Scaletron AccuPro-5000 User manual

AccuPro-5000™MEASUREMENT SYSTEM OPERATOR MANUAL
Issued by Department:
Engineering
Doc. Number:
5000-00-00-002
Revision:
02
Effective Date:
10/05/2021
File: 5000-00-00-002-r2_
AccuPro_5000_Operator_Manual
Copyright© 2021 Scaletron Industries, Ltd
All Rights Reserved
Page 1of 63
Scaletron Industries, LTD
53 Appletree Lane
Plumsteadville, PA 18949
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or implied, under any patent, copyright or trade secret right is granted or implied by the conveyance of this
document. No part of this document may be reproduced, transmitted, transcribed, stored in a retrieval
system, translated into any language or computer language, in any form or by any means, electronic,
mechanical, magnetic, optical, chemical, manual, or otherwise without the prior written permission of
Scaletron Industries, Ltd.
AccuPro-5000™
Measurement System
Operator Manual

AccuPro-5000™MEASUREMENT SYSTEM OPERATOR MANUAL
Issued by Department:
Engineering
Doc. Number:
5000-00-00-002
Revision:
02
Effective Date:
10/05/2021
File: 5000-00-00-002-r2_
AccuPro_5000_Operator_Manual
Copyright© 2021 Scaletron Industries, Ltd
All Rights Reserved
Page 2of 63
Table of Contents
1Introduction..................................................................................................................................................................6
1.1 Scope ......................................................................................................................................................................6
1.2 Acronyms and Abbreviations..............................................................................................................................6
1.3 Definitions.............................................................................................................................................................7
2System Specification Summary.................................................................................................................................. 8
3Assembly and Set-Up Instructions ..........................................................................................................................11
3.1 Factory Configuration........................................................................................................................................12
3.2 Control-Panel Preparation and Mounting......................................................................................................12
3.3 External Connections.........................................................................................................................................13
4System Hardware .......................................................................................................................................................14
4.1 Liquid Crystal Display (LCD) Board................................................................................................................14
4.2 Backplane Board.................................................................................................................................................15
4.3 Main Processor Board........................................................................................................................................17
4.4 Analog Input Board............................................................................................................................................19
4.5 Analog Output Board (4-20 mA Output)........................................................................................................20
4.6 Analog Output Board (0-5V/10V Output) ......................................................................................................22
4.7 Relay Output Board (Dual or Quad Relays) ...................................................................................................24
5User Controls ..............................................................................................................................................................25
5.1 Keypad .................................................................................................................................................................26
5.2 Rotary Knob ........................................................................................................................................................26
6User Indicators ...........................................................................................................................................................26
6.1 LCD Module ........................................................................................................................................................26
6.2 Channel Status LED Array ................................................................................................................................26
7System Modes .............................................................................................................................................................28
7.1 Run Mode ............................................................................................................................................................28
7.2 Setup Mode .........................................................................................................................................................28
8System Main Menu ....................................................................................................................................................29
8.1 Scale Display .......................................................................................................................................................32
8.2 Alerts/Alarms .....................................................................................................................................................32
8.3 Dead Weight........................................................................................................................................................35

AccuPro-5000™MEASUREMENT SYSTEM OPERATOR MANUAL
Issued by Department:
Engineering
Doc. Number:
5000-00-00-002
Revision:
02
Effective Date:
10/05/2021
File: 5000-00-00-002-r2_
AccuPro_5000_Operator_Manual
Copyright© 2021 Scaletron Industries, Ltd
All Rights Reserved
Page 3of 63
8.4 Calibrate Weight.................................................................................................................................................37
8.5 Capacity Weight..................................................................................................................................................39
8.6 System Config .....................................................................................................................................................40
8.7 Channel Config ...................................................................................................................................................43
8.8 Liquid Mass.........................................................................................................................................................45
8.9 Tare Adjust / Tare Secured ...............................................................................................................................47
8.10 Relay Setpoint.....................................................................................................................................................49
8.11 mA/V Output ......................................................................................................................................................52
8.12 Real-Time Clock .................................................................................................................................................54
8.13 About....................................................................................................................................................................57
9Maintenance................................................................................................................................................................59
9.1 Cleaning...............................................................................................................................................................59
9.2 Servicing the Control-Panel..............................................................................................................................59
9.3 Removing/Installing a Printed Circuit Board ................................................................................................59
9.4 Removing/Installing PCB Wire Connections.................................................................................................60
10 Troubleshooting .....................................................................................................................................................60
10.1 The Control-Panel is Not Receiving Power.....................................................................................................60
10.2 The Measurement Value is Blinking................................................................................................................61
10.3 The 4-to-20 mA Reading is Incorrect..............................................................................................................61
10.4 A Relay Output is Not Responding Correctly.................................................................................................62
10.5 Tare Weight Drift ...............................................................................................................................................62
11 Revision Log................................................................................................................................................................63

AccuPro-5000™MEASUREMENT SYSTEM OPERATOR MANUAL
Issued by Department:
Engineering
Doc. Number:
5000-00-00-002
Revision:
02
Effective Date:
10/05/2021
File: 5000-00-00-002-r2_
AccuPro_5000_Operator_Manual
Copyright© 2021 Scaletron Industries, Ltd
All Rights Reserved
Page 4of 63
Figure 1: LCD Board (Bottom Side).......................................................................................................................14
Figure 2: Backplane Board......................................................................................................................................16
Figure 3: Main Processor Board.............................................................................................................................18
Figure 4: Analog Input Board.................................................................................................................................20
Figure 5: Multiple Current AOBs with Shared Loop Power Supply..................................................................21
Figure 6: Analog Output Board - mA.....................................................................................................................22
Figure 7: Analog Output Board - V ........................................................................................................................23
Figure 8: Relay Output Board.................................................................................................................................24
Figure 9: Control-Panel Overlay (Keypad Version).............................................................................................25
Figure 10: System Menu Displays..........................................................................................................................29
Figure 11: Action Canceled Display........................................................................................................................30
Figure 12: SCALE DISPLAY Menu Option ...........................................................................................................32
Figure 13: Single versus Dual-Channel Measurement Display..........................................................................32
Figure 14: ALERTS/ALARMS Menu Option........................................................................................................33
Figure 15: ALERTS / ALARMS Messages.............................................................................................................34
Figure 16: DEAD WEIGHT Menu Option.............................................................................................................35
Figure 17: DEAD WEIGHT Control Flow Diagram .............................................................................................36
Figure 18: CALIBRATE WEIGHT Menu Option .................................................................................................37
Figure 19: CALIBRATE WEIGHT Control Flow Diagram..................................................................................38
Figure 20: CAPACITY WEIGHT Menu Option....................................................................................................39
Figure 21: CAPACITY WEIGHT Control Flow Diagram.....................................................................................40
Figure 22: SYSTEM CONFIGURATION Menu Option ......................................................................................41
Figure 23: SYSTEM CONFIGURATION Control Flow Diagram.......................................................................42
Figure 24: CHANNEL CONFIGURATION Menu Option ..................................................................................43
Figure 25: CHANNEL CONFIGURATION Control Flow Diagram...................................................................44
Figure 26: Bar-Graph Display ................................................................................................................................45
Figure 27: LIQUID MASS Menu Option...............................................................................................................46
Figure 28: LIQUID MASS Control Flow Diagram...............................................................................................47
Figure 29: TARE ADJUST & TARE SECURED Menu Option...........................................................................48
Figure 30: TARE ADJUST Control Flow Diagram ..............................................................................................48
Figure 31: TARE SECURED Control Flow Diagram............................................................................................49
Figure 32: RELAY SETPOINT Menu Option .......................................................................................................50
Figure 33: RELAY SETPOINT Control Flow Diagram........................................................................................51
Figure 34: mA/V OUTPUT Menu Option.............................................................................................................52
Figure 35: mA/V OUTPUT Control Flow Diagram .............................................................................................53
Figure 36: REALTIME CLOCK Menu Option......................................................................................................55
Figure 37: Setting the Time/Date Control Flow Diagram ..................................................................................56
Figure 38: ABOUT Menu Option ...........................................................................................................................57
Figure 39: ABOUT Control Flow Diagram............................................................................................................58

AccuPro-5000™MEASUREMENT SYSTEM OPERATOR MANUAL
Issued by Department:
Engineering
Doc. Number:
5000-00-00-002
Revision:
02
Effective Date:
10/05/2021
File: 5000-00-00-002-r2_
AccuPro_5000_Operator_Manual
Copyright© 2021 Scaletron Industries, Ltd
All Rights Reserved
Page 5of 63
Table 1: External Alarm Interface ................................................................................................................ 17
Table 2: System Mode Controls ................................................................................................................... 17
Table 3: Load-Cell Interface......................................................................................................................... 19
Table 4: Leak-Detect Sensor Interface......................................................................................................... 19
Table 5: Current Loop Interface................................................................................................................... 21
Table 6: Voltage Output Interface................................................................................................................23
Table 7: Relay Interface................................................................................................................................24
Table 8: Alerts/Alarms Priority Levels ........................................................................................................27
Table 9: Operational Menu Tree .................................................................................................................. 31

AccuPro-5000™MEASUREMENT SYSTEM OPERATOR MANUAL
Issued by Department:
Engineering
Doc. Number:
5000-00-00-002
Revision:
02
Effective Date:
10/05/2021
File: 5000-00-00-002-r2_
AccuPro_5000_Operator_Manual
Copyright© 2021 Scaletron Industries, Ltd
All Rights Reserved
Page 6of 63
1Introduction
The AccuPro-5000™is a weight and volume measurement system offering single/dual-channel
support. Its real-time measurement indication allows for precise monitoring during the process of
filling or emptying a chemical substance container.
1.1 Scope
This document describes the specifications, installation, capabilities, and basic operation of the Control-
Panel portion of the AccuPro-5000™ Measurement System. The Control-Panel represents the common
component used in multiple Measurement System configurations, differing mainly in the selection of a
Scale-Base. Detailed information for the Scale-Base is available in a separate document.
1.2 Acronyms and Abbreviations
•AC Alternating Current (reference to power-supply type)
•ADC Analog to Digital Converter
•AIB Analog Input Board
•AOB Analog Output Board (either mA or V)
•AWG American Wire Gauge
•DAC Digital to Analog Converter
•DC Direct Current (reference to power-supply type)
•DCS Distributed Control System
•EEPROM Electrically Erasable Programmable Read Only Memory
•HMI Human-Machine Interface (Controls, Indicators, and Display Menus)
•ICE In-Circuit Emulator (A device programmer/debugging tool)
•LCD Liquid Crystal Display
•LED Light-Emitting Diode
•MPB Main Processor Board
•N/A Not Applicable
•NC Normally Closed (contacts)
•NO Normally Open (contacts)
•PCBPrinted Circuit Board
•PLC Programmable Logic Controller
•POR Power-On Reset
•ROB Relay Output Board
•RTC Real Time Clock (MCP795W10 device on MPB)
•RU SURE Short for “Are You Sure?” prompt
•SCADA Supervisory Control And Data Acquisition
•SPDT Single-Pole, Double-Throw (Effective relay switch configuration)
•SRAM Static Random-Access Memory

AccuPro-5000™MEASUREMENT SYSTEM OPERATOR MANUAL
Issued by Department:
Engineering
Doc. Number:
5000-00-00-002
Revision:
02
Effective Date:
10/05/2021
File: 5000-00-00-002-r2_
AccuPro_5000_Operator_Manual
Copyright© 2021 Scaletron Industries, Ltd
All Rights Reserved
Page 7of 63
1.3 Definitions
•Assert: A term that describes the activation, triggering, or turning-ON of a device, indicator, or
machine state.
•Channel: A term synonymous with “Scale” in this context, a configuration of circuit boards
consisting of an Analog Input Board (required) and optional Analog Output Board and/or Relay
Output Board. Together, the boards enable the real-time weight and/or volume measurement of
material placed on a Scale-Base, then produce proportional output signals of the measurement by
way of an analog current (4-20 mA) or voltage (0-10 V) output signal. High-voltage relay switch
openings and closures can also be activated at predefined measurement setpoints for interfacing to
a user’s external circuitry.
•Control-Panel: The component of an AccuPro-5000™ Measurement System that houses the
electronics that support the Human-Machine Interface (HMI.) All wiring connections for scales,
sensors, alarms, and SCADA will terminate in the Control-Panel.
•ENTER: The act of selecting a given menu option or numeric entry as presented on the display by
way of pressing either the Enter Key or the Rotary Knob switch.
•Jumper-Shunt: A 2-position shorting pin placed on a jumper-field used to configure hardware.
•Keypad: An optional Control-Panel overlay having embedded dome-style, push-button membrane
switches used to navigate and operate the AccuPro-5000™ menus.
•Main Menu: A collection of high-level, user-control categories from which a user can access one
or more submenu control options for system calibration, configuration, and data entry.
•Measurement System: A term that describes a complete AccuPro-5000™Measurement System
consisting of the Control-Panel and Scale-Base components.
•Negate: A term that describes the de-activation, or turning-OFF, of a device, indicator, or machine
state.
•Rotary Knob: An optional rotary control device that generates a sequence of directionally-coded
pulses at a rate that is proportional to its rotational speed. The generated pulses are interpreted as
assertions of either the Down (CCW) or Up (CW) Arrow keys. In addition, pressing the knob causes
a switch-closure that is used to “Enter” a menu selection or numerical value.
•Scale-Base: The component of an AccuPro-5000™ system that houses the load-cell sensor(s) and
platform onto which the material being measured is placed.
•Setpoint: A user-defined scale measurement value, or threshold, that corresponds to a predefined
condition or event, such as the 4 mA and 20 mA output points of the Analog Output Board. A
setpoint may also be used to indicate an Alert/Alarm condition via assertion of the Relay Output
Board as a means to inform a user or SCADA system that some event has occurred or some action
is needed.
•Submenu: A low-level, HMI environment that is part of a main menu category within which system
calibration, configuration, or data entry actions are performed.
•Tare: A measurement allowance intended to offset the physical means of containing or packaging
a chemical substance so as to determine the net weight of goods.

AccuPro-5000™MEASUREMENT SYSTEM OPERATOR MANUAL
Issued by Department:
Engineering
Doc. Number:
5000-00-00-002
Revision:
02
Effective Date:
10/05/2021
File: 5000-00-00-002-r2_
AccuPro_5000_Operator_Manual
Copyright© 2021 Scaletron Industries, Ltd
All Rights Reserved
Page 8of 63
2System Specification Summary
System
Main Power
120/240 VAC +/- 10%, 50/60-Hz
Wattage: 74.7 W (maximum) @ 83% Efficiency
Fuse: 1.0A @ 120 VAC / 0.5A @ 240 VAC (5x20 mm, type slow-blow)
Connector: Sealed
DC Regulated
Power
Triple-Output: 5 VDC @ 4 A / +12 VDC @ 3 A / -12 VDC @ 0.5 A
Operational
Temperature
0oC to 60oC (32oF to 140oF)
Operational
Altitude
2000 meters (maximum)
Operational
Relative
Humidity
20% to 90% non-condensing
Enclosure
(Control-Panel)
Nominal Size: 8 x 8 x 4 Inches (LxWxD) with hinged cover
Weight: 6 lbs. (approx. maximum)
Material: Opaque Polycarbonate, UL Listed Type 4X NEMA
Location Recommendation: The Control-Panel should be operated in a
location that protects it from being soaked with liquids or exposed to
extreme weather conditions. If the system is to be located outdoors, you
must make sure not to exceed the operational temperature range. It is
further recommended that a covering be used to protect the indicator from
the elements. Locations inside buildings should be at a height that protects
it from chemical splashes and wash-down areas, but still allow for easy
operation of the Control-Panel.
Channels
Supports single or dual-channel configurations. Each channel is
independently controlled and operated.

AccuPro-5000™MEASUREMENT SYSTEM OPERATOR MANUAL
Issued by Department:
Engineering
Doc. Number:
5000-00-00-002
Revision:
02
Effective Date:
10/05/2021
File: 5000-00-00-002-r2_
AccuPro_5000_Operator_Manual
Copyright© 2021 Scaletron Industries, Ltd
All Rights Reserved
Page 9of 63
Measurement
Range: Up to (6) Digits. (5) Integer / (1) Fraction (user-selectable)
Working Capacity: Determined, in part, by factory limits and Scale-Base
specifications. Reference Scale-Base documentation.
Units: User-selectable units of Pound, Kilogram, Gallon, or Liter. Units of
volume require user-entry of chemical substance’s density or specific
gravity value.
Averaging: User-selectable smoothing filter of 10, 20, 50, or 100
samples/average.
Bar-graph: User-selectable graphical display showing relative tare, net
measurement, and system capacity components. With bar-graph enabled,
measurement display may be limited to a single channel.
Performance: Overall system accuracy is 0.1% to 0.25% Full Scale.
Liquid Crystal
Display
Size: 16-Characters x 2-Row, supports simultaneous measurement display
of (2) channels.
Backlighting: 16 user-adjustable LED brightness levels (via menu)
Contrast: User-adjustable (via potentiometer on LCD Board)
Indicators
(2) bi-color LED status indicators, (1) for each channel. Each indicator
yields up to four prioritized states as described herein.
Alarms
Internal: Audible buzzer, 3.4 kHz, 78 dB (max)
External: Support for a user-supplied, external alarm/indicator by way of a
switching relay offering a SPDT contact configuration (NO-COM-NC).
Switching capacity of 3A @ 250 VAC or 30 VDC resistive. Inductive loads
not recommended.
Controls
Options:
•(3) key membrane panel: Down-Arrow, Enter, Up-Arrow
oPress-&-Hold Arrow keys for (2) seconds to initiate a fine auto-
repeat function; hold an additional (8) seconds to initiate a coarse
repeat function.
•Optical rotary encoder knob with context-sensitive speed response
oCCW rotation substitutes for a Down-Arrow key-press
oCW rotation substitutes for an Up-Arrow key-press
oPush-button switch substitutes for an Enter key-press

AccuPro-5000™MEASUREMENT SYSTEM OPERATOR MANUAL
Issued by Department:
Engineering
Doc. Number:
5000-00-00-002
Revision:
02
Effective Date:
10/05/2021
File: 5000-00-00-002-r2_
AccuPro_5000_Operator_Manual
Copyright© 2021 Scaletron Industries, Ltd
All Rights Reserved
Page 10 of 63
Analog Input Board
Load Cells
Supports up to (4) 350-Ohm load cells producing a net 87.5 Ohm load.
Excitation
Voltage
+7.5 V @ 150 mA (max)
Sensors
Leak Detect: Active-Low, logic-level input (includes 5V supply)
Analog Output Board - mA
Loop Power
Options: (Selected via on-board jumper)
•Internal supply: 24 VDC, 1500 VDC isolation
•External supply: Range 12-30 VDC
Loop Current
Range: 3.5 mA to 20.5 mA (28 mA maximum for 2 minutes)
Resolution: < 0.001 mA
Configuration
Options
Programmable Setpoints: User-defined, net-measurement thresholds that
define the loop’s 4 mA and 20 mA output positions. The output current
follows a linear interpolation for all measurements that lie between the two
Setpoints.
Analog Output Board - V
Voltage Output
Range: (Selected via on-board jumper)
•0 VDC to 5 VDC, 1500 VDC isolation
•0 VDC to 10 VDC, 1500 VDC isolation
Resolution: < 0.0001 mV (0-5 V Range), < 0.0002 mV (0-10 V Range)
Load Resistance
2000 Ohm (nominal)
Configuration
Options
Programmable Setpoints: User-defined, net-measurement thresholds that
define the output’s lower and upper voltage limits. The output voltage
follows a linear interpolation for all measurements that lie between the two
Setpoints.