Rice Lake Counting Scales User Manual

IQ6200/6500
Counting Scales
Installation Manual
32224

Contents

About this Manual................................................................................................................................. 1
1.0 Introduction .............................................................................................................................. 1
1.1 Scale Resolution.............................................................................................. 2
2.0 Installation and Start-Up .......................................................................................................... 2
2.1 Unpacking and Inspecting ...............................................................................2
2.2 Repacking........................................................................................................ 2
2.3 Unlocking and Locking ....................................................................................3
2.5 Powering-Up the IQ6200 ................................................................................. 3
2.5.1 Sleep Time Function ................................................................................................... 4
2.6 Powering-Up the IQ6500 ................................................................................. 4
3.0 Configuration ............................................................................................................................ 5
3.1 IQ6200 Keypad and Display Panel.................................................................. 5
3.1.1 IQ6200 Keypad ........................................................................................................... 5
3.1.2 IQ6200 Indicator Lamps.............................................................................................. 7
3.2 IQ6500 Keypad and Display Panel.................................................................. 7
3.2.1 IQ6500 Keypad ........................................................................................................... 7
3.2.2 IQ6500 Indicator Lamps.............................................................................................. 8
3.3 Initial Performance Testing.............................................................................. 8
3.3.1 Unit Weight Display and Unit Weight Key Entry.......................................................... 8
3.3.2 One-Touch Tare.......................................................................................................... 8
3.3.3 Digital Tare Entry ........................................................................................................ 9
3.3.4 Weight, Unit Weight, and Quantity Display ................................................................. 9
3.3.5 Accumulation...............................................................................................................9
3.3.6 Fixed Sample .............................................................................................................. 9
4.0 Operating Instructions ............................................................................................................ 10
4.1 Determining a Unit Weight............................................................................. 10
4.1.1 Insufficient Sample.................................................................................................... 10
4.1.2 Improving Unit Weight with Recomputation .............................................................. 10
4.1.3 Entering a Known Unit Weight .................................................................................. 11
4.1.4 Using the IQ6500 Dual Scale.................................................................................... 11
4.2 Parts Counting............................................................................................... 11
4.2.1 Counting Parts on the Scale Platform ....................................................................... 11
4.2.2 Counting Parts into a Container ................................................................................ 11
4.2.3 Counting Parts in a Pre-Filled Container................................................................... 11
4.3 Negative Parts Counting................................................................................ 12
4.4 Accumulation ................................................................................................. 12
4.5 Programming Setpoints ................................................................................. 12
4.6 Parts “In-Out” Operation ................................................................................ 13
4.7 Sample and Count......................................................................................... 14
4.8 Operation Quick Tips..................................................................................... 14
4.9 Access Codes................................................................................................ 14
Copyright ©1998 Rice Lake Weighing Systems. All rights reserved. Printed in the United States of America.
Specifications subject to change without notice.
April 1998
39
5.0 Data Storage ........................................................................................................................... 15
5.1 Programming Unit Weight for a Code Number in Weighing Mode ................ 16
5.1.1 Reviewing Code Numbers Already in Memory ......................................................... 16
5.2 Check or Change Code Number Data........................................................... 16
5.2.1 Printing Code Number Formats ................................................................................ 16
5.3 Delete Items from Memory ............................................................................17
5.3.1 Deleting a Particular Code ........................................................................................ 17
5.3.2 Deleting Entire Memory............................................................................................. 17
5.3.3 Deleting All Inventory Values from Memory .............................................................. 17
5.3.4 Deleting All Unit Weights from Memory .................................................................... 17
5.3.5 Deleting All Tare Weights from Memory ................................................................... 17
5.3.6 Deleting All Part Numbers from Memory................................................................... 17
6.0 Setting Configuration.............................................................................................................. 18
6.1 Configuring Grads and Decimal Positions..................................................... 18
6.2 Configuring Display Resolution .....................................................................19
6.2.1 IQ6200 Display Resolution........................................................................................ 19
6.2.2 IQ6500 Display Resolution........................................................................................ 19
6.3 IQ6200 Configuration ....................................................................................20
6.4 IQ6500 Configuration ....................................................................................21
6.5 IQ6500 Second Channel Setup..................................................................... 23
7.0 Calibration .............................................................................................................................. 24
8.0 Display Messages................................................................................................................... 25
9.0 Optional Equipment ................................................................................................................ 26
9.1 Bar Code Input ..............................................................................................26
9.2 RS-232 Communications Port ....................................................................... 26
9.2.1 Connector Type......................................................................................................... 26
9.2.2 Baud Rate Selection ................................................................................................. 27
9.2.3 Data Format .............................................................................................................. 27
9.2.4 Data Output Format .................................................................................................. 27
9.2.5 Data Input Format ..................................................................................................... 27
9.2.6 RS-232 Installation Instructions ................................................................................ 28
9.3 IQ6500 Printer Configuration......................................................................... 29
9.3.1 Pin Connections ........................................................................................................ 29
9.3.2 Spec Code Settings .................................................................................................. 29
9.3.3 Sample Tickets.......................................................................................................... 30
9.3.4 Setting the Ticket Sequence Number ....................................................................... 30
9.4 Setpoint Outputs............................................................................................ 31
9.5 IQ6200 Battery Pack Installation ...................................................................32
10.0 Maintenance........................................................................................................................... 33
10.1 External Maintenance.................................................................................... 33
10.2 Internal Maintenance ..................................................................................... 33
10.3 Load Cell Replacement Procedure................................................................ 34
11.0 Specifications......................................................................................................................... 35
11.1 IQ6200........................................................................................................... 35
11.2 IQ6500........................................................................................................... 35
12.0 Appendix................................................................................................................................. 36
12.1 Code Number Form....................................................................................... 36
12.2 Character Code List....................................................................................... 36
12.3 Eltron Printer Interface................................................................................... 37
IQ6200/6500 Limited Warranty........................................................................................................... 38

About this Manual

This manual contains operating procedures for the IQ6200, IQ6500, and IQ6500 dual counting scales and provides the user with all the information necessary for set-up and operation. This manual is organized based on the procedures you will likely follow when setting-up and using your counting scale. When information is applicable to all three scales you will see the term “IQ6200/6500”. If information is specific to only one type of scale, a single name “IQ6200” or “IQ6500” appears. (IQ6500 includes the dual scale unless otherwise noted.) Keypad keys are shown in bold uppercase characters.

1.0 Introduction

The IQ6200/6500 counting scales offer practical solutions to a full range of precision counting applications. There are a variety of models available ranging from a weight capacity of 0.5 through 150 pounds utilizing an internally mounted load cell; there is also a full range from 0.5 through 60,000 pounds on an optional external second channel. Other features, such as 100-item memory, over/under weight and quantity checking capabil­ity based on programmable setpoint data, and the IQ6200’s optional battery power for stand-alone counting applications make the IQ series an obvi­ous and practical choice for your parts counting needs.
Sample Platform
Bulk Platform
Counting scale accuracy is primarily determined by the following factors:
Sample size (number of pieces)
Keypad
Total sample size as a percentage of full
scale capacity
Piece to piece weight variation
Sample weight is the most common cause of parts counting inaccuracy because operators tend to use the minimum number of sample pieces. For ex­ample, on an IQ6500 with a sample of 10 pieces and a total sample weight of 0.2% of full scale
Weight Display
Quantity Display
capacity, sample weight resolution is plus or minus (±) 1 part in 1000. This will give you a counting error of ±0.1 or higher. Increasing the total sample
IQ6500 Dual Counting Scale
weight to 0.5% of full scale capacity (25 pieces) would lower the counting error to ± 0.04 or higher. Weight display resolution does not affect the counting accuracy of your IQ6500. Displayed weight resolution is up to 1 part in 10,000.
On an IQ6200, a sample of 10 pieces and a total sample weight of 0.2% of full scale capacity would provide a sample weight resolution of (±) 1 part in 150 and a counting error of ±0.66 or higher. Increasing the total sample weight to 0.5% of full scale capacity would lower the counting error to ±0.26 or higher.
Unit-Weight Display
There is a direct relationship between piece to piece weight variation and counting accuracy. To achieve maximum efficiency from your counting scale, the sample piece weight should be as close as possible to the average piece weight.
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1.1 Scale Resolution

Counting scales specify two types of resolution:
Weight (or external)
Counting (or internal)
Weight resolution is displayed in increments of the full scale capacity which is divided into weight incre­ments. For example, a 5-lb. scale divided into 10000 weight increments would display weight with 0.0005 lb. incremental elements (10000 divisions x 0.005 lb. = 5.0 lbs.).
Counting resolution is based on the internal resolution of the scale. The weight and counting resolutions for the IQ6200/6500 scales are found in Section 6.2.

1.2 Choosing the Best Sample

To choose a sample that will give you the greatest accuracy:
The smallest part to be counted must be greater than one counting resolution of the scale.
A 10-piece sample of the smallest part must weigh more than .1% of the scale’s capacity to be
accepted.
The gross capacity of the scale should be greater than the heaviest box of any part to be counted.

2.0 Installation and Start-Up

For information about installing and operating optional equipment, see Section 9.

2.1 Unpacking and Inspecting

Each component of the IQ6200/6500 system is packed in a specially designed carton. Remove each compo­nent from its carton, separate the component from its polystyrene shell assembly, and set the assembly aside. Inspect the carton interior and inner panels to be sure that all accessories have been removed from the carton. Be sure to replace all packing materials within the carton set. Store the carton set in a secure area so it is available whenever shipment of the scale is required.
Immediately after unpacking, a visual inspection of the instrument should be performed. The shipper and Rice Lake Weighing Systems should be notified immediately if any damage occurred during transportation. Instructions for assessment of damage and further procedures will then be determined.

2.2 Repacking

If the IQ6200/6500 counting scale must be returned for modification, calibration, or repair, be sure that it is properly packed with sufficient cushioning materials and that it is locked to prevent damage to the load cells (see Section 2.3).
Whenever possible, the original carton assembly should be retained for this purpose. Any damage caused by improper packaging will not be covered by warranty.
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2.3 Unlocking and Locking

Your IQ6200/6500 scale is delivered in a locked position to prevent damage to the load cells during shipment. Use the following procedure to unlock the scale.
1. On underside of scale, use wrench to remove nut (1).
2. Use allen wrench provided with scale to turn bolt (2) in a counterclockwise direction and remove. Two nuts and two bolts must be removed on an IQ6500 dual scale as shown in diagram to right.
Nuts and bolts should be taped to the bottom of the scale or stored in some other safe location for possible future shipment. Scales must
be locked prior to shipment.
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2.4 Setting-Up
1. Place scale on a level surface.
2. While watching level bubble guide on front of scale, level scale using adjustable legs.

2.5 Powering-Up the IQ6200

The IQ6200 can be operated from an AC adaptor cord or with an optional rechargeable battery pack (DC power) that allows the unit to be completely portable. A fully-charged battery allows approximately 11 hours of continuous operation and then requires approximately 8 hours of recharging. The battery will recharge when the AC adaptor cord is plugged in regardless of whether the scale is on.
2
To power-up the IQ6200 with the AC adaptor cord:
1. Plug AC adaptor cord into a grounded AC 117 VAC receptacle.
2. Press ON/OFF and allow scale to warm up for 10 minutes. The display momentarily shows revision number, shows all digits from 0 to 9 in a “count-up” mode, goes blank, shows all 8s, and then enters regular weighing mode.
To power-up the IQ6200 with the battery option:
1. Remove AC adaptor cord from back of scale.
2. Press ON/OFF and allow scale to warm up for 10 minutes. The display momentarily shows revision number, shows all digits from 0 to 9 in a “count-up” mode, goes blank, shows all 8s, and then enters regular weighing mode.
Note:
If the scale displays erratic data, it may be caused by a power transient. Turn the scale off and momentarily unplug it from the wall outlet. Then restart by plugging the scale back in and pressing ON/OFF. The scale will go through a display check, and no warm up is needed.
3
2.5.1 Sleep Time Function
The IQ6200 includes a “sleep time” function that turns the scale off after a preset number of minutes if the scale is undisturbed (no keys are pressed and no weight is placed on the platform). This function works with AC or DC power and helps to prolong battery life when the battery is being used. The default (factory) setting is five minutes.
To set the sleep time:
1. Press MODE.
2. Use keypad to enter number of minutes, 01 to 99, until scale powers down. Entering “00” causes continuous operation.
3. Press +.
4. Press MODE. The displays return to weighing mode.
To check sleep time settings:
1. Press MODE.
2. Press +. Weight display shows P-oFF and Quantity display shows XX, with XX being number of minutes before power-down.
3. Press MODE. The displays return to weighing mode.

2.6 Powering-Up the IQ6500

1. Plug AC power cord into a grounded 115 VAC receptacle.
Caution
!
2. Press ON/OFF, and allow scale to warm up for 10 minutes. The display momentarily shows revision number, shows all digits from 0 to 9 in a “count-up” mode, goes blank, shows all 8s, and then enters regular weighing mode.
Notes:
If the scale has been connected to power while in the off condition, no warm-up is necessary.
If a second channel preamp has been installed, be sure that an external platform or a “dummy plug” is plugged in to the second channel.
When the scale is plugged in but not turned on, the Insuff. lamp is lit.
If the scale displays erratic data, it may be caused by a power transient. Turn the scale off and mo-
mentarily unplug it from the wall outlet. Then restart by plugging the scale back in and pressing ON/ OFF. The scale goes through a display check, and no warm up is needed.

2.7 Setting Date and Time on the IQ6500

You can set the date and time that you want to appear on IQ6500 print tickets. The IQ6200 does not use this function. To set the date and time:
1. Press MODE.
2. Use keypad to enter date and time in the format mmddyyhhhh, where hhhh is the time in 24-hour format (0000 is 12:00 a.m., 2300 is 11:00 p.m.). For example, to set the date and time for May 1, 1997 at 9:45 p.m., enter: 0501972145.
3. Press DATE.
4. Press MODE twice to return to weighing mode.
To view the current date and time setup:
1. Press MODE.
2. Press DATE. The date is shown in the upper displays, time is shown in the Quantity display.
3. Press MODE twice to return to weighing mode.
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3.0 Configuration

Sections 3.1 and 3.2 show and describe the keypads and display panels for the IQ6200 and IQ6500 scales.

3.1 IQ6200 Keypad and Display Panel

The following figure shows the IQ6200 display panel and keypad.
WEIGHT
lb
UNIT-WEIGHT
per 1000pcs
IQ
. . . . . .
ZERO GROSS RECOMP
TARE INSUFF. MEMORY
QUANTITY
6200
3.1.1 IQ6200 Keypad
The following table identifies the IQ6200 display keys and their functions.
7 8 9
4 5 6
1 2 3
Numeric Keypad
These keys let you enter numeric values in the system. Normally, you key a number and then press a function key. Each digit appears on the display screen as entered.
If you make a mistake entering a number, press CLEAR to erase a single digit. Continue pressing CLEAR to erase the remaining digits as necessary.
. . . . . .
OUT IN PROG.
LOW BAT.
kg lb
kg
lb
PIECES
TARE
RE
ZERO
UNIT
WEIGHT
7 8 9
4 5 6
1 2 3
0 .
NET/
GROSS
MOVEMENT
MODE
CLEAR
ON
OFF
-
+
*
#
0 .
CLEAR
.
MODE
Clear
Clears keyed-in data from the display starting with the last digit entered.
. (decimal)
Used to correctly enter numbers by showing the decimal point.
must be entered before the decimal point
“0.250”. Also used to display the code number currently in use.
. For example, .250 would be entered as
A numeric value
Mode
Toggles between the operating mode and the program mode. The PROG lamp is lit when the scale is in program mode and the Weight display reads ProG. The Quantity display shows the letter “C” and the total number of codes in memory.
5
RE
ZERO
T ARE
PIECES
kg
lb
UNIT
WEIGHT
Rezero
Eliminates weight from the Weight display with no tare in the system and causes it to show a true 0. The rezero button will not function when the indicator is in motion.
Tare
Zeroes the weight display by placing a displayed weight into the tare register. The system must be in a standstill condition before a tare can be registered. The tare register is normally used to store a value such as a container weight.
Pieces
Sets the number of sample pieces. Press after placing your 10-piece sample on the platform or keying in the sample size number with the numeric keys. On multichannel units, the correct scale must be selected.
kg - lb
Toggles the display between pound (lb) and kilogram (kg). The scale powers up in the pound mode.
Unit Weight
Used to enter weight per 1000 count of pieces or is pressed after you enter a weight value using the keypad.
When entering an average piece weight, remember to enter the total weight of 1000 pieces. This method provides an additional three decimal places of resolution in piece count calculations. For example, the weight per 1000 count of pieces weighing 0.1 lb each would be 100.0 lb (0.1 x 1000).
NET/
GROSS
MOVEMENT
ON
OFF
-
+
*
Net/Gross - Movement
Toggles between net weight and gross weight display modes. In the gross display mode the gross weight is displayed, the gross annunciator is lit, and a computation of piece weight is not available. A tare must be in the system to enter the net mode. In the net mode, the tare annunciator is lit.
On - Off
Powers up and powers down the scale.
- (minus)
Used to subtract parts in an accumulation operation.
+ (plus)
Used to add parts in an accumulation operation.
* (total)
Used to total an accumulation operation and exit the program mode.
#
# (code)
Used to enter product code numbers, enter parts into the scale inventory, and remove existing parts.
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3.1.2 IQ6200 Indicator Lamps
Use the following table to identify display indicator lamps that may be illuminated during operation.
Lamp Meaning
ZERO Scale is within 1/4 division of true zero TARE Presence of a tare weight GROSS Gross weight is shown INSUFF Sample size is too small RECOMP Unit weight may be recalculated by pressing PIECES MEMORY An accumulated total is in memory OUT Quantities being removed from inventory total IN Quantities being added to inventory total LOW BAT Scale battery power is low PROG Scale is in program mode kg Scale weighing in kg lb Scale weighing in lbs

3.2 IQ6500 Keypad and Display Panel

The following figure shows the IQ6500 display panel and keypad.
WEIGHT
IQ
QUANTITY
6500
lb
. . . . . . . . . . . .
ZERO GROSS RECOMP OUT SCALE2
TARE INSUFF. MEMORY IN PROG.
UNIT-WEIGHT
kg lb
per 1000pcs
kg
lb
SCALE
1.2
PIECES
TARE
RE
ZERO
UNIT
WEIGHT
7 8 9
4 5 6
1 2 3
0 .
NET/
GROSS
MOVEMENT
MODE
PART #
DATE
CLEAR
3.2.1 IQ6500 Keypad
Most of the keys on the IQ6500 also exist on the IQ6200. The following table identifies the keys that are unique to the IQ6500. See the IQ6200 keypad table for the remaining keypad descriptions.
SCALE
1.2
Scale - 1.2
Toggles between the two platforms on an IQ6500 dual scale or between the main platform and a remote scale.
ON
OFF
-
+
*
#
*
* (total)
Uses include totaling an accumulation operation, exiting the program mode, and initiating the print function.
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-
PART #
– / PART#
Used to subtract parts from an accumulation operation or view an alternate part number.
+
DATE
+ / DATE
Used to add parts from an accumulation operation or set the date and time in the program mode.
3.2.2 IQ6500 Indicator Lamps
Use the following table to identify display indicator lamps that may be illuminated during operation.
Lamp Function
ZERO Scale is within 1/4 division of true zero TARE Presence of a tare weight GROSS Gross weight is shown INSUFF Sample size is too small RECOMP Unit weight may be recalculated when lit by pressing the PIECES key MEMORY An accumulated total is in memory OUT Quantities being removed from inventory total IN Quantities being added to inventory total SCALE2 Scale 2 in use PROG Scale is in program mode kg Scale weighing in kg lb Scale weighing in lb

3.3 Initial Performance Testing

Use the procedures in this section to test your IQ6200/6500 keypad and display prior to its initial use. The procedures verify proper operation of the scale’s keypad and displays. Tests are available for the following functions:
Key Entry of Unit Weight
One-Touch Tare
Digital Tare Entry
Weight, Unit Weight, and Quantity Displays
Accumulation
User-Determined Sample
3.3.1 Unit Weight Display and Unit Weight Key Entry
1. Press 0, then UNIT WEIGHT to clear any unit weight.
2. Press 1 five times, then UNIT WEIGHT once. The Unit Weight display now shows 11111.
3. Press 0, then UNIT WEIGHT to clear the display.
4. Repeat for each number (2, 3....0).
5. Check decimal entry by entering 12.34, then press UNIT WEIGHT.
3.3.2 One-Touch Tare
1. Press 0, then TARE to reset any tare.
2. Press REZERO to re-zero scale.
3. Place empty container on scale, then press TARE once. The Weight display should now show zero with empty container on scale.
4. Remove container. With nothing on the scale, press TARE to reset tare to zero.
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3.3.3 Digital Tare Entry
1. Press 0, then TARE to reset any tare.
2. Press REZERO. After resetting, displays show zero.
3. Use keypad to enter number 0.2, then press TARE. For digital tare entry, decimal must be in appro-
priate place as they would be displayed in Weight display. For example, .250 would be entered as “0.250”, not “.250”. The Weight display shows weight entered with a negative sign indicating that it is a tare weight.
3.3.4 Weight, Unit Weight, and Quantity Display
1. From previous step, there should be a tare weight showing in Weight display. If it has been acciden-
tally cleared out, re-enter weight since Quantity display will not be activated unless a weight is displayed.
2. Enter number 123 through keypad and press PIECES. The display shows all dashes momentarily and
then an accuracy number such as ACC 99.98 (99.98%) is displayed on the Weight and Unit Weight displays. After a moment, 123 appears in Quantity window, and a unit weight is also computed and displayed. This operation takes a few seconds.
Note:
The accuracy number function can be turned off (default setting) using SPEC09. For more informa­tion, see Section 6.0, Setting Configuration.
3.3.5 Accumulation
After the previous step, the Quantity display shows 123.
1. Press +. Blank lines are momentarily shown, then Unit Weight display shows 123. The Quantity
display shows totAL. The memory lamp glows. After a moment, scale resumes operation mode. Since weight and unit weight have not been changed, Quantity display continues to show 123.
2. Press + again. The Weight display momentarily goes blank, Quantity display shows totAL, and Unit
Weight display shows accumulated value of 246.
3. Press * to clear memory. The Memory lamp goes out.
3.3.6 Fixed Sample
After the previous test, the Weight display shows -0.2.
1. Press 0, then UNIT WEIGHT. The unit weight is cleared.
2. Press PIECES. The Quantity display shows 10 and a unit weight is displayed.
3. Press TARE to clear tare weight.
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4.0 Operating Instructions

This section provides detailed instructions for operating your IQ6200/6500. Basic to all counting procedures is the requirement to establish the average unit weight of the parts to be counted. Typically this is done by taking a representative sample quantity of the parts, determining the total weight of that sample, and then obtaining the average unit weight by computation. The IQ6200/6500 does this all in one step. The IQ6200/ 6500 permits determination of average part weight to a very precise value by combining the following com­putational functions:
Insufficient sample level protection
Selectable accuracy enhancement by recomputation

4.1 Determining a Unit Weight

To determine a unit weight:
1. From net weighing mode, put a sample number of pieces, 10 or more, on platform. If the pieces being counted are small, count out the sample in your hand, then place all of the sample pieces on the scale at the same time.
2. If you used a sample of 10, press PIECES (this key defaults to 10). If you used a sample number other than 10, key-in number of sample pieces with numeric keys, then press PIECES. The unit weight per 1000 pieces is displayed on Unit Weight display.
4.1.1 Insufficient Sample
When sample pieces are put on the platform and the number of pieces is not sufficient, the Insuff lamp is lit. The Add line, followed by the number of pieces to add, appears in the Weight display when PIECES is pressed. This means that the weight of the sample is insufficient for the scale to make an accurate calculation. An example would be trying to weigh something as light as 10 paper clips on a 50 lb. IQ6200/6500 scale. You can override this message by pressing PIECES a second time without adding additional parts. However, using an insufficient sample may adversely affect scale accuracy.
To correct an insufficient sample, add the number of pieces requested and press PIECES. The weight, unit weight, and quantity of the item appears in each display.
The Insuff lamp normally lights when the sample weight is less than 0.1% of full scale capacity. To verify or change the threshold at which the Insuff lamp lights, do the following:
1. Press MODE. Hold REZERO and press PIECES.
2. The display should show the value 0.1 for normal operation. To change the Insuff lamp threshold, enter a value between 0.0 (off) and 0.9 (lamp on if sample is less than 0.9% of full scale capacity).
3. Press MODE twice to exit.
4.1.2 Improving Unit Weight with Recomputation
When the unit weight is developed through sampling, the accuracy of that computation can be improved by increasing the sample size using the recompute feature. This function works only when the RECOMP annunciator is on.
For pieces with a large weight variance, the average unit weight can be more precisely determined by using a large quantity in the sample. The scale determines the recompute range based on the existing sample. To recompute a sample:
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