KERN & Sohn GmbH

Ziegelei 1 Tel: +49-[0]7433- 9933-0

D-72336 Balingen Fax: +49-[0]7433-9933-149
E-Mail: info@kern-sohn.com Internet: www.kern-sohn.com

Service manual
Compact balances

KERN FCB
Version 1.1
4/2009
GB

FCB-SH-e-0911
 KERN FCB
GB Version 1.1 4/2009
Service manual
Compact balances

Table of Contents

1 Basic Information ___________________________________________________ 3

2 Introduction ________________________________________________________ 3
2.1 Features _____________________________________________________________ 3
2.2 Digital Auto Calibration Procedure _______________________________________ 4
2.3 Internal Calibration Procedure__________________________________________ 4
2.4 Display Segment Test _________________________________________________ 5
3 Functional Block Diagram / Description _________________________________ 5
3.1 Functional Block Diagram _________________________________________________ 5
3.2 Function Description _____________________________________________________ 6
4 Trouble Shooting ___________________________________________________ 7
5 To Replace PCB ____________________________________________________ 8
6 To Replace Load Cell Assembly _______________________________________ 9
7 Schematics _______________________________________________________ 10
8 Components Layout ________________________________________________ 14

2 FCB-SH-e-0911
1 Basic Information
Grundlegende Hinweise
The device must be repaired only by trained specialist staff or personnel with
professional formation (such as a repair-specialist accredited by law
concerning verification).
The service manual is obligatory for repair work.
After repair, original conditions of the device have to be restored.
Only original spare parts should be used.

Das Gerät darf nur von geschultem oder beruflich ausgebildetem

Fachpersonal (z. B. eichrechtlich anerkannter Instandsetzer) repariert werden.
Die Serviceanleitung ist bindend für Reparaturen.
Das Gerät muss nach erfolgter Reparatur wieder in den Originalzustand
zurückversetzt werden.
Es dürfen nur Originalersatzteile verwendet werden.

2 Introduction
2.1 Features
• Full Tare
• Memory function with indicator
• Stable indicator
• Negative value indication
• Two types of Digital Auto Calibration
• Solder pads to prevent end-user internal calibration
• RS232 interface, printing function
• Custom scale by going through SET manual
- Multiple serial interface modes
- Different communication baud rates selectable
- Auto off enable / disable
- Zero tracking enable / disable
- Multiple calibration weight selectable
- Backlight selectable
• Pre-Tare function
• Animal weighing mode
• Low battery indicator
• Auto off function (battery mode only)
• AC adaptable
• Display segment test function
• Overload protection
• Optional rechargeable battery
FCB-SH-e-0911 3
2.2 Digital Auto Calibration Procedure

1. Turn balance on and allow the unit to acclimatize and stabilize for 30 minutes.
2. Select the calibration weight through the manual with [Print], [Mode/Cal] and [Set/M]
keys.
3. Press and hold the [Mode/Cal] key until the display shows a flashing weight reading.
The flashing weight reading indicates the correct weight that must be placed on the
weighing pan.
4. Gently place the correct calibration weight on the center on the weighing pan. With the
display still flashing, press the [Set/M] key.
5. The display will now show [Cal F] and then return to normal operating mode. The
calibration is complete when the display correctly shows the weight that is placed on
the weighing pan while the display has stabilized.
6. Remove the calibration weight and press the [TARE] key to reset the zero point.

In case [CAL E] is displayed instead of [CAL F], this indicates a calibration

procedure error. Turn the scale off and then on and repeat the procedure.

2.3 Internal Calibration Procedure

1. Remove the top housing of the scale.

2. Connect J3 on the main board by soldering the pads together.
(J4 for FCB 8K0.1, FCB 16K0.2 and FCB 30K0.5)
3. Place scale on a hard level surface. With weighing pan installed, turn balance on.
Display shall show the internal counts.
4. The internal counts shall fall in the range from 60 000 to 85 000
(70 000 to 300 000 for FCB 8K0.1, FCB 16K0.2 and FCB 30K0.5).
In case out of this range, connect J10 left side or right side (J6 for FCB 8K0.1,
FCB 16K0.2 and FCB 30K0.5) to increase or reduce the reading.
Connecting or disconnecting pads on J7, J8 or J9 (J2, J3, J4 or J5 for FCB 8K0.1,
FCB 16K0.2 and FCB 30K0.5) can fine tune the reading.
5. Press [Set/M] key once. Display will show [CAL 0] and then the required calibration
weight. Place the corresponding calibration weight on the center of the weighing plate.
Press [Set/M] again while the weight placed on the weighing pan is stable.
6. Display will now show [CAL 1] and then the next calibration weight. Place the
corresponding calibration weight on the weighing plate. Repeat this step until display
shows [CAL F]. Remove all weights from weighing pan. Display shall return to zero.
7. Reset the zero point and check the accuracy at different weight.
8. Disconnect J3 (J4 for FCB 8K0.1, FCB 16K0.2 and FCB 30K0.5).
9. Install the top housing of scale.

In case [CAL E] is display instead of [CAL F], this indicates a calibration procedure error,
or wrong weight applied for calibration.
Turn the scale off and then on and repeat the procedure.

4 FCB-SH-e-0911
2.4 Display Segment Test

Whenever the scale is power on, all segments of the LCD will be turn on for 4 seconds.
Check for any missing segment.

3 Functional Block Diagram / Description

3.1 Functional Block Diagram

External
Computer /
Printer

Keyboard LCD RS232 Serial

Interface

9V Battery Power control /

Regulator & Microprocessor
or
Adaptor Low battery
detector
digital signal

Load cell Amplifier A/D Converter

(Sensor) analog
signal

FCB-SH-e-0911 5
3.2 Function Description

1. Load cell
This is the heart of the whole system. The load cell itself is arranged as a bridge.
The resistance change of the bridge elements is proportional to the load applied on
the load cell. Therefore, the output of the load cell is an analog signal, which is
proportional to the load applied on the scale.

2. Amplifier
The analog signal from the load cell is very small, of the order of micro-volt.
Hence, a linear and stable amplifier is applied to amplify the analog signal to an
appropriate level.

3. A/D Converter
In order for the analog signal can be input to the microprocessor, this part converts the
analog signal to its digital equivalent. The operation of the analog to digital converter
is using a SIGMA DELTA technique and under the control of the microprocessor.

4. Microprocessor
The microprocessor control all the functions of the scale, such as auto zero,
A/D conversion, timings, weight calculation, unit convertion, and display,
parts counting, percentage weight, RS232 interface, overload indication,
low battery indication, tare / memory function, etc….

5. Display
This is the part where the weight is shown out on the LCD display in digital form.
The whole display is driven by the microprocessor.

6. Power Regulator and Low Battery Detector

This part contains the ON/OFF power control. In order for the external power can be
used by other parts of the scale, a regulator is used to regulate the supply.
A low battery detector is employed to make sure that the power supply is strong
enough for normal operation of the scale. If rechargeable battery is installed,
it can be charged up by the charging circuit.

7. Keyboard
The keyboard provides on user interface. [On/Off], [Mode/Cal], [Set/M], [Print]
and [Tare] keys are employed to operate the scale.

8. RS232 Interface
The RS232 serial interface provides the communication to the external computer or
printer.

6 FCB-SH-e-0911
4 Trouble Shooting

Power on

↓
Full Segments?
If no display, check battery /adaptor; connection between keyboard—main
board, battery/adaptor—main board.
If missing segments, check fixing of LCD frame, zebra connector under LCD.

↓
Display Zero?
If display [LO], check battery>7.5v, adaptor>9v.
If display [ E] , check internal count.

↓
Proper readout?
If unstable reading, check weighing plate, overload stopper, load cell and wires,
environmental conditions and stable table.

↓
Correct reading?
If not accurate, perform internal calibration.
If cannot reach full capacity, check weighing plate, overload stopper, load cell
and internal zero point.
If always zero, check internal zero point. Internal calibration if necessary.

↓
Proper Data to External Device?
If external device not response, check correct RS232 cable and connection,
application software running correctly, wires connecting D-sub connector and main
PCB.

↓
Normal operation.

FCB-SH-e-0911 7
5 To Replace PCB
1. Disassemble top housing of scale.
2. Disconnect PL1, PL2, PL3 and JP2 from the PCB.
Disassemble the ground wire screw.
Replace a new PCB. Connect PL1, PL2, PL3 and JP2 again.
Assemble the ground wire with screw.
3. Assemble the top housing.
4. Perform internal calibration as described in section 2.
5. Check accuracy of scale at different weight.

FCB6K1 FCB12K1 FCB15K5 FCB24K1 FCB24K2

weight tol. weight tol. weight tol. weight tol. weight tol.
(g) (g) (g) (g) (g) (g) (g) (g) (g) (g)
1000 3 2000 3 1000 15 5000 3 5000 6
2000 3 4000 3 5000 15 10000 3 10000 6
4000 3 8000 3 10000 15 15000 3 15000 6
6000 3 12000 3 15000 15 20000 3 20000 6
24000 3 24000 6

FCB24K10 FCB3K0.1 FCB6K0.5N FCB30K1 FCB8K0.1

weight tol. weight tol. weight tol. weight tol. weight tol.
(g) (g) (g) (g) (g) (g) (g) (g) (g) (g)
5000 30 1000 0.2 1000 1 5000 2 1000 0.2
10000 30 2000 0.3 2000 1.5 10000 3 3000 0.3
15000 30 3000 0.3 4000 1.5 15000 3 5000 0.3
20000 30 5000 1.5 20000 3 7000 0.3
24000 30 6000 1.5 30000 4 8000 0.3

FCB16K0.2 FCB30K0.5
weight tol. weight tol.
(g) (g) (g) (g)
1000 0.4 5000 1
5000 0.6 10000 1.5
10000 0.6 15000 1.5
15000 0.6 20000 1.5
16000 0.6 30000 2

6. Check other functions, such as Tare, Memory, Print, Mode, and Auto-Off.

8 FCB-SH-e-0911
6 To Replace Load Cell Assembly
1. Disassemble top housing of scale.
2. Disconnect PL2 (SENSOR for FCB 8K0.1, FCB 16K0.2 and FCB 30K0.5) from
main PCB. Remove the four screws fixing the bottom plate of the
load cell assembly. Replace the load cell with a new one.
Connect PL2 (SENSOR for FCB 8K0.1, FCB 16K0.2 and FCB 30K0.5) and fix the
four screws.
3. Put 110% full capacity loading onto weight stand of scale. Adjust the overload screws
on the weight stand until they just not touch the bottom plate.
4. Assemble the top housing.
5. Perform internal calibration as described in section 2.
6. Check accuracy of scale at different weight.

FCB6K1 FCB12K1 FCB15K5 FCB24K1 FCB24K2

weight tol. weight tol. weight tol. weight tol. weight tol.
(g) (g) (g) (g) (g) (g) (g) (g) (g) (g)
1000 3 2000 3 1000 15 5000 3 5000 6
2000 3 4000 3 5000 15 10000 3 10000 6
4000 3 8000 3 10000 15 15000 3 15000 6
6000 3 12000 3 15000 15 20000 3 20000 6
24000 3 24000 6

FCB24K10 FCB3K0.1 FCB6K0.5N FCB30K1 FCB8K0.1

weight tol. weight tol. weight tol. weight tol. weight tol.
(g) (g) (g) (g) (g) (g) (g) (g) (g) (g)
5000 30 1000 0.2 1000 1 5000 2 1000 0.2
10000 30 2000 0.3 2000 1.5 10000 3 3000 0.3
15000 30 3000 0.3 4000 1.5 15000 3 5000 0.3
20000 30 5000 1.5 20000 3 7000 0.3
24000 30 6000 1.5 30000 4 8000 0.3

FCB16K0.2 FCB30K0.5
weight tol. weight tol.
(g) (g) (g) (g)
1000 0.4 5000 1
5000 0.6 10000 1.5
10000 0.6 15000 1.5
15000 0.6 20000 1.5
16000 0.6 30000 2
7. Check other functions, such as Tare, Memory, Print, Mode, and Auto-Off.

FCB-SH-e-0911 9
7 Schematics
FCB 6K1, FCB 12K1, FCB 15K5, FCB 24K1, FCB 24K2, FCB 24K10,
FCB 3K0.1, FCB 6K0.5, FCB 30K1

10 FCB-SH-e-0911
FCB-SH-e-0911 11
FCB 8K0.1, FCB 16K0.2, FCB 30K0.5

12 FCB-SH-e-0911
FCB-SH-e-0911 13
8 Components Layout
FCB 6K1, FCB 12K1, FCB 15K5, FCB 24K1, FCB 24K2, FCB 24K10,
FCB 3K0.1, FCB 6K0.5, FCB 30K1

14 FCB-SH-e-0911
FCB-SH-e-0911 15
FCB 8K0.1, FCB 16K0.2, FCB 30K0.5

16 FCB-SH-e-0911
FCB-SH-e-0911 17