Rice Lake Digi DC-788 Operation Manual

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DC-788

Counting Scale

Operation Manual

Version 1.09

91685

Contents

1.0 Introduction.................................................................................................................................. 1

1.1 Capacities and Resolutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.2 Modes of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1.2.1 Description of Modes of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1.3 Keyboard and Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1.3.1 Display Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1.3.2 Indicator Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1.3.3 Key Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.0 Installation ................................................................................................................................... 6

2.1 Unpacking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2.2 Repacking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2.3 Setting Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2.4 Powering Up the DC-788 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2.4.1 AC Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2.4.2 DC Battery Pack Replacement/Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2.4.3 Battery Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2.4.4 Start-Up Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2.5 Setting the Date . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

2.6 Replacement Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

2.7 Block Diagram of Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2.8 Physical Layout of Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3.0 Configuration Settings ............................................................................................................... 12

3.1 Configuring Specification 141 and 142 Settings from the Scale Keyboard . . . . . . . . . . . . . . . . 12

3.1.1 Customer Specification (141 Settings). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

3.1.2 Weight and Measurement Specifications (142 Settings). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

4.0 Calibration ................................................................................................................................. 19

5.0 Scale Operations........................................................................................................................ 21

5.1 Counting Scale Accuracy and the TEP (Teraoka Error Prediction) Mode . . . . . . . . . . . . . . . . . . 21

5.2 Weight Unit Switching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

5.3 Toggling Between Scales . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

5.4 Setting Tare Weights in Weighing Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

5.4.1 One Touch Tare (When the Tare Weight is Unknown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

5.4.2 Digital Tare (When Tare Weight is Known in Advance) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

5.4.3 Tare Addition or Subtraction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

5.4.4 Tare Override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

5.5 Entering Unit Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

5.5.1 Unit Weight Operation by Sampling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

5.5.2 Unit Weight Operation by Key Entry. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

5.6 Setting a Lot Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

5.7 Setting a Sequence Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

5.8 Operations Without Recalling an Item Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

5.8.1 A Single Counting Operation - Without Recalling an Item Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

5.8.2 Part Accumulation or Subtraction and Negative Counting - Without Recalling an Item Code . . . . . . . . 25

5.8.3 Setting a Temporary Lot Number, Part Number or Part Name - Without Recalling an Item Code. . . . . 27

5.9 Using Item Codes in Weighing Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

5.9.1 Recalling Item Codes using Item Code Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

5.9.2 View Item Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

5.9.3 Adding Parts To and Subtracting Parts From Inventory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

5.9.4 Tare Override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

5.9.5 Delete Item Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

6.0 Scale Programming................................................................................................................... 31

6.1 Checking Memory Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

6.2 Review the Item Code Numbers Programmed in Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

6.3 Program Item Code, Tare Weight, Unit Weight, Inventory, Part Number, Part Name, Lot Number, Setpoint 1 and Setpoint 2 32

6.4 View Item Code Programming in Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

6.5 Program a General Setpoint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

6.6 Resetting the Sequence Number to Zero. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

6.7 Programming a Temporary Lot Number, Part Number or Part Name . . . . . . . . . . . . . . . . . . . . 35

6.7.1 Change the Lot Number Temporarily . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

6.7.2 Change the Part Number Temporarily. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

6.7.3 Change the Part Name Temporarily . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

6.8 Delete Item Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

6.8.1 Delete All Item Codes in Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

6.8.2 Delete a Specific Item Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

6.8.3 Delete All Inventory Values from Memory. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

6.8.4 Delete All Unit Weight Values from Memory. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

6.8.5 Delete All Tare Weight Values From Memory. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

6.8.6 Delete all Part Numbers From Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

6.8.7 Delete All Setpoint Data in Memory. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

6.8.8 Delete All Part Names in Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

7.0 External Devices: Printers, PCs and Scales.............................................................................. 41

7.1 Printer Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

7.1.1 Zebra LP2844. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

7.1.2 DIGI GP460R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

7.1.3 Epson TM-U210 and TM-U290, Star SP2320 and SP298 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

7.2 Printer Label Formats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

7.2.1 No Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

7.2.2 DIGI GP460R Label Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

7.2.3 ZEBRA LP2844 Barcode Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

7.2.4 Epson TMU200 or Star SP2320 Tape Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

7.2.5 Epson TM-U295 or Star SP298 Ticket Printers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

7.2.6 DIGI TVP1000 Barcode Printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

7.3 Connecting to a PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

7.3.1 Setting the Scale Specifications for Communication to a PC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

7.3.2 Communication Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

7.3.3 Pin Assignments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

7.3.4 Characters That Can Be Transmitted by RS-232C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

7.3.5 RS-232C Data Transmission Formats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

7.4 Remote Scale Channel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

7.4.1 Setting the Specifications for Scale 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

7.4.2 Remote Platforms Available . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

8.0 Appendix .................................................................................................................................... 54

8.1 DC-788 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

8.2 DC-788 Error Message List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

8.3 ASCII Code Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

9.0 DC-788 Limited Warranty........................................................................................................... 57

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$PVSTFEFTDSJQUJPOTBOEEBUFTDBOCFWJFXFEBUXXXSJDFMBLFDPNPSPCUBJOFE

CZDBMMJOHBOEBTLJOHGPSUIFUSBJOJOHEFQBSUNFOU

Specifications subject to change without notice.

Version 1.09, July 2007

About This Manual

This manual contains operating procedures for the DC-788 counting scale and provides the user with all the information necessary for setup and operation. It is organized based on the procedures you will likely follow when setting up and using your counting scale. This manual applies to Version 1.09 of the DC-788 counting scale series.

Some procedures described in this manual require work inside the scale base. These procedures are to

#AUTION

be performed by qualified service personnel only.

Authorized distributors and their employees can view or download this manual from the DIGI distributor site at www.DigiScales.com.

1.0 Introduction

The DC-788 is a low cost counting scale that offers practical solutions for a full range of counting applications. Its counting resolution of 1/1,000,000 gives you maximum counting precision and accu racy. Its high-visibility red LCD display enables operators to easily see weights and quantities. With the ability to store an item code, part number, part name, lot number, tare weigh t, unit weight, inventory quantity and setpoint value for 100 of your pieces, parts, or items, the DC-788 is a self-contained inventory system. The RS-232 output allows you to connect to a printer or PC, while the remote scale channel lets you add another weighing platform. When portability is required, choose the battery operation option of the DC-788 for over 24 hours of continuous use in mobile workstations, outdoor applications, and rental fleets. It’s waterproof keyboard and splash-proof housing make the DC-788 rugged enough to operate reliably in many environments and withstand transport from one area of the plant to another or from one business to the next.

1.1 Capacities and Resolutions

Table 1-1 lists the scale capacities, minimum graduations, and tare ranges for all models of the DC-788 counting scales. The display resolution is 1/10,000 with an internal or counting resolution of 1/1,000,000. Units are selectable from lb to kg from the keyboard.

DC-788 Single Scale

DC-788 Capacity Minimum Graduation Ta r e R an g e

500 g 0.1 g (1e = 200IR) 0-249.9 g

1 kg 0.2 g (1e = 200IR) 0 - 0.4998 kg

2.5 kg 0.5 g (1e = 200IR) 0 - 0.9995 kg

5 kg 1 g (1e = 200IR) 0 - 2.499 kg

10 kg 2 g (1e = 200IR 0 - 9.998 kg

25 kg 5 g (1e = 200IR 0 - 9.995 kg

1 lb 0.0001 lb (1e = 100IR) 0 - 0.9998 lb

2 lb 0.0002 lb (1e = 100IR) 0 - 0.0095 lb

5 lb 0.0005 lb (1e = 100IR) 0 - 9.995 lb

10 lb 0.001 lb (1e = 100IR) 0 - 9.999 lb

20 lb 0.002 lb (1e = 100IR) 0 - 9.998 lb

50 lb 0.005 lb (1e = 100IR) 0 - 9.995 lb

Table 1-1. DC-788 Capacities, Minimum Graduations and Tar e Ranges

Introduction 1

1.2 Modes of Operation

1.2.1 Description of Modes of Operation

The DC-788 has three modes of operation:

• Weighing Mode – where all weighing, counting and printing operations take place.

• Programming Mode – where item and inventory data can be programmed into the memory of the scale. The display will show ProG to indicate that you are the Programming Mode.

• Maintenance Mode - where your DIGI dealer can set specifications, perform scale calibration and other maintenance functions.

1.3 Keyboard and Display

Figure 1-1 shows the DC-788 console with its indicator lamps, the function keyboard and the numeric keypad. Annunciators are described in Section 1.3.2. Section 1.3.3 describes the DC-788 keyboard and keypad.

Figure 1-1. DC-788 Display

1.3.1 Display Specifications

Tare weight display 5 digits

Weight display 5 digits

Unit weight display 5 digits

Quantity display 7 digits

Table 1-2. DC-788 Display Specifications

1.3.2 Indicator Lamps

Table 1-3 shows a list of the indicator lamps that the DC-788 uses to provide additional information about the value being displayed. The indicator lamps are illuminated when the specific function is being performed.

Indicator Lamp Function or Meaning

NET

RECOMP

INSUFF

On when the gross weight is zero and is stable

On when the display shows net weight (when a tare weight is entered or recalled)

On when the item is being weighed in kg units with [kg/lb] key pressed

On when the item is being weighed in lb units with [kg/lb] key pressed

On when unit weight recomputing is possible

On when the net weight is below the specified percentage of scale capacity

Table 1-3. DC-788 Indicator Lamps and Function

2 DC-788 Operation Manual

Indicator Lamp Function or Meaning

scale 1

scale 2

prog

wt/1000

apw

∑

out

batt

charge

On when scale 1 is in use (the built-in platform)

On when scale 2 is in use (an external platform)

On when the scale is in Programming Mode

On when the unit weight is being displayed per 1000 pcs.

On when the unit weight is displayed per one piece (average piece weight).

Quantity is accumulating

Item out of item inventory (subtracting from inventory)

Item in to item inventory (adding to inventory)

Battery warning when weak and needs charging (only for rechargeable battery type)

Battery charging (only for rechargeable battery type)

Table 1-3. DC-788 Indicator Lamps and Function

1.3.3 Key Functions

The DC-788 features many functions for managing inventory information and scale operation. Figure 1-2 shows the two key-sheet layouts and Table 1-4 lists the keys and key functions of the DC-788 keyboard and keypad.

Some keys have different functions depending on what mode or function you are in.

Key Description

ON/OFF - Turns the scale display on or off

Numeric keys - Used to enter numeric values. When using the scale, first enter a numeric

DECIMAL key - Used to set the decimal point.

Figure 1-2. Key Sheet Layout

value, then press the appropriate function key.

Table 1-4. DC-788 Key Functions

Introduction 3

Key Description

CLEAR key.

Weighing Mode - Used to clear the Unit Weight. Used to return to the weighing display when

doing accumulation.

Programming Mode - Used to delete an Item Code or associated value when programming item

codes. Used to Cancel input in programming SPC codes. Used to Reset Sequence Number to zero when programming Sequence Codes.

PCS key - Used for computing unit weight by sampling.

TARE key.

Weighing Mode - Used to set or clear the tare value. Programming Mode - Used to store SPC changes and escape to the Weighing Mode when

programming specifications.

Maintenance Mode - Used to escape to the Weighing Mode from the Maintenance Mode.

REZERO key.

Weighing Mode - Used to reset the weight display to zero. Maintenance Mode - Used to enter different parts of the Maintenance Mode when combined with

numeric codes.

CODE/IN-OUT key.

Weighing Mode - Used to recall Item Codes from memory and to determine inventory IN/OUT

status.

- (Minus) key.

Weighing Mode - Used to delete a character entered during operations. Used to subtract a

quantity during accumulation. Also prompts printing of a label if an external printer is connected.

Programming Mode - Used to navigate to the previous specification when programming SPC

codes. Used to move between item codes when reviewing already programmed item codes. Used to display the current date and time when programming the date and time.

+ (Plus) key.

Weighing Mode - Used to accumulate data. Also prompts printing of a label if an external

printer is connected.

Programming Mode - Used to navigate to the next specification when programming SPC codes.

Used to move between item codes when reviewing already programmed item codes. Used to store set point data when programming item codes.

* PRINT key - Print/Data setting key.

Weighing Mode - Used to print a label when an external printer is connected. Used to clear

TOTAL data when doing accumulation.

Programming Mode - Used to temporarily store changes to specification data when programming

SPCs. Used to store data to Item Code memory when programming Item Codes. Used to store changes to item codes when editing Item Code information. Used to store the date and time when programming Date and Time.

SCALE key. Used to select between Scale 1 and Scale 2 if an external scale is

connected.

MODE key - Used to enter the programming mode from the weighing mode. Used to

4 DC-788 Operation Manual

enter the command mode when using numeric commands.

Table 1-4. DC-788 Key Functions

Key Description

KG/LB/INVENT key- Used to convert the weighing units between kg and lb. Also used to toggle

on and off whether inventory stored in memory is being affected by the current transaction.

UNIT WEIGHT key - Used to set the unit weight and display all digits of the unit weight.

Table 1-4. DC-788 Key Functions

Introduction 5

2.0 Installation

This section describes the procedure for the installation and setup of the DC-788 counting scale.

2.1 Unpacking

Do not turn scale upside down. Always work with scale on its side! Damage to the load cell can occur if

#AUTION

1. Immediately after unpacking, visually inspect the DC-788 counting scale to ensure all components are

included and undamaged. If any were damaged in shipment, notify Rice Lake Weighing Systems and the shipper immediately.

2. The DC-788 counting scale is carefully packed for protection during shipping. After openin g the box,

remove all the components. Check the insides of the box carefully to make sure you have all of the pieces. The package should include the following:

• DC-788 counting scale

• Stainless steel platter

• AC power cord

• Operation Manual

the scale is turned upside down.

3. Remove the bag protecting the scale and the protective film covering the front panel and platter.

4. Seat the stainless steel platter on the platter supports, with the four corner pins inserted into the corner

rubber stops. For DC-788 scales with a 2 lb. capacity, the scale must first be unlocked using the following procedure.

• Take off the two Nuts A and Screw C. Then remove Screws D, Plate C and Nut B. Then turn the scale on its side to complete removal of the locking screw. REMINDER: Do not turn the scale upside down as this can damage the load cells.

• Remove Nut F and then Screw E. Then take off Screw G and Washer H.

5. After ensuring that all parts are present, store the DC-788 scale box for possible future use.

6 DC-788 Operation Manual

2.2 Repacking

If the DC-788 counting scale must be returned for modification, calibration or repair, it must be properly packed with sufficient cushioning materials. Whenever possible, use the original carton when shipping the DC-788. Damage caused by improper packaging is not covered by the warranty.

2.3 Setting Up

Place the scale on a solid, level surface away from fans, breezes, and sources of electrical interference. Level the scale by turning the four adjustable legs located on the bottom of the scale while referencing the bubble

level located on the front of the scale (see

NOTE: To ensure a higher degree of scale stability, turn in all four adjustable legs before leveling. Turn out adjustable legs to

level as needed.

Figure 2-1).

Figure 2-1. Leveling Bubble

2.4 Powering Up the DC-788

The DC-788 can be operated either from an AC power source or with a rechargeable battery pack (DC power). The DC power allows the unit to be completely portable. Instructions for DC operation are contained in Section 2.4.2.

2.4.1 AC Power Source

To power up the DC-788 using the AC power cord:

1. Connect the AC power cord under the scale base as shown in Figure 2-2.

Figure 2-2. AC Plug-in Location on Underside of DC-788

2. Plug the AC power cord into a grounded 115 VAC receptacle.

3. Press the ON/OFF key located on the front of the scale. The scale will run through a check of the LCD

Installation 7

display’s segments. How thorough the segment check is depends on the setting of SPC 20, Bit 2. The default is 1: Normal (For further instructions on how to set the scale’s specifications, see

Section 3.1.2):

• If SPC 20, Bit 2 is set to 0: Fast, the scale display’s 888’s for 1.5 seconds, then blanks for 1.5 seconds. It then displays 888’s again followed by a blank display for another 1.5 seconds before going into the normal weighing mode.

• If SPC 20, Bit 2 is set to 1: Normal, the scale’s display will test the LCD segments for each numeral from 0 to 9, asterisks, decimal points and annunciators before going into the normal weighing mode.

4. Once the scale is on, the time interval before the scale will automatically power itself off, if there no key is pressed and no weight is placed on the platter, is determined by SPC 00- Auto Power-Off Function. The default is 0000: Disabled. (For further instructions on how to set the scale’s specifications, see Section 3.1.1)

2.4.2 DC Battery Pack Replacement/Installation

An optional DC battery pack (PN 88933) for the DC-788 is available and can be purchased from RLWS to ship with the scale or retrofit in the field. The rechargeable 6V 5.0 AH battery pack allows for up to 24 hours of scale use without an AC power supply. It is located in the bottom of the scale base. Use the following procedure to install or replace the battery pack.

1. Unplug the scale from power source.

2. Place scale its left side.

Do not turn the scale upside down. Always work with the scale on its side. Damage to the load cell can

#AUTION

occur if the scale is turned upside down.

3. Unscrew the two thumb screws holding the battery compartment door closed.

Figure 2-3. Thumb Screws for Battery Compartment

4. Unscrew the two screws holding on the battery holding bracket and remove the bracket.

5. Remove the battery from its compartment, then disconnect the black (-) and red (+) electrical leads from the battery .

8 DC-788 Operation Manual

Figure 2-4. Removing Battery Bracket.

6. Attach the red lead to the positive (+) terminal of the new DC battery pack, and the black lead to the negative (-) terminal. Place new DC battery pack in battery compartment.

7. Replace the battery holding bracket and fasten it with its two screws.

8. Replace the battery compartment door and fasten it with its two thumb screws.

9. Put the scale back upright on its feet.

10. Press the ON/OFF key located on the front of the scale. The scale will run through a check of the LCD display’s segments. How thorough the segment check is depends on the setting of SPC 20, Bit 2. The default is 1: Normal (For further instructions on how to set the scale’s specifications, see

Section 3.1.2):

• If SPC 20, Bit 2 is set to 0: Fast, the scale display’s 888’s for 1.5 seconds, then blanks for 1.5

seconds. It then displays 888’s again followed by a blank display for another 1.5 seconds before going into the normal weighing mode.

• If SPC 20, Bit 2 is set to 1: Normal, the scale’s display will test the LCD segments for each numeral

from 0 to 9, asterisks, decimal points and annunciators before going into the normal weighing mode.

2.4.3 Battery Charging

A fully charged battery allows for approximately 24 hours of continuous use. When the battery is low the battery indicator light will light up. It will take approximately 8-10 hours to fully recharge a battery that has been completely dissipated. To charge the battery, plug in the AC power cord.

2.4.4 Start-Up Screens

1. If SPC 20, Bit 3 - Version Display When Power On is set to 0: Allow, the scale will display the current version of the firmware it is using as it powers up (For further instructions on how to set the specifications, see

Section 3.1.2).

2. After a test of the different elements of the display, the scale takes you to the stand-by screen in the Weighing Mode. SPC 20, Bit 2 - Selection of Segment-Check Style controls whether the startup test of the segments is Fast or Standard. At the stand-by screen the

TARE, WEIGHT, UNIT WEIGHT and PCS

displays show zeroes.

From this stand-by screen all of the basic weighing, counting and inventory operations can be performed

3. If there is anything on the platform(s) and it exceeds the scale start range, the display will show the error message OF indicating “weight overflow”.

Note: The Initial Start Range settings are controlled by SPC 20, Bit 1. The default setting is 0: ± 10% OF FULL SCALE.

If this error appears, remove the weight from the platform and the scale will continue its startup sequence.

Installation 9

2.5 Setting the Date

Without a power supply, the DC-788 will reset the time and date. For units that do have battery power, the time and date can be supported for up to 20 days in the OFF status without any AC power supply. After 20 days the unit will reset itself.

The procedure below can also be used to adjust the time when moving from Standard to Daylight Savings Time or when the scale is moved to a new facility in a different time zone.

NOTE: SPC 04, Bits 3 and 2 - ORDER OF MONTH, DATE AND YEAR allows you to set the format for the date that you prefer

the scale to display. The default is 00: Month/Date/Year. To change these specifications, see

Section 3.1.2).

1. Press the MODE key twice until the display shows ProG.

2. Press the – (Minus) key to display the current time and date.

3. Press the – (Minus) key again.

4. Using the keyboard, enter the desired date i.e.: [0] [6] [0] [9] [0] [5] for June 9th, 2005.

5. Press the * PRINT key to store the date setting.

6. Using the keyboard, enter the time, i.e.: [1] [5] [0] [5]

7. Press the * PRINT key to store the time setting

8. Press the MODE key to exit the weighing mode.

2.6 Replacement Parts

The following list contains the part numbers and descriptions of replacement parts available for the DC-788 counting scale.

RLWS Part Number Description

88933 Battery Pack, 6 V, 5.0AH lead acid

89994 Keysheet, 16 keys, DC-788

89997 Keysheet, 8 keys, DC-788

89999 Keyboard

90152 Mainboard for DC-788

90153 Loadcell, 2 lb

90154 Loadcell, 10 lbs

90155 Loadcell, 20 lbs

90156 Loadcell, 50 lbs

90157 Loadcell, 100 lbs

90188 Top c o v e r

90160 Support platter

90171 Platter cover, 10 lb to 100 lb

65956 Platter cover, 2 lb

10 DC-788 Operation Manual

Table 2-1. DC-788 Replacement Parts

2.7 Block Diagram of Electrical Connections

The following block diagram illustrates the electrical connections.

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2.8 Physical Layout of Electrical Connections

The following diagram illustrates the actual layout of electrical connections.

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Installation 11

3.0 Configuration Settings

This section presents the setup and configuration of the DC-788 counting scale to be used specifically by distributors and service technicians. Configuring these specifications allow you to tailor the DC-788 to your specific applications.

Setting the specifications allows you to modify the functionality of the DC-788. Use the tables in this section to view the options you can modify.

3.1 Configuring Specification 141 and 142 Settings from the Scale Keyboard

The following tables list the DC-788 specifications, their corresponding default values, and the other possible values to which they can be programmed. The default values are set at the factory when the scale is shipped. SPC 0 through SPC 19 ( through SPC 35 (Table 3-2) are weight and measurement specifications, and use the 142 access code

In programming specifications, the + (Plus) and – (Minus) keys allow you to move to the next or previous specification. The CLEAR key cancels any input you have made. The * PRINT key temporarily stores to memory any changes you have made. The TAR E you to the weighing mode. Note also th at when programming specifications, only th e 0 and 1 keys on the numeric keypad are enabled, since those are the only valid entries.

3.1.1 Customer Specification (141 Settings)

1. To configure customer specifications, press and hold the REZERO key and enter 141 using the numeric keypad. The first SPC code is displayed.

Table 3-1 ) are customer specifications and use the 141 access code, while SPC 20

key saves to memory the changes you have made and returns

The Weight display shows what specification you are in (in this case, SPC00). The Unit Weight display shows how this specification is currently programmed (Bit 3 = 0; Bit 2 = 0; Bit 1 = 0, and Bit 0 = 1 in this example, while the PCS display will show any changes you enter.

If this is the SPC that you want to modify, enter the new setting from the numeric keypad and press the * PRINT key to enter the change into temporary memory and move to the next SPC code.

2. Use the + (plus) and – (minus) keys to scroll through the specifications until you find the one you want. Then make your changes per the instructions in Step 1.

3. To change another SPC code before exiting, repeat Steps 1 and 2.

4. To save all the changed SPC settings currently in temporary memory and exit to the Weighing Mode, press the TARE key.

12 DC-788 Operation Manual

SPEC No. Bit 3 Bit 2 Bit 1 Bit 0

00 Auto Power-off Function (for no key operation and weighing operation)

0000: Auto power-off disable when scale is not in use (DEFAULT) 0001: 3 minutes 0010: 10 minutes 0011: 30 minutes 1011: 1 hour 0101: 3 hours 0110 ~ 1111 - not used (SP1_OFFT)

01 0: Not used

02 Buzzer

Error Alarm

Set Point Alarm

Not Used

0: On (DEFAULT) 1: Off (SP1_BUZZ)

03 Unit weight base per

1000PCS or 1 PCS

0: On (DEFAULT) 1: Off (SP1_ALARM)

Sampling time for unit weight calculation

display

0: 1000PCS (DEFAULT) 1: 1PCS (SP1_UWID)

0: 10 times 1: 5 times (DEFAULT)

(SP1_STFUWC) Note: When SPEC 27 Gross Mode is set to 0: Allow, the scale remains in UW/1000, regardless of how this SPEC 3 is set. See note under SPEC 27.

04 Order of month, date and year

00: MM/DD/YY (DEFAULT) 01: DD/MM/YY 10: YY/MM/DD 11: Not used (SP1_DATEO)

05 Function of RS-232 Interface

00: PC 01: Printer (DEFAULT) 10: Not used 11: Not used (SP1_RS232IF)

06 RTS/CTS Handshaking of

Baud Rate of RS-232C RS-232C

0: On (DEFAULT)

0: (DEFAULT) 1: Off (SP1_PALARM)

Negative Counting

0: Allow (DEFAULT) 1: Inhibit (SP1_NCOUNT)

Re-zero Function

0: Allow (DEFAULT)

1: Inhibit

(SP_RZF)

Set Point Type

00: % quantity (DEFAULT) 01: % weight 10: Quantity 11: Weight (SP1_SPT)

Extrent of insufficient samples

00: 0.1% (DEFAULT) 01: 0.2% 10: 0.0% 11: Not used (SP1_INSUFFRG)

0: On 1: Off (DEFAULT) (SP1_RTS)

07 Stop bit of RS-232C

0: 1 bit (DEFAULT) 1: 2 bit (SP1_STOP)

000: 1200 bps 100: 19200 bps 001: 2400 bps 101: Not used 010: 4800 bps 110: Not used 011: 9600 bps (DEFAULT) 111: Not used (SP1_BAUD)

Data length of RS-232C

0: 7 bit 1: 8 bit (DEFAULT) (SP1_DLEN)

Parity of RS-232C

00: None (DEFAULT) 10: Even 01: Odd 11: Not used (SP1_PAR)

Tab le 3-1. DC-788 (141) Settings

Configuration Settings 13

SPEC No. Bit 3 Bit 2 Bit 1 Bit 0

08 RS-232C PC Protocol

0000: Inhibit data transfer (DEFAULT) 0001: Standard stream type (continuous output 0010: Standard manual type 0011: Stand command type 0100~ 1111: Not used (SP1MODE)

09 External Printer Type

0000: No Printer (DEFAULT) 0001: DIGI GP460R Label Printer 0010: Zebra LP2844 Bar Code Printer 0011: Epson TMU200 or Star SP2320 Tape Printers 0100: Epson TM295 or Star SP298 Ticket Printers 0101: TVP1000 Bar Code Printer (SP1PRINTER)

10 Interval of Time Out Error of RS-232

Transmission Condition of RS-232

Additional Parity Code in Te x t o f R S -2 3 2

00: 1 Second 01: 3 Seconds (DEFAULT) 10: 5 Seconds 11: 10 Seconds (SP1TIME)

11 Tare Weight in Text of

RS-232

0: No 1: Yes (DEFAULT) (SP1_TW)

12 Date & Time in Text of

RS-232

0: No 1: Yes (DEFAULT) (SP1_DTIME)

13 Print When Pressing the +

or - Key

0: No (DEFAULT) 1: Yes

(SP1_PRTK) (*V1.09)

Unit Weight in Text of RS-232

0: No 1: Yes (DEFAULT) (SP1_UW)

Parts Information in Text of RS-232:

0: Include Parts Information 1: Include Only ID Code (Output like DC-180. Requires a setpoint value to be entered to work)

External Printer Print Format

000: Default Format (DEFAULT) 001: Customer Format 1 010: Customer Format 2 ~ 111: Customer Format 7 (SP1PRINTER)

0: Weight Stable (DEFAULT) 1: Unconditional

(SP1_COND)

Gross Weight in Text of RS-232

0: No 1: Yes (DEFAULT) (SP1_GW)

Header Code in Text of RS-232

0: No 1: Yes (DEFAULT) (SP1_HEAD)

0: No (DEFAULT) 1: Yes

(SP1_APAR)

Quantity in Text of RS-232

0: No 1: Yes (DEFAULT) (SP1_TP)

Weight Range of Data Output

0: Always (DEFAULT) 1: Over 20e (SP1_MINWTL)

14 DC-788 Operation Manual

Tab le 3-1. DC-788 (141) Settings

SPEC No. Bit 3 Bit 2 Bit 1 Bit 0

14 Clear Unit Weight When

Swap Scale

Rezero When Swap Scale

Auto Scale Switching

Zero Display

0: No (DEFAULT) 1: Yes

(SP1_UC) (*V1.06)

15 Display “MEM EXIST”

message reminding you that there is an accumulation in memory

0: No 1: Yes (DEFAULT)

(SP1_MEXIST) (V1.10)

16 - 19 Not Used

0: No (DEFAULT) 1: Yes

(SP1_RZ) (*V.106)

Clear TARE Weight When Swapping Scales

0: No (DEFAULT) 1: Yes

(SP1_ASS) (*V1.07)

Scale Number in Text of RS-232

0: No 1: Yes (DEFAULT)

0: Display 0 With ‘/’

1: Display 0 Without ‘/’

(DEFAULT)

(SP1_DIS0) (*V1.10)

Number of Setpoints

0: 2 Setpoints (Default)

1: 3 Setpoints

(SP1_SPN) (v1.10)

Tab le 3-1. DC-788 (141) Settings

3.1.2 Weight and Measurement Specifications (142 Settings)

To make changes to the Weight and Measurement Specifications, the span switch must be on. (For instructions on how to turn the span switch on, see

Section 4.0.)

1. To configure customer specifications, press and hold the REZERO key and enter 142 using the numeric keypad. The first SPC code is displayed.

The Weight display shows what specification you are in (in this case, SPC20). The Unit Weight display shows how this specification is currently programmed (Bit 3 = 1; Bit 2 = 0; Bit 1 = 0, and Bit 0 = 0), while the PCS display will show any changes you enter.

If this is the SPC that you want to modify, enter the new setting from the numeric keypad and press the * PRINT key to enter the change into temporary memory and move to the next SPC code.

2. Use the + (Plus) and – (Minus) keys to scroll through the specifications until you find the one you want. Then make your changes per the instructions in Step 1.

3. To change another SPC code before exiting, repeat Steps 1 and 2.

4. To save all the changed SPC settings currently in temporary memory and exit to the Weighing Mode, press the TARE key.

Configuration Settings 15

SPEC No. Bit 3 Bit 2 Bit 1 Bit 0

20 Version Display When

Power On

Selection of Segment-Check Style

Start Range

0: Allow (DEFAULT) 1: Inhibit

0: Fast (DEFAULT) 1: Standard

(SP_VER)

(SP_SEGCK)

21 Minimum Display (Scale 1)

00: 1 01: 2 (DEFAULT) 10: 5 11: 10 (SPMINID)

22 Selection of Resolution (Scale 1)

0000: 1/2500 0001: 1/5000 (NTEP Setting) 0010: 1/10000 (DEFAULT) 0011: 1/15000 0100: 1/20000 0101: 1/25000 0110: 1/30000 0111: 1/12500 (SPRES)

23 Not Used

0: (DEFAULT)

Weight Decimal Point Position (Scale 1)

000: No Decimal Point 001: 1st Digit (0000.0) 010: 2nd Digit (000.00) 011: 3rd Digit (00.000) 100: 4th Digit (0.0000) (SPWPT)

24 Selection of Resolution (Scale 2)

00: ±10% of Full Scale (DEFAULT) 01: ± 5% of Full Scale 10: ± 3% of Full Scale 11: ± 2% of Full Scale (SPSRANGE)

Minimum Display (Scale 2)

00: 1 01: 2 10: 5 (DEFAULT) 11: 10 SPMINID1)

0000: 1/2500 0001: 1/5000 (NTEP Setting) 0010: 1/10000 (DEFAULT) 0011: 1/15000 0100: 1/20000 0101: 1/25000 0110: 1/30000 0111: 1/12500 (SPRES1)

25 Not Used

0: (DEFAULT)

Tabl e 3-2. DC-788 Weight and Measurement Specifications

16 DC-788 Operation Manual

Weight Decimal Point Position (Scale 2)

000: No Decimal Point 001: 1st Digit (0000.0) (DEFAULT) 010: 2nd Digit (000.00) 011: 3rd Digit (00.000) 100: 4th Digit (0.0000) (SPWPT1)

SPEC No. Bit 3 Bit 2 Bit 1 Bit 0

26 Weight Stability Conditions

2nd Scale

Please note that the scale

IR Mode Protected by Span Switch

switch is not activated until the 2nd scale has been calibrated.

00: Loose 01: Normal (DEFAULT) 10: Tight 11: Stringent (S PWTATA BC)

27 Weight Unit Base

0: kg 1: lb (DEFAULT) (SPBASE)

28 Manual Tare

Cancellation

0: Allow (DEFAULT) 1: Inhibit (SP_MTC)

29 Digital Tare

Type of Decimal Point

0: .(Standard) (DEFAULT) 1: ,(Europe) (SP_DPF)

Ta r e S ub t r a c t i o n

0: Allow (DEFAULT) 1: Inhibit (SP_TS)

Accumulation When Ta r e

0: Inhibit (DEFAULT) 1: Enable

(SP_SCALET)

Negative Weight Display Mask

0: Minus Gross > 9e 1: Minus Gross Weight (DEFAULT) (SP_NMASK)

Ta r e A cc u mu l a t i o n

0: Allow (DEFAULT) 1: Inhbit (SP_TA)

Zero Tracking When Ta r e

0: No (DEFAULT) 1: Yes

(SP_SPSW)

Gross Mode

0: Allow 1: Inhibit (DEFAULT) (SP_GROSSM) Note: When the Gross Mode is enabled, it disables the ability to switch between lb/kg or to switch to APW because the lb/kg key is used for the gross mode. When Gross Mode is enabled, the scale stays in UW/1000 regardless of how SPEC 3 is set.

Auto Tare Clear When Rezero

0: Allow 1: Inhibit (DEFAULT) (SP_AUTOT)

Weight Reset When Tare

0: Allow 1: Inhibit (DEFAULT) (SP_DT)

30 Ta r e A u t o Cl e a r

0: Allow 1: Inhibit (DEFAULT)

(SP_TAUTO)

31 Accumulation

0: 0: Allow (DEFAULT) 1: Inhibit (SP_ACC)

Tabl e 3-2. DC-788 Weight and Measurement Specifications

0: Allow 1: Inhibit (DEFAULT) (SP_ACCT)

Unit Weight Auto Clear

0: Allow 1: Inhibit (DEFAULT)

(SP_UAUTO)

Accumulation Number Display

0: Allow (DEFAULT) 1: Inhibit (SP_ANO)

0: Allow (DEFAULT) 1: Inhibit (SP_ZTT)

Auto Clear Condition

0: >=Gross 21e & >=Net 5e 1: >=Net 1e & Quantity Not 0 (DEFAULT) (SP_AUTOCC)

WT Data Synchronization (+ key only)

0: Allow (DEFAULT) 1: Inhibit (SP_WDS)

Configuration Settings 17

0: Allow (DEFAULT) 1: Inhibit (SP_WR)

Not Used

0: (DEFAULT)

Accumulation Display Style

0: “Total” (DEFAULT) 1: “Add” (SP_ADS)

SPEC No. Bit 3 Bit 2 Bit 1 Bit 0

32 Exit From Accumulation

Mode After 15 Second Time Out

Exit From Acculumation Mode When Weight Change

Quantity Accumulation Without Removing Weight

Quantity Accumulation Without Changing Weight (for >= ±10e)

0: Allow (DEFAULT) 1: Inhibit (SP_EA15)

0: Allow (DEFAULT) 1: Inhibit (SP_EAWC)

33 Loadcell Sensitivity Selection mV/V (1st Scale)

0000: 0.95 ~ 1.09 (Default) 0100: 1,69 ~ 1.95 1000: 0.40 ~ 0.46 1100: 0.71 ~ 0.82 0001: 1.09 ~ 1.27 0101: 1.95 ~ 2.25 1001: 0.46 ~ 0.53 1101: 0.82 ~ 0.95 0010: 1.27 ~ 1.46 0110: 2.25 ~ 2.59 1010: 0.53 ~ 0.61 0011: 1.46 ~ 1.69 0111: 2.59 ~ 3.00 1011: 0.61 ~ 0.71 (SPSST)

34 Loadcell Sensitivity Selection mV/V (2nd Scale)

RLWS recommends a setting of 0000 for bench scales and 0011 for floor scales connected as a second scale.

0000: 0.95 ~ 1.09 0100: 1,69 ~ 1.95 1000: 0.40 ~ 0.46 1100: 0.71 ~ 0.82 0001: 1.09 ~ 1.27 0101: 1.95 ~ 2.25 1001: 0.46 ~ 0.53 1101: 0.82 ~ 0.95 0010: 1.27 ~ 1.46 0110: 2.25 ~ 2.59 1010: 0.53 ~ 0.61 0011: 1.46 ~ 1.69 (Default) 0111: 2.59 ~ 3.00 1011: 0.61 ~ 0.71 (SPSST1)

35 1st Scale Weight Unit

0: kg (DEFAULT) 1: g (SP_GBASE1) NOTE: Units for Scale 1 should be set to be the same as the units on Scale 2 (See SPEC 35, Bit 2)

2nd Scale Weight Unit

0: kg (DEFAULT) 1: g (SP_GBASE2) NOTE: Units for Scale 2 should be set to be the same as the units on Scale 1 (See SPEC 35, Bit 3)

0: Allow (DEFAULT) 1: Inhibit (SP_QARW)

Negative Weight Display Mask Range

0: Minus Gross > 9e 1: Minus Gross >20e (DEFAULT) (SP_NMRG)

0: Allow (DEFAULT) 1: Inhibit (SP_QACW)

Not Used

0: (DEFAULT)

Tabl e 3-2. DC-788 Weight and Measurement Specifications

18 DC-788 Operation Manual

4.0 Calibration

The DC-788 counting scale is a high-precision instrument. Although the scale needs very little maintenance, you may want to check the calibration after every month or so of normal usage. To do this you will need to have a test weight of approximately the total capacity of the scale (i.e. a 10 lb weight if you have a 10 lb capacity scale). After the scale is initially installed, put the weight on the platform and record the weight displayed. Then every month or so put the same weight on the scale and verify that it still reads the same.

Many facilities have a technician come in and check their units with certified test weights four times a year. If you are ISO certified, you will want to check to see if your certification specifies more stringent requirements in order to stay in compliance. Your DIGI scale dealer has the calibrated test weights, expertise and experience to perform this task for you as well as to check other operating parameters of your scale and help you effectively integrate scales into your operations. If you do not know who your local DIGI dealer is, call us at 1-715-736-0002 and we will help you find someone who can provide you with on-site support.

Follow the instructions below to calibrate your DC-788 scale to ensure its continued accuracy.

NOTE: You can exit the Maintenance Mode and return to the Weighing Mode at any time by pressing the TARE key. If you

have a remote scale attached to the DC-788, you must first set the SPECs for that remote scale before beginning the calibration process.

1. Turn the scale on, then press the span switch to reset it. (See Figure 4-1 below.)

2. The scale will display the model number, firmware version number and the message S ON indicating that the Span Switch is currently on.

3. While pressing the REZERO key, enter 8715 from the numeric keypad to enter the calibration mode.

Figure 4-1. Location of Span Switch

Calibration 19

4. The scale display will confirm that you are in the Calibration Mode.

5. You can select which scale you are calibrating, Scale 1 or Scale 2, by pressing the SCALE key. (If a 2nd scale is not installed and set in the specifications, pressing the SCALE key has no effect.) If you have not yet set up the remote scale in the specifications, press the TAR E key to exit the calibration process and and set the specifications. Then power down the scale to commit the changes to the scale’s memory before returning to calibration. (For information on setting specifications, see

“Configuration Settings”

on page 12.)

6. Make sure that there is no weight on the platform of the scale you are calibrating and press the * PRINT key. The scale will flash briefly as it searches for the zero point and then will display it.

7. Place a reference weight on the platform. It is preferable to calibrate the scale using a weight equal to the full capacity of the scale (i.e. a 5 lb weight for 5 lb capacity scale, etc.) If the reference weight is not equal to the full capacity of the scale, it must at least be greater than 10% of the full scale capacity.

If the reference weight is equal to the full capacity of the scale, press the * PRINT key. If the reference weight is less than the full capacity of the scale, enter the value of the weight placed on the platter using the numeric keys before pressing the * PRINT key. The weight you enter will appear in the Weight display.

8. The display will flash briefly again as the span settings for calibration of the scale are being temporarily saved. Then the display will return to the weighing mode with the calibrated weight showing in the Weight window..

9. To exit the Maintenance Mode and save your calibration, power down your DC-788 s cale. To exit the Maintenance Mode and return to the Weighing Mode without saving your calibration, press the TARE key.

20 DC-788 Operation Manual

5.0 Scale Operations

The following sections contain detailed operator instructions for the DC-530 counting scale (see Figure 5-1). Included are instructions on how to switch between scale platforms, how to enter tare weights, how to enter unit weights, and how to perform counting operations both in the regular Counting Mode and th e TEP (Teraoka Error Prediction) Mode.

Figure 5-1. DC-788 Counting Scale

5.1 Counting Scale Accuracy and the TEP (Teraoka Error Prediction) Mode

Counting scale accuracy is primarily determined by the following factors:

• S ample size (number of pieces)

• Total sample size as a percentage of full scale capacity

• P iece-to-piece weight variation

As a general rule when determining sample size of fairly uniform pieces, the larger the sa mple size the grea ter the total sample weight, therefore, the better the counting accuracy. Selecting the smallest capacity scale that can obtain the highest counting resolution should be considered, but should not sacrifice the capacity required for the heaviest container of parts. For this kind of application, a scale like the DC-530 with an extra scale channel is often the best selection.

There is a direct relationship between piece-to-piece weight variation (non-uniformity) and counting accuracy. Therefore, elimination of the piece-to-piece weight variations can be accomplished by:

1. Isolating the sample used to calculate the unit weight and use the same sample to re-check the scale.

2. Recalculating the unit weight from lot-to-lot of parts. Parts manufactured on one machine may vary slightly from another machine relative to weight.

3. Tightening the manufacturing tolerances on the parts reduces piece weight variations and increases count accuracy.

Parts can vary greatly in their value. With parts of lesser value per piece, the extra sampling and time involved in trying to achieve 100% accuracy as opposed to 99.5% may not be cost-effective. However, with high value items 100% accuracy is vital. To address this need, the DC-530 provides you with two counting modes: Regular Counting Mode and TEP (Teraoka Error Prediction) Mode. Regular Counting Mode offers you the same ultra-high-precision that all DIGI products are noted for. When you have high-value items, TEP Mode walks you through a more extensive sampling process from which the scale calculates and displays the number of parts that can be counted at a time with no counting error.

Scale Operations 21

5.2 Weight Unit Switching

The weight units displayed can be changed between Kg and Lb during weighing operations by pressing the kg/lb key. The appropriate annunicator will light. SPC27 - Base Weight Units sets the default weight unit to Kgs or Lbs. If you are using more than one scale, SPC35 sets the weighing units for the 1st and 2nd scales. (For further instructions on how to set the specifications, see

Section 3.1.2)

5.3 Toggling Between Scales

To toggle between Scales 1 and 2, press the SCALE key. The indicator lamp for the appropriate scale lights on the display.

NOTE: This function is available only when SPC26 - 2nd Scale is enabled. (For further instructions on how to set the

specifications, see

Section 3.1.2)

5.4 Setting Tare Weights in Weighing Mode

This section will describe the different tare-related operations you can perform from the weighing mode. Tare weight can be set by one touch tare using the TARE key or, if the value is known ahead of time, can be entered digitally using the digital tare function. Tare addition and subtraction can also be done digitally or by using the TARE key. Finally, an existing tare stored with an Item Code can be overridden temporarily in the Weighing Mode if needed.

Note: The following SPC codes must be set properly to allow these operations before continuing: SPC 28, Bit 1 - MANUAL TARE CANCELLATION sets whether or not the tare weight can be cancelled from the keyboard. SPC 28 also controls whether TARE SUBTRACTION (Bit 2) and TARE ACCUMULATION (Bit 1) are allowed or inhibited and whether AUTO TARE CLEAR WHEN REZERO (Bit 0) takes place or not. SPC 29 controls whether the scale allows DIGITAL TARE entry (Bit 3), whether the scale can do ACCUMULATION WHEN TARE (Bit 2), if there will be ZERO TRACKING WHEN TARE (Bit 1) and WEIGHT RESET WHEN TARE (Bit 0). SPC 30 sets whether or not TARE AUTO CLEAR is activated (Bit 3). (For further instructions on how to set the specifications, see

Section 3.1.2)

5.4.1 One Touch Tare (When the Tare Weight is Unknown)

1. While in the weighing mode, place a bin, box or other weight to be tared out on the platform.

2. Press the TAR E key to subtract the tare weight. The Net annuciator will light up, the Weight display should now show 0 and the tare weight will show in the Tare display.

3. If you remove the tare weig ht from the platform, the tare weight will show as a negative weight in the weight window and the Net annunciator will remain lit.

Note: This tare weight will be overridden by the weight stored with an Item Code when you call up an Item Code.

4. To clear this tare weight and return to the Weighing Mode, press the TA RE key again. The net annunciator will not longer be lit.

5.4.2 Digital Tare (When Tare Weight is Known in Advance)

1. While at the stand-by screen, enter the known tare weight by using the numeric keypad.

2. Press the TAR E key to subtract the tare weight. The Net annunciator will light up and the tare weight will be displayed in the weight display.

Note: This tare weight will be overridden by the weight stored with an Item Code when you call up an Item Code.

3. To clear this tare weight and return to the Weighing Mode, press the TA RE key again. The net annunciator will no longer be lit.

Note: For digital tare entry, the decimal must be in the appropriate place as it would be displayed in the weight display. For example,.250 would be entered as 0.250, not.250. The weight display shows weight entered with a negative sign indicating that it is a tare weight.

5.4.3 Tare Addition or Subtraction

Two tares can be accumulated or subtracted using the TAR E key as well. Tare weights cannot be accumulated or subtracted by digital entry.

Note: SPC 28, Bits 2 and 1 must be set to 00 to enable Tare Accumulation and Tare Subtraction. (For further

instructions on how to set the specifications, see

1. Place the container, box or item to be tared on the platform and press the TARE key. The weight display should show 0, the Net annunicator will illuminate and the tare weight will appear in the Tare display.

Section 3.1.2)

22 DC-788 Operation Manual

2. Place another tare weight on the platform and press the TAR E key again. This will add the two tare weights together (Tare Addition).

3. Tare weights can be subtracted individually by removing one from the platform and pressing the TARE key again. T o clear all the tare weights and return to the Weighing Mode, remove all the tare weights and press the TARE key. The Net annunicator will no longer be lit.

5.4.4 Tare Override

For instructions on how to temporarily override a tare that is called up with an Item Code, please see Section 5.9.4.

5.5 Entering Unit Weights

Entering unit weights can be done either by sampling, as presented in Section 5.5.1, or by key entry as described in Section 5.5.2.

NOTES: SPC 05 - EXTENT OF INSUFFICIENT SAMPLES controls unit weight sampling. The default setting for the SPC is 00:

0.1 percent.

SPC 14, Bit 3 - CLEAR UNIT WEIGHT WHEN SWAP SCALE sets whether the unit weight determined by sampling is automatically transferred from Scale 1 to Scale 2 or is cleared when you transfer scales. SPC 14, Bit 1 - AUTO SCALE SWITCHING, sets . When you have a procedure that involves sampling an item’s unit weight on the DC-788’s built-in platform and then want to go immediately to weighing and counting boxes or bins on a floor scale or other external scale, set SPC 14 to 1: YES. If the external Scale 2 is not necessarily going to be used for weighing the same item as is being sampled on Scale 1, set SPC 14 to 0: NO.

SPC 03 - UNIT WEIGHT BASE PER 1000PCS OR 1PCS controls whether the unit weight is displayed per 1000 pieces or per 1 piece. The default settings for this SPC is 0: 1000 pieces.

(For further instructions on how to set the specifications, see Section 3.1.1)

Unit Weight per 1000 Pieces vs. Unit Weight per 1 Piece

The scale’s internal microprocessor calculates unit weights to 7 or 8 decimal places. However, the scale display generally can only show Unit Weight to 5 characters. If this Unit Weight is recorded from the scale display and entered by key entry, this can introduce errors in the Unit Weight and consequently in the counts. This error increases as the Unit Weight of the parts being counted decreases.

Example: A sample of 10 zener diodes is placed on the scale. The Unit Weight is computed by the scale to be

0.0006536 lbs. However, the scale has a 5 character display for Unit Weight so the scale can only display.0065 as the Unit Weight. If this Unit Weight were recorded and keyboard entered in future counting operations, the resulting error would be: 00065 =.55%

.0006536 On the other hand, with entry of the Unit Weight as “weight per 1000 pieces” the decimal place is, in effect,

moved three places to the right, allowing 3 more decimal places of accuracy. In this example, the entry would be made as 0.6536 per 1000 pieces, eliminating the error.

As a practical note, entering unit weights per 1000 pieces also lessens the chances of entering the wrong number of zeros when keying in weights with many leading zeros. Misentry of unit weights is a common cause of inaccurate counting.

When might you want to use unit weight per 1 piece? Generally in one of two cases:

1. If you are working with other existing systems or procedures that are already set up to record unit weight per piece (inventory systems, labeling requirements, etc).

2. If the unit weight or your pieces is more than 100 lbs, as in the case of some castings, engine parts and the like. When the unit weight is over 100 lbs, the number of digits in the scale’s Quantity display will not be able to fully display counts of more than 100 pieces.

5.5.1 Unit Weight Operation by Sampling

Unit weight operation by sampling is accomplished by placing a 10 piece sample on the scale and then pressing the PCS key. The scale calculates a unit weight based on the capacity of the scale compared to the weight of the sample. If you wish to use a sample of more than 10 pieces, place the sample on the scale, then input the sample size before pressing the PCS key.

Scale Operations 23

If the sample size is insufficient to give an accurate unit weight, no unit weight will be displayed, the INSUFF lamp will be illuminated and you have the following options:

• You can add pieces to the sample (keeping track of how many you add) until the INSUFF lamp goes out Key in the new total sample quantity and press the PCS key. The scale will compute and display the unit weight.

• The scale will prompt you to add enough pieces to bring the sample up a weight that allows calculation of a more accurate unit weight The weight will appear in the Weight display, the word ADD in the Unit Weight display and the number of pieces to be added in the PCS display

• Add exactly the number of pieces requested (the PCS display will go down to 0) and press the PCS key. The scale will compute and display the unit weight and the INSUFF lamp will go out.

You can ignore or override the INSUFF indicator by pressing the PCS key again without adding more pieces to the sample. However, it may affect counting accuracy to use a Unit Weight calculated on the basis of an insufficient sample. If you do press the PCS key again, the scale will compute and display the unit weight based on the original sample you gave it.

If the RECOMP indicator is lit, the accuracy of the unit weight computation can be improved by adding approximately double the number of pieces currently on the scale and pressing the flash as it recomputes the unit weight, after which it will display the new Unit Weight.

PCS key again. The scale will

5.5.2 Unit Weight Operation by Key Entry

Unit weight operation by key entry is accomplished by using the numeric keypad to enter the known value of the unit weight and then pressing the UNIT WEIGHT key. An example of unit weight operation by key entry is shown below:

1. With the display in the weighing mode, enter the known unit weight using the keyboard, for example,

200.00.

2. Press UNIT WEIGHT key to enter the unit weight.

3. Place a 2 lb. weight on the scale. The scale displays the quantity for the weight placed on the scale, for example, the weight display reads 2.000, the unit weight display reads 200.00, and the quantity display reads 10).

4. Press the CLEAR key to clear the Unit Weight.

5.6 Setting a Lot Number

Lot numbers can be attached to Item Codes when programming item codes into memory. For instructions on how to set a lot number, see

A Lot Number which is not associated with a specific item code can also be set temporarily in the Weighing Mode. If the DC-788 is connected to an external printer or PC, this Lot Number will appear on labels an d receipts or be output to the PC as part of the data string. For instructions on how to set a temporary Lot Number not associated with an Item Code, see

Section 6.3.

Section 5.8.3.7 below.

5.7 Setting a Sequence Number

The scale can maintain and print a sequence number to aid in transaction tracking and auditing. If the sequence number is set to “0”, no sequence number will be incremented or tracked. Otherwise the sequence number will automatically increment by 1 each time a label is printed by pressing the + (Plus), - (Minus), or * PRINT keys.

24 DC-788 Operation Manual

1. At the stand-by screen, press the MODE key twice to enter the Programming Mode.

2. Press and hold the REZERO key while entering [.] [.] [7]. The scale will go to the Sequence Number Reset screen.

3. To save the new sequence number and exit, press the * PRINT key. To exit without saving the new sequence number, press the CLEAR key twice.

5.8 Operations Without Recalling an Item Code

The following sections describe ways to carry out operations without having to recall the Item codes.

5.8.1 A Single Counting Operation - Without Recalling an Item Code

At times you may want to perform a weighing and counting operation without recalling an Item Code from memory. This can be done from the keyboard in the Weighing Mode.

1. Place a 10 piece sample on the scale and press the PIECES key or enter the unit weight from the numeric keypad and press the UNIT WEIGHT key. The display will flash briefly, then return to normal.

2. To set a tare value, enter the tare from the numeric keypad and press the TAR E key or place the container to be tared on the platter and press the TARE key.

3. Place the product to be weighed and counted on the platter. The total weight and pieces count will be displayed. If a printer is connected to the DC-788, you can print a label with the data by pressing the * PRINT key .

4. To perform another weighing and counting operation, remove the product from the scale platter and press the CLEAR key.

5.8.2 Part Accumulation or Subtraction and Negative Counting - Without Recalling an Item Code

The DC-788 has the capability to acquire the total number of parts using the accumulation or reduction function of the scale (similar to the add/subtract functions of a calculator).

5.8.2.2 Part Accumulation or Subtraction

To find the total accumulated quantity of similar containers filled with parts, use the accumulation procedure detailed below . This does not af fect the inventory quantity for this item in the scale’s memory. To add or subtract from inventory, see

Section 5.9.3.

1. Enter the unit weight of the pieces (if known) or conduct a sampling process (Section 5.5.1) to determine the unit weight of the pieces. Press the PCS key.

2. Enter the known tare weight, or place an empty container on the scale to perform tare function

Section 5.4). Press the TAR E key.

(

NOTE: If SPC 3, Bit 1 - Negative Counting is set to 0: Allow, a quantity of pieces may be displayed if a tare is entered with no

weight on the scale. (For more information on how to set customer specifications, see

Section 3.1.1.)

3. Place container 1 (full of parts) on the scale.

4. Press the + (Plus) key to store the total in container 1. The Memory annunicator ∑ is now illuminated. The weight display briefly shows totAL 1 and the quantity display shows the total pieces in the first container.

Note: If the DC-788 is connected to a printer or PC, the data will be printed or outputted each time the + (plus), - (minus) or * PRINT keys are pressed. If SPC 32, Bit 3 - Exit From Accumulation Mode After 15 Sec Time Out is set to 0: Allow, the display will return to the weighing mode automatically after 15 seconds. If it is set to 1: Inhibit, you must press the CLEAR key to return to the weight display. (For more information on how to set the Weight and Measurement specifications, see

Section 3.1.2.)

Scale Operations 25

5. Remove container 1 and place container 2 (full of parts) on the scale.

6. Press the + (Plus) key (Total 2 is equal to container 1 plus container 2) The Memory indicator ∑ will be illuminated.

7. Continue with the remainder of the containers to be counted. The total number of parts stored in all the containers will be stored in the accumulation register.

8. To subtract pieces from the accumulation, place the container to be subtracted on the platform and press the - (Minus) key. The display will show CORR and the number of pieces being subtracted. The Memory indicator ∑ will continue to be illuminated.

Wait for the Total screen to clear and return to the Weighing Mode or press the CLEAR key.

9. When done with accumulation and subtraction, remove all products from the platter and press the CLEAR key to clear the Unit Weight. (Note: If you try to press the CLEAR key while there is data in the accumulation register, you will get an error message which says MEM EXIST. You must press the * PRINT key to clear the accumulation register before the CLEAR key can be used to clear any unit weight data on the display.

10. Press the + (Plus) key to display the accumulated total when the Unit Weight is zero. Wait for the Total screen to clear and return to the Weighing Mode or press the CLEAR key.

11. Press the TARE key to clear the Tare Weight.

12. Press the + (Plus) key to display the total accumulation data. Wait for the Total screen to clear and return to the Weighing Mode or press the CLEAR key.

13. Enter [3] [6] from the keyboard and press the - (Minus) key to subtract the data. Wait for the Total screen to clear and return to the Weighing Mode or press the CLEAR key.

14. Press the * PRINT key to clear the accumulation register. The Memory indicator ∑ will no longer be lit. If the DC-788 is connected to a printer or a PC, the total accumulation data will be printed or output.

5.8.2.3 Negative Counting

Just as you can count by adding parts to the scale, you can also count by removing parts from the scale. This is called “negative counting” because a negative weight is displayed while counting. Contrary to what may seem intuitively logical, you do not use the (-) key to do negative counting. The (-) key is only used to delete an entry in accumulation mode that you want to erase. This procedure does not affect the inventory quantity for this item stored in the scale. To reduce inventory, see

NOTE: To utilize the negative counting feature, SPC 3, Bit 1 - Negative Counting must be set to “0: ALLOW”. (For information on setting Customer specifications, see

Section 3.1.1.)

Section 5.9.3.

There are two ways to do this depending on whether at the end you want to see the total amount remaining in the container or the total amount removed from the container.

26 DC-788 Operation Manual

5.8.2.4 Counting Out of a Full Container - See Total Amount Remaining in the Container

To carry out this operation you must know the tare weight ahead of time.

1. Place the full container on the scale. Press the TAR E key.

2. Remove a 10 piece sample to the container and press the PIECES key. After the unit weight has been calculated, return the 10 piece sample to the container.

3. Remove a number of parts from the container. The QUANTITY window of the scale display will show the number of pieces you have removed. This process can be repeated as many times as desired.

4. If at the end of the procedure, if you want to see how many remain in the bin or container, you first have to know the tare weight of the bin or container. After removing the parts you want to take out of the bin, simply digitally enter the tare weight of the bin and press the TARE key. The scale will display how many parts were left in the bin.

If a printer or PC is connected to the DC-788, pressing the * PRINT key will print a label to put on the bin showing the new, lower, total quantity or output the data to the PC.

5.8.2.5 Negative Counting - Total Removed Displayed at the End

With this procedure you can count accurately out of a full container for kiting, shipping, etc.without having to know the tare weight of the container.

1. Place a full container on the scale and press TAR E.

2. Remove a 10 piece sample from the container and press PIECES. After the unit weight has been calculated, return the 10 piece sample to the container.

3. Remove the number of pieces you need for kiting, shipping, etc. The amount removed will be displayed in the QUANTITY window. If you need a label for each kit or container and an external printer is connected to the DC-788, press the + (Plus) key after removing each batch of pieces. The Memory indicator

∑ will be illuminated and the scale displays the accumulated total of pieces removed so far.

Then press the TARE key.

4. After removing each batch of pieces, press the + (Plus) key, then the TA RE key.

5. When you have removed the last batch of pieces, press the * PRINT key to show the total number of pieces you have counted out of the full container. If a printer or PC is connected to the DC-788, pressing the * PRINT key will print a label to put on the bin showing the number of pieces removed or output the data to the PC. The Memory indicator

∑ will no longer be illuminated.

5.8.2.6 Clearing Accumulated Data

T o cl ear accumu lated da ta, press the *PRINT key. The Memory indicator ∑ will no longer be illuminated. If you try to press the CLEAR key while there is data in the accumulation register, you will get an error message which says MEM EXIST. You must press the * PRINT key to clear the accumulation register before the CLEAR key can be used to clear any unit weight data on the display.

5.8.3 Setting a Temporary Lot Number, Part Number or Part Name - Without Recalling an Item Code

The Lot Number, Part Number and Part Name of an Item Code can be changed temporarily from the weighing mode without affecting the information stored in memory with that Item Code.

5.8.3.7 Change the Lot Number Temporarily

1. In the Weighing Mode, enter a “1” as a command code from the keypad, then press the MODE key.

2. Using the ASCII characters in Table 8-2, enter a Lot Number of up to 32 characters to be used temporarily.

3. Store the data by pressing the * PRINT key or press the MODE or TA R E keys to return to the Weighing Mode without saving the change.

5.8.3.8 Change the Part Number Temporarily

1. In the Weighing Mode, enter a “2” as a command code from the keypad, then press the MODE key.

2. Using the ASCII characters in Table 8-2, enter a Part Number of up to 16 characters to be used temporarily.

3. Store the data by pressing the * PRINT key or press the MODE or TA R E keys to return to the Weighing Mode without saving the change.

Scale Operations 27

5.8.3.9 Change the Part Name Temporarily

1. In the Weighing Mode, enter a “3” as a command code from the keypad, then press the MODE key.

2. Using the ASCII characters in Table 8-2, enter a Part Name of up to 32 characters to be used temporarily .

3. Store the data by pressing the * PRINT key or press the MODE or TA R E keys to return to the Weighing Mode without saving the change.

5.9 Using Item Codes in Weighing Mode

The following paragraphs describe the procedure to recall item codes, view the information stored in memory with an Item Code, carry out inventory operations related to the item code quantity, and delete an item code.

5.9.1 Recalling Item Codes using Item Code Number

The following procedure allows you recall item codes stored in memory.

1. To enter a numeric Item Code, enter the item code number using the numeric keypad. To enter an alphanumeric item code. press the [.] (Decimal) key to enter the ASCII mode. Enter item code number using the ASCII codes in Table 8-2.

2. Press the CODE/IN-OUT key.

If an Item Code not stored in memory is entered, the scale will display the error message NOT F (indicating NOT FOUND) next to the code entered. Press the CLEAR key to return to the weighing mode and enter a correct Item Code. (See

If an Item Code existing in memory is entered, the stored Unit Weight will be displayed after the CODE/IN-OUT key is pressed. Weighing operations can now be carried out utilizing the Tare Weight, Unit Weight, Inventory Quantity, and Set Point stored with that Item Code.

If you do not want the weighing and counting operations to affect the Inventory Quantity for a recalled Item Code, press the CODE/IN-OUT key until the the In/Out indicator is no longer illuminated. (The Inventory indicator will cycle from Out to In to not present as you press the CODE/IN-OUT key.

Press the CLEAR key to clear the item information and return to stand-by status.

Section 6.2 on how to display the item codes currently programmed in memory.)

5.9.2 View Item Information

The following procedure shows how to call up on the display a specific data field stored with an Item Code (Item Code, Part Number, Part Name, Lot Number, and Inventory Qua ntity). The data associated with the item in memory cannot be changed in this mode.

1. Recall the item from memory by entering the Item Code and pressing the CODE/IN-OUT key. Numeric item codes can be entered from the numeric keypad. To enter an alphanumeric item code. press the [.] (Decimal) key to enter the ASCII mode. Enter item code number using the ASCII codes in

Table 8-2.

2. Press the SCALE key repeatedly to scroll between the Item Code, Part Number, Part Name, Lot Number , and Inventory Quantity currently stored in memory. You can exit to the Weighing Mode at any time by pressing the TARE key.

3. Once all the fields have been scrolled through the scale will return you to the Weighing Mode, with the Unit Weight for the Item Code you entered being displayed.

5.9.3 Adding Parts To and Subtracting Parts From Inventory

The DC-788 is a self-contained inventory control system, capable of tracking movement of up to 100 items. In order to track the inventory of an item, it must first have been progra mmed into the DC-788’s memory. The following procedure is used to add inventory to and remove inventory from an Item Code’s memory using the In and Out functions.

Note: The Inventory IN and OUT functions are enabled by pressing the # CODE/IN-OUT key. When adding inventory quantities to an item code in memory you can add or subtract a single quantity or multiple quantities one after the other (if, for example, you are receiving, sending or counting several bins or boxes of the same part).

To Add or Subtract a Single Quantity to the Inventory of an Item Code in Memory

Table 8-2.

28 DC-788 Operation Manual

2. When an Item Code is recalled from memory, the Inventory indicator will start out pointing to OUT, meaning that inventory quantities will be subtracted. To add a quantity to inventory, press the

CODE/IN-OUT key once. The Inventory indicator will move from OUT to IN, indicating that inventory will be added.

3. If the tare weight and unit weight have alre ady been associated with the Item Code in memory, you can go to Step 5. Otherwise key in the known tare weight or put the empty bin on the scale and press the TARE key.

4. If the unit weight has already been associated with the Item Code in memory, you can go to Step 5. Otherwise place a sample of 10 pieces in the bin on the scale. For accuracy it is best to put the pieces in the same bin used to find the tare weight in Step 3. Press the PCS key.

5. Either pour into the bin the remaining pieces to be added or subtracted to inventory or, if the tare weight and the unit weight of the item were already programmed into the scale, put the full container on the scale. The DC-788 will display the Ta re Weight, Total Weight, Unit W eight, and Quantity of the pieces of the container.

6. Press the * PRINT key to add or subtract the quantity shown on the display to the amount already stored under the item code memory. The Memory indicator The Memory indicator

∑ will no longer be illuminated. If an external printer or PC are connected to the DC-788, pressing the * PRINT key will print or output the data.

7. To view the updated inventory total, press the SCALE key until the scale displays INVENT. To exit the inventory display , press the TAR E key to exit to the Weighing Mode or continue to press the SCALE key until you cycle back to the Weighing Mode.

8. Remove the parts from the platter and press the CLEAR key to exit this item code. The In or Out indicators will no longer be illuminated.

To Add or Subtract Multiple Quantities to the Inventory of an Item Code in Memory

Table 8-2.

2. When an Item Code is recalled from memory, the inventory indicator will start out pointing to Out, meaning that inventory quantities will be subtracted. To add a quantity to inventory, press the CODE/IN-OUT key once. The inventory indicator will move from Out to In, indicating that inventory will be added.

3. If the tare weight and unit weight have alre ady been associated with the Item Code in memory, you can go the Step 5. Otherwise key in the known tare weight or put the empty bin on the scale and press the TARE key.

6. Press the + (Plus) key. The Memory annunicator The Memory indicator ∑ will light up and the scale will display the Total accumulated so far.

7. Remove the first container of parts from the platter and place the second container on the platter. Press the + (Plus) key to add or subtract these parts to/from inventory. Each time you press the + (Plus) key, the scale will display the Total accumulated so far.

8. Repeat Step 7 above until you are done adding or subtracting all the bins or boxes of this item.

9. Press the * PRINT key to add or subtract the quantity shown on the display to the amount already stored under the item code memory. The Memory indicator

∑ will no longer be illuminated. If an external

printer or PC are connected to the DC-788, pressing the * PRINT key will print or output the data.

10. To view the updated inventory total, press the SCALE key until the scale displays INVENT. To exit the inventory display , press the TAR E key to exit to the Weighing Mode or continue to press the SCALE key until you cycle back to the Weighing Mode.

11. Remove the parts from the platter and press the CLEAR key to exit this item code. The In or Out

Scale Operations 29

indicators will no longer be illuminated. (Note: If you try to press the CLEAR key while there is data in the accumulation register, you will get an error message which says MEM EXIST. You must press the * PRINT key to clear the accumulation register before the CLEAR key can be used to clear any unit weight data on the display.)

5.9.4 Tare Override

This function allows you to temporarily override the tare weight called up with an Item Code. The change does not affect the tare weight programmed in memory with the Item Code.

1. Remove any bin or container from the scale.

2. Recall the Item Code information from memory by entering a numeric Item Code from the numeric keypad or enter an alphanumeric item code by pressing the [.] (Decimal) key to enter the ASCII mode and using the ASCII codes listed in

3. The scale will display the information programmed in memory for that Item Code, including the Tare Weight (if one was programmed).

4. If the new tare weight value is known, use the numeric keypad to key in the value and then press TA RE . The weight display will now show the new tare as a negative number and the Net indicator will illuminate.

If the new tare weight value is not known, put the container to be tared out on the platter and press the TARE key. The new tare will be entered, the weight display will show 0.000 lb and the Net indicator will illuminate.

5. You may now either place the product on the platter for weighing and counting or press the CLEAR key to return to the stand-by screen. If an external printer is connected to the DC-788, you can print a receipt or a label for the product by pressing the * PRINT key while the product is still on the platter. To clear the tare weight just entered when you return to the weighing screen, press the TAR E key again.

Table 8-2. Then press the CODE/IN-OUT key.

5.9.5 Delete Item Memory

Deletion of an Item Code with all of its associated information (Part Name, Part Number, Lot Number, Tare Weight, Unit Weight, Inventory Quantity, and Setpoints) can only be done from the item programming mode.

Section 6.8 for procedures on deleting item codes or specific items associated with item codes.

See

30 DC-788 Operation Manual

6.0 Scale Programming

The DC-788 can store information for the parts you count most frequently, eliminating the need for re-entering data during parts counting. With each Item Code you can specify a Tare Weight, Unit Weight, Part Number, Part Name, Lot Number, Inventory Quantity and Setpoint Value. With up to 100 item code numbers able to be programmed into your DC-788 counting scale, the unit can act as a stand-alone inventory system.

In any entering of data on the DC-788, you can use the following functions of the keyboard:

Key Description

To move the cursor to the right

To move the cursor to the left

To delete a character

Table 6-1. Item Storage Function Code Keys

6.1 Checking Memory Status

To see how many items of the 100 capacity have already been programmed, press the MODE key twice to enter the Programming Mode. The display will show ProG and the scale will display the that you are in the programming mode, will illuminate. The total number of Item Codes currently in memory will appear in the PCS column on the display.

PRG indicator, indicating the

Scale Programming 31

6.2 Review the Item Code Numbers Programmed in Memory

To see what Item Codes are currently programmed in the DC-788’s memory, press the MODE key twice to enter the Programming Mode. Then press the CODE/IN-OUT key to show the first Item Code number in memory. The left-hand side of the display will show the memory position starting with 001, while the right-hand side of the display will show the Item Code number you programmed in. (memory position 001 and Item Code 1234 in the example below)

You can scroll through the item codes in memory by pressing the + (Plus) and - (Minus) keys.

6.3 Program Item Code, Tare Weight, Unit Weight, Inventory, Part Number, Part Name, Lot Number, Setpoint 1 and Setpoint 2

The DC-788 has the capacity to store information on up to 100 items, making it a self-contained inventory system. This section details the procedure for storing the item code, tare weight, unit weight, inventory level, part number, part name, lot number and set points to be associated with and item code. You can enter all of this information for each item code or only the data pertinent to your application. T o exit at any time without saving your data press the TARE key. The memory fields associated with item codes can be programmed subject to the following parameters:

Parameters Format and Maximum Length Item Code 10 digits numeric or alphanumeric data Part No 16 digits alphanumeric data Part Name 32 digits alphanumeric data Lot Number 32 digits alphanumeric data Ta re Weight 5 digits plus the decimal point Unit Weight 5 digits plus the decimal point Inventory 8 digits numeric Setpoint Value 2 points

Table 6-2. Format and Length of Item Code Memory Fields

1. Press MODE key twice to enter the Programming Mode. The display will show ProG. The PRG indicator, indicating that you are in the programming mode, will illuminate. The number of items currently programmed into memory will appear in the QTY column on the scale display.

2. Enter the Item Code number. The maximum length of the field is 10 characters. To enter an alphanumeric character, press the . [DECIMAL] key and use the ASCII characters listed in Table 8-2. When entering alphanumeric characters using the ASCII codes, the Unit Weight display will briefly show the code you enter from the ASCII table, followed by the character that will be stored. The PCS

32 DC-788 Operation Manual

display will show the field that the data is being entered for.

Once the display of this character clears, the scale is ready to accept your next ASCII code.

NOTE: If you enter an Item Code that has already been stored in memory, the scale will ask you if you want to clear the stored

data associated with that Item Code. You can press the CLEAR key to erase the existing data and reprogram that Item Code, or press the

MODE key to return to the Programming screen and enter a new Item Code.

To store the Item Code and go on to program the tare weight, press the CODE/IN-OUT key.

3. Enter the tare weight value (refer to Section 5.4). The tare weight is limited to 5 digits plus the decimal symbol. This can be done by placing the bin, box or container on the platform and pressing the TA R E key or by digital entry . Note that if you enter a tare weight here to be associated in memory with this Item Code, when you recall an Item Code this stored Tare Weight will override any Tare Weight you have digitally entered into the scale or entered using the TARE key.

4. Enter Unit Weight (refer to Section 5.5). The unit weight is limited to 5 digits plus the decimal symbol. This can be done by sampling if the unit weight is unknown or by digital entry if known. Press the * PRINT key to store the unit weight.

5. To store an Inventory level, press the INVENT key. Then enter an inventory quantity of up to 8 digits. Press the * PRINT key to store the Inventory level and move to the Part Number field.

6. In the Part Number field, the scale will automatically be in alphanumeric mode. Using the ASCII characters in Table 8-2, enter a Part Number of up to 16 characters, Then press the * PRINT key to store the Part Number and move to the Part Name.

7. In the Part Name field the scale will again be automatically in alphanumeric mode. Using the ASCII characters in

Table 8-2, enter a Part Name of up to 32 characters. Then press the * PRINT key to store

the Part Name and move to the Lot Number.

8. Lot Numbers can also be alphanumeric, up to 32 characte rs. Using the ASCII characters in Table 8-2, enter a Lot Number. Then press the * PRINT key to store the Lot Number and move to Setpoint 1.

9. SPC 04, Bits 1 and 0 - Setpoin t Type determines what type of setpoint you are programming: 00: % Quantity, 01: % Weight, 10: Quantity, or 11: Weight. The setpoints are programmed by entering and storing a value (Setpoint 1) and then entering and storing a percentage or amount (Setpoint 2). Enter the value for Setpoint 1 (Ex. 100 pcs) and press the + (Plus) key to advance to Se tpoi nt 2. (For instru ction s on how to program Customer specifications, see

Table 3.1.1.)

10. Enter a value for Setpoint 2 (Ex. 85%) and press the * PRINT key to store the value.

NOTE:

•There are four types of setpoints which can be selected by setting SPC 04, Bits 1 and 0: % of Quantity (%QTY), % of Weight (%WT), Over/Under Quantity (QTY), or Over/Under Weight (WT).

• When entering weight setpoints, be sure that you enter in the weight values with decimal point and all leading and trailing zeros.

• All percentage values must be rounded to the nearest whole number, fractional percentages are not allowed.

• Setpoints involving % of quantity or weight are limited by the decimal places available on the display. For example: if Set Point value 1 specifies a Quantity of 9999999, then a Set Point value 2 of % of Quantity cannot be set for more than 100% because all 7 digits of the display are already in use.

Tabl e 6-3 below shows what to enter in each of the two set point values to program each type of set point. The alarm sounds with a rhythmic beeping at setpoint one and with a rapid beeping at setpoint two. For the Setpoint Alarm to be activated, SPC

Scale Programming 33

02: SET POINT ALARM must be set to “0: ON”. See Section 3.1.1 for instructions on how to set Customer specifications.).

% QTY QTY % WEIGHT WT

Program Set Point 1 value with . . . target quantity low value target weight low value

Program Set Point 2 value with . . . % of quantity target value % of weight target value

Table 6-3. Setpoint Configuration

Here are some examples of how the setpoints can be programmed. These examples can be adjusted to fit your application.

Setpoint Types % QTY QTY % WEIGHT WT

Setpoint 1 80 pieces (target) 50 pieces 2.0 lb (target) 1.2 lb

Setpoint 2 80% 75 pieces (target) 50% 1.5 lb (target)

Equation 80 x 80% = 64 N/A 2.0 x 50% = 1.0 N/A

Slow Beeping Occurs At 64 pieces 50 pieces 1.0 lb 1.2 lb

Rapid Beeping Occurs At 80 pieces 75 pieces 2.0 lb 1.5 lb

Table 6-4. Setpoint Examples

11. Press the + (Plus) key to finish the programming cycle for this Item Code. If you wish to program another Item Code’s information, enter a new Item Code and press the CODE/IN-OUT key.

12. When you are finished programming item codes, press the MODE key to exit the Programming Mode and return to the Weighing Mode.

6.4 View Item Code Programming in Memory

The following procedure allows you to view the information (tare weight, unit weight, inventory quantity, part number, part name, lot number and setpoint) stored in memory with an Item Code but will not change any of the information these codes.

Starting in the weighing mode, item codes can be recalled by entering the Item Code and pressing the CODE/ IN-OUT key. Numeric item codes can be entered from the numeric keypad. To enter an alphanumeric item code. press the [.] (Decimal) key to enter the ASCII mode. Enter item code number using the ASCII codes in Table 8-2.

If an Item Code not stored in memory is entered, the scale will display the error message NOT F indicating “Not Found”. Press the CLEAR key to clear the item information and return to the weighing mode to enter another Item Code.

If an Item Code existing in memory is entered, the unit weight will be displayed after the CODE/IN-OUT key is pressed. Press the SCALE key to scroll, in order, through the ICODE (Item Code), Pno (Part Number), Pname (Part Name), Lnum (Lot Number), and INVENT (Inventory Quantity) programmed with this item code. After Inventory Quantity, the display will return to the Unit Weight display.

Press the CLEAR key to escape from the review mode and return to the weighing mode.

6.5 Program a General Setpoint

You can program the DC-788 with a setpoint that will be enabled either when no Item Code is called up or when an Item Code is called up from memory that has no setpoint already associated with it in programming.

1. Press the MODE key twice to enter the Programming Mode. The scale display will show ProG.

2. SPC 04, Bits 1 and 0 - Setpoin t Type determines what type of setpoint you are programming: 00: % Quantity, 01: % We ight, 10: Quantity, or 11: Weight. (For instructions on how to program Customer specifications, see (Setpoint 1) and then entering and storing a percentage or amount (Setpoint 2). Enter the value for Setpoint 1 (Ex. 100 pcs) and press the + (Plus) key to save the change and advance to Setpoint 2.

3. Enter a value for Setpoint 2 and press the + (Plus) key to store the value and return to the Programming Mode Screen

NOTE:

Section 3.1.1.) The setpoints are programmed by entering and storing a value

34 DC-788 Operation Manual

•There are four types of setpoints which can be selected by setting SPC 04, Bits 1 and 0: % of Quantity (%QTY), % of Weight (%WT), Over/Under Quantity (QTY), or Over/Under Weight (WT).

• When entering weight setpoints, be sure that you enter in the weight values with decimal point and all leading and trailing zeros.

• All percentage values must be rounded to the nearest whole number, fractional percentages are not allowed.

Tabl e 6-5 below shows what to enter in each of the two set point values to program each type of set point. The alarm sounds with a rhythmic beeping at setpoint one and with a rapid beeping at setpoint two. For the Setpoint Alarm to be activated, SPC 02: SET POINT ALARM must be set to “0: ON”. See

% QTY QTY % WEIGHT WT

Program Set Point 1 value with . . . target quantity low value target weight low value

Program Set Point 2 value with . . . % of quantity target value % of weight target value

Section 3.1.1 for instructions on how to set Customer specifications.

Table 6-5. Setpoint Configuration

Here are some examples of how the setpoints can be programmed. These examples can be adjusted to fit your application.

Setpoint Types % QTY QTY % WEIGHT WT

Setpoint 1 80 pieces (target) 50 pieces 2.0 lb (target) 1.2 lb

Setpoint 2 80% 75 pieces (target) 50% 1.5 lb (target)

Equation 80 x 80% = 64 N/A 2.0 x 50% = 1.0 N/A

Slow Beeping Occurs At 64 pieces 50 pieces 1.0 lb 1.2 lb

Rapid Beeping Occurs At 80 pieces 75 pieces 2.0 lb 1.5 lb

Table 6-6. Setpoint Examples

4. Press the MODE key to quit the Programming Mode and return to the Weighing Mode.

6.6 Resetting the Sequence Number to Zero

The DC-788 has the ability to increment a sequence number every time a transaction is printed by pressing the + (Plus), - (Minus), or * PRINT keys. The sequence number can be reset to zero by carrying out the following

procedure:

1. From the Weighing Mode, press the MODE key twice to enter the Programming Mode.

2. While holding down the REZERO key, enter [.] [.] [7]. The display will read:

3. To reset the Sequence Number to zero, press the CLEAR key, or press the MODE key to exit without resetting the Sequence Number.

4. Press the MODE key to return to the Weighing Mode.

6.7 Programming a Temporary Lot Number, Part Number or Part Name

The Lot Number, Part Number and Part Name of an Item Code can be changed temporarily from the weighing mode without affecting the information stored in memory with that Item Code.

Scale Programming 35

6.7.1 Change the Lot Number Temporarily

1. In the Weighing Mode, enter a “1” as a command code from the keypad, then press the MODE key.

2. Using the ASCII characters in Table 8-2, enter a Lot Number of up to 32 characters to be used temporarily.

3. Store the data by pressing the * PRINT key or press the MODE or TA R E keys to return to the Weighing Mode without saving the change.

6.7.2 Change the Part Number Temporarily

1. In the Weighing Mode, enter a “2” as a command code from the keypad, then press the MODE key.

2. Using the ASCII characters in Table 8-2, enter a Part Number of up to 16 characters to be used temporarily.

3. Store the data by pressing the * PRINT key or press the MODE or TA R E keys to return to the Weighing Mode without saving the change.

6.7.3 Change the Part Name Temporarily

1. In the Weighing Mode, enter a “3” as a command code from the keypad, then press the MODE key.

2. Using the ASCII characters in Table 8-2, enter a Part Name of up to 32 characters to be used temporarily .

3. Store the data by pressing the * PRINT key or press the MODE or TA R E keys to return to the Weighing Mode without saving the change.

6.8 Delete Item Memory

The DC-788 offers you options to delete all items in memory, the values in one field across all items, or individual fields associated with a specific Item Code.

6.8.1 Delete All Item Codes in Memory

The following procedure describes the steps used to delete ALL information stored within each Item Code (tare weight, unit weight, inventory quantity, part number, part name, lot number and setpoints).

1. Press MODE key twice to enter the Programming Mode. The scale display will show ProG.

2. Press the REZERO key once. The display will show all 8’s, then return to the Programming display.

3. Hold the REZERO key while entering [.] [.] [0]

4. To delete all item codes in memory, press the CLEAR key. or press the MODE key to exit to the Programming screen without deleting the item codes. If you pressed the CLEAR key, all the item codes in memory will be deleted.

5. To exit to the weighing mode without clearing the memory, press the MODE key.

6.8.2 Delete a Specific Item Code

The following procedure describes the steps used to delete a single specific Item Code together will all of its associated information (tare weight, unit weight, inventory quantity, part number, part name, lot number and set point).

1. Press MODE key twice to enter the Programming Mode. The scale display will show ProG.

2. Enter the Item Code you wish to delete (the Item Code will appear in the Unit Weight display) and press the CODE/IN-OUT key. Numeric item codes can be entered from the numeric keypad. To enter an alphanumeric item code. press the [.] (Decimal) key to enter the ASCII mode. Enter item code number using the ASCII codes in

3. If the Item Code you entered does not exist in memory, the scale simply returns to the Weighing Mode.

Table 8-2.

36 DC-788 Operation Manual

If you have entered an existing Item Code, the display will ask you to confirm that you want to delete.

Press the CLEAR key to delete this Item Code and all of its data, or press the MODE key to cancel the deletion. If you pressed the CLEAR key, the Item Code will be deleted and the scale will return to the Programming Mode screen.

4. To return to the Weighing Mode, press the MODE key once.

6.8.3 Delete All Inventory Values from Memory

To clear all the inventory quantities associated with Item Codes in memory, perform the following steps.

1. Press MODE key twice to enter the Programming Mode. The scale display will show ProG.

2. Press the REZERO key once. The display will show all 8’s briefly, then return to the Programming screen.

3. Hold the REZERO key while entering [.] [.] [1] The display will ask you to confirm that you want to delete.

4. Press the CLEAR key to delete all inventory values in memory, or press the MODE key to cancel the deletion. If you pressed the CLEAR key, the inventory values will be deleted and the scale will return to the Programming Mode screen.

5. To return to the Weighing Mode, press the MODE key once.

6.8.4 Delete All Unit Weight Values from Memory

To clear all the unit weights associated with Item Codes in memory, perform the following steps.

1. Press MODE key twice to enter the Programming Mode. The scale display will show ProG.

2. Press the REZERO key once. The display will show all 8’s briefly, then return to the Programming screen.

3. Hold the REZERO key while entering [.] [.] [2] The display will ask you to confirm that you want to

Scale Programming 37

delete.

4. Press the CLEAR key to delete all unit weights in memory, or press the MODE key to cancel the deletion. If you pressed the CLEAR key, the unit weights will be deleted and the scale will return to the Programming Mode screen.

5. To return to the Weighing Mode, press the MODE key once.

6.8.5 Delete All Tare Weight Values From Memory

To clear all the tare weights associated with Item Codes in memory, perform the following steps.

1. Press MODE key twice to enter the Programming Mode. The scale display will show ProG.

2. Press the REZERO key once. The display will show all 8’s briefly, then return to the Programming screen.

3. Hold the REZERO key while entering [.] [.] [3] The display will ask you to confirm that you want to delete.

4. Press the CLEAR key to delete all tare weights in memory, or press the MODE key to cancel the deletion. If you pressed the CLEAR key, the tare weights will be deleted and the scale will return to the Programming Mode screen.

5. To return to the Weighing Mode, press the MODE key once.

6.8.6 Delete all Part Numbers From Memory

To clear all the part numbers associated with Item Codes in memory, perform the following steps.

1. Press MODE key twice to enter the Programming Mode. The scale display will show ProG.

2. Press the REZERO key once. The display will show all 8’s briefly, then return to the Programming screen.

3. Hold the REZERO key while entering [.] [.] [4] The display will ask you to confirm that you want to

38 DC-788 Operation Manual

delete.

4. Press the CLEAR key to delete all part numbers in memory, or press the MODE key to cancel the deletion. If you pressed the CLEAR key , the part numbers will be deleted and the scale will return to the Programming Mode screen.

5. To return to the Weighing Mode, press the MODE key once.

6.8.7 Delete All Setpoint Data in Memory

To clear all the setpoint data associated with Item Codes in memory, perform the following steps.

1. Press MODE key twice to enter the Programming Mode. The scale display will show ProG.

2. Press the REZERO key once. The display will show all 8’s briefly, then return to the Programming screen.

3. Hold the REZERO key while entering [.] [.] [5] The display will ask you to confirm that you want to delete.

4. Press the CLEAR key to delete all setpoint data in memory, or press the MODE key to cancel the deletion. If you pressed the CLEAR key, the setpoint data will be deleted and the scale will return to the Programming Mode screen.

5. To return to the Weighing Mode, press the MODE key once.

6.8.8 Delete All Part Names in Memory

To clear all the part names associated with Item Codes in memory, perform the follow i ng steps.

1. Press MODE key twice to enter the Programming Mode. The scale display will show ProG.

2. Press the REZERO key once. The display will show all 8’s briefly, then return to the Programming screen.

3. Hold the REZERO key while entering [.] [.] [6] The display will ask you to confirm that you want to

Scale Programming 39

delete.

4. Press the CLEAR key to delete all part names in memory , or press t he MODE key to cancel the deletion. If you pressed the CLEAR key, the part names will be deleted and the scale will return to the Programming Mode screen.

5. To return to the Weighing Mode, press the MODE key once.

40 DC-788 Operation Manual

7.0 External Devices: Printers, PCs and Scales

The DC-788 Counting Scale is equipped with an RS-232C po rt that allows the scale to communicate with either an external printer or a PC. SPC 05, Bit 3 and Bit 2-Function of RS-232C Interface must be set to 00: PC or 01: Printer for communication to take place (For instructions on how to program Customer specifications, see Section 3.1.1.). It also comes standard with a remote scale channel that enables you to add a second channel (See Section 7.4 for instructions on how to program the remote scale channel.)

7.1 Printer Connection

Because the DC-788 downloads label formats to external printers in some circumstances (see Section 7.2 below) external printers should be connected to the DC-788 and powered on before powering up the DC-788. The type and configuration of the printer cable needed will vary by printer. Below are the pin assignments for the connectors to the external printers that can be specified in SPC 09 - External Printer Type.

7.1.1 Zebra LP2844

9 PIN D-SUB (socket)

PIN SIGNAL

2RXD 3TXD 5 GND 7RTS 8CTS

7.1.2 DIGI GP460R

9 PIN D-SUB (socket)

PIN SIGNAL

Printer Side

DC-788 Side

9 PIN D-SUB (plug)

PIN SIGNAL

RXD 2 TXD 3 GND 5

RTS 7 CTS 8

DC-788 Side

9 PIN D-SUB (plug)

PIN SIGNAL

2RXD 3TXD 5 GND 4DTR

RXD 2 TXD 3 GND 5

RTS 7 CTS 8

External Devices: Printers, PCs and Scales 41

7.1.3 Epson TM-U210 and TM-U290, Star SP2320 and SP298

Printer Side

9 PIN D-SUB (socket)

PIN SIGNAL

2TXD 3RXD 7 GND 4RTS 5CTS

DC-788 Side

9 PIN D-SUB (plug)

PIN SIGNAL

RXD 2 TXD 3 GND 5

RTS 7 CTS 8

7.2 Printer Label Formats

SPC09 - External Printer Type sets the type of printer that is connected to the scale. This determines the format and content of the data that is transmitted to the printer. You have the following options:

7.2.1 No Printer

Set SPC09 to 0000, meaning that no printer is connected. No data will be output.

7.2.2 DIGI GP460R Label Printer

Set SPC09 to 0001. The DIGI GP460R Label Printer uses a label format native to the printer itself.

7.2.3 ZEBRA LP2844 Barcode Printer

Set SPC09 to 0010. The Zebra LP2844 Barcode Printer offers the maximum flexibility in label formatting, including a pre programmed or default format and seven user-programmable formats. Which format will be printed is set by SPC13, Bits 2, 1, and 0 - External Printer Print Format. When SPC13 is set to 000: Default Format, the DC-788 downloads the default format to the printer during power up. This default label format is named “L0”. When SPC13 is set to 001 ~ 111 Customer Formats 1-7, label formats are programmed on a PC using the printer’s application software, saved with the names “L1” to “L7”, and then downloaded to the printer.

The default label format is for a 60 x 100 mm label with Code 39 standard barcodes. Its content will v ary depending on whether you are recalling an Item Code from memory or not and whether you are printing a Total or Item Label. The default formats look like the following:

Zebra LP2844 Default Item Label While Recalling an Item Code

Prints when recalling an Item Code from memory and accumulating, then printing by pressing the + (Plus) or - (Minus) key.

Figure 7-1. Zebra Default Item Label Sample

42 DC-788 Operation Manual

Zebra LP2844 Default Total Label While Recalling an Item Code

Prints when recalling an Item Code from memory and accumulating, then printing by pressing the * PRINT key.

Figure 7-2. Zebra Default Total Label Sample

Zebra LP2844 Default Label When Not Recalling an Item Code

Prints when accumulating without recalling an Item Code from memory, then pressing the + (Plus) or - (Minus) key.

Figure 7-3. Zebra Default Label When Not Recalling Item Code Sample

T o pro gram the user-programmable free formats you will need to know the order in which the data is out put from the scale when SPC09 is set to this option:

V00 ID Code V01 Gross Weight V02 Net Weight V03 Unit Weight V04 Tare Weight V05 Quantity V06 Part Number V07 Part Name V08 Date and Time V09 Sequence Number V10 Unit Symbol V11 Inventory V12 IN/OUT Status V13 Unit Weight Base Symbol V14 Reserved V15 Reserved

Table 7-1. Output Data Order

External Devices: Printers, PCs and Scales 43

7.2.4 Epson TMU200 or Star SP2320 Tape Printer

Set SPC09 to 0011. These two tape printers use a default format which is downloaded to the printer when powering up.

The default format looks like the following:

Figure 7-4. Epson TMU200 or Star SP2320 Tape Printer Sample Default Label Format

7.2.5 Epson TM-U295 or Star SP298 Ticket Printers

Set SPC09 to 0100. These two ticket printers use the same default format as the Epson and Star tape printers in Section 7.2.4. See Figure 7-4 for a sample of the format.

7.2.6 DIGI TVP1000 Barcode Printer

Set SPC09 to 0101. This barcode printer has the sa me options and label formats as the Zebra LP2844. See Figure 7.2.3 above for the label format examples.

44 DC-788 Operation Manual

7.3 Connecting to a PC

7.3.1 Setting the Scale Specifications for Communication to a PC

The DC-788’s RS-232C port can be used to connect the scale to a PC and output the data string to the computer. The following specifications must be set for the data transfer to take place: (for more information on setting specifications, see

• SPC05, Bits 3 and 2-Function of RS-232C Interface, must be set to 00: PC.

• SPC06, Bits 3 and 2-RTS/CTS Handshaking of RS-232C must be set to 0: On or 1: Off depending on

• SPC06, Bits 1 and 0-Baud Rate of RS-232C must be set for the proper Baud Rate for your

• SPC07, Bit 3-Stop Bit of RS-232C must be set to the proper Stop Bit for your application.

• SPC07, Bit 2-Data Length of RS-232C must be set to the proper Data Length for your application.

• SPC07, Bits 1 and 0-Parity of RS-232C must be set to the proper Parity for your application.

• S PC10, Bits 3 and 2 - Interval of Time Out Error of RS-232C must be set to the proper Time Out

• SPC10, Bit 1 - Transmission Condition of RS-232C sets whether you want the data output only

7.3.2 Communication Method

SPC08-RS232C PC Protocol configures whether the data transfer to the computer is inhi bited (0000: Inhibit Data Transfer); is transmitted continuously to the computer (0001: Standard Stream Type (continuous output); is transmitted when pressing the + (Plus), - (Minus), or * PRINT keys (0010: Standard Manual Type); or is transmitted only when a command is received from the PC (0011: Standard Command Type).

Figure 3.1.1)

the application receiving the data.

application.

Interval for your application.

when the weight is stable or to be output unconditionally.

7.3.2.5 Standard Stream Data Transmission (Continuous)

Set SPC08-RS232C PC Protocol to 0001: Standard Stream Type (continuos output). The communication between the DC-788 and the computer flows as follows:

Figure 7-6. Continuous Stream Data Transmission Flowchart

External Devices: Printers, PCs and Scales 45

7.3.2.7 Standard Manual Data Transmission

Set SPC08-RS232C PC Protocol to 0010: Standard Manual Type. The communication between the DC-788 and the computer flows as follows:

Figure 7-8. Standard Manual Data Transmission Flowchart

46 DC-788 Operation Manual

7.3.2.9 Standard Command Data Transmission

Set SPC08-RS232C PC Protocol to 0011: Standard Command Type. The communication between the DC-788 and the computer flows as follows:

Figure 7-10. Standard Command Data Transmission Flowchart

External Devices: Printers, PCs and Scales 47

7.3.3 Pin Assignments

The DC-788 counting scale is connected to a PC using a 9 pin D-SUB connectors configured as follows:

Inside the DC-788

CN6 (5 pins)

1RXD 2RTS 3TXD 4CTS 5 GND

DC-788 Plug Side

CN6 (5 pins)

2RXD 7RTS 3TXD 8CTS 5 GND

PC Side

TXD

RXD

GND

If handshaking is not required for your RS-232 communication with the computer, the RTS and CTS do not need to be connected in the cable and SPC06, Bit 3 - RTS/CTS Handshaking of RS-232C can be set to 1: Off.

7.3.4 Characters That Can Be Transmitted by RS-232C

Table 7-2 shows the codes, headers, fields, and commands that can be transmitted from the RS-232C port.

Te rmination Code CR The end of the data 0DH

LF The end of a line of text 0AH

Data 0 - 9 Numeric data 30H - 39H

- (Minus) Minus sign 2DH . (Decimal) Decimal point 2EH Space Data error or empty 20H OF Overflow 4FH46H UF Underflow 55H46H

Header Codes 0 Net Weight 30H

1 Unit Weight 31H 2 Quantity 32H 3 ID Code 33H 4 Tare Weight 34H A Gross Weight 41H B Status 42H C Date and Time 43H I Total Quantity 49H K Inventory 4BH M Parts No 4DH N Parts Name 4EH V Scale Number 56H W Lot Number 57H

Table 7-2. RS-232C Codes, Headers, Fields and Commands

48 DC-788 Operation Manual

Command ENQ Enquiry 05H

ACK Acknowledge 06H NAK Unacknowledge 15H

Table 7-2. RS-232C Codes, Headers, Fields and Commands

7.3.5 RS-232C Data Transmission Formats

The basic data transmission string format output by the DC-788 is as follows (with a more detailed discussion of each element below):

Status

Flag

Weight

Condition

Flag

Status Flag:

Not Used Fixed to 1Not Used Weight

Bit 7: Not used; always set to zero. Bit 6: Fixed to one. Bit 5: Not used. Bit 4: Weight Base - 0: kg, 1: lb. Bit 3: Unit Weight Base - 0: /1000 pcs, 1: /1 pc Bit 2: Quantity Overflow - 0: when no overflow, 1: when overflow Bit 1: Net - 0: when tare subtraction not performed, 1: when tare subtraction performed Bit 0: Additional Parity Flag - 0: when additional parity flag not added in text, 1: when flag is added

Weight Condition Flag:

Not Used Fixed to 1Not Used Weight UFWeight OFNegative

CR Header

Code

ID Code CR ..... CR Additional

Parity

Base

Unit

Weight

Base

Quantity

Overflow

Net

Weight

Net Additional

Parity

Weight

Stable

Zero Sign

Bit 7: Not used; always set to zero Bit 6: Fixed to one Bit 5: Not used Bit 4: Weight UF - 0: when no weight underflow; 1: when weight underflow Bit 3: Weight OF - 0: when no weight overflow; 1: when weight overflow Bit 2: Negative Net Weight - 0: when net weight is not negative; 1: when net weight is negative Bit 1: Weight Stable - 0: when weight is stable; 1: when weight is not stable Bit 0: Zero Sign - 0: when zero sign is not set; 1: when zero sign is set.

CR:

A carriage return “CR” must appear at the end of the data for each ID Code.

Header Code:

Header codes in the RS-232C data output can be turned on and off using SPC12, Bit 1 - Header Code

in Text of RS-232C (0: No; 1: Yes). For a list of the possible header codes, please see

ID Code Data:

Table 7-2.

External Devices: Printers, PCs and Scales 49

Data about an ID Code is only transmitted if an ID Code has been recalled from the scale’s memory. The data transmitted (if present in memory and unless modified by the specifications discussed below) is as follows:

Specifications can be set to turn on and off the transmission of certain data fields in different

combinations:

Additional Parity:

If needed, additional parity can be added to the RS-232C data string. It is set in SPC10, Bit 0 Additional Parity Code in Text of RS-232C (0: No; 1: Yes). Note that if the additional parity is equal to 0DH, 0AH, or 00H, it will be automatically changed to 1DH, 1AH, or 10H.

LF:

A Line Feed (“LF”) must be added at the end as a transmission termination code.

1) ID Code

2) Set Point

3) Gross Weig ht

4) Net Weight

5) Unit Weight

6) Tare Weight

7) Quantity

8) Total Quantity

9) Status

10) Part Number

11) Part Name

12) Inventory

13) Scale Number

14) Date and Time

• SPC11, Bit 3 - Tare Weight in the Text of RS-232C

• SPC11, Bit 2 - Unit Weight in the Text of RS-232C

• SPC11, Bit 1 - Gross Weight in the Text of RS-232C

• SPC11, Bit 0 - Quantity in the Text of RS-232C

• SPC12, Bit 3 - Date & Time in the Text of RS-232C

Data Transmission Examples

Example 1:

If the following are true: Net Weight = 3.456

The data transmission will be as follows:

Status Flag: 0x42

Weight Condition Flag: 0x42

50 DC-788 Operation Manual

Tare Weight = 1.200 Unit Weight = 1.5000 (kg/1000 pcs) Quantity = 2304 Weight Status = Stable (with header codes and without additional parity)

0 1 0 0 0 0 1 0

Example 2:

If the same parameters are true as above but with a weight overflow The data transmission will be as follows:

By ASCII Code:

0x42 0x42 0x0d 0x30 0x30 0x33 0x2e 0x34 0x35 0x36 0x0d

0x34 0x30 0x31 0x2e 0x32 0x30 0x30 0x0d

0x31 0x31 0x2e 0x35 0x30 0x30 0x30 0x0d

0x32 0x30 0x30 0x30 0x32 0x33 0x30 0x34 0x0d 0x0a

0x42 0x48 0x0d 0x30 0x20 0x20 0x20 0x20 0x4f 0x46 0x0d

0x34 0x30 0x31 0x2e 0x32 0x30 0x30 0x0d

0x31 0x30 0x31 0x2e 0x35 0x30 0x30 0x0d

0x32 0x20 0x20 0x20 0x22 0x23 0x20 0x20 0x0d 0x0a

7.4 Remote Scale Channel

The Remote Scale Channel connector is on the back of the DC-788 housing.

Figure 7-11. Remote Scale Channel Connector

External Devices: Printers, PCs and Scales 51

Pin # Function Polarty Color

1 Sense (+) Orange 2 Sense (-) Blue 3 Excitation (+) Red 4 Excitation (-) White 5 Shield 6 Signal (+) Green 7 Signal (-) Yellow 8 Ground Black

Tab le 7-3. Remote Scale Channel Pin Configuration

7.4.1 Setting the Specifications for Scale 2

A scale connected to the Remote Scale Channel will be recognized by the DC-788 as Scale 2. The specifications that need to be set to configure the communication with the second scale are as follows:

• SPC 26. Bit 1 - 2nd Scale sets whether or not the Remote Scale Channel is enabled. Please note that the scale switch is not activated until the 2nd scale has been calibrated.

• SPC 35, Bit 2 - 2nd Scale Weight Unit sets whether the basic weight units for Scale 2 will be lbs or kgs.

• SPC 21, Bits 1 and 0 - Minimum Display (Scale 2) sets the display divisions displayed for Scale 2.

• SPC 24 - Selection of Resolution of 2nd Scale (Scale 2) sets the display resolution for Scale 2.

• SPC 25, Bits 2 through 0 - Weight Decimal Point Position of 2nd Scale (Scale 2) sets which digit the decimal point appears after in the Weight display.

• SPC 34 - Loadcell Sensitivities Selection mV/V (2nd Scale) sets the loadcell sensitivity range for Scale 2.

• SPC 30 - Set the Tare and Unit Weight Auto Clear conditions.

• SPC 14, Bit 3 - Clear Unit Weight When Swap Scale sets whether the Unit Weight is cleared automatically when the SCALE key is pressed to move from weighing on one scale to weighing on the other.

• S PC 14, Bit 2 - Rezero When Swap Scale sets whe ther the scale is rezeroed automatically whe n the SCALE key is pressed to move from weighing on one scale to weighing on the other

• SPC 14, Bit 1 - Auto Scale Switching sets whether or not a Unit Weight established on the built-in platform is automatically transferred to Scale 2. When Auto Scale Switching is enabled, the scale also automatically switches to Scale 2 once a stable unit weight is calculated.

For information on how to set the above Customer and Weight and Measurement specifications, see Section 3.1.

52 DC-788 Operation Manual

7.4.2 Remote Platforms Available

Platform Capacity Platform Dimensions

100.00 lbs 13" x 17" (DIGI S-SL Platform)

250.00 lbs 17" x 21" (DIGI S-TL Platform)

500.00 lbs 17" x 21" (DIGI S-TL Platform)

1500.0 lbs 24" x 28" (DIGI S-UL Platform)

2500.0 lbs 36" x 36” or 48" x 48" (DIGI Summit 3000 Platform)

5000.0 lbs 48" x 48" (DIGI Summit 3000 Platform)

10000.0 lbs 48" x 48" or 60" x 60" (DIGI Summit 3000 Platform)

25000.0 lbs 42" x 72" or 60" x 84" (DIGI Summit 3000 Platform)

50000.0 lbs 60" x 84" (DIGI Summit 3000 Platform)

NOTE: Other platform sizes are available; consult the factory or your dealer for more information. Units are selectable between lb and kg from the keyboard.

Ta ble 7-4. DC -78 8 Ext e rnal Plat form Capacities

External Devices: Printers, PCs and Scales 53

8.0 Appendix

8.1 DC-788 Specifications

Operating Conditions

• Power Source - AC117/100V

• Operating Temperature- -10°C ~ +40°C (OIML)

• Operating Humidity - 15 ~ 85% RH

• Power Consumption - 18W when using AC power

1W when using rechargeable battery

Charging Conditions (for rechargeable battery only)

• Power Source - AC117/100V

• Charge Current - 800 mA

• Charge Time - 8-10 hours

Analog Specification

• Input Sensitivity - 1mV/V

• Zero Adjust Range - 0 ± 5mV

• Zero Balance Range - 0 ± 0.5mV

• L/C Applied Voltage - DC 5V

• S peed of A/D Conversion - 30 times/second

• Internal Resolution - 1,000,000

External Connectors

• AC Receptacle

• RS-232C Interface

• 14 pin female amphenol for external loadcell

Main Components

• Microcomputer - Hitachi HD64F73687 (56K Flash) / HD64F3684 (32K Flash) /

HD6433687 (56k ROM) / HD6433686 (48K ROM) / HD6433685 (40K ROM) / HD6433684 (32K ROM) / HD6433683 (23K ROM)

• Crystal Oscillator - 10 MHz

• Display Device - Back-Lit LCD

• Loadcell Sensitivity - 1~3mV/V

8.2 DC-788 Error Message List

The DC-788’s alphanumeric display allows for detailed error messages. Use Table 8-1 below to find the error message, possible causes for the error and ways to correct the problem. If these suggestions fail to correct the situation, please contact your DIGI dealer for assistance.

Error Message Possible Causes Corrective Action

O F When the displayed weight exceeded

capacity+9d, or something is on the platter when the power is on.

U F When the displayed minus weight > = 9d. Rezero the scale or power the on/off button again.

Error0 When the communication between the main

board and the A/D board is not complete.

Error1 When the calibration operation is not correct. Repeat the calibration operation.

54 DC-788 Operation Manual

Remove the item on the platter.

Turn the power off and check the connections.

Ta ble 8-1. DC-788 Error Message List

Error Message Possible Causes Corrective Action

8 8 8 8 8 8 Happens when the scale is not stable when

the power is on. If a second scale is enabling, it must also be stable. If the second

Place the scale on a firm, flat surface. You can press [C] to ignore the second scale if it is not

stable. scale has not been calibrated, this will not apply.

Total FULL When the current total overflows the register Clear the current total.

APW When the unit weight is insufficient to display. Set the DC-788 to WT/1000 mode in SPEC 141 or

press any key to continue.

Ta ble 8-1. DC-788 Error Message List

8.3 ASCII Code Table

Code Char Code Char Code Char Code Char Code Char Code Char Code Char

“ # $

‘ ( ) *

B C D E F G H

J K

L M N

100

101

102

103

104

105

106

107

108

109

110

‘ a b c d e

f g h

j k

130

131

132

133

134

135

136

137

138

139

140

142

„

…

† ‡

‰

‹

161

162

‚

163

164

165

166

167

168

169

170

171

172

174

¡ ¢ £ ¤ ¥

ª « ¬

192

193

194

195

196

197

198

199

200

201

202

203

204

205

206

À Á Â Ã Ä Å

Ç È É Ê Ë

224

225

226

227

228

229

230

231

232

233

234

235

236

237

238

à á â ã ä å

ç è é ê ë

ì í î

/ 0 1 2 3 4 5

O P Q R S T U

Table 8-2. ASCII Code Table for Data Entry of Item Code Data

111

112

113

114

115

116

117

o p q

145

146

147

148

149

‘ ‘ “ ”

•

175

176

177

178

179

180

181

² ³ ´

207

208

209

210

211

212

213

239

Ï Ð Ñ Ò Ó Ô Õ

240

241

242

243

244

245

ï ð ñ ò ó ô õ

Appendix 55

Code Char Code Char Code Char Code Char Code Char Code Char Code Char

6 7 8 9

; < = > ?

X Y

[ \ ]

118

119

120

121

122

123

124

125

126

127 159

x y z

{ | }

150

151

152

153

154

155

156

158

—

™

–

›

ž Ÿ

182

183

184

185

186

187

188

189

190

191

· ¸ ¹ º

» ¼ ½ ¾

214

215

216

217

218

219

220

221

222

223

× Ø Ù Ú Û Ü Ý Þ

246

247

248

249

250

251

252

253

254

255

ö ÷ ø ù ú û ü ý þ ÿ

Table 8-2. ASCII Code Table for Data Entry of Item Code Data

56 DC-788 Operation Manual

9.0 DC-788 Limited Warranty

Rice Lake Weighing Systems (RLWS) warrants that all RLWS equipment and systems properly installed by a Distributor or Original Equipment Manufacturer (OEM) will operate per written specifications as confirmed by the Distributor/OEM and accepted by RLWS. All systems and components are warranted against defects in materials and workmanship for one year.

RLWS warrants that the equipment sold hereunder will conform to the current written specifications authorized by RLWS. RLWS warrants the equipment against faulty workmanship and defective materials. If any equipment fails to conform to these warranties, RLWS will, at its option, repair or replace such goods returned within the warranty period subject to the following conditions:

• Upon discovery by Buyer of such nonconformity, RLWS will be given prompt written notice with a detailed explanation of the alleged deficiencies.

• Individual electronic components returned to RLWS for warranty purposes must be packaged to prevent electrostatic discharge (ESD) damage in shipment. Packaging requirements are listed in a publication, Protecting Your Compon ents From Static Damage in Shipment, available from RLWS Equipment Return Department.

• Examination of such equipment by RLWS confirms that the nonconformity actually exists, and was not caused by accident, misuse, neglect, alteration, improper installation, improper repair or improper testing; RLWS shall be the sole judge of all alleged non-conformities.

• S uch equipment has not been modified, altered, or changed by any person other than RLWS or its duly authorized repair agents.

• RLWS will have a reasonable time to repair or replace the defective equipment. Buyer is responsible for shipping charges both ways.

• In no event will RLWS be responsible for travel time or on-location repairs, including assembly or disassembly of equipment, nor will RLWS be liable for the cost of any repairs made by others.

THESE WARRANTIES EXCLUDE ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING WITHOUT

LIMITATION WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. NEITHER

RLWS RLWS AND BUYER AGREE THAT RLWS’S SOLE AND EXCLU SIVE LIABILITY HEREUNDER IS LIMITED TO

REPAIR OR REPLACEMENT OF SUCH GOODS. IN ACCE PT ING THIS WARRANTY, THE BUYER WAIVES ANY AND ALL OTHER CLAIMS TO WARRANTY.

SHOULD THE SELLER BE OTHER THAN RLWS, THE BUYE R AGREES TO LOOK ONLY TO THE SELLER FOR

WARRANTY CLAIMS.

NO TERMS, CONDITIONS, UNDERSTANDING, OR AGREEMENTS PURPORTING TO MODIFY THE TERMS OF THIS

WARRANTY SHALL HAVE ANY LEGAL EFFECT UNLESS MADE IN WRITING AND SI GNED BY A CORPORATE OFFICER OF RLWS AND THE BUYER.

NOR DISTRIBUTOR WILL, IN ANY EVENT, BE LIABLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES.

RICE LAKE WEIGHING SYSTEMS • 230 WEST COLEMAN STREET • RICE LAKE, WISCONSIN 54868 • USA

DC-788 Limited Warranty 57

Rice Lake Digi DC-788 Operation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual