FX1 Service Manual
Contents
1. A SERVICE MANUAL PICOM X A WARNING Alta Semiconductor devices used in this equipment may be permanently damaged due to electrostatic potentials encountered in routine handling testing and storage Antistatic precautions MUST be followed when servicing this product i cONnixm COPYRIGHT 1997 2008 Iconix New Zealand Ltd All rights reserved No part of this manual may be copied or reproduced in any form or by any means without the prior written consent of Iconix New Zealand Ltd The information in this manual is subject to change without notice and should not be construed as a commitment by Iconix New Zealand Ltd Great care has been taken to verify the accuracy of this manual however Iconix New Zealand Ltd assumes no responsibility for any technical inaccuracies or typographical errors ICONIX NEW ZEALAND LTD 345 Thames Highway P O Box 220 Oamaru New Zealand Phone 64 3 4372548 Fax 64 3 4372175 CONTENTS SECTION PAGE 1 SPECIFICATIONS nenne ee ee 7 2 MEAN CAE ee 8 3 OPERATING INSTRUCTIONS Asus 9 E A ee 9 Weighing MOGGS estaras vi 9 4 SYSTEM CARE naar 10 Site Pr paration ii 10 5 CONNECTORS AS ee iin 11 6 SCALE BASE SELECTION sek 11 7 SPAN CALIBRATION essen ee 12 Restoring Default Calibration 444444444 HR nnnnnnnnnnnnnnnnnnnnnn 12 8 SETUP GENERAL sauna 13 9 SETUP AUTORAN CIN Giorla as 14 10 SERVICING He 16 11 PEB CONNECTIONS tana 17 12 RARISLIST SH ae E a ER 19 EEPROM Replaceme2. Ex Sg Sg 1 2 3DC DC Red Black Orange sE Black Green MIC Pin 3 Purple Dr i Red MIC Pin 2 White Grey Page 17 Early Model FX1 Indicators FX1 MAIN PCB Ex Ex Sg Sg 1 2A 2B 3 DC DC Pin 4 lt Red i Pin 1 Black S Pin3 lt Green White g Pin2 Orange 2 Black O Pin5 Le MIC Pin 3 4 L Purple IL Red l Pin 6 MIC Pin 2 xh Gre LL Pin 4 N Pin 3 Pin 3 Pin2 8 Pins Pin6 Purple Pin 7 ooo Page 18 FX1SM 09Jan08 12 PARTSLIST Description Iconix Part Number Indicator Assembly Chassis Socket Amphenol 0099407 Cap Chassis Socket Amphenol 0116838 Chassis Plug 3 Pin MIC 0147269 PCB Assembly FX1 27mm LCD 0400538 Decal FX1 27mm Upper English 0400611 Decal FX1 27mm Lower English 0400613 Decal Set FX1 English 3 pcs OLD for 21mm LCD 0400581 Case Front FX1 Window No Decals 0400041 Case Rear Assembly FX1 complete with Connectors 0400040 Case Insert Rear FX1 0198568 Key Cap Tact Switch 0159200 Screw FX1 Case 6G x Stainless T25 Pan Square 0157602 Components on Main PCB IC AT89S52 Microcontroller FX1 Programmed 0210017 IC AT24C02PC EEPROM 0400051 IC AY0438 P LCD Driver 0195307 If replacing 84521 with AY0438 change adjacent 4700pF ceramic to 100pF IC TC7650CPD Op Amp 0134573 IC TC500CPE A D Converter 0134658 LCD Custom 4 Digit 27mm for PCB4401G and later 0400528 Must be sourced from Iconix NZ Ltd LCD Custom 4 Digit 21mm OLD for PCB4401F and earl
3. is stored in EEPROM NOTE Having completed the span procedure the scale should be switched OFF then back ON and a series of test weights applied to confirm the accuracy of calibration RESTORING DEFAULT CALIBRATION If problems arise for example due to attempting to calibrate with no test weight on the scale and further attempts to calibrate fail for V2 06 onwards it is possible to return the FX1 to a default calibration point During calibration as soon as the message H I or LQ appears on the display press the ZERO key On return to the normal operating mode confirm that the FX1 responds when weight is applied to the scale then repeat the full calibration procedure Page 12 FX1SM 09Jan08 8 SET UP GENERAL NOTE The set up parameters detailed below are set independently for each scale 1 2 and 3 Access to set up is by holding down the WEIGH key at switch on as described in the Span Calibration section As soon as SEt is displayed release the WEIGH key then press ON ZERO The parameters are accessed in the following order 1 WEIGHT UNITS HG for kilograms Lb for pounds To change the setting use the ON ZERO key To accept the displayed setting and step on to the next parameter press WEIGH The standard factory setting is kg If pounds are selected the scale calibration is changed accordingly NOTE In span calibration the Test Weight must ALWAYS be entered in KILOGRAMS regardless of the weig
4. CTORS WEIGHING MODES FREE MODE At switch ON the scale operates in FREE MODE which is suitable for static load weighing The display is continuously updated with the weight currently on the scale The scale can be returned to FREE MODE by pressing the ON ZERO key noting that the scale should be empty since the scale will be zeroed HOLD MODE A press of the WEIGH key switches the scale to HOLD MODE which is suitable for live animal weighing A press of the WEIGH key starts an averaging process which then displays the accurate weight of a moving animal The weight is locked on the display until the next key press FX1SM 09Jan08 Page 9 4 SYSTEM CARE The FX1 weighing system has been designed to work reliably for long periods of time under adverse conditions However like any equipment common sense and care will assist in keeping it in good operating condition ESSENTIAL CARE Y Fit caps to cable ends and indicator sockets when not in use to protect from dirt and moisture Hang the cable ends up out of mud and dust Damage may occur if the capacity of the scale is exceeded Loadbar cables must be kept in good condition SITE PREPARATION The choice of weighing site is important for accurate weighing results and ease of use v Y o oo A well chosen site that is level will ensure the best conditions for accurate weighing The loadbars must be bolted to the platform or crate and be firm
5. ERO key Display reads rESn then for example 0 1 Y Press the ONIZERO key to scroll through the choices of resolution step Page 14 FX1SM 09Jan08 Y Press the WEIGH key to store the desired resolution step The display next shows the first range limit Display reads HI then for example 019 9 To change the Range Limit setting use ON ZERO Scroll A WEIGH Scroll Y One press of a scroll key will increase or decrease the Range Limit by the resolution step size for this range For large adjustments to the Range Limit hold down the required scroll key for more than 1 second for rapid repeat scrolling Y When the range limit setting is correct press no keys for 5 seconds Y Having accepted the new range limit setting the FX1 now displays the resolution step for the second range Repeat the steps above to examine and or modify the resolution step and range limit for each of the required ranges Y The number of ranges used in auto ranging may vary from 1 to 6 When the required number of ranges have been configured select zero as the value for the resolution step for the next range Press the WEIGH key to accept this value The indicator will display SAUE as it stores the new settings and returns to the normal weighing mode SINGLE RANGE EXAMPLE To set up the FX1 for a single range of 0 2000 kg in 5 kg steps Y Enter Autoranging Set Up as above Display reads rESn then for example 0 5 Y Set the first resolut
6. The span calibration procedure is performed independently for each scale 1 2 and 3 v Plug the scale base loadbars etc into the indicator Y Hold the WEIGH key down then press the ON ZERO key releasing the WEIGH key when SEt appears Display reads for example P2 06 then SEL then after 3 seconds 0 0 The indicator is now in a state that allows spanning to be performed Y With no weight on the scale zero the scale with the ON ZERO key Y Place the test weight e g 500kg on the scale allow a few seconds to settle then press ON ZERO and WEIGH simultaneously NOTE To ensure that system accuracy is maintained the test weight should be as close as possible to the maximum working capacity of the scale base To maintain system accuracy over the full range the minimum test weight value for a 2000 kg capacity scale base is 500 kg Y The display will show 5PAn while weighing the test weight then display to the nearest kilogram according to the present calibration e g B 52 3 Change the displayed weight to the correct value in kilograms using ON ZERO Scroll A WEIGH Scroll One press of a scroll key will increase or decrease the weight by 1 kg For large adjustments to the displayed weight hold down the required scroll key for more than 1 second for rapid repeat scrolling Y When the displayed reading is the same as the test weight press no keys for 5 seconds SAUE is displayed as the new calibration
7. fication 0 100kg 0 05 kg 0 200Ib 0 1 Ib 100 300 kg 0 1 kg 200 600 Ib 0 2 Ib 0 100 kg 0 5 kg 0 200 Ib 1 Ib 100 200 kg 1kg 200 400 Ib 2 lb 200 1000 kg 2 kg 400 2000 Ib 5 lb 1000 3000 kg 5 kg 2000 6000 Ib 10 Ib 0 5 of Displayed Reading 1 Division where 1 division is 0 1kg 0 5kg etc depending on weight range Maximum additional error in a 3V m RF field in the range 27 500 MHz is 2 divisions for 20 50 kg 1 division for 50 200 kg 0 division for 200 2000 kg Meets or exceeds the following standards 1EC801 2 Electrostatic discharge EM50081 1 Free radiation measurements EM50082 1 RF immunity The EMC Approvals apply to FX1 PCB4401 Version E and later Page 7 2 MECHANICAL Case Material Case Fixing Screws Connector Type Case Sealing Case Venting Key Pad Type Environmental Standard Dimensions in mm Page 8 Polycarbonate alloy 9 x self tap screws 6G x T25 pan square behind top and bottom front decals Loadbar connectors Amphenol 7 Pin C16 chassis socket Battery connector 3 pin MIC chassis plug Silicone rubber tubing silicone grease coated 0 7 mm breather hole drilled in back case or for older models 3mm bottom centre gap in silicone rubber tubing Alps PCB tact switches operated through polycarbonate decal Approved to IP65 FX1SM 09Jan08 3 OPERATING INSTRUCTIONS GETTING STARTED Either Attach the battery cable to
8. ht units setting 2 ZERO TRACKING if enabled eel 2 t 0 if disabled To change the setting use the ON ZERO key To accept the displayed setting and step on to the next parameter press WEIGH Zero tracking is a feature which automatically restores the scale to zero by tracking out small amounts of dung and dirt left on the scale It should be enabled for most weighing applications 3 DISPLAY RELEASE rEL 1 if enabled cr EL Q if disabled To change the setting use the ON ZERO key To accept the displayed setting and step on to the next parameter press WEIGH The standard factory setting is Display Release OFF which in HOLD mode keeps the last weighing locked on the display until the next weighing For Display Release ON when the animal that has been weighed is moved from the scale the displayed weight will not remain locked on the display 4 PERMANENT FREE MODE FrE l if enabled Version 2 03 firmware onwards FrE 0 if disabled To change the setting use the ON ZERO key The standard factory setting is Permanent Free Mode OFF which puts the indicator into HOLD mode whenever the WEIGH key is pressed locking the weight on the display When Permanent Free Mode is ON the WEIGH key may be pressed however the indicator will remain in FREE mode After the Permanent Free Mode has been viewed or modified WEIGH is pressed for the final time SAUE is displayed while the settings are being stored before retur
9. ier 0198940 Must be sourced from Iconix NZ Ltd Accessories Battery Cable Assembly 0147375 Instruction Card FX1 English 0208960 Race Bracket FX1 0199930 FX1SM 09Jan08 Page 19 EEPROM REPLACEMENT When the FX1 is switched on for the first time after replacement of the EEPROM the display will normally show P PEE Press the WEIGH key within 5 seconds of switch on to programme the EEPROM with default settings for span calibration and set up parameters This must be done with the scale base connected If the indicator is to be used with different scale types the same procedure must be followed for each After EEPROM replacement span calibration must be performed for each scale 1 2 or 3 used SERIAL NUMBER CODE Example 6 09 xMO1 123 where 6 Year of Manufacture 2006 09 Month of Manufacture September XM01 Model FX1 123 Serial Number FIRMWARE UPGRADES All generations of FX1 PCBs may be upgraded to the latest firmware When the microcontroller 0210017 is ordered it will be supplied with the latest version of the program Page 20 FX1SM 09Jan08
10. ion step to 5 kg using the ON ZERO key Display reads 5 Y Store resolution step 1 by pressing the WEIGH key Display reads HI then for example 0995 Change Range Limit 1 until it equals the required full scale capacity of 2000 kg using ON ZERO Scroll A WEIGH Scroll y Y Display now reads 2000 Y Press no keys for 5 seconds to accept the new setting Y Using the ON ZERO key change the setting of the resolution step for range 2 until Display reads 0 Y Press the WEIGH key to store the new settings and return to normal weighing Display reads SAUE FX1SM 09Jan08 Page 15 10 SERVICING NOTE All adjustable parameters are accessible by front panel key presses The FX1 has no internal adjustments DISASSEMBLY NOTE The front decals front panel labels can not be re used Obtain a replacement set before starting this procedure v Carefully lift up a corner of the top and bottom front decals Peel the complete decals off and discard Y Remove the five top and four bottom case screws Y Carefully split the case halves observing that the indicator PCB is attached to the front and the loadbar and battery connectors are attached to the rear REASSEMBLY NOTE Maintaining the IP65 waterproofing standard of the indicator requires that new decals must be fitted according to the following procedure Y Ensure that the silicone tubing embedded in the case front has an adequate coating of silicone grease applied to it For o
11. lder models check that there is a 3 mm gap between the ends of the silicone tubing in the bottom centre of the case case breather Newer models have a 0 7mm breather hole drilled in the recessed part of the case rear above where the plastic insert is fitted and there should be no gap between the ends of the silicone tubing Ensure that the silica gel desiccant pack is returned to the case rear Fit the case halves together and then fit the case screws Switch on the indicator and check that it is working properly e o Thoroughly clean the indicator surfaces ensuring that all traces of the old decals are removed Clean the surfaces with ISOPROPYL ALCOHOL and keep fingers etc off the surfaces prior to application of the decals This is particularly important around the screw holes as the decal provides water sealing of the screw holes Y Ensure that the plastic key caps are fitted to the three key switches Y Peel the protective backing off each decal and carefully fit in place ensuring no finger contact with adhesive backing or indicator surface Without damaging the decal surface firmly smooth the decal down paying particular attention to the perimeter of the decals and around the window area Page 16 FX1SM 09Jan08 11 PCB CONNECTIONS Current Model FX1 Indicators Pin 4 Pin 1 Pin 3 Pin 2 Pin 5 Pin 6 Pin 7 Loadbar 1 Pin 4 Pin 1 Pin 3 Pin 2 Pin 5 Pin 6 Pin 7 Loadbar 2 FX1SM 09Jan08 FX1 MAIN PCB Ex
12. ly attached to the ground or concrete pad Any rocking or twisting of the platform could result in weighing errors Adequate clearance around the platform is essential Any binding or rubbing with posts or gates will produce weighing errors The race bracket is best mounted on a fence or post and not the crate Mount the indicator in a well lit position for best readability A well chosen site will help animals flow smoothly through the system Mounting the indicator away from the crate will help to keep hands free of the crate when the weigh cycle is started Page 10 FX1SM 09Jan08 5 CONNECTORS POWER CONNECTOR MIC 3 Pin Male Pin 1 No Connection Pin 2 DC Pin 3 DC LOADBAR SOCKETS Amphenol C16 7 Pin Female Pin 1 Ex Black Pin 2 Sig White Pin 3 Sig Green Pin 4 Ex Red Pin 5 Scale Select 1 Pin 6 Scale Select 2 Pin 7 Scale Select 3 6 SCALE BASE SELECTION At switch ON the indicator automatically configures to a scale capacity determined by the position of wire links in the Amphenol plugs of the loadbars The scale capacities are factory set to suit standard loadbar types as follows Scale 1 2000 kg Loadbar Plug Link Pin 4 Pin 5 Scale 2 300 kg Loadbar Plug Link Pin 4 Pin 6 Scale 3 3000 kg Loadbar Plug Link Pin 4 Pin 7 Note Product made to specific order with non standard scale bases may have different settings from those shown FX1SM 09Jan08 Page 11 7 SPAN CALIBRATION NOTE
13. ning to the weighing mode FX1SM 09Jan08 Page 13 9 SET UP AUTORANGING It is possible to configure each scale 1 2 and 3 with up to six weight ranges with associated resolution steps up to the maximum scale capacity of the scale base The standard factory settings for the scales are Step kg Range Limit kg Scale 1 2000 kg loadbars 0 1 19 9 0 2 49 8 0 5 199 5 1 499 2 2200 Scale 2 300 kg vet scale 0 05 99 95 0 1 400 0 Scale 3 3000 kg loadbars 0 5 99 5 1 199 2 998 5 3300 WARNING The factory settings of resolution steps and range limits are the result of many years of experience in the live animal weighing industry The settings provide a compromise between stability repeatability and the versatility of the scale for weighing different animal types Changing to finer resolution settings than standard will probably result in unstable and non repeatable weight readings The auto ranging settings allow the FX1 system to be configured for one off applications or for the indicator to be used with alternative scale bases Please contact technical staff at conix for advice PROCEDURE Y Plug the scale base loadbars etc into the indicator Y Hold the WEIGH key down then press the ON ZERO key releasing the WEIGH key when SEt appears Display reads P2 06 then SEL then after 3 seconds 0 0 Y Press the ONIZERO and WEIGH keys simultaneously Display reads SPAN Y Immediately SP An appears press the ON Z
14. nt i 20 Serial Number Code aussetzen 20 Firmware Upgrades ti toda 20 1 SPECIFICATIONS Supply Voltage Low Battery Indication Supply Current Temperature Range Zero Tracking Resolution SCALE 1 Standard Loadbars Minimum Capacity SCALE 2 Vet Scale SCALE 3 Heavy Duty Loadbars Accuracy RF Immunity EMC Approvals Note FX1SM 09Jan08 Nominal 12V DC Maximum 19V DC Reverse polarity protection diode fitted Below 11 4 Volts the LOW BAT pointer A will be on The FX1 switches off at approximately 10 Volts Approximately 100 mA including loadbar set 5 C to 50 C Small residual weights left on the scale between weighings dirt build up are automatically zero tracked out and the scale restored to zero As this occurs the ZERO pointer A will indicate that ZERO has been reached The zero tracking amount is set to 0 5 of the weight displayed after the last press of the WEIGH key with a 2 2 kg maximum At switch on the zero tracking amount is initialised to 0 015 of capacity 0 3 kg for 2000 kg loadbar set Autoranges in graduated steps from the zero point of the scale Metric Model Resolution Imperial Model Resolution 0 20kg 0 1 kg 0 40lb 0 2 Ib 20 50kg 0 2 kg 40 100 Ib 0 5 Ib 50 200 kg 0 5 kg 100 400 Ib 1 lb 200 500 kg 1 kg 400 1000 Ib 2 Ib 500 2000 kg 2kg 1000 4000 Ib 5 Ib 20 kg The 0 20kg range is available but is not part of the EMC speci
15. the indicator and clip onto a 12V DC battery car tractor battery etc ENSURE CORRECT POLARITY red clip to black clip to Or Plug the conix AC adaptor optional accessory into the indicator for mains powered operation Y Connect the two loadbar cables to the loadbar sockets on the underside of the indicator Y Press the ON ZERO key The scale will automatically return to zero When complete the ZERO pointer A will show that the scale is at zero NOTE If a large load such as a partly filled wool bale in a wool press remains on the scale from previous use the last weight will be displayed The operator can continue the weighing session from where last finished Alternatively press ON ZERO to return the scale to zero Y Check that the ZERO pointer A is displayed Load the animal onto the platform Press the WEIGH key The animal is accurately weighed and the result locked on the display Y Remove the animal from the weighing platform The last animal s weight remains locked on the display Check that the ZERO pointer A is displayed between animal weighings If the ZERO A pointer does not appear hold the next animal back keep hands etc clear of the crate and press the ZERO key The scale will return to zero and the weighing session can proceed Y At the end of the weighing session switch the indicator OFF Disconnect the battery and loadbar cables ENSURE THAT THE CAPS ARE FIRMLY REPLACED ON THE LOADBAR AND INDICATOR CONNE
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