CS5000
Users Manual
Intercomp Co.
3839 County Road 116
Medina MN 55340 U.S.A.
(763)-476-2531
1-800-328-3336
Fax: 763-476-2613
www.intercompcompany.com
Manual#: 700008-V
Page 1 of 31
CS5000, Users
Rev V, January, 2008
Table of Contents
INTRODUCTION ............................................................................................................................................................ 3
S
PECIFICATIONS
Controls..................................................................................................................................................................... 3
Electrical................................................................................................................................................................... 3
Performance.............................................................................................................................................................. 3
Environmental ........................................................................................................................................................... 3
Physical..................................................................................................................................................................... 4
Radio ......................................................................................................................................................................... 5
P
ARTS AND OPTIONAL EQUIPMENT
OPERATIONS .................................................................................................................................................................. 7
D
ISPLAY (BASE
Indicators .................................................................................................................................................................. 7
C
ONTROLS - HEAD (SCALE
ON............................................................................................................................................................................. 7
C
ONTROLS - BASE (CONTROLLER
S
ETUP
........................................................................................................................................................................... 10
lb/kg Switching ........................................................................................................................................................ 10
Setting time and date............................................................................................................................................... 10
P
OWER/BATTERIES
CALIBRATION.............................................................................................................................................................. 12
.............................................................................................................................................................. 3
................................................................................................................................. 5
) ............................................................................................................................................................. 7
) ............................................................................................................................................ 7
) .................................................................................................................................. 8
....................................................................................................................................................... 11
H
OW TO TEST THE CALIBRATION
C
ALIBRATION SWITCH
H
OW TO CALIBRATE THE SCALE
L
EGAL-FOR-TRADE SEALING
ERROR MESSAGES ..................................................................................................................................................... 17
TROUBLESHOOTING ................................................................................................................................................. 18
PARTS AND ACCESSORIES....................................................................................................................................... 20
P
ARTS LIST:
P
ARTS LIST: 2K LB CAPACITY
P
ARTS LIST: 5K LB,
P
ARTS LIST:
SERIAL OUTPUT.......................................................................................................................................................... 28
E
XAMPLE CONNECTIONS
HOW TO REACH INTERCOMP SERVICE.............................................................................................................. 31
500
20K
.................................................................................................................................................. 12
LB CAPACITY
10K
LB,
30K
................................................................................................................................... 12
................................................................................................................................... 13
........................................................................................................................................ 16
..................................................................................................................................... 21
...................................................................................................................................... 23
LB CAPACITY
LB CAPACITY
.............................................................................................................................................. 29
......................................................................................................................... 25
....................................................................................................................... 27
"This document is the property of Intercomp Co. It contains material and
information that is confidential and protected under federal and/or state trade
secret, unfair competition, and copyright law. Any reproduction, use or
disclosure without written permission from Intercomp Co. is prohibited".
2
CS5000, Users
Rev V, January, 2008
Introduction
This manual contains specifications, operation instructions, and calibration instructions for
Intercomp's model CS5000 crane scale.
Specifications
Controls
General: Head:
Base:
Display: Base: 5 ½ digit LED.
Indicators: Head:
Base:
On (Base remotely turns the scale head off).
On/Off ,Zero, Print, Total, Display Total, Clear Total, Tare
Set, Tare Display, Tare Clear.
power.
lb/kg, Tare, Net, Gross, On-screen Motion, Total.
Electrical
Batteries:
(Base and Head)
Battery life: Up to 50 hours with alkaline batteries. Approximately 20
Resolution: 20 bit A/D delivers over 1,000,000 internal counts.
Filtering: 6 Pole, 10 Hertz low pass.
Auto off: Low battery, or after adjustable time without use or motion.
Auto-Zero: Satisfies all HB-44 requirements; selectable 0.6, 1, or 3
8 X D-size disposable alkaline dry cells or rechargeable
Nickel-Cadmium cells.
hours on a set of fully charged Ni-Cad cells.
graduations.
Performance
Accuracy: ±0.1% of applied load or ± display graduation, whichever
is greater.
Speed 2 readings / sec.
Transmitting Range Up to 500 ft / 150 meters
Environmental
Humidity: 10 to 95% Non-Condensing
Temperature: Storage: -40 C to +75 C. / -40 F to +170 F.
Operating -10 C to +50 C. / +14 F to +122 F.
3
Physical
CS5000, Users
Rev V, January, 2008
Capacity Graduation
500 lb
250 kg
2,000 lb
1,000 kg
5,000 lb
2,500 kg
10,000 lb
5,000 kg
20,000 lb
10,000 kg
30,000 lb
15,000 kg
50,000 lb
*
25,000 kg
70,000 lb
*
35,000 kg
100,000 lb
50,00 kg
*
0.1 kg
0.5 kg
0.5 kg
0.2 lb
1 lb
1 lb
2 lb
1 kg
5 lb
2 kg
10 lb
5 kg
10 lb
5 kg
20 lb
10 kg
20 lb
10 kg
A
in:
mm:
in:
mm:
in:
mm:
in:
mm:
in:
mm:
in:
mm:
in:
mm:
in:
mm:
in:
mm:
19.3
490
19.3
490
22.0
558
22.0
558
37.15
944
39.15
994
43.5
1105
48.6
1234
56.0
1422
B C D Hook Eye nut
3.06
77.7
3.06
77.7
3.06
77.7
3.06
7.77
6.25
159
6.25
159
6.00
152
6.00
152
7.75
197
1.44
35.1
1.44
35.1
1.82
44.5
1.75
44.5
2.60
65.8
3.00
76.2
3.66
93.0
4.56
116
5.06
129
1.41
35.8
1.41
35.8
1.69
42.9
1.69
42.9
2.41
61.2
3.19
81.3
3.62
92.0
3.75
92.3
4.25
108
The
dimensions
below are
top to
bottom
shackle,
eye to eye
on 25-50
ton / 12.5 –
25 metric
ton models
17.0
432
17.0
432
18.0
457
C/L 3 ton
S1 swivel
C/L 3 ton
S1 swivel
C/L 5 ton
S1 swivel
C/L 5 ton
S1 swivel
C/L 10 ton
S1 swivel
C/L 15 ton
S1 swivel
C/L 25 ton
S1 swivel
C/L 35 ton
S1 swivel
C/L 45 ton
S1 swivel
or
shackle
C/L #7
eye nut
C/L #7
eye nut
C/L #7 eye
nut
C/L #7 eye
nut
C/L # 11
eye nut
C/L # 11
eye nut
C/L 40 ton
#2140
C/L 40 ton
#2140
C/L 50 ton
#2140
Approx
Weight
48 lb
22 kg
50 lb
23 kg
58 lb
26 kg
58 lb
26 kg
97 lb
44 kg
122 lb
55 kg
220 lb
100 kg
248 lb
113 kg
392 lb
178 kg
4
CS5000, Users
!
Rev V, January, 2008
Radio
Radio frequency
(US/Canada)
License requirements None. Pre-approved US/FCC, CAN/IC, EUR/EN
Range 200’ / 60m indoor, 300’ / 90m line of sight
WARNING:
type transmitting devices, a separation distance of 20cm or more should
be maintained between the antenna of this device and persons during
operation, with the exception of hands, wrist, feet, and ankles. To ensure
2.4 GHz, FHSS, 50 mW output power
To satisfy FCC RF exposure requirements for mobile
Parts and Optional Equipment
Oversized top lifting eye (100744)
This part is applicable to 500 lb - 10,000 lb capacity models.
Oversized top shackle (100745)
This part is applicable to 20,000 lb and 30,000 lb capacity models.
Oversized top shackle (100746)
This part is applicable to 50,000 lb and 70,000 lb capacity models.
Oversized top shackle (100747)
This part is applicable to 100,000 lb capacity models.
Anti heat shield (100720)
Bottom plate with standard hook rated for 0° - 1000°.
Medium anti heat shield (100670)
1000° - 1500° protection. Includes oversized hook and custom swivel.
Extreme anti heat shield (100671)
1500° - 2500° protection. Includes oversized hook and custom swivel.
Remote load cell input and summing (100724)
Load cell input with electronic summing board. An external load cell can be connected to
the CS5000. The scale averages the signals from the 2 load cell outputs.
RS232 Serial data output (100721)
The CS5000 has an RS232 connection so the unit may communicate with a printer or
computer.
LED Display on crane unit (100725)
Optional LED (light emitting diode) display on the head. An LED display is fully readable
in pitch-dark lighting situations.
5
CS5000, Users
Rev V, January, 2008
LCD Display on crane unit (100726)
Optional LCD (liquid crystal display) display on the head.
Anti-magnetic shielding (100722)
Provides protection from high magnetic fields.
Battery pack and 120V external charger (100730)
Rechargeable Ni-Cad battery pack (8 D-cells) with 120V external charger. Standard
power uses 8 disposable alkaline dry cells.
Battery pack and 220V external charger (100731)
Rechargeable Ni-Cad battery pack (8 D-cells) with 220V external charger. Standard
power uses 8 disposable alkaline dry cells.
Battery pack, Ni-Cad (100733)
D size rechargeable battery pack (qty: 8).
Direct Power on crane unit, 120V (100723)
This option allows the CS5000 to use 120V power instead of batteries.
Direct Power on crane unit, 220V (100727)
This option allows the CS5000 to use 220V power instead of batteries.
6
Operations
Display (Base)
Total
kg Optional: displays ‘1’ or blank Gross
lb Tare
CS5000, Users
Rev V, January, 2008
Net
Indicators
kg: Indicates the scale is weighing in kilograms. When lit, the scale is in kg mode.
Press TOTAL DISPLAY and TARE DISPLAY together to toggle units.
Total: Indicates that the current number displayed is the total. The net indicator
will also be lit to represent that the total totalizes the net weights.
lb: Indicates the scale is weighing in pounds. When lit, the scale is in lb mode.
Press TOTAL DISPLAY and TARE DISPLAY together to toggle units.
Gross: This indicator is lit when the display represents that the gross weight is
being displayed.
Net: This indicator is lit when a tare value is set and the weight shown is the
calculated net weight.
Tare: This indicator is lit while the tare weight is being displayed.
Controls - Head (scale)
ON
Press this button to turn the scale on.
7
Controls - Base (controller)
ON/OFF
Press this button to turn the base unit on. The scale tests itself, then displays
“-----
-----“ or “HO-00
----------
displayed. Press this button again to turn the scale off. The head will turn off
automatically.
PRINT
Pressing this key will output an RS-232 signal containing the Gross, Net, Tare, total
weight, and the time and date. Note: The print key will only function when there is
no motion. Also see the ‘Serial Output' section in this manual.
ZERO
Tells the scale to display a zero weight. This button is used any time the scale
shows a non-zero value with no weight on the hook. If you press ZERO with
weight on the hook, that weight becomes the zero condition for the scale. This can
be useful to cancel the weight of any weighing fixtures, such as containers, chains
or cables. When this weight is removed, a negative weight shows until the system
is zeroed again.
NOTES: When ZERO is pressed, the CS5000 will display "-----
reading is taken. If there is continuous motion for more than 20 or 30 seconds, the
zero command will be rejected and the scale will return to normal weighing.
The scale contains a feature called Auto Zero Tracking (AZT), which corrects for
slight zero changes during normal operation. If small weights are added slowly, the
scale could zero them off.
TARE
Use this button to read a tare weight into memory. This tare weight will be
subtracted from a gross weight, giving you the net weight. This is useful for
canceling the weight of a container used in weighing. A segment on the right side
of the display shows that the net weight is being calculated.
NOTE: When TARE is pressed, the CS5000 will display "
reading is taken. If there is continuous motion for more than 20 or 30 seconds, the
tare command will be rejected and the scale will return to normal weighing.
HO-00”. When a weight is received from the scale head it will be
HO-00HO-00
8
CS5000, Users
Rev V, January, 2008
-----" until a stable
----------
-----
-----
----------
" until a stable
CS5000, Users
Rev V, January, 2008
TARE DISPLAY
You may press the TARE DISPLAY button to display the tare weight. Pressing the
TARE DISPLAY button a second time will return to the gross or net display.
TARE CLEAR
This button is used to clear a stored tare weight to zero.
TOTAL
By pressing this button, the current net weight is added to the total. Note: If the tare
weight is zero, the net weight is equal to the gross weight.
TOTAL DISPLAY
Pressing the TOTAL DISPLAY screen will switch the display to show the current
total weight. Pressing the key a second time will return to normal weighing.
TOTAL CLEAR
Clears the total to zero.
9
CS5000, Users
Rev V, January, 2008
Setup
Use the following procedure to setup and weigh:
1: Hook CS5000 scale head onto hoist.
2: Turn on CS5000 scale head.
3: Turn on CS5000 base.
4: Hook any weighing fixtures onto CS5000 hook (chains, etc.)
5: Hook any weighing bin or platform onto CS5000 hook or fixtures.
6: Hoist into air so that it is free swinging.
7: Press ZERO on base. The CS5000 will wait for a stable zero reading.
8: Proceed with weighing.
lb/kg Switching
Press the TOTAL DISPLAY and TARE DISPLAY keys together to switch lb/kg. This
toggles the weighing system between pound (English) and kilogram (SI metric) units of
measure. The current unit of measure is shown by the left indicators of the CS5000 base
(as shown in the section Display (Base) ).
Setting time and date
To set the time and date press the three keys labeled TARE, TARE DISPLAY, and TARE
CLEAR together and release. The scale will then ask you to enter seven numbers
representing the month, day, year, hour, minute, second, and am/pm. You increase the
number by pressing the TARE DISPLAY button. When the number is set, pressing the
TARE button moves on to the next number. When you have completed entry of all seven
numbers press the TARE CLEAR button to exit and start the clock running. The numbers
are displayed in the following format Hx-yy, were x is the number being set and yy is the
value. The following chart shows the seven values and their ranges.
Display Meaning Range
H1-yy
H1-yy
H1-yyH1-yy
H2-yy
H2-yy
H2-yyH2-yy
H3-yy
H3-yy
H3-yyH3-yy
H4-yy
H4-yy
H4-yyH4-yy
H5-yy
H5-yy
H5-yyH5-yy
H6-yy
H6-yy
H6-yyH6-yy
H7-yy
H7-yy
H7-yyH7-yy
If the year is set prior to '91 it will be displayed as 20xx.
Month 1-12
Day 1-31
Year 0-99
Hour 1-12
Minutes 0-59
Seconds 0-59
am/pm 0-1 (0 = am, 1 = pm)
10
CS5000, Users
Rev V, January, 2008
Power/Batteries
Head:
Remove the two caps in the back of the CS5000 head. Tip the old cells out.
Change the 8 ‘D’ cells, being careful to put the positive end in first (The end with
the bump). Replace the battery caps.
Base:
Loosen the 2 screws that latch the lid tight so the lid can be opened. Replace the 8
‘D’ cells, being careful to note the polarity indicated on the battery holders. Close
lid and retighten the screws for the latches.
You may use rechargeable 8 Nickel-Cadmium 'D' cells or 8 standard alkaline 'D'
cells in the CS3000.
Warning: If you have the optional charger, do not plug the charger in
while there are standard ‘D’ cells inside. This could result in damage
to the batteries and your scale.
The typical recharge time for Ni-cad cells is 16 hours. The rechargeable batteries
have a life span up to 1000 cycles.
11
CS5000, Users
Rev V, January, 2008
Calibration
How to test the calibration
This calibration procedure should be performed annually for normal operating conditions.
If the scale is dropped or damaged, or service has been performed on the scale, use this
calibration check.
1. Turn on the head and the base. The display does a lamp test; during this time the
scale does a quick check of itself. Then the weighing system starts weigh mode.
2. Intercomp recommends that you allow the electronics to operate for three minutes
after first turning power on. This allows the electronics to become stable for maximum
accuracy before you check the calibrations.
3. Make sure no weight is on the hook. Press the ZERO button. Press the TARE
CLEAR button to clear the tare. The weight shown is zero.
4. Apply weights throughout the weighing range, and verify the correct weight (+/- 0.1%)
is displayed at each step.
5. If possible apply a weight of 105% of capacity, and verify the scale shows OE on the
display.
6. Remove weights and verify the display returns to zero.
7. If there is a failure to meet any of the conditions above, please refer to the Calibration
Procedure.
8. When all the conditions above are correct, the scale is operational.
Calibration Switch
The calibration of the scale is protected from accidental change by a switch protected by
an access plug. The access plug is located on the front of the scale head above the “ON”
switch, and is covered by a calibration sticker (seal). The switch is set in the “calibration
blocked” mode at the factory.
Enabling the Calibration switch
First, remove the calibration sticker which covers the access plug. Using a ¼” Allen
wrench, remove the access plug. Insert the Allen wrench in to the hole and press
the switch once. The scale is now set to allow calibration.
How to enter a number
During this routine you will be asked to enter numbers at many points. You must use the
ZERO and PRINT switches to enter these numbers. The scale will show 5 digits but there
are actually 6 digits because the leftmost digit is initially invisible. The active digit will be
blinking. Press the ZERO key to increase the value of the blinking digit. Press the PRINT
key to move the blinking digit one place to the left. When you advance to the leftmost
digit, the display will initially be blank (value of 0). This display segment can be toggled
between 0 and 1. When you are finished entering the number press both the ZERO and
PRINT switches simultaneously to go on.
12
CS5000, Users
Rev V, January, 2008
Three point span
The scale has a three point calibration feature which reduces the effects on non-linearity
in the load cells. This requires that you place three weights on the cell during calibration.
The first weight must be greater than zero, the second greater than the first, and the final
weight somewhere between the second and the capacity.
How to Calibrate the Scale
There are three parameters that can be set without moving the calibration switch, followed
by three more parameters and the actual calibration which require the calibration switch to
be in the enabled position.
Default
Display Parameter Note
EE-00
EE-00
EE-00EE-00
EE-01
EE-01
EE-01EE-01
EE-02
EE-02
EE-02EE-02
EE-03
EE-03
EE-03EE-03
EE-04
EE-04
EE-04EE-04
EE-05
EE-05
EE-05EE-05
LL-00
LL-00
LL-00LL-00
LL-01
LL-01
LL-01LL-01
LL-02
LL-02
LL-02LL-02
LL-03
LL-03
LL-03LL-03
1. Access the calibration switch and press once if you intend to calibrate. See
2. Turn both the base and head on. Wait for scale to warm up (2-3 minutes).
3. Press ZERO and PRINT together and release to enter the calibration mode.
4. The scale displays “EE-00
Sample Rate 1 to 64 4
Update Rate 1 to 32 4
Power up in kg 1=kg, 0=lb 0
Information saved
Check for calibration blocking switch
AZT 0=off,1=0.6,2=1,3=3 2
Canadian Specifications 0=off, 1=on 0
Graduation 0 to 11 6
Information saved
Zero read Enter capacity
First weight Enter first weight
Second weight Enter second weight
Third weight Enter third weight
Information saved
Calibration Switch.
EE-00”. Press the ZERO and PRINT keys simultaneously.
EE-00EE-00
Enter the sample rate (1 to 64), ('4' is suggested, although if your readout is too
jumpy, you can increase this value). The sample rate is the number of past
readings that are averages together to make a reading. (Press ZERO and PRINT
keys to enter this number.)
13
CS5000, Users
Rev V, January, 2008
5. The scale displays “EE-01
EE-01”. Press the ZERO and PRINT keys. Enter the display
EE-01EE-01
update rate (1 to 32), ('4' is suggested). The display update rate is the speed at
which the display is updated, with 1 being the fastest. (Press the ZERO and PRINT
keys to enter this number.
6. The scale displays “EE-02
EE-02”. Press the ZERO and PRINT keys. Enter what unit of
EE-02EE-02
measure the scale should operate in; pounds or kilograms (0 to 1). (Press the
ZERO and PRINT keys to enter this number.)
Setting Units to operate in
0 pounds (lb)
1 kilograms (kg)
Note: At this point the changes you entered will be saved and the scale could be turned
off if you don't wish to change the calibration.
7. The scale shows “EE-03
EE-03”. Press the ZERO and PRINT keys. Enter the desired
EE-03EE-03
AZT size. The AZT size is the number of graduations the auto zero tracking can
remove. Note: At this point if the calibration blocking switch is not in the enabled
position, the scale will not save the new AZT value. It will instead display the “E1
E1”
E1E1
error message and return to normal weighing. See “Calibration switch” to
change this.
Setting AZT size
0 Off
1 0.6
2 1
3 3
8. The scale shows “EE-04
EE-04”. Press the ZERO and PRINT keys. The scale shows the
EE-04EE-04
current Canadian specification selection. Use the following table to select the
Canadian specifications setting.
Setting Canadian
Specification
0 Off
1 On
A '0' setting implies normal operation:
1: AZT size is determined by setting of EE-03
EE-03.
EE-03EE-03
2: Zero operates over full range of capacity.
3: Over capacity is 103% from the zero obtained at calibration.
A '1' setting implies Canadian specifications are used:
1: The AZT size fixed at 0.6d regardless of EE-03
EE-03 setting.
EE-03EE-03
14
CS5000, Users
Count by
Count by
Rev V, January, 2008
2: The IZSM (initial zero setting mechanism on power up) must be within +/- 10% of the
zero obtained at calibration.
3: The push-button zero and AZSM can only operate within +/- 2% of the IZSM.
4: The overcapacity point is 103% of capacity above the IZSM.
9. The scale shows “EE-05
EE-05”. Press the ZERO and PRINT keys. Enter the desired
EE-05EE-05
graduation. Use the following table to select a graduation value. (Press the ZERO
and PRINT keys to enter this value.)
Setting
in lb
in kg
0 100 50
1 50 20
2 20 10
3 10 5
4 5 2
5 2 1
6 1 0.5
7 0.5 0.2
8 0.2 0.1
9 0.1 0.05
10 0.05 0.02
11 0.02 0.01
NOTE: To meet stated accuracy statements, it is suggested that you choose your
graduation setting from the table below:
If your capacity is: Set your graduation to:
500 lb / 250 kg 0.2 lb / 0.1 kg (8)
1000 lb / 250 kg 0.5 lb / 0.2 kg (7)
2,000 lb / 1,000 kg 1 lb / 0.5 kg (6)
5,000 lb / 2,500 kg 1 lb / 0.5 kg (6)
10,000 lb / 5,000 kg 2 lb / 1 kg (5)
20,000 lb / 10,000 kg 5 lb / 2 kg (4)
30,000 lb / 15,000 kg 10 lb / 5 kg (3)
50,000 lb / 25,000 kg 10 lb / 5 kg (3)
70,000 lb / 35,000 kg 20 lb / 10 kg (2)
100,000 lb / 50,000 kg 20 lb / 10 kg (2)
Note: The changes will again be saved here and the scale could be turned off if you
don't wish to change the calibration.
15
CS5000, Users
Rev V, January, 2008
10. The scale displays “LL-00
enter the capacity, in the units (lb or kg) that you are calibrating in. With no weight
on the hook, press the ZERO and PRINT keys to enter in this capacity. Max
capacity is 99999 lbs. Special versions allow a max capacity of 199999 lbs.
11. The scale shows “LL-01
keys. On the next screen enter the weight being applied. With the weight on the
hook and its exact value shown on the CS5000 screen, press the ZERO and
PRINT keys to enter in the weight.
12. The scale shows “LL-02
PRINT keys. On the next screen enter the weight being applied. With the weight
on the hook and its exact value shown on the CS5000 screen, press the ZERO and
PRINT keys to enter in the weight.
13. The scale shows “LL-03
keys. On the next screen enter the weight being applied. With the weight on the
hook and its exact value shown on the CS5000 screen, press the ZERO and
PRINT keys to enter in the weight.
LL-00”. Press the ZERO and PRINT keys. On the next screen
LL-00LL-00
LL-01”. Apply the first weight and press the ZERO and PRINT
LL-01LL-01
LL-02”. Apply the second weight and press the ZERO and
LL-02LL-02
LL-03”. Apply the final weight and press the ZERO and PRINT
LL-03LL-03
Finish
The new calibration information is saved.
14. Press the calibration switch ONCE to disable calibration. This will prevent
accidental entry into the calibration mode. If you are unsure of whether the switch is
enabled or disabled, start going thorough the calibration menu again. After the
“AZT” menu item, the scale should return to normal weighing instead of saving the
AZT value and proceeding to EE-04
15. Replace the access plug which will cover the calibration switch.
16. Cover this plug with a new calibration seal (e.g. foil calibration sticker).
17. Verify the calibration.
18. Calibration complete.
EE-04. See the “calibration switch” section.
EE-04EE-04
Legal-for-Trade Sealing
For qualified calibration facilities:
1. After calibration push the calibration switch. The calibration switch is located on the
upper right hand corner on the backside (side with battery caps) of the scale.
2. Verify that the scale returns to normal weighing when trying to access the weight
calibration.
3. Replace the set screw that covers the cal switch.
4. Apply the protection sticker (sticker must adhere to Intercomp’s specifications).
16
Rev V, January, 2008
Error Messages
[display reads “-----
also occurs when the unit is first turned on, or after ZERO or TARE is pressed.
EE-00
EE-00
EE-00EE-00
OL-00
OL-00
OL-00OL-00
OE-00
OE-00
OE-00 OE-00
OS
OS
OSOS
HO-00
HO-00
HO-00HO-00
LB-00
LB-00
LB-00LB-00
BLB
BLB
BLBBLB
EO:
EO:
EO:EO:
E1
E1
E1E1
-----“]: The CS5000 is waiting for a stable reading to continue. This
----------
EEPROM error, the scale has had it's calibration corrupted or destroyed;
the scale will require recalibration.
Zero overload, the zero has moved outside it's limit. Return the scale's load
to the initial zero-set and press ZERO, or turn the unit off and then back on.
See 'Canadian specifications' (EE-04
The scale is over capacity. Reduce the load applied to the scale.
Display error, the scale is unable to display the number completely.
Head off, the scale head is turned off or the communication link between
the scale head and base has otherwise failed. If both base and head are on
and you get this message, try rotating or moving the base slightly. This can
sometimes have a substantial effect on the signal received.
The scale head is low in batteries. Turn the scale base off first, then replace
the 8 'D' cell batteries in the head.
The batteries in the base controller require recharging or replacement
This message occurs if the scale is turned on with a load applied which is
greater than ±10% capacity. Return the scale’s load to zero. This only
occurs when Canadian specifications are turned on. See EE-04
‘Calibration section’.
Error during calibration. It is caused by either the calibration strap being
disabled, or a failure in the communication link. The scale will then exit
calibration mode and return to normal weighing after a few seconds. See
“Calibration switch” section.
EE-04 in the 'calibration' section).
EE-04EE-04
EE-04 in the
EE-04EE-04
CS5000, Users
17
CS5000, Users
Rev V, January, 2008
Troubleshooting
Caution: Changing some parts on the circuit board may cause a large
change in calibration while others may or may not change the calibration,
depending on the nature of the problem.
The base unit contains the “MPC board” and the “GPI Display board” The head contains
the “A/D board”.
Problem: base only displays “HO-00
Problem: no power, nothing on display
Fix (applies to the base and the head):
Problem: random display (display usually reads “8888.8888.8888.”)
Fix:
Problem: low battery indication won’t turn off
Fix:
HO-00“, no communication
HO-00HO-00
Fix:
Check the power on the head (LED labeled POWER). If the head does have
sufficient power, this is probably a communication problem. Open the base unit
and locate the transceiver. If the LED lights labeled RXD Data and TXD Data are
not blinking, the transceivers are not communicating. Check to make sure the
base and head unit have power. Also make sure they are within range and rotate
units to try to get communication.
If nothing can be seen on the display, there is probably no power reaching the base
circuitry. Possible causes at: bad or shorted battery pack, bad switch circuit, bad
voltage regulator. Power might be reaching the unit, but the power supply might be
shorted by a component or PCB trace in the power supply circuitry.
On MPC board: check crystal (Y2). If the micro-controller is not receiving the
correct or any oscillation, the microprocessor is not able to function properly. Other
possibilities could be bad microprocessor (U1) on MPC board or display driver (U1
& U2 on “GPI DISPLAY” board) circuitry not functioning.
The display will show a low battery condition (“LB-00
base controller). Check if battery power is too low. Look at the cells and charger
circuit for these problems. If that is not the cause, the display driver( U1 & U2 on
the “GPI DISPLAY” board) or low voltage circuitry could be bad.
LB-00” for the head, or “BLB
LB-00LB-00
BLB” for the
BLBBLB
18
Problem: rechargeable battery life has decreased
Fix:
The rechargeable batteries provided by Intercomp are high quality, high capacity
Ni-Cad. However, all Ni-Cad batteries can exhibit some “memory” effects if they
are repeatedly discharged to a certain point before recharging. If your observed
battery life has decreased significantly from its initial performance, you may want to
try this battery-conditioning sequence: Fully discharge the batteries by running the
CS5000 until the display blinks “LB
LB” (low battery) and keep the unit powered until
LBLB
the batteries are fully discharged. Following this, recharge the battery completely
(typical charge time is 16 hours). This discharge/recharge cycle may need to be
repeated. If this does not help, you may need to replace the Ni-Cad batteries.
Problem: scale shuts off by itself
Fix:
Check the battery holder terminals. They may be bent and not making solid
contact. If the scale turns off immediately after you take your finger off the button,
there may be defective power circuitry or a bad keypad.
Problem: scale “locks up”
Fix:
The microprocessor (U1) on the MPC board may need to be replaced. The
microprocessor support circuitry could also be bad.
Problem: weights jump or drift
Fix:
Try increasing the sample rate as described in the calibration section (pg. 13).
Pertains to A/D board: If this does not help, the problem could be a bad load cell,
defective amplifier (U5), bad A/D chip (U6), or contamination on the A/D circuit
board.
CS5000, Users
Rev V, January, 2008
19
Parts and Accessories
Diagram: 500 lb capacity models
CS5000, Users
Rev V, January, 2008
See following page for parts list
20
Parts List: 500 lb capacity
Item # QTY Part # Description
1 1 00072 control harness
2 6 250058 button cover
3 12 600058 .375-16 screw
4 1 250089 keypad overlay
5 1 250090 logo overlay
6 1 500804 CS5000 display end
7 1 250095 window overlay
8 1 220063 4-pin MTA
9 1 603057 loadcell
10 1 insert
11 1 500817 display window
12 1 600064 .50-20unf screw
13 1 500838 loadcell threaded adapter
14 1 500739 loadcell retainer
15 1 500736 lower loadcell adapter
16 1 500824 loadcell housing
17 1 500710 retaining ring gasket
18 1 500709 top retaining ring
19 1 500713 retaining ring spacer
20 2 600020 .25-20 screw
21 4 600023 .25-20 set screw
22 2 600019 .25-20 screw
23 1 601039 eye nut
24 2 500805 housing gasket
25 1 500823 eye nut
26 2 500707 battery tube
27 20 600008 6-32 screw
28 4 330042 battery spring
29 2 500706 battery plate
30 2 500705 battery cap
31 2 600014 8-32 screw
32 2 500708 battery tube end
33 2 601047 wing nut
34 1 000075 battery harness assembly
35 1 603035 assembly screw
36 1 603035 swivel hook assembly
37 1 603035 assembly nut
38 16 601014 .031 nylon washer
39 4 601032 6-32 m/f standoff
40 4 601002 6-32 nut
41 1 500808 right board mount
42 4 601028 vibration mount
43 1 000095 display board
44 4 601015 .062 nylon washer
45 4 600035 8-32 screw
46 4 601018 6-32 standoff
47 1 000094 A/D board
48 1 500807 left board mount
49 4 600015 8-32 unc screw
50 1 500803 lower retaining ring
51 2 500818 bellows
52 1 820027 hose clamp
CS5000, Users
Rev V, January, 2008
21
CS5000, Users
Rev V, January, 2008
Diagram: 2K lb capacity models
Please see following page for parts table
22
Parts List: 2K lb capacity
Item # QTY Part # Description
1 1 00072 control harness
2 6 250058 button cover
3 12 600058 .375-16 screw
4 1 250089 keypad overlay
5 1 250090 logo overlay
6 1 500804 CS5000 display end
7 1 250095 window overlay
8 1 220063 4-pin MTA
9 4 600023 .25-20 set screw
10 1 000062 loadcell (2K capacity CS5000)
11 1 insert
12 1 500817 display window
13 1 500838 loadcell threaded adapter
14 1 500739 loadcell retainer
15 1 500824 loadcell housing
16 1 500710 retaining ring gasket
17 1 500709 top retaining ring
18 1 500713 retaining ring spacer
19 2 600020 .25-20 screw
20 2 600019 .25-20 screw
21 1 601039 eye nut
22 2 500805 housing gasket
23 1 500823 eye nut
24 2 500707 battery tube
25 20 600008 6-32 screw
26 4 330042 battery spring
27 2 500706 battery plate
28 2 500705 battery cap
29 2 600014 8-32 screw
30 2 500708 battery tube end
31 2 601047 wing nut
32 1 000075 battery harness assembly
33 1 603035 assembly screw
34 1 603035 swivel hook assembly
35 1 603035 assembly nut
36 16 601014 .031 nylon washer
37 4 601032 6-32 m/f standoff
38 4 601002 6-32 nut
39 1 500808 right board mount
40 4 601028 vibration mount
41 1 000095 display board
42 4 601015 .062 nylon washer
43 4 600035 8-32 screw
44 4 601018 6-32 standoff
45 1 000094 A/D board
46 1 500807 left board mount
47 4 600015 8-32 unc screw
48 1 500803 lower retaining ring
49 2 500818 bellows
50 1 820027 hose clamp
CS5000, Users
Rev V, January, 2008
23
Diagram: 5K lb, 10K lb capacities
CS5000, Users
Rev V, January, 2008
See the following page for parts list
24
Parts List: 5K lb, 10K lb capacity
Item # QTY Part # Description
1 1 00072 control harness
2 6 250058 button cover
3 12 600058 .375-16 screw
4 1 250089 keypad overlay
5 1 250090 logo overlay
6 1 500804 CS5000 display end
7 1 250095 window overlay
8 1 220063 4-pin MTA
9 4 600023 .25-20 set screw
10 1 000073 loadcell (5K and 10K capacity CS5000)
11 1 insert
12 1 500817 display window
13 1 500838 loadcell threaded adapter
14 1 500824 loadcell housing
15 1 500710 retaining ring gasket
16 1 500709 top retaining ring
17 2 600020 .25-20 screw
18 2 600019 .25-20 screw
19 1 601039 eye nut
20 2 500805 housing gasket
21 1 500823 eye nut
22 2 500707 battery tube
23 20 600008 6-32 screw
24 4 330042 battery spring
25 2 500706 battery plate
26 2 500705 battery cap
27 2 600014 8-32 screw
28 2 500708 battery tube end
29 2 601047 wing nut
30 1 000075 battery harness assembly
31 1 603035 assembly screw
32 1 603035 swivel hook assembly
33 1 603035 assembly nut
34 16 601014 .031 nylon washer
35 4 601032 6-32 m/f standoff
36 4 601002 6-32 nut
37 1 500808 right board mount
38 4 601028 vibration mount
39 1 000095 display board
40 4 601015 .062 nylon washer
41 4 600035 8-32 screw
42 4 601018 6-32 standoff
43 1 000094 A/D board
44 1 500807 left board mount
45 4 600015 8-32 unc screw
46 1 500803 lower retaining ring
47 2 500818 bellows
48 1 820027 hose clamp
CS5000, Users
Rev V, January, 2008
25
Diagram: 20K lb, 30K lb, capacities
CS5000, Users
Rev V, January, 2008
Please see following page for parts list
26
Parts List: 20K lb, 30K lb capacity
Item # QTY Part # Description
1 1 00072 control harness
2 6 250058 button cover
3 12 600058 .375-16 screw
4 1 250089 keypad overlay
5 1 250090 logo overlay
6 1 500804 CS5000 display end
7 1 250095 window overlay
8 1 220063 4-pin MTA
9 4 600023 .25-20 set screw
10 1 000073
000063
11 1 insert
12 1 500817 display window
13 1 601051 1-8 locking nut
14 1 500813 top loadcell adapter
15 2 602008 1-8 bolt
16 1 500824 loadcell housing
17 1 500710 retaining ring gasket
18 1 500709 top retaining ring
19 1 601039 eye nut
20 2 600019 .25-20 screw
21 2 600020 .25-20 screw
22 2 500805 housing gasket
23 1 500823 end plate
24 1 500946 lower loadcell adapter
25 2 500707 battery tube
26 20 600008 6-32 screw
27 4 330042 battery spring
28 2 500706 battery plate
29 2 500705 battery cap
30 2 600014 8-32 screw
31 2 500708 battery tube end
32 2 601047 wing nut
33 1 000075 battery harness assembly
34 1 603063 assembly screw
35 1 603063 swivel hook assembly
36 1 603063 assembly nut
37 16 601014 .031 nylon washer
38 4 601032 6-32 m/f standoff
39 4 601002 6-32 nut
40 1 500808 right board mount
41 4 601028 vibration mount
42 1 000095 display board
43 4 601015 .062 nylon washer
44 4 600035 8-32 screw
45 4 601018 6-32 standoff
46 1 000094 A/D board
47 1 500807 left board mount
48 4 600015 8-32 unc screw
49 1 500803 lower retaining ring
50 2 500818 bellows
51 1 820027 hose clamp
loadcell (20K capacity CS5000)
loadcell (30K capacity CS5000)
CS5000, Users
Rev V, January, 2008
27
CS5000, Users
Rev V, January, 2008
Serial Output
The CS5000 base has available two communications channels, the standard interface for
both is RS-232. One is equipped with a CTS (clear to send) line and designed primarily for
hookup to a printer. The second channel consists of signal wires only and is designed
primarily for hookup to a score board or computer.
Channel 1 outputs a ticket:
cr/lf
-XXXXXX.X lb G cr/lf
-XXXXXX.X lb N cr/lf
-XXXXXX.X lb T cr/lf
-XXXXXX.X lb TOTAL cr/lf
lf
lf
JAN DD, 19YY HH:MM:SSam cr/lf (the 19 could be 20, and the a could be p)
lf
lf
Channel 2 outputs the net weight:
-XXXXXX.X lb cr/lf
There is a five switch dip pak located on the main circuit board inside the base unit, it's
switches have the following meanings:
Switch # On Off Function
1
2 1200
3 on
4
5
The Items in bold indicate the suggested defaults.
NOTE: The RS-232 communication parameters: Fixed 8 data bits, no parity, 1 stop bit.
Each channel will print under two conditions:
1: If the print key is pressed.
2: If the continuous print is turned on.
1200
on
on
9600 Channel 1 baud rate
9600
off
off Channel 2 continuous print
off RF interface (must be turned on, on CS5000)
Channel 2 baud rate
Channel 1 continuous print
28
CS5000, Users
Rev V, January, 2008
The signals for the two channels exist the box through the six pin connector on the bottom
of the box. The wiring is listed on the following chart:
Pin# Connection
A CH1 TXD
B CH1 CTS
C CH1 GND
D CH2 TXD
E CH2 GND
F NC
Example Connections
The connection of CH1 to a 9-pin PC communications port is:
CS5000 9-pin PC
A (TXD) 2 (RXD)
B (CTS) 7 (RTS)
C (GND) 5 (GND)
NOTE: For some setups it may be necessary to jump pins [6, 1, and 4] together on
the PC port connector.
The connection of CH1 to a 25-pin PC communications port is:
CS5000 25-pin PC
A (TXD) 3 (RXD)
B (CTS) 4 (RTS)
C (GND) 7 (GND)
NOTE: For some setups it may be necessary to jump pins [6, 8, and 20] together
on the PC port connector.
The connection of CH2 to an Intercomp S400 display is:
CS5000 S400
D (TXD) 2 (RXD)
E (GND) 7 (GND)
The connection of CH2 to an Intercomp SA2000 display is:
CS5000 SA2000
D (TXD) 3 (RXD)
E (GND) 7 (GND)
cont’d on next page
29
CS5000, Users
Rev V, January, 2008
The connection of CH2 to a 9-pin PC communication port is:
CS5000 PC 9-pin
D (TXD) 2 (RXD)
E (GND) 5 (GND)
Note: For some setups it may be necessary to jump pins [6, 1, and 4] together, and
pins [7 and 8] together on the PC port connector.
The connection of CH2 to a 25-pin PC communication port is:
CS5000 PC 25-pin
D (TXD) 3 (RXD)
E (GND) 7 (GND)
Note: For some setups it may be necessary to jump pins [6, 8, and 20] together,
and pins [4 and 5] together on the PC port connector.
30
How to reach Intercomp Service
Things to know:
1. The service is for a CS5000 crane scale.
2. When did you purchase your scale?
3. What is your serial number?
4. Whom did you purchase the scale through?
For Intercomp Service call or fax:
FAX # (763)-476-2613
(763)-476-2531
1-800-328-3336
or fill out Service Support Form at:
www.intercompcompany.com
Copyright Intercomp Company 2008
All rights reserved
CS5000, Users
Rev V, January, 2008
31
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