Pols Electronics ltd.

Sindragata 10, 400 Isafjordur.

Tel : 354 456 4400
Fax : 354 456 4591

Calibration and
Field Service Manual

P-15 Scales
(S-210 Ver. 1.xx)

HI 04/12/00 PS1503 © Pols Electronics 1999-2000

This manual is intended for technicians during installation, calibration, troubleshooting and repairs
of the Pols P-15 S-210 Unique weight indicator. It also contains some basic metrological
information.

Table of contents Page

Metrological description ........................................................... 3
Indicator description ................................................................. 3
Markings ................................................................................... 3
Basic Functions ......................................................................... 3
User Instructions - Pols P-15, S-210 V1.03.............................. 4
Daily verification: ..................................................................... 4
Scale Settings ............................................................................ 5
Miscellaneous details:............................................................. 6
Capacity / resolution settings available .................................. 7
System troubleshooting............................................................. 8
Loadcells ................................................................................... 8
Loadcell Resistance measurements........................................... 9
Loadcell Voltage measurements............................................... 9
T-21 Main Circuit Board........................................................ 10
General information ................................................................ 11
Troubleshooting the T-21 ..................................................... 11
Analog section ........................................................................ 11
Loadcell Voltages ................................................................. 12
Amplifier Voltages ............................................................... 12
No-Load adjustment ............................................................. 12
T-21 Digital section ................................................................ 13
T-21 Power Supply section ..................................................... 14
AC-powered version............................................................. 14
Portable version .................................................................... 14
Troubleshooting.................................................................... 14
Display Unit – DISPL. 21........................................................ 15
Scale Assembly......................................................................... 16
Typical weighing platform assembly ..................................... 17
Schematics................................................................................ 18

Page 2 Calibration and Field Service Manual P-15 - V/S-210

Metrological description
The following sub-sections contain a description of the metrological aspects of the P-15 indicator.
Indicator description
The P-15 S-210 indicator is designed to function as a module in a class III, multi-interval weighing
instrument using strain gauge loadcells as weight sensors. It is microprocessor controlled and uses a
CS5501 A/D converter to digitize the analog loadcell signal amplified by a INA131 Instrumentation
Amplifier. The electronic components are contained in a stainless steel housing that meets IP65/67
requirements.

The S-210 indicator has an Acceleration Compensation feature as it is intended foruse aboard sea-
going vessels.

The P-15 indicator has a 12.5mm, 6-digit LED 7-segment weight display and LED-backlighted STB
status indicators.

The P-15 indicator is designed to comply with the metrological requirements of EN 45501:1662 for
non-automatic class III weighing instruments.

Markings
A unique serial number is stamped on the indicator base plate. A decal with the accuracy class,
electrical requirements and other general information is also located on the indicator base plate. A
separate decal identifies the sealed access hole to the calibration switch.

A decal describing the metrological characteristics of the instrument is located on the faceplate, in
direct view of the operator.

Weighing units can be selected during calibration to correspond with faceplate markings. Only one
unit can be used in each installation.

Basic Functions
The P-15 S-210 is equipped with the following devices:

Initial Zero-setting device with a maximum effect of 20% of maximum capacity.

Zero-tracking device with a maximum effect of 4% of maximum capacity. It operates only when
the equilibrium is stable and weight indication is at zero. The corrections are not less than 0.25d and
not more than 0.5d within one second (the target limit is 0.3d pr. second).

Combined semi-automatic zero-setting device and semi-automatic tare-balancing device

operated by the Tare toggle switch. The semi-automatic tare balancing device is a subtractive tare
device with a maximum effect of T = -Max.

P-15 - V/S-182/185 Calibration and Field Service Manual Page 3

User Instructions - Pols P-15, S-210 V1.03
The Pols S-210 Marine Scale is a simple acceleration-compensated scale with a minimum of
functions and is very simple to use. It has only 2 external switches, a Tare and a Reset switch.

Installation:
When the platform is installed, make sure there is sufficient clearance between the platform and
surrounding structures. The platform should be bolted to a stiff table or frame that will not move
around or vibrate excessively. Use a mild detergent for cleaning. Never use a high-pressure hose or
wire brushes.

Initial calibration (Roll Compensation):

The scale is acceleration-compensated during testing at the factory, but various effects are likely to
cause the scale to indicate unstable and incorrect weights after initial installation. Perform the
calibration step (see the Daily verification section below). As this will usually be done in calm
conditions, the roll compensation constants will not be suitable for the rougher sea conditions
encountered when at sea, causing the scale to become unstable. Repeat the calibration step
whenever weight indications become unstable. Once this has been done in sufficiently rough sea
conditions, the scale will have established compensation constants that are good for all conditions.

Normal use:
The scale will display the weight of any object placed on the platform.
Take care that the platform load (e.g. tray) does not touch any surrounding structures, such as the
support stand or adjacent walls or tables during weighing. This will cause unstable and erroneous
weight readings. The scale should always be connected and turned on, even when not in use.

Tare (Zero-setting scale):

Whenever the platform is empty, the display should indicate zero. Water and debris accumulation
on the weight platform may cause non-zero indications when the platform is empty. This is easily
compensated for by zero-setting the scale, and should be done at frequent intervals.
To zero-set the weight display, momentarily press the Tare switch.

Daily verification:
For various reason the scale may become unstable or weigh incorrectly after
a period of time. To prevent this, the following procedure should be performed
at leas once every 24 hours:
⇒ Keep an approved reference load handy beside the scale at all times.
⇒ Test the scale for correct weight indications at least every 24 hours using the reference
load.
⇒ If weight indication is incorrect or not stable, hold the TARE switch while flipping the
RESET switch (see instructions on the scale faceplate, or the Marine Scale Calibration
section on the back of this page).
⇒ Test the scale again, using the reference weight. If further action is needed, repeat the
above step, making sure no mistakes were made.

Page 4 Calibration and Field Service Manual P-15 - V/S-210

Scale Settings
The S-210 scale features a Tare switch, a Reset switch and an internal 16-way rotary switch, which
is sealed behind a protective screw. The rotary switch is a 4-bit binary code switch with positions 0-
15 (or 0-F hexadecimal), and is only used for initial installation and service.

Tare (Zero-setting scale):

To zero-set the weight display, momentarily press the Tare switch.

Marine Scale Calibration:

Press and hold the Tare switch while momentarily pressing the Reset switch.
The Tare switch must be released while the display test is in progress (values 0000-9999 roll
through the display). The Marine Scale Calibration sequence has 2 phases.
Phase 1:
The scale shows “PLPL 0.00”
0.00 to indicate that the platform should be CLEAN and EMPTY.
Momentarily press the Tare switch to initiate the empty-state calibration sequence.
The scale display will count down from 7 to 0.
Phase 2:
PL 5.00”
The scale shows e.g. “PL 5.00 or “PL PL 10.0”
10.0 to prompt the user to put a 5.00 or 10.0kg
reference weight on the platform. The actual value will depend on platform capacity.
Momentarily press the Tare switch to initiate the Span and Roll calibration sequence.
The scale display will count down from 7 to 0.
Following this the scale should correctly indicate the weight on the platform if the calibration
operation was successful.

Rotary Switch:
Remove the sealing screw and use a 2mm-diameter screwdriver to rotate the switch as required.
When the switch is in the “0” position the scale is in the Normal Operating Mode.
When the rotary switch is turned clockwise, various functions become available in the order shown
in the following list. Turning the rotary switch counter-clockwise accesses the function list in the
reverse order.

Rotary Switch Functions:

Switch
position Display Description
0 0.000 Normal Operating Mode
C 1 1. 30 Maximum Capacity
l 2 2. 3000 Maximum number of intervals
o 3 3 0.020 Minimum resolution (e = d)
c 4 4 5.00 Calibration (Reference) load value
k 5 5. 5 Sensitivity / Damping
w 6 6. 0 not used
i 7 7. 0 not used
s 8 8. 0 not used
e 9 9. 0 not used
! A -. 0 not used
B E. 0 not used
C H. 0 not used
D 0.0000 Calculated weight with 1 extra significant digit (for service purposes only)
E L.12345 Main Loadcell Direct Reading (internal A/D units)
F H.54321 Reference Loadcell Direct Reading (internal A/D units)
NOTE: Functions 1 through 5 can be changed by repeatedly flipping the Tare switch. This will
step through a list of predefined values. The available values will be different for each
function.
P-15 - V/S-182/185 Calibration and Field Service Manual Page 5
Miscellaneous details:
♦ If the scale is reset and the rotary switch is not in position 0, the scale will not read the setting
and calibration constants from protected, non-volatile memory (EEPROM). This can be handy,
e.g. at initial startup or any other time, when protected memory may contain erroneous data.
♦ During normal use the scale should always be reset with the rotary switch at position 0.
♦ Error Messages will appear on the display as “EEE X”. Flipping the Tare switch clears
errors. Possible error messages are:
EEE 1 Insufficient weight on platform (Marine Scale Calibration sequence).
EEE 2 Reference Loadcell signal too low.
EEE 3 Main Loadcell signal too high.
EEE 4 No Reference Load specified.
EEE 5 Checksum error when reading constants from non-volatile memory.

The scale faceplate contains abbreviated instructions how to perform the Marine Scale Calibration:
These instructions can be in one of many different languages:

Icelandic (Íslenska):
Núlla vog: Smella Törurofa.
Stilla vog: Halda Törurofa og smella Ræsirofa.
PL 0.00 : Pallur hreinn og tómur, smella Törurofa.
PL x.xx : Setja x.xxkg á pall, smella Törurofa

English:
Zero-set: Flip Tare switch.
Calibrate: Hold Tare switch and flip Reset switch.
PL 0.00 : Platform clean and empty, flip Tare switch.
PL x.xx : Put x.xxkg on platform, flip Tare switch.

Norwegian (Norsk):
Tarering: Trykk Tareringsknapp momentant.
Justering: Holl Tareringsknapp og trykk Tareringsknapp.
PL 0.00 : Platform ren og tom, trykk Tareringsknapp.
PL x.xx : Sett x.xxkg på platformen, trykk Tareringsknapp.

Portugese (Portugues):
Zero: Pressione o interruptor de Tara
Calibraçao: Mantenha Pressionado o interruptor de TARA e Pressione o interruptor de RESET
PL 0.00: Plataforma Limpa e Vazia, Pressione o interruptor de TARA
PL x.xx: Colocar 5.00 kg na plataforma,Pressioneo interruptor de TARA

Further languages will become available as required in the future.

Page 6 Calibration and Field Service Manual P-15 - V/S-210

Capacity / resolution settings available
Max. Cap Resolution g/kg & kg/t Max.Interv. Min.Interv. L/C Cap
6kg 1g/1kg 2g/4kg 5g/6kg 2000 0.001kg 10kg
20kg 2g/4kg 5g/10kg 10g/20kg 2000 0.002kg 30kg
30kg 5g/10kg 10g/20kg 20g/30kg 2000 0.005kg 50kg
60kg 10g/30kg 20g/60kg - 3000 0.010kg 100kg
80kg 20g/40kg 50g/80kg - 2000 0.020kg 100kg
150kg 50g/100kg 100g/150kg - 2000 0.050kg 200kg
2000kg 1kg/1.5t 2kg/2t - 1500 1.000kg 1000kg x 4

It is quite possible to set the Calibration Parameter settings to other values, but the above settings
must be used for scales that will have to be approved by the Weight and Measures authorities.
Scales for special applications (where approval is not required) can be configured differently, e.g. to
increase resolution to the practical limits of the weight sensing units and/or the capabilities of the P-
15 electronic components.

This will always result in reduced stability, repeatability and readability, even to the point where
practical use of the scale’s display will be impossible due to display fluctuations!

P-15 - V/S-182/185 Calibration and Field Service Manual Page 7

System troubleshooting
A S-210 scale consists of 3 main sections:
Weighing platform assembly (loadcells and cables).
T-21 Digital section T-21 card.
T-21 Analog section T-21 card.
T-21 Power Supply section T-21 card.
Display unit DISPL. T21.

A weighing platform is a weight sensing system using strain gauge loadcells that can be in any
configuration, from a small platform capable of weighing fractions of grams up to a complex
system with a number of loadcells (Truck or Hopper scales) or anything in between. The most
common version will be platform assemblies with a capacity of 20 kg through 150 kg.

When problems arise, it is very important to do the troubleshooting in an orderly manner using a
process of elimination to determine which section is causing the problem.
When the problem has been isolated to a single section (by verifying which sections are working
properly), the efforts can be concentrated on the faulty section to locate the failed component(s).
During this process of elimination, the best single tool is plain old common sense. Other tools
required are as follows:

Tool
Assorted screwdrivers
Assorted wrenches
Oscilloscope or Digital Probe
Volt / Ohmmeter
Use
Assembly / Disassembly
Assembly / Disassembly
Digital section troubleshooting
Analog section troubleshooting

The following sections of this manual contain hardware information and details of how to verify the
proper operation of each of the scale’s main sections.
Loadcells
The loadcells used can be of various physical versions, but the electrical parts are almost identical.
Four temperature-compensated strain gauges connected as a Whetstone bridge are bonded to
flexing beam in the loadcell. A controlled voltage is applied across the bridge and a load can be
sensed when resistance variations in the strain gauges cause the output voltage to change. The
loadcells can be tested by checking that these resistances and voltages are within certain limits.
When testing, refer to the diagram and table on the next page.

Loadcell up to 100kg Loadcell (60 kg scales and larger)

1042
Protective 1260
Loadcell Protective
Cover Loadcell Cover
Signal
Cable
Signal
Cable

Page 8 Calibration and Field Service Manual P-15 - V/S-210

Loadcell Resistance measurements
Disconnect the loadcell cables from the amplifier input connector and measure the resistances
between the loadcell connection pins with an accurate instrument. The readings should be as
follows:

Pins Resistance: +/- Deviation:

+5V & GND 415 Ohms 5 Ohms
+IN & -IN 350 Ohms 10 Ohms
+5 & -IN 195 Ohms 45 Ohms
+5 & +IN 195 Ohms 45 Ohms
-IN & GND 195 Ohms 45 Ohms
+IN & GND 195 Ohms 45 Ohms

Large deviations from these figures indicate a damaged loadcell, either due to corrosion or shock
loads. The same could be true for the cable, so check the cable carefully before replacing the
loadcell !!
If the resistance between any of the pins is "0" Ohm or infinite, check the cable, junction boxes
(connections) and connectors for shorts or open circuits.

Loadcell Voltage measurements

Please refer to the amplifier input card (T21) section for voltage measurements.

DO NOT TAMPER WITH THE LOADCELL ITSELF !!!

If a loadcell is damaged, please send it to POLS-ELECTRONICS Ltd. for inspection. Statistical
information on the various modes of failure is being collected for the purpose of improving the
loadcells and its protection technique!

ALWAYS use a screened cable with at least 4 or 8 conductors between the loadcells and the
amplifier input! It is preferred that the recommended colors are used to ease fault-finding as it
makes it easier to trace the connections. If however, the colors recommended are not available,
please use similar colors instead. If the loadcell is longer than 10 meters from the amplifier input,
please use two conductors for the feeding lines (+5V and GND) or use conductors with larger
diameter. You should also try to use a cable with as low characteristic impedance (less than 120
Ohm) and capacitance (less than 80pF/m) as possible.

TYPICAL CONNECTION OF LOADCELLS TO THE AMPLIFIER INPUT

Main (Weighing) Channel

Measured Weight
Black/Yellow BLACK
GND
White WHITE
-IN
Red RED
+IN

Loadcell Blue/Green BLUE

+5V

Reference Channel

Reference Weight Black/Yellow YELLOW

GND
White VIOLET
-IN
Red BROWN
+IN
Blue/Green GREEN
Loadcell +5V

P-15 - V/S-182/185 Calibration and Field Service Manual Page 9

T-21 Main Circuit Board
The T-21 printed circuit card contains a Hitachi H8/5xx microprocessor, and an integrated Power
Supply unit. It also has the circuitry for a dual-channel instrumentation amplifier and Analog to
Digital converter. In most land-based weighing application only one channel is populated with the
required components, while Marine Scale applications both channels are populated.

The T-21 is a single-sided hybrid card, i.e. Surface Mounting Technology is used for the CPU chip
while the remaining components are mounted using conventional methods. As a result the CPU is
mounted in a socket on the print-side of the board.

GND -IN +IN +5 GND -IN +IN +5 7805 7808 +8 RESET -5

+5 -5
V A ANALOG IDIG

GND
24C02N
REF
HITACHI H8/5xxx

Xtal CPU
A+
20Mhz Transformer
4VA
CS5501 Main Ch. A POLS T-21
V+
Shielded Amplifier(s) CS5501 Ref. Ch. V

ITARE
DISPLAY

Calibration
lock switch Pwr IN

Fig. 1: T21 component layout

The leftmost part of the card contains the Analog section while the rightmost section of the card
contains the Power Supply section. The Digital Section mainly consists of the H8/5xx CPU chip,
but the CS5501 A/D converter chips are part digital, part analog and, form the interface between the
analog and digital sections. They are, however, considered to belong to the digital section.

Component Function
CPU Micro-Controller Unit, HITACHI H8/532 or H8/534
24C02N 256 bit EEPROM. Non-volatile memory for Calibration and Basic Parameter storage.
7805 +5V loadcell excitation voltage regulator. Uses the regulated +8V supply.
Amplifier Shielded single/dual channel amplifier unit, based on INA131 instrumentation
amplifiers.
CS5501 Analog to Digital converters.
Cal. lock sw. Calibration lock switch, accessible only via a sealed hole in the instrument base
plate.
Xtal 20.000Mhz System Clock Crystal.

Test Points:
GND Analog and Digital ground (common)
+5V Regulated +5V supply (+/- 0.25V).
+8V Regulated +8V supply (+/- 0.30V).
-5V Regulated -5V supply (+/- 0.25V).
A+ Main amplifier channel output / A/D converter input voltage.
V+ Reference amplifier channel output / A/D converter input voltage.
REF A/D converter reference voltage (approx. 1.17V).

Page 10 Calibration and Field Service Manual P-15 - V/S-210

Loadcell connector +5V voltages (from the on-card 7805 regulator which in turn uses the regulated
+8V supply for improved stability) should measure within +/- 0.25V of the nominal voltage

The exact supply voltage levels are generally not critical, but they must be stable.

General information
A typical weighing instrument consists of 3 main sections: Weighing platform (loadcells and
cables), T21 Main electronics unit and Display.

Initial troubleshooting steps should be to verify if the Power Supply Unit and Loadcell sections are
faulty (see the Power Supply and Loadcells sections in this manual) before proceeding with
trouble-shooting the T-21 and Display unit.
The Loadcell section is the most likely to fail due to it’s exposure to abuse.

The circuitry on the T21 is divided into 3 main sections, an Analog section, a Digital section and a
Power Supply section. The analog section consists of the shielded amplifier, A/D-converter(s),
associated filtering circuitry and excitation voltage regulator (left side on Fig. 1) while the digital
section consists of the CPU and A/D converter(s) in the cener of Fig.1. The Power Supply section
is on the right side of Fig. 1.
NOTE: The A/D converters are “straddling the fence” between the sections as it are partly analog
and partly digital.
Troubleshooting the T-21
If a fault is traced to the T21, the first step is to determine which section is causing the problem.

Typical symptoms caused by digital section problems will be rather gross, such as the scale freezing
up with or without any display indications or missing display functions etc.
Typical symptoms caused by analog section problems will be more moderate, such as erroneous
weight readout, an “overload” condition or no change in the weight readout at all.
Analog section
Start by checking the Supply, Loadcell and Amplifier voltages for the relevant channel as described
in following sections.

Please note that any weight attached to the loadcell (platform and accessories) is part of the load,
and the minimum voltage of the relevant channel should reflect that. Similarly, the additional
weight required to reach a “full load” condition will depend on the loadcell size.

If the problem lies in the Loadcell section, the loadcell input can in many cases be corrected (see
the “No-load adjustment” section). If not, the loadcell has to be replaced and the scale re-
calibrated.
If the problem turns out to be an A/D converter or amplifier, replace the relevant component and
re-calibrate the scale.

The block diagram below shows the approximate location of the test points within the circuit
sections of each channel.
Block Diagram

P-15 - V/S-182/185 Calibration and Field Service Manual Page 11

 On-board regulated +5v +A or +V
REF
+5v
+in
Filter A/D
Loadcell -in Ampl. CPU
circuits conv.
gnd
-5V
GND

The analog section of the T21 (Amplifiers and A/D-converters) are the only components that use
the -5V supply.
NOTE: The A/D converters operate in unipolar mode in all current models, so the proper operating
range for +A and +V is between 0V and REF. If +A or +V voltages go below zero, the appropriate
channel A/D converter output will be zero.

Loadcell Voltages
Test point "-IN" is the common.
The loadcell voltages as measured between the "-IN" and "+IN" terminals are in the millivolt
range. Following is a list of the desired voltages for both loadcells under different load conditions.

Conditions Desired voltages Remarks

No load 0 - 3.5mV Empty loadcell / platform (depends on platform dead weight).
Full load 8 - 11mV Loadcell loaded to capacity.
Overload 12 - 16mV Loadcell overloaded (>150% full load).

A 4-loadcell platform installation typically operates over only 50% of the loadcell as opposed to a
single loadcell platform installation, which typically operates over 90-100% of the loadcell capacity.
A 4-loadcell platform will therefore operate at roughly half the voltages above.

Please note that these voltages are by no means absolute limits. While voltages outside these limits
indicate something is going wrong, a loadcell operating outside these limits may provide perfectly
adequate service for a long time. Refer to the "No-Load adjustment" section on how to
compensate for a loadcell that is outside the limits.
Amplifier Voltages
Test point "GND" is the common.
The amplifier output voltage (test points A+ / V+) on a correctly calibrated scale should be in the
0.2 - 2.3V range, depending on loadcell load. Abnormal loadcell voltages will be reflected in the
amplifier output and may require a "No-load adjustment" or loadcell replacement. If the amplifier
output is not within limits while the loadcell voltages are normal, the amplifier is most probably
faulty, requiring amplifier replacement.
At any rate, the desired amplifier output voltage range is 0.2 - 2.3V. While the P-15’s digital
calibration feature will compensate for a reduced voltage range, resolution and accuracy will suffer.

Please note that the amplifier output is also the A/D converter input. The absolute upper voltage
limit for the A/D converter input equals the voltage measured at the "REF" test point (1.17V).
Under normal operations the test point voltage under full load conditions should not exceed 1.0V.
The A+/V+ test voltages should never go below 0V or above the REF voltage!

Refer to the "No-Load adjustment" section on the next page on how to compensate for a loadcell
that is outside the 0 - 2.5 (REF) limits.

No-Load adjustment
A loadcell can receive a shock load that puts a permanent bias on it's output, indicated by loadcell
voltages outside the desired limits under no-load conditions. The loadcell circuit can be counter-
Page 12 Calibration and Field Service Manual P-15 - V/S-210
biased to compensate for this by connecting a resistor between the +5 and -IN/+IN terminals on the
desired channel. A handy method is to insert the resistor leads along with the loadcell wires under
the appropriate loadcell cable terminal screws.
To lower the loadcell voltage connect the resistor between the "+5" and "-IN" terminals.
To raise the loadcell voltage connect the resistor between the "+5" and "+IN" terminals.
The resistor value has to be varied according to the bias needed. A 470Kohm resistor will result in a
bias of approximately 1mV.
Analog section troubleshooting conclusion
If all analog section checks are normal, try replacing the CS5501 A/D converter chip(s)

NOTE:
Any changes to the analog section require the scale to be checked for correct weight readings using
approved reference weights. If weight readings are not correct, a complete recalibration of the scale
must be carried out.

T-21 Digital section

Digital section failures usually result in more dramatic symptoms. Partial failures usually result in
clearly defined symptoms. The following is a list of typical digital sub-section symptoms:

Scale will not start:

Disconnect the RESET switch to check if the switch has a short-circuit.
Check supply voltage & the voltage-sensitive RESET citcuit on versions T21 & later
Replace the CPU chip.

Scale reports an “EEPROM checksum error” on startup:

Replace the 24C02N EEPROM chip and re-calibrate the scale.

Weight readout inconsistent or gibberish:

Try re-calibrating the scale. Refer to the Display unit - DISPL. T21 section for display
troubleshooting.

Memory troubleshooting tips:

The firmware (Scale Control Program) is permanently burned into the T8/5xx CPU chip. The RAM
workspace is also internal to the chip. Anymemory problems can only be solved by replacing the
CPU.

If all else fails, try replacing the CPU chip with an identical chip. Many of the CPU lines are
used directly for I/O such as display and A/D converter. A partial failure could be caused by a single
failed CPU I/O line.
PLEASE NOTE that the CPU chip MUST contain the appropriate firmware!

Schematics of the T21 can be found at the back of this manual.

P-15 - V/S-182/185 Calibration and Field Service Manual Page 13

T-21 Power Supply section
The Power Supply section of the T-21 is normally configured for 110VAC or 220VAC external
power. A portable version is also available that uses a sealed 12-24V lead-acid battery mounted
inside the indicator support post.
The T-21 Power Supply uses a transformer, a rectifier bridge and a 15V regulator to obtain a
regulated 10-15VDC source. A switching regulator provides the regulated +5VDC digital power
source and –5VDC source for the analog circuits, while the main +5VDC analog power source is
provided by a pair of 8V and 5V regulators for improved stability.

AC-powered version
This version has a fully populated power supply section, and an external power cable is routed
directly to the 220V connector. The transformer dual primary windings are connected in series for a
220VAC configuration, or in parallell for a 110VAC configuration.
Portable version
This version does not have the transformer, rectifier or the high-voltage fuse. The 220VAC
connector is labeled “12-24VDC” and routed directly to the 15V regulator. A removeable, sealed
lead-acid battery located in the indicator support post provides power to run the scale without
external power for up to XX hours. The battery has to be removed for charging with a separate
battery charger unit.

Troubleshooting
The output voltages are used by the various modules as follows:
* +8V regulated DC is used by the T21 card as a supply for it’s own generation of an extremely
stable, independent +5V DC source for the analog circuits.
* -5V regulated DC is only used by the analog circuits of the T21 card.
* +5V regulated DC is used mainly by the T21 and various DISPLAY cards.

Nominal Voltage:Minimum: Maximum:

+5V +4.80V +5.20V Regulated
+8V +7.30V +8.30V Regulated
-5V -4.80V -5.20V Regulated

◊ Check the Thermal Circuit Breaker. They should auto-reset 10-20 seconds after power is turned
off.
◊ Check the input voltages. The 220V AC voltage is not very critical, but if the 12-24V DC input
is used, the voltage should not be lower than 11.5V, as the scale will automaticaly shut down at
around 11.2V and not restart until the voltage has reached 11.5V (approximate values).
◊ Check the output voltages according to the table above
◊ The exact +8V DC value is not very critical, but it must be stable. Any fluctuations may result
in unsteady weight readouts.
◊ Please note that the -5V voltage is generated by the MAX660 diode pump IC.
◊ The only field-replaceable components is the 315mA fuse (AC-powered version).
◊ If the Power Supply section fails, the best course of action is usually to replace the entire unit.

ONLY USE REPLACEMENT FUSES AND THERMAL CB’S WITH THE SAME RATING
AS THE ORIGINAL!

Page 14 Calibration and Field Service Manual P-15 - V/S-210

Display Unit – DISPL. 21
The DISPL. T21 Display Unit a 6-digit 7-segment LED display, a LED STB indicator and the
associated decoding circuitry.

DISPL: T21 component layout

7218
LED
Decoder
Display
7-segment LED digits cable
BC557

Status LED

The LED 7-segment display driver can drive up to 8 LED digits, and the unused segment drivers are
used to drive the 4 Status LED’s. Due to the heavier current requirements of the Status LED’s, a
pair of transistors are used to relieve the load from the LED decoder drivers.

Troubleshooting should be straightforward. It is very handy to have a spare unit at hand to verify if
the fault lies in the T21 CPU card or the display unit itself. The spare unit can also be
“cannibalized” to verify if individual components have failed.
Apart from the obvious checking of the cable, connectors and checking the circuit board and socket
for corrosion and broken tracks, check the following:

7-segment LED: Beside the obvious mechanical problems (corrosion or shorts in sockets or print
tracks), the most common problems are a failure of a single digit (a single segment or the whole
digit) and a failure of the same segment in all digits.
A single digit failure is usually cured by replacing the faulty digit while a failed segment in all digits
is usually caused by a 7218 LED decoder failure (NOTE: this can also be caused by a short circuit
in one of the LED digits). As a last resort, replace the LED decoder.

Status LED: If the STB status LED fails, replace the faulty LED chip.
A failure can also be caused by a failed BC557 driver transistor or the 7218 LED decoder chip. If
replacing the LED chip and/or driver transistor does not cure the problem, replace the 7218 LCD
decoder.

A schematic diagram of the DISPL.T21 can be found at the back of this manual.

P-15 - V/S-182/185 Calibration and Field Service Manual Page 15

Scale Assembly
The current Pols P-15 scale hardware versions are identified as follows:
Housing Type:
S-210 0 - Type 0 indicator with separate weighing platform

Based on T-21 electronics

Scale Type:
V - Land-based scale
S - Acceleration-compensated marine scale

Screws

Type 0 indicator with separate weighing platform.

Type 0 indicator disassembly

To disassemble a type 0 indicator, perform the following steps:

1. Remove the 2 screws on the right side plastic plate.

2. Pull the left plastic plate out of the indicator housing. The external power and loadcell cables are
folded up inside the indicator to allow the electronic assembly to be pulled all the way out of the
indicator housing. The same applies to the Tare and Reset toggle switch wires.

Reverse the above steps to re-assemble the indicator, taking care the cables and wirs fold up
correctly inside the housing..

Page 16 Calibration and Field Service Manual P-15 - V/S-210

Typical weighing platform assembly
The P-15 S-210 can be used with any weighing platform or weight sensing arrangement that uses
strain-gauge loadcells. The most commonly used platform are those manufactured by Pols
Electronics of Isafjordur, Iceland. A typical single-loadcell platform arrangement is as follows:

Heavy-gauge aluminium Top Plate

Overload stop Spacer Overload stop

Splash Cover Overload stop Level

Single-point loadcell
indicator

Heavy-gauge Aluminium Base Plate

Adjustable Support Pad Loadcell cable

Cable clamp
Typical Weighing Platform Arrangement

The structural construction material is heavy-gauge anodized aluminum except for the splash
protection cover, which is of light-gauge anodized aluminum. All bolts and screws are of stainless
steel.
Not shown is the stainless steel platform cover that snaps over the whole assembly.

The acceleration-compensated marine scale platform versions have an extra reference loadcell
installed, fitted with a reference weight.

Loadcell list:
The following is a list of the loadcells currently used in weighing platforms manufactured by Pols
Electronics. Other loadcell types from the same manufacturers may be used in future versions.

Manufacturer: Tedea/Huntleigh, England

Type Capacity Certificate #
1042 5 kg T1118/2
1042 8 kg -”-
1042 15 kg -”-
1042 30 kg -”-
1042 50 kg -”-
1042 100 kg -”-
1260 100 kg T1071/1
1260 120 kg -”-
3510 1000 kg NMI TC2272

Manufacturer: Revere, France

Type Capacity Certificate #
9102 2500 LB NMI TC2331

P-15 - V/S-182/185 Calibration and Field Service Manual Page 17

Schematics
The following pages contain the schematic diagrams applicable to the V-210 and S-210.

Diagram list:
1. T21b Main Board schematics.
2. Display-T21 schematics

Page 18 Calibration and Field Service Manual P-15 - V/S-210