Sterling Scale 820 User Manual

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DW800/820 Operation Manual

STERLING SCALE COMPANY

DW800 HIGH ACCURACY WEIGHT INDICATOR

820 HIGH ACCURACY PIECE COUNTER

USERS MANUAL

AND
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DW800/820 Operation Manual

Table of Contents

Pages

INSTALLATION-------------------------------------------------------------------------------------------------------1 - 4

Unpacking/Inspecting 1 Load Cell Wiring 2 Universal Bracket 3 880/820 Assembly Drawing 3 Installing the Platter Assembly 2 Connecting External Power Supply 2 Jumper Settings 4

OPERATION-----------------------------------------------------------------------------------------------------------5 - 6

Weighing Operation 5 Weigh Keys 5 Counting Operations 6 Count Keys 6

PARAMETER SETUP AND CALIBRATION------------------------------------------------------------------7 - 10

Parameter Setup 7 Parameter List with Parameter Explanation 7 - 9 Calibration Setup 9-10

PRINTERS--------------------------------------------------------------------------------------------------------------11

Ticket and Tape Printer Driver 11 Model 795 and 895 Printer Driver 11 Model LD-2 Printer Driver 11

COMMUNICATION------------------------------------------------------------------------------------------------- 12 - 16

RS-232 Serial Interface 12 RS-232 Connector 12 Output Protocol 12 Computer Output Format 143 Scoreboard Output Format 14 Remote Control Codes 14 External Zero Switch 14

SPECIFICATIONS--------------------------------------------------------------------------------------------------15 - 16

WARRANY INFORMATION--------------------------------------------------------------------------------------17

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DW800/820 Operation Manual

PLEASE READ BEFORE ASSEMBLY INSTALLATION

Unpacking and Inspecting

Unpacking and Inspecting
1. Upon receipt of the shipment, check for any shipping damage. If there is damage then report it to your shipping carrier immediately.
2. Carefully unpack all contents from the shipment.
3. Save all shipping material in case contents require transporting at a later date.
4. The content of the shipment should include the following:
Qty: Item:
1 Instrument with options installed. 1 External power supply if desk mount or NEMA 1 enclosure is provided. 1 Instruction sheet. 1 Hardware kit.
If any of the above items are missing, contact your dealer immediately.

Assembly

The instrumentation is shipped fully assembled. If the unit shipped to you is a desk mount indicator, it contains a built-in scale and connecting the load cell is not necessary. If you received a wall mount, a stainless steel or a standard enclosure the load cell may need to be connected.

Connecting Load Cell

1. Disconnect power to the indicator.
2. Set the unit on a flat surface, open unit and locate “P4” on the lower part of the board.
3. Feed the load cell cable through the strain relief on the left.
4. Connect the load cell cable to the load cell interface connector, “P4” on the circuit board.
5. Verify that jumpers “J2 and ”J3” are installed on the circuit board.
INSTALLATION
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DW800/820 Operation Manual
Pin Name Description
1 +EX + Excitation voltage (+10 VDC) 2 +SN(+EX2) + Sense line 3 +SG + Signal line 4 -SG - Signal line 5 -SN(-EX2) - Sense line 6 -EX - Excitation voltage (GND) 7 SHD Shield 8 +SG2 Do not connect 9 -SG2 Do not connect
The load cell interface connector is “P4” on the circuit board,
located in the lower left hand corner.

Connecting External Power Supply

NEMA 1 enclosures are supplied with a transformer power supply, which plugs into the wall.
Power Required – 117 VAC +/- 10 VAC, 60 Hz
NEMA 12 and NEMA 4 enclosures are supplied with a 6’ power cord with a standard 3-prong connector. Power Required – 117 VAC +/- 10 VAC, 60 Hz.
Desk enclosures are supplied with a transformer power supply, which plugs into the back of the instrument and the transformer plugs into the wall.
Power Required – 117 VAC +/- 10 VAC, 60 Hz
Mounting brackets are supplied with a NEMA 1 standard and NEMA 4 stainless steel enclosures.
(See diagram on the next page for proper positioning)

INSTALLATION

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DW800/820 Operation Manual

Desktop Enclosure Assembly Drawing

INSTALLATION
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DW800/820 Operation Manual

Jumper Settings

In order for the 800/820 to operate as desired hardware, Jumpers must be set properly. Most of the jumper setting’s are set correctly at the factory and never need to be altered, but occasionally there is a need to alter a jumper setting, therefore they are shown below
Jumper List
Number Name Setting Description
J1 Back light On Back light on
Off Back light off
J2* Load Cell Sense (+) On Not using load cell sense wires (+)
Off Using load cell sense wires (+)
J3* Load Cell Sense (-) On Not using load cell sense wires (-)
Off Using load cell sense wires (-)
J4* EPROM 256 Use 27C256 EPROM
512 Use 27C512 EPROM
J5 Ground On Chassis ground tied to digital ground
Off Chassis ground not tied to digital ground
J6 RAM 2K Use 2K RAM
8K Use 8K RAM J7 Not available J8 NTEP/CTS NTEP Enable NTEP operation
CTS Enable CTS flow control J9 RAM 8K Use 8K RAM
32K Use 32K RAM
*NOTE: Jumpers J2 and is J8 must both be either connected or disconnected to avoid
improper weighing and/or possible damage to the indicator.
INSTALLATION
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DW800/820 Operation Manual
Weighing Operation
Weigh Keys: During weighing operations the keys are used as follows:
The ZERO key is used to return the scale to the center of zero.
The TARE key is used to tare the weight on the scale. Place the empty container on the scale and then press the TARE key. The display will indicate the new weight.
The PRINT key is used to print a weigh ticket.
The GROSS/NET key is used to change the displayed weight from Gross Wt. (tare + net = gross) to the Net Wt. (gross – tare = net).
The UNITS key is used to switch between weights, units, lbs., kg., grams.
OPERATION
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DW800/820 Operation Manual
Counting Operation
The Counting Operation cannot be accessed, if the NTEP parameter is set to True (see parameter setup) or the Units of Weight parameter is set to LB/KG, LB/G, KG/G, or ALL. The Count Operation is started by pressing and holding the UNIT key. The indicator will toggle thru all allowable sample sizes, starting with the current sample size. When the desired sample size is displayed release the UNIT key. The indicator will sample the pieces and display the count.
Count Key Operation: During counting operations the key are used as follows:
The ZERO key is used to zero the scale.
The TARE key is used to tare the weight on the scale. Place the empty container on the scale and then press the TARE key. The display will indicate the new weight.
The PRINT key is used to print a weight ticket.
The GROSS/NET key is used to change the displayed weight from Gross Wt. (tare + net = gross) to the Net Wt. (gross – tare = net).
The UNITS key is used to switch count and weigh operation. If held down the count display will show the average piece weight.
OPERATION
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DW800/820 Operation Manual
Parameter Setup Operation
Parameter Setup may be accessed using the following method:
1. From the Weigh Mode press and hold the GROSS/NET key. The DW800/820 displays
“GRSNET” to signify that the GROSS/NET key has been pressed. After approximately 3 seconds the indicator displays “PARAMS” at which time the key may be released.
NOTE: Jumper J8 must be removed from the NTEP position, if NTEP is being utilized, before
access to Parameter Setup is allowed.
2. Once access is allowed to Parameter Setup, the NTEP F parameter
is displayed.
NOTE: NTEP value should always be “F”, unless you are using the NTEP standards.
3. Press the PRINT key to select the desired parameter.
4. Press the TARE key to select the value for the currently selected
parameter.
5. Press the PRINT key to save the currently selected parameter.
6. Repeat steps 3 thru 5 until parameters are set as desired.
7. Press the GROSS/NET key or RESET key to exit Parameter Setup.
Parameter List
Name Values Description
NTEP F If NTEP operation not required
T If NTEP operation required FCAL F If not calibrating and/or configuring indicator (Calibration) T if calibrating and/or configuring indicator
NOTE: If True then the DW800/820 will start the calibration routine
PCT 0 Minimum load % disabled (% of loading) 0.2 If minimum is .2% of full scale capacity
0.5 If minimum is .5% of full scale capacity 1 If minimum is 1% of full scale capacity
NOTE: The value is the minimum weight allowed for parts counting
MSQ 1 Allows any number of samples (Minimum 2 2 samples required sample 5 5 samples required quantity) 10 10 samples required 20 20 samples required NOTE: The value is the minimum number of samples allowed for an entered sample size.
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PARAMETER SETUP AND CALIBRATION
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Name Values Description
ZT 0 Zero tracking disabled (Zero Tracking) 0.2 Zero tracking at ± 0.2 graduations
0.6 Zero tracking at ± 0.6 graduations 1 Zero tracking at ± 1 graduations
3 Zero tracking at ± 3 graduations
NOTE: This scale will be re-zeroed within the chosen graduation DA OFF Digital averaging disabled (Fast display update)
(Digital Average LOW Digital averaging at low (Normal setting for counting/weighing)
MED Digital averaging at medium Counting/weighing moderate vibrations) HI Digital averaging at high (Counting and/weighing
heavy vibrations) ZR 1.5 Zero range at 1.5 percent of full scale
(Zero Range) 100 Zero range at 100 percent of full scale U LB. Pounds only
(Units) KG Kilograms only G Grams only LB/KG Pounds to Kilogram conversion, counting operation is disabled LB/G Pounds to Grams conversion, counting operation is disabled KG/G Kilogram to Gram conversion, counting operation is disabled ALL Pounds, Kilogram, Grams conversion counting operation is disabled
MB 0 Motion band disabled (Not recommended for normal operations) (Motion Band) 0.1 Motion band at 0.1 graduations (Most sensitive setting counting)
0.2 Motion band at 0.2 graduations (Counting/weighing with printer
0.3 Motion band at 0.3 graduations (Counting/weighing with printer)
0.4 Motion band at 0.4 graduations (Standard setting)
0.5 Motion band at 0.5 graduations
0.6 Motion band at 0.6 graduations
0.7 Motion band at 0.7 graduations
0.8 Motion band at 0.8 graduations
0.9 Motion band at 0.9 graduations (Least sensitive)
1.0 Motion band at 1.0 graduations (Least sensitive) OF CMP Computer output format (See Data Interface Section)
(Output Format) SCB Scoreboard output format (See Data Interface Section) 290 Output format for 290 and 695 printers (See Printer Section) 795 Output format for 795 printers * (See Printer Section)
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LD2 Output format for LD2 printers *(See Printer Section)
PARAMETERS SETUP AND CALIBRATION
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Name Values Description
CO F On demand output with PRINT key (Continuous Output) T Continuous output of data. Typically used for computers
or scoreboards RD 232 Serial interface is RS-232 (standard) (Interface) or 20 mA Current Loop (optional) 422 Serial interface is RS-422 (optional) 485 Serial interface is RS-485 (optional)
B 150 Baud rate at 150 bits per second (Baud Rate) 300 Baud rate at 300 bits per second 600 Baud rate at 600 bits per second 1200 Baud rate at 1,200 bits per second 24000 Baud rate at 2,400 bits per second 48000 Baud rate at 4,800 bits per second 9600 Baud rate at 9,600 bits per second 19200 Baud rate at 19,200 bits per second
P NONE Parity disabled (Parity) ODD Parity set for odd EVEN Parity set for even
DBIT 7 Data bits at 7 bits (Data Bits) 8 Data bits at 8 bits
FC F If not using flow control (Flow Control) T If using flow control
STTN F If a station number is not required (Station) T If a station number is required (Choose station 1 – 99)
SN F If the serial number does not need to be changed (Serial Number) T If the serial number must be changed (Incremented number for the output)
TIME F If not setting the time and date (Option) T If setting the time and date
LOCK F If not locking keyboard access to parameters (Parameter Lockout) T If locking keyboard access to parameters
Used in conjunction with Jumper J8 on the 800 - 820 boards
DR F Dual Range is disabled (Dual Range) T Dual Range is enabled
Calibration Setup Operation
1. From the Weigh Mode press and hold the GROSS/NET key. The
DW800/820
displays “GRSNET” to signify that the GROSS/NET key has been pressed. After approximately 5 seconds the indicator displays “PARAMS”, at which time the key may be released.
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2. Once access is allowed to Parameter Setup, the NTEP parameter, along with its current value is displayed.
NOTE: NTEP should always be set to F, unless used. Press the Print Key to move to the next
parameter.
PARAMETER SETUP AND CALIBRATION
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3. Press the PRINT key or ZERO key to select, FCAL, the scale calibration and configuration parameter.
4. Next parameter “FCAL F” change to “FCAL T” using the TARE key. Press the PRINT key to enter the Scale Calibration and Configuration mode.
5. The display shows the current capacity of the scale (Example “C00100”). The capacity may be changed by using the UNITS, TARE, and ZERO and then press the PRINT key.
6. The display shows the current graduation size (GR). The graduation size is changed by pressing the TARE key until the desired value is selected. When the desired graduation size is selected press the PRINT key.
7. The display shows the current graduation size (U). Select the units to be used for calibrating
with the TARE key. When the desired calibration unit type is selected, press the PRINT key.
8. The display shows “CAL F”. Select “CAL T” using the TARE key. Press the PRINT key
to begin calibrating.
9. The display will repeatedly flash “CLEAR” and “SCALE”.
NOTE: Make sure there is no weight applied at this time. When the scale is clear press the
PRINT key.
10. The display shows “STEP A8”. The indicator will count down to “STEP A0” and then display one of the following messages: “ENT LB”, “ENT KG”, or “ENT G”. Lightly Press the PRINT key to show you the last amount of weight used to calibrate the indicator.
11. The indicator prompts for the calibration weight. The display shows the current calibration weight. Use the ZERO, TARE, and UNITS keys to select the desired calibration weight. Once the desired calibration weight is entered, place that weight on the scale and press the PRINT key.
12. The display shows “STEP B8”. The indicator will count down to “STEP BO” .
13. The indicator is now at the Fine Span Adjust parameter, “SPN 00”.
14. Hit the GROSS/NET key twice to exit parameter setup.
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PARAMETER SETUP AND CALIBRATION
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Printer Drivers
The DW800/820 can be provided with the following optional print drivers. Each driver is programmed specifically for each printer and will not work with any other printer.
Only the computer and scoreboard outputs are available with any DW800/820 shipped without a printer.
Ticket and Tape Printer Driver
DW800/820 Program Revision 4.21 – Ticket and Tape Printer Format - Part No. 9500
TIME 10:58 AM Output if time and date option installed DATE 07-24-98 Output if time and date option installed GROSS WT. 1.018 lb. * TARE WT. 0.018 lb. *Output if a tare weight is entered NET WT. 1.000 lb. *Output if a tare weight is entered QUANTITY 10 pcs. *Output if in Count Mode
DW800/820 Program Revision 4.22 – Battery Operated Tape Printer Format - Part No. 8951
TIME 10:58 AM Output if time and date option installed DATE 07-24-98 Output if time and date option installed GROSS WT. 1.018 lb. TARE WT. 0.018 lb. *Output if a tare weight is entered NET WT. 1.000 lb. *Output if a tare weight is entered QUANTITY 10 pcs. *Output if in Count Mode
DW800/820 Program Revision 4.23 – LD-2 Thermal Label Printer Format - Part No. 9504
TIME 10:58 AM Output if time and date option installed DATE 07-24-98 Output if time and date option installed GROSS WT. 1.018 lb. TARE WT. 0.018 lb. *Output if a tare weight is entered NET WT. 1.000 lb. *Output if a tare weight is entered QUANTITY 10 pcs. *Output if in Count Mode
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DW800/820 Operation Manual
PRINTERS
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Serial Interface
The DW800/820 has the capability of using one of the following serial interface: RS-232, RS-422, RS-485, and 20 mA Current Loop. These serial interfaces allow the indicator to be connected to many different types of serial devices such as printers, computers, and scoreboards. The standard DW800/820 is equipped with the most common of the serial interfaces, RS-232.
Output Protocol Format
Baud Rate 150 to 19, 200 Parameter Start Bits 1 Fixed Date Bits 7 or 8 Parameter Parity None, Odd, or Even Parameter Stop Bits 1 Fixed
The format of the serial data is controlled using the following parameters: Baud Rate, Parity, and Data Bits.
RS-232
The RS-232 interface is the most commonly used of all serial interfaces and is standard on the DW800/820. It is used in point-to-point communications where the transmission line is less than 50 feet. If the RS-232 interface is to be used then the Serial interface parameter must be set to RS-232 (See Parameter Setup).
Flow control may be used with this interface to regulate the flow of data between the DW800/820 and another serial device. To enable flow control, set the Flow Control parameter to True (See Parameter Setup) and Jumper J8 to CTS. The Clear To Send (CTS) input must then be connected to the compatible flow control output, usually Data Terminal Ready (DTR) or Request To Send (RTS). The DW800/820 will now only transmit when CTS is high.
RS-232 Connector Pin Assignments
Pin Name Description
01 ZERO External zero 02 Do not connect 03 Do not connect 04 RxD Receive data (input) 05 TxD Transmit data (output) 06 DTR Data Terminal Ready (output) 07 CTS Clear To Send (input)
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DW800/820 Operation Manual
08 +5VDC +5 Volt DC power 09 GND Digital ground 10 SHIELD Shield The RS-232 interface connector is P3 on the circuit board
COMMUNICATIONS
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Output Formats
The DW800/820 is capable of transmitting one of the following formats: Optional Printer Output Format (See Printer Section), Computer Output Format, and Scoreboard Output Format. A format may be transmitted either on demand or continuously (See Parameter Setup). Motion is tested only when transmitting the Printer Output Format on demand.
Computer Output Format
If the Computer Output Format is to be used then the Output Format parameter must be set to CMP (See Parameter Setup).
The Computer Output Format is as follows:
STX Mode Value Pad Status Units CR LF
Name Characters Description
STX 1 ASCII Start of Text (02 Hex). Mode 1 “G” if gross weight mode
1 “N” if net weight mode
1 “Q” if quantity (count) mode Value 7 Displayed weight or quantity Pad 1 ASCII Space (20 Hex) Status 1
1 Units 3
3
3
4
“M” if scale is in motion “0” if scale is in overload. ASCII Space (20 Hex) if scale is stable
“lb.” if in weight mode and unit is pounds. “kg” if in weight mode and unit is kilograms. “g” if in weight mode and unit is grams, “pcs” if in count mode.
CR 1 ASCII Carriage Return (OD Hex)
LF 1 ASCII Line Feed (OA Hex)
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COMMUNICATION
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Scoreboard Output Format
If the Scoreboard Output Format is to be used then the Output Format parameter must be set to SCB (See Parameter Setup).
The Scoreboard Output Format is as follows: Value CR LF
Name Characters Description
Value 7 Displayed weight or quantity CR 1 ASCII Carriage Return (0D Hex) LF 1 ASCII Line Feed (0A Hex)
External Control
External Keys
The serial interface allows an external device to transmit data (external keys) to the DW800/820, which mimic the keypad operation completely.
External Key ASCII Value Hex Value Decimal Value
ZERO a 81 097 PRINT b 62 098 UNITS c 63 099 TARE d 64 100 GROSS/NET 9 67 103 PARAMETERS z 7A 122
External Switch
An external switch is a hardware switch used to mimic a keypad operation completely. The DW800/820 allows for only the ZERO external switch.
A momentary, normally open, switch must be connected between “Pin 01” and “Pin 09”. External ZERO is activated when the switch is closed. To avoid erratic operation the switch cable must be less than 10 feet.
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COMMUNICATION
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Specifications
DW800 Physical Specifications
Material: NEMA 1 Enclosure – ABS DFA/R with EMI/RFI shielding
NEMA 4 Enclosure – Stainless steel NEMA 12 Enclosure – Mild steel NEMA 7 Enclosure – Cast aluminum
Dimensions: NEMA 1 Enclosure – 6.25” H x 9.5” W x 1.25” D
NEMA 4 Enclosure – 6.25”H x 9.5”W x 2.50”D NEMA 12 Enclosure – 8.0”H x 10.0”W x 4.0”D NEMA 7 Enclosure – 14”W x 14”W x 6.00”D
Weight: NEMA 1 Enclosure – 3 lbs.
NEMA 4 Enclosure – 7 lbs NEMA 12 Enclosure – 10 lbs. NEMA 7 Enclosure – 50 lbs
Power Requirement: NEMA 1 Enclosure – 12VDC, 500 mA
NEMA 4 Enclosure – 117 VAC ± 10VAC, 60 Hz NEMA 12 Enclosure – 117 VAC ± 10VAC, 60Hz NEMA 7 Enclosure – 117 VAC ± 10VAC, 60 Hz
820 Physical Specifications
Dimensions: 12.375” W x 16.55” D x 3.5” H
Power Requirements: 117 VAC ± 10 VAC, 60 Hz
Operating Temperature: -19°C (14 F) to 40° C (104 F)
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DW800/820 Operation Manual
SPECIFICATIONS
Operational
Internal Counts: 18,777,215 Display Counts: 10,000 recommended (50,000 maximum) Display Update Rate: 10 times per second Input Sensitivity: 0.5uV per graduation Linearity: 0.01% of full scale Overload Capacity: 105% of full scale Load Cell Excitation: 10VDC (9,350 ohm load cells or 16,750 ohm load cells)
Calibration
Method: Digital calibration Range: 0.5 mV/V to 3.0 mV/V Capacity: 2 to 500,000 lb., kg., or g
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Display
Type: 6, 14 segment LCD with 20 annuniciators Enunciators: SCALE 1, 2, 3, 4 GROSS, NET, TARE k, g, lb., pcs,
Backlight: Yellow/Green LED
Serial Interface
Type: RS-232 (bi-directional, full-duplex)
Baud Rate: Selectable from 150 to 19,200 bits per second Parity: Selectable from none, odd, or even Data Bits: Selectable from 7 or 8 bits Start Bits 1 Stop Bits 1 Flow Control Hardware flow control available for RS-232 only
Options
SP3, SP2, SP1, LO BAT, M, -, ID,and ->0<-
*RS-422 (bi-directional, half-duplex) *RS-485 (bi-directional, half-duplex) *20mA Current Loop (transmit only)
* Battery Operation
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* Time and Date * RS-422, RS-485, or 20 mA Current Loop * 4-20 mA or 0 – 10 VDC Analog Output * 220 VAC, 50 Hz Operation
SPECIFICATIONS
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WARRANTY
Information
Sterling Scale Company warrants that the DW800/820 shall be free of defects in material and workmanship for a period of one (1) year from date of shipment.
Sterling Scale Company will repair or replace, at its discretion, free of charge (exclusive of shipping costs), any equipment covered by this warranty.
This warranty DOES NOT apply if:
1. The DW 800/820 has been repaired or modified by anyone other than Sterling Scale Company, if in their judgment such repair or modification has detrimentally effected the performance or reliability of the product.
2. The DW800/820 has been improperly installed or not setup in accordance with the instructions provided herein.
3. The DW800/820 has been mishandled, abused, or in the judgment of Sterling Scale Company has been exposed to an environment for which the product was not designed.
This warranty constitutes Sterling Scale Company’s exclusive warranty, there being no other warranties, expressed or implied, including any warranty of merchantability or fitness for a particular purpose.
Sterling Scale Company is not liable for any consequential damages.
Sterling Scale Company reserves exclusive rights to warranty repair determination.
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WARRANTY
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FCC NOTICE
This equipment generates, uses, and can radiate radio frequency energy. If this equipment is not installed and used in accordance with the instruction manual, it may cause interference to radio communications. This unit has been type tested and found to comply with the limits for a Class A computing device pursuant to Subpart J of Part 15 of FCC Rules, which are designed to provide reasonable protection against such interference in a commercial environment. Operation of this equipment in a residential area is likely to cause interference, in which case the user, at his own expense: will be required to take whatever measures may be required to correct the interference.
DISCLAIMER
All rights reserved. Reproduction or use, without express permission, of editorial or pictorial content, in any manner, is strictly prohibited. No patent liability is assumed with respect to the use of the information contained herein. While every precaution has been taken in the preparation of this manual, we assume no responsibility for errors or omissions. Neither is any liability assumed for damages resulting from the use of the information contained herein. All information has been checked for accuracy and ease of application. Since success and safety in applying the equipment depend upon individual accuracy, skill and caution, we are not able to guarantee the results of any procedure contained herein. Nor can we assume responsibility for damage to property or injury to persons engaging from the procedures. Persons engaging from the procedures do so entirely at their own risk.
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