Avery Weigh-Tronix XR Series Owner's manual

XR Series
LED Remote Displays
XR LED Remote Displays
Installation and Technical
Instructions
ENGLISH
AWT35-000043 Issue AC May 21, 2007
*43121-0012*

XR Series_i_AWT35-000043.book

XR Series Installation and Technical Instructions 3
©Avery Weigh-Tronix LLC, 2006. All rights reserved.
The information contained herein is the property of Weigh-Tronix,
Inc and is supplied without liability for errors or omissions. No part
may be reproduced or used except as authorized by contract or
other written permission. The copyright and the foregoing
restrictiononreproductionanduse extendtoall mediainwhichthe
information may be embodied.
Avery Weigh-Tronix is a trading name of Weigh-Tronix, Inc
Trademarks and acknowledgements
Avery Weigh-Tronix, Avery Berkel, Dillon, NCI and Salter
Brecknell are registered trademarks in certain jurisdictions.
All third party brands and product names used within this
document are trademarks or registered trademarks of their
respective holders.
IMPORTANT
Whenprogrammingorconfiguringtheequipmentyoumustensure
that you comply with all relevant standards and legislation. The
example settings given in this book may not be legal for trade with
the public.
Declarations of compliance
United States
This equipment has been tested and found to comply with the limits for a
Class A digital device, pursuant to Part 15 of the FCC Rules. These limits
are designed to provide reasonable protection against harmful interference
when the equipment is operated in a commercial environment. This
equipment generates, uses, and can radiate radio frequency energy and, if
not installed and used inaccordance withthe instructionmanual, may cause
harmful interference to radio communications. Operation of this equipment
in a residential area is likely to cause harmful interference in which case the
user will be required to correct the interference at his own expense.
Canada
This digital apparatus does not exceed the Class A limits for radio noise
emissions from digital apparatus set out in the Radio Interference
Regulations of the Canadian Department of Communications.
Les présent appareil numérique n’émet pas de bruits radioélectriques
dépassant les limites applicables aux appareils numériques de la Classe A
prescrites dans le Règlement sur le brouillage radioélectrique edicté par le
ministère des Communications du Canada.

4XR Series Installation and Technical Instructions

XR Series Installation and Technical Instructions 5
page
Chapter 1: Introduction..................................................................................................7
About This Manual ...................................................................................................7
Warnings .................................................................................................................. 7
Display......................................................................................................................8
Chapter 2: Installation....................................................................................................9
Installing the XR 4500, XR 4500TL or XR 6500.......................................................9
Pre-installation (Receiving Inspection)............................................................9
Opening an Unmounted Enclosure.................................................................9
Removing the Electronics Carriage...............................................................10
Mounting Instructions....................................................................................10
Opening the Enclosure (Mounted) ................................................................13
Installing the XR 2000 ............................................................................................16
Opening the XR 2000 Enclosure...................................................................16
Mounting Instructions....................................................................................16
Chapter 3: Wiring.........................................................................................................18
Wiring the XR 4500, 4500TL or 6500.....................................................................18
Power Wiring.................................................................................................18
Communications Wiring ................................................................................19
Wiring the XR 2000 ................................................................................................ 24
Power Wiring.................................................................................................24
Communication Wiring..................................................................................25
Chapter 4: Wireless Communication...........................................................................28
Wireless Set-up for All XR Models .........................................................................28
XR Remote Display.......................................................................................28
Indicator ........................................................................................................28
Base Station Wireless Transceiver ............................................................... 29
Wireless Connection Test .............................................................................31
Chapter 5: Start-Up......................................................................................................32
Power Up................................................................................................................32
Reset Button...........................................................................................................32
Auto-Learn..............................................................................................................32
LEARN Button........................................................................................................32
Diagnostic Indicator Lights. ....................................................................................33
Chapter 6: Configuration & Options.............................................................................34
CONFIG and OPTION Switches (XR 4500, 4500TL, and XR 6500)......................34
CONFIG Switches.........................................................................................35
OPTIONS Switches.......................................................................................37
CONFIG Switches (XR 2000).................................................................................39
Chapter 7: Traffic Light Control....................................................................................41
External Traffic Lights (XR 4500, XR 4500TL and XR 6500).................................41
Contents

6XR Series Installation and Technical Instructions
Built-in Traffic Light (XR 4500TL Only) ......................................................... 43
Chapter 8: XR Utility Programs ................................................................................... 44
XR 4500, XR 4500TL, and XR 6500 Utility Programs............................................ 44
Program 1: Normal Mode.............................................................................. 44
Program 2: Axle Weighing with Totals.......................................................... 44
Program 3: Axle Weighing - Driving On........................................................ 44
Program 4: Command Mode......................................................................... 45
XR 2000 Utility Programs....................................................................................... 47
Chapter 9: Troubleshooting & Error Messages........................................................... 49
Chapter 10: Spare Parts Lists ..................................................................................... 52
Chapter 11: Specifications........................................................................................... 56

XR Series Installation and Technical Instructions 7
Thank you for purchasing an XR series remote display. The XR series
incorporate the highest performance standards and the most standard
features of any weighing display, making them the best choice for virtually
any remote viewing application.
Like all Avery Weigh-Tronix products, the XR remote displays are designed
with durability, functionality and versatility in mind. If you should need
technical assistance, please contact your local, authorized Avery Weigh-
Tronix distributor.
1.1 About This Manual
Major sections of this manual are numbered and headed by titles in a black
bar like Introduction above. Subheadings appear in the left column.
Instructions and text appear on the right side of the page. Occasionally
notes, tips, and special instructions appear in the left column.
1.2 Warnings
Installation and configuration procedures (as described in this manual)
should only be carried out by qualified scale service technicians, as
authorized by Avery Weigh-Tronix.
Scale service technicians handling circuit boards must observe proper
electrostatic discharge (ESD) handling procedures.
CAUTION! HIGH VOLTAGES are present inside the XR enclosure.
ATTENTION! Unauthorized installation and service of this unit may
void the warranty.
Introduction
1

8XR Series Installation and Technical Instructions
Introduction
1.3 Display
Figure 1.1 Display samples: Top-XR 4500, Bottom-XR 2000
The weight display is made up of 6 LED digits of 7 segments each. Up to 2
decimal places can be displayed. (Five decimals on the XR 2000).
The units have four annunciators under the display with bright LED markers:
GR = Gross Weighing Mode
NT = Net Weighing Mode
lb = Pounds
kg = Kilograms

XR Series Installation and Technical Instructions 9
2.1 Installing the XR 4500, XR 4500TL or XR 6500
Pre-installation (Receiving
Inspection) It is always good practice to verify that the unit is complete and undamaged
upon receipt.
• Check over packaging for any signs of damage.
• Remove the XR from its protective packaging and check for damage.
• Verify that the shipment includes:
Correct XR remote display (complete and intact, with power cord).
Installation and Technical Manual.
• Displays ordered with the wireless option should include:
Radio module
External antenna
Internal antenna cable
Base station kit
Opening an Unmounted
Enclosure 1. When opening an XR unit (4500 / 4500TL / 6500) prior to mounting,
place the unit top-down on a smooth, flat, surface.
2. Make sure the unit is disconnected from power.
3. Remove the captive screws from the bottom of the enclosure.
4. Angle the electronics carriage so the tabs are at opposite corners of
the main enclosure opening.
5. Guide the electronics carriage out of the main enclosure, being
careful to avoid bending any LED leads. Each LED is mounted very
close to the PCB to prevent bending.
6. Place the electronics carriage bottom-down on the flat surface as
illustrated. See Figure 2.1
Installation
2

10 XR Series Installation and Technical Instructions
Installation
Figure 2.1 Opening the XR 4500 / 4500TL / 6500 (side view)
Removing the Electronics
Carriage 1. Once the electronics carriage has been removed from the main
enclosure, disconnect the AC power and ground connections from the
power supply board.
2. Disconnect the green ground wire from the Electronics Carriage
frame.
Mounting Instructions 1. Inspect the installation site for properly grounded power.
The electronics carriage may be
removed to reduce weight when
installing.
Mounting hole size in the case is
3/8”.
2. Ensure that mounting structures (walls, pole brackets, etc.) will bear
the weight of the display (XR 4500: 20 lbs, XR 6500 & 4500TL: 32
lbs).
3. Allow proper clearance for lowering and removing the electronics
carriage.
4. Use proper hardware, including wall anchors where necessary, when
mounting the enclosure. Secure the main enclosure to wall or pole
mounted bracket with 5/16ths bolts.
5. Run power and communication cables into the enclosure via strain
reliefs (as required).

XR Series Installation and Technical Instructions 11
Wall Mounting Hole patterns for the XR series are given in Figure 2.2.
XR 4500
XR 4500TL and XR 6500
Figure 2.2 Outline dimensions and hole pattern
Pole Mounting Bracket 1. Select appropriate height and fasten the small “C” bracket to the pole
using the mounting clamps provided.
The pole mounting bracket allows
use of poles or beams up to eight
inches in diameter.
2. Fasten the larger “C” bracket to the small “C” bracket using the
hardware provided.
3. Fasten the XR display to the pole mounting bracket as outlined in the
mounting instructions (See Figure 2.3).

12 XR Series Installation and Technical Instructions
Installation
Figure 2.3 Pole mounting bracket

XR Series Installation and Technical Instructions 13
Visor Option 1. Loosen the mounting hardware on the main enclosure 1/8th inch.
2. Rest the visor’s mounting brackets on the bolt between the bolt head
and the front of the side mounting plates.
3. Re-tighten the mounting hardware.
Figure 2.4 Optional visor
Opening the Enclosure
(Mounted) 1. Make sure the unit is disconnected from power.
2. Remove the captive screws from the bottom of the enclosure.
3. Slowly, guide the electronics carriage out of the main enclosure,
being careful to avoid bending any LED leads. Each LED is mounted
very close to the PCB to prevent bending.
4. The electronics carriage has tabs on either end that allow it to rest on
the main enclosure’s flange when mounted (As seen in Figure 2.5 &
2.6).
Figure 2.5 Front view

14 XR Series Installation and Technical Instructions
Installation
Figure 2.6 Back view
Lowering the Electronics Plate 1. Remove the two (2) captive screws holding the electronics plate to the
electronics carriage.
2. Slowly, allow the electronics plate to swing down, making access
easier for wiring and service. See Figure 2.7.
Figure 2.7 Side view

XR Series Installation and Technical Instructions 15
Remove the Electronics
Carriage 1. Once the electronics carriage has been lowered from the main enclosure, disconnect the AC power and ground connections from the
power supply board.
2. Disconnect the green ground wire from the electronics carriage
frame.
3. Angle the electronics carriage so the tabs are at opposite corners of
the main enclosure opening.
4. Guide the electronics carriage free of the main enclosure.

16 XR Series Installation and Technical Instructions
Installation
2.2 Installing the XR 2000
Opening the XR 2000
Enclosure 1. Make sure the unit is disconnected from power.
2. Remove the 6 screws (with sealing washers) from the front of the
enclosure.
3. Guide the front panel away from the main enclosure. Be sure to watch
the internal cable connections! See Figure 2.8
Figure 2.8 XR 2000 enclosure laid open
Mounting Instructions 1. Inspect the installation site for properly grounded power.
Mounting hole size in the case is
5/16”. 2. Ensure that mounting structures (walls, posts, etc.) will bear the weight of the display (XR 2000: 6 lbs).
3. Use proper hardware, including wall anchors where necessary, when
mounting the enclosure. Secure the main enclosure to wall or pole
mounted bracket with 5/16ths bolts.
4. Run power and communication cables into the enclosure via strain
reliefs (as required).

XR Series Installation and Technical Instructions 17
2.2 Installing the XR 2000
Figure 2.9 XR 2000 dimensions

18 XR Series Installation and Technical Instructions
Wiring
3.1 Wiring the XR 4500, 4500TL or 6500
Power Wiring XR displays are wired for power at the factory. The factory supplied power
cable can be removed for direct AC wiring if necessary.
HIGH VOLTAGE! Only trained
personnel should attempt this
procedure.
AC wiring must be terminated at
the AC Power Terminal Block, not
directly at the Power Supply board.
1. Ensure the unit is disconnected from power and open the enclosure.
Detach the electronics carriage to free up space.
2. Loosen the standoff nuts and remove the terminal block from the
mounting posts.
3. Disconnect the factory supplied power cord from the terminal block
and grounding post. Do not remove the internal ground wire.
4. Loosen the strain relief and pull the power cord through. Run the new
power cable through the strain relief. Leave about 6 inches of wire to
work with and tighten the strain relief.
5. Connect the new ground wire to the grounding post and tighten nut.
The internal ground wire runs from the grounding post to Pin 1 on the
terminal block.
6. Wire the new power cable to the terminal block. See the table below:
7. Replace the terminal block and fasten on mounting posts.
Wiring
3
AC POWER TO TERMINAL BLOCK
HOT (+) PIN 3
NEUTRAL (-) PIN 2
GROUND (GND) PIN 1

XR Series Installation and Technical Instructions 19
8. Ensure that the internal power cable is connected to the power supply
board. See Figure 3.1.
Figure 3.1 Power wiring
Communications Wiring All communications wiring terminates at the controller board.
Communications should be wired before applying power to the unit, if
possible.
Communication Input Jumper Acommunications inputtype (RS 232,RS422/485, or 20 mA Loop) must be
selected by placing the jumper on the appropriate pins. See photo and
illustrations in Figure 3.2. Photo shows the input select jumpers circled in a
thick white line.
Figure 3.2 Jumper positions

20 XR Series Installation and Technical Instructions
Wiring
RS 232 Wiring
1. Set the Communication Input Jumper (JP 1) to RS232.
2. Terminate the indicator’s communication wires at the RS 232 terminal
(J3), shown in Figure 3.3.
Figure 3.3 RS 232 Terminal shown at arrow
See the table below for pin assignments:
RS 232 Daisy Chain
INDICATOR TO XR
TRANSMIT (TX) RECEIVE (RX)
RECEIVE (RX) NO CONNECTION
SIGNAL GROUND (GND) SIGNAL GROUND (SIG GND)
INDICATOR TO RD 1 TO RD 2
TX RX
RX TX RX
GND GND GND