CS5000 Users Manual

Page 1 of 31

CS5000 Users Manual

Intercomp Co.

3839 County Road 116

Medina MN 55340 U.S.A.

(763)-476-2531

1-800-328-3336

Fax: 763-476-2613 www.intercompcompany.com

Manual#: 700008-V

CS5000, Users Rev V, January, 2008

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Table of Contents

INTRODUCTION ............................................................................................................................................................ 3

SPECIFICATIONS .............................................................................................................................................................. 3 Controls..................................................................................................................................................................... 3 Electrical................................................................................................................................................................... 3 Performance.............................................................................................................................................................. 3 Environmental........................................................................................................................................................... 3 Physical..................................................................................................................................................................... 4 Radio......................................................................................................................................................................... 5

PARTS AND OPTIONAL EQUIPMENT................................................................................................................................. 5

OPERATIONS.................................................................................................................................................................. 7

DISPLAY (BASE) ............................................................................................................................................................. 7 Indicators .................................................................................................................................................................. 7

CONTROLS - HEAD (SCALE) ............................................................................................................................................ 7 ON............................................................................................................................................................................. 7

CONTROLS - BASE (CONTROLLER) .................................................................................................................................. 8 SETUP ........................................................................................................................................................................... 10

lb/kg Switching........................................................................................................................................................ 10 Setting time and date............................................................................................................................................... 10

POWER/BATTERIES ....................................................................................................................................................... 11

CALIBRATION.............................................................................................................................................................. 12

HOW TO TEST THE CALIBRATION ................................................................................................................................... 12 CALIBRATION SWITCH .................................................................................................................................................. 12 HOW TO CALIBRATE THE SCALE ................................................................................................................................... 13 LEGAL-FOR-TRADE SEALING ........................................................................................................................................ 16

ERROR MESSAGES ..................................................................................................................................................... 17

TROUBLESHOOTING................................................................................................................................................. 18

PARTS AND ACCESSORIES....................................................................................................................................... 20

PARTS LIST: 500 LB CAPACITY ..................................................................................................................................... 21 PARTS LIST: 2K LB CAPACITY ...................................................................................................................................... 23 PARTS LIST: 5K LB, 10K LB CAPACITY......................................................................................................................... 25 PARTS LIST: 20K LB, 30K LB CAPACITY....................................................................................................................... 27

SERIAL OUTPUT.......................................................................................................................................................... 28

EXAMPLE CONNECTIONS .............................................................................................................................................. 29

HOW TO REACH INTERCOMP SERVICE.............................................................................................................. 31

"This document is the property of Intercomp Co. It contains material and information that is confidential and protected under federal and/or state trade secret, unfair competition, and copyright law. Any reproduction, use or disclosure without written permission from Intercomp Co. is prohibited".


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Introduction This manual contains specifications, operation instructions, and calibration instructions for Intercomp's model CS5000 crane scale.

Specifications

Controls General: Head:

Base: On (Base remotely turns the scale head off). On/Off ,Zero, Print, Total, Display Total, Clear Total, Tare Set, Tare Display, Tare Clear.

Display: Base: 5 ½ digit LED.

Indicators: Head: Base:

power. lb/kg, Tare, Net, Gross, On-screen Motion, Total.

Electrical Batteries: (Base and Head)

8 X D-size disposable alkaline dry cells or rechargeable Nickel-Cadmium cells.

Battery life: Up to 50 hours with alkaline batteries. Approximately 20 hours on a set of fully charged Ni-Cad cells.

Resolution: 20 bit A/D delivers over 1,000,000 internal counts.

Filtering: 6 Pole, 10 Hertz low pass.

Auto off: Low battery, or after adjustable time without use or motion.

Auto-Zero: Satisfies all HB-44 requirements; selectable 0.6, 1, or 3 graduations.

Performance Accuracy: ±0.1% of applied load or ± display graduation, whichever

is greater.

Speed 2 readings / sec.

Transmitting Range Up to 500 ft / 150 meters

Environmental Humidity: 10 to 95% Non-Condensing

Temperature: Storage: -40 C to +75 C. / -40 F to +170 F.

Operating -10 C to +50 C. / +14 F to +122 F.


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Physical

Capacity Graduation A

B C D Hook Eye nut

or

shackle

Approx

Weight

500 lb 250 kg

0.2 lb 0.1 kg

in:

mm:

19.3 490

3.06 77.7

1.44 35.1

1.41 35.8

C/L 3 ton S1 swivel

C/L #7 eye nut

48 lb 22 kg

2,000 lb 1,000 kg

1 lb 0.5 kg

in:

mm:

19.3 490

3.06 77.7

1.44 35.1

1.41 35.8

C/L 3 ton S1 swivel

C/L #7 eye nut

50 lb 23 kg

5,000 lb 2,500 kg

1 lb 0.5 kg

in:

mm:

22.0 558

3.06 77.7

1.82 44.5

1.69 42.9

C/L 5 ton S1 swivel

C/L #7 eye nut

58 lb 26 kg

10,000 lb 5,000 kg

2 lb 1 kg

in:

mm:

22.0 558

3.06 7.77

1.75 44.5

1.69 42.9

C/L 5 ton S1 swivel

C/L #7 eye nut

58 lb 26 kg

20,000 lb 10,000 kg

5 lb 2 kg

in:

mm:

37.15 944

6.25 159

2.60 65.8

2.41 61.2

C/L 10 ton S1 swivel

C/L # 11 eye nut

97 lb 44 kg

30,000 lb 15,000 kg

10 lb 5 kg

in:

mm:

39.15 994

6.25 159

3.00 76.2

3.19 81.3

The dimensions below are top to bottom shackle, eye to eye on 25-50 ton / 12.5 –25 metric ton models C/L 15 ton

S1 swivel C/L # 11 eye nut

122 lb 55 kg

50,000 lb 25,000 kg

10 lb 5 kg

in:

mm:

43.5 1105

6.00 152

3.66 93.0

3.62 92.0

17.0 432


C/L 40 ton #2140

220 lb 100 kg

70,000 lb 35,000 kg

20 lb 10 kg

in:

mm:

48.6 1234

6.00 152

4.56 116

3.75 92.3

17.0 432


C/L 40 ton #2140

248 lb 113 kg

100,000 lb 50,00 kg

20 lb 10 kg

in:

mm:

56.0 1422

7.75 197

5.06 129

4.25 108

18.0 457


C/L 50 ton #2140

392 lb 178 kg

*

*

*

*


5

Radio Radio frequency (US/Canada)

2.4 GHz, FHSS, 50 mW output power

License requirements None. Pre-approved US/FCC, CAN/IC, EUR/EN

Range 200’ / 60m indoor, 300’ / 90m line of sight

Parts and Optional Equipment

Oversized top lifting eye (100744) This part is applicable to 500 lb - 10,000 lb capacity models.

Oversized top shackle (100745) This part is applicable to 20,000 lb and 30,000 lb capacity models.

Oversized top shackle (100746) This part is applicable to 50,000 lb and 70,000 lb capacity models.

Oversized top shackle (100747) This part is applicable to 100,000 lb capacity models.

Anti heat shield (100720)

Bottom plate with standard hook rated for 0° - 1000°.

Medium anti heat shield (100670)

1000° - 1500° protection. Includes oversized hook and custom swivel.

Extreme anti heat shield (100671)

1500° - 2500° protection. Includes oversized hook and custom swivel.

Remote load cell input and summing (100724) Load cell input with electronic summing board. An external load cell can be connected to the CS5000. The scale averages the signals from the 2 load cell outputs.

RS232 Serial data output (100721) The CS5000 has an RS232 connection so the unit may communicate with a printer or computer.

LED Display on crane unit (100725) Optional LED (light emitting diode) display on the head. An LED display is fully readable in pitch-dark lighting situations.

WARNING: To satisfy FCC RF exposure requirements for mobile

type transmitting devices, a separation distance of 20cm or more should be maintained between the antenna of this device and persons during operation, with the exception of hands, wrist, feet, and ankles. To ensure compliance, operations at closer distance than this is prohibited.

!


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LCD Display on crane unit (100726) Optional LCD (liquid crystal display) display on the head.

Anti-magnetic shielding (100722) Provides protection from high magnetic fields.

Battery pack and 120V external charger (100730) Rechargeable Ni-Cad battery pack (8 D-cells) with 120V external charger. Standard power uses 8 disposable alkaline dry cells.

Battery pack and 220V external charger (100731) Rechargeable Ni-Cad battery pack (8 D-cells) with 220V external charger. Standard power uses 8 disposable alkaline dry cells.

Battery pack, Ni-Cad (100733) D size rechargeable battery pack (qty: 8).

Direct Power on crane unit, 120V (100723) This option allows the CS5000 to use 120V power instead of batteries.

Direct Power on crane unit, 220V (100727) This option allows the CS5000 to use 220V power instead of batteries.


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Operations

Display (Base)

kg Optional: displays ‘1’ or blank Gross

Total Net

lb Tare

Indicators

kg: Indicates the scale is weighing in kilograms. When lit, the scale is in kg mode. Press TOTAL DISPLAY and TARE DISPLAY together to toggle units.

Total: Indicates that the current number displayed is the total. The net indicator

will also be lit to represent that the total totalizes the net weights.

lb: Indicates the scale is weighing in pounds. When lit, the scale is in lb mode. Press TOTAL DISPLAY and TARE DISPLAY together to toggle units.

Gross: This indicator is lit when the display represents that the gross weight is being displayed.

Net: This indicator is lit when a tare value is set and the weight shown is the calculated net weight.

Tare: This indicator is lit while the tare weight is being displayed.

Controls - Head (scale)

ON Press this button to turn the scale on.


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Controls - Base (controller)

ON/OFF Press this button to turn the base unit on. The scale tests itself, then displays

“--------------------“ or “HO-00HO-00HO-00HO-00”. When a weight is received from the scale head it will be displayed. Press this button again to turn the scale off. The head will turn off automatically.

PRINT Pressing this key will output an RS-232 signal containing the Gross, Net, Tare, total weight, and the time and date. Note: The print key will only function when there is no motion. Also see the ‘Serial Output' section in this manual.

ZERO Tells the scale to display a zero weight. This button is used any time the scale shows a non-zero value with no weight on the hook. If you press ZERO with weight on the hook, that weight becomes the zero condition for the scale. This can be useful to cancel the weight of any weighing fixtures, such as containers, chains or cables. When this weight is removed, a negative weight shows until the system is zeroed again.

NOTES: When ZERO is pressed, the CS5000 will display "--------------------" until a stable reading is taken. If there is continuous motion for more than 20 or 30 seconds, the zero command will be rejected and the scale will return to normal weighing. The scale contains a feature called Auto Zero Tracking (AZT), which corrects for slight zero changes during normal operation. If small weights are added slowly, the scale could zero them off.

TARE Use this button to read a tare weight into memory. This tare weight will be subtracted from a gross weight, giving you the net weight. This is useful for canceling the weight of a container used in weighing. A segment on the right side of the display shows that the net weight is being calculated.

NOTE: When TARE is pressed, the CS5000 will display "--------------------" until a stable reading is taken. If there is continuous motion for more than 20 or 30 seconds, the tare command will be rejected and the scale will return to normal weighing.


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TARE DISPLAY You may press the TARE DISPLAY button to display the tare weight. Pressing the TARE DISPLAY button a second time will return to the gross or net display.

TARE CLEAR This button is used to clear a stored tare weight to zero.

TOTAL By pressing this button, the current net weight is added to the total. Note: If the tare weight is zero, the net weight is equal to the gross weight.

TOTAL DISPLAY Pressing the TOTAL DISPLAY screen will switch the display to show the current total weight. Pressing the key a second time will return to normal weighing.

TOTAL CLEAR Clears the total to zero.


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Setup

Use the following procedure to setup and weigh:

1: Hook CS5000 scale head onto hoist. 2: Turn on CS5000 scale head. 3: Turn on CS5000 base. 4: Hook any weighing fixtures onto CS5000 hook (chains, etc.) 5: Hook any weighing bin or platform onto CS5000 hook or fixtures. 6: Hoist into air so that it is free swinging. 7: Press ZERO on base. The CS5000 will wait for a stable zero reading. 8: Proceed with weighing.

lb/kg Switching Press the TOTAL DISPLAY and TARE DISPLAY keys together to switch lb/kg. This toggles the weighing system between pound (English) and kilogram (SI metric) units of measure. The current unit of measure is shown by the left indicators of the CS5000 base (as shown in the section Display (Base) ).

Setting time and date To set the time and date press the three keys labeled TARE, TARE DISPLAY, and TARE CLEAR together and release. The scale will then ask you to enter seven numbers representing the month, day, year, hour, minute, second, and am/pm. You increase the number by pressing the TARE DISPLAY button. When the number is set, pressing the TARE button moves on to the next number. When you have completed entry of all seven numbers press the TARE CLEAR button to exit and start the clock running. The numbers are displayed in the following format Hx-yy, were x is the number being set and yy is the value. The following chart shows the seven values and their ranges.

Display Meaning Range

H1-yyH1-yyH1-yyH1-yy Month 1-12

H2-yyH2-yyH2-yyH2-yy Day 1-31

H3-yyH3-yyH3-yyH3-yy Year 0-99

H4-yyH4-yyH4-yyH4-yy Hour 1-12

H5-yyH5-yyH5-yyH5-yy Minutes 0-59

H6-yyH6-yyH6-yyH6-yy Seconds 0-59

H7-yyH7-yyH7-yyH7-yy am/pm 0-1 (0 = am, 1 = pm)

If the year is set prior to '91 it will be displayed as 20xx.


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Power/Batteries

Head: Remove the two caps in the back of the CS5000 head. Tip the old cells out.

Change the 8 ‘D’ cells, being careful to put the positive end in first (The end with the bump). Replace the battery caps.

Base: Loosen the 2 screws that latch the lid tight so the lid can be opened. Replace the 8

‘D’ cells, being careful to note the polarity indicated on the battery holders. Close lid and retighten the screws for the latches.

You may use rechargeable 8 Nickel-Cadmium 'D' cells or 8 standard alkaline 'D' cells in the CS3000.

Warning: If you have the optional charger, do not plug the charger in

while there are standard ‘D’ cells inside. This could result in damage

to the batteries and your scale.

The typical recharge time for Ni-cad cells is 16 hours. The rechargeable batteries have a life span up to 1000 cycles.


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Calibration

How to test the calibration This calibration procedure should be performed annually for normal operating conditions. If the scale is dropped or damaged, or service has been performed on the scale, use this calibration check. 1. Turn on the head and the base. The display does a lamp test; during this time the

scale does a quick check of itself. Then the weighing system starts weigh mode. 2. Intercomp recommends that you allow the electronics to operate for three minutes

after first turning power on. This allows the electronics to become stable for maximum accuracy before you check the calibrations.

3. Make sure no weight is on the hook. Press the ZERO button. Press the TARE CLEAR button to clear the tare. The weight shown is zero.

4. Apply weights throughout the weighing range, and verify the correct weight (+/- 0.1%) is displayed at each step.

5. If possible apply a weight of 105% of capacity, and verify the scale shows OE on the display.

6. Remove weights and verify the display returns to zero. 7. If there is a failure to meet any of the conditions above, please refer to the Calibration

Procedure. 8. When all the conditions above are correct, the scale is operational.

Calibration Switch The calibration of the scale is protected from accidental change by a switch protected by an access plug. The access plug is located on the front of the scale head above the “ON” switch, and is covered by a calibration sticker (seal). The switch is set in the “calibration blocked” mode at the factory.

Enabling the Calibration switch First, remove the calibration sticker which covers the access plug. Using a ¼” Allen wrench, remove the access plug. Insert the Allen wrench in to the hole and press the switch once. The scale is now set to allow calibration.

How to enter a number During this routine you will be asked to enter numbers at many points. You must use the ZERO and PRINT switches to enter these numbers. The scale will show 5 digits but there are actually 6 digits because the leftmost digit is initially invisible. The active digit will be blinking. Press the ZERO key to increase the value of the blinking digit. Press the PRINT key to move the blinking digit one place to the left. When you advance to the leftmost digit, the display will initially be blank (value of 0). This display segment can be toggled between 0 and 1. When you are finished entering the number press both the ZERO and PRINT switches simultaneously to go on.


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Three point span The scale has a three point calibration feature which reduces the effects on non-linearity in the load cells. This requires that you place three weights on the cell during calibration. The first weight must be greater than zero, the second greater than the first, and the final weight somewhere between the second and the capacity.

How to Calibrate the Scale There are three parameters that can be set without moving the calibration switch, followed by three more parameters and the actual calibration which require the calibration switch to be in the enabled position.

Display Parameter Note Default

EE-00EE-00EE-00EE-00 Sample Rate 1 to 64 4

EE-01EE-01EE-01EE-01 Update Rate 1 to 32 4

EE-02EE-02EE-02EE-02 Power up in kg 1=kg, 0=lb 0

Information saved

Check for calibration blocking switch

EE-03EE-03EE-03EE-03 AZT 0=off,1=0.6,2=1,3=3 2

EE-04EE-04EE-04EE-04 Canadian Specifications 0=off, 1=on 0

EE-05EE-05EE-05EE-05 Graduation 0 to 11 6

Information saved

LL-00LL-00LL-00LL-00 Zero read Enter capacity

LL-01LL-01LL-01LL-01 First weight Enter first weight

LL-02LL-02LL-02LL-02 Second weight Enter second weight

LL-03LL-03LL-03LL-03 Third weight Enter third weight

Information saved

1. Access the calibration switch and press once if you intend to calibrate. See

Calibration Switch.

2. Turn both the base and head on. Wait for scale to warm up (2-3 minutes).

3. Press ZERO and PRINT together and release to enter the calibration mode.

4. The scale displays “EE-00EE-00EE-00EE-00”. Press the ZERO and PRINT keys simultaneously. Enter the sample rate (1 to 64), ('4' is suggested, although if your readout is too jumpy, you can increase this value). The sample rate is the number of past readings that are averages together to make a reading. (Press ZERO and PRINT keys to enter this number.)


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5. The scale displays “EE-01EE-01EE-01EE-01”. Press the ZERO and PRINT keys. Enter the display update rate (1 to 32), ('4' is suggested). The display update rate is the speed at which the display is updated, with 1 being the fastest. (Press the ZERO and PRINT keys to enter this number.

6. The scale displays “EE-02EE-02EE-02EE-02”. Press the ZERO and PRINT keys. Enter what unit of

measure the scale should operate in; pounds or kilograms (0 to 1). (Press the ZERO and PRINT keys to enter this number.)

Setting Units to operate in

0 pounds (lb)

1 kilograms (kg)

Note: At this point the changes you entered will be saved and the scale could be turned off if you don't wish to change the calibration.

7. The scale shows “EE-03EE-03EE-03EE-03”. Press the ZERO and PRINT keys. Enter the desired

AZT size. The AZT size is the number of graduations the auto zero tracking can remove. Note: At this point if the calibration blocking switch is not in the enabled

position, the scale will not save the new AZT value. It will instead display the “E1E1E1E1”

error message and return to normal weighing. See “Calibration switch” to

change this.

Setting AZT size

0 Off

1 0.6

2 1

3 3

8. The scale shows “EE-04EE-04EE-04EE-04”. Press the ZERO and PRINT keys. The scale shows the current Canadian specification selection. Use the following table to select the Canadian specifications setting.

Setting Canadian

Specification

0 Off

1 On

A '0' setting implies normal operation:

1: AZT size is determined by setting of EE-03EE-03EE-03EE-03. 2: Zero operates over full range of capacity. 3: Over capacity is 103% from the zero obtained at calibration. A '1' setting implies Canadian specifications are used:

1: The AZT size fixed at 0.6d regardless of EE-03EE-03EE-03EE-03 setting.


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2: The IZSM (initial zero setting mechanism on power up) must be within +/- 10% of the zero obtained at calibration.

3: The push-button zero and AZSM can only operate within +/- 2% of the IZSM. 4: The overcapacity point is 103% of capacity above the IZSM.

9. The scale shows “EE-05EE-05EE-05EE-05”. Press the ZERO and PRINT keys. Enter the desired graduation. Use the following table to select a graduation value. (Press the ZERO and PRINT keys to enter this value.)

Setting Count by

in lb

Count by

in kg

0 100 50

1 50 20

2 20 10

3 10 5

4 5 2

5 2 1

6 1 0.5

7 0.5 0.2

8 0.2 0.1

9 0.1 0.05

10 0.05 0.02

11 0.02 0.01

NOTE: To meet stated accuracy statements, it is suggested that you choose your graduation setting from the table below:

If your capacity is: Set your graduation to:

500 lb / 250 kg 0.2 lb / 0.1 kg (8)

1000 lb / 250 kg 0.5 lb / 0.2 kg (7)

2,000 lb / 1,000 kg 1 lb / 0.5 kg (6)

5,000 lb / 2,500 kg 1 lb / 0.5 kg (6)

10,000 lb / 5,000 kg 2 lb / 1 kg (5)

20,000 lb / 10,000 kg 5 lb / 2 kg (4)

30,000 lb / 15,000 kg 10 lb / 5 kg (3)

50,000 lb / 25,000 kg 10 lb / 5 kg (3)

70,000 lb / 35,000 kg 20 lb / 10 kg (2)

100,000 lb / 50,000 kg 20 lb / 10 kg (2)

Note: The changes will again be saved here and the scale could be turned off if you don't wish to change the calibration.


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10. The scale displays “LL-00LL-00LL-00LL-00”. Press the ZERO and PRINT keys. On the next screen enter the capacity, in the units (lb or kg) that you are calibrating in. With no weight on the hook, press the ZERO and PRINT keys to enter in this capacity. Max capacity is 99999 lbs. Special versions allow a max capacity of 199999 lbs.

11. The scale shows “LL-01LL-01LL-01LL-01”. Apply the first weight and press the ZERO and PRINT keys. On the next screen enter the weight being applied. With the weight on the hook and its exact value shown on the CS5000 screen, press the ZERO and PRINT keys to enter in the weight.

12. The scale shows “LL-02LL-02LL-02LL-02”. Apply the second weight and press the ZERO and PRINT keys. On the next screen enter the weight being applied. With the weight on the hook and its exact value shown on the CS5000 screen, press the ZERO and PRINT keys to enter in the weight.

13. The scale shows “LL-03LL-03LL-03LL-03”. Apply the final weight and press the ZERO and PRINT keys. On the next screen enter the weight being applied. With the weight on the hook and its exact value shown on the CS5000 screen, press the ZERO and PRINT keys to enter in the weight.

Finish

The new calibration information is saved.

14. Press the calibration switch ONCE to disable calibration. This will prevent accidental entry into the calibration mode. If you are unsure of whether the switch is enabled or disabled, start going thorough the calibration menu again. After the “AZT” menu item, the scale should return to normal weighing instead of saving the

AZT value and proceeding to EE-04EE-04EE-04EE-04. See the “calibration switch” section. 15. Replace the access plug which will cover the calibration switch. 16. Cover this plug with a new calibration seal (e.g. foil calibration sticker). 17. Verify the calibration. 18. Calibration complete.

Legal-for-Trade Sealing

For qualified calibration facilities: 1. After calibration push the calibration switch. The calibration switch is located on the

upper right hand corner on the backside (side with battery caps) of the scale. 2. Verify that the scale returns to normal weighing when trying to access the weight

calibration. 3. Replace the set screw that covers the cal switch. 4. Apply the protection sticker (sticker must adhere to Intercomp’s specifications).


17

Error Messages

[display reads “--------------------“]: The CS5000 is waiting for a stable reading to continue. This also occurs when the unit is first turned on, or after ZERO or TARE is pressed.

EE-00EE-00EE-00EE-00 EEPROM error, the scale has had it's calibration corrupted or destroyed; the scale will require recalibration.

OL-00OL-00OL-00OL-00 Zero overload, the zero has moved outside it's limit. Return the scale's load to the initial zero-set and press ZERO, or turn the unit off and then back on.

See 'Canadian specifications' (EE-04EE-04EE-04EE-04 in the 'calibration' section).

OE-00 OE-00 OE-00 OE-00 The scale is over capacity. Reduce the load applied to the scale.

OSOSOSOS Display error, the scale is unable to display the number completely.

HO-00HO-00HO-00HO-00 Head off, the scale head is turned off or the communication link between the scale head and base has otherwise failed. If both base and head are on and you get this message, try rotating or moving the base slightly. This can sometimes have a substantial effect on the signal received.

LB-00LB-00LB-00LB-00 The scale head is low in batteries. Turn the scale base off first, then replace the 8 'D' cell batteries in the head.

BLBBLBBLBBLB The batteries in the base controller require recharging or replacement

EO:EO:EO:EO: This message occurs if the scale is turned on with a load applied which is

greater than ±10% capacity. Return the scale’s load to zero. This only

occurs when Canadian specifications are turned on. See EE-04EE-04EE-04EE-04 in the ‘Calibration section’.

E1E1E1E1 Error during calibration. It is caused by either the calibration strap being disabled, or a failure in the communication link. The scale will then exit calibration mode and return to normal weighing after a few seconds. See “Calibration switch” section.


18

Troubleshooting

Caution: Changing some parts on the circuit board may cause a large

change in calibration while others may or may not change the calibration,

depending on the nature of the problem. The base unit contains the “MPC board” and the “GPI Display board” The head contains the “A/D board”.

Problem: base only displays “HO-00HO-00HO-00HO-00“, no communication

Fix: Check the power on the head (LED labeled POWER). If the head does have sufficient power, this is probably a communication problem. Open the base unit and locate the transceiver. If the LED lights labeled RXD Data and TXD Data are not blinking, the transceivers are not communicating. Check to make sure the base and head unit have power. Also make sure they are within range and rotate units to try to get communication.

Problem: no power, nothing on display

Fix (applies to the base and the head): If nothing can be seen on the display, there is probably no power reaching the base circuitry. Possible causes at: bad or shorted battery pack, bad switch circuit, bad voltage regulator. Power might be reaching the unit, but the power supply might be shorted by a component or PCB trace in the power supply circuitry.

Problem: random display (display usually reads “8888.8888.8888.”)

Fix: On MPC board: check crystal (Y2). If the micro-controller is not receiving the correct or any oscillation, the microprocessor is not able to function properly. Other possibilities could be bad microprocessor (U1) on MPC board or display driver (U1 & U2 on “GPI DISPLAY” board) circuitry not functioning.

Problem: low battery indication won’t turn off

Fix:

The display will show a low battery condition (“LB-00LB-00LB-00LB-00” for the head, or “BLBBLBBLBBLB” for the base controller). Check if battery power is too low. Look at the cells and charger circuit for these problems. If that is not the cause, the display driver( U1 & U2 on the “GPI DISPLAY” board) or low voltage circuitry could be bad.


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Problem: rechargeable battery life has decreased

Fix: The rechargeable batteries provided by Intercomp are high quality, high capacity Ni-Cad. However, all Ni-Cad batteries can exhibit some “memory” effects if they are repeatedly discharged to a certain point before recharging. If your observed battery life has decreased significantly from its initial performance, you may want to try this battery-conditioning sequence: Fully discharge the batteries by running the

CS5000 until the display blinks “LBLBLBLB” (low battery) and keep the unit powered until the batteries are fully discharged. Following this, recharge the battery completely (typical charge time is 16 hours). This discharge/recharge cycle may need to be repeated. If this does not help, you may need to replace the Ni-Cad batteries.

Problem: scale shuts off by itself

Fix: Check the battery holder terminals. They may be bent and not making solid contact. If the scale turns off immediately after you take your finger off the button, there may be defective power circuitry or a bad keypad.

Problem: scale “locks up”

Fix: The microprocessor (U1) on the MPC board may need to be replaced. The microprocessor support circuitry could also be bad.

Problem: weights jump or drift

Fix: Try increasing the sample rate as described in the calibration section (pg. 13). Pertains to A/D board: If this does not help, the problem could be a bad load cell, defective amplifier (U5), bad A/D chip (U6), or contamination on the A/D circuit board.


20

Parts and Accessories

Diagram: 500 lb capacity models

See following page for parts list


21

Parts List: 500 lb capacity Item # QTY Part # Description

1 1 00072 control harness

2 6 250058 button cover

3 12 600058 .375-16 screw

4 1 250089 keypad overlay

5 1 250090 logo overlay

6 1 500804 CS5000 display end

7 1 250095 window overlay

8 1 220063 4-pin MTA

9 1 603057 loadcell

10 1 insert

11 1 500817 display window

12 1 600064 .50-20unf screw

13 1 500838 loadcell threaded adapter

14 1 500739 loadcell retainer

15 1 500736 lower loadcell adapter

16 1 500824 loadcell housing

17 1 500710 retaining ring gasket

18 1 500709 top retaining ring

19 1 500713 retaining ring spacer

20 2 600020 .25-20 screw

21 4 600023 .25-20 set screw

22 2 600019 .25-20 screw

23 1 601039 eye nut

24 2 500805 housing gasket

25 1 500823 eye nut

26 2 500707 battery tube

27 20 600008 6-32 screw

28 4 330042 battery spring

29 2 500706 battery plate

30 2 500705 battery cap

31 2 600014 8-32 screw

32 2 500708 battery tube end

33 2 601047 wing nut

34 1 000075 battery harness assembly

35 1 603035 assembly screw

36 1 603035 swivel hook assembly

37 1 603035 assembly nut

38 16 601014 .031 nylon washer

39 4 601032 6-32 m/f standoff

40 4 601002 6-32 nut

41 1 500808 right board mount

42 4 601028 vibration mount

43 1 000095 display board

44 4 601015 .062 nylon washer

45 4 600035 8-32 screw

46 4 601018 6-32 standoff

47 1 000094 A/D board

48 1 500807 left board mount

49 4 600015 8-32 unc screw

50 1 500803 lower retaining ring

51 2 500818 bellows

52 1 820027 hose clamp


22

Diagram: 2K lb capacity models

Please see following page for parts table


23

Parts List: 2K lb capacity Item # QTY Part # Description



3 12 600058 .375-16 screw





8 1 220063 4-pin MTA

9 4 600023 .25-20 set screw

10 1 000062 loadcell (2K capacity CS5000)

11 1 insert



14 1 500739 loadcell retainer




18 1 500713 retaining ring spacer

19 2 600020 .25-20 screw

20 2 600019 .25-20 screw

21 1 601039 eye nut


23 1 500823 eye nut


25 20 600008 6-32 screw




29 2 600014 8-32 screw


31 2 601047 wing nut





36 16 601014 .031 nylon washer

37 4 601032 6-32 m/f standoff

38 4 601002 6-32 nut




42 4 601015 .062 nylon washer

43 4 600035 8-32 screw

44 4 601018 6-32 standoff

45 1 000094 A/D board


47 4 600015 8-32 unc screw


49 2 500818 bellows



24

Diagram: 5K lb, 10K lb capacities

See the following page for parts list


25

Parts List: 5K lb, 10K lb capacity Item # QTY Part # Description



3 12 600058 .375-16 screw





8 1 220063 4-pin MTA

9 4 600023 .25-20 set screw

10 1 000073 loadcell (5K and 10K capacity CS5000)

11 1 insert






17 2 600020 .25-20 screw

18 2 600019 .25-20 screw

19 1 601039 eye nut


21 1 500823 eye nut


23 20 600008 6-32 screw




27 2 600014 8-32 screw


29 2 601047 wing nut





34 16 601014 .031 nylon washer

35 4 601032 6-32 m/f standoff

36 4 601002 6-32 nut




40 4 601015 .062 nylon washer

41 4 600035 8-32 screw

42 4 601018 6-32 standoff

43 1 000094 A/D board


45 4 600015 8-32 unc screw


47 2 500818 bellows



26

Diagram: 20K lb, 30K lb, capacities

Please see following page for parts list


27

Parts List: 20K lb, 30K lb capacity Item # QTY Part # Description



3 12 600058 .375-16 screw





8 1 220063 4-pin MTA

9 4 600023 .25-20 set screw

10 1 000073 000063

loadcell (20K capacity CS5000) loadcell (30K capacity CS5000)

11 1 insert


13 1 601051 1-8 locking nut

14 1 500813 top loadcell adapter

15 2 602008 1-8 bolt




19 1 601039 eye nut

20 2 600019 .25-20 screw

21 2 600020 .25-20 screw


23 1 500823 end plate

24 1 500946 lower loadcell adapter


26 20 600008 6-32 screw




30 2 600014 8-32 screw


32 2 601047 wing nut





37 16 601014 .031 nylon washer

38 4 601032 6-32 m/f standoff

39 4 601002 6-32 nut




43 4 601015 .062 nylon washer

44 4 600035 8-32 screw

45 4 601018 6-32 standoff

46 1 000094 A/D board


48 4 600015 8-32 unc screw


50 2 500818 bellows



28

Serial Output The CS5000 base has available two communications channels, the standard interface for both is RS-232. One is equipped with a CTS (clear to send) line and designed primarily for hookup to a printer. The second channel consists of signal wires only and is designed primarily for hookup to a score board or computer. Channel 1 outputs a ticket:

Channel 2 outputs the net weight:

There is a five switch dip pak located on the main circuit board inside the base unit, it's switches have the following meanings:

Switch # On Off Function

1 1200 9600 Channel 1 baud rate

2 1200 9600 Channel 2 baud rate

3 on off Channel 1 continuous print

4 on off Channel 2 continuous print

5 on off RF interface (must be turned on, on CS5000)

The Items in bold indicate the suggested defaults.

NOTE: The RS-232 communication parameters: Fixed 8 data bits, no parity, 1 stop bit. Each channel will print under two conditions: 1: If the print key is pressed. 2: If the continuous print is turned on.

cr/lf -XXXXXX.X lb G cr/lf -XXXXXX.X lb N cr/lf -XXXXXX.X lb T cr/lf -XXXXXX.X lb TOTAL cr/lf lf lf JAN DD, 19YY HH:MM:SSam cr/lf (the 19 could be 20, and the a could be p) lf lf

-XXXXXX.X lb cr/lf


29

The signals for the two channels exist the box through the six pin connector on the bottom of the box. The wiring is listed on the following chart:

Pin# Connection

A CH1 TXD

B CH1 CTS

C CH1 GND

D CH2 TXD

E CH2 GND

F NC

Example Connections The connection of CH1 to a 9-pin PC communications port is:

CS5000 9-pin PC

A (TXD) 2 (RXD)

B (CTS) 7 (RTS)

C (GND) 5 (GND)

NOTE: For some setups it may be necessary to jump pins [6, 1, and 4] together on the PC port connector. The connection of CH1 to a 25-pin PC communications port is:

CS5000 25-pin PC

A (TXD) 3 (RXD)

B (CTS) 4 (RTS)

C (GND) 7 (GND)

NOTE: For some setups it may be necessary to jump pins [6, 8, and 20] together on the PC port connector. The connection of CH2 to an Intercomp S400 display is:

CS5000 S400

D (TXD) 2 (RXD)

E (GND) 7 (GND)

The connection of CH2 to an Intercomp SA2000 display is:

CS5000 SA2000

D (TXD) 3 (RXD)

E (GND) 7 (GND)

cont’d on next page


30

The connection of CH2 to a 9-pin PC communication port is:

CS5000 PC 9-pin

D (TXD) 2 (RXD)

E (GND) 5 (GND)

Note: For some setups it may be necessary to jump pins [6, 1, and 4] together, and pins [7 and 8] together on the PC port connector. The connection of CH2 to a 25-pin PC communication port is:

CS5000 PC 25-pin

D (TXD) 3 (RXD)

E (GND) 7 (GND)

Note: For some setups it may be necessary to jump pins [6, 8, and 20] together, and pins [4 and 5] together on the PC port connector.


31

How to reach Intercomp Service Things to know: 1. The service is for a CS5000 crane scale. 2. When did you purchase your scale? 3. What is your serial number? 4. Whom did you purchase the scale through? For Intercomp Service call or fax: FAX # (763)-476-2613 (763)-476-2531

1-800-328-3336 or fill out Service Support Form at: www.intercompcompany.com

Copyright Intercomp Company 2008

All rights reserved

Documents

CS5000 Users Manual