7 ANGLE SP NUMBER =3.50 CHANGE TO 4.80 38.25. Press ENTER key. Record value. ZONE 8 ANGLE SP NUMBER =3.50 CHANGE TO 4.80 LTS Scale Company, LLC 53 Rev B 1/26/16 LTS Scale Company, LLC 54 Rev B 1/26/16 LTS Scale Company, LLC 55 Rev B 1/26/16
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