Western Scale AURORA 45 User manual

AURORA 45 - AURORA 65 - AURORA 45 SL
SUPER BRIGHT REMOTE DISPLAYS
INSTALLATION & TECHNICAL MANUAL
SOFTWARE RELEASE 2.0, 01/2006
Copyright © 2005, 2006 Western Scale Co. Limited. All rights reserved.
Published by: Western Scale Co. Limited.
Information in this Installation / Technical Manual is subject to change without
notice due to correction or enhancement. The information described in this
manual is the property of Western Scale Co. Ltd. No part of this manual may be
reproduced or retransmitted in any form, without the expressed written
permission of Western Scale Co. Ltd.
Western Scale Co. Limited
1670 Kingsway Avenue
Port Coquitlam, B.C.
Canada
V3C 3Y9
Tel: [phone]
Fax: [phone]
www.westernscale.ca
[email protected]
FOR TECHNICAL SUPPORT REGARDING THIS PRODUCT, PLEASE CALL
YOUR AUTHORIZED WESTERN DEALER:

1
TABLE OF CONTENTS
INTRODUCTION ......................................................................................................................................................... 2
DISCLAIMER.......................................................................................................................................................... 2
AURORA FEATURES ............................................................................................................................................ 3
DISPLAY................................................................................................................................................................. 4
INSTALLATION .......................................................................................................................................................... 4
PRE-INSTALLATION ............................................................................................................................................. 4
OPENING THE AURORA ENCLOSURE (UNMOUNTED).................................................................................... 5
REMOVING THE ELECTRONICS CARRIAGE ..................................................................................................... 5
MOUNTING INSTRUCTIONS................................................................................................................................ 6
OPENING THE AURORA ENCLOSURE (MOUNTED) ......................................................................................... 8
LOWERING THE ELECTRONICS PLATE ............................................................................................................ 9
REMOVE THE ELECTRONICS CARRIAGE ......................................................................................................... 9
WIRING...................................................................................................................................................................... 10
POWER WIRING.................................................................................................................................................. 10
COMMUNICATIONS WIRING ............................................................................................................................. 11
Communication Input Jumper ......................................................................................................................... 11
RS 232 Wiring ................................................................................................................................................. 11
RS 232 Daisy Chain ........................................................................................................................................ 12
RS 422 Wiring ................................................................................................................................................. 12
RS 485 Multi-Drop Wiring................................................................................................................................ 12
20 mA Current Loop Wiring............................................................................................................................. 13
20 mA Current Loop Mode Switch .................................................................................................................. 13
START-UP................................................................................................................................................................. 14
POWER UP .......................................................................................................................................................... 14
RESET BUTTON.................................................................................................................................................. 14
AUTO-LEARN....................................................................................................................................................... 14
LEARN BUTTON.................................................................................................................................................. 14
DIAGNOSTIC INDICATOR LIGHTS .................................................................................................................... 15
CONFIGURATION & OPTIONS ............................................................................................................................... 16
CONFIG SWITCHES............................................................................................................................................ 16
Switches 1 & 2: Daytime Brightness .............................................................................................................. 16
Switches 3 & 4: Nighttime Brightness ............................................................................................................ 16
Switch 5: Mirror Display Mode........................................................................................................................ 17
Switch 6: Start-up Auto-Learn ........................................................................................................................ 17
Switch 7: Reserved for Future Use ................................................................................................................ 17
Switches 8 & 9: Multi-Drop ID ........................................................................................................................ 17
OPTIONS SWITCHES ......................................................................................................................................... 18
Switches 1, 2, 3, & 4: Utility Program Select.................................................................................................. 18
Switch 5: Power-Save Mode .......................................................................................................................... 18
Switch 6: Leading Zeros................................................................................................................................. 19
Switches 7, 8, & 9: Radio Channel Select...................................................................................................... 19
TRAFFIC LIGHT CONTROL..................................................................................................................................... 20
EXTERNAL TRAFFIC LIGHTS ............................................................................................................................ 20
BUILT-IN TRAFFIC LIGHT................................................................................................................................... 21
AURORA UTILITY PROGRAMS .............................................................................................................................. 22
WIRELESS SET-UP.................................................................................................................................................. 26
AURORA REMOTE DISPLAY ............................................................................................................................. 26
INDICATOR & BASESTATION ............................................................................................................................ 27
Wireless Connection Test ............................................................................................................................... 27
BASESTATION SET-UP ...................................................................................................................................... 28
Select the Radio Channel................................................................................................................................ 29
Set the Baud Rate ........................................................................................................................................... 30
TROUBLESHOOTING & ERROR MESSAGES....................................................................................................... 31

2
INSTALLATION & TECHNICAL MANUAL
INTRODUCTION
The Aurora Remote Display Series is the latest development from Western, the
company which first brought LED remote displays to the weighing industry in the
1980s.
New technologies, materials, and construction methods have allowed a
remarkable evolution in remote displays, making them more affordable, easier to
read, and a vital part of any scale system. Aurora Remote Displays incorporate
the most standard features of any weighing display, making it the best choice for
virtually any application.
Like all Western products, Aurora Remote Displays are designed with durability,
functionality, and versatility in mind. Users are assured that Aurora Remote
Displays meet the specified local Weights & Measures regulations for anywhere
in North America.
Western: Engineered for the diversity of the weighing industry.
DISCLAIMER
The following information is for the exclusive use of WESTERN Dealers and
Customers.
Since Aurora Remote Displays are a valuable component of your weighing
system, installation and configuration procedures (as described in this manual)
should only be carried out by qualified Scale Service Technicians as authorized
by Western.
Scale Service Technicians handling Aurora PCBs must observe
proper electrostatic discharge (ESD) handling procedures.
CAUTION! HIGH VOLTAGES are present inside the Aurora
enclosure.
ATTENTION! Unauthorized installation and service of this unit
may void the warranty.

3
AURORA FEATURES
HIGH VISIBILITY
•A bigger, brighter display (4.5 or 6.5 inches high) makes the Aurora easy to
read over wide viewing angles, in foul weather, and in direct sunlight.
EASY TO INSTALL & USE
•Auto-Learn Technology interprets the data format and output string of any
scale indicator, reducing set-up time.
•The Drop-down electronics carriage makes installation and service quick and
easy.
WIRELESS COMMUNICATIONS
•Go wireless. Make installation easy and use remote displays where you never
thought possible.
•The integrated radio option allows communications over several thousand feet.
•No external housings or radio knowledge required.
SAVE ENERGY
•Ultra-efficient LED technology is the smart choice for power conscious users.
•The photo sensor automatically adjusts LED intensity for efficient day or night
viewing.
•Power Save Mode reduces power consumption during long periods of
inactivity.
MORE…
•A ready to use, built-in traffic light (Aurora 45 SL model only).
•Selectable brightness levels.
•Built-in relay remotely controls traffic lights.
•Built-in utility programs for axle weighing, traffic light control, etc.
•Mirrored Display Mode.
•Multi-drop communications.

4
INSTALLATION & TECHNICAL MANUAL
DISPLAY
WEIGHT DISPLAY: 6 LED digits (7 segments). Up to 2 decimal places.
ANNUNCIATORS: GR = Gross Weighing Mode
NT = Net Weighing Mode
lb = Pounds
kg = Kilograms
INSTALLATION
PRE-INSTALLATION (Receiving Inspection)
It is always good practice to verify that the Aurora Remote Display is complete and
undamaged upon receipt.
•Check over packaging for any signs of damage.
•Remove the Aurora Remote Display from its protective packaging and check for
damage.
•Verify that the shipment includes:
oAurora Remote Display (complete and intact, with power cord).
oAurora Installation / Technical Manual.
•Auroras ordered with the Wireless option should include:
oRadio Module.
oExternal Antenna.
oInternal Antenna Cable.
oBaseStation kit including software and 2 interface cables.
WEIGHT DISPLAY
ANNUNCIATORS Fig. 1: Aurora 45 Display

5
OPENING THE AURORA ENCLOSURE (UNMOUNTED)
1. When opening an Aurora 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 (As seen in Fig. 2).
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.
Fig. 2: Open Aurora (side)
BOTTOM COVER/
ELECTRONICS CARRIAGE

6
INSTALLATION & TECHNICAL MANUAL
MOUNTING INSTRUCTIONS
1. Inspect the installation site for properly grounded power.
2. Ensure that mounting structures (walls, pole brackets, etc.) will bear the weight of
the display (Aurora 45: 20 lbs, Aurora 65 & 45SL: 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).
Wall Mounting
Hole patterns for the Aurora Remote Displays are given in the diagram below:
Aurora 45:
Aurora 65 & Aurora 45 SL:
NOTE: The Electronics Carriage may be removed to reduce weight
when installing.
23 inches
31 inches
6 inches
7 ¾ inches
Hole: 3/8 inch
Hole: 3/8 inch
Fig. 3: Hole patterns

7
Pole Mounting Bracket
1. Select appropriate height and fasten the small “C” bracket to the pole using the
mounting clamps provided.
2. Fasten the larger “C” bracket to the small “C” bracket using the hardware
provided.
3. Fasten the Aurora display to the Pole Mounting Bracket as outlined in the
Mounting Instructions (See Fig. 4).
Visor Option
1. Loosen the mounting hardware on the Aurora Main Enclosure 1/8th inch.
2. Rest the Visor’s mounting brackets on the bolt between the bolt head and the
front of the Aurora’s side mounting plates.
3. Re-tighten the mounting hardware.
NOTE: The Pole Mounting Bracket allows for poles or beams from up
to 8 inches in diameter.
Fig. 5: Optional Visor
Fig. 4: Pole Mounting Bracket

8
INSTALLATION & TECHNICAL MANUAL
OPENING THE AURORA 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 Fig. 6 & 7).
MAIN
ENCLOSURE
BOTTOM COVER/
ELECTRONICS
CARRIAGE
DISPLAY BOARDS (2)
CONTROLLER
BOARD
POWER SUPPLY
BOARD
Fig. 6: Front View
Fig. 7: Back View

9
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 (As seen in Fig. 8).
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.
Fig. 8: Side View
CAPTIVE
SCREWS

10
INSTALLATION & TECHNICAL MANUAL
WIRING
POWER WIRING
Aurora Remote Displays are wired for power at the factory. The factory supplied power
cable can be removed for direct AC wiring if necessary.
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 table below:
AC POWER TO TERMINAL BLOCK
HOT (+) PIN 3
NEUTRAL (-) PIN 2
GROUND (GND) PIN 1
7. Replace the Terminal Block and fasten on mounting posts.
8. Ensure that the Internal Power Cable is connected to the Power Supply board.
Please see Figure 9: Power Wiring.
CAUTION! HIGH VOLTAGE! Only trained personnel should attempt
this procedure.
A
TTENTION! AC wiring must be terminated at the AC Power Terminal
Block, not directly at the Power Supply board.

11
POWER WIRING (Continued)
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
A communications input type (RS 232, RS 422/485, or 20 mA Loop) must be selected by
placing the jumper on the appropriate pins.
RS 232 RS 422/485 20mA Current Loop
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). See
table below:
INDICATOR TO AURORA REMOTE DISPLAY
TRANSMIT (TX) RECEIVE (RX)
RECEIVE (RX) NO CONNECTION
SIGNAL GROUND (GND) SIGNAL GROUND (SIG GND)
Fig. 9: Power Wiring
Fig. 10: Jumper Positions

12
INSTALLATION & TECHNICAL MANUAL
RS 232 Daisy Chain
INDICATOR TO AURORA 1 TO AURORA 2
TX RX
RX TX RX
GND GND GND
Etc…
RS 422 Wiring
1. Set the Communication Input Jumper (JP 1) to RS485.
2. Terminate the indicator’s communication wires at the RS 485 terminal (J4). See
table below:
INDICATOR TO AURORA REMOTE DISPLAY
TRANSMIT A (TX A) RECEIVE A (RX A)
TRANSMIT B (TX B) RECEIVE B (RX B)
RS 485 Multi-Drop Wiring
1. Set the Communication Input Jumper (JP 1) to RS485.
2. Terminate the indicator’s communication wires at the RS 485 terminal (J4) using
one of the following methods:
Parallel Multi-drop wiring
SCALE
CONTROLLER
TO
AURORA 1
TO
AURORA 2
TO
AURORA 3 ETC.
TX A RX A RX A RX A RX A
TX B RX B RX B RX B RX B
Split Multi-Drop Wiring
TO AURORA 1
RX A
SCALE CONTROLLER RX B
TX A
TX B TO AURORA 2
RX A
RX B
NOTE: Multi-Drop IDs are set using the CONFIG Dip-switches.
For settings, see Switches 8 & 9: Multi-Drop ID, on page 17.

13
Passive
SW10
SW10
Active
20 mA Current Loop Wiring
1. Set the Communication Input Jumper (JP 1) to LOOP.
2. Terminate the indicator’s communication wires at the 20 mA Current Loop
terminal (J5). See table below:
INDICATOR TO AURORA REMOTE DISPLAY
20 mA TX + RECEIVE POSITIVE (RX +)
20 mA TX - RECEIVE NEGATIVE (RX -)
20 mA Current Loop Mode Switch
•After the current loop is wired, ACTIVE or PASSIVE mode must be selected (SW
10) on the Controller board.
•Select Active mode if the Aurora is required to supply the current to the
communicating device.
•Select Passive mode if the communicating device (indicator) supplies the current
to the Aurora.
•If unsure of these requirements, check the device’s manual.
Fig. 11: 20 mA Mode Switch

14
INSTALLATION & TECHNICAL MANUAL
START-UP
POWER UP
•The Aurora has no ON/OFF button or switch. Plugging the unit into AC
power will turn the unit ON.
•Disconnecting AC power will turn the unit OFF.
RESET BUTTON
•The RESET button on the Controller board allows the Technician to cycle
power on the unit without disconnecting/connecting AC power.
AUTO-LEARN
•On power up, the Aurora automatically enters Auto-Learn Mode, analyzing
the serial communications and string type.
•The indicator’s output string must contain number characters. An STX
character (ASCII 02) and/or CR character (ASCII 13) must also be
included.
•Once Auto-Learn is successful (about 10 seconds after power up) the
Aurora will display the current weight.
LEARN BUTTON
•If Automatic Start-up Auto-Learn is disabled, the LEARN button on the
Controller board must be pressed to enter Auto-Learn Mode.
NOTE: Automatic Start-up Auto-Learn may be disabled for custom
applications. See Switch 6: Start-up Auto-Learn, on page 17.

15
DIAGNOSTIC INDICATOR LIGHTS
The Aurora has 3 diagnostic indicator lights located on the Controller board.
STATUS Light:
•The Aurora’s “heartbeat”. BLINKS when power is applied to the unit.
•Regular blinking (Once per second) indicates that the Aurora has
successfully learned a data string and is running properly.
•Rapid blinking (3 times per second) indicates that the Aurora is in Auto-
Learn mode, attempting to interpret a data string.
COM Light:
•FLASHES ON each time the Aurora receives a character through any of
its COM Ports (including the radio).
RADIO Light:
•FLASHES ON when the Aurora’s Radio Module receives data.
•This light will only illuminate if the Radio Module is installed.
Fig. 12: Indicator Lights

16
INSTALLATION & TECHNICAL MANUAL
CONFIGURATION & OPTIONS
The Aurora uses two banks of Dip Switches on the Controller board (SW 3 &
SW 4) to set-up the configuration and options.
CONFIG SWITCHES
The “CONFIG” bank of dip switches (SW 3) is for the following features:
Switches 1 & 2: Daytime Brightness
There are 4 selectable brightness levels. The built-in photo sensor automatically
detects daylight conditions and sets the display brightness to this level.
BRIGHTNESS LEVEL SWITCH 1 SWITCH 2
High (Default) ON ON
Medium-High OFF ON
Medium-Low ON OFF
Low OFF OFF
Switches 3 & 4: Nighttime Brightness
There are 4 selectable brightness levels. The built-in photo sensor automatically
detects nighttime conditions and sets the display brightness to this level.
BRIGHTNESS LEVEL SWITCH 3 SWITCH 4
High ON ON
Medium-High OFF ON
Medium-Low ON OFF
Low (Default) OFF OFF
NOTE: Dip Switch settings take effect only after the Aurora has
been reset (Cycle power directly or press the “RESET” button).
NOTE: Lowering the brightness level at night helps reduce
nighttime glare and energy costs. Passing headlights,
spotlights, etc. will NOT activate the daytime brightness level.

17
Switch 5: Mirror Display Mode
The Aurora’s digits may be mirrored for applications where the display is viewed
from a vehicle’s rear-view or side-view mirrors.
MIRROR DISPLAY MODE SWITCH 5
OFF (Default – Digits normal) OFF
ON (Digits mirrored) ON
Switch 6: Start-up Auto-Learn
On power up, the Aurora automatically enters Auto-Learn Mode, analyzing the
serial communications and string type. In certain situations, it may be necessary
to disable this feature. Once disabled, the LEARN button on the Controller board
must be pressed before the Aurora will go into Auto-Learn Mode.
START-UP AUTO-LEARN SWITCH 6
ENABLED (Default) OFF
DISABLED ON
Switch 7: Reserved for Future Use
Switches 8 & 9: Multi-Drop ID
Up to four (4) Aurora displays can share a serial or radio connection. Messages
are sent to individual displays using control codes and these Multi-Drop IDs. For
Multi-Drop instructions, see page 25.
MULTI-DROP I.D. SWITCH 8 SWITCH 9
0 (Default) OFF OFF
1 ON OFF
2 OFF ON
3 ON ON
NOTE: If Multi-Drop is not being used, it is very important that
Switches 8 & 9 be set in the OFF position.

18
INSTALLATION & TECHNICAL MANUAL
OPTIONS SWITCHES
The “OPTIONS” bank of dip switches (SW 4) is for the following features:
Switches 1, 2, 3, & 4: Utility Program Select
The Aurora has built-in utility programs that run in conjunction with the normal
display functions.
PROGRAM SW 1 SW 2 SW 3 SW 4
1 – NORMAL Mode (No program) OFF OFF OFF OFF
2 – Axle Weighing with Totals OFF OFF ON OFF
3 – Axle Weighing (Driving On) OFF OFF OFF ON
4 – COMMAND mode. OFF OFF ON ON
Switch 5: Power-Save Mode
If there is no activity on the scale for 10 minutes, the display brightness will dim
one level below the selected brightness level (day or night, as applicable). The
Aurora will return to the selected brightness level when motion is detected on the
scale.
POWER SAVE MODE SWITCH 5
ENABLED (Default) OFF
DISABLED ON
NOTE: Please see the Aurora Utility Program section for
program overviews (Page 22).