KERN FTB, ITB, FTC, ITT, KMB Service Manual
...
KERN & Sohn GmbH
Ziegelei 1
D-72336 Balingen-Frommern
E-Mail: info@kern-sohn.com
Tel: 0049-[0]7433- 9933-0
Fax: 0049-[0]7433-9933-149
Internet: www.kern-sohn.com
GB
Service Manual
Compact Scales
Platform Balances and Terminals
Page 3
KERN FTB/FTC
KERN ITB/ITS/ITT
KERN KMB/KMS/KMT-TM
Version 2.0 03/2007
FTx/ITx-SH-e-0720 3
Contents
1 General .......................................................................................................................................... 5
1.1 How to use this service manual? ....................................................................................................... 5
1.2 Service concept ............................................................................................................................... 5
1.3 Introducing the product group ........................................................................................................... 6
1.4 Safety notes..................................................................................................................................... 7
2 Compact scales, small platform FTB/FTC (weighing pan 200x240mm) ............................................. 8
2.1 Scales with strain gauge weighing cells ............................................................................................. 8
2.2 Scales with strain gauge weighing cell and IP65 protection ................................................................. 12
2.3 Display unit FTB ............................................................................................................................... 16
2.4 Display unit FTC ............................................................................................................................... 18
3 Compact scales, large platform FTB/FTC (weighing pan 240x350mm) .............................................. 20
3.1 Scales with strain gauge weighing cell .............................................................................................. 20
3.2 Scales with strain gauge weighing cell and IP65 protection ................................................................. 25
3.3 Display unit FTB ............................................................................................................................... 29
3.4 Display unit FTC ............................................................................................................................... 31
4 Terminals ....................................................................................................................................... 33
4.1 KMB-TM terminal (ITB) ...................................................................................................................... 33
4.2 KMS-TM terminal (ITS) ...................................................................................................................... 35
4.3 KMT-TM terminal (ITT) ....................................................................................................................... 37
4.4 OptionPac ....................................................................................................................................... 39
4.5 Small parts set................................................................................................................................. 41
5 Replacing components with compact scales .................................................................................... 42
5.1 Important notes ............................................................................................................................... 42
5.2 Replacing the keypad overlay ........................................................................................................... 43
5.3 Replacing the AC adapter.................................................................................................................. 43
5.4 Replacing the battery ........................................................................................................................ 43
5.5 Replacing the charging PCB .............................................................................................................. 44
5.6 Replacing the analog PCB ................................................................................................................ 44
5.7 Replacing the display mounting plate, display unit and digital PCB ...................................................... 45
5.8 Replacing the weighing cell .............................................................................................................. 47
4 FTx/ITx-SH-e-0720
6 Repair of terminals ......................................................................................................................... 49
6.1 Important information ....................................................................................................................... 49
6.2 Disassembling/reassembling the terminal .......................................................................................... 49
6.3 Replacing the keypad overlay ........................................................................................................... 50
6.4 Replacing the AC adapter.................................................................................................................. 50
6.5 Replacing the analog board.............................................................................................................. 50
6.6 Replacing the display mounting plate, display unit, and digital board .................................................. 51
6.7 Repairing the OptionPac ................................................................................................................... 53
7 Scale definition, settings and diagnostics ...................................................................................... 54
7.1 Accessing and using the technician menu ......................................................................................... 54
7.2 Technician menu – Overview ............................................................................................................ 55
7.3 Admissibility for certification (SCALE –> Metrology) ............................................................................. 56
7.4 Selecting the scale to be configured (SCALE –> Scale 1/Scale 2) ......................................................... 56
7.5 Querying the value of the analog/digital converter (SCALE –> Ramp) ................................................... 56
7.6 Serial number of the scale or terminal (SCALE –> Serial Number) ........................................................ 56
7.7 Entering configuration data (SCALE –> Scale Build) ...........................................................................56
7.8 Setting the GEO adjustment value (SCALE –> Geo Value) .................................................................... 58
7.9 Linearization with simultaneous calibration (SCALE –> LIN-CAL) .......................................................... 58
7.10 Basic calibration (SCALE –> Calibration) ........................................................................................... 59
7.11 Activating control mode (SCALE –> Control Mode) .............................................................................. 59
7.12 Settings for the zero point (SCALE –> Zero) ....................................................................................... 59
7.13 Defining MinWeigh value (SCALE–> Minweigh) .................................................................................. 60
7.14 Settings in the “TERMINAL” menu block .............................................................................................. 60
7.15 Setting of country version ................................................................................................................. 60
8 Additional information .................................................................................................................... 61
8.1 Technical data and tolerances .......................................................................................................... 61
8.2 Notes on load cell capacities ............................................................................................................ 66
8.3 Overview of load cells and preloads .................................................................................................. 67
8.4 Table of geo values.......................................................................................................................... 68
8.5 Interface data .................................................................................................................................. 69
8.6 Attaching weighing platforms ............................................................................................................ 71
9 Software ......................................................................................................................................... 74
9.1 Software architecture ........................................................................................................................ 74
9.2 Error messages after service work ..................................................................................................... 75
9.3 Deleting the scale data in the EAROM ................................................................................................. 75
9.4 Loading new scale software into Flash memory .................................................................................. 76
FTx/ITx-SH-e-0720 5
1 General
1.1 How to use this service manual?
This service manual contains instructions for the repair and maintenance work to be performed by service engineers.
It is assumed that the reader is familiar with the operation of the scale and can refer to the relevant operating instructions when
necessary.
1.1.1 Layout of this service manual
This manual comprises nine main sections:
• General: This section which you are looking at now gives instructions on using the service manual, and also provides an
overview of the scales covered by it.
• FTB/FTC (small platform): This section contains the exploded view drawings and spare parts lists for compact scales
with the small platform (weighing pan 200 x 240 mm).
• FTB/FTC (large platform): This section contains the exploded view drawings and spare parts lists for compact scales
with the large platform (weighing pan 240 x 350 mm).
• KMB-/KMS-/KMT-TM: This section contains the exploded view drawings and spare parts lists for terminals.
• Replacing components with compact scales: This section describes all repair work and the replacement of components
for compact scales with large and small platforms. It also contains a list of the tools and working aids required.
• Replacing components with terminals: This section describes all repair work and the replacement of components for
terminals. It also contains a list of the tools and working aids required.
• Scale definition, settings and diagnostics: This section describes how to enter scale setup data, make various settings
and use the diagonstic functions.
• Additional information: This section contains certification tolerances and other technical information plus an overview of all
weighing cells and preloads and a table of geographical adjustment values.
• Software: This section contains information on the various software versions and their compatibility. It also describes
typical error messages that can appear following service work and provides troubleshooting instructions.
1.1.2 Working with the service manual
The exploded view drawings are provided as a guide for disassembly and assembly work and for identifying the order
numbers for spare parts.
When ordering spare parts, please use the information given in the spare parts lists. The item numbers in the first column
"Item" correspond to those on the exploded view drawing opposite.
1.2 Service concept
The scales have been designed so that defective components can be replaced with just a few simple tools. Technician mode
and supervisor mode will already be familiar to you, since this concept has already been used in other KERN & SOHN
products. As almost all parameters can be configured with the keyboard of the scale.
As you can see, we have kept it simple for efficient servicing.
6 FTx/ITx-SH-e-0720
1.3 Introducing the product group
The product group comprises the following models, which are all covered by this manual:
FTB, ITB, KMB-TM
The FTB-,ITB-scales and the KMB-terminal possess basic weighing functions for simple weighing duties. They are IP65
versions.
FTC, ITS, KMS-TM
In addition to basic weighing functions, counting scales also have built-in functions for piece counting. An extended keypad
and a display with a visual weighing-in aid are available in order to use these additional functions.
ITT, KMT-TM
In addition to the simple piece counting functions these scales have a numeric keypad as well as totalising, checking and
ID functions.
Common features
Apart from the differences with regard to functions and operating and display elements, all models have the following
common features:
– All models are designed either for direct connection to the AC power line or contain a built-in rechargeable battery.
Rechargeable battery scales are connected to the AC power line via an AC adapter.
– All models are also available as certifiable instruments.
– The weighing cells are strain gauge.
FTx/ITx-SH-e-0720 7
1.4 Safety notes
When carrying out service or repair work, always observe the following:
1.5 Environmental protection
Disposal of rechargeable batteries
Please note all current environmental directives when disposing of the terminal. If
the terminal is equipped with a rechargeable battery: The nickel-metal-hydride
(NiMH) storage battery may not be disposed of in the normal refuse. Please
observe local regulations when disposing of environmentally harmful materials.
Disposal of electronic components
Dispose of defective components in strict compliance with all local and national
regulations! In many countries electronic components are classified as hazardous
waste for whose disposal there are special regulations. In some countries
electronic components are collected separately for recycling. If necessary, find out
the applicable regulations from the local authorities!
• Before opening the scale, isolate it from the AC power line (pull out the plug).
• The scales contain precision electronic components that are sensitive to elec-
trostatic discharge. We recommend that you wear a grounding wrist strap
when doing any work in the interior of the scale, in order to prevent any
electrostatic charge building up. Grounding wrist straps are commercially
available from electronic component suppliers.
• Servicing work in explosion hazard zones is strictly prohibited! Ignition
power could inadvertently be generated, causing an explosion. Servicing work
should therefore only be undertaken in secure areas. Please also observe all
special instructions in this service manual relating to work on instruments that
are approved for use in potentially explosive environments. Such instructions
are indicated by the adjacent symbol.
8 FTx/ITx-SH-e-0720
2 Compact scales, small platform
FTB/FTC (weighing pan 200x240mm)
2.1 Scales with strain gauge weighing cells
2
3
4
1
6
7
5
8
FTx/ITx-SH-e-0720 9
Item Qty. Description Order No.
1 1 weighing pan 200 x 240 mm 21203071
2 4 rubber cushions
1)
21203073
3 2 countersunk Torx screw M6 x 30 *
4 1 pan support plate 200 x 240 mm –
5 1 housing, with small platform –
6 1 keypad overlay Chap. 2.3 – 2.4
7 1 mounting plate and display unit (digital PCB with LCD and backlighting unit) Chap. 2.3 – 2.4
8 2 EMV clamp 21203480
* included in the small parts set (Chapter 4.5)
1)
New rubber cushions have a hole in the surface to assist with assembly. A pin can be used to insert the cushion into the
corresponding drilled hole in the load plate support
10 FTx/ITx-SH-e-0720
Scales with strain gauge weighing cells (continued)
1
2
3
6
5
4
7
8
9
10
16
11
17
15
13
12
18
14
19
19c
19d
19b
19a
FTx/ITx-SH-e-0720 11
Item Qty. Description Order No.
1 4 adjustable foot Ø 44 mm (M10 x 0.75 mm) 21203434
2 6 countersunk Torx screw M4 x 12 *
3 1 bottom plate for small platform model –
4 4 button head Torx screw M4 x 12 *
5 4 wide flange washer 4.3 x 20 *
6 4 overload spring **
7 1 overload stop adjustment screw (with certain production series only) **
8 2 countersunk Torx screw M6 x 16 *
9 1 overload plate for small platform model –
10 1 weighing cell with cable (certifiable)
weighing range 3 kg:
LC0765-5-MRV (Standard cell) 21203873
LC0765-5-6TV (Premium cell) 21203877
weighing range 6 kg:
LC0765-10-MRV (Standard cell) 21203874
LC0765-10-6TV (Premium cell) 21203878
11 1 bench AC adapter (always order together with item 16):
EURO version 22011363
USA version 22011364
UK version 22011365
JAPAN version 22011366
Australian version 22011367
external power supply unit (battery charger) for operation with a storage battery
(without power cable) 22011300
socket for external power supply unit 22011311
12 2 spring clip *
13 1 analog PCB BBA AN DMS 7k 21203092
14 1 RS cable 460 mm 21203168
15 1 A/D cable 110 mm, for small platform model 21203164
16 1 adhesive patch for AC adapter or battery (for battery version order 2 pcs.) 21203184
17 1 RS connector plate –
(various types, depending on the equipment)
18 4 raised cheese head Torx screw M4 x 6 *
19 for scales with AccuPac only:
19a 1 accu 14.4V NiMH (always order together with item 16) 22011349
19b 1 battery connection cable –
19c 1 print charger NiMH 22011351
19d 1 battery cable (charging PCB – analog PCB) 21203233
*included in the small parts set (Chapter 4.5) ** see Chapter 5.8 "Replacing the weighing cell"
19d 1
battery cable (charging PCB - analog PCB)
21203233
12 FTx/ITx-SH-e-0720
2.2 Scales with strain gauge weighing cell and IP65 protection
1
2
3
4
5
6
7
8
9
FTx/ITx-SH-e-0720 13
Item Qty. Description Order No.
1 1 packing for cover plate 21203235
2 1 cover plate –
3 2 countersunk Torx screw M3 x 8 *
4 1 flange D = 100mm –
5 1 diap hragm 21203077
6 1 flange D = 58mm –
7 3 countersunk Torx screw M3 x 10 *
8 4 countersunk Torx screw M3 x 8 *
9 2 EMC clamp 21203480
* included in the small parts set (Chapter 4.5)
Note: Parts of the scale not numbered in the illustration are included in the normal version (Chapter 2.1).
14 FTx/ITx-SH-e-0720
Scales with strain gauge weighing cell and IP65 protection (continued)
6
2
1
3
5
4
8
10
9
8
10
9
FTx/ITx-SH-e-0720 15
Item Qty. Description Order No.
1 1 bottom plate for small platform model IP65 version 21203511
2 1 RS connector plate IP65 version (various types, depending on the equipment) –
3 1 air supply/extraction filter 21203860
4 1 packing for RS connector plate 21203236
5 6 raised cheese head Torx screw M4 x 6 *
6 1 RS cable 460mm IP65 21203717
8 1 pressure equalizer 21203611
9 1 pressure equalizer tube LA 21203862
10 1 adhesive patch for pressure equalizer 21203184
* included in the small parts set (Chapter 4.5)
Note: Parts of the scale not numbered in the illustration are included in the normal version (Chapter 2.1).
16 FTx/ITx-SH-e-0720
2.3 Display unit FTB
1
2
3
4
5
6
FTx/ITx-SH-e-0720 17
Item Qty. Description Order No.
1 1 keypad overlay for small platform model 22011400
2 1 display mounting plate (always order together with item 1) 21203120
3 1 LCD 21203134
4 1 backlighting unit 21203136
5 1 digital PCB with FLASH Memory Chip (soldered)
1)
21204025
6 1 Torx oval head tapping screw 2.9 x 13 (red) *
* included in the small parts set (Chapter 4.5)
1)
see Chapter 9.4 for information on loading the software
18 FTx/ITx-SH-e-0720
2.4 Display unit FTC
1
2
3
4
5
6
FTx/ITx-SH-e-0720 19
Item Qty. Description Order No.
1 1 keypad overlay for small platform model 22011401
2 1 BC display mounting plate (always order together with item 1) 21203120
3 1 LCD 21203687
4 1 backlighting unit 21203137
5 1 Digital PCB with FLASH Memory Chip soldered
1)
21204025
6 1 Torx oval head tapping screw 2.9 x 13 (red) *
* included in the small parts set (Chapter 4.5)
1)
see Chapter 9.4 for information on loading the software
20 FTx/ITx-SH-e-0720
2
3
4
1
6
7
5
8
3 Compact scales, large platform
FTB/FTC (weighing pan 240x350mm)
3.1 Scales with strain gauge weighing cell
FTx/ITx-SH-e-0720 21
Item Qty. Description Order No.
1 1 weighing pan 240 x 350 mm 21203072
2 4 rubber cushions
1)
21203073
3 2 countersunk Torx screw M6 x 30 *
4 1 pan support plate 240 x 350 mm –
5 1 housing, large platform –
6 1 keypad overlay Chap. 3.3 – 3.4
7 1 mounting plate and display unit (digital PCB with LCD and backlighting unit) Chap. 3.3 – 3.4
8 2 EMC clamp 21203480
* included in the small parts set (Chapter 4.5)
1)
New rubber cushions have a hole in the surface to assist with assembly. A pin can be used to insert the cushion into the
corresponding drilled hole in the load plate support
22 FTx/ITx-SH-e-0720
Scales with strain gauge weighing cell (continued)
1
3
2
7
5
4
11
16
17
18
14
19
19c
19d
19b
19a
10
9
8
6
12
15
13
FTx/ITx-SH-e-0720 23
Item Qty. Description Order No.
1 4 adjustable foot Ø 55mm (M10 x 0.75 mm) 21203433
2 11 countersunk Torx screw M4 x 10 *
3 1 bottom plate for large platform model –
4 4 button head Torx screw M5 x 12 *
5 4 wide flange washer 5.3 x 20 *
6 4 overload spring **
7 1 overload stop adjustment screw (with specific production series only) **
8 2 countersunk Torx screw M6 x 16 *
9 1 overload plate for large platform model –
10 1 weighing cell with cable (certifiable)
weighing range 15 kg:
LC0785-20-MRV (standard cell) 21203885
LC0785-20-6TV (premium cell) 21203889
weighing range 35 kg:
LC0785-50-MRV (standard cell) 21203886
LC0785-50-6TV (premium cell) 21203890
weighing range 60 kg:
LC0785-100-MRV (standard cell) 21203887
LC0785-100-6TV (premium cell) 21203891
11 1 bench AC adapter (always order together with item 16):
EURO version 22011363
USA version 22011364
UK version 22011365
JAPAN version 22011366
Australian version 22011367
external power supply unit (battery charger) for operation with a storage battery
(without power cable) 22011300
socket for external power supply 22011311
12 2 spring clip *
13 1 analog PCB BBA AN DMS 7k 21203092
14 1 RS cable 460 mm 21203168
15 1 A/D cable 300 mm for large platform model 21203167
16 1 adhesive patch for AC adapter 21203184
2 adhesive patch for battery, thick 21255260
2 adhesive patch for battery, thin 21203184
17 1 RS connector plate (various types, depending on the equipment) –
18 4 raised cheese head Torx screw M4 x 8 *
24 FTx/ITx-SH-e-0720
19 for scales with with AccuPac only:
19a 1 accu 14,4V NiMH (always order together with item 16) 22011349
19b 1 battery connection cable –
19c 1 print charger NiMH 22011351
19d 1 battery cable (charging PCB – analog PCB) 21203233
* included in the small parts set (Chapter 4.5)
** see section 5.8 "Replacing the weighing cell"
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