CL5000J Series

Service Manual
(English)

Rev. 2007. 12. 18

1
Table of Contents
1. Proper Operation .............................................................................................................................................5
1.1 Introduction ..........................................................................................................................................5
1.2 Model and Specificationl ......................................................................................................................6
1.3 Environmental Conditions & Safety .....................................................................................................7
1.4 Leveling and Footer Location ..............................................................................................................8
1.5 Power Outlet and Requirements ........................................................................................................10
2. Classification .................................................................................................................................................11
2.1 Scale Overview...................................................................................................................................11
2.2 Display and Indicators ........................................................................................................................12
2.3 Printer.................................................................................................................................................14
2.4 Commuication .....................................................................................................................................15
2.5 Key Pad ..............................................................................................................................................16
3. Getting Started ............................................................................................................................................17
3.1 Sealing Method ...................................................................................................................................17
3.2 Installation of the Label Roll ..............................................................................................................17
3.3 Turning Power On ................................................................................................................................19
3.4 Program Menu and Tree ....................................................................................................................19
3.4.1 How to access PROGRAM MODE ............................................................................................19
3.4.2 Program Menu Tree ...................................................................................................................20
3.4.3 Calibration Menu Tree .............................................................................................................21
4. Calibration Mode .........................................................................................................................................22
4.1 Calibration ..........................................................................................................................................22
4.1.1 Span Calibration (Menu Code 8110) .................................................................................................23
4.1.2 Span/Zero Fine Adjust (Menu Code 8120) .....................................................................................24
4.1.3 Capacity & Units (Menu Code 8130) ..............................................................................................25
4.1.4 Gravity Constant (Menu Code 8140) ..............................................................................................26
4.1.5 Hysteresis Calibration (Menu Code 8160)........................................................................................28
4.1.6 A/D Set (Menu Code 8180) ......................................................................................................29
4.1.6.1 A/D Initialize (Menu Code 8183) .............................................................................................29
4.1.6.2 A/D FirmWare Update (Menu Code 8187) ..............................................................................29
4.2 System Options...................................................................................................................................30
4.2.1 System Clear ...................................................................................................................................30
4.2.1.1 Clear PLU (Menu Code 8211) ...............................................................................................30
4.2.1.2 Clear Table (Menu Code 8212).............................................................................................30
4.2.1.2 Clear Table (Menu Code 8213).............................................................................................30
4.2.1.3 Clear All (Menu Code 8214) ....................................................................................................30
4.2.2 Set Scale Type ................................................................................................................................31

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 4.3 Printer Hardware................................................................................................................................32
4.3.1 Label Size (Menu Code 8320) ..................................................................................................32
4.3.2 Sensor Calibration (Menu Code 8330) .....................................................................................32
4.3.3 Sensor & Motor <<Peel >> (Menu Code 8340) .......................................................................32
4.3.4 Print Intensity (Menu Code 8350) ............................................................................................32
4.3.5 Adjust Feed Length (Menu Code 8360) ...................................................................................33
4.3.6 Label Pre-print (Menu Code 8370)..........................................................................................33
4.3.7 Printer Initialize (Menu Code 8380).........................................................................................33
4.7 Self Test .............................................................................................................................................34
4.7.1 Display Test (Menu Code 8510) ..............................................................................................34
4.7.2 A/D Test (Menu Code 8520) ....................................................................................................34
4.7.3 Keyboard Test (Menu Code 8530)...........................................................................................34
4.7.4 Chess Print (Menu Code 8540) ................................................................................................35
4.7.5 Print Sensor (Menu Code 8550) .................................................................................................35
5. Parameter ....................................................................................................................................................36
6. Servicing & Parts Replacement..................................................................................................................40
6.1 Platform Safety Overload Adjustment ...............................................................................................41
6.2 Removing the Upper Case..................................................................................................................42
6.3 Main board Replacement (TODO : change) .......................................................................................44
6.4 Power Supply Replacement................................................................................................................45
6.5 Load Cell & AD Converter Replacement ...........................................................................................46
6.6 Print Assembly Replacement .............................................................................................................47
6.7 Display Replacement ..........................................................................................................................48
6.8 Keyboard Replacement A,B(with/without breaking sealing).............................................................49
7. Update .........................................................................................................................................................50
7.1 F/W update .........................................................................................................................................50
8. Schematic & Diagrams................................................................................................................................53
8.1 System Block Diagram .......................................................................................................................53
8.2 Connection Diagram ...........................................................................................................................54
8.3 I/O Pin Connection..............................................................................................................................55
8.4 Main PCB ............................................................................................................................................56
8.5 A/D PCB..............................................................................................................................................61
8.6 Display PCB........................................................................................................................................62
8.7 Printer I/O PCB...................................................................................................................................67
9. Exploded Views...........................................................................................................................................68
9.1 Scale Assy (B,P,R-type) ....................................................................................................................68
9.2 Body Assy (B,P,R-type).....................................................................................................................69
9.3 Platform (B,P-type)............................................................................................................................71
9.4 Upper Case .........................................................................................................................................72

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 10.9 Pole display (R-type) .......................................................................................................................74
9.5 Pole display (P-type) .........................................................................................................................75
9.6 Printer Assembly................................................................................................................................76
9.7 Printer Header Assemble ...................................................................................................................77
9.8 Cartridge.............................................................................................................................................78
9.9 Tray assembly (B,P,R-type) ..............................................................................................................79
10. Part List.....................................................................................................................................................80
10.1 Electronic .........................................................................................................................................80
10.2 Mechnical..........................................................................................................................................80
12. Revision .......................................................................................................................................................84

4
1. Proper Operation

1.1 Introduction

Thank you for purchasing the CAS CL5000J price computing printer scale. We have designed this
equipment with advanced features, high quality construction, and user-friendly menu driven
programming. We are confident that you will find the CAS CL5000J scale will meet all of your most
demanding needs.

Sales data is easily acquired through many of the available. Also available: High speed printer, 53
preset keys (106 using the SHIFT key or double click) per department, and several operation modes
that enable you to control & access to the scale.

For larger operations, CL5000J has in-store network that can link-up to 32 scales. RS-232 port,
ethernet port enable to export and import program data for time-save mangement. On-time operation
possible because of PLU and all other data files are kept locally in each scale’ s memory bank; the
scale’ s speed is the same as a stand-alone unit in a network.

The CL5000J can use with label. Also cartridge loading mechanism helps to refill the label roll easyly.
Also you can print logos, templates, ingredient messages, advertisement lines, and more to promots
your store.

Remember, for proper installation and maintenance please read the CL5000J Manual before use. A
wide variety of supplies, accessories, and expansion options are available through CAS Corporation for
whatever your new and increasing demands may require

The CL5000J also comes with the SP-2 software package. This software runs on any PC using the
95/98/2000/XP Windows OS. You can design your own label formats on your computer screen and
save them to your hard drive. With this percise interface, the labels you see on-screen appear exactly
on the printer. You can also manage all of the CL5000J’ s programs and options like pricing, PLU
programming, etc. You can upload data from a CL5000J or download data. This is ideal solution for
an emergency scale backup system. All this and many more features are packed into the SP-2
software package. SP-2 software package enhances your business next level.

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1.2 Model and Specificationl

Model CL5000J Series

Capacity 6Kg 15Kg 30Kg
Interval 1g/2g 2g/5g 5g/10g
Max Tare -2.999Kg -5.998Kg -9.995Kg
7-segment VFD
Tare: 4 digit
Display Weight: 5 digit
Unit Price: 6 digit
Total Price : 6 digit
Zero Pass Range 1~50% (default 10%)
Re-Zero Range 1~50% (default 2%)
Overload Range Max Capa. ~ Max Capa. + 255d (default Max+9d)
A/D Conversion Rate Approx. 8/sec
Measurement type Load cell
Platter type SUS
Key PLU Key : 48, Function Key: 36 P,R- PLU Key : 72, Function Key: 36
B-Type
Speed Key PLU Key : 96 Type PLU Key : 144
PLU 1~999999 6000
Ingredient 400 Char 1~100 100
user defined Barcode Format 1~20 20
Department 1~99 99
Origin 1~500 500
Data Table Group 1~99 99
Label Format Default :30, User:10 40
Bitmap 1~5 5
Quantity Symbol 1~8 8
Tare Table 1~99 99

Report Scale, PLU, Misc. PLU, Group, Department, Hourly

Printing Resolution 202 dpi
Label Size Width: 40mm ~ 60mm, Length: 30mm ~ 80mm
Barcode Type EAN13, I2OF5, CODE128C ,
Offer varoius sizes of label format, e.g Small, Middle, Large Size, and on the label format, also offers
Font varioous types of fonts, such as Italic,Bold,Underline,Throgh Line, Double through line, Reverse,shadow,
outline etc.
Printer Type Direct Thermal Print
B-Type 408 x 432 x 173 mm
Dimensions P-Type 408 x 493 x 542 mm Tray : 380 x 244 mm
R-Type 408 x 493 x 607 mm

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1.3 Environmental Conditions & Safety

1) Please avoid the following hostile conditions

ƒ Temperatures below or exceeding: ƒ Ungrounded electrical outlet

-10° C ~ 40° C (14° F ~ 104° F)
ƒ Excessive vibration ƒ Unstable or flimsy surface
ƒ Wind or fans functioning in direct ƒ Shared electrical outlet
contact with weighing platform.
ƒ Direct sunlight ƒ Dust or dirt
ƒ High humidity ƒ Poor ventilation

2) Environmental Protection
The scale should be installed in a dry and liquid free environment. When the scale is installed in
a high humidity or wet-type environment, be sure to avoid spilling or spraying directly on any
surface of the scale.

3) Personal Safety
It is very important to be aware of personal safety whenever maintaining or operating this
equipment. We have tried to place warning labels and other indicators at the actual location on
the equipment where the danger is most likely to occur. Warnings and cautions that are
necessary for the safe operation of the scale are contained in this manual. Please, make sure
to read carefully ALL warnings and cautions before operating the scale.

4) Observe the following safety precautions

ƒ Shut the scale OFF and unplug the scale whenever you are changing the label roll or whenever
working in the printer bay.
ƒ The outlet that the scale is plugged into, should be properly grounded.
ƒ Whenever connecting or disconnecting ANY cables from the scale, be sure to hold the cables by
the end connector. Failure to do so may cause a short circuit.
ƒ Maintain a static-free work area.
ƒ The outlet used must have the proper voltage ratings.

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1.4 Leveling and Footer Location

1) Location
This scale must be placed on a flat and stable surface. Please keep the scale away from the
direct path of oscillating fans, ventilation systems, or strong drafts as these air disturbances can
be picked-up by the scale’ s very sensitive weighing platform and may cause incorrect weight
readings.

1.1) General Footer

Factory setting (Footer location is following picture)

1.2) Short Case Footer

Unscrow the footer and place in center hole for narrow place.

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2) Leveling
If the scale is not properly leveled, please adjust the 4 adjustable legs at the bottom of the scale.
Turn the legs clockwise or counterclockwise so as to center the bubble of the leveling gauge
inside the indicated circle. Turning the adjustable legs counter-clockwise (viewed from top of
scale) will lower that part of the scale. Turning the adjustable legs clockwise (viewed from top of
scale) will raise that part of the scale. (See Fig.)

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1.5 Power Outlet and Requirements
Power Source : AC 100~240V, 50/60Hz, 1.5A
Power consumption : Max 90W
CL5000J’s outlet is on bottom of scale.

RS232C

Power Outlet

Power Switch

1) The CL5000J is designed to be used almost anywhere in the world! Like the many appliances of
today, the CL5000J is designed with an automatically switching power supply. This allows
operation when connected to an AC source from 100V to 240V at 50/60Hz with 5% tolerance.

NOTE: Please make sure that the power lines used for the CL5000J are dedicated lines with
No high-noise devices (such as compressors, motors, etc) running on it.
Also, make sure that the wiring to the electrical socket is correct.
If you are uncertain as to the state of your work’ electrical lines,
please contact a certified electrician.

2) Once you are sure as to the safety of the electrical line, make sure to ONLY plug the scale into a
3- prong outlet. The third prong is a safety ground and an electrician should properly wire this if it
is not correct or if you are unsure. Failure to this CAN result in electrical shock from use of this or
any electronic scale.

3) Do not use any 3-prong to 2-prong adapters or break-off the third prong from the CLP power
cord. The third prong is necessary and must be properly connected.

4) If you have any problems or questions regarding this matter, make sure to contact the CAS
Service Department.

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2. Classification

2.1 Scale Overview

CL5000J has 2 differrnt type Standard Type, Pole Type(R,P).

■ Standard Type ■ Pole Type P

■ Pole Type R

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2.2 Display and Indicators

There is VFD display on CL5000J. VFD display indicates program tare, weight, unit price, total price.
Underbar inicates stable, net, zero, auto, save, prepack, D/C, shift, data transfer.

■ Display: 4/5/6/6

■ Indicators

SYMBOLS DESCRIPTION

ST (▼) Stable weight indicator

NET (▼) Net weight indicator

▶0◀ Zero weight indicator

AUTO Print Mode indicator

SAVE Auto clearing status indicator

PREPACK Auto clearing status indicator

DC (▼) Discount status indicator

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SHIFT (▼) Speed key shift status indicator

TR Data transmission status indicator

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2.3 Printer

•Cartridge type print mechanism

•High quality ROHM printer

head (50km/5x107pulses)
•Improved a rotating force by
using 2 independent motors
•Large compartment for 120mm
paper roll
•High speed at 75 mm/sec.
•5 intensity ranges for paper roll
quality adjustment

•Supports Paper
•Labels,
•Continuous strip labels,
•Lineless paper

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2.4 Commuication

■ Standard
① RS232
② Ethernet

① RS232

Ethernet

15
2.5 Key Pad

Key pad is like following picture (This may change depands on contury)

■ Standard Type Keypad

■ Pole Type Keypad

16
3. Getting Started
3.1 Sealing Method

3.2 Installation of the Label Roll

■ Label Specifications
Outer diameter of roll : 100mm
Inner diameter of roll : 40mm
Width of receipt roll : 40, 50, 60mm
Width of label roll : 60mm(MAX)

■ Print Area
Width of label : 60mm(MAX)
Length of label : 80mm(MAX)

17
 To install the label roll at ANY time you must follow the directions in this section:
1) Press the ON/OFF key and make sure that the display is completely off. Open the printer’ s side-
access panel. (See fig.1)

2) Lift up TPH lever as fig 2.

3) Remove cartridge as fig. 3.

4) Remove Pick-Up Spool assembley and paper guide from the cartridge as fig. 4.

5) Place the label in the scale as fig. 5

6) Press the FEED key.

NOTE: For auto label calibration press FEED key two or three times
* If label position is not correct, you have to check the followings:
a. Label size (Label setting menu)
b. Feed Adjustment (Feed adjustment menu)
c. Senseor calibration (Sensor Calibration menu)

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3.3 Turning Power On
When you turn on scale, display will show below scren.

CAS CL5000 vEr 1.1

0.000 0.000 0.00 0.00

3.4 Program Menu and Tree

3.4.1 How to access PROGRAM MODE

You can see the Program Menu screen by pressing the MENU key.

1100 PGm PLU

You can use both keys, DATE-TIME/▲ and PLU/▼ to move other menu. Once you choose a
suitable menu, press PRINT key to execute program.
NOTE: Refer to the function keys avaiable program and calibration menu.
Program and Calibration Menu, Function Key Description
DATE-TIME/▲, PLU/▼ Selects a different menu
PRINT Executes command or selects the submenu
X/ESC Exits the Menu

1100 PGm PLU

Digit 1100 indicates Menu code. You should press PRINT key at prior menu to see sub menu screen
as below.

1120 PLU Edit

Whole Program and Calibration Menu Tree is described from next pages.
Refer to each code of Program and Calibration Menu Tree in following pages.
19
3.4.2 Program Menu Tree

CODE Menu CODE Sub Menu CODE Sub Menu

1120 New/Edit
1144 Expand Item
1100 PLU
1150 LIST
1160 Speed Key
1240 Sales Message
1250 Origin
1200 PLU Table1 1260 Barcode
1270 Tare
1280 Unit Symbol
1300 PLU Table2 1310 Message
1400 Store Data Table 1410 Store
1510 Label Format
1500 Global Setting
1520 Barcode
1611 Scale
1612 PLU
1613 Misc. PLU
1610 Report Print
1600 Report 1614 Group
1615 Department
1616 Hourly
1650 Clear All
1710 Print Label Item
1732 Label Size
1733 Sensor Calibration
1734 Peel Sensor
1700 Printing
1730 H/W Setting 1735 Print Intensity
1736 Adjust Feed Length
1737 Label Preprint
1738 Initialize Printer
1830 Department/Store/speed key number
1840 Date/Time
1852 Change Password
1861 Display
1862 A/D
1860 Test 1863 Keypad
1800 Scale Config 1864 Chess Printer
1865 Printer Sensor
1870 Scale Parameter
1861 PLU
1862 Table1
1890 Clear Memory
1863 Table2
1864 All

20
 1912 DHCP
Network
1900 Communication 1910 1913 IP
Setting
1915 RS232C Baudrate

3.4.3 Calibration Menu Tree

CODE Menu CODE Sub Menu CODE Sub Menu

8110 Span Calibration
8120 Span/Zero Fine Adjust
8130 Capacity & Units
8100 Calibration 8140 Gravity Setting
8160 Hysteresis Calibration
8183 A/D Initialize
8180 A/D Set
8187 A/D F/W Update
8211 Clear PLU
8212 Clear Table1
8210 System Clear
8200 System Options 8213 Clear Table2
8214 Clear All
8220 Set Scale Type
8320 Label Size (Height)
8330 Sensor Calibration
8340 Peel Sensor
8300 Printer Hardware 8350 Printer Intensity
8360 Adjust Feed Length
8370 Label Pre-print
8380 Initialize Printer
8510 Display Test
8520 A/D Test
8500 Self Test 8530 Keyboard Test
8540 Printer Test(Chess)
8550 Printer Sensor
8600 Parameter Setting 8600 [Parameter Setting Mode]

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4. Calibration Mode

4.1 Calibration

Execute Weight Calibration and A/D related settings

(Access Authorized CAS Tester only)

Open the tray and remove the calibration sealing.

(CAUATION: Lift the tray Right side first and unlock the left side)

Order to access calibration mode:

Insert a stick into the CAL switch. Switch power on, while pushing the CAL button.

NOTE: For Hanging type: Pull forward the bottom handle to open
Refer to each code of Program and Calibration Menu Tree.

First page of Calibration mode

8100 CAL CALibr

22
4.1.1 Span Calibration (Menu Code 8110)
(Calibration MENU -> Calibration -> Span Calibration)

*Requires set of certified weights. (For best result prepare 15kg/6kg (max) weights)

① Select “Span Calibration”

8110 CALib SPAn

Press “PRINT”

8110 SPAn UnLoAd

② Empty tray and press “PRINT”

8110 SPAn Wait4 10329

While calibrating zero display shows “Wait4” ~ “Wait0” and follow next message for Span
Calibration.

8110 SPAn LoAd

③ Put on the Weight for Max. Capacities then press “PRINT”
*Menu 8130 sets the max capacity for calibration.

8110 SPAn Wait4 78048

Display shows “Wait4” ~ “Wait0” then following message

8110 SPAn SPAn

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4.1.2 Span/Zero Fine Adjust (Menu Code 8120)
(Calibration MENU -> Calibration -> Span/Zero Fine Adjust)
This mode is for fine tuning of scale after span Cal. Please put Max weight on the tray and adjust
A/D results at 60000, using the cursor key “ ◀ ▶ .” and Number key.

① Select menu “Span/Zero Fine Adjust”, no weight is on the tray

8120 FinE AdJUSt 0

If internal value is not set to zero, press “ ZERO” key..

② Put Max. Capacity weight on the tray

8120 FinE AdJUSt 60012

And this screen is a just sample data for testing. This sample data are perhaps not the same as the
data that you will have with your scale.
- Internal value 60012 needs to change 60000
Press ▶ X 12 Times to decrease internal value.

8120 FinE AdJUSt 60000

24
4.1.3 Capacity & Units (Menu Code 8130)
(Calibration MENU -> Calibration -> Capacity & Units)

Set scale’s Weighing unit, capacity, Interval, Cal Unit.

Caution: Span calibration must take place after “Capacity & Units” setting.
Do not change setting after Span calibration.

No Capacity Middle weight in Hysteresis Cal.

0 6 kg, dual 2 kg
1(default) 15 kg, dual 5 kg
2 30 kg, dual 10 kg
3 60 kg, dual 20 kg
4 150 kg, dual 50 kg
5 300 kg, dual 100 kg
6 600 kg, dual 200 kg
7 1,500 kg, dual 500 kg
8 3,000 kg, dual 1,000 kg
9 6,000 kg, dual 2,000 kg

8130 CALib CAPA 1

25
4.1.4 Gravity Constant (Menu Code 8140)
(Calibration MENU -> 1. Calibration -> 4. Gravity Constant)

CL-5000Jr scale enables to calibrate in any country. You can set according to country standard
gravity constant data. For case of full recalibration set the factory gravity first and then local area
gravity code.
(For span calibration Local gravity value is automatically matches with Factory gravity value)

First, Enter the gravity value in calibration area (Factory)

8140 Grvty G-CAL 9.7994

Second, Enter the gravity value in using area (local)

8140 Grvty G-USE 9.7799

Use the following table to determine the proper G-Constant for your area.
Country City G-Constant Country City G-Constant

Argentina Buenos Aires 9.7979 Mexico Mexico City 9.7799

Australia Sydney 9.7979 Morocco Rabat 9.7964

Austria Vienna 9.8099 Netherlands Amsterdam 9.8129

Belgium Brussels 9.8114 New Zealand Wellington 9.8039

Belize Manamah 9.7904 Norway Oslo 9.8189

Bolivia La Paz 9.7844 Panama Panama City 9.7814

Brazil Brasilia 9.7889 Peru Lima 9.7829

Canada Montreal 9.8069 Philippines Manila 9.7844

Ottawa 9.8069 Poland Swider 9.8159

Toronto 9.8054 Portugal Lisbon 9.8009

Vancouver 9.8099 Rumania Bucharest 9.8054

Check Republic Prague 9.8114 Saudi Arabia Riyad 9.7904

Chile Santiago 9.7979 Scotland Stockholm 9.8189

China Hong Kong 9.8099 Singapore Singapore 9.7814

Colombia Bogota 9.7799 South Africa Johannesburg 9.7919

Costa Rica San Jose 9.7829 Spain Madrid 9.8024

Cypress Nicosia 9.7979 Switzerland Bern 9.8084

Denmark Copenhagen 9.8159 Taiwan Taipei 9.7904

26
 Ecuador Quito 9.7724 Tunisia Tunis 9.7799

Finland Helsinki 9.8189 Turley Ankara 9.8024

Germany Dusseldorf 9.8129 Uruguay Montevideo 9.7964

Great Britain London 9.8144 USA Anchorage 9.8189

Greece Athens 9.8009 Atlanta 9.7964

Guatemala Guatemala 9.7844 Boston 9.8039

Hungary Budapest 9.8069 Chicago 9.8024

Indonesia Djakarta 9.7814 Dallas 9.7949

Iraq Baghdad 9.7964 Detroit 9.8039

Japan Mishima 9.7979 Los Angeles 9.7979

Korea Seoul 9.7994 New York 9.8024

Kuwait Kuwait 9.7919 Philadelphia 9.8024

Lebanon Beirut 9.7964 San Francisco 9.7994

Mauritius Port Louis 9.7859 Venezuela Caracas 9.7829

NOTE: The G-Constant is the acceleration of gravity in meters per second per second.

27
4.1.5 Hysteresis Calibration (Menu Code 8160)
(Calibration MENU -> Calibration -> Hysteresis Calibration )
You can re-adjust the med-range weight level for precise calibration.

8160 CALib HySt

Hysteresis Calibration for example 15 kg, middle value is 5 kg
① Press “print”.

8160 HySt UnLoAd 10329

② Clear the tray and press “PRINT”, then “Wait4” ~ “Wait0” will display.

8160 HySt middLE 40329

③ Put middle weight (5kg) on the tray and press “PRINT”, then “Wait4” ~ “Wait0” will display.

8160 HySt LoAd 70329

④ Put 15kg on the tray and press “PRINT”, then “Wait4” ~ “Wait0” will display.

8160 HySt middLE 40329

⑤ Put Clear middle weight (5kg) on the tray and press “PRINT”, then “Wait4” ~ “Wait0” will display.

8160 CALib HySt

28
 4.1.6 A/D Set (Menu Code 8180)
(Calibration MENU -> Calibration -> A/D Set)

4.1.6.1 A/D Initialize (Menu Code 8183)

(Calibration MENU -> Calibration -> A/D Set -> A/D Init )

8183 Ad-Se init

Wait for a moment after pressing “PRINT” ,and while display shows following message

8183 Ad-Se init wAit

CAUTION: Must record setting values before Executing menu . This will set the scale first default setting

4.1.6.2 A/D FirmWare Update (Menu Code 8187)

(Calibration MENU -> Calibration -> A/D Set -> Update )

8187 Ad-Se UPdAtE ConnEct

You can change the A/D firmware with your PC in this mode.

29
4.2 System Options
(Calibration MENU -> System Options)

4.2.1 System Clear

(Calibration MENU -> System Options -> System Clear)

8210 SyStE CLEAr

You can clear memory depends on options below.

4.2.1.1 Clear PLU (Menu Code 8211)

(Calibration MENU -> System Options -> System Clear -> Clear PLU)
Clear all PLU data.

8211 CLEAr PLU

4.2.1.2 Clear Table (Menu Code 8212)
(Calibration MENU -> System Options -> System Clear -> Clear Table1)
Clear all Table1 data.

8212 CLEAr tAbLE1

4.2.1.2 Clear Table (Menu Code 8213)
(Calibration MENU -> System Options -> System Clear -> Clear Table2)
Clear all Table2 data.

8213 CLEAr tAbLE2

4.2.1.3 Clear All (Menu Code 8214)
(Calibration MENU -> System Options -> System Clear -> Clear All )

30
 8214 CLEAr ALL
Clear PLU, Table1, Table2 and Shop data
Symbols and Speed key is initialized

4.2.2 Set Scale Type

(Calibration MENU -> System Options -> Set Scale Type)

8220 SyStE StyPE 1

This mode was setted by manufacturer. See the following table, and set value in order.
1 – Bench type, 2 – Pole type, 3 - Hanging, 4 – Self service

31
4.3 Printer Hardware

No. Sub-menus Description

1 Label Size Lable mode “Height(40)
* ( ) are default value.
2 Sensor You can mearsure “Gap” & “Peel” . And print out them.
Calibration Also you can test Sensor & Motor.
3 Sensor Setting Peel-off sensor.

4 Print Intensity Set the extent of intensity of label printed.

5 Adjust Feed Set adjusting values of feed length.

This value can be from “0” to “400”
Length
6 Label Pre-print You can set preprint length.

7 Printer Initialize You can reset printer.

4.3.1 Label Size (Menu Code 8320)

(Calibration MENU -> Printer Hardware -> Height)

You can input “Height” of label manually. (30 ~ 80mm)

4.3.2 Sensor Calibration (Menu Code 8330)

(Calibration MENU -> Printer Hardware -> Sensor Calibration)

This mode will automatically feed the label several times to calculate the measurement.
The average data of “Gap” & “Peel” are pronted out, and displayed on screen.

4.3.3 Sensor & Motor <<Peel >> (Menu Code 8340)

(Calibration MENU -> Printer Hardware -> Peel )

You can select [Y], [N] for “ACTIVE PEEL-OFF”

4.3.4 Print Intensity (Menu Code 8350)

(Calibration MENU -> Printer Hardware -> Print Intensity)

You can enter any value from “0” to “4” set the tension of label.
The 2 is default value.

32
4.3.5 Adjust Feed Length (Menu Code 8360)
(Calibration MENU -> Printer Hardware -> Adjust Feed Length)

User may enter any value of the feed alignment from “0” to “400”.
You can adjust the printing position detail with this menu.
* 1pixel = 0.125mm , 8pixel = 1mm Ex) Value “+80” will feed 10mm more
Value “-40” will feed 5mm less

4.3.6 Label Pre-print (Menu Code 8370)

(Calibration MENU -> Printer Hardware -> Label Pre-print)

User may select Preprint mode and any value of the preprint length from “0” to “10”.
It controls the length that label is pushed out.

4.3.7 Printer Initialize (Menu Code 8380)

(Calibration MENU -> Printer Hardware -> Printer Initialize)
Initialize printer setting.

33
4.7 Self Test

4.7.1 Display Test (Menu Code 8510)

(Calibration MENU -> Self Test -> Display Test)

Selecting 1 will start Display test, press any key to stop and exit.

4.7.2 A/D Test (Menu Code 8520)

(Calibration MENU -> Self Test -> A/D Test)

8520 tESt Ad

4.7.3 Keyboard Test (Menu Code 8530)

(Calibration MENU -> Self Test -> Keyboard Test)

8530 tESt KEy

You can test keyboard by pressing.

Press any keys to test Row Code.

* Raw Code is location of key. (Upper left Connor is 1)

* Press ESC will exit the test or display Row Code.
- ESC + ESC : End of test

34
 4.7.4 Chess Print (Menu Code 8540)
(Calibration MENU -> 5. Self Test -> 4. Chess Print)

Select Printer Test (Chess). The scale will then print a TPH (Thermal Print Head) test label. This
label print checker pattern helps to find problems with the TPH. You should clean the TPH before you
try this procedure. Follow the maintenance procedure for cleaning the TPH. The following
examples shows that some of problems that can occur.

1 2

There are several things that this printout sample can reveal:
1. The rubber roller may be dirty or have something stuck to it. Also, the roller may be perforated.
2. This is a clear indication that the TPH has been damaged or burned out.
If you need to replace the TPH, please contact the CAS Service Department.

4.7.5 Print Sensor (Menu Code 8550)

(Calibration MENU -> 5. Self Test ->5. Printer Sensor)

8550 SEnSo G128 P128H0

35
5. Parameter

8600 CAL PArAm

8600 PArAm nO 100

You can input Parameter number (“ Fuction Code: [ ]” ) for predefine settings.
If You need to Initial Parameter settings, Enter the number “ 999”
If You need to Initial Parameter settings and clear all data (include report), Enter the number “ 998”

No MODE VALUE DESCRIPTION REMARK

201 CAL 0~3 (3) Weight Decimal Position
202 CAL 0~3 (2) Price Decimal Position
204 0~1 (1) Display scale version at the initial time (0-No, 1-Yes)
205 0~1 (0) Test display at the initial time (0-No, 1-Yes)

301 0~10 (3) Key count threshold for confirming key value
(unit : 23.8 ms)
302 0~10 (5) Key time-out value for confirming continuous input
If this time is over, unit price will be cleared when next
key is entered. (unit : 1.7 sec)
304 1~4 Key type : 1-bench, 2-pole, 3-hanging, 4-self service no default
305 1~5 (1) Speed key table number

401 1~99 (1) Scale current department number

402 0~1 (1) Allow fixed price sale (0-No, 1-Yes)
403 0~2 (0) Change Unit Price :
0-No, 1-Temporary, 2-permanently
414 0~1 (0) Always Use global label number
417 0~1 (1) Allow printing multi label (using X key)
418 0~1000 (50) Threshold weight for auto printing (unit : weight)
ex) 50 -> 0.050g
419 0~1 (1) Automatically clear PLU after printing (0-No, 1-Yes)
420 CAL 0~20 (20) Minimun weight digit for printing (unit : division)
Ex) 20d -> 40g (15kg)
36
421 CAL 0~1 (0) Allow printing when weight is under min. weight
422 1~1000 (1000) Unit weight for unit price
423 0~100 (0) Unit for price round (unit price)
Ex) 10 -> 0.10 $
424 ------ password
425 1~100 (30) Time for waiting stable when printing (unit : 90 ms)
426 0~1 (0) Automatically clear sale information after printing
without tare and weight (0-No, 1-Yes)
427 0~1 (0) Use double speed key
430 0~1 (1) Automatically clear sale information after printing
with no weight (0-No, 1-Yes)
431 0~1 (1) Allow printing without checking previous sale
(0-No, 1-Yes)
432 0~1 (0) Change sale type from weight to fixed price
When print key is pressed without weight
(0-No, 1-Yes)
434 0~1 (0) Allow warning account over (0-No, 1-Yes)
435 0~1 (0) Allow printing only weight (0-No, 1-Yes)
436 1~10 (1) Current shop number
437 0~1 (0) Automatically misc. PLU sale when no PLU is called

501 1~255 (1) Current scale address

502 0~4 (3) 3 – 57,600 bps
503 0~999 (300) Time threshold for checking communication is running
(unit : 10 ms)
505 0~99 (20) Continuously interpreting time in sale mode
when communication is running (unit : 10 ms)
509 0~1 (0) Use DHCP (0-No, 1-Yes)
510 0~0xFF MAC address 0 HEX mode
511 0~0xFF MAC address 1 HEX mode
512 0~0xFF MAC address 2 HEX mode
513 0~0xFF MAC address 3 HEX mode
514 0~0xFF MAC address 4 HEX mode
515 0~0xFF MAC address 5 HEX mode
516 ---- IP address (Do not modify in parameter menu, use
program menu)
517 ---- Subnet mask (Do not modify in parameter menu, use
program menu)

37
518 ---- Gateway address (Do not modify in parameter menu,
use program menu)
519 0~99999(20304) TCP server port

601 240~640 (320) Label length (unit : dot / 8 dot = 1 mm)

602 448 Label width (unit : dot / 8 dot = 1 mm)
603 0 Label adjust value (Do not modify in parameter menu,
use program menu)
604 0~40 (16) Gap length (unit : dot / 8 dot = 1 mm)
605 0~12 (6) Printer intensity (Do not modify in parameter menu,
use program menu)
606 0~1 (1) Use Peel off sensor (0-No, 1-Yes)
607 80 (64) Pre-print length (unit : dot / 8 dot = 1 mm)
608 0~255 (128) Gap sensor threshold
609 0~255 (128) Peel off sensor threshold

701 0~1 (0) Year digit length ( 0-2 digit , 1-4 digit )
Ex) 0-07, 1-2007
702 0~9999 (2000) Year text for 4 digit year (last 2 digit must be 00)
Ex) if this year is 2017, year text is 2000
703 0~1 (0) Use month text (0-number, 1-text)
704 0~1 (0) Use 12 hour(AM/PM) (0-24, 1-12)
705 0~3 (1) Date type (0:YY MM DD, 1:DD MM YY, 2:MM DD YY
3:MM YY)
706 0~1 (1) Time type (0:HH MM SS, 1:HH MM)
707 0~255(.) Date division symbol (see ASC-II table)
708 0~255(:) Time division symbol (see ASC-II table)
709 0~1 (1) Enable printing serial number (0-No, 1-Yes)
710 0~1 (1) Enable printing packed date (0-No, 1-Yes)
711 0~1 (1) Enable printing packed time (0-No, 1-Yes)
712 0~1 (1) Enable printing sell-by date (0-No, 1-Yes)
713 0~1 (0) Enable printing sell-by time (0-No, 1-Yes)
714 0~1 (1) Enable printing shop data (0-No, 1-Yes)
715 0~1 (1) Enable printing PLU number (0-No, 1-Yes)
716 0~1 (0) Enable printing week (0-No, 1-Yes)
717 0~100 (0) Weight Cut-off in barcode data
Ex) value = 10, 1,000 ->100
718 0~100 (0) Price Cut-off in barcode data

38
 Ex) value = 10, 1,000 ->100
719 0~1 (0) Print Weight in by-count sale mode
720 0~1 (0) Print Group number instead of department number in
barcode data
721 0~3 (2) Print Origin in name field instead of Origin field
(0-origin, 1-name1, 2-name2, 3-name3)
722 0~1 (1) Print All date/time enable (0-No, 1-Yes)
724 0~1 (0) Print Weight in fixed price sale mode
725 0~1 (0) Enable Korea E-Mart week (only korea version)
726 1~99 (1) Global label number
727 1~99 (1) Total label number
728 1~20 (1) Global barcode number

801 - (Caption) Weight

802 - (Caption) Price
803 - (Caption) Packed On Date
804 - (Caption) Sell By Date
805 - (Caption) Produced Date

901 0~1 (0) Expand PLU item (0-No, 1-Yes)

998 --- Init parameter, clear all data and report

999 --- Init parameter

39
6. Servicing & Parts Replacement

40
6.1 Platform Safety Overload Adjustment

1) Turn power off and remove power cord

2) Remove tray from scale (make sure lift right side first and unlock the left hook)

3) Remove calibration cealing

4) Remove the upper case

5) Put 150% of max weight on platform rear right. This point Allen-bolt should not be
touched
6) Adjust Allen-bolt just about to touch the bottom frame
7) Contiune the procedure on each corner

B,P-type

41
6.2 Removing the Upper Case

1) Turn power off and remove power cord

2) Remove tray from scale (make sure lift right side first and unlock the left hook)
3) Remove printer cartridge
4) Remove 6 bolt from bottom case(for pole type: remove pole mount bolt first)

5) Remove 4bolt from upper case

42
6) Remove keybord and display cable to remove upper case

B,P type:

* Carefull with front key pad connector

43
6.3 Main board Replacement (TODO : change)
1) Turn power off and remove power cord
2) Remove following cables
- SMPS Line
- Key Board Line
- Display Board Line
- Printer Board Line
- A/D Board Line
3) Remove following bolt to remove main board
B,P type:

Connector locations

44
6.4 Power Supply Replacement
1) Turn power off and remove power cord
2) Remove upper case(following 6.2)
3) Remove power lines (white cables)

4) Remove bottom Power module(SMPS) bolt(4)

5) Full forward power module and remove power cables on SMPS

6) Disassamble support frame and remove side bolt(4) to remove power supply.

45
6.5 Load Cell & AD Converter Replacement
1) Turn power off and remove power cord
2) Remove upper case(6.2)
3) Remove upper frame(Load cell moult)bolt

Lodecell suspansion bolt

4) Remove bottom frame bolt

NOTE: Carefull with load cell this procedure may cause critical damage on scale

A/D mounting bolt

L/C Line

A/D connetor

5) Remove A/D module bolt(2) and cable(A/D data line, L/C line)

46
6.6 Print Assembly Replacement

1) Turn power off and remove power cord

2) Remove printer cartridge
3) Remove upper case(6.2)
4) Remove printer connecting bolt

Printer mounting bolt

(B,P type)
5) Remove printer module (lift upper right side first)

47
6.7 Display Replacement

1) Turn power off and remove power cord

2) Remove upper case (6.2)
3) Remove keyboard and display cable of main board

Display Cable

Key_Board Cable

4) Remove front display board B,P type: lift display board at arrow side
Remove rear display board by lifting bottom part to unlock

48
6.8 Keyboard Replacement A,B(with/without breaking sealing)
A: with break sealing
1) Turn power off and remove power cord
2) Remove upper case(6.2)
3) Remove keyboardm display cable from main bord and replace new keyboard

Key_Board Cable Display Cable

B: without break sealing

4) Remove keyboard from upper case
5) Remove keyboard support plate and disconnect key board cable by pull the calble lock
6) Connect keyboard cable by pushing keyboard suspend lock / add metal support plate
7) Stick the keyboard pad

49
 7. Update
7.1 F/W update
Step1: First, Power off the scale and then,
Connect RS232C to computer

Pin-layout is following diagram

Scale(DB-9 Female) PC (DB-9 Male)
(2) -------------------------------- (3)
(3) -------------------------------- (2)
(5) -------------------------------- (5)

Step2: Execute AVRfwupdate.exe

Step3: Select RS232C communication port by pressing

50
Step4: Select new firmware ROM by check the checkBOX

Step5: Press , ready to F/W –ROM download

* Software will not download if the firmware version is old or file desination is wrong
Window massage will show error massage

51
Step6: Turn on the scale. After few second download process will occure

When download finished, scale will reboot

NOTE: During this procedure power or communication connector is cut off
You must redo from step1

52
8. Schematic & Diagrams
8.1 System Block Diagram

53
8.2 Connection Diagram

54
8.3 I/O Pin Connection

55
8.4 Main PCB
1) part 1

56
2) part 2

57
3) part3

58
4) part4

59
5) part5

60
8.5 A/D PCB

61
8.6 Display PCB
1) Display Type B

62
2) Display Type P (Front)

63
3) Display Type P (Rear)

64
4) Display Type R (Front)

65
5) Display Type R (Rear)

66
8.7 Printer I/O PCB

67
9. Exploded Views
9.1 Scale Assy (B-type)

68
9.2 Scale Assy (P,R-type)

69
9.2 Body Assy (B,P,R-type)

70
9.3 Platform (B,P-type)

71
9.4 Upper Case

72
73
10.9 Pole display (R-type)

74
9.5 Pole display (P-type)

75
9.6 Printer Assembly

76
9.7 Printer Header Assemble

77
9.8 Cartridge

78
9.9 Tray assembly (B,P,R-type)

79
10. Part List
10.1 Electronic
AD PCB ASS'Y
반제품/자재 품명 규격 수량 비고
6120-PCL-0400-
1 6120PCL04000 PCB-ANALOG 1 PCB
0(CL5000)
2 6200IS078580 IC(CPU) W78E58BF-40(QFP) 1 U1
3 6205IS024020 IC(EEP ROM) AT24C02-SMD(2K) 1 U2
4 6236IS04011A IC(C MOS) SLS 4011BD(GATE) 1 IC5
SLS 4066BD(ANALOG
5 6236IS04066A IC(C MOS) 1 IC3
S/W)
6 6240IS001770 IC(OP AMP) OP-177GS 2 IC1,6
7 6240IS040720 IC(OP AMP) UPC 4072G2 2 IC2,4
8 6281I0015040 TRANSISTOR CHIP KTA1504 SY 3 Q1,2,3
9 6294ICP01810 DIODE-CHIP KDS181 1 D1
RESISTOR-CHIP
10 6527ID010000 RR1220P-101D(100Ω ) 2 R8,10
1/10W
RESISTOR-CHIP
11 6527ID300220 RR1220P-222D(2.2K) 1 R12
1/10W
RESISTOR-CHIP
12 6527ID301000 RR1220P-103D(10K) 6 R13~18
1/10W
RESISTOR-CHIP RR1220P-
13 6527ID304990 2 R4,5
1/10W 4992D(49.9K)
RESISTOR-CHIP
14 6527ID310000 RR1220P-104D(100K) 4 R3,7,9,11
1/10W
RESISTOR-CHIP RR1220P-
15 6527ID320000 1 R19
1/10W 204D(200KΩ )
RESISTOR-
16 6540LA303850 FLAY 38K500B 2 R1,2
PRECISION
17 6550RM00400A RESISTOR-NETWORK 2S-02(1K/10K) 1 R6
HB-1M2012-
18 6670T0001020 INDUCTANCE 5 L1~5
102JT(TP2,LP2,DBB)
CONDENSER-
19 6702CAP0106A 10MCS 106 MB2 TER 1 C19
TANTAL CHIP
CONDENSER-
20 6702CAP06850 16MCS 685 MB TER 2 C12,20
TANTAL CHIP
21 6706C2500470 CONDENSER- 47uF/25V ø6.3 2 C21,22

80
 ELECTRIC CHIP
C3,4,8,11,13~18,
22 6712CHP01040 CONDENSER-CHIP CL21F 104KBNC 14
23,24,26,27
23 6712CHP01050 CONDENSER-CHIP 105(1uF-0805 TYPE) 1 C25
24 6712CHP02000 CONDENSER-CHIP CL21C 200JBNC(20PF) 2 C57,58
CONDENSER-
25 6720CAP0105A 1uF/63V-J(BOX) 1 C10
POLYESTER
CONDENSER-
26 6720CAP0474A 0.47uF/63V-J(BOX) 3 C5,6,7
POLYESTER
27 6722CAP0224A CAPACITOR-P.P 0.22uF/67V-AC 1 C9
28 6800F0002200 EMI FILTER EFST221YTB(220PF) 2 C1,2
29 7010ZM02211A CRYSTAL 22.1184MHz(ATS-49/V) 1 Y1
12*12(SKHK)DJTA-
30 7600STA12120 TACT S/W 1 SW1
1103E
LW0640-08 (LPH01-
31 7801CLW00080 CONNECTOR(WAFER) 1 CN2
08)

CONTROLLER PCB ASS'Y

반제품/자재 품명 규격 수량 비고
6191-PCL-0100-
1 6191PCL01000 PCB-CONTROLLER 1 PCB
0(CL5000)
2 6224IS062190 IC(DRIVER) L6219DS 2 U2,3
3 6236IS001230 IC(C MOS) 74HC123(SOP) 1 U1
4 6281I0015040 TRANSISTOR CHIP KTA1504 SY 2 Q1,2
5 6281I0038750 TRANSISTOR CHIP KTC3875 SY 1 Q3
6 6513CJ000100 RESISTOR 1W CFR 1Ω (±5%) 4 R14,15,20,21
RESISTOR-CHIP
7 6527ID022000 RR1220P-221D (220Ω ) 2 R7,9
1/10W
RESISTOR-CHIP
8 6527ID033000 RR1220P-331D (330Ω ) 1 R10
1/10W
RESISTOR-CHIP R1,2,8,16,17,23,
9 6527ID300100 RR1220P-102D(1K) 7
1/10W 25
RESISTOR-CHIP
10 6527ID300220 RR1220P-222D(2.2K) 2 R3,4
1/10W
RESISTOR-CHIP
11 6527ID300470 RR1220P-472D(4.7 ㏀) 1 R12
1/10W
RESISTOR-CHIP
12 6527ID301000 RR1220P-103D(10K) 2 R11,26
1/10W

81
 RESISTOR-CHIP
13 6527ID301200 RR1220P-123D(12 ㏀) 2 R5,6
1/10W
RESISTOR-CHIP
14 6527ID302700 RR1220P-273D(27 ㏀) 1 R13
1/10W
RESISTOR-CHIP
15 6527ID304700 RR1220P-473D(47 ㏀) 4 R18,19,22,24
1/10W
HB-1M2012-
16 6670T0001020 INDUCTANCE 3 L1,2,3
102JT(TP2,LP2,DBB)
CONDENSER-
17 6706C2500470 47uF/25V ø6.3 1 CE3
ELECTRIC CHIP
CONDENSER-
18 6706C5000220 22uF/50V ø6.3 3 CE1,2,5
ELECTRIC CHIP
19 6712CHP01020 CONDENSER-CHIP CL21B 102KBNC 8 C9~16
20 6712CHP01040 CONDENSER-CHIP CL21F 104KBNC 9 C1~8,17
21 7805CCN67040 CONNECTOR(WAFER) 04-5267 2 J5,6
22 7805CCN67100 CONNECTOR(WAFER) 10-5267 1 J8
12512WS-04(53047-
23 7808CGD04100 CONNECTOR(WAFER) 2 J1,2
0410)
SOCKET 5332-20P(HIF-3FB-
24 7813C0000200 1 J7
CONNECTOR 20PA-DSA)LP-2
SOCKET
25 7813C0000260 5332-26P LP-Ⅱ 1 J4
CONNECTOR
2P*50(CL5000-
26 7840W0020500 CONNECTOR WIRE 1 J3
B,P,R,H)유상

INTERRUPT SENSOR PCB ASS'Y

반제품/자재 품명 규격 수량 비고
1 2010A0000010 SENSOR CAP 7.9*4.3*12(LP) 2
2 6154PLP01820 PCB-SENSOR-1 6154-PLP-0182-0 1 PCB
PHOTO
3 7236DPS02030 OPSI203UITL(LP-1) 1
INTERRUPTER
4P*100(CL5000-
4 7840W0041000 CONNECTOR WIRE 1
B,P,R,H)
PEEL OFF SENSOR PCB ASS'Y
반제품/자재 품명 규격 수량 비고
6154-PCL-0900-
1 6154PCL09000 PCB-SENSOR 1 PCB
0(CL5000)
2 7236DPS00010 PHOTO ITR20001/T 1

82
 INTERRUPTER
4P*100(CL5000-
3 7840W0041000 CONNECTOR WIRE 1
B,P,R,H)

10.2 Mechnical

83
12. Revision

84