Digital Diagnostic Junction Box Version 1.
Contents About This Manual ................................................................................................................................... 1 1.0 Introduction.................................................................................................................................. 1 1.1 System Configurations and Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 2.0 Installation ............................................
5.0 Calibration ................................................................................................................................. 31 5.1 920i Front Panel Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 5.1.1 5.1.2 5.1.3 5.1.4 Theoretical Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cal-Match Calibration . . . . . . . . . . . . .
About This Manual This manual is intended for use by service technicians responsible for installing and servicing 920i™ digital diagnostic junction boxes. This manual applies to Version 2145 or later of the iQUBE software and Version 2.05 or later of the 920i indicator software. Configuration and calibration of the iQUBE can be accomplished using the Revolution III configuration utility.
Configuration consists of the following steps: Define Load Cells: This is the electrical sensitivity (mV/V output) and capacity specification of the load cells. Load cell names and serial number can also be specified. Define Platforms: A platform is a contiguous weigh bridge. Any iQUBE board can assign load cells to two separate platforms. A maximum of four platforms can be defined in an iQUBE system. The relationship between load cells is also defined as a paired or circular arrangement.
2.0 Installation This section describes procedures for connecting load cell, analog output, power, and serial communications cables to the iQUBE junction box. Assembly drawings and replacement parts lists for the iQUBE are included for the service technician. Use a wrist strap to ground yourself and protect components from electrostatic discharge (ESD) when working inside the iQUBE enclosure. 2.
GND INPUT/OUTPUT LEDs: IO 1 IO 2 IO 3 IO 4 IO 6 4 5 6 7 CELL STATUS LEDs C2 C3 C4 8 D1 DIP SWITCH / S1 C5 4-Channel C6 C7 C8 J3 1 Version Label LED EXTENSION SW1 SETUP 1 8-Channel 1 ON GREEN = POWER ON PIN 1 CORE MODULE F1 J3 Y –SIG OFF J2 Z GND SHLD SHLD +SIG J7 C1 +EXC J8 –EXC ANALOG2 SHLD 1 J9 ANALOG 1 J10 BOARD POWER 1 1 J11 SECONDARY POWER 1 1 J4 SHLD –SIG +SIG 8-CHANNEL MODELS ONLY +SIG –SIG SHLD +PWR GND SHLD +PWR GND SHLD Figure 2-2
2.5 Serial Communications RS-485 Connections to Host 920i The J4 and J7 serial communications ports on the iQUBE connector board support communications between the iQUBE and a host device (indicator or PC) or other iQUBE units. • Port J7 supports full-duplex RS-232 or four-wire RS-485 communications between the primary iQUBE unit and a host device.
DIP switches on the core module of each iQUBE must be set to indicate whether the unit is a primary or secondary, the communication protocol and port used, and the secondary address. • For the primary unit, DIP switches 1–3 must all be set OFF. Set switches 5 and 6 based on the protocol (RS-232 or RS-485) and port (J7 or J6) used to communicate with the host device. • For secondary units, DIP switch 5 must be set ON; use switches 1–3 to set the secondary address as shown in Table 2-5.
NOTE! ALL SIX WIRES, INCLUDING SHIELD AND GROUND WIRES, MUST BE CONNECTED FOR COMMUNICATION BETWEEN iQUBE UNITS TO HOST INDICATOR OR PC PRIMARY iQUBE UNIT SECONDARY1 iQUBE UNIT 1 Z/TXD Y Y B A A 120Ω B Y Z GND SHLD 1 Z GND SHLD 1 SHLD GND SHLD GND Z/TXD Y 120Ω B A/RXD J7 B A/RXD J7 1 J4 J4 Figure 2-4.
2.7 Digital I/O The iQUBE junction box is available with support for eight channels of digital I/O. Digital inputs can be set to provide many indicator functions, including all keypad functions. Digital inputs are active low (0 VDC), inactive high (5 VDC). Digital outputs are typically used to control relays that drive other equipment. Outputs are designed to sink, rather than source, switching current. Each output is a normally-open collector circuit, capable of sinking 25 mA when active.
2.8 Analog Output The analog output option consists of either a 0-30mV (PN 77146) or 0-20mA (PN 77797) digital-to-analog (DAC) card that plugs into the iQUBE core module. The 0–30 mV output simulates the output of a load cell or standard junction box, allowing connection to standard indicators. A 0–20 mA (passive only) DAC is also available for PLC applications. the 0-20mA and the 0-30mV DAC cards connect to J4 on the iQUBE core module. See Figure 2-6 for J4 location.
2.9 Core Module DIP Switches The DIP switches on the iQUBE core module must be set to configure the iQUBE as a primary or secondary unit, and to specify the type of serial communications provided by the unit. Table 2-7 lists the DIP switches and their functions.
2.11 iQUBE Communications Configurations The following sections describe some of the ways digital or analog output from the iQUBE can be connected to weight indicators. 2.11.1 Copper-Wire Connection to the 920i A basic configuration of the iQUBE is shown in Figure 2-8. A single 6-conductor load cell cable can be used both to supply 6 VDC power to the iQUBE and to exchange serial data with the 920i indicator.
2.11.3 Remote Fiber-Optic Module (PN 77789) The optional remote fiber-optic module provides optically isolated digital-to-analog (DAC) conversion of digital data received from the iQUBE. The analog output from the module can be connected to the analog (load cell) signal input of a standard weight indicator that can read 0-30mV (0-20mA) referenced to ground (see Figure 2-10).
2.11.4 Analog Output The analog output from the iQUBE can be connected to the analog signal inputs of any weight indicator that can be read 0-30mV (0-20mA) referenced to ground (see Figure 2-12). Analog output from the iQUBE requires that a digital-to-analog (DAC) card be installed on the iQUBE core module. Both voltage- and current-based DAC cards are available. See Section 2.14.1 on page 15 for more information about DAC card installation.
2.12 Installing Tap and Run Connectors for 920i Power iQUBE installations that are remotely powered by the 920i indicator, and those that use the 920i internal fiber-optic module, require tap and run connectors to draw power from the 920i power supply (see Figures 2-13 and 2-14). To install tap and run connectors in the 920i indicator, do the following: 1. Place red (+6V) wire from 920i power supply inside the run channel of the tap and run connector.
2.13 Installing Supply the Optional Power The optional internal power supply provides 6VDC power for the iQUBE from 115 or 230 VAC power sources. It is required for iQUBE configurations that include the Ethernet option or that consist of more than two iQUBE units. Fiber-optic configurations can use the internal power supply to provide electrical isolation from the indicator. 2.14.
2.14.4 920i Internal Fiber-Optic Option To install the 920i internal fiber-optic interface, position the adhesive square on the top of the 920i power supply shield (see Figure 2-14 on page 14). Press the fiber-optic interface backplate onto the adhesive square, then install the interface board onto the backplate. Attach fiber-optic cables to connectors V1 (receive) and V2 (send). Attach RS-232 communications cables from connector J3 on the fiber-optic interface to any available 920i serial port.
2.17 Replacement Parts and Assembly Drawings Table 2-9 lists replacement parts for the iQUBE models, including all parts referenced in Figures 2-19 and 2-20. Ref Number PN Description (Quantity) 1 92938 iQUBE cover decal (1) 3 14822 Machine screws, 4-40NC x 1/2 (8) 4 77140 iQUBE connector board, 4-channel (1) 77139 iQUBE connector board, 8-channel (1) 77727 iQUBE connector board, 8-channel with digital I/O (1) 5 14637 Nuts (for power ground), 1/4-20NC (2) 6 31546 1/4-in.
1 3 4 5 6 7 8 10 12 11 Figure 2-19.
18 19 21 Figure 2-20.
3.0 920i Indicator Configuration To configure the 920i indicator, the indicator must be placed in setup mode. The setup switch is accessed by removing the large fillister head screw on the desktop and universal enclosures. Switch position is changed by inserting a screwdriver into the access hole and pressing the switch. When the indicator is placed in setup mode, a series of menus is shown across the top of the display, along with the words Scale Configuration.
SYSTEM: The system setup display is divided into three areas: • System (middle section): Highlight the system being configured, then use the left arrow key to move to the Available Platform section. • Available Platforms (left section): Use this section to assign platforms to the system. Use the up and down keys to highlight the desired platform, then press the Add softkey to assign the platform to the system. • Associated Platforms (right section): Lists platforms that have been assigned the system.
3.4 iQUBE-Specific Menu Structures and Parameter Descriptions The following sections provide graphic representations of iQUBE-specific 920i menu structures and tables describing the menu parameters. Default values are shown in bold type; numeric ranges and string values are shown in italic type. Parameters shown surrounded by a dotted-line box only appear under the special circumstances explained under each box. NOTE: Port 3 is the default port for most print formats.
SERIAL Menu (iQUBE Submenu) Parameter CONFIG CELLS Choices 8/0/0/0 8/4/0/0 8/4/4/0 8/8/0/0 4/0/0/0 4/4/0/0 4/4/4/0 4/4/4/4 4/8/0/0 CELLA1–CELLA8 List of cells for CONFIG type Description Specifies the iQUBE system configuration. The first value (8 or 4) designates the number of channels on the iQUBE primary board; the remaining three values represent attached secondary units, if any, and the number of channels on each secondary board. NOTE: The iQUBE allocates either 4 or 8 channels per board.
SERIAL Menu (iQUBE Submenu) Parameter Choices Description SOURCE OFF system_name Analog output source. If analog output DAC is installed, assign system name. FULLSC 300000.0 value (weight) Analog output full scale range. Specifies the weight value at the full scale analog output (30 mV or 20 mA). BIT 1 – BIT 8 — Specifies the function of the digital I/O bit. See the 920i Installation Manual, PN 67887, for more information.
3.4.2 iQUBE Submenu, IQDIAG Parameters Figure 3-3 shows the IQDIAG parameters on the IQUBE submenu. The IQDIAG parameters allow customization of the iQUBE’s diagnostic routines. DIGIO IQDIAG TESTCOM ZEROREF CELLBAL ENABLE THRH %THRH ON 0.125000 25 OFF number number DELAY ENABLE THRH %TOLR LOAD 900 ON number OFF 0.200000 25 5000.000 number number number If ENABLE = ON If ENABLE = ON LDRIFT PKtoPK ENABLE LIMIT ON 0.
iQUBE Submenu, IQDIAG Parameters Parameter IQDIAG Subparameter ZEROREF CELLBAL LDRIFT PKtoPK CELLEMU Choices Description See descriptions under Level 5 Submenus. Each group of iQUBE diagnostic parameters can be enabled or disabled using the ENABLE subparameter. See Section 6.0 on page 34 for more information about iQUBE diagnostic tests. Level 5 Submenus ZEROREF CELLBAL ENABLE ON OFF Enable zero reference diagnostics.
iQUBE Submenu, IQDIAG Parameters Parameter LDRIFT PKtoPK CELLEMU Subparameter Choices Description ENABLE ON OFF Enable loaded drift test diagnostics. Tests for drifting load cell output, which can indicate binding or a deteriorating cell, when the scale is loaded. The test begins after the load value has been exceeded and the scale is considered out of motion (see note.) Once the scale comes to a stable live load, the timer will start.
3.4.3 PFORMT Menu See the 920i Installation Manual, PN 67887, for general information about print formats. See Section 7.2 on page 39 for information about the ALERT print format. NOTE: Port 3 is the default port for most print formats. If the iQUBE is attached to the 920i using port 3, ensure that the serial print format is not also routed to port 3. Use the PORT parameter to change the print format serial port assignment.
4.0 PC Configuration When used with the 920i indicator, the iQUBE can be configured using a PC running either the iRev or the Revolution III program. iRev allows complete configuration of the 920i, with the capability to download the iQUBE configuration from the indicator to the junction box. Revolution III can be used to configure the iQUBE directly, for use with any indicator. iQUBE configurations created using Revolution III can be uploaded to the 920i. 4.
Platforms field. Click the Platform 1 box to assign Platform 1 to System 1. Use the Gen eral display to enter scale system parameters. 4.1.2 Downloading to the iQUBE Once configuration is complete, you must download the configuration data from the PC to the iQUBE. 1. Go to the Communications menu and select Connect… Revolution automatically detects the iQUBE communications port. 2. Return to the Communications menu and select Download Configuration. Click Begin to initiate the download.
5.0 Calibration The iQUBE can be calibrated using the 920i front panel or Revolution III. The following sections describe the calibration procedure for each of the calibration methods.
calibration. NOTE: Cal-Match calibration can be canceled by pressing the CLEAR key. 6. Ensure scale is empty, then use the up and down keys to select Corner Cal-Match (see Figure 5-2) or Section Cal-Match. Press enter. The iQUBE calculates the zero reference point. Tweaking can be performed following a Cal-Match calibration or when replacing a load cell. 5.1.
iQUBE calibration is complete. You can view the active status of the cells, platform, or system by returning to the Interactive menu and selecting Status Monitoring for cells, platforms, or systems. Click on the Auto Refresh box to automatically update the readings from the iQUBE.
6.0 Diagnostics 6.1 iQUBE Diagnostic 6.2 The iQUBE connector board provides bi-color cell status LEDs (see Figure 2-2 on page 4) that indicate the status of connected load cells. Table 6-1 lists the cell status indications shown by the LEDs. LED Color meaning Green Load cell good Red Load cell error Off Disabled/no load cell connected Cell Mate Relationships Cell mates to a specific load cell are defined as the load cells that are horizontally or vertically adjacent to each other.
Diagnostic Test Examples Zero Reference Error No Zero Reference Error C1 C1 Threshold 125 (m/v) Threshold 125(m/v) C2 25% Threshold 25% Threshold C3 C4 C2 C3 C4 Calibrated Dead Load Calibrated Dead Load Figure 6-2. Zero and No Zero Reference Errors Loaded Drift Error No Loaded Drift Error C1 C1 Limit 25 (m/v) Limit 25 (m/v) C2 C3 C4 C2 C3 10% Limit 10% Limit C4 Stable Live Load (10lb) Stable Live Load (10lb) Load Load Figure 6-3.
6.4 Diagnostic Setup Parameters associated with each of the iQUBE ’s diagnostic tests can be set using the 920i menus, iRev, or Revolution III. See Section 3.4.2 on page 25 for descriptions of the iQUBE diagnostic parameters for the 920i. • • Number of weighments Cell status for highlighted cell. Use the indicator navigation keys to select cells. NOTE: Displayed deadload and current values are raw millivolt values.
Table 6-4 lists the system and cell error messages.
7.0 Alerts When attached to the 920i indicator, diagnostic error messages generated by the iQUBE are shown on the indicator display. The 920i alert support also allows messages to be printed or, if the 920i is equipped with an Ethernet card attached to a network, routed via e-mail to an alert contact. 7.1 Network Alert Notification Figure 7-1 shows an example of a system configured to relay iQUBE alert messages through e-mail. The 920i indicator is equipped with an Ethernet card.
7.2 Alert Format The default 920i alert print format is as follows: Commands used in the 920i alert format are listed in Table 7-1.
7.3 FEATURE Menu, CONTACT Submenu SCALES SERIAL FEATURE PFORMT SETPTS DIG I/O ALGOUT VERS CONTACT CMPNY ADDR1 ADDR2 ADDR3 NAME1 NAME2 NAME3 company_name address_line_1 address_line_2 address_line_3 contact_name_1 contact_name_2 contact_name_3 PHONE1 PHONE2 PHONE3 EMAIL NEXTCAL phone_number phone_number phone_number email_address date Figure 7-2.
7.4 PFORMT Menu See the 920i Installation Manual, PN 67887, for general information about print formats. See Section 7.2 on page 39 for information about the ALERT print format. NOTE: Port 3 is the default port for most print formats. If the iQUBE is attached to the 920i using port 3, ensure that the serial print format is not also routed to port 3. Use the PORT parameter to change the print format serial port assignment.
8.0 920i Serial Commands The following section lists 920i serial commands used to configure and control the iQUBE . See the 920i Installation Manual, PN 67887, for more information about using serial commands. Command Description Values SJ.SERIAL_NUMBER#n iQUBE serial number Read-only output SJ.CONFIG#n iQUBE primary-secondary 8/0/0/0, 4/0/0/0, 4/8/0/0, 4/4/0/0, 4/4/4/0, 4/4/4/4, 8/4/0/0, 8/4/ 4/0, 8/8/0/0 configuration SJ.SECT_TYPE#n Section type PAIRED, CIRCULAR SJ.VERSION.
Command Description Values SJ.SYS.NAME.s#n System name System1, system_name (24 characters, maximum) SJ.SYS.PLATS.s#n System platforms 0,0,0,0 (specify platform numbers, 1–4, assigned to sytem) or NONE (to clear platform list) For system (SJ.SYS.) commands ending with “s#n”, s is the system number, n is the 920i serial port number. Table 8-4. 920i iQUBE System Serial Commands Command Description Values SJ.DIAG.ZEROREF#n Zero reference diagnostic enable ON, OFF SJ.DIAG.ZR.
Command Description Set digital output on (active) at bit b (9–24), for iQUBE connected to slot s. NOTE: Odd numbered ports use bits 9–16; even numbered ports use bits 17–24. DON.b#s Example: To turn on digital output bit 1 for an iQUBE attached to port 3 (slot 0), use DON.9#0. Set digital output off (inactive) at bit b (9–24), for iQUBE connected to slot s. NOTE: Odd numbered ports use bits 9–16; even numbered ports use bits 17–24.
9.0 9.1 Appendix Troubleshooting The following section provides information to assist for troubleshooting or repairing the iQUBE. Materials needed to accomplish these steps are: • Revolution III loaded onto a laptop PC. If using Virtui, iRev must be loaded on the PC • Digital voltmeter 9.1.1 General Steps To determine that the iQUBE has power, check LED D1 on the core module and LEDs for the load cells assigned on each connector board (see Figure 2-2 on page 4).
Symptom Cause/Remedy Very large trim factors Verify that the capacity and sensitivity of each configured load cell is correct. Cal-Match failure Try using a test weight with a smaller footprint. Verify communications. Calibration shift Possible mechanical problem or corrupted data stored in iQUBE. If another device connected to the iQUBE causes this, check for proper common grounding. No communication In setup of iQUBE, go to TESTCOM to verify communications.
Virtui _____________ 4. What communication method is being used? RS-232___________ RS-485___________ Fiber–optic_________ R/F______________ 5. What is the iQUBE configuration? 6. Do you have the manual for all the equipment in use? 7. After connection, is there Voltage at the iQUBE? 8. Is D1 On or Off on the connector board? 9. If using a 920i, continue to step 10.
20. Is the adjusted weight, in the lower right corner, reading a weight or 000000? If the adjusted weight is showing a good weight, the problem is within the 920i configuration If the adjusted weight is displaying 000000, the iQUBE has lost calibration or the core has gone bad. 21. Is one single cell reading bad? If yes, go to step 22. If no, go to step 26. 22. Is the single cell reading 62mV? If yes, the cell bridge is open or there is a bad cell. Check the signal and go to step 27. If no, go to step 23.
• iRite™ Programming Reference, PN 67888 Virtui Option Cards • Virtui Single-Channel A/D Card Installation Instructions, PN 69092 • Virtui Dual-Channel A/D Card Installation Instructions, PN 69090 • Virtui 24-Channel Digital I/O Expansion Card Installation Instructions, PN 69087 • Virtui Serial Expansion Card Installation Instructions, PN 69088 • Virtui Pulse Input Card Installation Instructions, PN 69086 • Virtui Memory Expansion Card Installation Instructions, PN 69085 520/920i Communications Options •
22. Replace the two jumpers J3 that were removed in step 2. 23. Place new label, 2145 on the CPU chip. 9.4 Software Version Updates Version Number 10243 Update Initial Release 12283 Protocol chagne from iQUBE - requires 920i version 2.
iQUBE Limited Warranty Rice Lake Weighing Systems (RLWS) warrants that all RLWS equipment and systems properly installed by a Distributor or Original Equipment Manufacturer (OEM) will operate per written specifications as confirmed by the Distributor/OEM and accepted by RLWS. All systems and components are warranted against defects in materials and workmanship for two years. RLWS warrants that the equipment sold hereunder will conform to the current written specifications authorized by RLWS.
