CS1500 Users Manual Intercomp Co. 3839 County Road 116 Minneapolis, MN 55340 U.S.A. (763)-476-2531 1-800-328-3336 Fax: 763-476-2613 www.intercompcompany.
CS1500, Users Rev S, June, 2009 Table of Contents INTRODUCTION .......................................................................................................................................................3 SPECIFICATIONS .........................................................................................................................................................3 Controls.....................................................................................................................
CS1500, Users Rev S, June, 2009 Introduction This manual contains specifications, operation instructions, and calibration instructions for Intercomp's model CS1500 crane scale. Specifications Controls General: Display: Indicators: Zero, lb/kg, Mode, Set, Print, Tare, On, Off 5 ½ digit LED or 5 digit LCD lb/kg, Gross/Net, Total/Peak Electrical Batteries: 8 X D-size disposable alkaline dry cells or rechargeable NickelCadmium cells. Up to 90 hours with alkaline batteries.
CS1500, Users Rev S, June, 2009 Physical 15" / 381mm C B 5.8" / 147mm A D F E 9" / 229mm Capacity Graduation A B C D E F Approx. Weight 250 lb 125 kg 500 lb 250 kg 1,000 lb 500 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 0.1lb .05 kg 0.2 lb 0.1 kg 0.5 lb 0.2 kg 1 lb 0.5 kg 2 lb 1 kg 5 lb 2 kg 10 lb 5 kg 10.5 in 267 mm 10.5 in 267 mm 10.5 in 267 mm 11.5 in 292 mm 19 in 482 mm 19 in 482 mm 23 in 584 mm 2.38 in 61 mm 2.38 in 61 mm 2.38 in 61 mm 2.38 in 61 mm 2.
CS1500, Users Rev S, June, 2009 Weights and Measures The CS1500 meets or exceeds class III standards for 3000 division accuracy from 300 lb to 2000 lb. The certification was completed by the National Type Evaluation Program (NTEP)s in accordance with the National Institute of Standards and Technology (NIST) Handbook 44. A NTEP Certificate of Conformance Number 96-135 was issued under the National Conference of Weights and Measures.
CS1500, Users Rev S, June, 2009 Operations Operating Practices Warning: The crane scale will be operated by qualified designated persons, trainees under the direct supervision of designated persons, maintenance and test personnel when in performance of their assigned duties, or lifting device inspectors. Warning: Do not exceed the rated load limit of the crane scale. Warning: The crane scale shall be applied to the load in accordance with the instruction manual.
CS1500, Users Rev S, June, 2009 Warning: Stay clear of suspended loads. Warning: Do not lift loads higher than necessary. Warning: Do not make alterations or modifications to the crane scale. Warning: Ensure all portions of the human body are kept clear of all device involved with the rigging during the lift.
CS1500, Users Rev S, June, 2009 Controls ON Press this button to turn the scale on. The scale tests itself; when these tests have completed successfully, the system begins weighing. Note: If you used the remote control to turn off the scale (the last time), you must first press the OFF key, then press the ON key. OFF Press this button to turn the scale off. 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.
CS1500, Users Rev S, June, 2009 corrects for slight zero changes during normal operation. If small weights are added slowly, the scale could zero them off. Lb/Kg Toggles the weighing system between pound (English) and kilogram (SI metric) units of measure. The current unit of measure is shown by the top indicator on the left side of the display. If the scale is displaying pounds the indicator is on, if the scale is displaying kilograms the indicator is off.
CS1500, Users Rev S, June, 2009 If a tare weight is set, pressing the TARE key will display the current value of the tare. The tare will be displayed as long as you hold the key. Clearing the tare: Pressing the ZERO key than the TARE key, and releasing together will reset the tare to zero. PRINT If the scale is configured to demand output, pressing the print button will print a ticket. NOTE: The print ticket will be delayed any time a change in weight is detected.
CS1500, Users Rev S, June, 2009 MODE Moves through the available display modes; each time you press the button the display steps to the next mode. The 3 display modes are: Weight on the scale (lower indicator will be off) Total accumulated weight (lower indicator will be on) The peak weight experienced (lower indicator will be blinking) Each press of the MODE key will move to the next piece of information.
CS1500, Users Rev S, June, 2009 Remote Control All keys on the remote control are functional for the CS1500. This diagram aims to clarify any remote control functions that may not be obvious. Notes: Need to press twice to turn on. The ON key on the scale must be pressed to initially turn on the CS1500.
CS1500, Users Rev S, June, 2009 Power/Batteries Replacement Remove the two caps in the back of the unit. Tip the old cells out. Change the cells, being careful to put the positive end in first (The end with the bump). Replace the battery caps. You may use rechargeable Nickel-Cadmium “D” cells or standard “D” cells in the CS1500. Warning: Do not plug the charger in while there are standard “D” cells inside. This could result in damage to the batteries and your scale.
CS1500, Users Rev S, June, 2009 Maintenance Periodic Inspection The crane scale and all associated adaptive devices require periodic inspection and maintenance. The frequency and recording of the inspection requirements are found in service categories below and are dependant on the type of service that the equipment is used in as described below. Service Categories Normal Service – Crane scale is operated at less than 85% of it’s capacity except for isolated instances.
CS1500, Users Rev S, June, 2009 4. Inspect for excessive wear at hoist hooking points and load support clevices or pins. 5. Inspect for any visible bends or twists of all used rigging devices. 6.
CS1500, Users Rev S, June, 2009 1. Press the ON switch. 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 switch. Press the TARE and ZERO key to clear tare.
CS1500, Users Rev S, June, 2009 Calibration switch The calibration of the scale is protected from accidental change by a shunt placed on “CAL” (instead of “RUN”) of J8, located on the top/middle of the A/D 20 BIT circuit board. Enabling the Calibration The shunt must be moved from “RUN” to “CAL”. When you are done calibrating, place the shunt back on “RUN” to protect the calibration from change. How to calibrate the scale The following details the calibration procedure for the crane scale.
CS1500, Users Rev S, June, 2009 2. Turn scale power ON and wait for scale to warm up (3 minutes from power on). 3. Press ZERO and lb/kg keys together and release to enter the calibration mode. First ten parameters 4. The scale shows “EE-EE EE-EE EE-EE”. Simultaneously press the ZERO and lb/kg keys. To skip to “EE-10 EE-10” LL-00” EE-10 enter a “1”. To skip to “L L-00 enter “2”. No skips will occur with an entry of “0”.
CS1500, Users Rev S, June, 2009 9. The scale shows “EE-04 EE-04”. EE-04 Simultaneously press the ZERO and lb/kg keys. Enter the auto off time in minutes (0 to 255). The auto off time is how long the scale will remain ON without any activity (a key being pressed or a change in weight). An entry of 0 turns the auto off feature OFF. 10. The scale shows “EE-05 EE-05”. EE-05 Simultaneously press the ZERO and lb/kg keys. Enter what unit of measure the scale should turn ON in; pounds or kilograms (0 to 1).
CS1500, Users Rev S, June, 2009 Check for calibration blocking switch •At this point the scale saves any changes that have been made. •A check is than made to see whether or not the calibration blocking switch is enabled. If enabled, (CAL), the calibration procedure will continue. if disabled, (RUN), the scale returns to normal weighing. Last five parameters 15. The scale shows “EE-10 EE-10”. EE-10 Simultaneously press the ZERO and lb/kg keys. Enter the AZT size (0 to 3).
CS1500, Users Rev S, June, 2009 3: The push-button zero and AZSM can only operate within +/2% of the IZSM. 4: The over-capacity point is 103% of capacity above the IZSM. 18. The scale shows “EE-13 EE-13”. EE-13 Simultaneously press the ZERO and lb/kg keys. The scale shows the current initial zero range setting.
CS1500, Users Rev S, June, 2009 If your capacity is: 300 lb / 150 kg 500 lb / 250 kg 1000 lb / 500 kg 2000 lb / 1000 kg 5000 lb / 2500 kg 10000 lb / 5000 kg 20000 lb / 10000 kg Set your graduation to: .1 lb / 0.05 kg (9) 0.2 lb / 0.1 kg (8) 0.5 lb / 0.2 kg (7) 1 lb / 0.5 kg (6) 2 lb / 1 kg (5) 5 lb / 2 kg (4) 10 lb / 5 kg (3) Save •At this point the scale saves any changes that have been made.
CS1500, Users Rev S, June, 2009 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 reference designators for the IC chips are on the “A/D 20-BIT” board unless indicated otherwise. Problem: no power, nothing on display Fix: If nothing can be seen on the display, there probably is no power reaching the scale circuitry.
CS1500, Users Rev S, June, 2009 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) may need to be replaced. The microprocessor support circuitry could also be bad.
CS1500, Users Rev S, June, 2009 Parts and Accessories Diagram: 250 lb, 500 lb capacity models See following page for parts list 25
CS1500, Users Rev S, June, 2009 Parts List: 250 lb, 500 lb capacity Item # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 QTY 1 1 1 1 1 1 2 2 26 4 2 2 2 2 2 1 1 1 1 1 1 1 18 2 4 6 4 4 2 2 1 1 1 35 36 37 38 39 40 41 42 43 44 45 1 2 2 1 2 1 1 1 1 1 1 Part # 601008 220063 603055 601008 500742 601003 500708 500707 600008 330030 500706 280074 500705 602422 600014 603000 500608 601055 601056 602009 500607 000094 601207 500703 600012 601002 601311 601315 601301 60120
CS1500, Users Rev S, June, 2009 Diagram: 1K lb - 20K lb capacity models Please see following page for parts table 27
CS1500, Users Rev S, June, 2009 Parts List: 1K lb - 20K lb capacity Item # 1 QTY 1 2 3 4 5 6 7 8 1 1 1 1 1 2 2 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 26 4 2 2 2 2 2 4 1 1 2 2 1 1 1 18 2 4 6 4 4 2 2 1 1 1 35 36 37 38 39 40 1 2 2 1 2 1 Part # 000062 000061 000063 603059 601804 603060 500742 601003 500708 500707 Description loadcell (1K, 2K capacity CS1500) loadcell (5K, 10K capacity CS1500) loadcell (20K capacity CS1500) yoke assembly cotter pin yoke pin scale h
CS1500, Users Rev S, June, 2009 Error Messages [Minus signs cycle across the display]: The CS1500 has entered sleep mode. Press any key or change the weight to return to normal weighing. NOTE: a pressed key here will perform its designated function as well as exit the scale from sleep mode. [Minus signs fill the display]: The CS1500 is waiting for a stable reading to continue. LB OE DISE EEPE OL E-0 Low batteries. This message blinks, and if ignored too long the unit will shut itself off.
CS1500, Users Rev S, June, 2009 Serial Output (Optional) The CS1500 can be set to output either a scoreboard (continuous) or printer ticket (demand). The default is a printer ticket, but this can be changed in the “calibration” section “EE-02 EE-02”. EE-02 The signal comes out of the 8-pin Serial I/O connector located on the side of the unit. The connector has the following pinout: Signal TXD GND Pin F B The transmitted signal has the following characteristics: Fixed 8 Data bits, no parity, 1 stop bit.
CS1500, Users Rev S, June, 2009 There are 3 pieces of data transmitted dependent on which display mode is selected: Data Identifier 0 1 2 Data Net/Gross weight Total weight Peak weight The scoreboard is designed to work with Intercomp's S400 (4 inch) and SA2000 (2 inch) scoreboards. The following describes how to configure the S400 or SA2000 to work with the scoreboard output. The above diagram is the S400 switch pack layout, The SA2000 has pack C below B.
CS1500, Users Rev S, June, 2009 Pack C, SW 1 to 4: Baud Rate C-1 9600 ON 4800 OFF 2400 ON 1200 OFF 600 ON 300 OFF 150 ON 75 OFF C-2 ON ON ON OFF OFF ON OFF OFF C-3 ON ON OFF ON OFF OFF OFF ON C-4 OFF OFF OFF OFF ON OFF OFF ON The connection to an Intercomp S400 display is: CS1500 S400 TXD (F) 2 (RXD) GND (B) 7 (GND) The connection to an Intercomp SA2000 display is: CS1500 SA2000 TXD (F) 3 GND (B) 7 The connection to a 9-pin PC communication port is: CS1500 PC 9-pin TXD (F) 2 GND (B) 5 Note: For some se
CS1500, Users Rev S, June, 2009 Printer Ticket The printer ticket output is an externally available signal designed to drive a printer or a computer's RS-232 input.
CS1500, Users Rev S, June, 2009 How to reach Intercomp Service Things to know: 1. 2. 3. 4. The service is for a CS1500 crane scale. When did you purchase your scale? What is your serial number? 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.
