Home

Service - Test Equipment Depot

1. gt 2 A 0000 0 10 11 11 12 12 13 13 14 14 15 15 16 16 17 17 18 8 9 19 N N SO N oo Q9 DN 000 gt RC N NO h2 0101 C0 FO 3 3 CHAPTER 3 INDICATOR TESTING 3 14 CALIBRATION VERIFICATION USING A LOAD CELL SIMULATOR To perform these tests the use of a Load Cell Simulator is required The basic function of a Simulator is to simulate the output of a full bridge Load Cell allowing the Indicator to be separated from the Load Cell for the purposes of troubleshooting and calibration 1 Remove power from the Indicator Refer to section 4 1 and open the Front Housing 2 See Figure 3 14 Printed Circuit Board Connections and remove the switch cover Retain the Screws and cover J10 709 J2 2000022 O ooo W2 SWITCH si COVER 09 Figure 3 14 Main Printed Circuit Board Connections 3 Connect the Simulator to Terminal strip J2 See Figure 3 14 Tighten all terminal screws securely 4 When connecting a 2mv v simulator jumper W1 is to be put in place shorting the two pins See Figure 3 15 OR
2. 3 32 M in PC e ds 3 3 3 2 1 Voltage MenSUIBITIBIIS escoria 3 3 3 2 2 Tes secano 3 6 3 9 Power SUPPIY TOS unieran eri ae Fin nibo Modi 3 7 3 3 1 Voltage measurements EE OO S DOS 3 7 STEEL Em 3 8 3 4 1 General Information ERE mS 3 8 3 4 2 Troubleshooting The BONON 3 9 9 5 Recharge Board session 3 10 3 5 1 Recharge Board 0 3 10 3 5 2 Recharge Board Testi auna mati 3 11 3 5 3 Voltage Measurements standar iaa 3 12 Relay Board TIM si SB DEEP DAC 3 13 SONNERIE opp 3 13 3 13 3 7 5322 RS422 485 Communication Testing etc 3 16 3 7 11 RS422 485 Communication Board Information 3 16 OW e 3 16 37 RAZ ULNIS oT TT m 3 18 2ug External Input FOSA sesiones 3 20 3 9 Op rationdl TeS iNg TU 3 21 3 9 1 Indicator Display Segment Test Power On Sequence 3 21 3 9 2 ning Off the Indicator socia aaa 3 22 39 3 3 22 3 9 4 Checking Menu Library 3 23 TABLE OF CONTENTS Cont CHAPTER 3 CKW 55 INDICATOR TESTING Cont 3 10 SPS CNC ONONG Pc 3 25 3 11 Calibration USING an Extern
3. 032 space 064 0 096 033 065 097 034 066 B 098 b 035 067 099 036 068 100 4 037 96 069 101 e 038 amp 070 F 102 f 039 071 6 103 9 040 072 H 104 h 041 073 105 i 042 074 J 106 j 043 075 107 044 076 1 108 045 077 109 m 046 078 110 047 079 0 111 o 048 0 080 P 112 p 049 1 081 113 q 050 2 082 R 114 051 3 083 5 115 052 4 084 T 116 t 053 5 085 U 117 u 054 6 086 V 118 v 055 7 087 W 119 w 056 8 088 X 120 x 057 9 089 Y 121 y 058 090 7 122 z 059 091 123 060 lt 092 124 061 093 1 125 062 gt 094 126 2 OHAUS With offices worldwide www ohaus com 8 0 2 5 1 0 6 5 P N 80251063 O Ohaus Corporation 2006 all rights reserved Printed in USA Test Equipment Depot 800 517 8431 99 Washington Street Melrose MA 02176 TestEquipmentDepot com
4. 001 P Tare 0 3 00 Ib oz Setpoint Input 2 Range Range Under O 1 00 Ib oz Range Over 0 2 00 Ib oz LIB ID 02 PART 002 03 00 16 07 Setpoint Input Range Range Under 0 1 00 Ib oz Range Over 0 2 00 Ib oz 3 24 Range Over 0 2 00 Ib oz NIN LIB ID 03 PART No 003 P Tare 0 3 00 Ib oz Setpoint Input 2 Range Range Under O 1 00 Ib oz Range Over 0 2 00 Ib oz LIB ID 04 PART 004 0 3 00 16 07 Setpoint Input Range Range Under O 1 00 Ib oz 3 10 SPECIFICATIONS CHAPTER 3 INDICATOR TESTING Table 3 4 lists the specifications for the Indicator Scale Model specifications are also included INDICATOR CKW 55 Maximum Displayed Resolution Approval Resolution Weighing Units Functions Weight Display Checkweigh Indication Keyboard Construction and Protection Load Cell Excitation Voltage Load Cell Input Sensitivity Load Cell Drive Stabilization Time Auto zero Tracking Zeroing Range Span Calibration Overall Dimensions W x D x H Net Weight Operating Temperature Range Power TABLE 3 4 SPECIFICATIONS 1 20 000 1 10 000 kg Ib g oz Ib oz 9o Static Weighing Checkweighing Accumulation 0 8 20 mm High 6 digit 7 segment LED with Adjustable Brightness Control 24 segment LED 3 color x 8 Bar Graph and Audible Beeper with Multiple User Setups 7 Function 12 N
5. 6 On the computer set the correct COM port and all settings on the communication program to match the settings on the Indicator The Indicator should now communicate with the computer See Table 3 1 for Interface Commands All RS485 commands sent to the Indicator must be preceeded by character and the address number and must also be terminated with a carriage return CR or carriage return line feed CRLF 7 When the commands can be transmitted from the computer to the Indicator and from the Indicator to the computer the RS485 is functional 8 Additional service commands are shown in Appendix A 3 19 CHAPTER 3 INDICATOR TESTING 3 8 EXTERNAL INPUT TESTING The CKW 55 Indicator I O menu contains an INPUT menu item that is used to define a function to be controlled by an optional external input device such as a foot switch The switch must to be a momentary contact type and the contacts must be normally open Table 3 3 identifies the various commands that can be set up to be activated when the external switch input is momentarily closed TABLE 3 3 EXTERNAL INPUT SELECTIONS To set up the input functions enter the menu settings This menu item is used to define a function to be controlled by an optional external input device such as a foot switch Selections are Off The external input is disabled Tare The external input initiates a Tare function Zero The external input initiates a Zero function Print The ex
6. Attention Risque d explosion si la batterie est remplac e par un type inappropri ou si elle est incorrectement branch e Jeter la batterie conform ment aux lois et r glements locaux SLIDE BATTERY OUT T 2 Y PUSH RETAINING CLIP DOWN RETAINING CLIP Figure 4 1 RTC Battery Removal Installation 5 To install a new battery into the holder hold the battery with the mark facing up Slide the battery under the Contact Clip until the Retaining Clip springs up and locks the battery in place CAUTION Do not dispose of used batteries in normal trash Follow the proper disposal or recycling requirements in accordance with local laws and regulations 6 Reassemble the Indicator housing 7 Refer to the Instruction manual and reset the current time and date 4 6 CHAPTER 5 PARTS LISTS 5 PARTS LISTS This section of the manual contains exploded views and parts lists for the CKW 55 Indicator The exploded view drawings identify the replaceable parts NOTE In all cases where a part is replaced the Indicator must be thoroughly checked after the replacement is made The Indicator MUST meets the parameters of all applicable specifications in this manual If further technical information is needed in the United States call toll free 1 800 526 0659 between 8 00 a m and 4 00 p m EST An Ohaus factory service technician will be available to provide assistance Outside the U S
7. 10 After Main PC Board replacement and assembly of the Indicator perform Operational Tests in section 3 9 3 6 CHAPTER 3 INDICATOR TESTING 3 3 POWER SUPPLY TESTING The Power Supply Board is located in the Rear Housing A replaceable fuse is located on the board This test is made when the Indicator fails to turn on when the power source is on and the indicator is plugged in WARNING HAZARDOUS VOLTAGES ARE PRESENT WITH THE INDICATOR HOUSING OPENED AND AC POWER IS APPLIED USE CARE WHEN MAKING ALL MEASUREMENTS 3 3 1 Voltage Measurements NOTE When the power cord is connected to the indicator the Power Supply Board has power applied to at all times 1 Disconnect power from the Indicator Remove the line cord plug from the power source 2 Open the Front Housing refer to procedure 4 1 3 Referto Figure 3 4 and locate the fuse on the Power Board Remove the protective cover and fuse Check the fuse with an Ohmmeter If defective replace with a new fuse of the same type Reinstall protective fuse cover and reconnect ac power and measure voltage at connector CN2 If voltage is not present replace the Power Supply board Refer to procedure 4 4 4 With a power cord connected to the power supply board connector CN1 and measure the voltage at connector CN2 that should be 12 V dc 0 24 V dc If 12 V dc is not present continue If 12 V dc is present the Power Supply board is good CAUTION THIS NEXT STEP CONTAINS ELECTRICAL
8. High Auto Zero Tracking 0 5d Display Brightness High Bar Brightness Mid Power Save Sleep min Power Save Auto off min Mode Menu Library ON Checkweigh ON Set Input Range Beeper Signal OFF Display Signal OFF Graph Incr Auto Graph Display Bar Print Menu Print Stable ON Auto Print 2 OFF Print Content On Date Time GMP User ID GMP Proj ID GMP Scale ID GMP Name ID Format 2 Column Feed OFF Communication Menu Baud Rate 2400 Parity None Data Length 7 Stop bit 2 Hand Shake XON XOFF Type RS232 Alternate Command Print 80 Tare 84 Zero 90 I O menu External Input Zero Input Beep OFF Output type Open Output Sequence Normal Contact Simultaneous GMP data menu USER ID PROJ ID SCALE ID Date Format M D Y Time Format 24hr Lockout menu Locked Menus Locked Functions END Typical Computer or Printer Output of Library Settings 6 Asecond function can be used to document library settings All data stored in the Library setup can be displayed on the computer or printer Enter the Print menu and select List Lib Yes The printer or computer will be sent every library setting Shown below is a typical print out or computer list of the library OHAUS CKW 55 Version Sr1 29 02 18 05 13 20 17 LIB ID 01 PART
9. Main PC board Peel off the protective film from the new Membrane Switch and carefully align and affix to the front Housing of the Indicator 8 Press the Membrane Switch down uniformly Using your fingers with a cloth roll from the center ofthe Membrane Switch outwards toward the edges to remove any air bubbles that may be trapped CAUTION DO NOT PRESS ON THE CLEAR WINDOW AREAS OR ON THE SWITCHES 4 1 CHAPTER 4 REPAIR PROCEDURES 4 2 REPLACING THE MEMBRANE SWITCH Cont 9 Connect the cable from the Membrane Switch to connector J1 on the Main PC board 10 Position the Front Housing into place over the Rear Housing and reassemble by replacing the four screws on the sides of the housing 4 3 REPLACING THE MAIN PC BOARD NOTE Read this procedure through first before proceeding The Main PC board when replaced contains the RTC Battery installed l 2 8 9 Remove power from the Indicator Refer to section 4 1 and open the Front Housing With the Housing opened disconnect the connector from J1 on the Main PC board This is the cable from the Membrane Switch Disconnect all cables leading to the Main PC board Remove switch cover and disconnect load cell cable if attached Remove the four screws holding the Main PC board in place and remove the Main PC board One screw contains a grounding clip Replace the Main PC board and install the four screws previously removed Make sure the grounding c
10. mVN Upon completion of calibration the Main PC Board can be further checked using the Simulator to simulate various weight values Review Table 3 6 and adjust the Simulator to simulate 096 load 5096 load and 100 load for the capacity that the Indicator is rated for If simulator settings and weight reading on the Indicator agree the Main PC Board is functional If the Indicator readings vary or are not linear the Main PC Board is defective and should be replaced Note The Indicator readings are only as accurate as the Load Cell Simulator 4 b If needed remove power from the Indicator and proceed with Section 4 3 and replace the Main PC Board After Main PC Board replacement and assembly of the Indicator perform Operational Tests in Section 3 9 3 33 CHAPTER 3 INDICATOR TESTING 3 14 1 Calibration Test Using a Simulator Cont TABLE 3 6 LOAD CELL OUTPUT READINGS FOR CKW BASES NOMINAL OUTPUT IN MILLIVOLTS AT 5 VOLTS EXCITATION CAPACITY ZERO 50 100 3 kg 4 3 42 0 Zero 2 3 Zero 4 4 7 6 kg 1 6 22 0 Zero 2 8 Zero 5 6 15 kg 1 7 2 0 Zero 2 4 Zero 4 4 8 30kg 1 3 2 0 Zero 2 7 Zero b 4 CHAPTER 4 REPAIR PROCEDURES 4 REPAIR PROCEDURES This section describes how to replace individual assemblies of the CKW 55 Indicator When doing this please refer to the exploded view drawings and parts lists in Section 5 Important After repairs are complete an operational test of the Indicator must always be carried
11. out see Section 3 9 4 1 OPENING THE INDICATOR HOUSING 1 Remove power from the Indicator 2 Unfasten the 4 side screws of the Indicator housing pull the front housing section forward Retain the screws CAUTION THE INDICATOR IS POWERED BY AC AND HAZARDOUS VOLTAGES ARE PRESENT WHEN CONNECTED TO EXTERNAL POWER DO NOT ATTEMPT TO REPLACE ANY ASSEMBLIES WHEN POWER IS APPLIED TO THE UNIT IF A RELAY OPTION IS INSTALLED AC VOLTAGE MAY BE CONNECTED TO THIS PCB REMOVE ALL POWER SOURCES TO THE INDICATOR BEFORE SERVICING 4 2 REPLACING THE MEMBRANE SWITCH NOTE Read this procedure through first before proceeding 1 Remove power from the Indicator 2 Refer to section 4 1 and open the Front Housing 3 With the Housing opened disconnect the connector from J1 on the Main PC board This is the cable from the Membrane Switch 4 Facing the front panel of the indicator carefully pry the Membrane Switch from the Indicator housing A sharp instrument such as a knife or razor blade may be necessary to get underneath the Membrane Switch 5 Carefully pull the Membrane Switch free of the Indicator housing 6 The Membrane Switch was affixed to the Housing with an adhesive Remove the adhesive froM the housing by using denatured alcohol a clean cloth and a razor blade Wipe thoroughly clean There should be no residual adhesive left on the housing 7 Insert the cable from the new Membrane Switch though the hole in the Front Housing and the
12. 55 indicator aA TERRE 5 3 5 2 Column PONS LISP asira socie 5 4 A 1 Service Mode 5 serca A 1 A 2 ASCII Number to Character Conversion iran A 2 LIST OF ILLUSTRATIONS FIGURE NO TITLE PAGE 9 1 Scale Membrane Switch Wiring Diagram tires 3 2 3 2 Interconnection DIGGIN t UO 3 4 ded Component Layout Diagram accio 3 5 3 4 Power Supply Location ascii csi 3 7 3 5 Battery Charging Indications 3 8 3 6 Battery and Recharge Board location 3 9 3 7 Relay Board With Terminal Cover asocia 3 14 3 8 Relay Board Without Terminal COVA escocia cars co eo 3 14 3 9 5422 485 Typical 4 wire Duplex Connection 3 18 3 10 RS422 485 Typical 2 Wire Half Duplex Connection 3 18 3 11 RS422 485 Location in Housing suecia iaa 3 19 3 12 Main Printed Circuit BOOFG ica podria 3 26 3 13 Open and Shorted JUITDBES criaron 3 28 3 14 Main Printed Circuit Board Connections 22 3 32 9 15 Open and Shorted iii 3 32 4 1 RTC Battery Removal Installation 2 4 6 5 1 Exploded View of CKW 55 Mal 5 2 5 2 Exploded View of CKW siio retra tt Re rtr 5 4 CHAPTER 1 INTRODUCTION 1 INTRODUCTION This service manual contains instructions for the diagnosis and repair work to be performed by qualified Ohaus se
13. 6 7 The battery contains a monitor chip that can be accessed to determine the battery temperature voltage number of charge cycles and present charging state To access data on the battery monitor chip connect an RS232 cable to the Indicator and a PC The Indicator should be powered on with ac power Send the following serial commands lt esc gt SV followed by the Battery dump command lt esc gt BD The indicator will output a text string containing the battery voltage battery temperature number of charge cycles and the present charging state See Appendix A 1 for more details Example shown on the PC screen 8 22v 24C 1CC 2 The 8 22v indicates the battery voltage 24C indicates the battery temperature 1CC indicates the number of complete charge cycles and 2 indicates the present charging state See 3 5 1 for charging information If the battery fails to produce any voltage it must be replaced OPTIONAL BATTERY 34 12VDC OUTPUT POWER SUPPLY OPTIONAL BATTERY RECHARGE 69 BOARD G OPTIONAL RELAY OUTPUT BOARD INDICATOR CASE Figure 3 6 Battery and Recharge Board Location Diagram 3 9 CHAPTER 3 INDICATOR TESTING 3 5 RECHARGE BOARD TESTING The Recharge Board is supplied with the optional rechargeable battery This test is made when the battery fails to charge properly The Recharge board is equipped with a soldered in place Fuse F1 located near connector J1 on the board If this fuse is o
14. 9 52 12 44 12 44 15 06 15 06 17 10 17 10 19 02 19 02 20 45 20 45 22 22 22 22 23 54 23 54 25 21 25 21 26 45 26 45 28 06 28 06 29 25 29 25 30 41 30 41 31 56 31 56 33 09 33 09 34 21 34 21 35 31 35 31 36 41 36 41 37 50 37 50 38 58 38 58 40 05 40 05 41 12 41 12 42 19 42 19 43 26 43 26 44 32 44 32 45 38 45 38 46 45 46 45 47951 47 51 48 58 48 58 50 06 50 06 51 13 51 13 52922 52 22 53931 53 31 54941 54 41 55952 55 52 57 04 57 04 58917 58917 59932 59932 60 49 60 49 62 09 62 90 63 30 63 30 64 55 64 55 66 24 66 24 67957 67 57 69935 69 35 7121 71 21 7316 73 16 75 24 75 24 77 52 77 52 80 56 80 56 85 45 85 45 90 00 00 14 4000 1 400010 25 gt FW cO P FOND gt HWW PN b Az d5doo0 000C h KRW CO cO P 0000 l2 I
15. APPENDIX A SERVICE A AXES 01 50 c m A 1 A 1 1 Service 5 t 1 LIST OF TABLES TABLE NO TITLE PAGE IESUS oo B hcc rc 1 2 2 1 Indicator Will Not Turn On With AC POWER user enn enne urere 2 1 2 2 Indicator Will Not Turn On Using Battery Power Optional 2 2 2 3 Indicator Does Not Respond Front Panel Controls 2 3 2 4 No LED or Bar Display or Partial 15 e 2 3 2 5 RS292 COMMUMICENGM FAUTO coran 2 4 2 6 RS422 485 Communication Failure Optional Board 2 4 2 7 Relay Operation Failure Optional 2 4 2 8 Indicator Display Incorrect or Unstable iioii iecit oria 2 5 2 9 Unable to Maintain Time and Date 2 5 2 10 Eror Code as isha tetas etus re rancia 2 6 3 1 Membrane Switch Continuity Test me 3 2 3 2 Serial Interface Commands Table ter vetta b ta ra ba pa HEX FR PER RR 3 17 3 3 0o 1 Oo MM 3 20 3 3 asno 3 25 3 5 Geographical Adjustment Values 3 31 3 6 Load Cell Output Readings for CKW Bases 22 3 34 9 CKW
16. HAZARDS USE EXTREME CARE WHEN MAKING MEASUREMENTS 5 Carefully measure the AC line voltage at the connector CN1 on the power supply Check that the power cord is not intermittent and is operational If the cord is defective refer to section 4 to open the housing and replace the cord Disconnect the power cord from the power source If the power cord was not defective continue with this procedure OPTIONAL BATTERY RECHARGE BOARD ONG CABLE TO CONNECTOR 410 TO EXTERNAL TOCASE CONNECTOR J5 PC BOARD CONTROLLED CIRCUITS GROUND MAIN PC BOARD Figure 3 4 Power Supply Location Diagram 3 7 CHAPTER 3 INDICATOR TESTING 3 4 BATTERY TESTING The optional rechargeable battery is supplied with a Recharge Board This test is made when the battery fails to charge properly or not at all Please read section 3 4 1 General Information and section 3 4 2 Recharge Board Information first before proceeding CAUTION DO NOT ATTEMPT TO CHARGE THE BATTERY USING AN EXTERNAL CHARGER DAMAGE TO THE BATTERY OR AN EXPLOSION COULD OCCUR USE ONLY THE RECHARGER IN THE CKW INDICATOR FOR PROPER CHARGING 3 4 1 General Information The optional battery used in the CKW 55 Indicator and the CKW 55 Series Scale is Nickel Metal Hydride NiMH 7 2 Volts rated at 3800mA and is rechargeable The battery assembly is internally fused and includes a battery monitor chip A defective battery assembly must be
17. INDICATOR TESTING 3 11 CALIBRATION USING AN EXTERNAL BASE Cont 10 wiring is completed and jumpers are in place the Indicator can now be calibrated 11 testing replace the cover OR OPEN JUMPERS SHORTED JUMPER Figure 3 13 Open and Shorted Jumpers 3 12 CALIBRATION When the CKW 55 Indicator is initially set up with a base it must be calibrated before use to ensure accurate weighing results Complete CKW Scale models are shipped pre calibrated from the factory However many conditions may require that the scale be recalibrated Temperature changes geographic gravity variations and rough handling are few reasons why a scale may need recalibration NOTES 1 Make sure that appropriate calibration masses are available before beginning calibration 2 Make sure that the scale base is level and stable during the entire calibration process 3 Masses required to perform the procedures should be in compliance with the requirements of the scale base being used with the Indicator 4 Calibration is unavailable if LFT set to On 5 Before calibration allowthe scaleto warm up for approximately 5 minutes after stabilizing to room temperature 6 To cancel calibration press the TARE button anytime during the process The Indicator will retain previously stored calibration data 3 12 1 Span Calibration Span Calibration uses two points to adjust the scale One point is called the zero value where there is no weight
18. OPEN JUMPERS SHORTED JUMPER Figure 3 15 Open and Shorted Jumpers 3 32 CHAPTER 3 INDICATOR TESTING 3 14 CALIBRATION VERIFICATION USING A LOAD CELL SIMULATOR Cont 9 When connecting a 3 mv v Simulator Jumper W1 must be removed or left in place with one pin uncovered See Figure 3 15 When connecting 4 wires with no sense wires Jumpers W2 and W3 must be in place shorting the two pins When connecting six wires that includes sense wires Jumpers W2 and W3 must be removed or in place with 1 pin uncovered When connecting a Simulator with an extra ground shield wire The shield wire may be connected to the center position of J2 After wiring is completed and jumpers are in place the Indicator can now be calibrated 10 After testing replace switch cover 3 14 1 Calibration Test Using a Simulator This test calibrates the Indicator using a Load Cell Simulator and can verify that the Main PC Board is functioning properly 1 With the Indicator CLr PAn ERROR 3 may be displayed this is normal Enter the menu and perform a span calibration Follow the Indicator prompts When the Indicator indicates a given mass should be placed on the base set the Simulator to an equivalent value to simulate the output for the base Alternate values from Table 3 6 can be set if a CKW Base is used For example when a span value of 6 kg for a 6 kg Indicator application is shown the simulator should be set to 7 2 1 6 4 5 6
19. below the minimum voltage DC minimum voltage 5 AC minimum voltage 24 gt Before testing the relays make sure that the Main PC board is functioning properly 1 Disconnect power from the Indicator Remove the line cord plug from the power source 2 Open the Front Housing refer to procedure 4 1 3 Locate the Relay board cover as shown in Figure 3 7 and remove the cover screws WARNING HAZARDOUS VOLTAGES ARE PRESENT WITH THE INDICATOR HOUSING OPENED AND AC POWER IS APPLIED USE CARE WHEN MAKING ALL MEASUREMENTS RELAY TERMINALS MAY BE CONNECTED TO EXTERNAL VOLTAGE SUPPLIES BE SURE TO REMOVE ALL POWER SOURCES BEFORE SERVICING RELAY BOARDS 3 13 CHAPTER 3 INDICATOR TESTING 3 6 2 Relay Testing Cont OPTIONAL BATTERY 69 6 4 m OPTIONAL BATEO POWER SUPPLY BOARD LONG CABLE TO CONNECTOR 410 TO FRONT CASE CONNECTOR J5 GNMAINPCRBOARB HOUSING GROUND ON MAIN PC BOARD Figure 3 7 Relay Board with Terminal Cover OPTIONAL BATTERY mos OPTIONAL BATTERY POWER SUPPLY RECHARGE BOARD TIONAL RELAY TPUT BOARD LONG CABLE TO CONNECTOR J10 TO FRONT CASE CONNECTOR J5 ON MAIN PC BOARD HOUSING GROUND ON MAIN PC BOARD Figure 3 8 Relay Board without Terminal Cover 3 14 CHAPTER 3 INDICATOR TESTING 3 6 2 Relay Testing Cont NOTE When testing the Relay board containing dc type r
20. board In addition an optional RS422 485 Communication Board is supplied as a kit for the CKW 55 Indicator and can provide a serial interface to Industry EIA 422 485 standards A failure of RS232 communications would require replacement of the Main PC board When the optional kit is installed either the RS232 or RS422 485 can be used not both Selection for the type of communication is made through the Communication menu see Instruction manual If the RS232 fails the RS422 485 will not work 3 7 1 RS422 485 Communication Board Information The RS422 485 Communication board is available as an optional kit for CKW Series Indicators Detailed technical information as to cabling terminations addressing interfacing and jumper setup may be found in Instruction Manual supplied with the Option Kit Setup information is located in the CKW 55 Indicator and CKW Series Scale Instruction manual part number 80251031 3 7 2 RS232 Testing To test the RS232 communications the Main PC board voltage checks should be normal in accordance with section 3 2 NOTE A possible failure could have occurred on the Main PC board RS232 components and still have normal operating voltages present To verify proper operation or failure you will need an interface cable with a Serial interface connector at one end for the computer and stripped tinned wires at the other end that can be connected to the Main PC board computer with a communication program installed is neces
21. duplex mode When RS422 485 is installed note the jumper arrangement shown in Figure 3 10 and 3 11 RS422 485 Typical 4 Wire and Typical 2 Wire Connections Note W1 must be shorted to allow 2 wire communications W2 must be shorted on the last scale connecting to the communcation link W2 connects the terminating resistance Twisted Pair Receive Lines Connect TX to RX Twisted Pair Connect TX to RX Receive Transmit Lines Figure 3 10 RS422 485 Typical 2 Wire Half Duplex Connection 3 18 CHAPTER 3 INDICATOR TESTING 3 7 3 RS422 485 Testing Cont 1 Disconnect power from the Indicator Remove the line cord plug from the power source 2 Open the Front Housing refer to procedure 4 1 NOTE Make sure the computer is equipped with RS422 485 communications or a suitable converter 3 Connect the interface cable to the computer and the other end of the cable as shown in Figures 3 9 or 3 10 9 mi OUTPUT OPTIONAL BATTERY POWER SUPPLY RECHARGE BOARD L LONG CABLE L TO CONNECTOR J10 TO FRONT CASE CONNECTOR J5 ON MAIN PC BOARD HOUSING GROUND MAIN PC BOARD Figure 3 11 RS422 485 Location in Housing 4 Close the Front Housing on the Indicator and connect to AC power b Turnonthe Indicator and enterthe COM menu and setthe Baud Rate Parity Data Length Stop Bit Handshake Type to RS485 and address number then exit the menu
22. dure 4 8 Refer to section 4 1 and open the scale Refer to section 3 7 and test the battery harness If OK proceed Refer to section 3 5 and test the Re charge Board Replace if necessary See Repair Procedure 4 5 If Recharge Board is OK proceed Refer to section 3 1 and test the Mem brane Switch Replace ifnecessary See Repair Procedure 4 2 2 2 CHAPTER 2 DIAGNOSIS TABLE 2 2 INDICATOR WILL NOT TURN ON USING BATTERY POWER OPTIONAL Cont SYMPTOM PROBABLE CAUSE REMEDY Indicator will notturn on using Main PC Board is defective The Main PC Board should be tested in battery power Cont accordance with section 3 2 The Main PC Board if defective should be replaced See Repair Procedures 4 3 After repair perform Operational Tests in section 3 9 TABLE 2 3 INDICATOR DOES NOT RESPOND TO FRONT PANEL CONTROLS SYMPTOM PROBABLE CAUSE REMEDY Indicator does not respond to Membrane Switch is defec Refer to section 3 1 and test the Mem front panel controls tive brane switch Replace ifnecessary See Repair Procedure 4 2 Main PC Board defective If membrane switches are OK refer to section 3 2 and test the Main PC Board If defective replace the Main PC Board See Repair Procedures 4 3 After repair perform Operational Tests in section 9 9 Locked out key function Review lockout menu in user manual TABLE 2 4 NO LED OR BAR DISPLAY OR PARTIAL DISPLAY SY
23. out 1 Press the GNT Menu button until MENU is displayed CAL will be displayed Press the Yes button to enter the CAL menu Repeatedly press the No button until the sub menu item CALTST is displayed Press the Yes button to select and initiate Calibration Test The display flashes O indicating that no weight should be placed on the platform at this time After ensuring that the scale platform is clear press the Yes button T is displayed while the zero point is measured The display flashes the calibration test mass If a different calibration test mass is desired enter the new value via the numeric keypad whole numbers only Place the corresponding test mass on the scale platform and press the Yes button T is momentarily displayed while the data is measured The display now indicates flashes the actual difference between the stored calibration data and the test mass data After approximately 5 seconds Calibration Test ends If enabled the result of the calibration test is printed The scale returns to the active weighing mode and displays the current weight on the platform 3 29 CHAPTER 3 INDICATOR TESTING 3 13 Geographical Adjustment Factor This menu item is used to allows entry of values from O to 31 and is used to compensate for variations in gravity at different geographical locations around the world Complete Geographical Adjustment Factors are listed in Table 3 5 This feat
24. replaced not repaired Fuses There are two internal fuses in the battery One of the fuses will reset after a temporary over heating or over current The reset is automatic afterthe assembly cools down The fuses are not servicable and a defective battery must be replaced as a complete assembly Battery Monitor Chip The battery assembly contains a monitor chip that monitors voltage and temperature The chip also contains a small amount of non volatile memory The number of charge cycles is stored in the non volatile memory An RS232 Service command can retrieve the chips data lt esc gt BD command In addition to the voltage and temperature the service command returns the number of charge cycles and the present charging status The center wire on the battery assembly is used to retreive the data from the monitor chip 3 4 2 Troubleshooting the Battery To troubleshoot the battery a DVM is required To check the memory of the battery a PC and an RS232 cable is required 1 Connect the Indicator to a suitable power source DO NOT TURN THE INDICATOR ON 2 Observe the bar display Figure 3 5 indicates the status of charging BATTERY CHARGING SYSTEM FAILURE GREEN Figure 3 5 Battery Charging Indications With the Indicator turned off and AC connected a flashing LED shows the battery charging status The first yellow LED shows the Pre charge yellow LED s 2 through 7 shows the Quick charge yellow LED 8 shows the Equa
25. section 3 8 2 6 CHAPTER 2 DIAGNOSIS TABLE 2 10 ERROR CODES Cont SYMPTOM PROBABLE CAUSE REMEDY Lo bAt Battery is discharged Connect Indicator to AC power and al low battery to charge Battery is defective Refer to section 3 4 and test the battery Replace if necessary See Repair Proce dure 4 8 CLr Pan Power on zero exceeds Clear platform of excess masses or 10 of original calibra tion zero recalibrate to establish a new zero point Refer to section 3 11 Note After several seconds NON LFT units will acceptthe new zero point LFT enabled units will change to Err 3 if condition is not corrected 2 7 CHAPTER 2 DIAGNOSIS 2 8 CHAPTER 3 INDICATOR TESTING 3 CKW 55 INDICATOR TESTING This section of the manual contains testing procedures of the individual replaceable assemblies of the CKW 55 Indicator Before and after servicing the CKW 55 Indicator an operational test and various performance tests should be made to ensure the Indicator meets all specifications 3 1 MEMBRANE SWITCH TESTING The Membrane Switch is part of the front panel controls When the Membrane Switch is disconnected from the Main PC Board a continuity test can be made to ascertain that all switches are functioning properly Using an Ohmmeter each switch can be tested in accordance with the Table 3 1 that lists the pin connections See Figure 3 1 for pin locations CAUTION REMOVE POWER FROM THE INDICATO
26. 1 Variance 2 Percent 96 xCU Set Under value as a Range Variance or Percent value depending on Checkweigh Input Mode setting xCO Set Over value as a Range Variance or Percent value depending on Checkweigh Input Mode setting xCT Set Target value used only in Variance and Percent Input Modes not used in range Mode XU Set weighing unit Where x 1 to 6 1 0 2 kg 3 Ib 4 02 5zlb ox 6 if x blank then increment to next available mode The unit can not be selected if it is not enabled PV Print model name software revision and LFT status if on eg CKW 55 Sr 1 0 LFT or CKW 55 Sr 1 1 Set a pre tare value of x in present weighing units Positive values only All commands sent to the Indicator must be terminated with a carriage return CR or carriage return line feed CRLP Up to 6 numeric characters an optional sign and single decimal point e g 1 000CU 2 3 2CU Use colon as a separator for Ib oz data entry Alternate characters can be assigned for Print Tare and Zero as described in the Instruction Manual 7 When the commands can be transmitted from the computer to the Indicator and from the Indicator to the computer the RS232 is functional Additional service commands are shown in Appendix A 3 17 CHAPTER 3 INDICATOR TESTING 3 7 3 RS422 485 Testing The RS422 485 Communication board can be wired to operate in a 4 wire duplex or 2 wire half
27. 19 2 Ib 9 8 kg 21 7 Ib 12 9 kg 28 5 lb 3 25 CHAPTER 3 INDICATOR TESTING 3 11 CALIBRATION USING AN EXTERNAL BASE After the indicator has been repaired calibration should be performed using a known good base It is not necessary to pass the cable through the liquid tight connectors for this procedure 1 Remove power from the Indicator 2 Referto section 4 1 and open the Front Housing 3 See Figure 3 12 and remove the switch cover Retain the screws and cover EXE GND OP 14 Figure 3 12 Main Printed Circuit Board 4 Refer to the manufacture s wiring code of the load cell cable and connect the wires to Terminal Strip J2 according to the proper signal names See Figure 3 12 Tighten all terminal screws securely 5 When connecting a 2 mv v load cell Jumper W1 is to be left in place shorting the two pins See Figures 3 12 and 3 13 6 When connecting a 3 mv v load cell Jumper W1 must be removed or left in place with one pin uncovered 7 When connecting a 4 wire load cell with no sense wires Jumpers W2 and W3 must be left in place shorting the two pins 8 When connecting a six wire load cell that includes sense wires Jumpers W2 and W3 must be removed or left in place with one pin uncovered 9 When connecting a load cell with an extra ground shield wire The shield wire may be connected to the center position of J2 3 26 CHAPTER 3
28. 3mV V output with a 5 00 Volt excitation voltage supplied by the CKW Indicator The Simulator selected should contain coarse and fine verniers with a step switch When using a simulator ensure jumper W1 is correct Refer to the Instruction Manual This test checks the Main PC Board circuitry by simulating load cell voltages at various scale capacities NOTE An 8 position simulator is used in this test 1 2 9 Disconnect power from the Indicator Open the Indicator housing refer to procedure 4 1 Disconnect the Load Cell cable from connector J2 on the Main PC Board Refer to Figure 3 3 for connector location Connect the Simulator to connector J2 See Figure 3 2 for terminal identification Connect the AC line cord to a power source Turn on the Indicator CLr Pan or Err 3 may be displayed This is OK Enter the menu on the Indicator and set the desired capacity units kg g etc Enter the span Calibration menu and calibrate using the simulator position 2 for zero setting and position 7 for full scale As an example an Indicator set up for a 6kg base would display Simulator Position Reading l Underload Error 2 2 Okg 9e 1 2kg 4 2 4kg 9e 3 6kg 6 4 8kg Te 6kg 8 Overload Error 1 Using the simulator adjust to simulate loads of 0 load 5096 load and 100 amp load for the capacity that the Indicator is setto If the readings are unstable the Main PC Board is defective and must be replaced
29. A please visit our site www ohaus com to locate the nearest Ohaus office Ohaus Corporation 19A Chapin Road P O Box 2033 Pine Brook NJ 07058 USA Tel 973 377 9000 Fax 973 944 7177 5 CHAPTER 5 PARTS LISTS CKW 55 INDICATOR EXPLODED VIEW 5 1 1 Exploded View of CKW 55 Indicator Figure 5 5 2 CHAPTER 5 PARTS LISTS 5 2 CKW 55 INDICATOR PARTS LIST ITEMNO PART NO 00 oa A oN 10 18 18 18 18 71154791 71209058 71152473 71173386 71209081 71209083 71167965 71167967 71173377 71209076 71152475 71209069 71172942 71169978 71167964 71169473 71209068 71209064 71209067 71209084 71209078 71209061 71154804 80251031 80251032 80251033 80251034 80251035 80251039 80251037 80251038 80251040 71172176 71172177 71172930 71209118 71209075 TABLE 5 1 CKW 55 INDICATOR PARTS LIST DESCRIPTION Switch Membrane CKW Hardware Kit Housing Screws PCB Main CKW Fuse Radial 2 5 250 TR5 UL DE CKW Relay AC CKW Relay DC CKW RS485 Kit DC CKW Accessory Relay Kit AC CKW Accessory Relay Kit DC CKW Accessory Fuse Recharger PCB CKW PCB Battery Charger CKW Cable Mounts Internal CKW Replacement Battery Rechargeable Accessory CKW PCB Power Supply CKW Wall Bracket Accessory CKW Knob Locking Wall bracket CKW CKW 1 0 Filler Plugs CKW 1 0 Fitting P7 CKW 7mm ID Fitting P9 CKW 9mm ID Cable Power Suppl
30. ABLE CAUSE REMEDY Incorrect Menu settings improperly set Refer to instruction manual and check the menu settings Perform Opera tional Tests in section 3 9 Loose or improper wiring Check wiring on connector J2 Unstable Improper calibration Recalibrate properly See section 3 11 Check base used with the Examine the base and check settings indicator on the indicator or test using load cell simulator Main PC Board defective The Main PC Board should be tested in accordance with section 3 2 The Main PC Board if defective should be re placed See Repair Procedures 4 3 After repair perform Operational Tests in section 3 9 TABLE 2 9 UNABLE TO MAINTAIN TIME AND DATE FUNCTIONS SYMPTOM PROBABLE CAUSE REMEDY Fails to maintain set time and date Real Time Clock RTC bat tery depleted Main PC Board defective Replace the Real Time Clock battery Refer to section 4 9 After repair reset the time and date in accordance with users local area If time and date cannot be set with a new battery pro ceed The Main PC Board should be tested in accordance with section 3 2 The Main PC Board if defective should be re placed See Repair Procedures 4 3 After repair perform Operational Tests in section 3 9 2 5 CHAPTER 2 DIAGNOSIS 2 4 ERROR CODE TABLE The CKW 55 Indicator is equipped with software which will display an error code under certain conditions Review the listed codes and follow instruct
31. MPTOM PROBABLE CAUSE REMEDY Display is not on or partial Main PC Board is defective The Main PC Board is replaced as a characters are displayed or LED may be defective whole assembly Check procedures in Table 2 1 first and verify that other prob lems do not exist Then referto section 3 2 and test the Main PC Board Replace Main PC Board See Repair Procedures 4 3 After repair perform Operational Tests in section 3 9 2 3 CHAPTER 2 DIAGNOSIS TABLE 2 5 RS232 COMMUNICATIONS FAILURE SYMPTOM PROBABLE CAUSE REMEDY Cannot communicate using RS232 Menu settings improperly set Main PC board defective Refer to the Instruction Manual and check the menu settings Test the RS232 communications see section 3 1 2 If communications cannot be estab lished the Main PC Board should be tested in accordance with section 3 2 The Main PC Board if defective should be replaced See Repair Procedures 4 3 Mfter repair perform Operational Tests in section 3 9 TABLE 2 6 RS422 485 COMMUNICATIONS FAILURE OPTIONAL BOARD SYMPTOM PROBABLE CAUSE REMEDY Cannot communicate using optional RS422 485 board NOTE The RS232 must be op erational orthe RS422 485 will not function Menu settings improperly set Loose wiring connections RS422 485 PC board defec tive Main PC board defective Refer to the Instruction Manual and check the menu se
32. R BEFORE TESTING With the Ohmmeter connected pressing a selected function switch should indicate less than 100 Ohms If the reading is higher than 100 Ohms the switch is defective and the membrane switches should be replaced NOTE Depending upon pressure placed on the individual switch the resistance reading can vary anywhere from approximately 15 to 70 Ohms This is normal Check each switch on the panel The open circuit resistance for each switch should be greater than 5 Megohms A switch that reads less than 5 Megohms for an open circuit or does not read 100 ohms or less when pressed is defective and the Membrane Switch panel requires replacement The Membrane switch can be tested after opening the Front Housing from the Rear Housing 1 Referto section 4 1 and open the Front Housing 2 Disconnect the membrane switch connector from the Main PC Board connector J1 3 Referto Table 3 1 Using an Ohmmeter measure the resistance across the pins indicated in the table If readings are not in range the membrane switch is defective Replace the Membrane Switch panel Refer to section 4 2 4 Check that the Membrane Switch is not shorted to the Front Housing case Check all pins to the case which should be open continuity if less than 5 Megohms replace the Membrane Switch Refer to section 4 2 5 Connect the Membrane connector to Main PC Board 6 Replace Front Housing to Rear Housing refer to section 4 1 3 CHAPTER 3 INDICATO
33. R TESTING PINS MEMBRANE SWITCH CONNECTOR Figure 3 1 Scale Membrane Switch Wiring Diagram TABLE 3 1 MEMBRANE SWITCH CONTINUITY TEST FUNCTION SWITCH MEASURE ACROSS PINS LIBRARY 2811 NEXT 2810 TARGET 3810 ON ZERO 8 amp 9 PRINT 4 amp 1 G N T 4 amp 10 TARE 3 amp 11 1 5 amp 10 2 5 amp ll 3 5 amp 12 4 6 amp 10 5 6 amp 11 6 6 amp 12 7 7 amp 10 8 7 amp 11 9 7 amp 12 0 1810 Decimal Point 1 amp 11 C 1 amp 12 CHAPTER 3 INDICATOR TESTING 3 2 MAIN PC BOARD TESTING The Main PC Board can be tested by measuring voltages on various components If defective components are found the entire PCB should be replaced The following tests are made when it is suspected that the Main PC Board is defective 3 2 1 Voltage Measurements Disconnect the Battery connector from the Recharge Board if installed NOTE When the power cord is connected to the indicator the Main PC Board has power applied to it even when the display is off When the On Zero Off switch is turned On the Indicator display will go through a turn on sequence and the LED displays will light If the Indicator fails to display after turn on continue with this procedure to identify the problem The following components operate as follows A Pressing the ON button activates Transistor Q1 and provides turn on of 12 V dc power to rest of circuit IC 013 regulator provides 5 V
34. TE All voltage measurements are made with respect to case ground AC POWER MEMBRANE SWITCHES MAIN PC BOARD RE CHARGE BATTERY POWER SUPPLY DAIA 1v i Jel all a se es TO EXTERNAL RS232 TO LOAD CELL RELAY OUTPUTS Figure 3 2 Interconnection Diagram 3 4 CHAPTER 3 INDICATOR TESTING 3 2 1 Voltage Measurements Cont co Figure 3 3 Component Layout Diagram Measure the voltage at transistor Q1 pin 2 location B it should be 12 V dc 0 24 V dc If this voltage is not present the Main PB Board must be replaced Refer to section 4 3 and replace the Main PC Board Measure voltage at regulator IC 013 pin 3 location C it should be 5 V dc 0 25V dc This is a supply voltage for the board If this voltage i
35. Test Equipment 99 Washington Street Depot Melrose MA 02176 Phone 781 665 1400 1 800 517 8431 Toll Free 1 800 517 8431 rc mesaaassenr OHAUS CKW 55 INDICATOR SERVICE MANUAL OHAUS CKW 55 Indicator SERVICE MANUAL CKW 55 Indicator The information contained in this manual is believed to be accurate at the time of publication but Ohaus Corporation assumes no liability arising from the use or misuse of this material Reproduction of this material is strictly prohibited Material in this manual is subject to change O Copyright 2006 Ohaus Corporation all rights reserved O Registered trademark of Ohaus Corporation TABLE OF CONTENTS CHAPTER 1 INTRODUCTION Page 1 1 1 Dal BCS TT 1 1 12 Tools and di 1 2 1 2 4 Standard Tools and Test aite peo dade dex s e edis 1 2 Loc Noo PE 1 2 1 3 Calibration Masses Bequiletl ed de Reda 1 2 1 carecer 1 3 1 5 and Environmental Protection enia iat 1 3 CHAPTER 2 DIAGNOSIS 2 2 1 A TET 2 1 2 1 2 39 Troubleshooting Bolo s 2 1 24 Erorcode 0 2 6 CHAPTER 3 CKW 55 INDICATOR TESTING 3 3 Membrane engins
36. al BASA 3 26 3 12 Calibration 3 28 3 12 1 Span Anno MP A 3 27 3 12 2 CONMONOD ini 3 28 A o 3 29 3 Geographical Adjustment 1 3 30 4 Calibration Verification using Load Cell 5 3 32 3 14 1 Calibration Test USING a MUI asii ari cs 3 33 CHAPTER 4 REPAIR PROCEDURES 4 od AAA E openen 4 1 4 1 Opening the Indicator 5 iso 4 4 2 Replacing the Membrane 5 4 4 3 Replacing the Main 4 2 Z Replacing the TOWEL ia 4 2 4 5 Replacing the Optional Recharge Ee tetas 4 3 4 6 Replacing the Optional Relay BOJA accord 4 3 4 6 1 Relay Board Replacement Procedure 4 3 05 2 Relay RODIOOOIDBDIE ssd sesenengan 4 4 4 7 Replacing the Optional RS422 485 Communication Board 4 4 4 8 Replacing the Optional Rechargeable Battery 4 5 4 9 Replacing the Real Time Clock RTC Battery 4 6 CHAPTER 5 PARTS LISTS 5 PATIS HISIS D M 5 1 CKW 55 Indicator Exploded 5 2 5 2 CKW 55 Indicator POMS eae eiia 5 3 5 3 ORW 55 Column Exploded VIEW ooo 5 4
37. alibration value and unit based on the Full Scale Capacity and Calibration Unit setting from the Setup Menu flashes on the display 3 28 CHAPTER 3 INDICATOR TESTING 3 12 2 Linearity Calibration Cont 5 If a different mid point Linearity Calibration value is desired enter the new value via the numeric keypad NOTE The mid range mass should be used for precise calibration If the correct mass is not available 25 to 7596 full scale Capacity mass can be used 6 Place the corresponding mass on the scale platform then press the Yes button C is momentarily displayed while the reading is stored After a few seconds the requested Full Scale calibration value and unit flashes on the display This is a fixed value based on the full scale capacity and cannot be changed Place the corresponding mass on the scale platform then press the Yes button C is momentarily displayed while the reading is stored If calibration was successful the calibration weight is displayed and the scale exits automatically to the active weighing mode Remove the weight and begin weighing operations 3 12 3 Calibration Test Calibration Test is used to compare a known calibration mass against the calibration data stored by the Indicator When any selection within the Read GMP menu is enabled calibration test results are automatically printed NOTE The Calibration Test function is available even when the CAL menu is locked
38. city is 1 kilogram or 1 pound to 100 full scale are accepted whole numbers only Note that values closerto the full span capacity will usually yield the most accurate calibration 8 Placethe corresponding mass on the platform then press the Yes button C is momentarily displayed while the reading is stored 9 If calibration was successful the calibration weight is displayed and the scale exits automatically to the active weighing mode Remove the weight and begin weighing operations 3 12 2 Linearity Calibration Linearity Calibration uses three points zero mid range and full scale The mid range value can be optionally changed by the user Mid range values closest to 1 2 full scale capacity are recommended to give the best performance over the entire weighing range Before calibrating the scale check that the weighing base is correctly leveled 1 Press and hold the G N T Menu button until MENU is displayed When the G N T Menu button is released CAL is displayed 2 With CAL displayed press the Yes button SPAN is displayed Press the No button to skip and proceed to the next sub menu item LIN 3 Press the Yes button to select and perform Linearity Calibration The display flashes O indicating that nothing should be placed on the platform at this time 4 After ensuring that the scale platform is clear press the Yes button C is displayed while the zero point is established After a few seconds the requested mid point c
39. command sets the scale into the Monitor mode The Monitor mode is exited when the scale is turned off with the ON ZERO Off button or a power off on cycle or a command is received which resets the scale The Monitor mode is exited regardless of the state of battery power Table A 1 lists the available service commands TABLE A 1 SERVICE MODE COMMANDS lt esc gt SV Enters the Monitor Mode lt esc gt RS Reset the scale similar to power off and on and exits the Monitor Mode lt esc gt EPX Indicator is set to 10 times expanded display mode X 1 ON X 0 OFF lt esc gt DF Resets all scale set ups to default values for a CKW55 lt esc gt BD Battery voltage temperature and charge state are printed x xxV zzzCC w where 777 the recorded number of full charge cycles w the present charge state O to 4 O off 1 precharge 2 fast 3 trickle 4 maintenance esc Indicates sending the ASCI code for the ESC key 27 The Service Commands marked with a will not be operational if the LFT menu selection has been set to On or if the LFT LOCK switch has been set to position NOTE All commands sent to the Indicator must be terminated with a carriage return CR or carriage return line feed CRLF APPENDIX A SERVICE MODE Table 2 lists the ASCII to Character conversions used to enter library data TABLE A 2 ASCII NUMBER TO CHARACTER CONVERSION ASCII Character ASCII Character ASCII Character
40. dc to the board IC 014 regulator provides the 5 V excitation for the external Load Cell IC U22 regulator provides 3 6 V to circuitry that controls the LED s and Bar Graph LED s real time clock battery RTC provides power to retain time and library information When depleted clock functions cannot be set or retained Error 10 may be indicated OQ 1 Disconnect power from the Indicator 2 Open the Front Housing refer to procedure 4 1 WARNING HAZARDOUS VOLTAGES ARE PRESENT WITH THE INDICATOR HOUSING OPENED AND AC POWER IS APPLIED USE CARE WHEN MAKING ALL MEASUREMENTS 3 Connect the power cord to a suitable power source and turn on the Indicator Observe the displays and note if problems are visible or if the displays fail to light 4 Referto Figure 3 2 Interconnection Diagram that illustrates the interconnections to the Main PC Board and is shown as a top view CHAPTER 3 INDICATOR TESTING 3 2 1 Voltage Measurements Cont 5 Using a DVM measure the power supply voltage across pins 1 and of J5 location A in Figure 3 3 it should be 12 volts dc 0 24V dc This is the power source for the Main PC board and is regulated If the voltage is low or is not present refer to section and test the Power Supply Board Ifthe Power Supply board is defective referto section 4 4 and replace the board and continue with this procedure If the board is OK continue with this procedure NO
41. e Relay board in place and remove the Relay board Replace the Relay board and install the four screws previously removed Reconnect wiring to the Relay board and replace terminal cover Reassemble the Indicator housing Refer to section 3 9 and perform Operational Tests 4 6 2 Relay Replacement To replace a relay proceed as follows 1 2 3 4 Perform procedure 4 6 1 steps 1 through 4 On the solder side of the Relay board unsolder the defective relay Install the new relay into position on the board and solder all connections Position the relay board into position and perform steps 5 through 8 of procedure 4 6 1 4 7 REPLACING THE OPTIONAL RS422 485 COMMUNICATION BOARD The RS422 485 Communication board is supplied as an optional kit NOTE Read this procedure through first before proceeding Ls 2 Remove AC power from the Indicator Refer to section 4 1 and open the Front Housing With the Housing opened remove connectors and wiring from the RS422 485 Communica tion board Remove the four screws holding the RS422 485 board in place and remove the board Note the position of the jumpers on the board You will want to return the Indicator set up for the proper mode when returned Also note if the RS422 485 board is set up for 4 wire duplex or 2 wire Half duplex operation on the interface connector Replace the RS422 485 board and install the four screws previously removed Replace wires in th
42. e base used The masses required to test the CKW 55 Indicator when connected to an Ohaus CKW base must meet the requirements of ASTM Class 4 or OIML F2 The mass values are listed in Table 1 1 TABLE 1 1 CALIBRATION MASSES MODEL Span Cal Linearity Cal Cal in kg Masses Totaling Masses Totaling CKW3R55 3kg 1kg amp 3kg CKW6R55 6kg 3kg amp 6kg CKW15L55 15kg 7kg amp 15kg CKW30L55 30kg 15kg amp 30kg NOTE During span calibration a new span value may be entered The span allowable range is 1kg or 15 to 100 full scale During linearity calibration a new midpoint value may be entered the allowable range is 2596 to 75 full scale capacity whole numbers only Values closest to 1 2 span capacity will result in more accurate linearity CHAPTER 1 INTRODUCTION 1 4 SERVICE STRATEGY The repair method for the CKW 55 Indicator is the direct replacement of major assemblies The CKW 55 Indicator contains the following replaceable assemblies Cover Assembly with Membrane Switch Main PC Board with LED and Bar Displays and Power Supply PCB Optional assemblies consist of NiMH Rechargeable Battery Battery Recharge PCB RS422 485 Communication PCB and an AC or DC Relay Board This service manual contains sufficient information to isolate the problem replace the assembly test and restore the Indicator to original factory specifications 1 5 SAFETY AND ENVIRONMENTAL PROTECTION When carrying out service or repair work always observe the follo
43. e same position as removed on the interface connector and replace jumpers W1 and W2 as previously installed Reconnect connectors to the RS422 485 board Reassemble the Indicator housing Refer to section 3 9 and perform Operational Tests 4 4 CHAPTER 4 REPAIR PROCEDURES 4 8 REPLACING THE OPTIONAL RECHARGEABLE BATTERY The rechargeable battery is supplied as part of an optional kit complete with a recharge board Ifthe battery requires replacement it can be replaced separately the recharge board does not have to be replaced with it unless defective NOTE Read this procedure through first before proceeding 15 2 Remove AC power from the Indicator Refer to section 4 1 and open the Front Housing With the Housing opened remove the 3 pin battery connector from the Recharge board Remove the two screws on each battery bracket and remove old battery Position the new battery with the wire leads to the left and facing forward Important make sure there is a foam cushion at each end of the battery See Figure 5 1 While holding the battery in place mount the center bracket using the supplied screws The mounting screws must remain loose at this step NOTE The center bracket is the part without the extra side tab 7 Install the bracket at the left side of the battery Before tightening the mounting screws slide the left bracket and battery fully to the right When the foam pad is slightly compressed tighten the
44. elays an Ohmmeter providing a minimum of 5 Volts DC can be used to verify operation When testing ac type Relays a small circuit consisting of a low voltage 24 V AC isolation transformer and small lamp 24 Volts are required 1 Remove each fuse and check for continuity Replace defective fuses See parts list at the rear of this manual If a fuse is defective there is also a possibility that the associated relay may also be defective due to over currents Apply power to the indicator Refer to the instruction manual and set the Indicator up to provide a test of each relay Fordcrelay types use an Ohmmeter providing a minimum of 5 Volts DC and check each relay operation for open and closed contact operation If a relay is defective refer to section 4 6 and replace the Relay or the complete board For ac type relays fabricate a small test circuit consisting of a small isolation transformer of 24 volts and atest lamp Wire in series with each relay output Check each relay for operation If a relay or relays are found to be defective refer to section 4 6 and replace the Relay or the complete board When testing is completed remove power from the Indicator and replace the relay cover previously removed Reassemble the Indicator 3 15 CHAPTER 3 INDICATOR TESTING 3 7 RS232 RS422 485 COMMUNICATION TESTING The CKW 55 Indicator is equipped with RS232 communication as standard The RS232 interface is part of the Main PC
45. he recharge board CAUTION DO NOT CONNECT THE A BATTERY TO THE RECHARGE BOARD DURING CONTINUITY TEST CHAPTER 3 INDICATOR TESTING 3 5 2 Recharge Board Testing Cont 9 Using an Ohmmeter check the fuse F1 refer to Figure 3 6 on the Recharge board to see if itis open If the fuse is open remove the Recharge board and replace the fuse Re install the recharge board in the housing 10 Connect the original battery to the Recharge board and repeat steps 1 through If the battery indicates charging allow it to charge for several hours If the battery is good and does not recharge after the fuse has been replaced replace the Recharge board see section 4 5 11 After the Recharge board has been replaced allow the battery to charge several hours WARNING HAZARDOUS VOLTAGES ARE PRESENT WITH THE INDICATOR HOUSING OPENED AND AC POWER IS APPLIED USE CARE WHEN MAKING ALL MEASUREMENTS 3 5 3 Voltage Measurements NOTE When the power cord is connected to the indicator the Power Supply Board has AC power applied to it at all times 1 Disconnect power from the Indicator Remove the line cord plug from the power source 2 OpentheFront Housing referto procedure 4 1 Locate the Recharge Board as shown in Figure 3 6 3 Reconnect power to the Indicator 4 Measure the dc voltage at connector J2 on the recharge board pins 1 and 3 Pin 1 is pin 3 is ground The voltage should be 12 Volts dc 0 24 V dc b If 12 Volts dc is not presen
46. ions to correct the problem TABLE 2 10 ERROR CODES SYMPTOM PROBABLE CAUSE REMEDY Err 1 Err 2 Err 3 LFT mode only Err 7 Err 10 Err 14 Err 21 Overload condition the load on the Platform exceeds the rated capacity of the base used with the Indicator Underload condition Poweron zero exceeds 1 090 of original calibration zero EEPROM data incorrect on Main PC board Library or Real Time Clock RTC data incorrect Zero value exceeds the zero setting value Calibration incorrect Remove excess load Turn Indicator off then on Perform calibration Refer to section 3 11 when using a base or section 3 14 when using a simulator Replace platform ifremoved cycle power offthen on see section 3 1 1 or3 14 and calibrate the Indicator Clear platform of excess mass or recalibrateto establish a new zero point Go through all menus and re establish all settings or go to each menu and reset to default settings Check operation of Indicator see section 3 9 If this fails the Main PC board is defective Refer to section 4 3 and replace the Main PC board Check operation of Indicator see section 3 9 Replace RTC Lithium back up battery Refer to section 4 9 and replace the battery Remove excess load from the base or platform Select a higher Zero Range value Non LFT only inthe Setup menu Perform calibration using proper masses Perform Operational Tests see
47. le AC power source Turn the Indicator on Refer to Section 3 9 1 and observe and record power on information codes and software revision Record all menu settings if possible as received See section 3 9 4 On indicators equipped with an optional battery allow the battery to charge up completely at least 4 hours with the indicator turned off The front panel bar LED s will indicate a full charge when the first green segment begins to blink If the battery fails to charge Lo Bat may display when the Indicator is turned on If a battery problem exists refer to section 3 7 for corrective actions and testing NOTE This manual covers only Indicator problems Some testing requires the Indicator to be connected to a known good base For base problems refer to the Base Service Manual If the Indicator is not supplied with a base testing will be done using a known good base and or Loadcell Simulator 2 3 TROUBLESHOOTING TABLES Troubleshooting tables 2 1 through 2 10 identify problems that could be encountered with the Indicator The troubleshooting tables refer to interconnection and wiring diagrams in this section to assist in locating the problem 2 1 INDICATOR WILL NOT TURN ON WITH AC POWER SYMPTOM PROBABLE CAUSE REMEDY Indicator will not turn on with Power cord defective Check the power cord for cuts or abra AC Power supply connected sions If OK proceed Refer to section 4 1 and open the indi cator CAUTION Hazardou
48. lip is in place under one of the screw heads Reconnect all connectors to the Main PC board and the Membrane Switch connector Connect a known good base or simulator 10 Refer to section 3 9 and perform Operational Tests and recalibrate the Indicator see section 3 12 Make sure all specifications are met 11 Replace switch cover using original screws 4 4 REPLACING THE POWER SUPPLY NOTE Read this procedure through first before proceeding ls 2 Remove AC power from the Indicator Refer to section 4 1 and open the Front Housing With the Housing opened disconnect connector CN2 from the Power board this is the 12 V dc output cable Red and Black wires Disconnect connector CN1 from the Power board this is the AC power input line Remove the four screws holding the Power board in place and remove the Power board One screw contains a grounding clip CHAPTER 4 REPAIR PROCEDURES 4 4 REPLACING THE POWER SUPPLY Cont 6 Replace the Power board and install the four screws previously removed Make sure the grounding clip is in place under the screw head shown in figure 3 11 7 Reconnect connectors CN1 and CN2 to the Power board 8 Reassemble the Indicator housing 9 Refer to section 3 9 and perform Operational Tests 4 5 REPLACING THE OPTIONAL RECHARGE BOARD The Recharge board is supplied as an optional kitthat includes a rechargeable battery The Recharge board can be ordered separately and replaced using
49. lizing charge the first green LED shows the Maintenance charge The battery is considered fully charged when the maintenance charge starts A red LED indicates the detection of a battery system failure 3 8 CHAPTER 3 INDICATOR TESTING 3 4 2 Troubleshooting the Battery Cont 3 Note the charging status of the battery If the red bar graph is lit either the battery and or the charging PCB has failed Note To force a charge cycle see section 3 5 1 4 Press the C button momentarily the Indicator will display the actual battery voltage Approximately 6 1 Volts dc or lower indicates a discharged battery 7 2 Volts is the nominal battery voltage and approximately 8 5 Volts dc is the maximum charge voltage Before replacing the battery force a charge cycle and allow the Indicator to remain plugged in for several hours and check the battery voltage by pressing the C button If the bar graph indicator for battery status fails to light or advance refer to testing of the Recharge Board see section 3 5 After recharging the battery remove AC power from the Indicator and operate the Indicator using battery power to determine if the battery retained a full charge A new battery should function for at least 10 hours When the battery operates the Indicator for less than 5 hours it should be replaced See section 4 8 for battery replacement procedures Note The power save function should be turned off to allow testing battery life
50. mounting screws Tighten the mounting screws of the center bracket After tightening all mounting screws check that the battery is held tightly in place Readjust the brackets if needed 10 Connect the cable from the battery to the Recharge board 11 Reassemble the Indicator housing 12 Refer to section 3 9 and perform Operational Tests Allow the replacement battery to reach full charge before testing the Indicator under battery operation Refer to the CKW Battery Option Kit manual P N 80251037 for a full description of battery charging and battery operation 4 5 CHAPTER 4 REPAIR PROCEDURES 4 9 REPLACING THE REAL TIME CLOCK RTC BATTERY The Real Time Clock battery is mounted on the Main PC board When the time and date cannot be set or loses the setting after AC power is removed the battery must be replaced NOTE Read this procedure through first before proceeding 1 Remove AC power from the Indicator 2 Refer to section 4 1 and open the Front Housing 3 With the Housing opened locate the RTC Battery on the Main PC board 4 The Real Time Clock RTC battery is a 3V lithium coin cell The recommended battery type is CR2032 Refer to figure 4 1 Remove the old battery as shown by pressing down on the Retaining Clip and sliding the battery up and out of the holder CAUTION RISK OF EXPLOSION IF BATTERY IS REPLACED WITH WRONG TYPE OR CONNECTED IMPROPERLY DISPOSE OF BATTERY ACCORDING TO LOCAL LAWS AND REGULATIONS
51. on the scale The other point is the Span value that is often but not necessarily at full capacity The CKW 55 Indicator allows the user to select alternate Span calibration values Span values closest to the full scale capacity are recommended to give the best performance over the entire weighing range Other Span values may be specified due to limited availability of calibration masses or for improved accuracy at a lower weight range Before calibrating the scale check that the weighing base is correctly level 1 Press hold the G N T Menu button until MENU is displayed When the G N T Menu button is released CAL is displayed 2 With CAL displayed press the Yes button SPAN is displayed CHAPTER 3 INDICATOR TESTING 3 12 1 Span Calibration Cont 3 Press the Yes button to select and perform Span Calibration 4 The display flashes O indicating that nothing should be placed on the platform at this time b After ensuring that the scale platform is clear press the Yes button C is displayed while the zero point is established 6 After a few seconds the requested calibration value and unit based on the Full Scale Capacity and Calibration Unit setting from the Setup Menu flashes on the display A Span Calibration value based on a Full Scale Capacity and Calibration Unit setting is displayed 7 different Span Calibration value is desired enter the new value via the numeric keypad NOTE The allowable span range capa
52. onment The bench area should be clean and should contain an antistatic mat with a personnel grounding clip to protect internal circuit boards The ideal electrical power source for the indicator should be a dedicated line to avoid sudden fluctuations or voltage drops caused by external equipment drawing heavy current Theservice area for the indicator should be away from direct sunlight overhead heating or air conditioning ducts magnetic fields such as motors or large transformers or near vibrating sources such as machinery motors or vibrating equipment The power outlet should be grounded for safety Sufficient space should be provided around the indicator as not to be affected by other equipment This will ensure that the indicator is operated under ideal conditions CHAPTER 1 INTRODUCTION 1 2 TOOLS AND EQUIPMENT 1 2 1 Standard Tools and Test Equipment The service shop should contain the following equipment Digital Voltmeter DVM Megohmeter Standard Electronics tool kit Desk magnifier on a stand Grounding mat and clip Flat blades and holder D M Ae 1 2 2 Special Tools To service the CKW 55 Indicator the following equipment is recommended 1 A Load Cell Simulator 2 A computer 3 RS232 Cable Printer SF42 PN 80500574 4 RS232 Cable PC 25 pin PN 80500553 5 RS232 Cable PC 9 pin PN 80500552 1 3 CALIBRATION MASSES REQUIRED The calibration masses required is dependent on the capacity and readability ofth
53. pen the battery will not charge See Figure 3 7 for the location of the board and fuse 3 5 1 Recharge Board Information The Recharge PC Board is a multi mode charger and has 4 charging states 1 Pre charge 2 Quick charge fast charge 3 Equalizing charge top off charge and 4 Maintenance charge Service mode commands can be used to determine the charging state See Appendix 1 With the Indicator turned off and AC connected a flashing LED shows the battery charging status The first yellow LED shows the Pre charge yellow LED s 2 through 7 shows the Quick charge yellow LED 8 shows the Equalizing charge the first green LED shows the Maintenance charge The battery is considered fully charged when the maintenance charge starts A red LED indicates the detection of a battery system failure If the battery is new and has never been charged a one time extended time trickle charge is started this one time initial charge is shown by 2 yellow LED s Figure 3 6 illustrates the bar displays during various charging modes The batteries do not continually charge Even the maintenance charge will end after several hours The charge sequence is enabled only after the low bat warning is detected Since the overall battery life is partially dependent on the total number of charge cycles even partial charge cycles limiting the number of charge cycles ensures the longest operating battery life The charge cycle can be forced manually at any
54. per terminals and then screw it tightly 4 Connect power to the Indicator and turn on the indicator 5 Enter the I O Menu INPUT menu and set each function as listed in Table 3 3 one by one and test each by pressing the external switch Observe the Indicator input for proper functions If the indicator fails to respond to the input replace the Main PC board See section 4 3 for replacement 0 CHAPTER 3 INDICATOR TESTING 3 9 OPERATIONAL TESTING This section ofthe manual contains operational testing procedures of the CKW 55 Indicator After servicing the CKW 55 Indicator and replacing defective boards an operational test and various performance tests should be made to ensure the Indicator meets all specifications Before checking the Indicator refer to sections 3 11 or 3 12 and calibrate Use a known good Base or Load Cell Simulator connected to the Indicator 3 9 1 Indicator Display Segment Test Power On Sequence With the Indicator connected to an appropriate power supply press the ON ZERO Off button The Indicator performs a self test momentarily indicating the battery status if installed model and options informa tion and then goes into the active weighing mode At this point the Indicator is ready for initial setup and operation LULL Power On Using AC Power nau Bn nau With AC power connected all segments and annunciators will light simul 0 00 taneously at the previously selected setup brightness for
55. rvice technicians or Ohaus authorized service centers Knowledge of the operation of the CKW 55 Indicator is assumed Instruction manuals may be required with this service manual For complete information on operation refer to the CKW 55 Indicator and CKW Series Scale Instruction Manual This manual covers troubleshooting repair and testing of the CKW 55 Indicator The contents ofthis manual are contained in five chapters and an Appendix with service menu instructions Chapter 1 Introduction Contains information about service facilities tools test equipment test masses and service strategy Chapter 2 Diagnosis Contains information on problem verification indicator examination preliminary checks troubleshooting tables interconnection diagrams and wiring diagrams Chapter 3 CKW 55 Indicator Testing and Calibration Contains testing procedures performance tests specifications and calibration of the CKW 55 Indicator Chapter 4 Repair Procedures Contains detailed repair procedures for all major assemblies of the CKW 55 Indicator including the optional Relay Board RS422 485 Communication Board the Recharge Board and Battery Chapter 5 Parts Lists Contains an exploded view identifying all serviceable replacement assemblies with associated parts lists Appendix A CKW 55 Indicator Service Menu Contains RS232 commands for the CKW 55 Indicator in service mode 1 1 SERVICEFACILITIES The service area should be a stable envir
56. ry option installed Vu L0 RLY OP ion is i when relay output option is installed n n n 485 OP when RS422 485 option is installed Total time of power on sequence is from 5 to 8 sec depending on options installed After power on display sequence above the Indicator will enter the last active weighing mode sample shows O kg gross weight kg g oz B G Net Tare PT NOTE The weighing mode and decimal point position may be different depending on the last set up of the Indicator When Tare is not active Gross weight is displayed by default If Tare is active NET weight is displayed 3 9 2 Turning Off the Indicator To turn the Indicator off press and hold the ON ZERO Off button until the display shows OFF The OFF function will operate in all modes 3 9 3 Performance Testing Performance testing can only be done when the Indicator has been repaired connected up to a known good base and has been calibrated To start testing refer to the Instruction manual and go though all of the menus verifying that all functions work properly This will include LFT and lock out procedures Refer to Table 3 4 Specifications The Indicator must meet the outlined specifications 3 22 CHAPTER 3 INDICATOR TESTING 3 9 4 Checking Menu Libary Settings In some cases improper menu settings give the appearance of a failure Ifthe Main PC board is func
57. s above or below this limit the Main PC Board should be replaced Refer to section 4 3 and replace the Main PC Board Measure the voltage at IC U14 pin location D it should be 5 V dc 0 19 V dc This supplies the analog section and the excitation voltage for the external load cell If this voltage is above or below these limits the Main PC Board should be replaced Referto section 4 3 and replace the Main PC Board Measure the voltage at IC 022 pin 2 location E it should be 3 6 V dc 0 14 V dc This supplies the operating voltage forthe LED displays and bar graph display drivers Ifthis voltage is above or below these limits the Main PC Board should be replaced Referto section 4 3 and replace the Main PC Board 10 Measure the real time clock battery voltage at location F it should be between 3 6 V dc and 2 0 V dc If lower than 2 0 volts replace See section 4 9 When all voltages are correct the unit should be tested with a load cell simulator or a known good base After replacement a full operational check should be made in accordance with section 3 9 3 5 CHAPTER 3 INDICATOR TESTING 3 2 2 SimulatorTesting To perform these tests the use of a load cell Simulator is required The basic function of a Simulator is to simulate the output of a full bridge load cell allowing the CKW Indicator to be separated from the Base for the purposes of troubleshooting The CKW Indicator can use a load cell Simulator rated at 2 or
58. s of the C button 3 Observe the bar display and note if the battery is charging normally refer to figure 3 5 for displays If the bar indicator is blinking in one of the yellow segments the recharge board is working To confirm this momentarily press the C button at 1 or 2 minute intervals and note the battery voltage on the indicator display It should increase slightly with each button press As an example the first press indicated 8 62v the second press should increase slightly A good Recharge board will continue to charge the battery until the first green LED is lit If the battery fails to indicate an increase in voltage after pressing the C button several times or the yellow LED does not icrement after a few hours either the battery or the recharge board is defective 4 Disconnect power from the Indicator and refer to section 4 1 and open the Indicator Verify that power is applied to the Recharge board See section 3 5 3 before continuing 5 Remove the battery connector on J1 from the Recharge board do not remove the battery Refer to Figure 3 2 6 Temporarily connect a known good battery to the Recharge board 7 Repeatsteps 1 through 3 if the Indicator display does not show increasing charging voltages tothe battery with successive presses of the C button the Recharge board is not functioning properly continue with step 7 8 Remove power from the Indicator by disconnecting the power cord and disconnect the battery from t
59. s voltages are present use extreme care when making measure ments Check ac voltage at the Power Supply Board on connector CN1 Move ihe power cord and see If the ac line voltage remains constant on the con nector If not replace the power cord If OK proceed 2 1 CHAPTER 2 DIAGNOSIS 2 1 INDICATOR WILL NOT TURN ON WITH AC POWER Cont SYMPTOM PROBABLE CAUSE REMEDY Indicator will not turn on with AC Power supply connected Cont Power Supply defective Membrane Switch defective Main PC Board is defective Refer to section 3 3 and test the Power Supply Replace if necessary See Re pair Procedure 4 4 If Power supply is OK proceed Refer to section 3 1 and test the Mem brane Switch Replace if necessary See Repair Procedure 4 2 If Membrane Switch is OK proceed The Main PC Board should be tested in accordance with section 3 2 The Main PC Board if defective should be replaced See Repair Procedures 4 3 After repair perform Operational Tests in section 3 9 TABLE 2 2 INDICATOR WILL NOT TURN ON USING BATTERY POWER OPTIONAL SYMPTOM PROBABLE CAUSE REMEDY Indicator will not turn on using battery power Battery discharged or defec tive Wiring harness defective or battery connection broken Recharge Board defective Membrane Switch defective Refer to section 3 7 and test the battery Replace ifnecessary See Repair Proce
60. sary to test the communications 1 Disconnect power from the Indicator Remove the line cord plug from the power source 2 Open the Front Housing refer to procedure 4 1 3 Connect the interface cable to the computer and the other end of the cable to connector J4 RS232 connections on the Main PC board Observe that the proper connections are made 4 Close the Front Housing on the Indicator and connect to AC power 5 Turn on the Indicator and enter the COM menu and set the Baud Rate Parity Data Length Stop Bit Handshake and Type to RS232 then exit the menu 6 Onthe compuler set the correct COM port and all settings on the communication program to match the settings on the Indicator The Indicator should now communicate with the computer See Table 3 2 for Interface Commands All commands sent to the Indicator must be terminated with a carriage return CR or carriage return line feed CRLF 3 16 CHAPTER 3 INDICATOR TESTING 3 7 2 RS232Testing Cont TABLE 3 2 SERIAL INTERFACE COMMANDS TABLE Command Description Command Character PU Print current weighing unit kg g Ib oz Ib oz 9o Same as pressing PRINT button Same as pressing TARE button Z Same as pressing ZERO button xS Enable print stable data only Where x 0 for Off x 1 for On xP Auto print condition Where x 1 to 3600 second intervals x 0 for Off x C for Continuous 5 for On Stable xCM Checkweigh Input Mode where x 0 for Range
61. second Simultaneously the Beeper will sound at the previously selected setup volume for 1 2 sec Power On Using Only Battery Power With No AC power connected 7 Segment digits light for 1 second then the Bar Graph segments light for 1 second then the Arrow announciators light for 1 second When the 7 segment digits turn on the Beeper will sound at the previously selected setup volume for 1 2 second nui ua After segment check additional Model information is displayed in sequence LOCOS UL Z1 rr Model number of Indicator or scale unit 2212 _ nun Version of software Sr xxx ald nm LFT status LFT On is shown only if the LFT menu setting is turned and LIE rot the Lock Switch is also set to ON If LFT or switch is OFF no display skip to next display Lock Switch status LOC On is shown only if the Lock switch is On and LFT LLL Lot Menu setting is set to OFF If Lock Switch is Off no display skip to next display am Geo code setting GEO xx LOL LO n ru ON BAT if running on battery power none if running on AC skip to next display 3 21 CHAPTER 3 INDICATOR TESTING 3 9 1 Indicator Display Segment Test Power On Sequence Cont After power source information Options list is displayed for 0 5 sec each if installed If none installed proceed directly to active weighing mode BAT OP when batte
62. t at connector J2 refer to section Power Supply testing before continuing 3 12 CHAPTER 3 INDICATOR TESTING 3 6 RELAY BOARD TESTING The Relay Board is supplied as an optional kit for the CKW 55 Indicator 3 6 1 Relay Kit Information Two optional Relay Kits are available for CKW Series Indicators The AC Relay Kit is used for controlling up to three external AC circuits The solid state AC relays are rated at 3 Amperes at 24 240 Volts The DC Relay Kit is used for controlling up to three external DC circuits The solid state DC relays are rated at 3 Amperes 5 60V dc Each solid state relay output is equivalent to a single pole single throw switch SPST Each relay circuit is protected by a replaceable fuse rated at 2 5 amperes 250 Volts The I O menu in the Indicator allows the relays to be programmed for normally open or normally closed operation on off or on hold sequencing simultaneous break before make BBM or make before break MBB contact switching The relays are replaceable The fuses one for each solid state relay output are replaceable 3 6 2 Relay Testing There are several reasons why the relays can fail they are listed as follows Improper menu settings see instruction manual Fuses are open Improper application AC on DC relays or DC on AC relays Excessive external currents were switched External inductive circuits causing high transient spiked voltages when switching Voltages to be switched are
63. ternal input initiates a Print function Units The external input changes to the next available weighing unit GNT The external input simulates the function of the G N T button Accumulation The external input increments a weighment totalizing function Start Stop 5 5 The first external input signal enables the output relay operation Start The second external input signal disables the relay operation Stop Tare Start Stop T S S The first external input signal initiates Tare function The second external input signal enables the output relay operation Start The third external input signal disables the relay operation Stop Note Start Stop and Tare Start Stop are only available when the Relay Option is installed When selected pressing the NEXT button will have the same effect as if a switching signal was received from an external device The accumulate function is not available if either of these 1 0 selections are made To test external input functions proceed as follows 1 Disconnect power from the Indicator Remove the line cord plug from the power source 2 Open the Front Housing refer to procedure 4 1 Connecta cable containing atest switch normally open contacts to connector J7 on the Main PC board Note Do not attempt testing by momentarily touching the screw contacts on top of connector J7 the screw heads may not be in contact with the circuitry You must connect the switch to the pro
64. the original battery supplied NOTE Read this procedure through first before proceeding 1 Remove AC power from the Indicator 2 Referto section 4 1 and open the Front Housing 3 With the Housing opened disconnect connectors J1 and J2 from the Recharge board 4 Remove the four screws holding the Recharge board in place and remove the Recharge board 5 Replace the Recharge board and install the four screws previously removed 6 Reconnect connectors J1 and J2 to the Recharge board 7 Reassemble the Indicator housing 8 Refer to section 3 9 and perform Operational Tests 4 6 REPLACING THE OPTIONAL RELAY BOARD The Relay board is supplied as part of an optional kit either AC or DC The replacement procedure is the same for either board the basic difference is the relay type If a relay is found to be defective it can be replaced separately See parts list in section 5 of this manual for part numbers To replace the entire relay board see procedure 4 6 1 To replace only a relay or relays see procedure 4 6 2 NOTE Read this procedure through first before proceeding 4 6 1 Relay Board Replacement Procedure 1 Remove all power sources from the Indicator 2 Referto section 4 1 and open the Front Housing 3 With the Housing opened remove terminal cover and disconnect wiring from the Relay board 4 3 CHAPTER 4 REPAIR PROCEDURES 4 6 1 Relay Board Replacement Procedure Cont 4 5 6 7 8 Remove the four screws holding th
65. time as long as ac power is applied To manually start a charge cycle the user holds down the button while the indicator is off Continued use of this method will shorten the life of the battery and is not recommended A short press of the C button will display the actual battery voltage Due to the alternating duty cycle of charging the display voltage may vary slighty with each button press Pressing the C button several times will allow an average reading to be taken 3 10 CHAPTER 3 INDICATOR TESTING 3 5 1 Recharge Board Information Cont The battery voltage and temperature are monitored while charging An over voltage or temperature condition during the charge cycle will halt the charge sequence A normal battery charge is about 5 hours This time may increase as the batteries age The faster charge times are achieved when the scale is off and connected to the AC power Charging will continue with the Indicator on but at a slower rate The battery run time is nominally greater then 10 hours with medium display brightness settings A flashing red LED indicates a charging error This may be due to battery over voltage over temperature battery an extremely low battery voltage or a malfunctioning Recharge board 3 5 2 Recharge Board Testing Begin testing with a battery connected to the recharge board 1 Connect the Indicator to a suitable ac power source Do not turn on the Indicator 2 Force a charge by a long pres
66. tional this check can be made easily It is required that either a printer or computer be connected to the Indicator RS232 terminals This test allows every menu setting library contents to be displayed or printed when first receiving the Indicator for service and can be used as a final check of all menu settings WARNING HAZARDOUS VOLTAGES ARE PRESENT WITH THE INDICATOR HOUSING OPENED AND AC POWER IS APPLIED 1 Disconnect power from the Indicator Remove the line cord plug from the power source 2 Openthe Front Housing refer to procedure 4 1 3 Refer to section 3 7 and connect a computer or printer to J4 RS232 connections to the Indicator 4 Apply power fo the Indicator and turn the Indicator on Use an appropriate software program and test communications between the Indicator and PC b Enter the Print menu and select List Menu Yes The computer or printer will be sent every menu setting Shown on the next page is a typical print out or computer list of the menu settings CHAPTER 3 INDICATOR TESTING 3 9 4 Checking Menu Library Settings Cont Typical Computer or Printer Output of Menu Settings OHAUS CKW 55 Software Version Sr1 29 02 18 05 13 13 59 Calibration Menu Geo 19 Setup Menu LFT OFF Cal Unit kg Capacity 6 Grad 0 005 Zero Range 2 Retain Zero Data OFF Auto Tare OFF Beeper Volumn Low Beeper Key OFF Readout Menu Units On kg Ib g OZ Ib oz 96 Stable Range 1d AVG Level
67. ttings If OK pro ceed Refer to Figure 3 2 for proper cable connections Refer to section 3 7 and test the RS422 485 board If defective replace see section 4 7 After repair perform Op erational Tests in section 3 9 The Main PC Board should be tested in accordance with section 3 2 The Main PC Board if defective should be re placed See Repair Procedures 4 3 After repair perform Operational Tests in section 3 9 TABLE 2 7 RELAY OPERATION FAILURE OPTIONAL BOARD SYMPTOM PROBABLE CAUSE REMEDY Relay functions not working Menu settings improperly set Relay Board defective Refer to the Instruction Manual and check the menu settings Refer to section 3 6 and test the Relay board If OK proceed If defective replace see section 4 6 After repair perform Operational Tests in section 3 9 2 4 CHAPTER 2 DIAGNOSIS TABLE 2 7 RELAY OPERATION FAILURE OPTIONAL BOARD Cont SYMPTOM PROBABLE CAUSE REMEDY Relay functions not working Cont Main PC Board defective Loose or improper wire con nections The Main PC Board should be tested in accordance with section 3 2 The Main PC Board if defective should be re placed See Repair Procedures 4 3 After repair perform Operational Tests in section 3 9 Refer to Figure 3 2 for proper wiring TABLE 2 8 INDICATOR DISPLAY INCORRECT OR UNSTABLE SYMPTOM PROB
68. umeric with dedicated Tare and Target Entry Buttons Stainless Steel NEMA 4X IP66 5V DC 2 or 3 mVN Up to 4 x 350 ohm Load Cells Within 2 Seconds Off 5 1 or 3 Divisions 296 18 or 10096 of Capacity 1 kg or 1 Ib to 100 Capacity 230 x 75 x 217 mm 9 x 3 x 8 5 includes bracket 3 0 kg 6 61 Ib 10 C to 40 C 14 F to 104 F 100 240 VAC 50 60 Hz Universal Power Supply Hardwire Cord Optional Internal Rechargeable NiMH Battery 10 hour operation is typical Interface Built in RS232 and External Input Optional RS422 485 Relay Output SCALE MODEL CKW3R55 CKW6R55 CKW15L55 CKW30L55 Capacity x Enhanced 3 kg x 0 0005 kg 6 kg x 0 001 15 kg x 0 002 kg 30 kg x 0 005 kg Readability 3000 g x 0 5 9 6000 g x 19 15000gx2g 30000 gx 5g 6 Ib x 0 001 Ib 15 Ib x 0 002 lb 30 Ib x 0 005 Ib 60 Ib x 0 01 Ib 96 oz x 0 02 oz 240 oz x 0 05 oz 480 oz x 0 1 oz 960 oz x 0 2 oz 6 Ib x 0 02 oz 15 02 16 Ib x 0 05 oz Ib oz 30 Ib x 0 1 oz Ib oz 60 Ib x 0 2 oz Ib oz Maximum Resolution 1 6000 1 6000 1 7500 1 6000 Capacity x Approvable 3 x 0 001 kg 6 x 0 002 kg 15 x 0 005 kg 30 x 0 01 kg Readability 3000 x 1g 6000 x 2 y 15000 x 5g 30000 x 10g 6 x 0 002 Ib 15 x 0 005 Ib 30 x 0 01 Ib 60 x 0 02 Ib 96 oz x 0 05 oz 240 oz x 0 02 oz 480 oz x 0 2 oz 960 oz x 0 5 oz Approval Resolution 1 3000 1 3000 1 3000 1 3000 Column Tubular 304 Stainless Steel 11 8 300 mm Fixed Height with Indicator and Base Mounting Brackets Net Weight 8 7 kg
69. ure allows authorized personnel to accurately calibrate the scale at a location other than the location where the scale is to be used Prior to calibration the Geo factor is set to correspond to the geographical location where the calibration is being performed Following calibration the Geo factor is changed to match the location where the scale is to being used If required the scale may also be sealed according to the required approval regulations NOTE Only an authorized manufacturer s representative or certified verification personnel should make these changes Changing the Geo Factor alters the calibration values 1 With CAL displayed press the Yes button SPAN is displayed Press the No button repeatedly to skip to the sub menu item GEO Pressthe Yes button to select and access the Geo Factor menu The current Geo Factor setting flashes on the display If a different Geo Factor setting is desired enter the new value via the numeric keypad Press the Yes button to confirm the displayed value The END is displayed Press Exit to exit to the active weighing mode 3 30 CHAPTER 3 INDICATOR TESTING 3 13 Geographical Adjustment Factor TABLE 3 5 GEOGRAPHICAL ADJUSTMENT VALUES away from the equator 325 650 975 1300 1625 1950 2275 2600 2925 3250 3575 North or South in Elevation above sea level in feet 1060 2130 3200 4260 5330 6400 7460 8530 9600 10660 11730 5 4 4 3 3 2 2 1 1 0 0 00 5 46 5 46 9 52
70. wing e Before opening the Indicator isolate it from the AC power line pull out the plug e The Indicator contains sensitive electronic components that are sensitive to electrostatic discharge We recommend that you wear a grounding wrist strap when doing any work in the interior of the Indicator in order to prevent any electrostatic charge building up Grounding wrist straps are commercially available from electronic component suppliers Use only ground straps that include a protective series resistor in the assembly e Indicators have a built in memory backup battery and may contain an optional rechargeable battery These contain heavy metals which could be hazardous to the environment Batteries must not be disposed of as normal domestic refuse Please ensure that used non working batteries are disposed of correctly in accordance with the relevant local regulations e When this symbol is displayed important information regarding mainte nance instructions should be carefully read before proceeding CHAPTER 1 INTRODUCTION CHAPTER 2 DIAGNOSIS 2 DIAGNOSIS This section contains information needed to properly evaluate the reported problem and diagnose its cause 2 1 BASIC EXAMINATION Set up the Indicator according to the Instruction manual Allow the Indicator to stabilize to room temperature Examine the Indicator for signs of corrosion or physical damage 2 2 PRELIMINARY CHECKS Connect the Indicator s power cord to a suitab
71. y CKW Fuse Power Supply Kit of 2 CKW LFT Cover with hardware CKW Gasket CKW Manual Instruction English CKW Manual Instruction Spanish CKW Manual Instruction French CKW Manual Instruction German CKW Manual Instruction Italian CKW Manual Instruction RS422 485 Interface Kit 5 lang CKW Manual Instruction Rechargeable Battery Kit CKW Manual Instruction AC DC Relay Kit EN CKW Manual Instruction Base 5 lang Power Cord AUS CKW not shown w P11 Fitting Power Cord EU CKW not shown w P11 Fitting Power Cord UK CKW not shown w P11 Fitting Power Cord US CKW not shown w P11 Fitting Shorting Jumpers CKW not shown Note Proper power cord is supplied pre wired to the Indicator to destination country 5 3 CHAPTER 5 PARTS LISTS 5 3 CKW 55 COLUMN EXPLODED VIEW ITEM NO 1 PART NO 71167972 80251059 71128010 71170889 71176886 Figure 5 2 Exploded View of CKW Column TABLE 5 2 CKW 55 COLUMN PARTS LIST DESCRIPTION Column Mount Accessory SS CKW Tube 230mm Column Mount Accessory SS CKW Tube 6800 mm Cable Clamp CKW Foot with locking nut for column CKW Column Mount Bolt Kit Kit of 4 5 4 APPENDIX A SERVICE MODE A 1 SERVICE MODE This section of the manual contains service mode commands A 1 1 Service Mode Commands The Service Commands are only enabled after the scale receives a esc SV command through the RS 232 interface This

Service - Test Equipment Depot

Contents

Download Pdf Manuals

Related Search

Related Contents