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ISHIDA BC-300 Service Manual
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ISHIDA BC-300 Service Manual

ISHIDA BC-300 Service Manual

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Retail Scale
BC-3000
SERVICE MANUAL
ISHIDA CO., LTD.
48775
Manual No. 0141A

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Summary of Contents for ISHIDA BC-300

  • Page 1 Retail Scale BC-3000 SERVICE MANUAL ISHIDA CO., LTD. 48775 Manual No. 0141A...

  • Page 2: Table Of Contents

    Contents HARDWARE SECTION INTRODUCTION ....................1-1 Main Components ....................1-1 Characteristics ......................1-2 SET UP ........................ 2-1 Parts Check ......................2-1 Installation Site Check .................... 2-1 Assembly ........................ 2-1 Set Up Sequence ....................2-2 PARTS DISASSEMBLY & REPLACEMENT ............3-1 Disassembly View and Part Names ...............
  • Page 3 SOFTWARE SECTION S1. OUTLINE OF SOFTWARE................S1-1 S1.1 Memory Map ......................S1-1 S2. PRINT FORMAT MODIFICATION ..............S2-1 S2.1 Print Format Overview ..................S2-1 S2.2 Label Format Modification Range ................. S2-1 S2.3 Format Modification Method ................. S2-1 S3. DISPLAY MODULE ................... S3-1 S3.1 Display Module Overview ..................

  • Page 4: Hardware Section

    HARDWARE SECTION...

  • Page 5: Introduction

    Chapter 1. Introduction INTRODUCTION 1.1 MAIN COMPONENTS BC-3000 • Service Manual • Rev. 1 1 - 1...

  • Page 6: Characteristics

    Chapter 1. Introduction 1.2 CHARACTERISTICS 16-Bit microprocessor The BC-3000 scale is equipped with a 16-bit microprocessor unit (V-40) which enables processing of large quantities of data. The use of E ROM ensures that important data is not lost. Resistance value and printing density settable via key entry The thermal head resistance value as well as printing density can be set by key entry.

  • Page 7: Set Up

    Chapter 2. Set Up SET UP 2.1 PARTS CHECK Open the shipping carton and confirm the following: • No parts are missing. • No parts are damaged. 2.2 INSTALLATION SITE CHECK Check that the installation site conforms to the following conditions: •...

  • Page 8: Set Up Sequence

    Chapter 2. Set Up 2.4 SET UP SEQUENCE 1. Perform RAM clear sequence. Insert the power plug into an outlet. Referring to Chapter S5 (Test Mode 2: RAM Clear), initialize all the RAM data. 2. Set print format, label length and sales mode according to user's specifications. Service manual reference sections: •...

  • Page 9: Parts Disassembly & Replacement

    Chapter 3. Parts Disassembly & Replacement PARTS DISASSEMBLY & REPLACEMENT This chapter explains the procedures for disassembling and replacing the main components. Please be careful not to drop or strongly impact fragile parts such as the display unit and circuit boards. Also, before disassembly, be sure to turn off the power switch and unplug the power cord.
  • Page 10 Chapter 3. Parts Disassembly & Replacement Part Name Key : y l c t i c t i : y l : t l * These parts vary with country. (Only the software of PWB: P-864 varies; the board itself is common to all countries.) Note: Only the main parts are listed here.

  • Page 11: Upper Cover Removal

    Chapter 3. Parts Disassembly & Replacement 3.2 UPPER COVER REMOVAL 1. Remove the weigh platter. 1) Place the scale on a level surface. Rotate the adjustment feet to level the scale if necessary. 2) Unplug the power plug from its outlet. 3) Lift off the weigh platter, keeping it horizontal.
  • Page 12 Chapter 3. Parts Disassembly & Replacement 3. Remove display unit. 1) Remove the two screws (M4) that secure the display pole to the main body. 2) Carefully lift up the display unit and disconnect connector A. 3) Remove the two screws (M4) which secure the plastic display housing to the display pole.
  • Page 13 Chapter 3. Parts Disassembly & Replacement 5. Remove the upper case. 1) Lower the side panel in the direction of the arrow. 2) Cut the seal wire, and remove the seal wire screws. 3) Remove the four screws which secure the upper case, then carefully lift the cover off the main body.

  • Page 14: Circuit Board Replacement

    Chapter 3. Parts Disassembly & Replacement 3.3 CIRCUIT BOARD REPLACEMENT 1. Remove the power unit. 1) Remove the two attachment screws from the power unit located in the lower part of the scale. 2) Remove connectors A & B. 2. Remove the main board. 1) Remove the attachment screw from the main board.

  • Page 15: Display Unit Replacement

    Chapter 3. Parts Disassembly & Replacement 3.4 DISPLAY UNIT REPLACEMENT Replace display unit. 1) Carefully remove the cover. 2) Remove the four screws which secure the display unit. CAUTION! • To avoid damage to the cover, open it slowly and carefully. •...

  • Page 16: Load Cell Replacement

    Chapter 3. Parts Disassembly & Replacement 3.5 LOAD CELL REPLACEMENT 1. Remove the upper cover. Refer to Section 3.2 of this manual for upper cover removal procedure. 2. Remove the load cell unit. 1) Remove the three screws which secure the load cell unit.

  • Page 17: Electronic Configurations

    Chapter 4. Electronic Configurations ELECTRONIC CONFIGURATIONS 4.1 CONNECTOR CONFIGURATION BC-3000 • Service Manual • Rev. 1 4 - 1...

  • Page 18: Power Unit

    Chapter 4. Electronic Configurations 4.2 POWER UNIT The power unit performs efficient voltage conversion, stabilizes low voltage, and supplies power to the various units. External View Block Diagram BC-3000 • Service Manual • Rev. 1 4 - 2...

  • Page 19: Main Board (P-864)

    Chapter 4. Electronic Configurations 4.3 MAIN BOARD (P-864) This board is equipped with a 16-bit microprocessor and is used to process scale data. The board is multi- layered, and its high precision construction is designed to reduce electrical impedance, electrical noise, and static electricity.
  • Page 20 Chapter 4. Electronic Configurations Board Functions • Control of overall unit via CPU (V40) *EPROM (Program memory) 4 Meg type (2) are installed • Process weight data from A/D board • Key data input • Price calculation • Display of weight, price and unit price data •...

  • Page 21: A/D Board (P-830)

    Chapter 4. Electronic Configurations 4.4 A/D BOARD (P-830) The A/D board converts analog weight data from the load cell into digital data, and performs automatic span control and zero compensation. External View 4.5 KEYBOARD This is a panel type keyboard. A flexible cable connects it to the main keyboard (CN9 and CN10).

  • Page 22: Display Unit (P-856)

    Chapter 4. Electronic Configurations 4.6 DISPLAY UNIT (P-856) • The BC-3000 is equipped with a 7-segment display module. • Weight, price, and unit price data are displayed. External View CAUTION! • The display modules are made of glass so care should be taken not to touch or impact the units. •...

  • Page 23: Dc/Dc Converter

    Chapter 4. Electronic Configurations 4.7 DC/DC CONVERTER The DC/DC converter transfers the voltage supplied to the display board. External View 4.8 CONNECTOR BRACKET Includes the power switch, power cord, fuse, and I NET connectors. External View BC-3000 • Service Manual • Rev. 1 4 - 7...

  • Page 24: Label Sensor

    Chapter 4. Electronic Configurations 4.9 LABEL SENSOR The label sensor utilizes a photo-interrupter to detect the gap between labels, and functions to ensure that labels are printed correctly one at a time. External View See Section 5.5 for adjustment procedures. Note: BC-3000 •...

  • Page 25: Thermal Head

    Chapter 5. Thermal Head THERMAL HEAD 5.1 OVERVIEW This 448 dot thermal head is specifically intended for use with label printers. 5.2 SPECIFICATIONS Specification Sheet l l a c t i Ω e i l Configuration BC-3000 • Service Manual • Rev. 1 5 - 1...

  • Page 26: Thermal Head Adjustment

    Chapter 5. Thermal Head 5.3 THERMAL HEAD ADJUSTMENT If the printing surface of the thermal head and the top line of the print roller are not properly aligned, then print quality across the width of the label will be poor. First, print a test label, and if the clarity of the printed characters is not satisfactory, perform adjustment according to the following procedure.

  • Page 27: Thermal Head Cleaning

    Chapter 5. Thermal Head 5.4 THERMAL HEAD CLEANING If ink, glue, or other foreign matter adheres to the print surface of the thermal head, head conductivity will be diminished, resulting in poor print quality. (1) Wipe the surface of the head clean using a soft cloth moistened with a specialized head cleaning formula.
  • Page 28 Chapter 5. Thermal Head 2. Label Sensor Adjustment Label sensing is based on detection of variations in light between labels and the inter-label gaps. This adjustment is performed to compensate for differences in light values which vary according to the type of label paper used.

  • Page 29: Troubleshooting

    Chapter 6. Troubleshooting TROUBLESHOOTING This chapter describes periodic parts replacement and troubleshooting countermeasures for error messages. 6.1 PERIODIC PARTS REPLACEMENT (MTBF*) The following parts need to be periodically replaced. *MTBF = Mean Time Between Failures 1. Thermal head • Replacement period: When label advance distance reaches 30 km. 2.

  • Page 30: Malfunction Troubleshooting Chart

    Chapter 6. Troubleshooting 6.2 MALFUNCTION TROUBLESHOOTING CHART v i t v i t c t i v i t c t i v i t v i t l l e v i t l l e " ( ) " - l l a v i t v i t...

  • Page 31: Error Messages

    Chapter 6. Troubleshooting 6.3 ERROR MESSAGES • . l l • . l l • • • • • • • • F " " T z i l • • r i f z i l • • t i l i •...
  • Page 32 Chapter 6. Troubleshooting BC-3000 • Service Manual • Rev. 1 6 - 4...

  • Page 33: Software Section

    SOFTWARE SECTION...

  • Page 34: S1 Outline Of Software

    Chapter S1. Outline of Software OUTLINE OF SOFTWARE S1.1 MEMORY MAP BC-3000 • Service Manual • Rev. 1 S1 - 1...

  • Page 35: S2 Print Format Modification

    Chapter S2. Print Format Modification PRINT FORMAT MODIFICATION Label printing area can be changed to conform to user's label specifications. S2.1 PRINT FORMAT OVERVIEW The BC-3000 has four types of default label formats. These types (shown in the table), serve as the base settings which can be modified as needed.

  • Page 36: S3 Display Module

    Chapter S3. Display Modules DISPLAY MODULE S3.1 DISPLAY MODULE OVERVIEW 1) Root menu No. 2) Submenu No. 3) Selected item's number 4) Selected parameter's number S3.2 ROOT AND SUBMENU SELECTION This section describes the procedures for selecting the root and submenus. Root Menu Selection Procedure •...

  • Page 37: S4 Setting Mode

    Chapter S4. Setting Mode SETTING MODE The Setting mode is used to input settings to conform with user requirements. Enter Setting Mode using password 6000, followed by the MODE key. S4.1 MENU SCHEMATIC Setting Mode Sub Menus Label Format Number Commodity Line 1 Label Format Field Title Print...
  • Page 38 Chapter S4. Setting Mode PLU File Departmennt 11 Registrationn Select Commodity Name Group (b11) (b11-**) Extra Message Operator Date/Time Machine Number Store Name, Address On-Line Setup Preset Key Nutrition PLU List Price Change Daily Total Total Mode Select Monthy Total (b12) (b12-**) Registration Mode...

  • Page 39: S4.2 Setting Procedures

    Chapter S4. Setting Mode S4.2 SETTING PROCEDURES This section describes setting procedures for the items in the setting menu. Label Format (b01) Label Format is used to set the label print format. For each item to be set, enter the number corresponding to the desired parameter, then press ENTER.

  • Page 40: Bar Code (B02)

    Chapter S4. Setting Mode Bar Code (b02) Bar Code is used to set bar code data. Enter the number corresponding to the desired parameters, then press ENTER. After setting, confirm that settings are correct. s t i s t i Default values: *1 UPC Barcode Flag (3 digits) *2 10 Digit Flag (4 digits)

  • Page 41: Initial Data Setting (B04)

    Chapter S4. Setting Mode Initial Data Setting (b04) Initial Data Setting is used to set reference values for PLU programming. Enter the number corresponding to the desired parameters, then press ENTER. After setting, confirm that settings are correct. t s i s t i →...

  • Page 42: Plu File (B08)

    Chapter S4. Setting Mode PLU File (b08) PLU File is used to set which PLU items can be entered. Enter a parameter number for each item, then press ENTER. After setting, confirm that settings are correct. All Item settings: 0 = Entry prohibit; 1 = Entry permit Note: BC-3000 •...

  • Page 43: Registration Select (B11)

    Chapter S4. Setting Mode Registration Select (b11) Registration Select is used to prohibit or permit items to be accessed from the Registration menu. Enter the desired parameter number for each item, then press ENTER. After setting, confirm that settings are correct.

  • Page 44: Total Mode Select (B12)

    Chapter S4. Setting Mode Total Mode Select (b12) Total Mode Select is used to set totals mode parameters (Daily, or Monthly totals). Enter the number corresponding to the desired parameter, then press ENTER. After setting, confirm that settings are correct. Note: All Item settings: 0 = Prohibit, 1 = Permit Password (b13)

  • Page 45: S5 Test Mode

    Chapter S5. Test Mode TEST MODE To access Test Mode: Turn on the power switch while holding down any key. Test Mode will be called up. S5.1 MENU SCHEMATIC Test Mode Sub Menus 1 Hardware Test A/D Check Key Check (C01) Display Check Net Check...

  • Page 46: S5.2 Test Mode Procedures

    Chapter S5. Test Mode S5.2 TEST MODE PROCEDURES Hardware Test (C01) 1. A/D Check (C01-01) This item is used to calibrate the scale. 4257 4257 A/D CONVERSION A/D CONVERSION AREA NO. VALUE INITIAL VALUE SPAN ADJUSTMENT Press ZERO Key. 1. A/D INITIAL Is initial A/D SETTING value 2000...
  • Page 47 Chapter S5. Test Mode (1) A/D Initial Value Setting A/D Initial Value Setting Press ZERO. The A/D conversion value is displayed in the unit price column. Check that the value is 2000 ±1. If it is, perform span adjustment as described below. If the value is not 2000 ±1, press ZERO again.
  • Page 48 Chapter S5. Test Mode 2. Key Check (C01-02) This item is used to verify key data. C01-02-00 Keyboard Reset Key 1) Pressing RESET returns the display to the submenu. Note: 2) If any keys do not work, check cable connections to the main board. 3) Once the membrane keyboard has been removed, it cannot be reused.
  • Page 49 Chapter S5. Test Mode 4. I NET Check (C01-04) This item is used to verify that I NET is functioning normally. NET RAM Check (C01-04-01) Press PRINT. Confirm that [PASS] is displayed. C01-04-01 PASS Loop Back Test (C01-04-02) Press PRINT. Confirm that [PASS] is displayed.

  • Page 50: Ram Clear (C02)

    Chapter S5. Test Mode RAM Clear (C02) 1. All RAM Clear (C02-01) This item is used to clear all data previously programmed in the Registration Menu. Press ZERO twice. When all RAM data C02-01 PASS has been cleared, [PASS] is displayed. 2.

  • Page 51: Thermal Head (C03)

    Chapter S5. Test Mode Thermal Head (C03) 1. Head Resistance Value (C03-01) This item is used to set the thermal head resistance value. Referring to the table below, enter the C03-01 resistance value according to the displayed data. Enter the value, then press ENTER.

  • Page 52: Sensor Check (C04)

    Chapter S5. Test Mode 3. Print Density (C03-03) This item is used to adjust the thermal head print density. Enter the density value 1 (light) - 9 (heavy), then C03-03 press ENTER. Press PRINT to print a test label to confirm correct density.

  • Page 53: Memory Check (C05)

    Chapter S5. Test Mode Memory Check (C05) This item is used to confirm the amount of total and remaining memory in kilobytes. C05-00 ROM Switch Number Select (C06) Total Memory Remaining Memory Note: ROM switches are used to change operational specifications and parameters. Press →...

  • Page 54: Label Format (C07)

    Chapter S5. Test Mode Label Format (C07) This item is used to change the label printing coordinates. 1. Enter the label format number (1 to 4), then press PLU. C07-01 0324 2. Select X or Y coordinate using → 0: X axis, 1: Y axis 0: X AXIS PRINT COORDINATE...

  • Page 55: Sales Mode (C08)

    Chapter S5. Test Mode Sales Mode (C08) 1. Sales Mode (C08-01) This item is used to set the sales mode most suitable for the user's application. Enter the number corresponding to the desired C08-01 mode, then press ENTER. SALES ENTERED MODE NUMBER BC-3000 •...

  • Page 56: Preset Function Key (C10)

    Chapter S5. Test Mode Preset Function Key (C10) Preset Function Key is used to set the functions of preset keys PF1 to PF4. Press ↓to select one of the function keys (PF1 to PF4). Enter the number corresponding to the desired function, then press ENTER.

  • Page 57: Data Send/Load (C99)

    Chapter S5. Test Mode Data Send/Load (C99) Data Send/Load is used for data communication with an IF-21FD interface unit. Preparation Before attempting to transmit data, make sure the BC-3000 is connected to the IF-21FD unit, and the scale and IF-21FD power switches are ON. 1) All IF-21FD operations are performed from the BC-3000.
  • Page 58 Chapter S5. Test Mode 1.2 Send (C99-02-02) This item is used to transmit data from the scale to an IF-21FD interface unit. Enter the number corresponding to the file(s) to be sent, then press ENTER. C99-02-02 No 0 To start transmission, press PRINT.
  • Page 59 Chapter S5. Test Mode 1.4 Verify (C99-02-04) This item is used to compare IF-21FD and BC- 3000 data. Enter the number corresponding to the file(s) to be compared, then press ENTER. C99-02-04 No 0 To execute press PRINT. e l i - - - e l i - - -...
  • Page 60 Chapter S5. Test Mode 2. INITIALIZE DISK (C99-03) Initialize Disk is used to initialize floppy disks. CAUTION! Executing Initialize Disk will delete all floppy disk data. 2.1 Delete file (C99-03-00) To delete files from the floppy disk, press CHAR DELETE. To terminate deletion in progress, press any other C99-03-00 key than...

  • Page 61: S6 If-21Fd Errors

    Chapter S6. IF-21FD Errors IF-21FD Errors Refer to the table below when an error occurs during data transfer between the BC-3000 and the IF-21FD Floppy Disk recorder. • f i r • • • • • • • • • f i r •...
  • Page 62 APPENDIX...
  • Page 63 Appendix DC/DC Converter Unit Schematic Diagram BC-3000 • Service Manual • Rev. 1 Appendix - 1...
  • Page 64 Appendix BC-3000 • Service Manual • Rev. 1 Appendix - 2...

  • Page 66: A3 Bc To Bc System Setup

    Appendix BC to BC System Setup - BC-3000 Master/Satellite Communication - (Firmware B-0209E & F-0194) 1. Overview The BC-3000 has limited communication capabilities as compared to the AC-3000 series. Important system considerations are listed here. • PLU and price changes programmed at the master scale are instantly sent to each satellite scale that is connected and set "on-line".
  • Page 67 Appendix 3. Hardware A shielded 4-conductor twisted-pair cable is used to inter-connect the scales. The cable is terminated at a 9-Pin Sub-Miniature D-Type male connector. Grounding is made at only one point - the master scale chassis. At each satellite scale the ground wires are "daisy chained". The ground cable at the last scale is not used.

  • Page 68: A4. Korean Language Firmware

    Appendix Korean/English Language Firmware (Firmware C-0840 & F-0208) Operation All operations remain the same as the standard BC-3000 except for the entry of text as described below. 1. Character Sizes available = 3 (large: 24 char. per line max., Korean and/or English) 2 (small: 24 char.
  • Page 69 Appendix Sample Labels BC-3000 • Service Manual • Rev. 1 Appendix - 8...

  • Page 70: A5. Chinese/Japanese Language Firmware

    Appendix Chinese/Japanese/English Language Firmware (Firmware C-0877 & F-0218) Operation All operations remain the same as the standard BC-3000 except for the entry of text as described below. 1. Character Sizes available = 3 (large: 24 char. per line max., Chinese, Japanese, and/or English) 2 (small: 24 char.
  • Page 71 Appendix Sample Labels BC-3000 • Service Manual • Rev. 1 Appendix - 10...

  • Page 72: A6 Label Format Worksheets

    Appendix Label Format Worksheets BC-3000 • Service Manual • Rev. 1 Appendix - 11...
  • Page 73 Appendix BC-3000 • Service Manual • Rev. 1 Appendix - 12...
  • Page 74 Appendix BC-3000 • Service Manual • Rev. 1 Appendix - 13...
  • Page 75 Appendix BC-3000 • Service Manual • Rev. 1 Appendix - 14...
  • Page 76 Appendix BC-3000 • Service Manual • Rev. 1 Appendix - 15...
  • Page 77 Appendix BC-3000 • Service Manual • Rev. 1 Appendix - 16...
  • Page 78 Appendix BC-3000 • Service Manual • Rev. 1 Appendix - 17...
  • Page 79 Appendix BC-3000 • Service Manual • Rev. 1 Appendix - 18...
  • Page 80 1. Revised Label Formats The four standard label formats have been altered. The format worksheets can be found in Appendix A6 and are posted in the Distributor section of the Rice Lake/Ishida web site at: http://www.ishidaretail.com. The four formats are: •...
  • Page 81 ISHIDA CO., LTD. 44 SANNO-CHO SHOGOIN SAKYO-KU KYOTO, 606 JAPAN PHONE: (075) 771-4141 FACSIMILE: (075) 751-1634 TELEX: 05422065 SCALES J CABLE ADD: “SCALES”KYOTO IW512P1003...