XR Series LED Remote Displays Installation Instructions NORTH AMERICA AWT35-500303 Issue AD
© Avery Weigh-Tronix, LLC 2012. All rights reserved. No part of this publication may be reproduced, stored in an electronic retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording or otherwise without the prior written consent of the copyright owner, or as permitted by law or under license. Full acknowledgment of the source must be given. Avery Weigh-Tronix is a registered trade mark of the Avery Weigh-Tronix, LLC.
Table of Contents page Chapter 1 General information and warnings ......................................................................................... 5 About this manual .............................................................................................................. 5 Installation .......................................................................................................................... 6 Electrical installation .............................................................
Parameter 1.2: Power-save Mode ............................................................................. 31 Parameter 1.3: Mirror Display Mode ......................................................................... 31 Parameter 1.4: Multi-Drop ID .................................................................................... 32 Parameter 1.5: Radio Channel Select ....................................................................... 32 Parameter 1.6: Utility Program Select ......................
1.1 1 General information and warnings 1.1 About this manual About this manual This manual is divided into chapters by the chapter number and the large text at the top of a page. Subsections are labeled as shown by the 1 and 1.1 headings shown above. The names of the chapter and the next subsection level appear at the top of alternating pages of the manual to remind you of where you are in the manual. The manual name and page numbers appear at the bottom of the pages.
1 General information and warnings 1.2 Installation DANGER: RISK OF ELECTRICAL SHOCK. NO USER SERVICEABLE PARTS. REFER TO QUALIFIED SERVICE PERSONNEL FOR SERVICE. 1.3 Electrical installation CAUTION: The power cable must be connected to an earth-grounded electrical outlet. The electrical supply must have a circuit breaker with an appropriate rating to protect from over-current conditions.
1.4 1.4 Routine maintenance Routine maintenance IMPORTANT: This equipment must be routinely checked for proper operation and calibration. Application and usage will determine the frequency of calibration required for safe operation. Always turn off the machine and isolate from the power supply before starting any routine maintenance to avoid the possibility of electric shock. Make sure that it is placed securely on a flat and level surface. 1.5 Cleaning the machine Table 1.
1 General information and warnings 1.7 FCC and EMC declarations of compliance United States This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment.
2.1 2 Display Introduction Thank you for purchasing an XR series remote display. The XR series incorporates the highest performance standards and the most standard features of any weighing display, making them the best choice for virtually any remote viewing application. Like all Avery Weigh-Tronix products, the XR remote displays are designed with durability, functionality and versatility in mind.
2 Introduction The units have four annunciators under the display with bright LED markers: 2.2 l GR = Gross Weighing Mode l NT = Net Weighing Mode l lb = Pounds l kg = Kilograms Keypad All models of the XR, except the XR 2000, have a keypad on the bottom of the unit. See illustration of the keypad in Figure 2.2. Figure 2.2 Keypad The keypad has three pushbuttons or keys and a light sensor window. Use the keys to set time and date and to access the configuration mode.
3.1 Installing the XR 4500, XR 4500TL or XR 6500 3 Installation 3.1 Installing the XR 4500, XR 4500TL or XR 6500 3.1.1 Pre-installation (Receiving Inspection) It is always good practice to verify that the unit is complete and undamaged upon receipt. l Check over packaging for any signs of damage. l Remove the XR from its protective packaging and check for damage. l Verify that the shipment includes: l m Correct XR remote display (complete and intact, with power cord).
3 Installation 3.1.3 Lowering the Electronics Plate 1. Remove the three (3) captive screws holding the electronics plate to the main enclosure. See Figure 3.2. Captive Screws Figure 3.2 Open enclosure 2. Slowly, allow the electronics plate to swing down. The controller board and power supply board are now accessible for installation, wiring and service. See Figure 3.3. Figure 3.3 Electronics plate down 3.1.4 Mounting Instructions 12 1. Inspect the installation site for properly grounded power.
3.1 5. Installing the XR 4500, XR 4500TL or XR 6500 Run power and communication cables into the enclosure via strain reliefs (as required). The electronics carriage may be removed to reduce weight when installing. Mounting hole size in the case is 3/8”. Wall Mounting Hole patterns for the XR series are given in Figure 3.4 and Figure 3.5. 24.00in.[609.6mm] 10.125in.[257.2mm] 8.88in.[225.6mm] 6.00in.[152.4mm] 23.00in.[584.2mm] Dia: .375in.[9.5mm] 3.5in.[89mm] Figure 3.
3 Installation 3. Fasten the XR display to the pole mounting bracket as outlined in the mounting instructions (See Figure 3.6). The pole mounting bracket allows use of poles or beams up to eight inches in diameter. Figure 3.6 Pole mounting bracket Visor Option 1. Loosen the mounting hardware on the main enclosure 1/8th inch. 2. Rest the visor’s mounting brackets on the bolt between the bolt head and the front of the side mounting plates. 3. Re-tighten the mounting hardware. Figure 3.
3.2 3.2 Installing the XR 2000 Installing the XR 2000 3.2.1 Opening the XR 2000 Enclosure 1. Make sure the unit is disconnected from power. 2. Remove the 6 screws (with sealing washers) from the front of the enclosure. 3. Guide the front panel away from the main enclosure. Be sure to watch the internal cable connections! See Figure 3.8 Figure 3.8 XR 2000 enclosure laid open 3.2.2 Mounting Instructions Mounting hole size in the case is 5/16”. 1.
3 Installation Figure 3.
4.1 4 Wiring 4.1 Wiring the XR 4500, 4500TL or 6500 Wiring the XR 4500, 4500TL or 6500 4.1.1 Power Wiring XR displays are wired for power at the factory. The factory supplied power cable can be removed for direct AC wiring if necessary. 4.1.2 Communications Wiring All communications wiring terminates at the controller board. Communications should be wired before applying power to the unit. J3 J4 J5 20mA Mode Switch (SW10) Figure 4.
4 Wiring RS 232 Daisy Chain / Multi-Drop Wiring INDICATOR TO RD 1 TO RD 2 TX RX No connection for Daisy Chain. RX for Multi-drop. TX RX GND GND GND RS 422/485 Wiring Terminate the indicator’s communication wires at the RS 485 terminal (J4), shown in Figure 4.1.
4.1 Wiring the XR 4500, 4500TL or 6500 RS 485 Daisy Chain / Multi-Drop Wiring Terminate the indicator’s communication wires at the RS 485 terminal (J4), shown in Figure 4.1, using one of the following methods: Parallel Multi-drop wiring SCALE CONTROLLER TO RD 1 TO RD 2 TO RD 3 ETC. TX A RX A RX A RX A RX A TX B RX B RX B RX B RX B Split Multi-Drop Wiring Multi-Drop IDs are set using the Configuration Mode. For instructions see Parameter 1.4: Multi-Drop ID on page 32.
4 Wiring 20mA Current Loop Wiring Terminate the indicator’s communication wires at the 20mA Current Loop terminal (J5), shown in Figure 4.1. See table below for pin assignments: INDICATOR TO XR 20 mA TX + RECEIVE POSITIVE (RX +) 20 mA TX - RECEIVE NEGATIVE (RX -) 20mA Current Loop Mode Switch l After the current loop is wired, ACTIVE or PASSIVE mode must be selected (SW 10) on the controller board. See Figure 4.2.
4.2 4.2 Wiring the XR 2000 Wiring the XR 2000 4.2.1 Power Wiring XR displays are wired for power at the factory. The factory supplied power cable can be removed for direct AC wiring if necessary. 4.2.2 Communication Wiring All communications wiring terminates at the controller board. Communications should be wired before applying power to the unit. Communication Input Jumper A communications input type (RS 232, RS 422/485, or 20 mA Loop) must be selected by placing the jumper on the appropriate pins.
4 Wiring 2. Terminate the indicator’s communication wires at the RS 232 terminal (J3). See table below: INDICATOR TO XR TRANSMIT (TX) RECEIVE (RX) RECEIVE (RX) NO CONNECTION SIGNAL GROUND (GND) SIGNAL GROUND (SIG GND) RS 422 Wiring 22 1. Set the Communication Input Jumper (JP 1) to RS422 / 485. 2. Terminate the indicator’s communication wires at the RS 422 / 485 terminal (J4).
4.2 Wiring the XR 2000 RS 485 Multi-Drop Wiring Set the Communication Input Jumper (JP 1) to RS422 / 485. Parallel Multi-drop wiring SCALE CONTROLLER TO RD 1 TO RD 2 TO RD 3 ETC. TX A RX A RX A RX A RX A TX B RX B RX B RX B RX B Split Multi-Drop Wiring Multi-Drop IDs are set using Parameter 1.4: Multi-Drop ID on page 32. 20 mA Current Loop Wiring 1. Set the Communication Input Jumper (JP 1) to 20mA LOOP. 2.
5 Wireless Communication 5 Wireless Communication 5.1 Wireless Set-up for All XR Models 5.1.1 XR Remote Display 1. Install the radio module. Plug the module into terminals on the main PC board. See Figure 5.1. The radio module plugs into the XR 2000 controller board in similar fashion. 2. Route the radio signal cable to the bottom of the electronics carriage and secure the SMA terminal through the available hole. Connect the external antenna to the SMA terminal. 3. Power up the XR.
5.1 Wireless Set-up for All XR Models 5.1.3 Base Station Wireless Transceiver The ScaleLink wireless transceiver is shown in Figure 5.2. Refer to the installation manual that is included with the ScaleLink for connection and configuration information. Figure 5.2 Base station (connects to the indicator) Figure 5.3 shows the inside of the ScaleLink. Figure 5.
5 Wireless Communication 5.2 Wireless Connection Test Verify that both the base station wireless transceiver and the XR are set to the same radio channel. If the XR’s readings are incorrect, erratic, or very slow, a different radio channel may need to be selected.
6.1 6 Start-Up 6.1 Power On/Off Power On/Off The XR has no ON/OFF button or switch. Plugging the unit into AC power will turn the unit ON. Disconnecting AC power will turn the unit OFF. When power is applied the XR performs a self test by counting up 1 to 9, flashing the annunciators and decimals, and displaying the software revision number. 6.
6 Start-Up 6.4 LEARN Button Automatic Start-up Auto-Learn may be disabled for custom applications. See AutoLearn Parameters on page 33. If Automatic Start-up Auto-Learn is disabled, the LEARN button (marked as LRN on the XR 2000) on the Controller board must be pressed to enter Auto-Learn mode. 6.5 Diagnostic Indicator Lights The XR has seven diagnostic indicator lights located on the controller board. See the arrows in Figure 6.2.
6.5 Diagnostic Indicator Lights Figure 6.3 Lights and switches on the XR 2000 controller board 3.3V Light Turns on when voltage is supplied to the controller board. 12V Light Turns on when voltage is supplied to the display boards. STATUS Light The STATUS light blinks when power is applied to the unit. Rapid blinking (3 times per second) indicates that the XR is in Auto-Learn mode, attempting to interpret a data string.
7 Configuration Mode 7 Configuration Mode To set the different parameters available in the XR series, you must enter a configuration mode and then set each parameter to your desired value. Follow the steps below to enter the configuration mode and to set the parameters. 7.1 Entering Configuration Mode 1. On the keypad on the bottom of the display press the UP and DOWN arrow keys together. Release the keys when … ConFig flashes on the display. This is followed very shortly by P1.0.
7.2 7.2 Configuration Parameters Configuration Parameters Use the instructions in ’Entering Configuration Mode’, section 7.1 change the following parameters. to access and 7.2.1 Parameter 1.0: Daytime Brightness Level Value Description 0 = Low 1 = Med Low 2 = Med High 3 = High< Set the brightness of the display for daytime viewing. The built-in light sensor automatically detects daylight conditions and sets the display brightness to this level. 7.2.2 Parameter 1.
7 Configuration Mode 7.2.5 Parameter 1.4: Multi-Drop ID Value Description 0 = ID 0< 1 = ID 1 2 = ID 2 3 = ID 3 Etc. Sets the unit ID if multiple remote displays are networked together. Up to four XR displays can be networked on a single serial or radio connection. Messages are sent to individual displays using control codes and these IDs. For Multi-Drop instructions see Multi-Drop addressing on page 48. IMPORTANT: If Multi-Drop is not being used, the ID must be set to 0. 7.2.6 Parameter 1.
7.3 7.3 Auto-Learn Parameters Auto-Learn Parameters 7.3.1 Parameter 2.0: Manual Learn (Assisted Learn) Value Description Lxxxxx Manual Learn activates Auto-Learn Mode from inside Configuration Mode. The remote display will analyze and attempt to learn the string. The message LEARN is displayed. When the remote display is successful, the weight will be shown on the display. A blinking L will be displayed in the left hand corner to indicate you are still in learning mode.
7 Configuration Mode 7.3.4 Parameter 2.3: Set Scale Over Value Description 0 = Auto< If there is no scale over status character in the weight string, or the Value for scale over target weight indicator continues to transmit past maximum capacity, the unit can be set to blank the display when the weight goes past a preset weight value. Use the UP/DOWN keys to set the weight threshold and press ENTER. Hold the keys down to cause the weight threshold to change in steps of 10000.
7.4 7.4 Time / Date / Temp Parameters Time / Date / Temp Parameters The XR remote display can cycle between displaying weight, time, date and temperature every five seconds when: a) the weight display is at zero AND; b) there is no activity on the scale for the selected time period. 7.4.1 Parameter 3.0: Time Display Value Description 0 = OFF< 1 = Time (AM/PM) 2 = Military (24 hour) Activates the time function in 12 hour or 24 hour clock formats. 7.4.2 Parameter 3.
7 Configuration Mode 7.5 Diagnostic Parameters 7.5.1 Parameter 9.0: Com Port Value Description 0 = RS232 1 = RADIO 2 = 20mA 3 = RS485 Displays the currently active Com Port. 7.5.2 Parameter 9.1: String Counter Value Description 0 to 65535 Counter indicates the number of characters received. Counter rolls over after 65535. 7.5.3 Parameter 9.2: Baud Rate Value Description 300 600 1200 4800 9600 19200 Displays the baud rate currently being used for serial communications. 7.5.4 Parameter 9.
7.5 Diagnostic Parameters 7.5.6 Parameter 9.8: Test Display Value Description N/A Cycles through time, digits, annunciators and decimal characters. 7.5.7 Parameter 9.9: Reset Defaults Value Description 0 = Do Not Reset 1 = RESET Resets the configuration parameters to factory defaults.
7 Configuration Mode 7.6 CONFIG Switches (XR 2000) The CONFIG bank of dip switches (SW 3), shown in Figure 7.1, is for the following features: Figure 7.1 SW 3 (CONFIG Switch bank) Switch 1: Brightness Level There are 2 selectable brightness levels. Outdoor (brighter) and indoor (less bright). BRIGHTNESS LEVEL SWITCH 1 Indoor (default) OFF Outdoor ON Switch 2: Leading Zeros (see note at left) Leading Zeros may also be disabled using the scale indicator (if possible).
7.6 CONFIG Switches (XR 2000) Switches 4 & 5: Multi-Drop ID If Multi-Drop is not being used, it is very important that Switches 4 & 5 be set in the OFF position. Up to four (4) XR displays can share a serial or radio connection. Messages are sent to individual displays using control codes and these Multi-Drop IDs. For Multi-Drop instructions, see Multi-Drop addressing on page 48. MULTI-DROP I.D.
7 Configuration Mode Switches 8 & 9: Utility Program Select Please see the XR 2000 Utility Programs on page 49 for program overviews. The XR 2000 has built-in utility programs that run in conjunction with the normal display functions. 40 PROGRAM SW 8 SW 9 1 – NORMAL Mode (No program) OFF OFF 2 – FREEZE Weight ON OFF 3 – Reserved for future use OFF ON 4 – COMMAND mode.
8.1 Built-in Traffic Light (XR 4500TL Only) 8 XR 4500 TL Traffic Light Control 8.1 Built-in Traffic Light (XR 4500TL Only) The built-in traffic light may be controlled by remote switch, serial commands, or the pre-installed utility programs. Remote Switch 1. Wire a dry contact, push to make switch to the Stop Light Remote Switch terminal (J23) on the Controller board. DO NOT supply any external power to this terminal. Figure 8.
9 Time and Date (not available on XR 2000) 9 Time and Date (not available on XR 2000) The XR remote display has a precision time clock that compensates for variable temperature conditions. The battery on the Controller board (J22) provides back-up power for this clock. 9.1 Set Time & Date 9.1.1 Adjust Time 1. Make sure Time is enabled in Configuration Mode (Parameter 3.0) 2. Press and hold the UP/TIME key. 3. Use the UP and DOWN ARROW keys to select the correct hour and press ENTER. 4.
10 Temperature Probe Installation (not on XR 2000) 1. Unpack the optional Temperature Probe Assembly. This assembly consists of the weather-sealed temperature probe contained in a Strain-Relief. A 4-conductor cable runs from the temperature probe to a 4 pin connector. 2. Ensure the XR display is disconnected from power and open the enclosure. 3. Remove the rubber plug from the hole in the bottom of the XR enclosure. 4.
10 Temperature Probe Installation (not on XR 2000) Figure 10.2 J9 terminal for temperature probe connection The XR’s Digital Temperature Probe ensures accuracy to within ± 1 degree and will never need to be calibrated.
11.1 XR 4500, XR 4500TL, and XR 6500 Utility Programs 11 XR Utility Programs 11.1 XR 4500, XR 4500TL, and XR 6500 Utility Programs The XR remote displays have several auxiliary functions that may be activated via Parameter 1.6 in Configuration Mode. 11.1.1 Program 0: Normal Operation No utility program is selected. 11.1.2 Program 1: Simple Traffic Light Traffic light is GREEN on zero weight. Otherwise the traffic light is RED. 11.1.
11 XR Utility Programs 11.1.6 Program 5: Command Mode All XR displays can be setup to receive commands directly from the scale system or PC. Supported commands include transmitting weights, basic alphanumeric messaging, traffic light control, and additional display functions. Command mode disables Auto-Learn and fixes communications at 9600-N-8-1. The XR looks only for specific commands sent by the indicator or scale controller. NOTE: This improved Command Mode is for the G2 Controller board.
11.1 XR 4500, XR 4500TL, and XR 6500 Utility Programs Control Commands Control commands are single ASCII characters (preceded by @ and followed by ) that are transmitted to the XR to control additional features such as the built-in traffic light (XR 4500 TL).
11 XR Utility Programs Multi-Drop addressing The XRs using Multi-drop networking must be in Command Mode. The Multi-drop ID (0 to 3) must also be set. (See Parameter 1.4: Multi-Drop ID on page 32). When using Multi-drop, the XR will only respond after it has been selected. To select a display, transmit a # character (ASCII 35) followed by the correct ID number and a character (ASCII 13).
11.2 XR 2000 Utility Programs 11.2 XR 2000 Utility Programs The XR 2000 has several auxiliary functions that may be activated via the CONFIG dip switches on the controller board. PROGRAM SW 8 SW 9 1 – NORMAL Mode (No program) OFF OFF 2 – FREEZE Weight ON OFF 3 – Reserved for future use OFF ON 4 – COMMAND mode. ON ON PROGRAM 1: NORMAL MODE NO SPECIAL PROGRAM IS SELECTED. PROGRAM 2: FREEZE WEIGHT FOR USE WITH CATTLE AUCTIONS, ETC.
11 XR Utility Programs Activating Command Mode 1. To enable command mode, CONFIG dip switches 8 and 9 on the controller board must be set as follows: PROGRAM SW 8 SW 9 4 – COMMAND Mode ON ON Switch settings do not take affect until the XR is reset or powered up again. Transmit a Weight String Use numeric ASCII characters followed by a character.
11.2 3. XR 2000 Utility Programs Send 3 different weights to 3 different scoreboards: “#0 2000LG#1 3000LG#2 5000LG“ 4. Send the text “hello” to scoreboard address 3.
12 Troubleshooting & Error Messages 12 Troubleshooting & Error Messages Problem Cause and/or Probable Solution Unit won’t power up: • • • • Unit has power, but there is no display. • • • Dashes across the display. • • • • Display reads “Err 1”. • • • • Display reads “Err 2”. • • • • Verify ribbon cable connections from controller board to the display board. Check 12V light and fuse on controller board. If the unit is in COMMAND mode, the display will remain blank until data is received.
RS485 light not flashing: • • 20mA light not flashing: • • • RADIO light not flashing: • • COM light not flashing: XR 2000 only • • • • XR Series Installation Instructions Verify the RS485 terminal is being used and check communications wiring at the indicator. Verify that data is being sent to the XR from the indicator and that the data string contains numeric characters. Verify the 20mA terminal is being used and check communications wiring at the indicator.
13 Spare Parts Lists 13 Spare Parts Lists Following are the part numbers for the spare parts needed for the XR series remote displays. Additional Parts for the XR 2000 AWT PN 60339 -4016 XR 2000 REMOTE DISPLAY, COMPLETE ASSY.
Additional Parts for the XR 4500 DESCRIPTION AWT25-500612 60314-0013 AWT25-500616 CONTROLLER BOARD GORTEX BREATHER VENT KEYPAD W/LIGHT SENSOR WINDOW 60339-0048 POWER SUPPLY BOARD 60339-0055 10" RIBBON CHT SENSOR WINDOW 60339-0063 20" RIBBON CABLE 60339-0071 9" GROUND WIRE 60339-0089 11" GROUND WIRE 60339-0097 POWER SUPPLY TO CONTROLLER BOARD CABLE 60339-0105 EXTERNAL POWER CORD 60339-0113 INTEGRATED WIRELESS RADIO MODULE WITH ANTENNA 60339-0121 BASE STATION WIRELESS RADIO MODULE WITH CABL
13 Spare Parts Lists Additional Parts for the XR 4500 TL 60339-3026 DISPLAY DIGIT WITH SIGNAL LIGHT 60339-3034 DISPLAY DIGIT PC BD 60339-2077 VISOR AWT05-503348 POLE MOUNT KIT AWT25-500617 TEMPERATURE OPTION Additional Parts for the XR 6500 DESCRIPTION AWT25-500612 XR CONTROLLER BOARD 60314-0013 GORTEX BREATHER VENT AWT25-500616 56 KEYPAD W/LIGHT SENSOR WINDOW 60339-0048 POWER SUPPLY BOARD 60339-0055 10" RIBBON CABLE 60339-0063 20" RIBBON CABLE 60339-0071 9" GROUND WIRE 60339-0089
14 Specifications Power: • Input - 90 to 240 VAC, 50/60 Hz • 115/230 VAC autosensing power supply • Consumption - XR2000: 25 watt (60 watt max) XR4500, 4500TL, 6500: 60 watt • 6 digit, 7 segment, high intensity (Precision Optical Performance) red LED lamp • 2” characters (XR 2000), 60 foot viewing range 4.5” characters (XR 4500 and XR 4500TL), 275 foot viewing range 6.
14 Specifications 58 XR Series Installation Instructions
Avery Weigh-Tronix USA 1000 Armstrong Dr. Fairmont MN 56031 USA Tel:507-238-4461 Fax:507-238-4195 Email: usinfo@awtxglobal.com www.wtxweb.com Avery Weigh-Tronix UK Foundry Lane, Smethwick, West Midlands, England B66 2LP Tel:+44 (0) 8453 66 77 88 Fax: +44 (0)121 224 8183 Email: info@awtxglobal.com www.averyweigh-tronix.
