Avery Weigh-Tronix PC-805 User manual

PC-805 Parts Counter
Service Manual

2PC-805 Parts Counter Service Manual

3PC-805 Parts Counter Service Manual
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
Zebra 2442 / Orion Printer Fixed Format Label Output .................... 16
Computer Protocol ............................................................................ 17
Disassembly Instructions ............................................................................. 19
PC-805 Technical Illustrations ..................................................................... 21

4PC-805 Parts Counter Service Manual
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) will occur at 9 divisions over rated
capacity or 102% of full scale capacity.
1 part in 2,000,000 (QDTTM)
Standard digital software filtering
Seven digits of seven-segment, high-contrast black LCD, .5" (1.3 cm) high
with blue electro-luminescent backlight
15VDC at 300mA from a 117VAC 60Hz inline transformer
Optional 12VDC lead acid battery
Bidirectional RS-232 output with 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:

5PC-805 Parts Counter Service Manual
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 following
sections:
• Scale Menu
• Diagnostic Menu
• Configuration Menu
• Communication
• Technical Drawings and Assemblies
The different modes of operation are accessed by placing the switches of
SW1 in the positions described in Table 1. Switch 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.
Switch SW1
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

6PC-805 Parts Counter Service Manual
Scale Menu
The first menu you see when entering the menu mode is the Scale menu.
Follow 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 shows SCALE. The
entire Scale menu is shown in
Figure 2 below.
2. Follow 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.
* = factory default value
Press any key
but
to abort the
calibration process
SAMPLE
To move , press the ke
y
.
To move , press the ke
y
.
To move , and to choose an option, press the ke
y
.
Press key to go up one menu level.
SAMPLE
TA RE
ZERO
COUNT/WEIGHT

7PC-805 Parts Counter Service Manual
CALib is the calibration function for the scale. Follow 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
weight.
2. Toggle between these two units
of measure by pressing the
SAMPLE key. With the unit of
measure you want displayed,
press the ZERO key. . . A weight capacity is shown on the
screen.
3. Press the SAMPLE key to scroll
through the choices of scale
capacity. With your choice
displayed, press the ZERO
key. . . LoAd 0 is displayed. Be sure all
weight is removed from the scale.
4. Press the ZERO key. . . bUSY is briefly displayed then LoAd
X. Xis the amount of weight to put
on the scale for calibration. You can
scroll to an alternate weight by
pressing the ZERO key. See Table 2
at left.
5. With LoAd X displayed, place X
weight 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. Below
are descriptions of each item in this submenu. Use the ZERO and SAMPLE
keys as you did in the calibration section to navigate through the choices
and select the configuration items you want.
0 rAngE Zero range
Choices: 100% or 2% of full capacity
Use this to set the allowable zero range.
0 Start Zero Start
Choices: YES or NO
If YES is select, the scale zeros when it powers up. If NO is
selected, the scale will display the weight on the platter when it
powers up.
Azt rng Auto zero tracking range
Choices: Off, 0.5d, 1d, 2d, 3d, 5d
Use this to set the allowable zero tracking range. This will not
affect the count or sample modes.
CALib (Calibration)
ConFig (Configuration)
Press any key except the
SAMPLE 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 defaults to 10,000d
resolution after 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
Tab le 2
A
lternate Span Weights

8PC-805 Parts Counter Service Manual
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 allowable 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 with 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 will not
be affected.
LFiLt LFilter
Choices: 4, 5
Sets filtering of the QDT®cell. A setting of 4 is more accurate
but slows response compared to a setting of 5.
done Done
Hit the SAMPLE key with this displayed to move back to the
ConFig display.
Restart is the next menu item. Use this to reinitialize the scale. You will need
to recalibrate if you choose yes.
Seal is the next menu item. Choose Yes if you want 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 will be displayed. Choose No if you
want 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.

9PC-805 Parts Counter Service Manual
Figure 3 shows the Diagnostic menu.
Diagnostic Menu
Access the diagnostic menu by following the instructions in the section
Accessing Menus and Modes. Below 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 will usually read from 11 to 13 volts. The Lo Bat annun-
ciator will show up when voltage drops to 11.5 volts. The scale
will shut off when voltage is 10 volts. While recharging, this
display will show 13-14.5 volts and if AC powered the display will
show approximately 14.5 volts.
C CRYSt Compression Crystal
Choose this to display the raw frequency from the compression
crystal in the Quartzell®. A typical count with no load on the
scale should be as stable as the other crystal frequency and
within 10% of each other. This number should increase as
weight is applied to the scale. Press the ZERO key to end the
test.
t CRYSt Tension Crystal
Choose this to display the raw frequency from the tension
crystal in the Quartzell®. A typical count with no load on the
scale should be as stable as the other crystal frequency and
within 10% of each other. This number should decrease as
weight is applied to the scale. Press the ZERO key to end the
Figure 3
Diagnostic menu
A PC-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 and
take about eight hours to
recharge.
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
A
ZT on
Lets you
check key
function
shows high
resolution w/o
A
Z
T
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

10 PC-805 Parts Counter Service Manual
test.
Count Count
Choose this to display the raw, digital counts from the
QuartzellTM. Count should be approximately 100,000-200,000
and as stable as the crystal counts.
SERIAL Choose this to perform a serial loopback test. You must connect
the transmit and receive lines together for this test to work.
Display will show pass or fail.
dISPLAY Display
Choose this to display the model number, software 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 show it is functioning properly. The
COUNT/WEIGHT key will return the display to bUttonS.
HI RESA High resolution with AZT enabled
Choose this to display weight data with 1,000,000 count resolu-
tion. AZT is enabled during this test. Press the SAMPLE or
COUNT/WEIGHT key to stop the test.
HI RESn High resolution with no AZT
Choose this to display weight data with 1,000,000 count resolu-
tion. AZT is disabled during this test. Press the SAMPLE or
COUNT/WEIGHT key to stop the test.

11PC-805 Parts Counter Service Manual
Config. (Configuration) Menu
The Config. menu is shown in Figure 4. Access the Config. menu by follow-
ing the instructions in the section Accessing Menus and Modes. Below are
explanations for each of the items in this menu.
Figure 4
Configuration menu

12 PC-805 Parts Counter Service Manual
UnitS Units
Choices: pounds, grams, kilograms, ounces
Enable the unit or units of measure you want to have available
when pressing the UNITS key. Default is all units are enabled.
Spl Lo Sample low
Choices: 1, 2, 5, 10, 25, 50, 100
Choose the minimum allowable sample size
AccY-Lo Accuracy low
Choices: Off, 95%, 98%, 99%
Choose the minimum desired sample accuracy. Reducing
sample accuracy requires fewer samples.
Spl-typE Sample type
Choices: bul (bulk) and dri (dribble)
Choose the type of sampling you want to use. Pick bulk sam-
pling if you want to place all the sample parts on the scale at the
same time. Pick dribble sampling if you will be counting (drib-
bling) parts onto the scale.
PIE-rnd Piece weight rounding
Choices: Off, 1%, 2%, 5%
Choose the percent of piece weight rounding you want.
Serial Serial
Use this submenu to configure the serial interface.
dEVICE Device
Choices: none, broadcast, imp printer, Orion, com-
puter
Use this to choose the device to be interfaced with
your scale. If you select imp, the output format will
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 Orion printer, the format shown
in the Print 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-
Bold selections are the factory
defaults.

13PC-805 Parts Counter Service Manual
ted transmission.
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
weight will automatically be printed after each weight
is added and stabilizes. Autoprint will re-arm after the
weight has returned to within 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 will remain powered
when operating under battery power. Choose off if you do not
want the scale to automatically shut off. The scale will not do the
power zero test if Off is chosen. Maximum battery life with
continuous backlight usage is approximately 12 hours on a full
charge. Without backlight enabled, battery life is approximately
24 hours and takes about eight hours to recharge.
Latch Sample Latching
Choices: 1, 2, OFF
Latching, if enabled, gives the appearance of stability immedi-
ately following the sample process. The sample latch is broken
when motion is detected or if the calculated count is over two
pieces away from the sample size. The latch will 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.

14 PC-805 Parts Counter Service Manual
The error messages you might see on the display are shown below.
EPr Err EEPROM error - press the TARE key to acknowledge the error
CAL Err Calibration error - perform calibration procedure to correct
Lo Bat Low battery voltage - this annunciator will appear when battery
voltage reaches 11.5 volts. The scale will shut off at 10 volts.
Pinout assignments for the serial communication are shown below.
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.

15PC-805 Parts Counter Service Manual
There are six preset serial print formats. Choose the one you want to use
during configuration of the scale. The formats are described below.
Abbreviations:
CR = carriage return
LF = line feed
SP = space
U = units character
W = weight character
C = count character
T = tare character
G = gross weight character
P = piece weight character
I = weight type identifier (G for gross, T for tare and N for net)
Net weight only:
WWWW.WW<CR><LF>
Net weight with units:
WWWW.WW<SP>UU<CR><LF>
GTN with 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 weight with identifier:
I<SP>WWWW.WW<CR><LF>
In Count Mode: N<SP>CCCC<SP>PCS<CR><LF>
In Weigh Mode: I<SP>WWWW.WW<SP>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

16 PC-805 Parts Counter Service Manual
Imp Printer Format 5
Imp Printer Format 6
Imp Printer Format 7
Zebra 2443 / Orion Printer
Fixed Format Label Output
Net weight with units, count and piece weight:
Net = WWWW.WW<SP>UU<CR><LF> (Net = or Gross =)
Count = CCCCCCC<CR><LF>
Piece Wt = .PPPPPP<SP>UU<CR><LF>
Fixed length (nine digits) displayed weight with units.
sxxxxx.xx uu<CR> (s= positive (a space) or negative (-) weight)
COUNT: CCCC<SP>PCS<CR><LF>
You may also choose to print an Orion printer bar code label. This printer
has one format shown below. It can be chosen through the configuration
menu explained in the Service Manual. The active unit of measure will be
printed. This example shows the weight in LB and the time and date line. If
your printer is not equipped with time and date capability, the time and date
line will not appear on the label.
Time and date line only appear if the printer
has time and date capability.

17PC-805 Parts Counter Service Manual
The scale's RS-232 bidirectional communication works in a master/slave
protocol. A computer or master sends a command code to the scale (slave)
which will return a response to the master device or perform a scale func-
tion. Commands to the scale are in uppercase, terminated with a carriage
return. Scale responses begin with the lowercase equivalent of the com-
mand code.
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 what the
scale is currently in.
6) Display messages are limited to seven characters.
COMMAND RESPONSE DESCRIPTION
CA<CR> none Clear Sample
CC<CR> cc_xxxxx<CR> Request piece count
CP<CR> cp_x.xxxxxxuu<CR> Request piece weight value
CM<CR> none Switch to count mode
DIxxxxxxxx<CR> none Display Message xxxx
(message is 8 characters max)
IC<CR> none Reset Scale (warm start)
PWx.xxxxx_uu<CR> none Loads x.xxxxx as piece weight
TR<CR> tr_ _ _ _x.xxxuu<CR> Request tare value
TZ<CR> none Clear the current tare
Txxxx.x_uu<CR> none Loads xxxx.x as tare
WD<CR> wd_ _ _xx.xxx<CR> Request net weight
WE<CR> we_ _ _xx.xxxuu<CR> Request net weight with units
W<CR> we_ _ _ _x.xxxuuHML<CR> Request net weight with units
and status
WG<CR> wg_ _ _xx.xxxuu<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

18 PC-805 Parts Counter Service Manual
Scale Status Byte H:
BIT: 7 6 5 4 3 2 1 0
0011XXXX
1: In motion
1: At zero
1: Under capacity
1: Tare active
Scale Status Byte M:
BIT: 7 6 5 4 3 2 1 0
0011XXXX
1: Negative
1: Over cap.
1: PROM checksum error
1: faulty calibration
Scale Status Byte L:
BIT: 7 6 5 4 3 2 1 0
0011000X
1: low battery
0: unused
0: unused
0: unused

19PC-805 Parts Counter Service Manual
Disassembly Instructions
If it is necessary to service the PC-805, follow this checklist for disassembly
and re-assembly.
✍
❒1. Disconnect the scale from the power source and remove the scale
shroud.
SEE WARNING TO THE LEFT.
❒2. Remove the two socket-head screws securing the top plate to the
weight sensor. Lift off the top plate. Do not lose the weight sensor
spacer located between the top plate and the weight sensor.
Figure 5
Spacer locations
❒3. Disconnect the display cable from the scale base.
❒4. Remove the four screws holding the electronics cover plate to the
base and lift off the cover.
❒5. Remove the weight sensor interface cable from the pins on the
power supply board.
❒6. Remove the screws 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 you
break loose the top screws.
To access the electronics:
To remove the power
supply/IO board:

20 PC-805 Parts Counter Service Manual