ISHIDA AC-4000 Series User manual

IMPORTANT

•Do not carry out installation, operation, service, or

maintenance until thoroughly understanding the contents

of this manual.

•Keep this manual available at all times for installation,

operation, service, and maintenance.

Manual No. 0181B

SERVICE MANUAL

System Scale Printer

You can help improve this manual by calling attention to errors and by recommending improvements.

Please convey your comments to the nearest Ishida Company regional representative. Thank you!

No part of this manual may be reproduced in any form, by mimeograph or any other means, without

written permission of the publisher.

To Provide Service Safely

In order to properly conduct maintenance and prevent the occurrence of accidents, be sure to perform

the operations below.

•Turn OFF the power switch, and unplug the power cord from the outlet.

•Keep the area around the machine clean.

Particularly with disassembly, if the power is switched ON when an object such as a detached screw is

left inside the main unit, serious damage may occur.

•Do not pull directly on the cords of the internal wiring. Doing so may result in broken wires or poor

connections. Always grasp the connector when plugging/unplugging a cord.

Pay particular attention to the thermal head cable.

•The thermal head and print head can be easily scratched, so be careful when cleaning them.

•Cautions are explained for each point of assembly and adjustment. To ensure proper operation, read

this manual thoroughly so that you fully understand it.

Precautions

i AC-4000 Service Manual No.0181B

SERVICE SAFETY

For correct maintenance, and to prevent accidents, please adhere to the following items dur-

ing service.

•Ensure that the power switch is OFF before any maintenance work and remove the power cable

from the main power outlet.

•Keep the machine surroundings clean and tidy. Take additional care, especially during disassembly,

not to leave screws etc. inside the machine as this may lead to serious injury.

•Do not pull internal wiring cables as cable breaks, poor contact, etc. may take place. Always hold

the connector end before removing. Take special care with thermal head cable, where poor contact

may lead to damage.

•Take care when cleaning thermal heads and print heads, as these are easily damaged.

•There are precautions relating to assembly and adjustment parts. Read and understand the manual

thoroughly before attempting maintenance.

SAFETY CONSIDERATIONS

For safe operation, the following safety considerations must be observed.

Grounding

This machine requires protective grounding for safe operation. To avoid potential shock hazards, a

protective grounding conductor for the machine must be securely connected to the main grounding

provision by qualified service personnel.

Do not remove covers or enclosures

To avoid personal injury and shock, do not open or remove any covers or enclosures of the machine

unless specified in the manual.

Do not perform unspecified maintenance

For your personal safety, do not perform any maintenance procedures which are not specified in the

manual.

Disconnect power supply before servicing

To ensure your personal safety, disconnect the power supply before servicing.

Precautions

AC-4000 Service Manual No. 0181B ii

When cleaning the machine, only use a

soft dry cloth or a cloth wetted with a

neutral cleanser.

Never use thinner or other volatile

liquids.

 Do not drop or apply a strong shock to the scale.

 Do not allow any liquids to come into con-

tact with the machine.

 Do not disassemble the machine.

Power Supply

•Use the appropirate voltage after referring to the specification

plate located on the machine.

•Use a dedicated power source.

(Voltage fluctuation may cause the machine to malfunction)

Precautions

iii AC-4000 Service Manual No.0181B

Avoid the following areas when installing the machine

Level adjustment

GAlways ensure that the machine is level. If the machine is not level, weighing may not be accurate.

GAdjust the machine to a level position using the four level adjustment feet located on the buttom of

the machine, until the bubble is completely centered in the round level indicator.

GAreas subject to high temperatures or high

humidity

GAreas exposed to direct sunlight

GAreas where water or other liquids are

easily spilled on the machine

GAreas subject to a lot of dust or dirt

GAreas with large voltage fluctuations

GAreas subject to excissive vibration or

unstable surfaces

GAreas exposed to direct cold air

GAreas subject to low temperatures

GAreas where the scale is not level

Contents

AC-4000 Service Manual No. 0181B iv

Contents

CHAPTER 1 OVERVIEW

1.1 Appearance and Name of Each Part .................................................................................. 1-1

1.2 Display ................................................................................................................................. 1-1

1.4 Printer ................................................................................................................................. 1-2

1.3 Key Sheet ............................................................................................................................ 1-2

1.5 Main Specifications .............................................................................................................. 1-3

1.6 Exploded Drawing ................................................................................................................ 1-4

CHAPTER 2 INSTALLATION

2.1 Packed Goods ..................................................................................................................... 2-1

2.2 Installation Environment ...................................................................................................... 2-2

2.3 Assembly.............................................................................................................................. 2-2

2.4 Weigh Platter Installation ..................................................................................................... 2-3

2.5 Label Loading ...................................................................................................................... 2-3

2.7 Power Switch “ON” ............................................................................................................... 2-4

2.6 Power Cable Connection ..................................................................................................... 2-4

2.8 Customer’s Specification Setup (Initialization, Setup, and Registration)............................ 2-5

2.9 Normal Mode Display ........................................................................................................... 2-6

2.10 Label Batch Print Mode ....................................................................................................... 2-7

2.10.1 Basic operation ....................................................................................................... 2-7

2.10.2 Additional functions ................................................................................................. 2-7

2.10.3 Label batch printing on continuous paper.............................................................. 2-8

2.11 Scroll Message Display ....................................................................................................... 2-9

2.12 Campaign Function ............................................................................................................. 2-9

CHAPTER 3 TEST MODE

3.1 Test Mode Menu List ........................................................................................................... 3-1

3.2 Test Mode Start .................................................................................................................... 3-2

3.3 Hardware Test ...................................................................................................................... 3-2

IA/D CHECK ....................................................................................................................... 3-3

IKEY CHECK ...................................................................................................................... 3-4

IDISPLAY CHECK .............................................................................................................. 3-4

IRS232C CHECK ............................................................................................................... 3-5

IAPPLICATION PROGRAM No. ......................................................................................... 3-5

IBIOS PROGRAM No. ........................................................................................................ 3-6

3.4 RAM Clear ........................................................................................................................... 3-7

ISRAM CLEAR ................................................................................................................... 3-7

ISETUP CLEAR ................................................................................................................. 3-8

ITEST DATA SET ............................................................................................................... 3-8

IAPPLICATION COPY ........................................................................................................ 3-9

IBIOS COPY....................................................................................................................... 3-9

IBOOT COPY .................................................................................................................. 3-10

Contents

v AC-4000 Service Manual No. 0181B

3.5 Printer Head ....................................................................................................................... 3-11

IRESISTANCE .................................................................................................................. 3-11

IPRINT USAGE IN km....................................................................................................... 3-12

IRESISTANCE VALUE ADJUSTMENT .............................................................................. 3-12

3.6 Label Sensor Check .......................................................................................................... 3-13

3.7 Total Memory ..................................................................................................................... 3-14

3.8 ROM Switch ....................................................................................................................... 3-15

3.9 Peel Sensor Check ............................................................................................................ 3-17

3.10 Machine Type Check ......................................................................................................... 3-18

CHAPTER 4

4.1 Setup Mode Menu ............................................................................................................... 4-1

4.2 Starting Procedure for Each Mode ...................................................................................... 4-2

4.3 Starting Procedure for Setup Mode .................................................................................... 4-2

4.4 Label Format ....................................................................................................................... 4-3

ILABEL FORMAT No.......................................................................................................... 4-3

ILABEL LENGTH + GAP .................................................................................................... 4-3

ILABEL WIDTH ................................................................................................................... 4-4

ILABEL SENSOR DISTANCE ............................................................................................. 4-4

ILABEL DIE-CUT, CONTINUOUS ....................................................................................... 4-4

ISTORE NAME, ADDRESS ................................................................................................ 4-4

IFIELD TITLE PRINT .......................................................................................................... 4-5

IPEEL SENSOR ................................................................................................................. 4-5

ITEST ITEM No. ................................................................................................................. 4-5

ITHERMAL HEAD CHECK .................................................................................................. 4-5

ISUBTOTAL LABEL FORMAT No. ..................................................................................... 4-6

ISHOP No. PRINT .............................................................................................................. 4-6

IMACHINE No. PRINT......................................................................................................... 4-6

ILABEL FORMAT EDIT ...................................................................................................... 4-7

IFORMAT No. + [PLU]........................................................................................................ 4-7

IUNIT ................................................................................................................................. 4-8

IDEFAULT PLU .................................................................................................................. 4-8

IUNIT DATA ........................................................................................................................ 4-9

INUMBER OF UNITS .......................................................................................................... 4-9

ILABEL LENGTH ................................................................................................................ 4-9

4.5 POS Code .......................................................................................................................... 4-10

IPOS FLAG 8/3 ................................................................................................................ 4-10

I10 DIGIT FLAG 8/13....................................................................................................... 4-10

IBARCODE TYPE ............................................................................................................ 4-10

IPOS TYPE ...................................................................................................................... 4-11

IITF ............................................................................................................................... 4-12

IMANUFACTURE CODE .................................................................................................. 4-12

4.6 Item Code........................................................................................................................... 4-13

IBARCODE POSITION ..................................................................................................... 4-13

IDEPARTMENT CODE..................................................................................................... 4-13

IGROUP CODE ................................................................................................................ 4-13

Contents

AC-4000 Service Manual No. 0181B vi

4.7 Default Data....................................................................................................................... 4-14

IDATA PRINT FLAG ......................................................................................................... 4-14

ISHELF LIFE .................................................................................................................... 4-14

IPACKING TIME FLAG ..................................................................................................... 4-14

IEXPIRY TIME FLAG ........................................................................................................ 4-15

IBEST BEFORE FLAG .................................................................................................... 4-15

IBEST BEFORE DATE..................................................................................................... 4-15

IUNIT TYPE ...................................................................................................................... 4-15

4.8 Total Mode Select .............................................................................................................. 4-16

IDAILY TOTAL ................................................................................................................. 4-16

IWEEKLY TOTAL ............................................................................................................. 4-16

IMONTHLY TOTAL .......................................................................................................... 4-16

IBATCH TOTAL ................................................................................................................ 4-16

4.9 Open Price ......................................................................................................................... 4-17

4.10 PLU Select ......................................................................................................................... 4-18

ISALES MODE ................................................................................................................. 4-18

IUNIT PRICE..................................................................................................................... 4-18

IMD (Mark Down) FLAG .................................................................................................. 4-18

IMD (Mark Down) PRICE ................................................................................................. 4-18

IFIXED WEIGHT ............................................................................................................... 4-19

IPCS ............................................................................................................................... 4-19

ITARE............................................................................................................................... 4-19

IDATE PRINT ................................................................................................................... 4-19

ISHELF LIFE .................................................................................................................... 4-19

IBEST BEFORE DATE FLAG .......................................................................................... 4-20

IBEST BEFORE DATE..................................................................................................... 4-20

IPACKING TIME FLAG ..................................................................................................... 4-20

IPACKING TIME DATE ..................................................................................................... 4-20

IEXPIRY TIME FLAG ........................................................................................................ 4-20

IEXPIRY TIME DATA ........................................................................................................ 4-21

IITEM CODE .................................................................................................................... 4-21

IBARCODE TYPE ............................................................................................................ 4-21

IPOS CODE TYPE ........................................................................................................... 4-21

IPOS CODE FLAG .......................................................................................................... 4-21

IPOS CODE ..................................................................................................................... 4-22

IOPEN PRICE .................................................................................................................. 4-22

ICOMMODITY MESSAGE ................................................................................................ 4-22

IINGREDIENTS MESSAGE .............................................................................................. 4-22

INIP MESSAGE ................................................................................................................ 4-22

ICOUPON MESSAGE ...................................................................................................... 4-23

ILOGO IMAGE 1 .............................................................................................................. 4-23

ILOGO IMAGE 2 .............................................................................................................. 4-23

ILABEL FORMAT No........................................................................................................ 4-23

IUPPER LIMIT .................................................................................................................. 4-23

ILOWER LIMIT ................................................................................................................. 4-24

IUNIT TYPE ...................................................................................................................... 4-24

IDEPARTMENT CODE..................................................................................................... 4-24

IGROUP CODE ................................................................................................................ 4-24

IREGISTER CODE .......................................................................................................... 4-24

ICOST PRICE .................................................................................................................. 4-25

Contents

vii AC-4000 Service Manual No. 0181B

IPOP NUMBER ................................................................................................................. 4-25

ISTORAGE MESSAGE .................................................................................................... 4-25

IADVISORY MESSAGE ................................................................................................... 4-25

4.11 System ............................................................................................................................... 4-26

ISYSTEM ......................................................................................................................... 4-26

IPLU ...............................................................................................................................4-26

ICOMMODITY NAME .......................................................................................................4-26

IPRESET KEY .................................................................................................................. 4-26

ISTORE ADDRESS .......................................................................................................... 4-26

IDATE/TIME ..................................................................................................................... 4-27

IEXTRA MESSAGE 1 ....................................................................................................... 4-27

IOPEN PLU ...................................................................................................................... 4-27

IITEM LIST ....................................................................................................................... 4-27

IRS232C COMMUNICATION ............................................................................................ 4-27

ICOUPON MESSAGE ...................................................................................................... 4-28

IINGREDIENT MESSAGE ................................................................................................ 4-28

INIP MESSAGE ................................................................................................................ 4-28

ITCP/IP COMMUNICATION .............................................................................................. 4-28

IOPERATOR NAME ......................................................................................................... 4-28

ITITLE MESSAGE ............................................................................................................ 4-29

IADVERTISEMENT MESSAGE 2 ..................................................................................... 4-29

4.12 Ethernet Setup .................................................................................................................. 4-30

IIP ADDRESS SETUP ...................................................................................................... 4-30

IGATEWAY ADDRESS SETUP ........................................................................................ 4-31

ISUBNET MASK SETUP .................................................................................................. 4-32

ISERVER ADDRESS SETUP ........................................................................................... 4-33

ILOG-IN NAME ADDRESS SETUP .................................................................................. 4-34

IPASSWORD SETUP .......................................................................................................4-34

IMAC ADDRESS SETUP .................................................................................................. 4-35

IDHCP SETUP ................................................................................................................. 4-35

INETWORK STATUS ....................................................................................................... 4-36

4.13 System Timer .....................................................................................................................4-37

4.14 Password Setup................................................................................................................. 4-38

IREGISTRATION .............................................................................................................. 4-38

ITOTAL ............................................................................................................................ 4-38

ISUBTRACTION ............................................................................................................... 4-39

ISETUP ............................................................................................................................ 4-39

4.15 Machine Number Setup ..................................................................................................... 4-40

CHAPTER 5 ELECTRICITY COMPOSITION

5.1 Block wiring diagram “P-950B” ............................................................................................ 5-1

5.2 Main Board [P-950B] ........................................................................................................... 5-2

5.3 Connector Specifications ..................................................................................................... 5-3

5.4 PK-229 (A/D board) ............................................................................................................. 5-8

5.5 Lithium Battery ..................................................................................................................... 5-8

5.6 Power Unit (LSF100 - 24S) ................................................................................................. 5-9

5.7 PK-232 (TCP/IP) ................................................................................................................ 5-10

5.8 PK-236 (Span switch) ........................................................................................................ 5-11

5.9 P-862 (Key board) ............................................................................................................. 5-11

Contents

AC-4000 Service Manual No. 0181B viii

CHAPTER 6 TROUBLESHOOTING

6.1 Error List .............................................................................................................................. 6-1

6.2 Symptom, Cause, And Measures ........................................................................................ 6-4

CHAPTER 7 PARTS REPLACEMENT

7.1 Detaching Each Part ........................................................................................................... 7-1

IDetach the weigh platter .................................................................................................. 7-1

IDetaching the platter holder ............................................................................................ 7-1

IDetaching the display unit. ............................................................................................... 7-1

IDetaching the front cover (key sheet) ............................................................................. 7-2

IDetaching the top case .................................................................................................... 7-3

7.2 Detaching Internal Parts ...................................................................................................... 7-4

IDetaching the keyboard relay board (P-862A) ............................................................... 7-4

IDetaching the key sheet .................................................................................................. 7-4

IDetaching the power supply ............................................................................................. 7-5

IDetaching the span switch (PK-236)................................................................................ 7-5

IDetaching the load cell..................................................................................................... 7-6

IDetaching the PK-229 (A/D board) .................................................................................. 7-7

IDetaching the PK-232 (TCP/IP) ....................................................................................... 7-7

IDetaching the PK-950A (Main board) .............................................................................. 7-8

IDetaching the thermal head ............................................................................................. 7-9

ICleaning the thermal head ............................................................................................. 7-10

IDetaching the display ..................................................................................................... 7-10

ICleaning the cassette sensor/peel sensor .................................................................... 7-11

IAdjusting the belt tension ............................................................................................... 7-11

7.3 Periodical Replacement Parts ........................................................................................... 7-12

Chapter 1 Overview

1-1 AC-4000 Service Manual No. 0181B

AC-4000B

AC-4000E

CHAPTER 1OVERVIEW

1.1 Appearance and Name of Each Part

1.2 Display

Customer display

Operator display

Weigh platter

Power switch

Power supply receptacle

Fuse

Key sheet

Upper surface: Operation key sheet

Lower surface: Program key sheet

Printer cassette

Chapter 1 Overview

AC-4000 Service Manual No. 0181B 1-2

1.3 Key Sheet

1.4 Printer

Roll holder

Roll stopper

Winding bobbin

U-pin

Peel shaft

Chapter 1 Overview

1-3 AC-4000 Service Manual No. 0181B

1.5 Main Specifications

Item

Weighing capacity

Minimum graduation

Weighing accuracy

Load cell

Size of main body

Weigh platter material and size

Printer

Label roll size

Label length

Sensor

Key

Display

Operating temperature

Operating humidity

Power supply

Power consumption

Weight

Memory capacity

Interface

Cash drawer

TCP/IP

LAN cable

SRAM

Content

15kg or 30lb

2g/5g or 0.005 lb/0.01 lb

1/3000 (Dual-range)

HBM made

450(W) x 420(D) x 440(H) mm

SUS430...400(W) x 250(D) mm

Backing paper width...Max. 67mm, Label width...38 to 64mm,

Effective print width...Max. 60mm, Print speed...80mm/second

Inner diameter: 40mm, Outer diameter: 100mm

30 to 175mm

Peel sensor

Membrane switch (120 keys)

Fluorescent display tube: 23 digits

(Both for customer and operator displays)

Character height: 10.1mm, 256 x 16 dots

-5 to 40°C

Main body: Max. 95% (40°C), No condensation

Printer: Max. 80% (40°C), No condensation

Varies depending on where the machine is used.

(Specified on the rating plate)

Stand-by: Approx. 40W

Operating: Approx. 100W

11kg

Standard: 1MB

Factory option: 2MB

RS232C (D-sub 9 pin)

Output: DC24V/500mA

10 baseT

Direct connection: Crossing cable

When using Hub: Straight cable

1M bytes (1,024k bytes)

SRAM mapping

1. Fixed data: Approx. 19k bytes

Approx. 1k bytes for fixed data year, print speed, and print density,

etc., and the remainder is the reserves.

2. Logo data: Approx. 56k bytes

3. SRAM file: Approx. 949k bytes

949k bytes for registration

9k bytes for file creation (940k bytes available after RAM is

cleared)

PLU, Store name/address, Extra message 1/2/3, Coupon,

Preset, Label format, Field title, and Operator

Chapter 1 Overview

AC-4000 Service Manual No. 0181B 1-4

1.6 Exploded Drawing

AC-4000

TARE kg

WEIGHT kg

UNIT PRICE $/kg TOTAL PRICE $

++

Operation panel (Key sheet)

P-950B

(Main board)

PK-229

(A/D board)

Power cord

Display

Printer cassette

Power supply

Fuse

Power switch

Module RS232C

Load cell

Top case

Platter holder

Weigh platter

Chapter 2 Installation

2-1 AC-4000 Service Manual No. 0181B

1. Stand

2. Power cable

3. Thermal head cleaner

4. Main body

5. Display

6. Weigh platter

7. Operation manual

CHAPTER 2INSTALLATION

2.1 Packed Goods

Open the packing case and check whether there are all the packed goods (machine and attachments)

and if there are any damaged parts.

Note: AC-4000 “B type” or “E type” can be identified by a description of the sticker on the case.

Chapter 2 Installation

AC-4000 Service Manual No. 0181B 2-2

AC-4000

Screw (B) (M4x8)

Screw (A) (M4x8)

Screw (A)

Display

Stand

Harness

Connector

Boss Main body

+

+ +

450mm

420mm 440mm

2.2 Installation Environment

•Install the machine on the stable and horizontal

place.

•Install the machine in the place where the liquid

such as water does not splash.

•Avoid the place where direct sunshine strikes for

a long time.

•Install the machine in the place where the influ-

ence such as the winds is not received.

• Secure the installation space enough.

2.3 Assembly

1. Run the display connector (harness) through

the stand, and fix the display and the stand

with the 4 screws (A).

2. Engage the connector with the connector on

the main body.

3. Insert the two bosses of the stand into the main

body.

4. Tighten the stand and the main body with the

2 screw (B).

Chapter 2 Installation

2-3 AC-4000 Service Manual No. 0181B

AC-4000

Weigh platter

1 Peel off the labels from the first 30 cm of the

roll.

2 Set the roll as shown in the figure below, and

turn the roll stopper clockwise so that the roll

does not come off.

3 Pass the label roll as shown in the figure below,

and fix the roll end with the U-pin.

4 Push the printer cassette to its original position.

2.4 Weigh Platter Installation

Insert the 4 pins of the weigh platter into the rubber feet on the platter holder.

2.5 Label Loading

•Pull out the printer cassette.

Roll stopper

Chapter 2 Installation

AC-4000 Service Manual No. 0181B 2-4

2.7 Power Switch “ON”

•Turn on the power switch located at the left side of

main body.

Note: Push the “O” side of the switch to urn off the

power.

AC-4000

TARE kg

WEIGHT kg

UNIT PRICE $/kgTOTAL PRICE $

0

I

ON

OFF

110 / 220 IN

110 220

Power supply

Power outlet

Power cord

Power receptacle

Note: The power outlet shape varies according to customers.

2.6 Power Cable Connection

•Insert the power cable into the receptacle at the left of the main body.

•Insert the power cable plug into the power outlet.

Ensure to establish a ground at the customer side.

110 V /220 V input power supply can be used. However, set the jumper lead to the required

voltage display side before the power is turned ON.

Chapter 2 Installation

2-5 AC-4000 Service Manual No. 0181B

2.8 Customer’s Specification Setup

(Initialization, Setup, and Registration)

Set up required specifications according to the following sequence.

Test mode (Refer to Chapter 3 “Test Mode”)

 1. Hardware test................................................................ P.3-2

 2. RAM clear...................................................................... P.3-7

 3. Printer head .................................................................. P.3-11

 4. Label sensor check ...................................................... P.3-13

 5. Total memory ................................................................ P.3-14

 6. ROM switch ................................................................... P.3-15

 7. Peel sensor check ........................................................ P.3-17

8. Machine type check ...................................................... P.3-18

Setup mode (Refer to Chapter 4 “Setup Mode”)

 1. Label format.................................................................. P.4-3

 2. POS code ...................................................................... P.4-10

 3. Item code....................................................................... P.4-13

 4. Default data .................................................................. P.4-14

 5. Total mode select.......................................................... P.4-16

 6. Open price .................................................................... P.4-17

 7. PLU selection ................................................................ P.4-18

 8. System .......................................................................... P.4-26

 9. Ethernet setup .............................................................. P.4-30

 10. System timer ................................................................. P.4-37

 11. Password setup ............................................................ P.4-38

12.Machine number setup ................................................. P.4-40

Chapter 2 Installation

AC-4000 Service Manual No. 0181B 2-6

2.9 Normal Mode Display

1. All segments blink three times when the power is turned on.

2. Then, the initial display appears.

IOperator display

ICustomer display

3. When calling up “Fixed price item” or “Weighing item”.

IWeighing item

IFixed price item

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ISHIDA AC-4000 Series User manual

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