Avery Weigh-Tronix PC-805 User manual

PC-805 Parts Counter
Service Manual

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Table of Contents
Table of Contents ................................................................................ 3
Specifications...................................................................................... 4
What's in This Manual? ........................................................................ 5
Accessing Menus and Modes ................................................... 5
Scale Menu ......................................................................................... 6
CALib Calibration) ................................................................... 7
ConFig Configuration) ............................................................. 7
rEStArt Restart) ....................................................................... 8
SEAL Seal) ............................................................................. 8
done Done) ............................................................................. 8
Diagnostic Menu.................................................................................. 9
ConFig. Configuration) Menu....................................................................... 11
Error Messages ........................................................................................... 14
Serial Communications ................................................................................ 14
Cable Pinouts .................................................................................... 14
Preset Print Formats ......................................................................... 15
1410 Printer Fixed Format Label Output ............................................ 16
Computer Protocol ............................................................................ 17
Disassembly Instructions .............................................................................. 19
PC-805 Technical Illustrations....................................................................... 21

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Capacity Normal Resolution Expanded Resolution
10 lb 0.001 lb 0.00005 lb
50 lb 0.005 lb 0.0002 lb
100 lb 0.01 lb 0.0005 lb
5 kg 0.0005 kg / 0.5 g 0.00002 kg / 0.02 g
25 kg 0.002 kg / 2 g 0.0001 kg / 0.1 g
50 kg 0.005 kg / 5 g 0.0002 kg / 0.2 g
Overcapacity indication (upper dashes) ill occur at 9 divisions over rated
capacity or 102% of full scale capacity.
1 part in 2,000,000 (QDTTM)
Standard digital soft are filtering
Seven digits of seven-segment, high-contrast black LCD, .5" (1.3 cm) high
ith blue electro-luminescent backlight
15VDC at 300mA from a 117VAC 60Hz inline transformer
Optional 12VDC lead acid battery
Bidirectional RS-232 output ith selectable baud rate
14° to 104° F (-10° to 40° C)
10 to 90% relative humidity, non-condensing
Specifications
Capacities and Resolutions:
Overcapacity Limits:
Internal Resolution:
Filters:
Display:
Power:
Output:
Operating environment:

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What's In This Manual?
This manual contains the information you need to configure, calibrate and
service the PC-805 counting scale. The manual is divided into the follo ing
sections:
 Scale Menu
 Diagnostic Menu
 Configuration Menu
 Communication
 Technical Dra ings and Assemblies
The different modes of operation are accessed by placing the s itches of
SW1 in the positions described in Table 1. S itch SW1 is located under the
scale shroud on the right side of the scale. See Figure 1. Calibration,
diagnostics, and configuration can also be accessed by pressing and
holding the PRINT key for five seconds.
witch W1
ON OFF Mode of Operation
1, 2 Normal Operation Mode
2 1 Menu Mode (Scale, Diag., Config.)
3 External Display Mode
Table 1
Switch settings
Figure 1
Switch SW1 location
Switches not listed in Table are
irrelevant to the mode. It does
not matter what position they
are in for that particular mode.
Accessing Menus and
Modes

6
Scale Menu
The first menu you see hen entering the menu mode is the Scale menu.
Follo these steps to explore the Scale menu.
1. Set SW1-2 to the ON position
and SW1-1 to the OFF position
OR hold the PRINT key for 5
seconds. The display sho s SCALE. The
entire Scale menu is sho n in
Figure 2 belo .
2. Follo the legend at the top of
the menu to navigate through the
menu. Each item is explained on
the next pages.
Figure 2
Scale Menu
Because a 7 segment display
cannot show all of the alpha-
bet, the words on the display
are the closest representations
of the words they stand for that
can be accomplished. The
menus show the words as all
caps and clarified in some
instances. The explanations in
the text will use the letters and
case you will see on the
display.
* = factor
y
default value
Press any key
but
to abort the
calibration process
SAMPLE
To move , press the key.
To move , press the key.
To move , and to choose an option, press the key.
Press key to go up one menu level.
SAMPLE
TARE ZERO
COUNT/WEIGHT

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CALib is the calibration function for the scale. Follo these steps to cali-
brate your scale:
1. With CALib displayed, press the
ZERO key. . . PoUnd or 1000 g is displayed.
These are your choices for unit of
measure for the calibration test
eight.
2. Toggle bet een these t o units
of measure by pressing the
AMPLE key. With the unit of
measure you ant displayed,
press the ZERO key. . . A eight capacity is sho n on the
screen.
3. Press the AMPLE key to scroll
through the choices of scale
capacity. With your choice
displayed, press the ZERO
key. . . LoAd 0 is displayed. Be sure all
eight is removed from the scale.
4. Press the ZERO key. . . bUSY is briefly displayed then LoAd
X. X is the amount of eight to put
on the scale for calibration. You can
scroll to an alternate eight by
pressing the ZERO key. See Table 2
at left.
5. With LoAd X displayed, place X
eight on the scale and press
the ZERO key. . . bUSY is briefly displayed then donE.
The display then returns to CALib.
ConFig (scale configuration) is the next item under the Scale menu. Belo
are descriptions of each item in this submenu. Use the ZERO and AMPLE
keys as you did in the calibration section to navigate through the choices
and select the configuration items you ant.
0 rAngE Zero range
Choices: 100% or 2% of full capacity
Use this to set the allo able zero range.
0 Start Zero Start
Choices: YE or NO
If YES is select, the scale zeros hen it po ers up. If NO is
selected, the scale ill display the eight on the platter hen it
po ers up.
Azt rng Auto zero tracking range
Choices: Off, 0.5d, 1d, 2d, 3d, 5d
Use this to set the allo able zero tracking range. This ill not
affect the count or sample modes.
CALib (Calibration)
ConFig (Configuration)
ress any key except the
AMPLE key to abort calibra-
tion. If you abort the procedure,
Abort is displayed briefly then
CALib.
During calibration the display
may show bUSY if scale
motion is detected. Wait to see
if the display clears. If not, turn
off the scale and turn back on.
Repeat the calibration proce-
dure
The scale de aults to 10,000d
resolution a ter calibration.
Scale
Capacity
5
10
25
50
75
100
125
150
200
250
300
500
Alt 1
N/A
N/A
10
10
10
10
10
10
50
50
50
50
Alt 2
N/A
N/A
25
25
50
50
50
50
100
100
100
200
Table 2
Alternate Span Weights

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ovr CAP Over capacity
Choices: 102% or full capacity or 9 divisions
Use this to set the overcapacity limit.
StAblE Stability
Choices: Off, 0.25d, 0.5d, 1d, 2d, 5d
Use this to set the stability limit. This is the allo able motion for
zero acceptance, tare acceptance and the stable indicator.
Off = 100d.
rESo Resolution
Choices: 5k, 10k, 12.5k, 15k, 20k, 25k, 30k, 40k, 50k, 75k,
100k, 125k, 150k, 200k, 250k, 300k, 400k, 500k
Use this to set the desired scale resolution.
FiLtEr Filter
Choices: Normal and Fast
Use this to set the amount of filtering needed for your situation.
Choose Fast in situations ith excess vibration.
UPdAtE Update
Choices: 1 time/second, 2 times/second, 8 times/second,
16 times/second
Use this to set the display update rate.
dEFAULt Default
Choices: Yes, No
Use this to reset the Config. factory defaults. Calibration ill not
be affected.
LFiLt LFilter
Choices: 4, 5
Sets filtering of the QDT® cell. A setting of 4 is more accurate
but slo s response compared to a setting of 5.
done Done
Hit the SAMPLE key ith this displayed to move back to the
ConFig display.
Restart is the next menu item. Use this to reinitialize the scale. You ill need
to recalibrate if you choose yes.
Seal is the next menu item. Choose Yes if you ant to disable access to the
scale menu through the front panel PRINT key. If yes is chosen and you try
to access the scale menu, SEALEd ill be displayed. Choose No if you
ant to leave front panel access to the scale menu available.
Done is the last menu item in the Scale menu. Press the COUNT/WEIGHT
key to return to the SCALE display.
rEStArt (Restart)
SEAL (Seal)
done (Done)
Bold selections are factory
defaults.

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Figure 3 sho s the Diagnostic menu.
Diagnostic Menu
Access the diagnostic menu by follo ing the instructions in the section
Accessing Menus and Modes. Belo are explanations for each of the items
in this menu. With the test name displayed, press the ZERO key to perform
the test.
BAttERY Battery
Choose this to display the current battery voltage. Battery
voltage ill usually read from 11 to 13 volts. The Lo Bat annun-
ciator ill sho up hen voltage drops to 11.5 volts. The scale
ill shut off hen voltage is 10 volts. While recharging, this
display ill sho 13-14.5 volts and if AC po ered the display ill
sho approximately 14.5 volts.
C CRYSt Compression Crystal
Choose this to display the ra digital counts from the compres-
sion crystal in the load cell. A typical count ith no load on the
scale is approximately 2.08 million. This number should in-
crease as eight is applied to the scale. Press the ZERO key to
end the test.
t CRYSt Tension Crystal
Choose this to display the ra digital counts from the tension
crystal in the load cell. A typical count ith no load on the scale
is approximately 2.08 million. This number should decrease as
eight is applied to the scale. Press the ZERO key to end the
test.
Figure 3
Diagnostic menu
A C-805 with the backlight
enabled and a fully charged
battery may be expected to last
12 hours before recharging is
necessary. With the backlight
disabled the battery will last
approximately 24 hours.
shows voltage shows raw
digital count
compression
crystal count tension crystal
count
performs
a serial
loopback
test
shows model #,
software
revision level
and performs a
display segment
test
shows high
resolution with
AZT on
Lets you
check key
function
shows high
resolution w/o
AZ
T
To move , press the ke
y
.
To move , press the key.
To move , and to choose an option, press the ke
y
.
Press key to go up one menu level.
SAMPLE
TARE ZERO
COUNT/WEIGHT
For version ? of the Quartzell
loadcell the counts should be
approximately 2.08 million for
the tension and compression.

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Count Count
Choose this to display the ra , digital counts from the
QuartzellTM. The ra count should be approximately 90,000. If
tension and compression crystal counts are present and stable,
the QDT cell is functioning properly.
SERIAL Choose this to perform a serial loopback test. You must connect
the transmit and receive lines together for this test to ork.
Display ill sho pass or fail.
dISPLAY Display
Choose this to display the model number, soft are version part
number and revision and to perform a display segment test.
bUttonS Buttons
Choose this to test the keys of the front panel. Each key press is
spelled out in the display to sho it is functioning properly. The
COUNT/WEIGHT key ill return the display to bUttonS.
HI RESA High resolution ith AZT enabled
Choose this to display eight data ith 1,000,000 count resolu-
tion. AZT is enabled during this test. Press the AMPLE or
COUNT/WEIGHT key to stop the test.
HI RESn High resolution ith no AZT
Choose this to display eight data ith 1,000,000 count resolu-
tion. AZT is disabled during this test. Press the AMPLE or
COUNT/WEIGHT key to stop the test.

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Config. (Configuration) Menu
The Config. menu is sho n in Figure 4. Access the Config. menu by follo -
ing the instructions in the section Accessing Menus and Modes. Belo are
explanations for each of the items in this menu.
Figure
Configuration menu

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UnitS Units
Choices: pounds, grams, kilograms, ounces
Enable the unit or units of measure you ant to have available
hen pressing the UNIT key. Default is all units are enabled.
Spl Lo Sample lo
Choices: 1, 2, 5, 10, 25, 50, 100
Choose the minimum allo able sample size
AccY-Lo Accuracy lo
Choices: Off, 95%, 98%, 99%
Choose the minimum desired sample accuracy. Reducing
sample accuracy requires fe er samples.
Spl-typE Sample type
Choices: bul (bulk) and dri (dribble)
Choose the type of sampling you ant to use. Pick bulk sam-
pling if you ant to place all the sample parts on the scale at the
same time. Pick dribble sampling if you ill be counting (drib-
bling) parts onto the scale.
PIE-rnd Piece eight rounding
Choices: Off, 1%, 2%, 5%
Choose the percent of piece eight rounding you ant.
Serial Serial
Use this submenu to configure the serial interface.
dEVICE Device
Choices: none, broadcast, imp printer, 1410, com-
puter
Use this to choose the device to be interfaced ith
your scale. If you select imp, the output format ill
be selected by the format menu. If you select com-
puter, the output is determined by the commands
received from the computer. Select broadcast to
continuously output the format selected in the format
menu. If you pick the 1410 printer, the format sho n
in the rint Formats section is sent.
bAUd Baud
Choices: 1200, 2400, 4800, 9600, and 19,200
Choose the baud rate for your serial communication.
dAtAbit Databit
Choices: 7 or 8
Choose the data bits to be used in serial communica-
tion.
PAritY Parity
Choices: none, even, odd
Choose the parity to be used in serial communica-
tion.
AdvAnCE Advance
Choices: 0, 1, 2, 3, 4, 5, 6, 7, 8, 9
If you are using an imp printer, use this to choose the
number of advances to be inserted after the format-
ted transmission.
Bold selections are the factory
defaults.

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ForNat Format
Choices: 0, 1, 2, 3, 4, 5, 6, 7
If you are using an imp printer or Broadcast, choose
from 8 preformatted outputs. These are described in
the Serial Communications section of this manual.
Auto Autoprint
Choices: No and Yes
If you are using an imp printer, choose no to disable
autoprint and yes to enable autoprint. If enabled the
eight ill automatically be printed after each eight
is added and stabilizes. Autoprint ill re-arm after the
eight has returned to ithin 10 divisions of net zero.
donE Done
Press the ZERO key to return to the Serial display.
IdLE Idle
Choices: off, 5, 10, 15, 20, 25, 30, 60 minutes
Choose the amount of idle time the scale ill remain po ered
hen operating under battery po er. Choose off if you do not
ant the scale to automatically shut off. The scale ill not do the
po er zero test if Off is chosen. Maximum battery life ith
continuous backlight usage is approximately 12 hours on a full
charge. Without backlight enabled, battery life is approximately
24 hours.
Latch Sample Latching
Choices: 1, 2, OFF
Latching, if enabled, gives the appearance of stability immedi-
ately follo ing the sample process. The sample latch is broken
hen motion is detected or if the calculated count is over t o
pieces a ay from the sample size. The latch ill not function
again until another sample process is completed.
Backlight Backlight
Choose to turn backlight on or off. On is the default setting.
donE Done
Press the ZERO key to return to the ConFig display.

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The error messages you might see on the display are sho n belo .
EPr Err EEPROM error - press the TARE key to ackno ledge the error
CAL Err Calibration error - perform calibration procedure to correct
Lo Bat Lo battery voltage - this annunciator ill appear hen battery
voltage reaches 11.5 volts. The scale ill shut off at 10 volts.
Pinout assignments for the serial communication are sho n belo .
9-pin Female
Scale
Pin Name Direction
2 TXD OUT
3 RXD IN
5SG -
Error Messages
Serial Communications
Cable Pinouts
A straight through cable (1 to 1,
2 to 2, etc.) can be used from a
9-pin computer serial port to
connect this scale.

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There are six preset serial print formats. Choose the one you ant to use
during configuration of the scale. See the Service Manual for configuration
instructions. The formats are described belo .
Abbreviations:
CR = carriage return
LF = line feed
SP = space
U = units character
W = eight character
C = count character
T = tare character
G = gross eight character
P = piece eight character
I = eight type identifier (G for gross, T for tare and N for net)
Net eight only:
WWWW.WW<CR><LF>
Net eight ith units:
WWWW.WW< P>UU<CR><LF>
GTN ith units:
'G'<SP>GGGG.GG<SP>UU<CR><LF>
'T'<SP>TTTT.TT<SP>UU<CR><LF>
'N'<SP>WWWW.WW<SP>UU<CR><LF>
Displayed eight ith identifier:
I< P>WWWW.WW<CR><LF>
In Count Mode: N< P>CCCC< P>PC <CR><LF>
In Weigh Mode: I< P>WWWW.WW< P>UU<CR><LF>
Preset Print Formats
Imp Printer Format 0
Imp Printer Format 1
Imp Printer Format 2
Imp Printer Format 3
If the scale is in count mode,
displayed weight formats will
send weight, not count.
Imp Printer Format 4

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Imp Printer Format 5
Imp Printer Format 6
Imp Printer Format 7
1410 Printer Fixed Format
Label Output
Net eight ith units, count and piece eight:
Net = WWWW.WW< P>UU<CR><LF> (Net = or Gross =)
Count = CCCCCCC<CR><LF>
Piece Wt = .PPPPPP< P>UU<CR><LF>
Fixed length (nine digits) displayed eight ith units.
sxxxxx.xx uu<CR> (s = positive (a space) or negative (-) eight)
COUNT: CCCC< P>PC <CR><LF>
You may also choose to print a 1410 printer bar code label. This printer has
one format sho n belo . It can be chosen through the configuration menu
explained in the Service Manual. The active unit of measure ill be printed.
This example sho s LB.

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The scale's RS-232 bidirectional communication orks in a master/slave
protocol. A computer or master sends a command code to the scale (slave)
hich ill return a response to the master device or perform a scale func-
tion. Commands to the scale are in uppercase, terminated ith a carriage
return. Scale responses begin ith the lo ercase equivalent of the com-
mand code.
COMMAND RESPONSE DESCRIPTION
CA<CR> none Clear Sample
CC<CR> cc_xxxxx<CR> Request piece count
CP<CR> cp_xxxxxx_uu<CR> Request piece weight value
CM<CR> none Switch to count mode
D xxxxxxxx<CR> none Display Message xxxx
(message is 8 characters max)
C<CR> none Reset Scale (warm start)
PWx.xxxxx_uu<CR> none Loads xxxx.x as piece weight
TR<CR> tr_x.xxx_uu<CR> Request tare value
TZ<CR> none Clear the current tare
Txxxx.x_uu<CR> none Loads xxxx.x as tare
WD<CR> ws_x.xxxx<CR> Request net weight
WE<CR> we_x.xxx_uu<CR> Request net weight with units
W<CR> we_x.xxxx_uuHML<CR> Request net weight with units
and status
WG<CR> wg_x.xxx_uu<CR> Request gross weight with units
WM<CR> none Switch to weight mode
WS<CR> ws_HML<CR> Request scale status
WZ<CR> none Zero the scale
Computer Protocol
Legend:
1) "_".......represents the ASCII space character
2) "u".......represents the units of measure character(s):
..........."LB" for pounds
..........."KG" for kilograms
..........."G" for grams
3) <CR> .. represents the ASCII carriage return
4) HML.... represents three bytes of scale status information as described
on the next page.
5) Value entered is assumed to be in same units of measure as hat the
scale is currently in.
6) Display messages are limited to seven characters.

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cale tatus Byte H:
BIT: 76543210
0011XXXX
1: In motion
1: At zero
1: Under capacity
1: Tare active
cale tatus Byte M:
BIT: 76543210
0011XXXX
1: Negative
1: Over cap.
1: PROM checksum error
1: faulty calibration
cale tatus Byte L:
BIT: 76543210
0011000X
1: lo battery
0: unused
0: unused
0: unused

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Disassembl Instructions
If it is necessary to service the PC-805, follo this checklist for disassembly
and re-assembly.
✍
❒ 1. Disconnect the scale from the po er source and remove the scale
shroud.
EE WARNING TO THE LEFT.
❒ 2. Remove the t o socket-head scre s securing the top plate to the
eight sensor. Lift off the top plate. Do not lose the eight sensor
spacer located bet een the top plate and the eight sensor.
Figure 5
Spacer locations
❒3. Disconnect the display cable from the scale base.
❒4. Remove the four scre s holding the electronics cover plate to the
base and lift off the cover.
❒ 5. Remove the eight sensor interface cable from the pins on the
po er supply board.
❒6. Remove the scre s holding the PC board to the base and lift out the
PC board.
WARNING! Be sure to counter
the torque force applied when
loosening or tightening screws
connected to the weight
sensor, or weight sensor
damage may result. Also do
not use a "T" handle allen
wrench and always lay the
palm of your hand on the
aluminum top plate when your
break loose the top screws.
To access the electronics:
To remove the power
supply/IO board:

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