DC-788 Service Manual
DC-788 Service Manual
Model: DC-788
Edition Date Remark
1st 2004.12
Shanghai Teraoka Electronic Co., Ltd
Jin Shan Ting Lin Industrial Estate, Shanghai, China Postcode:201505
TEL:+86-21-5723-4888 FAX:+86-21-5723-9330 E-mail: steservice@digi-scale.com
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Contents
1. General Layout..........................................................................................................3
2. Purpose......................................................................................................................4
3. Features......................................................................................................................4
4. Operating Conditions.................................................................................................4
5. Charging Conditions (for Rechargeable battery only)..............................................4
7. Display and Indicators...............................................................................................5
7.1. Display Specifications............................................................................................................5
7.2. Indicators................................................................................................................................5
8. Dimensions................................................................................................................5
9. External Connectors..................................................................................................6
10. Main Components...................................................................................................6
11. Existing parts to be used..........................................................................................6
12. Capacity/Minimum Graduation/Tare range............................................................6
12. Keysheet Layout......................................................................................................7
13. Key Functions..........................................................................................................7
14. Notable differences from current Teraoka scales:...................................................8
15. Block Diagram of Electrical Connection................................................................9
16. Physical layout of Electrical Connection..............................................................10
17. Hardware Description............................................................................................11
17.1. Microcomputer...................................................................................................................11
17.2. Pin Assignment...................................................................................................11
18. Maintenance Mode................................................................................................13
18.1. SPAN Adjustment..............................................................................................................13
18.2. Escape from Maintenance mode........................................................................................13
18.3. Specification Setting...........................................................................................................14
18.4. Internal Count & A/D Count Display.................................................................................14
18.5. Operational Specification List............................................................................................15
19. Operations In Weighing Mode..............................................................................19
19.1. ON/OFF..............................................................................................................................19
19.2. Tare Subtraction.................................................................................................................19
19.3. Unit Weight Entry Operation.............................................................................................19
19.4. Insufficient Sampling Weight Operation...........................................................................20
19.5. Parts Counting Operation...................................................................................................21
19.6. Net/Gross Operation...........................................................................................................22
19.7. kg/lb Operation...................................................................................................................22
19.8. Select 1st Scale or 2nd Scale Operation................................................................................22
20. Operations In Program Mode................................................................................24
20.1. Program Item Code............................................................................................................24
20.2. Delete Item Code in Memory.............................................................................................25
20.3. Review Item Code..............................................................................................................27
20.4. Program Setpoint to Operate all Items...............................................................................27
20.5. Date and Time....................................................................................................................27
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1. General Layout
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2. Purpose
To develop a low cost LCD display counting scale which caters to OIML, UL, EU Standard and meets requirement
of major customers.
3. Features
* Low cost counting scale.
* Quick response to weight changes.
* Capacity : 500g; 1kg; 2.5kg; 5kg; 10kg; 25kg; 50kg
* Resolution : Display Resolution 1/10,000.
Internal Resolution 1/1000,000.
* Rechargeable Battery backup for 24 hours of continuous usage (optional).
* Intelligent power control
A. When AC power is available, scale will use AC power only whatever rechargeable battery is installed or not.
When AC power is shut off, scale will use battery automatically.
B. When scale works on rechargeable battery, if the battery is weak, the battery indictor will light up.
When the power from battery becomes low such that the scale cannot compute accurately, all Displays will
shut off except the Battery indicator. The power is then shut off completely after 1 minute.
C. Scale detects rechargeable battery voltage and control battery charge process automatically.
The battery charge indicator lights up when rechargeable battery is being charged.
* Calibration by software.
* Waterproof keyboard and splash proof housing.
* 24 switch keys
- ON/OFF key.
- 10 Numeric keys.
- 13 Operational keys.
* Large platter : 340 x 243 mm.
* Plastic housing.
* 25 digits with 19 segments Back-light LCD Operator displays.
* RS-232C interface for data communication and printer connection.
- Gross Weight, Tare Weight, Net Weight, Unit Weight, Count, PLU code, Product Description, Product Lot
No.,
Accumulated count.
* Two scale channels, one for built-in platform, and another for remote platform.
* External printer connectible (RS-232C)
- Label printer : DIGI GP-460R
- Bar code printer : ZEBRA LP-2844
- Receipt printer :EPSON TM-U200
- Slip Printer :EPSON TM-U295
* 100 PLU, each PLU consists of Unit Weight, Tare Weight, Product Description (32 characters), Product Lot No.
(32 characters), Set point(Hi/OK/Low).
4. Operating Conditions
* Power Source : AC 240/230/220V, 117/100V.
: DC 6V 5Ah rechargeable battery (optional).
* Operating Temperature : -10℃ ~ +40℃ (OIML).
* Operating Humidity : 15 ~ 85% RH.
* Power Consumption : 18W when using AC power.
: 1W when using rechargeable battery.
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6. Analog Specification
* Input sensitivity : 1mV/V.
* Zero adjust range : 0 ± 5mV.
* Zero balance range : 0 ± 0.5mV.
* L/C applied voltage : DC 5V.
* Speed of A/D conversion : 30 times/sec.
* Internal Resolution : 1000,000.
7.2. Indicators
* ZERO : On when zero point is adjusted and weight is stable.
* NET : On when tare subtraction is performed.
* kg : On when the item is weighed in kg unit with [kg/lb] key pressed.(type B version only)
* lb : On when the item is weighed in lb unit with [kg/lb] key pressed. (type B version only)
* INSUFF : On when the net weight is below a specific percentage of capacity weight.
* GROSS : On when [Gross/Net] key is pressed. (type A version only)
*SCALE1 : On when the scale 1 is in use.
*SCALE2 : On when the scale 2 is in use.
* RECOMP : On when unit weight recomput is enable.
* PROG : On when in the programming mode.
* WT/1000 : On when the display unit weight is 1000PCS base. (type B version only)
* APW : On when the display unit weight is one PCS base. (type B version only)
*Σ : On when quantity is accumulating.
*OUT : On when remove a quantity of parts to item inventory.
*IN : On when add a quantity of parts to item inventory.
* BATT : On when Battery is weak and needs to charge (only for rechargeable battery type).
* CHARGE : On when Battery is charging (only for rechargeable battery type)..
8. Dimensions
* Platter size : 340 x 243 mm.
* Overall size: 354 x 349 x 115 mm.
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9. External Connectors
* AC receptacle.
* RS-232C interface.
* 14 pin female amphenol for external loadcell
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12. Keysheet Layout
Type A
Type B
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TYPE A
: PLU CODE key. Used to call out PLU data. Change In/OUT status.
: Data Setting key. Set up SPEC data or clear TOTAL data. Print.
: MODE SET key. Used to enter programming mode from weighing mode.
: NET/GROSS change key. Used to change display between Gross and Net.
: UNIT WEIGHT key. Used to set unit weight and display All digits of Unit Weight.
TYPE B
: PLU CODE key. Used to call out PLU data. Change In/OUT status.
: Data Setting key. Set up SPEC data or clear TOTAL data. Print.
: MODE SET key. Used to enter programming mode from weighing mode.
: kg/lb conversion key. Used to convert the weighing unit between kg and lb.
: UNIT WEIGHT key. Used to set unit weight and display All digits of Unit Weight.
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15. Block Diagram of Electrical Connection
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16. Physical layout of Electrical Connection
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17. Hardware Description
17.1. Microcomputer
The H8/3687 Series Microcomputer was chosen for the following reasons:
* Cheaper.
* High-speed CPU with sixteen 16-bit registers.
* 33 interrupt sources and efficient interrupt processing.
* Four versatile timers.
* Two on-chip serial communication interface channels.
* 8-channel 10-bit resolution A/D converter.
*I2C bus interface.
* Less chip count.
* Pin compatibility of similar package with difference ROM sizes.
* Instruction set is compatible with the H8/300 CPU.
* Good support.
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Pin I/O Assignment Device Remark
P85 I/O JUMPER&E7 JUMPER&E7 MODE SELECT
P86 I/O E7 E7 MODE SELECT
P87 I/O E7 E7 MODE SELECT
PB0/AN0 I -
PB1/AN1 I K1 Keyboard Key Return Line
PB2/AN2 I K2 Keyboard Key Return Line
PB3/AN3 I K3 Keyboard Key Return Line
PB4/AN4 I K4 Keyboard Key Return Line
PB5/AN5 I -
PB6/AN6 I BTV Battery Detects Battery Voltage
PB7/AN7 I -
NMI I - JUMPER MODE SELECT
OSC1 I - Oscillator 10 MHz Crystal
OSC2 O - Oscillator 10 MHz Crystal
X1 I - Oscillator 32.768 kHz Crystal
X2 O - Oscillator 32.768 kHz Crystal
AVCC - - - Analog power supply
VCL - - - Connected to VSS PIN
VCC - - - Power supply
VSS - - - Ground
TEST I - - Connected to VSS PIN
RES I - Reset device System Reset
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18. Maintenance Mode
18.1. SPAN Adjustment
1 - ZERO 2 - NET 3 - INSUFF 4 – SCALE1 5 – SCALE2 6 - MEMORY
OPERATION Key-in TARE WEIGHT U.Weight QTY. 1 2 3 4 5 6
0.0 0 0 0.0 0 0 0 0
SPAN Switch ON DC788 V x. x x S-On
[RE-ZERO] [RE-ZERO] 88888 88888 88888 8888888
[RE-ZERO] + [8] [7] [1] [5] [RE-ZERO] + CAL00 SCALE 1
Enter 8 7 1 5 while pressing. [RE-ZERO] [8] [7] [1] [5]
Select 1 Scale or 2 Scale by pressing [Scale Key]
st nd
CAL00 SCALE 2
[Scale Key]
Ensure no weight on platter, [*] [*] ----- ----- ----- -----
Calibrating zero point.
:
: CALSP 5 . 0 0 0 kg
Put weight on platter (e.g. 5kg) [5] [.] [0] [0] CALSP 5 . 0 0 kg
Enter the value of weight placed on the
platter using the numeric keys.* Note1
[*] [*] ----- ----- ----- -----
Calibrating full scale point
:
:
After calibration 0.0 0 0 5.0 0 0 0 0
Note1: Change Weight Unit kg or lb by pressing [kg/lb Key]. (Type B available only)
Note2: If didn’t enter weight using the numeric keys before press [*], the default calibration weight is FS.
(Corresponding to the SPEC settings Minimum display, Selection of resolution, Weight Decimal Point Position)
Note3: If use key enter weight to calibration, the reference weight must exceed 10% FS.
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18.3. Specification Setting
18.3.1. Specification Enter (141)
1 - ZERO 2 - NET 3 - INSUFF 4 – SCALE1 5 - RECOMP 6 - MEMORY
OPERATION Key-in TARE WEIGHT U.Weight QTY. 1 2 3 4 5 6
[RE-ZERO] [RE-ZERO] 88888 88888 88888 888888
[RE-ZERO] + [1] [4] [1] [RE-ZERO] + SPC00 0000 0000
Enter 1 4 1 while pressing. [RE-ZERO] [1] [4] [1]
'+' key only increase Specification. [+] SPC01 0000 0000
'-' key only decrease Specification. [-] SPC00 0000 0000
Only '1' & '0' are enable. [0] [1] [0] [0] SPC00 0000 0100
Cancel input [C] SPC00 0000 0000
[0] [1] [0] [1] SPC00 0000 0101
'*' to store Specification. [*] SPC01 0000 0000
[-] [-] SPC00 0101 0000
[+] [+] SPC01 0000 0000
Store SPECS to EEPROM & [T] 0.0 0 0 0.0 0 0 0 0
Escape to Weighing mode.
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18.5. Operational Specification List
0 - On 0 - On 0 - On 0 : Not used
1 – Off 1 – Off 1 – Off
(SP1_BUZZ) (SP1_ALARM) (SP1_PALARM)
3 Unit weight base per Sampling time for unit Negative counting Re-zero function
1000PCS or 1PCS Weight calculation
display
0 - 1000PCS 0 - 10 times 0 - Allow 0 - Allow
1 –1PCS 1 - 5 times 1 – Inhibit 1 – Inhibit
(SP1_UW1D) (SP1_STFUWC) (SP1_NCOUNT) (SP_RZF)
4 Order of month, date and year Set point type
00 - MM/DD/YY 00 - % quantity
01 - DD/MM/YY 01 - % Weight
10 - YY/MM/DD 10 - Quantity
11 - Not used 11 – Weight
(SP1_DATEO) (SP1_SPT)
5 Function of RS-232C interface Extent of insufficient samples
00 - PC 0 0 - 0.1 %
01 - Printer 0 1 - 0.2 %
10 - Not used 1 0 - 0.0 %
11 - Not used 1 1 : Not used
(SP1_RS232IF) (SP1_INSUFFRG)
6 RTS/CTS handshaking Baud rate of RS-232C
of RS-232C
000 - 1200 bps 100 - 19200 bps
0 - On 001 - 2400 bps 101 - Not used
1 – Off 010 - 4800 bps 110 - Not used
011 - 9600 bps 111 - Not used
(SP1_RTS) (SP1_BAUD)
7 Stop bit of RS-232C Data length of RS- Parity of RS-232C
232C
00 - None
0 - 1 bit 0 - 7 bit 01 - Odd
1 - 2 bit 1 - 8 bit 10 - Even
11 - Not used
(SP1_STOP) (SP1_DLEN) (SP1_PAR)
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SPEC NO. BIT 3 BIT 2 BIT 1 BIT 0
8 RS-232C PC protocol
0 - No 0 - No 0 - No 0 - No
1 – Yes 1 – Yes 1 – Yes 1 – Yes
(SP1_TW) (SP1_UW) (SP1_GW) (SP1_TP)
12 DATE&TIME in text Header Code in text of Weight range of data
of RS-232C RS-232C output
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For Weight & Measure - (1 4 2)
NOTE: It can only work when the SPAN Switch is on (Enable)
00 - 1 00 - 1
01 - 2 01 - 2
10 - 5 10 - 5
11 – 10 11 – 10
(SPMINID) (SPMINID1)
22 Selection of resolution (Scale 1)
000 - 1/2500
001 - 1/5000
010 - 1/10000
011 - 1/15000
100 - 1/20000
101 - 1/25000
110 - 1/30000
(SPRES)
23 Weight Decimal point position (Scale 1)
000 - 1/2500
001 - 1/5000
010 - 1/10000
011 - 1/15000
100 - 1/20000
101 - 1/25000
110 - 1/30000
(SPRES1)
25 Weight Decimal point position of 2nd Scale (Scale 2)
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SPEC NO. BIT 3 BIT 2 BIT 1 BIT 0
27 Weight unit base Type of Decimal point Negative weight Gross Mode
display mask
0 - kg 0 - kg
1-g 1-g
(SP_GBASE1) (SP_GBASE2)
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19. Operations In Weighing Mode
19.1. ON/OFF
1 - ZERO 2 - NET 3 - INSUFF 4 – SCALE1 5 - RECOMP 6 - MEMORY
OPERATION Key-in TARE WEIGHT U.Weight QTY. 1 2 3 4 5 6
Display for 1.5 seconds. *Note1 [ON/OFF] 8888888888 88888 888888
Blank for 1.5 seconds.
Display for 1.5 seconds. 88888 88888 88888 888888
Blank for 1.5 seconds.
Weighing mode. 0.0 0 0 0.0 0 0 0 0
OFF [ON/OFF]
Note: 1) Power On Segment Check Style can be selected by setting SPEC08.0. In this example assume SPEC08.0 = 0.
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19.3.2. Digital Unit Weight Operation
1 - ZERO 2 - NET 3 - INSUFF 4 – SCALE1 5 - RECOMP 6 – MEMORY
OPERATION Key-in TARE WEIGHT U.Weight QTY. 1 2 3 4 5 6
Put weight on platter 0.0 0 0 0.5 2 8 0 0
Key in unit weight. [5] [.] [2] [5] 5.2 5 7 8
[7] [8]
Set unit weight. [UNIT 0.0 0 0 0.5 2 8 5.2 5 7 8 100
WEIGHT]
Clear unit weight. [C] 0.0 0 0 0.5 2 8 0 0
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19.5. Parts Counting Operation
19.5.1. Single Counting Operation
1 - ZERO 2 - NET 3 - INSUFF 4 – SCALE1 5 - RECOMP 6 – MEMORY
OPERATION Key-in TARE WEIGHT U.Weight QTY. 1 2 3 4 5 6
Enter Unit weight by any means of 19.3 0.0 0 0 0.0 0 0 0.5 0 0 2 0
Unit Weight Entry Operation
Put bulk quantity on platter 0.0 0 0 0.4 0 0 0.5 0 0 2 800
[*] 0.0 0 0 0.4 0 0 0.5 0 0 2 800
Note: 1) If DC-788 is connected to printer/PC, the data is printed/output by pressing [*] key.
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Method B
Must know the tare weight of container to use this method,
1 - ZERO 2 - NET 3 - INSUFF 4 – SCALE1 5 - RECOMP 6 – MEMORY
OPERATION Key-in TARE WEIGHT U.Weight QTY. 1 2 3 4 5 6
Put container with parts on platter 0.0 0 0 1.2 5 5 0 0
Subtract the tare weight. [T] 1.2 5 5 0.0 0 0 0.0 0 0 0
Take 10 pcs of parts from container 1.2 5 5 - 0.0 2 5 0 0
Compute unit weight. [Pcs] ----- ----- ----- ------
:
1.2 5 5 - 0.0 2 5 2.4 7 8 10
Key in actual tare weight of container. [1] [.] [0] [0] 1.0
Subtract the tare weight. [TARE]
1.0 0 0 0.2 5 5 2.4 7 8 103
[*] 1.0 0 0 0.2 5 5 2.4 7 8 103
Note: 1) If DC-788 is connected to printer/PC, the data is printed/output by pressing [*] key.
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19.9. Item Code Call Up
19.9.1. Recall Numeric Item Code
1 - ZERO 2 - NET 3 - GROSS 4 - INSUFF 5 - IN 6 – OUT
OPERATION Key-in TARE WEIGHT U.Weight QTY. 1 2 3 4 5 6
Weighing mode. 0.0 0 0 0.0 0 0 0 0
Enter item code. [1] [0] [0] 100
Call up item code. [CODE] 0.0 0 0 0.0 0 0 1.6 9 8 0 0
Select “In-Out” status. [IN/OUT] 0.0 0 0 0.0 0 0 1.6 9 8 0 0
Put bulk parts on platter. 0.0 0 0 0.1 4 5 1.6 9 8 0 84
[*] 0.0 0 0 0.1 4 5 1.6 9 8 0 84
Note: 1) If DC-788 is connected to printer/PC, the data is printed/output by pressing [*] key.
And inventory value will update according to the IN/OUT status and Accumulation when quantity is
accumulating.
Subtract from inventory when OUT status. Accumulate inventory when IN status.
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Memory Field of Item Code
*Note1: To enter alphanumeric character to item code, press [] key to change the screen to the display of alphanumeric
entry.
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20.2. Delete Item Code in Memory
20.2.1. Delete a Certain Item Code
1 - ZERO 2 - NET 3 - GROSS 4 - INSUFF 5 - RECOMP 6 – PROG
OPERATION Key-in TARE WEIGHT U.Weight QTY. 1 2 3 4 5 6
Weighing mode. 0.0 0 0 0.0 0 0 0 0
Enter into Program mode. [MODE] ProG C 20
To program Item Code. [1] [0] [0] 100
100 CLEAr
Delete item code. [C] ProG C 19
Quit to Weighing mode. [MODE] 0.0 0 0 0.0 0 0 0 0
Note: *1) Press [MODE] key to go back to weighing mode without clearing.
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20.2.5. Delete all Tare Weight Value from Memory
1 - ZERO 2 - NET 3 - GROSS 4 - INSUFF 5 - RECOMP 6 – PROG
OPERATION Key-in TARE WEIGHT U.Weight QTY. 1 2 3 4 5 6
Weighing mode. 0.0 0 0 0.0 0 0 0 0
Enter into Program mode. [MODE] ProG C 20
[RE-ZERO] [RE-ZERO] 88888 88888 88888 8888888
[RE-ZERO] + [.] [.] [3] [RE-ZERO] + TAREW CLEAr
Enter . . 3 while pressing. [RE-ZERO] [.] [.] [3]
Delete all Tare Weight value. [C] ProG C 20
Quit to Weighing mode. [MODE] 0.0 0 0 0.0 0 0 0 0
Note: *1) Press [MODE] key to go back to weighing mode without clearing.
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20.2.9. Reset Sequence Number to 0
1 - ZERO 2 - NET 3 - GROSS 4 - INSUFF 5 - RECOMP 6 – PROG
OPERATION Key-in TARE WEIGHT U.Weight QTY. 1 2 3 4 5 6
Weighing mode. 0.0 0 0 0.0 0 0 0 0
Enter into Program mode. [MODE] ProG C 20
[RE-ZERO] [RE-ZERO] 88888 88888 88888 8888888
[RE-ZERO] + [.] [.] [7] [RE-ZERO] + SN CLEAr
Enter . . 7 while pressing. [RE-ZERO] [.] [.] [7]
Reset Sequence Number [C] ProG C 20
Quit to Weighing mode. [MODE] 0.0 0 0 0.0 0 0 0 0
Note: *1) Press [MODE] key to go back to weighing mode without clearing.
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21. Error Massage List
The following error message will appear when an incorrect operation is performed.
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