ISHIDA AC-2000 Service Manual
ISHIDA SCALES MFG.CO., LTD.
44
SANNO-CHO SHOGOIN SAKYO-KU KYOTO
606
JAPAN
REVISION
0
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Thank
You!
Copyright0
1991
by
lshida Scales
Mf
.
Co., Ltd.
All
Rights Reserved.
No part of this manual may be repro
d
uced in any form, by mimeograph or any
other means, without permission in writing from the publisher.
TABLE OF CONTENTS
H1 INTRODUCTION
1.1 External Views
1.2 Dimensions
1.3 Features
1.5 Key Switch and Reset Key
H2 MECHANICAL CONFIGURATION
2.1 Mechani'cal Components
2.2
Internal Components
H3 REPLACEMENT PROCEDURE
3.1 Outer Case Removal
3.2 Load Cell Replacement
3.3 Electrical Component Replacement
3.4 Display Panel Replacement
3.5 Cassette
'>d
H4 ELECTRICAL CONFIGURATION
Block Diagram
Connector Diagram
Power Unit
A/D Board (P704)
Main Board (P750)
Rom/Ram Board
(
P7
51
)
Battery Switch Check
Sensor Signal Relay Board (P755)
Display Unit
Peeling Sensor
Label Sensor
Cassette Sensor
B5
THERMAL
IIEAD
5.1 Outline
5.2 Specifications
5.3 Configuration
5.4 Adjustments
I16 ADJUSTMENTS
6.1 Overview
6.2 Adjustment Items
6.3 Four-Corner Limit Adjustments
6.4 Initial A/D Value Adjustment
6.5 Span Adjustment
6.6 Ad jus tlnent Sequence
6.7 Peeling Sensor Adjustment
H7 INSTALLAT'ION
7.1 Procedure For Installation
MA1N1.L'ENANCJ<
8.1 Outline
8.2 When Replacing
A
Defective Unit
8.3
Cleaning
8.4 Daily Inspection
8.5 Preventive Maintenance
8.6 Troubleshooting
PARTS
9.1 Ovcrvicw
9.2 Parts List
OUTLINE OF SOPTWRRE
1.1 Memory
1.2 PLU File
1.3 Label Formatting
1.4
Non-Keyboard Characters
LABEL
F0KMATTING:USA
TOTALS
SET
UP
MODE
TEST MODE
HI
INTRODUCTION
FIG.
1-1.4
EXTERNAL
VIEW
1
AC-2000 SERVICE REV 0
HI INTRODUCTION
LEVEL INDICATOR
DISPLAY PANEL
WEIGH PLATTE
P
AC-2000 SERVICE 0 REV 0
H1
INTRODUCTION
*
Display Stand heights vary by country
FIG,
t*2A
AC-2000
SERVICE REV
0
DIMENSION DIAGRAM
HI
INTRODUCTION
The
AC-2000
includes the following features:
Two
16
bit microprocessors
(V-40)
to process weight data
Dot matrix display
)
FIP256X64AB Flourescent Display Panel, 256x64 dot
)
Commercial message display capability
E2
Prom (EP-ROM)
)
Electronically readlwritelerase ROM
)
Essential data initial setting
)
Data is maintained even when power is cut
Lithium battery
)
Lithium battery for memory backup power. No need to recharge the battery upon installation (battery has'sufficient reserve that the battery
switch
is
set to
ON
at time of factory shipment).
CAUTION: Danger of explosion if battery
is
incorrectly replaced. Replace only with the same or equivalent type recommended by the manufacturer. Discard used batteries according to the manufacturer's
instructions.
12
NET (INC
003
used for data transmission. lshida transmission specs)
Label Cassette for easy changeover and reduced storage space
Simplified adjustment of thermal head voltage via software parameters
)
Thermal head resistance value can be entered via key panel. Voltage can
be set to desired value.
Monitoring of peeling sensor
)
Standard peeling sensor detection voltage level is displayed
)
No need to measure voltage using a meter
Selling mode can be set to user's specifications.
e
System expansion
For further information on features please refer to the Operation Manual.
AC-2000
SERVICE REV
0
HI INTRODUCTION
Item
Model
Description Remarks
Twin beam load cell
Accuracy
Capacity jingle range (USA)
Vlulti Range
Display Fluorescent tube display front and rear
Dot matrix display,for product name
I7 Kg
'ole type
nside main unit..
Total Weight
Electrical
Power
Power
Consumption
AC 1 15
V,
220
V,
240
V
50160
Hz
Stand by 50W
In operation 100W
Setup space 435 mm (W) 390 mm
(D)
height to top of platter : 170 mm
height to top of display stand
:
468 mm
Labels
2. Roll core inner dia,
40 mm
3.
Paper roll outer dia. 100 mm
4. Paper width
62 or 67 mm
Receipts
1. Role core inner dia. 12 mm
2.
Paper outer dia. 62 or 67 mm
3.
Paper width 100 mm
Label output
capacity
Fixed Price (Automatic)
80-85 per min.
Random weighing
(")
60-65 per min.
Label
replacement
method
Registration
Front loading cassette
1000 items: standard
Expandable up to 5,000 items
Varies according to
number of
charlproduct name
Time setting
Display panel
Built in clocklcalender
Flourescent dot matrix
(2)
Flourescent 7-segment (2)
256x64 dot
When using labels
Printing
method
Thermal serial dot
total dot count: 448 dot
dot dimensions 0.1 35 mm (W)
0.14 mm
(H)
Keys
Flat keys (Tact Sw)
29 function keys
36 preset keys
AC-2000
SERVICE
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HI
INTRODUCTION
Mode
positions
Input
connector
Description
Setup
/
Subtraction /Online / Offline
/
Registration / Report
12
Net
1
channel
RS-232
C
2
channel
AC-2000 SERVICE REV 0
Remarks
_i
inside: 1 channel
For ful keyboard
H1
INTRODUCTION
KEY
SWITCH RESET
KEY
Online
Used when using System.on line specifications
Offline Used when using free standing unit specifications
Registraiton Used when performing registration operations
Report Used when generating totals
Sub
Used when correcting statisical data
Setting Used during setup
Reset Key Used when there
is
a malfunction (in
test
mode)
AC-2000
SERVICE
REV
0
H2 MECHANICAL CONFIGURATION
SCALE COMPONENTS
BUBBLE LENS
AID CIRCUIT BOARD
LEVEL INDICATOR
OUTER CASIN
'
ROLL MECHANISM
\
\
MEMORY BOARD
AC-2000
SERVICE REV
0
H2 MECHANICAL CONFIGURATION
DESCRIPTION
0
Load cell (CLC-25L)
O
Thermal Head (E60-74C Mitsubishi)
Power Unit (DL-481, DL-482)
@
External Output/lnput connector
a
Printer Unit
bracket board (P-753)
@Thermal Head (Mitsubishi)
@
Fuse Holder (5A)
Cassette (for labels or receipts)
@
Power switch
@
Boards
Main Board (P-750)
*
For @ and @ see H2-1
RomIRam Board (P-751)
Scale AID board (P-704)
Label sensor (P-545)
AC-2000
SERVICE
REV
0
H3
REPLACEMENT PROCEDURE
Remove components in the following order:
PLATTER
II)
PLA'ITER SUPPORT
II)
OPERATION PANEL
II)
OUTER CASE
.
,
,
.
,
,
,,,,
\
,
,
,,
..
.
%.,
<
*",
:;'
*,
,
,
[
3.1 1
REMOVE PLAITER
(
,,
1.
Place the scale on a level
surface.
2.
Disconnect power plug
from outlet.
3.
Remove the platter
by
lifting straight up with both
hands.
113.1.2
REMOVE PLATTER SUPPORT
I
,,
+<
I
1.
Unscrew the four platter
su.pport screws with a Philips or
7mm
box screwdriv-
er.
2.
Remove the platter sup-
port by lifting up.
&j
,
lmm
BOX
SCREWDRIVER
AC-2000 SERVICE REV0
H3-1
H3
REPLACEMENT PROCEDURE
4. CAUTION:
Signal jack with cable
is
connected to the rear of
the operation panel. To
avoid damage, do not pull
the panel forward.
1.
Remove the two blanking
strips attached to the bot-
tom of the operation panel.
2.
Remove the two panel
screws with
a
philips screw-
driver.
3.
Remove the panel
by
pull-
ing it toward you in an up-
ward diagonal angle.
SIGNAL JACK AND CABLE
FROM MAIN BOARD
\
>'
<
13.1.4
REMOVE OUTER CASE
I
I
1.
After removing operation
panel remove the side cover strip.
2.
Remove the 5 outer case
screws with a phillips
screwdriver.
3.
Remove the 3 locking
screws at the lower front
of the operation panel.
SET
H3
REPLACEMENT PROCEDURE
1.
Remove the soldered ends
of the five load cell output
cables with a solder remov-
er.
2.
Remove the two load cell
bolts with
a
5
mm hexagon-
al wrench.
3.
Lift the load cell unit
straight up.
4.
To replace, reverse the
above procedure.
NOTE:
Be sure to replace the
wires in proper order.
RED
.
.
BLACK WHITE ' BLUE
1.
Remove the 2 board press
plate scres with a Phillips
screwdriver.
2.
Remove the board press
plate.
.
-
3.
Remove the board connec-
tors.
4.
Remove the 5 soldering
points from the
AID
board
(P-704)
input cables from
the load cell. (see
H3-3-A).
Another method
is
to
un-
fasten the lock pins at the
four courners of the board.
5.
To replace, reverse the
above procedure.
AC-2000
SERVICE
REV
o
H3-3
H3
REPLACEMENT PROCEDURE
n
3.3.2
POWER UNIT REMOVAL(DL-483, DL-482, DL-481)
I
',,
,,
%.
.
1.
Remove the 3 power unit
connectors from the power-
unit.
2.
Remove the 6 screws from
the power unit attachment
plate with a Phillips screw-
driver.
3.
Remove the connectors.
4.
Remove the power unit
from the main body base.
5.
Remove the power units
from the attachment
plates.
6.
To
replace, reverse the
above procedure.
POWER UNlT
/
CONECTORS
(3)
LOCKING SCREW
POWER UNlT
POWER UNlT
ATTACHMENT PLATE
POWER UNlT
-
-
DL-482
TYPE
DL-481
TYPE
AC-2000
SERVICE REV
0
H3
REPLACEMENT PROCEDURE
13.4.1
REMOVE THE FRONT COVER OF DISPLAY
I
I
1.
Remove the 2 lshida trademark plates.
2.
Remove the four screws.
3.
Remove the covers form
.both sides.
NOTE: Be careful not to
scratch the front covers dur-
ing removal.
1.
Remove the 8 locking screws from the upper display.
2.
Remove the four locking screws from the lower display.
3.
~emove the 2 screws form the
DC/DC
converter board.
4.
Remove the
DC/DC
converter board.
NOTE:
'
Be carEful with the connector connections.
FULL DOT DISPLAY PANEL
LOCKING SCREW
7-SEGMENT DIS
LOCKING SCREW
7-SEGMENT DISPLAY
&-,a
.
'.
'
DUDC CONVERTER BOARD
PLAY
AC-2000
SERVICE REV
0
H3 REPLACEMENT PROCEDURE
The printer cassette in the
AC-200
is
capable of printing labels and receipts.
By
replacing the label cassette the specifications for label or receipt format
are automatically altered.
NOTE:
Replacement andlor maintenance of cassette is done on
2
whnf~
llnit
ha&
AC-2000
SERVICE REV
0
H4
ELECTRICAL CONFIGURATION
Power Unit
(DL482)
(DL481)
FM-256-1
OOA
X
2
..............................
I
DUDC Converter X 1
7-Segment Display
UDD-348E
X
2
(DUDC)
Key Switch
1
?
f
Key Board
b
(P-752)
Stepping
Motor
ROMIRAM
Board
(P-75
1)
Main Board
(P-750)
Connector Bracket
Board (P-753)
Scale Sensor Board
Sensor
Inter-
*
(P-612) X 2
Label Sensor
Board (P-545)
Cassette Board
Scale
AID
Load Cell
-1
Board
hy
(P-704) CLC- 1 OL
AC-2000
SERVICE
REV
0
H4
ELECTRICAL
CONFIGURATION
,,,,.
%x
,
,>A,
.,,;,
,,',,
:
4.2
CONNECTOR DIAGRAM
, ,, . ,
I
,
'FiG.ti4-1'5
,A
(CONNECTORDIAGRAM
I
u,
u,
.a
.a
3
AC-2000 SERVICE REV 0
H4
ELECTRICAL CONFIGURATION
The AC-2000 uses
a
power unit which combines 2 components. This unit generates
efficient voltage conversion and stable low voltage.
s
NOTE: Current Overflow: Provides protection against short circuiting. Short circuit
time should be 10 seconds.or less.
1)
4.3.1
POWER UNIT
(DL-482)
(-
1
AC-2000
SERVICE
REV
0
H4
ELECTRICAL CONFIGURATION
14.3.2
FUNCTIONS
(
,
,
,\%
,
I.
Inputs
AC
power.
2.
Supplies power to the other Power unit (DL-481).
3.
Supplies Scale AID board (P-704) regulator power [(VSI) + 8V; (VS2)-15Vl.
4.
Supplies
+
12V
power to the full dot display
(V12).
5.
Supplies + 5V data signal transmission power.
6.
Supplies + 5Vdigital circuit (Vcc) power.
yv\a\a
7.
Input and output for reset signal
(NMI,
RES).
(~e[/-
side)
1
OOV,
1
1
5v
220V,
240V
CH5
POWER
SW
ITCH
RJSE(5A)
HOLDER
FILTER
-
L2
COIL
OR
RECTIFIER
I
RSWO
1
i
H
4-4
AC-2000
05ERVICE
REV
0
H4
ELECTRICAL CONFIGURATION
FIG.
H4-3-D
EXTERNAL
VIEW
1.
Receives power from the other power unit (DL-482).
2.
Supplies + 24 power to the thermal head and stepping motor
(VH).
3.
Stepping motor drive circuit.
Converts and outputs the signal from the main board into a stepping motor
drive signal.
AC-2000
SERVICE REV0
H4
ELECTRICAL CONFIGURATION
(i.ljhi.
de3
TI
TRANSFORMER
DL--
481
MOTOR
DRIVE
CIRCUIT
FIG.
H4-3-E
VH
GND
i
..............
CN5
BLOCK
DIAGRAM
t5V
IH
i
t5V
GND
i
ON/OFF
i
..............
STEPPING
MOTOR
AC-2000
SERVICE REV 0
H4
ELECTRICAL CONFIGURATION
14.3.3
POWER UNIT PERIPHERY
I
,
1. Power unit reset and control panel reset switch:
If the
AC
ower goes below
83-87%,
the internal reset circuit is activat-
ed and holds all scale and printer operations are terminated.
In the same way, the control panel reset switch resets the internal circuits. Therefore, this reset switch is used to recover after a malfunction.
2. Fuses
Glass fuse (5A: 100N/115V, 3A:220V/240V). Note: there are no fuse.s in-
side the power unit.
3.
Label advance motor
The AC-2000 uses a stepping motor to advance the labels. rotation and
stability can be precisely controlled.
Also since rotation speed
is
syn-
chronized with the print signal to the thermal head, the print quality
is
stabilized.
Stepping motor drive circuit configuration
Specifications
1. Stepping motor drive Hybrid
IC
San ken 51 -73OOOA
2.
Stepping motor
PH266-01
1.8" step
AC-2000 SERVICE REV
0
.
MAIN BOARD (P-750)
MOTOR CONTROL
--
4
.
GATE ARRAY
M60025
-
_
STEPBLDLG
MOTOR
-,
L
POWER UNIT
DL-48
1
STEPPING MOTOR DRIVE IC
J12
-,
*
-
CN4
CN3
A
-
-
H4
ELECTRICAL CONFIGURATION
\,
i
',
11
4.3.4
POWER
UNIT TYPES
I
,
,
, ,
I
Depending on the power source, the power unit model varies asfollows:
1
OOV,
11
5V power Type DL-481 L, DL-482L
22OV, 240V power
Type DL-481
H,
DL-482H
NOTE:
A
seal indicating model type
is
attached tothe power units.
-
DIA
CONVERTER
r
N;
oswAToR
CPU
(uPD75104
AMP
1
AID
CONVERTER
(ILD-1002)
L
LOAD
CELL
SIGNAL
CABLE
1
PUSH
BUTTON
SW
AC-2000
SERVICE
REV
0
H4
ELECTRICAL CONFIGURATION
% %
. .
,
\
...
%.
%.
I
FUNCTIONS
[
"
A\'
I
1. Supply load cell excitation voltage (-12V)
2. Amplifyload cell output signal (Amp type
....
LC-8000)
3.
Remove minute vibrations via filter circuit
4. AID conversion
AID converter ILDl001 (Ishida custom-made IC)
CPU
uPD75104 (4-bit microcomputer, 2K ROM
internal memory)
5.
CPU circuit
Process AID converter data and transfer data to main board (P-750)
Automatic monitoring and control of AID converter initial and span value.
Zero adjustment circuit control.
DIA conversion circuit control
NV-RAM data control
6.
Data write to NV-RAM
7. Reset circuit
Supply to CPU (uPD75104), AID converter (ILDlOOl), NV-RAM (5 245R25R)
8.
Oscillator circuit: 4.1975 MHz
Supply to CPU (uPD75401)
9. Generate
+
5V,
-1
2V
AC-2000
SERVICE REV
0
H4
ELECTRICAL CONFIGURATION
16-bit microprocessors (V40)
(2),
control all data processing for AC-2000.
Multi-layered type, higly condensed component mounting, with lowered
electrical impedance to improve endurance against electrical noise and
static electricity.
ON
OFF
14
IC1
}
uPD71051G
IC4
J
2
J
1
TO
SCALE
AID
NOT
IN
USE
BOARD
P-704
H'4-10
AC-2000
SERVICE
REV
0
H4
ELECTRICAL CONFIGURATION
14.5.2 FUNCTIONS
I
'
,
,
>"
I
Power input (VSI ,VS23, VH, Vcc)
Power reset (RESET, RSWO, RSW 1)
Weigh.data signal inputloutput control
All sensors (Label, scale, cassette) detection signal (AID conversion type) control
Display signal output (Dot matrix and multi-row displays)
Stepping motor control signal output
RS-232C inputloutput signal control (2 lines)
One of the 2 lines is also used for IFIRQ and fullkeyboard
12
Net inputloutput signal control (1 line)
Thermal head print data control
Cash drawer inputloutput signal control
Input/output signal control to ROMIRAM board.
Clock IC (Internal calendar) control
,
%%
,%
J*
,
.I
4.5.3
Main
IC (CPU)
I
,,
,2-,
.
,
.:
",
,
.
M6OO24
....
uPD71051G
Serial I10 port
uPD7001
1C
.....
uPD471 2GT
....
MB3745O
...
CPU (V40) UPD70208
....
16 bit microprocessors
(2)
For Thermal head, stepping motor gate array,
New type elements
Image scanner gate array. New type element
Serial control IC
Sensor signal AID converter (scale, label sensor)
RS232CsignaI transmeission, reception driver
INC 2003 (Ishida Custom IC)
for
12
NET (For INC3003 or later version)
32K RAM for INC2003 signal data memory
AC-2000 SERVICE REV 0
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