SERVICE MANUAL
DIGITAL COMPUTING PRINTING SCALE
SM-500MK4
Edition 1
COPYRIGHT © 2006 TERAOKA WEIGH-SYSTEM PTE LTD
Table of Content
i) Notice 1
ii) Safety Information ..............................................................................................................................2
1. GENERAL....................................................................................................................................................3
1.1 Model Specification ............................................................................................................................3
1.2 Operating Specification......................................................................................................................4
1.3 Type of Interface ................................................................................................................................4
1.4 Main Components ..............................................................................................................................4
2. OVERVIEW ..................................................................................................................................................5
2.1 Dimension ..........................................................................................................................................5
2.1.1 Pole ......................................................................................................................................5
2.1.2 Touch Screen Pole...............................................................................................................5
2.1.3 Bench ...................................................................................................................................6
2.2 Key sheet Layout ...............................................................................................................................7
2.3 Panel Layout ....................................................................................................................................10
3. SPAN SWITCH ..........................................................................................................................................11
3.1 Span Switch Jumper Setting Changing Procedure..........................................................................11
3.2 Span Switch located in Main Board..................................................................................................11
4. INITIAL SETUP..........................................................................................................................................12
4.1 Scale Assembly ................................................................................................................................12
4.1.1 Display Pole Kit Mounting ...................................................................................................12
4.1.2 Level Adjustment ................................................................................................................12
4.2 Software Setting ...............................................................................................................................12
4.2.1 Memory Initialization ...........................................................................................................12
4.3 Calibration ........................................................................................................................................16
4.4 User Spec Setup Procedure.............................................................................................................17
4.5 Weigh & Measurement Spec Setup Procedure ..............................................................................19
5. HARDWARE TESTING & MAINTENANCE ..............................................................................................21
5.1 Hardware Testing.............................................................................................................................21
5.1.1 RAM Read and Write Test ..................................................................................................21
5.1.2 SIO Loop Back Test............................................................................................................22
5.1.3 RS485 Loop Back Test .......................................................................................................22
5.1.4 Ethernet Loop Back Test ....................................................................................................22
5.1.5 ROM Checksum Test..........................................................................................................23
5.1.6 PLU Generator Test............................................................................................................23
5.1.7 Internal Count......................................................................................................................24
5.1.8 Span Switch Status.............................................................................................................25
5.2 Adjustment........................................................................................................................................25
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5.2.1 Location of Gap Sensor And Peel Sensor. .........................................................................25
5.2.2 Label Gap Sensor ...............................................................................................................25
5.2.3 Peel Sensor.........................................................................................................................26
5.2.4 Printing Position ..................................................................................................................27
5.3 Maintenance.....................................................................................................................................28
5.3.1 Thermal Head Cleaning ......................................................................................................28
5.3.2 Basic Maintenance.............................................................................................................29
5.3.3 Thermal Head cleaning and replacement ..........................................................................30
5.4 Method of Assembly Sealing Screw & Sticker .................................................................................31
6. DISASSEMBLY..........................................................................................................................................33
6.1 Pole Type Disassembly....................................................................................................................33
6.2 AD Board Disassembly ....................................................................................................................36
6.3 Loadcell Disassembly ......................................................................................................................37
6.4 Extra Bracket Disassembly for 30Kg................................................................................................38
7. FIRMWARE UPGRADE .............................................................................................................................39
7.1 Boot loader Downloading.................................................................................................................39
7.2 Firmware Downloading ....................................................................................................................42
8. HARDWARE SETTING..............................................................................................................................46
8.1 Main Board Jumper Setting..............................................................................................................46
9. MISCELLANEOUS ....................................................................................................................................46
9.1 Error Messages ................................................................................................................................46
9.2 Corresponding Key of IBM Keyboard............................................................................................... 48
9.3 ASCII Characters..............................................................................................................................48
9.4 TERAOKA Code...............................................................................................................................49
9.5 Wire And Connector .........................................................................................................................49
9.5.1 Straight & Crossover Ethernet Cable.................................................................................49
9.5.2 Cash Drawer Option (RJ11)...............................................................................................50
9.5.3 PS2 Keyboard Option ........................................................................................................51
9.5.4 RS232C and Multi-Drop (4 Line, RS485) Wire ..................................................................51
10. APPENDIX .................................................................................................................................................55
10.1 Block Diagram..................................................................................................................................55
10.1.1 Bench Type.........................................................................................................................55
10.1.2 Touch Screen Pole Type ....................................................................................................56
10.1.3 Elevated Type .....................................................................................................................57
10.2 Specification List.............................................................................................................................58
10.2.1 User Specification [REZERO] + [1][4][1] ............................................................................58
10.2.2 Weigh & Measure Specification [REZERO] + [1][4][2] .......................................................83
10.2.3 Weigh & Measure Specification [REZERO] + [1][4][1] (For SM90TS, SM500TS and
SM500MK4TS)...................................................................................................................
11. REVISION RECORDS ...............................................................................................................................92
91
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i) Notice
DIGI®
The material contained in this document is proprietary and for information only and is subject to change without
notice. Teraoka Weigh-System assumes no responsibility for any errors or damages arising from
misinterpretation of any procedure.
Screen displays, operating procedures and supporting features might vary with different software version
releases.
This document shall not be reproduced whether in part or whole without the written consent from Teraoka
Weigh-System Pte Ltd.
Teraoka Weigh-System Pte Ltd
4, Leng Kee Road
#06-01 SIS Building
Singapore 159088
1
ii) Safety Information
The operator of the equipment shall comply with the safety and warning indications and procedures outlined in
this document. Teraoka Weigh-System Pte Ltd assumes no responsibility or liability for failure to comply with
these requirements.
• To avoid electric shock, use only the supplied power cords and ensure product is connected to a
properly grounded supply.
• For continued protection against fire hazard replace only with fuse of same rating and type.
• Ensure product is placed on a firm and level surface before operation.
• Avoid overloading the product beyond its rated maximum capacity
• Ensure commodity to be weighed is loaded centrally on the platter.
- Avoid placing commodity on corners or edges.
• Care shall be taken during the following operations
o Receipt paper tearing – to prevent injuries from cutting from paper cutter
o Changing of labels and receipt paper - to prevent injuries from cutting from paper cutter and
movable printer mechanism.
• Trained and qualified personnel shall only carry out repair and servicing of product.
Disclaimer:
Specifications are subject to change without notice. All dimensions shown are approximate. Please be aware
that Teraoka has indicated that its hardware and software used in the product may require additional updates in
the future as our product is continually under development. The need for such updates most likely applies to the
Printer software.
CAUTIONS:
1. FOR PLUGGABLE EQUIPMENT, THAT THE SOCKET-OUTLET SHALL BE INSTALLED NEAR THE
EQUIPMENT AND SHALL BE EASILY ACCESSIBLE.
2. FOR CONTINUED PROTECTION AGAINST RISK OF FIRE, REPLACE ONLY WITH SAME TYPE
AND RATING OF FUSE.
3. DANGER OF EXPLOSION IF BATTERY IS INCORRECTLY REPLACED. REPLACE ONLY WITH
THE SAME OR EQUIVALENT TYPE THAT RECOMMENDED. DISPOSE OF USED BATTERY
ACCORDINGS TO THE MANUFACTURER’S INSTRUCTIONS.
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1. GENERAL
1.1 Model Specification
Model
Variation
Capacity
Key
Number Of Preset Key
Display Resolution
Internal Resolution
Printer Type
SM-500MK4
:
Dual Pole
:
Economic Bench
:
Elevated
:
6/ 15/ 30 Kg
:
Mechanical Switch
:
32/ 56/ 100 Preset keys
:
48/ 60/ 96/ 108/ 120 Preset keys (For Self-Service machine used)
:
1/3000 (Multiple Interval)
:
1/6000 or 1/7500 (Single Range)
1 / 60000
:
Cassette Type
:
A) Paper
B) Paper Width
:
C) Resolution
D) Speed
:
Note: For Best Speed and Printing Resolution, use Ricoh paper,
150LAB
Memory
2 M Byte (Standard)
:
SM500MK4 Service Manual
SM-500MK4 DP
-
SM-500MK4 EB
-
SM-500MK4 EV
-
Label & Receipt
:
Label (Standard)
Label (Option)
:
Receipt - 72mm / 80mm
:
8 dots / mm
:
Label
Receipt
:
40mm to 72mm
-
40mm to 80 mm
-
150mm / sec
-
150mm / sec
-
3
1.2 Operating Specification
Power Source
Frequency
Operating Temperature
Humidity
Waterproof
100V to 240V AC (Auto Switching)
:
50 - 60 Hz
:
-10 °C to 40 °C
:
15 % to 85 % RH
:
N.A.
:
(Please do not splash water on top or around the scale. Clean scale
only with a damp cloth)
1.3 Type of Interface
Standard
:
:
RS 232C (FL-1, PC connection)
:
PS2 Keyboard
Cash drawer (3 Pin for TWB-01750)
:
Cash drawer (RJ11 type for TWB-01750-1 onward)
RS 485 (PC connection) Optional
:
Ethernet (Client / Server, TCP / IP protocol)
Character Generator
:
* Interface with PC can either use RS 232C, RS 485 or Ethernet.
1.4 Main Components
1 XYLINX-XC95144XL-
10TQG144C.
It’s a 3.3V CPLD targeted for high-performance, low-voltage application in leadingedge communications and computing system.
(M/B-U1)
2 Motor Driver L6258EX.
(M/B-U5)
It’s a dual full bridge for motor control application realized in BCD technology, with
the capability of driver both winding of a bipolar stepper motor or bi-directional
control two DC motor.
3 RS232 Drv AX3232.
(M/B-U18)
4 Controller H8/3024F.
(CPU BD-U1)
It’s a device consists of two line driver, two receiver, and a dual change-pump circuit
with +-15kv ESD protection pin to pin.
It’s a high-performance single-chip microcomputer that integrates peripheral
functions necessary y for system configuration with an H8/300H CPU feature a 32bits internal architecture as its core.
5 SRAM
IS62WV51216BLL.
(CPU BD-U7 & U8)
6 AM29LV320DB90EI.
(CPU BD-U9)
It’s a high-performance, very low power CMOS static Random Access Memory
organized as 524,288 words by 16 bits and operates from a wide range of 2.4V to
5.5V supply voltage.
It’s a 32 megabit, 3.0 volt-only flash memory device, and is designed to be
programmed in-system with the standard 3.0 volt Vcc supply, and can also be
programmed in standard EPROM programmers.
7 LAN9115-MT.
(CPU BD-U10)
Is a full-featured, single chip 10/100 Ethernet controller designed for Embedded
applications where performance, flexibility, ease of integration and system cost
control are required
*Components are subject to change without notice.
SM500MK4 Service Manual
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2. OVERVIEW
2.1 Dimension
Dimensions are in mm
2.1.1 Pole
SM500MK4 Service Manual
570
480
335
2.1.2 Touch Screen Pole
408
570
480
335
408
5
2.1.3 Bench
SM500MK4 Service Manual
154
462
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2.2 Key sheet Layout
SM500MK4 Service Manual
32 Preset Keys
56 Preset Keys
100 Preset Keys
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ON / OFF KEY
NUMERIC KEYS
SM500MK4 Service Manual
* Turn display ON or OFF.
To
TARE KEY
CLEAR KEY
RE-ZERO KEY
PRE-PACK KEY
* Enter numeric data.
* Set or Clear Tare Value.
* Select " NO " in S and Z Mode.
* Item Test print in S Mode.
* Clear numeric values.
* Select " YES " in S and Z Mode.
* Reset weight to zero.
* Switch Manual mode and Pre-pack mode alternatively.
(The mode status will be indicated in the P and M indicator.)
▪P - PRE-PACK MODE ▪ M - MANUAL MODE
CHANGE KEY
MULTIPLE KEY
CLERK KEYS
* Calculate the Changed Amount.
* Escape the Programming screen without saving data in S mode.
* Register the number of Non-Weight products.
* Select programming item such as PLU data, Shop Name in S
mode.
* Select Report Type in X mode.
* Select Data Transaction Type in Z mode.
* Accumulate the Total Price.
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VOID KEY
SM500MK4 Service Manual
PLU KEY
FEED KEY
PRINT KEY
MODE SELECT KEY
PRESET KEYS
to
* Correct the Sales Data
* Call up PLU data.
* Store the programmed data in S mode.
* Feed Label or Receipt
* Print out Label or Receipt
* Five Modes can be selected using this key.
Indicator R - REGISTRATION MODE (All the sales transactions are
performed.)
Indicator X - CHECK MODE (Printing out and sales report.)
Indicator S - PROGRAM MODE (Programming preset data, such as
products, data, shop name, etc.)
Indicator Z - TOTAL MODE (Clear sales data stored.)
Indicator X (Blink) - PASWORD SETTING MODE (Setting ENTRY
PASSWORD for S, X and Z modes.)
* Call up Preset data such as PLU Data or Function Data in Reg.
Mode.
* Enter Alphabetic data in Program Mode.
Note: The following Preset Keys are used in entering Alphabetic (Pole Type).
Move the
cursor.
Change the
entry to
Move the
cursor.
Change the
entry to Left.
Code type
entered.
Insert Data. Switch Cap /
Lower case.
Right.
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Change Font
size.
Delete the
Data.
2.3 Panel Layout
Bench and Pole Type (For 300 LCD)
There are fifteen different indicators on Display Panel as shown below.
1.
Î0Í
: Lights when scale is stable at the zero point
SM500MK4 Service Manual
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
NET
P
MAN
AM
CH
PE
R
X
S
Z
A
B
C
D
: Lights when tare subtraction in performed.
: Lights when PRE-PACK Mode is selected.
: Lights when MANUAL Mode is selected.
: Lights when the amount is displayed.
: Lights when the amount of change is being displayed.
: Lights when label or receipt paper ends.
: Lights when REGISTRATION Mode is selected.
: Lights when CHECK Mode is selected.
: Light when PROGRAM Mode is selected.
: Lights when TOTAL Mode is selected.
: Lights when Sales Data is in Memory for CLERK 9995.
: Lights when Sales Data is in Memory for CLERK 9996.
: Lights when Sales Data is in Memory for CLERK 9997.
: Lights when Sales Data is in Memory for CLERK 9998.
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3. SPAN SWITCH
(
3.1 Span Switch Jumper Setting Changing Procedure
1. Bottom View of Machine.
2. Loosen the 4pcs SEMS B
screw M4X6, then open the
Bottom Cover.
Insulator
4. Loosen the 2pcs SEMS B
screw M3X6, then open the
5. Change [SW2] jumper to
Enable/Disable Span Switch.
Insulator.
3.2 Span Switch located in Main Board
Mainboard
Insulator
SM500MK4 Service Manual
Interface
Board
Cable
3. Loosen the 2pcs Truss Head
screw M4X6, and disconnect
the Interface Board cable.
Span Switch
SW2)
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4. INITIAL SETUP
4.1 Scale Assembly
4.1.1 Display Pole Kit Mounting
SM500MK4 Service Manual
1. Place the display Pole inside the pole
bottom (base AB)
2. Align the four holes of the display pole
and tighten screw Flat Head M4x16
4.1.2 Level Adjustment
Place the scale on the flat surface and
adjust the four legs until the bubble on the
level is in the center as shown above.
4.2 Software Setting
4.2.1 Memory Initialization
There are two methods of memory initialization.
4.2.1.1 Default Country Specification 1
Default Customer Specification and Weight & Measure Specification setting of individual country.
(Please turn on the span switch before proceed this process.)
KEY TO PRESS OPERATION
-- Show current country SPEC then default
Customer Specification setting.
+ Switch On the Power.
-- Follow the instruction:
a) Press the [Clear] then
b) Press the [Print] process to next step
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KEY TO PRESS OPERATION
(
SM500MK4 Service Manual
[0] To [8]
[0] To [1]
-- Select scale type.
OR
-- Select scale type.
&
Then
-- To set the scale type.
KEY TO PRESS OPERATION
-- Select label length.
OR
-- Select label length.
&
Then
-- To set the label length.
Scale Type:
0: Pole 6 Kg
1: Pole 15 Kg
2: Pole 30 Kg
3: Pole 30 Lb
4. Bench 6 Kg
5: Bench 15 Kg
6: Bench 30 Kg
7: Bench 30 Lb
8: Printer
Label Length:
0: Short
ÆLabel length up to
maximum 120mm.
1: Long
ÆLabel length up to
maximum 240mm
BP 80/90)
Key to press Operation
-- Reading Country Specification.
Key to press Operation
-- After Reading Country Spec, the display will
prompt MEMORY CLEAR message.
13
Key to press Operation
If Yes,
PLEASE WAIT
Key to press Operation
If No,
4.2.1.2 Default Country Specification 1
SM500MK4 Service Manual
-- Process of initialize.
-- Then go to segment check.
-- Go to segment check.
Key to press Operation
[9] + [3] Switch On the Power.
KEY TO PRESS OPERATION
[0] To [1]
OR
&
Then
-- Show current country SPEC then default
Customer Specification setting.
-- Follow the instruction:
a) Press the [Clear] then
b) Press the [Print] process to next step
-- Select label length.
-- Select label length.
-- To set the label length.
Label Length:
0: Short
ÆLabel length up to
maximum 120mm.
1: Long
ÆLabel length up to
maximum 240mm
14
Key to press Operation
SM500MK4 Service Manual
Key to press Operation
Key to press Operation
If Yes, press
-- Reading Country Specification.
-- After Reading Country Spec, the display will
prompt MEMORY CLEAR message.
-- Process of initialize.
-- Then go to segment check.
If No, press
OR
-- Go to segment check.
15
4.3 Calibration
Key to press Operation
SM500MK4 Service Manual
In the Weighing Mode, press
then turn On the Span Switch.
KEY TO PRESS OPERATION
+ [8][7][1][5]
KEY TO PRESS OPERATION
-- Go to Z mode
-- Access code to calibration mode.
-- To calibrate zero point.
-- Ensure no weight in platter
-- Wait until the ‘ SET WEIGHT & PRT ’ shows
KEY TO PRESS OPERATION
Place the capacity weight on the scale after the
following screen appears.
-- Place the capacity weight according to the scale
on the platter. E.g. for a 6 Kg scale, put a 6 Kg
capacity weight on the platter.
KEY TO PRESS OPERATION
Press Mode key exit -- Calibration finish
16
4.4 User Spec Setup Procedure
To Change the setting of the User SPEC, if there is some SPEC need to alter.
KEY TO PRESS OPERATION
SM500MK4 Service Manual
In the Weighing Mode, press
then turn On the Span Switch.
KEY TO PRESS OPERATION
+ [1][4][1]
-- Go to Z mode.
-- Go to User Specification Mode
-- To change the selection for the Spec, press the
Number of the selection
-- Press the key to Save go to next Spec
-- Press ‘-‘ key to go back to previous Spec
-- Press ‘PLU’ to save and exit
-- Press ‘Tare’ to exit without saving
KEY TO PRESS OPERATION
[0] To [2][0]
&
KEY TO PRESS OPERATION
-- Select data. (Refers to Customer Spec setting)
OR
-- To choose scale type.
Then
-- To set. (Save data and increase SPEC No)
-- Increase the SPEC number without saving data of
the previous SPEC number.
17
KEY TO PRESS OPERATION
SM500MK4 Service Manual
[1][0]
-- Decrease the SPEC number without saving data
of the previous SPEC number.
KEY TO PRESS OPERATION
-- To jump to desire SPEC number.
KEY TO PRESS OPERATION
OR
Save SPEC setting and Exit to R mode.
Do not save SPEC setting and Exit to R mode.
18
SM500MK4 Service Manual
4.5 Weigh & Measurement Spec Setup Procedure
To Change the setting of the Weight & Measurement SPEC, if there is some SPEC need to alter.
KEY TO PRESS OPERATION
In the Weighing Mode, press
then turn On the Span Switch.
KEY TO PRESS OPERATION
+ [1][4][2]
KEY TO PRESS OPERATION
-- Go to Z mode
-- Go to Weight and Measure Specification Mode
-- To change the selection for the Spec, press the
Number of the selection.
-- Press ‘PRINT’ key to Save go to next Spec
-- Pres ‘-‘ key to go back to previous Spec
-- Press ‘PLU’ to save and exit
-- Press ‘Tare’ to exit without saving
[0] To [1]
-- Select data. (Refer to Weight & Measurement
OR
&
Then
Spec setting)
-- To choose scale type
-- To set. (Save data and increase SPEC No)
KEY TO PRESS OPERATION
-- Increase the SPEC number without saving data of
the previous SPEC number.
19
KEY TO PRESS OPERATION
SM500MK4 Service Manual
[6][1][0]
-- Decrease the SPEC number without saving data
of the previous SPEC number.
KEY TO PRESS OPERATION
-- To jump to desire SPEC number.
KEY TO PRESS OPERATION
Save SPEC setting and Exit to R mode.
OR
Do not save SPEC setting and Exit to R mode.
Remarks: Please restart the scale every time after changing the SPEC.
20
5. HARDWARE TESTING & MAINTENANCE
5.1 Hardware Testing
KEY TO PRESS OPERATION
In the Weighing Mode, press
5.1.1 RAM Read and Write Test
SM500MK4 Service Manual
-- Go to Z mode
KEY TO PRESS OPERATION
+ [0] [0] [1]
-- Go to Hardware Testing Mode and first it will show
the RAM TEST Result
KEY TO PRESS OPERATION
-- If the RAM is Ok, It will show the message below.
OR
-- If the RAM is Fail, It will show the message below.
21
5.1.2 SIO Loop Back Test
KEY TO PRESS OPERATION
SM500MK4 Service Manual
-- Testing the RS232 port.
-- Please plug in the connector on the RS232C port
before proceed. (The test result is show at below).
OR
5.1.3 RS485 Loop Back Test
KEY TO PRESS OPERATION
-- Testing the 4-Line port.
-- Please plug in the test connector on the 4-Line
port before proceed. (The test result is show at
below)
OR
5.1.4 Ethernet Loop Back Test
KEY TO PRESS OPERATION
OR
-- Testing the Ethernet port.
-- If the port okay, it will display the message below
22
5.1.5 ROM Checksum Test
KEY TO PRESS OPERATION
SM500MK4 Service Manual
-- Testing the ROM Checksum.
-- Press the [PRINT] Key to start the testing.
After that
5.1.6 PLU Generator Test
KEY TO PRESS OPERATION
+
-- Testing the PLU Generator.
-- Press the [PRINT] key to start PLU Generator.
Then it will display how many PLU generated at the right top corner.
Then
KEY TO PRESS OPERATION
-- Go to Hardware Testing Mode again
After that
KEY TO PRESS OPERATION
-- It will show the message below.
23
5
4
KEY TO PRESS OPERATION
Remarks:
TEST JIG CONNECTOR for SIO Port
Connect pin 4 and pin 5
5.1.7 Internal Count
SM500MK4 Service Manual
-- Exit to Z mode.
1
6
TEST JIG CONNECTOR for 4 LINE RS485 Port
Connect pin 1 and pin 3
Connect pin 2 and pin 4
KEY TO PRESS OPERATION
In the Weighing Mode, press .
KEY TO PRESS OPERATION
+ [0][0][9]
-- Go to Z mode.
-- Then turn on the Span Switch.
-- Internal Count Mode
-- Press ‘Tare’ key to exit
24
5.1.8 Span Switch Status
KEY TO PRESS OPERATION
In the Weighing Mode, press .
KEY TO PRESS OPERATION
SM500MK4 Service Manual
-- Go to Z mode.
-- Then turn on the Span Switch.
+ [2][8][4]
5.2 Adjustment
5.2.1 Location of Gap Sensor And Peel Sensor.
-- Indicates SPAN Switch status.
-- Back to Z mode, after 1 second.
5.2.2 Label Gap Sensor
Adjust this variable resistor for
sensor level sensitivity.
The label sensor is to detect the gap between the
labels so as to identify the starting position of the label.
If the gap is not detected properly, the scale will issue
two or more labels. Also different material of label and
back paper will have different sensitivity level; the
variable resistor beside the label sensor is to adjust the
sensitivity to suitable level.
25
SM500MK4 Service Manual
5.2.3 Peel Sensor
To set the peel sensor voltage if the peel sensor is not working normally in some situations like temperature and
humidity changed.
The peel sensor voltage can be set automatically by press the # key.
KEY TO PRESS OPERATION
-- At R mode.
KEY TO PRESS OPERATION
+ [5][1][5]
KEY TO PRESS OPERATION
OR
Enter a value for sensor voltage then press
OR
-- Go to the Peel sensor adjustment.
-- Once the key is press, it will auto set the voltage
value and Exit to R mode.
-- You can enter the value of the peel sensor voltage
then press the PLU key to save and Exit to R mode.
-- Exit to R mode without doing anything.
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