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AFG/AFTI Mk 4

Service and Repair Manual

Number 022-614

Issue Number: 09

Page 43 of 47

900-296

– 900-301 kits consist of:

P/N

DESCRIPTION

QTY

329-187

4way header 0.1 PI G’plat

400-xxx-S01 Load cell

– to capacity required

406-408

Load cell stud 10/32 UNF

410-xxx

AFG Mk4 label to capacity

410-xxx

BFG Mk4 label to capacity

414-023

Heat shrink black 1.5mm

0.04mtr

420-138

10/32 half nut

420-265

Skt cap screw 6-

32 UNC x 5/8”

900-302

– 900-303 kits consist of:

P/N

DESCRIPTION

QTY

329-187

4way header 0.1 PI G’plat

400-xxx-S01 Load cell

– to capacity required

406-409

Load cell stud 5/16 UNC

410-xxx

AFG Mk4 label to capacity

410-xxx

BFG Mk4 label to capacity

414-023

Heat shrink black 1.5mm

0.04mtr

420-316

¼” half nut

420-401

M8 x 23 hex bolt (stainless)

China AFG kit

CAPACITY P/N

QTY DESCRIPTION

2.5N

900-305

CHINA AFG KIT FOR 2.5N - 500N

5N
10N
25N
50N
100N
250N
500N
1000N

900-306

CHINA AFG KIT FOR 1000

2500N

No sub-assembly

900-305 kits consist of:

P/N

DESCRIPTION

QTY

900-163

AFG Mk4 case assembly 2.5-500N
(contains
404-161-F11

– AFG Mk4 Battery cover and paint

408-428-F11

– AFG Mk4 2.5-500N Case and paint)

1

(1)
(1)

900-293

China AFG common parts

900-306 kits consist of:

P/N

DESCRIPTION

QTY

900-164

AFG Mk4 case assembly 1000 par M8
(contains

Summary of Contents for AFTI

Page 1: ... 4 Service and Repair Manual Number 022 614 Issue Number 09 Page 1 of 47 PDF copy stored in approved location by click on signature for validation Paper copy printed from approved PDF source by Name Signature Date ...

Page 2: ...y replacement 301 028 V01 13 11 Configuration of display 301 028 V1 06 V1 10 14 12 Configuration of Display 301 028 V01 V1 12 19 13 Charging socket replacement 329 355 22 14 Keypad Membrane Front Cover Plate replacement 23 15 Load cell removal 24 16 Load cell stud fitting 25 17 Load cell refitting 27 18 Battery lid insulator replacement 27 19 Firmware version Identification 28 20 Firmware release ...

Page 3: ... 1000N 2500N Pinned load cells Bad 8515 version error message 05 25 08 11 1847 1876 TF mV offset pins to use 1000N Pinned load cell removal V1 12 Config 301 028 V01 LCD Load cell stud removal 06 26 10 12 2038 TF LCD behaves unusually LCD Config 3179 3178 EEPROM Code 9876 06A S01 removed from 400 175 400 034 07 23 03 15 2318 TC Product variants added Sub assemblies added Add digital analogue output...

Page 4: ...CAL ANALOGUE 25N Analogue 850 416 Description Capacity Output 850 416 AFG 50N 50N Digital 850 416 BA AFG MK4 50N CAL ANALOGUE 50N Analogue 850 417 Description Capacity Output 850 417 AFG 100N 100N Digital 850 417 BA AFG MK4 100N CAL ANALOGUE 100N Analogue 850 418 Description Capacity Output 850 418 AFG 250N 250N Digital 850 418 BA AFG MK4 250N CAL ANALOGUE 250N Analogue 850 419 Description Capacit...

Page 5: ... to be pressed to enter certain modes of the software Words typed in bold and italic represent the keys on the keypad i e ENTER or UNITS 5 Latest software version V1 12 The version of software is displayed on the gauge start up screen bottom left hand corner Mecmesin Limited recommends that instruments have the latest version of software installed AFG AFTI software can be upgraded to the latest ve...

Page 6: ...see below If the low battery symbol is showing either Replace the batteries Check the existing batteries are not alkaline type and use the mains adaptor battery charger If alkaline batteries are fitted fit a serviceable set or remove them and use the mains adaptor battery charger 7 Check the loadcell offset Software pre V1 01 The Calibration menu displays a password menu and allows the user to che...

Page 7: ...display If the displayed offset is between 5 and 10 recalibration is recommended If the displayed offset is greater than 10 a replacement loadcell may be required These values are given as an indication only the need for calibration repair may vary according to the individual characteristics of the sensor To check the load cell mV offset Access the load cell connection with the PCB by removing the...

Page 8: ...overload in tension 7 Notes about 300 157 V03 Sensitivity of analogue gauges deemed too difficult to achieve calibration accuracy A note from Engineering as below The designed values of the pots used in the AFG with analogue output are such that adjustment is extremely coarse in relation to the desired tolerance Engineering do not consider the design to be fit for purpose and hence it is pot luck ...

Page 9: ...ual Number 022 614 Issue Number 09 Page 9 of 47 8 PCB replacement 300 157 V02 3 1 Rear view of AFG AFTI 2 Remove 2 off M3x6 csk slot machine screws 420 296 retaining the battery cover 3 Remove 5 off batteries 4 Remove Guarantee void label ...

Page 10: ... M3x6 pozi csk stainless steel screw 420 357 and 2 off M3x20 pozi csk zinc screws 420 378 retaining the front panel 6 Lift off front panel 7 Unplug front panel from PCB 8 Remove 2 off stand offs from D type female connector Removal of the stand off on the right hand side of the photograph is optional ...

Page 11: ...age 11 of 47 9 Peel back the ESD warning label and remove 2 off M3x6 csk stainless steel screws 420 357 fixing hex spacers to case 10 Remove 3 off M3x6 pan head taptite screws fixing PCB to casing 11 Lift out PCB 300 157 V01 Reassembly is the reverse of the above procedure ...

Page 12: ... De solder the sounder from the PCB and replace observing the correct polarity The positive longer pin should be inserted through the hole with a square solder pad After soldering trim off the excess sounder pins 14 Remove the sticker from the sounder 15 Test the Sounder Turn the instrument on The audible alarm should sound Reassembly is the reverse of the above procedure ...

Page 13: ...per instructions 1 to 7 in section 6 17 Open the LCD ribbon cable retaining clips located at end of the header by lifting them up and remove the ribbon cable from the header 18 Remove the 4 off nuts retaining the display to the PCB Remove and replace the display 19 Insert the ribbon cable into the header and secure by pushing the clips back down ...

Page 14: ...LCD manufacturer has resulted for the need in some instances for the codes 3179 or 3178 to be entered into the Calibration menu to reconfigure the display Introduction Screen Home Display If the configuration code 3179 has already been entered by the manufacturer the code 3178 will then have to be entered to display the text correctly If the LCD displays correctly the first time the gauge is switc...

Page 15: ...mber 09 Page 15 of 47 How to configure PCB to correct a display which starts up inverted Introduction Screen Home Display 22 Ensure both DIP switches on SW1 are set to the off position DIP switches set to off 23 Press and hold Units Menu key until menu is displayed ...

Page 16: ...4 Issue Number 09 Page 16 of 47 24 Press Units Menu key again to display page 2 of menu 25 Press TXD UP key once until arrow points to CALIBRATION 26 Press Reset Enter key to enter Calibration mode 27 Press TXD UP key three 3 times until 3000 is displayed ...

Page 17: ... 022 614 Issue Number 09 Page 17 of 47 28 Press Reset Enter key to enter first number 29 Press TXD UP key one 1 times until 100 is displayed 30 Press Reset Enter key to enter the second number 31 Press TXD UP key seven 7 times until 70 is displayed ...

Page 18: ...s Reset Enter key to enter the forth number The LCD should then display page 2 of the Calibration menu correctly If the text is still inverted 3178 should be entered as above Restart from instruction 6 35 Press Max Esc key to return to Home page 36 Turn PCB OFF and then back ON Text now should still be displayed correctly 37 DIP Switch SW1 should then be returned to the ON position Procedure ends ...

Page 19: ...the V1 12 software then the display will be blank and will need to be set up as described in this document 301 028 V01 Display requires V1 12 or later to function correctly See section 4 Protection switches 38 Ensure that the two PCB memory protection switches SW1 shown are in the OFF position Display Type Confirmation 39 Connect AFG Keypad to PCB if not already connected 40 Switch the PCB on and ...

Page 20: ...identify and configure for the display fitted 44 Ensure that the gauge is switched OFF 45 Press and hold ZERO TXD UNITS keys simultaneously 46 Press and release the ON key still holding ZERO TXD UNITS a buzzer should sound continuously while the keys are depressed 47 Release the ZERO TXD UNITS keys The screen may shown any of the options shown below continues on next page ...

Page 21: ...ach time ZERO is pressed 49 Once the 1 234 option is showing press the RESET key to store the display type to the eeprom and exit the display setup NOTE if required the MAX key can be pressed to exit the display setup mode without saving the new display settings 50 CHECK Turn the gauge OFF and then back ON again the AFG screen should show briefly before changing to 0 0 on the working screen 51 Ret...

Page 22: ...55 52 Remove PCB as per instructions 1 to 11 in section 6 53 De solder the damaged charging socket and replace with new Take care over correct alignment and quality of soldered joints Reassembly is the reverse of the above procedure 54 Once reassembled check the charging socket is aligned correctly by inserting a charger ...

Page 23: ... Service purposes the keypad is replaced as a complete assembly Procedures for preparing this assembly are detailed in AFG Mk 4 Assembly Work Instruction 020 555 55 Remove front panel assembly as per instructions 1 to 7 in section 6 56 Replace front panel assembly 57 Test keypad functions Reassembly is the reverse of the above procedure ...

Page 24: ...e replacement load cell MUST be refitted in an identical manner 60 Load cells for 2 5N 500N gauges are retained with 2 off 6 32 UNC x 5 8 socket cap screws 420 265 Remove with appropriate Allen key 2 5 5N load cells have spacers 408 392 fitted 61 Load cells for 1000N and 2500N gauges are retained with 2 off M8 x 23 hex head screws 421 401 Remove using appropriate socket 62 The 2500N load cell mayb...

Page 25: ... load cell fitted Gauge Load cell Stud Nut 2 5N 400 175 406 410 N a 5N 406 410 406 410 N a 10N 400 006 S01 406 408 420 138 25N 400 007 S01 406 408 420 138 50N 400 008 S01 406 408 420 138 100N 400 024 S01 406 408 420 138 250N 400 107 S01 406 408 420 138 500N 400 016 S01 406 408 420 138 1000N 900 302 406 409 420 316 2500N 900 164 V02 Pinned complete assembly Pinned complete assembly 63 Degrease the ...

Page 26: ...nnecting wire As thread becomes available screw on the nut 66 Tighten the load cell stud into position using a 2mm Allen key 67 Tighten nut with spanner possibly modified to fit into load cell 68 Note 1000 2500N load cells have no hole use pliers and the 5N and 2 5N have no nut just screw stud in with Loctite applied IMPORTANT Clean any Loctite residue from the stud load cell and nut ...

Page 27: ...off 6 32 UNC x 5 8 socket cap screws 420 265 2 5 5N load cells have spacers 408 392 fitted Tighten with appropriate allen key and torque to 4Nm 71 Load cells for 1000N gauges are retained with 2 off M8 x 23 hex head screws 421 401 tightened to 30Nm 2500N load cells are now pinned into position and come as a complete assembly 72 Remove the extension rod 73 Reconnect the load cell to the PCB Reassem...

Page 28: ...tine 20 Firmware release notes Implemented in version 1 12 DCR1847 from serial number 11 0176 06 to 11 0283 09 then returned to V1 10 as previous LCD procured 1 Different contrast setting added for new displays Implemented in version 1 11 DCR1847 Not released 1 Changes made to allow 3 different displays to be used Implemented in version 1 10 DCR1661 from serial number 10 0133 02 1 Incorrect Slopes...

Page 29: ...rrupted data to corrupted data image Implemented in version 1 07 DCR 1567 from serial number 09 0104 04 09 0125 02 09 0027 02 09 0130 02 09 0211 02 09 0130 03 09 0131 03 09 0132 03 09 0045 04 09 0046 04 09 0047 04 09 0048 04 09 0049 04 09 0050 04 09 0051 04 09 0052 04 09 0053 04 09 0054 04 FS 49 Menu Pages in Uncalibrated PCBs Before a PCB has been calibrated the menu pages are not configured corr...

Page 30: ...nstant in the menu pages accessed via the password page has no upper and lower limits This means it can not only be increased indefinitely but also decreased to a negative value It is suggested to limit the g constant to between 9 00000 and 9 99999 The g constant is not rounded correctly when being altered due to the addition subtraction of a floating point number to change it Implemented in versi...

Page 31: ...prom address moved as overwrote Rate in eeprom causing gauge to enter High Rate mode which was perceived as noise in the Orbis 2 Zero Blanking Flyspray ID28 Zero blanking added for high rate so that any load to be displayed that is less than the accuracy of the gauge is displayed as zero 3 Loadbar sign Flyspray ID29 Loadbar now always correct appearance 4 Calibration in non SI units Flyspray ID40 ...

Page 32: ... from load cell size select page up to but not including new Store Data page All interrupts disabled in correct place as gauge could lock up if auto off backlight enabled Calibration steps can be skipped using the TXD key Extra stage at end of calibration routine added to prompt user to store data 2 X Constant Floating point rounding error fixed when determining decimal places for new X constant v...

Page 33: ...Issue Number 09 Page 33 of 47 6 Overload Symbol Displaying and clearing the overload symbol in the timer interrupt routine removed as corruption to display could occur when 30 second timeout ended OL symbol now displayed cleared as appropriate in main loop ...

Page 34: ...en set as an ATFI press UNITS ENTER to access the calibration pages AFTI Mk4 PCB conversion to AFG Orbis Tornado Turn the gauge on without a Smart connected The display reads ERROR NO SMART Press UNITS ENTER at the same time once released the calibration menu is accessed The display reads 0000 Enter the code 9999 to enter the Calibration routine Enter the code one number at a time using the follow...

Page 35: ...ately 29Hz continuous transmission function operates at 25Hz at this baud rate At 115200 this is increased to approximately 70Hz continuous transmission function operates at 50Hz at this baud rate Note however that new data is only available for transmission every 20ms so sampling faster than 50Hz would result in the same data being repeated occasionally 3 Determining the maximum data transmission...

Page 36: ... by holding the MENU key down Select page 2 of the Menu by pressing the MENU key select CALIBRATION by using UP DOWN keys and press ENTER The display will now show 0000 Enter the code 7777 to go into the Contrast adjustment routine Enter the code one number at a time using the following keys UP increases the number DOWN reduces the number ENTER accepts the number Although it may not be visible the...

Page 37: ...ge and offset for internal load cell will be dependant the on mV V and offset of load cell and analogue circuit of the AFG External Load cell No load applied Pin 10 to Pin 1 1 25V Non calibrated Analogue output can range between 0 0V to 2 5V with offset 1 25V Pin 9 to Pin 1 0 0V Non calibrated Analogue output can range between 1 25V to 1 25V with offset 0 0V Non calibrated analogue output range an...

Page 38: ...AFG AFTI Mk 4 Service and Repair Manual Number 022 614 Issue Number 09 Page 38 of 47 The switching of Pin 9 functionality is automatically triggered by the presence absence of a smart connector ...

Page 39: ...V1 12 or later firmware Check display ribbon cable connection Check with a known working LCD Replace PCB 3 Display behaves unusually If the LCD gives an unusual display the ribbon cable may not have seated correctly in the header Unclip the ribbon cable remove and reinsert into the header Re secure and retest Check LCD ribbon cable connection See Section 10 Display Replacement Check with a known w...

Page 40: ...working keypad Replace PCB Keypad 7 LCD shows 0000 When the MENU key is pressed PASSWORD Function enabled Refer to latest Operating Manual Enter 6284 to unlock 8 LCD displays Reprogram the PCB with the latest version of firmware see section 4 whilst programming ensure that the lockbits and fuses are set correctly 9 LCD flashing and or buzzer sounding with a Smart connected When the AFG Mk4 was int...

Page 41: ... LABEL 410 538 1 AFG MK4 500N LABEL 410 537 1 AFG MK4 250N LABEL 410 536 1 AFG MK4 100N LABEL 410 535 1 AFG MK4 50N LABEL 410 534 1 AFG MK4 25N LABEL 410 533 1 AFG MK4 10N LABEL 410 532 1 AFG MK4 5N LABEL 410 531 1 AFG MK4 2 5N LABEL 410 515 1 AFG MK4 KEYPAD must be affixed to 404 159 420 378 2 M3 x 20 SCREW POZI CSK ZINC 420 357 3 SCREW M3 x 6 CSK POZI SS 404 159 1 AFG FRONT COVER PLATE 300 157 V...

Page 42: ... 6 32UNCx5 8 2 5 500N G 420 401 2 M8x23 Hex Bolt s s 1000 2500N 408 428 F11 1 AFG MK4 2 5 500N CASE FUTEK C 408 427 F11 1 AFG MK4 1000 2500N CASE PARRA M8 408 432 F11 1 AFTI MK4 CASE AFG XXX N Front panel complete comprising of 404 159 1 000 AFG MK4 FRONT COVER PLATE 420 230 3 000 PRESS STUD M3 x 8 424 027 2 000 HEXSPACER M3 x 14 F F MODIFIED 424 046 1 000 HEXSPACER M3 x 25 F F MODIFIED 410 515 1 ...

Page 43: ...1 Load cell to capacity required 1 406 409 Load cell stud 5 16 UNC 1 410 xxx AFG Mk4 label to capacity 1 410 xxx BFG Mk4 label to capacity 1 414 023 Heat shrink black 1 5mm 0 04mtr 420 316 half nut 1 420 401 M8 x 23 hex bolt stainless 2 China AFG kit CAPACITY P N QTY DESCRIPTION 2 5N 900 305 1 CHINA AFG KIT FOR 2 5N 500N 5N 10N 25N 50N 100N 250N 500N 1000N 900 306 1 CHINA AFG KIT FOR 1000 2500N No...

Page 44: ...614 Issue Number 09 Page 44 of 47 404 161 F11 AFG Mk4 Battery cover and paint 408 427 F11 AFG Mk4 1000N 2500N Case and paint 1 1 900 293 China AFG common parts 1 900 293 kit consists of all the common parts to make up the AFGs 28 Exploded parts diagram ...

Page 45: ...AFG AFTI Mk 4 Service and Repair Manual Number 022 614 Issue Number 09 Page 45 of 47 ...

Page 46: ... Page 46 of 47 29 Changes to 300 157 V03 Part No Description Qty 300 157 V03 AFG PCB Analogue cal 1 311 012 402 Ohm resistor 10ppm 1 315 505 200 Ohm pot trimmer 13 turn 100ppm 1 311 104 1k Ohm resistor 10ppm 1 1 Replace VR2 with 200 Ohm pot trimmer 13 turn 100ppm 315 505 ...

Page 47: ...AFG AFTI Mk 4 Service and Repair Manual Number 022 614 Issue Number 09 Page 47 of 47 2 Replace R63 with 1k Ohm resistor 10ppm 311 104 and R64 with 402 Ohm resistor 10ppm 311 012 ...

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